Sullair 900 User Manual
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Sullair 900 User Manual

Sullair 900 User Manual

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USER MANUAL
900/1600
T4 C
I
ONTROLLER
PART NUMBER:
02250201-742 R00
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 equipement will
compressor serial number:
VOID its warranty!
201200000
and all subsequent serial numbers.

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Summary of Contents for Sullair 900

  • Page 1 USER MANUAL 900/1600 T4 C ONTROLLER PART NUMBER: 02250201-742 R00 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 portable 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 TOWING PRESSURE RELEASE FIRE AND EXPLOSION MOVING PARTS HOT SURFACES, SHARP EDGES AND SHARP CORNERS TOXIC AND IRRITATING SUBSTANCES ELECTRICAL SHOCK LIFTING 1.10 ENTRAPMENT 1.11 JUMP STARTING 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT 1.13 CALIFORNIA PROPOSITION 65 1.14 SYMBOLS AND REFERENCES SECTION 2—STARTUP PROCEDURES...
  • Page 4 TABLE OF CONTENTS SECTION 5—TROUBLESHOOTING TROUBLESHOOTING INTRODUCTION TROUBLESHOOTING GUIDE INTRODUCTION COMPASS CONTROLLER TROUBLESHOOTING GUIDE...

  • Page 5: General

    ENTIRE INSTRUCTION MANUAL. GENERAL CAUTION Sullair Corporation designs and manufactures all of Estimated hose life based on a 5-day 8-hour its products so they can be operated safely. work week is 3 years. These conditions However, the responsibility for safe operation rests exist on an 8-hour shift only.
  • Page 6 SECTION 1 A. Prior to hitching the air compressor to the tow G. If provided, make sure chain length, brake and vehicle, inspect all attachment parts and equip- electrical interconnections provide sufficient ment, checking for (i) signs of excessive wear or slack to prevent strain when cornering and corrosion, (ii) parts that are cracked, bent, maneuvering, yet are supported so they cannot...
  • Page 7 SECTION 1 Make sure tires are in good condition and are the according to posted speed limits, weather, traffic, size (load range) specified and are inflated to the road or terrain conditions: specified pressures. DO NOT change the tire 1. Two axle four-wheel or three axle six-wheel size or type.
  • Page 8 SECTION 1 E. Set parking brakes and disconnect breakaway wheeled jack as you would for the standard switch cable and all other interconnecting electri- screw jack. Raise the screw jack to its full upright position and pull the pin connecting the jack to cal and/or brake connections, if provided.
  • Page 9 SECTION 1 air hose exceeding 1/2" (13 mm) inside diameter P. The ethyl ether in the replaceable cylinders used to reduce pressure in case of hose failure. in diesel ether starting aid systems (optional) is under pressure. DO NOT puncture or incinerate E.

  • Page 10: Moving Parts

    SECTION 1 the material. DO NOT use flammable solvents inders, or maintain or troubleshoot these sys- for cleaning purposes. tems only in well-ventilated areas away from heat, open flame or sparks. DO NOT install, E. Disconnect the grounded (negative) battery con- store or otherwise expose ether cylinders to tem- nection prior to attempting any repairs or clean- peratures above 160 °F (71 °C).

  • Page 11: Hot Surfaces, Sharp Edges And Sharp Corners

    SECTION 1 TOXIC AND IRRITATING E. Make sure all personnel are out of the way and SUBSTANCES clear of the compressor prior to attempting to start or operate it. A. DO NOT use air from this compressor for respi- F. Shut off engine before adding fuel, fluid, coolant ration (breathing) except in full compliance with lubricants, air line antifreeze compound or bat- OSHA Standards 29 CFR 1920 and any other...

  • Page 12: Electrical Shock

    SECTION 1 is spilled on skin or clothing, immediately flush D. Stay clear of the compressor during electrical with large quantities of water. storms! It can attract lightning. H. Ethyl ether used in diesel engine ether starting LIFTING aid systems is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid A.

