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Sullair Air Compressor

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ESGN-C-M-SA-EN-0000
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Table of Contents Sullair Air Compressor

Table of Contents
Preface..........................................................................................................................iii
Copyright...........................................................................................................................................iii
Revision Record – ESGN-C-M-SA...............................................................................v
Air Compressor Description .......................................................................................1
Principles of Operation................................................................................................3
Compressor Modulation.....................................................................................................................5
Compressor Unloading......................................................................................................................5
Compressor Reloading......................................................................................................................6
Q1 Controller.................................................................................................................7
Air Compressor Touchpad Operation................................................................................................7
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Graphic Display..................................................................................................................................9
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User Account Controls.......................................................................................................................9
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Menu Navigation..............................................................................................................................10
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Menu Map........................................................................................................................................12
N a
O ce er
Controller Symbols...........................................................................................................................16

I A nan t Op
L
Menu Detail......................................................................................................................................18

E R te en
Message Codes...............................................................................................................................21
Q1 Controller Settings for Joy GlobalAEMD08-30 T ain Compressor........................................................23
m
M r M qu i p
E
C E fo r E
Air Compressor Operation........................................................................................29
N fo Time...........................................................................29
Motor Rotation Check......................................................................................................................29
E Ufor S theEFirst
R
Starting Up the Air Compressor
E T (Subsequent S
Starting Up the Air F U
E
Compressor
O T
Starts)......................................................................30
NMode.........................................................................................................30
R Control
Load / Off Load:
O O
N
D O Mode........................................................................................................30
Continuous Run: Control
Shutting Down the Air DCompressor..................................................................................................30
Programming Sequencing................................................................................................................30
Special Site Requirements...............................................................................................................30
Safety Decals...................................................................................................................................32
Wiring Diagrams...............................................................................................................................34
Air Compressor Maintenance....................................................................................41
Inspecting the Air Compressor.........................................................................................................41
Adjusting the Air Compressor Modulation........................................................................................42
Checking and Adding Compressor Oil.............................................................................................43
Changing the Air Filter.....................................................................................................................43
Changing the Oil Filter.....................................................................................................................45
Changing the Oil Separator..............................................................................................................45

Copyright © 2013 P&H Mining Equipment Inc. -i- Version 0000 - 10/13
Sullair Air Compressor Table of Contents

Air Compressor Troubleshooting.............................................................................47

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Version 0000 - 10/13 -ii- Copyright © 2013 P&H Mining Equipment Inc.
Preface Sullair Air Compressor

Preface
This manual for Sullair Air Compressor (“Manual”) is provided as a guide to personnel involved with the
operation, maintenance and repair of this P&H® mining shovel. We recommend that such personnel
review and become familiar with the general procedures and information contained within this Manual. In
addition, we recommend that this Manual be kept readily available for reference when repairs or
maintenance are necessary.
Read and become familiar with this Sullair Air Compressor manual and the General Safety
Practices manual before attempting any procedures.
Due to the complexities of mining equipment and the environment in which it operates, situations may
arise which are not directly discussed in detail in this Manual. When such a situation arises, past
experience, availability of equipment and common sense play a large part in what steps are to be taken.
In addition, a Joy Global Service representative is available to answer your questions and assist you upon
request.
P&H Mining Equipment Inc. reserves the right to continually improve its products and associated
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documentation. Therefore, physical alterations to the P&H mining shovels may not be identified in this
Manual. Revisions may be frequently made to this Manual in an effort to ensure that information
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contained within is current as alterations occur to the P&H shovel. If you find an error or have other
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feedback regarding this Manual, please contact P&H Product Training and Publications at
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Pro.Train.Pub@joyglobal.com.

Copyright O ce e
I A L
an Op
E R tentreaties,
Copyright © 2013 P&H Mining Equipment Inc. All rights reserved.
e nt Allandmaterials contained herein are
n m the prior written permission of P&H
ATor broadcast
ai ipwithout
protected by United States copyright law and international may not be reproduced,
distributed, transmitted, displayed, published
Mining Equipment Inc. You may not alterM M any utrademark, copyright or other notice from copies
r materials
or remove
q
of the content. All rights in translationsEof these
o
N C E f r E shall remain exclusively with P&H Mining
E US E fo
Equipment Inc.
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Copyright © 2013 P&H Mining Equipment Inc. -iii- Version 0000 - 10/13
Sullair Air Compressor Preface

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Version 0000 - 10/13 -iv- Copyright © 2013 P&H Mining Equipment Inc.
Revision Record – ESGN-C-M-SA Sullair Air Compressor

Revision Record – ESGN-C-M-SA


Version Revision Description Author Date
0000 Initial release 10/13

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Copyright © 2013 P&H Mining Equipment Inc. -v- Version 0000 - 10/13
Sullair Air Compressor Revision Record – ESGN-C-M-SA

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Version 0000 - 10/13 -vi- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Description Sullair Air Compressor

Air Compressor Description


Figure 1: Sullair Air Compressor with Q1 Controller

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ESGN_C_AS_P_00009_1

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qbut withnsextra high pressure
Y E
L of to allow tio the compressor to be used
This shovel features an air compressor package similar to Sullair ES-8,
capabilities, a robust structure, and available enclosures, allNdesigned a
O ce er
in mining shovel applications.
L p
ndirectional
This rotary screw compressor has a 30 HP, 3-phaseIA a O
nt rotation can be observed. The motor
en emotor
soRthat tcorrect
motor. A arrow is provided on the fan
shroud between the motor and the compressorE
A a in mThe compressor features a heavy duty air
T coupling.
is direct-coupled to the compressor with a flexible
filter with remote air intake, a Mark phaseMreversalMrelay, p a 1-micron fiberglass fluid filter. An air-
iand
r u
cooled aftercooler with separator and E
C fo helps
drain trap
r Eqremove moisture.
E
A Q1 controller provides compressor
S E foand control, and provides users at several levels with
N monitoring
R U appropriate
monitoring and adjustment capabilities
E S E for their level of access.
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Copyright © 2013 P&H Mining Equipment Inc. -1- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Description

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Version 0000 - 10/13 -2- Copyright © 2013 P&H Mining Equipment Inc.
Principles of Operation Sullair Air Compressor

Principles of Operation
Figure 2: Air Compressor Operation

03 04

07 08 09

02

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R
E T US ESGN_C_SA_D_00001_1

F
E NO T
LEGEND R O NO04 - Inlet Control Valve
01 - Oil Filter
D
02 - Air / Oil Separator O 05 - Cooling Fan
07 - Air
08 - Air / Oil
03 - Intake Air D 06 - Compressor Unit 09 - Oil

This compressor has an air filter for incoming air. Air will pass through an inlet control valve as it enters
the compressor. The inlet control valve is a pneumatically controlled valve, controlled by air pressure
entering the valve at a small control air line. At peak demand, this inlet control valve will be wide open. As
the system pressure approaches the maximum set point, the inlet control valve will gradually close. At the
maximum set point, the inlet control valve will be in its fully closed position and will prevent any further
compression until demand lowers system pressure below the maximum set point.

Copyright © 2013 P&H Mining Equipment Inc. -3- Version 0000 - 10/13
Sullair Air Compressor Principles of Operation

The compressor unit consists of two screws, one male and one female. The male is turned by the motor
and the female is an idler. As these screws are turned past the inlet port they create a vacuum which
draws air through the filter and inlet control valve and into the compressor. Oil is also introduced into the
compressor to keep the screws and bearings lubricated. There is no oil pump; the oil is pushed into the
compressor by pressure in the oil sump. As the screws rotate an air/oil mix is compressed between the
screws and expelled out the outlet port of the compressor into the sump area. Most of the heavy oil falls
to the bottom of the sump due to gravity. A small amount of oil remains in the air in the sump. As the air in
the sump is pushed out the air outlet at the top of the sump, the air passes through the separator, which
removes the remaining oil. A minimum pressure/check valve at the outlet ensures the pressure in the
sump area stays above 60 psi (4.2 bar), which is necessary for good oil flow. The minimum pressure/
check valve also ensures system pressure can not be forced back into the compressor when the
compressor motor is shut down.
Air exiting the compressor is directed through an after cooler and a moisture separator, and then on to the
air system main receiver.

