USER MANUAL 900/1600 IT4 CONTROLLER R00 WARRANTY NOTICE

Transcription

1 USER MANUAL 900/1600 IT4 CONTROLLER WARRANTY NOTICE Failure to follow the instructions and procedures in this manual or, misuse of this equipement will VOID its warranty! PART NUMBER: R00 KEEP FOR FUTURE REFERENCE 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.

2 AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on portable compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair s corporate headquarters training facility located 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. These seminars are recommended for maintenance, contractor maintenance, and service personnel. For detailed course outlines, schedule, and cost information contact: SULLAIR TRAINING DEPARTMENT SULLAIR or (ext. 5623) training@sullair.com - Or Write - Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN Attn: Service Training Department.

3 TABLE OF CONTENTS SECTION 1 SAFETY GENERAL TOWING PRESSURE RELEASE FIRE AND EXPLOSION MOVING PARTS HOT SURFACES, SHARP EDGES AND SHARP CORNERS TOXIC AND IRRITATING SUBSTANCES ELECTRICAL SHOCK LIFTING ENTRAPMENT JUMP STARTING IMPLEMENTATION OF LOCKOUT/TAGOUT CALIFORNIA PROPOSITION SYMBOLS AND REFERENCES SECTION 2 STARTUP PROCEDURES INTRODUCTION COMPASS CONTROLLER PANEL LAYOUT COMPASS CONTROLLER POWER UP INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION NORMAL OPERATION SECTION 3 ADJUSTMENT PROCEDURE INTRODUCTION SETTINGS AND DIAGNOSTIC SECTION 4 DESCRIPTION INTRODUCTION OPERATING MODES

4 TABLE OF CONTENTS SECTION 5 TROUBLESHOOTING TROUBLESHOOTING INTRODUCTION TROUBLESHOOTING GUIDE INTRODUCTION COMPASS CONTROLLER TROUBLESHOOTING GUIDE

5 Section 1 SAFETY NOTE DO NOT modify the compressor except with written factory approval. Each day, walk around the air compressor and inspect for leaks, loose or missing parts, damaged parts or parts out of adjustment. Perform all recommended daily maintenance. OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL. 1.1 GENERAL Sullair Corporation designs and manufactures all of its products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment. Read the CIMA Safety Manual prior to compressor operation and towing, if applicable in your area. The air compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operator s Manual. Failure to follow the instructions, procedures and safety precautions in this manual can result in accidents and injuries. NEVER start the air compressor unless it is safe to do so. DO NOT attempt to operate the air compressor with a known unsafe condition. Tag the air compressor and render it inoperative by disconnecting the battery so others who may not know of the unsafe condition will not attempt to operate it until the condition is corrected. Inspect for torn, frayed, blistered or otherwise deteriorated and degraded hoses. Replace as required. 1.2 TOWING PREPARING TO TOW CAUTION Estimated hose life based on a 5-day 8-hour work week is 3 years. These conditions exist on an 8-hour shift only. Any other operation of the equipment other than 8- hour shifts would shorten the hose life based on hours of operation. (I) WARNING Do NOT tow the compressor should its weight exceed the rated limit of the tow vehicle, as the vehicle may not brake safely with excess weight. See rated limit in tow vehicle Operator's Manual, and review its instructions and other requirements for safe towing. Use and operate the air compressor only in full compliance with all pertinent OSHA requirements and/or all pertinent Federal, State and Local codes or requirements. (I) WHILE NOT TOWED IN THE USUAL SENSE OF THE WORD, MANY OF THESE INSTRUCTIONS ARE DIRECTLY APPLICABLE TO SKID-MOUNTED PORTABLE AIR COMPRESSORS AS WELL. 5

6 SECTION 1 A. Prior to hitching the air compressor to the tow vehicle, inspect all attachment parts and equipment, checking for (i) signs of excessive wear or corrosion, (ii) parts that are cracked, bent, dented or otherwise deformed or degraded, and (iii) loose nuts, bolts or other fasteners. Should any such condition be present, DO NOT TOW until the problem is corrected. B. Back the tow vehicle to the compressor and position it in preparation for coupling the compressor. C. If the compressor is provided with a drawbar latched in the vertical upright position, carefully unlatch drawbar and lower it to engage the coupling device. If not, raise drawbar with the jack to engage coupling device or otherwise couple the compressor to the towing vehicle. WARNING This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. Use the screw jack provided or a chain fall if you cannot lift or lower it without avoiding injury to yourself or others. Keep hands and fingers clear of the coupling device and all other pinch points. Keep feet clear of drawbar to avoid injury in case it should slip from your hands. D. Make sure the coupling device is fully engaged, closed and locked. E. If chains are provided, pass each chain through its point of attachment on the towing vehicle; then hook each chain to itself by passing the grab hook over (not through) a link. Cross chains under the front of drawbar before passing them through points of attachment on towing vehicle to support the front of drawbar in case it should accidentally become uncoupled. F. Make sure that the coupling device and adjacent structures on the towing vehicle (and also, if utilized, chain adjustment, brake and/or electrical interconnections) DO NOT interfere with or restrict motion of any part of the compressor, including its coupling device, with respect to the towing vehicle when maneuvering over any anticipated terrain. G. If provided, make sure chain length, brake and electrical interconnections provide sufficient slack to prevent strain when cornering and maneuvering, yet are supported so they cannot drag or rub on road, terrain or towing vehicle surfaces which might cause wear that could render them inoperative. WARNING This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. CAUTION Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. H. On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack, and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full upright position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. 6

7 SECTION 1 I. Make sure tires are in good condition and are the size (load range) specified and are inflated to the specified pressures. DO NOT change the tire size or type. Also, make sure wheel bolts, lugs or nuts are tightened to the specified torques. J. If provided, make sure all dual stop, tail directional and clearance lights are operating properly and that their lenses are clean and functional. Also, make sure all reflectors and reflecting surfaces, including the slow moving vehicle emblem on compressors provided with same, are clean and functional. K. Make sure all service air hoses (not air brake hoses) are disconnected or are fully stowed and secured on hose reels, if provided. L. Make sure all access doors and tool box covers are closed and latched. If the compressor is large enough to hold a man, make sure all personnel are out before closing and latching access doors. M. Make sure parking brakes in towing vehicle are set, or that its wheels are chocked or blocked, or that it is otherwise restrained from moving. Then, release the compressor parking brakes, if provided. N. Make sure the compressor wheels are not chocked or blocked, and that all tie-downs, if any, are free. O. Test running brake operation, including breakaway switch operation if provided, before attempting to tow the compressor at its rated speed or less when conditions prevail. P. DO NOT carry loose or inappropriate tools, equipment or supplies on or in the compressor. Q. DO NOT load this equipment with accessories or tools such that it is unbalanced from side to side or front to back. Such unbalance will reduce the towability of this equipment and may increase the possibility of tipping, rolling over, jackknifing, etc. Loss of control of the towing vehicle may result. TOWING A. Observe all Federal, State, and Local laws while towing this equipment (including those specifying minimum speed). B. DO NOT exceed the towing speeds listed below under ideal conditions. Reduce your speed according to posted speed limits, weather, traffic, road or terrain conditions: 1. Two axle four-wheel or three axle six-wheel steerable models: 15 MPH (24 km/h). 2. All other models: 55 MPH (88 km/h). C. Remember that the portable air compressor may approach or exceed the weight of the towing vehicle. Maintain increased stopping distances accordingly. DO NOT make sudden lane changes, U-turns or other maneuvers. Such maneuvers can cause the compressor to tip, roll over, jackknife or slide and cause loss of control of the towing vehicle. Tipping, rolling over, etc. can occur suddenly without warning. U-turns especially should be made slowly and carefully. D. Avoid grades in excess of 15 (27%). E. Avoid potholes, rocks and other obstructions, and soft shoulders or unstable terrain. F. Maneuver in a manner that will not exceed the freedom of motion of the compressor s drawbar and/ or coupling device, in or on the towing vehicle s coupling device and/or adjacent structure whether towing forward or backing up, regardless of the terrain being traversed. G. DO NOT permit personnel to ride in or on the compressor. H. Make sure the area behind, in front of, and under the compressor is clear of all personnel and obstructions prior to towing in any direction. I. DO NOT permit personnel to stand or ride on the drawbar, or to stand or walk between the compressor and the towing vehicle. PARKING OR LOCATING COMPRESSOR A. Park or locate compressor on a level surface, if possible. If not, park or locate compressor across grade so the compressor does not tend to roll downhill. DO NOT park or locate compressor on grades exceeding 15 (27%). B. Make sure compressor is parked or located on a firm surface that can support its weight. C. Park or locate compressor so the wind, if any, tends to carry the exhaust fumes and radiator heat away from the compressor air inlet openings, and also where the compressor will not be exposed to excessive dust from the work site. D. On steerable models, park compressor with front wheels in straight-ahead position. 7

