Ingersoll-Rand Intellisys System Controller Operators / Instruction Manual, Parts List
INTELLISYS SYSTEM
CONTROLLER
OPERATORS/
INSTRUCTION MANUAL
PARTS LIST
Before installation or starting the Intellisys System Controller
for the first time, this manual should be studied carefully to
obtain a clear knowledge of the unit and or the duties to be
performed while operating and maintaining the unit.
RETAIN THIS MANUAL WITH UNIT. This Technical manual contains IMPORTANT SAFETY DATA and should be kept with the
Intellisys System Controller at all times.
FORM: APDD 565B
April 2002
More Than Air . Answers.
Online answers: http://www.air.irco.com
PHONE: 1-800-526-3615
CCN#: 80440290
AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in
material and workmanship for a period of twelve months (see extended airend warranty) from the date of placing
the Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from
Davidson, NC, whichev er shall first occur. The Purchaser shall be obligated to promptly report any failure to conf orm
to this warranty, in wr iting to the Company in said period, whereupon the Company shall, at its option, correct such
nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B.point of shipment, provided the Purchaser has stored, installed, maintained, and operated such Equipment in accordance with good industry practices and has complied with specific recommendations of the Company.Accessories or equipment furnished
by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to
the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs,
replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser or others without
Company’s prior written approval.
The effects of corrosion, erosion, and normal wear and tear are specifically excluded.Performance warranties are
limited to those specifically stated within the Company’s proposal. Unless responsibility for meeting such performance warranties are limited to specified tests, the Company’s obligation shall be to correct in the manner and for
the period of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based
on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such
Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company
in writing of its intention to do so. Any such use of Equipment will be at Purchaser’s sole r isk and liability.
Limitation of Liability
The remedies of the Purchaser set forth herein are exclusive, and the total liability of the Company with respect to
this contract or the Equipment and services furnished hereunder, in connection with the performance or breach
thereof, or from the manufacture, sale, delivery, installation, repair or technical direction covered by or furnished
under this contract, whether passed on contract, warranty negligence, indemnity, strict liability or otherwise, shall not
exceed the purchase price of the unit of Equipment upon which such liability is based.
The Company and its suppliers shall in no event be liable to the Purchaser, any successors in interest or any beneficiary or assignee of this contract for any consequential, incidental, indirect, special or punitive damages arising
out of this contract or any breach thereof, or any defect in, or failure of, or malfunction of the Equipment hereunder,
whether based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other
goods, loss by reason of shutdown or non-operation, increased expenses of operation, cost of purchase of replacement power or claims of Purchaser or customers of Purchaser for service interruption whether or not such loss or
damage is based on contract, warranty, negligence, indemnity, strict liability or otherwise.
©INGERSOLL-RAND COMPANY
This unit was purchased from
______________________________________________________
______________________________________________________
______________________________________________________
Ingersoll-Rand Company reserves the right to make changes or add
improvements without notice and without incurring any obligation to
make such changes or add such improvements to products sold
previously.
Customer Order No:______________________________________
Ingersoll-Rand Co.Order No:_______________________________
For ready reference:
Record the serial number and model number of your unit here.
