XFE/EPE/HPE 50 XF/EP/HP 60 XF/EP/HP/XP 75-100 ML/MM/MH 37-75 OPERATORS/ INSTRUCTION MANUAL OPTIONS 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. CCN : 80440332 REV. : D DATE : JUNE 2007 More Than Air. Answers. Online answers: http://www.air.irco.com Phone: 1-800-526-3615
Before installation or starting the compressor for thefirst time, this manual should be studied carefully toobtain a clear knowledge of the unit and of the dutiesto be performed while operating and maintaining theunit.
RETAIN THIS MANUAL WITH UNIT.This Technical manual contains IMPORTANT SAFETYDATA and should be kept with the air compressor at alltimes.
CCN : 80440332REV. : DDATE : JUNE 2007
More Than Air. Answers.Online answers: http://www.air.irco.comPhone: 1-800-526-3615
BONDED WARRANTY & REGISTERED START UPWarrantyThe 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 from the date of placing the Equipment in operation or eighteen monthsfrom the date of shipment from Davidson, NC, whichever shall first occur. The Purchaser shall be obligated to promptlyreport any failure to conform to this warranty, in writing 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. pointof shipment, provided the Purchaser has stored, installed maintained and operated such Equipment in accordance withgood industry practices and has complied with specific recommendations of the Company. Accessories or equipmentfurnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyedto 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 withoutCompany’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 warrantiesare limited to specified tests, the Company’s obligation shall be to correct in the manner and for the period of timeprovided 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 MERCHANTABILITYAND 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 timeprovided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based oncontract, 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 inwriting 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. Any warranty in force at the time of purchase of the compressor ornegotiated as part of the purchase order may take precendence over this warranty.
1
ROTARY SCREW AIR COMPRESSOR
This unit was purchased from:
_______________________________________________
_______________________________________________
_______________________________________________
Ingersoll Rand Company reserves the right to makechanges or add improvements without notice and withoutincurring any obligation to make such changes or add suchimprovements to products sold previously.
Number of units on order: __________________________
Customer Order Number: __________________________
Ingersoll Rand Company Order Number: _____________
For ready reference, record the serial number andmodel number of your unit here:
Serial Number: ___________________________________
Model Number:___________________________________
TYPICAL UNIT
0.0 SAFETY AND WARNINGS0.1 safety instructions0.2 safety precautions0.3 decals
1.0 RECEIPT OF EQUIPMENT1.1 inspection1.2 unpacking and handling1.3 tools
3.0 INTELLISYS3.1 emergency stop switch3.2 power on light3.3 power indicator light3.4 push buttons3.5 set point procedure3.6 warnings3.7 alarms
4.0 SYSTEMS4.1 general systems4.2 aircooled compressors4.3 coolant system4.4 compressed air system4.5 coolant/air separation system4.6 electrical system4.7 compressor control system4.8 options
5.0 MAINTENANCE5.1 maintenance schedule5.2 maintenance records5.3 maintenance procedures5.4 inlet air filter5.5 coolant filter5.6 coolant5.7 separator tank scavenge orifice/screen5.8 coolant separator element5.9 cooler cores5.10 drive motor lubrication5.11 long term storage5.12 coolant/lubricant changeout5.13 intellisys removal5.14 coolant hoses5.15 airend discharge hose5.16 fluid and vibration monitoring
2
TABLE OF CONTENTS5.17 coolant sampling procedure
6.0 TROUBLE SHOOTING
7.0 REFERENCE DRAWINGS7.1 electrical schematic - full voltage7.2 electrical schematic - star delta7.3 foundation plan - air cooled7.4 foundation plan - water cooled7.5 foundation plan - outdoor mod7.6 basic flow schematic - air cooled7.7 basic flow schematic - water cooled7.8 typical system flow diagrams
8.0 WATER QUALITY RECOMMENDATIONS
9.0 MAINTENANCE RECORD
GENERAL INFORMATIONWeight: See foundation plan, Section 7.0
Cooling Air Flow: See foundation plan, Section 7.0
Ambient Temperature Limit: 35°F to 115°F (2°C to 46°C)
Coolant: Factory Filled Ultra Coolant
Coolant Change: 8000 hours or two years, whichevercomes first
Power Inlet Wiring: Recommended conduit: metallicflexible Greenfield, or equivalent,
Tools: U.S. Standard and metric are requiredto perform maintenance
3
0.0 SAFETY AND WARNINGS0.1 SAFETY INSTRUCTIONSBefore you install this air compressor you should take thetime to carefully read all the instructions contained in thismanual.
Electricity and compressed air have the potential to causesevere personal injury or property damage.
Before installing, wiring, starting, operating or making anyadjustments, identify the components of the aircompressor using this manual as a guide.
The operator should use common sense and goodworking practices while operating and maintaining thisunit. Follow all codes, pipe adequately, understand thestarting and stopping sequence. Check the safety devicesby following the procedure contained in this manual.
Maintenance should be done by qualified personnel,adequately equipped with proper tools. Follow themaintenance schedules as outlined in the operatorsmanual to ensure problem free operation after start up.
Safety instructions in the operators manual are bold-facedfor emphasis. The signal words DANGER, WARNING andCAUTION are used to indicate hazard seriousness levelsas follows:
Danger is used to indicate the presence ofa hazard which will cause severe personalinjury, death, or substantial propertydamage if the warning is ignored.
Warning is used to indicate the presence ofa hazard which can cause severe personalinjury, death, or substantial propertydamage if the warning is ignored.
Caution is used to indicate the presence ofa hazard which will or can cause minorpersonal injury or property damage if thewarning is ignored.
Notice is used to notify people ofinstallation, operation, or maintenanceinformation which is important but nothazard-related.
D! DANGER
! WARNING
! CAUTION
NOTICE
WARNING
COMPRESSED AIR AND ELECTRICITYARE DANGEROUS.
BEFORE DOING ANY WORK ON THISUNIT, BE SURE THE ELECTRICAL SUPPLYHAS BEEN CUT OFF–LOCKED & TAGGEDAND THE ENTIRE COMPRESSOR SYSTEMHAS BEEN VENTED OF ALL PRESSURE.
1. Do not remove the covers, loosen orremove any fittings, connections ordevices when this unit is in operation. Hotliquid and air under pressure that arecontained within this unit can causesevere injury or death.
2. The compressor has high anddangerous voltage in the motor starter andcontrol box. All installations must be inaccordance with recognized electricalcodes. Before working on the electricalsystem, be sure to remove voltage fromthe system by use of a manual-disconnect-switch. A circuit breaker orfuse safety switch must be provided in theelectrical supply line leading to thecompressor.
Those responsible for installation of thisequipment must provide suitable grounds,maintenance clearance and lightningarrestors for all electrical components asstipulated in O.S.H.A. 1910.308 through1910.329.
3. Do not operate the compressor at higherdischarge pressure than those specifiedon the Compressor Nameplate or motoroverload will occur. This condition willresult in compressor motor shutdown.
4. Use only safety solvent for cleaning thecompressor and auxiliary equipment.
5. Install a manual shut off valve (isolationtype) in the discharge line. When a safetyvalve is installed between the isolationvalve and the compressor, it must havesufficient capacity to relieve the fullcapacity of the compressor(s).
6. Whenever pressure is released throughthe pressure relief valve, it is due toexcessive pressure in the system. Thecause for the excessive pressure shouldbe investigated immediately.
7. Before doing any mechanical work onthe compressor:
a.) Shut the unit down.
b.) Electrically isolate the compressor byuse of the manual disconnect switch in thepower line to the unit. Lock and tag theswitch so that it cannot be operated.
c.) Vent pressure from the compressor andisolate the unit from any other source ofair.
8. There can be adverse effects ifcompressor lubricants are allowed to enterplant air systems.
Air line separators, properly selected andinstalled, will minimize any liquid carry-over.
The use of plastic bowls on line filterswithout metal guards can be hazardous.From a safety standpoint, metal bowlsshould be used on any pressurizedsystem. Review of your plant air linesystem is recommended.
9. When a receiver is installed, it isrecommended that occupational safetyand health standards as covered in theFederal Register, Volume 36, number 105,part 11, paragraph 1910.169 be adhered toin the installation and maintenance of thisreceiver.
10. Before starting the compressor, itsmaintenance instructions should bethoroughly read and understood.
11. After maintenance functions arecompleted, covers and guards must bereplaced.
0.2 SAFETY PRECAUTIONS
SAFETY PRECAUTIONSBEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
COMPRESSOR OR PERFORMING ANY MAINTENANCE
4
Failure to adhere to these recommendations can result in mechanical failure, property damage and serious injury or death.
All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must takeinto account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In addition, itshould be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility betweendischarge piping, system accessories and software must be assured.
For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is notrecommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fitthe operating parameters of the system.
It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine.
WARNING
CHECK HIGH AIR TEMPERATUREThere is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory pre-setat 228°F (109°C). This function should be checked at regular intervals for 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 temperature setting of the Intellisys. The display shouldindicate “HIGH AIREND TEMP” and the alarm light will be illuminated.
The actual temperature at which shutdown occurs should be recorded for comparison to the Intellisys set point and withsimilar future test results.
SAFETY SHUTDOWN
WARNING
“Ingersoll Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll Randdoes not approve specialized equipment for breathing air application and assumes no responsibility or liability forcompressors used for breathing air services.”
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!
!
5
0.3 DECALS
This section contains representative examples of decalswhich will be appearing throughout this manual and areapplied to the compressor unit. If for some reason a decal is defaced, painted over, or parts are replaced, we
recommend that you obtain a replacement kit as listed inthe spare parts section of the Parts List Manual(80440456).
Air discharge.
INGERSOLL RAND ®
DANGER!
Discharge air.Can contain carbon monoxide orother contaminants. Will causesevere injury or death.
Do not breathe this air.
INGERSOLL RAND ®
Lift here.
INGERSOLL RAND ®
Condensate drain.
INGERSOLL RAND ®
(50-100 HP)
(4) 2 EACH END
(37-75 KW)
NOTICE
NOTICE
NOTICE
To obtain satisfactory compressoroperation and maintenance, aminimum of 3 feet clearance on 3sides is required. 3 1/2 feet is requiredin front of the control panel (orminimum required by latest nationalElectrical Code or applicable localcodes).
Refer to the Operators/InstructionManual before performing anymaintenance.
Do not operate without enclosurepanels & forklift covers in place.
Enclosure panels will affectperformance.
Motors must be greased periodically.
See Operators Manual for procedure.
