Ingersoll-Rand Intellisys SSR 10-40 Serviceman's Manual
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Ingersoll-Rand Intellisys SSR 10-40 Serviceman's Manual

Ingersoll-Rand Intellisys SSR 10-40 Serviceman's Manual

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Intellisys
Serviceman's Guide
SSR® 10 - 40 Horsepower Models
SSR
50 - 450 Horsepower Models

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Summary of Contents for Ingersoll-Rand Intellisys SSR 10-40

  • Page 1 Intellisys Serviceman's Guide SSR® 10 - 40 Horsepower Models 50 - 450 Horsepower Models...

  • Page 2: Table Of Contents

    INDEX PAGE INTRODUCTION ..................1 COMPONENTS....................1 SENSORS ....................4 OPERATION....................4 INDICATOR LIGHTS ..................6 MESSAGES....................6 MESSAGE -01- STARTER FAILURE ............6 MESSAGE -02- MOTOR OVERLOAD ............7 MESSAGE -03- HIGH DISCHARGE AIR TEMPERATURE ......7 MESSAGE -04- HIGH DISCHARGE AIR PRESSURE ........8 MESSAGE -05- TEMPERATURE SENSOR FAILURE ........9 MESSAGE -06- PRESSURE SENSOR FAILURE ........
  • Page 3 PAGE STARTER FAULT - ALARM ............... 49 ALARM ....................... 50 PROCEDURE FOR SETTING THE PROPER BLOWDOWN SEQUENCE .................... 53 INTELLISYS 50-200 HORSEPOWER ............54 PROGRAM CONTROLLER TO READ INLET FILTER CONDITION ..55 PROCEDURE FOR CHANGING THE INTELLISYS CONTROLLER ..56 PROCEDURE FOR CHANGING STARTER INTERFACE BOARD ...

  • Page 4: Introduction

    Injection molding was selected as the manufacturing process due to its high precision. The CPU Assembly is an Ingersoll-Rand design. This board is not intended for general service and never requires field trou- bleshooting.
  • Page 5 The prom contains permanent memory which supplies the Intellisys controller with some additional information required for the respective option and triggers a code in the microprocessor. The communications port is for communication with other Ingersoll-Rand Products.

  • Page 7: Sensors

    SENSORS There are 2 sensors utilized on the SSR 10-40 HP range. One is a pressure sensor. The other is a temperature sensor. The temperature sensor is a thermistor located in the discharge air circuit. It comes complete with a 6 foot lead that directly connects it to the Starter Interface Board.
  • Page 8 To run the compressor in modulate mode merely press the load switch again. This will put the compressor in modulate/ACS and it will operate automatically from this point. Each time the load button is depressed the compressor will switch to another mode of operation.

  • Page 9: Indicator Lights

    If the Intellisys is allowed to remain in the SET POINT mode with no change for more than fifteen seconds the system will return to READY mode as announced by the 0 in the display. The set button also serves the functions of clearing an alarm. Pressing the set button twice will clear the alarm.

  • Page 10: Message -02- Motor Overload

    If this is functioning properly, then check the functioning of the main starter coils. This can be done by disconnecting the wires to the coil and applying 115 volts to the coil from a near by wall outlet. Before proceeding be sure to remove the 115 volts applied to the starter coil for safety.

  • Page 11: Message -04- High Discharge Air Pressure

    The range adjustment is between 200°F and 228°F. At 97% of the shutdown value the red alarm light will start flashing. This is a warning indication of rising temperature. A compressor that is experiencing a higher air temperature condition may have the following symptoms.

  • Page 12: Message -05- Temperature Sensor Failure

    Press display select to obtain a discharge air pressure reading in the display window. This is the shutdown pressure. The controller can be set for 100-125-150 or 175 psig. The controller will shut down if the discharge pressure exceeds 15 psig over any of the preset discharge pressures programmed into the controller by the factory.

  • Page 13: Message -06- Pressure Sensor Failure

    it is completely out of range it shuts the unit down on temperature failure. While investigating, remember to open the electrical disconnect and lock and tag. The next step is to press the display-select button twice and check the value of the shutdown temperature.

  • Page 14: Message -07- Emergency Stop

    In this case, check the male-female connection on the end of the sensor. Also disassemble the male cable and insure that all wires are intact as was done for fault number -04-. Check for continuity on each wire of the cable after disconnecting it from the interface board.

