Ingersoll-Rand R90IU-125, R110IU-125, R110IU-140, R150IU-100, R150IU-125 User Manual
...
Fault Finding Guide for the R90-160 IU
More than Air Answers
Online answers: http://www.air.irco.com
PHONE: 1-800-820-0308
WSV June 07
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. Maintain dry footing, stand on insulating surfaces and
do not contact any other portion of the compressor when making adjustments or repairs to exposed
live parts of the compressor electrical system. Close and lock all access doors when the compressor
is left unattended.
Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only
extinguishers suitable for class BC or class ABC fires. Attempt repairs only in clean, dry, well lighted
and ventilated areas. Connect the compressor only to electrical systems that are compatible with its
electrical characteristics and that are within it’s rated capacity.
WARNING
Imposing a normal or emergency stop on the compressor will only relieve pressure upstream
of the minimum pressure valve on top of the separator tank. If maintenance work is required
downstream of this valve, ensure that all pressure is relieved at the process vent point
external to the compressor This state is advised by selecting PACKAGE DISCHARGE
PRESSURE on the control panel.
2
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. Soft Start Electrical Schematic --------------------------------------------------------------------16-17
8. Line Start Electrical Schematic -------------------------------------------------------------------18-19
9. Process and Instrumentation Diagram ------------------------------------------------------------20-21
10. General Overview of the Compressor ------------------------------------------------------------22
11. Input/Output and Alarm Information for The Intellisys S3 Controller -----------------------23-25
• Analog Inputs/Outputs Information and Comments
• Digital Inputs/Outputs
12. S3 Intellisys Controller Serial Communications Information --------------------------------26
13. Eiger Maintenance Intervals ----------------------------------------------------------------------27-30
14. S3 Intellisys Input/Out Overview ---------------------------------------------------------------- 31
15. S3 Intellisys Fault Descriptions ------------------------------------------------------------------ 32-33
16. S3 Intellisys Operator Display Icons ------------------------------------------------------------ 34-41
17. Eiger Options ----------------------------------------------------------------------------------------42
• Low Ambient
• PORO
• Scheduled Start Stop
• Integral Sequencing
• Modulation Option and Adjustments ----------------------------------------------------43-44
16. Table 12 Standard S3 Menu Structure and Parameters ---------------------------------------45-48
17. Table 13 Modbus Register Listing ---------------------------------------------------------------49-50
18. Trip Codes List -------------------------------------------------------------------------------------51
19. Appendix 1 Thermistor Temperature Resistance Chart (2ATT) ---------------------------- 52-57
20. General Specifications for Eiger Packages ----------------------------------------------------- 58-79
3
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. If the compressor is ordered
with a standard controller the compressor can be upgraded to an enhanced unit with an upgrade kit CCN
23083637. The upgrade kit includes instruction for retrofitting a standard controller to an enhanced controller.
The controller has 3 analog inputs, 8 digital inputs, 6 relay outputs, 1 analog output and two serial 485
communication ports. The controller has a 24VAC input while the internal power supply is a 24 VDC unit that
must sustain a 40 ms power loss before resetting. The S3 controls all aspects of machine operation including
starting, stopping, loading and unloading, safety shutdowns, and user interface as well as compressor remote
connectivity to other devices.
This controller is different than other Intellisys controllers in that the relay outputs are not solid state triacs,
they are relays that are turned on an off by an internal 24 VDC power supply controlled by the internal
software. There will be no voltage leakage as you find with triacs. So fault finding will be easer due to fact that
if a relay output is on or off due to a problem with the controller simply replace the controller, there are no user
serviceable parts. The analog output (X06 term 1-2) for the PORO horn ( 4-20 Ma output ) simply energizes
the solid state relay when the unit starts after a power outage.
A user interface shows the status of the compressor while it is running. The display uses ISO symbols to
convey information to the operator and it will be necessary to learn the symbols as well as the menu structure to
troubleshoot the compressor. Pass codes are required to enter the Set up Access screen, and Fault History
(0000), and Advanced Set Up (0101). These codes are provided in this manual and the operator’s manuals. This
troubleshooting guide also includes the pass code for the Factory Setup that is to only be used by IR service
technicians and not given to customers (Code is 1954). The next pages give an overview of the buttons on the
controller as well as the ISO symbols and software navigation.
