ssr intellisys rotary troubleshooting guide centac/2015 tech...not all flowchart pages pertain to...
TRANSCRIPT
SSR INTELLISYS ROTARYTROUBLESHOOTING GUIDE
• Original Intellisys• SE & SG
• Problems• Procedures
• Warranty Information
APDD 749September 1999
1
SSR INTELLISYS ROTARYTROUBLESHOOTING GUIDE
The following is a guide to be used when identifying the root cause of acompressor problem.
Forms have also been developed for the SE and SG controller and must be filledin if the controller is to be returned to the factory under warranty.
Any controller returned to the factory must have all shaded areas of the formfilled in completely and a copy of the form sent with the controller.
Flowcharts follow the forms. Use the flow charts to help identify the root cause.
Not all flowchart pages pertain to all controllers. Look in the top left corner to seewhat controllers the particular page covers.
ORIG = Original Intellisys controller SSR 50-450HPSE = SE Intellisys controller SSR 20-100HPSG = SG Intellisys controller SSR 125-450HPFSM = Field Service Manuals
9/16//99 Rev 5
2
TABLE OF CONTENTSINTRODUCTION .........................................................................................................................................1
TABLE OF CONTENTS..............................................................................................................................2
HOW TO USE...............................................................................................................................................4
SE INTELLISYS CONTROLLER WARRANTY INFORMATION SHEET ........................................5
SG INTELLISYS CONTROLLER WARRANTY INFORMATION SHEET........................................6
PROBLEMS
SE CONTROLLER - SHUTS DOWN WITH READY TO START IN THE DISPLAY...................................................7SG CONTROLLER - SHUTS DOWN WITH READY TO START IN THE DISPLAY...................................................8ORIGINAL, SE, SG - CONTROLLER LOCKS-UP ..........................................................................................9ORIGINAL, SE SG - TRIAC DOES NOT OPERATE PROPERLY.....................................................................10ORIGINAL, SG - CHECK INLET CONTROL SYSTEM ALARM .....................................................................11ORIGINAL, SG - CHECK INLET CONTROL ALARM ..................................................................................12ORIGINAL, SE , SG - LOW UNLOADED SUMP ALARM ............................................................................13ORIGINAL, SE , SG - HIGH SUMP PRESSURE ALARM .............................................................................14ORIGINAL, SE , SG - HIGH AIREND TEMPERATURE ALARM ..................................................................15ORIGINAL, SE , SG - MAIN MOTOR OVERLOAD ALARM ........................................................................16ORIGINAL, SE , SG - STARTER FAULT ALARM .......................................................................................17ORIGINAL, STARTER FAULT ALARM CONTINUED...................................................................................18SE , SG - NO CONTROL POWER ALARM ....................................................................................................19ORIGINAL, SE , SG - CHECK MOTOR ROTATION ALARM .......................................................................20ORIGINAL, SG - STEPPER LIMIT SWITCH ALARM ..................................................................................21ORIGINAL, SE , SG - REMOTE STOP FAILURE ALARM ...........................................................................22ORIGINAL, SE , SG - REMOTE START FAILURE ALARM .........................................................................23ORIGINAL, SE , SG - SHORT SEPARATOR ELEMENT LIFE........................................................................24NOTES........................................................................................................................................................25
PROCEDURES
1.1 SE POWER OUTAGEBackground ...............................................................................................................................................26Procedure...................................................................................................................................................261.2 SE VOLTAGE SAGBackground................................................................................................................................................26Procedure...................................................................................................................................................261.3 GROUNDING PROBLEMSBackground................................................................................................................................................27Procedure...................................................................................................................................................271.4 SE INTELLISYS 16 VAC SUPPLYBackground................................................................................................................................................29Procedure...................................................................................................................................................291.5 SE EXTERNAL 5 VDC SHORT CIRCUITBackground................................................................................................................................................30Procedure...................................................................................................................................................30
ENVIRONMENTAL PROBLEMS1.6 MOISTUREBackground................................................................................................................................................31Procedure .................................................................................................................................................31
3
1.7 TEMPERATUREBackground................................................................................................................................................31Procedure .................................................................................................................................................321.8 VIBRATIONBackground................................................................................................................................................32Procedure .................................................................................................................................................32
OTHER1.9 REMOTE ALARM APPLICATIONBackground................................................................................................................................................32Procedure .................................................................................................................................................322.1 STEPPER MOTOR TESTBackground................................................................................................................................................34Procedure .................................................................................................................................................342.2 DRIVER CHIP TESTBackground................................................................................................................................................34Procedure .................................................................................................................................................352.3 LIMIT BOARD TESTBackground................................................................................................................................................36Procedure .................................................................................................................................................362.4 PRESSURE SENSOR CHECK OUTBackground................................................................................................................................................37Procedure .................................................................................................................................................382.5 TRIAC OUTPUTSBackground................................................................................................................................................37Procedure .................................................................................................................................................372.6 AUXILIARY CONTACTSBackground................................................................................................................................................38Procedure .................................................................................................................................................383.1 SG POWER OUTAGEBackground ...............................................................................................................................................40Procedure...................................................................................................................................................403.2 SG VOLTAGE SAGBackground ...............................................................................................................................................40Procedure...................................................................................................................................................403.3 SG INTELLISYS 24 VAC SUPPLYBackground................................................................................................................................................41Procedure...................................................................................................................................................413.4 SG EXTERNAL 5 VDC SHORT CIRCUITBackground................................................................................................................................................41Procedure...................................................................................................................................................424.0 EXTERNAL ELECTRICAL DISTURBANCESBackground................................................................................................................................................435.0 MEMBRANE SWITCH CHECKBackground................................................................................................................................................46Procedure .................................................................................................................................................46Figure 1 - SE Membrane Schematic ..........................................................................................................46Figure 2 - SG Membrane Schematic..........................................................................................................47Figure 3 - ORIGINAL Membrane Schematic............................................................................................48
4
USER INSTRUCTIONS
Identify the problem that is being experienced with the controller or compressor.Locate the problem in the table of contents under the PROBLEMS section.Turn to that page and follow the flow chart through the diagnostics. If the flowchart refers to another paragraph, find the paragraph number in the table ofcontents and turn to that page. Then follow any procedures within that section.
EXAMPLE:
Compressor is experiencing CHECK INLET CONTROL SYS alarm.Find CHECK INLET CONTROL SYS in the table of contents under the problemssection. That refers to page 11. As you follow the diagnostics, the flow chartsays to see paragraph 2.3. Find paragraph 2.3 in the table of contents. Thatrefers to page 36 for background and procedure information. Turn to that pageand follow any instructions. REMEMBER WHEN WORKING ON ENERGIZED PANELS FOLLOW ALL THE SAFETY PROCEDURES AND WEAR YOU PPE IS THE LAY IS YOUR LIFE Use this manual in combination with the corresponding electrical drawing and control manual of the compressor you are working on. All information was obtained using a FLUKE 87 recording voltmeter. When doing troubleshooting please use a Meter that has the same or belter characteristics. Remember IR Recommends Use a class III meter or belter. SAFETY IS # 1 ALWAYS – BE SAFE TODAY- SEE THE DAY LIGHT TOMARROW
5
SE INTELLISYS CONTROLLER GENERAL INFORMATIONDate: Customer: Distributor: Technician:Machine S/N: Model Number Total Hours: Loaded Hours:NEMA Rating: Starter Type: Ambient Temp: Start-up Date:Problem Description (What, How, When):
INTELLISYS SE INFORMATIONIntellisys S/N EPROM Version: Offline Pressure: Online Pressure:Mode of Operation: Options: Comm. Link: Last Alarm:
POWER SUPPLY INFORMATION POWER ONCircuit Test Point Expected Value Measured ValueControl TransformerPrimary VAC
T1 200-575 VAC
Control TransformerSecondary : 120 VAC
J5-36 to J5-35 120 VAC +/- 18 VAC
Control TransformerSecondary : 16 VAC(center-tap)
J4-30,31J4-29,30J4-29,31
16 VAC +/- 2.4 VAC8 VAC +/- 1.2 VAC8 VAC +/- 1.2 VAC
Rectified Intellisys DC J4-28,29 10.5 VDC +/- 1.6 VDCIntellisys Digital 5 VDC J11-1,5 5 VDC +/- .2 VDCIntellisys Analog 5 VDC J3-25,24 5 VDC +/- .2 VDCBattery Voltage BAT +/- 3.0 VDC +/- .6 VDCGround Fault Current:Machine running inloaded condition
Customer Groundconductor
0.0 Amps AC/DC+/- .25 Amps AC/DCsee Paragraph 1.3
GROUND RESISTANCE CHECK INFORMATION POWER OFFCircuit Test Point Expected Value Measured ValueIntellisys Ground J1-1, GND LUG < .5 Ohm120 VAC Neutral T1, GND Lug < .5 OhmMotor Frame Motor chassis, base < .5 OhmSensor Ground 3APT chassis, base < .5 OhmAirend Ground Air end chassis, base lug < .5 OhmPackage Ground Machine Base, GND lug < .5 OhmCustomer Ground Structural Earth, base lug < .5 Ohm
I/O RESISTANCE CHECK POWER OFFPressureJ3 Connected to board
Black to GNDGreen to GNDWhite to GND
<.5 ohm185 +/- 50850 ohm +/- 100
TemperatureJ2 Connected to board
White to GND 140 ohm +/- 10 @ 77 F
Digital I/OJ1 (a)
N.C.N.O.
< .5 ohm> 1 meg ohm
(a) Only test wired contacts and list only connections out of range.t.
SE Version USA Dwg 39899794 SE Version ESA – Pegasus Dwg 22182364.
