R90-150 Manual de Operador

R 90160 IUOPERATION AND MAINTENANCE MANUAL

This manual contains important safety information and must be made available to personnel who operate and maintain this machine.

ENGLISH

ESTONIAN

HUNGARIAN

NORWEGIAN

SLOVAK

BULGARIANCZECH

FINNISHFRENCH

ITALIANLATVIAN

POLISHPORTUGUESE

SLOVENIANSPANISH

DANISH

GERMAN

LITHUANIAN

ROMANIAN

SWEDISH

C.C.N. REV. DATE

: 80443054 :A : JULY 2007

DUTCH

GREEK

MALTESE

RUSSIAN

AIR COMPRESSOR GROUP 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 months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be obligated to promptly report 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. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment in accordance with good industry practices and has complied with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser or others without Companys 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 Companys proposal. Unless responsibility for meeting such performance warranties are limited to specified tests, the Companys obligation shall be to correct in the manner and for the period of time provided above. THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED. Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time provided above, shall constitute fulfilment of all liabilities of the Company for such nonconformities whether based on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment. The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in writing of its intention to do so. Any such use of Equipment will be at Purchasers sole risk and liability. Note that this is IngersollRand standard warranty. Any warranty in force at the time of purchase of the compressor or negotiated as part of the purchase order may take precedence over this warranty.

Register online at air.irco.com/registration.htmIngersollRand Industrial Air Solutions Swan Lane Hindley Green Wigan WN2 4EZ

Ingersoll Rand Asia Pacific C/O IngersollRand South East Asia (Pte) Ltd. 42 Benoi Road Singapore 629903

IngersollRand Industrial Air Solutions P.O. Box 1840 800D Beaty Street Davidson, NC 28036

CONTENTS & ABBREVIATIONSCONTENTS 1 2 3 8 9 11 38 44 49 52 CONTENTS FOREWORD ISO SYMBOLS DECALS SAFETY GENERAL INFORMATION INSTALLATION / HANDLING OPERATING INSTRUCTIONS MAINTENANCE FAULT FINDING #### ABBREVIATIONS & SYMBOLS Contact Ingersoll Rand for serial number

1

>#### Up to Serial No. ####> From Serial No. * NR AR HA WC AC ERS ppm Not illustrated Option Not required As required High ambient machine Watercooled machine Aircooled machine Energy recovery system parts per million

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FOREWORDTABLE 1 Use of the machine to produce compressed air for: a) direct human consumption b) indirect human consumption, without suitable filtration and purity checks. Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION of this manual. Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or vapours. THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES, INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR VAPOURS MAY BE PRESENT. Use of the machine fitted with non Ingersoll Rand approved components. Use of the machine with safety or control components missing or disabled. Connection to an electrical supply of incorrect voltage and/or frequency. The company accepts no responsibility for errors in translation of this manual from the original English version. ULTRA COOLANT is a registered trademark of IngersollRand Company USA. INTELLISYS is a registered trademark of IngersollRand Company USA.

The contents of this manual are considered to be proprietary and confidential to Ingersoll Rand and should not be reproduced without the prior written permission of Ingersoll Rand. Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll Rand products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such products, which are available upon request. This manual contains instructions and technical data to cover all routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be referred to an authorised Ingersoll Rand service department. Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European Union Territories require that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid. All components, accessories, pipes and connectors added to the compressed air system should be: . of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Ingersoll Rand. . clearly rated for a pressure at least equal to the machine maximum allowable working pressure. . compatible with the compressor lubricant/coolant. . accompanied with instructions for safe installation, operation and maintenance. Details of approved equipment are available from Ingersoll Rand Service departments. The use of repair parts other than those included within the Ingersoll Rand approved parts list may create hazardous conditions over which Ingersoll Rand has no control. Therefore Ingersoll Rand cannot be held responsible for equipment in which nonapproved repair parts are installed. Ingersoll Rand reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. The intended uses of this machine are outlined below and examples of unapproved usage are also given, however Ingersoll Rand cannot anticipate every application or work situation that may arise. IF IN DOUBT CONSULT SUPERVISION. This machine has been designed and supplied for use only in the following specified conditions and applications: . Compression of normal ambient air containing no known or detectable additional gases, vapours. or particles . Operation within the ambient temperature range specified in the GENERAL INFORMATION section of this manual. The use of the machine in any of the situation types listed in table 1: a) Is not approved by Ingersoll Rand, b) May impair the safety of users and other persons, and c) May prejudice any claims made against Ingersoll Rand.

