Related Manuals for Sullair SUPERVISOR CONTROLLER
Summary of Contents for Sullair SUPERVISOR CONTROLLER
- Page 1 SUPERVISOR CONTROLLER™ and WS CONTROLLER SEQUENCING & PROTOCOL MANUAL (Including Supervisor II Deluxe Controller™) INSTRUCTION MANUAL KEEP FOR FUTURE REFERENCE Part Number 02250161-162 ©Sullair Corporation...
- Page 2 Sullair Air Care Seminars are courses that provide hands-on instruction in the proper operation, maintenance and service of Sullair equipment. Individual seminars on Industrial compressors and compressor electrical systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
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Page 3: Table Of Contents
TABLE OF CONTENTS OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL 1. SAFETY AND INTRODUCTION SAFETY SUPERVISOR CONTROLLER, SUPERVISOR II AND WS CONTROLLERS SEQUENCED COMPRESSOR SYSTEMS 2. SEQUENCING WITH MULTIPLE CONTROLLERS NORMAL OPERATION COMPRESSOR SYSTEM WIRING AND PIPING MACHINE PREPARATION PRIOR TO SEQUENCING... - Page 4 TABLE OF CONTENTS 5. SEQUENCING TIMERS FOR EFFICIENT OPERATION RECOVERY TIME AND DELAYED START TIMER TIMER OPERATION EXAMPLES 5.2.1 EXAMPLE 1– UNLOAD OPERATION 5.2.2 EXAMPLE 2– LOAD OPERATION 5.2.3 EXAMPLE 3– STARTING EXAMPLE 5.2.4 EXAMPLE 4– STARTING EXAMPLE SEQUENCING TIMERS SUMMARY 6.
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Page 5: Safety And Introduction
Unexpected machine operation may occur. SUPERVISOR CONTROLLER, SUPERVISOR II AND WS CONTROLLERS NOTE For information specific to the Supervisor Controller, Supervisor II Deluxe, or WS Controller, consult the Instruction Manual for that specific controller model. This manual describes sequencing of multiple compressors with Supervisor Controller, Supervisor II Deluxe or WS Controller. - Page 6 Both the Supervisor Controller and WS Controller can be configured with up to 16 machines in a sequence system. When one or more Supervisor II Deluxe Controllers are in the system, the maximum number of machines is eight.
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Page 7: Sequencing With Multiple Controllers
The remaining compressors will continue to operate as needed. The Supervisor Controller has a Remote keypad on the display module that is used to enable and disable the controller from any sequencing mode currently programmed. When the Remote key is first pressed after sequencing has been programmed, the sequencing mode will be enabled and the REMOTE LED on the Display Module will illuminate. -
Page 8: Wiring And Piping
Section 2 SEQUENCING WITH MULTIPLE CONTROLLERS one machine. DO NOT enable this mode in systems with more than two machines (See ROTATE hours parameter setting for more information). Digital inputs for remote control are disabled. DO NOT enable the Rotate Hours mode when the above situation is NOT true. Unexpected starts and stops may occur when manually starting or stopping a machine in the sequence. -
Page 9: System Operation
Section 2 SEQUENCING WITH MULTIPLE CONTROLLERS UNLOAD psi LOAD psi BAUD RATE (Supervisor II only). Baud Rate for Supervisor and WS is fixed at 9600. SEQUENCE mode (COM ID or HOURS) LAST COM LOWEST (minimum pressure before a machine is started) RECOVER time (normally set at 10) Leave ROTATE hours disabled except for the specific application described Section... -
Page 10: System Setup And Tuning
Section 2 SEQUENCING WITH MULTIPLE CONTROLLERS If, after Recovery Time, the pressure is still above 108 psig (7.4 bar) then the current trim machine will unload. This process can continue until all machines are unloaded. If the pressure falls below load pressure +2 psig (0.14 bar) or 102 psig (7.03 bar) the first machine in the sequence will load and operate as the trim machine. -
Page 11: General Sequencing Rules
Section 2 SEQUENCING WITH MULTIPLE CONTROLLERS time setpoint. Note that the timer starts when a machine is added or taken away from the system. If the pressure recovers within the RECOVER time, and then at a later time the pressure drops below the Trim Low setpoint, the next machine in sequence will load immediately. -
Page 12: Sequence Parameter Names
Section 2 SEQUENCING WITH MULTIPLE CONTROLLERS 4. Press Enter to select the parameter for editing. 5. If a numeric value is to be entered, Use the Right and Left arrow keys to position the cursor over the number digit to be changed. 6. - Page 13 Section 2 SEQUENCING WITH MULTIPLE CONTROLLERS decrement by 100 hours. The maximum value for this parameter is 30,000 hours. The number will roll over to zero if this number is exceeded. Com Number (COM ID#[7]) - Must be unique ID number for every machine in the system.
