Sullair SR

Refrigerated Dryer

MICROPROCESSOR SERVICE MANUAL

All the specifications given concern the standard electronic control unit
for Sullair SR model refrigerated compressed air dryers.

Part Number: 02250140-347

 SR MICROPROCESSOR MANUAL
_________________________________________________________________________________________01 December 2002 - Rev. 00

CONTENTS

1. GENERAL DESCRIPTION 3

1.1 Input Devices 3

1.2 Output Devices 3
1.3 Technical Characteristics 3
1.4 Layout and Identification (Typical) 4

2. GENERAL FUNCTIONS 5

2.1 USER AREA - View Alarm Report and Hour Counter 5

2.2 MANUFACTURER AREA - Change Display Temperature and 6
Reset Hour Counter
2.3 MAINTENANCE AREA - Clear Alarm Report and 7
Set Last Service Date

3. START-UP CYCLE 8

3.1 STAGE 1 - Control unit power-up 8

3.2 STAGE 2 - Start-up procedure 8

4. OPERATING MODES 9

4.1 Stand-by 9
4.2 Local Control 9
4.3 Remote Control 9
4.3.1 Remote Operating Mode 1 9
4.3.2 Remote Operating Mode 2 - Cold Mass 10

5. CONNECTIONS 13

5.1 Terminal Board 13

5.2 Line Diagram 13

6. ALARMS, WARNINGS and MESSAGES 14

6.1 Alarms 14
6.2 Warnings 15
6.3 Messages 15

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 SR MICROPROCESSOR MANUAL
_________________________________________________________________________________________01 December 2002 - Rev. 00

1. GENERAL DESCRIPTION

The microprocessor that is found in the SR dryer is a control system developed specifically for
this product. The unit controls all the procedures relative to the refrigerant compressor start-
up and shutdown. The equipment also performs a check on the machine and returns
diagnostic information in the presence of malfunctions.

Available functions include:

 Alarm Report - Memory storage of the last 8 warnings or alarms
 Hour Counter - Memory storage of operating hours
 Last Service Date - Memory storage of the date of the most recent service
 Remote and “Cold Mass” energy saving operating modes

1.1 INPUT DEVICES

 Compressor high outlet temperature thermostat

 High pressure switch
 Low pressure switch
 Remote control (On-Off)
 Dew point temperature sensor

1.2 OUTPUT DEVICES

 Compressor contactor control

 Machine signaling contacts: Off / On / Alarm / Warning

1.3 TECHNICAL CHARACTERISTICS

Unit of
MINIMUM TYPICAL MAXIMUM
Measure
Power supply 207 230 253 Vac
Power consumption 3 Va
Working temperature -10 25 64 C
IEC801-4 3 CLASS
Sensor temperature range -9/14 37/99 C/F
ST input voltage 230 Vac
HP input voltage 230 Vac
LP input voltage 230 Vac
Remote control input voltage 230 Vac

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 SR MICROPROCESSOR MANUAL
_________________________________________________________________________________________01 December 2002 - Rev. 00

1.4 LAYOUT AND IDENTIFICATION (TYPICAL)

PRESSURE MAIN POWER DIGITAL [ ON-OFF ] &

GAUGE SWITCH DISPLAY [  ] BUTTON

"alarm" LED

"remote off"
LED

"on" LED

"line" LED

[ RESET ] &
[ REPORT ]
BUTTON

ALARM & WARNING SYNOPTIC

CODES DISPLAY

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 SR MICROPROCESSOR MANUAL
_________________________________________________________________________________________01 December 2002 - Rev. 00

2. GENERAL FUNCTIONS

2.1 USER AREA - View Alarm Report and Hour Counter

NOTE: The USER AREA can only be accessed when the unit is in stand-by.
The unit is in standby only if the yellow "line" LED ( ) Is
illuminated but all other LED’s and displays are off.

To enter the USER AREA:

a) Press and hold it down for 6 seconds.

Once inside the USER AREA you can:
 View the Alarm Report (the previous 8 alarms or warnings that have been recorded)
 View the Hour Counter (the current operating hours)

To View the Alarm Report:

b) Press .
The display will show (Report).

c) Press to scroll through the last 8 alarm or warning events in chronological order:
1 --- Last event ---
2 --- Second last event ---
..
.
8 --- Eighth last event ---

To view the Hour Counter:

b) Press .

The unit can record up to 99,999 operating hours. It counts these hours in 20-minute
intervals. To show these on a two digit display, the current operating hours are displayed
as three separate numbers, each one appearing 2 seconds after the other:
First number: This indicates THOUSANDS of hours.
The red "alarm" LED will flash.

Second number: This indicates HUNDREDS of hours.

The yellow "off remote" LED will flash.

Third number: This indicates TENS of hours.

The green "on" LED will flash.

