User Manual Sperre Controller

36
User Manual
Sperre controller
GB www.sperre.com
User manual Z-controller
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Contents
1 Introduction ............................................................................................ 4
1.1 Purpose ............................................................................................................................. 4
1.2 Annotations ....................................................................................................................... 4
1.3 Abbreviations ..................................................................................................................... 4
1.4 Warranty ............................................................................................................................ 5
2 Personal safety ....................................................................................... 6
3 System description ................................................................................ 7

3.1 Starter cabinet ................................................................................................................... 7
4 User Interface ......................................................................................... 8

4.1 User interface – main screen ............................................................................................ 8
4.2 Information ........................................................................................................................ 9
5 Menu ...................................................................................................... 10
5.1 Menu structure ................................................................................................................ 10
5.2 Setup menu ..................................................................................................................... 14
6 General Operation ................................................................................ 17

6.1 Normal operation ............................................................................................................. 17
6.2 Optional functions............................................................................................................ 18
6.3 Remote operation ............................................................................................................ 20
6.4 Emergency operation ...................................................................................................... 21
7 Service and ordering............................................................................ 22

7.1 Service Schedule ............................................................................................................ 22
7.2 Service Warnings ............................................................................................................ 23
7.3 Service Alarms ................................................................................................................ 24
7.4 Service Alarm Tags ......................................................................................................... 26
8 Appendix ............................................................................................... 27
8.1 Abbreviations ................................................................................................................... 27
8.2 Alarm list (30 Bar)............................................................................................................ 28
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www.sperre.com Operation Manual Z-controller 3

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 Note
operation, as well as basic information regarding inspection and maintenance.
Please note that all pictures and
It is important that operators familiarize themselves with the contents of this instruction drawings in this manual are for
manual, to ensure that use and maintenance work are carried out in the correct and illustration only.
safe manner from the outset.
The maintenance intervals and individual technical data are average values based on
experience, and may vary depending on the compressor’s operational parameters. Note
The manufacturer accepts no responsibility for damage resulting from careless Original instructions in English.
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:
Indicates possibilities for hazards or unsafe practices, which COULD result in fatal or
Warning 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

Note obvious, or highlights important remarks in the procedures to follow.
1.3 Abbreviations
Abbreviation Description
Barg Unit of pressure (Barg = Bar gauge)
CW Cooling Water
DOL Direct On Load
HP High Pressure
LP Low Pressure
C Classic range compressor
XA X-range compressor Air-cooled
XW X-range compressor Water-cooled

1.4 Warranty
Sperre compressors 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.
Sperre starting air compressors are designed to fulfil requirements from

classification companies and are not supposed to operate continuously.
Sperre type approval and classification certificates are only valid when
genuine Sperre parts are used for maintenance.
Genuine Sperre parts are certified with certificate of conformity and authenticity as shown below.

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 equipment 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.

3 System description
3.1 Starter cabinet
The Z-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 control system 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.

4 User Interface
This chapter describes the user interface and the basics of the control system.
4.1 User interface – main screen

*Note
Depending on configuration, this view
will include only functions that are
enabled for the current project.
Note
If the compressor control system is not
centralized with the ships central alarm
system, the controller needs daily
inspection to observe fault, warning or
alarm conditions.
Letter Description Letter Description
a Start – push to start the f* Lead / Follow

compressor, or to set in a
started condition
b Stop – push to stop the g* Local / Remote
compressor.
c Reset h* Sea / Harbour
d Menu i* Heater on / off
e Auto / Manual
Start [a] and Stop [b] have one defined function and are not used for any other purpose.
Reset [c] will acknowledge and reset any active alarm or shutdown statuses.
Reset [d] will enter the menu screen.
Reset [e-f] will activate / deactivate the function indicated.

Indicators
Steady Compressor motor running

Flashing Compressor in stand-by
Steady One or more alarms active

Flashing New alarm condition not acknowledged
Steady One or more shutdowns active

Flashing New shutdown-condition not acknowledged
Steady Space heater on
4.2 Information
The normal operational display is described and illustrated below.
a. Delivery pressure.
b. Delivery air temperature.
c. Additional information depending on compressor type.
d. Running hours.
e. Time to next service.
f. Compressor status and state-diagram reference.
g. Alarm tag of the last alarm or shutdown.
h. Current load and unload pressure settings.
i. Time since last service.

