Sullair Deluxe Microprocessor Controller1 Operation Manual

DELUXE MICROPROCESSOR CONTROLLER I OPERATION

MANUAL

SHENZHEN SULLAIR ASIA INDUSTRIAL CO., LTD. Part No.: 88290010-484 Rev. 00, Jan, 2008

CATALOGUE 1. Functions of the Controller …………………………………………1 2. Key Pad………………………………………………………………1 3. Status Display ………………………………………………………3 4. Indicator ……………………………………………………………8 5. Setting of Running Parameters ……………………………………8 6. Running Mode of the Compressor …………………………………14 7. Main Functions ……………………………………………………15

Deluxe Microprocessor Controller I –Operation Manual

1．Functions of Deluxe Microprocessor Controller I To ensure the normal operation of the controller, operators shall understand the meanings of the marks on the control panel and have correct discretion on parameters and signals displayed at the control panel. Deluxe microprocessor controller I is powerful and reliable. The controller displays the current, temperature, pressure, operation hours and run status on a LCD. With the keyboard at the control panel, operators can control the compressor, set control parameters and display the preset parameters. Indicators at the diagram show the position of each parameter (Figure 1). When the light is on, there is an alarm.

2. Key Pad STOP — Manually shut down the machine and eliminate the alarming. Press the key when the machine is running, the machine will immediately shift to the unloading mode and shut down the machine after 10 seconds. MANUAL — Start up the machine at the operation mode and select manual operation mode. When the machine is not in the alarming-at-stop status under operation mode, pressing the key will eliminate the alarming and run the machine in manual mode. AUTO – Start up the machine in operation mode and select automatic operation mode. When the machine is in the alarming-at-stop status under operation mode, pressing the key will eliminate the alarming and run the machine in AUTO mode. DISPLAY – Display the pressure, temperature and other operation parameters. PROGRAM – Press the key in operation mode to enter into the site parameter setup screen, press the Sullair mark key to go to the password verification screen. UP ARROW key – Used to change the displayed parameters in Status Display Mode. Used to increase the value of parameters in parameter setup mode. DOWN ARROW, Indicator Test - Used to change the displayed parameters in Status Display Mode. Used to decrease the value of parameters in parameter setup mode. Used to test indicators in default mode. When pressing the key, all normal indicators will be lit for 3 seconds Sullair Mark key – to complete specific operations in combination with other keys. Press this key to check back in parameter setup mode. Functions of keys combination: then

1． History Records: Press Records screen appears, press next record. Press

and then or

. When History

to display the previous record or

to display other parameters of a record. Parameters

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Deluxe Microprocessor Controller I –Operation Manual recorded in monitor include P1, P2, P3, T1, T2, T3, Dp2, voltage deviation, current time and total running time. 2． Alarm Records: Press or

then

, alarm record screen displays. Press

to display the previous record or next record. then

3． To set up and display operation parameters that need a password: Press , password verification screen displays, use the keys alter the parameters (press and hold

to enter parameters setup screen. then

, clock screen will display.

to move the cursor to next setting and press

Press

to

, the parameter changes quickly. After the

parameters are set according to rules, press 4． The check and modify Clock: Press

and

or

to

and then

to

modify. 5． To check communication status: Press

then

enter communication status screen. Your can check current machine ID, other machines’ working condition, current machine working mode and current machine P1 and P2 value displayed in units selected in run status screen. Meaning of communication status codes: R-Sequencing stop condition; U-Unloading condition; T-Trimming loading condition; F-Force loading condition; L-Loading condition. The first line displays “communication status”. This is the machine’s communication status screen. The second line displays the communication ID of current machine on the left. The two rows on the right (including the third row under corresponding machine ID) display the communication ID and current working status of all machines online. The third line displays working condition of current machine on the left, “D” for Disabled mode, “R” for remote control mode, “T” for time sequencing, “C” for ID sequencing and “M” for Modbus mode. The fourth line displays the current value of P1 and P2 of the current machine for the convenience of online tuning and observation. 6． Three filters and dew point status records: Press , use

and

then

and then

to select items to be displayed.

