MP 3 Controller Device Troubleshooting - Tp0002

CENTAC 
MP3 Controller Device

Field Test Procedures
INGERSOLL-RAND
AIR COMPRESSORS
MP3 CONTROLLER DEVICE FIELD TEST PROCEDURES
Copyright Notice
Copyright 1992 Ingersoll-Rand Company

THE CONTENTS OF THIS MANUAL ARE PROVIDED “AS IS” AND WITHOUT ANY IMPLIED
WARRANTIES WHATSOEVER.
Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air
applications. Ingersoll-Rand does not approve specialized equipment for breathing air
applications and assumes no responsibility or liability for compressors used for breathing air
service.
TP0002 Rev3.doc
1992, 1994 Ingersoll-Rand Company
Date of Issue: 18 July, 2000, Supersedes all previous
Table of Contents
Vibration Transmitter: ________________________________________________________ 1

Procedure for Verifying Operation of the Vibration Transmitter: __________________ 2
Figure 1. Vibration transmitter troubleshooting sketches_______________________ 3
2 Wire RTD (with External Transmitter): _________________________________________ 4
Procedure for Verifying Correct Voltage to Transmitter: _________________________ 6
Procedure for Verifying Correct Operation of the MP3 and Faceplate: _____________ 6
Procedure for Verifying Correct Operation of the RTD Transmitter: _______________ 7
Procedure for Determining a Faulty RTD:______________________________________ 7
Figure 2. Two wire RTD troubleshooting sketches ____________________________ 8
Table 3A. Degrees F versus Ohms value chart for Platinum RTD________________ 9
Table 3B. Degrees Celsius versus Ohms value chart for Platinum RTD _________ 10
3 Wire RTD ( No External Transmitter):_________________________________________ 11
Procedure for Verifying Operation of the MP3 and Faceplate: ___________________ 12
Procedure for Determining Faulty RTD: ______________________________________ 12
Figure 3. Three wire RTD troubleshooting sketches _________________________ 13
I/P Transducer: _____________________________________________________________ 14
Procedure for Verifying Operation of the MP3: ________________________________ 15
Procedure for Verifying Operation of the I/P:__________________________________ 15
Figure 4. I/P troubleshooting sketches _____________________________________ 16
Pt Transducer: _____________________________________________________________ 17
Procedure for Verifying Operation of the PT:__________________________________ 18
Procedure for Calibration of the PT: _________________________________________ 18
Figure 5. PT Troubleshooting sketches ____________________________________ 19
Discrete Input Devices ( 115 V Ac Switches):____________________________________ 20
Procedure for Verifying Operation of the Discrete Devices:_____________________ 21
Figure 6. Discrete device troubleshooting sketches__________________________ 22
Figure 7. Remote start circuit connections __________________________________ 23
Figure 8. CT configurations _______________________________________________ 24
TP0002 Rev3.doc
Dry Run Procedure for MP3 with Version 5.00 Eprom: ____________________________ 25
Procedure for Dry Run MP3 Control Panels with Installed Starter: _______________ 25
Procedure for Dry Run of MP3 Control Panels with Remote Starter:______________ 26
Figure 9: MP3 version 5.00 Dry Run Test Cable: _____________________________ 28
Erratic Face Plate Reading:___________________________________________________ 29
Procedure for Calibration of the MP3 Axial Position Transmitter ___________________ 30
Figure 10. Axial position probe reference locations __________________________ 31
General Use MP3 Electrical and Location Diagrams: _____________________________ 33
Figure 11. General MP3 electrical schematic diagram, primary circuits __________ 33
Figure 12. General MP3 electrical schematic diagram, secondary circuits________ 34
Figure 13. General MP3 electrical schematic diagram, input circuits ____________ 35
Figure 14. Microprocessor board key component layout ______________________ 36
TP0002.doc Rev.3
MP3 CONTROLLER DEVICE FIELD TEST PROCEDURES 1
Vibration Transmitter:
Description:
The vibration transmitter is used to convert the proximity probe signal into a 4 to 20 mA
signal, which in turn inputs to the MP3. The system is based on a 15-foot (4.575 m) total
electrical length.
Component specification:
Transmitter:
100 mv/mil = 0.1 volt per 0.001 in (0.0254 mm)
4 mil (0.1016 mm) scale
4 to 20 mA output
Probe:
Gap setting 0.030 to 0.060 in (0.762 to 1.524 mm), 0.050 in (1.27 mm) is nominal gap
Probe gap corresponds to 3 to 6 volt vdc, 5 vdc nominal
Probe ohmic value 7-12 ohms
Problems indicated on faceplate:
Faceplate reads BLANK
Faceplate reads MAXIMUM
Reading is ERRATIC or ZERO
Vibration reading is (NOT ZERO) when machine is stopped
Troubleshooting:
Problem indication Probable cause
Faceplate reads zero Open circuit/cable disconnected
Blank faceplate readout Loss of power to transmitter
Blank faceplate readout Open in circuit
Blank faceplate readout Malfunctioning transmitter
High probe voltage Open circuit
Low probe voltage Short circuit
Erratic faceplate readout Loose wire/terminal/connector
Blank faceplate readout Transmitter not calibrated
TP0002 Rev3.doc
2 MP3 CONTROLLER DEVICE FIELD TEST PROCEDURES
Procedure for Verifying Operation of the Vibration

Transmitter:
A. Connect a DC voltmeter to the + and - terminals of the transmitter. With power on the
MP3 there should be 24 vdc present at the terminals.
1. If 24 vdc is not present, check for 24 vdc at the MP3 terminals on TS-5 for the
respective vibration reading.
2. If 24 vdc is not present at the MP3 terminals for stages 1 or 2 vibration the MP3 is
faulty. If 24 vdc is not present at the terminals for stage 3 or higher suspect fault with
the external 24 vdc power supply (Check MP3 fuse 501 for open).
3. If 24 vdc is present at the MP3 terminals but not at the transmitter then there is an
open circuit in the connecting wires.
B. With power on the MP3: Check the dc voltage at the C and T terminals on the
transmitter. A reading of 3 to 6 vdc should be present [corresponds to 0.030 to 0.060 in
(0.762 to 1.524 mm) probe gap]. Check gap as in first step, then:
1. If less than 3 volts is present suspect wrong probe gap is set or a short circuit exists.
Power down the MP3 and disconnect the probe extension cable. Check resistance.
The cable and probe together should read 7 to 20 ohms. The probe alone should read
7 to 12 ohms. The component with the low or high ohms is faulty.
2. If more than 6 volts is present the probe may be improperly gapped or an open circuit
may exist. Check the cable connections and cable. High ohms indicate a faulty
component.
C. With power off to the MP3 connect a 4 to 20 mA source in 2 wire mode at the transmitter
+ or - terminal, observe correct polarity. Power up the MP3 and vary the 4 to 20 mA
source. The faceplate reading should follow the varying mA source. See chart below. If
there is continuity between the MP3 and the transmitter with 24 vdc present and there is
no reading on the faceplate then the MP3 or faceplate is faulty.
Conversion chart
mA percent MM Mils mA
100% 0.1016 4.0 20
50% 0.508 2.0 12
0% 0.0 0.0 4
Note: See Figure 1 Vibration transmitter troubleshooting sketches.
TP0002 Rev3.doc
Date of Issue:18 July, 2000 Supersedes all previous
volts A. Test cable and probe

0
o hm s
5 00
B. Test probe
0 00
Sat test = 7 = 20 ohms
VA C VDC Sat test = 7 to 12 ohms
mA O HM S
volts
+ C V 0 5 00
o hm s
0 00
VAC VD C
C. Test probe gap voltage mA O HM S
+ C V
Sat test = 3 to 6 vdc (Nom = 5 vdc)

5 vdc = 0.050 gap
MP-3 D. Test MP3 and connecting wire

MICR OC ON TR OL LER
20 19 18 17 16
Sat test = 4 mA = 0 mils
TS-3 + - 20 mA = 4 mils on faceplate
vo lts MP-3
0 500
0
ohm s
00
MICR OC ON TR OLL ER
20 19 18 17 16
VAC V DC
TS-3 + -
mA OH MS
+ C V
+ - C T
TR A NS MIT TER
20
+ -
0000
R 4
MILLIAMP
M P-3 mA source in 2 wire mode

M IC R OCON T ROLLE R
E. Test for voltage 20 19 18 17 16
TS-3 + -
vo lt s
0 500
ohm s
0 00
VAC VDC
mA OH MS
+ C V
+ - C T
TR AN SMI TTE R
Figure 1. Vibration transmitter troubleshooting sketches
TP0002 Rev3.doc
2 Wire RTD (with External Transmitter):

Description:
RTD (Resistance Temperature Detector-2 Wire) with external transmitter is used by the
MP3 for temperature readout from stage 2 & 3 air temperature, discharge air temperature,
water temperature and the optional AA through EE readings. An RTD resistance (ohmic
value) varies with temperature. The variable resistance is utilized to vary a 4 to 20 mA signal
that is produced by the external transmitter. The 4 to 20 mA output signal from the
transmitter provides the source for the temperature readout and related control functions of
the MP3.
Component specification:
100 ohm Platinum resistance at 32 ° (0°C). Two types used: 0 to 200°F (-17.7 to +93.3°C)
for TE-3 and 0-500°F (-17.7 to +260°C) for TE-4 through TE-11.
Transmitter may be in the RTD connection head fitting or in the control panel enclosure. The
transmitter is supplied 24 vdc and outputs 4 to 20 mA over the resistance range of the RTD.
All (2-wire) transmitter type RTDs are found on MP3 terminal strip TS-4 and are supplied 24
vdc from the external 24 vdc power supply.