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Page 14: System Display- Supervisor Controller
9600. SYSTEM DISPLAY- SUPERVISOR CONTROLLER The Supervisor Controller System Menu allows the user to observe the status of other compressors in a sequence. The option is useful when monitoring, troubleshooting and calibrating the compressor system. -
Page 15: System Display- Ws Controller
To restore a machine to the network: 1. Restore power to the compressor. 2. Pull out the E-stop if it has been pressed. 3. To enable a Supervisor Controller in the system, press the START pad and REMOTE pad on the keypad. -
Page 16: Calibration Of P2 Pressure Transducers
Perform the calibration when the system is at a stable pressure. 2.13.1 SUPERVISOR P2 PRESSURE TRANSDUCER CALIBRATION Perform the following steps to calibrate the Supervisor Controller P2 pressure reading: 1. Measure the pressure using an independent certified gauge. 2. Enter the password to access the Supervisor Calibration menu. -
Page 17: 2.13.2 Supervisor Ii Deluxe P2 Pressure Transducer Calibration
Section 2 SEQUENCING WITH MULTIPLE CONTROLLERS 2.13.2 SUPERVISOR II DELUXE P2 PRESSURE TRANSDUCER CALIBRATION Perform the following steps to calibrate the Supervisor II Deluxe Controller pressure reading: Measure the pressure using an independent certified gauge. Enter the following special key sequence to enter the Calibration menu: Logo , Up arrow , Display... - Page 18 NOTES...
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Page 19: Sequencing With Variable Speed Drive Compressors
Alternately, the Full Load solenoid valve may be rewired to the Load output with any of the controllers (Supervisor Controller, Supervisor II Deluxe, or WS) to achieve the same results. In all cases, care must be taken to not overload the compressors by limiting operation to pressures within the capability of the drive motor. -
Page 20: Setup For Multiple Vsd Compressors
Section 3 SEQUENCING WITH VARIABLE SPEED DRIVE COMPRESSORS the VSD Unload time in AUTO mode and the fixed-speed restart times, rapid cycling and hunting can be minimized. The pressure regulator of a fixed-speed L (100 psi) compressor does not begin to throttle until 101 - 102 psi. -
Page 21: Operation With Remote Controllers
Any unit can be stopped by pressing the Stop key. The remaining machines in the system will continue to operate as needed. CONTROLS WIRING AND ADJUSTMENT – SUPERVISOR CONTROLLER There are three inputs and one output that are enabled when in Remote mode: Remote Stop/Start Input D5... -
Page 22: Controls Wiring And Adjustment - Supervisor Ii Deluxe
Section 4 OPERATION WITH REMOTE CONTROLLERS Changing Parameter Values – Supervisor Perform the following steps to change parameter values using the Supervisor Controller: Press the Down arrow key until SEQUENCING menu is displayed. Press Enter Use the Up and Down arrow keys to navigate through the menu selections to the parameter to be edited. -
Page 23: Controls Wiring And Adjustment - Ws Controller
The WS Controller may be field configured to enable all the remote input and output functions described for the Supervisor Controller and Supervisor II Deluxe models plus additional capabilities. The additional inputs apply only in the REMOTE sequence mode. -
Page 25: Sequencing Timers For Efficient Operation
Section 5 SEQUENCING TIMERS FOR EFFICIENT OPERATION SEQUENCING TIMERS FOR EFFICIENT OPERATION RECOVERY TIME AND DELAYED START TIMER The Recovery Timer is used to keep machines from starting, loading or unloading all at the same time. The Delayed Start timer is used to keep machines from starting unnecessarily due to temporary load changes. -
Page 26: Timer Operation Examples
Section 5 SEQUENCING TIMERS FOR EFFICIENT OPERATION 85, the machine will start in about 60 seconds 70, the machine will start in about 30 seconds Because of varying pressures and other delays these times are approximate. TIMER OPERATION EXAMPLES The following examples show how the Recovery and Delayed Start timers function. 5.2.1 EXAMPLE 1–... -
