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Congratulations on your X-range compressor! Innovations: Patented X-drive

Patented cooling

Registered design

The extraordinary X-range compressor is a new generation of true 1800 rpm compressors, and covers all capacities for the marine market. The Sperre X-range compressor is based on more than 70 years of experience.

This excellent compressor gives you several benefits:  Safety first – a fully enclosed structure

 Easy plug-in for sensors

 Green and clean – no oil mist to the environment

 25% fewer wear parts – 50% more reliable

 A new level of control

 Best cooling efficiency in the market

 Easy to learn – one common platform

 Low vibration level – high grade of isolation

 Less installation time – no special alignment

 Improved standard scope of supply

Sperre has developed a unique chain of value, that‟s what it takes to produce reliable compressors that function smoothly for the life of the ship. Sperre congratulates you on your choice of compressor!

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Contents 1

Introduction ............................................................................................ 5

1.1 1.2 1.3 1.4 1.5

Purpose ........................................................................................................................ 5 Annotations .................................................................................................................. 5 Abbreviations ................................................................................................................ 5 Tags on the compressor ............................................................................................... 6 Warranty....................................................................................................................... 6

2

Personal safety....................................................................................... 7

3

System description ................................................................................ 8

3.1 3.2

X-range compressor ..................................................................................................... 8 X-control ..................................................................................................................... 10

4

Technical data ...................................................................................... 11

5

User Interface ....................................................................................... 12

5.1 5.2 5.3 5.4 5.5

Keypad ....................................................................................................................... 12 LED indicators ............................................................................................................ 13 Display ....................................................................................................................... 14 Symbols ..................................................................................................................... 16 Menu structure............................................................................................................ 18

6

Installation and Operation ................................................................... 22

6.1 6.2 6.3 6.4 6.5

Installation .................................................................................................................. 22 Before and after operation .......................................................................................... 23 General operation ....................................................................................................... 24 Internal system control (ISC) ....................................................................................... 28 Emergency operation .................................................................................................. 31

7

Troubleshooting ................................................................................... 32

7.1 7.2 7.3 7.4 7.5 7.6

Abbreviations .............................................................................................................. 32 Service warning (SW) and alarm (SA) ......................................................................... 32 Alarms (A) .................................................................................................................. 34 Start inhibits (S) .......................................................................................................... 36 Immediate stop shutdown errors (E) ............................................................................ 37 Errors when no alerts are displayed ............................................................................ 40

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1 Introduction 1.1 Purpose Sperre has produced this manual to provide information for all users of the compressor equipment. This includes information about the compressor‟s construction and operation, as well as basic information regarding inspection and maintenance. It is important that operators familiarize themselves with the contents of this instruction manual, to ensure that use and maintenance work are carried out in the correct and safe manner from the outset.

Note Please note that all pictures and drawings in this manual are for illustration only.

The maintenance intervals and individual technical data are average values based on experience, and may vary depending on the compressor‟s operational parameters. The supplier accepts no responsibility for damage resulting from careless operation or inadequate maintenance. Keep the compressor in good mechanical condition, and remember that preventive maintenance of the equipment reduces the danger of damage and unnecessary operational interruptions. Sperre reserves the right to modify details without prior warning.

1.2 Annotations All safety directions must be respected in order to avoid damage to personnel, the environment and equipment. In this manual the annotations are used, as illustrated below:

Warning

Note

Indicates possibilities for hazards or unsafe practices, which COULD result in fatal or severe personnel injuries or substantial product or property damage, if the required precautions are not taken.

Draws attention to specific information of technical significance that might not be obvious, or highlights important remarks in the procedures to follow.

1.3 Abbreviations Abbreviation Barg CFD CR CW dBA DOL HP LP IMO ISC MR PMS RPM XA XW

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Description Unit of pressure (Barg = Bar gauge) Computerized Fluid Dynamics Class Recommendation Cooling Water Decibel Direct On Load High Pressure Low Pressure International Maritime Organization Internal System Control Makers Recommendation Planned Maintenance System Revolutions Per Minute X-range compressor Air-cooled X-range compressor Water-cooled

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1.4 Tags on the compressor

Danger The compressor is remotely controlled May start without warning

Danger Hazardous voltage Risk of electric shock

Caution Burn hazard Risk of hot surface

Before using or servicing the compressor Read and understand the user manual

The cover must always be on when running

To connect the signal cable, carefully turn the plug to find the right insert point, then push carefully until a click appear To disconnect, pull the ring on the plug

Without the cover the compressor will be damaged after running even for a short period

The oil has been drained from the compressor Do not start the compressor before the correct oil quantity has been added

Compressor oil type. For oil reference, visit www.sperre.com

Level sight glass Correct oil level should be in centre of level sight glass

Drain oil

Delivery air outlet

Unloading and drain high pressure

The lifting eye bolt is certified for lifting the single compressor with el-motor only

Rotation direction is counter clock wise, seen from compressor front.

Compressor rating plate

1.5 Warranty The X-range compressor has a limited warranty that is valid only with use of original spare parts purchased through our Sperre office in Norway, Singapore, the Netherlands or China. Please note that the warranty will be void if the equipment is misused or not handled in accordance with prescribed operating and service standards.

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2 Personal safety Please make yourself familiar with the content in this user manual before operating the compressor. It is the responsibility of the user to ensure that appropriate controls and precautions are identified and applied in relation to the work envisaged by this document in accordance with relevant statutory, legal and industry requirements to protect the health and safety of the persons undertaking the work. All operation and service of the compressor is to be carried out by personnel who are familiar with the contents of this manual. The compressor is a high pressure machine that must only be used to compress air. Unauthorized remodelling or modification of the compressor may result in a safety hazard, and is not permitted. The compressor must never be operated without cover: the high temperature machine with rotating parts pose a great risk for the crew. Before any form of work is commenced on the compressor, the electrical power must be turned off at the starter panel and at the main switchboard, and the switch on the main switchboard must be marked with a notice indicating that repair work is in progress. The manual valve between the compressor and the air receiver must be closed, and the pressure must be released in all pressurized parts of the compressor. The safety valves for LP air, HP air, cooling water and any other safety equipments must be inspected regularly. Damaged components should be replaced with new, original parts. Please note that all safety valves are security sealed and any adjustment of these valves is not recommended. The compressor must never be used if the safety equipment is defective.

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3 System description 3.1 X-range compressor

The X-range compressor is a two stage, two cylinder compressor. The radial fan [a] feeds fresh new ambient air to the inlet air filter [b] and further to the LP valve [c]. After first stage of compression the air is carried through the LP cooler [d] and further to the HP side of the compressor [e]. After last stage of compression the air is carried through the HP cooler [f] further through the cyclone separator [g] before the pressurized air is delivered to the air receiver.

X-cover The robust steel cover protects the operator from hot surfaces and moving parts, the cover also protects the components and minimizes potential damage during transport and installation. The radial fan and the distinctive shape of the cover are specially designed to work together. The radial fan builds up cooling air pressure, and the cover directs the flow of cooling air in the optimal direction, ensuring that every component gets optimized cooling air.

NOTE: The compressor must never be operated without cover: the high temperature machine with rotating parts pose a great risk for the crew and the compressor will overheat without cover.

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Cyclone separator The high pressure cyclone ensures virtually water-free air, for XA and XW. The effective cyclone separator removes at least 80% of remaining water droplets at 30 barg. It is equipped with an integrated non-return valve on the HP side. The compressor has one automatic solenoid valve on HP side, for combined draining and unloading functions.

