900/1600 IT4 CONTROLLER...SECTION 1 6 A. Prior to hitching the air compressor to the tow vehicle, inspect all attachment parts and equip-ment, checking for (i) signs of excessive wear

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

misuse of this equipement will VOID its warranty!

WARRANTY NOTICE

PART NUMBER:

KEEP FORFUTURE REFERENCE

USER MANUAL

©SULLAIR CORPORATIONThe information in this manual is currentas of its publication date, and applies tocompressor serial number:

and all subsequent serial numbers.

02250201-742 R00

201200000

900/1600 IT4 CONTROLLER

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 electricalsystems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facilitylocated at Michigan City, Indiana.

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

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

SULLAIR TRAINING DEPARTMENT

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

[email protected]

- Or Write -

Sullair Corporation3700 E. Michigan Blvd.Michigan City, IN 46360

Attn: Service Training Department.

TABLE OF CONTENTSSECTION 1—SAFETY

5 1.1 GENERAL

5 1.2 TOWING

8 1.3 PRESSURE RELEASE

9 1.4 FIRE AND EXPLOSION

10 1.5 MOVING PARTS

11 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

11 1.7 TOXIC AND IRRITATING SUBSTANCES

12 1.8 ELECTRICAL SHOCK

12 1.9 LIFTING

13 1.10 ENTRAPMENT

13 1.11 JUMP STARTING

14 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT

15 1.13 CALIFORNIA PROPOSITION 65

16 1.14 SYMBOLS AND REFERENCES

SECTION 2—STARTUP PROCEDURES 19 2.1 INTRODUCTION

19 2.2 COMPASS CONTROLLER PANEL LAYOUT

19 2.3 COMPASS CONTROLLER POWER UP

20 2.4 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

21 2.5 NORMAL OPERATION

SECTION 3—ADJUSTMENT PROCEDURE 23 3.1 INTRODUCTION

24 3.2 SETTINGS AND DIAGNOSTIC

SECTION 4—DESCRIPTION 33 4.1 INTRODUCTION

33 4.2 OPERATING MODES

TABLE OF CONTENTS

SECTION 5—TROUBLESHOOTING 41 5.1 TROUBLESHOOTING INTRODUCTION

41 5.2 TROUBLESHOOTING GUIDE INTRODUCTION

42 5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE

Section 1

5

SAFETY

1.1 GENERAL

Sullair Corporation designs and manufactures all ofits products so they can be operated safely.However, the responsibility for safe operation restswith those who use and maintain these products. Thefollowing safety precautions are offered as a guidewhich, if conscientiously followed, will minimize thepossibility of accidents throughout the useful life ofthis equipment. Read the CIMA Safety Manualprior to compressor operation and towing, ifapplicable in your area.

The air compressor should be operated only by thosewho have been trained and delegated to do so, andwho have read and understood this Operator’sManual. Failure to follow the instructions, proceduresand safety precautions in this manual can result inaccidents and injuries.

NEVER start the air compressor unless it is safe todo so. DO NOT attempt to operate the aircompressor with a known unsafe condition. Tag theair compressor and render it inoperative bydisconnecting the battery so others who may notknow of the unsafe condition will not attempt tooperate it until the condition is corrected.

Use and operate the air compressor only in fullcompliance with all pertinent OSHA requirementsand/or all pertinent Federal, State and Local codes orrequirements.

DO NOT modify the compressor except with writtenfactory approval.

Each day, walk around the air compressor andinspect for leaks, loose or missing parts, damagedparts or parts out of adjustment. Perform allrecommended daily maintenance.

Inspect for torn, frayed, blistered or otherwisedeteriorated and degraded hoses. Replace asrequired.

1.2 TOWING

PREPARING TO TOW

NOTE

OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL.

CAUTIONEstimated 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)

WARNINGDo 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.

(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.

SECTION 1

6

A. Prior to hitching the air compressor to the towvehicle, inspect all attachment parts and equip-ment, checking for (i) signs of excessive wear orcorrosion, (ii) parts that are cracked, bent,dented or otherwise deformed or degraded, and(iii) loose nuts, bolts or other fasteners. Shouldany such condition be present, DO NOT TOWuntil the problem is corrected.

B. Back the tow vehicle to the compressor and posi-tion it in preparation for coupling the compressor.

C. If the compressor is provided with a drawbarlatched in the vertical upright position, carefullyunlatch drawbar and lower it to engage the cou-pling device. If not, raise drawbar with the jack toengage coupling device or otherwise couple thecompressor to the towing vehicle.

D. Make sure the coupling device is fully engaged,closed and locked.

E. If chains are provided, pass each chain throughits point of attachment on the towing vehicle;then hook each chain to itself by passing thegrab hook over (not through) a link. Cross chainsunder the front of drawbar before passing themthrough points of attachment on towing vehicle tosupport the front of drawbar in case it shouldaccidentally become uncoupled.

F. Make sure that the coupling device and adjacentstructures on the towing vehicle (and also, if uti-lized, chain adjustment, brake and/or electricalinterconnections) DO NOT interfere with orrestrict motion of any part of the compressor,including its coupling device, with respect to thetowing vehicle when maneuvering over anyanticipated terrain.

G. If provided, make sure chain length, brake andelectrical interconnections provide sufficientslack to prevent strain when cornering andmaneuvering, yet are supported so they cannotdrag or rub on road, terrain or towing vehicle sur-faces which might cause wear that could renderthem inoperative.

H. On two-wheeled models, fully retract front screwjack and any rear stabilizer legs. If a caster wheelis provided on the screw jack it is part of thescrew jack, and can not be removed. Follow thesame procedure for stowing away the wheeledjack as you would for the standard screw jack.Pull the pin connecting the jack to the drawbarand raise the screw jack to its full upright posi-tion. 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 totowing.

WARNINGThis 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.


CAUTIONRetract the front screw jack only after attaching the compressor to the tow vehi-cle. Raise the screw jack to its full up posi-tion 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 posi-tion, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

SECTION 1

7

I. Make sure tires are in good condition and are thesize (load range) specified and are inflated to thespecified pressures. DO NOT change the tiresize or type. Also, make sure wheel bolts, lugs ornuts are tightened to the specified torques.

J. If provided, make sure all dual stop, tail direc-tional and clearance lights are operating properlyand that their lenses are clean and functional.Also, make sure all reflectors and reflecting sur-faces, including the slow moving vehicle emblemon compressors provided with same, are cleanand functional.

K. Make sure all service air hoses (not air brakehoses) are disconnected or are fully stowed andsecured on hose reels, if provided.

L. Make sure all access doors and tool box coversare closed and latched. If the compressor islarge enough to hold a man, make sure all per-sonnel are out before closing and latchingaccess doors.

M. Make sure parking brakes in towing vehicle areset, or that its wheels are chocked or blocked, orthat it is otherwise restrained from moving. Then,release the compressor parking brakes, if pro-vided.

N. Make sure the compressor wheels are notchocked or blocked, and that all tie-downs, if any,are free.

O. Test running brake operation, including break-away switch operation if provided, beforeattempting to tow the compressor at its ratedspeed 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 ortools such that it is unbalanced from side to sideor front to back. Such unbalance will reduce thetowability of this equipment and may increasethe possibility of tipping, rolling over, jackknifing,etc. Loss of control of the towing vehicle mayresult.

TOWING

A. Observe all Federal, State, and Local laws whiletowing this equipment (including those specifyingminimum speed).

B. DO NOT exceed the towing speeds listed belowunder 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-wheelsteerable models: 15 MPH (24 km/h).

2. All other models: 55 MPH (88 km/h).

C. Remember that the portable air compressor mayapproach or exceed the weight of the towingvehicle. Maintain increased stopping distancesaccordingly. DO NOT make sudden lanechanges, U-turns or other maneuvers. Suchmaneuvers can cause the compressor to tip, rollover, jackknife or slide and cause loss of controlof the towing vehicle. Tipping, rolling over, etc.can occur suddenly without warning. U-turnsespecially 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 thefreedom of motion of the compressor’s drawbarand/ or coupling device, in or on the towing vehi-cle’s coupling device and/or adjacent structurewhether towing forward or backing up, regard-less of the terrain being traversed.

G. DO NOT permit personnel to ride in or on thecompressor.

H. Make sure the area behind, in front of, and underthe compressor is clear of all personnel andobstructions prior to towing in any direction.

I. DO NOT permit personnel to stand or ride on thedrawbar, or to stand or walk between the com-pressor and the towing vehicle.

PARKING OR LOCATING COMPRESSOR

A. Park or locate compressor on a level surface, ifpossible. If not, park or locate compressor acrossgrade so the compressor does not tend to rolldownhill. DO NOT park or locate compressor ongrades exceeding 15° (27%).

B. Make sure compressor is parked or located on afirm surface that can support its weight.

C. Park or locate compressor so the wind, if any,tends to carry the exhaust fumes and radiatorheat away from the compressor air inlet open-ings, and also where the compressor will not beexposed to excessive dust from the work site.

D. On steerable models, park compressor with frontwheels in straight-ahead position.

SECTION 1

8

E. Set parking brakes and disconnect breakawayswitch cable and all other interconnecting electri-cal and/or brake connections, if provided.

F. Block or chock both sides of all wheels.

G. If provided, unhook chains and remove themfrom the points of chain attachment on the towingvehicle, then hook chains to bail on drawbar orwrap chains around the drawbar and hook themto themselves to keep chains off the groundwhich might accelerate rusting.

H. Lower front screw jack and/or any front and rearstabilizer legs. Make sure the surface they con-tact has sufficient load bearing capability to sup-port the weight of the compressor.

I. If a caster wheel is provided on the screw jack, itis part of the screw jack and cannot be removed.Follow the same procedure for stowing away the

wheeled jack as you would for the standardscrew jack. Raise the screw jack to its full uprightposition and pull the pin connecting the jack tothe drawbar. Rotate the screw jack to its stowedposition, parallel to the drawbar and reinsert thepin. Make sure the jack is secured in place priorto towing.

J. Disconnect coupling device, keeping hands andfingers clear of all pinch points. If the compressoris provided with a drawbar, DO NOT attempt tolift the drawbar or if hinged, to raise it to theupright position by hand, if the weight is morethan you can safely handle. Use a screwjack orchain fall if you cannot lift or raise the drawbarwithout avoiding injury to yourself or others.

K. Move the towing vehicle well clear of the parkedcompressor and erect hazard indicators, barri-cades and/or flares (if at night) if compressor isparked on or adjacent to public roads. Park so asnot to interfere with traffic.

1.3 PRESSURE RELEASE

A. Open the pressure relief valve at least weekly tomake sure it is not blocked, closed, obstructed orotherwise disabled.

