Ingersoll-Rand P425AWIR User manual

Portable Power
P.O. Box 868 -- 501 Sanford Ave
Mocksville, N.C. 27028
SERVICE MANUAL FOR
ELECTRICAL/ELECTRONIC
www.portablepower.irco.com Book No. 22235428 (11/03)
P425AWIR (7/120)
XP375AWIR (9/110)
HP375AWIR (10/105)
VHP300AWIR (14/85)
P600WIR
HP450WIR
VHP400WIR

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
TABLE OF CONTENTS
SECTION1.......ManualDescription
SECTION2.......GeneralInformationAndOperationalTheory
SECTION3.......ServiceTools
SECTION4.......ElectronicSystemsTroubleshooting
Procedures And Techniques
SECTION5.......SystemSchematicDiagrams
SECTION6.......ElectronicComponent Location Drawings
SECTION7.......IndividualCircuitDiagrams
SECTION8.......ElectricalConnector Information
SECTION9.......ElectricalPartsList
SECTION10......AlertsandShutdownsList
SECTION11......RecommendedSpareParts
SECTION 12 IR Engine....

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
SECTION 1
MANUAL DESCRIPTION
This manual contains all of the information concerning the electrical and electronic systems for
the P425 Familyof compressors. It provides all information necessarytoservice,troubleshoot
and order parts for this machine.
It is organized into 12 sections.
Sections 2 -- 4 cover systems operation and troubleshooting procedures.
Sections 5 -- 7 have location diagrams, drawings of specific circuits and systems schematics.
Section8hasinformationconcerningtheelectricalconnectors used, including removal andre-
placement.
Section 9 contains the parts list with ordering information.
Section 10 contains the list of Alerts and Shutdowns.
Section 11 contains a list of recommended spare parts for servicing.
Section 12 contains engine information.

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
SECTION 2
GENERAL INFORMATION
and
OPERATIONAL THEORY

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
GENERAL INFORMATION AND OPERATIONAL
THEORY
General
The P425 Family of machines has an electronic
monitor and control system to provide discharge air
pressure control and engine and package monitor
functions. The system uses the WEDGE controller to
perform these functions. The electrical system
connects all the necessary switches, sensors and
transducers to the WEDGE controller in order for it to
perform the monitor and control functions.
WEDGE Controller
The WEDGE controller is the heart of the machine
monitor and control system. It provides data
collection, alarming and control functions for
compressor operations. It is a microcontroller based
unit with analog and digital inputs and outputs.
The WEDGE controller is attached to the back of the
control panel. The LED annunciators are part of the
front panel of the WEDGE. They can be seen through
the laminate on the front of the control panel.
The WEDGE is attached to the control panel with four
#10 size nuts.
ThefirstfunctionoftheWEDGEcontrolleristoscanall
analog and digital inputs at a fixed interval. These
inputsarescannedevery50milliseconds. Theanalog
values are then compared against minimum and
maximum values and an ALERT or SHUTDOWN is
issued,ifavalueisoutofrange. ThevariousALERTS
and SHUTDOWNS are listed in Section 10 of this
manual.
The second function of the WEDGE controller is
machine discharge pressure control. The WEDGE
monitorstheregulationsystemairpressureandvaries
the engine throttle to maintain the setpoint discharge
air pressure. The setpoint pressure is set using the
regulator on the separator tank.
The third function of the WEDGE controller is to
communicate with the diesel engine via the J1939
CAN network. It retrieves diagnostic information over
J1939.

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
FIGURE 2--1
P425/P600 HARNESS SYSTEM SCHEMATIC
WEDGE Controller
CONTROL PANEL SWITCHES
GAUGES
24VDC HEATERS
ENGINE ECM DIAGNOSTIC
INTERFACE
ESTOP SWITCHES
SOLENOID VALVES
SPEED SENSOR
FUEL LEVEL SWITCH
PRESSURE TRANSDUCERS
TEMPERATURE SENSORS BATTERY STARTING AND CHARGING SYSTEM
W1
P4
W1
P1
HOURMETER
CONTROL PANEL HARNESS
W1W1

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
FIGURE 2--2
WEDGE
CONTROLLER
WEDGE TO ENGINE INTERFACE
IR ENGINE
J1--34 J1--35 J1--24
IR 41RD5AE 61IRF8TE
ENGINE
CONTROLLER
J50--G1 J50--J1
J50--A2 J50--F2
CAN LO
CAN HI
CANSHLD
J1--38 J1--13
ANALOG THROTTLE RANGE = 1.10VDC (1400RPM) TO 3.7VDC (2400 RPM)
ANALOG THROTTLE
KEY SWITCH

