Ingersoll-Rand R150IU-140 User manual

Fault Finding Guide for the R90-160 IU

More than Air Answers

Online answers: http://www.air.irco.com

PHONE: 1-800-820-0308

WSV June 07

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.

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

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.

5

S3 Intellisys Controller Operating Instructions

6

Software Navigation

7

Eiger Controller Fault Indicators

020 Tr

Motor PTC Open (High Motor Temperature)

8

Eiger Fault Finding

’Power on’. L.E.D.

does Not

illuminate.

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

Insufficient Coolant

Circulation,

insufficient cooling.

Compressor trips

indicating a high

compressor

temperature.

Fault T 13, W 13

Check coolant level

Intellisys indicates

a tripped condition.

Compressor is

stopped but

Intellisys indicates

that it is still

running (STD

controller only)

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).

9

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.

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 trips and

indicates motor

overload.

Fault T 3

Compressor shutdown

display shows

OVERPRESSURE.

Fault T 12, W 12

Isolation valve

Check for leaks, open service

valves or exceptionally high

demand.

Offline pressure set

too low

Air Demand too

high

Compressor will not

build up rated pressure.

Check the offline pressure

setting.

10

Excessive coolant

consumption.

Blocked scavenge line

Ruptured or fouled

separator element

Clear the blockage.

Change the element.

Rapid cycling or

receiver will not

blow down to

unloaded running

p

ressure.

System is not using enough

air, increase consumption.

Minimum pressure valve

(MPV) stuck open.

Strip the MPV, examine and

repair if necessary.

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.

Check the operation of

the inlet valve.

Check the offline/online pressure

setting.

Check the operation of

the load solenoid valve

1SV.

Check the inlet filter for

contamination. The L.E.D. should

indicate if it is blocked.

(ENH controller only)

11

.

Safety valve blows

when compressor

loads.

Minimum pressure valve

(MPV) stuck closed.

Strip the MPV, examine and

repair if necessary.

Blocked separator element

Check differential pressure

and replace element

Check the setting of the

safety valve and the rated

pressure.

Safety valve faulty

Motor reverse

rotation

Fault T 1

Emergency stop activated

Change any 2 of the

incoming power wires to

change motor rotation

Emergency Stop

Fault T 2

Incoming power wired to

package incorrectly

Clear fault hazard twist

emergency stop button to

reset.

Compressor will not start

below 2 deg C (28 deg F),

unless fitted with low

ambient option (−10_C)

(

14 de

g

F

)

Low ambient

temperature

Fault T 4

Wait until compressor

package air temperature

rises above minimum starting

temp requirement.

Blocked separator element

Blow down system

ineffective

Replace separator element

Check the operation of the

load solenoid valve.

Check un-loader valve − strip

and clean if necessary.

High sump air

pressure.

Faults T 5, W 5

MPV stuck closed Strip MPV, examine and repair

if necessary.

12

Low sump air

pressure.

Fault T 6

Incoming power wired to

package incorrectly

Check main motor rotation if

incorrect change any two wires

to reverse rotation.

P2 Sensor

calibration

failure.

Fault T 11

Motor PTC Open

(High Motor Temp)

Fault T 20

Check for overload

condition

Checking motor cooling

Inlet valve not opening

Check valve and make sure it

operates freely

Check load solenoid valve and

controller operation.

P1 Sensor

calibration

failure.

Fault T 10

Check sensor connection and calibrate or replace if

necessary

P1 Sensor Failure

Fault T 7

P2 Sensor Failure

Fault T8

Temperature Sensor

Failure

Fault T 9

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.

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

Integral sequencing

communication

failure.

Fault W 19

Wiring or communication

fault

Check wiring

Maintenance due

immediately.

Fault W 15

Maintenance timer has

reached 2000 hrs of runtime

or 8760 hours clock time

Reset time in factory set up

menu using access code

1954

Change oil filter.

Fault W 16

Check differential pressure

switch for fault

Change oil filter

Change air filter.

Fault W 17

Change air filter Check air pressure switch

for fault

Change separator

element

Fault W 18

Change separator element Recalibrate sump pressure

transducer.

(

3APT

)

14

Star Delta Wiring Diagram

15

16

Soft Start Wiring Diagram

17

18

Line Start Schematic

19

20

Process and Instrumentation Diagram

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Ingersoll-Rand R150IU-140 User manual

Ingersoll-Rand R150IU-140 User manual

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