Ingersoll-Rand SE Installation guide

Rotary Training Manual Page 1
Ingersoll Rand Global Service Education Team
Issue: 05/Davidson, December, 2008. Ingersoll Rand Proprietary Information
Controls
SE Controller
SE Controller............................................................. 3
Software.................................................................... 4
Current Status........................................................... 6
SE Panel Display ...................................................... 7
Hidden Buttons ......................................................... 8
Warnings................................................................... 9
Alarms....................................................................... 10
Options...................................................................... 12
Calibration Procedure ............................................... 14
UP Series Controller ................................................. 16
Short Test ................................................................. 17
Basic Rotary Manual
GDSTP-24280-MAN-0005_P1
CP-1010-010, 020, 030
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SE Controller
In this section, we will review the functions of the SE
Controller used on the 50-100hp (37-75kW) IR
Contact Cooled Rotary Compressors.
SE is the microprocessor based controller and uses a
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 list
of temperature and pressure readings.
The Intellisys monitors the compressor and when any
pre-programmed limit be exceeded, the controller
automatically displays a warning or issues an alarm to
shut the compressor down. A group of pressure and
temperature sensors, relays and switches support the
decision making process.
ALARM will shut down the compressor
When WARNING is displayed, the compressor will
continue to operate.
Operation of the control system will be easy after the
following explanation of the control system
components is read and understood.
SE Training Module
SE Controller
In this section, you will learn
x SE Controller major functions
x SE Basic hardware relationship
x SE Electrical Diagram
x SE Input/Outputs
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Software
The term software refers to
the program or set of
instructions that the
central processing unit
(CPU) requires and will
obey for all of the
compressor’s operating
functions.
The software is
programmed (or written)
into a 28-pin chip called
an EPROM (Erasable
Programmable, Read
Only Memory), located in
the controller. The
EPROM can be erased if
exposed to ultraviolet
light. From time to time,
software is updated to
incorporate improvements
or additional features. In such cases, the updated
software is a new revision. It moves up one level and
can be purchased as an upgrade. For example,
Original software revision 1.0 may become Revision
1.1 etc.
The new revision would be programmed into a new
EPROM and the original would have to be replaced.
There is a danger when replacing EPROM, as the
static electricity from your body could discharge and
damage the EPROM. For this reason you should
always use anti-static kit CPN 93457596. The EPROM
that has been removed should be returned to Ingersoll
-Rand for recycling.
SE Controller Description
The controller uses touch membrane technology, with
back lit LCD display and green LED (Light Emitting
Diode) indicators.
The touch pad is made up of Start, Scroll Arrows,
Unloaded Stop, Set, Unload/Load, Hidden Right,
Display Select and Hidden buttons.
J5 115/120 Vac. J4 16Vac. J3 5Vdc. J2 5Vdc. J1 5Vdc.
EPROM
CPU
Printed Circuit of SE Controller
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INGERSOLL-RAND
INTELLISYS
Arrows.
These up and down buttons have multiple
functions. When lists are presented, the
buttons are used to move up and down
through the items on the list. The keys
are used to increase and decrease the
values of set points within the Intellisys
controller. They are also used to calibrate
4APT - Package Discharge Pressure
Transducer.
Start button.
Pressing this button will start the
compressor if the display shows
Ready To Start. The compressor will
start and load if there is sufficient
demand for air.
Stop button.
Pressing this button will activate the unloaded
stop sequence. If the compressor is running
loaded, it will unload and continue to run
unloaded 5 - 10 seconds and then stop. If the
compressor is running unloaded and the button
is pressed, it will stop immediately. Pressing this
button when the unit is stopped will cause an
LED self test to occur and display the installed
Software inside the Intellisys Controller.
“SET” Buttons.
This is used to scroll through the operator set
points and if a value is changed by the operator
then pressing this button again will save the
new value into the Intellisys Controller.
Display Select Button.
This is used to scroll through the
package display select menu that will
show the current status of the unit.
Hidden Left Hidden Right
Unload button.
