Intellisys SSR Series

SSR INTELLISYS ROTARY
TROUBLESHOOTING GUIDE
• Original Intellisys
• SE & SG
• Problems
• Procedures
• Warranty Information
APDD 749
September 1999
SSR INTELLISYS ROTARY
TROUBLESHOOTING GUIDE
The following is a guide to be used when identifying the root cause of a

compressor problem.
Forms have also been developed for the SE and SG controller and must be filled
in 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 form
filled 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 see
what controllers the particular page covers.
ORIG = Original Intellisys controller SSR 50-450HP

SE = SE Intellisys controller SSR 20-100HP
SG = SG Intellisys controller SSR 125-450HP
FSM = Field Service Manuals
9/16//99 Rev 5
1
TABLE OF CONTENTS
INTRODUCTION.........................................................................................................................................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 ...................................................7
SG CONTROLLER - SHUTS DOWN WITH READY TO START IN THE DISPLAY ...................................................8
ORIGINAL, SE, SG - CONTROLLER LOCKS-UP ..........................................................................................9
ORIGINAL, SE SG - TRIAC DOES NOT OPERATE PROPERLY .....................................................................10
ORIGINAL, SG - CHECK INLET CONTROL SYSTEM ALARM .....................................................................11
ORIGINAL, SG - CHECK INLET CONTROL ALARM ..................................................................................12
ORIGINAL, SE , SG - LOW UNLOADED SUMP ALARM ............................................................................13
ORIGINAL, SE , SG - HIGH SUMP PRESSURE ALARM .............................................................................14
ORIGINAL, SE , SG - HIGH AIREND TEMPERATURE ALARM ..................................................................15
ORIGINAL, SE , SG - MAIN MOTOR OVERLOAD ALARM ........................................................................16
ORIGINAL, SE , SG - STARTER FAULT ALARM .......................................................................................17
ORIGINAL, STARTER FAULT ALARM CONTINUED ...................................................................................18
SE , SG - NO CONTROL POWER ALARM ....................................................................................................19
ORIGINAL, SE , SG - CHECK MOTOR ROTATION ALARM .......................................................................20
ORIGINAL, SG - STEPPER LIMIT SWITCH ALARM ..................................................................................21
ORIGINAL, SE , SG - REMOTE STOP FAILURE ALARM ...........................................................................22
ORIGINAL, SE , SG - REMOTE START FAILURE ALARM .........................................................................23
ORIGINAL, SE , SG - SHORT SEPARATOR ELEMENT LIFE ........................................................................24
NOTES ........................................................................................................................................................25
PROCEDURES
1.1 SE POWER OUTAGE
Background ...............................................................................................................................................26
Procedure...................................................................................................................................................26
1.2 SE VOLTAGE SAG
Background................................................................................................................................................26
Procedure...................................................................................................................................................26
1.3 GROUNDING PROBLEMS
Background................................................................................................................................................27
Procedure...................................................................................................................................................27
1.4 SE INTELLISYS 16 VAC SUPPLY
Background................................................................................................................................................29
Procedure...................................................................................................................................................29
1.5 SE EXTERNAL 5 VDC SHORT CIRCUIT
Background................................................................................................................................................30
Procedure...................................................................................................................................................30
ENVIRONMENTAL PROBLEMS
1.6 MOISTURE
Background................................................................................................................................................31
Procedure .................................................................................................................................................31
2
1.7 TEMPERATURE
Background................................................................................................................................................31
Procedure .................................................................................................................................................32
1.8 VIBRATION
Background................................................................................................................................................32
Procedure .................................................................................................................................................32
OTHER
1.9 REMOTE ALARM APPLICATION
Background................................................................................................................................................32
Procedure .................................................................................................................................................32
2.1 STEPPER MOTOR TEST
Background................................................................................................................................................34
Procedure .................................................................................................................................................34
2.2 DRIVER CHIP TEST
Background................................................................................................................................................34
Procedure .................................................................................................................................................35
2.3 LIMIT BOARD TEST
Background................................................................................................................................................36
Procedure .................................................................................................................................................36
2.4 PRESSURE SENSOR CHECK OUT
Background................................................................................................................................................37
Procedure .................................................................................................................................................38
2.5 TRIAC OUTPUTS
Background................................................................................................................................................37
Procedure .................................................................................................................................................37
2.6 AUXILIARY CONTACTS
Background................................................................................................................................................38
Procedure .................................................................................................................................................38
3.1 SG POWER OUTAGE
Background ...............................................................................................................................................40
Procedure...................................................................................................................................................40
3.2 SG VOLTAGE SAG
Background ...............................................................................................................................................40
Procedure...................................................................................................................................................40
3.3 SG INTELLISYS 24 VAC SUPPLY
Background................................................................................................................................................41
Procedure...................................................................................................................................................41
3.4 SG EXTERNAL 5 VDC SHORT CIRCUIT
Background................................................................................................................................................41
Procedure...................................................................................................................................................42
4.0 EXTERNAL ELECTRICAL DISTURBANCES
Background................................................................................................................................................43
5.0 MEMBRANE SWITCH CHECK
Background................................................................................................................................................46
Procedure .................................................................................................................................................46
Figure 1 - SE Membrane Schematic ..........................................................................................................46
Figure 2 - SG Membrane Schematic..........................................................................................................47
Figure 3 - ORIGINAL Membrane Schematic............................................................................................48
3
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 flow
chart refers to another paragraph, find the paragraph number in the table of
contents 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 problems
section. That refers to page 11. As you follow the diagnostics, the flow chart
says to see paragraph 2.3. Find paragraph 2.3 in the table of contents. That
refers to page 36 for background and procedure information. Turn to that page
and follow any instructions.
4
SE INTELLISYS CONTROLLER GENERAL INFORMATION
Date: 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 INFORMATION
Intellisys S/N EPROM Version: Offline Pressure: Online Pressure:
Mode of Operation: Options: Comm. Link: Last Alarm:
POWER SUPPLY INFORMATION POWER ON

Circuit Test Point Expected Value Measured Value
Control Transformer T1 200-575 VAC
Primary VAC
Control Transformer J5-36 to J5-35 120 VAC +/- 18 VAC
Secondary : 120 VAC
Control Transformer J4-30,31 16 VAC +/- 2.4 VAC
Secondary : 16 VAC J4-29,30 8 VAC +/- 1.2 VAC
(center-tap) J4-29,31 8 VAC +/- 1.2 VAC
Rectified Intellisys DC J4-28,29 10.5 VDC +/- 1.6 VDC
Intellisys Digital 5 VDC J11-1,5 5 VDC +/- .2 VDC
Intellisys Analog 5 VDC J3-25,24 5 VDC +/- .2 VDC
Battery Voltage BAT +/- 3.0 VDC +/- .6 VDC
Ground Fault Current: Customer Ground 0.0 Amps AC/DC
Machine running in conductor +/- .25 Amps AC/DC
loaded condition see Paragraph 1.3
GROUND RESISTANCE CHECK INFORMATION POWER OFF

Intellisys Ground J1-1, GND LUG < .5 Ohm
120 VAC Neutral T1, GND Lug < .5 Ohm
Motor Frame Motor chassis, base < .5 Ohm
Sensor Ground 3APT chassis, base < .5 Ohm
Airend Ground Air end chassis, base lug < .5 Ohm
Package Ground Machine Base, GND lug < .5 Ohm
Customer Ground Structural Earth, base lug < .5 Ohm
I/O RESISTANCE CHECK POWER OFF

Pressure Black to GND <.5 ohm
J3 Connected to board Green to GND 185 +/- 50
White to GND 850 ohm +/- 100
Temperature White to GND 140 ohm +/- 10 @ 77 F
J2 Connected to board
Digital I/O N.C. < .5 ohm
J1 (a) N.O. > 1 meg ohm
(a) Only test wired contacts and list only connections out of range.
5
SG INTELLISYS CONTROLLER GENERAL INFORMATION
Date: 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 INFORMATION
Intellisys S/N EPROM Version: Offline Pressure: Online Pressure:
Mode of Operation: Options: Comm. Link: Last Alarm:
POWER SUPPLY INFORMATION POWER ON

Control Transformer T1 200-575 VAC +/- 10%
Primary VAC
Control Transformer P1-1, P1-10 120 VAC +/- 18 VAC
Secondary : 120 VAC
Control Transformer Power Supply Board 24 VAC +/- 3.6 VAC
Secondary : 24 VAC J1-1, J1-2
Rectified Intellisys DC Power Supply Board 12 VDC +/- .6 VDC
J2-1,J2-2
Intellisys Digital 5 VDC P9-1,5 5 VDC +/- .2 VDC
Intellisys Analog 5 VDC P5-7,8 5 VDC +/- .2 VDC
Pressure Signal @ 0 psi P5 white to Black .5 VDC +/- .1 VDC
Battery Voltage BAT +/- 3.0 VDC +/- .6 VDC
Ground Fault Current: Customer Ground 0.0 Amps AC/DC
Machine running in conductor +/- .25 Amps AC/DC
loaded condition see Paragraph 1.3
GROUND RESISTANCE CHECK INFORMATION POWER OFF

