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SSR INTELLISYS ROTARY

TROUBLESHOOTING GUIDE

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Original Intellisys

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SE & SG

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Problems

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Procedures

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Warranty Information

APDD 749
September 1999

Содержание INTELLISYS SSR Series

Страница 1: ...SSR INTELLISYS ROTARY TROUBLESHOOTING GUIDE Original Intellisys SE SG Problems Procedures Warranty Information APDD 749 September 1999...

Страница 2: ...ed 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...

Страница 3: ...IGINAL SE SG HIGH AIREND TEMPERATURE ALARM 15 ORIGINAL SE SG MAIN MOTOR OVERLOAD ALARM 16 ORIGINAL SE SG STARTER FAULT ALARM 17 ORIGINAL STARTER FAULT ALARM CONTINUED 18 SE SG NO CONTROL POWER ALARM 1...

Страница 4: ...7 Procedure 38 2 5 TRIAC OUTPUTS Background 37 Procedure 37 2 6 AUXILIARY CONTACTS Background 38 Procedure 38 3 1 SG POWER OUTAGE Background 40 Procedure 40 3 2 SG VOLTAGE SAG Background 40 Procedure...

Страница 5: ...raph 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...

Страница 6: ...tellisys Digital 5 VDC J11 1 5 5 VDC 2 VDC Intellisys Analog 5 VDC J3 25 24 5 VDC 2 VDC Battery Voltage BAT 3 0 VDC 6 VDC Ground Fault Current Machine running in loaded condition Customer Ground condu...

Страница 7: ...5 VDC 1 VDC Battery Voltage BAT 3 0 VDC 6 VDC Ground Fault Current Machine running in loaded condition Customer Ground conductor 0 0 Amps AC DC 25 Amps AC DC see Paragraph 1 3 GROUND RESISTANCE CHECK...

Страница 8: ...ECK CUSTOMER GROUND INTEGRITY CHECK FOR FAULT CURRENT IN GROUND LEG CHECK GROUND RESISTANCE BACK TO J4 29 INSPECT BOND INTEGRITY SEE PARAGRAPH 1 3 2ATT BLACK WIRE TO GROUND 1 MEG OHM 3APT RED WIRE TO...

Страница 9: ...ING FROM T1 TO J1 1 2 SEE PARAGRAPH 3 3 CHECK CUSTOMER GROUND INTEGRITY CHECK FOR FAULT CURRENT IN GROUND LEG CHECK GROUND RESISTANCE BACK TO J4 29 INSPECT BOND INTEGRITY SEE PARAGRAPH 1 3 2ATT BLACK...

Страница 10: ...ING FROM T1 TO J1 1 2 SEE PARAGRAPH 3 3 BAD MEMBRANE USE SE I O MEMBRANE TEST KIT TO VERIFY BAD MEMBRANE TEST MEMBRANE SEE PARAGRAPH 5 0 EXCESSIVE TEMPERATURE REDUCE CONTROLLER AMBIENT TO 160 F SEE PA...

Страница 11: ...10 ORIG SE SG TRIAC IS ON AND SHOULD BE OFF OR TRIAC IS OFF AND SHOULD BE ON SE CONTROLLER SG CONTROLLER ORIGINAL INTELLISYS USE SE I O TEST KIT SEE PARAGRAPH 2 5 SEE BLUE FSM SECTION B SHEET 28...

Страница 12: ...CLOSED LIMIT SWITCH AND STOP YES SUSPECT BAD CONTROLLER NO IS THE BLOWDOWN AIR HITTING THE VALVE PLATE AND KEEPING IT FROM MOVING CLOSED YES MAKE SURE BLOW DOWN DEFLECTOR IS IN PLACE IF NECESSARY BEN...

Страница 13: ...YES IS THE AIREND TURNING YES SUSPECT 1AVPT TRANSDUCER PROBLEM OR LEAK IN SENSING LINE NO SUSPECT SLIPPING GEAR NO ORIGINAL CONTROLLER CHECK FOR SLIPPING COUPLING SG CONTROLLER CHECK POSITION OF CLOSE...

Страница 14: ...EN IF PUMPING INTO AN OPEN SYSTEM IF NONE OF THE ABOVE THEN PROBABLY A BINDING INLET VALVE IF NOT OK THEN REPAIR AND RETEST IF OK IS BLOWDOWN AIR CAUSING THE VALVE TO CLOSE TOO FAR YES MAKE SURE BLOW...

Страница 15: ...E INLET VALVE SLIPPING COUPLING FAULTY 4APT SENSOR SEE PROCEDURE 2 4 BAD COOLANT BYPASS OR BAD AIR FILTER WATER IN THE SYSTEM WATER IN THE SYSTEM CAUSING CORROSION IN THE VALVE SE CONTROLLER BLOCKAGE...