Compressor Package DataCOMPRESSOR MODEL ............................CAPACITY..................................................... CFMRATED OPERATING PRESSURE ............. PSIGMAX. DISCHARGE PRESSURE................ PSIGMAX. MODULATE PRESSURE ................ PSIGNOMINAL DRIVE MOTOR ....................... H.P.NOMINAL FAN MOTOR ........................... H.P.TOTAL PACKAGE AMPS ...........................VOLTS............................................................PHASE/HERTZ ............................................CONTROL VOLTAGE..................................SERIAL NUMBER........................................
ROTOARY RECIPROCATING COMPRESSOR DIVISIONDAVIDSON, NORTH CAROLINA 28036
6
WARNING!
Exposed fan blade. Can cause severezinjury.
Do not operate with covers removed.Disconnect power. Lock and tag.
INGERSOLL RAND ®
WARNING!
Moving parts.Can cause severe injury.
Do not operate with covers removed.Service only with machine blocked toprevent turn over.
INGERSOLL RAND ®
WARNING!
Exposed moving parts.Can cause severeinjury or death.
Stay clear or movingparts when machine is operating.
INGERSOLL RAND ®
CAUTION!
Incorrect lifting ofmachine can cause injuryor property damage.
Lift only from basechannels.
INGERSOLL RAND ®
NOTICE
NOTICERotation.
Rotation.
INGERSOLL RAND ®
7
WARNING!
High pressure air.Can cause severe injury or death.
Relieve pressure before removing filterplugs / caps, fittings or covers.
INGERSOLL RAND ®
CAUTION!Improper coolant filter replacementwill cause compressor damage.
Replace filter element after first 150hours of operation and every 2000 hours thereafter or when coolant ischanged.
INGERSOLL RAND ®
WARNING!
Hot surface.Can cause severe injury.
Do not touch. Allow to cool beforeservicing.
INGERSOLL RAND ®
INGERSOLL RAND ®
!
Filler Cap.Use only
recommended coolant.Read instruction book
before servicing.
INGERSOLL RAND ®
39543921
NOTICE
Rotation.
INGERSOLL RAND ®
3 REQUIRED - ONE ON LEFT PLENUM WALL
CAUTION!Use of incorrect coolant can causesystem contamination.
Use only ULTRA COOLANT.
INGERSOLL RAND ®
8
WA
RN
ING
!
Haz
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jury
or
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Onl
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Ope
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rs/
Inst
ruct
ion
man
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ING
ERSO
LL R
AN
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NO
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rest
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with
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.
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AN
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Elec
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ERSO
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WA
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!
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ERSO
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!
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Can
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Dis
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Lock
and
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.
See
Ope
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Ins
truc
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Man
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ING
ERSO
LL R
AN
D®
WA
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!
Mov
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part
s.C
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Do
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.S
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nly
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ING
ERSO
LL R
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WA
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ERSO
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ERSO
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Inte
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9
1.0 RECEIPT OF EQUIPMENT
1.1 INSPECTIONWhen you receive the compressor please inspect itclosely. Any indication of careless handling by the carriershould be noted on the delivery receipt especially if thecompressor will not be immediately uncrated. Obtainingthe delivery man’s signed agreement to any noteddamages will facilitate any future insurance claims.
1.2 UNPACKING AND HANDLINGThe compressor package has been mounted on a basewhich provides for forklifting between the two sidechannels to facilitate handling during shipment. Care inpositioning the forklifts is important because the locationof the center of gravity is strongly affected by the locationof the compression module and drive motor.
Slings can be used to lift the crates, but spreader barsmust be used to prevent the slings from exerting a forceagainst the sides of the crates.
1.3 TOOLSRemove compressor unit from wooden skid. A crowbarand hammer will be needed.
IMPORTANTREAD THIS
LOST OR DAMAGED GOODS
THOROUGHLY INSPECT THIS SHIPMENTIMMEDIATELY UPON ARRIVAL
OUR RESPONSIBILITY FOR THIS SHIPMENTCEASED WHEN THE CARRIER SIGNED
BILL OF LADING
If goods are received short or in damaged condition, it is important thatyou notify the carrier and insist on a notation of the loss or damageacross the face of the freight bill. Otherwise no claim can be enforcedagainst the transportation company.
If concealed loss or damage is discovered, notify your carrier at onceand request an inspection. This is absolutely necessary. Unless you dothis the carrier will not entertain any claim for loss or damage. The agentwill make an inspection and grant a concealed damage notation. If yougive the transportation company a clear receipt for goods that have beendamaged or lost in transit, you do so at your own risk and expense.
WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLEMANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THEWILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLEFOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL.THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOURRESPONSIBILITY.
Ingersoll Rand CompanyDavidson, North Carolina
APDDGFO-99-79
FORKLIFT PADDINGWILL REDUCE SCRATCHES
AND MARS
SPREADERBARS
2.0 INSTALLATION
2.1 VENTILATION Oil flooded rotary air compressors produce largeamounts of heat. Because of this large heat production,the compressor must be placed in a room with adequateventilation.
If heated air from the compressor exhaust is allowed torecirculate back to the compressor, the compressor willoverheat and shut down. This heat must be exhaustedfrom the room. You should take this into considerationwhen you decide where to place the compressor withinyour plant. Consider that the required maintenanceclearance is 3 ft (.9 m) all around the compressor.However 42” (1.06m), or minimum required by latest NECor applicable local codes, must be maintained in front ofstarter box door.
Ambient temperatures higher than 115°F (46°C)should be avoided as well as areas of high humidity.
Consider also the environment surrounding or nearthe compressor. The area selected for the location ofthe compressor should be free of dust, chemicals,metal filings, paint fumes and overspray.
2.2 FOUNDATION REQUIREMENTSRefer to the foundation plan for the particular modelcompressor to be installed. See Section 7.0.
The compressor can be installed on any level floor that iscapable of supporting it. Compressor weights are listedon the foundation plans.
When sound transmission is of particular importance it isoften helpful to install a sheet of rubber-fabric-matting, orcork under the compressor to reduce the possibility ofresonant sounds being transmitted or amplified throughthe floor.
2.3 PIPINGThe use of plastic bowls on line filters without metalguards can be hazardous. Their safety can be affected byeither synthetic lubricants or the additives used in mineraloil. From a safety standpoint, metal bowls should be usedon any pressurized system. Review of your plant air linesystem is recommended.
The built-in aftercooler reduces the discharge airtemperature well below the dew point (for most ambientconditions), therefore, considerable water vapor iscondensed. To remove this condensation, eachcompressor with built-in aftercooler is furnished with acombination condensate separator/trap.
DUST CHEMICALS
METALFILINGS
PAINTSPRAY
OVERSPRAY
Do not use plastic pipe, soldered copper fittings or rubber hose for discharge piping.
WARNING
Never elevate the compressor unit above the floor level. This may allow air
to enter the cabinet under the base.Performance will be affected.
NOTICE
36”(.9 m)
42” (1.06 m) ORCODE MINIMUM
10
AIR INTAKE
!
!
11
ROTARY-RECIP IN PARALLEL
Do not use the compressor to support the discharge pipe.
Careful review of piping size from the compressorconnection point is essential. Length of pipe, size of pipe,number and type of fittings and valves must beconsidered for optimum efficiency of your compressor.
It is essential when installing a new compressor to reviewthe total plant air system. This is to ensure a safe andeffective total system.
Liquid water occurs naturally in air lines as a result ofcompression. Moisture vapor in ambient air isconcentrated when pressurized and condenses whencooled in downstream air piping.
Moisture in compressed air is responsible for costlyproblems in almost every application that relies oncompressed air. Some common problems caused bymoisture are rusting and scaling in pipelines, clogging ofinstruments, sticking of control valves, and freezing ofoutdoor compressed air lines. Any of these could result inpartial or total plant shutdown.
Compressed air dryers reduce the water vapor con-centration and prevent liquid water formation incompressed air lines. Dryers are a necessary companionto filters, aftercoolers, and automatic drains for improvingthe productivity of compressed air systems.
NOTICE
2.3 PIPING (Continued)A dripleg assembly and isolation valve should bemounted near the compressor discharge. A drain lineshould be connected to the condensate drain.
IMPORTANT: The drain line must slope downward fromthe compressor to work properly.
NOTE: For ease of inspection of the automatic drain trapoperation, the drain piping should include an open funnel.
It is possible that additional condensation can occur if thedownstream piping cools the air even further and lowpoints in the piping systems should be provided withdriplegs and traps.
IMPORTANT: Discharge piping should be at least aslarge as the discharge connection at the compressorenclosure. All piping and fittings must be suitable for themaximum operating temperature of the unit and, at aminimum, rated for the same pressure as the compressorsump tank.
MOISTURE CONTENT OF COMPRESSED AIR
200
160
120
80
40
0
DEW POINT
withoutAftercooling
100°F/38°C (withAftercooler)
35°F /1.7°C(RefrigeratedDryer)
-40°F/-40°C(DesiccantDryer)
Gal
lon
s o
f Wat
er/2
4h
ou
rs/1
000
acfm
DISCHARGE PIPING WITH AFTERCOOLER
DRIP LEG
ISOLATIONVALVE
ROTARYCOMPRESSOR
SAFETYVALVE
PRESSUREGAUGE
ISOLATIONVALVE
RECIPROCATINGCOMPRESSOR
TRAP
STRAINER
NOTE:SEPARATE LINESGOING TO THERECEIVER DRIP
LEG
SAFETYVALVE
ISOLATIONVALVE
DRIPLEG
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12
2.4 ELECTRICAL INSTALLATION
Before proceeding further, we recommend that youreview the safety data in the front of this manual.
Locate the compressor data plate on the left rear cornerof the unit.
The data plate lists the rated operating pressure, themaximum discharge pressure and the electric motorcharacteristics and power.
Confirm that the line voltage and compressor nameplatevoltage are the same and that the standard starter boxmeets the intent of NEMA 1 guidelines.
Open the starter box door. Confirm that all electricalconnections are made and tightened. Confirm that thecontrol transformer is wired correctly for supply voltage.See Figure 2.4-1 on next page for typical controltransformer wiring.
Two types of dryers, refrigerated or desiccant, are usedto correct moisture related problems in a compressed airsystem. Refrigerated dryers are normally specified wherecompressed air pressure dew points of 33°F (1°C) to39°F (4°C) are adequate. Desiccant dryers are requiredwhere pressure dew points must be below 33°F (1°C).
Contact your local Ingersoll Rand distributor forassistance in selecting correct Ingersoll Rand filtrationor drying products.
NOTE: Screw type compressors should not be installedin air systems with reciprocating compressors without ameans of pulsation isolation, such as a common receivertank. We recommend both types of compressor units bepiped to a common receiver utilizing individual air lines.
When two rotary units are operated in parallel, provide anisolation valve and drain trap for each compressor beforethe common receiver.
