Sullair Supervisor Controller Manual - 02250146-049

®I TABLE OF CONTENTS OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL Section 1 SAFETY page 1 1.1 GENERAL 1 1.2 ELECTRIC SHOCK 1 1.3 VARIABLE SPEED DRIVE 1 1.4 DECALS 5 2.1 SUPERVISOR KEYBOARD LAYOUT 5 2.2 MAIN DISPLAY 5 2.3 FUNCTION MENU 6 2.4 STATUS- CURRENT PRESSURES, TEMPERATURES, INPUTS AND OUTPUTS 6 2.5 CONTROL PARAMETERS- PRESSURE, TEMPERATURE AND TIMER SETTINGS 7 2.6 MAINTENANCE- PREVENTIVE MAINTENANCE INFORMATION AND TIMERS 7 2.7 FAULT LOG- LOG OF PREVIOUS FAULTS 7 2.8 SENSOR LOG 7 2.9 SEQUENCING- SEQUENCING & COMMUNICATION PARAMETERS 8 2.10 SYSTEM DISPLAY- DISPLAY OF MODES OF MACHINES IN A SEQUENCING SYSTEM 8 2.11 CALIBRATION- CORRECTION FACTORS FOR PRESSURES 10 Table 2-1 Supervisor Controller Menu Tree 11 3.1 MOTOR ROTATION DIRECTION CHECK 11 3.2 INITIAL START-UP PROCEDURE 11 3.3 SUBSEQUENT START-UP PROCEDURE 11 3.4 SHUTDOWN PROCEDURE Section 2 SUPERVISOR DESCRIPTION Section 3 START-UP PROCEDURES TABLE OF CONTENTS Section 4 TROUBLESHOOTING page 13 13 4.1 TROUBLESHOOTING INTRODUCTION 4.2 TROUBLESHOOTING GUIDE- SUPERVISOR CONTROLLER 16 Table 4-1AAnalog Alarms (Flooded Screw Compressors 17 Less Than 200 psi) Table 4-1 B Analog Alarms (LS-16T, LS-20T and 18 LS-20TS Compressors) Table 4-2 Parameters 19 19 19 19 19 4.3 MACHINE BEHAVIOR AFTER A POWER OUTAGE 4.4 REMOTE STOP/START INPUT 4.5 BROWN OUT INPUT Table 4-3 Machine Power Outage Behavior Table 4-4 Remote Start/Stop Input Section 5 WIRING SCHEMATIC 21 DIAGRAMS 5.1 WIRING DIAGRAM- SUPERVISOR COMMUNICATION MODULE 22 5.2 WIRING DIAGRAM- SUPERVISOR CONTROL 23 6.1 SAFETY 23 6.2 OVERVIEW 24 Table 6-1: Cable and Fuse Sizes- 460V Ratings 24 6.3 INSTALLATION 24 6.4 SUPERVISOR DISPLAY AND MENUS 24 6.1.1 VSD STATUS Section 6 VARIABLE SPEED DRIVE 25 6.4.2 CONTROL PARAMETERS 25 6.4.3 CALIBRATION 25 6.4.4 FACTORY SETUP 25 6.4.5 VSD SETUP 26 6.5 STARTUP OF NEW COMPRESSOR PACKAGE 26 6.6 FAULT AND WARNING CODES if conscientiously followed. Tag the compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to operate it until the condition is corrected. 1. as well as those following. procedures and safety precautions listed here and in the Operator's Manual may result in accidents and injuries. and Local codes or requirements. are offered as a guide which. The compressor should be operated only by those who have been trained and delegated to do so. contact your nearest Sullair Distributor or the Sullair Corporation factory Service Department for replacement parts (Note: When ordering new decals. State.1 GENERAL Sullair Corporation and its subsidiaries design and manufacture all of their products so they can be operated safely. the responsibility for safe operation rests with those who use and maintain these products. However.4 DECALS See Figures 1-1 A and 1-1 8. 1. C. will minimize the possibility of accidents throughout the useful life of this equipment. DO NOT modify the compressor and/or controls in any way except with written factory approval. Attempt repairs only in clean.Section 1 SAFETY 1.).2 ELECTRICAL SHOCK A. . 1. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed live parts of electrical system. Failure to follow the instructions. Use and operate the air compressor only in full compliance with all pertinent OSHA requirements or any pertinent Federal.3 VARIABLE SPEED DRIVE Refer to Section 6 for safety information on prducts with variable speed drives. These decals should never be removed. use part number printed on decal face. dry and well lighted and ventilated areas. The precautions listed there. NEVER start the compressor unless it is safe to do so. Stay clear of the compressor during electrical storms! It can attract lightning. Maintain dry footing. and who have read and understood their compressor's Operator's Manual. For safe machine operation it is vitally important to review all safety precautions noted in the Safety Section of your compressor's Operator's Manual. If a decal becomes damaged. stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. DO NOT attempt to operate the compressor with a known unsafe condition. The Supervisor control panel contains several decals which contain necessary information for safe performance. B. Section 1 SAFETY Figure 1-1 A Decals A WARNING 250027-935 250017·903 2 . 3 .Section 1 SAFETY Fi ure 1-1 B Decals part key number description number quantity 1 decal. State or Local regulations whenever applicable. auto start 041065 i (I) OSHA and FDA guidelines are superseded by any Federal. danger breath air (I) 250027-935 3 sign. warning auto start 250017-903 2 decal. warning "food grade" lube 250003-144 1 4 decal. Section 2 SUPERVISOR DESCRIPTION Figure 2-1 Supervisor Control Panel SUPERVISOR CONTROLLER™ CD®SUUAIR® P2 4 . This menu is used to view status or edit parameters. Factory Setup .Pressure and temperature and timer settings.T1 . Help key. Remote Stop . Stop. This can be used to disable sequencing. Clears faults and warn- Control Parameters . Stopped . E).Line pressure • Used to edit text or numbers (move cursor right).Current pressures. (Used only in sequencing modes). last line of display.1 SUPERVISOR KEYBOARD LAYOUT Refer to Figure 2-1.P2 .Used to select an item from a menu. After entering a function. Line 3 . they will be shown for 2 seconds each. ~ The function menu has the following entries : The bottom row has four keys : VSD Satus.Run.(VSD Packages only) See Section 6.Correction factors for pressures.Machine running. 2.Section 2 SUP RVISOR DESCRI 2. To select a function. ~ . n· Used to change numbers or text. or scroll. used to display possible causes of Trim ·Machine running. The machine will start when the remote start contact is closed. The Display module has eleven keys grouped in two rows. ON The top row has the following seven keys : Seq Stop .Machine not running. if any of the arrow keys are pressed. [~. stops machine. loaded and modulating in a sequenced system.(VSD packages only) See Section 6. Test .E. Sequencing • Sequencing parameters. If an alarm is active. Unloaded -Machine running unloaded. the function menu is displayed. The machine will start when the sequencing conditions meet the criteria to start. . .Model settings. Status . the information can be viewed by using the up and down arrow keys.Machine state : E-Stop . Line 4 .Machine forced to full load.Log of sensor readings leading up to a fault. then the values can be changed. !! ·Used to change numbers or text. Full Load. ~ Line 2 • Fault or Warning.Log of previous faults.Discharge Temperature 2. then press the enter ~ key. VSD Setup. use the up and down arrow keys to scroll to the desired function as indicated on Loaded . Fault Log . and correction for an alarm or fault. To change a value. loaded and modulating. Maintenance • Preventive maintenance information and timers. ings if machine is stopped. temperatures. If there are multiple alarms.Used by Sullair personnel for troubleshooting serial communications.2 MAIN DISPLAY Line 1 . System Display . scroll to the line to be changed 5 . blank means no fault or warning is present. If the function displays parameters. -Toggles Local/Remote mode. NOTE: the machine may start at any time. NOTE : the machine may start at any time. I ·Returns to main display.Compressor is off but armed to start. starts machine.Stop button pressed.Toggles auto mode. pressing the '?' key will give troubleshooting information on that alarm. Sensor Log . ~ -Used to edit text or numbers (move cursor left). Clears warnings if machine is running.3 FUNCTION MENU While in the main display. If the function shows status then values cannot be changed.Display of modes of machines in a sequencing system.Compressor is off but armed to start. Calibration . or start and end an edit on a parameter. or auxiliary estop present. inputs and outputs. or scroll. bar. Drain Interval • If the machine has an electric solenoid drain. If disabled parameter is zero. Aux E-Stop -Auxiliary E-Stop. machine are viewed and set using this display. which is not controlled or monitored by the Supervisor. The speed will be adjusted to maintain this pressure. Time to wait after power up before starting machine. Restart time - Load Cycles • Number of load/unload cycles. Unload Time . pushing the enter key will fix the value. This is normally adjusted near the bottom of the load/unload band above. Digital inputs and outputs are shown either as a '0' (zero) or '1' (one). wired by customer. When editing is finished.