8 SECTION 1 E. Set parking brakes and disconnect breakaway switch cable and all other interconnecting electrical and/or brake connections, if provided. F. Block or chock both sides of all wheels. G. If provided, unhook chains and remove them from the points of chain attachment on the towing vehicle, then hook chains to bail on drawbar or wrap chains around the drawbar and hook them to themselves to keep chains off the ground which might accelerate rusting. H. Lower front screw jack and/or any front and rear stabilizer legs. Make sure the surface they contact has sufficient load bearing capability to support the weight of the compressor. WARNING This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. CAUTION Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. I. If a caster wheel is provided on the screw jack, it is part of the screw jack and cannot be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Raise the screw jack to its full upright position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar and reinsert the pin. Make sure the jack is secured in place prior to towing. J. Disconnect coupling device, keeping hands and fingers clear of all pinch points. If the compressor is provided with a drawbar, DO NOT attempt to lift the drawbar or if hinged, to raise it to the upright position by hand, if the weight is more than you can safely handle. Use a screwjack or chain fall if you cannot lift or raise the drawbar without avoiding injury to yourself or others. K. Move the towing vehicle well clear of the parked compressor and erect hazard indicators, barricades and/or flares (if at night) if compressor is parked on or adjacent to public roads. Park so as not to interfere with traffic. NOTE While not towed in the usual sense of the word, many of these instructions are directly applicable to skidmounted portable air compressors as well. 1.3 PRESSURE RELEASE A. Open the pressure relief valve at least weekly to make sure it is not blocked, closed, obstructed or otherwise disabled. B. Install an appropriate flow-limiting valve between the compressor service air outlet and the shutoff (throttle) valve, when an air hose exceeding 1/2" (13 mm) inside diameter is to be connected to the shutoff (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR (b) (7) or any applicable Federal, State and Local codes, standards and regulations. C. When the hose is to be used to supply a manifold, install an additional appropriate flow-limiting valve between the manifold and each air hose exceeding 1/2" (13 mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure. D. Provide an appropriate flow-limiting valve for each additional 75 feet (23 m) of hose in runs of 8

9 SECTION 1 air hose exceeding 1/2" (13 mm) inside diameter to reduce pressure in case of hose failure. E. Flow-limiting valves are listed by pipe size and rated CFM. Select appropriate valve accordingly. F. DO NOT use tools that are rated below the maximum rating of this compressor. Select tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer s rated safe operating pressures for these items. G. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled. H. Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the sump (receiver) to zero internal pressure before removing the cap. I. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before attempting to refill optional air line anti-icer systems with antifreeze compound. J. Keep personnel out of line with and away from the discharge opening of hoses, tools or other points of compressed air discharge. K. DO NOT use air at pressures higher than 30 psig (2.1 bar) for cleaning purposes, and then only with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR (b) or any applicable Federal, State and Local codes, standards and regulations. L. DO NOT engage in horseplay with air hoses as death or serious injury may result. M. This equipment is supplied with an ASME designed pressure vessel protected by an ASME rated relief valve. Lift the handle once a week to make sure the valve is functional. DO NOT lift the handle while machine is under pressure. N. If the machine is installed in an enclosed area it is necessary to vent the relief valve to the outside of the structure or to an area of non-exposure. O. DO NOT remove radiator filler cap until the coolant temperature is below its boiling point. Then loosen cap slowly to its stop to relieve any excess pressure and make sure coolant is not boiling before removing cap completely. Remove radiator filler cap only when cool enough to touch with a bare hand. P. The ethyl ether in the replaceable cylinders used in diesel ether starting aid systems (optional) is under pressure. DO NOT puncture or incinerate those cylinders. DO NOT attempt to remove the center valve core or side pressure relief valve from these cylinders regardless of whether they are full or empty. Q. If a manual blowdown valve is provided on the receiver, open the valve to ensure all internal pressure has been vented prior to servicing any pressurized component of the compressor air/ fluid system. 1.4 FIRE AND EXPLOSION WARNING Do not attempt to operate the compressor in any classification of hazardous environment or potentially explosive atmosphere unless the compressor has been specially designed and manufactured for that duty. A. Refuel at a service station or from a fuel tank designed for its intended purpose. If this is not possible, ground the compressor to the dispenser prior to refueling. B. Clean up spills of fuel, fluid, battery electrolyte or coolant immediately if such spills occur. C. Shut off air compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away and DO NOT permit smoking in the vicinity when adding fuel, checking or adding electrolyte to batteries, checking or adding fluid, checking diesel engine ether starting aid systems, replacing cylinders, or when refilling air line anti-icer systems antifreeze compound. D. DO NOT permit liquids, including air line anti-icer system antifreeze compound or fluid film, to accumulate on bottom covers or on, under or around acoustical material, or on any external or internal surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary, remove acoustical material, clean all surfaces and then replace acoustical material. Any acoustical material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids or fluid film within 9

10 SECTION 1 the material. DO NOT use flammable solvents for cleaning purposes. E. Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning inside the enclosure. Tag the battery connections so others will not unexpectedly reconnect it. F. Keep electrical wiring, including the battery terminals and other terminals, in good condition. Replace any wiring that has cracked, cut abraded or otherwise degraded insulation or terminals that are worn, discolored or corroded. Keep all terminals clean and tight. G. Turn off battery charger before making or breaking connections to the battery. H. Keep grounded conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition. I. Replace damaged fuel tanks or lines immediately rather than attempt to weld or otherwise repair them. DO NOT store or attempt to operate the compressor with any known leaks in the fuel system. Tag the compressor and render it inoperative until repair can be made. J. Remove any acoustical material or other material that may be damaged by heat or that may support combustion prior to attempting weld repairs. Remove diesel engine ether starting aid cylinders and air line anti-icer system components containing antifreeze compound, prior to attempting weld repairs in any place other than the fuel system. DO NOT weld on or near the fuel system. K. Keep a suitable, fully charged class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor. L. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor. M. Open all access doors and allow the enclosure to ventilate thoroughly prior to attempting to start the engine. N. DO NOT operate compressor under low overhanging leaves or permit such leaves to contact hot exhaust system surfaces when operating the compressor in forested areas. O. Ethyl ether used in diesel engine ether starting aid systems is extremely flammable. Change cylinders, or maintain or troubleshoot these systems only in well-ventilated areas away from heat, open flame or sparks. DO NOT install, store or otherwise expose ether cylinders to temperatures above 160 F (71 C). Remove ether cylinder from the compressor when operating in ambient temperatures above 60 F (16 C). P. DO NOT attempt to use ether as a starting aid in gasoline engines or diesel engines with glow plugs as serious personnel injury or property damage may result. Q. DO NOT spray ether into compressor air filter or into an air filter that serves both the engine and the compressor as serious damage to the compressor or personal injury may result. R. Antifreeze compound used in air line anti-icer systems contains methanol which is flammable. Use systems and refill with compound only in well-ventilated areas away from heat, open flames or sparks. DO NOT expose any part of these systems or the antifreeze compound to temperatures above 150 F (66 C). Vapors from the antifreeze compound are heavier than air. DO NOT store compound or discharge treated air in confined or unventilated areas. DO NOT store containers of antifreeze compound in direct sunlight. S. Store flammable fluids and materials away from your work area. Know where fire extinguishers are and how to use them, and for what type of fire they are intended. Check readiness of fire suppression systems and detectors if so equipped. 1.5 MOVING PARTS A. Keep hands, arms and other parts of the body and also clothing away from belts, pulleys and other moving parts. B. DO NOT attempt to operate the compressor with the fan or other guards removed. C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts inside the enclosure. D. Keep access doors closed except when making repairs or adjustments, performing service or when starting or stopping the compressor. 10