Intellisys Ground J1-5, GND LUG < .5 Ohm
120 VAC Neutral T1, GND Lug < .5 Ohm
Motor Frame Motor chassis, base lug < .5 Ohm
Sensor Ground 3APT chassis, base lug < .5 Ohm
1AVPT chassis, base lug < .5 Ohm
4APT chassis, base lug < .5 Ohm
Airend Ground Air end chassis, base lug < .5 Ohm
Package Ground Machine Base, GND lug < .5 Ohm
Customer Ground Structural Earth, base lug < .5 Ohm
I/O RESISTANCE CHECK POWER OFF

Pressure Black to GND <.5 ohm
P5 Connected to board White to GND 20K +/- 3K
Temperature White to GND Temperature dependent
P6 Connected to board Black to GND <.5 ohm
Digital I/O (a) N.C. <.5 ohm
P3 1-2, 3-4, 5-6 ,…..32 N.O. >1 meg ohm
Stepper motor Power Supply Board 4” & 6” valve = 5-7 Ohms
connections J3,1-2 J3,3-4 8” valve = 11-13 Ohms
(a) Only test wired connections and list only connections out of range.
6
SE CONTROLLER:
SHUT DOWN “READY TO START” = MACHINE WAS OPERATIONAL AND IN THE RUNNING MODE. MACHINE STOPS AND DISPLAYS
“READY TO START” OR SHUTS DOWN WITH BLANK DISPLAY
INCOMING VOLTAGE DIPS BELOW 30% SERVICE APPLICATION, CHECK PHASE UNBALANCE, and SERVICE WIRE
AMPACITY.
CHECK WIRING FROM T1 TO J4-29, 30, 31.

16 VAC C.T. FEED CIRCUIT INTERMITTENT SEE PARAGRAPH 1.4
CHECK CUSTOMER GROUND INTEGRITY. CHECK FOR FAULT CURRENT IN GROUND

INTERMITTENT/IMPROPER GROUND LEG. CHECK GROUND RESISTANCE BACK TO J4-29. INSPECT BOND INTEGRITY.
SEE PARAGRAPH 1.3
2ATT - BLACK WIRE TO GROUND < 1 MEG OHM

INTERMITTENT SHORT ON 5 VDC ANALOG 3APT - RED WIRE TO GROUND < 1 MEG OHM
SEE PARAGRAPH 1.5
OPTION PROM INTERMITTENT

CONNECTION TO J11 SEE PARAGRAPH 1.5
EXCESSIVE TEMPERATURE REDUCE CONTROLLER AMBIENT TO <160°F

SEE PARAGRAPH 1.7
REMOTE ALARM ARCING INSURE PROPER SUPPRESSOR. SEE PARAGRAPH 1.9
EXCESSIVE MOISTURE
WATER LEAKING INTO CONTROLLER. SEE PARAGRAPH 1.6
INTERMITTENT POWER OUTAGE PROBLEM WITH CUSTOMER POWER SUPPLY. SEE PARAGRAPH 1.1
VIBRATION
SEE PARAGRAPH 1.8
BATTERY CONNECTION OR VOLTAGE LOOK FOR CORROSION ON THE BATTERY TERMINAL. VERIFY THAT
VOLTAGE IS 3.0 VDC +/- .6 VDC
INCOMING POWER DISTURBANCES
SEE PARAGRAPH 4.0
7
SG CONTROLLER:
SHUTDOWN “READY TO START” = MACHINE WAS OPERATIONAL AND IN THE RUNNING MODE. MACHINE STOPS AND DISPLAYS
“READY TO START” OR SHUTS DOWN WITH BLANK DISPLAY
INCOMING VOLTAGE DIPS BELOW 30% SERVICE APPLICATION, CHECK PHASE UNBALANCE, and SERVICE WIRE
AMPACITY.
CHECK WIRING FROM T1 TO J1 - 1 & 2.

24 VAC C.T. FEED CIRCUIT INTERMITTENT SEE PARAGRAPH 3.3
CHECK CUSTOMER GROUND INTEGRITY. CHECK FOR FAULT CURRENT IN GROUND

INTERMITTENT/IMPROPER GROUND LEG. CHECK GROUND RESISTANCE BACK TO J4-29. INSPECT BOND INTEGRITY
SEE PARAGRAPH 1.3
2ATT - BLACK WIRE TO GROUND < 1 MEG OHM

INTERMITTENT SHORT ON 5 VDC 3APT - RED WIRE TO GROUND < 1 MEG OHM
SEE PARAGRAPH 3.4
OPTION PROM INTERMITTENT

CONNECTION TO J11 SEE PARAGRAPH 3.4
EXCESSIVE TEMPERATURE REDUCE CONTROLLER AMBIENT TO

<160°F
REMOTE ALARM ARCING INSURE PROPER SUPPRESSOR. SEE PARAGRAPH 1.9
EXCESSIVE MOISTURE
WATER LEAKING INTO CONTROLLER. SEE PARAGRAPH 1.6
INTERMITTENT POWER OUTAGE PROBLEM WITH CUSTOMER POWER SUPPLY. SEE PARAGRAPH 3.1
VIBRATION
SEE PARAGRAPH 1.8
BATTERY CONNECTION OR VOLTAGE LOOK FOR CORROSION ON THE BATTERY TERMINAL. VERIFY THAT
VOLTAGE IS 3.0 VDC +/- .6 VDC
INCOMING POWER DISTURBANCES SEE PARAGRAPH 4.0
8
ORIG,SE,SG: = UNIT RUNNING. PUSHING THE STOP BUTTON DOES NOT CAUSE ANYTHING TO
CONTROLLER LOCK-UP. UNIT WILL NOT STOP HAPPEN AND NO ALARMS ARE INDICATED, OR READY TO START IN THE DISPLAY
OR READY TO START WILL NOT START AND PRESSING THE START BUTTON DOES NOT CAUSE START OR ALARM. CYCLING
POWER WILL RESET BUT PROBLEM OCCURS AGAIN.
SE CONTROLLER ORIGINAL INTELLISYS SG CONTROLLER
16 VAC C.T. FEED 24 VAC FEED CIRCUIT

CIRCUIT INTERMITTENT INTERMITTENT
115 VAC FEED CIRCUIT
INTERMITTENT
CHECK WIRING FROM T1 TO CHECK WIRING FROM T1
J4-29, 30, 31. TO J1 - 1 & 2.
SEE PARAGRAPH 1.4 CHECK WIRING AND SEE PARAGRAPH 3.3
VOLTAGE FROM BTS1 -
33 & 3.
BAD MEMBRANE BAD MEMBRANE BAD MEMBRANE
SEE PARAGRAPH IS IT 110-130 VAC?
5.0
USE SE I/O TEST MEMBRANE
MEMBRANE TEST SEE PARAGRAPH
NO. PROBLEM WITH T1
KIT TO VERIFY 5.0
TRANSFORMER OR
COMM PORT
YES. CHECK VOLTAGE AT TRANSFORMER T3
AND CONNECTION J1
SE USE I/O TEST KIT J1 1 & 6 SHOULD BE 110-130 VAC
J1 2 & 5 SHOULD BE 12-14 VAC
IF NOT, BAD T3 TRANSFORMER
EXCESSIVE TEMPERATURE EXCESSIVE MOISTURE. WATER

REDUCE CONTROLLER AMBIENT SEE SHEET FOR BLANK DISPLAY
LEAKING INTO CONTROLLER. SEE
TO <160°F FOR OTHER OPTIONS, PAGE 7 & 8
PARAGRAPH 1.6
SEE PARAGRAPH 1.7
9
ORIG,SE,SG:
TRIAC IS ON AND SHOULD BE OFF OR
TRIAC IS OFF AND SHOULD BE ON
SE CONTROLLER ORIGINAL INTELLISYS SG CONTROLLER
SEE BLUE FSM SECTION SEE PARAGRAPH 2.5

B, SHEET 28
USE SE I/O TEST KIT
10
ORIG, SG: CHECK INLET CONTROL SYS = VALVE COMMANDED TO MOVE TO OPEN OR CLOSED LIMIT SWITCH AND CONTROLLER NEVER
RECEIVES SIGNAL FROM LIMIT SWITCH CONFIRMING THE VALVE MADE IT THERE.
YES SUSPECT BAD OPEN LIMIT SWITCH
CONFIRM 24 VAC TO BOARD SEE PROCEDURE 2.3
DID VALVE MOVE PAST YES. SUSPECT BAD CONTROLLER

