WSPC 02250167-859 R01

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 currentas of its publication date, and applies tocompressor serial number:

and all subsequent serial numbers.

02250167-859 R01

200710010000

WSPC USER INTERFACE MANUALFOR THE WS CONTROLLER™

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 Industrial compressors and compressor electricalsystems are offered at regular intervals throughout the year at Sullair’s 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 CUSTOMER CARE TRAINING DEPARTMENT

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

www.sullair.com

- Or Write -Sullair Corporation

3700 E. Michigan Blvd.Michigan City, IN 46360

Attn: Service Training Department.

TABLE OF CONTENTSSECTION 1—SAFETY

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

SECTION 2—OVERVIEW 11 2.1 MANUAL CONTENTS 12 2.2 SYSTEM COMPATIBILITY 12 2.3 INSTALLING THE WSPC USER INTERFACE SOFTWARE 12 2.4 INSTALLING OR UPDATING THE FRAMEWORK 12 2.5 UNINSTALL THE WSPC SOFTWARE

SECTION 3—GETTING STARTED 13 3.1 ACCESS PRIVILEGES 13 3.2 STARTING THE SOFTWARE 14 3.3 WINDOWS® BASIC 15 3.4 CONNECTING THE PC TO THE CONTROLLER 15 3.5 CONNECTING / DISCONNECTING THE WSPC USER INTERFACE AND

THE WS CONTROLLER 17 3.6 THE WSPC DISPLAY SCREEN 17 3.7 COMPRESSOR STATUS BAR 18 3.8 FILE MENU 19 3.9 REPORT 19 3.10 COM PORT 19 3.11 ABOUT

TABLE OF CONTENTS

SECTION 4—DISPLAY DESCRIPTIONS 21 4.1 COMPRESSOR STATUS BAR 22 4.2 COMPRESSOR DATA DISPLAY (DEFAULT SCREEN) 24 4.3 MACHINE INFO DISPLAY 24 4.4 SERVICE DISPLAY 27 4.5 MAINTENANCE DISPLAY 28 4.6 DISTRIBUTOR INFORMATION 29 4.7 SEQUENCE SYSTEM DISPLAY 30 4.8 ADJUSTMENTS DISPLAY

SECTION 5—MENU BAR 39 5.1 FILE MENU—USER PROFILES AND PREFERENCES 43 5.2 REPORTS 44 5.3 COMMUNICATIONS PORT 45 5.4 INFORMATION ABOUT WSPC

SECTION 6—VARIABLE SPEED DRIVE (VSD) 47 6.1 VSD OPERATION 47 6.2 COMPRESSOR DATA TAB 48 6.3 VSD PERFORMANCE DATA 49 6.4 CLEAR RECENT DATA 49 6.5 DELIVERY HISTORY 50 6.6 SERVICE DISPLAY TAB 50 6.7 MAIN MOTOR VFD STATUS BOX 51 6.8 ADJUSTMENTS TAB 52 6.9 ADMINISTRATOR LEVEL VSD ADJUSTMENTS

SECTION 7—ADMININISTRATOR LEVEL FUNCTIONS 53 7.1 ADMINISTRATOR LEVEL FUNCTIONS 53 7.2 ACCESSING THE ADMINISTRATOR LEVEL 54 7.3 COMMISSIONING A CONTROLLER 56 7.4 MAINTENANCE DISPLAY 59 7.5 ADMINISTRATOR ADJUSTMENTS (ADMIN) DISPLAY 67 7.6 MODBUS FUNCTIONS 69 7.7 DRYER SETUP DISPLAY

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 also clothing away from couplings, fans andother 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.

10

BLANK PAGE

Section 2

11

WSPC USER INTERFACE MANUAL

OVERVIEWThe WSPC User Interface is a Windows-basedsoftware program that allows complete monitoringand control of Sullair air compressors equipped witha Sullair WS Controller. The software can monitor asingle compressor operating as an individual unit ormultiple machines connected in a sequence. TheWSPC program receives data about the compressorfrom the WS Controller, assigns control parametersto the controller, displays controller operatingcharacteristics including faults and warningmessages, and provides functionality that assists theuser with controller diagnostics.

2.1 MANUAL CONTENTS This manual describes the features and operation ofthe WSPC User Interface program. Part 1 coversmaterial pertaining specifically to persons operatingthe program with User Level access. Part 2 coversadvanced functions available to experienced usersand persons with Administrator Level access.

This manual describes WSPC software part number02250174-081 when operated with WS Controllersoftware 02250174-082 or later. This version ofWSPC is compatible with all previously releasedversions of WS Controller software, but certainfeatures described in this manual are not available inearlier versions.

Part 1:

Section 2: OVERVIEW provides the necessaryinformation to install the WSPC software. Includedare the minimum hardware and softwarerequirements.

Section 3: GETTING STARTED presents steps togetting the program up and running quickly. BasicMS Windows functions and those features necessaryto using the software are explained in this section.

Section 4: DISPLAY DESCRIPTIONS provides anexplanation of each display screen available to userlevel operators. Detailed descriptions of theoperation of each display component are provided.

Section 5: MENU BAR provides steps to setting userpreferences for operating the WSPC program. Thissection guides the user in creating and modifyinguser profiles.

Section 6: VARIABLE SPEED DRIVE (VSD)describes the WSPC functions that apply to VariableSpeed Drive compressors.

Part 2:

Section 7: ADMININISTRATOR LEVEL FUNCTIONSdescribes those functions that apply specifically toAdministrator level operators. Each administratorlevel display is presented and details of the displaycomponents are described.

Features of the WSPC User Interface softwareinclude:

• Two-way communication channel between the userand the compressor controller.

• A comprehensive view of the compressor control-ler’s operation at the WSPC interface.

• Adjustment of all modifiable parameters of the com-pressor controller.

• Ability to control the compressor remotely.• Access to data relating to all compressors con-

nected as a sequence system.• Password protection capabilities to limit access to

data and controls.• A data log feature which compiles operational, ser-

vice, and error data of the compressor or compres-sor system.

WSPC USER INTERFACE MANUAL SECTION 2

12

2.2 SYSTEM COMPATIBILITY • Before beginning the installation process, your

computer should meet the following minimumrequirements.

• PC–compatible computer (Pentium® IV based, 1.0Ghz processor recommended)

• Windows 2000 or Windows XP operating systems.Windows 2000 may require special processing soft-ware to properly operate the WSPC software.

• CD ROM drive• 125 Mb of available hard disk space• 256 Mb of available RAM memory• Color monitor• RS232 communications capability

2.3 INSTALLING THE WSPC USER INTERFACE SOFTWARE

Follow the instructions accompanying the WSPCInstallation package. The actual installation mediamay be CD, internet, network, USB drive, or othermeans, and the procedure will be specific to thatmedia. This installation will create a folder on yourdisk drive, and install the necessary files into thatfolder. Make a note of this location, as it may benecessary for future updates. The default location forall saved files will also be in that folder, but you maybrowse to save into any other location in your PC asdesired. By default, the folder will be "WSPC" and willbe located in a "Sullair" folder. Recommendedlocations are "C:\Sullair\WSPC" or"D:\Sullair\WSPC”.

2.4 INSTALLING OR UPDATING THE FRAMEWORK

The WSPC software requires the Microsoft .net®Framework support program in order to run on thePC. If Microsoft .net is already on the PC, you will beable to run as soon as the installation is completed.To install the framework, or update to the latestversion, use the following procedure for a freedownload.

1. Connect the PC to the internet.

2. Go to the site: www.microsoft.com/down-loads

3. Search for “.NET Framework”

4. Follow the instructions for downloading andinstallation.

2.5 UNINSTALL THE WSPC SOFTWARE

To uninstall the WSPC software:

1. Right-click any desktop shortcuts that werecreated.

2. Click “Delete” to delete the shortcut.

3. Open “My Computer” and browse to thefolder created in Section 2.3.

4. Delete the folder and its contents.

NOTEContact your network administrator if you are unable to perform the softwareinstallation due to access limitations.

Section 3

13


GETTING STARTED3.1 ACCESS PRIVILEGES The WSPC User Interface program may beaccessed at two levels.

User Level: Allows users to access the programwithout entering a password. The user should be anindividual with specific authorization to use theWSPC software and knowledge of the compressoroperation. This level includes all data andadjustments for normal applications of thecompressor. At this level a user has access to thefollowing displays: Compressor Data, Machine Info,Service, Maintenance, Sequencing, andAdjustments.

Administrator Level: This provides additionalfunctions for maintenance, service, and setup fortrained compressor technicians. Administrator levelfunctions are described in Part 2 of this manual. Apassword is required to access this level.

3.2 STARTING THE SOFTWARE 1. Click the shortcut located on the computer

desktop to start the WSPC User Interfaceprogram.

2. When the program opens, a dialog box willappear as shown in Figure 3-1. Click OK toopen the WSPC program. If the programwas last closed while operating at theAdministrator level the dialog box will requirea password as shown in Figure 3-2.

Do the following to select a user-level profile:

A. Click the down arrow next to the “User Name”box. A drop-down list of user profiles will be pre-sented. See Figure 3-3.

B. Click on a profile that is set for “User Level”access (Default User) and click “OK”. User levelprofiles do not require password access. Moreprofile options may be available in the UserName list than the ones shown in Figure 3-3.

Figure 3-1: WSPC User Interface password request

Figure 3-2: WSPC User Interface password request


14

The program will open to the “Compressor DataDisplay” with user level access. See Figure 3-4.From the opening screen the user may navigate to allother features of the program.

3.3 WINDOWS® BASIC This section presents basic MS Windows® functionsthat will be useful to using the WSPC program. Theactive presentations of information on the computerscreen are referred to as “Displays.” At the top of

each display is a tab showing the display title. Tomake a display active, click on the desired displaytab. See Figure 3-5. The active display allows theuser to see the data related to the tab title and toperform functions on the display page.

Figure 3-3: User Option

Figure 3-4: WSPC Opening Window – Compressor Data Display

SECTION 3 WSPC USER INTERFACE MANUAL

15

Some screens allow for entry of values into fields onthe screen. To enter data into a field:

A. Click in the field to be modified.

B. Select the data currently contained in the field (ifany). Data in a field can be selected by double-clicking on a character in a field. The entire datafield will be selected. Data can also be high-lighted for editing by holding down the left mousebutton and dragging the cursor across the data inthe field.

C. Type the new data into the field. Typing the newdata will replace the old data.

Typically an option can be chosen by pressing“Enter” on the computer keyboard. Some optionspresent a dialog box that allow the user to confirmthe entries by clicking an “OK” button or cancel theentries by clicking “Cancel.” A window can bereduced, expanded, or closed by clicking on therespective button located in the upper right corner ofthe display:

3.4 CONNECTING THE PC TO THE CONTROLLER

The standard connection of the PC Interface to theWS Controller is via a specially designed RS-232connector. This serial line connects to the computer’sDB9 socket and runs directly to a custom designedterminal located on the left side of the controllercabinet. The PC may also be connected to thecontroller by other means such as through RS-485connections or remotely via modem or wirelessnetwork.

3.5 CONNECTING / DISCONNECTING THE WSPC USER INTERFACE AND THE WS CONTROLLER

After the communication lines are attached and theWSPC software is running, the WSPC program canbe connected to the controller to begin receivingmachine operation data. Control data can also besent from the PC to the WS Controller to configurethe machine control parameters.

1. To establish connection between the WSPCand the WS Controller click

(“Connect” button)

in the status bar. The box left of the Connectbutton will appear bright green indicating theconnection is active. The software willsearch for communication from the control-ler, and fill the display with machine informa-tion.

