USER MANUAL

WS CONTROLLER USER INTERFACE MANUAL

PART NUMBER:
02250202-046 R01
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
SULLAIR CORPORATION
and procedures in this manual or, The information in this manual is current as
of its publication date, and applies to
misuse of this equipment will software part number:
VOID its warranty!
02250201-216
and all subsequent software part numbers.
 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 Stationary 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.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.

For detailed course outlines, schedule, and cost information contact:

SULLAIR TRAINING DEPARTMENT

1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
[email protected]
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
 TABLE OF CONTENTS
SECTION 1—SAFETY
5 1.1 GENERAL
5 1.2 PERSONAL PROTECTIVE EQUIPMENT
5 1.3 PRESSURE RELEASE
6 1.4 FIRE AND EXPLOSION
6 1.5 MOVING PARTS
7 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
7 1.7 TOXIC AND IRRITATING SUBSTANCES
8 1.8 ELECTRICAL SHOCK
8 1.9 LIFTING
9 1.10 ENTRAPMENT
9 1.11 SAFETY WARNINGS

SECTION 2—STARTUP PROCEDURES

11 2.1 INTRODUCTION
11 2.2 WS CONTROLLER PANEL LAYOUT
12 2.3 WS START UP PROCEDURES
13 2.4 SHUTDOWN PROCEDURE

SECTION 3—ADJUSTMENTS
15 3.1 INTRODUCTION
15 3.2 COMPRESSOR ADJUSTMENT PROCEDURES
16 3.3 USER ADJUSTABLE CONTROL PARAMETERS
18 3.4 CALIBRATION OF P2 PRESSURE TRANSDUCERS
18 3.5 REMOTE UNLOAD

SECTION 4—DESCRIPTION
19 4.1 INTRODUCTION
19 4.2 TOUCH PAD BUTTON DESCRIPTION
19 4.3 INDICATOR LED DESCRIPTION
20 4.4 DISPLAY SCREEN
21 4.5 OPERATING MODES
TABLE OF CONTENTS

21 4.6 OPERATING STATES

22 4.7 NORMAL VIEW SERVICE REMINDERS
23 4.8 WARNING MESSAGES
24 4.9 FAULT MESSAGES
25 4.10 DIAGNOSTIC VIEWS

SECTION 5—TROUBLESHOOTING
27 5.1 TROUBLESHOOTING INTRODUCTION
27 5.2 TROUBLESHOOTING GUIDE
32 5.3 WS CONTROLLER FAULTS AND WARNINGS
32 5.4 MACHINE BEHAVIOR AFTER A POWER INTERRUPTION
32 5.5 INTERNAL BATTERY

SECTION 6—VARIABLE SPEED DRIVE

35 6.1 OVERVIEW
35 6.2 INSTALLATION
 Section 1

SAFETY
the precautionary statements contained herein are
NOTE applicable to most compressors and the concepts
behind these statements are generally applicable to
all compressors.

1.2 PERSONAL PROTECTIVE

EQUIPMENT
A. Prior to installing or operating the compressor,
OPERATOR IS REQUIRED TO READ
owners, employers and users should become
ENTIRE INSTRUCTION MANUAL.
familiar with, and comply with, all applicable
OSHA regulations and/or any applicable Federal,
State and Local codes, standards, and regula-
1.1 GENERAL tions relative to personal protective equipment,
Sullair Corporation and its subsidiaries design and such as eye and face protective equipment,
manufacture all of their products so they can be respiratory protective equipment, equipment
operated safely. However, the responsibility for safe intended to protect the extremities, protective
operation rests with those who use and maintain clothing, protective shields and barriers and elec-
these products. The following safety precautions are trical protective equipment, as well as noise
offered as a guide which, if conscientiously followed, exposure administrative and/or engineering con-
will minimize the possibility of accidents throughout trols and/or personal hearing protective equip-
the useful life of this equipment. ment.

The compressor should be operated only by those 1.3 PRESSURE RELEASE

who have been trained and delegated to do so, and
who have read and understood this Operator's A. Install an appropriate flow-limiting valve between
Manual. Failure to follow the instructions, procedures the service air outlet and the shut-off (throttle)
and safety precautions in this manual may result in valve, either at the compressor or at any other
accidents and injuries. NEVER start the compressor point along the air line, when an air hose exceed-
unless it is safe to do so. DO NOT attempt to operate ing 1/2" (13mm) inside diameter is to be con-
the compressor with a known unsafe condition. Tag nected to the shut-off (throttle) valve, to reduce
the compressor and render it inoperative by pressure in case of hose failure, per OSHA Stan-
disconnecting and locking out all power at source or dard 29 CFR 1926.302(b)(7) and/or any applica-
otherwise disabling its prime mover so others who ble Federal, State and Local codes, standards
may not know of the unsafe condition cannot attempt and regulations.
to operate it until the condition is corrected.
B. When the hose is to be used to supply a mani-
Install, use and operate the compressor only in full fold, install an additional appropriate flow-limiting
compliance with all pertinent OSHA regulations and/ valve between the manifold and each air hose
or any applicable Federal, State, and Local codes, exceeding 1/2" (13mm) inside diameter that is to
standards and regulations. DO NOT modify the be connected to the manifold to reduce pressure
compressor and/or controls in any way except with in case of hose failure.
written factory approval.
C. Provide an appropriate flow-limiting valve at the
While not specifically applicable to all types of beginning of each additional 75 feet (23m) of
compressors with all types of prime movers, most of hose in runs of air hose exceeding 1/2" (13mm)

5
 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. If necessary,
flow-rated. Select appropriate valves accordingly,
remove acoustical material, clean all surfaces
in accordance with their manufacturer's recom-
and then replace acoustical material. Any acous-
mendations.
tical material with a protective covering that has
E. DO NOT use air tools that are rated below the been torn or punctured should be replaced
maximum rating of the compressor. Select air immediately to prevent accumulation of liquids or
tools, air hoses, pipes, valves, filters and other fluid film within the material. DO NOT use flam-
fittings accordingly. DO NOT exceed manufac- mable solvents for cleaning purposes.
turer's rated safe operating pressures for these
D. Disconnect and lock out all power at source prior
items.
to attempting any repairs or cleaning of the com-
F. Secure all hose connections by wire, chain or pressor or of the inside of the enclosure, if any.
other suitable retaining device to prevent tools or
E. Keep electrical wiring, including all terminals and
hose ends from being accidentally disconnected
pressure connectors in good condition. Replace
and expelled.
any wiring that has cracked, cut, abraded or oth-
G. Open fluid filler cap only when compressor is not erwise degraded insulation, or terminals that are
running and is not pressurized. Shut down the worn, discolored or corroded. Keep all terminals
compressor and bleed the receiver tank to zero and pressure connectors clean and tight.
internal pressure before removing the cap.
F. Keep grounded and/or conductive objects such
H. Vent all internal pressure prior to opening any as tools away from exposed live electrical parts
line, fitting, hose, valve, drain plug, connection or such as terminals to avoid arcing which might
other component, such as filters and line oilers, serve as a source of ignition.
and before attempting to refill optional air line
G. Remove any acoustical material or other material
anti-icer systems with antifreeze compound.
that may be damaged by heat or that may sup-
I. Keep personnel out of line with and away from port combustion and is in close proximity, prior to
the discharge opening of hoses or tools or other attempting weld repairs.
points of compressed air discharge.
H. Keep suitable fully charged Class BC or ABC fire
J. DO NOT use air at pressures higher than 2.1 bar extinguisher or extinguishers nearby when ser-
for cleaning purposes, and then only with effec- vicing and operating the compressor.
tive chip guarding and personal protective equip-
I. Keep oily rags, trash, leaves, litter or other com-
ment per OSHA Standard 29 CFR 1910.242 (b)
bustibles out of and away from the compressor.
and/or any applicable Federal, State, and Local
codes, standards and regulations. J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate
K. DO NOT engage in horseplay with air hoses as
flow of lubricant or with degraded lubricant.
death or serious injury may result.
K. DO NOT attempt to operate the compressor in
1.4 FIRE AND EXPLOSION any classification of hazardous environment
unless the compressor has been specially
A. Clean up spills of lubricant or other combustible designed and manufactured for that duty.
substances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool. 1.5 MOVING PARTS
Then keep sparks, flames and other sources of
A. Keep hands, arms and other parts of the body
ignition away and DO NOT permit smoking in the
and clothing away from couplings, belts, pulleys,
vicinity when checking or adding lubricant or
fans and other moving parts.
when refilling air line anti-icer systems with anti-
freeze compound. B. DO NOT attempt to operate the compressor with
the fan, coupling or other guards removed.
C. DO NOT permit fluids, including air line anti-icer
system antifreeze compound or fluid film, to

