COMPASS

CONTROLLER™

OPERATORS MANUAL

KEEP FOR
FUTURE
REFERENCE
Part Number

02250167-454
©Sullair Corporation
 AIR CARE SEMINAR
TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction in the proper operation, maintenance
and service of Sullair equipment. Individual seminars on Portable compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s
corporate headquarters in Michigan City, Indiana.

Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the
most common problems, and actual equipment operation. The seminars are recommended for maintenance
and service personnel.

For detailed course outlines, schedule and cost information contact:

Sullair Corporate Training Department

1-888-SULLAIR or 219-879-5451 (ext. 5363)
www.sullair.com

Or Write -

Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
 TABLE OF CONTENTS

OPERATOR IS REQUIRED TO READ

ENTIRE INSTRUCTION MANUAL

1. SAFETY .............................................................................................................................................................. 1
1.1 INTRODUCTION....................................................................................................................................... 1
1.2 ELECTRICAL SHOCK .............................................................................................................................. 1
1.3 EMERGENCY STOP ................................................................................................................................ 1
1.4 DECALS .................................................................................................................................................... 1
2. STARTUP PROCEDURES................................................................................................................................. 4
2.1 INTRODUCTION....................................................................................................................................... 5
2.2 COMPASS CONTROLLER PANEL LAYOUT .......................................................................................... 5
2.3 COMPASS CONTROLLER POWER UP .................................................................................................. 5
2.3.1 Self Test ......................................................................................................................................... 7
2.3.2 Communication Bus Checks.......................................................................................................... 7
2.3.3 General Safety Condition Checks.................................................................................................. 7
2.3.4 System Pressure Checks............................................................................................................... 8
2.4 NORMAL OPERATION............................................................................................................................. 9
3. ADJUSTMENTS ............................................................................................................................................... 11
3.1 INTRODUCTION..................................................................................................................................... 11
3.1.1 Message Display Center.............................................................................................................. 11
3.1.2 Line 2 Display Selection............................................................................................................... 11
3.2 Settings and Diagnostic........................................................................................................................... 11
3.2.1 Diagnostic Menu .......................................................................................................................... 11
3.2.2 Menu Structure ............................................................................................................................ 11
3.2.3 Set Units....................................................................................................................................... 12
3.2.4 Set Language............................................................................................................................... 12
3.2.5 Contrast........................................................................................................................................ 13
3.2.6 The Compass Controller Diagnostics .......................................................................................... 13
3.2.7 Gauge Test .................................................................................................................................. 13
3.2.8 Lamp Test .................................................................................................................................... 14
3.2.9 LCD Test ...................................................................................................................................... 14
3.2.10 Binary Inputs ................................................................................................................................ 15
3.2.11 Analog Inputs ............................................................................................................................... 16
3.2.12 Pressure Calibration .................................................................................................................... 16
3.2.13 Auxiliary Temperature Calibration ............................................................................................... 17
3.2.14 Backlight Adjust ........................................................................................................................... 18
3.2.15 Engine Diagnostics ...................................................................................................................... 18
3.2.16 Engine Shutdown History............................................................................................................. 18
3.3 Configuration Menu ................................................................................................................................. 19
3.3.1 Line 2 Parameter Display............................................................................................................. 19
3.3.2 Self Test ....................................................................................................................................... 19
3.3.3 Remote Start................................................................................................................................ 19
3.4 USER ADJUSTABLE CONTROL PARAMETERS (ucp) ........................................................................ 20
4. COMPASS CONTROLLER DESCRIPTION .................................................................................................... 23
4.1 INTRODUCTION..................................................................................................................................... 23
4.2 OPERATING MODES ............................................................................................................................. 23
4.2.1 Sleep Mode .................................................................................................................................. 23
4.2.2 Start-up Mode .............................................................................................................................. 23
TABLE OF CONTENTS
4.2.3 Waiting Mode ............................................................................................................................... 24
4.2.4 Failure to start .............................................................................................................................. 25
4.2.5 Run Mode..................................................................................................................................... 25
4.2.6 Auto-Start (Remote) Operation .................................................................................................... 26
4.2.7 Shut Down.................................................................................................................................... 26
4.2.8 Gauges Display............................................................................................................................ 27
4.2.9 Message Display Center.............................................................................................................. 27
4.2.10 Priority Messages ........................................................................................................................ 28
4.2.11 Power-Up Options Menu.............................................................................................................. 28
4.2.12 Main Screen While Not In Running State .................................................................................... 29
4.2.13 Backlighting.................................................................................................................................. 29
4.2.14 Gauges Internal Warning Indicators ............................................................................................ 29
4.2.15 Warning Bank Indicators.............................................................................................................. 29
4.3 Compressor Shutdown............................................................................................................................ 30
4.3.1 Normal Shutdowns....................................................................................................................... 30
4.3.2 Abnormal Shutdown..................................................................................................................... 31
4.3.3 Main Screen While In Running State........................................................................................... 32
5. TROUBLESHOOTING...................................................................................................................................... 35
5.1 TROUBLESHOOTING INTRODUCTION ............................................................................................... 35
5.2 TROUBLESHOOTING GUIDE INTRODUCTION ................................................................................... 35
5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE................................................................... 36
5.4 CONTROL PARAMETERS ..................................................................................................................... 41
 Section 1
SAFETY
1. SAFETY
1.1 INTRODUCTION
Sullair Corporation and its subsidiaries design and manufacture all of their products so
they can be operated safely. However, the responsibility for safe operation rests with
those who use and maintain these products. For safe machine operation it is vitally
important to review all safety precautions noted in the Safety Section of the compressor’s
Operator’s Manual. The precautions listed in the Operator’s Manual, as well as those
noted here 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 persons who have been trained and
delegated to do so, and who have read and understood this manual and the compressor
Operator’s Manual. Failure to follow the instructions, procedures and safety precautions
listed here and in the Operator’s Manual may result in accidents and injuries.
NEVER start the compressor unless it is safe to do so.
DO NOT attempt to operate the compressor with a known unsafe condition. Tag the
compressor and render it inoperative by disconnecting and locking out all power at the
source, or disable its prime mover so others who may not know of the unsafe condition
cannot attempt to operate it until the condition is corrected. Use and operate the air
compressor only in full compliance with all pertinent OSHA requirements or any pertinent
Federal, State, and Local codes or requirements.
DO NOT modify the compressor and/or controls in any way except with written factory
approval.

1.2 ELECTRICAL SHOCK

A. Keep all parts of the body, any hand-held tools, or other conductive objects away
from exposed live wiring and components of the electrical system. Maintain dry
footing, stand on insulated surfaces and DO NOT contact any other portion of the
compressor when making adjustments or repairs to exposed live components of the
electrical system.
B. Attempt repairs only in clean, dry, well lighted and well ventilated areas.
C. Stay clear of the compressor during electrical storms.

1.3 EMERGENCY STOP

A large red Emergency Stop (E-STOP) button is located near the controller panel. Press
the E-STOP button in the event of an emergency to immediately shutdown the machine
and override all controller functions. The E-STOP button must be reset prior to restarting
the machine. When hazardous conditions no longer exist, reset the E-STOP by pulling
the button out. Press the Reset switch to reset the controls. The machine will be ready
for restart if the system pressure is below 10 psi.

1.4 DECALS
The Compass Controller panel displays several decals which provide necessary
information for safe performance. See Table 1A. These decals should never be
removed or modified. If a decal becomes damaged, contact your nearest Sullair
Distributor or the Sullair Corporation factory Parts Department for replacement parts.
Note: When ordering new decals, use part number printed on the decal face.

1
Section 1
SAFETY

Table 1A Safety Decals, Information Decals and Part Numbers (1 of 2)

Key No. Decal Description Sullair Part Number Quantity

1 decal, warning group 250028-258 1
2 decal, warning oil fill 049685 1
3 decal, warning sever-belt 049964 2
4 decal, warning sever-fan 049965 2
5 decal, warning hot 407408 2

2
 Section 1
SAFETY
Table 1A Safety Decals, Information Decals and Part Number (2 of 2)

Key Decal Description Sullair Part Number Quantity

No.
6 decal, pressurized clg sys 02250051-826 1
7 decal, proposition 65 02250118-638 1
8 decal, doors closed 250038-030 4
9 decal, rated 1800 idle 1400 250023-695 1
10 decal, Sullair AWF 250032-902 1
11 decal, manual container 0220166-383 1
12 decal, diesel fuel 040248 1
13 decal, radiator fill 02250166-384 1
14 decal, containment drain 02250166-385 5

3
 NOTES

2. STARTUP PROCEDURES

4
 Section 2
STARTUP PROCEDURES
2.1 INTRODUCTION
This compressor is equipped with a Sullair Compass Controller for controlling the
compressor system operation, adjusting the machine parameters and performing
maintenance operations. The Compass Controller utilizes digital technology that ensures
accurate and safe operation of the compressor system. When fault conditions occur, the
controller automatically shuts down the machine to prevent injury to the operator or
damage to the equipment.
Features of the Compass Controller include:
• Dual gauges for display of pressure, engine temp, compressor temp, engine rpm,
and fuel level
• LCD screen displaying machine status and operating information
• Remote start capabilities
• Automatic self diagnosis at startup
• Multiple language support
• An external diagnostics port which allows PC interface for configuration of the
system parameters.
• Backlighting of gauges with green LED to allow clear view of gauges in low light
areas.

