Sullair SUPERVISOR CONTROLLER Series User manual

Part Number
02250146-049
©Sullair Corporation
SUPERVISOR
CONTROLLER™
INSTRUCTION MANUAL
ALL MODELS
OPERATOR’S
MANUAL
KEEP FOR
FUTURE
REFERENCE

AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are 3-day courses that provide hands-on instruction in the proper operation,
maintenance and service of Sullair equipment. Individual seminars on Industrial compressors and com-
pressor electrical systems are presented at regular intervals throughout the year at a dedicated training
facility at Sullair’s corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of
the most common problems, and actual equipment operation. The seminars are recommended for main-
tenance and service personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1-888-SULLAIR or
219-879-5451 (ext. 5363)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department

Section 1 page
SAFETY 11.1 GENERAL
11.2 ELECTRIC SHOCK
11.3 VARIABLE SPEED DRIVE
11.4 DECALS
Section 2
SUPERVISOR
DESCRIPTION 52.1 SUPERVISOR KEYBOARD LAYOUT
52.2 MAIN DISPLAY
52.3 FUNCTION MENU
62.4 STATUS- CURRENT PRESSURES, TEMPERATURES,
INPUTS AND OUTPUTS
62.5 CONTROL PARAMETERS- PRESSURE, TEMPERATURE
AND TIMER SETTINGS
72.6 MAINTENANCE- PREVENTIVE MAINTENANCE
INFORMATION AND TIMERS
72.7 FAULT LOG- LOG OF PREVIOUS FAULTS
72.8 SENSOR LOG
72.9 SEQUENCING- SEQUENCING & COMMUNICATION
PARAMETERS
82.10 SYSTEM DISPLAY- DISPLAY OF MODES OF MACHINES
IN A SEQUENCING SYSTEM
82.11 CALIBRATION- CORRECTION FACTORS FOR PRESSURES
10 Table 2-1 Supervisor Controller Menu Tree
Section 3
START-UP
PROCEDURES 11 3.1 MOTOR ROTATION DIRECTION CHECK
11 3.2 INITIAL START-UP PROCEDURE
11 3.3 SUBSEQUENT START-UP PROCEDURE
11 3.4 SHUTDOWN PROCEDURE
TABLE OF CONTENTS
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL

Section 4 page
TROUBLESHOOTING 13 4.1 TROUBLESHOOTING INTRODUCTION
13 4.2 TROUBLESHOOTING GUIDE- SUPERVISOR CONTROLLER
16 Table 4-1A Analog Alarms (Flooded Screw Compressors
Less Than 200 psi)
17 Table 4-1B Analog Alarms (LS-16T, LS-20T and
LS-20TS Compressors)
18 Table 4-2 Parameters
19 4.3 MACHINE BEHAVIOR AFTER A POWER OUTAGE
19 4.4 REMOTE STOP/START INPUT
19 4.5 BROWN OUT INPUT
19 Table 4-3 Machine Power Outage Behavior
19 Table 4-4 Remote Start/Stop Input
Section 5
WIRING SCHEMATIC
DIAGRAMS 21 5.1 WIRING DIAGRAM- SUPERVISOR COMMUNICATION
MODULE
22 5.2 WIRING DIAGRAM- SUPERVISOR CONTROL
Section 6
VARIABLE SPEED
DRIVE 23 6.1 SAFETY
23 6.2 OVERVIEW
24 Table 6-1: Cable and Fuse Sizes- 460V Ratings
24 6.3 INSTALLATION
24 6.4 SUPERVISOR DISPLAY AND MENUS
24 6.1.1 VSD STATUS
25 6.4.2 CONTROL PARAMETERS
25 6.4.3 CALIBRATION
25 6.4.4 FACTORY SETUP
25 6.4.5 VSD SETUP
26 6.5 STARTUP OF NEW COMPRESSOR PACKAGE
26 6.6 FAULT AND WARNING CODES
TABLE OF CONTENTS