6
SECTION 1

C. Wear snug-fitting clothing and confine long hair

when working around this compressor, especially
when exposed to hot or moving parts. DANGER
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.
F. Disconnect and lock out all power at source and
verify at the compressor that all circuits are de- Death or serious injury can result from
energized to minimize the possibility of acciden- inhaling compressed air without using
tal start-up, or operation, prior to attempting proper safety equipment. See OSHA stan-
repairs or adjustments. This is especially impor- dards and/or any applicable Federal, State,
tant when compressors are remotely controlled. and Local codes, standards and regulations
on safety equipment.
G. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water or other
liquids to minimize the possibility of slips and B. DO NOT use air line anti-icer systems in air lines
falls. supplying respirators or other breathing air utili-
zation equipment and DO NOT discharge air
from these systems into unventilated or other
1.6 HOT SURFACES, SHARP confined areas.
EDGES AND SHARP
CORNERS C. Operate the compressor only in open or ade-
quately ventilated areas.
A. Avoid bodily contact with hot fluid, hot coolant,
hot surfaces and sharp edges and corners. D. Locate the compressor or provide a remote inlet
so that it is not likely to ingest exhaust fumes or
B. Keep all parts of the body away from all points of other toxic, noxious or corrosive fumes or sub-
air discharge. stances.
C. Wear personal protective equipment including E. Coolants and lubricants used in this compressor
gloves and head covering when working in, on or are typical of the industry. Care should be taken
around the compressor. to avoid accidental ingestion and/or skin contact.
D. Keep a first aid kit handy. Seek medical assis- In the event of ingestion, seek medical treatment
tance promptly in case of injury. DO NOT ignore promptly. Wash with soap and water in the event
small cuts and burns as they may lead to infec- of skin contact. Consult Material Safety Data
tion Sheet for information pertaining to fluid of fill.
F. Wear goggles or a full face shield when adding
1.7 TOXIC AND IRRITATING antifreeze compound to air line anti-icer systems.
SUBSTANCES G. If air line anti-icer system antifreeze compound
A. DO NOT use air from this compressor for respi- enters the eyes or if fumes irritate the eyes, they
ration (breathing) except in full compliance with should be washed with large quantities of clean
OSHA Standards 29 CFR 1910 and/or any appli- water for fifteen minutes. A physician, preferably
cable Federal, State or Local codes or regula- an eye specialist, should be contacted immedi-
tions. ately.
H. DO NOT store air line anti-icer system antifreeze
compound in confined areas.
I. The antifreeze compound used in air line anti-
freeze systems contains methanol and is toxic,
harmful or fatal if swallowed. Avoid contact with
the skin or eyes and avoid breathing the fumes. If

7
 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
teaspoons of baking soda in a glass of clean
water. Have patient lay down and cover eyes to
DANGER
exclude light. Call a physician immediately.
All field equipment must be tested for elec-
trostatic fields prior to servicing or making
1.8 ELECTRICAL SHOCK contact with the machine using the follow-
ing or equivalent test equipment:
A. This compressor should be installed and main-
tained in full compliance with all applicable Fed- • 90-600 VAC: Volt detector such as
eral, State and Local codes, standards and Fluke Model 1AC-A
regulations, including those of the National Elec- • 600-7000 VAC: Voltage detector
trical Code, and also including those relative to such as Fluke Networks Model
equipment grounding conductors, and only by C9970
personnel that are trained, qualified and dele- It is the responsibility of each organization
gated to do so. to provide/arrange training for all their
associates expected to test for electrostatic
B. Keep all parts of the body and any hand-held
fields.
tools or other conductive objects away from
exposed live parts of electrical system. Maintain
dry footing, stand on insulating surfaces and DO 1.9 LIFTING
NOT contact any other portion of the compressor
when making adjustments or repairs to exposed A. If the compressor is provided with a lifting bail,
live parts of the electrical system. Make all such then lift by the bail provided. If no bail is provided,
adjustments or repairs with one hand only, so as then lift by sling. Compressors to be air-lifted by
to minimize the possibility of creating a current helicopter must not be supported by the lifting
path through the heart. bail but by slings instead. In any event, lift and/or
C. Attempt repairs in clean, dry and well lighted and handle only in full compliance with OSHA stan-
ventilated areas only. dards 29 CFR 1910 subpart N and/or any appli-
cable Federal, State, and Local codes, standards
D. DO NOT leave the compressor unattended with and regulations.
open electrical enclosures. If necessary to do so,
then disconnect, lock out and tag all power at B. Inspect points of attachment for cracked welds
source so others will not inadvertently restore and for cracked, bent, corroded or otherwise
power. degraded members and for loose bolts or nuts
prior to lifting.
E. Disconnect, lock out, and tag all power at source
prior to attempting repairs or adjustments to C. Make sure entire lifting, rigging and supporting
rotating machinery and prior to handling any structure has been inspected, is in good condi-
ungrounded conductors. tion and has a rated capacity of at least the
weight of the compressor. If you are unsure of
the weight, then weigh compressor before lifting.
D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and
latched on the bail or slings.
E. Use guide ropes or equivalent to prevent twisting
or swinging of the compressor once it has been
lifted clear of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away
from the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.

8
SECTION 1

I. Keep lift operator in constant attendance when- 1.11 SAFETY WARNINGS

ever compressor is suspended.
The following special instructions apply to VSD
J. Set compressor down only on a level surface
packages provided with electronic adjustable speed
capable of safely supporting at least its weight
motor drives. These cautions that apply to VSD
and its loading unit.
operation.
K. When moving the compressor by forklift truck,
utilize fork pockets if provided. Otherwise, utilize
pallet if provided. If neither fork pockets or pallet
are provided, then make sure compressor is
WARNING
secure and well balanced on forks before Ground the unit following the instructions in this
attempting to raise or transport it any significant manual. Ungrounded units may cause electric
distance. shock and/or fire. The variable speed drive has a
L. Make sure forklift truck forks are fully engaged large capacitive leakage current during operation,
and tipped back prior to lifting or transporting the which can cause enclosure parts to be above
compressor. ground potential. Proper grounding, as described
in this manual, is required. Failure to observe this
M. Forklift no higher than necessary to clear obsta- precaution could result in death or severe injury.
cles at floor level and transport and corner at
minimum practical speeds.
N. Make sure pallet-mounted compressors are WARNING
firmly bolted or otherwise secured to the pallet
prior to attempting to forklift or transport them. Before applying power to the variable speed
NEVER attempt to forklift a compressor that is drive, make sure that the front and cable covers
not secured to its pallet, as uneven floors or sud- are closed and fastened to prevent exposure to
den stops may cause the compressor to tumble potential electrical fault conditions. Failure to
off, possibly causing serious injury or property observe this precaution could result in death or
damage in the process. severe injury.

1.10 ENTRAPMENT
A. If the compressor enclosure, if any, is large
WARNING
enough to hold a man and if it is necessary to Refer all drive service to trained technicians. This
enter it to perform service adjustments, inform equipment should be installed, adjusted, and
other personnel before doing so, or else secure serviced by qualified electrical maintenance
and tag the access door in the open position to personnel familiar with the construction and
avoid the possibility of others closing and possi- operation of this type of equipment and the hazards
bly latching the door with personnel inside. involved and in accordance with published service
B. Make sure all personnel are out of compressor manuals. Failure to observe this precaution could
result in death or severe injury.
before closing and latching enclosure doors.

WARNING
Line terminals (L1, L2, L3), motor terminals (U, V,
W) and the DC link/brake resistor terminals (-/+)
are live when the drive is connected to power,
even if the motor is not running. Contact with this
voltage is extremely dangerous and may cause
death or severe injury.