WARNING
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Do not open or remove any of the compressor components
while the compressor contains air pressure. Opening the oil
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fill plug or opening the compressor to atmosphere in any
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other way while the compressor contains air pressure will
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allow compressed air and possibly hot oil to escape, which
could cause severe personal injury.
O ce e
As the compressor begins operating, pressure in the sump L
A aforces n oilOpto a temperature bypass valve. This
valve will allow cold oil to bypass the oil cooler, but Ias thenoil t the bypass valve directs the oil
R
E in t e e n
warms,

T
through the oil cooler to maintain proper oil temperature.
A Ma seals
The
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temperature bypass valve works similar to a
thermostat on an automobile cooling system. The
compressor screws. The oil lubricates theMcompressor,
oil
i p the small gapsthebetween
continues on through oil filter and into the
r q u the screws, and
also cools the compressor. A temperature E
C E fo rises
sensor Eabove 235ºF (113ºC).
located in the bottom of the oil sump will cut out the
compressor motor power if the oilN r
E US E fo
temperature
R
E T US
F O CAUTION
RE O N OT
D OtheNand
In cold weather
up before opening
temperature bypass valve must allow the oil to warm

D remainsending
open, the oil will
oil through the cooler. If the valve sticks
cold and will load up with moisture, which could
cause the oil to froth and the separator to send oil through to the rest of
the air system.

Version 0000 - 10/13 -4- Copyright © 2013 P&H Mining Equipment Inc.
Principles of Operation Sullair Air Compressor

Compressor Modulation
If less than the rated capacity of compressed air is being used, the service line pressure will rise above
160 psi (11.2 bar). The pressure regulator valve gradually opens, directing air pressure to the inlet control
valve, reducing air entering the compressor until it matches the amount of air being used. The control
system functions continually in this manner between the limits of 160 – 170 psi (11.2 – 11.9 bar) in
response to varying demands from the system air demands rising and dropping. The pressure regulator
has an orifice which vents a small amount of air to the atmosphere when the pressure regulator controls
the inlet control valve.

Figure 3: Pressure Regulator Valve

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C E fo r E ESGN_C_SA_D_00010_1

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LEGEND R S
E T 03 U- Bell
01 - Orifice
E F O 04 - Adjustment Screw
R O N T
NO
02 - Diaphragm Assembly
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DO
Compressor Unloading
If less than the rated capacity of compressed air is being used, the system air line pressure will rise above
175 psi (12.1 bar). At this point the Setpoint in the Q1 controls will activate an unloading. The unloader
solenoid valve will open and air pressure will force the inlet control valve to fully close. The pilot operated
de-energizes the solenoid valve allowing sump air pressure to be supplied directly to close the inlet valve.
Simultaneously, the solenoid valve sends a pneumatic signal to the blowdown valve. The blowdown valve
opens the sump to the atmosphere, reducing the sump pressure to approximately 20 – 30 psi (1.4 – 2.1
bar). The MPV minimum pressure/discharge check valve in the air service line prevents line pressure
from returning to the sump.

Copyright © 2013 P&H Mining Equipment Inc. -5- Version 0000 - 10/13
Sullair Air Compressor Principles of Operation

Compressor Reloading
When the line pressure drops to the low setting (cut-in pressure; usually 175 psig (12.1 bar), the Q1
controls will energize the unload solenoid valve, and allows the blowdown valve to close. The re-
energized solenoid valve again removes the pressure, and the inlet control valve is in the fully open
position as long as the compressor is running. Should the pressure begin to rise, the pressure regulator
will resume its normal function as previously described. The pressure regulator for modulation is set at
160 psig (11.2 bar).

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Version 0000 - 10/13 -6- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Q1 Controller
The Q1 controller is designed for positive displacement rotary screw compressor applications.

Air Compressor Touchpad Operation


Figure 4: Q1 Touchpad and Display

01 02

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03 ESGN_C_AS_P_00001_2

M r qu
LEGEND
01 - Message Display
E fo r EButtons
C02 -EFunction 03 - Navigation Buttons
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Copyright © 2013 P&H Mining Equipment Inc. -7- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

Table 2: Touchpad Buttons

Button Name

Start

Stop

Reset

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Enter
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Up
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I A nan t Op
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E R te Down n
T i n me
A a
M r M quip
C E fo E Escape
E N SE for
E R U SE
E F OT U
R O N OT E-Stop
D O N
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Version 0000 - 10/13 -8- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Graphic Display
The graphic display is intuitively arranged.

Figure 5: Controller Display

01 02 03

04
05

06

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ESGN_C_AS_P_00002_1

N L of
a tio
LEGEND O ce e05r - Menu Content and
01 - Device State Message 03 - Device State
I
L
A State an Op Navigation
R Text en ent 06 - Menu Page Name,
Symbols 04 - Equipment and
02 - Device Pressure Display E
T ain m
Condition t
and PL or PH State A i p Number, and Navigation
Symbol M r M qu
E folightrlevel
C display E will reduce until a key is pressed.
N
After a period of non-use, the graphic
E
S Eand
E power-up, o
f where the display will return after a period of non-use.
P00 is the default menu view R after U
F T USbetween menus.
E to navigate
E N T
Use the Up and Down buttons O
Where applicable, theRmenu O
DO O N
item highlighted will toggle between the default menu display and additional
menu information.
For Example: P00.02 D
Control Mode
Load / Off Load

User Account Controls


The controller is supplied with four user accounts:

• Operator
• JoyGlobal
• Admin
• Sequence

Copyright © 2013 P&H Mining Equipment Inc. -9- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

For security purposes, some of the four-digit PIN code ‘USER’ account information and PIN codes may
not be printed in this manual. Please contact Joy Global Service for more information.
‘USER’ account four-digit PIN codes:

• ‘Operator’ user account PIN: 2012


• ‘JoyGlobal’ user account PIN: Contact Joy Global Service

The ‘Default User’ can view all compressor operating values, and menus P00 – P09 only. Changes
cannot be entered until one of the PIN codes is activated.
The ‘Operator’ account is protected via a four-digit PIN code. If you enter a four-digit PIN code incorrectly,
after pressing the Enter button, the user will be returned to Menu P09.01 (i.e., ‘Default’ user). The
‘Operator’ can view all compressor operating values, and menus P00 – P08 only.
The ‘JoyGlobal’ account is protected via a four-digit PIN code. The ‘JoyGlobal’ account can view all
compressor operating values on menus P00 – P09, and can edit pressure setpoints, language, time
settings, date settings, units, drain intervals, and service timers on menus P10 and P011 .
The ‘Admin’ user PIN code is intentionally not printed. It is for factory use only.
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The ‘Sequence’ user PIN code is intentionally not printed. This account is not used.
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Menu Navigation u ip
Y n s
q interface
E o
NLis indicated
of raonti the vertical scroll bar.
Menu tabs are arranged sequentially and in a continuous loop. The graphical inverts to identify
the on-screen navigation location, and the navigation location
O ce e
L n OpFor example:
A nalocation.
Additionally, the menu tab extends to identify the navigation
I
E e ent
R tDescription
n m
AT MaiMenu:
Item
P02
M r quip Utilization
C E fo E
E N SE for
E R U SENOTICE
F OT sequentially
Menu itemsEare indexed
U
N T
R it isOnot configured
and without omission. If a menu item is not
displayed,
N O for the particular air compressor or not allowed for
D O
editing under the current user account.
D

ESGN_C_AS_P_00003_1

Version 0000 - 10/13 -10- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Use the Enter and Escape buttons to toggle between menu page navigation and menu content
navigation. Entering the menu content area navigates to the first item of the menu.

ESGN_C_AS_P_00004_1

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Use the Up and Down buttons to navigate between menu parameters. Menu parameters are vertically
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assembled and in a continuous loop. For example, the following screen indicates the user has navigated
to P01 menu item 06.
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Copyright © 2013 P&H Mining Equipment Inc. -11- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

To edit an accessible and editable menu item, navigate to it and press the Enter button.

ESGN_C_AS_P_00006_1

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An edit menu pop-up window will appear. Use the Up and Down buttons to select an available option.
en
Press and hold the Up or Down button to increase the speed at which a selectable value is reached.
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Press the Enter button to confirm a selection or use the Escape button to exit without making a new
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selection. With the pop-up window displayed, press and hold the Enter button to alternate between
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display text and display value.