1
Section 1
SAFETY
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture all of their products so they can be
operated safely. However, the responsibility for safe
operation rests with those who use and maintain
these products. For safe machine operation it is
vitally important to review all safety precautions
noted in the Safety Section of your compressor’s
Operator’s Manual. The precautions listed there, as
well as those following, are offered as a guide
which, if conscientiously followed, will minimize the
possibility of accidents throughout the useful life of
this equipment.
The compressor should be operated only by those
who have been trained and delegated to do so, and
who have read and understood their compressor’s
Operator’s Manual. Failure to follow the instruc-
tions, procedures and safety precautions listed
here and in the Operator’s Manual may result in
accidents and injuries.
NEVER start the compressor unless it is safe to do
so. DO NOT attempt to operate the compressor
with a known unsafe condition. Tag the compressor
and render it inoperative by disconnecting and lock-
ing out all power at source or otherwise disabling its
prime mover so others who may not know of the
unsafe condition cannot attempt to operate it until
the condition is corrected.
Use and operate the air compressor only in full
compliance with all pertinent OSHA requirements or
any pertinent Federal, State, and Local codes or
requirements.
DO NOT modify the compressor and/or controls in
any way except with written factory approval.
1.2 ELECTRICAL SHOCK
A. Keep all parts of the body and any hand-held
tools or other conductive objects away from
exposed live parts of electrical system. Maintain dry
footing, stand on insulating surfaces and DO NOT
contact any other portion of the compressor when
making adjustments or repairs to exposed live parts
of the electrical system.
B. Attempt repairs only in clean, dry and well light-
ed and ventilated areas.
C. Stay clear of the compressor during electrical
storms! It can attract lightning.
1.3 VARIABLE SPEED DRIVE
Refer to Section 6 for safety information on prducts
with variable speed drives.
1.4 DECALS
See Figures 1-1A and 1-1B. The Supervisor control
panel contains several decals which contain neces-
sary information for safe performance. These
decals should never be removed. If a decal
becomes damaged, contact your nearest Sullair
Distributor or the Sullair Corporation factory Service
Department for replacement parts (Note: When
ordering new decals, use part number printed on
decal face.).

Section 1
SAFETY
2
Figure 1-1A Decals

3
Section 1
SAFETY
Figure 1-1B Decals
key part
number description number quantity
1 decal, warning auto start 250017-903 1
2 decal, danger breath air (I) 250027-935 1
3 sign, warning “food grade” lube 250003-144 1
4 decal, auto start 041065 1
(I) OSHA and FDA guidelines are superseded by any Federal, State or Local regulations whenever
applicable.

4
Section 2
SUPERVISOR DESCRIPTION
Figure 2-1 Supervisor Control Panel

5
Section 2
SUPERVISOR DESCRIPTION
2.1 SUPERVISOR KEYBOARD LAYOUT
Refer to Figure 2-1. The Display module has eleven
keys grouped in two rows.
The top row has the following seven keys :
- Help key, used to display possible causes of
and correction for an alarm or fault.
-Returns to main display.
-Used to edit text or numbers (move cursor
left).
-Used to edit text or numbers (move cursor
right).
-Used to change numbers or text, or scroll.
-Used to change numbers or text, or scroll.
-Used to select an item from a menu, or start
and end an edit on a parameter.
The bottom row has four keys :
-Stop, stops machine. Clears faults and warn-
ings if machine is stopped.
- Run, starts machine. Clears warnings if
machine is running.
-Toggles auto mode.
-Toggles Local/Remote mode. This can be
used to disable sequencing.
2.2 MAIN DISPLAY
Line 1 - Machine state :
E-Stop - E- Stop button pressed, or auxiliary e-
stop present.
Stopped - Machine not running.
Unloaded - Machine running unloaded.
Loaded - Machine running, loaded and modu-
lating.
Full Load - Machine forced to full load. (Used
only in sequencing modes).
Remote Stop - Compressor is off but armed to
start. The machine will start when the remote
start contact is closed. NOTE : the machine
may start at any time.
Seq Stop - Compressor is off but armed to
start. The machine will start when the sequenc-
ing conditions meet the criteria to start. NOTE:
the machine may start at any time.
Trim - Machine running, loaded and modulating
in a sequenced system.
Line 2 - Fault or Warning, blank means no fault or
warning is present.
If there are multiple alarms, they will be shown for 2
seconds each. If an alarm is active, pressing the ‘?’
key will give troubleshooting information on that
alarm.
Line 3 - P2 - Line pressure
Line 4 - T1 - Discharge Temperature
2.3 FUNCTION MENU
While in the main display, if any of the arrow keys
are pressed, the function menu is displayed. This
menu is used to view status or edit parameters.
The function menu has the following entries :
Status - Current pressures, temperatures, inputs
and outputs.
VSD Satus - (VSD packages only) See Section 6.
Control Parameters - Pressure and temperature
and timer settings.
Maintenance - Preventive maintenance informa-
tion and timers.
Fault Log - Log of previous faults.
Sensor Log - Log of sensor readings leading up to
a fault.
Sequencing - Sequencing parameters.
System Display - Display of modes of machines in
a sequencing system.
Calibration - Correction factors for pressures.
Test - Used by Sullair personnel for troubleshooting
serial communications.
Factory Setup - Model settings.
VSD Setup - (VSD Packages only) See Section 6.
To select a function, use the up and down arrow
keys to scroll to the desired function as indicated on
last line of display, then press the enter key.
After entering a function, the information can be
viewed by using the up and down arrow keys. If the
function shows status then values cannot be
changed. If the function displays parameters, then
the values can be changed.
To change a value, scroll to the line to be changed