B. Install an appropriate flow-limiting valve betweenthe compressor service air outlet and the shutoff(throttle) valve, when an air hose exceeding 1/2"(13 mm) inside diameter is to be connected tothe shutoff (throttle) valve, to reduce pressure incase of hose failure, per OSHA Standard 29 CFR1926.302 (b) (7) or any applicable Federal, Stateand Local codes, standards and regulations.

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

D. Provide an appropriate flow-limiting valve foreach additional 75 feet (23 m) of hose in runs of


CAUTIONRetract the front screw jack only after attaching the compressor to the tow vehi-cle. Raise the screw jack to its full up posi-tion 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 posi-tion, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

NOTEWhile not towed in the usual sense of the word, many of these instructions are directly applicable to skidmounted porta-ble air compressors as well.

SECTION 1

9

air hose exceeding 1/2" (13 mm) inside diameterto reduce pressure in case of hose failure.

E. Flow-limiting valves are listed by pipe size andrated CFM. Select appropriate valve accordingly.

F. DO NOT use tools that are rated below the maxi-mum rating of this compressor. Select tools, airhoses, pipes, valves, filters and other fittingsaccordingly. DO NOT exceed manufacturer’srated safe operating pressures for these items.

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

H. Open fluid filler cap only when compressor is notrunning and is not pressurized. Shut down thecompressor and bleed the sump (receiver) tozero internal pressure before removing the cap.

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

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

K. DO NOT use air at pressures higher than 30 psig(2.1 bar) for cleaning purposes, and then onlywith effective chip guarding and personal protec-tive equipment per OSHA Standard 29 CFR1910.242 (b) or any applicable Federal, Stateand Local codes, standards and regulations.

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

M. This equipment is supplied with an ASMEdesigned pressure vessel protected by an ASMErated relief valve. Lift the handle once a week tomake sure the valve is functional. DO NOT liftthe handle while machine is under pressure.

N. If the machine is installed in an enclosed area itis necessary to vent the relief valve to the outsideof the structure or to an area of non-exposure.

O. DO NOT remove radiator filler cap until the cool-ant temperature is below its boiling point. Thenloosen cap slowly to its stop to relieve anyexcess pressure and make sure coolant is notboiling before removing cap completely. Removeradiator filler cap only when cool enough to touchwith a bare hand.

P. The ethyl ether in the replaceable cylinders usedin diesel ether starting aid systems (optional) isunder pressure. DO NOT puncture or incineratethose cylinders. DO NOT attempt to remove thecenter valve core or side pressure relief valvefrom these cylinders regardless of whether theyare full or empty.

Q. If a manual blowdown valve is provided on thereceiver, open the valve to ensure all internalpressure has been vented prior to servicing anypressurized component of the compressor air/fluid system.

1.4 FIRE AND EXPLOSION

A. Refuel at a service station or from a fuel tankdesigned for its intended purpose. If this is notpossible, ground the compressor to the dis-penser prior to refueling.

B. Clean up spills of fuel, fluid, battery electrolyte orcoolant immediately if such spills occur.

C. Shut off air compressor and allow it to cool. Thenkeep sparks, flames and other sources of ignitionaway and DO NOT permit smoking in the vicinitywhen adding fuel, checking or adding electrolyteto batteries, checking or adding fluid, checkingdiesel engine ether starting aid systems, replac-ing cylinders, or when refilling air line anti-icersystems antifreeze compound.

D. DO NOT permit liquids, including air line anti-icersystem antifreeze compound or fluid film, toaccumulate on bottom covers or on, under oraround acoustical material, or on any external orinternal surfaces of the air compressor. Wipedown using an aqueous industrial cleaner orsteam clean as required. If necessary, removeacoustical material, clean all surfaces and thenreplace acoustical material. Any acoustical mate-rial with a protective covering that has been tornor punctured should be replaced immediately toprevent accumulation of liquids or fluid film within

WARNINGDo not attempt to operate the compressor in any classification of hazardous environ-ment or potentially explosive atmosphere unless the compressor has been specially designed and manufactured for that duty.

SECTION 1

10

the material. DO NOT use flammable solventsfor cleaning purposes.

E. Disconnect the grounded (negative) battery con-nection prior to attempting any repairs or clean-ing inside the enclosure. Tag the batteryconnections so others will not unexpectedlyreconnect it.

F. Keep electrical wiring, including the battery ter-minals and other terminals, in good condition.Replace any wiring that has cracked, cutabraded or otherwise degraded insulation or ter-minals that are worn, discolored or corroded.Keep all terminals clean and tight.

G. Turn off battery charger before making or break-ing connections to the battery.

H. Keep grounded conductive objects such as toolsaway from exposed live electrical parts such asterminals to avoid arcing which might serve as asource of ignition.

I. Replace damaged fuel tanks or lines immediatelyrather than attempt to weld or otherwise repairthem. DO NOT store or attempt to operate thecompressor with any known leaks in the fuel sys-tem. Tag the compressor and render it inopera-tive until repair can be made.

J. Remove any acoustical material or other materialthat may be damaged by heat or that may sup-port combustion prior to attempting weld repairs.Remove diesel engine ether starting aid cylin-ders and air line anti-icer system componentscontaining antifreeze compound, prior toattempting weld repairs in any place other thanthe fuel system. DO NOT weld on or near thefuel system.

K. Keep a suitable, fully charged class BC or ABCfire extinguisher or extinguishers nearby whenservicing and operating the compressor.

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

M. Open all access doors and allow the enclosure toventilate thoroughly prior to attempting to startthe engine.

N. DO NOT operate compressor under low over-hanging leaves or permit such leaves to contacthot exhaust system surfaces when operating thecompressor in forested areas.

O. Ethyl ether used in diesel engine ether startingaid systems is extremely flammable. Change cyl-

inders, or maintain or troubleshoot these sys-tems only in well-ventilated areas away fromheat, open flame or sparks. DO NOT install,store or otherwise expose ether cylinders to tem-peratures above 160 °F (71 °C). Remove ethercylinder from the compressor when operating inambient temperatures above 60 °F (16 °C).

P. DO NOT attempt to use ether as a starting aid ingasoline engines or diesel engines with glowplugs as serious personnel injury or propertydamage may result.

Q. DO NOT spray ether into compressor air filter orinto an air filter that serves both the engine andthe compressor as serious damage to the com-pressor or personal injury may result.

R. Antifreeze compound used in air line anti-icersystems contains methanol which is flammable.Use systems and refill with compound only inwell-ventilated areas away from heat, openflames or sparks. DO NOT expose any part ofthese systems or the antifreeze compound totemperatures above 150 °F (66 °C). Vapors fromthe antifreeze compound are heavier than air.DO NOT store compound or discharge treatedair in confined or unventilated areas. DO NOTstore containers of antifreeze compound in directsunlight.

S. Store flammable fluids and materials away fromyour work area. Know where fire extinguishersare and how to use them, and for what type offire they are intended. Check readiness of firesuppression systems and detectors if soequipped.

1.5 MOVING PARTS

A. Keep hands, arms and other parts of the bodyand also clothing away from belts, pulleys andother moving parts.

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

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

D. Keep access doors closed except when makingrepairs or adjustments, performing service orwhen starting or stopping the compressor.

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11

E. Make sure all personnel are out of the way andclear of the compressor prior to attempting tostart or operate it.

F. Shut off engine before adding fuel, fluid, coolantlubricants, air line antifreeze compound or bat-tery electrolyte, or before replacing ether startingaid cylinders.

G. Disconnect the grounded negative battery con-nection to prevent accidental engine operationprior to attempting repairs or adjustments. Tagthe battery connection so others will not unex-pectedly reconnect it.

H. When adjusting the controls, it may require oper-ation of the equipment during adjustment. DONOT come in contact with any moving partswhile adjusting the control regulator and settingthe engine RPM. Make all other adjustments withthe engine shut off. When necessary, makeadjustment, other than setting control regulatorand engine RPM, with the engine shut off. If nec-essary, start the engine and check adjustment. Ifadjustment is incorrect, shut engine off, readjust,then restart the engine to recheck adjustment.

I. Keep hands, feet, floors, controls and walkingsurfaces clean and free of fluid, water, antifreezeor other liquids to minimize possibility of slips andfalls.

1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

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

B. Keep all parts of the body away from all points ofair discharge and away from hot exhaust gases.

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

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

1.7 TOXIC AND IRRITATING SUBSTANCES

A. DO NOT use air from this compressor for respi-ration (breathing) except in full compliance withOSHA Standards 29 CFR 1920 and any otherFederal, State or Local codes or regulations.

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

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

D. If the compressor is operated indoors, dischargeengine exhaust fumes outdoors.

E. Locate the compressor so that exhaust fumes arenot apt to be carried towards personnel, air intakesservicing personnel areas or towards the air intakeof any portable or stationary compressor.

F. Fuels, fluids, coolants, lubricants and batteryelectrolyte used in the compressor are typical ofthe industry. Care should be taken to avoid acci-dental ingestions and/or skin contact. In theevent of ingestion, seek medical treatmentpromptly. DO NOT induce vomiting if fuel isingested. Wash with soap and water in the eventof skin contact.

G. Wear an acid-resistant apron and a face shield orgoggles when servicing the battery. If electrolyte

DANGER

INHALATION HAZARD!

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

SECTION 1

12

is spilled on skin or clothing, immediately flushwith large quantities of water.

H. Ethyl ether used in diesel engine ether startingaid systems is toxic, harmful or fatal if swallowed.Avoid contact with the skin or eyes and avoidbreathing the fumes. If swallowed, DO NOTinduce vomiting and call a physician immediately.

I. Wear goggles or a full face shield when testingether starting aid systems or when adding anti-freeze compound to air line anti-icer systems.Keep openings of valve or atomizer tube of etherstarting aid system pointed away from yourselfand other personnel.

J. If ethyl ether or air line anti-icer system anti-freeze compound enters the eyes or if fumes irri-tate the eyes, they should be washed with largequantities of clean water for 15 minutes. A physi-cian, preferably any eye specialist, should becontacted immediately.

K. DO NOT store ether cylinders or air line anti-icersystem antifreeze compound in operator’s cabsor in other similar confined areas.

L. The antifreeze compound used in air line anti-icer systems contains methanol and is toxic,harmful or fatal if swallowed. Avoid contact withthe skin or eyes and avoid breathing the fumes. Ifswallowed, induce vomiting by administering atablespoon of salt in a glass of clean warm water.Do this until vomit is clear, then administer twotablespoons of baking soda in a glass of cleanwater. Have patient lay down and cover eyes toexclude light. Call a physician immediately.

1.8 ELECTRICAL SHOCK

A. Keep the towing vehicle or equipment carrier,compressor hoses, tools and all personnel atleast 10 feet (3 m) from power lines and buriedcables.