  • Page 15: Message -09- Microprocessor Failure

    MESSAGE -09- MICROPROCESSOR FAILURE The CPU Printed Circuit Board Assembly contains a circuit called the watchdog. The way the watchdog functions is that on each cycle of the program, it signals the watchdog that it is functioning OK. The watchdog starts a timer. If before the timer times out, the program has not come back and signaled the watchdog, the watchdog shuts the unit down as a microprocessor failure.

  • Page 16: Message -12- Incorrect Compressor Rotation

    MESSAGE -12- INCORRECT COMPRESSOR ROTATION Generally this fault will only occur during initial start up where the operator has connected the cables wrong so that the compressor is being driven backwards. Check the main incoming and power leads to insure that they are correct. In earlier versions the controller will try to read a positive 10 psig sump pressure in the first 3 seconds of operation.
  • Page 17 If you experience intermittent shut downs on the Intellisys equipped units, indicated by the appearance of all 8888’s or-01-in the display window, check the female connector on the gray ribbon. We have learned that this connector may not be making a good contact with the male pins on the interface boards.
  • Page 18 7. Slide the socket connector back 6. Bend an arc back into the socket into the plastic housing. You can connector to insure good contact hear the latch click when it is all the with the mating pin. way in. 8.

  • Page 19: Intellisys Hour Timer

    To check for a grounded cable condition, remove the ground wire on Terminal 27. Before performing this function, disconnect all electrical power, lock and tag. Run the compressor and if it continues to run, then this is an indication that the transducer cable is defective and should be repaired or replaced.

  • Page 20: Option Installation Remote Stop/Start

    operate as long as the plant line-pressure remains above the on line set point of the Intellisys controller. If the timer continues to operate for as long as its adjusted time setting, a relay contact in the Intellisys opens to de-energize the compressor motor starter coil. At the same time, an amber light on the Intellisys panel is lit to indicate the compressor has shut down automatically and will restart automatically.
  • Page 21 For safety, a selection is available in the Intellisys setpoints to disable the remote stop and start switches. This allows the compressor to be fully controlled by the Intellisys controller and not from the remote stop/start station. If the remote start switch is momentarily closed, the Intellisys controller starts the compressor.
  • Page 22 -19-...

  • Page 23: Intellisys Controller Inactivated

    WIRING SCHEMATIC Refer to Page 30 for Schematic INTELLYSIS CONTROLLER INACTIVATED The photo on page 21 illustrates a condition that can render the Intellysis controller inoperative; display error codes 01 through 06 or 8’s appearing on the display. SYMPTOMS: 1. The Intellysis controller does not power up, even though power is present at the primary and secondary contacts of the transformer and interface board or intermittent contact will give various error codes.

  • Page 24: Auto Control Selector

    TO CORRECT THE PROBLEM: 1. Loosen nut A. Pull slightly on cable B. See photo C below. If you have a unit that is showing symptons as described, contact the customer service department in Davidson. It may be necessary to repair or replace the exisiting cable.

  • Page 25: Ssr 10-40 Horsepower Intellisys Code 12 Shutdowns

    The operation of ACS is as follows: Original Controller. While running in the ON/ OFF LINE MODE , and the machine cycles three times in three minutes, the controller will automatically shift to modulation. While running in the modulate mode and the machine runs unloaded for three minutes the controller will shift back to ON/OFF LINE.

  • Page 26: Ssr 10-40 Horsepower Transducer Calibration

    NOTE: IT IS VERY IMPORTANT TO HAVE THE AIR PRESSURE REMOVED FROM THE TRANSDUCER PRIOR TO CALIBRATION. INTELLISYS INTERFACE BOARD (SSR 10-40 Horsepower) Some of the Rev. 3.0 Interface Boards give symptoms of intermittent contact and open circuits. This can result in various error codes displayed on the Intellisys. We have learned that the Rev.
  • Page 27 -24-...

  • Page 28: Interface Board Test For Pressure Sensor Failure

    INTERFACE BOARD TEST FOR PRESSURE SENSOR FAILURE Shut downs may occur that display an error code of -06- and -12-. After checking the pressure transducer calibration, and its cable for shorts, the following procedure will tell you if the circuit through the interface board is defective. 1.