2.2 COMPASS CONTROLLER PANEL LAYOUT

The Compass Controller panel is shown in Figure 2-1. The controller components and
functions are described in detail in Section 4.

2.3 COMPASS CONTROLLER POWER UP

The compass controller is used to start the compressor either manually or remotely.
Manual Start: Start the machine by pressing the “OFF/ON/START” button to the
“START” position on the controller panel. Once the switch has been set to the start
position, the Compass Controller will automatically continue to energize the starter until
either the engine starts or the maximum crank duration is reached.
Auto Start: The compressor can be started remotely if the remote start function has
been enabled during setup. If this option is activated, an “r.” will display in reverse
characters in the upper right corner of the LCD display.

5
Section 2
STARTUP PROCEDURES
Figure 2-1 Compass Controller Panel

19 20 13

4
18

3
12

16 2

21
17

6
1

14 8

15 5 11 9
10

1 Mode Button (m) 12 Engine Warning Indicator

2 Trip / Reset Button (t) 13 Engine Diagnostic Shutdown
Indicator
3 LCD Graphic Display 14 Engine Controller Diagnostic
Service Port
4 Service Air Pressure Gauge (P1) 15 Engine Diagnostic Port Cover
5 Low Fuel Indicator 16 Compressor Shutdown Indicator
6 Fuel Level Gauge 17 Compressor Warning Indicator
7 High Compressor Temperature Warning 18 High/Low Selector Switch
8 Engine RPM Gauge 19 Reset Switch
9 Compressor Temperature Gauge 20 Power Of/On/Start Switch
10 High Engine Temperature Warning 21 Cabinet Latch
11 Engine Temperature Gauge

6
 Section 2
STARTUP PROCEDURES
2.3.1 Self Test
When the controller is initially powered up, the system will initiate a “Self Test” sequence
to verify its operational integrity and safety status. During this process, the following self
tests will be performed.
1. Gauge pointers will move to the zero position, then to half and full scale, then back to
zero, and finally to the actual value reading.
2. The LCD display will turn on all its segments for one second, off for one second, and
then display the Sullair logo followed by the software product number with revision
level.
3. All warning lights will turn on for 5 seconds and then turn off, then set to the actual
indicator state.
The Self Test feature may be bypassed by disabling the sequence as describe in Section
3 of this manual.

2.3.2 Communication Bus Checks

After successful completion of the self test, the Compass Controller system will check the
communication status of system.
In the event of a problem, the LCD will display one of the following messages:

Listening For Engine

Checking Compass Comm

The Compass Controller system will prevent the user from operating the compressor until
all communication problems are resolved.
See Section 5 of this manual for troubleshooting recommendations.

2.3.3 General Safety Condition Checks

After successful completion of the Communication Bus checks, the Compass Controller
system will perform safety checks on the compressor and the engine.
In the event of a problem with either the compressor or engine, a message will display in
the LCD indicating the nature of the trouble (example shown below). The Controller will
wait for user- interaction to either correct the fault or send the system to Sleep mode.

Checking System r.
Low Fuel Level

27.6 V Batt V

7
Section 2
STARTUP PROCEDURES

Table 2A below lists the safety conditions that are checked by the Compass Controller
during startup and the fault that will be displayed on the LCD screen if a fault occurs.

Table 2A Safety Conditions

Parameter Fault Condition User Controlled LCD Message
Parameter
Fuel Low fuel level Very Low Level Alert Low fuel level
(% full)
Fuel sender open None Low fuel level
circuit
Battery Low battery voltage None Battery Voltage Error
(<18.0Vdc)
Compressor Signal short circuit None T1 Signal Error
Discharge Compressor Temp High Max T1 during run or at Comp HighI Temp
Temperature (CDT) start-up
Receiver Tank Receiver Tank Temp None RTT High
Temperature (RTT) High
Discharge Air DP High Aftercooler filter AfterFilters Equipped Primary Shutdown
DP
Air Pressure (P1) Transducer signal short None P1 Signal Error
or open circuit
High compressor Max P1 at start-up (psi High Compressor
pressure Pressure
Control Pressure (P2) Transducer signal short None P2 Signal Error
or open circuit

See Section 5 of this manual for troubleshooting recommendations.

2.3.4 System Pressure Checks

Following the successful completion of the general safety checks, the Compass
Controller will check the status of the Service Pressure (P1), Control Pressure (P2), and
Wet Sump (P3). If there is a problem with any of these inputs a message will be
displayed on the LCD display indicating the nature of the problem.
(Example shown below):

Checking Pressures r.
P1 Signal Error

27.6 V Batt V
The controller will prevent compressor startup if either of the following conditions exists:
• P1 pressure is greater than the maximum P1 pressure permitted at startup. The
maximum P1 pressure is an adjustable parameter which can be modified as
describe in Section 3 of this manual.
• P1 and P2 pressures are out of range.

8
 Section 2
STARTUP PROCEDURES
See Section 5 of this manual for troubleshooting recommendations.

2.4 NORMAL OPERATION

Following the successful completion of all startup sequences, the system is ready for
normal operation.
During normal operation the controller will be in one of the following five operating
modes: Waiting, Start-Up and Autostart (remote), Run, Sleep, and Shutdown. Each
of these modes is described in detail in Section 4.

9
 NOTES

10
 Section 3
ADJUSTMENTS
3. ADJUSTMENTS
3.1 INTRODUCTION
This section describes steps for using the Compass Controller to modify specific
parameters that control the machine operation. Additional parameters can be viewed
and adjusted using the PC User Interface.

3.1.1 Message Display Center

The message display is a graphical LCD that displays information to the compressor
operator. The screen is backlit to allow the display characters to be clearly visible under
any lighting conditions. In addition to basic operational information, a variety of user-
defined options may also be displayed when specified. Fault messages are displayed
whenever a fault condition occurs. The LCD display also allows the operator to view
instrumentation diagnostic data to aid in controlling the system operation and
troubleshooting problems.

3.1.2 Line 2 Display Selection

Pressing the m button for less than five (<5) seconds allows the selection of the
parameter to be displayed on the second line. The parameter will highlight in reverse
characters indicating it is selected. Press the m or t button to scroll the display through
the various parameters that are available for user adjustment.

3.2 SETTINGS AND DIAGNOSTIC

3.2.1 Diagnostic Menu

The operator can enter the diagnostic menu at any time by pressing and holding the “m”
button for more than five seconds. If the operator enters the diagnostic menu prior to
getting past the Waiting state, the compressor will not be permitted to start until the
diagnostic menu is exited. When the Compass Controller is in Waiting mode, pressing
the “m” button for more than five (>5) seconds brings up the following screen:

1-Set Units
2-Set Language
3-Contrast
▲ Select ▼
Pressing both the “m” and “t” buttons simultaneously will make the highlighted parameter
active for editing. Pressing the “m” or “t” button separately will move the highlight
through the parameter list allowing other items to be selected.

3.2.2 Menu Structure

The diagnostic menu will appear in the LCD display as shown below. Use the “m” and “t”
buttons to scroll through the available menu selections. The present menu item will
display in reverse characters.
There are nine diagnostic menu selections which can be chosen from this menu:
1. Set Units
2. Set Language
3. Contrast

11
Section 3
ADJUSTMENTS
4. COMPASS Diagnostics*
5. Pressure Calibration
6. Auxiliary Temperature Calibration
7. Backlight Adjust
8. Engine Diagnostics*
9. Engine Shutdown History

To select a present menu item, press both the “m” and “t” buttons at the same time. The
operator can then use the “m” and “t” buttons to modify the selected parameter.

3.2.3 Set Units

When “Set Units” is selected, the LCD display will show the following:

Current Units
ENGLISH

Press t for METRIC

Press m to exit

The operator can choose between English and Metric units by pressing the “t” button. To
make the units active, press the “m” button or simply let the screen time out (approx. five
seconds).

3.2.4 Set Language

When “Set Language” is selected, the LCD display will present six international
languages for the system display. The operator can scroll between the available
languages by pressing the “m” or “t” buttons. The selected option will appear in reverse
characters. To make the selected language active, press both the “m” and “t” buttons at
the same time.

1-English
2-French
3-Spanish
▲ Select ▼
4-German
5-Italian
6-Portuguese
▲ Select ▼
A confirmation screen will appear indicating “Language changed” before exiting back to
Diagnostic menu.