LOADING
THE OPEN LIMIT SWITCH?
NO. DID VALVE MOVE TO

THE OPEN LIMIT SWITCH AND STOP?
NO. SUSPECT SLIPPING COUPLING

BAD STEPPER MOTOR. SEE PROCEDURE 2.1
BAD DRIVER CHIP. SEE PROCEDURE 2.2
IF NONE OF THE ABOVE THEN PROBABLY A
BINDING INLET VALVE.
YES. SUSPECT BAD CLOSED LIMIT
SWITCH
DID VALVE MOVE PAST THE

UNLOADING YES. SUSPECT BAD CONTROLLER
CLOSED LIMIT SWITCH?
YES. MAKE SURE BLOW DOWN

NO. DID VALVE MOVE TO THE DEFLECTOR IS IN PLACE. IF NECESSARY,
CLOSED LIMIT SWITCH AND STOP? BEND DEFLECTOR TO DEFLECT AIR
UPWARD
NO. IS THE BLOWDOWN AIR

HITTING THE VALVE PLATE
AND KEEPING IT FROM MOVING
CLOSED?
NO. SUSPECT SLIPPING COUPLING.

BAD STEPPER MOTOR. SEE PROCEDURE
2.1
NO. SUSPECT SLIPPING COUPLING. IF NONE OF THE ABOVE THEN PROBABLY
BAD STEPPER MOTOR. SEE PROCEDURE A BINDING INLET VALVE.
AT STARTING AFTER TRANSITION 2.1
IF NONE OF THE ABOVE THEN PROBABLY
A BINDING INLET VALVE.
11
ORIG, SG: CHECK INLET CONTROL = UNIT UNLOADED AND INLET VACUUM LESS THAN THREE PSI.
YES. SUSPECT 1AVPT TRANSDUCER PROBLEM, OR LEAK IN SENSING

LINE
YES. IS THE AIREND TURNING?
NO. SUSPECT SLIPPING GEAR
UNLOADED IS THE INLET VALVE CLOSED?
NO. ORIGINAL CONTROLLER - CHECK FOR SLIPPING

COUPLING
SG CONTROLLER - CHECK POSITION OF CLOSED LIMIT SWITCH
12
ORIG, SE, SG: LOW UNLOADED SUMP = UNIT UNLOADED AND SUMP PRESSURE IS LESS THAN 15 PSI FOR 10 SECONDS
NO. SUSPECT SLIPPING COUPLING

BAD STEPPER MOTOR. SEE PROCEDURE 2.1
MPCV STUCK OPEN IF PUMPING INTO AN OPEN
SYSTEM
IF NONE OF THE ABOVE THEN PROBABLY
A BINDING INLET VALVE.
IF OK, IS BLOWDOWN AIR CAUSING THE VALVE TO CLOSE TOO FAR?
YES. MAKE SURE BLOW DOWN

DEFLECTOR IS IN PLACE. IF NECESSARY,
UNLOADED OR STARTING CHECK SENSING LINE TO 3APT BEND DEFLECTOR TO DEFLECT AIR
AFTER TRANSITION AND SENSOR 3APT. SEE PROCEDURE 2.4 UPWARD
SE CONTROLLER
IF NOT OK, THEN REPAIR AND RETEST
BLOCKAGE IN SENSOR LINE FROM SUMP

TO 10SV
NO. CHECK BLOW DOWN SILENCER ADJUSTMENT.

MAKE SURE MAKE UP PORTS IN INLET VALVE ARE OPEN.
FULL VOLTAGE? YES OR
YES. CHECK FOR INLET VALVE STUCK CLOSED OR

BROKEN SPRING IN INLET VALVE.
13
ORIG, SG, SE: HIGH SUMP PRESSURE = SUMP PRESSURE IS GREATER THAN 15 PSIG ABOVE THE RATED PRESSURE OF THE UNIT.
BAD COOLANT
BYPASS OR BAD AIR
FILTER.
WATER IN THE SYSTEM
CLOGGED SEPARATOR ELEMENT
WATER IN THE SYSTEM CAUSING CORROSION IN THE

VALVE.
STICKING MINIMUM PRESSURE CHECK VALVE
BLOCKAGE OR LEAK IN SENSING LINE TO 4APT CHECK SPECIAL TEE ON TOP OF MOISTURE
SEPARATOR WHERE 4 APT CONNECTS.
OLD STYLE INLET VALVE

SLIPPING COUPLING FAULTY 4APT SENSOR
SEE PROCEDURE 2.4
SE CONTROLLER
NO.
BLOCKAGE IN SENSING LINE TO 10SV BROKEN SPRING IN INLET VALVE
1SV STILL ENERGIZED, STICKING OR LEAKING AIR SIGNAL TO OPEN INLET
VALVE. BLOWDOWN VALVE NOT OPENING
FULL VOLTAGE? YES OR NO
YES
NO AIR SIGNAL TO CLOSE THE VALVE. FAULTY 1SV OR SHUTTLE VALVE.
STICKING INLET VALVE, BLOWDOWN VALVE NOT OPENING.
14
ORIG, SG, SE: HIGH AIREND TEMPERATURE = AIREND DISCHARGE TEMPERATURE EQUAL TO OR GREATER THAN 228°F.
NO. CORRECT COOLANT AND TRY AGAIN.
YES. IS COOLANT LEVEL CORRECT?
DOES UNIT SHUT DOWN IN LESS THAN 10 SECONDS AFTER START-UP? YES. SUSPECT PROBLEM WITH COOLANT STOP VALVE.
CHECK WIRING AND VALVE OPERATION (SEE PROCEDURE 2.5)
AIR-COOLED = BAD ENVIRONMENT

NO WATER-COOLED = BAD WATER
FOULING TUBES
DIRTY COOLERS
EXTERNAL COOLANT LEAK CAUSING

AIR-COOLED HEAT EXCHANGER TO CLOG
WITH DIRT
HIGH AMBIENT RESTRICTIVE EXHAUST DUCTING

ABOVE 115°F > .25” WATER COLUMN
RECIRCULATION OF COOLING AIR
FAULTY THERMOSTATIC VALVE IS THE VALVE BYPASSING THE COOLER?
FAULTY THERMISTOR 2ATT SWAP WITH 4ATT FOR QUICK DETERMINATION (NOT SE)
CHECK FOR HIGH MOTOR AMPS

FAULTY AIREND
UNUSUAL NOISE
HIGHER VIBRATION THAN NORMAL
METAL IN THE COOLANT FILTER
15
ORIG, SG, SE: MAIN OR FAN MOTOR OVERLOAD = OVERLOAD CONTACT OPEN FOR MORE THAN ONE SECOND.
PLACE OVERLOAD RELAY IN MANUAL

RESET MODE NO. CORRECT HEATER SELECTION OR OVERLOAD SETTING.
NO. POTENTIAL PROBLEM WITH WIRING FROM OVERLOAD TO CONTROLLER OR CONTROLLER.

ORIGINAL & SE INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 5 VDC WHEN
IS THE HEATER ELEMENT OR CONTACT IS OPEN AND 0 VDC WHEN CONTACT IS CLOSED.
OVERLOAD RELAY THE PROPER SIZE? (MAIN MOTOR, ORIG BTS2 10-11, SE-J1 15&16. FAN MOTOR, ORIG- BTS2 8&9. SE- J1 13&14)
SG INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 10-12VDC WHEN
CONTACT IS OPEN AND 0 VDC WHEN CONTACT IS CLOSED
(MAIN MOTOR P3 11&12, FAN MOTOR P3 13&14)
YES. DID OVERLOAD RELAY REQUIRE

RESETTING BEFORE BEING ABLE TO LESS THEN 95% NOMINAL
YES. ARE THE AMPS
RESET THE INTELLISYS CONTROLLER?
HIGHER?
MORE THAN 1% UNBALANCE

YES. CHECK FOR LOW VOLTAGE
VOLTAGE UNBALANCE
OVERPRESSURE
TIGHT AIREND
LOSS OF PHASE LOSS OF STAGE ON 2 STAGE UNIT
STARTING UNDER A LOAD
NO. IS THE STARTER ENCLOSURE HOTTER THAN NORMAL? BLOWN FUSE
BAD CONNECTION
BURNT CONTACTOR
YES. CHECK FOR BAD CONNECTIONS
AND MAKE SURE CONDUIT FROM MOTOR IS
SEALED WITH ELECTRICAL PUTTY
BLOWDOWN VALVE NOT OPEN
INLET VALVE NOT CLOSED
NO. ARE THE TEMPERATURES OF THE THREE
STARTER POLES THE SAME OR ARE THEY HOTTER
THAN 160°F? ANY SIGNS OF HOT SPOTS ON STARTER?
YES. BAD CONNECTION WITHIN THE STARTER
NO. POTENTIAL PROBLEM WITH OVERLOAD RELAY, CONTROLLER, OR RIBBON CABLE ON ORIGINAL INTELLISYS
16
ORIG, SG, SE: YES. DOES UNIT SHUT DOWN IN LESS
STARTER FAULT THAN 12 SECONDS AFTER START-UP?
YES. IS AIREND DISCHARGE TEMPERATURE GREATER THAN
210°F AT TIME OF SHUTDOWN?
IS THIS THE ORIGINAL INTELLISYS CONTROLLER?
NO. CORRECT COOLANT AND TRY AGAIN
YES. IS COOLANT LEVEL CORRECT?