  • Page 29: Ssr 10-40 Horsepower Nuisance -01- Shutdown Problem

    Conditions that may contribute to low voltage would be undersize wiring, incorrect or undersize step down transformer or undersize buck boost transformers. SSR 10-40 HORSEPOWER NUISANCE -01- SHUTDOWN PROBLEM Presently, the starter auxiliary contact is used by the controller to determine starter operation.

  • Page 30: Loose Cable In Temperature Sensor

    LOOSE CABLE IN TEMPERATURE SENSOR Please be advised that we have determined a potential field failure may exist in the temperature sensor. Units affected are: SSR 10 - 40 Horsepower SSR 50 - 200 Horsepower Visual inspection of the thermistor (sensor) cable will reveal that the shielded cable is loose within the body of the thermistor caused by the potting material (epoxy) that does not bond to the cable.

  • Page 31: Emergency Stop Button

    The revised sequence is as follows: Close the main disconnect. The display window will show 0. Power and unload indicator lights will be on. Push “Unloaded Stop” for lamp check. All lights will be on and “8888” will be displayed in the window until the “Unloaded Stop” button is released. After the lamp test has been completed, the unit will display 0.
  • Page 32 -29-...
  • Page 33 -30-...

  • Page 34: Field Installation Of Sequencer Interface I Ssr

    FIELD INSTALLATION OF SEQUENCER INTERFACE I SSR® 10-40 HORSEPOWER UNITS WITH INTELLISYS (FOR CONNECTION OF COMPRESSORS WITH INTELLISYS TO STANDARD INGERSOLL-RAND SEQUENCER) THE PURPOSE OF THESE INSTRUCTIONS IS TO IDENTIFY THE COR- RECT PARTS REQUIRED WHEN INSTALLING A STANDARD INGERSOLL- RAND SEQUENCER AND WIRING IT TO AN INTELLISYS COMPRESSOR.
  • Page 35 5. Connect the modular cable (P/N39547880) between the communication port jack on the Squencer Interface I and the communication port jack on the compressor starter interface board (see figure 2). Route cable and secure away from primary voltage wiring/components. 6. Connect 115 V. A. C. wiring between the Sequencer Interface I and the starter interface board as shown in the wiring diagram (figure 2).
  • Page 36 FIGURE 1 INTERFACE MOUNTING LOCATION FIGURE 2 - WIRING DIAGRAM -33-...

  • Page 37: Sequence Controller Instructions

    SEQUENCE CONTROLLER INSTRUCTIONS FOR MODELS: SSR 10-450 HORSEPOWER TWO, THREE, FOUR OR FIVE UNIT COMPRESSOR INSTALLATIONS When two or more compressors, each designed for automatic start-up control, operate together one should always be the “lead” unit. If this “lead” compressor can maintain the required plant air pressure, all other compressors should be set to shut down.
  • Page 38 NOTE: REFER TO OPERATORS MAN- UAL OR APPLICABLE WIRING SCHE- MATIC FOR COMPLETE COMPRESSOR ELECTRICAL SYSTEM NOTE: THE JUMPER WIRE BETWEEN THREE UNIT CONTROLLER SHOWN ITB-7 AND ITB-10 (ON COMPRESSOR CONTROL PANEL) MUST BE REMOVED THREE SETS OF CORRESPONDING WHEN SEQUENCE CONTROLLER IS IN- CONTACTS IN ROWS A, B, AND C HAVE BEEN INTERCONNECTED IN STALLED...
  • Page 39 For proper operation when using the Sequencer Interface I with an Intellisys Unit, the following hardware is required. PART NUMBER DESCRIPTION 39786470 (1) Intellisys Controller (Rev. 8.9 or current software) 39179585 (2) EPROM, Programmed (Software Rev. 8.9 Onward) 39666672 Automatic Start/Stop Option Field Kit (Units Not Already Equipped With Auto Start/Stop) NOTES:...

  • Page 40: Testing Software With A Sequencer

    IF COMPRESSOR THEN A. Has Auto Start/Stop Prom No Changes Required B. Does Not Have Auto Start/ Install Auto Start/Stop Stop Prom Field Kit 39666672 TOOLS REQUIRED: ONLY WHAT WOULD BE FOUND IN ANY REASONABLY EQUIPPED SERVICEMAN’S TOOL BOX. PARTS LIST (KIT P/N 39674387) ITEM PART NUMBER DESCRIPTION...

