Operation Manual XW200 - Version02

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!
Mareno K. Nakken
Technical Director
www.sperre.com Operation Manual XW200 Version 02 3

Contents
1 Introduction ............................................................................................ 5
1.1 Purpose ........................................................................................................................ 5
1.2 Annotations .................................................................................................................. 5
1.3 Abbreviations ................................................................................................................ 5
1.4 Tags on the compressor ............................................................................................... 6
1.5 Warranty....................................................................................................................... 7
2 Personal safety....................................................................................... 8
3 System description ................................................................................ 9

3.1 X-range compressor ..................................................................................................... 9
3.2 X-control ..................................................................................................................... 11
4 Technical data ...................................................................................... 12
5 User Interface ....................................................................................... 13

5.1 Keypad ....................................................................................................................... 13
5.2 LED indicators ............................................................................................................ 14
5.3 Display ....................................................................................................................... 15
5.4 Symbols ..................................................................................................................... 17
5.5 Menu structure............................................................................................................ 19
6 Installation and Operation ................................................................... 23

6.1 Installation .................................................................................................................. 23
6.2 Before and after operation .......................................................................................... 24
6.3 General operation ....................................................................................................... 25
6.4 Internal system control (ISC) ....................................................................................... 29
6.5 Emergency operation .................................................................................................. 32
7 Troubleshooting ................................................................................... 33
7.1 Abbreviations .............................................................................................................. 33
7.2 Service warning (SW) and alarm (SA) ......................................................................... 33
7.3 Alarms (A) .................................................................................................................. 35
7.4 Start inhibits (S) .......................................................................................................... 37
7.5 Immediate stop shutdown errors (E) ............................................................................ 38
7.6 Errors when no alerts are displayed ............................................................................ 41

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.
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:
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)
CFD Computerized Fluid Dynamics
CR Class Recommendation
CW Cooling Water
dBA Decibel
DOL Direct On Load
HP High Pressure
LP Low Pressure
IMO International Maritime Organization
ISC Internal System Control
MR Makers Recommendation
PMS Planned Maintenance System
RPM Revolutions Per Minute
XA X-range compressor Air-cooled
XW X-range compressor Water-cooled

1.4 Tags on the compressor
Danger Danger Caution

The compressor is remotely controlled Hazardous voltage. Burn hazard
May start without warning Risk of electric shock Risk of hot surface
Before using or servicing the compressor The cover must always be on when To connect the signal cable, carefully
Read and understand the user manual running. turn the plug to find the right insert point,
Without the cover the compressor will be then push carefully until a click appear
damaged after running even for a short To disconnect, pull the ring on the plug
period
The oil has been drained from the Compressor oil type. Sight glass
compressor. For oil reference, visit www.sperre.com Correct oil level should be in centre of
Do not start the compressor before the sight glass
correct oil quantity has been added
Drain oil Delivery air outlet Unloading and drain high pressure
Unloading and drain low pressure Cooling water outlet Cooling water inlet
The lifting lug is certified for lifting the Rotation direction is counter clock wise,
single compressor with el-motor only when looking at 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.

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.

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. The main cooling for this compressor is done with cooling water.
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.

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.
On water-cooled compressors, the LP cyclone eliminates condensation before the air
goes further to the HP stage, and the X-design prevents cold surfaces in the crankcase.
The compressor has two automatic solenoid valves, one on the HP side and one on the
LP 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.

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.

4 Technical data
For further information and drawings regarding technical data, please refer to www.sperre.com.
Compressor XW200 – 30 barg

