Ingersoll-Rand R90IU-125, R110IU-125, R110IU-140, R150IU-100, R150IU-125 User Manual

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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

WSV 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. 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.

Page 3

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

Page 4

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.

Page 5

S3 Intellisys Controller Operating Instructions

Page 6

Software Navigation

Page 7

020 Tr

Motor PTC Open (High Motor Temperature)

Eiger Controller Fault Indicators

Page 8

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).

Page 9

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

Check for leaks, open service valves or exceptionally high demand.

Check the offline pressure setting.

Page 10

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.

Strip the MPV, examine and repair if necessary.

Page 11

(

)

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

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.

Page 12

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

Checking motor cooling

Page 13

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

Page 14

Star Delta Wiring Diagram

Page 15

Page 16

Soft Start Wiring Diagram

Page 17

Page 18

Line Start Schematic

Page 19

Page 20

Process and Instrumentation Diagram

Page 21

Page 22

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.

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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.

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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.

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.

STD Condensate Drain - This is an output provided to control a condensate drain solenoid valve.

This output is a timed output that toggles on for a period of time defined by the Condensate Drain Time set point. The drain valve remains off for a period defined by the Condensate Drain Interval Time set point.

Condensate Drain Time Default - 5 Sec

Minimum - 1 Sec

Maximum - 30 Sec.

Condensate Interval Time Default - 180 Sec Minimum - 90 Sec Maximum - 300 Sec

ENH Modulation - The modulation output is used to turn on the modulation solenoid valve anytime

the modulation set point is turned on and the machine is in a loaded state. If the modulation set point is turned off the output remains off.

1.5 Control Power Supply - 24 VAC +/- 20%, 24 VA, 50/60 Hz, Floating -non-grounded, and

the controller must sustain a 40ms power outage before resetting.

Input Description Control Term

Supply Controller Power X01 1-2

I/O Functionality

STD Contact De-bounce Times are not adjustable and are for information only. .

Dig Input #

1 50 ms 2 15 sec 3 15 sec 4 2 sec 5 2 sec - Closed

.5 sec - Open 6 50 ms 7 50 ms

Delay Time

STD Combine MOL FOL into a common digital input called Motor Overload. Overload contact

current must be minimum 17vdc and 5 ma.

ENH Remote Start / Stop using a single contact.

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 X07 1-2

CMC Multi-485, Serial Programming

ENH Port #2 Remote Monitor / Control, X08 1-2

Modbus RTU

STD Port#2 Modbus Read Only X08 1-2

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. Software - CMC Multi-485.

ENH Serial Port #2 - IEO, ASC, Remote Monitoring and control of the compressor. Hardware -

RS485, 2 Wire Half Duplex, Opto-isolated,and capable for communicating up to 4000 ft from a host device. Software - Modbus Slave, RTU, Selectable Baud Rate, 2 Stop bits, 8 Data bits, No Parity.

Modbus Baud Rate - Selectable from any one of the following standard Baud rates. 1200, 2400,

4800,9600, 19200, 38400, 57600, 76800, 115200.

Modbus Registers - See Paragraph 13 “Modbus Register Listing” for the compete register listing with detailed descriptions. Modbus Commands Supported - At a minimum Modbus 03 Read Holding Register, and 06 Preset Single Register.

This serial port must be capable of connecting to a multi-drop, RS485 network with up to 32 devices functioning as a Modbus Slave only. This serial port will be exposed to all Modbus network traffic intended for any device on the network. Serial communication handling must not hinder safe and timely machine control. The serial port should be capable of servicing communications at least twice per second. Any serial communications intended for this slave device must be responded to within 500 milliseconds.

ENH Serial Control - Starting the compressor using serial communications can be accomplished

only if RC, Remote Control, is set to Modbus control. See Section12

For Modbus control commands to operate, the Status Register (1) bit 0 must be set High for all Status Register write commands to enable and maintain Host control. To remain in Host control mode, serial communications (any serial communication) must be maintained with a maximum of 2 seconds between communications. If for any reason serial communications is lost (not accessed within 2 seconds), the compressor reverts to Local control and continues to run using the local set points.

The compressor is started by placing the compressor in Host Control, Status Register 1, bit 0 to a 1 (Host), and bit 1 to a 1 (Run) or a Hex 03 command. This will start the compressor and place it in a run condition. If the pressure is such that the compressor needs to run (depending on the mode of operation) the compressor will start and run until the compressor no longer needs to run to maintain pressure. When the compressor is in a run mode, but no longer needed to make air, the compressor motor will be stopped in “Auto Restart” but will restart any time air is needed. Local Control stopping should always remain active and of the highest priority for safety of the compressor. If the compressor is stopped locally, all remote control operation is cancelled The Units of Measure for the Pressures read serially will always be read in PSI and temperatures in Deg F.