Splash lubrication system The splash lubrication system is a closed system. Extensive testing and simulation prove that this is an efficient and cost-effective solution. The closed air breathing system ensures no oil mist to the environment:  Takes up oil mist from crankcase [a].  Condensed in the oil separator [b].  Most of the oil mist is condensed and led back into the oil sump [c].  The remaining oil mist is led into the intake air [d].

X-drive The X-drive solution results in substantial benefits. The flywheel function is integrated in rotating components. Flexible but torsion-proof coupling, combined with the directly flanged electric motor, eliminates the need for alignment between the electric motor and the compressor. Torsion-proof coupling makes it possible for the moving parts in the electric motor to function as the flywheel. The new coupling principle without wear parts ensures greater operational reliability. The configuration with the counterweight provides optimal balancing. The result is a solution which is compact, easy to assemble and easy to maintain.

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3.2 X-control

The X-control provides a complete package of easy-to-use control and monitoring functions in one standard, configurable module.

The controller is installed with a full graphic display with multiple languages. The display shows: 

Start counter and running hours,



Instant readout of status information,



Logging of alarms and service history.



And more ...

The X-control simplifies preventive maintenance with an easy to read service countdown so there is no need to remove the cover of the compressor to find out if maintenance necessary. If any blackout on board occurs, the compressor restart is automatically delayed to avoid power failure. Items that an operator may need to view during routine operation, for example; pressure or temperature can easily be read from the display. If a fault condition is active, the display will show a fault code and identification.

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4 Technical data For further information and drawings regarding technical data, please refer to www.sperre.com.

Compressor XA150 – 30 barg Charging capacity at 1775 / 1475 RPM Power requirements 1775 / 1475 RPM Heat dissipation 1775 / 1475 RPM Weight complete (standard motor) Dimensions Oil volume Oil type

165 / 135 m3 /h 31 / 26 kW 29 / 24 kW 555 kg 1450 x 950 x 850 mm (L x W x H) 11 litres Fully synthetic, ISO 100, piston comp.

Design No. of cylinders / Cylinder arrangement No. of compression stages Cooling Valve LP / Valve HP

2 / 90°V 2 Air cooled 1 Plate valve / 1 Reed valve

Operation parameters Max. delivery pressure Start – stop pressure Max. ambient temp. compressor Max. ambient temp. controller Max. ambient temp. electric motor Air outlet temperature Max. noise level Max. vibration level / Min. isolation grade Safety valve LP / HP Rotation Start Inhibits

40 barg 25 - 30 barg 55°C 55°C 45°C (55°C on request) Approx 25°C above ambient 95 dBA (1800 rpm) 20mm/s-RMS / 90 % 8 barg / 33 barg Counter clockwise (compressor front) Temp > 85°C / LP > x barg / HP> x barg

Alarm at 31 barg, shutdown at 32 barg (fan needed above 50°C)

Below the IMO norm of 110 dBA Gen. rec. 30 mm/s -RMS / 70%

Mechanical components Non return valve air outlet Oil & water separator HP Safety valve LP / HP Oil level sight glass Air suction filter Inter- and after-cooler Three vibration isolators One lifting lug Flexible tube air outlet Flexible tube drain /unload

Integrated Integrated Integrated Integrated Integrated Integrated Integrated Integrated Loose Loose

Electrical components Starter with controller Transmitter LP Transmitter HP Trans. temp. outlet Transmitter oil level

Loose Integrated Integrated Integrated Integrated

Valve drain - unload HP

Integrated

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Operation Manual XA150 Version 02

Alarm at 6 barg, shutdown at 7 barg Alarm at 31 barg, shutdown at 32 barg Alarm at 85°C, shutdown at 90°C Alarm 0%, shutdown - 10%, switch 20%, temp. switch 100°C

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5 User Interface This chapter describes the user interface and the basics of the X-control. For further information see User Manual, X-range air compressors, X-control.

5.1 Keypad

Start – push to start the compressor, or to set in a started condition.

e.

b.

Stop – push to stop the compressor.

f.

Enter – push to confirm selection or value adjustment.

c.

Escape / cancel – push to step back one menu navigation level.

g.

Menu – push to enter the menus.

h.

d.

Minus / down – Push to scroll down through menu, menu item options or decrement value.

Reset – push to reset and clear fault condition.

a.

Plus / up – Push to scroll up through menu, menu item options or increment value.

Note Access codes are needed to enter the different levels of menu level User level: Use access code 0000 Service level: Use access code 0100

Start [a] and Stop [b] have one defined function and are not used for any other purpose. Reset [h] will initiate a display jump to the fault code item if a fault condition remains active, or initiate a display jump to the status item if no active faults exist in normal display mode. If reset [h] is pressed and held for longer than two seconds in menu mode, the system will exit menu mode to the normal operational display mode, page 00. Enter [f] will lock a selected displayed menu item. This prevents the menu item from returning to the default value, after a short delay. When locked, the „lock‟ symbol will show. To unlock, press Escape [c]. Escape / cancel [c] will initiate a display jump to the information item in normal display mode, page 00. Plus[e], Minus [d], Enter [g] and Escape [c] are used to navigate menu mode and adjust menu parameters. Press the menu button [g], to enter menu mode. www.sperre.com

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5.2 LED indicators The LED indicators on the front of the X-control are illustrated and described below: a.

Green LED indicator – continuously light indicates on; the compressor is running.

b.

Yellow LED indicator – flashing light indicates service warning, needs attention soon.

c.

Red LED indicator – flashing light indicates fault or alarm, needs immediate attention.

When the controller is activated the LED indicators can appear as:  Continuous light – ON  Fast flash (on / off four times per second)  Slow flash (on / off once per second)  Intermittent flash (on / off every four seconds)

Information regarding the LED indicator flash will be displayed on the controller.

Machine state number in display

Machine state or condition

Status

Fault

Service

1

Controller initialization

ON

ON

ON

2

Start inhibit condition

Slow flash

Slow flash

OFF

3

No start inhibit condition

OFF

OFF**

OFF

4

Semi standby

OFF

OFF**

OFF

5, 9, 14, 17

Drain unload time start

Fast flash

OFF**

OFF

6, 7, 10, 11, 18, 19

Running

ON

OFF**

OFF

8, 12, 16, 22

Drain unload time stop

Fast flash

OFF**

OFF

13

Fully standby

Slow flash*

OFF**

OFF

20

Stop while pressure is loaded for leak test Slow flash*

OFF**

OFF

21

Stop and drain

Slow flash*

OFF**

OFF

10

Alarm error

ON

Slow flash

OFF

23

Shut down error

OFF

Fast flash

OFF

Service warning

OFF

OFF**

Slow flash

Service alarm

OFF

OFF**

Fast flash

OFF**

OFF

No start inhibit condition and auto restart Slow flash* function active

*SF = standby state, indicates that the compressor may start running at any time. **SF = alarm condition

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5.3 Display The normal operational display, which is continuously displayed, if no fault code occurs, is described and illustrated below.

Note The displayed values are updated once each 500ms, but faster update-rates are used internally (for example when triggering alarms).

a.

Delivery pressure value.

e.

Units.

b.

Symbol showing receiver.

f.

c.

Activated functions are represented symbolically.

Symbols for pressure and compressor status.

g.

Information text.

d.

