Professional Documents
Culture Documents
TABLE OF CONTENTS
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL
Section 1
SAFETY
page
1
1.1 GENERAL
1.4 DECALS
10
11
11
11
11
Section 2
SUPERVISOR
DESCRIPTION
Section 3
START-UP
PROCEDURES
TABLE OF CONTENTS
Section 4
TROUBLESHOOTING
page
13
13
16
17
18
LS-20TS Compressors)
Table 4-2 Parameters
19
19
19
19
19
Section 5
WIRING SCHEMATIC
21
DIAGRAMS
22
23
6.1 SAFETY
23
6.2 OVERVIEW
24
24
6.3 INSTALLATION
24
24
Section 6
VARIABLE SPEED
DRIVE
25
25
6.4.3 CALIBRATION
25
25
26
26
Section 1
SAFETY
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture all of their products so they can be
operated safely. However, the responsibility for safe
operation rests with those who use and maintain
these products. For safe machine operation it is
vitally important to review all safety precautions
noted in the Safety Section of your compressor's
Operator's Manual. The precautions listed there, as
well as those following, are offered as a guide
which, if conscientiously followed, will minimize the
possibility of accidents throughout the useful life of
this equipment.
The compressor should be operated only by those
who have been trained and delegated to do so, and
who have read and understood their compressor's
Operator's Manual. Failure to follow the instructions, procedures and safety precautions listed
here and in the Operator's Manual may result in
accidents and injuries.
NEVER start the compressor unless it is safe to do
so. DO NOT attempt to operate the compressor
with a known unsafe condition. Tag the compressor
and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its
prime mover so others who may not know of the
unsafe condition cannot attempt to operate it until
the condition is corrected.
Use and operate the air compressor only in full
compliance with all pertinent OSHA requirements or
Section 1
SAFETY
Figure 1-1 A Decals
A WARNING
250027-935
250017903
Section 1
SAFETY
Fi ure 1-1 B Decals
part
key
number
description
number
quantity
250017-903
250027-935
250003-144
041065
(I) OSHA and FDA guidelines are superseded by any Federal, State or Local regulations whenever
applicable.
Section 2
SUPERVISOR DESCRIPTION
Figure 2-1 Supervisor Control Panel
SUPERVISOR CONTROLLER
CDSUUAIR
P2
Section 2
ON
left).
key.
Section 2
SUPERVISOR DESCRIPTION
using the up arrow and down arrow keys, and push
the enter button. The value can be changed by
using the up arrow or down arrow keys. When editing is finished, pushing the enter key will fix the
value. If during a change the ESC key is pushed,
editing is terminated and the original value is reset.
The left and right arrow keys can be used to move
to other digits or letters in a value. For example to
change a value from 100 to 500, the left arrow key
can be used to position the cursor to the 1 digit in
the 100, and the up arrow key used to increment
the digit to 5.
Text fields can also be edited in the same manner.
Push the enter key to start the edit, use the left and
right arrow keys to move to the letter to be changed,
then use the up and down arrow to change the letter. Push the enter key to complete the edit.
Setpoint- (VSD packages only) The targeted pressure for the variable speed controls. This is normally adjusted near the bottom of the load/unload band
above. The speed will be adjusted to maintain this
pressure. Refer to Section 6 for additional details.
Drain Interval If the machine has an electric solenoid drain, this parameter and the following parameter (Drain Time) are used to turn on the drain. The
interval is the time between activations of the drain
and the Drain Time is the length of the time energized. This does not apply to the Sullair SCD zero
loss drain, which is not controlled or monitored by
the Supervisor.
Drain Time- Length of time that drain is energized.
Restart time -
Section 2
SUP RVISOR
number larger than zero, the machine restarts after
a delay defined by this time. For example, if the
Restart Time is set to 10 seconds, then the machine
will be enabled to start after 10 seconds.
Wye to delta transition timer - Also used to control the closed inlet start valve. Disable by setting to
zero (0), standard for full voltage start. Requires
approximately 4-6 seconds for wye-delta or solid
state starting.
Modulate- Default state is Yes for normal machine
control. Select No for Load/No Load operation.