4
S3 Intellisys Controller Operating Instructions
5
Software Navigation
6
020 Tr
Motor PTC Open (High Motor Temperature)
Eiger Controller Fault Indicators
7
Eiger Fault Finding
’Power on’. L.E.D.
does Not
illuminate.
Intellisys indicates
a tripped condition.
Compressor is
stopped but
Intellisys indicates
that it is still
running (STD
controller only)
Control Voltage
not available
Control Circuit
Interrupted By a
Safety Circuit
Device
Control voltage
not available to
relay inputs
Check the control fuses.
Confirm Incoming Power is correct
voltage
Check the transformer secondary
windings for 24 VAC control
voltage and 110 VAC.
Check machine for indicated fault
and repair.
Attempt to ’reset’ the controller by
removing power to the controller.
Check MCB3 for voltage, Controller
has no power to relay outputs.
This controller has no provision to
detect a power loss to the relay
outputs.
Reset controller
Compressor trips
indicating a high
compressor
temperature.
Fault T 13, W 13
Insufficient Coolant
Circulation,
insufficient cooling.
Check coolant level
Check Temperature sensors
Check thermostatic valve
AC, Check cooling air flow, cooler
restrictions, exhaust vents, inlet
restrictions.
WC, check water flow, strainer,
and water temperature
Excessively high ambient
Temperature / Humidity
(i.e. greater than 46C (115F).
8
Compressor trips and
indicates motor
overload.
Fault T 3
Excessive current has
caused the motor
overload to trip
Check the actual operating
pressure and lower the
setting if it is too high.
Isolate the electrical supply
and check that the air end
and motor rotate freely.
Check the separator element
for excessive pressure drop.
Set the motor overload on
star-delta at .67 * FLA * SF
of motor name plate data
tag. Measure current at
bottom of MOL
Compressor shutdown
display shows
OVERPRESSURE.
Fault T 12, W 12
Isolation valve
Blowdown system
Open the valve and
restart.
Check the operation of
the load solenoid
mechanically and
electrically
Check the operation of
the unloader valve −
strip and clean if
necessary.
Compressor will not
build up rated pressure.
Air Demand too
high
Offline pressure set
too low
9
Check for leaks, open service
valves or exceptionally high
demand.
Check the offline pressure
setting.
p
Compressor will not
load.
Inlet valve not opening
Check that the valve is free
to open.
Check the operation of the
load solenoid valve 1SV.
Compressor fails to
deliver rated
capacity.
Excessive coolant
consumption.
Check the operation of
the inlet valve.
Check the operation of
the load solenoid valve
1SV.
Blocked scavenge line
Ruptured or fouled
separator element
Check the offline/online pressure
setting.
Check the inlet filter for
contamination. The L.E.D. should
indicate if it is blocked.
(ENH controller only)
Clear the blockage.
Change the element.
Rapid cycling or
receiver will not
blow down to
unloaded running
ressure.
System is not using enough
air, increase consumption.
Minimum pressure valve
(MPV) stuck open.
10
Strip the MPV, examine and
repair if necessary.
(
)
Safety valve blows
when compressor
loads.
.
Motor reverse
rotation
Fault T 1
Emergency Stop
Fault T 2
Low ambient
temperature
Fault T 4
High sump air
pressure.
Faults T 5, W 5
Minimum pressure valve
(MPV) stuck closed.
Safety valve faulty
Incoming power wired to
package incorrectly
Emergency stop activated
Compressor will not start
below 2 deg C (28 deg F),
unless fitted with low
ambient option (−10_C)
14 deg F
MPV stuck closed Strip MPV, examine and repair
Blocked separator element
Blow down system
ineffective
11
Strip the MPV, examine and
repair if necessary.
Check the setting of the
safety valve and the rated
pressure.
Blocked separator element
Check differential pressure
and replace element
Change any 2 of the
incoming power wires to
change motor rotation
Clear fault hazard twist
emergency stop button to
reset.
Wait until compressor
package air temperature
rises above minimum starting
temp requirement.
