compass controller 02250167-454 r03 final · according to posted speed limits, weather, traffic,...

Failure to follow the instructions and procedures in this manual or,

misuse of this equipement will VOID its warranty!

WARRANTY NOTICE

PART NUMBER:

KEEP FORFUTURE REFERENCE

USER MANUAL

©COPYRIGHT 2012 SULLAIR The information in this manual is currentas of its publication date, and applies tocompressor serial number:

and all subsequent serial numbers.

02250167-454 R03

201201010000

COMPASS CONTROLLER™

AIR CARE SEMINAR TRAINING

Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,and servicing of Sullair products. Individual seminars on portable compressors and compressor electricalsystems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facilitylocated at Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting commonfaults 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 or219-861-5623

[email protected]

- Or Write -

Sullair3700 E. Michigan Blvd.Michigan City, IN 46360

Attn: Service Training Department.

TABLE OF CONTENTSSECTION 1—SAFETY

5 1.1 GENERAL

5 1.2 TOWING

8 1.3 PRESSURE RELEASE

9 1.4 FIRE AND EXPLOSION

10 1.5 MOVING PARTS

11 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

11 1.7 TOXIC AND IRRITATING SUBSTANCES

12 1.8 ELECTRICAL SHOCK

12 1.9 LIFTING

13 1.10 ENTRAPMENT

13 1.11 JUMP STARTING

14 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT

15 1.13 CALIFORNIA PROPOSITION 65

16 1.14 SYMBOLS AND REFERENCES

SECTION 2—STARTUP PROCEDURES 19 2.1 INTRODUCTION

19 2.2 CONTROLLER PANEL LAYOUT

19 2.3 COMPASS CONTROLLER POWER UP

21 2.4 NORMAL OPERATION

SECTION 3—ADJUSTMENTS 23 3.1 INTRODUCTION

23 3.2 SETTINGS AND DIAGNOSTIC

30 3.3 CONFIGURATION MENU

32 3.4 USER ADJUSTABLE CONTROL PARAMETERS (UCP)

SECTION 4—DESCRIPTION 35 4.1 INTRODUCTION

35 4.2 OPERATING MODES

TABLE OF CONTENTS

41 4.3 COMPRESSOR SHUTDOWN

SECTION 5—TROUBLESHOOTING 45 5.1 TROUBLESHOOTING INTRODUCTION

45 5.2 TROUBLESHOOTING GUIDE INTRODUCTION

46 5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE

Section 1

5

SAFETY

1.1 GENERAL

Sullair designs and manufactures all of its productsso they can be operated safely. However, theresponsibility for safe operation rests with those whouse and maintain these products. The followingsafety precautions are offered as a guide which, ifconscientiously followed, will minimize the possibilityof accidents throughout the useful life of thisequipment. Read the CIMA Safety Manual prior tocompressor operation and towing, if applicablein your area.

The air compressor should be operated only by thosewho have been trained and delegated to do so, andwho have read and understood this Operator’sManual. Failure to follow the instructions, proceduresand safety precautions in this manual can result inaccidents and injuries.

NEVER start the air compressor unless it is safe todo so. DO NOT attempt to operate the aircompressor with a known unsafe condition. Tag theair compressor and render it inoperative bydisconnecting the battery so others who may notknow of the unsafe condition will not attempt tooperate it until the condition is corrected.

Use and operate the air compressor only in fullcompliance with all pertinent OSHA requirements

and/or all pertinent Federal, State and Local codes orrequirements.

DO NOT modify the compressor except with writtenfactory approval.

Each day, walk around the air compressor andinspect for leaks, loose or missing parts, damagedparts or parts out of adjustment. Perform allrecommended daily maintenance.

Inspect for torn, frayed, blistered or otherwisedeteriorated and degraded hoses. Replace asrequired.

1.2 TOWING

PREPARING TO TOW

NOTE

OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL.

CAUTIONEstimated hose life based on a 5-day 8-hour work week is 3 years. These conditions exist on an 8-hour shift only. Any other operation of the equipment other than 8-hour shifts would shorten the hose life based on hours of operation.

(I)

WARNINGDo NOT tow the compressor should its weight exceed the rated limit of the tow vehicle, as the vehicle may not brake safely with excess weight. See rated limit in tow vehicle Operator's Manual, and review its instructions and other requirements for safe towing.

(I) WHILE NOT TOWED IN THE USUAL SENSE OF THE WORD, MANY OF THESE INSTRUCTIONS ARE DIRECTLY APPLICABLE TO SKID-MOUNTED PORTABLE AIR COMPRESSORS AS WELL.

SECTION 1

6

A. Prior to hitching the air compressor to the towvehicle, inspect all attachment parts and equip-ment, checking for (i) signs of excessive wear orcorrosion, (ii) parts that are cracked, bent,dented or otherwise deformed or degraded, and(iii) loose nuts, bolts or other fasteners. Shouldany such condition be present, DO NOT TOWuntil the problem is corrected.

B. Back the tow vehicle to the compressor and posi-tion it in preparation for coupling the compressor.

C. If the compressor is provided with a drawbarlatched in the vertical upright position, carefullyunlatch drawbar and lower it to engage the cou-pling device. If not, raise drawbar with the jack toengage coupling device or otherwise couple thecompressor to the towing vehicle.

D. Make sure the coupling device is fully engaged,closed and locked.

E. If chains are provided, pass each chain throughits point of attachment on the towing vehicle;then hook each chain to itself by passing thegrab hook over (not through) a link. Cross chainsunder the front of drawbar before passing themthrough points of attachment on towing vehicle tosupport the front of drawbar in case it shouldaccidentally become uncoupled.

F. Make sure that the coupling device and adjacentstructures on the towing vehicle (and also, if uti-lized, chain adjustment, brake and/or electricalinterconnections) DO NOT interfere with orrestrict motion of any part of the compressor,including its coupling device, with respect to thetowing vehicle when maneuvering over anyanticipated terrain.

G. If provided, make sure chain length, brake andelectrical interconnections provide sufficientslack to prevent strain when cornering andmaneuvering, yet are supported so they cannotdrag or rub on road, terrain or towing vehicle sur-faces which might cause wear that could renderthem inoperative.

H. On two-wheeled models, fully retract front screwjack and any rear stabilizer legs. If a caster wheelis provided on the screw jack it is part of thescrew jack, and can not be removed. Follow thesame procedure for stowing away the wheeledjack as you would for the standard screw jack.Pull the pin connecting the jack to the drawbarand raise the screw jack to its full upright posi-tion. Rotate the screw jack to its stowed position,parallel to the drawbar, and reinsert the pin.Make sure the jack is secured in place prior totowing.

WARNINGThis equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle.

Use the screw jack provided or a chain fall if you cannot lift or lower it without avoiding injury to yourself or others. Keep hands and fingers clear of the coupling device and all other pinch points. Keep feet clear of drawbar to avoid injury in case it should slip from your hands.


CAUTIONRetract the front screw jack only after attaching the compressor to the tow vehi-cle. Raise the screw jack to its full up posi-tion and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed posi-tion, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

SECTION 1

7

I. Make sure tires are in good condition and are thesize (load range) specified and are inflated to thespecified pressures. DO NOT change the tiresize or type. Also, make sure wheel bolts, lugs ornuts are tightened to the specified torques.

J. If provided, make sure all dual stop, tail direc-tional and clearance lights are operating properlyand that their lenses are clean and functional.Also, make sure all reflectors and reflecting sur-faces, including the slow moving vehicle emblemon compressors provided with same, are cleanand functional.

K. Make sure all service air hoses (not air brakehoses) are disconnected or are fully stowed andsecured on hose reels, if provided.

L. Make sure all access doors and tool box coversare closed and latched. If the compressor islarge enough to hold a man, make sure all per-sonnel are out before closing and latchingaccess doors.

M. Make sure parking brakes in towing vehicle areset, or that its wheels are chocked or blocked, orthat it is otherwise restrained from moving. Then,release the compressor parking brakes, if pro-vided.

N. Make sure the compressor wheels are notchocked or blocked, and that all tie-downs, if any,are free.

O. Test running brake operation, including break-away switch operation if provided, beforeattempting to tow the compressor at its ratedspeed or less when conditions prevail.

P. DO NOT carry loose or inappropriate tools,equipment or supplies on or in the compressor.

Q. DO NOT load this equipment with accessories ortools such that it is unbalanced from side to sideor front to back. Such unbalance will reduce thetowability of this equipment and may increasethe possibility of tipping, rolling over, jackknifing,etc. Loss of control of the towing vehicle mayresult.

TOWING

A. Observe all Federal, State, and Local laws whiletowing this equipment (including those specifyingminimum speed).

B. DO NOT exceed the towing speeds listed belowunder ideal conditions. Reduce your speed

according to posted speed limits, weather, traffic,road or terrain conditions:

1. Two axle four-wheel or three axle six-wheelsteerable models: 15 MPH (24 km/h).

2. All other models: 55 MPH (88 km/h).

C. Remember that the portable air compressor mayapproach or exceed the weight of the towingvehicle. Maintain increased stopping distancesaccordingly. DO NOT make sudden lanechanges, U-turns or other maneuvers. Suchmaneuvers can cause the compressor to tip, rollover, jackknife or slide and cause loss of controlof the towing vehicle. Tipping, rolling over, etc.can occur suddenly without warning. U-turnsespecially should be made slowly and carefully.

D. Avoid grades in excess of 15° (27%).

E. Avoid potholes, rocks and other obstructions,and soft shoulders or unstable terrain.

F. Maneuver in a manner that will not exceed thefreedom of motion of the compressor’s drawbarand/ or coupling device, in or on the towing vehi-cle’s coupling device and/or adjacent structurewhether towing forward or backing up, regard-less of the terrain being traversed.

G. DO NOT permit personnel to ride in or on thecompressor.

H. Make sure the area behind, in front of, and underthe compressor is clear of all personnel andobstructions prior to towing in any direction.

I. DO NOT permit personnel to stand or ride on thedrawbar, or to stand or walk between the com-pressor and the towing vehicle.

PARKING OR LOCATING COMPRESSOR

A. Park or locate compressor on a level surface, ifpossible. If not, park or locate compressor acrossgrade so the compressor does not tend to rolldownhill. DO NOT park or locate compressor ongrades exceeding 15° (27%).

B. Make sure compressor is parked or located on afirm surface that can support its weight.

C. Park or locate compressor so the wind, if any,tends to carry the exhaust fumes and radiatorheat away from the compressor air inlet open-ings, and also where the compressor will not beexposed to excessive dust from the work site.

D. On steerable models, park compressor with frontwheels in straight-ahead position.

SECTION 1

8

E. Set parking brakes and disconnect breakawayswitch cable and all other interconnecting electri-cal and/or brake connections, if provided.

F. Block or chock both sides of all wheels.

G. If provided, unhook chains and remove themfrom the points of chain attachment on the towingvehicle, then hook chains to bail on drawbar orwrap chains around the drawbar and hook themto themselves to keep chains off the groundwhich might accelerate rusting.

H. Lower front screw jack and/or any front and rearstabilizer legs. Make sure the surface they con-tact has sufficient load bearing capability to sup-port the weight of the compressor.

I. If a caster wheel is provided on the screw jack, itis part of the screw jack and cannot be removed.Follow the same procedure for stowing away the

wheeled jack as you would for the standard screwjack. Raise the screw jack to its full upright posi-tion and pull the pin connecting the jack to thedrawbar. Rotate the screw jack to its stowed posi-tion, parallel to the drawbar and reinsert the pin.Make sure the jack is secured in place prior totowing.

J. Disconnect coupling device, keeping hands andfingers clear of all pinch points. If the compressoris provided with a drawbar, DO NOT attempt to liftthe drawbar or if hinged, to raise it to the uprightposition by hand, if the weight is more than youcan safely handle. Use a screwjack or chain fall ifyou cannot lift or raise the drawbar without avoid-ing injury to yourself or others.

