Ingersoll-Rand Intellisys S3 User manual

S3
Intellisys Controller
Technician Guide
August 2008

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© 2008 Ingersoll-Rand company
Confidential and trade secret information. This
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necessary to use or service the equipment
disclosed herein; and shall disclose such
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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.

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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

©2008 Ingersoll Rand Company Page 5
Ohms Temperature Ohms Temperature
33631 32 14301 63
32668 33 13933 64
31736 34 13575 65
30834 35 13227 66
29960 36 12890 67
29114 37 12562 68
28295 38 12244 69
27501 39 11934 70
26733 40 11634 71
25988 41 11342 72
25267 42 11058 73
24568 43 10782 74
23891 44 10514 75
23235 45 10254 76
22599 46 10000 77
21983 47 9754 78
21385 48 9515 79
20806 49 9282 80
20244 50 9055 81
19699 51 8835 82
19171 52 8621 83
18658 53 8413 84
18161 54 8210 85
17679 55 8013 86
17211 56 7821 87
16757 57 7635 88
16317 58 7453 89
15889 59 7277 90
15475 60 7105 91
15072 61 6937 92
14681 62 6774 93

©2008 Ingersoll Rand Company Page 6
Ohms Temperature Ohms Temperature
6616 94 3287 125
6461 95 3218 126
6311 96 3150 127
6165 97 3083 128
6022 98 3019 129
5883 99 2955 130
5748 100 2894 131
5616 101 2833 132
5488 102 2775 133
5363 103 2717 134
5241 104 2661 135
5123 105 2607 136
5007 106 2553 137
4894 107 2501 138
4784 108 2450 139
4677 109 2400 140
4573 110 2352 141
4472 111 2304 142
4372 112 2258 143
4276 113 2213 144
4182 114 2169 145
4090 115 2125 146
4000 116 2083 147
3913 117 2042 148
3828 118 2001 149
3745 119 1962 150
3663 120 1924 151
3584 121 1886 152
3507 122 1849 153
3432 123 1813 154
3359 124 1778 155

©2008 Ingersoll Rand Company Page 7
Ohms Temperature Ohms Temperature
1744 156 978.8 187
1710 157 961.5 188
1677 158 944.6 189
1645 159 928.1 190
1614 160 911.9 191
1583 161 896 192
1553 162 880.5 193
1523 163 865.2 194
1495 164 850.3 195
1466 165 835.6 196
1439 166 821.3 197
1412 167 807.2 198
1386 168 793.4 199
1360 169 779.9 200
1335 170 766.7 201
1310 171 753.7 202
1286 172 741 203
1262 173 728.5 204
1239 174 716.3 205
1216 175 704.3 206
1194 176 692.5 207
1172 177 681 208
1151 178 669.7 209
1130 179 658.6 210
1110 180 647.7 211
1090 181 636.9 212
1071 182 626.5 213
1051 183 616.2 214
1033 184 606.1 215
1014 185 596.3 216
996.4 186 586.6 217

©2008 Ingersoll Rand Company Page 8
Ohms Temperature Ohms Temperature
577.1 218 355.7 249
567.8 219 350.4 250
558.6 220 345.2 251
549.7 221 340.1 252
540.9 222 335.1 253
532.2 223 330.2 254
523.8 224 325.4 255
515.4 225
507.3 226
499.3 227
491.4 228
483.7 229
476.1 230
468.7 231
461.4 232
454.2 233
447.2 234
440.3 235
433.5 236
426.9 237
420.3 238
413.9 239
407.6 240
401.4 241
395.3 242
389.4 243
383.5 244
377.7 245
372.1 246
366.5 247
361.1 248

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Digital Inputs
Emergency Stop Switch [Std] – Located on
the front of the compressor next to the controller,
it is intended to stop the compressor only in an
emergency. This switch has two sets of normally
closed contacts that open when the red button is
pressed. One contact is wired into the 120-volt
AC power circuit and the other is wired into the
24-volt DC logic circuit. These parallel contacts
ensure that power is removed from the starter
and solenoids as well as the Intellisys controller;
this will stop the compressor immediately. Once
the switch has been pressed in, it will lock open
and must be manually reset by rotating the red
button clockwise.
Coolant Filter Condition [Enh] – A
differential pressure-sensing switch is installed
to monitor the condition of the coolant filter. This
switch is normally open and closes when the
differential across the filter exceeds 20 psi. This
switch is designated as 1DPS on the electrical
schematic and is wired into the controller at
terminal XO4 pins 1 and 3.
Inlet Filter Condition [Enh] – This sensor is
installed to monitor the vacuum at the inlet
valve. This switch is a normally opened switch
and will close when the vacuum across the inlet,
while unloaded, exceeds 15 psi and 1 psi when
unit is running loaded. The inlet filter switch is
labeled as 1VAC on all schematics and is wired
into XO4 pins 1 and 4.