Serial Number:__________________________________________
Model Number:__________________________________________
NGERSOLrAND
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INGERSOLL-RAND®
0.0 SAFETY AND WARNINGS
1.0 INTRODUCTION
1.1 application
1.2 features
2.0 RECEIPT OF EQUIPMENT
3.0 INSTALLATION
3.1 ISC mounting
3.2 pressure transducer mounting/piping
3.3 pressure transducer wiring
3.4 ISC power wiring
3.5 ISC communication wiring
3.6 power on confirmation
3.7 pressure transducer calibration
4.0 OPERATION
4.1 operator panel layout
4.1.1 sequencer start button
4.1.2 sequencer stop button
4.1.3 sequencer status button
4.1.4 compressor status/right
arrow button
4.1.5 set button
4.1.6 up and down arrow buttons
4.1.7 “power”led
4.1.8 “sequencer”led
4.1.9 compressor unit status led’s
4.1.10 “alarm”led
4.2 setting up the ISC
4.2.1 initialization
4.2.2 pressure set up and control
4.2.3 sequence set up
4.2.4 compressor control
4.2.5 sequence rotation modes
4.3 starting and stopping
4.4 ISC status
4.5 compressor status
4.6 alarms
5.0 TROUBLE SHOOTING CHART
6.0 REFERENCE DRAWINGS
6.1 ISC set point map
6.2 “compressor control” set points
6.3 “initial set up”set points
6.4 “pressure settings”set points
6.5 “pressure control” set points
6.6 “sequence set up”set points
6.7 “sequence rotation mode” set points
6.8 installing modular plug connector
6.9 modular plug connections
6.10 electrical schematic
6.11 general arrangement
6.12 typical ISC installation
6.13 typical air system
7.0 PARTS LIST
8.0 MAINTENANCE RECORDS
TABLE OF CONTENTS
2
0.0 SAFETY AND WARNINGS
Before you install this Intellisys System Controller (ISC)
you should take the time to carefully read all the instructions contained in this manual, and the compressor manual.
Electricity and compressed air have the potential to
cause severe personal injury or property damage.
The operator should use common sense and good working practices while operating and maintaining this unit.
All applicable codes should be strictly adhered to.
Maintenance should be done by qualified personnel,
adequately equipped with proper tools.
3
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1.0 INTRODUCTION
One Intellisys System Controller (ISC) can sequence
both rotary and reciprocating compressors.To do this, it
must have software EPROM version 1.1 or higher.
1.1 APPLICATION The ISC will operate any size SSR rotary, Sierra oilfree rotary or Intellisys equipped reciprocating compressor.Recip units can be two, three or five step loading, whether inlet valve or clearance pocket controlled.
Intellisys controlled compressors connect directly to the
ISC and communicate through twisted pair cable.Rotary
non-Intellisys controlled compressors require an
Ingersoll-Rand supplied interface device to be installed
between the compressor and the ISC.An Intellisys
Retrofit Kit is available to upgrade Ingersoll-Rand recip
PHE, LLE or XLE compressors which are not presently
equipped with Intellisys.
1.2 FEATURES The ISC is capable of controlling the loading and unloading of multiple air compressors for the purpose of keeping a compressed air system’s pressure at or near a user set value.It is a microprocessor based, self-contained unit that is mounted and powered independently from any compressor.
The ISC has a variety of simple, user adjustable modes
of operation that enable it to be customized for specific
compressed air system conditions. In response to system air pressure variations, as measured by the ISC’s
own sensor, it adds or subtracts air compressors in an
order selected by the user.
There are many conveniences provided by the ISC that
simplify both its set up and use.The following list outlines
its many installation and operational features.
1.The ISC can manage from 2 to 8 air compressors.
2. Compressors can be either Intellisys or preIntellisys
(rotary) models.
3. System air pressure control is based on a single pressure point, not multiple pressure bands.
4. System air pressure settings can be user programmed
to change, based on preset time of day and day of week.
5. Load and unload delay times can be independently set
to account for air system characteristics.
6.The ISC can be located remotely from the air compressors.
7. Connection to compressors is by telephone-type wire
and connectors.
8.There can be up to 8 user programmable compressor
sequences.
9. Rotation from one sequence to another can be user
programmed based on running time, time of day and day
of week, or manually.
10.The ISC will not start more than one compressor at a
time.
11. Smooth rotation of sequences will avoid disruptions
to system air pressure.
12. ISC operating parameters can be changed without
stopping the system.
13.The ISC will automatically resume operation following
a power outage.
