WS Controller User Interface

Failure to follow the instructions and procedures in this manual or,

misuse of this equipment will VOID its warranty!

WARRANTY NOTICE

PART NUMBER:

KEEP FORFUTURE REFERENCE

USER MANUAL

SULLAIR CORPORATIONThe information in this manual is current asof its publication date, and applies tosoftware part number:

and all subsequent software part numbers.

02250202-046 R01

02250201-216

WS CONTROLLER USER INTERFACE MANUAL

AIR CARE SEMINAR TRAININGSullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,and servicing of Sullair products. Individual seminars on Stationary compressors and compressor electricalsystems are offered at regular intervals throughout the year at Sullairs corporate headquarters training facilitylocated at Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting commonfaults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,contractor maintenance, and service personnel.

For detailed course outlines, schedule, and cost information contact:

SULLAIR TRAINING DEPARTMENT

1-888-SULLAIR or219-879-5451 (ext. 5623)

[email protected]

- Or Write -Sullair Corporation

3700 E. Michigan Blvd.Michigan City, IN 46360

Attn: Service Training Department.

TABLE OF CONTENTSSECTION 1SAFETY

5 1.1 GENERAL 5 1.2 PERSONAL PROTECTIVE EQUIPMENT 5 1.3 PRESSURE RELEASE 6 1.4 FIRE AND EXPLOSION 6 1.5 MOVING PARTS 7 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 7 1.7 TOXIC AND IRRITATING SUBSTANCES 8 1.8 ELECTRICAL SHOCK 8 1.9 LIFTING 9 1.10 ENTRAPMENT 9 1.11 SAFETY WARNINGS

SECTION 2STARTUP PROCEDURES 11 2.1 INTRODUCTION 11 2.2 WS CONTROLLER PANEL LAYOUT 12 2.3 WS START UP PROCEDURES 13 2.4 SHUTDOWN PROCEDURE

SECTION 3ADJUSTMENTS 15 3.1 INTRODUCTION 15 3.2 COMPRESSOR ADJUSTMENT PROCEDURES 16 3.3 USER ADJUSTABLE CONTROL PARAMETERS 18 3.4 CALIBRATION OF P2 PRESSURE TRANSDUCERS 18 3.5 REMOTE UNLOAD

SECTION 4DESCRIPTION 19 4.1 INTRODUCTION 19 4.2 TOUCH PAD BUTTON DESCRIPTION 19 4.3 INDICATOR LED DESCRIPTION 20 4.4 DISPLAY SCREEN 21 4.5 OPERATING MODES

TABLE OF CONTENTS

21 4.6 OPERATING STATES 22 4.7 NORMAL VIEW SERVICE REMINDERS 23 4.8 WARNING MESSAGES 24 4.9 FAULT MESSAGES 25 4.10 DIAGNOSTIC VIEWS

SECTION 5TROUBLESHOOTING 27 5.1 TROUBLESHOOTING INTRODUCTION 27 5.2 TROUBLESHOOTING GUIDE 32 5.3 WS CONTROLLER FAULTS AND WARNINGS 32 5.4 MACHINE BEHAVIOR AFTER A POWER INTERRUPTION 32 5.5 INTERNAL BATTERY

SECTION 6VARIABLE SPEED DRIVE 35 6.1 OVERVIEW 35 6.2 INSTALLATION

Section 1

5

SAFETY

1.1 GENERALSullair Corporation and its subsidiaries design andmanufacture all of their products so they can beoperated safely. However, the responsibility for safeoperation rests with those who use and maintainthese products. The following safety precautions areoffered as a guide which, if conscientiously followed,will minimize the possibility of accidents throughoutthe useful life of this equipment.

The compressor should be operated only by thosewho have been trained and delegated to do so, andwho have read and understood this Operator'sManual. Failure to follow the instructions, proceduresand safety precautions in this manual may result inaccidents and injuries. NEVER start the compressorunless it is safe to do so. DO NOT attempt to operatethe compressor with a known unsafe condition. Tagthe compressor and render it inoperative bydisconnecting and locking out all power at source orotherwise disabling its prime mover so others whomay not know of the unsafe condition cannot attemptto operate it until the condition is corrected.

Install, use and operate the compressor only in fullcompliance with all pertinent OSHA regulations and/or any applicable Federal, State, and Local codes,standards and regulations. DO NOT modify thecompressor and/or controls in any way except withwritten factory approval.

While not specifically applicable to all types ofcompressors with all types of prime movers, most of

the precautionary statements contained herein areapplicable to most compressors and the conceptsbehind these statements are generally applicable toall compressors.

1.2 PERSONAL PROTECTIVE EQUIPMENT

A. Prior to installing or operating the compressor,owners, employers and users should becomefamiliar with, and comply with, all applicableOSHA regulations and/or any applicable Federal,State and Local codes, standards, and regula-tions relative to personal protective equipment,such as eye and face protective equipment,respiratory protective equipment, equipmentintended to protect the extremities, protectiveclothing, protective shields and barriers and elec-trical protective equipment, as well as noiseexposure administrative and/or engineering con-trols and/or personal hearing protective equip-ment.

1.3 PRESSURE RELEASEA. Install an appropriate flow-limiting valve between

the service air outlet and the shut-off (throttle)valve, either at the compressor or at any otherpoint along the air line, when an air hose exceed-ing 1/2" (13mm) inside diameter is to be con-nected to the shut-off (throttle) valve, to reducepressure in case of hose failure, per OSHA Stan-dard 29 CFR 1926.302(b)(7) and/or any applica-ble Federal, State and Local codes, standardsand regulations.

B. When the hose is to be used to supply a mani-fold, install an additional appropriate flow-limitingvalve between the manifold and each air hoseexceeding 1/2" (13mm) inside diameter that is tobe connected to the manifold to reduce pressurein case of hose failure.

C. Provide an appropriate flow-limiting valve at thebeginning of each additional 75 feet (23m) ofhose in runs of air hose exceeding 1/2" (13mm)

NOTE

OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL.

SECTION 1

6

inside diameter to reduce pressure in case ofhose failure.

D. Flow-limiting valves are listed by pipe size andflow-rated. Select appropriate valves accordingly,in accordance with their manufacturer's recom-mendations.

E. DO NOT use air tools that are rated below themaximum rating of the compressor. Select airtools, air hoses, pipes, valves, filters and otherfittings accordingly. DO NOT exceed manufac-turer's rated safe operating pressures for theseitems.

F. Secure all hose connections by wire, chain orother suitable retaining device to prevent tools orhose ends from being accidentally disconnectedand expelled.

G. Open fluid filler cap only when compressor is notrunning and is not pressurized. Shut down thecompressor and bleed the receiver tank to zerointernal pressure before removing the cap.

H. Vent all internal pressure prior to opening anyline, fitting, hose, valve, drain plug, connection orother component, such as filters and line oilers,and before attempting to refill optional air lineanti-icer systems with antifreeze compound.

I. Keep personnel out of line with and away fromthe discharge opening of hoses or tools or otherpoints of compressed air discharge.

J. DO NOT use air at pressures higher than 2.1 barfor cleaning purposes, and then only with effec-tive chip guarding and personal protective equip-ment per OSHA Standard 29 CFR 1910.242 (b)and/or any applicable Federal, State, and Localcodes, standards and regulations.

K. DO NOT engage in horseplay with air hoses asdeath or serious injury may result.

1.4 FIRE AND EXPLOSIONA. Clean up spills of lubricant or other combustible

substances immediately, if such spills occur.

B. Shut off the compressor and allow it to cool.Then keep sparks, flames and other sources ofignition away and DO NOT permit smoking in thevicinity when checking or adding lubricant orwhen refilling air line anti-icer systems with anti-freeze compound.

C. DO NOT permit fluids, including air line anti-icersystem antifreeze compound or fluid film, to

accumulate on, under or around acoustical mate-rial, or on any external surfaces of the air com-pressor. Wipe down using an aqueous industrialcleaner or steam clean as required. If necessary,remove acoustical material, clean all surfacesand then replace acoustical material. Any acous-tical material with a protective covering that hasbeen torn or punctured should be replacedimmediately to prevent accumulation of liquids orfluid film within the material. DO NOT use flam-mable solvents for cleaning purposes.

D. Disconnect and lock out all power at source priorto attempting any repairs or cleaning of the com-pressor or of the inside of the enclosure, if any.

