WSPC 02250167-859 R01

USER MANUAL WSPC USER INTERFACE MANUAL FOR THE WS CONTROLLER™

PART NUMBER:

02250167-859 R01

WARRANTY NOTICE Failure to follow the instructions and procedures in this manual or, misuse of this equipment will VOID its warranty!

KEEP FOR FUTURE REFERENCE SULLAIR CORPORATION

©

The information in this manual is current as of its publication date, and applies to compressor serial number :

200710010000 and all subsequent serial numbers.

AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility located at Michigan City, Indiana. Instruction includes training on the function and installation of Sullair service parts, troubleshooting common faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance, contractor maintenance, and service personnel. For detailed course outlines, schedule, and cost information contact:

SULLAIR CUSTOMER CARE TRAINING DEPARTMENT 1-888-SULLAIR or 219-879-5451 (ext. 5623) www.sullair.com - Or Write -

Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Depart ment.

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 Industrial compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility located at Michigan City, Indiana. Instruction includes training on the function and installation of Sullair service parts, troubleshooting common faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance, contractor maintenance, and service personnel. For detailed course outlines, schedule, and cost information contact:

SULLAIR CUSTOMER CARE TRAINING DEPARTMENT 1-888-SULLAIR or 219-879-5451 (ext. 5623) www.sullair.com - Or Write -

Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Depart ment.

TABLE OF CONTENTS SECTION 1—SAFETY 5

1.1

GENERAL

5

1.2

PERSONAL PROTECTIVE EQUIPMENT

5

1.3

PRESSURE RELEASE

6

1.4

FIRE AND EXPLOSION

6

1.5

MOVING PARTS

7

1.6

HOT SURFACES, SHARP EDGES AND SHARP CORNERS

7

1.7

TOXIC AND IRRITATING SUBSTANCES

8

1.8

ELECTRICAL SHOCK

8

1.9

LIFTING

9

1.10

ENTRAPMENT

SECTION 2—OVERVIEW 11 11

2.1

MANUAL CONTENTS

12 12

2.2

SYSTEM COMPATIBILITY

12 12

2.3

INSTALLING THE WSPC USER INTERFACE SOFTWARE

12 12

2.4

INSTALLING OR UPDATING THE FRAMEWORK

12 12

2.5

UNINSTALL THE WSPC SOFTWARE

SECTION 3—GETTING STARTED 13 13

3.1

ACCESS PRIVILEGES

13 13

3.2

STARTING THE SOFTWARE

14 14

3.3

WINDOWS® BASIC

15 1 5

3.4

CONNECTING THE PC TO THE CONTROLLER

15

3.5

CONNECTI CTING / DISCON CONNECT ECTING THE WSP WSPC USER INTE NTERFACE ACE AND AND THE WS CONTROLLER

17 1 7

3.6

THE WSPC DISPLAY SCREEN

17 17

3.7

COMPRESSOR STATUS BAR

18 18

3.8

FILE MENU

19 1 9

3.9

REPORT

19 19

3.10

COM PORT

19 1 9

3.11

ABOUT

TABLE OF CONTENTS

SECTION 4—DISPLAY DESCRIPTIONS 21

4.1


22

4.2

COMPRESSOR DATA DISPLAY (DEFAULT SCREEN)

24

4.3

MACHINE INFO DISPLAY

24

4.4

SERVICE DISPLAY

27

4.5

MAINTENANCE DISPLAY

28

4.6

DISTRIBUTOR INFORMATION

29

4.7

SEQUENCE SYSTEM DISPLAY

30

4.8

ADJUSTMENTS DISPLAY

SECTION 5—MENU BAR 3 9

5.1

FILE MENU—USER PROFILES AND PREFERENCES

43

5.2

REPORTS

44

5.3

COMMUNICATIONS PORT

45

5.4

INFORMATION ABOUT WSPC

SECTION 6—VARIABLE SPEED DRIVE (VSD) 47

6.1

VSD OPERATION

47

6.2

COMPRESSOR DATA TAB

48

6.3

VSD PERFORMANCE DATA

49

6.4

CLEAR RECENT DATA

49

6.5

DELIVERY HISTORY

50

6.6

SERVICE DISPLAY TAB

50

6.7

MAIN MOTOR VFD STATUS BOX

51

6.8

ADJUSTMENTS TAB

52

6.9

ADMINISTRATOR LEVEL VSD ADJUSTMENTS

SECTION 7—ADMININISTRATOR LEVEL FUNCTIONS 53

7.1

ADMINISTRATOR LEVEL FUNCTIONS

53

7.2

ACCESSING THE ADMINISTRATOR LEVEL

54

7.3

COMMISSIONING A CONTROLLER

56

7.4

MAINTENANCE DISPLAY

59

7.5

ADMINISTRATOR ADJUSTMENTS (ADMIN) DISPLAY

67

7.6

MODBUS FUNCTIONS

69

7.7

DRYER SETUP DISPLAY

Section 1

SAFETY NOTE

the precautionary statements contained herein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors.

1.2 OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL.

1.1

GENERAL

Sullair Corporation and its subsidiaries design and manufacture all of their products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment. The compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operator's Manual. Failure to follow the instructions, procedures and safety precautions in this manual may result in accidents and injuries. NEVER start the compressor unless it is safe to do so. DO NOT attempt to operate the compressor with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to operate it until the condition is corrected. Install, use and operate the compressor only in full compliance with all pertinent OSHA regulations and/ or any applicable Federal, State, and Local codes, standards and regulations. DO NOT modify the compressor and/or controls in any way except with written factory approval. While not specifically applicable to all types of compressors with all types of prime movers, most of

PERSONAL PROTECTIVE EQUIPMENT

A. Prior to installing or operating the compressor, owners, employers and users should become familiar with, and comply with, all applicable OSHA regulations and/or any applicable Federal, State and Local codes, standards, and regulations relative to personal protective equipment, such as eye and face protective equipment, respiratory protective equipment, equipment intended to protect the extremities, protective clothing, protective shields and barriers and electrical protective equipment, as well as noise exposure administrative and/or engineering controls and/or personal hearing protective equipment.

1.3

PRESSURE RELEASE

A. Install an appropriate flow-limiting valve between the service air outlet and the shut-off (throttle) valve, either at the compressor or at any other point along the air line, when an air hose exceeding 1/2" (13mm) inside diameter is to be connected to the shut-off (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302(b)(7) and/or any applicable Federal, State and Local codes, standards and regulations. B. When the hose is to be used to supply a manifold, install an additional appropriate flow-limiting valve between the manifold and each air hose exceeding 1/2" (13mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure. C. Provide an appropriate flow-limiting valve at the beginning of each additional 75 feet (23m) of hose in runs of air hose exceeding 1/2" (13mm)

5

SECTION 1 inside diameter to reduce pressure in case of hose failure.

accumulate on, under or around acoustical material, or on any external surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary, remove acoustical material, clean all surfaces and then replace acoustical material. Any acoustical material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids or fluid film within the material. DO NOT use flammable solvents for cleaning purposes.

D. Flow-limiting valves are listed by pipe size and flow-rated. Select appropri ate valves accordingly, in accordance with their manufacturer's recommendations. E. DO NOT use air tools that are rated below the maximum rating of the compressor. Select air tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer's rated safe operating pressures for these items. F.

Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled.

G. Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the receiver tank to zero internal pressure before removing the cap. H. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before attempting to refill optional air line anti-icer systems with antifreeze compound. I.

J.

Keep personnel out of line with and away from the discharge opening of hoses or tools or other points of compressed air discharge.

DO NOT use air at pressures higher than 2.1 bar for cleaning purposes, and then only with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR 1910.242 (b) and/or any applicable Federal, State, and Local codes, standards and regulations.

K. DO NOT engage in horseplay with air hoses as death or serious injury may result.

1.4

FIRE AND EXPLOSION

A. Clean up spills of lubricant or other combustible substances immediately, if such spills occur. B. Shut off the compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away and DO NOT permit smoking in the vicinity when checking or adding lubricant or when refilling air line anti-icer systems with antifreeze compound. C. DO NOT permit fluids, including air line anti-icer system antifreeze compound or fluid film, to

6

D. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the compressor or of the inside of the enclosure, if any. E. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring that has cracked, cut, abraded or otherwise degraded insulation, or terminals that are worn, discolored or corroded. Keep all terminals and pressure connectors clean and tight. F.

Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition.

G. Remove any acoustical material or other material that may be damaged by heat or that may support combustion and is in close proximity, prior to attempting weld repairs. H. Keep suitable fully charged Class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor. I.

Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.

J. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant. K. DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been specially designed and manufactured for that duty.

1.5

MOVING PARTS

A. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and other moving parts. B. DO NOT attempt to operate the compressor with the fan, coupling or other guards removed.

SECTION 1 C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts.

DANGER

D. Keep access doors, if any, closed except when making repairs or adjustments. E. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it. F.

Disconnect and lock out all power at source and verify at the compressor that all circuits are deenergized to minimize the possibility of accidental start-up, or operation, prior to attempting repairs or adjustments. This is especially important when compressors are remotely controlled.

G. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water or other liquids to minimize the possibility of slips and falls.

1.6

HOT SURFACES, SHARP EDGES AND SHARP CORNERS

A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners. B. Keep all parts of the body away from all points of air discharge. C. Wear personal protective equipment including gloves and head covering when working in, on or around the compressor. D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore small cuts and burns as they may lead to infection

1.7

TOXIC AND IRRITATING SUBSTANCES

A. DO NOT use air from this compressor for respiration (breathing) except in full compliance with OSHA Standards 29 CFR 1910 and/or any applicable Federal, State or Local codes or regulations.

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment. B. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas. C. Operate the compressor only in open or adequately ventilated areas. D. Locate the compressor or provide a remote inlet so that it is not likely to ingest exhaust fumes or other toxic, noxious or corrosive fumes or substances. E. Coolants and lubricants used in this compressor are typical of the industry. Care should be taken to avoid accidental ingestion and/or skin contact. In the event of ingestion, seek medical treatment promptly. Wash with soap and water in the event of skin contact. Consult Material Safety Data Sheet for information pertaining to fluid of fill. F.

Wear goggles or a full face shield when adding antifreeze compound to air line anti-icer systems.

G. If air line anti-icer system antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for fifteen minutes. A physician, preferably an eye specialist, should be contacted immediately. H. DO NOT store air line anti-icer system antifreeze compound in confined areas. I.

The antifreeze compound used in air line antifreeze systems contains methanol and is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing t he fumes. If

7

SECTION 1 swallowed, induce vomiting by administering a tablespoon of salt, in each glass of clean, warm water until vomit is clear, then administer two teaspoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light. Call a physician immediately.

1.8

DANGER All field equipment must be tested for electrostatic fields prior to servicing or making contact with the machine using the following or equivalent test equipment: • 90-600 VAC: Volt detector such as Fluke Model 1AC-A • 600-7000 VAC: Voltage detector such as Fluke Networks Model C9970 It is the responsibility of each organization to provide/arrange training for all their associates expected to test for electrostatic fields.

ELECTRICAL SHOCK

A. This compressor should be installed and maintained in full compliance with all applicable Federal, State and Local codes, standards and regulations, including those of the National Electrical Code, and also including those relative to equipment grounding conductors, and only by personnel that are trained, qualified and delegated to do so. B. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed live parts of electrical system. Maintain dry footing, stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. Make all such adjustments or repairs with one hand only, so as to minimize the possibility of creating a current path through the heart. C. Attempt repairs in cl ean, dry and well lighted and ventilated areas only. D. DO NOT leave the compressor unattended with open electrical enclosures. If necessary to do so, then disconnect, lock out and tag all power at source so others will not inadvertently restore power. E. Disconnect, lock out, and tag all power at source prior to attempting repairs or adjustments to rotating machinery and prior to handling any ungrounded conductors.

1.9

LIFTING

A. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided, then lift by sling. Compressors to be air-lifted by helicopter must not be supported by the lifting bail but by slings instead. In any event, lift and/or handle only in full compliance with OSHA standards 29 CFR 1910 subpart N and/or any applicable Federal, State, and Local codes, standards and regulations. B. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting. C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight, then weigh compressor before lifting. D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail or slings. E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground. F.

DO NOT attempt to lift in high winds.

G. Keep all personnel out from under and away from the compressor whenever it is suspended. H. Lift compressor no higher than necessary.

