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Ingersoll-Rand Intellisys SSR 10-40, Руководство для обслуживающего персонала

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POWER TEST INTERFACE BOARD

(50-450 ROTARY)

Measure voltages on interface boards at locations shown to determine normal
operation.

`

STEPPER MOTOR DRIVER CHIPS

50-450 Horsepower

The Electronics group has identified some susceptible driver chip components.

Most of the units were either replaced or retested by the vendor.  There is a
chance that some units with this date code will exhibit problems.  These chips
have identifiable data codes printed on them.

The two date codes to look for are 89015 and 89018.  These codes will appear
on "U14" or "U15" on the starter interface P/N 39182175.

-85-

-86-

REPLACEMENT OF STEPPER ASSEMBLY COMPONENTS

Replacing the stepper couplings:

Begin by removing the air filter element(s).
Remove the stepper motor assembly from the inlet valve body.  The stepper limit
switch and male half of the coupling will come off along with the stepper motor,
and motor mounting plate.  Remove both halves of the coupling from their
respective shafts.

When installing the male half of the coupling onto the stepper shaft, first open
it with a small screwdriver and then slide it onto the shaft.  Leave the shaft end
recessed from the surface of the coupling approximately 1/8" as shown.  NOTE!!
Use only the nut and bolt provided by I-R for clamping the coupling.  Regular
hardware will cause concentrated stresses within the coupling resulting in rapid
failure.  This bolt should be torqued to 150 inch-lbs.  Mark a line on the end of
the stepper shaft and the coupling with a permanent marker so that if any rotation
occurs later on, it can be easily detected.

Replace the female half of the coupling on the valve shaft, using the nut and bolt
originally provided.  The coupling should be positioned on the shaft so that the
upper surface of the coupling is 1-1/8" from the surface where the stepper
mounting plate mounts on the valve body.  This dimension is important as
deviation will cause the coupling to become misaligned.  The bolt requires 120
inch-lbs of torque.

Since the female coupling is always 1-1/8" from the stepper motor mounting
plate, a simple tool can be made to allow for easy positioning of this coupling half
on all sizes of Intellisys machines (see drawing).

Содержание Intellisys SSR 10-40

Страница 1: ...gersoll Rand Co IntellisysTM Serviceman s Guide SSR 10 40 Horsepower Models SSR 50 450 Horsepower Models Simplicity Serviceability Reliability Rotary Reciprocating Compressor Division Ingersoll Rand C...

Страница 2: ...NUMBERS 39 REMOTE ALARM CONTACTS 40 SSR 10 40 HP INTERFACE BOARD TROUBLESHOOTING CHART 40 50 450 HORSEPOWER INTELLISYS INDEX 41 COMPRESSOR ALARMS 42 SSR 50 HORSEPOWER AND HIGHER INTELLISYS COMPONENTS...

Страница 3: ...NUMBERS 39 REMOTE ALARM CONTACTS 40 SSR 10 40 HP INTERFACE BOARD TROUBLESHOOTING CHART 40 50 450 HORSEPOWER INTELLISYS INDEX 41 COMPRESSOR ALARMS 42 SSR 50 HORSEPOWER AND HIGHER INTELLISYS COMPONENTS...

Страница 4: ...rcuits are arranged in a matrix grid that terminates in a plug The fourth layer is the back of the membrane and it is also printed to provide a static shield The layers of the membrane switch are adhe...

Страница 5: ...rcuits are arranged in a matrix grid that terminates in a plug The fourth layer is the back of the membrane and it is also printed to provide a static shield The layers of the membrane switch are adhe...

Страница 6: ...ired is to hook up main power to the starter and operate the compressor There are no adjustments required The initial settings will vary according to the stated operating pressure of the compressor Pl...

Страница 7: ...ired is to hook up main power to the starter and operate the compressor There are no adjustments required The initial settings will vary according to the stated operating pressure of the compressor Pl...

Страница 8: ...wn step arrows the value shown in the window will change When the desired value is selected press the set button to fix it into memory The display will shift down to the next setable parameter The uni...