9
 SECTION 1

WARNING CAUTION
Before opening the variable speed drive covers:
Make sure that no power correction capacitors
• Disconnect all power to the variable speed drive.
are connected to the variable speed drive out-
• Wait a minimum of 5 (five) minutes after all the
put or the motor terminals to prevent variable
lights on the keypad are off. This allows time for
speed drive malfunction and potential damage.
the DC bus capacitors to discharge.
• A hazard voltage may still remain in the DC bus
capacitors even if the power has been turned off.
Confirm that the capacitors have fully discharged
by measuring their voltage using a multimeter set
CAUTION
to measure DC voltage. Failure to follow the above
Make sure that the variable speed drive output
precautions may cause death or severe injury.
terminals (U, V, W) are not connected to the
utility line power as severe damage to the VSD
may occur.
CAUTION
Do not perform any meggar or voltage withstand
tests on any part of the variable speed drive or its
NOTE
components. Improper testing may result in
Interior electrical wiring is performed at the
damage. Prior to any tests or measurements of
factory. Required customer wiring is minimal,
the motor or the motor cable, disconnect the
but should be done by a qualified electrician
motor cable at the variable speed drive output
in compliance with OSHA, National Electrical
terminals (U, VW) to avoid damaging the variable
Code, and/or any other applicable State,
speed drive during motor or cable testing.
Federal, and local electrical codes concern-
ing isolation switches, fused disconnects,
etc. Sullair provides a wiring diagram for use
CAUTION by the installer.

Do not touch any components on the circuit

boards. Static voltage discharge may damage NOTE
the components.
Customer must provide electrical supply
power disconnect within sight of machine.

CAUTION
Install the variable speed drive in a well venti-
lated room that is not subject to temperature
extremes, high humidity, or condensation, and
avoid locations that are directly exposed to
sunlight, or have high concentrations of dust,
corrosive gas, explosive gas, inflammable gas,
grinding fluid mist, etc. Improper installation
may result in a fire hazard.

10
 WS CONTROLLER USER INTERFACE MANUAL

Section 2

STARTUP PROCEDURES
2.1 INTRODUCTION • Display Screen for displaying machine status

This compressor is equipped with an WS Controller • START pad for machine startup
for controlling the compressor system operation,
setting the machine parameters and performing • STOP pad for stopping machine operation
maintenance operations. The WS Controller is and for clearing fault messages while the machine
designed for the safe operation and protection of the is stopped
compressor system. When fault conditions occur,
the controller automatically shuts down the machine • UP arrow and DOWN arrow pads for
before the conditions can cause damage to the navigation through the various panel displays and
equipment. The WS Controller also contains features for changing parameter values
that enable sequential interface with other machines.
• ENTER pad for selecting and accessing vari-
2.2 WS CONTROLLER PANEL ous screen displays and for entering values
LAYOUT • • Machine status indicator lights for identifying the
current machine operational status.
The WS Controller panel is shown in Figure 2-1. The
controller panel consists of : Each of the controller components and functions is
described in detail in Section 4.

DISPLAY
SCREEN
START
PAD

STOP
PAD

ENTER
PAD
UP ARROW
PAD POWER ON
INDICATOR
FAULT (GREEN)
INDICATOR
RUN MODE
(RED) MAINTENANCE DOWN INDICATOR
INDICATOR ARROW (GREEN)
(AMBER) PAD

Figure 2-1: WS Controller Panel

11
WS CONTROLLER USER INTERFACE MANUAL SECTION 2

2.3 WS START UP PROCEDURES FAN MOTOR ROTATION CHECK (AT

INSTALLATION)
COMPRESSOR MOTOR ROTATION
The VSD fan direction is affected by installation.
DIRECTION CHECK (AT
Verify the correct fan rotation using the following
INSTALLATION) steps:
After the compressor has been installed and the 1. With the compressor running, visually check
electrical wiring is completed, perform following steps that the fan rotation is correct.
to verify the direction of the compressor motor
rotation. 2. If it is incorrect, change the direction of the
fan motor by disconnecting power from the
1. If the display screen shows AUTOMATIC, compressor.
press the UP arrow pad twice to navi- 3. Disconnect and lockout power according to
gate to the Mode parameter. Press the lockout/tagout procedure.
ENTER pad. The screen will display 4. Exchange any two of the three fan motor
leads at the fan motor starter. Refer to the
reverse characters indicating change mode
compressor Operator’s Manual.
is active. Press the DOWN arrow pad
5. Recheck the direction of the fan motor.
to highlight the MANUAL selection (it will
appear in reverse text in the display). Press INITIAL START-UP AFTER INSTALLATION
the ENTER pad to accept the change and
place the machine in the Manual operating Perform the following procedure at the initial START-
mode. up of the compressor following installation.
1. Verify that all preparations and checks nec-
2. Press the START and STOP essary for proper installation have been
pads in succession to “bump start” the com- made. Refer to the compressor Operator’s
pressor. Manual.
3. Observe the direction of rotation of the com- 2. Read the preceding pages of this manual
pressor motor shaft. Verify with Operators thoroughly.
Manual for correct rotation.
3. Slowly open the shut-off valve to the service
4. Disconnect and lockout power according to line.
lockout/tagout procedure.
4. Press the START pad to START the
5. If the motor shaft is not turning in the proper
direction, disconnect the power to the starter compressor. Compressor will begin operat-
and exchange any two of the three power ing in the default mode (Automatic) set at the
input leads. Refer to the Compressor Oper- factory.
ator’s Manual. 5. Check for possible leaks in piping.
6. Perform above steps 1 - 3 again to confirm 6. Slowly close the service line shut-off valve to
proper motor/compressor rotation. verify nameplate pressure unload setting is
correct. The compressor should unload
when nameplate pressure is achieved. If
NOTE adjustments are necessary, see Compressor
Adjustment Procedures on page 15.
Variable speed drive (VSD) packages do
not require a main motor direction check 7. Observe the operating temperature. Refer to
sincethe variable speed motor is set at compressor Operator’s Manual for accept-
the time of manufacture. able operating range. If temperature
exceeds this range, check the cooling sys-
tem and installation environment.
8. Open the shut-off valve to the service line.

12
SECTION 2 WS CONTROLLER USER INTERFACE MANUAL

9. After operating the machine for 24 hours, 4. When the compressor is running, observe
inspect the compressor for fluid leaks and the display panel and maintenance indica-
proper operating temperature. tors to ensure the values displayed are
within the proper ranges.
SUBSEQUENT START-UP PROCEDURE
1. On subsequent start-ups, check the fluid 2.4 SHUTDOWN PROCEDURE
sight glass for proper fluid level. Service if
necessary. See compressor Operator’s Shut down the compressor by pressing the STOP
Manual. pad on the WS Controller panel.

2. Press the START pad on the display

screen. The machine will prepare to start up NOTE
in the last operating mode existing at shut-
down. The current Machine mode will The system may require sump blowdown
appear on the display screen. (typically below 10 psi) to be completed
prior to restarting.
3. If a different operating mode is desired, use
the arrow pads to navigate to the Mode

parameter. Press the ENTER pad to

ENTER the Change Mode. Navigate to the
desired mode (Automatic or Manual). Press
WARNING
the ENTER pad to accept and save
the mode setting. The compressor may restart automatically
after a power failure or after the E-Stop but-
ton has been reset.

13
NOTES

14
 WS CONTROLLER USER INTERFACE MANUAL

Section 3

ADJUSTMENTS
3.1 INTRODUCTION 3.2 COMPRESSOR
ADJUSTMENT
This section describes steps for using the WS PROCEDURES
Controller to modify specific parameters that control
the machine operation. The following steps apply while Show Setting -------
is indicated in the display. The control parameter
described in the display can be modified by the user.
NOTE Use these steps to modify a parameter value:

Control parameters described in this 1. Press the UP arrow or DOWN

manual are those which can be adjusted arrow pad on the controller panel to navigate
via the WS controller. Additional parame- to the parameter to be change.
ters that control the operation of the com-
pressor and sequencing of multiple
machines can be viewed and edited using 2. Press the ENTER pad to select the
the WSPC Software program. See the parameter and access the CHANGE mode.
WSPC User Interface Manual for more The change mode is indicated by the text
details. Change Setting ----- appearing in
reverse (negative) characters on the top
Typically, the top line of the Controller Display line of the display. The parameter name will
Screen will display the line pressure and compressor appear on the second line and the current
temperature; the bottom line will display the current parameter value or setting will appear in
operating mode. As the user presses the down reverse characters on the bottom line.
navigation arrow, the screen will display various
machine statistics appearing under the heading 3. Use the UP arrow or DOWN arrow
Compressor Status:. These values are not pad to change the value or mode of the
adjustable at the WS Controller. Navigating past parameter.
these screens, the first line of the screen will display
4. When the desired value or mode name
the words Show Setting -------. This indicates that
the controller is in the Adjustment mode. When in appears on the display, Press ENTER
Adjustment mode, control parameters will be
described in the second line of the display screen. to accept and save this new value for the
These control parameters can be modified by the selected parameter. The display will return
user. The bottom line of the display will show the to the ADJUSTMENT view and the new
current value or setting of the control parameter. value or mode will be displayed.