Value items.

P00 User menu This is the user menu page, which is available to all users. Items are “view only” and cannot be adjusted. The menu contains all items that an operator may need to view during routine operation, such as pressure or temperature values. All available items can easily be selected using the up / + or down / - buttons on the front of the controller at any time. Information regarding system settings and values will be displayed on the information text line [g]. Values, parameters and option settings are grouped into menu page lists. Items are assigned to a list according to type and classification. Page lists are identified by page number, the normal operational display / user view menu is page 00 as illustrated. All adjustable parameters and options are assigned to menu P01 or higher: an access code is required to access pages higher than user view menu in P00.

The pages on user level which require an access code are:  P01: User settings  P02: Fault log  P03: Service log  P80: ISC operational The default access code for these pages is = 0000. The display will provide clear and early warning for temperature, high pressure stage, low pressure stage and oil level, making it possible to respond to any potential problems while the situation is easy and inexpensive to correct. When a fault condition occurs the fault code becomes the first page 00 list item, and the display will automatically jump to display the fault code. Several fault codes can be viewed at the same time by pressing the up / + or down / - buttons. The user menu item will disappear when the fault condition is resolved and reset.

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Display invert The display back light level has been set to enable a “continuous use” display service life, providing good readability in all ambient light conditions. LCD display service life is defined as the time period before the backlight reduces to 50 % of initial brightness. Increasing the back light level setting above the default will reduce the display service life.

When a keypad button is pressed the display backlight will automatically increase 2 levels in brightness. The backlight will remain at this brightness level for a period of 10 minutes after keypad activity ceases. The standard display and the inverted display are illustrated below. Please refer to configuration menu P09 in the “X-control User manual” for more details regarding the display back light settings procedure.

0 = standard

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1 = inverted

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5.4 Symbols Symbols that can be displayed on the controller are illustrated and explained in the tables below.

Control pressure status symbols Pressure is below the Unload pressure set point value.

Pressure is above the load pressure set point value.

Note Status symbols are continuously displayed.

Pressure is between the unloaded and load pressure set point values

Compressor status symbols Stopped, not in an active stat.

Running, not loaded.

Standby, not running but in an active stat.

Loaded.

Note Status symbols are continuously displayed.

Menu mode navigation symbols User level

Note

Service level

These symbols show the menu access level.

Menu mode navigation symbols User settings

Fault log

Service log

Shutdown settings

Alarm settings

Inhibit settings

Diagnostics

Sensor calibration

User, “view only”

Internal system control

Configuration settings

Service reset

Note These symbols show the general menu type.

Function symbols Indicates that all items in the menu page are locked and cannot be adjusted.

Time

Unlocked symbol; item is editable.

Oil level

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Function symbols Locked symbol; display adjustment is inhibited.

Motor current

Real time clock

Alarm, warning

Pressure

Drain output is energized

Temperature

Service

Start counter

Full automatic mode

RS485 network pressure regulation control, (flashing = data link fault)

Test safety valve mode

Power failure automatic restart

Test drain valve mode

Remote Pressure Control

Semi automatic mode

Remote start/stop control

Short circuit

Emergency stop activated

Start inhibit

Heater “on”

Time delay

Running

Drain interval

Air receiver

Motor current start up delay

Item “ID”

Menu

Running hours

Service hours

Language setting symbol English

Italian

German

Dutch

French

Turkish

Spanish

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5.5 Menu structure The display menu is divided in to several levels; the table below gives you an overview and a description of the menu levels and structure.

Level

Menu page

P00: User view

C> I> N> P1 P2 P3 T1 A6 L1 A7 HR ST HS IS SC

Compressor status / RTC Information screen Compressor name Delivery pressure Compressor HP pressure Compressor LP pressure Delivery temperature Analogue input 6 Compressor oil level ** Compressor motor current Total running hours Start counter Hours until service due ISC sequence ISC seq. change int. counter

P02: Fault log

P80: ISC operational

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** Sensor for oil level L1 has 2 channels: 1 Digital + 1 Analog, only shown when oil level is enabled

M> MH PU PL D1 D2 DI DO P> T> L> SS LS Ct SN

Mode (Semi or Full) Motor heating function Unload pressure Load pressure Drain unload time start Drain unload time stop Drain interval time Drain time open Pressure units Temperature units Language selection Start source Load source Compressor type Serial number (controller)

The user setting menu contains adjustable parameters and options. Further information regarding these settings is described on next page.

01

Logged error #1 v Logged error #30

The fault log menu contains the last 30 fault codes in chronological order.

65

Logged service item #1 v Logged service item #65

The service log menu contains a complete service overview. The items are view only.

En PU PL SC

Enable ISC ISC unload pressure ISC load pressure Sequence interval

30

P03: Service log

The user menu shows normal operational values and information. This is the default display menu, no access code is required. Items are view only and cannot be adjusted.

Access code required: The default code = 0000

Access code, user level

P01: User settings

Description

01

Operation Manual XA150 Version 02

Pressure units: Bar PSI kPa MPa kg/cm2

Temperature units: °C °F

18

P01 User settings: Menu page

Description

Mode Semi or Full

Mode settings for Semi or Full operation mode.

Motor heating function

Motor heating function. Always off when motor is running.

Unload pressure

Setting of the unload pressure (stop).

Load pressure

Setting of the load pressure (start).

Drain unload time start

Time period setting for the unloaded start.

Drain unload time stop

Time period setting for the unloaded stop.

Drain comp. Interval time

Time period setting for the drain interval time during load operation.

Drain open time

Time period setting for the drain opening time during load operation.

Pressure units

Types of pressure units to be chosen.

Temp units

Types of temperature units to be chosen.

Language selection

Selection of language. English is the default.

Start source

Setting of different start sources. The default is the keypad start / stop key on X-control. Options are network or remote digital input.

Load source

Setting of different load sources. The default is start / stop pressure transmitter on receiver or pressure line. Options are network or remote digital input.

Compressor type

View of compressor type

Serial number

View of controller serial number

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Operation Manual XA150 Version 02

Note If ISC operation in menu P80 is enabled, the network option is locked and cannot be changed before ISC is disabled.

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Menu navigation Access to menu mode pages is dependent on authority level determined by the access code used. To enter menu mode: 1. Press the menu button

.

An access code will be displayed and the first code numeric character will flash. 1. Use the + / - buttons to select a number. 2. Confirm the number by pressing the enter button

.

Repeat procedure until all numeric code characters are selected. When the code is selected you will get access to the menu mode pages. An invalid code will return the display to normal operational mode; page 00.

Each menu mode page is identified symbolically and by language text. The first left symbol defines the menu page access level. The second right symbol defines the general menu type. 3. Press the + / - buttons to scroll through the menu pages. 4. Press the enter button desired menu page

to enter the

Each menu page contains a number of items. The first item on the list will be highlighted, as illustrated below. 5. Press the + / - buttons to scroll through the items on the list. The list will wrap around. 6. Press the enter button to confirm the selection or value. To abandon an adjustment at any time press the escape button , the original value or option will be maintained in memory, and the screen will return to page item list.

Note When the first list item is highlighted the last list item can be seen at the top of the list; this immediately indicates the number of listed items.

7. Press the escape button to return to the menu page selection screen. A menu page may contain items that are “view only”. A key symbol will be displayed to indicate that all items on the menu page are locked and cannot be adjusted, as illustrated. To immediately exit menu mode and return to the normal operational display, press and hold the reset button for several seconds at any time.