©2008 Ingersoll Rand Company Page 10
Motor Overloads – There are possibly three
sets of overload contacts with this controller. On
a standard controller there is an overload for the
main motor and one for the fan motor, both of
these overloads are normally closed. For an
enhanced controller and the compressor has an
integrated dryer installed there will also be a
normally closed dryer overload. All three of
these overloads will be wired in series at
terminal XO4 pins 1 and 5. Electrical schematic
labeling for these three overloads are as follows:
MOL – Main Motor Overload [Std]
FMS – Fan Motor Overload [Std]
DMS – Dryer Motor Overload [Enh]
Remote Start and Stop [Enh]– The customer
can install this single contact onto the controller
at terminal XO4 pins 1 and 6. This switch allows
the customer to remotely start and stop his or
her compressor. The remote contact must be
sized for 24 volts DC and 200ma max. To use
this feature you must enable the software in
Parameter P03 RC.
Remote Load Enabled [Enh] – This normally
closed contact can be installed by the customer
or service technician to allow the enabling of a
remote load/unload switch. If the remote
enabled contact is opened, the controller will use
its load and unload pressure settings as
operating the compressor. If the contact is
closed then the controller will use the remote
load/unload input for loading or unloading the

©2008 Ingersoll Rand Company Page 11
compressor. The controller will still compare its
discharge pressure to the discharge level high
warning value. If the discharge pressure reaches
this value, the controller will automatically
unload and issue a high discharge pressure
warning. This function can also be performed by
the IEO using an ISCI-II module connected to
terminal XO4 pins 1 and 7. The X4I and X8I
controllers can also be used by the S3 controller
by simply connecting to the X07 RS485-1
Network connector. To use this feature you must
enable the software in Parameter P03 RC (See
remote control).
Remote Load/Unload [Enh] – this single
normally opened contact is wired into terminal
XO4 pins 1 and 8 and allows the user to
remotely load or unload his or her compressor. If
the Remote Load Enabled contact is closed and
the Remote Load/Unload contact is open the
unit will run unloaded. If the Remote
Load/Unload contact closes, the unit will load.
An IEO can be installed with an ISCI-II module
and wired into the above-mentioned terminal
and pins. To use this feature you must enable
the software in Parameter P03 RC (See remote
control).
Motor PTC [Enh] – This is a positive
temperature coefficient (PTC) switch that is
embedded into the motor and it is used to detect
the temperature of the motor windings. This PTC
is wired into the controller at terminal XO4 pins 1
and 9. If the motor windings get to hot the

©2008 Ingersoll Rand Company Page 12
controller will shut the unit down on a (code 20)
Main motor Over Temp alarm.
Digital Outputs
All digital outputs are connected to terminal XO3
on the back of the controller.
1M / 2M Starter Contacts [Std] – YΔLogic
uses two digital contacts on one common
output. The S3 controllers start and run logic
remains the same but the 2M output is not used
for the starters. A normally closed electrical
interlock (KMS-3) from 1S (KM3) contactors
keeps the 2M (KM2) contactor from energizing
anytime the 1S contactor is energized. Electrical
interlocks are wired such that when the 1S
(KM3) output is de-energized at Star Delta
transition time causing the 1S (KM3) contactor
to open, the 1S normally closed interlock (KM3-
2) falls back to the closed position energizing the
2M (KM2) contactor. A second electrical
interlock from 1S (KM3) contactor is wired in
series with 1M (KM1) contactor to ensure the 1S
(KM3) is pulled in before 1M (KM1) will be
energize. An interlock from 1M (KM1) contactor
is used to seal around the 1S (KM3-1) contact to
allow the 1M (KM1) contact to remain energized
when the 1S (KM3) contact is de-energized at
the Star Delta transition.
1S Starter Contact [Std] – This contactor is
only installed and used in the YΔtype of starter.

©2008 Ingersoll Rand Company Page 13
Load Valve (1SV) [Std] – Normally closed 3-
way solenoid valve connected within the control
system to direct pressurized air into, or allow it
to vent out of, the airend inlet valve. The follow
of the pressurized air into or out of the inlet valve
causes the valve to open or close thereby load
or unload the compressor. This solenoid valve is
known schematically as 1SV, has a 120-volt AC
coil.
Blowdown Valve (3SV) [Std] – 3SV is the
schematic designation for the blowdown
solenoid valve. This valve is a 2-way normally
opened valve with a 120-volt AC coil. This valve
is wired in parallel with 1SV and when de-
energized allows the pressurized air in the sump
to be released back to the inlet valve allowing
the compressor to run in the unload mode. 3SV
is piped directly into the top of the separator lid
but prior to the minimum pressure check valve.
The exhaust port of 3SV is piped back into the
inlet filter housing to reduce noise as the
pressurized air vents. When the compressor is
stopped, 3SV automatically releases all internal
pressure.
Important: Always ensure that internal
pressure has been completely released prior to
removing caps, plugs, filters, etc.
Modulation Valve (5SV & 6SV) [Enh] – If the
modulation set point in the Intellisys controller is
turned off the modulation output stays off. If the

©2008 Ingersoll Rand Company Page 14
modulation set point is turned on then the
modulation output is used to turn on the
modulation solenoid valves whenever the
requirements for modulation have been met.
When the compressor first starts and loads, the
modulation set point is off. If the unit cycles
(loads and unloads) 3 times in 3 minutes, the
compressor will start modulating. If the unit is
modulating, the modulation output will follow the
load output. Modulation output will be on if the
unit is loaded and off if the unit is unloaded. If
the compressor unloads and stays unloaded for
3 minutes, the compressor will stop modulating.
The compressor will have to repeat the 3 load
cycles within 3 minutes to start modulation
again. If the unit stops in auto start/stop while
modulating, it will continue modulating if it
restarts in less than 3 minutes after unloading. If
it restarts more than 3 minutes after unloading it
will have to load and unload 3 times in 3 minutes
again to start modulating. If the operator or a
fault stops the unit, the modulation output will be
off when the unit is restarted. Again, it will have
to cycle 3 times in 3 minutes for the modulation
output to be turned on.
Condensate Drain Valve (9SV) [Std] – This
120-volt coiled normally closed solenoid valve is
used to remove the condensate that has been
collected at the moisture drain with is piped into
the discharge of the aftercooler. This solenoid
valve has an output timer that toggles on for a
period defined by the Condensate Drain Time
set point. The drain valve will remain off for a