Ingersoll-Rand R90IU-100 Manual

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Fault Finding Guide for the R90-160 IU

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WILMER HERNANDEZ

April 14, 2025

Requiero informacion sobre: NOMBRE:Conector; APLIC_ESPEC_PARTES_COMPRESOR:Sistema de aire; FABRICANTE:INGERSOLL RAND; MODELO:39; Documento No. ACTIVO/OK ; Tp: PN 39156393

1 comments:

Mr. Anderson

April 15, 2025

The Ingersoll-Rand R90IU-100 air compressor system uses the S3 Intellisys controller, which includes the following input/output connections:

- 3 analog inputs
- 8 digital inputs
- 6 relay outputs
- 1 analog output
- 2 serial RS-485 communication ports

The controller operates with a 24VAC input and has an internal 24VDC power supply that can handle a 40 ms power loss without resetting.

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Summary of Contents for Ingersoll-Rand R90IU-100

Page 1 Fault Finding Guide for the R90-160 IU More than Air Answers Online answers: http://www.air.irco.com PHONE: 1-800-820-0308 June 07...
Page 2 Safety First Compressed air and electricity can be dangerous. Before undertaking any work on the compressor, ensure that the electrical supply has been isolated and the compressor has been relieved of all pressure. Use proper Lock Out Tag Out procedures to ensure you and your coworkers safety. Keep all parts of the body and any hand-held tools or other conductive objects, away from exposed live parts of the compressor electrical system.
Page 3: Table Of Contents
Table of Contents Page 1. Overview of the Eiger control system ----------------------------------------------------------- 4 2. S3 Intellisys Controller Operating Instructions --------------------------------------------------5 3. S3 Intellisys Controller Software Navigation ---------------------------------------------------6 4. S3 Intellisys Controller Fault Indicators ---------------------------------------------------------7 5. Eiger Fault Finding ---------------------------------------------------------------------------------8-13 6. Star Delta Electrical Schematic -------------------------------------------------------------------14-15 7.
Page 4: Overview Of The Eiger Control System
Overview of the Eiger Control System The S3 Intellisys controller is used to control the operations of the air compressor. The following troubleshooting guide will allow you to troubleshoot the compressor components. The controller will come in two standard configurations, one is STD (standard) the other is ENH (enhanced). The difference is the options that are enabled in the software of the controller when the compressor is ordered.
Page 5: S3 Intellisys Controller Operating Instructions
S3 Intellisys Controller Operating Instructions...
Page 6 Software Navigation...
Page 7 Eiger Controller Fault Indicators Motor PTC Open (High Motor Temperature) 020 Tr...
Page 8: Eiger Fault Finding
Eiger Fault Finding ’Power on’. L.E.D. Control Voltage Check the control fuses. not available does Not illuminate. Confirm Incoming Power is correct voltage Check the transformer secondary windings for 24 VAC control voltage and 110 VAC. Intellisys indicates Control Circuit Check machine for indicated fault a tripped condition.
Page 9 Compressor trips and Excessive current has Check the actual operating indicates motor caused the motor pressure and lower the overload. overload to trip setting if it is too high. Fault T 3 Isolate the electrical supply and check that the air end and motor rotate freely.
Page 10 Compressor will not Inlet valve not opening Check that the valve is free load. to open. Check the operation of the load solenoid valve 1SV. Compressor fails to Check the operation of Check the offline/online pressure deliver rated the inlet valve. setting.
Page 11 Safety valve blows Minimum pressure valve Strip the MPV, examine and when compressor (MPV) stuck closed. repair if necessary. loads. Safety valve faulty Check the setting of the safety valve and the rated pressure. Blocked separator element Check differential pressure and replace element Motor reverse Incoming power wired to...