E. Keep electrical wiring, including all terminals andpressure connectors in good condition. Replaceany wiring that has cracked, cut, abraded or oth-erwise degraded insulation, or terminals that areworn, discolored or corroded. Keep all terminalsand pressure connectors clean and tight.

F. Keep grounded and/or conductive objects suchas tools away from exposed live electrical partssuch as terminals to avoid arcing which mightserve as a source of ignition.

G. Remove any acoustical material or other materialthat may be damaged by heat or that may sup-port combustion and is in close proximity, prior toattempting weld repairs.

H. Keep suitable fully charged Class BC or ABC fireextinguisher or extinguishers nearby when ser-vicing and operating the compressor.

I. Keep oily rags, trash, leaves, litter or other com-bustibles out of and away from the compressor.

J. DO NOT operate the compressor without properflow of cooling air or water or with inadequateflow of lubricant or with degraded lubricant.

K. DO NOT attempt to operate the compressor inany classification of hazardous environmentunless the compressor has been speciallydesigned and manufactured for that duty.

1.5 MOVING PARTSA. Keep hands, arms and other parts of the body

and clothing away from couplings, belts, pulleys,fans and other moving parts.

B. DO NOT attempt to operate the compressor withthe fan, coupling or other guards removed.

SECTION 1

7

C. Wear snug-fitting clothing and confine long hairwhen working around this compressor, especiallywhen exposed to hot or moving parts.

D. Keep access doors, if any, closed except whenmaking repairs or adjustments.

E. Make sure all personnel are out of and/or clear ofthe compressor prior to attempting to start oroperate it.

F. Disconnect and lock out all power at source andverify at the compressor that all circuits are de-energized to minimize the possibility of acciden-tal start-up, or operation, prior to attemptingrepairs or adjustments. This is especially impor-tant when compressors are remotely controlled.

G. Keep hands, feet, floors, controls and walkingsurfaces clean and free of fluid, water or otherliquids to minimize the possibility of slips andfalls.

1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

A. Avoid bodily contact with hot fluid, hot coolant,hot surfaces and sharp edges and corners.

B. Keep all parts of the body away from all points ofair discharge.

C. Wear personal protective equipment includinggloves and head covering when working in, on oraround the compressor.

D. Keep a first aid kit handy. Seek medical assis-tance promptly in case of injury. DO NOT ignoresmall cuts and burns as they may lead to infec-tion

1.7 TOXIC AND IRRITATING SUBSTANCES

A. DO NOT use air from this compressor for respi-ration (breathing) except in full compliance withOSHA Standards 29 CFR 1910 and/or any appli-cable Federal, State or Local codes or regula-tions.

B. DO NOT use air line anti-icer systems in air linessupplying respirators or other breathing air utili-zation equipment and DO NOT discharge airfrom these systems into unventilated or otherconfined areas.

C. Operate the compressor only in open or ade-quately ventilated areas.

D. Locate the compressor or provide a remote inletso that it is not likely to ingest exhaust fumes orother toxic, noxious or corrosive fumes or sub-stances.

E. Coolants and lubricants used in this compressorare typical of the industry. Care should be takento avoid accidental ingestion and/or skin contact.In the event of ingestion, seek medical treatmentpromptly. Wash with soap and water in the eventof skin contact. Consult Material Safety DataSheet for information pertaining to fluid of fill.

F. Wear goggles or a full face shield when addingantifreeze compound to air line anti-icer systems.

G. If air line anti-icer system antifreeze compoundenters the eyes or if fumes irritate the eyes, theyshould be washed with large quantities of cleanwater for fifteen minutes. A physician, preferablyan eye specialist, should be contacted immedi-ately.

H. DO NOT store air line anti-icer system antifreezecompound in confined areas.

I. The antifreeze compound used in air line anti-freeze systems contains methanol and is toxic,harmful or fatal if swallowed. Avoid contact withthe skin or eyes and avoid breathing the fumes. If

DANGER

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA stan-dards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment.

SECTION 1

8

swallowed, induce vomiting by administering atablespoon of salt, in each glass of clean, warmwater until vomit is clear, then administer twoteaspoons of baking soda in a glass of cleanwater. Have patient lay down and cover eyes toexclude light. Call a physician immediately.

1.8 ELECTRICAL SHOCKA. This compressor should be installed and main-

tained in full compliance with all applicable Fed-eral, State and Local codes, standards andregulations, including those of the National Elec-trical Code, and also including those relative toequipment grounding conductors, and only bypersonnel that are trained, qualified and dele-gated to do so.

B. Keep all parts of the body and any hand-heldtools or other conductive objects away fromexposed live parts of electrical system. Maintaindry footing, stand on insulating surfaces and DONOT contact any other portion of the compressorwhen making adjustments or repairs to exposedlive parts of the electrical system. Make all suchadjustments or repairs with one hand only, so asto minimize the possibility of creating a currentpath through the heart.

C. Attempt repairs in clean, dry and well lighted andventilated areas only.

D. DO NOT leave the compressor unattended withopen electrical enclosures. If necessary to do so,then disconnect, lock out and tag all power atsource so others will not inadvertently restorepower.

E. Disconnect, lock out, and tag all power at sourceprior to attempting repairs or adjustments torotating machinery and prior to handling anyungrounded conductors.

1.9 LIFTINGA. If the compressor is provided with a lifting bail,

then lift by the bail provided. If no bail is provided,then lift by sling. Compressors to be air-lifted byhelicopter must not be supported by the liftingbail but by slings instead. In any event, lift and/orhandle only in full compliance with OSHA stan-dards 29 CFR 1910 subpart N and/or any appli-cable Federal, State, and Local codes, standardsand regulations.

B. Inspect points of attachment for cracked weldsand for cracked, bent, corroded or otherwisedegraded members and for loose bolts or nutsprior to lifting.

C. Make sure entire lifting, rigging and supportingstructure has been inspected, is in good condi-tion and has a rated capacity of at least theweight of the compressor. If you are unsure ofthe weight, then weigh compressor before lifting.

D. Make sure lifting hook has a functional safetylatch or equivalent, and is fully engaged andlatched on the bail or slings.

E. Use guide ropes or equivalent to prevent twistingor swinging of the compressor once it has beenlifted clear of the ground.

F. DO NOT attempt to lift in high winds.

G. Keep all personnel out from under and awayfrom the compressor whenever it is suspended.

H. Lift compressor no higher than necessary.

DANGERAll field equipment must be tested for elec-trostatic fields prior to servicing or making contact with the machine using the follow-ing or equivalent test equipment:

90-600 VAC: Volt detector such as Fluke Model 1AC-A

600-7000 VAC: Voltage detector such as Fluke Networks Model C9970

It is the responsibility of each organization to provide/arrange training for all their associates expected to test for electrostatic fields.

SECTION 1

9

I. Keep lift operator in constant attendance when-ever compressor is suspended.

J. Set compressor down only on a level surfacecapable of safely supporting at least its weightand its loading unit.

K. When moving the compressor by forklift truck,utilize fork pockets if provided. Otherwise, utilizepallet if provided. If neither fork pockets or palletare provided, then make sure compressor issecure and well balanced on forks beforeattempting to raise or transport it any significantdistance.

L. Make sure forklift truck forks are fully engagedand tipped back prior to lifting or transporting thecompressor.

M. Forklift no higher than necessary to clear obsta-cles at floor level and transport and corner atminimum practical speeds.

N. Make sure pallet-mounted compressors arefirmly bolted or otherwise secured to the palletprior to attempting to forklift or transport them.NEVER attempt to forklift a compressor that isnot secured to its pallet, as uneven floors or sud-den stops may cause the compressor to tumbleoff, possibly causing serious injury or propertydamage in the process.

1.10 ENTRAPMENTA. If the compressor enclosure, if any, is large

enough to hold a man and if it is necessary toenter it to perform service adjustments, informother personnel before doing so, or else secureand tag the access door in the open position toavoid the possibility of others closing and possi-bly latching the door with personnel inside.

B. Make sure all personnel are out of compressorbefore closing and latching enclosure doors.

1.11 SAFETY WARNINGSThe following special instructions apply to VSDpackages provided with electronic adjustable speedmotor drives. These cautions that apply to VSDoperation.