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
P425/P600 J1939 CAN COMMUNICATIONS SCHEMATIC
ENGINE ECM WEDGE
CONTROLLER
TERMINATOR TERMINATOR
ENGINE DIAGNOSTICS JACK
J57
R4
P11 R5
P10
FIGURE 2--3
P6

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
The wedge uses an analog signal to communicate
withtheJohnDeereengine.Thissignalhasarangeof
1.1V to 3.7V. This range corresponds to an engine
speed range of 1400 to 2400 RPM.
Figure 2--2 shows the signals between the engine
controller and the WEDGE controller.
Sensors and Transducers
The electronics system contains sensors and trans-
ducersthatareused tocollectdatafrom thecompres-
sor. The temperature is measured by a thermistor.
Thisdeviceexhibitsachangeinresistanceasthetem-
perature changes. The resistance causes an input
voltage change to the WEDGE controller input and is
interpreted as a temperature change.
The electronics system also uses pressure transduc-
erstomeasurecompressorpressurechanges. These
devices have an output signal of .45 VDC to 4.5 VDC,
corresponding to 0 psi and the maximum measured
psi for a particular device. The maximum pressure
transducer ranges are 100 or 225 psi. The 100 and
225 psi devices are gauge pressure devices. These
transducers are provided with 5 VDC excitation to
power the device. These are three wire devices: ex-
citation, signal and ground.
Digital Inputs and Outputs
The WEDGE controller scans digital inputs such as
switch contacts. These are either “ON” (24VDC) or
“OFF” (0 VDC). These digital inputs are connected to
switches within the package such as the key start
switch, air filter switches and IQ filter switches.
The WEDGE controller provides 24 VDC digital
outputstocontrolsolenoids,startcompressorandDC
heaters. These are 24 VDC “ON” and 0 VDC “OFF”.
They are current limited and short circuit protected.
Controller Outputs
The WEDGE controller has four types of outputs: fre-
quency, pulse width modulated, analog and 24VDC
digital (ON/OFF). The analog output is used as the
throttle signal to the engine.
TheWEDGEvariestheanalogsignalfrom1.25to4.25
volts,correspondingto1400to2100RPM. Thissignal
is used with the John Deere engine. The frequency
throttle signal is used with the Cummins engine and
thepulse widthmodulated signalis usedwith the CAT
engine.
Pressure Control
The discharge pressure is controlled by manipulating
theenginespeedandcompressorinletvalveposition.
Theinletvalvepositioniscontrolledpneumaticallyand
the engine speed is determined by the WEDGE con-
troller. The WEDGE measures the pneumatic system
regulation pressure and computes an engine throttle
setting.Thisthrottlesettingissenttotheengineviathe
frequencythrottle,Analog,PWMorJ1939throttle,de-
pending on which technique is used. The engine con-
troller will control engine speed to this throttle setting.
Electronic Engine -- P425 Family of Machines
The P425 Family of machines contains an emissions
certifieddieselengine. In ordertomeetthe emissions
requirements, the engine has an electronic control
system.
The control system handles all monitor, alarm and
controlfunctionsfortheengine. TheWEDGEcontrol-
ler communicates with the engine controller over the
J1939 CAN network.
The WEDGE controller sends throttle settings to the
engineandreceivesdiagnosticandruntimedatafrom
the engine over the J1939 CAN network. An analog
throttle interface is currently used with the engine.
Figure 2--2 shows the connections between the
WEDGE controller and the engine controller.

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
J1939 Data Link
The CAN network is a single pair shielded cable
located with the W1 main harness. Figure 2--3 shows
a layout of the CAN harness or “backbone” as it is
referredto. The terminationresistors (Terminator)are
important to prevent reflections on the transmission
line and must be in place for the network to function
properly.
Theenginediagnosticsconnectorislocatedontheleft
side of the engine. This is used to connect the engine
manufacturer’sservicetoolstotheCANnetwork. This
connector also provides 24 VDC to power these
service tools.
Electrical System
Theelectricalsystemconsistsofthewiringharnesses
and associated electrical devices such as relays,
switches, lights, solenoids and alarm horn. There is
one wiring harnesses in the P425 machine.
P/N 22199061 W1 Chassis Main Harness
Theschematicdiagramsshowtheconnectionsforthis
harness. Figure 2--1 is a system schematic showing
harnessconnectionwithdevicesandcontrollers. Sec-
tion 8 includes information on connectors used in the
harness.
The electrical circuits are protected using ATC style
fuses. A fuse should only be replaced with one of the
same rating. Replacing a fuse with one of a large
rating could lead to harness damage. If a fault occurs
andthecircuitdoesnothavetheappropriatesizefuse,
wires could be burned in the harness and damage
other circuits.
Machine ID
Software versions 1.60 and greater use software to
setthemachine ID. Versions lessthan 1.60use an ID
resistor plug, R2. The ID plug is located behind the
control panel box on the W1 harness trunk. The
resistor plugs are molded in colors for easy
identification. Refer to Section 7, Individual Circuit
Diagrams and the page entitled R @ MACHINE ID
PLUG for details.
It is recommended that all machines be upgraded to
Version1.60orgreater.ThesoftwaresetmachineIDis
much more reliable than the resistor plug.