6
Section 2
SUPERVISOR DESCRIPTION
using the up arrow and down arrow keys, and push
the enter button. The value can be changed by
using the up arrow or down arrow keys. When edit-
ing is finished, pushing the enter key will fix the
value. If during a change the ESC key is pushed,
editing is terminated and the original value is reset.
The left and right arrow keys can be used to move
to other digits or letters in a value. For example to
change a value from 100 to 500, the left arrow key
can be used to position the cursor to the 1 digit in
the 100, and the up arrow key used to increment
the digit to 5.
Text fields can also be edited in the same manner.
Push the enter key to start the edit, use the left and
right arrow keys to move to the letter to be changed,
then use the up and down arrow to change the let-
ter. Push the enter key to complete the edit.
The following are detailed descriptions of the vari-
ous displays.
2.4 STATUS - CURRENT PRESSURES, TEMPERA -
TURES, INPUTS AND OUTPUTS
All inputs and outputs are displayed showing both
the designator and the description (eg. T1-
Discharge) along with the selected temperature (C
or F) or pressure (psi, bar, kPa) units. Digital inputs
and outputs are shown either as a ‘0’ (zero) or ‘1’
(one). Zero is off and one is on. This is a view only
display.
The order of display is :
Temperatures - T1 through T5 depending on
model.
Pressures - P1 through P4 depending on model.
Delta pressures - dp1 through dp3 depending on
model.
Load Hours - Hours machine has run loaded.
Run Hours - Hours machine has run loaded or
unloaded.
Load Cycles - Number of load/unload cycles.
Starts - Number of times machine has started.
E-Stop String - E-Stop push button.
Aux E-Stop - Auxiliary E-Stop, wired by customer.
Digital Inputs - D1 through D10, depending on
model.
Relay Outputs - K1 through K8, depending on
model.
2.5 CONTROL PARAMETERS - PRESSURE, TEM-
PERATURE AND TIMER SETTINGS
Parameters that control the operation of the
machine are viewed and set using this display.
These parameters may vary by machine model.
The Control Parameters are :
Unload pressure - The pressure where the
machine is unloaded. For example if this parameter
is set to 110 psi (7.6 bar) the machine will unload
when the line pressure is above 110 psi (7.6 bar).
Load delta - The pressure differential below the
unload pressure where the machine is loaded. For
example if the unload pressure is set to 110 psi (7.6
bar) and the load differential is set to 10 psid (0.7
bar), the machine will load when the line pressure
goes below 100 psi (6.9 bar).
Setpoint - (VSD packages only) The targeted pres-
sure for the variable speed controls. This is normal-
ly adjusted near the bottom of the load/unload band
above. The speed will be adjusted to maintain this
pressure. Refer to Section 6 for additional details.
Unload Time - If the machine is running in AUTO
mode, this parameter specifies the amount of time
that the machine will run unloaded before shutting
off. If the time is set less than 15 minutes (for
example 5), there may be times when the machine
will run unloaded for more than 15 minutes. This is
because there is another timer that keeps the
machine from being started more than four times an
hour. This secondary timer is disabled when a
machine is configured for VSD motor control.
Drain Interval - If the machine has an electric sole-
noid drain, this parameter and the following param-
eter (Drain Time) are used to turn on the drain. The
interval is the time between activations of the drain
and the Drain Time is the length of the time ener-
gized. This does not apply to the Sullair SCD zero
loss drain, which is not controlled or monitored by
the Supervisor.
Drain Time - Length of time that drain is energized.
Restart time -
Time to wait after power up before starting machine.
This parameter is used to keep several machines
from starting at the same time after power up, or to
delay start until other equipment is started. If dis-
abled parameter is zero, the machine will not auto-
matically start after power up. If this parameter is a
Enabling this function also enables automatic
restart after power recovery. Be sure to depress
the Emergency Stop button to defeat this function
when automatic start is to be prevented.