2. During normal connection, communicationactivity will be shown on the bottom edge ofthe WSPC screen, as shown in Figure 3-7.The progress bar and block numbers simplyindicate that communications are occurring.The WS Controller also provides led indica-tors for communication near J13. Red indi-cates a request was received from the PC,Green indicates a message is being sent tothe PC.

Figure 3-5: User Interface display tab

Reduce Expand Close

Figure 3-6: User Option


16

3. If communication with the machine could notbe established, an error message will displayon the communication status line as depictedin Figure 3-8. If this occurs, check the RS-232 connection and other terminals forproper connection.

4. To disconnect communication between theWSPC and the controller, click on the “Con-nect” button. The box left of the button willchange from bright green to dark, shadedgreen, indicating that the WSPC is discon-nected from the controller. The controller willcontinue to operate according to the latestset of parameters entered.

Figure 3-7: WSPC User Interface Display Screen


User Profile Name

Communication Status Indicator

Logging Indicator

Menu Bar

Compressor Status Bar

Connection Button

Machine Operation Data and

Parameters

Title Bar


Display Tabs


17

3.6 THE WSPC DISPLAY SCREEN

The WSPC display screen consists of the title bar,the pull-down menu bar, the compressor status bar,display tabs, machine operation data display, and thecommunication status bar. Refer to Figure 3-9. Thedefault screen is the Compressor Data display whichappears each time the WSPC software is opened.Listed below are main elements of the screen displaythat enable the user to access and view the machineoperation data, and modify the machine controlparameters.

Title Bar—Contains the name of the WSPC softwareprogram.

"Menu Bar - Click to activate drop-down menus orother screens to select WSPC configurations.Section 5 provides additional details.

Connection Button—When activated, establishesconnection between the PC Interface and the WSController unit.

Compressor Status Bar—Located on the leftmargin of every display, the Compressor Status Barprovides real-time data of the machine’s currentoperation and condition. The Compressor Status Baris described in detail in Section 3.7.

Display Tabs—Allow for the selection of the desireddisplay. Section 4 provides a detailed description ofeach display screen.

Machine Operation Data—Area where the machineparameter data and operational information isdisplayed.

Communication Status Indicator—Located at thebottom of the display window, this line providescommunication status information.

User Profile Name—The name of the current userprofile is displayed. In Figure 3-9, the active profile isnamed “Default User”.

Logging Indicator—This field will light when the PCis recording data.

3.7 COMPRESSOR STATUS BAR The Compressor Status Bar, which is located left ofthe main window, displays real-time data regardingthe status of the compressor. The status bar isconstantly displayed whenever the WSPC softwareis connected to the controller. This feature allows theuser to quickly view the status of the compressoroperation regardless of which display screen isactive. Information presented in the status barincludes the compressor operating mode, operatingstate, compressor temperature, sump pressure, anddischarge pressure. See Figure 3-9.

The Compressor Status Bar can be displayed as astand alone compressor operation monitor as shownin Figure 3-10. The full display window can be hiddenleaving only the status bar information appearing onthe screen. This feature allows the user to continuemonitoring the compressor operation whileperforming other tasks on the PC.

To reduce the display to show only the status bar:

1. Place the cursor on the right border of theWSPC display window.

2. Press and hold the left mouse button.

3. “Drag” the display border to the left until itstops. The compressor data window will behidden leaving the status bar in the display.

4. To return to the full screen presentation, clickon the expand window icon in the upperright corner of the display.

5. To return again to the status bar only view,click on the reduce window icon in the upperright corner of the display.


18

3.8 FILE MENU The File Menu contains options that allow the user toconfigure and set preferences that control how theprogram functions. See Figure 3-10 From the “File”menu, the user can choose three options:

Profiles—Allows the user to create and edit profiles.A profile will contain settings that configure theWSPC program according to the operator or group’spreferences. The features of the Profiles menuoption are described in Section 5 of this manual.

Login—Presents the Login box which allows theuser to choose a profile from a list of available Userprofiles. See Figure 3-12.

Exit—Closes the WSPC User Interface program.Exiting the software does not affect the compressoror controller operation.

Communication Operating Mode

Communication Operating State

Communication Temperature Measurement

Sump Pressure Measurement

Communication Pressure

Discharge

Figure 3-10: Compressor Status Bar (Reduced)

File Menu

Figure 3-11: File Menu Options


19

3.9 REPORT This menu Item will request a folder location and filename in which to file a comprehensive service report.See Figure 3-13

3.10 COM PORT This provides a dialog to select the communicationsport of the PC on which the program is running. Thisis typically COM1, but your PC may be equipped withadditional ports. See Figure 3-15

3.11 ABOUT This provides information about the WSPC program.See Figure 3-14

Figure 3-12: Login Screen A

Figure 3-13: Report Dialog

Figure 3-14: About Information Box


20

Figure 3-15: Com Port Dialog

Section 4

21


DISPLAY DESCRIPTIONS4.1 COMPRESSOR STATUS BAR Located on the left edge of the WSPC User Interfaceprogram window, the Compressor Status Bardisplays information related to the compressorcurrent operation. See Figure 4-1. The informationappearing in the Status Bar is machine generated,view only data.

Above the Status Bar is a button that allows the user

to connect or disconnect communication between theWSPC and the WS Controller. Clicking the “Connect”button will alternately connect and disconnectcommunication between the software and thecontroller. An additional button (labeled Unload) mayappear in the Status Bar when the WSPC interface isconfigured to control the compressor operationremotely. Refer to Sequencing and Protocol Manualfor an explanation of this feature.

Compressor Operating

Mode

Operating State

Compressor T1 Temperature

Sump Pressure

Compressor Line Pressure

Controller Control Voltage

STATUS BAR

Figure 4-1: Default Screen: Compressor Data Display


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STATUS BAR COMPONENTS Listed below is the information that is displayed in thefields of the Compressor Status Bar.

Compressor Operating Mode—The OperatingMode is the manner in which the machine operationis being controlled. There are five Operating Modes:AUTOMATIC, MANUAL, OFF, FAULT, and UICOMM.

Operating State—The state of the compressoroperation in response to the current mode andcurrent conditions. The operating state essentiallydescribes what the machine is currently doing.

Compressor Temperature 1—The internaltemperature of the compressor.

Sump Pressure—The compressor sump pressure.

Line Pressure—The discharge pressure of thecompressor.

Control Volts—The actual voltage of thecompressor control supply.

Additional data may be displayed in the CompressorStatus Bar depending on user access level andmachine configuration. These include dryer dewpointtemperature and spiral valve modulation indicators.

4.2 COMPRESSOR DATA DISPLAY (DEFAULT SCREEN)

The “Compressor Data” display is the window thatappears when the WSPC Interface is initialized. SeeFigure 4-2. If the Compressor Data display is notshowing on the monitor, access the display byclicking on the “Compressor Data” tab. At this displaythe user can monitor compressor operatinginformation.

Machine Operation

Data

Figure 4-2: Compressor Data Display


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COMPRESSOR RUN DATA The information presented at the Compressor Datadisplay is described below.

Machine hours—Total number of hours thecontroller has been monitoring compressoroperation.

Compressor enabled hours—Total number ofhours the compressor has been enabled to run.

Motor running hours—Total number of hours thecompressor motor has been running.

Compressor loaded hours—Total number of hoursthe compressor has run loaded.

Compressor full load hours—Total number ofhours the compressor has run at full load.

Number of starts—Total number of times thecompressor has been started automatically ormanually.

Number of load cycles—Total number of loadcycles the compressor has completed.

DIGITAL INPUTS AND RELAY OUTPUTS The digital inputs and relay outputs indicate that asignal from an input/output device has beenreceived.

Digital Inputs—Each indicates that the input hasbeen activated by a machine action. When active,the box next to the input will be bright green in color.

E-stop—Indicates that an emergency stop switchhas been pressed. The E-stop is normally closed andthe box next to the E-stop input is bright green. Whenthe button is pressed, the E-stop input indicator willappear dark.

Relay Outputs—Each indicates that the output relayhas been activated by the controller. When active,the box next to the output will be bright red in color.

Inputs and outputs are assigned at the factory toindicate specific actions, and will vary with thecompressor model. Typical factory assignments ofinputs and outputs are as follows:

Digital Inputs: Definition Relay Outputs: Definition

Input 1: Main Motor Overload-Fault Input 2: Aux. Motor Overload-Fault Input 3: Starter Aux. Contact-Fault Input 4: NOT USEDInput 5: High Air Filter dP-Warning Input 6: High Fluid Filter-Warning Input 7: Remote Unload (Option) Input 8: Fault (Option)Input 9: Warning (Option)E-Stop: Emergency Stop Activated

Output 1: RunOutput 2: WyeOutput 3: DeltaOutput 4: LoadOutput 5: Full LoadOutput 6: DrainOutput 7: Fault Signal


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4.3 MACHINE INFO DISPLAY The “Machine Info” display presents informationrelating to the current compressor/controller modeland configuration. See Figure 4-3. This information isview only and cannot be changed by the operator.

The information presented in the “Machine Info”display is described below.

CONTROLLER SOFTWARE INFO

Version Date—Displays the date version of the WSController internal software.

I/O Version Pn—Displays the WS Controller I/O unitpart number.

U/I Version Pn—Displays the WS Controller UserInterface part number.

COMPRESSOR INFO

This information about the compressor package isrecorded during the WS Controller’s commissioning

Model—The model number

HP—Motor Horsepower

Pressure—Nominal pressure rating Hz – Line

frequency (50 or 60 Hz)

Cooling—Method of cooling (air cooled or watercooled)

Motor—The motor control (Y-delta, full voltage,variable -speed)

Volts—Nominal Starter line voltage

Dryer—Dryer type

4.4 SERVICE DISPLAY The Service display provides information related tocompressor events which require service actions. Ahistory of the 16 most recent fault messages aredisplayed on the service page along with informationdetailing the time and date of the fault occurrence.See Figure 4-4. The fault history can aid the user inidentifying related events and recurring problems thatmay cause machine malfunctions or limit operation.Refer to the WS Controller User Instruction Manualfor actions to be taken when a fault or warningcondition occurs. The first row of the fault listingsdisplays the most recent fault. Column one providesa description of the fault cause. Column two displaysthe number of hours the compressor has run when

Figure 4-3: Machine Info Display


25

the fault occurred. Column three shows the monthand day on which the fault occurred. The remainingcolumns display the time of day that the faultoccurred in hour:minutes:seconds.

The lower portion reports communication errorsbetween the WS controller and its User Interface,and between the WS controller and other controllersin a group of sequenced compressors. The upperbox, labeled "Up/Down Count" shows recentcommunication errors. The lower box shows thetotal number of communication errors.

SENSOR LOG BUTTON It is possible for the user to view the readings of up toeleven sensors during the last ten minutes leading upto a fault. While at the “Service” display screen, clickon the “Sensor Log” button (see Figure 4-5) to bringup the “Sensor Log.” This log, shown in Figure 4-6,displays each sensor reading in ten one-minutedecrements down to one minute before the last faultoccurred.

In the example shown, the log shows sensorreadings for Temperature 1, Sump Pressure, LinePressure, and Controller Voltage. The final minute of

sensor readings leading up to a fault is displayed in12 five-second decrements. The last sensor readingis at zero (0) seconds recorded shortly before thefault occurrence. Using this data a user or servicetechnician can observe the progression of a fault asan aid in diagnosing the problem. Refer to the WSController User Instruction Manual for actions to betaken when a warning or fault condition occurs.

