302 Rotary Certification Training – SE Controller

Intellisys SE

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 302 Rotary Certification Training – SE Controller
SE controller description

• Exclusive Ingersoll Rand design

• A finger touch membrane is used for compressor
operation and setting control parameters
parameters.
• Operating status is displayed on a Liquid Crystal
Display (LCD)

• SE displays warnings or alarms

• Pressure and temperature sensors,
sensors relays and
switches support the decision making process.

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
Intellisys SE Applications

• SSR 15-50HP Oil Flooded Rotary

• M22-M150 KW Oil Flooded ESA
• 45
45-75
75 kW Sierra
• 45-75kW SSR
• 18-37kW Small Rotary

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
SE controller - simulator

IR Global Service Education Team

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IR Global Service Education Team

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IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
Simulator arrangement

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller

J4
16Vac

J5 115/120 Vac J3 J2 5Vdc. J1 5Vdc.

5Vdc.

IR Global Service Education Team

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39568159
Rev 02
 302 Rotary Certification Training – SE Controller
Component Legend Piping Legend

Abbrev Description
AF Inlet Air Filter
A/E Compressor
Control Piping
SEP Separator Receiver Tank Air Piping
MPCV Minimum Press Check Valve
AFTCLR Aftercooler p g
Coolant Piping
CF Coolant Filter
CLR Coolant Cooler
MS Moislture Separator
TCV Thermostatic Control Valve
SSCVFO Separator Scavenge
Check Valve / Filter / Orifice
PRV Sep Tank Press Relief Value
DV Coolant Drain Valve
3APT Air Pressure Transducer
2ATT Air Temperature Sensor 39568159
IATS High Air Temperature Switch Rev 02
ISV Unload Solenoid Valve
2SV Modulation Solenoid Valve
3SV Blowdown Solenoid Valve
65V Modulation Solenoid Valve
10SV Line/Sump Solenoid Valve
MV Modulation Valve
IV Inlet Valve
BS Blowdown Silencer

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 302 Rotary Certification Training – SE Controller

39904297
Rev 01 IR Global Service Education Team
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302 Rotary Certification Training – SE Controller

IR Global Service Education Team

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Part of 39904297
Rev 01
Part A
 302 Rotary Certification Training – SE Controller
1FU & 2 FU

• Transformer
T f protection
t ti fuses
f
o Have time delay feature to handle short
d ti
duration
o Can handle high inrush current when
transformer is powered up
o CC class high performance

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Part of 39904297
Rev 01
Part A

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
3/4/5 FU

• Dual element fuses on the secondary

side of transformer – Intellisys protection
• Two individual elements in series
• Overlaod section 5-6
5 6 times fuse current rating
• Short circuit section

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 302 Rotary Certification Training – SE Controller
3/4/5 FU

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller

39904297
Rev 01 IR Global Service Education Team
©Ingersoll-Rand Proprietary Information. Rev – July, 2003
 302 Rotary Certification Training – SE Controller

Part of 39904297
Rev 01
Part B IR Global Service Education Team
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302 Rotary Certification Training – SE Controller

IR Global Service Education Team

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39568159
Rev 02
 302 Rotary Certification Training – SE Controller

J3 5Vdc.
J4 5Vdc. J1 5Vdc.
J 4 16Vac.
J5 115/120 Vac.

Comm.

PROM

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 302 Rotary Certification Training – SE Controller
SE Button Functions

INGERSOLL-RAND
INTELLISYS

Power on
IR Global Service Education Team
©Ingersoll-Rand Proprietary Information. Rev – July, 2003
 1SV
N.C. 6SV
N.O. 302 Rotary Certification Training – SE
AFTER CLRController

2SV 3SV
N.C. N.O.

MV
MOISTURE
SEPARATOR
AND TRAP
MPCV
CYL
SO

SE
A/E
RELIEF
VALVE
DISC CHECK
AF Inlet Valve VALVE
10SV
5SV 2ATT SEPARATOR
1ATS TANK

CLR 1ATS
A C
TCV 3APT

CF B
STATUS: UNIT STOPPED
NO POWER
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SE Button Functions

INGERSOLL-RAND
INTELLISYS

AUTO-RESTART
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 302 Rotary Certification Training – SE Controller
SE Button Functions

INGERSOLL-RAND
INTELLISYS

Start
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 302 Rotary Certification Training – SE Controller

Part of 39904297
Rev 01
Part B IR Global Service Education Team
©Ingersoll-Rand Proprietary Information. Rev – July, 2003
 1SV
N.C. 6SV
N.O. 302 Rotary Certification Training – SE
AFTER CLRController

2SV 3SV
N.C. N.O.