Note Menu items can be locked for “view only” when the compressor is running. The compressor must then be stopped before adjustments can be performed.

Any value or option adjustment that has not been confirmed and entered into memory will be abandoned and the original setting will be maintained.

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Fault, warning and alarm The controller will indicate if a fault, warning or alarm condition occurs in the system. The different fault state conditions will be displayed with specific codes. The active fault code becomes an additional item on the display until the fault condition is resolved and reset. Each fault type is identified symbolically and each fault code is unique. Each code character gives you specific information regarding the fault condition, as described below: a.

The first letter and number of the code indicates the fault type.

b.

The second number indicates the input location number.

c.

The third number indicates the input number.

d.

The last number indicates the fault description number.

A fault condition is a detected abnormality that must be indicated to operator personnel. It may require controller automated safety action, depending on fault type and definition. The fault, warning and alarm conditions that can be displayed are:

Start inhabit fault (Code S): A start inhibit fault is a condition that may present a danger or cause damage to the compressor if started whilst the condition is present. Start inhibit faults are only triggered if a compressor start from the “ready to start” condition is attempted. Start inhibit faults are not triggered during an automated motor start sequence from the standby condition. Start inhibit faults are self-resetting. A start inhibit fault code (S) is displayed when triggered but is not recorded in the fault log.

Alarm fault (Code A): An alarm fault is a warning condition that does not present an immediate danger or potential damage to the compressor. Alarm states will not shutdown the compressor or affect normal operation. An alarm fault code (A) is displayed and must be manually reset to clear once the condition has been resolved or no longer exists.

Shutdown fault (Code E): A shutdown fault is a condition that may present danger or potential damage to the compressor if the condition persists. A shutdown fault will cause the controller to stop the compressor. A shutdown fault code (E) is displayed that must be manually reset to clear once the condition has been resolved or no longer exists.

Service warning (Code SW) / Service alarm (Code SA): A service warning or alarm fault is a warning condition that does not present an immediate danger or potential damage to the compressor. A service warning or alarm state will not shutdown the compressor or affect normal operation. A service warning fault code (SW) is displayed and must be manually reset. If a service alarm fault code (SA) is displayed it must be manually reset by entering an ID-number, or simply by entering to clear once the service condition has been resolved or no longer exists. However, if a service alarm is triggered before its related service warning has been reset, the warning will be reset by the alarm. See P04 Service alarm reset menu for further details.

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6 Installation and Operation 6.1 Installation All deliveries of compressor installations are accompanied by documentation of the installation‟s dimensions and mounting points. The documentation will also include installation instructions, illustrating the recommended assembly of equipment and pipe connections. To achieve problem-free operation, it is important that the base-plate is sufficiently rigid and free from vibrations caused by other machinery. The base of the compressor must lie flat on the base-plate.

Note Please refer to the General Arrangement and Installation drawings for specific details.

The normal ambient air temperature is 20-45°C and must not exceed 55°C. Warm intake air increases the risk of coking. Transmitters and solenoid valves must not be exposed to temperatures above 80 °C. The cooling water pipes must be installed correctly to avoid air pockets. The compressed air outlet temperature should be approximately 15-30°C above cooling water inlet temperature. Adjust cooling water flow (l/min) to achieve this temperature difference. The compressor installation must not be closely surrounded by other equipment, which could inhibit maintenance performances. The recommended maintenance space on all sides is 600 mm. This manual includes instructions for handling of the compressor after installation. It is important that the instructions are followed carefully to avoid problems during commissioning and further use of the compressor.

ISC installation ISC:

Warning Wire polarity is important.

Use 2-wire, 0.3-0.5mm2, twisted pair earth shielded data cable with a total system network length no greater than 1.0km (3280ft). Data cable terminal connections vary.

Consult the manuals and drawings for details before installing the ISC communication between the compressors. RS485 data communications and other low voltage signals may be subject to electrical interference. This potential can result in intermittent malfunction or anomaly that is difficult to diagnose. To avoid this possibility always:  Use earth shielded cables, securely bonded to a known good earth at one end. In addition, give careful consideration to cable routing during installation.  Never route an RS485 data communications or low voltage signal cable alongside a high voltage or 3-phase power supply cable. If it is necessary to cross the path of a power supply cable(s), always cross at a right angle.  If it is necessary to follow the route of power supply cables for a short distance (for example: from a compressor to a wall along a suspended cable tray) attach the RS485 or signal cable on the outside of an earthed cable tray so that the cable tray forms an earthed electrical interference shield. Where possible, never route an RS485 or signal cable near to equipment or devices that may be a source of electrical interference (for example: 3-phase power supply transformer, high voltage switchgear unit, frequency inverter drive module, radio communications antenna).

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Pressure transmitter location: The system pressure transmitter (PT11) must be located in a position that will continuously experience pressure that is common to the delivery of all compressors in the system. Pressure side pressure control:

6.2 Before and after operation Before operation The Sperre compressor sensors and starter are real-time tested in our test facilities before delivery from the factory. Before initial start-up, and after long periods out of use, the following operations need to be carried out in the sequence given: 1. Check the oil level (sight glass). 2. If the compressor has been out of service for more than 6 months, lubricate the valves, cylinder walls and crank bearings. 3. Turn the compressor shaft a few revolutions, by turning the fan. 4. Open valves on the air discharge line between the compressor and the receiver. 5. Ensure that power is available and that the electrical plug-in cables are fitted properly. 6. Turn the power switch to the “on” position. When power is switched on, all display elements and LED indicators will be switched on for three seconds. The display will then show the software version code for a further 3 seconds before starting-up is completed and the normal operating display will show.

Note If the X-control is not centralized with the ships central alarm system, the controller needs daily inspection to observe fault, warning or alarm conditions.

The display will be switched on, and “ready to start” will be displayed if no alarms or shutdowns are active. 7. Start the compressor, by pressing the green start button (if not in standby mode). The compressor is now in active condition ready to respond to changes in delivery pressure. The Sperre compressors are designed to maintain safe operation with a minimum of maintenance. The operation procedures for the different modes are described on the following pages.

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Preservation If the compressor is to remain unused for a long period, lubricate the valves and cylinder walls with oil. The compressor must be started from time to time: please refer to procedure “before operation”. The following precautions must be taken when storing the compressor: 1. Store in a dry place with the lowest possible relative humidity. 2. Shut off the cooling water circulation. 3. Coat relevant surfaces, especially unpainted surfaces, with rust inhibiting oil or similar. 4. Turn the compressor shaft a few revolutions, by turning the fan, once a month. 5. For storing longer than six months, lubricate all valves and cylinder walls with corrosion inhibiting oil. Clean and check before starting up.

6.3 General operation This chapter provides important information regarding normal, ISC and emergency operation of the compressor. Before operating the equipment, please refer to Chapter 2 for the personal safety instructions.

Warning If any malfunction, warning or alarm is detected during operation, the malfunction must be given immediate attention.

The compressor can be set to two different normal operating modes:  Semi-automatic mode S>  Full-automatic mode F> In the semi-automatic mode of operation, the operator is in command of when the compressor runs. In full-automatic mode, the delivery pressure controls the start and stop of the compressor once the operator has started the compressor. The operator can also choose to start the compressor in two different test modes:  Test mode TS  Test mode TD When exiting the test mode, the compressor will automatically return to the normal set mode S> or F>. The compressor can also be remotely started and stopped.