5 Menu
5.1 Menu structure
The menu is availiable from the main screen by pressing the ‘MENU’ button.
Menu
|
Setpoints --> Load and Unload pressures
Alarms --> Active and logged alarms
Service log --> Service Log
User Setting --> Language

Pressure unit
Temperature unit
Screen timeout
IO config code
Software Version
Controller serial number
Compressor type
IP adress
Setup menu --> Refer to chapter 5.2

Setpoints
Depending on the configuration as many as eight pressures-values can be set.
Load Lead: Start pressure when the compressor is set as lead compressor.
Load Follow: Start pressure when the compressor is set as lead compressor.
Unload Lead: Stop pressure when the compressor is set as lead compressor.
Unload Follow: Stop pressure when the compressor is set as follow compressor.
If sea/harbour mode is activated; two set of pressures can be set.
Sea / harbour mode allow for a lower load/unload setting to be used during periodes when less air is required (eg.
transit).
Note
In a two compressor set-up using lead/follow functions, both compressor pressure settings should be set identical.

Alarms
Active alarms tab
The Active alarm tab show all alarm, shutdown and inhibit conditions that has not been cleared.
Refer to Chapter 8.2 for a complete list of alarm and shutdown conditions.
Alarm log tab
The latest 30 alarms are shown in the alarmlog.
Red Shutdown condition

Yellow Alarm and inhibit conditions
Green Time of reset of alarm and shutdown conditions

Service log
Refer to chapter ‘Service and ordering’ for information regarding service procedures.
User Setting
On this page the user can adjust the following parameters:
Parameter Possible values Default

Langauge En En
Pressure Unit Bar, PSI,kPA, Mpa, kg/cm2 Bar
Temperature unit C/F C
Screen timeout 1-360 min 5
The following read only information is also available on this page:

- IO configuration code
- Software version
- Controller serial number
- Compressor type
- IP address
Have this information available when contacting Sperre.

5.2 Setup menu
Menu
Setup menu
Note
(Service Level)
Access codes are needed to enter the
| different levels of menu level
Service Settings --> Drain Start Time Service level: Use access code 0100
Drain Stop Time
Note
Drain Interval Time The setup-menu button is deactivated when
Drain Time Open the compressor is running
Auto Restart Time
Lead / Follow Switchover Time
Confirm Service Done

Adjust System Clock
Restore Factory Default
Alarm Limits --> HP Pressure High

Inhibit HP Pressure High
Delivery Air Temp High
Inhibit Delivery Air Temp LOW
Custom Alarm / Shutdown
HIGH
Custom Alarm / Shutdown
LOW
LP Pressure HIGH
Inhibit LP Pressure HIGH
Delivery Pressure HIGH
Delivery Pressure LOW
Oil Level LOW
Oil Pressure LOW
Diagnostic --> Diagnostic screen

Service Settings
The following parameters can be adjusted:
Parameter Possible values Default

Drain Start Time 2 -20 sec. 10
Drain Stop Time 2 - 20 sec. 10
Drain Interval Time 10 - 50 min. 30
Drain Time Open 1 - 2 sec. 2
Auto Restart TimeΎ 0 - 120 sec. 60
Lead/follow Switchover time 1 - 4320 min. 720
* If Auto Restart Time is set to 0, the function is deactivated.

Alarm Limits
All alarm limits are pre-set from our factory, contact Sperre before making changes.
Diagnostic
The diagnostic screen gives information about the status and values of the digital and analogue IO.