11 SECTION 1 E. Make sure all personnel are out of the way and clear of the compressor prior to attempting to start or operate it. F. Shut off engine before adding fuel, fluid, coolant lubricants, air line antifreeze compound or battery electrolyte, or before replacing ether starting aid cylinders. G. Disconnect the grounded negative battery connection to prevent accidental engine operation prior to attempting repairs or adjustments. Tag the battery connection so others will not unexpectedly reconnect it. H. When adjusting the controls, it may require operation of the equipment during adjustment. DO NOT come in contact with any moving parts while adjusting the control regulator and setting the engine RPM. Make all other adjustments with the engine shut off. When necessary, make adjustment, other than setting control regulator and engine RPM, with the engine shut off. If necessary, start the engine and check adjustment. If adjustment is incorrect, shut engine off, readjust, then restart the engine to recheck adjustment. I. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water, antifreeze or other liquids to minimize possibility of slips and falls. 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 of air discharge and away from hot exhaust gases. C. Wear personal protective equipment including gloves and head covering when working in, on or around the compressor. D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore small cuts and burns as they may lead to infection. 1.7 TOXIC AND IRRITATING SUBSTANCES A. DO NOT use air from this compressor for respiration (breathing) except in full compliance with OSHA Standards 29 CFR 1920 and any other Federal, State or Local codes or regulations. DANGER INHALATION HAZARD! Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment. B. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas. C. Operate the compressor only in open or wellventilated areas. D. If the compressor is operated indoors, discharge engine exhaust fumes outdoors. E. Locate the compressor so that exhaust fumes are not apt to be carried towards personnel, air intakes servicing personnel areas or towards the air intake of any portable or stationary compressor. F. Fuels, fluids, coolants, lubricants and battery electrolyte used in the compressor are typical of the industry. Care should be taken to avoid accidental ingestions and/or skin contact. In the event of ingestion, seek medical treatment promptly. DO NOT induce vomiting if fuel is ingested. Wash with soap and water in the event of skin contact. G. Wear an acid-resistant apron and a face shield or goggles when servicing the battery. If electrolyte 11

12 SECTION 1 is spilled on skin or clothing, immediately flush with large quantities of water. H. Ethyl ether used in diesel engine ether starting aid systems is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, DO NOT induce vomiting and call a physician immediately. I. Wear goggles or a full face shield when testing ether starting aid systems or when adding antifreeze compound to air line anti-icer systems. Keep openings of valve or atomizer tube of ether starting aid system pointed away from yourself and other personnel. J. If ethyl ether or air line anti-icer system antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for 15 minutes. A physician, preferably any eye specialist, should be contacted immediately. K. DO NOT store ether cylinders or air line anti-icer system antifreeze compound in operator s cabs or in other similar confined areas. L. The antifreeze compound used in air line antiicer systems contains methanol and is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, induce vomiting by administering a tablespoon of salt in a glass of clean warm water. Do this until vomit is clear, then administer two tablespoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light. Call a physician immediately. 1.8 ELECTRICAL SHOCK A. Keep the towing vehicle or equipment carrier, compressor hoses, tools and all personnel at least 10 feet (3 m) from power lines and buried cables. B. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed live parts of electrical system. Maintain dry footing, 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. C. Attempt repairs only in clean, dry and well-lighted and ventilated areas. D. Stay clear of the compressor during electrical storms! It can attract lightning. 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 by helicopter must not be supported by the lifting bail, but by slings instead. In any event, lift only in full compliance with OSHA Standards 29 CFR 1910 subpart N or any other Local, State, Military and Federal regulations that may apply. B. Inspect lifting bail and points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting. C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity of at least the net weight of the compressor plus an additional 10% allowance for weight of water, snow, ice, mud, stored tools, and equipment. If your are unsure of the weight, then weigh compressor before lifting. D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail. E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground. F. DO NOT attempt to lift in high winds. G. Keep all personnel out from under and away from the compressor whenever it is suspended. H. Lift compressor no higher than necessary. I. Keep lift operator in constant attendance whenever compressor is suspended. J. Set compressor down only on a level surface capable of supporting at least its net weight plus an additional 10% allowance for the weight of water, snow, ice, mud, stored tools, and/or equipment. K. If the compressor is provided with parking brakes, make sure they are set, and in any event, block or chock both sides of all running wheels before disengaging the lifting hook. 12

13 SECTION ENTRAPMENT A. Make sure all personnel are out of compressor before closing and engaging enclosure doors. B. If the compressor is large enough to hold a man and if it is necessary to enter it to perform service adjustments, inform other personnel before doing so, or else secure the access door in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside JUMP STARTING A. Observe all safety precautions mentioned elsewhere in this manual. B. Batteries may contain hydrogen gas which is flammable and explosive. Keep flames, sparks and other sources of ignition away. C. Batteries contain acid which is corrosive and poisonous. DO NOT allow battery acid to contact eyes, skin, fabrics or painted surfaces as serious personal injury or property damage could result. Flush any contacted areas thoroughly with water immediately. Always wear an acid-resistant apron and face shield when attempting to jump start the compressor. D. Remove all vent caps (if so equipped) from the battery or batteries in the compressor. DO NOT permit dirt or foreign matter to enter the open cells. E. Check fluid level. If low, bring fluid to proper level before attempting to jump start (not applicable to maintenance-free batteries). F. DO NOT attempt to jump start if fluid is frozen or slushy. Bring batteries up to at least 60 F (16 C) before attempting to jump start or it may explode. G. Cover open cells of all compressor batteries with clean dampened cloths before attempting to jump start. H. Attempt to jump start only with a vehicle having a negative ground electrical system with the same voltage, and is also equipped with a battery or batteries of comparable size or larger than supplied in the compressor. DO NOT attempt to jump start using motor generator sets, welders or other sources of DC power as serious damage may result. I. Bring the starting vehicle alongside the compressor, but DO NOT permit metal to metal contact between the compressor and the starting vehicle. J. Set the parking brakes of both the compressor (if provided) and the starting vehicle or otherwise block both sides of all wheels. K. Place the starting vehicle in neutral or park, turn off all non-essential accessory electrical loads and start its engine. L. Use only jumper cables that are clean, in good condition and are heavy enough to handle the starting current. M. Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of either the compressor or the starting vehicle to minimize the possibility of uncontrolled arcing which might serve as a source of ignition. N. Positive battery terminals are usually identified by a plus (+) sign on the terminal and the letters POS adjacent to the terminal. Negative battery terminals are usually identified by the letters NEG adjacent to the terminal or a negative (-) sign. O. Connect one end of a jumper cable to the positive (POS) (+) battery terminal in the starting vehicle. When jump starting 24V compressors and if the starting vehicle is provided with two (2) 12V batteries connected in series, connect the jumper cable to the positive (POS) (+) terminal of the ungrounded battery. P. Connect the other end of the same jumper cable to the positive (POS) (+) terminal of the starter motor battery in the compressor when jump starting 24V compressors, to the positive (POS) (+) terminal of the ungrounded battery in the compressor. Q. Connect one end of the other jumper cable to the grounded negative (NEG) (-) terminal of the battery in the starting vehicle. When jump starting 24V compressors and if the starting vehicle is provided with two (2) 12V batteries connected in series, connect the jumper cable to the negative (NEG) (-) terminal of the grounded battery. R. Check your connections. DO NOT attempt to start a 24V compressor with one 12V battery in the starting vehicle. DO NOT apply 24V to one 12V battery in the compressor. S. Connect the other end of this same jumper cable to a clean portion of the compressor engine 13