4
2.0 RECEIPT OF EQUIPMENT
When you receive the Intellisys System Controller (ISC)
please inspect it closely. Any indication of careless handling by the carrier should be noted on the delivery receipt
especially if the ISC will not be immediately unboxed.
Obtaining the delivery man’s signed agreement to any
noted damages will facilitate any future insurance claims.
IMPORTANT
READ THIS
LOST OR DAMAGED GOODS
THOROUGHLY INSPECT THIS SHIPMENT
IMMEDIATELY UPON ARRIVAL
OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNED BILL OF LADING
If goods are received short or in damaged condition, it is important that you
notify the carrier and I nsist 0 n a notation of the loss or damage across the
face of the freight bill. Otherwise no claim can be enforced against the transportation company.
If concealed loss or damage is discovered, notify your carrier at once and
request an inspection This is absolutely necessary. Unless you do this the
carrier will not entertain any claim for loss or damage.The agent will make
an inspection and grant a concealed damage notation. If you give the transportation company a clearreceipt for goods that have been damaged or lost
in transit, you do so at your own risk and expense.
WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE. BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR
COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL. THE
ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR RESPONSIBILITY.
Ingersoll-Rand Company
Davidson, North Carolina
APODGFO-99-79
5
3.0 INSTALLATION
Before beginning Intellisys System Controller (ISC)
installation and system operation, the following requirements and recommendations must be satisfied.
1. Each Intellisys compressor must have its controller
software revision at or above a certain minimum level to
work with the ISC.The machine types and the required
software EPROM minimum version levels are listed
below. Check each machine to be controlled by the ISC
for appropriate EPROM’s. If the EPROM is not of the
correct minimum version level, an appropr iate EPROM
may be ordered from your local Ingersoll-Rand
Distributor or Air Center.
Machine EPROM Min.
Type Version Level
U-Series (10-40 Horsepower) 9.3
15-50 Horsepower SE 1.1
SSR 50-450 Horsepower 1.9
SSR 50-450 Horsepower 2.0
Extended Memory
Sierra 100-200 Horsepower 2.0
Recip 1.5
2.The Automatic Start/Stop feature is required to be
installed on each compressor to receive the full energy
saving benefits of the ISC.Compressors without the
Auto Start/Stop function will continue to run after the ISC
tells them to unload. Compressors with Auto Start/Stop
could stop themselves after their stop-time criteria are
met.
3.The mounting location of the ISC’s pressure transducer is very important. The ISC will load and unload compressors based on the air pressure it measures at the
transducer’s location.Because the transducer will typically be mounted in a receiver tank or large common air
header, it will likely be reading pressures lower than the
compressor discharge pressures.The transducer location and the user-set TARGET PRESSURE must allow
for these pressure differences. Be sure to follow the
instructions for setting the TARGET PRESSURE as
detailed in Section 4.2.2 PRESSURE SET UP AND
CONTROL.
Perfor m the following tasks to install the ISC system.
Each is described in numbered steps that can be
checked off to help ensure a trouble-free installation.
ISC Mounting
Pressure Transducer Mounting/Piping
Pressure Transducer Wiring
ISC Power Wiring
ISC Communication Wiring
Power On Confirmation
Pressure Transducer Calibration
3.1 ISC MOUNTING
1.The ISC can be easily installed on any suitable surface in the general vicinity of the air compressors.Refer
to the typical air system drawing (Figure 6.12) for
requirements.
2. Mount the ISC and associated wir ing conduits using
general arrangement drawing (Figure 6.10) for mounting
dimensions.
3.2 PRESSURE TRANSDUCER MOUNTING/PIPING
1. Choose one of two typical locations for the transducer.
It can be installed in a receiver tank or in a common discharge air header, as long as either one serves all the
sequenced compressors. See Figure 3.2-2 for Choice A,
the tank; and Choice B, the header.The tank is the recommended location as long as it is close to the compressors.
2. In either location, mount the transducer with a dripleg
and isolation valve to allow for calibration and repairs.
