ingersoll rand intellisys operation manual
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ingersoll rand intellisys operation manualThe warning The alarm can be reset by When in the set point routine, depressing An alarm reset is obtained by depressing this When the compressor is running, the. The CPU Assembly is an Ingersoll-Rand design. This board is not intended for general service and never requires field trou- bleshooting. The communications port is for communication with other Ingersoll-Rand Products. One is a pressure sensor. The other is a temperature sensor. The temperature sensor is a thermistor located in the discharge air circuit. It comes complete with a 6 foot lead that directly connects it to the Starter Interface Board. Each time the load button is depressed the compressor will switch to another mode of operation. The set button also serves the functions of clearing an alarm. Pressing the set button twice will clear the alarm. This can be done by disconnecting the wires to the coil and applying 115 volts to the coil from a near by wall outlet. Before proceeding be sure to remove the 115 volts applied to the starter coil for safety. This is a warning indication of rising temperature. A compressor that is experiencing a higher air temperature condition may have the following symptoms. This is the shutdown pressure. The controller can be set for 100-125-150 or 175 psig. The controller will shut down if the discharge pressure exceeds 15 psig over any of the preset discharge pressures programmed into the controller by the factory. While investigating, remember to open the electrical disconnect and lock and tag. The next step is to press the display-select button twice and check the value of the shutdown temperature. Also disassemble the male cable and insure that all wires are intact as was done for fault number -04-. Check for continuity on each wire of the cable after disconnecting it from the interface board. The way the watchdog functions is that on each cycle of the program, it signals the watchdog that it is functioning OK. The watchdog starts a timer.http://www.perfekt-dom.pl/designhome/admin/userfiles/hunter-33288-manual.xml
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If before the timer times out, the program has not come back and signaled the watchdog, the watchdog shuts the unit down as a microprocessor failure. Check the main incoming and power leads to insure that they are correct. In earlier versions the controller will try to read a positive 10 psig sump pressure in the first 3 seconds of operation. We have learned that this connector may not be making a good contact with the male pins on the interface boards. You can connector to insure good contact hear the latch click when it is all the with the mating pin. way in. 8. Before performing this function, disconnect all electrical power, lock and tag. Run the compressor and if it continues to run, then this is an indication that the transducer cable is defective and should be repaired or replaced. If the timer continues to operate for as long as its adjusted time setting, a relay contact in the Intellisys opens to de-energize the compressor motor starter coil. At the same time, an amber light on the Intellisys panel is lit to indicate the compressor has shut down automatically and will restart automatically. If the remote start switch is momentarily closed, the Intellisys controller starts the compressor. SYMPTOMS: 1. The Intellysis controller does not power up, even though power is present at the primary and secondary contacts of the transformer and interface board or intermittent contact will give various error codes. It may be necessary to repair or replace the exisiting cable. This can result in various error codes displayed on the Intellisys. We have learned that the Rev. After checking the pressure transducer calibration, and its cable for shorts, the following procedure will tell you if the circuit through the interface board is defective. 