  • Page 13: 1.10 Entrapment

    SECTION 1 1.10 ENTRAPMENT Bring the starting vehicle alongside the compres- sor, but DO NOT permit metal to metal contact between the compressor and the starting vehicle. Make sure all personnel are out of compressor before closing and engaging enclosure doors. J.

  • Page 14: Implementation Of Lockout/Tagout

    SECTION 1 block away from fuel lines, the crank case 4. Turn off the equipment using normal shutdown procedure. breather opening and the battery. 5. Disconnect the energy sources: T. Start the compressor in accordance with normal procedure. Avoid prolonged cranking. a.

  • Page 15: California Proposition

    SECTION 1 1.13 CALIFORNIA b. verified that the “Authorized” person who PROPOSITION 65 applied the device is not in the facility. c. noted that all reasonable efforts to con- tact the “Authorized” person have been WARNING made to inform him or her that the lock- out or tagout device has been removed.

  • Page 16: Symbols And References

    SECTION 1 1.14 SYMBOLS AND REFERENCES The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable symbols. DIESEL PARTICULATE FILTER REGENERATION INHIBIT HIGH EXHAUST SYS. TEMP WAIT TO START REMOTE START CABIN LIGHTS / iT4...
  • Page 17 SECTION 1 Safety Symbols-2...
  • Page 18 SECTION 1 Safety Symbols-3...

  • Page 19: Introduction

    Manual Start: Start the machine by toggling the <ON> switch to the “start” position on the Controller This compressor is equipped with a Sullair Controller panel. Once the switch has been set to the “start” for controlling the compressor system operation,...

  • Page 20: Instrument Panel Group, Functional Description

    CONTROLLER USER MANUAL SECTION 2 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION 29-30 HIGH START FORCE SELECT MENU MENU CABIN REGEN PRESSURE LIGHTS TOGGLE SELECT INHIBIT EXIT Figure 2-1: Instrument Panel Group Lamp Indicators Switches/Gauges/Features Compressor OK Lamp 19. Power On/Off Switch Compressor Warning Lamp 20.

  • Page 21: Normal Operation

    SECTION 2 CONTROLLER USER MANUAL The Controller system will prevent the user from operating the compressor until all communication problems are resolved. See Section 5 of this manual for troubleshooting recommendations. ENERAL AFETY ONDITION HECKS Figure 2-3: P2 signal error screen After successful completion of the communication bus checks, the Controller system will perform safety The Controller will prevent compressor startup if...
  • Page 22 CONTROLLER USER MANUAL SECTION 2 Table 2-1: Safety Conditions User Controlled Parameter Fault Condition LCD Message Parameter Fuel Low fuel level Very Low Level Alert Low fuel level (% full) Fuel sender open circuit None Low fuel level Battery Low battery voltage None Battery Voltage Error (<18.0Vdc)

  • Page 23: Introduction

    CONTROLLER USER MANUAL Section 3 ADJUSTMENT PROCEDURE INTRODUCTION This section describes steps for using the Controller to modify specific parameters that control the machine operation. Additional parameters (UCP) can be viewed and adjusted using the PC User Interface. Figure 3-2: Display key See Figure 3-1.