MV
MOISTURE
SEPARATOR
AND TRAP
MPCV
CYL
SO

SE
A/E
RELIEF
VALVE
DISC CHECK
AF Inlet Valve VALVE
10SV
5SV 2ATT SEPARATOR
1ATS TANK

CLR 1ATS
A C
TCV 3APT

CF B
STATUS: UNIT UNLOADED
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IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Unload/Load button.
button
INGERSOLL-RAND
INTELLISYS
• Loads the compressor if
the Discharge Pressure is
less than the Online
Pressure.

• Returns the compressor to

the operating mode Load/Unload
specified
p by
y the Mode of
Operation set point.

IR Global Service Education Team

©Ingersoll-Rand Proprietary Information. Rev – July, 2003
 1SV
N.C. 6SV
N.O. 302 Rotary Certification Training – SE
AFTER CLRController

2SV 3SV
N.C. N.O.

MV
MOISTURE
SEPARATOR
AND TRAP
MPCV
CYL
SO

SE
A/E
RELIEF
VALVE
DISC CHECK
AF Inlet Valve VALVE
10SV
5SV 2ATT SEPARATOR
1ATS TANK

CLR 1ATS
A C
TCV 3APT

CF B
STATUS: UNIT LOADED
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Direct Operated

3-way with the

coilil d
de-energized
i d

1SV Control Solenoid and 6SV

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 302 Rotary Certification Training – SE Controller

Direct Operated

3-way with the

coil energized

1SV Control Solenoid and 6SV

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Direct Operated

2-way normally
closed valve with the
coil de-energized
and valve closed

2SV Modulation Solenoid

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 302 Rotary Certification Training – SE Controller

Direct Operated

2-way normally
closed valve with the
coil energized
and valve open

2SV Modulation Solenoid

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 302 Rotary Certification Training – SE Controller

Pilot Operated

2-way
2 way normally
open valve with the
coil de-energized
de energized
and valve open

3SV Blowdown Valve

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 302 Rotary Certification Training – SE Controller

Pilot Operated

2-way normally
open valve with the
coil energized
and valve closed

3SV Blowdown Valve

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 302 Rotary Certification Training – SE Controller

Pil t O
Pilot Operated
t d

2-way
2 a normall
normally
closed valve with the
coil de-energized
de energized
and valve closed

5SV Coolant Stop Valve

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 302 Rotary Certification Training – SE Controller
Pilot Operated

2-way normally
closed valve with
th coilil energized
the i d
and valve open

5SV Coolant Stop Valve

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 302 Rotary Certification Training – SE Controller

Part of 39904297
Rev 01
Part B IR Global Service Education Team
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 302 Rotary Certification Training – SE Controller

2ATT

1ATS- N.C.
2450 F.

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 3APT 302 Rotary Certification Training – SE Controller
6-SV
1 SV
1-SV
2-SV

10-SV
es.
3 Microne

15H 2 O.

FSM Small Rotary

IR Global Service Education Team
Typical arrangement for 30 - 40 Hp SE units .
©Ingersoll-Rand Proprietary Information. Rev – July, 2003
 1SV
N.C. 6SV
N.O. 302 Rotary Certification Training – SE
AFTER CLRController

2SV 3SV
N.C. N.O.

MV
MOISTURE
SEPARATOR
AND TRAP
MPCV
CYL
SO

SE
A/E
RELIEF
VALVE
DISC CHECK
AF Inlet Valve VALVE
10SV
5SV 2ATT SEPARATOR
1ATS TANK

CLR 1ATS
A C
TCV 3APT

CF B Status: Unit Loaded

And Modulating
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IR Global Service Education Team

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302 Rotary Certification Training – SE Controller

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
Sump pressure drop

INGERSOLL-RAND
INTELLISYS

• Sump Pressure Drop 6 PSI

IR Global Service Education Team

©Ingersoll-Rand Proprietary Information. Rev – July, 2003
 1SV
N.C. 6SV
N.O. 302 Rotary Certification Training – SE
AFTER CLRController

2SV 3SV
N.C. N.O.

