Sullair SUPERVISOR CONTROLLER User manual

SSUUPPEERRVVIISSOORR
CCOONNTTRROOLLLLEERR™™
SEQUENCING & PROTOCOL
MANUAL
(Including Supervisor II Controller)
OPERATOR’S
MANUAL
KEEP FOR
FUTURE
REFERENCE
Part Number
02250154-014
©Sullair Corporation

AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction in the proper operation, mainte-
nance and service of Sullair equipment. Individual seminars on Industrial compressors and compressor
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

TABLE OF CONTENTS
PAGE
Section 1
SAFETY AND INTRODUCTION
11.1 SAFETY
11.2 SUPERVISOR CONTROLLERS
11.3 SEQUENCED COMPRESSOR SYSTEMS
Section 2
SEQUENCING WITH MULTIPLE SUPERVISOR CONTROLLERS
32.1 NORMAL OPERATION
32.2 COMPRESSOR SYSTEM
42.3 CONTROLS WIRING
42.4 MACHINE PREPARATION PRIOR TO
SEQUENCING
42.5 SYSTEM OPERATION
52.6 SYSTEM SETUP AND TUNING
62.7 CHANGING SEQUENCE PARAMETERS
62.7.1 FOR SUPERVISOR
72.7.2 FOR SUPERVISOR II DELUXE
82.8 SYSTEM DISPLAY- SUPERVISOR
82.9 SYSTEM DISPLAY- SUPERVISOR II DELUXE
92.10 REMOVING A MACHINE FROM SEQUENCE
FOR MAINTENANCE
92.11 CALIBRATION OF P2 PRESSURE
TRANSDUCERS- SUPERVISOR
10 2.12 CALIBRATION OF P2 PRESSURE
TRANSDUCERS- SUPERVISOR II DELUXE
10 2.13 FULL LOAD FEATURE
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL
Continued...

TABLE OF CONTENTS
PAGE
Section 3
SEQUENCING WITH VARIABLE SPEED DRIVE COMPRESSORS
11 3.1 VARIABLE SPEED DRIVE APPLICATIONS
11 3.2 SETUP FOR FIXED SPEED MACHINES
AND A VSD COMPRESSOR
12 3.3 SETUP FOR MULTIPLE VSD COMPRESSORS
Section 4
OPERATION WITH REMOTE CONTROLLERS
13 4.1 NORMAL OPERATION
13 4.2 CONTROLS WIRING AND ADJUSTMENT-
SUPERVISOR
14 4.3 CONTROLS WIRING AND ADJUSTMENT-
SUPERVISOR II DELUXE
Section 5
SEQUENCING TIMERS
15 5.1 RECOVERY TIME & DELAYED START TIMER
16 5.1.1 Example 1: Unload Operation
16 5.1.2 Example 2: Load Operation
17 5.1.3 Example 3: Starting Example
(pressure drops below lowest pressure setting)
17 5.1.4 Example 4: Starting Example
(pressure between lowest and load pressure setting)
19 5.2 SUMMARY
Section 6
SUPERVISOR PROTOCOL
21 6.1 OVERVIEW
21 6.2 ADVANTAGES OF BROADCAST MODE
22 6.3 RS-486 SERIAL CHANNEL
22 6.4 TIME SLICING OF THE RS-485 SERIAL
CHANNEL
Continued...

Section 6 PAGE
SUPERVISOR PROTOCOL (CONTINUED)
24 6.5 MESSAGE FORMAT
24 6.6 MESSAGE TYPES
26 6.7 DATA TYPES
BACK COVER ADDRESSES AND TELEPHONE
NUMBERS
TABLE OF CONTENTS

