Ingersoll-Rand INTELLISYS SSR Series User manual

SSR INTELLISYS ROTARY
TROUBLESHOOTING GUIDE
•Original Intellisys
• SE & SG
•Problems
• Procedures
• Warranty Information
APDD 749
September 1999

1
SSR INTELLISYS ROTARY
TROUBLESHOOTING GUIDE
The following is a guide to be used when identifying the root cause of a
compressor problem.
Forms have also been developed for the SE and SG controller and must be filled
in if the controller is to be returned to the factory under warranty.
Any controller returned 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 cause.
Not all flowchart pages pertain to all controllers. Look in the top left corner to see
what controllers the particular page covers.
ORIG = Original Intellisys controller SSR 50-450HP
SE = SE Intellisys controller SSR 20-100HP
SG = SG Intellisys controller SSR 125-450HP
FSM = Field Service Manuals
9/16//99 Rev 5

2
TABLE OF CONTENTS
INTRODUCTION.........................................................................................................................................1
TABLE OF CONTENTS..............................................................................................................................2
HOW TO USE...............................................................................................................................................4
SE INTELLISYS CONTROLLER WARRANTY INFORMATION SHEET........................................5
SG INTELLISYS CONTROLLER WARRANTY INFORMATION SHEET........................................6
PROBLEMS
SE CONTROLLER - SHUTS DOWN WITH READY TO START IN THE DISPLAY ...................................................7
SG CONTROLLER - SHUTS DOWN WITH READY TO START IN THE DISPLAY...................................................8
ORIGINAL, SE, SG - CONTROLLER LOCKS-UP ..........................................................................................9
ORIGINAL, SE SG - TRIAC DOES NOT OPERATE PROPERLY .....................................................................10
ORIGINAL, SG - CHECK INLET CONTROL SYSTEM ALARM.....................................................................11
ORIGINAL, SG - CHECK INLET CONTROL ALARM ..................................................................................12
ORIGINAL, SE , SG - LOW UNLOADED SUMP ALARM............................................................................13
ORIGINAL, SE , SG - HIGH SUMP PRESSURE ALARM .............................................................................14
ORIGINAL, 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....................................................................................................19
ORIGINAL, SE , SG - CHECK MOTOR ROTATION ALARM .......................................................................20
ORIGINAL, SG - STEPPER LIMIT SWITCH ALARM ..................................................................................21
ORIGINAL, SE , SG - REMOTE STOP FAILURE ALARM ...........................................................................22
ORIGINAL, SE , SG - REMOTE START FAILURE ALARM .........................................................................23
ORIGINAL, SE , SG - SHORT SEPARATOR ELEMENT LIFE ........................................................................24
NOTES........................................................................................................................................................25
PROCEDURES
1.1 SE POWER OUTAGE
Background ...............................................................................................................................................26
Procedure...................................................................................................................................................26
1.2 SE VOLTAGE SAG
Background................................................................................................................................................26
Procedure...................................................................................................................................................26
1.3 GROUNDING PROBLEMS
Background................................................................................................................................................27
Procedure...................................................................................................................................................27
1.4 SE INTELLISYS 16 VAC SUPPLY
Background................................................................................................................................................29
Procedure...................................................................................................................................................29
1.5 SE EXTERNAL 5 VDC SHORT CIRCUIT
Background................................................................................................................................................30
Procedure...................................................................................................................................................30
ENVIRONMENTAL PROBLEMS
1.6 MOISTURE
Background................................................................................................................................................31
Procedure .................................................................................................................................................31