Section 3.2 provides general steps to modifying the

compressor control parameters. A description of
each user modifiable parameter is provided in
Section 3.3.

15
WS CONTROLLER USER INTERFACE MANUAL SECTION 3

unloaded for more than 15 minutes. This is because

5. Press the START pad when running
there is another timer that keeps the machine from
or STOP pad when stopped to return being started more than four times an hour. This
secondary timer is disabled when a machine is
the display to the NORMAL view.
configured for VSD motor control.
Drain Interval Mins. - Set interval in minutes
NOTE between activation of the drain cycle for machines
equipped with an electric solenoid drain. This does
If during the adjustment process, the not apply to the Sullair SCD zero loss drain, which is
START or STOP pad is not controlled or monitored by the WS Controller.
pressed prior to pressing the ENTER Drain Time Seconds - Set time in seconds that the
drain remains energized.
pad, the display will return to the
Wye Delta Seconds - Set time for wye to delta
NORMAL view and the parameter value starter transition. Also used to control the closed inlet
will not be changed. start valve. Disable by setting to zero (0), standard
for full voltage start. Requires approximately 4-6
3.3 USER ADJUSTABLE seconds for wye-delta or solid state starting.
CONTROL PARAMETERS Modulate - Manner in which the machine is set to
regulate compressor flow. Default state is “YES” for
Listed below are descriptions of the parameter that proportional control. Select “NO” for Load/No Load
can be adjusted at the WS Controller: operation.
Unload Pressure - Set point (psi, bar, or kpa) at Operating Mode - The mode set for controlling the
which the system pressure will begin unloading. For compressor motor operation (Manual / Automatic).
example if this parameter is set to 110 psi (7.6 bar) Manual mode runs continuously. Automatic mode
the machine will unload when the line pressure is refer to “Unload Minutes”.
above 110 psi (7.6 bar).
Language - The choice of language for text that will
Load Delta Pressure - The pressure differential (psi, appear on the display screen.
bar, or kpa) below the unload pressure at which the
machine will begin loading. For example if the unload The Diagram of Figure 3-1 shows the flow of the
pressure is set to 110 psi (7.6 bar) and the load screens that appear on the WS Controller display
differential is set to 10 psid (0.7 bar), the machine will screen for a typical standard compressor package.
load when the line pressure goes below 100 psi (6.9 This diagram illustrates how adjustment parameters
bar). are accessed.

VSD Setpoint Press. - (VSD packages only) The Ethernet Address - (Models with Ethernet only) This
targeted pressure (psi, bar, or kpa) for the variable selects the address for the service Ethernet
speed controls. This is normally adjusted near the connector of the control box. The default is “LAN”
bottom of the load/unload delta. The speed will be which is used for a local area network. The factory
adjusted to maintain this pressure. default address is 192.168.1.3, but may be modified
as desired. The other selection is “Link Local” which
Unload Minutes - Set time that the machine will run may be used for simple connection to a PC. This puts
unloaded in Automatic mode before shutting off. If the controller at address 169.254.250.249, port 502.
the time is set less than 15 minutes (for example 5),
there may be times when the machine will run

16
SECTION 3 WS CONTROLLER USER INTERFACE MANUAL

NORMAL VIEW

Compressor Status:
Temperature 1

Compressor Status:
Temperature 2

Compressor Status:
Temperature 3

Compressor Status:
Dewpoint Temperature

Compressor Status:
Sump Pressure

Compressor Status:
Line Pressure

Compressor Status:
Pressure 3

Compressor Status:
Sparator Pressure

Compressor Status:
Run Hours

Compressor Status:
Spiral Valve

Compressor Status:
VSD Temperature

Compressor Status:
VSD Capacity

Show Setting Change Setting

Unload Pressure Unload Pressure

Show Setting Change Setting

Load Delta Pressure Load Delta Pressure

Show Setting Change Setting

VSD Setpoint Press. VSD Setpoint Press.

Show Setting Change Setting

Unload Minutes Unload Minutes

Show Setting Change Setting

Drain Interval Mins. Drain Interval Mins.

Show Setting Change Setting

Drain Time Seconds Drain Time Seconds

Show Setting Change Setting

Wye Delta Seconds Wye Delta Seconds

Show Setting Change Setting

Modulate Modulate

Show Setting Change Setting

Operating Mode Operating Mode

Show Setting Change Setting

Language Language

Show Setting Change Setting

Ethernet Address Ethernet Address

(adjustments may be
locked by Admin using WSPC)

Figure 3-1: Controller Display Flow Diagram

17
WS CONTROLLER USER INTERFACE MANUAL SECTION 3

3.4 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:
pressure. Over time, the pressure transducer may
Remote, Hours, or Com Number. Remote
vary slightly producing an inaccurate reading at the
operation is disabled if the sequencing mode
controller. Periodically and prior to operating multiple
is Disabled or Slave.
controllers in a sequence, the controller should be re-
calibrated to reflect the same measurement of P2 3. Once enabled, the controller will respond to
pressure through out the system. The re-calibration the wired input.
is best done when the system is at a stable pressure.
• If the contact is closed, the compressor unloads
Calibration of the WS Controller P2 pressure reading and stops delivering air to the system. If the oper-
is accomplished using the WSPC User Interface ating mode is AUTOMATIC, the compressor will
Software Program. Refer to the WSPC User stop after running unloaded for the period set in the
Interface Manual for details on calibrating the P2 Unload Minutes setting. When operating in a
system pressure measurement. group of sequenced compressors, this removes
only this compressor for service.
3.5 REMOTE UNLOAD • If the contact is open, the compressor operates nor-
mally.
As a default configuration, the compressor is
provided with one input to allow user-furnished The WS Controller is field configurable for other
external remote control. This may be wired to a remote functions with additional contacts or fieldbus
remote switch, timer, or other controls to halt commands. Refer to the WSPC manual for details.
operation of the compressor as desired. To enable
remote control of the compressor:

18
 WS CONTROLLER USER INTERFACE MANUAL

Section 4

DESCRIPTION
4.1 INTRODUCTION 4.3 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.
display screen. Descriptive lists of all messages
appearing in the display are also provided.
Power On Indicator (GREEN LED)—Lights
whenever power is applied to the controller. This
4.2 TOUCH PAD BUTTON LED will blink very slowly if the compressor is set to
DESCRIPTION automatically restart after power failure.
The WS Controller Panel has five touch pads that
allow the operator control of the compressor and Automatic or Manual Run Mode Indicator
enable adjustment of the machine operating
(GREEN LED—Lights when the compressor
parameters. Each touch pad and its functions are
operation is set to start and run automatically. This
described below:
LED lights steadily when the motor is running. The
LED will blink slowly if the compressor motor is
Start Pad —Large green pad button used to
stopped while in Automatic mode as a warning that
START the compressor operation. The pad is also the machine may restart at any time. The display
pressed to reset warnings while the machine is screen will periodically indicate The compressor is
running and to return the display to the Normal View. Standing by. The Automatic Mode LED will blink
rapidly if machine restart is imminent. The display
Stop Pad —Large red key pad used to stop screen will periodically display a message to indicate
the compressor operation. The STOP pad is also the state of the machine prior to restart (e.g., Waiting
pressed to clear fault messages when the machine is for Blowdown).
stopped and to return the display to the Normal View.

Up Arrow Pad —Used to navigate “UP” the list Maintenance/Warning Indicator (AMBER
of display messages and to increase or change LED)—Lights when recommended maintenance or
parameter values for adjustments. service warning is issued. In most cases the
machine will continue to operate normally. The
Down Arrow Pad —Used to navigate “DOWN” display screen will periodically display the
the list of display messages and to decrease or recommended maintenance actions or the cause of
change parameter values for adjustments. the warning. Refer to Section 5: Troubleshooting on
page 27 to resolve maintenance conditions.

Enter Pad —Angled arrow key pad used to

select the parameter that is displayed on the screen. Fault Warning Indicator (RED LED)—Lights
After adjusting the desired parameter value using the when a compressor fault has occurred. The indicator
UP or DOWN arrow pads, the ENTER pad selects will remain lit and the compressor will remain
the parameter value displayed on the screen and inoperative until the fault condition is remedied. The
saves it as the new value. controller display screen will indicate FAULTED and
periodically a brief description of the cause of the
fault. Refer to Section 5: Troubleshooting on page
27 to resolve fault conditions.