WARNINGGround the unit following the instructions in thismanual. Ungrounded units may cause electricshock and/or fire. The variable speed drive has alarge capacitive leakage current during operation,which can cause enclosure parts to be aboveground potential. Proper grounding, as describedin this manual, is required. Failure to observe thisprecaution could result in death or severe injury.

WARNINGBefore applying power to the variable speeddrive, make sure that the front and cable coversare closed and fastened to prevent exposure topotential electrical fault conditions. Failure toobserve this precaution could result in death orsevere injury.

WARNINGRefer all drive service to trained technicians. Thisequipment should be installed, adjusted, andserviced by qualified electrical maintenancepersonnel familiar with the construction andoperation of this type of equipment and the hazardsinvolved and in accordance with published servicemanuals. Failure to observe this precaution couldresult in death or severe injury.

WARNINGLine terminals (L1, L2, L3), motor terminals (U, V,W) and the DC link/brake resistor terminals (-/+)are live when the drive is connected to power,even if the motor is not running. Contact with thisvoltage is extremely dangerous and may causedeath or severe injury.

SECTION 1

10

WARNINGBefore opening the variable speed drive covers: Disconnect all power to the variable speed drive. Wait a minimum of 5 (five) minutes after all thelights on the keypad are off. This allows time forthe DC bus capacitors to discharge. A hazard voltage may still remain in the DC buscapacitors even if the power has been turned off.Confirm that the capacitors have fully dischargedby measuring their voltage using a multimeter setto measure DC voltage. Failure to follow the aboveprecautions may cause death or severe injury.

CAUTIONDo not perform any meggar or voltage withstandtests on any part of the variable speed drive or itscomponents. Improper testing may result indamage. Prior to any tests or measurements ofthe motor or the motor cable, disconnect themotor cable at the variable speed drive outputterminals (U, VW) to avoid damaging the variablespeed drive during motor or cable testing.

CAUTIONDo not touch any components on the circuit boards. Static voltage discharge may damage the components.

CAUTIONInstall the variable speed drive in a well venti-lated room that is not subject to temperature extremes, high humidity, or condensation, and avoid locations that are directly exposed to sunlight, or have high concentrations of dust, corrosive gas, explosive gas, inflammable gas, grinding fluid mist, etc. Improper installation may result in a fire hazard.

CAUTIONMake sure that no power correction capacitors are connected to the variable speed drive out-put or the motor terminals to prevent variable speed drive malfunction and potential damage.

CAUTIONMake sure that the variable speed drive output terminals (U, V, W) are not connected to the utility line power as severe damage to the VSD may occur.

NOTEInterior electrical wiring is performed at the factory. Required customer wiring is minimal, but should be done by a qualified electrician in compliance with OSHA, National Electrical Code, and/or any other applicable State, Federal, and local electrical codes concern-ing isolation switches, fused disconnects, etc. Sullair provides a wiring diagram for use by the installer.

NOTECustomer must provide electrical supply power disconnect within sight of machine.

Section 2

11


STARTUP PROCEDURES2.1 INTRODUCTION This compressor is equipped with an WS Controllerfor controlling the compressor system operation,setting the machine parameters and performingmaintenance operations. The WS Controller isdesigned for the safe operation and protection of thecompressor system. When fault conditions occur,the controller automatically shuts down the machinebefore the conditions can cause damage to theequipment. The WS Controller also contains featuresthat enable sequential interface with other machines.

2.2 WS CONTROLLER PANEL LAYOUT

The WS Controller panel is shown in Figure 2-1. Thecontroller panel consists of :

Display Screen for displaying machine status

START pad for machine startup

STOP pad for stopping machine operationand for clearing fault messages while the machineis stopped

UP arrow and DOWN arrow pads fornavigation through the various panel displays andfor changing parameter values

ENTER pad for selecting and accessing vari-ous screen displays and for entering values

Machine status indicator lights for identifying thecurrent machine operational status.

Each of the controller components and functions isdescribed in detail in Section 4.

FAULTINDICATOR

(RED)

STARTPAD

UP ARROWPAD

MAINTENANCEINDICATOR

(AMBER)

DOWNARROW

PAD

RUN MODEINDICATOR

(GREEN)

POWER ONINDICATOR

(GREEN)

DISPLAYSCREEN

STOPPAD

ENTERPAD

Figure 2-1: WS Controller Panel

WS CONTROLLER USER INTERFACE MANUAL SECTION 2

12

2.3 WS START UP PROCEDURES COMPRESSOR MOTOR ROTATION

DIRECTION CHECK (AT INSTALLATION)

After the compressor has been installed and theelectrical wiring is completed, perform following stepsto verify the direction of the compressor motorrotation.

1. If the display screen shows AUTOMATIC,press the UP arrow pad twice to navi-gate to the Mode parameter. Press the

ENTER pad. The screen will displayreverse characters indicating change mode

is active. Press the DOWN arrow padto highlight the MANUAL selection (it willappear in reverse text in the display). Pressthe ENTER pad to accept the change andplace the machine in the Manual operatingmode.

2. Press the START and STOP pads in succession to bump start the com-pressor.

3. Observe the direction of rotation of the com-pressor motor shaft. Verify with OperatorsManual for correct rotation.

4. Disconnect and lockout power according tolockout/tagout procedure.

5. If the motor shaft is not turning in the properdirection, disconnect the power to the starterand exchange any two of the three powerinput leads. Refer to the Compressor Oper-ators Manual.

6. Perform above steps 1 - 3 again to confirmproper motor/compressor rotation.

FAN MOTOR ROTATION CHECK (AT INSTALLATION)

The VSD fan direction is affected by installation.Verify the correct fan rotation using the followingsteps:

1. With the compressor running, visually checkthat the fan rotation is correct.

2. If it is incorrect, change the direction of thefan motor by disconnecting power from thecompressor.


4. Exchange any two of the three fan motorleads at the fan motor starter. Refer to thecompressor Operators Manual.

5. Recheck the direction of the fan motor.

INITIAL START-UP AFTER INSTALLATION Perform the following procedure at the initial START-up of the compressor following installation.

1. Verify that all preparations and checks nec-essary for proper installation have beenmade. Refer to the compressor OperatorsManual.

2. Read the preceding pages of this manualthoroughly.

3. Slowly open the shut-off valve to the serviceline.

4. Press the START pad to START thecompressor. Compressor will begin operat-ing in the default mode (Automatic) set at thefactory.

5. Check for possible leaks in piping.

6. Slowly close the service line shut-off valve toverify nameplate pressure unload setting iscorrect. The compressor should unloadwhen nameplate pressure is achieved. Ifadjustments are necessary, see CompressorAdjustment Procedures on page 15.

7. Observe the operating temperature. Refer tocompressor Operators Manual for accept-able operating range. If temperatureexceeds this range, check the cooling sys-tem and installation environment.

8. Open the shut-off valve to the service line.

NOTEVariable speed drive (VSD) packages do not require a main motor direction check sincethe variable speed motor is set at the time of manufacture.

SECTION 2 WS CONTROLLER USER INTERFACE MANUAL

13

9. After operating the machine for 24 hours,inspect the compressor for fluid leaks andproper operating temperature.

SUBSEQUENT START-UP PROCEDURE 1. On subsequent start-ups, check the fluid

sight glass for proper fluid level. Service ifnecessary. See compressor OperatorsManual.

2. Press the START pad on the displayscreen. The machine will prepare to start upin the last operating mode existing at shut-down. The current Machine mode willappear on the display screen.

3. If a different operating mode is desired, usethe arrow pads to navigate to the Mode

parameter. Press the ENTER pad toENTER the Change Mode. Navigate to thedesired mode (Automatic or Manual). Press

the ENTER pad to accept and savethe mode setting.

4. When the compressor is running, observethe display panel and maintenance indica-tors to ensure the values displayed arewithin the proper ranges.

2.4 SHUTDOWN PROCEDURE Shut down the compressor by pressing the STOP

pad on the WS Controller panel.

NOTEThe system may require sump blowdown (typically below 10 psi) to be completed prior to restarting.

WARNINGThe compressor may restart automatically after a power failure or after the E-Stop but-ton has been reset.

14

NOTES

Section 3

15


ADJUSTMENTS3.1 INTRODUCTION This section describes steps for using the WSController to modify specific parameters that controlthe machine operation.