Pressing this button will cause the compressor to
unload and remain unloaded. The display will
indicate the machine is Running Unloaded, and
Mode: UNLOAD.
Load button.
Pressing this button will cause the compressor to
load if the machine has been started and the
Discharge Pressure is less than the Online
Pressure. This also returns the compressor to the
operating mode that is specified by the Mode of
Operation set point.
Package Disch. Pressure
Airend Disch. Temp
Sump Pressure
Separator Pressure Drop
Total Hours
Loaded Hours
Unload
Green LEDs
(Display Current Status
Alarm (Red LED)
Set Offline Air Pressure
Set On line Air Pressure
Select Control Mode
Set Display Time
Select Options
Green LEDs
(Customer Set
Points)
100 PSI
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Current Status
x PACKAGE DISCHARGE PRESSURE
x AIREND DISCHARGE TEMPERATURE
x SUMP PRESSURE
x SEPARATOR DELTA P
x TOTAL HOURS
x LOADED HOURS
The controller automatically returns the display to the
CURRENT STATUS screen showing PACKAGE
DISCHARGE PRESSURE if no other buttons are
pressed within 30 seconds.
Pressing Display Select button will scroll to the next
status display and the appropriate green LED on the
left hand side of the SE will light up.
Note
The Intellisys controller calculates separator pressure
drop by:
x Monitoring sump pressure
x Subtracting current line pressure
x Subtracting 5 psi (.3 bar) to allow for minimum
pressure valve, aftercooler and moisture separator
pressure drops, for example
Sump Pressure 120 PSI / 8.3 Bar
Line Pressure 109 PSI / 7.5 Bar
Calculation: 120 PSI - 109 PSI - 5 PSI = 6 PSI
8.3 Bar - 7.5 Bar - 0.3 Bar = 0.5 Bar
The Intellisys controller display would indicate 6 PSI or
0.5 Bar.
Maximum separator pressure drop 12 PSI or 0.8 Bar.
SE Panel Display
Normal Display - Not Running
The normal display message when the compressor is
not running will be Ready To Start. However, if the
Remote Start/Stop feature is enabled, the message
will read Start Local/Remote. Neither message will be
displayed if an Alarm condition exists.
Normal Display - Running
The normal display when a unit is running will be the
current line pressure value and units of measure. As
an example: 102 PSI or 7 BAR. The green LED
beside Package Discharge Pressure will be on.
Display Select Operation
The operator can press the Display Select button and
scroll through the following listed values. If the
Display Select button is pressed to observe any value
other than Package Discharge Pressure and then not
pressed again within the period of time selected in the
Display Time set point, the display returns
automatically to the normal display selection. The
display time is selectable between 10 and 600
seconds and is part of the customer set-point routine.
Remember: the "normal display" is Ready to Start or
Start Local/Remote when the compressor is not
running and Package Discharge Pressure when in
operation.
Package Discharge Pressure
This is the normal display when the compressor is
running; the green LED will be on and the display will
show the current value of the Package Discharge
Pressure and unit of measure. Pressure sensor 3APT
provides the information.
Airend Discharge Temperature
The Airend Discharge Temperature LED will be on
and the display will show the current value of the
temperature and the units of measure. Temperature
sensor 2ATT is installed within the airend discharge
port and provides this information to the controller. An
example would be "207 DEG F" or “97 DEG C”.
Sump Pressure
When Sump Pressure has been selected, the green
LED will be on, the Line/Sump solenoid 10SV will be
energized and the display will show the current sump
pressure and unit of measure. The sump is constantly
scanned as long as the compressor remains loaded or
manually unloaded.
The controller understands pressure sensor 3APT is
connected to the sump and when loaded must make
an adjustment to ensure the unit unloads at, or very
near, the original Off-Line setting that is associated
with the customers air pressure.
To do this, the controller automatically makes a
calculation and unloads the compressor when the
sump pressure is 5PSI (.3 bar) plus the separator
pressure drop above the Off-Line setting.
