Ingersoll-Rand NHP1500WCU User manual

Utility Equipment
P.O. Box 868 -- 501 Sanford Ave
Mocksville, N.C. 27028
SERVICE MANUAL FOR
ELECTRICAL/ELECTRONIC
www.portablepower.irco.com Book No. 22103592 (7/05)
NHP1500WCU (10/425)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Revised (10-12)

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Book No. 22103592 (7/05) NHP1500 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 OSX15 Engine....

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
SECTION 1
MANUAL DESCRIPTION
This manual contains all of the information concerning the electrical and electronic systems for
the NHP1500 compressor. It provides all information necessary to service, 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. 22103592 (7/05) NHP1500 Electrical Manual
SECTION 2
GENERAL INFORMATION
and
OPERATIONAL THEORY

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
GENERAL INFORMATION AND OPERATIONAL
THEORY
General
The NHP1500 machine has and electronic monitor
and control system to provide discharge air pressure
control and engine and package monitor functions.
The system uses the INTELLISYS controller to
perform these functions. The electrical system
connects all the necessary switches, sensors and
transducerstotheINTELLISYScontrollerinorderforit
to perform the monitor and control functions.
INTELLISYS Controller
The INTELLISYS controller is the heart of the
NHP1500 machine monitor and control system. It
provides data collection, alarming and control
functions for compressor operations. It is an Intel
microcontroller based unit with analog and digital
inputs and outputs.
The first function of the INTELLISYS controller is to
scan all analog and digital inputs at a given time
interval. The analog and digital inputs are scanned
every 100 milliseconds. The analog values are then
comparedagainstminimumandmaximumvaluesand
anALERTorSHUTDOWNisissued,ifavalueisoutof
range. The various ALERTS and SHUTDOWNS are
listed in Section 10 of this manual.
ThesecondfunctionoftheINTELLISYScontrolleristo
control air discharge pressure based on machine
demand. The INTELLISYS controller monitors
machine discharge air pressure, PT4, and varies the
enginespeedtomaintainthedischargeairpressureat
the desired setpoint.
The third function of the INTELLISYS controller is to
communicate with the diesel engine via the J1939
CAN network. The INTELLISYS controller can read
various engine parameters and diagnostic
information. The INTELLISYS controller provides the
engine throttle setting via the J1939 CAN on software
versions 2.0 and greater.
Softwareversionsunder2.0usethefrequencythrottle
to communicate with the engine. A square wave
frequency signal from 150 Hz to 375 Hz is sent from
the INTELLISYS controller to the engine controller.
Thesignalisalinearsignalfrom150Hzatengineidle
(1200 RPM) to 375 Hz at maximum run speed (1800
RPM).
Figure 2--1 on page 5 shows the signal connections
from the INTELLISYS controller and the engine
controller.
Sensors and Transducers
The electronics system contains sensors and
transducers that are used to collect data from the
compressor. There are two types of temperature
sensors, RTD’s and thermistors. Both of these
devices exhibit a change in resistance as the
temperaturechanges. Theresistancecausesaninput
voltage change to the INTELLISYS controller input
and is interpreted as a temperature change. These
temperature probes look similar, but have different
connectors. They are not interchangeable.
The electronics system also uses pressure
transducers to measure compressor pressure
changes. 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 15, 100 or
225psi. The0 --15psiisa vacuumtransducer andthe
100 and 225 are gauge pressure devices. These
transducers are provided with 5 VDC excitation to
power the device. There are three wire devices:
excitation, signal and ground.
Digital Inputs and Outputs
The INTELLISYS controller scans digital inputs such
asswitchcontacts. Theseareeither“ON”(24VDC)or
“OFF” (0 VDC). They are devices such as the
emergency stop button and Auto Start contact.