K. Move the towing vehicle well clear of the parkedcompressor and erect hazard indicators, barri-cades and/or flares (if at night) if compressor isparked on or adjacent to public roads. Park so asnot to interfere with traffic.

1.3 PRESSURE RELEASE

A. Open the pressure relief valve at least weekly tomake sure it is not blocked, closed, obstructed orotherwise disabled.

B. Install an appropriate flow-limiting valve betweenthe compressor service air outlet and the shutoff(throttle) valve, when an air hose exceeding 1/2"(13 mm) inside diameter is to be connected to theshutoff (throttle) valve, to reduce pressure in caseof hose failure, per OSHA Standard 29 CFR1926.302 (b) (7) or any applicable Federal, Stateand Local codes, standards and regulations.

C. When the hose is to be used to supply a manifold,install an additional appropriate flow-limiting valvebetween the manifold and each air hose exceed-ing 1/2" (13 mm) inside diameter that is to be con-nected to the manifold to reduce pressure in caseof hose failure.

D. Provide an appropriate flow-limiting valve for eachadditional 75 feet (23 m) of hose in runs of airhose exceeding 1/2" (13 mm) inside diameter toreduce pressure in case of hose failure.


CAUTIONRetract the front screw jack only after attaching the compressor to the tow vehi-cle. Raise the screw jack to its full up posi-tion and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed posi-tion, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

NOTEWhile not towed in the usual sense of the word, many of these instructions are directly applicable to skidmounted porta-ble air compressors as well.

SECTION 1

9

E. Flow-limiting valves are listed by pipe size andrated CFM. Select appropriate valve accordingly.

F. DO NOT use tools that are rated below the maxi-mum rating of this compressor. Select tools, airhoses, pipes, valves, filters and other fittingsaccordingly. DO NOT exceed manufacturer’srated safe operating pressures for these items.

G. Secure all hose connections by wire, chain orother suitable retaining device to prevent tools orhose ends from being accidentally disconnectedand expelled.

H. Open fluid filler cap only when compressor is notrunning and is not pressurized. Shut down thecompressor and bleed the sump (receiver) tozero internal pressure before removing the cap.

I. Vent all internal pressure prior to opening anyline, fitting, hose, valve, drain plug, connection orother component, such as filters and line oilers,and before attempting to refill optional air lineanti-icer systems with antifreeze compound.

J. Keep personnel out of line with and away fromthe discharge opening of hoses, tools or otherpoints of compressed air discharge.

K. DO NOT use air at pressures higher than 30 psig(2.1 bar) for cleaning purposes, and then onlywith effective chip guarding and personal protec-tive equipment per OSHA Standard 29 CFR1910.242 (b) or any applicable Federal, Stateand Local codes, standards and regulations.

L. DO NOT engage in horseplay with air hoses asdeath or serious injury may result.

M. This equipment is supplied with an ASMEdesigned pressure vessel protected by an ASMErated relief valve. Lift the handle once a week tomake sure the valve is functional. DO NOT liftthe handle while machine is under pressure.

N. If the machine is installed in an enclosed area itis necessary to vent the relief valve to the outsideof the structure or to an area of non-exposure.

O. DO NOT remove radiator filler cap until the cool-ant temperature is below its boiling point. Thenloosen cap slowly to its stop to relieve anyexcess pressure and make sure coolant is notboiling before removing cap completely. Removeradiator filler cap only when cool enough to touchwith a bare hand.

P. The ethyl ether in the replaceable cylinders usedin diesel ether starting aid systems (optional) is

under pressure. DO NOT puncture or incineratethose cylinders. DO NOT attempt to remove thecenter valve core or side pressure relief valvefrom these cylinders regardless of whether theyare full or empty.

Q. If a manual blowdown valve is provided on thereceiver, open the valve to ensure all internalpressure has been vented prior to servicing anypressurized component of the compressor air/fluid system.

1.4 FIRE AND EXPLOSION

A. Refuel at a service station or from a fuel tankdesigned for its intended purpose. If this is notpossible, ground the compressor to the dis-penser prior to refueling.

B. Clean up spills of fuel, fluid, battery electrolyte orcoolant immediately if such spills occur.

C. Shut off air compressor and allow it to cool. Thenkeep sparks, flames and other sources of ignitionaway and DO NOT permit smoking in the vicinitywhen adding fuel, checking or adding electrolyteto batteries, checking or adding fluid, checkingdiesel engine ether starting aid systems, replac-ing cylinders, or when refilling air line anti-icersystems antifreeze compound.

D. DO NOT permit liquids, including air line anti-icersystem antifreeze compound or fluid film, toaccumulate on bottom covers or on, under oraround acoustical material, or on any external orinternal surfaces of the air compressor. Wipedown using an aqueous industrial cleaner orsteam clean as required. If necessary, removeacoustical material, clean all surfaces and thenreplace acoustical material. Any acoustical mate-rial with a protective covering that has been tornor punctured should be replaced immediately toprevent accumulation of liquids or fluid film withinthe material. DO NOT use flammable solventsfor cleaning purposes.

WARNINGDo not attempt to operate the compressor in any classification of hazardous environ-ment or potentially explosive atmosphere unless the compressor has been specially designed and manufactured for that duty.

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10

E. Disconnect the grounded (negative) battery con-nection prior to attempting any repairs or clean-ing inside the enclosure. Tag the batteryconnections so others will not unexpectedlyreconnect it.

F. Keep electrical wiring, including the battery ter-minals and other terminals, in good condition.Replace any wiring that has cracked, cutabraded or otherwise degraded insulation or ter-minals that are worn, discolored or corroded.Keep all terminals clean and tight.

G. Turn off battery charger before making or break-ing connections to the battery.

H. Keep grounded conductive objects such as toolsaway from exposed live electrical parts such asterminals to avoid arcing which might serve as asource of ignition.

I. Replace damaged fuel tanks or lines immediatelyrather than attempt to weld or otherwise repairthem. DO NOT store or attempt to operate thecompressor with any known leaks in the fuel sys-tem. Tag the compressor and render it inopera-tive until repair can be made.

J. Remove any acoustical material or other materialthat may be damaged by heat or that may sup-port combustion prior to attempting weld repairs.Remove diesel engine ether starting aid cylin-ders and air line anti-icer system componentscontaining antifreeze compound, prior toattempting weld repairs in any place other thanthe fuel system. DO NOT weld on or near thefuel system.

K. Keep a suitable, fully charged class BC or ABCfire extinguisher or extinguishers nearby whenservicing and operating the compressor.

L. Keep oily rags, trash, leaves, litter or other com-bustibles out of and away from the compressor.

M. Open all access doors and allow the enclosure toventilate thoroughly prior to attempting to startthe engine.

N. DO NOT operate compressor under low over-hanging leaves or permit such leaves to contacthot exhaust system surfaces when operating thecompressor in forested areas.

O. Ethyl ether used in diesel engine ether startingaid systems is extremely flammable. Change cyl-inders, or maintain or troubleshoot these sys-tems only in well-ventilated areas away from

heat, open flame or sparks. DO NOT install,store or otherwise expose ether cylinders to tem-peratures above 160 °F (71 °C). Remove ethercylinder from the compressor when operating inambient temperatures above 60 °F (16 °C).

P. DO NOT attempt to use ether as a starting aid ingasoline engines or diesel engines with glowplugs as serious personnel injury or propertydamage may result.

Q. DO NOT spray ether into compressor air filter orinto an air filter that serves both the engine andthe compressor as serious damage to the com-pressor or personal injury may result.

R. Antifreeze compound used in air line anti-icersystems contains methanol which is flammable.Use systems and refill with compound only inwell-ventilated areas away from heat, openflames or sparks. DO NOT expose any part ofthese systems or the antifreeze compound totemperatures above 150 °F (66 °C). Vapors fromthe antifreeze compound are heavier than air.DO NOT store compound or discharge treatedair in confined or unventilated areas. DO NOTstore containers of antifreeze compound in directsunlight.

S. Store flammable fluids and materials away fromyour work area. Know where fire extinguishersare and how to use them, and for what type offire they are intended. Check readiness of firesuppression systems and detectors if soequipped.

1.5 MOVING PARTS

A. Keep hands, arms and other parts of the bodyand also clothing away from belts, pulleys andother moving parts.

B. DO NOT attempt to operate the compressor withthe fan or other guards removed.

C. Wear snug-fitting clothing and confine long hairwhen working around this compressor, especiallywhen exposed to hot or moving parts inside theenclosure.

D. Keep access doors closed except when makingrepairs or adjustments, performing service orwhen starting or stopping the compressor.

E. Make sure all personnel are out of the way andclear of the compressor prior to attempting tostart or operate it.

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F. Shut off engine before adding fuel, fluid, coolantlubricants, air line antifreeze compound or bat-tery electrolyte, or before replacing ether startingaid cylinders.

G. Disconnect the grounded negative battery con-nection to prevent accidental engine operationprior to attempting repairs or adjustments. Tagthe battery connection so others will not unex-pectedly reconnect it.

H. When adjusting the controls, it may require oper-ation of the equipment during adjustment. DONOT come in contact with any moving partswhile adjusting the control regulator and settingthe engine RPM. Make all other adjustments withthe engine shut off. When necessary, makeadjustment, other than setting control regulatorand engine RPM, with the engine shut off. If nec-essary, start the engine and check adjustment. Ifadjustment is incorrect, shut engine off, readjust,then restart the engine to recheck adjustment.

I. Keep hands, feet, floors, controls and walkingsurfaces clean and free of fluid, water, antifreezeor other liquids to minimize possibility of slips andfalls.

1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

A. Avoid bodily contact with hot fluid, hot coolant,hot surfaces and sharp edges and corners.

B. Keep all parts of the body away from all points ofair discharge and away from hot exhaust gases.

C. Wear personal protective equipment includinggloves and head covering when working in, on oraround the compressor.

D. Keep a first aid kit handy. Seek medical assis-tance promptly in case of injury. DO NOT ignoresmall cuts and burns as they may lead to infec-tion.

1.6.1 TIER 4 EMISSIONS MODULE

General Guidelines: Thermal Protection. The mainexhaust piping routes exhaust gas from the engine tothe Clean Emissions Module (CEM). Normaloperating temperatures can reach up to 530 °C (986°F). During regeneration of the Diesel ParticulateFilter (DPF), the Auxiliary Regeneration Device(ARD) will be in operation, this creating temperaturesabove normal engine exhaust temperatures. Gastemperatures during the regeneration period canreach 750 °C (1382 °F).

WARNINGIncreased DPF skin temperature and exhaust gas temperature may occur in the event of an unexpected engine/aftertreat-ment failure. An unexpected failure of the engine/aftertreatment may increase temper-ature at the DPF as high as 900 °C (1652 °F) gas temperature and 750 °C (1382 °F) skin temperature. This may result in fire, burn, or explosion hazards, which may result in per-sonal injury or death. Do not expose flam-mable material or explosive atmospheres to exhaust gas or exhaust system components during regeneration. The aftertreatment skin temperature and the gas temperature are difficult to measure and/or simulate and are dependent upon many factors including the following: the nature of the engine/after-treatment failure, the design and packaging of the aftertreatment, the engine speed/load conditions, the condition of the aftertreat-ment and ambient conditions. Therefore, the potential temperatures are provided as a guideline even under conditions of unex-pected engine and/or aftertreatment failure. Proper precautions should be taken to ensure that the aftertreatment device is not mounted in close proximity to components that may be damaged by heat.

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1.7 TOXIC AND IRRITATING SUBSTANCES

A. DO NOT use air from this compressor for respi-ration (breathing) except in full compliance withOSHA Standards 29 CFR 1920 and any otherFederal, State or Local codes or regulations.

B. DO NOT use air line anti-icer systems in air linessupplying respirators or other breathing air utili-zation equipment and DO NOT discharge airfrom these systems into unventilated or otherconfined areas.