8

SECTION 1 I.

Keep lift operator in constant attendance whenever compressor is suspended.

J.

Set compressor down only on a level surface capable of safely supporting at least its weight and its loading unit.

K. When moving the compressor by forklift truck, utilize fork pockets if provided. Otherwise, utilize pallet if provided. If neither fork pockets or pallet are provided, then make sure compressor is secure and well balanced on forks before attempting to raise or transport it any significant distance. L. Make sure forklift truck forks are fully engaged and tipped back prior to lifting or transporting the compressor. M. Forklift no higher than necessary to clear obstacles at floor level and transport and corner at minimum practical speeds.

N. Make sure pallet-mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. NEVER attempt to forklift a compressor that is not secured to its pallet, as uneven floors or sudden stops may cause the compressor to tumble off, possibly causing serious injury or property damage in the process.

1.10 ENTRAPMENT A. If the compressor enclosure, if any, is large enough to hold a man and if it is necessary to enter it to perform service adjustments, inform other personnel before doing so, or else secure and tag the access door in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside. B. Make sure all personnel are out of compressor before closing and latching enclosure doors.

9

BLANK PAGE

10

WSPC USER INTERFACE MANUAL

Section 2

OVERVIEW The WSPC User Interface is a Windows-based software program that allows complete monitoring and control of Sullair air compressors equipped with a Sullair WS Controller. The software can monitor a single compressor operating as an individual unit or multiple machines connected in a sequence. The WSPC program receives data about the compressor from the WS Controller, assigns control parameters to the controller, displays controller operating characteristics including faults and warning messages, and provides functionality that assists the user with controller diagnostics.

2.1

MANUAL CONTENTS

This manual describes the features and operation of the WSPC User Interface program. Part 1 covers material pertaining specifically to persons operating the program with User Level access. Part 2 covers advanced functions available to experienced users and persons with Administrator Level access. This manual describes WSPC software part number 02250174-081 when operated with WS Controller software 02250174-082 or later. This version of WSPC is compatible with all previously released versions of WS Controller software, but certain features described in this manual are not available in earlier versions.

Part 1: Section 2: OVERVIEW provides the necessary information to install the WSPC software. Included are the minimum hardware and software requirements. Section 3: GETTING STARTED presents steps to getting the program up and running quickly. Basic MS Windows functions and those features necessary to using the software are explained in this section.

Section 4: DISPLAY DESCRIPTIONS provides an explanation of each display screen available to user level operators. Detailed descriptions of the operation of each display component are provided. Section 5: MENU BAR provides steps to setting user preferences for operating the WSPC program. This section guides the user in creating and modifying user profiles. Section 6: VARIABLE SPEED DRIVE (VSD) describes the WSPC functions that apply to Variable Speed Drive compressors.

Part 2: Section 7: ADMININISTRATOR LEVEL FUNCTIONS describes those functions that apply specifically to Administrator level operators. Each administrator level display is presented and details of the display components are described.

Features of the WSPC User Interface software include: • Two-way communication channel between the user and the compressor controller. • A comprehensive view of the compressor controller’s operation at the WSPC interface. • Adjustment of all modifiable parameters of the compressor controller. • Ability to control the compressor remotely. • Access to data relating to all compressors connected as a sequence system. • Password protection capabilities to limit access to data and controls. • A data log feature which compiles operational, service, and error data of the compressor or compressor system.

11


2.2

SYSTEM COMPATIBILITY

• Before beginning the installation process, your computer should meet the following minimum requirements. • PC–compatible computer (Pentium® IV based, 1.0 Ghz processor recommended) • Windows 2000 or Windows XP operating systems. Windows 2000 may require special processing software to properly operate the WSPC software.

SECTION 2

2.4

INSTALLING OR UPDATING THE FRAMEWORK

The WSPC software requires the Microsoft .net® Framework support program in order to run on the PC. If Microsoft .net is already on the PC, you will be able to run as soon as the installation is completed. To install the framework, or update to the latest version, use the following procedure for a free download.

• CD ROM drive

1. Connect the PC to the internet.

• 125 Mb of available hard disk space

2.

• 256 Mb of available RAM memory

Go to the site: www.microsoft.com/downloads

• Color monitor

3. Search for “.NET Framework”

• RS232 communications capability

4.

2.3

INSTALLING THE WSPC USER INTERFACE SOFTWARE

Follow the instructions accompanying the WSPC Installation package. The actual installation media may be CD, internet, network, USB drive, or other means, and the procedure will be specific to that media. This installation will create a folder on your disk drive, and install the necessary files into that folder. Make a note of this location, as it may be necessary for future updates. The default location for all saved files will also be in that folder, but you may browse to save into any other location in your PC as desired. By default, the folder will be "WSPC" and will be located in a "Sullair" folder. Recommended locations are "C:\Sullair\WSPC" or "D:\Sullair\WSPC”.

12

Follow the instructions for downloading and installation.

2.5

UNINSTALL THE WSPC SOFTWARE

To uninstall the WSPC software: 1.

Right-click any desktop shortcuts that were created.

2.

Click “Delete” to delete the shortcut.

3.

Open “My Computer” and browse to the folder created in Section 2.3.

4.

Delete the folder and its contents.

NOTE Contact your network administrator if you are unable to perform the software installation due to access limitations.


Section 3

GETTING STARTED 3.1

ACCESS PRIVILEGES

The WSPC User Interface accessed at two levels.

program

may

be

User Level: Allows users to access the program without entering a password. The user should be an individual with specific authorization to use the WSPC software and knowledge of the compressor operation. This level includes all data and adjustments for normal applications of the compressor. At this level a user has access to the following displays: Compressor Data, Machine Info, Service, Maintenance, Sequencing, and Adjustments.

Figure 3-1: WSPC User Interface password request

Administrator Level: This provides additional functions for maintenance, service, and setup for trained compressor technicians. Administrator level functions are described in Part 2 of this manual. A password is required to access this level.

3.2

STARTING THE SOFTWARE

1.

Click the shortcut located on the computer desktop to start the WSPC User Interface program.

2.

When the program opens, a dialog box will appear as shown in Figure 3-1. Click OK to open the WSPC program. If the program was last closed while operating at the Administrator level the dialog box will require a password as shown in Figure 3-2 .

Figure 3-2: WSPC User Interface password request Do the following to select a user-level profile:

A. Click the down arrow next to the “User Name” box. A drop-down list of user profiles will be presented. See Figure 3-3. B. Click on a profile that is set for “User Level” access (Default User) and click “OK”. User level profiles do not require password access. More profile options may be available in the User Name list than the ones shown in Figure 3-3.

13


SECTION 3 The program will open to the “Compressor Data Display” with user level access. See Figure 3-4. From the opening screen the user may navigate to all other features of the program.

Figure 3-3: User Option

Figure 3-4: WSPC Opening Window – Compressor Data Display

3.3

WINDOWS® BASIC

This section presents basic MS Windows® functions that will be useful to using the WSPC program. The active presentations of information on the computer screen are referred to as “Displays.” At the top of

14

each display is a tab showing the display title. To make a display active, click on the desired display tab. See Figure 3-5 . The active display allows the user to see the data related to the tab title and to perform functions on the display page.

SECTION 3


Figure 3-5: User Interface display tab Some screens allow for entry of values into fields on the screen. To enter data into a field:

A. Click in the field to be modified. B. Select the data currently contained in the field (if any). Data in a field can be selected by doubleclicking on a character in a field. The entire data field will be selected. Data can also be highlighted for editing by holding down the left mouse button and dragging the cursor across the data in the field. C. Type the new data into the field. Typing the new data will replace the old data. Typically an option can be chosen by pressing “Enter” on the computer keyboard. Some options present a dialog box that allow the user to confirm the entries by clicking an “OK” button or cancel the entries by clicking “Cancel.” A window can be reduced, expanded, or closed by clicking on the respective button located in the upper right corner of the display:

3.4

CONNECTING THE PC TO THE CONTROLLER

The standard connection of the PC Interface to the WS Controller is via a specially designed RS-232 connector. This serial line connects to the computer’s DB9 socket and runs directly to a custom designed terminal located on the left side of the controller cabinet. The PC may also be connected to the controller by other means such as through RS-485 connections or remotely via modem or wireless network.

3.5

CONNECTING / DISCONNECTING THE WSPC USER INTERFACE AND THE WS CONTROLLER

After the communication lines are attached and the WSPC software is running, the WSPC program can be connected to the controller to begin receiving machine operation data. Control data can also be sent from the PC to the WS Controller to configure the machine control parameters. 1.

To establish connection between the WSPC and the WS Controller click (“Connect” button)

Reduce

Expand

in the status bar. The box left of the Connect button will appear bright green indicating the connection is active. The software will search for communication from the controller, and fill the display with machine information.

Close

Figure 3-6: User Option 2.

During normal connection, communication activity will be shown on the bottom edge of the WSPC screen, as shown in Figure 3-7 . The progress bar and block numbers simply indicate that communications are occurring. The WS Controller also provides led indicators for communication near J13. Red indicates a request was received from the PC, Green indicates a message is being sent to the PC.

15


SECTION 3

Figure 3-7: WSPC User Interface Display Screen

Figure 3-8: WSPC User Interface Display Screen 3.

If communication with the machine could not be established, an error message will display on the communication status line as depicted in Figure 3-8 . If this occurs, check the RS232 connection and other terminals for proper connection.

Title Bar

4.

To disconnect communication between the WSPC and the controller, click on the “Connect” button. The box left of the button will change from bright green to dark, shaded green, indicating that the WSPC is disconnected from the controller. The controller will continue to operate according to the latest set of parameters entered.

Display Tabs

Menu Bar

Connection Button

Compressor Status Bar

Machine Operation Data and Parameters

Communication Status Indicator

User Profile Name

Figure 3-9: WSPC User Interface Display Screen

16

Logging Indicator

SECTION 3

3.6

THE WSPC DISPLAY SCREEN

The WSPC display screen consists of the title bar, the pull-down menu bar, the compressor status bar, display tabs, machine operation data display, and the communication status bar. Refer to Figure 3-9. The default screen is the Compressor Data display which appears each time the WSPC software is opened. Listed below are main elements of the screen display that enable the user to access and view the machine operation data, and modify the machine control parameters.

Title Bar —Contains the name of the WSPC software program. "Menu Bar - Click to activate drop-down menus or other screens to select WSPC configurations. Section 5 provides additional details.

Connection Button—When activated, establishes connection between the PC Interface and the WS Controller unit. Compressor Status Bar —Located on the left margin of every display, the Compressor Status Bar provides real-time data of the machine’s current operation and condition. The Compressor Status Bar is described in detail in Section 3.7 . Display Tabs—Allow for the selection of the desired display. Section 4 provides a detailed description of each display screen.


3.7

The Compressor Status Bar, which is located left of the main window, displays real-time data regarding the status of the compressor. The status bar is constantly displayed whenever the WSPC software is connected to the controller. This feature allows the user to quickly view the status of the compressor operation regardless of which display screen is active. Information presented in the status bar includes the compressor operating mode, operating state, compressor temperature, sump pressure, and discharge pressure. See Figure 3-9. The Compressor Status Bar can be displayed as a stand alone compressor operation monitor as shown in Figure 3-10 . The full display window can be hidden leaving only the status bar information appearing on the screen. This feature allows the user to continue monitoring the compressor operation while performing other tasks on the PC. To reduce the display to show only the status bar: 1.

Place the cursor on the right border of the WSPC display window.

2.

Press and hold the left mouse button.

3.

“Drag” the display border to the left until it stops. The compressor data window will be hidden leaving the status bar in the display.

4.

To return to the full screen presentation, click on the expand window icon in the upper right corner of the display.

5.

To return again to the status bar only view, click on the reduce window icon in the upper right corner of the display.

Machine Operation Data—Area where the machine parameter data and operational information is displayed. Communication Status Indicator —Located at the bottom of the display window, this line provides communication status information.

User Profile Name —The name of the current user profile is displayed. In Figure 3-9, the active profile is named “Default User”.


Logging Indicator —This field will light when the PC is recording data.

17


SECTION 3

3.8

FILE MENU

The File Menu contains options that allow the user to configure and set preferences that control how the program functions. See Figure 3-10 From the “File” menu, the user can choose three options:

Communication Operating Mode

Profiles—Allows the user to create and edit profiles. A profile will contain settings that configure the WSPC program according to the operator or group’s preferences. The features of the Profiles menu option are described in Section 5 of this manual.