(VSD packages only) The targeted pressure for the variable speed controls. If the time is set less than 15 minutes (for example 5). This is a view only display. INPUTS AND OUTPUTS All inputs and outputs are displayed showing both the designator and the description (eg. this parameter specifies the amount of time that the machine will run unloaded before shutting off. Text fields can also be edited in the same manner. the machine will not automatically start after power up. depending on model. The interval is the time between activations of the drain and the Drain Time is the length of the time energized. The following are detailed descriptions of the various displays. then use the up and down arrow to change the letter. Be sure to depress the Emergency Stop button to defeat this function when automatic start is to be prevented. Zero is off and one is on. Setpoint. Digital Inputs • D1 through D10.The pressure differential below the unload pressure where the machine is loaded.6 bar).The pressure where the machine is unloaded. T1Discharge) along with the selected temperature (C or F) or pressure (psi.4 STATUS -CURRENT PRESSURES. editing is terminated and the original value is reset.5 CONTROL PARAMETERS • PRESSURE. The left and right arrow keys can be used to move to other digits or letters in a value. For example if this parameter is set to 11 0 psi (7 . Run Hours . Push the enter key to complete the edit. 2. These parameters may vary by machine model. Load delta . This parameter is used to keep several machines from starting at the same time after power up. The value can be changed by using the up arrow or down arrow keys. This does not apply to the Sullair SCD zero loss drain.P1 through P4 depending on model. there may be times when the machine will run unloaded for more than 15 minutes. TEMPERATURES. Delta pressures .Hours machine has run loaded or unloaded. If this parameter is a . For example to change a value from 100 to 500. 2. Relay Outputs . If during a change the ESC key is pushed. kPa) units. and the up arrow key used to increment the digit to 5. For example if the unload pressure is set to 11 0 psi (7 .Section 2 SUPERVISOR DESCRIPTION using the up arrow and down arrow keys. E-Stop String .E-Stop push button. The order of display is : Temperatures . This secondary timer is disabled when a machine is configured for VSD motor control.dp1 through dp3 depending on model. depending on model. Load Hours . This is because there is another timer that keeps the machine from being started more than four times an hour. or to delay start until other equipment is started. this parameter and the following parameter (Drain Time) are used to turn on the drain.Hours machine has run loaded.T1 through T5 depending on model.If the machine is running in AUTO mode.Length of time that drain is energized. Starts • Number of times machine has started. Drain Time.9 bar). Refer to Section 6 for additional details.6 bar) the machine will unload when the line pressure is above 110 psi (7 .K1 through K8. the machine will load when the line pressure goes below 100 psi (6.6 bar) and the load differential is set to 10 psid (0. Push the enter key to start the edit. Pressures. 7 bar). TEMPERATURE AND TIMER SETTINGS Parameters that control the operation of the 6 Enabling this function also enables automatic restart after power recovery. use the left and right arrow keys to move to the letter to be changed. the left arrow key can be used to position the cursor to the 1 digit in the 100. and push the enter button. The Control Parameters are : Unload pressure . the machine restarts after a delay defined by this time. standard for full voltage start. When then 'Sequence By' parameter is set to 'Hours'.Temperature units may be set to degrees For degrees C. if the Restart Time is set to 10 seconds. .Section 2 SUP RVISOR number larger than zero.Hours before oil change. Each line represents readings that are 5 seconds apart for one minute.Secondary separator part number.Communications number. Spanish. then the machine will be enabled to start after 10 seconds. Oil Anal. PN . Pressing the down arrow displays the previous fault etc). 2. Com Number . The top line of the display shows the run hours where the fault occurred. Unload pressure MUST be lowered to rated pressure when using Load/No Load mode. Ser. 2. (VSD packages only) . T4. Prim. There is a second set of readings for T3. Italian and French may be selected for display language.8 SENSOR LOG Log of sensor readings leading up to a fault. or kPa. Air Filter hours • Hours before air filter change. German. . Press Units ·Pressure units may be set to psi.Also used to control the closed inlet start valve. No -Serial number of machine. Separator hours ·Hours before separator change.When the following drop below this number. T2.Default state is Yes for normal machine control. the machine with the least amount of Seq Hrs is started first. Modulate. • Primary separator part number.This is an hour counter used when the 'Sequence By' parameter is set to 'Hours'. Remote . Remote Load/Unload and Local/Master inputs Hours . (ie. language select • English.Uses the Com Number to determine order of sequencing Seq Hrs . Prim. Sequence By . P1 & P2.7 FAULT LOG -LOG OF PREVIOUS FAULTS The fault log shows the last 16 faults that occurred. When two or more machines are connected together using the network (RS-485 channel). P3 & P4. a warning is issued.Primary air filter part number.Enables Remote Start/Stop.Hours before oil filter change.Oil part number. Oil hours . Machines . and the second line shows the fault. For example in a three machine system the machine communications numbers should be 1. Wye to delta transition timer . 2. when the function is entered the most recent fault is displayed. The faults can be scrolled through using the up and down arrow keys. They are ordered by most recent first. PN . For example a distributor can put in his name and telephone number. each machine must have a unique number or address. Select No for Load/No Load operation. Sec. Oil Filter hours .This is the total number of machines 7 . These must be assigned in numerical order. Sec.6 MAINTENANCE • PREVENTIVE MAINTENANCE INFORMATION AND TIMERS The following lines are on the Maintenance display. ESC PTI N These hours and part numbers can be changed using the enter and arrow keys.Control does not do any sequencing. The following lines show T1. Each hour that the machine is running increments this counter. and the machine with the most Seq Hrs is shut off first. Information -The top two lines may be changed to advise what to do when there is a maintenance warning. • Secondary air filter part number.Additional adjustments for VSD operation are shown in Section 6.Sequencing mode can be set to: Disabled . Warn at . 