MODEL SS2 SERIES

MICROCONTROLLER
AIR MONITOR ASC

OPERATION SUPPLEMENT

CompAir LeROI
P.O. Box 927
211 E. Russell Road
Sidney, OH 45365-0927

Telephone: +01 (937) 498-2500

Facsimile: +01 (937) 492-3923

URL www.compairusa.com
O/M SS2 SERIES
6/09
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 AIR MONITOR ASC
Table of Contents
Page

Control Panel Diagram .............................................................................................................. 4

General Information................................................................................................................... 5

Analog Inputs............................................................................................................................. 6

Digital Inputs .............................................................................................................................. 6

Safety Functions ........................................................................................................................ 6

Starting ...................................................................................................................................... 7

Stopping..................................................................................................................................... 7

Emergency Stop ........................................................................................................................ 7

Pressure Control........................................................................................................................ 8

Fault Finding .............................................................................................................................. 9

Pressure & Operation Settings ................................................................................................ 12

Programmable Service Timers ................................................................................................ 13

Machine Configuration Settings............................................................................................... 14

Menu Key Functions................................................................................................................ 14

Menu Display Functions .......................................................................................................... 14

Setting Service Timers ............................................................................................................ 15

Wiring Schematic .................................................................................................................... 16

Menu Tree, Complete.............................................................................................................. 17

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 GENERAL INFORMATION

SAFETY FUNCTIONS • Separator differential

• Reverse rotation
• Emergency stop • Over pressure
• High temp. shut down • Main motor overload
• Wrong motor rotation • Fan motor overload
• Excess pressure • High oil discharge temp.
• Pressure probe fault • High air discharge temp.
• Temp. probe fault
• High temp. warning
• Air filter warning
• Oil filter warning
• Oil separator warning
• Air filter lifetime
• Oil lifetime
• Oil filter lifetime
• Oil separator lifetime
• Running hours
• Loaded hours
• Last ten faults stored
• With clock time and date

COMPRESSOR MOTOR START

• Keyboard on controller
• Digital input
• RS485 communication line

COMPRESSOR MOTOR STOP

• Keyboard on controller
• Digital input contact
• RS485 communication port

CONTROL MODES

Standard “Air Monitor”

• Continuous
• Auto – dual

STATUS / READOUT

• Temperature degrees celsius or

Fahrenheit
• Pressure psig or bar

MIMIC PANEL INDICATORS

• Air filter differential

• Oil filter differential

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ANALOG INPUTS
The AIR MONITOR ASC controller analog
inputs are as follows:
1. DELIVERY AIR PRESSURE - This
input is to monitor the delivery air
pressure and prevent dangerous
overpressure.
2. COMPRESSOR DISCHARGE TEMP-
ERATURE - This input is used to
monitor the outlet air / oil mixture
temperature, which will protect the
compressor element from overheating.
3. SEPARATOR DISCHARGE TEMP-
ERATURE - This input is used to
monitor delivery air temperature.
DIGITAL INPUTS
The digital inputs are as follows:
1. EMERGENCY STOP - This is the only
fixed input that stops the machine
instantly.
2. OIL FILTER DIFFERENTIAL SWITCH
– Not used on SS2 Series Compressors
3. AIR FILTER DIFFERENTIAL SWITCH -
This input monitors high differential
pressure in the systems air filter. An
alarm warning will be given if this signal
is detected.
4. AIR/OIL SEPERATOR DIFFERENTIAL
SWITCH - This input monitors high
differential pressure in the systems air /
oil separator. An alarm warning will be
given if this signal is detected.
5. MOTOR ROTATION SWITCH - This
input checks that the compressor motor
is running in the proper direction when
the machine is started. If the motor is
turning in the wrong direction the
compressor will immediately shut down.
6. EXCESS PRESSURE SWITCH - This
input protects the system from
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producing a too high pressure. If a too
high pressure is detected, the
compressor will immediately shut down.
The standard set point is set above the
HP rating.
7. START/STOP SWITCH - This input is
for remote starting and stopping by use
of a single pole, single throw switch.
Close to start, open to stop.
SAFETY FUNCTIONS
SHUTDOWN CONDITIONS - Protects unit
and operator. From dangerous conditions.
ALARM WARNING CONDITIONS -
Indicates conditions that may lead to a
compressor shutdown. The alarm warning
gives prior notice to shutdown indicating that
the compressor may need service.
MAINTENANCE CONDITIONS - These
conditions are signaled to indicate that
routine maintenance is necessary for the
unit to operate correctly.
START INHIBIT FUNCTIONS - These
conditions prevent the unit from starting,
Thus making sure the unit does not start
while in a state that may cause damage to
the compressor.
Each safety function generates an error
code when activated. The various codes are
as follows:
ERROR 1: EMERGENCY STOP; Shutdown
ERROR 2: COMPRESSOR DISCHARGE
TEMPERATURE TOO HIGH; Shutdown
ERROR 3: WRONG MOTOR ROTATION;
Shutdown
ERROR 4: EXCESS PRESSURE;
Shutdown
ERROR 5: PRESSURE PROBE FAULT;
Shutdown
ERROR 6: TEMPERATURE PROBE
FAULT; Shutdown
ERROR 7: COMPRESSOR & FAN MOTOR • The motor starter is activated
OVERLOAD; Shutdown
• After the compressor is running, the
ERROR 8: SEPARATOR ELEMENT start procedure is terminated and control
OUTLET TEMPERATURE TOO HIGH; is passed to the pressure control system
Shutdown