1. SSR 10-40 HORSEPOWER NUISANCE -01- SHUTDOWN PROBLEM Presently, the starter auxiliary contact is used by the controller to determine starter operation.http://2014.muces.es/admin/fck/hunter-34357-manual.xml Units affected are: SSR 10 - 40 Horsepower SSR 50 - 200 Horsepower Visual inspection of the thermistor (sensor) cable will reveal that the shielded cable is loose within the body of the thermistor caused by the potting material (epoxy) that does not bond to the cable. The display window will show 0. Power and unload indicator lights will be on. Push “Unloaded Stop” for lamp check. All lights will be on and “8888” will be displayed in the window until the “Unloaded Stop” button is released. After the lamp test has been completed, the unit will display 0. If this “lead” compressor can maintain the required plant air pressure, all other compressors should be set to shut down. If multiple alarms have occurred the display will show SCROLL FOR ALARMS instead of the alarm messages. In this situation the up and down arrows will be used to view the alarm messages. STARTER DOOR OPEN This alarm will occur if the start door is opened.Other starter interface connections: Terminal 24 volt supply 3-36 15 volt supply BTS1 31-32 Manual Hats 29-30 Jumper (OPT phase monitor) 33-34 Emergency Stop Button 14-15 1M Interlock 12-13 1S and 2M Interlock BTS2. After these 10 seconds pass, the alarm becomes active.) The alarm shutdown point is 15 PSI. Check BTS - 1 Terminals 23 - 28 Trace wiring to main coils. If partial transition, troubleshoot auxiliary contacts. Use great care during the checking procedures to prevent serious injuries or death. Power OFF Checks Remove the inlet air filter and the mounting bracket. Manually move the inlet air valve with your fingers. There are two sets of Stepper Motor windings. Wires 6 and 7 are a pair and 5-6 OHMs should be measured between these two wires on 50-200 horsepower units. If voltage is not available at this point, a faulty Starter Interface Board is indicated and must be replaced. Check for 5 Volts DC between terminals 2 and 3 on BTS-3 terminal strip of the Starter Interface Board when the inlet valve is closed.http://www.bosport.be/newsletter/bose-lifestyle-25-user-manual These two sets of words will flash back and forth about every 3 seconds. Also, a small white light over the “Set” button and a red “Test” light will appear. Remove the back cover from the defective controller. (Be careful not to break the ground strip that is connected to the back cover.) Disconnect the two ribbon cables inside the controller. Remove the controller mounting screws and remove the controller out the front of the starter door. The controller pressure will display in the window, plus a red up and down arrow will appear under the set button. Sever any tie wraps that may be attached to tube. Remove and discard the four metric socket head bolts that mount inlet valve. Attached are the instructions which outline the procedure for using the “show” prom. Be careful not to bend the contacts. This prom will be reinstalled after the show. 6. Carefully install the “Show Prom” in socket location U2. 7. All three sensors connect to their respective areas of the Analog Board in a similar manner. The 5 volt DC source for the sensors is supplied by a small but extremely accurate voltage regulator mounted on the upper left side of the Analog Board. This problem will cause an Alarm shutdown on the Airend Discharge Tempera- ture sensor 2ATT only. STEPPER MOTOR DRIVER CHIPS 50-450 Horsepower The Electronics group has identified some susceptible driver chip components. Most of the units were either replaced or retested by the vendor. There is a chance that some units with this date code will exhibit problems. Remove the stepper motor assembly from the inlet valve body. The stepper limit switch and male half of the coupling will come off along with the stepper motor, and motor mounting plate. Remove the male coupling from the stepper motor shaft. Disconnect the leads going to the board or motor. Replace the old component for the new one on the stepper mounting plate. Replace with a new limit board if any physical damage is seen.http://irukene.com/images/canon-40d-service-manual-free.pdf Always replace both halves of the coupling if either side shows appreciable wear. If vacuum is present, this assures the airend is turning in the correct direction. Check for 5VDC on the transducer cable red and black wires at the analog board. This CFSM sheet is issued for information purposes only and field conversions are not warrantable. CONTROL VOLTAGE TRANSFORMER CONNECTIONS (ALL UNITS) When changing a unit from a lower operating voltage to a higher operating voltage (Example: 230V to 460V) the control voltage transformer must be. Program the controller to look at inlet filter condition (i.e., psi vacuum) during operation. Ingersoll-Rand recommends using the kit everytime Intellisys components (EPROMS, option proms, interface boards, etc.) are handled. The ESD kit is now available through Ingersoll-Rand Air Compressor Parts. -95-. Mail Purchase Order with Order Form to: Steve Mullen Ingersoll-Rand Co. ACG Multi-Media 220 North Hamilton Street Painted Post, NY 14870 -97-. Form APDD422C. Day Cab, E7 460hp. Owatonna, Mustang 332, 342. World's leading marketplace. Download Love At The show shortcuts and save 146 pages. Ingersoll Rand Intellisys Manual from cloud storage. SIGN UP FREE LOGIN. Ingersoll Rand Intellisys Controlled And. He is an excellent and save yourself time skilled mechanic, and a. Ingersoll Rand Intellisys Manual from instagram. Ltd. Find best value and selection for your INGERSOLL RAND INTELLISYS SSR EPE25U AIR COMPRESSOR search on eBay. 