INGERSOLL-RAND AIR COMPRESSORS INGERSOLL-RAND Ur RE} eo Original Intellisys SE &SG Problems Procedures Warranty Information APDD 749 September 1909SSR INTELLISYS ROTARY TROUBLESHOOTING GUIDE The following is a guide to be used when identifying the root cause of a compressor problem. Forms have also been developed for the SE and SG controller and must be filled in if the controller is to be returned to the factory under warranty. Any controller retumed to the factory must have all shaded areas of the form filled in completely and a copy of the form sent with the controller. Flowcharts follow the forms. Use the flow charts to help identify the root cause. Not all flowchart pages pertain to all controllers. Look in the top left corner to see What controllers the particular page covers. ORIG = Original Intellisys controller SSR 50-450HP SE = SE Intellisys controller SSR 20-100HP. SG = SG Intellisys controller SSR 125-450HP- FSM = Field Service Manuals 9/16/'99 Rev STABLE OF CONTENTS INTRODUCTION... TABLE OF CONTENTS. HOW TO USE vsnnennnsnone SE INTELLISYS CONTROLLER WARRANTY INFORMATION SHEET. SG INTELLISYS CONTROLLER WARRANTY INFORMATION SHEET... PROBLEMS ‘SE CONTROLLER - SHUTS DOWN WITH READY To START INTHE ISLAY, 7 ‘SG CONTROLLER - SHUTS DOWN WITH READY TO START IN THE DISPLAY. ronson semen ORIGINAL, SE, SG - CONTROLLER LOCKS-UP os snenne ORIGINAL, SE SG - TRAC DOES NOT OPERATE PROPERLY 10 ORIGINAL, SG - CxEcK INLET CONTROL SYSTEM ALARM. u ORIGINAL, SG - CHECK INLET CONTROL ALARM 12 ORIGINAL, SE , SG - LOW UNLOADED SUMP ALARM, 2B ORIGINAL, SE | SG - HIGH SUMP PRESSURE ALARM . sons 14 ORIGINAL, SE | SG - HIGH AIREND TEMPERATURE ALARM 15 ORIGINAL, SE , SG- Mary Motor OVERLOAD ALARM 16 ORIGINAL, SE , SG - STARTER FAULT ALARM, 17 ORIGINAL, STARTER FAULT ALARM CONTINUED. 18 SE , SG ~ NO CONTROL POWER ALARM o.com a rome ORIGINAL, SE , SG - CHECK MOTOR ROTATION ALARM. 20 ORIGINAL, SG - STEPPER LIMIT SWITCH ALARM sonsusnonnsninnnnnnannnn ioe ORIGINAL, SE , SG - REMOTE STOP FAILURE ALARM 22 ORIGINAL, SE , SG REMOTE START FAILURE ALARM... 23 ORIGINAL, SE , SG - SHORT SEPARATOR ELEMENT LEE . ns nana NOTES snennninnnninnneinninennenn sone rnd PROCEDURES 1.1 SE POWER OUTAGE Background 26 Procedure. " sca nic ininson sts 1.2 SE VOLTAGE SAG 26 Procedure, 26 1.3 GROUNDING PROBLEMS. Background, 27 Procedure... nat 1.4 SE INTELLISYS 16 VAC SUPPLY Background 29 Procedure, 29 15 SE EXTERNAL 5 VDC SHORT CIRCUIT Background, sonnei 30 Procedure, 30 ENVIRONMENTAL PROBLEMS 1.6 MOISTURE Background, o sn son vee se 3D Procedure aL1.7 TEMPERATURE Background Procedure 1.8 VIBRATION Background, Procedure OTHER 1.9 REMOTE ALARM APPLICATION Background... Procedure 2.1 STEPPER MOTOR TEST Background. Procedure... 2.2 DRIVER CHIP TEST Background Procedure 2.3 LIMIT BOARD TEST Background... Procedure . 2.4 PRESSURE SENSOR CHECK OUT Background Procedure 2.5 TRIAC OUTPUTS Backgrowné.... Procedure 2.6 AUXILIARY CONTACTS Background. Procedure... 3.1 SG POWER OUTAGE 3.2 SG VOLTAGE SAG. Background... Procedure. 3.3 SG INTELLISYS 24 VAC SUPPLY Background, Procedure, 3.4 SGEXTERNAL 5 VDC SHORT CIRCUIT Backgrowné.... Procedure... 4.0 EXTERNAL ELECTRICAL DISTURBANCES 5.0 MEMBRANE SWITCH CHECK Background, Procedure... Figue | - SE Membrane Schematic Figure 2 - SG Membrane Schematic Figure 3 - ORIGINAL Membrane Schematic. 34 34 a4 35 Al al 4u 43 46 46 46 a7 48USER INSTRUCTIONS Identify the problem that is being experienced with the controller or compressor. Locate the problem in the table of contents under the PROBLEMS section Tum to that page and follow the flow chart through the diagnostics. If the flow chart refers to another paragraph, find the paragraph number in the table of contents and turn to that page. Then follow any procedures within that section. EXAMPLE: Compressor is experiencing CHECK INLET CONTROL SYS alarm. Find CHECK INLET CONTROL SYS in the table of contents under the problems section. That refers to page 11. As you follow the diagnostics, the flow chart says to see paragraph 2.3. Find paragraph 2.3 in the table of contents. That refers to page 36 for background and procedure information. Turn to that page and follow any instructions.SE INTELLISYS CONTROLLER GENERAL INFORMATION Date: ‘Customer: Distributor: ‘Techaiviaa: ‘Machine SN: ‘Model Number Total Hows? ‘Loaded Hours ‘NEMA Rating ‘Starter Type: “Ambient Temp: ‘Start-up Date: ‘Problem Description (What, How, When}: INTELLISYS SE INFORMATION Tatellisys SIN EPROM Venion! (Ofline Pressure Oaline Pressure: “Mode of Operation: | Options: ‘Comm, Link: Last Alarm: POWER SUPPLY INFORMATION __ POWER ON Circuit ‘Test Point Expected Value “Measured Value Control Transformer | TL 200-575 VAC Primary VAC Conttol Transformer Secondary : 120 VAC 120 VAC 1-18 VAC Control Transformer Secondary : 16 VAC (center-tap) T6 VAC =" 2.4 VAC 8VAC 4-12 VAC S8VAC+/ 1.2 VAC Rectified Intellisys DC 10.5 VDC =" 1.6 VDC Intellisys Digital 5 VDC ‘SVDC += 2 VDC Intellisys Analog 5 VDC | 33-2524 SVDC=- 2 VDC Battery Voltage BAT =~ 30 VDC+- 6 VDC Ground Fault Current) | Customer Ground (0.0 Amps AC/DC Machine running in | conductor +/- 25 Amps AC/DC loaded condition see Paragraph 1.3 GROUND RESISTANCE CHECK INFORMATION _ POWER OFF Circuit ‘Test Point Expected Value “Measured Value Intellisys Ground Il, GND LUG =.5 Ohm 120 VAC Neutral TI, GND Lu, Motor Frame ‘Motor chassis, base SOhm ‘Sensor Ground ‘SAPT chassis, base Ohm Alrend Ground ‘Air end chassis, base lug | <.5 Ohm Package Ground ‘Machine Base, GND lug Customer Ground ‘Structural Earth, base lu UO RESISTANCE CHECK POWER OFF Pressure Black to GND = ohm 33 Connected to board | Green to GND 185 +/- 50 White to GND 850 ohm +/- 100 Temperature White to GND 140 ohm += 10@ 77F 32 Connected t0 board Digital TO Ne = Sohm Te) NO. > 1 meg obm (a) Only test wired contacts and list only connections out of rangeSG INTELLISYS CONTROLLER GENERAL INFORMATION Date: ‘Customer: Distributor: ‘Techaiviaa: ‘Machine SIN ‘Model Number Total Hows? ‘Loaded Hours ‘NEMA Rating! ‘Starter Type: “Ambient Temp: ‘Start-up Date: ‘Problem Description (What, How, When}: INTELLISYS SG INFORMATION Tatellisys SIN EPROM Venion Offline Pressure Oaline Prewure: “Mode of Operation: | Options: ‘Comm. Link: Tast Alarm: POWER SUPPLY INFORMATION _ POWER ON Cireuit Test Point Expected Value “Measured Value Control Transformer | TL 200-575 VAC +7 10% Primary VAC Control Transformer | PI-1,PI-10 Secondary : 120 VAC 120 VAC 4" 18 VAC Control Transformer | Power Supply Board | 24 VAC 4-36 VAC Secondary: 24VAC__| 31-1, 11-2 Reciified Intellisys DC | Power Supply Board | 12 VDC>-.6 VDC D122 Tntellisys Digital 5 VDC | P9-1.5 SvpC+= 2 VDE Tntellisys Analog 5 VDC | P5-7.8 ‘SWDC+= 2 VDC Pressure Signal @ 0 psi_| PS white to Black SVDC+" 1 VDC Battery Voltaze BAI ~ 3.0 VDC=- 6 VDC Ground Fault Current: | Customer Ground 0.0 Amps AC/DC Machine running in | conductor +/- 25 Amps AC/DC loaded condition see Paragraph 1.3 GROUND RESISTANCE CHECK INFORMATION _ POWER OFF Circuit ‘Test Point Expected Value “Measured Value Intelisys Ground IIS. GND LUG <.5 Ohm 120 VAC Neutral TI, GND Lug =.5 Ohm. Motor Frame Motor chassis, base lug | <.5 Ohm Sensor Ground BAPT chassis, base lug | <.5 Ohm LAVPT chassis, base lug | <5 Obm APT chassis, base lug _| <5 Ohm ‘Alrend Ground Air end chassis, base lug | <.5 Ohm Package Ground ‘Machine Base. GND lug | =.5 Ohm ‘Customer Ground ‘Structural Earth, base lug | =.5 Ohm UO RESISTANCE CHECY ___ POWER OFF Pressure = ohm. PS Connected to board 20K +/-3K Temperature White to GND ‘Temperature dependent P6 Connected to board | Black to GND <5 ohm NG. =F ohm 22_| No. >1 meg olim ‘Stepper motor Power Supply Board | 4° & 6” valve=5-7 Ohms connections J312 1334 8° valve = 11-13 Ohms (a) Only test wired connections and list only connections out of range.