19
WS CONTROLLER USER INTERFACE MANUAL SECTION 4

4.4 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: and temperature at temperature probe 1.
Compressor Adjustment: or Show Setting ------- .
Temperature 2—Displays the current compressor
NORMAL VIEW temperature at temperature probe 2.

The Normal View is the default view for the display Temperature 3—Displays the current compressor
temperature at temperature probe 3.
screen. When in Normal View, information regarding
the compressor current operating conditions appears Dewpoint Temperature—Displays the current dryer
on the display screen. See Figure 4-1. The top line temperature at temperature probe 3.
of the display screen in Normal View shows the Sump Pressure—Displays the current sump
discharge pressure and the internal temperature of pressure (P1).
the compressor package. The lower line of the Line Pressure—Displays the current line output
Display Screen displays the current compressor pressure (P2).
operating mode. Pressure 3—Displays the pressure (P3) at the
specified transducer location.
Separator Pressure ^ —Displays the current
separator pressure differential.
Run Hours—Displays the total time the compressor
has been running loaded or unloaded.
Spiral Valve—Approximate percent of full capacity
controlled by the compressor's spiral valve
Figure 4-1: Display Screen
Normal View Example VSD Capacity—This is displayed as an approximate
percentage (%) of the maximum capacity for the
Under normal operating conditions, the lower line of package.
the Controller Display Screen will alternately
display the compressor operating state, warning VSD Temperature—High temperatures usually
messages, service reminders, and fault conditions indicate a need for cleaning of the VSD fan or heat
when they occur. sink by a trained service technician.

COMPRESSOR STATUS VIEW COMPRESSOR ADJUSTMENT VIEW –

The Compressor Status: View shows real-time
CONTROL PARAMETERS
machine measurement information. The Compressor Adjustment View shows current
machine parameters which are conditions and limits
This information is quickly accessed using the Down
that can be modified by the operator. This view is
navigational arrow. The top line of the display screen
accessed using the navigational arrows and is
will indicate Compressor Status:. See Figure 4-2.
indicated by the text Show Setting ------- appearing
The second line will show the name of the
on the first line of the display screen. See Figure 4-3.
measurement (e.g., Line Pressure). The bottom
line will display the current value of the measurement Pressing ENTER at the Show Setting screen
being viewed.
accesses the Change Mode. This mode is indicated
by the text Change Setting----- appearing as
reverse characters on the first line of the display
screen and the change parameter appearing on the
second line. See Figure 4-4. The value of the
parameter is displayed as reverse characters on
the bottom line. Refer to Section 3: Adjustments on
Figure 4-2: Display Screen Compressor Status page 15, for instructions on changing the compressor
View Example control parameters and a list of the control
parameters that can be modified by the user.

20
SECTION 4 WS CONTROLLER USER INTERFACE MANUAL

Off mode—Indicated by the word OFF appearing in

the lower line of the display window. This mode
Show Setting - - - - - - - indicates that the compressor and motor have been
Unload Pressure turned off under normal conditions. When in this
Adjustment View
mode the machine will not operate until the START
110 psi
pad is pressed.
Figure 4-3: Adjustment View—
Show Setting Example Fault mode—Indicated by the word FAULTED
appearing in the lower line of the display window.
This mode indicates that a machine problem has
Change Setting - - - - - - - occurred causing the controller to shut down the
Unload Pressure machine until the condition is cleared. After a fault
Change View
condition has been resolved, the fault indication can
110 psi be cleared from the controller by pressing the STOP
Figure 4-4: Adjustment View— pad. Refer to Section 5: Troubleshooting on
Change Setting Example page 27, for information on resolving fault conditions.
UI Comm mode—Indicated by the word UI COMM
4.5 OPERATING MODES appearing in the lower line of the display window.
This mode indicates that the User Interface has lost
The Operating Mode is the manner in which the communication and, as a result, the machine
machine operation is being controlled. There are five operating mode or status is unknown.
Operating Modes: AUTOMATIC, MANUAL, OFF,
FAULT and UI COMM. 4.6 OPERATING STATES
The active operating mode of the compressor Operating States describe the state of the
appears on the lower line of the display screen’s compressor operation in response to the current
Normal View. See Figure 4-5. mode and current conditions. Essentially, the
operating state is what the machine is doing at a
particular moment. Most operating states occur
118 psi 70°F automatically as normal functions of the compressor
Automatic Mode and require no direct action from the operator.
AU TO MA TIC (Normal View)

Figure 4-5: Compressor Operating

Mode Display
NOTE
The compressor operating modes are described Machine operating states may vary
below: depending on compressor model.

Automatic mode—Indicated by the word

AUTOMATIC appearing in the lower line of the Text descriptions of operating states appear
display window. This is a user selected mode that periodically on the lower line of the display screen
sets the compressor motor to automatically start while in Normal View. See Figure 4-6. The leading
when conditions necessitate and stop when motor line will read The compressor is below which the
operation is not required. operating state description will be displayed.
Manual Mode—Indicated by the word MANUAL
appearing in the lower line of the display window.
This is a user selected mode that allows the operator
to manually control the compressor motor operation.
When the START pad is pressed while in
Manual Mode the compressor motor will run Figure 4-6: Controller Display Normal View:
continuously until the STOP pad is pressed. Operating State
The compressor pump and all other machine
parameters function the same in both Manual and The list below provides an explanation of each
Automatic modes. Operating State message that may appear in the

21
WS CONTROLLER USER INTERFACE MANUAL SECTION 4

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.
operator.
Remote Unloaded—Displayed when the
Initializing—Displayed as the compressor is compressor has been unloaded remotely.
powered up.
Restarting—Displayed during the restart waiting
Stopping—May be briefly displayed as the period after the starter has dropped out
compressor is being stopped via the Controller unexpectedly.
Panel.
Manually Stopped—Displayed when the 4.7 NORMAL VIEW SERVICE
compressor operation is stopped. REMINDERS
Remote Stopping—May be briefly displayed as the Service reminders may alternately appear in the
compressor is being stopped remotely. Normal View display. See Figure 4-7. The Service
Remote Stopped—Displayed when the compressor Reminder screen is indicated by the words
operation is stopped but is armed to restart. The Recommended Service: appearing on the second
machine will start when the remote start contact is line of the display. The bottom line displays a brief
close. NOTE: The machine may start at any time description of the recommended service required.
when conditions are met. When a service reminder appears, the machine will
continue to operate normally, however, the
Standing by—Displayed when the compressor is appropriate service should be scheduled and
stopped and waiting for proper conditions before accomplished within a short period of time.
restarting.
Faulting—Displayed as a fault condition is occurring.
Faulted—Displayed after a fault condition has
occurred.
Waiting for Blowdown—Displayed when the
compressor is waiting for the sump to reach a set Figure 4-7: Controller Display Normal View:
minimum pressure prior to starting. After the Service Reminder
pressure has reduced to the set level, the
compressor will start automatically. The list below provides an explanation of the Service
Reminders that may appear in the Normal View
Starting 1—Displayed as compressor initiates stage
1 startup processes. display. Refer to Section 5: Troubleshooting on page
27, for additional instructions on actions to be taken
Starting 2—Displayed as compressor initiates stage when a service reminder appears.
2 startup processes.
Change Fluid Filter—The compressor fluid filter
Starting 3—Displayed as compressor initiates stage should be changed within the time frame noted in the
3 startup processes.
machine operation specifications.
Precooling the Dryer—Displayed while initially
cooling an integrated dryer with the compressor Change Separator—The compressor fluid separator
unloaded should be changed within the time frame noted in the
machine operation specifications.
Loading—Displayed as the compressor begins
delivering air. Change Air Filter—The compressor air filter should
be changed within the time frame noted in the
Loaded & Modulating—Displayed when the
machine operation specifications.
compressor is delivering air.
Fully Loaded—Displayed when the compressor is Analyze Fluid—A fluid analysis should be scheduled
delivering air at full rated capacity. per machine operation specifications.

Unloading—Displayed as the compressor is being Change Fluid—The compressor fluid should be

unloaded automatically. changed within the time frame noted in the machine
operation specifications.
Remote Unloading—Displayed as the compressor
is being unloaded remotely. Maintenance A—Periodic maintenance should be
scheduled per machine operation specifications.