B. Keep all parts of the body and any hand-heldtools or other conductive objects away fromexposed live parts of electrical system. Maintaindry footing, stand on insulating surfaces and DONOT contact any other portion of the compressorwhen making adjustments or repairs to exposedlive parts of the electrical system.

C. Attempt repairs only in clean, dry and well-lightedand ventilated areas.

D. Stay clear of the compressor during electricalstorms! 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 byhelicopter must not be supported by the liftingbail, but by slings instead. In any event, lift only infull compliance with OSHA Standards 29 CFR1910 subpart N or any other Local, State, Militaryand Federal regulations that may apply.

B. Inspect lifting bail and points of attachment forcracked welds and for cracked, bent, corroded orotherwise degraded members and for loose boltsor nuts prior to lifting.

C. Make sure entire lifting, rigging and supportingstructure has been inspected, is in good condi-tion and has a rated capacity of at least the netweight of the compressor plus an additional 10%allowance for weight of water, snow, ice, mud,stored tools, and equipment. If your are unsureof the weight, then weigh compressor before lift-ing.

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

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

F. DO NOT attempt to lift in high winds.

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

H. Lift compressor no higher than necessary.

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

J. Set compressor down only on a level surfacecapable of supporting at least its net weight plusan additional 10% allowance for the weight ofwater, snow, ice, mud, stored tools, and/or equip-ment.

K. If the compressor is provided with parkingbrakes, make sure they are set, and in anyevent, block or chock both sides of all runningwheels before disengaging the lifting hook.

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1.10 ENTRAPMENT

A. Make sure all personnel are out of compressorbefore closing and engaging enclosure doors.

B. If the compressor is large enough to hold a manand if it is necessary to enter it to perform serviceadjustments, inform other personnel beforedoing so, or else secure the access door in theopen position to avoid the possibility of othersclosing and possibly latching the door with per-sonnel inside.

1.11 JUMP STARTING

A. Observe all safety precautions mentioned else-where in this manual.

B. Batteries may contain hydrogen gas which isflammable and explosive. Keep flames, sparksand other sources of ignition away.

C. Batteries contain acid which is corrosive and poi-sonous. DO NOT allow battery acid to contacteyes, skin, fabrics or painted surfaces as seriouspersonal injury or property damage could result.Flush any contacted areas thoroughly with waterimmediately. Always wear an acid-resistantapron and face shield when attempting to jumpstart the compressor.

D. Remove all vent caps (if so equipped) from thebattery or batteries in the compressor. DO NOTpermit dirt or foreign matter to enter the opencells.

E. Check fluid level. If low, bring fluid to proper levelbefore attempting to jump start (not applicable tomaintenance-free batteries).

F. DO NOT attempt to jump start if fluid is frozen orslushy. Bring batteries up to at least 60 °F (16°C) before attempting to jump start or it mayexplode.

G. Cover open cells of all compressor batteries withclean dampened cloths before attempting tojump start.

H. Attempt to jump start only with a vehicle having anegative ground electrical system with the samevoltage, and is also equipped with a battery orbatteries of comparable size or larger than sup-plied in the compressor. DO NOT attempt tojump start using motor generator sets, welders orother sources of DC power as serious damagemay result.

I. Bring the starting vehicle alongside the compres-sor, but DO NOT permit metal to metal contactbetween the compressor and the starting vehicle.

J. Set the parking brakes of both the compressor (ifprovided) and the starting vehicle or otherwiseblock both sides of all wheels.

K. Place the starting vehicle in neutral or park, turnoff all non-essential accessory electrical loadsand start its engine.

L. Use only jumper cables that are clean, in goodcondition and are heavy enough to handle thestarting current.

M. Avoid accidental contact between jumper cableterminal clips or clamps and any metallic portionof either the compressor or the starting vehicle tominimize the possibility of uncontrolled arcingwhich might serve as a source of ignition.

N. Positive battery terminals are usually identifiedby a plus (+) sign on the terminal and the lettersPOS adjacent to the terminal. Negative batteryterminals are usually identified by the lettersNEG adjacent to the terminal or a negative (-)sign.

O. Connect one end of a jumper cable to the posi-tive (POS) (+) battery terminal in the startingvehicle. When jump starting 24V compressorsand if the starting vehicle is provided with two (2)12V batteries connected in series, connect thejumper cable to the positive (POS) (+) terminal ofthe ungrounded battery.

P. Connect the other end of the same jumper cable tothe positive (POS) (+) terminal of the starter motorbattery in the compressor when jump starting 24Vcompressors, to the positive (POS) (+) terminal ofthe ungrounded battery in the compressor.

Q. Connect one end of the other jumper cable to thegrounded negative (NEG) (-) terminal of the bat-tery in the starting vehicle. When jump starting24V compressors and if the starting vehicle isprovided with two (2) 12V batteries connected inseries, connect the jumper cable to the negative(NEG) (-) terminal of the grounded battery.

R. Check your connections. DO NOT attempt tostart a 24V compressor with one 12V battery inthe starting vehicle. DO NOT apply 24V to one12V battery in the compressor.

S. Connect the other end of this same jumper cableto a clean portion of the compressor engine

SECTION 1

14

block away from fuel lines, the crank casebreather opening and the battery.

T. Start the compressor in accordance with normalprocedure. Avoid prolonged cranking.

U. Allow the compressor to warm up. When thecompressor is warm and operating smoothly atnormal idle RPM, disconnect the jumper cablefrom the engine block in the compressor, thendisconnect the other end of this same cable fromthe grounded negative (NEG) (-) terminal of thebattery in the starting vehicle. Then disconnectthe other jumper cable from the positive (POS)(+) terminal of the battery in the compressor, or ifprovided with two (2) 12V batteries connected inseries, from the ungrounded battery in the com-pressor, and finally, disconnect the other end ofthis same jumper cable from the positive (POS)(+) terminal of the battery in the starting vehicleor from the positive (POS) (+) terminal of theungrounded battery in the starting vehicle, if it isprovided with two (2) 12V batteries connected inseries.

V. Remove and carefully dispose of the dampenedcloths, as they may now be contaminated withacid, then replace all vent caps.

1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT

The energy control procedure defines actionsnecessary to lockout a power source of any machineto be repaired, serviced or set-up, where unexpectedmotion, or an electrical or other energy source, wouldcause personal injury or equipment damage. Thepower source on any machine shall be locked out byeach employee doing the work except when motionis necessary during setup, adjustment or trouble-shooting.

A. The established procedures for the application ofenergy control shall cover the following elementsand actions and shall be initiated only by Autho-rized Persons and done in the followingsequence:

1. Review the equipment or machine to belocked and tagged out.

2. Alert operator and supervisor of whichmachine is to be worked on, and that powerand utilities will be turned off.

3. Check to make certain no one is operatingthe machine before turning off the power.

4. Turn off the equipment using normalshutdown procedure.

5. Disconnect the energy sources:

a. Air and hydraulic lines should be bled,drained and cleaned out. There should beno pressure in these lines or in the reser-voir tanks. Lockout or tag lines or valves.

b. Any mechanism under tension or pres-sure, such as springs, should bereleased and locked out or tagged.

c. Block any load or machine part prior toworking under it.

d. Electrical circuits should be checked withcalibrated electrical testing equipmentand stored energy and electrical capaci-tors should be safely discharged.

6. Lockout and/or Tagout each energy sourceusing the proper energy isolating devicesand tags. Place lockout hasp and padlock ortag at the point of power disconnect wherelockout is required by each personperforming work. Each person shall beprovided with their own padlock and havepossession of the only key. If more than oneperson is working on a machine each personshall affix personal lock and tag using amulti-lock device.

7. Tagout devices shall be used only whenpower sources are not capable of beinglocked out by use of padlocks and lockouthasp devices. The name of the personaffixing tag to power source must be on tagalong with date tag was placed on powersource.

8. Release stored energy and bring theequipment to a “zero mechanical state”.

9. Verify Isolation: Before work is started, testequipment to ensure power is disconnected.

B. General Security

1. The lock shall be removed by the“Authorized” person who put the lock on theenergy-isolating device. No one other thanthe person/persons placing padlocks andlockout hasps on power shall removepadlock and lockout hasps and restorepower. However, when the authorizedperson who applied the lock is unavailable toremove it his/her Supervisor may removepadlock/padlocks and lockout hasps andrestore power only if it is first:

a. verified that no person will be exposed todanger.

SECTION 1

15

b. verified that the “Authorized” person whoapplied the device is not in the facility.

c. noted that all reasonable efforts to con-tact the “Authorized” person have beenmade to inform him or her that the lock-out or tagout device has been removed.

d. ensured that the “Authorized” person isnotified of lock removal before returningto work.

2. Tagout System—Tags are warning devicesaffixed at points of power disconnect and arenot to be removed by anyone other that theperson placing tag on power lockout. Tagsshall never be by-passed, ignored, orotherwise defeated

1.13 CALIFORNIA PROPOSITION 65

WARNINGCALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its con-stituents are known to the State of Califor-nia to cause cancer, birth defects and other reproductive harm.

Battery posts, terminals and related acces-sories contain lead and other compounds known to the State of California to cause cancer and birth defects and other repro-ductive harm. Wash hands after handling.

SECTION 1

16

1.14 SYMBOLS AND REFERENCES

The symbols below may or may not be used. Pleaserefer to the decals set forth on the machine forapplicable symbols.

Safety Symbols-1 T4

DIESEL PARTICULATE FILTER

REGENERATION INHIBIT

HIGH EXHAUST SYS. TEMP

WAIT TO START

REMOTE START

CABIN LIGHTS

/ iT4

/ iT4

/ iT4

SECTION 1

17

Safety Symbols-2

SECTION 1

18

Safety Symbols-3

Section 2

19

CONTROLLER USER MANUAL

STARTUP PROCEDURES2.1 INTRODUCTION

This compressor is equipped with a Sullair Controllerfor controlling the compressor system operation,adjusting the machine parameters and performingmaintenance operations. The Controller utilizesdigital technology that ensures accurate and safeoperation of the compressor system. When faultconditions occur, the Controller automatically shutsdown the machine to prevent injury to the operator ordamage to the equipment. Features of the Controllerinclude:

• Multiple gauges for display of pressure,engine temp, compressor temp, enginerpm, and fuel level

• LCD screen displaying machine status andoperating information

• Remote start capabilities

• Automatic self diagnosis at startup

• Multiple language support

• An external diagnostics port which allowsPC interface for configuration of the systemparameters.

• Backlighting of gauges with green LED toallow clear view of gauges in low lightareas.

2.2 COMPASS CONTROLLER PANEL LAYOUT

The Controller panel is shown in Figure 2-1 on page18. The Controller components and functions aredescribed in detail in Section 4.

2.3 COMPASS CONTROLLER POWER UP

The Controller is used to start the compressor eithermanually or remotely.