This record screen stores the time of last clogging/alarm and the time that clogging/alarm is cleared. If repair time is later than alarm/clogging time, it means that alarm/clogging has been cleared. Duration is calculated as repair time minus clogging/alarm time, and actual running interval in the screen as running interval. If repair time is prior to alarm/clogging time, it means that corresponding parts are in fault condition and need to be serviced.

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Deluxe Microprocessor Controller I –Operation Manual

3. Status Display In default conditions, the screen displays 4 lines of data. The first line is the status of the machine, the second and third lines are discharge pressure P1, side discharge pressure P2, discharge temperature T1 and side discharge pressure T2. The last line displays corresponding pressure and temperature unit. The followings are various statuses that may be displayed on the screen. Temperature unit is ℃ and pressure unit is bar. (You may also select the English unit such as oF and PSI, please refer to the UNIT SETUP in PARAMETER SETUP for details.) ※ STOP - Shut down the machine. ※ STANDBY – Shut down the machine on a temporary basis. When the power fails or when unloading relay is in action, the machine goes to STANDBY mode. Please note that the machine in STANDBY mode may resume at any time. ※ STARTING – The compressor is being started. ※ OFF LOAD – The compressor is running but does not supply compressed air. ※ ON LOAD – The compressor is running and supplies compressed air. ※ FULL LOAD – The compressor is running and has full load. It is displayed only when the machine is in online control mode and there is a full load valve. ※ RTM STOP – Remote Stop. When the remote starting contactors are closed, the machine restarts. Please note that the machine in RTM STOP mode may resume at any time. ※ SEQ STOP – Sequence control Stop. When the requirements set by the preset sequence for starting the machine are met, the machine restarts. Please note that the machine in this mode may resume at any time.

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Deluxe Microprocessor Controller I –Operation Manual

Figure 1. Control Panel of the Monitor (Deluxe Microprocessor Controller I) ※ Boot-up Screen (illustrated in the following sample): SULLAIR is the mark of the Company, ES-11DRY is the mode of the machine, CO3-CXXXXX is the serial number, XXXXX is the only number determined when the machine was delivered from the factory and is the same as that of the supporting machines. REV: XX.XX is version of the software, 2004/01 means the date on which the controller was delivered from the factory. - refers to a space. SULLAIRˇES-11DRY ˇˇˇCO3-CXXXXXˇˇˇ ˇRUNˇˇˇXXXXXHRSˇ REV:XX.XXˇ2004/01

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Deluxe Microprocessor Controller I –Operation Manual *IMPORTANT! In no cases shall the users attempt to modify the serial number of the machine, otherwise the serial number shall be reset to zero. In such case Sullair takes no responsibility for the replacement and repair of the Deluxe Microprocessor Controller I. If you need to change the serial number please contact the Service Department of Sullair. ※ Operation Screen: There are 4 screens as shown below. ˇ refers to a space; TD refers to dew point, T0 refers to the chip temperature of controller main-board (approximately the ambient temperature), U refers to voltage deviation and I refers to main motor (or machine)’s current. The accumulated run time and loading time are only displayed as RUN and LOAD. Operation mode:

STOP P1：xx.xx T1：xxx P2：xx.xx T2：xxx P：BARˇˇˇˇT：

STOP P3：xx.xx T3：xxx P4：xx.xx T4：xxx P：BARˇˇˇˇT：

STOP T5：xxx TD：xxx T6：xxx T0：xxx T：℃ ΔP1：xxx

STOP RUN ˇ ˇ ˇ ˇ ˇ XXXXXHRS LOAD ˇ ˇ ˇ ˇ

In Chinese or English

Currently selected unit

! Caution For unused analog input channel, no value will be shown after corresponding code on operation screen. For instance, in case T5 and T6 are not selected, values for T5 and T6 are blank as shown below. For selected analog input channels, “- - -” after corresponding codes indicates that open circuit or short circuit fault may present. Meanwhile alarm shall occur. See the following figure of disconnected T1, “T1: - - -” is shown on the screen. Press START button in operation screen. The machine may not respond due to minimum stop time is not met. In such case a countdown timer (in second) will appear on the upper left corner of the display showing the time before machine start allowed. Once the timer counts down to zero and disappears, the machine is allowed to start. ※ STOP – The Machine is in STOP mode. The default display is as below: STOP P1：xx.xx T1：xxx P2：xx.xx T2：xxx P：BARˇˇˇˇT： Page 5 of 16