NO. SEE PAGE 18
NO. ANY CONTROLLER

INCLUDING? YES. SUSPECT PROBLEM WITH COOLANT STOP VALVE
THE ORIGINAL INTELLISYS CHECK WIRING AND VALVE OPERATION (SEE
PROCEDURE 2.6)
DO 1S AND 1M ENGERIZE WHEN

THE START BUTTON IS PRESSED?
NO. POTENTIAL PROBLEM WITH TRIAC ON STARTER INTERFACE BOARD,
CONTROLLER
YES. DOES THE UNIT SHUT DOWN 2-3

SECONDS AFTER 1S AND 1M ENERGIZED? YES. POTENTIAL PROBLEM WITH WIRING OR AUXILIARY CONTACTS 1Ma OR 1Sa
SE & ORIGINAL INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 5 VDC WHEN
CONTACT IS OPEN AND 0 VDC WHEN CONTACT IS CLOSED.
SG INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 10-12 VDC WHEN
SEE PARAGRAPH 2.6
NO. DOES 1S DE-ENERGIZE AND 2M
ENERGIZE AT TRANSITION (10 SEC)?
NO. POTENTIAL PROBLEM WITH TRIAC ON STARTER INTERFACE BOARD, CONTROLLER,
1S CONTACTOR STICKING OR AUXILIARY CONTACT 1Sc OR 1Sd.
YES. POTENTIAL PROBLEM WITH WIRING OR AUXILIARY CONTACTS 1Sa OR 2Ma

SE & ORIGINAL INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 5 VDC WHEN
SG INTELLISYS: VOLTAGE ACROSS CONTACT SHOULD BE 10-12 VDC WHEN
SEE PARAGRAPH 2.6
17
FROM STARTER FAULT CHART
ORIGINAL INTELLISYS CONTROLLER

MEASURE VOLTAGE AC
TERMINAL BTS1-33 AND BTS1-3
IS THE VOLTAGE GREATER THAN

110 VAC?
NO. BAD CONTACT ON E-STOP
YES. MEASURE VOLTAGE AC


110 VAC?
NO. BAD 1ATS

DOES VOLTAGE CONTINUOUSLY

READ 110-130 VAC AT TIME OF YES. CHECK FOR BAD CONTROLLER OR RIBBON CABLE. RECHECK STARTER
SHUTDOWN? SEQUENCE.
NO CHECK FOR PHASE MONITOR OR ANY OTHER SHUTDOWN WIRED TO BTS1-33 & 29
18
SG, SE: NO CONTROL POWER = 115 VOLTS AC IS NOT APPLIED TO THE CONTROLLER BUT CONTROLLER IS POWERED-UP.
SG CONTROLLER:
SE CONTROLLER: MEASURE VOLTAGE AC
MEASURE VOLTAGE AC P1 10 AND TERMINAL 1TB-1
TERMINAL BTS1-6 AND J4-29
IS THE VOLTAGE GREATER THAN 110 VAC?
110 VAC?
NO. FUSE 2FU IS BAD, LOW VOLTAGE OR

NO. FUSE 3FU IS BAD, LOW VOLTAGE OR
THE TRANSFORMER IS BAD
THE TRANSFORMER IS BAD

YES. MEASURE VOLTAGE AC P1 - 10 AND TERMINAL 1TB2
TERMINAL BTS1-7 AND J4-29

IS THE VOLTAGE GREATER THAN 110 VAC?
110 VAC?
NO. BAD CONTACT ON E-STOP

NO. BAD CONTACT ON E- STOP
YES. IS AIREND DISCHARGE TEMPERATURE GREATER THAN

DOES UNIT SHUT DOWN IN LESS 210°F AT TIME OF SHUTDOWN?
THAN 12 SECONDS AFTER START-UP?
NO
NO. CORRECT COOLANT AND TRY AGAIN.
SE CONTROLLER: SG CONTROLLER:
MEASURE VOLTAGE AC MEASURE VOLTAGE AC YES. IS COOLANT LEVEL CORRECT?
TERMINAL BTS1-8 AND J4-29 P1 - 10 AND TERMINAL 1TB-4
DOES VOLTAGE CONTINUOUSLY YES. SUSPECT PROBLEM WITH COOLANT STOP VALVE.
DOES VOLTAGE CONTINUOUSLY
READ 110-130 VAC AT TIME OF CHECK WIRING AND VALVE OPERATION (SEE
READ 110-130 VAC AT TIME OF
SHUTDOWN? PROCEDURE 2.5)
SHUTDOWN?
YES. SE: CHECK FOR PHASE MONITOR

NO. CHECK SG: CHECK FOR INTERSTAGE PRESSURE SWITCH ON 2 STAGE OR PHASE MONITOR.
1ATS
19
ORIG, SG, SE: CHECK MOTOR ROTATION = NO INLET VACUUM SENSED 2 SECONDS AFTER STARTING.
SE CONTROLLER: NO SUMP PRESSURE SENSED 2 SECONDS AFTER STARTING.
IS THE ROTATION CORRECT? NO. DISCONNECT, LOCK AND TAG POWER IN OFF POSITION. INTERCHANGE TWO LEADS
AND TRY AGAIN.
ORIG AND SG CONTROLLER NO. IS THE MOTOR TURNING ?
IS THE AIREND TURNING? NO. CHECK VOLTAGE,

SE CONTROLLER STARTER AND MOTOR.
YES. CHECK FOR LEAK IN 1AVPT YES. ARE THE

IS THE AIREND TURNING? SENSING LINE OR FAULTY 1AVPT. SEE GEARS SPINNING ON
PROCEDURE 2.4 THE SHAFT?
NO. IS THE MOTOR TURNING?

YES. CHECK FOR LOCKED-UP
AIREND
NO. BROKEN AIREND DRIVE SHAFT

YES. IS 10SV ENERGIZING AT START?
NO. CHECK VOLTAGE, STARTER AND MOTOR.
NO. CHECK THE TRIAC, WIRING

OR BAD 10SV.
YES. ARE THE BELTS SLIPPING?
NO. BROKEN AIREND DRIVE SHAFT

YES. TIGHTEN THE BELTS
YES. CHECK FOR BLOCKAGE IN SENSING LINE FOR 10SV TO SUMP
20
ORIG, SG: STEPPER LIMIT SWITCH = BOTH LIMIT SWITCHES ARE ENGAGED AT THE SAME TIME.
MEASURE THE VOLTAGE ON THE RED AND BLACK WIRE OF THE LIMIT BOARD
..
ORIGINAL INTELLISYS CONTROLLER: SG INTELLISYS CONTROLLER:
IS THE VOLTAGE 5VDC? IS THE VOLTAGE 2VDC?
NO. POTENTIAL PROBLEM WITH

NO. CHECK FOR PROBLEM CONTROLLER. MOVE RED WIRE TO
WITH RIBBON CABLES OR TERMINAL 31 ON P3 AND MEASURE
CONTROLLER. VOLTAGE AGAIN.
MEASURE VOLTAGE BETWEEN MEASURE VOLTAGE BETWEEN IS THE VOLTAGE 2VDC?