Language Changed

12
 Section 3
ADJUSTMENTS
3.2.5 Contrast
Selecting the Contrast option allows the operator to adjust the contrast of the LCD
display.
Press the “m”(+) button to increase contrast. Press the “t”(-) button to decrease contrast.

CONTRAST ADJUST
+ -

3.2.6 The Compass Controller Diagnostics

The Compass Controller Diagnostics menu contains five tests that verify the functionality
of specific controller components. The Diagnostics menu can only be entered if the
compressor is in the Waiting mode (Prior to start-up).
Selecting this menu option will present a sub-menu as shown below. To make a
selection in the sub menu, scroll to the desired option and press both the “m” and “t”
buttons at the same time. The diagnostic menu exits after a short time-delay of inactivity.

1-Gauge Test
2-Lamp Test
3-LCD Test
? Select ?

4-Binary Inputs
5-Analog Inputs Test

▲ Select ▼

Note: This sub-menu and all content accessible from it will always be in English,
regardless of the language chosen.
As previously noted, the system must be in Waiting mode prior to entering the
Diagnostics menu. An attempt to enter the diagnostics while the machine is running will
cause the following message to be displayed:

Not permitted
while running

3.2.7 Gauge Test

The Gauge Test verifies that both gauges are functional. During the test, the gauge
pointers will cycle from 0 to full scale pausing at 0%, 50%, 100%, then return to zero (or
its true position). The LCD display will show which gauge is being tested and indicate the
gauge’s corresponding position (as depicted below for engine speed). Pressing the “m”
button at anytime during the test will cause the test to end.

13
Section 3
ADJUSTMENTS
1-Gauge Test Engine Speed
2-Lamp Test 0%
3-LCD Test EXIT
▲ Select ▼

Engine Speed
50%
EXIT

Engine Speed
100%
EXIT

3.2.8 Lamp Test

Selecting the Lamp Test option will turn on all warning and binary LED’s (except for
Engine Crank Relay). Each output will turn on, then off and the LCD display will indicate
which output is being tested (as depicted below for R/S Relay). Pressing the “m” button
at any time will end the test and return to the COMPASS Diagnostic menu. The outputs
tested during the lamp test are:
1. Manifold Solenoid Output
2. Hi / Low Pressure Relay Output
3. Run / Start Relay Output
4. Non-Engine Warning Lamp
5. Non-Engine Shutdown Lamp
6. Engine Warning Lamp
7. Engine Diagnostics Lamp

1-Gauge Test R/S Relay

2-Lamp Test
3-LCD Test EXIT ON
▲ Select ▼

R/S Relay

EXIT OFF

3.2.9 LCD Test

Selecting the LCD Test option will test all the pixels in the LCD display by flashing the
Sullair logo in normal and reverse characters. Pressing the “m” button will end the test.

14
 Section 3
ADJUSTMENTS
1-Gauge Test
2-Lamp Test
3-LCD Test
▲ Select ▼

3.2.10 Binary Inputs

Selecting the Binary Inputs menu option will allow the operator to check the status of
each of the binary inputs to the Compass Controller. The Binary Inputs display, as
shown, will indicate the module being checked, the pin number of the connector for the
input, and real-time status of each binary input defined in the system. The “High” and
“Low” designation refers to the voltage level at the connector pin.

Pin # Input Status of input

Module

4-Binary Inputs S-1 DP-Prv Wrn High

5-Analog Inputs S-2 DP-APF Shtd Low
S-3 Unused 1 High
▲ Select ▼ S-4 Unused 2 Low

Press “t” to scroll through and view the status of the various binary inputs. Press “m” to
exit the module and return to the COMPASS Diagnostic menu.
The 15 Binary Input items available from this menu are listed below. Note that the “S”
designation is for the slave warning bank input and the “M” designation is for master
gauge input.

S-1 Dp-Pry Wrn High

S-2 Dp-Pry Shtdn Low
S-3 UNUSED 1 High
S-4 UNUSED 2 Low

S-5 Hi/Low Press Low

S-6 Engine Wrn High
S-7 T3 - RTT Low
S-8 Engine Diag High

M-11 Ign ON High

M-12 Engine Start Low
M-13 Remote Start High
M-14 DP1-EIAF Low

15
Section 3
ADJUSTMENTS
M-15 E-Stop High
M-16 DP2-CIAF Low

3.2.11 Analog Inputs

Selecting the Analog Inputs screen allows the operator to check the status of each of the
analog inputs coming to the Compass Controller system. This LCD screen displays the
master gauge pin number and real-time status of each analog input defined in the
system.
Pin #

Module Input
Value

4-Binary Inputs
M-1 Fuel 100%
5-Analog Inputs
M-2 P1 Serv P. 0 psi
M-3 P2 Ctrl P. 0 psi
▲ Select ▼
M-4 P3 Wet P. 0 psi

Press “t” to scroll through and view the status of the various analog inputs. Press “m” to
exit the module and return to the COMPASS Diagnostic menu.
The eight analog input items available from this menu are listed below. Note that the “M”
designation in the module number indicates “master” gauge input.

M-1 Fuel 55%

M-2 P1 Serv p 0 psi
M-3 P2 Ctrl p 0 psi
M-4 P3 Wet p 0 psi

M-5 Vdc Ref 5.00V

M-6 T1 CompT 198 °F
M-7 FaultReset Off
M-8 T2 Aux T 109 °F

3.2.12 Pressure Calibration

Over time the P1, P2, and P3 pressure transducer values might drift resulting in an
inaccurate reading showing on the pressure gauge. Using the Pressure Calibration
function the operator can adjust the actual zero pressure to 0.00 BAR when no pressure
is present in the compressor. The offset value will be subtracted from the transducer
value to obtain an adjusted reading used for indication and calculation.
To calibrate a pressure transducer:
1. Select the transducer (P1, P2, or P3) to be calibrated by pressing both the “m”
and “t” buttons at the same time.

16
 Section 3
ADJUSTMENTS
2. The following screen sequence will be presented (example).

1-P1 (Service)
2-P2 (Control) + P1 Calibration -
3-P3 (Wet)
▲ Select ▼ 0.60 BAR 0

Actual Pressure Correction /

being sent from Offset
the transducer

This example shows a P1 pressure of .60 BAR on a machine that is known to

actually be at zero pressure. The current pressure value is displayed in metric
units only (1 kPa = 0.01 bar).
3. Calibrate the actual pressure reading back down to 0.00 by increasing the value
of the correction / offset by pressing the “t” button until the Actual Pressure reads
0.00. Once this is done, simply press both the “m” and “t” buttons together to
store this value in the system. The offset value will be subtracted from the
transducer value to obtain the adjusted reading. The calibration offset is
configurable in 1 kPa increments. A total offset of 0-50 kPa (0-7.25 PSI) is
allowable

3.2.13 Auxiliary Temperature Calibration

Occasionally and when the auxiliary temperature input is first configured, the input may
require calibration to adjust the input to the actual known temperature. This is
accomplished using the Auxiliary Temperature Calibration function. The auxiliary
temperature calibration offset is configurable in 0.5°C increments. A total offset of +/-
10°C is allowable. The offset will be applied to the RTD input signal and used for
indication and calculation during compressor operation.
To calibrate the Auxiliary Temperature input:
1. Select the Aux Temp input by simultaneously pressing both the “m” and “t”
buttons when the input is highlighted.
2. The following screen will be presented (example).
3. Adjust the offset value using the m and t buttons.
4. Simultaneously press m and t to exit screen.

+ Aux Temp Cal -

42.5°C

17
Section 3
ADJUSTMENTS
3.2.14 Backlight Adjust
With this function the operator can adjust the intensity of the gauge backlighting (both the
master gauge, and the 4-in-1 gauge) to within 60%-90% full-intensity.
To adjust the backlight intensity:
1. Press the “m” button to increase the light intensity.
2. Press the “t” button to decrease the light intensity.
3. Simultaneously press “m” and “t” to exit the screen.

BACK LIGHT ADJUST

+ -

3.2.15 Engine Diagnostics

The Engine Diagnostic screen is a real-time display of active operation messages being
transmitted by the engine. Messages that become inactive are automatically erased. No
messages are stored in the controller memory.
When this function is selected, up to 5 of the most recent active engine Fault Mode
Indicators (FMI) or Suspect Parameter Number (SPN) codes being received from the
Caterpillar engine will be displayed. Use the “m” and “t” buttons to scroll through the
various codes. Simultaneously press “m” and “t” to exit.