Страница 9: ...wn step arrows the value shown in the window will change When the desired value is selected press the set button to fix it into memory The display will shift down to the next setable parameter The uni...

Страница 10: ...the opposite coil connection and terminal 8 on the starter interface board If these check out OK check for continuity between 8 on the interface board and pin 1 on the 115 volt connector This is the w...

Страница 11: ...the opposite coil connection and terminal 8 on the starter interface board If these check out OK check for continuity between 8 on the interface board and pin 1 on the 115 volt connector This is the w...

Страница 12: ...25 150 or 175 psig The controller will shut down if the discharge pressure exceeds 15 psig over any of the preset discharge pressures programmed into the controller by the factory SYMPTOMS 1 The Intel...

Страница 13: ...25 150 or 175 psig The controller will shut down if the discharge pressure exceeds 15 psig over any of the preset discharge pressures programmed into the controller by the factory SYMPTOMS 1 The Intel...

Страница 14: ...of the program it signals the watchdog that it is functioning OK The watchdog starts a timer If before the timer times out the program has not come back and signaled the watchdog the watchdog shuts t...

Страница 15: ...of the program it signals the watchdog that it is functioning OK The watchdog starts a timer If before the timer times out the program has not come back and signaled the watchdog the watchdog shuts t...

Страница 16: ...n though rotation is correct To help alleviate this potential situation we are revising the logic within the Intellisys to look for a positive pressure within 3 seconds of start up This will eliminate...

Страница 17: ...n though rotation is correct To help alleviate this potential situation we are revising the logic within the Intellisys to look for a positive pressure within 3 seconds of start up This will eliminate...

Страница 18: ...s which have a widely varying plant air demand larger air storage capacity and or want automatically available standby air capacity Automatic Stop Start Control Option is available During periods of l...

Страница 19: ...s which have a widely varying plant air demand larger air storage capacity and or want automatically available standby air capacity Automatic Stop Start Control Option is available During periods of l...

Страница 20: ...one a connection for a normally closed stop switch terminals 3 and 4 and one for a normally open momentary contact start switch terminals 1 and 2 17 For safety a selection is available in the Intelli...

Страница 21: ...one a connection for a normally closed stop switch terminals 3 and 4 and one for a normally open momentary contact start switch terminals 1 and 2 17 For safety a selection is available in the Intelli...

Страница 22: ...imary and secondary contacts of the transformer and interface board or intermittent contact will give various error codes CAUSE The electrical signal in the pressure transducer can ground itself fully...

Страница 23: ...imary and secondary contacts of the transformer and interface board or intermittent contact will give various error codes CAUSE The electrical signal in the pressure transducer can ground itself fully...

Страница 24: ...ot shift position INTELLISYS CODE 12 SHUTDOWNS SSR 10 40 Horsepower Code 12 is activated by the pressure transducer which must sense 10 psig sump pressure within three seconds after depressing the sta...

Страница 25: ...ot shift position INTELLISYS CODE 12 SHUTDOWNS SSR 10 40 Horsepower Code 12 is activated by the pressure transducer which must sense 10 psig sump pressure within three seconds after depressing the sta...

Страница 26: ...problems with different components not operating electrically These components could be the 1M contactor 1SV Load Solenoid 2SV Modulate Solenoid and 10SV Line Sump Solenoid The problem could be in an...

Страница 27: ...problems with different components not operating electrically These components could be the 1M contactor 1SV Load Solenoid 2SV Modulate Solenoid and 10SV Line Sump Solenoid The problem could be in an...

Страница 28: ...unload hours to match units operating in the field Specify this requirement with your order if it is an important consideration Keep in mind that the parts manual also lists a new controller order ki...

Страница 29: ...unload hours to match units operating in the field Specify this requirement with your order if it is an important consideration Keep in mind that the parts manual also lists a new controller order ki...

Страница 30: ...isplayed in the window until the Unloaded Stop button is released After the lamp test has been completed the unit will display 0 Ready to Start Units equipped with the Revision 9 0 E Prom will not sho...

