Micro Compressor Controller (MCC)

Operation Manual

SHENZHEN SULLAIR ASIA INDUSTRIAL CO., LTD .

Part No.: 88290016-026
Rev. 06– Feb 2009
 Preface

This manual describes the system structure, function, usage and

maintenance method for Micro Compressor Controllers.
Before installing and operating this machine, customer shall
carefully read this manual. After fully understanding the structure and
function of each part of the machine set can they operate and maintain the
machine set.
From time to time, the product is being redesigned to seek
improvement. After certain period, there will be discrepancies between
this manual and the product itself. The user should be aware of it.
If there is any point that is not described in this manual but is
unclear during the operation and use by the user, you can contact your
local distributor of Sullair co., or Customer Care by Sullair of Sullair Co.

——Editor
January, 2008
 TABLE OF CONTENTS

1. GENERAL INFORMATION ..............................................................................................1

2. SAFETY INSTRUCTION ....................................................................................................1
3. INTRODUCTION.................................................................................................................2
4. SPECIFICATION..................................................................................................................2
5. OPERATORS' INTERFACE ...............................................................................3
6. DISPLAYS, CONFIGURATION & SETPOINTS................................................................4
6.1 STARTUP ............................................................................................................................4
6.2 STATUS DISPLAY..............................................................................................................4
6.3 SETUP GUIDE ....................................................................................................................4
6.4 CUSTOMER SETTING ......................................................................................................5
7. INSTALLATION ..................................................................................................................6
7.1 MECHANICAL INSTALLATION ......................................................................................6
7.2 ELECTRICAL WIRING DIAGRAM..................................................................................7
7.3 CONTROLLER CONNECT TERMINALS........................................................................7
8. CONTROL FUNCTIONS.....................................................................................................8
8.1 AUTOMATIC CONTROL – LOCAL MODE.....................................................................8
8.2 AUTOMATIC CONTROL – REMOTE MODE..................................................................8
9. ALARM AND FAILURE PROTECTION...........................................................................9
9.1 FAILURE STOP AND EMERGENCY STOP .....................................................................9
9.2 AIR FILTER ALARM .........................................................................................................9
9.3 OIL FILTER ALARM..........................................................................................................9
9.4 OIL SEPARATOR ALARM.................................................................................................9
9.5 FLUID ALARM...................................................................................................................9
9.6 GREASE ALARM ...............................................................................................................9
9.7 HIGH DISCHARGE PROTECTION ..................................................................................9
9.8 COMPRESSOR ANTI-REVERSION PROTECTION........................................................9
9.9 SENSOR FAILURE PROTECTION ...................................................................................9
10. TROUBLESHOOTING GUIDE........................................................................................10
11. MCC CONTROLLER REPLACEMENT AND SET-UP INSTRUCTIONS..................... 11
 Micro Compressor Controller (MCC) Operation Manual

1. GENERAL INFORMATION
Warning:
DO NOT install, operate, maintain, adjust or service Micro Compressor Controllers
without thoroughly reading this manual.

Disclaimer:
The information in this document is subject to change without notice. While Sullair
assumes and believes the information contained herein to be accurate, the company
assumes no responsibility for any errors or omissions.

Copyright notice:
No part of this document may be reproduced in any form without prior written consent of
Sullair. The software described in this document is furnished under a license and may
only be used or copied in accordance with the terms of the license.

2. SAFETY INSTRUCTION
When using air compressors and compressed air accessories, basic safety rules and
precautions must always be followed including the following:
I) Read all instructions fully.
II) Electrical Safety Precautions.

! WARNING : Risk of Danger

WARNING : Risk of Electric Shock

WARNING : Risk of High Pressure

!

WARNING : Consult Manual

When installing, commissioning, operating or carrying out maintenance on the MCC unit, the
respective persons must use safe working practices and observe all relevant local health and
safety requirements and regulations.