J1 # 1 to 16J1 # 1 to 16
J2 # 17 to 22
J2 # 6 to 1J3 # 23 to 27
J3 # 5 to 1
J4 # 4 to 1
J5 # 11 to 1
J4 # 28 to 31
J3 # 32 to 42
6
SG INTELLISYS CONTROLLER GENERAL INFORMATIONDate: Customer: Distributor: Technician:Machine S/N: Model Number Total Hours: Loaded Hours:NEMA Rating: Starter Type: Ambient Temp: Start-up Date:Problem Description (What, How, When):
INTELLISYS SG INFORMATIONIntellisys S/N EPROM Version: Offline Pressure: Online Pressure:Mode of Operation: Options: Comm. Link: Last Alarm:
POWER SUPPLY INFORMATION POWER ONCircuit Test Point Expected Value Measured ValueControl TransformerPrimary VAC
T1 200-575 VAC +/- 10%
Control TransformerSecondary : 120 VAC
P1-1, P1-10 120 VAC +/- 18 VAC
Control TransformerSecondary : 24 VAC
Power Supply BoardJ1-1, J1-2
24 VAC +/- 3.6 VAC
Rectified Intellisys DC Power Supply BoardJ2-1,J2-2
12 VDC +/- .6 VDC
Intellisys Digital 5 VDC P9-1,5 5 VDC +/- .2 VDCIntellisys Analog 5 VDC P5-7,8 5 VDC +/- .2 VDCPressure Signal @ 0 psi P5 white to Black .5 VDC +/- .1 VDCBattery Voltage BAT +/- 3.0 VDC +/- .6 VDCGround Fault Current:Machine running inloaded condition
Customer Groundconductor
0.0 Amps AC/DC+/- .25 Amps AC/DCsee Paragraph 1.3
GROUND RESISTANCE CHECK INFORMATION POWER OFFCircuit Test Point Expected Value Measured ValueIntellisys Ground J1-5, GND LUG < .5 Ohm120 VAC Neutral T1, GND Lug < .5 OhmMotor Frame Motor chassis, base lug < .5 OhmSensor Ground 3APT chassis, base lug
1AVPT chassis, base lug4APT chassis, base lug
< .5 Ohm< .5 Ohm< .5 Ohm
Airend Ground Air end chassis, base lug < .5 OhmPackage Ground Machine Base, GND lug < .5 OhmCustomer Ground Structural Earth, base lug < .5 Ohm
I/O RESISTANCE CHECK POWER OFFPressureP5 Connected to board
Black to GNDWhite to GND
<.5 ohm20K +/- 3K
TemperatureP6 Connected to board
White to GNDBlack to GND
Temperature dependent<.5 ohm
Digital I/O (a)P3 1-2, 3-4, 5-6 ,…..32
N.C.N.O.
<.5 ohm>1 meg ohm
Stepper motorconnections
Power Supply BoardJ3,1-2 J3,3-4
4” & 6” valve = 5-7 Ohms8” valve = 11-13 Ohms
(a) Only test wired connections and list only connections out of range.
7
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LOA
DIN
G
AT
ST
AR
TIN
G A
FT
ER
TR
AN
SIT
ION
DID
VA
LVE
MO
VE
PA
ST
TH
E O
PE
N L
IMIT
SW
ITC
H?
DID
VA
LVE
MO
VE
PA
ST
TH
EC
LO
SE
D L
IMIT
SW
ITC
H?
YE
S
S
US
PE
CT
BA
D O
PE
N L
IMIT
SW
ITC
HS
EE
PR
OC
ED
UR
E 2
.3
NO
.
DID
VA
LVE
MO
VE
TO
TH
E O
PE
N L
IMIT
SW
ITC
H A
ND
ST
OP
?
YE
S.
SU
SP
EC
T B
AD
CO
NT
RO
LLE
R
NO
.
S
US
PE
CT
SLI
PP
ING
CO
UP
LIN
GB
AD
ST
EP
PE
R M
OT
OR
. S
EE
PR
OC
ED
UR
E 2
.1B
AD
DR
IVE
R C
HIP
. S
EE
PR
OC
ED
UR
E 2
.2IF
NO
NE
OF
TH
E A
BO
VE
TH
EN
PR
OB
AB
LY A
BIN
DIN
G I
NLE
T V
AL
VE
.Y
ES
.
S
US
PE
CT
BA
D C
LOS
ED
LIM
ITS
WIT
CH
NO
.
D
ID V
ALV
E M
OV
E T
O T
HE
CLO
SE
D L
IMIT
SW
ITC
H A
ND
ST
OP
?
YE
S.
SU
SP
EC
T B
AD
CO
NT
RO
LLE
R
NO
.
IS
TH
E B
LOW
DO
WN
AIR
HIT
TIN
G T
HE
VA
LVE
PL
AT
EA
ND
KE
EP
ING
IT F
RO
M M
OV
ING
CL
OS
ED
?
YE
S.
M
AK
E S
UR
E B
LOW
DO
WN
DE
FLE
CT
OR
IS IN
PL
AC
E. I
F N
EC
ES
SA
RY
,B
EN
D D
EF
LEC
TO
R T
O D
EF
LEC
T A
IRU
PW
AR
D
NO
.
S
US
PE
CT
SLI
PP
ING
CO
UP
LIN
G.
BA
D S
TE
PP
ER
MO
TO
R. S
EE
PR
OC
ED
UR
E2
.1B
AD
DR
IVE
R C
HIP
. S
EE
PR
OC
ED
UR
E 2
.2IF
NO
NE
OF
TH
E A
BO
VE
TH
EN
PR
OB
AB
LYA
BIN
DIN
G I
NLE
T V
AL
VE
.
NO
.
S
US
PE
CT
SLI
PP
ING
CO
UP
LIN
G.
BA
D S
TE
PP
ER
MO
TO
R. S
EE
PR
OC
ED
UR
E2
.1B
AD
DR
IVE
R C
HIP
. S
EE
PR
OC
ED
UR
E 2
.2IF
NO
NE
OF
TH
E A
BO
VE
TH
EN
PR
OB
AB
LYA
BIN
DIN
G I
NLE
T V
AL
VE
.
= V
ALV
E C
OM
MA
ND
ED
TO
MO
VE
TO
OP
EN
OR
CLO
SE
D L
IMIT
SW
ITC
H A
ND
CO
NT
RO
LLE
R N
EV
ER
RE
CE
IVE
S S
IGN
AL
FR
OM
LIM
IT S
WIT
CH
CO
NF
IRM
ING
TH
E V
ALV
E M
AD
E I
T T
HE
RE
.
CO
NF
IRM
24
VA
C T
O B
OA
RD
12
OR
IG,
SG
: C
HE
CK
IN
LET
CO
NT
RO
L
UN
LOA
DE
DIS
TH
E I
NLE
T V
ALV
E C
LOS
ED
?
YE
S.
IS T
HE
AIR
EN
D T
UR
NIN
G?
YE
S.
SU
SP
EC
T 1
AV
PT
TR
AN
SD
UC
ER
PR
OB
LEM
, O
R L
EA
K I
N S
EN
SIN
GLI
NE
NO
.
S
US
PE
CT
SLI
PP
ING
GE
AR
NO
.
OR
IGIN
AL
CO
NT
RO
LLE
R -
CH
EC
K F
OR
SLI
PP
ING
CO
UP
LIN
GS
G C
ON
TR
OLL
ER
- C
HE
CK
PO
SIT
ION
OF
CLO
SE
D L
IMIT
SW
ITC
H
= U
NIT
UN
LOA
DE
D A
ND
IN
LET
VA
CU
UM
LE
SS
TH
AN
TH
RE
E P
SI.
13
OR
IG,
SE
, S
G:
LOW
UN
LOA
DE
D S
UM
P
UN
LOA
DE
D O
R S
TA
RT
ING
AF
TE
R T
RA
NS
ITIO
N
= U
NIT
UN
LOA
DE
D A
ND
SU
MP
PR
ES
SU
RE
IS
LE
SS
TH
AN
15
PS
I F
OR
10
SE
CO
ND
S
CH
EC
K S
EN
SIN
G L
INE
TO
3A
PT
AN
D S
EN
SO
R 3
AP
T.
SE
E P
RO
CE
DU
RE
2.4
NO
.
S
US
PE
CT
SLI
PP
ING
CO
UP
LIN
GB
AD
ST
EP
PE
R M
OT
OR
. S
EE
PR
OC
ED
UR
E 2
.1B
AD
DR
IVE
R C
HIP
. S
EE
PR
OC
ED
UR
E 2
.2M
PC
V S
TU
CK
OP
EN
IF
PU
MP
ING
IN
TO
AN
OP
EN
SY
ST
EM
IF N
ON
E O
F T
HE
AB
OV
E T
HE
N P
RO
BA
BLY
A B
IND
ING
IN
LET
VA
LV
E.
IF N
OT
OK
, TH
EN
RE
PA
IR A
ND
RE
TE
ST
IF O
K,
IS B
LOW
DO
WN
AIR
CA
US
ING
TH
E V
ALV
E T
O C
LOS
E T
OO
FA
R?
YE
S.
M
AK
E S
UR
E B
LOW
DO
WN
DE
FLE
CT
OR
IS IN
PL
AC
E. I
F N
EC
ES
SA
RY
,B
EN
D D
EF
LEC
TO
R T
O D
EF
LEC
T A
IRU
PW
AR
D
SE
CO
NT
RO
LLE
R
FU
LL V
OLT
AG
E?
YE
S O
R
YE
S.
C
HE
CK
FO
R I
NLE
T V
ALV
E S
TU
CK
CLO
SE
D O
RB
RO
KE
N S
PR
ING
IN
IN
LET
VA
LVE
.
NO
.
CH
EC
K B
LO
W D
OW
N S
ILE
NC
ER
AD
JUS
TM
EN
T.
MA
KE
SU
RE
MA
KE
UP
PO
RT
S I
N IN
LET
VA
LVE
AR
E O
PE
N.
BLO
CK
AG
E I
N S
EN
SO
R L
INE
FR
OM
SU
MP
TO
10
SV
14
OR
IG,
SG
, S
E:
HIG
H S
UM
P P
RE
SS
UR
E=
SU
MP
PR
ES
SU
RE
IS
GR
EA
TE
R T
HA
N 1
5 P
SIG
AB
OV
E T
HE
RA
TE
D P
RE
SS
UR
E O
F T
HE
UN
IT.
CL
OG
GE
D S
EP
AR
AT
OR
EL
EM
EN
T
ST
ICK
ING
MIN
IMU
M P
RE
SS
UR
E C
HE
CK
VA
LVE
BLO
CK
AG
E
OR
LE
AK
IN
SE
NS
ING
LIN
E T
O 4
AP
TC
HE
CK
SP
EC
IAL
TE
E O
N T
OP
OF
MO
IST
UR
ES
EP
AR
AT
OR
WH
ER
E 4
AP
T C
ON
NE
CT
S.
OLD
ST
YLE
IN
LET
VA
LVE
SLI
PP
ING
CO
UP
LIN
GF
AU
LTY
4A
PT
SE
NS
OR
SE
E P
RO
CE
DU
RE
2.4
BA
D C
OO
LA
NT
BY
PA
SS
OR
BA
D A
IRF
ILT
ER
.W
AT
ER
IN
TH
E S
YS
TE
M
WA
TE
R I
N T
HE
SY
ST
EM
CA
US
ING
CO
RR
OS
ION
IN
TH
EV
ALV
E.
SE
CO
NT
RO
LLE
R
BLO
CK
AG
E I
N S
EN
SIN
G L
INE
TO
10
SV
FU
LL V
OLT
AG
E?
YE
S O
R N
O
YE
SN
O A
IR S
IGN
AL
TO
CLO
SE
TH
E V
ALV
E.