Typically, the top line of the Controller DisplayScreen will display the line pressure and compressortemperature; the bottom line will display the currentoperating mode. As the user presses the downnavigation arrow, the screen will display variousmachine statistics appearing under the headingCompressor Status:. These values are notadjustable at the WS Controller. Navigating pastthese screens, the first line of the screen will displaythe words Show Setting -------. This indicates thatthe controller is in the Adjustment mode. When inAdjustment mode, control parameters will bedescribed in the second line of the display screen.These control parameters can be modified by theuser. The bottom line of the display will show thecurrent value or setting of the control parameter.

Section 3.2 provides general steps to modifying thecompressor control parameters. A description ofeach user modifiable parameter is provided inSection 3.3.

3.2 COMPRESSOR ADJUSTMENT PROCEDURES

The following steps apply while Show Setting -------is indicated in the display. The control parameterdescribed in the display can be modified by the user.Use these steps to modify a parameter value:

1. Press the UP arrow or DOWN arrow pad on the controller panel to navigateto the parameter to be change.

2. Press the ENTER pad to select theparameter and access the CHANGE mode.The change mode is indicated by the textChange Setting ----- appearing in

(negative) characters on the topline of the display. The parameter name willappear on the second line and the currentparameter value or setting will appear in

characters on the bottom line.

3. Use the UP arrow or DOWN arrowpad to change the value or mode of theparameter.

4. When the desired value or mode name

appears on the display, Press ENTER to accept and save this new value for theselected parameter. The display will returnto the ADJUSTMENT view and the newvalue or mode will be displayed.

NOTEControl parameters described in this manual are those which can be adjusted via the WS controller. Additional parame-ters that control the operation of the com-pressor and sequencing of multiple machines can be viewed and edited using the WSPC Software program. See the WSPC User Interface Manual for more details.

reverse

reverse


16

5. Press the START pad when running

or STOP pad when stopped to returnthe display to the NORMAL view.

3.3 USER ADJUSTABLE CONTROL PARAMETERS

Listed below are descriptions of the parameter thatcan be adjusted at the WS Controller:

Unload Pressure - Set point (psi, bar, or kpa) atwhich the system pressure will begin unloading. Forexample if this parameter is set to 110 psi (7.6 bar)the machine will unload when the line pressure isabove 110 psi (7.6 bar).

Load Delta Pressure - The pressure differential (psi,bar, or kpa) below the unload pressure at which themachine will begin loading. For example if the unloadpressure is set to 110 psi (7.6 bar) and the loaddifferential is set to 10 psid (0.7 bar), the machine willload when the line pressure goes below 100 psi (6.9bar).

VSD Setpoint Press. - (VSD packages only) Thetargeted pressure (psi, bar, or kpa) for the variablespeed controls. This is normally adjusted near thebottom of the load/unload delta. The speed will beadjusted to maintain this pressure.

Unload Minutes - Set time that the machine will rununloaded in Automatic mode before shutting off. Ifthe time is set less than 15 minutes (for example 5),there may be times when the machine will run

unloaded for more than 15 minutes. This is becausethere is another timer that keeps the machine frombeing started more than four times an hour. Thissecondary timer is disabled when a machine isconfigured for VSD motor control.

Drain Interval Mins. - Set interval in minutesbetween activation of the drain cycle for machinesequipped with an electric solenoid drain. This doesnot apply to the Sullair SCD zero loss drain, which isnot controlled or monitored by the WS Controller.

Drain Time Seconds - Set time in seconds that thedrain remains energized.

Wye Delta Seconds - Set time for wye to deltastarter transition. Also used to control the closed inletstart valve. Disable by setting to zero (0), standardfor full voltage start. Requires approximately 4-6seconds for wye-delta or solid state starting.

Modulate - Manner in which the machine is set toregulate compressor flow. Default state is YES forproportional control. Select NO for Load/No Loadoperation.

Operating Mode - The mode set for controlling thecompressor motor operation (Manual / Automatic).Manual mode runs continuously. Automatic moderefer to Unload Minutes.

Language - The choice of language for text that willappear on the display screen.

The Diagram of Figure 3-1 shows the flow of thescreens that appear on the WS Controller displayscreen for a typical standard compressor package.This diagram illustrates how adjustment parametersare accessed.

Ethernet Address - (Models with Ethernet only) Thisselects the address for the service Ethernetconnector of the control box. The default is LANwhich is used for a local area network. The factorydefault address is 192.168.1.3, but may be modifiedas desired. The other selection is Link Local whichmay be used for simple connection to a PC. This putsthe controller at address 169.254.250.249, port 502.

NOTEIf during the adjustment process, the

START or STOP pad is pressed prior to pressing the ENTER

pad, the display will return to the NORMAL view and the parameter value will not be changed.


17

NORMAL VIEW

Compressor Status:

Compressor Status:

Compressor Status:

Compressor Status:

Compressor Status:

Compressor Status:

Compressor Status:

Compressor Status:

Compressor Status:

Compressor Status:

Compressor Status:

Compressor Status:

Show Setting Change Setting











(adjustments may belocked by Admin using WSPC)

Temperature 1

Temperature 2

Temperature 3

Dewpoint Temperature

Sump Pressure

Line Pressure

Pressure 3

Sparator Pressure

Run Hours

Spiral Valve

VSD Temperature

VSD Capacity

Unload Pressure Unload Pressure

Load Delta Pressure Load Delta Pressure

VSD Setpoint Press. VSD Setpoint Press.

Unload Minutes Unload Minutes

Drain Interval Mins. Drain Interval Mins.

Drain Time Seconds Drain Time Seconds

Wye Delta Seconds Wye Delta Seconds

Modulate Modulate

Operating Mode Operating Mode

Language Language

Ethernet Address Ethernet Address

Figure 3-1: Controller Display Flow Diagram


18

3.4 CALIBRATION OF P2 PRESSURE TRANSDUCERS

The compressor is equipped with a pressuretransducer that measures the output line (P2)pressure. Over time, the pressure transducer mayvary slightly producing an inaccurate reading at thecontroller. Periodically and prior to operating multiplecontrollers in a sequence, the controller should be re-calibrated to reflect the same measurement of P2pressure through out the system. The re-calibrationis best done when the system is at a stable pressure.

Calibration of the WS Controller P2 pressure readingis accomplished using the WSPC User InterfaceSoftware Program. Refer to the WSPC UserInterface Manual for details on calibrating the P2system pressure measurement.

3.5 REMOTE UNLOAD As a default configuration, the compressor isprovided with one input to allow user-furnishedexternal remote control. This may be wired to aremote switch, timer, or other controls to haltoperation of the compressor as desired. To enableremote control of the compressor:

1. Wire the remote contact to junction J4-7 andany vacant J3 terminal.

2. Access the PC User Interface software. Atthe User Adjustments display screen, selectone of the following sequencing modes:Remote, Hours, or Com Number. Remoteoperation is disabled if the sequencing modeis Disabled or Slave.

3. Once enabled, the controller will respond tothe wired input.

If the contact is closed, the compressor unloadsand stops delivering air to the system. If the oper-ating mode is AUTOMATIC, the compressor willstop after running unloaded for the period set in theUnload Minutes setting. When operating in agroup of sequenced compressors, this removesonly this compressor for service.

If the contact is open, the compressor operates nor-mally.

The WS Controller is field configurable for otherremote functions with additional contacts or fieldbuscommands. Refer to the WSPC manual for details.

Section 4

19


DESCRIPTION4.1 INTRODUCTION This section describes the components of the WSController, the function of each component, and thevarious types of displays that may appear on thedisplay screen. Descriptive lists of all messagesappearing in the display are also provided.

4.2 TOUCH PAD BUTTON DESCRIPTION

The WS Controller Panel has five touch pads thatallow the operator control of the compressor andenable adjustment of the machine operatingparameters. Each touch pad and its functions aredescribed below:

Start Pad Large green pad button used toSTART the compressor operation. The pad is alsopressed to reset warnings while the machine isrunning and to return the display to the Normal View.

Stop Pad Large red key pad used to stopthe compressor operation. The STOP pad is alsopressed to clear fault messages when the machine isstopped and to return the display to the Normal View.

Up Arrow Pad Used to navigate UP the listof display messages and to increase or changeparameter values for adjustments.

Down Arrow Pad Used to navigate DOWNthe list of display messages and to decrease orchange parameter values for adjustments.