MV
MOISTURE
SEPARATOR
AND TRAP
MPCV
CYL
SO

SE
A/E
RELIEF
VALVE
DISC CHECK
AF Inlet Valve VALVE
10SV
5SV 2ATT SEPARATOR
1ATS TANK

CLR 1ATS
A C
TCV 3APT

CF B
Status: Unit Loaded,
Modulating &IR10sv Shifted
Global Service Education Team
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 302 Rotary Certification Training – SE Controller
SE Button Functions

Di l Select
Display S l t Button
B tt INGERSOLL-RAND
INTELLISYS

This is used to scroll through

the package display select
menu which will show the
currentt status
t t off the
th unit.
it

Display Select

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 302 Rotary Certification Training – SE Controller
Display Standards

INGERSOLL-RAND
• Package Discharge INTELLISYS

Pressure
• Airend Discharge
Temperature
p
• Sump Pressure Drop
• Separator Pressure Drop
• Total Hours
• Loaded Hours

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Arro s
Arrows
INGERSOLL-RAND
• The up and down buttons INTELLISYS

h
have multiple
lti l ffunctions.
ti

• move up p and down through

g
the items on the list.
• increase and decrease the
values of set points
points.
• calibrate 4APT Package Up/down arrows
Discharge Pressure
T
Transducer.
d

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 302 Rotary Certification Training – SE Controller
SE Button Functions

“SET”Button.
Scrolls through the INGERSOLL-RAND
INTELLISYS

operator set points and if

a value is changed by the
operator then pressing
this button again will save
the new value into the
Intellisys Controller. Set

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 302 Rotary Certification Training – SE Controller
SE Button Functions

INGERSOLL-RAND
Customer Set Points
INTELLISYS
 Off-line Pressure
 On-line Pressure
 Dual Band > = Rev 1.4
Upper Band
Lower Band

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Customer Set Points

INGERSOLL-RAND
INTELLISYS Regulation Mode
• On-Offline
• Modulation
• MOD
O / ACSCS

ACS=Automatic Control Selector

If unit Loads & Unloads 3X

in 3 mins - change to Mod

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Customer Set Points

INGERSOLL RAND
INGERSOLL-RAND
• Display
p y Time
INTELLISYS
• Star-Delta Timer If Supplied
• Lead/Lagg
• Lag Offset
• Low Ambient

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Customer Set Points

INGERSOLL-RAND
INTELLISYS • Auto S/S - On/Off
• Auto S/S Timer
• S
Sequencer - On/Off
O /Off
• Remote S/S - On/Off
• PORO - On/Off
• Delayy - To - Start Time
• Delay - To - Load Time

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 302 Rotary Certification Training – SE Controller
SE Button Functions

INGERSOLL-RAND
Customer Set Points
INTELLISYS

Star Delta Time

Star-Delta
5 - 15 seconds

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SE Button Functions

Customer Set Points

INGERSOLL-RAND
INTELLISYS
Auto Restart Time

• 6 - 20 mins
• 10 - 20 mins
• 2 - 20 mins via PCS

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Customer Set Points

INGERSOLL-RAND
INTELLISYS

Select Options:
Sequence

 ON / OFF

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SE Button Functions

Customer Set Points

INGERSOLL-RAND
INTELLISYS Rem Start Stop

• ON / OFF

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Customer Set Points

INGERSOLL-RAND
INTELLISYS

Load Delay

• 0 - 60 seconds

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Hidden left Button.

Button

INGERSOLL-RAND Have “READY TO START”. Press

INTELLISYS
the Unload/load button once and
then press hidden left button within
three seconds

Last Alarm Recall ( 15 alarms)

Hidden Left To exit press select button twice

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Hidden Right Button.