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Reload to refresh your session. Our employees connect to customers for life by delivering proven expertise, productivity and efficiency improvements. Visit arozone.com We stand behind our products and services and beside our customers during planning, installation, and maintenance. Our advanced engineering and manufacturing have a standard of excellence often copied, but never matched. When it comes to assembly tools, industrial tools, cordless tools and vehicle service tools, don't settle for less. Count on genuine Ingersoll Rand tools, accessories, and equipment. REAL WORK deserves the best, because the best is what your real life demands. For products and services specific to your area, please choose your country or region below. Select your desired site language below. Our advanced engineering and manufacturing have a standard of excellence often copied, but never matched. Count on genuine Ingersoll Rand tools, accessories and equipment. Ensure that the Operation and Maintenance manual is not removed permanently from the machine. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals. Next Warranty. The Company warrants that the equipment manufactured by it. Page 3: 1.0 CONTENTS 1.0 contentsMachine models represented in this manual may be Details of approved equipment are available from IngersollThe use of the machine in any of the situation types listed in table 1:?When using compressed air always use appropriate The above information contains data supplied in supportCondensate disposal Coolant disposal. Depending on point of manufacture and point of use, the compressor and this manual will show symbols. Page 12 5.0 SAFETYImproper coolant filter replacement will causeReplace filter element after first 150. Page 14 5.0 SAFETYConsult the Operation WARNING. For operating. Page 17 5.0 SAFETY. Use fork lift truck from this side only. Emergency stop. Tie down pointAny indication of careless. Page 21: 7.0 INSTALLATION 7.0 INSTALLATION. For technical information see section 8.0.Water piping to and from the compressor. Page 26 7.0 INSTALLATION. Water quality recommendations Cooling Water Analysis Chart. Water quality recommendations Water quality is often Substances Test interval. Page 27 7.0 INSTALLATIONStrainers are No oil cooler. Page 28 7.0 INSTALLATIONInstalling a Nirvana compressor outside. Page 29: 8.0 GENERAL INFORMATION 8.0 GENERAL INFORMATIONSound pressure level. Page 34 8.0 GENERAL INFORMATIONKEY H INTELLISYS Controller. A 2” NPT Air discharge (Female). Page 39 8.0 GENERAL INFORMATIONA 4”. Page 44 8.0 GENERAL INFORMATIONEnsure that all protective. Page 68 9.0 OPERATING INSTRUCTIONS. Start sequence Blowdown mode. The compressor will initially start by the operator pressing the All 2. Page 69 9.0 OPERATING INSTRUCTIONSPressing this switch stops the compressor immediately. The. Page 70 9.0 OPERATING INSTRUCTIONSAutomatic stop pressure Condensate Release. The compressor will stop once the system pressure rises to this. Page 75 9.0 OPERATING INSTRUCTIONSScheduled start Scheduled stop. This option will cause the unit to start on the scheduled start. Page 77 9.0 OPERATING INSTRUCTIONSPage 81: 10.0 MAINTENANCE 10.0 MAINTENANCENote. On some sea watercooled models the oil cooler and aftercooler are fitted with sacrificial zinc anodes. Page 84 10.0 MAINTENANCE. Compressed air can be dangerous if incorrectly handled. Prior to attempting any maintenance work on a. Before. Page 85 10.0 MAINTENANCEBlower motor Re?Grease Run the compressor for about 10 minutes by ventingFollowing are instructions for tilting the cooler away from Instructions for cleaning the coolers while. Page 90 10.0 MAINTENANCE. Shut off the cooling water. Page 92 10.0 MAINTENANCE. Page 93: 11.0 FAULT FINDING 11.0 FAULT FINDINGWhen attempting to identify and remedy any fault or failure, ensure it. Page 94 11.0 FAULT FINDINGThe drive controller is directly linked to the. Page Count: 93 Accessories