Страница 31: ...isplayed in the window until the Unloaded Stop button is released After the lamp test has been completed the unit will display 0 Ready to Start Units equipped with the Revision 9 0 E Prom will not sho...

Страница 32: ...29...

Страница 33: ...30...

Страница 34: ...ing screws provided in the kit 5 Connect the modular cable P N39547880 between the communication port jack on the Squencer Interface I and the communication port jack onthecompressorstarterinterfacebo...

Страница 35: ...ing screws provided in the kit 5 Connect the modular cable P N39547880 between the communication port jack on the Squencer Interface I and the communication port jack onthecompressorstarterinterfacebo...

Страница 36: ...ed electrically A three compressor installation in a plant which has a minimum pressure requirement of 90 psig could have its sequence controller pressure switches set as follows using varying pressur...

Страница 37: ...ed electrically A three compressor installation in a plant which has a minimum pressure requirement of 90 psig could have its sequence controller pressure switches set as follows using varying pressur...

Страница 38: ...AND ITB 10 ON COMPRESSOR CONTROL PANEL MUST BE REMOVED WHEN SEQUENCE CONTROLLER IS IN STALLED 36 For proper operation when using the Sequencer Interface I with an Intellisys Unit the following hardwa...

Страница 39: ...AND ITB 10 ON COMPRESSOR CONTROL PANEL MUST BE REMOVED WHEN SEQUENCE CONTROLLER IS IN STALLED 36 For proper operation when using the Sequencer Interface I with an Intellisys Unit the following hardwa...

Страница 40: ...mount of time that the auto restart timer is set for When this time has expired the unit should shut off 10 Open the discharge valve The line pressure should drop and the unit should restart The unit...

Страница 41: ...mount of time that the auto restart timer is set for When this time has expired the unit should shut off 10 Open the discharge valve The line pressure should drop and the unit should restart The unit...

Страница 42: ...166 1439 167 1412 168 1386 169 1360 170 1335 171 1310 172 1286 173 1262 174 1239 175 1216 176 1194 177 1172 178 1151 179 1130 180 1110 181 1090 182 1071 183 1051 SSR 10 40 HP INTERFACE BOARD TROUBLESH...

Страница 43: ...166 1439 167 1412 168 1386 169 1360 170 1335 171 1310 172 1286 173 1262 174 1239 175 1216 176 1194 177 1172 178 1151 179 1130 180 1110 181 1090 182 1071 183 1051 SSR 10 40 HP INTERFACE BOARD TROUBLESH...

Страница 44: ...VPT is less than 1 psi vacuum This alarm is not checked during the first 2 seconds of operation 10 CK INLET CONTROL SYS If the inlet valve is to move to the fully open or fully closed position and the...

Страница 45: ...VPT is less than 1 psi vacuum This alarm is not checked during the first 2 seconds of operation 10 CK INLET CONTROL SYS If the inlet valve is to move to the fully open or fully closed position and the...

Страница 46: ...mpletely open 2 CHG COOLANT FILTER Thiswarningwilloccuriftheoilfilterdeltapswitchcloses 2CTTisgreater than 120 degrees and the unit is loading 3 CHANGE SEPR ELEMENT This warning will occur if 3APT 4AP...

Страница 47: ...mpletely open 2 CHG COOLANT FILTER Thiswarningwilloccuriftheoilfilterdeltapswitchcloses 2CTTisgreater than 120 degrees and the unit is loading 3 CHANGE SEPR ELEMENT This warning will occur if 3APT 4AP...

Страница 48: ...nated and the above situations would give a low sump pressure shutdown If any of these problems exist changing a 1 4 to a 1 5 Eprom will not correct the problem but it will give you a low sump pressur...

Страница 49: ...nated and the above situations would give a low sump pressure shutdown If any of these problems exist changing a 1 4 to a 1 5 Eprom will not correct the problem but it will give you a low sump pressur...

