Ingersoll-Rand P425AWIR, XP375AWIR, HP375AWIR, VHP300AWIR, P600WIR HP450WIR, VHP400WIR Electrical / Electronic Service Repair Ma

Portable Power P.O. Box 868 -- 501 SanfordAve Mocksville, N.C. 27028 SERVICE MANUAL FOR ELECTRICAL/ELECTRONIC www.portablepower.irco.com Book No. 22235428 (11/03) P425AWIR (7/120) XP375AWIR (9/110) HP375AWIR (10/105) VHP300AWIR (14/85) P600WIR HP450WIR VHP400WIR

1 ( ) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual TABLE OF CONTENTS SECTION 1 ....... Manual Description SECTION 2 ....... General Information And Operational Theory SECTION 3 ....... Service Tools SECTION 4 ....... Electronic Systems Troubleshooting Procedures And Techniques SECTION 5 ....... System Schematic Diagrams SECTION 6 ....... Electronic Component Location Drawings SECTION 7 ....... Individual Circuit Diagrams SECTION 8 ....... Electrical Connector Information SECTION 9 ....... Electrical Parts List SECTION 10 ...... Alerts and Shutdowns List SECTION 11 ...... Recommended Spare Parts SECTION 12 IR Engine ....

2 ( ) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual SECTION 1 MANUAL DESCRIPTION This manual contains all of the information concerning the electrical and electronic systems for the P425 Family of compressors. It provides all information necessary to service, troubleshoot and order parts for this machine. It is organized into 12 sections. Sections 2 -- 4 cover systems operation and troubleshooting procedures. Sections 5 -- 7 have location diagrams, drawings of specific circuits and systems schematics. Section 8 has information concerning the electrical connectors used, including removal and re- placement. Section 9 contains the parts list with ordering information. Section 10 contains the list of Alerts and Shutdowns. Section 11 contains a list of recommended spare parts for servicing. Section 12 contains engine information.

3 ( ) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual SECTION 2 GENERAL INFORMATION and OPERATIONAL THEORY

4 ( ) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual GENERAL INFORMATION AND OPERATIONAL THEORY General The P425 Family of machines has an electronic monitor and control system to provide discharge air pressure control and engine and package monitor functions. The system uses the WEDGE controller to perform these functions. The electrical system connects all the necessary switches, sensors and transducers to the WEDGE controller in order for it to perform the monitor and control functions. WEDGE Controller The WEDGE controller is the heart of the machine monitor and control system. It provides data collection, alarming and control functions for compressor operations. It is a microcontroller based unit with analog and digital inputs and outputs. The WEDGE controller is attached to the back of the control panel. The LED annunciators are part of the front panel of the WEDGE. They can be seen through the laminate on the front of the control panel. The WEDGE is attached to the control panel with four #10 size nuts. The first function of the WEDGE controller is to scan all analog and digital inputs at a fixed interval. These inputs are scanned every 50 milliseconds. The analog values are then compared against minimum and maximum values and an ALERT or SHUTDOWN is issued, if a value is out of range. The various ALERTS and SHUTDOWNS are listed in Section 10 of this manual. The second function of the WEDGE controller is machine discharge pressure control. The WEDGE monitors the regulation system air pressure and varies the engine throttle to maintain the setpoint discharge air pressure. The setpoint pressure is set using the regulator on the separator tank. The third function of the WEDGE controller is to communicate with the diesel engine via the J1939 CAN network. It retrieves diagnostic information over J1939.

5 ( ) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual FIGURE 2--1 P425/P600 HARNESS SYSTEM SCHEMATIC WEDGE Controller CONTROL PANEL SWITCHES GAUGES 24VDC HEATERS ENGINE ECM DIAGNOSTIC INTERFACE ESTOP SWITCHES SOLENOID VALVES SPEED SENSOR FUEL LEVEL SWITCH PRESSURE TRANSDUCERS TEMPERATURE SENSORS BATTERY STARTING AND CHARGING SYSTEM W1 P4 W1 P1 HOURMETER CONTROL PANEL HARNESS W1 W1

6 ( ) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual FIGURE 2--2 WEDGE CONTROLLER WEDGE TO ENGINE INTERFACE IR ENGINE J1--34 J1--35 J1--24 IR 41RD5AE 61IRF8TE ENGINE CONTROLLER J50--G1 J50--J1 J50--A2 J50--F2 CAN LO CAN HI CANSHLD J1--38 J1--13 ANALOG THROTTLE RANGE = 1.10VDC (1400RPM) TO 3.7VDC (2400 RPM) ANALOG THROTTLE KEY SWITCH

