REMOTE MONITORING SOFTWARE FOR IntelliGuard

VERSION 2.1 INTELLISERV SOFTWARE SOFTWARE INSTALLATION AND USERS MANUAL.

More Than Air. Answers.

Online answers: http://www.air.irco.com

APDD 716B
December 2001

LICENSE TO USE SOFTWARE

Section 1.0 Grant of License to Use Software I-R hereby grants USER for the duration of this Agreement, a non-exclusive, non-assignable license without the right to grant sub-licenses solely to use the SOFTWARE to monitor operation of I-R machines or other non-I-R machines designated by I-R, and shall not use the SOFTWARE to monitor operation of an other machine, equipment or the like not designated by I-R. Under the SOFTWARE license, the USER shall be permitted to use each licensed copy of the SOFTWARE on a single computer. I-R only grants USER the right to use the SOFTWARE to monitor operation of I-R machines or other machines designated by I-R, and USER shall not copy, modify or reverse engineer the SOFTWARE without IRs prior written approval. USER will take all measures necessary to prevent others from copying the SOFTWARE.

(d) forthwith by I-R if USER or any of its employees, agents or contractors, commits an act or fails to take any appropriate action to prevent the commission of an act which in I-Rs opinion, vitiates or could vitiate IRs right, title or interest in the SOFTWARE; or (e) at anytime by written mutual agreement between IR and USER.

SECTION 4.0
Consequences of Termination Unless otherwise indicated in writing by I-R, upon termination of this Agreement for whatever reason, USERs right to use the SOFTWARE shall immediately cease; and USER shall return all copies of the SOFTWARE to I-R at USERs expense.

SECTION 5.0
Warranty Not withstanding anything to the contrary in this Agreement, I-R shall not be liable to USER by reason of any representation or implied warranty, condition or other term or any duty at common law, or under the express terms of this Agreement, for any loss or damage arising out of use of the SOFTWARE by user.

SECTION 2.0
Term of license to use SOFTWARE The non-exclusive license granted by I-R in Section 1.0 shall commence on the calendar year day the SOFTWARE is first accessed by the USER and, shall continue until terminated by I-R or under one of the provisions of Section 3.0

SECTION 6.0
Applicable Law This agreement shall be construed and the legal relations between the parties shall be determined in accordance with the laws of the state of New Jersey.

SECTION 3.0
Termination of This Agreement This agreement is without limit of period but shall be terminated as follows: (a) forthwith by I-R giving USER thirty (30) days written notice of its intention to terminate this Agreement; or (b) forthwith upon termination of the relationship with IR; or (c) forthwith by I-R upon USER entering into an arrangement for the benefit of creditors, appointment of a receiver, entry into liquidation or passage of any resolution for that purpose by USER; or

SECTION 7.0
Entire Agreement and Amendments This instrument contains the entire Agreement between the parties respecting the subject matter hereof, and supersedes or cancels all previous negotiation, agreement, commitments and writings in respect to the subject matter hereof. This Agreement may not be amended, supplemented, released, discharged, abandoned, changed, or modified in any manner, orally or otherwise, except by an instrument in writing of concurrent or subsequent date signed by duly authorized officers or representatives of each of the parties hereto.

INGERSOLL-RAND COMPANY

TABLE OF CONTENTS
Section 1.0 Introduction 2.0 Currently Supported Intellisys Controllers and EPROM Versions 3.0 Retaining Previously Entered Customer Information 4.0 Software Installation 5.0 Hardware Security Key 6.0 Running the Intelliserv Software 7.0 Main Menu Screen 8.0 View Current Status 9.0 View Setpoints / Options 10.0 View Alarm History 11.0 Data Logging 12.0 View Data Log File 13.0 Compressor Connection 14.0 Intelliserv Setup 15.0 Machine Modem Initialization For IntelliGuard 16.0 Creating Reports 17.0 Using Intelliserv Screens In Other Applications 18.0 Printing Reports To A File When A Printer Is Not Available 19.0 Intelliserv Troubleshooting 20.0 Removing the Intelliserv Software 21.0 Hardware Key Kit - Parts List Page 2 2 3 3 4 4 5 6 9 10 11 13 14 16 17 18 19 19 21 23 24

1.0 INTRODUCTION
Intelliserv is a PC-based software service tool that provides a means of accessing real-time vital machine information from an Ingersoll-Rand Intellisys controlled air compressor. From an IBM compatible PC, the user can retrieve almost all information about the compressor that the Intellisys controller can access. Information such as pressures and temperatures may be viewed real-time or plotted graphically over a specified period of time, or even saved to disk for later retrieval. Set points, alarm history and machine status information can all be retrieved while connected for real-time viewing. New features have been added to Intelliserv since the original release of version 1.0. Intelliserv Version 1.5 brought about the addition of the Sierra machines to the current] supported Intellisys Controllers, and the added capability of printing reports using the viewed Intelliserv data. Also added was the ability to append data to an existing Datalog file. Version 2.1 makes possible the use of an additional service offered to the customer called IntelliGuard. IntelliGuard is a value-added service that provides notification to the appropriate IR Service Center when an Intellisys controlled compressor has sensed a warning or alarm condition. Using the Intelliserv hardware, IntelliGuard allows the Intellisys controller to place a call to the IntelliGuard call center and report the compressors current condition. At the IntelliGuard call center, a software application called ICU answers the incoming call, collects the customer site and compressor information, then alerts the appropriate IR Service Center that an alarm or warning has occured. This allows the service organization to be aware of the actual status of a customers compressor shortly after an alarm or warning condition has occurred. The Intelliserv software, IntelliGuard, and the ICU application are all used in conjunction with the Ingersoll-Rand Intellisys Remote Interface (IRI) to retrieve information fron the Intellisys Controller. Some later model Intellisys SG controllers have the Modbus Protocol built-in. For these controllers the IRI is not required. The Intelliserv software may be used by the IR Service Provider at the customers compressor site. This is considered a local connection and is made by connecting the PC to the IRI and or Intellisys Controller, via an RS-232 to RS-485 converter. It can also be used

remotely, using standard telephone modems at the PC and customer locations. This is considered a remote connection. Intelliserv, IntelliGuard, and ICU can only monitor machine information and at this time have no machine control capability built in. Intelliserv will run on any standard IBM compatible computer, which meets or exceeds the following minimum requirements: Windows 95 or Windows NT 4.0 486 / 66 Mhz Math Co-processor (required) 16 Megabytes RAM 40 Megabytes free hard drive space 1 available serial port VGA 640X480 monitor resolution