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ISO SYMBOLSGRAPHIC FORM AND MEANING OF ISO SYMBOLS

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Prohibition / Mandatory

Information / Instructions

Warning

WARNING: Electrical shock risk.

WARNING Pressurised component or system.

WARNING Hot surface.

WARNING Pressure control.

WARNING Corrosion risk.

WARNING Air/gas flow or Air discharge.

X,XWARNING Pressurised vessel. WARNING Hot and harmful exhaust gas.

BAR

WARNING Maintain correct tyre pressure. (Refer to the GENERAL INFORMATION section of this manual).

0_C

WARNING Flammable liquid.

WARNING Before connecting the tow bar or commencing to tow consult the operation and maintenance manual.en

WARNING For operating temperature below 0_C, consult the operation and maintenance manual.R 90160 IU

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ISO SYMBOLS

WARNING Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved.

WARNING Consult the operation and maintenance manual before commencing any maintenance.

Do not breathe the compressed air from this machine.

Do not remove the Operating and Maintenance manual and manual holder from this machine.

Do not stack.

Do not operate the machine without the guard being fitted.

Do not stand on any service valve or other parts of the pressure system.

Do not operate with the doors or enclosure open.

Do not use fork lift truck from this side.

XX km/h Do not open the service valve before the airhose is attached.

Do not exceed the trailer speed limit.

No naked lights.

Use fork lift truck from this side only.

Emergency stop.

Tie down point

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ISO SYMBOLS

5

Lifting point.

On (power).

Off (power).

aRead the Operation and Maintenance manual before operation or maintenance of this machine is undertaken. When parking use prop stand, handrake and wheel chocks. Contains asbestos.

SET

SEQUENCER STATUS

LOAD

SEQUENCER (AUTOMATIC CONTROL)

COMPRESSOR

OFF LOAD (UNLOADED)

RESET

COMPRESSOR STATUS

MODULATE

MALFUNCTION

POWER

SOILED FILTER

POWER INLET

ELECTRIC MOTOR

HOURS

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ISO SYMBOLS

COOLANT SEPARATOR

PRESSURE

AIR DISCHARGE

PRESSURISED TANK

ON / OFF CYCLE

COOLANT FILTER

AIR FILTER

ON / OFF PUSH BUTTON

COOLANT PRESSURE

AIR PRESSURE

STAR DELTA IEC 6177

AUTOMATIC RESTART

HEAT EXCHANGER

MAINTENANCE

MAINTENANCE PROHIBITED

COOLANT DRAIN

CONDENSATE DRAIN

PRESSURE CONTROL

MANUAL (SELECT)

TEMPERATURE

HIGH TEMPERATURE

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ISO SYMBOLS

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BELT TENSION

FILTER

MOTOR LUBRICATION

FRAGILE

KEEP DRY

THIS WAY UP

USE NO HOOKS

NO SIDE CLAMPS

ROTATION

POWER INLET (AC)

WATER IN

WATER OUT

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DECALS (I.S.O.)