Deluxe Microprocessor Controller I –Operation Manual If there is a fault signal, in default situation, the fault signal is displayed alternatively, each screen is displayed for two seconds. The default is displayed as below (for example: machine overload): M1 Overload P1：xx.xx T1：xxx P2：xx.xx T2：xxx P：BARˇˇˇˇT： When the machine is running, the default operation screen displays 5 messages i.e. operation mode, discharge pressure P1, side discharge pressure P2, discharge temperature T1 and side discharge temperature T2. STOP P1：xx.xx T1：xxx P2：xx.xx T2：xxx P：BARˇˇˇˇT： Press the Emergency Stop button, the machine stops immediately and gives an alarm. Press the STOP button at the controller, the machine enter into unloading condition immediately and stops after 10 seconds. In this case the following screen is displayed: Unloading P1：xx.xx T1：xxx P2：xx.xx T2：xxx P：BARˇˇˇˇT： ! Caution * In the process of Unloading, press the MANUAL RUN button or AUTO RUN button the machine will enter into operation mode immediately. * It is recommended that always use the STOP button at the panel for normal shutdown. Press

button to display other parameters. You can check temperature, pressure,

accumulated time, voltage deviation and current, etc. in this mode. Press parameters to display. Press the button

to select

to return to the original screen of operation mode.

※ P3 and P4 are the pressures before and after oil filter; T3 is oil injection temperature and T4 is inter-level temperature (if these measures are not used by the machine, 0 and –80 will be displayed for pressure and temperature respectively): STOP P3：xx.xx T3：xxx P4：xx.xx T4：xxx P：BARˇˇˇˇT：

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Deluxe Microprocessor Controller I –Operation Manual ※ Compressor discharge temperature alarming set point and alarming and stop set point; NO：77 T1 WARN 107 ℃

NO：78 T1 MAX 113 ℃

When the discharge temperature reaches the alarming set point, the T1 alarming indicator is lit and shows the T1 is high. At this time the machine does not stop. When the discharge temperature exceeds the alarming and stop set point, the T1 alarming indicator is lit and shows the T1 is too high. At this time the machine will stop immediately. ※ Compressor dry side discharge temperature alarming set point and alarming stop set point; NO：79 T1 WARN 107 ℃

NO：80 T2 MAX 113 ℃

When the dry side discharge temperature exceeds the alarming set point, T2 alarming indicator is lit and shows T2 is slightly high. At this time, the machine is not stopped. If the dry side discharge temperature exceeds the alarming and stop set point, T2 alarming indicator is lit and shows T2 is too high. At this time, the machine will stop immediately. ※ Accumulated running time (hour) of the compressor, accumulated loading time (hour) of the compressor. Accumulated running time (hour) of the compressor, accumulated loading time (hour) of the compressor can be displayed in operation screen. STOP RUNˇ XXXXXHRS LOADˇXXXXXHRS U：-20%ˇI：XXXXA ※ Stop fault information – Last 40 stop triggering fault signals are recorded along with time. See Sullair’s Air Compressor Button Operation Manual. Warn Notes 0 03-11-19 10：27 M1 Over load

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Deluxe Microprocessor Controller I –Operation Manual

4. Indicator 11 indicators are located on the controller panel. On the operation screen, press

key,

and all the indicators will be lit for about 3 seconds; otherwise the indicator is faulted. The function of each indicator: P1 – Pressure inside the separator. If the indicator is lit, it means the controller has given alarm. P2 – Pipeline pressure. If the indicator is lit, it means the controller has given alarm. T1 – Main unit discharge temperature. If the indicator is lit, it means the controller has given alarm. T2 – Dry side discharge temperature. If the indicator is lit, it means the controller has given alarm. △P1 – Pressure difference before and after the separator. If the indicator is lit, it means the filtering element must be replaced. △P2 – Pressure difference before and after the oil filter. If the indicator is lit, it means the oil filtering element must be replaced. MOTOR ------ Motor overload indicator. If the indicator flashes, it means the motor overload contact has been disconnected. POWER ------ Power indicator. If the monitor is connected with 110V AC power, this indicator will be always time. ON ------ Running indicator. If the light is stable, it indicates the machine is running; if it flashes, it indicates the machine is under Standby mode and can be started at any time. AUTO ------ Auto run indicator. If the light is stable, it indicates the machine is auto running; if it flashes, it indicates the machine is under Standby mode and can be started at any time. AIR FILTER ------ Air filter alarming indicator. If the light is lit, it indicates the air filter needs maintenance.