INGERSOLL-RAND
INTELLISYS
Have “READY TO START”. Press
the Unload/load button once and
then press hidden right button
within three seconds

Bi
Brings ffactory
t sett points
i t
Hidden Right
To exit press select button once or
wait 30 sec

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Factory Set Points

INGERSOLL-RAND
INTELLISYS

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Factory Set Points

• Language
INGERSOLL-RAND
INTELLISYS • Units of Measure
• Rated Pressures
• Starter Options
• Hour Meter Settings
• LCD Contrast
• Modulation On/Off

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Factory Set Points

INGERSOLL-RAND
Language
INTELLISYS

Choice of 4:
• English
• French
• S
Spanish
i h
• Portuguese

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Factory Set Points

INGERSOLL RAND
INGERSOLL-RAND
Units of Measure
INTELLISYS

• Degrees F. and PSI

• Degrees C
C. and KPA
• Degrees C. and PSI
• Degrees C. and BAR
• Degrees C. and KG/CM²

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Factory Set Points

• Rated Pressures
INGERSOLL RAND
INGERSOLL-RAND
INTELLISYS
• PSI = XF@100 / EP@125 /
HP@140 / Special@150 /
165/ XHP@200
• BAR = 7 / 8.5 / 9.6 / 10.3 /
11.4/ 13.8
• KG/CM² = 7 / 8.5 / 9.8 / 10.5 /
11.4/ 14.0
• KPA = 700 / 850 / 960 / 1030
/ 1380 / 1140

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Factory Set Points

INGERSOLL-RAND
• Starter Options
INTELLISYS

• Star - Delta
• Full Voltage
• No Starter

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 302 Rotary Certification Training – SE Controller
SE Button Functions

Factory Set Points

INGERSOLL-RAND
INTELLISYS
• LCD Contrast –
Darker / Brighter
• Hour Meter Settings
• Modulation On/Off

IR Global Service Education Team

©Ingersoll-Rand Proprietary Information. Rev – July, 2003
J 5 5Vdc. J4 5Vdc. J3 5Vdc. J 2 16Vac. J1 115/120 Vac.
302 Rotary Certification Training – SE Controller

Comm.

PROM

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
Intellisys SE Analogue inputs

• SE controller circuitry rectifies and regulates the

8VAC input voltage and provide 5VDC control supply

• 2 Analogue inputs ( power supply 5 VDC)

3 APT -Pressure
Pressure Transmitter
PRESSURE RANGE 0-200 psig
SUPPLY VOLTAGE 5 VDC
OUTPUT VOLTAGE 0-50 mv

2ATT Temperature Thermistor

Negative temperature coefficient

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 302 Rotary Certification Training – SE Controller

Part of 39904297
Rev 01
Part B IR Global Service Education Team
©Ingersoll-Rand Proprietary Information. Rev – July, 2003
 302 Rotary Certification Training – SE Controller
SE Pressure Transducer

PRESSURE (PSI)
( ) OUTPUT mV
0 0.4
20 5.9
50 13.25
70 18.15
100 25.5
150 37.75
200 50

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 302 Rotary Certification Training – SE Controller
Pressure Transducer Output

Pressure Transducer Input/Output

50mvdc

Pressure
14 0 bar
14.0
IR Global Service Education Team
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 302 Rotary Certification Training – SE Controller
Pressure Transducer
+5vdc

RED

GREEN
SUPPLY
0 -14bar

0 - 50mvdc Output

BLACK
WHITE
0vdc(GND)
( )

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 302 Rotary Certification Training – SE Controller
Intellisys SE Analogue inputs

Temperature:

NTC Th
Thermistors
i t
(Negative Temperature Coefficient)

TEMP ºC RESISTANCE

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 302 Rotary Certification Training – SE Controller
Thermistors

TEMPERATURE RESISTANCE (ohms)

( h )
0 32292
20 12411
40 5276
60 2443
80 1219
100 649
110 484

Note 109 deg C= 499 ohms

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
Intellisys SE Digital Inputs

• 6 Digital Inputs ( 5VDC)

• Main Motor Overload (NC)

• Emergency Stop (NC)
• 1M interlock (NO)
• 1S & 2M interlock (NO)
( )
• Remote Start ( optional) (NO)
• Remote Stop ( Optional)

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 302 Rotary Certification Training – SE Controller
Intellisys SE Digital Inputs

Part of 39904297
Rev 01
Part C
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 302 Rotary Certification Training – SE Controller
Intellisys SE Digital Outputs

• 5 Di
Digital
it l Outputs
O t t
(48VAC ESA, 120 VAC US)

• Line contactor 1M and Delta contactor 2M

• Star
St contactor
t t 1S
• Unload (1SV) & Blowdown (3SV) sol.
valves
• Load (6SV) & Modulation (2SV) sol. valves
• Line/Sump
Li /S Solenoid
S l id valve
l

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 302 Rotary Certification Training – SE Controller

Part of 39904297
Rev 01
Part B IR Global Service Education Team
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 302 Rotary Certification Training – SE Controller
No Control Power Alarm

• 1 ATS –
Normally closed temp
temp. switch

• 245oF / 118oC ( +/
+/- 3 oC)

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller

2ATT

1ATS- N.C.
2450 F.