Charging capacity at 1775 / 1475 RPM 220 / 185 m3 /h
Power requirements 1775 / 1475 RPM 41 / 35 kW
Heat dissipation amb. 1775 / 1475 RPM 6 / 5 kW
Heat dissipation, wat. 1775 / 1475 RPM 32 / 27 kW
Cooling water req. 1775 / 1475 RPM 80 / 65 l/min
Weight complete (standard motor) 920 kg
Dimensions 1580 x 1260 x 1110 mm (L x W x H)
Oil volume 23 litres
Oil type Fully synthetic, ISO 100, piston comp.
Design
No. of cylinders / Cylinder arrangement 2 / 90°V
No. of compression stages 2
Cooling Fresh water
Valve LP / Valve HP 1 Plate valve / 1 Reed valve
Operation parameters
Max. delivery pressure 40 barg
Start – stop pressure 25 - 30 barg Alarm at 31 barg, shutdown at 32 barg
Max. amb. temp. compressor / controller 55°C / 55°C / 45°C (55°C on request) (controller needs fan above 50°C)
/ el. motor
Air outlet temperature Approx 25°C above ambient
Max. cooling water inlet temperature 40°C
Max. noise level 98 dBA (1800 rpm) Below the IMO norm of 110 dBA
Max. vibration level / Min. isolation grade 30 mm/s-RMS / 90 % Gen. rec. 30 mm/s -RMS / 70%
Safety valve LP / HP / CW 9 barg / 33 barg / 6 barg
Rotation Counter clockwise (compressor front)
Start Inhibits Temp > 85°C / LP > x barg / HP> x barg
Mechanical components
Non return valve air outlet Integrated
Oil & water separator LP / HP Integrated
Safety valve LP / HP / CW Integrated
Oil level sight glass Integrated
Air suction filter Integrated
Inter- and after-cooler Integrated
Three vibration isolators Integrated
One lifting lug Integrated
Flexible tube air outlet / drain - unload Loose / Loose
Flexible tube water inlet / outlet Loose / Loose
Electrical components
Starter with controller Loose
Transmitter LP Integrated Alarm at 7 barg, shutdown at 8 barg
Transmitter HP Integrated Alarm at 31 barg, shutdown at 32 barg
Trans. temp. outlet Integrated Alarm at 85°C, shutdown at 90°C
Transmitter oil level Integrated Alarm 0% /shutdown - 10% / switch -
20% / temp. switch 100°C
Valve drain - unload LP / HP Integrated / Integrated

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
a. Start – push to start the e. Plus / up – Push to scroll up through

compressor, or to set in a started menu, menu item options or
condition. increment value. Note
b. Stop – push to stop the f. Enter – push to confirm selection or Access codes are needed to enter the
compressor. value adjustment. different levels of menu level
c. Escape / cancel – push to step g. Menu – push to enter the menus. User level: Use access code 0000
back one menu navigation level. Service level: Use access code 0100
h. Reset – push to reset and clear fault
d. Minus / down – Push to scroll condition.
down through menu, menu item
options or decrement value.
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.

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
No start inhibit condition and auto restart Slow flash* OFF** OFF
function active
*SF = standby state, indicates that the compressor may start running at any time.
**SF = alarm condition

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. Symbols for pressure and
compressor status.
c. Activated functions are represented
symbolically. 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.

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 1 = inverted

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 above the
Pressure is below the Unload
load pressure set point
pressure set point value.
value.
Note
Pressure is between the Status symbols are continuously
unloaded and load pressure set displayed.
point values
Compressor status symbols
Stopped, not in an active stat. Running, not loaded. Note

Status symbols are continuously
Standby, not running but in an displayed.
Loaded.
active stat.
Menu mode navigation symbols

User level
Note
These symbols show the menu access
Service level level.
Menu mode navigation symbols

User settings Fault log Note
These symbols show the general menu
Service log Shutdown settings type.
Alarm settings Inhibit settings
Diagnostics Sensor calibration
User, “view only” Internal system control
Configuration settings Service reset
Function symbols
Indicates that all items in the
menu page are locked and Time
cannot be adjusted.
Unlocked symbol; item is

Oil level
editable.