3
1.7 TEMPERATURE
Background................................................................................................................................................31
Procedure .................................................................................................................................................32
1.8 VIBRATION
Background................................................................................................................................................32
Procedure .................................................................................................................................................32
OTHER
1.9 REMOTE ALARM APPLICATION
Background................................................................................................................................................32
Procedure .................................................................................................................................................32
2.1 STEPPER MOTOR TEST
Background................................................................................................................................................34
Procedure .................................................................................................................................................34
2.2 DRIVER CHIP TEST
Background................................................................................................................................................34
Procedure .................................................................................................................................................35
2.3 LIMIT BOARD TEST
Background................................................................................................................................................36
Procedure .................................................................................................................................................36
2.4 PRESSURE SENSOR CHECK OUT
Background................................................................................................................................................37
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...................................................................................................................................................40
3.3 SG INTELLISYS 24 VAC SUPPLY
Background................................................................................................................................................41
Procedure...................................................................................................................................................41
3.4 SG EXTERNAL 5 VDC SHORT CIRCUIT
Background................................................................................................................................................41
Procedure...................................................................................................................................................42
4.0 EXTERNAL ELECTRICAL DISTURBANCES
Background................................................................................................................................................43
5.0 MEMBRANE SWITCH CHECK
Background................................................................................................................................................46
Procedure .................................................................................................................................................46
Figure 1 - SE Membrane Schematic..........................................................................................................46
Figure 2 - SG Membrane Schematic..........................................................................................................47
Figure 3 - ORIGINAL Membrane Schematic............................................................................................48

4
USER INSTRUCTIONS
Identify the problem that is being experienced with the controller or compressor.
Locate the problem in the table of contents under the PROBLEMS section.
Turn to that page and follow the flow chart through the diagnostics. If the flow
chart refers to another paragraph, find the paragraph 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 in the table of contents under the problems
section. That refers to page 11. As you follow the diagnostics, the flow chart
says to see paragraph 2.3. Find paragraph 2.3 in the table of contents. That
refers to page 36 for background and procedure information. Turn to that page
and follow any instructions.

5
SE INTELLISYS CONTROLLER GENERAL INFORMATION
Date: Customer: Distributor: Technician:
Machine S/N: Model Number Total Hours: Loaded Hours:
NEMA Rating: Starter Type: Ambient Temp: Start-up Date:
Problem Description (What, How, When):
INTELLISYS SE INFORMATION
Intellisys S/N EPROM Version: Offline Pressure: Online Pressure:
Mode of Operation: Options: Comm. Link: Last Alarm:
POWER SUPPLY INFORMATION POWER ON
Circuit Test Point Expected Value Measured Value
Control Transformer
Primary VAC T1 200-575 VAC
Control Transformer
Secondary : 120 VAC J5-36 to J5-35 120 VAC +/- 18 VAC
Control Transformer
Secondary : 16 VAC
(center-tap)
J4-30,31
J4-29,30
J4-29,31
16 VAC +/- 2.4 VAC
8 VAC +/- 1.2 VAC
8 VAC +/- 1.2 VAC
Rectified Intellisys DC J4-28,29 10.5 VDC +/- 1.6 VDC
Intellisys 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
conductor 0.0 Amps AC/DC +/- .25 Amps AC/DC
see Paragraph 1.3
GROUND RESISTANCE CHECK INFORMATION POWER OFF
Circuit Test Point Expected Value Measured Value
Intellisys Ground J1-1, GND LUG < .5 Ohm
120 VAC Neutral T1, GND Lug < .5 Ohm
Motor Frame Motor chassis, base < .5 Ohm
Sensor Ground 3APT chassis, base < .5 Ohm
Airend Ground Air end chassis, base lug < .5 Ohm
Package Ground Machine Base, GND lug < .5 Ohm
Customer Ground Structural Earth, base lug < .5 Ohm
I/O RESISTANCE CHECK POWER OFF
Pressure
J3 Connected to board Black to GND Green to GND
White to GND
<.5 ohm
185 +/- 50
850 ohm +/- 100
Temperature
J2 Connected to board White to GND 140 ohm +/- 10 @ 77 F
Digital I/O
J1 (a) N.C. N.O. < .5 ohm > 1 meg ohm
(a) Only test wired contacts and list only connections out of range.