‘SE CONTROLLER: SHUT DOWN “READY TO START” MACHINE WAS OPERATIONAL AND IN THE RUNNING MODE. MACHINE STOPS AND DISPLAYS INCOMING VOLTAGE DIPS BELOW 20% | > ‘SERVICE APPLICATION, CHECK PHASE UNBALANCE, and SERVICE WIRE AMPACITY 16 WAC CIT FEED CIRCUIT INTERMITTENT TNTERMITTENTIMPROPER GROUND |] SEE PARAGRAPH 1s ‘CHECK CUSTOMER GROUND INTEGRITY. CHECK FOR FAULT CURRENT IN GROUND LEG. CHECK GROUND RESISTANCE BACK TO 14-29. INSPECT BOND INTEGRITY. SEE PARAGRAPH 13 INTERMITTENT SHORT ONS VDCANALOG_|—p| TATT- BLACK WIRE To GROUND = 1 MEG OFM ‘SEE PARAGRAPH 1S ‘OPTION PROM INTERMITTENT CONNECTION TOIL |_| ‘SEE PARAGRAPH IS [EXCESSIVE TEMPERATURE ¥ ‘REDUCE CONTROLLER AMBIENT T0 “16°F SEE PARAGRAPH 17 REMOTE ALARMTARENG |» » EXCESSIVE MOISTURE >i WATER LEAKING INTO CONTROLLER SEE PARAGRAPH 1.6 ol INTERMITTENT POWER OUTAGE | ‘PROBLEN WITH CUSTOMER POWER SUPPLY, SEE PARAGRAPH 11 Lo vipration |____»y ‘SEE PARAGRAPH 1S | +] BATTERY CONNECTION OR VOLTAGE |< VOLTAGE IS 30 VDC == 6 VDC L,I COMNOPOWERDETURANES | eranaaramaa‘SG CONTROLLER: SHUTDOWN “READY TO START” MACHINE WAS OPERATIONAL AND IN THE RUNNING MODE. MACHINE STOPS AND DISPLAYS |_,] iNcoMiNG VOLTAGE Dips BELOW 30% |___p[ SERVICE APPLICATION, CHECK PHASE UNBALANCE, and SERVICE WIRE AMPACITY |g] 2a Vac Crt FEED CIRCUIT INTERMITTENT SEE PARAGRAPH 33 ‘CHECK CUSTOMER GROUND INTEGRITY. CHECK FOR FAULT CURRENT IN GROUND po steamer intrnorer aroun |} 6. CHECK GROUND RESISTANCE BACK 10 1429. INSPECT BOND INTEGRITY SEE PARAGRAPH 13 TATT- BLACK WIRE To GROUND = 1 MEG OFM |_,[ TNTERMATTENT SHORT ONS WDC [5] sarr-RED Wine To GROUND <1 MEG oF ‘SEE PARAGRAPH 34 |_,/ ormion Rost INTERMITTENT CONNECTION TOIL |__| see raracnariss p[ EXCESSIVE TEMPERATURE p[ REDUCE CONTROLLER AMBIENT TO | —>[ REMOTE atanst anemia | > TsSURE PROPER SUPPRESSOR SEE PARAGRAPHEL9 p[ EXCESSIVE MOISTURE >i WATER LEAKING INTO CONTROLLER SEE PARAGRAPH 1.6 |_,[isrersarmextPoweR ourace |__| PROBLEM WITH CUSTOMER POWER SUPPLY. SEE PARAGRAPH. 1 “1 | —______ > |_,[vipration ‘SEE PARAGRAPHS + BATTERY CONNECTION oR VOLTAGE |____ [00K Fox CORROSION ON THE BATTERY TEIOENAL, VERIFY THAT op] NCONENG POWER DISTURBANCES ‘SEE PARAGRAPH AOORIGSESG: CONTROLLER LOCK-UP, UNIT WILL NOT STOP (OR READY TO START WILL NOT START LUSITRUNNING. PUSHING THE STOP BUTTON DOES NOT CAUSE ANYTHING TO AND PRESSING THE START BUTTON DOES NOT CAUSE START OR ALARM, CYCLING POWER WILL RESET BUT PROBLEM OCCURS AGAIN. SE CONTROLLER ORIGINAL INTELLISYS SG CONTROLLER 16 VAC C1, FEED CIRCUIT INTERMITTENT + 14.29.30, 31 SEE PARAGRAPH 1 | TiS VAC FEED CIRCUIT INTERMITTENT ¥ CHECK WIRING AND ¥ Hea T Fa ‘SEE PARAGRAPH, [BAD MEMBRANE ¥ TDEWAC FEED IRCUT INTERMITTENT ¥ ‘CHECK WIRING FROM TI Ton-182 SEE PARAGRAPH 33, BAD MEMBRANE SIT LOOVAG, 1 USESETO MEMBRANE TEST KIT TO VERIFY COMMPORT = TEST MEMBRANE ‘NO PROBLEM WITH TI SEE PARAGRAPH so ¥ ‘YES. CHECK VOLTAGE AT TRANSFORMER TS AND CONNECTION 31 2&4 SHOULD BE 6-7 VAC 313.85 SHOULD BE 627 VAC IF NOT, BAD T3 TRANSFORMER REDUCE CONTROLLER AMBIENT TO-160'F SEE PARAGRAPH 1.7 LEAKING INTO CONTROLLER. SEE PARAGRAPH 1.6 “SEE SHEET FOR BLANK DISPLAYORIGSESG: TRIAC IS ON AND SHOULD BE OFF OR a ‘SE CONTROLLER ORIGINAL INTELLISYS SG CONTROLLER SEEPARAGRAPH2S ‘SEEBLUE FSMSECTION SHEET 25 USESENO TEST RIT‘ORIG SG CHECK INEET CONTROL SYS VALVE COMMANDED TO MOVE TO OPEN OR CLOSED LIMIT SWITCH AND CONTROLLER NEVER —— ‘YES. SUSPECT BAD OFEN LIMIT SWITCH ‘CONFIRM 24 VAC TOBOARD Se cent 3 DID VALVE MOVE FAST ‘THE OPEN LIMIT SWITCH? sy[YES._ SUSPECT BAD CONTROLLER “lea araaaonarae ‘THE OPEN LIMIT SWITCH AND STOP? SN [BAD STEPPER MOTOR, SEE PROCEDURE 2.1 BAD DRIVER CHIP. SEE PROCEDURE 2.2 IP NONE OF THE ABOVE THEN PROBABLY A UNLOADING AT STARTING AFIER TRANSITION YES. SUSPECT BAD CLOSED LIMIT Z swiren DID VALVE MOVE PAST THE [>] crosep taar swires YES SUSPECT BAD CONTROLLER NY oe YES. MAKE SURE BLOW DOWN ‘NO,_ DID VALVE MOVE TO THE DEFLECTOR Is IN PLACE. IF NECESSARY, CLOSED LIMIT SWITCH AND STOP? | BEND DEFLECTOR TO DEFLECT AIR NY HITTING THE VALVE PLATE AND KEEPING IT FROM MOVING. NO. SUSPECT SLIPPING COUPLING. fF 2 ‘BAD DRIVER CHIP. SEE PROCEDURE 22 IF NONE OF THE ABOVE THEN PROBABLY ABINDING INLET VALVE. SUSPECT SLIPPING COUPLING, xO. “SL BAD STEPPER MOTOR, SEE PROCEDURE [BAD DRIVER CHIP. SEE PROCEDURE 2.> IF NONE OF THE ABOVE THEN PROBABLY‘ORIG, SG: CHECK INLET CONTROL | ~UNITUNLOADED AND INLET VACUUM LESS THAN THREE PSL UNE YESS THE AIREND TURNING? NO. SUSPECT SLIPPING GEAR ‘UNLOADED | if sirarasier carve crane 'NO,_ ORIGINAL CONTROLLER - CHECK FOR SLIPPING SG CONTROLLER - CHECK POSITION OF CLOSED LIMIT SWITCHNO, _ SUSPECT SLIPPING COUPLING BAD STEPPER MOTOR. SEE PROCEDURE 2.1 SYSTEM If NONE OF THE ABOVE THEN PROBABLY ABINDING INLET VALVE IF 0k. I BLOWDOWN AIR CAUSING THE VALVE TO CLOSE TOO FAR? NY DEFLECTOR IS I PLACE, PSECESSARY, BEND DEFLECTOR TODEFLECT AIR UPWARD, t x UNLOADED OR STARTING | _ [CHECK SENSING LINE TO 3APT AFTER TRANSITION [| AND SENSOR 2APT. SEE PROCEDURE 24 FD SE CONTROLLER oN IF NOT OK, THEN REPAIR AND RETEST TBLOCKAGE IN SENSOR LINE FROM SUMP ¥ FULL VOLTAGE? VESOR ‘NO._ CHECK BLOW DOWN SILENCER ADIUSIMENT. ¥ [MA PORTS INLET VALVE AE OPEN YES. CHECK FOR INLET VALVE STUCK CLOSED OR BROKEN SPRING IN INLET VALVE‘ORIG, SG, SE: HIGH SUMP PRESSURE | ~ SUMP PRESSURE IS GREATER THAN 15 PSIG ABOVE THE RATED PRESSURE OF THE UNIT, BYPASS OR BAD AIR, FILTER {> [ LOGGED SEPARATOR ELEMENT \WATERIN THE SYSTEM ‘WATER IN THE SYSTEM CAUSING CORROSION IN THE A VALVE, [>| STICKING MINIMA PRESSURE CHECK VALVE BLOCKAGE OR LEAK IN SENSING ENE TO AFT | ——p| CHECK SPECIAL TEE ON TOP OF MOISTURE na SEPARATOR WHERE 4 APT CONNECTS ‘OLD STYLE INLET VALVE SLIPPING COUPLING FAULTY 4APT SENSOR ‘ SEE PROCEDURE 24 t BLOCKAGE IN SENSING LINE TO 10S BROKEN SPRING RVINEET VALVE t ISVSHILL ENERGIZED, STICKING OR LEAKING AIR SIGNAL TO OPEN INLET ‘VALVE. BLOWDOWN VALVE NOT OPENING FULL VOLTAGE! YES ORNO ¥ STICKING INLET VALVE, BLOWDOWN VALVE NOT OPENING.(ORIG, SG, SE: HIGH AIREND TEMFERATURE | = aIREND DISCHARGE TEMPERATURE EQUAL TO OR GREATER THAN 228°F Saaz ae DOES UNIT SHUTDOWN IN LESS THAN 10 SECONDS AFTER START-UP? | ] YES. SUSPECT FROBLEM WITH COOLANTSTOP VALVE ‘AIR-COOLED = BAD ENVIRONMENT o WATER COOLED = BAD WATER FOULING TUBES | ——f oiery coorees | ENTERNAL COOLANT LEAK CAUSING ‘AIR-COOLED HEAT EXCHANGER TO CLOG WITHDIRT RESTRICTIVE EXHAUST DUCTING 25" WATER COLUMN HIGH AMBIENT }———> anove 1isF |e] Facury THERMOSTATIC VALVE [>[ 1S THE VALVE BYPASSING THE COOLER? |» [enn emearon ane? |] —»] Swarwit aa on qUICK DETERMINATION BOTS) (CHECK FOR HIGH MOTOR ANS UNUSUAL NOISE > FAULTY AIREND >|‘ORIG, SG, SE: MAIN OR FAN MOTOR OVERLOAD = OVERLOAD CONTACT OPEN FOR MORE THAN ONE SECOND, PLACE OVERLOAD RELAY IN MANUAL RESET MODE ‘NO. POTENTIAL PROBLEM WITH WIRING FROM OVERLOAD TO CONTROLLER OR CONTROLLER. ORIGINAL & SE INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE VDC WHEN OVERLOAD RELAY THE PROPER SIZE? |_| (MAIN MOTOR, ORIG BTS? 1011, SELJI [S&6 FAN MOTOR. ORIG. BTS2 S89. E11 3814) SSGINTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 10-12VDC WHEN CONTACT IS OPEN AND 0 VDC WHEN CONTACT IS CLOSED x YES, DID OVERLOAD RELAY REQUIRE RESETTING BEFORE BEING ABLE TO. RESET THE INTELLISYS CONTROLLER? YES ARETHE AMPS LESS THEN 99% NOMINAL (MORE THAN 1% UNBALANCE, YES__ CHECK FOR LOW VOLTAGE, > VOLTAGE UNBALANCE OVERPRESSURE TIGHT AIREND 5 SarAEES TOSS OF STAGE ON2 STAGE UNIT NO__IS THE STARTER ENCLOSURE HOTTER THAN NORMAL? || STARTING UNDER A Lo, BADCONNECTION BURNT CONTACTOR Tt YES. CHECK FOR BAD CONNECTIONS AND MAKE SURE CONDUIT FROM MOTOR IS NO. _ ARE THE TEMPERATURES OF THE THREE INET VAEVEMODCLOSED STARTER POLES THE SAME OR ARE THEY HOTTER ‘THAN 160°F? ANY SIGNS OF HOT SPOTS ON STARTER? ‘YES._BAD CONNECTION WITHIN THE STARTER NO. POTENTIAL PROBLEM WITH OVERLOAD RELAY, CONTROLLER, OR RIBBON CABLE ON ORIGINAL INTELLISYSORIG. SG, SE YES, DOES UNIT SHUT DOWN INLESS STARTER FAULT | q| THAN [2 SECONDS AFTER START-UP? 21°F AT TIME OF SHUTDOWN? 