WHITE AND BLACK WIRE. WHITE AND BLACK WIRE.
MEASURE VOLTAGE BETWEEN MEASURE VOLTAGE BETWEEN
GREEN AND BLACK WIRE. GREEN AND BLACK WIRE.
YES. IS ALARM NO. POTENTIAL BAD
STILL OCURRING? CONTROLLER, LIMIT
BOARD OR WIRING.
ARE BOTH MEASUREMENTS ARE BOTH MEASUREMENTS
5 VDC? 10-12 VDC?
YES NO. THEN YOU ARE FINISHED
NO. POTENTIAL PROBLEM WITH NO. POTENTIAL PROBLEM WITH

YES. CHECK FOR DIRT RIBBON CABLE OR CONTROLLER.
RIBBON CABLE OR CONTROLLER.
ON LIMIT SWITCHES OR
BAD LIMIT BOARD.
21
ORIG, SG, SE: REMOTE STOP FAILURE = REMOTE START BUTTON IS PRESSED WHILE REMOTE STOP CONTACT IS STILL OPEN.
ORIGINAL INTELLISYS CONTROLLER SG INTELLISYS CONTROLLER SE INTELLISYS CONTROLLER
MEASURE VOLTAGE
MEASURE VOLTAGE MEASURE VOLTAGE
BETWEEN P3 TERMINAL 19 & 20
BETWEEN BTS2-6 AND BTS2-7 BETWEEN J1 TERMINAL 3 & 4
IS THE VOLTAGE 0VDC?
YES. TRY REMOTE START AGAIN. NO. SUSPECT REMOTE STOP CONTACT IS STILL OPEN.
IF ALARM STILL OCCURS, SUSPECT PROBLEM CORRECT PROBLEM AND TRY AGAIN. TO SIMULATE A CLOSED STOP CONTACT,
WITH RIBBON CABLE OR CONTROLLER FOR THE INSTALL A TEMPORARY JUMPER BETWEEN THE TERMINALS LISTED ABOVE.
ORIGINAL INTELLISYS CONTROLLER OR JUST THE
CONTROLLER FOR THE SG.
22
ORIG, SG, SE: REMOTE START FAILURE = REMOTE START BUTTON IS PRESSED AND HELD CLOSED FOR MORE THAN 7
SECONDS AFTER A CONFIRMED START.
ORIGINAL INTELLISYS CONTROLLER: SG INTELLISYS CONTROLLER:
CONNECT DC VOLT METER TO BTS2-4 AND BTS2-5. CONNECT DC VOLT METER TO P3 TERMINAL 21 & 22
START UNIT USING LOCAL START BUTTON. START UNIT USING REMOTE START BUTTON AND MONITOR
LOAD UNIT. VOLTAGE FROM ABOVE.
STOP UNIT USING REMOTE STOP BUTTON. VOLTAGE SHOULD CHANGE FROM 10-12 VDC TO 0 VDC WHILE THE
RESTART UNIT USING REMOTE START BUTTON AND MONITOR BUTTON IS PRESSED AND RETURN TO 10-12 VDC WHEN THE BUTTON
VOLTAGE FROM ABOVE. IS RELEASED.
VOLTAGE SHOULD CHANGE FROM 5 VDC TO 0 VDC WHILE THE
BUTTON IS PRESSED AND RETURN TO 5 VDC WHEN THE BUTTON
IS RELEASED. REMEMBER, THE BUTTON MUST BE CLOSED FOR
TWO SECONDS AND NO LONGER THAN 7 SECONDS.
DID THE VOLTAGE STAY AT 0 VDC?
YES. SUSPECT STICKING CONTACT ON REMOTE START NO. TRY REMOTE START AGAIN.
BUTTON OR PLC. IF ALARM STILL OCCURS, SUSPECT PROBLEM
WITH INTELLISYS CONTROLLER.
SE INTELLISYS CONTROLLER.
CONNECT DC VOLT METER TO J1 TERMINAL 5 & 6

START UNIT USING REMOTE START BUTTON AND MONITOR
VOLTAGE FROM ABOVE.
VOLTAGE SHOULD CHANGE FROM 5 VDC TO 0 VDC WHILE THE
BUTTON IS PRESSED AND RETURN TO 5 VDC WHEN THE BUTTON
IS RELEASED.
23
ORIG, SG, SE: SHORT SEPARATOR ELEMENT LIFE
HIGH PRESSURE DIFFERENTIAL? YES BYPASSED INLET FILTER
NO. LOW DIFFERENTIAL OR COOLANT CARRY OVER INADEQUATE INLET FILTER FOR ENVIRONMENT
BAD MPCV
BAD OR OLD COOLANT
HOLE IN THE ELEMENT
UNIT QUICK CYCLING

WATER IN THE COOLANT UNIT RUNNING TOO COLD
CLOGGED SCAVENGE ORIFICE
OR SCREEN
CLOGGED SCAVENGE ORIFICE LEAK IN WATER-COOLED
OR SCREEN COOLANT COOLER
SCAVENGE TUBE TOO SHORT FOR ELEMENT
SCAVENGE TUBE TOO SHORT FOR ELEMENT
CRACKED BAFFLE IN SEPARATOR TANK
24
USE THIS PAGE FOR NOTES:
25
1.1 Power Outage:
Background
Power outage may have occurred during operation. Any power outage in excess
of 250 ms (.25 sec) will cause the control circuit to reset. This can occur in
installations with automatic reset circuit breakers. Electrical disturbances can
also occur from power company interruptions such as lightning storms. This loss
of power will de-energize the contact coils, relays, and solenoids. The loss of
power to the Intellisys power supply (16 VAC) will cause the system to reset to
an off state which causes the displayed message of “Ready to Start”.
Procedure
Power outages can be diagnosed by using power line recording and
measurement instrumentation. A low cost method of measuring this type
occurrence is to utilize a FLUKE 87 recording voltmeter. This meter can detect
the loss of power as short as 100 ms (.1 Sec). By measuring secondary 120
VAC 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 to
J5 terminal 36 & 35. To measure the 16 VAC, connect the meter to J5 terminal
31 and 30.
1.2 Voltage Sag:
Background
Incoming 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 cause
the control circuit to reset. This can occur in installations with phase unbalance
problems, loss of phase, harmonic distortion, poorly distributed power
management (i.e. undersized step down transformers for application loading),
excessive wire length, and undersized wiring. Electrical disturbances, such as
lightning storms, can also cause voltage sags. The voltage sag will de-energize
the contact coils, relays, and solenoids. The voltage sag to the Intellisys power
supply (16 VAC) will cause the system to reset to an off state which causes the
displayed message of “Ready to Start”.
Procedure
Voltage sags can be diagnosed by using power line recording and measurement
instrumentation. A low cost method of measuring this type occurrence is to
utilize a FLUKE 87 recording voltmeter. This meter can detect the voltage sag as
short as 100 ms (.1 Sec). By measuring secondary 120 VAC or 16 VAC circuits
with the meter set to “VOLTS AC”, 100 ms record mode, the voltage sag can be
measured. 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.
26
1.3 Grounding Problems:
Background
A poor ground system can cause severe electrical problems. Electrical control
systems can experience both over voltage and voltage sag conditions due to a
poor ground. This can cause nuisance shutdowns, damage to power supply
circuits, communications errors, and even be a safety hazard for fault conditions.
Electrical fault conditions must have a low resistance path to earth ground. The
ground conductor supplied to the machine should be sized and installed per NEC
and any additional local wiring requirements. The utilization of metal conduit or
air piping that is attached to the air compressor is not considered an adequate
ground.
Typically, building codes require that structural steel must be grounded per NEC.
Structural supports such as steel girders and beams should be electrically
attached to earth ground via a buried grid. Verify the supplied ground wire meets
ampacity requirements per code and that it connects to the approved building
earth ground grid.
Some environments may have a distorted or noisy ground. This is usually an

indication that current is flowing into earth ground. This can be caused by faulty
electrical equipment in the area that is attached to the ground grid. Ground
currents can be present in environments that utilize variable speed inverter type
motor drives, such as variable frequency drive (VFD). Environments that utilize a
large number of switching power supplies can also cause ground currents. Most
all computer systems use switching power supplies. Many of these ground
currents can be generated by high frequency (above 60 HZ) disturbances that
are known as harmonic distortion. Because of the high frequency, they are hard
to analyze and measure. An effective safeguard against this type of ground
current is to minimize the length of wire to the ground grid. The use of braided
ground 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 3X
the rated value.
Verify the ground grid point is free from corrosion or moisture that may prohibit a
low resistance ground. It is important to verify that other electrical equipment that
is electrically bonded to the air compressor is properly grounded as well. This
will include any electrical device that is structurally connected to conductive air
piping/plumbing originating at the air compressor. Wired interfaces such as
remote start/stop, remote starters, sequencers, sequencer interfaces, Intellisys
Sequence Control, Intellisys Remote Interface should also be properly grounded.
Procedures
A 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.
27
Disconnect power from machine.
Set the meter for amps AC and connect the meter in series with the ground wire
provided to the machine. If a recording meter is used (Fluke 87), set to 100 ms
record mode. A recording meter is the preferred measurement for intermittent
problems.
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 of
ground current.
Internally induced ground current, power on state:

