Ingersoll-Rand Intellisys S3 Technician Manual

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Intellisys Controller

Technician Guide

August 2008

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Page 1 Intellisys Controller Technician Guide August 2008...
Page 3 © 2008 Ingersoll-Rand company Confidential and trade secret information. This manual contains confidential and trade secret information owned by Ingersoll Rand Company (hereinafter referred to as “Proprietary Matter”). In consideration of the disclosure of the Proprietary Matter herein to the authorized recipient hereof, the recipient shall treat the Proprietary Matter as secret and confidential;...
Page 4: Table Of Contents
Contents General Information ........... 1 Component Review ..........2 Analog Inputs ..........2 4APT ............2 3APT ............3 2ATT ............3 Digital Inputs ........... 9 Emergency Stop Switch ......9 ...
Page 5 Power Out Restart ........18 Scheduled Start/Stop ........ 19 Soft Starter ..........20 Auto Stop Timer ........21 Maintenance Intervals ........22 Multiple level maintenance intervals ..22 Reset Maintenance Timer ......23 Warnings ............
Page 6 Condensate Interval Timer ......45 Service Due Timer ........45 Scheduled Start and Stop ......45 Scheduled Start Time ....... 45 Scheduled Stop Time ........ 45 Power Out Restart Option Timer ....46 Low Ambient Load Delay ......46 ...
Page 7: General Information
General Information The Intellisys S3 Controller is designed as a global controller to be used on all 90 - 160kW (125 - 200Hp) units. This Controller has replaced all wording with symbols eliminating the need of multiple language programming. The...
Page 8: Component Review
Intellisys and depending on the voltage the controller may cause a change in the pressure readout on the display, load or unload the compressor, or even shut the compressor down if conditions dictate. ©2008 Ingersoll Rand Company Page 2...
Page 9: 3Apt
It is wired into the controller at terminal XO5 pins 3 and 4. The thermistor has a range of -34 to 124°C (-29 to 255°F) the following pages shows the relationship between resistance and temperature for this thermistor. ©2008 Ingersoll Rand Company Page 3...
Page 10 154733 55924 149156 54233 143578 52598 138000 51017 134004 49490 130037 48012 126070 46584 122104 45202 118137 43865 114170 42573 110204 41322 106623 40112 102300 38941 99802 37808 96650 36712 93399 35650 89768 34623 ©2008 Ingersoll Rand Company Page 4...
Page 11 22599 10000 21983 9754 21385 9515 20806 9282 20244 9055 19699 8835 19171 8621 18658 8413 18161 8210 17679 8013 17211 7821 16757 7635 16317 7453 15889 7277 15475 7105 15072 6937 14681 6774 ©2008 Ingersoll Rand Company Page 5...
Page 12 4784 2450 4677 2400 4573 2352 4472 2304 4372 2258 4276 2213 4182 2169 4090 2125 4000 2083 3913 2042 3828 2001 3745 1962 3663 1924 3584 1886 3507 1849 3432 1813 3359 1778 ©2008 Ingersoll Rand Company Page 6...
Page 13 1360 779.9 1335 766.7 1310 753.7 1286 1262 728.5 1239 716.3 1216 704.3 1194 692.5 1172 1151 669.7 1130 658.6 1110 647.7 1090 636.9 1071 626.5 1051 616.2 1033 606.1 1014 596.3 996.4 586.6 ©2008 Ingersoll Rand Company Page 7...
Page 14 558.6 345.2 549.7 340.1 540.9 335.1 532.2 330.2 523.8 325.4 515.4 507.3 499.3 491.4 483.7 476.1 468.7 461.4 454.2 447.2 440.3 433.5 426.9 420.3 413.9 407.6 401.4 395.3 389.4 383.5 377.7 372.1 366.5 361.1 ©2008 Ingersoll Rand Company Page 8...
Page 15: Digital Inputs
15 psi and 1 psi when unit is running loaded. The inlet filter switch is labeled as 1VAC on all schematics and is wired into XO4 pins 1 and 4. ©2008 Ingersoll Rand Company Page 9...
Page 16: Motor Overloads
If the contact is closed then the controller will use the remote load/unload input for loading or unloading the ©2008 Ingersoll Rand Company Page 10...
Page 17: Remote Load/Unload
This PTC is wired into the controller at terminal XO4 pins 1 and 9. If the motor windings get to hot the ©2008 Ingersoll Rand Company Page 11...
Page 18: Digital Outputs
1M (KM1) contact to remain energized when the 1S (KM3) contact is de-energized at the Star Delta transition. [Std] – This contactor is 1S Starter Contact only installed and used in the YΔ type of starter. ©2008 Ingersoll Rand Company Page 12...
Page 19: Load Valve
(5SV & 6SV) [Enh] – If the Modulation Valve modulation set point in the Intellisys controller is turned off the modulation output stays off. If the ©2008 Ingersoll Rand Company Page 13...
Page 20: Condensate Drain Valve
This solenoid valve has an output timer that toggles on for a period defined by the Condensate Drain Time set point. The drain valve will remain off for a ©2008 Ingersoll Rand Company Page 14...