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
FIGURE 2--1
NHP--1500 PIONEER HARNESS SYSTEM SCHEMATIC
Controller
CONTROL PANEL SWITCHES
ENGINE ECM DIAGNOSTIC
HOURMETER
ALARM LIGHT
ESTOP SWITCHES
RELAY/FUSE BOX
SOLENOID VALVES
SPEED SENSOR
LEVEL SWITCH
PRESSURE TRANSDUCERS
TEMPERATURE SENSORS
ALARM LIGHT
RELAY/FUSE BOX
24V HEATERS
ESTOP SWITCHES
BATTERY
STARTING AND CHARGING
SYSTEM
FUEL PUMP
W2
P18
W4
P20
W3
P17
W1
J1 J2
J3
INTERFACE
INTELLISYS
P1
P2
P3

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
FIGURE 2--2
INTELLISYS CONTROLLER TO ENGINE INTERFACE
CUMMINS ENGINE
J1--40 J1--30 J1--17 J2--18
J4--46 J4--37 J4--36 J5--22 J5--16
CAN HI
CAN LO
CANSHLD
J2--37 J2--38
FREQ -- THT
RANGE = 150 Hz (1200 RPM) to 375 Hz (1800 RPM) AT 24VDC
FREQ -- THT --
INTELLISYS
CONTROLLER
CONTROLLER
CUMMINS
ENGINE
J2--38 J1--24
KEY SWITCH

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
FIGURE 2--3
J1939 CAN COMMUNICATIONS SCHEMATIC
ENGINE
P22
RESISTOR TERMINATOR RESISTOR TERMINATOR
P19
ENGINE DIAGNOSTICS JACK
P21
INTELLISYS
CONTROLLER
CONTROLLER

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
Controller Outputs
TheINTELLISYScontrollerhasthreetypesofoutputs:
frequency,pulsewidthmodulated(PWM)and24VDC
digital (ON /OFF). The frequency output is used as a
throttle signal for the engine. The INTELLISYS
controllervariesthefrequencyfrom150 Hzto375Hz,
corresponding to 1200 to 1800 RPM. The frequency
signal is a 50% duty cycle, 24 VDC, square wave.
The PWM signal is used to control the speed of the
aftercooler fan. It is a 125 Hz frequency signal, 24
VDC with a duty cycle of 5 % to 90%.
The INTELLISYS controller provides 24 VDC digital
outputsto controlsolenoids,alarm horn,strobe lights,
DC heaters and the fuel pump. These are 24 VDC
“ON” and 0 VDC “OFF”. They are current limited and
short circuit protected.
Theymayhaveavoltagelevelof.5VDCto1.4VDCin
the OFF state due to transistor leakage of the
darlington drivers in the circuit.
Pressure Control Loop
The INTELLISYS controller controls discharge
pressurebymodulatingenginespeed. Thedischarge
pressure setpoint is entered at the INTELLISYS
controller front panel. The control loop will modulate
the engine speed between 1200 RPM and 1800 RPM
to maintain the selected discharge pressure. The
INTELLISYS controller is actually providing a throttle
signaltotheenginecontrollerwhichinturncontrolsthe
engine speed.
Electronic Engine
The NHP1500 machine contains an emissions
certifieddieselengine. Inorderto meettheemissions
requirements, the engine has an electronic control
system.
The control system handles all monitor, alarm and
control functions for the engine. The INTELLISYS
controller communicates with the engine controller
over the J1939 CAN network.
The INTELLISYS controller receives diagnostic and
run time data from the engine over the J1939 CAN
network. Afrequencythrottleinterfacewiththeengine
is used. Figure 2--2 shows the connections between
the INTELLISYS controller and the engine controller.
J1939 Data Link
The CAN network is a single pair shielded cable
located with or attached to the W1 main harness.
Figure 2--3 shows a layout of the CAN harness or
“backbone” as it is referred to. The termination
resistors (Terminator) are important to prevent
reflections on the transmission line and must be in
place for the network to function properly. The shield
from the cable is connected to the machine metal at
theINTELLISYScontrollerend. Thisconnectionmust
be properly made with good metal--to--metal contact
between the wire terminal and the machine metal.
Theenginediagnosticsconnectorislocatedinsidethe
control panel. This is used to connect the engine
manufacturer’sservicetoolstotheCANnetwork. This
connector also provides 24 VDC to power these
service tools. If computer based service tools are not
available, the lamp and switch panel, or engine status
menuor IRElectronicServiceManual,canbe usedto
extractenginecodes. Referto engineservicemanual
for details of their use.
Electrical System
Theelectricalsystemconsistsofthewiringharnesses
and associated electrical devices such as relays,
switches, lights, solenoids and alarm horn. There are
fourwiringharnessesintheNHP1500machine. They
are as follows:
22079180 W1 Chassis Main Harness
54597497 W2 Control Panel Harness
54633003 W3 Fuse Box Harness
The schematic diagrams show the connections for
these harnesses. Figure 2--1 is a system schematic
showing harness connection with devices and
controllers. Section 8 includes information on
connectors used in the harnesses.