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, Test safety valve mode
(flashing = data link fault)
Power failure automatic

Test drain valve mode
restart
Remote Pressure Control Semi automatic mode
Remote start/stop control Short circuit
Emergency stop activated Start inhibit
Heater “on” Time delay
Running Drain interval
Motor current start up

Air receiver
delay
Item “ID” Menu
Running hours Service hours
Language setting symbol

English Italian
German Dutch
French Turkish
Spanish

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 Description
C> Compressor status / RTC The user menu shows normal operational
P00: User view I> Information screen values and information. This is the default
N> Compressor name display menu, no access code is required.
P1 Delivery pressure Items are view only and cannot be
P2 Compressor HP pressure adjusted.
P3 Compressor LP pressure
T1 Delivery temperature
A6 Analogue input 6
L1 Compressor oil level **
A7 Compressor motor current
HR Total running hours
ST Start counter
HS Hours until service due ** Sensor for oil level L1 has 2
IS ISC sequence channels: 1 Digital + 1 Analog, only
SC ISC seq. change int. counter shown when oil level is enabled
Access code required:

Access code, user level The default code = 0000
M> Mode (Semi or Full) The user setting menu contains adjustable
P01: User settings MH Motor heating function parameters and options. Further
PU Unload pressure information regarding these settings is
PL Load pressure described on next page.
D1 Drain unload time start
D2 Drain unload time stop
DI Drain interval time
DO Drain time open
P> Pressure units Pressure units: Temperature units:
T> Temperature units Bar °C
L> Language selection PSI °F
SS Start source kPa
LS Load source MPa
Ct Compressor type kg/cm2
SN Serial number (controller)
01 Logged error #1 The fault log menu contains the last

P02: Fault log v 30 fault codes in chronological order.
30 Logged error #30
01 Logged service item #1 The service log menu contains a

P03: Service log v complete service overview.
65 Logged service item #65 The items are view only.
En Enable ISC
P80: ISC operational PU ISC unload pressure
PL ISC load pressure
SC Sequence interval

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
Note
on receiver or pressure line. Options are If ISC operation in menu P80 is
network or remote digital input. enabled, the network option is locked
and cannot be changed before ISC is
disabled.
Compressor type View of compressor type

Serial number View of controller serial number

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.
2. Use the + / - buttons to select a
number.
3. 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.
4. Press the + / - buttons to scroll through
the menu pages.
5. Press the enter button to enter the

desired menu page
Each menu page contains a number of items. The first item on the list will be highlighted,
as illustrated below.
6. Press the + / - buttons to scroll through
the items on the list. The list will wrap Note
around.
When the first list item is highlighted the
7. Press the enter button to confirm last list item can be seen at the top of
the selection or value. To abandon an the list; this immediately indicates the
adjustment at any time press the number of listed items.
escape button , the original value or
option will be maintained in memory,
and the screen will return to page item
list.
8. 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 Note
to indicate that all items on the menu page
are locked and cannot be adjusted, as Menu items can be locked for “view
illustrated. only” when the compressor is running.
The compressor must then be stopped
To immediately exit menu mode and return before adjustments can be performed.
to the normal operational display, press
and hold the reset button for several
seconds at any time.
Any value or option adjustment that has not been confirmed and entered into memory will
be abandoned and the original setting will be maintained.

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.

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 Note
installation instructions, illustrating the recommended assembly of equipment and pipe
connections. Please refer to the General
Arrangement and Installation drawings
To achieve problem-free operation, it is important that the base-plate is sufficiently rigid for specific details.
and free from vibrations caused by other machinery. The base of the compressor must lie
flat on the base-plate.
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).

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 Note
switched on for three seconds. The
display will then show the software version If the X-control is not centralized with
code for a further 3 seconds before the ships central alarm system, the
starting-up is completed and the normal controller needs daily inspection to
operating display will show. 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.

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. Warning
Before operating the equipment, please refer to Chapter 2 for the personal safety
instructions. 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.

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:
1. Press the start button to start the compressor Warning
If the pressure is below the load level the compressor is started and the pressure will In automatic mode, the compressor
begin to rise. When the unload pressure level is achieved, the compressor will stop and will automatically start.
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.
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.