An important point...the controller makes an automatic
2 second check of the separator differential every
loaded hour and stores the information to use during
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the above calculation. When the check is made, the
line pressure must be above 90 PSI (6.2 bar), the unit
loaded and the line pressure may only change 2 PSI
(0.1 bar) during the check. Should any of the
parameters be out of range during the check, the
controller continues checking until a reading is
obtained. Once a reading is obtained and in the
memory, the controller waits for another loaded hour
before updating the information.
When the compressor unloads and Sump Pressure
remains selected, the Line/Sump solenoid 10SV
alternates every 15 seconds between Line and Sump.
The Line is read for 13 seconds and the Sump for 2
seconds and the Sump pressure is updated on the
display after each 2 second check.
There is no display concerning line pressure at this
time because Sump Pressure has been selected.
However, the controller is aware because it reads the
line pressure as the Line/Sump solenoid alternates
back and forth. The controller reloads the compressor
when the customer's air pressure falls to the On-Line
Setting.
Remember; the Sump Pressure reading will
automatically return to Package Discharge Pressure at
the end of the pre-selected Display time.
Separator Pressure Drop
This check is made by the Intellisys once every loaded
hour and stored in the memory or can be selected on
the Display by an operator.
When an operator selects Separator Pressure Drop on
the display, the check is made every 15 seconds.
The actual check takes 2 seconds and 10SV will be
energized during this time as the solenoid alternates
between Line and Sump.
If the differential is 3 PSI (0.2 bar) or less, the
controller will display 3 PSI (0.2 bar). If the differential
is greater than 15 PSI (1 bar), the controller will
display 15 PSI (1 bar).
The display will show RUN COMP TO CK, LOAD
COMP TO CK or WAIT - LOADING if the compressor
has not been running loaded for at least 8 seconds
when this display is selected.
A warning feature is associated with the Separator
Pressure Drop and will cause the message "Change
Separator Element" to appear in the display if the
following conditions occur.
If the Intellisys calculation is greater than 12 PSI (.8
bar), the warning message "Change Separator
Element" will appear in the display and the red Alarm
LED will begin to flash. The compressor continues to
run and deliver air to the customers system. If the
pressure drop across the separator increases to 15
PSI (1 bar) then the Intellisys controller will shut the
unit down on a “Change Separator Element” alarm.
The red alarm LED will also turn on and stay on.
Running Hours
The green LED will be on and the total number of
hours the compressor has run will be in the display. If
the unit has operated less than 1 hour, the display will
show minutes.
This information has value for scheduling
maintenance.
Loaded Hours
The green LED will be on and the number of hours the
compressor has been in a loaded condition will be in
the display. If the unit has been loaded less than one
hour, the display will show minutes.
This information indicates usage of the compressor to
air delivery.
Hidden Buttons
The information enclosed in this part of the program
should be restricted to trained and authorised Ingersoll
-Rand Service personnel only for safety of operation
reasons.
(EPROM revision level 1.3 or higher)
Hidden Left (Last Alarm Recall)
Located between the Power Indicator light and the
Start button.
To Access
Have "READY TO START" or "START LOCAL/
REMOTE" showing in the message display. Press
the Unload/Load button once and then press the
Hidden Left button within three seconds.
Content
Last Alarm Recall plus operating conditions at the
instant of the alarm are stored in the memory and
can be reviewed using the Display Select button.
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Hidden Right (Factory Set Points)
Located between the Automatic Restart Indicator
light and the Unloaded Stop button.
To Access
Have "READY TO START" or "START LOCAL/
REMOTE" showing in the message display. Press
the Unload/Load button once and then press the
Hidden Right button within three seconds.
To Exit Either Hidden Button Function
Press the Set button twice.
