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Sullair WSPC User Interface Manual

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WSPC
USER INTERFACE MANUAL
™
FOR THE WS CONTROLLER
KEEP FOR
FUTURE
REFERENCE
Part Number
02250167-859
©Sullair Corporation

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Summary of Contents for Sullair WSPC

  • Page 1 WSPC USER INTERFACE MANUAL ™ FOR THE WS CONTROLLER KEEP FOR FUTURE REFERENCE Part Number 02250167-859 ©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.

  • Page 3: Table Of Contents

    Access PRIVILEGES ................. 7 Starting the Software ................. 7 Windows® Basic..................9 Connecting the PC to the Controller ............10 Connecting / Disconnecting the WSPC User Interface and the WS Controller ....................10 The WSPC Display Screen..............12 Compressor Status Bar................12 File Menu ....................
  • Page 4 WSPC USER INTERFACE 3.4.1 Sensor Details Button..............20 3.4.2 Log Data Button ................22 Maintenance Display ................23 3.5.1 Warning Messages............... 23 3.5.2 Service Reminders ............... 24 Distributor Information................25 Sequence System Display ............... 25 Adjustments Display ................27 3.8.1 Adjusting Control Parameters ............28 3.8.2 Adjustable Control Parameters.............
  • Page 5 WSPC USER INTERFACE PART 2 ADVANCED FUNCTIONS ....55 SECTION 6 ADMINISTRATOR LEVEL FUNCTIONS ......... 57 Administrator Level Functions..............57 Accessing the Administrator Level............57 Commissioning a Controller..............58 Maintenance Display ................60 6.4.1 Warning History Window .............. 62 6.4.2 Maintenance History Window ............63 Administrator Adjustments (Admin) Display..........
  • Page 6 WSPC USER INTERFACE...

  • Page 7: Part 1 User Level

    WSPC USER INTERFACE PART 1 USER LEVEL...
  • Page 8 WSPC USER INTERFACE...

  • Page 9: Overview

    Sullair air compressors equipped with a Sullair WS Controller. The software can monitor a single compressor operating as an individual unit or multiple machines connected in a sequence. The WSPC program receives data about the compressor from the WS Controller, assigns...

  • Page 10: System Compatibility

    Features of the WSPC User Interface software include: • Two-way communication channel between the user and the compressor controller. • A comprehensive view of the compressor controller’s operation at the WSPC interface. • Adjustment of all modifiable parameters of the compressor controller.

  • Page 11: Installing Or Updating The Framework

    WSPC USER INTERFACE INSTALLING OR UPDATING THE FRAMEWORK The WSPC software requires the Microsoft .net® Framework support program in order to run on the PC. If Microsoft .net is already on the PC, you will be able to run as soon as the installation is completed. To install the framework, or update to the latest version, use the following procedure for a free download.
  • Page 12 Part 1: User Level WSPC USER INTERFACE NOTES...

  • Page 13: Getting Started

    The WSPC User Interface program may be accessed at two levels. User Level: Allows users to access the program without entering a password. The user should be an individual with specific authorization to use the WSPC software and knowledge of the compressor operation. This level includes all data and adjustments for normal applications of the compressor.
  • Page 14 Part 1: User Level WSPC USER INTERFACE Figure 2.1b WSPC User Interface password request Do the following to select a user-level profile: Click the down arrow next to the “User Name” box. A drop-down list of user profiles will be presented. See Figure 2.2.

  • Page 15: Windows® Basic

    This section presents basic MS Windows® functions that will be useful to using the WSPC program. The active presentations of information on the computer screen are referred to as “Displays.” At the top of each display is a tab showing the display title.

  • Page 16: Connecting The Pc To The Controller

    2. During normal connection, communication activity will be shown on the bottom edge of the WSPC screen, as shown in Fig 2.5a. The progress bar and block numbers simply indicate that communications are occurring.
  • Page 17 Figure 2.5b WSPC User Interface Display Screen 4. To disconnect communication between the WSPC and the controller, click on the “Connect” button. The box left of the button will change from bright green to dark, shaded green, indicating that the WSPC is disconnected from the controller.

  • Page 18: The Wspc Display Screen

    Part 1: User Level WSPC USER INTERFACE THE WSPC DISPLAY SCREEN The WSPC display screen consists of the title bar, the pull-down menu bar, the compressor status bar, display tabs, machine operation data display, and the communication status bar. Refer to Figure 2.6.
  • Page 19 PC. To reduce the display to show only the status bar: Place the cursor on the right border of the WSPC display window. Press and hold the left mouse button. “Drag” the display border to the left until it stops. The compressor data window will be hidden leaving the status bar in the display.