ERROR 9: AIR FILTER PRESSURE COMPRESSOR MOTOR STOP

DIFFERENCE TOO HIGH; Warning
The compressor can be stopped for two
ERROR 10: OIL FILTER PRESSURE
reasons: through a stop command
DIFFERENCE TOO HIGH; Warning
(keyboard, digital input or RS-485
(Disabled)
communication line) or because a shutdown
condition was detected. This will result in the
ERROR 11: OIL SEPARATOR PRESSURE
following sequence being executed.
DIFFERENCE TOO HIGH; Warning

ERROR 12: AIR FILTER LIFETIME • Unload the compressor and initiate a
EXPIRED: REPLACE; Maintenance programmable unload run on timer.
Condition (Timer = 0 in case of shutdown)

ERROR 13: OIL LIFETIME EXPIRED: • Allow the run on timer to count down to
REPLACE; Maintenance Condition 0 while keeping the compressor running.

ERROR 14: OIL FILTER LIFETIME • Stop the compressor. (Starter OFF)
EXPIRED: REPLACE; Maintenance
Condition • Initiate a blow down timer to allow the
motor to stop and completely blow down
ERROR 15: OIL SEPARATOR LIFETIME the internal pressure.
EXPIRED: REPLACE; Maintenance
Condition
EMERGENCY STOP
COMPRESSOR MOTOR START
In case of an emergency, press the
The compressor will start by means of the emergency stop button and the unit will stop
keyboard, digital control input or the RS-485 immediately and the system will blow down.
communication line. Before the unit will start
a check procedure is done to see that: NOTE:
THE EMERGENCY STOP BUTTON
• There is no start inhibit condition SHOULD ONLY BE USED IN A GENUINE
EMERGENCY AND MUST NOT BE USED
• There is no shutdown condition AS THE NORMAL METHOD OF
STOPPING THE COMPRESSOR.
• The unit has blown down properly

• The unit is not running already

• The operator is not running a diagnostic

test or con-figuring the machine

If all off the above is O.K. the start

procedure will continue as follows:

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PRESSURE CONTROL

The basic software supports the pressure

control modes described below to control
the delivered air pressure; all of these are
based on the delivery air pressure reading.

CONTINUOUS CONTROL - In this mode

the compressor runs continuously after a
start command until a stop command is
given. If the delivered air pressure is below
the (programmable) unload pressure the
compressor intake valve modulates allowing
air to be delivered to the pressure network.
When the air pressure reaches the
(programmable) unload pressure the
compressor unloads, air is then no longer
being delivered to the pressure net.