6
SG INTELLISYS CONTROLLER GENERAL INFORMATION
Date: Customer: Distributor: Technician:
Machine S/N: Model Number Total Hours: Loaded Hours:
NEMA Rating: Starter Type: Ambient Temp: Start-up Date:
Problem Description (What, How, When):
INTELLISYS SG INFORMATION
Intellisys S/N EPROM Version: Offline Pressure: Online Pressure:
Mode of Operation: Options: Comm. Link: Last Alarm:
POWER SUPPLY INFORMATION POWER ON
Circuit Test Point Expected Value Measured Value
Control Transformer
Primary VAC T1 200-575 VAC +/- 10%
Control Transformer
Secondary : 120 VAC P1-1, P1-10 120 VAC +/- 18 VAC
Control Transformer
Secondary : 24 VAC Power Supply Board J1-1, J1-2 24 VAC +/- 3.6 VAC
Rectified Intellisys DC Power Supply Board
J2-1,J2-2 12 VDC +/- .6 VDC
Intellisys Digital 5 VDC P9-1,5 5 VDC +/- .2 VDC
Intellisys Analog 5 VDC P5-7,8 5 VDC +/- .2 VDC
Pressure Signal @ 0 psi P5 white to Black .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 INFORMATION POWER OFF
Circuit Test Point Expected Value Measured Value
Intellisys Ground J1-5, GND LUG < .5 Ohm
120 VAC Neutral T1, GND Lug < .5 Ohm
Motor Frame Motor chassis, base lug < .5 Ohm
Sensor Ground 3APT chassis, base lug
1AVPT chassis, base lug
4APT chassis, base lug
< .5 Ohm
< .5 Ohm
< .5 Ohm
Airend Ground Air end chassis, base lug < .5 Ohm
Package Ground Machine Base, GND lug < .5 Ohm
Customer Ground Structural Earth, base lug < .5 Ohm
I/O RESISTANCE CHECK POWER OFF
Pressure
P5 Connected to board Black to GND White to GND <.5 ohm 20K +/- 3K
Temperature
P6 Connected to board White to GND Black to GND Temperature dependent <.5 ohm
Digital I/O (a)
P3 1-2, 3-4, 5-6 ,…..32 N.C. N.O. <.5 ohm >1 meg ohm
Stepper motor
connections Power Supply Board J3,1-2 J3,3-4 4” & 6” valve = 5-7 Ohms 8” valve = 11-13 Ohms
(a) Only test wired connections and list only connections out of range.

7
= MACHINE WAS OPERATIONAL AND IN THE RUNNING MODE. MACHINE STOPS AND DISPLAYS
“READY TO START” OR SHUTS DOWN WITH BLANK DISPLAY
INCOMING VOLTAGE DIPS BELOW 30%
16 VAC C.T. FEED CIRCUIT INTERMITTENT
INTERMITTENT SHORT ON 5 VDC ANALOG
OPTION PROM INTERMITTENT
CONNECTION TO J11
EXCESSIVE TEMPERATURE
REMOTE ALARM ARCING
EXCESSIVE MOISTURE
INTERMITTENT POWER OUTAGE
VIBRATION
SERVICE APPLICATION, CHECK PHASE UNBALANCE, and SERVICE WIRE
AMPACITY.
CHECK WIRING FROM T1 TO J4-29, 30, 31.
SEE PARAGRAPH 1.4
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 WIRE TO GROUND < 1 MEG OHM
3APT - RED WIRE TO GROUND < 1 MEG OHM
SEE PARAGRAPH 1.5
SEE PARAGRAPH 1.5
REDUCE CONTROLLER AMBIENT TO <160°F
SEE PARAGRAPH 1.7
INSURE PROPER SUPPRESSOR. SEE PARAGRAPH 1.9
WATER LEAKING INTO CONTROLLER. SEE PARAGRAPH 1.6
PROBLEM WITH CUSTOMER POWER SUPPLY. SEE PARAGRAPH 1.1
SEE PARAGRAPH 1.8
INTERMITTENT/IMPROPER GROUND
BATTERY CONNECTION OR VOLTAGE
INCOMING POWER DISTURBANCES SEE PARAGRAPH 4.0
LOOK FOR CORROSION ON THE BATTERY TERMINAL. VERIFY THAT
VOLTAGE IS 3.0 VDC +/- .6 VDC
SE CONTROLLER:
SHUT DOWN “READY TO START”