No Active Codes OR SPN 100 FMI 1

SPN 110 FMI 0
End of list
▲ exit ▼ ▲ exit ▼

3.2.16 Engine Shutdown History

This function allows up to 5 of the most recent abnormal shutdown faults to be viewed.
The Engine Shutdown History is an instantaneous snapshot of the Compass Controller
parameters. For each fault the LCD will display the fault that occurred and the engine
hours at the time of the fault. Use the “m” and “t” buttons to scroll thru each of the faults.
Press “m” and “t” to exit. Pressing the Compass Reset button will cycle through the
warnings active at time of shutdown.
An example of a “High Compressor Temp” shutdown with 150 hours on the engine is
shown below.

Comp High Temp

150.00 hrs
▲ exit ▼

18
 Section 3
ADJUSTMENTS
3.3 CONFIGURATION MENU
The Compass configuration menu allows for end-user adjustment of three User
Controlled Parameters (UCP). The UCPs do not adversely affect the controller’s
operational functionality. The configuration menu allows for end-user customization of
the Compass Controller. The configuration menu will compile and store to the controller
memory any changes to the factory programmed UCP profile.
To enter the Configuration Menu:
1. Hold down the “m” and “t” buttons while cycling Compass Controller power to
ON. The configuration menu will appear.
2. Use the “m” and “t” buttons to navigate within the menu and to make
adjustments to the selected parameters.
3. Exit the Configuration Menu by simultaneously pressing “m” and “t” buttons.
After exiting, the master gauge will perform a system reset and then enter
Start-up mode.

3.3.1 Line 2 Parameter Display

The Line 2 parameter display typically shows the operational parameters the Compass
controller. Disabling this feature will only affect the parameter display. Priority messages
will still utilize the lower portion of the LCD to display messages as necessary. Select
“yes” to enable the parameter display or “no” to disable the display.
Line 2 Parameter?
yes no

Ok Exit Toggle

3.3.2 Self Test

The Self-Test function of the Start-up mode can be enabled or disabled using the
configuration menu. Select “yes” to enable or “no” to disable the Self-Test feature.
Self Test?
yes no

Ok Exit Toggle

3.3.3 Remote Start

The ability Compass Controller to recognize a remote start actuation can be enabled or
disabled using the configuration menu. Note: a hardware remote start signal must be
provided in addition to enabling the software feature. Select “yes” to the remote start
feature or “no” to disable the feature.
Enable Remote Start?
yes no

Ok Exit Toggle

19
Section 3
ADJUSTMENTS

3.4 USER ADJUSTABLE CONTROL PARAMETERS (UCP)

The following settings are configurable using the Compass Controller interface software.
The parameters listed in bold font are those which can cause abnormal shutdowns to
occur.
Engine Crank Default Value Range/Option
Crank On Duration (sec) 5 3-7
Crank Off Duration (sec) 30 4-30
Number of Cycles 3 1-5
Engine Cranked Speed (RPM) 250 200-500
Time Required At Cranked Speed (msec) 480 240-1000

Throttle Control Default Value Range/Option

Low pressure Max PWM Duty Cycle (%) 92.5 70-92.5
High Pressure Max PWM Duty Cycle (%) 92.5 70-92.5
LO Idle Engine Speed (RPM) 1400 1300-2000
HI Idle Engine Speed (RPM) 1800 1500-2100
Alt Throttle Control 100-120
100-120
Low Pressure Range – 300 PSI controller 125-145
150-170
Alt Throttle Control
150-170 175-195
High Pressure Range – 300 PSI controller
200-220
Alt Throttle Control 205-225
205-225
Low Pressure Range – 600 PSI controller 350-370
350-370
Alt Throttle Control
350-370 425-445
High Pressure Range – 600 PSI controller
500-520
Enabled
Low Speed Shutdown Settings Disabled
Disabled
800
900
Low Speed Shutdown RPM 800
1000
1100
5
7
Low Speed Shutdown Time (sec) 5
9
11

Fuel Level Default Value Range/Option

Cancel Low Level Alert (% full) 23 13-43
Low Level Alert (% full) 20 10-40
Cancel Very Low Level Alert (% full) 11 7-13
Very Low Level Alert (% full) 8 4-10

Temperature Settings Default Value Range/Option

Max T1 at run-time or startup (°F) 250 200-400
Max Aux Temp at run-time/startup (°F) 250 200-400
Engine Temp. for warm-up complete (°F) 70 64-91
AfterFilter Freeze Assert Temp. (°F) 39 (-40)-50
AfterFilter Freeze Cancel Temp. (°F) 45 (-40)-68

20
 Section 3
ADJUSTMENTS
Continued…
Temperature Settings Default Value Range/Option
Startup Aids Settings
Low Point Temp (°F) (-40) (-40)-(-16)
Low Point Time (min) 60 31-75
Middle Point Temp (°F) (-15) (-15)-9
Middle Point Time (min) 30 16-30
High Point Temp (°F) 10 10-20
High Point Time (min) 15 5-15

Pressure Settings Default Value Range/Option

Max P1 at run-time (PSI) 200 145-600
Max P3 at run-time (PSI) 200 145-600
1
5
Allowable time for Max P1 or P3 (sec) 1
15
30
Max Air-Oil-Sep at run-time (PSI) 15 10-20
Air-Oil-Sep alert time (sec) 15 10-60
Max P1 at startup (PSI) 10 0-15
Manifold Solenoid Open/Assert Pressure (PSI) 60 30-90
Manifold Solenoid Close/Cancel Pressure (PSI) 55 25-85
P1 Calibration Offset (in kPa… 1PSI = 6.9kPa) 0 0-50
P2 Calibration Offset (in kPa… 1PSI = 6.9kPa) 0 0-50
P3 Calibration Offset (in kPa… 1PSI = 6.9kPa) 0 0-50
P1 to shutdown from auto-start (PSI) 100 70-600
Required time for P1 > Above Value to shutdown
from auto-start (sec) 900 300-1800
P1,2,3 Pressure for Cooldown Completion (PSI) 10 5-15
P2 Pressure for max RPM at run-time (PSI) 5 0-10

System ID Default Value Range/Option

20 character
ID TAG N/A
user entry

Miscellaneous Settings Default Value Range/Option

Warmup Complete Speed (RPM) 1375 1375-1450
Minimum Engine Warm-up Time (sec) 30 5-60
Maximum Engine Warm-up Time (sec) 240 60-360
Compressor Cool-down Time (sec) 300 5-600
DP1-2 Alert Time (sec) 15 10-60
English
Spanish
Italian
LANGUAGE English
French
German
Portuguese
ECM Power-Off Interval At Cooldown (sec) 5 3-10

21
Section 3
ADJUSTMENTS
Continued…

Miscellaneous Settings Default Value Range/Option

Metric
Unit Of Measurement English
English
300
PSI System 600
600
Large
Fuel Tank Large Small
None
Enabled
Display 2nd Line Parameter Enabled
Disabled
Enabled
Enable Gauge Self-Test Enabled
Disabled
Enabled
Remote Start Permitted Disabled
Disabled
Enabled
C9 Engine Used Disabled
Disabled
Enabled
AfterFilters Equipped Disabled
Disabled
Enabled
Intake Louvers Equipped Disabled
Disabled
Enabled
Enable Inactivity Auto-Sleep? Enabled
Disabled
Inactivity Timeout (min) 10 5-20

22
 Section 4
COMPASS CONTROLLER DESCRIPTION
4. COMPASS CONTROLLER DESCRIPTION
4.1 INTRODUCTION
This section describes the operation of the Compass Controller, the function of the
controller components, and the various types of displays that may appear on the display
screen. Descriptive lists of all messages appearing in the display are also provided.

4.2 OPERATING MODES

4.2.1 Sleep Mode

Sleep mode occurs when the Compass Controller is not powered on. All electrical
components are inactive during Sleep mode to prevent battery drainage (i.e.
microprocessor, relays, indication lamps, etc).
Sleep mode is dependent upon the position of the Off/On/Start switch and current
operating status of the compressor. If the compressor is in any state other than running,
then placing the Off/On/Start switch in the OFF position will enter Sleep mode. If the
compressor is running, placing the Off/On/Start switch in the OFF position will initiate
Waiting mode followed by Sleep mode.
If the compressor has shutdown due to fault condition, then the fault must be
acknowledged by pressing the reset switch and switching the Start/On switch to the OFF
position.
If the compressor was enabled via Remote Start, a compressor malfunction will allow
entering Waiting mode only. The malfunction must be acknowledged by pressing the
Reset switch and Off/On/Start switch must be in the OFF position to enter into Sleep
mode.