  • Page 41: Temperature/Resistance Chart

    TEMPERATURE/RESISTANCE CHART DEGREE DEGREE DEGREE F. TEMP. RES. F. TEMP. RES. F. TEMP. RES. 19171 5241 89768 18658 5123 86914 18161 5007 84161 17679 4894 81503 17211 4784 78938 16757 4677 76463 16317 4573 74072 15889 4472 71765 15475 4372 69536 15072 4276...

  • Page 42: E-Proms And Kit Numbers

    DEGREE DEGREE DEGREE F. TEMP. RES. F. TEMP. RES. F. TEMP. RES. 1744 1033 636.9 1710 1014 626.5 1677 996.4 616.2 1645 978.8 606.1 1614 961.5 596.3 1583 944.6 586.6 1553 928.1 577.1 1523 911.9 567.8 1495 896.0 558.6 1466 880.5 549.7 1439...

  • Page 43: Remote Alarm Contacts

    ALARM CONTACT POSITIONS SSR 10 THROUGH 40 HORSEPOWER BEFORE E-PROM REVISION LEVEL 9.0 NO POWER POWER POWER WITH ALARM • • • N.O.14 • • • COM. 13 • • • N.C. 12 REVISION LEVEL 9.0 AND HIGHER NO POWER POWER POWER WITH ALARM •...

  • Page 44: Horsepower Intellisys Index

    INGERSOLL-RAND 50-450 HORSEPOWER INTELLISYS SERVICEMAN’S GUIDE INDEX Page 50-450 HORSEPOWER INTELLISYS INDEX ..........41 COMPRESSOR ALARMS ................42 SSR 50 HORSEPOWER AND HIGHER INTELLISYS COMPONENTS ..44 SHUTDOWNS ON HIGH INLET VACUUM ..........45 CHECK INLET CONTROL - ALARM ............46 LOW UNLOADED SUMP PRESSURE - ALARM ........

  • Page 45: Compressor Alarms

    COMPRESSOR ALARMS When an alarm occurs, the display will alternately show the following messages: the actual alarm message, PRESS TEST-FOR VALUES, and PRESS RESET 2X-CLEAR. If multiple alarms have occurred the display will show SCROLL FOR ALARMS instead of the alarm messages. In this situation the up and down arrows will be used to view the alarm messages.
  • Page 46 STEPPER LIMIT SWITCH This alarm will occur if the open and close limit switches of the stepper limit switch board are made at the same time. STARTER DOOR OPEN This alarm will occur if the start door is opened. REMOTE STOP FAILURE If the REMOTE START/STOP option is enabled and the remote stop button is not wired in, this alarm will occur.

  • Page 47: Ssr 50 Horsepower And Higher Intellisys Components

    CHG COOLANT FILTER This warning will occur if the oil filter delta p switch closes, 2CTT is greater than 120 degrees, and the unit is loading. CHANGE SEPR ELEMENT This warning will occur if [(3APT - (4APT + CONSTANT)) >= 12], the unit is loading, 2CTT is greater than 120 degrees, and 4APT is greater than 90 psig.

  • Page 48: Shutdowns On High Inlet Vacuum

    mentioned connection boards connect to the Intellisys controller through a ribbon cable. Other starter interface connections: Terminal 24 volt supply 3-36 15 volt supply BTS1 31-32 Manual Hats 29-30 Jumper (OPT phase monitor) 33-34 Emergency Stop Button 14-15 1M Interlock 12-13 1S and 2M Interlock BTS2...

  • Page 49: "Check Inlet Control" - Alarm

    to remain closed. Sticking or binding inlet valve Starter Interface Board drive chips and circuit Stepper motor and cable Slipping or broken coupling On machines with Intellisys software of 1.5 and higher, the high inlet vacuum shutdown has been eliminated and the above situations would give a low sump pressure shutdown.

  • Page 50: Low Unloaded Sump Pressure - Alarm

    If the unit was modulating and the lower limit switch gave a false indication of being closed, possibly due to a faulty connection. False reading on the inlet vacuum transducer due to mis-calibration or disconnected tubing. *Most likely causes of alarm Use the following procedure to investigate and correct if the alarm occurs.
  • Page 51 NOTE: This signal (alarm) is ignored after the start button is engaged. (The period the signal is ignored is actually 10 seconds after Star-Delta transition to “run”, or 10 seconds after full voltage starter contactor engagement. After these 10 seconds pass, the alarm becomes active.) The alarm shutdown point is 15 PSI.