ROTARY TWO COMPRESSOR SYSTEM
Compressor Package DataCOMPRESSOR MODEL ............................CAPACITY..................................................... CFMRATED OPERATING PRESSURE ............. PSIGMAX. DISCHARGE PRESSURE................ PSIGMAX. MODULATE PRESSURE ................ PSIGNOMINAL DRIVE MOTOR ....................... H.P.NOMINAL FAN MOTOR ........................... H.P.TOTAL PACKAGE AMPS ...........................VOLTS............................................................PHASE/HERTZ ............................................CONTROL VOLTAGE..................................SERIAL NUMBER........................................
If the compressor is operated in theopposite direction of rotation, airend damage
can result and is not warrantable.
CAUTION
ELECTRICAL INSTALLATION (Continued)Inspect the motor and control wiring for tightness.
Close and fasten the starter box door.
Rotation CheckLocate the rotation decal on each motor.
Drive MotorThe correct compressor drive motor rotation isclockwise when viewed from the rear or non-driveend of the motor. See Figure 2.4-2.
FIGURE 2.4-2 DRIVE MOTOR ROTATION
DRIVEEND
NON-DRIVEEND
FIGURE 2.4-1 TYPICAL CONTROL TRANSFORMER WIRING
LINE VOLTS HZ LINE SEC VOLTS LINE200 60 H4-H5 120 X1-X2
8 X3-X48 X4-X5
220/230 60 H3-H5 120 X1-X28 X3-X48 X4-X5
380 60 H3-H5 120 X1-X28 X3-X48 X4-X5
440/460 60 H2-H5 120 X1-X28 X3-X48 X4-X5
575 60 H1-H5 120 X1-X28 X3-X48 X4-X5
LINE VOLTS HZ LINE SEC VOLTS LINE
220 50 H5-H6 110 X1-X28 X3-X48 X4-X5
380 50 H4-H6 110 X1-X28 X3-X48 X4-X5
415 50 H2-H6 110 X1-X28 X3-X48 X4-X5
550 50 H1-H6 110 X1-X28 X3-X48 X4-X5
110V
H4 H5 H6
16VC.T.
H1 H2 H3
X1X4 X3 X2
120V
H4 H5
16VC.T.
H1 H2 H3
X1X4 X3 X2
HIGH VOLTAGEPRIMARY
SIDE
LOW VOLTAGESECONDARY
SIDE
HIGH VOLTAGEPRIMARY
SIDE
LOW VOLTAGESECONDARY
SIDE
*TYPICAL 60HZ CONTROL TRANSFORMER
*TYPICAL 50HZ CONTROL TRANSFORMER
*THESE DIAGRAMS ARE REFERENCE ONLY. LOCATE THE WIRING DIAGRAM AFFIXED TO THE TOP OF THECONTROL TRANSFORMER TO DETERMINE PROPER WIRE CONNECTIONS.
!
14
ELECTRICAL INSTALLATION (Continued)
The Intellisys will automatically shut the unit down if thecompressor rotation is incorrect, and “CK MTRROTATION” will appear in the display, also the alarm lightwill be on. See Section 6.
For the compressor motor rotation check, the motorjogging time must be as short as possible.
After depressing the start button, IMMEDIATELYdepress the “EMERGENCY STOP” button. Should themotor rotation be incorrect, put main disconnect inthe OFF position, lock and tag. See Figure 2.4-3.
Fan motor rotation is clockwise when viewed fromthe fan motor side.
Intellisys Operating InstructionsRead and understand the following Intellisys OperatingInstructions (See Figure 2.4-4) prior to operating the unit.
NOTE: These instructions are also contained onthe decal near the Intellisys panel of the unit.
FIGURE 2.4-3 MAIN DISCONNECTLOCKED AND TAGGED
Open the starter box door.
Interchange any two line connections (L1, L2 or L3) atthe starter. Close and fasten the starter box door.Recheck for correct rotation.
Fan MotorObserve the compressor cooling fan. The rotation shouldbe in accordance with the fan rotation decal affixed to thefan motor. Cooling air should exhaust through fan end ofcompressor enclosure.
Should the motor rotation not be correct, put the maindisconnect in the OFF position, lock and tag.
Interchange any two fan motor leads at the fan motoroverload relay (FMS/OL). Close and fasten the starterbox door. Recheck for correct rotation.
FIGURE 2.4-4 INTELLISYS OPERATING INSTRUCTIONS
NOTICEIntellisys Operating Instructions
Before installing, operating, or performing any maintenance on this unit, read and understand the instructions in the Operators / Instruction Manual
Before Starting1. Check coolant level. Add coolant if
necessary.2. Verify that main isolation valve is open.3. If water-cooled, turn on water.4. Close main disconnect switch. The
“POWER” light indicates that line and control voltages are available for starting.“UNLOAD” indicator light will be on.
Starting1. Push “START”. Compressor will load
automatically and the air pressure will riseif there is sufficient demand for air.
Stopping1. Push “UNLOADED STOP”. Compressor
will immediately unload and continue to rununloaded approximately 7 seconds.Compressor will then stop. If compressoris running unloaded when “UNLOADEDSTOP” is pushed, compressor will stopimmediately.
2. Open main disconnect switch.
Stopping - Emergency1. If there is a need to stop the compressor
immediately or if the “UNLOADED STOP”does not stop the compressor after 7seconds, push “EMERGENCY STOP”
2. Open main disconnect switch.
HASP
KEY LOCK
TAG
LEVER
15
2.5 OUTDOOR SHELTERED INSTALLATIONMany times a compressor must be installed outside dueto jobsite conditions or limited space within amanufacturing facility. When this occurs there are certainitems that should be incorporated into the installation tohelp ensure trouble free operation. These items havebeen listed below plus Figure 2.5-1 has been included toshow a typical outdoor sheltered installation. The unitmust be purchased with the Outdoor Modification Optionto provide NEMA 4 electrics, TEFC motor, and a cabinetexhaust on the side of the unit rather than the top toprevent recirculation of cooling air.
■ The compressor should be on a concrete paddesigned to drain water away. If the concrete pad issloped, then the compressor must be leveled. In orderto properly pull cooling air through the enclosure, thebase/skid must be sealed to the concrete pad.
■ The roof of the shelter should extend a minimum of 4 ft (1.2 m) around all sides of the compressor to pre-vent direct rain and snow from falling on the unit.
■ Air-cooled machines must be arranged under theshelter in a way that prevents air recirculation (i.e. hotexhaust back to the package inlet).
■ If the installation includes more than one compressor,the hot air exhaust should not be directed towards thefresh air intake of the second unit or an Air Dryer.
■ If a standard machine is to be installed outside, theambient temperature must never drop below 35°F(1.7°C).
■ If ambient temperature drops below 35°F (1.7°C) to aslow as –10°F (–23°C) the unit must be supplied withthe Low Ambient Option. Installations below –10°F(–23°C) ambient are not recommended. The LowAmbient Option requires a separate power source tooperate internal heaters.
■ Arrange the machine with the Intellisys con-troller/starter enclosure facing away from the sun asradiant heat can affect starter/lntellisys performance.Also direct sunlight and UV rays will degrade themembrane touch panel. This is not a warrantablesituation.
■ Power disconnect switch should be within line of sightand in close proximity to the unit. N.E.C. and localelectrical codes must be followed when installing thepower disconnect switch.
■ Condensate drains must never be allowed to drain onthe ground. Run to a suitable sump for futurecollection and disposal or separation of lubricant andwater mixture.
■ Incoming power connections must use suitableconnectors for outdoor weather tight service.
■ A minimum of 3 ft (.9 m) clearance must be allowedon all four sides of the unit for service access.However 42” (1.06m), or minimum required by latestNEC or applicable local code, must be maintained infront of starter box door.
■ If possible, access by a forklift and/or an overheadbeam hoist should be kept in mind (for eventualservice to airend or motor).
■ If the area around the installation contains fineairborne dust or lint and fibers etc., then the unitshould be purchased with the High Dust Filter Option.
■ Some type of protection such as a fence or securitysystem, should be provided to prevent unauthorizedaccess.
16
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3.0 INTELLISYS
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18
3.0 INTELLISYS
3.1 EMERGENCY STOP SWITCH
Pressing this switch stops the compressorimmediately. Compressor cannot be restarted untilswitch is manually reset. Turn clockwise to reset.
3.2 POWER ON LIGHT (Inside Starter Box)
Indicates control voltage is available to the controlcircuit and line voltage is available for starting.
POWER ON3.3 POWER INDICATOR LIGHT
Indicates voltage is available to the intellisyscontroller.
3.4 PUSH BUTTONS
START
If the display shows READY TO START, pressing thisbutton will start the compressor. The compressorwill start and load automatically if there is a demandfor air.
If in the display table press this button to exit thedisplay table. Display will show “CHECKINGMACHINE” then “READY TO START”.
EMERG
POWER
UNLOAD STOP
Pressing this button will activate the unload stop. Ifthe compressor is running loaded, it will unload.Seven seconds later it will stop. if the compressor isrunning unloaded, it will stop immediately. Pressingthis button with the unit stopped will flash all L.E.D.’sfor a light check and flash the software versionnumber in the display.
UNLOAD/LOAD
If the unit is running loaded, pressing this button willcause the unit to unload, the unload indicator lightwill be on. The unit will not load until the button ispressed again. If the unit is running unloaded,pressing this button will load the unit in the ON/OFFLINE or MOD/ACS control mode previouslyoperating.
START
UNLOAD/LOAD
STOPUNLOADED
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3.4 PUSH BUTTONS (Continued)
DISPLAY SELECT
Pressing this button will change the informationselected for the display. The display table will beincremented. If the button is held, this display tablewill scroll. This button can also be used to exit theset point procedure.
NOTE: For readings less than 1 hr., hourmeter displays minutes. After 1 hr. the hourmeter displayshours.
SET
The SET button is used to enter the set pointprocedure. The set button is also used to resetwarnings and alarms. Pressing this button once willreset a warning, twice will clear an alarm.
ARROWS
These buttons have several functions. If theIntellisys is in the set point mode, the ARROWS areused to change the set point values. If the unit hasmultiple alarms or warnings, the ARROWS are usedto scroll through these conditions. The ARROWShave a function in the calibration routine, which willbe described later.
PRESSURE SENSOR CALIBRATION (ZEROING)ROUTINE
This routine is entered if the unit is not running andboth the up and down arrows button are pressed atthe same time. Make sure all pressure is relievedfrom the compressor before calibration. The displaywill flash the message “CALIBRATING”. Aftercalibration is completed the display will indicate“READY TO START”. Zeroing should only be doneafter a pressure sensor has been replaced or anycontroller change.DISPLAY
SELECT
SET
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3.6 WARNINGS
When a warning occurs, the alarm indicator will flashand the display will alternate between the currentmessage and the warning message. If multiplewarnings exist, the message
SCROLL FOR WARN
will be substituted for the warning messages. The upand down arrows can be used to obtain thewarnings
A warning needs to be reset by an operator. Thewarning will clear when the SET button is pressedonce. The following is a list of the warningmessages.