7
Section 2
SUPERVISOR DESCRIPTION
number larger than zero, the machine restarts after
a delay defined by this time. For example, if the
Restart Time is set to 10 seconds, then the machine
will be enabled to start after 10 seconds.
Wye to delta transition timer - Also used to con-
trol the closed inlet start valve. Disable by setting to
zero (0), standard for full voltage start. Requires
approximately 4-6 seconds for wye-delta or solid
state starting.
Modulate - Default state is Yes for normal machine
control. Select No for Load/No Load operation.
Language select - English, German, Spanish,
Italian and French may be selected for display lan-
guage.
Temp Units - Temperature units may be set to
degrees F or degrees C.
Press Units - Pressure units may be set to psi, bar,
or kPa.
(VSD packages only) - Additional adjustments for
VSD operation are shown in Section 6.
2.6 MAINTENANCE - PREVENTIVE MAINTENANCE
INFORMATION AND TIMERS
The following lines are on the Maintenance display.
Information - The top two lines may be changed to
advise what to do when there is a maintenance
warning. For example a distributor can put in his
name and telephone number.
Ser. No - Serial number of machine.
Warn at - When the following drop below this num-
ber, a warning is issued.
Oil Filter hours - Hours before oil filter change.
PN - Oil Filter part number.
Separator hours - Hours before separator change.
Prim. - Primary separator part number.
Sec. - Secondary separator part number.
Air Filter hours - Hours before air filter
change.
Prim. - Primary air filter part number.
Sec. - Secondary air filter part number.
Oil hours - Hours before oil change.
PN - Oil part number.
Oil Anal. - Hours before oil analysis.
These hours and part numbers can be changed
using the enter and arrow keys.
2.7 FAULT LOG - LOG OF PREVIOUS FAULTS
The fault log shows the last 16 faults that occurred.
The top line of the display shows the run hours
where the fault occurred, and the second line
shows the fault. The faults can be scrolled through
using the up and down arrow keys. They are
ordered by most recent first. (ie. when the function
is entered the most recent fault is displayed.
Pressing the down arrow displays the previous fault
etc).
2.8 SENSOR LOG
Log of sensor readings leading up to a fault.
The sensor log shows the sensor readings leading
up to a fault. The top line shows the last fault. The
following lines show T1, T2, P1 & P2. Each line rep-
resents readings that are 5 seconds apart for one
minute, then one minute apart for 10 minutes.
There is a second set of readings for T3, T4, P3 &
P4.
2.9 SEQUENCING - SEQUENCING & COMMUNICA-
TION PARAMETERS
The following parameters can be viewed and edit-
ed. For more details on sequencing see the
Supervisor Sequencing and Protocol Manual.
Sequence By - Sequencing mode can be set to:
Disabled - Control does not do any sequenc-
ing.
Remote - Enables Remote Start/Stop, Remote
Load/Unload and Local/Master inputs
Hours - Uses the Seq Hrs parameter to deter
mine order of sequencing
Number - Uses the Com Number to determine
order of sequencing
Seq Hrs - This is an hour counter used when the
‘Sequence By’ parameter is set to ‘Hours’. Each
hour that the machine is running increments this
counter. When then ‘Sequence By’ parameter is set
to ‘Hours’, the machine with the least amount of
Seq Hrs is started first, and the machine with the
most Seq Hrs is shut off first.
Com Number - Communications number. When
two or more machines are connected together
using the network (RS-485 channel), each machine
must have a unique number or address. These
must be assigned in numerical order. For example
in a three machine system the machine communi-
cations numbers should be 1, 2 & 3.
Machines - This is the total number of machines
Unload pressure MUST be lowered to rated pres-
sure when using Load/No Load mode.