Figure 4-4: Service Display

Figure 4-5: Sensor Log Button


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LOG DATA BUTTON WSPC may be used to log data about compressoroperation for extended periods. These files arestored in the PC. A line of data is stored at least onceper minute. Additional data lines are stored if anysignificant change occurs. A “Logging” indicator isbright green whenever logging is turned on. This isintended as an aid for troubleshooting. This reportmay be viewed as a text file, or imported into aspreadsheet for formatted analysis and graphing.

The data on each line includes:

1. The time of the record

2. The WS Controller operating mode

3. The compressor operating state

4. Digital input and Output condition (shown asa hex number)

5. Data from all 11 analog inputs, including tem-peratures and pressures

6. Data from the variable frequency drive.

To log data, click the "Log Data" button on theService page. A dialog box will be presented with thedefault folder location and file name. If desired,another directory can be selected and a descriptivefilename can be typed into the Filename field to savethe log data to a user specified location. Whenassigning a user specified location, be sure to note

Figure 4-6: Sensor Log Window

Figure 4-7: Saved Sensor Log File Example


27

the directory path and filename information so thatthe log data can be easily located later. Click the"Save" button to begin logging. To stop logging, clickon the "Log Data" button again on the Service page.

To view data, simply browse to the folder, and doubleclick on the file created. The data may be viewedwith any text editor. To create an Excel spreadsheet,right click on the file name, and select "Open With" >"Excel". This will put all the data into a worksheet forfurther analysis or formatting. In Excel, select allcolumns, then click on "Format" > "Column" > "AutoFit" to adjust columns to appropriate sizes for thenew data. When saving, Select "Save As" andselect a spreadsheet in "Save as Data Type". Referto the Help pages in Excel for more information onusing the data.

4.5 MAINTENANCE DISPLAY The Maintenance Display contains listings of recentWarnings and Recommended Service messagesthat have been displayed at the controller. SeeFigure 4-8. Also displayed are the hours remaining tothe next recommended service activity. When awarning message is displayed, the compressor willstill operate. However, the condition which caused

the warning must be resolved within a short period oftime to prevent a fault condition from occurring ordamage to the machine. Refer to the WS ControllerUser Instruction Manual for actions to be taken whena warning or fault condition occurs.

WARNING MESSAGES Warning messages that may appear on theMaintenance Display are listed below.

High Oil (Fluid) Filter dP—Indicates the fluid filterpressure differential is high. The fluid filter needs tobe checked or changed.

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

High Air Filter dP—Air filter pressure differential ishigh indicating that the air filter unit needs to bechecked or changed.

High Temperature 1, 2, or 3—CompressorTemperature at the specified temp probe location isapproaching the set high limit.

Low Temperature 1, 2, or 3—CompressorTemperature at the specified temp probe location isapproaching the set low limit.

Figure 4-8: Maintenance Display


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Power Interruption—An interruption in power to thecompressor has occurred.

Sequence Comm Error—Communication problemexists between the compressor controllers set up forsequential operation.

User Warning—A user furnished switch has beenactivated.

Low Computer Battery—Indicates that thecontroller internal battery is low and needs to bereplaced.

Dryer Warning—Indicates that the compressorsystem dryer needs to be serviced. Refer to the WSController Instruction Manual for additionalinstructions on actions to be taken when warningconditions exists.

The following warnings apply to optionalconstruction. If these occur, refer to the machinemanuals for additional information.

VFD Overtemp—indicates that the variablefrequency drive is operating near its design limit.Check for unrestricted flow of cooling air, and keepambient temperatures below the design rating.Check the heatsink for dust or dirt buildup, and cleanif necessary.

Dryer Relay Fault—indicates that the dryer'sinternal protection has tripped.

Dryer Overload Fault—indicates that a dryer'smotor overload relay has tripped.

Dryer High DP Fault—indicates very hightemperatures that caused a dryer fault.

Dryer Low DP Fault—indicates very lowtemperatures that cause a dryer fault.

High Dryer Dewpoint—indicates dryer operationnear the high temperature limit.

Low Dryer Dewpoint—indicates dryer operationnear the low temperature limit.

SERVICE REMINDERS Service Reminders may inform the user that aparticular component of the compressor isrecommended for servicing. An Administrator mayset service intervals and reset the service reminders.The following service reminders can appear underthe “Recommended Service” heading:

Oil (Fluid) Filter Change—The compressor fluidfilter life interval has expired. Change the fluid filter

within the time frame noted in the machine operationspecifications.

Separator Change—The compressor fluid separatorlife interval has expired. Change the separator withinthe time frame noted in the machine operationspecifications.

Air Filter Change—The compressor air filter lifeinterval has expired. Change the air filter within thetime frame noted in the machine operationspecifications.

Oil (Fluid) Analysis—Fluid analysis interval hasexpired. Schedule the compressor fluid analysis permachine operation specifications.

Oil (Fluid) Change—The compressor fluid lifeinterval has expired. Change the compressor fluidwithin the time frame noted in the machine operationspecifications.

Other Maintenance—Other periodic maintenanceshould be performed as scheduled per machineoperation specifications. The “Interval” fields showthe recommended hours remaining until the nextservicing is due for the above listed items. A zerovalue indicates the reminder is disabled.

4.6 DISTRIBUTOR INFORMATION

Distributor Information can be accessed by clickingon the “Distributor Info” button on the “CompressorData” display. A window will appear, similar to Figure4-9, presenting previously entered information. Enteradditional information here as desired in the lowerpane.

Figure 4-9: Distributor Information


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4.7 SEQUENCE SYSTEM DISPLAY

The status of compressors connected in sequencecan be viewed at the Sequence System Display. SeeFigure 4-10. The top line of the Sequence SystemDisplay shows the total system pressure. Thesequence information contained in the table candisplay compressor data for up to sixteen machinesin a sequence. The compressors are listed down theleft side of the sequence information table in order ofcom number. Refer to the Adjustments Displayscreen to verify the com number and sequencingmode of the current machine.

Status—displays the operating state of eachcompressor in the sequence. The sequence statedescribes the operational role a machine isperforming as a part of the sequence. The variousstates that may appear in the “Sequence status”column are:

Starting—Indicates the compressor is starting up.

Full Load—Indicates the compressor is fully loaded.

Trim—Indicates the compressor is operating as thetrim machine in the sequence.

Loaded—Indicates the compressor is runningloaded.

Unloaded—Indicates the compressor is runningunloaded.

Manual Stop—Indicates the compressor is stoppedby the operator.

Remote Disable—Indicates the compressor isremoved from sequencing remotely.

Remote Stop—Indicates the compressor has beenstopped remotely.

E-Stop—Indicates a compressor fault.

Mode—displays the Operating Mode of eachcompressor in the sequence. The mode is themanner in which the machine’s operation is beingcontrolled. When running and operating normally, acompressor’s operating mode will be either “Manual”or “Automatic” as selected by the user. Other modesare “Stopped” when the machine’s operation hasbeen stopped and “Faulted” when a fault hasoccurred.

Hours—displays the sequence hours of a particularcompressor. Sequence hours are the number ofhours set for a machine to run in sequence. This

Figure 4-10: Sequence System Display


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parameter can be adjusted at the AdjustmentsDisplay to assign the compressor to run in a specificorder in the sequence system. When the operatingmode is set to Automatic, the machine with thelowest number of sequence hours will be the next tostart and the machine with the highest number ofsequence hours will be the next to stop.

PSI—displays the output pressure of the relatedcompressor. This may be displayed as BAR or Kpadepending on user profile preferences. Thismeasurement is taken at the P2 pressure transducerof the compressor and may be a different value thanthe overall system pressure.

ACFM—shows the capacity of the specificcompressor. Capacity is the volume of air in cubicfeet per minute (cfm) being delivered by thecompressor.

Remote—indicates whether the compressoroperation is being controlled remotely (including

sequencing control) or by the local controller only.

Service—displays “Yes” when the compressor is inneed of service. This indication is accompanied byeither a service reminder or warning message toinform the user of the nature of the service required.Refer to the WS Controller Sequencing and ProtocolManual for details on operating compressors insequence.

4.8 ADJUSTMENTS DISPLAY Both the compressor control parameters andsequencing parameters can be edited at theAdjustments display of the WSPC User Interface.SeeFigure 4-11. At this display the user can view thecurrent settings of the machine control parametersand make adjustments as necessary. Changes to thecontrol parameters will be reflected at the WSController located on the compressor.

Figure 4-11: Control Parameter Adjustments Display


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ADJUSTING CONTROL PARAMETERS Listed below are the control parameters that can beedited by the user at the “Adjustments” display. Theunits and language appearing in the “Adjustments”display correspond to the settings applied when theUser Profile was created. The WSPC must beconnected to the controller (by clicking the “Connect”button) before parameter changes are allowed.

Many changes to the control parameters at theWSPC interface will be reflected in the WS Controllerdisplay on the compressor. However, thecompressor list is intentionally short, and limited toadjustments that might be made frequently.

When a parameter change is made at the WSPCinterface, the corresponding change appears at thecontroller after “Enter” is pressed on the PCkeyboard or the cursor is positioned outside of thechanged field. Likewise, a change made at the WSController unit causes the corresponding value tochange at the WSPC interface.

To edit a control parameter value:

1. Select “Connect” in the Status Bar to connectcommunication between the WSPC interfaceand the WS Controller. Connection must beenabled before adjustments can be made atthe Adjustments Display.

2. Click in the field of the parameter to bechanged and delete the current value. Adouble-click in the parameter field will high-light the entire value. When the parametervalue is highlighted, typing over the currentvalue will delete it and replace it with the newvalue.

3. Type the new value into the selected field.

4. Press “Enter” on the PC keyboard or clickthe mouse cursor on a different item. Theparameter value will turn red to indicate thatthe request has been made.

5. If the request is valid, the new setting willnow be active (indicated by the color changefrom red to black). If the parameter is invalidor out of range the color will change to blackand the parameter will return to its previousvalue.

ADJUSTABLE CONTROL PARAMETERS The following three settings affect the compressor’sresponse to line pressure. The compressor starts todeliver air to the system whenever pressure falls

below the “Load” pressure and stops delivering airwhenever pressure rises above the “Unload”pressure. “Load delta” is the difference between thetwo”.

(Load Delta) = (Unload pressure) – (Load pressure)

Unload Pressure—Line pressure setpoint (psi, bar,or kpa) at which the compressor will unload and stopdelivering air. When the Unload Pressure ischanged, the Load pressure will usually be heldconstant, and the Load delta pressure differential willchange automatically.

Load Pressure—Pressure (psi, bar, or kpa) at whichthe compressor motor will start and the compressorwill begin to deliver air. When the Load Pressure ischanged, the Unload pressure will usually be heldconstant, and the Load delta pressure differential willchange automatically.

Load Delta—The pressure differential (psi, bar, orkpa) below the unload pressure at which the machinewill begin loading. When the Load delta Pressuredifferential is changed, the Unload Pressure willusually be held constant, and the Load pressure willbe adjusted automatically.

VSD Setpoint Pressure— Available only with VSDequipped machines. The targeted pressure for thevariable speed controls. This is normally adjustednear the bottom of the load/unload band. The speedwill be adjusted to maintain this pressure. Mostpackages will allow adjustment of this over a widerange to allow tailoring of the pressure to the needsof the application. Adjustments will be automaticallymade to the maximum speed to operate the motor atits full capacity at any pressure.

