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Ingersoll-Rand INTELLISYS SSR Series User Manual

Ingersoll-Rand INTELLISYS SSR Series
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40
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
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Ingersoll-Rand INTELLISYS SSR Series Specifications

General IconGeneral
TypeRotary Screw
Motor PowerVaries by model
Flow RateVaries by model
Air DeliveryVaries by model (e.g., 100 to 1500 CFM)
Drive TypeDirect Drive
Cooling TypeAir
Control SystemINTELLISYS
Noise LevelVaries by model
VoltageVaries by model

Summary

User Instructions and Guide Overview

SE Intellisys Controller General Information

SG Intellisys Controller General Information

SE Controller Shutdown Troubleshooting

Voltage and Power Supply Issues

Diagnose issues related to incoming voltage dips, sags, and power disturbances.

Circuit Intermittency and Grounding

Troubleshoot intermittent faults in 16 VAC, ground, and 5 VDC analog circuits.

Environmental and External Factors

Address environmental factors like temperature, moisture, and vibration.

SG Controller Shutdown Troubleshooting

Voltage and Power Supply Issues

Diagnose issues related to incoming voltage dips, sags, and power disturbances.

Circuit Intermittency and Grounding

Troubleshoot intermittent faults in 24 VAC, ground, and 5 VDC circuits.

Environmental and External Factors

Address environmental factors like temperature, moisture, and vibration.

Controller Lock-Up and Blank Display

Feed Circuit and Membrane Faults

Diagnose feed circuit intermittency and membrane faults.

Other Lock-Up Causes

Address communication, environmental, and display issues causing lock-up.

Triac Output Fault Diagnosis

Triac Testing by Controller Type

Test Triac outputs using controller-specific methods.

Inlet Control System Diagnostics

Power, Limit Switch, and Controller Checks

Verify power supply and diagnose limit switch/controller faults.

Motor, Valve, and Deflector Issues

Troubleshoot motor, valve, coupling, and deflector issues.

Inlet Control Valve Operation Checks

Sensing Line and Transducer Issues

Diagnose 1AVPT transducer and sensing line faults.

Gear, Coupling, and SG Limit Switch

Inspect gears, coupling, and SG limit switch position.

Low Unloaded Sump Pressure

Component Failure Diagnosis

Diagnose coupling, motor, driver chip, or MPCV faults.

Sensing Line and Valve Checks

Inspect sensing lines, deflector, silencer, and inlet valve.

High Sump Pressure Troubleshooting

Coolant, Filter, and System Water Checks

Check coolant, filter, and water contamination.

Component and Valve Operation

Diagnose component and valve operation issues.

High Airend Temperature Causes

Coolant, Cooler, and Ambient Conditions

Address coolant, cooler cleanliness, and ambient temperature.

Valve, Thermistor, and Airend Component Checks

Diagnose valve, thermistor, and airend component faults.

Motor Overload Diagnosis

Heater, Settings, and Wiring Verification

Verify heater selection, overload settings, and wiring.

Amperage, Voltage, and Starter Checks

Analyze amperage, voltage, and starter component conditions.

Potential Relay, Controller, Cable Issues

Troubleshoot overload relay, controller, or ribbon cable.

Starter Fault Troubleshooting

Temperature, Coolant, and Valve Checks

Verify temperature, coolant status, and valve operation.

Energization and Timing Checks

Check component energization and operational timing.

Wiring and Auxiliary Contact Issues

Diagnose wiring and auxiliary contact problems.

Original Intellisys Voltage Checks

BTS1 Terminal Voltage Measurements

Measure AC voltages at BTS1 terminals.

E-Stop, 1ATS, and Shutdown Wiring Checks

Identify faulty E-stop, 1ATS, and verify shutdown wiring.

Controller and Cable Verification

Verify controller and ribbon cable integrity.

No Control Power Troubleshooting

Controller Voltage and Fuse Checks

Measure controller voltages and check fuses/transformer.

Common Faults and Shutdown Verification

Address common faults and verify shutdown conditions.

Motor Rotation and Airflow Checks

Rotation Correction and Airend Issues

Correct rotation and diagnose airend problems.

Sensing Line, Motor, and Belt Component Checks

Diagnose sensing lines, motor, belts, and related components.

Stepper Limit Switch Testing

Limit Board Voltage Measurements

Measure voltage on limit board wires for controller type.

Controller, Cable, and Switch Integrity

Diagnose controller, cable, and switch faults.

Remote Stop Failure Troubleshooting

Voltage Measurement by Controller

Measure voltage on controller terminals for remote stop.

Stop Contact and Cable/Controller Faults

Diagnose stop contact, cable, or controller faults.

Remote Start Failure Troubleshooting

Voltage Measurement by Controller

Connect meter to check remote start voltage.

Start Button and Controller Faults

Diagnose start button, PLC, or controller faults.

Short Separator Element Life Causes

Pressure, Filter, and Coolant Checks

Inspect pressure, filter, and coolant conditions.

Component and System Condition Checks

Check component condition and system operation.

Power Outage Diagnostics

Procedure

Methods to diagnose power outages using measurement tools.

Grounding Problems Analysis

Procedures

Practical methods to measure ground current and identify issues.

Intellisys 16 VAC Supply Checks

Procedure

Steps to measure 16 VAC supply and diagnose faults.

External 5 VDC Short Circuit Diagnosis

Procedure

Procedure to measure 5 VDC signals and identify shorts.

Moisture Related Problems

Procedure

Visually inspect connections and components for moisture damage.

Temperature Limits and Measurement

Procedure

Test system for temperature related problems using a probe.

Vibration Effects on Connections

Procedure

Inspect electrical connections for loose wiring due to vibration.

Remote Alarm Application Interface

Stepper Motor Test Procedure

Driver Chip Signal Testing

Procedure

Determine if driver chips are sending signals to the stepper motor.

Limit Board Test Procedure

Pressure Sensor Check Out

Procedure

Check pressure sensor supply and signal voltages.

Triac Output Testing

Procedure

Test Triac outputs using a light or voltmeter.

Auxiliary Contacts Testing

PROCEDURE

Test auxiliary contacts in low voltage circuits.

SG Controller Power Outage Diagnostics

Procedure

Diagnose power outages using measurement tools for SG.

SG Controller Voltage Sag Diagnostics

Procedure

Diagnose voltage sags using measurement tools for SG.

Intellisys 24 VAC Supply Checks

Procedure

Measure 24 VAC supply and diagnose faults.

SG External 5 VDC Short Circuit Diagnosis

Procedure

Measure 5 VDC signals and identify shorts for SG.

External Electrical Disturbances Analysis

Membrane Switch Testing

Procedure

Steps to test individual membrane switches with an ohmmeter.

SE Membrane Switch Schematic

SG Membrane Schematic

Original Intellisys Membrane Schematic

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