Communication Operating State

Login—Presents the Login box which allows the user to choose a profile from a list of available User profiles. See Figure 3-12 .

Communication Temperature Measurement

Exit—Closes the WSPC User Interface program. Exiting the software does not affect the compressor or controller operation.

Sump Pressure Measurement

Communication Pressure Discharge

Figure 3-10: Compressor Status Bar (Reduced)

File Menu

Figure 3-11: File Menu Options

18

SECTION 3


3.11 ABOUT This provides information about the WSPC program. See Figure 3-14

Figure 3-12: Login Screen A

3.9

REPORT

This menu Item will request a folder location and file name in which to file a comprehensive service report. See Figure 3-13

3.10 COM PORT This provides a dialog to select the communications port of the PC on which the program is running. This is typically COM1, but your PC may be equipped with additional ports. See Figure 3-15

Figure 3-14: About Information Box

Figure 3-13: Report Dialog

19


Figure 3-15: Com Port Dialog

20

SECTION 3


Section 4

DISPLAY DESCRIPTIONS 4.1


Located on the left edge of the WSPC User Interface program window, the Compressor Status Bar displays information related to the compressor current operation. See Figure 4-1. The information appearing in the Status Bar is machine generated, view only data. Above the Status Bar is a button that allows the user

to connect or disconnect communication between the WSPC and the WS Controller. Clicking the “Connect” button will alternately connect and disconnect communication between the software and the controller. An additional button (labeled Unload) may appear in the Status Bar when the WSPC interface is configured to control the compressor operation remotely. Refer to Sequencing and Protocol Manual for an explanation of this feature.

Compressor Operating Mode Operating State Compressor T1

Temperature Sump Pressure Compressor Line Pressure Controller Control Voltage

STATUS BAR

Figure 4-1: Default Screen: Compressor Data Display

21


SECTION 4

STATUS BAR COMPONENTS Listed below is the information that is displayed in the fields of the Compressor Status Bar.

Compressor Operating Mode—The Operating Mode is the manner in which the machine operation is being controlled. There are five Operating Modes: AUTOMATIC, MANUAL, OFF, FAULT, and UI COMM. Operating State—The state of the compressor operation in response to the current mode and current conditions. The operating state essentially describes what the machine is currently doing. Compressor Temperature temperature of the compressor.

1—The

internal

Sump Pressure—The compressor sump pressure. Line Pressure—The discharge pressure of the compressor.

Control Volts—The actual compressor control supply.

voltage

the

Additional data may be displayed in the Compressor Status Bar depending on user access level and machine configuration. These include dryer dewpoint temperature and spiral valve modulation indicators.

4.2

COMPRESSOR DATA DISPLAY (DEFAULT SCREEN)

The “Compressor Data” display is the window that appears when the WSPC Interface is initialized. See Figure 4-2 . If the Compressor Data display is not showing on the monitor, access the display by clicking on the “Compressor Data” tab. At this display the user can monitor compressor operating information.

Machine Operation Data

Figure 4-2: Compressor Data Display

22

of

SECTION 4


COMPRESSOR RUN DATA

DIGITAL INPUTS AND RELAY OUTPUTS

The information presented at the Compressor Data display is described below.

The digital inputs and relay outputs indicate that a signal from an input/output device has been received.

Machine hours—Total controller has been operation.

number of hours the monitoring compressor

Compressor enabled hours—Total number of hours the compressor has been enabled to run. Motor running hours—Total number of hours the compressor motor has been running. Compressor loaded hours—Total number of hours the compressor has run loaded. Compressor full load hours—Total number of hours the compressor has run at full load. Number of starts—Total number of times the compressor has been started automatically or manually. Number of load cycles—Total number of load cycles the compressor has completed.

Digital Inputs: Definition

Digital Inputs—Each indicates that the input has been activated by a machine action. When active, the box next to the input will be bright green in color. E-stop—Indicates that an emergency stop switch has been pressed. The E-stop is normally closed and the box next to the E-stop input is bright green. When the button is pressed, the E-stop input indicator will appear dark. Relay Outputs—Each indicates that the output relay has been activated by the controller. When active, the box next to the output will be bright red in color. Inputs and outputs are assigned at the factory to indicate specific actions, and will vary with the compressor model. Typical factory assignments of inputs and outputs are as follows:

Relay Outputs: Definition

Input 1: Main Motor Overload-Fault

Output 1: Run

Input 2: Aux. Motor Overload-Fault

Output 2: Wye

Input 3: Starter Aux. Contact-Fault

Output 3: Delta

Input 4: NOT USED

Output 4: Load

Input 5: High Air Filter dP-Warning

Output 5: Full Load

Input 6: High Fluid Filter-Warning

Output 6: Drain

Input 7: Remote Unload (Option)

Output 7: Fault Signal

Input 8: Fault (Option) Input 9: Warning (Option) E-Stop: Emergency Stop Activated

23


4.3

MACHINE IN INFO DI DISPLAY

The “Machine Info” display presents information relating to the current compressor/controller model and configuration. See Figure 4-3. 4-3. This information is view only and cannot be changed by the operator. The information presented in the “Machine Info” display is described below.

SECTION 4 frequency (50 or 60 Hz)

Cooling—Method of cooling (air cooled or water cooled) —The motor control (Y-delta, full voltage, Motor —The variable -speed)

Volts—Nominal Starter line voltage —Dryer type Dryer —Dryer

CONTROLLER SOFTWARE INFO Version Date—Displays the date version of the WS Controller internal software. I/O Version Pn —Displays the WS Controller I/O unit part number. U/I Version Pn —Displays the WS Controller User Interface part number. COMPRESSOR INFO This information about the compressor package is recorded during the WS Controller’s commissioning

Model—The model number HP—Motor Horsepower Pressure—Nominal pressure rating Hz – Line

4.4

SERVICE DISPLAY

The Service display provides information related to compressor events which require service actions. A history of the 16 most recent fault messages are displayed on the service page along with information detailing the time and date of the fault occurrence. See Figure 4-4. 4-4. The fault history can aid the user in identifying related events and recurring problems that may cause machine malfunctions or limit operation. Refer to the WS Controller User Instruction Manual for actions to be taken when a fault or warning condition occurs. The first row of the fault listings displays the most recent fault. Column one provides a description of the fault cause. Column two displays the number of hours the compressor has run when

Figure 4-3: Machine Info Display

24

SECTION 4


Figure 4-4: Service Display the fault occurred. Column three shows the month and day on which the fault occurred. The remaining columns display the time of day that the fault occurred in hour:minutes:seconds. The lower portion reports communication errors between the WS controller and its User Interface, and between the WS controller and other controllers in a group of sequenced compressors. The upper upper box, labeled "Up/Down Count" shows recent communication errors. The lower box shows the total number of communication errors.

SENSOR LOG BUTTON It is possible for the user to view the readings of up to eleven sensors during the last ten minutes leading up to a fault. While at the “Service” display screen, click on the “Sensor Log” button (see Figure 4-5 ) to bring up the “Sensor Log.” This log, shown in Figure 4-6 , displays each sensor reading in ten one-minute decrements down to one minute before the last fault occurred.

Figure 4-5: Sensor Log Button sensor readings leading up to a fault is displayed in 12 five-second decrements. The last sensor reading is at zero (0) seconds recorded shortly before the fault occurrence. Using this data a user or service technician can observe the progression of a fault as an aid in diagnosing the problem. Refer to the WS Controller User Instruction Manual for actions to be taken when a warning or fault condition occurs.

In the example shown, the log shows sensor readings for Temperature 1, Sump Pressure, Line Pressure, and Controller Voltage. The final minute of

25


SECTION 4

Figure 4-6: Sensor Log Window

Figure 4-7: Saved Sensor Log File Example

LOG DATA BUTTON

3.

The compressor operating state

WSPC may be used to log data about compressor operation for extended periods. These files are stored in the PC. A line of data is stored at least once per minute. Additional data lines are stored if any significant change occurs. A “Logging” indicator is bright green whenever logging is turned on. This is intended as an aid for troubleshooting. This report may be viewed as a text file, or imported into a spreadsheet for formatted analysis and graphing.

4.

Digital input and Output condition (shown as a hex number)

5.

Data from all 11 analog inputs, including temperatures and pressures

6.

Data from the variable frequency drive.

The data on each line includes: 1. The time of the record 2.

26

The WS Controller operating mode

To log data, click the "Log Data" button on the Service page. A dialog box will be presented with the default folder location and file name. If desired, another directory can be selected and a descriptive filename can be typed into the Filename field to save the log data to a user specified location. When assigning a user specified location, be sure to note

SECTION 4


the directory path and filename information so that the log data can be easily located later. Click the "Save" button to begin logging. To stop logging, click on the "Log Data" button again on the Service page. To view data, simply browse to the folder, and double click on the file created. The data may be viewed with any text editor. To create an Excel spreadsheet, right click on the file name, and select "Open With" > "Excel". This will put all the data into a worksheet for further analysis or formatting. In Excel, select all columns, then click on "Format" > "Column" > "Auto Fit" to adjust columns to appropriate sizes for the new data. When saving, Select "Save As" and select a spreadsheet in "Save as Data Type". Refer to the Help pages in Excel for more information on using the data.

4.5

MAINTENANCE DISPLAY

The Maintenance Display contains listings of recent Warnings and Recommended Service messages that have been displayed at the controller. See Figure 4-8 . Also displayed are the hours remaining to the next recommended service activity. When a warning message is displayed, the compressor will still operate. However, the condition which caused

the warning must be resolved within a short period of time to prevent a fault condition from occurring or damage to the machine. Refer to the WS Controller User Instruction Manual for actions to be taken when a warning or fault condition occurs.

WARNING MESSAGES Warning messages that may appear Maintenance Display are listed below.

on

the

High Oil (Fluid) Filter dP —Indicates the fluid filter pressure differential is high. The fluid filter needs to be checked or changed. High Separator dP—Indicates the fluid separator pressure differential is high. The separator unit needs to be checked or changed. High Air Filter dP —Air filter pressure differential is high indicating that the air filter unit needs to be checked or changed. High Temperature 1, 2, or 3 —Compressor Temperature at the specified temp probe location is approaching the set high limit. Low Temperature 1, 2, or 3—Compressor Temperature at the specified temp probe location is approaching the set low limit.

Figure 4-8: Maintenance Display

27


SECTION 4

Power Interruption—An interruption in power to the compressor has occurred.

within the time frame noted in the machine operation specifications.

Sequence Comm Error —Communication problem exists between the compressor controllers set up for sequential operation.

Separator Change—The compressor fluid separator life interval has expired. Change the separator within the time frame noted in the machine operation specifications.

User Warning—A user furnished switch has been activated. Low Computer Battery—Indicates that the controller internal battery is low and needs to be replaced. Dryer Warning—Indicates that the compressor system dryer needs to be serviced. Refer to the WS Controller Instruction Manual for additional instructions on actions to be taken when warning conditions exists. The following warnings apply to optional construction. If these occur, refer to the machine manuals for additional information.

VFD Overtemp—indicates that the variable frequency drive is operating near its design limit. Check for unrestricted flow of cooling air, and keep ambient temperatures below the design rating. Check the heatsink for dust or dirt buildup, and clean if necessary. Dryer Relay Fault—indicates internal protection has tripped.

that

the

dryer's

Dryer Overload Fault—indicates that a dryer's motor overload relay has tripped. Dryer High DP Fault—indicates temperatures that caused a dryer fault.

very

high

Dryer Low DP Fault—indicates temperatures that cause a dryer fault.

very

low

Air Filter Change—The compressor air filter life interval has expired. Change the air filter within the time frame noted in the machine operation specifications. Oil (Fluid) Analysis—Fluid analysis interval has expired. Schedule the compressor fluid analysis per machine operation specifications. Oil (Fluid) Change—The compressor fluid life interval has expired. Change the compressor fluid within the time frame noted in the machine operation specifications. Other Maintenance—Other periodic maintenance should be performed as scheduled per machine operation specifications. The “Interval” fields show the recommended hours remaining until the next servicing is due for the above listed items. A zero value indicates the reminder is disabled.

4.6

DISTRIBUTOR INFORMATION

Distributor Information can be accessed by clicking on the “Distributor Info” button on the “Compressor Data” display. A window will appear, similar to Figure 4-9, presenting previously entered information. Enter additional information here as desired in the lower pane.