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 Note
procedure:
Please note that a push button with
 Start source (SS) setting: 0 = keypad, 1 = network, 2 = remote digital input. return cannot be used for remote
operating. Only a switch or a push
This is the remote function replacing the start / stop buttons on the local control panel, for
button with locked positions can be
optional start operating. The signal, if closed, set the compressor in started condition and
used.
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).
 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 X-
control 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 , to
confirm the selection.
6. Use the + / - buttons to select the number 2. Press the enter button to confirm the
selection.
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.

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: Local mode: Remote mode:

Local Side Remote Side Local Side Remote Side
SEMI AUTO and FULL AUTO Start Stop Start Stop Start Stop Start Stop
O O X X X O O O

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 non-
preferred compressor(s).
Rotation:
Each time the set rotation interval elapses a sequence rotation occurs and the sequence
1 2 3 4 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

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 When ISC operation is enabled, the
access code “0000”, confirm each load source will automatically be set to
number by pressing the enter button (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 to
confirm the ISC setting.
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.

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 to enter user

setting menu page.
5. Use the + / - buttons to select the “LS”

item, load source. Press the enter Note
button to select. Please see X-control user manual for
6. Use the + / - buttons to select the further details regarding using the ISC
function.
default “1”. Press the enter button
to confirm the selection.
7. The first slave controller is now set.
Repeat the procedure for the next
slave controllers until all are set.

6.5 Emergency operation
The system can be overridden using an emergency run switch on the inside of the X-
starter. If normal control of the compressor fails, and power is available, the emergency Warning
switch will force the compressor to run.
For emergency operation of the compressor please follow the procedure below: 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 Warning
the compressor by using a
screwdriver. Never carry out the emergency
3. Turn the emergency switch [a] on the operation alone. Monitor the air-
inside of the X-starter to the receiver pressure and shut down the
emergency position. The compressor compressor immediately when
will now start. pressure level is reached.
No surveillance or alarms will function,
4. Manually close the drain valve [b] on except for local emergency stop and
the compressor by using a motor overload control, which will be in
screwdriver. an active state.
5. Observe and manually check that the
compressed air temperature is not
above normal.
6. The pressure increase should be Warning
monitored during all running period.
7. Before the compressor is stopped, Always make sure that there is water
carefully open the drain valve [b]. in the system. The outlet water
temperature must never exceed the
8. Stop the compressor by turning the inlet water temperature with more than
emergency switch [a] to the “normal” 20 degree Celsius based on max
position. cooling water inlet temperature 40
degree Celsius.
Without cooling water the compressor
can run for only few minutes and then
it has to be cooled down for 30
minutes each time a new running for a
few minutes is needed.

7 Troubleshooting
7.1 Abbreviations
Abbreviation Description Comments
CT1 Current transmitter
DV1 Drain valve HP
DV2 Drain valve LP Only for water-cooled XW200-500
F1 Thermal overload relay
F11 MCB - Motor circuit breaker Only for water-cooled with cw pump
F12 MCB - Motor circuit breaker Only for pressure lub. compressors
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
PTC Electric motor thermistor control
RTC Real time clock
S0 Local emergency stop button
TT14 Temperature transmitter HP outlet
XPC Expansion card
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 slow-
flash. 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 Note
service warnings will not occur again. This facility is intended to provide pre-warning
enabling service arrangements. The text line on the display will indicate
2. Order the Sperre service kit. Please refer to “Service procedures overview” in the the type of service.
Service manual, for the service kit ordering number. Service A will only appear once,
throughout the life time of the
A Sperre service kit (A, B, C, D or E) contains all necessary spare parts with the relevant compressor, and will only be indicated
step by step service procedures. with a service alarm.