Manual Start: Start the machine by toggling the<ON> switch to the “start” position on the Controllerpanel. Once the switch has been set to the “start”position and the Controller has successfullyinitialized (see Self Test, Communication Checksand Parameter/Safety Checks in this section forfurther information), the Controller will check status,and automatically continue to energize the starteruntil either the engine starts or the maximum crankduration is reached.

Auto Start: The compressor can be started remotelyif the remote start function has been enabled duringsetup.

SELF TEST

When the Controller is initially powered up, thesystem will initiate a “Self Test” sequence to verify itsoperational integrity and safety status. During thisprocess, the following actions will be performed.

1. Gauge pointers will move to the zero posi-tion, then to half and full scale, then back tozero, and finally to the actual value reading.

2. The LCD display will turn on all its segmentsfor one second, off for one second, and thendisplay the Sullair logo followed by the soft-ware product number with revision level.

3. All warning lights will turn on for 2.5 secondsand then turn off, then set to the actual indi-cator state.

The self test feature may be bypassed by disablingthe sequence as describe in Section 3 of thismanual.

COMMUNICATION CHECKS

After successful completion of the self test, theController system will check the communicationstatus of the system.

CONTROLLER USER MANUAL SECTION 2

20

2.4 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

HIGH

REGEN PRESSURE ONMENUTOGGLE

MENUSELECT

CABINLIGHTS

LOW

SELECT

START

OFFEXIT

FORCE

INHIBIT

8

3

2

1

2229-30 23 24 21 20 19

31 31

10 926 7

2528

12 13

14

15

16

18

17

6

5

4

3227

11

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

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 ondual 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

Lamp Indicators Switches/Gauges/Features

Figure 2-1: Instrument Panel Group

SECTION 2 CONTROLLER USER MANUAL

21

The Controller system will prevent the user fromoperating the compressor until all communicationproblems are resolved.

See Section 5 of this manual for troubleshootingrecommendations.

GENERAL SAFETY CONDITION CHECKS

After successful completion of the communicationbus checks, the Controller system will perform safetychecks on the compressor and the engine.

In the event of a problem with either the compressoror engine, a message will display in the LCDindicating the nature of the trouble (example shownbelow). The Controller will wait for user-interaction toeither correct the fault or send the system to Sleepmode. See Figure 2-2.

Table 2-1 lists the safety conditions that are checkedby the Controller during startup and the fault that willbe displayed on the LCD screen if a fault occurs.


SYSTEM PRESSURE CHECKS

Following the successful completion of the generalsafety checks, the Controller will check the status ofthe service pressure (P1), control pressure (P2), andwet sump (P3). If there is a problem with any ofthese inputs a message will be displayed on the LCDdisplay indicating the nature of the problem.

See Figure 2-3.

The Controller will prevent compressor startup ifeither of the following conditions exists:

• P1 pressure is greater than the maximumP1 pressure permitted at startup. Themaximum P1 pressure is an adjustableparameter which can be modified asdescribe in Section 3 of this manual.

• P1 and P2 pressures are out of range.


2.5 NORMAL OPERATION

Following the successful completion of all startupsequences, the system is ready for normal operation.During normal operation the Controller will be in oneof the following five operating modes: Waiting,Start-Up and Autostart (remote), Run, Sleep, andShutdown. Each of these modes is described indetail in Section 4.

Figure 2-2: Communications checks display

Figure 2-3: P2 signal error screen

Figure 2-4: Operational Flow Diagram


22

Table 2-1: Safety Conditions

Parameter Fault ConditionUser Controlled

ParameterLCD 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)

Signal short circuit None T1 Signal Error

Compressor Temp High Max T1 during run or at start-up

Comp High Temp

Receiver Tank Temper-ature (RTT)

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 Pres-sure

Control Pressure (P2) Transducer signal short or open circuit


Air Pressure (P3) Transducer signal short or open circuit


Section 3

23


ADJUSTMENT PROCEDURE3.1 INTRODUCTION

This section describes steps for using the Controllerto modify specific parameters that control themachine operation. Additional parameters (UCP) canbe viewed and adjusted using the PC User Interface.See Figure 3-1.

MESSAGE DISPLAY CENTER

The message display is a graphical LCD that displaysinformation to the compressor operator. The screen isbacklit to allow the display characters to be clearlyvisible under any lighting conditions. In addition tobasic operational information, a variety of user-definedoptions may also be displayed when specified. Up tofour different parameters may be displayed at onetime; viewable parameters are displayed in Table 4-1.Fault messages are displayed whenever a faultcondition occurs. The LCD display also allows theoperator to view instrumentation diagnostic data to aidin controlling the system operation and introubleshooting problems. The screen is broken upinto two different information types' parameter displayand system display. See Figure 3-2.

CONTRAST

The two buttons at the bottom right of Controller'scluster panel can be used during normal operation toadjust LCD contrast up and down. The end useradjusts contrast by press and hold operation of eitherbutton until satisfactory contrast level is achieved.Any changes made by the end user are subsequentlyretained in the Controller’s memory.

PARAMETER SECTION NAVIGATION

During normal operation the LCD displays real-timevalues of up to four different system parameters atonce. The following table lists all availableparameters. To navigate the parameters you wish todisplay, use Controllers selection and toggleswitches as follows:

• A short press and release of the <MENU SELECT>switch, in the select position, will select one of theparameter display lines. A different parameter dis-play line can be selected by continued short pressand release of the <MENU TOGGLE> switch.

• Once the desired parameter display line isselected, press the <MENU TOGGLE> switch, tothe <UP> or <DOWN> positions to scroll throughthe different parameters available for viewing atthat line.

• The selected parameter display line will becomeunselected after a period of no <UP>, <DOWN>,<MENU SELECT> activity for 5 seconds.

The parameters chosen for display will be retainedacross subsequent system power-ups and usageuntil changed by the same procedure. Figure 3-3below shows the screen layout.

Figure 3-1: J1939 Data communication cable

Part Number 02250173-104

Figure 3-2: Display key


24

3.2 SETTINGS AND DIAGNOSTIC

MENU

Once the initialization sequence is complete, theoperator can enter the settings and diagnostic menuat any time by holding the <MENU SELECT> switch,in the “select” position for 2 seconds. This will bringup the screen below.

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 switchwill continuously scroll upward thru the menu).

• <DOWN>A toggle on the <MENU TOGGLE>switch. Use to scroll downward down thru the cur-rent menu list. (Note that continuing to press andhold the switch will continuously scroll downwardthru the menu).

• <SELECT>A toggle on the <MENU SELECT>.Use this to choose the selected item in the menulist.

• <EXIT>A toggle on the <MENU SELECT>switch. Use to move back up one level in the menustructure.

Figure 3-3: Settings Menu

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


25

3.2.1 SET UNITS

The operator can change the units of measure for alldata represented on the LCD screen. All parametersdisplayed in any subsequent <OPERATION> modeswill use the selected unit of measurement. Theselected unit of measurement will be retained innonvolatile memory for subsequent unit use. Belowis an example of changing this setting.

3.2.2 LARGE DISPLAY INFO

In <WAITING> and <OPERATION> modes,parameter display can be configured to show eithertwo parameters, in large font, or four parameters, insmaller font. The configuration for this large fontdisplay is chosen using this menu entry. Navigationof 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 innonvolatile memory. See Figure 3-5.

3.2.3 SET LANGUAGE

Selecting <SET LANGUAGE>, a sub-menu of allavailable display languages is shown. Upon entry tothis sub-menu, the current language is displayed inreverse video. See following diagrams for supportedlanguages. If a new language is selected, a<LANGUAGE CHANGED> confirmation screen(displayed in the language in use prior to making thechange) will appear before returning to the sub-menuof available display languages, as shown in Figure 3-6 and Figure 3-7.

3.2.4 OPERATIONAL CONFIGURATION

This menu, to which Controller permits entry onlyprior to system entering <OPERATION> mode,allows end-user configuration of certain keyoperational User Controlled Parameters, UCP, items.A context-sensitive sub-menu (ie, entries in thesubmenu are dynamic and may or may not bepresent depending on other operation configurationsettings, as discussed below) of entries is displayedwhen this menu item is selected.

ENABLE REMOTE START

This setting specifies whether pin 37 of the MainInterface Connector is to be used as a system wake-up. If enabled, the remote start enabled indicator lighton the cluster overlay is illuminated, severaladditional items in the operational configuration sub-menu become available, and the <AUTO SLEEPCFG.> item in the operational configuration menusub-menu become unavailable, since it is notapplicable when remote start is enabled. Figure 3-8.

Figure 3-4: Unit set menu screen

Figure 3-5: Font size menu screen

Figure 3-6: Language menu screen

Figure 3-7: Language confirmed menu screen

Figure 3-8: Remote start menu screen


26

REM. START MOMENTARY

This item is only present and applicable if <ENABLEREMOTE START> is set to yes. This setting allowseither a static or momentary (> 750 ms) LS switch to beused to drive remote start operation. See Figure 3-9.

REM. START P1 VAL

This item is only present and applicable if momentaryremote start is enabled. Along with the subsequentitem, <REM. START P1 TIME>, this settingdetermines the required condition for shutdown froma prior momentary remote start. If P1 pressure of thislevel is achieved for the time duration specified in<REM. START P1 TIME> after a prior momentaryremote start, Controller automatically begins thenormal shutdown automatically. Using the <MENUTOGGLE>, and <MENU SELECT> switches, thisvalue can be adjusted in increments of roughly 10 psifrom 65 psi (min) to 645 psi (max). Internal units ofmeasurement are kPa, and some rounding mayoccur as user increments/decrements through to thedesired setting. ie, some increments/decrementsmay be 11 psi instead of 10. Figure 3-10.

REM. START P1 TIME

This item is only present and applicable if momentaryremote start is enabled. Along with the previous item,<REM. START P1 VAL>, this setting determines therequired condition for shutdown from a priormomentary remote start. If P1 pressure of magnitudespecified in <REM. START P1 VAL> for the timeduration specified here, after a prior momentaryremote start, Controller automatically begins the

normal shutdown automatically. Using the <MENUTOGGLE>, and <MENU SELECT> switches, thisvalue can be adjusted in increments of 1 minute,from 5 minutes (minimum) to 33 minutes (maximum).See Figure 3-11.

USES CANOPY

This item specifies whether or not a canopyenclosure is present for the compressor system. Thisinformation is used to determine fan controlalgorithm. See Figure 3-12.

AUTO SLEEP CFG.

This item is only present and applicable if <REMOTESTART> is disabled. This setting specifies theamount of idle time (ie, Controller detects no activityfrom the keypad) that must elapse in <WAITNGMODE> before Controller will automatically transitionto <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 thissetting only applies in Controller configurations thatare not enabled for <REMOTE START>. See Figure3-13.