8
SG CONTROLLER:
SHUTDOWN “READY TO START” = MACHINE WAS OPERATIONAL AND IN THE RUNNING MODE. MACHINE STOPS AND DISPLAYS
“READY TO START” OR SHUTS DOWN WITH BLANK DISPLAY
INCOMING VOLTAGE DIPS BELOW 30%
24 VAC C.T. FEED CIRCUIT INTERMITTENT
INTERMITTENT SHORT ON 5 VDC
OPTION PROM INTERMITTENT
CONNECTION TO J11
EXCESSIVE TEMPERATURE
REMOTE ALARM ARCING
EXCESSIVE MOISTURE
INTERMITTENT POWER OUTAGE
VIBRATION
SERVICE APPLICATION, CHECK PHASE UNBALANCE, and SERVICE WIRE
AMPACITY.
CHECK WIRING 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 WIRE TO GROUND < 1 MEG OHM
3APT - RED WIRE TO GROUND < 1 MEG OHM
SEE PARAGRAPH 3.4
SEE PARAGRAPH 3.4
REDUCE CONTROLLER AMBIENT TO
<160°F
INSURE PROPER SUPPRESSOR. SEE PARAGRAPH 1.9
WATER LEAKING INTO CONTROLLER. SEE PARAGRAPH 1.6
PROBLEM WITH CUSTOMER POWER SUPPLY. SEE PARAGRAPH 3.1
SEE PARAGRAPH 1.8
INTERMITTENT/IMPROPER GROUND
BATTERY CONNECTION OR VOLTAGE LOOK FOR CORROSION ON THE BATTERY TERMINAL. VERIFY THAT
VOLTAGE IS 3.0 VDC +/- .6 VDC
INCOMING POWER DISTURBANCES SEE PARAGRAPH 4.0

9
ORIG,SE,SG:
CONTROLLER LOCK-UP. UNIT WILL NOT STOP
OR READY TO START WILL NOT START
= UNIT RUNNING. PUSHING THE STOP BUTTON DOES NOT CAUSE ANYTHING TO
HAPPEN AND NO ALARMS ARE INDICATED, OR READY TO START IN THE DISPLAY
AND PRESSING THE START BUTTON DOES NOT CAUSE START OR ALARM. CYCLING
POWER WILL RESET BUT PROBLEM OCCURS AGAIN.
SE CONTROLLER SG CONTROLLER
ORIGINAL INTELLISYS
16 VAC C.T. FEED
CIRCUIT INTERMITTENT
CHECK WIRING FROM T1 TO
J4-29, 30, 31.
SEE PARAGRAPH 1.4
24 VAC FEED CIRCUIT
INTERMITTENT
CHECK WIRING 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 PARAGRAPH 1.7
EXCESSIVE MOISTURE. WATER
LEAKING INTO CONTROLLER. SEE
PARAGRAPH 1.6
COMM PORT
SE USE I/O TEST KIT
SEE SHEET FOR BLANK DISPLAY
FOR OTHER OPTIONS, PAGE 7 & 8
115 VAC FEED CIRCUIT
INTERMITTENT
CHECK WIRING AND
VOLTAGE FROM BTS1 -
33 & 3.
YES. CHECK VOLTAGE AT TRANSFORMER T3
AND CONNECTION J1
J1 1 & 6 SHOULD BE 110-130 VAC
J1 2 & 5 SHOULD BE 12-14 VAC
J1 2 & 4 SHOULD BE 6-7 VAC
J1 3 & 5 SHOULD BE 6-7 VAC
IF NOT, BAD T3 TRANSFORMER
IS IT 110-130 VAC?
NO. PROBLEM WITH T1
TRANSFORMER OR
BAD MEMBRANE
SEE PARAGRAPH
5.0