  • Page 24: Settings And Diagnostic

    CONTROLLER USER MANUAL SECTION 3 SETTINGS AND achieved by using the <MENU TOGGLE> and DIAGNOSTIC <MENU SELECT> switches in the following manner:  • <UP> A toggle on the <MENU TOGGLE> switch. Use to scroll upward thru the current menu list. Once the initialization sequence is complete, the (Note that continuing to press and hold the switch operator can enter the settings and diagnostic menu...
  • Page 25 SECTION 3 CONTROLLER USER MANUAL 3.2.1 S NITS The operator can change the units of measure for all data represented on the LCD screen. All parameters displayed in any subsequent <OPERATION> modes will use the selected unit of measurement. The selected unit of measurement will be retained in nonvolatile memory for subsequent unit use.
  • Page 26 CONTROLLER USER MANUAL SECTION 3 normal shutdown automatically. Using the <MENU TART OMENTARY TOGGLE>, and <MENU SELECT> switches, this This item is only present and applicable if <ENABLE value can be adjusted in increments of 1 minute, REMOTE START> is set to yes. This setting allows from 5 minutes (minimum) to 33 minutes (maximum).
  • Page 27 SECTION 3 CONTROLLER USER MANUAL value is stored in memory, so it is retained through FTER OOLERS subsequent system power-ups. This item specifies whether or not the compressor is In Figure 3-17 displayed below, the service pressure installed with aftercoolers. See Figure 3-14. (P1) calibration screen is displayed.
  • Page 28 CONTROLLER USER MANUAL SECTION 3 In Figure 3-19 displayed below, the Compressor aborted by engaging the <START> switch to the Discharge Temperature (CDT) calibration screen is “exit” position during its execution. displayed. The same screen is available for the AUGE Aftercooler Discharge Temperature (ADT) and Hydraulic Temperature (HT) sensors.
  • Page 29 The LCD test verifies that all pixels in the Controller's indicator lights on the cluster panel. The test turns all LCD are able to turn on and off. The Sullair logo is lamps off, then toggles on each lamp one at a time, displayed in normal, reverse, and normal video in for approximately.
  • Page 30 CONTROLLER USER MANUAL SECTION 3 3.2.6 BACKLIGHT ADJUST INARY NPUTS The Binary Inputs screen displays the pin number This menu entry contains two sub-menu entries that and real-time status of each binary input defined in allow the user to set backlighting of the Controller's the system.
  • Page 31 SECTION 3 CONTROLLER USER MANUAL 3.2.7 E The information logged shutdown includes: NGINE IAGNOSTICS • Run time eng-hours accumulated The Engine Diagnostic screen is a real-time display of active operation messages being transmitted by • bit mask of all active shutdown flags the engine.
  • Page 32 CONTROLLER USER MANUAL SECTION 3 A sample screenshot is displayed below: 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 is stored, is shown.

