IRI APDD 635B - 80440985 - may 2003

INTELLISYS REMOTE INTERFACEOPERATORS/ INSTRUCTION MANUAL PARTS LIST

Before installation or starting the compressor for the first time, this manual should be studied carefully to obtain a clear knowledge of the unit and of the duties to be performed while operating and maintaining the unit. RETAIN THIS MANUAL WITH UNIT. This Technical manual contains IMPORTANT SAFETY DATA and should be kept with the Intellisys Remote Interface at all times.

More Than Air. Answers.Online answers: http://www.air.irco.com Phone: 1-800-526-3615 CCN: APDD 635B 80440985 REV.BMay 2003

AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UPWarranty The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve months (see extended airend warranty) from the date of placing the Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from Davidson, NC, whichever shall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed maintained and operated such Equipment in accordance with good industry practices and has complied with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser or others without Companys prior written approval. The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are limited to those specifically stated within the Companys proposal. Unless responsibility for meeting such performance warranties are limited to specified tests, the Companys obligation shall be to correct in the manner and for the period of time provided above. THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED. Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment. The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in writing of its intention to do so. Any such Equipment will be at Purchasers sole risk and liability. Note that this is Ingersoll-Rands standard warranty. Any warranty in force at the time of purchase of the compressor or negotiated as part of the purchase order may take precendence over this warranty.

COPYRIGHT 1998 INGERSOLL-RAND COMPANY

This unit was purchased from: _______________________________________________ _______________________________________________ _______________________________________________ Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. Number of units on order: __________________________ Customer Order Number: __________________________ Ingersoll-Rand Company Order Number: ______________ For ready reference, record the serial number and model number of your unit here: Serial Number: ___________________________________ Model Number:___________________________________

2.72" (69mm)

6.69" (170mm)5.12" (130mm)

1

TABLE OF CONTENTS0.0 SAFETY AND WARNINGS 1.0 INTRODUCTION . . . . . . . . . . . . . . . .3 6.0 IRI SET POINT MAP . . . . . . . . . . . . . . . . . . . .76

. . . . . . . . . . . . . . . . . . . . . . . .3

7.0 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . .77 GENERAL INFORMATION Operating Temperature . . . . . . . . . . . . . . . .0 to 50C Operating Humidity . . . . .0 to 95% (non-condensing) Power . . . . .9-18 Volt DC, 500mA maximum @ 9VDC Communication: Network Port - 2400, 4800, 9600, or 19200 Baud using Modbus Protocol Service Port - 2400, 4800, 9600, or 19200 Baud using Modbus Protocol and address F0 Ingersoll-Rand Port - Proprietary Information Dimensions: . . . . . . . . . . . . . . . . . .2.72" (69mm) High x 5.12" (130mm) Wide x 6.69" (170mm) Deep

2.0 RECEIPT OF EQUIPMENT . . . . . . . . . . . . . . . .4 3.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .4 3.1 Intellisys Remote Interface Mounting . . . .4 3.2 IRI To Intellisys Controller Wiring . . . . . . .6 3.3 IRI To Network Wiring . . . . . . . . . . . . . . . . .7 3.4 Terminating Resistors . . . . . . . . . . . . . . . . .8 3.5 Power Supply Connections . . . . . . . . . . . .9 3.5.1 Wall Adaptor Connections . . . . . . . . .9 3.5.2 Chassis Mount Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . .10 3.6 Power On Confirmation . . . . . . . . . . . . . .11 4.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .11 4.1 Operator Panel Layout . . . . . . . . . . . . . . .11 4.1.1 Pushbutton . . . . . . . . . . . . . . . . . . . . .12 4.1.2 "POWER" LED . . . . . . . . . . . . . . . . . .12 4.1.3 "NETWORK PORT" LED (1) . . . . . . .12 4.1.4 "INGERSOLL-RAND PORT" LED (2) 12 4.1.5 "SERVICE PORT" LED (3) . . . . . . . . .12 4.1.6 Two Character Display . . . . . . . . . . .12 4.1.7 Setting Up The IRI . . . . . . . . . . . . . . .12 4.1.8 Address [Ad] . . . . . . . . . . . . . . . . . . . .12 4.1.9 Baud Rate [b1] . . . . . . . . . . . . . . . . . .12 4.1.10 Baud Rate [b3] . . . . . . . . . . . . . . . . .12 4.1.11 Communications Mode [CO] . . . . . .12 4.1.12 Call Up [Cu] . . . . . . . . . . . . . . . . . . . .13 4.1.13 Display Check [dc] . . . . . . . . . . . . . .13 4.2 IRI Communications . . . . . . . . . . . . . . . . .13 4.2.1 Modbus Read Command . . . . . . . . . .13 4.2.2 Modbus Write Command . . . . . . . . . .14 4.3 Register Listing . . . . . . . . . . . . . . . . . . . . .15 4.3.1 SSR Controller . . . . . . . . . . . . . . . . . .15 4.3.2 SSR SG Controller . . . . . . . . . . . . . . .18 4.3.3 SE 15-100 HP Controller . . . . . . . . . . .24 4.3.4 SIERRA 50-100 HP Controller . . . . . .27 4.3.5 SIERRA 100-200 HP Controller . . . . .30 4.3.6 SIERRA 125-400 HP SG Controller . .33 4.3.7 SIERRA SS Booster 125-200 HP SG Controller . . . . . . . . . . . . . . . . . . . . . . . . . . .37 4.3.8 RECIP Controller . . . . . . . . . . . . . . . . .41 4.3.9 RECIP SG Controller . . . . . . . . . . . . . .46 4.3.10 RECIP Booster controller . . . . . . . . .50 4.3.11 NIRVANA SGN Controller . . . . . . . . .55 4.3.12 NIRVANA SGNe Controller . . . . . . . .61 4.3.13 Pegasus SE Controller . . . . . . . . . . .67 4.3.14 ESA SE 22-150 KW Controller . . . . .70 5.0 IRI TROUBLE SHOOTING CHART . . . . . . . . .74 2

0.0 SAFETY AND WARNINGSBefore you install the Intellisys Remote Interface (IRI) you should take the time to carefully read all the instructions contained in this manual, and the compressor manual. Electricity and compressed air have the potential to cause severe personal injury or property damage. The operator should use common sense and good working practices while operating and maintaining this unit. All applicable codes should be strictly adhered to. Maintenance should be done by qualified personnel, adequately equipped with proper tools.

Communication

Port 1

RS-485

IRIPort 3

Port 2

NETWORK

INTELLISYS CONTROLLER

RS-232

Communication

SERVICE

FIGURE 1-2 IRI COMMUNICATION LINKS and receive data with a Network. The second port provides communication with an Intellisys controller. The third port provides RS-232 communication for Service personnel. The IRI receives commands from the Network port (Port 1) and passes the commands to the Intellisys controller through the Ingersoll-Rand port (Port 2). In return, the Intellisys controller responds back to the Network port by sending the response to the IRI (via Port 2), which in turn, relays the response back to the Network (via port 1). In addition to communication taking place between the Network port and the Intellisys controller, communication is allowed to take place between the Service port and the Intellisys controller. Communication between the Service port and the Intellisys controller is transparent to the operation of the communication taking place between the Network port and the Intellisys controller. The IRI receives commands from the Service port (Port 3) and passes them to the Intellisys controller through the Ingersoll-Rand port (Port 2). In return, the Intellisys controller responds back to the Service port by sending the response to the IRI (via Port 2), which in turn, relays the response back to Service (via port 3) The Network port is the main communication port for Intellisys control. The Network port allows both read and write operations to the registers of the Intellisys controller, allowing control functions to be performed via the Network port. The Service port provides only the ability to read registers from the Intellisys controller. There is no ability to control the Intellisys controller through the Service port. Write commands sent through the Service port to registers are ignored by the IRI. The Service port is provided to allow only reading of registers, transparent to the Network port operations.