Section 1
SAFETY AND INTRODUCTION
1
1.1 SAFETY
1.2 SUPERVISOR CONTROLLERS
This manual describes sequencing of multiple compressors with Supervisor or Supervisor
II Deluxe electronic controllers. Although these differ considerably in individual compressor
functions and user interface, they behave similarly in sequence capabilities, and can be
mixed within a compressed air system. This manual will use the term "controller" to apply
to either device, and will highlight specific differences in the few places where they apply.
Refer to the controller manuals for details on compressor operation and adjustment of the
controller.
1.3 SEQUENCED COMPRESSOR SYSTEMS
Compressor sequencing refers to using multiple compressors to meet the demands for
compressed air. This may be a simple duplex system or may be multiple compressors for
applications with widely varying demands. In any case, the compressors automatically stop,
if not needed, to reduce operating costs. A properly designed system can offer substantial
reductions in operating cost over a single large compressor. Many systems are designed
with one spare compressor, allowing the system to remain operational during maintenance
of a machine. The controls system does the job of efficiently running the compressors as
needed to meet the varying demands during the day, or to run the backup compressor only
when needed.
Supervisor and Supervisor II Deluxe controllers all feature internal sequencing functions.
Supervisor requires a communications module for these features. These operate as a dis-
tributed control system (rather than a master-slave relationship), so the system remains
operational even if a member is taken off-line. Refer to Section 2 for details.
A system with one or more variable-speed compressors offers some additional opportuni-
ties for control. Refer to Section 3 for details.
For information specific to the Supervisor Controller or Supervisor II, also
consult the Supervisor Controller manual, or Supervisor II Instruction manu-
al (for Supervisor II Deluxe models).
Operator should be familiar with all safety measures as described in the
Supervisor Controller™ or Supervisor II Instruction manuals (whichever per-
tains).
Machines should be off-line and not running when making parameter
changes. Unexpected machine operation may occur.

2
Section 1
SAFETY AND INTRODUCTION
Section 4 covers application of controllers in master-controlled systems.
Timers used in internal sequencing are described in Section 5.
Section 6 contains technical details of the hardware and protocol used on the communica-
tion bus. Other equipment may monitor this for data and presentation of system perform-
ance.

Section 2
SEQUENCING WITH MULTIPLE SUPERVISOR CONTROLS
3
2.1 NORMAL OPERATION
Supervisor and Supervisor II Deluxe controllers all feature internal sequencing functions. To
enable any Supervisor in the system, press theAuto key and Remote key on the key-
pad. Enable the Supervisor II Deluxe by simply pressing the Auto button. Any unit can
be stopped by pressing the STOP key , and remaining members will continue to operate
as needed.
The Supervisor Controller has a Remote keypad on the display module that is used to
enable and disable the controller from any sequencing mode that is currently programmed.
When the Remote key is first pressed after sequencing has been programmed, it will
enable that mode and light the REMOTE LED on the Display Module. Pressing that keypad
again will turn off the LED and disable the sequencing mode.The compressor will then oper-
ate as though it is not in any sequencing mode. The process will be reversed when the key-
pad is pressed again.
2.2 COMPRESSOR SYSTEM
Internal controller sequencing is designed to operate a group (2-16) of compressors feed-
ing a common header. As air demands change, the compressors will be controlled to deliv-
er the required compressed air in an efficient manner. If a group of similar compressors is
used, the controllers can be set up to automatically rotate operation to equalize run time.
Or, the controllers can be set up for a desired order of compressor operation. The three
modes of sequencing are:
SEQUENCE HOURS - In this mode, machines are started and loaded depending on the
SEQUENCE HOURS parameter. The sequence hours parameter is similar to run hours
except that it can be changed. Digital inputs for Remote control are disabled. ROTATE hours
are disabled.
COM NUM - In this mode, machines are started and loaded depending on the COMMUNI-
CATION NUMBER parameter. Operation is exactly the same as the SEQUENCE HOURS
method (see above) except the communications number is used to determine machine
sequence instead of sequence hours. Digital inputs for Remote control are disabled.
SEQUENCE HOURS with ROTATE Hours Enabled - A special version of SEQUENCE
hours for balancing run hours for use in only two-machine applications that has a demand
for only one machine. DO NOT use with more than two machines (See ROTATE hours
parameter setting for more information). Digital inputs for remote control are disabled.
It is best if the P2 (line pressure) transducers of all machines are connected to a common
header, down stream of individual dryers, etc. Note that the dP1 (separator maintenance
DO NOT enable this mode when the above situation is NOT true, because unexpected starts
and stops may occur when manually starting or stopping a machine in the sequence for main-
tenance.

