Ingersoll-Rand P425AWIR Setup guide

Book: 22600498 (1/05) 1
INSTALLATION, OPERATION AND SERVICE MANUAL
FOR
AUTO START STOP SYSTEM
OPTION FOR COMPRESSORS
P.O. Box 868
501 Sanford Ave
Mocksville, N.C. 27028
www.portablepower.irco.com
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Revised (09-12)

Book: 22600498 (1/05) 2
TABLE OF CONTENTS
SECTION 1 . . . . . . . Safety
SECTION 2 . . . . . . . Manual Description
SECTION 3 . . . . . . . General Information And Operational Theory
SECTION 4 . . . . . . . Installation
SECTION 5 . . . . . . . Troubleshooting Procedures
SECTION 6. . . . . . . Schematic Diagrams
SECTION 7 . . . . . . . Electrical/Electronic Component Locations
SECTION 8 . . . . . . . Electrical Connector Information
SECTION 9 . . . . . . . Electrical Parts List
SECTION 10 . . . . . . Alerts and Shutdown List

Book: 22600498 (1/05) 3
FOREWORD
This manual provides installation and operating instructions for field installation
of Auto Start capabilities for certain model air compressors.
Read these instructions before beginning the installation and check that all kit
parts are included. Assure all decals are attached.

Book: 22600498 (1/05) 4
SECTION 1
SAFETY
Follow all safety instructions in the air compressor operator’s manual and decals on the
machine and those included with the kit below.
WARNING
22306617
NOTICE
36573421

Book: 22600498 (1/05) 5
SECTION 2
MANUAL DESCRIPTION
This manual contains complete information for the electrical and electronic components for the Auto Start
Stop system. It provides installation, operation, troubleshooting and parts information for the system.
There are 10 sections.
Sections 2 – 4 cover systems operation, installation and troubleshooting procedures.
Sections 5 – 6 contain electrical schematics and component location information.
Section 7 contains electrical component locations.
Section 8 contains electrical connector information.
Section 9 contains the electrical parts list.
Section 10 contains the alerts and shutdowns list.
This Auto Start Stop option kit is for machine models:
P425AWIR XP375WIR HP375WIR
VHP300WIR P600WIR HP450WIR
VHP400WIR
IMPORTANT SAFETY INFORMATION
The auto start system can cause the machine to start at any time. Follow all
safety recommendations outlined in this manual to avoid injury to personnel.
DISCONNECT BATTERY BEFORE SERVICING.
WARNING

Book: 22600498 (1/05) 6
SECTION 3
GENERAL INFORMATION
And
OPERATIONAL THEORY

Book: 22600498 (1/05) 7
The following is a list of the items included in the Auto Start Kit. Make sure the kit contains all items
before beginning an installation.
Auto Start Module 22221063 Wiring Harness 22149157
Warning Lamp 22307698 Alarm Horn LS1 36785145
Terminal Strip TB1 22307706 Auto/Manual Switch S1 54615091
Switch Bracket 22311823 Battery Charger 54715941
Battery Charger harness 22600514 Battery Charger Bracket 22329411
Bag of fasteners “T” Harness 22600506
OPERATING INSTRUCTIONS decal 22313597
WARNING decal 22306617 (2 pieces)
NOTICE decal 36523421
Auto / Manual decal 22311815
AUTOSTART decal 36511244
Installation/Operation/Service Manual 22600498

Book: 22600498 (1/05) 8
GENERAL INFORMATION AND OPERATIONAL
THEORY
General
The auto start stop module provides a means of automatic start and stop capabilities for
compressors. It is designed to operate with any compressor that has the WEDGE
control system. It is a plug-and-play module that can be field installed.
The auto start module communicates with the WEDGE controller via the J1939 CAN
network on the machine. The auto start module commands the WEDGE controller to
perform machine start, load and stop functions based on external inputs to the auto start
module.
Machine CAN Network
The auto start stop module connects to the machine CAN communications network.
The CAN network is established by the WEDGE controller and the engine controller.
These are the two basic modules on the CAN network. The CAN network supports the
J1939 protocol as defined by the Society of Automotive Engineers (SAE).
The machine wiring harness contains two stubs for CAN / power access. These stubs
can be used for connection of any of the CAN network modules, including auto start
stop.
Figure 2-1 shows a schematic of the CAN network with compressor and engine
controllers and CAN stubs. One CAN stub is located behind the control panel of the
compressor and the other is near the lifting bail.
Sensors and Switches
Inputs
The Auto Start Module uses a pressure switch input to activate the automatic start-stop
function. This pressure switch is normally user provided and contains a single set of
normally open (N.O.) contacts. The N.O. contact closes to activate the auto start
feature and opens to disable the auto start feature. TB1 terminal strip (included in this
strip) has the input terminals for the pressure switch:
TB1-3 Start Switch