14 SECTION 1 block away from fuel lines, the crank case breather opening and the battery. T. Start the compressor in accordance with normal procedure. Avoid prolonged cranking. U. Allow the compressor to warm up. When the compressor is warm and operating smoothly at normal idle RPM, disconnect the jumper cable from the engine block in the compressor, then disconnect the other end of this same cable from the grounded negative (NEG) (-) terminal of the battery in the starting vehicle. Then disconnect the other jumper cable from the positive (POS) (+) terminal of the battery in the compressor, or if provided with two (2) 12V batteries connected in series, from the ungrounded battery in the compressor, and finally, disconnect the other end of this same jumper cable from the positive (POS) (+) terminal of the battery in the starting vehicle or from the positive (POS) (+) terminal of the ungrounded battery in the starting vehicle, if it is provided with two (2) 12V batteries connected in series. V. Remove and carefully dispose of the dampened cloths, as they may now be contaminated with acid, then replace all vent caps IMPLEMENTATION OF LOCKOUT/TAGOUT The energy control procedure defines actions necessary to lockout a power source of any machine to be repaired, serviced or set-up, where unexpected motion, or an electrical or other energy source, would cause personal injury or equipment damage. The power source on any machine shall be locked out by each employee doing the work except when motion is necessary during setup, adjustment or troubleshooting. A. The established procedures for the application of energy control shall cover the following elements and actions and shall be initiated only by Authorized Persons and done in the following sequence: 1. Review the equipment or machine to be locked and tagged out. 2. Alert operator and supervisor of which machine is to be worked on, and that power and utilities will be turned off. 3. Check to make certain no one is operating the machine before turning off the power. 4. Turn off the equipment using normal shutdown procedure. 5. Disconnect the energy sources: a. Air and hydraulic lines should be bled, drained and cleaned out. There should be no pressure in these lines or in the reservoir tanks. Lockout or tag lines or valves. b. Any mechanism under tension or pressure, such as springs, should be released and locked out or tagged. c. Block any load or machine part prior to working under it. d. Electrical circuits should be checked with calibrated electrical testing equipment and stored energy and electrical capacitors should be safely discharged. 6. Lockout and/or Tagout each energy source using the proper energy isolating devices and tags. Place lockout hasp and padlock or tag at the point of power disconnect where lockout is required by each person performing work. Each person shall be provided with their own padlock and have possession of the only key. If more than one person is working on a machine each person shall affix personal lock and tag using a multi-lock device. 7. Tagout devices shall be used only when power sources are not capable of being locked out by use of padlocks and lockout hasp devices. The name of the person affixing tag to power source must be on tag along with date tag was placed on power source. 8. Release stored energy and bring the equipment to a zero mechanical state. 9. Verify Isolation: Before work is started, test equipment to ensure power is disconnected. B. General Security 1. The lock shall be removed by the Authorized person who put the lock on the energy-isolating device. No one other than the person/persons placing padlocks and lockout hasps on power shall remove padlock and lockout hasps and restore power. However, when the authorized person who applied the lock is unavailable to remove it his/her Supervisor may remove padlock/padlocks and lockout hasps and restore power only if it is first: a. verified that no person will be exposed to danger. 14

15 SECTION 1 b. verified that the Authorized person who applied the device is not in the facility. c. noted that all reasonable efforts to contact the Authorized person have been made to inform him or her that the lockout or tagout device has been removed. d. ensured that the Authorized person is notified of lock removal before returning to work. 2. Tagout System Tags are warning devices affixed at points of power disconnect and are not to be removed by anyone other that the person placing tag on power lockout. Tags shall never be by-passed, ignored, or otherwise defeated 1.13 CALIFORNIA PROPOSITION 65 WARNING CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. Battery posts, terminals and related accessories contain lead and other compounds known to the State of California to cause cancer and birth defects and other reproductive harm. Wash hands after handling. 15

16 SECTION SYMBOLS AND REFERENCES The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable symbols. DIESEL PARTICULATE FILTER REGENERATION INHIBIT HIGH EXHAUST SYS. TEMP WAIT TO START REMOTE START CABIN LIGHTS / it4 / it4 / it4 Safety Symbols-1 T4 16

17 SECTION 1 Safety Symbols-2 17

18 SECTION 1 Safety Symbols-3 18

19 CONTROLLER USER MANUAL Section 2 STARTUP PROCEDURES 2.1 INTRODUCTION This compressor is equipped with a Sullair Controller for controlling the compressor system operation, adjusting the machine parameters and performing maintenance operations. The Controller utilizes digital technology that ensures accurate and safe operation of the compressor system. When fault conditions occur, the Controller automatically shuts down the machine to prevent injury to the operator or damage to the equipment. Features of the Controller include: Multiple gauges for display of pressure, engine temp, compressor temp, engine rpm, and fuel level LCD screen displaying machine status and operating information Remote start capabilities Automatic self diagnosis at startup Multiple language support An external diagnostics port which allows PC interface for configuration of the system parameters. Backlighting of gauges with green LED to allow clear view of gauges in low light areas. 2.2 COMPASS CONTROLLER PANEL LAYOUT The Controller panel is shown in Figure 2-1 on page 18. The Controller components and functions are described in detail in Section COMPASS CONTROLLER POWER UP The Controller is used to start the compressor either manually or remotely. Manual Start: Start the machine by toggling the <ON> switch to the start position on the Controller panel. Once the switch has been set to the start position and the Controller has successfully initialized (see Self Test, Communication Checks and Parameter/Safety Checks in this section for further information), the Controller will check status, and automatically continue to energize the starter until either the engine starts or the maximum crank duration is reached. Auto Start: The compressor can be started remotely if the remote start function has been enabled during setup. SELF TEST When the Controller is initially powered up, the system will initiate a Self Test sequence to verify its operational integrity and safety status. During this process, the following actions will be performed. 1. Gauge pointers will move to the zero position, then to half and full scale, then back to zero, and finally to the actual value reading. 2. The LCD display will turn on all its segments for one second, off for one second, and then display the Sullair logo followed by the software product number with revision level. 3. All warning lights will turn on for 2.5 seconds and then turn off, then set to the actual indicator state. The self test feature may be bypassed by disabling the sequence as describe in Section 3 of this manual. COMMUNICATION CHECKS After successful completion of the self test, the Controller system will check the communication status of the system. 19

20 CONTROLLER USER MANUAL SECTION INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION HIGH START FORCE SELECT CABIN MENU MENU REGEN PRESSURE ON LIGHTS TOGGLE SELECT INHIBIT LOW EXIT OFF Figure 2-1: Instrument Panel Group Lamp Indicators 1. Compressor OK Lamp 2. Compressor Warning Lamp 3. Compressor Shut Down Lamp 4. Engine OK Lamp 5. Check Engine Lamp 6. Engine Shutdown Lamp 7. Battery Disconnect Lamp 8. Compressor Air Filter Warning Lamp 9. High Compressor Temperature Lamp 10. Cabin Light Lamp 11. Remote Start Lamp 12. Diesel Particulate Filter (DPF) Lamp 13. High Exhaust System Temperature (HEST) Lamp 14. Regeneration Inhibit Lamp 15. Low Fuel Lamp 16. High Coolant Temperature Lamp 17. Engine Air Filter Warning Lamp 18. Wait to Start Lamp Switches/Gauges/Features 19. Power On/Off Switch 20. Menu Select/Exit Switch 21. Menu Toggle Switch 22. Force/Inhibit Regeneration Switch 23. Cabin Light Switch 24. High/Low Pressure Selector Switch (only on dual pressure models) 25. Service Air Pressure Gauge (P1) 26. Compressor Temperature Gauge 27. Engine Temperature Gauge 28. Fuel Level Gauge 29. Engine Controller Diagnostics Service Port 30. Engine Controller Port Cover 31. Key Port 32. Contrast Buttons 20