Use extreme cautions when carrying out electrical checks. Isolate the power supply before
starting any maintenance work.

Do not operate the MCC unit with damaged wiring/ parts after the controller unit have been
dropped or damaged in any manner. Notify authorized service facility for examination, repair
or other adjustments.

It is not possible to anticipate every circumstance, which might represent a potential hazard. If
the user employs an operating procedure, an item of equipment or a method of working which
is not specifically recommended, the user must ensure that unit will not be damaged or made
unsafe and that there is no risk to persons or property. Failure to observe safety precautions or
implement safe working practices may be considered dangerous practice or misuse of the
product.

Page 1 of 12
 Micro Compressor Controller (MCC) Operation Manual

3. INTRODUCTION

Micro Compressor Controller (Abbr. MCC) displays temperature, pressure, operation time
and working status of the compressor through 2×8 liquid crystal display (LCD).

The information can be displayed in Chinese or English or other languages (The language
requirement should be stated in sales order).Compressor information can be uploaded via
RS485 Modbus protocol.

Operator can control the compressor, set parameters and display needed parameters through
the keypad on the control panel. Indicator lights on the panel reflect the basic status of the
device (refer to Fig.1).

4. SPECIFICATION
1. Digital Inputs: Digital input 4-channel
2. Digital Output: Digital switching output 5-channel.
3. Analog Inputs: Pt1000 temperature input 1-channel; 4～20mA transferred
input 1-channel;
4. USB port for program downloads in different languages.
5. Power supply: 90-130VAC, 50/60HZ, 40mA .
6. Display ranges
a) Temperature: -20～150℃; Accuracy: ±1℃
b) Run time: 0～999999H
7． Temperature Protection: When the actual temperature is higher than the rated
allowed temperature, the function will be activated in less than 2s.
8. Output relay contactor capacity: 250VAC/5A; 500000 switching times;
9. Ambient temperature: -20°C – 65°C

Page 2 of 12
 Micro Compressor Controller (MCC) Operation Manual

5. OPERATORS' INTERFACE

Fig. 1

Pantone RAL6021 Pantone Pantone White

423 Black 7 Red 032

Start Key: Press this key to start the compressor.

Stop Key: Press this key to stop the compressor (when pressing this key, the
compressor immediately turns to unload mode and stops after ** seconds (which can be set in
CUSTOMER SET). If the compressor has been unloaded for ** seconds (saved number)
before pressing the key, the unit will stop immediately.)

S Set key / Load / Unload: Press this key to save modified data. When compressor is
running, press this key to send load or unload command to the compressor.
▲ Up key: Press this key to move upward (add) in data modification or move upward
scroll in menu operation.
▼ Down key: Press this key to move downward (reduce) during data modification or
downward scroll in menu operation.
► Cursor/Confirm Key: This key is treated as cursor during data modification and as
confirm key during menu selection
Return / Reset Key: Press this key to return to upper menu during the menu operation
/ long held to reset the unit current state when the compressor is stopped due to a failure.
Press this key to stop buzzing.

Page 3 of 12
 Micro Compressor Controller (MCC) Operation Manual

6. DISPLAYS, CONFIGURATION & SETPOINTS

6.1 STARTUP

After power on, the MCC will display the following two interfaces. Each menu lasts up to 3
seconds before turn to main interface, e.g.:

SULLAIR RUN: xxxxxx H

CO3-CXXXXXX REV:03 2007/01
SULLAIR is the logo of SULLAIR Corporation.
CO3-CXXXXXX is the serial number of the compressor unit.
RUN: XXXXXX H is overall operation time of the device.
REV: 03 is the software version.
2007/01 is shipping date of MCC.

The main interface:

STOP
180℉ 75PSI

6.2 STATUS DISPLAY

Press “▼” key to read the running parameters directly. For example, if pressing “▼” key
for the first time, the overall operation time displayed as bellow.