Enter Pad Angled arrow key pad used toselect the parameter that is displayed on the screen.After adjusting the desired parameter value using theUP or DOWN arrow pads, the ENTER pad selectsthe parameter value displayed on the screen andsaves it as the new value.

4.3 INDICATOR LED DESCRIPTION

Four LEDs on the WS Controller Panel provideindication of the general state of the machine.

Power On Indicator (GREEN LED)Lightswhenever power is applied to the controller. ThisLED will blink very slowly if the compressor is set toautomatically restart after power failure.

Automatic or Manual Run Mode Indicator (GREEN LEDLights when the compressoroperation is set to start and run automatically. ThisLED lights steadily when the motor is running. TheLED will blink slowly if the compressor motor isstopped while in Automatic mode as a warning thatthe machine may restart at any time. The displayscreen will periodically indicate The compressor isStanding by. The Automatic Mode LED will blinkrapidly if machine restart is imminent. The displayscreen will periodically display a message to indicatethe state of the machine prior to restart (e.g., Waitingfor Blowdown).

Maintenance/Warning Indicator (AMBERLED)Lights when recommended maintenance orservice warning is issued. In most cases themachine will continue to operate normally. Thedisplay screen will periodically display therecommended maintenance actions or the cause ofthe warning. Refer to Section 5: Troubleshooting onpage 27 to resolve maintenance conditions.

Fault Warning Indicator (RED LED)Lightswhen a compressor fault has occurred. The indicatorwill remain lit and the compressor will remaininoperative until the fault condition is remedied. Thecontroller display screen will indicate FAULTED andperiodically a brief description of the cause of thefault. Refer to Section 5: Troubleshooting on page27 to resolve fault conditions.


20

4.4 DISPLAY SCREEN Information relevant to the compressor operation ispresented in three views on the controller displayscreen: Normal View, Compressor Status: andCompressor Adjustment: or Show Setting ------- .

NORMAL VIEW The Normal View is the default view for the displayscreen. When in Normal View, information regardingthe compressor current operating conditions appearson the display screen. See Figure 4-1. The top lineof the display screen in Normal View shows thedischarge pressure and the internal temperature ofthe compressor package. The lower line of theDisplay Screen displays the current compressoroperating mode.

Under normal operating conditions, the lower line ofthe Controller Display Screen will alternatelydisplay the compressor operating state, warningmessages, service reminders, and fault conditionswhen they occur.

COMPRESSOR STATUS VIEW The Compressor Status: View shows real-timemachine measurement information.

This information is quickly accessed using the Downnavigational arrow. The top line of the display screenwill indicate Compressor Status:. See Figure 4-2.The second line will show the name of themeasurement (e.g., Line Pressure). The bottomline will display the current value of the measurementbeing viewed.

Listed below are compressor attributes that may beviewed in the Compressor Status View. This list willvary based on specific machine configurations.

Temperature 1Displays the current compressortemperature at temperature probe 1. Temperature 2Displays the current compressortemperature at temperature probe 2. Temperature 3Displays the current compressortemperature at temperature probe 3. Dewpoint TemperatureDisplays the current dryertemperature at temperature probe 3.Sump PressureDisplays the current sumppressure (P1). Line PressureDisplays the current line outputpressure (P2). Pressure 3Displays the pressure (P3) at thespecified transducer location. Separator Pressure ^ Displays the currentseparator pressure differential. Run HoursDisplays the total time the compressorhas been running loaded or unloaded. Spiral ValveApproximate percent of full capacitycontrolled by the compressor's spiral valve

VSD CapacityThis is displayed as an approximatepercentage (%) of the maximum capacity for thepackage.

VSD TemperatureHigh temperatures usuallyindicate a need for cleaning of the VSD fan or heatsink by a trained service technician.

COMPRESSOR ADJUSTMENT VIEW CONTROL PARAMETERS

The Compressor Adjustment View shows currentmachine parameters which are conditions and limitsthat can be modified by the operator. This view isaccessed using the navigational arrows and isindicated by the text Show Setting ------- appearingon the first line of the display screen. See Figure 4-3.

Pressing ENTER at the Show Setting screenaccesses the Change Mode. This mode is indicatedby the text Change Setting----- appearing as

characters on the first line of the displayscreen and the change parameter appearing on thesecond line. See Figure 4-4. The value of theparameter is displayed as characters onthe bottom line. Refer to Section 3: Adjustments onpage 15, for instructions on changing the compressorcontrol parameters and a list of the controlparameters that can be modified by the user.

Figure 4-1: Display ScreenNormal View Example

Figure 4-2: Display Screen Compressor Status View Example

reverse

reverse


21

4.5 OPERATING MODES The Operating Mode is the manner in which themachine operation is being controlled. There are fiveOperating Modes: AUTOMATIC, MANUAL, OFF,FAULT and UI COMM.

The active operating mode of the compressorappears on the lower line of the display screensNormal View. See Figure 4-5.

The compressor operating modes are describedbelow:

Automatic modeIndicated by the wordAUTOMATIC appearing in the lower line of thedisplay window. This is a user selected mode thatsets the compressor motor to automatically startwhen conditions necessitate and stop when motoroperation is not required.

Manual ModeIndicated by the word MANUALappearing in the lower line of the display window.This is a user selected mode that allows the operatorto manually control the compressor motor operation.

When the START pad is pressed while inManual Mode the compressor motor will run

continuously until the STOP pad is pressed.The compressor pump and all other machineparameters function the same in both Manual andAutomatic modes.

Off modeIndicated by the word OFF appearing inthe lower line of the display window. This modeindicates that the compressor and motor have beenturned off under normal conditions. When in thismode the machine will not operate until the START

pad is pressed.

Fault modeIndicated by the word FAULTEDappearing in the lower line of the display window.This mode indicates that a machine problem hasoccurred causing the controller to shut down themachine until the condition is cleared. After a faultcondition has been resolved, the fault indication canbe cleared from the controller by pressing the STOP

pad. Refer to Section 5: Troubleshooting onpage 27, for information on resolving fault conditions.

UI Comm modeIndicated by the word UI COMMappearing in the lower line of the display window.This mode indicates that the User Interface has lostcommunication and, as a result, the machineoperating mode or status is unknown.

4.6 OPERATING STATES Operating States describe the state of thecompressor operation in response to the currentmode and current conditions. Essentially, theoperating state is what the machine is doing at aparticular moment. Most operating states occurautomatically as normal functions of the compressorand require no direct action from the operator.

Text descriptions of operating states appearperiodically on the lower line of the display screenwhile in Normal View. See Figure 4-6. The leadingline will read The compressor is below which theoperating state description will be displayed.

The list below provides an explanation of eachOperating State message that may appear in the

Show Setting - - - - - - -Unload Pressure

110 psiAdjustment View

Figure 4-3: Adjustment ViewShow Setting Example

Change Setting - - - - - - -Unload Pressure

110 psiChange View

Figure 4-4: Adjustment ViewChange Setting Example

118 psi 70FAUTOMATIC

Automatic Mode(Normal View)

Figure 4-5: Compressor OperatingMode Display NOTE

Machine operating states may vary depending on compressor model.

Figure 4-6: Controller Display Normal View:Operating State


22

Normal View display. Some operating states occurinstantaneously and may not be seen by theoperator.

InitializingDisplayed as the compressor ispowered up.

StoppingMay be briefly displayed as thecompressor is being stopped via the ControllerPanel.

Manually StoppedDisplayed when thecompressor operation is stopped.

Remote StoppingMay be briefly displayed as thecompressor is being stopped remotely.

Remote StoppedDisplayed when the compressoroperation is stopped but is armed to restart. Themachine will start when the remote start contact isclose. NOTE: The machine may start at any timewhen conditions are met.

Standing byDisplayed when the compressor isstopped and waiting for proper conditions beforerestarting.

FaultingDisplayed as a fault condition is occurring. FaultedDisplayed after a fault condition hasoccurred.

Waiting for BlowdownDisplayed when thecompressor is waiting for the sump to reach a setminimum pressure prior to starting. After thepressure has reduced to the set level, thecompressor will start automatically.

Starting 1Displayed as compressor initiates stage1 startup processes.



Precooling the DryerDisplayed while initiallycooling an integrated dryer with the compressorunloaded

LoadingDisplayed as the compressor beginsdelivering air.