High Dryer Dewpoint—indicates dryer operation near the high temperature limit. Low Dryer Dewpoint—indicates dryer operation near the low temperature limit.

SERVICE REMINDERS Service Reminders may inform the user that a particular component of the compressor is recommended for servicing. An Administrator may set service intervals and reset the service reminders. The following service reminders can appear under the “Recommended Service” heading:

Oil (Fluid) Filter Change —The compressor fluid filter life interval has expired. Change the fluid filter

28

Figure 4-9: Distributor Information

SECTION 4


Figure 4-10: Sequence System Display

4.7

SEQUENCE SYSTEM DISPLAY

The status of compressors connected in sequence can be viewed at the Sequence System Display. See Figure 4-10 . The top line of the Sequence System Display shows the total system pressure. The sequence information contained in the table can display compressor data for up to sixteen machines in a sequence. The compressors are listed down the left side of the sequence information table in order of com number. Refer to the Adjustments Display screen to verify the com number and sequencing mode of the current machine.

Status—displays the operating state of each compressor in the sequence. The sequence state describes the operational role a machine is performing as a part of the sequence. The various states that may appear in the “Sequence status” column are: Starting—Indicates the compressor is starting up. Full Load—Indicates the compressor is fully loaded. Trim—Indicates the compressor is operating as the trim machine in the sequence.

Loaded—Indicates loaded.

the

compressor

is

running

Unloaded—Indicates the compressor is running unloaded. Manual Stop—Indicates the compressor is stopped by the operator. Remote Disable—Indicates the compressor removed from sequencing remotely.

is

Remote Stop—Indicates the compressor has been stopped remotely. E-Stop—Indicates a compressor fault. Mode—displays the Operating Mode of each compressor in the sequence. The mode is the manner in which the machine’s operation is being controlled. When running and operating normally, a compressor’s operating mode will be either “Manual” or “Automatic” as selected by the user. Other modes are “Stopped” when the machine’s operation has been stopped and “Faulted” when a fault has occurred. Hours—displays the sequence hours of a particular compressor. Sequence hours are the number of hours set for a machine to run in sequence. This

29

WSPC USER INTERFACE MANUAL parameter can be adjusted at the Adjustments Display to assign the compressor to run in a specific order in the sequence system. When the operating mode is set to Automatic, the machine with the lowest number of sequence hours will be the next to start and the machine with the highest number of sequence hours will be the next to stop.

PSI—displays the output pressure of the related compressor. This may be displayed as BAR or Kpa depending on user profile preferences. This measurement is taken at the P2 pressure transducer of the compressor and may be a different value than the overall system pressure. ACFM—shows the capacity of the specific compressor. Capacity is the volume of air in cubic feet per minute (cfm) being delivered by the compressor. whether the compressor Remote—indicates operation is being controlled remotely (including

SECTION 4 sequencing control) or by the local controller only.

Service—displays “Yes” when the compressor is in need of service. This indication is accompanied by either a service reminder or warning message to inform the user of the nature of the service required. Refer to the WS Controller Sequencing and Protocol Manual for details on operating compressors in sequence.

4.8

ADJUSTMENTS DISPLAY

Both the compressor control parameters and sequencing parameters can be edited at the Adjustments display of the WSPC User Interface. SeeFigure 4-11. At this display the user can view the current settings of the machine control parameters and make adjustments as necessary. Changes to the control parameters will be reflected at the WS Controller located on the compressor.

Figure 4-11: Control Parameter Adjustments Display

30

SECTION 4

ADJUSTING CONTROL PARAMETERS Listed below are the control parameters that can be edited by the user at the “Adjustments” display. The units and language appearing in the “Adjustments” display correspond to the settings applied when the User Profile was created. The WSPC must be connected to the controller (by clicking the “Connect” button) before parameter changes are allowed. Many changes to the control parameters at the WSPC interface will be reflected in the WS Controller display on the compressor. However, the compressor list is intentionally short, and limited to adjustments that might be made frequently. When a parameter change is made at the WSPC interface, the corresponding change appears at the controller after “Enter” is pressed on the PC keyboard or the cursor is positioned outside of the changed field. Likewise, a change made at the WS Controller unit causes the corresponding value to change at the WSPC interface. To edit a control parameter value: 1.

Select “Connect” in the Status Bar to connect communication between the WSPC interface and the WS Controller. Connection must be enabled before adjustments can be made at the Adjustments Display.

2.

Click in the field of the parameter to be changed and delete the current value. A double-click in the parameter field will highlight the entire value. When the parameter value is highlighted, typing over the current value will delete it and replace it with the new value.

3.

Type the new value into the selected field.

4.

Press “Enter” on the PC keyboard or click the mouse cursor on a different item. The parameter value will turn red to indicate that the request has been made.

5.

If the request is valid, the new setting will now be active (indicated by the color change from red to black). If the parameter is invalid or out of range the color will change to black and the parameter will return to its previous value.

ADJUSTABLE CONTROL PARAMETERS The following three settings affect the compressor’s response to line pressure. The compressor starts to deliver air to the system whenever pressure falls

WSPC USER INTERFACE MANUAL below the “Load” pressure and stops delivering air whenever pressure rises above the “Unload” pressure. “Load delta” is the difference between the two”. (Load Delta) = (Unload pressure) – (Load pressure)

Unload Pressure—Line pressure setpoint (psi, bar, or kpa) at which the compressor will unload and stop delivering air. When the Unload Pressure is changed, the Load pressure will usually be held constant, and the Load delta pressure differential will change automatically. Load Pressure—Pressure (psi, bar, or kpa) at which the compressor motor will start and the compressor will begin to deliver air. When the Load Pressure is changed, the Unload pressure will usually be held constant, and the Load delta pressure differential will change automatically. Load Delta—The pressure differential (psi, bar, or kpa) below the unload pressure at which the machine will begin loading. When the Load delta Pressure differential is changed, the Unload Pressure will usually be held constant, and the Load pressure will be adjusted automatically. VSD Setpoint Pressure — Available only with VSD equipped machines. The targeted pressure for the variable speed controls. This is normally adjusted near the bottom of the load/unload band. The speed will be adjusted to maintain this pressure. Most packages will allow adjustment of this over a wide range to allow tailoring of the pressure to the needs of the application. Adjustments will be automatically made to the maximum speed to operate the motor at its full capacity at any pressure. Unload Time (seconds)—Set this to the time that the machine is to run unloaded in Automatic mode before shutting off. This value is displayed in units of minutes at the WS Controller. Drain Interval (seconds)—Set this time as the desired interval between activation of the drain cycle for machines equipped with an electric solenoid drain. This value is displayed in units of minutes at the WS Controller. Drain Time (seconds)—Set this time as the number of seconds that the drain is to remain energized. Restart Time (seconds)—Set this time to the desired number of seconds before auto restart is to occur on power up. Set it to zero (0) to disable auto restart. Wye-Delta Time (seconds)—Set this as the time for

31


SECTION 4

the wye to delta starter transition. This can also be used to control the closed inlet valve with other motor controls.

other remote connection. The Administrator may set the controller for remote unloading via modbus. If so, an additional button labeled “Unload” will appear under the “Connection” button in the Status Bar when “Remote” mode is selected. See Figure 4-13.

Cost per KWH—Available only with VSD equipped machines. Sets the KWH cost value, in dollars or other currency, used in operating cost calculations. Modulation—Assigns the manner in which the machine will be delivering air (Load/Unload or Modulate).

When active, the allows the Load/Unload operation of the compressor to be manually controlled. A bright yellow box next to the Unload button indicates that the machine is being forced to unload. When the button is inactive, indicated by a darkened yellow box next to the button, the machine will operate normally.

Mode—Assigns the desired mode for controlling the compressor motor operation (Automatic or Manual).

ADJUSTING SEQUENCE PARAMETERS This group of adjustments set the controller for operation with other Sullair compressors or for remote control. Refer to the WS Controller Sequencing and Protocol Manual for the principles of operating compressors in sequence. Section 4.6 of this manual describes the features of the Sequence System Display which allows the user to monitor the operation of all the compressors connected in sequence. To configure a machine for sequencing operation: 1.

c.

The “Slave” mode is not currently used in this version. When selected, the controller will behave the same as if “Disabled” is selected.

Click in the “Sequence Mode” field to select the mode by which sequencing of the compressor is to be controlled. See Figure 4-12 .

a.

Select “Disabled” when no sequencing is desired. The machine will not operate in sequence with other machines. The compressor can still be operated as a stand alone machine.

b. Select “Remote” when the compressor is to be controlled remotely by the PC or

Figure 4-13: Unload Button During Remote Operation

Figure 4-12: Sequence Parameters

32

SECTION 4 d. Select “Hours” if the compressor is set to run in a sequence based on the machine’s sequence hour meter. Sequence hours can be adjusted to cause the compressor to run in a specific order in the sequence. e.

WSPC USER INTERFACE MANUAL 8.

Click in “eConnect ID” to provide a name that enables communication for eConnect communication. Each machine should have a unique identification between 1 and 16.

9.

Click in “Modbus address” to enter a modbus address for the compressor modbus communications on the RS232 port. The address may be between 1 and 247. The default value for the WS Controller and for WSPC software is 1. This change takes affect after the controller power is cycled off and on.

Select “COMM Number ” if the compressor is to sequence in an order based on the communication number assigned to the machine.

2. If desired, click in “Sequence hours” to preset the order the machine is to run in a sequence operation based on its hour meter. 3.

4.

5.

6.

7.

NOTE

Click in “Com number ” to select a unique communication number in relation to other machines in a sequence system. The highest com number for the compressor can be no greater the maximum number of machines set in the Machines field (step 4). This also sets the order the machine is to run in a sequence operation based on the communication number assigned to the machine. Click in “Machines” to set the total number of machines in the sequence configuration. The maximum number of machines that can be connected in a sequence consisting of WS Controllers and/or Supervisor Controllers is 16. The maximum number of machines that can be connected in a sequence that contains at least one Supervisor II Deluxe Controller is eight. Click in “Low press” to set the lowest allowable system pressure before a machine in the sequence has to start. The minimum value for the Low pressure setting is 30 psi. Click in “Recover time” to add a delay, in seconds, between subsequent start, load, and unload actions of machines in sequence. The minimum value for the Recover time is 2 seconds and the maximum is 60 seconds. Click in “Rotate” to set the time that a compressor will force a rotation between machines. This should be used for twomachine systems only. Set to 0 to disable. Typical forced rotations are daily or weekly.

The Modbus address assigned here must match the modbus address assigned in the WSPC User Profile or other Modbus applications. If the ID’s do not match, communication between the PC and the controller will be lost when the controller is cycled.

CHANGING CONTROLLER UNITS AND LANGUAGE PREFERENCES The WSPC Interface program allows the user to change display preferences of the WS Controller. The units of measure for pressure and temperature, and language preferences can be changed at the “Adjustments” display of the WSPC User Interface program. These changes are reflected in the WS Controller display. To change the WS Controller Display preferences: 1.

Change the UI Pressure unit of measure by clicking the drop-down arrow and selecting the desired unit: PSI, Bar, or kPA. See Figure 4-14.

2.

Change the UI Temperature unit of measure by clicking the drop-down arrow and selecting the desired unit: Deg F or Deg C.

3.

Change the Language preference by clicking the drop-down arrow and selecting the desired language: English, French, Spanish, German, or Italian.

33


SECTION 4

Time Field Hours:Minutes :Seconds

Figure 4-14: Units and Language Preferences

NOTE

Click to Synchronize with PC Clock

Changes to the WS Controller user interface preferences do not affect the display of units and language in the WSPC software. WSPC preferences are set as User Profiles.

TIME AND DATE ADJUSTMENTS Figure 4-15: Time and Date Adjustment

Synchronize Time and Date with PC Clock The date and time of the WS Controller internal clock can be synchronized with the PC clock at the “Adjustments” display.

To adjust the time setting: 1.

To synchronize the clocks, click on the “Synch with PC clock” button. See Figure 4-15 . The program will automatically adjust the controller clock and calendar to the same time as the computer clock.

Double-click in the hour field to select the hour value.

2.

Type the hour of the day in 24 hour format.

3.

Double-click in the minutes field and type the current minutes on the hour.

4.

Double-click in the seconds field and type the current seconds.

5.

Press Enter. The new set time will be assigned to all logs and data generated by the WS Controller.