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
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.
Aftercooler Fan Control Loop
The NHP1500 machine has a variable speed
aftercoolerfan. Thiscontrolloopvariesthespeed ofa
hydraulically driven fan, using a pulse width
modulated (PWM) signal. The signal has a base
frequency of 125 Hz and a duty cycle of 10% to 75%.
The fan speed range is from 300 to 1640 RPM.

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
KEY ELECTRICAL COMPONENTS FUNCTION
PT1: PT1 is a 0--30 psi vacuum pressure transducer that measures airend
inlet vacuum.
PT2: PT2 is a 0--100 psi gauge pressure transducer that measures airend
Interstage pressure.
PT3: PT3 is a 0--225 psi gauge pressure transducer that measures airend
stage 2 discharge pressure.
PT4: PT4 is a 0--225 psi gauge pressure transducer that measures package
discharge pressure.
PT5: PT5 is a 0--100 psi gauge pressure transducer that measures airend
oil filter inlet pressure.
PT6: PT6 is a 0--100 psi gauge pressure transducer that measures airend
oil filter outlet pressure.
PT7: PT7 is a 0--225 psi gauge pressure transducer that measures
pressure from a remote air header or other plant air connection.
U2: U1 is a capacitive level probe that measures the hydraulic tank oil
level. It is used to indicate a low oil level only. It does not provide
a continuous level reading.
U1: U1 is resistive level detector that measures the fuel level in the fuel tank.
It provides a continuous reading of fuel level.
RT1: RT1 is a 100 ohm RTD temperature sensor that measures stage 1 discharge temperature.
Its range is --12 to 580_F.
RT2: RT2 is a 100 ohm RTD temperature sensor that measures stage 2
Inlet temperature. Its range is --12 to 580_F.
RT3: RT3 is a 100 ohm RTD temperature sensor that measures stage 2
outlet temperature. Its range is --12 to 580_F.

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
RT4: RT4 is a 100 ohm RTD temperature sensor that measures package discharge air temperature.
Its range is --12 to 580_F.
RT5: RT5 is a 10K ohm thermistor temperature sensor that measures compressor oil supply temperature.
Its range is --30 to 255_F.
RT6: RT6 is a 10K ohm thermistor temperature sensor that measures stage 1 inlet temperature.
Its range is --30 to 255_F.
RT7: RT7 is a 100 ohm RTD temperature sensor that measures engine coolant temperature.
Its range is --12 to 580_F.
RT8: RT8 is a 100 ohm RTD temperature sensor that measures aftercooler temperature.
Its range is --12 to 580_F.
K1: K1 is a SPST, 24VDC relay used to activate the engine starter.
K2: K2 is a SPDT, 24VDC relay used to activate the fuel pump.
K3: K3 is a SPDT, 24VDC relay used to activate the DC heaters
K4: K4 is a SPDT, 24VDC relay used to activate one of the fuel heaters.
K5: K5 is a SPDT, 24VDC relay used to activate one of the fuel heaters.

