Sullair 02250165-411 R01 User Manual
  1. Manuals
  2. Brands
  3. Sullair Manuals
  4. Controller
  5. 02250165-411 R01
  6. User manual
Sullair 02250165-411 R01 User Manual

Sullair 02250165-411 R01 User Manual

Ws controller
Hide thumbs
Table of Contents

Advertisement

Quick Links

USER MANUAL
WS C
U
I
M
ONTROLLER
SER
NTERFACE
ANUAL
PART NUMBER:
02250165-411 R01
KEEP FOR
FUTURE
WARRANTY NOTICE
REFERENCE
SULLAIR CORPORATION
©
Failure to follow the instructions
The information in this manual is current
and procedures in this manual or,
as of its publication date, and applies to
misuse of this equipment will
compressor serial number:
VOID its warranty!
20080301000
and all subsequent serial numbers.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 02250165-411 R01 and is the answer not in the manual?

Questions and answers

Related Manuals for Sullair 02250165-411 R01

Summary of Contents for Sullair 02250165-411 R01

  • Page 1 USER MANUAL WS C ONTROLLER NTERFACE ANUAL PART NUMBER: 02250165-411 R01 KEEP FOR FUTURE WARRANTY NOTICE REFERENCE SULLAIR CORPORATION © Failure to follow the instructions The information in this manual is current and procedures in this manual or, as of its publication date, and applies to...
  • Page 2 AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility located at Michigan City, Indiana.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1—SAFETY GENERAL PERSONAL PROTECTIVE EQUIPMENT PRESSURE RELEASE FIRE AND EXPLOSION MOVING PARTS HOT SURFACES, SHARP EDGES AND SHARP CORNERS TOXIC AND IRRITATING SUBSTANCES ELECTRICAL SHOCK LIFTING 1.10 ENTRAPMENT SECTION 2—STARTUP PROCEDURES INTRODUCTION WS CONTROLLER PANEL LAYOUT WS START UP PROCEDURES SHUTDOWN PROCEDURE SECTION 3—ADJUSTMENTS...
  • Page 4 TABLE OF CONTENTS NORMAL VIEW SERVICE REMINDERS WARNING MESSAGES FAULT MESSAGES SECTION 5—TROUBLESHOOTING TROUBLESHOOTING INTRODUCTION TROUBLESHOOTING GUIDE WS CONTROLLER FAULTS AND WARNINGS MACHINE BEHAVIOR AFTER A POWER INTERRUPTION INTERNAL BATTERY REPLACEMENT CONNECTOR PLUGS SECTION 6—VARIABLE SPEED DRIVE SAFETY OVERVIEW INSTALLATION WS CONTROLLER DISPLAY AND MENUS STARTUP OF NEW VSD COMPRESSOR PACKAGE VSD COMPRESSOR TROUBLESHOOTING...

  • Page 5: Section 1-Safety

    GENERAL tions relative to personal protective equipment, such as eye and face protective equipment, Sullair Corporation and its subsidiaries design and respiratory protective equipment, equipment manufacture all of their products so they can be intended to protect the extremities, protective operated safely.

  • Page 6: Moving Parts

    SECTION 1 inside diameter to reduce pressure in case of accumulate on, under or around acoustical mate- hose failure. rial, or on any external surfaces of the air com- pressor. Wipe down using an aqueous industrial D. Flow-limiting valves are listed by pipe size and cleaner or steam clean as required.

  • Page 7: Hot Surfaces, Sharp Edges And Sharp Corners

    SECTION 1 C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially DANGER when exposed to hot or moving parts. D. Keep access doors, if any, closed except when making repairs or adjustments. E. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it.

  • Page 8: Electrical Shock

    SECTION 1 swallowed, induce vomiting by administering a tablespoon of salt, in each glass of clean, warm water until vomit is clear, then administer two DANGER teaspoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light.