Book: 22600498 (1/05) 9
J1939CANCOMMUNICATIONSSCHEMATIC
P15
ENGINEDIAGNOSTICSJACK
J8
R5
R4
P7
P11
P6
ENGINE
CONTROLLERWEDGE
CONTROLLER
TERMINATORTERMINATOR
AUTOSTARTOPTION
CANNODEWITHPOWER
FIGURE3-1

Book: 22600498 (1/05) 10
An AUTO-MANUAL switch, S1, is provided to establish the mode of operation. It is an
input to the controller. When set in the AUTO position, the auto start stop feature will
function as described in this section. When placed in the MANUAL position, auto start
stop is disabled and the machine will function as it would normally.
Outputs
The auto start module provides four 24 VDC outputs for indicators. They are: low fuel,
compressor operating, crank alarm, and auto mode enabled. These outputs provide 24
VDC at 2 amps and can be used to drive indicator lamps or relays. They are typically
used to provide remote indication to a control room of the auto start compressor status.
The output to the alarm horn is provided through the wiring harness and is not brought
out to TB1.
The connections to the outputs are located on the terminal strip, TB1, provided with the
kit. They are as follows:
TB1-1 Auto start active output 24VDC
TB1- 5 Machine running output 24 VDC
TB1- 7 Low fuel indication 24 VDC
SECTION 5 of this manual provides schematic diagrams of the auto start system and
wiring harness connections.
Auto Start Stop Operation
Install the auto start kit as described in the Installation section. Make all electrical
connections before turning the machine power ON at the control panel. Once power is
turned ON, the WEDGE controller will automatically recognize the auto start module
and accept commands from it. To activate the auto start stop, place the AUTO-
MANUAL switch, S1, in the AUTO position. The DS1 lamp should illuminate.
The functional sequence is as follows:
1. When the external start switch (pressure switch) contact closes, the start
sequence begins. The contact closure must be maintained for 10 seconds
for the start sequence to initiate.
2. The auto start module instructs the machine controller to crank the engine.
The auto start module will sound the alarm horn 10 seconds before the
engine starter is engaged and during the cranking process. The machine
controller (WEDGE) will crank the engine until the engine starts or 20
seconds has elapsed.

Book: 22600498 (1/05) 11
3. If the engine starts, the machine controller will signal the auto start module
the engine is started. If the engine did not start the controller signals a no
start condition.
4. If a no start condition exists, the auto start module will wait 30 seconds
and then issue another crank signal to the machine controller. The events
of steps 2 and 3 will take place. If the engine fails to start, a third attempt
will be made. If within three crank attempts the engine does not start, the
auto start module will issue a shutdown condition to the machine
controller. A code 73 will be displayed on the control panel diagnostic
display.
5. If the engine does start, the auto start module will issue a load command
to the machine controller. Normal machine operation will take place until
the auto start module issues a machine stop to the machine controller.
6. When the external contact opens, the machine will stop. The system will
operate once again when the contact closes.
If communications between the machine controller and the auto start module is
lost, the machine will perform a shutdown, indicating such. This shutdown only
occurs if the auto start module was activated with the machine under auto start
stop control.