A Fluke 87 (or equivalent) meter can be used to measure ground current.
provided to the machine. If a recording meter is used (Fluke 87) then set to 100
ms record mode. A recording meter is the preferred measurement for
intermittent problems.
Apply power to machine.
Isolate electrical devices in compressor package and determine the source of
ground current.
Causes may include: faulty wiring, moisture contamination of any electrical
connections, 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.
provided to the machine. If a recording meter is used (Fluke 87), set to 100 ms
record mode. A recording meter is the preferred measurement for intermittent
problems.
Apply power to machine.
Start machine.
Load machine.
28
Isolate electrical devices in compressor package and determine the source of
ground current.
Causes may include: faulty wiring, moisture contamination of electrical
connections, 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:
Background
The Intellisys power supply is fed from the 16 VAC center-tap secondary of the
control power transformer T1. The center-tap indicates a central tap between the
16 VAC winding. This means the expected voltage across one end of the
winding and the center-tap will be 8 VAC. The expected reading of the 16 VAC
signal should have a tolerance of +/-15 %. The 16 VAC center-tap signal is fed
to the Intellisys through the J4 connector. The signal is rectified by diodes CR1
and CR2. The resulting rectified DC signal is approximately 10.5 VDC. The
Intellisys is designed to accommodate +/- 25 % tolerance. Deviations in excess
of +/-25%, or a loss of this signal, can cause the machine to shut down and reset
to “Ready to Start”.
Procedure
This voltage measurement can be made with a Fluke 87 meter (or equivalent). A
recording meter (Fluke 87) is preferred for intermittent problems. Set meter for
Volts AC and connect as noted.
Connect from J4-30 to J4-31.

Expected value =16 VAC +/- 2.4 VAC
Expected value = 8 VAC +/- 1.2 VAC
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 or
crimp, frayed ends, insulation breakdown, moisture contamination.
Fuse problem: blown fuse (primary or secondary), loose connection, voltage drop
across fuse: >.5 VAC excessive control system current: Remove power and
disconnect all but J5 connector to Intellisys (also remove option prom and
communications wiring). Apply power and record measurements. If
29
measurements return to normal, repeat procedure and use process of elimination
to find cause.
1.5 External 5 VDC Short Circuit:
Background
The Intellisys provides two 5 VDC signals for external use. The logic supply
voltage is used by the Intellisys to supply power for internal circuitry such as the
EPROM, RAM, Microprocessor, etc. The logic supply is also used to supply
power to an external device known as the “Option Module”. This connection is
made via connector J11. J11 is a 5-pin connector located on the left side of the
controller (viewed from the front). The “Option Module” should always be
installed or removed with power off. Note: the “Option Module” can be potentially
damaged if installed with power on. Installing the module with power on can
cause a latch-up condition which can create an excessive amount of current
draw. 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-up
condition as installing it with power on. Intermittent connections can be caused
by improper installation, bent connection pins, moisture contamination, corrosion
of electrical contacts, or excessive vibration.
Procedure
recording meter (Fluke 87) is preferred for intermittent problems. Remove power
from machine. Remove back cover of Intellisys and locate J11 connector.
Insure static precautions are used when handling circuit board. Re-apply power
to machine. Set meter for Volts DC and connect and take measurements as
noted:
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 the
sensors. This signal is externally supplied through J2 and J3 connectors. This
signal is provided for both pressure transducers and thermistors (temperature). If
this signal is short circuited externally, abnormal controller behavior will occur.
This could cause sensor reading errors, invalid calibration, sensor faults, sensor
warnings, or general shutdown “Ready to Start”. Potential root causes include
wiring fault to ground (chassis, sensor ground, or shield wire), moisture/corrosion
contamination of connector or sensor, and solenoid fault to pressure transducer
chassis.
30
Volts DC and connect and take measurements as noted:
Connect from J3-25 to J3-24

Expected value = 5.0 VDC +/- .2 VDC
1.6 Environmental Problems:
Moisture:
Background
Moisture problems are typically encountered in outdoor applications. NEMA 4-
rated starter enclosures should be specified for these environments to minimize
moisture contamination. Moisture contamination can also be caused by the
condensation of saturated air inside the starter enclosure. The presence of
moisture can lead to a multitude of electrical connection related problems.
Moisture can accelerate corrosion build-up on metal surfaces typically found in
electrical connection points. The corrosion can create an open circuit between
the wire and the electrical contact. Corrosion can even cause a short circuit to
adjacent contact points. These types of faults are generally intermittent and are
affected by temperature, the total amount of moisture, and vibration. Visual
inspection is the best method of detecting these types of problems.
Procedure:
Remove power from machine.
Visually inspect all terminal connections inside the starter enclosure. This
includes 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 before
handling circuit board. Visually inspect all electrical connectors. This includes
battery contact BAT1 (if available).
1.7 Temperature:
Background
Ambient operating temperature range is specified as 35° F to 115° F. Outdoor
modification 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
31
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 ambient
inside the starter enclosure is 20° F. This is due to heat generated by the
electrical equipment inside the enclosure, such as the control transformer,
contactors,etc. External factors can cause the rise above ambient to exceed this
value. These factors include improper installation spacing requirements,
ventilation problems, direct sunlight exposure, etc.
Exceeding these temperature limits can cause many electrical problems

including the Intellisys. Intellisys problems include shutdown “Ready to Start”,
blank or abnormal display problems, and memory problems.
Procedure
To test the system for temperature related problems a temperature probe can be
used. Measurements should be made inside the starter enclosure with the
enclosure door shut. If possible, take the measurements in the upper half of the
enclosure to get worst case readings.
1.8 Vibration:
Background
Excessive 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 to
occur. This can lead to arcing and even faults to adjacent circuits. Crimped
connections, such as terminal spade lugs (Faston), can fatigue and also cause
open circuit conditions.
Procedure
To inspect for loose wiring caused by vibration and shock use the following
procedure:
Remove power from machine.

Visually inspect all electrical connections for evidence of loose wiring, arcing, and
frayed wiring.
Manually pull each wire at the terminated end and inspect for loose wiring. 5-10
pounds of pull force should be asserted.
1.9 Remote Alarm applications:
Background
The remote alarm feature of the Intellisys provides a volt-free form “C” relay
contact 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
32
lamp. If an inductive load is used, such as a relay coil, the rating should be
reduced 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 the
Intellisys. An effective way to minimize this interference is to install a RC network
known as an “Arc Suppressor”. The RC network can be installed across the
form “C” contacts that are used in the application. Arc suppressors are normally
sized for specific applications. The general-purpose arc suppressor
P/N…39203443 used in the starter circuit (RC1) can be used for most
applications.
33
2.1 STEPPER MOTOR TEST PROCEDURE
Background
The stepper motor is a motor that can be moved in discrete increments of .9° for
the Original Intellisys and .45° for the SG Intellisys. The motor is a constant
torque device that is controlled by driver chips on the starter interface board or
the power supply board. The main problem that can occur is that a winding
shorts either to itself, the other winding or to the casing.
Procedure
Disconnect 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 OHMS

8” 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
Background
The stepper motor is moved by electrical signals received from components
called driver chips. The driver chips are located at position U14 and U15 on the
starter interface board for the Original Intellisys and at positions U2 and U7 on
the power supply board for the SG Intellisys. The signal turns off and on and
34
reverses polarity to cause the stepper motor to move in the proper direction. A
shorted stepper motor will almost always damage the driver chips on the Original
Intellisys but will simply illuminate an overload on the SG Intellisys. See FSM for
more information on the SG.
Procedure
Disconnect the Stepper Motor leads from the board. Measure resistance
between (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 not
read 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 Field
Service 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 lights
fails to light or stay on continuously, either the driver chips are bad or the
controller is not sending the step and direction signal.
Next, determine if the controller is sending the direction and step signal. See
below for SG Controller. On the original Intellisys Starter Interface Board
connect 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 then
back 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 on
the Power Supply Board. Connect a DC voltmeter to terminal number J4
Terminal 3 and J4 Terminal 2.
Power the compressor up and see if the voltage changes from 0 to 6-12 and then
back 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 on
direction and step signal for the SG Controller.
35
2.3 LIMIT BOARD TEST PROCEDURE
Background
The limit board contains two optical switches each of which emits an infrared light
beam. When the light beam is interrupted, the voltage changes in a circuit that
tells the controller the position of the valve.
Procedure
To perform this procedure, disconnect, lock and tag the incoming power. Make
the volt meter connections leaving the limit board wired. Then reapply power to
take 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 the
Starter Interface Board. If not, there is a problem with the controller or ribbon
cable.
On the SG Controller, a measurement of 2 VDC is good. Zero volts mean a bad