  • Page 9: 1.10 Entrapment

    SECTION 1 Keep lift operator in constant attendance when- N. Make sure pallet-mounted compressors are ever compressor is suspended. firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. J. Set compressor down only on a level surface NEVER attempt to forklift a compressor that is capable of safely supporting at least its weight not secured to its pallet, as uneven floors or sud-...
  • Page 10 BLANK PAGE...

  • Page 11: Introduction

    WS CONTROLLER USER INTERFACE MANUAL Section 2 STARTUP PROCEDURES INTRODUCTION • Display Screen for displaying machine status • START pad for machine startup This compressor is equipped with an WS Controller for controlling the compressor system operation, • STOP pad for stopping machine operation setting the machine parameters and performing and for clearing fault messages while the machine maintenance operations.

  • Page 12: Ws Start Up Procedures

    WS CONTROLLER USER INTERFACE MANUAL SECTION 2 WS START UP FAN MOTOR ROTATION CHECK ( PROCEDURES INSTALLATION The VSD fan direction is affected by installation. COMPRESSOR MOTOR ROTATION Verify the correct fan rotation using the following DIRECTION CHECK ( steps: INSTALLATION 1.

  • Page 13: Shutdown Procedure

    SECTION 2 WS CONTROLLER USER INTERFACE MANUAL 8. Open the shut-off valve to the service line. 4. When the compressor is running, observe the display panel and maintenance indica- 9. After operating the machine for 24 hours, tors to ensure the values displayed are inspect the compressor for fluid leaks and within the proper ranges.
  • Page 14 BLANK PAGE...

  • Page 15: Introduction

    WS CONTROLLER USER INTERFACE MANUAL Section 3 ADJUSTMENTS INTRODUCTION COMPRESSOR ADJUSTMENT PROCEDURES This section describes steps for using the WS Controller to modify specific parameters that control The following steps apply while “Show Setting------- “ the machine operation. is indicated in the display. The control parameter described in the display can be modified by the user.

  • Page 16: User Adjustable Control Parameters

    ENTER equipped with an electric solenoid drain. This does not apply to the Sullair SCD zero loss drain, which is pad, the display will return to the not controlled or monitored by the WS Controller.
  • Page 17 SECTION 3 WS CONTROLLER USER INTERFACE MANUAL NORMAL VIEW Compressor Status: Temperature 1 Dewpoint Temperature Temperature 3 Compressor Status: Sump Pressure Compressor Status: Line Pressure Compressor Status: Δ Separator Pressure Compressor Status: Run Hours Show Setting Change Setting Unload Pressure Unload Pressure (ENTER) Show Setting...

  • Page 18: Calibration Of P2 Pressure Transducers

    WS CONTROLLER USER INTERFACE MANUAL SECTION 3 CALIBRATION OF P2 1. Wire the remote contact to junction J4-7 and PRESSURE TRANSDUCERS any vacant J3 terminal. 2. Access the PC User Interface software. At The compressor is equipped with a pressure the User Adjustments display screen, select transducer that measures the output line (P2) one of the following sequencing modes:...

  • Page 19: Introduction

    WS CONTROLLER USER INTERFACE MANUAL Section 4 DESCRIPTION INTRODUCTION INDICATOR LED DESCRIPTION This section describes the components of the WS Controller, the function of each component, and the Four LED’s on the WS Controller Panel provide various types of displays that may appear on the indication of the general state of the machine.

  • Page 20: Display Screen

    WS CONTROLLER USER INTERFACE MANUAL SECTION 4 DISPLAY SCREEN Listed below are compressor attributes that may be viewed in the Compressor Status View. This list will Information relevant to the compressor operation is vary based on specific machine configurations. presented in three views on the controller display Temperature 1—Displays the current compressor screen: Normal View, Compressor Status Views, temperature at temperature probe 1.