5. Setting of Running Parameters Before the compressor is started, the running parameters must be set first. (1) Press “PROG” key, and the monitor enters the program control mode. At this time, all user parameters can be checked but are not editable (press Up Arrow and Down Arrow keys may change value display but controller will not confirm). Press “Sullair Mark Key” and then “PRG” key, password verification screen will appear. Modify the value according to user class password setting principles and all user parameters will appear. User may modify all user parameters using this method. Press Up Arrow key to increase the parameter value; press Down Arrow key to decrease the parameter value. The lowest line at the parameter setting screen indicates the allowable range of the parameter setting.

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Deluxe Microprocessor Controller I –Operation Manual The parameters are displayed based on the following sequence: ※ Display language – Choose 0 to display in Chinese; choose 1 to display in English. NO：1 LANGUAGE Chinese Chinese/English ※ Temperature unit – Choose ℃ to display temperature in ℃; choose OF to display temperature in OF. NO：3 T.UNIT ℃ ℃/oF ※ Pressure unit - Choose bar to display pressure in Bar; choose PSI to display pressure in PSI. NO：4 P.UNIT Bar Bar/PSI ※ Unloading pressure ------ When the parameter setting is 7.6bar, the machine will unload when P2 reaches 7.6bar. NO：5 UNLOAD 7.6Bar 2.0~15.1Bar ※ Loading pressure difference ------ Difference between loading pressure and unloading pressure. If the unloading pressure is set at 7.5bar and the loading pressure difference is set at 0.6bar, then when the pipeline pressure is the below 6.9bar, the machine will load. NO: 6 LOAD 0.7Bar 0.4~4.8Bar

※ Y-△ conversion time (second) – If a full voltage starter is used, set this value to 0. NO：7 WYE-DELTA TIME 6sec 0--15sec

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Deluxe Microprocessor Controller I –Operation Manual ※ Start load delay time ------ If 5 is selected, it indicates after the machine has Y-△ conversion, 5sec later, the machine will enter the loading status. NO：8 LOAD DELAY TIME 5sec 0--30sec ※ K5 output selection – when drain valve is selected, K5 relay acts according to drain interval and drain time parameters. When remote output is selected in REMOTE operation mode, K5 will close during allowed remote operation (for instance, select Remote operation mode after the machine is stopped and press ON key, or change to Remote mode from other operation modes during operation, etc.). NO：9 K5 select Remote Drain /Remote ※ Drain interval – The interval between two draining operations. NO：10 Drain interval 10 min 0—30 min ※ Drain time – Duration of drain valve action. NO：11 Drain time 5 sec 0—10 sec

※ Backlight selection – Select the background color for LCD display. NO：15 Backlight color White White/blue/yellow/ green

※ Unloading shutdown time – Under the auto mode, decide the allowable unload delay time for the machine from unloading status to auto stop. NO：17 UNLD TIME 15 min 15—120 min

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Deluxe Microprocessor Controller I –Operation Manual ※ Minimum shutdown time – Interval between last shutdown and restart, during which the controller does not respond to Start instruction. NO：18 STOP TIME 10 sec 0—30 sec ※ Power recovery start delay time – If main power fails during normal machine operation and recovers, the controller will not respond to Start instruction until “Power recovery start delay time” expires. NO：19 DELAY TIME 10 sec 0—30 sec ※ Control mode – Set working mode of the machine. For how to set the machine in which mode, please refer to the section of “Compressor running mode”. NO：31 Control mode Disabled

※ Capacity – Please refer to Sullair Sequence control and communication protocol manual of deluxe microprocessor controller I. NO：36 Capacity 21 0—10000m2/min ※ Rotation time – Please refer to Sullair Sequence control and communication protocol manual of deluxe microprocessor controller I. NO：37 Shift time 50 hours 10—250 hours ※ Communication ID – Please refer to Sullair Sequence control and communication protocol manual of monitor deluxe microprocessor controller I. NO：38 COM ID# 1 1--16 Page 11 of 16