6 General Operation
6.1 Normal operation
The compressor can be set to two different normal operating modes:
 Manual mode
Warning
 Automatic mode
In the manual mode of operation, the operator can start the compressor and the
compressor will only run once and stop when the pressure reach unload pressure.
When the stop button is pressed, the
In auto mode, the delivery pressure controls the start and stop of the compressor once compressor will not stop immediately.
the operator has pressed start. It will run unloaded before stopping.
Operation mode is selected by sliding the selector switch In case of malfunction the
located at the main screen to the preferred mode. ‘Emergency stop’ button must be
used to stop the compressor.
Manual mode
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, the compressor will start if the
reciever pressure is below the unload/stop pressure.
When the unload pressure level is achieved the compressor will stop. The compressor
will only start again if the operator presses the start button again.
Stop:
2. Press the stop button. The operator can stop the compressor at any time.
Auto mode
Start:
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.
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.
Stop:
2. Press the stop button to exit auto operation, and stop the compressor.

6.2 Optional functions
Lead / Follow
Lead / Follow and Load Sharing functionality levels out the running hours on the
compressors and can be configured as explained below. Note
Compressor 1 decides which is lead and follow. Optional functionality only available if
specified by the customer when
Lead and follow pressure settings should be equal for both compressors, as seen in ordering.
figure below. Pressure settings are found under menu->set-points.
If this function is desired later on,
please contact Sperre Aftersales
Department for purchasing upgrade kit.
In this example the lead compressor
will start at 26 Bar and stop at 30
Bar. Follow compressor will start at
25 Bar and stop at 30 Bar.
Normally the unload pressure is set
to the same pressure.
Compressor 1 Compressor 2
Compressor 1 decides if compressor 2 should use its lead or follow pressures, by giving
a signal from one of the relay outputs to one of the digital inputs on compressor 2.
The connection between compressor 1 and compressor 2 is fail-safe. If connection
between compressors is lost, compressor 2 becomes ‘lead’ as default.
Load Sharing
When the lead/follow function is activated a timer switches between lead and follow
pressures for the compressors. Note
The timer can be adjusted in the controller configuration (menu->setup menu). Access code 0100 is required to enter
the setup menu.
The timer counts time and is by default set to 12 hours (720 min).

Sea / Harbour mode
Sea / harbour mode allow for a lower load/unload setting to be used during periodes when less air is required (eg. transit).
If Sea / harbor mode Is enabled, a additional set of load / unload pressures appear in the Setpoint screen.
A example of how a 30Bar system could be set up is shown below.
Note
Optional functionality only available if
ordering.
If this function is desired later on,
Selection of Sea / Harbour mode is availiable on the main screen.

Remote operation is also possible, refer to chapter 6.3.
.

6.3 Remote operation
Remote operation by IAS or Switches
The compressors can be operated from a remote location by connecting a switch (not
push buttons) or a relay output from IAS to one of the digital inputs DI3 - DI8. Note
‘Local / Remote’ selection does only
affect the ‘Start / Stop’ function.
Remote Start / Stop:
If any of the other functions are set to
As long as the input is closed the compressor will enter standby or running mode remote operation, they remain remote
depending on the current reciver pressure, and then be controlled depending on the controlled even when the controller is
mode selected (Automatic or Manual). set to local.
When the input is opened the compressor will be set to stopped mode.
The following selections are normally done locally on the display, but can also be
connected to a digital input. *
 Load / Unload
*Note
 Lead / Follow
Optional functionality. All inputs for
 Sea / Harbour Mode remote operation are only available if
 Automatic / Manual
ordering.
 Local / Remote If this function is desired later on,
When any of these functions are coupled to a digital input, the selector-switch on the
main screen will be dimmed and become inoperatable. It will still indicate the current
state of the input.

6.4 Emergency operation
The system can be overridden using an emergency run switch on the inside of the starter Warning
cabinet. 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:
The compressor must not be left
1. Manually check the oil level, and unattended while running in
visually observe that there are no emergency mode!
abnormalities with the compressor.
2. Turn the emergency switch [a] on the
inside of the starter cabinet to the
‘Unloaded' position. The compressor Warning
will now start.
3. After a few seconds; turn the
emergency switch [a] to the ‘Loaded' Never carry out the emergency
position. The drain valve will close operation alone. Monitor the air-
and the compressor will start to build receiver pressure and shut down the
pressure. compressor immediately when
4. Observe and manually check that the pressure level is reached.
compressed air temperature is not No surveillance or alarms will function,
above normal. except for local emergency stop and
motor overload control, which will be in
5. The pressure increase should be an active state.
monitored during all running period.
6. Stop the compressor by reversing the
above procedure; leaving the switch
in the unloaded position for a few Warning
seconds before stopping the
compressor by turning the switch to
the 'normal' position.
For water cooled compressors:
Do not run the compressor without
cooling water, this will cause damage
to the air coolers.
Ensure there is water circulation in the
system before starting the compressor.