Service alarm (service due now): Note
When the service interval time expires the controller will display the “service alarm” The
Service warnings / alarms will not
yellow service LED-indicator will appear as fast-flash.
interfere with compressor running. For
3. The service type displayed must be performed with the relevant Sperre service kit. safe running, all services should be
executed according to service
4. The Service alarm indication can be reset before the service is complete and the schedule.
“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.
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.
the Service manual
SW4844 “SERVICE D” Pre-alarm, service D due soon Press the “reset” button. Order service kit.
the Service manual
SW4854 “SERVICE E” Pre-alarm, service E due soon Press the “reset” button. Order service kit.
the Service manual
Service alarm
Service alarm code Text displayed Failure Corrective action

SA5814 “SERVICE A” Service hours countdown time Service A must be performed, refer to “Service
expired procedure overview” in the Service manual
SA5824 “SERVICE B” Service hours countdown time Service B must be performed, refer to “Service
SA5834 “SERVICE C” Service hours countdown time Service C must be performed, refer to “Service
SA5844 “SERVICE D” Service hours countdown time Service D must be performed, refer to
expired “Service procedure overview” in the Service
manual
SA5854 “SERVICE E” Service hours countdown time Service E must be performed, refer to “Service

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 Possible cause Remedy

A_2112 “DEL PRESS LOW” Delivery pressure X-control unit setting Check alarm parameter settings in alarm menu (see
low (PT11) X-control manual).
Transmitter out of Check values in diagnostic menu (see X-control

range manual). Fine calibrate in calibration menu (see X-
control 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 Check and replace if defective.
valve(s) or drain
valve(s) failure
Safety valve(s) Check and replace if defective.
failure
A_2118 “DEL PRESS HIGH” Delivery pressure Transmitter out of Check values in diagnostic menu (see X-control
high (PT11) range manual). Fine calibrate in calibration menu (see X-
Emergency run Switch to normal mode
mode
A_2148 “DEL TEMP HIGH” Delivery X-control unit setting Check alarm parameter settings in alarm menu (see
temperature high X-control manual).
(TT14)
Air coolers pressure Check all air coolers (LP, Pre-cooler HP and HP).
drop Replace if defective.
Cooling water Check cooling water temperature and ensure that
temperature and cooling water flows.
flow.
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 Check valve HP and LP for leakage / failure. Replace
if defective.
Air cooler failure Water-cooled compressor. Check cooler for internal
leakage. Replace cooler if defective.
A_2126 “LEAKAGE HIGH” HP pressure leak Air leakage Check piping, hoses, valves (valve HP / LP and drain
test failure valves) and coolers.

Alarm code Text displayed Failure Possible cause Remedy
A_2128 “HP PRESS HIGH” Compressor HP X-control unit Check alarm parameter settings in alarm menu (see
pressure high (PT12) setting X-control manual).
Air blockage Check piping and outlet valve
Non return valve Check non return valve and replace if defective.
failure
Emergency run Switch of emergency run mode if used and use full or
mode semi-automatic mode.
A_2138 “LP PRESS HIGH” Compressor LP X-control unit Check alarm parameter settings in alarm menu (see
pressure high (PT13) setting X-control manual).
Non return drain Check non return drain valve and replace if defective.
valve failure
Valve HP failure Check gaskets and valve for internal leakage and
replace if defective.
Emergency run Switch of emergency run mode if used and use full or
mode semi-automatic mode.
A_2145 “DEL TEMP Delivery temperature Transmitter failure Check temperature transmitter and replace if
SENSOR” sensor fault (TT14) defective.
Cables connection Fix or change cables / connections
failure
A_2152 “OIL LEVEL LOW” Compressor oil level X-control unit Check alarm parameter settings in alarm menu (see
low (LT15) setting X-control manual).
Oil level too low Fill to correct oil level (check sight glass and X-
Compressor oil control display).
(Optional) “OIL PRESSURE
LOW” pressure low (PT16) Oil pressure too low Check oil level / oil filter / oil pump
A_2155 “OIL LEVEL Compressor oil level Transmitter failure Check temperature transmitter and replace if
SENSOR” transmitter LT15 fault defective.
failure
Transmitter failure Check temperature transmitter and replace if
A_2165 "ANA6_SENSOR" defective.
Analogue input 6 fault
failure
A_2175 “CURRENT Compressor motor Transmitter failure Check temperature transmitter and replace if
SENSOR” current sensor (CT1) defective.
failure
Motor current start Increase time setting in config. menu 09, item 03 -
up delay too short CT
A_2816 “POWER FAILURE” Power failure 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.

