Sullair 02250165-411 R01 User Manual Download Page 1

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Failure to follow the instructions

and procedures in this manual or,

misuse of this equipment will

VOID its warranty!

WARRANTY NOTICE

PART NUMBER:

KEEP FOR
FUTURE
REFERENCE

USER MANUAL

SULLAIR CORPORATION

The information in this manual is current

as of its publication date, and applies to

compressor

serial number

and all subsequent serial numbers.

02250165-411 R01

20080301000

WS C

ONTROLLER

SER

NTERFACE

ANUAL

Summary of Contents for 02250165-411 R01

Page 1: ...s warranty WARRANTY NOTICE PART NUMBER KEEP FOR FUTURE REFERENCE USER MANUAL SULLAIR CORPORATION The information in this manual is current as of its publication date and applies to compressor serial n...

Page 2: ...cated at Michigan City Indiana Instruction includes training on the function and installation of Sullair service parts troubleshooting common faults and malfunctions and actual equipment operation The...

Page 3: ...2 STARTUP PROCEDURES 11 2 1 INTRODUCTION 11 2 2 WS CONTROLLER PANEL LAYOUT 12 2 3 WS START UP PROCEDURES 13 2 4 SHUTDOWN PROCEDURE SECTION 3 ADJUSTMENTS 15 3 1 INTRODUCTION 15 3 2 COMPRESSOR ADJUSTMEN...

Page 4: ...UBLESHOOTING GUIDE 31 5 3 WS CONTROLLER FAULTS AND WARNINGS 31 5 4 MACHINE BEHAVIOR AFTER A POWER INTERRUPTION 31 5 5 INTERNAL BATTERY 33 5 6 REPLACEMENT CONNECTOR PLUGS SECTION 6 VARIABLE SPEED DRIVE...

Page 5: ...rein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors 1 2 PERSONAL PROTECTIVE EQUIPMENT A Prior to installing or operating the co...

Page 6: ...luids including air line anti icer system 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...

Page 7: ...codes or regula tions B DO NOT use air line anti icer systems in air lines supplying respirators or other breathing air utili zation equipment and DO NOT discharge air from these systems into unventi...

Page 8: ...andling any ungrounded conductors 1 9 LIFTING A 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...

Page 9: ...a cles at floor level and transport and corner at minimum practical speeds N Make sure pallet mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift o...

Page 10: ...10 BLANK PAGE...

Page 11: ...roller panel is shown in Figure 2 1 The controller panel consists of Display Screen for displaying machine status START pad for machine startup STOP pad for stopping machine operation and for clearing...

Page 12: ...the following steps 1 With the compressor running visually check that the fan rotation is correct 2 If it is incorrect change the direction of the fan motor by disconnecting power from the compressor...

Page 13: ...ear on the display screen 3 If a different operating mode is desired use the arrow pads to navigate to the Mode parameter Press the ENTER pad to enter the Change Mode Navigate to the desired mode Auto...

Page 14: ...14 BLANK PAGE...

Page 15: ...Section 3 3 3 2 COMPRESSOR ADJUSTMENT PROCEDURES The following steps apply while Show Setting is indicated in the display The control parameter described in the display can be modified by the user Us...

Page 16: ...ps the machine from being started more than four times an hour This secondary timer is disabled when a machine is configured for VSD motor control Drain Interval Mins Set interval in minutes between a...

Page 17: ...Change Setting Load Delta Pressure Show Setting Unload Minutes Change Setting Unload Minutes Show Setting Drain Interval Mins Change Setting Drain Interval Mins Show Setting Drain Time Seconds Change...

Page 18: ...rnished external remote control This may be wired to a remote switch timer or other controls to halt operation of the compressor as desired To enable remote control of the compressor 1 Wire the remote...

Page 19: ...value 4 3 INDICATOR LED DESCRIPTION Four LED s on the WS Controller Panel provide indication of the general state of the machine Power On Indicator GREEN LED Lights whenever power is applied to the co...

Page 20: ...mperature 2 Displays the current compressor temperature at temperature probe 2 Temperature 3 Displays the current compressor temperature at temperature probe 3 Dewpoint Temperature Displays the curren...

Page 21: ...e display window This mode indicates that a machine problem has occurred causing the controller to shut down the machine until the condition is cleared After a fault condition has been resolved the fa...

Page 22: ...layed when the compressor is delivering air at full rated capacity Unloading Displayed as the compressor is being unloaded automatically Remote Unloading Displayed as the compressor is being unloaded...