4.2.2 Start-up Mode

Start-up mode initializes the system instrumentation components for operation. Start-up
mode is internal to the Compass Controller and does not permit engine/compressor
activation.
Start-up mode is enabled by one of the following two methods:
1. Press the Off/On/Start switch to ON.
2. Activating the Remote Start switch (if enabled).
Placing the Off/On/Start switch to the ON position will energize the Master Gauge and
begin initializing the system for Waiting mode.
Start-up mode may be exited/cancelled before reaching Waiting mode. If Start-up is
entered by placing the Off/On/Start switch in the ON position, placing the switch in the
OFF position powers down the entire system. If a start-up initialization parameter is out-
of-tolerance, the Compass Controller will enter a safe-shutdown state and demand user
interaction to completely power down the unit.
Note: If the Start-up mode is entered via Remote Start, then only a start-up initialization
parameter “out-of-tolerance” failure and “Remote Start binary input not low” will
exit Start-up mode and prevent entering Waiting mode. Otherwise, the Compass
Controller will maintain Start-up mode status waiting for allowable conditions to
begin initializing Waiting mode.
It is during Start-up mode that system integrity is verified. System integrity verification
involves checks of functional instrumentation, communication status, and confirmation of

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Section 4
COMPASS CONTROLLER DESCRIPTION
proper initial parameter settings. A successful completion of Start-up mode transitions
the Compass Controller to the Waiting mode.

4.2.3 Waiting Mode

When the controller is in Waiting mode the LCD display will indicate that the system is
ready to be started, as shown below.

Ready . . .

ok (P3-P1)

The compressor can be started in one of the two ways as described in Section 2.
When the compressor is waiting to be started remotely, an “r.” in the upper right corner of
the LCD will display in reverse characters as shown below.
Ready . . . r.

198°F Comp Temp

Note: For remote start applications, the UCP in the Compass Controller labeled
“Enable inactivity auto sleep?” must be set to “Disabled”. In addition, an
appropriate trickle charge must be applied to the batteries in order for the
compressor to maintain Start-up readiness.
When the appropriate remote start conditions are met, the system will automatically enter
the Start-up mode, and the compressor will start.
While the compressor is attempting to start in both Manual and Remote start mode, the
LCD will display the following:
Engine Cranking r.

0 PSI Serv Pres…

Ok Exit Toggle

Waiting mode is a transitional state between initialization of the Compass Controller,

operation of the compressor and compressor shutdown. In Waiting mode, the Compass
Controller is ready to enter an operational state. However, the compressor is not active
in Waiting mode. Waiting mode is characterized by “Ready… ” appearing on the LCD
1st line parameter display. If Remote Start is configured then “Ready… r. ” will be
displayed.
Ready . . . r.

198°F Comp Temp

24
 Section 4
COMPASS CONTROLLER DESCRIPTION
Ready . . . r.
Starting Aids Required

198°F Comp Temp

Waiting mode to Run mode is dependent on user initiation of a compressor start

enabler.
• Manual Start – initiated by the Start/On switch placed in the Start position.
• Auto (Remote) Start – Remote Start enabled.

In Waiting mode, the Compass Controller is analyzing specific system parameters to

determine if entering Sleep mode is allowable. When the necessary conditions are met,
the system enters Sleep mode and all electrical components are de-energized. If the
compressor was enabled via Remote Start, the Start/On/Off switch is disabled and only a
compressor malfunction will allow entering Waiting mode and then Sleep mode.

4.2.4 Failure to start

In manual mode, if the engine does not start, the Compass Controller will attempt another
start cycle as long as the maximum number of crank attempts is not exceeded. This is
an automatic process until the Start attempts equal the set maximum.
If the maximum number of crank cycle attempts (a preset value) is exceeded, the system
will display an error message in the LCD display as shown below, and the system will
wait until the “Reset” switch is pressed. Once the “Reset” switch is pressed, the
Compass Controller system will shut down. Restart the compressor switching the
Start/On switch to ON.

Engine Over Crank

Ok Exit Toggle

When Remote is enabled, if the engine does not start, the “Fault / Reset” switch will need
to be depressed to reset and shut the machine down. The system will then wait
appropriate start-up conditions then activate the remote start input restart the
compressor.

4.2.5 Run Mode

Once the compressor has completed the warm up cycle, it will phase into Run mode.
When in Run mode, the LCD display will look similar to the display shown below.

Remote Start
System Service enabled icon
Pressure 110 PSI r.

0 PSI Serv Pres…

Scrollable
2nd line

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Section 4
COMPASS CONTROLLER DESCRIPTION
In Run mode, the compressor is ready to supply service air. The engine RPM will
automatically be adjusted to maintain the desired air pressure. If the 2nd line scroll (UCP)
has been turned on, the operator can scroll thru the list of available parameters by
momentarily pressing the “m” button. Each press of <5 seconds will scroll one parameter.
The available parameters are listed below.

Engine Speed % Engine Load

Engine Hours (Hourglass symbol) Fuel Rate
P1 Service Pressure Fuel Pressure
P2 Control Pressure Fuel Temperature
P3 Wet Pressure Engine Air Temperature
(P3-P1) Differential Pressure Oil Pressure
Compressor Tank Temperature Boost Pressure
Ambient –or- Service Temperature Desired Engine Speed
Ambient (if no after-coolers) Aux 1 Pressure
Engine Coolant Temp Aux 1 Temperature
Battery Voltage

4.2.6 Auto-Start (Remote) Operation

When using the Auto-Start feature, there are two parameters that can be set by using the
Compass Controller Communicator Software tool on a laptop computer. The first is the
P1 System Service Pressure, and the second is the time duration that the compressor
must stay at or above the P1 pressure. These values are settable when the Compass
Communicator software and communication adapter are installed. When the compressor
is operating in Auto-Start Mode, it will not enter a normal Shutdown mode until both
conditions below are met.
a. The System Service Pressure (P1) is greater than the UCP (User Configurable
Parameter) specified level for the UCP specified duration.
b. The “Remote Start” input has returned to its normally open position.
In the event that an abnormal shutdown occurs, the compressor could shut down without
these conditions being met. See Section 4.3.2, Troubleshooting, for handling abnormal
shutdowns.

4.2.7 Shut Down

The Shutdown mode can be entered when either of the following conditions occurs:
If the Compass Controller system was started manually, the operator must press the
“Off/On/Start” switch to the OFF position.
If the Compass Controller system was auto-started (Remote), the system will enter
Shutdown mode when both the Service Pressure (P1) is greater than the specified level
for the user-specified duration (Note: Both of these values are pre-set), and when the
remote start binary input is deactivated.
When the system enters the Shutdown mode, the compressor will complete the
following tasks before shutting down:

26
 Section 4
COMPASS CONTROLLER DESCRIPTION
1. The LCD will display the message shown below.
Stop Initiated
Cool Down Cycle

1400 rpm eng speed

2. The engine will go to the low idle setting (1400 RPM) for a preset period of time.
3. When the cool-down cycle is complete, the engine will shut down.
4. The Compass Controller will continue to monitor P1, P2, and P3 inputs until they
fall below the specified level (Note: This value is pre-set), and the LCD will
display a message similar to the one shown below.
Monitoring Pressures

0 PSI Serv Pres…

This is displayed as a safety measure that indicates to the user that the system is
under pressure.
5. When the system pressures fall below the pre-determined levels, the controller
will enter Sleep mode.
Note: If while the engine is cooling down during the normal shutdown phase, but is still
running, the operator presses the "Off / On / Start" switch back to the momentary
"Start" position (or if the Remote Start input becomes active and the Compass
Controller is configured to accept Remote Start), the system will immediately re-
enter the Warm Up phase of the Start-up mode.
However, during the final portion of shutdown, after the Compass Controller has stopped
the compressor’s engine, the Compass Controller no longer pays attention to the "Off /
On / Start" switch (or Remote Start). The operator must wait until this phase completes
to restart the compressor.

4.2.8 Gauges Display

Master Gauge –Service Air pressure
The air pressure gauge is driven by the air pressure sender analog input. Open and
shorts of the P1 Pressure sender analog input are considered out of range and will force
the pointer to fluctuate full scale.
4-in-1 Gauge
The 4-in-1 slave gauge displays Engine Coolant Temperature, Engine Speed
Compressor Temperature and Fuel Level. Compressor Temperature and Fuel Level are
driven by analog inputs. Open and shorts of the fuel level sender analog input are
considered out of range and will force the pointer to fluctuate full scale.

4.2.9 Message Display Center

The message display consists of a graphical, backlit, LCD display on the master gauge.
Two input buttons located directly below the LCD, the “m” (mode) and “t” (task) buttons,
allow user to navigate through the LCD display
As the Compass Controller system is executing in any of its states the LCD displays
information to the user that is pertinent to its operation and the compressor state. In

27
Section 4
COMPASS CONTROLLER DESCRIPTION
addition, through navigation with the “m” and “t” buttons, menus may be solicited to alter
system behavior, modify the information displayed, and make selection of the display
parameters.

4.2.10 Priority Messages

Priority messages are displayed in the LCD due to various inputs or data messages. The
priority message will take over the second line (parameter line) of the screen. Multiple
messages may be displayed by continually showing the message for 2 seconds before
displaying the next message. Some messages can be acknowledged by pressing the
“m” button while the message is being displayed. Once acknowledged, the priority
message will leave the display. Certain acknowledged priority messages may redisplay
if the condition still exists after three minutes, others will not reoccur until the next key-on
cycle.