Faceplate reads BLANK on one or more of the readouts
Faceplate reads MAXIMUM [ 200°F or 500°F (93.3 or 260°C)]
Faceplate reads MINIMUM [0°F (-17.7°C)]
Faceplate reading is INTERMITTENT [Blank then reading appears]
Temperature readout is known to be INCORRECT.
TP0002 Rev3.doc
Troubleshooting:
Blank faceplate readout Loss of 24 vdc external power to transmitter & RTD
Blank faceplate readout Open connection
Blank faceplate readout Transmitter failure
Blank faceplate readout RTD failure
Maximum faceplate readout High resistance connection
Maximum faceplate readout Transmitter not calibrated
Maximum faceplate readout RTD failure
Maximum faceplate readout Transmitter failure
Minimum faceplate readout Low resistance
Minimum faceplate readout Transmitter failure
Minimum faceplate readout RTD failure
Intermittent faceplate readout Loose terminal connection
Intermittent faceplate readout RTD internal wire fault
Intermittent faceplate readout Transmitter failure
Incorrect faceplate readout Transmitter not calibrated
Incorrect faceplate readout RTD or transmitter failure
TP0002 Rev3.doc
Procedure for Verifying Correct Voltage to Transmitter:

A. With voltmeter check for 24 vdc at terminals #1 and #2 on the transmitter.
See Figure 2 A.
1. If no vdc exits at the transmitter then check for 24 vdc at respective transmitter
terminal on TS-4.
• If 24 vdc exists at the TS-4 terminal then there is an open circuit condition in the
terminal to transmitter wiring.
2. If no 24 vdc in exists at the TS-4 terminal and other RTDs on TS-4 are reading
correct then MP3 is faulty.
B. If all RTDs on TS-4 and components fed by TS-5 are also reading blank then check MP3
fuse FU-501 for continuity. See Figure 2 D.
1. If fuse is open, replace fuse (once) if fuse blows again there is a short circuit fault.
Correct short circuit before installing another fuse.
2. If no 24 vdc is present and fuse FU-501 is not faulty then suspect fault with external
24 vdc power supply or connecting wires.
Procedure for Verifying Correct Operation of the MP3 and

Faceplate:
A. Insure control power is off.
B. At the affected RTD transmitter, disconnect the wires at transmitter terminal #1 and #2.
C. Connect a 4 to 20 mA simulator to these terminals (Observe correct polarity).
D. Power up the control panel and then vary the simulator output.
1. At 12 mA (50%) the faceplate should read 1/2 the RTD range – 100 or 250°F
(37.7 or 121.1°C). – The readout should change as the simulator output is varied.
See Figure 2 B.
a. If the read out is incorrect or does not change: Power down the control panel and
reconnect the 4 to-20 mA simulator at the respective TS-4 terminals for the RTD.
Power up the MP3 and observe readout while varying the 4 to 20 mA. If reading is
correct there is an open or short in the wire or terminals connecting the MP3 to
the RTD transmitter. If reading is not correct the MP3 is faulty.
b. If all RTDs and other device readings are not reading correct suspect that MP3
requires calibration. P301 may be out of adjustment.
TP0002 Rev3.doc
Procedure for Verifying Correct Operation of the RTD

Transmitter:
A. With power off the MP3 connect a 100 ohm resistor to terminals #3 & #4 of the
transmitter.
B. Power up MP3, reading should be 32°F (0°C) ±10%. If reading is not within specification
the transmitter is faulty. See Figure 2 C.
Procedure for Determining a Faulty RTD:

A. Insure operation of the transmitter has been verified before proceeding: Power down the
MP3, remove the RTD from the compressor and immerse it in an ice water bath along
with a thermometer.
B. Power up the MP3. The faceplate readout should be nearly the same as the temperature
shown on the thermometer. When RTD is removed from the ice water the reading
should increase to near ambient temperature. If the reading is incorrect or does not
change with warming the RTD is faulty. See Figure 2 E.
C. An alternate test to use if MP3 power is not available is to check ohms versus
temperature. Use an Ohmmeter and values on Table 3A and 3B (RTD ohmic value
chart). See Figure 2.
Note: See Figure 2 for 2-wire RTD troubleshooting sketches and Figure 3A and 3B RTD
Ohmic value charts.
TP0002 Rev3.doc
B. Test MP3 and read out

A. Test power to RTD Sat test = 12 mA = 100 or 250 deg F
MP3
Sat test = 22.8 to 24 vdc MICROCONTROLLER
FU-501
5A
MP3
TS-4 1 2 MICROCONTROLLER
FU-501
5A
volts
0
oh ms
50 0 TS-4 1 2
0 00
VAC VDC
mA OHMS
1 2 3 4
++ C
C V
V
TRANSMITTER
20
R 00 00
T
4
C. Test transmitter through MP3 D
Sat test = @ 32 deg F on faceplate MIL LIAMP