2.0 CURRENTLY SUPPORTED INTELLISYS CONTROLLERS AND EPROM VERSIONS

USA - SSR 50 - 450 HP SG Software Ver. 1.00, 1.01, 1.10, 1.20, 1.21, 1.23, 1.30, 1.40. (Machine Type 0) USA - SSR 50 - 450 HP SSR Software Ver. 2.30, 2.40. (Machine Type 3) USA - SSR 15 - 100 HP SE Software Ver. 1.40, 1.50, 1.60, 1.70. (Machine Type 1) USA - Sierra 100 - 200 HP SSR Software Ver. 2.50, 2.60. (Machine Type 8) USA - Sierra 50 - 100 HP SE Software Ver. 1.20. (Machine Type 6) ESA - SSR 75 - 350 KW SG Software Ver. 1.00, 1.10, 1.11. (Machine Type 4) ESA SSR 200 - 350 KW SSR Software Ver. 1,20. (Machine Type 5) ESA SSR 22 - 150 KW SE Software Ver. 1.70, 1.80. (Machine Type 2) WW - SSR 50 - 450 HP SG Software Ver. 1.30. (Machine Type 10) WW - Sierra 125-400 HP SG Software Ver. 1.00, 1.10, 1.12, 1.20, 1.23. (Machine Type 9) WW - Sierra 50-100 HP SE Software Ver. 1.00, 1.10. (Machine Type 7) WW - Nirvana CC SGN Software Ver. 1.00, 1.10 (Machine Type 14)

3.0 RETAINING PREVIOUSLY ENTERED CUSTOMER INFORMATION

Please Read before Installing the Software If customer information has been entered into the Customer Directory using Intelliserv 1.0 or Intelliserv 1.5, these files will not be compatible with Intelliserv 2.1. Customer information should be printed and manually reentered creating a new Customer Directory file using Intelliserv 2.1. Printing the file named Intlserv.dir located in the Intelliserv Installation Directory must be done before beginning to install the Intelliserv 2.1 software.

(7) If a previous version of Intelliserv has already been installed, several of these original files will be recognized during the new software installation. Setup will respond with File C:\Intlserv\?????.??? Is already present. Shall we replace it?. Press Yes for each of these files. (8) Once all files have been copied, and no problems have been encountered, the install program will respond with Intelliserv installation successful! Press OK. If problems were encountered or the installation was not successful, exit and restart the software installation. (9) Device drivers for the hardware security key will be installed into the c:\Intlserv directory during the software installation. This will be done automatically as the install program closes down. Press OK to continue. You must reboot the computer before attempting to run the Intelliserv program. (10) Once the install program has successfull completed the installation, a program group called Intelliserv will have been created. Within this program group an Intelliserv 2.1 icon will have been created.

4.0 SOFTWARE INSTALLATION

Please Read Section 3.0 Retaining Previously Entered Customer Information before beginning the software installation. (1) With Windows running and all other applications closed, log in to IR Service Net. Contact Aftermarket Customer Service for a login and password. (2) Choose North America, then Aftermarket, then IntelliGuard, then Software. (3) Click the ArticleID for the Intelliserv software (not the manuals), then click the Intelliservxx.exe for the software. (4) Choose Save file to disk, and remove the [1] from the file extension. Choose a location for the file, and choose Save. (5) When the file has been saved, run the Intelliservxx.exe file (From the Start menu, choose Run, and Browse to find the Intelliservxx.exe file. Choose Open then OK). You will need to unzip the files. The Intelliserv program will make an intlserv folder in you C:/Programs folder. (6) Run Setup.exe (From the Start, Run menu, Browse for C:/Programs/intlserv and choose Setup.exe.) Continue through the setup dialogue. The Setup program will install the Intelliserv software.

6.0 RUNNING THE INTELLISERV SOFTWARE

To run the Intelliserv program, double click the Intelliserv icon.

5.0 HARDWARE SECURITY KEY

A hardware security key is required for Intelliserv to run properly. This key must be installed on the proper PC parallel port before data can be retrieved. The key is completely transparent to normal computer-to printer communication and should present no problems with any existing printer connections. Remove any previously installed hardware security keys or printer cables from the PC printer port. Attach the Intelliserv security key directly to the PC printer port. Reinstall the previously mounted security keys and/or printer cables, behind the Intelliserv security key. The hardware security key should normally be mounted on the LPT1 printer port. In cases where this port will not be used, the port settings can be changed in the Intelliserv Setup screen. See the Intelliserv Setup in Section 14.0 for further details.

The Intelliserv title page will be displayed for several seconds then go directly to the Main Menu. The following message may be displayed when trying to run the Intelliserv program. ActiveX Automation Libraries could not be initialized. You need to install DCOM 1.1 for Windows 95 or greater. These libraries do not require updating for Intelliserv 1.5 or 2.1 to operate properly. Press OK to continue. Intelliserv should continue to load properly. If updated DCOM drivers are installed, this message will no longer appear. Each type of Intellisys controller as well as each Intellisys EPROM version reports machine information differently. For the proper operation of Intelliserv, the correct Machine Type and Software Version must be entered into the Compressor Connection screen before a connection is attempted.

7.0 MAIN MENU SCREEN

a source other than an Intellisys controller. Verify the proper setup of Intelliserv and the connection between Intelliserv and the controller. View Current Status (Control) Retrieves and displays in real-time the current pressure, temperature, hours and status information that is being read by the Intellisys controller. This indication is updated approximately every two seconds. View Setpoints / Options (Control) Retrieves and displays the current factory setpoints, operator setpoints, and options that are currently programmed or installed in the Intellisys controller. View Alarm History (Control) Retrieves and displays the alarm history (last 15 alarms) previously recorded by the Intellisys controller. Data Logging (Control) Retrieves and graphically displays all pressure and temperature information over time. Also has the ability to save data to a file for later retrieval. View Datalog File (Control) Displays previously saved datalog file and graphically displays pressure and temperature information over time. Compressor Connection (Control) Provides a means for entering specific machine information for connection to each compressor. Each type of Intellisys controller as well as each Intellisys EPROM version, reports machine information differently. For the proper operation of Intelliserv, the proper Machine Type and Software Version must be entered in the Compressor Connection screen before a connection is attempted. Setup (Control) Provides a means for entering specific computer system information used by Intelliserv when accessing the PCs communication ports. Also provides a means of initializing the compressors site modem before installation at the compressor site. Exit (Control) Exits Intelliserv and returns to Windows.