1) CHG SEPR ELEMENT This warning will occur if the pressure on theSeparator is 12 psig (.8 bar) greater than thepressure at the Package discharge and the unit isfully loaded.
2) HIGH AIREND TEMP This will occur if the Airend Discharge Temperature(2ATT) exceeds 221°F (105°C).
3) HIGH AIR PRESSThis will occur if the unit is connected to an ISC(sequencer), and the line pressure exceeds the max.offline pressure for 3 seconds.
4) T2 SENSOR FAILURE This will occur when the Low Ambient Option isturned on and either the low ambient sensor is notinstalled or is broken.
3.5 SET POINT PROCEDURE
This procedure allows the customer to modify 14variables in the controller logic.
At this time, press the SET button to enter thesetpoint routine. The SET OFFLINE AIRPRESSURE indicator will light and the display willshow:
XXXX PSI
OFFLINE AIR PRESSURE is the first set point andXXXX stands for the value of the set point. Press theSET button to select the set point to be adjusted.Press the up or down arrow buttons to raise or lowerthe set point value. Press the SET button to move tothe next set point. If the set point value has beenadjusted, press the SET button to enter the newvalue. The display will flash to acknowledge.The nextset point will then be displayed. If the value of the setpoint was not changed, pressing the SET button willonly step to the next set point. When the SELECTOPTIONS set point is entered, the SELECTOPTIONS indicator will light, and the setpoints forAuto Start/Stop or Remote Start/Stop will beaccessible and displayed. The Power Outage Restartsetpoints will be accessible and displayed. The setpoint routine can be exited by pressing theDISPLAY/SELECT button or exit will be automaticafter 30 sec.
The following is a list of the set points. Also includedare maximum and minimum limits, step size, andunits of measure.
MIN MAX STEP UNIT
OFFLINE PRESSURE 75 RATED + 3 1 PSI
ONLINE PRESSURE 65 OFFLINE - 10 1 PSI
CONTROL MODE MOD/ACS - MODULATION - ON/OFF LINE
DISPLAY TIME 10 600 10 SEC
AUTO RESTART OFF ON --- ---
AUTO RESTART TIME 2 60 1 MIN
SEQUENCER OFF ON --- ---
REMOTE START/STOP OFF ON --- ---
POWER OUT/RESTART OFF ON --- ---
POWER OUT RESTART 10 120 1 SECTIME
DELAY LOAD TIME 0 60 1 SEC
LEAD/LAG** --- --- --- ---
LAG OFFSET 0 45 1 PSI
LOW AMBIENT OFF ON --- ---
** The lead/lag feature allows the customer to chooseone compressor as the “lead” compressor and anyothers as the “lag” compressor (simulates the mode of asequencer). The lag compressor’s on-line and off-linepressures are determined by subtracting the lag offsetset-point from the on-line and off-line pressure set-points of the lead compressor.
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3.7 ALARMS
When an alarm occurs, the alarm indicator will lightand display will show actual alarm message. Ifalternately multiple alarms have occurred the displaywill show SCROLL FOR ALARM. In this situation theup and down arrows will be used to view the alarmmessages. All alarms (with the exception of theemergency stop) will be reset by twice pressing theSET button. Any exceptions to the above will beexplained in the alarm description.
The following is a list of the alarm messages.
1) LOW SUMP PRESS This will occur if the unit is running and sumppressure is too low.
2) HIGH AIR PRESS This will occur if the unit is running and sumppressure is greater than unit rated operatingpressure plus 20 psig (1.4 bar), plus the separatorpressure drop, or the line pressure is 15 psig (1.0bar) above the rated pressure.
3) HIGH AIREND TEMP This will occur if airend discharge temperature isgreater than 228°F (109°C).
4) STARTER FAULT 1SL (2SL)This alarm will occur if the starter contacts openwhile the unit is running. This alarm will also occur ifthe unit is given the stop command and the startercontacts do not open. 1SL refers to the auxiliarycircuit on starter contactor 1M. 2SL refers to theauxiliary circuit on starter contacts 2M and 1S.
5) MAIN MTR OVERLD This will occur if a motor overload is sensed.
6) FAN MTR OVERLOAD This will occur if a fan motor overload is sensed.
7) TEMP SENSOR FAIL This will occur when the sensor temperature is recognized as missing or broken.
8) REMT STOP FAILThis will occur if the momentary remote stop switchdoes not disengage by the time the unit attempts tostart.
9) REMT START FAILThis will occur if the momentary remote start switchdoes not disengage by the time star-delta transitionoccurs.
10) CK MTR ROTATION This alarm will occur if a unit is started andcompressor has incorrect rotation.
11) CALIBRATION FAIL This alarm will occur if the sensor calibration routineis executed and the sensor reading exceeds 10% ofscale.
12) NO CONTROL POWER This alarm will occur when the controller senses aloss of control power.
13) PRES SENSOR FAIL Whenever the pressure sensor is recognized asmissing or broken, a pressure sensor failure alarmwill occur.
14) LOW UNLOAD SUMPThis alarm will occur if the unit is running unloadedand sump pressure is less than 15 psig (1.0 bar).
INITIAL CHECK ALARMS
15) HIGH AIREND TEMP
This will occur if airend discharge temperature isgreater than 217°F (103°C).
This alarm will only occur when the machine is notrunning. When it occurs, the message MUST COOLDOWN is added to the alternating group of alarmmessages.
EMERGENCY STOP
This will occur when the EMERGENCY STOP buttonis engaged. The alarm indicator will light and displaywill show:
EMERGENCY STOP
Disengage the EMERGENCY STOP button andpress the SET button twice to reset this alarm.
Cooling Fan Motor
In a standard compressor, the cooling fan motorsare wired at the factory. They are three-phase-motors. Each is protected by a fan motorstarter/overload. The fan motor is energized at thesame time the compressor drive motor is energized.The fan motor starter/overload is wired in series withthe compressor drive motor overload. If an overloadoccurs in the fan motor circuit, both the fan motorand compressor drive motor will stop.
Aftercooler
The discharge air aftercooling system consists of aheat exchanger (located at the cooling air dischargeof the machine), a condensate separator, and anautomatic drain trap.
By cooling the discharge air, much of the watervapor naturally contained in the air is condensedand eliminated from the downstream plant-pipingand equipment.
4.3 COOLANT SYSTEM
Coolant is forced by pressure from the receiver-separator sump to the inlet port of the coolant coolerand the bypass port of the thermostatic controlvalve.
The thermostatic control valve controls the quantityof coolant necessary to provide a suitablecompressor injection temperature. When thecompressor starts cold, part of the coolant willbypass the cooler. As the system temperature risesabove the valve setting, the coolant will be directedto the cooler. During periods of operation in higherambient temperatures, all the coolant flow will bedirected through the cooler.
The compressor injection minimum temperature iscontrolled to preclude the possibility of water vaporcondensing in the receiver. By injecting coolant at asufficiently high temperature, temperature of the discharge air and lubricant mixture will be keptabove the dew point.
The controlled temperature coolant passes througha filter to the airend under constant pressure.
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4.0 SYSTEMS
4.1 GENERAL SYSTEM INFORMATION
The compressor is an electric motor driven, singlestage, screw compressor—complete withaccessories piped, wired and baseplate mounted. Itis a totally self-contained air compressor package.
A standard compressor is composed of the following:
Inlet air filtrationCompressor and motor assemblyPressurized coolant system with coolerSeparation systemCapacity control systemMotor starting control systemInstrumentationSafety provisionsAftercooler Moisture separator and drain trap
Optional accessories can provide for such things asremote starting or stopping and sequencer.
4.2 AIR COOLED COMPRESSORS
Design Temperatures
The standard compressor is designed for operationin an ambient range of 35°F. to 115°F. (1.7°C. to46°C.). When conditions other than design levelsdescribed are encountered, we recommend youcontact your nearest Ingersoll Rand representativefor additional information.
The standard maximum temperature (115°F.) isapplicable up to an elevation of 3300 ft. (1000meters) above sea level. Above this altitude,significant reductions in ambient temperature arerequired if a standard drive motor is to be used.
Coolant Cooler
The cooler is an integral assembly of core, fan andfan-motor, mounted in the compressor. The coolingair flows in through the left side of the enclosure,through the vertically mounted cooler core, anddischarges upward through the top of the enclosure.
Air enters the compressor, passing through the inletair filter and inlet valve.
Compression in the screw-type air compressor iscreated by the meshing of two helical rotors (maleand female) on parallel shafts, enclosed in a heavy-duty cast iron housing, with air inlet and outlet portslocated on opposite ends. The grooves of the femalerotor mesh with, and are driven by, the male rotor.Tapered roller bearings at the discharge end preventaxial movement of the rotors.
The air-coolant mixture discharges from thecompressor into the separation system. This system,self-contained in the receiver tank, removes all but afew PPM of the coolant from the discharge air. Thecoolant is returned to the system and the air passesto the aftercooler. The aftercooling system consistsof a heat exchanger, a condensate separator, and adrain trap. By cooling the discharge air, much of thewater vapor naturally contained in the air iscondensed and eliminated from the downstreamplant-piping and equipment.
During unloaded operation, the inlet valve closesand the blowdown solenoid valve opens, expellingany compressed air back to the compressor inlet.
4.5 COOLANT/AIR SEPARATION SYSTEM
The coolant/air separation system is composed of aseparator tank with specially designed internals, atwo-stage, coalescing-type separator element, andprovision for return of the separated fluid back to thecompressor.
Operation
The coolant and air discharging from thecompressor flow into the separator tank through atangential inlet. This inlet directs the mixture alongthe inner circumference of the separator tank,allowing the coolant stream to collect and drop tothe separator tank sump.
Internal baffles maintain the circumferential flow ofremaining coolant droplets and air. In an almostcontinuous change of direction of flow, more andmore droplets are removed from the air by inertialaction and then returned to the sump.
The air stream, now essentially a very fine mist, isdirected to the separator element.
The separator element is constructed with twoconcentric, cylindrical sections of closely packedfibers, each held in steel mesh. It is flange-mountedat the receiver-outlet-cover.
The air stream enters the separator element radiallyand the mist coalesces to form droplets. Thedroplets collected on the outer first stage fall to thereceiver sump. Those collected on the inner secondstage collect near the outlet of the element, and aredrawn back to the compressor inlet through a filter-screen and orifice fitting installed in the separatorscavenge line.
The air stream, now essentially free of coolant, flowsfrom the separator to the aftercooler, then to thecondensate separator, and on to the plant airsystem.