  • Page 52: Starter Fault - Alarm

    STARTER FAULT - ALARM Reasons for the Alarm: Star Delta Starters Incorrect Starter Function. a. Loose wiring. b. Bad starter coil. c. Foreign material. d. Damaged or welded contacts. e. No output 110 Voltage to starter coils from BTS - 1 terminals 27-28 M1 coil.

  • Page 53: Alarm

    c. Jumper 29 and 30 on BTS - 1. Check wiring at terminals 29 and 30 BTS - 1. Between terminal 29 and ground should have 110 Volts. Check BTS - 1 Terminals 23 - 28 Trace wiring to main coils. If partial transition, troubleshoot auxiliary contacts.
  • Page 54 WARNING! Several of the following checks must be made with the starter door open which exposes HIGH and DANGEROUS VOLTAGE conditions. Use great care during the checking procedures to prevent serious injuries or death. Power OFF Checks Remove the inlet air filter and the mounting bracket. Manually move the inlet air valve with your fingers.
  • Page 55 Check the OHM value of the Stepper Motor windings by removing the four motor wires from BTS-3 terminals 6, 7, 8 and 9 of the Starter Interface Board. There are two sets of Stepper Motor windings. Wires 6 and 7 are a pair and 5-6 OHMs should be measured between these two wires on 50-200 horsepower units.

  • Page 56: Procedure For Setting The Proper Blowdown Sequence

    Check for 5 Volts DC between terminals 2 and 5 on BTS-3 terminal strip of the Starter Interface Board. If voltage is not available at this point, a faulty Starter Interface Board is indicated and must be replaced. Check for 5 Volts DC between terminals 2 and 3 on BTS-3 terminal strip of the Starter Interface Board when the inlet valve is closed.

  • Page 57: Intellisys 50-200 Horsepower

    Also, a small white light over the “Set” button and a red “Test” light will appear. e. Press the “Down” arrow of the “Display Select” and the Mod/ACS button at the same time once. f. You should see the words “Scroll for Sensor” and 2 red arrows appear.

  • Page 58: Program Controller To Read Inlet Filter Condition

    Press “Set” once...then you should see the words "Ready-To-Start” change to “Press Set Chg Values” and/or “Press Test - Light Ck”. These two sets of words will flash back and forth about every 3 seconds. Also, a small white light over the “Set” button and a red “Test” light will appear.

  • Page 59: Procedure For Changing The Intellisys Controller

    PROCEDURE FOR CHANGING THE INTELLISYS CONTROLLER SSR 50-450 Horsepower Remove the power from the machine. Remove the back cover from the defective controller. (Be careful not to break the ground strip that is connected to the back cover.) Disconnect the two ribbon cables inside the controller. Remove the controller mounting screws and remove the controller out the front of the starter door.

  • Page 60: Ssr 50-450 Change Rated Pressure

    SSR 50-450 CHANGE RATED PRESSURE (Setting the Controller Pressure Range) “Ready to start” in display window. Press Set. Press Unload and ON/OFF Line buttons twice at the same time. The controller pressure will display in the window, plus a red up and down arrow will appear under the set button.
  • Page 61 INSTRUCTIONS: Remove inlet air filter assembly located on top of the inlet valve. Remove and discard blowdown tube between separator tank and fitting “A". Sever any tie wraps that may be attached to tube. Remove and discard the four metric socket head bolts that mount inlet valve.

  • Page 62: Temperature/Resistance Chart

    TEMPERATURE/RESISTANCE CHART °F °F °F TEMP. RES. TEMP. RES. TEMP. RES. 19171 5241 89768 18658 5123 86914 18161 5007 84161 17679 4894 81503 17211 4784 78938 16757 4677 76463 16317 4573 74072 15889 4472 71765 15475 4372 69536 15072 4276 67384 14681 4182...
  • Page 63 °F °F TEMP. RES. TEMP. RES. TEMP. RES. 1744 1033 636.9 1710 1014 626.5 1677 996.4 616.2 1645 978.8 606.1 1614 961.5 596.3 1583 944.6 586.6 1553 928.1 577.1 1523 911.9 567.8 1495 896.0 558.6 1466 880.5 549.7 1439 865.2 540.9 1412 850.3...