Страница 50: ...ter the start button is engaged The period the signal is ignored is actually 10 seconds after Star Delta transition to run or 10 seconds after full voltage starter contactor engagement After these 10...

Страница 51: ...ter the start button is engaged The period the signal is ignored is actually 10 seconds after Star Delta transition to run or 10 seconds after full voltage starter contactor engagement After these 10...

Страница 52: ...tch c Jumper 29 and 30 on BTS 1 2 Check wiring at terminals 29 and 30 BTS 1 3 Between terminal 29 and ground should have 110 Volts 4 Check BTS 1 Terminals 23 28 Trace wiring to main coils 5 If partial...

Страница 53: ...tch c Jumper 29 and 30 on BTS 1 2 Check wiring at terminals 29 and 30 BTS 1 3 Between terminal 29 and ground should have 110 Volts 4 Check BTS 1 Terminals 23 28 Trace wiring to main coils 5 If partial...

Страница 54: ...d There are two sets of Stepper Motor windings Wires 6 and 7 are a pair and 5 6 OHMs should be measured between these two wires on 50 200 horsepower units Wires 8 and 9 are the second pair and 5 6 OHM...

Страница 55: ...d There are two sets of Stepper Motor windings Wires 6 and 7 are a pair and 5 6 OHMs should be measured between these two wires on 50 200 horsepower units Wires 8 and 9 are the second pair and 5 6 OHM...

Страница 56: ...chine which will change automatically to Ready to Start d Press Set once then you will see the words Ready To Start change to Press Set Chg Values and or Press Test Light Ck These two sets of words wi...

Страница 57: ...chine which will change automatically to Ready to Start d Press Set once then you will see the words Ready To Start change to Press Set Chg Values and or Press Test Light Ck These two sets of words wi...

Страница 58: ...the transformer connec tor 55 56 3 Press Set once then you should see the words Ready To Start change to Press Set Chg Values and or Press Test Light Ck These two sets of words will flash back and for...

Страница 59: ...the transformer connec tor 55 56 3 Press Set once then you should see the words Ready To Start change to Press Set Chg Values and or Press Test Light Ck These two sets of words will flash back and for...

Страница 60: ...ling and a replacement bottom gasket for the inlet valve 3 If the customer has a machine built prior to July 16 1990 and he wants to convert to resilient mounting using the old style valve he should o...

Страница 61: ...ling and a replacement bottom gasket for the inlet valve 3 If the customer has a machine built prior to July 16 1990 and he wants to convert to resilient mounting using the old style valve he should o...

Страница 62: ...18 51017 19 49490 20 48012 21 46584 22 45202 23 43865 24 42573 25 41322 26 40112 27 38941 28 37808 29 36712 30 35650 31 34623 32 33631 33 32668 34 31736 35 30834 36 29960 37 29114 38 28295 39 27501 40...

Страница 63: ...18 51017 19 49490 20 48012 21 46584 22 45202 23 43865 24 42573 25 41322 26 40112 27 38941 28 37808 29 36712 30 35650 31 34623 32 33631 33 32668 34 31736 35 30834 36 29960 37 29114 38 28295 39 27501 40...

Страница 64: ...46 266 21 5 9 7 19 75 501 63 268 98 4 9 9 8 19 95 506 80 271 75 4 8 9 9 20 16 511 97 274 53 4 7 10 20 36 517 14 277 30 4 6 10 1 20 56 522 32 280 07 61 62 VACUUM CONVERSIONS PSIA PSI INCHES MM INCHES V...

Страница 65: ...46 266 21 5 9 7 19 75 501 63 268 98 4 9 9 8 19 95 506 80 271 75 4 8 9 9 20 16 511 97 274 53 4 7 10 20 36 517 14 277 30 4 6 10 1 20 56 522 32 280 07 61 62 VACUUM CONVERSIONS PSIA PSI INCHES MM INCHES V...