4.6 ELECTRICAL SYSTEM
The electrical system of each compressor is builtaround the microprocessor-based Intellisyscontroller.
The standard electrical/electronic components,enclosed in a readily accessible enclosure include:
1. Intellisys controller 2. Control transformers and fuses3. Compressor motor starter, with auxiliary contacts
and overload relays4. Cooling fan motor starter/overload
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4.7 COMPRESSOR CONTROL SYSTEM
The Intellisys® controls the various operating modes ofthe compressor, monitors key compressor operatingparameters, and shuts the compressor down in thecase of an operating problem. The control system hascustomer adjustable inputs as described in theIntellisys® section 3.0. The compressor control systemhas the following standard features.
The following paragraphs provide a description of thestandard features. Please also refer to the flowschematic in section 7.0.
Automatic Unloaded Start
Pushing the start button signals the Intellisys® toengage the starter coils and opens the oil stop valve(5SV). The compressor will always start in theunloaded mode, with the inlet valve in the closedposition and the blowdown valve open to vent thepressure from the separator tank. The unloaded startensures that the compressor has a low starting torquerequirement and that proper oil flow is establishedbefore the compressor loads. Compressors with fullvoltage starters will not load for seven seconds afterthe starter button is pressed. Compressors withoptional star-delta starters will not load until twoseconds after star-delta transition. If system pressureis below the on line set point pressure, the compressorwill automatically load at this time. Press theload/unload button to prevent the compressor fromloading.
Adjustment Of Unloaded Sump Pressure.
During unloaded operation, the inlet valve must allowsome air flow past it to maintain sump pressure forproper lubricant flow. This air is compressed by thecompression module and vented through theblowdown valve (3SV). By adjusting the closed positionof the inlet valve plate, the unloaded sump pressurecan be varied. The unloaded sump pressure is set atthe factory and should not need adjustment undermost circumstances. If adjustment is required use thefollowing procedure.
Tools Required
• 1/2" open end wrench.• 9/16" open end wrench.• Loctite® 242 or equivalent.
With the compressor shut down remove the nut thatfastens the inlet valve pivot anchor to the bracket on theinlet valve. Apply Loctite® 242 or equivalent to threadson spacer and loosely install nut. Start compressor andpress the unload button so that the compressor will notload. Use the display select button to indicate sumppressure on the display. Move the position of the pivotanchor to alter the sump pressure until the sumppressure is between 25-35 psig (1.7-2.4 bar). Moving thepivot towards the inlet valve will raise the sumppressure. Moving the pivot away from the inlet valve willlower the sump pressure. Once the position is correct,fully tighten the nut.
On/Off Line Control
The standard control system provides for either fullcompressor capacity flow or zero flow based on thesystem pressure. If the system pressure falls below theon line set point, the Intellisys® energizes theload/unload solenoid (1SV) and the blowdown solenoid(3SV). This causes the inlet valve to open and theblowdown valve to close. Compressed air flows into thesystem.
If system pressure reaches the off line setting, thecompressor unloads to minimize power demands. TheIntellisys® de-energizes the load/unload solenoid (1SV) and the blowdown solenoid (3SV). This causesthe inlet valve to close and vents the separator tank.The minimum pressure check valve (MPCV) closes toprevent back flow from the compressed air system. Thecompressor operates at minimum power until thesystem pressure falls to the on-line pressure setting.
Delay Load Time
This is the amount of time the line pressure mustremain below the on line set point before thecompressor will load or start (if the unit was stoppeddue to an auto start/stop situation). This timer will notdelay loading after a start or if the time is set to zero.The delay load time feature is useful if the compressoris operating as a backup to another compressor and isnormally stopped in auto start/stop mode. The delayload time prevents the compressor from starting andloading if the system air pressure momentarily dropsbelow the on line setting of the backup compressor. Ifno delay is desired the delay load time setting shouldbe set to zero.
25
Unloaded Stop
If the compressor is running at full load and theunloaded stop button is depressed, the compressor willunload and stop only after running unloaded for sevenseconds. If the compressor is already unloaded, thecompressor will stop immediately. Use of the unloadedstop button is the preferred method of stopping thecompressor. If an immediate shutdown is required theEMERGENCY STOP button should be used.
Automatic Start/Stop Control
Many plant air systems have widely varying airdemands or large air storage capacity which allows forautomatic standby air capacity control.
The Intellisys system has been designed to carry out thisfunction utilizing a software option module. AutomaticStart/Stop is available as a factory installed option or asa field installation kit.
During periods of low air demand, if the line pressurerises to the upper set point, the Intellisys begins to timeout. If the line pressure remains above the lower setpoint for as long as the set time, the compressor willstop. At the same time, the display will indicate thecompressor has shut down automatically and will restartautomatically. An automatic restart will occur when theline pressure drops to the lower set point.
The upper and lower set points and shutdown delay timeare set on the Intellisys control panel. There is a 10second delay after shutdown during which thecompressor will not restart even if line air pressure dropsbelow the lower set point. This is to allow the motor tocome to a complete stop and the Intellisys controller tocollect current data of operating conditions. If line airpressure is below the lower set point at the end of 10seconds, the unit will start unless the load delay timer isset greater than 10 seconds.
Delay Load Time
This is the amount of time the line pressure must remainbelow the online set point before the compressor willload or start (if the unit was stopped due to an autostart/stop situation). This timer will not delay loading aftera start or if the time is set to 0. When the delay loadtimer becomes active, the display will show the delayload countdown. Once the countdown reaches 0, the unitwill load or start.
Automatic Start/Stop Operation
When in operation, the compressor must meet twospecific timing intervals before the Intellisys controller willstop the unit in an Automatic Start/Stop situation.
For this discussion, the timers will be called timer "A"and timer "B".
FIRSTTimer "A" prevents the compressor from automaticallystarting more than 6 times an hour by requiring the unitto run at least 10 minutes after each automatic start.
This 10 minute run period can be loaded, unloaded or acombination of the two and allows dissipation of heatgenerated within the motor windings at start.
SECONDAfter the compressor has started and reached the off-line setting and has unloaded, timer "B" requires the unitto run unloaded for a period of time that the operator canadjust between 2 and 60 minutes.
The setting of timer "B" is part of the options setpointroutine and the timer cancels any accumulated time ifthe compressor reloads before the timer cycle hasfinished.
An important point... This unloaded run time may, or maynot, be included in the mandatory 10 minute run timeused to cool the motor windings.
When the compressor has completed the settings ofboth timer "A" and timer "B", the Intellisys controllerstops the compressor and displays "STOPPED IN AUTORESTART."
Pressure sensor 3APT continues to monitor the packagedischarge pressure and sends information to thecontroller which automatically restarts the compressorwhen the pressure falls to the on-line setting.
An advantage to this method of automatic start/stopcontrol is allowing the compressor to stop much soonerin certain situations and timer settings, thereby reducingpower costs.
Remote Start/Stop Operation
Remote start/stop allows the operator to control thecompressor from a remote mounted start/stop station.
26
Two different switches can be wired to the controller forremote start/stop. (Refer to Electrical Schematics 7.1 or7.2 for wiring locations). The switches are customersupplied and must be of momentary type. The stopswitch contacts are normally closed and the start switchcontacts are normally open.
When starting the compressor from the remote location,the Start button must be held depressed forapproximately 2 seconds to activate the remote startfunction and then released within a maximum of 7seconds or a Remote Start Failure alarm will occur.
Power Outage Restart Operation
For customers that have interruption in their incomingpower supply to the compressor and must maintain anuninterrupted supply of compressor air, the PowerOutage Restart Option allows an Intellisys® compressorto automatically restart after incoming power isrestored.The Power Outage Restart Option is turned on byenabling it through the set point routine. The restart timedelay, which is adjustable from 10-120 seconds, canalso be adjusted while in the set point routine on theIntellisys® controller. Any time power is restored to thecompressor after a power interruption, a horn locatedon the side of the starter box will sound during therestart time delay (10-120 seconds) , after which thecompressor will automatically start. After starting, thecompressor will return to the mode of operation that thecompressor was in prior to the power interruption.
Some Examples of Operation
EXAMPLE 1The operator selects an unloaded run time of 2 minutesin the OPTION routine and starts the compressor. Theunit runs loaded for 8 minutes, unloads and then runsunloaded for two more minutes.
The total running time is 10 minutes which satisfiestimer “A” plus the unit ran two minutes unloaded whichalso satisfies timer “B,” therefore, the unit stopsautomatically.
This example shows how timer “B” can sometimes beincluded within the timer “A” interval. Think of the twotimers as running parallel.
EXAMPLE 2The operator selects an unloaded run time of 3 minutesin the OPTION routine and starts the compressor. Theunit runs loaded for 10 minutes and then unloads.
At this point, timer “A” has been satisfied but timer “B”still wants the compressor to run unloaded 3 moreminutes before allowing an automatic stop.
The total run time for this example will be 13 minutes.
Remember.... If the unit reloads before timer “B”finishes the 3 minute setting, the partial time iscanceled and timer “B” must restart the 3 minute cyclewhen thecompressor unloads again.
EXAMPLE 3The operator selects an unloaded run time of 10minutes in the OPTION routine and starts thecompressor. The unit runs loaded 12 minutes and thenunloads.
After 12 minutes of running, the 10 minute mandatoryrun-time for timer “A” has been met but the compressormust continue to run unloaded an additional 10minutes to satisfy timer “B”.
After 10 minutes of unloaded run time, the compressoris stopped automatically and the total run time was 22minutes.
4.8 OPTIONS
Several options are available with the Intellisys®control. These include starter options, sequencercontrol, and modulation control.
4.8.1 Starter Options
The standard compressor is supplied with an automaticacross-the-line (full voltage) starter. This starter is fullycontrolled by the Intellisys® and supplies full linevoltage to the compressor motor at startup.
Optional reduced voltage (star-delta) starting isavailable, fully installed, at the factory and is alsocontrolled by the Intellisys®. This starter initiallyprovides a reduced voltage to the compressor motor toreduce starting current spike. After the compressormotor is at full speed, the starter transitions to supplyfull line voltage to the compressor motor.
4.8.2 Sequencer Control
Sequencer control capability can be added to theIntellisys® system by using a sequencer interface. Thisoption is available as a field installation kit.
27
4.8.3 Modulation
On/Off Line control is the most efficient mode ofoperation for the compressor. For compressed airsystems that have a continuous demand near the fullcapacity of the compressor, modulation control willprevent excessive cycling of the compressor andprovide a more constant supply pressure. Modulationcontrol will also prevent excessive cycling if thecompressed air system volume is small. An aircompressor should never be installed in acompressed air system volume with a ratio of receivervolume (in gallons) to total compressor capacity (incubic feet per minute) of less than one.