Item 1 2 3 4 5 6 7 8 9 10 11 12

ccn 23038474 92867407 92867498 93166486 92867522 92867530 93165983 93166478 93187813 92930585 92930593

Qty. 4 1 1 1 1 2 3 2 1 1 1 1

Description Decal, Ingersoll Rand logo Decal, do not inhale Decal, air discharge Decal, power inlet Plate, data Decal, warning maintenance Decal, hot surface Decal, rotation arrow notice Decal, condensate drain Decal, motor lubrication Decal, warning pressurized vessel Decal, electric shock

Item 13 14 15 16 17 18 19 20 21 22

ccn 93165967 93166494 93166502 23116452 93557510 93166403 93166411 92930627 93165959 93166460

Qty. 1 1 1 1 1 1 1 1 1 1

Description Decal, cold start/maintenance Decal, caution ultracoolant Decal, replacement filter element Decal, Intellisys S3 facia Decal, auto remote start/stop Decal, water in Decal, water out Decal, general warning Decal, use guards when running Decal, coolant drain

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SAFETYWARNINGS Warnings call attention to instructions which must be followed precisely to avoid injury or death. CAUTIONS Cautions call attention to instructions which must be followed precisely to avoid damaging the product, process or its surroundings. NOTES Notes are used for supplementary information.

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WARNING Imposing a normal or emergency stop on the compressor will only relieve pressure upstream of the minimum pressure valve on top of the separator tank. If maintenance work is required downstream of this valve, ensure that all pressure is relieved at the process vent point external to the compressor This state is advised by selecting PACKAGE DISCHARGE PRESSURE on the control panel. Avoid bodily contact with compressed air.

General Information Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the Operation and Maintenance manual, and the manual holder, are not removed permanently from the machine. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals. Compressed air and electricity can be dangerous. Before undertaking any work on the compressor, ensure that the electrical supply has been isolated and the compressor has been relieved of all pressure. Make sure that all protective covers are in place and that the canopy/doors are closed during operation. Installation of this compressor must be in accordance with recognised electrical codes and any local Health and Safety Codes. The use of plastic bowls on line filters without metal guards can be hazardous. Their safety can be affected by either synthetic lubricants, or the additives used in mineral oils. Metal bowls should be used on a pressurised system. Compressed air Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel. All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine rated pressure. If more than one compressor is connected to one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidentally be pressurised / over pressurised by another. Compressed air must not be used for a direct feed to any form of breathing apparatus or mask. The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible. If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided. When using compressed air always use appropriate personal protective equipment. All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions. The safety valve located in the separator tank must be checked periodically for correct operation. Materials The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: . preservative grease . rust preventative . compressor coolant AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES For further information, consult Material Data Sheets ACGP 011/96 (ULTRA COOLANT) and IRACA145 (food grade coolant). Should compressor lubricant come into contact with the eyes, then irrigate with water for at least 5 minutes. Should compressor lubricant come into contact with the skin, then wash off immediately. Consult a physician if large amounts of compressor lubricant are ingested. Consult a physician if compressor lubricant is inhaled. Never give fluids or induce vomiting if the patient is unconscious or having convulsions. Transport When loading or transporting machines ensure that the specified lifting and tie down points are used. Electrical Keep all parts of the body and any handheld tools or other conductive objects, away from exposed live parts of the compressor electrical system. Maintain dry footing, stand on insulating surfaces and do not contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the compressor electrical system. Close and lock all access doors when the compressor is left unattended. Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only extinguishers suitable for class BC or class ABC fires. Attempt repairs only in clean, dry, well lighted and ventilated areas. Connect the compressor only to electrical systems that are compatible with its electrical characteristics and that are within its rated capacity.

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SAFETY

Condensate disposal Condensate cannot be discharged into fresh/surface water drains. In some regions compressor condensate containing ULTRA COOLANT can be fed directly into a drainage system that has downstream sewerage treatment. As waste water regulations vary by country and region it is the responsibility of the user to establish the limitations and regulations in their particular area. Ingersoll Rand and its associated distributors are happy to advise and assist in these matters. Coolant disposal Steps to be taken in the case of spillage: Soak up with a suitable absorbent material, then sweep into a plastic bag for disposal. Burn in an approved incinerator, or according to local area or country regulations. For further information, consult Material Data Sheets: ULTRA COOLANT 80440043 (en) 88309612 (EU) 80440068 (es) 80440050 (pt)