1S THIS THE ORIGINAL INTELLISYS CONTROLLER? in _E ETASO T YES,_IS COOLANT LEVEL CORRECT? No, AN CONTROLLER Ys, SPECT PORE WHTH COOLANT TOP VALNE FE ORG peELLisys Cice WIRNG ee ‘THE START BUTTON IS PRESSED? Soares ‘NO_POTENTIAL PROBLEM WITH TRIAC ON STARTER INTERFACE BOARD, YES. DOES THEUNIT SHUTDOWN 23 SECONDS AFTER 1S AND IM ENERGIZED? ‘YES. POTENTIAL PROBLEM WITH WIRING OR AUXILIARY CONTACTS IMs OR 1S SE & ORIGINAL INTELLISY'S: VOLTAGE ACROSS CONTACT SHOULD BE 5 VDC WHEN CONTACT IS OFEN AND 0 VDC WHEN CONTACT IS CLOSED. CONTACT IS OFEN AND 0 VDC WHEN CONTACT IS CLOSED. SEE PARAGRAPH 26 ENERGIZE AT TRANSITION (10 SEC)? WA | IS contactor Sticks 08 AUNILIARY CONTACT 1S+ OR 84 ‘YES _ POTENTIAL PROBLEM WITH WIRING OR AUNILIARY CONTACTS [Ss OR 23a SE & ORIGINAL INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 5 VDC WHEN CONTACT IS OPEN ANDO VDC WHEN CONTACT IS CLOSED. SG INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 10-12 VDC WHEN CONTACT IS OPEN ANDO VDC WHEN CONTACT IS CLOSED. SEE PARAGRAPH2.6FROM STARTER FAULT CHART ‘ORIGINAL INTELLISYS CONTROLLER TERMINAL BTSI-38 AND BIS1-3 ¥ 1S THE VOLTAGE GREATER THAN Havact? NO BAD CONTACT ONE-STOP YES MEASURE VOLTAGE AC I Ho VAC? ‘NO.BAD ATS TERMINAL BTSI-29 AND BTS1-3 ¥ ‘DOES VOLTAGE CONTINUOUSLY READ 110-130 VAC AT TIME OF as [of YES. CHECK FOR BAD CONTROLLER OR RIBBON CABLE, RECHECK STARTER SHUTDON SEQUENCE ¥ "NO_ CHECK FOR PHASE MONITOR OR ANY OTHER SHUTDOWN WIRED TOBTSI-33 629SG SE-NO CONTROL POWER |= 1/5 VOLTS ACISNOT APPLIED TO THE CONTROLLER BUT CONTROLLER IS POWERED-UP. ‘SG CONTROLLER: ‘SE CONTROLLER: MEASURE VOLTAGE AC TERMINAL BTSI-6 AND 5-3 ¥ ¥ TS THE VOLTAGE GREATER THAN 1S THE VOLTAGE GREATER THAN lio vac? Havact? ‘THE TRANSFORMER IS BAD. ‘THE TRANSFORMER IS BAD a eee one I a aaa TERE oy iad ‘NO. BAD CONTACT ONE-STOP ‘NO, BAD CONTACT ONE: STOP YES_ IS AIREND DISCHARGE TEMPERATURE GREATER THAN ZO AT TIME OF SHUTDOWN? DOES UNIT SHUT DOWNINLESS No A ao SE CONTROLLER: ‘SG CONTROLLER: [MEASURE VOLTAGE AC MEASURE VOLTAGE AC YES, IS COOLANT LEVEL CORRECT? TERMINAL BTSI-S AND 1629 | | PL-10 AND TERMINAL ITB-4 4 = ‘YES,_ SUSPECT PROBLEN WITH COOLANT STOP VALVE, DOES VOLTAGE CONTINUOUSLY ee ee ere ory | | CHECK WIRING AND VALVE OPERATION (SEE READ 110-130 VAC AT TIME OF SHUTDOWN? SHUTDOWN? PROCEDURE? 5) YES__ SE CHECK FOR PHASE MONITOR SG: CHECK FOR INTERSTAGE PRESSURE SWITCH ON 2 STAGE OR PHASE MON‘ORIG, SG, SE: CHECK MOTOR ROTATION _ | =NO INLET VACUUM SENSED 2 SECONDS AFTER STARTING. t ‘SE CONTROLLER: NO SUMP PRESSURE SENSED 2 SECONDS AFTER STARTING IS THE ROTATION CORRECT? NODC: AND TRY AG. ECT, LOCK AND TAG POWER IN OFF POSITION INTERCHANGE TWO LEADS TRG NDSG CONROE | No STE MOTOR TURNING? ISTHE AIREND TURNING? ‘NO. CHECK VOLTAGE, SE CONTROLLER J STARTER AND MOTOR x : ‘YES, CHECK FOR LEARIN AVF YES, ARE THE 15 THE AIREND TURNING USanC ENE Grist ny ator Spe GEARS SPINNING ON PROCEDURES! THE SHAFT? YES. CHECK FOR LOCKEDUP [NO,_BROKEN AIREND DRIVE SHAFT YES. IS WSVENERGIZINGATSTART? NO CHECK THE TRIAG, WIRING ORBAD 10 ‘YES, ARE THE BELTS SLIPPING? NO. BROKEN AIREND DRIVE SHAFT YES _TIGHTENTHE BELTS| ‘YES. _ CHECK FOR BLOCKAGE IN SENSING LINE FOR 10S TO SUNP‘ORIG, SG: STEPPER LIMIT SWITCH + {OTH LIMIT SWITCHES ARE ENGAGED AT THE SAME TIME, ‘ORIGINAL BNTELLISYS CONTROLLER: IS THE VOLTAGE SDC? — ‘SG INTELLISYS CONTROLLER: IS THE VOLTAGE 2vDc? NM a No_ POTENTIAL PRORLEW wit $OcaecKron OBLENT CSernorEER Move RED tae To ‘issnton canton TERMINAL STON PS AND MEASURE Coenen WouTAct aca ¥ SS MEASURE VOLTAGE BETWEEN BE VOrTAGENDS? ure ssp stack wine Metre SD BLACK WIRE TESURS VoLEAGe BEFEEN MEASURE VOLTAGE BETWEEN yee GREEW AND BUCK WIRE Gres sD Bt ACK WIRE Ts watawr_][ so pores wan I i a as Soak on wine me =a fd I YE] [ ho. THEN VOU ane FevSHED pEreer Eee ‘NO. POTENTIAL PROBLEM WITH YES, _ CHECK FOR DIRT RIBBON CABLE OR CONTROLLER || YES: CHECK FOR DIRT BAD LIMIT BOARD, ‘NO. POTENTIAL PROBLEM WITH RIBBON CABLE OR CONTROLLER.‘ORIG, SG, SE| REMOTE STOP FAILURE] REMOTE START BUTTON IS PRESSED WHILE REMOTE STOP CONTACT IS STILL OPEN. ORIGINAL INTELLISYS CONTROLLER SG INTELLISYS CONTROLLER [semen contmoceen ] + + ¥ MEASURE VOLTAGE BETWEEN BTS1-6 AND BTS27 BETWEEN 3 TERMINAL 19 &2 SEAS VE a IS THE VOLTAGE ovDCr YES_TRY REMOTE START AGAIN IF ALARM STILL OCCURS, SUSPECT PROBLEM ORIGINAL INTELLISYS CONTROLLER OR JUST THE CONTROLLER FOR THE SG. ‘NO, SUSPECT REMOTE STOP CONTACT IS STILL OPEN, CORRECT PROBLEM AND TRY AGAIN, TO SIMULATE A CLOSED STOP CONTACT,(ORIG, SG,SE:_ REMOTE START FAILURE ¥ = REMOTE START BUTTON IS PRESSED AND HELD CLOSED FOR MORE THAN 7 SG INTELLISYS CONTROLLER: LOAD UN. STOP UNIT USING REMOTE STOP BUTTON, VOLTAGE FROM ABOVE VOLTAGE SHOULD CHANGE FROM 5 VDC TO 0 VDC WHILE THE TWO SECONDS AND NO LONGER THAN 7 SECONDS, ‘CONNECT DC VOLT METER TOPS TERMINAL 21 & 22 START UNIT USING REMOTE START BUTTON AND MONITOR VOLTAGE FROM ABOVE, VOLTAGE SHOULD CHANGE FROM 10-12 VDC TO 0 VDC WHILE THE BUTTON Is PRESSED AND RETURN TO 1012 VDC WHEN THE BUTTON ISRELEASED. ‘YES. SUSPECT STICKING CONTACT ON REMOTE START BUTTON OR PLC. ‘SE INTELLIYS CONTROLLER ‘NO. TRY REMOTE START AGAIN. IP ALARMSTILL OCCURS, SUSPECT PROBLEM. WITH INTELLISYS CONTROLLER. ‘CONNECT DC VOLT METER TON TERMINAL 5&6 VOLTAGE FROM ABOVE, VOLTAGE SHOULD CHANGE FROM 5 VDC TO 0 VDC WHILE THE ISRELEASED,(ORIG, SG, SE: SHORT SEPARATOR ELEMENT LIFE THIGH PRESSURE DIFFERENTIAL? of ves + ainassse REET TER Ge ‘NO. _ LOW DIFFERENTIAL OR COOLANT CARRY OVER A BaD Mercy sf BAD OROLD COOLANT p[ WATERIN THE COOLANT ‘HOLE IN THE ELEMENT ‘UNIT QUICK CYCLING ‘CLOGGED SCAVENGE ORIFICE OR SCREEN UNITRUNNINGTOO COLD ‘CLOGGED SCAVENGE ORIFICE [Por screey TLEAK IN WATER COOLED COOLANT COOLER SCAVENGE TUBE T00 SHORT FOR ELEMENT ‘CRACKED BAFFLE IN SEPARATOR TANK ‘SCAVENGE TUDE TOO SHORT FOR ELEMENTUSE THIS PAGE FOR NOTES:4.1 Power Outage: Background Power outage may have occurred during operation. Any power outage in excess of 250 ms (.25 sec) will cause the control circuit to reset. This can occur in installations with automatic reset circuit breakers. Electrical disturbances can also occur from power company interruptions such as lightning storms. This loss of power will de-energize the contact coils, relays, and solenoids. The loss of power to the Intellisys power supply (16 VAC) will cause the system to reset to an off state which causes the displayed message of “Ready to Start” Procedure Power outages can be diagnosed by using power line recording and measurement instrumentation. A low cost method of measuring this type occurrence is to utilize a FLUKE 87 recording voltmeter. This meter can detect the loss of power as short as 100 ms (.1 Sec). By measuring secondary 120 VAC or 16 VAC circuits with the meter set to "VOLTS AC”, 100 ms record mode, loss of power can be measured. To measure the 120 VAC, connect the meter to J5 terminal 36 & 35, To measure the 16 VAC, connect the meter to J5 terminal 31 and 30. 