Factory Set Points
Content
¨Language
English
French
Spanish
Portuguese
¨Temperature and pressure selections
1) Degrees F. and PSI
2) Degrees C. and KPA
3) Degrees C. and PSI
4) Degrees C. and BAR
5) Degrees C. and KG/CM²
¨Rated pressures
1) PSI = from 100 to 200 in increments of 1 PSI
2) BAR = 7 / 8.5 / 9.6 / 10.3 / 11.4/ 13.8
3) KG/CM² = 7 / 8.5 / 9.8 / 10.5 / 11.4/ 14.0
4) KPA = 700 / 850 / 960 / 1030 / 1380 / 1140
¨Starter options
1) Star-Delta (Timer adjusts between 5 and 15
seconds)
2) Full voltage
3) No starter
¨LCD (Liquid Crystal Display) contrast
1) Use the Up/Down arrows to adjust the contrast
and then press the Set button.
¨Hour meter settings
¨Modulation On/Off
To Exit
Press the Display Select button once or wait for 30
seconds.
General Conversion Factors
x 1 BAR = 14.5 PSI
x 1 KPA (Kilo Pascal) = BAR X 100
x 1 KG/CM² = 14.22 PSI
x Degrees Celsius = ( Fahrenheit - 32 ) ÷ 1.8
x Degrees Fahrenheit = 1.8 X Celsius + 32
Customer Set Points
There are ten main set points that the operator may
wish to change: -
x OFF-LINE PRESSURE
x ON-LINE PRESSURE
x MODULATION/ACS
x ON-LINE/OFF LINE
x MODULATION ONLY
x DISPLAY TIME
x STAR-DELTA TIMER IF SUPPLIED
x LEAD/LAG
x LAG OFFSET
x LOW AMBIENT
Pressing the SET key with the machine stopped,
power on, will enable access to set parameters. The
current value will display on the LCD and the
appropriate green LED light on the right hand side of
the controller’s face will be on.
The arrow keys can be used to change values.
Pressing SET for a second time will store the setting
and automatically, move down to the next set point.
The controller automatically returns the display to the
current status showing Package Discharge Pressure if
no other buttons are pressed within 30 seconds.
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SE Intellisys Warning Messages
In the event of a warning condition, the controller will
display a message and the alarm LED will flash. The
warning message will alternate with the normal display
every one second, the compressor will continue to
run.
The fault should be rectified as soon as possible. The
arrow keys should be used to index the display for any
additional warning messages if SCROLL FOR WARN
is displayed.
A warning message may be reset by depressing the
set button once. This can be done with the
machine in operation. The warning will re-occur if the
fault has not been rectified.
There are 3 pre-programmed warnings that can be
displayed; the warnings and the conditions under
which they might occur are listed.
HIGH AIR END DISCHARGE
TEMPERATURE
This warning will occur when the airend discharge
temperature reaches 97% of the high temperature set
point 221°F (106°C). The warning AIREND TEMP will
be displayed.
CHANGE SEPARATOR ELEMENT
If a separator element pressure differential of 12 psi
(0.9 bar) or greater is detected during normal
operating conditions. Separator element warning will
only occur if the above condition exists for 3
consecutive hours.
INGERSOLL-RAND
INTELLISYS
CHANGE SEPARATOR ELEMENTS
SERVICE DUE
This warning occurs when an internal timer reaches
150 hours after startup of a new unit. This warning
uses an internal timer that corresponds with the
compresses Running Hours. To reset this warning all
anyone has to do is press the set button twice. Once
the Set button has been pressed this will reset the
internal timer for 2000 hours.
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SE Intellisys Alarm
Shutdowns
In event of an alarm
condition the controller will
execute an emergency stop
to:
x De-energize all
contactors and solenoids
x Energize alarm relay
x Illuminate alarm LED
x Display alarm message
The arrow keys should be
used to index for any
additional alarm messages if
SCROLL FOR ALARM is
displayed.
x LOW SUMP PRESSURE
x HIGH AIR PRESSURE
x HIGH AIREND TEMPERATURE
x STARTER FAULT
x MAIN MOTOR OVERLOAD
x FAN MOTOR OVERLOAD
x REMOTE STOP FAILURE TEMPERATURE
SENSOR FAILURE
x REMOTE START FAILURE
x CHECK MOTOR ROTATION
x CALIBRATION FAILURE
x NO CONTROL POWER
x PRESSURE SENSOR FAILURE
x EMERGENCY STOP
Alarm Reset
An alarm is reset by depressing the set button twice
within a three second period, after the fault has been
rectified.