This is the main menu from which all machine information can be accessed. Indicators are available to display specific machine information. Controls are available to maneuver around the Intelliserv program. Below is a brief description of each. Currently Connected To (Indicator) Modbus Address (Indicator) Displays specific machine information for the compressor that is currently being monitored. This information is entered by manually filling in the blanks in the Compressor Connection screen or selecting an entry in the Customer Directory. Comm OK / No Comm (Indicator) Indicates whether or not communication is currently established with an Intellisys controller. Comm OK (green) indicates that communication with the controller is successful. No Comm (red) indicates a communication failure has occurred. Date / Time (Indicator) Displays current date and time obtained from the computers internal clock. The data is displayed in the 4 digit year format for Y2K compatibility. Unrecognized response from Intellisys (Dialog Box - Indicator) Warns when Intelliserv has attempted to communicate with an Intellisys controller and the proper response was not returned. This is an indication that the Intellisys controller is not responding, or communication between Intelliserv and the controller is not reliable. Intelliserv may also be receiving a response from

8.0 VIEW CURRENT STATUS

connections may be OK for voice communication but not reliable enough for data communication. If multiple CRC failures occur try hanging up and re-dialing the compressor. Pressure (Indicator) Indicates the pressure values being read from the Intellisys controller. Different types of controllers will display different numbers of indicators. Only pressures read by the controller can be displayed. For SE type controllers, the controller can only read one pressure input at any one time. Therefore the Sump Pressure and Package Discharge Pressure cannot be read simultaneously. The active indicator will have the blue background. Normally the Package Discharge pressure will be active with the ability to manually update the Sump Pressure by pressing the Update Sump control. The pressure units of measure (PSI, Bar, ...) are also read from the controllers setup and displayed. Update Sump-SE Only (Control) For SE types of controllers with only one pressure input, the Sump pressure is manually retrieved. Normally the Sump pressure indicator will be grayed out and the indication will be the last Sump pressure reading. To update the display, press the Update Sump button. The Sump pressure indicator will momentarily turn blue with the new Sump pressure indication, then return to grayed out. The Status Bar will indicate an L for Line and an S for Sump indicating which pressure is currently being read. Temperature (Indicator) Indicates the temperature values being read from the Intellisys controller. Different types of controllers will display different numbers of indicators. Only temperatures read by the controller can be displayed. For controllers that may have the Low Ambient option capability, the Low Ambient Coolant Temperature indicator will be visible. If the Low Ambient option is turned on, this indicator will be active. If the option is turned off, the indicator will be grayed out.

The View Current Status screen retrieves and graphically, as well as numerically, displays all pressures, temperatures, hours and status information read from the Intellisys controller. Each indicator is updated every one to two seconds. This allows viewing of the compressor operation with almost real-time data retrieval. A quick observation of the compressors overall operation can be made while viewing the information available through this screen. Currently Connected To (Indicator) Modbus Address (Indicator) Intellisys Software Version (Indicator) Displays specific machine information for the compressor that is currently being monitored. This information is entered by manually filling in the blanks in the Compressor Connection screen or selecting an entry in the Customer Directory. Comm Ok / No Comm (Indicator) Indicates whether or not communication is currently established with an Intellisys controller. Comm Ok (green) indicates that communication with the controller is successful. No Comm (red) indicates a communication failure has occurred. CRC Failures (indicator) If a compressor fails to communicate or data being received is noisy, a CRC failure count is displayed. This is an indication that the data string received could be erroneous. In such cases the received data is throw away and not displayed. It is fairly common to have a few CRC failures over long periods of time, especially if the machine is loading and unloading and unloading often. Multiple CRC failures, every few seconds, indicates a failure to communicate reliably. Some phone 6

Hours (Indicator) Indicates the actual machine Total and Loaded hours read from the controller. Status (Indicator) The Status bar indicates the current status of the compressor. Modes such as Running or Stopped, Loaded or Unloaded and Alarm or Warning will be indicated here. When an Alarm or Warning mode is detected, the Alarm or Warning message will also be displayed. Create Report (Control) Reports can be easily generated using the displayed screen data by pressing the Create Report button. Pressing this button opens a text box that allows the user to enter up to 20 lines of text at up to 120 characters per line. This text will be placed on the report form with the displayed screens data. Any additional information may be added to the viewed screen that the end user may need to see. Further details on creating reports can be found in Section 16.0 Creating Reports. Return to Main Menu (Control) Pressing this control returns to Intelliservs Main Menu. Unused Intellisys Inputs (Indicator) The Unused Intellisys Inputs indicators are used when the SG Intellisys Controller has input signals connected to the unused pressure inputs located on the SG Intellisys Controllers P5 port. Only SG Intellisys Controllers and only certain EPROM versions will have this capability. When this capability is made available, any unused pressure input port may be used to read other sensors output signals. This must be a 05 Vdc maximum signal and must be at the same ground potential as the Intellisys Controller. IR Engineering must approve any device connected to an unused port before any connection is made. Failure to follow the above instructions may damage the Intellisys controller. This unused input information will not be accessible from the front panel of the Intellisys Controller and cannot be used for control of the compressor. This information can only be accessed via the serial port.

Unused Intellisys Inputs Setup (Control) The Unused Intellisys Input Setup screen is used to activate, and correctly display the signal connected to any of the Intellisys unused pressure input channels. When an unused pressure input is to be used, press the Unused Intellisys Inputs Setup button to turn on and setup each inputs corresponding indicator. Each channel can be activated, labeled with the desired engineering units, properly scaled using multiplier and offset values, and entering the proper number of digits to be displayed on the front panel.