O ce e
A nan t Op
L
Menu Map
I
R te en
E
NOTICE n
AT Mai ipm
Display menus M r basedq uon device configuration.
E o
will vary
C Ef rE
N
E US ENOTICE fo
R
E T US
F
Menu P00,EP01, N O P03,
R P02, T P04, P05, P07, and P08 are read-only menus. P06,
P09, P10, andOP11 areOread and edit menus (edit using ECO card option only).
D ON
D a sub menu item (e.g., P02.10.01).
Press the Enter button to access

Version 0000 - 10/13 -12- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Table 3: Q1 Menu Map – P00, P01, P02, and P03

P00 – Home P01 – Service Timers P02 – Utilization P03 – Error Log
01 Any Active Alarm 01 Total Hours 01 EQUIP Status 01 Error 1
02 Control Mode 02 Load / Off Load HRS 02 Load / Offload Hours
03 P00.03 User DEF 03 Load Hours 03 MTR STR Last HR 50 Error 50
04 P00.04 User DEF 04 Off Load Hours 04 MTR STR Last 24H
05 P00.05 User DEF 05 Stopped Hours 05 Load Frequency
06 COMP OUT TEMP 06 Service Hours 1 06 Load % Last Hour
07 Load % Last 24
07 EQUIP OUT PRESS 07 Service Hours 2
Hours
08 EQUIP INT PRESS 08 Service Hours 3 08 Load Time Last Hour
09 Load Time Last 24
09 DIFF Pressure 09 Service Hours 4
HRS
t
11 Main MTR Current 10 Service Hours 5 en
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12 Fan MTR Current 11 Service Hours 6
Y E
13 Time 12 Service Hours 7
N L of
atio
14 Date 13 Service Hours 8 O ce er
15 Daylight Saving 14 Weekly Service I A nan t Op
L
15 Annual Service E
R te en
16 ISC Sequence
A T ain m
17 ISC Rotate in HRS SERV M
16 Bi-Annual M
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E fo Eq r
18 ISC XPM Pressure C
N SE for
E
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E
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Copyright © 2013 P&H Mining Equipment Inc. -13- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

Table 4: Q1 Menu Map – P04, P05, P06, and P07

P04 – Event Log P05 – Service Provider P06 – Controller Data P07 – Equipment Data
01 Event 1 01 Company Name 01 Controller ID 01 MANUF NAME
02 Company Name 02 Serial Number 02 EQUIP Model
200 Event 200 03 Street Name 03 Software ID 03 MDL SER Number
04 Street Name 04 Software Version 04 MDL Rated PRESS
05 City 05 Software Time 05 MDL Rated Output
06 State/Province 06 Software Date 06 MDL YR MANUF
07 Zip/Postal 07 Software CFG 07 COMP SER NUM
08 Country 08 Software © 08 COMP YR MANUF
09 Telephone 09 MTR SER NUM
10 Fax 10 MTR YR MANUF
t
11 E Mail e11n CLR SER NUM
m
12 Web
uip 12 CLR YR MANUF
Y Eq ns13 PV Inspect Date
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Version 0000 - 10/13 -14- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Table 5: Q1 Menu Map – P08, P09, P10, and P11

P10 – Equipment P11 – Equipment


P08 – Message Codes P09 – Access Menu
Settings 1 Settings 2
Refer to Menu Detail on
01 DEFAULT USER 01 Control Mode* 01 Star Delta TRANS
page 18.
02 OPERATOR USER 02 Allow Force Offload 02 MIN MTR Run
03 ‘JGS’ USER 04 Load Pressure 03 Load INH Time
04 ‘ADMIN’ USER 05 Off Load Pressure 04 Reload INH Time
05 USER 3 06 Run Period 05 Off load run Time
06 USER 4 07 Offload Period 06 Stop MIN Time
07 USER 5 09 RS485: 1 CONFIG 07 Vent Time
08 USER 6 10 RS485: 2 CONFIG 08 AUTO Restart INH
09 USER 7 11 Start Source*
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09 CNDS Drain Open
10 USER 8 12 Load Source* e10n CNDS Drain INT
m
u ip 11 Off Load Drain Time
q ns12 MTR STR HR INH
11 USER 9 13 Language
14 TimeLY E
12 USER 10
N o f atio
15 O
c e per
Time Format 13 DP Inhibit Time
L n
RIA16 Daylight
n O
a tSaving 14 Service Hours 1

TE in17teDateen 15 Service Hours 2


m
A Ma 18 iDate
M r qu p Format 16 Service Hours 3
E
C E fo r E 20 Pressure Unit 17 Service Hours 4
N
E US E f o
R
E T US
21 Temperature Unit 18 Service Hours 5

E F O 19 Service Hours 6
R O N OT 20 Service Hours 7
D O N 21 Service Hours 8
D 22 Weekly Service
23 Annual Service
24 Bi-Annual Service
* Edit in device stopped state only.

Copyright © 2013 P&H Mining Equipment Inc. -15- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

Controller Symbols
The Q1 controller uses a variety of symbols alongside text descriptions to annunciate compressor
conditions or states of operation. Symbols are used individually or with other symbols to annunciate a
specific message. The following figure and table describe each symbol and its intended use.

Figure 6: Symbol Definitions Sheet

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ESGN_C_SA_P_00005_1

Version 0000 - 10/13 -16- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Table 6: Symbol Definitions

Symbol Description Symbol Description Symbol Description

Management or sequence
Phase angle Immediate stop
control

Remote control Upper or Lower range Warning

Start inhibit Fan Status (animated)

Running, load Running, off load Stopped

Run inhibit Load inhibit Condensate drain

t
Time Edit enSensor
m
uip
Temperature User configurable
Y Eq ns Compressor or package
o
NL of rati
Schedule O ce
Key
A L n Ope Timer

R I na t
Motor Range
T te en
E orindetect Total hours
A Ma ipm
M r qu
Set point
C E o point,
fSet E upper limit Set point, lower limit
N SE f o r
E
R U SERead only
Oil E
F OT U
Unlocked or accessible
E
R O N OT Date
D ON
Locked or not accessible Start delta

D
Delta pressure Up Auto restart

Filter Down Audible alarm

Service or maintenance Stop Time

Set point Enter or inlet Exit or outlet

Emergency stop Next forward Page back

Copyright © 2013 P&H Mining Equipment Inc. -17- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

Symbol Description Symbol Description Symbol Description

Status Compressor ‘air end’ Frequency

Daylight Water Controller, Q1

4 – 20mA output Number or frequency Percent

Compressor, Cabinet door


Average Analogue
open

Up Down Enter

Stop Start Edit


t
en
m
Less than Greater than
uip Last 24 hours

Y Eq ns
Starts last hour L o
Starts last 24 hours
N of rati Last hour
O ce e
Normally open/normally A nan t Op
L
Digital Iinput
closed
E R te en Relay output

T ain m
APhase,
Phase, L1
M r M L2quip Phase, L3

C E fo E
r
N SE Current
Phase E fo sensor Running (animated)
E R U SE
F OT U
Analogue value E
R O N OT Network or system Inlet

D ON
Separator filter D Valve Belt drive

Power Pressure set point Yes

Menu Detail
Home
The home page is the where the display will default after any period of non-use. The home page provides
routine status and condition information.

Version 0000 - 10/13 -18- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Table 7: Home Menu

Menu Code Menu Text Description


Where present, any one active alarm will be displayed. If
more than one active alarm exists, active alarms will be
displayed in chronological order. The active alarm with the
highest chronological priority only will be displayed. Active
P00.01 Any Active Alarm alarms are displayed until action has been taken to remove
the alarm condition.
To view all active alarms, press the Enter button. Use the Up
and Down buttons to view all active alarms. Press the Enter
or Escape button to reset to P00.01.
P00.02 Control Mode The control mode selected
P00.03 P00.03 User DEF User-defined home page P00.02 display menu item
P00.04 P00.04 User DEF User-defined home page P00.03 display menu item

nt
P00.05 P00.05 User DEF User-defined home page P00.04 display menu item
e
pm value
P00.06 COMP OUT TEMP The compressor (air end or engine) outlet temperature

uipressure
P00.07 EQUIP OUT PRESS The equipment or device outlet
Y E q ns
The equipment orLdevicef internal opressure value
N o rati
P00.08 EQUIP INT PRESS
O pressure
ce valuee (EQUIP INT PRESS minus
P00.09 DIFF Pressure L
The differential
n p
EQUIP OUT
R IA na t O
PRESS)
e en value
P00.11 Main MTR Current
T i nt mcurrent
TheEmain motor
A Mamotoripcurrent value
P00.12 Fan MTR Current
M Ther fan q u
P00.13 Time E o
C E f r E time (configured)
The current
P00.14 DateE N S The focurrent date (configured)
R U E
P00.15
F
Daylight T USIndicates any active daylight saving
E Saving
O
E N T Indicates if ISC Sequence control is on or off. When on,
P00.16 RISC O O
Sequence
D ON annunciates the active Sequence assignment.