  • Page 20: File Menu

    Login – Presents the Login box which allows the user to choose a profile from a list of available User profiles. See Figure 2.9 (a & b). Exit – Closes the WSPC User Interface program. Exiting the software does not affect the compressor or controller operation.

  • Page 21: Wspc Display Descriptions

    Part 1: User Level WSPC USER INTERFACE SECTION 3 WSPC DISPLAY DESCRIPTIONS COMPRESSOR STATUS BAR Located on the left edge of the WSPC User Interface program window, the Compressor Status Bar displays information related to the compressor current operation. See Figure 3.1.

  • Page 22: Compressor Data Display (Default Screen)

    COMPRESSOR DATA DISPLAY (DEFAULT SCREEN) The “Compressor Data” display is the window that appears when the WSPC Interface is initialized. See Figure 3.2. If the Compressor Data display is not showing on the monitor, access the display by clicking on the “Compressor Data”...

  • Page 23: Digital Inputs And Relay Outputs

    Part 1: User Level WSPC USER INTERFACE Compressor loaded hours – Total number of hours the compressor has run loaded. Compressor full load hours – Total number of hours the compressor has run at full load. Number of starts – Total number of times the compressor has been started automatically or manually.

  • Page 24: Machine Info Display

    Part 1: User Level WSPC USER INTERFACE MACHINE INFO DISPLAY The “Machine Info” display presents information relating to the current compressor/controller model and configuration. See Figure 3.3. This information is view only and cannot be changed by the operator. Figure 3.3 Machine Info Display The information presented in the “Machine Info”...

  • Page 25: Service Display

    Part 1: User Level WSPC USER INTERFACE Cooling – Method of cooling (air cooled or water cooled) Motor –The motor control (Y-delta, full voltage, variable -speed) Volts – Nominal Starter line voltage Dryer – Dryer type SERVICE DISPLAY The Service display provides information related to compressor events which require service actions.

  • Page 26: Sensor Details Button

    Sensor Data window will be presented. See Figure 3.7. Click Save to save the log using the filename and default directory provided. By default, the log data will be saved in the same folder as the WSPC program files, typically: ..\Sullair\WSPC\SensorLog_n.txt where “_n”...
  • Page 27 Part 1: User Level WSPC USER INTERFACE Figure 3.6 Sensor Log - Fault Figure 3.7 Save Sensor Data Window To open a saved sensor log, go to the location where the log is saved. When the directory is opened, click on the file name of the sensor log to be opened. The log file will open with the Windows Notepad application.

  • Page 28: Log Data Button

    Figure 3.8a Saved Sensor Log File Example 3.4.2 Log Data Button WSPC may be used to log data about compressor operation for extended periods. These files are stored in the PC. A line of data is stored at least once per minute.

  • Page 29: Maintenance Display

    Part 1: User Level WSPC USER INTERFACE MAINTENANCE DISPLAY Maintenance Display contains listings recent Warnings Recommended Service messages that have been displayed at the controller. The display can list 12 warning messages and six service reminders. See Figure 3.9. Also displayed are the hours remaining to the next recommended service activity.

  • Page 30: Service Reminders

    Part 1: User Level WSPC USER INTERFACE High Air Filter dP – Air filter pressure differential is high indicating that the air filter unit needs to be checked or changed. High Temperature 1, 2, or 3 – Compressor Temperature at the specified temp probe location is approaching the set high limit.

  • Page 31: Distributor Information

    Part 1: User Level WSPC USER INTERFACE DISTRIBUTOR INFORMATION Distributor Information can be accessed by clicking on the “Distributor Info” button on the “Compressor Data” display. A window will appear, similar to Figure 3.10, presenting previously entered information. Enter additional information here as desired in the lower pane.
  • Page 32 Part 1: User Level WSPC USER INTERFACE Figure 3.11 Sequence System Display Status – displays the operating state of each compressor in the sequence. The sequence state describes the operational role a machine is performing as a part of the sequence. The various states that may appear in the “Sequence status”...

  • Page 33: Adjustments Display

    ADJUSTMENTS DISPLAY Both the compressor control parameters and sequencing parameters can be edited at the Adjustments display of the WSPC User Interface. See Figure 3.12. At this display the user can view the current settings of the machine control parameters and make adjustments as necessary.