1.0 INTRODUCTIONThe Intellisys Remote Interface (IRI) is a device to allow electronic communication with an Intellisys controller through a serial communication link (See FIGURE 1-1).

2.72" (69mm)

6.69" (170mm)5.12" (130mm)

FIGURE 1-1 INTELLISYS REMOTE INTERFACE The IRI allows 2 different paths of communication. First, the IRI allows communication between a Network port and an Intellisys controller port . Second, the IRI allows communication between a Service port and an Intellisys controller port (See FIGURE 1-2) The IRI has three communication ports. The first port is an RS-485 serial communication link to transmit

3

Two Character Display Service Port LED Intellisys Controller Port LED Network Port LED

Power LED

Each Intellisys controller must have its controller software revision at or above a certain minimum level to work with the IRI. The machine types and required software EPROM minimum version levels are listed below. Check the machine to be connected to an IRI for the appropriate EPROM. If the EPROM is not of the correct minimum version level, the appropriate EPROM may be ordered from your local IngersollRand Distributor or Air Center.Machine Type EPROM Minimum Version Level SSR 50-450 Horsepower - 1 stage (Red Eye) . . . . . . . . . . . . . .2.3 SSR 50-450 Horsepower - 2 stage (Red Eye) . . . . . . . . . . . . . .2.3 SSR SG Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 15-50 Horsepower SE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Sierra 50-100 Horsepower (SE) . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Sierra 100-200 Horsepower (Red Eye) . . . . . . . . . . . . . . . . . . .2.5 Sierra 125-400 HP SG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 Recip (Red Eye) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 Recip SG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 Nirvana SGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 Nirvana SGNe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.0 Pegasus SE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 ESA SE 22-150 KW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

FIGURE 1-3 FRONT PANEL OF IRI FIGURE 1-3 shows the front view of the IRI. Indicators consisting of 4 LEDs and a two character display provide status on the operating conditions of the IRI. An amber LED luminates to show that input power is applied. Three dual color (red/green) LED's provide information on the operating status of each of the three serial communication ports. A two character display provides various information depending upon the current mode of the IRI.

9-18 VDC

Switch Input Power Input Service Port Intellisys Controller Port Network Port

When monitoring compressor data only, no options are required to be installed in the Intellisys controller. If machine control is desired, the Remote Start/Stop and Sequence options must be installed and turned "On". Perform the following tasks to install the IRI. Each task is described in steps that can be checked off to help insure trouble-free installation. IRI Mounting IRI to Intellisys Controller Wiring IRI to Network Wiring Terminating Resistors Power Supply Connection Power On Confirmation 3.1 INTELLISYS REMOTE INTERFACE MOUNTING The IRI can be installed on any suitable surface in the general vicinity of the Intellisys controller and the Network computer. NOTE the MAXIMUM lengths that the cables can be for proper operation is shown in FIGURE 3-1.4000 Ft. Max. (1219m)Port 1

FIGURE 1-4 REAR VIEW OF IRI FIGURE 1-4 shows the rear view of the IRI. The rear has a power input port - PWR, the Network communication port - COM1, the Intellisys Controller communication port - COM2, the Service communication port - COM3, and a switch input - SW1.

2.0 RECEIPT OF EQUIPMENTWhen you receive the Intellisys Remote Interface (IRI) please inspect it closely. Any indication of careless handling by the carrier should be noted on the delivery receipt especially if the IRI will not be immediately unboxed. Obtaining the delivery person's signed agreement to any noted damages will facilitate any future insurance claims.

1000 Ft. Max. (305m)

IRIPort 3

Port 2

3.0 INSTALLATIONBefore beginning Intellisys Remote Interface installation and system operation, the following requirements and recommendations must be satisfied: 4

NETWORK50 Ft. Max.

INTELLISYS CONTROLLER(15.2m)

SERVICE

FIGURE 3-1 IRI MAXIMUM CABLE LENGTHS

A location should be selected that provides access for connection of the IRI's external power supply. Additional consideration should be given for accessibility of the Service port and wire routing for the Network port and Ingersoll-Rand port. A NEMA 4 type enclosure

should be provided for the IRI if mounting in harsh environments. Use FIGURE 3-2 to locate the four mounting holes for the IRI.

CUT HERE AND REMOVE FROM MANUAL

FIGURE 3-2 IRI DRILL TEMPLETE 5

3.2 IRI TO INTELLISYS CONTROLLER WIRINGGE STR IPE

WHIT

EW

IR

RAN EO

N ORA

E WIR GE

WHIT

RIPE E ST

The IRI is connected to the Intellisys controller using 22 gauge, 4 conductor twisted pair (only 1 pair of conductors is utilized) telephone type wire (P/N 39204508 Cable, Communication 1000 Feet). This wire should be routed in grounded electrical conduit. This wire should be the only wire in the conduit(s), e.g. do not mix this wire with other high voltage conductor in the conduit. This wire should not be any longer than 1000 feet. Install one modular plug (P/N 39204466 Plug, Modular) on each end of the wire using a hand crimping tool (P/N 39204458 Tool, Hand Crimping). Refer to FIGURE 3-3 and FIGURE 3-4 for instructions on the tool and for proper wire color codes and pin numbers. Be careful to match color codes and pin numbers.

FIGURE 3-3 MODULAR PLUG CONNECTIONS FOR INTELLISYS CONTROLLER WIRING

6 5 4 3 2 1RE N AB O SE T LEA BOT TOM

FIGURE 3-4 INSTALLING MODULAR PLUG CONNECTOR

For IRI connections to an SGN or Nirvana controller, the P7 port will be used. P7 is a 6 position, pluggable screw terminal connection like other sensor inputs on the SG and SGN controllers. A 6 position plug, IR Part Number 39186093, or a 2 position plug, IR Part Number 39242367, is required to make connections to this port. P7 pin 1 should be connected to the modular phone plug terminal #2 using the orange wire white stripe. P7 pin 2 should be connected to the modular phone plug terminal #4 using the white wire orange stripe.

6

3.3 IRI TO NETWORK WIRING The connection of the IRI to the Network is dependent upon the particular Network being used at the installation site. The following instructions are suggested for connecting the IRI to the Network. Adaptations may be needed to match the IRI's Network port to the installation site's Network. The IRI's Network port is an RS-485 interface that can be used in a full-duplex or half-duplex mode. The Network port pinout on the IRI is configured as shown in FIGURE 3-6. The Network connector on the IRI is a 6 conductor RJ-11 style connector. The IRI Network port can be connected to the installation site's Network port using 22 gauge, 4 conductor twisted pair telephone type wire (only 1 pair of conductors is needed for half-duplex mode; P/N 39204508 Cable, Communication 1000 Feet). This wire should be routed in grounded electrical conduit. This wire should be the only wire in the conduit(s), e.g. do not mix this wire with other high voltage conductor in the conduit. The length of this wire should not exceed 4000 feet. For both full-duplex and half-duplex operation, Pin 2 A(+) Full-Duplex Receiver / Half-Duplex Transceiver and Pin 4 B(-) Full-Duplex Receiver / Half-Duplex Transceiver should be a twisted pair, e.g. Pin 2 Orange wire with white stripe paired with Pin 4 white wire with orange stripe. Optionally, for full-duplex operation, Pin 3 A(+) Full-Duplex Transmitter and Pin 5 B(-) Full-Duplex Transmitter should be a twisted pair, e.g. Pin 3 Blue wire with white stripe paired with Pin 5 white wire with blue stipe. Following this wiring scheme, the connections would appear as shown in FIGURE 3-5.