7 Service and ordering
7.1 Service Schedule
The following schedule is a guideline for normal service procedures. However, the
compressors operating conditions vary widely from installation to installation, based on Warning
climatic differences. It is very important to adapt the maintenance schedule to the
running conditions of the individual compressor.
The controller will automatically inform the operator when to run scheduled services
according to the manufacturers recommended service cycle and intervals. Before any work is performed the
electrical power must be turned off.
There are four main service routine types; each requires the use of the appropriate Please refer to chapter 2 for safety
service kit. instructions.
Indicated service interval in hours or years depending on which comes first.
Note
Sperre takes no responsibility for
damage caused by use of non-original
parts.
Service procedure A is change of filters and running in oil, and should always be
performed 250 running hours after first time start up. Note
Service procedures should be performed according to the intervals mentioned in the *Use access code 0100 to enter the
compressor manual depending og the compressor type.. Service procedures A2 (X- menus.
range only), B, C, D and E are to be performed in the order illustrated above.
When a service is complete the service technician must confirm service done for that
service type. The controller will automatically increment to the next service type using
the recommended service interval for the compressor type.
Note
Service Warning Please make sure that a complete
gasket kit always is available.
A service warning will occur 200 running hours or 30 days prior to a service, providing a
pre-warning enabling service arrangements, and/or service kit parts, to be organised
prior to the service becoming due. To see the service warning, press “Menu” -> “Alarms”.
Service Alarm
A ‘Service Alarm’ indication will occur when the ‘service interval’ run hours counter
reaches 0(zero) hours, or the service interval ‘time’ expires (whichever occurs sooner).
The Service Alarm will be displayed on the start screen and in the active alarms list
(Menu->Alarms).
The ‘Service Due’ indication on the start screen will be calculated from ‘next service
hours value’ minus ‘current running hours’.

7.2 Service Warnings
When a service warning appears in the Active Alarms list
When a service warning occurs the controller will display the “Service Due in 200
Running Hours or 30 days” in the active alarm list (Menu->Alarms). The service counter
on the start screen always shows when the next service is due and which service kit is
needed for the service.
1. Reset the service warning by pressing the “Reset” button in the “Active” alarms
list. The service warnings will not occur again. This facility is intended to provide Note
pre-warning enabling service arrangements.
2. Order the Sperre service kit. Please refer to “Service procedures overview” in the The text line on the start screen will
compressor service manual for the service kit ordering number. indicate the type of service.
Service A will only appear once,
A Sperre service kit contains all necessary spare parts. throughout the life time of the
When a ‘service warning’ is generated no further service warnings for the service type compressor, and will only be indicated
will be generated. A service warning will only be generated once prior to a service with a service alarm.
becoming due and a service alarm being generated.
Service ‘A’:
Service type ‘A’ does not have a ‘Warning’ indication. The controller will show an ‘Alarm’ when the running hours counter reaches 250
hours.
Service type ‘A’ is a unique service type. When a service type ‘A’ has been carried out once no future service type ‘A’ alarms will be
generated. A Service type ‘A’ normally occurs only once in the operational life of the compressor.

7.3 Service Alarms
When a service alarm appears on the display (SA)
When a service alarm occurs the controller will display the “Service Due: [servicename]
0 h” message on the start screen. In the active alarms list there will be displayed a
“Service Due Now” message.
Note
Please make sure that a complete
gasket kit always is available.
1. The service type displayed must be performed with the relevant Sperre service
kit. Please refer to “Service procedures overview” in the compressor service
manual for service kit information.
2. The Service alarm indication can be reset before the service is completed. In this
case the service alarm indication will re-occur again after 24 hours. This goes
on until the “Confirm Service Done” reset procedure has been carried out.