On/Off Line Control
The modulation control system retains all the featuresof on-line/off-line control but provides for throttling ofthe compressed air flow to match system demand.The compressor can be set to operate in "ON/OFFLINE" control using the set point procedure even if thecompressor has the modulation option. If thecompressor is set in the on line/off line control mode,it operates as described in section 4.7.
Modulation Only
The "MODULATlON" control mode can be selectedduring the set point procedure on a compressor thathas the modulation option installed. To load, theIntellisys® energizes the load solenoid (1SV) andblowdown solenoid (3SV) as in on line/off line control.The Intellisys® also energizes the modulationsolenoids (2SV and 6SV). This connects regulated pressure from the modulator valve (MV) tothe air cylinder. The regulated pressure decreaseswith increasing system pressure near the set point ofthe modulation valve. This causes the inlet valve tothrottle the compressor flow. The modulator valve isfactory set such that the compressor will modulate toapproximately 60% of rated capacity before the off linepressure is reached. If the system pressure continuesto increase, the compressor will unload at the off linepressure setting. If the system pressure falls below theon line set point, the compressor will load in themodulation control mode.
Modulate/ACS Control
In compressors equipped with the modulation optionthe "MOD/ACS" control mode allows the Intellisys® toselect the most appropriate control mode to matchsystem demands. This eliminates the need for manualselection of the control mode to accommodate variouscompressed air demand cycles.
When operating in the MOD/ACS" control mode, thecompressor automatically defaults to the on line/offline control mode. If the compressor completes threeload/unload cycles within a three minute time periodthe Intellisys® determines that there is a high demandfor compressed air. The Intellisys® switches tomodulation control in an attempt to match thecompressed air demand by regulating the flow. Thecompressor continues to operate in the modulationcontrol mode until the compressor operates unloadedfor three minutes. This is an indication thatcompressed air usage has fallen off and that on/offline is a more appropriate control mode. TheIntellisys® changes the control mode to on/off line andcontinues to operate in this manner until threeload/unload cycles occur within three minutes.
Modulate Control Valve Adjustment
Tools Required
• 7/16" open end wrench.• Pressure Gauge 0-100 PSIG (0-6.9 barg)• Loctite® PST or equivalent.
The modulator valve is set at the factory to modulateat the compressor's rated pressure. For example acompressor with a 125 psig (8.6 bar) pressure ratingwill modulate up to 60% capacity when the systempressure is near the default off line setting of 128 psig.(8.8 bar). The following procedure describes themethod of setting the modulation valve. The desiredpressure should never be more than 3 psig (.2 bar)below the off line pressure entered during the setpoint routine. For example if the off line pressure is setat 96 psig (6.6 bar), the desired set point pressureshould be 93 psig (6.4 bar).
Ensure that the compressor is isolated from thecompressed air system by closing the isolation valveand venting pressure from the system.
28
Ensure that the main power disconnect switch islocked open and tagged.
1. Remove the 1/8" NPT plug from the tee in thecontrol piping and connect a pressure gauge to thisport.
2. Reconnect power to the compressor. When displayreads "READY TO START," enter the set pointsroutine and set control mode to "MODULATION".
3. Start the compressor and elevate system pressureto desired set point pressure. This pressure must bemaintained while adjusting the modulator valve.
4. Loosen the lock nut on the bottom of the modulatorvalve and turn the adjusting screw to modify themodulation valve set pressure. Turning the screwcounterclockwise (as viewed from the top) raises theset point pressure. Turning the screw clockwise lowersthe set point pressure.
5. Adjust the screw while maintaining system pressureat the desired value until the output pressure of themodulator valve is 30 psig (2.1 bar). Tighten thelocknut.
6. Stop the compressor and lock open the maindisconnect. Ensure that all pressure is vented from thesystem.
7. Remove pressure gauge from modulation valve andre-install 1/8" NPT plug in tee in control piping usingLoctite® PST or equivalent to seal threads.
29
NOTES:
30
5.0 SCHEDULED PREVENTATIVE MAINTENANCE
5.1 MAINTENANCE SCHEDULETHE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THECOMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THATNUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST.
5.2 MAINTENANCE RECORDSIt is very important that you, the owner, keep accurateand detailed records of all maintenance work you, or theIngersoll Rand Distributor or Customer Center performon your compressor. This includes but is not limited tocoolant filter, separator, inlet air filter and so forth. Thisinformation must be kept by you, the owner, should yourequire warranty service work by your Ingersoll RandDistributor or Customer Center. Maintenance recordsheets are located at the back of this manual.
5.3 MAINTENANCE PROCEDURESBefore starting any maintenance, be certain the followingis heeded.
1. Read Safety Instructions.2. Use correct tools.3. Have recommended spares on hand.
SPECIAL NOTE:Replace separator element when the separatordifferential pressure ( ▲▲ P) reaches three times theinitial pressure drop or a maximum pressuredifferential of 12 psi (.8 bar) at full load or if theIntellisys warning CHG SEPR ELEMENT is displayed.See Section 3.6.
* In very clean operating environments and where inlet filter is changed at the above prescribed intervals.In extremely dirty environments change coolant, filters, and separator elements more frequently.
** Clean cooler cores if discharge air temperature is excessive or if unit shutdown occurs on high air temperature.
Action Part or ItemTime Interval (whichever comes first)
Running Hours 1 Week 1 Mo 3 Mo 6 Mo Yearly 2 Years
Inspect Coolant level Weekly X
Inspect Discharge temperature (air) Weekly X
Inspect Separator element differential Weekly X
Inspect Air filter Delta P (at full load) Weekly X
Replace Coolant filter* 150 X (initial change only)Check Temperature sensor 1000 X
Replace Food grade coolant (when used) 1000 X
Replace Hoses 8000 X
Replace Coolant filter* 2000 X (subsequent changes)
Analysis Coolant 2000 See Section 5.16 X
Analysis Vibration 2000 See Section 5.16 X
Clean Separator scavenge screen andorifice 4000 X
Clean Cooler cores** 4000 X
Replace Air filter* 4000 X
Replace Separator element* *See special note.
Replace Coolant* 8000 X
Inspecr Starter contactors 8000 X
Sercive Drive/Fan motor lubrication See Section 5.10.
5.4 INLET AIR FILTER
The filter should be changed when the filter indicatorshows red.
The filter should be changed every 4000 hours and morefrequently in dirty environments because coolant, coolantfilter, separator element, and airend life are a directfunction of how well you maintain and replace the inlet airfilter.
To change inlet filter elements, loosen wing nut on top ofinlet filter housing. Lift cover up and away to exposeelement/s.
Carefully remove the old element/s to prevent dirt fromentering the inlet valve. Discard old element/s.
Thoroughly clean the element housing and wipe allsurfaces.
Install new element/s and inspect to ensure that theyhave seated properly.
Install top of inlet filter housing.
Inspect the rubber seal on the retainer wing nut andreplace seal if required.
Tighten wing nut.
Start machine and run in the load mode to verify filtercondition.
5.5 COOLANT FILTER
The coolant filter should be changed after the first 150hours of operation and every 2000 hours thereafter, orwhen the coolant is being changed. In dirty operatingenvironments the filter should be changed morefrequently.
Use a suitable device and loosen the old element. Usedrain pan to catch any leakage during removal. Discardold element.
Wipe the sealing surface of the filter with a clean, lint-freerag to prevent the entry of dirt into the system.
Remove the replacement element from its protectivepackage. Apply a small amount of clean lubricant on therubber seal and install the element.
Screw element/s on until the seal makes contact with thehead of the filter assembly. Tighten approximatelyone-half turn additional.
Start unit and check for leaks.
INLET AIR FILTER75-100 HP (55-75 kw)
REQUIRES TWO (2) ELEMENTS
COOLANT FILTER 50-100 HP (37-75 kw)
NOTICE
Improper coolant filter replacementwill cause compressor damage.
Replace filter element after first 150hours of operation and every 2000 hoursthereafter or when coolant is changed.
Ultra Coolant is a polyglycol base coolant. Change UltraCoolant after every 8000 hours or every two years,whichever comes first.
X-TEND Food Grade Coolant is a polyalphaolefin basecoolant. Change after every 8000 hours or every twoyears whichever comes first.
Items RequiredIn addition to the tools normally found in any reasonablyequipped serviceman’s toolbox, the following itemsshould be available at the work site:
1) Suitable drain pan and container to hold lubricantdrained from unit.
2) A quantity of proper lubricant sufficient to refill thecompressor.
3) A minimum of one replacement coolant filter elementof the proper type for the unit to be worked on.
There is a coolant drain hose supplied with eachcompressor. The drain hose is placed in the starter boxwhen shipped from the factory.
The coolant should be drained soon after the compressorhas been shut down. When the coolant is hot, drainagewill be more complete and any particles in suspension inthe coolant will be carried out with the coolant.
Hot coolant can cause severe injury. Use care whendraining separator tank.
To drain the unit, remove plug from drain valve located onthe bottom of the separator tank. Install supplied drainhose and fitting assembly in end of drain valve and placeend of hose in a suitable pan. Open drain valve to startdrainage. After draining is complete, close valve, removehose and fitting assembly from valve, and store in asuitable location for future use. Replace plug in end ofdrain valve.
Do not store drain hose in starter box after it hasbeen used to drain the separator tank.
50 hp (37 kw).....................5.0 gallons (19.0 liters)
60 hp (45 kw).....................5.0 gallons (19.0 liters)
75/100 hp (55-75 kw) ........9.0 gallons (34.2 liters)
Coolant fill quantity
WARNING
Hot coolant can cause severe injury.Use care when near this area.
NOTICE
Filler Cap.Use only recommended
coolant.
Read instruction book beforeservicing.
!
33
5.6 COOLANT (Continued)
After the unit is drained and a new coolant filter elementis installed, refill the system with fresh coolant. Bring thereceiver level of coolant up to the midpoint of the sightglass. Replace the fill cap. Start the compressor and runit for a short time. The correct coolant level is at themidpoint of the sight glass with the unit running in the‘UNLOADED” mode.
5.7 SEPARATOR TANK SCAVENGE SCREEN/ORIFICE
Tools Required■ Open end wrench■ Pliers
ProcedureThe screen/orifice assemblies are similar in appearanceto a straight tubing connector and will be locatedbetween two pieces of 1/4 inch O.D. scavenge linetubing.
The main body is made from 1/2 inch hexagon shapedsteel and the diameter of the orifice and a direction-of-flow arrow is stamped in flat areas of the hexagon.
A removable screen and orifice is located in the exit endof the assembly (See Figure 5.7-1) and will requirecleaning as outlined in the Maintenance Schedule,Section 5.1.
To remove the screen/orifice, disconnect the scavengeline tubing from each end. Hold the center section firmlyand use a pair of pliers to gently grasp the exit end of theassembly that seals against the scavenge line tubing.Pull the end out of the center section while using care toprevent damage to the screen or sealing surfaces.