MP3
MICROCONTROLLER
FU-501 D. Test RTD fuse FU-501
5A Sat test = 0 ohms
TS-4 1 2
vol ts
0 50 0
o hms
0 00
VAC VDC
100 OHM
mA OHMS
+ C V
1 2 3 4
TRANSMITTER
FU-501
E. Test RTD against thermometer 5A
Sat test = face plate and thermometer equal
MP3
F. Test RTD ohms against ohmic value chart
MICROCONTROLLER vo lts Sat test = ohms and temperature agree
FU-501 0 5 00
o hms
5A 0 00
TS-4 1 2 VAC VDC
mA OH MS
+ C V
1 2 3 4
TRANSMITTER
ice water ice water
Figure 2. Two wire RTD troubleshooting sketches
TP0002 Rev3.doc
Table 3A. Degrees F versus Ohms value chart for Platinum RTD
Degree 0 1 2 3 4 5 6 7 8 9
F Degrees vs. ohms – accurate to ± 0.15 ohms
0 93.01 93.22 93.44 93.66 93.88 94.1 94.32 94.54 94.76 94.98
10 95.2 95.42 95.63 95.85 96.07 96.29 96.51 96.73 96.95 97.17
20 97.38 97.6 97.82 98.04 98.26 98.47 98.69 98.91 99.13 99.35
30 99.56 99.78 100 100.2 100.4 100.7 100.9 101.1 101.3 101.5
40 101.7 102 102.2 102.4 102.6 102.8 103 103.3 103.5 103.7
50 103.9 104.1 104.3 104.6 104.8 105 105.2 105.4 105.6 105.8
60 106.1 106.3 106.5 106.7 106.9 107.1 107.4 107.6 107.8 108
70 108.2 108.4 108.7 108.9 109.1 109.3 109.5 109.7 109.9 110.2
80 110.4 110.6 110.8 111 111.2 111.5 111.7 111.9 112.1 112.3
90 112.5 112.7 113 113.2 113.4 113.6 113.8 114 114.3 114.5
100 114.7 114.9 115.1 115.3 115.5 115.8 116 116.2 116.4 116.6
110 116.8 117 117.3 117.5 117.7 117.9 118.1 118.3 118.5 118.8
120 119 119.2 119.4 119.6 119.8 120 120.2 120.5 120.7 120.9
130 121.1 121.3 121.5 121.7 122 122.2 122.4 122.6 122.8 123
140 123.2 123.4 123.6 123.9 124.1 124.3 124.5 124.7 124.9 125.2
150 125.4 125.6 125.8 126 126.2 126.4 126.6 126.9 127.1 127.3
160 127.5 127.7 127.9 128.1 128.3 128.6 128.8 129 129.2 129.4
170 129.6 129.8 130 130.3 130.5 130.7 130.9 131.1 131.3 131.5
180 131.7 132 132.2 132.4 132.6 132.8 133 133.2 133.4 133.6
190 133.9 134.1 134.3 134.5 134.7 134.9 135.1 135.3 135.5 135.8
200 136 136.2 136.4 136.6 136.8 137 137.2 137.4 137.7 137.9
210 138.1 138.3 138.5 138.7 138.9 139.1 139.3 139.6 139.8 140
220 140.2 140.4 140.6 140.8 141 141.2 141.4 141.7 141.9 142.1
230 142.3 142.5 142.7 142.9 143.1 143.3 143.5 143.8 144 144.2
240 144.4 144.6 144.8 145 145.2 145.4 145.6 145.9 146.1 146.3
250 146.5 146.7 146.9 147.1 147.3 147.5 147.7 147.9 148.2 148.4
260 148.6 148.8 149 149.2 149.4 149.6 149.8 150 150.2 150.5
270 150.7 150.9 151.1 151.3 151.5 151.7 151.9 152.1 152.3 152.5
280 152.7 153 153.2 153.4 153.6 153.8 154 154.2 154.4 154.6
290 154.8 155 155.2 155.4 155.7 155.9 156.1 156.3 156.5 156.7
300 156.9 157.1 157.3 157.5 157.7 157.9 158.1 158.4 158.6 158.8
310 159 159.2 159.4 159.6 159.8 160 160.2 160.4 160.6 160.8
320 161 161.3 161.5 161.7 161.9 162.1 162.3 162.5 162.7 162.9
330 163.1 163.3 163.5 163.7 163.9 164.1 164.3 164.6 164.8 165
340 165.2 165.4 165.6 165.8 166 166.2 166.4 166.6 166.8 167
350 167.2 167.4 167.6 167.8 168.1 168.3 168.5 168.7 168.9 169.1
360 169.3 169.5 169.7 169.9 170.1 170.3 170.5 170.7 170.9 171.1
370 171.3 171.5 171.8 172 172.2 172.4 172.6 172.8 173 173.2
380 173.4 173.6 173.8 174 174.2 174.4 174.6 174.8 175 175.2
390 175.4 175.6 175.8 176 176.3 176.5 176.7 176.9 177.1 177.3
400 177.5 177.7 177.9 178.1 178.3 178.5 178.7 178.9 179.1 179.3
410 179.5 179.7 179.9 180.1 180.3 180.5 180.7 180.9 181.1 181.3
420 181.5 181.8 182 182.2 182.4 182.6 182.8 183 183.2 183.4
430 183.6 183.8 184 184.2 184.4 184.6 184.8 185 185.2 185.4
440 185.6 185.8 186 186.2 186.4 186.6 186.8 187 187.2 187.4
450 187.6 187.8 188 188.2 188.4 188.6 188.8 189 189.2 189.4
460 189.7 189.9 190.1 190.3 190.5 190.7 190.9 191.1 191.3 191.5
470 191.7 191.9 192.1 192.3 192.5 192.7 192.9 193.1 193.3 193.5
480 193.7 193.9 194.1 194.3 194.5 194.7 194.9 195.1 195.3 195.5
490 195.7 195.9 196.1 196.3 196.5 196.7 196.9 197.1 197.3 197.5
500 197.7 197.9 198.1 198.3 198.5 198.7 198.9 199.1 199.3 199.5
TP0002 Rev3.doc
Table 3B. Degrees Celsius versus Ohms value chart for Platinum RTD
Degree 0 0.62 1.23 1.85 2.47 3.09 3.70 4.32 4.94 5.56
Celsius Degrees vs. ohms
-17.78 93.01 93.22 93.44 93.66 93.88 94.10 94.32 94.54 94.76 94.98
-12.22 95.20 95.42 95.63 95.85 96.07 96.29 96.51 96.73 96.95 97.17
-6.67 97.38 97.60 97.82 98.04 98.26 98.47 98.69 98.91 99.13 99.35
-1.11 99.56 99.78 100.00 100.22 100.43 100.65 100.87 101.08 101.30 101.52
4.44 101.74 101.95 102.17 102.39 102.60 102.82 103.04 103.25 103.47 103.69
10.00 103.90 104.12 104.34 104.55 104.77 104.98 105.20 105.42 105.63 105.85
15.56 106.07 106.28 106.50 106.71 106.93 107.14 107.36 107.58 107.79 108.01
21.11 108.22 108.44 108.66 108.87 109.09 109.30 109.52 109.73 109.95 110.16
26.67 110.38 110.60 110.81 111.03 111.24 111.46 111.67 111.89 112.10 112.32
32.22 112.53 112.75 112.96 113.18 113.39 113.61 113.82 114.04 114.25 114.47
37.78 114.68 114.89 115.11 115.32 115.54 115.75 115.97 116.18 116.40 116.61
43.33 116.83 117.04 117.25 117.47 117.68 117.90 118.11 118.32 118.54 118.75
48.89 118.97 119.18 119.39 119.61 119.82 120.04 120.25 120.46 120.68 120.89
54.44 121.11 121.32 121.53 121.75 121.96 122.17 122.39 122.60 122.81 123.03
60.00 123.22 123.43 123.65 123.87 124.08 124.30 124.51 124.73 124.94 125.16
65.56 125.37 125.58 125.79 126.01 126.22 126.43 126.65 126.86 127.07 127.28
71.11 127.50 127.71 127.92 128.13 128.35 128.56 128.77 128.98 129.20 129.41
76.67 129.62 129.83 130.04 130.26 130.47 130.68 130.89 131.10 131.32 131.53
82.22 131.74 131.95 132.16 132.38 132.59 132.80 133.01 133.22 133.43 133.65
87.78 133.86 134.07 134.28 134.49 134.70 134.91 135.12 135.34 135.55 135.76
93.33 135.97 136.18 136.39 136.60 136.81 137.02 137.24 137.45 137.66 137.87
98.89 138.08 138.29 138.50 138.71 138.92 139.13 139.34 139.55 139.76 139.97
104.44 140.18 140.39 140.60 140.81 141.02 141.24 141.45 141.66 141.87 142.08
110.00 142.29 142.50 142.71 142.92 143.13 143.34 143.55 143.76 143.97 144.18
115.56 144.39 144.59 144.80 145.01 145.22 145.43 145.64 145.85 146.06 146.27
121.11 146.48 146.69 146.90 147.11 147.32 147.53 147.73 147.94 148.15 148.36
126.67 148.57 148.78 148.99 149.20 149.41 149.61 149.82 150.03 150.24 150.45
132.22 150.66 150.87 151.08 151.28 151.49 151.70 151.91 152.12 152.33 152.54
137.78 152.74 152.95 153.16 153.37 153.58 153.78 153.99 154.20 154.41 154.62
143.33 154.82 155.03 155.24 155.45 155.66 155.86 156.07 156.28 156.49 156.69
148.89 156.90 157.11 157.32 157.52 157.73 157.94 158.15 158.35 158.56 158.77
154.44 158.98 159.18 159.39 159.60 159.80 160.01 160.22 160.42 160.63 160.84
160.00 161.05 161.25 161.46 161.67 161.87 162.08 162.29 162.49 162.70 162.91
165.56 163.11 163.32 163.52 163.73 163.94 164.14 164.35 164.56 164.76 164.97
171.11 165.17 165.38 165.59 165.79 166.00 166.20 166.41 166.62 166.82 167.03
176.67 167.23 167.44 167.64 167.85 168.06 168.26 168.47 168.67 168.88 169.08
182.22 169.29 169.49 169.70 169.90 170.11 170.32 170.52 170.73 170.93 171.14
187.78 171.34 171.55 171.75 171.96 172.16 172.37 172.57 172.78 172.98 173.19
193.33 173.39 173.59 173.80 174.00 174.21 174.41 174.62 174.82 175.03 175.23
198.89 175.44 175.64 175.84 176.05 176.25 176.46 176.66 176.86 177.07 177.27
204.44 177.48 177.68 177.88 178.09 178.29 178.49 178.70 178.90 179.11 179.31
210.00 179.51 179.72 179.92 180.12 180.33 180.53 180.73 180.94 181.14 181.35
215.56 181.55 181.75 181.95 182.16 182.36 182.56 182.77 182.97 183.17 183.38
221.11 183.58 183.78 183.98 184.19 184.39 184.59 184.80 185.00 185.20 185.40
226.67 185.60 185.81 186.01 186.21 186.41 186.62 186.82 187.02 187.22 187.43
232.22 187.63 187.83 188.03 188.24 188.44 188.64 188.84 189.04 189.25 189.45
237.78 189.65 189.85 190.05 190.25 190.46 190.66 190.86 191.06 191.26 191.46
243.33 191.67 191.87 192.07 192.27 192.47 192.67 192.87 193.08 193.28 193.48
248.89 193.68 193.88 194.08 194.28 194.48 194.68 194.88 195.09 195.29 195.49
254.44 195.69 195.89 196.09 196.29 196.49 196.69 196.89 197.09 197.29 197.49
260.00 197.69 197.89 198.09 198.29 198.49 198.70 198.90 199.10 199.30 199.50
Note: This chart converted from Fahrenheit chart Figure 3 A using formula C= ((Deg F-32)/1.8)
TP0002 Rev3.doc
3 Wire RTD ( No External Transmitter):