Mount as shown in Figure 3.2-1, and refer to the general
arrangement drawing (Figure 6.10) for mounting dimensions.
3. If the transducer is to be mounted in the air header,
Choice B, connect it to the TOP of the header to prevent
moisture accumulation in the transducer. If the header
runs at floor level, mount the transducer to the wall
above the header and connect it to the top of the header
using pipe or tubing.This will prevent moisture accumulation and damage to the transducer.
NOTE: If there are dryers or filters installed in the system between the compressors and the ISC pressure
transducer, the ISC’s user-set TARGET PRESSURE
must be adjusted to compensate for the pressure drop
caused by these devices.Proper adjustment must be
done to prevent overloading the compressor main drive
motors.This procedure is described in Section 4.2.2
PRESSURE SET UP and CONTROL.
FIGURE 3.2-1 PRESSURE TRANSDUCER
INSTALLATION
6
TO RECEIVER TANK
OR AIR HEADER
DRIP LEG
3.3 PRESSURE TRANSDUCER WIRING
Before beginning any work on the ISC, open, lock
and tag the electrical disconnect for the ISC.
1.The transducer cable assembly included in the ISC kit
comes with a preattached transducer connector.Route
the free end of the cable from the transducer to the ISC,
preferably in its own grounded conduit.
2. Connect the cable to the terminal str ip inside the ISC
using the electrical schematic in Figure 6.9 as a reference. Be careful to match color codes and terminal
numbers.
3.4 ISC POWER WIRING
Before beginning any work on the ISC, open, lock
and tag the electrical disconnect for the ISC.
1.The ISC will operate on either a 115 or 230 volts AC,
single phase, 50 or 60 Hz power source.Position the
voltage selection slide on switch SW1, located inside the
ISC at the top left surface of the controller when viewed
from the back, so the number showing on the switch
matches the chosen power source voltage level.
2. Attach the ISC to the power source through an isolation circuit breaker, and protect all wires in conduit.The
ISC draws less than 2 amps.Refer to the electrical
schematic in Figure 6.9.
3. Confir m that all electrical connections are made properly and tightened.
TRAP
FIGURE 3.2-2 ROTARY TWO COMPRESSOR SYSTEM
WITH PRESSURE TRANSDUCERS IN RECEIVER OR HEADER
7
STRAINER
SAFETY
VALVE
PRESSURE
GAUGE
RECEIVER
ISOLATION
VALVE
PRESSURE
DRAIN
TRANSDUCER
A
DRIP
LEG
DRIP
LEG
ISOLATION
VALVE
DRIP
B
PRESSURE
TRANSDUCER
LEG
ISOLATION
VALVE
DRIP
LEG
INGERSOLL-RAND
INGERSOLL-RAND
!
WARNING
Hazardous voltage. Can cause
severe injury or death.
Disconnect power before servicing.
Lockout/Tagout machine.
INGERSOLLrAND ®
3.5 ISC COMMUNICATION WIRING
1.The ISC is connected to each compressor using the
telephone type wire supplied in the ISC kit. Cut appropr iate lengths for each compressor and route the wires in
grounded electrical conduit.These wires should be the
only wires in the conduit(s).
2. Install one modular plug (supplied in the kit, along with
a special tool) on each end of each wire, one end in the
compressor and one in the ISC enclosure. Refer to
Figure 6.7 and 6.8 for instructions on the tool, and for
proper wire color codes and pin numbers. Be careful to
match color codes and pin numbers.
3. Plug the compressor end of each wire into the communication port on the compressor’s Intellisys panel or
Intellisys circuit board, whichever is appropriate.
4. Plug the ISC end of each wire into the communication
port on top of the ISC controller that corresponds to the
channel number you choose for each compressor.
Compressors must be connected to ports in consecutive
order, starting with port number 1. For example, if there
are five compressors, they must be plugged into ports 1
through 5, with no unused ports between the first and
the last.