FA
ULT
Y 1
SV
OR
SH
UT
TLE
VA
LVE
.S
TIC
KIN
G I
NLE
T V
ALV
E,
BLO
WD
OW
N V
ALV
E N
OT
OP
EN
ING
.NO
.B
RO
KE
N S
PR
ING
IN
IN
LET
VA
LVE
1SV
ST
ILL
EN
ER
GIZ
ED
, S
TIC
KIN
G O
R L
EA
KIN
G A
IR S
IGN
AL
TO
OP
EN
IN
LET
VA
LVE
. B
LOW
DO
WN
VA
LVE
NO
T O
PE
NIN
G
15
OR
IG,
SG
, S
E:
HIG
H A
IRE
ND
TE
MP
ER
AT
UR
E=
AIR
EN
D D
ISC
HA
RG
E T
EM
PE
RA
TU
RE
EQ
UA
L T
O O
R G
RE
AT
ER
TH
AN
22
8°F
.
FA
ULT
Y T
HE
RM
OS
TA
TIC
VA
LVE
DIR
TY
CO
OLE
RS
HIG
H A
MB
IEN
TA
BO
VE
11
5°F
DO
ES
UN
IT S
HU
T D
OW
N I
N L
ES
S T
HA
N 1
0 S
EC
ON
DS
AF
TE
R S
TA
RT
-UP
?
YE
S.
IS C
OO
LAN
T L
EV
EL
CO
RR
EC
T?
NO
NO
.
CO
RR
EC
T C
OO
LA
NT
AN
D T
RY
AG
AIN
.
YE
S.
SU
SP
EC
T P
RO
BLE
M W
ITH
CO
OLA
NT
ST
OP
VA
LVE
.C
HE
CK
WIR
ING
AN
D V
ALV
E O
PE
RA
TIO
N (
SE
E P
RO
CE
DU
RE
2.5
)
AIR
-CO
OLE
D =
BA
D E
NV
IRO
NM
EN
TW
AT
ER
-CO
OLE
D =
BA
D W
AT
ER
FO
ULI
NG
TU
BE
S
EX
TE
RN
AL
CO
OLA
NT
LE
AK
CA
US
ING
AIR
-CO
OLE
D H
EA
T E
XC
HA
NG
ER
TO
CLO
GW
ITH
DIR
T
RE
ST
RIC
TIV
E E
XH
AU
ST
DU
CT
ING
> .
25
” W
AT
ER
CO
LUM
N
RE
CIR
CU
LA
TIO
N O
F C
OO
LIN
G A
IR
IS T
HE
VA
LVE
BY
PA
SS
ING
TH
E C
OO
LER
?
SW
AP
WIT
H 4
AT
T F
OR
QU
ICK
DE
TE
RM
INA
TIO
N (
NO
T S
E)
CH
EC
K F
OR
HIG
H M
OT
OR
AM
PS
UN
US
UA
L N
OIS
EH
IGH
ER
VIB
RA
TIO
N T
HA
N N
OR
MA
LM
ET
AL
IN T
HE
CO
OL
AN
T F
ILT
ER
FA
ULT
Y T
HE
RM
IST
OR
2A
TT
FA
ULT
Y A
IRE
ND
16
OR
IG,
SG
, S
E:
MA
IN O
R F
AN
MO
TO
R O
VE
RLO
AD
PLA
CE
OV
ER
LOA
D R
ELA
Y I
N M
AN
UA
LR
ES
ET
MO
DE
YE
S.
DID
OV
ER
LOA
D R
ELA
Y R
EQ
UIR
ER
ES
ET
TIN
G B
EF
OR
E B
EIN
G A
BLE
TO
RE
SE
T T
HE
IN
TE
LLIS
YS
CO
NT
RO
LLE
R?
NO
.
PO
TE
NT
IAL
PR
OB
LEM
WIT
H W
IRIN
G F
RO
M O
VE
RLO
AD
TO
CO
NT
RO
LLE
R O
R C
ON
TR
OLL
ER
.O
RIG
INA
L &
SE
IN
TE
LLIS
YS
: V
OLT
AG
E A
CR
OS
S C
ON
TA
CT
SH
OU
LD B
E 5
VD
C W
HE
NC
ON
TA
CT
IS
OP
EN
AN
D 0
VD
C W
HE
N C
ON
TA
CT
IS
CLO
SE
D.
(M
AIN
MO
TO
R,
OR
IG B
TS
2 1
0-1
1,
SE
-J1
15
&1
6.
FA
N M
OT
OR
, O
RIG
- B
TS
2 8
&9
. S
E-
J1 1
3&
14
)S
G I
NT
ELL
ISY
S:
VO
LTA
GE
AC
RO
SS
CO
NT
AC
T S
HO
ULD
BE
10-
12V
DC
WH
EN
CO
NT
AC
T I
S O
PE
N A
ND
0 V
DC
WH
EN
CO
NT
AC
T I
S C
LOS
ED
(MA
IN M
OT
OR
P3
11
&1
2,
FA
N M
OT
OR
P3
13
&1
4)
YE
S.
AR
E T
HE
AM
PS
HIG
HE
R?
NO
.
A
RE
TH
E T
EM
PE
RA
TU
RE
S O
F T
HE
TH
RE
ES
TA
RT
ER
PO
LES
TH
E S
AM
E O
R A
RE
TH
EY
HO
TT
ER
TH
AN
160
°F?
AN
Y S
IGN
S O
F H
OT
SP
OT
S O
N S
TA
RT
ER
?
NO
.
IS
TH
E S
TA
RT
ER
EN
CLO
SU
RE
HO
TT
ER
TH
AN
NO
RM
AL?
YE
S.
CH
EC
K F
OR
LO
W V
OLT
AG
EV
OLT
AG
E U
NB
ALA
NC
EO
VE
RP
RE
SS
UR
ET
IGH
T A
IRE
ND
LOS
S O
F P
HA
SE
ST
AR
TIN
G U
ND
ER
A L
OA
D
NO
.
C
OR
RE
CT
HE
AT
ER
SE
LEC
TIO
N O
R O
VE
RLO
AD
SE
TT
ING
.
YE
S.
C
HE
CK
FO
R B
AD
CO
NN
EC
TIO
NS
AN
D M
AK
E S
UR
E C
ON
DU
IT F
RO
M M
OT
OR
IS
SE
ALE
D W
ITH
ELE
CT
RIC
AL
PU
TT
Y
YE
S.
B
AD
CO
NN
EC
TIO
N W
ITH
IN T
HE
ST
AR
TE
R
NO
.
P
OT
EN
TIA
L P
RO
BLE
M W
ITH
OV
ER
LOA
D R
ELA
Y,
CO
NT
RO
LLE
R,
OR
RIB
BO
N C
AB
LE O
N O
RIG
INA
L IN
TE
LLIS
YS
LES
S T
HE
N 9
5%
NO
MIN
AL
MO
RE
TH
AN
1%
UN
BA
LAN
CE
LOS
S O
F S
TA
GE
ON
2 S
TA
GE
UN
IT
BLO
WN
FU
SE
BA
D C
ON
NE
CT
ION
BU
RN
T C
ON
TA
CT
OR
BLO
WD
OW
N V
ALV
E N
OT
OP
EN
INLE
T V
ALV
E N
OT
CLO
SE
D
= O
VE
RLO
AD
CO
NT
AC
T O
PE
N F
OR
MO
RE
TH
AN
ON
E S
EC
ON
D.
IS T
HE
HE
AT
ER
ELE
ME
NT
OR
OV
ER
LOA
D R
ELA
Y T
HE
PR
OP
ER
SIZ
E?
17
YE
S.
IS C
OO
LAN
T L
EV
EL
CO
RR
EC
T?
NO
.
CO
RR
EC
T C
OO
LAN
T A
ND
TR
Y A
GA
IN
YE
S.
SU
SP
EC
T P
RO
BLE
M W
ITH
CO
OLA
NT
ST
OP
VA
LVE
CH
EC
K W
IRIN
G A
ND
VA
LVE
OP
ER
AT
ION
(S
EE
PR
OC
ED
UR
E 2
.6)
IS T
HIS
TH
E O
RIG
INA
L IN
TE
LLIS
YS
CO
NT
RO
LLE
R?
NO
.
A
NY
CO
NT
RO
LLE
RIN
CLU
DIN
G?
TH
E O
RIG
INA
L IN
TE
LLIS
YS
YE
S.
I
S A
IRE
ND
DIS
CH
AR
GE
TE
MP
ER
AT
UR
E G
RE
AT
ER
TH
AN
210°
F A
T T
IME
OF
SH
UT
DO
WN
?
NO
.
S
EE
P
AG
E 1
8
DO
1S
AN
D 1
M E
NG
ER
IZE
WH
EN
TH
E S
TA
RT
BU
TT
ON
IS
PR
ES
SE
D?
NO
.
PO
TE
NT
IAL
PR
OB
LEM
WIT
H T
RIA
C O
N S
TA
RT
ER
IN
TE
RF
AC
E B
OA
RD
,C
ON
TR
OLL
ER
YE
S.
DO
ES
TH
E U
NIT
SH
UT
DO
WN
2-3
SE
CO
ND
S A
FT
ER
1S
AN
D 1
M E
NE
RG
IZE
D?
YE
S.
PO
TE
NT
IAL
PR
OB
LEM
WIT
H W
IRIN
G O
R A
UX
ILIA
RY
CO
NT
AC
TS
1M
a O
R 1
Sa
SE
& O
RIG
INA
L IN
TE
LLIS
YS
: V
OLT
AG
E A
CR
OS
S C
ON
TA
CT
SH
OU
LD B
E 5
VD
C W
HE
NC
ON
TA
CT
IS
OP
EN
AN
D 0
VD
C W
HE
N C
ON
TA
CT
IS
CLO
SE
D.
SG
IN
TE
LLIS
YS
: V
OLT
AG
E A
CR
OS
S C
ON
TA
CT
SH
OU
LD B
E 1
0-12
VD
C W
HE
NC
ON
TA
CT
IS
OP
EN
AN
D 0
VD
C W
HE
N C
ON
TA
CT
IS
CLO
SE
D.
SE
E P
AR
AG
RA
PH
2.6
NO
.
DO
ES
1S
DE
-EN
ER
GIZ
E A
ND
2M
EN
ER
GIZ
E A
T T
RA
NS
ITIO
N (
10
SE
C)?
NO
.
P
OT
EN
TIA
L P
RO
BLE
M W
ITH
TR
IAC
ON
ST
AR
TE
R I
NT
ER
FA
CE
BO
AR
D,
CO
NT
RO
LLE
R,
1S C
ON
TA
CT
OR
ST
ICK
ING
OR
AU
XIL
IAR
Y C
ON
TA
CT
1S
c O
R 1
Sd.
YE
S.
PO
TE
NT
IAL
PR
OB
LEM
WIT
H W
IRIN
G O
R A
UX
ILIA
RY
CO
NT
AC
TS
1S
a O
R 2
Ma
SE
& O
RIG
INA
L IN
TE
LLIS
YS
: V
OLT
AG
E A
CR
OS
S C
ON
TA
CT
SH
OU
LD B
E 5
VD
C W
HE
NC
ON
TA
CT
IS
OP
EN
AN
D 0
VD
C W
HE
N C
ON
TA
CT
IS
CLO
SE
D.
