Ingersoll-Rand Intellisys S3 User manual

S3
Intellisys Controller
Technician Guide
August 2008

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Proprietary Notices and Disclaimer
© 2008 Ingersoll-Rand company
Confidential and trade secret information. This
manual contains confidential and trade secret
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(hereinafter referred to as “Proprietary Matter”).
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shall not disclose or give such Proprietary Matter
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use the Proprietary Matter except to the extent
necessary to use or service the equipment
disclosed herein; and shall disclose such
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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

©2008 Ingersoll Rand Company Page 1
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,

©2008 Ingersoll Rand Company Page 2
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.

©2008 Ingersoll Rand Company Page 3
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.

©2008 Ingersoll Rand Company Page 4
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