Deluxe Microprocessor Controller I –Operation Manual ※ Communication baud rate – Please refer to Sullair Sequence control and communication protocol manual of monitor deluxe microprocessor controller I. NO：40 BAUDRATE 9600

※

Recover time – Please refer to Sullair Sequence control and communication protocol manual of monitor deluxe microprocessor controller I. NO：41 Recover time

5 sec 2-30 sec ※ A1 OUT SELECT – When this parameter is designated to T1, A1 analog output port outputs 0 to 10V analog value corresponding to T1 variation; when this parameter is designated to P2 LOAD, A1 analog output port outputs 0 to 10V analog value corresponding to P2 LOAD for connection with transducer. NO：48 A1 SELECT T1 T1/P2 LOAD ※ High-voltage pulse time – This parameter determines action duration of K7 and K8 (this function is not available). NO：49 H-volt pulse time 1.5 sec 0.7—3.0 sec ※ T1 calibration – Used for correcting the measuring error. NO：50 T1 CAL 0℃ -7--+7℃

※ T2 calibration – Used for correcting the measuring error. NO：51 T2 CAL 0℃ -7--+7℃ Page 12 of 16

Deluxe Microprocessor Controller I –Operation Manual ※ T3 calibration – Used for correcting the measuring error. NO：52 T3 CAL 0℃ -7--+7℃ ※ T4 calibration – Used for correcting the measuring error. NO：53 T4 CAL 0℃ -7--+7℃

※ T5 calibration – Used for correcting the measuring error. NO：54 T5 CAL 0℃ -7--+7℃ ※ T6 calibration – Used for correcting the measuring error. NO：55 T6 CAL 0℃ -7--+7℃ ※ TD calibration – Used for correcting the measuring error. NO：56 T7 CAL 0 Bar -2.0--+2.0Bar ※ P1 calibration – Used for correcting the measuring error. NO：57 P1 CAL 0 Bar -2.0--+2.0Bar ※ P2 calibration – Used for correcting the measuring error. NO：58 P2 CAL 0 Bar -2.0--+2.0Bar

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Deluxe Microprocessor Controller I –Operation Manual ※ P3 calibration – Used for correcting the measuring error. NO：59 P3 CAL 0 Bar -2.0--+2.0Bar

※ P4 calibration – Used for correcting the measuring error. NO：60 P4 CAL 0 Bar -2.0--+2.0Bar ※ dP1 calibration – Used for correcting the measuring error. NO：61 ΔP1 CAL 0 Bar -1.0--+1.0Bar ※ dp2 calibration – Used for correcting the measuring error. NO：62 ΔP2 CAL 0 Bar -1.0--+1.0Bar

6. Running Mode of the Compressor The compressor have the following running modes. (1) Manual run mode (select “Disabled” control mode correspondingly) Press

key to start the compressor. At this time, the compressor will be put at

manual run mode. If the compressor is running and under auto run mode, when pressing

key, the auto

mode can be changed into manual mode. If the compressor is running under manual run mode, when pressing

key, the alarming signal can be cleared and the indicator is

extinguished. To turn off the unit, press

key.

If the unit is stopped already, press

key again to clear the alarming signal and

extinguish the alarming indicator. (2) Auto run mode (select “Disabled” control mode correspondingly)

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Deluxe Microprocessor Controller I –Operation Manual Press

key to start the compressor. At this time, the compressor is under the auto run

mode. key, the manual mode

If the compressor is under manual run mode, when pressing can be changed into auto mode. If the compressor is under auto run mode, when pressing

key, the alarming signal

can be cleared and the indicator is extinguished. Under auto run mode, press

key to stop the compressor. At this time, the monitor

will be under manual stop mode. (3) Sequencing control mode The following will describe briefly the sequencing control mode. For details, please refer to “Sequencing control and communication protocol manual of monitor deluxe microprocessor controller I”. ※

Disabled – Respond to the inquiry command and can send back the machine status and

parameter message; but doesn’t respond to the start, stop, load and unload command of the main unit (computer). ※

Remote control – Respond to the inquiry command and can send back the machine

status and parameter message; but doesn’t respond to the start, stop, load and unload command of the main unit (computer). This mode allows remote input of “start/stop” signal. ※

Master/Slave – Respond to all the commands. Note under this status, if the slave unit

doesn’t receive the command sent from the main unit, it can’t be started or loaded. The slave unit is controlled from the main unit (computer). ※

Sequence time – Send the status message about once a second. Control the machine

based on the sequence time (start, load or unload). ※ Communication ID – Send the status message about once a second. Control the machine (start, load or unload) based on the machine number (COM ID#). ※ MODBUS – Adopt MODBUS communication. This method is used when using upper unit for the control.