1.2 Voltage Sag: Background Incoming voltage dips below 30% of rated voltage (example 460 VAC nominal = 322 VAC). Any voltage sag in excess of 250 ms (.25 sec) in duration will cause the control circuit to reset. This can occur in installations with phase unbalance problems, loss of phase, harmonic distortion, poorly distributed power management (i.e. undersized step down transformers for application loading), excessive wire length, and undersized wiring. Electrical disturbances, such as lightning storms, can also cause voltage sags. The voltage sag will de-energize the contact coils, relays, and solenoids. The voltage sag to the Intellisys power supply (16 VAC) will cause the system to reset to an off state which causes the displayed message of “Ready to Start’ Procedure Voltage sags can be diagnosed by using power line recording and measurement instrumentation. A low cost method of measuring this type occurrence is to utilize a FLUKE 87 recording voltmeter. This meter can detect the voltage sag as short as 100 ms (.1 Sec). By measuring secondary 120 VAC or 16 VAC circuits with the meter set to “VOLTS AC’, 100 ms record mode, the voltage sag can be measured. To measure the 120 VAC, connect the meter to J5 terminal 36 & 35. To measure the 16 VAC, connect the meter to J5 terminal 31 and 30.4.3. Grounding Problems: Background A poor ground system can cause severe electrical problems. Electrical control systems can experience both over voltage and voltage sag conditions due to a poor ground. This can cause nuisance shutdowns, damage to power supply circuits, communications errors, and even be a safety hazard for fault conditions. Electrical fault conditions must have a low resistance path to earth ground. The ground conductor supplied to the machine should be sized and installed per NEC and any additional local wiring requirements. The utilization of metal conduit or air piping that is attached to the air compressor is not considered an adequate ground Typically, building codes require that structural steel must be grounded per NEC. Structural supports such as steel girders and beams should be electrically attached to earth ground via a buried grid. Verify the supplied ground wire meets ampacity requirements per code and that it connects to the approved building earth ground grid. Some environments may have a distorted or noisy ground. This is usually an indication that current is flowing into earth ground. This can be caused by faulty electrical equipment in the area that is attached to the ground grid. Ground currents can be present in environments that utilize variable speed inverter type motor drives, such as variable frequency drive (VFD). Environments that utilize a large number of switching power supplies can also cause ground currents. Most all computer systems use switching power supplies. Many of these ground currents can be generated by high frequency (above 60 HZ) disturbances that are known as harmonic distortion. Because of the high frequency, they are hard to analyze and measure. An effective safeguard against this type of ground current is to minimize the length of wire to the ground grid. The use of braided ground wire minimizes high frequency distortion. If braided wire is not available, then standard stranded wire can be used if ampacity of wire is increased to 3X the rated value. Verify the ground grid point is free from corrosion or moisture that may prohibit a low resistance ground. It is important to verify that other electrical equipment that is electrically bonded to the air compressor is properly grounded as well. This will include any electrical device that is structurally connected to conductive air piping/plumbing originating at the air compressor. Wired interfaces such as remote start/stop, remote starters, sequencers, sequencer interfaces, Intellisys Sequence Control, Intellisys Remote Interface should also be properly grounded Procedures A practical way to measure the ground current is to use an ammeter Externally induced ground current (noise), power off state: A Fluke 87 or equivalent meter can be used to measure ground current.Disconnect power from machine Set the meter for amps AC and connect the meter in series with the ground wire provided to the machine. Ifa recording meter is used (Fluke 87), set to 100 ms record mode. A recording meter is the preferred measurement for intermittent problems. Record value in A rms. Set the meter for DC amps and record value in Amps DC. The expected measured value should be 0 .0 Amps. if measured value is greater than, or equal to, .25 Amps, a problem exists Isolate compressor package from other equipment to determine the source of ground current. Internally induced ground current, power on state: A Fluke 87 (or equivalent) meter can be used to measure ground current Disconnect power from machine. Set the meter for amps AC and connect the meter in series with the ground wire provided to the machine. if a recording meter is used (Fluke 87) then set to 100 ms record mode. A recording meter is the preferred measurement for intermittent problems. Apply power to machine Record value in A rms. Set the meter for DC amps and record value in Amps DC. The expected measured value should be 0 .0 Amps. if measured value is greater than, or equal to, .25 Amps, a problem exists. Isolate electrical devices in compressor package and determine the source of ground current. Causes may include: faulty wiring, moisture contamination of any electrical connections, motor overioads (current transformer type), control transformer, insulation breakdown of power leads, externally wired devices (remote start/stop, remote starter wiring, Sequencer, etc.) Internally induced ground current, Compressor Run Mode: ‘A Fluke 87 (or equivalent) meter can be used to measure ground current. Disconnect power from machine. Set the meter for amps AC and connect the meter in series with the ground wire provided to the machine. Ifa recording meter is used (Fluke 87), set to 100 ms record mode. A recording meter is the preferred measurement for intermittent problems. Apply power to machine. Start machine. Record value in A rms. Set the meter for DC amps and record value in Amps DC. The expected measured value should be 0 .0 Amps. Load machine. Record value in A rms.Set the meter for DC amps and record value in Amps DC. If measured value is greater than, or equal to, .25 Amps, a problem exists. Isolate electrical devices in compressor package and determine the source of ground current. Causes may include: faulty wiring, moisture contamination of electrical connections, motor overloads (current transformer type), control transformer, insulation breakdown of power leads, externally wired devices (remote start/stop, remote starter wiring, Sequencer, IRI, etc.) 1.4 Intellisys 16 VAC supply: Background The Intellisys power supply is fed from the 16 VAC center-tap secondary of the control power transformer 71. The center-tap indicates a central tap between the 16 VAC winding. This means the expected voltage across one end of the winding and the center-tap will be 8 VAC. The expected reading of the 16 VAC signal should have a tolerance of #/-15 %. The 16 VAC center-tap signal is fed to the intellisys through the J4 connector. The signal is rectified by diodes CR1 and CR2. The resulting rectified DC signal is approximately 10.5 VDC. The Intellisys is designed to accommodate +/- 25 % tolerance. Deviations in excess of +/-25%, or a loss of this signal, can cause the machine to shut down and reset to “Ready to Start’. Procedure This voltage measurement can be made with a Fluke 87 meter (or equivalent). A recording meter (Fluke 87) is preferred for intermittent problems. Set meter for Volts AC and connect as noted. Connect from J4-30 to J4-31. Expected value =16 VAC +#/- 2.4 VAC Connect from J4-29 to J4-30. Expected value = 8 VAC +/- 1.2 VAC Conneet from J4-29 to J4-31 Expected value = 8 VAC +/- 1.2 VAC Connect from J4-28 to J4-29. Expected value = 10.5 VDC +/- 1.6 VDC. If the expected values are not observed, possible causes may include: Primary voltage is in excess of 15% tolerance. Wiring fault: Check primary and secondary wiring for errors, loose connection or crimp, frayed ends, insulation breakdown, moisture contamination Fuse problem: blown fuse (primary or secondary), loose connection, voltage drop across fuse: >.5 VAC excessive control system current: Remove power and disconnect all but JS connector to Intellisys (also remove option prom and communications wiring). Apply power and record measurements. Ifmeasurements return to normal, repeat procedure and use process of elimination to find cause. 