123456

COM1BACK VIEW OF IRI NETWORK PORT PIN 1: . . . .IRI Ground (Normally No Connection) PIN 2: . . . .Orange Wire White Stripe A(+) Full-Duplex Receiver/ A(+) Half-Duplex Transceiver PIN 3: . . . .Blue Wire White Stripe A(+) Full-Duplex Transmitter PIN 4: . . . .White Wire Orange Stripe B(-) Full-Duplex Receiver/ B(-) Half-Duplex Transceiver PIN 5: . . . .White Wire Blue Stripe B(-) Full-Duplex Transmitter PIN 6: . . . .RESERVED - No Connection FIGURE 3-6 PINOUT OF IRI RS-485 NET-WORK PORT Install a modular plug (P/N 39204466 Plug, Modular) using a hand crimping tool (P/N 39204458 Tool, Hand Crimping) on the IRI end of the wire as described in the FIGURE 3-4 and using FIGURE 3-5 for the wiring guideline. Be careful to match color codes and pin numbers as shown in FIGURE 3-5. Refer to the installation site's Network manuals for proper mating and connections to the site's network port.

RIPE IPE E ST BLU STR IRE NGE RIPE W ORA ST ITE IPE WH IRE HITE STR EW W HITE WHIT WIRE EW E WIR BLU NGE ORA6

NOTE: NO CONNECTION TO PIN 1 OR PIN 6.3

FIGURE 3-5 MODULAR PLUG CONNECTIONS FOR NETWORK WIRING

5 4 2 1

RE

N AB O SE T LEA

BOT

TOM

WHITE WIRE BLUE STRIPE WHITE WIRE ORANGE

7

As an example, FIGURE 3-7 shows-the configuration of three IRIs connected to a single Network set to operate in full-duplex mode.Pin 2

A(+)J6 R1 485

485

A(+) B(-) A(+)

Pin 2 Pin 4

A(+) B(-) 485 A(+) B(-) INTELLISYS CONTROLLER485

Pin 4

B(-)

Pin 3 Pin 5

485

T*

B(-) NETWORK COMPUTERPin 2 Pin 4

INTELLISYS CONTROLLERPin 3

IRI

A(+)J7 R7 485

A(+) B(-) 485 A(+) B(-) INTELLISYS CONTROLLER485

Pin 5

B(-)

Pin 3 Pin 5

IRI

IRI

FULL-DUPLEXPin 2 Pin 4

A(+)T* 485

B(-)Pin 3 Pin 5

A(+) B(-)

INTELLISYS CONTROLLER485

FIGURE 3-9 FULL-DUPLEX TERMINATING RESISTOR ORIENTATION 3.4 TERMINATING RESISTORS The IRI is delivered with termination resistors already installed. Under normal circumstances these termination resistors will work properly as shipped, however, if your configuration demands extra attention, the termination(s) can be removed, as needed, by removing jumper(s) on the IRI circuit board. Jumper J6 provides a 1K Ohm resistor (R1) across A(+) and B(-) of pins 2 and 4 of the IRI's Network port. Jumper V provides a 1K Ohm resistor (R7) across A(+) and B(-) of pins 3 and 5 of the IRI's Network port The orientation of terminating resistors for a full-duplex configuration is shown in FIGURE 3-9. A terminating resistor should be in place on the receiver of the last IRI on the bus. A terminating resistor resides on the receiver of the Network port side as well (refer to FIGURE 3-7). Access may be gained to the termination jumpers by removing the four screws of the rear enclosure plate of the IRI, exposing the IRI circuit board. To remove the terminating resistor from the A(+) and B(-) lines, remove the appropriate jumper(s). FIGURE 3-10 on the next page shows the location of the terminating jumpers.

IRI T*-Terminating Resistor

FIGURE 3-7 MULTIPLE IRI's CONFIGURED FOR FULL-DUPLEX MODE As an example of half-duplex configuration, FIGURE 3-8 shows the configuration of three IRIs connected to a single Network set to operate in haif-duplex mode.

FIGURE 3-8 MULTIPLE IRI's CONFIGURED FOR HALF-DUPLEX MODEA(+)T 485 T* Pin 2 Pin 4

A(+) B(-)

B(-)

T 485

INTELLISYS CONTROLLER

NETWORK COMPUTERPin 2 Pin 4

IRI

A(+) B(-)

T 485

INTELLISYS CONTROLLER

IRI

Pin 2 Pin 4

A(+)T*

B(-)

T 485

INTELLISYS CONTROLLER

IRI T*-Terminating Resistor

8

FIGURE 3-10 LOCATION OF TERMINATING RESISTOR JUMPERS Proper termination for a half-duplex configuration is shown in FIGURE 3-11 with a terminating resistor in place at the transceiver of the last IRI on the bus. A termination resistor resides on the tranceiver of the Network port as well (refer to FIGURE 3-8). 3.5.1 WALL ADAPTOR CONNECTIONS Insert the female plug, FIGURE 3-12, of the wall adaptor power supply into the back jack of the IRI labeled "918VDC". Next, connect the wall adaptor power supply to the appropriate wall connector.

3.5 POWER SUPPLY CONNECTIONS Connect the power supply according to the appropriate instructions for the type power supply supplied with the IRI.

Pin 2

A(+)J6 485

INTELLISYS CONTROLLERR1

Pin 4

B(-)

IRI

HALF-DUPLEX

FIGURE 3-11 HALF-DUPLEX TERMINATING RESISTOR ORIENTATION

FIGURE 3-12 EXTERNAL POWER SUPPLY FEMALE PLUG

9

3.5.2 CHASSIS MOUNT POWER SUPPLY CONNECTIONS FIGURE 3-13 may be used to locate 2 mounting holes for the chassis mount power supply

2 x 0.13 (3.3mm) DIA.

FIGURE 3-13 CHASSIS MOUNT POWER SUPPLY MOUNTING HOLES TEMPLATE

10

FIGURE 3-14 CHASSIS MOUNT POWER SUPPLY CONNECTIONS

With power disconnected from the power source, attach the stripped ends of the female plug cable to the chassis mount power supply. Attach the wire connected to the outside of the female plug to "-V" on the chassis mount power supply. Attach the wire connected to the inner tip of the female plug cable to "+V" on the chassis mount power supply (Refer to schematic shown on FIGURE 314). Attach an 18 gauge wire between a chassis ground point of the chassis and the chassis ground of the power supply, G. With power disconnected from the power source, connect the chassis mount power supply to the power source connections. Attach an 18 gauge wire between VAC-NEUTRAL of the power source to the "N" connection of the chassis mount power supply. Attach an 18 gauge wire between VAC-HOT of the power source to the "L" connection of the chassis mount power supply. The adjustment screw on the power supply is factory set. If an adjustment is necessary, adjust screw so that 12 Volt DC signal is measured on the output of the power supply between "+V" and "-V". Insert the female plug, FIGURE 3-12 , into the back jack of the IRI labeled "9-18VDC".