The combination of the three numbers gives the total operating hours.

c) Press to exit.
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 SR MICROPROCESSOR MANUAL
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2.2 MANUFACTURER AREA - Change Display Temperature and Reset Hour Counter

To enter the MANUFACTURER AREA:

a) Switch on the MAIN POWER SWITCH ( ) while holding down the button.
The display will read (Celsius / Fahrenheit).
Once inside the MANUFACTURER AREA you can:
 Change the Display Temperature (from Fahrenheit to Celsius or vice-versa)
 Reset the Hour Counter (set current operating hours to zero)

To change the Display Temperature:

b) Press to select the desired unit of measure.

c) Switch off and then on the MAIN POWER SWITCH ( ) to store the selected unit
of measure.

To reset the Hour Counter:

b) Press .
The counter will automatically return to zero.

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 SR MICROPROCESSOR MANUAL
_________________________________________________________________________________________01 December 2002 - Rev. 00

2.3 MAINTENANCE AREA - Clear Alarm Report and Set Last Service Date
To enter the MAINTENANCE AREA:
a) Switch On the MAIN POWER SWITCH ( ) while holding down the
button.
The display will show the code (Clear Report).
Once inside the MAINTENANCE AREA you can:
 Clear the Alarm Report (delete the last 8 recorded alarms or warnings).
 Set the Last Service Date (set the present date for future reference).

To clear the Alarm Report:

b) Press .
This will clear the Alarm Report. The display will show the year of the Last Service Date.

c) Press 3 times. This will scroll through year month and day of the Last
Service Date.

To set the Last Service Date:

b) Press .
The display will show to indicate the year.
The red "alarm" LED will flash.

c) Press repeatedly to get to the current year.

The display will scroll in single digit increments from 00 to 99.

d) Press .
The display will show to indicate the month.
The yellow "off remote" LED will flash.

e) Press repeatedly to get to the current month.

The display will scroll in single digit increments from 00 to 12.

f) Press .
The display will show to indicate the day.
The green "on" LED will flash.

g) Press repeatedly to get to the current day of the month.

The display will scroll in single digit increments from 00 to 31.

h) Press to exit.
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 SR MICROPROCESSOR MANUAL
_________________________________________________________________________________________01 December 2002 - Rev. 00

3. START – UP CYCLE

The start – up cycle can be divided into two stages:

3.1 STAGE 1 - Control unit power up

When the control unit is powered up it will:

1. Conduct a digital display and LED test lasting 3 seconds.
2. Display the currently selected temperature scale “C” or “F” for a further 3 seconds. The
signaling relay contact is now closed.
3. Verify whether the unit was ON or OFF when the power was last disconnected. If it was
OFF, the control unit enters Stand-by mode to await a start-up command. If it was ON, the
control unit performs a start-up routine.

3.2 STAGE 2 - Start-up procedure

Press .
The control unit will perform a start-up cycle, consisting of 2 steps:

Step 1: Stand-by for Start up

The green "on" LED ( ) will flash for five seconds. During this time the
unit checks for alarms. If alarms are detected, the cycle is interrupted and the display will
show the corresponding alarm code. If no alarm is detected, the unit will proceed to the
next step.

Step 2: Compressor Start

The compressor contactor control relay is energized and the temperature reading is
displayed. The dryer will monitor all alarms and warnings constantly to guarantee correct
operation.

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 SR MICROPROCESSOR MANUAL
_________________________________________________________________________________________01 December 2002 - Rev. 00

4. OPERATING MODES

4.1 STAND – BY

The yellow "line" LED ( ) will be illuminated at all times when there is power
supplied to the dryer. If this this LED is illuminated, but all other LED’s and displays are off,
the control unit is in stand-by status. When in stand-by status, the sensors, displays, alarms
and warnings will not function and the compressor is off.

4.2 LOCAL CONTROL

The dryer can be operated locally from the control panel with no external signals.

4.3 REMOTE CONTROL

In order to take advantage of the remote on – off functions, a remote signal (eg. flow
switch, compressor start-stop) must be connected to the dryers remote on – off contacts.
Also, the control unit must be switched on in advance by pressing the button. If the
unit is not switched on, the remote signal will have no effect.

The dryer has two modes of operation when using a remote signal:

4.3.1 - REMOTE OPERATING MODE 1

The remote control function allows powering down or powering up the control unit from a
remote location.

When the remote contacts are OPEN, the yellow "off remote" LED ( ) will
illuminate and the control unit will be in “off remote” status. The dryer will shut down.

When the remote contacts are CLOSED, the start-up cycle will commence as described in
Section 3.

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 SR MICROPROCESSOR MANUAL
_________________________________________________________________________________________01 December 2002 - Rev. 00

4.3.2 - REMOTE OPERATING MODE 2 – Cold Mass

The control unit also provides a “Cold Mass” energy saving function.

When the remote contacts are OPEN, the yellow "off remote" LED ( ) will
illuminate and the control unit will be in “off remote” status. The dryer will however cycle
the refrigerant compresor on and off according to preset dewpoint temperature limits.

When the remote contacts are CLOSED, the dryer will return to normal operation.