4
Section 2
SEQUENCING WITH MULTIPLE SUPERVISOR CONTROLS
delta pressure) may need to be calibrated to take into account the extra pressure drop of
the down stream equipment.
2.3 CONTROLS WIRING
Control signals are passed along a simple network cable, Belden 9842 or similar. This cable
has two twisted pairs with a shield. One twisted pair is connected to ISO + and ISO - on the
Supervisor Comm module. Twisted pairs usually have one colored wire twisted with a black
or white wire. Make sure that the colored wire is on ISO + and the white or black wire is on
ISO -. Both wires of the other twisted pair are connected to ISO GND. The shield should be
connected to ground at one end only.
For Supervisor II Deluxe controllers, connect the colored wire to J2-16 and the white or
black wire to J2-17. Connect both wires of the other twisted pair is connected to J2-18.
2.4 MACHINE PREPARATION PRIOR TO SEQUENCING
1. Complete all machine startup procedures for stand-alone operation for the machines that
are to be sequenced together per the compressor operator’s manual.
2. Relocate the P2 signal for all machines to read the common header pressure. To recali-
brate the P2 signal for each machine so that they match within 1 psi of each other, use
the system display mode described later to view P2 on all machines. Recalibrate P2 on
each machine to match P2 on the other machines.
3. Program each machine with a different COM ID number (i.e.1, 2, 3, etc.).
4. Set UNLOAD psi, LOAD psi, BAUD RATE (Supervisor is fixed at 9600), SEQUENCE
mode (COM ID or HOURS), LAST COM, LOWEST and RECOVER time (normally set at
10) the same for each machine (except for VSD applications). Leave ROTATE hours dis-
abled except for the specific application described elsewhere. Set all SEQ HRS the same
unless it is desired to force certain machines to initially run more than others in the
HOURS mode.
5. Set the machines to run in AUTO mode. On the Supervisor, also press the Remote key
to arm the machines for sequencing. Machines will start immediately if the P2 system
pressure is low. On a fully pressurized system the machines will go into SEQ STOP until
a demand is seen. The following operation describes how machines are started, fully
loaded and unloaded by the sequencing mode selected. The AUTO mode provides the
means for each machine to SEQ STOP by timing out on its unload timer (UNLD TIM)
when the sequencing order decides the machine is to be unloaded.
2.5 SYSTEM OPERATION
For this example three machines are in a system with the load pressure set at 100, unload
at 110 psig (7.6 bar), lowest pressure at 90 psig (6.2 bar), and Recovery Time at 10 sec-
onds (default value). All machines are in sequence stop (top line of the display is SEQ
STOP). When the pressure drops below 102 psig (7.6 bar) a timer starts counting down from

Section 2
SEQUENCING WITH MULTIPLE SUPERVISOR CONTROLS
5
120 seconds, if the pressure continues to drop the timer will count down faster. When the
timer expires or the pressure drops below 90 psig (6.2 bar) the first machine is started. If
the pressure does not go above 90 psig (6.2 bar) for 10 seconds (Recovery Time) the next
machine will start and so on until all machines are started.
As machines are started and loaded, there will be only one machine that is modulating, the
others will be forced to "FULL LOAD". The modulating (trim) machine will load at 2psig (.14
bar) above the load pressure parameter, 102 psig (7.03 bar) in this example, and unload at
2 psig (.14 bar) below unload pressure parameter, 108 psig (7.4 bar) in this example. The
reason for this narrower load/unload band is to keep all machines from loading and unload-
ing at the same time. The trim machine will be identified on the display as "TRIM" operat-
ing state. If the pressure rises above the unload pressure -2 psig (.14 bar)(108 psig (7.4bar)
the trim machine will unload (display will say "UNLOADED") and the next machine in the
sequence will switch from full load to trim. If after Recovery Time the pressure is still above
108 psig (7.4 bar) then the trim machine will unload and so on until all machines are
unloaded. Then if the pressure falls below load pressure + 2 psig (.14 bar) or 102 psig (7.03
bar) the first machine in the sequence will load and be the trim machine. If after the
Recovery Time the pressure is still below 102 psig (7.03 bar) then the trim machine will go
to full load and the next machine in the sequence will load and become the trim machine.
2.6 SYSTEM SETUP AND TUNING
The following shows the settings for a system of low pressure 90-100 psig (6.2 to 6.9 bar)
machines. The Trim High & Low Setpoints are not settable parameters, they are calculated
from the Unload and Load pressures. The Trim High Setpoint is 2 PSI (.14 bar) below the
Unload pressure and the Trim Low Setpoint is 2 PSI (.14bar) above the Load pressure.
100 psig (6.9 bar) Unload
98 psig (6.8 bar) Trim High Setpoint (calculated parameter)
92 psig (6.3 bar) Trim Low Setpoint (calculated parameter)
90 psig (6.2 bar) Load
85 psig (5.9 bar) Lowest pressure
10 Recover time (seconds)
Note that the unload pressure is set to 100 psi (6.9 bar) and not 110 psi (7.6 bar) as is nor-
mal on a stand alone machine.A stand alone machine set up at 100 psi (6.9 bar) to 110 psi
(7.6 bar) , starts to modulate above 100 psi (6.9 bar) and the horsepower is reduced.
However, in a sequenced system a machine may be forced to full load, which would draw
more than the rated horsepower above 100 psi (6.9 bar). Therefore the modulation band
of machines in a system should be set up to be 10 psi (.7 bar) lower than their rated pres-
sure.
All running machines operate either at full load or unloaded except for the one that will here-
after be called the trim machine. The trim machine unloads when the line pressure rises
above the Trim High setpoint.
The Trim High and Low setpoints are necessary because the trim machine must unload
before the fully loaded machines and load before the unloaded machines, otherwise all