Figure 3-9: Remote start momentary menu screen

Figure 3-10: Remote pressure val screen

Figure 3-11: Remote start pressure value screen

Figure 3-12: Canopy menu screen

Auto Sleep Cfg. 5 min

Figure 3-13: Auto sleep configuration screen


27

AFTER COOLERS

This item specifies whether or not the compressor isinstalled with aftercoolers. See Figure 3-14.

AFTER FILTERS

This item is only present and applicable if <AFTERCOOLERS> is enabled. See Figure 3-15.

FUEL TANK CFG.

This item specifies which fuel tank and/or fuel levelsensor is installed in the compressor system. SeeFuel Sender information for information on the fueltanks and level sensors supported by Controller. SeeFigure 3-16.

PRESSURE CALIBRATION

Each of the pressure transducer inputs supported byController can be calibrated to counter sensor/circuittolerance using the sub-menus displayed when theuser selects this menu entry. These screens areused to specify a calibration offset, if needed. Thescreens support a range of -100 to +100 kpa (factorydefault is 0 kpa) for the pressure calibration offset.This offset is added to the reading that Controllersees from the respective pressure transducer and isapplied throughout subsequent operation. The offset

value is stored in memory, so it is retained throughsubsequent system power-ups.

In Figure 3-17 displayed below, the service pressure(P1) calibration screen is displayed. The samescreen is available for P2 (control pressure) and P3(wet pressure). The current value (with calibrationoffset applied) is shown in large font at the bottom ofthe screen, displayed in either psi or bar dependingon UCP units of measurement setting. Thecalibration value, which is always in units of kPa (1kPa = 0.01 bar), regardless of UCP units ofmeasurement, is displayed in smaller font to the farright of the screen.

In Figure 3-18 immediately below, an example P1 isdisplayed, with the factory default 0 kpa calibrationoffset in use. If the end-user knows that, in fact, therelative pressure level at the P1 sensor is 0 psi, thenthe 2 psi value being read at Controller needs to becalibrated. As can be seen from the second diagrambelow, when an offset of -13 kPa is applied and set,the P1 service pressure reading is adjusted to 0 psi.

TEMP CALIBRATION

Each of the temperature sensor transducer inputssupported by Controller can be calibrated to countersensor/circuit tolerance using the sub-menusdisplayed when the user selects this menu entry.These screens are used to specify a calibrationoffset, if needed. The screens support a range of -10.0 to +10.0 F in units of 0.5 C (factory default is 0.0C) for the temperature calibration offset. This offset isadded to the reading that Controller sees from therespective temperature transducer and is appliedthroughout subsequent operation. The offset value isstored in memory, so it is retained throughsubsequent system power-ups.

Figure 3-14: Aftercooler menu screen

After Filters no

yes

Figure 3-15: Afterfilter menu screen

Figure 3-16: Fuel tank configuration screen

Figure 3-17: Uncalibrated service pressure

Figure 3-18: Calibrated service pressure


28

In Figure 3-19 displayed below, the CompressorDischarge Temperature (CDT) calibration screen isdisplayed. The same screen is available for theAftercooler Discharge Temperature (ADT) andHydraulic Temperature (HT) sensors. The currentvalue (with calibration offset applied) is shown inlarge font at the bottom of the screen, displayed ineither F or C depending on UCP units ofmeasurement. The calibration value, which is alwaysin units of 0.5 C, regardless of UCP units ofmeasurement, is displayed in smaller font to the farright of the screen.

In Figure 3-20 immediately below, an example CDTtemperature is displayed, with the factory default 0.0C 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 tobe calibrated. Calibration. As can be seen from thesecond diagram below, when an offset of 6.5C isapplied and set, the CDT reading is adjusted to 88 F.

3.2.5 CONTROLLER DIAGNOSTICS

This menu entry, to which permits entry only prior tosystem entering operation, Wait Mode, containsseveral component-level tests and are intended toprovide the end-user with a means for verifyingspecific system component functionality (i.e.troubleshooting). While performing functionality tests,the device, in a testing scenario, will be controlled bythe diagnostic software momentarily. Once theapplicable tests are complete, the device will returnto its normal functional status. Any active test may be

aborted by engaging the <START> switch to the“exit” position during its execution.

GAUGE TEST

The gauge test verifies the gauge pointer needlefunctionality. The test proceeds sequentially from leftto right of the cluster panel, one gauge at a time. Foreach gauge, the active gauge's pointer needle will bedriven to three reference positions pausing at eachposition 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 thefuel gauge.

Figure 3-19: Uncalibrated temperature example

Figure 3-20: Calibrated temperature example

1-Gauge Test2-Lamp Test3-LCD Test

SelectFigure 3-21: Test menu

Figure 3-22: Example gauge test sequence


29

LAMP TEST

The lamp test verifies the functionality of each of theindicator lights on the cluster panel. The test turns alllamps off, then toggles on each lamp one at a time,for approximately. 1.5 seconds, moving in aclockwise direction on the panel, starting at the lowerleft side. As each lamp is toggled on, its numericvalue (1-18) as well as its position ID per theindicator lamp table, are displayed on the cluster'sLCD. Below is an example of the informationdisplayed.

LCD TEST

The LCD test verifies that all pixels in the Controller'sLCD are able to turn on and off. The Sullair logo isdisplayed in normal, reverse, and normal video inthat order. Each phase lasts approximately 2seconds. Below is an example of the imagesequence.

Figure 3-23: Lamp test information screen

Figure 3-24: Panel lamp test

Figure 3-25: LCD test sequence


30

BINARY INPUTS

The Binary Inputs screen displays the pin numberand real-time status of each binary input defined inthe system. Pressing the <EXIT> on the <MENUSELECT> switch exits the screen and returns to theController diagnostic menu.

ANALOG INPUTS

The Analog Inputs screen displays the pin numberand real-time status of each analog input defined inthe system. Pressing the <EXIT> on the <MENUSELECT> switch exits the screen and returns to theController diagnostic menu.

3.2.6 BACKLIGHT ADJUST

This menu entry contains two sub-menu entries thatallow the user to set backlighting of the Controller'skeypad and cluster. See Figure 3-26.

BACKLIGHT COLOR

This menu entry permits the cluster panelbackground color to be specified. The value is storedin memory for use in all subsequent Controlleroperation. Available colors are: Red, Green, Blue,Yellow, Light Blue, Violet, and White.

BACKGROUND LEVEL

This menu entry permits the cluster panelbackground level color to be specified. The value isselectable in increments of 2% from 0% (full OFF) to100% (full ON). At levels of 10% or greater, the LCDdisplay backlighting intensity level is also adjusted tothis same level. At less than 10% panel backlighting,the LCD backlighting is always 100% (full ON),independent of user-selected panel backlightinglevel. The value is stored in memory for use in allsubsequent Controller operation. See Figure 3-27.

Figure 3-26: Backlight adjustment menu screen

Figure 3-27: Background level menu screen


31

3.2.7 ENGINE DIAGNOSTICS

The Engine Diagnostic screen is a real-time displayof active operation messages being transmitted bythe engine. Messages that become inactive areautomatically erased. No messages are stored in thecontroller memory.

When this function is selected, up to 5 of the mostrecent active engine Fault Mode Indicators (FMI) orSuspect Parameter Number (SPN) codes beingreceived from the Caterpillar engine will bedisplayed. See Figure 3-28.

3.2.8 I/O MODULE DIAG.

Active J1939 Diagnostic Trouble Codes (DTCs)originating internally from the LCC component of theController as DM1 messages are displayed in thisscreen in a real-time view.

3.2.9 ENGINE SHUTDOWN HISTORY

When/ If any abnormal shutdown event occurs, theController automatically logs operational parametersthat were present at the time of the shutdown andstores them in memory for subsequent analysis ifnecessary. The engine shutdown history contains thefive most recent fault-induced compressorshutdowns stored in memory. The history log is afirst-in-first-out (FIFO) format, so that if a shutdownevent occurs when five or more previous shutdownevents were already logged in the history, the oldestentry is removed and overwritten with the currentshutdown 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/ occurrencecount if active

• First active I/O module FMI/SPN/occur-rence 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 sta-tus

• number of active I/O module DTCS, lampstatus

• 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 ofthe Controller communicator PC application, whichalso allows the end user to clear the five-entry historybuffer.

Locally, at the cluster LCD, selection of this menuitem, <ENGINE SHUTDOWN HISTORY>, willdisplay a subset of the above information, including:

• triggering shutdown fault ID

• run time eng-hours accumulated

• all active warnings at time of shutdown

1.1.1 ENGINE ACTIVE DTCS: 2 100, 17 110, 15

Figure 3-28: Example diagnostic screen display


32

A sample screenshot is displayed below:

• The shutdown fault/cause is listed at thetop of the screen in large font.

• The engine hours time stamp, if available,at time of the shutdown is listed at the bot-tom of the screen in large font

• In smaller font, in the middle section of thescreen, all active warnings at time of the

shutdown are displayed. Up to three warn-ings per page are listed.

At entry to the <ENGINE SHUTDOWN HISTORY>menu item, the most recent shutdown event, if any isstored, is shown. To cursor to older shutdownrecords, press the down arrow on the <MENUTOGGLE> switch. To cursor forward again, pressthe up arrow on the <MENU TOGGLE> switch. For agiven shutdown record, pressing <MENU SELECT>will cursor through to the next set of up to threeactive warnings if more than three were present atthe time of the shutdown event. To exit <ENGINESHUTDOWN HISTORY>, press <EXIT> on the<MENU SELECT> switch at any time.

If no shutdowns have been recorded at the time ofentry to the <ENGINE SHUTDOWN HISTORY>menu item, the message "No Shutdowns Stored" willbe displayed for a 1 – 2 seconds, followed by a returnto the previous menu list.

Figure 3-29: Error message screen

Section 4

33


DESCRIPTION4.1 INTRODUCTION

This section describes the operation of theController, the function of the controller components,and the various types of displays that may appear onthe display screen. Descriptive lists of all messagesappearing in the display are also provided.

4.2 OPERATING MODES

4.2.1 SLEEP MODE

When the Controller is de-energized, all componentsof the system are in <SLEEP> mode. Electricalcomponents are not active in <SLEEP> mode toprevent battery drainage. The Controller allows thesystem to enter <SLEEP> mode by deactivating its24V -to- 12V power supply converter signal anddeactivating its switched power output signal that isfed out to Sullair components (fuel sensor and powerto 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 willgenerate a hardware wake-up at the LCC high-sideIgnition binary input. Placing the <REMOTE START>binary input low will generate a hardware wake-up ifheld low for greater than 750ms.

4.2.2 START-UP MODE

<START-UP> mode initializes the systeminstrumentation components for operation. <START-UP> mode is internal to the Controller and does notpermit engine/compressor activation.