  • Page 33: Introduction

    24V -to- 12V power supply converter signal and NOTE deactivating its switched power output signal that is fed out to Sullair components (fuel sensor and power to engine ECU). If the <START-UP> mode is entered via <REMOTE START>, then only a <START- The Controller has two hardware wake-up inputs.
  • Page 34 CONTROLLER USER MANUAL SECTION 4 4.2.3 W • Auto (Remote) Start or <REMOTE START AITING MOMENTARY> - remote start enabled. When the Controller is in <WAITING> mode the LCD display will indicate that the system is ready to be In <WAITING> mode, the Controller is analyzing started, as shown below.
  • Page 35 SECTION 4 CONTROLLER USER MANUAL 4.2.4 F and then activate the remote start input to start the AILURE TART compressor. In manual mode, if the engine does not start, the 4.2.5 R Controller will attempt another start cycle as long as the maximum number of crank attempts is not Once the compressor has completed the warm up exceeded.
  • Page 36 CONTROLLER USER MANUAL SECTION 4 4.2.6 A Both of these values are pre-set), and when the START EMOTE PERATION remote start binary input is deactivated. If <WAITING> mode is exited due to a remote (i.e., When the system enters the manual <SHUTDOWN> Automatic) start trigger, a momentary alert state, mode, the compressor will complete the following during which the Controller alerts that an automatic...
  • Page 37 SECTION 4 CONTROLLER USER MANUAL Figure 4-8: Normal shutdown sequence momentary switch, shutdown is initiated when 4. 4. Monitor System Pressures remote start input transitions from closed (active) to a. Display new LCD message open (inactive). In either case, the following shutdown sequence then occurs: b.
  • Page 38 CONTROLLER USER MANUAL SECTION 4 4.2.8 • Battery Voltage AUGES ISPLAY • % Engine Load The air pressure gauge is driven by the air pressure • Fuel Rate sender analog input. Open and shorts of the P1 pressure sender analog input is considered out of •...
  • Page 39 SECTION 4 CONTROLLER USER MANUAL 2. When currently in the <RUN> mode and the 5. P1,P2,P3 Signal Error Controller system was auto started, the sys- 6. Engine Comm Error tem service pressure P1 exceeds the UCP specified level for a UCP specified duration 7.
  • Page 40 CONTROLLER USER MANUAL SECTION 4 4.2.13 A BNORMAL HUTDOWN VENTS Abnormal shutdown information is stored and retained across power-up sessions of the system in the Controller memory. The abnormal shutdown event data can be retrieved, displayed and analyzed using the Communicator Software program. Refer to Section 5 for steps to troubleshooting abnormal shutdown events.
  • Page 41 Should your problem persist after making the recommended check, consult your nearest Sullair Distributor or the Sullair Corporation factory service department.
  • Page 42 CONTROLLER USER MANUAL SECTION 5 COMPASS CONTROLLER TROUBLESHOOTING GUIDE Error Message Warning/Shutdown/ Description Recommended Action Prevent Startup 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.
  • Page 43 SECTION 5 CONTROLLER USER MANUAL Error Message Warning/Shutdown/ Description Recommended Action Prevent Startup Primary Shutdown Shutdown/Prevent After filter restriction too high (filters Replace filters. Startup dirty) After filters dp module malfunction Check source voltage and ground and correct if necessary. Visually inspect for damage and replace if necessary.
  • Page 44 CONTROLLER USER MANUAL SECTION 5 Error Message Warning/Shutdown/ Description Recommended Action Prevent Startup Fuel Sender Error Warning The fuel level sensor signal is out of Check connections at range sensor on tank. Verify source voltage and ground. Wires possibly reversed. Fuel sensor is defective.
  • Page 45 SECTION 5 CONTROLLER USER MANUAL Error Message Warning/Shutdown/ Description Recommended Action Prevent Startup Comp Air Filter Warning DP2 switch, normally closed, has Engine air filters clogged. opened for the specified amount of Replace filters. time Check circuit for continuity Check the air filter switch for continuity.
  • Page 46 CONTROLLER USER MANUAL SECTION 5 Error Message Warning/Shutdown/ Description Recommended Action Prevent Startup 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.
  • Page 47 SECTION 5 CONTROLLER USER MANUAL 5.3.1 C The following settings are configurable using the ONTROL ARAMETERS Controller communicator program. Note that Control parameters for the Controller are shown in parameters listed in bold font below affect the Table 5-1. The Parameter Description column threshold at which abnormal shutdowns may occur.
  • Page 48 CONTROLLER USER MANUAL SECTION 5 Fuel Level Default Value Range/Option Cancel Low Level Alert (% full) 13-43 Low Level Alert (% full) 10-40 Cancel Very Low Level Alert (% full) 7-13 Very Low Level Alert (% full) 4-10 Fuel Tank/Level Sensor None None 185-724...
  • Page 49 SECTION 5 CONTROLLER USER MANUAL Primary Control PWM 1 (%) Primary Control PWM 2 (%) Primary Control PWM 3 (%) Primary Control PWM 4 (%) Primary Control PWM 5 (%) Primary Control PWM 6 (%) Primary Control Temperature 0 (°F) Primary Control Temperature 1 (°F) Primary Control Temperature 2 (°F) Primary Control Temperature 3 (°F)
  • Page 50 CONTROLLER USER MANUAL SECTION 5 Inactivity Timeout (minutes) 5-20 P1,2,3 Pressure for Cooldown Completion (PSI) 5-15 P2 Pressure for max RPM at run-time (PSI) 0-10 600 psi low-pressure discharge alarm armed? (applies only to 600 psi No/Yes UCP systems) Miscellaneous Settings Default Value Range/Option Warmup Complete Speed (RPM)
  • Page 51 NOTES...
  • Page 52 Always air. Always there. WWW.SULLAIR.COM SULLAIR CORPORATION 3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A. Telephone: 1-219-879-5451 Printed in the U.S.A. Specifications subject to change without prior notice. E12EP...

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