A_2836 “RTC FAILURE” RTC failure Real time clock Contact Sperre.
failure.
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 Possible causes Remedy

code
S_3143 “DEL TEMP LOW” Delivery temperature X-control unit setting Check alarm parameter settings in start inhibit
low (TT14) menu (see X-control manual).
Ambient temperature Check ambient temperature.
too low
S_3127 “HP PRESS HIGH” Compressor HP Transmitter out of Check values in diagnostic menu (see X-control
pressure high (PT12) range manual). Fine calibrate in calibration menu (see X-
Internal pressure too Check drain valve(s) and replace if defective.
high
Air blockage Check drain piping.
S_3137 “LP PRESS HIGH” Compressor LP Transmitter out of Check values in diagnostic menu (see X-control
pressure high (PT13) range manual). Fine calibrate in calibration menu (see X-
Internal pressure too Check drain valve(s) and replace if defective. Only
high for water cooled XW200-500.
Air blockage Check drain piping.

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 Failure Possible causes Remedy

code
E_0010 “LOCAL EM`CY Local emergency Emergency stop engaged Check that neither personnel nor machinery
STOP” stop (S0) locally can be harmed before disengage.
Loose wires Check and tighten all loose connections.
E_0020 “EXT.EM`CY STOP” External or remote Emergency stop engaged Check that neither personnel nor machinery
emergency stop remotely can be harmed before disengage.
E_0030 “MOTOR Compressor motor Thermal overload relay Check and replace if defective.
OVERLOAD” current high (F1) failure.
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.
E_0060 “DIG:INPUT 6” Digital input 6 open Loose wires Check and tighten all loose connections.
circuit
Cooling water pump Check pump and pump motor for failure and
Multi function input overload or MCB (F10) replace defect. Switch MCB on if off.
1. CW pump overload switched off
2. CW flow low
3. CW pressure low Cooling water flow low Check cooling water flow and adjust flow to
4. Optional equipment correct level.
Cooling water pressure Check cooling water pressure and adjust
low pressure to correct level.
Dig. Input 6 failure Check optional equipment.
E_0070 “OIL_ LEVEL /TEMP” Oil level low (LS15) Oil level too low Fill to 100% (check sight glass and X-control
display).
Oil temp high Oil temperature too high Check cooling system or ambient temperature
(LS15)
(Optional) “OIL_PUMP” Overload oil pump Check oil pump
MCB Off MCB switched off Check MCB, switch on if switched off.
E_0080 “MOTOR Digital input 8 PTC Electric motor failure Check motor temperature and replace motor if
OVERHEAT” 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.

Analogue input shutdown errors

code
E_0115 “DEL PRESS Delivery pressure Transmitter failure Check delivery pressure transmitter and
SENSOR” transmitter failure (PT11) replace if defective.
Cables connection failure Fix or change cables / connections
E_0119 “DEL PRESS HIGH” Delivery pressure high Transmitter out of range Check values in diagnostic menu (see X-
(PT11) control manual). Fine calibrate in
calibration menu (see X-control manual).
Replace transmitter if defective.
Outlet valve failure Check piping and valves
Non return valve failure Check piping and valves
Wrong ISC damping Check ISC damping setting.
setting
E_0125 “HP PRESS Compressor HP pressure Transmitter failure Check delivery pressure transmitter and
SENSOR” sensor failure (PT12) replace if defective.

E_0129 “HP PRESS HIGH” Compressor HP pressure X-control unit setting Check alarm parameter settings in alarm
high (PT12) menu (see X-control manual).
Transmitter out of range Check values in diagnostic menu (see X-
control manual). Fine calibrate in
Air blockage Check piping outlet, outlet valve and
safety valve HP.
Non return valve failure Check non return valve and replace if
defective.
E_0135 “LP PRESS Compressor LP pressure Transmitter failure Check delivery pressure transmitter and
SENSOR” sensor failure (PT13) replace if defective.
E_0139 “LP PRESS HIGH” Compressor LP pressure X-control unit setting Check alarm parameter settings in alarm
high (PT13) menu (see X-control manual).
Non return drain valve Check non return drain valve and replace
failure if defective.
Valve HP failure Check gaskets and valve for internal
leakage and replace if defective.