<START-UP> mode is enabled by one of thefollowing two methods:

1. Press the <ON> switch to “on”.

2. Activating the <REMOTE START> (ifenabled).

Placing the <ON> switch to the “on” position willenergize the gauges and begin initializing the systemfor <WAITING> mode.

<START-UP> mode may be exited/cancelled beforereaching <WAITING> mode. If <START-UP> isentered by placing the <ON> switch in the “on”position, placing the switch in the OFF positionpowers down the entire system. If a <START-UP>initialization parameter is out-of-tolerance, theController will enter a safe-shutdown state anddemand user interaction to completely power downthe unit.

It is during <START-UP> mode that system integrityis verified. System integrity verification involveschecks of functional instrumentation, communicationstatus, and confirmation of proper initial parametersettings.

A successful completion of <START-UP> modetransitions the Controller to the <WAITING> mode.

NOTEIf 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 condi-tions to begin initializing <WAITING> mode.


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4.2.3 WAITING MODE

When the Controller is in <WAITING> mode the LCDdisplay will indicate that the system is ready to bestarted, as shown below. See Figure 4-1.

The compressor can be started in one of the twoways as described in Section 2. When thecompressor is <WAITING> to be started remotely, a"Impending Remote Start" message at the top of theLCD will display. When the appropriate remote startconditions are met, the system will automaticallyenter the <START-UP> mode, and the compressorwill start. While the compressor is attempting to startin both manual and remote start mode, the LCD willdisplay the following screen in Figure 4-2.

<WAITING> mode is a transitional state betweeninitialization of the Controller, operation of thecompressor and compressor shutdown. In<WAITING> mode, the Controller is ready to enteran operational state. However, the compressor is notactive in <WAITING> mode. <WAITING> mode ischaracterized by "Ready..." appearing on the LCDtop status message section. If remote start isconfigured then "Ready..." will be displayed. SeeFigure 4-3.

<WAITING> mode to <RUN> mode is dependent onuser initiation of a compressor start enabler.

• Manual Start - initiated by the <ON> switchplaced in the “start” position.

• Auto (Remote) Start or <REMOTE STARTMOMENTARY> - remote start enabled.

In <WAITING> mode, the Controller is analyzingspecific system parameters to determine if

entering <SLEEP> mode is allowable. When thenecessary conditions are met, the system enters

<SLEEP> mode and all electrical components arede-energized. If the compressor was enabled via

<REMOTE START>, the <ON> switch is disabledand only a compressor malfunction will allowentering <WAITING> mode and then <SLEEP>mode.

The Controller can turn the compressor's cabinlighting on and off via the <CABIN LIGHT> switch. In<WAITING> mode, since the CAT engine is notrunning, it is possible that cabin lighting could drainsystem battery. The Controller monitors the batteryvoltage and cabin lighting to guard against thiscondition during the <WAITING> mode phase. Insuch case, a cycled UCP lighting sequence, to warnusers who may be performing cabin maintenance ofthe condition, is executed. The Controller clusterscreen also indicates this condition, as in thefollowing example screen. Note that after the UCPnumber of warning cycles, cabin lighting isautomatically disabled regardless of keypad switchposition. See Figure 4-4.

While in <WAITING> mode the Controller monitorsthe ambient air temperature. When temperature isbelow the UCP start-up aids set value while in<WAITING> mode is as in Figure 4-5.

Figure 4-1: Unit ready display

Figure 4-2: Engine cranking display

Figure 4-3: Unit ready display

Figure 4-4: Cabin lights “on” display

Figure 4-5: Start aids required display


35

4.2.4 FAILURE TO START

In manual mode, if the engine does not start, theController will attempt another start cycle as long asthe maximum number of crank attempts is notexceeded. This is an automatic process until the startattempts equal the set maximum. If the maximumnumber of crank cycle attempts (a preset value) isexceeded, the system will display an error messagein the LCD display as shown below. During enginecrank cycle, the Controller transmits speed control tothe Electronic Control Module (ECM). If the settingsare not fulfilled, the Controller will abort crank cyclingand display user-interface instructions for shutdownin alternating reverse video. To clear this messagetoggle the <MENU SELECT> switch to the <EXIT>position. See Figure 4-6.

When <REMOTE START> is enabled, if the enginedoes not start, the <ON> switch will need to betoggled to off to shut the machine down. The systemwill then wait for the appropriate start-up conditions

and then activate the remote start input to start thecompressor.

4.2.5 RUN MODE

Once the compressor has completed the warm upcycle, it will phase into <RUN> mode. When in<RUN> mode, the LCD display will look similar to thedisplay shown below.

In <RUN> mode, the compressor is ready to supplyservice air. The engine RPM will automatically beadjusted to maintain the desired air pressure. Theoperator can scroll thru the list of availableparameters, viewing up to four simultaneously, bymomentarily moving the <MENU SELECT> switch tothe select location. This will highlight one of theparameters in reverse video. Press the <MENUTOGGLE> switch in either direction will scroll oneparameter. The available parameters are listedbelow.

Figure 4-6: Engine overcrank display

Figure 4-7: Run mode display

Table 4-1: Viewable Parameters

Service Pressure Fuel Rate

Control Pressure Fuel Pressure (1 or 2)

Wet Pressure Fuel Temperature

Fuel Level Engine Inlet Air Temperature

Engine Speed Oil Pressure

Engine Hours Boost Pressure

Engine Total Fuel Consumed Desired Engine Speed

Compressor Temperature Auxiliary Pressure

ADT Temp (if After-Cooler configured) Auxiliary Temperature

Hydraulic Temperature Charge Air Temperature

Coolant Temperature Inlet Air Temperature

Battery Voltage Soot Level

Engine Load


36

4.2.6 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 automaticsystem startup is about to be attempted, takes place.The duration of this alert state is configurable througha Controller UCP. During this temporary alert state,the LCD displays the text "Impending Remote Start"in its bottom status area. The Controller's siren andstrobe light outputs are also activated. At the end ofthe configured duration, the siren and strobe lightoutputs are de-activated and the Controller attemptsto crank-start the CAT engine to enter warm up.

When using the auto-start feature, there are twoparameters 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 thecompressor must stay at or above the P1 pressure.These values are settable when the Communicatorsoftware 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 aremet.

a. The system service pressure (P1) is greaterthan the UCP (User Configurable Parame-ter) specified level for the UCP specifiedduration.

b. The "remote start" input has returned to itsnormally open position.

In the event that an abnormal shutdown occurs, thecompressor could shut down without theseconditions being met. See Section 5:TroubleShooting on page 41 for handling abnormalshutdowns.

4.2.7 SHUTDOWN

Placing the switch in the OFF position will trigger thenormal shutdown state. Normal shutdown can beinitiated in any mode of compressor operation. The<SHUTDOWN> mode can be entered when either ofthe following conditions occurs:

If the Controller system was started manually, theoperator must press the <ON> switch to the “off”position.

If the Controller system was auto-started (remote),the system will enter <SHUTDOWN> mode whenboth the service pressure (P1) is greater than thespecified level for the user-specified duration (Note:

Both of these values are pre-set), and when theremote start binary input is deactivated.

When the system enters the manual <SHUTDOWN>mode, the compressor will complete the followingtasks before shutting down:

1. De-energize the engine crank output (if ener-gized)

2. Display "Stop Initiated" shutdown LCD mes-sage

3. Enter cool-down cycle

a. Energize start/run output to put start/runsolenoid in Start position

b. UCP Compressor Cool-down Time

c. TSC1 commanded to UCP Low Engine Idle

4. Momentarily de-energize Switched Poweroutput

a. Display new LCD message

b. UCP ECM Power-Off Interval at Cool-down

5. Monitor System Pressures


b. UCP P1,2,3 Pressure for Cool-down Com-pletion

6. Monitor Engine Speed


b. Engine Speed must decrease to at least 10rpm

7. Enter <WAITING> mode

However, during the final portion of shutdown, afterthe Controller has stopped the compressor's engine,the Controller no longer pays attention to the <ON>switch (or remote start). The operator must wait untilthis phase completes to restart the compressor.

When the Controller is initialized in auto-start, fromthe remote start binary wake-up input, the front panel<ON> switch is inoperable.

If remote start is UCP-configured as a momentaryswitch, shutdown is initiated if the service pressuredemand violates UCP criteria. UCP P1 to shutdownfrom auto-start is the maximum service pressureallowed. If the service pressure exceeds the set pointfor longer than UCP time allowed then shutdown isinitiated. See images in sequence below for details.

If remote start is not UCP-configured as a


37

momentary switch, shutdown is initiated whenremote start input transitions from closed (active) toopen (inactive). In either case, the followingshutdown sequence then occurs:

1. 1. Display shutdown LCD message

2. 2. Enter Cool-down cycle

a. Energize Start/Run relay to put Start/Runsolenoid in Start position

b. Energize Recirculation Manifold solenoid

c. UCP Compressor Cool-down Time

d. TSC1 commanded to UCP Low Engine Idle

3. 3. Momentarily de-energize Switched Powerrelay


b. UCP ECM Power-Off Interval at Cool-down

4. 4. Monitor System Pressures


b. UCP P1,2,3 Pressure for Cool-down Com-pletion

5. 8. Monitor J1939 Engine Speed


b. J1939 Engine Speed must decrease to atleast 10 rpm

6. 5. Exit <OPERATION> mode

a. Remote Start binary is active --> enter<OPERATION> mode & attempt to restartcompressor

b. Remote Start binary is inactive --> enter<SLEEP> mode

Figure 4-8: Normal shutdown sequence

Figure 4-9: Auto shutdown sequence


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4.2.8 GAUGES DISPLAY

The air pressure gauge is driven by the air pressuresender analog input. Open and shorts of the P1pressure sender analog input is considered out ofrange and will force the pointer to fluctuate full scale.The compressor temperature and fuel level are bothdriven by analog resistive temperature senderslocated in the fuel tank and unit respectively. Theengine temperature indicator is driven by ECMmessaging. All gauges interfaces directly with theController unit.

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 automaticsystem startup is about to be attempted, takes place.The duration of this alert state is configurable througha Controller UCP. During this temporary alert state,the LCD displays the text "Impending Remote Start"in its bottom status area. the Controller's siren andstrobe light outputs are also activated. At the end ofthe configured duration, the siren and strobe lightoutputs are de-activated and the Controller attemptsto crank-start the CAT engine to enter<OPERATION> mode.

4.2.9 PRIORITY MESSAGES

Priority messages are messages that are displayedon the LCD due to state of various inputs or receipt ofvarious data messages by the Controller. Dependingupon the severity of the status, system operationmay be stopped (shutdown) or permitted to continue(warning). Warning messages are displayed alongthe bottom status section of the LCD; shutdownmessages are displayed on both the top and bottomstatus sections of the LCD.