Unload Time (seconds)—Set this to the time thatthe machine is to run unloaded in Automatic modebefore shutting off. This value is displayed in units ofminutes at the WS Controller.

Drain Interval (seconds)—Set this time as thedesired interval between activation of the drain cyclefor machines equipped with an electric solenoiddrain. This value is displayed in units of minutes atthe WS Controller.

Drain Time (seconds)—Set this time as the numberof seconds that the drain is to remain energized.

Restart Time (seconds)—Set this time to thedesired number of seconds before auto restart is tooccur on power up. Set it to zero (0) to disable autorestart.

Wye-Delta Time (seconds)—Set this as the time for


32

the wye to delta starter transition. This can also beused to control the closed inlet valve with other motorcontrols.

Cost per KWH—Available only with VSD equippedmachines. Sets the KWH cost value, in dollars orother currency, used in operating cost calculations.

Modulation—Assigns the manner in which themachine will be delivering air (Load/Unload orModulate).

Mode—Assigns the desired mode for controlling thecompressor motor operation (Automatic or Manual).

ADJUSTING SEQUENCE PARAMETERS This group of adjustments set the controller foroperation with other Sullair compressors or forremote control. Refer to the WS ControllerSequencing and Protocol Manual for the principles ofoperating compressors in sequence. Section 4.6 ofthis manual describes the features of the SequenceSystem Display which allows the user to monitor theoperation of all the compressors connected insequence. To configure a machine for sequencingoperation:

1. Click in the “Sequence Mode” field to selectthe mode by which sequencing of the com-pressor is to be controlled. See Figure 4-12.

a. Select “Disabled” when no sequencingis desired. The machine will not operatein sequence with other machines. Thecompressor can still be operated as astand alone machine.

b. Select “Remote” when the compressoris to be controlled remotely by the PC or

other remote connection.

The Administrator may set the controllerfor remote unloading via modbus. If so,an additional button labeled “Unload” willappear under the “Connection” button inthe Status Bar when “Remote” mode isselected. See Figure 4-13.

When active, the allows the Load/Unloadoperation of the compressor to be manu-ally controlled. A bright yellow box nextto the Unload button indicates that themachine is being forced to unload. Whenthe button is inactive, indicated by adarkened yellow box next to the button,the machine will operate normally.

c. The “Slave” mode is not currently usedin this version. When selected, the con-troller will behave the same as if “Dis-abled” is selected.

Figure 4-12: Sequence Parameters

Figure 4-13: Unload Button During Remote Operation


33

d. Select “Hours” if the compressor is setto run in a sequence based on themachine’s sequence hour meter.Sequence hours can be adjusted tocause the compressor to run in a specificorder in the sequence.

e. Select “COMM Number” if the compres-sor is to sequence in an order based onthe communication number assigned tothe machine.

2. If desired, click in “Sequence hours” to pre-set the order the machine is to run in asequence operation based on its hour meter.

3. Click in “Com number” to select a uniquecommunication number in relation to othermachines in a sequence system. The high-est com number for the compressor can beno greater the maximum number ofmachines set in the Machines field (step 4).This also sets the order the machine is to runin a sequence operation based on the com-munication number assigned to the machine.

4. Click in “Machines” to set the total numberof machines in the sequence configuration.The maximum number of machines that canbe connected in a sequence consisting ofWS Controllers and/or Supervisor Control-lers is 16. The maximum number ofmachines that can be connected in asequence that contains at least one Supervi-sor II Deluxe Controller is eight.

5. Click in “Low press” to set the lowest allow-able system pressure before a machine inthe sequence has to start. The minimumvalue for the Low pressure setting is 30 psi.

6. Click in “Recover time” to add a delay, inseconds, between subsequent start, load,and unload actions of machines insequence. The minimum value for theRecover time is 2 seconds and the maximumis 60 seconds.

7. Click in “Rotate” to set the time that a com-pressor will force a rotation betweenmachines. This should be used for two-machine systems only. Set to 0 to disable.Typical forced rotations are daily or weekly.

8. Click in “eConnect ID” to provide a namethat enables communication for eConnectcommunication. Each machine should havea unique identification between 1 and 16.

9. Click in “Modbus address” to enter a mod-bus address for the compressor modbuscommunications on the RS232 port. Theaddress may be between 1 and 247. Thedefault value for the WS Controller and forWSPC software is 1. This change takesaffect after the controller power is cycled offand on.

CHANGING CONTROLLER UNITS AND LANGUAGE PREFERENCES

The WSPC Interface program allows the user tochange display preferences of the WS Controller.The units of measure for pressure and temperature,and language preferences can be changed at the“Adjustments” display of the WSPC User Interfaceprogram. These changes are reflected in the WSController display.

To change the WS Controller Display preferences:

1. Change the UI Pressure unit of measure byclicking the drop-down arrow and selectingthe desired unit: PSI, Bar, or kPA. See Figure4-14.

2. Change the UI Temperature unit of measureby clicking the drop-down arrow and select-ing the desired unit: Deg F or Deg C.

3. Change the Language preference by clickingthe drop-down arrow and selecting thedesired language: English, French, Spanish,German, or Italian.

NOTEThe Modbus address assigned here must match the modbus address assigned in the WSPC User Profile or other Modbus applications. If the ID’s do not match, communication between the PC and the controller will be lost when the controller is cycled.


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TIME AND DATE ADJUSTMENTS Synchronize Time and Date with PC Clock

The date and time of the WS Controller internal clockcan be synchronized with the PC clock at the“Adjustments” display.

To synchronize the clocks, click on the “Synch withPC clock” button. See Figure 4-15. The program willautomatically adjust the controller clock and calendarto the same time as the computer clock.

Manual Time/Date Adjustment

The WS Controller date and time can be manuallyadjusted when synchronizing the controller with thePC is not desired. Follow the steps below tomanually adjust the time and date settings.

To adjust the time setting:

1. Double-click in the hour field to select thehour value.

2. Type the hour of the day in 24 hour format.

3. Double-click in the minutes field and type thecurrent minutes on the hour.

4. Double-click in the seconds field and typethe current seconds.

5. Press Enter. The new set time will beassigned to all logs and data generated bythe WS Controller.

NOTEChanges to the WS Controller user inter-face preferences do not affect the display of units and language in the WSPC soft-ware. WSPC preferences are set as User Profiles.

Figure 4-14: Units and Language Preferences

Click to Synchronize

with PC Clock

Time Field Hours:Minutes

:Seconds

Figure 4-15: Time and Date Adjustment


35

To adjust the Date setting:

1. Click the arrow at the edge of the monthfield. The Month popup list will appear.

2. Select the current month.

3. Double-click in the Day field and enter thecurrent day of the month.

4. Double-click on the Year field and enter thecurrent year using four digits.

5. Press Enter on the PC keyboard. The newdate setting will be assigned to all logs anddata generated by the WS Controller.

COMMUNICATION PARAMETERS Communication Parameters control the transmissionof data to and from the WS Controller via an RS-485serial interface. These settings allow the controller tobe configured to communicate with a device havingRS-485 capabilities. The RS-485 configurableparameters are listed below. See Figure 4-16.

Modbus Address—Click in “Modbus address” toenter a modbus address for the compressor modbuscommunications on the RS485 port. The addressmay be between 1 and 247. This change takes affectafter the controller power is cycled off and on.

Baud Rate—The rate of data transmission in bits persecond. The overall range is 1200 to 57,600 baud.The default baud rate is 19200 bps.

Parity—Data checking method for verifying accuracyof data transmission. Parity options for data checkingare odd, even, none. The default setting is “Even.”

INTERNET TRANSMISSION SETTINGS Some controllers may be configured to allow accessand transmission of data via the internet. Thesesettings have no effect on standard controllers. TheTCP/IP parameters are:

IP Address—The unique address the WSPC will useto identify and communicate with another computervia the internet or other network utilizing the InternetProtocol standard.

Net Mask—used to determine what subnet an IPaddress belongs to.

Name Server—computer server that implements aname service protocol used to correlate the servername with the IP address.

Gateway—The access address allowing data topass to and from the network.

Figure 4-16: Port E (RS-485) Parameters

NOTEThe Modbus settings assigned here must match the modbus settings assigned in the WSPC User Profile or other Modbus applications. If the settings do not match, communication with the controller will be lost when the controller is cycled.


36

SAVING PARAMETER SETTINGS The settings for the current control parametersdisplayed on the Adjustments display can be savedto a file which can be accessed and loaded to theWS Controller at a later date.

To save the current parameter settings:

1. Access the “Adjustments” display by clickingon the “Adjustments” tab.

2. Click the Load/Save button on the “Adjust-ments” display. See Figure 4-17.

3. The “Machine Profiles” window will appear.

4. Click “Read from Controller” to load the cur-rent parameter settings from the controller tothe WSPC.

5. The program will read the settings from thecontroller, and will generate a new profile.The new name will appear on the list as a“New Profile”

EDITING AND SEARCHING MACHINE PROFILES The descriptions may be edited to make searchingeasier. This is helpful if many profiles are saved onyour PC.

1. Click on a profile to select it.

2. Click the “Edit” button.

3. Click in the Category 1 or Category 2descriptions at the top of the page, and editas desired. See Figure 4-18.

4. Click the “Save Edits” button. To sort and/orfilter the Machine Profile name list:

a. Sort a column by clicking in the topspace above of a column by which val-ues are to be sorted. One click will sortthe column in ascending order. A secondclick will sort the column in descendingorder. Click the “Clear Sort” button toclear all sorting.

b. Filter a column by clicking on the expan-sion arrow in the space above the col-umn containing the filter criteria. Thearrow will present a list of the contents ofthe column. Select the item in the list bywhich the column is to be filtered. Clickthe “Clear Filter” to show all profiles.

c. Delete a Machine Profile by clicking onthe profile name and then clicking“Delete.” A confirmation dialog box willappear. Click “Yes” to confirm deletion or“No” to cancel.

Figure 4-17: Load/Save Button


37

LOADING PARAMETER SETTINGS At the “Machine Profiles” window, control parametersfrom a saved profile can be loaded to the WSController. The values stored in the saved profile willreplace the parameter values displayed on theAdjustments display. When an adjustment register isloaded, the new parameter values becomeimmediately effective at the WS Controller.

To load a saved Machine Profile:

1. Access the “Adjustments” display by clickingon the “Adjustments” tab.

2. Click the Load/Save button on the “Adjust-ments” display (Figure 4-17).

3. Click on the Name of the saved machine pro-file to be loaded. Saved Machine Profiles arelisted in the lower portion of the MachineProfiles window. The control parameter val-ues for the selected profile will be shown inthe upper portion of the window. These val-ues are presented for reference only andcannot be edited.

4. Click “Write to Controller” to load the param-eters of the selected profile to the WS Con-troller. The parameters will immediatelybecome active at the controller and the com-pressor and/or compressor system will beginoperating using the new parameter values.

Figure 4-18: Machine Profiles Window

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BLANK PAGE

Section 5

39


MENU BAR5.1 FILE MENU—USER

PROFILES AND PREFERENCES

User Profiles are used to configure the WSPCsoftware for a specific user or group of users.Settings made in a profile only change theappearance and action of the software program anddo not affect the operation of the WS Controller orcompressor. The User Profiles option allows theoperator to view profile settings, modify a profile,create a new profile, save current settings as a newprofile, and switch profiles.