2 & 3.9 SEQUENCING ·SEQUENCING & COMMUNICA· TION PARAMETERS The following parameters can be viewed and edited. The sensor log shows the sensor readings leading up to a fault. then one minute apart for 10 minutes.Uses the Seq Hrs parameter to deter mine order of sequencing Number . • Hours before oil analysis. For more details on sequencing see the Supervisor Sequencing and Protocol Manual. Requires approximately 4-6 seconds for wye-delta or solid state starting. Disable by setting to zero (0). The top line shows the last fault. Temp Units . 2. bar.Oil Filter part number. For example. The rotate forces the machine to stop after it's Seq Hrs. The factory setup display is used by Sullair personnel to initially set up the machine. the time and date can be set using these parameters. Day. forces the machine to unload. Recovery Time . Year. protects the control parameters from change. If the password is non-zero.10 SYSTEM DISPLAY. P2. Minute. Up to sixteen machines may be networked if all have Supervisor Controllers and limited to eight if some have Supervisor ll's. The calibrated reading dle of the line. The of the line is added give the calibrated is shown in the mid- Cap and KW calibration (VSD packages only) may be used to adjust values shown on VSD Status displays.Not used at this time. the next machine will not start unless the Recovery Time has elapsed.Unloaded L ·Loaded T -Trim machine F ·Full load Sequencing Hours Capacity. The following val- . 2. are greater that the other machines.13 FACTORY SETUP.Force fault on warning. The four pressures P1. and the pressure has not recovered (i. Fault on Warn . unloading and starting at the same time.Emergency Stop M . all the time. low Press .. For example in a two machine system. These are factory set to nominal values (1 00%). the unload timer never expires).DISPLAY OF MODES OF MACHINES IN A SEQUENCING SYSTEM Note that this display is only applicable when there are two or more machines connected to the communications network (RS-485) and the Sequence By parameters on each machine are set to 'Hours' or 'Number'.Section 2 SUPERVISOR DESCRIPTION connected to the network (RS-485 channel). 2.CORRECTION FACTORS FOR PRESSURES The first line of this display is the password.If the Communications Module is present in the system.Standby 8 S -Starting U. The right hand number on the top line is the system pressure. then enter the displayed number plus 4 to enable changing the parameters. The only time this parameter should be used is in a Leave this parameter disabled unless instructed by Sullair Service Personnel. The machine that is running will shut off when the Seq Hrs. 2. this parameter should be set to 3.11 CALIBRATION. once a machine is started. In this case the machine will never unload and shut off.Manual stop R .Pressure read by machines pressure transducer.This parameter keeps multiple machines from loading. This can happen when the load matches the output of the machine. If the password is 0 then the following parameters are not protected and can be changed. Force Unload . situation where. Month.Remote stop B. There are also three other parameters in the calibration function: Protect • When set to yes.When set to yes. Rotate -This parameter is used only in very special cases. For example if a low pressure condition causes a machine to start. & P4 as well as the be calibrated. has risen over 'Low Press'). For example in a three machine system. it never stops (ie. The system pressure transducers on all machines should read within 1(one) psi of one another.Model settings. Local System Pressure .e.12 TEST.Used by Sullair personnel for troubleshooting of serial communications. Note that the local pressure readings can be used to determine what machines may need to be calibrated.This is the lowest pressure allowed before immediately starting a machine. with Rotate set at 100 hrs. are 100 more that the machine that is stopped. The calibration function can be used to set the readings to be the same. The columns are described below Communication Number StatusE . P3 differential pressure dP1 can number on the right hand side to the transducer reading to reading. The top line is a legend that describes each column. Hour. but may be adjusted as desired. The system pressure is the highest pressure reading of all the machines. 2. For example if the number displayed is 10 then changing the password to 14 will enable editing. Run Hours . Oil Switch -Oil pressure differential switch.Describes signal from Supervisor controls to the VSD controls: None. Com Module . Separator Maintenance warning is disabled for loaded P1 pressures below this value (i.Yes/No Enables or disables the communication module if installed.Number of load/unload cycles.Hours machine was running and loaded.e.Time to run machine before stopping. Yes or No. Protect . Min Load Psi. Spiral Valve. 250. Oil pump prelube and postlube control. Serial • The drive is connected on the Supervisor serial data bus K8 Option .Minimum acceptable load Pi pressure setting. indicating fluid. during start-up).K8 output relay function selector Disabled. P1 Max • Maximum discharge pressure. Starts . Stop Timer.Protect control parameters. indicating spiral valve control.Yes/No Enables or disables the motor actuator module if installed. Load Cycles . 500. Master Control for special external sequence control.Model number of machine.Hours machine was running loaded and unloaded. VSD. KT Fluid -Yes or No.(VSD packages only) Yes or No. Model ..Pre-lube/ Post-lube function timer .Number of machine starts.0 seconds (disabled) to 30 seconds.No VSD Pressure • The Supervisor pressure singal is connected to a drive analog input Lube Cycle . Cooling ·Air or Water. Speed • The Supervisor provides a speed signal to a drive analog input. Yes or No. Capacity • Maximum capacity of machine. 9 . Water Switch -Water pressure switch.Section 2 SUP RVI ues reflect the machine configuration. Press Trans ·Pressure transducer range 200. Mtr Module . ON Load Hours . I l I Control Parameters Unload Psi Load Psi Setpoint' Unload Time Drain Interval Drain Time Restart Time Wye-Delta Time Modulate YiN Language Temp Units FiC Press Units PsiibarikPa Cost/KWH' Saving VS' Reset Load Est' (") 0 Sequencing Sequence By xxxxx Sequence Hrs xxxxx Com Number xx Machines xx Low Press xxx Recover Time sec Rotate (hours) Minute xx Hour xx Day XX Month xx Year xxxx I Fault Log I Last 16 faults recorded j Maintenance I j Sensor Log I Info to be loaded by Distributor for all consumables * These parameters do not apply to some models.. (/) c:: '0 Cll ~- 0 I I Status I T1 -Discharge T2 -Dry Side' T3-0il' T4 lnterstage• P1-Sump P2-Line P3-0il Filter• P4-0il' dP1-Separator dP2-0il Fill' dP3-0il' Load Hours Run Hours Load Cycles Starts E-Stop String Aux E-Stop D1-Motor Ovid D2-Aux Ovid D3-Air Filter• D4-Water Press• D5-Remole Start D6-Remote Unload D7-Master Control DB-Brownout D9-Not Defined D10-Not Defined K1-Run K2-Wye-Delta K3-Load K4-Full Load K5-Drain K6-Common Faull K7-Common Warn K8-0ption I j VSD Status* I Capacity• Capacity%' Power• Power o/o'* Recent Usage----· Hours' Capactiy' Capacity%' Power• Power%' KCF' KWH' Cost' Savings• Lifetime Usages--· Hours• Capacity' Capacity%' Power' Power o/o .. KCF' KWH* Cost' Savings• Drive Status-----· P2' Motor RPM' Frequency' Drive Temp' Motor Prot• ...... T1 T2 P1 P2 T3T4P3P4 System Display Machine status of Sequenced machines ~ 0 a .t VSD Auto Set' Nominal HP' Nominal Volts' VSD Max Amps' Motor FLA' Motor SF' MotorV' Motor Hz' Motor RPM' Cll Cll c m en (") ...a -"tJ -0 ~ z ...a :::J I I rc~b~~ti~nl Password P1 P2 dP P3 P4 Cap KW Protect NIY Fault on Warn YiN Force Unload YiN en CIJCD c n "tJ 0 m :J N ~ .Cll Factory Setup Password Set Defaults Model Cooling Press Trans P1 Max KT Fluid Water Switch Oil Switch Aux OverlOad Min Load Psi Stop Timer Lube Cycle K8 Option Load Hours Run Hours Load Cycles Starts Capactiy Sprial Valve' VSD NIY Com Module NIY I Test I Serial communications diagnostic screen VSD Setup* ~ ::J c:: :. en ::::: .Oil o- MAIN SCREEN Machine Status Trouble State xxxPsi P2-Line xxxF T 1-Discharge 0 (0 ':"' ...... Observe the operating temperature. it is necessary to check the direction of the motor rotation. simply press the STOP ti button. 