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

11
ORIG, SG: CHECK INLET CONTROL SYS
LOADING
UNLOADING
AT STARTING AFTER TRANSITION
DID VALVE MOVE PAST
THE OPEN LIMIT SWITCH?
DID VALVE MOVE PAST THE
CLOSED LIMIT SWITCH?
YES SUSPECT BAD OPEN LIMIT SWITCH
SEE PROCEDURE 2.3
NO. DID VALVE MOVE TO
THE OPEN LIMIT SWITCH AND STOP?
YES. SUSPECT BAD CONTROLLER
NO. SUSPECT SLIPPING COUPLING
BAD STEPPER MOTOR. SEE PROCEDURE 2.1
BAD DRIVER CHIP. SEE PROCEDURE 2.2
IF NONE OF THE ABOVE THEN PROBABLY A
BINDING INLET VALVE.
YES. SUSPECT BAD CLOSED LIMIT
SWITCH
NO. DID VALVE MOVE TO THE
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,
BEND DEFLECTOR TO DEFLECT AIR
UPWARD
NO. SUSPECT SLIPPING COUPLING.
BAD STEPPER MOTOR. SEE PROCEDURE
2.1
BAD DRIVER CHIP. SEE PROCEDURE 2.2
IF NONE OF THE ABOVE THEN PROBABLY
A BINDING INLET VALVE.
NO. SUSPECT SLIPPING COUPLING.
BAD STEPPER MOTOR. SEE PROCEDURE
2.1
BAD DRIVER CHIP. SEE PROCEDURE 2.2
IF NONE OF THE ABOVE THEN PROBABLY
A BINDING INLET VALVE.
= VALVE COMMANDED TO MOVE TO OPEN OR CLOSED LIMIT SWITCH AND CONTROLLER NEVER
RECEIVES SIGNAL FROM LIMIT SWITCH CONFIRMING THE VALVE MADE IT THERE.
CONFIRM 24 VAC TO BOARD

12
ORIG, SG: CHECK INLET CONTROL
UNLOADED IS THE INLET VALVE CLOSED?
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 CLOSED LIMIT SWITCH
= UNIT UNLOADED AND INLET VACUUM LESS THAN THREE PSI.

13
ORIG, SE, SG: LOW UNLOADED SUMP
UNLOADED OR STARTING
AFTER TRANSITION
= UNIT UNLOADED AND SUMP PRESSURE IS LESS THAN 15 PSI FOR 10 SECONDS
CHECK SENSING LINE TO 3APT
AND SENSOR 3APT. SEE PROCEDURE 2.4
NO. SUSPECT SLIPPING COUPLING
BAD STEPPER MOTOR. SEE PROCEDURE 2.1
BAD DRIVER CHIP. SEE PROCEDURE 2.2
MPCV STUCK OPEN 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 DOWN
DEFLECTOR IS IN PLACE. IF NECESSARY,
BEND DEFLECTOR TO DEFLECT AIR
UPWARD
SE CONTROLLER
FULL VOLTAGE? YES OR
YES. CHECK FOR INLET VALVE STUCK CLOSED OR
BROKEN SPRING IN INLET VALVE.
NO. CHECK BLOW DOWN SILENCER ADJUSTMENT.
MAKE SURE MAKE UP PORTS IN INLET VALVE ARE OPEN.
BLOCKAGE IN SENSOR LINE FROM SUMP
TO 10SV

14
ORIG, SG, SE: HIGH SUMP PRESSURE = SUMP PRESSURE IS GREATER THAN 15 PSIG ABOVE THE RATED PRESSURE OF THE UNIT.
CLOGGED SEPARATOR ELEMENT
STICKING MINIMUM PRESSURE CHECK VALVE
BLOCKAGE OR LEAK IN SENSING LINE TO 4APT CHECK SPECIAL TEE ON TOP OF MOISTURE
SEPARATOR WHERE 4 APT CONNECTS.
OLD STYLE 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 IN SENSING LINE TO 10SV
FULL VOLTAGE? YES OR NO
YES
NO AIR SIGNAL TO CLOSE THE VALVE. FAULTY 1SV OR SHUTTLE VALVE.
STICKING INLET VALVE
,
BLOWDOWN VALVE NOT OPENING.
NO.
BROKEN SPRING IN INLET VALVE
1SV STILL ENERGIZED, STICKING OR LEAKING AIR SIGNAL TO OPEN INLET
VALVE. BLOWDOWN VALVE NOT OPENING

