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Compass Controller Manual 2007 version

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USER MANUAL
COMPASS CONTROLLER™
PART NUMBER:
02250167-454 R01
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual or,
misuse of this equipement will
VOID its warranty!
KEEP FOR
FUTURE
REFERENCE
SULLAIR CORPORATION
©
The information in this manual is current
as of its publication date, and applies to
compressor serial number:
200710010000
and all subsequent serial numbers.
AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on portable compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
For detailed course outlines, schedule, and cost information contact:
SULLAIR CUSTOMER CARE TRAINING DEPARTMENT
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
- Or Write Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
TABLE OF CONTENTS
SECTION 1—SAFETY
3
1.1
GENERAL
3
1.2
TOWING
6
1.3
PRESSURE RELEASE
7
1.4
FIRE AND EXPLOSION
8
1.5
MOVING PARTS
9
1.6
HOT SURFACES, SHARP EDGES AND SHARP CORNERS
9
1.7
TOXIC AND IRRITATING SUBSTANCES
10
1.8
ELECTRICAL SHOCK
10
1.9
LIFTING
10
1.10
ENTRAPMENT
11
1.11
JUMP STARTING
12
1.12
IMPLEMENTATION OF LOCKOUT/TAGOUT
13
1.13
CALIFORNIA
PROPOSITION 65
14
1.14
SYMBOLS AND REFERENCES
SECTION 2—STARTUP PROCEDURES
17
2.1
INTRODUCTION
17
2.2
COMPASS CONTROLLER PANEL LAYOUT
17
2.3
COMPASS CONTROLLER POWER UP
19
2.4
NORMAL OPERATION
SECTION 3—ADJUSTMENTS
21
3.1
INTRODUCTION
21
3.2
SETTINGS AND DIAGNOSTIC
28
3.3
CONFIGURATION MENU
30
3.4
USER ADJUSTABLE CONTROL PARAMETERS (UCP)
SECTION 4—DESCRIPTION
33
4.1
INTRODUCTION
TABLE OF CONTENTS
33
4.2
OPERATING MODES
39
4.3
COMPRESSOR SHUTDOWN
SECTION 5—TROUBLESHOOTING
43
5.1
TROUBLESHOOTING INTRODUCTION
43
5.2
TROUBLESHOOTING GUIDE INTRODUCTION
44
5.3
COMPASS CONTROLLER TROUBLESHOOTING GUIDE
51
5.4
CONTROL PARAMETERS
Section 1
SAFETY
NOTE
DO NOT modify the compressor except with written
factory approval.
Each day, walk around the air compressor and
inspect for leaks, loose or missing parts, damaged
parts or parts out of adjustment. Perform all
recommended daily maintenance.
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL.
1.1
Inspect for torn, frayed, blistered or otherwise
deteriorated and degraded hoses. Replace as
required.
GENERAL
Sullair Corporation designs and manufactures all of
its products so they can be operated safely.
However, the responsibility for safe operation rests
with those who use and maintain these products. The
following safety precautions are offered as a guide
which, if conscientiously followed, will minimize the
possibility of accidents throughout the useful life of
this equipment. Read the CIMA Safety Manual
prior to compressor operation and towing, if
applicable in your area.
The air compressor should be operated only by those
who have been trained and delegated to do so, and
who have read and understood this Operator’s
Manual. Failure to follow the instructions, procedures
and safety precautions in this manual can result in
accidents and injuries.
NEVER start the air compressor unless it is safe to
do so. DO NOT attempt to operate the air
compressor with a known unsafe condition. Tag the
air compressor and render it inoperative by
disconnecting the battery so others who may not
know of the unsafe condition will not attempt to
operate it until the condition is corrected.
CAUTION
Estimated 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 8hour shifts would shorten the hose life
based on hours of operation.
1.2
TOWING (I)
PREPARING TO TOW
WARNING
Do 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.
Use and operate the air compressor only in full
compliance with all pertinent OSHA requirements
and/or all pertinent Federal, State and Local codes or
requirements.
(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.
3
SECTION 1
A. Prior to hitching the air compressor to the tow
vehicle, inspect all attachment parts and equipment, checking for (i) signs of excessive wear or
corrosion, (ii) parts that are cracked, bent,
dented or otherwise deformed or degraded, and
(iii) loose nuts, bolts or other fasteners. Should
any such condition be present, DO NOT TOW
until the problem is corrected.
B. Back the tow vehicle to the compressor and position it in preparation for coupling the compressor.
C. If the compressor is provided with a drawbar
latched in the vertical upright position, carefully
unlatch drawbar and lower it to engage the coupling device. If not, raise drawbar to engage coupling device or otherwise couple the compressor
to the towing vehicle.
WARNING
This 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.
D. Make sure the coupling device is fully engaged,
closed and locked.
E. If chains are provided, pass each chain through
its point of attachment on the towing vehicle;
then hook each chain to itself by passing the
grab hook over (not through) a link. Cross chains
under front of drawbar before passing them
through points of attachment on towing vehicle to
support front of drawbar in case it should accidentally become uncoupled.
F.
4
Make sure that the coupling device and adjacent
structures on the towing vehicle (and also, if utilized, chain adjustment, brake and/or electrical
interconnections) DO NOT interfere with or
restrict motion of any part of the compressor,
including its coupling device, with respect to the
towing vehicle when maneuvering over any
anticipated terrain.
G. If provided, make sure chain length, brake and
electrical interconnections provide sufficient
slack to prevent strain when cornering and
maneuvering, yet are supported so they cannot
drag or rub on road, terrain or towing vehicle surfaces which might cause wear that could render
them inoperative.
WARNING
This 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.
CAUTION
Retract the front screw jack only after
attaching the compressor to the tow vehicle. Raise the screw jack to its full up position 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 position, parallel to the drawbar, and reinsert
the pin. Make sure the jack is secured in
place prior to towing.
H. 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 upright position. 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.
SECTION 1
I.
according to posted speed limits, weather, traffic,
road or terrain conditions:
Make sure tires are in good condition and are the
size (load range) specified and are inflated to the
specified pressures. DO NOT change the tire
size or type. Also, make sure wheel bolts, lugs or
nuts are tightened to the specified torques.
J. If provided, make sure all dual stop, tail directional and clearance lights are operating properly
and that their lenses are clean and functional.
Also, make sure all reflectors and reflecting surfaces, including the slow moving vehicle emblem
on compressors provided with same, are clean
and functional.
K. Make sure all service air hoses (not air brake
hoses) are disconnected or are fully stowed and
secured on hose reels, if provided.
L. Make sure all access doors and tool box covers
are closed and latched. If the compressor is
large enough to hold a man, make sure all personnel are out before closing and latching
access doors.
1. Two axle four-wheel or three axle six-wheel
steerable models: 15 MPH (24 km/h).
2. All other models: 55 MPH (88 km/h).
C. Remember that the portable air compressor may
approach or exceed the weight of the towing
vehicle. Maintain increased stopping distances
accordingly. DO NOT make sudden lane
changes, U-turns or other maneuvers. Such
maneuvers can cause the compressor to tip, roll
over, jackknife or slide and cause loss of control
of the towing vehicle. Tipping, rolling over, etc.
can occur suddenly without warning. U-turns
especially 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.
M. Make sure parking brakes in towing vehicle are
set, or that its wheels are chocked or blocked, or
that it is otherwise restrained from moving. Then,
release the compressor parking brakes, if provided.
N. Make sure the compressor wheels are not
chocked or blocked, and that all tie-downs, if any,
are free.
O. Test running brake operation, including breakaway switch operation if provided, before
attempting to tow the compressor at its rated
speed 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 or
tools such that it is unbalanced from side to side
or front to back. Such unbalance will reduce the
towability of this equipment and may increase
the possibility of tipping, rolling over, jackknifing,
etc. Loss of control of the towing vehicle may
result.
TOWING
A. Observe all Federal, State, and Local laws while
towing this equipment (including those specifying
minimum speed).
B. DO NOT exceed the towing speeds listed below
under ideal conditions. Reduce your speed
Maneuver in a manner that will not exceed the
freedom of motion of the compressor’s drawbar
and/ or coupling device, in or on the towing vehicle’s coupling device and/or adjacent structure
whether towing forward or backing up, regardless of the terrain being traversed.
G. DO NOT permit personnel to ride in or on the
compressor.
H. Make sure the area behind, in front of, and under
the compressor is clear of all personnel and
obstructions prior to towing in any direction.
I.
DO NOT permit personnel to stand or ride on the
drawbar, or to stand or walk between the compressor and the towing vehicle.
PARKING OR LOCATING COMPRESSOR
A. Park or locate compressor on a level surface, if
possible. If not, park or locate compressor across
grade so the compressor does not tend to roll
downhill. DO NOT park or locate compressor on
grades exceeding 15° (27%).
B. Make sure compressor is parked or located on a
firm surface that can support its weight.
C. Park or locate compressor so the wind, if any,
tends to carry the exhaust fumes and radiator
heat away from the compressor air inlet openings, and also where the compressor will not be
exposed to excessive dust from the work site.
D. On steerable models, park compressor with front
wheels in straight-ahead position.
5
SECTION 1
E. Set parking brakes and disconnect breakaway
switch cable and all other interconnecting electrical and/or brake connections, if provided.
F.
Block or chock both sides of all wheels.
G. If provided, unhook chains and remove them
from the points of chain attachment on the towing
vehicle, then hook chains to bail on drawbar or
wrap chains around the drawbar and hook them
to themselves to keep chains off the ground
which might accelerate rusting.
H. Lower front screw jack and/or any front and rear
stabilizer legs. Make sure the surface they contact has sufficient load bearing capability to support the weight of the compressor.
WARNING
This 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.
CAUTION
Retract the front screw jack only after
attaching the compressor to the tow vehicle. Raise the screw jack to its full up position 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 position, parallel to the drawbar, and reinsert
the pin. Make sure the jack is secured in
place prior to towing.
I.
6
If a caster wheel is provided on the screw jack, it
is 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
screw jack. Raise the screw jack to its full upright
position 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.
J. Disconnect coupling device, keeping hands and
fingers clear of all pinch points. If the compressor
is provided with a drawbar, DO NOT attempt to
lift the drawbar or if hinged, to raise it to the
upright position by hand, if the weight is more
than you can safely handle. Use a screwjack or
chain fall if you cannot lift or raise the drawbar
without avoiding injury to yourself or others.