3. 3. check that the proper level is visible in the fluid sight glass and simply D iJ or AUTO MODE button. Slowly open the shut-off valve to the service line. 9.3 SUBSEQUENT START-UP PROCEDURE On subsequent start-ups. Read the preceding pages of this manual thoroughly. observe the instrument panel and maintenance indicators.2 INITIAL START-UP PROCEDURE The following procedure should be used to make the initial start-up of the compressor. press the START When the compressor is running. The compressor will unload at nameplate pressure. 3. 10.Section 3 RES 3. 2.1 ). then recheck rotation. and counterclockwise on direct drive models.1 MOTOR ROTATION DIRECTION CHECK After the electrical wiring has been done. 4. disconnect the power and exchange any two of the three fan motor leads at the fan motor starter. If adjustments are necessary. but the fan direction is affected by installation. Check for possible leaks in piping. A "Direction of Rotation" decal is located on the coupling guard between the motor and compressor to show proper motor/compressor rotation. If temperature exceeds this range. see Control System Adjustment section in the compressor operator's manual. Jog motor to check for correct rotation of fan (refer to Section 3. 11 . With the control system in MANUAL mode. To change direction. Open shut-off valve to the service line. Be sure that all preparations and checks described in the Installation Section have been made. press 0 and pads in succession to bump start the the compressor. Reinspect the compressor for temperature and leaks the following day. ensure that fan rotation is correct. 5. Refer to compressor operator's manual for acceptable operating range. 3. Start the compressor in the desired operating mode or il. If the motor shaft is not turning in the proper direction. 8. 1 . Variable speed drive packages will have main motor direction set at the time of construction. the cooling system and installation environment should be checked. 7. the shaft should be turning clockwise on all gear driven models. disconnect the power to the starter and exchange any two of the three power input leads. When looking at the motor from the end opposite the compressor unit.4 SHUTDOWN PROCEDURE To shut the compressor down. 6. If fan-cooled. Slowly close the shut-off valve to assure proper nameplate pressure unload setting is correct. NOTES 12 . Check wiring. Oil Pump or Other Motor Reset auxiliary overload after heater element cools. It contains symptoms and usual causes for the described problems.7bar) Check for closed valves or broken pipes. consult the Troubleshooting Section in the machine's operator's manual. E-Stop Button Active Release button. 13 . Oil Change Due. The information contained in the Troubleshooting chart has been compiled from factory experience. However. ALL ALWAYS Check motor starter contact for proper operation. Check for loose connections.2 portray common systematic setbacks that can occur during controller operation. Gant1nueB. Check for parts damaged by heat or an electrical short circuit.1 and 4. E-Stop ALL ALWAYS E-Stop Push Button ALL ALWAYS E-Stop ALL ALWAYS E-Stop String ALL ALWAYS Low Water Pressure ALL Watercooled Cooling Water Pressure Below 10 psi (0.1 TROUBLESHOOTING INTRODUCTION Whereas Sections 4. Auxiliary Motor Tripped on Cooling Fan. Air Filter Change. Maintenance Due ALL ALWAYS Maintenance Due Select Maintenance from menu to see service due and part numbers. c. Auxiliary E-Stop String Open Check auxiliary E-Stop devices. Always remember to: a. consult your nearest Sullair Distributor or the Sullair Corporation factory Service Department. if low consult power company. Check wiring. ALL ALWAYS Make sure compressor is properly configurated. Check for damaged piping... Oil Filter Change. Check for loose wiring. Should your problem persist after making the recommended check. for a more thoroughly in-depth coverage of machine operation setbacks. Verify correct motor amps. usually apparent by discoloration or a burnt odor.SUPERVISOR CONTROLLER PROBABLE CAUSE MESSAGE MODEL ENABLE Air Filter Maint Aux Motor Overload ALL ALWAYS ALL ALWAYS ALL ALWAYS ALL ALWAYS Differential Pressure Across Inlet Filter High REMEDY Replace filter. All available data concerning the trouble should be systematically analyzed before undertaking any repairs or component replacement procedures. 4 2 TROUBLESHOOTING GUIDE. A detailed visual inspection is worth performing for almost all problems and may avoid unnecessary additional damage to the compressor. Main Motor Overload ALL ALWAYS Main Motor Overload Reset overload after heater element cools down. Oil Analysis Due. ALL ALWAYS Make sure load pressure is set below limit of compressor.Section 4 u 4. Separator Change Due. b. Check inlet filter pressure switch. ALL ALWAYS Check line voltage. DO NOT assume that these are the only problems that may occur. FLOODED ALWAYS Oil pump may be required for remote coolers. ALL ALWAYS ALL ALWAYS Oil filter clogged. Replace module referred to in error message. T5 Sensor Fail ALL ALWAYS dP1 Separator High FLOODED 110 Mod Com Error.. FLOODED ALWAYS Sump oil level low. wiring and tubing. ALWAYS Pressure Across Separator High Plugged separator elements. if problem persists replace display module. 1/0 Module and Other Optional Modules is Not Working Correctly Check wiring. ALL ALWAYS Sensor failure. replace. check sensor wiring. consult Sullair service department.SUPERVISOR CONTROLLER (CONTINUED) MESSAGE MODEL ENABLE PROBABLE CAUSE Main Motor Overload (CONTINUED) REMEDY ALL ALWAYS ALL ALWAYS ALL ALWAYS ALL ALWAYS ALL ALWAYS FLOODED ALWAYS Low ambient temperature. T1 Sensor Fail. Com Mod Com Error. Slowdown or Pneumatic Valve Failed) Check valves. P2 Sensor Fail. The Network that Connects the Display Module. Check Sullicon adjustment (see Control Adjustment section in the compressor operator's manual). T3 Sensor Fail. Factory Setup Error ALL ALWAYS The Factory Setup Information Needs to be Reviewed for Correct Values If problem persists replace Supervisor. FLOODED ALWAYS Low ambient temperature. Oil pump failure. T2 Sensor Fail. sump heater may be required in ambients below 40•F WC). Pressure Across Oil Filter Above 20 psi (1. Module Network Error. T4 Sensor Fail. check sensor. Motor Mod Com Error. Spiral. if low consult power company. Check sensor wiring. P3 Sensor Fail. sump heater may be required in ambients below 40•F WC). Sullicon. P1 Sensor Fail.Section 4 TROUBLESHOOTING 4 2 TROUBLESHOOTING GUIDE.4 bar) While Running Oil Pressure Low Sensor or Wiring Failure Oil filter clogged. Pressure sensor failure. Check line voltage. Check sensor. Contmued••• 14 .) Check motor starter contacts for proper operation. replace oil filter. replenish oil to proper level. VSD Com Error Oil Filter Maint. dP3 Oil Pressure Low Main Motor Overload (cont. replace oil filter. dP2 Oil Filter High P3 Oil Pressure Low. P1 Sump Pressure High FLOODED ALWAYS Sump Pressure High (Poppet. P4 