C. Operate the compressor only in open or well-ventilated areas.

D. If the compressor is operated indoors, dischargeengine exhaust fumes outdoors.

E. Locate the compressor so that exhaust fumesare not apt to be carried towards personnel, airintakes servicing personnel areas or towards theair intake of any portable or stationary compres-sor.

F. Fuels, fluids, coolants, lubricants and batteryelectrolyte used in the compressor are typical ofthe industry. Care should be taken to avoid acci-dental ingestions and/or skin contact. In theevent of ingestion, seek medical treatmentpromptly. DO NOT induce vomiting if fuel isingested. Wash with soap and water in the eventof skin contact.

G. Wear an acid-resistant apron and a face shield orgoggles when servicing the battery. If electrolyte

is spilled on skin or clothing, immediately flushwith large quantities of water.

H. Ethyl ether used in diesel engine ether startingaid systems is toxic, harmful or fatal if swallowed.Avoid contact with the skin or eyes and avoidbreathing the fumes. If swallowed, DO NOTinduce vomiting and call a physician immediately.

I. Wear goggles or a full face shield when testingether starting aid systems or when adding anti-freeze compound to air line anti-icer systems.Keep openings of valve or atomizer tube of etherstarting aid system pointed away from yourselfand other personnel.

J. If ethyl ether or air line anti-icer system anti-freeze compound enters the eyes or if fumes irri-tate the eyes, they should be washed with largequantities of clean water for 15 minutes. A physi-cian, preferably any eye specialist, should becontacted immediately.

K. DO NOT store ether cylinders or air line anti-icersystem antifreeze compound in operator’s cabsor in other similar confined areas.

L. The antifreeze compound used in air line anti-icer systems contains methanol and is toxic,harmful or fatal if swallowed. Avoid contact withthe skin or eyes and avoid breathing the fumes. Ifswallowed, induce vomiting by administering atablespoon of salt in a glass of clean warm water.Do this until vomit is clear, then administer twotablespoons of baking soda in a glass of cleanwater. Have patient lay down and cover eyes toexclude light. Call a physician immediately.

1.8 ELECTRICAL SHOCK

A. Keep the towing vehicle or equipment carrier,compressor hoses, tools and all personnel atleast 10 feet (3 m) from power lines and buriedcables.

B. Keep all parts of the body and any hand-heldtools or other conductive objects away fromexposed live parts of electrical system. Maintaindry footing, stand on insulating surfaces and DONOT contact any other portion of the compressorwhen making adjustments or repairs to exposedlive parts of the electrical system.

C. Attempt repairs only in clean, dry and well-lightedand ventilated areas.

D. Stay clear of the compressor during electricalstorms! It can attract lightning.

DANGER

INHALATION HAZARD!

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA stan-dards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment.

SECTION 1

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1.9 LIFTING

A. If the compressor is provided with a lifting bail,then lift by the bail provided. If no bail is provided,then lift by sling. Compressors to be air lifted byhelicopter must not be supported by the liftingbail, but by slings instead. In any event, lift only infull compliance with OSHA Standards 29 CFR1910 subpart N or any other Local, State, Militaryand Federal regulations that may apply.

B. Inspect lifting bail and points of attachment forcracked welds and for cracked, bent, corroded orotherwise degraded members and for loose boltsor nuts prior to lifting.

C. Make sure entire lifting, rigging and supportingstructure has been inspected, is in good condi-tion and has a rated capacity of at least the netweight of the compressor plus an additional 10%allowance for weight of water, snow, ice, mud,stored tools, and equipment. If your are unsureof the weight, then weigh compressor before lift-ing.

D. Make sure lifting hook has a functional safetylatch or equivalent, and is fully engaged andlatched on the bail.

E. Use guide ropes or equivalent to prevent twistingor swinging of the compressor once it has beenlifted clear of the ground.

F. DO NOT attempt to lift in high winds.

G. Keep all personnel out from under and awayfrom the compressor whenever it is suspended.

H. Lift compressor no higher than necessary.

I. Keep lift operator in constant attendance when-ever compressor is suspended.

J. Set compressor down only on a level surfacecapable of supporting at least its net weight plusan additional 10% allowance for the weight ofwater, snow, ice, mud, stored tools, and/or equip-ment.

K. If the compressor is provided with parkingbrakes, make sure they are set, and in anyevent, block or chock both sides of all runningwheels before disengaging the lifting hook.

1.10 ENTRAPMENT

A. Make sure all personnel are out of compressorbefore closing and engaging enclosure doors.

B. If the compressor is large enough to hold a manand if it is necessary to enter it to perform serviceadjustments, inform other personnel beforedoing so, or else secure the access door in theopen position to avoid the possibility of othersclosing and possibly latching the door with per-sonnel inside.

1.11 JUMP STARTING

A. Observe all safety precautions mentioned else-where in this manual.

B. Batteries may contain hydrogen gas which isflammable and explosive. Keep flames, sparksand other sources of ignition away.

C. Batteries contain acid which is corrosive and poi-sonous. DO NOT allow battery acid to contacteyes, skin, fabrics or painted surfaces as seriouspersonal injury or property damage could result.Flush any contacted areas thoroughly with waterimmediately. Always wear an acid-resistantapron and face shield when attempting to jumpstart the compressor.

D. Remove all vent caps (if so equipped) from thebattery or batteries in the compressor. DO NOTpermit dirt or foreign matter to enter the opencells.

E. Check fluid level. If low, bring fluid to proper levelbefore attempting to jump start (not applicable tomaintenance-free batteries).

F. DO NOT attempt to jump start if fluid is frozen orslushy. Bring batteries up to at least 60 °F (16°C) before attempting to jump start or it mayexplode.

G. Cover open cells of all compressor batteries withclean dampened cloths before attempting tojump start.

H. Attempt to jump start only with a vehicle having anegative ground electrical system with the samevoltage, and is also equipped with a battery orbatteries of comparable size or larger than sup-plied in the compressor. DO NOT attempt tojump start using motor generator sets, welders orother sources of DC power as serious damagemay result.

SECTION 1

14

I. Bring the starting vehicle alongside the compres-sor, but DO NOT permit metal to metal contactbetween the compressor and the starting vehicle.

J. Set the parking brakes of both the compressor (ifprovided) and the starting vehicle or otherwiseblock both sides of all wheels.

K. Place the starting vehicle in neutral or park, turnoff all non-essential accessory electrical loadsand start its engine.

L. Use only jumper cables that are clean, in goodcondition and are heavy enough to handle thestarting current.

M. Avoid accidental contact between jumper cableterminal clips or clamps and any metallic portionof either the compressor or the starting vehicle tominimize the possibility of uncontrolled arcingwhich might serve as a source of ignition.

N. Positive battery terminals are usually identifiedby a plus (+) sign on the terminal and the lettersPOS adjacent to the terminal. Negative batteryterminals are usually identified by the lettersNEG adjacent to the terminal or a negative (-)sign.

O. Connect one end of a jumper cable to the posi-tive (POS) (+) battery terminal in the startingvehicle. When jump starting 24V compressorsand if the starting vehicle is provided with two (2)12V batteries connected in series, connect thejumper cable to the positive (POS) (+) terminal ofthe ungrounded battery.

P. Connect the other end of the same jumper cableto the positive (POS) (+) terminal of the startermotor battery in the compressor when jump start-ing 24V compressors, to the positive (POS) (+)terminal of the ungrounded battery in the com-pressor.

Q. Connect one end of the other jumper cable to thegrounded negative (NEG) (-) terminal of the bat-tery in the starting vehicle. When jump starting24V compressors and if the starting vehicle isprovided with two (2) 12V batteries connected inseries, connect the jumper cable to the negative(NEG) (-) terminal of the grounded battery.

R. Check your connections. DO NOT attempt tostart a 24V compressor with one 12V battery inthe starting vehicle. DO NOT apply 24V to one12V battery in the compressor.

S. Connect the other end of this same jumper cableto a clean portion of the compressor engine

block away from fuel lines, the crank casebreather opening and the battery.

T. Start the compressor in accordance with normalprocedure. Avoid prolonged cranking.

U. Allow the compressor to warm up. When thecompressor is warm and operating smoothly atnormal idle RPM, disconnect the jumper cablefrom the engine block in the compressor, thendisconnect the other end of this same cable fromthe grounded negative (NEG) (-) terminal of thebattery in the starting vehicle. Then disconnectthe other jumper cable from the positive (POS)(+) terminal of the battery in the compressor, or ifprovided with two (2) 12V batteries connected inseries, from the ungrounded battery in the com-pressor, and finally, disconnect the other end ofthis same jumper cable from the positive (POS)(+) terminal of the battery in the starting vehicleor from the positive (POS) (+) terminal of theungrounded battery in the starting vehicle, if it isprovided with two (2) 12V batteries connected inseries.

V. Remove and carefully dispose of the dampenedcloths, as they may now be contaminated withacid, then replace all vent caps.

1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT

The energy control procedure defines actionsnecessary to lockout a power source of any machineto be repaired, serviced or set-up, where unexpectedmotion, or an electrical or other energy source, wouldcause personal injury or equipment damage. Thepower source on any machine shall be locked out byeach employee doing the work except when motionis necessary during setup, adjustment or trouble-shooting.

A. The established procedures for the application ofenergy control shall cover the following elementsand actions and shall be initiated only by Autho-rized Persons and done in the followingsequence:

1. Review the equipment or machine to belocked and tagged out.

2. Alert operator and supervisor of whichmachine is to be worked on, and that powerand utilities will be turned off.

3. Check to make certain no one is operatingthe machine before turning off the power.

SECTION 1

15

4. Turn off the equipment using normalshutdown procedure.

5. Disconnect the energy sources:

a. Air and hydraulic lines should be bled,drained and cleaned out. There shouldbe no pressure in these lines or in thereservoir tanks. Lockout or tag lines orvalves.

b. Any mechanism under tension or pres-sure, such as springs, should bereleased and locked out or tagged.

c. Block any load or machine part prior toworking under it.

d. Electrical circuits should be checked withcalibrated electrical testing equipmentand stored energy and electrical capaci-tors should be safely discharged.

6. Lockout and/or Tagout each energy sourceusing the proper energy isolating devicesand tags. Place lockout hasp and padlock ortag at the point of power disconnect wherelockout is required by each personperforming work. Each person shall beprovided with their own padlock and havepossession of the only key. If more than oneperson is working on a machine each personshall affix personal lock and tag using amulti-lock device.

7. Tagout devices shall be used only whenpower sources are not capable of beinglocked out by use of padlocks and lockouthasp devices. The name of the personaffixing tag to power source must be on tagalong with date tag was placed on powersource.

8. Release stored energy and bring theequipment to a “zero mechanical state”.

9. Verify Isolation: Before work is started, testequipment to ensure power is disconnected.

B. General Security

1. The lock shall be removed by the“Authorized” person who put the lock on theenergy-isolating device. No one other thanthe person/persons placing padlocks and

lockout hasps on power shall removepadlock and lockout hasps and restorepower. However, when the authorizedperson who applied the lock is unavailable toremove it his/her Supervisor may removepadlock/padlocks and lockout hasps andrestore power only if it is first:

a. verified that no person will be exposed todanger.

b. verified that the “Authorized” person whoapplied the device is not in the facility.

c. noted that all reasonable efforts to con-tact the “Authorized” person have beenmade to inform him or her that the lock-out or tagout device has been removed.

d. ensured that the “Authorized” person isnotified of lock removal before returningto work.

2. Tagout System—Tags are warning devicesaffixed at points of power disconnect and arenot to be removed by anyone other that theperson placing tag on power lockout. Tagsshall never be by-passed, ignored, orotherwise defeated

1.13 CALIFORNIA PROPOSITION 65

WARNINGCALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its con-stituents are known to the State of Califor-nia to cause cancer, birth defects and other reproductive harm.

Battery posts, terminals and related acces-sories contain lead and other compounds known to the State of California to cause cancer and birth defects and other repro-ductive harm. Wash hands after handling.

SECTION 1

16

1.14 SYMBOLS AND REFERENCES

The symbols below may or may not be used. Pleaserefer to the decals set forth on the machine forapplicable symbols.