XTEND FOOD GRADE COOLANT 80442254

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GENERAL INFORMATION

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PROCESS AND INSTRUMENTATION DIAGRAM KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. Air discharge Compressor Air filter Vacuum switch 1VAC Cooler, air Cooler, coolant Condensate discharge Coolant filter Pressure switch, coolant filter 1DPSen R 90160 IU

10. Drain valve, coolant 11. Load valve 1SV 12. Air inlet check valve 13. Electronic drain trap 14. Minimum pressure check valve 15. Moisture separator 16. Pressure transducer 4APT 17. Pressure relief valve

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GENERAL INFORMATIONPIPING LEGEND A. B. C. D. E. F. G. H. Air/coolant Air Coolant Condensate Cooling water (W.C. only) Compressor enclosure Sensor connection Modulation

18. Scavenge filter / orifice / check 19. Separator tank (primary/secondary) 20. Oil temperature control valve 21. Temperature thermistor 2ATT 22. 3SV blowdown solenoid valve 23. Drive motor 24. Fan motor 25. Cooling fan 26. Cooling water inlet (W.C. only) 27. Cooling water outlet (W.C. only) 28. Pressure transducer 3APT 29. Water stop valve 4SV 30. Modulation valve 6SV 31. Modulation valve 5SV 32. Regulator 33. Shuttle valve 34. Ball valve M(o)Modulation (optional)

NOTES 1. 2. For customer connection sizes and locations see foundation plan of unit. Post filter must be supplied by customer.

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GENERAL INFORMATIONGENERAL OPERATION The compressor is an electric motor driven, single stage screw compressor, complete with accessories piped, wired and baseplate mounted. It is a totally self contained air compressor package. The standard compressor is designed to operate in an ambient range of 2_C to 46_C (35_F to 115_F). The standard maximum temperature of 46_C (115_F) is applicable up to an elevation of 1000m (3280ft) above sea level. Above this altitude significant reductions in ambient temperature are required if a standard motor is to be used. Compression in the screw type air compressor is created by the meshing of two (male & female) helical rotors. The air/coolant mixture discharges from the compressor into the separation system. This system removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the cooling system and the air passes to the aftercooler and out of the compressor through the moisture separator (optional). Air is pulled into the machine by the cooling fan and is pushed through the combined cooler / aftercooler. By cooling the discharge air and passing it through the separator, much of the water vapour which is naturally present in the air, can be removed. The coolant system consists of a sump, cooler, thermostatic valve and a filter. When the unit is operating, the coolant is pressurised and forced to the compressor bearings. The compressor load control system is automatic OnOff line. The compressor will operate to maintain a set discharge line pressure and is provided with an auto restart system for use in plants where the air demand varies widely. Panel instrumentation is provided to indicate the compressor operating conditions and general status. CAUTION LOW DEMAND APPLICATIONS During periods of low demand, the compressor may not reach its normal operating temperature. Sustained operation at low demand can result in the build up of condensate in the coolant. If this situation occurs, the lubricating characteristics of the coolant can be impaired which may lead to damage of the compressor. THE COMPRESSOR SHOULD BE ALLOWED AMPLE LOADED RUNNING TIME. OPTIONAL FEATURES