AUTOMATIC CONTROL -
This mode is essentially the same as
continuous control with one additional
feature: if the compressor remains unloaded
for a (programmable) number of minutes the
compressor motor is stopped. After stopping
the motor the controller keeps monitoring
the system pressure, if it goes below the
load pressure the compressor is
automatically restarted.

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 FAULT FINDING
Below is a list of shutdown and warning fault should occur use the list below to as a
messages along with the possible causes guideline to resolve the problem.
and the action required for servicing. If a

1. SHUTDOWN MESSAGES

Message Displayed Possible Cause Action Required

“Emergency Stop” (1) Emergency Stop (1) Check cause of fault and rectify.
Switch operated. Turn Emergency Stop Switch to
release latch. Press RESET.

(2) Starter circuit fuse blown. (2) Check cause and rectify.

“Motor fault” (1) High ambient temperature. (1) Check room ventilation.
(Motor Overload
Amperage) (2) Insufficient cooling air flow. (2) Inspect/clean: enclosure filter,
ducting; motor cooling air intake.

(3) Fan operation/rotation incorrect. (3) Check and rectify electrical circuit.

(4) Low voltage/high current. (4) Check power supply

(5) Thermal overload. (5) Check setting and reset

Incorrectly set.

“Air Temp Fault” (1) High ambient temperature (1) Check room ventilation
(Air Temperature
Fault) (2) Insufficient cooling water flow (2) Check water supply. Check
adjustment of water valve
Inspect/clean water strainer
Inspect/clean oil cooler

(3) Temperature sensor fault. (3) Rectify/renew

(4) Sensor wiring fault. (4) Check wiring

“High press fault” (1) Compressor is failing to unload. (1) Check/renew solenoid. Operated
(High Receiver unloader valve. Check that suction
Pressure) regulator inlet valve is closing
fully. Rectify if necessary.

(2) Pressure transmitter fault. (2) Check/renew pressure

transmitter.

“Motor rot fault” (1) Supply wiring configuration (1) Check supply wiring
(Motor Reverse Incorrect, motor rotation connections. Reverse 2
Rotation) Will be incorrect. Incoming power lines.

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2. WARNING MESSAGES

Message Displayed Possible Cause Action Required

“Air filt P warn” (1) Intake air filter blocked. (1) Check/renew element.
(High Air Filter
Differential (2) Filter pressure switch fault. (2) Check operation. Renew
Pressure) if necessary.

(3) Filter pressure switch (3) Check and rectify.

wiring fault.

“Comp temp warn” (1) High ambient temperature. (1) Check room ventilation.
(High Discharge
Temperature) (2) Insufficient cooling water flow. (2) Check water supply. Check
adjustment of water valve.
Inspect/clean water strainer.
Inspect/clean oil cooler.

(3) Temperature sensor fault. (3) Rectify/renew.

(4) Sensor wiring fault. (4) Check wiring.

(5) Pre-conditioner card fault. (5) Renew card.

“Oil sep P warn” (1) Oil separator element blocked. (1) Renew separator filter
(Separator
Differential (2) Differential pressure switch (2) Check operation. Renew if
Pressure) fault necessary

(3) Filter pressure switch (3) Check and rectify

wiring fault

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MENU KEY FUNCTIONS
The following explains the function of each “Fault log nr. 1” Press “PLUS” key
key as marked by symbols on the control one (1) time to
panel. The functions are as follows: display. This menu
shows and stores
“PLUS” key + – This allows you to go to the latest fault in
the next menu. the unit.

“DOWN” key ∇ - This allows you to go to
the next menu item.
“MINUS” key - - This allows you to go
back to the previous
menu.
“UP” key Δ - This allows you to go
back to the previous
menu item.
1. This function stores the last ten (10)
faults. Which can be seen by pressing
the “DOWN” key one time for each fault.
2. Press “RESET” key to return to start.
“Timers” Press “PLUS” key two (2)
times to display. This menu
shows the run hours on the
unit.