ON (Control) On/ OFF Clicking this control will make this indicator visible. DP: (Control) Decimal Place This is the number of decimal places that will be shown in the displayed value. EU: (Control) Engineering Units Enter the engineering units that the displayed value will be shown in. This unit can be up to five characters long. (Psi, Volts, Amps, Dbsv) Mx: (Control) Multiplier or Slope If the 0-5vdc sensor input signal read by the Intellisys controller has a linear relationship with the desired units of display, the input signal can be converted to the desired engineering units by using the Mx multiplier and the +b offset values. Mx is the value the input signal is to be multiplied by to convert the measured voltage signal to the desired engineering units. +b: (Control) Offset or Intercept The offset value that must be added to the input signal or calculated value to convert the final result to the desired engineering units.

Unused Intellisys Input Example

Sensor Used Bearing Monitor Module Output Signal: 1-5 Vdc Output Units: 0-80 Dbsv Input Setup On = Selected DP = I EU = Dbsv Mx = 20 +b = -20 Calculation If the input signal = 1.00 Vdc Dbsv = ([Input Signal]*Mx)+b Dbsv = (1.00*20)+-20 Dbsv = 20+-20 Dbsv = 0.0 If the input signal = 5.00 Vdc Dbsv = (5.00*20)+-20 Dbsv = 100+-20 Dbsv = 80.0

Once the proper entries have been made, press Ok to save the changes and continue. Press Cancel to exit without saving any of the previous changes. If Ok is pressed, Intelliserv will ask to save the changes to the Unused Inputs.ini file. To save these changes, press Replace to replace the existing file. Pressing Cancel will continue without saving any changes that have been made. Once any unused input has been activated, this value will be read each time the Current Status is viewed for any compressor of that same type.

9.0 VIEW SETPOINTS/OPTIONS

Comm Ok / No Comm (Indicator) Indicates whether or not communication is currently established with an Intellisys controller. Comm Ok (green) indicates that communication with the controller is successful. No Comm (red) indicates a communication failure has occurred. CRC Failures (indicator) If a compressor fails to communicate or data being received is noisy, a CRC failure count is displayed. This is an indication that the data string received could be erroneous. In such cases the received data is throw away and not displayed. It is fairly common to have a few CRC failures over long periods of time, especially if the machine is loading and unloading often. Multiple CRC failures, every few seconds, indicates a failure to communicate reliably. Some phone connections may be OK for voice communication but not reliable enough for data communication. If multiple CRC failures occur try hanging up and re-dialing the compressor.

The View Setpoints / Options screen displays the current Factory and Operator setpoints as well as any options that are currently installed. These values cannot be changed using Intelliserv, however the PC will quickly reflect any changes made to the setpoints at the Intellisys Controller. This screen is updated approximately every second. Different types of controllers and EPROM version will indicate different amounts of information. Setpoints that are available on the controller will also be available through Intelliserv. Currently Connected To (Indicator) Modbus Address (indicator) Intellisys Software Version (Indicator) Displays specific machine information for the compressor that is currently being monitored. This information is entered by manually filling in the blanks in the Compressor Connection screen or selecting an entry in the Customer Directory.

Create Report (Control) Reports can be easily generated using the displayed screen data by pressing the Create Report button. Pressing this button opens a text box that allows the user to enter up to 20 lines of text at up to 120 characters per line. This text will be placed on the report form with the displayed screen data. Any additional information may be added to the viewed screen that the end user may need to see. Further details on creating reports can be found in Section 16.0 Creating Reports. Return to Main Menu (Control) Pressing this control returns to Intelliservs Main Menu.

10.0 VIEW ALARM HISTORY

Alarm Status (Control) For some Intellisys EPROM versions, the machine status at the time of each alarm can be displayed. If this is not available the Alarm Status controls will be grayed out.

The View Alarm History screen displays the Alarm History information logged by the Intellisys controller. The Intellisys controller retains a history of the last 15 alarms with the #1 Alarm being the most recent. The Alarm Condition along with all pressures, temperatures, machine hours and machine status will be displayed. Retrieve Alarms (Control) Pressing the Retrieve Alarms button starts the alarm retrieval process. Intelliserv begins to collect all alarm information that the Intellisys controller has logged. The Alarm Retrieval Status indicator should progressively increase from 0 to 100 percent complete. Any alarm logged by the Intellisys controller after the Retrieve Alarms button has been pressed will not be displayed until the alarm information is again retrieved. Alarm Retrieval Status (Indicator) The Alarm Retrieval Status indicator will indicate the progress of the Alarm information being retrieved from the controller. Normally the status should smoothly increase from 0 to 100 percent as the alarm information is read in. An erratic or slow increase indicates the data being received may contain errors. Intelliserv will make 3 attempts to retrieve the alarm information error free. If data cannot be retrieved 100 percent error free, the Alarm Retrieval Status indicator will flash with a red background.

Create Report (Control) Reports can be easily generated using the displayed screen data by pressing the Create Report button. Pressing this button opens a text box that allows the user to enter up to 20 lines of text at up to 120 characters per line. This text will be placed on the report form with the displayed screen data. Any additional information may be added to the viewed screen that the end user may need to see. Further details on creating reports can be found in Section 16.0 Creating Reports. Return to Main Menu (Control) Pressing this control returns to Intelliservs Main Menu.

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11.0 DATA LOGGING

Data Window (Indicator) The data window displays the real-time data read from the Intellisys controller with a 15 minute running history. When this window is first opened, the horizontal and vertical scale values are automatically adjusted to the type of data viewed. Each scale may be manually adjusted by clicking and highlighting any scale value and entering a new desired value. This is useful when wanting to zoom in or out to see a particular point of data. Exiting and returning to Datalogging will reset the horizontal and vertical scales to their default values. Hours (Indicator) Displays the machines current total and loaded hours. Save Data (Control) Saving machine data to a file is started by pressing the Save Data button and entering the proper Scan Interval and Scan Duration times.