21 SECTION 2 CONTROLLER USER MANUAL The Controller system will prevent the user from operating the compressor until all communication problems are resolved. See Section 5 of this manual for troubleshooting recommendations. GENERAL SAFETY CONDITION CHECKS After successful completion of the communication bus checks, the Controller system will perform safety checks on the compressor and the engine. In the event of a problem with either the compressor or engine, a message will display in the LCD indicating the nature of the trouble (example shown below). The Controller will wait for user-interaction to either correct the fault or send the system to Sleep mode. See Figure 2-2. Figure 2-3: P2 signal error screen The Controller will prevent compressor startup if either of the following conditions exists: P1 pressure is greater than the maximum P1 pressure permitted at startup. The maximum P1 pressure is an adjustable parameter which can be modified as describe in Section 3 of this manual. P1 and P2 pressures are out of range. See Section 5 of this manual for troubleshooting recommendations. 2.5 NORMAL OPERATION Figure 2-2: Communications checks display Table 2-1 lists the safety conditions that are checked by the Controller during startup and the fault that will be displayed on the LCD screen if a fault occurs. See Section 5 of this manual for troubleshooting recommendations. SYSTEM PRESSURE CHECKS Following the successful completion of the general safety checks, the Controller will check the status of the service pressure (P1), control pressure (P2), and wet sump (P3). If there is a problem with any of these inputs a message will be displayed on the LCD display indicating the nature of the problem. See Figure 2-3. Figure 2-4: Operational Flow Diagram Following the successful completion of all startup sequences, the system is ready for normal operation. During normal operation the Controller will be in one of the following five operating modes: Waiting, Start-Up and Autostart (remote), Run, Sleep, and Shutdown. Each of these modes is described in detail in Section 4. 21

22 CONTROLLER USER MANUAL SECTION 2 Table 2-1: Safety Conditions Parameter Fault Condition User Controlled Parameter LCD Message Fuel Low fuel level Very Low Level Alert (% full) Low fuel level Fuel sender open circuit None Low fuel level Battery Low battery voltage (<18.0Vdc) None Battery Voltage Error Compresor Discharge Temperature (CDT) Receiver Tank Temperature (RTT) Signal short circuit None T1 Signal Error Compressor Temp High Max T1 during run or at start-up Comp High Temp Receiver Tank Temp High None RTT High Discharge Air DP High Aftercooler filter DP AfterFilters Equipped Primary Shutdown Air Pressure (P1) Transducer signal short or open circuit None P1 Signal Error High compressor pressure Max P1 at start-p (psi) High Compressor Pressure Control Pressure (P2) Transducer signal short or open circuit None P2 Signal Error Air Pressure (P3) Transducer signal short or open circuit None P3 Signal Error 22

23 CONTROLLER USER MANUAL Section 3 ADJUSTMENT PROCEDURE 3.1 INTRODUCTION This section describes steps for using the Controller to modify specific parameters that control the machine operation. Additional parameters (UCP) can be viewed and adjusted using the PC User Interface. See Figure 3-1. CONTRAST Figure 3-2: Display key The two buttons at the bottom right of Controller's cluster panel can be used during normal operation to adjust LCD contrast up and down. The end user adjusts contrast by press and hold operation of either button until satisfactory contrast level is achieved. Any changes made by the end user are subsequently retained in the Controller s memory. PARAMETER SECTION NAVIGATION During normal operation the LCD displays real-time values of up to four different system parameters at once. The following table lists all available parameters. To navigate the parameters you wish to display, use Controllers selection and toggle switches as follows: Figure 3-1: J1939 Data communication cable Part Number MESSAGE DISPLAY CENTER The message display is a graphical LCD that displays information to the compressor operator. The screen is backlit to allow the display characters to be clearly visible under any lighting conditions. In addition to basic operational information, a variety of user-defined options may also be displayed when specified. Up to four different parameters may be displayed at one time; viewable parameters are displayed in Table 4-1. Fault messages are displayed whenever a fault condition occurs. The LCD display also allows the operator to view instrumentation diagnostic data to aid in controlling the system operation and in troubleshooting problems. The screen is broken up into two different information types' parameter display and system display. See Figure 3-2. A short press and release of the <MENU SELECT> switch, in the select position, will select one of the parameter display lines. A different parameter display line can be selected by continued short press and release of the <MENU TOGGLE> switch. Once the desired parameter display line is selected, press the <MENU TOGGLE> switch, to the <UP> or <DOWN> positions to scroll through the different parameters available for viewing at that line. The selected parameter display line will become unselected after a period of no <UP>, <DOWN>, <MENU SELECT> activity for 5 seconds. The parameters chosen for display will be retained across subsequent system power-ups and usage until changed by the same procedure. Figure 3-3 below shows the screen layout. 23

24 CONTROLLER USER MANUAL SECTION SETTINGS AND DIAGNOSTIC MENU Once the initialization sequence is complete, the operator can enter the settings and diagnostic menu at any time by holding the <MENU SELECT> switch, in the select position for 2 seconds. This will bring up the screen below. Figure 3-3: Settings Menu Navigation, to any selection, within this menu is achieved by using the <MENU TOGGLE> and <MENU SELECT> switches in the following manner: <UP> A toggle on the <MENU TOGGLE> switch. Use to scroll upward thru the current menu list. (Note that continuing to press and hold the switch will continuously scroll upward thru the menu). <DOWN> A toggle on the <MENU TOGGLE> switch. Use to scroll downward down thru the current menu list. (Note that continuing to press and hold the switch will continuously scroll downward thru the menu). <SELECT> A toggle on the <MENU SELECT>. Use this to choose the selected item in the menu list. <EXIT> A toggle on the <MENU SELECT> switch. Use to move back up one level in the menu structure. MENU STRUCTURE 1. Set Units 2. Large Font Display 3. Set Language a. English b. French c. Spanish d. German e. Italian f. Portuguese 4. Operational Configuration a. Enable Remote Start b. Rem. Start momentary c. Rem. Start P1 Val d. Rem. Start P1 Time e. Uses Canopy f. Auto Sleep Cfg. g. After Coolers h. After Filters i. Fuel Tank Configuration j. Pressure Cal. k. Temp. Cal. 5. Controller Diagnostic a. Gauge Test b. Lamp Test c. LCD Test d. Binary Inputs e. Analog Inputs 6. Backlight Adjust a. Backlight Color 1. Red 2. Green 3. Blue 4. Yellow 5. Light Blue 6. Violet 7. White b. Background Level 7. Engine Diagnostic 8. I/O Module Diagnostic 9. Eng Shutdown History 24

25 SECTION 3 CONTROLLER USER MANUAL SET UNITS The operator can change the units of measure for all data represented on the LCD screen. All parameters displayed in any subsequent <OPERATION> modes will use the selected unit of measurement. The selected unit of measurement will be retained in nonvolatile memory for subsequent unit use. Below is an example of changing this setting. Figure 3-6: Language menu screen Figure 3-4: Unit set menu screen LARGE DISPLAY INFO In <WAITING> and <OPERATION> modes, parameter display can be configured to show either two parameters, in large font, or four parameters, in smaller font. The configuration for this large font display is chosen using this menu entry. Navigation of the screen is similar to <SET UNITS> navigation. All parameters displayed in subsequent <WAITING>/ operational modes will use the selected font display. The selected font display will be retained in nonvolatile memory. See Figure 3-5. Figure 3-5: Font size menu screen SET LANGUAGE Selecting <SET LANGUAGE>, a sub-menu of all available display languages is shown. Upon entry to this sub-menu, the current language is displayed in reverse video. See following diagrams for supported languages. If a new language is selected, a <LANGUAGE CHANGED> confirmation screen (displayed in the language in use prior to making the change) will appear before returning to the sub-menu of available display languages, as shown in Figure 3-6 and Figure 3-7. Figure 3-7: Language confirmed menu screen OPERATIONAL CONFIGURATION This menu, to which Controller permits entry only prior to system entering <OPERATION> mode, allows end-user configuration of certain key operational User Controlled Parameters, UCP, items. A context-sensitive sub-menu (ie, entries in the submenu are dynamic and may or may not be present depending on other operation configuration settings, as discussed below) of entries is displayed when this menu item is selected. ENABLE REMOTE START This setting specifies whether pin 37 of the Main Interface Connector is to be used as a system wakeup. If enabled, the remote start enabled indicator light on the cluster overlay is illuminated, several additional items in the operational configuration submenu become available, and the <AUTO SLEEP CFG.> item in the operational configuration menu sub-menu become unavailable, since it is not applicable when remote start is enabled. Figure 3-8. Figure 3-8: Remote start menu screen 25

