Ingersoll-Rand 125-200 HP/90-160 KW, 100-200 HP/75-160 KW Remote LOAD/UNLOAD, Modbus

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7.9 REMOTE LOAD/UNLOAD

The remote load/unload option gives the operator the ability to control the loading and unloading of the compressor. This option is enabled when two switches are wired to the Intellisys to perform this function. The firstswitch is the master/local input (P3, 25 & 26) and the second switch is the load/unload input (P3, 27 & 28). If the master/local switch is closed, the Intellisys will read the load/unload switch for loading and unloading the compressor. If the load/unload switch is closed, the Intellisys will load the compressor.

If the load/unload switch is open, the Intellisys will unload the compressor. If the master/local switch is open, the Intellisys will ignore the load/unload switch and operate the compressor normally.

7.10 MODBUS

The Modbus option uses the Modbus protocol and modbus address set points in the OPTIONS menu. This is used by the Ingersoll-Rand service organization.

7.11 INTEGRAL SEQUENCING

Integral sequencing allows one compressor, the lead, to sequence up to 3 other compressors. The compressors are daisy chained together using port P8 on the Intellisys. Each compressor has a unique address and the lead compressor will sequence the other units in numerical order based on that address.

The lead compressor will be the first to load and the last to unload. It is also the only compressor that can modulate. If the lead compressor’s mode of operation is Mod/ACS or Modulation Only, it will modulate when it is loaded. Once loaded, if pressure falls to its online set point, the lead compressor will transmit a load command to the next compressor in sequence. The lead compressor will then wait for a period of time for the line pressure to rise. This time period is determined by the load delay time set point. At the end of this time period, if line pressure is not rising, the lead compressor will transmit a load command to the next compressor in sequence. This will be repeated until the line pressure starts to rise.

When line pressure rises to the lead compressor’s offline set point, it will transmit an unload command to the last loaded compressor in the sequence. The lead compressor will do this every 10 seconds until the line pressure starts to fall.

After a certain amount of time or at a certain time, the lead compressor can change the sequence by transferring the lead to the next compressor in the sequence. If the set point, Lead Change - Hours, is set to a value greater than 0, the unit will operate as the lead compressor for that number of hours before transferring the lead. If Lead Change - Hours is set to 0, the set points Lead Change - Day and Lead Change - Time will be used to determine when the lead will be transferred. The Lead Change - Day set point will contain the day of the week the lead will be transferred. The time of the day will be contained in the Lead Change - Time set point. The lead will be transferred when the real time clock matches these 2 set points.

To connect the compressors for integral sequencing put the 4 position connector into port P8. One connector, I-R part number 39186101, will be needed for each compressor. The total length of cable for an integral sequencing system is not to exceed 1000 feet. For the cable, use I-R part number 39204508 or equivalent. This is a 4 wire, twisted pair cable. Use one pair for pins 1 and 2 and the other pair for pins 3 and 4. The connection on port P8 is a one to one connection. The wire on pin 1 on the first compressor will connect to pin 1 on the second compressor and so on. This is true for all 4 wires.

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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 MotorOutdoor Sheltered Installation 1 Typical Outdoor Sheltered Installation Intellisys Controller IntellisysStop Power on LightIntellisys Controls Emergency Stop StartDisplay Screen Current StatusCurrent Status Items Intellisys DiagramOperator Panel Flow FigureOperator Setpoints Main MenuOptions Items Range Step Unit OptionsOptions Alarm History Sensor CalibrationSensor 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 DrainProcedure CoolantSeparator 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 Cleaning AftercoolerAftercooler 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 ControlModulation only Automatic START/STOP ControlFirst Second Some Examples of OperationExample 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