Error Log D
The error log provides a log of error conditions. Error conditions can be grouped into four categories:

• Warning conditions
• Immediate stop (or shutdown) conditions
• Start inhibit conditions
• Run inhibit conditions

Each error condition consists of an error code and condition text. A list of error codes and condition text is
contained in Message Codes on page 21. When an error condition occurs, the error is immediately
logged and stored in the internal memory of the controller.
In addition to the error condition being logged, additional key data is simultaneously logged and stored
with the error condition. The error log stores the previous 50 errors in chronological order, beginning with
the most recent error condition at menu location P03.01.

Copyright © 2013 P&H Mining Equipment Inc. -19- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

To view additional data relating to any error condition, navigate to the error condition in the error log and
press the Enter button. Then use the Up and Down buttons to view the data relating to the selected error
condition. Press the Reset button to clear the error.

Table 8: Error Log

Menu Code Menu Text Description


P03.01 - 50 Error Log 1 - 50 Error condition code and condition text
P03.##.01 Index Where ## = 01 to 50, Error index
Where ## = 01 to 50, Error message code and short
P03.##.02 Error Code / Description
description of error
P03.##.03 Time Where ## = 01 to 50, Time when error occurred
P03.##.04 Date Where ## = 01 to 50, Date when error occurred
P03.##.05 EQUIP Status Where ## = 01 to 50, Equipment status when error occurred
Where ## = 01 to 50, Equipment outlet pressure when error
nt
P03.##.06 EQUIP OUT PRESS
occurred
e
P03.##.07 EQUIP INT PRESS ipm pressure when
Where ## = 01 to 50, Equipment internal
error occurred
q u s
Y E tionoutlet temperature when
Where ## = 01 toL50, Compressor
f
error occurred N o
O ce era
P03.##.08 COMP OUT TEMP

A L 01 ton50, Main p motor current when error


Where ## =
I a O
R ten ent
P03.##.09 Main MTR Current
occurred
E
T a##in= 01 m
P03.##.10 Fan MTR Current
AWhere p
to 50, Fan current when error occurred
M r M qui
Event Log E
C E fo r E
The event log provides a log of E N Sor reset
event conditions.foEvent conditions include Start button pressed, Stop
E R
button pressed, parameter adjustment, U S E of parameter to default and user access.
T
Foccurs,Othe event
U is immediately logged and stored in the internal memory of the
When an event condition E N T
device. In addition to R O logged, additional data is simultaneously logged and stored with the
D O
event. The event log stores
O
the event being
the N
previous 200 events in chronological order beginning with the most recent
D
event at menu location P04.01.
To view additional data relating to any event, navigate to the event in the event log and press the Enter
button. Then use the Up and Down buttons to view the data relating to the event. Press the Reset button
to clear the event.

Version 0000 - 10/13 -20- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Table 9: Event Log

Menu Code Menu Text Description


P04.01 ~ 200 Event log 1 - 200 Event
P04.###.01 Index Where ### = 001 - 200, Event index
P04.###.02 Event description Where ### = 001 - 200, Description of the event
P04.###.03 Time Where ### = 001 - 200, Time when event occurred
P04.###.04 Date Where ### = 001 - 200, Date when event occurred

NOTICE
Service provider, Brabazon Q1 controller, and equipment data are menus that
retain specific data regarding the device and the device service provider. These
menus cannot be configured from the controller keypad. Menus can be
t
en
configured via a browser.

m
Message Codes
u ip
Y q nscode form. Message
inEmessage
tio
Message codes are used to annunciate equipment alarm conditions
N L language
o f restrictions
codes are used to allow information to pass more freely where
O left e r a may exist. Message
codes are supported by message text and condition symbols
c delay
the right of the message code indicates that a softwareLhard-coded p e offset exists (i.e., thesymbol
and right of text. A flashing to

IA na t On offset
R
E inte en
timer must decrement before the error is annunciated).
Alarm condition key to prefix letter: T
A Ma ipm
M r qu
• A = Warning
E
C E fo r E
• E = Immediate Stop
N
E US E fo
• R = ‘Run’ Inhibit
R
E T US
• S = ‘Start’ Inhibit
F O
RE O N OT Table 10: Message Codes
D N
Menu Code Menu TextO Description
D
P08.06 A:0083 Motor phase IMB. Main motor phase imbalance.
P08.07 A:0085 Motor starts HR INH. Number of permissible motor starts exceeded.
P08.08 A:0119 EO PRESS high. Equipment outlet pressure high.
P08.09 A:0129 COMP out TEMP HI. Compressor outlet temperature high.
P08.10 A:0139 EI PRESS high. Equipment internal pressure high.
P08.11 A:0200 Not Activated
P08.12 A:0201 CNDS drain alarm. Condensate drain alarm. Digital input not OK.
DIFF PRESS high. Differential pressure high. EI – EO pressure out of
P08.13 A:0809
permissible range.
P08.21 A:2035 SEP filter DP HI. Separator filter differential pressure high.

Copyright © 2013 P&H Mining Equipment Inc. -21- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

Menu Code Menu Text Description


P08.23 A:2040 Oil filter DP. Oil filter differential pressure. Digital input not OK.
P08.25 A:2240 Oil / water SEP ALM. Oil water separator. Digital input not OK.
P08.32 A:2816 Power failure. 24v @ X13 is below permissible level.
P08.33 A:2831 Airbus™ RS485 HW (Hardware not detected in X04)
P08.34 A:2832 Airbus RS485 HW (Hardware not detected in X05)
P08.35 A:2833 Airbus RS485 HW (Hardware not detected in X06)
P08.36 A:2836 RTC error. A real time clock error
ISC XPM DI alarm. An Internal System Control ‘XPM’ digital input
P08.37 A:2970
alarm.
P08.58 A:5100 Default CONFIG. Invalid settings. Reset to default configuration.
Default CONFIG. Parameter consistency error. Reset to default
P08.59 A:5200
configuration.
n t
e
P08.60 E:0010
m
Emergency stop. Digital input not OK, emergency stop button pressed!

u ip
q ns
P08.66 E:0080 Main MTR short.
Y E
P08.67 E:0081 Main motor lock.
N L of
atio
P08.68 E:0082 Main MTR OVLD. MainO
L
motor e
c er
overload.
p
P08.69 E:0083 Motor phase IMB.IMain an phase
A nmotor t O imbalance.
R
E inte en
P08.73 E:0090 T
Afault.Ma ipm
Phase sequence.
P08.74 E:0091 M r qu
Phase L1
P08.75 E:0092
E
C L2
Phase fo r E
fault.
N E fo
E:0093 EPhaseSL3 fault.
P08.76
R
E EO U E
S sensor. Equipment outlet pressure sensor. Wiring error or
F T PRESS
U
O
RE O N faultyT sensor.
P08.77 E:0115
O
P08.78 D O NEO PRESS high. Equipment outlet pressure high.
E:0119

P08.79 E:0125
D CO TEMP sensor. Compressor outlet temperature sensor. Wiring error
or faulty sensor.
P08.80 E:0129 COMP out TEMP HI. Compressor outlet temperature high.
P08.81 E:0131 INT PRESS low. Internal pressure low.
INT PRESS sensor. Internal pressure sensor. Wiring error or faulty
P08.82 E:0135
sensor.
P08.83 E:0139 INT PRESS high. Internal pressure high.
P08.84 E:0179 EQUIP out TEMP HI. Equipment outlet temperature high.
DIFF PRESS high. P1 – P2 differential pressure out of permissible
P08.92 E:0809
range.
P08.93 E:0814 Venting error. Excess pressure after vent time has elapsed.