Low Sump Pressure
An alarm that will cause a running compressor to be
stopped should the wet-side sump pressure fall below
15 psi (1 bar). Note: wet-side sump pressure is
defined as the pressure between the discharge port of
the airend and the separator element.
High Air Pressure
This alarm can occur from two separate pressure
sources.
The first, and most likely, is for the controller to sense
Package Discharge Pressure to be 15 psi (1bar)
above the rated pressure of the controller. This
pressure source is the normal connection for 3APT
because the Intellisys always returns to Package
Discharge Pressure at the end of the Display Select
timer.
High Airend Temperature
A sensor known as 2ATT is located within the
discharge port to monitor the air/oil temperature
leaving the airend.
Should the temperature of the discharge port rise
above 228°F. (109°C.) on an SE that is running, the
Intellisys controller will shut the compressor down on
an alarm condition and place HIGH AIREND TEMP in
the message display.
In addition, should the temperature of the airend
discharge port of a stopped compressor be greater
than 217°F. (103°C.), the display will show HIGH
AIREND TEMP and then alternate that message back
and forth with MUST COOL DOWN. This condition is
also a HIGH AIREND TEMP alarm and the controller
will not allow the compressor to be started.
Either of the above two situations require 2ATT to cool
below 217°F. (103°C.) before the Intellisys will clear
the alarm when the Set button is pressed twice.
INGERSOLL-RAND
INTELLISYS
LOW SUMP PRESSURE
ALARM
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Starter Fault
The Intellisys control system uses an auxiliary contact
(1Sa, 1Ma and 2Ma) on each contactor to indicate
when the contactor is either open or closed.
When the compressor is in operation and one of the
contactors opens while the controller logic indicates it
should be closed, the auxiliary contact also opens to
signal the controller there is a problem. The controller
issues a STARTER FAULT alarm. A loose wire, faulty
starter coil or burned triac could cause the problem.
This alarm is also issued if the starter is directed to
open and the contactor remains in the closed position.
Main Motor Overload
This alarm occurs whenever the contacts of the
overload relay (1OL) open and remain open for at
least 1 second. The relay contacts operate a 5 Volt
DC circuit, are normally-closed and shipped from the
factory in the automatic reset position.
Basically, 1OL has a heater element for each of the
three phases supplying current to the main motor and
each is sized for the amperage drawn at full load.
Should an overload condition develop to draw higher
than normal current, the heater elements produce
additional amounts of heat. This additional heat is
sensed by a small strip made of two dissimilar metals
bonded together that have 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
and MAIN MTR OVERLD will appear in the message
display.
Fan Motor Overload
An alarm that occurs and will shut the compressor
down whenever the fan motor overload relay 2OL
opens and remains open for at least one second. The
operation of 2OL is the same as 1OL.
Some causes for a Fan Motor Overload alarm could
include low incoming voltage, loose connections,
wrong fan blade installed or improperly sized heater
elements. The message display will show FAN MTR
OVERLOAD as long as 2OL remains open.
Temperature Sensor Failure
This alarm can be caused by an extremely high and
unusual resistance value across 2ATT such as can be
measured at approximately 0°F. (-17.8°C.) and below,
a loose connection at junction J2, a broken wire in the
temperature sensor 2ATT circuit or a faulty sensor.
Remote Stop Failure
This alarm will be issued when the momentary remote
stop switch is held open longer than 1 second to stop
a unit but has not re-closed
by the time the next restart attempt is made.
The restart attempt must be a result of an operator
pressing the Intellisys Start button or the Remote Start
button.
This alarm is only active if the Remote Start/Stop
option prom is installed and the Remote Start/Stop
feature turned ON in the Option Selection set-point
routine.