DIESEL FUEL HEARING PROTECTION

HARD HAT

SAFETY GLASSES

HEARING PROTECTION

DO NOT REMOVE MANUAL

DO NOT BREATHECOMPRESSED AIR

DO NOT STAND ONSERV. VALVE

DO NOT OPERATEW/ DOORS OPEN

DO NOT OPEN

DO NOT STACK

ELECTRICAL SHOCK

AIR FLOW

HOT SURFACE

PRESSURIZED VESSEL

PRESSURIZED COMPONENT

CLOSED MECHANICAL

FUSE

LOW PRESSURE

READ MANUAL

BRAKES

ROTARY COMPRESSOR

TEST RUN

DRAIN

HIGH PRESSURE

NO

ENGINE

COMPRESSOR

ENGINE OIL

ENGINE COOLANT

WATER

OIL

DO NOT

SHUT-OFF VALVEW/ SAFETY

SAFETY SYMBOLS 1

SECTION 1

17

DANGEROUS OUTLET

CORROSIVE

WARNING

BELOW TEMPERATURE

DO NOT TOW

BAR/PSI

BATTERY

BATTERY DISCONNECT

OFF

ON

RESET

REMOTELY CONTROLLED

DO NOT MAINTENANCE

ENGINE START

ENGINE ECM

READ/WRITE DATA

INTAKE AIR

EXHAUST GAS

FAN GUARD

BELT GUARD

SERVICE POINT

LOW TEMPERATURE

STD AIR

A/C AIR

24 HOURS

BELTS

FILTER

STRAINERFORK LIFT HERE

DIRECTION OF ROTATION

NO FORKLIFT

SAFETY SYMBOLS 2

SECTION 1

18

RADIATOR

LUBRICATION

AXEL

HOUR METER

START

CONTROL

ENGINE WARNING

FUEL LEVEL

ENGINE RPM

ENGINE OILPRESSURE

ENGINE COOLANTTEMPERATURE

COMPRESSORTEMPERATURE

DO NOT MIXCOOLANTS

AFTERCOOLER BYPASS VALVE

COMPRESSOROIL HEAT

STACKING LIMITBY NUMBER

DRAIN HEATER

BATTERY HEATER

ENGINE PREHEATLOW TEMP AID

COMPRESSOR AIR PRESSURE

AIR-CIRCULATINGFAN

AIR-COOLEDOIL COOLER

LIQUID-COOLEDOIL COOLER

TRAILER TOWINGMODE

CRUSH/PINCH POINT

FUNCTIONAL ARROW

PRESSURE CONTROL

INTERNAL FUEL

EXTERNAL FUEL

SIDE DOOR T-LATCH

INLET VALVE SPRING

ENGINE INTAKE AIR FILTER

LUBRICANT GREASE

EXAMINE, CHECK

SAFETY SYMBOLS 3

SECTION 1

19

DO NOT OPERATEWHILE STACKED

DO NOT MIX FLUIDS

AUTO START/STOP

FLUID DRAIN

PRESSURIZED SPRING

WATER DRAIN

SEVER (FAN)

DEF FLUID ONLY

RUN

SAFETY SYMBOLS 4

Safety Symbols-3

20

BLANK PAGE

Section 2

19

COMPASS CONTROLLER USER MANUAL

STARTUP PROCEDURES2.1 INTRODUCTION

This compressor is equipped with a Sullair CompassController for controlling the compressor systemoperation, adjusting the machine parameters andperforming maintenance operations. The CompassController utilizes digital technology that ensuresaccurate and safe operation of the compressorsystem. When fault conditions occur, the controllerautomatically shuts down the machine to preventinjury to the operator or damage to the equipment.Features of the Compass Controller include:

• Dual gauges for display of pressure,engine temp, compressor temp, enginerpm, and fuel level

• LCD screen displaying machine status andoperating information

• Remote start capabilities

• Automatic self diagnosis at startup

• Multiple language support

• An external diagnostics port which allowsPC interface for configuration of the systemparameters.

• Backlighting of gauges with green LED toallow clear view of gauges in low lightareas.

2.2 CONTROLLER PANEL LAYOUT

The Compass Controller panel is shown in Figure 2-1. The controller components and functions aredescribed in detail in Section 4.

2.3 COMPASS CONTROLLER POWER UP

The compass controller is used to start thecompressor either manually or remotely.

Manual Start: Start the machine by pressing the

“OFF/ON/START” button to the “START” position onthe controller panel. Once the switch has been set tothe START position and the controller hassuccessfully initialized (see Self Test, Bus Checks,Safety Checks this section for further information),the Compass Controller will check status, then willautomatically continue to energize the starter untileither the engine starts or the maximum crankduration is reached.

Auto Start: The compressor can be startedremotely if the remote start function has beenenabled during setup. If this option is activated, an

“ ” will display in characters in the upperright corner of the LCD display.

SELF TEST

When the controller is initially powered up, thesystem will initiate a “Self Test” sequence to verify itsoperational integrity and safety status. During thisprocess, the following self tests will be performed.

1. Gauge pointers will move to the zero posi-tion, then to half and full scale, then back tozero, and finally to the actual value reading.

2. The LCD display will turn on all its segmentsfor one second, off for one second, and thendisplay the Sullair logo followed by the soft-ware product number with revision level.

3. All warning lights will turn on for 5 secondsand then turn off, then set to the actual indi-cator state.

The Self Test feature may be bypassed by disablingthe sequence as describe in Section 3 of thismanual.

COMMUNICATION BUS CHECKS

After successful completion of the self test, theCompass Controller system will check thecommunication status of system.

r. reverse

COMPASS CONTROLLER USER MANUAL SECTION 2

20

Figure 2-1: Compass Controller Panel

1 Mode Button (m) 12 Engine Warning Indicator

2 Trip/Reset Button (t) 13 Engine Diagnostic Shutdown Indicator

3 LCD Graphic Display 14 Engine Controller Diagnostic Service Port

4 Service Air Pressure Gauge (P1) 15 Engine Diagnostic Port Cover

5 Low Fuel Indicator 16 Compressor Shutdown Indicator

6 Fuel Level Gauge 17 Compressor Warning Indicator

7 High Compressor Temperature Warning 18 High/Low Selector Switch

8 Engine RPM Gauge 19 Reset Switch

9 Compressor Temperature Gauge 20 Power Off/On/Start Switch

10 High Engine Temperature Warning 21 Cabinet Latch

11 Engine Temperature Gauge

SECTION 2 COMPASS CONTROLLER USER MANUAL

21

In the event of a problem, the LCD will display one ofthe following messages:

The Compass Controller system will prevent the userfrom operating the compressor until allcommunication problems are resolved.

See Section 5 of this manual for troubleshootingrecommendations.

GENERAL SAFETY CONDITION CHECKS

After successful completion of the CommunicationBus checks, the Compass Controlfler system willperform safety checks on the compressor and theengine.

In the event of a problem with either the compressoror engine, a message will display in the LCDindicating the nature of the trouble (example shownbelow). The Controller will wait for user-interaction toeither correct the fault or send the system to Sleepmode.

Table 2-1 lists the safety conditions that are checkedby the Compass Controller during startup and thefault that will be displayed on the LCD screen if afault occurs.


SYSTEM PRESSURE CHECKS

Following the successful completion of the generalsafety checks, the Compass Controller will check thestatus of the Service Pressure (P1), Control Pressure(P2), and Wet Sump (P3). If there is a problem withany of these inputs a message will be displayed onthe LCD display indicating the nature of the problem.

(Example shown below):

The controller will prevent compressor startup ifeither of the following conditions exists:

• P1 pressure is greater than the maximumP1 pressure permitted at startup. Themaximum P1 pressure is an adjustableparameter which can be modified asdescribe in Section 3 of this manual.

• P1 and P2 pressures are out of range.


2.4 NORMAL OPERATION

Following the successful completion of all startupsequences, the system is ready for normal operation.During normal operation the controller will be in oneof the following five operating modes: Ready, Start-Up and Autostart (remote), Run, Sleep, andShutdown. Each of these modes is described indetail in Section 4.

Listening For Engine

Checking Compass Comm

r.

27.6 V Batt V

Low Fuel LevelChecking System

r.Checking PressuresP1 Signal Error

27.6 V Batt V


22

Table 2-1: Safety Conditions

Parameter Fault ConditionUser Controlled

ParameterLCD Message

Fuel Low fuel level Very Low Level Alert (% full)

Low fuel level

Fuel sender open circuit None Low fuel level

Battery Low battery voltage(<18.0Vdc)

None Battery Voltage Error

Compresor Discharge Temperature (CDT)

Signal short circuit None T1 Signal Error

Compressor Temp High Max T1 during run or at start-up

Comp High Temp

Receiver Tank Temper-ature (RTT)

Receiver Tank Temp High None RTT High

Discharge Air DP High Aftercooler filter DP AfterFilters Equipped Primary Shutdown

Air Pressure (P1) Transducer signal short or open circuit

None P1 Signal Error

High compressor pressure Max P1 at start-p (psi) High Compressor Pres-sure

Control Pressure (P2) Transducer signal short or open circuit


Air Pressure (P3) Transducer signal short or open circuit


Section 3

23


ADJUSTMENTS3.1 INTRODUCTION

This section describes steps for using the CompassController to modify specific parameters that controlthe machine operation. Additional parameters can beviewed and adjusted using the PC User Interface.

MESSAGE DISPLAY CENTER

The message display is a graphical LCD thatdisplays information to the compressor operator.The screen is backlit to allow the display charactersto be clearly visible under any lighting conditions. Inaddition to basic operational information, a variety ofuser- defined options may also be displayed whenspecified. Fault messages are displayed whenever afault condition occurs. The LCD display also allowsthe operator to view instrumentation diagnostic datato aid in controlling the system operation and introubleshooting problems.

LINE 2 DISPLAY SELECTION

Pressing the “m” button for less than five (<5)seconds allows the selection of the parameter to be

displayed on the second line. The parameter will

highlight in characters indicating it isselected. Press the “m” or “t” button to scroll thedisplay through the various parameters that areavailable for user adjustment.

3.2 SETTINGS AND DIAGNOSTIC

DIAGNOSTIC MENU

Once the initialization sequence is complete, theoperator can enter the diagnostic menu at any timeby pressing and holding the “m” button for more thanfive seconds. If the operator enters the diagnosticmenu prior to getting past the Ready state, thecompressor will not be permitted to start until thediagnostic menu is exited. When the CompassController is in Ready mode, pressing the “m” buttonfor more than five (>5) seconds brings up thefollowing screen:

Pressing both the “m” and “t” buttons simultaneouslywill make the highlighted parameter active for editing.Pressing the “m” or “t” button separately will movethe highlight through the parameter list allowing otheritems to be selected.

MENU STRUCTURE

The diagnostic menu will appear in the LCD displayas shown below. Use the “m” and “t” buttons toscroll through the available menu selections. The

present menu item will display in characters. There are nine diagnostic menuselections which can be chosen from this menu:

1. Set Units

Part Number 02250173-104

reverse

1-Set Units2-Set Language3-Contrast

Select

reverse


24

2. Set Language

3. Contrast

4. COMPASS Diagnostics* (real-time data only)

5. Pressure Calibration

6. Auxiliary Temperature Calibration

7. Backlight Adjust

8. Engine Diagnostics* (real-time data only)

9. Engine Shutdown History

To select a present menu item, press both the “m”and “t” buttons at the same time. The operator canthen use the “m” and “t” buttons to modify theselected parameter.

SET UNITS

When “Set Units” is selected, the LCD display willshow the following:

The operator can choose between English andMetric units by pressing the “t” button. To make theunits active, press the “m” button or simply let thescreen time out (approx. five seconds).

SET LANGUAGE

When “Set Language” is selected, the LCD displaywill present six international languages for thesystem display. The operator can scroll between theavailable languages by pressing the “m” or “t”

buttons. The selected option will appear in characters. To make the selected language active,press both the “m” and “t” buttons at the same time.