Страница 66: ...ISYS CONTROLLER DISPLAYS INLET VACUUM IN PSI VAC UUM FOR INSTANCE IF THE INLET VACUUM DISPLAY READS 128 THIS IS 12 8 PSI VACUUM FOR THOSE OF YOU WHO ARE USED TO OTHER SCALES SUCH AS H2 0 OR HG WE HAVE...

Страница 67: ...ISYS CONTROLLER DISPLAYS INLET VACUUM IN PSI VAC UUM FOR INSTANCE IF THE INLET VACUUM DISPLAY READS 128 THIS IS 12 8 PSI VACUUM FOR THOSE OF YOU WHO ARE USED TO OTHER SCALES SUCH AS H2 0 OR HG WE HAVE...

Страница 68: ...top 39179593 1 E PROM Programmed Software Rev 1 5 Onward 66 65 5 Using your fingers do not use tools and or the prom ejector carefully pull out the production prom Be careful not to bend the contacts...

Страница 69: ...top 39179593 1 E PROM Programmed Software Rev 1 5 Onward 66 65 5 Using your fingers do not use tools and or the prom ejector carefully pull out the production prom Be careful not to bend the contacts...

Страница 70: ...ponents 3 Connect 115 V A C wiring between the Sequencer Interface I and the Starter Interface board as shown in the wiring diagram figure 3 4 Connect wiring from terminals 1 5 on the Sequencer Interf...

Страница 71: ...ponents 3 Connect 115 V A C wiring between the Sequencer Interface I and the Starter Interface board as shown in the wiring diagram figure 3 4 Connect wiring from terminals 1 5 on the Sequencer Interf...

Страница 72: ...70 FIGURE 1 INTERFACE MOUNTING LOCATION FIGURE 2 INTELLISYS CONTROLLER FIGURE 3 WIRING DIAGRAM 69...

Страница 73: ...70 FIGURE 1 INTERFACE MOUNTING LOCATION FIGURE 2 INTELLISYS CONTROLLER FIGURE 3 WIRING DIAGRAM 69...

Страница 74: ...71...

Страница 75: ...72...

Страница 76: ...72...

Страница 77: ...rd in a similar manner The 5 volt DC source for the sensors is supplied by a small but extremely accurate voltage regulator mounted on the upper left side of the Analog Board The input voltage to this...

Страница 78: ...rd in a similar manner The 5 volt DC source for the sensors is supplied by a small but extremely accurate voltage regulator mounted on the upper left side of the Analog Board The input voltage to this...

Страница 79: ...ut at this time The main display of the panel will begin to show High A E Disch Temp 229 Deg alternately with Press Test For Values followed by Press Reset 2X Clear The first response to any Alarm shu...

Страница 80: ...ut at this time The main display of the panel will begin to show High A E Disch Temp 229 Deg alternately with Press Test For Values followed by Press Reset 2X Clear The first response to any Alarm shu...

Страница 81: ...small nut only enough to compress the rubber grommet around the wire that prevents dirt or liquid from entering the connector Put a drop or two of Coolant on the sensor threads and O Ring prior to ins...

Страница 82: ...small nut only enough to compress the rubber grommet around the wire that prevents dirt or liquid from entering the connector Put a drop or two of Coolant on the sensor threads and O Ring prior to ins...

Страница 83: ...interrupted for any reason to include a direct short circuit condition the compressor will shut down in an Alarm condition If this ground condition exists on the Black wire going to any of the three...

Страница 84: ...interrupted for any reason to include a direct short circuit condition the compressor will shut down in an Alarm condition If this ground condition exists on the Black wire going to any of the three...

Страница 85: ...61359 13 59485 14 57674 15 55924 16 54233 17 52598 18 51017 19 49490 20 48012 21 46584 22 45202 23 43865 24 42573 25 41322 26 40112 27 38941 28 37808 29 36712 30 35650 31 34623 32 33631 33 32668 34 31...

Страница 86: ...61359 13 59485 14 57674 15 55924 16 54233 17 52598 18 51017 19 49490 20 48012 21 46584 22 45202 23 43865 24 42573 25 41322 26 40112 27 38941 28 37808 29 36712 30 35650 31 34623 32 33631 33 32668 34 31...