K. When possible, stow hinged drawbar in the vertical upright position. Make certain it is securely
latched in the vertical upright position. Keep feet
clear of drawbar at all times to avoid crushing
accidents in case it should slip from your hands
or otherwise fall to the ground.
L. Move the towing vehicle well clear of the parked
compressor and erect hazard indicators, barricades and/or flares (if at night) if compressor is
parked on or adjacent to public roads. Park so as
not to interfere with traffic.
NOTE
While not towed in the usual sense of the
word, many of these instructions are
directly applicable to skidmounted portable air compressors as well.
1.3
PRESSURE RELEASE
A. Open the pressure relief valve at least weekly to
make sure it is not blocked, closed, obstructed or
otherwise disabled.
B. Install an appropriate flow-limiting valve between
the 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
the shutoff (throttle) valve, to reduce pressure in
case of hose failure, per OSHA Standard 29 CFR
1926.302 (b) (7) or any applicable Federal, State
and Local codes, standards and regulations.
C. When the hose is to be used to supply a manifold, install an additional appropriate flow-limiting
valve between the manifold and each air hose
SECTION 1
exceeding 1/2" (13 mm) inside diameter that is to
be connected to the manifold to reduce pressure
in case of hose failure.
D. Provide an appropriate flow-limiting valve for
each additional 75 feet (23 m) of hose in runs of
air hose exceeding 1/2" (13 mm) inside diameter
to reduce pressure in case of hose failure.
E. Flow-limiting valves are listed by pipe size and
rated CFM. Select appropriate valve accordingly.
F.
DO NOT use tools that are rated below the maximum rating of this compressor. Select tools, air
hoses, pipes, valves, filters and other fittings
accordingly. DO NOT exceed manufacturer’s
rated safe operating pressures for these items.
G. Secure all hose connections by wire, chain or
other suitable retaining device to prevent tools or
hose ends from being accidentally disconnected
and expelled.
H. Open fluid filler cap only when compressor is not
running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) to
zero internal pressure before removing the cap.
I.
Vent all internal pressure prior to opening any
line, fitting, hose, valve, drain plug, connection or
other component, such as filters and line oilers,
and before attempting to refill optional air line
anti-icer systems with antifreeze compound.
J. Keep personnel out of line with and away from
the discharge opening of hoses, tools or other
points of compressed air discharge.
K. DO NOT use air at pressures higher than 30 psig
(2.1 bar) for cleaning purposes, and then only
with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR
1910.242 (b) or any applicable Federal, State
and Local codes, standards and regulations.
L. DO NOT engage in horseplay with air hoses as
death or serious injury may result.
M. This equipment is supplied with an ASME
designed pressure vessel protected by an ASME
rated relief valve. Lift the handle once a week to
make sure the valve is functional. DO NOT lift
the handle while machine is under pressure.
N. If the machine is installed in an enclosed area it
is necessary to vent the relief valve to the outside
of the structure or to an area of non-exposure.
O. DO NOT remove radiator filler cap until the coolant temperature is below its boiling point. Then
loosen cap slowly to its stop to relieve any
excess pressure and make sure coolant is not
boiling before removing cap completely. Remove
radiator filler cap only when cool enough to touch
with a bare hand.
P. The ethyl ether in the replaceable cylinders used
in diesel ether starting aid systems (optional) is
under pressure. DO NOT puncture or incinerate
those cylinders. DO NOT attempt to remove the
center valve core or side pressure relief valve
from these cylinders regardless of whether they
are full or empty.
Q. If a manual blowdown valve is provided on the
receiver, open the valve to ensure all internal
pressure has been vented prior to servicing any
pressurized component of the compressor air/
fluid system.
1.4
FIRE AND EXPLOSION
WARNING
Do not attempt to operate the compressor
in any classification of hazardous environment or potentially explosive atmosphere
unless the compressor has been specially
designed and manufactured for that duty.
A. Refuel at a service station or from a fuel tank
designed for its intended purpose. If this is not
possible, ground the compressor to the dispenser prior to refueling.
B. Clean up spills of fuel, fluid, battery electrolyte or
coolant immediately if such spills occur.
C. Shut off air compressor and allow it to cool. Then
keep sparks, flames and other sources of ignition
away and DO NOT permit smoking in the vicinity
when adding fuel, or when checking or adding
electrolyte to batteries, or when checking or adding fluid, or when checking diesel engine ether
starting aid systems or replacing cylinders, or
when refilling air line anti-icer systems antifreeze
compound.
D. DO NOT permit liquids, including air line anti-icer
system antifreeze compound or fluid film, to
accumulate on bottom covers or on, under or
around acoustical material, or on any external or
internal surfaces of the air compressor. Wipe
down using an aqueous industrial cleaner or
7
SECTION 1
steam clean as required. If necessary, remove
acoustical material, clean all surfaces and then
replace acoustical material. Any acoustical material with a protective covering that has been torn
or punctured should be replaced immediately to
prevent accumulation of liquids or fluid film within
the material. DO NOT use flammable solvents
for cleaning purposes.
E. Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning inside the enclosure. Tag the battery
connections so others will not unexpectedly
reconnect it.
F.
Keep electrical wiring, including the battery terminals and other terminals, in good condition.
Replace any wiring that has cracked, cut
abraded or otherwise degraded insulation or terminals that are worn, discolored or corroded.
Keep all terminals clean and tight.
G. Turn off battery charger before making or breaking connections to the battery.
H. Keep grounded conductive objects such as tools
away from exposed live electrical parts such as
terminals to avoid arcing which might serve as a
source of ignition.
I.
Replace damaged fuel tanks or lines immediately
rather than attempt to weld or otherwise repair
them. DO NOT store or attempt to operate the
compressor with any known leaks in the fuel system. Tag the compressor and render it inoperative until repair can be made.
J. Remove any acoustical material or other material
that may be damaged by heat or that may support combustion prior to attempting weld repairs.
Remove diesel engine ether starting aid cylinders and air line anti-icer system components
containing antifreeze compound, prior to
attempting weld repairs in any place other than
the fuel system. DO NOT weld on or near the
fuel system.
K. Keep a suitable, fully charged class BC or ABC
fire extinguisher or extinguishers nearby when
servicing and operating the compressor.
L. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.
M. Open all access doors and allow the enclosure to
ventilate thoroughly prior to attempting to start
the engine.
8
N. DO NOT operate compressor under low overhanging leaves or permit such leaves to contact
hot exhaust system surfaces when operating the
compressor in forested areas.
O. Ethyl ether used in diesel engine ether starting
aid systems is extremely flammable. Change cylinders, or maintain or troubleshoot these systems only in well-ventilated areas away from
heat, open flame or sparks. DO NOT install,
store or otherwise expose ether cylinders to temperatures above 160 °F (71 °C). Remove ether
cylinder from the compressor when operating in
ambient temperatures above 60 °F (16 °C).
P. DO NOT attempt to use ether as a starting aid in
gasoline engines or diesel engines with glow
plugs as serious personnel injury or property
damage may result.
Q. DO NOT spray ether into compressor air filter or
into an air filter that serves both the engine and
the compressor as serious damage to the compressor or personal injury may result.
R. Antifreeze compound used in air line anti-icer
systems contains methanol which is flammable.
Use systems and refill with compound only in
well-ventilated areas away from heat, open
flames or sparks. DO NOT expose any part of
these systems or the antifreeze compound to
temperatures above 150 °F (66 °C). Vapors from
the antifreeze compound are heavier than air.
DO NOT store compound or discharge treated
air in confined or unventilated areas. DO NOT
store containers of antifreeze compound in direct
sunlight.
S. Store flammable fluids and materials away from
your work area. Know where fire extinguishers
are and how to use them, and for what type of
fire they are intended. Check readiness of fire
suppression systems and detectors if so
equipped.
1.5
MOVING PARTS
A. Keep hands, arms and other parts of the body
and also clothing away from belts, pulleys and
other moving parts.
B. DO NOT attempt to operate the compressor with
the fan or other guards removed.
C. Wear snug-fitting clothing and confine long hair
when working around this compressor, especially
SECTION 1
when exposed to hot or moving parts inside the
enclosure.
D. Keep access doors closed except when making
repairs or adjustments, performing service or
when starting or stopping the compressor.
E. Make sure all personnel are out of and clear of
the compressor prior to attempting to start or
operate it.
F.
1.7
A. DO NOT use air from this compressor for respiration (breathing) except in full compliance with
OSHA Standards 29 CFR 1920 and any other
Federal, State or Local codes or regulations.
DANGER
Shut off engine before adding fuel, fluid, coolant
lubricants, air line antifreeze compound or battery electrolyte, or before replacing ether starting
aid cylinders.
G. Disconnect the grounded negative battery connection to prevent accidental engine operation
prior to attempting repairs or adjustments. Tag
the battery connection so others will not unexpectedly reconnect it.
H. When adjusting the controls, it may require operation of the equipment during adjustment. DO
NOT come in contact with any moving parts
while adjusting the control regulator and setting
the engine RPM. Make all other adjustments with
the engine shut off. When necessary, make
adjustment, other than setting control regulator
and engine RPM, with the engine shut off. If necessary, start the engine and check adjustment. If
adjustment is incorrect, shut engine off, readjust,
then restart the engine to recheck adjustment.
I.
Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water, antifreeze
or other liquids to minimize possibility of slips and
falls.
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 of
air discharge and away from hot exhaust gases.
C. Wear personal protective equipment including
gloves and head covering when working in, on or
around the compressor.
D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore
small cuts and burns as they may lead to infection.
TOXIC AND IRRITATING
SUBSTANCES
INHALATION HAZARD!
Death or serious injury can result from
inhaling compressed air without using
proper safety equipment. See OSHA standards and/or any applicable Federal, State,
and Local codes, standards and regulations
on safety equipment.
B. DO NOT use air line anti-icer systems in air lines
supplying respirators or other breathing air utilization equipment and DO NOT discharge air
from these systems into unventilated or other
confined areas.
C. Operate the compressor only in open or wellventilated areas.
D. If the compressor is operated indoors, discharge
engine exhaust fumes outdoors.
E. Locate the compressor so that exhaust fumes
are not apt to be carried towards personnel, air
intakes servicing personnel areas or towards the
air intake of any portable or stationary compressor.
F.
Fuels, fluids, coolants, lubricants and battery
electrolyte used in the compressor are typical of
the industry. Care should be taken to avoid accidental ingestions and/or skin contact. In the
event of ingestion, seek medical treatment
promptly. DO NOT induce vomiting if fuel is
ingested. Wash with soap and water in the event
of skin contact.