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
KEY ELECTRICAL COMPONENTS FUNCTION
PT1: PT1 is a 0--225 psi gauge pressure transducer that measures discharge air pressure.
PT2: PT2 is a 0--100 psi gauge pressure transducer that measures regulation system pressure.
U1: U1 is resistive level detector that measures the fuel level in the fuel tank.
It provides a continuous reading of fuel level. It also has a switch for low fuel level and low fuelshutdown.
These switches connect to WEDGE.
RT1: RT1 is a 10K ohm Thermistor temperature sensor that measures separator tank temperature.
Its range is --30 to 255_F.
RT2: RT2 is a 10K ohm Thermistor temperature sensor that measures airend discharge temperature.
Its range is --30 to 255_F.
K1: K1 is SPST, 24VDC relay used to activate the engine starter.
K2: K2 is a SPST, 24VDC relay used to activate the engine inlet heater.

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
CONTROL PANEL
DIAGNOSTIC SHUTDOWN (Standard)
1. Compressor Fault: Indicates shutdown due
to compressor system fault. Refer to fault
code list in Section 10.
2. Engine Fault: Indicates shutdown due to
engine fault. Refer to fault code list in Section
10.
3. Hourmeter: Indicates machine operating
hours.
4. Discharge Air Pressure Gage: Indicates
pressure in receiver tank, psi (kPa).
5. Fuel Level Gage: Indicate fuel level in tank.
CONTROLS (Standard)
6. PowerSwitch: Flip“ON”toactivatesystems
prior to starting. Flip ’off” to stop engine.
7. Service Air Switch: After warm--up, PUSH.
Providesfullairpressureattheserviceoutlet.
OPTIONAL CONTROLS
8. Engine Speed Gauge: Indicates engine
speed.
9. DischargeAirTemp.Gauge: Indicatesin_F
and _C. Normal operating range:
185_F/85_C to 248_F/120_C.
10. Engine Oil Pressure Gauge: Indicates
engine oil pressure psi (kPa).
11. Engine Water Temp Gauge: Indicates
coolant temperature with normal operating
range from 180_F/82_C to 210_F/99_C.
12. Voltmeter: Indicates battery condition.
13. Spare
14. Wait to Start Lamp

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
OPERATIONAL INFORMATION
Power “ON” at Control Panel:
1. Key switch signal (24VDC) supplied to engine controller by WEDGE controller
Engine Start--up:
When the key is switched to the engine crank position:
1. K1 auxiliary start relay is energized.
2. Run/Start solenoid valve (L1) is opened (energized).
Note: Run/start solenoid stays open for 10 seconds after the key is released if the engine does not start.
When the engine speed reaches 600 RPM (engine start declared):
1. Engine speed is set to 1600 RPM.
When the engine speed reaches 1450 RPM:
1. Unloader solenoid valve is opened (energized), L2.
2. Run/Start solenoid valve is closed (de--energized, L1).
When the separator tank pressure reaches 50 psi:
1. Run/Start solenoid valve is opened (energized), L1.
After 5 seconds:
1. Engine speed is set to idle (1400 RPM if air end discharge temperature is approximately
150 degrees F or (if J1939 CAN is functioning) the engine coolant is 100 degrees F.
Otherwise, the engine idle stays at 1500 RPM.
Loading:
When the “Service Air” switch is pushed:
1. Engine speed is set to 2400 RPM
When engine speed reaches 2200 RPM:
1. Run/Start solenoid valve is closed (de--energized).
After 2 seconds and if the regulation system pressure is 4 psi or greater:
1. Compressor pressure control is engaged.