USER PROFILE OPTION To view the preferences of the current runningprofile:

1. Click “File” in the menu bar (Figure 5-1).

2. Select “Profiles”. The User Profiles windowwill open displaying settings for the currentprofile. See Figure 5-2.

3. To see the settings of a different profile, clickthe name of a profile to be viewed from thelist in the lower half of the window. The set-tings for the selected profile will be pre-sented in the fields in the upper section ofthe window.

4. The “User Name” displays the name of theactive profile. The name can be an individualname, group name, machine, etc.

5. The “Notes” field displays information relat-ing to the profile entered when the profilewas created.

6. The “Language” field displays the currentlanguage setting for the WSPC displays.

7. “Units” settings display the units of measuredisplayed by the WSPC software. Setting ofthe units here will not affect the units dis-played on the WS Controller interface. Thefollowing unit settings are available.Pressure—Displays pressures in units ofPSI, Bar, or kPa.

Temperature – Displays temperatures inunits of Deg F or Deg C.

Flow—Displays air flow in units of ACFM,M3/hr, M3/min, L/min, and L/sec.

Power—Displays power in units of KW orHP.

Volume—Displays volume in units of KCF,Feet3, Gallons (US), Liters, M3, and KM3.

8. Under “Communication Port” the settingsthat control communication between the WS

Figure 5-1: Profiles Menu Selection


40

Controller and the WSPC software can beviewed and modified as necessary. All fourmust be set properly for the programs tocommunicate. The following communicationparameters can be adjusted from the UserProfiles window:

Modbus Address—displays the modbuscommunication ID. The default modbus IDvalue is 1 in the WS Controller, but is adjust-able.

Com Port—This is the PC’s communicationtransmission channel through which data ispassed to and from the computer.

Baud Rate—The communication speed inbits per second between the WS Controllerand the PC interface. RS232 communica-tions of the WS Controller is always 38400

Baud. RS485 is 19200 Baud by default, butis adjustable.

Parity—The method used for checking theaccuracy of the flow of data between thecomputer and communication devices. Theparity setting helps to determine if a trans-mission error has occurred between devices.RS232 communications of the WS Controlleris always “None.” RS485 communication is“Even” by default, but is adjustable.

When done viewing the profile settings, clickcancel to exit the profile window. The “EnterPassword” option box will be presented. SeeFigure 5-3.

9. Select a profile and click OK to make theprofile active.

Figure 5-2: User Profiles Window


41

EDIT A PROFILE To edit an existing profile:

1. Click “File” on the menu bar.

2. Select “Profiles”. The User Profiles windowwill be presented showing the settings for thecurrent profile.

3. Select a profile for editing from the list in thelower portion of the User Profiles window.

4. Click “Edit” to allow editing of the profile onthe upper part of the scrren.

5. Change the profile name” by entering a newname in the “User Name” field. See Figure 5-4.

6. In the “Notes” field, enter a brief note relatingto the compressor system.

7. In the “Language” field, click on the dropdown arrow and select the desired languagefor the WSPC software.

8. Select the desired “Units of Measure.” Thesesettings determine the units of measure to bedisplayed by the WSPC software. Unitsselected here will not affect units displayedon the WS Controller user interface.

a. At the “Pressure” field, click on the drop-down arrow and select the pressure unitas PSI, Bar, or Kpa.

b. At the “Temperature” field, click on thedrop-down arrow and select the temper-ature unit as Deg F or Deg C.

c. At the "Flow" field, click on the drop-down arrow and select the air flow unitas ACFM, M3/hr, M3/min, L/min, L/sec.

d. At the "Power" field, click on the drop-down arrow and select the power unit asKW or HP.

e. At the "Volume" field, click on the drop-down arrow and select the volume unitas KCF, Feet3, Gallons (US), Liters, M3,and KM3.

9. Select the desired “Communication Port”settings. These settings control communica-tion between the WS Controller and theWSPC software.

a. At the “Modbus Address” field, click theup/down arrows to increment to therequired modbus communication ID. Thedefault modbus value is set to 1. Thisnumber should be changed only if themodbus interface has been configuredfor a different port.

b. At the “Com Port” field, enter the numberof the communication port to use for con-necting to the PC. There are 16 com portoptions listed. The actual number of comports available will vary depending onthe computer system being used. Thedefault Com Port is set to 1

Figure 5-3: Select Profile (Password Box)

NOTEThe Modbus Address, Baud Rate, and Parity assigned here must match the modbus parameters of the controller. If the settings do not match, communica-tion between the PC and the controller will not occur.


42

c. At the "Baud Rate" field, click on thedrop-down arrow and select the desiredBaud Rate for data transmission. Theoverall range is 300 to 57,600 baud. TheWS Controller RS232 baud rate is 38400bps.

d. At the "Parity" field, click on the drop-down arrow and select the desired Parityoption for data checking: odd, even,none. The WS Controller RS232 settingis “None.”

10. When all edits are complete, click “SaveEdits” to save the modified profile to memory.Clicking cancel will discard changes to theprofile and exit.

11. Click the “close window button” in the upperright corner of the window to exit the UserProfiles window.

The edited profile will not become the active

profile until the it has been activated select-ing the desired profile at the “Enter Pass-word” box. Refer to Activate a Profile.

COPY A CURRENT PROFILE TO A NEW PROFILE The preferences of the current running profile can becopied to a new profile with a different name. Whenselected, the preferences of the current profile will bepresented in the fields of the new profile. The usercan keep all the profile settings or make changes toany of the profile preferences, and save the newprofile with a unique name.

To copy an existing profile as a new profile:

1. While in the User Profiles window, select anexisting profile with the same user level.

2. Click the “Copy” button.

3. In the “User Name” field, enter the new nameof the profile to be saved. The name can be

Figure 5-4: Edit Profile Window


43

an individual name, group name, machine,etc.

4. Make changes to the preferences in the pro-file window as necessary. Edit a Profiledetails the steps to entering profile prefer-ences.

5. When the profile information has been com-pleted, click “Saved Copied Profile” to savethe profile.

6. Click the “close window button” in the upperright corner of the window to exit the UserProfiles window. The edited profile will notbecome the active profile until it has beenactivated selecting the desired profile at the“Enter Password” box. Refer to Activate aProfile.

ACTIVATE A PROFILE A profile can be made active using the “Profiles”option. To activate a profile:

1. Click “File” on the menu bar.

2. Select “Login”.

3. The “Enter Password” box will be presented.See Figure 5-5. At the User Name field, clickthe down arrow to display a list of availableprofiles.

4. Click on the desired profile from the list pro-vided. If an Administrator profile is selected,a password will be required for access.

5. Click “OK” to activate the selected profile.Clicking “Cancel” will close the WSPC pro-gram.

5.2 REPORTSWSPC may be used to generate a comprehensivereport of the controller's setup and machine history.These reports are small files that may be filed forfuture reference, emailed, or pasted into otherdocuments. They may be viewed with any commontext editor.

CREATE A REPORT To create a new report for the compressor:

1. Click "Report" on the menu bar. A "Save As"box will open (Figure 5-6).

2. Select the folder location to save the report.This is similar to any Windows(c) application.The large buttons on the left may be used tostart browsing on a computer. The little but-tons to the right of the "Save in:" box may beused to browse through folders. The largebox shows other similar documents that arein the selected folder.

3. Type in the desired File name. This is"Report.txt" in Figure 5-6. Any Windows(c)-permitted name may be used, but alwaysend it in .txt so that it can be automaticallyopened later.

4. Click "Save". Messages will appear todescribe the progress.

NOTEA new profile cannot be given the same name of an already existing profile.

Figure 5-5: Switch Profile (Password Box)


44

VIEWING A REPORT 1. Browse to the folder that holds the report.

Use the "My Documents" or "My Computer"browsers provided with Windows(c).

2. Locate the report file. If it ends with ".txt",simply double-click it to open. Most PC's areset up to use "Notepad" as the text file editor.See Figure 5-9.

3. Use the menu "Format" > "Font" to select asuitable font for viewing. Text reports aregenerally best when viewed with a fixed font."Courier New" and "8pt" are a good selectioninitially.

4. This is a text version of the on-screen infor-mation normally viewed with WSPC. Referto sections of this manual for a completedescription.

5. Additional text may be inserted by clicking onthe desired point in the report, and simplytyping. When complete, click "File" > "Saveas", and give the file a new name to preservethe original data.

5.3 COMMUNICATIONS PORT Use the "Com Port" menu item to select differentcommunications ports on the PC. In most cases, aPC will use its first communications port (COM1) asthe connection to external devices like the WScontroller. However, some PC's may have additionalports already assigned to other devices. WSPCmust be set up with the number of the PC port that isbeing used to connect to the WS controller. Whenthis is done, the new port will be saved in the activeuser profile.

To select a different port:

1. If the "Connect" indicator in the left bar isbright green, click on the connect button todisconnect WSPC.

2. Click on the "Com port" menu item. See Fig-ure 5-7.

3. WSPC will search and list the ports availableon the PC

4. Click to select the port being used for thecable to the controller.

Figure 5-6: Report


45

5. Click OK

6. Click the "Connect: button on the left pane tostart communications with the controller.

5.4 INFORMATION ABOUT WSPC

Click on the "About" menu item to find informationabout the WSPC program. This includes the defaultfolder location used for the program and its files. SeeFigure 5-8.

Figure 5-7: Com Port Menu Figure 5-8: About Information Box


46

Figure 5-9: Report.txt

Section 6

47


VARIABLE SPEED DRIVE (VSD)

6.1 VSD OPERATION Generally the WSPC functions operate in the samemanner for VSD machines as with non-VSDmachines. When a VSD compressor is connected tothe WSPC, the program provides additionalfunctionality for monitoring and controlling VSDoperation. This section defines those additionalWSPC functions that are available for VSDcompressors.

6.2 COMPRESSOR DATA TAB When a VSD machine is connected to the controller,additional VSD related parameters are displayed atthe Compressor Data screen. See Figure 6-1. Thedata shown indicate current, recent and lifetimeperformance of the VSD compressor package.Lifetime data are averages or totals since the timethe compressor was commissioned. Recent data areaverages and totals since the last reset. Current datashow instantaneous flow rate and power estimates ofthe compressor package.

VSD Performance

Data

Figure 6-1: Compressor Display Tab – VSD Compressor


48

6.3 VSD PERFORMANCE DATA Figure 6-2 shows a sample display of VSDperformance data for a compressor operating undernormal conditions. A description of the VSD data ispresented below:

Capacity indicates approximately how much air isbeing delivered by the compressor package in CFMand percent of the compressor's full capacity. TheCurrent data is updated frequently and shows theinstantaneous delivery rates. Recent shows therecent average since the Clear Recent Data buttonwas clicked and Lifetime shows the average sincethe machine was commissioned.

Capacity % shows approximately how much air isbeing delivered by the compressor package as apercentage of the compressor's full capacity. TheCurrent data is updated frequently and shows theinstantaneous delivery rates. Recent shows therecent average, and Lifetime shows the averagesince commissioning.

Power indicates the amount of power being used to

operate the VSD compressor. The power ispresented in kilowatts (KW) approximating thecompressor’s total power usage. The Current powerdata is updated frequently and shows theinstantaneous power usage rates. Recent shows therecent power usage average, and Lifetime shows theaverage power usage since the machine wascommissioned.

Power % shows the amount of power being used tooperate the VSD compressor expressed as apercentage of the compressor’s estimated usagewhen operating at full capacity. The Current powerdata is updated frequently and shows theinstantaneous power usage rates. Recent shows therecent power usage average, and Lifetime shows theaverage power usage since the machine wascommissioned.