7 ( ) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual P425/P600 J1939 CAN COMMUNICATIONS SCHEMATIC ENGINE ECM WEDGE CONTROLLER TERMINATOR TERMINATOR ENGINE DIAGNOSTICS JACK J57 R4 P11 R5 P10 FIGURE 2--3 P6

8 ( ) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual The wedge uses an analog signal to communicate with the John Deere engine. This signal has a range of 1.1V to 3.7V. This range corresponds to an engine speed range of 1400 to 2400 RPM. Figure 2--2 shows the signals between the engine controller and the WEDGE controller. Sensors and Transducers The electronics system contains sensors and transducers that are used to collect data from the compressor. The temperature is measured by a thermistor. This device exhibits a change in resistance as the temperature changes. The resistance causes an input voltage change to the WEDGE controller input and is interpreted as a temperature change. The electronics system also uses pressure transducers to measure compressor pressure changes. These devices have an output signal of .45 VDC to 4.5 VDC, corresponding to 0 psi and the maximum measured psi for a particular device. The maximum pressure transducer ranges are 100 or 225 psi. The 100 and 225 psi devices are gauge pressure devices. These transducers are provided with 5 VDC excitation to power the device. These are three wire devices: excitation, signal and ground. Digital Inputs and Outputs The WEDGE controller scans digital inputs such as switch contacts. These are either “ON” (24VDC) or “OFF” (0 VDC). These digital inputs are connected to switches within the package such as the key start switch, air filter switches and IQ filter switches. The WEDGE controller provides 24 VDC digital outputs to control solenoids, start compressor and DC heaters. These are 24 VDC “ON” and 0 VDC “OFF”. They are current limited and short circuit protected. Controller Outputs The WEDGE controller has four types of outputs: frequency, pulse width modulated, analog and 24VDC digital (ON/OFF). The analog output is used as the throttle signal to the engine. The WEDGE varies the analog signal from 1.25 to 4.25 volts, corresponding to 1400 to 2100 RPM. This signal is used with the John Deere engine. The frequency throttle signal is used with the Cummins engine and the pulse width modulated signal is used with the CAT engine. Pressure Control The discharge pressure is controlled by manipulating the engine speed and compressor inlet valve position. The inlet valve position is controlled pneumatically and the engine speed is determined by the WEDGE controller. The WEDGE measures the pneumatic system regulation pressure and computes an engine throttle setting. This throttle setting is sent to the engine via the frequency throttle, Analog, PWM or J1939 throttle, de- pending on which technique is used. The engine controller will control engine speed to this throttle setting. Electronic Engine -- P425 Family of Machines The P425 Family of machines contains an emissions certified diesel engine. In order to meet the emissions requirements, the engine has an electronic control system. The control system handles all monitor, alarm and control functions for the engine. The WEDGE controller communicates with the engine controller over the J1939 CAN network. The WEDGE controller sends throttle settings to the engine and receives diagnostic and run time data from the engine over the J1939 CAN network. An analog throttle interface is currently used with the engine. Figure 2--2 shows the connections between the WEDGE controller and the engine controller.

9 ( ) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual J1939 Data Link The CAN network is a single pair shielded cable located with the W1 main harness. Figure 2--3 shows a layout of the CAN harness or “backbone” as it is referred to. The termination resistors (Terminator) are important to prevent reflections on the transmission line and must be in place for the network to function properly. The engine diagnostics connector is located on the left side of the engine. This is used to connect the engine manufacturer’s service tools to the CAN network. This connector also provides 24 VDC to power these service tools. Electrical System The electrical system consists of the wiring harnesses and associated electrical devices such as relays, switches, lights, solenoids and alarm horn. There is one wiring harnesses in the P425 machine. P/N 22199061 W1 Chassis Main Harness The schematic diagrams show the connections for this harness. Figure 2--1 is a system schematic showing harness connection with devices and controllers. Sec- tion 8 includes information on connectors used in the harness. The electrical circuits are protected using ATC style fuses. A fuse should only be replaced with one of the same rating. Replacing a fuse with one of a large rating could lead to harness damage. If a fault occurs and the circuit does not have the appropriate size fuse, wires could be burned in the harness and damage other circuits. Machine ID Software versions 1.60 and greater use software to set the machine ID. Versions less than 1.60 use an ID resistor plug, R2. The ID plug is located behind the control panel box on the W1 harness trunk. The resistor plugs are molded in colors for easy identification. Refer to Section 7, Individual Circuit Diagrams and the page entitled R @ MACHINE ID PLUG for details. It is recommended that all machines be upgraded to Version 1.60 or greater. The software set machine ID is much more reliable than the resistor plug.

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Ingersoll-Rand P425AWIR, XP375AWIR, HP375AWIR, VHP300AWIR, P600WIR HP450WIR, VHP400WIR Electrical / Electronic Service Repair Ma

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