Check Motor Rotation
After applying incoming power to an SE compressor,
this alarm will occur if the controller has not measured
positive sump pressure within 2 seconds after starting.
When positive pressure is not sensed, the controller
instantly obtains a negative pressure signal from 3APT
to determine if a vacuum is in the sump. If vacuum is
read, the controller assumes reverse rotation and
issues the alarm to stop the compressor and place CK
MTR ROTATION in the message display.
After the controller has once confirmed correct
rotation, this alarm will not be checked again until the
power supply has been removed from the unit.
Calibration Failure
An alarm activated when attempting to calibrate 3APT
with pressure still applied in excess of 10% of the
sensor rating.
The alarm serves to alert the operator of calibration
error which could overload the unit or cause the relief
valve to lift.
No Control Power
This alarm will be issued when the Intellisys controller
senses a loss of the 120 volt AC power supply to the
triac circuit that controls the starter coils and
solenoids.
A blown fuse (3FU), opening of the 120 volt contacts
of the Emergency Stop switch, opening of the High Air
Temperature switch (1ATS) or a loose/broken wire will
cause this alarm.
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Pressure Sensor Failure
When the Intellisys controller receives a value from
pressure sensor 3APT indicating the sensor has failed
and remained failed for at least 1 second initiates this
alarm.
Typically, a broken or loose wire is the reason. Check
for a good connection at the points where the cable
connects to the sensor and at J3.
Emergency Stop
This alarm results when the Emergency Stop button
has been pressed to open both the 120V AC contact
and the 5V DC contact.
To reset, the Emergency Stop button must be rotated
slightly in a clockwise direction to release the contacts.
Then, pressing the Set button twice will clear the
alarm from the controller.
Memory Fault
Options
The SELECT OPTIONS set point will break down into
the following menu:
AUTO S/S.............................ON/OFF
SEQUENCER.......................ON/OFF
REMOTE S/S........................ON/OFF
LOW AMBIENT.....................ON/OFF
The arrow keys can be used to change values.
Pressing SET for a second time will store the setting
and automatically, move down to the next set point.
The controller automatically returns the display to the
current status showing Package Discharge Pressure if
no other buttons are pressed within 30 seconds.
The remote start/stop feature will only function if it
has been enabled through the customer set point
routine.
If enabled the display will show START LOCAL/REM
in place of the normal display READY TO START.
Remote Start
The controller will only accept a momentary normally
open signal, connected across terminals 5 and 6
If the Start button is held in for longer then 7 seconds
the controller will abort the start and issue a REM
START FAIL alarm.
Remote Stop
The controller will only accept a normally closed
signal across terminals 3 and 4 which open to stop
the compressor. If the unit is stopped by the remote
stop signal the message REMOTE STOP will replace
the normal UNLOADED STOP message
The remote stop procedure follows the unloaded stop
format, if the remote stop signal is open when a
remote start signal is received, then the controller will
display REMOTE STOP FAILURE alarm.
Note
Maximum distance from compressor to remote
station 20 meters (65 feet). If distances greater than
20 meters (65 feet) are required, slave relays should
be incorporated to protect Intellisys low voltage
signals
!
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Auto Shutdown Power Conservation System
(PCS)
The auto shutdown incorporated as standard utilizes a
power conservation system which allows reduced off
load running prior to shut down (and hence reduced
power).
To achieve this it is possible to select and program,
via the Intellisys Controller, an auto shutdown of only 2
minutes. However, the compressor must first have
run for at least 8 minutes to satisfy a fixed built in
timer.
The drawing below indicates this.
If the compressor has already been running Loaded or
Unloaded 8 minutes or more, then the 2 minutes auto
shutdown will apply (if set).
Where additional options can be purchased which
require a hardware key to enable the function and
include the option in the operator set point menu:
PORO ..............................ON/OFF
PORO TIME.....................10 - 60 Seconds
The hardware key is installed to the Intellisys by the
J11 port on the side of the controller.