  • Page 64: Vacuum Conversions

    VACUUM CONVERSIONS PSIA INCHES INCHES VACUUM MERCURY MERCURY WATER 14.7 0.00 0.00 0.00 14.6 0.20 5.17 2.77 14.5 0.41 10.34 5.55 14.4 0.61 15.51 8.32 14.3 0.81 20.69 11.09 14.2 1.02 25.86 13.86 14.1 1.22 31.03 16.64 1.43 36.20 19.41 13.9 1.63 41.37...
  • Page 65 PSIA INCHES INCHES VACUUM MERCURY MERCURY WATER 10.18 258.57 138.65 10.38 263.74 141.42 10.59 268.91 144.20 10.79 274.09 146.97 10.99 279.26 149.74 11.20 284.43 152.51 11.40 289.60 155.29 11.61 294.77 158.06 11.81 299.94 160.83 12.01 305.11 163.61 12.22 310.29 166.38 12.42 315.46 169.15...
  • Page 66 PSIA INCHES INCHES VACUUM MERCURY MERCURY WATER 10.2 20.77 527.49 282.85 10.3 20.97 532.66 285.62 10.4 21.17 537.83 288.39 10.5 21.38 543.00 291.16 10.6 21.58 548.17 293.94 10.7 21.79 553.34 296.71 10.8 21.99 558.52 299.48 10.9 22.19 563.69 302.26 22.40 568.86 305.03 11.1...

  • Page 67: Intellisys Units With An E-Prom Labeled "Show

    50-200 HORSEPOWER ROTARY INTELLISYS EQUIPPED INTELLISYS UNITS WITH AN E-PROM LABELED “SHOW” The purpose of the “Show” software is to demonstrate the display functions of the Intellisys controller. Attached are the instructions which outline the procedure for using the “show” prom.
  • Page 68 5. Using your fingers (do not use tools) and/or the prom ejector, carefully pull out the production prom. Be careful not to bend the contacts. This prom will be reinstalled after the show. 6. Carefully install the “Show Prom” in socket location U2. 7.

  • Page 69: Field Installation Of Sequencer Interface I

    FIELD INSTALLATION OF SEQUENCER INTERFACE I SSR 50-450 HORSEPOWER UNITS WITH INTELLISYS (FOR CONNECTION OF COMPRESSORS WITH INTELLISYS TO STANDARD INGERSOLL-RAND SEQUENCER). THE PURPOSE OF THESE INSTRUCTIONS IS TO IDENTIFY THE COR- RECT PARTS REQUIRED WHEN INSTALLING A STANDARD INGERSOLL- RAND SEQUENCER AND WIRING IT TO AN INTELLISYS COMPRESSOR.
  • Page 70 IF CONTROLLER HAS THEN A. Software Revisions 1.11, Install new E-PROM 39179593 1.20, 1.3 or 1.4 Revision 1.5 onward In Existing Controller B. Software Rev. 1.5 No Changes Required Onward IF COMPRESSOR THEN A. Has Auto Start/Stop No Changes Required Prom B.
  • Page 71 5. The 115 V.A.C. wiring and the 5 wires connecting the Sequencer Interface I to the sequencer should be separated from existing ribbon cables and 5 V.D.C. wiring, as much as possible. INTELLISYS CONTROLLER E-PROM VERIFICATION/REPLACEMENT 1. Remove the aluminum back cover from the Intellisys Controller. (See Figure 2).
  • Page 72 FIGURE 1 INTERFACE MOUNTING LOCATION FIGURE 2 INTELLISYS CONTROLLER -69-...
  • Page 73 FIGURE 3 WIRING DIAGRAM -70-...
  • Page 74 -71-...
  • Page 75 -72-...
  • Page 76 -72-...