ESC
PTI N
Section 2
SUPERVISOR DESCRIPTION
connected to the network (RS-485 channel). For
example in a three machine system, this parameter
should be set to 3. Up to sixteen machines may be
networked if all have Supervisor Controllers and
limited to eight if some have Supervisor ll's.
low Press - This is the lowest pressure allowed
before immediately starting a machine.
Recovery Time - This parameter keeps multiple
machines from loading, unloading and starting at
the same time. For example if a low pressure condition causes a machine to start, the next machine
will not start unless the Recovery Time has elapsed,
and the pressure has not recovered (i.e., has risen
over 'Low Press').
Rotate -This parameter is used only in very special
cases.
The only time this parameter should be used is in a
S -Starting
U- Unloaded
L Loaded
T -Trim machine
F Full load
Sequencing Hours
Capacity- Not used at this time.
Local System Pressure - Pressure read by
machines pressure transducer.
The top line is a legend that describes each column.
The right hand number on the top line is the system
pressure. The system pressure is the highest pressure reading of all the machines. Note that the local
pressure readings can be used to determine what
machines may need to be calibrated. The system
pressure transducers on all machines should read
within 1(one) psi of one another. The calibration
function can be used to set the readings to be the
same.
2.11 CALIBRATION- CORRECTION FACTORS FOR
PRESSURES
The first line of this display is the password. If the
password is 0 then the following parameters are not
protected and can be changed. If the password is
non-zero, then enter the displayed number plus 4 to
enable changing the parameters. For example if the
number displayed is 10 then changing the password to 14 will enable editing.
The four pressures P1, P2, P3
differential pressure dP1 can
number on the right hand side
to the transducer reading to
reading. The calibrated reading
dle of the line.
be calibrated. The
of the line is added
give the calibrated
is shown in the mid-
Section 2
SUP RVI
ues reflect the machine configuration.
Model - Model number of machine.
Cooling Air or Water.
Press Trans Pressure transducer range 200, 250,
500.
ON
Spiral Valve- (VSD packages only) Yes or No, indicating spiral valve control.
K8 Option - K8 output relay function selector Disabled, Oil pump prelube and postlube control,
Master Control for special external sequence control.
Oil
o-
MAIN SCREEN
Machine Status
Trouble State
xxxPsi
P2-Line
xxxF
T 1-Discharge
(0
':"'
.....
(/)
c::
'0
Cll
~-
I Status I
T1 -Discharge
T2 -Dry Side'
T3-0il'
T4 lnterstage
P1-Sump
P2-Line
P3-0il Filter
P4-0il'
dP1-Separator
dP2-0il Fill'
dP3-0il'
Load Hours
Run Hours
Load Cycles
Starts
E-Stop String
Aux E-Stop
D1-Motor Ovid
D2-Aux Ovid
D3-Air Filter
D4-Water Press
D5-Remole Start
D6-Remote Unload
D7-Master Control
DB-Brownout
D9-Not Defined
D10-Not Defined
K1-Run
K2-Wye-Delta
K3-Load
K4-Full Load
K5-Drain
K6-Common Faull
K7-Common Warn
K8-0ption
j VSD Status* I
Capacity
Capacity%'
Power
Power o/o'*
Recent Usage----
Hours'
Capactiy'
Capacity%'
Power
Power%'
KCF'
KWH'
Cost'
Savings
Lifetime Usages--
Hours
Capacity'
Capacity%'
Power'
Power o/o ..
KCF'
KWH*
Cost'
Savings
Drive Status-----
P2'
Motor RPM'
Frequency'
Drive Temp'
Motor Prot
....