Page 27

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. The machine will only load/unload without ever

stopping the motor.

1.9 Eiger Maintenance Intervals STD Multiple level maintenance intervals STD 150 Hours Runtime -150 Hrs after the initial start-up of the compressor, one time timer. STD 2000 Hours Runtime - 2000 hours of compressor runtime since the last maintenance timer reset. STD 8760 Hours Real Time Clock Time - (1Yr) after initial startup of the compressor or after the

maintenance timers have been reset.

STD Maintenance Indicator - How to display time to maintenance; the maintenance timer will display

the maintenance timer value in hours and in percentage, (2000 or 8760) closest to reaching its respective predetermined maintenance interval time. Once the maintenance timer value reaches 10% (or 90%) of the preprogrammed time, (1800 hrs of runtime or 7884 hours clock time) the Wrench Icon will flash. Once the maintenance timer value reaches 0% (or 100%) of the preprogrammed time, (2000 hrs of runtime or 8760 hours clock time) the Red LED will flash (Warning) and wrench icon should be on continuously and remain on until maintenance is performed and the timers are reset.

STD Reset Maintenance Timer - Once service has been performed the Maintenance Timer values

can be reset by entering the Factory Setup Menu and scrolling to the Maintenance Timer Reset screen and performing the reset. If for any reason a time other than 2000 hours needs to be entered it can be done in the Maintenance rest menu. Simply set the hours wanted and press enter.

Page 28

Maintenance

Page 29

Maintenance

Page 30

Maintenance

Page 31

S3 Controller Input/Output Overview

AI = Analog Input DI = 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” clear key. The trips will remain on the display until acknowledged. The trips displayed will take precedence over the warnings. A log will be retained of the warnings / trips that have occurred.

Trip Faults Comments

ENH Motor Reverse Rotation - Sump pressure has not indicated a positive pressure, 2 seconds

after the machine has loaded, first time after a power-up. This time is increased to 6 seconds if the soft starter option is turned on. Once correct motor rotation is verified, this is not checked again until power is removed from the controller.

STD Emergency Stop - Emergency Stop low level contact has opened. STD Motor Overload - Main motor or Fan motor Overload contact has opened. STD High Package Discharge Pressure – refer to table in section 12 - (Not Adjustable, Information

Only)

STD High A/E Discharge Temperature - refer to table in section 12 - (Not Adjustable, Information

Only)

STD Low Ambient Temperature - The air-end temperature sensor is measuring a temperature less

than 2°C. The compressor will be in an alarm state and not start if the temperature is below 2°C. The compressor will start if the temperature is above 2°C. This is only active if Low Ambient, LA, option is installed.

ENH Low Sump Air Pressure - The sump air pressure has not increased above 15 psi. This is

measured 15 seconds after starting and operational anytime the compressor is running.

ENH High Sump Air Pressure - refer to table in section 12 (Not Adjustable, Information Only) STD Discharge Pressure Sensor Failure - The discharge pressure sensor input reading is beyond

the normal measurement range below 3.4 ma or above 20.8 ma.

ENH Sump Pressure Sensor Failure - The sump pressure sensor input reading is beyond the

normal measurement range below 3.4 ma or above 20.8 ma.

STD / ENH Sensor Calibration Failure - A sensor calibration has been attempted and the measured

value is outside of the +/- 10 % Full Scale value.

ENH Motor PTC Trip The motor TC is open due to high motor Temperature.

Warning Faults

STD High Package Discharge Pressure - refer to table 12 (Not Adjustable, Information Only) ENH High Sump Pressure – refer to table 12 (Not Adjustable, Information Only) STD High Air end Discharge Temperature - refer to table 12. (Not Adjustable, Information Only) STD Maintenance Due soon - refer to table 12 (Not Adjustable, Information Only) STD Maintenance Due immediately - refer to table 12 (Not Adjustable, Information Only) ENH Change Oil Filter - ENH Change Inlet Filter - ENH Change Separator Filter - ENH Integral Sequencing Communication Failure -

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. The icon and button oval are not raised.

Fault Symbols

LED Indicators - Green - On when the compressor is running and no fault conditions are detected.