controller 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 closed
limit 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 open
limit 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 more
information pertaining to the limit board on the SG Controller.
36
2.4 PRESSURE SENSOR CHECK OUT
Background
The pressure sensors used on the Intellisys controllers use a 5 VDC supply and
turn it into a varying voltage signal to the controller. The SE and Original use a
0-50 mv signal and the SG uses a .5-4.5 VDC signal. Both supply and signal
voltages can be measured. The Sensor can also be checked out with it removed
from the unit.
Procedure
Original 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. The
resistance should be 405 to 600 ohms.
Disconnect sensor and measure resistance between white and green wire. The
resistance 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
Background
Triacs can be thought of as a solid state relay operated by a 5 VDC signal. One
of the unusual things about a Triac is that the output voltage cannot be
determined if the Triac is off or on unless there is a load such as a solenoid
connected to the output. It is a good practice to carry a known good
incandescent light that can be connected to the output when testing for output
voltage using a digital voltmeter.
One of the main causes of a failed triac is the coil or solenoid that it operates has
a short circuit causing the current to exceed the capabilities of the triac.
37
Procedure
With a known good incandescent light connected to the output terminal, a digital
voltmeter can easily read whether or not the triac is on or off. 115 VAC means
on, a 0 VAC means off. This is the best way to monitor outputs on any Intellisys
Controller.
For the original Intellisys Controller there is an additional problem to determine

whether the faulty part is the controller or the Starter Interface Board.
Refer to Section B, Page 28, in the blue Field Service Manual for assistance
in determining the faulty part.
2.6 AUXILIARY CONTACTS
BACKGROUND
Auxiliary contacts are small contacts that are mounted on the front or sides of
starters. These contacts operate at the same time as the starter. The contacts
can be either normally open or normally closed. Some of the contacts are used
in both the 120 VAC control circuit and the low voltage control circuit for feedback
to the Intellisys controller. The procedure below covers how and where to test
the auxiliary contacts that are in the low voltage circuits.
PROCEDURE
Original Intellisys Controller
Contact 1Ma (mounted on the 1M starter contactor.)
Connect voltmeter set to volts DC to terminals BTS2-15 & 14 on the starter
interface board. You should read 5 VDC when 1M is de-energized and 0 VDC
when 1M is energized.
Star Delta Starting Only

Contact 1Sa (mounted on the 1S starter contactor).
interface board. You should read 5 VDC when 1S is de-energized and 0 VDC
when 1S is energized.

Contact 2Ma (mounted on the 2M starter contactor).
interface board. You should read 5 VDC when 2M is de-energized and 0 VDC
when 2M starter is energized.
SE Intellisys Controller
38
Connect voltmeter set to volts DC to terminals J1-10 & 9. You should read 5 VDC
when 1M is de-energized and 0 VDC when 1M is energized.

when 1S is de-energized and 0 VDC when 1S is energized.

when 2M is de-energized and 0 VDC when 2M starter is energized.
SG Intellisys Controller
Connect voltmeter set to volts DC to terminals P3-8 & 7. You should read 10-12
VDC when 1M is de-energized and 0 VDC when 1M is energized.

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.

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.
39
3.1 Power Outage:
Background
Power outage may have occurred during operation. Any power outage in excess
of 250 ms (.25 sec) will cause the control circuit to reset. This can occur in
installations with automatic reset circuit breakers. Electrical disturbances can
also occur from power company interruptions such as lightning storms. This loss
of power will de-energize the contact coils, relays, and solenoids. The loss of
power to the Intellisys power supply (24 VAC) will cause the system to reset to
an off state which causes the displayed message of “Ready to Start”.
Procedure
Power outages can be diagnosed by using power line recording and
measurement instrumentation. A low cost method of measuring this type
occurrence is to utilize a FLUKE 87 recording voltmeter. This meter can detect
the loss of power as short as 100 ms (.1 Sec). By measuring secondary 120
VAC 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 to
P1 terminal 1 & 10 on the controller. To measure the 24 VAC, connect the meter
to J1 terminal 1 and 2 on the power supply board. To measure the 12 VDC to the
controller, connect the meter set in volts DC to J4 terminal 1 & 2 on the power
supply board.
3.2 Voltage Sag:
Background
Incoming 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 cause
the control circuit to reset. This can occur in installations with phase unbalance
problems, loss of phase, harmonic distortion, poorly distributed power
management (i.e. undersized step down transformers for application loading),
excessive wire length, and undersized wiring. Electrical disturbances, such as
lightning storms, can also cause voltage sags. The voltage sag will de-energize
the contact coils, relays, and solenoids. The voltage sag to the Intellisys power
supply (24VAC) will cause the system to reset to an off state which causes the
displayed message of “Ready to Start”.
Procedure
Voltage sags can be diagnosed by using power line recording and measurement
instrumentation. A low cost method of measuring this type occurrence is to utilize
a FLUKE 87 recording voltmeter. This meter can detect the loss of power as
short as 100 ms (.1 Sec). By measuring secondary 120 VAC 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 to P1 terminal 1 & 10 on
40
the controller. To measure the 24 VAC, connect the meter to J1 terminal 1 and 2
on the power supply board. To measure the 12 VDC to the controller, connect
the meter set in volts DC to J4 terminal 1 & 2 on the power supply board.
3.3 Intellisys 24 VAC Supply:
Background
The Intellisys power supply is fed from the 24 VAC secondary of the control
power transformer T1. The expected reading of the 24 VAC signal should have a
tolerance of +/-15 %. The 24 VAC is fed to the power supply board through the
J1 connector. The signal is rectified by diodes. The resulting rectified DC signal
is approximately 12 VDC. The Intellisys is designed to accommodate +/- 25 %
tolerance. Deviations in excess of +/-25%, or a loss of this signal, can cause the
machine to shut down and reset to “Ready to Start”.
Procedure
volts AC and connect as noted.

Set meter to volts DC
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 or
crimp, frayed ends, insulation breakdown, moisture contamination.
Fuse problem: Blown fuse (primary or secondary), loose connection, voltage
drop across fuse: >.5 VAC, excessive control system current: Remove power and
disconnect all but J2 connector to Intellisys (also remove option prom and
communications wiring). Apply power and record measurements. If
measurements return to normal, repeat procedure and use process of elimination
to find cause.
3.4 External 5 VDC Short Circuit:
Background
The Intellisys provides two 5 VDC signals for external use. The logic supply
voltage is used by the Intellisys to supply power for internal circuitry such as the
EPROM, RAM, Microprocessor, etc. The logic supply is also used to supply
power to an external device known as the “Option Module”. This connection is
41
made via connector P9. P9 is a 5-pin connector located on the left side of the
controller (viewed from the front). The “Option Module” should always be
installed or removed with power off. Note: the “Option Module” can be potentially
damaged if installed with power on. Installing the module with power on can
cause a latch-up condition which can create an excessive amount of current
draw. 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-up
condition as installing it with power on. Intermittent connections can be caused
by improper installation, bent connection pins, moisture contamination, corrosion
of electrical contacts or excessive vibration.
Procedure
recording meter (Fluke 87) is preferred for intermittent problems. Remove power
from machine. Remove back cover of Intellisys and locate P9 connector. Insure
static precautions are used when handling circuit board. Re-apply power to
machine. 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 the
sensors. This signal is externally supplied through P5 and P6 connectors. This
signal is provided for both pressure transducers and thermistors (temperature). If
this signal is shorted externally, abnormal controller behavior may occur. This
could cause sensor reading errors, invalid calibration, sensor faults, sensor
warnings, or general shutdown “Ready to Start”. Potential root causes include
wiring fault to ground (chassis, sensor ground, or shield wire), moisture/corrosion
contamination of connector or sensor and solenoid fault to pressure transducer
chassis.
volts DC and connect and take measurements as noted:
Connect from P5-1 to P5-2.