Control
Parameters
Unload Psi
Load Psi
Setpoint'
Unload Time
Drain Interval
Drain Time
Restart Time
Wye-Delta Time
Modulate YiN
Language
Temp Units FiC
Press Units PsiibarikPa
Cost/KWH'
Saving VS'
Reset Load Est'
(")
0
Sequencing
Sequence By xxxxx
Sequence Hrs xxxxx
Com Number xx
Machines xx
Low Press xxx
Recover Time sec
Rotate
(hours)
Minute xx
Hour
xx
Day
XX
Month
xx
Year xxxx
I Fault Log I
Last 16 faults
recorded
T1 T2 P1 P2
T3T4P3P4
System
Display
Machine status
of Sequenced
machines
0
a ;a
:::J
I
I rc~b~~ti~nl
Password
P1
P2
dP
P3
P4
Cap
KW
Protect NIY
Fault on Warn YiN
Force Unload YiN
en CIJCD
c n
"tJ 0
m :J
N
~
......
en
:::::
....Cll
Factory
Setup
Password
Set Defaults
Model
Cooling
Press Trans
P1 Max
KT Fluid
Water Switch
Oil Switch
Aux OverlOad
Min Load Psi
Stop Timer
Lube Cycle
K8 Option
Load Hours
Run Hours
Load Cycles
Starts Capactiy
Sprial Valve'
VSD NIY
Com Module NIY
I Test I
Serial
communications
diagnostic
screen
VSD
Setup*
~
::J
c::
:;t
VSD Auto Set'
Nominal HP'
Nominal Volts'
VSD Max Amps'
Motor FLA'
Motor SF'
MotorV'
Motor Hz'
Motor RPM'
Cll
Cll
c
m
en
(")
;a
-"tJ
-0
Section 3
RES
3.1 MOTOR ROTATION DIRECTION CHECK
After the electrical wiring has been done, it is necessary to check the direction of the motor rotation.
With the control system in MANUAL mode, press
and
pads in succession to bump start
the
the compressor. When looking at the motor from the
end opposite the compressor unit, the shaft should
be turning clockwise on all gear driven models, and
counterclockwise on direct drive models. If the
motor shaft is not turning in the proper direction,
disconnect the power to the starter and exchange
any two of the three power input leads, then recheck rotation. A "Direction of Rotation" decal is
located on the coupling guard between the motor
and compressor to show proper motor/compressor
rotation.
Variable speed drive packages will have main motor
direction set at the time of construction, but the fan
direction is affected by installation. If fan-cooled,
ensure that fan rotation is correct. To change direction, disconnect the power and exchange any two of
the three fan motor leads at the fan motor starter.
3.2 INITIAL START-UP PROCEDURE
The following procedure should be used to make
the initial start-up of the compressor.
1 . Be sure that all preparations and checks
described in the Installation Section have been
made.
2. Read the preceding pages of this manual thoroughly.
or
il.
iJ
or AUTO MODE
button.
press the START
When the compressor is running, observe the
instrument panel and maintenance indicators.
3.4 SHUTDOWN PROCEDURE
To shut the compressor down, simply press the
STOP
ti button.
11
NOTES
12
Section 4
u
4.1 TROUBLESHOOTING INTRODUCTION
ALL
ALWAYS
ALL
ALWAYS
ALL
ALWAYS
ALL
ALWAYS
REMEDY
Replace filter.
Check inlet filter pressure switch.
ALL
ALWAYS
ALL
ALWAYS
E-Stop
ALL
ALWAYS
ALL
ALWAYS
E-Stop
ALL
ALWAYS
E-Stop String
ALL
ALWAYS
ALL
Watercooled
ALL
ALWAYS
Maintenance Due
ALL
ALWAYS
ALL
ALWAYS
ALL
ALWAYS
Release button.
Check wiring.
Gant1nueB...
13
Section 4
TROUBLESHOOTING
4 2 TROUBLESHOOTING GUIDE- SUPERVISOR CONTROLLER (CONTINUED)
MESSAGE
MODEL
ENABLE
PROBABLE CAUSE
Main Motor Overload
(CONTINUED)
REMEDY
ALL
ALWAYS
ALL
ALWAYS
ALL
ALWAYS
ALL
ALWAYS
ALL
ALWAYS
FLOODED
ALWAYS
ALL
ALWAYS
ALL
ALWAYS
ALL
ALWAYS
FLOODED
ALWAYS
FLOODED
ALWAYS
FLOODED
ALWAYS
P1 Sensor Fail, P2
Sensor Fail, P3 Sensor
Fail, P4 Sensor Fail, T1
Sensor Fail, T2 Sensor
Fail, T3 Sensor Fail, T4
Sensor Fail, T5 Sensor
Fail
ALL
ALWAYS
FLOODED
Check wiring.