6
Section 2
SEQUENCING WITH MULTIPLE SUPERVISOR CONTROLS
machines would load and unload at the same time.
The LOWEST pressure parameter specifies the lowest pressure allowed before immedi-
ately starting a machine.Amachine may also be started if the line pressure drops below the
Trim Low setpoint for a period of time.
The RECOVER time is used to keep multiple machines from loading, unloading or starting
at the same time. A timer is reset when a machine loads, unloads or loads after a start.
Decisions to load, unload or start another machine are deferred until the timer reaches the
RECOVER time setpoint. Note that the timer starts when a machine is added or taken away
from the system. If the pressure recovers within the RECOVER time, and then at a later time
the pressure drops below the Trim Low setpoint, another machine will load immediately. The
shorter the recovery time the more responsive the system to load changes, but the less
energy efficient it is because machines may not shut off as often. The more often a machine
loads the less likely it is to stay unloaded and shut off after the Unload timer expires. The
RECOVER TIME has a default value of 10 sec. and may be adjusted from 2 to 59 sec.
In the following discussion 'highest' refers to the machine with the highest SEQ HRS or
COM ID and 'lowest' refers to the machine with the lowest SEQ HRS or COM ID.
The following rules are used to load, unload and start :
1. Only the highest loaded machine will trim; the rest will be forced to full load.
2. The trim machine will unload when the line pressure rises above the Trim High setpoint.
The next highest loaded machine will then become the trim machine. If pressure remains
above the Trim High setpoint, the new Trim machine will unload after Recovery Time
expires. This process will continue until only enough machines are running and loaded to
maintain proper system pressure.
3. The lowest unloaded machine will load (trim) when the line pressure drops below the Trim
Low setpoint. If the pressure remains below the Trim Low setpoint the next Unloaded or
Sequence Stopped machine will load or start after the Recovery Timer expires. This
process will continue until only enough machines are running and loaded to maintain
proper system pressure.
4. The lowest stopped machine will start when the line pressure drops below the Trim Low
set point, and after a variable time out period. This time out is dependent on how far the
line pressure is below the Trim Low set point. The farther below the set point the shorter
the time to start.
5. The lowest stopped machine will override the above variable time out feature and start
when the line pressure drops below the Lowest Pressure set point, and after the recov-
ery timer expires.
2.7 CHANGING SEQUENCE PARAMETERS
2.7.1 FOR SUPERVISOR CONTROLLER:
To change parameters on the Supervisor Controller, push the Down arrow key until
Sequencing menu is displayed. Press Enter . To select a parameter for change, move up
and down the menu with the Up and Down arrow keys. Press Enter to select the