5.Write the compressor model number and capacity,
corresponding to each chosen channel/compressor number, into Figure 6.2 at the back of this manual.
3.6 POWER ON CONFIRMATION
1. After all physical installation and wiring is complete,
apply power to the ISC and confirm the “Power” LED is
on.
If problems are encountered with any part of the ISC
operation, refer to the Trouble Shooting Chart,
Section 5.0.
2.The display will read “INITIALIZING”while the ISC
automatically goes through its internal initialization logic
which checks the pressure transducer and retrieves
compressor status information.
3. Confir m the display reads “READY TO START” following the initializing operation.
4. If necessar y, adjust the display contrast using the
adjustment screw located at the top left surface of the
controller when viewed from the back.
3.7 PRESSURE TRANSDUCER CALIBRATION
This should always be done after first installing the ISC,
or after servicing the ISC or pressure transducer.
1.Vent the transducer to atmospheric pressure by closing the isolation valve and opening the dripleg valve.
2.With the ISC stopped and the display showing
“READY TO STAR T”, press the Up and Down Arrow
keys simultaneously to start the ISC’s autocalibrate routine.The display will show the message “CALIBRATING”
while calibration is taking place.When calibration is successful, the display will return to “READY TO START”.If
calibration is unsuccessful, the display will show “CALI-
BRATION FAIL”. If this occurs, refer to Trouble Shooting
Chart, Section 5.0.
3. Retur n the transducer to system air pressure .
The ISC is now ready for entering the Set Points that
configure it for specific air system requirements.Proceed
to Section 4.2 “Setting Up The ISC”, and follow the
instructions there.
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4.0 OPERATION
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FIGURE 4.0-1 INTELLISYS SYSTEM CONTROLLER PANEL
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4.0 OPERATION
Air system performance can be enhanced by carefully
setting up the Intellisys System Controller (ISC).This
includes selecting operating parameters that customize
the ISC for the specific air system to which it is attached.
This section of the manual first describes the front panel
controls of the ISC, then gives detailed instructions of
how to use these controls to set up and/or adjust the
operating parameters.This is followed with instructions
for Starting and Stopping the ISC, plus how to view ISC
or compressor status information, and finally a description of Alarm conditions.
4.1 OPERATOR PANEL LAYOUT
The ISC panel contains seven buttons, twenty LED (light
emitting diode) lamps and a sixteen character alphanumeric display. The buttons are used for operator input,
the LED’s indicate continuous status infor mation, and the
display provides additional status information during the
setting of Set Points (See Figure 4.0-1).
The following sections outline the functions of each button and the meaning of each LED.The display messages and their use are described in Section 4.2,
“Setting Up The ISC,” where detailed instructions are
provided for each ISC function.
The phrase “Set Point Routine”, used throughout this
manual, refers to the procedures used for observing or
changing the user-selectable variables in the ISC logic.
Figure 6.1 provides a graphical “map”of the Set Points
and how to get to each one.
4.1.1 SEQUENCER START BUTTON
Pressing this button will start the sequencing operation if
pressed while the display shows “READY TO STAR T ”.
The ISC will resume operation in the rotation mode
(Timed, Event or Manual) that was active when the
SEQUENCER STOP button was pressed. However, if
the Set Point routine was used to change to a different
rotation mode while the ISC was stopped, then operation
in that new rotation mode will be started when the button
is pressed.
Pressing this button while in the Sequencer Status or
Compressor Status display modes will return the display
to “READY TO STAR T”if the ISC is not sequencing, but
will display the System Pressure if it is sequencing.
4.1.2 SEQUENCER STOP BUTTON
Pressing this button will stop the sequencing operation if
it is running, as indicated by the “Sequencing” LED being
on. It also retur ns all compressors to their local control.
NOTE: At this time, each compressor might start, stop,
load, or unload itself depending on its own local conditions and set points.