G. Wear an acid-resistant apron and a face shield or
goggles when servicing the battery. If electrolyte
9
SECTION 1
is spilled on skin or clothing, immediately flush
with large quantities of water.
H. Ethyl ether used in diesel engine ether starting
aid systems is toxic, harmful or fatal if swallowed.
Avoid contact with the skin or eyes and avoid
breathing the fumes. If swallowed, DO NOT
induce vomiting, but call a physician immediately.
I.
Wear goggles or a full face shield when testing
ether starting aid systems or when adding antifreeze compound to air line anti-icer systems.
Keep openings of valve or atomizer tube of ether
starting aid system pointed away from yourself
and other personnel.
J. If ethyl ether or air line anti-icer system antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large
quantities of clean water for 15 minutes. A physician, preferably any eye specialist, should be
contacted immediately.
K. DO NOT store ether cylinders or air line anti-icer
system antifreeze compound in operator’s cabs
or in other similar confined areas.
L. The antifreeze compound used in air line antiicer systems contains methanol and is toxic,
harmful or fatal if swallowed. Avoid contact with
the skin or eyes and avoid breathing the fumes. If
swallowed, induce vomiting by administering a
tablespoon of salt in each glass of clean warm
water until vomit is clear, then administer two
tablespoons of baking soda in a glass of clean
water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately.
1.8
ELECTRICAL SHOCK
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 by
helicopter must not be supported by the lifting
bail, but by slings instead. In any event, lift only in
full compliance with OSHA Standards 29 CFR
1910 subpart N or any other Local, State, Military
and Federal regulations that may apply.
B. Inspect lifting bail and points of attachment for
cracked welds and for cracked, bent, corroded or
otherwise degraded members and for loose bolts
or nuts prior to lifting.
C. Make sure entire lifting, rigging and supporting
structure has been inspected, is in good condition and has a rated capacity of at least the net
weight of the compressor plus an additional 10%
allowance for weight of snow, ice, mud or stored
tools and equipment. If your are unsure of the
weight, then weigh compressor before lifting.
D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and
latched on the bail.
E. Use guide ropes or equivalent to prevent twisting
or swinging of the compressor once it has been
lifted clear of the ground.
F.
DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away
from the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I.
Keep lift operator in constant attendance whenever compressor is suspended.
A. Keep the towing vehicle or equipment carrier,
compressor hoses, tools and all personnel at
least 10 feet (3 m) from power lines and buried
cables.
J. Set compressor down only on a level surface
capable of supporting at least its net weight plus
an additional 10% allowance for the weight of
snow, ice, mud or stored tools and equipment.
B. Keep all parts of the body and any hand-held
tools or other conductive objects away from
exposed live parts of electrical system. Maintain
dry footing, stand on insulating surfaces and DO
NOT contact any other portion of the compressor
when making adjustments or repairs to exposed
live parts of the electrical system.
K. If the compressor is provided with parking
brakes, make sure they are set, and in any
event, block or chock both sides of all running
wheels before disengaging the lifting hook.
C. Attempt repairs only in clean, dry and well-lighted
and ventilated areas.
D. Stay clear of the compressor during electrical
storms! It can attract lightning.
10
1.10 ENTRAPMENT
A.
Make sure all personnel are out of compressor
before closing and latching enclosure doors.
B.
If the compressor is large enough to hold a man
and if it is necessary to enter it to perform service
SECTION 1
adjustments, inform other personnel before
doing so, or else secure the access door in the
open position to avoid the possibility of others
closing and possibly latching the door with personnel inside.
1.11 JUMP STARTING
A. Observe all safety precautions mentioned elsewhere in this manual.
B. Batteries may contain hydrogen gas which is
flammable and explosive. Keep flames, sparks
and other sources of ignition away.
C. Batteries contain acid which is corrosive and poisonous. DO NOT allow battery acid to contact
eyes, skin, fabrics or painted surfaces as serious
personal injury or property damage could result.
Flush any contacted areas thoroughly with water
immediately. Always wear an acid-resistant
apron and face shield when attempting to jump
start the compressor.
D. Remove all vent caps (if so equipped) from the
battery or batteries in the compressor. DO NOT
permit dirt or foreign matter to enter the open
cells.
E. Check fluid level. If low, bring fluid to proper level
before attempting to jump start (not applicable to
maintenance-free batteries).
F.
DO NOT attempt to jump start if fluid is frozen or
slushy. Bring batteries up to at least 60 °F (16
°C) before attempting to jump start or it may
explode.
G. Cover open cells of all compressor batteries with
clean dampened cloths before attempting to
jump start.
H. Attempt to jump start only with a vehicle having a
negative ground electrical system with the same
voltage, and is also equipped with a battery or
batteries of comparable size or larger than supplied in the compressor. DO NOT attempt to
jump start using motor generator sets, welders or
other sources of DC power as serious damage
may result.
I.
Bring the starting vehicle alongside the compressor, but DO NOT permit metal to metal contact
between the compressor and the starting vehicle.
J. Set the parking brakes of both the compressor (if
provided) and the starting vehicle or otherwise
block both sides of all wheels.
K. Place the starting vehicle in neutral or park, turn
off all non-essential accessory electrical loads
and start its engine.
L. Use only jumper cables that are clean, in good
condition and are heavy enough to handle the
starting current.
M. Avoid accidental contact between jumper cable
terminal clips or clamps and any metallic portion
of either the compressor or the starting vehicle to
minimize the possibility of uncontrolled arcing
which might serve as a source of ignition.
N. Positive battery terminals are usually identified
by a plus (+) sign on the terminal and the letters
POS adjacent to the terminal. Negative battery
terminals are usually identified by the letters
NEG adjacent to the terminal or a negative (-)
sign.
O. Connect one end of a jumper cable to the positive (POS) (+) battery terminal in the starting
vehicle. When jump starting 24V compressors
and if the starting vehicle is provided with two (2)
12V batteries connected in series, connect the
jumper cable to the positive (POS) (+) terminal of
the ungrounded battery.
P. Connect the other end of the same jumper cable
to the positive (POS) (+) terminal of the starter
motor battery in the compressor, or when jump
starting 24V compressor, to the positive (POS)
(+) terminal of the ungrounded battery in the
compressor.
Q. Connect one end of the other jumper cable to the
grounded negative (NEG) (-) terminal of the battery in the starting vehicle. When jump starting
24V compressors and if the starting vehicle is
provided with two (2) 12V batteries connected in
series, connect the jumper cable to the negative
(NEG) (-) terminal of the grounded battery.
R. Check your connections. DO NOT attempt to
start a 24V compressor with one 12V battery in
the starting vehicle. DO NOT apply 24V to one
12V battery in the compressor.
S. Connect the other end of this same jumper cable
to a clean portion of the compressor engine
block away from fuel lines, the crank case
breather opening and the battery.
T.
Start the compressor in accordance with normal
procedure. Avoid prolonged cranking.
U. Allow the compressor to warm up. When the
compressor is warm and operating smoothly at
11
SECTION 1
normal idle RPM, disconnect the jumper cable
from the engine block in the compressor, then
disconnect the other end of this same cable from
the grounded negative (NEG) (-) terminal of the
battery in the starting vehicle. Then disconnect
the other jumper cable from the positive (POS)
(+) terminal of the battery in the compressor, or if
provided with two (2) 12V batteries connected in
series, from the ungrounded battery in the compressor, and finally, disconnect the other end of
this same jumper cable from the positive (POS)
(+) terminal of the battery in the starting vehicle
or from the positive (POS) (+) terminal of the
ungrounded battery in the starting vehicle, if it is
provided with two (2) 12V batteries connected in
series.
V. Remove and carefully dispose of the dampened
cloths, as they may now be contaminated with
acid, then replace all vent caps.
1.12 IMPLEMENTATION OF
LOCKOUT/TAGOUT
The energy control procedure defines actions
necessary to lockout a power source of any machine
to be repaired, serviced or set-up, where unexpected
motion, or an electrical or other energy source, would
cause personal injury or equipment damage. The
power source on any machine shall be locked out by
each employee doing the work except when motion
is necessary during setup, adjustment or troubleshooting.
A. The established procedures for the application of
energy control shall cover the following elements
and actions and shall be initiated only by Authorized Persons and done in the following
sequence:
1. Review the equipment or machine to be
locked and tagged out.
2. Alert operator and supervisor of which
machine is to be worked on, and that power
and utilities will be turned off.
3. Check to make certain no one is operating
the machine before turning off the power.
4. Turn off the equipment
shutdown procedure.
using
normal
5. Disconnect the energy sources:
a. Air and hydraulic lines should be bled,
drained and cleaned out. There should
be no pressure in these lines or in the
12
reservoir tanks. Lockout or tag lines or
valves.
b. Any mechanism under tension or pressure, such as springs, should be
released and locked out or tagged.
c. Block any load or machine part prior to
working under it.
d. Electrical circuits should be checked with
calibrated electrical testing equipment
and stored energy and electrical capacitors should be safely discharged.
6. Lockout and/or Tagout each energy source
using the proper energy isolating devices
and tags. Place lockout hasp and padlock or
tag at the point of power disconnect where
lockout is required by each person
performing work. Each person shall be
provided with their own padlock and have
possession of the only key. If more than one
person is working on a machine each person
shall affix personal lock and tag using a
multi-lock device.
7. Tagout devices shall be used only when
power sources are not capable of being
locked out by use of padlocks and lockout
hasp devices. Name of person affixing tag to
power source must be on tag along with date
tag was placed on power source.
8. Release stored energy and bring the
equipment to a “zero mechanical state”.
9. Verify Isolation: Before work is started, test
equipment to ensure power is disconnected.
B. General Security
1. The lock shall be removed by the
“Authorized” person who put the lock on the
energy-isolating device. No one other than
the person/persons placing padlock ad
lockout hasp on power shall remove padlock
and lockout hasps and restore power.
However, when the authorized person who
applied the lock is unavailable to remove it
his/her Supervisor may remove padlock/
padlocks and lockout hasps and restore
power only if it is first:
a. verified that no person will be exposed to
danger.
b. verified that the “Authorized” person who
applied the device is not in the facility.
c. noted that all reasonable efforts to contact the “Authorized” person have been
made to inform him or her that the lockout or tagout device has been removed.