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
OPERATIONAL INFORMATION
Power “ON” (S1) at Control Panel:
Key switch signal (24VDC) supplied to engine controller
by Intellisys controller
Frequency throttle signal OFF
Fuel Pump OFF
DC Heaters “ON” if RT6 Temp < 45 degrees F.
“START” button on Intellisys Controller pressed:
Key switch signal at 24VDC
Fuel Pump ON
Frequency throttle signal ON
Alarm horn ON just before engine started activated (10 sec)
Alarm strobe ON
Engine starter engaged for 10 sec crank cycle (Intellisys will perform
3 engine crank cycles and if engine is not started, a shutdown
for too many start attempts will be issued)
Engine at idle, machine unloaded:
Key switch signal at 24VDC
Frequency throttle signal on
Machine loaded, engine at 1800 rpm:
Key switch signal at 24VDC
Frequency throttle signal on
Inlet solenoid, L1, at 24VDC (opened)

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
TYPICAL OPERATING PARAMETER VALUES
*** Values taken at : ambient temp = 77_F
Parameter Loaded Unloaded Units
Hydraulic Press 2250 1150 -- 1250 psi
Hydraulic Temp Amb+30 Amb+15 _F
RT4, Package Discharge Temp Amb+25 N/A _F
PT4, Package Discharge Press 150 0 -- 2 psi
RT6, Stage 1 Inlet Temp Amb+10 Amb+10 _F
RT1, Stage 1 Discharge Temp 350 -- 370 180 _F
PT1, Stage 1 Vacuum Press 0.3 -- 0.6 10.8 -- 11.3 psi
PT2, Stage 2 Inlet Press 28 -- 32 0 psi
RT2, Stage 2 Inlet Temp Amb+25 Amb+10 _F
RT3, Stage 2 Discharge Temp 360 -- 380 173 _
PT3, Stage 2 Discharge Press 152 0 -- 4 psi
PT6, Comp Oil Press 42 -- 44 27 -- 30 psi
RT5, Comp Oil Injection Temp 136 132 _F
RT7, Engine Coolant Temp 179 171 _F
Engine Speed 1818 -- 1830 1198 -- 1204 rpm
Aftercooler Fan speed @1200 1050 -- 1150 rpm
Aftercooler Fan speed @1800 1630 -- 1644 rpm

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
SECTION 3
SERVICE TOOLS

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Book No. 22103592 (7/05) NHP1500 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 onnectors

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Book No. 22103592 (7/05) NHP1500 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

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
22221303 Service Tool Kit
Kit consists of the following P/N’s: 22216691 22216667
22216675 22216683 54729660 54749643 54699657
22146393 22147540 22073878 54749635 22168868
22216709 22216725 22216733 54740675
22254775 ATC Fuse Assorlment Kit
Kit contains 5, 7--1/2, 10, 15,20,25, and 30 Amp fuses
22254734 Packard Crimp Tool (12014254) Crimps Sealed
Weather Pack Connector pins

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
Tool No. Tool Description Tool Illustration
22216691 Digital Multimeter
54729660 Weather--Pack Terminal Removal Tool
54699632 Deutsch Terminal Removal Tool (Blue)
54699640 Deutsch Terminal Removal Tool (Red)
54699624 Deutsch Terminal Removal Tool (Yellow)
22216667 Deutsch Crimp Tool

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Book No. 22103592 (7/05) NHP1500 Electrical Manual
54729710 Electrical Contact Cleaner
54729728 Virtual Technician Service Tool Kit
54699616 Deutsch Terminal Removal Tool
54749544 RTD Simulator Plug
22073878 Thermistor Plug
54749635 Connector Repair kit
54699657 Deutsch Terminal Removal Tool