Manual Time/Date Adjustment The WS Controller date and time can be manually adjusted when synchronizing the controller with the PC is not desired. Follow the steps below to manually adjust the time and date settings.

34

SECTION 4


NOTE The Modbus settings assigned here must match the modbus settings assigned in the WSPC User Profile or other Modbus applications. If the settings do not match, communication with the controller will be lost when the controller is cycled. Modbus Address—Click in “Modbus address” to enter a modbus address for the compressor modbus communications on the RS485 port. The address may be between 1 and 247. This change takes affect after the controller power is cycled off and on. Baud Rate—The rate of data transmission in bits per second. The overall range is 1200 to 57,600 baud. The default baud rate is 19200 bps. Parity—Data checking method for verifying accuracy of data transmission. Parity options for data checking are odd, even, none. The default setting is “Even.”

INTERNET TRANSMISSION SETTINGS Figure 4-16: Port E (RS-485) Parameters

To adjust the Date setting: 1.

Click the arrow at the edge of the month field. The Month popup list will appear.

2.

Select the current month.

3.

Double-click in the Day field and enter the current day of the month.

4. 5.

Double-click on the Year field and enter the current year using four digits. Press Enter on the PC keyboard. The new date setting will be assigned to all logs and data generated by the WS Controller.

COMMUNICATION PARAMETERS

Some controllers may be configured to allow access and transmission of data via the internet. These settings have no effect on standard controllers. The TCP/IP parameters are:

IP Address—The unique address the WSPC will use to identify and communicate with another computer via the internet or other network utilizing the Internet Protocol standard. Net Mask—used to determine what subnet an IP address belongs to. Name Server —computer server that implements a name service protocol used to correlate the server name with the IP address. Gateway—The access address allowing data to pass to and from the network.

Communication Parameters control the transmission of data to and from the WS Controller via an RS-485 serial interface. These settings allow the controller to be configured to communicate with a device having RS-485 capabilities. The RS-485 configurable parameters are listed below. See Figure 4-16 .

35


SECTION 4

SAVING PARAMETER SETTINGS

EDITING AND SEARCHING MACHINE PROFILES

The settings for the current control parameters displayed on the Adjustments display can be saved to a file which can be accessed and loaded to the WS Controller at a later date.

The descriptions may be edited to make searching easier. This is helpful if many profiles are saved on your PC.

To save the current parameter settings: 1.

Access the “Adjustments” display by clicking on the “Adjustments” tab.

2.

Click the Load/Save button on the “Adjustments” display. See Figure 4-17 .

3.

The “Machine Profiles” window will appear.

4.

Click “Read from Controller” to load the current parameter settings from the controller to the WSPC.

5.

The program will read the settings from the controller, and will generate a new profile. The new name will appear on the list as a “New Profile”

1. Click on a profile to select it. 2. Click the “Edit” button. 3.

Click in the Category 1 or Category 2 descriptions at the top of the page, and edit as desired. See Figure 4-18 .

4.

Click the “Save Edits” button. To sort and/or filter the Machine Profile name list:

a.

Sort a column by clicking in the top space above of a column by which values are to be sorted. One click will sort the column in ascending order. A second click will sort the column in descending order. Click the “Clear Sort” button to clear all sorting.

b. Filter a column by clicking on the expansion arrow in the space above the column containing the filter criteria. The arrow will present a list of the contents of the column. Select the item in the list by which the column is to be filtered. Click the “Clear Filter” to show all profiles. Figure 4-17: Load/Save Button

36

c.

Delete a Machine Profile by clicking on the profile name and then clicking “Delete.” A confirmation dialog box will appear. Click “Yes” to confirm deletion or “No” to cancel.

SECTION 4


Figure 4-18: Machine Profiles Window

LOADING PARAMETER SETTINGS

3.

Click on the Name of the saved machine profile to be loaded. Saved Machine Profiles are listed in the lower portion of the Machine Profiles window. The control parameter values for the selected profile will be shown in the upper portion of the window. These values are presented for reference only and cannot be edited.

4.

Click “Write to Controller” to load the parameters of the selected profile to the WS Controller. The parameters will immediately become active at the controller and the compressor and/or compressor system will begin operating using the new parameter values.

At the “Machine Profiles” window, contr ol parameters from a saved profile can be loaded to the WS Controller. The values stored in the saved profile will replace the parameter values displayed on the Adjustments display. When an adjustment register is loaded, the new parameter values become immediately effective at the WS Controller. To load a saved Machine Profile: 1.

Access the “Adjustments” display by clicking on the “Adjustments” tab.

2.

Click the Load/Save button on the “Adjustments” display (Figure 4-17 ).

37

BLANK PAGE

38


Section 5

MENU BAR 5.1

FILE MENU—USER PROFILES AND PREFERENCES

User Profiles are used to configure the WSPC software for a specific user or group of users. Settings made in a profile only change the appearance and action of the software program and do not affect the operation of the WS Controller or compressor. The User Profiles option allows the operator to view profile settings, modify a profile, create a new profile, save current settings as a new profile, and switch profiles.

4.

The “User Name” displays the name of the active profile. The name can be an individual name, group name, machine, etc.

5.

The “Notes” field displays information relating to the profile entered when the profile was created.

6.

The “Language” field displays the current language setting for the WSPC displays.

7.

“Units” settings display the units of measure displayed by the WSPC software. Setting of the units here will not affect the units displayed on the WS Controller interface. The following unit settings are available. Pressure—Displays pressures in units of PSI, Bar, or kPa.

USER PROFILE OPTION To view the preferences of the current running profile: 1.

Click “File” in the menu bar (Figure 5-1).

2.

Select “Profiles”. The User Profiles window will open displaying settings for the current profile. See Figure 5-2 .

3.

Temperature – Displays temperatures in units of Deg F or Deg C. Flow—Displays air flow in units of ACFM, M3/hr, M3/min, L/min, and L/sec.

To see the settings of a different profile, click the name of a profile to be viewed from the list in the lower half of the window. The settings for the selected profile will be presented in the fields in the upper section of the window.

Power —Displays power in units of KW or HP. Volume—Displays volume in units of KCF, Feet3, Gallons (US), Liters, M3, and KM3. 8.

Under “Communication Port” the settings that control communication between the WS

Figure 5-1: Profiles Menu Selection

39


SECTION 5

Figure 5-2: User Profiles Window Controller and the WSPC software can be viewed and modified as necessary. All four must be set properly for the programs to communicate. The following communication parameters can be adjusted from the User Profiles window:

Baud. RS485 is 19200 Baud by default, but is adjustable.

Parity—The method used for checking the accuracy of the flow of data between the computer and communication devices. The parity setting helps to determine if a transmission error has occurred between devices. RS232 communications of the WS Controller is always “None.” RS485 communication is “Even” by default, but is adjustable.

Modbus Address—displays the modbus communication ID. The default modbus ID value is 1 in the WS Controller, but is adjustable. Com Port—This is the PC’s communication transmission channel through which data is passed to and from the computer. Baud Rate—The communication speed in bits per second between the WS Controller and the PC interface. RS232 communications of the WS Controller is always 38400

40

When done viewing the profile settings, click cancel to exit the profile window. The “Enter Password” option box will be presented. See Figure 5-3. 9.

Select a profile and click OK to make the profile active.

SECTION 5


Figure 5-3: Select Profile (Password Box)

EDIT A PROFILE

d. At the "Power" field, click on the dropdown arrow and select the power unit as KW or HP.

To edit an existing profile: 1.

Click “File” on the menu bar.

2.

Select “Profiles”. The User Profiles window will be presented showing the settings for the current profile.

3.

Select a profile for editing from the list in the lower portion of the User Profiles window.

4.

Click “Edit” to allow editing of the profile on the upper part of the scrren.

5.

Change the profile name” by entering a new name in the “User Name” field. See Figure 54.

6.

In the “Notes” field, enter a brief note relating to the compressor system.

7.

In the “Language” field, click on the drop down arrow and select the desired language for the WSPC software.

8.

Select the desired “Units of Measure.” These settings determine the units of measure to be displayed by the WSPC software. Units selected here will not affect units displayed on the WS Controller user interface.

a. At the “Pressure” field, click on the dropdown arrow and select the pressure unit as PSI, Bar, or Kpa. b. At the “Temperature” field, click on the drop-down arrow and select the temperature unit as Deg F or Deg C. c. At the "Flow" field, click on the dropdown arrow and select the air flow unit as ACFM, M3/hr, M3/min, L/min, L/sec.

e. At the "Volume" field, click on the dropdown arrow and select the volume unit as KCF, Feet3, Gallons (US), Liters, M3, and KM3. 9.

Select the desired “Communication Port” settings. These settings control communication between the WS Controller and the WSPC software.

a. At the “Modbus Address” field, click the up/down arrows to increment to the required modbus communication ID. The default modbus value is set to 1. This number should be changed only if the modbus interface has been configured for a different port.

NOTE The Modbus Address, Baud Rate, and Parity assigned here must match the modbus parameters of the controller. If the settings do not match, communication between the PC and the controller will not occur. b. At the “Com Port” field, enter the number of the communication port to use for connecting to the PC. There are 16 com port options listed. The actual number of com ports available will vary depending on the computer system being used. The default Com Port is set to 1

41


SECTION 5

Figure 5-4: Edit Profile Window

c. At the "Baud Rate" field, click on the drop-down arrow and select the desired Baud Rate for data transmission. The overall range is 300 to 57,600 baud. The WS Controller RS232 baud rate is 38400 bps. d. At the "Parity" field, click on the dropdown arrow and select the desired Parity option for data checking: odd, even, none. The WS Controller RS232 setting is “None.” 10. When all edits are complete, click “Save Edits” to save the modified profile to memory. Clicking cancel will discard changes to the profile and exit. 11. Click the “close window button” in the upper right corner of the window to exit the User Profiles window. The edited profile will not become the active

42

profile until the it has been activated selecting the desired profile at the “Enter Password” box. Refer to Activate a Profile.

COPY A CURRENT PROFILE TO A NEW PROFILE The preferences of the current running profile can be copied to a new profile with a different name. When selected, the preferences of the current profile will be presented in the fields of the new profile. The user can keep all the profile settings or make changes to any of the profile preferences, and save the new profile with a unique name. To copy an existing profile as a new profile: 1.

While in the User Profiles window, select an existing profile with the same user level.

2.

Click the “Copy” button.

3.

In the “User Name” field, enter the new name of the profile to be saved. The name can be

SECTION 5


an individual name, group name, machine, etc.

5.

Click “OK” to activate the selected profile. Clicking “Cancel” will close the WSPC program.

NOTE A new profile cannot be given the same name of an already existing profile. 4.

Make changes to the preferences in the profile window as necessary. Edit a Profile details the steps to entering profile preferences.

5.

When the profile information has been completed, click “Saved Copied Profile” to save the profile.

6.

Click the “close window button” in the upper right corner of the window to exit the User Profiles window. The edited profile will not become the active profile until it has been activated selecting the desired profile at the “Enter Password” box. Refer to Activate a Profile.

ACTIVATE A PROFILE A profile can be made active using the “Profiles” option. To activate a profile: 1.

Click “File” on the menu bar.

Figure 5-5: Switch Profile (Password Box)

5.2

WSPC may be used to generate a comprehensive report of the controller's setup and machine history. These reports are small files that may be filed for future reference, emailed, or pasted into other documents. They may be viewed with any common text editor.

CREATE A REPORT To create a new report for the compressor: 1.

Click "Report" on the menu bar. A "Save As" box will open (Figure 5-6 ).

2.

Select the folder location to save the report. This is similar to any Windows(c) application. The large buttons on the left may be used to start browsing on a computer. The little buttons to the right of the "Save in:" box may be used to browse through folders. The large box shows other similar documents that are in the selected folder.

3.

Type in the desired File name. This is "Report.txt" in Figure 5-6 . Any Windows(c)permitted name may be used, but always end it in .txt so that it can be automatically opened later.

4.

Click "Save". Messages will appear to describe the progress.

2. Select “Login”. 3.

The “Enter Password” box will be presented. See Figure 5-5 . At the User Name field, click the down arrow to display a list of available profiles.

4.

Click on the desired profile from the list provided. If an Administrator profile is selected, a password will be required for access.

REPORTS

43


SECTION 5

Figure 5-6: Report

VIEWING A REPORT

5.3

1.

Browse to the folder that holds the report. Use the "My Documents" or "My Computer" browsers provided with Windows(c).