Sensor Fail. SUF ERVISOR CONTROLLER (CONTINUED MESSAGE ENABLE PROBABLE CAUSE MODEL P1 Sump Pressure High (CONTINUED) P1 Sump Pressure Low Sump Pressure High (Poppet. FLOODED ALWAYS Sump Pressure Low T1 lnterstage High. clean tubes and shell. VSD Com Fault ALL VSD Communication Error Detected by Drive Check for intermittent control wiring to drive. wiring and tubing. T4 lntercool High. Fault Ambient above 105'F (41 'C). T3 Oil Temp High. FLOODED ALWAYS Thermal valve. T1 Discharge High. Intermittent Control Power Check line voltage and connections. T2 Discharge High. replenish to proper level. T2 Dry Side High. T5 Discharge High. High water temperature. ALL Airceoled Cooler fins dirty. VSD Param Lim Fault ALL VSD Communication Error at Powerup or Setup Check centro! wiring to drive. if plugging persists. check for valve closed. Sullicen. ALL ALWAYS Motor Starter(s) Not Working Check starter controls and wiring.Section 4 NG 4.) FLOODED ALL ALWAYS Pressure regulator. Machine may have failed to start. use cleaner water. Spiral or Slowdown. High Temp. No Contatct to Input D8 Check wiring to input. FLOODED ALWAYS Fluid level low.2 TROUBLESHOOTING GUIDE. Check pressure sensor. increase flow or lower water temperature. check operation. check adjustment and operation. ALL Watercooled ALL Watercooled Low water flow. check operation and wiring. improve local ventilation. clean fins and fan. T3 Oil Temp High. or Pneumatic Valve Failed) (cent. ALL ALWAYS Sensor failure. VSD Drive Fault_ ALL VSD 15 . Fault Detected by Drive See Section 6. VSD Emergency Stop ALL VSD E-Stop Button Active Release button. check sensor and wiring. pump off or broken pipe. FLOODED ALWAYS Check minimum pressure check valve (not applicable to Oil Free compressors). T4 lnterstage High Power Interruption REMEDY ALWAYS FLOODED ALWAYS ALL ALWAYS Solenoid valves. ALL Watercooled Cooler plugged. Incorrect Factory or VSD Setup Check setup menus and drive rating. if parameter is non-zero At Start · will not allow start if alarm present Over Min Psi • machine is loaded and above min load pressure 16 30 30 0 0 0 0 30 30 0 0 0 0 Comment At Start High sump psi at start When Running Immediate Fault Constantly Sensor failure fault Constantly Sensor failure fault Constantly Sensor failure fault Constantly Sensor failure fault Constantly Constantly Sensor failure fault Delayed for temp spikes Constantly Constantly Constantly Constantly Delayed for temp spikes Immediate Warning Immediate Fault Sensor failure fault Constantly Constantly Sensor failure fault Delayed for temp spikes Constantly Constantly Delayed for temp spikes Sensor failure warning Constantly Sensor failure warning Constantly Sensor failure fault Constantly Sensor failure fault . alarms are checked: Constantly .Section 4 TROUBLESHOOTING Table 4-1A Analog Alarms (Flooded Screw Compressors Less Than 200 psi) Sensor Type Limit Start Delay Run Delay Check(*) p 1 p _1 p _1 p 2 High Inhibit P_3 p 4 T 1 T_1 T_1 T_1 T_1 T_1 T_2 T_2 T_2 T_3 T_3 T 4 T_4 High Fault 5 5 500 500 500 500 -40 225 235 245 255 500 -40 225 235 -40 500 -40 500 0 5 0 0 0 0 0 5 5 0 0 0 0 5 5 0 0 0 0 0 0 0 0 0 0 0 Low Fault High Fault High Fault High Fault Low Fault High Warn High High High High Fault Warn Fault Fault Low Fault High Warn High Fault Low Warn High Warn Low Fault High Fault (*) In the 'Check' column above.if machine is running If Enabled .if machine running or stopped When Running . alarms are checked: Constantly .will not allow start if alarm present Over Min Psi . LS-20T and LS-20TS Compressors) Run Start Sensor P_1 Low Fault p 1 High Inhibit p _1 High Fault p 2 High Fault P_3 High Fault p 4 High Fault T_1 T_1 T 1 T 1 T_1 T_1 T_2 T_2 T_2 T_2 T 2 T_2 T 3 T_3 T_4 T_4 T_4 T_4 T 4 T_4 Low Fault High Warn High Warn High Fault High Fault High Fault Low Fault High Warn High Warn High Fault High Fault High Fault Low Warn High Warn Low Fault High Warn High Warn High Fault High Fault High Fault 5 5 500** 500** 500** 500** -40 245 255 255 265 500 -40 245 255 255 265 500 -40 500 -40 245 255 255 265 500 5 0 0 0 0 0 0 5 0 5 0 0 0 5 0 5 0 0 0 0 0 5 0 5 0 0 0 0 0 0 0 0 0 30 0 30 0 0 0 30 0 30 0 0 0 0 0 30 When Running Constantly Delayed for temp spikes 0 Constantly Immediate Warning 30 Constantly Delayed for temp spikes 0 Constantly Immediate Fault 0 Constantly Sensor failure fault At Start Immediate Fault High sump psi at start Constantly Sensor failure fault Constantly Sensor failure fault Constantly Sensor failure fault Constantly Sensor failure fault Constantly Sensor failure fault Constantly Delayed for temp spikes Constantly Immediate Warning Constantly Delayed for temp spikes Constantly Immediate Fault Constantly Sensor failure fault Constantly Sensor failure fault Constantly Delayed for temp spikes Constantly Immediate Warning Constantly Delayed for temp spikes Constantly Immediate Fault Constantly Sensor failure fault Constantly Sensor failure warning Constantly Sensor failure warning Constantly Sensor failure fault (*) In the 'Check' column above.Section 4 Table 4-1 B Analog Alarms (LS-16T.if machine running or stopped When Running .machine is loaded and above min load pressure (**) 750 psi for 750 psi transducers.if machine is running If Enabled -if parameter is non-zero At Start . 17 . kPa Disabled. Time Of Day etc. Master Control Hours machine has been loaded Hours machine has been running Number of load cycles Number of starts Used by monitor to determine system load Setup Setup Setup Setup Setup Setup Always X200 X250 X500 X750 Always 1 135 135 250 400 0 0 50 50 150 300 0 2 225 195 495 560 1 Press Trans P1 Max P1 Max P1 Max P1 Max Water Switch Setup Flooded 0 0 1 Oil Switch Setup Setup Always Always 65 0 20 0 200 30 Min Load Psi Stop Timer Setup Setup Setup Setup Setup Setup Setup Cal Cal Cal Cal Cal Cal User User User User User User Always Always Always Always Always Always Always Always Always Always Always Always Always X200 X250 X500 X750 Always Always 0 0 0 0 0 0 0 0 0 0 0 0 0 110 110 150 150 10 15 0 0 0 0 0 0 0 -7 -7 -20 -7 -7 0 30 30 150 150 3 0 30 2 100000 100000 100000 100000 10000 7 7 10 7 7 1 220 185 360 560 70 59 Lube Cycle K8 Option Load Hours Run Hours Load Cycles Starts Capacity P1 P2 dP1 P3 P4 Fault on Warn Unload Unload Unload Unload Load Delta Unload Time User User User User Always Always Always Always 0 0 0 0 0 0 0 0 30 10 59 15 Drain Interval Drain Time Restart Time Wye Delta User User User Seq Always Always Always Com Mod 0 0 0 0 0 0 0 0 2 1 2 4 Language Temp Units Press Units Sequence by Seq Seq Seq Seq Seq Always Always Always Always Always 0 1 1 70 10 0 1 1 20 2 100000 16 16 185 59 Seq Hrs Com Number Machines Low Press Recover Time Seq Always 0 0 250 Rotate 18 Force shutdown on warning 250psi transducer unload pressure 200psi transducer unload pressure 500psi transducer unload pressure 750psi transducer unload pressure Differential pressure from unload pressure Auto mode shut down after unloaded for this time Time between drains (Minutes) Duration of drain (Seconds) Auto restart on power up if not 0 (Seconds) Wye to delta starter transition time (Seconds) French. run unloaded for this time before stopping Prelube/Postlube timer Disable. Remote. German. Used for Hours sequencing mode Communications ID number Number of machines in a system Panic start next machine in sequence Keeps multiple machines from starting at same time (seconds) Used to force a machine to stop . Celsius Pressure units.250.Section 4 TROUBLESHOOTING Table 4-2 Parameters Type Enable Default Min Max Display Text Comment 200. Lube Pump. Hours.500.Com. English Fahrenheit. Psi. Bar. Italian. Spanish. 