22
SECTION 4 WS CONTROLLER USER INTERFACE MANUAL

4.8 WARNING MESSAGES High Air Filter dP—Indicates the air filter pressure
differential is high. The air filter unit needs to be
When a Warning: condition occurs a warning checked or changed.
message will alternately appear on the lower line of
High Oil Filter dP—Indicates the fluid filter pressure
the Normal View display. See Figure 4-8. Under a
differential is high. The fluid filter needs to be
Warning condition, the machine will continue to
checked or changed.
operate normally, however, appropriate maintenance
action must be taken to remedy the warning High Separator dP—Indicates the fluid separator
condition. Refer to Section 5: Troubleshooting on pressure differential is high. The separator unit
page 27, for additional instructions on actions to be needs to be checked or changed.
taken when warning conditions exists.
High Temperature 1—Indicates that the compressor
Temperature at temp probe location 1 is approaching
the set high limit.
High Temperature 2—Indicates that the compressor
Temperature at temp probe location 2 is approaching
the set high limit.
Figure 4-8: Controller Display Normal View:
Warning Message High Temperature 3—Indicates that the compressor
Temperature at temp probe location 3 is approaching
The list below provides an explanation of the the set high limit.
Warning Messages that may appear in the display Low Temperature 1—Indicates that the compressor
when an error occurs. Temperature at temp probe location 1 is approaching
High Dryer Dewpoint—Indicates that the integrated the set low limit.
dryer is running with high dewpoint temperature. Low Temperature 2—Indicates that the compressor
Consult the dryer manual and/or dryer manufacturer. Temperature at temp probe location 2 is approaching
Dryer High DP Fault—Indicates that the integrated the set low limit.
dryer has stopped operation due to high dewpoint Low Temperature 3—Indicates that the compressor
temperature. Consult the dryer manual and/or dryer Temperature at temp probe location 3 is approaching
manufacturer. the set low limit.
Low Dryer Dewpoint—Indicates that the integrated Not Commissioned—A controller was replaced but
dryer is running with low dewpoint temperature. has not been commissioned for a specific
Consult the dryer manual and/or dryer manufacturer. compressor model.
Dryer Low DP Fault—Indicates that the integrated Power Interruption—Indicates that a power
dryer has stopped operation due to low dewpoint interruption has occurred.
temperature. Consult the dryer manual and/or dryer
manufacturer. Replace Battery—Indicates the I/O backup battery
is low.
Dryer Overload Fault—Indicates that the integrated
dryer has stopped operation due to a compressor Sequence Comm Error—Indicates a
motor overload. Consult the dryer manual and/or communication problem exists between the
dryer manufacturer. compressor controllers set up for sequential
operation.
Dryer Relay Fault—Indicates that the integrated
dryer has stopped operation due to internal Starter—The main motor starter failed to operate,
problems. Consult the dryer manual and/or dryer and was restarted.
manufacturer. User Option Warning—Indicates a user furnished
Dryer Service—Indicates a dryer is running while a switch has been activated.
malfunction is occurring. Consult the dryer manual VFD Overtemp—Operating temperatures are
and/or dryer manufacturer. approaching the VSD limits.
Ethernet disabled—Ethernet was turned off due to
excessive network traffic.

23
WS CONTROLLER USER INTERFACE MANUAL SECTION 4

and the controller module has resulted in an open

circuit.
High Dryer Dewpoint—Indicates that the integrated
WARNING dryer has stopped all package operation due to high
dewpoint temperature. Consult the dryer manual
The compressor may restart automatically and/or dryer manufacturer.
after power has been restored following a High Interstage Pres—Interstage pressure is above
power failure. the unit limits.
High Package Press—Package Discharge pressure
4.9 FAULT MESSAGES has exceeded the set high limit.

When a Fault condition occurs, the machine will shut High Plant Pressure—Plant line pressure has
down and the display will indicate FAULTED on the exceeded the set high limit.
lower line of the display window. A Fault Message High Pressure A…B—Pressure at specified
will alternately appear in the lower line of the Normal transducer (A or B) has exceeded the set high limit.
View display briefly describing the nature of the fault.
See Figure 4-9. High Separator dP—Separator pressure differential
has exceeded the set high limit.
High Spiral Valve Pr—Excessive pressure was
applied to the spiral valve actuator.
The fault cause is: High Sump Pressure—Compressor sump pressure
has risen above the set limits.
E-Stop Push Button
Figure 4-9: Controller Display Normal View: High Temperature 1…3—The temperature at
Fault Message specified temp probe (1 through 3) has risen above
the set high limit.
The list below provides an explanation of the Fault
Messages that may appear when problems occur. High Voltage Failed—No voltage is available at the
Refer to Section 5: Troubleshooting on page 27, for high voltage motor starter.
instructions on actions to be taken when a FAULT HIGH VOLT SENSOR—Indicates the system high
condition occurs. voltage sensor has failed.
Aux Motor Overload—The auxiliary motor overload Illegal State—Controller operating error.
relay has been tripped due to a power overload in the
auxiliary motor. Internal Com Error—An error in communication
between the controller and the compressor has
CE Voltage too high / Low—The internal 24 volt occurred.
supply is out of range.
LOW AN0 SENSOR (AN0 - AN9)—Device assigned
Controller Watchdog—Controller watchdog timer to sensor input AN0 through AN9 (temp probe,
error. transducer unit, etc.) or wiring between the device and
Dryer Fault—Indicates a dryer malfunction has the controller module has resulted in a short circuit.
occurred. Consult the dryer manual and/or dryer Low Dryer Dewpoint—Indicates that the integrated
manufacturer. dryer has stopped all package operation due to low
Dryer Overload—Indicates a dryer overload has dewpoint temperature. Consult the dryer manual
occurred. Consult the dryer manual and/or dryer and/or dryer manufacturer.
manufacturer. Low Line Pressure—The line pressure has fallen
E-Stop Push Button—Emergency Stop button has below the Low Fluid Pressure set low limit.
been pressed. Low Fluid Pressure—Compressor fluid pressure
HIGH AN0 SENSOR (AN0-AN9)—Device assigned has fallen below the set low limit.
to sensor input AN0 through AN9 (temp probe, Low Sump Pressure—Compressor sump pressure
transducer unit, etc.) or wiring between the device has fallen below the set limits.

24
SECTION 4 WS CONTROLLER USER INTERFACE MANUAL

Low Temperature 1 ... 3—Temperature at the 4.10 DIAGNOSTIC VIEWS

specified temp probe (1 through 3) has fallen below
the set low limit.
While in the Normal View use the ENTER Pad
LOW VOLT SENSOR—Indicates the system low
voltage sensor has failed. to access the Diagnostic View.

Low Water Pressure—The water pressure switch Use the UP or DOWN arrow pads to access
has been tripped due to low water pressure. the next Diagnostic view.

Main Motor Overload—The main motor overload

relay has been tripped due to a power overload in the Use the ENTER Pad to return to the Normal
main motor. View.
Memory Error—The controller I/O board has failed. Figure 4-13 Illustrates how to navigate between the
Normal View and the Diagnostic Views.
OPTION INPUT—User option error.
OPTION INPUT RUN—User option error.
DIAGNOSTIC: ANALOG INPUT VIEW
The analog inputs are displayed in their order on the
Phase Protection.—Indicates external phase analog input terminal block in a left to right, top to
protection relay has tripped. bottom order. Inputs not used by the machine are not
Ethernet Comm Error—Communications have shown.
failed to a keypad.
Power Interruption—A power interruption has
occurred at the controller.
Pump Motor Overload—The pump motor's
overload relay has tripped.
Pump Starter Contact—The pump starter did not Figure 4-10: Typical Analog Input Status
operate as expected.
The analog values are typically displayed in the
Starter—Starter auxiliary contact failed to connect
selected units of measure.
power to the starter.
The input labels typically refer to the pressure and
UI Voltage too high—The voltage to the User
temperature sensor references in the Piping and
Interface has risen above the set limit.
Instrumentation drawing.
UI Voltage too low—The voltage to the User
Interface has fallen below the set limit.
DIAGNOSTIC: DIGITAL I/O VIEW
The status of the digital inputs and relay outputs are
High Plant Pressure—The inlet valve failed to close shown from left to right in the order in which they are
as expected found on the terminal blocks.
VSD1 Response—The A1000 drive is not
responding to run commands
VSD1 Comm Fault—An error in communication
between the controller and the specified VSD
compressor has occurred.
VSD1 parameter error—An error has occurred
during setup of the VSD adjustments. Figure 4-11: Typical Digital I/O Status

The values of one and zero refer to active or inactive

states respectively.
The labels refer to the controller input and output
naming on the wiring diagram.

