Ingersoll-Rand 125-200 HP/90-160 KW Intellisys Controls Emergency Stop, Power on Light, Start

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3.0INTELLISYS

3.1INTELLISYS CONTROLS

EMERGENCY STOP

Pressing this switch stops the compressor immediately. The compressor can not be restarted until the switch is manually reset. Turn the switch knob clockwise to reset.

EMEG

STOP

POWER ON LIGHT

This indicates the control voltage and the line voltage are available for starting.

POWER

ON

The operator panel is divided into two areas. The bottom row of four buttons provides direct control over the starting, stopping, unloading and loading of the compressor. These are defined by the symbols printed on the buttons themselves, as shown here.

START

Pressing this button will start the compressor if the display shows “Ready To Start”. The compressor will start and load if there is sufficient demand for air.

STOP

Pressing this button will activate the unloaded stop sequence. If the compressor is running loaded, it will unload and continue to run unloaded for an adjustable 10 to 30 seconds and then stop. If the compressor is running unloaded, it will stop immediately.

UNLOAD

Pressing this button will cause the compressor to unload and remain unloaded. The display will indicate the machine is “Running Unloaded”, and “Mode: UNLOAD”.

LOAD

Pressing this button will cause the compressor to load if the compressor is running and if the “Discharge Pressure” is less than the “Online Pressure”. This also returns the machine to the operating mode that is specified by the “Mode of Operation” set point.

The other five buttons provide access to various operator-selectable functions and machine operating conditions. The purpose of each of these buttons is defined by the display screen and the particular function being performed at that time.

ARROWS

These up and down buttons have multiple functions relating to the right half of the display screen. When lists are presented, the buttons are used to move up or down through the items on the list. The small arrow(s) displayed in the upper right corner of the display screen indicate when you can move up (designated by arrow head pointing up) and/or down (designated by arrow head pointing down) through the list.

When the value of a specific machine operating parameter is highlighted on the display screen for the purpose of changing that value, the buttons are used to change the value itself.

DISPLAY BUTTONS

The functions of the three buttons below the display screen change and are defined by the words immediately above them in the bottom line of the screen. Each function, such as MAIN MENU, STATUS, SET, etc., is described in appropriate sections in this manual.

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Contents Form Apdd 738B Phone CCN 80440415 REV BAIR Compressor Group Bonded Warranty & Registered Start UP This unit was purchased from Rotary Screw AIR CompressorTable of Contents Safety and Warnings Safety Shutdown Decals Lift HereViewed From Rear DecalsCompressor Package Data Tools InspectionIngersoll-Rand Company Davidson, North Carolina Unpacking and HandlingPerformance will be affected VentilationFoundation Requirements Never elevate the compressor unitDischarge Piping with Aftercooler ROTARY-RECIP in Parallel Moisture Content of Compressed AIRPiping Do not use the compressor to support the discharge pipeRotary TWO Compressor System Electrical InstallationDrive Motor Rotation CheckIntellisys Operating Instructions Electrical InstallationHasp Lever TAG KEY Lock FAN Motor Outdoor Sheltered Installation 1 Typical Outdoor Sheltered Installation Intellisys Controller IntellisysStop Power on LightIntellisys Controls Emergency Stop StartCurrent Status Display ScreenCurrent Status Items Intellisys DiagramOperator Panel Flow FigureOperator Setpoints Main MenuOptions Items Range Step Unit OptionsOptions Sensor Calibration Alarm HistorySensor Calibration Items Clock Functions Alarm History ItemsIntegral Sequencing Range Step Unit Integral SequencingStatus Main Menu Reset Alarm Main Menu AlarmsPage Number of Running HOURS, Whichever Occurs First Maintenance ScheduleMaintenance Records Maintenance ProceduresElements Inlet AIR FilterCoolant Filter 200 HP/132-160 KW Requires 2 ElementsHot coolant can cause severe injury CoolantItems Required Coolant DrainCoolant ProcedureSeparator Tank Scavenge SCREEN/ORIFICE Tools Required 125/200 HP Coolant Separator ElementTank cover bolt torque values Recommended Bolt Tightening Cross PatternCoolant Coolers Cooler Cores CleaningAftercooler Aftercooler CleaningAftercooler Relubrication amount Lubricant Amount Motor Frame Size Grams Motor LubricationHazardous voltage. Can cause severe injury or death Motor Bearing Maintenance Stored UnitsMotor Lubrication Recommended Motor GreaseController Removal Long Term Storage GeneralIntellisys Removal ToolsRemoval InstallationCoolant Sampling Procedure Coolant HosesCooling FAN Motor AIR Cooled Compressors Design TemperaturesGeneral System Information Coolant CoolerElectrical System Compressed AIR System The air system is composedCOOLANT/AIR Separation System OperationAutomatic Unloaded Start STAR-DELTA Type StarterStepper Motor Inlet Control Capacity ControlAutomatic START/STOP Control Modulation onlyFirst Some Examples of Operation SecondExample Remote START/STOP Troubleshooting Chart Troubleshooting Chart Separator DELTA-P Solenoid Power Outage Restart OptionSequencer LOW AmbientModbus Remote LOAD/UNLOADReference Drawings Electrical Schematic Star DeltaPage Foundation Plan 125-150 HP/90-110KW Aircooled Single Stage Foundation Plan 125-150 HP/90-110 KW Aircooled Single Stage Foundation Plan 200 HP/132-160 KW Aircooled Single Stage Foundation Plan 200 HP/132-160 KW Aircooled Single Stage REV C REV C Foundation Plan 200 HP/132-160 KW Watercooled Single Stage Foundation Plan 200 HP/132-160 KW Watercooled Single Stage 100-150 HP/75-110 KW TWO Stage Foundation Plan AircooledFoundation Plan Aircooled 100-150 HP/75-110 KW TWO Stage Foundation Plan Aircooled 200 HP/132-160 KW TWO Stage Foundation Plan Aircooled 200 HP/132-160 KW TWO Stage Foundation Plan -WATERCOOLED Foundation Plan -WATERCOOLED 100-150 HP/75-110 KW TWO Stage Foundation Plan -WATERCOOLED 200 HP/132-160 KW TWO Stage Foundation Plan -WATERCOOLED 200 HP/132-160 KW TWO Stage Flow Schematic Aircooled Single Stage Page Flow Schematic Watercooled 90F 32C Single Stage Page Flow Schematic Watercooled 115F 46 Single Stage Page Flow Schematic AIR-COOLED TWO Stage Page Flow Schematic Watercooled 90F 32C TWO Stage Page Flow Schematic Watercooled 115F 46C TWO Stage Page Typical System Flow Diagrams Typical System Flow DiagramTypical System Flow Diagrams Typical System Flow Diagrams Typical System Flow Diagrams Typical System Flow Diagrams Parameter Concentration Frequency of Analysis ScaleCorrosion FoulingPage Alkalinity ppm Temperature FTotal dissolved solids ppm Hardness ppmMaintenance Record Maintenance Record Maintenance Record Maintenance Record