Page 12 Low sump air Incoming power wired to Check main motor rotation if pressure. package incorrectly incorrect change any two wires Fault T 6 to reverse rotation. Inlet valve not opening Check valve and make sure it operates freely Check load solenoid valve and controller operation.
Page 13 Maintenance due Maintenance timer has Reset time in factory set up reached 1800 hrs of runtime menu using access code soon. or 7884 hours clock time. 1954 Fault W 14 Maintenance due Maintenance timer has Reset time in factory set up immediately.
Page 14 Star Delta Wiring Diagram...
Page 16 Soft Start Wiring Diagram...
Page 18 Line Start Schematic...
Page 20: Process And Instrumentation Diagram
Process and Instrumentation Diagram...
Page 22: General Overview Of The Compressor
GENERAL OVERVIEW OF THE COMPRESSOR The compressor is an electric motor driven, single stage screw compressor, complete with accessories piped, wired and base plate mounted. It is a totally self contained air compressor package. The standard compressor is designed to operate in an ambient range of 2_C to 46_C (35_F to 115_F).
Page 23 Input/Output and Alarm Information for Intellisys S3 Controller Hardware Input / Output Information Each I/O and software function is labeled as STD where the function is available in the standard controller (Rapidly Developing Economies) and ENH where the function is available in the enhanced controller (RDE –...
Page 24 1.3 Digital Inputs - 24 Vdc internally supplied source, 200ma max, DI #1 = 140 ma., DI #2 - #7 = 10 ma., DI #8 = 1.4 ma. typical current. Input Fault Description Control Term STD #1 Open Emergency Stop ENH #2 Closed Oil Filter Condition ENH #3...
Page 25 STD Common Fault Relay - This is an output provided for customer use. This relay energizes during normal operation and returns to its Normally Open, N.O., state, when a shutdown or trip condition is detected. The Fault relay should only toggle when the controller has detected a Shutdown or Trip (Alarm) condition.
Page 26 1.6 Intellisys S3 Serial Communications - RS-485, 500 to 1000 Meters Port Description Control Term ENH Port #1 Integral Sequencing, X4I, X8I CMC Multi-485, Serial Programming ENH Port #2 Remote Monitor / Control, Modbus RTU STD Port#2 Modbus Read Only Serial Communications Comments ENH Serial Port #1 - S1 Integral Sequencing, X4I, X8I, Hardware - RS485, 2 Wire Half Duplex, Opto-isolated, and capable for communicating up to 4000 ft from a host device.
Page 27: Eiger Maintenance Intervals
1.7 Remote Control The compressor will not automatically restart after a power failure unless a PORO kit is installed. The compressor can be restarted using the Green start button only if the compressor is getting a remote run command. 1,8 Auto Stop Timer The auto stop timer has a range of 30 to 360 seconds. Zero (0) can be selected, which will prevent the motor from stopping.
Page 28 Maintenance...
Page 29 Maintenance...
Page 30 Maintenance...
Page 31 S3 Controller Input/Output Overview Analog Input Digital Input DO = Digital Output...
Page 32 S3 Fault Descriptions 2.0 Faults An Intellisys S3 – A WARNING will not shutdown the compressor. The warning will remain on the display until acknowledged. It can be cleared by pressing the “C” clear key. A log will be retained of the warnings / trips that have occurred. An Intellisys S3 TRIP will shutdown the compressor and must be manually cleared by pressing the “C”...
Page 33 Fault History STD Retention of Fault History last 15 trip and warning faults with compressor information Real Time Clock STD The real time clock will be used to count down the 8760hrs before maintenance. This time is reset when the maintenance hour indicator is reset. The customer can not view the clock. User Interface Buttons - The 8 buttons located on the controller are to be a raised membrane button used to activate the membrane switch.
Page 34: S3 Intellisys Operator Display Icons
S3 Intellisys Operator Display Icons The backlight for the LCD should be left on all the time as long as this does not significantly reduce the life of the backlight. Icons in the standard LCD display: --------------------Shutdown in Auto Restart (Pressure Control) -------------------Power Out Restart Active (PORO) -------------------Scheduled Start / Stop Active ------------------Change Air Filter Warning...