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Modulation hardware extends the control types to Modulation (capacity control) and Automatic Control System when the compressor switches between OnOff line and modulation as demand varies. Safety of operation is provided for as the compressor will shut down if excessive temperatures, electrical overload conditions, or system over pressure should occur. Low Ambient Option (Standard & Enhanced Compressors) When the low ambient option is installed and selected and the A/E Discharge Temperature is measured to be at or below 2_C (35_F), the compressor will be started when commanded but will delay to load a period of time defined by the Low Ambient Delay Time. This will allow the coolant temperature to rise above an allowable level before loading the compressor in cold environments. When the low ambient option is not installed, the machine will not start if the A/E Discharge Temperature is below 2_C (35_F). CAUTION If PORO or Scheduled Start / Stop are installed, additional hardware is required to provide an audible warning of pending restart. Contact IR for details. Power Out Restart Option (PORO) (Dependant on installed options and/or installed controls) For PORO to execute, the PORO option must be installed and the PORO set point must be set to ON. If power is lost to the compressor while the unit is running or is stopped in auto start/stop, the controller will store the current operating conditions in memory. When power is restored, the controller will energize the horn and start a countdown on the display. The red LED will flash indicating a warning condition and the horn will blow for the number of seconds set in the PORO time set point. At the end of the countdown, the horn will stop blowing and the compressor will start. The PORO countdown may be stopped at any time by pressing the Stop / Reset button on the user interface. Pressing any button will cause the horn to stop blowing and the countdown to stop. The control will power up normally in a ready to start mode. Scheduled Start / Stop (Dependant on installed options and/or installed controls) The scheduled start / stop option enables starting and stopping the compressor at specified times. This mode of operation can be turned on and off by selecting the desired mode in the Scheduled Start Stop On / Off Setpoint. When enabled, the horn will blow for 10 seconds to warn anyone in the surrounding area that the compressor is about to start. The display screen will display the warning message Scheduled Start in X seconds, where X is a countdown from 10 to 0 seconds. After 10 seconds, the compressor will automatically start as long as the compressor is not in a fault condition or manually stopped by pressing the stop / reset button. When a scheduled stop occurs, the compressor can be manually restarted by pressing the control panel start button or closing the remote start signal.

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GENERAL INFORMATIONR90IU100 R90IU125 R90IU140

ROTARY 125 HP 60 Hz GENERAL COMPRESSOR DATA Capacity FAD (1) Compressor Power Full Load Rated Package Discharge Pressure Maximum Off Line Pressure Minimum Reload Pressure Rotor Diameter Male Rotor Speed COOLING DATA GENERAL 115_F MAXIMUM AMBIENT Operating Temperature Airend Injection Temperature Heat Removal Oil Cooler Oil Cooler and After Cooler Oil Flow AFTERCOOLED DATA Aftercooler CTD (2) Fan Air Flow Maximum Added Static Pressure WATERCOOLED DATA Aftercooler CTD (2) Cooling Water Required (recommend 2560 GPM (95227 litres / min)) @ 50_F (10_C) @ 70_F (21_C) @ 90_F (32_C) @ 115_F (46_C) Water Temperature Rise Water Pressure Drop @ max flow rate condition (50 deg F water) Oil Cooler Oil Cooler and After Cooler Fan Air Flow Maximum Added Static Pressure LUBRICATION DATA Sump Capacity Total Lubrication System Capacity SOUND LEVELS Aircooled Watercooled dB(A) dB(A) USgal (litres) USgal (litres) psid(bar) psid(bar) CFM (m3/min) in (mm) H2O GPM (litres / min) GPM (litres / min) GPM (litres / min) GPM (litres / min) _F (_C) _F (_C) _F (_C) CFM (m3/min) in (mm) H2O 1000 BTU/hr (1000 kJ/hr) 1000 BTU/hr (1000 kJ/hr) GPM (litres / min) _F (_C) _F (_C) CFM (m3/min) bhp (kW) psig (barg) psig (barg) psig (barg) mm RPM

647 (18.3) 137.5 (102.5) 100 (6.9) 103 (7.1) 65 (4.5) 226 1,804

563 (15.9) 137.5 (102.5) 125 (8.6) 128 (8.8) 65 (4.5) 226 1,612

511 (14.5) 137.5 (102.5) 140 (9.7) 143 (9.9) 65 (4.5) 226 1,496

204 (96) 172 (78) 307 (324) 389 (410) 40 (151)

201 (94) 172 (78) 316 (333) 390 (411) 45 (170)

200 (93) 172 (78) 321 (339) 389 (410) 47 (178)

15 (8) 13,000 (368) 0.25 (6.4)

15 (8) 13,000 (368) 0.25 (6.4)

15 (8) 13,000 (368) 0.25 (6.4)

25 (14)

25 (14)

25 (14)

35 (132) 33 (125) 31 (117) 28 (106) 25 (14)