  • Page 34: Adjusting Control Parameters

    “Adjustments” display. The units and language appearing in the “Adjustments” display correspond to the settings applied when the User Profile was created. The WSPC must be connected to the controller (by clicking the “Connect” button) before parameter changes are allowed.

  • Page 35: Adjustable Control Parameters

    Part 1: User Level WSPC USER INTERFACE Click in the field of the parameter to be changed and delete the current value. A double-click in the parameter field will highlight the entire value. When the parameter value is highlighted, typing over the current value will delete it and replace it with the new value.

  • Page 36: Adjusting Sequence Parameters

    (Automatic or Manual). 3.8.3 Adjusting Sequence Parameters This group of adjustments set the controller for operation with other Sullair compressors or for remote control. Refer to the WS Controller Sequencing and Protocol Manual for the principles of operating compressors in sequence.
  • Page 37 Part 1: User Level WSPC USER INTERFACE Select “Remote” when the compressor is to be controlled remotely by the PC or other remote connection. The Administrator may set the controller for remote unloading via modbus. If so, an additional button labeled “Unload” will appear under the “Connection”...

  • Page 38: Changing Controller Units And Language Preferences

    RS232 port. The address may be between 1 and 247. The default value for the WS Controller and for WSPC software is 1. This change takes affect after the controller power is cycled off and on. NOTE The Modbus address assigned here must match the modbus address assigned in the WSPC User Profile or other Modbus applications.

  • Page 39: Time And Date Adjustments

    Italian. NOTE Changes to the WS Controller user interface preferences do not affect the display of units and language in the WSPC software. WSPC preferences are set as User Profiles. Figure 3.15 Units and Language Preferences 3.8.5 Time and Date Adjustments...

  • Page 40: Communication Parameters

    Part 1: User Level WSPC USER INTERFACE Figure 3.16 Time and Date Adjustment TIME FIELD Hour:Minutes:Seconds Click to Synchronize with PC Clock To adjust the time setting: Double-click in the hour field to select the hour value. Type the hour of the day in 24 hour format.

  • Page 41: Internet Transmission Settings

    These settings have no effect on standard controllers. The TCP/IP parameters are: IP Address – The unique address the WSPC will use to identify and communicate with another computer via the internet or other network utilizing the Internet Protocol standard.

  • Page 42: Saving Parameter Settings

    The “Machine Profiles” window will appear. Click “Read from Controller” to load the current parameter settings from the controller to the WSPC. The program will read the settings from the controller, and will generate a new profile. The new name will appear on the list as a “New Profile”...

  • Page 43: Loading Parameter Settings

    Part 1: User Level WSPC USER INTERFACE Filter a column by clicking on the expansion arrow in the space above the column containing the filter criteria. The arrow will present a list of the contents of the column. Select the item in the list by which the column is to be filtered.
  • Page 44 Part 1: User Level WSPC USER INTERFACE Click on the Name of the saved machine profile to be loaded. Saved Machine Profiles are listed in the lower portion of the Machine Profiles window. The control parameter values for the selected profile will be shown in the upper portion of the window.

  • Page 45: Setting User Preferences

    SECTION 4 SETTING USER PREFERENCES USER PROFILES User Profiles are used to configure the WSPC software for a specific user or group of users. Settings made in a profile only change the appearance and action of the software program and do not affect the operation of the WS Controller or compressor.
  • Page 46 Figure 4.2 User Profiles Window 8. Under “Communication Port” the settings that control communication between the WS Controller and the WSPC software can be viewed and modified as necessary. All four must be set properly for the programs to communicate.

  • Page 47: Edit A Profile

    Part 1: User Level WSPC USER INTERFACE When done viewing the profile settings, click cancel to exit the profile window. The “Enter Password” option box will be presented. See Figure 4.3. 9. Select a profile and click OK to make the profile active.
  • Page 48 WSPC software. 8. Select the desired “Units of Measure.” These settings determine the units of measure to be displayed by the WSPC software. Units selected here will not affect units displayed on the WS Controller user interface.

  • Page 49: Copy A Current Profile To A New Profile

    Part 1: User Level WSPC USER INTERFACE to 1. This number should be changed only if the modbus interface has been configured for a different port. NOTE The Modbus Address, Baud Rate, and Parity assigned here must match the modbus parameters of the controller. If the settings do not match, communication between the PC and the controller will not occur.