SG
IN
TE
LLIS
YS
: V
OLT
AG
E A
CR
OS
S C
ON
TA
CT
SH
OU
LD B
E 1
0-12
VD
C W
HE
NC
ON
TA
CT
IS
OP
EN
AN
D 0
VD
C W
HE
N C
ON
TA
CT
IS
CLO
SE
D.
SE
E P
AR
AG
RA
PH
2.6
OR
IG,
SG
, S
E:
ST
AR
TE
R F
AU
LTY
ES
.
DO
ES
UN
IT S
HU
T D
OW
N I
N L
ES
ST
HA
N 1
2 S
EC
ON
DS
AF
TE
R S
TA
RT
-UP
?
18
FR
OM
ST
AR
TE
R F
AU
LT C
HA
RT
NO
CH
EC
K F
OR
PH
AS
E M
ON
ITO
R O
R A
NY
OT
HE
R S
HU
TD
OW
N W
IRE
D T
O B
TS
1-33
& 2
9
OR
IGIN
AL
INT
ELL
ISY
S C
ON
TR
OL
LER
ME
AS
UR
E V
OLT
AG
E A
CT
ER
MIN
AL
BT
S1
-33
AN
D B
TS
1-3
IS T
HE
VO
LTA
GE
GR
EA
TE
R T
HA
N1
10
VA
C?
NO
. B
AD
CO
NT
AC
T O
N E
-ST
OP
YE
S.
M
EA
SU
RE
VO
LTA
GE
AC
TE
RM
INA
L B
TS
1-3
1 A
ND
BT
S1
-3
IS T
HE
VO
LTA
GE
GR
EA
TE
R T
HA
N1
10
VA
C?
NO
. B
AD
1A
TS
YE
S.
ME
AS
UR
E V
OLT
AG
E A
CT
ER
MIN
AL
BT
S1
-29
AN
D B
TS
1-3
DO
ES
VO
LTA
GE
C
ON
TIN
UO
US
LY R
EA
D 1
10
-13
0 V
AC
AT
TIM
E O
FS
HU
TD
OW
N?
YE
S.
C
HE
CK
FO
R B
AD
CO
NT
RO
LLE
R O
R R
IBB
ON
CA
BLE
. R
EC
HE
CK
ST
AR
TE
RS
EQ
UE
NC
E.
19
YE
S.
IS C
OO
LAN
T L
EV
EL
CO
RR
EC
T?
NO
.
CO
RR
EC
T C
OO
LAN
T A
ND
TR
Y A
GA
IN.
YE
S.
SU
SP
EC
T P
RO
BLE
M W
ITH
CO
OLA
NT
ST
OP
VA
LVE
.C
HE
CK
WIR
ING
AN
D V
ALV
E O
PE
RA
TIO
N (
SE
EP
RO
CE
DU
RE
2.5
)
SG
, S
E:
NO
CO
NT
RO
L P
OW
ER
YE
S.
I
S A
IRE
ND
DIS
CH
AR
GE
TE
MP
ER
AT
UR
E G
RE
AT
ER
TH
AN
210°
F A
T T
IME
OF
SH
UT
DO
WN
?
NO
DO
ES
VO
LTA
GE
C
ON
TIN
UO
US
LY R
EA
D 1
10
-13
0 V
AC
AT
TIM
E O
FS
HU
TD
OW
N?
NO
.
CH
EC
K1
AT
S
YE
S.
S
E:
CH
EC
K F
OR
PH
AS
E M
ON
ITO
RS
G: C
HE
CK
FO
R IN
TE
RS
TA
GE
PR
ES
SU
RE
SW
ITC
H O
N 2
ST
AG
E O
R P
HA
SE
MO
NIT
OR
.
= 1
15
VO
LTS
AC
IS
NO
T A
PP
LIE
D T
O T
HE
CO
NT
RO
LLE
R B
UT
CO
NT
RO
LLE
R I
S P
OW
ER
ED
-UP
.
DO
ES
UN
IT S
HU
T D
OW
N I
N L
ES
ST
HA
N 1
2 S
EC
ON
DS
AF
TE
R S
TA
RT
-UP
?
SE
CO
NT
RO
LLE
R:
ME
AS
UR
E V
OLT
AG
E A
CT
ER
MIN
AL
BT
S1-
6 A
ND
J4
-29
SG
CO
NT
RO
LLE
R:
ME
AS
UR
E V
OLT
AG
E A
CP
1 1
0 A
ND
TE
RM
INA
L 1
TB
-1
IS T
HE
VO
LTA
GE
GR
EA
TE
R T
HA
N1
10
VA
C?
IS T
HE
VO
LTA
GE
GR
EA
TE
R T
HA
N1
10
VA
C?
NO
. F
US
E 3
FU
IS
BA
D,
LOW
VO
LTA
GE
OR
TH
E T
RA
NS
FO
RM
ER
IS
BA
D
NO
. F
US
E 2
FU
IS
BA
D,
LOW
VO
LTA
GE
OR
TH
E T
RA
NS
FO
RM
ER
IS
BA
D
YE
S.
M
EA
SU
RE
VO
LTA
GE
AC
TE
RM
INA
L B
TS
1-7
AN
D J
4-2
9
IS T
HE
VO
LTA
GE
GR
EA
TE
R T
HA
N1
10
VA
C?
NO
. B
AD
CO
NT
AC
T O
N E
- S
TO
P
SG
CO
NT
RO
LLE
R:
ME
AS
UR
E V
OLT
AG
E A
CP
1 -
10
AN
D T
ER
MIN
AL
1T
B-4
IS T
HE
VO
LTA
GE
GR
EA
TE
R T
HA
N1
10
VA
C?
NO
. B
AD
CO
NT
AC
T O
N E
-ST
OP
SE
CO
NT
RO
LLE
R:
ME
AS
UR
E V
OLT
AG
E A
CT
ER
MIN
AL
BT
S1-
8 A
ND
J4
-29
DO
ES
VO
LTA
GE
C
ON
TIN
UO
US
LY R
EA
D 1
10
-13
0 V
AC
AT
TIM
E O
FS
HU
TD
OW
N?
YE
S.
M
EA
SU
RE
VO
LTA
GE
AC
P1
- 1
0 A
ND
TE
RM
INA
L 1
TB
2
20
IS T
HE
RO
TA
TIO
N C
OR
RE
CT
?N
O.
DIS
CO
NN
EC
T,
LOC
K A
ND
TA
G P
OW
ER
IN
OF
F P
OS
ITIO
N.
INT
ER
CH
AN
GE
TW
O L
EA
DS
AN
D T
RY
AG
AIN
.
YE
S.
CH
EC
K F
OR
LE
AK
IN
1A
VP
TS
EN
SIN
G L
INE
OR
FA
ULT
Y 1
AV
PT
. SE
EP
RO
CE
DU
RE
2.4
= N
O I
NLE
T V
AC
UU
M S
EN
SE
D 2
SE
CO
ND
S A
FT
ER
ST
AR
TIN
G.
SE
CO
NT
RO
LLE
R:
NO
SU
MP
PR
ES
SU
RE
SE
NS
ED
2 S
EC
ON
DS
AF
TE
R S
TA
RT
ING
.
SE
CO
NT
RO
LLE
R
YE
S.
IS 1
0S
V E
NE
RG
IZIN
G A
T S
TA
RT
?
OR
IG A
ND
SG
CO
NT
RO
LLE
R
IS T
HE
AIR
EN
D T
UR
NIN
G?
IS T
HE
AIR
EN
D T
UR
NIN
G? NO
.
IS
TH
E M
OT
OR
TU
RN
ING
?
NO
.
C
HE
CK
VO
LTA
GE
, S
TA
RT
ER
AN
D M
OT
OR
.
YE
S.
AR
E T
HE
BE
LTS
SLI
PP
ING
?
NO
.
B
RO
KE
N A
IRE
ND
DR
IVE
SH
AF
TY
ES
.
T
IGH
TE
N T
HE
BE
LTS
NO
.
CH
EC
K T
HE
TR
IAC
, W
IRIN
GO
R B
AD
10S
V.
YE
S.
CH
EC
K F
OR
BLO
CK
AG
E I
N S
EN
SIN
G L
INE
FO
R 1
0SV
TO
SU
MP
NO
.
IS
TH
E M
OT
OR
TU
RN
ING
?
NO
. C
HE
CK
VO
LTA
GE
,S
TA
RT
ER
AN
D M
OT
OR
.
YE
S.
A
RE
TH
EG
EA
RS
SP
INN
ING
ON
TH
E S
HA
FT
?
YE
S.
C
HE
CK
FO
R L
OC
KE
D-U
PA
IRE
ND
NO
.
BR
OK
EN
AIR
EN
D D
RIV
E S
HA
FT
OR
IG,
SG
, S
E:
CH
EC
K M
OT
OR
RO
TA
TIO
N
21
..
ME
AS
UR
E T
HE
VO
LTA
GE
ON
TH
E R
ED
AN
D B
LA
CK
WIR
E O
F T
HE
LIM
IT B
OA
RD
SG
IN
TE
LLIS
YS
CO
NT
RO
LLE
R:
IS T
HE
VO
LTA
GE
2V
DC
?
= B
OT
H L
IMIT
SW
ITC
HE
S A
RE
EN
GA
GE
D A
T T
HE
SA
ME
TIM
E.
OR
IGIN
AL
INT
ELL
ISY
S C
ON
TR
OL
LER
:IS
TH
E V
OLT
AG
E 5
VD
C?
NO
.
CH
EC
K F
OR
PR
OB
LEM
WIT
H R
IBB
ON
CA
BLE
S O
RC
ON
TR
OLL
ER
.
NO
.
P
OT
EN
TIA
L P
RO
BLE
M W
ITH
CO
NT
RO
LLE
R.
MO
VE
RE
D W
IRE
TO
TE
RM
INA
L 3
1 O
N P
3 A
ND
ME
AS
UR
EV
OLT
AG
E A
GA
IN.
IS T
HE
VO
LTA
GE
2V
DC
?
NO
.
PO
TE
NT
IAL
BA
DC
ON
TR
OLL
ER
, LI
MIT
BO
AR
D O
R W
IRIN
G.
YE
S.
I
S A
LA
RM
ST
ILL
OC
UR
RIN
G?
ME
AS
UR
E V
OLT
AG
E B
ET
WE
EN
WH
ITE
AN
D B
LA
CK
WIR
E.
ME
AS
UR
E V
OLT
AG
E B
ET
WE
EN
GR
EE
N A
ND
BL
AC
K W
IRE
.
AR
E B
OT
H M
EA
SU
RE
ME
NT
S5
VD
C?
ME
AS
UR
E V
OLT
AG
E B
ET
WE
EN
WH
ITE
AN
D B
LA
CK
WIR
E.
ME
AS
UR
E V
OLT
AG
E B
ET
WE
EN
GR
EE
N A
ND
BL
AC
K W
IRE
.