Version 0000 - 10/13 -22- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Menu Code Menu Text Description


P08.94 E:0821 Short circuit. Wiring error.
P08.101 E:1887 Main motor fault. Digital input not OK.
P08.102 E:1888 Run CHK IMM stop. Digital input not OK.
P08.109 E:2960 ISC XPM COMMS
P08.110 E:2980 ISC XPM DI

Q1 Controller Settings for Joy Global EMD08-30 Compressor

NOTICE
In the following settings table, there is a blank space for the operator to write in
the current equipment’s “Actual Settings”. Some settings are “INH” or inhibit
delay, restrain, or prevention settings. t
en
pm
Table 11: Q1 Controller Settings
ui
Menu Item Actual Settings q
Y n s Settings
E o
P10.01 Control mode NLRunof rati
Cont. Load / OFF Load
O ce e
P10.02 Allow force load
I A L
a n Op OFF
P10.04 Load pressure
E R ten ent 145 psi
n
P10.05 Off load pressure
AT Mai ipm 175 psi
Start source M r q u
P10.12
E o
C Ef rE
Keypad
P10.13 N
E US E fo
Load source Equip Out Press
P10.14 R
E T US
Language English
F
P10.15
RETime NO OT
Time Current Time
P10.16
DO OformatN 24:00:00
P10.17
D
Daylight saving +0h
P10.18 Date Current Date
P10.19 Date format MM / DD / YYYY
P10.20 LCD light level 90%
P10.21 Pressure unit psi
P10.22 Temperature unit °F
P11.01 Start/delta TRANS 5 sec
P11.02 Load INH time 1 sec
P11.03 Reload INH time 1 sec
P11.04 Off load run time 600 sec

Copyright © 2013 P&H Mining Equipment Inc. -23- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

Menu Item Actual Settings Settings


P11.05 Stop MIN time OFF
Vent time (same as Sump
P11.06 40 sec
Blow Down)
P11.07 AUTO restart INH 10 sec
P11.08 CNDS drain open 5 sec
P11.09 CNDS drain interval 300 sec
P11.10 CNDS off load –
P11.11 MTR SRT HR INH –
P11.12 DP inhibit time 1 sec
P11.13 Service hours 1 OFF
P11.14 Service hours 2 OFF
t
en
P11.15 Service hours 3 OFF
m
ip
P11.16 Service hours 4 OFF
P11.17 Service hours 5 u
q ns OFF
Y E o
P11.18 Weekly service NL of rati OFF
O ce e
P11.19 Annual service
I A L
an Op OFF
P11.20 Bi-annual service
E R ten ent OFF
n
P14.01 Main MTR protect
AT Mai ipm OFF “NOT used”
Fan MTR protect M r q u
P14.02
E o
CCURE f r E
OFF “NOT used”
P14.03 Main MTR NOM N
ESDTTF S E fo
39 “NOT used”
P14.04 R
E T US
Main MTR U 3
P14.05 Main F
E NROT
MTR O TLOC 3
RMain
P14.06
DOMTR NPHOIMB 15%
P14.07 Fan MTRDONOM CURR 1 “NOT used”
P14.08 Fan MTR OVLD IMH 5 sec
P15.01 Operator OFF “NOT used”
P15.02 Door open OFF “NOT used”
P15.03 Low temperature 32°F “NOT used”
P15.04 INT PRESS HIGH 6 psi
COMP OUT TEMP
P16.12 221°F
WARNING
EQUIP OUT PRESS
P16.13 185 psi
WARNING

Version 0000 - 10/13 -24- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Menu Item Actual Settings Settings


EQUIP INT PRESS
P16.14 185 psi
WARNING
P16.15 DIFF pressure WARNING 12 psi
P16.16 Oil Air SEP DP HI OFF “NOT used”
P16.17 Phase detection ON
P16.18 HI MTR STR HR OFF “NOT used”
P16.19 Door open OFF “NOT used”
P16.20 CAB filter DP OFF “NOT used”
P16.21 Air filter DP OFF “NOT used”
P16.22 Oil filter DP OFF “NOT used”
P16.23 SEP FILTER DP HI “Oil Air” OFF “NOT used”
P16.24 Fan motor alarm t “NOT used”
nOFF
e
P16.25 CNDS drain alarm
pm current drain.
“OFF” Not available with
i
u used”
OFFq“NOT s
P16.26 Cool water alarm
Y E on
P16.27 Oil level alarm NL of rati OFF “NOT used”
O e
P16.28 RD alarm
A L nc Ope OFF “NOT used”
I a
P16.29 Line FTR DP alarm
E R ten ent OFF “NOT used”
n
P16.30 FTR drain alarm
AT Mai ipm OFF “NOT used”
Oil/WTR SEP ALMM r q u
P16.31
C E f o E
OFF “NOT used”
P16.32 AMBIENT TEMP
E N high
S E for OFF “NOT used”
COMP OUTRTEMPU FAULTE
P17.01
F E T U S 235°F
SHUTDOWN
O
RE OOUT
EQUIP
N PRESS
O
T
P17.03
D SHUTDOWN
FAULT N 190 psi

P17.04
EQUIP INT DOPRESS FAULT
190 psi
SHUTDOWN
P17.07 Main motor lock OFF
P17.08 Main motor OVLD ON
P17.09 Motor phase IMB ON
P17.10 Fan MTR overload ON
P17.11 Phase detection ON
P17.12 Door open OFF “NOT used”
P17.13 Fan motor alarm OFF “NOT used”
P17.14 Cool water alarm OFF “NOT used”

Copyright © 2013 P&H Mining Equipment Inc. -25- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

Menu Item Actual Settings Settings


P17.15 Oil level alarm OFF “NOT used”
P17.16 Belt drive alarm OFF “NOT used”
P17.17 RD alarm OFF “NOT used”
P17.18 Water flow OFF “NOT used”
P17.19 Inverter fault OFF “NOT used”
P17.20 Main MTR temp HI OFF “NOT used”
P17.21 Conf IMM stop 1 OFF “NOT used”
P17.22 Conf IMM stop 2 OFF “NOT used”
P17.23 Conf IMM stop 3 OFF “NOT used”

Table 12: User and Menu Access

Menu USER 1
ent USER 2
P09.03.01 Edit user name Operator
ipmJGS Joy Global Services
q u s
E tion
P09.03.02 User PIN code 2012
L Y f
P09.03.03 Language N o ra
English
O 1c
e pe
P09.03.04 Time format L n
RIAMM /nDD
a / YYYY
t O
E inte en
P09.03.05 Date format
P09.03.06 Pressure unit T
A Ma ipmpsi
Temperature unit M r q u F
P09.03.07
E o
C E f r E Edit Access
P09.03.08 P00 Home
E N S fo Edit Access
P09.03.09
E R timers
P01 Service U SE Edit Access Edit Access
T
F Utilization
P09.03.10 E
P02
N O TU Edit Access Edit Access
R P03
P09.03.11
DO Error NOlog Edit Access Edit Access
P09.03.12 O log
P04DEvent Edit Access Edit Access
P09.03.13 P05 Service provider Edit Access Edit Access
P09.03.14 P06 Controller data Edit Access Edit Access
P09.03.15 P07 Equipment data Edit Access Edit Access
P09.03.16 P08 Message codes Edit Access Edit Access
P09.03.17 P09 Access Locked or No Access Edit Access
P09.03.18 P10 Equip settings 1 Locked or No Access Edit Access
P09.03.19 P11 EQUIP settings 2 Locked or No Access Edit Access
P09.03.20 P12 EQUIP settings 3 Locked or No Access Edit Access
P09.03.21 P13 settings Locked or No Access Locked or No Access

Version 0000 - 10/13 -26- Copyright © 2013 P&H Mining Equipment Inc.
Q1 Controller Sullair Air Compressor

Menu USER 1 USER 2


P09.03.22 P14 Motor protection Locked or No Access Edit Access
P09.03.23 P15 Inhibits Locked or No Access Edit Access
P09.03.24 P16 Warning alarm Locked or No Access Edit Access
P09.03.25 P17 IMM stop alarm Locked or No Access Edit Access
P09.03.26 P18 I/O CONFIG Locked or No Access Locked or No Access
P09.03.27 P19 Sensor CONFIG Locked or No Access Locked or No Access
P09.03.28 P20 Diagnostics Locked or No Access Locked or No Access
P09.03.29 P21 Run schedule Locked or No Access Locked or No Access
P09.03.30 P80 ISC Main menu Locked or No Access Locked or No Access
P09.03.31 P81 ISC Settings Locked or No Access Locked or No Access
P09.03.32 P82 ISC Priority Locked or No Access Locked or No Access
t
en
m
uip
Y Eq ns
o
NL of rati
O ce e
I A nan t Op
L
E R te en
n
AT Mai ipm
M r qu
E
C E fo r E
N
E US E fo
R
E T US
F O
RE O N OT
D ON
D