Hours indicates the amount of time (in hours andminutes) that the machine has been operated sincethe Clear Recent Data button was clicked for Recentand since the machine was commissioned forLifetime.

Figure 6-2: VSD Performance Data


49

Total Delivery indicates the estimated total amountof air delivered since the last reset for Recent dataand since the machine was commissioned forLifetime data; measured in thousands of cubic feet(KCF).

Total Energy indicates the estimated total electricalenergy consumption since the last reset for Recentdata and since the machine was commissioned forLifetime data; measured in Kilowatt-Hours (KWH).

Total Cost indicates the cost for the electrical energysince the last reset for Recent data and since themachine was commissioned for Lifetime data;calculated as dollars (or other units of currency).

Savings vs Load/Unload shows the estimatedadditional cost to deliver the same quantity of airusing load/unload compressor control since the lastreset for Recent data and since the machine wascommissioned for Lifetime data; calculated asDollars. This value is calculated using theCompressed Air Challenge curve for Load/Unload.

Savings vs Inlet Mod. shows the estimatedadditional cost to deliver the same quantity of airusing inlet modulation compressor control since thelast reset for Recent data and since the machine wascommissioned for Lifetime data; calculated asDollars. This value is calculated using theCompressed Air Challenge curve for InletModulation.

Savings vs Variable Displacement shows theestimated additional cost to deliver the same quantityof air using variable displacement compressorcontrol since the last reset for Recent data and sincethe machine was commissioned for Lifetime data;calculated as Dollars. This value is calculated usingthe Compressed Air Challenge curve for VariableDisplacement.

Refer to the WS Controller Instruction Manual fordescriptions of VSD functions and handling of

warning and fault messages.

6.4 CLEAR RECENT DATA The Recent data column displays average and totalvalues since the date of the last reset. Recent datahistory may be reset to zero (like a trip odometer in acar) by clicking the Clear Recent Data button at thebottom of the VSD Performance box. A few secondsafter the button is pressed, all values in the Recentcolumns of the VSD Performance group and theDelivery History window will be set to zero. Newmachine statistics will immediately begin to becalculated and the Recent columns will soon bepopulated with the new Recent data values.

6.5 DELIVERY HISTORY Click on the Delivery History button to open theDelivery Profile window. See Figure 6-3. This windowdisplays a detailed breakdown of the compressoroperation over a Recent period or over the Lifetimeof the machine. The Delivery Profile shows theamount of time the compressor has operated atvarious rates of delivery. For example, the valuesshown in Figure 6-3 correspond to a compressor thathas been delivering approximately 15% of its ratedcapacity for 24 minutes; it ran 10 minutes at 25%capacity, etc. These values may be used for furtherestimates of compressor options during plantsurveys and evaluations. The Recent values shownin the Delivery Profile window are reset to zero whenthe Clear Recent Data button is pressed at the VSDperformance box.

Click on the "Report" menu item to make acomprehensive text file that may be viewed or copiedinto other documents. This includes the adjustmentsfor the variable speed drive and a report of itsperformance. See Section 5.2.


50

6.6 SERVICE DISPLAY TAB This page lists the last 16 faults to occur with thecompressor. It will also contain VSD related faultsshould they occur. The WSPC provides additionalservice data while operating a variable speed drivecompressor. To view VSD service data, click the"Service" tab. See Figure 6-5. The display will showthe Main Motor VFD Status box containing certaintechnical details of the motor and drive. Thisinformation may be useful in diagnosing drive ormotor problems should they occur.

6.7 MAIN MOTOR VFD STATUS BOX

Service data related to VSD Compressors isdisplayed in the Main Motor VFD Status box. SeeFigure 6-4. The VFD Status box contains thefollowing information:

Motor speed displays the motor speed in revolutionsper minute (RPM).

Motor current displays the motor current measuredin Amps.

Frequency displays the motor frequency measuredin Hertz.

Motor temp protection displays the percent ofmotor temperature rise.

Drive temperature displays the current drivetemperature measured in degrees Fahrenheit orCelsius.

DC link voltage displays the drive DC link voltage.

Drive Com Faults provides a count of the drivecommunication faults.

Up/down count is the number of recent faults.

Total count is the total number of drivecommunication faults that have occurred.

Figure 6-3: Delivery (History) Profile Window

Figure 6-4: Main Motor VFD Status Box


51

6.8 ADJUSTMENTS TAB As discussed earlier in this manual, the adjustmenttab allows the user to modify certain controlparameters of the compressor operation. In additionto the general control parameters previouslydescribed, two VSD adjustments become availablewhen the WSPC is connected to a VSD compressor.These VSD control parameters are setpoint pressureand cost per kilowatt-hour. See Figure 6-6.

To view the VSD control parameters, click theAdjustments tab to present the Adjustments display.The additional VSD parameters are located in the leftcolumn of the display.

The VSD control parameters are defined as follows(ref. Figure 6-6):

VSD Setpoint pressure—The targeted pressure forthe variable speed controls. This is normally adjusted

near the bottom of the load/unload band. The speedwill be adjusted to maintain this pressure. Mostpackages will allow adjustment of this over a widerange to allow tailoring of the pressure to the needsof the application. Adjustments will be automaticallymade to the maximum speed to operate the motor atits full capacity at any pressure.

Cost per KWH—The cost per kilowatt-hour ofenergy is entered here. This setting is used in thecost estimates displayed in the VSD Performancebox of the Compressor Data display. Value is set indollars or other units of currency. For example, anentry of 0.070 equals 7 cents per KWH.

Adjustment of the VSD control parameters isaccomplished in the same manner as theadjustments of the general parameters described inSection 4.8 of this manual.

Figure 6-5: Service Tab—VSD Status


52

6.9 ADMINISTRATOR LEVEL VSD ADJUSTMENTS

Refer to Section 6: Press “Enter” or click the mouseoutside of the entry field to attach the variance value.The variance value will be added to or subtractedfrom each measurement received by the controller.

The value change can be immediately observed atthe controller and at the PC. on page 64 of thismanual for administrator level control parameteradjustments to VSD compressors.

Figure 6-6: Adjustments Tab – VSD Parameters

Section 7

53


ADMININISTRATOR LEVEL FUNCTIONS

7.1 ADMINISTRATOR LEVEL FUNCTIONS

Persons with Administrator privileges can perform alluser level functions plus additional administratoroptions that allow greater control and more detailedadjustments of the machine parameters. These allowsetups for special applications and advancedservicing by trained technicians. This section appliesspecifically to Administrator level operations. Userlevel functions are described in the precedingsections of this manual and are not repeated hereexcept where necessary in describing a specificadministrator function. Therefore, persons using theprogram at the administrator level must beknowledgeable in all user level functions as well. It isassumed that these persons have read all previoussections of this manual before proceeding.

7.2 ACCESSING THE ADMINISTRATOR LEVEL

Administrator access requires a “key” file to beinstalled to the admin user’s PC. The WSPCinstallation includes the special key file along with theWSPC files. This key file requires periodic updates.The key is not required for normal Userleveloperation of WSPC.

Administrator privileges are assigned when a profileis created. Accessing an Administrator Profilerequires a specific password.

To open the program with Administrator level access:

1. Click on the shortcut located on the com-puter desktop. The WSPC program will opento the Password Entry Box. See Figure 7-1.

2. Click the drop-down arrow on User Nameand select “Default Admin” or anotherdesired Administrator profile. When anAdministrator level profile is selected, a fieldfor password entry will be present.

3. Type the access password and click “OK” (orpress Enter).

a. If the correct password was entered, theprogram will open with Administratorlevel access.

b. If no password is entered or if the pass-word entered was incorrect, an alert willappear indicating either “No passwordentered” or “Password incorrect”. Click“OK”, enter the correct password andpress “Enter”.

c. If the key is missing or expired, an alertwill appear. Contact Sullair for update.WSPC may still be used at User level.NOTE This section is not required fornormal machine operation.

4. The WSPC program will open with access toAdministrator Level Functions.

If the program opens without displaying a passwordentry field then a User level profile was selected.Click on the down arrow next to the User Name fieldand select an Administrator profile for access toadministrator level functions.

NOTEThis section is not required for normal machine operation.

Figure 7-1: Password Entry Box


54

7.3 COMMISSIONING A CONTROLLER

Commissioning is the process of initializing the WSController for operation with a specific compressormodel and type. During the commissioning process,all previous stored data (parameter values, logs,history information, etc.) is erased from the controllermemory. The new default parameter values are thenloaded to the controller that configure it for aparticular compressor model and application.

To commission a controller for a compressor model:

1. Press the emergency stop button and leaveit depressed throughout the commissioningprocedure.

2. On the Menu Bar select the “File” menu andclick “Commission” in the drop-down optionlist. See Figure 7-2. The “Commission” win-dow will be presented.

NOTEController commissioning is normally a one-time event when a new controller is installed. The compressor must be stopped before beginning the commissioning process. When the compressor is running, the “Commission” option is inoperable.

NOTEDepending on the selected model, the commissioning procedure may alter the functions of inputs and outputs. Depress the Emergency Stop button to prevent output relays from operating inappropri-ately during the process.

Figure 7-2: Commission Option


55

3. Click the down arrows for the machine modelfor which the controller is to be commis-sioned. See Figure 7-3.

4. After the Model has been chosen, select theattributes that apply to the specific machinebeing commissioned. Only those options thathave multiple choices may be selected.

a. Click “Hp” to select the horsepower ofthe compressor motor.

b. Click “Hz” to select the compressormotor frequency.

c. Click “Pressure” to select the compres-sor pressure rating.

d. Click “Cooling” to select the compressorcooling method.

e. Click “Motor” to select the compressormotor phase type.

f. Click “Volts” to select the compressoroperating voltage.

g. Click “Dryer” to select the compressordryer type.

5. When all appropriate attributes have beenselected, click “OK”. The program will pres-ent a “Continue to Commission” option box.See Figure 7-4.

6. Click “Yes” to confirm commissioning thecontroller to the selected compressor model.Commissioning will begin and the progressof the commissioning process will be shownin the commissioning window. See Figure 7-5.

7. As the default settings are loaded to the con-troller, a commissioning progress meter willbe presented to allow the administrator tomonitor the progress of the commissioningprocess. When the default settings have fin-ished loading to the controller, a final confir-mation box will appear indicating thatcommissioning is complete (Figure 7-6).

NOTEUse care to select the proper machine model. All machine attributes must match the model selected during commissioning to ensure proper and safe operation.

Figure 7-3: Commission Select

Figure 7-4: Commissioning Confirmation


56

8. Turn the controller power off, then click “OK”to confirm.

9. To verify, restore power and reconnect tocontroller. Pull the Emergency Stop button,and clear the controller fault. Verify machineinformation (refer to Section 4.3).

Once a controller has been commissioned, it can beused to control and monitor the operation of thecompressor and log new compressor operation data.Parameters set during commissioning can be lateradjusted by the end user to customize thecompressor for a specific application.

.

7.4 MAINTENANCE DISPLAY The Maintenance Display at the Administrator leveldisplays the same warning and maintenanceinformation as at the User level (Refer to Section4.5). The Administrator level Maintenance displayincludes additional functions that allow the

administrator to view the maintenance information ingreater detail and to reset the service and warningmessages. See Figure 7-7. The additional functionsof the administrator level Maintenance display aredescribed below.

“Warning History” button—When selected,presents a table displaying a history of the 16 mostrecent warning occurrences.

“Maintenance History” button—When selected,presents a table displaying a history of the 16 mostrecent service reminders.