750 250psi transducer 200psi transducer 500psi transducer 750psi transducer Water pressure switch enable for water cooled machines Oil switch enable for flooded screw machines Minimum acceptable Loaded P1 value If not 0. Slave. 4.3 MACHINE BEHAVIOR AFTER A POWER OUTAGE Condition: Machine was in a running or ready condition when power was lost. The Run Mode column the machine run mode (Auto button on the display panel). It can be Disabled. & P1< 5 psig Remote Remote Local Local xxxx xxxx Cont Auto Manual Stop Start after Restart delay & P2 < Load psi. The Local/Remote column refers to the Local/Remote Button on the display panel. See previous table for column descriptions. Mode column pertains to the Sequencing mode parameter. 4. Table 4-3 below describes how a machine behaves after a power up under various conditions if the Restart timer is greater than 0. & P1 < 5 psig Remote Remote Off Cant Remote Stop Remote Remote Off Auto Remote Stop Remote Remote Remote Remote On On Cont Auto Start after Restart delay Start after Restart delay & P2 < Load psi . If the Restart timer is 0 the machine powers up in the Manual Stop state. The controller will then re-engage the starter after normal start permissives are satisfied. this feature is used to enable the compressor to properly recover from very short-cycle power loss or voltage dips for those installations that are susceptible to this kind of power interruption. If the Restart Timer is zero then the machine always powers up in Manual Stop. Note that this table only applies if the Restart Timer has a value other than zero.5 BROWN OUT INPUT 4. Table 4-4 Remote Start/Stop Input Local/ Remote Remote Start/Stop Run Mode Action (State) Local Local xxxx xxxx Cont Auto Normal Cant Operation Normal Auto Operation Remote Remote Off Off Cant Auto Remote Stop Remote Stop Remote Remote On On Cont Auto Start if stopped Normal Auto Operation 19 . The Seq. set to Remote Start/Stop or to other sequencing modes (Seq). The controller alone is not as sensitive to these interruptions as is the switchgear. the Sequencing Mode parameter must be set to Remote to enable Remote Start/Stop input. Mode Local/ Remote Remote Start/Stop Run Mode Disabled Disabled xxxx xxxx xxxx xxxx Cont Auto Manual Stop Start after Restart delay & P2 < Load psi.u 4 the Remote Start/Stop input.4 REMOTE STOP/START INPUT Table 4-4 below describes how a machine reacts to Normally not wired by factory. & P1< 5 Note: 'xxxx' means Action (State) 'has no effect'. Table 4-3 Machine Power Outage Behavior Seq. The Remote Start/Stop column pertains to the Remote Start/Stop input. A normally closed starter contact wired to the Brownout input (D8) forces the controller into a standby state if the starter drops out. and must be told that the loss has occurred. NOTES 20 . 1 WIRING DIAGRAM. z 1'U.5 5. ~· :0::: c:::: u 5.: ._ LJ z c:::: ~ Gi >· --------~ (_:::: LJ L{ CL LC u: [I LJ <( (_j > Ct: >02250131-248R01 21 . C.SUPERVISOR COMMUNICATION MODULE ::2 !_._ c.J :__)--' ~('-. 0 [L 2 < L. ...H 0 AUX :::0 ..n en ('!) 0 !::!: 0 :l 0'1 .AON T Alit 1 (QMM(1tJ WARN 120 VAC CONTROL VOL TAG[ )> G) ~ s: I< 1-K":.n (") 0 :::0 @]1][0 :1 G) s:: :I: U PW!-.'[M(.N(I AIR TEMP ~ u..( (. -.. (11(1 [' _ ___.... -. ~1 l l Ll' !NTtR:. z z ·11-l·-. (") z ~] c.10FWt. -1r {)"'I ID {... 0 S l(lP ~ ''j -i :::0 -- 18< 0 r TB:. ..TA(..... -~·:1M(1l .. IM ~IARI/:.tRN .' Q 3 TBJ 01 R( l'.. [ 0 c......_ll[ -~-···~R[I...lj 1::J 24 'v'A( :..n j......1 G) VI)( 0 GNO 0 0 )> G) j/(1 :::0 MClDL•L t )> I en =-~-·· c m ..::f.N[l 7 tN""D! ~ COIJI. FL' m s: ~ . I ?MOl PR"f:~·SttR( WAT[R SWlT(H -· f..IJTf [\/.."f.N N 0 N N <. ~ ~ ~ ~ ~ --Cl ?4VAC ------~~------------------ ~• OA(' ~ ~4 ((•1...o(HASZJS C-NQ ~ 0 ~ .l(IP L!NLC•A[l ·-·-·tlllA)l[R C(lNlROL (lR{JWNOl1 R(:( T c. "' RI-'N .:{+-. Failure to observe this precaution could result in death or severe injury. disconnect the motor cable at the variable speed drive output terminals (U. grinding fluid mist. Before opening the variable speed drive covers: • Disconnect all power to the variable speed drive. Confirm that the capacitors have fully discharged by measuring their voltage using a multimeter set to measure DC voltage. adjusted. Before applying power to the variable speed drive. or condensation. 6. robust design. Do not perform any meggar or voltage with· stand tests on any part of the variable speed drive or its components. Do not touch any components on the circuit boards. Ungrounded units may cause electric shock and/or fire. Ground the unit following the instructions in this manual. V. The Supervisor monitors drive performance to provide motor thermal and other protections in an easy-to-use. high humidity. even if the motor is not running. • A hazard voltage may still remain in the DC bus capacitors even if the power has been turned off. Prior to any tests or measurements of the motor or the motor cable. Relevant drive status data and compressor performance are presented on the Supervisor display. Make sure that no power correction capacitors are connected to the variable speed drive output or the motor terminals to prevent variable speed drive malfunction and potential damage. and avoid locations that are directly exposed to sunlight. make sure that the front and cable covers are closed and fastened to prevent exposure to potential electrical fault conditions. Failure to follow the above precautions may cause death or severe injury. corrosive gas. V. install the variable speed drive in a well-ventilated room that is not subject to temperature extremes. explosive gas. W) to avoid damaging the variable speed drive during motor or cable testing. Proper grounding. or have high concentrations of dust. Refer all drive service to trained technicians. These are in addition to other warnings and cautions. Static voltage discharge may damage the components. L2. Improper testing may result in damage. W) and the DCiinklbrake resistor terminals (-/+) are live when the drive is connected to power. Drive controls are coordinated with internal compressor controls. 23 .1 SAFETY The following special instructions apply to VSD packages provided with electronic adjustable speed motor drives. L3). which can cause enclosure parts to be above ground potential. Failure to observe this precaution could result in death or severe injury. is required. • Wait a minimum of 5 (five) minutes after all the lights on the keypad are off. Its keypad provides simple setup and adjustment of necessary drive parameters. The drive functions as a module on the Supervisor communications bus. This equipment should be installed. inflammable gas. motor terminals (U. Contact with this voltage is extremely dangerous and may cause death or severe injury. This allows time for the DC bus capacitors to discharge.2 OVERVIEW The Sullair VSD drive application is custom designed for operation of air compressors. etc. Line terminals (L 1. as described in this manual. The variable speed drive drive has a large capacitive leakage current during operation. V. Failure to observe this precaution could result in death or severe injury. and serviced by qualified electrical maintenance personnel familiar with the construction and operation of this type of equipment and the hazards involved and in accordance with published service manuals.6 6. W) are not connected to the utility line power as severe damage to the variable speed drive may occur. Improper installation may result in a fire hazard. Make sure that the variable speed drive output terminals (U. All necessary control functions are performed through the Supervisor keypad. and with other Supervisor compressors in sequenced systems. Average percent of power at full capacity. _Based on a maximum environment of 104•F (40. The next eight lines indicate recent longer-term performance. • Consistent with UL listing requirements. for maximum protection of the variable speed drive. and tested prior to shipment of the compressor package. Capacity % . 