15
ORIG, SG, SE: HIGH AIREND TEMPERATURE = AIREND DISCHARGE TEMPERATURE EQUAL TO OR GREATER THAN 228°F.
FAULTY THERMOSTATIC VALVE
DIRTY COOLERS
HIGH AMBIENT
ABOVE 115°F
DOES UNIT SHUT DOWN IN LESS THAN 10 SECONDS AFTER START-UP?
YES. IS COOLANT LEVEL CORRECT?
NO
NO. CORRECT COOLANT AND TRY AGAIN.
YES. SUSPECT PROBLEM 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 TO CLOG
WITH DIRT
RESTRICTIVE EXHAUST DUCTING
> .25” WATER COLUMN
RECIRCULATION OF COOLING AIR
IS THE VALVE BYPASSING THE COOLER?
SWAP WITH 4ATT FOR QUICK DETERMINATION (NOT SE)
CHECK FOR HIGH MOTOR AMPS
UNUSUAL NOISE
HIGHER VIBRATION THAN NORMAL
METAL IN THE COOLANT FILTER
FAULTY THERMISTOR 2ATT
FAULTY AIREND

16
ORIG, SG, SE: MAIN OR FAN MOTOR OVERLOAD
PLACE OVERLOAD RELAY IN MANUAL
RESET MODE
YES. DID OVERLOAD RELAY REQUIRE
RESETTING BEFORE BEING ABLE TO
RESET THE INTELLISYS CONTROLLER?
NO. POTENTIAL PROBLEM WITH WIRING FROM OVERLOAD TO CONTROLLER OR CONTROLLER.
ORIGINAL & SE INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 5 VDC WHEN
CONTACT IS OPEN AND 0 VDC WHEN CONTACT IS CLOSED.
(MAIN MOTOR, ORIG BTS2 10-11, SE-J1 15&16. FAN MOTOR, ORIG- BTS2 8&9. SE- J1 13&14)
SG INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 10-12VDC WHEN
CONTACT IS OPEN AND 0 VDC WHEN CONTACT IS CLOSED
(MAIN MOTOR P3 11&12, FAN MOTOR P3 13&14)
YES. ARE THE AMPS
HIGHER?
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
VOLTAGE UNBALANCE
OVERPRESSURE
TIGHT AIREND
LOSS OF PHASE
STARTING UNDER A LOAD
NO. CORRECT HEATER SELECTION OR OVERLOAD SETTING.
YES. CHECK FOR BAD CONNECTIONS
AND MAKE SURE CONDUIT FROM MOTOR IS
SEALED WITH ELECTRICAL PUTTY
YE
S.
BAD
CONN
E
C
TI
ON
W
ITHI
N
THE
S
TARTER
NO. POTENTIAL PROBLEM WITH OVERLOAD RELAY, CONTROLLER, OR RIBBON CABLE ON ORIGINAL INTELLISYS
LESS THEN 95% NOMINAL
MORE THAN 1% UNBALANCE
LOSS OF STAGE ON 2 STAGE UNIT
BLOWN FUSE
BAD CONNECTION
BURNT CONTACTOR
BLOWDOWN VALVE NOT OPEN
INLET VALVE NOT CLOSED
= OVERLOAD CONTACT OPEN FOR MORE THAN ONE SECOND.
IS THE HEATER ELEMENT OR
OVERLOAD RELAY THE PROPER SIZE?