Pressing this button while the ISC is stopped will do a
display test by lighting all the LED’s. This will also cause
the version number of the ISC’s software to be dis-
played.
4.1.3 SEQUENCER STATUS BUTTON
Repeatedly pressing this button will step the display
through the ISC status messages. See Section 4.4 for
details of the messages.
Pressing this button when in the Set Point routine will
exit the routine.
4.1.4 COMPRESSOR STATUS/RIGHT ARROW BUTTON
Repeatedly pressing this button when not in the Set
Point routine will step the display through the individual
compressor status messages. See Section 4.5 for details
of the messages.
When in the Set Point routine, this button is used as a
Right Arrow to step through the five groups of Set Points,
and to move the display cursor to the right. See Section
4.2 for details of these functions.
SEQUENCER
START
SEQUENCER
STOP
SEQUENCER
STATUS
COMPRESSOR
STATUS
10
UNLOADED
STOP
START
SET
SET
4.1.5 SET BUTTON
This button has numerous functions in the Set Point routine. It is used to enter the routine, to step through portions of the routine and to “lock in” new set point values.
See appropriate portions of Section 4.2 for details of its
use.
A failure of the ISC’s pressure sensor is one reason for
the “Alarm” LED to light up. Pressing the SET button
when the sensor failure has been corrected will clear the
alarm and turn off the LED. See Section 4.6 for details
concerning all the alarm conditions that could cause the
“Alarm” LED to be on, and when it will go off.
4.1.6 UP AND DOWN ARROW BUTTONS
These are used when in the Set Point routine for changing Set Point values.They are also used in the Rotation
Set Up portion to select among modes.
Pressing both buttons simultaneously will calibrate the
pressure transducer when the display shows “READY T O
START”. See Section 3.7 for details on when and how to
calibrate.
4.1.7 “POWER” LED
This LED lights to indicate there is power applied to the
ISC and that its power supply is working.
4.1.8 “SEQUENCING”LED
This LED lights to indicate the ISC SEQUENCER START
button has been pressed and the ISC is sequencing
compressors.
4.1.9 COMPRESSOR UNIT STATUS LED’s
There is a pair of status LED’s, “ Sequence” and
“Loaded”, for each compressor under the control of the
ISC. Each “Sequence” LED lights to indicate that compressor is in Sequence mode through the communication channel to the ISC. Each “Loaded” LED lights to
indicate that compressor is running loaded.
4.1.10 “ALARM”LED
An alarm status from any of the compressors, a communication failure detected by the ISC or a system pressure
transducer failure detected by the ISC will turn on this
LED. See Section 4.6 for details of each alarm condition
and how each is cleared.
4.2 SETTING UP THE ISC
Setting up, or programming, the ISC is done by entering
chosen values for the ISC operating parameters, which
are called set points. Figure 6.1 is a map of all the ISC
set points and provides a quick reference of how to step
the display to each one.Figures 6.2 through 6.7 list the
set points, show the value limits for each one, and provide space for recording the values chosen for specific
air system requirements.
Before entering any set points, the following set up
instruction sections should be read and used for deciding the exact set point values needed.While reading
these sections and deciding on values, record them in
the ISC Set Up Log, Figures 6.2 through 6.7 (or a copy
of it).Then, using the entries in the log as a guide, execute the steps listed below to enter each set point.
The following guidelines apply when viewing or changing
set point values.
1. Press the SET button to enter the set point routine
while the ISC is operating normally.
2. Press the Right Arrow (COMPRESSOR STATUS) button to step between set point groups, and press the SET
button to step between set points within each group.This
is described in detail in the following sections and is outlined by Figure 6.1.
3. Press Up or Down Arrow buttons to change set point
values.
4. Press the Right Arrow button to select characters within set points, where appropriate.The selected character
will be indicated by an underline cursor in the display.
SET
11
SET
POWER
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