Section 2
SEQUENCING WITH MULTIPLE SUPERVISOR CONTROLS
7
parameter for editing. The Up arrow and Down arrow keys will adjust the settings. If a
numeric value is to be entered, position to the character space with the Right and Left
arrow keys. Adjust the value with the Up and Down keys. To save the changed value,
push the Enter key.
2.7.2 FOR SUPERVISOR II:
To change parameters on the Supervisor II Deluxe, push the Program key until the top
line of the display identifies the parameter to be changed. The Up arrow and Logo
keys will increment the parameter value; the Lamp Test will decrement. Push
the Program key to save the changed value. The next parameter will then be dis-
played.
Parameter names and numerical order of screen appearance are shown in [brackets]
below.
The following parameters may need to be changed for sequencing:
Sequence by (SEQUENCE [9]) – Select the desired sequencing mode
Seq Hrs - To change this parameter in the Supervisor, push the key and change the values
as described above. The maximum value for sequence hours is 100,000. A rollover to zero
will occur if that number is exceeded.
(SEQ HRS [17]) - To change this parameter in the Supervisor II Deluxe, push the Program
key until SEQ HRS is displayed on the top line of the display. Pushing the Logo
key will increment by 1000 hours, the Up arrow key will increment by 100 hours and
the Lamp Test key will decrement by 100 hours. The number will roll over at 30,000
hours. To set the hours to a lower number it may be easier to push the Logo key until
the display reads 30,000, then hit the Up arrow key, the display will then go to 0.
Com Number (COM ID #[7]) - Must be unique for every machine in the system. If there are
three machines in a system, for example, they must be numbered 1, 2 and 3. Up to 16
machines may be sequenced with the Supervisor Controller.
Machines (LAST COM [12]) - Set to total number of machines in a system.
Low Press (LOWEST [13]) - This should be set to the lowest allowable pressure before a
machine has to start. Normally this is 5 to 10 psi (.3 to .7 bar) below the load pressure. If
the system pressure drops below this limit then the machine with the lowest SEQ HRS or
COM ID is started immediately. A machine will also start if the pressure is below the Trim
Low Setpoint for a period of time. The length of this time is 0 to 120 seconds depending on
the pressure. The closer the pressure is to LOWEST pressure the shorter the time. For
example if the pressure drops below the Trim Low Setpoint by 1 psi (.07 bar), and stays
there a machine will start in 120 seconds. If the pressure drops near LOWEST PRESSURE
then a machine will start in just a few seconds.
Recover Time (RECOVER [14]) - Recovery time. This parameter adds a delay between
subsequent start, load and unload commands. See Sequencing Timer Section for further

8
explanation.
Rotate (ROTATE [15]) - Rotate time for two-machine systems. There are some systems
where the trim machine never unloads or stops and the second machine is never required;
specifically a two-machine system where one machine runs all the time and the other is
used only for backup. The rotate parameter forces the trim machine to stop (allowing the
other machine to start). The trim machine will stop when its sequencing hours are more than
a stopped machine sequencing hours by the rotate hours value.
For example, consider a two-machine system with SEQUENCING hours of 1000 and
ROTATE of 50 hours on each machine. If one machine is started and continuously loaded,
it will run until it's sequence hours are 1050 (50 hours more than the stopped machine) then
stop. The other machine will start and run until it's sequence hours are 1100 (50 more than
the stopped machine) then stop, and so the machine will rotate back and forth every 100
hours.
Min, Hour, Day, Month, Year – (Supervisor only) Use to set the clock in the communica-
tions module. This time is displayed while in sequence mode of operation.
(BAUD RATE [8]) – Supervisor II Deluxe has adjustment of the serial communications baud
rate, almost always set to 9600. The Supervisor is fixed at 9600 baud. All controllers in the
system must be the same speed.
2.8 SYSTEM DISPLAY- SUPERVISOR
The SYSTEM menu selection is helpful for trouble-shooting, and calibration. The first col-
umn of the display shows the numbers 1 through the number of machines in the system (set
by parameter LAST COM). The second column shows the status of each machine. The sta-
tus letters are:
E - E-Stop U - Unloaded
M - Manual stop B - Standby
L - Loaded F - Full Load
T - Trim (loaded and modulating) S - Starting
R - Remote or sequence stop
The third column displays the capacities of the machines that are running. The fourth col-
umn indicates first the highest system P2 value and then P2 for each compressor in the
sequence. Lower case letters indicate that service is needed.
2.9 SYSTEM DISPLAY- SUPERVISOR II DELUXE
There is a system display that may be helpful for trouble-shooting, and calibration. While in
Section 2
SEQUENCING WITH MULTIPLE SUPERVISOR CONTROLS
DO NOT enable this mode when the above situation is NOT true, because unexpected starts
and stops may occur when manually starting or stopping a machine in the sequence for main-
tenance.