  • Page 50: Activate A Profile

    Part 1: User Level WSPC USER INTERFACE NOTE A new profile cannot be given the same name of an already existing profile. 4. Make changes to the preferences in the profile window as necessary. Section 4.1.2 details the steps to entering profile preferences.

  • Page 51: Variable Speed Drive (Vsd)

    SECTION 5 VARIABLE SPEED DRIVE (VSD) VSD OPERATION Generally the WSPC functions operate in the same manner for VSD machines as with non-VSD machines. When a VSD compressor is connected to the WSPC, the program provides additional functionality for monitoring and controlling VSD operation.

  • Page 52: Vsd Performance Data

    Part 1: User Level WSPC USER INTERFACE VSD PERFORMANCE DATA Figure 5.2 shows a sample display of VSD performance data for a compressor operating under normal conditions. A description of the VSD data is presented below: Figure 5.2 VSD Performance Data Capacity indicates approximately how much air is being delivered by the compressor package in CFM and percent of the compressor's full capacity.

  • Page 53: Clear Recent Data

    Part 1: User Level WSPC USER INTERFACE Power % shows the amount of power being used to operate the VSD compressor expressed as a percentage of the compressor’s estimated usage when operating at full capacity. The “Current” power data is updated frequently and shows the instantaneous power usage rates.

  • Page 54: Delivery History

    Part 1: User Level WSPC USER INTERFACE zero. New machine statistics will immediately begin to be calculated and the Recent columns will soon be populated with the new Recent data values. DELIVERY HISTORY Click on the Delivery History button to open the Delivery Profile window. See Figure 5.3.

  • Page 55: Service Display Tab

    This page lists the last 16 faults to occur with the compressor. It will also contain VSD related faults should they occur. The WSPC provides additional service data while operating a variable speed drive compressor. To view VSD service data, click the "Service" tab. See Figure 5.4.

  • Page 56: Main Motor Vfd Status Box

    Part 1: User Level WSPC USER INTERFACE Figure 5.4 Service Tab – VSD Status MAIN MOTOR VFD STATUS BOX Service data related to VSD Compressors is displayed in the Main Motor VFD Status box. See Figure 5.5. The VFD Status box contains the following information: Motor speed displays the motor speed in revolutions per minute (RPM).

  • Page 57: Adjustments Tab

    In addition to the general control parameters previously described, two VSD adjustments become available when the WSPC is connected to a VSD compressor. These VSD control parameters are setpoint pressure and cost per kilowatt-hour. See Figure 5.6.

  • Page 58: Administrator Level Vsd Adjustments

    Part 1: User Level WSPC USER INTERFACE Figure 5.6 Adjustments Tab – VSD Parameters VSD Setpoint pressure - The targeted pressure for the variable speed controls. This is normally adjusted near the bottom of the load/unload band. The speed will be adjusted to maintain this pressure.
  • Page 59 Part 1: User Level WSPC USER INTERFACE NOTES...
  • Page 60 Part 1: User Level WSPC USER INTERFACE...

  • Page 61: Part 2 Advanced Functions

    Part 2: Administrator Level WSPC USER INTERFACE PART 2 ADVANCED FUNCTIONS...
  • Page 62 Part 2: Administrator Level WSPC USER INTERFACE...

  • Page 63: Administrator Level Functions

    Administrator access requires a “key” file to be installed to the admin user’s PC. The WSPC installation includes the special key file along with the WSPC files. This key file requires periodic updates. The key is not required for normal User- level operation of WSPC.

  • Page 64: Commissioning A Controller

    Part 2: Administrator Level WSPC USER INTERFACE Figure 6.1 Password Entry Box The WSPC program will open with access to Administrator Level Functions. If the program opens without displaying a password entry field then a User level profile was selected. Click on the down arrow next to the User Name field and select an Administrator profile for access to administrator level functions.
  • Page 65 Part 2: Administrator Level WSPC USER INTERFACE Click the down arrows for the machine model for which the controller is to be commissioned. See Figure 6.3. NOTE Use care to select the proper machine model. All machine attributes must match the model selected during commissioning to ensure proper and safe operation.

  • Page 66: Maintenance Display

    Part 2: Administrator Level WSPC USER INTERFACE Click “Yes” to confirm commissioning the controller to the selected compressor model. Commissioning will begin and the progress of the commissioning process will be shown in the commissioning window. See Figure 6.5. Figure 6.5 Commissioning Progress Monitor...
  • Page 67 Part 2: Administrator Level WSPC USER INTERFACE “Warning History” button – When selected, presents a table displaying a history of the 16 most recent warning occurrences. “Maintenance History” button – When selected, presents a table displaying a history of the 16 most recent service reminders.