Semi-automatic mode S> Semi automatic is a mode of operation in which the operator controls compressor start and the delivery pressure controls stop operation. After the compressor has stopped the operator have to manually start the compressor again. Start: 1. Press the start button to start the compressor The compressor will achieve the set unload pressure and then stop. When the operator presses the start button again, and the pressure is above the load level, the controller will hold and wait for the pressure to fall before automatically starting the compressor; if the pressure is below the load level the compressor is started immediately and the pressure will rise. When the unload pressure level is achieved the compressor will stop. The compressor will only start again if the operator presses the start button. The green LED indicator will appear as a slow flash to indicate semi standby, and that the compressor can be started again at any time. The compressor will only start again if the operator presses the start button. Stop: 1. Press the stop button. The operator can stop the compressor at any time. www.sperre.com

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Full automatic mode F> Fully automatic is a mode of operation in which the delivery pressure controls compressor start and stop operation once the operator has started the compressor. Start:

Warning

1. Press the start button to start the compressor If the pressure is below the load level the compressor is started and the pressure will begin to rise. When the unload pressure level is achieved, the compressor will stop and the compressor will remain active in a standby condition.

In automatic mode, the compressor will automatically start.

The compressor will automatically start again when the delivery pressure falls below the load pressure level. This cycle will continue until the compressor is stopped by pressing the stop button. When the delivery pressure is below the unload level, but above the load level, the compressor can be started again immediately by pressing the start button. This will cause the compressor to start and increase pressure to the unload level, without the need to wait for pressure to decrease to the load level. The green LED indicator will appear as a slow flash to indicate fully standby, and that the compressor may start running at any time. Stop: 1. Press the stop button, to exit fully automatic operation, and stop the compressor.

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Remote modes For remote operation the remote digital input start source and load source must be manually set to remote digital input on the controller, as described in the following procedure:

Note

 Start source (SS) setting: 0 = keypad, 1 = network, 2 = remote digital input. This is the remote function replacing the start / stop buttons on the local control panel, for optional start operating. The signal, if closed, set the compressor in started condition and will start the compressor if it is ready to start. The signal, if open, will set the compressor in stopped condition. The remote start / stop function must be set in X-control user setting menu P01 – item SS = 2 (remote digital input). Default is SS = 0 (local start / stop button).

Please note that a push button with return cannot be used for remote operating. Only a switch or a push button with locked positions can be used.

 Load source (LS) setting: 0 = pressure transmitter, 1 = network, 2 = remote digital input. This is the remote function replacing the local receiver pressure transmitter, for optional remote pressure control. If the pressure transmitter on the receiver is not being used for this purpose (local control), a digital remote signal from vessel automation system can be used for this purpose. Closed signal contact for start / loading condition and open signal contact for stop / unloading condition / stand by. The remote function must be set in Xcontrol user setting menu P01 – item LS = 2 (remote digital input). Default is LS = 0 (receiver pressure transmitter). Setting start source: 1. Press the menu button

.

2. Select the access code 0000, confirm each number by pressing the enter button

.

3. Use the + / - buttons to select page P01 / user setting menu. 4. Press the enter button

to enter the menu P01.

5. Use the + / - buttons to select the start source (SS) and press the enter button confirm the selection. 6. Use the + / - buttons to select the number 2. Press the enter button selection.

, to

to confirm the

Setting load source: 1. Use the same procedure to set to the Load source LS. 2. The controller is now set to remote operation only, but the stop function will always be available locally. Remote start: When the remote start/stop function is enabled in X-control user setting menu P01, the compressor will execute a normal start sequence when the remote start/stop input changes state from open to closed circuit. If closed, the remote start/stop input must be opened and closed again to initiate a new remote start sequence. Local controller start function is inhibited. When the delivery pressure is below the unload level, but above the load level, the compressor can be started again immediately by switching the remote signal contact of an on again within one second. This will cause the compressor to start and increase pressure to the unload level, without the need to wait for pressure to decrease to the load level. Remote stop: When the remote start/stop function is enabled in the X-control operation menu P01, the compressor will execute a controlled stop, as if the control panel stop button had been pressed, when the remote start/stop input is open circuit. Local control panel stop will still be available.

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Remote unload: When the remote load source function is enabled in the X-control operation menu P01 an open circuit remote digital signal will automatically stop the compressor and go to a stand-by mode. Remote load: When the remote load source function is enabled in the X-control operation menu P01 a closed circuit remote digital signal will automatically start the compressor again if operation mode is "Full automatic". In "Semi automatic" the green start key has to be pressed for a restart.

Local / remote operation philosophy for start and stop commands Start and stop commands: O = possible X = not possible

Mode: SEMI AUTO and FULL AUTO

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Local mode:

Remote mode:

Local Side

Remote Side

Local Side

Start

Stop

Start

Stop

Start

Stop

Start

Stop

O

O

X

X

X

O

O

O

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Remote Side

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6.4 Internal system control (ISC) The controller is equipped with a function that will enable pressure control regulation and sequence management. This feature can be used to create an air compressor system, of up to 8 compressors, operating coherently to a single pressure target with automated timed sequence rotation. The ISC‟s control strategy consists of two sub-strategies: 1. The compressor „Rotation‟ strategy 2. The compressor load „Control‟ strategy The rotation strategy defines how the compressors are re-arranged, or re-ordered, into a new sequence at each routine „Rotation‟ event. Rotation events are triggered by a cyclic interval timer. The compressor load „Control‟ strategy defines how the compressors are utilized in response to variations in system pressure. Each compressor in a system is initially assigned to the ISC with a fixed and unchanging number reference, 1 to 8. The „duty‟ that a compressor is assigned in any set „Rotation‟ sequence arrangement is defined by a letter, A to H: A = the „Duty‟ compressor, the first to be utilized. B = the „Standby‟ compressor, the second to be utilized. C = the „Second Standby‟ compressor, the third to be utilized. D = the „Third Standby‟ compressor, the forth to be utilized, and so on. The primary function of rotation is to efficiently operate a compressed air system consisting of fixed capacity output compressors. The routine rotation assignments can be modified using „Priority‟ settings to accommodate for a differentially sized, preferred or nonpreferred compressor(s). Rotation: 1

2

3

4

Each time the set rotation interval elapses a sequence rotation occurs and the sequence assignment for each compressor is re-arranged. The compressor that was assigned for duty (A) is re-assigned as last standby (D) and all other compressor assignments are incremented by one

#1

A

B

C

D

#2

D

A

B

C

#3

C

D

A

B

#4

B

C

D

A

Control: The compressors are utilized, in response to changing demand, using a „FILO‟ (First In, Last Out) strategy. The „duty‟ compressor (A) is utilized first followed by (B) if demand is greater than the output capacity of (A). As demand increases (C) is utilized followed by (D) if demand increases further. As demand is reduced (D) is the first compressor to be unloaded, followed by (C) and then (B) if demand continues to fall. The last compressor to be unloaded, if demand reduces significantly, is (A). The compressor assigned as (A) in the sequence is the first to be loaded and the last to be unloaded

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Activating ISC, (menuP80 and P01) Please follow the procedures below to accomplish correct activating of the ISC: The master controller must be set to enabled = network item “En” in X-control menu P80 as described below:

Note The X-controller with the lowest serial number is recommended for use as the master controller.