17
YES. IS COOLANT LEVEL CORRECT?
NO. CORRECT COOLANT AND TRY AGAIN
YES. SUSPECT PROBLEM WITH COOLANT STOP VALVE
CHECK WIRING AND VALVE OPERATION (SEE
PROCEDURE 2.6)
IS THIS THE ORIGINAL INTELLISYS CONTROLLER?
NO. ANY CONTROLLER
INCLUDING?
THE ORIGINAL INTELLISYS
YES. IS AIREND DISCHARGE TEMPERATURE GREATER THAN
210°F AT TIME OF SHUTDOWN?
NO. SEE PAGE 18
DO 1S AND 1M ENGERIZE WHEN
THE START BUTTON IS PRESSED? NO. POTENTIAL PROBLEM WITH TRIAC ON STARTER INTERFACE BOARD,
CONTROLLER
YES. DOES THE UNIT SHUT DOWN 2-3
SECONDS AFTER 1S AND 1M ENERGIZED? YES. POTENTIAL PROBLEM WITH WIRING OR AUXILIARY CONTACTS 1Ma OR 1Sa
SE & ORIGINAL INTELLISYS: 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 CONTACT IS CLOSED.
SEE PARAGRAPH 2.6
NO. DOES 1S DE-ENERGIZE AND 2M
ENERGIZE AT TRANSITION (10 SEC)? NO. POTENTIAL PROBLEM WITH TRIAC ON STARTER INTERFACE BOARD, CONTROLLER,
1S CONTACTOR STICKING OR AUXILIARY CONTACT 1Sc OR 1Sd.
YES. POTENTIAL PROBLEM WITH WIRING OR AUXILIARY CONTACTS 1Sa OR 2Ma
SE & ORIGINAL INTELLISYS: 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 CONTACT IS CLOSED.
SEE PARAGRAPH 2.6
ORIG, SG, SE:
STARTER FAULT YES. DOES UNIT SHUT DOWN IN LESS
THAN 12 SECONDS AFTER START-UP?

18
FROM STARTER FAULT CHART
NO CHECK FOR PHASE MONITOR OR ANY OTHER SHUTDOWN WIRED TO BTS1-33 & 29
ORIGINAL INTELLISYS CONTROLLER
MEASURE VOLTAGE AC
TERMINAL BTS1-33 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
TERMINAL BTS1-29 AND BTS1-3
DOES VOLTAGE CONTINUOUSLY
READ 110-130 VAC AT TIME OF
SHUTDOWN? YES. CHECK FOR BAD CONTROLLER OR RIBBON CABLE. RECHECK STARTER
SEQUENCE.

19
YES. IS COOLANT LEVEL CORRECT?
NO. CORRECT COOLANT AND TRY AGAIN.
YES. SUSPECT PROBLEM WITH COOLANT STOP VALVE.
CHECK WIRING AND VALVE OPERATION (SEE
PROCEDURE 2.5)
SG, SE: NO CONTROL POWER
YES. IS AIREND DISCHARGE TEMPERATURE GREATER THAN
210°F AT TIME OF SHUTDOWN?
NO
DOES VOLTAGE CONTINUOUSLY
READ 110-130 VAC AT TIME OF
SHUTDOWN?
NO. CHECK
1ATS
YES. SE: CHECK FOR PHASE MONITOR
SG: CHECK FOR INTERSTAGE PRESSURE SWITCH ON 2 STAGE OR PHASE MONITOR.
= 115 VOLTS AC IS NOT APPLIED TO THE CONTROLLER BUT CONTROLLER IS POWERED-UP.
DOES UNIT SHUT DOWN IN LESS
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 VOLTAGE GREATER THAN
110 VAC?
NO. FUSE 3FU IS BAD, LOW VOLTAGE OR
THE TRANSFORMER IS BAD
NO. FUSE 2FU IS BAD, LOW VOLTAGE OR
THE TRANSFORMER IS BAD
YES. MEASURE VOLTAGE AC
TERMINAL BTS1-7 AND J4-29
IS THE VOLTAGE GREATER THAN
110 VAC?
NO. BAD CONTACT ON E- STOP
SG CONTROLLER:
MEASURE VOLTAGE AC
P1 - 10 AND TERMINAL 1TB-4
IS THE VOLTAGE GREATER THAN
110 VAC?
NO. BAD CONTACT ON E-STOP
SE CONTROLLER:
MEASURE VOLTAGE AC
TERMINAL BTS1-8 AND J4-29
DOES VOLTAGE CONTINUOUSLY
READ 110-130 VAC AT TIME OF
SHUTDOWN?
YES. MEASURE VOLTAGE AC
P1 - 10 AND TERMINAL 1TB2