34 (129) 33 (125) 31 (117) 29 (110) 25 (14)

35 (132) 32 (121) 31 (117) 29 (110) 25 (14)

1.9 (0.13) 0.36 (0.02) 4,000 (113) 0.25 (6.4)

2.0 (0.14) 0.30 (0.02) 4,000 (113) 0.25 (6.4)

2.1 (0.14) 0.32 (0.02) 4,000 (113) 0.25 (6.4)

16 (61) 25 (95)

16 (61) 25 (95)

16 (61) 25 (95)

75 70

75 70

75 70

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GENERAL INFORMATIONPACKAGE DATA PACKAGE DIMENSIONS (3) L x W x H Discharge Air Connection NPT (Female) Water Inlet & Outlet NPT (Female) ELECTRICAL DATA (4) Full Load Power Drive Motor Full Load Power Fan Motor Full Load Power Package Full Load Amps Drive Motor Full Load Amps Fan Motor (Aircooled) Full Load Amps Fan Motor (Watercooled) Full Load Amps Package (Aircooled) Full Load Amps Package (Watercooled) Fan Motor Horsepower (Watercooled) Drive Motor RPM Drive Motor Frame Size: IP55 (IEC 60034) Drive Motor Locked Rotor Amps (5) Drive Motor Efficiency Drive Motor Power Factor NOTES: (1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996. Amps % bhp (kW) bhp (kW) bhp (kW) Amps Amps Amps Amps Amps bhp (kW) RPM Inch (mm) Inch Inch 102.5 (2600) 2.5 1.5 380V 137.5 (102.5) 8.3 (6.2) 145.8 (108.7) 182.9 11.4 2.0 194.3 184.9 1.0 (0.75) 1780 280M1 1,198 94.5 0.85 65.5 (1661) 2.5 1.5 460V 137.5 (102.5) 8.3 (6.2) 145.8 (108.7) 144.5 9.4 1.6 153.9 146.1 1.0 (0.75) 1780 280M1 1,182 95.5 0.89

152.5 1.5 575V

92 (2330)

137.5 (102.5) 8.3 (6.2) 145.8 (108.7) 120.9 7.5 1.3 128.4 122.2 1.0 (0.75) 1780 280M1 791 94.5 0.85

(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures. Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity. (3) For weights, and piping connection positions, see general arrangement drawings 23057581 (aircooled), 23057573 (watercooled). (4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others. (5) Star Delta starting current inrush is 33% of full voltage KVA inrush.

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783 (22.2) 165 (123.0) 100 (6.9) 103 (7.1) 65 (4.5) 226 2,175

690 (19.5) 165 (123.0) 125 (8.6) 128 (8.8) 65 (4.5) 226 1,944

618 (17.5) 165 (123.0) 140 (9.7) 143 (9.9) 65 (4.5) 226 1,803

214 (101) 176 (80) 360 (380) 468 (494) 40 (151)

211 (99) 176 (80) 371 (391) 468 (494) 45 (170)

210 (99) 176 (80) 379 (400) 467 (493) 47 (178)

15 (8) 13,000 (368) 0.25 (6.4)

15 (8) 13,000 (368) 0.25 (6.4)

15 (8) 13,000 (368) 0.25 (6.4)

25 (14)

25 (14)

25 (14)

41 (155) 40 (151) 37 (140) 34 (129) 25 (14)

41 (155) 39 (148) 37 (140) 34 (129) 25 (14)

40 (151) 39 (148) 37 (140) 35 (132) 25 (14)

2.6 (0.18) 0.52 (0.04) 4,000 (113) 0.25 (6.4)

2.8 (0.19) 0.45 (0.03) 4,000 (113) 0.25 (6.4)

2.9 (0.20) 0.39 (0.03) 4,000 (113) 0.25 (6.4)

16 (61) 25 (95)

16 (61) 25 (95)

16 (61) 25 (95)