or equipment furnished by the Company, but manuf actured by others, shall carry whatever w arranty the manuf acturers hav e conv e yed to the Company and which can be passed on to the Purchaser. The Company shall not be liable f or an y repairs, replacements, or adjustments to the Equipment or an y costs of labor performed by the Purchaser or others without Compan y’ s prior written approval. The effects of corrosion, erosion and normal wear and tear are specifically e xcluded. Perf ormance warranties are limited to those specifically stated within the Company’ s proposal. Unless responsibility for meeting such perf ormance warranties are limited to specified tests, the Company’ s obligation shall be to correct in the manner and for the period of time provided abov e. THE COMP ANY MAKES NO OTHER W ARRANTY OR REPRESENT A TION OF ANY KIND WHA TSOEVER, EXPRESSED OR IMPLIED, EXCEPT THA T OF TITLE, AND ALL IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P ARTICULAR PURPOSE, ARE HEREBY DISCLAIMED. Correction by the Company of nonconf ormities whether patent or latent, in the manner and for the period of time provided abov e, shall constitute fulfillment of all liabilities of the Compan y for such nonconf ormities whether based on contract, warranty negligence, indemnity, str ict liability or otherwise with respect to or arising out of such Equipment. The purchaser shall not operate Equipment which is considered to be def ective, without first notifying the Company in writing of its intention to do so. Any such Equipment will be at Purchaser’ s sole risk and liability. Note that this is Ingersoll-Rand’ s standard warranty.Electricity and compressed air have the potential to cause severe per sonal injury or property damage. Before installing, wiring, star ting, operating or making any adjustments, identify the components of the air compressor using this manual as a guide. The operator should use common sense and good working practices while operating and maintaining this unit. Follow all codes, pipe adequatel y, understand the starting and stopping sequence. Check the safety de vices by f ollowing the pr ocedure contained in this manual. Maintenance should be done by qualified per sonnel, adequately equipped with pr oper tools. Follow the maintenance schedules as outlined in the operators manual to ensure pr oblem free operation after start up. Safety instructions in the operators man ual are bold-faced for emphasis. The signal words D ANGER, W ARNING and CA UTION are used to indicate hazar d seriousness levels as follo ws: Danger is used to indicate the presence of a hazard which will cause se vere personal injury, death, or substantial property damage if the warning is ignored. W arning is used to indicate the presence of a hazard which can cause se vere personal injury, death, or substantial property damage if the warning is ignored. Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored. Notice is used to notify people of installation, operation, or maintenance information which is important but not hazard-related.Bef ore working on the electrical system, be sure to remove v oltage fr om the system by use of a manual- disconnect-switch. A circuit breaker or fuse safety switc h must be pr ovided in the electrical supply line leading to the compressor. Those responsible for installation of this equipment must pr ovide suitab le grounds, maintenance clearance and lightning arrestors f or all electrical components as stipulated in O.S.H.A. 1910.308 through 1910.329. 3. Do not operate the compressor at higher discharge pressure than those specified on the Compressor Nameplate or motor overload will occur. This condition will result in compressor motor shutdown. 4. Use only safety solvent f or c leaning the compressor and auxiliary equipment. 5. Install a manual shut off valve (isolation type) in the discharge line. When a safety valve is installed between the isolation valve and the compressor, it m ust have sufficient capacity to relieve the full capacity of the compressor(s). 6. Whenever pressure is released through the pressure relief valve, it is due to excessive pressure in the system. The cause for the e xcessive pressure should be in vestigated immediately. 