26 CONTROLLER USER MANUAL SECTION 3 REM. START MOMENTARY This item is only present and applicable if <ENABLE REMOTE START> is set to yes. This setting allows either a static or momentary (> 750 ms) LS switch to be used to drive remote start operation. See Figure 3-9. normal shutdown automatically. Using the <MENU TOGGLE>, and <MENU SELECT> switches, this value can be adjusted in increments of 1 minute, from 5 minutes (minimum) to 33 minutes (maximum). See Figure Figure 3-9: Remote start momentary menu screen REM. START P1 VAL This item is only present and applicable if momentary remote start is enabled. Along with the subsequent item, <REM. START P1 TIME>, this setting determines the required condition for shutdown from a prior momentary remote start. If P1 pressure of this level is achieved for the time duration specified in <REM. START P1 TIME> after a prior momentary remote start, Controller automatically begins the normal shutdown automatically. Using the <MENU TOGGLE>, and <MENU SELECT> switches, this value can be adjusted in increments of roughly 10 psi from 65 psi (min) to 645 psi (max). Internal units of measurement are kpa, and some rounding may occur as user increments/decrements through to the desired setting. ie, some increments/decrements may be 11 psi instead of 10. Figure Figure 3-10: Remote pressure val screen REM. START P1 TIME This item is only present and applicable if momentary remote start is enabled. Along with the previous item, <REM. START P1 VAL>, this setting determines the required condition for shutdown from a prior momentary remote start. If P1 pressure of magnitude specified in <REM. START P1 VAL> for the time duration specified here, after a prior momentary remote start, Controller automatically begins the Figure 3-11: Remote start pressure value screen USES CANOPY This item specifies whether or not a canopy enclosure is present for the compressor system. This information is used to determine fan control algorithm. See Figure Figure 3-12: Canopy menu screen AUTO SLEEP CFG. This item is only present and applicable if <REMOTE START> is disabled. This setting specifies the amount of idle time (ie, Controller detects no activity from the keypad) that must elapse in <WAITNG MODE> before Controller will automatically transition to <SLEEP> mode in order to save battery power. The setting can either be disabled completely ( set to "---" ) or turned on from 1-20 minutes. Note that this setting only applies in Controller configurations that are not enabled for <REMOTE START>. See Figure Auto Sleep Cfg. 5 min Figure 3-13: Auto sleep configuration screen 26

27 SECTION 3 CONTROLLER USER MANUAL AFTER COOLERS This item specifies whether or not the compressor is installed with aftercoolers. See Figure Figure 3-14: Aftercooler menu screen AFTER FILTERS This item is only present and applicable if <AFTER COOLERS> is enabled. See Figure no yes After Filters value is stored in memory, so it is retained through subsequent system power-ups. In Figure 3-17 displayed below, the service pressure (P1) calibration screen is displayed. The same screen is available for P2 (control pressure) and P3 (wet pressure). The current value (with calibration offset applied) is shown in large font at the bottom of the screen, displayed in either psi or bar depending on UCP units of measurement setting. The calibration value, which is always in units of kpa (1 kpa = 0.01 bar), regardless of UCP units of measurement, is displayed in smaller font to the far right of the screen. In Figure 3-18 immediately below, an example P1 is displayed, with the factory default 0 kpa calibration offset in use. If the end-user knows that, in fact, the relative pressure level at the P1 sensor is 0 psi, then the 2 psi value being read at Controller needs to be calibrated. As can be seen from the second diagram below, when an offset of -13 kpa is applied and set, the P1 service pressure reading is adjusted to 0 psi. Figure 3-15: Afterfilter menu screen FUEL TANK CFG. This item specifies which fuel tank and/or fuel level sensor is installed in the compressor system. See Fuel Sender information for information on the fuel tanks and level sensors supported by Controller. See Figure Figure 3-17: Uncalibrated service pressure Figure 3-18: Calibrated service pressure Figure 3-16: Fuel tank configuration screen PRESSURE CALIBRATION Each of the pressure transducer inputs supported by Controller can be calibrated to counter sensor/circuit tolerance using the sub-menus displayed when the user selects this menu entry. These screens are used to specify a calibration offset, if needed. The screens support a range of -100 to +100 kpa (factory default is 0 kpa) for the pressure calibration offset. This offset is added to the reading that Controller sees from the respective pressure transducer and is applied throughout subsequent operation. The offset TEMP CALIBRATION Each of the temperature sensor transducer inputs supported by Controller can be calibrated to counter sensor/circuit tolerance using the sub-menus displayed when the user selects this menu entry. These screens are used to specify a calibration offset, if needed. The screens support a range of to F in units of 0.5 C (factory default is 0.0 C) for the temperature calibration offset. This offset is added to the reading that Controller sees from the respective temperature transducer and is applied throughout subsequent operation. The offset value is stored in memory, so it is retained through subsequent system power-ups. 27

28 CONTROLLER USER MANUAL SECTION 3 In Figure 3-19 displayed below, the Compressor Discharge Temperature (CDT) calibration screen is displayed. The same screen is available for the Aftercooler Discharge Temperature (ADT) and Hydraulic Temperature (HT) sensors. The current value (with calibration offset applied) is shown in large font at the bottom of the screen, displayed in either F or C depending on UCP units of measurement. The calibration value, which is always in units of 0.5 C, regardless of UCP units of measurement, is displayed in smaller font to the far right of the screen. In Figure 3-20 immediately below, an example CDT temperature is displayed, with the factory default 0.0 C calibration offset in use. If the end-user knows that, in fact, the correct CDT temperature is currently 88 F, then the 77 F value being read at Controller needs to be calibrated. Calibration. As can be seen from the second diagram below, when an offset of 6.5C is applied and set, the CDT reading is adjusted to 88 F. aborted by engaging the <START> switch to the exit position during its execution. GAUGE TEST The gauge test verifies the gauge pointer needle functionality. The test proceeds sequentially from left to right of the cluster panel, one gauge at a time. For each gauge, the active gauge's pointer needle will be driven to three reference positions pausing at each position for 1 second. The reference position value, represented as a percentage, is shown on the LCD. Below is an example of the screen sequence for the fuel gauge. 1-Gauge Test 2-Lamp Test 3-LCD Test Select Figure 3-21: Test menu Figure 3-19: Uncalibrated temperature example Figure 3-20: Calibrated temperature example CONTROLLER DIAGNOSTICS This menu entry, to which permits entry only prior to system entering operation, Wait Mode, contains several component-level tests and are intended to provide the end-user with a means for verifying specific system component functionality (i.e. troubleshooting). While performing functionality tests, the device, in a testing scenario, will be controlled by the diagnostic software momentarily. Once the applicable tests are complete, the device will return to its normal functional status. Any active test may be Figure 3-22: Example gauge test sequence 28

29 SECTION 3 CONTROLLER USER MANUAL Figure 3-24: Panel lamp test LAMP TEST The lamp test verifies the functionality of each of the indicator lights on the cluster panel. The test turns all lamps off, then toggles on each lamp one at a time, for approximately. 1.5 seconds, moving in a clockwise direction on the panel, starting at the lower left side. As each lamp is toggled on, its numeric value (1-18) as well as its position ID per the indicator lamp table, are displayed on the cluster's LCD. Below is an example of the information displayed. LCD TEST The LCD test verifies that all pixels in the Controller's LCD are able to turn on and off. The Sullair logo is displayed in normal, reverse, and normal video in that order. Each phase lasts approximately 2 seconds. Below is an example of the image sequence. Figure 3-23: Lamp test information screen Figure 3-25: LCD test sequence 29

