Ingersoll-Rand SG Quick start guide

Medium Industrial Systems
Davidson, North Carolina 28036
© Ingersoll-Rand 2000
Printed in U.S.A.
Simplicity
Serviceability
Reliability SG
Control System
Technicians Guide
Form APDD672A
August 2000

CONTENTS
TOPIC PAGE
SG INTELLISYS CONTROLLER INTRODUCTION ...... 1
COMPONENT REVIEW .............................................. 2
SG INTELLISYS INPUT/OUTPUT INFORMATION .... 27
INTELLISYS CONTROLLER .................................... 29
SG DISPLAY SCREEN ............................................. 35
OPERATOR SETPOINTS ......................................... 37
OPTIONS ................................................................ 38
FACTORY SETPOINTS ............................................ 39
SENSOR CALIBRATION .......................................... 42
WARNINGS ............................................................ 43
ALARMS ................................................................. 48
STEPPER MOTOR OPERATION .............................. 54
WIRING SCHEMATICS ........................................... 65
DIAGRAMS ............................................................. 70

-1-
SG INTELLISYS CONTROLLER
INTRODUCTION
WORLDWIDE EPROM REVISION LEVEL 1.3
AND HIGHER
The Intellisys control system is an exclusive
Ingersoll-Rand design developed for reliable
compressor operation. The controller display can
be programmed in nine languages and various
unitsofmeasureforthepressureandtemperature
readings.
Themicroprocessorbasedcontrollerusesa finger
touch membrane for operation of the compressor
and setting control parameters.
Information about the current operating status is
available on a Liquid Crystal Display (LCD) from a
15-item list of temperature, pressure and filter
condition readings.
TheIntellisysmonitorsthecompressorandshould
any pre-programmed limit be exceeded, the
controller automatically displays a warning or
issues an alarm to shut the compressor down.
The major components of the control system
include the Intellisys, thePowerSupplyBoardand
aSteppingMotortopositionthecompressor’sinlet
valve.
A group of pressure and temperature sensors,
relays and switches support the decision making
process.

-3--2-
Operation of the control system will be easy
after the following explanation of the control
system components is read and understood.
The explanation follows a logical path and begins
at the primary side of the control voltage trans-
former. Use the electrical schematics provided in
this publication or the Operator’s Manual as a
guide.
COMPONENT REVIEW
1FU - Fuses
1FU is the schematic designation for identical
fuses designed for control transformer applica-
tions. Afuseisinstalledineachofthetwowires
connecting line voltage to the primary side of
the control voltage transformer (T1). These
fuses provide a degree of protection should a
short-circuit develop in the transformer.
The fuses have a time-delay feature to handle
the short duration, but very high, inrush current
when power is first applied to the transformer.
For an instant, the inrush current drawn by the
transformercan be several times greater than the
full-load rating.
These fuses are also current limiting to protect
downstream components from damage and the
magnetic effects of short-circuit currents. Current
limiting is defined as being able to cut off a
short-circuit current in less than one-half cycle
(.008 second, 60 Hz). Generally speaking, this is
long before damaging current levels are reached.
The fuses are Class CC high performance and
have a unique shape on one end to fit into a
corresponding shaped fuse holder. The shape is
intended to prevent slower response fuses from
being installed in the circuit.
Thecurrentratingofthefusesdependsonthesize
of the control voltage transformer applied to the
starter of the compressor. A chart is provided on
the electrical schematic of the compressor to
select replacement fuses.
T1 - Control Transformer
A step-down transformer (T1) reduces the in-
cominglinevoltage to levels suitable as the power
source for the Intellisys control system.
The reduced voltage levels are called secondary
connections and there are two.
One secondary circuit is rated at 120 VAC-1-60
(110 VAC-1-50) and is basically used to energize
solenoid valves and starter coils. The “hot”
connection is X2 and the neutral connection X1 is
grounded to the starter chassis.
Theother secondary circuit israted at 24VAC and
the connections are X3 and X4. This circuit is
described as an isolated secondary because
neitherX3norX4isgroundedtothechassisatthis
point.
The voltage is connected to a bridge rectifier
located on the Power Supply Board andconverted
toapproximately 33 VDC. A portionof the33 VDC
powers the stepping motor and a portion is