AR
E B
OT
H M
EA
SU
RE
ME
NT
S1
0-1
2 V
DC
?
NO
.
PO
TE
NT
IAL
PR
OB
LEM
WIT
HR
IBB
ON
CA
BLE
OR
CO
NT
RO
LLE
R.
YE
S.
CH
EC
K F
OR
DIR
TO
N L
IMIT
SW
ITC
HE
S O
RB
AD
LIM
IT B
OA
RD
.
NO
.
PO
TE
NT
IAL
PR
OB
LEM
WIT
HR
IBB
ON
CA
BLE
OR
CO
NT
RO
LLE
R.NO
.
TH
EN
YO
U A
RE
FIN
ISH
ED
YE
S
OR
IG, S
G: S
TE
PP
ER
LIM
IT S
WIT
CH
22
OR
IG,
SG
, S
E:
RE
MO
TE
ST
OP
FA
ILU
RE
= R
EM
OT
E S
TA
RT
BU
TT
ON
IS
PR
ES
SE
D W
HIL
E R
EM
OT
E S
TO
P C
ON
TA
CT
IS
ST
ILL
OP
EN
.
OR
IGIN
AL
INT
ELL
ISY
S C
ON
TR
OL
LER
SG
IN
TE
LLIS
YS
CO
NT
RO
LLE
R
ME
AS
UR
E V
OLT
AG
EB
ET
WE
EN
BT
S2
-6 A
ND
BT
S2
-7
IS T
HE
VO
LTA
GE
0
VD
C?
YE
S.
T
RY
RE
MO
TE
ST
AR
T A
GA
IN.
IF A
LAR
M S
TIL
L O
CC
UR
S,
SU
SP
EC
T P
RO
BLE
MW
ITH
RIB
BO
N C
AB
LE O
R C
ON
TR
OL
LER
FO
R T
HE
OR
IGIN
AL
INT
ELL
ISY
S C
ON
TR
OLL
ER
OR
JU
ST
TH
EC
ON
TR
OLL
ER
FO
R T
HE
SG
.
ME
AS
UR
E V
OLT
AG
EB
ET
WE
EN
P3
TE
RM
INA
L 1
9 &
20
NO
.
S
US
PE
CT
RE
MO
TE
ST
OP
CO
NT
AC
T
IS S
TIL
L O
PE
N.
CO
RR
EC
T P
RO
BLE
M A
ND
TR
Y A
GA
IN.
TO
SIM
ULA
TE
A C
LOS
ED
ST
OP
CO
NT
AC
T,
INS
TA
LL
A T
EM
PO
RA
RY
JU
MP
ER
BE
TW
EE
N T
HE
TE
RM
INA
LS L
IST
ED
AB
OV
E.
SE
IN
TE
LLIS
YS
CO
NT
RO
LLE
R
ME
AS
UR
E V
OLT
AG
EB
ET
WE
EN
J1
TE
RM
INA
L 3
& 4
23
OR
IG,
SG
, S
E:
RE
MO
TE
ST
AR
T F
AIL
UR
E=
RE
MO
TE
ST
AR
T B
UT
TO
N I
S P
RE
SS
ED
AN
D H
ELD
CLO
SE
D F
OR
MO
RE
TH
AN
7S
EC
ON
DS
AF
TE
R A
CO
NF
IRM
ED
ST
AR
T.
OR
IGIN
AL
INT
ELL
ISY
S C
ON
TR
OL
LER
:S
G I
NT
ELL
ISY
S C
ON
TR
OLL
ER
:
DID
TH
E V
OLT
AG
E S
TA
Y A
T 0
VD
C?
YE
S.
S
US
PE
CT
ST
ICK
ING
CO
NT
AC
T O
N R
EM
OT
E S
TA
RT
BU
TT
ON
OR
PLC
.
CO
NN
EC
T D
C V
OLT
M
ET
ER
TO
P3
TE
RM
INA
L 21
& 2
2S
TA
RT
UN
IT U
SIN
G R
EM
OT
E S
TA
RT
BU
TT
ON
AN
D M
ON
ITO
RV
OLT
AG
E F
RO
M A
BO
VE
.V
OLT
AG
E S
HO
ULD
CH
AN
GE
FR
OM
10
-12
VD
C T
O 0
VD
C W
HIL
E T
HE
BU
TT
ON
IS
PR
ES
SE
D A
ND
RE
TU
RN
TO
10
-12
VD
C W
HE
N T
HE
BU
TT
ON
IS R
ELE
AS
ED
.
NO
. T
RY
RE
MO
TE
ST
AR
T A
GA
IN.
IF A
LAR
M S
TIL
L O
CC
UR
S, S
US
PE
CT
PR
OB
LEM
WIT
H I
NT
ELL
ISY
S C
ON
TR
OL
LER
.
SE
IN
TE
LLIS
YS
CO
NT
RO
LLE
R.
CO
NN
EC
T D
C V
OLT
M
ET
ER
TO
J1
TE
RM
INA
L 5
& 6
ST
AR
T U
NIT
US
ING
RE
MO
TE
ST
AR
T B
UT
TO
N A
ND
MO
NIT
OR
VO
LTA
GE
FR
OM
AB
OV
E.
VO
LTA
GE
SH
OU
LD C
HA
NG
E F
RO
M 5
VD
C T
O 0
VD
C W
HIL
E T
HE
BU
TT
ON
IS
PR
ES
SE
D A
ND
RE
TU
RN
TO
5 V
DC
WH
EN
TH
E B
UT
TO
NIS
RE
LEA
SE
D.
CO
NN
EC
T D
C V
OLT
ME
TE
R T
O B
TS
2-4
AN
D B
TS
2-5
.S
TA
RT
UN
IT U
SIN
G L
OC
AL
ST
AR
T B
UT
TO
N.
LOA
D U
NIT
.S
TO
P U
NIT
US
ING
RE
MO
TE
ST
OP
BU
TT
ON
.R
ES
TA
RT
UN
IT U
SIN
G R
EM
OT
E S
TA
RT
BU
TT
ON
AN
D M
ON
ITO
RV
OLT
AG
E F
RO
M A
BO
VE
.V
OLT
AG
E S
HO
ULD
CH
AN
GE
FR
OM
5 V
DC
TO
0 V
DC
WH
ILE
TH
EB
UT
TO
N I
S P
RE
SS
ED
AN
D R
ET
UR
N T
O 5
VD
C W
HE
N T
HE
BU
TT
ON
IS R
ELE
AS
ED
. R
EM
EM
BE
R,
TH
E B
UT
TO
N M
US
T B
E C
LOS
ED
FO
RT
WO
SE
CO
ND
S A
ND
NO
LO
NG
ER
TH
AN
7 S
EC
ON
DS
.
24
OR
IG,
SG
, S
E:
SH
OR
T S
EP
AR
AT
OR
ELE
ME
NT
LIF
E
HIG
H P
RE
SS
UR
E D
IFF
ER
EN
TIA
L?Y
ES
BY
PA
SS
ED
IN
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1.1 Power Outage:
BackgroundPower outage may have occurred during operation. Any power outage in excessof 250 ms (.25 sec) will cause the control circuit to reset. This can occur ininstallations with automatic reset circuit breakers. Electrical disturbances canalso occur from power company interruptions such as lightning storms. This lossof power will de-energize the contact coils, relays, and solenoids. The loss ofpower to the Intellisys power supply (16 VAC) will cause the system to reset toan off state which causes the displayed message of “Ready to Start”.
ProcedurePower outages can be diagnosed by using power line recording andmeasurement instrumentation. A low cost method of measuring this typeoccurrence is to utilize a FLUKE 87 recording voltmeter. This meter can detectthe loss of power as short as 100 ms (.1 Sec). By measuring secondary 120VAC or 16 VAC circuits with the meter set to “VOLTS AC”, 100 ms record mode,loss of power can be measured. To measure the 120 VAC, connect the meter toJ5 terminal 36 & 35. To measure the 16 VAC, connect the meter to J5 terminal31 and 30.
1.2 Voltage Sag:
BackgroundIncoming voltage dips below 30% of rated voltage (example 460 VAC nominal =322 VAC). Any voltage sag in excess of 250 ms (.25 sec) in duration will causethe control circuit to reset. This can occur in installations with phase unbalanceproblems, loss of phase, harmonic distortion, poorly distributed powermanagement (i.e. undersized step down transformers for application loading),excessive wire length, and undersized wiring. Electrical disturbances, such aslightning storms, can also cause voltage sags. The voltage sag will de-energizethe contact coils, relays, and solenoids. The voltage sag to the Intellisys powersupply (16 VAC) will cause the system to reset to an off state which causes thedisplayed message of “Ready to Start”.
ProcedureVoltage sags can be diagnosed by using power line recording and measurementinstrumentation. A low cost method of measuring this type occurrence is toutilize a FLUKE 87 recording voltmeter. This meter can detect the voltage sag asshort as 100 ms (.1 Sec). By measuring secondary 120 VAC or 16 VAC circuitswith the meter set to “VOLTS AC”, 100 ms record mode, the voltage sag can bemeasured. To measure the 120 VAC, connect the meter to J5 terminal 36 & 35.To measure the 16 VAC, connect the meter to J5 terminal 31 and 30.
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1.3 Grounding Problems:
BackgroundA poor ground system can cause severe electrical problems. Electrical controlsystems can experience both over voltage and voltage sag conditions due to apoor ground. This can cause nuisance shutdowns, damage to power supplycircuits, communications errors, and even be a safety hazard for fault conditions.Electrical fault conditions must have a low resistance path to earth ground. Theground conductor supplied to the machine should be sized and installed per NECand any additional local wiring requirements. The utilization of metal conduit orair piping that is attached to the air compressor is not considered an adequateground.
Typically, building codes require that structural steel must be grounded per NEC.Structural supports such as steel girders and beams should be electricallyattached to earth ground via a buried grid. Verify the supplied ground wire meetsampacity requirements per code and that it connects to the approved buildingearth ground grid.
Some environments may have a distorted or noisy ground. This is usually anindication that current is flowing into earth ground. This can be caused by faultyelectrical equipment in the area that is attached to the ground grid. Groundcurrents can be present in environments that utilize variable speed inverter typemotor drives, such as variable frequency drive (VFD). Environments that utilize alarge number of switching power supplies can also cause ground currents. Mostall computer systems use switching power supplies. Many of these groundcurrents can be generated by high frequency (above 60 HZ) disturbances thatare known as harmonic distortion. Because of the high frequency, they are hardto analyze and measure. An effective safeguard against this type of groundcurrent is to minimize the length of wire to the ground grid. The use of braidedground wire minimizes high frequency distortion. If braided wire is not available,then standard stranded wire can be used if ampacity of wire is increased to 3Xthe rated value.