Service alarm reset
Service alarm reset procedure: Note

Using the menu navigation press “Menu” -> “Setup menu” -> Enter code 0100 –> Access code 0100 is required to enter
“Confirm Service Done” and then confirm with pressing “OK”. the setup menu.
When confirming with “OK” the controller will start the reset procedure which applies to
all service types. When the “Confirm service done” has been executed, the service
alarm is reset and the controller will automatically increment to the next service type in
the service cycle.
If the “Confirm Service Done” button is colored light gray there is no service alarm
reset procedure necessary or even available.
Service Alarm Overlap:

If a ‘Service Alarm’ indication is still active for more than 200 running hours or 30 days, the service will be logged not
done and the service incremented to the next service.

Service log
Using the menu navigation press “Menu”-> “Service Log” on the startscreen to enter the
service log. In the service log all completed and non-completed services will be stored
with a date, run hours and number of motor starts.
In the service log is also an overview over total running hours, running hours to next
service, time since last service, time to next service and total motor starts.
7.4 Service Alarm Tags

Service alarm tags
Service alarm tag Text displayed Failure Corrective action

AS1-[service type] “Service [service Service hours countdown has 200 Press the “reset button”. Order service
type] due in 200 RH running hours or 30 days left to next kit. Please refer to “Service procedures
or 30 days” service. overview” in the Service manual.
AS2-[service type] “Service [service Service hours countdown time expired. The service type displayed on the start
type] is due now!” screen/alarm must be performed.
Please refer to “Service procedure
overview” in the Service manual.

8 Appendix
8.1 Abbreviations
Abbreviation Description Comments
DV1 Drain valve HP
DV2 Drain valve LP Only for water-cooled XW200-500
F1 Thermal overload relay
PT11 Receiver pressure transmitter
PT12 Compressor HP Pressure transmitter
PT13 Compressor LP Pressure transmitter
PT14 Compressor oil pressure transmitter Only for pressure lub. compressors
LT15 Compressor oil level transmitter LT15 and LS15 are located in same unit
LS15 Compressor oil level switch For splash lubricated
S0 Local emergency stop button
TT14 Temperature transmitter HP outlet
RH Running hours

ALARM LIST
Factory default
Start Inhibit Tag Signal type Signal Range Classic XAW 60-90 XAW 120-300 XW350-400 Unit
Delivery temperature low IA3 4-20mA -20 120 Disabled [Celsius]
HP Pressure High IA1 4-20mA 0 45 2 2 2 [Bar]
LP Pressure High IA2 4-20mA 0 8 1 1 1 [Bar]
Alarm:
Delivery Pressure low level AA7 4-20mA 0 45 Disabled [Bar]
HP Pressure Alarm AA1 4-20mA 0 45 31 31 31 [Bar]
LP Pressure Alarm AA2 4-20mA 0 8 6.5 6.5 6.5 [Bar]
Delivery Pressure Alarm AA3 4-20mA 0 45 33 33 33 33 [Bar]
Oil Pressure AA5 4-20mA 0 10 0.3 2 [Bar]
High Temperature AA6 4-20mA -20 120 85 85 85 85 [Celsius]
Long Run Alarm AL1 0 1440 Disabled [min]
Shutdown:
HP Pressure Shutdown SA1 4-20mA 0 45 32 32 32 [Bar]
LP Pressure Shutdown SA2 4-20mA 0 8 7.5 7.5 7.5 [Bar]
Delivery Pressure Shutdown SA3 4-20mA 0 45 34 34 34 34 [Bar]
Oil Pressure SA5 4-20mA 0 10 0.2 1.5 [Bar]
Air Temperature SA6 4-20mA -20 120 90 90 90 90 [Celsius]
Oil Level Switch SD2 Digital NC   n/a
Emergency stop SD1 Digital NC     n/a
Motor Overload SD3 Digital NO     n/a
Low Feed Pressure SD5 Digital NO Used only for Booster compressors
Sensor Faults SA2x Controller Refer to controller manual chapter 8.3
Service pre-warning:
Service Warning AS1-x Controller Refer to controller manual chapter 7
Service Alarms AS2-x Controller Refer to controller manual chapter 7
8.3 Troubleshooting
Start Inhibit codes