“ENTER” key - This allows you to modify 1. Press “DOWN” key to show the load
a menu or menu item. hours on the unit.

“RESET” key - This allows you to return
to the beginning of the
menu tree or the “Ready
to Start” menu.
For example following the menu tree a
“Programmable Service Timer” can be set
as follows:
Start from the “Ready to Start” menu and
press the “PLUS” key two (2) times. Then
press the “DOWN” key five (5) times to get
to the “Oil chg tm” menu item. To modify this
item, press the “ENTER” key. The display
will start to flash and the “PLUS” or “MINUS”
key will allow you to change the time that
you prefer. Press the “ENTER” key to store
your modifications.
MENU DISPLAY FUNCTIONS
“Ready To Start” This menu shows the
date and time set at
the factory before
shipping.
2. Press “DOWN” key to show the
remaining life of the air filter (Air fl tm)
3. Press “DOWN” key to show the
remaining life of the oil filter (Oil fl tm)
4. Press “DOWN” key to show the
remaining life of the oil separator (Oil
sep tm).
5. Press “DOWN” key to show the
remaining life of the oil (Oil chg tm).
The air filter time through the oil change
time can be modified. These menu
items show the remaining life on a filter,
separator or the oil itself.
FOR EXAMPLE:
A new unit may show the oil filter time to be
2000 hours. Each hour the machine runs the
remaining life is less. When the time
reaches zero the filter is ready to be
changed.
6. Press “RESET” key to return to start.

1. Press “DOWN” key to show air

temperature.

2. Press “RESET” key to return to start.

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“Operate settings” Press “PLUS” key
three (3) times to
display. This menu
shows pressure
controls.
The default for the Econotrol unit is (RCN)
Regulated Continuous Pressure.
The default for the Standard unit is (CNT)
Continuous Pressure.
load for new pressure schedule entry.
See note on diagram.
3. Press “RESET” to return to start.
“SETTING SERVICE TIMERS”
The “SERVICE TIMERS” are programmable
to aid in preventative maintenance. These
timers must be reset when service is
performed. The timers can be set as follows:

1. Press “DOWN” key to show unload
pressure (P. unload psi). See chart at
bottom of menu tree for defaults with
and without Econotrol.
2. Press “DOWN” key to show the load
pressure (P. load psi).
3. Press “DOWN” key to show run on time
(Run on tm). This default is set for 10
minutes.
4. Press “DOWN” key to show P. schedule
which the default is set for “OFF”. If this
is turned “ON” it can be programmed to
start target pressure on any day at any
time.
5. Press “DOWN” key to show the PRESS.
Schedule.
1. From the “Ready to Start” prompt press
“+” four times to obtain “Main
selection/Mach config”.
2. Press the down arrow three times to
obtain “Main selection/Service settings.
3. Press “+” one time to obtain “Service
settings/Air fl tm”. The time remaining
will be displayed. A negative number will
display if the time had expired before
service.
4. The down key can be used to select any
of the four timer settings.
5. To reset a given timer press enter. The
“Air Monitor” will request a code. Use
the “+” & “-“ to enter 012. Then press
enter.

6. Press “DOWN” key to show the drain 6. The value will flash. The “+” & “-“ keys
spit time (Drain sp tm). This default is are used to select a new value. Press
set for 5 seconds. enter to accept the new value.

7. Press “DOWN” key to show the drain 7. The arrow keys can be used to make
dwell time (Drain dw tm). This default is another selection or press enter to
set for 30 seconds. return to “Ready to Start”.

Now press the “UP” key two (2) times to go

back to P. schedule then press the “PLUS”
key to go to the:

“Time” This menu shows the

date/month/day/time which
is factory set but can be
modified.

1. Press “DOWN” key to show the Time/P

load for day and time. This allows you to
program the unit to start target pressure
on a certain day at a certain time, if the
P. schedule is on.
2. Press “DOWN” key to show the Time/P

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