1. Select one of the X-controls to be system master controller.

Note

2. Press the menu button .Select access code “0000”, confirm each number by pressing the enter button

When ISC operation is enabled, the load source will automatically be set to (1) network. To enable delivery pressure sensor (0) or remote (2) load source; disable the ISC operation and set the wanted function in menu P01.

.

3. Use the + / - buttons to select P80 ISC operational. 4. Press the enter button to confirm and enter the menu page P80.

5. Use the + / - buttons to select the “En” line as illustrated, and press the enter button

to select.

6. Use the + / - buttons to select item 1 enabled, press the enter button confirm the ISC setting.

to

0 = disable. 1 = enable.

7. The ISC setting is now activated, as illustrated.

The other adjustable settings on this page (P80) can easily be adjusted:  SC: Sequence interval is set to default 24 hours. Range 1 – 750 hours. Sets the sequence „Rotation‟ interval or time. The compressor sequence assignments will be rotated each time the sequence change interval time expires.  Pu: Unload pressure is set to default 29,0 bar.  PL: Load pressure is set to default 26,0 bar. Once ISC is activated ISC can be started and stopped independently of the master air compressor. Navigate to the ISC sequence display item in the user view of the master controller.

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All slave controllers must be set to Load source = network at item “LS” in X-control menu P01, as described below: 1. Select one of the slave controllers Press the menu button

.

2. Select the access code 0000, confirm each digit by pressing the enter button .

3. Use the + / - buttons to select page P01 / user setting menu. 4. Press the enter button setting menu page.

to enter user

5. Use the + / - buttons to select the “LS” item, load source. Press the enter button

to select.

6. Use the + / - buttons to select the default “1”. Press the enter button to confirm the selection.

Note Please see X-control user manual for further details regarding using the ISC function.

7. The first slave controller is now set. Repeat the procedure for the next slave controllers until all are set.

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6.5 Emergency operation The system can be overridden using an emergency run switch on the inside of the Xstarter. If normal control of the compressor fails, and power is available, the emergency switch will force the compressor to run. For emergency operation of the compressor please follow the procedure below:

Warning The compressor must not be left unattended while running in emergency mode!

1. Manually check the oil level, and visually observe that there are no abnormalities with the compressor. 2. Manually open the drain valve [b] on the compressor by using a screwdriver. 3. Turn the emergency switch [a] on the inside of the X-starter to the emergency position. The compressor will now start. 4. Manually close the drain valve [b] on the compressor by using a screwdriver.

Warning Never carry out the emergency operation alone. Monitor the airreceiver pressure and shut down the compressor immediately when pressure level is reached. No surveillance or alarms will function, except for local emergency stop and motor overload control, which will be in an active state.

5. Observe and manually check that the compressed air temperature is not above normal. 6. The pressure increase should be monitored during all running period. 7. Before the compressor is stopped, carefully open the drain valve [b]. 8.

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Stop the compressor by turning the emergency switch [a] to the “normal” position.

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7 Troubleshooting 7.1 Abbreviations Abbreviation CT1 DV1 DV2 F1 F11 F12 PT11 PT12 PT13 PT14 LT15 LS15 PTC RTC S0 TT14 XPC

Description Current transmitter Drain valve HP Drain valve LP Thermal overload relay MCB - Motor circuit breaker MCB - Motor circuit breaker Receiver pressure transmitter Compressor HP Pressure transmitter Compressor LP Pressure transmitter Compressor oil pressure transmitter Compressor oil level transmitter Compressor oil level switch Electric motor thermistor control Real time clock Local emergency stop button Temperature transmitter HP outlet Expansion card

Comments

Only for water-cooled XW200-500 Only for water-cooled with cw pump Only for pressure lub. compressors

Only for pressure lub. compressors LT15 and LS15 are located in same unit

7.2 Service warning (SW) and alarm (SA) When a service warning or alarm appears on the display (SW / SA) Service warning (pre-alarm): When a service warning occurs the controller will display the “Service Warning” indicating the service type, code and contact details for service arrangements. A service warning will occur 200 running hours or 3 months prior to a service. The yellow service LED- indicator will appear as slowflash. The Service Warning indication will alternate with the normal running display. 1. Reset the service warning by pressing the reset button on the controller. The service warnings will not occur again. This facility is intended to provide pre-warning enabling service arrangements. 2. Order the Sperre service kit. Please refer to “Service procedures overview” in the Service manual, for the service kit ordering number. A Sperre service kit (A, B, C, D or E) contains all necessary spare parts with the relevant step by step service procedures.

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Operation Manual XA150 Version 02

Note The text line on the display will indicate the type of service. Service A will only appear once, throughout the life time of the compressor, and will only be indicated with a service alarm.

32

Note

Service alarm (service due now): When the service interval time expires the controller will display the “service alarm” The yellow service LED-indicator will appear as fast-flash. 3. The service type displayed must be performed with the relevant Sperre service kit. 4. The Service alarm indication can be reset before the service is complete and the “service interval reset procedure” has been carried out. In this case, the “Service indicator” (yellow LED) will change to be illuminated continuously. 24 hours after the alarm has been reset, the indicator will start flashing again and the screen will toggle again. This goes on until the proper reset procedure has been carried out.

Service warnings / alarms will not interfere with compressor running. For safe running, all services should be executed according to service schedule.

Please refer to the “X-control Manual” for the “Service alarm reset procedure”.

Service warnings Service warning code Text displayed Failure

Corrective action

SW4824

“SERVICE B”

Pre-alarm, service B due soon

Press the “reset” button. Order service kit. Please refer to “Service procedure overview” in the Service manual

SW4834

“SERVICE C”

Pre-alarm, service C due soon

Press the “reset” button. Order service kit. Please refer to “Service procedure overview” in the Service manual

SW4844

“SERVICE D”

Pre-alarm, service D due soon

Press the “reset” button. Order service kit. Please refer to “Service procedure overview” in the Service manual

SW4854

“SERVICE E”

Pre-alarm, service E due soon

Press the “reset” button. Order service kit. Please refer to “Service procedure overview” in the Service manual

Service alarm Service alarm code

Text displayed Failure

Corrective action

SA5814

“SERVICE A”

Service hours countdown time expired

Service A must be performed, refer to “Service procedure overview” in the Service manual

SA5824

“SERVICE B”

Service hours countdown time expired

Service B must be performed, refer to “Service procedure overview” in the Service manual

SA5834

“SERVICE C”

Service hours countdown time expired

Service C must be performed, refer to “Service procedure overview” in the Service manual

SA5844

“SERVICE D”

Service hours countdown time expired

Service D must be performed, refer to “Service procedure overview” in the Service manual

SA5854

“SERVICE E”

Service hours countdown time expired

Service E must be performed, refer to “Service procedure overview” in the Service manual

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7.3 Alarms (A) When an analogue input alarm occurs on the display When an analogue input alarm occurs the controller will display one of the fault codes listed below. The fault code must be manually reset on the controller to clear once the condition has been resolved or no longer exist. Alarm states will not shutdown the compressor or affect normal operation.

Analogue input alarm errors Alarm code Text displayed Failure A_2112

A_2118

A_2148

Possible cause Remedy

“DEL PRESS LOW” Delivery pressure low (PT11)

“DEL PRESS HIGH” Delivery pressure high (PT11)

“DEL TEMP HIGH” Delivery temperature high (TT14)

X-control unit setting Check alarm parameter settings in alarm menu (see X-control manual). Transmitter out of range

Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see Xcontrol manual). Replace transmitter if defective.