ALWAYS
ALL
ALWAYS
FLOODED
ALWAYS
Contmued
14
Section 4
NG
4.2 TROUBLESHOOTING GUIDE- SUF ERVISOR CONTROLLER (CONTINUED
MESSAGE
ENABLE
PROBABLE CAUSE
MODEL
P1 Sump Pressure High
(CONTINUED)
FLOODED
ALL
ALWAYS
FLOODED
ALWAYS
FLOODED
ALWAYS
Sump Pressure Low
T1 lnterstage High, T2
Discharge High, T3 Oil
Temp High, T4 lntercool
High, T5 Discharge
High, T1 Discharge
High, T2 Dry Side High,
T3 Oil Temp High, T4
lnterstage High
Power Interruption
REMEDY
ALWAYS
FLOODED
ALWAYS
ALL
ALWAYS
FLOODED
ALWAYS
FLOODED
ALWAYS
ALL
Airceoled
ALL
Watercooled
ALL
Watercooled
ALL
Watercooled
ALL
ALWAYS
ALL
ALWAYS
No Contatct to Input D8
ALL
VSD
Release button.
ALL
VSD
ALL
VSD
See Section 6.
ALL
VSD
15
Section 4
TROUBLESHOOTING
Table 4-1A Analog Alarms (Flooded Screw Compressors Less Than 200 psi)
Sensor
Type
Limit
Start
Delay
Run
Delay Check(*)
p 1
p _1
p _1
p 2
High Inhibit
P_3
p 4
T 1
T_1
T_1
T_1
T_1
T_1
T_2
T_2
T_2
T_3
T_3
T 4
T_4
High Fault
5
5
500
500
500
500
-40
225
235
245
255
500
-40
225
235
-40
500
-40
500
0
5
0
0
0
0
0
5
5
0
0
0
0
5
5
0
0
0
0
0
0
0
0
0
0
0
Low Fault
High Fault
High Fault
High Fault
Low Fault
High Warn
High
High
High
High
Fault
Warn
Fault
Fault
Low Fault
High Warn
High Fault
Low Warn
High Warn
Low Fault
High Fault
16
30
30
0
0
0
0
30
30
0
0
0
0
Comment
At Start
When Running
Immediate Fault
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Section 4
Table 4-1 B Analog Alarms (LS-16T, LS-20T and LS-20TS Compressors)
Run
Start
Sensor
P_1
Low Fault
p 1
High Inhibit
p _1
High Fault
p 2
High Fault
P_3
High Fault
p 4
High Fault
T_1
T_1
T 1
T 1
T_1
T_1
T_2
T_2
T_2
T_2
T 2
T_2
T 3
T_3
T_4
T_4
T_4
T_4
T 4
T_4
Low Fault
High Warn
High Warn
High Fault
High Fault
High Fault
Low Fault
High Warn
High Warn
High Fault
High Fault
High Fault
Low Warn
High Warn
Low Fault
High Warn
High Warn
High Fault
High Fault
High Fault
5
5
500**
500**
500**
500**
-40
245
255
255
265
500
-40
245
255
255
265
500
-40
500
-40
245
255
255
265
500
5
0
0
0
0
0
0
5
0
5
0
0
0
5
0
5
0
0
0
0
0
5
0
5
0
0
0
0
0
0
0
0
0
30
0
30
0
0
0
30
0
30
0
0
0
0
0
30
When Running
Constantly
Constantly
Immediate Warning
30
Constantly
Constantly
Immediate Fault
Constantly
At Start
Immediate Fault
High sump psi at start
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Constantly
Immediate Warning
Constantly
Constantly
Immediate Fault
Constantly
Constantly
Constantly
Constantly
Immediate Warning
Constantly
Constantly
Immediate Fault
Constantly
Constantly
Constantly
Constantly
17
Section 4
TROUBLESHOOTING
Table 4-2 Parameters
Type
Enable
Default
Min
Max
Display Text
Comment
200,250,500, 750
250psi transducer
200psi transducer
500psi transducer
750psi transducer
Water pressure switch enable for water
cooled machines
Oil switch enable for flooded screw
machines
Minimum acceptable Loaded P1 value
If not 0, run unloaded for this time before
stopping
Prelube/Postlube timer
Disable, Lube Pump, Master Control
Hours machine has been loaded
Hours machine has been running
Number of load cycles
Number of starts
Used by monitor to determine system load
Setup
Setup
Setup
Setup
Setup
Setup
Always
X200
X250
X500
X750
Always
1
135
135
250
400
0
0
50
50
150
300
0
2
225
195
495
560
1
Press Trans