“Ready” Off when the compressor is in a Shutdown - Faulted condition. Off when the compressor is not running.

Red - Flashing indicates a Warning condition. (Along with the Green LED still illuminated). On Solid

indicates a Shutdown condition.

Page 34

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

------------------Change Oil 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.

Compressor Running Unloaded (Manual Unloaded)

Compressor Running and Loaded (Flash Icon when the compressor is Unloaded due to pressure)

Remote Control Active

Disch Press Below Load Set point

Disch Press Between Load and Unload Set points

Disch Press Above Unload Set point

Stopped Auto Restart

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. Package Discharge Pressure with Units should be continuously displayed for all Status and Setup displays.

Satus screen Data in Yellow will only be displayed is ENH

Default Ae: 0 0 0 0 °C Airend Discharge Temp

(1) Ip: 0 0 0 0 PSI Sump Pressure (2) DL: 0 0 0 0 PSI Delta pressure DL will not be displayed while running unloaded

(3) Rn: _ _ _ _ 000 Run Hours ------------------------------------------

(4) Ld: _ _ _ _ 000 Load Hours -------------------------------------------

(5) Mn _ _ _ _ 000 Maintenance Hours (before Maintenance due) -

(6) Mn _ _ _._ Maintenance % (% of hours before Maint due) --------------- (7) IS_ _ _ _ Displays the number of hours before Sequencing occurs if IS is enabled

Setup screen Data in Yellow will only be changeable in an ENH controller. The data will be viewable in a STD controller.

Page 37

Setup Display - The Setup Display is entered by pressing the Menu button while the compressor is 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.

Un: 0 0 0 0 PSI Unload Pressure -------------------------------------------

Ld: 0 0 0 0 PSI Load Pressure --------------------------------------------

As: 0 0 0 0 SEC Unloaded Run Timer ------------------------------

Md: _ _ _ _ On_ Modulation On/Off ------------------------------------------

Eu: _ _ _ _ _°C Engineering Units

Dt: 0 0.0 0 _00 Current Date

Tm: 0 0:0 0 _ _ _ Current Time ------------------------------------------

Setup screen Data in Yellow will only be changeable in an ENH controller. The data will be viewable in a STD controller.

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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. The Status Icons should be displayed as the recorded status

he machine was in when the Trip occurred. The following information will be automatically scrolled through for each Trip.

Fc: _ 0 0 1 _ _ _ Fault Code Pd: _ _ 6 5 PSI Package Discharge Pressure Ae: 2 2 1.0 °F Airend Discharge Temperature Rn: _ _ _ _ 1 2 3 Run Hours Sp: _ _ 6 9PSI Sump Pressure Dt: 1 0.3 0 _06 Date Tm: 1 0:0 5 Time

Advanced Setup Menu - If the Password entered in the Pass Code entry screen is 0 1 0 1, the

Trip History display is entered by pressing the Up arrow from the Shutdown History display. Pd: _ C A L _ OK Package Discharge Pressure

Transducer Calibration

Ip: _ C A L _ OK Sump Pressure Transducer

Calibration

: 0 0 0 0 SEC Star Delta Time --------------------------------------------

Sf: 0 0 0 0 SEC Soft Starter Time ---------------------------------------------

Cd: 0 0 0 0 SEC Condensate Drain Time -------------------------------------------

Ci: 0 0 0 0 SEC Condensate Interval Time -----------------------------------------

Sd: 0 0 0 0 Service due Timer --------------------------------------

Ss: _ _ _ _ OFF Scheduled Start Stop --------------------------------------

On/Off

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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 --------------------------------------

Cn: 0 0 0 1 Multi 485 Compressor # -------------------------------------

Ad: 0 0 0 1 _ _ _ Modbus Address --------------------------------------

Bd: _ _ _ 9 6 0 0 Modbus Baud Rate --------------------------------------

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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.

T Indicates Trip

T20 Motor PTC Trip

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Warnings - Red Alarm LED flashing, green LED on

W Indicates Warning

Environmental Requirements -

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.

All units shall be designed such that the package can operate

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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. This will allow the coolant temperature to rise above an allowable level before loading the compressor in cold environments. When the Low ambient option is not installed the machine will not start if the A/E Discharge Temperature is below 2°C. The machine will trip on a Low ambient fault. This trip will be logged in the fault table. The user can re-start the compressor by holding the start button in for 10 seconds. Each time the compressor faults on a Low Ambient trip the customer will have to manually restart and the trip will be recorded in the fault table.