75 70

75 70

75 70

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GENERAL INFORMATIONPACKAGE DATA PACKAGE DIMENSIONS (3) L x W x H Discharge Air Connection NPT (Female) Water Inlet & Outlet NPT (Female) ELECTRICAL DATA (4) Full Load Power Drive Motor Full Load Power Fan Motor Full Load Power Package Full Load Amps Drive Motor Full Load Amps Fan Motor (Aircooled) Full Load Amps Fan Motor (Watercooled) Full Load Amps Package (Aircooled) Full Load Amps Package (Watercooled) Fan Motor Horsepower (Watercooled) Drive Motor RPM Drive Motor Frame Size: IP55 (IEC 60034) Drive Motor Locked Rotor Amps (5) Drive Motor Efficiency Drive Motor Power Factor NOTES: (1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996. Amps % bhp (kW) bhp (kW) bhp (kW) Amps Amps Amps Amps Amps bhp (kW) RPM Inch (mm) Inch Inch 102.5 (2600) 2.5 1.5 380V 165 (123.0) 8.3 (6.2) 173.3 (129.2) 220.0 11.4 2.0 231.4 222.0 1.0 (0.75) 1780 280M2 1,379 95.0 0.85 65.5 (1661) 2.5 1.5 460V 165 (123.0) 8.3 (6.2) 173.3 (129.2) 177.1 9.4 1.6 186.5 178.7 1.0 (0.75) 1780 280M2 1,592 95.2 0.87

172.5 1.5 575V

92 (2330)

165 (123.0) 8.3 (6.2) 173.3 (129.2) 145.0 7.5 1.3 152.5 146.3 1.0 (0.75) 1780 280M2 911 95.0 0.85


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1004 (28.4) 220 (164.1) 100 (6.9) 103 (7.1) 65 (4.5) 226 2,740

875 (24.8) 220 (164.1) 125 (8.6) 128 (8.8) 65 (4.5) 226 2,439

837 (23.7) 220 (164.1) 140 (9.7) 143 (9.9) 65 (4.5) 226 2,347

215 (102) 176 (80) 481 (507) 622 (656) 50 (189)

213 (101) 176 (80) 497 (524) 623 (657) 56 (212)

212 (100) 176 (80) 502 (530) 623 (657) 59 (223)

15 (8) 13,000 (368) 0.25 (6.4)

15 (8) 13,000 (368) 0.25 (6.4)

15 (8) 13,000 (368) 0.25 (6.4)

25 (14)

25 (14)

25 (14)

55 (208) 53 (201) 50 (189) 46 (174) 25 (14)

54 (204) 52 (197) 50 (189) 46 (174) 25 (14)

54 (204) 52 (197) 50 (189) 46 (174) 25 (14)

4.3 (0.30) 0.77 (0.05) 4,000 (113) 0.25 (6.4)

4.5 (0.31) 0.66 (0.05) 4,000 (113) 0.25 (6.4)

4.6 (0.32) 0.63 (0.04) 4,000 (113) 0.25 (6.4)

16 (61) 25 (95)

16 (61) 25 (95)

16 (61) 25 (95)

75 70

75 70

75 70

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R 90160 IU

GENERAL INFORMATIONPACKAGE DATA PACKAGE DIMENSIONS (3) L x W x H Discharge Air Connection NPT (Female) Water Inlet & Outlet NPT (Female) ELECTRICAL DATA (4) Full Load Power Drive Motor Full Load Power Fan Motor Full Load Power Package Full Load Amps Drive Motor Full Load Amps Fan Motor (Aircooled) Full Load Amps Fan Motor (Watercooled) Full Load Amps Package (Aircooled) Full Load Amps Package (Watercooled) Fan Motor Horsepower (Watercooled) Drive Motor RPM Drive Motor Frame Size: IP55 (IEC 60034) Drive Motor Locked Rotor Amps (5) Drive Motor Efficiency Drive Motor Power Factor NOTES: (1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996. Amps % bhp (kW) bhp (kW) bhp (kW) Amps Amps Amps Amps Amps bhp (kW) RPM Inch (mm) Inch Inch 102.5 (2600) 2.5 1.5 380V 220 (164.1) 8.3 (6.2) 228.3 (170.2) 316.3 11.4 2.0 327.7 318.3 1.0 (0.75) 1780 315M2 1,984 95.0 0.79 65.5 (1661) 2.5 1.5 460V 220 (164.1) 8.3 (6.2) 228.3 (170.2) 245.2 9.4 1.6 254.6 246.8 1.0 (0.75) 1780 315M2 2,126 95.5 0.84