4.5 External 5 VDC Short Circuit: Background The Intellisys provides two 5 VDC signals for external use. The logic supply voltage is used by the Intellisys to supply power for internal circuitry such as the EPROM, RAM, Microprocessor, etc, The logic supply is also used to supply power to an external device known as the "Option Module”. This connection is made via connector J11. J11 isa 5-pin connector located on the left side of the controller (viewed from the front). The “Option Module” should always be installed or removed with power off. Note: the “Option Module” can be potentially damaged if installed with power on. Installing the module with power on can cause a latch-up condition which can create an excessive amount of current draw. This condition can cause the 5 VDC logic supply to sag below 4.5 VDC, which will create abnormal controller behavior. An intermittent connection to the “Option Module” can cause the same latch-up condition as installing it with power on. intermittent connections can be caused by improper installation, bent connection pins, moisture contamination, corrosion of electrical contacts, or excessive vibration Procedure This voltage measurement can be made with a Fluke 87 meter (or equivalent). A recording meter (Fluke 87) is preferred for intermittent problems. Remove power from machine. Remove back cover of Intellisys and locate J11 connector. Insure static precautions are used when handling circuit board. Re-apply power to machine. Set meter for Volts DC and connect and take measurements as noted: Connect from J11-1 to J11-5 (Top and bottom pin) Expected value = 5 VDC 4/- .2 VDC Asecond 5 VDC signal from the Intellisys is supplied to provide power for the sensors. This signal is extemally supplied through J2 and J3 connectors. This signal is provided for both pressure transducers and thermistors (temperature). If this signal is short circuited externally, abnormal controller behavior will occur. This could cause sensor reading errors, invalid calibration, sensor faults, sensor warnings, or general shutdown "Ready to Start’, Potential root causes include wiring fault to ground (chassis, sensor ground, or shield wire), moisture/corrosion contamination of connector or sensor, and solenoid fault to pressure transducer chassis,This voltage measurement can be made with a Fluke 87 meter (or equivalent). A recording meter (Fluke 87) is preferred for intermittent problems. Set meter for Volts DC and connect and take measurements as noted: Connect from J3-25 to J3-24 Expected value = 5.0 VDC +/- .2 VDC 4.6 Environmental Problems: Moisture: Background Moisture problems are typically encountered in outdoor applications. NEMA 4- rated starter enclosures should be specified for these environments to minimize moisture contamination. Moisture contamination can also be caused by the condensation of saturated air inside the starter enclosure. The presence of moisture can lead to a multitude of electrical connection related problems. Moisture can accelerate corrosion build-up on metal surfaces typically found in electrical connection points. The corrosion can create an open circuit between the wire and the electrical contact. Corrosion can even cause a short circuit to adjacent contact points. These types of faults are generally intermittent and are affected by temperature, the total amount of moisture, and vibration. Visual inspection is the best method of detecting these types of problems. Procedure: Remove power from machine. Visually inspect all terminal connections inside the starter enclosure. This includes all wiring that originates and ends at a screw terminal Unplug all connectors from the Intellisys controller. Remove “Option Module” Visually inspect all mating contact points at these connections. Remove back cover from Intellisys. Insure static precautions are utilized before handling circuit board. Visually inspect all electrical connectors. This includes battery contact BAT1 (if available). 1.7. Temperature: Background Ambient operating temperature range is specified as 35° F to 115° F. Outdoor modification option extends the ambient operating temperature range from -10° F to 115° F. If these limits have been exceeded, abnormal operation can occur. Many semiconductors inside the Intellisys have a maximum operatingtemperature of 158° F. Although this is 43° F margin above ambient conditions, the rise above ambient must be accounted for. The typical rise above ambient inside the starter enclosure is 20° F. This is due to heat generated by the electrical equipment inside the enclosure, such as the control transformer, contactors,etc. External factors can cause the rise above ambient to exceed this value. These factors include improper installation spacing requirements, ventilation problems, direct sunlight exposure, etc. Exceeding these temperature limits can cause many electrical problems including the Intellisys. Intellisys problems include shutdown “Ready to Start’, blank or abnormal display problems, and memory problems Procedure To test the system for temperature related problems a temperature probe can be used. Measurements should be made inside the starter enclosure with the enclosure door shut. If possible, take the measurements in the upper half of the enclosure to get worst case readings 1.8 Vibration: Background Excessive vibration or shock can cause intermittent electrical connections. Excessive vibration and shock can cause poor terminal and crimp connections. Screw terminals can become loose which will cause intermittent open circuits to occur. This can lead to arcing and even faults to adjacent circuits. Crimped connections, such as terminal spade lugs (Faston), can fatigue and also cause open circuit conditions. Procedure To inspect for loose wiring caused by vibration and shock use the following procedure: Remove power from machine Visually inspect all electrical connections for evidence of loose wiring, arcing, and frayed wiring. Manually pull each wire at the terminated end and inspect for loose wiring. 5-10 pounds of pull force should be asserted. 4.9 Remote Alarm applications: Background The remote alarm feature of the Intellisys provides a volt-free form "C’ relay contact for application use. The contacts are rated for a maximum of 5 Amps, 250 VAC. This rating is specified for a resistive load, such as an incandescentlamp. If an inductive load is used, such as a relay coil, the rating should be reduced to maximum of 2.5 Amps, 250 VAC. The use of inductive loads can cause excessive arcing of these contacts Excessive arcing can cause radiated interference (RF) that can affect the Intellisys. An effective way to minimize this interference is to install a RC network known as an “Arc Suppressor’. The RC network can be installed across the form “C* contacts that are used in the application. Arc suppressors are normally sized for specific applications. The general-purpose arc suppressor PIN. ..39203443 used in the starter circuit (RC1) can be used for most applications. B2.1 STEPPER MOTOR TEST PROCEDURE Background The stepper motor is a motor that can be moved in discrete increments of .9° for the Original Intellisys and .45° for the SG Intellisys. The motor is a constant torque device that is controlled by driver chips on the starter interface board or the power supply board. The main problem that can occur is that a winding shorts either to itseff, the other winding or to the casing Procedure Disconnect the Stepper Motor from the board. Measure the resistance between the brown and blue wires. Measure the resistance between the green/yellow and black wires. Both sets of measurements should be per below. 