8
Section 2
SUPERVISOR DESCRIPTION
connected to the network (RS-485 channel). For
example in a three machine system, this parameter
should be set to 3. Up to sixteen machines may be
networked if all have Supervisor Controllers and
limited to eight if some have Supervisor II’s.
Low Press - This is the lowest pressure allowed
before immediately starting a machine.
Recovery Time - This parameter keeps multiple
machines from loading, unloading and starting at
the same time. For example if a low pressure con-
dition causes a machine to start, the next machine
will not start unless the Recovery Time has elapsed,
and the pressure has not recovered (i.e., has risen
over ‘Low Press’).
Rotate - This parameter is used only in very special
cases.
The only time this parameter should be used is in a
situation where, once a machine is started, it never
stops (ie. the unload timer never expires). This can
happen when the load matches the output of the
machine, all the time. In this case the machine will
never unload and shut off. The rotate forces the
machine to stop after it’s Seq Hrs. are greater that
the other machines. For example in a two machine
system, with Rotate set at 100 hrs. The machine
that is running will shut off when the Seq Hrs. are
100 more that the machine that is stopped.
Minute, Hour, Day, Month, Year- If the
Communications Module is present in the system,
the time and date can be set using these parame-
ters.
2.10 SYSTEM DISPLAY - DISPLAY OF MODES OF
MACHINES IN A SEQUENCING SYSTEM
Note that this display is only applicable when there
are two or more machines connected to the com-
munications network (RS-485) and the Sequence
By parameters on each machine are set to ‘Hours’
or ‘Number’.
The columns are described below
Communication Number
Status -
E - Emergency Stop
M - Manual stop
R - Remote stop
B - Standby
S - Starting
U - Unloaded
L-Loaded
T - Trim machine
F - Full load
Sequencing Hours
Capacity - Not used at this time.
Local System Pressure - Pressure read by
machines pressure transducer.
The top line is a legend that describes each column.
The right hand number on the top line is the system
pressure. The system pressure is the highest pres-
sure reading of all the machines. Note that the local
pressure readings can be used to determine what
machines may need to be calibrated. The system
pressure transducers on all machines should read
within 1(one) psi of one another. The calibration
function can be used to set the readings to be the
same.
2.11 CALIBRATION - CORRECTION FACTORS FOR
PRESSURES
The first line of this display is the password. If the
password is 0 then the following parameters are not
protected and can be changed. If the password is
non-zero, then enter the displayed number plus 4 to
enable changing the parameters. For example if the
number displayed is 10 then changing the pass-
word to 14 will enable editing.
The four pressures P1, P2, P3 & P4 as well as the
differential pressure dP1 can be calibrated. The
number on the right hand side of the line is added
to the transducer reading to give the calibrated
reading. The calibrated reading is shown in the mid-
dle of the line.
Cap and KW calibration (VSD packages only) may
be used to adjust values shown on VSD Status dis-
plays. These are factory set to nominal values
(100%), but may be adjusted as desired.
There are also three other parameters in the cali-
bration function:
Protect - When set to yes, protects the control
parameters from change.
Fault on Warn - Force fault on warning.
Force Unload - When set to yes, forces the
machine to unload.
2.12 TEST- Used by Sullair personnel for troubleshoot-
ing of serial communications.
2.13 FACTORY SETUP- Model settings.
The factory setup display is used by Sullair person-
nel to initially set up the machine. The following val-
Leave this parameter disabled unless instructed
by Sullair Service Personnel.

9
Section 2
SUPERVISOR DESCRIPTION
ues reflect the machine configuration.
Model - Model number of machine.
Cooling - Air or Water.
Press Trans - Pressure transducer range 200, 250,
500.
P1 Max - Maximum discharge pressure.
KT Fluid - Yes or No, indicating fluid.
Water Switch - Water pressure switch, Yes or No.
Oil Switch - Oil pressure differential switch, Yes or
No.
Min Load Psi - Minimum acceptable load P1 pres-
sure setting. Separator Maintenance warning is dis-
abled for loaded P1 pressures below this value (i.e.,
during start-up).
Lube Cycle - Pre-lube/ Post-lube function timer - 0
seconds (disabled) to 30 seconds.
K8 Option - K8 output relay function selector -
Disabled, Oil pump prelube and postlube control,
Master Control for special external sequence con-
trol.
Stop Timer - Time to run machine before stopping.
Protect - Protect control parameters.
Load Hours - Hours machine was running and
loaded.
Run Hours - Hours machine was running loaded
and unloaded.
Load Cycles - Number of load/unload cycles.
Starts - Number of machine starts.
Capacity - Maximum capacity of machine.
Spiral Valve - (VSD packages only) Yes or No, indi-
cating spiral valve control.
VSD- Describes signal from Supervisor controls to
the VSD controls:
None - No VSD
Pressure - The Supervisor pressure singal is
connected to a drive analog input
Serial - The drive is connected on the
Supervisor serial data bus
Speed - The Supervisor provides a speed sig-
nal to a drive analog input.
Com Module - Yes/No Enables or disables the
communication module if installed.
Mtr Module - Yes/No Enables or disables the
motor actuator module if installed.