Page 21: General Alarm Contact
10 seconds prior to the unit starting. Serial Communication (terminal XO7) [Enh] - Used for Serial Port 1 Integral Sequencing, Ingersoll Rand X4I, or Compressor room and energy management controllers. ©2008 Ingersoll Rand Company Page 15...
Page 22: Serial Port 2
Master controller. The sequence assignment is displayed in the status menu item of the Master controller. The status of each compressor is also ©2008 Ingersoll Rand Company Page 16...
Page 23 Master controller is disrupted, a Slave compressor will automatically switch to local regulation control. When the Master becomes available again, the Slave pressure regulation will automatically revert to the Master and the “Remote Pressure Control” symbol will remain. ©2008 Ingersoll Rand Company Page 17...
Page 24: Options
Once power is returned the flag is evaluated and the compressor is returned to its previous operational state. PORO when activated will work in all Local and Remote control modes. For ©2008 Ingersoll Rand Company Page 18...
Page 25: Scheduled Start/Stop
PORO kit is not installed. [Enh] – This is an auto Scheduled Start/Stop stop/start mode of operation based on the Real Time clock. A scheduled start time set point is used to automatically start the compressor when ©2008 Ingersoll Rand Company Page 19...
Page 26: Soft Starter
[Std] – Outputs XO3-2 and XO3-3 Soft Starter can be configured to operate an Allen Bradley SMC-3 soft starter. The operating sequence of XO3-2 and XO3-3, when the soft starter staring method is selected follows: Xo3-3 energizes ©2008 Ingersoll Rand Company Page 20...
Page 27: Auto Stop Timer
(Ld). It will load and unload; however, it will not stop if it runs unloaded for 30 seconds unless it has been one hour since the ©2008 Ingersoll Rand Company Page 21...
Page 28: Maintenance Intervals
Icon will appear and flash. Once the maintenance timer value reaches 0% of the preprogrammed time (2000 hrs runtime or 8760 hrs clock time) the Red LED will flash indicating a Warning and the Wrench Icon will be on ©2008 Ingersoll Rand Company Page 22...
Page 29: Reset Maintenance Timer
Press the red C button until display returns to AE. You have now exited out of the programming menu. If the wrench icon is still displayed, please contact local service representative. If a value less than 2000 hours is ©2008 Ingersoll Rand Company Page 23...
Page 30: Warnings
Maintenance Hour reset menu (Mn) Warnings An Intellisys S3 Warning will not shutdown the compressor however, it will remain on the display until acknowledged. It is cleared by pressing the “C” clear key. A log is retained in alarm history.
Page 31 (19) Integral Sequencing Communication [Enh] – This occurs when the Master Failure compressor loses or is unable to communicate ©2008 Ingersoll Rand Company Page 25...
Page 32: Alarms (Trip)
All units must be in the integral sequencing mode. Alarms (Trip) An Intellisys S3 Trip will shut the compressor down and must be manually cleared by pressing the “C” clear key. A trip will take precedence over a warning and an entry will be made in the alarm history log.
Page 33 XO5. Also, check for a damaged sensor and broken or damaged wire. (09) [Std] - Temperature Sensor Failure This alarm occurs if the airend Discharge temperature sensor is recognized as missing or ©2008 Ingersoll Rand Company Page 27...
Page 34 (20) . [Enh] – This Main Motor Over Temp alarm indicates that the PTC sensor embedded in the motor has tripped. The main cause of this ©2008 Ingersoll Rand Company Page 28...
Page 35: Fault History
Once a fault is selected, the controller will automatically scroll through all the status menu screens and display the values at the time of fault. This function is available in both standard and enhanced controllers. Controller User Interface ©2008 Ingersoll Rand Company Page 29...
Page 36 If the compressor has stopped in auto start/stop, pressing this button will have the same effect as pressing the stop key. Enter Key – Used for entering set point values. ©2008 Ingersoll Rand Company Page 30...
Page 37 Alarm Indicator – Flashing Red indicates a warning condition. On solid indicates a shutdown alarm condition LCD Display The displays backlight will always be on as long as the unit is powered up and running. Display Symbols Change Oil Filter ©2008 Ingersoll Rand Company Page 31...
Page 38 Remote Control Active Discharge Pressure below Load set point Discharge Pressure is between Load and Unload set points Discharge Pressure is above Unload set point Running Hours Loaded Hours Maintenance Hours Maintenance % Pass Code ©2008 Ingersoll Rand Company Page 32...