Remote Start - determines whether the activation ofthe normally open low-side remote start input canattempt to start the engine once in the ready state.

Warning Indicator Lamps

• Engine Speed

• Engine Hours (hourglass symbol)

• P1 Service Pressure

• P2 Control Pressure

• P3 Wet Pressure

• (P3-P1) Air-Oil Separator Pressure

• Compressor Tank Temperature

• Ambient -or- Service Temperature

• Engine Coolant Temp

• Battery Voltage

• % Engine Load

• Fuel Rate

• Fuel Pressure

• Fuel Temperature

• Engine Inlet Air Temperature

• Oil Pressure

• Boost Pressure

• Desired Engine Speed

• Aux 1 Pressure

• Aux 1 Temperature

4.2.10 WAITING ABNORMAL SHUTDOWN

Waiting abnormal shutdown is defined as anyshutdown that occurs for any reason, in <WAITING>mode, other than that discussed in the NormalShutdown section. Any of the following conditions willcause the compressor to be shut down after<WAITING> mode is initiated:

1. Low Fuel Level

2. Compressor High Temp

3. High Compressor Pressure (P3)

4. High Compressor Pressure (P1)

5. P1,P2,P3 Signal Error

6. RTT High

7. Primary Shutdown

8. E-Stop Pressed

9. Engine Communication Error

10. I/O Module Communication Error

11. Switch Module Communication Error

12. Oil Pressure Low

13. Coolant Temperature High

14. Engine Overspeed

15. Low Coolant Level

16. High Fuel Temperature

4.2.11 NORMAL SHUTDOWN

The Controller enters the shut down state inpreparation for a normal shutdown when either of thefollowing conditions is met:

1. When currently in the <START-UP>, or any<OPERATION> mode and the manual startmethod is used, the operator presses the<ON> switch to the “off” position.


39

2. When currently in the <RUN> mode and theController system was auto started, the sys-tem service pressure P1 exceeds the UCPspecified level for a UCP specified durationand the remote start input has been returnedto its normally open (disabled) position.

4.2.12 OPERATIONAL ABNORMAL SHUTDOWN

An abnormal shutdown is defined as any shutdownthat occurs for any reason, in any <OPERATION>mode, other than that discussed in the NormalShutdown section. Any of the following conditions willcause the compressor to be shut down after<WARM-UP> mode is initiated:

1. Low Fuel Level

2. Comp High Temp

3. High Comp Pressure

4. High Comp Pressure

5. P1,P2,P3 Signal Error

6. Engine Comm Error

7. I/O Module Comm Error

8. Switch Module Comm Error

9. Oil Pressure Low

10. Coolant Temp High

11. Eng. Overspeed

12. Low Coolant Level

13. High Fuel Temp

14. E-Stop Pressed

15. Engine Overcrank

16. Warm-up Failed

17. Eng Speed Too Low

18. Low Discharge Pres

Any of the preceding conditions will cause thecompressor to stop immediately. The LCD displaywill indicate what the cause of the shutdown is,similar to Figure 4-10.

The Controller system will prevent the compressorfrom restarting until the operator acknowledges thefault by pressing the “Reset” switch.

NOTEIf the operator switches the <ON> switch back to the momentary start position before the Con-troller transitions to the OFF state, the Control-ler will re-enter the Warm-up phase of the Starting state.

NOTEIf the Remote Start is once again enabled before the Controller transitions to the OFF state during the shutdown sequence from an auto-start operation, the Controller will re-enter the Warm-up phase of the Starting state.

Figure 4-10: Signal error screen


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4.2.13 ABNORMAL SHUTDOWN EVENTS

Abnormal shutdown information is stored andretained across power-up sessions of the system inthe Controller memory. The abnormal shutdownevent data can be retrieved, displayed and analyzedusing the Communicator Software program. Refer toSection 5 for steps to troubleshooting abnormalshutdown events.

The following information is stored for each of thefive most recent abnormal shutdown events thathave occurred within the Controller.

• Shutdown Fault Type

• Engine Hours at time of Fault

• P1, P2, P3 pressure at time of Fault

• T1, Aux Temp at time of Fault

• Fuel Level at time of Fault

• Vdc reference voltage at time of Fault

• Pending Warnings at time of Fault

• State of DP1-6 and RTT switch inputs timeof Fault

• Start Switch and Remote Start Switchinputs at time of Fault

• Hi/Lo pressure switch at time of Fault

• Lin bus and J1939 bus status at time ofFault

• Engine Speed at time of Fault

• Battery Voltage at time of Fault

• Engine Boost Pressure at time of Fault

• Engine Inlet Manifold Temperature at timeof Fault

• Engine Coolant Temperature at time ofFault

• Engine Fuel Temperature at time of Fault

• Engine Oil Pressure at time of Fault

• Engine Fuel Pressure at time of Fault

• Engine Load at time of Fault

• Number of Active FMIs from Engine at timeof Fault

• First FMI/SPN data if active from Engine attime of Fault

• Engine Lamp Status if any active FMIs fromEngine at time of Fault

Section 5

41


TROUBLESHOOTING5.1 TROUBLESHOOTING

INTRODUCTION

This Troubleshooting section is provided as a guideto aid in diagnosing and resolving compressorproblems when they occur. The informationcontained in Table 5-1:Troubleshooting Guide, hasbeen compiled from factory experience and containssymptoms and usual causes for the describedproblems. Each warning or fault message is listedwith conditions of when the problem may occur, aprobable cause, and a suggested solution to theproblem. DO NOT assume that these are the onlyproblems that may occur. This document cannotaddress every possible adverse condition that mayoccur nor does it provide every solution for thepotential troubles listed. All available data concerningthe trouble should be systematically analyzed beforeundertaking any repairs or component replacementprocedures.

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

Always remember to:

a. Check for loose wiring, loss of ground, wiretermination, etc.

b. Check for damaged piping.

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

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

5.2 TROUBLESHOOTING GUIDE INTRODUCTION

The following guide contains symptoms and usualcauses for the problems that may occur throughoutthe compressor system. Each warning or faultmessage that may appear is listed along withconditions for the problem, a probable cause, and asuggested solution to the problem. DO NOT assumethat these are the only troubles that may occur. Thefollowing table denotes all warning/shutdownconditions that the Controller will sense. Shutdownconditions will display the associated message onthe LCD, light the compressor shutdown panel lamp,shut the system down, and wait for operator to togglethe <MENU TOGGLE> switch to “EXIT” toacknowledge the fault condition before a restart maybe attempted. Warning conditions display theassociated message on the LCD and light thecompressor warning lamp. Under a warningcondition the system will continue to operatenormally.

NOTESection 5.3 portrays common systematic problems that can occur during Controller operation. For a more thoroughly in-depth coverage of the compressor operation trou-bles, consult the Troubleshooting Section in the machine’s operator’s manual.


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5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE

Error Message Warning/Shutdown/Prevent Startup

Description Recommended Action

No Message Prevent Startup No power or initialization of controller Turn OFF/ON/START switch to ON position.

Make sure E-stop is not engaged (pull out).

Turn Battery Disconnect Switch to ON position.

Check battery voltage.

Check connections between Controller and harness and at the starter and harness.

Make sure Controller internal circuit breakers (4) are closed.

Check Controller Comms

Prevent Startup No communication between Controller and engine ECM

Verify bus resistance at 120 Ω.

Ensure proper connection between engine ECM and Compass Controller.

Low Fuel Level Shutdown/Prevent Startup

Fuel level low shutdown threshold reached

Add fuel and restart.

P2 Signal Error Shutdown/Prevent Startup

Transducer has no source voltage Verify 5±.25Vdc to transducer.

Transducer has lost ground Verify path to ground.

Output voltage to controller is lost Verify .5-4.5Vdc to controller.

Transducer malfunction Replace transducer.

Comp High Temp Shutdown/Prevent Startup

T1 Compressor temperature sensor is above shutdown setpoint

Verify thermistor resistance between 803Ω @ -50˚C and 1573Ω @ 150˚C.

Coolers dirty Clean coolers.

Fan slipping Check/Adjust Fan belt tension

Compressor oil thermostat malfunction Replace thermostat.

RTT High Shutdown/Prevent Startup

RTT (Receiver Tank Temperature) switch,normally closed, has opened

Verify compressor tempera-ture via controller display (tog-gle to proper parameter). If compressor temp is less than the setpoint on all others then replace the RTT switch.


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Primary Shutdown Shutdown/Prevent Startup

After filter restriction too high (filters dirty)

Replace filters.

After filters dp module malfunction Check source voltage and ground and correct if necessary.

Visually inspect for damage and replace if necessary.

Compass Comm Error

Shutdown/Prevent Startup

Internal cabling inside the Controller is not properly connected

Open Controller and ensure that all gauge and warning bank connectors are well seated/engaged.

High Comp Pressure Shutdown/Prevent Startup

P1 (Dry) or P3 (Wet) pressure is above setpoint

Pressure above 10 psi (recent shutdown). Wait for pressure to fall below 10 psi.

Transducers out of calibration Transducers need to be calibrated using the gauge calibration subroutine (See “Pressure Calibration” on page 27).

Engine Overcrank Shutdown The maximum number of engine crank cycles has been exceeded

Check battery voltage & recharge if necessary.

Check starter relay for short to ground.

Check source voltage to starter relay.

Engine Comm Error Shutdown/Prevent Startup

The Controller is not properly receiving J1939 messages from the engine ECM.

Check connections at engine ECM and Compass Control-ler.

Check the termination resistor in the harness ECM connec-tor and replace if necessary.

E-Stop Pressed Shutdown/Prevent Startup

The Controller will not power up/initialize (NO MESSAGE AT CONTOLLER!)

Disengage E-stop.

The E-stop was used to shut machine down.

Once conditions are deemed safe, toggle the <ON> switch OFF.

Eng Speed Too Low Shutdown Engine speed dropped below preset value for a preset amount of time. This is to protect the vulcanized rubber drive coupling between the engine and com-pressor.

Check fuel level.

Check the inlet valve for pre-mature opening during the warmup phase.

P1,P2,P3 Signal Error Shutdown Error loss of all transducer inputs dur-ing run phase

Check voltage source and ground for good connection.

Low Fuel Level Warning Fuel light is on. Compressor warning light is on. Fuel level is below 20%

Add fuel soon




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Fuel Sender Error Warning The fuel level sensor signal is out of range

Check connections at sensor on tank. Verify source voltage and ground.

Wires possibly reversed.

Fuel sensor is defective. Replace

Controller is configured incor-rectly (configured for tank when no tank is present). Reprogram the Controller using the Controller communi-cation software, communica-tion adapter, and PC.

P1 Signal Error Warning Transducer has no source voltage Verify 5V dc to transducer.


Output voltage to controller is lost Verify .5-4.5 Vdc to controller.