-5--4-
regulated down to 12 VDC and sent onward to the
Intellisys.
A connection diagram for possible primary volt-
ages is shown on the transformer and in the
Operator’s Manual. The transformer must be
connected properly to avoid control system
damage.
120/110 VAC Circuit - Transformer (T1) to
Intellisys
The Intellisys controller receives 120/110 VAC
power from T1 and, depending on operating
conditions, sends the voltage onward to specific
areas at specific times. Examples: energizing a
starter coil at start-up or energizing a solenoid
valve when the compressor loads.
The circuit begins at X2 and connects to the
Intellisys in the following sequence.
2FU - Fuse
Adualelementfuseinthe120/110VACsecondary
side of the control voltage transformer circuit to
provide a degree of protection for the Intellisys
controller.
Dual element fuses have two individual elements
inside the fuse body.
One element, a spring actuated trigger assembly,
operates on overloads up to 5-6 times the fuse
current rating. When the overload has lasted long
enough to soften a soldered area, the spring pulls
the area apart to break the circuit.
The other element, the short-circuit section,
operates on short-circuits up to the interrupting
rating of the fuse.
Achartonthecompressor’selectricalschematicis
provided to select a replacement fuse.
RFI Filter
A device within the 120/110 VAC circuit used to
filter Radio Frequency Interference (RFI) and
prevent undesirable electrical disturbances from
entering the Intellisys.
In extreme instances, RFI can cause erratic
control problems because the power supply is not
steady.
Emergency Stop Switch
Located next to the Intellisys controller in the
starter door and intended to stop the compressor
in an emergency.
The switch has two sets of normally closed
contactsthatopenwhentheredbuttonispressed.
Refer to the electrical schematic and observe one
contacttobeinthe120/110VACcircuit(ES-1)and
theother contact in the12 VDClogic circuit (ES-2)
at P3 terminals 17 and 18.
These parallel contacts ensure power is removed
from the starter coils and solenoids to cause the
compressor to stop immediately.
Theswitchremainsintheopenpositionuntilmanu-
ally reset by rotating the red button clockwise.

-7--6-
1TB - Terminal Block
A double row terminal block having 14 poles that
serveascommonconnectionpointsforwireswithin
the control system. A decal identifies the terminal
block (1TB) and each pole is numbered 1 through
14 reading from left to right.
When reading an electrical schematic, wires con-
necting to 1TB indicate which pole the wire con-
nects to. Examples: 1TB-1 is the first pole and
1TB-7 is the seventh pole.
1ATS - High Air Temperature Switch
A normally closed switch installed in the discharge
port of the airend that opens when the discharge
temperature rises above 245°F (118°C). The
mechanical switch serves as a back-up for the
usual Intellisys temperature shutdown at 228°F
(109°C).
1ATS is connected in the 120/110 VAC circuit and
should it open, the Intellisys shuts the compressor
downinanALARMconditionandcausesthewords
“Control Power Loss” to appear in the display.
1PS-InterstagePressureSwitch(2-StageUnits
/ 250-450 Horsepower)
A normally closed switch monitoring interstage
pressure on 2-stage airends and opens should
pressureexceedapproximately100psi. When the
switch opens, the Intellisys stops the compressor
in an ALARM condition and “Control Power Loss”
appears in the display. 1PS must be manually
reset.
This switch is not used on single stage compres-
sors and a jumper wire is installed at the 1TB
connection points.
P1 through P10 - Quick Connect/Disconnect
Plugs
A group of different size plug-type connectors and
mating receptacles used to attach wires to the
Intellisys. The plugs and their receptacles are
identified on the electrical schematic and back
cover of the Intellisys. The plugs are designed to
be inserted in one direction only.
The large receptacles at the lower edge of the
Intellisys are a double-row design and care must
be taken to ensure the single row plugs are
inserted at the correct location.
As an example: P3 receptacle has two rows and
each row has 16 connections.
Thefirstrowisclosetothesheetmetalstarterdoor
and numbered 1 through 16 reading left to right.
The second row is away from the sheet metal
starter door and numbered 17 through 32 reading
left to right.
Remember.... the small numbers are close to the
door, the large numbers are away from the door
and the number sequence reads from left to right.
The 120/110 VAC circuit passes through a filter
anda seriesofswitchesto connect totheIntellisys
with the X2 “hot” wire at P1-1 and the X1 neutral
wire at P1-10.