10
Section 2
SUPERVISOR DESCRIPTION
Table 2-1 Supervisor Controller Menu Tree
T1 -Discharge T2 -Dry Side* T3- Oil* T4 Interstage* P1-Sump P2-Line P3-Oil Filter* P4-Oil* dP1-Separator dP2-Oil Filt* dP3-Oil* Load Hours Run Hours Load Cycles Starts E-Stop String Aux E-Stop D1-Motor Ovld D2-Aux Ovld D3-Air Filter* D4-Water Press* D5-Remote Start D6-Remote Unload D7-Master Control D8-Brownout D9-Not Defined D10-Not Defined K1-Run K2-Wye-Delta K3-Load K4-Full Load K5-Drain K6-Common Fault K7-Common Warn K8-Option
Unload Psi Load Psi Setpoint* Unload Time Drain Interval Drain Time Restart Time Wye-Delta Time Modulate Y/N Language Temp Units F/C Press Units Psi/bar/kPa Cost/KWH* Saving VS* Reset Load Est*
Info to be loaded by Distributor for all con- sumables
Last 16 faults
recorded
Capacity* Capacity %* Power* Power %* Recent Usage-------* Hours* Capactiy* Capacity %* Power* Power %* KCF* KWH* Cost* Savings* Lifetime Usages-----* Hours* Capacity* Capacity %* Power* Power %* KCF* KWH* Cost* Savings* Drive Status---------* P2* Motor RPM* Frequency* Drive Temp* Motor Prot*
Status VSD Status* Control
Parameters
Maintenance Sensor Log
Sequencing
System
Display
Calibration
Test
Factory
Setup
VSD
Setup*
MAIN SCREEN
Machine Status
Trouble State
P2-Line xxxPsi T1-Discharge xxxF
Fault Log
T1 T2 P1 P2 T3 T4 P3 P4
Sequence By xxxxx Sequence Hrs xxxxx Com Number xx Machines xx Low Press xxx Recover Time sec Rotate (hours) Minute xx Hour xx Day xx Month xx Year xxxx
Machine status
of Sequenced
machines
Password P1 P2 dP P3 P4 Cap KW Protect N/Y Fault on Warn Y/N Force Unload Y/N
Serial
communications
diagnostic
screen
Password Set Defaults Model Cooling Press Trans P1 Max KT Fluid Water Switch Oil Switch Aux Overl0ad Min Load Psi Stop Timer Lube Cycle K8 Option Load Hours Run Hours Load Cycles Starts Capactiy Sprial Valve* VSD N/Y Com Module N/Y
VSD Auto Set* Nominal HP* Nominal Volts* VSD Max Amps* Motor FLA* Motor SF* Motor V* Motor Hz* Motor RPM*
*These parameters do not apply to some models.

11
Section 3
START-UP PROCEDURES
3.1 MOTOR ROTATION DIRECTION CHECK
After the electrical wiring has been done, it is nec-
essary to check the direction of the motor rotation.
With the control system in MANUAL mode, press
the and pads in succession to bump start
the compressor. When looking at the motor from the
end opposite the compressor unit, the shaft should
be turning clockwise on all gear driven models, and
counterclockwise on direct drive models. If the
motor shaft is not turning in the proper direction,
disconnect the power to the starter and exchange
any two of the three power input leads, then re-
check rotation. A “Direction of Rotation” decal is
located on the coupling guard between the motor
and compressor to show proper motor/compressor
rotation.
Variable speed drive packages will have main motor
direction set at the time of construction, but the fan
direction is affected by installation. If fan-cooled,
ensure that fan rotation is correct. To change direc-
tion, disconnect the power and exchange any two of
the three fan motor leads at the fan motor starter.
3.2 INITIAL START-UP PROCEDURE
The following procedure should be used to make
the initial start-up of the compressor.
1. Be sure that all preparations and checks
described in the Installation Section have been
made.
2. Read the preceding pages of this manual thor-
oughly.
3. Jog motor to check for correct rotation of fan
(refer to Section 3.1).
4. Start the compressor in the desired operating
mode or .
5. Slowly open the shut-off valve to the service line.
6. Check for possible leaks in piping.
7. Slowly close the shut-off valve to assure proper
nameplate pressure unload setting is correct.
The compressor will unload at nameplate pres-
sure. If adjustments are necessary, see Control
System Adjustment section in the compressor
operator’s manual.
8. Observe the operating temperature. Refer to
compressor operator’s manual for acceptable
operating range. If temperature exceeds this
range, the cooling system and installation envi-
ronment should be checked.
9. Open shut-off valve to the service line.
10. Reinspect the compressor for temperature and
leaks the following day.
3.3 SUBSEQUENT START-UP PROCEDURE
On subsequent start-ups, check that the proper
level is visible in the fluid sight glass and simply
press the START or AUTO MODE button.
When the compressor is running, observe the
instrument panel and maintenance indicators.
3.4 SHUTDOWN PROCEDURE
To shut the compressor down, simply press the
STOP button.