“Reset” buttons—Resets warning messages andservice reminders. Click a “Reset” button next to awarning or service reminder to delete the messagefrom the list and clear it from the WS Controllerdisplay. “Reset All” button – Clears all warningmessages and resets all service reminders. Click“Reset All” at the bottom of the list of warnings orservice reminders to clear all the messages in therespective list.

Service Interval fields—Allows intervals for “HoursTo Next” recommended service to be set. Theintervals are entered into fields of the “Hours ToNext” box in the right-hand column. When a serviceinterval is changed, the change does not becomeaffective until the “Reset All” button underRecommended Service is clicked (Refer to Figure 7-7). When a service interval has expired, the relatedservice reminder message will appear in a field of theRecommended Service box. A service interval set tozero (0) will disable the service reminder for thatitem.

Figure 7-5: Commissioning Progress Monitor

Figure 7-6: Commissioning Confirmation


57

WARNING HISTORY WINDOW A history of the 16 most recent Warning messagesmay be viewed in the “Warning History” window. SeeFigure 7-8.

1. To access the “Warning History” window,click the “Warning History” button on the“Maintenance” display.

2. The “Warning History” window will appeardisplaying the following elements:

a. Top row header: Displays abbreviatedheadings corresponding to warnings thatmay appear on WS Controller displaypanel. These are broken into a com-pressor and dryer group - select with thetabs. Also along the top row are head-

ings for the machine “hours”, “date”, and“time” of the warning occurrence.

b. Columns: Boxes below each warningheading will change from shaded gold tobright gold when a warning is indicated.

c. Rows: The most recent warnings areindicated on the first row below theheadings. Each preceding warning isindicated chronologically down the tablecolumn.

3. Close the table by clicking the “Close” but-ton.

Warning history is also included in thecomprehensive text report. See Section 5.2.

“Reset All” must be clicked to allow service interval change to

become effective.

Figure 7-7: Maintenance Display – Admin Level


58

MAINTENANCE HISTORY WINDOW A chronological history of the 16 most recent ServiceReminders may be viewed in the MaintenanceHistory Window. See Figure 7-9.

1. To access the “Maintenance History” win-dow, click the “Maintenance History” buttonon the “Maintenance” display.

2. The “Maintenance History” window willappear displaying the following elements:

a. Top row header: Displays six abbrevi-ated headings corresponding to servicereminders that may appear on WS Con-troller display panel. Also along the toprow are headings for the machine“hours”, “date”, and “time” of the warningoccurrence.

b. Columns: Boxes below each mainte-nance heading will change from shadedyellow to bright yellow when a servicereminder is indicated.

c. Rows: The most recent service remind-ers are indicated on the first row belowthe headings. Each preceding servicereminder is indicated chronologicallydown the table column.

3. Close the table by clicking the “Close” but-ton.

Maintenance history is also included in thecomprehensive text report. See Section 5.2.

Figure 7-8: Warning History Window


59

7.5 ADMINISTRATOR ADJUSTMENTS (ADMIN) DISPLAY

The Administrator Adjustments (Admin) display tab isavailable only when an administrator level profile isactive. This display allows the administrator to editthe ID’s of specific controller inputs and to make zerocalibration adjustments of measured values betweenthe compressor system and the controller. TheAdmin user can view the current assignments of thecontroller input registers and make adjustments asnecessary. See Figure 7-10. The inputs shown in thefigure are for reference and vary based on specificmachine configurations.

Changes can only be made at the Admin displaywhile the compressor is stopped. When thecompressor is running, the fields of the Admindisplay are inactive. Changes made at the Admindisplay will be applied to the WS Controller within afew seconds after entry. Some changes may not beshown properly on WSPC. To ensure correctinformation, always click the "Connect" button whenfinished with this page to disconnect from thecontroller. Click "Connect" again to reconnect andupdate the WSPC displays.

Figure 7-9: Maintenance History Window


60

Described below are parameters that can be editedby the Administrator at the “Admin” display. The unitsand language appearing in the “AdministratorAdjustment” display correspond to the settingsapplied when the Administrator profile was created.

SIGNAL ADDRESS FUNCTION Refer to Figure 7-10. The left section contains a listof controller functions, and allows selection of signalsto operate the function. This allows special fieldsetups for special applications.

General Fault—Generates an Option Input Faultwhen on.

General Warning—Generates User Option Warningwhen on.

General Runtime Fault—Generates an Option InputRun Fault when on. This fault is enabled a fewseconds after the compressor starts.

General Runtime Warning—Generates a UserOption Warning when on. This warning is enabled a

few seconds after the compressor starts.

Remote Operate—Operates the compressor whenon. Remote Master – Uses Remote inputs when on.

Remote Unload—Forces the compressor to unloadwhen on. Refer to the Sequencing manual for detailson using the remote inputs.

Dryer Warning—Generates Dryer Warning whenon.

Dryer Fault—Generates Dryer Fault when on.

Phase Monitor Fault—Generates Phase MonitorFault when on.

Water Pressure Fault—Generates Water PressureFault when on.

Factory-Defined A through E—Operates thefactory defined relay when on. Actual relayassignments are shown, and depend on compressormodel.

Figure 7-10: Administrator Adjustment Display


61

DIGITAL INPUT OPTIONS (DROP-DOWN ARROWS)

The following options may be selected for a DigitalInput by clicking on the associated drop-down arrow(refer to Figure 7-10):

ON—Activates the function continuously. The inputsignal is ON.

Off—Deactivates the function. The input signal isOFF.

Running—Activates the function when theCompressor is running.

Din 7, 8, 9, 4 ON—Activates the function when theinput signal at the respective input (7, 8, 9, or 4) isON. The list of available inputs varies with models.

Din 7, 8, 9, 4 OFF—Activates the function when theinput signal at the respective input (7, 8, 9, or 4) isOFF. The list of available inputs varies with models.

MB Remote ON—Activates the function when theModbus Remote signal is ON.

MB Timer 1, 2, 3 ON—Activates the function whenthe respective Modbus Timer signal (1, 2, 3) is ON.

MB Remote OFF—Activates the function when theModbus Remote signal is OFF.

MB Timer 1, 2, 3 OFF—Activates the function whenthe respective Modbus Timer signal (1, 2, 3) is ON.

FACTORY-DEFINED OUTPUT OPTIONS (DROP-DOWN ARROWS)

The following options may be selected for a FactoryDefined Relay (A – E) by clicking on the associateddrop-down arrow (refer to Figure 7-10):

ON—Turns the relay ON.

OFF—Turns the relay OFF.

Drain—Activates the relay when the Drain solenoidis actuated.

Running—Activates the relay when the compressoris Running.

Enabled—Activates the relay when the compressoris Enabled.

Fault—Activates the relay when a Fault conditionoccurs.

Warning—Activates the relay when a Warningcondition occurs.

Fault or Warn—Activates the relay when either aFault or a Warning occurs.

Master Enabled—Activates the relay when thecontroller is enabled as the Master device in asequence.

Dryer Running—Activates the relay to operate anintegrated refrigerated dryer.

ANALOG SIGNAL ZERO TRIMS The Analog Zero Trim settings allow for calibration ofvarious analog inputs. Refer to Figure 7-10. Analoginputs are assigned to sensors used to measurespecific characteristics of the compressor system.The Analog Signal Zero Trims function is used toadjust the displayed value of the measurements toequal the measured value at the analog device.

Sensor Calibration on page 63 provides steps oncalibrating analog input measurements.

The inputs used vary with compressor models anddesign. The display will indicate which sensors areactive by indicating their function.

Typical analog input assignments are shown below.


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MAXIMUM USER UNLOAD SETTINGS The Maximum User Unload settings allow themaximum limit to be set for the compressor unloadpressure. These limit the setting for the User-leveladjustment of unload pressure.

Refer to Figure 7-10.

Load/Unload Mode—Sets the maximum Unloadpressure limit for the compressor when the machineis operated in Load/Unload mode.

Modulating Mode—Sets the maximum Unloadpressure limit for the compressor when the machineis operated in Modulating mode.

DISABLE WARNING RESET Current versions of WS Controllers reset warningswhenever the start or stop button is pressed on thekeypad. The administrator may disable this feature,and require all warnings to be reset by WSPC only.Refer to Figure 7-10.

1. Select the “Start Button” check box to disablereset by the start button.

2. Select the “Stop Button” check box to disablereset by the stop button.

ASSIGNING DIGITAL INPUTS To make adjustments at the “Admin” Display (Referto Figure 7-11):

1. Click at the WSPCto connect communication between the com-puter and the WS Controller. Connectionmust be enabled before adjustments can bemade at the Admin display.

2. Press (Stop) at the controller tostop the compressor operation. The com-pressor must be stopped before adjustmentscan be made at the Admin display.

3. Click on the drop-down arrow at the right ofthe row containing the name of the functionto be reassigned.

4. In the drop-down list, select the input toassign to the corresponding function. Thenew assignment will become active a fewseconds after entry.

AI0 AI1 AI2 AI3 AI4 AI5 Separator

Temp 1 Temp 2 Temp 3 Sump Pressure

LinePressure

Other Pressure

(Sump-Line) Pressure


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UNLOAD (REMOTE) BUTTON The administrator may set up the controller forremote control by Modbus. To do so, select the“Modbus timer 1” to control the “Remote Unload”function above. Also select “Remote”, Hours”, or“ComNum” Sequence mode on the User’s“Adjustments” tab to enable remote control.

When this is done, an additional button labeled“Unload” will appear under the “Connection” button inthe Status Bar. See Figure 7-12. Click on the“Unload” button to toggle the compressor operation.A bright yellow box next to the Unload buttonindicates that the machine is being forced to unload.A darkened yellow box next to the button indicatesthat the machine will operate normally.

If continuous communication from the PC is notreceived, the compressor will revert to normaloperation within a couple minutes.

SENSOR CALIBRATION The compressor is equipped with sensors thatmonitor and measure various characteristics of thecompressor performance. These values are receivedat the WS Controller as analog input signals from thesensor. Most sensors input can be adjusted tocalibrate the reading at the controller with the actualmeasured value at the sensor location. This sectionwill describe the steps necessary to calibrate the LinePressure transducer. Calibrate other sensors in thesystem in a similar manner.

Click Connect to enable Admin Adjustments

Click drop-down arrow to select input

assignment

Analog Signal Zero Trims for calbration

adjustments}

Figure 7-11: Administrator Adjustment Display

Figure 7-12: Unload Button During Remote Operation


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P2 PRESSURE TRANSDUCER CALIBRATION The Line pressure transducer input measurement isassigned to analog input AI4 at the controller. Thispressure transducer measures the output linepressure at the compressor main header. Over time,the pressure transducer may vary slightly producingan inaccurate reading at the controller. Periodicallyand prior to operating multiple controllers in asequence, the controller should be calibrated toreflect the same pressure measurement as thatmeasured at the Line transducer location. Thecalibration should be performed when the system isat a stable pressure with minimal load on the outputlines. Use the following steps to calibrate the WSController Line pressure reading (refer to Figure 7-11):

1. Measure the parameter (Line pressure) atthe sensor (transducer) location using anindependent certified gauge.

2. At the WSPC interface, observe the Linepressure reading in the “Compressor StatusBar.” Compare this reading with the mea-surement at the transducer location.

3. If the measurement on the external gauge atthe transducer does not match the dischargepressure reading at the PC, click on the“Admin” tab to access the AdministratorAdjustments display.

4. Under the category “Analog Signal ZeroTrims,” highlight the values in the analogsensor field labeled AI4 (Line pressureinput).