Description:
The 3 Wire RTD is used by the MP3 for the Lube oil and 1st stage Air temperatures. These
are designated as TE-1 & TE-2. The transmitter device for these components is an integral
part of the MP3 electronics.
Specification:
100 ohms Platinum resistance at 32°F (0°C)
Range 0-200°F (-17.7 to +93.3°C)
Powered by internal 24 vdc power supply
TE-1 & TE-2 are found on MP3 terminal strip TS-3

• Faceplate reads CONTROLLER FAILURE with code 8 status flag and 1st stage air
temperature reads blank.
• Faceplate reads MAXIMUM i.e.: 200°F (93.3°C)
• Faceplate reads MINIMUM i.e.: 0°F ( -17.3°C)
• Faceplate reading is INTERMITTENT i.e.: Blank then reading appears
Troubleshooting:
Maximum value readout High resistance connection RTD
Maximum value readout RTD failure
Minimum value readout RTD failure
Controller failure readout 1st stage RTD disconnected
Intermittent value readout Loose terminal connection
Intermittent value readout RTD internal wire fault
Readout known to be incorrect RTD or MP3 fault
TP0002 Rev3.doc
Procedure for Verifying Operation of the MP3 and Faceplate:

A. Insure control power is off.
B. Disconnect the RTD from its respective TS-3 terminals,
C. Connect a 100 ohm resistor at terminals #9 & #8 (if Lube oil) or #6 & #5 (if air temp).
D. Connect a jumper wire at terminals #7& #8 (if Lube oil) or #4 & #5 (if air temp).
E. Power up MP3, reading should be 32°F (0°C) ± 10%. See Figure 3A.
• If no reading the MP3 is faulty.
• If reading is satisfactory then suspect faulty wire, connections, or a faulty RTD.
Procedure for Determining Faulty RTD:

A. Power down the MP3, remove the RTD from the compressor, and immerse it in an ice
water bath along with a thermometer.
B. Power up the MP3. The faceplate readout should be nearly the same as the temperature
shown on the thermometer. When RTD is removed from the ice water the reading
should increase to near ambient temperature. If the reading is incorrect or does not
change with warming the RTD is faulty. See Figure 3C
C. A backup test to use if the MP3 is not available is to check ohms versus temperature.
Use Ohmmeter and Figure 3 (RTD ohmic value chart) See Figure 3B.
Note: See Figure 3. Three wire RTD troubleshooting sketches.
TP0002 Rev3.doc
A. Test MP3 ability to read RTD

Sat test = Face plate reads @ 32 deg F (0 deg C)
MP3
MICROCONTROLLER
TS-3 4 5 6
B. Test RTD for continuity and resistance

100 OHM
Sat test = Continuity between all wires
v olts
0 500
o hm s
0 00
VAC VD C
mA OH MS
C. Test RTD against ohmic value chart + C V
Sat test = ohms vs temperature agree

W
W
vol ts
0
oh ms
50 0 Y
0 00 C. Test RTD against ohmic value chart
Sat test = Ohms vs. temperature = chart
VAC VD C
mA OHMS
R
+ C V T
D
ice water
Platinum RTD
White
White
Yellow
3 wire RTD schematic diagram
Figure 3. Three wire RTD troubleshooting sketches
TP0002 Rev3.doc
I/P Transducer:
Description:
The I/P (current to pressure) transducer is used to convert the 4 to-20 mA signal generated
by the MP3 controller into a 3-15 psi instrument air signal for the inlet (IV) and bypass (BV)
valve positioners.
Specification:
4 to 20 mA input = 3 to 15 psi output
20 PSIG instrument air input to I/P

Discharge pressure above or below normal.
Troubleshooting:
IV or BV not operating Failure of MP3

IV or BV not operating Positioner or actuator malfunction
IV or BV not operating Control air shut off
IV or BV not operating Failure of I/P
I/P output minimum Failure of I/P
I/P output maximum Failure of I/P
I/P output erratic Failure of I/P
TP0002 Rev3.doc
Procedure for Verifying Operation of the MP3:

A. With control power off, install the Test Box at the connector plug near the (IV or BV)
valve to be checked.
B. Connect a milliamp meter to the Test Box. Turn power on and then at the respective
valve (IV or BV), check that a 4 mA signal is present. See Figure 4A.
1. If there is a 4 mA signal present, control wiring is satisfactory to the MP3.
2. If there is no signal either the wiring has an open or short or the MP3 is
malfunctioning.
• At TS-3 (#23 &#24 for IV), (#21 & #22 for BV), power down the MP3, and connect
mA meter to respective terminals and power up MP3. If 4 mA is not present the
MP3 is faulty. If 4 mA is present there is an open circuit or short in the wiring.
C. To verify that the MP3 is sending out a controlled signal: Connect mA meter in series
with the IV or BV, test run the compressor and observe signal fluctuations. Observe for
proper P1 value, @ 20 mA at full load, etc. If correct values are not observed the MP3 is
faulty. See Figure 4C.
Procedure for Verifying Operation of the I/P:

A. Use Test Box and connect 4 to 20 mA simulator to the I/P, install a pressure gauge on
the I/P psi output fitting, Insure instrument air supply to I/P.
B. Vary the simulator between 4 and 20 mA. The output of the I/P should follow. (Nominal 3
to 15 PSIG output with stand alone I/P). See Figure 4B.
1. If output PSIG is satisfactory but IV or BV does not function properly there is a
problem with the positioner, the actuator, or the valve itself.
2. If output is not linear between 4 to 20 mA: Calibrate the zero and span of the
transducer.
• If I/P fails to zero and or span: Disassemble and clean nozzle/orifice and pilot
valve, reassemble and recheck. Insure instrument air filter and regulator are clean
and functional. The I/P is faulty if on re-test the I/P fails to out put correct PSIG
when appropriate mA signal is applied.
Note: There are several different shaped I/P's in general use. All function the same way. See
Figure 4. I/P troubleshooting sketches.
TP0002 Rev3.doc
A. Test MP3 out put

Sat test = 4 mA at BV and IV terminals with power on MP3
MP-3
MIC ROCON TRO LL ER
BV IV
TS-3
21 22 23 24 20
vo lts
psig
0 500
oh ms
0 00 P1 4 mA = 3 psig
in
VAC VDC
I/P
out
20 mA=15 psig
positioner
mA OHMS
Use same tests on this type I/P
+ C V
65
INGERSOLL RAND
IV or BV psig
POSITIONER
B. Test I/P reaction to mA signal

Sat test = 4 mA IV closed, 20 mA IV open
20 + - Sat test = 4 mA BV open, 20 mA BV closed
0000
4
MILLIAMP
MP-3
MIC ROCON TR OLL ER C. Test MP3 output to I/P
BV IV
TS-3
volts Sat test = I/P follows out put ( See Dry Run procedures)
21 22 23 24 0 50 0
oh ms
0 00
VAC VDC
65
mA OH MS INGERSOLL RAND
IV or BV psig
+ C V POSITIONER
Figure 4. I/P troubleshooting sketches
TP0002 Rev3.doc
Pt Transducer:
Description:
The Pressure Transducer (PT) is used to convert air or lube oil pressure (psi) to a 4-to 20
mA signal.
Specification:
0 - 50 PSIG(344.75 kPa) range ( Lube oil pressure)
0 - 200 PSIG (1379 kPa) range ( System air pressure, Stages 2 and 3)
2 wire, 24 vdc
PT1 and PT2 are supplied from internal 24 vdc supply; other pressure transducers supplied
from external 24 vdc supply.