12
NOTES

13
Section 4
TROUBLESHOOTING
4.2 TROUBLESHOOTING GUIDE- SUPERVISOR CONTROLLER
MESSAGE MODEL ENABLE PROBABLE CAUSE REMEDY
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
Watercooled
ALWAYS
ALWAYS
ALWAYS
ALWAYS
Air Filter Maint
Aux Motor Overload
E-Stop
E-Stop Push Button
E-Stop
E-Stop String
Low Water Pressure
Oil Change Due, Oil
Filter Change,
Separator Change Due,
Air Filter Change, Oil
Analysis Due,
Maintenance Due
Main Motor Overload
Replace filter.
Check inlet filter pressure switch.
Reset auxiliary overload after heater
element cools. Verify correct motor
amps.
Check for loose connections.
Check motor starter contact for
proper operation.
Check line voltage, if low consult
power company.
Release button.
Check wiring.
Check auxiliary E-Stop devices.
Check wiring.
Check for closed valves or broken
pipes.
Select Maintenance from menu to
see service due and part numbers.
Reset overload after heater element
cools down.
Make sure compressor is properly
configurated.
Make sure load pressure is set
below limit of compressor.
Differential Pressure Across
Inlet Filter High
Auxiliary Motor Tripped on
Cooling Fan, Oil Pump or Other
Motor
E-Stop Button Active
Auxiliary E-Stop String Open
Cooling Water Pressure Below
10 psi (0.7bar)
Maintenance Due
Main Motor Overload
4.1 TROUBLESHOOTING INTRODUCTION
The information contained in the Troubleshooting
chart has been compiled from factory experience. It
contains symptoms and usual causes for the
described problems. However, DO NOT assume
that these are the only problems that may occur. All
available data concerning the trouble should be
systematically analyzed before undertaking any
repairs or component replacement procedures.
A detailed visual inspection is worth performing for
almost all problems and may avoid unnecessary
additional damage to the compressor. Always
remember to:
a. Check for loose wiring.
b. Check for damaged piping.
c. Check for parts damaged by heat or an electrical
short circuit, usually apparent by discoloration or a
burnt odor.
Should your problem persist after making the rec-
ommended check, consult your nearest Sullair
Distributor or the Sullair Corporation factory Service
Department.
Whereas Sections 4.1 and 4.2 portray common
systematic setbacks that can occur during con-
troller operation, for a more thoroughly in-depth
coverage of machine operation setbacks, con-
sult the Troubleshooting Section in the
machine’s operator’s manual.
Continued...

14
Section 4
TROUBLESHOOTING
ALL
ALL
ALL
ALL
ALL
FLOODED
ALL
ALL
ALL
FLOODED
FLOODED
FLOODED
ALL
FLOODED
ALL
FLOODED
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
Main Motor Overload
(CONTINUED)
I/O Mod Com Error,
Com Mod Com Error,
Motor Mod Com Error,
VSD Com Error
Oil Filter Maint., dP2 Oil
Filter High
P3 Oil Pressure Low,
dP3 Oil Pressure Low
P1 Sensor Fail, P2
Sensor Fail, P3 Sensor
Fail, P4 Sensor Fail, T1
Sensor Fail, T2 Sensor
Fail, T3 Sensor Fail, T4
Sensor Fail, T5 Sensor
Fail
dP1 Separator High
Factory Setup Error
P1 Sump Pressure High
Main Motor Overload (cont.)
Module Network Error; The
Network that Connects the
Display Module, I/O Module and
Other Optional Modules is Not
Working Correctly
Pressure Across Oil Filter
Above 20 psi (1.4 bar) While
Running
Oil Pressure Low
Sensor or Wiring Failure
Pressure Across Separator High
The Factory Setup Information
Needs to be Reviewed for
Correct Values
Sump Pressure High (Poppet,
Sullicon, Spiral, Blowdown or
Pneumatic Valve Failed)
Check motor starter contacts for
proper operation.
Check line voltage, if low consult
power company.
Check wiring.
Replace module referred to in error
message, if problem persists
replace display module.
Oil filter clogged, replace oil filter.
Low ambient temperature, sump
heater may be required in ambients
below 40°F (4°C).
Sensor failure, check sensor, wiring
and tubing.
Oil pump failure, consult Sullair
service department.
Oil filter clogged; replace oil filter.
Sump oil level low, replenish oil to
proper level.
Low ambient temperature, sump
heater may be required in ambients
below 40°F (4°C).
Oil pump may be required for
remote coolers.
Check sensor wiring.
Check sensor.
Plugged separator elements,
replace.
Pressure sensor failure, check sen-
sor wiring.
If problem persists replace
Supervisor.
Check valves. Check Sullicon
adjustment (see Control Adjustment
section in the compressor operator’s
manual).
4.2 TROUBLESHOOTING GUIDE- SUPERVISOR CONTROLLER (CONTINUED)
MESSAGE MODEL ENABLE PROBABLE CAUSE REMEDY
Continued...