Verify the ground grid point is free from corrosion or moisture that may prohibit alow resistance ground. It is important to verify that other electrical equipment thatis electrically bonded to the air compressor is properly grounded as well. Thiswill include any electrical device that is structurally connected to conductive airpiping/plumbing originating at the air compressor. Wired interfaces such asremote start/stop, remote starters, sequencers, sequencer interfaces, IntellisysSequence Control, Intellisys Remote Interface should also be properly grounded.
ProceduresA practical way to measure the ground current is to use an ammeter:Externally induced ground current (noise), power off state:A Fluke 87 or equivalent meter can be used to measure ground current.
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Disconnect power from machine.Set the meter for amps AC and connect the meter in series with the ground wireprovided to the machine. If a recording meter is used (Fluke 87), set to 100 msrecord mode. A recording meter is the preferred measurement for intermittentproblems.Record value in A rms.Set the meter for DC amps and record value in Amps DC.The expected measured value should be 0 .0 Amps.If measured value is greater than, or equal to, .25 Amps, a problem exists.Isolate compressor package from other equipment to determine the source ofground current.
Internally induced ground current, power on state:A Fluke 87 (or equivalent) meter can be used to measure ground current.Disconnect power from machine.Set the meter for amps AC and connect the meter in series with the ground wireprovided to the machine. If a recording meter is used (Fluke 87) then set to 100ms record mode. A recording meter is the preferred measurement forintermittent problems.Apply power to machine.Record value in A rms.Set the meter for DC amps and record value in Amps DC.The expected measured value should be 0 .0 Amps.If measured value is greater than, or equal to, .25 Amps, a problem exists.Isolate electrical devices in compressor package and determine the source ofground current.Causes may include: faulty wiring, moisture contamination of any electricalconnections, motor overloads (current transformer type), control transformer,insulation breakdown of power leads, externally wired devices (remote start/stop,remote starter wiring, Sequencer, etc.)
Internally induced ground current, Compressor Run Mode:A Fluke 87 (or equivalent) meter can be used to measure ground current.Disconnect power from machine.Set the meter for amps AC and connect the meter in series with the ground wireprovided to the machine. If a recording meter is used (Fluke 87), set to 100 msrecord mode. A recording meter is the preferred measurement for intermittentproblems.Apply power to machine.Start machine.Record value in A rms.Set the meter for DC amps and record value in Amps DC.The expected measured value should be 0 .0 Amps.Load machine.Record value in A rms.
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Set the meter for DC amps and record value in Amps DC.If measured value is greater than, or equal to, .25 Amps, a problem exists.Isolate electrical devices in compressor package and determine the source ofground current.Causes may include: faulty wiring, moisture contamination of electricalconnections, motor overloads (current transformer type), control transformer,insulation breakdown of power leads, externally wired devices (remote start/stop,remote starter wiring, Sequencer, IRI, etc.)
1.4 Intellisys 16 VAC supply:
BackgroundThe Intellisys power supply is fed from the 16 VAC center-tap secondary of thecontrol power transformer T1. The center-tap indicates a central tap between the16 VAC winding. This means the expected voltage across one end of thewinding and the center-tap will be 8 VAC. The expected reading of the 16 VACsignal should have a tolerance of +/-15 %. The 16 VAC center-tap signal is fedto the Intellisys through the J4 connector. The signal is rectified by diodes CR1and CR2. The resulting rectified DC signal is approximately 10.5 VDC. TheIntellisys is designed to accommodate +/- 25 % tolerance. Deviations in excessof +/-25%, or a loss of this signal, can cause the machine to shut down and resetto “Ready to Start”.
ProcedureThis voltage measurement can be made with a Fluke 87 meter (or equivalent). Arecording meter (Fluke 87) is preferred for intermittent problems. Set meter forVolts AC and connect as noted.
Connect from J4-30 to J4-31.Expected value =16 VAC +/- 2.4 VACConnect from J4-29 to J4-30.Expected value = 8 VAC +/- 1.2 VACConnect from J4-29 to J4-31.Expected value = 8 VAC +/- 1.2 VACConnect from J4-28 to J4-29.Expected value = 10.5 VDC +/- 1.6 VDC
If the expected values are not observed, possible causes may include:Primary voltage is in excess of 15% tolerance.Wiring fault: Check primary and secondary wiring for errors, loose connection orcrimp, frayed ends, insulation breakdown, moisture contamination.Fuse problem: blown fuse (primary or secondary), loose connection, voltage dropacross fuse: >.5 VAC excessive control system current: Remove power anddisconnect all but J5 connector to Intellisys (also remove option prom andcommunications wiring). Apply power and record measurements. If
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measurements return to normal, repeat procedure and use process of eliminationto find cause.
1.5 External 5 VDC Short Circuit:
BackgroundThe Intellisys provides two 5 VDC signals for external use. The logic supplyvoltage is used by the Intellisys to supply power for internal circuitry such as theEPROM, RAM, Microprocessor, etc. The logic supply is also used to supplypower to an external device known as the “Option Module”. This connection ismade via connector J11. J11 is a 5-pin connector located on the left side of thecontroller (viewed from the front). The “Option Module” should always beinstalled or removed with power off. Note: the “Option Module” can be potentiallydamaged if installed with power on. Installing the module with power on cancause a latch-up condition which can create an excessive amount of currentdraw. This condition can cause the 5 VDC logic supply to sag below 4.5 VDC,which will create abnormal controller behavior.An intermittent connection to the “Option Module” can cause the same latch-upcondition as installing it with power on. Intermittent connections can be causedby improper installation, bent connection pins, moisture contamination, corrosionof electrical contacts, or excessive vibration.
ProcedureThis voltage measurement can be made with a Fluke 87 meter (or equivalent). Arecording meter (Fluke 87) is preferred for intermittent problems. Remove powerfrom machine. Remove back cover of Intellisys and locate J11 connector.Insure static precautions are used when handling circuit board. Re-apply powerto machine. Set meter for Volts DC and connect and take measurements asnoted:
Connect from J11-1 to J11-5 (Top and bottom pin)Expected value = 5 VDC +/- .2 VDC
A second 5 VDC signal from the Intellisys is supplied to provide power for thesensors. This signal is externally supplied through J2 and J3 connectors. Thissignal is provided for both pressure transducers and thermistors (temperature). Ifthis signal is short circuited externally, abnormal controller behavior will occur.This could cause sensor reading errors, invalid calibration, sensor faults, sensorwarnings, or general shutdown “Ready to Start”. Potential root causes includewiring fault to ground (chassis, sensor ground, or shield wire), moisture/corrosioncontamination of connector or sensor, and solenoid fault to pressure transducerchassis.
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This voltage measurement can be made with a Fluke 87 meter (or equivalent). Arecording meter (Fluke 87) is preferred for intermittent problems. Set meter forVolts DC and connect and take measurements as noted:
Connect from J3-25 to J3-24Expected value = 5.0 VDC +/- .2 VDC
1.6 Environmental Problems:
Moisture:BackgroundMoisture problems are typically encountered in outdoor applications. NEMA 4-rated starter enclosures should be specified for these environments to minimizemoisture contamination. Moisture contamination can also be caused by thecondensation of saturated air inside the starter enclosure. The presence ofmoisture can lead to a multitude of electrical connection related problems.Moisture can accelerate corrosion build-up on metal surfaces typically found inelectrical connection points. The corrosion can create an open circuit betweenthe wire and the electrical contact. Corrosion can even cause a short circuit toadjacent contact points. These types of faults are generally intermittent and areaffected by temperature, the total amount of moisture, and vibration. Visualinspection is the best method of detecting these types of problems.
Procedure :
Remove power from machine.
Visually inspect all terminal connections inside the starter enclosure. Thisincludes all wiring that originates and ends at a screw terminal.
Unplug all connectors from the Intellisys controller. Remove “Option Module”.Visually inspect all mating contact points at these connections.
Remove back cover from Intellisys. Insure static precautions are utilized beforehandling circuit board. Visually inspect all electrical connectors. This includesbattery contact BAT1 (if available).
1.7 Temperature:
BackgroundAmbient operating temperature range is specified as 35° F to 115° F. Outdoormodification option extends the ambient operating temperature range from –10°F to 115° F. If these limits have been exceeded, abnormal operation can occur.Many semiconductors inside the Intellisys have a maximum operating
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temperature of 158° F. Although this is 43° F margin above ambient conditions,the rise above ambient must be accounted for. The typical rise above ambientinside the starter enclosure is 20° F. This is due to heat generated by theelectrical equipment inside the enclosure, such as the control transformer,contactors,etc. External factors can cause the rise above ambient to exceed thisvalue. These factors include improper installation spacing requirements,ventilation problems, direct sunlight exposure, etc.
Exceeding these temperature limits can cause many electrical problemsincluding the Intellisys. Intellisys problems include shutdown “Ready to Start”,blank or abnormal display problems, and memory problems.
ProcedureTo test the system for temperature related problems a temperature probe can beused. Measurements should be made inside the starter enclosure with theenclosure door shut. If possible, take the measurements in the upper half of theenclosure to get worst case readings.
1.8 Vibration:
BackgroundExcessive vibration or shock can cause intermittent electrical connections.Excessive vibration and shock can cause poor terminal and crimp connections.Screw terminals can become loose which will cause intermittent open circuits tooccur. This can lead to arcing and even faults to adjacent circuits. Crimpedconnections, such as terminal spade lugs (Faston), can fatigue and also causeopen circuit conditions.
ProcedureTo inspect for loose wiring caused by vibration and shock use the followingprocedure:
Remove power from machine.Visually inspect all electrical connections for evidence of loose wiring, arcing, andfrayed wiring.Manually pull each wire at the terminated end and inspect for loose wiring. 5-10pounds of pull force should be asserted.
1.9 Remote Alarm applications:
BackgroundThe remote alarm feature of the Intellisys provides a volt-free form “C” relaycontact for application use. The contacts are rated for a maximum of 5 Amps,250 VAC. This rating is specified for a resistive load, such as an incandescent
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lamp. If an inductive load is used, such as a relay coil, the rating should bereduced to maximum of 2.5 Amps, 250 VAC.
The use of inductive loads can cause excessive arcing of these contacts.Excessive arcing can cause radiated interference (RFI) that can affect theIntellisys. An effective way to minimize this interference is to install a RC networkknown as an “Arc Suppressor”. The RC network can be installed across theform “C” contacts that are used in the application. Arc suppressors are normallysized for specific applications. The general-purpose arc suppressorP/N…39203443 used in the starter circuit (RC1) can be used for mostapplications.
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2.1 STEPPER MOTOR TEST PROCEDURE
BackgroundThe stepper motor is a motor that can be moved in discrete increments of .9° forthe Original Intellisys and .45° for the SG Intellisys. The motor is a constanttorque device that is controlled by driver chips on the starter interface board orthe power supply board. The main problem that can occur is that a windingshorts either to itself, the other winding or to the casing.
ProcedureDisconnect the Stepper Motor from the board.
Measure the resistance between the brown and blue wires.Measure the resistance between the green/yellow and black wires.