SECTION 1
d. ensured that the “Authorized” person is
notified of lock removal before returning
to work.
2. Tagout System—Tags are warning devices
affixed at points of power disconnect and are
not to be removed by anyone other that the
person placing tag on power lockout. Tags
shall never be by-passed, ignored, or
otherwise defeated
1.13 CALIFORNIA
PROPOSITION 65
WARNING
CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other
reproductive harm.
Battery posts, terminals and related accessories contain lead and other compounds
known to the State of California to cause
cancer and birth defects and other reproductive harm. Wash hands after handling.
13
SECTION 1
1.14 SYMBOLS AND
REFERENCES
The symbols below may or may not be used. Please
refer to the decals set forth on the machine for
applicable symbols.
Safety Symbols-1
14
SECTION 1
Safety Symbols-2
15
SECTION 1
Safety Symbols-3
16
COMPASS CONTROLLER USER MANUAL
Section 2
STARTUP PROCEDURES
2.1
INTRODUCTION
This compressor is equipped with a Sullair Compass
Controller for controlling the compressor system
operation, adjusting the machine parameters and
performing maintenance operations. The Compass
Controller utilizes digital technology that ensures
accurate and safe operation of the compressor
system. When fault conditions occur, the controller
automatically shuts down the machine to prevent
injury to the operator or damage to the equipment.
Features of the Compass Controller include:
• Dual gauges for display of pressure,
engine temp, compressor temp, engine
rpm, and fuel level
• LCD screen displaying machine status and
operating information
• Remote start capabilities
• Automatic self diagnosis at startup
• Multiple language support
• An external diagnostics port which allows
PC interface for configuration of the system
parameters.
• Backlighting of gauges with green LED to
allow clear view of gauges in low light
areas.
2.2
COMPASS CONTROLLER
PANEL LAYOUT
The Compass Controller panel is shown in Figure 21. The controller components and functions are
described in detail in Section 4.
2.3
COMPASS CONTROLLER
POWER UP
The compass controller is used to start the
compressor either manually or remotely.
Manual Start: Start the machine by pressing the
“OFF/ON/START” button to the “START” position on
the controller panel. Once the switch has been set to
the start position, the Compass Controller will
automatically continue to energize the starter until
either the engine starts or the maximum crank
duration is reached.
Auto Start:
The compressor can be started
remotely if the remote start function has been
enabled during setup. If this option is activated, an
“ r. ” will display in reverse reverse characters in
the upper right corner of the LCD display.
SELF TEST
When the controller is initially powered up, the
system will initiate a “Self Test” sequence to verify its
operational integrity and safety status. During this
process, the following self tests will be performed.
1. Gauge pointers will move to the zero position, then to half and full scale, then back to
zero, and finally to the actual value reading.
2. The LCD display will turn on all its segments
for one second, off for one second, and then
display the Sullair logo followed by the software product number with revision level.
3. All warning lights will turn on for 5 seconds
and then turn off, then set to the actual indicator state.
The Self Test feature may be bypassed by disabling
the sequence as describe in Section 3 of this
manual.
COMMUNICATION BUS CHECKS
After successful completion of the self test, the
Compass Controller system will check the
communication status of system.
17
COMPASS CONTROLLER USER MANUAL
SECTION 2
Figure 2-1: Compass Controller Panel
18
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
In the event of a problem, the LCD will display one of
the following messages:
by the Compass Controller during startup and the
fault that will be displayed on the LCD screen if a
fault occurs.
See Section 5 of this manual for troubleshooting
recommendations.
Listening For Engine
SYSTEM PRESSURE CHECKS
Following the successful completion of the general
safety checks, the Compass Controller will check the
status of the Service Pressure (P1), Control Pressure
(P2), and Wet Sump (P3). If there is a problem with
any of these inputs a message will be displayed on
the LCD display indicating the nature of the problem.
Checking Compass Comm
(Example shown below):
Checking Pressures
P1 Signal Error
The Compass Controller system will prevent the user
from
operating
the
compressor
until
all
communication problems are resolved.
See Section 5 of this manual for troubleshooting
recommendations.
GENERAL SAFETY CONDITION CHECKS
After successful completion of the Communication
Bus checks, the Compass Controlfler system will
perform safety checks on the compressor and the
engine.
In the event of a problem with either the compressor
or engine, a message will display in the LCD
indicating the nature of the trouble (example shown
below). The Controller will wait for user-interaction to
either correct the fault or send the system to Sleep
mode.
27.6 V
27.6 V
r.
Batt V
Batt V
The controller will prevent compressor startup if
either of the following conditions exists:
• P1 pressure is greater than the maximum
P1 pressure permitted at startup. The
maximum P1 pressure is an adjustable
parameter which can be modified as
describe in Section 3 of this manual.
• P1 and P2 pressures are out of range.
See Section 5 of this manual for troubleshooting
recommendations.
2.4
Checking System
Low Fuel Level
r.
NORMAL OPERATION
Following the successful completion of all startup
sequences, the system is ready for normal operation.
During normal operation the controller will be in one
of the following five operating modes: Waiting,
Start-Up and Autostart (remote), Run, Sleep, and
Shutdown. Each of these modes is described in
detail in Section 4.
Table 2-1 lists the safety conditions that are checked
19
COMPASS CONTROLLER USER MANUAL
SECTION 2
Table 2-1: Safety Conditions
Parameter
Fuel
Fault Condition
User Controlled
Parameter
LCD Message
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 Temperature (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 Pressure
Transducer signal short or
open circuit
None
P2 Signal Error
Control Pressure (P2)
20
COMPASS CONTROLLER USER MANUAL
Section 3
ADJUSTMENTS
3.1
INTRODUCTION
This section describes steps for using the Compass
Controller to modify specific parameters that control
the machine operation. Additional parameters can be
viewed and adjusted using the PC User Interface.
MESSAGE DISPLAY CENTER
The message display is a graphical LCD that
displays information to the compressor operator.
The screen is backlit to allow the display characters
to be clearly visible under any lighting conditions. In
addition to basic operational information, a variety of
user- defined options may also be displayed when
specified. Fault messages are displayed whenever a
fault condition occurs. The LCD display also allows
the operator to view instrumentation diagnostic data
to aid in controlling the system operation and in
troubleshooting 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 reverse characters indicating it is
selected. Press the “m” or “t” button to scroll the
display through the various parameters that are
available for user adjustment.
3.2
SETTINGS AND
DIAGNOSTIC
DIAGNOSTIC MENU
The operator can enter the diagnostic menu at any
time by pressing and holding the “m” button for more
than five seconds.
If the operator enters the
diagnostic menu prior to getting past the Waiting
state, the compressor will not be permitted to start
until the diagnostic menu is exited. When the
Compass Controller is in Waiting mode, pressing the
“m” button for more than five (>5) seconds brings up
the following screen:
1-Set Units
2-Set Language
3-Contrast
Select
Pressing both the “m” and “t” buttons simultaneously
will make the highlighted parameter active for editing.
Pressing the “m” or “t” button separately will move
the highlight through the parameter list allowing other
items to be selected.
MENU STRUCTURE
The diagnostic menu will appear in the LCD display
as shown below. Use the “m” and “t” buttons to
scroll through the available menu selections. The
present menu item will display in reverse
characters. There are nine diagnostic menu
selections which can be chosen from this menu:
1. Set Units
2. Set Language
3. Contrast
4. COMPASS Diagnostics*
5. Pressure Calibration
6. Auxiliary Temperature Calibration
7. Backlight Adjust
8. Engine Diagnostics*
9. Engine Shutdown History
To select a present menu item, press both the “m”
and “t” buttons at the same time. The operator can
then use the “m” and “t” buttons to modify the
selected parameter.
21
COMPASS CONTROLLER USER MANUAL
SECTION 3
SET UNITS
When “Set Units” is selected, the LCD display will
show the following:
Language Changed
Current Units
ENGLISH
CONTRAST
Press t for METRIC
Press m to exit
The operator can choose between English and
Metric units by pressing the “t” button. To make the
units active, press the “m” button or simply let the
screen time out (approx. five seconds).
SET LANGUAGE
Selecting the Contrast option allows the operator to
adjust the contrast of the LCD display. Press the
“m”(+) button to increase contrast. Press the “t”(-)
button to decrease contrast.
CONTRAST ADJUST
When “Set Language” is selected, the LCD display
will present six international languages for the
system display. The operator can scroll between the
available languages by pressing the “m” or “t”
buttons. The selected option will appear in reverse
characters. To make the selected language active,
press both the “m” and “t” buttons at the same time.
1-English
2-French
3-Spanish
-
THE COMPASS CONTROLLER DIAGNOSTICS
The Compass Controller Diagnostics menu contains
five tests that verify the functionality of specific
controller components. The Diagnostics menu can
only be entered if the compressor is in the Waiting
mode (Prior to start-up).
Selecting this menu option will present a sub-menu
as shown below. To make a selection in the sub
menu, scroll to the desired option and press both the
“m” and “t” buttons at the same time. The diagnostic
menu exits after a short time-delay of inactivity.
Select
4-German
5-Italian
6-Portuguese
1-Gauge Test
2-Lamp Test
3-LCD Test
Select
A confirmation screen will appear
“Language changed” before exiting
Diagnostic menu.
+
indicating
back to
Select
4-Binary Inputs
5-Analog Inputs Test
Select
22
SECTION 3
COMPASS CONTROLLER USER MANUAL
GAUGE TEST
NOTE
This sub-menu and all content accessible
from it will always be in English, regardless of
the language chosen.
As previously noted, the system must be in Waiting
mode prior to entering the Diagnostics menu. An
attempt to enter the diagnostics while the machine is
running will cause the following message to be
displayed:
The Gauge Test verifies that both gauges are
functional. During the test, the gauge pointers will
cycle from 0 to full scale pausing at 0%, 50%, 100%,
then return to zero (or its true position). The LCD
display will show which gauge is being tested and
indicate the gauge’s corresponding position (as
depicted below for engine speed). Pressing the “m”
button at anytime during the test will cause the test to
end.
1-Gauge Test
2-Lamp Test
3-LCD Test
Select
Not permitted
while running
Engine Speed
0%
EXIT
Engine Speed
50%
EXIT
Engine Speed
100%
EXIT
23
COMPASS CONTROLLER USER MANUAL
SECTION 3
LAMP TEST
LCD TEST
Selecting the Lamp Test option will turn on all
warning and binary LED’s (except for Engine Crank
Relay). Each output will turn on, then off and the
LCD 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 the
COMPASS Diagnostic menu. The outputs tested
during the lamp test are:
Selecting the LCD Test option will test all the pixels in
the LCD display by flashing the Sullair logo in normal
and reverse characters. Pressing the “m” button will
end the test.