Blank faceplate readout
High pressure reading
Low pressure reading
Erratic faceplate reading
Troubleshooting:
Blank faceplate readout Loss of power

Blank faceplate readout Faulty PT or MP3
Blank faceplate readout Loose connection or faulty wire
High or low pressure reading PT out of calibration
High or low pressure reading Faulty PT
Erratic faceplate readout Loose connections
Erratic faceplate readout Faulty PT
TP0002 Rev3.doc
Procedure for Verifying Operation of the PT:

A. With MP3 power off: Disconnect the PT at its respective MP3 terminal: TS-3 for System
air and Lube oil, TS-5 for other PTs.
B. Connect a 4-to 20 source to the MP3 terminals. Power up the MP3 and vary the 4-to 20
mA signal. A 4 mA signal should result in a 0 pressure reading and 20 mA should result
in a maximum range reading. See Figure 5A.
1. If reading remains blank for PTs supplied off TS-3 or does not change there is a fault
in the MP3 board.
2. If reading remains blank for PTs supplied off TS-5 suspect external 24 vdc power
supply is faulty.
a. Check terminals on TS-3 and TS-5 for 24 vdc.
b. If reading changes as the 4-to 20 mA is varied and is correct value then there is a
fault in the PT or connecting wire.
C. Connect an Ohmmeter to the disconnected wires coming from the PT. A completed
circuit through the source will check continuity of wire and internal PT circuits. If there is
no continuity either the wiring or the PT is faulty. If PT being checked is other than CA or
Lube oil check for continuity at plug P-4 to the wires and to the PTs.
D. To perform a field test of the I/P: Connect a regulated air supply to the pressure
connection. Insure power is off to the MP3 and reconnect PT wires to terminals TS3 or
TS5 as the case may be. Power up the MP3 and vary the regulated air supply. The
faceplate should read the pressure being applied. If it doesn't then the PT is faulty or out
of calibration.
Procedure for Calibration of the PT:

A. Removal of the PT to a test bench area is preferred. If this cannot be done, calibration
on the machine can be accomplished by using a regulated air supply, the faceplate, and
a mA meter for obtaining the readouts to perform calibration. See Figure 5B.
1. Remove Zero and Span cover screws. Set air supply to zero, adjust reading to zero,
4 mA on meter.
2. Apply operating air pressure to the PT. Adjust Span to obtain maximum available air
pressure ( within range of the PT ) readout on faceplate. Reduce pressure and
recheck zero.
3. Alternate calibration between Zero and Span repeating as many times as necessary
until faceplate reads zero and maximum pressure correctly as pressure is varied.
4. Check readout at 25%,50%, and 75% of the test pressure to insure calibration is
satisfactory.
B. If PT cannot be calibrated it is defective.
Note: See Figure 5. PT troubleshooting sketches.
TP0002 Rev3.doc
A. Test face plate and MP3

Sat test = Face plate reading follows sinulator mA
MP-3
MICROCONTROLLER
TS-3
12 13 15 16
B. Test P/T with air regulator

Sat test = Face plate follows regulator pressure
20
+ -
0000
4
MP-3 volts
MICROCO NTROLLER 0
ohms
500
MILLIAMP 0 00
TS-3
12 13 15 16 VA C VDC
mA OHMS
+ C V
SS Z
PP E PRESSURE
AA R TRANSMITTER
N
N O 0-50
4 Ma/0PSI
20 Ma /50PSI
IN GERSOLL RAND
2
0
p
s
ig
Figure 5. PT Troubleshooting sketches
TP0002 Rev3.doc
Discrete Input Devices ( 115 V Ac Switches):

Description:
The discrete devices associated with the MP3 are on/off type devices unlike the other
devices such as the I/P that sends an analog signal to the controller.
Specification:
115 vac on/off switching devices.
Under abnormal condition switch opens and de-energizes circuit.
Discrete device name and type:

1. Surge sensor (Differential pressure)
2. Low seal air pressure (Pressure)
3. Low cooling water flow (Flapper)
4. Low oil level (Float)
5. High condensate level (Float)
6. Dirty inlet filter (Differential pressure)
7. Dirty oil filter (Differential pressure)
8. High motor temperature (Thermistor controlled)

Faceplate reads BLANK
False alarm or shutdown condition indicated
Troubleshooting:
Blank faceplate readout MP3 or faceplate faulty

False alarm condition Switch or wiring malfunction
TP0002 Rev3.doc
Procedure for Verifying Operation of the Discrete Devices:

A. Power down the MP3. The discrete devices operate off a 115 vac power supply. This is
a lethal voltage.
B. Take appropriate action to insure circuit is de-energized before coming in contact with
any potentially energized-component of any discreet device.
1. Install a jumper across the MP3 terminals on TS-2 for the affected device.
2. Power up the MP3. If the abnormal condition shows as being cleared on the power
up, there is an open in the circuit to the device.
3. Check continuity of the device and connecting wire by use of an ohmmeter after de-
energizing the MP3. If abnormal condition does not clear with the jumper in place
there is a fault in the MP3.
Notes:
1. The LOW WATER FLOW switch is on a 5 second delay timer. Dry running of the MP3
panel may be necessary to prove fault with the MP3.
2. Insure normal running condition is established. The electrical schematic for the MP3
shows the discrete devices in their shut down and de-energized state. i.e.: make sure
seal air is on, etc.
TP0002 Rev3.doc
A. Test MP3 discrete

functions Surge sensor (delta P
Sat test = Alarm condition clears when jumper is switch)
installed
High
TS-2 14 13
115 vac
MIC R OC ON TR OLLER
micro switch
MP-3
Low
Dirty oil filter

Dirty inlet filter
High motor
temperature
T HERM ISTER
micr o switch Stage
Flow control
valve
Low oil level High level Low seal air Low water flow
condensat switch
micr o switch
Figure 6. Discrete device troubleshooting sketches
TP0002 Rev3.doc
Compressor control panel
Warning: Powered by remote starter
CR1
Remote starter
TB
L1 L2 L3
4
5
6
7
To start push button 8
maintaining circuit 9
Ma
M
Aux contacts close
T1 T2 T3
when starter M contacts close
MP3 Microcontroller
TS-3 2 1
TB
CT1
CT2
To motor
CT is in any line that will reflect

line current through the motor
Figure 7. Remote start circuit connections
TP0002 Rev3.doc
L1
Figure 8A illustrates a control panel installed
Wye-Delta starter. In this configuration the
current transformer used for the MP3 motor
2M 1M current input is physically located after the 1M
contactor as shown. This CT reads motor phase
amperage. The MP3 requires a line amperage
8A 1S input. The MP3 has a built in factory
a b programmable function which causes the
amperage signal from the CT to be multiplied by
1S 1S
1.73 ( the phase factor). This multiplier results in
1M 2M the MP3 having the correct amperage signal it
needs to control the compressor. If the MP3 is
L3 c L2
improperly programmed the motor amperage as
2M 1M
L1 read on the face plate and the control amperage
signal will be off by a factor of 1.73.
Example: Line amperage is 100 amps. The
2M 1M clamp on ammeter reads 100 amps. The CT
located in C phase reads 57.8 amps. The MP3
will multiply this by 1.73 if it is programmed for an
8B 1S
installed Wye-Delta starter to obtain the 100 amp
a b signal needed.
1S 1S
If the compressor has a control panel installed
starter and face plate Motor Current is
1M 2M approximately equal to switch board line current
L3 c L2
divided by 1.73 the MP3 is most probably
1M
incorrectly programmed.
2M
L1
Figure 8B illustrates a remote Wye-Delta starter.
1M The MP3 is programmed to accept a CT signal
from a CT that is installed in a line phase lead to
the motor. The MP3 multiplier factor is 1.0 times
CT signal.
If the starter is remote and the MP3 is incorrectly
8C programmed for an installed starter the face
a b plate motor current reading will be approximately
switch board line current times 1.73.
Figure 8C illustrates an across the line starter.
The CT is installed in the line. MP3 is
L3 L2
programmed for a multiplier of 1.0. If CT is
c installed in a motor phase lead instead of the line
1M 1M
lead the face plate will read approximately switch
board line current divided by 1.73
MP3s, which are incorrectly programmed
Figure 8. CT configurations with the wrong type of starter, are normally
returned to the factory for re-programming.
TP0002 Rev3.doc
Dry Run Procedure for MP3 with Version 5.00 Eprom:

The procedures listed here are used to verify the overall operation of the MP3
microcontrollers that have the version 5.00 EPROM.
CAUTION
Severe damage and electrical shock hazards are possible if these procedures
are improperly followed. FOLLOW PROCEDURES IN STEP BY STEP SEQUENCE
AS LISTED.
The procedures listed require the use of a Dry Run Test Cable. This cable will be referred to
as the test harness in the procedure. See Figure 9 for a description of the construction and
connection of the Dry Run Test Cable.
Procedure for Dry Run MP3 Control Panels with Installed