-9--8-
24 VAC Circuit - Transformer (T1) to Power
Supply Board (PCB1)
The 24 VAC power from T1 connects to a bridge
rectifier on the Power Supply Board and is
converted to 33 VDC. A portion of the 33 VDC is
used to power the stepping motor and a portion is
regulated down to 12 VDC and sent onward to the
Intellisys controller.
The circuit is between X3 and X4 and connects to
thePowerSupplyboardinthefollowingsequence.
3FU - Fuse
A fast-blow fuse on the 24 VAC secondary side of
the control voltage transformer provides a degree
ofprotectionforthePowerSupplyBoard. Thefuse
isratedat5ampsforcompressorsfittedwitheither
4 inch or 6 inch diameter inlet valves. The fuse is
rated at 6 amps for compressors fitted with 8 inch
diameter inlet valves.
The fuse is a non-time delay type and is intended
to blow instantly when either a short-circuit is
experiencedorthevoltageexceedsapproximately
38 volts AC.
The short-circuit protection is basic but the high
voltage protection works with the help of a Silicon
ControlRectifier(SCR)onthePowerSupplyBoard.
WhentheSCRsenseshighvoltage(approximately
38 volts AC), it diverts the circuit to ground and
3FU quickly blows before components beyond the
fuse, such as the stepping motor drive chips, are
damaged by high voltage.
Always use a BBS type fuse (or equivalent) rated
for the amperage required by the specific
compressor.
Power-On Light (24 VAC - Starter Door) (2LT)
A “Power-On” light is located on the starter box
door next to the Intellisys controller.
When incoming power has been applied to the
control voltage transformer and 3FU is in good
condition,thislightindicates24VACisavailableto
the Power Supply Board at J1 terminals 1 and 2.
As indicated, a “Power-On” condition exists and
care must be taken to prevent injury or damage
from contact with any part of the electrical circuit.
NEVERuseanindicatorlight toconfirmpowerhas
beenturnedoff! Afaultybulborloosewirewillgive
a false indication.
Power Supply Board (PCB1)
Aprintedcircuitboardislocatedinthemainstarter
box to supply power to the stepping motor and
Intellisys controller.
Major items on the board include diodes, a bridge
rectifier to convert 24 VAC to 33 VDC, two voltage
regulators, capacitors, resistors, two drive chips
for the stepping motor and a programmable (PAL)
chip to provide logic for the drive chips.
Thereare four plug-in junctions(J1, J2,J3 and J4)
on the board. J1 brings 24 VAC to the board from
T1 transformer, J2 sends a 12 VDC power supply

-11--10-
to the Intellisys and J4 receives input from the
Intellisystotellthedrivechipshowfarandinwhich
direction to rotate the stepping motor. J3 sends
power from the two drive chips on the Power
Supply Board to the stepping motor.
Stepping Motor (3MTR)
The stepping motor is directly connected to the
inletvalveofthecompressorandoperatesonaDC
voltage supply. The motor is bi-directional and as
itrotates,theinletvalveiseitheropenedorclosed.
The stepping motor has multiple North/South
permanent magnet poles on the rotor andtwosets
of interlaced windings in the housing. As the drive
chips send variable strength electrical pulses to
the two sets of windings, the windings are rapidly
turned on and off in an exact sequence.
As the variable pulse is applied to the two sets of
windings, one winding has an increase in pulse
strength while the other set of windings has
reduction of pulse strength. The combination of
pulse sequence and strength causes the motor to
turn in very short and precise .45°steps. The
motor can rotate either clockwise or counter-
clockwise.
Thedirection, distance and speedof rotation are a
result of the drive chips varying the pulse strength
in response to input from the Intellisys.
Stepper Limit (PCB2)
The Stepper Limit PCB2 is a printed circuit board
located on the inlet valve that limits the inlet valve
rotation to approximately 90 degrees. The board
has two optical limit switches and each emits an
infrared light beam. When the light beam is
interrupted,thecontrollerreceivesanindicationof
valve position (open or closed).
Auxiliary Contacts
Small switches mounted directly on the side of the
main motor contactors that serve to confirm the
position of the contactor or energize electrical
components.
There is a mechanical linkage between the
auxiliary contact and the main contactor. As the
main contactor closes, or opens, the mechanical
inkage causes small switches within the auxiliary
contact to change position.
The internal switches, usually two, can be nor-
mally open, normally closed or a combination of
the two.
Auxiliary contacts are identified on electrical
schematics according to which contactor they are
attached. Examples... auxiliary contact 1Sa is
attachedtocontactor1Sandauxiliarycontact2Ma
is attached to contactor 2M.
When a contactor has more than one auxiliary
contact attached, each auxiliary will be identified
on the electrical schematic as 2Ma, 2Mb, etc.
Overload Relays (1OL/2OL)
The main motor and the fan motor are each
equipped with overload relays that monitor the