Страница 16: ...LEM WITH COOLANT STOP VALVE CHECK WIRING AND VALVE OPERATION SEE PROCEDURE 2 5 AIR COOLED BAD ENVIRONMENT WATER COOLED BAD WATER FOULING TUBES EXTERNAL COOLANT LEAK CAUSING AIR COOLED HEAT EXCHANGER T...

Страница 17: ...NO ARE THE TEMPERATURES OF THE THREE STARTER POLES THE SAME OR ARE THEY HOTTER THAN 160 F ANY SIGNS OF HOT SPOTS ON STARTER NO IS THE STARTER ENCLOSURE HOTTER THAN NORMAL YES CHECK FOR LOW VOLTAGE VO...

Страница 18: ...NTELLISYS VOLTAGE ACROSS CONTACT SHOULD BE 5 VDC WHEN CONTACT IS OPEN AND 0 VDC WHEN CONTACT IS CLOSED SG INTELLISYS VOLTAGE ACROSS CONTACT SHOULD BE 10 12 VDC WHEN CONTACT IS OPEN AND 0 VDC WHEN CONT...

Страница 19: ...1 33 AND BTS1 3 IS THE VOLTAGE GREATER THAN 110 VAC NO BAD CONTACT ON E STOP YES MEASURE VOLTAGE AC TERMINAL BTS1 31 AND BTS1 3 IS THE VOLTAGE GREATER THAN 110 VAC NO BAD 1ATS YES MEASURE VOLTAGE AC T...

Страница 20: ...ESS THAN 12 SECONDS AFTER START UP SE CONTROLLER MEASURE VOLTAGE AC TERMINAL BTS1 6 AND J4 29 SG CONTROLLER MEASURE VOLTAGE AC P1 10 AND TERMINAL 1TB 1 IS THE VOLTAGE GREATER THAN 110 VAC IS THE VOLTA...

Страница 21: ...IS 10SV ENERGIZING AT START ORIG AND SG CONTROLLER IS THE AIREND TURNING IS THE AIREND TURNING NO IS THE MOTOR TURNING NO CHECK VOLTAGE STARTER AND MOTOR YES ARE THE BELTS SLIPPING NO BROKEN AIREND DR...

Страница 22: ...AIN IS THE VOLTAGE 2VDC NO POTENTIAL BAD CONTROLLER LIMIT BOARD OR WIRING YES IS ALARM STILL OCURRING MEASURE VOLTAGE BETWEEN WHITE AND BLACK WIRE MEASURE VOLTAGE BETWEEN GREEN AND BLACK WIRE ARE BOTH...

Страница 23: ...TE START AGAIN IF ALARM STILL OCCURS SUSPECT PROBLEM WITH RIBBON CABLE OR CONTROLLER FOR THE ORIGINAL INTELLISYS CONTROLLER OR JUST THE CONTROLLER FOR THE SG MEASURE VOLTAGE BETWEEN P3 TERMINAL 19 20...

Страница 24: ...TE START AGAIN IF ALARM STILL OCCURS SUSPECT PROBLEM WITH INTELLISYS CONTROLLER SE INTELLISYS CONTROLLER CONNECT DC VOLT METER TO J1 TERMINAL 5 6 START UNIT USING REMOTE START BUTTON AND MONITOR VOLTA...

Страница 25: ...OLANT WATER IN THE COOLANT UNIT RUNNING TOO COLD LEAK IN WATER COOLED COOLANT COOLER CLOGGED SCAVENGE ORIFICE OR SCREEN SCAVENGE TUBE TOO SHORT FOR ELEMENT NO LOW DIFFERENTIAL OR COOLANT CARRY OVER HO...

Страница 26: ...25 USE THIS PAGE FOR NOTES...

Страница 27: ...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 circu...

Страница 28: ...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...

Страница 29: ...y 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 pr...

Страница 30: ...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 do...

Страница 31: ...ermittent connections can be caused by improper installation bent connection pins moisture contamination corrosion of electrical contacts or excessive vibration Procedure This voltage measurement can...

Страница 32: ...sion 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 inspec...

Страница 33: ...urements 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...

Страница 34: ...ated interference RFI 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 for...

Страница 35: ...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...

Страница 36: ...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 ste...

Страница 37: ...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...

Страница 38: ...s 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 v...

Страница 39: ...trol 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...

Страница 40: ...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...

Страница 41: ...rd 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 exa...

Страница 42: ...olts 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...

Страница 43: ...ck 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 note...

Страница 44: ...irective 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...

Страница 45: ...ent 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...

Страница 46: ...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...

Страница 47: ...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 P...

Страница 48: ...47 Figure 2 SG Membrane Schematic S1 1 2 S2 1 4 S3 5 4 S4 Start 3 2 S5 Unload 3 4 S6 Load 5 6 S7 Unloaded Stop 7 6 S8 Down Arrow 7 8 S9 Up Arrow 5 8...

Страница 49: ...ect 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 M...

Страница 50: ...____ Title ____________________________________________________________________________________ Address ____________________________________________________________________________________ City State...

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