Data logging graphically displays all pressure and temperature information over a preset period of time. This allows the user to graphically view all current information as well as a running 15 minute history. Data can be saved to a file for longer histories or for later review. The update time for this screen is approximately 5 seconds. Currently Connected To (Indicator) Modbus Address (indicator) Displays specific machine information for the compressor that is currently being monitored. This information is entered by manually filling in the blanks in the Compressor Connection screen or selecting an entry in the Customer Directory. Comm Ok / No Comm (Indicator) Indicates whether or not communication is currently established with an Intellisys controller. Comm Ok (green) indicates that communication with the controller is successful. No Comm (red) indicates a communication failure has occurred. CRC Failures (Indicator) If a compressor fails to communicate or data being received is noisy, a CRC failure count is displayed. This is an indication that the data string received could be erroneous. In such cases the received data is throw away and not displayed. It is fairly common to have a few CRC failures over long periods of time, especially if the machine is loading and unloading often. Multiple CRC failures, every few seconds, indicates a failure to communicate reliably. Some phone connections may be OK for voice communication but not suitable for data communication. If multiple CRC failures occur try hanging up and re-dialing the compressor.

Scan Interval is how often each datapoint will be saved to the file. Scan Duration is the complete time span over which the datapoints will be saved. Example: Scan Duration = 30 seconds Scan Interval = 5 seconds

All datapoints viewed on the screen will be saved to the file every 5 seconds over a period of 30 seconds. After the Scan Duration time is reached, the datalog file will be closed and no further data will be saved. Once the desired scan times have been entered press OK to continue.

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Next choose a file name in which to store the machine information.

Sump Pressure Update in XX Seconds (Indicator) For the SE style Intellisys controllers, the Sump Pressure indication is updated approximately once a minute. This indication is shown on the chart only when a valid reading has been taken. The Sump Pressure Update in XX Seconds indicates when the next Sump Pressure reading will be made. Create Report (Control) Reports can be easily generated using the displayed screen data by pressing the Create Report button. Pressing this button opens a text box that allows the user to enter up to 20 lines of text at up to 120 characters per line. This text will be placed on the report form with the displayed screens data. Any additional information may be added to the viewed screen that the end user may need to see. Further details on creating reports can be found in Section 16.0 Creating Reports. Return to Main Menu (Control) Pressing this control returns to Intelliservs Main Menu.

This can be any file name with a 3-letter extension (.dlf). Data can be saved to a new or preexisting .dlf file. If a new file name is entered, Intelliserv will create the new file for you. If a pre-existing file is chosen, Intelliserv will ask to Replace or Append data to the existing file. If Replace is chosen, any data currently in the file will be lost. If Append is chosen, the new data being logged will be added to the end of the original datalog file. After entering the file name, press Save. Data will now be written to the file using the above chosen Scan Interval and Scan Duration times. The Save Data button below the Data window will change to Stop Saving Data. Once the scan duration time is reached, the file will be closed and no further data will be saved. To stop saving data to a file before the duration time has been met, press the Stop Saving Data button. This will close the current datalog file and return to a normal viewing only mode.

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12.0 VIEW DATALOG FILE

Read Data File (Control) To read and view a previously saved datalog file, press the Read Data File button. This will open a Windows File dialog box that will allow you to choose a datalog file to read. Locate the proper file then press Open. Intelliserv will begin to read information from this file as if it were

View Datalog File allows the reading and viewing of a datalog file that had been previously saved using the Datalogging Save Data option. To view a file press the Read Data File button. This opens a Windows file dialog box that will enable the user to choose a file to read. After the desired file has been chosen, Press Open. Intelliserv will now begin to read information from the file as if it were connected to the machine. Connected To (Indicator) Indicates the compressor information that was stored in the datalog file being read. The Customer Name, Customer Location, Machine Name and Machine Serial Number will be displayed. Reading (Indicator) Indicates Reading when data is being read from a datalog file. When data is not being read this indicator will be blank. Controller Hourmeter (Indicator) Indicates the machine Total and Loaded hours read from the datalog file. Time Interval (Control) Controls the time interval that data is read from the datalog file and displayed. This control is used to speed up or slow the playback time of the data file. A typical time of approximately 2 seconds is the default value. If this value is decreased, the speed of the playback time will be increased. If this value is increased, the speed of the playback time will be decreased.

actually connected to the machine. The actual Date and Time the file was recorded will be displayed. While data is being read from a file the Read Data File button will indicate Reading Data File. Once the file has been completely read this button will return to Read Data File To pause the data retrieval process in the middle of the file, press Reading Data File. To restart, press Read Data File once again and the reading will continue. Return to Main Menu (Control) Pressing this control returns to Intelliservs Main Menu. Create Report (Control) Reports can be easily generated using the displayed screen data by pressing the Create Report button. Pressing this button opens a text box that allows the user to enter up to 20 lines of text at up to 120 characters per line. This text will be placed on the report form with the displayed screen data. Any additional information may be added to the viewed screen that the end user may need to see. Further details on creating reports can be found in Section 16.0 Creating Reports.

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13.0 COMPRESSOR CONNECTION

Phone Number (Control, Required for remote connections only) Enter the complete phone number to be dialed for a remote connection. If any number must be dialed to get an outside line it must be entered along with the phone number. Use commas in the phone number for a 2-second pause when pauses are needed during dialing. Multiple commas can be used for longer delays. Pager 1, Pager 2 These entries are for IntelliGuard use only. Numbers should not be entered here for Intelliserv operation. Machine Type (Control, Required) This is the Type of compressor being monitored. Press the down arrow and select the proper type of machine being monitored. Local or Remote Connection (Control, Required) A Local connection is when Intelliserv is running at the same location as the compressor and the compressor is accessible by connecting directly to the machine without going through a modem. A Remote connection is used when calling a machine from an off-site location. The machine must have the proper hardware installed. A Site Hardware Kit, PN: 42457614, must be installed at the customers location and a Machine Hardware Kit, PN: 42457622, must be installed on each machine that does not have a built in modbus. See Section 21.0 Parts List for further details. Remote Connect (Control) Initiates a remote connection by initializing the PC modem, dialing the entered phone number, and connecting to the remote modem. When a remote connection is made to a customers site with more than one machine, each machine may be accessed by remotely connecting to an machine at that location then simply selecting the desired machine entry from the customer directory and click Done. Remote Disconnect (Control) Disconnects from the remote modem and hangs up the phone line. Add (Control) Adds to the Customer Directory the machine information that has been manually entered. Pressing this button will create a new entry in the Customer Directory using the currently displayed customer and machine information. Once an entry has been added it can only be deleted using the Directory Editor.