20
2
80
T adjustable 2
to 20 minutes
auto shutdown
Run time
from start
T fixed 8
minutes
Start Stop
T minimum
2 minutes
The arrow keys can be used to change values.
Pressing SET for a second time will store and
automatically move down to the next set point.
The controller automatically returns the display to the
current status showing Package Discharge Pressure if
no other buttons are pressed within 30 seconds.
Consult the compressors operational manual for
proper wiring of the PORO horn.
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Basic Rotary
SE Controls
Rotary Training Manual Page 14
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Calibration of the Pressure Transducer
The calibration procedure will only execute if the com-
pressor is not running with mains power applied.
When the unit is displaying “Ready To Start” press the
up/down arrows simultaneously twice, within three
seconds.
The line/sump solenoid will energies to monitor sump
pressure.
The display will flash the message CALIBRATING.
The sump pressure at this time should be zero be-
cause the machine is stopped and fully blown down.
The transducer milli-volt output voltage level is stored
into the controllers memory as a zero reference.
Only one pressure transducer 3APT is installed. To
check for 5Vdc supply technician will need to check
the Red and Black wires of transducer. To check the
transducers output voltage the White and Green wires
are to be checked.
3APT Pressure Transducer Input/Output
Information
Note
Calibration will be required if the controller or
transducer are replaced
!
Pressure PSI (BAR) Transducer Output
millivolts
0 (0) 0
10 (.7) 3.45
20 (1.4) 5.9
30 (2) 8.35
40 (2.8) 10.8
50 (3.5) 13.25
60 (4) 15.7
70 (4.8) 18.15
80 (5.5) 20.6
90 (6.2) 23.05
100 (6.8) 25.5
110 (7.6) 27.95
120 (8.3) 30.4
130 (9) 32.85
140 (9.7) 35.3
150 (10) 37.75
160 (11) 40.2
170 (11.7) 42.65
180 (12.4) 45.1
190 (13) 47.55
200 (13.8) 50
50mv
PRESSURE
13.8 bar
(200 PSI)
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Basic Rotary
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2 ATT Temperature Sensor
A thermally sensitive resistor called a Thermistor
installed to the airend discharge port continually
monitors the temperature of the air/oil at the discharge
of the airend.
These Thermistors are made from a mixture of
sintered metal oxides such as manganese, cobalt or
nickel sealed within a glass bead and then place in a
stainless steel housing.
A constant 5 volts DC is applied to the sensor and, as
an example, at 228°F (109°C), the voltage allowed
through the Thermistor will be reduced to
approximately 1.5 volts DC to ground. The resistance
decreases as the temperature increases. As the
temperature changes, either higher or lower, the
output voltage will change a corresponding amount.
This carrying DC voltage is processed by an
Analogue - Digital converter and forwarded to the
Intellisys controller.
Depending on the output voltage, the Intellisys makes
decisions that may only change a temperature
number on the panel display or could possibly shut
the compressor down if conditions dictate.
The Thermistor housing has SAE straight threads.
There is no adjustment capability and if replacement
is required, disconnect the wires from the sensors and
unscrew the sensor from the airend.
Controller Chart
Input/Output Terminals Voltage
Closed
Contact
Voltage
Open
Contact
OPEN 1&2
Rem Stop 3&4 4-5Vdc 0Vdc
Rem Start 5&6 4-5Vdc 0Vdc
1Sa / 2Ma 7&8 4-5Vdc 0Vdc
1Ma 9&10 4-5Vdc 0Vdc
E-Stop 11&12 4-5Vdc 0Vdc
FMS/OL 13&14 4-5Vdc 0Vdc
MM/OL 15&16 4.5Vdc 0Vdc
OPEN 17,18,&19
2ATT input 20&21 4-5Vdc 0Vdc
2ATT output 20&22 1.5-
5Vdc 0Vdc
3APT shld/grn 23 0Vdc 0Vdc
3APT input 24&25 4-5Vdc 0Vdc
3APT output 26&27 0-50mV 0Vdc
OPEN 28
Transformer 29&30 8Vac 0Vac
Transformer 29&31 8Vac 0Vac
Transformer 30&31 16Vac 0Vac
Transformer 29&36 120Vac 0Vac
Rem Contacts 32&33 N. O. N. O.