3.6 POWER ON CONFIRMATION After all physical installation and wiring is complete, apply power to the external power supply, confirm the "Power LED is on. If problems are encountered with any part of the IRI operation, refer to Section 5.0 IRI TROUBLE SHOOTING CHART.

4.0 OPERATIONThis section of the manual describes the panel controls of the IRI, detailed instructions of how to use these controls to setup the IRI, and commands for communicating with the IRI.

4.1 OPERATOR PANEL LAYOUT The IRI has one push button, four LED (light emitting diode) lamps and two seven-segment displays. The push button is used for operator input, the LED's provide continuous status information, and the display exhibits the IRI address and set point information. 11

The following sections outline the function of the button and the meaning of the LEDs. The display information is described in Section 4.1.7, SETTING UP THE IRI, where detailed instructions are provided for each IRI function. 4.1.1 PUSH BUTTON The push button on the IRI is a multi-functional input. It allows the operator to enter the set point mode, move within the set points, and alter set points. There are two methods for using the push button, the "short" depress and "long" depress. The "short" depress is defined as depressing the button for less than two seconds. In contrast, the "long" depress is defined as depressing the button for longer than two seconds. "Long" depresses are used to enter the menu structure, select set points to alter and accept new set points. "Short" depresses are used to cycle through the various set points and the selections of each set point. 4.1.2 "POWER" LED This amber LED lights to indicate there is power supplied to the IRI. 4.1.3 "NETWORK PORT" LED (1)

To alter any of the set points, go into the set point mode by performing a "long" depress on the push button. The IRI will display a two character code showing which set point the menu is on. To move through the set points, perform a series of "short" depresses. To change one of the set points, select the set point to alter and perform a "long" depress. The IRI will display the current value of the set point. To alter a set point, perform a series of "short" depresses which will allow the user to move through the choices for that particular set point. To enter a particular choice for a set point, perform a "long" depress which will cause the display to flash the display as a way to indicate acceptance of the set point, The IRI will then exit the set point mode and display the current address. The IRI will automatically exit the set point mode if the push button is not depressed within ten seconds. Note: When changing the address, the most significant digit (MSD) is changed first. To accept it, perform a long depress. The MSD will flash then the least significant digit( LSD) can be changed. Perform a "long" depress to accept the new address. The following sections provide descriptions on all the set points within the IRI. The letters within the brackets are the two letter designations exhibited on the IRI display. 4.1.8 ADDRESS [Ad]

This LED flashes a green light whenever bytes are received on the network port. 4.1.4 "INGERSOLL-RAND PORT" LED (2) This LED flashes a green light whenever bytes are received on the Ingersoll-Rand port. Also, this LED will light up red if the IRI does not receive status information from the Intellisys controller after several status requests. 4.1.5 "SERVICE PORT" LED (3) This LED flashes a green light whenever bytes are received on the service port. 4.1.6 TWO CHARACTER DISPLAY This multifunction display is used to show the device address during normal operations. The display is also used when setting parameters. 4.1.7 SETTING UP THE IRI Setting up the IRI is done by entering chosen values for the IRI operating parameters, which are called set points. Section 6 displays a chart of all the IRI set points and the range of values for each one.

The operator uses this set point to give the IRI and its corresponding Intellisys controller a unique device address that the Network will use in order to communicate with it. Addresses range from 0 to 255 (00 - FF hex). 4.1.9 BAUD RATE [bl] The baud rate for the Network port is set through this set point. The user can select a 2400, 4800, 9600, or 19200 baud rate. 4.1.10 BAUD RATE [b3] The baud rate for the Service port is set through this set point. The user can select a 2400, 4800, 9600, or 19200 baud rate. 4.1.11 COMMUNICATIONS MODE [CO] The communications mode for the Network port can either be RTU mode (8 data bits, no parity, two stop bits) or ASCII mode (7 data bits, no parity, two stop bits). Refer to Modicon Modbus Protocol Reference Guide (PIMBUS-300 Rev. E) for more information on Modbus transmission modes.

12

4.1.12 CALL UP [Cu] This menu function is used to control the ICU function of the IRI. This function is only used in conjunction with IntelliGuard. Consult the factory for further information. "OF" = Call up Off. "on" = Call up On. 4.1.13 DISPLAY CHECK [dc] This menu function will perform a display check by lighting up the display with "88" and the IRI software version number. In addition, the LEDs cycle from green to red then off.

The form of the query is: IRI address Function Starting Address Hi Starting Address Lo Number of points Hi Number of points Lo Error check (CRC or LRC) The form of the response is: IRI Address Function Byte Count Data 1Hi Data 1 Lo Data 2 Hi Data 2 Lo Error check (CRC or LRC)

(Hex) = XX =03 = XX = XX = XX = XX = XX (Hex) = XX =03 = XX = XX = XX = XX = XX = XX

4.2 IRI COMMUNICATIONS The IRI uses Modbus protocol to communicate with personal computers or Programmable Logic Controllers (PLCs) over the Network port. The IRI only responds to two Modbus commands, Read Holding Register (03) and Preset Single Register (06) (See Modicon Modbus Protocol Reference Guide, PI-MBUS-300 Rev. E, for more details on Modbus). There are several types of Intellisys controllers with each having its own unique set points and sensors. All the values are stored within registers in the controllers. The register listings for each Intellisys controller are in section 4.3.

Here is an example of a request to read offline pressure (register 40112 and online pressure (register 40113 from IRI address 22(Hex) using RTU mode:

4.2.1 MODBUS READ COMMAND To read the registers from an Intellisys controller, a Read Holding Registers command (03) needs to be sent to the IRI. A maximum of 32 registers can be read at one time. The formats for the query and response are as follows:

The form of the query is: IRI address Function Starting Address Hi Starting Address Lo Number of points Hi Number of points Lo Error check (CRC hi) Error check (CRC lo) The form of the response is: IRI Address Function Byte Count Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo Error check (CRC hi) Error check (CRC lo)

(Hex) =22 =03 =00 =6F =00 =02 =F3 =45 (Hex) =22 =03 =04 =00 =5F =00 =55 =18 =DC

13

4.2.2 MODBUS WRITE COMMAND To write to the registers in an Intellisys controller, a Preset Single Register command (06) needs to be sent to the IRI. Note: Writing to registers can only be executed when the compressor is stopped. The formats for the query and response are as follows:

The form of the query is: IRI address Function Starting Address Hi Starting Address Lo Number of points Hi Number of points Lo Error check (CRC or LRC) The form of the response is: IRI Address Function Byte Count Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo Error check (CRC or LRC)

(Hex) = XX =06 = XX = XX = XX = XX = XX (Hex) = XX =06 = XX = XX = XX = XX = XX = XX

Here is an example to set offline pressure (register 40112 to 95 through IRI address 22(Hex) using RTU mode: The form of the query is: IRI address Function Starting Address Hi Starting Address Lo Data Hi Data Lo Error check (CRC hi) Error check (CRC lo) The form of the response is: IRI Address Function Starting Address Hi Starting Address Lo Data 2 Hi Data 2 Lo Error check (CRC hi) Error check (CRC lo) (Hex) =22 =06 =00 =6F =00 =5F =FE =BC (Hex) =22 =06 =00 =6F =00 =5F =FE =BC