4.2.11 Power-Up Options Menu

The menu is activated by pressing and holding down both the “m” and “t” buttons while
powering-on the Compass Controller by pressing the “Off/On/Start” button on the front
panel. When performed, the following “yes/no” options will appear. The current setting
(either yes or no) is displayed in Reverse characters.
Navigation of the menu is as follows:
o Press “m” to move circularly through the options.
o Press “t” to toggle the yes / no setting of the current option
o Press both “m” and “t” to exit the menu, saving the current settings in the
Compass Controller’s non-volatile memory.
Line 2 Parameter - enables the display of an additional compressor / engine parameter
during Running state. The first line parameter during Running state is always the
system service pressure (P1). The second line may display any of several possible
parameters.

Line 2 Parameter?
yes no

Ok Exit Toggle
m t

Self Test - determines whether the gauge self test is performed at start-up upon entry to
the System Power-up, Check & Initialize state.
Self Test?
yes no

Ok Exit Toggle
m t

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 Section 4
COMPASS CONTROLLER DESCRIPTION

Remote Start - determines whether the activation of the normally open low-side remote
start input can attempt to start the engine once in the Waiting state.
Enable Remote Start?
yes no

Ok Exit Toggle
m t

4.2.12 Main Screen While Not In Running State

Prior to transitioning into the Running state, the Compass Controller displays messaging
indicating the operational state of the Compass Controller system. For example, while in
the System Pressure Checking phase of the System Power-up, Check & Initialize
state, the Compass Controller will indicate “Checking Pressures” on the LCD display.
During the Engine Cranking phase of the Starting state, the Compass Controller displays
“Cranking Engine”.

4.2.13 Backlighting
Gauge backlighting is a user configurable parameter specified using a menu entry. Lower
and upper levels of the UCP are 60% and 90% intensity, respectively. The specific
parameter value is stored in the Compass Controller (EEprom) memory.

4.2.14 Gauges Internal Warning Indicators

High Coolant Temperature
The High Coolant Temperature indicator light will turn on when the Compass Controller
receives the corresponding output signal from the Caterpillar engine.
Low Fuel Level
The Low Fuel Level indicator light will turn on when the fuel level is less than UCP “low
fuel level assert” value. It will turn off when the level is above the UCP “low fuel level
cancel” value.
High Compressor Temperature
The High Compressor Temperature indicator light will turn on when the T1 compressor
temperature is greater than or equal to the UCP specified for Maximum T1 Compressor
Temperature.

4.2.15 Warning Bank Indicators

Engine Warning
The engine warning indicator is on when the engine warning input is pulled to ground.
The state of this indicator lamp directly follows the engine warning output signal from the
Caterpillar engine.
Engine Diagnostic
The engine diagnostic indicator is on when the engine diagnostic input is pulled to
ground. The state of this indicator lamp directly follows the engine diagnostic output
signal from the Caterpillar engine.

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Section 4
COMPASS CONTROLLER DESCRIPTION
Compressor Warning
The compressor warning indicator lamp is turned on when one or more of the following
conditions exists:
1. Aux Temperature > Maximum Aux Temp. at Run Time (UCP)
2. Aux Temperature out of range
3. DP1, 2, (3, 5 if equipped with After-coolers) active for a UCP-specified time
duration
4. P1 or P3 pressure out of range
5. (P3-P1) > Max Permitted Air-Oil Pressure (UCP)
6. Fuel Level Low
7. Fuel Sender out of range
8. T1 Compressor Temperature out of range
9. After-cooler Freeze-up Imminent or Louver Closed conditions

4.3 COMPRESSOR SHUTDOWN

The compressor shutdown indicator lamp is turned on when one or more of the following
conditions exists. In addition, the system is immediately shutdown when the condition
occurs.
1. T1 Compressor Temperature > Max.T1 Temp. At Run Time (UCP)
2. RTT switch input is active (Includes the Interstage Temperature switch (IT) on
XH and XHH machines)
3. DP4, 6 (if equipped with After-coolers) active for a UCP-specified time duration
4. Very Low Fuel Level
5. P2, P1, P3 pressure signals out of range
6. P1 > Max. permitted P1 pressure at run-time
7. P3 > Max. permitted P3 pressure at run-time

4.3.1 Normal Shutdowns

The Compass Controller enters the Shutting Down state in preparation for a normal
shutdown when either of the following conditions is met:
1. When currently in the Starting or Running state and the Compass Controller
system was started manually, the operator presses the “Off/On/Start” switch to
the OFF position.
2. When currently in the Running state and the Compass Controller system was
auto-started, the system service pressure P1 exceeds the UCP specified level
for a UCP specified duration AND the Remote Start input has been returned to its
normally open (disabled) position.
Note: If the operator switches the “On/Off/Start” switch back to the momentary Start
position before the Compass Controller transitions to the OFF state, the
Compass Controller will re-enter the Warm-up phase of the Starting state.

Note: If the Remote Start is once again enabled before the Compass Controller
transitions to the OFF state during the shutdown sequence from an auto-start

30
 Section 4
COMPASS CONTROLLER DESCRIPTION
operation, the Compass Controller will re-enter the Warm-up phase of the
Starting state.
4.3.2 Abnormal Shutdown
An abnormal shutdown is defined as any shutdown that occurs for any reason other than
that discussed in the Normal Shutdown section. Any of the following conditions will
cause the compressor to be shut down:
1. Engine sends a “Stop Engine” command over the data bus
2. Fuel level reached the “Very Low” level
3. P1 Air pressure exceeds P1 maximum value allowed
4. P2 Control pressure goes out of range
5. P3 Pressure exceeds P3 maximum value allowed
6. T1 Compressor temperature exceeds T1 Maximum value allowed
7. RTT/IT/ input becomes activated
8. DP4 after-cooler is activated (if system uses after-coolers)
9. DP6 after-cooler is activated (if system uses after-coolers)
10. Loss of the Compass Controller internal data bus
11. Engine crank cycle is exceeded
12. Engine crank cycle engine speed is unknown (not reported to the Compass
Controller by engine)
13. Engine speed while in running phase is unknown (not reported to the Compass
Controller by engine)
14. Emergency Stop is activated
Note: Those conditions listed in bold font above are User-Configurable Parameters.
Any of the preceding conditions will cause the compressor to stop immediately. The LCD
display will indicate what the cause of the shutdown is, similar to the example shown
below:

Engine Over Crank

Ok Exit Toggle

The Compass Controller system will prevent the compressor from restarting until the
operator acknowledges the fault by pressing the “Reset” switch.

Abnormal Shutdown Events

Abnormal shutdown information is stored and retained across power-up sessions of the
system in the Compass Controller memory. The abnormal shutdown event data can be
retrieved, displayed and analyzed using the Compass Communicator Software program.
Refer to Section 5 for steps to troubleshooting abnormal shutdown events.

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Section 4
COMPASS CONTROLLER DESCRIPTION

The following information is stored for each of the five most recent abnormal shutdown
events that have occurred within the Compass Controller.
• Shutdown Fault Type
• Engine Hours at time of Fault
• P1, P2, P3 pressure at time of Fault
• T1, Aux Temp at time of Fault
• Fuel Level at time of Fault
• Vdc reference voltage at time of
Fault
• Pending Warnings at time of Fault
• State of DP1-6 and RTT switch
inputs time of Fault
• Start Switch and Remote Start
Switch inputs at time of Fault
• Hi/Lo pressure switch at time of
Fault
• Lin bus and J1939 bus status at
time of Fault
• Engine Speed at time of Fault
• Battery Voltage at time of Fault
• Engine Boost Pressure at time of
Fault
• Engine Inlet Manifold Temperature
at time of Fault
• Engine Coolant Temperature at time
of Fault
• Engine Fuel Temperature at time of
Fault
• Engine Oil Pressure at time of Fault
• Engine Fuel Pressure at time of
Fault
• Engine Load at time of Fault
• Number of Active FMIs from Engine
at time of Fault
• First FMI/SPN data if active from
Engine at time of Fault
• Engine Lamp Status if any active
FMIs from Engine at time of Fault

4.3.3 Main Screen While In Running State

Once the Compass Controller transitions into the Running state, it continuously displays
the system service pressure on the top half of the LCD display. The bottom half of the
screen will display associated engine/compressor parameters. The parameter last
displayed when the controller was shutdown will be the active display parameter at the
next power-up session.
An example display while in the Running state is shown below. The presence of the “r.”
in the upper right hand corner of the display indicates that the Compass Controller is
remote start enabled.

110 PSI r.

23 PSI Boost Pres

Note: The “r.” indication does not indicate that the current Running state was entered
via the Remote Start input, but only that remote start is enabled.