Clean and inspect all parts prior to reinstallation.
When the assembly is installed, confirm the direction offlow to be correct. Observe the small arrow stamped inthe center section and ensure the direction flow to befrom the separator tank to the airend.
FIGURE 5.7-1 SEPARATOR TANK SCAVENGESCREEN/ORIFICE
SCREWHOUSING
SCREEN
O-RING
ORIFICE
34
RECOMMENDED BOLT TIGHTENINGCROSS PATTERN
5.8 COOLANT SEPARATOR ELEMENT
To check condition of separator element, runcompressor in full load mode and at rated pressureand select "SEPARATOR PRESSURE DROP" indisplay table. If display says "XX PSI", then nomaintenance is required. If warning light is on anddisplay says "CHG SEPR ELEMENT" then theseparator should be replaced.
Loosen the fitting that holds the scavenge tube into thetank and withdraw the tube assembly.
Disconnect blowdown valve from elbow in tank cover.
Disconnect tube from fitting on minimum pressurecheck valve. Loosen tube nut on same tube ataftercooler inlet then swing tube away from tank cover.
Use a suitable wrench and remove the bolts that holdthe tank cover in position. Remove cover by lifting up and away.
Carefully lift the separator element up and out of thetank. Discard the faulty element.
Clean the gasket surface on both the tank and itscover. Exercise care to prevent pieces of the oldgasket from falling down into the tank.
Check the tank to be absolutely certain that no foreign objects such as rags or tools have beenallowed to fall into the tank. Install replacement element down into the tank after checking the newelement gaskets for possible damage. Center theelement up within the tank.
Place the tank cover in its correct position and installbolts. Tighten the bolts in a cross-pattern (ReferenceFigure 5.8-1) to prevent over-tightening one side of thecover. An improperly tightened cover will likely result ina leak.
Tank Cover Bolt Torque Values
5/8 UNC 150 ft. Ib.(203 N-M)
Inspect tank scavenge screen and orifice. Clean ifnecessary following instructions in Section 5.7.
Install scavenge tube down into the tank until the tubejust touches the separator element. Tighten fittings.
Install the regulation lines in their original position.
Start unit, check for leaks, place in service.
FIGURE 5.8-1
WARNING!
High pressure air.Can cause severe injury or death.
Relieve pressure before removing filterplugs / caps, fittings or covers.
7
1
5
3
4
6
2
8
35
Coolant CoolersFollowing are instructions for removal and internalcleaning of coolant/aftercooler.
1) Remove right side panel.2) Remove 6 screws in right side plenum wall and
remove plenum wall.3) Remove 8 screws in left side plenum wall and remove
plenum wall.4) Remove hose from aftercooler discharge (right side)
and plug hole.5) Disconnect tube from aftercooler inlet (left side).
Loosen tube nut on opposite end of tube and rotatetube away. Plug hole in aftercooler.
6) Loosen hose nuts 1/4 turn on oil cooler inlet and outlethoses. This will allow hose fittings to swivel withoutcausing kink in hose.
7) Remove 6 screws in cooler support panel to allowcooler to swing out on hinges.
8) Cover opening that exposes fan and fan motor toensure water does not spray onto motors.
9) Before cleaning coolers, check to ensure allconnections are plugged to prevent contamination ofcompressor system.
10) After cleaning is complete, reassemble in reverse order.
11) Replace enclosure panels.
5.9-2 Water Cooled Coolers
Procedure
A periodic inspection and maintenance programshould be implemented for water cooled heatexchangers. The following steps should be taken.
1. Inspect filters in system and replace or clean asrequired.
2. Carefully examine tubes for scale and clean ifnecessary. If a cleaning solution is used, be sure towash out all chemicals thoroughly with clean waterbefore returning the compressor to service. Aftercleaning, examine the cooler for erosion or corrosion.
5.9 COOLER CORES: CLEANING
Ensure that the compressor is isolated from thecompressed air system by closing the isolation valveand venting pressure from the drip leg.
Ensure that the main power disconnect switch islocked open and tagged. (See Figure 5.9-1).
Tools Required■ Screwdriver■ Wrench set■ Air hose equipped with approved O.S.H.A. nozzle.
On units sold outside the U.S.A. consult local codes.
5.9-1 Air Cooled Coolers
ProcedureVisually check the outside of the cooler cores to becertain that a complete outside cleaning of the cooler isrequired. Frequently, dirt, dust or other foreign material,may only need to be removed with an air hose to remedythe problem.
When the cooler is covered with a combination ofoil, grease or other heavy substances that mayaffect the unit’s cooling, then it is recommendedthat the cooler cores be thoroughly cleaned on theoutside.
If it is determined that the compressor operatingtemperature is higher than normal due to the internalpassages of the cooler cores being restricted withdeposits or foreign material, then the cooler should beremoved for internal cleaning.
Strong cleaners can harm aluminum cooler parts. Follow cleaner
manufacturer’s instructions for use.
Wear appropriate safety equipment.
CAUTIONFIGURE 5.9-1 MAIN DISCONNECTLOCKED AND TAGGED
TAG
LEVER
KEY LOCK
HASP
!
Overgreasing can be a cause of bearing and motor failure. Make sure dirt and contaminants
are not introduced when adding grease.
CAUTION5.10 MOTOR LUBRICATION
The induction-type squirrel cage motors have antifrictionball or roller bearings front and rear. At periodic intervalsthey require relubrication.
NOTICE: 50 Hz TEFC motors have sealed bearingsthat do not require relubrication.
Improper lubrication can be a cause of motor bearingfailure. The quantity of grease added should be carefullycontrolled. The smaller motors must be greased with alesser amount of grease than larger motors.
When regreasing, stop motor. Disconnect power; lock outand tag. Remove outlet plugs (or spring-loaded greaserelief plugs if present). The outlet plug may not beaccessible on the fan end of some TEFC motors.
Grease should be added when the motor is stopped and power disconnected.
CAUTION
Procedure for relubrication
36
NOTICE
Motors MUST be greasedperiodically. See OperatorsManual for procedure.
395z70098
5.9-2 Water Cooled Coolers (Continued)
Cleaning
The interior tube surfaces can be cleaned by severalmethods. Flushing a high velocity stream of waterthrough the tubes will remove many forms of deposits.More severe deposits may require running wire brushesor rods through the tubes. Also, rubber plugs can beforced through the tubes if a special air or water gun isavailable for this procedure.
A qualified cleaning service should be used for thecleaning process. These organizations can evaluate thetype of deposit to be removed and supply theappropriate solution and method for a complete cleaningjob.
Precautions
When re-installing bonnets to cooler shell, tighten boltsuniformly in a cross-pattern. Overtightening can result incracking of bonnet.
Cleaning solutions must be compatible with metallurgyof cooler.
Care must be taken to avoid damaging tubes ifmechanical cleaning procedure is used.
* No greasing required (permanently lubricated bearings)
Lubricant Amount
Motor Frame Size in3 cc oz grams
56 a 145* -- -- -- --182 a 215 0.5 8 0.4 11254 a 286 1.0 16 0.8 23324 a 365 1.5 25 1.2 34404 a 449 2.5 40 2.0 57
Relubrication amount
!
!
37
5.10 MOTOR LUBRICATION (Continued)
Grease relief along shaft can occur, precluding necessityof removing this plug if inaccessible. The inlet grease gunfittings and outlet plugs (or spring-loaded reliefs) arelocated at each end of the motor housing. The drive endreliefs protrude out the circumference of the lower portionof the end bell near a flange bolt. The drive end outletplugs are located just behind the flange in the air intakearea at about the 5 or 6 o’clock position.
1) Free drain hole of any hard grease (use piece of wireif necessary).
2) Use a hand lever type grease gun. Determine inadvance the quantity of grease delivered with eachstroke of the lever. A graduated cylinder showingcubic centimeters (cc) may be used, or a 35mm filmcanister can give a close approximation for 2 cubicinches when filled.
3) Add the recommended volume of the recommendedlubricant. Do not expect grease to appear at theoutlet, but if it does, discontinue greasing atonce.
4) Run motor for about 30 minutes before replacing out-let plugs or reliefs. BE SURE TO SHUT MOTORDOWN, DISCONNECT POWER, LOCK OUT ANDTAG, AND REPLACE THESE DRAIN FITTINGS TOPRECLUDE LOSS OF NEW GREASE ANDENTRANCE OF CONTAMINANTS!
Use the grease as indicated on a special greaseinformation nameplate on the motor. Use of alternativegreases can result in shortened motor life due toincompatibility of greases.
Motor Bearing Maintenance (Stored Units)
To ensure that complete contact is maintained betweenthe motor bearings and the bearing grease on units to beplaced in storage for extended intervals, the followingmotor maintenance procedure should be adhered to:
1) Prior to placing a unit in storage, rotate the motorseveral revolutions by hand in the proper direction ofrotation.
2) Thereafter, rotate the motor as described in Step 1 atthree month intervals until such time as the unit isplaced in service.
3) If the storage time is to exceed a total of nine (9)months duration, the compressor must be orderedwith long term storage option.
WARNING!
Hazardous voltage. Can causesevere injury or death.
Disconnect power before servicing.Lockout/Tagout machine.
5.11 LONG TERM STORAGE
GeneralThe factory, upon special request, prepares compressorunits for long term storage. In such cases, a specialbulletin is supplied for storage and start-up procedures.
The bulletin provides special procedures for rotation andlubrication of compressors during storage.
Before actual start-up of the compressor, the unit mustbe drained of coolant containing vapor space inhibitors.Procedure for long term storage start-up is covered in thespecial bulletin 80440142.
5.12 COOLANT/LUBRICANT CHANGEOUT
Ingersoll Rand does not recommend changeout ofcoolant/lubricants, however, if a coolant/lubricantchange cannot be avoided, procedure APDD 106should be obtained from your Ingersoll Randrepresentative.
5.13 INTELLISYS REMOVAL
Ensure that the compressor is isolated from thecompressed air system by closing the isolationvalve and venting pressure from the drip leg.
Ensure that the main power disconnect switch islocked open and tagged (See Figure 5.13-1).
FIGURE 5.13-1 MAIN DISCONNECT LOCKED AND TAGGED
Follow these precautions to minimize damage fromstatic electricity. Static can cause severe damage tomicrocircuits.
1) Make the least possible movement to avoid build-ing up static electricity from your clothing or tools.
2) Discharge potential static electricity by touching (grounding) yourself to the starter box.
3) Handle circuit boards only by their edges.
4) Do not place the controller or power supply assembly on any metal surface.
5) Leave the replacement parts in their protective bags until ready for installation.