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
READING AND SETTING THE DISPLAY
UNITS
The WEDGE has four choices for display units:
_F, PSI
_C, Bars
_C, kPa
_C, Kg/cm2
To determine which units the WEDGE has been configured for:
1. With the machine power off (Key turned OFF)
2. Press and hold the “Service Air” Switch
3. Turn the key switch directly to the crank position.
4. Hold these switch positions until the 4 digit LED display on the WEDGE goes blank.
5. Release “Service Air” switch, release key switch to “ON”.
Units will be displayed for 2 seconds after which the current selection will be displayed as:
_F, PSI will be displayed as “PSI”
_C, Bars will be displayed as “bAr”
_C, kPa will be displayed as “HPA”
_C, Kg/cm2 will be displayed as “H9C”
To change the units setting:
1.WiththeWEDGEshowingthecurrentsetting,pressandreleasethe“ServiceAir”switchuntilthedesiredsetting
appears on the display.
2. Once it appears, do not release the “Service Air” switch. Hold it in the ON position until the WEDGE restarts.
This will select units selection that was displayed.
3. Release the “Service Air” switch. The compressor is ready to start.

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
WEDGE SERVICE DIAGNOSTICS
The WEDGE controller provides a diagnostic capability that allows various internal parameters to be viewed on
the 4--digit LED display. These can be accessed with the machine stopped or while it is operating. If the machine
is stopped, the “Service Air” switch on the control panel is used to toggle through the list of parameters. If thema-
chine is operating, the “Start” position of the key switch is used. To view the parameters, toggle the switch or key
and a number (2--20) will appear on the LED display. After 3 seconds, it will extinguish and the parameter will be
displayed. The toggle only works in the ascending order direction, but it will wrap around and start over.
Display Parameter Remarks
2 RPM From Engine Flywheel Sensor
3 Engine RPM Filtered RPM Value
4 Reg. Sys. Pressure PSI
5 Sep. Tank Pressure PSI
6 Discharge Temperature Deg F
7 Sep. Tank Temperature Deg F
8 Engine Target RPM Wedge Signal to Engine
9 Machine Type *
10 Engine Coolant Temp. From CAN, Deg F
11 Engine Oil Temp. From CAN, Deg F
12 Engine Oil Pressure From CAN, PSI
13 Intake Manifold Temp. From CAN, Deg F
14 RPM From CAN
15 Fault Code List Cummins/CAT codes
16 Throttle Position
17 Boost Pressure
18 Engine Hours
19 Load At Speed Percent
20 Set Machine ID

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
ENTERING MACHINE ID FOR WEDGE CONTROL SYSTEMS with V1.60 or Greater Software
For machines with the WEDGE controller mounted inside the control panel/instrument panel box, the “Service
Air” switch is used to enter the machine ID. Disconnect the fuel level gauge (located in the fuel tank) before
starting the process and reconnect once the process is completed.
For machines with the WEDGE controller mounted in the engine compartment, the rocker switch beside the
WEDGE is used to enter the machine ID.
For the instructions below, the “Service Air” or rocker switch will be referred to as the “data input switch”.
1. Examine the machine data plate to confirm the machine model.
Using the machine model and the machine models list on page 2 of this document, locate the proper
machine ID.
2. Turn power to the ”ON” position. Machine must not be operating.
3. Toggle the data input switch twice and the number “2” will appear on the WEDGE 4--digit LED display.
Continue to toggle the switch until the number “9” is reached. Read the machine ID on the
display, if it matches the proper machine ID in Step 1, stop. If not, proceed to step 4.
4. Continue to toggle the switch until number “19” is reached. Push and hold the data input switch and the
number“20”willappear.Continuetoholdtheswitch.After1second,thecurrentmachineIDwillappearin
the display. Continue to hold for 9 more seconds and a blinking “--” will appear. Release the switch.
5. Togglethedatainputswitch,thedisplaywillshow“0”.Togglethedatainputswitchuntilthepropermachine
ID appears on the display, then stop the toggle sequence.
6. Wait until the controller performs a reset function (or power up) (approximately 10 seconds). At reset, the
controllerdisplayfirstgoesblank,thenal110annunciatorLED’slight,the4--digitLEDdisplayshowsall8’s,
the display then shows the installed software version andfinally the display goes blank and the engine oil
pressureandalternatorLEDbeginflashing.AtthispointthecontrollerhasstoredthemachineIDselected
in step 5.
7. Using the data input switch, toggle to service diagnostic number “9”.
The number “9” will appear for 1 second and then the machine ID will appear. The ID should be the same
as the one entered in steps 4--6. If not, go back to step 4 and enter the ID again.