TOTAL RUN TIME:

****** H **M

Press “▼” key to read the following status:

LOADED TIME FLUID PRODUCTION DATE

GREASE SERIAL NO.
THIS RUN TIME ALARM1 CUSTOMER SET
THIS LOADING ALARM2 FACTORY SET
OIL FILTER ALARM3
A-O SEPARATOR ALARM4
AIR FILTER ALARM5

6.3 SETUP GUIDE

Note: The customer and factory parameters are prevented from being modified
while the unit is running or in the stop delaying period.

Navigate to the last two menus: ‘CUSTOMER SET’ and ‘FACTORY SET’ by pressing
‘▼’,or by pressing ‘▲’ on the main interface to the ‘CUSTOMER SET’ and ‘FACTORY
SET’ immediately.

CUSTOMER SET
FACTORY SET

Ö From a menu, the various items within it can be viewed by scrolling with the “▼” or

Page 4 of 12
 Micro Compressor Controller (MCC) Operation Manual

“▲” key.
Ö Menus are accessed with the “►”key, pressing this key will a sub-menu is displayed will
activated that particular sub-menu:
LOAD PRESS:
006.5BAR

Ö To scroll to another sub-menu press “▼”.

Ö To modify parameter within the same menu, press “►” on the parameter, the password
input screen will be displayed.
PASSWORD ****

Note: Customer password can be modified in customer parameter.

If the entered password is correct the parameter to be modified will return to the display and
flash.
Ö The parameter now can be modified by pressing “▼” or “▲” key.
Ö To modify another parameter within the same menu,”►” is used to move the cursor to
the next number. Press “S” key as confirmation.
Ö To modify other parameters within the same menu, scroll to the new parameter and
depress “►”key.
Ö To end the parameters modification, press “ “key to return to the main interface.

6.4 CUSTOMER SETTING

All the customer parameters have been preset by SULLAIR according to SULLAIR product
requirements.

Parameter Preset Value Description

LOAD PRESS ***.* BAR Load pressure value
UNLOAD PRESS ***.* BAR Unload pressure value
To protect motor, MTR START TIME must be longer than the
MTR START TIME 0008 S
STAR DELTA TIME plus LOAD DELAY TIME
When set as DRAIN, the No. 18 terminal is the connector for
drain control, draining periodically. When ON/OFF MODE is
DRAIN/REMOTE Remote
set as REMOTE and here set as REMOTE, the No. 18 terminal
is the connector for remote control indication.
Y-△ starting transition time. For full voltage starting, set the
STAR-DELTA TIME 0006S
value as “0”
The delayed time from star-delta transition or full-voltage
LOAD DELAY TIME 0002S
starting completion to be on loading.
UNLOAD RUN TIME 1200S Maximum time from unloading to standby mode.
STOP DELAY TIME 0010S The delayed time from pressing the stop key to be shutdown.
RESTART TIME 0060S Delay time before restart.
Press key to enable remote control mode. If compressor is
ON/OFF MODE LOCAL
shutdown by pressing , remote control will be disabled.
The Load / Unload function can be modified by pressing “S”
LOAD MODE AUTO
key in manual mode.