30 CONTROLLER USER MANUAL SECTION 3 BINARY INPUTS The Binary Inputs screen displays the pin number and real-time status of each binary input defined in the system. Pressing the <EXIT> on the <MENU SELECT> switch exits the screen and returns to the Controller diagnostic menu BACKLIGHT ADJUST This menu entry contains two sub-menu entries that allow the user to set backlighting of the Controller's keypad and cluster. See Figure ANALOG INPUTS The Analog Inputs screen displays the pin number and real-time status of each analog input defined in the system. Pressing the <EXIT> on the <MENU SELECT> switch exits the screen and returns to the Controller diagnostic menu. Figure 3-26: Backlight adjustment menu screen BACKLIGHT COLOR This menu entry permits the cluster panel background color to be specified. The value is stored in memory for use in all subsequent Controller operation. Available colors are: {Red, Green, Blue, Yellow, Light Blue, Violet, and White}. BACKGROUND LEVEL This menu entry permits the cluster panel background level color to be specified. The value is selectable in increments of 2% from 0% (full OFF) to 100% (full ON). At levels of 10% or greater, the LCD display backlighting intensity level is also adjusted to this same level. At less than 10% panel backlighting, the LCD backlighting is always 100% (full ON), independent of user-selected panel backlighting level. The value is stored in memory for use in all subsequent Controller operation. See Figure Figure 3-27: Background level menu screen 30

31 SECTION 3 CONTROLLER USER MANUAL ENGINE DIAGNOSTICS The Engine Diagnostic screen is a real-time display of active operation messages being transmitted by the engine. Messages that become inactive are automatically erased. No messages are stored in the controller memory. When this function is selected, up to 5 of the most recent active engine Fault Mode Indicators (FMI) or Suspect Parameter Number (SPN) codes being received from the Caterpillar engine will be displayed. See Figure ENGINE ACTIVE DTCS: 2 100, , 15 Figure 3-28: Example diagnostic screen display I/O MODULE DIAG. Active J1939 Diagnostic Trouble Codes (DTCs) originating internally from the LCC component of the Controller as DM1 messages are displayed in this screen in a real-time view ENGINE SHUTDOWN HISTORY When/ If any abnormal shutdown event occurs, the Controller automatically logs operational parameters that were present at the time of the shutdown and stores them in memory for subsequent analysis if necessary. The engine shutdown history contains the five most recent fault-induced compressor shutdowns stored in memory. The history log is a first-in-first-out (FIFO) format, so that if a shutdown event occurs when five or more previous shutdown events were already logged in the history, the oldest entry is removed and overwritten with the current shutdown event and its data. The information logged shutdown includes: Run time eng-hours accumulated bit mask of all active shutdown flags bit mask of all active warning flags First active engine FMI/SPN/ occurrence count if active First active I/O module FMI/SPN/occurrence count if active P1 pressure P2 pressure P3 pressure CDT comp discharge temp ADT aftercooler discharge temp 5V dc ref voltage engine speed battery voltage number of active engine DTCs, lamp status number of active I/O module DTCS, lamp status operational state triggering shutdown fault ID fuel level coolant temp fuel temp oil pressure fuel pressure engine load This data is fully available for review through use of the Controller communicator PC application, which also allows the end user to clear the five-entry history buffer. Locally, at the cluster LCD, selection of this menu item, <ENGINE SHUTDOWN HISTORY>, will display a subset of the above information, including: triggering shutdown fault ID run time eng-hours accumulated all active warnings at time of shutdown 31

32 CONTROLLER USER MANUAL SECTION 3 A sample screenshot is displayed below: Figure 3-29: Error message screen The shutdown fault/cause is listed at the top of the screen in large font. The engine hours time stamp, if available, at time of the shutdown is listed at the bottom of the screen in large font In smaller font, in the middle section of the screen, all active warnings at time of the shutdown are displayed. Up to three warnings per page are listed. At entry to the <ENGINE SHUTDOWN HISTORY> menu item, the most recent shutdown event, if any is stored, is shown. To cursor to older shutdown records, press the down arrow on the <MENU TOGGLE> switch. To cursor forward again, press the up arrow on the <MENU TOGGLE> switch. For a given shutdown record, pressing <MENU SELECT> will cursor through to the next set of up to three active warnings if more than three were present at the time of the shutdown event. To exit <ENGINE SHUTDOWN HISTORY>, press <EXIT> on the <MENU SELECT> switch at any time. If no shutdowns have been recorded at the time of entry to the <ENGINE SHUTDOWN HISTORY> menu item, the message "No Shutdowns Stored" will be displayed for a 1 2 seconds, followed by a return to the previous menu list. 32

33 CONTROLLER USER MANUAL Section 4 DESCRIPTION 4.1 INTRODUCTION This section describes the operation of the Controller, the function of the controller components, and the various types of displays that may appear on the display screen. Descriptive lists of all messages appearing in the display are also provided. 4.2 OPERATING MODES SLEEP MODE When the Controller is de-energized, all components of the system are in <SLEEP> mode. Electrical components are not active in <SLEEP> mode to prevent battery drainage. The Controller allows the system to enter <SLEEP> mode by deactivating its 24V -to- 12V power supply converter signal and deactivating its switched power output signal that is fed out to Sullair components (fuel sensor and power to engine ECU). The Controller has two hardware wake-up inputs. 1. The <ON> switch 2. The <REMOTE START> switch (if enabled). Placing the <ON> switch in the on position will generate a hardware wake-up at the LCC high-side Ignition binary input. Placing the <REMOTE START> binary input low will generate a hardware wake-up if held low for greater than 750ms START-UP MODE <START-UP> mode initializes the system instrumentation components for operation. <START- UP> mode is internal to the Controller and does not permit engine/compressor activation. <START-UP> mode is enabled by one of the following two methods: 1. Press the <ON> switch to on. 2. Activating the <REMOTE START> (if enabled). Placing the <ON> switch to the on position will energize the gauges and begin initializing the system for <WAITING> mode. <START-UP> mode may be exited/cancelled before reaching <WAITING> mode. If <START-UP> is entered by placing the <ON> switch in the on position, placing the switch in the OFF position powers down the entire system. If a <START-UP> initialization parameter is out-of-tolerance, the Controller will enter a safe-shutdown state and demand user interaction to completely power down the unit. NOTE If the <START-UP> mode is entered via <REMOTE START>, then only a <START- UP> initialization parameter "out-of-tolerance" failure and "Remote Start binary input not low" will exit <START-UP> mode and prevent entering <WAITING> mode. Otherwise, the Controller will maintain <START-UP> mode status while <WAITING> for allowable conditions to begin initializing <WAITING> mode. It is during <START-UP> mode that system integrity is verified. System integrity verification involves checks of functional instrumentation, communication status, and confirmation of proper initial parameter settings. A successful completion of <START-UP> mode transitions the Controller to the <WAITING> mode. 33