2.

Locate the report file. If it ends with ".txt", simply double-click it to open. Most PC's are set up to use "Notepad" as the text file editor. See Figure 5-9.

3.

Use the menu "Format" > "Font" to select a suitable font for viewing. Text reports are generally best when viewed with a fixed font. "Courier New" and "8pt" are a good selection initially.

Use the "Com Port" menu item to select different communications ports on the PC. In most cases, a PC will use its first communications port (COM1) as the connection to external devices like the WS controller. However, some PC's may have additional ports already assigned to other devices. WSPC must be set up with the number of the PC port that is being used to connect to the WS controller. When this is done, the new port will be saved in the active user profile.

4.

5.

44

This is a text version of the on-screen information normally viewed with WSPC. Refer to sections of this manual for a complete description. Additional text may be inserted by clicking on the desired point in the report, and simply typing. When complete, click "File" > "Save as", and give the file a new name to preserve the original data.

COMMUNICATIONS PORT

To select a different port: 1.

If the "Connect" indicator in the left bar is bright green, click on the connect button to disconnect WSPC.

2.

Click on the "Com port" menu item. See Figure 5-7 .

3.

WSPC will search and list the ports available on the PC

4.

Click to select the port being used for the cable to the controller.

SECTION 5 5.

Click OK

6.

Click the "Connect: button on the left pane to start communications with the controller.

5.4


INFORMATION ABOUT WSPC

Click on the "About" menu item to find information about the WSPC program. This includes the default folder location used for the program and its files. See Figure 5-8 .

Figure 5-7: Com Port Menu

Figure 5-8: About Information Box

45


SECTION 5

Figure 5-9: Report.txt

46


Section 6

VARIABLE SPEED DRIVE (VSD) 6.1

VSD OPERATION

Generally the WSPC functions operate in the same manner for VSD machines as with non-VSD machines. When a VSD compressor is connected to the WSPC, the program provides additional functionality for monitoring and controlling VSD operation. This section defines those additional WSPC functions that are available for VSD compressors.

6.2

COMPRESSOR DATA TAB

When a VSD machine is connected to the controller, additional VSD related parameters are displayed at the Compressor Data screen. See Figure 6-1. The data shown indicate current, recent and lifetime performance of the VSD compressor package. Lifetime data are averages or totals since the time the compressor was commissioned. Recent data are averages and totals since the last reset. Current data show instantaneous flow rate and power estimates of the compressor package.

VSD Performance Data

Figure 6-1: Compressor Display Tab – VSD Compressor

47


6.3

VSD PERFORMANCE DATA

Figure 6-2 shows a sample display of VSD performance data for a compressor operating under normal conditions. A description of the VSD data is presented below:

Capacity indicates approximately how much air is being delivered by the compressor package in CFM and percent of the compressor's full capacity. The Current data is updated frequently and shows the instantaneous delivery rates. Recent shows the recent average since the Clear Recent Data button was clicked and Lifetime shows the average since the machine was commissioned. Capacity % shows approximately how much air is being delivered by the compressor package as a percentage of the compressor's full capacity. The Current data is updated frequently and shows the instantaneous delivery rates. Recent shows the recent average, and Lifetime shows the average since commissioning. Power indicates the amount of power being used to

SECTION 6 operate the VSD compressor. The power is presented in kilowatts (KW) approximating the compressor’s total power usage. The Current power data is updated frequently and shows the instantaneous power usage rates. Recent shows the recent power usage average, and Lifetime shows the average power usage since the machine was commissioned.

Power % shows the amount of power being used to operate the VSD compressor expressed as a percentage of the compressor’s estimated usage when operating at full capacity. The Current power data is updated frequently and shows the instantaneous power usage rates. Recent shows the recent power usage average, and Lifetime shows the average power usage since the machine was commissioned. Hours indicates the amount of time (in hours and minutes) that the machine has been operated since the Clear Recent Data button was clicked for Recent and since the machine was commissioned for Lifetime.

Figure 6-2: VSD Performance Data

48

SECTION 6 Total Delivery indicates the estimated total amount of air delivered since the last reset for Recent data and since the machine was commissioned for Lifetime data; measured in thousands of cubic feet (KCF). Total Energy indicates the estimated total electrical energy consumption since the last reset for Recent data and since the machine was commissioned for Lifetime data; measured in Kilowatt-Hours (KWH). Total Cost indicates the cost for the electrical energy since the last reset for Recent data and since the machine was commissioned for Lifetime data; calculated as dollars (or other units of currency). Savings vs Load/Unload shows the estimated additional cost to deliver the same quantity of air using load/unload compressor control since the last reset for Recent data and since the machine was commissioned for Lifetime data; calculated as Dollars. This value is calculated using the Compressed Air Challenge curve for Load/Unload. Savings vs Inlet Mod. shows the estimated additional cost to deliver the same quantity of air using inlet modulation compressor control since the last reset for Recent data and since the machine was commissioned for Lifetime data; calculated as Dollars. This value is calculated using the Compressed Air Challenge curve for Inlet Modulation. Savings vs Variable Displacement shows the estimated additional cost to deliver the same quantity of air using variable displacement compressor control since the last reset for Recent data and since the machine was commissioned for Lifetime data; calculated as Dollars. This value is calculated using the Compressed Air Challenge curve for Variable Displacement. Refer to the WS Controller Instruction Manual for descriptions of VSD functions and handling of

WSPC USER INTERFACE MANUAL warning and fault messages.

6.4

CLEAR RECENT DATA

The Recent data column displays average and total values since the date of the last reset. Recent data history may be reset to zero (like a trip odometer in a car) by clicking the Clear Recent Data button at the bottom of the VSD Performance box. A few seconds after the button is pressed, all values in the Recent columns of the VSD Performance group and the Delivery History window will be set to zero. New machine statistics will immediately begin to be calculated and the Recent columns will soon be populated with the new Recent data values.

6.5

DELIVERY HISTORY

Click on the Delivery History button to open the Delivery Profile window. See Figure 6-3. This window displays a detailed breakdown of the compressor operation over a Recent period or over the Lifetime of the machine. The Delivery Profile shows the amount of time the compressor has operated at various rates of delivery. For example, the values shown in Figure 6-3 correspond to a compressor that has been delivering approximately 15% of its rated capacity for 24 minutes; it ran 10 minutes at 25% capacity, etc. These values may be used for further estimates of compressor options during plant surveys and evaluations. The Recent values shown in the Delivery Profile window are reset to zero when the Clear Recent Data button is pressed at the VSD performance box. Click on the "Report" menu item to make a comprehensive text file that may be viewed or copied into other documents. This includes the adjustments for the variable speed drive and a report of its performance. See Section 5.2 .

49


SECTION 6

6.7

MAIN MOTOR VFD STATUS BOX

Service data related to VSD Compressors is displayed in the Main Motor VFD Status box. See Figure 6-4. The VFD Status box contains the following information:

Motor speed displays the motor speed in revolutions per minute (RPM). Motor current displays the motor current measured in Amps. Frequency displays the motor frequency measured in Hertz. Motor temp protection displays the percent of motor temperature rise. Drive temperature displays the current drive temperature measured in degrees Fahrenheit or Celsius. DC link voltage displays the drive DC link voltage. Drive Com Faults provides a count of the drive communication faults. Up/down count is the number of recent faults. Total count is the total number communication faults that have occurred.

of

Figure 6-3: Delivery (History) Profile Window

6.6

SERVICE DISPLAY TAB

This page lists the last 16 faults to occur with the compressor. It will also contain VSD related faults should they occur. The WSPC provides additional service data while operating a variable speed drive compressor. To view VSD service data, click the "Service" tab. See Figure 6-5 . The display will show the Main Motor VFD Status box containing certain technical details of the motor and drive. This information may be useful in diagnosing drive or motor problems should they occur.

50

Figure 6-4: Main Motor VFD Status Box

drive

SECTION 6


Figure 6-5: Service Tab—VSD Status

6.8

ADJUSTMENTS TAB

As discussed earlier in this manual, the adjustment tab allows the user to modify certain control parameters of the compressor operation. In addition to the general control parameters previously described, two VSD adjustments become available when the WSPC is connected to a VSD compressor. These VSD control parameters are setpoint pressure and cost per kilowatt-hour. See Figure 6-6 . To view the VSD control parameters, click the Adjustments tab to present the Adjustments display. The additional VSD parameters are located in the left column of the display. The VSD control parameters are defined as follows (ref. Figure 6-6 ):

VSD Setpoint pressure—The targeted pressure for the variable speed controls. This is normally adjusted

near the bottom of the load/unload band. The speed will be adjusted to maintain this pressure. Most packages will allow adjustment of this over a wide range to allow tailoring of the pressure to the needs of the application. Adjustments will be automatically made to the maximum speed to operate the motor at its full capacity at any pressure.

Cost per KWH—The cost per kilowatt-hour of energy is entered here. This setting is used in the cost estimates displayed in the VSD Performance box of the Compressor Data display. Value is set in dollars or other units of currency. For example, an entry of 0.070 equals 7 cents per KWH. Adjustment of the VSD control parameters is accomplished in the same manner as the adjustments of the general parameters described in Section 4.8 of this manual.

51


SECTION 6

Figure 6-6: Adjustments Tab – VSD Parameters

6.9

ADMINISTRATOR LEVEL VSD ADJUSTMENTS

Refer to Section 6: Press “Enter” or click the mouse outside of the entry field to attach the variance value. The variance value will be added to or subtracted from each measurement received by the controller.

52

The value change can be immediately observed at the controller and at the PC. on page 64 of this manual for administrator level control parameter adjustments to VSD compressors.


Section 7

ADMININISTRATOR LEVEL FUNCTIONS

NOTE This section is not required for normal machine operation.

7.1

ADMINISTRATOR LEVEL FUNCTIONS

Persons with Administrator privileges can perform all user level functions plus additional administrator options that allow greater control and more detailed adjustments of the machine parameters. These allow setups for special applications and advanced servicing by trained technicians. This section applies specifically to Administrator level operations. User level functions are described in the preceding sections of this manual and are not repeated here except where necessary in describing a specific administrator function. Therefore, persons using the program at the administrator level must be knowledgeable in all user level functions as well. It is assumed that these persons have read all previous sections of this manual before proceeding.

7.2

Figure 7-1: Password Entry Box 2.

Click the drop-down arrow on User Name and select “Default Admin” or another desired Administrator profile. When an Administrator level profile is selected, a field for password entry will be present.

3.

Type the access password and click “OK” (or press Enter).

a.

b. If no password is entered or if the password entered was incorrect, an alert will appear indicating either “No password entered” or “Password incorrect”. Click “OK”, enter the correct password and press “Enter”.

ACCESSING THE ADMINISTRATOR LEVEL

Administrator access requires a “key” file to be installed to the admin user’s PC. The WSPC installation includes the special key file along with the WSPC files. This key file requires periodic updates. The key is not required for normal Userlevel operation of WSPC. Administrator privileges are assigned when a profile is created. Accessing an Administrator Profile requires a specific password. To open the program with Administrator level access: 1.

Click on the shortcut located on the computer desktop. The WSPC program will open to the Password Entry Box. See Figure 7-1.

If the correct password was entered, the program will open with Administrator level access.

c.

If the key is will appear. WSPC may NOTE This

missing or expired, an alert Contact Sullair for update. still be used at User level. section is not required for

normal machine operation. 4.

The WSPC program will open with access to Administrator Level Functions.

If the program opens without displaying a password entry field then a User level profile was selected. Click on the down arrow next to the User Name field and select an Administrator profile for access to administrator level functions.

53


7.3

COMMISSIONING A CONTROLLER

SECTION 7 To commission a controller for a compressor model: 1.

Commissioning is the process of initializing the WS Controller for operation with a specific compressor model and type. During the commissioning process, all previous stored data (parameter values, logs, history information, etc.) is erased from the controller memory. The new default parameter values are then loaded to the controller that configure it for a particular compressor model and application.

NOTE Depending on the selected model, the commissioning procedure may alter the functions of inputs and outputs. Depress the Emergency Stop button to prevent output relays from operating inappropriately during the process.

NOTE Controller commissioning is normally a one-time event when a new controller is installed. The compressor must be stopped before beginning the commissioning process. When the compressor is running, the “Commission” option is inoperable.

Press the emergency stop button and leave it depressed throughout the commissioning procedure.

2.