7. Main Functions (1) The system features 2 RS485 ports. 1# RS485 port uses sequencing communication protocol and 2# RS485 port uses Modbus communication protocol. In sequencing mode, no upper unit or other devices are needed. Simply connect 1# RS485 port of each controller and set all controllers into sequencing mode. All machines will work in networked control mode. (2) The system features dew point and main unit current real-time display and alarming functions. (3) 4 channels of external switch input are provided to monitor post treatment devices and alarm. (4) 40 entries of alarm records and 60 entries of rolling history operation records in 2 hours (1 entry in every 2 minutes) are provided for the convenience of maintenance and analysis.

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Deluxe Microprocessor Controller I –Operation Manual (5) Fault and fault clearance records for the three filters (oil/air separator filter element, air filter and oil filter) and dew point temperature. (6) Clock in Year/Month/Date/Hour/Minute. It records the time of history event and fault accurately for the convenience of maintenance and analysis. (7) 2 channels of analog output ports to output 3 types of analog DC0 ~10V value of T1 and P2 value in real-time and loading pressure for user to collect analog value and connection of transducer. * Note: Either T1 or loading pressure set point can be output, but not both. (8) 4 LCD backlight colors (White, Yellow, Blue and Green) are available for different ambient conditions. (9) The system features ambient temperature detecting function. The system alarms when temperature of control IC exceeds 63℃, and machine will be shutdown automatically if temperature exceeds 68℃. (10) The system features main unit current protection function. Together with main unit heat relay, this function protect main unit from being damaged by high current. If current exceeds the safety current of main unit for over 135 seconds, controller will give “Main Unit Over Current” alarm and shutdown the machine.

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Global Sale and Service

US Headquarter：SULLAIR CORPORATION Subsidiary of Hamilton-Sundstrand Corporation 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 001-219-879-5451 or 1-800-Sullair (U.S.A. only) Fax: 001-219-874-1273 Fax: 001-219-874-1835 (Parts) Fax: 001-219-874-1805 (Service) European Headquarter; SULLAIR EUROPE, S.A. Zone Des Granges BP 82 42602 Montbrison Cedex, France Telephone: 0033-4-77968470 Fax: 0033-4-77968499 Asia Headquarter：SULLAIR ASIA LIMITED 518068 Zuo Paotai Road, Shekou Chiwan, Shenzhen, China Telephone: 0755-26851686 Fax: 0755-26853473, 26853475 Service hotline: 800-830-3977 Website: http://www.sullair-asia.com Shanghai Branch Company: 1504 room, GangLu Square, No.18 Tibet Middle Road,Shanghai City Post Code: 200001 Telephone: 021-53852036, 53852038 Fax: 021-53852035 Beijing Branch Company: 1506 room, B unit in Xingfu Mansion, No.3 Dong SanhuanNorth Road, Beijing City Post Code: 100027 Telephone: 010-64629770, 64629768 Fax: 010-64629773 Chengdu Branch Company: H unit, 28th floor, Guancheng Square, No. 308 Shuncheng Street, Chengdu City. Post Code: 610017 Telephone: 028-86764845, 86528048 Fax: 028-86527505 Shenyang Branch Company: 1601 room, gaoDeng International Mansion, No.355Zhongshan Road, Shenhe District, Shenyang City Post Code: 110014 Telephone: 024-22818550, 22818650, 22818450 Fax: 024-22818590 Xi’an Branch Company: 701A, 7th floor, Jinxin International Mansion, No.99 Heping Road, Xi’an City Post Code: 710000 Telephone: 029-87206201/87206202 Fax: 029-87206204 Wuhan Branch Company: 2909 room, B unit Zhongshang Square, No.7 Zhongnan Road, Wuchang, Wuhan City Post Code:430071 Telephone: 027-87322745 Fax: 027-873225