6. adjusted. . The following may be used for evaluation of system performance. hp Size (A) Fuse (A) Wire Size Power Wire Size Ground 40 50 60 75 100 125 150 200 61 72 87 105 140 170 205 261 80 100 110 125 175 200 250 350 2 2 1 1/0 3/0 4/0 350MCM 2 X 250MCM 8 6 6 2 2 2 1/0 1/0 NOTE ON ELECTRICAL PREPARATION: Interior electrical wiring is performed at the factory. and/or any other applicable State. Power % .1. Power .Percent of power at full capacity.Average percent of full package capacity. use UL recognized fuses. • The minimum input line cable and line fuses must be sized in accordance with the rated input current of the unit. 6. Refer to the package wiring diagram for specific connection information.Average total package power in KW. Sullair provides a wiring diagram for use by the installer.4 SUPERVISOR DISPLAY AND MENUS Refer to Section 2 for a general description of the Supervisor and its displays and adjustments.Section 6 VARIABLE SPEED DRIVE Table 6-1: Cable and Fuse Sizes. Capacity % .OOOA. Capacity -Average delivery in CFM. Power . To ensure proper wiring to the package. Customer must provide electrical supply power disconnect within sight of machine.Total package power in KW. etc.460V Ratings _ UL recognized type RK. Federal and local electrical codes concerning isolation switches.C). Inspect the unit to ensure it was not damaged during shipment. KCF . This 24 section addresses special functions applicable to VSD packages. in accordance with the drive's requirements.4. See Section 6. + 75°C or higher. Do not alter factory wiring. National Electrical Code. The first four lines indicate real-time conditions: Capacity . See Table 6-1.4. Power % . 6.Percent of full package capacity.3 INSTALLATION This variable speed AC drive has been properly mounted.Running total of air delivered in thousands of cubic feet.2 for reset procedure. but should be done by a qualified electrician in compliance with OSHA. Required customer wiring is minimal. type RK5. fused disconnects. use the following guidelines: • Use heat-resistant copper cables only.Delivery in CFM. VSD STATUS This group of displays shows the performance of the variable speed compressor package. The package provides a terminal block for connection of threephase power and ground. • Suitable for circuits delivering fault currents up to 1OO. All internal wiring to the drive and motors has been provided by the factory. -This resets the "Recent Usage" values to zero in the VSD Status calculations. This functions similarly to a trip odometer in a car. and V200TS models. VSD . Cap ·for adjustment of delivery values.The descriptions in this section apply only to packages with integrated drive controls operating in serial communications with the Supervisor. Cost . 6. Spiral Valve .2 CONTROL PARAMETERS The following adjustments apply specifically to VSD packages. The cost of VSD operation can be compared to Inlet modulation. Saving vs -The basis for savings estimates.The features in this section apply only to V120. KWH .4.Running total of energy used in kilowatthours.This should be set to "Yes" for all normal applications. Setpoint • The targeted pressure for the variable speed controls. The last five lines indicate real-time control system parameters for service evaluation. Power % -Average percent of power at full capacity. or for display in other units of measure. Frequency . Cost/KWH -The cost per kilowatt-hour of energy is entered here. KCF . These can be used to fine tune nominal values used in VSD Status displays. Load/Unload. for use in cost estimates in the VSD Status displays.Running total of air delivered in thousands of cubic feet. V160. Reset Load Est. 6.Estimated savings compared to other control methods.Running total of cost of operation.4. VSD Auto-Set .Running total of cost of operation. or variable displacement Model .Running total of energy used in kilowatthours. but are protected by the password in the Factory Setup group. This may be used for adjustment to actual conditions.3 CALIBRATION Two additional calibration adjustments are provided in VSD. along with maximum speed. This performs automatic adjustment of several parameters based on operating conditions and user adjustments.5 VSD SETUP This group of adjustments sets up the parameters of the drive for the construction of the compressor package.4. The next eight lines indicate long-term performance during the entire life of the compressor. Savings .Output frequency of the drive in Hertz.4. These packages are designed specifically for integrated drive control. Motor Prot . Drive Temp . These may be viewed at any time. The valve will be opened for light demands.This should be set as appropriate for the package. enter 0. Nominal HP • The nameplate horsepower of the main drive motor. Capacity· This number will be adjusted.Internal temperature of the drive. KW -This may be used for adjustment to calibrated meters under actual operating conditions. Savings . Adjustments will be automatically made to the maximum speed to operate the motor at its full capacity at any pressure.4 FACTORY SETUP Factory adjustments are generally the same as conventional packages.070 for 7 cents per KWH. Power -Average total package power in KW. (spiral valve) control systems. V200S. Motor RPM . For example. 6. whenever a change is made to the setpoint pressure. Nominal Volts • The compressor package rated nominal voltage VSD Max Amps • The rated maximum current of the drive 25 . The spiral valve will be closed for highest efficiency at all moderate to heavy demands. Capacity % . V200. with a few additions. Most packages will allow adjustment of this over a wide range. Cost. This model selection will affect the choices available in the VSD Setup group. 6.Estimated percentage of motor temperature rise. to allow tailoring to the needs of the application. This is normally adjusted near the bottom of the load/unload band above. Each is adjustable from 0 to 200% of nominal. The speed will be adjusted to maintain this pressure.Motor speed.Average percent of full package capacity. Capacity ·Average delivery in CFM. P2 -System pressure.6 KWH .Estimated savings compared to other control methods. Compressor rotation is factory set. Drive fault codes are used for least-likely faults. VSD Emergency Stop (VSD Code 51) Emergency Stop is pressed Break in Estop wiring Clear the package emergency stop. communication faults will be indicated for either improper communication wiring or improper application or communication software in the drive.The motor's rated full load amps at nominal HP(I) • Visually check all power and controls connections to the drive to ensure that no damage has occurred. Contmuetl••• 26 . Refer to fault codes in table below. • short in the cables to the motor • unsuitable motor The DC-Iink voltage has exceeded its high limit due to: • too short a deceleration time • high voltage levels or surges in the utility supply Make the deceleration time longer.The motor's rated voltage{l) 3. If the fan rotates incorrectly. If a keypad service tool is plugged into the drive. Check Estop wiring to the drive input. Check VSD control power and check for board faults. FAULT POSSIBLE CAUSE SOLUTION VSD Param Lim Fault Incorrect model. D then the Stop ~ key on the Supervisor. The Supervisor will establish communications and report errors if correct conditions are not found. Connect to the utility and switch the power on. Check cables. CODE FAULT Overcurrent 2 Overvoltage POSSIBLE CAUSE SOLUTION The variable speed drive has detected a high current (>4xln) in its output due to: • sudden heavy load increase • short in the motor Check loading. 