Air-Oil Separator Warning The differential pressure (P3 - P1) is above the setpoint for the specified period.

Separator elements are dirty. Replace.

Aux Temp High Warning T2 (Aftercooler discharge temp or ambient temp on non-aftercooled machines)

Clean coolers.

Check/Adjust Fan belt tension.

Check T2 (RTD) for short circuit to ground.

Engine Air Filter Warning DP1 switch, normally closed, has opened for the specified amount of time

Engine air filters clogged. Replace filters

Check circuit for continuity.

Check the air filter switch for continuity. Replace if open.




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Comp Air Filter Warning DP2 switch, normally closed, has opened for the specified amount of time

Engine air filters clogged. Replace filters.

Check circuit for continuity

Check the air filter switch for continuity. Replace if open.

Primary Warning Warning Aftercooler restriction increasing (becoming clogged)

service filters soon

P4/P5 Signal Error Warning Aftercooler differential pressure signal module is encountering a malfunction

Check connections between the filter module and the two pressure transducers (P4 & P5) at the aftercooler

check source voltage and ground to transducers and to dp module

replace transducers

replace dp signal module

Louvers Closed Warning Informs operator of louver position. None unless machine over-heats. Otherwise check Ambi-ent Temp Sensor reading on LCD display. If the Ambient Temp reading is higher than the 70°F and the louvers are closed, check louver solenoid for proper operation. Also check louver air cylinders for proper operation. If the Ambi-ent Temp Sensor is reading lower than atmospheric condi-tions, then check the temp sensor for proper operation and replace is necessary.

AC Freeze Imminent Warning If the Controller is configured with an aftercooler and no louvers installed and the temperature at the discharge of the aftercooler falls below the setpoint, this message is displayed.

Bypass the aftercooler service air discharge circuit by locking out the aftercooler from the system and using non- aftercooled air.

Install Louvers on the aftercooler (if equipped) or the canopy intake.

Wait to Start Warning Message from CAT engine ECM. J1939 Shutdown SPN1081 - Wait to Start active

Check Engine ECM for active codes/faults and possible configuration errors. Contact your nearest CAT servicing dealer for resolution.

Oil Pressure Low Warning CAT DM1 Message (Engine ECM) Check oil level and add if nec-essary. If condition persists, contact your nearest CAT ser-vicing dealer for resolution




46

Coolant Temp High Warning CAT DM1 Message (Engine ECM) Check coolant level and add if necessary. Clean radiator if dirty. Check fan belt tension and tighten if needed.

Eng. OverSpeed Warning CAT DM1 Message (Engine ECM) If problem persists, shut machine down and check for volatiles in the atmosphere. Don’t restart machine until condition is removed. If ECM still displays message, con-tact your nearest CAT servic-ing dealer for resolution.

High Inlet Air Temp Warning CAT DM11 Message (Engine ECM) Check wind direction and make sure engine/package exhaust is not being recircu-lated to air intakes. Relocate compressor if necessary.

Low Coolant Level Warning CAT DM1 Message (Engine ECM) Check coolant level and add if necessary. Check connection between the coolant level sensor and the harness. Replace sensor if necessary.

High Fuel Temp Warning CAT DM1 Message (Engine ECM) Make sure cooling air intake is facing prevailing winds. Make sure all cooling air openings in canopy are not obstructed. Add fuel if tank is near empty.

High Fuel Pressure Warning CAT DM1 Message (Engine ECM) Fuel delivery system relief valve malfunction—contact you local CAT servicing dealer.

High Exhaust Temp Warning CAT DM1 Message (Engine ECM) Check wind direction and make sure engine/package exhaust is not being recircu-lated to air intakes. Relocate compressor if necessary.

Exhaust valve timing incor-rect—Contact your local CAT servicing dealer




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5.3.1 CONTROL PARAMETERS

Control parameters for the Controller are shown inTable 5-1. The Parameter Description columnindicates the text appearing on the Controller displayscreen. Default Value shows the factory defaultsetting for the parameter. Min/Max Value permittedare the minimum and maximum possible for theparameter.

The following settings are configurable using theController communicator program. Note thatparameters listed in bold font below affect thethreshold at which abnormal shutdowns may occur.

Table 5-1: Controller Control Parameters Options Menu

Engine Crank Default Value Range/Option

Crank On Duration (sec) 10 3-30

Crank Off Duration (sec) 10 4-30

Number of Cycles 3 1-5

Engine Cranked Speed (RPM) 250 200-500

Time Required At Cranked Speed (msec) 480 240-1000

Throttle Control Default Value Range/Option

Low pressure Max PWM Duty Cycle (%) 92 70-92

High Pressure Max PWM Duty Cycle (%) 92 70-92

LO Idle Engine Speed (RPM) 1800 700-4000

HI Idle Engine Speed (RPM) 1800 700-4000

Alt Throttle Control

Low Pressure Range – 300 PSI Controller

125-145 100-120

125-145


High Pressure Range – 300 PSI Controller

150-170 150-170

175-195

200-220


Low Pressure Range – 600 PSI Controller

350-370 205-225

350-370


High Pressure Range – 600 PSI Controller

350-370 350-370

425-445

500-520

Low Speed Shutdown Settings Enabled Enabled

Disabled

Low Speed Shutdown RPM 800 800

900

1000

1100

Low Speed Shutdown Time (sec) 5 5

7

9

11


48

Fuel Level Default Value Range/Option

Cancel Low Level Alert (% full) 23 13-43

Low Level Alert (% full) 20 10-40

Cancel Very Low Level Alert (% full) 11 7-13

Very Low Level Alert (% full) 8 4-10

Fuel Tank/Level Sensor None None

185-724

185-725

Temperature Settings Default Value Range/Option

Max T1 at run-time or startup (°F) 250 200-400

Max Aux Temp at run-time/startup (°F) 250 200-400

Engine Temp. for warm-up complete (°F) 70 64-150

Aftercoolers Equipped? No Yes/No

Aftercoolers Filters Equipped? No Yes/No

AfterFilter Freeze Assert Temp. (°F) 39 (-40) -50

AfterFilter Freeze Cancel Temp. (°F) 45 (-40) -68

ADT Temp Calibration Offset (°C) 0 -10.0 - 10.0

CDT Temp Calibration Offset (°C) 0 -10.0 - 10.0

HT Temp Calibration Offset (°C) 0 -10.0 - 10.0

Startup Aids Settings

Low Point Temp (°F) (-40) (-40) - (-16)

Low Point Time (min) 60 31-75

Middle Point Temp (°F) (-15) (-15) - 9

Middle Point Time (min) 30 16-30

High Point Temp (°F) 10 10-20

High Point Time (min) 15 5-15

Fan 1 Control Settings Default Value Range/Option

Min PWM (%) 0 0-100%

Max PWM (%) 75 0-100%

CDT Trigger Temp (°F) 180

CDT Temp Limit (°F) 205

Coolant Trigger Temp (°F) 200

Coolant Temp Limit (°F) 210

CAC Trigger Temp (°F) 105

CAC Temp Limit (°F) 122

Cooldown/Idle PWM 48 0-100%

Delay Time (secs) 15

Fan 1 Min T3 Ambient Temp (°F) 40

Fan 1 Aftercooler Approach Target Temp (°F) 10

Primary Control PWM 0 (%) 50


49







Primary Control Temperature 0 (°F) 20






Fan1 Increase Max Rate Crank and Warm-Up 100 1-100

Fan1 Decrease Max Rate Crank and Warm-Up 100 1-100

Fan1 Increase Max Rate Normal Operation 4 1-100

Fan1 Decrease Max Rate Normal Operation 4 1-100

Fan2 Increase Max Rate Crank and Warm-Up 100 1-100

Fan2 Decrease Max Rate Crank and Warm-Up 100 1-100

Fan2 Increase Max Rate Normal Operation 3 1-100

Fan2 Decrease Max Rate Normal Operation 3 1-100

Pressure Settings Default Value Range/Option

Max P1 at run-time (PSI) 200 145-600

Max P3 at run-time (PSI) 200 145-600

Allowable time for Max P1 or P3 (sec) 1 1

5

15

30

Max Air-Oil-Sep at run-time (PSI) 15 10-20

Air-Oil-Sep alert time (sec) 15 10-60

Max P1 at startup (PSI) 10 0-15

P1 Calibration Offset (kPA) 0 -50 to +50



Remote Start Enabled No No/Yes

Remote Start Momentary No No/Yes

P1 to shutdown from auto-start (PSI) 100 70-600

Required time for P1 > Above Value to shutdown

from auto-start (sec)

900 300-1800

Remote Start Imminent warning time duration (secs) 5 0-10

Enable Inactivity Auto-Sleep (applies only if Remote Start Enabled isNo)

Yes No/Yes


50

Inactivity Timeout (minutes) 10 5-20

P1,2,3 Pressure for Cooldown Completion (PSI) 10 5-15

P2 Pressure for max RPM at run-time (PSI) 5 0-10

600 psi low-pressure discharge alarm armed? (applies only to 600 psiUCP systems)

Yes No/Yes

Miscellaneous Settings Default Value Range/Option

Warmup Complete Speed (RPM) 1375 1375-1450

Minimum Engine Warm-up Time (sec) 30 5-60

Maximum Engine Warm-up Time (sec) 240 60-1200

Compressor Cool-down Time (sec) 300 5-600

Air Filter Alert Time (sec) 15 10-60

LANGUAGE English English

Spanish

Italian

French

German

Portuguese

ECM Power-Off Interval At Cooldown (sec) 10 3-10

Unit Of Measurement English Metric

English

300 PSI System or 600 PSI System (same Controller software supports both)

600 300-600

Enable Gauge Self-Test Disabled Enabled

Disabled

C9 Engine Used Disabled Enabled

Disabled

Standard Warmup rules Disabled Enabled

Disabled

Display Contract (%) 69 57-81

Cluster Backlighting Color Green Red, Green, Blue, Yellow, Light Blue,

Violet, White

Cluster Backlighting Level (%) 100 0-100

Large Font Display Mode No Yes/No

Cabin Lights Low Voltage Alert Settings

Cabin Lights Low Voltage Level (V) 20.0 18.0 - 25.0

Cabin Lights Low Voltage On Cycle Time (secs) 10 1 - 10

Cabin Lights Low Voltage Off Cycle Time (secs) 2 1 - 10

Cabin Lights Low Voltage Number of Cycles 5 1 - 20

NOTES

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

without prior notice.E12EP

Always air. Always there.

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

Telephone: 1-219-879-5451

WWW.SULLAIR.COM

Documents

900/1600 IT4 CONTROLLER...SECTION 1 6 A. Prior to hitching the air compressor to the tow vehicle, inspect all attachment parts and equip-ment, checking for (i) signs of excessive wear