Starter:
1. Lock out all incoming power to the control panel and disconnect the panel test plug and
receptacle inside the control panel enclosure. Insure panel control power switch is in
"Off" position.
2. Disconnect the wires connected to CT1 and CT2 on MP3 terminal strip three (TS-3).
Connect the wires together with a wire nut. This connection short circuits the motor lead
current transformer secondary as an electrical safety precaution.
3. Connect the loose "pig tail" wires of the test harness to the terminals marked CT1 and
CT2 on TS-3. Note: Polarity has no importance.
4. Connect the test harness female plug (J2) to the control panel male test plug. The
control power was de-energized in step 1.
5. Check to insure all disconnections and connections performed in steps 1 through 4 are
correct.
6. Connect 120 vac through use of an Extension Cord to the male plug of the test harness.
Power is now available to the control panel.
7. Turn on control power by switching the control power switch to the "On" position.
TP0002 Rev3.doc
8. Enter the "Program" mode with the key switch and program the following values:
• P1 = 10
• System Pressure Setpoint = 200
• CHL = 200 or higher
• CLL = 150
• CT Ratio = Lower this setting until the MP3 face plate Motor Current reads between
10 and 70 amperes. Typical values for CT Ratio for the dry run procedure range
between 10, 20, and 30.
• Oil Pressure: Alert = 0; Trip = 0. The prelube pump will continue to run as long as
the trip set point is at 0. Prelube timer is bypassed.
9. Select "Run" mode with the key switch, Select "Unload" on the load switch.
10. To perform dry run: Depress "Start" then step to the "Motor Current" display and read
motor amperes.
a. If motor amps are higher than 150 amps; enter "Program" mode and reset CLL to 5
amps above the motor amp reading. Select "Modulate" on the load switch.
b. If motor amps are below 150 amps. Select "Modulate" on the load switch.
11. To force the MP3 to load: Select "Program" and lower CLL to a value 5 amps below the
motor amps reading.
12. Observe normal functioning of the starter and control valve operation. The Inlet should
open and Bypass should close. The Prelube pump will remain running.
13. On completion of dry run depress "Stop" and configure the control panel for operation by
restoring all set points, Turn control power "Off" and remove extension cord, reconnect
the wires removed in step 2 to CT1 and CT2, reconnect control panel test plug.
Procedure for Dry Run of MP3 Control Panels with Remote

Starter:
1. Rack out the motor starter to prevent motor start. Lock out all incoming power to the
control panel and disconnect the panel test plug and receptacle inside the control panel
enclosure. Insure panel control power switch is in "Off" position.
WARNING
The starter feedback connections at Terminals 4 & 5, 7 & 9 in the control panel
may have power present even though the starter is disabled. To avoid electric shock
use a reliable voltmeter and test these connections to one another and from terminal
to ground. If power is present it must be de-energized before proceeding with the dry
run. Failure to observe this warning may result in injury or death from electrical shock.
TP0002 Rev3.doc
2. Remove the wires from Terminals 4, 5, 7, and 9. Place a jumper wire between start
contact Terminal 4 and start button maintaining circuit Terminal 7. Place a jumper wire
between start contact Terminal 5 and start button maintaining circuit Terminal 9. The
jumper allows relay CR-1 to act as the start button maintaining contact.
3. Disconnect the wires connected to CT1 and CT2 on MP3 terminal strip three (TS-3).
Connect the wires together with a wire nut. This connection short circuits the motor lead
current transformer as an electrical safety precaution.
4. Connect the loose "pig tail" wires of the test harness to the terminals marked CT1 and
CT2 on TS-3. Polarity of the CT leads has no importance.
5. Connect the test harness female plug (J2) to the control panel male test plug. Control
power was de-energized in step 1.
6. Check to insure all disconnections and connections performed in steps 1 through 4 are
correct.
7. Connect 120 vac through use of an Extension Cord to the male plug of the test harness.
Power is now available to the control panel.
• If control power is not provided by the starter and comes from a separate source to
the control panel the male plug of the test harness can be connected to the female
test plug in the control panel in lieu of using an extension cord. Energizing the control
panel power de-energized in step 1 will provide control power for the test run.
8. Turn on control power by switching the control power switch to the "On" position.
9. Enter the "Program" mode with the key switch and program the following values:
• P1 = 10
• System Pressure Setpoint = 200
• CHL = 200 or higher
• CLL = 150
• CT Ratio = Lower this setting until the MP3 face plate Motor Current reads between
10 and 70 amperes. Typical values for CT Ratio for the dry run procedure range
between 10, 20, and 30.
• Oil Pressure: Alert = 0; Trip = 0 The prelube pump will continue to run as long as
the Trip set point is at 0. Prelube timer is bypassed.
10. Select "Run" mode with the key switch, Select "Unload" on the load switch.
11. To perform dry run: Depress "Start" then step to the "Motor Current" display and read
motor amperes.
a. If motor amps are higher than 150 amps; enter "Program" mode and reset CLL to 5
amps above the motor amp reading. Select "Modulate" on the load switch.
b. If motor amps are below 150 amps. Select "Modulate" on the load switch.
12. To force the MP3 to load: Select "Program" and lower CLL to a value 5 amps below the
motor amps reading.
13. Observe normal functioning of the starter and control valve operation. Bypass should
close and Inlet should open. Prelube will remain running.
TP0002 Rev3.doc
14. On completion of dry run depress "Stop" and configure the control panel for operation
by restoring all set points, Turn control power "Off" and remove extension cord ( if used),
remove the jumpers and reconnect the wires removed in step 2 at Terminals 4, 5, 7 and
9, reconnect the wires removed in step 3 to CT1 and CT2, reconnect control panel test
plug.
15. Re-establish normal power as required.
Control power transformer
X1 P
X3 N
TEST PLUG FEMALE TEST PLUG MALE
Compressor control panel

J1 PLUG AC FEMALE J2
PL UG AC MA LE
1 foot lengths
5 foot lengths
Dry run test harness shown connected
TS 3-1 TS 3-2
MP3
Dry Run Test Cable
J1 J2
CT
All wire to be size AWG 12
Figure 9: MP3 version 5.00 Dry Run Test Cable:
TP0002 Rev3.doc
Erratic Face Plate Reading:

Whenever all else has failed and the MP3 is suspected of causing erratic vibration,
temperature, pressure, or other readings the cause may be a fault in the grounding of the
controller. To investigate for potential faulty ground perform the following checks and make
corrections as may be indicated.
Signs of erratic display or changes of calibration can usually be linked to electrical noise
problems (EMI and/or RFI). Microcontroller boards returned commonly are found to have no
problem on the factory test stand. A new board has solved the problem but only because of
slight differences in mounting provide different grounding characteristics. A "hard, healthy"
ground is needed.
Note: In may cases of an erratic MP3 it has been found that the incoming power supply or
the external DC power supply is not providing stable power. Check to insure the power
source is stable before completing any of the following.
1. Insure the MP3 board is securely tightened to the control panel door by checking the
tightness of the four mounting nuts.
2. Insure that the grounding screw on the MP3 board (bottom left on board) is tight. There
are no connections to this screw.
3. Insure that all shielded wires are grounded on one end only. The preferred method of
grounding shielded wire is to attach the shield to ground at the device rather than at the
MP3 board terminal strip.
4. If the above checks fail to resolve problem being experienced do one or all the following:
a. Add a ground wire from the MP3 ground screw (item 2 above) to the equipment
grounding strap. The equipment ground strap is usually installed by the customer and
is attached to the base plate.
b. If no equipment ground strap is available, connect the grounding wire in 4 a above to
the ground lead of the incoming power supply.
Note: On units that have a control power transformer the secondary of the
transformer my be the only ground available. Use this as a last resort. The control
power transformer ground is relying on the panel enclosure ground through the panel
support. Any number of conditions such as paint or foreign matter may prevent this
from being a reliable ground. Use an Ohmmeter to verify that proper ground exists.
c. If an erratic device does not use shielded wire have it replaced with a shielded wire.
The type wire used on the vibration transmitters is preferred.
TP0002 Rev3.doc
Procedure for Calibration of the MP3 Axial Position