4° and 6” inlet valve = 5-7 OHMS 8" inlet valves = 11-13 OHMS. if not within this range, replace the Stepper Motor. Measure resistance between the brown wire and the case of the motor. Measure resistance between the blue wire and the case of the motor. Measure resistance between the green/yellow wire and the case of the motor. Measure resistance between the black wire and the case of the motor. All of these should measure as an open circuit or “OL” on a digital meter. If not, this indicates a short in the motor windings and the motor should be replaced. Measure resistance between the brown wire and the green/yellow wire. Measure resistance between the brown wire and the black wire. Measure resistance between the blue wire and the green/yellow wire. Measure resistance between the blue wire and the black wire. All of these should measure as an open circuit or “OL” on a digital meter. If not, this Indicates a short in the motor windings and the motor should be replaced, 2.2 DRIVER CHIP TEST Background The stepper motor is moved by electrical signals received from components called driver chips. The driver chips are located at position U14 and U15 on the starter interface board for the Original Intellisys and at positions U2 and U7 on the power supply board for the SG Intellisys. The signal turns off and on andreverses polarity to cause the stepper motor to move in the proper direction. A shorted stepper motor will almost always damage the driver chips on the Original Intellisys but will simply illuminate an overload on the SG Intellisys. See FSM for more information on the SG. Procedure Disconnect the Stepper Motor leads from the board. Measure resistance between (starter interface board BTS-3 and BTS3-7, also BTS3-8 and BTS3-9), SG Power Supply Board J3 & 2 and J3 182 and J3 384). If any of these do not read as an open circuit, then the associated board is faulty Next, determine if the driver chips are sending a signal to the Stepper Motor. Use a driver signal indicator as per page 34 in section "B" of the blue Field Service Manual Connect the signal indicator in parallel with the Stepper Motor leads. Power the unit up. The lights should sequence as indicated on the signal sheet. If either set of lights fails to light or stay on continuously, either the driver chips are bad or the controller is not sending the step and direction signal. Next, determine if the controller is sending the direction and step signal. See below for SG Controller. On the original intellisys Starter Interface Board connect a DC voltmeter to terminal number 17 on PAL chip U13 and BTS3-1 Power the compressor up and see if the voltage changes from 0 to 5 and then back to 0. If $0, the controller is sending the correct direction signal. Next, connect the DC voltmeter to Terminal 18 on component U13 and BTS3-1. The step and direction signal for the SG Controller connects to Terminal J4 on the Power Supply Board. Connect a DC voltmeter to terminal number J4 Terminal 3 and J4 Terminal 2. Power the compressor up and see if the voltage changes from 0 to 6-12 and then back to 0. If so, the controller is sending the correct direction signal. Next connect the DC voltmeter to Terminal 18 on component U13 and BTS3-1 See FSM Section B, Sheet 26 in the Blue Book for more information on direction and step signal for the SG Controller. a52.3 LIMIT BOARD TEST PROCEDURE Background The limit board contains two optical switches each of which emits an infrared light beam. When the light beam is interrupted, the voltage changes in a circuit that tells the controller the position of the valve. Procedure To perform this procedure, disconnect, lock and tag the incoming power. Make the volt meter connections leaving the limit board wired. Then reapply power to take the readings. Connect a DC voltmeter to the red wire and black wire. You should measure approx. 5 VDC for the original Intellisys Controller with the Starter Interface Board. If not, there is a problem with the controller or ribbon cable On the SG Controller, a measurement of 2 VDC is good. Zero volts mean a bad controller and 12 volts means a bad limit board. Next connect a DC volt meter to white and black wire. Power up the unit and manually move the inlet valve so the tang is in the closed limit switch. The Originally controller should measure 5 VDC. The SG controller should measure 10-12 volts DC. If not, the limit board is bad. Next, connect a DC voltmeter to green and black wire. Power up the unit and manually move the inlet valve so the tang is in the open limit switch. The Original controller should measure § VDC. ‘The SG controller should measure 10-12 volts DC. If not, the limit board is bad. See FSM Section B, Sheet 27, in the blue Field Service Manual for more information pertaining to the limit board on the SG Controller.2.4 PRESSURE SENSOR CHECK OUT Background The pressure sensors used on the Intellisys controllers use a 5 VDC supply and tum it into a varying voltage signal to the controller. The SE and Original use a 0-50 my signal and the SG uses a .5-4.5 VDC signal. Both supply and signal voltages can be measured. The Sensor can also be checked out with it removed from the unit. Procedure Original intellisys Controller or SE Intellisys Measure voltage on red and black wire. Should be 5 VDC+/- 2 VDC Measure voltage between white and green: 0 psi = 0.0 mv +/- 5.0 mv Disconnect sensor and measure resistance between red and black wire. The resistance should be 405 to 600 ohms. Disconnect sensor and measure resistance between white and green wire. The resistance should be 575 to 1195 ohms. Disconnect sensor and measure from each wire to the casing of the sensor, Should read as an open circuit. SG Intellisys Controller Measure voltage on red and black wire. Should be 5 VDC #/-.2 VDC. Measure voltage white to black: 0 psi = 0.5 VDC #/-.1V (i.e. 1 psi = 01777 VDC) Disconnect sensor and measure from each wire to the casing of the sensor: Should read as an open circuit. 2.5 TRIAC OUTPUTS Background Triacs can be thought of as a solid state relay operated by a 5 VDC signal. One of the unusual things about a Triac is that the output voltage cannot be determined if the Triac is off or on unless there is a load such as a solenoid connected to the output. It is a good practice to carry a known good incandescent light that can be connected to the output when testing for output voltage using a digital voltmeter. One of the main causes of a failed triac is the coil or solenoid that it operates has a short circuit causing the current to exceed the capabilities of the triac.Procedure With a known good incandescent light connected to the output terminal, a digital voltmeter can easily read whether or not the triac is on or off. 115 VAC means on, a 0 VAC means off. This is the best way to monitor outputs on any Intellisys Controller, For the original Intellisys Controller there is an additional problem to determine whether the faulty part is the controller or the Starter Interface Board. Refer to Section B, Page 28, in the blue Field Service Manual for assistance in determining the faulty part. 2.6 AUXILIARY CONTACTS BACKGROUND Auxiliary contacts are small contacts that are mounted on the front or sides of starters. These contacts operate at the same time as the starter. The contacts can be either normally open or normally closed. Some of the contacts are used in both the 120 VAC control circuit and the low voltage control circuit for feedback to the Intellisys controller. The procedure below covers how and where to test the auxiliary contacts that are in the low voltage circuits. PROCEDURE Original intellisys Controller Contact 1Ma (mounted on the 1M starter contactor.) Connect voltmeter set to volts DC to terminals BTS2-15 & 14 on the starter interface board. You should read 5 VDC when 1M is de-energized and 0 VDC when 1M is energized ing Onh Contact 1Sa (mounted on the 1S starter contactor). Connect voltmeter set to volts DC to terminals BTS2-13 & 12 on the starter interface board. You should read 5 VDC when 15 is de-energized and 0 VDC when 15 is energized. Star Delta Starting Only Contact 2Ma (mounted on the 2M starter contactor). Connect voltmeter set to volts DC to terminals BTS2-13 & 12 on the starter interface board. You should read 5 VDC when 2M is de-energized and 0 VDC when 2M starter is energized SE Intellisys Controller Contact 1Ma (mounted on the 1M starter contactor). 