Ingersoll-Rand Intellisys System Controller Operators / Instruction Manual, Parts List
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Ingersoll-Rand Intellisys System Controller Operators / Instruction Manual, Parts List

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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 con-
tains IMPORTANT SAFETY DATA and should be kept with the
Intellisys System Controller at all times.
More Than Air. Answers.
Online answers: http://www.air.irco.com
PHONE: 1-800-526-3615
CCN#: 80440290
INTELLISYS SYSTEM
CONTROLLER
OPERATORS/
INSTRUCTION MANUAL
PARTS LIST
FORM: APDD 565B
April 2002

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Summary of Contents for Ingersoll-Rand Intellisys System Controller

  • Page 1 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.
  • Page 2 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...
  • Page 3 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 0.0 SAFETY AND WARNINGS 5.0 TROUBLE SHOOTING CHART 6.0 REFERENCE DRAWINGS 1.0 INTRODUCTION 6.1 ISC set point map 1.1 application 6.2 “compressor control” set points 1.2 features 6.3 “initial set up” set points 6.4 “pressure settings” set points 2.0 RECEIPT OF EQUIPMENT 6.5 “pressure control”...

  • Page 5: Safety And Warnings

    The operator should use common sense and good work- Before you install this Intellisys System Controller (ISC) ing practices while operating and maintaining this unit. you should take the time to carefully read all the instruc- All applicable codes should be strictly adhered to.

  • Page 6: Introduction

    1. The ISC can manage from 2 to 8 air compressors. 1.0 INTRODUCTION 2. Compressors can be either Intellisys or preIntellisys One Intellisys System Controller (ISC) can sequence (rotary) models. both rotary and reciprocating compressors. To do this, it must have software EPROM version 1.1 or higher.

  • Page 7: Receipt Of Equipment

    2.0 RECEIPT OF EQUIPMENT When you receive the Intellisys System Controller (ISC) please inspect it closely. Any indication of careless han- dling by the carrier should be noted on the delivery receipt especially if the ISC will not be immediately unboxed.

  • Page 8: Installation

    3.0 INSTALLATION 3.1 ISC MOUNTING Before beginning Intellisys System Controller (ISC) 1. The ISC can be easily installed on any suitable sur- installation and system operation, the following require- face in the general vicinity of the air compressors. Refer ments and recommendations must be satisfied.

  • Page 9: Pressure Transducer Wiring

    SAFETY VALVE PRESSURE PRESSURE TRANSDUCER GAUGE ISOLATION VALVE INGERSOLL-RAND DRIP RECEIVER DRIP TRAP ISOLATION VALVE INGERSOLL-RAND DRAIN PRESSURE TRANSDUCER ISOLATION VALVE DRIP STRAINER DRIP FIGURE 3.2-2 ROTARY TWO COMPRESSOR SYSTEM WITH PRESSURE TRANSDUCERS IN RECEIVER OR HEADER 3.3 PRESSURE TRANSDUCER WIRING 1.

  • Page 10: Isc Communication Wiring

    3.5 ISC COMMUNICATION WIRING 3.7 PRESSURE TRANSDUCER CALIBRATION 1. The ISC is connected to each compressor using the This should always be done after first installing the ISC, telephone type wire supplied in the ISC kit. Cut appropri- or after servicing the ISC or pressure transducer. ate lengths for each compressor and route the wires in grounded electrical conduit.
  • Page 11 • • SEQUENCE SEQUENCE UNIT 7 UNIT 3 SEQUENCER COMPRESSOR • • LOADED LOADED STATUS STATUS • • SEQUENCE SEQUENCE UNIT 8 UNIT 4 • LOADED • LOADED SEQUENCING SEQUENCING SEQUENCING SEQUENCING START STOP FIGURE 4.0-1 INTELLISYS SYSTEM CONTROLLER PANEL...

  • Page 12: Operation

    4.0 OPERATION 4.1.2 SEQUENCER STOP BUTTON Air system performance can be enhanced by carefully setting up the Intellisys System Controller (ISC). This UNLOADED SEQUENCER includes selecting operating parameters that customize STOP STOP the ISC for the specific air system to which it is attached.

  • Page 13: Set Button

    4.1.5 SET BUTTON 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 com- pressor is in Sequence mode through the communica- tion channel to the ISC.

  • Page 14: Initialization

    4.2 SETTING UP THE ISC (Continued) Step Action 5. Press the SET button to lock in any changed value and to move to the next set point within a set point Press the SET button once, observe the group. If a value has been changed, the display will flash currently selected language.

  • Page 15: Pressure Set Up And Control

    4.2.2 PRESSURE SET UP AND CONTROL 2. Each Setting is enabled by specifying its Target Pressure, Day of the Week and Time of Day, or it is dis- The ISC controls the loading and unloading of air com- abled by specifying it as “UNUSED” in place of selecting pressors for the purpose of maintaining a steady system a Target Pressure.
  • Page 16 PRESSURE CONTROL Step Action The ISC will maintain the Target Pressure by loading While not in any Set Point routine, press the compressors when the pressure is below the “lower SET button once and observe pressure limit”, which is defined as the Target Pressure “PRESSURE SET UP”...