On the Menu Bar select the “File” menu and click “Commission” in the drop-down option list. See Figure 7-2 . The “Commission” window will be presented.

Figure 7-2: Commission Option

54

SECTION 7 3.


Click the down arrows for the machine model for which the controller is to be commissioned. See Figure 7-3.

5.

When all appropriate attributes have been selected, click “OK”. The program will present a “Continue to Commission” option box. See Figure 7-4.

NOTE Use care to select the proper machine model. All machine attributes must match the model selected during commissioning to ensure proper and safe operation. 4.

After the Model has been chosen, select the attributes that apply to the specific machine being commissioned. Only those options that have multiple choices may be selected.

a.

Click “Hp” to select the horsepower of the compressor motor.

Figure 7-4: Commissioning Confirmation 6.

Click “Yes” to confirm commissioning the controller to the selected compressor model. Commissioning will begin and the progress of the commissioning process will be shown in the commissioning window. See Figure 75 .

7.

As the default settings are loaded to the controller, a commissioning progress meter will be presented to allow the administrator to monitor the progress of the commissioning process. When the default settings have finished loading to the controller, a final confirmation box will appear indicating that commissioning is complete (Figure 7-6 ).

b. Click “Hz” to select the compressor motor frequency. c.

Click “Pressure” to select the compressor pressure rating.

d. Click “Cooling” to select the compressor cooling method. e.

Click “Motor” to select the compressor motor phase type.

f.

Click “Volts” to select the compressor operating voltage.

g. Click “Dryer” to select the compressor dryer type.

Figure 7-3: Commission Select

55


SECTION 7

Figure 7-5: Commissioning Progress Monitor 8.

Turn the controller power off, then click “OK” to confirm.

9.

To verify, restore power and reconnect to controller. Pull the Emergency Stop button, and clear the controller fault. Verify machine information (refer to Section 4.3).

Once a controller has been commissioned, it can be used to control and monitor the operation of the compressor and log new compressor operation data. Parameters set during commissioning can be later adjusted by the end user to customize the compressor for a specific application. .

Figure 7-6: Commissioning Confirmation

7.4

MAINTENANCE DISPLAY

The Maintenance Display at the Administrator level displays the same warning and maintenance information as at the User level (Refer to Section 4.5 ). The Administrator level Maintenance display includes additional functions that allow the

56

administrator to view the maintenance information in greater detail and to reset the service and warning messages. See Figure 7-7 . The additional functions of the administrator level Maintenance display are described below. selected, “Warning History” button—When presents a table displaying a history of the 16 most recent warning occurrences.

“Maintenance History” button—When selected, presents a table displaying a history of the 16 most recent service reminders. “Reset” buttons—Resets warning messages and service reminders. Click a “Reset” button next to a warning or service reminder to delete the message from the list and clear it from the WS Controller display. “Reset All” button – Clears all warning messages and resets all service reminders. Click “Reset All” at the bottom of the list of warnings or service reminders to clear all the messages in the respective list. Service Interval fields—Allows intervals for “Hours To Next” recommended service to be set. The intervals are entered into fields of the “Hours To Next” box in the right-hand column. When a service interval is changed, the change does not become affective until the “Reset All” button under Recommended Service is clicked (Refer to Figure 77 ). When a service interval has expired, the related service reminder message will appear in a field of the Recommended Service box. A service interval set to zero (0) will disable the service reminder for that item.

SECTION 7


“Reset All” must be clicked to allow service interval change to become effective.

Figure 7-7: Maintenance Display – Admin Level

WARNING HISTORY WINDOW

ings for the machine “hours”, “date”, and “time” of the warning occurrence.

A history of the 16 most recent Warning messages may be viewed in the “Warning History” window. See Figure 7-8 . 1.

2.

b. Columns: Boxes below each warning heading will change from shaded gold to bright gold when a warning is indicated.

To access the “Warning History” window, click the “Warning History” button on the “Maintenance” display.

c.

The “Warning History” window will appear displaying the following elements:

a.

Top row header: Displays abbreviated headings corresponding to warnings that may appear on WS Controller display panel. These are broken into a compressor and dryer group - select with the tabs. Also along the top row are head-

3.

Rows: The most recent warnings are indicated on the first row below the headings. Each preceding warning is indicated chronologically down the table column.

Close the table by clicking the “Close” button.

Warning history is also included in comprehensive text report. See Section 5.2 .

the

57


SECTION 7

Figure 7-8: Warning History Window

MAINTENANCE HISTORY WINDOW

b. Columns: Boxes below each maintenance heading will change from shaded yellow to bright yellow when a service reminder is indicated.

A chronological history of the 16 most recent Service Reminders may be viewed in the Maintenance History Window. See Figure 7-9. 1.

To access the “Maintenance History” window, click the “Maintenance History” button on the “Maintenance” display.

2.

The “Maintenance History” window will appear displaying the following elements:

a.

58

Top row header: Displays six abbreviated headings corresponding to service reminders that may appear on WS Controller display panel. Also along the top row are headings for the machine “hours”, “date”, and “time” of the warning occurrence.

c.

3.

Rows: The most recent service reminders are indicated on the first row below the headings. Each preceding service reminder is indicated chronologically down the table column.

Close the table by clicking the “Close” button.

Maintenance history is also included in comprehensive text report. See Section 5.2 .

the

SECTION 7


Figure 7-9: Maintenance History Window

7.5

ADMINISTRATOR ADJUSTMENTS (ADMIN) DISPLAY

The Administrator Adjustments (Admin) display tab is available only when an administrator level profile is active. This display allows the administrator to edit the ID’s of specific controller inputs and to make zero calibration adjustments of measured values between the compressor system and the controller. The Admin user can view the current assignments of the controller input registers and make adjustments as necessary. See Figure 7-10 . The inputs shown in the figure are for reference and vary based on specific machine configurations.

Changes can only be made at the Admin display while the compressor is stopped. When the compressor is running, the fields of the Admin display are inactive. Changes made at the Admin display will be applied to the WS Controller within a few seconds after entry. Some changes may not be shown properly on WSPC. To ensure correct information, always click the "Connect" button when finished with this page to disconnect from the controller. Click "Connect" again to reconnect and update the WSPC displays.

59


SECTION 7

Figure 7-10: Administrator Adjustment Display

Described below are parameters that can be edited by the Administrator at the “Admin” display. The units and language appearing in the “Administrator Adjustment” display correspond to the settings applied when the Administrator profile was created.

SIGNAL ADDRESS FUNCTION

few seconds after the compressor starts.

Remote Operate—Operates the compressor when on. Remote Master – Uses Remote inputs when on. Remote Unload—Forces the compressor to unload when on. Refer to the Sequencing manual for details on using the remote inputs.

Refer to Figure 7-10 . The left section contains a list of controller functions, and allows selection of signals to operate the function. This allows special field setups for special applications.

Dryer Warning—Generates Dryer Warning when on.

General Fault—Generates an Option Input Fault when on.

Phase Monitor Fault—Generates Phase Monitor Fault when on.

General Warning—Generates User Option Warning when on.

Water Pressure Fault—Generates Water Pressure Fault when on.

General Runtime Fault—Generates an Option Input Run Fault when on. This fault is enabled a few seconds after the compressor starts.

Factory-Defined A through E—Operates the factory defined relay when on. Actual relay assignments are shown, and depend on compressor model.

General Runtime Warning—Generates a User Option Warning when on. This warning is enabled a

60

Dryer Fault—Generates Dryer Fault when on.

SECTION 7


DIGITAL INPUT OPTIONS (DROP-DOWN ARROWS)

OFF—Turns the relay OFF.

The following options may be selected for a Digital Input by clicking on the associated drop-down arrow (refer to Figure 7-10 ):

Drain—Activates the relay when the Drain solenoid is actuated. Running—Activates the relay when the compressor is Running.

ON—Activates the function continuously. The input signal is ON.

Enabled—Activates the relay when the compressor is Enabled.

Off —Deactivates the function. The input signal is OFF.

Fault—Activates the relay when a Fault condition occurs.

Running—Activates the Compressor is running.

the

Warning—Activates the relay when a Warning condition occurs.

Din 7, 8, 9, 4 ON—Activates the function when the input signal at the respective input (7, 8, 9, or 4) is ON. The list of available inputs varies with models.

Fault or Warn—Activates the relay when either a Fault or a Warning occurs.

function

when

Din 7, 8, 9, 4 OFF—Activates the function when the input signal at the respective input (7, 8, 9, or 4) is OFF. The list of available inputs varies with models. MB Remote ON—Activates the function when the Modbus Remote signal is ON. MB Timer 1, 2, 3 ON —Activates the function when the respective Modbus Timer signal (1, 2, 3) is ON. MB Remote OFF—Activates the function when the Modbus Remote signal is OFF. MB Timer 1, 2, 3 OFF —Activates the function when the respective Modbus Timer signal (1, 2, 3) is ON.

FACTORY-DEFINED OUTPUT OPTIONS (DROPDOWN ARROWS) The following options may be selected for a Factory Defined Relay (A – E) by clicking on the associated drop-down arrow (refer to Figure 7-10 ):

ON—Turns the relay ON.

Master Enabled—Activates the relay when the controller is enabled as the Master device in a sequence. Dryer Running—Activates the relay to operate an integrated refrigerated dryer.

ANALOG SIGNAL ZERO TRIMS The Analog Zero Trim settings allow for calibration of various analog inputs. Refer to Figure 7-10 . Analog inputs are assigned to sensors used to measure specific characteristics of the compressor system. The Analog Signal Zero Trims function is used to adjust the displayed value of the measurements to equal the measured value at the analog device. Sensor Calibration on page 63 provides steps on calibrating analog input measurements. The inputs used vary with compressor models and design. The display will indicate which sensors are active by indicating their function. Typical analog input assignments are shown below.

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ASSIGNING DIGITAL INPUTS MAXIMUM USER UNLOAD SETTINGS The Maximum User Unload settings allow the maximum limit to be set for the compressor unload pressure. These limit the setting for the User-level adjustment of unload pressure.

To make adjustments at the “Admin” Display (Refer to Figure 7-11):

1.

Refer to Figure 7-10 .

Load/Unload Mode—Sets the maximum Unload pressure limit for the compressor when the machine is operated in Load/Unload mode. Modulating Mode—Sets the maximum Unload pressure limit for the compressor when the machine is operated in Modulating mode.

DISABLE WARNING RESET Current versions of WS Controllers reset warnings whenever the start or stop button is pressed on the keypad. The administrator may disable this feature, and require all warnings to be reset by WSPC only. Refer to Figure 7-10 . 1.

Select the “Start Button” check box to disable reset by the start button.

2.

Select the “Stop Button” check box to disable reset by the stop button.

62

Click at the WSPC to connect communication between the computer and the WS Controller. Connection must be enabled before adjustments can be made at the Admin display.

2. Press (Stop) at the controller to stop the compressor operation. The compressor must be stopped before adjustments can be made at the Admin display. 3.

Click on the drop-down arrow at the right of the row containing the name of the function to be reassigned.

4.

In the drop-down list, select the input to assign to the corresponding function. The new assignment will become active a few seconds after entry.

AI0

AI1

AI2

AI3

AI4

AI5

Separator

Temp 1

Temp 2

Temp 3

Sump Pressure

Line Pressure

Other Pressure

(Sump-Line) Pressure

SECTION 7


UNLOAD (REMOTE) BUTTON The administrator may set up the controller for remote control by Modbus. To do so, select the “Modbus timer 1” to control the “Remote Unload” function above. Also select “Remote”, Hours”, or “ComNum” Sequence mode on the User’s “Adjustments” tab to enable remote control. When this is done, an additional button labeled “Unload” will appear under the “Connection” button in the Status Bar. See Figure 7-12 . Click on the “Unload” button to toggle the compressor operation. A bright yellow box next to the Unload button indicates that the machine is being forced to unload. A darkened yellow box next to the button indicates that the machine will operate normally. If continuous communication from the PC is not received, the compressor will revert to normal operation within a couple minutes.

Click Connect to enable Admin Adjustments

Figure 7-12: Unload Button During Remote Operation

SENSOR CALIBRATION The compressor is equipped with sensors that monitor and measure various characteristics of the compressor performance. These values are received at the WS Controller as analog input signals from the sensor. Most sensors input can be adjusted to calibrate the reading at the controller with the actual measured value at the sensor location. This section will describe the steps necessary to calibrate the Line Pressure transducer. Calibrate other sensors in the system in a similar manner.