14

4.3 REGISTER LISTING The following sections contain register definitions for the various Ingersoll-Rand Intellisys Controllers. 4.3.1 SSR CONTROLLER Register (40XXX) 001 003 004 005 006 007 008 009 064 065 096 097 098 099 112 113 114 115 116 117 118 119 120 121 122 123 124 125 255 256-270 272-286 288-302 304-318 320-334 336-350 352-366 368-382 8-8 400-414 512-526 999 Variable Read/ Write R/W R R R R R R R R R R R R R R/W R/W R/W R R/W R R R R/W R R/W R/W R/W R/W R R R R R R R R R R R R R Range Notes

Status/Control Discharge Pressure Sump Pressure Inlet Vacuum Coolant Temperature Airend Temperature Discharge Temperature Low Ambient Coolant Temp. Total Hours (hours) Loaded Hours (hours) Language Selection Units of Measure Rated Pressure Rated Horse Power Offline Pressure Online Pressure Display Timer (seconds) Star-Delta Time (seconds) Auto Start/Stop (AS/S) Time (minutes) Auto Start/Stop (AS/S) On/Off Sequence Control On/Off Remote Start/Stop On/Off Mod Only On/Off Power Out Restart Option (PORO)On/Off PORO Time (seconds) Load Delay Time (seconds) Min. Cooler Out Load Temp Unloaded Stop Time Warning Code Alarm Code History Inlet Vacuum Alarm History Sump Preisure Alarm History Dischage Pressure Alarm History Coolant Temperature Alarm History Airend Temperature Alarm History Discharge Temperature Alarm History Low Ambient Coolant Temp. History Run Hours Alarm History Load Hours Alarm History Status Alarm History IRI Version Number

See FIGURE 4-2

Divide Value by 10

Low Ambient Option

See FIGURE 4-3 See FIGURE 4-3 See FIGURE 4-3 rated = rated pressure offline = offline pressure

75 - (rated+3) 65-(offline-10) 10-600 2-60 0 or 1 0 or 1 0 or 1 0 or 1 0 or 1 10-120 0-60 30-150 10-30

No Write if AS/S is off 0=Off, 1=On 0=Off, 1=On 0=Off, 1=On 0=Off, 1 =On 0=Off, 1=On No Write if PORO is off Low Ambient Option See FIGURE 4-5 See FIGURE 4-5

Low Ambient Option

See FIGURE 4-4 Reads from IRI only

FIGURE 4-1 INTELLISYS SSR CONTROLLER REGISTER STRUCTURE

15

Bit 0: Host/Local (R/W) 0 = Local 1 = Host Bit 1: Run/Stop (R/W) 0 = Stop 1 = Run Bit 2: Load/Unload (R/W) 0 = Unload 1 = Load Bit 3: Modulating (R) 0 = Not Modulating 1 = Modulating Bit 4: Unused Bit 5: Stopped in Auto Restart (R) 0 = Not Stopped in Auto Restart 1 = Stopped in Auto Restart

Bit 6: Alarm (R) 0 = No Alarms 1 = Alarms Bit 7: Warning (R) 0 = No Warnings 1 = Warnings Bit 8: On/Off Line Mode (R) 0 = Not in On/Off Line Mode 1 = On/Off Line Mode Bit 9: Mod/ACS or Mod Only (R) 0 = Not in Mod/ASC Mode 1 = Mod/ASC Mode Bits 10-12: Unused Bits 13-15: Unit Type (R) 001 = SSR controller

FIGURE 4-2 INTELLISYS SSR CONTROLLER REGISTER 01-STATUS/CONTROL

Register 096: Languane 0 = English 1 = Spanish 2 = French 3 = Portuguese Register 99: Rated Horse Power 0 = 50 1 = 60 2 = 75 3 = 100 4 = 125 5 = 150

Register 097: Units of Measure 0 = F and PSI 1 = C and PSI 2 = C and Bar 3 = C and kPa 4 = C and kg/cm2 6 = 200 7 = 250 8 = 300 9 = 350 10 = 400 11 = 450

FIGURE 4-3 INTELLISYS SSR CONTROLLER REGISTER CODES

Bit 0: Run/Stop (R) 0 = Stop 1 = Run Bit 1: On/Off Line Mode (R) 0 = Not in On/Off Line Mode 1 = On/Off Line Mode Bit 2: MOD/ACS Mode (R) 0 = Not in Mod/ACS Mode 1 = Mod/ACS Mode Bit 3: Load/Unload (R) 0 = Unload 1 = Load

Bit 4: Stopped Auto Restart (R) 0 = Not Stopped in Auto Restart 1= Stopped in Auto Restart Bit 5: Unused

Bit 6: Unused

Bit 7: Unused

FIGURE 4-4 INTELLISYS SSR CONTROLLER STATUS ALARM HISTORY 16

Code 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37

Description Sensor Failure 1AVPT Sensor Failure 3APT Sensor Failure 4APT Sensor Failure P4 (Spare) Sensor Failure P5 (Spare) Sensor Failure P6 (Spare) Sensor Failure P7 (Spare) Sensor Failure P8 (Spare) Sensor Failure 2CTT Sensor Failure 2ATT Sensor Failure 4ATT Sensor Failure 3CTT (Optional) Sensor Failure T5 (Spare) Sensor Failure T6 (Spare) Sensor Failure T7 (Spare) Sensor Failure T8 (Spare) Starter Fault Motor Overload (Main) Fan Motor Overload Door Open (Starter) Stepper Limit Switch Check Motor Rotation Check Inlet Control System Remote Stop Failure Remote Start Failure Check Inlet Control Low Unload Sump Pressure High Air Pressure Low Sump Air Pressure High A/E Discharge Temperature Emergency Stop Change Inlet Filter Change Separator Element Change Coolant Filter 1AVPT Sensor Error (Calibration) Memory Fault

FIGURE 4-5 INTELLISYS SSR CONTROLLER ALARM & WARNING CODES

17

4.3.2 SSR SG CONTROLLER

Register (40XXX) 001 003 004 005 006 007 008 009 010 011

Variable

Read/ Write R/W R R R R R R R R R

Range

Notes

Status/Control Discharge Pressure Sump Pressure Inlet Vacuum Coolant Temperature Airend Temperature Discharge Temperature Low Ambient Coolant Temp. Separator Pressure Drop Coolant Pressure

See FIGURE 4-7

Divided by 10

Low Ambient Option Spare Pressure Input #4 if no coolant pressure option Spare Pressure Input #5 if no separator delta-p sensor option

012

Dry Side Sump Pressure

R

013 014 015 016 017 018 019 064 065 066 067 096 097 098 099 100 101 102 103 104 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127

Spare Pressure Input 6 Spare Pressure Input 7 Spare Pressure Input 8 Spare Temperature Input 5 Spare Temperature Input 6 Spare Temperature Input 7 Spare Temperature Input 8 Total Hours (hours) Loaded Hours (hours) Ten Thousand Total Hours Ten Thousand Loaded Hours Language Selection Units of Measure Rated Pressure Rated Horse Power/Kilowatt Starter Type Service Level Service Type Service Interval Coolant Pressure Sensor Offline Pressure Online Pressure Mode of Operation Star-Delta Time (seconds) Auto Start/Stop (AS/S) Time (minutes) Auto Start/Stop (AS/S) On/Off Sequence Control On/Off Remote Start/Stop On/Off Solenoid Delta-P Power Out Restart Option (PORO)On/Off PORO Time (seconds) Auto Start/Stop Delay Time (seconds) Min. Cooler Out Load Temp Unloaded Stop Time Low Ambient Option On/Off Contrast