  • Page 77: E-Proms And Kit Numbers

    E-PROMS AND KIT NUMBERS 50-450 Horsepower Current main program E-prom 39179593 Auto Start and Stop Prom only 39479399 Remote Start and Stop Prom only 39479423 % Modulation Prom only 39479407 Sequence Control Prom only 39479415 Sequencer Interface I 39805312 Show Prom 39183702 APDD404-90 Instruction Installation APDD405-90 Instruction Sequencer Controller...
  • Page 78 terminal 21, the Black wire connected to terminal 22 and the Ground wire connected to terminal 23. All three sensors connect to their respective areas of the Analog Board in a similar manner. The 5 volt DC source for the sensors is supplied by a small but extremely accurate voltage regulator mounted on the upper left side of the Analog Board.
  • Page 79 4ATT - Package Discharge Temperature Sensor Monitors the temperature of the compressed air downstream of the unit's aftercooler prior to the air exiting the package. Typically, this sensor is located in the top of the combination moisture separator/trap assembly. This sensor (4ATT) also sends a variable DC voltage signal to the Intellisys to provide temperature information for "Package Discharge Temperature"...
  • Page 80 The first response to any "Alarm" shutdown should be to push "Test" which automatically activates the Up/Down Display Select arrows of the panel, turns on the small green indicator light next to the fourteen (14) possible displays on the right side of the panel and causes the "Reset" light to disappear. Use the "Down"...
  • Page 81 Carefully record the thermometer and ohmmeter readings and compare them with the charts (pages 81, 82) in the following sequence. First...locate the temperature on the chart that corresponds with the temperature measured with the test thermometer in the heated liquid. Second...observe the resistance value shown on the chart next to the correct temperature.
  • Page 82 -78-...
  • Page 83 The compressor will shut down and the display will indicate the specific sensor in an alternating message with whatever message was on the display at the moment the Alarm condition began. These messages will continue to alternate until the problem is corrected and "Reset" is pushed. If an open circuit condition is experienced on the Package Discharge Tempera- ture Sensor (4ATT), the compressor will not shut down but "Warn"...
  • Page 84 After correcting the ground condition, press "Reset" to clear the panel. D) Black Short Circuited to White causes the particular temperature sensor to display "246 DEG" on the Intellisys panel if that display has been selected. This problem will cause an Alarm shutdown on the Airend Discharge Tempera- ture sensor 2ATT only.

  • Page 85: Temperature/Resistance Chart

    TEMPERATURE/RESISTANCE CHART DEGREE DEGREE DEGREE F. TEMP. RES. F. TEMP. RES. F. TEMP. RES. 19171 5241 89768 18658 5123 86914 18161 5007 84161 17679 4894 81503 17211 4784 78938 16757 4677 76463 16317 4573 74072 15889 4472 71765 15475 4372 69536 15072 4276...
  • Page 86 DEGREE DEGREE DEGREE F. TEMP. RES. F. TEMP. RES. F. TEMP. RES. 1744 1033 636.9 1710 1014 626.5 1677 996.4 616.2 1645 978.8 606.1 1614 961.5 596.3 1583 944.6 586.6 1553 928.1 577.1 1523 911.9 567.8 1495 896.0 558.6 1466 880.5 549.7 1439...

  • Page 87: Interface Ground

    50-450 HORSEPOWER ROTARY INTERFACE GROUND Electro-Magnetic Interference generated by radio frequencies, DC generators, arc welding, etc. has the potential to cause intermittent shutdowns on SSR 50 through 450 horsepower Intellisys units. This interference usually shows up as random pressure reading fluctuations, erroneous pressure sensor indication, erratic LED displays or unit shutdown with "Ready to Start"...
  • Page 88 ALARM CONTACT POSITIONS SSR 10 THROUGH 40 HORSEPOWER BEFORE E-PROM REVISION LEVEL 9.0 NO POWER POWER POWER WITH ALARM • • • N.O.14 • • • COM. 13 • • • N.C. 12 REVISION LEVEL 9.0 AND HIGHER NO POWER POWER POWER WITH ALARM •...

  • Page 89: Power Test Interface Board

    POWER TEST INTERFACE BOARD (50-450 ROTARY) Measure voltages on interface boards at locations shown to determine normal operation. STEPPER MOTOR DRIVER CHIPS 50-450 Horsepower The Electronics group has identified some susceptible driver chip components. Most of the units were either replaced or retested by the vendor. There is a chance that some units with this date code will exhibit problems.

  • Page 90: Replacement Of Stepper Assembly Components

    REPLACEMENT OF STEPPER ASSEMBLY COMPONENTS Replacing the stepper couplings: Begin by removing the air filter element(s). Remove the stepper motor assembly from the inlet valve body. The stepper limit switch and male half of the coupling will come off along with the stepper motor, and motor mounting plate.
  • Page 91 Replacing the stepper motor or limit board: When replacing the stepper motor or limit switch board, remove the stepper motor assembly from the valve body. Remove the male coupling from the stepper motor shaft. Disconnect the leads going to the board or motor. Replace the old component for the new one on the stepper mounting plate.