A confirmation screen will appear indicating“Language changed” before exiting back toDiagnostic menu.

CONTRAST

Selecting the Contrast option allows the operator toadjust the contrast of the LCD display. Press the“m”(+) button to increase contrast. Press the “t”(-)button to decrease contrast.

Current Units ENGLISH

Press t for METRIC

Press m to exit

reverse

1-English

3-Spanish2-French

Select

4-German

6-Portuguese5-Italian

Select

Language Changed

CONTRAST ADJUST

+ -


25

THE COMPASS CONTROLLER DIAGNOSTICS

The Compass Controller Diagnostics menu containsfive tests that verify the functionality of specificcontroller components. The Diagnostics menu canonly be entered if the compressor is in the Readymode (Prior to start-up).

Selecting this menu option will present a sub-menuas shown below. To make a selection in the submenu, scroll to the desired option and press both the“m” and “t” buttons at the same time. The diagnosticmenu exits after a short time-delay of inactivity.

As previously noted, the system must be in Readymode prior to entering the Diagnostics menu. Anattempt to enter the diagnostics while the machine isrunning will cause the following message to bedisplayed:

GAUGE TEST

The Gauge Test verifies that both gauges arefunctional. During the test, the gauge pointers willcycle from 0 to full scale pausing at 0%, 50%, 100%,then return to zero (or its true position). The LCDdisplay will show which gauge is being tested andindicate the gauge’s corresponding position (asdepicted below for engine speed). Pressing the “m”button at anytime during the test will cause the test toend.

NOTEThis sub-menu and all content accessible from it will always be in English, regardless of the language chosen.

1-Gauge Test2-Lamp Test3-LCD Test

Select

5-Analog Inputs Test

Select

4-Binary Inputs

Not permittedwhile running

Engine Speed

0% EXIT

Engine Speed

50% EXIT

Engine Speed

100% EXIT

1-Gauge Test 2-Lamp Test 3-LCD Test

Select


26

LAMP TEST

Selecting the Lamp Test option will turn on allwarning and binary LED’s (except for Engine CrankRelay). Each output will turn on, then off and theLCD display will indicate which output is being tested(as depicted below for R/S Relay). Pressing the “m”button at any time will end the test and return to theCOMPASS Diagnostic menu. The outputs testedduring the lamp test are:

1. Recirculation Solenoid Output

2. Hi / Low Pressure Relay Output

3. Run / Start Relay Output

4. Compressor Warning Lamp

5. Compressor Shutdown Lamp

6. Engine Warning Lamp

7. Engine Diagnostics Lamp

LCD TEST

Selecting the LCD Test option will test all the pixels inthe LCD display by flashing the Sullair logo in normaland reverse characters. Pressing the “m” button willend the test.

R/S Relay

EXIT ON


Select

R/S Relay

EXIT OFF


Select


27

BINARY INPUTS

Selecting the Binary Inputs menu option will allow theoperator to check the status of each of the binaryinputs to the Compass Controller. The Binary Inputsdisplay, as shown, will indicate the module beingchecked, the pin number of the connector for theinput, and real-time status of each binary inputdefined in the system. The “High” and “Low”designation refers to the voltage level at theconnector pin.

Press “t” to scroll through and view the status of thevarious binary inputs. Press “m” to exit the moduleand return to the COMPASS Diagnostic menu. The15 Binary Input items available from this menu arelisted to the right. Note that the “S” designation is forthe slave warning bank input and the “M” designationis for master gauge input.

4-Binary Inputs 5-Analog Inputs

Select

S-1 DP-Prv Wrn High S-2 DP-APF Shtd Low S-3 Unused 1 High S -4 Unused 2 Low

Module

Pin # Status of input Input

S-1 Dp-Pry Wrn HighS-2 Dp-Pry Shtdn LowS-3 UNUSED 1 HighS-4 UNUSED 2 Low

S-5 Hi/Low Press LowS-6 Engine Wrn HighS-7 T3 - RTT LowS-8 Engine Diag High

M-11 Ign ON HighM-12 Engine Start LowM-13 Remote Start HighM-14 DP1-EIAF Low

M-15 E-Stop HighM-16 DP2-CIAF Low


28

ANALOG INPUTS

Selecting the Analog Inputs screen allows theoperator to check the status of each of the analoginputs coming to the Compass Controller system.This LCD screen displays the master gauge pinnumber and real-time status of each analog inputdefined in the system.

Press “t” to scroll through and view the status of thevarious analog inputs. Press “m” to exit the moduleand return to the COMPASS Diagnostic menu. Theeight analog input items available from this menu arelisted below. Note that the “M” designation in themodule number indicates “master” gauge input.

4-Binary Inputs 5-Analog Inputs

Select

M-1 Fuel 100% M-2 P1 Serv P. 0 psi M-3 P2 Ctrl P. 0 psi M-4 P3 Wet P. 0 psi

Module

Pin #

Input

Value

M-1 Fuel 55%M-2 P1 Serv p 0 psiM-3 P2 Ctrl p 0 psiM-4 P3 Wet p 0 psi

M-5 Vdc Ref 5.00VM-6 T1 CompT 198 °FM-7 FaultReset OffM-8 T2 Aux T 109 °F


29

PRESSURE CALIBRATION

Over time the P1, P2, and P3 pressure transducervalues might drift resulting in an inaccurate readingshowing on the pressure gauge. Using the PressureCalibration function the operator can adjust theactual zero pressure to 0.00 BAR when no pressureis present in the compressor. The offset value will besubtracted from the transducer value to obtain anadjusted reading used for indication and calculation.

To calibrate a pressure transducer:

1. Select the transducer (P1, P2, or P3) to becalibrated by pressing both the “m” and “t”buttons at the same time.

2. The following screen sequence will be pre-sented (example below). This exampleshows a P1 pressure of .60 BAR on amachine that is known to actually be at zeropressure. The current pressure value is dis-played in metric units only (1 kPa = 0.01bar).

3. Calibrate the actual pressure reading backdown to 0.00 by increasing the value of thecorrection / offset by pressing the “t” buttonuntil the Actual Pressure reads 0.00. Oncethis is done, simply press both the “m” and“t” buttons together to store this value in thesystem. The offset value will be subtractedfrom the transducer value to obtain theadjusted reading. The calibration offset isconfigurable in steps of -50 to +50 with 0 thefactory default. Each step is approximatelyequal to ±1 kPa (±0.15 psi) on machinesless than 300 psi and ±3.25 kPa (±0.47 psi)on machines over 300 psi.

AUXILIARY TEMPERATURE CALIBRATION

Occasionally, and when the auxiliary temperatureinput is first configured, the input may requirecalibration to adjust the input to the actual knowntemperature. This is accomplished using theAuxiliary Temperature Calibration function. Theauxiliary temperature calibration offset isconfigurable in 0.5°C increments. A total offset of +/-10°C is allowable. The offset will be applied to theRTD input signal and used for indication andcalculation during compressor operation.

To calibrate the Auxiliary Temperature input:

1. Select the Aux Temp input by simultaneouslypressing both the “m” and “t” buttons whenthe input is highlighted.

2. The following screen will be presented(example).

3. Adjust the offset value using the m and t but-tons.

4. Simultaneously press m and t to exit screen.

1-P1 (Service) 2-P2 (Control) 3-P3 (Wet)

Select

+ P1 Calibration -

0.60 BAR 0

Actual Pressure being sent from the transducer

Correction / Offset

42.5°C

+ Aux Temp Cal -


30

BACKLIGHT ADJUST

With this function the operator can adjust theintensity of the gauge backlighting (both the mastergauge, and the 4-in-1 gauge) from 0% (off) to 100%(full intensity). The factory default is 20%.

To adjust the backlight intensity:

1. Press the “m” button to increase the lightintensity.

2. Press the “t” button to decrease the lightintensity.

3. Simultaneously press “m” and “t” to exit thescreen.

ENGINE DIAGNOSTICS

The Engine Diagnostic screen is a real-time displayof active operation messages being transmitted bythe engine. Messages that become inactive areautomatically erased. No messages are stored in thecontroller memory.

When this function is selected, up to 5 of the mostrecent active engine Fault Mode Indicators (FMI) orSuspect Parameter Number (SPN) codes beingreceived from the Caterpillar engine will bedisplayed. Use the “m” and “t” buttons to scrollthrough the various codes. Simultaneously press“m” and “t” to exit.

ENGINE SHUTDOWN HISTORY

This function allows up to 5 of the most recentabnormal shutdown faults to be viewed. The EngineShutdown History is an instantaneous snapshot ofthe Compass Controller parameters. For each fault,the LCD will display the fault that occurred and theengine hours at the time of the fault. Use the “m” and“t” buttons to scroll thru each of the faults. Press “m”and “t” to exit. Pressing the Compass Reset buttonwill cycle through the warnings active at time ofshutdown. An example of a “High CompressorTemp” shutdown with 150 hours on the engine isshown below.

3.3 CONFIGURATION MENU

The Compass configuration menu allows for end-user adjustment of five User Controlled Parameters(UCP). The UCPs do not adversely affect thecontroller’s operational functionality. Theconfiguration menu allows for end-usercustomization of the Compass Controller. Theconfiguration menu will compile and store to thecontroller memory any changes to the factoryprogrammed UCP profile.

To enter the Configuration Menu:

1. Hold down the “m” and “t” buttons whilecycling Compass Controller power to ON.The configuration menu will appear.

2. Use the “m” and “t” buttons to navigatewithin the menu and to make adjustments tothe selected parameters.

3. Exit the Configuration Menu by simultane-ously pressing “m” and “t” buttons. After exit-ing, the master gauge will perform a systemreset and then enter Start-up mode.

BACK LIGHT ADJUST

+ -

No Active Codes

exit

SPN 100 FMI 1 SPN 110 FMI 0 End of list

exit

OR

Comp High Temp

150.00 hrs exit


31

LINE 2 PARAMETER DISPLAY

The Line 2 parameter display typically shows theoperational parameters of the Compass Controller.Disabling this feature will only affect the parameterdisplay. Priority messages will still utilize the lowerportion of the LCD to display messages asnecessary. Select “yes” to enable the parameterdisplay or “no” to disable the display.

SELF TEST

The Self-Test function of the Start-up mode can beenabled or disabled using the configuration menu.Select “yes” to enable or “no” to disable the Self-Testfeature.

REMOTE START

The ability of the Compass Controller to recognize aremote start actuation can be enabled or disabledusing the configuration menu.

Ok Exit Toggle

Line 2 Parameter?yes no

Ok Exit Toggle


Ok Exit Toggle


Ok Exit Toggle

Self Test?yes no

NOTEA hardware remote start signal must be provided in addition to enabling the soft-ware feature. Select “yes” to activate the remote start feature or “no” to disable the feature.

WARNINGDO NOT adjust this parameter unless spe-cifically instructed to do so by the factory. Changing this setting will cause the machine to run improperly.

Ok Exit Toggle

Enable Remote Start?yes no


32

3.4 USER ADJUSTABLE CONTROL PARAMETERS (UCP)

The following settings are configurable using theCompass Controller interface software. The

parameters listed in bold font are those which cancause abnormal shutdowns to occur.