P1 Max
P1 Max
P1 Max
P1 Max
Water Switch
Setup
Flooded
Oil Switch
Setup
Setup
Always
Always
65
0
20
0
200
30
Setup
Setup
Setup
Setup
Setup
Setup
Setup
Cal
Cal
Cal
Cal
Cal
Cal
User
User
User
User
User
User
Always
Always
Always
Always
Always
Always
Always
Always
Always
Always
Always
Always
Always
X200
X250
X500
X750
Always
Always
0
0
0
0
0
0
0
0
0
0
0
0
0
110
110
150
150
10
15
0
0
0
0
0
0
0
-7
-7
-20
-7
-7
0
30
30
150
150
3
0
30
2
100000
100000
100000
100000
10000
7
7
10
7
7
1
220
185
360
560
70
59
Lube Cycle
K8 Option
Load Hours
Run Hours
Load Cycles
Starts
Capacity
P1
P2
dP1
P3
P4
Fault on Warn
Unload
Unload
Unload
Unload
Load Delta
Unload Time
User
User
User
User
Always
Always
Always
Always
0
0
0
0
0
0
0
0
30
10
59
15
Drain Interval
Drain Time
Restart Time
Wye Delta
User
User
User
Seq
Always
Always
Always
Com Mod
0
0
0
0
0
0
0
0
2
1
2
4
Language
Temp Units
Press Units
Sequence by
Seq
Seq
Seq
Seq
Seq
Always
Always
Always
Always
Always
0
1
1
70
10
0
1
1
20
2
100000
16
16
185
59
Seq Hrs
Com Number
Machines
Low Press
Recover Time
Seq
Always
250
Rotate
18
Condition: Machine was in a running or ready condition when power was lost. Table 4-3 below
describes how a machine behaves after a power up
under various conditions if the Restart timer is
greater than 0. If the Restart timer is 0 the machine
powers up in the Manual Stop state.
The Seq. Mode column pertains to the Sequencing
mode parameter. It can be Disabled, set to Remote
Start/Stop or to other sequencing modes (Seq). The
Local/Remote column refers to the Local/Remote
Button on the display panel. The Remote Start/Stop
column pertains to the Remote Start/Stop input. The
Run Mode column the machine run mode (Auto button on the display panel). Note that this table only
applies if the Restart Timer has a value other than
zero. If the Restart Timer is zero then the machine
always powers up in Manual Stop.
Local/
Remote
Remote
Start/Stop
Run
Mode
Disabled
Disabled
xxxx
xxxx
xxxx
xxxx
Cont
Auto
Manual Stop
Start after Restart delay & P2 < Load psi, &
P1< 5 psig
Remote
Remote
Local
Local
xxxx
xxxx
Cont
Auto
Manual Stop
Start after Restart delay & P2 < Load psi, &
P1 < 5 psig
Remote
Remote
Off
Cant
Remote Stop
Remote
Remote
Off
Auto
Remote Stop
Remote
Remote
Remote
Remote
On
On
Cont
Auto
Note:
'xxxx' means
Action (State)
'has no effect'.
Remote
Start/Stop
Run
Mode
Action (State)
Local
Local
xxxx
xxxx
Cont
Auto
Remote
Remote
Off
Off
Cant
Auto
Remote Stop
Remote Stop
Remote
Remote
On
On
Cont
Auto
Start if stopped
Normal Auto Operation
19
NOTES
20
5
5.1 WIRING DIAGRAM- SUPERVISOR COMMUNICATION MODULE
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6
6.1 SAFETY
The following special instructions apply to VSD
packages provided with electronic adjustable speed
motor drives. These are in addition to other warnings and cautions.
install the variable speed drive in a well-ventilated room that is not subject to temperature
extremes, high humidity, or condensation, and
avoid locations that are directly exposed to sunlight, or have high concentrations of dust, corrosive gas, explosive gas, inflammable gas,
grinding fluid mist, etc. Improper installation
may result in a fire hazard.