34 CONTROLLER USER MANUAL SECTION WAITING MODE When the Controller is in <WAITING> mode the LCD display will indicate that the system is ready to be started, as shown below. See Figure 4-1. Figure 4-1: Unit ready display The compressor can be started in one of the two ways as described in Section 2. When the compressor is <WAITING> to be started remotely, a "Impending Remote Start" message at the top of the LCD will display. When the appropriate remote start conditions are met, the system will automatically enter the <START-UP> mode, and the compressor will start. While the compressor is attempting to start in both manual and remote start mode, the LCD will display the following screen in Figure 4-2. Figure 4-2: Engine cranking display <WAITING> mode is a transitional state between initialization of the Controller, operation of the compressor and compressor shutdown. In <WAITING> mode, the Controller is ready to enter an operational state. However, the compressor is not active in <WAITING> mode. <WAITING> mode is characterized by "Ready..." appearing on the LCD top status message section. If remote start is configured then "Ready..." will be displayed. See Figure 4-3. Auto (Remote) Start or <REMOTE START MOMENTARY> - remote start enabled. In <WAITING> mode, the Controller is analyzing specific system parameters to determine if entering <SLEEP> mode is allowable. When the necessary conditions are met, the system enters <SLEEP> mode and all electrical components are de-energized. If the compressor was enabled via <REMOTE START>, the <ON> switch is disabled and only a compressor malfunction will allow entering <WAITING> mode and then <SLEEP> mode. The Controller can turn the compressor's cabin lighting on and off via the <CABIN LIGHT> switch. In <WAITING> mode, since the CAT engine is not running, it is possible that cabin lighting could drain system battery. The Controller monitors the battery voltage and cabin lighting to guard against this condition during the <WAITING> mode phase. In such case, a cycled UCP lighting sequence, to warn users who may be performing cabin maintenance of the condition, is executed. The Controller cluster screen also indicates this condition, as in the following example screen. Note that after the UCP number of warning cycles, cabin lighting is automatically disabled regardless of keypad switch position. See Figure 4-4. Figure 4-4: Cabin lights on display While in <WAITING> mode the Controller monitors the ambient air temperature. When temperature is below the UCP start-up aids set value while in <WAITING> mode is as in Figure 4-5. Figure 4-3: Unit ready display <WAITING> mode to <RUN> mode is dependent on user initiation of a compressor start enabler. Manual Start - initiated by the <ON> switch placed in the start position. Figure 4-5: Start aids required display 34

35 SECTION 4 CONTROLLER USER MANUAL FAILURE TO START In manual mode, if the engine does not start, the Controller will attempt another start cycle as long as the maximum number of crank attempts is not exceeded. This is an automatic process until the start attempts equal the set maximum. If the maximum number of crank cycle attempts (a preset value) is exceeded, the system will display an error message in the LCD display as shown below. During engine crank cycle, the Controller transmits speed control to the Electronic Control Module (ECM). If the settings are not fulfilled, the Controller will abort crank cycling and display user-interface instructions for shutdown in alternating reverse video. To clear this message toggle the <MENU SELECT> switch to the <EXIT> position. See Figure 4-6. Figure 4-6: Engine overcrank display When <REMOTE START> is enabled, if the engine does not start, the <ON> switch will need to be toggled to off to shut the machine down. The system will then wait for the appropriate start-up conditions and then activate the remote start input to start the compressor RUN MODE Once the compressor has completed the warm up cycle, it will phase into <RUN> mode. When in <RUN> mode, the LCD display will look similar to the display shown below. Figure 4-7: Run mode display In <RUN> mode, the compressor is ready to supply service air. The engine RPM will automatically be adjusted to maintain the desired air pressure. The operator can scroll thru the list of available parameters, viewing up to four simultaneously, by momentarily moving the <MENU SELECT> switch to the select location. This will highlight one of the parameters in reverse video. Press the <MENU TOGGLE> switch in either direction will scroll one parameter. The available parameters are listed below. Table 4-1: Viewable Parameters Service Pressure Fuel Rate Control Pressure Fuel Pressure (1 or 2) Wet Pressure Fuel Level Engine Speed Engine Hours Engine Total Fuel Consumed Compressor Temperature ADT Temp (if After-Cooler configured) Hydraulic Temperature Coolant Temperature Battery Voltage Fuel Temperature Engine Inlet Air Temperature Oil Pressure Boost Pressure Desired Engine Speed Auxiliary Pressure Auxiliary Temperature Charge Air Temperature Inlet Air Temperature Soot Level Engine Load 35

36 CONTROLLER USER MANUAL SECTION AUTO-START (REMOTE) OPERATION If <WAITING> mode is exited due to a remote (i.e., Automatic) start trigger, a momentary alert state, during which the Controller alerts that an automatic system startup is about to be attempted, takes place. The duration of this alert state is configurable through a Controller UCP. During this temporary alert state, the LCD displays the text "Impending Remote Start" in its bottom status area. The Controller's siren and strobe light outputs are also activated. At the end of the configured duration, the siren and strobe light outputs are de-activated and the Controller attempts to crank-start the CAT engine to enter warm up. When using the auto-start feature, there are two parameters that can be set by using the Controller. The first is the P1 system service pressure value, and the second is the time duration that the compressor must stay at or above the P1 pressure. These values are settable when the Communicator software and communication adapter are installed. When the compressor is operating in <AUTO- START> mode, it will not enter a normal <SHUTDOWN> mode until both conditions below are met. a. The system service pressure (P1) is greater than the UCP (User Configurable Parameter) specified level for the UCP specified duration. b. The "remote start" input has returned to its normally open position. In the event that an abnormal shutdown occurs, the compressor could shut down without these conditions being met. See Section 5: TroubleShooting on page 41 for handling abnormal shutdowns SHUTDOWN Placing the switch in the OFF position will trigger the normal shutdown state. Normal shutdown can be initiated in any mode of compressor operation. The <SHUTDOWN> mode can be entered when either of the following conditions occurs: If the Controller system was started manually, the operator must press the <ON> switch to the off position. If the Controller system was auto-started (remote), the system will enter <SHUTDOWN> mode when both the service pressure (P1) is greater than the specified level for the user-specified duration (Note: Both of these values are pre-set), and when the remote start binary input is deactivated. When the system enters the manual <SHUTDOWN> mode, the compressor will complete the following tasks before shutting down: 1. De-energize the engine crank output (if energized) 2. Display "Stop Initiated" shutdown LCD message 3. Enter cool-down cycle a. Energize start/run output to put start/run solenoid in Start position b. UCP Compressor Cool-down Time c. TSC1 commanded to UCP Low Engine Idle 4. Momentarily de-energize Switched Power output a. Display new LCD message b. UCP ECM Power-Off Interval at Cool-down 5. Monitor System Pressures a. Display new LCD message b. UCP P1,2,3 Pressure for Cool-down Completion 6. Monitor Engine Speed a. Display new LCD message b. Engine Speed must decrease to at least 10 rpm 7. Enter <WAITING> mode However, during the final portion of shutdown, after the Controller has stopped the compressor's engine, the Controller no longer pays attention to the <ON> switch (or remote start). The operator must wait until this phase completes to restart the compressor. When the Controller is initialized in auto-start, from the remote start binary wake-up input, the front panel <ON> switch is inoperable. If remote start is UCP-configured as a momentary switch, shutdown is initiated if the service pressure demand violates UCP criteria. UCP P1 to shutdown from auto-start is the maximum service pressure allowed. If the service pressure exceeds the set point for longer than UCP time allowed then shutdown is initiated. See images in sequence below for details. If remote start is not UCP-configured as a 36

37 SECTION 4 CONTROLLER USER MANUAL momentary switch, shutdown is initiated when remote start input transitions from closed (active) to open (inactive). In either case, the following shutdown sequence then occurs: Display shutdown LCD message Enter Cool-down cycle a. Energize Start/Run relay to put Start/Run solenoid in Start position b. Energize Recirculation Manifold solenoid c. UCP Compressor Cool-down Time d. TSC1 commanded to UCP Low Engine Idle Momentarily de-energize Switched Power relay a. Display new LCD message b. UCP ECM Power-Off Interval at Cool-down Figure 4-8: Normal shutdown sequence Monitor System Pressures a. Display new LCD message b. UCP P1,2,3 Pressure for Cool-down Completion Monitor J1939 Engine Speed a. Display new LCD message b. J1939 Engine Speed must decrease to at least 10 rpm Exit <OPERATION> mode a. Remote Start binary is active --> enter <OPERATION> mode & attempt to restart compressor b. Remote Start binary is inactive --> enter <SLEEP> mode Figure 4-9: Auto shutdown sequence 37