38Connect voltmeter set to volts DC to terminals J1-10 & 9. You should read 5 VDC when 1M is de-energized and 0 VDC when 1M is energized Star Delta Starting Only Contact 1Sa (mounted on the 1S starter contactor). Connect voltmeter set to volts DC to terminals J1-8 & 7. You should read 5 VDC when 1S is de-energized and 0 VDC when 1S is energized Star Delta Starting Only Contact 2Ma (mounted on the 2M starter contactor). Connect voltmeter set to volts DC to terminals J1-8 & 7. You should read 5 VDC when 2M is de-energized and 0 VDC when 2M starter is energized SG Intellisys Controller Contact 1Ma (mounted on the 1M starter contactor). Connect voltmeter set to volts DC to terminals P3-8 & 7. You should read 10-12 VDC when 1M is de-energized and 0 VDC when 1M is energized Star Delta Starting Only Contact 1Sa (mounted on the 1S starter contactor). Connect voltmeter set to volts DC to terminals P3-9 &1 0. You should read 10- 12 VDC when 1S is de-energized and 0 VDC when 15 is energized. Star Delta Starting Only Contact 2Ma (mounted on the 2M starter contactor). Connect voltmeter set to volts DC to terminals P3-9 & 10. You should read 10- 12 VDC when 2M is de-energized and 0 VDC when 2M starter is energized. 393.1 Power Outage: Background Power outage may have occurred during operation. Any power outage in excess of 250 ms (.25 sec) will cause the control circuit to reset. This can occur in installations with automatic reset circuit breakers. Electrical disturbances can also occur from power company interruptions such as lightning storms. This loss of power will de-energize the contact coils, relays, and solenoids. The loss of power to the Intellisys power supply (24 VAC) will cause the system to reset to an off state which causes the displayed message of "Ready to Start” Procedure Power outages can be diagnosed by using power line recording and measurement instrumentation. A low cost method of measuring this type occurrence is to utilize a FLUKE 87 recording voltmeter. This meter can detect the loss of power as short as 100 ms (.1 Sec). By measuring secondary 120 VAC or 24 VAC circuits with the meter set to "VOLTS AC’, 100 ms record mode, loss of power can be measured. To measure the 120 VAC, connect the meter to P1 terminal 1 & 10 on the controller. To measure the 24 VAC, connect the meter to J1 terminal 1 and 2 on the power supply board. To measure the 12 VDC to the controller, connect the meter set in volts DC to J4 terminal 1 & 2 on the power supply board, 3.2 Voltage Sag: Background incoming voltage dips below 30% of rated voltage (example 460 VAC nominal = 322 VAC). Any voltage sag in excess of 250 ms (.25 sec) in duration will cause the control circuit to reset. This can occur in installations with phase unbalance problems, loss of phase, harmonic distortion, poorly distributed power management (i.e. undersized step down transformers for application loading), excessive wire length, and undersized wiring. Electrical disturbances, such as lightning storms, can also cause voltage sags. The voltage sag will de-energize the contact coils, relays, and solenoids. The voltage sag to the Intellisys power supply (24VAC) will cause the system to reset to an off state which causes the displayed message of “Ready to Start” Procedure Voltage sags can be diagnosed by using power line recording and measurement instrumentation. A low cost method of measuring this type occurrence is to utilize a FLUKE 87 recording voltmeter. This meter can detect the loss of power as short as 100 ms (.1 Sec). By measuring secondary 120 VAC or 24 VAC circuits with the meter set to “VOLTS AC’, 100 ms record mode, loss of power can be measured. To measure the 120 VAC, connect the meter to P1 terminal 1 & 10 on 40the controller. To measure the 24 VAC, connect the meter to J1 terminal 1 and 2 on the power supply board. To measure the 12 VDC to the controller, connect the meter set in volts DC to J4 terminal 1 & 2 on the power supply board. 3.3. Intellisys 24 VAC Supply: Background The Intellisys power supply is fed from the 24 VAC secondary of the control power transformer T1. The expected reading of the 24 VAC signal should have a tolerance of +/-15 %. The 24 VAC is fed to the power supply board through the J1 connector. The signal is rectified by diodes. The resulting rectified DC signal is approximately 12 VDC. The Intellisys is designed to accommodate +/- 25 % tolerance. Deviations in excess of +/-25%, or a loss of this signal, can cause the machine to shut down and reset to “Ready to Start’. Procedure This voltage measurement can be made with a Fluke 87 meter (or equivalent). A recording meter (Fluke 87) is preferred for intermittent problems. Set meter for volts AC and connect as noted. Connect from J1-1 to J1-2. Expected value = 24 VAC +/- 3.6 VAC Set meter to volts DC Connect from J2-1 to J2-2. Expected value = 12 VDC +/-.6 VDC If the expected values are not observed, possible causes may include: Primary voltage in excess of 15% tolerance. Wiring fault: Check primary and secondary wiring for errors, loose connection or crimp, frayed ends, insulation breakdown, moisture contamination. Fuse problem: Blown fuse (primary or secondary), loose connection, voltage drop across fuse: >.5 VAC, excessive control system current: Remove power and disconnect all but J2 connector to Intellisys (also remove option prom and communications wiring). Apply power and record measurements. If measurements return to normal, repeat procedure and use process of elimination to find cause. 3.4 External 5 VDC Short Circuit: Background The Intellisys provides two 5 VDC signals for external use. The logic supply voltage is used by the Intellisys to supply power for internal circuitry such as the EPROM, RAM, Microprocessor, etc. The logic supply is also used to supply power to an external device known as the "Option Module”. This connection is almade via connector P9. P9is a 5-pin connector located on the left side of the controller (viewed from the front). The “Option Module” should always be installed or removed with power off. Note: the “Option Module” can be potentially damaged if installed with power on. Installing the module with power on can cause a latch-up condition which can create an excessive amount of current draw. This condition can cause the 5 VDC logic supply to sag below 4.5 VDC which will create abnormal controller behavior An intermittent connection to the “Option Module” can cause the same latch-up condition as installing it with power on. Intermittent connections can be caused by improper installation, bent connection pins, moisture contamination, corrosion of electrical contacts or excessive vibration Procedure This voltage measurement can be made with a Fluke 87 meter (or equivalent). A recording meter (Fluke 87) is preferred for intermittent problems. Remove power from machine. Remove back cover of Intellisys and locate P9 connector. Insure static precautions are used when handling circuit board. Re-apply power to machine. Set meter for volts DC and connect and take measurements as noted: Connect from P9-1 to P9-5 (top and bottom pin). Expected value = 5 VDC #/- .2 VDC. Asecond 5 VDC signal from the Intellisys is supplied to provide power for the sensors. This signal is externally supplied through PS and P6 connectors. This signal is provided for both pressure transducers and thermistors (temperature). If this signal is shorted externally, abnormal controller behavior may ocour. This could cause sensor reading errors, invalid calibration, sensor faults, sensor warnings, or general shutdown “Ready to Start’, Potential root causes include wiring fault to ground (chassis, sensor ground, or shield wire), moisture/corrosion contamination of connector or sensor and solenoid fault to pressure transducer chassis, This voltage measurement can be made with a Fluke 87 meter (or equivalent). A recording meter (Fluke 87) is preferred for intermittent problems. Set meter for volts DC and connect and take measurements as noted: Connect