Page 5 of 12
 Micro Compressor Controller (MCC) Operation Manual

CLEAR OIL FILT 0000H Reset time after oil filter changed
CLEAR A-O SEP 0000H Reset time after oil separator changed
CLEAR AIR FILT 0000H Reset time after air filter changed
CLEAR FLUID ALM 0000H Reset time after fluid changed
CLEAR GREASE AL 0000H Reset time after grease changed
OIL FILT CHANGE 1000H Set to ‘0000H’ to disable the oil filter alarm function
A-O SEP CHANGE 4000H Set to ‘0000H’ to disable the oil separator alarm function
AIR FILT CHANGE 1000H Set to ‘0000H’ to disable the air filter alarm function
FLUID CHANGE 8000H Set to ‘0000H’ to disable the fluid alarm function
GREASE REQ 2000H Set to ‘0000H’ to disable the grease alarm function
USER PASSWORD **** To modify the customer password
If DISABLE, communication cannot work. If SEQ, multiple
COM MODE: PC machines can work in sequence mode. If PC, communicate as
slave with external equipment according to MODBUS protocol
COM ADDRESS 0001 Communication address
Master or Slave mode when there are more than one
SEQUENCE STATE MASTER
compressors running in SEQUENCE mode
SEQUENCE NO. 0004 Total number of compressors in sequence network.
During sequence control, when master pressure is lower than
SEQ LOAD PRESS ***.*BAR SEQ LOAD PRESS, and SEQ DELAY is up, the master will
find a compressor in the net to load or start.
During sequence control, when master pressure is higher than
SEQ UNLOAD PR ***.*BAR SEQ UNLOAD PR, and SEQ DELAY is up, the master will
find a loading compressor in the net to unload or stop.
During sequence control, continuously send control interval
SEQ DELAY 0015S
time.
LANGUAGE SEL CHINESE Select display languages

Draining time in auto drain control (only effective in on load

DRAIN OPEN 0010S
mode)
DRAIN CLOSE 0003M Interval time in draining (only effective in on load mode)

TEMP UNITS ℃ Temperature unit can be set as ℃ or ℉.

PRESSURE UNITS BAR Pressure unit can be set as BAR or PSI

ROTATE HOURS 0001H Rotate hours between slaves in sequencing network

7. INSTALLATION

7.1CONTROLLER INSTALLATION

The controller is installed with bolts’ size 72 x 122. Certain space should be left around controller
for wiring. The specific dimensions are as follows:

Page 6 of 12
 Micro Compressor Controller (MCC) Operation Manual

Fig.2 Controller outline dimensions

7.2 ELECTRICAL WIRING DIAGRAM

REMOTE START/STOP

MOTOR OVERLOAD

E-STOP

COM 1

RS485 A

RS485 B
P

FR1
T 28
E-STOP

s
p SW1 a

1 2 3 4 5 6 7 8 9 10 11 12

MCC
POWER
AC 110V
13 15 17 18 19 20 21 22 23 24 25 26

PE
KM3 KM2
a
33 35 E-STOP

E-STOP AC 110V
YV1 KM1 KM2 KM3

26
DRAIN/ LOAD/ Main Y △
REMOTE UNLOAD
PE

Figure 3. Electrical wiring diagram

7.3 CONTROLLER CONNECT TERMINALS

Controller terminals:

Page 7 of 12
 Micro Compressor Controller (MCC) Operation Manual

4 and 5 are RTD signal input; 6 is remote controlled on/off signal input terminal; 7 is PR XDCR
signal input terminal; 8 is input terminal for overheat signal of fan motor; 9 is input terminal for
emergent stop signal; 10 is common terminal for input signals; 11 is RS485 A; 12 is RS485 B;
18 is electronic drain valve/remote control (optional) output; 19 loading valve; 20 controls main
contact switch; 21 star contactor; 22 delta contactor; 23 is common terminal COM1 of output relay;
24 is the analog grounding; 25 and 26 are the AC 110V power source input.

NOTE! The magnetic coils of valves and contactor must be connected to a surge
absorber.

8. CONTROL FUNCTIONS
8.1 AUTOMATIC CONTROL – LOCAL MODE
(Load mode: Automatic On/off, local start control mode)

① MOTOR STARTING:
The controllers perform a 6 seconds self-checking after power on during which the key can
not start the machine. Starting procedure of compressor is: KM1 (Main/Line contactor) power on
Æ, Motor in Y startingÆTransition time over(Y—△ transition time) ,KM2 power off(KM2 and
KM3 interlocked)ÆMotor running in △ mode, motor starting over.
Note: All the solenoid valves are power off during the motor starting to ensure the no-load starting.
If compressor is full voltage (not Y—△) starting, power on KM1.