R R R R R R R R R R R R R R R R R R R R R/W R/W R/W R R/W R R R R R R/W R/W R/W R/W R R

0-9999 0-9999

0-11 0-4 0 - 21 0-4 0 or 1 0 or 1 0-3 0 or 1 75 - (rated+3) 65-(offline-10) 0-2 5-20 2-60 0 or 1 0 or 1 0 or 1 0 or 1 0 or 1 10-120 0-60 30-150 10-30 0 or 1 0-10

Less Than 10000 Less Than 10000 Multiply by 10000 Multiply by 10000 See FIGURE 4-8 See FIGURE 4-8 See FIGURE 4-8 See FIGURE 4-8 0=Level 1, 1 =Level 2 0=Hours, 1 =Months 3, 6, 9, or 12 months 0=Off, 1 =On rated = rated pressure offline = offline pressure See FIGURE 4-8 No Write if AS/S is off 0=Off, 1 =On 0=Off, 1 =On 0=Off, 1 =On 0=Off, 1 =On No Write if PORO is off Low Ambient Option 0=Off, 1 =On

FIGURE 4-6 INTELLISYS SSR SG CONTROLLER REGISTER STRUCTURE (CONTINUED)

18

Register (40XXX) 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 250 251 252 253 254 255 256-270 272-286 288-302 304-318 320-334 336-350 352-366 368-382 384-398 400-414 416-430 432-446 448-462 464-478 480-494 512-526 528-542 544-558 560-574 576-590 592-606 999

Variable

Read/ write R/W R/W R/W R/W R/W R/W R/W R/W R R R R/W R/W R/W R/W R/W R/W R/W R/W R R R R R R R R R R R R R R R R R R R R R R R R R R R R R

Range

Notes

Lead/Lag Lag Offset Max Modulation Pressure Lead/Lag Cycle Length (Hours) Scheduled Start (Hour) Scheduled Start (Minute) Scheduled Stop (Hour) Scheduled Stop (Minute) Modbus Protocol Modbus Address High Dust Filter Integral Sequencing Lead Integral Sequencing Address Integral Sequencing Total Integral Sequencing Load Delay Integral Sequencing Lead Change (Hours) Integral Sequencing Lead Change - Day Integral Sequencing Lead Change - Hour Integral Sequencing Lead Change - Min Separator Delta-P Sensor Options Unloaded Inlet Vacuum Software Part Number - Most Significant Software Part Number - Least Significant Software Version Number Warning Code Alarm Code History Inlet Vacuum Alarm History Sump Pressure Alarm History Discharge Pressure Alarm History Coolant Temperature Alarm History Airend Temperature Alarm History Discharge Temperature Alarm History Low Ambient Coolant Temp. History Total Hours Alarm History 10000 Total Hours Alarm History Loaded Hours Alarm History 10000 Loaded Hours Alarm History Unloaded Inlet Vacuum Alarm History Coolant Pressure Alarm History Dry Side Sump Pressure Alarm History Status Alarm History Real Time Clock Alarm History - Hours Real Time Clock Alarm History - Minutes Real Time Clock Alarm History - Month Real Time Clock Alarm History - Date Real Time Clock Alarm History - Year IRI Version Number

0 or 1 0-10 (Online+10) (Offline + 7) 0-750 0-23 0-59 0-23 0-59 0 or 1 1-247 0 or 1 0-3 1-4 2-4 10-60 0-750 0-9 0-23 0-45 0 or 1

0=Off, 1 =On

0=Off, 1 =On 0=Off, 1 =On 0=Off, 1 =On, 2=Always, 3=Never

See FIGURE 4-8 Steps of 0, 15, 30, 45 0=Off, 1 =On See FIGURE 4-8 High Digits Low Digits See FIGURE 4-10 See FIGURE 4-10

Low Ambient Option Less Than 10000 Hours Multiply by 10000 Less Than 10000 Hours Multiply by 10000

See FIGURE 4-9

Reads from IRI only

FIGURE 4-6 INTELLISYS SSR SG CONTROLLER REGISTER STRUCTURE

19

Bit 0: Host/Local (R/W) 0 = Local 1 = Host Bit 1: Run/Stop (R/W) 0 = Stop 1 = Run Bit 2: Load/Unload (R/W) 0 = Unload 1 = Load Bit 3: Modulating (R) 0 = Not Modulating 1 = Modulating Bit 4: Unused Bit 5: Stopped in Auto Restart (R) 0 = Not Stopped in Auto Restart 1 = Stopped in Auto Restart

Bit 6: Alarm (R) 0 = No Alarms 1 = Alarms Bit 7: Warning (R) 0 = No Warnings 1 = Warnings Bit 8: On/Off Line Mode (R) 0 = Not in On/Off Line Mode 1 = On/Off Line Mode Bit 9: Mod/ACS or Mod Only (R) 0 = Not in Mod/ASC Mode 1 = Mod/ASC Mode Bits 10-12: Unused Bits 13-15: Unit Type (R) 001 = SSR controller

FIGURE 4-7 INTELLISYS SSR SG CONTROLLER REGISTER 01-STATUS/CONTROL

20

Register 096: Language 0 = English 1 = Spanish 2 = Portuguese 3 = French 4 = Italian 5 = Dutch

6 = German 7 = Danish 8 = Norwegian 9 = Swedish 10 = Finnish 11 = Turkish

Register 097: Units of Measure 0 = F and PSI 1 = C and PSI 2 = C and Bar 3 = C and kPa 4 = C and kg/cm2

Register 99: Rated Horse Power/Kilowatt 0 1 2 3 4 5 6 7 = = = = = = = = 50hp 60hp 75hp 100hp 125hp 150hp 200hp 250hp 8 = 300hp 9 = 350hp 10 = 400hp 11 = 450hp 12 = 500hp 13 = 75kw 14 = 90kw 15 16 17 18 19 20 21 = 110kw = 132kw = 150kw = 200kw = 250kw =300kw = 250kw

Register 100: Starter Type 0 1 2 3 4 = = = = = Star-Delta Full Voltage Remote Star-Delta Remote Full Voltage Soft Starter

Register 114: Mode of Operation 0 = MOD/ACS 1 = On/Off Line 2 = Modulation Only

Register 144: Integral Sequencing Lead Change - Day 0= Sunday 1 = Monday 2 = Tuesday 3 = Wednesday 4 = Thursday 5 = Friday 6 = Saturday 7 = Daily 8 = Weekdays 9 = Weekends

Register 250: Options Bit 0: Power Out Restart and Scheduled Start/Stop 0 = Off 1 = On

FIGURE 4-8 INTELLISYS SSR SG CONTROLLER REGISTER CODES

21

Bit 0: Run/Stop (R) 0 = Stop 1 = Run Bit 1: On/Off Line Mode (R) 0 = Not in On/Off Line Mode 1 = On/Off Line Mode Bit 2: MOD/ACS Mode (R) 0 = Not in Mod/ACS Mode 1 = Mod/ACS Mode Bit 3: Load/Unload (R) 0 = Unload 1 = Load