Page 27: Example 3- Starting Example
Section 5 SEQUENCING TIMERS FOR EFFICIENT OPERATION Trim Unloaded (Next machine in sequence) The next machine in sequence will wait for 10 seconds before loading if the pressure stays at 101 or 100. If the pressure goes above 101 loading will be unnecessary. If the pressure goes below 100 the machine will load immediately (regardless of the recovery timer). -
Page 28: Sequencing Timers Summary
Section 5 SEQUENCING TIMERS FOR EFFICIENT OPERATION Machine Status Trim Stopped (Next machine in sequence) Stopped If the system pressure drops below the Sequence Load pressure (102) but is above the Lowest Pressure (70), the next machine in sequence (2) will start and trim, and the previously trimming machine (1) will go to full load after the Delay Start timer expires. -
Page 29: Controller Communication Protocol
Section 6 CONTROLLER COMMUNICATION PROTOCOL CONTROLLER COMMUNICATION PROTOCOL RECOVERY TIME AND DELAYED START TIMER - OVERVIEW Communications connections are internal features of the Supervisor II Deluxe and WS controllers. A separate communications module is added to Supervisor Controllers for any external communications. Most features are common to each controller, unless specifically noted below. -
Page 30: Rs-485 Serial Channel
Section 6 CONTROLLER COMMUNICATION PROTOCOL • There are no extra communications for monitoring. Since each machine sends its status every second, the monitor does not need to send messages. However, the monitor may send messages to get other status or change parameters. •... -
Page 31: Message Format
Section 6 CONTROLLER COMMUNICATION PROTOCOL MESSAGE FORMAT Messages are RS-485 half-duplex, 9600 baud, 8 bit, 1 stop bit, no parity. Control characters are used to frame a message. These characters mark the start of the message and the end of the message. All messages have the following format: - Start of text. - Page 32 Section 6 CONTROLLER COMMUNICATION PROTOCOL Table 6.2 Controller Message Types (Continued) MESSAGE TYPE FORMAT EXAMPLE i – Display Response ##i1,2,3,4,5,6,7,8,9,10,11,12, 13,14,15,16,17,18xx EXAMPLE: 01i104,95,41,78,110,127,101,83,186,3,2,0008,3C2,3C2,0,0,E,c26 The controller’s response to a valid message type D request. COMMENT: 1- P1 pressure in psig 2- P2 pressure in psig 3- P3 pressure in psig 4- P4 pressure in psig 5- T1 temperature in deg F...
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Page 33: Data Types
Section 6 CONTROLLER COMMUNICATION PROTOCOL Table 6.2 Controller Message Types (Continued) MESSAGE TYPE FORMAT EXAMPLE g – Get parameter ##g22,21xx 01g3,4A5 Response The controller’s response to a valid message type G request. COMMENT: 22- Parameter number (See DATA TYPES) 21- Value of the parameter (See DATA TYPES P –... - Page 34 "02dT1 Discharge High, T2 Dry Side High 45". The WS Controller sends two 20-Character strings similar in form to those of the Supervisor Controller. These are internally generated by the controller and are independent of the user interface of the machine.
- Page 35 Section 6 CONTROLLER COMMUNICATION PROTOCOL 22- Parameters are identified by parameter number over serial communications, as shown in Table 6.3 below. Parameters for Supervisor II Deluxe and WS Controllers are as noted the in second and fourth columns. Text parameters 61-69 are not available through the external bus.
- Page 36 Section 6 CONTROLLER COMMUNICATION PROTOCOL Table 6.3 Parameter Descriptions NetTag Description Digits Units RW RW RW Language list Units of measure list RW Temp units of measure list RW RW RW Unload Pressure RW RW RW Load Pressure delta RW RW RW Unload Time RW RW RW Wye-Delta time...
- Page 37 WORLDWIDE SALES AND SERVICE SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A. Sullair Road, No. 1 Zone Des Granges BP 82 Chiwan, Shekou 42602 Montbrison Cedex, France Shenzhen, Guangdong PRV. Telephone: 33-477968470 PRC POST CODE 518068 Fax: 33-477968499 Telephone: 755-6851686 www.sullaireurope.com Fax: 755-6853473 www.sullair-asia.com...