Tag Text displayed Failure Possible causes Remedy
Check values in diagnostic menu. Replace transmitter if
Transmitter out of range
Delivery temperature low defective.
IA3 Delivery temp low start inhibit
(TT14)
Ambient temperature too low Check ambient temperature.
defective.
Compressor HP pressure
IA1 HP Pressure high start inhibit Internal pressure too high Check drain valve(s) and replace if defective.
high (PT12)
Air blockage Check drain piping.
defective.
Compressor LP pressure Check drain valve(s) and replace if defective. Only for
IA2 LP Pressure high start inhibit Internal pressure too high
high (PT13) water cooled XW200-500.
Air blockage Check drain piping.
Alarms
Analogue input alarm errors
Tag Text displayed Failure Possible cause Remedy
Parameter setting in controller Check alarm parameter settings in alarm menu.

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

Delivery pressure low
AA7 Delivery Pressure low alarm Air leakage
(PT11)
Check air receivers.
Check compressors.
Compressor valve(s) or drain valve(s)

Check and replace if defective.
failure
Safety valve(s) failure Check and replace if defective.

Delivery pressure high defective.
AA3 Delivery pressure high alarm
(PT11)
Emergency run mode Switch to normal mode

defective.
Check all air coolers (LP, Pre-cooler HP and HP).

Air coolers pressure drop
Replace if defective.
Check cooling water temperature and ensure that cooling

Cooling water temperature and flow.
water flows.
Delivery temperature high
AA6 Delivery air temp high alarm
(TT14)
Check that enclosure and fan is correctly mounted and
Enclosure and fan
ensure that no air inlet or outlet is blocked.
Check and reconnect cables in el-motor connection box if

Compressor running direction
wrong direction.
Check valve HP and LP for leakage / failure. Replace if

Valve failure
defective.
Water-cooled compressor. Check cooler for internal

Air cooler failure
leakage. Replace cooler if defective.
Page 1/4

defective.
AA1 HP Pressure high alarm
high (PT12) Air blockage Check piping and outlet valve
Non return valve failure Check non return valve and replace if defective.
Switch of emergency run mode if used and use auto or

Emergency run mode
semi-automatic mode.

defective.
Compressor LP pressure
AA2 LP Pressure high alarm Non return drain valve failure Check non return drain valve and replace if defective.
high (PT13)
Check gaskets and valve for internal leakage and

Valve HP failure
replace if defective.
Switch of emergency run mode if used and use full or

Emergency run mode
semi-automatic mode.
Compressor oil level low

AA4 Oil level low alarm Check values in diagnostic menu. Replace transmitter if
(LT15) Transmitter out of range
defective.
Fill to correct oil level (check sight glass and X-control

Oil level too low
display).
Compressor oil pressure

AA5 Oil pressure low alarm Oil pressure too low Check oil level / oil filter / oil pump
low
Shutdowns
Digital input shutdown errors
Emergency stop engaged locally or Check that no personnel nor machinery can be harmed
remotly and disengage.
Local or remote Emergency
SD1 Emergency stop shutdown
stop
Loose wires Check and tighten all loose connections.

Oil level too low
display).
SD2 Oil level shutdown
Loose wires Check and tighten all loose connections.
Thermal overload relay failure Check and replace if defective.
Cooling water pump MCB failure Check and replace if defective.
Oil pump MCB failure Check and replace if defective.