Air leakage

Check piping between compressors and air receiver. Check if drain valve(s) are open or closed. Check air receivers. Check compressors.

Compressor valve(s) or drain valve(s) failure

Check and replace if defective.

Safety valve(s) failure

Check and replace if defective.

Transmitter out of range

Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see Xcontrol manual). Replace transmitter if defective.

Emergency run mode

Switch to normal mode

X-control unit setting Check alarm parameter settings in alarm menu (see X-control manual). Transmitter out of range

Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see Xcontrol manual). Replace transmitter if defective.

Air coolers pressure Check all air coolers (LP, Pre-cooler HP and HP). drop Replace if defective. Cooling water temperature and flow.

Check cooling water temperature and ensure that cooling water flows.

Enclosure and fan

Check that enclosure and fan is correctly mounted and ensure that no air inlet or outlet is blocked.

Compressor running Check and reconnect cables in el-motor connection direction box if wrong direction. Valve failure Air cooler failure A_2126

“LEAKAGE HIGH”

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HP pressure leak test failure

Air leakage

Check valve HP and LP for leakage / failure. Replace if defective. Water-cooled compressor. Check cooler for internal leakage. Replace cooler if defective. Check piping, hoses, valves (valve HP / LP and drain valves) and coolers.

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Alarm code Text displayed Failure A_2128

A_2138

A_2145

Possible cause Remedy

“HP PRESS HIGH” Compressor HP X-control unit pressure high (PT12) setting

“LP PRESS HIGH”

“DEL TEMP SENSOR”

Transmitter out of range

Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see Xcontrol manual). Replace transmitter if defective.

Air blockage

Check piping and outlet valve

Non return valve failure

Check non return valve and replace if defective.

Emergency run mode

Switch of emergency run mode if used and use full or semi-automatic mode.

Compressor LP X-control unit pressure high (PT13) setting

“OIL LEVEL LOW”

Check alarm parameter settings in alarm menu (see X-control manual).

Transmitter out of range

Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see Xcontrol manual). Replace transmitter if defective.

Non return drain valve failure

Check non return drain valve and replace if defective.

Valve HP failure

Check gaskets and valve for internal leakage and replace if defective.

Emergency run mode

Switch of emergency run mode if used and use full or semi-automatic mode.

Delivery temperature Transmitter failure sensor fault (TT14) Cables connection failure

A_2152

Check alarm parameter settings in alarm menu (see X-control manual).

Compressor oil level X-control unit low (LT15) setting Transmitter out of range

Check temperature transmitter and replace if defective. Fix or change cables / connections Check alarm parameter settings in alarm menu (see X-control manual). Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see Xcontrol manual). Replace transmitter if defective.

(Optional)

“OIL PRESSURE LOW”

Oil level too low Fill to correct oil level (check sight glass and Xcontrol display). Compressor oil pressure low (PT16) Oil pressure too low Check oil level / oil filter / oil pump

A_2155

“OIL LEVEL SENSOR”

Compressor oil level Transmitter failure transmitter LT15 fault

A_2165

A_2175

A_2816

"ANA6_SENSOR"

“CURRENT SENSOR”

Analogue input 6 fault

Cables connection failure

Fix or change cables / connections

Transmitter failure

Check temperature transmitter and replace if defective.

Cables connection failure

Fix or change cables / connections

Compressor motor Transmitter failure current sensor (CT1)

“POWER FAILURE” Power failure

Check temperature transmitter and replace if defective.

Check temperature transmitter and replace if defective.

Cables connection failure

Fix or change cables / connections

Motor current start up delay too short

Increase time setting in config. menu 09, item 03 CT

Voltage out of range Check main voltage, adjust voltage to right level. Check transformer voltage and input voltage on the X-control power supply and replace transformer if defect. Power failure when Compressor will not restart automatically when set to auto restart is set “0”. Press the start button and the compressor will to”0” automatically restart and the fault code will only appear in the error log.

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A_2836

“RTC FAILURE”

RTC failure

Real time clock failure.

Contact Sperre.

7.4 Start inhibits (S) When a Start inhibit error code appears on the display If temperature (T1) is below the set limit when a start is attempted the motor will not start and a start inhibit error code will be displayed. The temperature must increase above the set limit before a start is allowed. Non-Adjustable Start Inhibit Items: HP Pressure:  P2 if compressor HP pressure level is over the set limit when a start is attempted the motor will not start and a start inhibit error code will be displayed. The HP pressure level must decrease to below the set limit before a start is allowed.  The P2 pressure limit is determined by the compressor type selection.

LP Pressure:  P3: If compressor LP pressure level is over the set limit when a start is attempted the motor will not start and a start inhibit error code will be displayed. The LP pressure level must decrease under the set limit before a start is allowed.  The P3 pressure limit is determined by the compressor type selection.

The start inhibit error codes are self-resetting.

Start inhibit error codes Start inhibit Text displayed Failure code S_3143

“DEL TEMP LOW”

Possible causes Remedy

Delivery temperature X-control unit setting low (TT14) Transmitter out of range

Check alarm parameter settings in start inhibit menu (see X-control manual). Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see Xcontrol manual). Replace transmitter if defective.

Ambient temperature Check ambient temperature. too low S_3127

S_3137

“HP PRESS HIGH” Compressor HP Transmitter out of pressure high (PT12) range

“LP PRESS HIGH”

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Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see Xcontrol manual). Replace transmitter if defective.

Internal pressure too high

Check drain valve(s) and replace if defective.

Air blockage

Check drain piping.

Compressor LP Transmitter out of pressure high (PT13) range

Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see Xcontrol manual). Replace transmitter if defective.

Internal pressure too high

Check drain valve(s) and replace if defective. Only for water cooled XW200-500.

Air blockage

Check drain piping.

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7.5 Immediate stop shutdown errors (E) When an immediate stop shutdown error occurs on the display When an immediate stop shutdown error occurs the controller will display one of the fault codes listed below. A shutdown fault will cause the controller to stop the compressor. The error code must be manually reset on the controller to clear once the condition has been resolved or no longer exist.

Digital input shutdown errors Shutdown Text displayed code E_0010

“LOCAL EM`CY STOP”

Failure

Possible causes

Local emergency stop (S0)

Emergency stop engaged Check that neither personnel nor machinery locally can be harmed before disengage. Loose wires

E_0020

E_0030

E_0060

“EXT.EM`CY STOP”

“MOTOR OVERLOAD”

External or remote emergency stop

Compressor motor current high (F1)

Loose wires

Check and tighten all loose connections.

Thermal overload relay failure.

Check and replace if defective.

Cable failure

Check cable dimension and connections.

Contactor failure

Check and replace if defective.

Electric motor failure

Check and replace if defective.

Compressor failure

Check if it is possible to turn compressor manually by hand. Check thoroughly all mechanical moving parts for wear.

“DIG:INPUT 6”

Digital input 6 open Loose wires circuit Cooling water pump Multi function input overload or MCB (F10) switched off 1. CW pump overload 2. CW flow low Cooling water flow low 3. CW pressure low 4. Optional equipment Cooling water pressure low

“OIL_ LEVEL /TEMP” Oil level low (LS15) Oil level too low

E_0080

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Check pump and pump motor for failure and replace defect. Switch MCB on if off. Check cooling water flow and adjust flow to correct level. Check cooling water pressure and adjust pressure to correct level. Check optional equipment. Fill to 100% (check sight glass and X-control display). Check and tighten all loose connections.