6.2 OVERVIEW
The Sullair VSD drive application is custom
designed for operation of air compressors. All necessary control functions are performed through the
Supervisor keypad. The drive functions as a module on the Supervisor communications bus.
Relevant drive status data and compressor performance are presented on the Supervisor display.
Its keypad provides simple setup and adjustment of
necessary drive parameters. Drive controls are
coordinated with internal compressor controls, and
with other Supervisor compressors in sequenced
systems. The Supervisor monitors drive performance to provide motor thermal and other protections
in an easy-to-use, robust design.
23
Section 6
hp
Size (A)
Fuse (A)
Wire Size
Power
Wire Size
Ground
40
50
60
75
100
125
150
200
61
72
87
105
140
170
205
261
80
100
110
125
175
200
250
350
2
2
1
1/0
3/0
4/0
350MCM
2 X 250MCM
8
6
6
2
2
2
1/0
1/0
6
KWH - Running total of energy used in kilowatthours.
Cost - Running total of cost of operation.
Savings - Estimated savings compared to other
control methods.
The next eight lines indicate long-term performance during the entire life of the compressor.
Capacity Average delivery in CFM.
Capacity % - Average percent of full package
capacity.
25
Section 6
Visually check all power and controls connections to the drive to ensure that no damage has occurred.
2. At installation ensure:
That the incoming power and ground wires
are properly connected to terminal blocks in
the electrical control box.
then the Stop ~ key on the Supervisor. Compressor rotation is factory set. If the fan rotates
incorrectly, disconnect power and simply interchange two of the fan motor leads at the fan
starter.
POSSIBLE CAUSE
SOLUTION
Drive fault codes are used for least-likely faults. The Supervisor will display these as "Drive Fault" with a code
number. If a keypad service tool is plugged into the drive, it will display the fault code and the fault name
shown in the first two columns.
CODE FAULT
Overcurrent
Overvoltage
POSSIBLE CAUSE
SOLUTION
Check loading.
Check motor.
Check cables.
26
6
CODE
3
FAULT
Ground Fault
(Earth Fault)
POSSIBLE CAUSE
Current sensing indicates that the sum of
motor phase currents is not zero.
insulation failure in motor or motor cables
Charging Switch
SOLUTION
Remove faults from ungrounded systems.
Check the motor and motor cables.
Reset the fault and restart.
Should the fault re-occur, contact Sullair service.
faulty operation
component failure
Emergency stop
Saturation trip
defective component
System fault
component failure
faulty operation
Reset the fault and restart. Should the fault reoccur, contact Sullair service.
Undervoltage
10
Input line
supervision
11
Output line
supervision
13
Undertemperature
14
15
Motor stalled
16
22
Motor
over-temperature
EEPROM
checksum fault
motor is overloaded
motor overheating has been detected by
the variable speed drive motor temperature
model
Parameter save fault
faulty operation
component failure
27
Section 6
FAULT
POSSIBLE CAUSE
SOLUTION
24
Counter fault
25
Microprocessor
watchdog fault
faulty operation
component failure
Reset the fault and restart. Should the fault reoccur, contact Sullair service.
26
Startup prevented
31
IGBT Inverter Bridge overtemperature protection has detected a high short-term overload
current
Check loading.
32
Fan cooling
36
Control Unit
37
Device change
(same type)
Reset.
38
Device added
(same type)
Reset.
39
Device removed
Reset.
drive removed
40
41
IGBT temperature
IGBT Inverter Bridge overtemperature protection has detected a high short-term overload
current
Check loading.
Device change
(different type)
Reset.
44
Device added
(different type)
Reset.
50
51
External fault
53
Communication
bus fault
The data connection between the communica- Check Supervisor bus cable.
tion bus master and the communication bus
Set Supervisor VSD to "Serial".
board has failed
If installation is correct contact Sullair service.
54
Slot fault
28
29