9
the main display, push the Logo key followed by the Display key. The top line of
the display should show the numbers 1 through the number of machines in the system (set
by parameter LAST COM). The second line shows the status of each machine. If the status
letter is lower case then the machine has a fault or warning. The status letters are:
E - E-Stop U - Unloaded
M - Manual stop B - Standby
L - Loaded F - Full Load
T - Trim (loaded and modulating) S - Starting
R - Remote or sequence stop
If the Up arrow key is pushed the system line pressure is displayed. If the Up arrow
key is pushed again the line pressure and run hours of the first machine is displayed, if the
arrow key is pushed again the second machine is displayed and so on. The Lamp Test
key changes to the previous display.
2.10 REMOVING A MACHINE FROM SEQUENCE FOR MAINTENANCE
To temporarily disable a machine from sequencing for maintenance, simply press the STOP
pad and/or E-Stop Button, remove power to that machine and apply the appropriate
Lockout/Tagout procedure. The rest of the networked machines will continue to sequence
properly. When restoring the machine to the network, simply restore power, pull out the E-
Stop, press STOP thenAUTO for Supervisor II Deluxe. If the sequencing param-
eters have not been changed, the machine will sequence in at the appropriate time. By
revising that machine's SEQUENCE HOURS before enabling sequencing, one may force it
to move up or down in the start priority in the HOURS sequencing mode.
To permanently remove a machine from sequence, reprogram the other compressors as
though the downed machine/s is/are not there. (Relocate the COM NUMBERS as needed
and change the LAST COM value per the number of machines removed.) Remember that
any program changes must be done while the machine is manually stopped.
2.11 CALIBRATION OF P2 PRESSURE TRANSDUCERS - SUPERVISOR
Because each machine has it's own pressure transducer it is possible that after a long peri-
od of time these can read differently. If this happens the Supervisors should be re-calibrat-
ed. This re-calibration is best done when the system is at a stable pressure. Measure the
pressure using an independent gauge then change the calibration parameter for P2 so that
the Supervisor reads the same as the gauge. Changing of the calibration parameters is
Section 2
SEQUENCING WITH MULTIPLE SUPERVISOR CONTROLS
DO NOT enable this mode when the above situation is NOT true, because unexpected starts
and stops may occur when manually starting or stopping a machine in the sequence for main-
tenance.

10
Section 2
SEQUENCING WITH MULTIPLE SUPERVISOR CONTROLS
entered by a separate password in the Calibration menu to protect from inadvertent
changes. If the password is not equal to zero, cursor to the password line, press the ENTER
key and then enter a value that is four more than the existing number. Press the ENTER
key and the number should go to zero. Repeat process if a keying error occurs that does
not release the password.
Cursor to the line that reads CAL P2. The display will show the (current P2 reading) and the
calibration parameter ( + 7 to -7). Press the ENTER key to adjust the value. The Up
arrow key will increase the reading and the Down arrow key will decrease the reading.
Use these keys to correct the P2 reading, then push the ENTER key. The ENTER key
must be pressed after setting the calibration parameter to make it permanent. Return to the
main display by pressing ESC and check to make sure the pressure is correct.
2.12 CALIBRATION OF P2 PRESSURE TRANSDUCERS – SUPERVISOR II
DELUXE
Because each machine has it's own pressure transducer it is possible that after a long peri-
od of time these can read differently. If this happens the supervisors should be re-calibrat-
ed. This re-calibration is best done when the system is at a stable pressure. Measure the
pressure using an independent gauge then change the calibration parameter for P2 so that
the supervisor reads the same as the gauge. The changing of the calibration parameters is
entered by a special key sequence to protect from inadvertent change. The key sequence
is : Logo , Up arrow , Display ; Lamp Test , Program . The first line
of the display should read CAL P1 , if not push the Display key and try again. If the first line
of the display reads CAL P1 push the Program key, and the first line of the display should
read CAL P2. The second line of the display will show the calibration parameter ( + 7 to -7)
and the current P2 reading corrected by the calibration parameter. The Up arrow key
will increase the reading and the Lamp Test will decrease the reading. Use these keys
to correct the P2 reading, then push the program key. The program key must be pressed
after setting the calibration parameter to make it permanent. Return to the main display and
check to make sure the pressure is correct.
2.13 FULL LOAD FEATURE
The full load feature energizes a solenoid valve on the machine that forces the base
machine/s to full load when being sequenced. Spiral valve machines may also require a
relay that de-energizes the spiral control solenoid valve during full load mode.