IR Global Service Education Team

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39904297
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 302 Rotary Certification Training – SE Controller

INGERSOLL-RAND
INTELLISYS

Unloaded Stop
& Software Display & LED Test
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Alarms
Warning/
Alarm
INGERSOLL-RAND
INTELLISYS

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
Alarms
Alarm

INGERSOLL-RAND
INTELLISYS

ALARM !

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 302 Rotary Certification Training – SE Controller
Alarms
Alarms
• Low Sump Pressure
INGERSOLL-RAND • High Air Pressure
INTELLISYS
• High Airend Temperature
• Starter Fault
• Main Motor Overload
• Fan Motor Overload
• Remote Stop Failure Temperature
• Sensor Failure
• Remote Start Failure
• Check Motor Rotation
• Calibration Failure
• No Control Power
• Pressure Sensor Failure
• Emergency Stop
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 302 Rotary Certification Training – SE Controller
Intellisys Software 1.7
17

Warning
INGERSOLL-RAND
INTELLISYS

CHANGE SEPARATOR ELEMENT

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 302 Rotary Certification Training – SE Controller
Intellisys Software 1.7
17

Warning
INGERSOLL-RAND
INTELLISYS

SERVICE

Press Reset Button

Clears Warningg For 24 Hrs Only
y
IR Global Service Education Team
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 302 Rotary Certification Training – SE Controller
Intellisys Software 1.7
17
Warning
INGERSOLL-RAND
INTELLISYS

SERVICE

1) Press
HIDDEN
LEFT
2) Press
Clears Warning For 2000 Hrs
IR Global Service Education Team
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 302 Rotary Certification Training – SE Controller
Intellisys Software 1.7
17

Premat re Compressor Service:-

Premature Ser ice

• “MASTER
MASTER RESET”
RESET must be performed to
prevent warning for another 2000 hours

• To clear display of “SERVICE” MESSAGE:-

“CUSTOMER RESET” must be performed
f
first, then “MASTER
“ S RESET”
S

IR Global Service Education Team

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Intellisys Software 1.7
17

INGERSOLL-RAND
INTELLISYS
Alarm

STARTER FAULT 1SL

Compressor Running:-
Indicates faulty signal to Intellisys from the Main
Contactor Auxillary KM1 - 2

IR Global Service Education Team

©Ingersoll-Rand Proprietary Information. Rev – July, 2003
 302 Rotary Certification Training – SE Controller
Intellisys Software 1.7
17

INGERSOLL-RAND
INTELLISYS
Alarm

STARTER FAULT 2SL

During Star:-
Indicates Faulty Signal To Intellisys From The Star Contactor
Auxillary Km3 - 2

IR Global Service Education Team

©Ingersoll-Rand Proprietary Information. Rev – July, 2003
 302 Rotary Certification Training – SE Controller
Intellisys Software 1.7
17

INGERSOLL-RAND
INTELLISYS
Alarm

STARTER FAULT 2SL

After Transition:-
IIndicates
di t Faulty
F lt Signal
Si l To
T Intellisys
I t lli From
F The
Th Delta
D lt
Contactor Auxillary Km2 - 2

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
SSR M22-150kW

• Rev 1.7 To 1.8

• Introduction of last 15 Alarms
Alarms.
• Rotation Check Removed From No Starter Option
• Call Out Facility Added

IR Global Service Education Team

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 302 Rotary Certification Training – SE Controller
Last 15 Alarms
Alarm

INGERSOLL-RAND
INTELLISYS

ALARM 1

2
FOLLOWED BY :-
1
1+2 = < 2 seconds
IR Global Service Education Team
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Last 15 Alarms
Alarm

INGERSOLL-RAND
INTELLISYS

ALARM 1 - 15

Use Display Select To Use Arrows To Scroll Up

View Trip Values And Last 15 Alarms

IR Global Service Education Team

©Ingersoll-Rand Proprietary Information. Rev – July, 2003