}

Analog Signal Zero Trims for calbration adjustments

Click drop-down arrow to select input assignment Figure 7-11: Administrator Adjustment Display

63


P2 PRESSURE TRANSDUCER CALIBRATION The Line pressure transducer input measurement is assigned to analog input AI4 at the controller. This pressure transducer measures the output line pressure at the compressor main header. Over time, the pressure transducer may vary slightly producing an inaccurate reading at the controller. Periodically and prior to operating multiple controllers in a sequence, the controller should be calibrated to reflect the same pressure measurement as that measured at the Line transducer location. The calibration should be performed when the system is at a stable pressure with minimal load on the output lines. Use the following steps to calibrate the WS Controller Line pressure reading (refer to Figure 711): 1.

Measure the parameter (Line pressure) at the sensor (transducer) location using an independent certified gauge.

2.

At the WSPC interface, observe the Line pressure reading in the “Compressor Status Bar.” Compare this reading with the measurement at the transducer location.

SECTION 7 3.

If the measurement on the external gauge at the transducer does not match the discharge pressure reading at the PC, click on the “Admin” tab to access the Administrator Adjustments display.

4.

Under the category “Analog Signal Zero Trims,” highlight the values in the analog sensor field labeled AI4 (Line pressure input).

5.

Enter the value necessary to increase or decrease the Discharge reading at the PC to equal the measurement at the transducer. The calibration variance limits are –7.5 to +7.6.

6.

Press “Enter” or click the mouse outside of the entry field to attach the variance value. The variance value will be added to or subtracted from each measurement received by the controller. The value change can be immediately observed at the controller and at the PC.

VSD Package Settings

Figure 7-13: Administrator Adjustments

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VSD PACKAGE SETTINGS When a VSD compressor is connected to the WSPC, additional VSD related adjustments are available on the Admin display. See Figure 7-13. These values, located in the right side of the screen are only displayed when a VSD machine is connected. In most cases, the factory settings are satisfactory for normal compressor operation. Should modification of the parameters be necessary, adjust the VSD Package Settings in the same manner as described in Assigning Digital Inputs on page 62. VSD Package Settings The VSD Package Settings are described below (ref. Figure 7-14):

WSPC USER INTERFACE MANUAL Gain control I and Gain control P—A value of 10 is recommended for each of these controls for almost all end-use applications. Additional stability functions are built into the controls that make these values non-critical and virtually eliminate the need for tuning. However, extremely large- or small-volume systems may benefit from some adjustment. Consult the factory if stability problems are encountered. Autoset %—Allows speed adjustments to be made automatically when changes in the Setpoint pressure are made causing the compressor to operate at its full rated power capability. This should normally be set to 100. If it is desired to run the compressor at less than full capacity, simply set this to a lower value. For example, set the Autoset % to 80 to operate a 50HP compressor at 40HP maximum. The WS Controller will calculate the necessary speed adjustments whenever the setpoint is changed. Autoset may be disabled by setting this value to 0 % allowing the speed to be adjusted manually. However, this is not recommended and can cause improper machine operation. Minimum Speed—is normally left at the factory setting, but may be increased. Enter the desired frequency multiplied by 10 (e.g., 250 for 25.0 Hz). Maximum Speed—If Autoset is enabled, the maximum speed will be set automatically as appropriate for the machine and setpoint pressure. If Autoset is disabled, the frequency will be required to be entered manually to control the range of operation. Enter the desired frequency multiplied by 10 (e.g., 814 for 81.4 Hz). Motor Protect Amps—Maximum amp setting for VSD operation. This should be set for the LOWER of: 1.

Maximum motor amps. This is FLA times service factor, unless a specific SFA is shown. For 460V/60Hz motors connected 400V/60Hz, multiply the 460V nameplate ratings by 1.15.

2.

Rated drive current. This is shown on the drive nameplate. This will usually be the limit for most 460V compressors.

Figure 7-14: VSD Package Settings

Flow calibration—The flow indicator sets the nominal (100%) flow value for the machine operating under typical conditions. This value may be adjusted as needed for specific applications and operating conditions. Power calibration—The power indicator sets the nominal (100%) power value for the machine operating under typical conditions. This value may be adjusted as needed for specific applications and operating conditions.

Slow Acc/Dec—Setting for controlling VSD acceleration and deceleration. The factory settings are based on standard motors, and this setting is 0. If a special motor is applied, this setting may be increased to eliminate drive overvoltage during deceleration. Slower settings will reduce system stability, and may require additional air storage.

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Figure 7-15: Import Data Screen

SAVING AND LOADING ADMINISTRATOR PARAMETERS Administrator parameters may be Saved and loaded by using the Load/Save button on the “Admin” tab. The procedures are identical to those described for User Adjustments in Saving Parameter Settings on page 36 and Editing and Searching Machine Profiles on page 36.

IMPORT COMMISSION DATA The commissioning parameters will be updated from time to time as new models or features are added to the line of compressors. When this happens, a commission data text file will be distributed. This allows easier distribution, including simple e-mail attachments. It also will allow the update without affecting other WSPC preferences and saved information. The procedure is simple and fast, and should be done following any distribution from Sullair.

66

1.

Copy the new file to your PC. The preferred location is with the other WSPC program files. You may use “Import Other Data” to copy files from other locations to this folder.

2.

Start WSPC. You do not need to be connected to a controller.

3. Select the “Admin” tab. 4.

Click the “Import Commission Data” tab.

5.

Select the file with the new commission data. See Figure 7-15 . You may browse to other locations, if necessary.

6. Click the “Open” button 7.

Confirm or Cancel on the confirmation box. All old commissioning data is cleared when you confirm.

8.

Wait while the data is updated. This takes about a minute.

9.

A final confirmation box will confirm that the job is completed.

SECTION 7

IMPORT OTHER DATA This is provided simply as a tool to copy files from other locations into the WSPC folder. This may be used on some update distributions. To import: 1.

Start WSPC. You do not need to be connected to a controller.

2.

Select the “Admin” tab.

3.

Click the “Import Other Data” tab.

4.

Browse to the folder and select the desired file.

5. Click the “Open” button 6.

Confirm or cancel the action.

RESTORE FACTORY DEFAULTS This button may be used to restore all adjustments to the settings following the most recent commissioning. This may be used to correct inadvertent misadjustments. All machine history will be retained. This feature is available only if the controller has been previously commissioned with WSPC 2.0 or later, and with controller software 02250165-315 or later. Use the "Machine Info" tab of WSPC to check prior commissioning. If the Model and other boxes in the lower section are filled, the adjustments may be restored. To restore default settings: 1.

Stop the machine and press the Emergency Stop button.

2.

Create a report to record the adjustments prior to restoring defaults.

3.

Click the Admin Tab. Click the "Restore Factory Defaults" button.

4.

Click the "Connect" button to disconnect from the controller.

WSPC USER INTERFACE MANUAL 5.

Disconnect and restore power to the controller.

6.

Click the "Connect" button one more time to reconnect to the controller.

7.

Create a second report to record the adjustments after the restoration.

8.

Pull out the Emergency Stop button. Clear the fault. Check the machine for proper operation.

7.6

MODBUS FUNCTIONS

The “Modbus” display is available only when an Administrator level profile is active. Communication transactions between the WSPC program and the WS Controller may be monitored at the “Modbus” display. None of this is essential for machine operation, but may be used for demonstration purposes if setting up a dedicated Modbus network. See Figure 7-16 . Refer to the WS Controller Modbus Specification for information on using modbus with the WS Controller and a complete list of associated commands. The data communicated represents compressor operating mode and states, including faults and warning signals, compressor temperatures and pressures, machine run times and intervals, VSD performance, digital I/O states, sequence status, and other machine parameters. The messages appear in hexadecimal or decimal form. The WSPC transmits a request for information or send commands to control the compressor operation. The controller responds with the requested data or an acknowledgement to the control command. Communication must be “Connected” between the PC and the controller to perform modbus functions. Connection is indicated by the box left of the “Connect” button appearing bright green.

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SECTION 7

Figure 7-16: Modbus Display

MONITORING MODBUS COMMUNICATIONS Three modes of monitoring may be selected by clicking the radio button. When monitoring, the WSPC request will always be shown in the “Command” data window in hex form. The WS data will be shown in the lower window in either Hex or Decimal format.

3.

Use the drop down list to select a block of data of that type. These will be in blocks of up to 50 registers.

4.

Click the “Step” button to refresh the data.

Off —Stops monitoring, but continues to display the most recent communication. Continuous – monitors the normal WSPC communication with the controller. Step—Allows the Administrator to select a given block of data for monitoring. See Figure 7-17 . To use step monitoring: 1.

Click Step radio button in the Mode box.

2.

Use the drop-down list to select a parameter type. Options are User Inputs, Admin Inputs, User Holding, and Admin Holding. Figure 7-17: Modbus Monitoring

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READING AND WRITING SPECIFIC REGISTERS The Administrator is also able to select a specific register for monitoring or changing. Always use the decimal format when doing this. See Figure 7-18 . To read a register: 1.

Click the “Decimal” format.

2.

Click in the Address box for the Input or Holding register, and enter the desired register number.

3.

Click the “Read” button to get the current value.

To change a holding register: 1.

Click the “Decimal” format.

2.

Click in the Address box for the Holding register, and enter the desired register number.

3.

Click the “Read” button to get the current value.

4.

Click in the Value box, and enter the desired value.

5.

Click the “Write” button to send the request to the controller.

6.

Click the “Read” button to verify the new value.

7.7

DRYER SETUP DISPLAY

This tab is for use with compressor packages with integrated dryer controls. This is available on WS controller software version 02250174-082. These packages should have been factory commissioned as dryer models, and will be shown as such on the Machine Info Display (see Section 4.3) and on reports. This commissioning procedure sets up all the necessary functions for normal integrated dryer

operation. Adjustments on this display are intended for special applications where the default settings may need to be changed. These settings are administrator-level and are intended for trained servicers only. Stop the compressor prior to making any adjustments. Since these adjustments also affect operation of an output relay, depress the emergency stop button to prevent relay operation until all adjustments are completed. Click the "Dryer" tab to show the dryer setup display. This will always show the current settings. If the compressor is stopped, the settings may be changed.

Integrated Dryer —Whenever this setting is changed, the controller will alter all remaining settings, and change its operations as appropriate. This may be used to disable all dryer functions during service. Be sure to disconnect all wiring and piping to the dryer during service, and to reconnect all wiring and piping when service is completed. Restore power, click the down arrow and select "Integrated Dryer" or "None" to set up default settings: Compressor Runs on Dryer Fault—This is unchecked by default. If a dryer fault occurs, the dryer and compressor will both stop, and a fault will be recorded into the WS controller. Correct the source of the fault, then reset the fault using the WS controller keypad and resume operation. If this is checked, dryer faults will stop operation of the dryer only. The compressor will continue to run. This will be recorded as a WS controller warning.

Start Up Load Delay —This is set to 5 minutes default whenever integrated dryer operation is initially selected. When initially starting the compressor package, the dryer also starts, but the compressor will initially be forced to run unloaded for

Figure 7-18: Modbus Registers

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this amount of time. The WS controller will indicate that the compressor is precooling the dryer. Once this period is over, the compressor operates normally, and the dryer runs continuously.

the adjustment shown on the "Admin" Display, and is presented here for convenience when setting up a dryer. Set this for the additional drop in pressure from the dryer.

Dewpoint High Warning Temperature—This is set to 50 degrees F (15 degrees C) default whenever integrated dryer operation is initially selected. The warning functions become active when the dryer is running. A dryer warning occurs if temperature cannot be brought below this temperature. If the temperature remains 5 degrees higher than this setting, the dryer will stop and the controller will record a high temperature fault or warning.

Digital Output 7 —This setting will be adjusted to a "Dryer Running" function whenever integrated dryer operation is initially selected. This is a duplicate of the adjustment shown on the "Admin" Display, and is presented here for convenience when setting up a dryer. This is the proper setting if the dryer control is wired to digital output 7 of the WS controller. If the dryer is controlled by other means, this relay is free to be used to signal other information. This setting will be adjusted to an "Alarm" function whenever integrated dryer operation is disabled.

Separator offset—This setting will be adjusted to a model-specific setting whenever integrated dryer operation is initially selected. This is a duplicate of

Figure 7-19: Dryer Setup Display

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WSPC 02250167-859 R01

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