② AUTOMATIC RUNNING CONTROL:

The load solenoid valve power on after the motor is running in △ mode for certain time (LOAD
DELAY TIME), the inlet valve opens and pressure rises.
The load solenoid valve will power off when the air pressure reaches the rated unload pressure
(UNLOAD PRESS), the compressor will change into unload process.
If in the specified time (UNLOAD RUN TIME) the air pressure turns to be lower than the set load
pressure (LOAD PRESS), the load solenoid valve will restart and the compressor will changes
into on-load process.
If the unload run time exceeds the “UNLOAD RUN TIME” set in the customer parameters, the
compressor will automatically stop.
Only if the pressure reaches lower than the load pressure limit (LOAD PRESS), the compressor
will restart according to the normal starting process and so on.

③ NORMAL STOPPING:
By pressing the key the load solenoids valve powers off, after certain time (STOP DELAY
TIME), all controller relays will power off, main and fan motor stop running. The compressor can
be restarted only after the restart delay time decrease to “0”.

④ ANTI-FREQUENTLY-STARTING CONTROL
The motor can not be started immediately after stopping unless after (RESTART TIME), or if the
compressor stopped after (UNLOAD RUN TIME). Whatever the situation is, the controller will
display remain time of delay (such as 90s). The motor can only be started when the delay time is
0.
8.2 AUTOMATIC CONTROL – REMOTE MODE
(Load mode: Automatic On/off, Remote start control mode)

① MOTOR STARTING:
The controller performs a 6 second self-check prior to press the ‘ ’ key to start the machine. If
“DRAIN/REMOTE” is set as remote, the No.18 terminal serves as remote control enable signal
input. After key has been pressed, the compressor can be started or stopped by controller No.

Page 8 of 12
 Micro Compressor Controller (MCC) Operation Manual

6 terminal. Start signal is to be received via the No.6 terminal, the motor starts as in the local
control mode.

② AUTOMATIC RUNNING CONTROL:

Refer to the local automatic running mode.

③ REMOTE STOPPING:
To signal a remote stop, terminals 6 and 10 must be open circuit and then the load solenoid valve
will lose power, all controller relays will lose power after the stop delay time (STOP DELAY
TIME), the main and fan motor will stop running thus remotely stopped the compressor. Only
when the restart delay time counts to “0” can the compressor be restarted remotely by remote start
signal from terminals 6 and 10. Only when user presses the local key will the remote
start/stop enable signal clear off, the compressor can not be started by remote control.

④ FREQUENT STARTING PREVENTION CONTROL

Refer to local starting procedure descript above.

9. ALARM AND FAILURE PROTECTION

9.1 FAILURE STOP AND EMERGENCY STOP
When there is any electronic sensor failure, overload failure or high discharge temperature failure,
the controller will stop the motor running immediately. The motor can only be restarted after the
failures are cleared.
The emergency stop key is to be pressed to cut off the power supply of the controller and
contactors in any emergent errors situation, which will immediately stop the compressor motor.

9.2 AIR FILTER ALARM

When air filter reaches the set run time limit, the display will read “AIR FILTER ALM”.

9.3 OIL FILTER ALARM

When oil filter reaches the set run time limit, the display will read “OIL FILTER ALM”.

9.4 OIL SEPARATOR ALARM

When oil separator reaches the set run time limit, the display will read “A-O SEPARATOR”.

9.5 FLUID ALARM

When lube reaches the set run time limit, the display will read “FLUID CHANGE”.

9.6 GREASE ALARM

When grease reaches the set run time limit, the display will read “GREASE CHANGE”

9.7 HIGH DISCHARGE PROTECTION

When discharge temperature exceeds the set temperature limit, the controller will alarm or stop,
the display will read “HIGH DISCH TEMP”

9.8 SENSOR FAILURE PROTECTION

When a pressure or temperature sensor fails, controller will alarm and stop. The failure displayed
on the controller is “PR XDCR FAULT” or “RTD FAULT”.