The Compressor Connection screen provides the user with the means of connecting to the Intellisys Controller through either a local or remote connection. The main screen provides for manual entry of specific machine information, which can be stored and later retrieved from the Customer Directory. The Customer Name, Customer Location, Machine Identifier and Machine Serial Number are all optional inputs and are used as a means too quickly and easily identify the machine that Intelliserv is currently connected to. All other inputs are required to be correctly entered to obtain accurate data from the Intellisys controller. Intelliserv uses this information when connecting to and communicating with the controller. The Modbus Address, Software Version, Machine Type and Local or Remote Connection are all required to be properly entered for all connections. For remote connections, the Phone Number is also required. Customer Name (Control, Optional) Customer Location (Control, Optional) Machine Identifier (Control, Optional) Machine SN (Control, Optional) Used to identify the machine and its location. Software Version (Control, Required) This is the EPROM version in the Intellisys controller that is being monitored . It must contain 3 digits. For example 1.00 or 1.50, not 1.0 or 1.5. Modbus Address (Control, Required) Modbus address that the IRI or Intellisys controller is set to respond too.

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Directory (Control) A machine directory has been provided to store machine information for easy retrieval. Once information has been manually entered in the main Compressor Connection screen, pressing the Add button adds this information to the machine directory. Pressing the Directory button brings up the Customer Directory window and displays the entries currently in the Customer Directory.

Change any information that needs to be changed then press the Save button. This will save the entry to the customer directory file with the updated changes and return to the Customer Directory. Pressing Cancel will cancel any changes and return to the Customer Directory. If any part of the information about a particular machines entry is known, the directory Search function can be used to quickly search through the machine entries. Pressing the Search button will open a search window.

Select the desired machine entry and press Accept to bring this machines information to the Current Compressor Selection window. Pressing Cancel will close the Customer Directory without selecting any of the machine entries. Delete will delete the selected entry from the customer directory file. Once an entry has been deleted it cannot be recovered. To change any information for a particular entry in the customer directory, select the desired machine entry and press the Edit button. This will open the Directory editor and display all of the customer information for the selected entry.

Enter the information to search for then press Search. This string of information is case sensitive, therefore the proper capitalization must be used. Pressing Cancel will cancel the search and return to the Customer Directory. Status Window (Indicator) The Status window indicates the status of a connection. When a remote connection is attempted the status of the connection will be reported. The Com Port setting is selected b the Local or Remote Connection selection and the Intelliserv Setup screen. When attempting to communicate with a Local Com Port selection the Local Com Port selected in the Intelliserv Setup screen will be used. Likewise, when attempting to communicate with a Remote Com Port selection the Remote Com Port selected in the Intelliserv Setup screen will be used. The Time Out counter is the amount of time that Intelliserv will wait for a connection to be made with a remote modem. This counter value is also entered in the Intelliserv Setup screen. Done (Control) Pressing the Done button exits the Current Compressor Selection screen and returns to the Main Menu. . 15

14.0 INTELLISERV SETUP

of F0. For all other installations use the Modbus address displayed on the front panel of the IRI. Successfully passing this test will verify the connection between the PC and the IRI. Remote Communication Port The Remote Communication Port setting is used when connecting to a compressor remotely and modems are used to make the connection. Press the Serial Port down arrow and select the PC serial port to which the modem is connected. Also select a Serial Port Baud Rate of at least 19,200. A remote test can be performed to verify that all connections between the PC and the modem are functioning properly. This test communicates with the modem to verify that it is connected and functioning properly. Hardware Key The hardware security key used by Intelliserv must be connected to a PC parallel port. This would normally be the LPT1 port. Report Header This information is used when printing reports by pressing the Create Report button on any of the Intelliserv screens. Six lines with 29 characters each are provided for data entry. A Report header is created using this information. See Section 16.0 Creating Reports for further information on how this information is used. Modem Connect Command The Modem Connect Command is a special connect command that may be needed for some types of modems to properly establish communication with the Intellisys controller. A default entry of ATZ should be used until a special connect command is determined to be needed. Cancel call if not connected within: This is the time that Intelliserv will wait before automatically aborting a remote connection if the remote modem has not answered. Sixty seconds is the default value, however this can be changed to suit each application.

The Intelliserv Setup screen provides a means of entering computer system information that Intelliserv uses when communicating to external devices such as a modem or local IRI. Once these selections have been made the setup information is saved and automatically recalled each time Intelliserv is started. Printer The Printer button is located in the top left comer of the screen. It allows access to the Windows Printer Setup dialog box used when printing reports to select and setup the desired printer. Any installed printers should be accessible through this window. Selection between different printers is accomplished by pressing the Down arrow located beside the Printer Name box. After the desired printer has been chosen press OK to return to the Setup screen. Return to the Main Menu by pressing Quit Without Saving. The selections made in Windows Printer Setup will be retained. Local Communication Port The Local Communication port setting is used when connecting directly to a compressor without going through a modem. Press the Serial Port down arrow and select the appropriate PC serial port to be used. Press the Serial Port Baud Rate down arrow and select the appropriate Serial Port Baud Rate. This setting must be the same baud rate setting selected on the IRI. If an IRI is used, a Local Port Test can be performed to verify that all connections and settings are setup correctly. Press the Local Port test button and enter the appropriate Modbus Address. For single machine installations where the PC serial port is connected directly to the IRIs COM3 port, use a Modbus address 16

15.0 MACHINE MODEM INITIALIZATION FOR IntelliGuard

When a machine is to be remotely monitored using the IntelliGuard Service, the Machine (if necessary), and Site Hardware Kits must be installed at the customer site. In each Site Kit a standard US Robotics Modem is included for remote connection to the customers machine. This modem must be initialized to be able to call the ICU and to identify the customer site. This initialization must be performed before the modem can be installed at the customers site. Each US Robotics modem has an 8 position DIP switch located on the back. Verify that each switch is set to the proper position called out below. 1 2 3 4 On On On On (Down) (Down) (Down) (Down) 5 6 7 8 OFF (Up) OFF (Up) OFF (Up) ON (Down)