Book: 22600498 (1/05) 12
SECTION 4
INSTALLATION

Book: 22600498 (1/05) 13
INSTALLATION
Before beginning the installation, disconnect the machine batteries. The installation begins with the
mounting of the Auto Start Module on the baffle wall, on the right side of the machine (facing drawbar)
inside the machine. Use two of the tap-tights supplied to attach the module to the box. Mount the
module with the connectors pointing down. The module should be located in upper part of the baffle,
close to the outside of the machine to accommodate harness length and allow access to drill the
mounting holes. Refer to figure 4-1.
The mounting location is shown in the picture below.
Figure 4-1
Connect the wiring harness to the two connectors on the Auto Start Module, P1 and P2. Locate
connector P10 on the machine harness. P10 is located behind the compressor oil filter on the left side
(facing drawbar) of the machine. Unplug the termination resistor, P11, from P10. Plug the “T” harness,
226005016, connector, J10, into the machine harness connector, P10. Route the “T” harness over the
air end and plug connector J7 on the auto start module harness into connector P101 on the “T” harness.
Plug the previously removed termination resistor, P11, into P100 on the “T” harness.
Refer to Figure 4-2 and 4-3.

Book: 22600498 (1/05) 14
Figure 4-2
Figure 4-3
The TB1 terminal strip in installed on the same baffle wall as the auto start controller. The TB1 decal,
22311815, is installed to the left of the terminal strip. The auto/manual switch is installed on the baffle
wall to the left of the TB1 terminal strip. Screws are provided in the kit to mount these components.
Connect the harness wires, TB1-1 to TB1-8 to the terminal strip (refer to Figure 4-3), starting with TB-1 at
the top left. Mount the switch bracket and then mount the switch, S1, into the bracket. Refer to Figure 4-
4. Install the switch with the wire terminals to the right as shown. Install the decal, 22311807, on the
bracket, over the switch so the “MANUAL” indication is to the right side. Connect the two wires from the
harness branch, S1, to the switch. The blue wire connects to the right terminal and the brown wire
connects to the left terminal.

Book: 22600498 (1/05) 15
Figure 4-4
The “Auto Start Active” lamp, DS1, is installed in the sheet metal above the control panel. Refer to Figure
4-5. A 1” hole is required to mount the lamp. The lamp is inserted from the front side of the panel and
the lock washer and nut are attached from the back of the panel to hold it in place.
Figure 4-5
Connect the wires from the harness branch labeled, “DS1” to the lamp. Polarity is not important, the
wires can be connected to either lamp holder terminal.
The alarm horn, LS1, is mounted on the machine above the control panel as shown. Refer to Figure 4-6.
It requires a 30mm mounting hole. There is a knurled screw cap on the front of the alarm module, LS1.

Book: 22600498 (1/05) 16
Unscrew this cap and insert the threaded portion through the mounting hole on the machine. Screw the
cap back onto the threaded portion. This will secure the horn in the hole.
Figure 4-6
The operating instructions decal, 22313597, is attached just under the control panel door. Refer to Figure
4-7.
Figure 4-7
Install the “AUTO-START” decal, 36511244, on the front of the machine, to the right of the discharge air
valve as shown. Refer to Figure 4-8.

Book: 22600498 (1/05) 17
Figure 4-8
A warning decal, 22306617, is installed near the door handle on each of the machine’s 2 doors as shown
in Figure 4-9.
Figure 4-9
The battery charger is installed on the cooler housing as shown in Figure 4-10. The charger is attached
to the mounting plate supplied with the kit. Fasteners are included.

Book: 22600498 (1/05) 18
Figure 4-10
The battery charger harness, 22600514, plugs into the charger output cable and then connects to the
battery cable connectors that attach to the battery posts. Ring tongue terminals are provided to connect
under the screw clamps of the battery cable lugs. See Figure 4-11.
Figure 4-11
This completes installation of the auto start kit.

Book: 22600498 (1/05) 19
SECTION 5
TROUBLESHOOTING PROCEDURES

Book: 22600498 (1/05) 20
General
A thorough analysis of the problem is the key to successful troubleshooting. The more
information known about a problem, the faster and easier the problem can be solved.
Troubleshooting charts are included to act as a guide to the troubleshooting process.
They are organized so the easiest and most logical things are performed first. It is not
possible to include all the solutions to problems that can occur or list all possible
problems. The charts are designed to stimulate a thinking process that will lead to
solution of the problem.
Basic Troubleshooting Steps
Collect all facts concerning the problem
Analyze the problem thoroughly
Relate the symptoms to the basic electrical / electronic systems and components
Consider any recent repairs that could relate to the problem
Double check before replacing components
Review the controller fault log for clues as to the problem
Determine the cause of the problem and make a thorough repair
Never inspect or service unit without first disconnecting battery
cables to prevent accidental starting.
WARNING