Bit 4: Stopped Auto Restart (R) 0 = Not Stopped in Auto Restart 1 = Stopped in Auto Restart Bit 5: Unused

Bit 6: Unused

Bit 7: Unused

FIGURE 4-9 INTELLISYS SSR SG CONTROLLER STATUS ALARM HISTORY

22

Code 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Description Sensor Failure 1AVPT Sensor Failure 3APT Sensor Failure 4APT Sensor Failure 5CPT (Optional) Sensor Failure 6APT (Optional) Sensor Failure P6 (Spare) Sensor Failure P7 (Spare) Sensor Failure P8 (Spare) Sensor Failure 2CTT Sensor Failure 2ATT Sensor Failure 4ATT Sensor Failure 3CTT (Optional) Sensor Failure T5 (Spare) Sensor Failure T6 (Spare) Sensor Failure T7 (Spare) Sensor Failure T8 (Spare) Starter Fault Motor Overload (Main) Fan Motor Overload Control Power Loss Stepper Limit Switch Check Motor Rotation Check Inlet Control System Remote Stop Failure Remote Start Failure Check Inlet Control Low Unload Sump Pressure High Air Pressure Low Sump Air Pressure High A/E Discharge Temperature Emergency Stop Change Inlet Filter Change Separator Element Change Coolant Filter 1AVPT Sensor Error (Calibration) Memory Fault 100 Hours/14 Days To Service Service Required Alarm - Service Required Auxiliary 2 Auxiliary 1 High Line/Sump Differential Communication Failure 1 Communication Failure 2 Communication Failure 3 Communication Failure 4 Low Coolant Pressure

FIGURE 4-10 INTELLISYS SSR SG CONTROLLER ALARM & WARNING CODES

23

4.3.3 SE 15-100 HP CONTROLLER

Register (40XXX) 001 003 004 005 006 064 065 096 097 098 099 100 101 102 112 113 114 115 116 117 118 119 120 121 122 123 124 125 252 253 255 256-270 272-286 288-302 304-318 320-334 336-350 352-366 368-382 999

Variable

Read/ Write R/W R R R R R R R R R R R R R/W R/W R/W R/W R/W R R/W R R R R/W R/W R/W R/W R/W R R R R R R R R R R R R

Range

Notes

Status/Control Discharge Pressure Sump Pressure Separator Pressure Drop Airend Temperature Total Hours (hours) Loaded Hours (hours) Language Selection Units of Measure Rating Indicator Starter Type Star-Delta Timer (seconds) Contrast Modulation On/Off Offline Pressure Online Pressure Mode of Operation Display Timer (seconds) Auto Start/Stop (AS/S) On/Off Auto Start/Stop Time (minutes) Sequence Control On/Off Remote Start/Stop On/Off Power Out Restart Option(PORO) On/Off PORO Time (seconds) Load Delay Time (seconds) Lead/Lag On/Off Lag Offset Low Ambient On/Off Software Part Number High Word Software Part Number Low Word Warning Code Alarm Code History Discharge Pressure Alarm History Sump Pressure Alarm History Airend Temperature Alarm History Separator Pressure Alarm History Run Hours Alarm History Load Hours Alarm History Status Alarm History IRI Version Number

See FIGURE 4-12

See FIGURE 4-13 See FIGURE 4-13 See FIGURE 4-13

0 or 1 75 - (rated+3) 65-(offline-10) 0-2 10-600 0 or 1 2-20 0 or 1 0 or 1 0 or 1 10-120 0-60 0 or 1 0-10 0 or 1

0=Off 1=On

See FIGURE 4-13 0=Off, 1 =On No Write if AS/S is off 0=Off, 1 =On 0=Off, 1 =On 0=Off, 1 =On No Write if PORO is off 0=Off 1=On 0=Off 1=On

See FIGURE 4-15 See FIGURE 4-15

See FIGURE 4-14 Reads from IRI only

FIGURE 4-11 INTELLISYS SE 15-100 HP CONTROLLER REGISTER STRUCTURE

24

Bit 0: Host/Local (R/W) 0 = Local 1 = Host Bit 1: Run/Stop (R/W) 0 = Stop 1 = Run Bit 2: Load/Unload (R/W) 0 = Unload 1 = Load Bit 3: Modulating (R) 0 = Not Modulating 1 = Modulating Bit 4: Sump Pressure (R/W) 1 = Get Sump Pressure Bit 5: Stopped in Auto Restart (R) 0 = Not Stopped in Auto Restart 1 = Stopped in Auto Restart

Bit 6: Alarm (R) 0 = No Alarms 1 = Alarms Bit 7: Warning (R) 0 = No Warnings 1 = Warnings Bit 8: On/Off Line Mode (R) 0 = Not in On/Off Line Mode 1 = On/Off Line Mode Bit 9: Mod/ACS or Mod Only (R) 0 = Not in Mod/ASC or Mode 1 = Mod/ASC or Mod Mode Bits 10-12: Unused

Bits 13-15: Unit Type (R) 010 = SE controller

FIGURE 4-12 INTELLISYS SE 15-100HP CONTROLLER REGISTER 01-STATUS/CONTROL Register 096: Language 0 = English 1 = Spanish 2 = French 3 = Portuguese Register 097: Units of Measure 0 =C and Bar 1 =C and PSI 2 =C and kPa 3 =F and PSI 4 =C and kg/cm2 Register 114: Mode of Operation 0 = MOD/ACS 1 = Modulation Only 2 = On/Off Line

Register 099: Starter Type 0 = Full Voltage 1 = Star-Delta 2 = No Starter

FIGURE 4-13 INTELLISYS SE 15-100HP CONTROLLER REGISTER CODES Bit 0: Run/Stop (R) 0 = Stop 1 = Run Bit 1: On/Off Line Mode (R) 0 = Not in On/Off Line Mode 1 = On/Off Line Mode Bit 2: MOD/ACS Mode (R) 0 = Not Modulating 1 = Modulating Bit 3: Load/Unload (R) 0 = Unload 1 = Load Bit 4: Stopped Auto Restart (R) 0 = Not Stopped in Auto Restart 1 = Stopped in Auto Restart Bit 5: Unused

Bit 6: Unused

Bit 7: Unused

FIGURE 4-14 INTELLISYS SE 15-100HP CONTROLLER STATUS ALARM HISTORY 25

Code 01 02 04 05 06 07 08 09 10 12 15 16 17 18 19 20 21

Description Pressure Sensor Failure Temperature Sensor Failure 1 Starter Fault Motor Overload Reverse Rotation Remote Stop Failure Remote Start Failure Calibration Error High Airend Discharge Temperature High Pressure Separator Element Control Power Loss Fan Motor Overload Emergency Stop Low Sump Pressure Memory Fault Low Unloaded Sump Pressure

FIGURE 4-15 INTELLISYS SE 15-100HP CONTROLLER ALARM & WARNING CODES

26

4.3.4 SIERRA 50-100 HP CONTROLLER

Register (40XXX) 001 003 004 005 006 007 008 064 065 096 097 098 099 100 101 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 252 253 254 255 256-270 272-286 288-302 304-318 320-334 336-350 352-366 368-382 384-398 400-414 999

Variable

Read/ Write R/W R R R R R R R R R R R R R R R/W R/W R/W R R/W R R R R R/W R/W R/W R/W R/W R/W R R R R R R R R R R R R R R R