Compressor motor current
high
SD3 Motor fault shutdown Cooling water pump motor
Cable failure Check cable dimension and connections.
high current
Oil pump motor high current
Contactor failure Check and replace if defective.
Electric motor failure Check and replace if defective.
Check if it is possible to turn compressor manually by

Compressor failure hand. Check thoroughly all mechanical moving parts for
wear.
Page 2/4
Analogue input shutdown errors

defective.
Outlet valve failure Check piping and valves

Delivery pressure high Delivery pressure high
SA3
shutdown (PT11)
Non return valve failure Check piping and valves
Wrong ISC damping setting Check ISC damping setting.

defective.
SA1 HP pressure high shutdown
high (PT12)
Air blockage Check piping outlet, outlet valve and safety valve HP.
Non return valve failure Check non return valve and replace if defective.

defective.
Compressor LP pressure
SA2 LP pressure high shutdown
high (PT13)
Non return drain valve failure Check non return drain valve and replace if defective.
Check gaskets and valve for internal leakage and

Valve HP failure
replace if defective.

defective.
Check all Air coolers (LP, Pre cooler HP and HP).

Air coolers pressure drop
Replace if defective.
Check cooling water temperature and ensure that cooling

Cooling water temperature and flow.
water flows.
Delivery air temp high Delivery temperature high
SA6
shutdown (TT14)
Check that enclosure and fan is correctly mounted and
Enclosure and fan
ensure that no air inlet or outlet is blocked.
Check and reconnect cables in el-motor connection box if

Compressor running direction
wrong direction.
Check valve HP and LP for leakage / failure. Replace if

Valve failure
defective.
Water cooled compressor. Check cooler for internal

Air cooler failure
leakage. Replace cooler if defective.

defective.
Compressor oil level low
SA4 Oil level low shutdown
(LT15)
Oil level too low
display).
Poor oil quality Check oil quality/viscosity
Compressor oil pressure

SA5 Oil pressure low shutdown Oil pressure too low Check oil level / oil filter / oil pump
low
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Transmitter failure PT11 Check transmitter and replace if defective.
Delivery pressure sensor Delivery pressure
SA20
error shutdown, AI1 transmitter failure
Cables connection failure Fix or change cables / connectionsFKHFNSRODULW\
Transmitter failure LT15 or PT16 Check transmitter and replace if defective.

Oil pressure/level sensor
SA21 Oil transmitter failure
error shutdown, AI2
Cables connection failure Fix or change cables / connections
Transmitter failure TT14 Check transmitter and replace if defective.

Temperatur sensor error Delivery air temperature
SA22
shutdown, AI3 transmitter failure
Cables connection failure Fix or change cables / connectionsFKHFNSRODULW\

HP pressure sensor error HP pressure transmitter
SA23
shutdown, AI4 failure

LP pressure sensor error LP pressure transmitter
SA24
shutdown, AI4 failure
Transmitter failure Check transmitter and replace if defective.

Custom alarm sensor
SA25 Sensor error shutdown AI6
failure
Page 4/4

User Manual Sperre Controller

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User Manual Sperre Controller

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36

2 Personal safety ....................................................................................... 6

3 System description ................................................................................ 7

4 User Interface ......................................................................................... 8

6 General Operation ................................................................................ 17

7 Service and ordering............................................................................ 22

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Draws attention to specific information of technical significance that might not be

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Sperre starting air compressors are designed to fulfil requirements from

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4.1 User interface – main screen

Letter Description Letter Description

a Start – push to start the f* Lead / Follow

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Steady Compressor motor running

Steady One or more alarms active

Steady One or more shutdowns active

Steady Space heater on

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Alarms --> Active and logged alarms

Service log --> Service Log

User Setting --> Language

Setup menu --> Refer to chapter 5.2

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Depending on the configuration as many as eight pressures-values can be set.

If sea/harbour mode is activated; two set of pressures can be set.

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Active alarms tab

Alarm log tab

The latest 30 alarms are shown in the alarmlog.

Red Shutdown condition

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On this page the user can adjust the following parameters:

Parameter Possible values Default

The following read only information is also available on this page:

Have this information available when contacting Sperre.

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Confirm Service Done

Alarm Limits --> HP Pressure High

Diagnostic --> Diagnostic screen

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The following parameters can be adjusted:

Parameter Possible values Default

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Selection of Sea / Harbour mode is availiable on the main screen.

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When a service warning appears in the Active Alarms list

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When a service alarm appears on the display (SA)

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Service alarm reset procedure: Note

Service Alarm Overlap:

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7.4 Service Alarm Tags