1. Manifold Solenoid Output
2. Hi / Low Pressure Relay Output
3. Run / Start Relay Output
4. Non-Engine Warning Lamp
5. Non-Engine Shutdown Lamp
6. Engine Warning Lamp
7. Engine Diagnostics Lamp
1-Gauge Test
2-Lamp Test
3-LCD Test
Select
R/S Relay
EXIT
ON
R/S Relay
EXIT
24
OFF
1-Gauge Test
2-Lamp Test
3-LCD Test
Select
SECTION 3
COMPASS CONTROLLER USER MANUAL
BINARY INPUTS
Selecting the Binary Inputs menu option will allow the
operator to check the status of each of the binary
inputs to the Compass Controller. The Binary Inputs
display, as shown, will indicate the module being
checked, the pin number of the connector for the
input, and real-time status of each binary input
defined in the system. The “High” and “Low”
designation refers to the voltage level at the
connector pin.
Press “t” to scroll through and view the status of the
various binary inputs. Press “m” to exit the module
and return to the COMPASS Diagnostic menu. The
15 Binary Input items available from this menu are
listed to the right. Note that the “S” designation is for
the slave warning bank input and the “M” designation
is for master gauge input.
S-1
S-2
S-3
S-4
Dp-Pry Wrn
Dp-Pry Shtdn
UNUSED 1
UNUSED 2
High
Low
High
Low
S-5
S-6
S-7
S-8
Hi/Low Press
Engine Wrn
T3 - RTT
Engine Diag
Low
High
Low
High
M-11
M-12
M-13
M-14
Ign ON
Engine Start
Remote Start
DP1-EIAF
High
Low
High
Low
M-15
M-16
E-Stop
DP2-CIAF
High
Low
Pin #
Input
Status of input
Module
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
25
COMPASS CONTROLLER USER MANUAL
SECTION 3
ANALOG INPUTS
Selecting the Analog Inputs screen allows the
operator to check the status of each of the analog
inputs coming to the Compass Controller system.
This LCD screen displays the master gauge pin
number and real-time status of each analog input
defined in the system.
Press “t” to scroll through and view the status of the
various analog inputs. Press “m” to exit the module
and return to the COMPASS Diagnostic menu. The
eight analog input items available from this menu are
listed below. Note that the “M” designation in the
module number indicates “master” gauge input.
M-1
M-2
M-3
M-4
Fuel
P1 Serv p
P2 Ctrl p
P3 Wet p
M-5
M-6
M-7
M-8
Vdc Ref
T1 CompT
FaultReset
T2 Aux T
55%
0 psi
0 psi
0 psi
5.00V
198 °F
Off
109 °F
Pin #
Input
Module
Value
4-Binary Inputs
5-Analog Inputs
Select
26
M-1
M-2
M-3
M-4
Fuel
100%
P1 Serv P. 0 psi
P2 Ctrl P. 0 psi
P3 Wet P. 0
psi
SECTION 3
COMPASS CONTROLLER USER MANUAL
PRESSURE CALIBRATION
AUXILIARY TEMPERATURE CALIBRATION
Over time the P1, P2, and P3 pressure transducer
values might drift resulting in an inaccurate reading
showing on the pressure gauge. Using the Pressure
Calibration function the operator can adjust the
actual zero pressure to 0.00 BAR when no pressure
is present in the compressor. The offset value will be
subtracted from the transducer value to obtain an
adjusted reading used for indication and calculation.
Occasionally, and when the auxiliary temperature
input is first configured, the input may require
calibration to adjust the input to the actual known
temperature.
This is accomplished using the
Auxiliary Temperature Calibration function.
The
auxiliary
temperature
calibration
offset
is
configurable in 0.5°C increments. A total offset of +/10°C is allowable. The offset will be applied to the
RTD input signal and used for indication and
calculation during compressor operation.
To calibrate a pressure transducer:
1. Select the transducer (P1, P2, or P3) to be
calibrated by pressing both the “m” and “t”
buttons at the same time.
2. The following screen sequence will be presented (example below). This example
shows a P1 pressure of .60 BAR on a
machine that is known to actually be at zero
pressure. The current pressure value is displayed in metric units only (1 kPa = 0.01
bar).
3. Calibrate the actual pressure reading back
down to 0.00 by increasing the value of the
correction / offset by pressing the “t” button
until the Actual Pressure reads 0.00. Once
this is done, simply press both the “m” and
“t” buttons together to store this value in the
system. The offset value will be subtracted
from the transducer value to obtain the
adjusted reading. The calibration offset is
configurable in 1 kPa increments. A total offset of 0-50 kPa (0-7.25 PSI) is allowable.
1-P1 (Service)
2-P2 (Control)
3-P3 (Wet)
Select
To calibrate the Auxiliary Temperature input:
1. Select the Aux Temp input by simultaneously
pressing both the “m” and “t” buttons when
the input is highlighted.
2. The following screen will be presented
(example).
3. Adjust the offset value using the m and t buttons.
4. Simultaneously press m and t to exit screen.
+ Aux Temp Cal 42.5°C
+ P1 Calibration 0.60 BAR 0
Actual Pressure
being sent from
the transducer
Correction /
Offset
27
COMPASS CONTROLLER USER MANUAL
SECTION 3
BACKLIGHT ADJUST
ENGINE SHUTDOWN HISTORY
With this function the operator can adjust the
intensity of the gauge backlighting (both the master
gauge, and the 4-in-1 gauge) to within 60%-90% fullintensity.
This function allows up to 5 of the most recent
abnormal shutdown faults to be viewed. The Engine
Shutdown History is an instantaneous snapshot of
the Compass Controller parameters. For each fault,
the LCD will display the fault that occurred and the
engine 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 button
will cycle through the warnings active at time of
shutdown. An example of a “High Compressor
Temp” shutdown with 150 hours on the engine is
shown below.
To adjust the backlight intensity:
1. Press the “m” button to increase the light
intensity.
2. Press the “t” button to decrease the light
intensity.
3. Simultaneously press “m” and “t” to exit the
screen.
Comp High Temp
150.00 hrs
exit
BACK LIGHT ADJUST
+
-
3.3
ENGINE DIAGNOSTICS
The Engine Diagnostic screen is a real-time display
of active operation messages being transmitted by
the engine. Messages that become inactive are
automatically erased. No messages are stored in the
controller memory.
When this function is selected, up to 5 of the most
recent active engine Fault Mode Indicators (FMI) or
Suspect Parameter Number (SPN) codes being
received from the Caterpillar engine will be
displayed. Use the “m” and “t” buttons to scroll
through the various codes. Simultaneously press
“m” and “t” to exit.
No Active Codes
exit
OR
SPN 100
SPN 110
End of list
FMI 1
FMI 0
exit
28
CONFIGURATION MENU
The Compass configuration menu allows for enduser adjustment of three User Controlled Parameters
(UCP). The UCPs do not adversely affect the
controller’s
operational
functionality.
The
configuration
menu
allows
for
end-user
customization of the Compass Controller.
The
configuration menu will compile and store to the
controller memory any changes to the factory
programmed UCP profile.
To enter the Configuration Menu:
1. Hold down the “m” and “t” buttons while
cycling Compass Controller power to ON.
The configuration menu will appear.
2. Use the “m” and “t” buttons to navigate
within the menu and to make adjustments to
the selected parameters.
3. Exit the Configuration Menu by simultaneously pressing “m” and “t” buttons. After exiting, the master gauge will perform a system
reset and then enter Start-up mode.
SECTION 3
COMPASS CONTROLLER USER MANUAL
LINE 2 PARAMETER DISPLAY
SELF TEST
The Line 2 parameter display typically shows the
operational parameters of the Compass Controller.
Disabling this feature will only affect the parameter
display. Priority messages will still utilize the lower
portion of the LCD to display messages as
necessary. Select “yes” to enable the parameter
display or “no” to disable the display.
The Self-Test function of the Start-up mode can be
enabled or disabled using the configuration menu.
Select “yes” to enable or “no” to disable the Self-Test
feature.
Line 2 Parameter?
yes
Ok
Exit
no
Toggle
Self Test?
yes
Ok
no
Exit
Toggle
REMOTE START
The ability of the Compass Controller to recognize a
remote start actuation can be enabled or disabled
using the configuration menu.
NOTE
A hardware remote start signal must be
provided in addition to enabling the software feature. Select “yes” to activate the
remote start feature or “no” to disable the
feature.
Enable Remote Start?
yes
no
Ok
Exit
Toggle
29
COMPASS CONTROLLER USER MANUAL
3.4
SECTION 3
USER ADJUSTABLE CONTROL PARAMETERS (UCP)
The following settings are configurable using the
Compass Controller interface software. The
Engine Crank
parameters listed in bold font are those which can
cause abnormal shutdowns to occur.
Default Value
Range/Option
Crank On Duration (sec)
5
3-7
Crank Off Duration (sec)
30
4-30
3
1-5
Engine Cranked Speed (RPM)
Number of Cycles
250
200-500
Time Required At Cranked Speed (msec)
480
240-1000
Default Value
Range/Option
Throttle Control
Low pressure Max PWM Duty Cycle (%)
92.5
70-92.5
High Pressure Max PWM Duty Cycle (%)
92.5
70-92.5
LO Idle Engine Speed (RPM)
1400
1300-2000
HI Idle Engine Speed (RPM)
1800
1500-2100
100-120
100-120
Alt Throttle Control
Low Pressure Range – 300 PSI controller
Alt Throttle Control
125-145
150-170
High Pressure Range – 300 PSI controller
150-170
175-195
200-220
Alt Throttle Control
205-225
Low Pressure Range – 600 PSI controller
Alt Throttle Control
205-225
350-370
350-370
High Pressure Range – 600 PSI controller
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
30
SECTION 3
Fuel Level
COMPASS CONTROLLER USER MANUAL
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
Default Value
Range/Option
Max T1 at run-time or startup (°F)
250
200-400
Temperature Settings
Max Aux Temp at run-time/startup (°F)
250
200-400
Engine Temp. for warm-up complete (°F)
70
64-91
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
1
1
Allowable time for Max P1 or P3 (sec)
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 (in kPa… 1PSI = 6.9kPa)
0
0-50
P2 Calibration Offset (in kPa… 1PSI = 6.9kPa)
0
0-50
P3 Calibration Offset (in kPa… 1PSI = 6.9kPa)
0
0-50
P1 to shutdown from auto-start (PSI)
100
70-600
Required time for P1 > Above Value to shutdown
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
from auto-start (sec)
31
COMPASS CONTROLLER USER MANUAL
System ID
ID Tag
Miscellaneous Settings
Warmup Complete Speed (RPM)
SECTION 3
Default Value
Range/Option
N/A
20 character user
entry
Default Value
Range/Option
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)
Unit Of Measurement
5
English
3-10
Metric
English
PSI System
Fuel Tank
600
300-600
Large
Large
Small
None
Display 2nd Line Parameter
Enabled
Enabled
Disabled
Enable Gauge Self-Test
Enabled
Enabled
Disabled
Remote Start Permitted
Disabled
Enabled
Disabled
C9 Engine Used
Disabled
AfterFilters Equipped
Disabled
Enabled
Disabled
Enabled
Disabled
Intake Louvers Equipped
Disabled
Enabled
Disabled
Enable Inactivity Auto-Sleep?