Both sets of measurements should be per below.
4” and 6” inlet valve = 5-7 OHMS8” inlet valves = 11-13 OHMS
If not within this range, replace the Stepper Motor.
Measure resistance between the brown wire and the case of the motor.Measure resistance between the blue wire and the case of the motor.Measure resistance between the green/yellow wire and the case of the motor.Measure resistance between the black wire and the case of the motor.
All of these should measure as an open circuit or “OL” on a digital meter. If not,this indicates a short in the motor windings and the motor should be replaced.
Measure resistance between the brown wire and the green/yellow wire.Measure resistance between the brown wire and the black wire.Measure resistance between the blue wire and the green/yellow wire.Measure resistance between the blue wire and the black wire.
All of these should measure as an open circuit or “OL” on a digital meter. If not,this indicates a short in the motor windings and the motor should be replaced.
2.2 DRIVER CHIP TEST
BackgroundThe stepper motor is moved by electrical signals received from componentscalled driver chips. The driver chips are located at position U14 and U15 on thestarter interface board for the Original Intellisys and at positions U2 and U7 onthe power supply board for the SG Intellisys. The signal turns off and on and
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reverses polarity to cause the stepper motor to move in the proper direction. Ashorted stepper motor will almost always damage the driver chips on the OriginalIntellisys but will simply illuminate an overload on the SG Intellisys. See FSM formore information on the SG.
ProcedureDisconnect the Stepper Motor leads from the board. Measure resistancebetween (starter interface board BTS-3 and BTS3-7, also BTS3-8 and BTS3-9),SG Power Supply Board J3 & 2 and J3 1&2 and J3 3&4). If any of these do notread as an open circuit, then the associated board is faulty.
Next, determine if the driver chips are sending a signal to the Stepper Motor.
Use a driver signal indicator as per page 34 in section “B” of the blue FieldService Manual.Connect the signal indicator in parallel with the Stepper Motor leads.Power the unit up.The lights should sequence as indicated on the signal sheet. If either set of lightsfails to light or stay on continuously, either the driver chips are bad or thecontroller is not sending the step and direction signal.
Next, determine if the controller is sending the direction and step signal. Seebelow for SG Controller. On the original Intellisys Starter Interface Boardconnect a DC voltmeter to terminal number 17 on PAL chip U13 and BTS3-1.Power the compressor up and see if the voltage changes from 0 to 5 and thenback to 0. If so, the controller is sending the correct direction signal.
Next, connect the DC voltmeter to Terminal 18 on component U13 and BTS3-1.
The step and direction signal for the SG Controller connects to Terminal J4 onthe Power Supply Board. Connect a DC voltmeter to terminal number J4Terminal 3 and J4 Terminal 2.Power the compressor up and see if the voltage changes from 0 to 6-12 and thenback to 0. If so, the controller is sending the correct direction signal.
Next connect the DC voltmeter to Terminal 18 on component U13 and BTS3-1.See FSM Section B, Sheet 26 in the Blue Book for more information ondirection and step signal for the SG Controller.
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2.3 LIMIT BOARD TEST PROCEDURE
Background
The limit board contains two optical switches each of which emits an infrared lightbeam. When the light beam is interrupted, the voltage changes in a circuit thattells the controller the position of the valve.
ProcedureTo perform this procedure, disconnect, lock and tag the incoming power. Makethe volt meter connections leaving the limit board wired. Then reapply power totake the readings.
Connect a DC voltmeter to the red wire and black wire.
You should measure approx. 5 VDC for the original Intellisys Controller with theStarter Interface Board. If not, there is a problem with the controller or ribboncable.
On the SG Controller, a measurement of 2 VDC is good. Zero volts mean a badcontroller and 12 volts means a bad limit board.
Next connect a DC volt meter to white and black wire.Power up the unit and manually move the inlet valve so the tang is in the closedlimit switch.
The Originally controller should measure 5 VDC.The SG controller should measure 10-12 volts DC.If not, the limit board is bad.
Next, connect a DC voltmeter to green and black wire.Power up the unit and manually move the inlet valve so the tang is in the openlimit switch.
The Original controller should measure 5 VDC.The SG controller should measure 10-12 volts DC.If not, the limit board is bad.
See FSM Section B, Sheet 27, in the blue Field Service Manual for moreinformation pertaining to the limit board on the SG Controller.
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2.4 PRESSURE SENSOR CHECK OUT
BackgroundThe pressure sensors used on the Intellisys controllers use a 5 VDC supply andturn it into a varying voltage signal to the controller. The SE and Original use a0-50 mv signal and the SG uses a .5-4.5 VDC signal. Both supply and signalvoltages can be measured. The Sensor can also be checked out with it removedfrom the unit.
ProcedureOriginal Intellisys Controller or SE Intellisys
Measure voltage on red and black wire.Should be 5 VDC+/- .2 VDC.Measure voltage between white and green: 0 psi = 0.0 mv +/- 5.0 mv.Disconnect sensor and measure resistance between red and black wire. Theresistance should be 405 to 600 ohms.Disconnect sensor and measure resistance between white and green wire. Theresistance should be 575 to 1195 ohms.Disconnect sensor and measure from each wire to the casing of the sensor.Should read as an open circuit.
SG Intellisys Controller
Measure voltage on red and black wire.Should be 5 VDC +/- .2 VDC.Measure voltage white to black: 0 psi = 0.5 VDC +/-.1V (i.e. 1 psi = .01777 VDC)Disconnect sensor and measure from each wire to the casing of the sensor:Should read as an open circuit.
2.5 TRIAC OUTPUTS
BackgroundTriacs can be thought of as a solid state relay operated by a 5 VDC signal. Oneof the unusual things about a Triac is that the output voltage cannot bedetermined if the Triac is off or on unless there is a load such as a solenoidconnected to the output. It is a good practice to carry a known goodincandescent light that can be connected to the output when testing for outputvoltage using a digital voltmeter.
One of the main causes of a failed triac is the coil or solenoid that it operates hasa short circuit causing the current to exceed the capabilities of the triac.
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ProcedureWith a known good incandescent light connected to the output terminal, a digitalvoltmeter can easily read whether or not the triac is on or off. 115 VAC meanson, a 0 VAC means off. This is the best way to monitor outputs on any IntellisysController.
For the original Intellisys Controller there is an additional problem to determinewhether the faulty part is the controller or the Starter Interface Board.
Refer to Section B, Page 28, in the blue Field Service Manual for assistancein determining the faulty part.
2.6 AUXILIARY CONTACTS
BACKGROUNDAuxiliary contacts are small contacts that are mounted on the front or sides ofstarters. These contacts operate at the same time as the starter. The contactscan be either normally open or normally closed. Some of the contacts are usedin both the 120 VAC control circuit and the low voltage control circuit for feedbackto the Intellisys controller. The procedure below covers how and where to testthe auxiliary contacts that are in the low voltage circuits.
PROCEDUREOriginal Intellisys ControllerContact 1Ma (mounted on the 1M starter contactor.)Connect voltmeter set to volts DC to terminals BTS2-15 & 14 on the starterinterface board. You should read 5 VDC when 1M is de-energized and 0 VDCwhen 1M is energized.
Star Delta Starting OnlyContact 1Sa (mounted on the 1S starter contactor).Connect voltmeter set to volts DC to terminals BTS2-13 & 12 on the starterinterface board. You should read 5 VDC when 1S is de-energized and 0 VDCwhen 1S is energized.
Star Delta Starting OnlyContact 2Ma (mounted on the 2M starter contactor).Connect voltmeter set to volts DC to terminals BTS2-13 & 12 on the starterinterface board. You should read 5 VDC when 2M is de-energized and 0 VDCwhen 2M starter is energized.
SE Intellisys ControllerContact 1Ma (mounted on the 1M starter contactor).
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Connect voltmeter set to volts DC to terminals J1-10 & 9. You should read 5 VDCwhen 1M is de-energized and 0 VDC when 1M is energized.
Star Delta Starting OnlyContact 1Sa (mounted on the 1S starter contactor).Connect voltmeter set to volts DC to terminals J1-8 & 7. You should read 5 VDCwhen 1S is de-energized and 0 VDC when 1S is energized.
Star Delta Starting OnlyContact 2Ma (mounted on the 2M starter contactor).Connect voltmeter set to volts DC to terminals J1-8 & 7. You should read 5 VDCwhen 2M is de-energized and 0 VDC when 2M starter is energized.
SG Intellisys ControllerContact 1Ma (mounted on the 1M starter contactor).Connect voltmeter set to volts DC to terminals P3-8 & 7. You should read 10-12VDC when 1M is de-energized and 0 VDC when 1M is energized.
Star Delta Starting OnlyContact 1Sa (mounted on the 1S starter contactor).Connect voltmeter set to volts DC to terminals P3-9 &1 0. You should read 10-12 VDC when 1S is de-energized and 0 VDC when 1S is energized.
Star Delta Starting OnlyContact 2Ma (mounted on the 2M starter contactor).Connect voltmeter set to volts DC to terminals P3-9 & 10. You should read 10-12 VDC when 2M is de-energized and 0 VDC when 2M starter is energized.
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3.1 Power Outage:
BackgroundPower outage may have occurred during operation. Any power outage in excessof 250 ms (.25 sec) will cause the control circuit to reset. This can occur ininstallations with automatic reset circuit breakers. Electrical disturbances canalso occur from power company interruptions such as lightning storms. This lossof power will de-energize the contact coils, relays, and solenoids. The loss ofpower to the Intellisys power supply (24 VAC) will cause the system to reset toan off state which causes the displayed message of “Ready to Start”.
ProcedurePower outages can be diagnosed by using power line recording andmeasurement instrumentation. A low cost method of measuring this typeoccurrence is to utilize a FLUKE 87 recording voltmeter. This meter can detectthe loss of power as short as 100 ms (.1 Sec). By measuring secondary 120VAC or 24 VAC circuits with the meter set to “VOLTS AC”, 100 ms record mode,loss of power can be measured. To measure the 120 VAC, connect the meter toP1 terminal 1 & 10 on the controller. To measure the 24 VAC, connect the meterto J1 terminal 1 and 2 on the power supply board. To measure the 12 VDC to thecontroller, connect the meter set in volts DC to J4 terminal 1 & 2 on the powersupply board.
3.2 Voltage Sag:
BackgroundIncoming voltage dips below 30% of rated voltage (example 460 VAC nominal =322 VAC). Any voltage sag in excess of 250 ms (.25 sec) in duration will causethe control circuit to reset. This can occur in installations with phase unbalanceproblems, loss of phase, harmonic distortion, poorly distributed powermanagement (i.e. undersized step down transformers for application loading),excessive wire length, and undersized wiring. Electrical disturbances, such aslightning storms, can also cause voltage sags. The voltage sag will de-energizethe contact coils, relays, and solenoids. The voltage sag to the Intellisys powersupply (24VAC) will cause the system to reset to an off state which causes thedisplayed message of “Ready to Start”.