Transmitter
The axial position measurement system consists of a proximity probe a transmitter and the
MP3. The proximity probe is the same type of probe that is used for vibration measurement,
the axial position transmitter is functionally the same as the vibration transmitter with the
exception that the position transmitters range is 20 to 80 mils versus the 0 to 4 mils range of
the vibration probe transmitter. Troubleshooting of the axial position probe and transmitter is
done the same as for a vibration transmitter and probe. Values are different with the axial
position probe and transmitter.
The 20 to 80 mils range of the axial position transmitter has a 100 millivolt/mil scale factor.
The scale factor equates to 10 mils per volt (10 mils/volt)
The optional axial position probe is normally located in a stage thrust bearing cover. The
probe tip senses the distance from it to the thrust collar. The system is calibrated to read
Zero when the thrust collar is seated against the reverse (inactive) trust bearing. At this point
the actual distance of travel from the inactive to the active thrust bearing is called the COLD
FLOAT of the pinion.
The axial position measurement system measures the movement of the pinion in relation to
the inactive thrust position of the pinion while the compressor is operating. Alert and
shutdown setpoints as given on the electrical schematic are calculated and may need to be
adjusted on the actual running machine. Typical values for alarm and shutdown for a 75L
XFLO are Alert = 5 mil, Shutdown = 8 mil.
1. Set all clearances using standard procedures. The compressor should be uncoupled
from the driver.
2. Locate the axial position transmitter, normally in a proximeter box on the side of the
baseplate. Transmitter for axial position has I-R part number 1x11525 and are marked
20 - 80 mils. DO NOT CONFUSE THE POSITION TRANSMITTER WITH THE 0 - 4 MIL
VIBRATION TRANSMITTERS THAT WILL ALSO BE FOUND IN THE PROXIMETER
BOX. THE 0 -4 MIL TRANSMITTERS ARE CALIBRATED BY THE FACTORY AND
SHOULD NOT BE ADJUSTED.
3. Connect a voltmeter to the Common and Test connections on the 20 - 80 mil axial
position transmitter. Positive lead (+) connects to “TEST” and negative (-) to “COM”.
4. Rotate the bull gear shaft clockwise (CW) when facing the shaft to move the rotating
assembly into the full reverse (inactive) thrust position.
5. With the rotating assembly in the inactive thrust position, set the axial position probe gap
by screwing it in or out as necessary to obtain 3 volts (3 volts = 30 mils) on the
voltmeter. Lock the probe in the 3 volt position by tightening the lock nuts.
6. Rotate bull gear counter clockwise (CCW) to move the rotating assembly into the full
active thrust position. Read the voltage on the voltmeter, turn the bull gear to obtain the
highest reading. Subtract 3 volts from this highest reading. The sum is the “COLD
FLOAT” in volts. Cold float is the distance the pinion travels from its’ full inactive to full
active thrust position. To obtain the mils travel multiply the Cold float volts times 10 mils
per volt. Example: Highest voltage read at full active thrust = 4.8 volts. 4.8 volts - 3 volts
= 1.8 volts. 1.8 volts X 10 mil/volt = 18 mils. Cold float is 18 mils.
TP0002 Rev3.doc
7. With the rotating assembly in the active thrust position. Locate the “SPAN” adjust screw
on the axial position transmitter and adjust the transmitter until the MP3 faceplate reads
the cold float value divided by 10. The MP3 reads one digit to the left of the decimal point.
Using the above example the MP3 faceplate would read 1.80. A tag on the MP3 panel
instructs that the display should be multiplied by 10 to get actual position.
8. Rotate the Bull gear clockwise to the move the rotating assembly to the inactive thrust
position. The voltmeter should read 3 volts. Locate and adjust the “ZERO” adjust screw
on the axial position transmitter until the MP3 display read zero.
9. Repeat steps 7 and 8 until the MP3 display reads the proper value when the pinion is in
the active and inactive thrust position.. SPAN and ZERO affect one another so several
iterations of steps 7 and 8 may be necessary before proper values are read.
10. Set Alert and Shutdown values in accordance with the values given on the compressor
electrical schematic. The values on the schematic are calculated and may not be
completely appropriate for actual running conditions.
SET GAP AT 3 VOLTS = (30 mils)
MP3 READING = 0
REVERSE THRUST
TRANSMITTER ZERO = 0 ON MP3
MP3 READING = X.XX (COLD FLOAT)

FLOAT)
ACTIVE THRUST
TRANSMITTER SPAN = COLD FLOAT ON MP3
Figure 10. Axial position probe reference locations
TP0002 Rev3.doc
TP0002 Rev3.doc
General Use MP3 Electrical and Location Diagrams:

1S
1M
1M
MAIN
1M MOTOR
L3
3CT
2M
L2
INCOMING 2M 2CT
POWER
L1 1CT
2M
TO CT1 & CT2 ON

MICROPROCESSOR BOARD
1 OL
4FU 5FU 6FU

OIL
HTR-2
RESERVOIR
HEATER
HTR 1
P 2 OL
P 2 OL PRE LUBE
MOTOR
P 2 OL
1FU 2FU
PRIMARY SIDE OF
CONTROL POWER TRANSFORMER
H1 H2
SEE SECONDARY SIDE OF OIL RESERVOIR

CONTROL POWER TRANSFORMER
CIRCUIT ON FOLLOWING PAGES
Figure 11. General MP3 electrical schematic diagram, primary circuits
TP0002 Rev3.doc
SECONDARY SIDE OF CONTROL POWER TRANSFORMER