Loaded & ModulatingDisplayed when thecompressor is delivering air.

Fully LoadedDisplayed when the compressor isdelivering air at full rated capacity.

UnloadingDisplayed as the compressor is beingunloaded automatically.

Remote UnloadingDisplayed as the compressoris being unloaded remotely.

Running UnloadedDisplayed when the system isrunning with the compressor unloaded.

Remote UnloadedDisplayed when thecompressor has been unloaded remotely.

RestartingDisplayed during the restart waitingperiod after the starter has dropped outunexpectedly.

4.7 NORMAL VIEW SERVICE REMINDERS

Service reminders may alternately appear in theNormal View display. See Figure 4-7. The ServiceReminder screen is indicated by the wordsRecommended Service: appearing on the secondline of the display. The bottom line displays a briefdescription of the recommended service required.When a service reminder appears, the machine willcontinue to operate normally, however, theappropriate service should be scheduled andaccomplished within a short period of time.

The list below provides an explanation of the ServiceReminders that may appear in the Normal Viewdisplay. Refer to Section 5: Troubleshooting on page27, for additional instructions on actions to be takenwhen a service reminder appears.

Change Fluid FilterThe compressor fluid filtershould be changed within the time frame noted in themachine operation specifications.

Change SeparatorThe compressor fluid separatorshould be changed within the time frame noted in themachine operation specifications.

Change Air FilterThe compressor air filter shouldbe changed within the time frame noted in themachine operation specifications.

Analyze FluidA fluid analysis should be scheduledper machine operation specifications.

Change FluidThe compressor fluid should bechanged within the time frame noted in the machineoperation specifications.

Maintenance APeriodic maintenance should bescheduled per machine operation specifications.

Figure 4-7: Controller Display Normal View:Service Reminder


23

4.8 WARNING MESSAGES When a Warning: condition occurs a warningmessage will alternately appear on the lower line ofthe Normal View display. See Figure 4-8. Under aWarning condition, the machine will continue tooperate normally, however, appropriate maintenanceaction must be taken to remedy the warningcondition. Refer to Section 5: Troubleshooting onpage 27, for additional instructions on actions to betaken when warning conditions exists.

The list below provides an explanation of theWarning Messages that may appear in the displaywhen an error occurs.

High Dryer DewpointIndicates that the integrateddryer is running with high dewpoint temperature.Consult the dryer manual and/or dryer manufacturer.

Dryer High DP FaultIndicates that the integrateddryer has stopped operation due to high dewpointtemperature. Consult the dryer manual and/or dryermanufacturer.

Low Dryer DewpointIndicates that the integrateddryer is running with low dewpoint temperature.Consult the dryer manual and/or dryer manufacturer.

Dryer Low DP FaultIndicates that the integrateddryer has stopped operation due to low dewpointtemperature. Consult the dryer manual and/or dryermanufacturer.

Dryer Overload FaultIndicates that the integrateddryer has stopped operation due to a compressormotor overload. Consult the dryer manual and/ordryer manufacturer.

Dryer Relay FaultIndicates that the integrateddryer has stopped operation due to internalproblems. Consult the dryer manual and/or dryermanufacturer.

Dryer ServiceIndicates a dryer is running while amalfunction is occurring. Consult the dryer manualand/or dryer manufacturer.

Ethernet disabledEthernet was turned off due toexcessive network traffic.

High Air Filter dPIndicates the air filter pressuredifferential is high. The air filter unit needs to bechecked or changed.

High Oil Filter dPIndicates the fluid filter pressuredifferential is high. The fluid filter needs to bechecked or changed.

High Separator dPIndicates the fluid separatorpressure differential is high. The separator unitneeds to be checked or changed.

High Temperature 1Indicates that the compressorTemperature at temp probe location 1 is approachingthe set high limit.



Low Temperature 1Indicates that the compressorTemperature at temp probe location 1 is approachingthe set low limit.



Not CommissionedA controller was replaced buthas not been commissioned for a specificcompressor model.

Power InterruptionIndicates that a powerinterruption has occurred.

Replace BatteryIndicates the I/O backup batteryis low.

Sequence Comm ErrorIndicates acommunication problem exists between thecompressor controllers set up for sequentialoperation.

StarterThe main motor starter failed to operate,and was restarted.

User Option WarningIndicates a user furnishedswitch has been activated.

VFD OvertempOperating temperatures areapproaching the VSD limits.

Figure 4-8: Controller Display Normal View:Warning Message


24

4.9 FAULT MESSAGES When a Fault condition occurs, the machine will shutdown and the display will indicate FAULTED on thelower line of the display window. A Fault Messagewill alternately appear in the lower line of the NormalView display briefly describing the nature of the fault.See Figure 4-9.

The list below provides an explanation of the FaultMessages that may appear when problems occur.Refer to Section 5: Troubleshooting on page 27, forinstructions on actions to be taken when a FAULTcondition occurs.

Aux Motor OverloadThe auxiliary motor overloadrelay has been tripped due to a power overload in theauxiliary motor.

CE Voltage too high / LowThe internal 24 voltsupply is out of range.

Controller WatchdogController watchdog timererror.

Dryer FaultIndicates a dryer malfunction hasoccurred. Consult the dryer manual and/or dryermanufacturer.

Dryer OverloadIndicates a dryer overload hasoccurred. Consult the dryer manual and/or dryermanufacturer.

E-Stop Push ButtonEmergency Stop button hasbeen pressed.

HIGH AN0 SENSOR (AN0-AN9)Device assignedto sensor input AN0 through AN9 (temp probe,transducer unit, etc.) or wiring between the device

and the controller module has resulted in an opencircuit.

High Dryer DewpointIndicates that the integrateddryer has stopped all package operation due to highdewpoint temperature. Consult the dryer manualand/or dryer manufacturer.

High Interstage PresInterstage pressure is abovethe unit limits.

High Package PressPackage Discharge pressurehas exceeded the set high limit.

High Plant PressurePlant line pressure hasexceeded the set high limit.

High Pressure ABPressure at specifiedtransducer (A or B) has exceeded the set high limit.

High Separator dPSeparator pressure differentialhas exceeded the set high limit.

High Spiral Valve PrExcessive pressure wasapplied to the spiral valve actuator.

High Sump PressureCompressor sump pressurehas risen above the set limits.

High Temperature 13The temperature atspecified temp probe (1 through 3) has risen abovethe set high limit.

High Voltage FailedNo voltage is available at thehigh voltage motor starter.

HIGH VOLT SENSORIndicates the system highvoltage sensor has failed.

Illegal StateController operating error.

Internal Com ErrorAn error in communicationbetween the controller and the compressor hasoccurred.

LOW AN0 SENSOR (AN0 - AN9)Device assignedto sensor input AN0 through AN9 (temp probe,transducer unit, etc.) or wiring between the device andthe controller module has resulted in a short circuit.

Low Dryer DewpointIndicates that the integrateddryer has stopped all package operation due to lowdewpoint temperature. Consult the dryer manualand/or dryer manufacturer.

Low Line PressureThe line pressure has fallenbelow the Low Fluid Pressure set low limit.

Low Fluid PressureCompressor fluid pressurehas fallen below the set low limit.

Low Sump PressureCompressor sump pressurehas fallen below the set limits.

WARNINGThe compressor may restart automatically after power has been restored following a power failure.

The fault cause is:E-Stop Push Button Figure 4-9: Controller Display Normal View:

Fault Message


25

Low Temperature 1 ... 3Temperature at thespecified temp probe (1 through 3) has fallen belowthe set low limit.

LOW VOLT SENSORIndicates the system lowvoltage sensor has failed.

Low Water PressureThe water pressure switchhas been tripped due to low water pressure.

Main Motor OverloadThe main motor overloadrelay has been tripped due to a power overload in themain motor.

Memory ErrorThe controller I/O board has failed.

OPTION INPUTUser option error.

OPTION INPUT RUNUser option error.

Phase Protection.Indicates external phaseprotection relay has tripped.

Ethernet Comm ErrorCommunications havefailed to a keypad.

Power InterruptionA power interruption hasoccurred at the controller.

Pump Motor OverloadThe pump motor'soverload relay has tripped.

Pump Starter ContactThe pump starter did notoperate as expected.