Page 39: Display Abbreviations
Maintenance Timer Integrated Sequencer Code Unloaded Pressure Loaded Pressure (in setup menu) Auto Stop Timer Modulation Engineering Units Date Time Fault Code Discharge Pressure YΔ Star Delta Timer Soft Start Timer Condensate Drain Timer ©2008 Ingersoll Rand Company Page 33...
Page 40 Scheduled Stop Time Power Out Restart Option Low Ambient Load Delay Remote control Multi 485 Communication ModBus Address Baud Rate Starter Type Rated Pressure Low Ambient Dryer Enabled Starts per Hour DΔ Differential Pressure PORO Timer ©2008 Ingersoll Rand Company Page 34...
Page 41: S3 Controller Parameters
0=°F & psi 1=°C & psi 2= °C & Bar 3=°C & KPa 0:00 – 24:00 YΔ 8-20 Sec 1-30 sec 90-300 sec 0-2000 2000 2000 0-1 (Off/On) 0-24 hrs 7:00 0-24 hrs 17:00 0-1 (Off/On) ©2008 Ingersoll Rand Company Page 35...
Page 42 Input control, ModBus read only 4=Digital input, Load/Unload control, No remote Start/Stop control, Modbus read only 1200, 2400, 4800, 9600, 19200, 38400, 9600 57600, 76800, 115200 0=Full Voltage 1= Star Delta 2= Soft start/VFD ©2008 Ingersoll Rand Company Page 36...
Page 43: Real Clock Function
4 years. This real time clock does not recognize day light savings time and must be adjusted accordingly. ©2008 Ingersoll Rand Company Page 37...
Page 44: Menu Screens
These screens are read only and consist of the following: Default Screen This is the main Status screen, it will display the package pressure, airend discharge temperature, and ©2008 Ingersoll Rand Company Page 38...
Page 45: Sump Pressure
This screen will only be available on the enhanced controller. When the integrated sequence is enabled it will allow up to three machines to be controlled without the extra components needed to sequence compressors. ©2008 Ingersoll Rand Company Page 39...
Page 46: Pass Code Screen
If unit runs unloaded for a preset time then it may go into Auto Stop / Restart. ©2008 Ingersoll Rand Company Page 40...
Page 47: Load Pressure
°F and PSI, °C and PSI, °C and Bar, and finally °C and KPa. Date and Time These next two screens are for the real time clock. These need to be accessed and setup to ©2008 Ingersoll Rand Company Page 41...
Page 48: Fault History (P02)
Fault History (P02) The Intellisys S3 controller has the capability of saving the last 15 alarms. The most recent alarm will always be displayed first. The alarm will display a fault code.
Page 49: Advanced Setup Menu (P03)
The pass code is “0101.” Once this code is entered the technician will be allowed to make changes in the menu. Pressure Calibration Entering this screen will allow the technician to ©2008 Ingersoll Rand Company Page 43...
Page 50: Sump Pressure Calibration
This setting needs to be adjusted so that just as it shuts off there is a small amount of air coming out. If condensate is still purging from the drain when it ©2008 Ingersoll Rand Company Page 44...
Page 51: Condensate Interval Timer
NOTE: This is a seven-day a week timer and will start the compressor everyday at the same time. Scheduled Stop Time This screen will be viewable if the scheduled start/stop option has been turned on. This ©2008 Ingersoll Rand Company Page 45...
Page 52: Power Out Restart Option Timer
30 – 360 seconds. If the timer is set and the ambient temperature is below the recommended Ingersoll Rand temperature of 2°C (35°F) the compressor will not allow the compressor to load until this timer is satisfied. This will allow the compressor to run unloaded and create some heat to warm up the compressor.
Page 53: Modbus Address
NOTE: This setting is only available on the enhanced controller. Baud Rate This screen allows the technician to change the rate of speed at which the controller will communicate with a remote control device. ©2008 Ingersoll Rand Company Page 47...
Page 54: Factory Setup Menu (P04)
This function comes in very handy when a technician is replacing a controller. Maintenance Hours Reset This screen allows the technician to reset the maintenance timer back to ©2008 Ingersoll Rand Company Page 48...
Page 55: Starter Type
Advanced Menu to be adjusted. Dryer Enabled In this screen, the technician can enable or disable the dryer on any 45-75kW (60- 100Hp) units. This screen is only available with the enhanced mode controller. ©2008 Ingersoll Rand Company Page 49...
Page 56: Poro Enabled
Once the PORO option has been installed, the technician needs to enable the option in this screen. If PORO is turned off then the PORO timer in the Advanced Setup Menu will not be visible. ©2008 Ingersoll Rand Company Page 50...

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