X1 X3
CONTROL POWER
ON OFF GND
L 3FU N
SUP
TST-1 TST-2 LUBE OIL
L 3 C
HEATER RELAY
MTR FAN MOTOR

SUP
CR-6 DEMISTER MOTOR RELAY
CR-6 CR-6
MTR DEMISTER MOTOR
R POWER ON (RED)
CR-1
1 4 5 1MM 1M 1M STARTER
CR-2 1S
2M 2M STARTER
CR-3 2M
1S 1S SHORTING RELAY
CR-1
45
44
TR-2 N POST RUN WATER TIMER
TR-2
42 N COOLING WATER
N.O.T.O
SV-1
OFF DELAY TIMER SOLINOID
LINE
1A NA
FILTER
AUTO HOT START
TR-1 PB-2 STOP LOCAL
REMOTE PS-2
1A 6 43 9
MAINTAINED
ON DELAY TIMER
Pa PB-1 START
7A MOMENTARY
1M 2M
7 8 9
1 OL
9A
TS1-5
MICROCONTROLLER
7
TS1-13
BOARD
TS1-10
1A
TS1-8 JUMPER SUP
2 OL PRE LUBE PUMP
TS1-3 13 14 14A P
UNLOAD MODULATE STARTER
AUTO DUAL
TS1-6 A NA PRE LUBE RUNNING
11
+ LT-2
TS1-4 (+) TS5-20 24 VDC POWER SUPPLY
12
-
CR 34 (-) TS5-19
UNLOAD INDICATION RELAY TS1-2
4
TO 1A
SUP
10 CR
CR 35 TS1-16 1M STARTER RELAY
TROUBLE INDICATION RELAY TS1-1 1
5
SUP
SUP
CR
RUNNING UNLOADED TR TS1-15 2M 2M STARTER RELAY
36 TS2-18 2
SHUTDOWN TIMER 1
SUP
SUP
37 CR
AUDIBLE ALARM HORN TS2-17 1S SHORTING RELAY
TS1-14 1S
3
TO NA SUP
Figure 12. General MP3 electrical schematic diagram, secondary circuits
TP0002 Rev3.doc
18 GA. TWISTED PAIR
TO MASTER COMPUTER
MICROCONTROLLER
INCOM
BOARD
CT1 TS3-1 P3
TS3-9 1
2 LUBE OIL
CT2 TS3-2 TS3-8 TEMPERATURE
TS3-7 3 TE-1
P1 4
TS3-6 AIR TEMPERATURE
5
1 TS3-5 STAGE 1
TS3-24
INLET VALVE I/P 6 TE-2
TS3-4
TRANSDUCER 1 2
TS3-23 7
(+) TS4-18 1 3
3 WATER
BYPASS VALVE TS3-22 TT-3 TEMPERATURE
I/P 8 TE-3
TRANSDUCER 4 (-) TS4-17 2 4
2 TS3-21
9
(+) TS4-16 1 3 AIR TEMPERATURE
TT-4 STAGE 2
10 TE-4
P2 (-) TS4-15 2 4
PDS-1 1
TS2-1 11
SURGE (+) TS4-14 1 3
SENSOR 2 AIR TEMPERATURE
TS2-2 TT-5 STAGE 3
12 4 TE-5
(-) TS4-13 2
LS-1 3 TS2-3
LOW WATER
4 13
FLOW TS2-4 (+) TS4-12 1 3
AIR TEMPERATURE
PS-1 5 TT-6 DISCHARGE
TS2-5 14 TE-6
LOW SEAL AIR (-) TS4-11 2 4
PRESSURE 6
TS2-6
15
PDS-2 7 (+) TS4-10 1 3
TS2-7 TEMPERATURE
DIRTY INLET TT-7
16 AA
FILTER 8 (-) TS4-9 2 4 TE-7
TS2-8
PDS-3 9
TS2-9 17
DIRTY OIL (+) TS4-8 1 3
FILTER 10 TEMPERATURE
TS2-10 TT-8 BB
18 TE-8
(-) TS4-7 2 4
LS-1 11
LOW OIL TS2-11
19
LEVEL 12 (+) TS4-6 1 3
TS2-12 TEMPERATURE
TT-9 CC
LS-2 13 20 4 TE-9
HIGH CONDENSATE TS2-13 (-) TS4-5 2
LEVEL 14
TS2-14 21
(+) TS4-4 1 3
TEMPERATURE
TM-1 46 TT-10 DD
TS2-15 22 TE-10
HIGH MOTOR (-) TS4-3 2 4
TEMPERATURE
47 TS2-16
23
(+) TS4-2 1 3
15 TEMPERTATURE
(+) TS5-20(+) TT-11
VIBRATION 24 TE-11 EE
STAGE 1 VB-1 (-) TS4-1 2 4
16
(-) TS3-19(-)
17 19
(+) TS5-18(+) (+) TS3-16 PT-1
VIBRATION SYSTEM DISCHARGE
VB-2 0-200 PRESSURE
STAGE 2 18 20
(-) TS3-17(-) (SIG) TS3-15 PSIG
26 22
(+) TS5-18(+) (+) TS3-13 PT-2 LUBE OIL
VIBRATION VB- 3 0-50 PRESSURE
STAGE 3 27 23 PSIG
(-) TS5-17(-) (SIG) TS3-12
P4
28 1
(+) TS5-16(+) (+) TS5-9 PT-3 DISCHARGE PRESSURE
VIBRATION VB- 4 0-50 STAGE 1
STAGE 4 29 2 PSIG
(-) TS5-15 (-) (SIG) TS5-8
30 4
(+) TS5-14(+) (+) TS5-6 PT-4
VIBRATION DISCHARGE PRESSURE
VB- A 0-200
SHAFT A STAGE 2
(-) 31 5 PSIG
TS5-13 (-) (SIG) TS5-5
32 7
(+) TS5-12(+) (+) TS5-3 PT-5
TVIBRATION
VB- B 0-200 DISCHARGE PRESSURE
SHAFT B
33 8 PSIG STAGE 3
(-) TS5-11 (-) (SIG) TS5-2
Figure 13. General MP3 electrical schematic diagram, input circuits
TP0002 Rev3.doc
SPARE
RS 232
SPARE
Faceplate connector
MOTOR CURRENT READOUT ADJUSTMENT
CURR
CT1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
MTR
CT2
P3-6
1st Air
TEMP
TE 2
P3-5
P3-4 P 401
P3-3
TEMP
T 801
TE-1
OIL
P3-2
P3-1 INTERNAL 24 VDC
PRESS
-
24
TE1 & 2 mV DC
OIL
TS3 ANALOG
s +
23
CR 1 K 601
22
Wire Numbers
PRESS
-
21
SYS
s +
20 CR 2 K 602
19
VB 1 VB 2
-
18
CR 3 K 603
+ -
17
16
TS 1 DISCRETE
+ -
15 Emerg. K 604
P1-4 Stop
115 VAC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CR1 10
BV
+ -
P1-3 CR2 2M
P1-2
IV
CR3 1S
+
P1-1 7
STOP
P3-24 NA
TE 3 TE 4 TE 5 TE 6 TE 7 TE 8 TE 9 TE10 TE11
1
NEU
-
F 601
EE
P3-23
2 3 4 5 6
+ - +
P3-22 120 v 1A
DD
P3-21
EXTERNAL 24 VDC
P3-20 MOD. 11
- + -
BB CC
TS4 ANALOG
P3-19 START 9/9A

4 - 20 Ma
12
7 8 9 10 11 12 13 14 15 16 17 18
P3-18 A/D
+
P3-17 PRELUBE 13
P3-16 UNLOAD 34
-
Wtr Stg 2 Stg 3 DSCG AA
P3-15 35
+ -
K 605 TROUBLE
PRELUBE
P3-14
+ -
P3-13 F 801 F 701

U 101 UNLOAD K 606
P3-12
+
P3-11
-
P3-10 HORN K 607

+ -
P3-9
P3-8 EPROM U 105
+
P3-7 7 8 9 10 11 12 13 14 15 16 17 18
UNLOAD TMR. 36
HORN 37
P4-9
1
-
Stg 3
47
HCL HMT
EXTERNAL 24 VDC
s +
P4-8
2 3 4 5 6
PT5 46
P4-7
TS5 ANALOG
P2-14
TS 2 DISCRETE
P4-6
-
4 - 20 Ma
Stg 2
P2-13
P4-5 PT4
s +
P2-12
115 VAC
DOF LOL
P4-4
P2-11
7 8 9 10 11 12 13 14 15 16 17 18 19 20
P4-3
-
Stg 1
P2-10
P4-2 PT3
s +
SW 207 P2-9
P4-1
P2-8
DIF
P2-7
33
- +
VB B P2-6
LSA
32
P2-5
1 2 3 4 5
31 NOT USED
- + -
VB A P2-4
LWF
30
P2-3
29
VB 4 P 301 P2-2
SS
+ - +
28
P2-1
27
VB 3
26
(-)
- +
Ext 24 V FACEPLATE READOUT VALUE ADJUSTMENT

F 501
(+)
Figure 14. Microprocessor board key component layout
TP0002 Rev3.doc

MP 3 Controller Device Troubleshooting - Tp0002

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MP 3 Controller Device Troubleshooting - Tp0002

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CENTAC 

MP3 Controller Device

Copyright 1992 Ingersoll-Rand Company

Vibration Transmitter: ________________________________________________________ 1

Procedure for Verifying Operation of the Vibration

Note: See Figure 1 Vibration transmitter troubleshooting sketches.

volts A. Test cable and probe

C. Test probe gap voltage mA O HM S

Sat test = 3 to 6 vdc (Nom = 5 vdc)

MP-3 D. Test MP3 and connecting wire

M P-3 mA source in 2 wire mode

Figure 1. Vibration transmitter troubleshooting sketches

2 Wire RTD (with External Transmitter):

Problems indicated on faceplate:

Procedure for Verifying Correct Voltage to Transmitter:

Procedure for Verifying Correct Operation of the MP3 and

Procedure for Verifying Correct Operation of the RTD

Procedure for Determining a Faulty RTD:

B. Test MP3 and read out

Sat test = @ 32 deg F on faceplate MIL LIAMP

TS-4 1 2 VAC VDC

ice water ice water

Figure 2. Two wire RTD troubleshooting sketches

3 Wire RTD ( No External Transmitter):

Problems indicated on faceplate:

Procedure for Verifying Operation of the MP3 and Faceplate:

Procedure for Determining Faulty RTD:

A. Test MP3 ability to read RTD

B. Test RTD for continuity and resistance

C. Test RTD against ohmic value chart + C V

Sat test = ohms vs temperature agree

3 wire RTD schematic diagram

Figure 3. Three wire RTD troubleshooting sketches

Problems indicated on faceplate:

Problem indication Probable cause

IV or BV not operating Failure of MP3

Procedure for Verifying Operation of the MP3:

Procedure for Verifying Operation of the I/P:

A. Test MP3 out put

B. Test I/P reaction to mA signal

Figure 4. I/P troubleshooting sketches

Problems indicated on faceplate:

Problem indication Probable cause

Blank faceplate readout Loss of power

Procedure for Verifying Operation of the PT:

Procedure for Calibration of the PT:

A. Test face plate and MP3

B. Test P/T with air regulator

Figure 5. PT Troubleshooting sketches

Discrete Input Devices ( 115 V Ac Switches):

Discrete device name and type:

Problems indicated on faceplate:

Blank faceplate readout MP3 or faceplate faulty

Procedure for Verifying Operation of the Discrete Devices:

A. Test MP3 discrete

Dirty oil filter

micr o switch Stage

Figure 6. Discrete device troubleshooting sketches

Compressor control panel

Warning: Powered by remote starter

CT is in any line that will reflect

Figure 7. Remote start circuit connections

Dry Run Procedure for MP3 with Version 5.00 Eprom:

Procedure for Dry Run MP3 Control Panels with Installed