11
Section 3
SEQUENCING WITH VARIABLE SPEED DRIVE COMPRESSORS
3.1 VARIABLE SPEED DRIVE APPLICATIONS
Multiple compressor systems can be designed using a variable-speed-drive (VSD) com-
pressor combined with either fixed speed or other VSD compressors. The most efficient
use of a VSD machine in sequencing is to make it always be the trim machine and always
be running. This can be accomplished using the existing Sullair sequence logic.
3.2 SETUP FOR FIXED SPEED MACHINES AND A VSD COMPRESSOR
The fixed-speed machine(s) must be set up for load/unload operation. If controlled with
Supervisor II Deluxe controllers, the pressure regulator/s must be made to have no effect
by operating the system below their effective range. If controlled by the Supervisor
Controller, the controls may be programmed for Load/No load operation whereby the Full
Load valve is energized any time the machine is running, thus defeating modulation.
Alternately, the Full Load solenoid valve may be rewired to the Load output with either the
Supervisor Controller or Supervisor II Deluxe to accomplish the same thing. In any case
care must be taken to not overload these compressors by only operating at pressures with-
in the capability of the drive motor.See the following chart for suggested settings.
Since this machine is to always be the trim machine, no Full Load action is needed. The
Max Speed input signal should be disabled unless more than one VSD machine is in the
same sequence.
In this configuration, only the fixed-speed compressors are sequenced and the VSD is run
with its sequencing disabled. Sequence hours mode can then be used to automatically
rotate the fixed-speed machines, or you may select to sequence based on Com#.
Depending on the application and system demands, the VSD compressor can either be run
continuously or in the AUTO mode to minimize the unload time to as little as an immediate
stop on unload. In this arrangement, the VSD machine will always be operating as the trim
machine because it will restart at a higher pressure than the fixed-speed machines. By
adjusting the VSD Unload time in AUTO mode and the fixed-speed Restart times, rapid
cycling and hunting can be minimized.
Target system pressure at discharge of compressors: 99 psi
VSD Compressor Fixed-Speed Compressor(s)
Unload Setpoint 104 102
Load Delta 6 6
VSD Setpoint 99
Com # COM #1, 2 (, 3, 4, etc.)
Lowest Pressure 90
Since a fixed-speed L (100 psi) compressor's pressure regulator doesn't begin to throttle
until 101- 102 psi, it should have no effect, thereby causing the machine to operate
Load/Unload with or without the Full Load solenoid valve. The net result would have the
VSD always running and be able to modulate; the fixed-speed machines would come on
and go off as necessary but operate Load/Unload. Note that the normal load delta becomes
narrower while operating a sequenced system; the settings above will load at 97 and unload

Section 3
SEQUENCING WITH VARIABLE SPEED DRIVE COMPRESSORS
12
at 101 psi. The system will normally cruise at 98-100 psi.
3.3 SETUP FOR MULTIPLE VSD COMPRESSORS
With pressure-controlled VSD circuits, configure all compressors by Sequence Hours or
Com Number, as desired. Enable the Max. Speed Input function. All but one of the com-
pressors will be full-loaded, thus limiting the pressure to the rated value of the machines.
With serial-controlled VSD circuits, configure all compressors by Sequence Hours or Com
Number, as desired. The Supervisors allow all machines to run at reduced speeds, to
match delivery to demand. Unneeded machines will be stopped automatically. If the com-
pressors are L (100 psi) machines, set the program points as listed below:
Target system pressure at discharge of compressors: 95 psi
Unload Setpoint 102
Load Delta 8
VSD Setpoint 98
Lowest Pressure 90
Recover Time 10 sec.
Parameters may require adjustment based on system capacity and application. Unload
Setpoint should NEVER be more than 2 psi above package rating. Note that the normal
load delta becomes narrower while operating a sequenced system; the settings above will
load at 95 and unload at 101 psi. The system will normally cruise at 97-99 psi.