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
ESA Models/Wedge Machine ID
Models Machine ID
7/120,9/110. 10/105, 14/85 7
7/170. 10/125.14/115 8
9/230,9/270,9/300. 12/235 5
17/235,21/215 6
MSA Models/Wedge Machine ID
Models Machine ID
P425AWIR, XP375AWIR, HP375WIR 7
VHP300AWIR
P600WIR, HP450WIR, VHP400WIR 8
XP1060WCU, HP935WCU, MHP825WCU 5
VHP750WCU
XHP750WCU 6
MHP825WCAT, VHP750WCAT 2
XP1060HACAT,XP950HACAT
SHP825WCAT, XHP750WCAT. XHP650WCAT 3
HP1300CWCU,HP1600CWCU 0
XHP1170WCU 1
XHP1070AWCAT, XHP1170WCAT. XHP1170SCAT 4
HP1600WCAT 9
SIRC Models/Wedge Machine ID
Models Machine ID
P1060WCAT, XP950WCAT, HP935WCAT 2
MHP825WCAT .VHP750WCAT
XHP750WCAT 3

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
SECTION 3
SERVICE TOOLS

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
SERVICE TOOLS
Service Tools
The following special tools are recommended to perform service procedures in this manual. The tools can
be purchased from Ingersoll Rand or other sources as listed.
Tool Tool Description
22216691 Digital Multimeter (Fluke 87)
Used to measure electrical circuits; Volts, amps, ohms
54729660 Packard Weather--Pack Terminal Removal Tool
Used to repair Packard Electric Weather--Pack Connectors
54699632 Deutsch Terminal Removal Tool (Blue)
Used to repair Deutsch connectors
54699640 Deutsch Terminal Removal Tool (Red)
Used to repair Deutsch connectors
54699624 Deutsch Terminal Removal Tool (Yellow)\
Used to repair Deutsch connectors
22216667 Deutsch Terminal Crimp Tool (HDT--48--00)
Used to crimp Deutsch connector terminals
54729710 Electrical Contact Cleaner
Used to clean electrical contacts and connectors
54729728 PDA Service Tool
Used to load software & extract service and fault logs
54699616 Deutsch Terminal Removal Tool
Used to repair Deutsch connectors
54749544 RTD Simulator Plug
Used to test RTD circuits
54749551 Thermistor Simulator Plug
Used to test thermistor circuits for INTELLISYS controller systems
22073878 Thermistor Simulator Plug
Used to test thermistor circuits for WEDGE controller systems
54749635 Connector Repair Kit
Used to make connector repairs for Deutsch and Packard Electric Connectors
54699657 Deutsch Terminal removal Tool
Used to repair Deutsch connectors
54749643 Packard Metri--Pack Terminal Removal Tool
Used to repair Packard Electric connectors

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Book No. 22235428 (11/03) P425AWIR Family Electrical Manual
22168868 Pressure Transducer Simulator
Used to test pressure transducer circuits
22147540 Test Adapter Kit Test adapters for various connectors to be
Used when making electrical measurements
22146393 Removal Tool Kit Assortment of most used Deutsch removal tools
22216675 Deutsch Crimp Tool (DTT --20--00)
Used to crimp Deutsch connector terminals
22216683 Packard Electric Crimp Tool (12155975)
Crimps 150 and 280 series pins
22255947 Packard Electric Crimp Tool (12039500)
Crimps 150 series pull to seat pins
22216709 Fluke Test Lead Set (TL20)
Contains needle probes, alligator clips, test leads
heat shrink tubing that are used on harnesses
22216725 Fluke Insulation Piercing Probe (AC--89)
Used to connect to a wire for measurements
22216733 Fluke Meter Case (C25)
Case for Fluke 87 meter including storage for test leads and probes
54740675 RS232 Heavy Duty Serial Cable
Connects lap top computer or PDA Service Tool
to WEDGE or Intellisys controller
22252969 Wire Terminal Kit
Contains a selection of terminals with
corresponding heat shrink tubing that are used on harnesses
22281588 Connector Wrench
22282107 5/32 “T” hex screwdriver wrench
22282172 1/4” Flex Shaft Nutdriver
Used to remove ECM connector on John Deere engines
22252993 WEDGE Connector Kit
Includes the 40--pin connector housing and pins for the harness connector
22253009 CAN Communications Adapter
Converts RS232 to J1939 CAN, used with lap top computer
or PDA Service T 001
22253017 Adhesive Heat Shrink Assortment
Selection of most used heat shrink sizes