code
E_0149 “DEL TEMP HIGH” Delivery temperature high X-control unit setting Check alarm parameter settings in alarm
(TT14) menu (see X-control manual).
Air coolers pressure drop Check all Air coolers (LP, Pre cooler HP
and HP). Replace if defective.
Cooling water Check cooling water temperature and
temperature and flow. 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
direction connection box if wrong direction.
Valve failure Check valve HP and LP for leakage /
failure. Replace if defective.
Air cooler failure Water cooled compressor. Check cooler
for internal leakage. Replace cooler if
defective.
E_0151 “OIL LEVEL LOW” Compressor oil level low X-control unit setting Check alarm parameter settings in alarm
(LT15) menu (see X-control manual).
Oil level too low Fill to correct oil level (check sight glass
and X-control display).
Poorly oil quality Check oil quality/viscosity
E_0505 “SHORTCIRCUIT” Short circuit on XPC Transmitter failure Check and replace transmitter(s) if
analogue input defective.
Wiring failure Check wiring and replace defective
wire(s).
Input failure Check values in diagnostic menu (see X-
control manual). Check analogue input
and replace X-control unit if defective.
E_0821 “SHORTCIRCUIT” Short circuit on analogue Transmitter failure Check and replace transmitter(s) if
inputs defective.
Wiring failure Check wiring and replace defective
wire(s).
Input failure Check values in diagnostic menu (see X-
control manual). Check analogue input
and replace X-control unit if defective.
E_0836 “SYSTEM ERROR” PLL unlock trip Control unit failure Replace X-control unit if defective.
E_0837 “COMMUNICATION” XPC expansion card Communication failure Check communication between main
communication error module and expansion module inside the
X-control. Replace X-control if defective.
E_0866 “POWER SUPLLY Power supply low Power supply failure Check power supply voltage.
LOW”

7.6 Errors when no alerts are displayed
Error symptom Possible cause Remedy
High oil consumption 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 Amp reading 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.
High vibration levels 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
High noise level 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.
Low HP pressure 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.
Safety valve(s) failure Check and replace if defective.
Low LP pressure 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.
Safety valve(s) failure Check and replace if defective.
Compressor running Check and reconnect cables in electric motor connection box if
direction wrong direction.
Compressor do not load 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.

NOTE:

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Congratulations on your X-range compressor!

Patented X-drive Patented cooling Registered design

This excellent compressor gives you several benefits:

 Safety first – a fully enclosed structure  Easy plug-in for sensors

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3 System description ................................................................................ 9

4 Technical data ...................................................................................... 12

5 User Interface ....................................................................................... 13

6 Installation and Operation ................................................................... 23

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

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Danger Danger Caution

Compressor rating plate

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The X-range compressor is a two stage, two cylinder compressor.

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Splash lubrication system

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Compressor XW200 – 30 barg

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a. Start – push to start the e. Plus / up – Push to scroll up through

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a. Green LED indicator – continuously

**SF = alarm condition

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a. Delivery pressure value. e. Units.

The pages on user level which require an access code are:

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Control pressure status symbols

Compressor status symbols

Stopped, not in an active stat. Running, not loaded. Note

Menu mode navigation symbols

Menu mode navigation symbols

Alarm settings Inhibit settings

Diagnostics Sensor calibration

User, “view only” Internal system control

Configuration settings Service reset

Unlocked symbol; item is

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Real time clock Alarm, warning

Pressure Drain output is energized

Start counter Full automatic mode

RS485 network pressure

Power failure automatic

Remote Pressure Control Semi automatic mode

Remote start/stop control Short circuit

Emergency stop activated Start inhibit

Heater “on” Time delay

Running Drain interval

Motor current start up

Item “ID” Menu

Running hours Service hours

Language setting symbol

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Level Menu page Description

Access code required:

01 Logged error #1 The fault log menu contains the last