ProcedureVoltage sags can be diagnosed by using power line recording and measurementinstrumentation. A low cost method of measuring this type occurrence is to utilizea FLUKE 87 recording voltmeter. This meter can detect the loss of power asshort as 100 ms (.1 Sec). By measuring secondary 120 VAC or 24 VAC circuitswith the meter set to “VOLTS AC”, 100 ms record mode, loss of power can bemeasured. To measure the 120 VAC, connect the meter to P1 terminal 1 & 10 on
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the controller. To measure the 24 VAC, connect the meter to J1 terminal 1 and 2on the power supply board. To measure the 12 VDC to the controller, connectthe meter set in volts DC to J4 terminal 1 & 2 on the power supply board.
3.3 Intellisys 24 VAC Supply:
BackgroundThe Intellisys power supply is fed from the 24 VAC secondary of the controlpower transformer T1. The expected reading of the 24 VAC signal should have atolerance of +/-15 %. The 24 VAC is fed to the power supply board through theJ1 connector. The signal is rectified by diodes. The resulting rectified DC signalis approximately 12 VDC. The Intellisys is designed to accommodate +/- 25 %tolerance. Deviations in excess of +/-25%, or a loss of this signal, can cause themachine to shut down and reset to “Ready to Start”.
ProcedureThis voltage measurement can be made with a Fluke 87 meter (or equivalent). Arecording meter (Fluke 87) is preferred for intermittent problems. Set meter forvolts AC and connect as noted.
Connect from J1-1 to J1-2.Expected value = 24 VAC +/- 3.6 VACSet meter to volts DCConnect from J2-1 to J2-2.Expected value = 12 VDC +/- .6 VDC
If the expected values are not observed, possible causes may include:Primary voltage in excess of 15% tolerance.Wiring fault: Check primary and secondary wiring for errors, loose connection orcrimp, frayed ends, insulation breakdown, moisture contamination.Fuse problem: Blown fuse (primary or secondary), loose connection, voltagedrop across fuse: >.5 VAC, excessive control system current: Remove power anddisconnect all but J2 connector to Intellisys (also remove option prom andcommunications wiring). Apply power and record measurements. Ifmeasurements return to normal, repeat procedure and use process of eliminationto find cause.
3.4 External 5 VDC Short Circuit:
BackgroundThe Intellisys provides two 5 VDC signals for external use. The logic supplyvoltage is used by the Intellisys to supply power for internal circuitry such as theEPROM, RAM, Microprocessor, etc. The logic supply is also used to supplypower to an external device known as the “Option Module”. This connection is
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made via connector P9. P9 is a 5-pin connector located on the left side of thecontroller (viewed from the front). The “Option Module” should always beinstalled or removed with power off. Note: the “Option Module” can be potentiallydamaged if installed with power on. Installing the module with power on cancause a latch-up condition which can create an excessive amount of currentdraw. This condition can cause the 5 VDC logic supply to sag below 4.5 VDCwhich will create abnormal controller behavior.An intermittent connection to the “Option Module” can cause the same latch-upcondition as installing it with power on. Intermittent connections can be causedby improper installation, bent connection pins, moisture contamination, corrosionof electrical contacts or excessive vibration.
ProcedureThis voltage measurement can be made with a Fluke 87 meter (or equivalent). Arecording meter (Fluke 87) is preferred for intermittent problems. Remove powerfrom machine. Remove back cover of Intellisys and locate P9 connector. Insurestatic precautions are used when handling circuit board. Re-apply power tomachine. Set meter for volts DC and connect and take measurements as noted:
Connect from P9-1 to P9-5 (top and bottom pin).Expected value = 5 VDC +/- .2 VDC.
A second 5 VDC signal from the Intellisys is supplied to provide power for thesensors. This signal is externally supplied through P5 and P6 connectors. Thissignal is provided for both pressure transducers and thermistors (temperature). Ifthis signal is shorted externally, abnormal controller behavior may occur. Thiscould cause sensor reading errors, invalid calibration, sensor faults, sensorwarnings, or general shutdown “Ready to Start”. Potential root causes includewiring fault to ground (chassis, sensor ground, or shield wire), moisture/corrosioncontamination of connector or sensor and solenoid fault to pressure transducerchassis.
This voltage measurement can be made with a Fluke 87 meter (or equivalent). Arecording meter (Fluke 87) is preferred for intermittent problems. Set meter forvolts DC and connect and take measurements as noted:
Connect from P5-1 to P5-2.Expected value = 5.0 VDC +/- .2 VDC.
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4.0 External Electrical Disturbances:
BackgroundThese are defined as sources of interference that can adversely affect signalintegrity of control systems and wiring interfaces. These types of problems canbe caused by Radio Frequency Interference (RFI), Electro-Magnetic Interference(EMI), Electro-Static Discharge (ESD), lightning disturbances, and power linetransients and surges. Control circuits that are the most susceptible to thesedisturbances include power supplies, sensors (pressure and temperature), andexternal interface wiring such as remote starter interface and communicationsport interfaces. Note: The effects of external electrical disturbances aremagnified if the equipment is not properly grounded (see Grounding Problems).
Intellisys based control systems have been designed and tested for immunityagainst external electrical disturbances. The test standard is derived from theEC Directive (European Community Directive) for heavy industrial applicationsand is known as EN50082-2. These test standards are specified to simulatesevere electrical disturbances that can occur in heavy industrial applications.Intellisys control systems have passed at the levels specified.
The test parameters and compliance criteria are listed below:
EN 61000-4-2 Electrostatic Discharge Immunity+/-4 KV contact discharge, +/- 8 KV air discharge
ENV50140 Radiated Electromagnetic Field Immunity10 V/m, 80 to 1000 MHz (80% AM w/1kHz sinewave)900 +/- MHz, 10 V/m pulse modulated at 200 Hz to 50 % dutycycle per ENV50204
ENV50141 Conducted RF Disturbance Immunity10 V rms (80% AM w/ 1 kHz sinewave) on all power and signallines
EN 610004-4 Electrical Fast Transient/Burst Immunity+/- 2 kV on all power signals lines
EN 61000-4-8 Power Frequency Magnetic Field Immunity30 A rms/m continuous at 50 Hz
RFI and EMI disturbances can be airborne as well as conducted into theequipment. The source of this type of disturbance includes radio transmitters,variable speed motor drives (VFD), switching power supplies, arc welding
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equipment, or other equipment that exhibits excessive electrical arcing duringoperation (i.e. DC brush motors). The level of disturbance is generally known asfield strength. The electric field strength is measured in volts per meter (V/m). Ahand held 5 watt transmitter can generate 10 V/m electric field strength at adistance of approximately 1 foot. To alleviate potential RFI and EMI disturbances,ensure the equipment is properly grounded (see Grounding Problems) andeliminate close range exposure to radiating devices.
ESD disturbances can be airborne as well as conducted into the equipment. TheESD event occurs when an electrical charge is dissipated into the equipment.This event is usually random and normally occurs with human interaction. Ahuman can carry an extremely high electrical charge (8 kV) by simply walkingacross an insulated surface. Other sources include charged ungroundedmaterial that can come into contact with the equipment (example: The presenceof air flowing through a plastic pipe can cause an electrical charge to propagatealong the surface of the pipe and arc into a conductive surface). ESD safeguardmeasures should be used when handling electronic circuit boards andequipment. (See Field Service manual - Large Rotary (blue book) Section “B”Sheet 12).
Lightning disturbances will generally occur more often in outdoor applications.Obvious direct exposure to weather conditions will increase the chances of alightning strike. Direct lightning strikes can cause severe electrical damage tocontrols, motors and wiring. The best precaution for this is to avoid openexposure and ensure adequate facility protection such as lightning arrestors.
Power line transients and surges can cause a variety problems in the electricalsystem . The transient or surge is defined as a random abnormal condition thatresults in a distorted power signal. The distortion can usually be detected bymeasuring the voltage of the incoming power signal. Power line transientstypically occur in fractions of seconds (less than 100 ms) and are hard to detectwith standard volt meters. An oscilloscope is usually required for measuringtransients. Power line surges occur at longer intervals (>100 ms) and can bedetected more easily with the use of a recording voltmeter (such as Fluke 87). Ifthe voltage level of the transient or surge is high enough, abnormal systembehavior can occur. These problems include:
Erratic control system behavior:Fuse blowingControl resetErratic Triac operation (output)
Control power transformer insulation breakdown:Motor winding insulation damageSolenoid coil winding insulation damage
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Transients and surges can be caused by a variety of reasons. A few of theseinclude:
Poor or ungrounded equipment.Improperly sized power distribution systems that generate disturbances whenswitching large inductive or capacitive loads.Ground fault conditions.Equipment phase to ground or phase to phase conditions.Arc welding to compressor or surrounding equipment.Lightning strike to electrical distribution systemVariable speed drive applications (Induction or DC motors)
Intellisys control systems have sufficient protection against typical electricaldisturbances that can occur in the industrial environment. These systems havebeen designed to exceed the highest levels specified within EN50082-2 (seeabove). If the level of electrical disturbance is known to exceed these levels,added measures of protection will be required.
These could include:
Inspection and certification of grounding systems.Power line conditioning.The use of three phase isolation transformer.
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5.0 Membrane Switch
BackgroundThe membrane switch is part of the user interface to the Intellisys control. It is amatrix of switches bonded to the Intellisys controller and electrically connected tothe control circuit board. The internal membrane switch wiring to the physicalswitches is accomplished through conducted traces made of silver conductiveink. These electrical traces vary in length but will always measure less than 100ohms when tested. The electrical schematic to Intellisys membrane switches isshown in the diagrams below. The continuity of these switches can be testedwith the use of an ohmmeter. To test the individual switches use the followingprocedure:
Procedure1. Remove control power.2. Disconnect the membrane switch tail connector from the controller.3. Connect the ohmmeter to connector position that is wired to the switch (see
schematic below).4. Verify ohmmeter reads O.L. (open circuit).5. Press the membrane switch under test.6. Verify ohmmeter reads less than 100 ohms.
Figure 1. SE Membrane Schematic
Start 1-4Hidden Left 1-5Hidden Right 1-6Unload/Load 2-4Down Arrow 2-5Set 2-6Display Select 3-4Up Arrow 3-5Unloaded Stop 3-6
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Figure 2. SG Membrane Schematic
S1 1-2S2 1-4S3 5-4S4 Start 3-2S5 Unload 3-4S6 Load 5-6S7 Unloaded Stop 7-6S8 Down Arrow 7-8S9 Up Arrow 5-8
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Mod/ACS 1-8Select Up Arrow 1-7Setpoint Down Arrow 1-6On/Offline 2-8Select Down Arrow 2-7Set 2-6Unload 3-8Reset 3-7Setpoint Up Arrow 3-6Start 4-8Unloaded Stop 4-7Test 4-6
Figure 3. SSR Original Intellisys Membrane Schematic
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