15
Section 4
TROUBLESHOOTING
P1 Sump Pressure High
(CONTINUED)
P1 Sump Pressure Low
T1 Interstage HIgh, T2
Discharge High, T3 Oil
Temp HIgh, T4 Intercool
High, T5 Discharge
High, T1 Discharge
High, T2 Dry Side High,
T3 Oil Temp High, T4
Interstage High
Power Interruption
VSD Emergency Stop
VSD Com Fault
VSD Param Lim Fault
VSD Drive Fault__
FLOODED
ALL
FLOODED
FLOODED
FLOODED
ALL
FLOODED
FLOODED
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
ALWAYS
Aircooled
Watercooled
Watercooled
Watercooled
ALWAYS
ALWAYS
VSD
VSD
VSD
VSD
Sump Pressure High (Poppet,
Sullicon, Spiral or Blowdown, or
Pneumatic Valve Failed) (cont.)
Sump Pressure Low
High Temp. Fault
Motor Starter(s) Not Working
No Contatct to Input D8
Intermittent Control Power
E-Stop Button Active
Communication Error Detected
by Drive
Communication Error at Power-
up or Setup
Incorrect Factory or VSD Setup
Fault Detected by Drive
Solenoid valves, check operation
and wiring.
Pressure regulator, check adjust-
ment and operation.
Check minimum pressure check
valve (not applicable to Oil Free
compressors).
Check pressure sensor, wiring and
tubing.
Machine may have failed to start.
Ambient above 105°F (41°C),
improve local ventilation.
Fluid level low, replenish to proper
level.
Thermal valve, check operation.
Cooler fins dirty, clean fins and fan.
Low water flow, check for valve
closed, pump off or broken pipe.
High water temperature, increase
flow or lower water temperature.
Cooler plugged, clean tubes and
shell, if plugging persists, use clean-
er water.
Sensor failure, check sensor and
wiring.
Check starter controls and wiring.
Check wiring to input.
Check line voltage and connections.
Release button.
Check for intermittent control wiring
to drive.
Check control wiring to drive.
Check setup menus and drive rat-
ing.
See Section 6.
4.2 TROUBLESHOOTING GUIDE- SUPERVISOR CONTROLLER (CONTINUED)
MESSAGE MODEL ENABLE PROBABLE CAUSE REMEDY

16
Section 4
TROUBLESHOOTING
Table 4-1A Analog Alarms (Flooded Screw Compressors Less Than 200 psi)
Start Run
Sensor Type Limit Delay Delay Check (*) Comment
P_1 High Inhibit 5 0 0 At Start High sump psi at start
P_1 Low Fault 5 5 0 When Running Immediate Fault
P_1 High Fault 500 0 0 Constantly Sensor failure fault
P_2 High Fault 500 0 0 Constantly Sensor failure fault
P_3 High Fault 500 0 0 Constantly Sensor failure fault
P_4 High Fault 500 0 0 Constantly Sensor failure fault
T_1 Low Fault -40 0 0 Constantly Sensor failure fault
T_1 High Warn 225 5 30 Constantly Delayed for temp spikes
T_1 High Fault 235 5 30 Constantly Delayed for temp spikes
T_1 High Warn 245 0 0 Constantly Immediate Warning
T_1 High Fault 255 0 0 Constantly Immediate Fault
T_1 High Fault 500 0 0 Constantly Sensor failure fault
T_2 Low Fault -40 0 0 Constantly Sensor failure fault
T_2 High Warn 225 5 30 Constantly Delayed for temp spikes
T_2 High Fault 235 5 30 Constantly Delayed for temp spikes
T_3 Low Warn -40 0 0 Constantly Sensor failure warning
T_3 High Warn 500 0 0 Constantly Sensor failure warning
T_4 Low Fault -40 0 0 Constantly Sensor failure fault
T_4 High Fault 500 0 0 Constantly Sensor failure fault
(*) In the ‘Check’ column above, alarms are checked:
Constantly - if machine running or stopped
When Running - if machine is running
If Enabled - if parameter is non-zero
At Start - will not allow start if alarm present
Over Min Psi - machine is loaded and above min load pressure