Page 35 Status Display - When power is applied to the controller the LCD check will be performed for 3 seconds and the Controller Software Version will be displayed. Status Icons indicating machine operational or fault status will be continuously displayed for all Status displays.
Page 36 PORO Active I(Arrow to point to the left) Scheduled Start / Stop Active Pressing the Up and Down arrow buttons will toggle through the following items to be displayed in the Multi-use display area. If no buttons are pressed within 30 seconds, the display should revert back to the default display item.
Page 37 The Setup Display is entered by pressing the Menu button while the compressor is Setup Display not running mode. The Setup display can be exited by pressing the Clear button. A security code of 0 0 0 0 will be required to enter the Setup Display. CD: 0 0 0 0 Pass Code If no buttons are pressed within 30 seconds, the display will revert back to the default Status display item.
Page 38: Scheduled Start Stop
Trip History Menu - The Trip History display is entered by pressing the Up arrow from the Setup Menu display. The display will default to the most recent Trip and will automatically cycle through the recorded values. The last 15 Trips will be recorded. The Trip History can be cycled through by pressing the Up and Down arrows to select the desired Trip for viewing.
Page 39 St: 0 0:0 0 _ _ _ Scheduled Start Time ----------------------------- Sp: 0 0:0 0 _ _ _ Scheduled Stop Time ---------------------------- Po: off PORO on/off -------------------------------------- Pt: 0 0 1 0 SEC PORO Time ----------------------------- Lt: 0 0 2 0 SEC Low Ambient Load Delay Time -------------------------------- RC: 0 0 0 0 _ Remote Control Selection ------------------------------------- Is: _ _ _ _ OFF Integral sequencing...
Page 40 Fault Indicators- Trips - Red Trip LED on solid, green LED off. When a trip or warning is detected by the controller, the following codes and icons should be displayed on the bottom line of the LCD display. Indicates Trip Motor PTC Trip...
Page 41 Warnings - Red Alarm LED flashing, green LED on W Indicates Warning Environmental Requirements - All units shall be designed such that the package can operate continuously in ambient temperatures between 35°F (2°C) and 115°F (46°C) with non condensing humidity from 0-95% from the front of the controller. The temperature at the rear of the controller can reach 60C.
Page 42 EIGER OPTIONAL FEATURES STD Low Ambient - The low ambient kit is designed to protect the compressor when starting in temperatures below 2° C. The temperature is measured at the air-end discharge. The temperature is read using the standard Air-end temperature sensor. When the Low ambient option is installed and selected and the A/E Discharge Temperature is measured to be below 2°C, the compressor will be started when commanded but will delay to load a period of time defined by the Low Ambient Delay Time, Section 12.
Page 43 manually be re-started by any of the standard starting methods. Pressing the control panel start button, or if Remote Control has been turned on, closing the Remote Start signal or sending a serial start command. ENH Integral Sequencing - It will be possible to sequence three Intellisys controllers without a system controller.
Page 44 MODULATE CONTROL VALVE ADJUSTMENT Ensure that the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg. Ensure that the main power disconnect switch is locked open and tagged. 1. Put the compressor in the MODULATION mode. 2.
Page 45 Standard S3 Menu Structure and Parameters Table 12...
Page 46 Standard S3 Menu Structure and Parameters Table 12...
Page 47 Standard S3 Menu Structure and Parameters Table 12...
Page 48 Standard S3 Menu Structure and Parameters Td – Air Temp High Level Trip Fixed Value 109 C 109 C Table 13...
Page 49 Modbus Register Listing...
Page 50: Table 13 Modbus Register Listing
Table 13 Modbus Register Listing...
Page 51 Here is a list of trip codes that are very handy to carry with you on a service call. Motor PTC Open (High Motor Temperature)
Page 52 Thermistor 2ATT -34 to 124 °C (255 F) Air end Discharge Appendix 1...
Page 58: General Specifications For Eiger Packages
General Specifications for Eiger Packages...

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