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Ingersoll-Rand 125-200 User Manual

Ingersoll-Rand 125-200
93 pages
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Before installation or starting the compressor for the
first time, this manual should be studied carefully to
obtain a clear knowledge of the unit and of 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 air compressor at
all times.
125-200 HP/90-160 KW
SINGLE STAGE
AND
100-200 HP/75-160 KW
TWO STAGE UNITS
OPERATORS/
INSTRUCTION MANUAL
OPTIONS
FORM: APDD 738B
November 2002
More Than Air. Answers.
Online answers: http://www.air.irco.com
Phone: 1-800-526-3615
CCN: 80440415 REV: B

Table of Contents

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Ingersoll-Rand 125-200 Specifications

General IconGeneral
BrandIngersoll-Rand
Model125-200
CategoryAir Compressor
LanguageEnglish

Summary

Safety and Warnings

Safety Instructions

General instructions for safe installation and operation of the compressor.

Safety Precautions

Detailed safety guidelines before installation or maintenance.

Operational Safety and Warnings

Safety Shutdown

Information on high air temperature shutdown function and procedure.

Warning Information

Cautionary notes on piping, lubricants, and air quality.

Decals and Labeling

Hazard Warning Decals

Visual warnings for hazards like voltage, hot surfaces, and high pressure.

Installation Procedures

Ventilation and Environment

Guidelines for adequate ventilation and environmental considerations.

Foundation Requirements

Information on compressor placement on a level floor.

Installation Details

Ventilation Specifics

Specifics on heat dissipation, clearances, and environmental factors.

Electrical Installation

Electrical Installation Details

Intellisys Controls

Motor Rotation Check

Checking compressor and fan motor rotation with Intellisys.

Intellisys Operating Instructions

Guidance on operating the Intellisys controller.

Intellisys Controller

Control Panel Overview

Description of the Intellisys controller interface and buttons.

Intellisys Controls and Functions

Emergency Stop and Power On

Operation of the Emergency Stop button and Power On indicator.

Operator Panel Buttons

Functions of START, STOP, UNLOAD, LOAD, and arrow buttons.

Display Button Functions

Functionality of display screen buttons for navigation.

Intellisys Display Screen

Display Screen Layout

Description of the display screen's functional areas and navigation.

Current Status Screen

Normal display showing package discharge pressure and status.

Intellisys Navigation

Menu Navigation Flowchart

Diagram illustrating navigation between Intellisys menus and functions.

Intellisys Menus and Setpoints

Main Menu Access

Accessing operator functions from the Main Menu.

Operator Setpoints Overview

User-adjustable variables in controller logic.

Operator Setpoints and Options

Setpoint Descriptions

Detailed explanation of operator setpoints like Lead/Lag, Pressure, Mode.

Option Screen Configuration

Setting on/off values for options like Auto Restart, Sequencer.

Configurable Options

Option Descriptions

Details on Auto Restart, Sequencer, Low Ambient, and other options.

Sensor Calibration and Alarms

Sensor Calibration Procedure

Steps for calibrating pressure sensors when the machine is stopped.

Alarm History Display

Viewing recent alarms and associated operating conditions.

Sequencing and Warnings

Integral Sequencing Setup

Configuring compressors for automatic lead/lag operation.

Warning Messages

Explanation of various warning messages and their causes.

Detailed Warning Information

Communication and Service Warnings

Warnings for communication failures and service requirements.

Alarms and Status

Alarm Occurrence and Reset

How alarms are indicated and the procedure to reset them.

Alarm Status Display

Viewing machine operating conditions at the time of an alarm.

Troubleshooting Alarms

Common Alarm Messages

List and explanation of potential alarm messages and their causes.

Preventative Maintenance Schedule

Maintenance Interval Schedule

Table outlining maintenance actions and intervals based on hours or time.

Filter Maintenance

Coolant Filter Service

Checking and replacing the coolant filter based on Intellisys prompts.

Coolant Management

Separator Tank Maintenance

Separator Element Replacement

Separator Element Replacement

Steps for replacing the separator element and tank cover.

Cooler Core Cleaning

Motor Lubrication and Maintenance

Relubrication Intervals and Amounts

Schedule and quantity of grease for motor relubrication.

Motor Lubrication Procedures

Motor Lubrication Steps

Detailed steps for applying grease to motor bearings, including safety.

System Monitoring and Sampling

Compressor Systems Overview

Compressor System Components

Electrical and Control Systems

Capacity Control Modes

Description of MOD/ACS, On-Off Line, and Modulation Only control modes.

Capacity Control and Auto Start/Stop

Modulation/ACS Control

Continuous monitoring and selection of control modes for efficiency.

Automatic Start/Stop Operation

How the compressor automatically starts and stops based on air demand.

Automatic Control Features

Automatic Start/Stop Timers

Explanation of Timer A and Timer B for automatic start/stop control.

Remote Start/Stop Operation

Troubleshooting Guide

Compressor Fails to Start

Troubleshooting steps for compressor startup failures.

Compressor Shuts Down

Causes and solutions for compressor shutdown issues.

Troubleshooting Common Issues

Optional Features

Advanced Optional Features

Flow Schematics (Aircooled)

Flow Schematics (Watercooled Single Stage)

Flow Schematics (Watercooled Single Stage High Temp)

Flow Schematics (Aircooled Two Stage)

Flow Schematics (Watercooled Two Stage)

Flow Schematics (Watercooled Two Stage High Temp)

Water Quality Recommendations

Water Quality Analysis

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