  • Page 68: Warning History Window

    Part 2: Administrator Level WSPC USER INTERFACE 6.4.1 Warning History Window A history of the 16 most recent Warning messages may be viewed in the “Warning History” window. See Figure 6.8. To access the “Warning History” window, click the “Warning History”...

  • Page 69: Maintenance History Window

    Part 2: Administrator Level WSPC USER INTERFACE 6.4.2 Maintenance History Window A chronological history of the 16 most recent Service Reminders may be viewed in the Maintenance History Window. See Figure 6.9. To access the “Maintenance History” window, click the “Maintenance History”...

  • Page 70: Administrator Adjustments (Admin) Display

    Part 2: Administrator Level WSPC USER INTERFACE ADMINISTRATOR ADJUSTMENTS (ADMIN) DISPLAY The Administrator Adjustments (Admin) display tab is available only when an administrator level profile is active. This display allows the administrator to edit the ID’s of specific controller inputs and to make zero calibration adjustments of measured values between the compressor system and the controller.

  • Page 71: Signal Address Function

    Part 2: Administrator Level WSPC USER INTERFACE 6.5.1 Signal Address Function Refer to Figure 6.10. The left section contains a list of controller functions, and allows selection of signals to operate the function. This allows special field setups for special applications.

  • Page 72: Factory-Defined Output Options (Drop-Down Arrows)

    Part 2: Administrator Level WSPC USER INTERFACE MB Timer 1, 2, 3 OFF – Activates the function when the respective Modbus Timer signal (1, 2, 3) is ON. 6.5.3 Factory-Defined Output Options (drop-down arrows) The following options may be selected for a Factory Defined Relay (A – E) by clicking on the associated drop-down arrow (refer to Figure 6.10):...

  • Page 73: Disable Warning Reset

    Current versions of WS Controllers reset warnings whenever the start or stop button is pressed on the keypad. The administrator may disable this feature, and require all warnings to be reset by WSPC only. Refer to Figure 6.10. Select the “Start Button” check box to disable reset by the start button.

  • Page 74: Unload (Remote) Button

    Part 2: Administrator Level WSPC USER INTERFACE 6.5.8 Unload (Remote) Button The administrator may set up the controller for remote control by Modbus. To do so, select the “Modbus timer 1” to control the “Remote Unload” function above. Also select “Remote”, Hours”, or “ComNum” Sequence mode on the User’s “Adjustments”...

  • Page 75: Vsd Package Settings

    PC. 6.5.11 VSD Package Settings When a VSD compressor is connected to the WSPC, additional VSD related adjustments are available on the Admin display. See Figure 6.13. These values, located in the right side of the screen are only displayed when a VSD machine is connected.
  • Page 76 Part 2: Administrator Level WSPC USER INTERFACE The VSD Package Settings are described below (ref. Figure 6.14): Figure 6.14 VSD Package Settings Flow calibration - The flow indicator sets the nominal (100%) flow value for the machine operating under typical conditions. This value may be adjusted as needed for specific applications and operating conditions.

  • Page 77: Saving And Loading Administrator Parameters

    Sullair. Copy the new file to your PC. The preferred location is with the other WSPC program files. You may use “Import Other Data” to copy files from other locations to this folder.

  • Page 78: Import Other Data

    Figure 6.15 VSD Package Settings 6.5.14 Import Other Data This is provided simply as a tool to copy files from other locations into the WSPC folder. This may be used on some update distributions. To import: Start WSPC. You do not need to be connected to a controller.

  • Page 79: Modbus Functions

    VSD performance, digital I/O states, sequence status, and other machine parameters. The messages appear in hexadecimal or decimal form. The WSPC transmits a request for information or send commands to control the compressor operation. The controller responds with the requested data or an acknowledgement to the control command.

  • Page 80: Monitoring Modbus Communications

    Three modes of monitoring may be selected by clicking the radio button. When monitoring, the WSPC request will always be shown in the “Command” data window in hex form. The WS data will be shown in the lower window in either Hex or Decimal format.
  • Page 81 Part 2: Administrator Level WSPC USER INTERFACE Click in the Address box for the Input or Holding register, and enter the desired register number. Click the “Read” button to get the current value. Figure 6.18 Modbus Registers To change a holding register: Click the “Decimal”...
  • Page 83 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...

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