When the IntelliGuard Service is being implemented, the customers Site Phone Number and the ICU Phone Number must be entered into the modem. If IntelliGuard is not being used, these entries should be left blank. The Site Phone Number is the number that must be dialed to connect to the machine modem when it is installed at the customer site. Try to enter this number just as it would appear in Intelliservs Customer Directory. Dialing codes to get an outside line is not necessary for this entry. The ICU Phone Number is the number that must be called from the machines location to connect to the IntelliGuard ICU. This entry must include any numbers necessary to reach an outside phone line from the customers site and the complete phone number necessary to reach the IntelliGuard ICU. The Modem Initialization entry will contain a default initialization string that should not be changed except in extreme cases when the default string is not sufficient. The default initialization string should contain the following characters and are defined as follows: atv0e0s19=5s10=10&b1&n6&d0&w0 at v0 e0 s19=5 = = = = = = = = = Required command prefix Numeric result codes Echo off Modem inactivity timer in minutes Hang up after loss of carrier in x seconds Fixed serial port rate Connect at 9600bps only DTR override Writes current config to NVRAM

To perform the modem initialization, the modem must be connected to a PCs serial port for programming. To

begin press the Machine Modem Initialization button and follow the instructions. Select the Proper Serial Port Baud Rate. When using the IRI this rate should be set to 19200 but can be adjusted as desired. When using the Modbus function

s10=10 &b1 &n6 &d0 &w0

built into the SG controller this must be set to 9600. Select the PCs serial port the modem is now connected to for programming.

Once all above entries have been made, press OK and follow the remaining initialization instructions. Pressing Done at anytime through the loop will exit without making any changes to the modem setup. Once the initialization has been successfully performed, the modem power will be cycled and the initialization string will be read back from the modem. Click into the Modem Response window. Under Template YO, verify the response from the modem contains the settings entered in the initialization string above. Some of these settings may not be found, however the ones listed should be shown set correctly.

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16.0 CREATING REPORTS

Reports can easily be generated using Intelliservs displayed information by pressing the Create Report button from any of the following screens. View Current Status View Setpoints / Options View Alarm History Datalogging View Datalog File Pressing the Create Report button opens a text box that allows the user to enter up to 20 lines of text at up to 120 characters per line. This can be used to enter any additional information that may need to be added to a report. This information is printed on the report under the Comments section. The text box and report layout can be seen below:

The report heading information consisting of the Company Name, Address, City/ State, Point of Contact, Phone Number and Miscellaneous can all be changed to suit the desire of the user. This information is entered in the Intelliserv Setup screen under Report Header and is used each time a report is printed. Printing of the report is accomplished by pressing the Print button after all text has been entered. The Windows Default printer is used as the print device. Other printers can be selected in the Intelliserv Setup screen. See Section 14.0 Intelliserv Setup for further details on changing the printers.

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17.0 USING INTELLISERV SCREENS IN OTHER APPLICATIONS

Creating reports using Intelliserv collected data can be accomplished in several different ways. The recomended way is to use the Create Reports button on each screen. When this is not sufficient, other ways of printing the data are made available. (1) For creating reports, use the Create Reports button on any screen. See Section 16.0 Creating Reports. (2) Any Intelliserv screen, currently being viewed, can be copied to the Windows Clipboard by pressing the Print Screen button or holding the Alt key and pressing Print Screen button on the keyboard. Pressing the Print Screen button copies the screen as viewed to the Clipboard. Pressing Alt and Print Screen copies only the active window to the clipboard. The clipboard contents can then be pasted into any other Windows application such as Microsoft Word or Excel. To paste the contents into another application, run the desired application then click Edit from the menu bar and select Paste. (3) Any previously saved datalog file may be viewed using Microsoft Excel. To open a datalog file in Excel, click File on Excels menu bar and select Open. To locate the desired file, change the file type box to All Files and maneuver in the directory to where the datalog file is located. Highlight the desired file then click Open. The Excel Text Import Wizard will recognize the datalog file format (Tab delimited) and will begin to reformat the data for Excel. Using the default values, click Next to step through the reformatting process. Once the data is reformatted, Excel will display the data in a Column and Row format. Each column represents each particular pressure or temperature reading while each row represents a new scan of the data.

18.0 PRINTING TO A FILE WHEN A PRINTER IS NOT AVAILABLE

When using Intelliserv away from the office environment it may be desireable to create reports using the real-time data when a printer may not be immediately available. In such situations it is possible to print the displayed data or report to a file then print the file when a printer is available. Windows makes this possible by setting up a printer that actually sends the information to a file as if it were a printer connected locally. This file can then be sent to a printer when available. Perform the following setup procedure to create a printer file to be used. The printer to be used must already be installed for local printing. (1) From the Windows 95 Front Panel, click START, SETTINGS, and PRINTERS to open the Printers window.

(2) Select the printer to eventually be used to print the reports. Click File, and Properties. The Printers properties window should now be opened.

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(1) Using any text editor (such as Notepad), create a file called Printer.bat and add the following line copy %1 lpt<x>/b where x is the correct LPT port number (such as LPT1). (2) Save this file in the Windows folder. (3) Start Windows Explorer, and click Options on the View menu. (4) On the File Types tab, click New Type. (5) In the Description Of Type box, type Printer. (6) In the Associated Extension box, type PRN or PS as appropriate for your printer driver. (7) Click New. (8) In the Action box, type print. (9) In the Application Used To Perform Action box, type: c:\windows\printer.bat 3) Click the Details tab to show the printers connection details as seen above. For future use you may want to record the entry currently shown in the Print to the Following port: box. Click the Down Arrow to the right of the Print to the Following port: box and change this entry to File: (Creates a file on disk). Press OK to accept these changes and close the Printer Properties window. Close the Printers window to return to the Win 95 Front Panel. (4) When using Intelliserv or any other application, select this printer and all data will be saved to disk available for future printing. (10) Click OK. (11) Click Set Default. (12) Using Windows Explorer, locate the Printer.bat file in the Windows folder. Use the right mouse button to highlight the file, then click Properties on the menu that appears. (13) Click the Program tab, then click the Close On Exit check box to select it. Click OK. (14) Using the right mouse button, drag the Printer.bat file to the desktop, then click Create Shortcut Printing of previously saved files should now be accomplished by any of the following methods. Drag a file onto a printer icon. Drag a file onto the Print.bat shortcut on the desktop. This describes how to print files containing raw printer data (.prn or .ps files) in Windows. These files are created by printing from a program to a file using a PCL or PostScript printer driver. To enable Drag and Drop Printing for prn or ps files, follow these steps: Use the right mouse button to click a file, and then click Print on the menu that appears. Double-click the file. NOTE: For the correct output, you must create the file using the same printer type as the printer you plan to use to print the file. In other words, you must send a file created with a PCL printer driver to a PCL printer; a file created with a PostScript printer driver must be sent to a PostScript printer.