Engine Crank Default Value Range/Option

Crank On Duration (sec) 10 3-10

Crank Off Duration (sec) 10 4-30

Number of Cycles 3 1-5

Engine Cranked Speed (RPM) 250 200-500

Time Required At Cranked Speed (msec) 480 240-1000

Throttle Control Default Value Range/Option

Low pressure Max Duty Cycle (%) 92 70-92

High Pressure Max Duty Cycle (%) 92 70-92

LO Idle Engine Speed (RPM) 1400 1300-2000

HI Idle Engine Speed (RPM) 1800 1500-2100

Alt Throttle Control

Low Pressure Range – 300 PSI controller

100-120 100-120

125-145


High Pressure Range – 300 PSI controller

150-170 150-170

175-195

200-220


Low Pressure Range – 600 PSI controller

205-225 205-225

350-370


High Pressure Range – 600 PSI controller

350-370 350-370

425-445

500-520

Low Speed Shutdown Settings Disabled Enabled

Disabled

Low Speed Shutdown RPM 800 800

900

1000

1000

Low Speed Shutdown Time (sec) 5 5

7

9

11


33

Fuel Level Default Value Range/Option

Cancel Low Level Alert (% full) 23 13-43

Low Level Alert (% full) 20 10-40

Cancel Very Low Level Alert (% full) 11 7-13

Very Low Level Alert (% full) 8 4-10

Temperature Settings Default Value Range/Option

Max CDT at run-time or startup (°F) 250 200-400

Max Aux Temp at run-time/startup (°F) 250 200-400

Engine Temp. for warm-up complete (°F) 70 64-150

AfterFilter Freeze Assert Temp. (°F) 39 (-40) -50

AfterFilter Freeze Cancel Temp. (°F) 45 (-40) -68

Startup Aids Settings - -

Low Point Temp (°F) (-40) (-40) -16

Low Point Time (min) 60 31-75

Middle Point Temp (°F) (-15) (-15) -9

Middle Point Time (min) 30 16-30

High Point Temp (°F) 10 10-20

High Point Time (min) 15 5-15

Pressure Settings Default Value Range/Option

Max P1 at run-time (PSI) 200 145-600

Max P3 at run-time (PSI) 200 145-600

Allowable time for Max P1 or P3 (sec) 1 1

5

15

30

Max Air-Oil-Sep at run-time (PSI) 15 10-20

Air-Oil-Sep alert time (sec) 15 10-60

Max P1 at startup (PSI) 10 0-15

Manifold Solenoid Open/Assert Pressure (PSI) 60 30-90

Manifold Solenoid Close/Cancel Pressure (PSI) 55 25-85

P1 Calibration Offset 0 -50 to +50



P1 to shutdown from auto-start (PSI) 100 70-600

Required time for P1 > Above Value to shutdown

from auto-start (sec)

900 300-1800

P1,2,3 Pressure for Cooldown Completion (PSI) 10 5-15

P2 Pressure for max RPM at run-time (PSI) 5 0-10


34

System ID Default Value Range/Option

ID Tag N/A 20 character user entry

Miscellaneous Settings Default Value Range/Option

Warmup Complete Speed (RPM) 1375 1375-1450

Minimum Engine Warm-up Time (sec) 30 5-60

Maximum Engine Warm-up Time (sec) 240 60-360

Compressor Cool-down Time (sec) 300 5-600

DP1-2 Alert Time (sec) 15 10-60

LANGUAGE English English

Spanish

Italian

French

German

Portuguese

ECM Power-Off Interval At Cooldown (sec) 5 3-10

Unit Of Measurement English Metric

English

PSI System 600 300-600

Fuel Tank Large 02250154-804

02250141-157

02250160-656

02250190-811

No Tank

Display 2nd Line Parameter Enabled Enabled

Disabled

Enable Gauge Self-Test Enabled Enabled

Disabled

Remote Start Permitted Disabled Enabled

Disabled

C9 Engine Used Disabled Enabled

Disabled

AfterFilters Equipped Disabled Enabled

Disabled

Intake Louvers Equipped Disabled Enabled

Disabled

Enable Inactivity Auto-Sleep? Enabled Enabled

Disabled

Inactivity Timeout (min) 10 5-20

Section 4

35


DESCRIPTION4.1 INTRODUCTION

This section describes the operation of the CompassController, the function of the controller components,and the various types of displays that may appear onthe display screen. Descriptive lists of all messagesappearing in the display are also provided.

4.2 OPERATING MODES

SLEEP MODE

Sleep mode occurs when the Compass Controller isnot powered on. All electrical components areinactive during Sleep mode to prevent batterydrainage (i.e. microprocessor, relays, indicationlamps, etc).

Sleep mode is dependent upon the position of theOff/On/Start switch and current operating status ofthe compressor. If the compressor is in any stateother than running, then placing the Off/On/Startswitch in the OFF position will enter Sleep mode. Ifthe compressor is running, placing the Off/On/Startswitch in the OFF position will initiate Cooldownmode followed by Sleep mode.

If the compressor has shutdown due to faultcondition, then the fault must be acknowledged bypressing the reset switch and switching the Off/On/Start switch to the OFF position.

If the compressor was enabled via Remote Start, acompressor malfunction will allow entering Readymode only. The malfunction must be acknowledgedby pressing the Reset switch and Off/On/Start switchmust be in the OFF position to enter into Sleepmode.

START-UP MODE

Start-up mode initializes the system instrumentationcomponents for operation. Start-up mode is internalto the Compass Controller and does not permitengine/compressor activation.

Start-up mode is enabled by one of the followingtwo methods:

1. Press the Off/On/Start switch to ON.

2. Activating the Remote Start switch (ifenabled).

Placing the Off/On/Start switch to the ON position willenergize the Master Gauge and begin initializing thesystem for Ready mode.

If Start-up is entered by placing the Off/On/Startswitch in the ON position, placing the switch in theOFF position powers down the entire system. If astart-up initialization parameter is out-of-tolerance,the Compass Controller will enter a safe-shutdownstate and demand user interaction to completelypower down the unit.

It is during Start-up mode that system integrity isverified. System integrity verification involves checksof functional instrumentation, communication status,and confirmation of proper initial parameter settings.A successful completion of Start-up mode transitionsthe Compass Controller to the Ready mode.

NOTEIf the Start-up mode is entered via Remote Start, then only a start-up initialization parameter “out-of-tolerance” failure and “Remote Start binary input not low” will exit Start-up mode and prevent entering Waiting mode. Otherwise, the Compass Controller will maintain Start-up mode sta-tus while waiting for allowable conditions to begin initializing Waiting mode.


36

READY MODE

When the controller is in Ready mode the LCDdisplay will indicate that the system is ready to bestarted, as shown below.

The compressor can be started in one of the twoways as described in Section 2. When the

compressor is waiting to be started remotely, an “ ”in the upper right corner of the LCD will display in

characters as shown below.

When the appropriate remote start conditions aremet, the system will automatically enter the Start-upmode, and the compressor will start.

While the compressor is attempting to start in bothManual and Remote start mode, the LCD will displaythe following:

Ready mode is a transitional state betweeninitialization of the Compass Controller, operation ofthe compressor and compressor shutdown. InReady mode, the Compass Controller is ready toenter an operational state. However, the compressoris not active in Ready mode. Ready mode ischaracterized by “Ready… ” appearing on the LCD1st line parameter display. If Remote Start is

configured then “Ready… ” will be displayed.

Ready mode to Run mode is dependent on userinitiation of a compressor start enabler.

• Manual Start – initiated by the Start/Onswitch placed in the Start position.

• Auto (Remote) Start or Remote StartMomentary – Remote Start enabled.

In Ready mode, the Compass Controller is analyzingspecific system parameters to determine if enteringSleep mode is allowable. When the necessaryconditions are met, the system enters Sleep modeand all electrical components are de-energized. Ifthe compressor was enabled via Remote Start, theStart/On/Off switch is disabled and only acompressor malfunction will allow entering Ready

NOTEFor remote start applications, an appro-priate trickle charge must be applied to the batteries in order for the compressor to maintain Start-up readiness.If configured for remote start, the inactiv-ity auto sleep UCP is disregarded and no auto-sleep transitions will occure.

(P3-P1)

Ready . . .

ok

r.

reverse

r.

Comp Temp198°F

Ready . . .

Ok Exit Toggle

Engine Cranking

0 PSI Serv Pres…

r.

r.

r.

Comp Temp198°F

Ready . . .

r.

Comp Temp

Ready . . .

198°FStarting Aids Required


37

mode and then Sleep mode.

FAILURE TO START

In manual mode, if the engine does not start, the Compass Controller will attempt another start cycle as long as the maximum number of crank attempts is not exceeded. This is an automatic process until the Start attempts equal the set maximum.

If the maximum number of crank cycle attempts (apreset value) is exceeded, the system will display anerror message in the LCD display as shown below,and the system will wait until the “Reset” switch ispressed. Once the “Reset” switch is pressed, theCompass Controller system will shut down. Restartthe compressor by switching the Start/On switch toON.

When Remote is enabled, if the engine does notstart, the “Fault / Reset” switch will need to bedepressed to reset and shut the machine down. Thesystem will then wait for the appropriate start-upconditions and then activate the remote start input tostart the compressor.

RUN MODE

Once the compressor has completed the warm upcycle, it will phase into Run mode. When in Runmode, the LCD display will look similar to the displayshown below.

In Run mode, the compressor is ready to supplyservice air. The engine RPM will automatically beadjusted to maintain the desired air pressure. If the2nd line parameter (UCP) has been turned on, theoperator can scroll thru the list of availableparameters by momentarily pressing the “m” button.Each press of <5 seconds will scroll one parameter.The available parameters are listed below.

Engine Speed

Engine Hours (Hourglass symbol)

P1 Service Pressure

P2 Control Pressure

P3 Wet Pressure

(P3-P1) Air-Oil Separator Pressure

Compressor Tank Temperature

Ambient –or- Service Temperature

Engine Coolant Temp

Battery Voltage

% Engine Load

Fuel Rate

Fuel Pressure

Fuel Temperature

Engine Inlet Air Temperature

Oil Pressure

Boost Pressure

Desired Engine Speed

Aux 1 Pressure

Aux 1 Temperature

Press Reset to Clear

Engine Over Crank

110 PSI r.

Serv Pres …0 PSIScrollable

2nd line

Remote Start enabled icon System Service

Pressure


38

AUTO-START (REMOTE) CONFIGURATION

When using the Auto-Start feature, there are two parameters that can be set by using the Compass Controller Communicator Software tool on a laptop computer. The first is the P1 System Service Pres-sure, and the second is the time duration that the compressor must stay at or above the P1 pressure. These values are settable when the Compass Com-municator software and communication adapter are installed. When the compressor is operating in Auto-Start Mode, it will not enter a normal Shutdown mode until both conditions below are met.

a. The System Service Pressure (P1) is greaterthan the UCP (User Configurable Parame-ter) specified level for the UCP specifiedduration.

b. The “Remote Start” input has returned to itsnormally open position.

In the event that an abnormal shutdown occurs, thecompressor could shut down without theseconditions being met. See Section 5:TroubleShooting for handling abnormal shutdowns.

SHUT DOWN

The Shutdown mode can be entered when either of the following conditions occurs:

If the Compass Controller system was started manu-ally, the operator must press the “Off/On/Start” switch to the OFF position.

If the Compass Controller system was auto-started (Remote), the system will enter Shutdown mode when both the Service Pressure (P1) is greater than the specified level for the user-specified duration (Note: Both of these values are pre-set), and when the remote start binary input is deactivated.

When the system enters the Shutdown mode, the compressor will complete the following tasks before shutting down:

1. The LCD will display the message shownbelow.

2. The engine will go to the low idle setting(1400 RPM) for a preset period of time.

3. When the cool-down cycle is complete, theengine will shut down.

4. The Compass Controller will continue tomonitor P1, P2, and P3 inputs until they fallbelow the specified level (Note: This value ispre-set), and the LCD will display a messagesimilar to the one shown below.

This is displayed as a safety measure thatindicates to the user that the system is underpressure.

5. When the system pressures fall below thepre-determined levels, the controller willenter Sleep mode.

However, during the final portion of shutdown, afterthe Compass Controller has stopped thecompressor’s engine, the Compass Controller nolonger pays attention to the "Off / On / Start" switch(or Remote Start). The operator must wait until thisphase completes to restart the compressor.

Stop Initiated Cool Down Cycle

eng speed1400 rpm

NOTEIf while the engine is cooling down during the normal shutdown phase, but is still running, the operator presses the "Off / On / Start" switch back to the momentary "Start" position (or if the Remote Start input becomes active and the Compass Controller is configured to accept Remote Start), the system will immediately re- enter the Warm Up phase of the Start-up mode.