13
Section 4
OPERATION WITH REMOTE CONTROLLERS
4.1 NORMAL OPERATION
The controllers are capable of operation from remote-control devices. Depending on sys-
tem design, these may simply enable automatic operation, or may be responsible for load-
ing the compressor. When a remote-controlled system is set up, each compressor must be
programmed for remote sequencing, and enabled locally. To enable any Supervisor in the
system, press the Auto key and Remote key on the keypad. Enable the Supervisor
II Deluxe by simply pressing the Start button. Any unit can be stopped by pressing the
Stop key, and remaining members will continue to operate as needed.
The Supervisor Controller has a Remote keypad on the display module that is used to
enable and disable the controller from any sequencing mode that is currently programmed.
When the Remote key is first pressed after sequencing has been programmed, it will
enable that mode and light the REMOTE LED on the Display Module. Pressing that keypad
again will turn off the LED and disable the sequencing mode.The compressor will then oper-
ate as though it is not in any sequencing mode. The process will be reversed when the key-
pad is pressed again.
4.2 CONTROLS WIRING AND ADJUSTMENT – SUPERVISOR
There are three inputs and one output that are enabled in this mode:
Remote Stop/Start Input D5
Remote Load/Unload Input D6
Local/Master Input D7
Local/Master Output K8
D5, D6 and D7 are wired through customer furnished relay contacts to ground (Supervisor
Signal GND). If D5 is open the machine will stop, and be held stopped. If D5 is grounded,
the machine will be enabled to start; the following table describes how the other inputs work:
Local/Master Load/Unload Operation
Open Open Normal load and unload
Open Closed Force unload
Closed Open Force load, unload at P1 max - 3
Closed Closed Force unload
The Local/Master Output (K8) is closed when the Local/Master Input is on and the machine
is not in E-stop or Stop. The Local/Master Output is a relay contact that can handle 250VAC
at 10 amperes.
To change parameters on the Supervisor, push the Down arrow key until Sequencing
menu is displayed. Press Enter . To select a parameter for change, move up and down
the menu with the Up and Down arrow keys. Press Enter to select the parameter
for editing. The Up arrow and Down arrow keys will adjust the settings. If a numeric value is

14
Section 4
OPERATION WITH REMOTE CONTROLLERS
to be entered, position to the character space with the Right and Left arrow keys.
Adjust the value with the Up and Down keys. To save the changed value, push the
Enter key.
Select the sequencing group, and adjust Sequence by. Select the REMOTE mode. This
enables three digital inputs for Remote Start/Stop, Unload/Load and Master Control. These
inputs are normally controlled by remote relay contacts or a PLC controller. The Supervisor
may then be interfaced with custom sequencing panels, which provide signals for a 2-wire
stop/start operation. The remaining adjustments in the sequencing group have no effect in
REMOTE mode.
4.3 CONTROLS WIRING AND ADJUSTMENT – SUPERVISOR II DELUXE
There are three inputs and one output that are enabled in this mode:
Remote Start/Stop Input D10 J3-19
Remote Load/Unload Input D9 J3-18
Local/Master Input D8 J3-17
Local/Master Output K6 J1-14,15
Inputs D8, D9 and D10 are wired through customer furnished relay contacts to ground
(Supervisor II Deluxe Common J3-20). If D10 is open the machine will stop, and be held
stopped. If D10 is grounded the machine will be enabled to start. If remote start/stop is not
needed then jumper D10 (J3-19) to GND (J3-20). The following table describes how the
other inputs work when D10 connected to GND J3-20:
Local/Master Load/Unload Operation
Open Open Normal load and unload
Open Closed Force unload
Closed Open Force load, unload at P1 max - 3
Closed Closed Force unload
The Local/Master Output is on when the Local/Master Input is on and the machine is not in
E-stop or Stop. If the Local/Master output is on the display will have two stars (**) in the mid-
dle of the bottom line. The Local/Master Output is a relay contact that can handle 250VAC
at 8 amperes. (J1-14 & J1-15)
To change parameters on the Supervisor II Deluxe, push the Program key until the top
line of the display identifies the parameter to be changed. The Up arrow and Logo
keys will increment the parameter value; the Lamp Test will decrement. Push
the Program key to save the changed value. The next parameter will then be dis-
played. From the main screen, press the program key 9 times and adjust SEQUENCE.
Select the REMOTE sequencing mode. This enables three digital inputs for Remote
Start/Stop, Unload/Load and Master Control. These inputs are normally controlled by remote
relay contacts or a PLC controller. The Supervisor may then be interfaced with custom
sequencing panels, which provide signals for a 2-wire stop/start operation.