Oil temperature too high

Check cooling system or ambient temperature

Loose wires

Check and tighten all loose connections.

Overload oil pump

Check oil pump

MCB Off

MCB switched off

Check MCB, switch on if switched off.

Digital input 8 PTC

Electric motor failure

Check motor temperature and replace motor if defective.

Thermistor failure

Measure the thermistors.

Connection failure

Check if motor is correctly connected with the right cable dimensions. Always connect according to the motor rating plate information.

“OIL_PUMP”

“MOTOR OVERHEAT”

Check and tighten all loose connections.

Loose wires Oil temp high (LS15) (Optional)

Check and tighten all loose connections.

Emergency stop engaged Check that neither personnel nor machinery remotely can be harmed before disengage.

Dig. Input 6 failure E_0070

Remedy

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Analogue input shutdown errors Shutdown Text displayed code E_0115

“DEL PRESS SENSOR”

Failure

Possible causes

Delivery pressure Transmitter failure transmitter failure (PT11)

Remedy Check delivery pressure transmitter and replace if defective.

Cables connection failure Fix or change cables / connections E_0119

E_0125

“DEL PRESS HIGH”

“HP PRESS SENSOR”

Delivery pressure high (PT11)

Transmitter out of range

Check values in diagnostic menu (see Xcontrol manual). Fine calibrate in calibration menu (see X-control manual). Replace transmitter if defective.

Outlet valve failure

Outlet valve failure

Non return valve failure

Check piping and valves

Wrong ISC damping setting

Check ISC damping setting.

Compressor HP pressure Transmitter failure sensor failure (PT12)

Check delivery pressure transmitter and replace if defective.

Cables connection failure Fix or change cables / connections E_0129

E_0135

“HP PRESS HIGH”

“LP PRESS SENSOR”

Compressor HP pressure X-control unit setting high (PT12)

Check alarm parameter settings in alarm menu (see X-control manual).

Transmitter out of range

Check values in diagnostic menu (see Xcontrol manual). Fine calibrate in calibration menu (see X-control manual). Replace transmitter if defective.

Air blockage

Check piping outlet, outlet valve and safety valve HP.

Non return valve failure

Check non return valve and replace if defective.

Compressor LP pressure Transmitter failure sensor failure (PT13)

Check delivery pressure transmitter and replace if defective.

Cables connection failure Fix or change cables / connections E_0139

“LP PRESS HIGH”

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Compressor LP pressure X-control unit setting high (PT13)

Check alarm parameter settings in alarm menu (see X-control manual).

Transmitter out of range

Check values in diagnostic menu (see Xcontrol manual). Fine calibrate in calibration menu (see X-control manual). Replace transmitter if defective.

Non return drain valve failure

Check non return drain valve and replace if defective.

Valve HP failure

Check gaskets and valve for internal leakage and replace if defective.

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Shutdown Text displayed code E_0149

“DEL TEMP HIGH”

Failure

Possible causes

Delivery temperature high X-control unit setting (TT14) Transmitter out of range

Remedy Check alarm parameter settings in alarm menu (see X-control manual). Check values in diagnostic menu (see Xcontrol manual). Fine calibrate in calibration menu (see X-control manual). Replace transmitter if defective.

Air coolers pressure drop Check all Air coolers (LP, Pre cooler HP and HP). Replace if defective. Cooling water temperature and flow.

Check cooling water temperature and ensure that cooling water flows.

Enclosure and fan

Check that enclosure and fan is correctly mounted and ensure that no air inlet or outlet is blocked.

Compressor running direction

Check and reconnect cables in el-motor connection box if wrong direction.

Valve failure

Check valve HP and LP for leakage / failure. Replace if defective.

Air cooler failure

E_0151

E_0505

E_0821

“OIL LEVEL LOW”

“SHORTCIRCUIT”

“SHORTCIRCUIT”

Compressor oil level low X-control unit setting (LT15)

Short circuit on XPC analogue input

Water cooled compressor. Check cooler for internal leakage. Replace cooler if defective. Check alarm parameter settings in alarm menu (see X-control manual).

Transmitter out of range

Check values in diagnostic menu (see Xcontrol manual). Fine calibrate in calibration menu (see X-control manual). Replace transmitter if defective.

Oil level too low

Fill to correct oil level (check sight glass and X-control display).

Transmitter failure

Check and replace transmitter(s) if defective.

Wiring failure

Check wiring and replace defective wire(s).

Input failure

Check values in diagnostic menu (see Xcontrol manual). Check analogue input and replace X-control unit if defective.

Short circuit on analogue Transmitter failure inputs

Check and replace transmitter(s) if defective.

Wiring failure

Check wiring and replace defective wire(s).

Input failure

Check values in diagnostic menu (see Xcontrol manual). Check analogue input and replace X-control unit if defective.

Control unit failure

Replace X-control unit if defective.

E_0836

“SYSTEM ERROR”

E_0837

“COMMUNICATION” XPC expansion card communication error

Communication failure

Check communication between main module and expansion module inside the X-control. Replace X-control if defective.

E_0866

“POWER SUPLLY LOW”

Power supply failure

Check power supply voltage.

www.sperre.com

PLL unlock trip

Power supply low

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7.6 Errors when no alerts are displayed Error symptom High oil consumption

Wrong Amp reading

High vibration levels

High noise level

Low HP pressure

Possible cause

Remedy

Oil type

Only use Sperre approved oil - change if wrong.

Piston ring wear

Check piston rings and change if defective.

Cylinder lining wear

Check cylinder lining for wear and change if defect.

Oil leakage

Check for oil leakage.

High oil level

Check oil level, drain to below 120 %

Wrong transmitter range

Check calibration menu (see X-control manual).

Electric motor failure

Measure electric motor and replace if defective.

Transmitter out of range

Check values in diagnostic menu (see X-control manual). Fine calibrate in calibration menu (see X-control manual). Replace transmitter if defective.

Weak deck structure

Check deck structure – strengthen if defective.

Weak base plate

Check base plate – strengthen if defective.

Faulty isolator

Check vibration isolators – change if defective.

Connection flexible tubes

Check tube lengths, bending and air pulsation

Loose enclosure

Fasten enclosure screws.

Loose motor cables

Check and fasten motor cables if loose connection.

Bearing failure

Check all electric motor and compressor bearings and replace if defective.

Air leakage

Check if drain valve(s) are open or closed. Check air receivers. Check compressors.

Compressor valve(s) or drain Check valve HP and LP for leakage / failure. Check drain valve. valve(s) failure Check gaskets and replace if defective.

Low LP pressure

Safety valve(s) failure

Check and replace if defective.

Air leakage

Check if drain valve(s) are open or closed. Check air coolers. Check compressors.

Compressor valve(s) or drain Check valve LP for leakage / failure. Check drain valve. Check valve(s) failure gaskets and replace if defective.

Compressor do not load

www.sperre.com

Safety valve(s) failure

Check and replace if defective.

Compressor running direction

Check and reconnect cables in electric motor connection box if wrong direction.

Defect drain/unload valve

Check if voltage is available X* sec after start Check if drain open time is set to X* sec (default) in menu P01 (*X depends of compressor type) If voltage is ok, check if coil is ok Check if valve is clean, if clogged with dirt it will not close Check if relay output 2 (R2) is closed.

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NOTE: