Sullair 900 1150 Controller

USER MANUAL
900/1600 IT4 CONTROLLER
PART NUMBER:
02250201-742 R00
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions
SULLAIR CORPORATION
and procedures in this manual or, The information in this manual is current
as of its publication date, and applies to
misuse of this equipement will compressor serial number:
VOID its warranty!
201200000
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 Sullairs 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 TRAINING DEPARTMENT
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
[email protected]
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
TABLE OF CONTENTS
SECTION 1SAFETY
5 1.1 GENERAL
5 1.2 TOWING
8 1.3 PRESSURE RELEASE
9 1.4 FIRE AND EXPLOSION
10 1.5 MOVING PARTS
11 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
11 1.7 TOXIC AND IRRITATING SUBSTANCES
12 1.8 ELECTRICAL SHOCK
12 1.9 LIFTING
13 1.10 ENTRAPMENT
13 1.11 JUMP STARTING
14 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT
15 1.13 CALIFORNIA PROPOSITION 65
16 1.14 SYMBOLS AND REFERENCES
SECTION 2STARTUP PROCEDURES

19 2.1 INTRODUCTION
19 2.2 COMPASS CONTROLLER PANEL LAYOUT
19 2.3 COMPASS CONTROLLER POWER UP
20 2.4 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION
21 2.5 NORMAL OPERATION
SECTION 3ADJUSTMENT PROCEDURE

23 3.1 INTRODUCTION
24 3.2 SETTINGS AND DIAGNOSTIC
SECTION 4DESCRIPTION
33 4.1 INTRODUCTION
33 4.2 OPERATING MODES
TABLE OF CONTENTS
SECTION 5TROUBLESHOOTING
41 5.1 TROUBLESHOOTING INTRODUCTION
41 5.2 TROUBLESHOOTING GUIDE INTRODUCTION
42 5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE
Section 1
SAFETY
DO NOT modify the compressor except with written
NOTE 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.
Inspect for torn, frayed, blistered or otherwise
deteriorated and degraded hoses. Replace as
OPERATOR IS REQUIRED TO READ required.
ENTIRE INSTRUCTION MANUAL.
1.1 GENERAL CAUTION

Sullair Corporation designs and manufactures all of
its products so they can be operated safely. Estimated hose life based on a 5-day 8-hour
However, the responsibility for safe operation rests work week is 3 years. These conditions
with those who use and maintain these products. The exist on an 8-hour shift only. Any other
following safety precautions are offered as a guide operation of the equipment other than 8-
which, if conscientiously followed, will minimize the hour shifts would shorten the hose life
possibility of accidents throughout the useful life of based on hours of operation.
this equipment. Read the CIMA Safety Manual
prior to compressor operation and towing, if
applicable in your area. 1.2 TOWING (I)
The air compressor should be operated only by those
PREPARING TO TOW
who have been trained and delegated to do so, and
who have read and understood this Operators
Manual. Failure to follow the instructions, procedures
and safety precautions in this manual can result in WARNING
accidents and injuries.
Do NOT tow the compressor should its
NEVER start the air compressor unless it is safe to weight exceed the rated limit of the tow
do so. DO NOT attempt to operate the air vehicle, as the vehicle may not brake safely
compressor with a known unsafe condition. Tag the with excess weight. See rated limit in tow
air compressor and render it inoperative by vehicle Operator's Manual, and review its
disconnecting the battery so others who may not instructions and other requirements for
know of the unsafe condition will not attempt to safe towing.
operate it until the condition is corrected.
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.
5
SECTION 1
A. Prior to hitching the air compressor to the tow G. If provided, make sure chain length, brake and
vehicle, inspect all attachment parts and equip- electrical interconnections provide sufficient
ment, checking for (i) signs of excessive wear or slack to prevent strain when cornering and
corrosion, (ii) parts that are cracked, bent, maneuvering, yet are supported so they cannot
dented or otherwise deformed or degraded, and drag or rub on road, terrain or towing vehicle sur-
(iii) loose nuts, bolts or other fasteners. Should faces which might cause wear that could render
any such condition be present, DO NOT TOW
them inoperative.
until the problem is corrected.
B. Back the tow vehicle to the compressor and posi-
tion it in preparation for coupling the compressor. WARNING
C. If the compressor is provided with a drawbar
latched in the vertical upright position, carefully This equipment may be tongue heavy. DO
unlatch drawbar and lower it to engage the cou- NOT attempt to raise or lower the drawbar
pling device. If not, raise drawbar with the jack to by hand if the weight is more than you can
engage coupling device or otherwise couple the safely handle.
compressor to the towing vehicle.
WARNING CAUTION
This equipment may be tongue heavy. DO
NOT attempt to raise or lower the drawbar Retract the front screw jack only after
by hand if the weight is more than you can attaching the compressor to the tow vehi-
safely handle. cle. Raise the screw jack to its full up posi-
tion and pull the pin connecting the jack to
Use the screw jack provided or a chain fall the drawbar. Rotate the screw jack to its
if you cannot lift or lower it without avoiding stowed position, parallel to the drawbar,
injury to yourself or others. Keep hands and reinsert the pin. Make sure the jack is
and fingers clear of the coupling device and secured in place prior to towing.
all other pinch points. Keep feet clear of
drawbar to avoid injury in case it should If a caster wheel is provided on the screw
slip from your hands. 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
D. Make sure the coupling device is fully engaged,
would for the standard screw jack. Pull the
closed and locked.
pin connecting the jack to the drawbar and
E. If chains are provided, pass each chain through raise the screw jack to its full up position.
its point of attachment on the towing vehicle; Rotate the screw jack to its stowed posi-
then hook each chain to itself by passing the tion, parallel to the drawbar, and reinsert
grab hook over (not through) a link. Cross chains the pin. Make sure the jack is secured in
under the front of drawbar before passing them place prior to towing.
through points of attachment on towing vehicle to
support the front of drawbar in case it should H. On two-wheeled models, fully retract front screw
accidentally become uncoupled. jack and any rear stabilizer legs. If a caster wheel
F. Make sure that the coupling device and adjacent is provided on the screw jack it is part of the
structures on the towing vehicle (and also, if uti- screw jack, and can not be removed. Follow the
lized, chain adjustment, brake and/or electrical same procedure for stowing away the wheeled
interconnections) DO NOT interfere with or jack as you would for the standard screw jack.
restrict motion of any part of the compressor, Pull the pin connecting the jack to the drawbar
including its coupling device, with respect to the and raise the screw jack to its full upright posi-
towing vehicle when maneuvering over any tion. Rotate the screw jack to its stowed position,
anticipated terrain. parallel to the drawbar, and reinsert the pin.
Make sure the jack is secured in place prior to
towing.
6
SECTION 1
I. Make sure tires are in good condition and are the according to posted speed limits, weather, traffic,
size (load range) specified and are inflated to the road or terrain conditions:
specified pressures. DO NOT change the tire
1. Two axle four-wheel or three axle six-wheel
size or type. Also, make sure wheel bolts, lugs or steerable models: 15 MPH (24 km/h).
nuts are tightened to the specified torques.
2. All other models: 55 MPH (88 km/h).
J. If provided, make sure all dual stop, tail direc-
tional and clearance lights are operating properly C. Remember that the portable air compressor may
and that their lenses are clean and functional. approach or exceed the weight of the towing
Also, make sure all reflectors and reflecting sur- vehicle. Maintain increased stopping distances
faces, including the slow moving vehicle emblem accordingly. DO NOT make sudden lane
on compressors provided with same, are clean changes, U-turns or other maneuvers. Such
and functional. maneuvers can cause the compressor to tip, roll
over, jackknife or slide and cause loss of control
K. Make sure all service air hoses (not air brake of the towing vehicle. Tipping, rolling over, etc.
hoses) are disconnected or are fully stowed and can occur suddenly without warning. U-turns
secured on hose reels, if provided. especially should be made slowly and carefully.
L. Make sure all access doors and tool box covers D. Avoid grades in excess of 15 (27%).
are closed and latched. If the compressor is
large enough to hold a man, make sure all per- E. Avoid potholes, rocks and other obstructions,
sonnel are out before closing and latching and soft shoulders or unstable terrain.
access doors. F. Maneuver in a manner that will not exceed the
M. Make sure parking brakes in towing vehicle are freedom of motion of the compressors drawbar
set, or that its wheels are chocked or blocked, or and/ or coupling device, in or on the towing vehi-
that it is otherwise restrained from moving. Then, cles coupling device and/or adjacent structure
release the compressor parking brakes, if pro- whether towing forward or backing up, regard-
vided. less of the terrain being traversed.
N. Make sure the compressor wheels are not G. DO NOT permit personnel to ride in or on the
chocked or blocked, and that all tie-downs, if any, compressor.
are free. H. Make sure the area behind, in front of, and under
O. Test running brake operation, including break- the compressor is clear of all personnel and
away switch operation if provided, before obstructions prior to towing in any direction.
attempting to tow the compressor at its rated I. DO NOT permit personnel to stand or ride on the
speed or less when conditions prevail. drawbar, or to stand or walk between the com-
P. DO NOT carry loose or inappropriate tools, pressor and the towing vehicle.
equipment or supplies on or in the compressor. PARKING OR LOCATING COMPRESSOR
Q. DO NOT load this equipment with accessories or A. Park or locate compressor on a level surface, if
tools such that it is unbalanced from side to side possible. If not, park or locate compressor across
or front to back. Such unbalance will reduce the grade so the compressor does not tend to roll
towability of this equipment and may increase downhill. DO NOT park or locate compressor on
the possibility of tipping, rolling over, jackknifing, grades exceeding 15 (27%).
etc. Loss of control of the towing vehicle may
result. B. Make sure compressor is parked or located on a
firm surface that can support its weight.
TOWING
C. Park or locate compressor so the wind, if any,
A. Observe all Federal, State, and Local laws while tends to carry the exhaust fumes and radiator
towing this equipment (including those specifying heat away from the compressor air inlet open-
minimum speed). ings, and also where the compressor will not be
B. DO NOT exceed the towing speeds listed below exposed to excessive dust from the work site.
under ideal conditions. Reduce your speed D. On steerable models, park compressor with front
wheels in straight-ahead position.
7
SECTION 1
E. Set parking brakes and disconnect breakaway wheeled jack as you would for the standard
switch cable and all other interconnecting electri- screw jack. Raise the screw jack to its full upright
cal and/or brake connections, if provided. position and pull the pin connecting the jack to
the drawbar. Rotate the screw jack to its stowed
F. Block or chock both sides of all wheels.
position, parallel to the drawbar and reinsert the
G. If provided, unhook chains and remove them pin. Make sure the jack is secured in place prior
from the points of chain attachment on the towing to towing.
vehicle, then hook chains to bail on drawbar or
J. Disconnect coupling device, keeping hands and
wrap chains around the drawbar and hook them
fingers clear of all pinch points. If the compressor
to themselves to keep chains off the ground
is provided with a drawbar, DO NOT attempt to
which might accelerate rusting.
lift the drawbar or if hinged, to raise it to the
H. Lower front screw jack and/or any front and rear upright position by hand, if the weight is more
stabilizer legs. Make sure the surface they con- than you can safely handle. Use a screwjack or
tact has sufficient load bearing capability to sup- chain fall if you cannot lift or raise the drawbar
port the weight of the compressor. without avoiding injury to yourself or others.
K. Move the towing vehicle well clear of the parked
compressor and erect hazard indicators, barri-
WARNING cades and/or flares (if at night) if compressor is
parked on or adjacent to public roads. Park so as
This equipment may be tongue heavy. DO not to interfere with traffic.
NOT attempt to raise or lower the drawbar
by hand if the weight is more than you can
safely handle. NOTE
While not towed in the usual sense of the
CAUTION word, many of these instructions are

directly applicable to skidmounted porta-
ble air compressors as well.
Retract the front screw jack only after
attaching the compressor to the tow vehi-
cle. Raise the screw jack to its full up posi- 1.3 PRESSURE RELEASE
tion and pull the pin connecting the jack to
the drawbar. Rotate the screw jack to its A. Open the pressure relief valve at least weekly to
stowed position, parallel to the drawbar, make sure it is not blocked, closed, obstructed or
and reinsert the pin. Make sure the jack is otherwise disabled.
secured in place prior to towing. B. Install an appropriate flow-limiting valve between
On two-wheeled models, fully retract front the compressor service air outlet and the shutoff
screw jack and any rear stabilizer legs. If a (throttle) valve, when an air hose exceeding 1/2"
caster wheel is provided on the screw jack (13 mm) inside diameter is to be connected to
it is part of the screw jack and can not be the shutoff (throttle) valve, to reduce pressure in
removed. Follow the same procedure for case of hose failure, per OSHA Standard 29 CFR
stowing away the wheeled jack as you 1926.302 (b) (7) or any applicable Federal, State
would for the standard screw jack. Pull the and Local codes, standards and regulations.
pin connecting the jack to the drawbar and C. When the hose is to be used to supply a mani-
raise the screw jack to its full up position. fold, install an additional appropriate flow-limiting
Rotate the screw jack to its stowed posi- valve between the manifold and each air hose
tion, parallel to the drawbar, and reinsert exceeding 1/2" (13 mm) inside diameter that is to
the pin. Make sure the jack is secured in be connected to the manifold to reduce pressure
place prior to towing. in case of hose failure.
I. If a caster wheel is provided on the screw jack, it D. Provide an appropriate flow-limiting valve for
is part of the screw jack and cannot be removed. each additional 75 feet (23 m) of hose in runs of
Follow the same procedure for stowing away the
8
SECTION 1
air hose exceeding 1/2" (13 mm) inside diameter P. The ethyl ether in the replaceable cylinders used
to reduce pressure in case of hose failure. in diesel ether starting aid systems (optional) is
under pressure. DO NOT puncture or incinerate
E. Flow-limiting valves are listed by pipe size and
those cylinders. DO NOT attempt to remove the
rated CFM. Select appropriate valve accordingly.
center valve core or side pressure relief valve
F. DO NOT use tools that are rated below the maxi- from these cylinders regardless of whether they
mum rating of this compressor. Select tools, air are full or empty.
hoses, pipes, valves, filters and other fittings
Q. If a manual blowdown valve is provided on the
accordingly. DO NOT exceed manufacturers
receiver, open the valve to ensure all internal
rated safe operating pressures for these items.
pressure has been vented prior to servicing any
G. Secure all hose connections by wire, chain or pressurized component of the compressor air/
other suitable retaining device to prevent tools or fluid system.
hose ends from being accidentally disconnected
and expelled. 1.4 FIRE AND EXPLOSION
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.
WARNING
I. Vent all internal pressure prior to opening any Do not attempt to operate the compressor
line, fitting, hose, valve, drain plug, connection or in any classification of hazardous environ-
other component, such as filters and line oilers, ment or potentially explosive atmosphere
and before attempting to refill optional air line unless the compressor has been specially
anti-icer systems with antifreeze compound. designed and manufactured for that duty.
J. Keep personnel out of line with and away from
the discharge opening of hoses, tools or other A. Refuel at a service station or from a fuel tank
points of compressed air discharge. designed for its intended purpose. If this is not
possible, ground the compressor to the dis-
K. DO NOT use air at pressures higher than 30 psig penser prior to refueling.
(2.1 bar) for cleaning purposes, and then only
with effective chip guarding and personal protec- B. Clean up spills of fuel, fluid, battery electrolyte or
tive equipment per OSHA Standard 29 CFR coolant immediately if such spills occur.
1910.242 (b) or any applicable Federal, State C. Shut off air compressor and allow it to cool. Then
and Local codes, standards and regulations. keep sparks, flames and other sources of ignition
L. DO NOT engage in horseplay with air hoses as away and DO NOT permit smoking in the vicinity
death or serious injury may result. when adding fuel, checking or adding electrolyte
to batteries, checking or adding fluid, checking
M. This equipment is supplied with an ASME diesel engine ether starting aid systems, replac-
designed pressure vessel protected by an ASME ing cylinders, or when refilling air line anti-icer
rated relief valve. Lift the handle once a week to systems antifreeze compound.
make sure the valve is functional. DO NOT lift
the handle while machine is under pressure. D. DO NOT permit liquids, including air line anti-icer
system antifreeze compound or fluid film, to
N. If the machine is installed in an enclosed area it accumulate on bottom covers or on, under or
is necessary to vent the relief valve to the outside around acoustical material, or on any external or
of the structure or to an area of non-exposure. internal surfaces of the air compressor. Wipe
O. DO NOT remove radiator filler cap until the cooldown using an aqueous industrial cleaner or
ant temperature is below its boiling point. Then steam clean as required. If necessary, remove
loosen cap slowly to its stop to relieve any acoustical material, clean all surfaces and then
excess pressure and make sure coolant is not replace acoustical material. Any acoustical mate-
boiling before removing cap completely. Remove rial with a protective covering that has been torn
radiator filler cap only when cool enough to touch or punctured should be replaced immediately to
with a bare hand. prevent accumulation of liquids or fluid film within
9
SECTION 1
the material. DO NOT use flammable solvents inders, or maintain or troubleshoot these sys-
for cleaning purposes. tems only in well-ventilated areas away from
heat, open flame or sparks. DO NOT install,
E. Disconnect the grounded (negative) battery con-
store or otherwise expose ether cylinders to tem-
nection prior to attempting any repairs or clean-
peratures above 160 F (71 C). Remove ether
ing inside the enclosure. Tag the battery
cylinder from the compressor when operating in
connections so others will not unexpectedly
ambient temperatures above 60 F (16 C).
reconnect it.
P. DO NOT attempt to use ether as a starting aid in
F. Keep electrical wiring, including the battery ter-
gasoline engines or diesel engines with glow
minals and other terminals, in good condition.
plugs as serious personnel injury or property
Replace any wiring that has cracked, cut
damage may result.
abraded or otherwise degraded insulation or ter-
minals that are worn, discolored or corroded. Q. DO NOT spray ether into compressor air filter or
Keep all terminals clean and tight. into an air filter that serves both the engine and
the compressor as serious damage to the com-
G. Turn off battery charger before making or break-
pressor or personal injury may result.
ing connections to the battery.
R. Antifreeze compound used in air line anti-icer
H. Keep grounded conductive objects such as tools
systems contains methanol which is flammable.
away from exposed live electrical parts such as
Use systems and refill with compound only in
terminals to avoid arcing which might serve as a
well-ventilated areas away from heat, open
source of ignition.
flames or sparks. DO NOT expose any part of
I. Replace damaged fuel tanks or lines immediately these systems or the antifreeze compound to
rather than attempt to weld or otherwise repair temperatures above 150 F (66 C). Vapors from
them. DO NOT store or attempt to operate the the antifreeze compound are heavier than air.
compressor with any known leaks in the fuel sys- DO NOT store compound or discharge treated
tem. Tag the compressor and render it inopera- air in confined or unventilated areas. DO NOT
tive until repair can be made. store containers of antifreeze compound in direct
sunlight.
J. Remove any acoustical material or other material
that may be damaged by heat or that may sup- S. Store flammable fluids and materials away from
port combustion prior to attempting weld repairs. your work area. Know where fire extinguishers
Remove diesel engine ether starting aid cylin- are and how to use them, and for what type of
ders and air line anti-icer system components fire they are intended. Check readiness of fire
containing antifreeze compound, prior to suppression systems and detectors if so
attempting weld repairs in any place other than equipped.
the fuel system. DO NOT weld on or near the
fuel system. 1.5 MOVING PARTS
K. Keep a suitable, fully charged class BC or ABC
A. Keep hands, arms and other parts of the body
fire extinguisher or extinguishers nearby when
and also clothing away from belts, pulleys and
servicing and operating the compressor.
other moving parts.
L. Keep oily rags, trash, leaves, litter or other com-
B. DO NOT attempt to operate the compressor with
bustibles out of and away from the compressor.
the fan or other guards removed.
M. Open all access doors and allow the enclosure to
C. Wear snug-fitting clothing and confine long hair
ventilate thoroughly prior to attempting to start
when working around this compressor, especially
the engine.
when exposed to hot or moving parts inside the
N. DO NOT operate compressor under low over- enclosure.
hanging leaves or permit such leaves to contact
D. Keep access doors closed except when making
hot exhaust system surfaces when operating the
repairs or adjustments, performing service or
compressor in forested areas.
when starting or stopping the compressor.
O. Ethyl ether used in diesel engine ether starting
aid systems is extremely flammable. Change cyl-
10
SECTION 1
E. Make sure all personnel are out of the way and 1.7 TOXIC AND IRRITATING
clear of the compressor prior to attempting to SUBSTANCES
start or operate it.
A. DO NOT use air from this compressor for respi-
F. Shut off engine before adding fuel, fluid, coolant
ration (breathing) except in full compliance with
lubricants, air line antifreeze compound or bat-
OSHA Standards 29 CFR 1920 and any other
tery electrolyte, or before replacing ether starting
aid cylinders. Federal, State or Local codes or regulations.
G. Disconnect the grounded negative battery con-

nection to prevent accidental engine operation DANGER
prior to attempting repairs or adjustments. Tag
the battery connection so others will not unex-
pectedly reconnect it.
H. When adjusting the controls, it may require oper-
ation of the equipment during adjustment. 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
INHALATION HAZARD!
adjustment, other than setting control regulator
and engine RPM, with the engine shut off. If nec- Death or serious injury can result from
essary, start the engine and check adjustment. If inhaling compressed air without using
adjustment is incorrect, shut engine off, readjust, proper safety equipment. See OSHA stan-
then restart the engine to recheck adjustment. dards and/or any applicable Federal, State,
and Local codes, standards and regulations
I. Keep hands, feet, floors, controls and walking
on safety equipment.
surfaces clean and free of fluid, water, antifreeze
or other liquids to minimize possibility of slips and
B. DO NOT use air line anti-icer systems in air lines
falls.
supplying respirators or other breathing air utili-
zation equipment and DO NOT discharge air
1.6 HOT SURFACES, SHARP from these systems into unventilated or other
EDGES AND SHARP confined areas.
CORNERS
C. Operate the compressor only in open or well-
A. Avoid bodily contact with hot fluid, hot coolant, ventilated areas.
hot surfaces and sharp edges and corners.
D. If the compressor is operated indoors, discharge
B. Keep all parts of the body away from all points of engine exhaust fumes outdoors.
air discharge and away from hot exhaust gases.
E. Locate the compressor so that exhaust fumes are
C. Wear personal protective equipment including not apt to be carried towards personnel, air intakes
gloves and head covering when working in, on or servicing personnel areas or towards the air intake
around the compressor. of any portable or stationary compressor.
D. Keep a first aid kit handy. Seek medical assis- F. Fuels, fluids, coolants, lubricants and battery
tance promptly in case of injury. DO NOT ignore electrolyte used in the compressor are typical of
small cuts and burns as they may lead to infec- the industry. Care should be taken to avoid acci-
tion. dental 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
11
SECTION 1
is spilled on skin or clothing, immediately flush D. Stay clear of the compressor during electrical
with large quantities of water. storms! It can attract lightning.
H. Ethyl ether used in diesel engine ether starting
aid systems is toxic, harmful or fatal if swallowed. 1.9 LIFTING
Avoid contact with the skin or eyes and avoid
A. If the compressor is provided with a lifting bail,
breathing the fumes. If swallowed, DO NOT
then lift by the bail provided. If no bail is provided,
induce vomiting and call a physician immediately.
then lift by sling. Compressors to be air lifted by
I. Wear goggles or a full face shield when testing helicopter must not be supported by the lifting
ether starting aid systems or when adding anti- bail, but by slings instead. In any event, lift only in
freeze compound to air line anti-icer systems. full compliance with OSHA Standards 29 CFR
Keep openings of valve or atomizer tube of ether 1910 subpart N or any other Local, State, Military
starting aid system pointed away from yourself and Federal regulations that may apply.
and other personnel.
B. Inspect lifting bail and points of attachment for
J. If ethyl ether or air line anti-icer system anti- cracked welds and for cracked, bent, corroded or
freeze compound enters the eyes or if fumes irri- otherwise degraded members and for loose bolts
tate the eyes, they should be washed with large or nuts prior to lifting.
quantities of clean water for 15 minutes. A physi-
C. Make sure entire lifting, rigging and supporting
cian, preferably any eye specialist, should be
structure has been inspected, is in good condi-
contacted immediately.
tion and has a rated capacity of at least the net
K. DO NOT store ether cylinders or air line anti-icer weight of the compressor plus an additional 10%
system antifreeze compound in operators cabs allowance for weight of water, snow, ice, mud,
or in other similar confined areas. stored tools, and equipment. If your are unsure
of the weight, then weigh compressor before lift-
L. The antifreeze compound used in air line anti-
ing.
icer systems contains methanol and is toxic,
harmful or fatal if swallowed. Avoid contact with D. Make sure lifting hook has a functional safety
the skin or eyes and avoid breathing the fumes. If latch or equivalent, and is fully engaged and
swallowed, induce vomiting by administering a latched on the bail.
tablespoon of salt in a glass of clean warm water.
E. Use guide ropes or equivalent to prevent twisting
Do this until vomit is clear, then administer two
or swinging of the compressor once it has been
tablespoons of baking soda in a glass of clean
lifted clear of the ground.
water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately. F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away
1.8 ELECTRICAL SHOCK from the compressor whenever it is suspended.
A. Keep the towing vehicle or equipment carrier, H. Lift compressor no higher than necessary.
compressor hoses, tools and all personnel at
I. Keep lift operator in constant attendance when-
least 10 feet (3 m) from power lines and buried
ever compressor is suspended.
cables.
J. Set compressor down only on a level surface
B. Keep all parts of the body and any hand-held
capable of supporting at least its net weight plus
tools or other conductive objects away from
an additional 10% allowance for the weight of
exposed live parts of electrical system. Maintain
water, snow, ice, mud, stored tools, and/or equip-
dry footing, stand on insulating surfaces and DO
ment.
NOT contact any other portion of the compressor
when making adjustments or repairs to exposed K. If the compressor is provided with parking
live parts of the electrical system. brakes, make sure they are set, and in any
event, block or chock both sides of all running
C. Attempt repairs only in clean, dry and well-lighted
wheels before disengaging the lifting hook.
and ventilated areas.
12
SECTION 1
1.10 ENTRAPMENT I. Bring the starting vehicle alongside the compres-

sor, but DO NOT permit metal to metal contact
A. Make sure all personnel are out of compressor between the compressor and the starting vehicle.
before closing and engaging enclosure doors.
J. Set the parking brakes of both the compressor (if
B. If the compressor is large enough to hold a man provided) and the starting vehicle or otherwise
and if it is necessary to enter it to perform service block both sides of all wheels.
adjustments, inform other personnel before
K. Place the starting vehicle in neutral or park, turn
doing so, or else secure the access door in the
off all non-essential accessory electrical loads
open position to avoid the possibility of others
and start its engine.
closing and possibly latching the door with per-
sonnel inside. L. Use only jumper cables that are clean, in good
condition and are heavy enough to handle the
1.11 JUMP STARTING starting current.
M. Avoid accidental contact between jumper cable
A. Observe all safety precautions mentioned else-
terminal clips or clamps and any metallic portion
where in this manual.
of either the compressor or the starting vehicle to
B. Batteries may contain hydrogen gas which is minimize the possibility of uncontrolled arcing
flammable and explosive. Keep flames, sparks which might serve as a source of ignition.
and other sources of ignition away.
N. Positive battery terminals are usually identified
C. Batteries contain acid which is corrosive and poi- by a plus (+) sign on the terminal and the letters
sonous. DO NOT allow battery acid to contact POS adjacent to the terminal. Negative battery
eyes, skin, fabrics or painted surfaces as serious terminals are usually identified by the letters
personal injury or property damage could result. NEG adjacent to the terminal or a negative (-)
Flush any contacted areas thoroughly with water sign.
immediately. Always wear an acid-resistant
O. Connect one end of a jumper cable to the posi-
apron and face shield when attempting to jump
tive (POS) (+) battery terminal in the starting
start the compressor.
vehicle. When jump starting 24V compressors
D. Remove all vent caps (if so equipped) from the and if the starting vehicle is provided with two (2)
battery or batteries in the compressor. DO NOT 12V batteries connected in series, connect the
permit dirt or foreign matter to enter the open jumper cable to the positive (POS) (+) terminal of
cells. the ungrounded battery.
E. Check fluid level. If low, bring fluid to proper level P. Connect the other end of the same jumper cable to
before attempting to jump start (not applicable to the positive (POS) (+) terminal of the starter motor
maintenance-free batteries). battery in the compressor when jump starting 24V
compressors, to the positive (POS) (+) terminal of
F. DO NOT attempt to jump start if fluid is frozen or
the ungrounded battery in the compressor.
slushy. Bring batteries up to at least 60 F (16
C) before attempting to jump start or it may Q. Connect one end of the other jumper cable to the
explode. grounded negative (NEG) (-) terminal of the bat-
tery in the starting vehicle. When jump starting
G. Cover open cells of all compressor batteries with
24V compressors and if the starting vehicle is
clean dampened cloths before attempting to
provided with two (2) 12V batteries connected in
jump start.
series, connect the jumper cable to the negative
H. Attempt to jump start only with a vehicle having a (NEG) (-) terminal of the grounded battery.
negative ground electrical system with the same
R. Check your connections. DO NOT attempt to
voltage, and is also equipped with a battery or
start a 24V compressor with one 12V battery in
batteries of comparable size or larger than sup-
the starting vehicle. DO NOT apply 24V to one
plied in the compressor. DO NOT attempt to
12V battery in the compressor.
jump start using motor generator sets, welders or
other sources of DC power as serious damage S. Connect the other end of this same jumper cable
may result. to a clean portion of the compressor engine
13
SECTION 1
block away from fuel lines, the crank case 4. Turn off the equipment using normal
breather opening and the battery. shutdown procedure.
T. Start the compressor in accordance with normal 5. Disconnect the energy sources:
procedure. Avoid prolonged cranking. a. Air and hydraulic lines should be bled,
U. Allow the compressor to warm up. When the drained and cleaned out. There should be
compressor is warm and operating smoothly at no pressure in these lines or in the reser-
normal idle RPM, disconnect the jumper cable voir tanks. Lockout or tag lines or valves.
from the engine block in the compressor, then b. Any mechanism under tension or pres-
disconnect the other end of this same cable from sure, such as springs, should be
the grounded negative (NEG) (-) terminal of the released and locked out or tagged.
battery in the starting vehicle. Then disconnect
the other jumper cable from the positive (POS) c. Block any load or machine part prior to
(+) terminal of the battery in the compressor, or if working under it.
provided with two (2) 12V batteries connected in d. Electrical circuits should be checked with
series, from the ungrounded battery in the com- calibrated electrical testing equipment
pressor, and finally, disconnect the other end of and stored energy and electrical capaci-
this same jumper cable from the positive (POS) tors should be safely discharged.
(+) terminal of the battery in the starting vehicle
or from the positive (POS) (+) terminal of the 6. Lockout and/or Tagout each energy source
using the proper energy isolating devices
ungrounded battery in the starting vehicle, if it is and tags. Place lockout hasp and padlock or
provided with two (2) 12V batteries connected in tag at the point of power disconnect where
series. lockout is required by each person
performing work. Each person shall be
V. Remove and carefully dispose of the dampened provided with their own padlock and have
cloths, as they may now be contaminated with possession of the only key. If more than one
acid, then replace all vent caps. person is working on a machine each person
shall affix personal lock and tag using a
1.12 IMPLEMENTATION OF multi-lock device.
LOCKOUT/TAGOUT 7. Tagout devices shall be used only when
power sources are not capable of being
The energy control procedure defines actions locked out by use of padlocks and lockout
necessary to lockout a power source of any machine hasp devices. The name of the person
to be repaired, serviced or set-up, where unexpected affixing tag to power source must be on tag
motion, or an electrical or other energy source, would along with date tag was placed on power
source.
cause personal injury or equipment damage. The
power source on any machine shall be locked out by 8. Release stored energy and bring the
each employee doing the work except when motion equipment to a zero mechanical state.
is necessary during setup, adjustment or trouble- 9. Verify Isolation: Before work is started, test
shooting. equipment to ensure power is disconnected.
A. The established procedures for the application of B. General Security
energy control shall cover the following elements 1. The lock shall be removed by the
and actions and shall be initiated only by Autho- Authorized person who put the lock on the
rized Persons and done in the following energy-isolating device. No one other than
sequence: the person/persons placing padlocks and
lockout hasps on power shall remove
1. Review the equipment or machine to be padlock and lockout hasps and restore
locked and tagged out. power. However, when the authorized
2. Alert operator and supervisor of which person who applied the lock is unavailable to
machine is to be worked on, and that power remove it his/her Supervisor may remove
and utilities will be turned off. padlock/padlocks and lockout hasps and
restore power only if it is first:
3. Check to make certain no one is operating
the machine before turning off the power. a. verified that no person will be exposed to
danger.
14
SECTION 1
b. verified that the Authorized person who 1.13 CALIFORNIA

applied the device is not in the facility. PROPOSITION 65
c. noted that all reasonable efforts to con-
tact the Authorized person have been
made to inform him or her that the lock-
out or tagout device has been removed.
WARNING
d. ensured that the Authorized person is CALIFORNIA PROPOSITION 65 WARNING
notified of lock removal before returning Diesel engine exhaust and some of its con-
to work. stituents are known to the State of Califor-
2. Tagout SystemTags are warning devices nia to cause cancer, birth defects and other
affixed at points of power disconnect and are reproductive harm.
not to be removed by anyone other that the
person placing tag on power lockout. Tags Battery posts, terminals and related acces-
shall never be by-passed, ignored, or sories contain lead and other compounds
otherwise defeated known to the State of California to cause
cancer and birth defects and other repro-
ductive harm. Wash hands after handling.
15
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.
DIESEL PARTICULATE FILTER
REGENERATION INHIBIT
HIGH EXHAUST SYS. TEMP
WAIT TO START
REMOTE START
CABIN LIGHTS
/ iT4
/ iT4
/ iT4
Safety Symbols-1 T4
16
SECTION 1
Safety Symbols-2
17
SECTION 1
Safety Symbols-3
18
CONTROLLER USER MANUAL
Section 2
STARTUP PROCEDURES
2.1 INTRODUCTION Manual Start: Start the machine by toggling the
<ON> switch to the start position on the Controller
This compressor is equipped with a Sullair Controller panel. Once the switch has been set to the start
for controlling the compressor system operation, position and the Controller has successfully
adjusting the machine parameters and performing initialized (see Self Test, Communication Checks
maintenance operations. The Controller utilizes and Parameter/Safety Checks in this section for
digital technology that ensures accurate and safe further information), the Controller will check status,
operation of the compressor system. When fault and automatically continue to energize the starter
conditions occur, the Controller automatically shuts until either the engine starts or the maximum crank
down the machine to prevent injury to the operator or duration is reached.
damage to the equipment. Features of the Controller
Auto Start: The compressor can be started remotely
include:
if the remote start function has been enabled during
Multiple gauges for display of pressure, setup.
engine temp, compressor temp, engine
rpm, and fuel level SELF TEST
LCD screen displaying machine status and When the Controller is initially powered up, the
operating information system will initiate a Self Test sequence to verify its
Remote start capabilities operational integrity and safety status. During this
process, the following actions will be performed.
Automatic self diagnosis at startup
Multiple language support 1. Gauge pointers will move to the zero posi-
tion, then to half and full scale, then back to
An external diagnostics port which allows
zero, and finally to the actual value reading.
PC interface for configuration of the system
parameters. 2. The LCD display will turn on all its segments
Backlighting of gauges with green LED to for one second, off for one second, and then
allow clear view of gauges in low light display the Sullair logo followed by the soft-
areas. ware product number with revision level.
3. All warning lights will turn on for 2.5 seconds
2.2 COMPASS CONTROLLER and then turn off, then set to the actual indi-
PANEL LAYOUT cator state.
The Controller panel is shown in Figure 2-1 on page The self test feature may be bypassed by disabling
18. The Controller components and functions are the sequence as describe in Section 3 of this
described in detail in Section 4. manual.
COMMUNICATION CHECKS
2.3 COMPASS CONTROLLER
POWER UP After successful completion of the self test, the
Controller system will check the communication
The Controller is used to start the compressor either status of the system.
manually or remotely.
19
CONTROLLER USER MANUAL SECTION 2
2.4 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION
31 31
25 11
26 7 28
9 12
10 13
14
15
8 16
17
3 18
2 5
4
1
32
27
22 23 24 21 20 19
29-30
HIGH START
FORCE SELECT
CABIN MENU MENU

REGEN PRESSURE ON
LIGHTS TOGGLE SELECT
OFF
INHIBIT LOW EXIT
Figure 2-1: Instrument Panel Group
Lamp Indicators Switches/Gauges/Features

1. Compressor OK Lamp 19. Power On/Off Switch
2. Compressor Warning Lamp 20. Menu Select/Exit Switch
3. Compressor Shut Down Lamp 21. Menu Toggle Switch
4. Engine OK Lamp 22. Force/Inhibit Regeneration Switch
5. Check Engine Lamp 23. Cabin Light Switch
6. Engine Shutdown Lamp 24. High/Low Pressure Selector Switch (only on
dual pressure models)
7. Battery Disconnect Lamp
25. Service Air Pressure Gauge (P1)
8. Compressor Air Filter Warning Lamp
26. Compressor Temperature Gauge
9. High Compressor Temperature Lamp
27. Engine Temperature Gauge
10. Cabin Light Lamp
28. Fuel Level Gauge
11. Remote Start Lamp
29. Engine Controller Diagnostics Service Port
12. Diesel Particulate Filter (DPF) Lamp
30. Engine Controller Port Cover
13. High Exhaust System Temperature (HEST)
Lamp 31. Key Port
14. Regeneration Inhibit Lamp 32. Contrast Buttons
15. Low Fuel Lamp
16. High Coolant Temperature Lamp
17. Engine Air Filter Warning Lamp
18. Wait to Start Lamp
20
SECTION 2 CONTROLLER USER MANUAL
The 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
Figure 2-3: P2 signal error screen
After successful completion of the communication
bus checks, the Controller system will perform safety
checks on the compressor and the engine. The Controller will prevent compressor startup if
either of the following conditions exists:
In the event of a problem with either the compressor
or engine, a message will display in the LCD P1 pressure is greater than the maximum
indicating the nature of the trouble (example shown P1 pressure permitted at startup. The
below). The Controller will wait for user-interaction to maximum P1 pressure is an adjustable
either correct the fault or send the system to Sleep parameter which can be modified as
mode. See Figure 2-2. describe in Section 3 of this manual.
P1 and P2 pressures are out of range.
recommendations.
2.5 NORMAL OPERATION
Figure 2-2: Communications checks display
Table 2-1 lists the safety conditions that are checked

by the Controller during startup and the fault that will
be displayed on the LCD screen if a fault occurs.
recommendations.
SYSTEM PRESSURE CHECKS Figure 2-4: Operational Flow Diagram
Following the successful completion of the general
safety checks, the Controller will check the status of
the service pressure (P1), control pressure (P2), and Following the successful completion of all startup
wet sump (P3). If there is a problem with any of sequences, the system is ready for normal operation.
these inputs a message will be displayed on the LCD During normal operation the Controller will be in one
display indicating the nature of the problem. of the following five operating modes: Waiting,
Start-Up and Autostart (remote), Run, Sleep, and
See Figure 2-3. Shutdown. Each of these modes is described in
detail in Section 4.
21
Table 2-1: Safety Conditions
User Controlled
Parameter Fault Condition LCD Message
Parameter
Fuel Low fuel level Very Low Level Alert Low fuel level
(% full)
Fuel sender open circuit None Low fuel level
Battery Low battery voltage None Battery Voltage Error

(<18.0Vdc)
Compresor Discharge Signal short circuit None T1 Signal Error

Temperature (CDT)
Compressor Temp High Max T1 during run or at Comp High Temp
start-up
Receiver Tank Temper- Receiver Tank Temp High None RTT High
ature (RTT)
Discharge Air DP High Aftercooler filter DP AfterFilters Equipped Primary Shutdown
Air Pressure (P1) Transducer signal short or None P1 Signal Error

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

sure
Control Pressure (P2) Transducer signal short or None P2 Signal Error

open circuit
Air Pressure (P3) Transducer signal short or None P3 Signal Error

open circuit
22
Section 3
ADJUSTMENT PROCEDURE
3.1 INTRODUCTION
This section describes steps for using the Controller
to modify specific parameters that control the
machine operation. Additional parameters (UCP) can
be viewed and adjusted using the PC User Interface. Figure 3-2: Display key
See Figure 3-1.
CONTRAST
The two buttons at the bottom right of Controller's
cluster panel can be used during normal operation to
adjust LCD contrast up and down. The end user
adjusts contrast by press and hold operation of either
button until satisfactory contrast level is achieved.
Any changes made by the end user are subsequently
retained in the Controllers memory.
PARAMETER SECTION NAVIGATION
During normal operation the LCD displays real-time
values of up to four different system parameters at
once. The following table lists all available
parameters. To navigate the parameters you wish to
display, use Controllers selection and toggle
switches as follows:
A short press and release of the <MENU SELECT>
Figure 3-1: J1939 Data communication cable switch, in the select position, will select one of the
Part Number 02250173-104 parameter display lines. A different parameter dis-
play line can be selected by continued short press
MESSAGE DISPLAY CENTER and release of the <MENU TOGGLE> switch.
Once the desired parameter display line is
The message display is a graphical LCD that displays
selected, press the <MENU TOGGLE> switch, to
information to the compressor operator. The screen is
the <UP> or <DOWN> positions to scroll through
backlit to allow the display characters to be clearly
the different parameters available for viewing at
visible under any lighting conditions. In addition to
that line.
basic operational information, a variety of user-defined
options may also be displayed when specified. Up to The selected parameter display line will become
four different parameters may be displayed at one unselected after a period of no <UP>, <DOWN>,
time; viewable parameters are displayed in Table 4-1. <MENU SELECT> activity for 5 seconds.
Fault messages are displayed whenever a fault The parameters chosen for display will be retained
condition occurs. The LCD display also allows the across subsequent system power-ups and usage
operator to view instrumentation diagnostic data to aid until changed by the same procedure. Figure 3-3
in controlling the system operation and in below shows the screen layout.
troubleshooting problems. The screen is broken up
into two different information types' parameter display
and system display. See Figure 3-2.
23
3.2 SETTINGS AND achieved by using the <MENU TOGGLE> and

DIAGNOSTIC <MENU SELECT> switches in the following manner:
<UP>A toggle on the <MENU TOGGLE> switch.

MENU
Use to scroll upward thru the current menu list.
Once the initialization sequence is complete, the (Note that continuing to press and hold the switch
operator can enter the settings and diagnostic menu will continuously scroll upward thru the menu).
at any time by holding the <MENU SELECT> switch,
<DOWN>A toggle on the <MENU TOGGLE>
in the select position for 2 seconds. This will bring
up the screen below. switch. Use to scroll downward down thru the cur-
rent menu list. (Note that continuing to press and
hold the switch will continuously scroll downward
thru the menu).
<SELECT>A toggle on the <MENU SELECT>.
Use this to choose the selected item in the menu
list.
<EXIT>A toggle on the <MENU SELECT>
Figure 3-3: Settings Menu switch. Use to move back up one level in the menu
structure.
Navigation, to any selection, within this menu is
MENU STRUCTURE j. Pressure Cal.
1. Set Units k. Temp. Cal.
2. Large Font Display 5. Controller Diagnostic
3. Set Language a. Gauge Test
a. English b. Lamp Test
b. French c. LCD Test
c. Spanish d. Binary Inputs
d. German e. Analog Inputs
e. Italian 6. Backlight Adjust
f. Portuguese a. Backlight Color
4. Operational Configuration 1. Red
a. Enable Remote Start 2. Green

3. Blue
b. Rem. Start momentary
4. Yellow
c. Rem. Start P1 Val
5. Light Blue
d. Rem. Start P1 Time
6. Violet
e. Uses Canopy
7. White
f. Auto Sleep Cfg.
b. Background Level
g. After Coolers
7. Engine Diagnostic
h. After Filters
8. I/O Module Diagnostic
i. Fuel Tank Configuration
9. Eng Shutdown History
24
3.2.1 SET UNITS

The operator can change the units of measure for all
data represented on the LCD screen. All parameters
displayed in any subsequent <OPERATION> modes
will use the selected unit of measurement. The
selected unit of measurement will be retained in
nonvolatile memory for subsequent unit use. Below
is an example of changing this setting. Figure 3-6: Language menu screen
Figure 3-4: Unit set menu screen Figure 3-7: Language confirmed menu screen
3.2.2 LARGE DISPLAY INFO 3.2.4 OPERATIONAL CONFIGURATION

In <WAITING> and <OPERATION> modes, This menu, to which Controller permits entry only
parameter display can be configured to show either prior to system entering <OPERATION> mode,
two parameters, in large font, or four parameters, in allows end-user configuration of certain key
smaller font. The configuration for this large font operational User Controlled Parameters, UCP, items.
display is chosen using this menu entry. Navigation A context-sensitive sub-menu (ie, entries in the
of the screen is similar to <SET UNITS> navigation. submenu are dynamic and may or may not be
All parameters displayed in subsequent <WAITING>/ present depending on other operation configuration
operational modes will use the selected font display. settings, as discussed below) of entries is displayed
The selected font display will be retained in when this menu item is selected.
nonvolatile memory. See Figure 3-5.
ENABLE REMOTE START
This setting specifies whether pin 37 of the Main
Interface Connector is to be used as a system wake-
up. If enabled, the remote start enabled indicator light
on the cluster overlay is illuminated, several
additional items in the operational configuration sub-
menu become available, and the <AUTO SLEEP
Figure 3-5: Font size menu screen CFG.> item in the operational configuration menu
sub-menu become unavailable, since it is not
3.2.3 SET LANGUAGE applicable when remote start is enabled. Figure 3-8.
Selecting <SET LANGUAGE>, a sub-menu of all

available display languages is shown. Upon entry to
this sub-menu, the current language is displayed in
reverse video. See following diagrams for supported
languages. If a new language is selected, a
<LANGUAGE CHANGED> confirmation screen
(displayed in the language in use prior to making the
change) will appear before returning to the sub-menu Figure 3-8: Remote start menu screen
of available display languages, as shown in Figure 3-
6 and Figure 3-7.
25
REM. START MOMENTARY normal shutdown automatically. Using the <MENU

TOGGLE>, and <MENU SELECT> switches, this
This item is only present and applicable if <ENABLE value can be adjusted in increments of 1 minute,
REMOTE START> is set to yes. This setting allows from 5 minutes (minimum) to 33 minutes (maximum).
either a static or momentary (> 750 ms) LS switch to be See Figure 3-11.
used to drive remote start operation. See Figure 3-9.
Figure 3-11: Remote start pressure value screen

Figure 3-9: Remote start momentary menu screen
USES CANOPY
REM. START P1 VAL This item specifies whether or not a canopy
This item is only present and applicable if momentary enclosure is present for the compressor system. This
remote start is enabled. Along with the subsequent information is used to determine fan control
item, <REM. START P1 TIME>, this setting algorithm. See Figure 3-12.
determines the required condition for shutdown from
a prior momentary remote start. If P1 pressure of this
level is achieved for the time duration specified in
<REM. START P1 TIME> after a prior momentary
remote start, Controller automatically begins the
normal shutdown automatically. Using the <MENU
TOGGLE>, and <MENU SELECT> switches, this
value can be adjusted in increments of roughly 10 psi
Figure 3-12: Canopy menu screen
from 65 psi (min) to 645 psi (max). Internal units of
measurement are kPa, and some rounding may AUTO SLEEP CFG.
occur as user increments/decrements through to the
desired setting. ie, some increments/decrements This item is only present and applicable if <REMOTE
may be 11 psi instead of 10. Figure 3-10. START> is disabled. This setting specifies the
amount of idle time (ie, Controller detects no activity
from the keypad) that must elapse in <WAITNG
MODE> before Controller will automatically transition
to <SLEEP> mode in order to save battery power.
The setting can either be disabled completely ( set to
"---" ) or turned on from 1-20 minutes. Note that this
setting only applies in Controller configurations that
are not enabled for <REMOTE START>. See Figure
Figure 3-10: Remote pressure val screen
3-13.
REM. START P1 TIME
This item is only present and applicable if momentary
remote start is enabled. Along with the previous item,
Auto Sleep Cfg.
<REM. START P1 VAL>, this setting determines the 5 min
required condition for shutdown from a prior
momentary remote start. If P1 pressure of magnitude
specified in <REM. START P1 VAL> for the time
duration specified here, after a prior momentary Figure 3-13: Auto sleep configuration screen
remote start, Controller automatically begins the
26
AFTER COOLERS value is stored in memory, so it is retained through

subsequent system power-ups.
This item specifies whether or not the compressor is
installed with aftercoolers. See Figure 3-14. In Figure 3-17 displayed below, the service pressure
(P1) calibration screen is displayed. The same
screen is available for P2 (control pressure) and P3
(wet pressure). The current value (with calibration
offset applied) is shown in large font at the bottom of
the screen, displayed in either psi or bar depending
on UCP units of measurement setting. The
calibration value, which is always in units of kPa (1
kPa = 0.01 bar), regardless of UCP units of
Figure 3-14: Aftercooler menu screen measurement, is displayed in smaller font to the far
right of the screen.
AFTER FILTERS In Figure 3-18 immediately below, an example P1 is
This item is only present and applicable if <AFTER displayed, with the factory default 0 kpa calibration
COOLERS> is enabled. See Figure 3-15. offset in use. If the end-user knows that, in fact, the
relative pressure level at the P1 sensor is 0 psi, then
After Filters the 2 psi value being read at Controller needs to be

calibrated. As can be seen from the second diagram
below, when an offset of -13 kPa is applied and set,
no the P1 service pressure reading is adjusted to 0 psi.
yes
Figure 3-15: Afterfilter menu screen
FUEL TANK CFG.

This item specifies which fuel tank and/or fuel level
sensor is installed in the compressor system. See Figure 3-17: Uncalibrated service pressure
Fuel Sender information for information on the fuel
tanks and level sensors supported by Controller. See
Figure 3-16.
Figure 3-18: Calibrated service pressure
TEMP CALIBRATION
Figure 3-16: Fuel tank configuration screen Each of the temperature sensor transducer inputs
supported by Controller can be calibrated to counter
PRESSURE CALIBRATION sensor/circuit tolerance using the sub-menus
Each of the pressure transducer inputs supported by displayed when the user selects this menu entry.
Controller can be calibrated to counter sensor/circuit These screens are used to specify a calibration
tolerance using the sub-menus displayed when the offset, if needed. The screens support a range of -
user selects this menu entry. These screens are 10.0 to +10.0 F in units of 0.5 C (factory default is 0.0
used to specify a calibration offset, if needed. The C) for the temperature calibration offset. This offset is
screens support a range of -100 to +100 kpa (factory added to the reading that Controller sees from the
default is 0 kpa) for the pressure calibration offset. respective temperature transducer and is applied
This offset is added to the reading that Controller throughout subsequent operation. The offset value is
sees from the respective pressure transducer and is stored in memory, so it is retained through
applied throughout subsequent operation. The offset subsequent system power-ups.
27
In Figure 3-19 displayed below, the Compressor aborted by engaging the <START> switch to the
Discharge Temperature (CDT) calibration screen is exit position during its execution.
displayed. The same screen is available for the
Aftercooler Discharge Temperature (ADT) and GAUGE TEST
Hydraulic Temperature (HT) sensors. The current The gauge test verifies the gauge pointer needle
value (with calibration offset applied) is shown in functionality. The test proceeds sequentially from left
large font at the bottom of the screen, displayed in to right of the cluster panel, one gauge at a time. For
either F or C depending on UCP units of each gauge, the active gauge's pointer needle will be
measurement. The calibration value, which is always driven to three reference positions pausing at each
in units of 0.5 C, regardless of UCP units of position for 1 second. The reference position value,
measurement, is displayed in smaller font to the far represented as a percentage, is shown on the LCD.
right of the screen. Below is an example of the screen sequence for the
In Figure 3-20 immediately below, an example CDT fuel gauge.
temperature is displayed, with the factory default 0.0
C calibration offset in use. If the end-user knows that,
in fact, the correct CDT temperature is currently 88 F,
then the 77 F value being read at Controller needs to 1-Gauge Test
be calibrated. Calibration. As can be seen from the
2-Lamp Test
second diagram below, when an offset of 6.5C is
applied and set, the CDT reading is adjusted to 88 F. 3-LCD Test
Select
Figure 3-21: Test menu
Figure 3-19: Uncalibrated temperature example
Figure 3-20: Calibrated temperature example
3.2.5 CONTROLLER DIAGNOSTICS

This menu entry, to which permits entry only prior to
system entering operation, Wait Mode, contains
several component-level tests and are intended to
provide the end-user with a means for verifying
specific system component functionality (i.e.
troubleshooting). While performing functionality tests,
the device, in a testing scenario, will be controlled by
the diagnostic software momentarily. Once the Figure 3-22: Example gauge test sequence
applicable tests are complete, the device will return
to its normal functional status. Any active test may be
28
Figure 3-24: Panel lamp test
LAMP TEST LCD TEST

The lamp test verifies the functionality of each of the The LCD test verifies that all pixels in the Controller's
indicator lights on the cluster panel. The test turns all LCD are able to turn on and off. The Sullair logo is
lamps off, then toggles on each lamp one at a time, displayed in normal, reverse, and normal video in
for approximately. 1.5 seconds, moving in a that order. Each phase lasts approximately 2
clockwise direction on the panel, starting at the lower seconds. Below is an example of the image
left side. As each lamp is toggled on, its numeric sequence.
value (1-18) as well as its position ID per the
indicator lamp table, are displayed on the cluster's
LCD. Below is an example of the information
displayed.
Figure 3-23: Lamp test information screen
Figure 3-25: LCD test sequence
29
BINARY INPUTS 3.2.6 BACKLIGHT ADJUST

The Binary Inputs screen displays the pin number This menu entry contains two sub-menu entries that
and real-time status of each binary input defined in allow the user to set backlighting of the Controller's
the system. Pressing the <EXIT> on the <MENU keypad and cluster. See Figure 3-26.
SELECT> switch exits the screen and returns to the
Controller diagnostic menu.
ANALOG INPUTS
The Analog Inputs screen displays the pin number Figure 3-26: Backlight adjustment menu screen
and real-time status of each analog input defined in
the system. Pressing the <EXIT> on the <MENU BACKLIGHT COLOR
SELECT> switch exits the screen and returns to the
Controller diagnostic menu. This menu entry permits the cluster panel
background color to be specified. The value is stored
in memory for use in all subsequent Controller
operation. Available colors are: {Red, Green, Blue,
Yellow, Light Blue, Violet, and White}.
BACKGROUND LEVEL
This menu entry permits the cluster panel
background level color to be specified. The value is
selectable in increments of 2% from 0% (full OFF) to
100% (full ON). At levels of 10% or greater, the LCD
display backlighting intensity level is also adjusted to
this same level. At less than 10% panel backlighting,
the LCD backlighting is always 100% (full ON),
independent of user-selected panel backlighting
level. The value is stored in memory for use in all
subsequent Controller operation. See Figure 3-27.
Figure 3-27: Background level menu screen
30
3.2.7 ENGINE DIAGNOSTICS The information logged shutdown includes:
The Engine Diagnostic screen is a real-time display Run time eng-hours accumulated
of active operation messages being transmitted by bit mask of all active shutdown flags
the engine. Messages that become inactive are bit mask of all active warning flags
automatically erased. No messages are stored in the
First active engine FMI/SPN/ occurrence
controller memory.
count if active
When this function is selected, up to 5 of the most First active I/O module FMI/SPN/occur-
recent active engine Fault Mode Indicators (FMI) or rence count if active
Suspect Parameter Number (SPN) codes being
P1 pressure
received from the Caterpillar engine will be
displayed. See Figure 3-28. P2 pressure
P3 pressure
1.1.1 ENGINE ACTIVE DTCS: 2 CDT comp discharge temp
100, 17 ADT aftercooler discharge temp
110, 15 5V dc ref voltage
engine speed
battery voltage
Figure 3-28: Example diagnostic screen display
number of active engine DTCs , lamp sta-
3.2.8 I/O MODULE DIAG. tus
number of active I/O module DTCS, lamp
Active J1939 Diagnostic Trouble Codes (DTCs)
status
originating internally from the LCC component of the
Controller as DM1 messages are displayed in this operational state
screen in a real-time view. triggering shutdown fault ID
3.2.9 ENGINE SHUTDOWN HISTORY fuel level
coolant temp
When/ If any abnormal shutdown event occurs, the
Controller automatically logs operational parameters fuel temp
that were present at the time of the shutdown and oil pressure
stores them in memory for subsequent analysis if fuel pressure
necessary. The engine shutdown history contains the engine load
five most recent fault-induced compressor
shutdowns stored in memory. The history log is a This data is fully available for review through use of
first-in-first-out (FIFO) format, so that if a shutdown the Controller communicator PC application, which
event occurs when five or more previous shutdown also allows the end user to clear the five-entry history
events were already logged in the history, the oldest buffer.
entry is removed and overwritten with the current Locally, at the cluster LCD, selection of this menu
shutdown event and its data. item, <ENGINE SHUTDOWN HISTORY>, will
display a subset of the above information, including:
triggering shutdown fault ID
run time eng-hours accumulated
all active warnings at time of shutdown
31
A sample screenshot is displayed below: shutdown are displayed. Up to three warn-

ings per page are listed.
At entry to the <ENGINE SHUTDOWN HISTORY>
menu item, the most recent shutdown event, if any is
stored, is shown. To cursor to older shutdown
records, press the down arrow on the <MENU
TOGGLE> switch. To cursor forward again, press
the up arrow on the <MENU TOGGLE> switch. For a
Figure 3-29: Error message screen given shutdown record, pressing <MENU SELECT>
will cursor through to the next set of up to three
The shutdown fault/cause is listed at the active warnings if more than three were present at
top of the screen in large font. the time of the shutdown event. To exit <ENGINE
SHUTDOWN HISTORY>, press <EXIT> on the
The engine hours time stamp, if available,
<MENU SELECT> switch at any time.
at time of the shutdown is listed at the bot-
tom of the screen in large font If no shutdowns have been recorded at the time of
In smaller font, in the middle section of the entry to the <ENGINE SHUTDOWN HISTORY>
screen, all active warnings at time of the menu item, the message "No Shutdowns Stored" will
be displayed for a 1 2 seconds, followed by a return
to the previous menu list.
32
Section 4
DESCRIPTION
4.1 INTRODUCTION 1. Press the <ON> switch to on.
2. Activating the <REMOTE START> (if
This section describes the operation of the
enabled).
Controller, the function of the controller components,
and the various types of displays that may appear on Placing the <ON> switch to the on position will
the display screen. Descriptive lists of all messages energize the gauges and begin initializing the system
appearing in the display are also provided. for <WAITING> mode.
<START-UP> mode may be exited/cancelled before
4.2 OPERATING MODES reaching <WAITING> mode. If <START-UP> is
entered by placing the <ON> switch in the on
4.2.1 SLEEP MODE position, placing the switch in the OFF position
When the Controller is de-energized, all components powers down the entire system. If a <START-UP>
of the system are in <SLEEP> mode. Electrical initialization parameter is out-of-tolerance, the
components are not active in <SLEEP> mode to Controller will enter a safe-shutdown state and
prevent battery drainage. The Controller allows the demand user interaction to completely power down
system to enter <SLEEP> mode by deactivating its the unit.
24V -to- 12V power supply converter signal and
deactivating its switched power output signal that is NOTE
fed out to Sullair components (fuel sensor and power
to engine ECU). If the <START-UP> mode is entered via
The Controller has two hardware wake-up inputs. <REMOTE START>, then only a <START-
UP> initialization parameter "out-of-tolerance"
1. The <ON> switch failure and "Remote Start binary input not low"
2. The <REMOTE START> switch (if enabled). will exit <START-UP> mode and prevent
entering <WAITING> mode. Otherwise, the
Placing the <ON> switch in the on position will Controller will maintain <START-UP> mode
generate a hardware wake-up at the LCC high-side status while <WAITING> for allowable condi-
Ignition binary input. Placing the <REMOTE START> tions to begin initializing <WAITING> mode.
binary input low will generate a hardware wake-up if
held low for greater than 750ms. It is during <START-UP> mode that system integrity
4.2.2 START-UP MODE is verified. System integrity verification involves
checks of functional instrumentation, communication
<START-UP> mode initializes the system status, and confirmation of proper initial parameter
instrumentation components for operation. <START- settings.
UP> mode is internal to the Controller and does not
permit engine/compressor activation. A successful completion of <START-UP> mode
transitions the Controller to the <WAITING> mode.
<START-UP> mode is enabled by one of the
following two methods:
33
4.2.3 WAITING MODE Auto (Remote) Start or <REMOTE START

MOMENTARY> - remote start enabled.
When the Controller is in <WAITING> mode the LCD
display will indicate that the system is ready to be In <WAITING> mode, the Controller is analyzing
started, as shown below. See Figure 4-1. 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-energized. If the compressor was enabled via
<REMOTE START>, the <ON> switch is disabled
and only a compressor malfunction will allow
Figure 4-1: Unit ready display entering <WAITING> mode and then <SLEEP>
The compressor can be started in one of the two mode.
ways as described in Section 2. When the The Controller can turn the compressor's cabin
compressor is <WAITING> to be started remotely, a
"Impending Remote Start" message at the top of the lighting on and off via the <CABIN LIGHT> switch. In
LCD will display. When the appropriate remote start <WAITING> mode, since the CAT engine is not
conditions are met, the system will automatically running, it is possible that cabin lighting could drain
enter the <START-UP> mode, and the compressor system battery. The Controller monitors the battery
will start. While the compressor is attempting to start voltage and cabin lighting to guard against this
in both manual and remote start mode, the LCD will
display the following screen in Figure 4-2. condition during the <WAITING> mode phase. In
such case, a cycled UCP lighting sequence, to warn
users who may be performing cabin maintenance of
the condition, is executed. The Controller cluster
screen also indicates this condition, as in the
following example screen. Note that after the UCP
number of warning cycles, cabin lighting is
automatically disabled regardless of keypad switch
position. See Figure 4-4.
Figure 4-2: Engine cranking display
<WAITING> mode is a transitional state between

initialization of the Controller, operation of the
compressor and compressor shutdown. In
<WAITING> mode, the 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
Figure 4-4: Cabin lights on display
top status message section. If remote start is
configured then "Ready..." will be displayed. See While in <WAITING> mode the Controller monitors
Figure 4-3. the ambient air temperature. When temperature is
below the UCP start-up aids set value while in
<WAITING> mode is as in Figure 4-5.
Figure 4-3: Unit ready display
<WAITING> mode to <RUN> mode is dependent on

user initiation of a compressor start enabler. Figure 4-5: Start aids required display
Manual Start - initiated by the <ON> switch
placed in the start position.
34
4.2.4 FAILURE TO START and then activate the remote start input to start the
compressor.
In manual mode, if the engine does not start, the
Controller will attempt another start cycle as long as 4.2.5 RUN MODE
the maximum number of crank attempts is not
Once the compressor has completed the warm up
exceeded. This is an automatic process until the start
cycle, it will phase into <RUN> mode. When in
attempts equal the set maximum. If the maximum
<RUN> mode, the LCD display will look similar to the
number of crank cycle attempts (a preset value) is
display shown below.
exceeded, the system will display an error message
in the LCD display as shown below. During engine
crank cycle, the Controller transmits speed control to
the Electronic Control Module (ECM). If the settings
are not fulfilled, the Controller will abort crank cycling
and display user-interface instructions for shutdown
in alternating reverse video. To clear this message
toggle the <MENU SELECT> switch to the <EXIT> Figure 4-7: Run mode display
position. See Figure 4-6.
In <RUN> mode, the compressor is ready to supply
service air. The engine RPM will automatically be
adjusted to maintain the desired air pressure. The
operator can scroll thru the list of available
parameters, viewing up to four simultaneously, by
momentarily moving the <MENU SELECT> switch to
the select location. This will highlight one of the
Figure 4-6: Engine overcrank display parameters in reverse video. Press the <MENU
TOGGLE> switch in either direction will scroll one
When <REMOTE START> is enabled, if the engine parameter. The available parameters are listed
does not start, the <ON> switch will need to be below.
toggled to off to shut the machine down. The system
will then wait for the appropriate start-up conditions
Table 4-1: Viewable Parameters

Service Pressure Fuel Rate
Control Pressure Fuel Pressure (1 or 2)
Wet Pressure Fuel Temperature
Fuel Level Engine Inlet Air Temperature
Engine Speed Oil Pressure
Engine Hours Boost Pressure
Engine Total Fuel Consumed Desired Engine Speed
Compressor Temperature Auxiliary Pressure
ADT Temp (if After-Cooler configured) Auxiliary Temperature
Hydraulic Temperature Charge Air Temperature
Coolant Temperature Inlet Air Temperature
Battery Voltage Soot Level
Engine Load
35
4.2.6 AUTO-START (REMOTE) OPERATION Both of these values are pre-set), and when the
remote start binary input is deactivated.
If <WAITING> mode is exited due to a remote (i.e.,
Automatic) start trigger, a momentary alert state, When the system enters the manual <SHUTDOWN>
during which the Controller alerts that an automatic mode, the compressor will complete the following
system startup is about to be attempted, takes place. tasks before shutting down:
The duration of this alert state is configurable through 1. De-energize the engine crank output (if ener-
a Controller UCP. During this temporary alert state, gized)
the LCD displays the text "Impending Remote Start"
in its bottom status area. The Controller's siren and 2. Display "Stop Initiated" shutdown LCD mes-
strobe light outputs are also activated. At the end of sage
the configured duration, the siren and strobe light 3. Enter cool-down cycle
outputs are de-activated and the Controller attempts
to crank-start the CAT engine to enter warm up. a. Energize start/run output to put start/run
solenoid in Start position
When using the auto-start feature, there are two
parameters that can be set by using the Controller. b. UCP Compressor Cool-down Time
The first is the P1 system service pressure value, c. TSC1 commanded to UCP Low Engine Idle
and the second is the time duration that the
compressor must stay at or above the P1 pressure. 4. Momentarily de-energize Switched Power
These values are settable when the Communicator output
software and communication adapter are installed. a. Display new LCD message
When the compressor is operating in <AUTO-
START> mode, it will not enter a normal b. UCP ECM Power-Off Interval at Cool-down
<SHUTDOWN> mode until both conditions below are 5. Monitor System Pressures
met.
a. Display new LCD message
a. The system service pressure (P1) is greater
than the UCP (User Configurable Parame- b. UCP P1,2,3 Pressure for Cool-down Com-
ter) specified level for the UCP specified pletion
duration. 6. Monitor Engine Speed
b. The "remote start" input has returned to its a. Display new LCD message
normally open position.
b. Engine Speed must decrease to at least 10
In the event that an abnormal shutdown occurs, the rpm
compressor could shut down without these
conditions being met. See Section 5: 7. Enter <WAITING> mode
TroubleShooting on page 41 for handling abnormal However, during the final portion of shutdown, after
shutdowns. the Controller has stopped the compressor's engine,
the Controller no longer pays attention to the <ON>
4.2.7 SHUTDOWN switch (or remote start). The operator must wait until
this phase completes to restart the compressor.
Placing the switch in the OFF position will trigger the
normal shutdown state. Normal shutdown can be When the Controller is initialized in auto-start, from
initiated in any mode of compressor operation. The the remote start binary wake-up input, the front panel
<SHUTDOWN> mode can be entered when either of <ON> switch is inoperable.
the following conditions occurs: If remote start is UCP-configured as a momentary
If the Controller system was started manually, the switch, shutdown is initiated if the service pressure
operator must press the <ON> switch to the off demand violates UCP criteria. UCP P1 to shutdown
position. from auto-start is the maximum service pressure
allowed. If the service pressure exceeds the set point
If the Controller system was auto-started (remote), for longer than UCP time allowed then shutdown is
the system will enter <SHUTDOWN> mode when initiated. See images in sequence below for details.
both the service pressure (P1) is greater than the
specified level for the user-specified duration (Note: If remote start is not UCP-configured as a
36
Figure 4-8: Normal shutdown sequence

momentary switch, shutdown is initiated when 4. 4. Monitor System Pressures
remote start input transitions from closed (active) to
open (inactive). In either case, the following
shutdown sequence then occurs: b. UCP P1,2,3 Pressure for Cool-down Com-
pletion
1. 1. Display shutdown LCD message
5. 8. Monitor J1939 Engine Speed
2. 2. Enter Cool-down cycle
a. Energize Start/Run relay to put Start/Run
solenoid in Start position b. J1939 Engine Speed must decrease to at
least 10 rpm
b. Energize Recirculation Manifold solenoid
6. 5. Exit <OPERATION> mode
c. UCP Compressor Cool-down Time
a. Remote Start binary is active --> enter
d. TSC1 commanded to UCP Low Engine Idle
<OPERATION> mode & attempt to restart
3. 3. Momentarily de-energize Switched Power compressor
relay
b. Remote Start binary is inactive --> enter
a. Display new LCD message <SLEEP> mode
b. UCP ECM Power-Off Interval at Cool-down
Figure 4-9: Auto shutdown sequence
37
4.2.8 GAUGES DISPLAY Battery Voltage

% Engine Load
The air pressure gauge is driven by the air pressure
sender analog input. Open and shorts of the P1 Fuel Rate
pressure sender analog input is considered out of Fuel Pressure
range and will force the pointer to fluctuate full scale. Fuel Temperature
The compressor temperature and fuel level are both
Engine Inlet Air Temperature
driven by analog resistive temperature senders
located in the fuel tank and unit respectively. The Oil Pressure
engine temperature indicator is driven by ECM Boost Pressure
messaging. All gauges interfaces directly with the Desired Engine Speed
Controller unit.
Aux 1 Pressure
If <WAITING> mode is exited due to a remote (i.e., Aux 1 Temperature
Automatic) start trigger, a momentary alert state,
during which the Controller alerts that an automatic 4.2.10 WAITING ABNORMAL SHUTDOWN
system startup is about to be attempted, takes place. Waiting abnormal shutdown is defined as any
The duration of this alert state is configurable through shutdown that occurs for any reason, in <WAITING>
a Controller UCP. During this temporary alert state, mode, other than that discussed in the Normal
the LCD displays the text "Impending Remote Start" Shutdown section. Any of the following conditions will
in its bottom status area. the Controller's siren and cause the compressor to be shut down after
strobe light outputs are also activated. At the end of <WAITING> mode is initiated:
the configured duration, the siren and strobe light
outputs are de-activated and the Controller attempts 1. Low Fuel Level
to crank-start the CAT engine to enter 2. Compressor High Temp
<OPERATION> mode.
3. High Compressor Pressure (P3)
4.2.9 PRIORITY MESSAGES 4. High Compressor Pressure (P1)
Priority messages are messages that are displayed 5. P1,P2,P3 Signal Error
on the LCD due to state of various inputs or receipt of
6. RTT High
various data messages by the Controller. Depending
upon the severity of the status, system operation 7. Primary Shutdown
may be stopped (shutdown) or permitted to continue 8. E-Stop Pressed
(warning). Warning messages are displayed along
9. Engine Communication Error
the bottom status section of the LCD; shutdown
messages are displayed on both the top and bottom 10. I/O Module Communication Error
status sections of the LCD. 11. Switch Module Communication Error
Remote Start - determines whether the activation of 12. Oil Pressure Low
the normally open low-side remote start input can
13. Coolant Temperature High
attempt to start the engine once in the ready state.
14. Engine Overspeed
Warning Indicator Lamps
15. Low Coolant Level
Engine Speed
16. High Fuel Temperature
Engine Hours (hourglass symbol)
P1 Service Pressure 4.2.11 NORMAL SHUTDOWN
P2 Control Pressure The Controller enters the shut down state in
P3 Wet Pressure preparation for a normal shutdown when either of the
following conditions is met:
(P3-P1) Air-Oil Separator Pressure
Compressor Tank Temperature 1. When currently in the <START-UP>, or any
<OPERATION> mode and the manual start
Ambient -or- Service Temperature
method is used, the operator presses the
Engine Coolant Temp <ON> switch to the off position.
38
2. When currently in the <RUN> mode and the 5. P1,P2,P3 Signal Error
Controller system was auto started, the sys-
6. Engine Comm Error
tem service pressure P1 exceeds the UCP
specified level for a UCP specified duration 7. I/O Module Comm Error
and the remote start input has been returned
8. Switch Module Comm Error
to its normally open (disabled) position.
9. Oil Pressure Low
NOTE 10. Coolant Temp High
11. Eng. Overspeed
If the operator switches the <ON> switch back
to the momentary start position before the Con- 12. Low Coolant Level
troller transitions to the OFF state, the Control-
13. High Fuel Temp
ler will re-enter the Warm-up phase of the
Starting state. 14. E-Stop Pressed
15. Engine Overcrank
NOTE 16. Warm-up Failed
If the Remote Start is once again enabled 17. Eng Speed Too Low
before the Controller transitions to the OFF 18. Low Discharge Pres
state during the shutdown sequence from an
auto-start operation, the Controller will re-enter Any of the preceding conditions will cause the
the Warm-up phase of the Starting state. compressor to stop immediately. The LCD display
will indicate what the cause of the shutdown is,
similar to Figure 4-10.
4.2.12 OPERATIONAL ABNORMAL SHUTDOWN
An abnormal shutdown is defined as any shutdown
that occurs for any reason, in any <OPERATION>
mode, other than that discussed in the Normal
Shutdown section. Any of the following conditions will
cause the compressor to be shut down after
<WARM-UP> mode is initiated:
1. Low Fuel Level Figure 4-10: Signal error screen
2. Comp High Temp
The Controller system will prevent the compressor
3. High Comp Pressure from restarting until the operator acknowledges the
4. High Comp Pressure fault by pressing the Reset switch.
39
4.2.13 ABNORMAL SHUTDOWN EVENTS

Abnormal shutdown information is stored and
retained across power-up sessions of the system in
the Controller memory. The abnormal shutdown
event data can be retrieved, displayed and analyzed
using the 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 Controller.
Shutdown Fault Type
Engine Hours at time of Fault
P1, P2, P3 pressure at time of Fault
T1, Aux Temp at time of Fault
Fuel Level at time of Fault
Vdc reference voltage at time of Fault
Pending Warnings at time of Fault
State of DP1-6 and RTT switch inputs time
of Fault
Start Switch and Remote Start Switch
inputs at time of Fault
Hi/Lo pressure switch at time of Fault
Lin bus and J1939 bus status at time of
Fault
Engine Speed at time of Fault
Battery Voltage at time of Fault
Engine Boost Pressure at time of Fault
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 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 5
TROUBLESHOOTING
5.1 TROUBLESHOOTING
INTRODUCTION
This Troubleshooting section is provided as a guide
NOTE
to aid in diagnosing and resolving compressor Section 5.3 portrays common systematic
problems when they occur. The information problems that can occur during Controller
contained in Table 5-1:Troubleshooting Guide, has operation. For a more thoroughly in-depth
been compiled from factory experience and contains coverage of the compressor operation trou-
symptoms and usual causes for the described bles, consult the Troubleshooting Section in
problems. Each warning or fault message is listed the machines operators manual.
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
5.2 TROUBLESHOOTING GUIDE
address every possible adverse condition that may
INTRODUCTION
occur nor does it provide every solution for the The following guide contains symptoms and usual
potential troubles listed. All available data concerning causes for the problems that may occur throughout
the trouble should be systematically analyzed before the compressor system. Each warning or fault
undertaking any repairs or component replacement message that may appear is listed along with
procedures. conditions for the problem, a probable cause, and a
Always perform a detailed visual inspection when a suggested solution to the problem. DO NOT assume
machine problem occurs prior to attempting any that these are the only troubles that may occur. The
repairs. Doing so may avoid unnecessary repair and/ following table denotes all warning/shutdown
or additional damage to the compressor. conditions that the Controller will sense. Shutdown
conditions will display the associated message on
Always remember to: the LCD, light the compressor shutdown panel lamp,
a. Check for loose wiring, loss of ground, wire shut the system down, and wait for operator to toggle
termination, etc. the <MENU TOGGLE> switch to EXIT to
acknowledge the fault condition before a restart may
b. Check for damaged piping. be attempted. Warning conditions display the
c. Check for parts damaged by heat or an elec- associated message on the LCD and light the
trical short circuit, usually apparent by discol- compressor warning lamp. Under a warning
oration or a burnt odor. condition the system will continue to operate
normally.
Should your problem persist after making the
recommended check, consult your nearest Sullair
Distributor or the Sullair Corporation factory service
department.
41
5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE
Error Message Warning/Shutdown/ Description Recommended Action

Prevent Startup
No Message Prevent Startup No power or initialization of controller Turn OFF/ON/START
switch to ON position.
Make sure E-stop is not
engaged (pull out).
Turn Battery Disconnect
Switch to ON position.
Check battery voltage.
Check connections between
Controller and harness and at
the starter and harness.
Make sure Controller internal
circuit breakers (4) are
closed.
Check Controller Prevent Startup No communication between Controller Verify bus resistance at 120
Comms and engine ECM .
Ensure proper connection
between engine ECM and
Compass Controller.
Low Fuel Level Shutdown/Prevent Fuel level low shutdown threshold Add fuel and restart.
Startup reached
P2 Signal Error Shutdown/Prevent Transducer has no source voltage Verify 5.25Vdc to transducer.
Startup Transducer has lost ground Verify path to ground.
Output voltage to controller is lost Verify .5-4.5Vdc to
controller.
Transducer malfunction Replace transducer.
Comp High Temp Shutdown/Prevent T1 Compressor temperature sensor is Verify thermistor
Startup above shutdown setpoint resistance between
803 @ -50C and
1573 @ 150C.
Coolers dirty Clean coolers.
Fan slipping Check/Adjust Fan belt
tension
Compressor oil thermostat malfunction Replace thermostat.
RTT High Shutdown/Prevent RTT (Receiver Tank Temperature) Verify compressor tempera-
Startup switch,normally closed, has opened ture via controller display (tog-
gle to proper parameter). If
compressor temp is less than
the setpoint on all others then
replace the RTT switch.
42

Prevent Startup
Primary Shutdown Shutdown/Prevent After filter restriction too high (filters Replace filters.
Startup dirty)
After filters dp module malfunction Check source voltage
and ground and correct
if necessary.
Visually inspect for
damage and replace if
necessary.
Compass Comm Shutdown/Prevent Internal cabling inside the Controller is Open Controller and ensure
Error Startup not properly connected that all gauge and warning
bank connectors are well
seated/engaged.
High Comp Pressure Shutdown/Prevent P1 (Dry) or P3 (Wet) pressure is above Pressure above 10 psi (recent
Startup setpoint shutdown). Wait for pressure
to fall below 10 psi.
Transducers out of calibration Transducers need to be
calibrated using the gauge
calibration subroutine (See
Pressure Calibration on
page 27).
Engine Overcrank Shutdown The maximum number of engine crank Check battery voltage &
cycles has been exceeded recharge if necessary.
Check starter relay for
short to ground.
Check source voltage to
starter relay.
Engine Comm Error Shutdown/Prevent The Controller is not properly Check connections at engine
Startup receiving J1939 messages from the ECM and Compass Control-
engine ECM. ler.
Check the termination resistor
in the harness ECM connec-
tor and replace if necessary.
E-Stop Pressed Shutdown/Prevent The Controller will not power Disengage E-stop.
Startup up/initialize (NO MESSAGE AT
CONTOLLER!)
The E-stop was used to shut machine Once conditions are deemed
down. safe, toggle the <ON> switch
OFF.
Eng Speed Too Low Shutdown Engine speed dropped below preset Check fuel level.
value for a preset amount of time. This Check the inlet valve for pre-
is to protect the vulcanized rubber drive mature opening during the
coupling between the engine and com- warmup phase.
pressor.
P1,P2,P3 Signal Error Shutdown Error loss of all transducer inputs dur- Check voltage source and
ing run phase ground for good connection.
Low Fuel Level Warning Fuel light is on. Compressor warning Add fuel soon
light is on. Fuel level is below 20%
43

Prevent Startup
Fuel Sender Error Warning The fuel level sensor signal is out of Check connections at
range sensor on tank. Verify
source voltage and
ground.
Wires possibly reversed.
Fuel sensor is defective.
Replace
Controller is configured incor-
rectly (configured for tank
when no tank is present).
Reprogram the Controller
using the Controller communi-
cation software, communica-
tion adapter, and PC.
P1 Signal Error 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.
Air-Oil Separator Warning The differential pressure (P3 - P1) is Separator elements are
above the setpoint for the specified dirty. Replace.
period.
Aux Temp High Warning T2 (Aftercooler discharge temp or Clean coolers.
ambient
temp on non-aftercooled machines) Check/Adjust Fan belt
tension.
Check T2 (RTD) for
short circuit to ground.
Engine Air Filter Warning DP1 switch, normally closed, has Engine air filters clogged.
opened for the specified amount of Replace filters
time Check circuit for
continuity.
Check the air filter switch for
continuity. Replace if open.
44

Prevent Startup
Comp Air Filter Warning DP2 switch, normally closed, has Engine air filters clogged.
opened for the specified amount of Replace filters.
time
Check circuit for
continuity
Check the air filter switch for
continuity. Replace if open.
Primary Warning Warning Aftercooler restriction increasing service filters soon
(becoming clogged)
P4/P5 Signal Error Warning Aftercooler differential pressure signal Check connections between
module is encountering a malfunction the filter module and the two
pressure transducers (P4 &
P5) at the aftercooler
check source voltage and
ground to transducers and to
dp module
replace transducers
replace dp signal module
Louvers Closed Warning Informs operator of louver position. None unless machine over-
heats. Otherwise check Ambi-
ent Temp Sensor reading on
LCD display. If the Ambient
Temp reading is higher than
the 70F and the louvers are
closed, check louver solenoid
for proper operation. Also
check louver air cylinders for
proper operation. If the Ambi-
ent Temp Sensor is reading
lower than atmospheric condi-
tions, then check the temp
sensor for proper operation
and replace is necessary.
AC Freeze Imminent Warning If the Controller is configured with an Bypass the aftercooler
aftercooler and no louvers installed and service air discharge circuit by
the temperature at the discharge of the locking out the aftercooler
aftercooler falls below the setpoint, this from the system and using
message is displayed. non- aftercooled air.
Install Louvers on the
aftercooler (if equipped)
or the canopy intake.
Wait to Start Warning Message from CAT engine ECM. Check Engine ECM for active
J1939 Shutdown SPN1081 - Wait to codes/faults and possible
Start active 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 nec-
essary. If condition persists,
contact your nearest CAT ser-
vicing dealer for resolution
45

Prevent Startup
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.
Dont restart machine until
condition is removed. If ECM
still displays message, con-
tact your nearest CAT servic-
ing dealer for resolution.
High Inlet Air Temp Warning CAT DM11 Message (Engine ECM) Check wind direction and
make sure engine/package
exhaust is not being recircu-
lated to air intakes. Relocate
compressor if necessary.
Low Coolant Level Warning CAT DM1 Message (Engine ECM) Check coolant level and add if
necessary. Check connection
between the coolant level
sensor and the harness.
Replace sensor if necessary.
High Fuel Temp Warning CAT DM1 Message (Engine ECM) Make sure cooling air intake is
facing prevailing winds. Make
sure all cooling air openings in
canopy are not obstructed.
Add fuel if tank is near empty.
High Fuel Pressure Warning CAT DM1 Message (Engine ECM) Fuel delivery system relief
valve malfunctioncontact
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 recircu-
lated to air intakes. Relocate
compressor if necessary.
Exhaust valve timing incor-
rectContact your local CAT
servicing dealer
46
5.3.1 CONTROL PARAMETERS The following settings are configurable using the
Controller communicator program. Note that
Control parameters for the Controller are shown in parameters listed in bold font below affect the
Table 5-1. The Parameter Description column threshold at which abnormal shutdowns may occur.
indicates the text appearing on the Controller display
screen. Default Value shows the factory default
setting for the parameter. Min/Max Value permitted
are the minimum and maximum possible for the
parameter.
Table 5-1: Controller Control Parameters Options Menu

Engine Crank Default Value Range/Option
Crank On Duration (sec) 10 3-30
Crank Off Duration (sec) 10 4-30
Number of Cycles 3 1-5
Engine Cranked Speed (RPM) 250 200-500
Time Required At Cranked Speed (msec) 480 240-1000
Throttle Control Default Value Range/Option

Low pressure Max PWM Duty Cycle (%) 92 70-92
High Pressure Max PWM Duty Cycle (%) 92 70-92
LO Idle Engine Speed (RPM) 1800 700-4000
HI Idle Engine Speed (RPM) 1800 700-4000
Alt Throttle Control 125-145 100-120
Low Pressure Range 300 PSI Controller 125-145
High Pressure Range 300 PSI Controller 175-195
200-220
Low Pressure Range 600 PSI Controller 350-370
High Pressure Range 600 PSI Controller 425-445
500-520
Low Speed Shutdown Settings Enabled Enabled
Disabled
Low Speed Shutdown RPM 800 800
900
1000
1100
Low Speed Shutdown Time (sec) 5 5
7
9
11
47
Fuel Level Default Value Range/Option

Cancel Low Level Alert (% full) 23 13-43
Low Level Alert (% full) 20 10-40
Cancel Very Low Level Alert (% full) 11 7-13
Very Low Level Alert (% full) 8 4-10
Fuel Tank/Level Sensor None None
185-724
185-725
Temperature Settings Default Value Range/Option

Max T1 at run-time or startup (F) 250 200-400
Max Aux Temp at run-time/startup (F) 250 200-400
Engine Temp. for warm-up complete (F) 70 64-150
Aftercoolers Equipped? No Yes/No
Aftercoolers Filters Equipped? No Yes/No
AfterFilter Freeze Assert Temp. (F) 39 (-40) -50
AfterFilter Freeze Cancel Temp. (F) 45 (-40) -68
ADT Temp Calibration Offset (C) 0 -10.0 - 10.0
CDT Temp Calibration Offset (C) 0 -10.0 - 10.0
HT Temp Calibration Offset (C) 0 -10.0 - 10.0
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
Fan 1 Control Settings Default Value Range/Option

Min PWM (%) 0 0-100%
Max PWM (%) 75 0-100%
CDT Trigger Temp (F) 180
CDT Temp Limit (F) 205
Coolant Trigger Temp (F) 200
Coolant Temp Limit (F) 210
CAC Trigger Temp (F) 105
CAC Temp Limit (F) 122
Cooldown/Idle PWM 48 0-100%
Delay Time (secs) 15
Fan 1 Min T3 Ambient Temp (F) 40
Fan 1 Aftercooler Approach Target Temp (F) 10
Primary Control PWM 0 (%) 50
48

Primary Control Temperature 0 (F) 20
Fan1 Increase Max Rate Crank and Warm-Up 100 1-100
Fan1 Decrease Max Rate Crank and Warm-Up 100 1-100
Fan1 Increase Max Rate Normal Operation 4 1-100
Fan1 Decrease Max Rate Normal Operation 4 1-100
Fan2 Increase Max Rate Crank and Warm-Up 100 1-100
Fan2 Decrease Max Rate Crank and Warm-Up 100 1-100
Fan2 Increase Max Rate Normal Operation 3 1-100
Fan2 Decrease Max Rate Normal Operation 3 1-100
Pressure Settings Default Value Range/Option

Max P1 at run-time (PSI) 200 145-600
Max P3 at run-time (PSI) 200 145-600
Allowable time for Max P1 or P3 (sec) 1 1
5
15
30
Max Air-Oil-Sep at run-time (PSI) 15 10-20
Air-Oil-Sep alert time (sec) 15 10-60
Max P1 at startup (PSI) 10 0-15
P1 Calibration Offset (kPA) 0 -50 to +50
Remote Start Enabled No No/Yes
Remote Start Momentary No No/Yes
P1 to shutdown from auto-start (PSI) 100 70-600
Required time for P1 > Above Value to shutdown 900 300-1800
from auto-start (sec)
Remote Start Imminent warning time duration (secs) 5 0-10
Enable Inactivity Auto-Sleep (applies only if Remote Start Enabled is Yes No/Yes
No)
49
Inactivity Timeout (minutes) 10 5-20

P1,2,3 Pressure for Cooldown Completion (PSI) 10 5-15
P2 Pressure for max RPM at run-time (PSI) 5 0-10
600 psi low-pressure discharge alarm armed? (applies only to 600 psi Yes No/Yes
UCP systems)
Miscellaneous Settings Default Value Range/Option

Warmup Complete Speed (RPM) 1375 1375-1450
Minimum Engine Warm-up Time (sec) 30 5-60
Maximum Engine Warm-up Time (sec) 240 60-1200
Compressor Cool-down Time (sec) 300 5-600
Air Filter Alert Time (sec) 15 10-60
LANGUAGE English English
Spanish
Italian
French
German
Portuguese
ECM Power-Off Interval At Cooldown (sec) 10 3-10
Unit Of Measurement English Metric
English
300 PSI System or 600 PSI System (same Controller software 600 300-600
supports both)
Enable Gauge Self-Test Disabled Enabled
Disabled
C9 Engine Used Disabled Enabled
Disabled
Standard Warmup rules Disabled Enabled
Disabled
Display Contract (%) 69 57-81
Cluster Backlighting Color Green Red, Green, Blue,
Yellow, Light Blue,
Violet, White
Cluster Backlighting Level (%) 100 0-100
Large Font Display Mode No Yes/No
Cabin Lights Low Voltage Alert Settings
Cabin Lights Low Voltage Level (V) 20.0 18.0 - 25.0
Cabin Lights Low Voltage On Cycle Time (secs) 10 1 - 10
Cabin Lights Low Voltage Off Cycle Time (secs) 2 1 - 10
Cabin Lights Low Voltage Number of Cycles 5 1 - 20
50
NOTES
Always air. Always there.
WWW.SULLAIR.COM
SULLAIR CORPORATION
3700 East Michigan Boulevard Michigan City, Indiana, 46360 U.S.A.
Telephone: 1-219-879-5451
Printed in the U.S.A.

Specifications subject to change
without prior notice.
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USER MANUAL

900/1600 IT4 CONTROLLER

For detailed course outlines, schedule, and cost information contact:

SULLAIR TRAINING DEPARTMENT

SECTION 2STARTUP PROCEDURES

SECTION 3ADJUSTMENT PROCEDURE

1.1 GENERAL CAUTION

CAUTION word, many of these instructions are

G. Disconnect the grounded negative battery con-

1.10 ENTRAPMENT I. Bring the starting vehicle alongside the compres-

b. verified that the Authorized person who 1.13 CALIFORNIA

1.14 SYMBOLS AND

DIESEL PARTICULATE FILTER

HIGH EXHAUST SYS. TEMP

2.4 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

CABIN MENU MENU

Figure 2-1: Instrument Panel Group

Lamp Indicators Switches/Gauges/Features

The Controller system will prevent the user from

2.5 NORMAL OPERATION

Figure 2-2: Communications checks display

Table 2-1 lists the safety conditions that are checked

Table 2-1: Safety Conditions

Fuel sender open circuit None Low fuel level

Battery Low battery voltage None Battery Voltage Error

Compresor Discharge Signal short circuit None T1 Signal Error

Discharge Air DP High Aftercooler filter DP AfterFilters Equipped Primary Shutdown

Air Pressure (P1) Transducer signal short or None P1 Signal Error

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

Control Pressure (P2) Transducer signal short or None P2 Signal Error

Air Pressure (P3) Transducer signal short or None P3 Signal Error

3.2 SETTINGS AND achieved by using the <MENU TOGGLE> and

<UP>A toggle on the <MENU TOGGLE> switch.

MENU STRUCTURE j. Pressure Cal.

1. Set Units k. Temp. Cal.

2. Large Font Display 5. Controller Diagnostic

3. Set Language a. Gauge Test

a. English b. Lamp Test

b. French c. LCD Test

c. Spanish d. Binary Inputs

d. German e. Analog Inputs

e. Italian 6. Backlight Adjust

f. Portuguese a. Backlight Color

4. Operational Configuration 1. Red

a. Enable Remote Start 2. Green

3.2.1 SET UNITS

3.2.2 LARGE DISPLAY INFO 3.2.4 OPERATIONAL CONFIGURATION

Selecting <SET LANGUAGE>, a sub-menu of all

REM. START MOMENTARY normal shutdown automatically. Using the <MENU

Figure 3-11: Remote start pressure value screen

AFTER COOLERS value is stored in memory, so it is retained through

After Filters the 2 psi value being read at Controller needs to be

FUEL TANK CFG.

Figure 3-18: Calibrated service pressure

Figure 3-19: Uncalibrated temperature example

Figure 3-20: Calibrated temperature example

3.2.5 CONTROLLER DIAGNOSTICS

Figure 3-24: Panel lamp test

LAMP TEST LCD TEST

Figure 3-23: Lamp test information screen