25
WS CONTROLLER USER INTERFACE MANUAL SECTION 4

DIAGNOSTIC: ALARM VIEWS

Any current fault, alarm or service reminder message
will be available to view here. Multiple messages NORMAL VIEW Analog Inputs View

may be scrolled through using the UP and

Compressor Status:
DOWN arrow pads. Temperature 1
Digital I/O View

Compressor Status: Alarm View

Temperature 2 Message #1

Recommended Service: Compressor Status:

Temperature 3
...

Change Air Filter Compressor Status: Alarm View

Dewpoint Temperature Last Message

Compressor Status:
Sump Pressure
Figure 4-12: Typical Alarm View
Compressor Status:
Line Pressure

Compressor Status:
Pressure 3

Compressor Status:
Sparator Pressure

Compressor Status:
Run Hours

Compressor Status:
Spiral Valve

Compressor Status:
VSD Temperature

Compressor Status:
VSD Capacity

Show Setting ------- Change Setting -----

Unload Pressure Unload Pressure

Show Setting ------- Change Setting -----

Load Delta Pressure Load Delta Pressure

Show Setting ------- Change Setting -----

VSD Setpoint Pressure VSD Setpoint Pressure

Show Setting ------- Change Setting -----

Unload Minutes Unload Minutes

Show Setting ------- Change Setting -----

Drain Interval Mins. Drain Interval Mins.

Show Setting ------- Change Setting -----

Drain Time Seconds Drain Time Seconds

Show Setting ------- Change Setting -----

Wye Delta Seconds Wye Delta Seconds

Show Setting ------- Change Setting -----

Modulate Modulate

Show Setting ------- Change Setting -----

Operating Mode Operating Mode

Show Setting ------- Change Setting -----

Language Language

Show Setting ------- Change Setting -----

Ethernet Address Ethernet Address

(adjustments may be
locked by Admin using WSPC)

Figure 4-13: Navigation between the

Normal and Diagnostic view

26
 WS CONTROLLER USER INTERFACE MANUAL

Section 5

TROUBLESHOOTING
5.1 TROUBLESHOOTING c. Check for parts damaged by heat or an elec-
INTRODUCTION trical short circuit, usually apparent by discol-
oration or a burnt odor.
This Troubleshooting section is provided as a guide
Should your problem persist after making the
to aid in diagnosing and resolving compressor
recommended check, consult your nearest Sullair
problems when they occur. The information
Distributor or the Sullair Corporation factory Service
contained in Table 5-1, Troubleshooting Guide, has
been compiled from factory experience and contains Department.
symptoms and usual causes for the described
problems. Each Service Reminder, Warning, or
Fault Message is listed with conditions of when the
NOTE
problem may occur, a probable cause, and a
Section 5.2 and Section 5.4 portray com-
suggested solution to the problem. DO NOT assume
mon systematic problems that can occur
that these are the only problems that may occur.
during controller operation. For a more
This document cannot address every possible thoroughly in-depth coverage of machine
adverse condition that may occur nor does it provide operation troubles, consult the Trouble-
every solution for the potential troubles listed. All shooting Section in the machine’s opera-
available data concerning the trouble should be tor’s manual.
systematically analyzed before undertaking any
repairs or component replacement procedures.
5.2 TROUBLESHOOTING GUIDE
Always perform a detailed visual inspection when a
machine problem occurs prior to attempting any Table 5-1 contains symptoms and usual causes for
repairs. Doing so may avoid unnecessary repair the problems that may occur throughout the
and/or additional damage to the compressor. compressor system. Each warning or fault message
that may appear is listed along with conditions for the
Always remember to:
problem, a probable cause, and a suggested solution
a. Check for loose wiring. to the problem. DO NOT assume that these are the
only troubles that may occur.
b. Check for damaged piping.

Table 5-1: WS Controller Troubleshooting Guide

MESSAGE PROBABLE CAUSE REMEDY
Analyze Fluid Service interval has expired. Select Maintenance from menu to see
Maintenance due. service due and part numbers.
Aux Motor Overload Auxiliary Motor Tripped on Cooling Reset auxiliary overload after element
Fan, Fluid Pump or Other Motor. cools. Verify correct motor amps.
Check for loose connections.
Check motor starter contact for proper
operation.
Check line voltage, if low consult power
company.

27
WS CONTROLLER USER INTERFACE MANUAL SECTION 5

Table 5-1: WS Controller Troubleshooting Guide

MESSAGE PROBABLE CAUSE REMEDY
CE Voltage too high Excessive voltage form power Check connections and adjustments.
supply or transformer.
CE Voltage too low Inadequate voltage form power Check connections and adjustments.
supply or transformer.
Excessive load or short in 24v Check wiring, coils, and solenoid valves.
control devices.
Change Air Filter Service interval has expired. Perform recommended maintenance and
Change Fluid Maintenance due. reset the reminder using WSPC.

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.
High Dryer Dewpoint The dryer is unable to cool below Consult the dryer manual and/or
Dryer High DP Fault the high dewpoint temperature Sullair Factory Service.
setting.
Low Dryer Dewpoint The dryer is cooling below the low Consult the dryer manual and/or
Dryer Low DP Fault dewpoint temperature setting. Sullair Factory Service.

Dryer Overload Indicates a dryer overload has Consult the dryer manual and/or
Dryer Overload Fault occurred. Sullair Factory Service.
Dryer Relay Fault Indicates a general dryer Consult the dryer manual and/or
malfunction has occurred Sullair Factory Service.
Dryer Service Dryer malfunction is imminent. Consult the dryer manual and/or
Sullair Factory Service.
E-Stop Push Button E-Stop Button Active. Release button.
Faulty E-Stop Button. Check wiring.
Ethernet disabled Excessive Ethernet traffic Install a router to reduce the traffic on the
compressor's LAN.
High Air Filter dP Differential Pressure Across Inlet Replace filter.
Filter High. Check inlet filter pressure switch.
HIGH AN0 SENSOR Sensor (Pressure Transducer, Check sensor wiring.
Temp Probe, etc.) or Wiring Check sensor.
Failure.
High Dryer Dewpoint The dryer is unable to cool below Consult the dryer manual and/or
the high dewpoint temperature Sullair Factory Service.
setting.
High Oil Filter dP Pressure across fluid filter above Replace fluid filter.
20 psi (1.4 bar) while running.
Fluid filter clogged. Sump heater may be required in ambients
Low ambient temperature. below 40°F (4°C).
Sensor failure. Check sensor, wiring and tubing.
High Interstage Pres Compressor Interstage Blockage Inspect for: interstage flow restriction, or
or second stage failure damaged air end and repair

28
SECTION 5 WS CONTROLLER USER INTERFACE MANUAL

Table 5-1: WS Controller Troubleshooting Guide

MESSAGE PROBABLE CAUSE REMEDY
High Package Press High pressure. Check operation of valves and controls.
High Pressure A Faulty pressure sensor. Check and replace pressure sensor if
High Pressure B defective.

High Separator dP High Separator pressure drop Inspect separator and replace
High Spiral Valve Pr Misadjustment Check setting of the pressure regulator for
the spiral valve actuator.
High Sump Pressure Sump Pressure High (Poppet, Check valves. Check Sullicon adjustment
Sullicon, Spiral, Blowdown or (see Control Adjustment section in the
Pneumatic Valve Failed). compressor operator’s manual).
Faulty solenoid valves. Check solenoid valve operation and wiring.
Faulty pressure regulator. Check pressure regulator adjustment and
operation.
Check minimum pressure check valve (not
applicable to Fluid Free compressors).
High Temperature 1 High Temp Fault. Ambient above 105°F (41°C), improve local
High Temperature 2 ventilation.

High Temperature 3 Fluid level low. Replenish fluid to proper level.

Thermal valve fault. Check thermal valve operation.
Cooler fins dirty. Clean Cooler fins and fan blades.
Low water flow. Check for valve closed, pump off or broken
pipe.

High water temperature. Increase water flow or lower water

temperature.

Cooler plugged. Clean cooler tubes and shell. If plugging

persists, use cleaner water.

Temp probe or sensor failure. Check sensor and wiring.