Monitoring Pressures

Serv Pres …0 PSI


39

GAUGES DISPLAY

Master Gauge –Service Air pressure

The air pressure gauge is driven by the air pressuresender analog input. Open and shorts of the P1Pressure sender analog input are considered out ofrange and will force the pointer to fluctuate full scale.

4-in-1 Gauge

The 4-in-1 slave gauge displays Engine CoolantTemperature, Engine Speed CompressorTemperature and Fuel Level. CompressorTemperature and Fuel Level are driven by analoginputs. Open and shorts of the fuel level senderanalog input are considered out of range and willforce the pointer to fluctuate full scale.

MESSAGE DISPLAY CENTER

The message display consists of a graphical, backlit,LCD display on the master gauge. Two input buttonslocated directly below the LCD, the “m” (mode) and“t” (task) buttons, allow user to navigate through theLCD display.

As the Compass Controller system is executing inany of its states, the LCD displays information to theuser that is pertinent to its operation and thecompressor state. In addition, through navigationwith the “m” and “t” buttons, menus may be solicitedto alter system behavior, modify the informationdisplayed, and make selection of the displayparameters.

PRIORITY MESSAGES

Priority messages are displayed in the LCD due tovarious inputs or data messages. The prioritymessage will take over the second line (parameterline) of the screen. Multiple messages may bedisplayed by continually showing the message for 2seconds before displaying the next message. Somemessages can be acknowledged by pressing the “m”button while the message is being displayed. Onceacknowledged, the priority message will leave thedisplay. Certain acknowledged priority messagesmay redisplay if the condition still exists after threeminutes, others will not reoccur until the next key-oncycle.

POWER-UP OPTIONS MENU

The menu is activated by pressing and holding downboth the “m” and “t” buttons while powering-on theCompass Controller by pressing the “Off/On/Start”button on the front panel. When performed, thefollowing “yes/no” options will appear. The current

setting (either yes or no) is displayed in characters.

Navigation of the menu is as follows:

• Press “m” to move circularly through theoptions.

• Press “t” to toggle the yes / no setting ofthe current option

• Press both “m” and “t” to exit the menu,saving the current settings in the CompassController’s non-volatile memory.

Momentary Start—(Only displayed when BOTHRem Start Momentary? AND Remote Start Enabled?are set to Yes). The remote stop will operate asoutlined in the Auto-Start (Remote) Operation inthis section. Alternatively, if Momentary Start is set to“No”, the remote start input will act in the samemanner as the Off/On/Start switch on the panel inthat if the circuit is closed the machine will start and ifthe circuit is opened then the machine will go intoshutdown mode and ultimately power down.

750psi P2 Transducer - When “Yes” is selected thecontroller is using an algorithm with suitable scaling

NOTEThis configuration is typical of a manned remote control room/station where a machine(s) are manually started and stopped as needed.

reverse

m t

Ok Exit Toggle

Momentary Start?yes no


40

to send proper engine speed commands to the CATECM. When “No” is selected a 250spi (control)transducer is used and the engine speed controlalgorithm is switched accordingly to maintain properengine speed..

Line 2 Parameter – enables the display of anadditional compressor / engine parameter duringRunning state. The first line parameter duringRunning state is always the system service pressure(P1) The second line may display any of severalpossible parameters.

Self Test - determines whether the gauge self test isperformed at start-up upon entry to the SystemPower-up, Check & Initialize state.

Remote Start - determines whether the activation ofthe normally open low-side remote start input can

attempt to start the engine once in the Ready state.

MAIN SCREEN WHILE NOT IN RUNNING STATE

Prior to transitioning into the Running state, theCompass Controller displays messaging indicatingthe operational state of the Compass Controllersystem. For example, while in the System PressureChecking phase of the System Power-up, Check &Initialize state, the Compass Controller will indicate“Checking Pressures” on the LCD display. During theEngine Cranking phase of the Starting state, theCompass Controller displays “Cranking Engine”.

BACKLIGHTING

Gauge backlighting is a user configurable parameterspecified using a menu entry. Lower and upper levelsof the UCP are 0% to 100% intensity. The specificparameter value is stored in the Compass Controller(EEprom) memory.

GAUGES INTERNAL WARNING INDICATORS

High Coolant Temperature

The High Coolant Temperature indicator light willturn on when the Compass Controller receives thecorresponding output signal from the Caterpillarengine.

Low Fuel Level

The Low Fuel Level indicator light will turn on whenthe fuel level is less than UCP “low fuel level assert”value. It will turn off when the level is above the UCP“low fuel level cancel” value.

High Compressor Temperature

The High Compressor Temperature indicator lightwill turn on when the T1 compressor temperature isgreater than or equal to the UCP specified forMaximum T1 Compressor Temperature.

m t

Ok Exit Toggle

750PSI P2?yes no

m t

Ok Exit Toggle


m t

Ok Exit Toggle

Self Test?yes no

m t

Ok Exit Toggle

Enable Remote Start?yes no


41

WARNING BANK INDICATORS

Engine Warning

The engine warning indicator is on when the enginewarning input is pulled to ground. The state of thisindicator lamp directly follows the engine warningoutput signal from the Caterpillar engine.

Engine Diagnostic

The engine diagnostic indicator is on when theengine diagnostic input is pulled to ground. The stateof this indicator lamp directly follows the enginediagnostic output signal from the Caterpillar engine.

Compressor Warning

The compressor warning indicator lamp is turned onwhen one or more of the following conditions exists:

1. Aux Temperature > Maximum Aux Temp. atRun Time (UCP)

2. Aux Temperature out of range

3. DP1, 2, (3, 5 if equipped with After-coolers)active for a UCP-specified time duration

4. P1, P2 or P3 pressure out of range

5. (P3-P1) > Max Permitted Air-Oil Pressure(UCP)

6. Fuel Level Low

7. Fuel Sender out of range

8. T1 Compressor Temperature out of range

9. After-cooler Freeze-up Imminent or LouverClosed conditions

4.3 COMPRESSOR SHUTDOWN

The compressor shutdown indicator lamp is turnedon when one or more of the following conditionsexists. In addition, the system is immediatelyshutdown when the condition occurs.

1. T1 Compressor Temperature > Max.T1Temp. At Run Time (UCP)

2. RTT switch input is active (Includes the Inter-stage Temperature switch (IT) on XH andXHH machines)

3. DP4, 6 (if equipped with After-coolers) activefor a UCP-specified time duration

4. Very Low Fuel Level

5. P1, P2, & P3 pressure signals out of rangesimultaneously

6. P1 > Max. permitted P1 pressure at run-time

7. P3 > Max. permitted P3 pressure at run-time

NORMAL SHUTDOWNS

The Compass Controller enters the Shutting Downstate in preparation for a normal shutdown wheneither of the following conditions is met:

1. When currently in the Starting or Runningstate and the Compass Controller systemwas started manually, the operator pressesthe “Off/On/Start” switch to the OFF position.

2. When currently in the Running state and theCompass Controller system was auto-started, the system service pressure P1exceeds the UCP specified level for a UCPspecified duration AND the Remote Startinput has been returned to its normally open(disabled) position.

ABNORMAL SHUTDOWN

An abnormal shutdown is defined as any shutdownthat occurs for any reason other than that discussedin the Normal Shutdown section. Any of the followingconditions will cause the compressor to be shutdown:

1. Engine sends a “Stop Engine” commandover the data bus

NOTEIf the operator switches the “On/Off/Start” switch back to the momentary Start position before the Compass Controller transitions to the OFF state, the Compass Controller will re-enter the Warm-up phase of the Starting state.

NOTEIf the Remote Start is once again enabled before the Compass Controller transitions to the OFF state during the shutdown sequence from an auto-start operation, the Compass Controller will re-enter the Warm-up phase of the Starting state.


42

2. Fuel level reached the “Very Low” level

3. P1 Air pressure exceeds P1 maximum valueallowed

4. P1, P2, & P3 pressure signals out of rangesimultaneously

5. P3 Pressure exceeds P3 maximum valueallowed

6. T1 Compressor temperature exceeds T1Maximum value allowed

7. RTT/IT/ input becomes activated

8. DP4 after-cooler is activated (if system usesafter-coolers)

9. DP6 after-cooler is activated (if system usesafter-coolers)

10. Loss of the Compass Controller internal databus

11. Engine crank cycle is exceeded

12. Engine crank cycle engine speed is unknown(not reported to the Compass Controller byengine)

13. Engine speed while in running phase isunknown (not reported to the CompassController by engine)

14. Emergency Stop is activated

15. Engine Speed too slow (if enabled)

16. Low discharge pressure (in 600PSI systemsif P3 is less than 70PSI for 30 sec. duringruntime)

Any of the preceding conditions will cause thecompressor to stop immediately. The LCD displaywill indicate what the cause of the shutdown is,similar to the example shown below:

The Compass Controller system will prevent thecompressor from restarting until the operatoracknowledges the fault by pressing the “Reset”switch.

ABNORMAL SHUTDOWN EVENTS

Abnormal shutdown information is stored andretained across power-up sessions of the system inthe Compass Controller memory. The abnormalshutdown event data can be retrieved, displayed andanalyzed using the Compass CommunicatorSoftware program. Refer to Section 5 for steps totroubleshooting abnormal shutdown events.

The following information is stored for each of thefive most recent abnormal shutdown events thathave occurred within the Compass Controller.

• Shutdown Fault Type

• Engine Hours at time of Fault

• P1, P2, P3 pressure at time of Fault

• T1, Aux Temp at time of Fault

• Fuel Level at time of Fault

• Vdc reference voltage at time of Fault

• Pending Warnings at time of Fault

• State of DP1-6 and RTT switch inputs timeof Fault

• Start Switch and Remote Start Switchinputs at time of Fault

• High/Low pressure switch at time of Fault

• Lin bus and J1939 bus status at time ofFault

• Engine Speed at time of Fault

• Battery Voltage at time of Fault

• Engine Boost Pressure at time of Fault

• Engine Inlet Manifold Temperature at timeof Fault

• Engine Coolant Temperature at time ofFault

NOTEThose conditions listed in bold font above are User-Configurable Parameters.

Press Reset to Clear

Engine Over Crank


43

• Engine Fuel Temperature at time of Fault

• Engine Oil Pressure at time of Fault

• Engine Fuel Pressure at time of Fault

• Engine Load at time of Fault

• Number of Active FMIs from Engine at timeof Fault

• First FMI/SPN data if active from Engine attime of Fault

• Engine Lamp Status if any active FMIs fromEngine at time of Fault

MAIN SCREEN WHILE IN RUNNING STATE

Once the Compass Controller transitions into theRunning state, it continuously displays the systemservice pressure on the top half of the LCD display.The bottom half of the screen will display associatedengine/compressor parameters. The parameter lastdisplayed when the controller was shutdown will bethe active display parameter at the next power-upsession.

An example display while in the Running state isshown below. The presence of the “r.” in the upperright hand corner of the display indicates that theCompass Controller is remote start enabled.

Once in the Running state (Assuming the 2nd LineParameter is turned on), momentarily pressing the“m” button (<5 seconds) will scroll the second linethrough all available parameters. The list of availableparameters is as follows:

NOTEThe “r.” indication does not indicate that thecurrent Running state was entered via theRemote Start input, but only that remote start isenabled.