18.1 PRINTING FROM A PREVIOUSLY SAVED PRINT FILE

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19.0 INTELLISERV TROUBLESHOOTING

19.1 Intelliservs Communication Path The Intellisys Controller communicates with the IRI at a fixed Baud Rate of 9600-baud using the IngersollRand Protocol. The IR protocol is not made available to the outside world. This is where the IRI comes in. The IRI provides a bridge between the fixed baud rate, IR protocol and the outside world. To the outside world a variable baud rate and Modbus protocol are made available from the IRI. When programming the remote modem, the baud rate setting of the modem must match the IRIs baud rate setting. Both COM 1 and COM 3 have their own IRI baud rate settings. COM 1 is set using the IRIs b1 setting while COM 3 is set using b3.

The IRI provides two Ports for outside communication: Com 1 is the most commonly used port. Its connection is RS-485 and uses the Modbus protocol. It provides addressability which is required when more than one compressor/IRI will be connected to the same bus / modem. Each IRI must have a unique address to communicate on the bus. This port must be used when Intelliguard is being implemented. Com 3 is the Service Port and can only be used when locally connecting to an IR Service provider PC. Its connection is RS-232 and uses the Modbus protocol. It has a Fixed Modbus Address of F0. When using an Intellisys Controller with built in Modbus Protocol, there will be no IRI and the communication band rate will be fixed at 9600.

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Intelliservs No Comm Failure

When communication with the Intellisys controller cannot be established or when reliable communication has been broken, the Comm OK indicator on the Intelliserv screen will change to No Comm and the CRC Failure counter will begin to increment. This can happen during normal communication, but should not happen very often. Normal phone connections, especially across long distances, can be noisy. For a data connection noise can sometimes be passed along as data. When this happens the Intelliserv program counts these bogus data transmissions as noise and does not treat them as it would good data. Each time the bogus data is received, Intelliserv indicates this to the user by displaying the No Comm indicator and counting the comm failures that have occurred. If the No Comm indicator is lit and continues to stay in that mode, this indicates a failure to communicate with the Intellisys Controller. The mode of failure can be tracked down by following the path of the communication until a breakdown is found.

Using the Intelliserv software, attempt to connect to the remote modem by entering all information into the Compressor Connection screen and pressing the Remote Connect button. The modem should be heard dialing the appropriate phone number and attempting to connect to the remote modem. When a connection with the remote modem is made, Intelliserv will respond with Connect XXXX where XXXX is the connection baud rate. The remote modems CD light will be turned on. At the customer site follow the communication path to find where the communication is breaking down.

INTELLISERV COMMUNICATION PATH Action Intelliserv sends request If Remote Modem RD flashing If Telebytes TD flashing If IRIs LED#1 flashing If SG top left corner is flashing Intellisys Responds to request If IRIs LED#2 flashing brightly If Telebytes RD flashing If remote modems SD flashes Reaction Remote Modem RD light flashes Telebytes TD light flashes IRIs LED#1 flashes (Green) Intellisys Controller (SG) flashes top left corner of display. Intellisys Controller receives communication. IRIs LED#2 flashes (Green)* Telebytes RD light flashes Remote Modems SD flashes Intelliserv receives the request.

*The IRIs LED #2 normally flashes dimly about once per second. This is normal communication between the IRI and the Intellisys. When Intelliserv communication is taking place, this LED should flash brighter and more often than the normal, once per second dim flash.

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20.0 REMOVING THE INTELLISERV SOFTWARE

The Intelliserv software is easily removed by first deleting the security hardware key driver then simply deleting the Intlserv directory. Perform the following steps to completely remove the software. (1) With the Intelliserv software not running, select START from the Windows Task Bar, then RUN. (2) In the Run window select BROWSE and go to the directory on the hard drive in which Intelliserv is currently installed. Select the Setup.exe file from the Intlserv folder. If you have two Intlserv folders, choose the folder containing the Intelliserv.exe file, not that which contains the dcom95.exe. Click Open. (3) The command line should now display the path to the SETUP.exe file. At the end of this path add /U. Be sure there is a space between the .exe and the forward slash. C:\intlserv\Setup.exe /U (4) Click OK. The setup program should now remove the hardware key driver.

(5) The complete Intlserv directory can now be deleted from the hard drive using Windows Explorer. This will delete all files located in the Intlserv directory. Any customer director or data log files located in this directory that should not be deleted must be backed up before continuing. (6) From the windows taskbar Select START then WINDOWS EXPLORER. (7) Select the currently installed Intlserv directory. On Exploring tool bar select FILE then DELETE. Selecting YES will completely remove the Intlserv directory and any files that it contains. (8) Select the directory that contains the original Intelliserv install files and delete the following: Setup.exe Data.001 Data.002 Data.003 Data.004 Data.005 Data.006

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21.0 HARDWARE KEY KIT - PARTS LIST

Supplied: Part Number 39260641 APDD 716B Quantity 1 1 Description Hardware Security Key Remote Monitoring Software for IntelliGuard Installation Manual IntelliGuard Service Technician Manual Intelliserv Software Registration Card

APDD 778 APDD 726

1 1

Additional Hardware Required Machine Hardware Kit: Part Number: 42457622 This kit contains the hardware neccessary to connect one Intellisys controlled compressor to the converter and modem contained in the Site Hardware Kit. If more than one compressor is located at a customers site, additional machine kits are required for each compressor. When using an Intellisys Controller with built in modbus protocol, the machine hardware kit is not required. Site Hardware Kit: Part Number: 42457614 This kit, along with at least one of the Machine Hardware Kits, contains the hardware necessary for being able to remotely access information from one or more machines at one particular customers location. All machines must be located such that communications wiring can be installed between each machine and the converter / modem supplied in this kit.

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