High Voltage Failed No power to the high voltage Close the disconnect switch
starter Check main motor fuses or circuit breaker
Illegal State Controller fault. Contact Sullair Factory Service.
Ethernet Comm Error Module Network Error; Check wiring.
Communication has failed between
the Display Module, I/O Module
and other modules.
LOW AN0 SENSOR Sensor (Pressure Transducer, Check sensor wiring.
Temp Probe, etc.) or Wiring Check sensor.
Failure.
Low Dryer Dewpoint The dryer is cooling below the low Consult the dryer manual and/or
dewpoint temperature setting. Sullair Factory Service.
Low Line Pressure Demand exceeds capacity. Reduce demands.
Leaks in supply lines. Increase capacity.
Check for leaks or open lines in air supply.
Repair as necessary.

29
WS CONTROLLER USER INTERFACE MANUAL SECTION 5

Table 5-1: WS Controller Troubleshooting Guide

MESSAGE PROBABLE CAUSE REMEDY
Low Fluid Pressure Fluid filter clogged. Replace fluid filter.
Sump fluid level low. Replenish fluid to proper level.
Low ambient temperature. Sump heater may be required in ambients
below 40°F (4°C).
Fluid pump may be required for remote
coolers.
Fluid pump failure. Consult Sullair Factory Service.

Low Sump Pressure Bad sensor or connections. Check pressure sensor, wiring and tubing.
Machine may have failed to start. Check machine operation.
Low Temperature 1 Low ambient air temperature Sump heater may be required in ambients
Low Temperature 2 below 40°F (4°C).

Low Temperature 3
Low Water Pressure Cooling Water Pressure below 10 Check for closed valves or broken pipes.
psi (0.7 bar).
Low Water Pressure Switch is shorted or open. Replace switch. Check wiring for shorts,
arcing or loose connections.
Main Motor Overload Main Motor Overload Relay Reset overload after heater element cools
Tripped. down.
Check that compressor is properly
configured.
Ensure load pressure is set below limit of
compressor.
Check line voltage, if low consult power
company.
Maintenance A Service interval has expired. Perform recommended maintenance and
Maintenance due. reset the reminder using WSPC.

Memory Error The controller I/O board has failed. Board replacement required. Contact Sullair
Factory Service.
Not Commissioned Controller replacement Follow commissioning procedures to set up
for the specific compressor package.
Option Input User furnished switch has Check operation of optional device.
Option Input Run operated.
User Option Warning User furnished external phase Check operation of optional device. Refer to
relay protection relay has tripped. user supplied phase relay documentation
and troubleshooting steps.
PortC Comm Error (C or E) Wiring fault between the controller Check the cable and connections
and keypad
Power Interruption Intermittent Control Power. Check line voltage and connections.
Pump Motor Overload Auxiliary Motor Tripped on Fluid Reset auxiliary overload after element
Pump Motor cools. Verify correct motor amps.
Check for loose connections.
Check motor starter contact for proper
operation.
Check line voltage, if low consult power
company.

30
SECTION 5 WS CONTROLLER USER INTERFACE MANUAL

Table 5-1: WS Controller Troubleshooting Guide

MESSAGE PROBABLE CAUSE REMEDY
Pump Starter Contact Pump starter failed to operate. Check starter and control wiring.
Faulty auxiliary contact. Check contact and contact wiring.
Replace Battery Controller I/O backup battery is Replace battery.
low.
Pressure Differential Across Replace separator.
High Separator dP Separator High.
Plugged separator elements. Check sensor wiring.
Pressure sensor failure.
Sequence Comm Error Cable or connection fault between Check wiring.
compressors.
Improper sequence adjustments. Check sequence settings of all
compressors in the sequence.
Starter Main starter failed to operate. Check starter and control wiring.
Faulty auxiliary contact. Check contact and contact wiring.
Momentary Line Power loss or Check Line Power quality
brownout
UI Voltage too high Controller fault. Contact Sullair Factory Service.
UI Voltage too low Controller fault. Contact Sullair Factory Service.
High Plant Pressure Compressor failed to unload Check operation of the inlet valve and
controls
User Option Warning User furnished switch has Check function of optional device.
operated.
HIGH VOLT SENSOR Controller fault. Contact Sullair Factory Service.
LOW VOLT SENSOR Controller fault. Contact Sullair Factory Service.
VSD1 Comm Fault Communications lost with the VSD Check connections to the VSD.
Check VSD control power and check for
board faults.
VFD Overtemp Warns that the variable frequency Ensure adequate ventilation
drive is too hot Schedule cleaning before a High Temp fault
occurs
VSD1 parameter error Controller commissioned Commission the controller per the machine
incorrectly. nameplate
Incorrect VSD Replace with proper drive rating
VSD1 Response The A1000 drive is not responding Remove power for 1 minute
to WS control. Restore power for 1 minute
Restart the machine

31
WS CONTROLLER USER INTERFACE MANUAL SECTION 5

5.3 WS CONTROLLER FAULTS AND WARNINGS

High Low
Parameter Type Sensor Comment
Limit Limit

Separator Pressure ^ Warning P2-P1+offset 10 psid offset for aftercooler or dryer

Sump Pressure Fault P1 135 psig 5 psig 100 psig machine

150 psig 5 psig 125 psig machine

175 psig 5 psig 150 psig machine

200 psig 5 psig 175 psig machine

165 psig 5 psig 100-140 psig VSD machine

200 psig 5 psig 150-175 psig VSD machine

Line Pressure Fault P2 125 psig 10 psig 100 psig machine

150 psig 10 psig 125 psig machine

175 psig 10 psig 150 psig machine

200 psig 10 psig 175 psig machine

155 psig 10 psig 100-140 psig VSD machine

200 psig 10 psig 150-175 psig VSD machine

Warning T1 225 F 0F
Air End Discharge Temperature
Fault T1 235/255F 0F Time delayed/immediate

5.4 MACHINE BEHAVIOR AFTER integrity of the controller memory records when
A POWER INTERRUPTION power is disconnected from the controller. For best
performance, ensure that the battery is functioning.
If the compressor was faulted prior to the power If the controller is operated with a drained or dead
interruption, the controller will resume the FAULTED battery, the time-of-day records will not work properly
condition and display the reason for the fault. Repair and loss of recent records could occur. If recent
records are lost due to an inoperative battery (or
the cause of the fault and press the STOP
other reason), the controller will revert to the last
pad to reset the controller. saved versions of settings and records.
If the compressor was manually stopped prior to the The internal battery is located inside the controller I/
power interruption, the controller will return to the O module and will operate for several years without
manually stopped mode. Press the START button to requiring maintenance. When the battery voltage
manually restart operation. gets low, the controller will issue a “Replace Battery”
If the restart timer is greater than zero AND the warning. Perform the following steps to replace the
controller was in Automatic or Manual mode prior to battery.
the interruption, the controller will resume that mode
after the restart timer expires. No key press is 1. Press the STOP pad to stop the com-
necessary to restart the compressor. pressor.
2. Disconnect and lockout power according to
5.5 INTERNAL BATTERY lockout/tagout procedure.
The WS Controller employs an internal battery that 3. Open the controller enclosure and locate the
maintains the real-time clock and maintains the I/O Control Module.

32
SECTION 5 WS CONTROLLER USER INTERFACE MANUAL

4. Remove six screws from I/O Control Module

cover and remove cover.
5. Locate the internal battery. The battery is
located near one end of the I/O circuit board
(usually oriented towards the top).
6. Remove the battery and replace with a bat-
tery type BR2330.
7. Replace the cover, close the enclosure, fol-
low normal startup procedures.

Remove Remove

I/O Control Module

Internal Battery
Type BR2330

Small I/O Control Module

Circuit Board

Large I/O Control Module

Circuit Board

33
NOTES

34
 WS CONTROLLER USER INTERFACE MANUAL

Section 6

VARIABLE SPEED DRIVE

6.1 OVERVIEW 6.2 INSTALLATION
The Sullair VSD drive application is custom designed Refer to the VSD Installation and Service manual
for operation of air compressors. All necessary that came with the compressor for installation
control functions are performed through the WS information.
Controller keypad and WSPC software. The drive
functions as a module on the WS Controller
communications bus. WSPC provides detailed
information about relevant drive status data and
compressor performance. Drive controls are
coordinated with internal compressor controls, and
with other Supervisor or WS controlled compressors
in sequenced systems. The WS Controller monitors
drive performance to provide motor thermal and
other protections in an easy-to-use, robust design.

35
NOTES

36
NOTES

37
 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