6. for improved performance. At installation ensure: • That the incoming power and ground wires are properly connected to terminal blocks in the electrical control box. Use a chopper and brake resistor. Motor Hz .the motor's nameplate frequency 4.6 FAULT AND WARNING CODES The Supervisor constantly monitors drive performance through the serial channel. disconnect power and simply interchange two of the fan motor leads at the fan starter. HP or Voltage selected in Factory & VSD Setup Make proper selections. VSD Com Error Communications lost with the VSD Check connections to the VSD. The Supervisor will display these as "Drive Fault" with a code number. The following messages are specifically displayed by the Supervisor in the event of problems. Check VSD control power and check for board faults. If replacing a drive. Add input impedance to limit surges.the motor's nameplate full-load speed {l)some package designs employ motors connected for voltages lower (and FLA higher) than the nominal voltage of the package. Check that moisture has not condensed inside the variable speed drive. Correct utility supply voltage (level is too high).Section 6 VARIABLE SPEED DRIVE Motor FLA . 5. To check rotation.5 STARTUP OF NEW COMPRESSOR PACKAGE 1 . it will display the fault code and the fault name shown in the first two columns. quickly press first the Start 2. Motor SF • The motor's nameplate service factor Motor V . 6. Read and follow all safety warnings and cautions in this manual. VSD Com Fault (VSD code 53) Drive Fault xx Communications problems detected reported by the VSD Problem reported by the VSD Check connections to the VSD. Motor RPM . Check motor. An overtemperature warning is issued when the heat sink temperature exceeds 185°F (85°C). 10 Input line supervision Input line phase is low or missing. Check the supply voltage. Make sure that the switching frequency is not set too high in relation to ambient temperature and motor load. If this fault appears simultaneously with Fault 1. Check for the correct amount and unrestricted flow of cooling air. Check the heatsink for dust or dirt buildup. 14 Over-temperature Heatsink temperature is over 194°F(90°C). rlontlll:ueCJ••• 27 . If no motor overload exists. If the fault reoccurs. DO NOT RE-CONNECT POWER! Contact Sullair service. 8 System fault • component failure • faulty operation Reset the fault and restart. • motor or load mechanical failure • load is too high • stall parameter settings incorrect 16 22 Motor over-temperature EEPROM checksum fault • motor is overloaded • motor overheating has been detected by the variable speed drive motor temperature model Parameter save fault • faulty operation • component failure Decrease the motor load. Confirm the stall parameter settings. cables and connections. • motor or motor cable short IF THE PROBLEM IS NOT IN THE MOTOR OR ITS CABLES. Note: exceptional fault data record. Should the fault re-occur. Reset the fault and restart. 11 Output line supervision Current sensing indicates that there is no current in one motor phase. If it was within specification at the time of the fault.6 CODE 3 FAULT Ground Fault (Earth Fault) POSSIBLE CAUSE Current sensing indicates that the sum of motor phase currents is not zero. an internal failure has occurred. contact Sullair service. Check the motor cables. Check all parameter settings after reset. Switch off power. connections and motor. 7 Saturation trip • defective component Cannot be reset from the keypad. Contact Sullair service. see the Active Fault Menu and Fault Time Data Record for more information 9 Undervoltage DC-Iink voltage is less than the minimum safe operating voltage limit. the variable speed drive will automatically reload the parameter default settings. 15 Motor stalled Check motor. mechanical system and load level. contact Sullair service. check the motor and motor cables. • most probable cause: too low a supply voltage • variable speed drive internal fault If there was a supply voltage loss or dip. reset the fault and restart the variable speed drive. Check the motor and motor cables. a fault occurs at 194 oF (90°C). Check the utility supply voltage. 13 Undertemperature Heatsink temperature is under 14°F(-10°C) Provide supplemental heating or relocate the variable speed drive to a warmer location. • insulation failure in motor or motor cables 5 Charging Switch The charging switch was open when the START command was been given due to: SOLUTION Remove faults from ungrounded systems. contact Sullair service. check the temperature model parameters. Check the highest ambient temperature level. Upon reset of this fault. Should the fault reoccur. • faulty operation • component failure 6 Emergency stop An Emergency stop signal was received from one of the digital inputs Determine the reason for the Emergency stop and remedy it. 40 Device unknown Unknown option board or drive Contact Sullair service. 44 Check motor size. contact Sullair service. Check motor size. Check Start Enable/Interlock settings. 41 IGBT temperature IGBT Inverter Bridge overtemperature protection has detected a high short-term overload current Check loading. 36 Control Unit The control unit cannot control the power unit and vice-versa Change the control unit. Adjust parameter 2. 54 Slot fault Defective option board or slot 28 Check Estop wiring to the drive input Check that the board is properly installed and seated in slot.Section 6 VARIABLE SPEED DRIVE CODE FAULT POSSIBLE CAUSE SOLUTION 24 Counter fault Values displayed on the counters are incorrect 25 Microprocessor watchdog fault • faulty operation • component failure Reset the fault and restart. 32 Fan cooling The variable speed drive cooling fan did not start when commanded Contact Sullair service. 51 External fault Digital input set as an external fault input has been triggered Clear the package emergency stop 53 Communication bus fault The data connection between the communica.1 to "None". Note: Application parameter values restored to default. 37 Device change (same type) • option board changed Reset. • different power rating of drive Note: No Fault Time Data Record is made.Check Supervisor bus cable. 26 Startup prevented Startup of the drive has been prevented. . Device change (different type) • option board changed Reset. • drive removed Note: No Fault Time Data Record is made. tion bus master and the communication bus Set Supervisor VSD to "Serial". Note: Application parameter values restored to default. board has failed If installation is correct contact Sullair service. • drive of different power ratiQg added Note: No Fault Time Data Record is made. 39 Device removed • option board removed Reset. 45 Device added (different type) • option board added Reset. contact Sullair service. • different power rating of drive Note: No Fault Time Data Record is made. 31 IGBT temperature (hardware) IGBT Inverter Bridge overtemperature protection has detected a high short-term overload current Check loading.6. Should the fault reoccur. 50 Analog input lin <4 rnA Current at the analog input is< 4 rnA. 38 Device added (same type) • option board added Reset. • drive of different power rating added Note: No Fault Time Data Record is made. If the installation is correct. 29 . 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