In order to use the Cold Mass function, first it must be confirmed that jumper “J3”, found on
the top left corner of the control board is in the “OFF” position as shown in the following
diagram:

Jumper J3

The preset variables are as follows:

" tC " Compressor Off Time Delay - The time delay between when the remote contacts
are opened and the compressor is stopped.
" tA " Upper Dewpoint Limit - The temperature at which the compressor is turned on.
" tB " Lower Dewpoint Limit - The temperature at which the compressor is turned off.

These preset values can be changed to the suit the users requirements as follows:

a) Switch on the MAIN POWER SWITCH ( ) while holding down the

button.
The display will read (Celsius / Fahrenheit).

b) Hold down the button.

The display will show (Cold Mass Control)

c) Press .
The red "alarm" LED will flash.
The Compressor Off Time delay (tC), in minutes, will be shown.

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 SR MICROPROCESSOR MANUAL
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4.3.2 - REMOTE OPERATING MODE 2 – Cold Mass (Continued…)

d) Press repeatedly to set the desired number of minutes.

The display will scroll in increasing single digit increments.

e) Press .
The yellow "off remote" LED will flash.
The Lower Dewpoint Limit (tB), in degrees, will be shown.
The factory setting is 37F.

f) Press repeatedly to set the desired temperature.

The display will scroll in increasing single digit increments.

g) Press .
The green "on" LED will flash.
The Upper Dewpoint Limit (tA), in degrees, will be shown.
The factory setting is 50F.

g) Press repeatedly to set the desired temperature.

The display will scroll in increasing single digit increments.

h) Press to store your settings.

You can now start the dryer by pressing .

NOTE: If the tC (Compressor Off Time Delay) is set to zero, the unit will
operate in OPERATING MODE 1, without the Cold Mass energy
saving function.

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4.3.2 - REMOTE OPERATING MODE 2 – Cold Mass (Continued…)

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 SR MICROPROCESSOR MANUAL
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5. CONNECTIONS

5.1 TERMINAL BOARD

230 V 230 VAC 50/60 Hz power supply

230 V 230 VAC 50/60 Hz power supply
1 Compressor contactor control output
2 Common output
3 On / Off / Alarm / Warning signaling relay output
4 High pressure switch contact input
5 High outlet temperature thermostat input
6 Remote control input
7 Low pressure switch input
8 Common input
NTC Sensor input
NTC Sensor input

5.2 LINE DIAGRAM

SUPPLY OUTPUT INPUT SENSOR

230 230 1 2 3 4 5 6 7 8 NTC NTC

R
NTC SENSOR

N
COMMON INPUT

N
COMPRESSOR
CONTACTOR COIL
N LOW PRESSURE
nc SWITCH
R
COMMON OUTPUT
nc
N
WARNING / ALARM REMOTE CONTROL
OUTPUT nc
nc
R

HIGH TEMPERATURE
HIGH PRESSURE SWITCH nc THERMOSTAT
nc R
R

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 SR MICROPROCESSOR MANUAL
_________________________________________________________________________________________01 December 2002 - Rev. 00

6. ALARMS, WARNINGS and MESSAGES

6.1 ALARMS

- High Pressure alarm - alternating with: - Internal Protection alarm

CAUSE - Refrigerant Compressor inlet pressure exceeds high pressure set point.
RESULT - Stops compressor.
CLEAR - Press .

- Low Pressure alarm

CAUSE - Inlet pressure below low pressure set point for more than 3 minutes.
ACTION - Stops compressor.
CLEAR - Press .

- High outlet temperature alarm

CAUSE - Outlet temperature above 248F.

RESULT - Stops compressor.
CLEAR - Press .

- Low dew point temperature alarm - alternating with temperature reading

CAUSE - Dewpoint temperature below 28F for more than 3 minutes.

RESULT - Stops compressor.
CLEAR - Cannot be cleared. Alarm will clear and dryer can only be restarted when
temperature exceeds 32F.

- EPROM error alarm

CAUSE - EPROM memory chip is faulty.

RESULT - Stops compressor. All functions are inhibited.
CLEAR - Cannot be cleared. Control unit must be fixed or replaced.

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 SR MICROPROCESSOR MANUAL
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6.2 WARNINGS

- High temperature warning - alternating with temperature reading

CAUSE - Temperature exceeds 59F for more than 3 minutes.

RESULT - Compressor is NOT stopped.
CLEAR - Cannot be cleared. Warning will clear when temperature falls below 55F.

- Sensor fault warning

CAUSE - Temperature sensor circuit is short or open.

RESULT - Compressor is NOT stopped. Low temperature alarm and high
temperature warning will not function.
CLEAR - Cannot be cleared. Warning will clear when circuit is corrected.

- Full scale warning

CAUSE - Temperature reading is outside of the range of the sensor.

RESULT - Compressor is NOT stopped.
CLEAR - Cannot be cleared. Warning will clear when the temperature reading
returns within 16F to 99F range.

6.3 MESSAGES

- Power-on error message

CAUSE - button was pressed while in “off remote” status.

RESULT - None.
CLEAR - Message will clear in two seconds.

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 Sullair Corporation
3700 East Michigan Boulvard
Michigan City, IN 46360

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