7. Before doing an y mechanical w ork on the compressor: a.) Shut the unit down. b.) Electrically isolate the compressor b y use of the manual disconnect switc h in the power line to the unit. Lock and tag the switch so that it cannot be operated. c.) V ent pressure from the compressor and isolate the unit from an y other source of air. 8. There can be ad verse effects if compressor lubricants are allowed to enter plant air systems. Air line separators, properly selected and installed, will minimiz e any liquid carry- over. The use of plastic bowls on line filters without metal guards can be hazar dous. From a safety standpoint, metal bowls should be used on any pressurized system. Review of your plant air line system is recommended. 9. When a receiver is installed, it is recommended that occupational safety and health standards as co vered in the Federal Register, V olume 36, number 105, part 11, paragraph 1910.169 be adhered to in the installation and maintenance of this receiver. 10. Before starting the compressor, its maintenance instructions should be thoroughl y read and understood. 11. After maintenance functions are completed, covers and guar ds m ust be replaced. 0.2 SAFETY PRECA UTIONS SAFETY PRECA UTIONS BEFORE PROCEEDING, READ CAREFULL Y BEFORE INST ALLING THE COMPRESSOR OR PERFORMING ANY MAINTENANCE All air and water inlet, and air and w ater discharge pipew ork to and from the inlet and discharge por t connections must take into account vibration, pulsations, temper ature, maxim um pressure applied, corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some oil into the air stream; theref ore, compatibility between discharge piping, system accessories and software must be assured. F or the f oregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is not recommended. It is the responsibility of the installer and owner to pro vide the appropriate ser vice pipework to and from the machine. W ARNING CHECK HIGH AIR TEMPERA TURE There is a high discharge air temperature shutdown function b uilt into the Intellisys on each compressor. This function should be checked at regular intervals f or proper operation, once a month is recommended. The procedure is: 1. Block off the cooling air discharge. 2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge temperature reaches the pre-set maximum discharge air temper ature setting of the Intellisys. The display should indicate “HIGH AIREND DISCH TEMP” and flash “ALARM”. The actual temperature at which shutdown occurs should be recorded f or compar ison to the Intellisys set point and with similar future test results. SAFETY SHUTDO WN “Ingersoll-Rand air compressors are not designed, intended, or approv ed f or breathing air. Ingersoll-Rand does not approve specialized equipment f or breathing air application and assumes no responsibility or liability f or compressors used f or breathing air ser vices. ” If f or some reason a decal is def aced, painted ov er, or par ts are replaced, we recommend that you obtain a replacement kit as listed in the spare par ts section of the P ar ts List Manual F orm APDD 735 f or single stage and F orm APDD 736 for two stage units. W ARNING ! Hazardous v oltage. Can cause severe injury or death. Disconnect power bef ore servicing. W ARNING ! Hot surface. Can cause severe injury. Do not touch. Allow to cool before servicing. W ARNING ! High pressure air. Can cause severe injury or death. CA UTION Improper maintenance of coolant filter can cause compressor damage. Change coolant filter after first 150 hours of operation and ev ery 2000 hours thereafter or when coolant is changed. W ARNING ! Moving parts. Can cause severe injury. Do not operate with cov ers removed. Service only with machine blocked to prev ent turn over. Filler Cap. Use only recommended coolant. Use of incorrect coolant can cause system contamination.Hot surface. Can cause severe injury. Do not touch. Allow to cool before servicing. W ater out. W ater in. Lift Here Condensate drain. Air Dischar ge Electrical power inlet. D ANGER ! Discharge air. Can contain carbon monoxide or other contaminants. Will cause severe injury or death. Do not breathe this air. Service only with machine blocked to prev ent turn over. CA UTION ! Incorrect lifting of machine can cause injury or property damage. Exposed fan blade. Can cause se vere injury. Disconnect power. Lock and tag. 39540190 Rev. 04 39857552 Rev. 04 Motors must be greased periodically. See Operators Manual for procedure. Do not operate without enclosure panels and forklift cov ers in place. Enclosure panels will affect perf ormance. NO TICE Compressor Package Data COMPRESSOR MODEL. CAP ACITY. RA TED OPERA TING PRESSURE. MAX. DISCHARGE PRESSURE. MAX. MODULA TE PRESSURE. NOMINAL DRIVE MOTOR.Hazardous v oltage. Can cause severe injury or death. Only use factory supplied inlet for incoming power. Electrical power inlet.