Range

Notes

Status/Control Discharge Pressure Package Discharge Temp. Bearing Oil Temp. 2nd Stage Inlet Temp. 2nd State Discharge Temp. 1st Stage Discharge Temp. Total Hours (hours) Loaded Hours (hours) Language Selection Units of Measure Rated Pressure Starter Type Star-Delta Timer (seconds) Contrast Off line Pressure Online Pressure Display Timer (seconds) Auto Start/Stop On/Off Auto Start/Stop Time (minutes) Condensate Switch On/Off Sequence Control On/Off Remote Start/Stop On/Off PORO On/Off PORO Time (seconds) Load Delay Time (seconds) Lead/Lag Lag Offset Condensate Discharge Time (seconds) Condensate Interval Time (seconds) Part Number Part Number Software Version Warning Code Alarm Code History Discharge Pressure Alarm History Package Disch. Temp. Alarm History Bearing Oil Temp. Alarm History 2nd Stage Inlet Temp. Alarm History 2nd Stage Disch. Temp. Alarm History 1st Stage Disch. Temp. Alarm History Run Hours Alarm History Load Hours Alarm History Status Alarm History IRI Version Number

See FIGURE 4-17

See FIGURE 4-18 See FIGURE 4-18 See FIGURE 4-18

75 - (rated+3) 65-(offline-10) 10-600 0 or 1 2-60 0 or 1 0 or 1 0 or 1 0 or 1 10-120 0-60 0 or 1 0-45 psi 2-10 90-270

0=Off, 1 =On No Write if AS/S is off 0=Off, 1=On 0=Off, 1 =On 0=Off, 1 =On 0=Off, 1=On No Write if PORO is off 0=Lead, 1=Lag

High 16-bits Lower 16-bits See FIGURE 4-20 See FIGURE 4-20

See FIGURE 4-19 Reads from IRI only

FIGURE 4-16 INTELLISYS SIERRA 50-100HP CONTROLLER REGISTER STRUCTURE

27

Bit 0: Host/Local (R/W) 0 = Local 1 = Host Bit 1: Run/Stop (R/W) 0 = Stop 1 = Run Bit 2: Load/Unload (R/W) 0 = Unload 1 = Load Bit 3: Unused Bit 4: Sump Pressure (R/W) 1 = Get Sump Pressure Bit 5: Stopped in Auto Restart (R) 0 = Not Stopped in Auto Restart 1 = Stopped in Auto Restart

Bit 6: Alarm (R) 0 = No Alarms 1 = Alarms Bit 7: Warning (R) 0 = No Warnings 1 = Warnings Bit 8: On/Off Line Mode (R) 0 = Not in On/Off Line Mode 1 = On/Off Line Mode Bit 9: Unused Bits 10-12: Unused Bits 13-15: Unit Type (R) 110 = Sierra SE controller

FIGURE 4-17 INTELLISYS SIERRA 50-100 HP CONTROLLER REGISTER 01-STATUS/CONTROL

Register 096: Language 0 = English 1 = Spanish 2 = French 3 = Portuguese Register 099: Starter Type 0 = Full Voltage 1 = Star-Delta 2 = No Starter

Register 097: Units of Measure 0 = C and Bar 1 = C and PSI 2 = C and kPa 3 = F and PSI 4 = C and kg/cm2

FIGURE 4-18 INTELLISYS SIERRA 50-100 HP CONTROLLER REGISTER CODES

Bit 0: Run/Stop (R) 0 = Stop 1 = Run Bit 1: OnlOff Line Mode (R) 0 = Not in On/Off Line Mode 1 = On/Off Line Mode Bit 2: Unused Bit 3: Load/Unload (R) 0 = Unload 1 = Load

Bit 4: Stopped Auto Restart (R) 0 = Not Stopped in Auto Restart 1 = Stopped in Auto Restart Bit 5: Unused

Bit 6: Unused Bit 7: Unused

FIGURE 4-19 INTELLISYS SIERRA 50-100 HP CONTROLLER STATUS ALARM HISTORY

28

Code 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22

Description Pressure Sensor Failure Package Disch. Temp. Sensor Failure Bearing Oil Temp. Sensor Failure Starter Fault Motor Overload 2nd Stage Inlet Temp. Sensor Failure Remote Stop Failure Remote Start Failure Calibration Error 2nd Stage Disch. Temp. Sensor Failure 1st Stage Disch. Temp. Sensor Failure High Pressure Oil Pressure Switch Condensate Level High Package Disch. Temp. Control Power Loss High Bearing Oil Temp. Emergency Stop High 2nd Stage Inlet Temp. Memory Fault High 1st Stage Disch. Temp. High 2nd Stage Disch. Temp.

FIGURE 4-20 INTELLISYS SIERRA 50-100HP CONTROLLER ALARM & WARNING CODES

29

4.3.5 SIERRA 100-200 HP CONTROLLER

Register (40XXX) 001 003 004 005 006 007 008 009 010 011 012 013 064 065 066 067 096 097 098 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 255 256-270 272-286 288-302 304-318 320-334 336-350 352-366 368-382 384-398 400-414 512-526 528-542 544-558 560-574 576-590 592-606 608-622 999

Variable

Read/ Write R/W R R R R R R R R R R R R R R R R R R R/W R/W R/W R/W R R/W R/W R/W R/W R R R R R R R R R R R R R R R R R R R R R R R R R

Range

Notes

Status/Control Discharge Pressure 2nd Stage Inlet Pressure 2nd Stage Discharge Pressure Inlet Vacuum Oil Filter In Pressure Bearing Oil Pressure 1 st Staqe Discharge Temp. 1st Stage lnlet Temp. 2nd Stage Discharge Temp. Bearing Oil Temp. Packaqe Discharge Temp. Running Hours (2 Seconds) Short Baud Rate (b3) Baud Rate (b3) Long Select Baud Rate Long Select mode Long Long Short Short Call Up (CU) Long Select On/Off LongCall Up 'On'=ON 'OF'=OFF

Short

Short Display Check (dc)

Address (Ad)

Long

Comm mode (CO) Long

Enter Data Select Baud Rate Long

Long

Long

Address 00 - FF

Baud Rate (b1) 24 = 2400 48 = 4800 96 = 9600 19 = 19200

Baude Rate (b3) 24 = 2400 48 = 4800 96 = 9600 19 = 19200

Comm Mode ru = RTU Mode AC = ASCII mode

7.0 PARTS LISTSUPPLIED: IRI with Chassis Mount Power Supply BOM 42412122 QTY 1 1 PART NO. 39866629 39237979 DESCRIPTION Assembly, Intellisys Remote Interface Power-Supply, Chassis Mount, 85-265 VAC 47-440 Hz Input, 12 VDC 850 mA Output Cable, Power Supply IRI

1

39238001

IRI with Wall Adaptor Power Supply BOM 42412130 QTY 1 1 PART NO. 39866629 39237987 DESCRIPTION Assembly, Intellisys Remote Interface Power-Supply, Wall Adaptor 120 VAC 60 Hz Input, 9 VDC 500 mA Output

NOT REQUIRED, HOWEVER, REFERRED TO IN MANUAL: QTY 1 A/R A/R PART NO. 39204458 39204508 39204466 DESCRIPTION Tool, Hand Crimping Cable, Communication 1000 Feet Plug, Modular (RJ-11)

77