Replace separator element
Check the operation of the
load solenoid valve.
Check un-loader valve − strip
and clean if necessary.
Low sump air
pressure.
Fault T 6
P1 Sensor Failure
Fault T 7
P2 Sensor Failure
Fault T8
Temperature Sensor
Failure
Fault T 9
P1 Sensor
calibration
failure.
Fault T 10
P2 Sensor
calibration
failure.
Fault T 11
Incoming power wired to
package incorrectly
Check main motor rotation if
incorrect change any two wires
to reverse rotation.
Inlet valve not opening
Check valve and make sure it
operates freely
Check load solenoid valve and
controller operation.
Check wiring to transducer Recalibrate Transducer or
Replace
Controller measured value
is outside of the +/- 10 %
range of the full scale value.
Check resistance using
chart on pages 52-57.
Replace sensor if resistance
does not equal ambient
temp.
Check sensor connection and calibrate or replace if
necessary
Motor PTC Open
(High Motor Temp)
Fault T 20
Check for overload
condition
12
Checking motor cooling
Maintenance due
soon.
Fault W 14
Maintenance timer has
reached 1800 hrs of runtime
or 7884 hours clock time.
Reset time in factory set up
menu using access code
1954
Maintenance due
immediately.
Fault W 15
Change oil filter.
Fault W 16
Change air filter.
Fault W 17
Maintenance timer has
reached 2000 hrs of runtime
or 8760 hours clock time
Change oil filter
Change air filter Check air pressure switch
Reset time in factory set up
menu using access code
1954
Check differential pressure
switch for fault
for fault
Change separator
element
Fault W 18
Integral sequencing
communication
failure.
Fault W 19
Change separator element Recalibrate sump pressure
transducer. (3APT)
Wiring or communication
fault
Check wiring
13
Star Delta Wiring Diagram
14
15
Soft Start Wiring Diagram
16
17
Line Start Schematic
18
19
Process and Instrumentation Diagram
20
21
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). The standard maximum temperature of 46_C (115_F) is applicable up to an elevation of
1000m (3280ft) above sea level. Above this altitude significant reductions in ambient temperature are
required if a standard motor is to be used. Compression in the screw type air compressor is created
by the meshing of two (male & female) helical rotors.
The air/coolant mixture discharges from the compressor into the separation system. This system
removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the
cooling system and the air passes to the after cooler and out of the compressor through the moisture
separator (optional).
Air is pulled into the machine by the cooling fan and is pushed through the combined cooler / after
cooler. By cooling the discharge air and passing it through the separator, much of the water vapor
which is naturally present in the air, can be removed.
The coolant system consists of a sump, cooler, thermostatic valve and a filter. When the unit is
operating, the coolant is pressurized and forced to the compressor bearings. The compressor load
control system is automatic ’On−Off line’. This is accomplished by the Intellisys S3 Controller
monitoring the discharge pressure and operating the SV1 solenoid valve. When the load valve is on
(Loading) the blow down solenoid valve SV3 is off and this logic reverses when the unit unloads. The
compressor will operate to maintain a set discharge line pressure and is provided with an auto restart
system for use in plants where the air demand varies widely. Panel instrumentation is provided to
indicate the compressor operating conditions and general status.
CAUTION
LOW DEMAND APPLICATIONS
During periods of low demand, the compressor may not reach its normal operating
temperature. Sustained operation at low demand can result in the build up of condensate in
the coolant. If this situation occurs, the lubricating characteristics of the coolant can be
impaired which may lead to damage of the compressor.
THE COMPRESSOR SHOULD BE ALLOWED AMPLE LOADED RUNNING TIME.
22
Input/Output and Alarm Information for
Intellisys S3 Controller
1.0 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 – Options and Developed Markets).
1.1 Analog Inputs - 10 bit resolution. .5% Full scale accuracy. Pressure Transducer, 2 Wire, 4-
20 ma, Loop Powered.
Sensor Range Description Control Term
STD 4APT 0-232 Psi Package Discharge X05 1-2
ENH 3APT 0-232 Psi Sump, Wet Side X05 5-6
Temperature, 2 Wire, 10 K ohm Thermistor, see appendix 1 for Resistance table!