STD Power Out Restart - At loss of power to the machine, a software or hardware flag is set

indicating the operational status of the compressor. Once power returns, the flag is evaluated and the compressor is returned to its previous operational state. PORO when enabled will be active in all Local and Remote control modes of the compressor. For PORO to execute, the PORO option must be installed and the PORO enable must be set to ON in the factory set-up menu. The customer then has visibility to turn off/on and set the time delay of the PORO option in the advanced set-up menu. Assuming this is the case, if power is lost to the compressor while the unit is running or is stopped in auto start/stop, the control will store in memory the current operating conditions. When power returns to the unit, the control will first verify the PORO option is installed, enabled and turned ON. Next the control will check to see if the unit was running or stopped in auto start/stop when power was lost. If it is determined this was the case, it will start the PORO sequence. The control will energize the PORO horn and start a count down on the display. The RED light will flash indicating a Warning condition and the horn will blow for the number of seconds (see table 12) the operator set in the PORO time set point. At the end of the count down the horn will stop blowing and the compressor will start. The PORO count down can be stopped at anytime by pressing the Stop / Reset button on the user interface. Pressing any button will cause the horn to stop blowing and the count down to stop. The control will power up normally in a ready to start mode. If unit is being operated using remote control, the compressor will not automatically restart after power returns if PORO kit is not installed.

ENH Scheduled Start / Stop - This is an auto start / stop mode of operation based on the Real

Time Clock current time. A Scheduled Start Time set point is used to automatically start the compressor when the current time equals the Scheduled Start Time entered for the set point. A scheduled Stop Time set point is used to automatically stop the compressor when the current time equals the Scheduled Stop time entered for the set point. This mode of operation can be turned on and off by selecting the desired mode in the Scheduled Start Stop

On/Off Set point, When Scheduled Start/Stop is turned on and the current time equals the Scheduled Start Time set point, and the compressor is not currently running, the compressor will automatically activate the output for the PORO horn for 10 seconds (hard coded) to warn anyone in the surrounding area that the compressor is about to start.

The UI will display a Warning message “Scheduled Start in X seconds”. X is a countdown from 10 to 0 seconds. After 10 seconds the compressor will automatically start as long as the compressor is not in a Fault condition or manually stopped by pressing the Stop / Reset button. When Scheduled Start/Stop is turned on, and the current time equals the Scheduled Stop Time set point, and the compressor is currently running, the compressor will automatically stop. The compressor can

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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. This is possible through a cable connecting, up to three Intellisys S3 controllers, and using one of the controllers as a system controller.

MODULATION CONTROL OPTION

Modulation hardware extends the control types to Modulation (capacity control) and Automatic Control System when the compressor switches between ’On/Off line’ and modulation as demand varies. Safety of operation is provided for as the compressor will shut down if excessive temperatures, electrical overload conditions, or system over pressure should occur.

For those plants which have relatively high constant air demand relative to the compressor capacity, the recommended control mode is modulation. The modulation control system retains the features of the on-line / off-line control, but also provides for throttling of the inlet flow up to the off-line air pressure set point value. By applying line pressure to an adjustable modulator valve, the throttling position of the inlet valve is controlled, thus allowing the modulator to ”trim” the inlet valve position as dictated by the line pressure. The modulating pressure range is about 0.3 bar (4.0 psid) and the modulator normally should be set to straddle the compressor rated pressure. Modulation begins when the line pressure reaches about 99 percent of the compressor rated pressure and continues as/if the line pressure rises. Modulation becomes stable when the compressor output equals the plant air demand. When the modulation is at the factory setting, the maximum capacity reduction will be approximately 60 percent of the compressor rated capacity (as indicated in Figure 1).

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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. Connect a pressure gauge to outlet port of modulation valve with 1/4” tubing tee.

3. Loosen the adjustment screw locknut and back out adjusting screw 3 turns. See Figure 2

4. Put the main power disconnect switch in the ON position.

5. Open the isolation valve and start the compressor.

6. Adjust the isolation valve to bring the discharge air pressure to the rated discharge pressure (100, 125, or 140 psig).

7. While maintaining the rated discharge pressure, turn the adjustment screw on the modulation valve (see Figure 2) so that the test pressure gauge reads:30 psig for modulate 60% capacity Tighten the adjustment screw locknut.

8. Press UNLOADED STOP. Wait for sump pressure to go 0 psig. Close the isolation valve or vent off all system air.

9. Put the compressor in the desired control mode.

10.Remove the test pressure gauge and replace 1/4” plastic plug.

Table 12

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