Copyright © 2013 P&H Mining Equipment Inc. -27- Version 0000 - 10/13
Sullair Air Compressor Q1 Controller

t
en
m
u ip
Y E q ns
N L of
atio
O Left
This Page Intentionally
L c p er
e Blank
I A nan t O
E R te en
n
AT Mai ipm
M r qu
E
C E fo r E
N
E US E fo
R
E T US
F O
RE O N OT
D ON
D

Version 0000 - 10/13 -28- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Operation Sullair Air Compressor

Air Compressor Operation


Motor Rotation Check
After the electrical installation has been done, it is necessary to check the direction of motor rotation.
EMD08 Compressors
Pull out the E-Stop button and press once, quickly and in succession, the Start and Stop buttons. This
action will bump-start the motor for a very short time.
When looking at the motor from the control panel side, view the coupling by looking through the air inlet
duct on the lower side of the adapter fan housing. The coupling should be turning clockwise. If the
reverse rotation is noted, disconnect the power to the starter and exchange any two of the three power
input leads, then recheck rotation. A Direction of Rotation decal is located on the motor and cooler shroud
to show proper motor/compressor rotation.

Starting Up the Air Compressor for the First Time


t
en
If a new air compressor has been installed, confirm the following have been completed:
m
Vibration mounts are in place.
u ip
Y Eq ns
o
No structure that would inhibit cooling air flow is obstructing the compressor.
NL of rati
Compressor is connected to properly installed air supply piping.
Coupling alignment has been completed. O ce e
I A nan t Op
L
Compressor oil has been installed and is at the correct level.

E R te en
Electrical connections have been completed and inspected.
n
AT Mai ipm
M r qu
E o E
C E fNOTICE
E N S f or
Requirements E
R 30
All controller parametersU mayare
S Eneed
factory-set. Values listed in Special Site
F on pageT U to be modified by Joy Global Service.
O
Step 1: REto check
Jog the motor
O
T rotation of motor and fan.
N forOcorrect
D valve N
Step 2: Open the shutoff
D O to the service line.
Step 3: Check for possible leaks in piping.
Step 4: Slowly close the shutoff valve to assure proper nameplate pressure unload setting is correct –
175 psi (12 bar).
The compressor will unload at nameplate pressure.
Step 5: Observe the operating temperature.
If the operating temperature exceeds 200°F (93°C), check the cooling system and installation
environment. If the unit’s discharge temperature rises to the maximum limit of 235°F (113°C), a
COMP OUT TEMP shutdown will occur.
Step 6: Open the shutoff valve to the service line.
Step 7: Re-inspect the compressor for temperature and leaks the following day.

Copyright © 2013 P&H Mining Equipment Inc. -29- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Operation

Starting Up the Air Compressor (Subsequent Starts)


Step 1: Check that the proper level is visible in the fluid level sight glass.
Step 2: Press the Start button on the controller for automatic operation.
Step 3: When the compressor is running, observe the various parameters and displays.

Load / Off Load: Control Mode


The compressor runs loaded in modulation until reaching the setpoint for higher discharge pressure to off
load the compressor between the compressor starts and compressor stop. The compressor will run
unloaded for the length of time specified in parameter P11.04. The compressor will stop, go to ‘standby
state’, and automatically restart when system pressure drops below parameter P10.04. This is needed for
sequencing.

Continuous Run: Control Mode


The compressor runs loaded in modulation until reaching the setpoint for higher discharge pressure to off
t
load the compressor. The compressor motor runs continuously load or off load. The compressor motor
en
does not stop unless manually with the Stop button, or an Emergency Safety trips the compressor motor
off. m
uip
Shutting Down the Air Compressor Y E q ns
N L of
a tio
O ce er
To shut the compressor down, push the controller Stop button.

I A nan t Op
L
CAUTION
E R te en
A T ain m
M r M quand
After completion of any configuration, ip controller interface, return the
E ffor
controls to the Home screen
C o proper
E operation of the compressor.
N SE f o r
Programming Sequencing E
R U SE
E
Sequencing allows two orFmore O
T U
E N
Sullair compressors
T
to operate with a common pressure range.
R O IfOtwo compressors are present, they can be manually rotated by
Sequencing is not recommended.
turning one compressor D N other off at regularly scheduled maintenance intervals to keep the run
D O
on and the
hours the same on both compressors.
For high-altitude applications, it may be necessary to set up both compressors as single units and have
them run together due to derating.

Special Site Requirements


Joy Global Service may modify the following parameters to meet special site requirements:

• P10.04 – LOAD PRESSURE


• P10.05 – OFF LOAD PRESSURE
• P10.14 – LANGUAGE
• P10.15 – TIME
• P10.16 – TIME FORMAT
• P10.21 – PRESSURE UNIT
• P10.22 – TEMPERATURE UNIT

Version 0000 - 10/13 -30- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Operation Sullair Air Compressor

• P11.09 – CNDS (condensate) DRAIN OPEN


• P11.10 – CNDS (condensate) DRAIN INTERVAL

t
en
m
uip
Y Eq ns
o
NL of rati
O ce e
I A nan t Op
L
E R te en
n
AT Mai ipm
M r qu
E
C E fo r E
N
E US E fo
R
E T US
F O
RE O N OT
D ON
D

Copyright © 2013 P&H Mining Equipment Inc. -31- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Operation

Safety Decals
Figure 7: Safety Decals

t
en
m
uip
Y Eq ns
o
NL of rati
O ce e
I A nan t Op
L
E R te en
n
AT Mai ipm
M r qu
E
C E fo r E
N
E US E fo
R
E T US
F O
RE O N OT
D ON
D

ESGN_C_SA_P_00001_1

Version 0000 - 10/13 -32- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Operation Sullair Air Compressor

Table 13: Decal Explanations

Hazard Type Decal Text


Death or serious injury can occur from inhaling compressed air without using
Danger proper safety equipment.
See OSHA standards on safety equipment.*
This unit is equipped with an auto stall sequence that will start the unit in the
event of a power failure automatically after the sump pressure drops to 10 PSIG
Warning and the power is restored.
When performing maintenance follow your company’s prescribed safety
practices for electrical equipment.
Do not permit air from this equipment to contact food stuff except in full
Warning compliance with FDA Standard 21CFR178.3570, and all other applicable
federal, state and local codes, standards and regulations.*
This machine is equipped with automatic stop / start control system. DO NOT
Caution t
ATTEMPT to make any adjustment without disconnecting both main line and
control circuit electrical power. en
m
ip
* OSHA and FDA guidelines are superceded by any Federal, State or Local regulations whenever
u
applicable.
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Copyright © 2013 P&H Mining Equipment Inc. -33- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Operation

Wiring Diagrams
Figure 8: 380V 50Hz

M3

12
10
11
M2
L3

3
380V 50HZ
L2

2
L1

1
M1
t

13
2A
en
X2

117
116
m

ESGN_C_SA_P_00002_1
12
ip
380 V
120V

u
q ns
Y E
X1

o
NL of rati
2A
2A

O ce e
I A nan t Op
L
102

101

E R te en
n
AT Mai ipm
M r qu
120V

E
10
11

C E fo r E
09

N
E US E fo
08

07

R
24V

E T US
101

F O
RE O N OT
109

105
107
115

113

L3
L1
L2

D ON
CR
CR

06
R8

CR
R7

R6

R4

CR
R5

R3
R2
R1

24V
AC

D
M1

M3
M2
C-ANA3
C-ANA1

C-ANA2
ANA2

ANA3
ANA1

C-D1
D1

M3

M2
03
05
05

206
202

M1
M3
04
04
04

02

01

102
105

107
P1

P2

206
RTD

Version 0000 - 10/13 -34- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Operation Sullair Air Compressor

LEGEND
01 - Motor O/L 06 - Phase Monitor 10 - Drain SOL
02 - E-Stop 07 - Wye / Delta 11 - Full Load SOL
03 - White 08 - Closed Inlet SOL 12 - Aux Contact
04 - Red 09 - Load-Unload SOL 13 - Thermal Overload
05 - Black

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Copyright © 2013 P&H Mining Equipment Inc. -35- Version 0000 - 10/13
Version 0000 - 10/13
Sullair Air Compressor

R8
415V 50HZ
CR
115
11 L1 L2 L3
R7

F
04 C-ANA1 CR
P1

D
05 ANA1
113
10

R
04 C-ANA2 R6
P2 109
05 ANA2

O
R5

D ON
N
04 C-ANA3 R4 09
RTD
03 ANA3 CR

RE O N OT
E
206
02 206
08
C-D1 102
R3
202 R2 107

E T US
D1
105 07 X1 X2
01 R1 2A 120V
CR 101 101

E US E fo
L1 2A 2A

I
415V

C E fo r E
L2

-36-
06

L
L3

M r qu
24V

AT Mai ipm
AC
Figure 9: 415V 50Hz

R te en
116
M3
M1
A nan t Op 12
M3
E

M1 M2
O ce e
M1 M3
105 117
M2
u
NL of rati
ip
o

107 M2 24V 120V


13
m

M3
q ns
en

102
t

ESGN_C_SA_P_00004_1 1 2 3 11 10 12
Air Compressor Operation

Copyright © 2013 P&H Mining Equipment Inc.