Page 23: ...ufacturer Dryer Service Indicates a dryer is running while a malfunction is occurring Consult the dryer manual and or dryer manufacturer High Air Filter dP Indicates the air filter pressure differenti...

Page 24: ...ressure at specified transducer A or B has exceeded the set high limit High Sump Pressure Compressor sump pressure has risen above the set limits High Temperature 1 3 The temperature at specified temp...

Page 25: ...rter auxiliary contact failed to connect power to the starter UI Voltage Too High The voltage to the User Interface has risen above the set limit UI Voltage Too Low The voltage to the User Interface h...

Page 26: ...26 BLANK PAGE...

Page 27: ...c Check for parts damaged by heat or an elec trical short circuit usually apparent by discol oration or a burnt odor Should your problem persist after making the recommended check consult your nearest...

Page 28: ...ton Release button Check wiring High Air Filter P Differential Pressure Across Inlet Filter High Replace filter Check inlet filter pressure switch High analog input AN0 through AN9 Sensor Pressure Tra...

Page 29: ...er is cooling below the low dewpoint temperature setting Consult the dryer manual and or Sullair Factory Service Low Line Pressure Demand exceeds capacity Leaks in supply lines Reduce demands Increase...

Page 30: ...ol Power Check line voltage and connections Replace Battery Controller I O backup battery is low Replace battery Separator dP High fault High Separator dP warning Pressure Differential Across Separato...

Page 31: ...dead battery the time of day records will not work properly and loss of recent records could occur If recent records are lost due to an inoperative battery or other reason the controller will revert...

Page 32: ...ule 4 Remove six screws from I O Control Module cover and remove cover 5 Locate the internal battery The battery is located near one end of the I O circuit board usually oriented towards the top 6 Rem...

Page 33: ...5V Com PB 485C O J12 3 02250161 734 O Input T2 J13 3 02250161 734 O 5V Com PF 485 O J14 3 02250161 734 O Input T3 PF 485 O J15 10 02250161 737 O 5V Com PF 485C O J16 6 02250161 735 Rx O Tx O O 24V Sup...

Page 34: ...34 BLANK PAGE...

Page 35: ...he variable speed drive make sure that the front and cable covers are closed and fastened to prevent exposure to potential electrical fault condi tions Failure to observe this precaution could result...

Page 36: ...heir voltage using a multimeter set to measure DC voltage Failure to follow the above precautions may cause death or severe injury CAUTION Do not perform any meggar or voltage with stand tests on any...

Page 37: ...al but should be done by a quali fied electrician in compliance with OSHA National Electrical Code and or any other applicable State Federal and local elec trical codes concerning isolation switches f...

Page 38: ...00 4 0 1 0 150 205 250 300MCM 2 0 200 261 350 2 x 4 0 3 0 250 300 400 2 x 250MCM 300MCM 300 385 700 2 x 300MCM 300MCM 350 460 1250 2 x 400MCM 400MCM Table 6 2 Cable and Fuse Sizes 575V Ratings _ UL re...

Page 39: ...pper cables only 75 C or higher The minimum input line cable and line fuses must be sized in accordance with the rated input current of the unit See Table 6 1 and 6 2 Consistent with UL listing requir...

Page 40: ...d Delta Pressure Change Setting Load Delta Pressure Show Setting VSD Setpoint Change Setting VSD Setpoint Show Setting Unload Minutes Change Setting Unload Minutes Show Setting Drain Interval Mins Cha...

Page 41: ...ontrols The setpoint pressure is normally adjusted near the bottom of the load unload delta The compressor speed will be adjusted to maintain this pressure Most packages will allow adjustment of this...

Page 42: ...possible causes and some likely solutions The controller monitors communications with the inverter and will display a fault message if these communications are broken The WS Controller will display a...

Page 43: ...service V09 Undervoltage DC link voltage is less than the minimum safe operating voltage limit most probable cause supply volt age too low variable speed drive internal fault If there was a supply vol...

Page 44: ...s fault the variable speed drive will automatically reload the parameter default settings Check all parameter settings after reset If the fault reoccurs contact Sullair service V24 Counter Fault Value...

Page 45: ...r Fault This fault is disabled A display of this message indicates that the components or settings of the variable frequency drive have been changed Correct drive parameters need to be downloaded Cont...

Page 46: ...correct contact Sullair service V56 PT100 Board This fault is disabled A display of this message indicates that the components or settings of the variable frequency drive have been changed Correct dr...

Page 47: ...47 BLANK PAGE...

Page 48: ...s LTD Princess Highway Hallam Victoria 3803 Australia Telephone 61 3 9796 4000 Fax 61 3 9703 8053 www championcompressors com au SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indiana...

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