Enabled
Enabled
Disabled
Inactivity Timeout (min)
32
10
5-20
COMPASS CONTROLLER USER MANUAL
Section 4
DESCRIPTION
4.1
INTRODUCTION
This section describes the operation of the Compass
Controller, the function of the controller components,
and the various types of displays that may appear on
the display screen. Descriptive lists of all messages
appearing in the display are also provided.
4.2
OPERATING MODES
SLEEP MODE
Sleep mode occurs when the Compass Controller is
not powered on. All electrical components are
inactive during Sleep mode to prevent battery
drainage (i.e. microprocessor, relays, indication
lamps, etc).
Sleep mode is dependent upon the position of the
Off/On/Start switch and current operating status of
the compressor. If the compressor is in any state
other than running, then placing the Off/On/Start
switch in the OFF position will enter Sleep mode. If
the compressor is running, placing the Off/On/Start
switch in the OFF position will initiate Waiting mode
followed by Sleep mode.
If the compressor has shutdown due to fault
condition, then the fault must be acknowledged by
pressing the reset switch and switching the Off/On/
Start switch to the OFF position.
If the compressor was enabled via Remote Start, a
compressor malfunction will allow entering Waiting
mode only. The malfunction must be acknowledged
by pressing the Reset switch and Off/On/Start switch
must be in the OFF position to enter into Sleep
mode.
START-UP MODE
Start-up mode initializes the system instrumentation
components for operation. Start-up mode is internal
to the Compass Controller and does not permit
engine/compressor activation.
Start-up mode is enabled by one of the following
two methods:
1. Press the Off/On/Start switch to ON.
2. Activating the Remote Start switch (if
enabled).
Placing the Off/On/Start switch to the ON position will
energize the Master Gauge and begin initializing the
system for Waiting mode.
Start-up mode may be exited/cancelled before
reaching Waiting mode. If Start-up is entered by
placing the Off/On/Start switch in the ON position,
placing the switch in the OFF position powers down
the entire system.
If a start-up initialization
parameter is out-of-tolerance, the Compass
Controller will enter a safe-shutdown state and
demand user interaction to completely power down
the unit.
NOTE
If 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 status while waiting for allowable conditions
to begin initializing Waiting mode.
It is during Start-up mode that system integrity is
verified. System integrity verification involves checks
of functional instrumentation, communication status,
and confirmation of proper initial parameter settings.
33
COMPASS CONTROLLER USER MANUAL
A successful completion of Start-up mode transitions
the Compass Controller to the Waiting mode.
When the controller is in Waiting mode the LCD
display will indicate that the system is ready to be
started, as shown below.
Ready . . .
(P3-P1)
The compressor can be started in one of the two
ways as described in Section 2. When the
compressor is waiting to be started remotely, an “ r. ”
in the upper right corner of the LCD will display in
reverse characters as shown below.
Ready . . .
198°F
r.
0 PSI
Ok
r.
Serv Pres…
Exit
Toggle
Waiting mode is a transitional state between
initialization of the Compass Controller, operation of
the compressor and compressor shutdown.
In
Waiting mode, the Compass Controller is ready to
enter an operational state. However, the compressor
is not active in Waiting mode. Waiting mode is
characterized by “Ready… ” appearing on the LCD
1st line parameter display. If Remote Start is
configured then “Ready… r. ” will be displayed.
Ready . . .
198°F
r.
Comp Temp
Comp Temp
NOTE
For remote start applications, the UCP in
the Compass Controller labeled “Enable
inactivity auto sleep?” must be set to
“Disabled”. In addition, an appropriate
trickle charge must be applied to the batteries in order for the compressor to
maintain Start-up readiness.
When the appropriate remote start conditions are
met, the system will automatically enter the Start-up
mode, and the compressor will start.
While the compressor is attempting to start in both
Manual and Remote start mode, the LCD will display
34
the following:
Engine Cranking
WAITING MODE
ok
SECTION 4
Ready . . .
Starting Aids Required
198°F
r.
Comp Temp
Waiting mode to Run mode is dependent on user
initiation of a compressor start enabler.
• Manual Start – initiated by the Start/On
switch placed in the Start position.
• Auto (Remote) Start – Remote Start
enabled.
In Waiting mode, the Compass Controller is
analyzing specific system parameters to determine if
entering Sleep mode is allowable.
When the
necessary conditions are met, the system enters
Sleep mode and all electrical components are de-
SECTION 4
COMPASS CONTROLLER USER MANUAL
energized. If the compressor was enabled via
Remote Start, the Start/On/Off switch is disabled and
only a compressor malfunction will allow entering
Waiting 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 (a
preset value) is exceeded, the system will display an
error message in the LCD display as shown below,
and the system will wait until the “Reset” switch is
pressed. Once the “Reset” switch is pressed, the
Compass Controller system will shut down. Restart
the compressor by switching the Start/On switch to
ON.
In Run mode, the compressor is ready to supply
service air. The engine RPM will automatically be
adjusted to maintain the desired air pressure. If the
2nd line scroll (UCP) has been turned on, the
operator can scroll thru the list of available
parameters 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) Differential Pressure
Compressor Tank Temperature
Ambient –or- Service Temperature
Ambient (if no after-coolers)
Engine Coolant Temp
Engine Over Crank
Battery Voltage
% Engine Load
Ok
Exit
Toggle
When Remote is enabled, if the engine does not
start, the “Fault / Reset” switch will need to be
depressed to reset and shut the machine down. The
system will then wait for the appropriate start-up
conditions and then activate the remote start input to
start the compressor.
RUN MODE
Fuel Pressure
Fuel Temperature
Engine Air Temperature
Oil Pressure
Boost Pressure
Desired Engine Speed
Once the compressor has completed the warm up
cycle, it will phase into Run mode. When in Run
mode, the LCD display will look similar to the display
shown below.
System Service
Pressure
Fuel Rate
110 PSI
0 PSI
Aux 1 Pressure
Aux 1 Temperature
r.
Remote Start
enabled icon
Serv Pres …
Scrollable
2 nd line
35
COMPASS CONTROLLER USER MANUAL
AUTO-START (REMOTE) OPERATION
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 Pressure, 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 Communicator software and communication adapter are
installed. When the compressor is operating in AutoStart Mode, it will not enter a normal Shutdown
mode until both conditions below are met.
a. The System Service Pressure (P1) is greater
than the UCP (User Configurable Parameter) specified level for the UCP specified
duration.
b. The “Remote Start” input has returned to its
normally open position.
In the event that an abnormal shutdown occurs, the
compressor could shut down without these
conditions 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 manually, 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 shown
below.
Stop Initiated
Cool Down Cycle
1400 rpm
36
eng speed
SECTION 4
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, the
engine will shut down.
4. The Compass Controller will continue to
monitor P1, P2, and P3 inputs until they fall
below the specified level (Note: This value is
pre-set), and the LCD will display a message
similar to the one shown below.
Monitoring Pressures
0 PSI
Serv Pres …
This is displayed as a safety measure that
indicates to the user that the system is under
pressure.
5. When the system pressures fall below the
pre-determined levels, the controller will
enter Sleep mode.
NOTE
If 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 reenter the Warm Up phase of the Start-up
mode.
However, during the final portion of shutdown, after
the Compass Controller has stopped the
compressor’s engine, the Compass Controller no
longer pays attention to the "Off / On / Start" switch
(or Remote Start). The operator must wait until this
phase completes to restart the compressor.
SECTION 4
COMPASS CONTROLLER USER MANUAL
GAUGES DISPLAY
POWER-UP OPTIONS MENU
Master Gauge –Service Air pressure
The menu is activated by pressing and holding down
both the “m” and “t” buttons while powering-on the
Compass Controller by pressing the “Off/On/Start”
button on the front panel.
When performed, the
following “yes/no” options will appear. The current
setting (either yes or no) is displayed in reverse
characters.
The air pressure gauge is driven by the air pressure
sender analog input. Open and shorts of the P1
Pressure sender analog input are considered out of
range and will force the pointer to fluctuate full scale.
4-in-1 Gauge
The 4-in-1 slave gauge displays Engine Coolant
Temperature,
Engine
Speed
Compressor
Temperature and Fuel Level. Compressor
Temperature and Fuel Level are driven by analog
inputs. Open and shorts of the fuel level sender
analog input are considered out of range and will
force 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 buttons
located directly below the LCD, the “m” (mode) and
“t” (task) buttons, allow user to navigate through the
LCD display.
As the Compass Controller system is executing in
any of its states, the LCD displays information to the
user that is pertinent to its operation and the
compressor state. In addition, through navigation
with the “m” and “t” buttons, menus may be solicited
to alter system behavior, modify the information
displayed, and make selection of the display
parameters.
PRIORITY MESSAGES
Priority messages are displayed in the LCD due to
various inputs or data messages. The priority
message will take over the second line (parameter
line) of the screen. Multiple messages may be
displayed by continually showing the message for 2
seconds before displaying the next message. Some
messages can be acknowledged by pressing the “m”
button while the message is being displayed. Once
acknowledged, the priority message will leave the
display. Certain acknowledged priority messages
may redisplay if the condition still exists after three
minutes, others will not reoccur until the next key-on
cycle.
Navigation of the menu is as follows:
• Press “m” to move circularly through the
options.