Air Compressor Operation Sullair Air Compressor

LEGEND
01 - Motor O/L 06 - Phase Monitor 10 - Drain SOL
02 - E-Stop 07 - Wye / Delta 11 - Full Load SOL
03 - White 08 - Closed Inlet SOL 12 - Aux Contact
04 - Red 09 - Load-Unload SOL 13 - Thermal Overload
05 - Black

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Copyright © 2013 P&H Mining Equipment Inc. -37- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Operation

Figure 10: 460V 60Hz

13
L3

3
460V 60HZ
L2

2
L1

1
14
X2

117
116

12
120V

11
X1
2A

t
102

101

en
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o

120V
NL of rati

101

102
10

09

O ce e
08

I A nan t Op
L
07

R te en

24V
E
101

n
AT Mai ipm
109

M r qu
105
115

113

L1
L2
L3

E
C E fo r E
CR
CR

N
R8

CR
R7

R6

R4

CR
R5

E US E fo
R3
R2
R1

06

24V
AC

R
E T US
F O
RE O N OT
D ON
D
C-ANA3
C-ANA1

C-ANA2
ANA2

ANA3
ANA1

C-D1
D1
206
202
05

05

03

ESGN_C_SA_P_00003_1
04

04

04

02

01
P1

P2

206
RTD

Version 0000 - 10/13 -38- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Operation Sullair Air Compressor

LEGEND
01 - Motor O/L 06 - Phase Monitor 11 - 11 Amp Fuses
02 - E-Stop 07 - Starter 12 - Aux Contact
03 - White 08 - Load-Unload SOL 13 - Starter
04 - Red 09 - Drain SOL 14 - Thermal Overload
05 - Black 10 - Full Load SOL

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Copyright © 2013 P&H Mining Equipment Inc. -39- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Operation

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Version 0000 - 10/13 -40- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Maintenance Sullair Air Compressor

Air Compressor Maintenance


Perform the following maintenance per Life Cycle Management’s recommended maintenance intervals
and schedules:

• Replace air filter


• Replace oil filter
• Replace air/oil separator
• Replace lubricant
• Rebuild/replace minimum pressure valve
• Rebuild inlet valve
• Rebuild/replace inlet regulator

Maintenance of these components may be required sooner that the recommended maintenance intervals
depending on operating conditions.
t
Inspecting the Air Compressor en
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Figure 11: Compressor Components

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LEGEND
01 - Oil Sight Tube 05 - Oil Cooler 09 - Inlet Control Valve
02 - Pressure Relief Valve 06 - Moisture Separator 10 - Cooling Fan
03 - Air/Oil Separator Access 07 - After Cooler 11 - Oil Filter
04 - Air Filter 08 - Motor

Copyright © 2013 P&H Mining Equipment Inc. -41- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Maintenance

CAUTION
The rotary screw compressor can be seriously damaged in a very short
time if it is operated backwards. The shovel’s phase monitoring relay will
protect against compressor damage if the shovel main power is connected
in reverse phase; however, this reverse phase detection will not detect
incorrectly connected motor wires. When changing a motor or when first
applying power, confirm correct motor rotation (a directional arrow is
provided on the fan shroud between the motor and the compressor)
before connecting the motor coupling to the compressor.

Step 1: Check for loose connections or leaks.


Step 2: Check for worn, damaged, or missing components.
Step 3: Confirm that oil is visible in the oil level sight tube. Check oil level when the compressor motor is
not running, as the oil level will go down in the sight tube when the compressor is operating.

t
WARNING en
m
uip
Hot oil spray can penetrate skin and eyes. Do not open the oil
Y E q ns
fill plug or open the compressor to atmosphere in any other
o
NL of rati
way while the compressor contains air pressure. Do not open
O ce e
or remove any of the compressor components while the

A nan t Op
L
compressor contains air pressure.
I
ER inte en
Adjusting the Air CompressorTModulation
Figure M
A Ma Regulator
i pm Valve
r qu
12: Pressure
E
C Ef rE o
N
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D 03

02
04

01

ESGN_C_SA_D_00010_1

LEGEND
01 - Orifice 03 - Bell 04 - Adjustment Screw
02 - Diaphragm Assembly

Step 1: Turn the compressor off.

Version 0000 - 10/13 -42- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Maintenance Sullair Air Compressor

Step 2: Back the adjustment screw outward at least four turns to limit the maximum output pressure.
The screw is located upside down on the back right side of the after cooler unit as you are facing
the touch panel.
Step 3: Start the compressor and let it build system pressure.
Step 4: Turn the regulator adjustment screw inward to increase system pressure up to the modulation
point (170 psi [11.9 bar]). Turn the screw slowly in smaller increments when the pressure nears
the modulation point. If the screw is turned too far, the compressor will reach the unload point
(175 psi [12.25 bar]) and the compressor will unload.
Step 5: Turn the compressor off.

Checking and Adding Compressor Oil


Confirm that oil is visible in the oil level sight tube. Check oil level when the compressor motor is not
running, as the oil level will go down in the sight tube when the compressor is operating.

WARNING
ent
pmin any other
Hot oil spray can penetrate skin and eyes. Do not open the oil
fill plug or open the compressor to atmosphere
u i
way while the compressor contains air pressure.
Y E q nsDowhilenot open
o
NL of rati
or remove any of the compressor components the
compressor contains air pressure.
O ce e
L
A nanto ensure p the compressor is not
Step 1: I
Turn off compressor. Use lockout/tagout procedures O
accidentally started.
E R te ent
n
Step 2: Remove the oil fill plug. AT Mai ipm
M r qu
E
C E fo CAUTION
N orE
f
US SE with oil can lead to discharge of oil at the air
REcompressor
OverfillingEthe
F O T U
R OE
outlet, which
N
could damage
T
the air dryer. Fill oil to the correct level and
check the oil
O
level when compressor motor is not running.
Noil is visible approximately half-way up the sight tube.
Step 3: Add compressor Doil until
O
D
Changing the Air Filter
Step 1: Turn off the compressor.
Step 2: Pull the yellow tab out.

Copyright © 2013 P&H Mining Equipment Inc. -43- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Maintenance

Figure 13: Air Filter Housing

nt
ESGN_C_SA_P_00006_1

e
Step 3: Rotate the housing cap counterclockwise until it releases, then remove
ipm it.
q u s
E tion
Step 4: Pull the old filter out of the housing and replace with a new filter.
Y
Figure 14: AirLFilterf
N o
O ce era
I AL nan t Op
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C E fo r E
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D ESGN_C_SA_P_00007_1

Step 5: Attach housing cap by rotating clockwise until it clicks into place.
Step 6: Push the yellow tab in until it clicks into place.

Version 0000 - 10/13 -44- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Maintenance Sullair Air Compressor

Changing the Oil Filter

WARNING
Hot oil spray can penetrate skin and eyes. Do not open the oil
fill plug or open the compressor to atmosphere in any other
way while the compressor contains air pressure. Do not open
or remove any of the compressor components while the
compressor contains air pressure.

Step 1: Turn off the compressor.