Expected value = 5.0 VDC +/- .2 VDC.
42
4.0 External Electrical Disturbances:
Background
These are defined as sources of interference that can adversely affect signal
integrity of control systems and wiring interfaces. These types of problems can
be caused by Radio Frequency Interference (RFI), Electro-Magnetic Interference
(EMI), Electro-Static Discharge (ESD), lightning disturbances, and power line
transients and surges. Control circuits that are the most susceptible to these
disturbances include power supplies, sensors (pressure and temperature), and
external interface wiring such as remote starter interface and communications
port interfaces. Note: The effects of external electrical disturbances are
magnified if the equipment is not properly grounded (see Grounding Problems).
Intellisys based control systems have been designed and tested for immunity
against external electrical disturbances. The test standard is derived from the
EC Directive (European Community Directive) for heavy industrial applications
and is known as EN50082-2. These test standards are specified to simulate
severe 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 Immunity

10 V/m, 80 to 1000 MHz (80% AM w/1kHz sinewave)
900 +/- MHz, 10 V/m pulse modulated at 200 Hz to 50 % duty
cycle per ENV50204
ENV50141 Conducted RF Disturbance Immunity

10 V rms (80% AM w/ 1 kHz sinewave) on all power and signal
lines
EN 610004-4 Electrical Fast Transient/Burst Immunity

+/- 2 kV on all power signals lines
EN 61000-4-8 Power Frequency Magnetic Field Immunity

30 A rms/m continuous at 50 Hz
RFI and EMI disturbances can be airborne as well as conducted into the
equipment. The source of this type of disturbance includes radio transmitters,
variable speed motor drives (VFD), switching power supplies, arc welding
43
equipment, or other equipment that exhibits excessive electrical arcing during
operation (i.e. DC brush motors). The level of disturbance is generally known as
field strength. The electric field strength is measured in volts per meter (V/m). A
hand held 5 watt transmitter can generate 10 V/m electric field strength at a
distance of approximately 1 foot. To alleviate potential RFI and EMI disturbances,
ensure the equipment is properly grounded (see Grounding Problems) and
eliminate close range exposure to radiating devices.
ESD disturbances can be airborne as well as conducted into the equipment. The
ESD event occurs when an electrical charge is dissipated into the equipment.
This event is usually random and normally occurs with human interaction. A
human can carry an extremely high electrical charge (8 kV) by simply walking
across an insulated surface. Other sources include charged ungrounded
material that can come into contact with the equipment (example: The presence
of air flowing through a plastic pipe can cause an electrical charge to propagate
along the surface of the pipe and arc into a conductive surface). ESD safeguard
measures should be used when handling electronic circuit boards and
equipment. (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 a
lightning strike. Direct lightning strikes can cause severe electrical damage to
controls, motors and wiring. The best precaution for this is to avoid open
exposure and ensure adequate facility protection such as lightning arrestors.
Power line transients and surges can cause a variety problems in the electrical
system . The transient or surge is defined as a random abnormal condition that
results in a distorted power signal. The distortion can usually be detected by
measuring the voltage of the incoming power signal. Power line transients
typically occur in fractions of seconds (less than 100 ms) and are hard to detect
with standard volt meters. An oscilloscope is usually required for measuring
transients. Power line surges occur at longer intervals (>100 ms) and can be
detected more easily with the use of a recording voltmeter (such as Fluke 87). If
the voltage level of the transient or surge is high enough, abnormal system
behavior can occur. These problems include:
Erratic control system behavior:

Fuse blowing
Control reset
Erratic Triac operation (output)
Control power transformer insulation breakdown:

Motor winding insulation damage
Solenoid coil winding insulation damage
44
Transients and surges can be caused by a variety of reasons. A few of these
include:
Poor or ungrounded equipment.

Improperly sized power distribution systems that generate disturbances when
switching 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 system
Variable speed drive applications (Induction or DC motors)
Intellisys control systems have sufficient protection against typical electrical

disturbances that can occur in the industrial environment. These systems have
been designed to exceed the highest levels specified within EN50082-2 (see
above). 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.
45
5.0 Membrane Switch
Background
The membrane switch is part of the user interface to the Intellisys control. It is a
matrix of switches bonded to the Intellisys controller and electrically connected to
the control circuit board. The internal membrane switch wiring to the physical
switches is accomplished through conducted traces made of silver conductive
ink. These electrical traces vary in length but will always measure less than 100
ohms when tested. The electrical schematic to Intellisys membrane switches is
shown in the diagrams below. The continuity of these switches can be tested
with the use of an ohmmeter. To test the individual switches use the following
procedure:
Procedure
1. 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.
Start 1-4
Hidden Left 1-5
Hidden Right 1-6
Unload/Load 2-4
Down Arrow 2-5
Set 2-6
Display Select 3-4
Up Arrow 3-5
Unloaded Stop 3-6
Figure 1. SE Membrane Schematic
46
S1 1-2
S2 1-4
S3 5-4
S4 Start 3-2
S5 Unload 3-4
S6 Load 5-6
S7 Unloaded Stop 7-6
S8 Down Arrow 7-8
S9 Up Arrow 5-8
Figure 2. SG Membrane Schematic
47
Mod/ACS 1-8
Select Up Arrow 1-7
Setpoint Down Arrow 1-6
On/Offline 2-8
Select Down Arrow 2-7
Set 2-6
Unload 3-8
Reset 3-7
Setpoint Up Arrow 3-6
Start 4-8
Unloaded Stop 4-7
Test 4-6
Figure 3. SSR Original Intellisys Membrane Schematic
48
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SSR INTELLISYS ROTARY

The following is a guide to be used when identifying the root cause of a

ORIG = Original Intellisys controller SSR 50-450HP

HOW TO USE ...............................................................................................................................................4

SE INTELLISYS CONTROLLER WARRANTY INFORMATION SHEET ........................................5

SG INTELLISYS CONTROLLER WARRANTY INFORMATION SHEET........................................6

Compressor is experiencing CHECK INLET CONTROL SYS alarm.

POWER SUPPLY INFORMATION POWER ON

GROUND RESISTANCE CHECK INFORMATION POWER OFF

I/O RESISTANCE CHECK POWER OFF

POWER SUPPLY INFORMATION POWER ON

GROUND RESISTANCE CHECK INFORMATION POWER OFF

I/O RESISTANCE CHECK POWER OFF

CHECK WIRING FROM T1 TO J4-29, 30, 31.

CHECK CUSTOMER GROUND INTEGRITY. CHECK FOR FAULT CURRENT IN GROUND

2ATT - BLACK WIRE TO GROUND < 1 MEG OHM

OPTION PROM INTERMITTENT

EXCESSIVE TEMPERATURE REDUCE CONTROLLER AMBIENT TO <160°F

REMOTE ALARM ARCING INSURE PROPER SUPPRESSOR. SEE PARAGRAPH 1.9

CHECK WIRING FROM T1 TO J1 - 1 & 2.

CHECK CUSTOMER GROUND INTEGRITY. CHECK FOR FAULT CURRENT IN GROUND

2ATT - BLACK WIRE TO GROUND < 1 MEG OHM

OPTION PROM INTERMITTENT

EXCESSIVE TEMPERATURE REDUCE CONTROLLER AMBIENT TO

REMOTE ALARM ARCING INSURE PROPER SUPPRESSOR. SEE PARAGRAPH 1.9

SE CONTROLLER ORIGINAL INTELLISYS SG CONTROLLER

16 VAC C.T. FEED 24 VAC FEED CIRCUIT

EXCESSIVE TEMPERATURE EXCESSIVE MOISTURE. WATER

SE CONTROLLER ORIGINAL INTELLISYS SG CONTROLLER

SEE BLUE FSM SECTION SEE PARAGRAPH 2.5

USE SE I/O TEST KIT

DID VALVE MOVE PAST YES. SUSPECT BAD CONTROLLER

NO. DID VALVE MOVE TO

NO. SUSPECT SLIPPING COUPLING

DID VALVE MOVE PAST THE

YES. MAKE SURE BLOW DOWN

NO. IS THE BLOWDOWN AIR

NO. SUSPECT SLIPPING COUPLING.

YES. SUSPECT 1AVPT TRANSDUCER PROBLEM, OR LEAK IN SENSING

YES. IS THE AIREND TURNING?

NO. SUSPECT SLIPPING GEAR

UNLOADED IS THE INLET VALVE CLOSED?

NO. ORIGINAL CONTROLLER - CHECK FOR SLIPPING

NO. SUSPECT SLIPPING COUPLING

IF OK, IS BLOWDOWN AIR CAUSING THE VALVE TO CLOSE TOO FAR?

YES. MAKE SURE BLOW DOWN

BLOCKAGE IN SENSOR LINE FROM SUMP

NO. CHECK BLOW DOWN SILENCER ADJUSTMENT.

YES. CHECK FOR INLET VALVE STUCK CLOSED OR

WATER IN THE SYSTEM CAUSING CORROSION IN THE

OLD STYLE INLET VALVE

YES. IS COOLANT LEVEL CORRECT?

AIR-COOLED = BAD ENVIRONMENT

EXTERNAL COOLANT LEAK CAUSING

HIGH AMBIENT RESTRICTIVE EXHAUST DUCTING

RECIRCULATION OF COOLING AIR

FAULTY THERMOSTATIC VALVE IS THE VALVE BYPASSING THE COOLER?

CHECK FOR HIGH MOTOR AMPS

PLACE OVERLOAD RELAY IN MANUAL

NO. POTENTIAL PROBLEM WITH WIRING FROM OVERLOAD TO CONTROLLER OR CONTROLLER.

YES. DID OVERLOAD RELAY REQUIRE

MORE THAN 1% UNBALANCE

YES. BAD CONNECTION WITHIN THE STARTER