  • Page 17: Sequence Set Up

    If the system pressure should ever rise above the “maxi- mum pressure limit”, which is defined as 5 PSI above the Step Action “upper pressure limit”, the ISC will tell all compressors to unload at once. If the pressure then drops to the “upper pressure limit”...
  • Page 18 SEQUENCE SET UP RULES: Step Action 1. Compressors are numbered 1 through 8 with no gaps in the numbering. For example, if there are five compressors, While not in any Set Point routine, press they must be connected to communication channels 1 the SET button once and observe through 5.

  • Page 19: Compressor Control

    4.2.4 COMPRESSOR CONTROL automatically by the ISC or manually by the operator. Automatic rotation occurs when the ISC is put in either Each compressor can be set to Local or Sequence con- TIMED Mode or EVENT Mode. Manual rotation occurs trol through the ISC.
  • Page 20 EVENT ROTATION MODE Step Action In the EVENT rotation mode, the ISC rotates from the While not in any Set Point routine, press currently running sequence to the sequence specified to the SET button once and observe be active at the moment an Event matches the present “PRESSURE SET UP”...
  • Page 21 6. In case two or more Events have the same Day of the Week and Time of Day entries, the lower numbered Event Step Action will have priority. Press SET once, observe something like 7. When Event Mode is selected to be active, the “1 A MON 6:45”.
  • Page 22 MANUAL ROTATION MODE In the MANUAL Rotation Mode, the ISC rotates from what- ever sequence is currently running, regardless of the cur- rent rotation mode, directly to the sequence designated M that is set up in the Manual mode Set Point. This occurs immediately upon exiting the Set Point routine after select- ing MANUAL Mode.

  • Page 23: Starting And Stopping

    The following list outlines was in when stopped. what to do for each of five types of Ingersoll-Rand Intellisys compressors to enable them to give control to NOTE: When the ISC is stopped, each compressor the ISC.

  • Page 24: Compressor Status

    4.5 COMPRESSOR STATUS 4.6 ALARMS As described in Section 4.1.9 there is a pair of front The “Alarm” LED on the ISC’s front panel will light for panel status LED’s “Sequence” and “Loaded”, for each any one of the following three reasons. compressor under the control of the ISC.

  • Page 25: Trouble Shooting Chart

    5.0 ISC TROUBLE SHOOTING CHART TROUBLE CAUSE AND/OR DISPLAY WHAT TO DO ISC POWER light is off. No message in display, no lights on. 1. Check fuse and wiring connections. 2. Check power source disconnect box. Bad system air pressure readings. “SENSOR FAILURE”...

  • Page 26: Reference Drawings

    6.0 REFERENCE DRAWINGS 6.1 ISC SET POINT MAP...

  • Page 27: Pressure Settings" Set Points

    6.4 “PRESSURE SETTINGS” SET POINTS 6.5 “PRESSURE CONTROL” SET POINTS...

  • Page 28: Sequence Rotation Mode" Set Points

    FIGURE 6.6 “SEQUENCE SET UP ” SET POINTS FIGURE 6.7 “SEQUENCE ROTATION MODE” SET POINTS...

  • Page 29: Installing Modular Plug Connector

    The following are instructions to attach 6 position modu- 5. Insert modular plug connector - TAB UP - into die set. lar plugs to communication cable. LOCKING TAB MUST SNAP INTO CAVITY. 1. Trim cable end flush. 6. Squeeze tool handles together until movable anvil is completely bottomed.

  • Page 30: Electrical Schematic

    FIGURE 6.10 ELECTRICAL SCHEMATIC...

  • Page 31: General Arrangement

    FIGURE 6.11 GENERAL ARRANGEMENT...
  • Page 32 LOADED • STATUS STATUS STATUS STATUS • LOADED LOADED SEQUENCE SEQUENCE • • SEQUENCE SEQUENCE UNIT 8 UNIT 4 LOADED LOADED • • LOADED LOADED SEQUENCING SEQUENCING SEQUENCING SEQUENCING START START STOP STOP NOTICE INGERSOLL-RAND® INCOMING INTELLISYS SYSTEM CONTROLLER POWER...

  • Page 33: Typical Air System

    FIGURE 6.13 TYPICAL AIR SYSTEM...

  • Page 34: Parts List

    7.0 PARTS LIST...
  • Page 35 39839253 REV 03...
  • Page 36 39841838 REV 02...
  • Page 37 PRESSURE TRANSDUCER ASSEMBLY ITEM PART NUMBER QTY. DESCRIPTION 39841630 ENCLOSURE 39566500 TRANSDUCER,PRESSURE 39153861 BUSHING 50677459 BULKHEAD ASSY. (3 PARTS) 39131859 O-RING 42368530 CABLE ASSEMBLY 39173935 LOCKNUT 39173927 GLAND...
  • Page 38 ISC KIT (PART NO. 42367813) PART NUMBER OTY. DESCRIPTION 39839253 ISC ASSEMBLY 39841838 ISC PRESSURE TRANSDUCER ASSEMBLY (225 PSI) 39204508 CABLE, COMMUNICATION (1000 FEET) 39204466 PLUG, MODULAR 39204458 TOOL, HAND CRIMPING APDD 565B ISC OPERATORS MANUAL...
  • Page 39 8.0 MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...

  • Page 40: Maintenance Records

    MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...

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