  • Page 21: Operating Modes

    SECTION 4 WS CONTROLLER USER INTERFACE MANUAL parameters function the same in both Manual and Automatic modes. Show Setting - - - - - - - Off mode—Indicated by the word OFF appearing in Unload Pressure the lower line of the display window. This mode Adjustment View 110 psi...
  • Page 22 WS CONTROLLER USER INTERFACE MANUAL SECTION 4 The list below provides an explanation of each Remote Unloading—Displayed as the compressor is being unloaded remotely. Operating State message that may appear in the Normal View display. Some operating states occur Running Unloaded—Displayed when the system is instantaneously and may not be seen by the running with the compressor unloaded.
  • Page 23 SECTION 4 WS CONTROLLER USER INTERFACE MANUAL WARNING MESSAGES differential is high. The air filter unit needs to be checked or changed. When a Warning condition occurs a warning High Fluid Filter dP—Indicates the fluid filter message will alternately appear on the lower line of pressure differential is high.

  • Page 24: Fault Messages

    WS CONTROLLER USER INTERFACE MANUAL SECTION 4 FAULT MESSAGES transducer (A or B) has exceeded the set high limit. High Sump Pressure—Compressor sump pressure When a Fault condition occurs, the machine will shut has risen above the set limits. down and the display will indicate FAULTED on the lower line of the display window.
  • Page 25 SECTION 4 WS CONTROLLER USER INTERFACE MANUAL Power Interruption—A power interruption has UI Voltage Too Low—The voltage to the User occurred at the controller. Interface has fallen below the set limit. Separator dP High—Separator pressure differential VSD1 VSD2 Comm Fault—An error has exceeded the set high limit.
  • Page 26 BLANK PAGE...

  • Page 27: Troubleshooting Introduction

    Sullair problems when they occur. The information Distributor or the Sullair Corporation factory Service contained in Table 5.1, Troubleshooting Guide, has Department. been compiled from factory experience and contains...
  • Page 28 WSPC. Change Fluid Maintenance due. Change Fluid Filter Change Separator Controller Watchdog Controller fault. Contact Sullair Factory Service. Dryer Fault Indicates a general dryer Consult the dryer manual and/or malfunction has occurred. Sullair Factory Service. Dryer High DP...
  • Page 29 Cooler plugged. persists, use cleaner water. Check sensor and wiring. Temp probe or sensor failure. Illegal State Controller fault. Contact Sullair Factory Service. Internal Com Error Module Network Error; Check wiring. Communication has failed between the Display Module, I/O Module and other modules.
  • Page 30 Perform recommended maintenance and reset the reminder using WSPC. Maintenance due. Memory Fault The controller I/O board has failed. Board replacement required. Contact Sullair Factory Service. Option Input Option Input Run User furnished switch has Check operation of optional device.

  • Page 31: Ws Controller Faults And Warnings

    SECTION 5 WS CONTROLLER USER INTERFACE MANUAL WS CONTROLLER FAULTS AND WARNINGS High Parameter Type Sensor Comment Limit Limit Separator dP Warning P2-P1+offset 10 psid offset for aftercooler or dryer Sump Pressure Fault 135 psig 5 psig 100 psig machine 150 psig 5 psig 125 psig machine...
  • Page 32 WS CONTROLLER USER INTERFACE MANUAL SECTION 5 5. Locate the internal battery. The battery is 1. Press the STOP pad to stop the com- located near one end of the I/O circuit board pressor. (usually oriented towards the top). 2. Disconnect and lockout power according to 6.

  • Page 33: Replacement Connector Plugs

    SECTION 5 WS CONTROLLER USER INTERFACE MANUAL REPLACEMENT CONNECTOR PLUGS Replacement connector plugs < 5V Com 24V Sup > Terminal Part Number < 5V Sup E Stop > 02250161-737 < Input P1 24V Com > 02250161-735 < 5V Com PB 485+ > 02250161-735 <...
  • Page 34 BLANK PAGE...