-13--12-
current drawn by the motors. Should either motor
draw excessive current, the relay will open to
cause the compressor to stop. The relays are
normally closed, operate on a 12-volt DC circuit
and are shipped from the factory in the automatic
reset position. The relays are identified on
electrical schematics as 1OL for the main motor
and 2OL for the fan motor.
Basically, the overload relay has a heat-generat-
ingelement for eachofthethreephasessupplying
current to the motor. The heater element is sized
for the current drawn by the motor at full load
conditions. Should an overload condition develop
to draw higher than normal current, the heater
elements produce additional amounts of heat.
Theadditionalheatissensedbyasmallstripmade
of two dis-similar metals bonded together having
different rates of expansion. As the bi-metal strip
heats up, it bends as a result of the two different
expansion rates until it trips the overload relay
contacts to the open position. As the contacts
open, the compressor is shut down in an alarm
condition.
After cooling, the relay can be reset manually or
automatically.
Coolant Filter Differential Pressure Switch
(CPS)
A differential pressure-sensing switch is installed
to monitor the condition of the coolant filter. The
switchisnormallyopenandclosesacrossa12volt
DC circuit when the filter differential exceeds 20
psi.
Emergency Stop - Logic Circuit (ES-2)
A normally closed contact in the 12 volt DC circuit
that opens when the Emergency Stop button is
pressed. As the contact opens, power is removed
from the controller circuit. See the emergency
stop switch section for further information.
Remote Stop Button (RSP) (Optional)
The button is intended to stop a running com-
pressor from a remote location.
When the Remote Start/Stop option is installed
and turned on in the set point routine, a normally
closed switch must be connected between P3
terminals 19 and 20. The switch must be a
momentary opening type (approximately .1
second). If a start attempt is made while the
switch remains open, the controller will issue a
Remote Stop alarm.
Remote Start Button (RST) (Optional)
Thebuttonisintendedto start a stopped compres-
sor from a remote location.
When the Remote Start/Stop option is installed
and turned on in the set point routine, a normally-
open switch must be connected between P3
terminals 21 and 22. The switch must be a
momentaryclosingtype(approximately2seconds).
ARemote Start alarm will be issued by the control-
ler if the button is not released by the end of the
star-delta transition time on star-delta units or 7

-15--14-
seconds after the button is pressed on full-voltage
starters.
Pressure Sensors - 1AVPT, 3APT, 4APT, 5CPT
and 6APT
Pressuretransducersusedtoconvertairpressure
signalstoavoltagesignalbetween.5and4.5volts
DC.
The transducer contains a metal diaphragm
connected to a small piece of steel called the
beam which in turn has a strain gauge attached.
As pressure pushes the diaphragm, the beam
flexes and bends the strain gauge.
A continuous 5 volt DC supply is attached to the
strain gauge assembly.
As the strain gauge bends due to the changing
pressure on the diaphragm, the resistance value
throughthestraingaugechangesacorresponding
amount. The result is a variable output signal that
ranges from .5 volts DC to 4.5 volts DC.
The output signal is processed by an analog-to-
digital converter within the Intellisys controller.
Depending on the voltage level, decisions are
made by the Intellisys that may cause a change in
the pressure reading on the display panel, unload
the compressor or possibly shut the compressor
down if conditions dictate.
If a pressure sensor is replaced, it is important to
calibrate the new sensor. Basically, calibration
allows the controller to read the sensor’s output
signal with the diaphragm in a totally relaxed state
and then correct for any minor deviations from .5
volts DC. Calibration directions are included in the
Operator’s Manual.
Therearenoadjustmentstothepressuresensors.
1AVPT - Inlet Vacuum
A pressure sensor having a range between 0 and
15 psi vacuum connected to the airend inlet to
providevacuuminformationforthecontroller. The
output voltage is .5 volts DC at 0 psi vacuum and
4.5 volts DC at 15 psi vacuum.
The controller uses inlet vacuum information to
confirm the drive motor is rotating in the correct
direction, to indicate the condition of the inlet air
filter and to provide logic for positioning the inlet
valve during modulation or unloaded operation.
3APT - Separator Tank Pressure
A pressure sensor applied to a range between
0 and 225 psi used to provide information
aboutpressurewithinthecompressor’sreceiver-
separator tank. The connection point in the
receiver-separator tank is referred to as sump
pressure. The sump pressure is taken on the wet
side (before air enters) the separator element.
The sump pressure is monitored for several
reasons to include comparison to line pressure
during the separator element differential check
and to provide logic for the controller to position
the inlet valve during unloaded operation.
The normal unloaded sump pressure is maintained