Step 2: Place a drip pan under the compressor drain to catch oil.
Step 3: Remove the drain cap and allow the oil from the compressor to drain.
Step 4: Remove the spin-on-type oil filter.
Step 5: Install the new oil filter.
t
Step 6: Replace the drain cap.
en
m
Step 7: Add oil.
u ip
Y E q ns
o
NL of rati
Changing the Oil Separator
O ce e
WARNINGI A nan t Op
L
Hot oil spray can T
ER inteskin eand
n
penetrate
fill plug or openAthe compressor
m
a ip to atmosphere
eyes. Do not open the oil

way while E
M r M qucontains air pressure. Do in any other

C o E compressor components while


the compressor
any f of the
not open
or remove
N E o rair pressure. the

R E US E f
compressor contains

F E T US
E NO T
Step 1: Turn off the compressor.
Step 2: Place a dripR theOcompressor drain to catch oil.
O
pan under
D O N
Step 3: Remove the separator.
D
Step 4: Pull out the separator.
Step 5: Install a new O-ring on the inboard stem of the new separator.
Step 6: Insert the new separator into the compressor housing.
Step 7: Remove the old O-ring from the separator cap. Install a new O-ring onto the separator cap.
Step 8: Install the cap into the compressor housing.

Copyright © 2013 P&H Mining Equipment Inc. -45- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Maintenance

Figure 15: Change Oil Separator

LEGEND
01 - Separator Cap 02 - O-ring 03 - Separator

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Version 0000 - 10/13 -46- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Troubleshooting Sullair Air Compressor

Air Compressor Troubleshooting


Check for:

• Loose wiring.
• Damaged piping.
• 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 Joy Global Service.

Table 14: Troubleshooting

Symptom Probable Cause Remedy


Compressor outlet Discharge temperature exceeded
temperature is too 221°F (105°C) for pre-alarm
high.
t
en
Discharge temperature exceeded
Q1 controller displays 235°F (113°C) for shutdown
m
message P00.06:
Ambient temperature exceeded
u ip
Improve local ventilation or remote
COMP OUT TEMP
recommendations
Y Eq ns
intake of process and/or cooling air.
Cooler fins are dirty NL Clean tio fins.
of rcooler
a
O ce e
Fluid level in sump is too lowL p
A nan t Check/correct
I O fluid level.

E R te en Check/replace thermal valve.


Thermal valve malfunctioned
T ain m Check connections from RTD. If
Temperature RTDAmalfunction
M r M quip adequate, replace RTD.
E o
Compressor outlet MAXIMUMCpressure
N E or E for
f exceeded
pressure is too high. E US E f
shutdown
R
F E Tdevice
Q1 controller displays Unloading
U S(blowdown valve) Check operation of unloading valve.
message P00.07: E N T
failed O
to operate
COMP OUT PRESSR
O NO
DPressure regulator misadjusted Check operation of pressure regulator.

DO valve failed to operate


Solenoid Check operation of solenoid valve.
Check tubework feeding control signal
Control air signal leaks
for leaks.
Control air signal filter clogged Service filter assembly.
Differential pressure is Plugged separator Replace separator elements.
too high.
Maximum differential pressure
Q1 controller displays between Equipment Inlet (EI, or Check the EO and EI pressure
message P00.09: "sump") and EO (Equipment Outlet, or transducers.
DIFF Pressure Discharge) exceeded.

Copyright © 2013 P&H Mining Equipment Inc. -47- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Troubleshooting

Symptom Probable Cause Remedy


Check air service lines for open valves
or leaks.
Air demand exceeds supply
Check air dryer for leaks/service
problems.
Compressor does not
build full discharge Check for obstructions.
pressure Inlet air filter clogged Inspect and/or change inlet filter
Q1 controller displays
element.
message P00.07:
COMP OUT PRESS Check actuation and disc position.
Inlet valve not fully open
Check/rebuild inlet valve.
Pressure sensor and/or connections at Check connections from transducer. If
fault adequate, replace transducer.
Check connections from transducer. If
Faulty EO transducer
nt
adequate, replace transducer.
Unloading device (blowdown valve) e
pm
Check operation of unloading device.
Line pressure rises
failed to operate
i
u s of solenoid valve.
Checkqoperation
above unload setting Solenoid valve failed to operate
L Y f E tion
o rtubework
N Check a feeding control signal
Control air signal leaks O ce for leaks.
e
p
AL nan t Service
I O filter assembly.
R te en
Control air signal filter clogged
E n
AT Mai ipm
Motor Phase IMB
Main MTR short M r qu
E fo r E voltage, Review compressor voltage,
C compressor
Imbalance with
Main MTR OVLD
E S E
overload,Nor short-circuit
fo connections, and rotation.
Phase Sequence
E R U SE
Phase L1, L2, L3 Fault F
T U
E O
R O N OT
DCloggedNreturn line strainer or orifice Clean strainer – screen and O-ring

DO
replacement kit available. Clean
orifice.
Damaged or improperly gasketed Inspect separator elements and
Excessive fluid separator elements gaskets. Replace if damaged.
consumption
Fluid system leaks Check tube/pipework for leaks.
Fluid level too high Drain excess fluid.
Excessive fluid foaming Drain and change fluid.

Version 0000 - 10/13 -48- Copyright © 2013 P&H Mining Equipment Inc.
Air Compressor Troubleshooting Sullair Air Compressor

NOTICE
Whenever a sensor is suspected of fault, the recommended action is to
measure the signal (pressure, temperature, etc.) with an alternate calibrated
instrument and compare readings. If readings conflict, the electrical and/or
tubing connections should be inspected, and if no faults are evident, then
replace the sensor and re-evaluate against the calibrated instrument.

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Copyright © 2013 P&H Mining Equipment Inc. -49- Version 0000 - 10/13
Sullair Air Compressor Air Compressor Troubleshooting

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Version 0000 - 10/13 -50- Copyright © 2013 P&H Mining Equipment Inc.
Index Sullair Air Compressor

Index
A
Air compressor
description ...................................................................................................................................1
inspecting ...................................................................................................................................41
modulation
adjusting ............................................................................................................................42
oil
checking / adding ...............................................................................................................43
oil filter
changing ............................................................................................................................45
oil separator
changing ............................................................................................................................45
operation
t
principles ..............................................................................................................................3
Touchpad
en
m
Operation .............................................................................................................................7

uip
unloading .................................................................................................................................5, 6
Air Compressor
Y Eq ns
o
NL of rati
Air Filter
O ce e
Changing ...........................................................................................................................43

A nan t Op
L
Initial Start-Up ............................................................................................................................29
I
Maintenance ..............................................................................................................................41
R te en
E
Safety Decals .............................................................................................................................32
n
AT Mai ipm
Shutting Down ...........................................................................................................................30
M r qu
Subsequent Start-Up .................................................................................................................30
Touchpad E
C E fo r E
Graphic Display ...................................................................................................................9
N
E US E fo
Joy Global Settings ............................................................................................................23
R
E T US
Menu Detail ..................................................................................................................18, 21
F O
Menu Map ..........................................................................................................................12
RE O N OT
Menu Navigation ................................................................................................................10

D ON
Symbols .............................................................................................................................16
User Account Controls .........................................................................................................9
D
Troubleshooting .........................................................................................................................47
Air Compressor Controls
Q1 Controller ...............................................................................................................................7
Air Compressor Operation
Motor Rotation Check ................................................................................................................29

C
Continuous Run
Control Mode .............................................................................................................................30
Copyright .............................................................................................................................................iii

L
Load / Off Load
Control Mode .............................................................................................................................30

Copyright © 2013 P&H Mining Equipment Inc. -51- Version 0000 - 10/13
Sullair Air Compressor Index

P
Preface ................................................................................................................................................iii

R
Revision Record ...................................................................................................................................v

S
Sequencing
Programming .............................................................................................................................30
Special Site Requirements ................................................................................................................30

W
Wiring Diagrams ................................................................................................................................34

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Version 0000 - 10/13 -52- Copyright © 2013 P&H Mining Equipment Inc.
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All designs, specifications and components of the equipment described above are subject to change at the manufacturer’s sole discretion at any time
without advance notice. Data and descriptions published herein are informational in nature and shall not be construed to warrant the service or the
suitability of the equipment for any particular purpose as performance may vary with the conditions encountered. The only warranty applicable is our
standard written warranty for this equipment or service.
P&H, Centurion, PreVail, Optima, TripRite, Delta, ProMiner and ProManual are trademarks of Joy Global Inc. or one of its affiliates.
2013 P&H Mining Equipment Inc. All rights reserved.