StarterStarter auxiliary contact failed to connectpower to the starter.

UI Voltage too highThe voltage to the UserInterface has risen above the set limit.

UI Voltage too lowThe voltage to the UserInterface has fallen below the set limit.

High Plant PressureThe inlet valve failed to closeas expected

VSD1 ResponseThe A1000 drive is notresponding to run commands

VSD1 Comm FaultAn error in communicationbetween the controller and the specified VSDcompressor has occurred.

VSD1 parameter errorAn error has occurredduring setup of the VSD adjustments.

4.10 DIAGNOSTIC VIEWS

While in the Normal View use the ENTER Padto access the Diagnostic View.

Use the UP or DOWN arrow pads to accessthe next Diagnostic view.

Use the ENTER Pad to return to the NormalView.

Figure 4-13 Illustrates how to navigate between theNormal View and the Diagnostic Views.

DIAGNOSTIC: ANALOG INPUT VIEWThe analog inputs are displayed in their order on theanalog input terminal block in a left to right, top tobottom order. Inputs not used by the machine are notshown.

Figure 4-10: Typical Analog Input Status

The analog values are typically displayed in theselected units of measure.

The input labels typically refer to the pressure andtemperature sensor references in the Piping andInstrumentation drawing.

DIAGNOSTIC: DIGITAL I/O VIEWThe status of the digital inputs and relay outputs areshown from left to right in the order in which they arefound on the terminal blocks.

Figure 4-11: Typical Digital I/O Status

The values of one and zero refer to active or inactivestates respectively.

The labels refer to the controller input and outputnaming on the wiring diagram.


26

DIAGNOSTIC: ALARM VIEWSAny current fault, alarm or service reminder messagewill be available to view here. Multiple messagesmay be scrolled through using the UP and DOWN arrow pads.

Figure 4-12: Typical Alarm View

Figure 4-13: Navigation between the Normal and Diagnostic view

Recommended Service:

Change Air Filter

NORMAL VIEW Analog Inputs View

Digital I/O View

Alarm ViewMessage #1

...

Alarm View

Last Message

(adjustments may be

locked by Admin using WSPC)

Compressor Status:Temperature 1



Compressor Status:Dewpoint Temperature

Compressor Status:Sump Pressure

Compressor Status:Line Pressure

Compressor Status:Pressure 3

Compressor Status:Sparator Pressure

Compressor Status:Run Hours

Compressor Status:Spiral Valve

Compressor Status:VSD Temperature

Compressor Status:VSD Capacity

Unload Pressure

Load Delta Pressure

VSD Setpoint Pressure

Unload Minutes

Drain Interval Mins.

Drain Time Seconds

Show Setting -------











Wye Delta Seconds

Modulate

Operating Mode

Language

Ethernet Address

Change Setting -----Unload Pressure

Change Setting -----Load Delta Pressure

Change Setting -----VSD Setpoint Pressure

Change Setting -----Unload Minutes

Change Setting -----Drain Interval Mins.

Change Setting -----Drain Time Seconds

Change Setting -----Wye Delta Seconds

Change Setting -----Modulate

Change Setting -----Operating Mode

Change Setting -----Language

Change Setting -----Ethernet Address

Section 5

27


TROUBLESHOOTING5.1 TROUBLESHOOTING

INTRODUCTION This Troubleshooting section is provided as a guideto aid in diagnosing and resolving compressorproblems when they occur. The informationcontained in Table 5-1, Troubleshooting Guide, hasbeen compiled from factory experience and containssymptoms and usual causes for the describedproblems. Each Service Reminder, Warning, orFault Message is listed with conditions of when theproblem may occur, a probable cause, and asuggested solution to the problem. DO NOT assumethat these are the only problems that may occur.

This document cannot address every possibleadverse condition that may occur nor does it provideevery solution for the potential troubles listed. Allavailable data concerning the trouble should besystematically analyzed before undertaking anyrepairs or component replacement procedures.

Always perform a detailed visual inspection when amachine problem occurs prior to attempting anyrepairs. Doing so may avoid unnecessary repairand/or additional damage to the compressor.

Always remember to:

a. Check for loose wiring.

b. Check for damaged piping.

c. Check for parts damaged by heat or an elec-trical short circuit, usually apparent by discol-oration or a burnt odor.

Should your problem persist after making therecommended check, consult your nearest SullairDistributor or the Sullair Corporation factory ServiceDepartment.

5.2 TROUBLESHOOTING GUIDE Table 5-1 contains symptoms and usual causes forthe problems that may occur throughout thecompressor system. Each warning or fault messagethat may appear is listed along with conditions for theproblem, a probable cause, and a suggested solutionto the problem. DO NOT assume that these are theonly troubles that may occur.

NOTESection 5.2 and Section 5.4 portray com-mon systematic problems that can occur during controller operation. For a more thoroughly in-depth coverage of machine operation troubles, consult the Trouble-shooting Section in the machines opera-tors manual.

Table 5-1: WS Controller Troubleshooting GuideMESSAGE PROBABLE CAUSE REMEDYAnalyze Fluid Service interval has expired.

Maintenance due.Select Maintenance from menu to see service due and part numbers.

Aux Motor Overload Auxiliary Motor Tripped on Cooling Fan, Fluid Pump or Other Motor.

Reset auxiliary overload after element cools. Verify correct motor amps.

Check for loose connections.

Check motor starter contact for proper operation.

Check line voltage, if low consult power company.


28

CE Voltage too high Excessive voltage form power supply or transformer.

Check connections and adjustments.

CE Voltage too low Inadequate voltage form power supply or transformer.

Excessive load or short in 24v control devices.

Check connections and adjustments.

Check wiring, coils, and solenoid valves.

Change Air Filter

Change Fluid

Change Fluid Filter

Change Separator

Service interval has expired.

Maintenance due.

Perform recommended maintenance and reset the reminder using WSPC.

Controller Watchdog Controller fault. Contact Sullair Factory Service.

Dryer Fault Indicates a general dryer malfunction has occurred.

Consult the dryer manual and/or Sullair Factory Service.

High Dryer Dewpoint

Dryer High DP Fault

The dryer is unable to cool below the high dewpoint temperature setting.


Low Dryer Dewpoint

Dryer Low DP Fault

The dryer is cooling below the low dewpoint temperature setting.

Consult the dryer manual and/orSullair Factory Service.

Dryer OverloadDryer Overload Fault

Indicates a dryer overload has occurred.


Dryer Relay Fault Indicates a general dryer malfunction has occurred


Dryer Service Dryer malfunction is imminent. Consult the dryer manual and/or Sullair Factory Service.

E-Stop Push Button E-Stop Button Active.

Faulty E-Stop Button.

Release button.

Check wiring.

Ethernet disabled Excessive Ethernet traffic Install a router to reduce the traffic on the compressor's LAN.

High Air Filter dP Differential Pressure Across Inlet Filter High.

Replace filter.

Check inlet filter pressure switch.

HIGH AN0 SENSOR Sensor (Pressure Transducer, Temp Probe, etc.) or Wiring Failure.

Check sensor wiring.

Check sensor.

High Dryer Dewpoint The dryer is unable to cool below the high dewpoint temperature setting.


High Oil Filter dP Pressure across fluid filter above 20 psi (1.4 bar) while running.

Fluid filter clogged.

Low ambient temperature.

Sensor failure.

Replace fluid filter.

Sump heater may be required in ambients below 40F (4C).

Check sensor, wiring and tubing.

High Interstage Pres Compressor Interstage Blockage or second stage failure

Inspect for: interstage flow restriction, or damaged air end and repair

Table 5-1: WS Controller Troubleshooting GuideMESSAGE PROBABLE CAUSE REMEDY


29

High Package Press

High Pressure A

High Pressure B

High pressure.

Faulty pressure sensor.

Check operation of valves and controls.

Check and replace pressure sensor if defective.

High Separator dP High Separator pressure drop Inspect separator and replace

High Spiral Valve Pr Misadjustment Check setting of the pressure regulator for the spiral valve actuator.

High Sump Pressure Sump Pressure High (Poppet, Sullicon, Spiral, Blowdown or Pneumatic Valve Failed).

Faulty solenoid valves.

Faulty pressure regulator.

Check valves. Check Sullicon adjustment (see Control Adjustment section in the compressor operators manual).

Check solenoid valve operation and wiring.

