Ingersoll-Rand P425AWIR Setup guide

Book: 22600498 (1/05) 1

INSTALLATION, OPERATION AND SERVICE MANUAL

FOR

AUTO START STOP SYSTEM

OPTION FOR COMPRESSORS

P.O. Box 868

501 Sanford Ave

Mocksville, N.C. 27028

www.portablepower.irco.com

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,

service marks, logos, or other proprietary identifying marks belonging

to Ingersoll-Rand Company in this manual is historical or nominative

in nature, and is not meant to suggest a current affiliation between

Ingersoll-Rand Company and Doosan Company or the products of

either.

Revised (09-12)

Book: 22600498 (1/05) 2

TABLE OF CONTENTS

SECTION 1 . . . . . . . Safety

SECTION 2 . . . . . . . Manual Description

SECTION 3 . . . . . . . General Information And Operational Theory

SECTION 4 . . . . . . . Installation

SECTION 5 . . . . . . . Troubleshooting Procedures

SECTION 6. . . . . . . Schematic Diagrams

SECTION 7 . . . . . . . Electrical/Electronic Component Locations

SECTION 8 . . . . . . . Electrical Connector Information

SECTION 9 . . . . . . . Electrical Parts List

SECTION 10 . . . . . . Alerts and Shutdown List

Book: 22600498 (1/05) 3

FOREWORD

This manual provides installation and operating instructions for field installation

of Auto Start capabilities for certain model air compressors.

Read these instructions before beginning the installation and check that all kit

parts are included. Assure all decals are attached.

Book: 22600498 (1/05) 4

SECTION 1

SAFETY

Follow all safety instructions in the air compressor operator’s manual and decals on the

machine and those included with the kit below.

WARNING

22306617

NOTICE

36573421

Book: 22600498 (1/05) 5

SECTION 2

MANUAL DESCRIPTION

This manual contains complete information for the electrical and electronic components for the Auto Start

Stop system. It provides installation, operation, troubleshooting and parts information for the system.

There are 10 sections.

Sections 2 – 4 cover systems operation, installation and troubleshooting procedures.

Sections 5 – 6 contain electrical schematics and component location information.

Section 7 contains electrical component locations.

Section 8 contains electrical connector information.

Section 9 contains the electrical parts list.

Section 10 contains the alerts and shutdowns list.

This Auto Start Stop option kit is for machine models:

P425AWIR XP375WIR HP375WIR

VHP300WIR P600WIR HP450WIR

VHP400WIR

IMPORTANT SAFETY INFORMATION

The auto start system can cause the machine to start at any time. Follow all

safety recommendations outlined in this manual to avoid injury to personnel.

DISCONNECT BATTERY BEFORE SERVICING.

WARNING

Book: 22600498 (1/05) 6

SECTION 3

GENERAL INFORMATION

And

OPERATIONAL THEORY

Book: 22600498 (1/05) 7

The following is a list of the items included in the Auto Start Kit. Make sure the kit contains all items

before beginning an installation.

Auto Start Module 22221063 Wiring Harness 22149157

Warning Lamp 22307698 Alarm Horn LS1 36785145

Terminal Strip TB1 22307706 Auto/Manual Switch S1 54615091

Switch Bracket 22311823 Battery Charger 54715941

Battery Charger harness 22600514 Battery Charger Bracket 22329411

Bag of fasteners “T” Harness 22600506

OPERATING INSTRUCTIONS decal 22313597

WARNING decal 22306617 (2 pieces)

NOTICE decal 36523421

Auto / Manual decal 22311815

AUTOSTART decal 36511244

Installation/Operation/Service Manual 22600498

Book: 22600498 (1/05) 8

GENERAL INFORMATION AND OPERATIONAL

THEORY

General

The auto start stop module provides a means of automatic start and stop capabilities for

compressors. It is designed to operate with any compressor that has the WEDGE

control system. It is a plug-and-play module that can be field installed.

The auto start module communicates with the WEDGE controller via the J1939 CAN

network on the machine. The auto start module commands the WEDGE controller to

perform machine start, load and stop functions based on external inputs to the auto start

module.

Machine CAN Network

The auto start stop module connects to the machine CAN communications network.

The CAN network is established by the WEDGE controller and the engine controller.

These are the two basic modules on the CAN network. The CAN network supports the

J1939 protocol as defined by the Society of Automotive Engineers (SAE).

The machine wiring harness contains two stubs for CAN / power access. These stubs

can be used for connection of any of the CAN network modules, including auto start

stop.

Figure 2-1 shows a schematic of the CAN network with compressor and engine

controllers and CAN stubs. One CAN stub is located behind the control panel of the

compressor and the other is near the lifting bail.

Sensors and Switches

Inputs

The Auto Start Module uses a pressure switch input to activate the automatic start-stop

function. This pressure switch is normally user provided and contains a single set of

normally open (N.O.) contacts. The N.O. contact closes to activate the auto start

feature and opens to disable the auto start feature. TB1 terminal strip (included in this

strip) has the input terminals for the pressure switch:

TB1-3 Start Switch

Book: 22600498 (1/05) 9

J1939CANCOMMUNICATIONSSCHEMATIC

P15

ENGINEDIAGNOSTICSJACK

P11

ENGINE

CONTROLLERWEDGE

CONTROLLER

TERMINATORTERMINATOR

AUTOSTARTOPTION

CANNODEWITHPOWER

FIGURE3-1

Book: 22600498 (1/05) 10

An AUTO-MANUAL switch, S1, is provided to establish the mode of operation. It is an

input to the controller. When set in the AUTO position, the auto start stop feature will

function as described in this section. When placed in the MANUAL position, auto start

stop is disabled and the machine will function as it would normally.

Outputs

The auto start module provides four 24 VDC outputs for indicators. They are: low fuel,

compressor operating, crank alarm, and auto mode enabled. These outputs provide 24

VDC at 2 amps and can be used to drive indicator lamps or relays. They are typically

used to provide remote indication to a control room of the auto start compressor status.

The output to the alarm horn is provided through the wiring harness and is not brought

out to TB1.

The connections to the outputs are located on the terminal strip, TB1, provided with the

kit. They are as follows:

TB1-1 Auto start active output 24VDC

TB1- 5 Machine running output 24 VDC

TB1- 7 Low fuel indication 24 VDC

SECTION 5 of this manual provides schematic diagrams of the auto start system and

wiring harness connections.

Auto Start Stop Operation

Install the auto start kit as described in the Installation section. Make all electrical

connections before turning the machine power ON at the control panel. Once power is

turned ON, the WEDGE controller will automatically recognize the auto start module

and accept commands from it. To activate the auto start stop, place the AUTO-

MANUAL switch, S1, in the AUTO position. The DS1 lamp should illuminate.

The functional sequence is as follows:

1. When the external start switch (pressure switch) contact closes, the start

sequence begins. The contact closure must be maintained for 10 seconds

for the start sequence to initiate.

2. The auto start module instructs the machine controller to crank the engine.

The auto start module will sound the alarm horn 10 seconds before the

engine starter is engaged and during the cranking process. The machine

controller (WEDGE) will crank the engine until the engine starts or 20

seconds has elapsed.

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