Ingersoll-Rand Intellisys S3 Bedienungsanleitung

Intellisys Controller

Technician Guide

August 2008

Proprietary Notices and Disclaimer

Confidential and trade secret information. This

manual contains confidential and trade secret

information owned by Ingersoll Rand Company

(hereinafter referred to as “Proprietary Matter”).

In consideration of the disclosure of the

Proprietary Matter herein to the authorized

recipient hereof, the recipient shall treat the

Proprietary Matter as secret and confidential;

shall not disclose or give such Proprietary Matter

to third parties without the express written

authorization of INGERSOLL RAND; shall not

use the Proprietary Matter except to the extent

necessary to use or service the equipment

disclosed herein; and shall disclose such

Proprietary Matter only to those of its employees

whose use or knowledge of the Proprietary

Matter is necessary. This manual shall be

returned upon request by Ingersoll Rand

Company. The unauthorized use of this manual

may be punishable by law.

DISCLAIMERS

PROVIDED “AS IS”. THIS MANUAL AND THE

CONTENTS THEREOF ARE PROVIDED “AS

IS” AND WITHOUT ANY IMPLIED

WARRANTIES.

Contents



General Information ...........................................1

Component Review............................................2

Analog Inputs..................................................2

4APT ...........................................................2

3APT ...........................................................3

2ATT ...........................................................3

Digital Inputs...................................................9

Emergency Stop Switch..............................9

Coolant Filter Condition ..............................9

Inlet Filter Condition ....................................9

Motor Overloads .......................................10

Remote Start and Stop .............................10

Remote Load Enabled ..............................10

Remote Load/Unload ................................11

Motor PTC.................................................11

Digital Outputs ..............................................12

1M / 2M Starter Contacts ..........................12

1S Starter Contact ....................................12

Load Valve ................................................13

Blowdown Valve........................................13

Modulation Valve ......................................13

Condensate Drain Valve ...........................14

General Alarm Contact .............................15

PORO Relay .............................................15

Serial Communication ..................................15

Serial Port 1 ..............................................15

Serial Port 2 ..............................................16

Integral Sequencing ..................................16

Options .........................................................18

Low Ambient .............................................18

Power Out Restart ....................................18

Scheduled Start/Stop ................................19

Soft Starter................................................20

Auto Stop Timer ........................................21

Maintenance Intervals ..................................22

Multiple level maintenance intervals .........22

Reset Maintenance Timer.........................23

Warnings.......................................................24

Alarms (Trip).................................................26

Fault History..................................................29

Display Abbreviations ...................................33

S3 Controller Parameters .............................35

Real Clock Function .....................................37

Menu Screens ..............................................38

Status Screens (P00) ...................................38

Default Screen ..........................................38

Sump Pressure .........................................39

Running Hours ..........................................39

Loaded Hours ...........................................39

Integrated Sequence Control....................39

Pass Code Screen ....................................40

Unload Pressure Screen...........................40

Load Pressure...........................................41

Auto Stop Timer ........................................41

Modulation.................................................41

Engineering Units......................................41

Date and Time ..........................................41

Fault History (P02)........................................42

Advanced Setup Menu (P03) .......................43

Pressure Calibration .................................43

Sump Pressure Calibration .......................44

Star Delta Timer........................................44

Soft Start Timer.........................................44

Condensate Drain Time ............................44

Condensate Interval Timer........................45

Service Due Timer ....................................45

Scheduled Start and Stop .........................45

Scheduled Start Time ...............................45

Scheduled Stop Time................................45

Power Out Restart Option Timer ..............46

Low Ambient Load Delay..........................46

Remote Control Selection .........................46

Modbus Address .......................................47

Baud Rate .................................................47

Factory Setup Menu (P04) ...........................48

Running Hours Adjust ...............................48

Loaded Hours Adjust ................................48

Maintenance Hours Reset ........................48

Starter Type ..............................................49

Rated Pressure .........................................49

Low Ambient .............................................49

Dryer Enabled ...........................................49

PORO Enabled .........................................50

Flow Diagrams

Schematic Diagram

General Information

The Intellisys S3 Controller is designed as a

global controller to be used on all 90 - 160kW

(125 - 200Hp) units. This Controller has

replaced all wording with symbols eliminating

the need of multiple language programming. The

below picture shows the basic layout of the S3

controller, this controller is designed for easy

use by the end-user as well as the service

technician.

This controller was developed to be used in both

rapidly Developing Economies as well as

Developed Markets around the world making

this controller a common worldwide solution for

the Rotary Screw compressor line.

The S3 controller controls all aspects of machine

operation including; starting, stopping, loading

and unloading, safety shutdowns, user interface,

and compressor remote connectivity to other

devices.

This controller is offered in either a standard

configuration or an enhanced configuration. The

differences will be indicated in this manual by

show the following guides after each input or

output device or software function.

Std – Standard Controller

Enh – Enhanced Controller

The S3 controller has three (3) Analog Inputs,

one (1) Analog Output, eight (8) Digital Inputs,

and six (6) Digital Outputs. This controller also

has capabilities of using both Multi-485 and

Modbus communication protocols.

Component Review

Analog Inputs

4APT [Std] – This pressure transducer used to

convert the package discharge pressure of the

compressor into a 4-20ma analog signal to the

controller. This sensor has a supply voltage of

24VDC, and wired into terminal block XO5 pins

1 & 2 on the backside of the controller. The

output analog signal ranges from 4ma at 0 psi to

20ma at 232psi.The output signal is processed

by the Intellisys and depending on the voltage

the controller may cause a change in the

pressure readout on the display, load or unload

the compressor, or even shut the compressor

down if conditions dictate.

There are no adjustments to this pressure

transducer and if problems arise, the transducer

will need to be replaced. Although the

transducer is non-adjustable, it must be

calibrated periodically. Calibrating the

transducer allows the controller to read the

transducers output at zero gauge pressure and

make any corrections in deviation from the 4ma.

This sensor has an accuracy of 0.5%.

Sensor calibration will be discussed later in this

handbook.

3APT [Enh]– This sensor is the same as 4APT

and can be interchangeable however, 3APT

measures the pressure from the wet side of the

sump. Only available with the enhanced

controller option, this transducer is connected to

the controller at terminal XO5 pins 5 and 6.

2ATT [Std] – This 10K ohm NTC (negative

temperature coefficient) thermistor is located at

the airend discharge. This thermally sensitive

resistor increases the resistant value as the

temperature decreases. It is wired into the

controller at terminal XO5 pins 3 and 4. The

thermistor has a range of -34 to 124°C (-29 to

255°F) the following pages shows the

relationship between resistance and

temperature for this thermistor.

Ohms Temperature Ohms Temperature

251311 -30 86914 1

243422 -29 84161 2

235533 -28 81503 3

227644 -27 78938 4

219756 -26 76463 5

211867 -25 74072 6

203978 -24 71765 7

196089 -23 69536 8

188200 -22 67384 9

182622 -21 65306 10

177044 -20 63298 11

171467 -19 61359 12

165888 -18 59485 13

160311 -17 57674 14

154733 -16 55924 15

149156 -15 54233 16

143578 -14 52598 17

138000 -13 51017 18

134004 -12 49490 19

130037 -11 48012 20

126070 -10 46584 21

122104 -9 45202 22

118137 -8 43865 23

114170 -7 42573 24

110204 -6 41322 25

106623 -5 40112 26

102300 -4 38941 27

99802 -3 37808 28

96650 -2 36712 29

93399 -1 35650 30

89768 0 34623 31

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