110 PSI r.

Boost Pres23 PSI

Parameter Title Displayed on LCD Line 2 Parameter Description Eng speed Engine Speed as reported by engine

Hour glass icon Cumulative Engine Operation Hours

Serv pres Current P1 service pressure measurement

Cntrl pres Current P2 control pressure measurement

Wet pres Current P3 control pressure measurement

(P3-P1)Current P3 minus P1 (differential pressure of separatorelement)

Comp temp Compressor Tank temperature (T1 sensor)

Amb temp –or- Serv temp

Aux1 sensor temperature (displays as ambient if

after-coolers not configured for system)

Coolant Temp Engine Coolant Temperature – J1939

Batt V Battery Voltage – J1939

Eng Load Engine Load % - J1939

Fuel Rate Fuel Consumption Rate – J1939

Fuel pres Fuel Pressure – J1939

Fuel temp Fuel Temperature – J1939

Eng Air Temp Engine Air Temperature – J1939

Oil Pres Engine Oil Pressure – J1939

Boost Pres Engine Boost Pressure – J1939

Des Speed Desired Engine Speed – J1939

Aux1 pres Engine Aux1 Sensor Pressure – J1939

Aux1 temp Engine Aux1 Sensor Temperature – J1939

44

NOTES

Section 5

45


TROUBLESHOOTING5.1 TROUBLESHOOTING

INTRODUCTION

This Troubleshooting section is provided as a guideto aid in diagnosing and resolving compressorproblems when they occur. The informationcontained in Table 5A, Troubleshooting Guide, hasbeen compiled from factory experience and containssymptoms and usual causes for the describedproblems. Each warning or fault message is listedwith conditions of when the problem may occur, aprobable cause, and a suggested solution to theproblem. DO NOT assume that these are the onlyproblems that may occur. This document cannotaddress every possible adverse condition that mayoccur nor does it provide every solution for thepotential troubles listed. All available dataconcerning the trouble should be systematicallyanalyzed before undertaking any repairs orcomponent replacement procedures.

Always perform a detailed visual inspection when amachine problem occurs prior to attempting anyrepairs. Doing so may avoid unnecessary repairand/or additional damage to the compressor.

Always remember to:

a. Check for loose wiring, loss of ground, wiretermination, etc.

b. Check for damaged piping.

c. Check for parts damaged by heat or an elec-trical short circuit, usually apparent by discol-oration or a burnt odor.

Should your problem persist after making therecommended check, consult your nearest SullairDistributor or the Sullair factory Service Department.

5.2 TROUBLESHOOTING GUIDE INTRODUCTION

The following guide contains symptoms and usualcauses for the problems that may occur throughoutthe compressor system. Each warning or faultmessage that may appear is listed along withconditions for the problem, a probable cause, and asuggested solution to the problem. DO NOT assumethat these are the only troubles that may occur. Thefollowing table denotes all warning/shutdownconditions that the Compass Controller will sense.Shutdown conditions will display the associatedmessage on the LCD, light the CompressorShutdown panel light, shut the system down, andwait for operator to press the Fault/Reset button toacknowledge the fault condition before a restart maybe attempted. Warning conditions display theassociated message on the LCD and light theCompressor Warning panel light. Under a warningcondition the system will continue to operatenormally. In addition, the operator may dismiss thewarning message from the LCD screen by pressingthe “m” (mode) and “t” (trip) buttons on the mastergauge.

NOTESection 5.3 portrays common systematic problems that can occur during controller operation. For a more thoroughly in-depth coverage of the compressor operation trou-bles, consult the Troubleshooting Section in the machine’s operator’s manual.


46

5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE

Error Message Warning/Shutdown/Prevent Startup

Description Recommended Action

No Message Prevent Startup No power or initialization of controller Turn OFF/ON/START

switch to ON position.

Make sure E-stop is not

engaged (pull out).

Turn Battery Disconnect

Switch to ON position.

Check Battery Voltage.

Check Connections

between Compass

Controller and harness

and at the starter and

harness.

Make sure Controller

internal circuit breakers

(4) are closed.

Listening For Engine Prevent Startup No communication between Compass Controller and engine ECM

Verify bus resistance at 120 Ω.

Ensure proper

connection between

engine ECM and

Compass Controller.

Low Fuel Level Shutdown/Prevent Startup

Fuel Level Low Shutdown threshold reached

Add fuel and restart.

P2 Signal Error Shutdown/Prevent Startup

Transducer has no source voltage Verify 5Vdc to transducer.

Transducer has lost ground Verify path to ground.

Output voltage to controller is lost Verify .5-4.5Vdc to

controller.

Transducer malfunction Replace transducer.

Comp High Temp Shutdown/Prevent Startup

T1 Compressor temperature sensor is above shutdown setpoint

Verify thermistor

resistance between

803Ω @ -50˚C and

1573Ω @ 150˚C.

Coolers dirty Clean coolers.

Fan slipping Check/Adjust Fan belt

tension

Compressor Oil Thermostat malfunction

Replace thermostat.


47

RTT High Shutdown/Prevent Startup

RTT (Receiver Tank Temperature) switch,normally closed, has opened

Verify compressor

temperature via

controller display (toggle

to proper parameter). If

compressor temp is less

than the setpoint on all

others then replace the

RTT switch.

Primary Shutdown Shutdown/Prevent Startup

Afterfilter restriction too high (filters dirty)

Replace filters.

Afterfilters dp module malfunction Check source voltage

and ground and correct

if necessary.

Visually inspect for

damage and replace if

necessary.

Compass Comm

Error

Shutdown/Prevent Startup

Internal Cabling inside the Compass

Controller is not properly connected

Open Controller and

ensure that all gauge

and warning bank

connectors are well

seated/engaged.

High Comp Pressure Shutdown/Prevent Startup

P1 (Dry) or P3 (Wet) pressure is above setpoint

Pressure above 10 psi

(recent shutdown). Wait

for pressure to fall below

10 psi.

Transducers out of calibration Transducers need to be

calibrated using the

Gauge calibration

subroutine (see Section

3.2.12).

Engine Overcrank Shutdown The maximum number of engine crank cycles has been exceeded

Check battery voltage &

recharge if necessary.

Check starter relay for

short to ground.

Check source voltage to

starter relay.

Engine Comm Error Shutdown/Prevent Startup

The Compass Controller is not properly

receiving J1939 messages from the

engine ECM.

Check connections at

engine ECM and

Compass Controller.

Check the termination

resistor in the harness

ECM connector and

replace if necessary.




48

E-Stop Pressed Shutdown/Prevent Startup

The Compass Controller will not power

up/initialize (NO MESSAGE AT

CONTOLLER!)

Disengage E-stop.

The E-stop was used to shut machine down.

Once conditions are

deemed safe, press the

Reset switch, Press the

OFF/ON/START switch

to OFF.

Eng Speed Too Low Shutdown Engine speed dropped below preset value for a preset amount of time. This is to protect the vulcanized rubber drive coupling between the engine and compressor.

Check fuel level.

Check the inlet valve forpremature opening during thewarmup phase.

P1,P2,P3 Signal Error Shutdown Error Loss of all transducer inputs during run phase

Check voltage source and ground for good connection.

Low Fuel Level Warning Fuel light in 4-in-1 gauge is on. Compressor warning light is on. Fuel level is below 20%

Add fuel soon

Fuel Sender Error Warning The fuel level sensor signal is out of range

Check connections at

sensor on tank. Verify

source voltage and

ground.

Wires possibly reversed.

Fuel sensor is defective.

Replace

Controller is configured

incorrectly (configured

for tank when no tank is

present). Reprogram

the Compass Controller

using the Compass

Controller

Communication

Software,

Communication

Adapter, and PC.

P1 Signal Error Warning Transducer has no source voltage Verify 5V dc to transducer.


Output voltage to controller is lost Verify .5-4.5 Vdc to controller.









49





Air-Oil Separator Warning The differential pressure (P3 - P1) is above the setpoint for the specified period.

Separator elements are

dirty. Replace.

Aux Temp High Warning T2 (Aftercooler discharge temp or ambient

temp on non-aftercooled machines)

Clean coolers.

Check/Adjust Fan belt

tension.

Check T2 (RTD) for

short circuit to ground.

Aux Temp Error Warning Check T2 (RTD) for

short circuit to ground or

open circuit.

Engine Air Filter Warning DP1 switch, normally closed, has opened for the specified amount of time

Engine air filters clogged. Replace filters

Check circuit for

continuity.

Check the air filter

switch for continuity.

Replace if open.

Comp Air Filter Warning DP2 switch, normally closed, has opened for the specified amount of time

Engine air filters

clogged. Replace filters.

Check circuit for

continuity

Check the air filter

switch for continuity.

Replace if open.

Primary Warning Warning Afterfilters restriction increasing (becoming clogged)

service filters soon

P4/P5 Signal Error Warning Afterfilters differential pressure signal module is encountering a malfunction

Check connections between the filter module and the two

pressure transducers (P4 & P5) at the afterfilters

check source voltage and ground to transducers and to dp module

replace transducers

replace dp signal module




50

Louvers Closed Warning Informs operator of louver position. None unless machine overheats. Otherwise check Ambient Temp Sensor reading on LCD display. If the Ambient Temp reading is higher than the 70°F and the louvers are closed, check louver solenoid for proper operation. Also check louver air cylinders for proper operation. If the Ambient Temp Sensor is reading lower than atmospheric conditions, then check the temp sensor for proper operation and replace is necessary.

AC Freeze Imminent Warning If the Compass Controller is configured with an aftercooler and no louvers installed and the temperature at the discharge of the aftercooler falls below the setpoint, this message is displayed.

Bypass the aftercooler service air discharge circuit by locking out the aftercooler from the system and using non- aftercooled air.

Install Louvers on the aftercooler (if equipped) or the canopy intake.

Overflow Condition Warning A minimum service pressure must be maintained to prevent overflowing the oil separator filter. If the service pressure drops below required value for a period of 15 seconds, Compass will override any throttle control and command TSC1 to UCP Low Engine Idle. “Overflow Condition” will be displayed to inform end-user of condition. The warning message can be end-user acknowledged. Message acknowledgement does not release TSC1 control.

The service pressure must rise above the programmed set point, to normal operating pressure, for longer than 5 seconds to clear the fault condition. When the service pressure returns above the set point, throttle control reverts back to previous method and un-acknowledged warning message will clear. The 300 PSI Compass set point is 85 PSI, 600 PSI Compass set point is 150 PSI.

Wait to Start Warning Message from CAT engine ECM. J1939 Shutdown SPN1081 - Wait to Start active

Check Engine ECM for active codes/faults and possible configuration errors. Contact your nearest CAT servicing dealer for resolution.

Oil Pressure Low Warning CAT DM1 Message (Engine ECM) Check oil level and add if necessary. If condition persists, contact your nearest CAT servicing dealer for resolution

Coolant Temp High Warning CAT DM1 Message (Engine ECM) Check coolant level and

add if necessary. Clean

radiator if dirty. Check

fan belt tension and

tighten if needed.




51

Eng. OverSpeed Warning CAT DM1 Message (Engine ECM) If problem persists, shut

machine down and

check for volatiles in the

atmosphere. Don’t

restart machine until

condition is removed. If

ECM still displays

message, contact your

nearest CAT servicing

dealer for resolution.

High Inlet Air Temp Warning CAT DM1 Message (Engine ECM) Check wind direction

and make sure

engine/package exhaust

is not being recirculated

to air intakes. Relocate

compressor if necessary.

Low Coolant Level Warning CAT DM1 Message (Engine ECM) Check coolant level and

add if necessary.

Check connection

between the coolant

level sensor and the

harness. Replace

sensor if necessary.

High Fuel Temp Warning CAT DM1 Message (Engine ECM) Make sure cooling air

intake is facing

prevailing winds. Make

sure all cooling air

openings in canopy are

not obstructed. Add fuel

if tank is near empty.

High Fuel Pressure Warning CAT DM1 Message (Engine ECM) Fuel delivery system

relief valve malfunction -

contact you local CAT

servicing dealer.




52

High Exhaust Temp Warning CAT DM1 Message (Engine ECM) Check wind direction

and make sure

engine/package exhaust

is not being recirculated

to air intakes. Relocate

compressor if necessary.

Exhaust valve timing

incorrect - Contact your

local CAT servicing

dealer



Printed in the U.S.A.Specifications subject to change

without prior notice.E12EP

SULLAIR3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A.

Telephone: 1-219-879-5451

WWW.SULLAIR.COM

compass controller 02250167-454 r03 final · according to posted speed limits, weather, traffic,...

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