  • Page 92: Check Motor Rotation Shutdown

    Reassembly: Prior to reassembly, inspect the limit switch board for any signs of physical damage, contact at the limit switches or "burned" looking areas. Replace with a new limit board if any physical damage is seen. Always replace both halves of the coupling if either side shows appreciable wear.

  • Page 93: Voltage Change For Amber "Power On" Lights

    Make sure that a vacuum is felt at the transducer end of the flex tube during a start attempt. If vacuum is present, this assures the airend is turning in the correct direction. Check for 5VDC on the transducer cable red and black wires at the analog board.

  • Page 94: Control Voltage Transformer Connections (All Units)

    Whenever installing replacement bulbs on any unit, confirm the light voltage supply matches the voltage rating of the bulb being installed. This CFSM sheet is issued for information purposes only and field conversions are not warrantable. CONTROL VOLTAGE TRANSFORMER CONNECTIONS (ALL UNITS) When changing a unit from a lower operating voltage to a higher operating voltage (Example: 230V to 460V) the control voltage transformer must be...

  • Page 95: Shutdowns Related To Inlet Valve Failure

    SHUTDOWNS RELATED TO INLET VALVE FAILURE Follow this procedure if a 50 to 450 HP Intellisys machine shutsdown because the inlet valve failed to open after Star Delta transition. Program the controller to look at inlet filter condition (i.e., psi vacuum) during operation.

  • Page 96: Ssr 50-450 Hp Starter Interface Board Voltage Chart

    SSR 50-450 HP STARTER INTERFACE BOARD VOLTAGE CHART SSR Voltage Chart Starter Interface Printed Circuit Board BTS-1 TERMINAL #'S VOLTAGE CONDITION 24 VAC POWER ON 0 VAC POWER OFF 36,3 115 VAC POWER ON 36,3 0 VAC POWER OFF 32,3 115 VAC HATS CLOSED 32,3...
  • Page 97 T3 ELECTRONIC CONTROL TRANSFORMER TERMINAL J1 TERMINAL #'S VOLTAGE CONDITION 115VA C POWER ON 0 VAC POWER OFF 7.1VA C POWER ON 0 VAC POWER OFF 7.1VA C POWER ON 0 VAC POWER OFF BTS-3 TERMINAL #'S VOLTAGE CONDITION GROUN D +5VD C POWER ON 0VDC...

  • Page 98: Ssr 50-450 Hp Analog Barrier Board Voltage Chart

    SSR 50-450 HP ANALOG BARRIER BOARD VOLTAGE CHART Analog Barrier Terminal Printed Circuit Board BTS-1 TERMINAL #'S VOLTAGE CONDITION +5VD C POWER ON # 3 RED 5 VDC SUPPLY 0VDC POWER OFF # 4 BLACK GND VARIABLE WITH PRESSURE 0-50mVDC POWER ON LINEA R 0 VDC...

  • Page 99: Electro-Static Discharge Field Service Kit Ccn 39198619

    An Electro-Static Discharge (ESD) kit has been developed to eliminate the risk of transmitting electricity to electronic components. Ingersoll-Rand recommends using the kit everytime Intellisys components (EPROMS, option proms, interface boards, etc.) are handled. The ESD kit is now available through Ingersoll-Rand Air Compressor Parts. -95-...
  • Page 100 -96-...

  • Page 101: Order Form

    Intellisys Serviceman's Guide $8.00 Form APDD422C EACH $8.00 Sierra Serviceman's Guide EACH Form APDD522-93 *Price Includes Shipping and Handling. Mail Purchase Order with Order Form to: Steve Mullen Ingersoll-Rand Co. ACG Multi-Media 220 North Hamilton Street Painted Post, NY 14870 -97-...
  • Page 102 NOTES -98-...
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  • Page 105 NOTES -101-...
  • Page 106 NOTES -102-...
  • Page 107 Rotary - Reciprocating Compressor Division Ingersoll-Rand Company Davidson, North Carolina 28036 Printed In USA ©1993 Ingersoll-Rand Co. Form APDD422C...

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