Check pressure regulator adjustment and operation.

Check minimum pressure check valve (not applicable to Fluid Free compressors).

High Temperature 1

High Temperature 2

High Temperature 3

High Temp Fault.

Fluid level low.

Thermal valve fault.

Cooler fins dirty.

Low water flow.

High water temperature.

Cooler plugged.

Temp probe or sensor failure.

Ambient above 105F (41C), improve local ventilation.

Replenish fluid to proper level.

Check thermal valve operation.

Clean Cooler fins and fan blades.

Check for valve closed, pump off or broken pipe.

Increase water flow or lower water temperature.

Clean cooler tubes and shell. If plugging persists, use cleaner water.

Check sensor and wiring.

High Voltage Failed No power to the high voltage starter

Close the disconnect switch Check main motor fuses or circuit breaker

Illegal State Controller fault. Contact Sullair Factory Service.

Ethernet Comm Error Module Network Error; Communication has failed between the Display Module, I/O Module and other modules.

Check wiring.

LOW AN0 SENSOR Sensor (Pressure Transducer, Temp Probe, etc.) or Wiring Failure.


Check sensor.

Low Dryer Dewpoint The dryer is cooling below the low dewpoint temperature setting.


Low Line Pressure Demand exceeds capacity.

Leaks in supply lines.

Reduce demands.

Increase capacity.

Check for leaks or open lines in air supply.

Repair as necessary.



30

Low Fluid Pressure Fluid filter clogged.

Sump fluid level low.

Low ambient temperature.

Fluid pump failure.

Replace fluid filter.

Replenish fluid to proper level.

Sump heater may be required in ambients below 40F (4C).

Fluid pump may be required for remote coolers.

Consult Sullair Factory Service.

Low Sump Pressure Bad sensor or connections. Machine may have failed to start.

Check pressure sensor, wiring and tubing. Check machine operation.

Low Temperature 1

Low Temperature 2

Low Temperature 3

Low ambient air temperature Sump heater may be required in ambients below 40F (4C).

Low Water Pressure Cooling Water Pressure below 10 psi (0.7 bar).

Check for closed valves or broken pipes.

Low Water Pressure Switch is shorted or open. Replace switch. Check wiring for shorts, arcing or loose connections.

Main Motor Overload Main Motor Overload Relay Tripped.

Reset overload after heater element cools down.

Check that compressor is properly configured.

Ensure load pressure is set below limit of compressor.


Maintenance A Service interval has expired.

Maintenance due.

Perform recommended maintenance and reset the reminder using WSPC.

Memory Error The controller I/O board has failed. Board replacement required. Contact Sullair Factory Service.

Not Commissioned Controller replacement Follow commissioning procedures to set up for the specific compressor package.

Option Input Option Input Run

User furnished switch has operated.

Check operation of optional device.

User Option Warning User furnished external phase relay protection relay has tripped.

Check operation of optional device. Refer to user supplied phase relay documentation and troubleshooting steps.

PortC Comm Error (C or E) Wiring fault between the controller and keypad

Check the cable and connections

Power Interruption Intermittent Control Power. Check line voltage and connections.

Pump Motor Overload Auxiliary Motor Tripped on Fluid Pump Motor

Reset auxiliary overload after element cools. Verify correct motor amps.

Check for loose connections.

Check motor starter contact for proper operation.




31

Pump Starter Contact Pump starter failed to operate. Faulty auxiliary contact.

Check starter and control wiring. Check contact and contact wiring.

Replace Battery Controller I/O backup battery is low.

Replace battery.

High Separator dP

Pressure Differential Across Separator High.

Plugged separator elements.

Pressure sensor failure.

Replace separator.


Sequence Comm Error Cable or connection fault between compressors.

Improper sequence adjustments.

Check wiring.

Check sequence settings of all compressors in the sequence.

Starter Main starter failed to operate.Faulty auxiliary contact.Momentary Line Power loss or brownout

Check starter and control wiring.Check contact and contact wiring.Check Line Power quality

UI Voltage too high Controller fault. Contact Sullair Factory Service.

UI Voltage too low Controller fault. Contact Sullair Factory Service.

High Plant Pressure Compressor failed to unload Check operation of the inlet valve and controls

User Option Warning User furnished switch has operated.

Check function of optional device.

HIGH VOLT SENSOR Controller fault. Contact Sullair Factory Service.

LOW VOLT SENSOR Controller fault. Contact Sullair Factory Service.

VSD1 Comm Fault Communications lost with the VSD Check connections to the VSD.

Check VSD control power and check for board faults.

VFD Overtemp Warns that the variable frequency drive is too hot

Ensure adequate ventilation Schedule cleaning before a High Temp fault occurs

VSD1 parameter error Controller commissioned incorrectly.

Incorrect VSD

Commission the controller per the machine nameplate

Replace with proper drive rating

VSD1 Response The A1000 drive is not responding to WS control.

Remove power for 1 minute Restore power for 1 minuteRestart the machine



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5.3 WS CONTROLLER FAULTS AND WARNINGS

5.4 MACHINE BEHAVIOR AFTER A POWER INTERRUPTION

If the compressor was faulted prior to the powerinterruption, the controller will resume the FAULTEDcondition and display the reason for the fault. Repair

the cause of the fault and press the STOP pad to reset the controller.

If the compressor was manually stopped prior to thepower interruption, the controller will return to themanually stopped mode. Press the START button tomanually restart operation.

If the restart timer is greater than zero AND thecontroller was in Automatic or Manual mode prior tothe interruption, the controller will resume that modeafter the restart timer expires. No key press isnecessary to restart the compressor.

5.5 INTERNAL BATTERY The WS Controller employs an internal battery thatmaintains the real-time clock and maintains the

integrity of the controller memory records whenpower is disconnected from the controller. For bestperformance, ensure that the battery is functioning.If the controller is operated with a drained or deadbattery, the time-of-day records will not work properlyand loss of recent records could occur. If recentrecords are lost due to an inoperative battery (orother reason), the controller will revert to the lastsaved versions of settings and records.

The internal battery is located inside the controller I/O module and will operate for several years withoutrequiring maintenance. When the battery voltagegets low, the controller will issue a Replace Batterywarning. Perform the following steps to replace thebattery.

1. Press the STOP pad to stop the com-pressor.


3. Open the controller enclosure and locate theI/O Control Module.

Parameter Type Sensor High LimitLow Limit Comment

Separator Pressure ^ Warning P2-P1+offset 10 psid offset for aftercooler or dryer

Sump Pressure Fault P1 135 psig 5 psig 100 psig machine

150 psig 5 psig 125 psig machine



165 psig 5 psig 100-140 psig VSD machine


Line Pressure Fault P2 125 psig 10 psig 100 psig machine






Air End Discharge TemperatureWarning T1 225 F 0 F

Fault T1 235/255F 0 F Time delayed/immediate


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4. Remove six screws from I/O Control Modulecover and remove cover.

5. Locate the internal battery. The battery islocated near one end of the I/O circuit board(usually oriented towards the top).

6. Remove the battery and replace with a bat-tery type BR2330.

7. Replace the cover, close the enclosure, fol-low normal startup procedures.

I/O Control Module

Remove Remove

Small I/O Control Module Circuit Board

Internal Battery Type BR2330

Large I/O Control Module Circuit Board

NOTES

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Section 6

35


VARIABLE SPEED DRIVE6.1 OVERVIEW The Sullair VSD drive application is custom designedfor operation of air compressors. All necessarycontrol functions are performed through the WSController keypad and WSPC software. The drivefunctions as a module on the WS Controllercommunications bus. WSPC provides detailedinformation about relevant drive status data andcompressor performance. Drive controls arecoordinated with internal compressor controls, andwith other Supervisor or WS controlled compressorsin sequenced systems. The WS Controller monitorsdrive performance to provide motor thermal andother protections in an easy-to-use, robust design.

6.2 INSTALLATION Refer to the VSD Installation and Service manualthat came with the compressor for installationinformation.

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NOTES

NOTES

37

Printed in the U.S.A.Specifications subject to change

without prior notice.E12EP

Always air. Always there.

SULLAIR CORPORATION3700 East Michigan Boulevard Michigan City, Indiana, 46360 U.S.A.

Telephone: 1-219-879-5451

WWW.SULLAIR.COM

Documents

WS Controller User Interface