Sensor Range Description Control Term
STD 2ATT -34 to 124 °C (255 F) Air end Discharge X05 3-4
1.2 Analog Output - 0-20ma, 24Vdc, max load 500 Ohms, .020ma resolution,
Output Description Control Term
STD #1 PORO Horn (Using Solid State Relay) X06 1-2
Analog Inputs Comments
STD Pressure Input Calibration - Initiates an automatic calibration routine for reading and
correcting the pressure transducer inputs with a known zero Psi input. A zero offset calibration should
be performed by first the user verifying the pressure applied to the pressure transducer is in fact 0
PSI. Initiating this calibration routine will read and store a new zero offset value for the analog inputs.
This value is used as an offset for all future pressure readings. The display (UI) should indicate to the
user that a zero Psi reading has been successfully made and stored for the new zero PSI offset value
by displaying a successful message or icon. If when reading the analog input for the 0 PSI value, the
actual reading is greater than +/- 10% of the scale, the calibration will not be performed for that
particular sensor and the previous pressure offset value will be retained. A Sensor Calibration Failure
will be displayed indicating which input has failed and also adding an entry into the Alarm Log. If the
Developed Markets features are enabled, the Sump Pressure transducer will be present and should
be calibrated along with the Package Discharge Pressure transducer. Span calibration is not
accessible by the customer. The calibration is done through the advanced set up menu as shown in
the flow chart on page 6.
23
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 X04 1-2
ENH #2 Closed Oil Filter Condition X04 1-3
ENH #3 Closed Inlet Filter Condition X04 1-4
STD #4 Open Motor Over load (Main, Fan, Dryer) X04 1-5
*ENH #5 Remote Start and Stop X04 1-6
*ENH #6 Remote Load Enable X04 1-7
*ENH #7 Remote Load/Unload X04 1-8
ENH #8 Motor PTC X04 1-9
*IEO and ASC can control the compressors using an ISCII module
connected to digital inputs #5, #6 and #7.
1.4 Digital Outputs - Internal relay, 24 Vdc @ 8 Adc, 240 Vac @ 8Aac
resistive,
Output Description Control Term
Control Voltage Input, DO #1- #3 X03 1
STD #1 Starter Contact 1M X03 2-Comn
STD #2 Starter Contact 1S X03 3-Comn
STD #3 Load / Blowdown Solenoid Valve X03 4-Comn
Control Voltage Input, DO #4 X03 5
ENH #4 Modulation X03 6-Comn
STD #5 Condensate Drain X02 1-2
STD #6 General Alarm Contact (NO) X02 3-4
Digital Output Comments
STD Star Delta Logic Using Two Digital Outputs - Combine 1M / 2M on one common output, a
normally closed electrical interlock (KM3-2) from the 1S (KM3) contactor keeps the 2M (KM2)
contactor from energizing anytime the 1S (KM3) contactor is energized.
Electrical interlocks are wired such that when the 1S (KM3) output is de-energized at Star Delta
transition time causing the 1S (KM3) contactor to open, the 1S normally closed interlock (KM3-2) falls
back to the closed position energizing the 2M (KM2) contactor.
A second electrical interlock from the 1S (KM3) contactor is wired in series with the 1M (KM1)
contactor to insure the 1S (KM3) is pulled in before the 1M (KM1) will be energized. An interlock from
the 1M (KM1) contactor is used to seal around the 1S (KM3-1) contact to allow the 1M (KM1) contact
to remain energized when the 1S (KM3 contact is de-energized at the Star Delta transition.
STD Allen Bradley SMC-3 Soft Start Logic Using Two Digital Outputs
Outputs X03-2 and X03-3 can be configured to operate an Allen Bradley SMC-3 soft starter. The
operating sequence of X03-2 and X03-3, when the soft starter starting method is selected, follows.
X03-3 energizes immediately at the start command. 1/2 seconds later X03-2 energizes. Both outputs
maintain an energized state while the motor is given a run signal. When the motor is given a stop
signal the operating sequence of X03-2 and X03-3 are reversed from the starting sequence.
24
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