Tools:Screwdriver Size #1, flathead3/8 inch hex driver
Before removing any components, open the starter boxdoor and check all wiring for tightness. A loose wire orbad connection may be the cause of problems.
Controller Removal:
1) Open the starter box door.
2) Remove the five electrical plug-in connectors fromthe top of the controller.
3) Remove (2) mounting rails that attach theIntellisys® Controller at the side of the control box.
4) Remove the controller. Remove any option modules which must be installed in the newcontroller.
38
TAG
LEVER
KEY LOCK
HASP
39
5.14 COOLANT HOSES
The flexible hoses that carry coolant to and from the oilcooler may become brittle with age and will requirereplacement. Have your local Ingersoll Rand distributorreplace them every 2 years.
Ensure that the compressor is isolated from thecompressed air system by closing the isolation valveand venting pressure from the drip leg.
Ensure that the main power disconnect switch islocked open and tagged.
Removal
Remove enclosure panels.
Drain coolant into a clean container. Cover the containerto prevent contamination. If the coolant is contaminated,a new charge of coolant must be used.
Hold fitting securely while removing hose.
Installation
Install the new hoses and reassemble the package byreversing the disassembly procedure. Start thecompressor and check for leaks.
5.15 AIREND DISCHARGE HOSE
The flexible hose from the airend discharge to separatortank may become brittle with age and requirereplacement. Check this hose as per the maintenanceschedule in Section 5.1.
Removal
Ensure that the compressor is isolated from thecompressed air system by closing the isolation valveand venting pressure from the drip leg.
Ensure that the main power disconnect switch islocked and tagged.
50 & 60 HP (37-45 KW) Machines:
Disconnect hose nut from piping at each end ofdischarge hose and remove. Hold fittings securely whileremoving hose.
75 & 100 HP (55-75 KW) Machines:
Remove (4) bolts in flange at each end of dischargehose. Retain flanges and bolts for replacement.
5.16 FULID AND VIBRATION MONITORING
Ingersoll Rand recommends incorporating predictivemaintenance, specifically the use of coolant and vibrationanalysis, into all Preventative Maintenance programs.Predictive Maintenance is designed to increase systemreliability and prevent costly downtime. Through the useof sophisticated diagnostic tools, including fluid, vibration,and optional air analysis, Ingersoll Rand CertifiedService Technicians can identify and correct potentialproblems BEFORE they can cause expensiveunscheduled downtime.
How does predictive analysis work? By establishing aninitial baseline for normal operation, and then regularlymonitoring fluid and vibration conditions, any suddendeviation or significant increase from this baseline can beidentified and investigated to pinpoint the cause. Morequickly diagnosing potential problems can directly savemoney by preventing costly failures and reducing oreliminating downtime. In addition, regular conditionmonitoring also helps to maximize the time betweenexpensive preventative maintenance intervals, such ascomponent rebuilds and coolant changes.
5.17 COOLANT SAMPLING PROCEDURE
Bring unit up to operating temperature. Draw sample,using pump kit, from separator tank port. DO NOT drawsample from drain port or oil filter. Use a new hose onpump for each sample, failure to do this can give falsereadings.
100%
50%
OIL FILTER
40
6.0 TROUBLE SHOOTING CHART
TROUBLE CAUSE &/OR DISPLAY WHAT TO DOCompressor fails to start. 110/120V control voltage not available. — Check fuses. Check transformers and
"MAIN MTR OVER LD" or — Manually reset main or fan motor over-"FAN MTR OVERLOAD" load relay, and press "SET"button twice."PRES SENSOR FAIL" or — Check for defective sensor, bad sensor"TEMP SENSOR FAIL" connection, or broken sensor wires.
Compressor shuts down. "HIGH AIREND TEMP" — Insure that installation area hasadequate ventilation.
— Insure that cooling fan is operating. Ifnot reset circuit breaker inside starterbox.
NOTE: If a shutdown oc- "HIGH AIR PRESS" — Check for restricted or malfunctioningcurs, press the DISPLAY blowdown valve or minimum pressureSELECT button once to check valve.activate the L.E.D. display "LOW SUMP PRESS" — Check for air leak from tank ortable. Using the adjacent up blowdown piping.and down arrows, the values — Adjust sump pressure.displayed will be those im- "PRES SENSOR FAIL" or — Check for defective sensor, bad sensormediately preceding shut- "TEMP SENSOR FAIL" connection, or broken sensor wires.down. Use these valueswhen trouble shooting a "CK MOTOR ROTATION" — Interchange any two line connectionsproblem. (L1,L2,L3) at the starter.
Low system air pressure Compressor running in "Unload" Mode. — Press "UNLOAD/LOAD" button.
Controller off-line set point too low. — Press "UNLOAD/STOP" button, set off-line set point at a higher value.
Dirty air filter element. — Check filter condition. Replaceas required.
Air leak. — Check air system piping.
Moisture separator trap drain stuck open. — Inspect and repair.
Inlet valve not fully open. — Inspect and repair. Check controlsystem operation.
System demand exceeds compressor — Install larger or an additionaldelivery. compressor.
TROUBLE SHOOTING CHART (Continued)
TROUBLE CAUSE &/OR DISPLAY WHAT TO DO
High coolant Excessive coolant level. — Check level, lower if necessary byconsumption/coolant draining.in air system Plugged separator element. — Check separator pressure drop.
Separator element leak. — Check separator pressure drop. If low,replace element.
Plugged separator scavenge orifice/ — Remove and inspect orifice/screen.screen. Clean if required.
Compressor operating at low pressure — Operate at rated pressure.(75 psig / 5 barg) or below. — Reduce system load.
Coolant system leak. — Inspect and repair leaks.
Water in Air System Defective moisture separator/drain trap — Inspect and clean if required. Replaceseparator/trap if defective.
Trap drain or drain piping plugged. — Inspect and clean.
Aftercooler core dirty. — Inspect and clean.
Enclosure panels not in place. — Install enclosure panels.
Drain line/drip leg incorrectly installed. — Slope drain line away from trap. Installdrip leg.
No refrigerated or desiccant dryer in — Contact local Ingersoll Randair system. Distributor or Customer Center.
Excessive noise level Compressor defective. (Bearing — Contact authorized Distributor or Customerfailure or rotor contact.) Center immediately, do not operate
unit.Enclosure panels not in place. — Install enclosure panels.Loose component mounting. Inspect and tighten.
Excessive vibration Loose components — Inspect and tighten.
Motor or compressor bearing failure. — Contact authorized Distributor or CustomerCenter immediately, do not operateunit.
External sources. — Inspect area for other equipment.
Pressure relief valve opens Compressor operating over pressure. — Adjust Intellisys set points.
GLANDHAND Emergency Standby Air Hook Up. Complete with Necessary Fittingfor Protable of IR Rental Air Unit from Local IR Distributor
VALVE Water, Or Ball Type Valve
UNION Aids in Disconnecting Compressor from the System
PRESSURE GAUGE
THERMOMETER
DRIP LEG
MANOMETER
DIFFERENTAL PRESSURE INDICATOR
I-R AUTOMATIC DRAIN VALVE
FALSE LOADER Blows off Air Outside of Compressor Room
SYSTEM INSTRUMENTATION INCLUDES:Nephelometer; Hygrometer; Presure; Temperature
VENTILATION
AFTERCOOLER/SEPARATOR, ISOLATION VALVE, UNION, STRAINER AND TRAP
Motorized Louvers, Exhaust Fans
TOP
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8.0 WATER QUALITY RECOMMENDATIONS
Water quality is often overlooked when the coolingsystem of a water cooled air compressor is examined.Water quality determines how effective the heat transferrate, as well as the flow rate will remain during theoperation life of the unit. It should be noted that thequality of water used in any cooling system does notremain constant during the operation of the system. Thewater makeup is affected by evaporation, corrosion,chemical and temperature changes, aeration, scale, andbiological formations. Most problems in a cooling systemshow up first in a reduction in the heat transfer rate, thenin a reduced flow rate, and finally with damage to thesystem.
There are many constituents in the water system thatmust be balanced to have a good stable system. Thefollowing is a list of the major components that should bemonitored:
SCALEScale formation inhibits effective heat transfer, yet it doeshelp prevent corrosion. Therefore, a thin uniform coatingof calcium carbonate is desired on the inner surfaces.
Perhaps the largest contributor to scale formation is theprecipitation of calcium carbonate out of the water. This isdependent on temperature and pH. The higher the pHvalue the greater the chance of scale formation. Scalecan be controlled with water treatment.
CORROSIONIn contrast to scale formation is the problem of corrosion.Chlorides cause problems because of their size andconductivity. Low pH levels promote corrosion, as well ashigh levels of dissolved oxygen.
FOULINGBiological and organic substances (slime) can also causeproblems, but in elevated temperature environments suchas cooling processes, they are not major concerns. Ifthey create problems with clogging, commercial shocktreatments are available.
To ensure good operation life and performance of thecompressor cooling system, the recommendedacceptable ranges for different water constituents areincluded below:
PARAMETER
Corrosivity (hardness,pH, total dissolved solids,temperature at inlet,alkalinity)
Iron
Sulfate
Chloride
Nitrate
Silica
Dissolved oxygen
Oil and grease
Ammonia
CONCENTRATION
Langelier Index 0 to 1
< 2 ppm
< 50 ppm
< 50 ppm
< 2 ppm
< 100 ppm
0 ppm (as low as possible)
< 5 ppm
< 1 ppm
FREQUENCY OF ANALYSIS
Monthly (if stable for 3 to 4 months,
analyze quarterly)
Monthly
Monthly
Monthly
Monthly
Monthly
Daily (if stable, analyze weekly)
Monthly
Monthly
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Recommended equipment for on-site analysis includes athermometer, pH meter, and dissolved oxygen meter.Dissolved oxygen and temperature must be measuredon-site and it is recommended that pH be measuredon-site. All other analyses should be performed by aprofessional water quality analyst. The Langelier Index(Ll) is calculated using the following equation and thetables found on the following pages.
Ll = pH - (9.30 + Total Dissolved Solids chart value +Temperature chart value ) + Hardness chart valve +Alkalinity chart value)
The Ll is zero when the water is in chemical balance. Ifthe Ll is greater than zero, there is a tendency to formscale. If the Ll is less than zero, the water tends to becorrosive.
Dissolved oxygen may be controlled in closed coolingtowers. Several types of treatments are commerciallyavailable to remove dissolved oxygen. For open coolingtowers, dissolved oxygen is not an easily controlledparameter. Also, a filtration system is recommended forthe water going into the air compressor when using anopen cooling tower.
It should be noted that Ingersoll Rand’s guidelines andrecommendations should be used in evaluating the watersystems and the problems that may occur in the normaloperation of our air compressors. If water problemspersist or are not covered above, you should consult aprofessional.