Once in the Running state (Assuming the 2nd Line Parameter is turned on),
momentarily pressing the “m” button (<5 seconds) will scroll the second line
through all available parameters. The list of available parameters is as follows:

32
 Section 4
COMPASS CONTROLLER DESCRIPTION
Parameter Title Displayed on Parameter Description
LCD Line 2
Eng speed Engine Speed as reported by engine
Hour glass icon Cumulative Engine Operation Hours
Serv pres Current P1 service pressure measurement
Cntrl pres Current P2 control pressure measurement
Wet pres Current P3 control pressure measurement
(P3-P1) Current P3 minus P1 (differential pressure of
separator element)
Comp temp Compressor Tank temperature (T1 sensor)
Amb temp –or- Serv temp Aux1 sensor temperature (displays as ambient if
after-coolers not configured for system)
Coolant Temp Engine Coolant Temperature – J1939
Batt V Battery Voltage – J1939
Eng Load Engine Load % - J1939
Fuel Rate Fuel Consumption Rate – J1939
Fuel pres Fuel Pressure – J1939
Fuel temp Fuel Temperature – J1939
Eng Air Temp Engine Air Temperature – J1939
Oil Pres Engine Oil Pressure – J1939
Boost Pres Engine Boost Pressure – J1939
Des Speed Desired Engine Speed – J1939
Aux1 pres Engine Aux1 Sensor Pressure – J1939
Aux1 temp Engine Aux1 Sensor Temperature – J1939

33
 NOTES

34
 Section 5
TROUBLESHOOTING
5. TROUBLESHOOTING
5.1 TROUBLESHOOTING INTRODUCTION
This Troubleshooting section is provided as a guide to aid in diagnosing and resolving
compressor problems when they occur. The information contained in Table 5A,
Troubleshooting Guide, has been compiled from factory experience and contains
symptoms and usual causes for the described problems. Each warning or fault
message is listed with conditions of when the problem may occur, a probable cause,
and a suggested solution to the problem. DO NOT assume that these are the only
problems that may occur. This document cannot address every possible adverse
condition that may occur nor does it provide every solution for the potential troubles
listed. All available data concerning the trouble should be systematically analyzed
before undertaking any repairs or component replacement procedures.
Always perform a detailed visual inspection when a machine problem occurs prior to
attempting any repairs. Doing so may avoid unnecessary repair and/or additional
damage to the compressor.
Always remember to:
a. Check for loose wiring, loss of ground, wire termination, etc.
b. Check for damaged piping.
c. Check for parts damaged by heat or an electrical short circuit,
usually apparent by discoloration or a burnt odor.
Should your problem persist after making the recommended check, consult your
nearest Sullair Distributor or the Sullair Corporation factory Service Department.

NOTE
Section 5.3 portrays common systematic problems that can occur during
controller operation. For a more thoroughly in-depth coverage of the
compressor operation troubles, consult the Troubleshooting Section in the
machine’s operator’s manual.

5.2 TROUBLESHOOTING GUIDE INTRODUCTION

The following guide contains symptoms and usual causes for the problems that may
occur throughout the compressor system. Each warning or fault message that may
appear is listed along with conditions for the problem, a probable cause, and a
suggested solution to the problem. DO NOT assume that these are the only troubles
that may occur.
The following table denotes all warning/shutdown conditions that the Compass
Controller will sense. Shutdown conditions will display the associated message on the
LCD, light the Compressor Shutdown panel light, shut the system down, and wait for
operator to press the Fault/Reset button to acknowledge the fault condition before a
restart may be attempted.
Warning conditions display the associated message on the LCD and light the
Compressor Warning panel light. Under a warning condition the system will continue
to operate normally. In addition, the operator may dismiss the warning message from
the LCD screen by pressing the “m” (mode) and “t” (trip) buttons on the master gauge.

35
 Section 5
TROUBLESHOOTING

5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE

Error Message Warning/Shutdown/ Description Recommended Action
Prevent Statup
No Message Prevent Startup No power or initialization of controller Turn OFF/ON/START
switch to ON position.
Make sure E-stop is not
engaged (pull out).
Turn Battery Disconnect
Switch to ON position.
Check Battery Voltage.
Check Connections
between Compass
Controller and harness
and at the starter and
harness.

Make sure Controller

internal circuit breakers
(4) are closed.
Listening For Engine Prevent Startup No communication between Compass Verify bus resistance at
Controller and engine ECM 120 Ω.
Ensure proper
connection between
engine ECM and
Compass Controller.
Low Fuel Level Shutdown/Prevent Fuel Level Low Shutdown threshold reached Add fuel and restart.
Startup
P2 Signal Error Shutdown/Prevent Transducer has no source voltage Verify 5Vdc to
Startup transducer.
Transducer has lost ground Verify path to ground.
Output voltage to controller is lost Verify .5-4.5Vdc to
controller.
Transducer malfunction Replace transducer.
Comp High Temp Shutdown/Prevent T1 Compressor temperature sensor is above Verify thermistor
Startup shutdown setpoint resistance between
803Ω @ -50˚C and
1573Ω @ 150˚C.
Coolers dirty Clean coolers.
Fan slipping Check/Adjust Fan belt
tension
Compressor Oil Thermostat malfunction Replace thermostat.
RTT High Shutdown/Prevent RTT (Receiver Tank Temperature) switch, Verify compressor
Startup normally closed, has opened temperature via
controller display (toggle
to proper parameter). If
compressor temp is less
than the setpoint on all
others then replace the
RTT switch.
Primary Shutdown Shutdown/Prevent Afterfilter restriction too high (filters dirty) Replace filters.
Startup

36
 Section 5
TROUBLESHOOTING
5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE (CONTINUED)
Error Message Warning/Shutdown/ Description Recommended Action
Prevent Startup
Primary Shutdown Shutdown/Prevent Afterfilters dp module malfunction Check source voltage
(continued) Startup and ground and correct
if necessary.
Visually inspect for
damage and replace if
necessary.
Compass Comm Shutdown/Prevent Internal Cabling inside the Compass Open Controller and
Error Startup Controller is not properly connected ensure that all gauge
and warning bank
connectors are well
seated/engaged.

High Comp Pressure Shutdown/Prevent P1 (Dry) or P3 (Wet) pressure is above Pressure above 10 psi
Startup setpoint (recent shutdown). Wait
for pressure to fall below
10 psi.
Transducers out of calibration Transducers need to be
calibrated using the
Gauge calibration
subroutine (see Section
3.2.12).
Engine Overcrank Shutdown The maximum number of engine crank Check battery voltage &
cycles has been exceeded recharge if necessary.
Check starter relay for
short to ground.
Check source voltage to
starter relay.
Engine Comm Error Shutdown/Prevent The Compass Controller is not properly Check connections at
Startup receiving J1939 messages from the engine engine ECM and
ECM. Compass Controller.
Check the termination
resistor in the harness
ECM connector and
replace if necessary.
E-Stop Pressed Shutdown/Prevent The Compass Controller will not power Disengage E-stop.
Startup up/initialize (NO MESSAGE AT
CONTOLLER!)
The E-stop was used to shut machine down. Once conditions are
deemed safe, press the
Reset switch, Press the
OFF/ON/START switch
to OFF.
Eng Speed Too Low Shutdown Engine speed dropped below preset value for Check fuel level.
a preset amount of time. This is to protect Check the inlet valve for
the vulcanized rubber drive coupling between premature opening
the engine and compressor. during the warmup
phase.

37
 Section 5
TROUBLESHOOTING

5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE (CONTINUED)

Error Message Warning/Shutdown/ Description Recommended Action
Prevent Statup

P1,P2,P3 Signal Shutdown Loss of all transducer inputs during run Check voltage source
Error phase and ground for good
connection.
Low Fuel Level Warning Fuel light in 4-in-1 gauge is on. Compressor Add fuel soon
warning light is on. Fuel level is below 20%
Fuel Sender Error Warning The fuel level sensor signal is out of range Check connections at
sensor on tank. Verify
source voltage and
ground.
Wires possibly reversed.
Fuel sensor is defective.
Replace
Controller is configured
incorrectly (configured
for tank when no tank is
present). Reprogram
the Compass Controller
using the Compass
Controller
Communication
Software,
Communication
Adapter, and PC.
P1 Signal Error Warning Transducer has no source voltage
Transducer has lost ground
Output voltage to controller is lost
Transducer malfunction
P3 Signal Error Warning Transducer has no source voltage
Transducer has lost ground
Output voltage to controller is lost
Transducer malfunction
Air-Oil Separator Warning The differential pressure (P3 - P1) is above Separator elements are
the setpoint for the specified period. dirty. Replace.
Aux Temp High Warning T2 (Aftercooler discharge temp or ambient Clean coolers.
temp on non-aftercooled machines)
Check/Adjust Fan belt
tension.
Check T2 (RTD) for
short circuit to ground.
Aux Temp Error Warning Check T2 (RTD) for
short circuit to ground or
open circuit.
Engine Air Filter Warning DP1 switch, normally closed, has opened for Engine air filters
the specified amount of time clogged. Replace filters
Check circuit for
continuity.
Check the air filter
switch for continuity.
Replace if open.