from P5-1 to P5-2. Expected value = 5.0 VDC +/-.2 VDC.4.0 External Electrical Disturbances: Background These are defined as sources of interference that can adversely affect signal integrity of control systems and wiring interfaces. These types of problems can be caused by Radio Frequency Interference (RFI), Electro-Magnetic Interference (EM), Electro-Static Discharge (ESD), lightning disturbances, and power line transients and surges. Control circuits that are the most susceptible to these disturbances include power supplies, sensors (pressure and temperature), and external interface wiring such as remote starter interface and communications port interfaces. Note: The effects of external electrical disturbances are magnified if the equipment is not properly grounded (see Grounding Problems). Intellisys based control systems have been designed and tested for immunity against extemal electrical disturbances. The test standard is derived from the EC Directive (European Community Directive) for heavy industrial applications and is known as EN50082-2. These test standards are specified to simulate severe electrical disturbances that can occur in heavy industrial applications. Intellisys control systems have passed at the levels specified The test parameters and compliance criteria are listed below: EN 61000-4-2 Electrostatic Discharge Immunity +/-4 KV contact discharge, +/- 8 KV air discharge ENV50140 —_Radiated Electromagnetic Field Immunity 10 Vim, 80 to 1000 MHz (80% AM w/1kHz sinewave) 900 +/- MHz, 10 Vim pulse modulated at 200 Hz to 50 % duty cycle per ENV50204 ENV50141 Conducted RF Disturbance Immunity 10 V rms (80% AM wi 1 kHz sinewave) on all power and signal lines EN 610004-4 Electrical Fast TransienvBurst Immunity +/- 2 KV on all power signals lines, EN 61000-4-8 Power Frequency Magnetic Field Immunity 30 A rmsim continuous at 50 Hz RFI and EMI disturbances can be airborne as well as conducted into the equipment. The source of this type of disturbance includes radio transmitters, variable speed motor drives (VFD), switching power supplies, arc welding aequipment, or other equipment that exhibits excessive electrical arcing during operation (i.e. DC brush motors). The level of disturbance is generally known as field strength. The electric field strength is measured in volts per meter (Vim). A hand held 5 watt transmitter can generate 10 V/m electric field strength at a distance of approximately 1 foot. To alleviate potential RFI and EMI disturbances, ensure the equipment is properly grounded (see Grounding Problems) and eliminate close range exposure to radiating devices ESD disturbances can be airborne as well as conducted into the equipment. The ESD event occurs when an electrical charge is dissipated into the equipment. This event is usually random and normally occurs with human interaction. A human can carry an extremely high electrical charge (8 KV) by simply walking across an insulated surface. Other sources include charged ungrounded material that can come into contact with the equipment (example: The presence of air flowing through a plastic pipe can cause an electrical charge to propagate along the surface of the pipe and arc into a conductive surface). ESD safeguard measures should be used when handling electronic circuit boards and equipment. (See Field Service manual - Large Rotary (blue book) Section “B” Sheet 12) Lightning disturbances will generally occur more often in outdoor applications. Obvious direct exposure to weather conditions will increase the chances of a lightning strike. Direct lightning strikes can cause severe electrical damage to controls, motors and wiring. The best precaution for this is to avoid open exposure and ensure adequate facility protection such as lightning arrestors. Power line transients and surges can cause a variety problems in the electrical system . The transient or surge is defined as a random abnormal condition that results in a distorted power signal. The distortion can usually be detected by measuring the voltage of the incoming power signal. Power line transients typically occur in fractions of seconds (less than 100 ms) and are hard to detect with standard volt meters. An oscilloscope is usually required for measuring transients. Power line surges occur at longer intervals (>100 ms) and can be detected more easily with the use of a recording voltmeter (such as Fluke 87). If the voltage level of the transient or surge is high enough, abnormal system behavior can occur. These problems include: Erratic control system behavior: Fuse blowing Control reset Erratic Triac operation (output) Control power transformer insulation breakdown Motor winding insulation damage Solenoid coil winding insulation damage 44Transients and surges can be caused by a variety of reasons. A few of these include: Poor or ungrounded equipment. Improperiy sized power distribution systems that generate disturbances when switching large inductive or capacitive loads. Ground fault conditions. Equipment phase to ground or phase to phase conditions. ‘Arc welding to compressor or surrounding equipment. Lightning strike to electrical distribution system Variable speed drive applications (Induction or DC motors) Intellisys control systems have sufficient protection against typical electrical disturbances that can occur in the industrial environment. These systems have been designed to exceed the highest levels specified within EN50082-2 (see above). If the level of electrical disturbance is known to exceed these levels, added measures of protection will be required. These could include: Inspection and certification of grounding systems. Power line conditioning. The use of three phase isolation transformer.5.0 Membrane Switch Background The membrane switch is part of the user interface to the Intellisys control. Itis a matrix of switches bonded to the Intellisys controller and electrically connected to the control circuit board. The internal membrane switch wiring to the physical switches is accomplished through conducted traces made of silver conductive ink. These electrical traces vary in length but will always measure less than 100 ohms when tested. The electrical schematic to Intellisys membrane switches is shown in the diagrams below. The continuity of these switches can be tested with the use of an ohmmeter. To test the individual switches use the following procedure: Procedure 1. Remove control power. 2. Disconnect the membrane switch tail connector from the controller. 3. Connect the ohmmeter to connector position that is wired to the switch (see schematic below) 4. Verify ohmmeter reads O.L. (open circuit). 5. Press the membrane switch under test. 6. Verify ohmmeter reads less than 100 ohms. START CATDDEN_CEFT) CHIBDEN ALIGHT) fcc erie, 5p ole Start 1-4 Hidden Left 1-5 Hidden Right 1-6 Unload/Load 2-4 Down Arrow 2-5 Set 2-6 Display Select 3-4 Up Arrow 3-5 Unloaded Stop 3-6 WNLOAD/LOAD DISPLAY SELECT + UNLOADED. ‘STOP. T a4 pir Figure 1. SE Membrane Schematic + cRoUNo. conn. SHIELD 8 PIN 46PIN2 PIN4 PING PIN 8 sly) Sy, PIN 1 + * SH) By PIN 3 2 = s3,,] se] se. PIN 5 | 4 me mf 87, $0. PIN 7 ms “4 $1 1-2 821-4 $3 5-4 S4 Start 3-2 $5 Unload 3-4 S6 Load 5-6 S7 Unloaded Stop 7-6 $8 Down Arrow 7-8 S9 Up Arrow 5-8 Figure 2. SG Membrane SchematicMod/ACS 1-8 Select Up Arrow 1-7 Setpoint Down Arrow 1-6 On/Offline 2-8 Select Down Arrow 2-7 Set 2-6 Unload 3-8 Reset 3-7 Setpoint Up Arrow 3-6 Start 4-8 Unloaded Stop 4-7 Test 4-6 Figure 3. SSR Original Intellisys Membrane Schematic 48Purchase Order No. Date Name (last) (First) m1) Company Title Address City State Zip Phone Price* Title laty. Req’ $6.00 EACH | Intelisys Rotary Troubleshooting Guide Form APDD 749, $1.00PAD | APDD 749 SUP 1 $1.00PAD | APDD 749 SUP 2 *Price Includes Shipping and Handling. Mail or Fax Purchase Order with Order Form to: Fax: (607) 936-3187 Multi Media Services 41186 River Road Coming, NY 14830