Page 9 of 12
 Micro Compressor Controller (MCC) Operation Manual

10. TROUBLESHOOTING GUIDE

Example: The fault caused by exterior parts can be display on the control panel. e.g.
STOP:
RTD FAULT

In this condition check the temperature sensor to see whether wire is broken or damaged.

The relevant warning information shall popup on the screen in case of other faults.

The following table listed minor issues, causes and solutions.

Alarm Causes Solutions

Improper parameter setting and

OIL FILTER ALM Parameter adjustment, maintenance
consumable life expires
Improper parameter setting and
A-O SEPARATOR Parameter adjustment, maintenance
consumable life expires
Improper parameter setting and
AIR FILTER ALM Parameter adjustment, maintenance
consumable life expires
Improper parameter setting and
FLUID CHANGE Parameter adjustment, maintenance
consumable life expires
Improper parameter setting and
GREASE CHANGE Parameter adjustment, maintenance
consumable life expires
Poor cooling, oil shortage, Parameter adjustment, vent
HIGH DISCH TEMP
improper parameter setting enhancement, proper lubrication

The following table lists big issues, causes and solutions.

Faults Causes Solutions

Wire broken, transducer damaged, Check wiring, replace damaged

PR XDCR FAULT
etc transducer

RTD FAULT Cable off, PT1000 failure, etc Check wiring, Replace PT1000

High temperature, inaccurate Check machine temperature

HIGH DISCH TEMP
sensor and wrong parameter sensors, check parameter
Over pressure, inaccurate sensor Check machine pressure, pressure
HIGH PRESSURE
and wrong parameter sensor, check parameter
Low voltage, high pressure,
Check the set data, Voltage,
MOTOR bearing failure, separator blocked
bearings, separator tubes and other
OVERLOAD or other mechanical damages or
mechanical faults
data distortion etc.

Main contactor failure Emergency stop key wiring loose Check wiring. Check Contactor

Page 10 of 12
 Micro Compressor Controller (MCC) Operation Manual

11. MCC CONTROLLER REPLACEMENT AND SET-UP

INSTRUCTIONS

1 Read Section 1—Safety in MCC Controller User Interface Manual. Follow all safety
guidelines.
2 Disconnect incoming power.
3 Open starter enclosure door and unplug connectors from existing controller.
4 Loosen screws on installation clips and remove controller.
5 Install new controller and gasket.
6 Plug connectors into controller, close enclosure door and turn on power to machine.
7 Modify setting accordingly
8 Confirm pressure setting as follows:
ٛ a. Slowly open the shut-off valve to the service line.
ٛ b. Press the START pad to start the compressor in default mode (AUTO).
ٛ c. Check for leaks in service air piping.
ٛ d. Slowly close the service line shut-off valves to verify nameplate pressure unload setting.
The compressor should unload when nameplate pressure is achieved.
9 Adjust other customer settings (maintenance intervals, units, operating mode) as desired.
Refer to the Micro Compressor Controller Operation Manual
Section 6.4— Customer setting

Page 11 of 12
 Global Sales and Service

Headquarter USA: SULLAIR CORPORATION

Subsidiary of Hamilton-Sundstrand Corporation, a UTC company

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)

SULLAIR EUROPE

Zone Des Granges BP 82

42602 Montbrison Cedex, France
Telephone: 0033-4-77968470
Fax: 0033-4-77968499

SULLAIR ASIA

Zuo Paotai Road, Chiwan, Shekou, Shenzhen, P. R. China 518068

Tel: 0755-26851686
Fax: 0755-26853473, 26853475
Service hotline: 800-830-3977

SULLAIR AUSTRALIA

11-15 Marlo Place, Hallam, Victoria 3803, Australia

Tel: 61-3-9703-8000
Fax: 61-3-9703-8077