• Press “t” to toggle the yes / no setting of
the current option
• Press both “m” and “t” to exit the menu,
saving the current settings in the Compass
Controller’s non-volatile memory.
Momentary Start - When “Yes” is selected and
Remote Start is enabled, the remote stop will operate
as outlined in the Auto-Start (Remote) Operation in
this section. Alternatively, if Momentary Start is set to
“No”, the remote start input will act in the same
manner as the Off/On/Start switch on the panel in
that if the circuit is closed the machine will start and if
the circuit is opened then the machine will go into
shutdown mode and ultimately power down.
NOTE
This configuration is typical of a manned
remote control room/station where a
machine(s) are manually started and
stopped as needed.
Momentary Start?
yes
Ok
m
Exit
no
Toggle
t
750psi P2 Transducer - When “Yes” is selected the
controller is using an algorithm with suitable scaling
to send proper engine speed commands to the CAT
37
COMPASS CONTROLLER USER MANUAL
ECM. When “No” is selected a 250spi (control)
transducer is used and the engine speed control
algorithm is switched accordingly to maintain proper
engine speed..
750PSI P2?
yes
Ok
Toggle
m
t
Line 2 Parameter - enables the display of an
additional compressor / engine parameter during
Running state. The first line parameter during
Running state is always the system service pressure
(P1). The second line may display any of several
possible parameters.
Line 2 Parameter?
yes
Ok
Exit
Toggle
t
Self Test - determines whether the gauge self test is
performed at start-up upon entry to the System
Power-up, Check & Initialize state.
Self Test?
yes
Ok
m
no
Exit
Exit
m
Toggle
t
MAIN SCREEN WHILE NOT IN RUNNING STATE
Prior to transitioning into the Running state, the
Compass Controller displays messaging indicating
the operational state of the Compass Controller
system. For example, while in the System Pressure
Checking phase of the System Power-up, Check &
Initialize state, the Compass Controller will indicate
“Checking Pressures” on the LCD display. During the
Engine Cranking phase of the Starting state, the
Compass Controller displays “Cranking Engine”.
Gauge backlighting is a user configurable parameter
specified using a menu entry. Lower and upper levels
of the UCP are 60% and 90% intensity, respectively.
The specific parameter value is stored in the
Compass Controller (EEprom) memory.
GAUGES INTERNAL WARNING INDICATORS
High Coolant Temperature
The High Coolant Temperature indicator light will
turn on when the Compass Controller receives the
corresponding output signal from the Caterpillar
engine.
Low Fuel Level
Toggle
t
Remote Start - determines whether the activation of
the normally open low-side remote start input can
38
Enable Remote Start?
yes
no
BACKLIGHTING
no
m
attempt to start the engine once in the Waiting state.
Ok
no
Exit
SECTION 4
The Low Fuel Level indicator light will turn on when
the 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 light
will turn on when the T1 compressor temperature is
greater than or equal to the UCP specified for
Maximum T1 Compressor Temperature.
SECTION 4
COMPASS CONTROLLER USER MANUAL
WARNING BANK INDICATORS
6. P1 > Max. permitted P1 pressure at run-time
Engine Warning
7. P3 > Max. permitted P3 pressure at run-time
The engine warning indicator is on when the engine
warning input is pulled to ground. The state of this
indicator lamp directly follows the engine warning
output signal from the Caterpillar engine.
NORMAL SHUTDOWNS
Engine Diagnostic
The engine diagnostic indicator is on when the
engine diagnostic input is pulled to ground. The state
of this indicator lamp directly follows the engine
diagnostic output signal from the Caterpillar engine.
Compressor Warning
The compressor warning indicator lamp is turned on
when one or more of the following conditions exists:
1. Aux Temperature > Maximum Aux Temp. at
Run Time (UCP)
The Compass Controller enters the Shutting Down
state in preparation for a normal shutdown when
either of the following conditions is met:
1. When currently in the Starting or Running
state and the Compass Controller system
was started manually, the operator presses
the “Off/On/Start” switch to the OFF position.
2. When currently in the Running state and the
Compass Controller system was autostarted, the system service pressure P1
exceeds the UCP specified level for a UCP
specified duration AND the Remote Start
input has been returned to its normally open
(disabled) position.
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 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
NOTE
If 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.
8. T1 Compressor Temperature out of range
9. After-cooler Freeze-up Imminent or Louver
Closed conditions
4.3
COMPRESSOR SHUTDOWN
The compressor shutdown indicator lamp is turned
on when one or more of the following conditions
exists.
In addition, the system is immediately
shutdown when the condition occurs.
1. T1 Compressor Temperature > Max.T1
Temp. At Run Time (UCP)
2. RTT switch input is active (Includes the Interstage Temperature switch (IT) on XH and
XHH machines)
3. DP4, 6 (if equipped with After-coolers) active
for a UCP-specified time duration
4. Very Low Fuel Level
5. P2, P1, P3 pressure signals out of range
NOTE
If 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.
ABNORMAL SHUTDOWN
An abnormal shutdown is defined as any shutdown
that occurs for any reason other than that discussed
in the Normal Shutdown section. Any of the following
conditions will cause the compressor to be shut
down:
1. Engine sends a “Stop Engine” command
over the data bus
39
COMPASS CONTROLLER USER MANUAL
2. Fuel level reached the “Very Low” level
3. P1 Air pressure exceeds P1 maximum value
allowed
4. P2 Control pressure goes out of range
5. P3 Pressure exceeds P3 maximum value
allowed
6. T1 Compressor temperature exceeds T1
Maximum value allowed
7. RTT/IT/ input becomes activated
8. DP4 after-cooler is activated (if system uses
after-coolers)
9. DP6 after-cooler is activated (if system uses
after-coolers)
SECTION 4
The Compass Controller system will prevent the
compressor from restarting until the operator
acknowledges the fault by pressing the “Reset”
switch.
ABNORMAL SHUTDOWN EVENTS
Abnormal shutdown information is stored and
retained across power-up sessions of the system in
the Compass Controller memory. The abnormal
shutdown event data can be retrieved, displayed and
analyzed using the Compass Communicator
Software program. Refer to Section 5 for steps to
troubleshooting abnormal shutdown events.
The following information is stored for each of the
five most recent abnormal shutdown events that
have occurred within the Compass Controller.
10. Loss of the Compass Controller internal data
bus
• Shutdown Fault Type
11. Engine crank cycle is exceeded
• P1, P2, P3 pressure at time of Fault
12. Engine crank cycle engine speed is unknown
(not reported to the Compass Controller by
engine)
• T1, Aux Temp at time of Fault
13. Engine speed while in running phase is
unknown
(not reported to the Compass
Controller by engine)
• Pending Warnings at time of Fault
14. Emergency Stop is activated
• Start Switch and Remote Start Switch
inputs at time of Fault
• Engine Hours at time of Fault
• Fuel Level at time of Fault
• Vdc reference voltage at time of Fault
• State of DP1-6 and RTT switch inputs time
of Fault
• Hi/Lo pressure switch at time of Fault
NOTE
• Lin bus and J1939 bus status at time of
Fault
Those conditions listed in bold font above
are User-Configurable Parameters.
• Engine Speed at time of Fault
• Battery Voltage at time of Fault
• Engine Boost Pressure at time of Fault
Any of the preceding conditions will cause the
compressor to stop immediately. The LCD display
will indicate what the cause of the shutdown is,
similar to the example shown below:
• Engine Inlet Manifold Temperature at time
of Fault
• Engine Coolant Temperature at time of
Fault
• Engine Fuel Temperature at time of Fault
• Engine Oil Pressure at time of Fault
• Engine Fuel Pressure at time of Fault
Engine Over Crank
Ok
Exit
Toggle
• Engine Load at time of Fault
• Number of Active FMIs from Engine at time
of Fault
• First FMI/SPN data if active from Engine at
time of Fault
• Engine Lamp Status if any active FMIs from
Engine at time of Fault
40
SECTION 4
COMPASS CONTROLLER USER MANUAL
MAIN SCREEN WHILE IN RUNNING STATE
Once the Compass Controller transitions into the
Running state, it continuously displays the system
service pressure on the top half of the LCD display.
The bottom half of the screen will display associated
engine/compressor parameters. The parameter last
displayed when the controller was shutdown will be
the active display parameter at the next power-up
session.
An example display while in the Running state is
shown below. The presence of the “r.” in the upper
right hand corner of the display indicates that the
Compass Controller is remote start enabled.
r.
110 PSI
23 PSI
NOTE
The “r.” indication does not indicate that the
current Running state was entered via the
Remote Start input, but only that remote start is
enabled.
Once in the Running state (Assuming the 2nd Line
Parameter is turned on), momentarily pressing the
“m” button (<5 seconds) will scroll the second line
through all available parameters. The list of available
parameters is as follows:
Boost Pres
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 separator
element)
Comp temp
Compressor Tank temperature (T1 sensor)
Aux1 sensor temperature (displays as ambient if
Amb temp –or- Serv temp
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
41
BLANK PAGE
42
COMPASS CONTROLLER USER MANUAL
Section 5
TROUBLESHOOTING
5.1
TROUBLESHOOTING
INTRODUCTION
This Troubleshooting section is provided as a guide
to aid in diagnosing and resolving compressor
problems when they occur.
The information
contained in Table 5A, Troubleshooting Guide, has
been compiled from factory experience and contains
symptoms and usual causes for the described
problems. Each warning or fault message is listed
with conditions of when the problem may occur, a
probable cause, and a suggested solution to the
problem. DO NOT assume that these are the only
problems that may occur. This document cannot
address every possible adverse condition that may
occur nor does it provide every solution for the
potential troubles listed.
All available data
concerning the trouble should be systematically
analyzed before undertaking any repairs or
component replacement procedures.
Always perform a detailed visual inspection when a
machine problem occurs prior to attempting any
repairs. Doing so may avoid unnecessary repair
and/or additional damage to the compressor.
Always remember to:
a. Check for loose wiring, loss of ground, wire
termination, etc.
b. Check for damaged piping.
c. Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor.
Should your problem persist after making the
recommended check, consult your nearest Sullair
Distributor or the Sullair Corporation factory Service
Department.
NOTE
Section 5.3 portrays common systematic
problems that can occur during controller
operation. For a more thoroughly in-depth
coverage of the compressor operation troubles, consult the Troubleshooting Section in
the machine’s operator’s manual.