Страница 87: ...450 horsepower Intellisys units This interference usually shows up as random pressure reading fluctuations erroneous pressure sensor indication erratic LED displays or unit shutdown with Ready to Star...

Страница 88: ...450 horsepower Intellisys units This interference usually shows up as random pressure reading fluctuations erroneous pressure sensor indication erratic LED displays or unit shutdown with Ready to Star...

Страница 89: ...le half of the coupling onto the stepper shaft first open it with a small screwdriver and then slide it onto the shaft Leave the shaft end recessed from the surface of the coupling approximately 1 8 a...

Страница 90: ...le half of the coupling onto the stepper shaft first open it with a small screwdriver and then slide it onto the shaft Leave the shaft end recessed from the surface of the coupling approximately 1 8 a...

Страница 91: ...witch Close the inlet valve Replace the stepper motor assembly back onto the inlet valve housing After tightening the bolts that secure the stepper motor assembly to the inlet valve housing rotate the...

Страница 92: ...witch Close the inlet valve Replace the stepper motor assembly back onto the inlet valve housing After tightening the bolts that secure the stepper motor assembly to the inlet valve housing rotate the...

Страница 93: ...e Board terminal strip BTS1 between terminals 4 and 35 The part number for a complete 110V Power On light is 39478961 and the part number for a replacement 110V bulb is 39132667 Newer units have 24V a...

Страница 94: ...e Board terminal strip BTS1 between terminals 4 and 35 The part number for a complete 110V Power On light is 39478961 and the part number for a replacement 110V bulb is 39132667 Newer units have 24V a...

Страница 95: ...alve plate See figure A for the location of the hole 7 16 HOLE W BEVEL FIGURE A All future production SSR compressors that use the 6 butterfly valve will use the valve with the 7 16 hole in the plate...

Страница 96: ...alve plate See figure A for the location of the hole 7 16 HOLE W BEVEL FIGURE A All future production SSR compressors that use the 6 butterfly valve will use the valve with the 7 16 hole in the plate...

Страница 97: ...0VDC POWER OFF 4 BLACK GND 1 2 VARIABLE WITH PRESSURE 0 50mVDC POWER ON LINEAR 0 VDC POWER OFF 5 GROUN D 22 23 5VDC POWER ON 22 BLK 5 VDC SUPPLY 22 23 0VDC POWER OFF 23 SHLD GND 21 22 VARIABLE DUE TO...

Страница 98: ...0VDC POWER OFF 4 BLACK GND 1 2 VARIABLE WITH PRESSURE 0 50mVDC POWER ON LINEAR 0 VDC POWER OFF 5 GROUN D 22 23 5VDC POWER ON 22 BLK 5 VDC SUPPLY 22 23 0VDC POWER OFF 23 SHLD GND 21 22 VARIABLE DUE TO...

Страница 99: ...r handle during the day Electronic devices such as those found on Ingersoll Rand compressors can be damaged by this electricity Even though the part will function properly for a while the component li...

Страница 100: ...r handle during the day Electronic devices such as those found on Ingersoll Rand compressors can be damaged by this electricity Even though the part will function properly for a while the component li...

Страница 101: ..._________________________ Address _____________________________________________________ City State ___________________ ___________________________ Zip Phone Price Title Qty Req d Intellisys Serviceman...

Страница 102: ..._________________________ Address _____________________________________________________ City State ___________________ ___________________________ Zip Phone Price Title Qty Req d Intellisys Serviceman...

Страница 103: ...99 100 NOTES NOTES...

Страница 104: ...99 100 NOTES NOTES...

Страница 105: ...101 102 NOTES NOTES...

Страница 106: ...101 102 NOTES NOTES...

Страница 107: ...gersoll Rand Co IntellisysTM Serviceman s Guide SSR 10 40 Horsepower Models SSR 50 450 Horsepower Models Simplicity Serviceability Reliability Rotary Reciprocating Compressor Division Ingersoll Rand C...

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