5. Enter the value necessary to increase ordecrease the Discharge reading at the PC toequal the measurement at the transducer.The calibration variance limits are –7.5 to+7.6.

6. Press “Enter” or click the mouse outside ofthe entry field to attach the variance value.The variance value will be added to or sub-tracted from each measurement received bythe controller. The value change can beimmediately observed at the controller and atthe PC.

VSD Package Settings

Figure 7-13: Administrator Adjustments


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VSD PACKAGE SETTINGS When a VSD compressor is connected to the WSPC,additional VSD related adjustments are available onthe Admin display. See Figure 7-13. These values,located in the right side of the screen are onlydisplayed when a VSD machine is connected. Inmost cases, the factory settings are satisfactory fornormal compressor operation.

Should modification of the parameters be necessary,adjust the VSD Package Settings in the samemanner as described in Assigning Digital Inputs onpage 62. VSD Package Settings

The VSD Package Settings are described below (ref.Figure 7-14):

Flow calibration—The flow indicator sets thenominal (100%) flow value for the machine operatingunder typical conditions. This value may be adjustedas needed for specific applications and operatingconditions.

Power calibration—The power indicator sets thenominal (100%) power value for the machineoperating under typical conditions. This value may beadjusted as needed for specific applications andoperating conditions.

Gain control I and Gain control P—A value of 10 isrecommended for each of these controls for almostall end-use applications. Additional stability functionsare built into the controls that make these valuesnon-critical and virtually eliminate the need fortuning. However, extremely large- or small-volumesystems may benefit from some adjustment. Consultthe factory if stability problems are encountered.

Autoset %—Allows speed adjustments to be madeautomatically when changes in the Setpoint pressureare made causing the compressor to operate at itsfull rated power capability. This should normally beset to 100. If it is desired to run the compressor atless than full capacity, simply set this to a lowervalue. For example, set the Autoset % to 80 tooperate a 50HP compressor at 40HP maximum. TheWS Controller will calculate the necessary speedadjustments whenever the setpoint is changed.Autoset may be disabled by setting this value to 0 %allowing the speed to be adjusted manually.However, this is not recommended and can causeimproper machine operation.

Minimum Speed—is normally left at the factorysetting, but may be increased. Enter the desiredfrequency multiplied by 10 (e.g., 250 for 25.0 Hz).

Maximum Speed—If Autoset is enabled, themaximum speed will be set automatically asappropriate for the machine and setpoint pressure. IfAutoset is disabled, the frequency will be required tobe entered manually to control the range ofoperation. Enter the desired frequency multiplied by10 (e.g., 814 for 81.4 Hz).

Motor Protect Amps—Maximum amp setting forVSD operation. This should be set for the LOWER of:

1. Maximum motor amps. This is FLA timesservice factor, unless a specific SFA isshown. For 460V/60Hz motors connected400V/60Hz, multiply the 460V nameplate rat-ings by 1.15.

2. Rated drive current. This is shown on thedrive nameplate. This will usually be the limitfor most 460V compressors.

Slow Acc/Dec—Setting for controlling VSDacceleration and deceleration. The factory settingsare based on standard motors, and this setting is 0. Ifa special motor is applied, this setting may beincreased to eliminate drive overvoltage duringdeceleration. Slower settings will reduce systemstability, and may require additional air storage.

Figure 7-14: VSD Package Settings


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SAVING AND LOADING ADMINISTRATOR PARAMETERS

Administrator parameters may be Saved and loadedby using the Load/Save button on the “Admin” tab.The procedures are identical to those described forUser Adjustments in Saving Parameter Settings onpage 36 and Editing and Searching Machine Profileson page 36.

IMPORT COMMISSION DATA The commissioning parameters will be updated fromtime to time as new models or features are added tothe line of compressors. When this happens, acommission data text file will be distributed. Thisallows easier distribution, including simple e-mailattachments. It also will allow the update withoutaffecting other WSPC preferences and savedinformation. The procedure is simple and fast, andshould be done following any distribution fromSullair.

1. Copy the new file to your PC. The preferredlocation is with the other WSPC programfiles. You may use “Import Other Data” tocopy files from other locations to this folder.

2. Start WSPC. You do not need to be con-nected to a controller.

3. Select the “Admin” tab.

4. Click the “Import Commission Data” tab.

5. Select the file with the new commission data.See Figure 7-15. You may browse to otherlocations, if necessary.

6. Click the “Open” button

7. Confirm or Cancel on the confirmation box.All old commissioning data is cleared whenyou confirm.

8. Wait while the data is updated. This takesabout a minute.

9. A final confirmation box will confirm that thejob is completed.

Figure 7-15: Import Data Screen


67

IMPORT OTHER DATA This is provided simply as a tool to copy files fromother locations into the WSPC folder. This may beused on some update distributions. To import:

1. Start WSPC. You do not need to be con-nected to a controller.

2. Select the “Admin” tab.

3. Click the “Import Other Data” tab.

4. Browse to the folder and select the desiredfile.

5. Click the “Open” button

6. Confirm or cancel the action.

RESTORE FACTORY DEFAULTS This button may be used to restore all adjustments tothe settings following the most recentcommissioning. This may be used to correctinadvertent misadjustments. All machine history willbe retained.

This feature is available only if the controller hasbeen previously commissioned with WSPC 2.0 orlater, and with controller software 02250165-315 orlater. Use the "Machine Info" tab of WSPC to checkprior commissioning. If the Model and other boxes inthe lower section are filled, the adjustments may berestored.

To restore default settings:

1. Stop the machine and press the EmergencyStop button.

2. Create a report to record the adjustmentsprior to restoring defaults.

3. Click the Admin Tab. Click the "Restore Fac-tory Defaults" button.

4. Click the "Connect" button to disconnectfrom the controller.

5. Disconnect and restore power to the control-ler.

6. Click the "Connect" button one more time toreconnect to the controller.

7. Create a second report to record the adjust-ments after the restoration.

8. Pull out the Emergency Stop button. Clearthe fault. Check the machine for properoperation.

7.6 MODBUS FUNCTIONS The “Modbus” display is available only when anAdministrator level profile is active. Communicationtransactions between the WSPC program and theWS Controller may be monitored at the “Modbus”display. None of this is essential for machineoperation, but may be used for demonstrationpurposes if setting up a dedicated Modbus network.See Figure 7-16.

Refer to the WS Controller Modbus Specification forinformation on using modbus with the WS Controllerand a complete list of associated commands.

The data communicated represents compressoroperating mode and states, including faults andwarning signals, compressor temperatures andpressures, machine run times and intervals, VSDperformance, digital I/O states, sequence status, andother machine parameters.

The messages appear in hexadecimal or decimalform. The WSPC transmits a request for informationor send commands to control the compressoroperation. The controller responds with therequested data or an acknowledgement to thecontrol command.

Communication must be “Connected” between thePC and the controller to perform modbus functions.Connection is indicated by the box left of the“Connect” button appearing bright green.


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MONITORING MODBUS COMMUNICATIONS Three modes of monitoring may be selected byclicking the radio button. When monitoring, theWSPC request will always be shown in the“Command” data window in hex form. The WS datawill be shown in the lower window in either Hex orDecimal format.

Off—Stops monitoring, but continues to display themost recent communication. Continuous – monitorsthe normal WSPC communication with the controller.

Step—Allows the Administrator to select a givenblock of data for monitoring. See Figure 7-17. To usestep monitoring:

1. Click Step radio button in the Mode box.

2. Use the drop-down list to select a parametertype. Options are User Inputs, Admin Inputs,User Holding, and Admin Holding.

3. Use the drop down list to select a block ofdata of that type. These will be in blocks ofup to 50 registers.

4. Click the “Step” button to refresh the data.

Figure 7-16: Modbus Display

Figure 7-17: Modbus Monitoring


69

READING AND WRITING SPECIFIC REGISTERS The Administrator is also able to select a specificregister for monitoring or changing. Always use thedecimal format when doing this. See Figure 7-18. Toread a register:

1. Click the “Decimal” format.

2. Click in the Address box for the Input orHolding register, and enter the desired regis-ter number.

3. Click the “Read” button to get the currentvalue.

To change a holding register:

1. Click the “Decimal” format.

2. Click in the Address box for the Holding reg-ister, and enter the desired register number.

3. Click the “Read” button to get the currentvalue.

4. Click in the Value box, and enter the desiredvalue.

5. Click the “Write” button to send the requestto the controller.

6. Click the “Read” button to verify the newvalue.

7.7 DRYER SETUP DISPLAYThis tab is for use with compressor packages withintegrated dryer controls. This is available on WScontroller software version 02250174-082. Thesepackages should have been factory commissionedas dryer models, and will be shown as such on theMachine Info Display (see Section 4.3) and onreports. This commissioning procedure sets up allthe necessary functions for normal integrated dryer

operation. Adjustments on this display are intendedfor special applications where the default settingsmay need to be changed.

These settings are administrator-level and areintended for trained servicers only. Stop thecompressor prior to making any adjustments. Sincethese adjustments also affect operation of an outputrelay, depress the emergency stop button to preventrelay operation until all adjustments are completed.

Click the "Dryer" tab to show the dryer setup display.This will always show the current settings. If thecompressor is stopped, the settings may bechanged.

Integrated Dryer—Whenever this setting ischanged, the controller will alter all remainingsettings, and change its operations as appropriate.This may be used to disable all dryer functions duringservice. Be sure to disconnect all wiring and pipingto the dryer during service, and to reconnect allwiring and piping when service is completed.Restore power, click the down arrow and select"Integrated Dryer" or "None" to set up defaultsettings:

Compressor Runs on Dryer Fault—This isunchecked by default. If a dryer fault occurs, thedryer and compressor will both stop, and a fault willbe recorded into the WS controller. Correct thesource of the fault, then reset the fault using the WScontroller keypad and resume operation.

If this is checked, dryer faults will stop operation ofthe dryer only. The compressor will continue to run.This will be recorded as a WS controller warning.

Start Up Load Delay—This is set to 5 minutesdefault whenever integrated dryer operation isinitially selected. When initially starting thecompressor package, the dryer also starts, but thecompressor will initially be forced to run unloaded for

Figure 7-18: Modbus Registers


70

this amount of time. The WS controller will indicatethat the compressor is precooling the dryer. Oncethis period is over, the compressor operatesnormally, and the dryer runs continuously.

Dewpoint High Warning Temperature—This is setto 50 degrees F (15 degrees C) default wheneverintegrated dryer operation is initially selected. Thewarning functions become active when the dryer isrunning. A dryer warning occurs if temperaturecannot be brought below this temperature. If thetemperature remains 5 degrees higher than thissetting, the dryer will stop and the controller willrecord a high temperature fault or warning.

Separator offset—This setting will be adjusted to amodel-specific setting whenever integrated dryeroperation is initially selected. This is a duplicate of

the adjustment shown on the "Admin" Display, and ispresented here for convenience when setting up adryer. Set this for the additional drop in pressurefrom the dryer.

Digital Output 7—This setting will be adjusted to a"Dryer Running" function whenever integrated dryeroperation is initially selected. This is a duplicate ofthe adjustment shown on the "Admin" Display, and ispresented here for convenience when setting up adryer. This is the proper setting if the dryer control iswired to digital output 7 of the WS controller. If thedryer is controlled by other means, this relay is freeto be used to signal other information. This settingwill be adjusted to an "Alarm" function wheneverintegrated dryer operation is disabled.

Figure 7-19: Dryer Setup Display

71

BLANK PAGE

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