38
 Section 5
TROUBLESHOOTING
5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE (CONTINUED)
Error Message Warning/Shutdown/ Description Recommended Action
Prevent Statup
Comp Air Filter Warning DP2 switch, normally closed, has opened for Engine air filters
the specified amount of time clogged. Replace filters
Check circuit for
continuity
Check the air filter
switch for continuity.
Replace if open.
Primary Warning Warning Afterfilters restriction increasing (becoming service filters soon
clogged)
DP Signal Error Warning Afterfilters differential pressure signal module check connections
is encountering a malfunction between the filter
module and the two
pressure transducers
(P4 & P5) at the
afterfilters

check source voltage

and ground to
transducers and to dp
module
replace transducers
replace dp signal
module
Engine comm error Warning The Compass Controller is not properly Check connections
receiving J1939 massages from the engine. between the engine
If this occurs while engine is cranking, a ECM and harness and
shutdown results. Otherwise it is only a between the Compass
warning. Controller and harness.

Louvers Closed Warning

AC Freeze Imminent Warning If the Compass Controller is configured with Bypass the aftercooler
an aftercooler and no louvers installed and service air discharge
the temperature at the discharge of the circuit by locking out the
aftercooler falls below the setpoint, this aftercooler from the
message is displayed. system and using non-
aftercooled air.

install Louvers on the

aftercooler (if equipped)
or the canopy intake
Wait to Start Warning Message from CAT engine ECM. J1939 Check Engine ECM for
Shutdown SPN1081 - Wait to Start active active codes/faults and
possible configuration
errors. Contact your
nearest CAT servicing
dealer for resolution.

39
 Section 5
TROUBLESHOOTING
5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE (CONTINUED)
Error Message Warning/Shutdown/ Description Recommended Action
Prevent Statup
Oil Pressure Low Warning CAT DM1 Message (Engine ECM) Check oil level and add
if necessary. If
condition persists,
contact your nearest
CAT servicing dealer for
resolution
Coolant Temp High Warning CAT DM1 Message (Engine ECM) Check coolant level and
add if necessary. Clean
radiator if dirty. Check
fan belt tension and
tighten if needed.

Eng. OverSpeed Warning CAT DM1 Message (Engine ECM) If problem persists, shut
machine down and
check for volatiles in the
atmosphere. Don’t
restart machine until
condition is removed. If
ECM still displays
message, contact your
nearest CAT servicing
dealer for resolution.
High Inlet Air Temp Warning CAT DM1 Message (Engine ECM) Check wind direction
and make sure
engine/package exhaust
is not being recirculated
to air intakes. Relocate
compressor if
necessary.

Low Coolant Level Warning CAT DM1 Message (Engine ECM) Check coolant level and
add if necessary.
Check connection
between the coolant
level sensor and the
harness. Replace
sensor if necessary.
High Fuel Temp Warning CAT DM1 Message (Engine ECM) Make sure cooling air
intake is facing
prevailing winds. Make
sure all cooling air
openings in canopy are
not obstructed. Add fuel
if tank is near empty.

40
 Section 5
TROUBLESHOOTING
5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE (CONTINUED)
Error Message Warning/Shutdown/ Description Recommended Action
Prevent Statup
High Fuel Pressure Warning CAT DM1 Message (Engine ECM) fuel delivery system
relief valve malfunction -
contact you local CAT
servicing dealer
High Exhaust Temp Warning CAT DM1 Message (Engine ECM) Check wind direction
and make sure
engine/package exhaust
is not being recirculated
to air intakes. Relocate
compressor if
necessary.
Exhaust valve timing
incorrect - Contact your
local CAT servicing
dealer

5.4 CONTROL PARAMETERS

Control Parameters for the Compass Controller are shown in Table 5.2. The Display
Text column indicates the text appearing on the controller display screen. Type
denotes the parameter as a factory setup, a calculated value, a user set parameter, or
sequence parameter. Enable refers to the machine type that the parameter and
values apply. Default shows the factory default setting for the parameter. Min/Max
are the minimum and maximum values. Comments provides a brief explanation of the
parameter function.
The following settings are configurable using the Compass Controller Communicator
program. Note that those listed in bold font below affect the threshold at which
abnormal shutdowns may occur.

Table 5B Compass Controller Control Parameters Power-up Options Menu

Minimum Value Maximum Value
Parameter Description Permitted Permitted Default Value
Crank On Duration (seconds) 3 7 5
Crank Off Duration (seconds) 4 30 10
Maximum # of Crank Cycles Permitted 1 5 3
Engine Cranked Speed (rpm) 200 500 250
Required Time At Cranked Speed
(milliseconds) 240 1000 480

Fuel Level Low Warning (% full) 10 40 20

41
 Section 5
TROUBLESHOOTING
Table 5B Compass Controller Control Parameters Power-up Options Menu (Continued)
Minimum Value Maximum Value
Parameter Description Permitted Permitted Default Value
Cancel Fuel Level Low Warning (% full) 13 43 23
Fuel Level Low Shutdown (% full) 4 10 8
Cancel Fuel Level Low Shutdown (% full) 7 13 11
Fuel Tank Type – large, small, or switched large

T1 Compressor Temperature Max (deg. F) 200 300 250

Aux Temp Max at run-time (deg F) 200 265 250
Minimum Engine Temp at warm-up complete
(deg. F) 65 90 70
Max allowed P1 @ Run-Time (PSI) 145 600 200
Max allowed Air-Oil-Sep pressure @ Run-
Time (PSI), P3 - P1 10 20 15
Air-Oil-Sep Pressure alert time (secs) 10 60 15

Max allowed P1 @ Startup (PSI) 0 15 10

P1 pressure level for stopping from auto-start
(PSI) 70 600 100
Time >= above pressure before stopping from
auto-start (secs) 300 1800 900

Engine Speed @ Warm-up Complete (rpm) 1375 1450 1375

Minimum Engine Warm-up Time (secs) 5 60 30
Maximum Engine Warm-up Time at normal
temperatures (secs) 60 360 240
Temperature low starting aids (deg. F) -40 -16 -40
Maximum Engine Warm-up Time low starting aids
(minutes) 31 75 60
Temperature mid starting aids (deg. F) -15 9 -15
Maximum Engine Warm-up Time mid starting aids
(minutes) 16 30 30
Temperature hi starting aids (deg. F) 10 20 10
Maximum Engine Warm-up Time hi starting aids
(minutes) 5 15 15
Engine Type Is C9? yes no No
Freeze-up Assert Temperature (deg F) -40 50 40

42
 Section 5
TROUBLESHOOTING
Table 5B Compass Controller Control Parameters Power-up Options Menu (Continued)
Minimum Value Maximum Value
Parameter Description Permitted Permitted Default Value
Freeze-up Cancel Temperature (deg F) -40 68 45
Compressor Cool-down Time (secs) 5 600 300

300 PSI/600 PSI system 300 PSI

Second-line parameter display enabled Yes
Metric/English Units English
Remote Start Enabled No
Intake Louvers Equipped No
After-filters Equipped No
Gauge Self-test At Power-On Yes

DP1-6 alert time (secs) 10 60 15

The Compass Controller Language at

Display { English, French, Spanish,
German, Italian, Portuguese} English

Switched Power Off Interval At Cool Down

(secs) 3 10 5
P1,P2, P3 pressure threshold for cool down
termination (PSI) 5 15 10

Recirculation Solenoid Open P2 Pressure

(PSI) 30 90 60
Recirculation Solenoid Close P2 Pressure
(PSI) 25 85 55

Auto-Sleep Timeout (minutes) 5 20 or 0 to not use 10

Gauge Backlighting Level (%) 60 90 60

LCD Contrast Level (%) 0 85 0
Line 2 parameter displayed
1 of 20 parameters...
See “Run Mode” section of this document. Eng RPM

43
 Section 5
TROUBLESHOOTING
Table 5B Compass Controller Control Parameters Power-up Options Menu (Continued)
Minimum Value Maximum Value
Parameter Description Permitted Permitted Default Value
P1 Calibration Offset (kPa) 0 50 0
P2 Calibration Offset (kPa) 0 50 0
P3 Calibration Offset (kPa) 0 50 0

LO Idle Engine Speed (rpm) 1300 2000 1400

HI Idle Engine Speed (rpm) 1500 4000 1800
Low pressure Max PWM Duty Cycle (%) 70 92.5 92.5
High Pressure Max PWM Duty Cycle (%) 70 92.5 92.5

Minimum P2 pressure for Max Speed (PSI) 0 10 5

44
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E06
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