  • Page 35: Safety

    WS CONTROLLER USER INTERFACE MANUAL Section 6 VARIABLE SPEED DRIVE SAFETY WARNING The following special instructions apply to VSD packages provided with electronic adjustable speed Refer all drive service to trained techni- motor drives. These alcautions that apply to VSD cians.

  • Page 36: Overview

    (U, VW) to avoid damaging the variable OVERVIEW speed drive during motor or cable testing. The Sullair VSD drive application is custom designed for operation of air compressors. All necessary control functions are performed through the WS CAUTION Controller keypad and WSPC software.
  • Page 37 OSHA, National Electrical Code, and/or any other applicable State, Federal, and local elec- trical codes concerning isolation switches, fused disconnects, etc. Sullair provides a wiring diagram for use by the installer.
  • Page 38 WS CONTROLLER USER INTERFACE MANUAL SECTION 6 Table 6-1: Cable and Fuse Sizes—460V Ratings _ UL recognized type RK Based on a maximum environment of 104°F (40°C) Wire Size Wire Size Size (A) Fuse (A) Power Ground 300MCM 2 x 4/0 2 x 250MCM 300MCM 2 x 300MCM...

  • Page 39: Installation

    SECTION 6 WS CONTROLLER USER INTERFACE MANUAL INSTALLATION • Consistent with UL listing requirements, for maxi- mum protection of the variable speed drive, use UL recognized fuses, type RK, suitable for circuits The variable speed AC drive has been properly mounted, adjusted, and tested prior to shipment of delivering fault currents up to 100,000A.
  • Page 40 WS CONTROLLER USER INTERFACE MANUAL SECTION 6 NORMAL VIEW Compressor Status: Temperature 1 Compressor Status: Sump Pressure Compressor Status: Line Pressure Compressor Status: Δ Separator Pressure Compressor Status: Run Hours Compressor Status: VSD Temperature Compressor Status: VSD Capacity Show Setting Change Setting Unload Pressure Unload Pressure...
  • Page 41 SECTION 6 WS CONTROLLER USER INTERFACE MANUAL VSD STATUS compressor speed will be adjusted to maintain this pressure. Most packages will allow adjustment of In addition to the general status messages displayed this parameter over a wide range, to allow tailoring to on the WS Controller, two status messages will the needs of the application.

  • Page 42: Startup Of New Vsd Compressor Package

    WS CONTROLLER USER INTERFACE MANUAL SECTION 6 STARTUP OF NEW VSD 4. Check the direction of the fan rotation. To COMPRESSOR PACKAGE observe the rotation, quickly press START then the STOP on the WS Read and follow all safety warnings and cautions in Controller.
  • Page 43 SOLUTION Charging Switch The charging switch was open when Reset the fault and restart. the START command was given due Should the fault re-occur, contact Sullair service. • faulty operation • component failure Emergency Stop An Emergency stop signal was...
  • Page 44 Upon reset of this fault, the variable speed drive will automatically reload the • faulty operation parameter default settings. Check all • component failure parameter settings after reset. If the fault reoccurs, contact Sullair service. Counter Fault Values displayed on the counters are Reset counters. incorrect µprocessor Watchdog •...
  • Page 45 Drive parameters need to be settings have been changed. downloaded. Contact Sullair service. FieldBus The data connection between the Check WS Controller bus cable. If communication bus master and the installation is correct contact Sullair communication bus board has failed service.
  • Page 46 Defective option board or slot Check that the board is properly installed and seated in slot. If the installation is correct, contact Sullair service. PT100 Board This fault is disabled. A display of this Correct drive parameters need to be message indicates that the downloaded.
  • Page 47 BLANK PAGE...
  • Page 48 ORLDWIDE ALES AND ERVICE SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A. Sullair Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82 Chiwan, Shekuo Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France Shenzen, Gunagdong PRV. www.sullair.com Telephone: 33-477968470 PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A.

This manual is also suitable for:

Ws

Table of Contents

Save PDF