Rem Contacts 33&34 N.C. N. C.
10SV 35&37 120Vac 0Vac
6SV & 2SV 35&38 120Vac 0Vac
1SV&3SV 35&39 120Vac 0Vac
1S & 2Mb 35&40 120Vac 0Vac
2M, 1M, 1Sc,
1Sb, & 1Mb 35&42 120Vac 0Vac
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Rotary Training Manual Page 16
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UP Series SE Intellisys Controller
Although the UP series compressor has a SE
controller fitted on it as an option this controller
actually has a few added features that the normal
fixed speed, contact-cooled rotary compressor does
not have. This section of the manual will examine and
explain these different features.
Dual Pressure Set-points and Sequence Control
The UP series software allows the user to set two
different on-line and off-line pressures. The user can
then toggle between the two settings by pressing the
up and down arrows. This feature allows the user the
ability to simply sequence two machines by biasing
the two pressures.
This feature also allows for energy reduction, when
reduced system pressure can be accepted and having
set the ranges appropriately the user can toggle
between the two set pressure bands and operate at a
lower pressure when appropriate to save energy cost.
Units of Measure
The following units of measure are available for
selection;
xBAR AND DEGREES C
xPSI AND DEGREES C
xKPA AND DEGREES C
xPSI AND DEGREES F
xKG/CM² AND DEGREES C
UP Series Control Panel
Up series compressors that do not have the SE
controller option added to them will have a standard
control panel like the one described below.
Front Panel
The standard Small UP compressor front panel
consists of buttons and an hour indicator.
The red emergency stop (E-Stop) is used to stop the
compressor and fan immediately. It is used ONLY in
an emergency. The emergency stop must be
disengaged (rotate clockwise), and the green push
button switch pressed for the compressor to resume
producing air.
The green indicator light indicates the presence of
control voltage. It is lit when the green On Push Button
Switch has been depressed.
The “On” Push Button Switch is depressed to start the
unit. The compressor will run in a loaded condition if
there is demand for air. If there is no demand for air,
the compressor will stop automatically.
The Stopped / Auto Restart Indicator is illuminated
only when the machine has shut-down due to low air
demand. When demand for air returns, the machine
will restart and load automatically.
The hour meter indicator displays the hours the
machine has been running. An optional Maintenance
Indicator is available for the Small UP compressor.
Details about it’s function are found later in the
chapter.
The Pressure Gage, located behind the cover to the
right of the Control Panel, indicates system pressure.
The Dew Point Indicator, present only on units with the
TAS dryer option, indicates dew point status. Green
behind the crosshair indicates a good dew point. Red
indicates that the dew point is above 50°F / 10°C. Blue
indicates freezing temperatures.
Start Button Power On
Indicator
Auto
Restart
Indicator
Hour Meter
Indicator Stop Button
Pressure Gauge
TAS Option Dew
Point Indicator
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Basic Rotary
Short Test
Rotary Training Manual Page 17
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Short Test
Answer each question as fully as you can, or tick the best option.
When you finish, check your answers by reading through the section again.
1When the warning "Change Separator Element" appears in the message display,
the compressor will
a) Shut down when the separator element differential exceeds 15 psi
b) Continue to run, but the red Alarm LED flashes on and off while the message "Change Separator
Element" alternates with the normal display message.
c) Automatically adjust the inlet valve to maintain less than 12 psi separator element differential
2The blowdown solenoid valve (3SV) is normally open and closes when energised.
a) False
b) True
3How do you access the Factory Set Point on an SE Controller?
4How does the SE Controller calculate the Separator Delta P?
5If the compressor shuts down on High Airend Temperature, what is the maximum
allowable airend temperature before the Intellisys lets you restart the unit?
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