5.2
TROUBLESHOOTING GUIDE
INTRODUCTION
The following guide contains symptoms and usual
causes for the problems that may occur throughout
the compressor system. Each warning or fault
message that may appear is listed along with
conditions for the problem, a probable cause, and a
suggested solution to the problem. DO NOT assume
that these are the only troubles that may occur. The
following table denotes all warning/shutdown
conditions that the Compass Controller will sense.
Shutdown conditions will display the associated
message on the LCD, light the Compressor
Shutdown panel light, shut the system down, and
wait for operator to press the Fault/Reset button to
acknowledge the fault condition before a restart may
be attempted. Warning conditions display the
associated message on the LCD and light the
Compressor Warning panel light. Under a warning
condition the system will continue to operate
normally. In addition, the operator may dismiss the
warning message from the LCD screen by pressing
the “m” (mode) and “t” (trip) buttons on the master
gauge.
43
COMPASS CONTROLLER USER MANUAL
5.3
SECTION 5
COMPASS CONTROLLER TROUBLESHOOTING GUIDE
Error Message
Warning/Shutdown/ Description
Prevent Startup
Recommended Action
No Message
Prevent Startup
Turn OFF/ON/START
No power or initialization of controller
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.
Comp High Temp
Shutdown/Prevent
Startup
Transducer malfunction
Replace transducer.
T1 Compressor temperature sensor is
above shutdown setpoint
Verify thermistor
resistance between
803Ω @ -50˚C and
1573Ω @ 150˚C.
Coolers dirty
Fan slipping
Clean coolers.
Check/Adjust Fan belt
tension
Compressor Oil Thermostat malfunction
44
Replace thermostat.
SECTION 5
COMPASS CONTROLLER USER MANUAL
Error Message
Warning/Shutdown/ Description
Prevent Startup
Recommended Action
RTT High
Shutdown/Prevent
Startup
Verify compressor
RTT (Receiver Tank Temperature)
switch,normally closed, has opened
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)
Afterfilters dp module malfunction
Replace filters.
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
Open Controller and
Controller is not properly connected
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
Check connections at
receiving J1939 messages from the
engine ECM and
engine ECM.
Compass Controller.
Check the termination
resistor in the harness
ECM connector and
replace if necessary.
45
COMPASS CONTROLLER USER MANUAL
SECTION 5
Error Message
Warning/Shutdown/ Description
Prevent Startup
Recommended Action
E-Stop Pressed
Shutdown/Prevent
Startup
Disengage E-stop.
The Compass Controller will not power
up/initialize (NO MESSAGE AT
CONTOLLER!)
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.
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.
Add fuel soon
Compressor warning light is on. Fuel level
is below 20%
Fuel Sender Error
Warning
The fuel level sensor signal is out of range Check connections at
Check the inlet valve for
premature opening during
the warmup phase.
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
46
Warning
Transducer has no source voltage
Verify 5V dc to transducer.
Transducer has lost ground
Verify path to ground.
Output voltage to controller is lost
Verify .5-4.5 Vdc to
controller.
Transducer malfunction
Replace transducer.
SECTION 5
COMPASS CONTROLLER USER MANUAL
Error Message
Warning/Shutdown/ Description
Prevent Startup
P3 Signal Error
Warning
Recommended Action
Transducer has no source voltage
Transducer has lost ground
Output voltage to controller is lost
Transducer malfunction
Air-Oil Separator
Warning
The differential pressure (P3 - P1) is
Separator elements are
above the setpoint for the specified period. dirty. Replace.
Aux Temp High
Warning
T2 (Aftercooler discharge temp or ambient Clean coolers.
temp on non-aftercooled machines)
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
47
COMPASS CONTROLLER USER MANUAL
SECTION 5
Error Message
Warning/Shutdown/ Description
Prevent Startup
Recommended Action
DP Signal Error
Warning
Check connections
between the filter
Afterfilters differential pressure signal
module is encountering a malfunction
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
Engine comm error
Warning
The Compass Controller is not properly
receiving J1939 massages from the
engine. If this occurs while engine is
cranking, a shutdown results. Otherwise it
is only a warning.
Check connections
between the engine
ECM and harness and
between the Compass
Controller and harness.
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 nonaftercooled air.
Install Louvers on the
aftercooler (if equipped)
or the canopy intake.
48
SECTION 5
COMPASS CONTROLLER USER MANUAL
Error Message
Warning/Shutdown/ Description
Prevent Startup
Recommended Action
Wait to Start
Warning
Check Engine ECM for
Message from CAT engine ECM. J1939
Shutdown SPN1081 - Wait to Start active
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.
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.
49
COMPASS CONTROLLER USER MANUAL
Error Message
Warning/Shutdown/ Description
Prevent Startup
High Fuel Temp
Warning
CAT DM1 Message (Engine ECM)
SECTION 5
Recommended Action
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.
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
50
SECTION 5
5.4
CONTROL PARAMETERS
Control Parameters for the Compass Controller are
shown in Table 5.2. The Display Text column indicates the text appearing on the controller display
screen. Type denotes the parameter as a factory
setup, a calculated value, a user set parameter, or
sequence parameter. Enable refers to the machine
type that the parameter and values apply. Default
shows the factory default setting for the parameter.
Min/Max are the minimum and maximum values.
COMPASS CONTROLLER USER MANUAL
Comments provides a brief explanation of the parameter function.
The following settings are configurable using the
Compass Controller Communicator program. Note
that those listed in bold font below affect the threshold at which abnormal shutdowns may occur.
Table 5B Compass Controller Control Parameters Power-up Options Menu
Parameter Description
Minimum Value
Permitted
Maximum Value Default Value
Permitted
Crank On Duration (seconds)
3
7
5
Crank Off Duration (seconds)
4
30
10
Maximum # of Crank Cycles Permitted
1
5
3
Engine Cranked Speed (rpm)
200
500
250
Required Time At Cranked Speed (milliseconds)
240
1000
480
Fuel Level Low Warning (% full)
10
40
20
Cancel Fuel Level Low Warning (% full)
13
43
23
Fuel Level Low Shutdown (% full)
4
10
8
Cancel Fuel Level Low Shutdown (% full)
7
13
11
Fuel Tank Type – large, small, or switched
large
T1 Compressor Temperature Max (deg F)
200
300
250
Aux Temp Max at run-time (deg F)
200
265
250
Minimum Engine Temp at warm-up complete (deg F)
65
90
70
Max allowed P1 @ Run-Time (PSI)
145
600
200
Max allowed Air-Oil-Sep pressure @ Run-Time (PSI), P3 P1
10
20
15
Air-Oil-Sep Pressure alert time (secs)
10
60
15
Max allowed P1 @ Startup (PSI)
0
15
10
P1 pressure level for stopping from auto-start (PSI)
70
600
100
Time >= above pressure before stopping from auto-start
(secs)
300
1800
900
Engine Speed @ Warm-up Complete (rpm)
1375
1450
1375
5
60
30
Maximum Engine Warm-up Time at normal
temperatures (secs)
60
360
240
Temperature low starting aids (deg F)
-40
-16
-40
Minimum Engine Warm-up Time (secs)
51
COMPASS CONTROLLER USER MANUAL
Parameter Description
Maximum Engine Warm-up Time low starting aids
SECTION 5
Minimum Value
Permitted
Maximum Value Default Value
Permitted
31
75
60
Temperature mid starting aids (deg F)
-15
9
-15
Maximum Engine Warm-up Time mid starting aids
16
30
30
Temperature hi starting aids (deg F)
10
20
10
Maximum Engine Warm-up Time hi starting aids
5
15
15
Engine Type Is C9?
yes
no
no
Freeze-up Assert Temperature (deg F)
-40
50
40
Freeze-up Cancel Temperature (deg F)
-40
68
45
5
600
300
(minutes)
(minutes)
(minutes)
Compressor Cool-down Time (secs)
300 PSI/600 PSI system
300 PSI
Second-line parameter display enabled
Yes
Metric/English Units
English
Remote Start Enabled
No
Intake Louvers Equipped
No
After-filters Equipped
No
Gauge Self-test At Power-On
Yes
DP1-6 alert time (secs)
10
60
The Compass Controller Language at Display { English,
French, Spanish, German, Italian, Portuguese}
15
English
Switched Power Off Interval At Cool Down (secs)
3
10
5
P1,P2, P3 pressure threshold for cool down termination
(PSI)
5
15
10
Recirculation Solenoid Open P2 Pressure (PSI)
30
90
60
Recirculation Solenoid Close P2 Pressure (PSI)
25
85
55
Auto-Sleep Timeout (minutes)
5
20 or 0 to not use
10
Gauge Backlighting Level (%)
60
90
60
LCD Contrast Level (%)
0
85
0
Line 2 parameter displayed
1 of 20 parameters...
See “Run Mode” section of this document.
52
Eng RPM
SECTION 5
Parameter Description
COMPASS CONTROLLER USER MANUAL
Minimum Value
Permitted
Maximum Value Default Value
Permitted
P1 Calibration Offset (kPa)
0
50
0
P2 Calibration Offset (kPa)
0
50
0
P3 Calibration Offset (kPa)
0
50
0
LO Idle Engine Speed (rpm)
1300
2000
1400
HI Idle Engine Speed (rpm)
1500
4000
1800
Low pressure Max PWM Duty Cycle (%)
70
92.5
92.5
High Pressure Max PWM Duty Cycle (%)
70
92.5
92.5
Minimum P2 pressure for Max Speed (PSI)
0
10
5
53
BLANK PAGE
54
BLANK PAGE
55
WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD.
SULLAIR CORPORATION
SULLAIR EUROPE, S.A.
Sullair Road, No. 1
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Shenzen, Gunagdong PRV.
PRC POST CODE 518068
Telephone: 755-6851686
Fax: 755-6853473
www.sullair-asia.com
3700 East Michigan Boulevard
Michigan City, Indiana, 46360 U.S.A.
www.sullair.com
Telephone: 1-800-SULLAIR (U.S.A. only)
Fax: 219-874-1273
Zone Des Granges BP 82
42602 Montbrison, France
Telephone: 33-477968470
Fax: 33-477968499
www.sullaireurope.com
CUSTOMER CARE
for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835
Champion Compressors, LTD.
Princess Highway
Hallam, Victoria 3803
Australia
Telephone: 61-3-9796-4000
Fax: 61-3-9703-8053
www.championcompressors.com.au
Printed in the U.S.A.
Specifications subject to
change without prior notice.
E07EP