Ingersoll-Rand EP50-PE Power L.E.D, Automatic Restart L.E.D, On Line OFF Line Control, AIR Filter

OPERATING INSTRUCTIONS – INTELLISYS OPTION 31

27 POWER L.E.D.

This will illuminate when the 8V controller supply is available.

28 AUTOMATIC RESTART L.E.D.

This will illuminate when the machine has shutdown due to low air demand. The compressor will restart and load automatically as soon as the demand for air resumes.

DISPLAY MESSAGES

When the compressor is running normally, the display will indicate the package discharge pressure and illuminate the corresponding L.E.D. [1]. An arrow will also appear in the far right of the display indicating pressure band selection. Pressing display select [19] will change the display value and the corresponding L.E.D. will illuminate. The controller monitors all aspects of the compressor while running and will display warnings or in severe conditions execute an emergency stop and display alarm conditions.

MACHINE CONTROL MODES

CAPACITY CONTROL

The compressor is designed to work with two types of capacity control, to suit the individual plant requirements. These controls are:–

A.On line – Off line. (Fitted as standard)

B.On line – Off line, with Upper Range Modulation. (Optional extra) Either is available by selection at the control panel.

ON LINE – OFF LINE CONTROL

For applications that require a widely varying air demand, this mode of control will deliver air at full capacity or zero capacity with low receiver pressure.

This mode of operation is controlled by the pressure transducer responding to changes in plant air pressure. This sensor energizes the load solenoid valve which in turn operates the venting valve (blowdown) and the closing of the atmospheric vent opening in the air inlet valve.

The compressor then delivers full capacity air to the plant system. If the air pressure in this system rises to the upper set point of the pressure setting, the load solenoid valve is de–energized allowing the inlet valve to close. At the same time, the venting valve opens allowing the receiver pressure to drop.

The pressure setting has a range of 12 psi (0.83 bar) between its upper and lower set points.The upper set point is set at 3 psi (0.2 bar) above the compressor rated discharge pressure.

UPPER RANGE MODULATION CONTROL (Optional Extra)

For plants having a relatively high and constant air demand, Upper Range Modulation is the recommended mode of control.

Upper range modulation retains the features of On line – Off line control but provides the throttling of the inlet air flow as the line pressure rises to the upper set point of the off–linepressure setting.

By bleeding off a small amount from the regulator valve, which energises the Modulate Solenoid Valve, a reduction in the air signal to the pneumatic cylinder on the inlet valve allows the cylinder to ‘trim’ the inlet valve position as dictated by changing line pressure. Modulation begins when the compressor reaches about 94% of the rated line pressure and is factory set to modulate down to approximately 70% of rated capacity.

If the air demand decreases to a level below the 70% modulated output, the line pressure will increase slightly to the upper limit of the pressure setting, when the compressor then changes to the Off line control position and operates with the receiver vented.

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CONTROLLER WARNING MESSAGES

In the event of a warning, the controller will display a message and the alarm L.E.D. [10] will flash. The warning message will alternate with the normal display every 4 seconds, the compressor will continue to run but the fault should be rectified as soon as possible. The arrow keys

[23]should be used to index the display for any additional warning messages. A warning message may be reset by depressing set [21] once.

NOTE:

The warning will recur if the fault has not been rectified. The following warning messages may be displayed:

COOLANT FILTER (OPTIONAL)

The pressure differential across the coolant filter exceeds 15 psi (1 bar)

.

AIR FILTER

The air filter is dirty or blocked and should be replaced.

SEPARATOR ELEMENT

The separator element is dirty or blocked and should be replaced.

AIREND TEMPERATURE

The airend temperature reaches 97% of the high airend temperature set point (i.e. 223°F (106°C)).

CONTROLLER ALARMS

In the event of an alarm, the controller will execute an emergency stop, the alarm L.E.D. [10] will illuminate and an alarm message will be displayed. The arrow keys [23] should be used to index the display for any additional alarm messages. An alarm is reset by depressing set

[21]twice within a 3 second period after the fault has been rectified. The compressor will restart only when all alarm conditions have been rectified. The following alarm messages may be displayed (For fault correction see the Fault Finding section):

STARTER FAULT

The contactor sequence during start or stop is incorrect.

AIREND TEMPERATURE

The airend discharge temperature is above the high temperature set point.

MOTOR OVERLOAD

The motor overload contacts are open. The motor overload must be reset before the controller can be reset.

REVERSE ROTATION

No sump pressure is detected after the first 2 seconds of running. Isolate the machine and reverse the mains supply connections before resuming.

OVER PRESSURE

The line pressure is 15 psi (1 bar) greater than the rated discharge pressure.

TEMPERATURE SENSOR 1

The airend temperature sensor/ connecting cable has failed.

TEMPERATURE SENSOR 2

The separator tank temperature sensor/connecting cable has failed.

PRESSURE SENSOR

Indicates pressure transducer failure / connecting cable fault.

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