192.5 1.5 575V

92 (2330)

220 (164.1) 8.3 (6.2) 228.3 (170.2) 209.0 7.5 1.3 216.5 210.3 1.0 (0.75) 1780 315M2 1,311 95.0 0.79


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R 90160 IU

20

GENERAL INFORMATIONR90IU7.5 R90IU8.5 R90IU10

ROTARY 90 kW 50 Hz GENERAL COMPRESSOR DATA Capacity FAD (1) Compressor Power Full Load Rated Package Discharge Pressure Maximum Off Line Pressure Minimum Reload Pressure Rotor Diameter Male Rotor Speed COOLING DATA GENERAL 46_C MAXIMUM AMBIENT Operating Temperature Airend Injection Temperature Heat Removal Oil Cooler Oil Cooler and After Cooler Oil Flow AFTERCOOLED DATA Aftercooler CTD (2) Fan Air Flow Maximum Added Static Pressure WATERCOOLED DATA Aftercooler CTD (2) Cooling Water Required (recommend 95227 litres / min (2560 GPM)) @ 50_F (10_C) @ 70_F (21_C) @ 90_F (32_C) @ 115_F (46_C) Water Temperature Rise Water Pressure Drop @ max flow rate condition (10 deg C water) Oil Cooler Oil Cooler and After Cooler Fan Air Flow Maximum Added Static Pressure LUBRICATION DATA Sump Capacity Total Lubrication System Capacity SOUND LEVELS Aircooled Watercooled dB(A) dB(A) litres (USgal) litres (USgal) bar (psid) bar (psid) m3/min (CFM) mm (in) H2O litres / min (GPM) litres / min (GPM) litres / min (GPM) litres / min (GPM) _C (_F) _C (_F) _C (_F) m3/min (CFM) mm (in) H2O 1000 kJ/h (1000 BTU/h) 1000 kJ/h (1000 BTU/h) litres / min (GPM) _C (_F) _C (_F) m3/min (CFM) kW (bhp) barg (psig) barg (psig) barg (psig) mm RPM

16.7 (590) 99 (133) 7.5 (109) 7.7 (112) 4.5 (65) 226 1,693

15.3 (540) 99 (133) 8.5 (123) 8.7 (126) 4.5 (65) 226 1,513

14.0 (495) 99 (133) 10.0 (145) 10.2 (148) 4.5 (65) 226 1,404

95 (203) 78 (172) 315 (299) 399 (378) 151 (40)

93 (200) 78 (172) 324 (307) 398 (377) 151 (45)

93 (200) 78 (172) 328 (311) 398 (377) 151 (47)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

14 (25)

14 (25)

14 (25)

125 (33) 121 (32) 114 (30) 102 (27) 14 (25)

129 (34) 121 (32) 114 (30) 106 (28) 14 (25)

129 (34) 117 (31) 114 (30) 106 (28) 14 (25)

0.12 (1.7) 0.02 (.33) 113 (4,000) 6.4 (0.25)

0.13 (1.9) 0.02 (.32) 113 (4,000) 6.4 (0.25)

0.13 (1.9) 0.02 (.32) 113 (4,000) 6.4 (0.25)

61 (16) 95 (25)

61 (16) 95 (25)

61 (16) 95 (25)

75 70

75 70

75 70

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R 90160 IU

GENERAL INFORMATIONPACKAGE DATA PACKAGE DIMENSIONS (3) L x W x H Discharge Air Connection BSPT (Female) Water Inlet & Outlet BSPT (Female) ELECTRICAL DATA (4) Full Load Power Drive Motor Full Load Power Fan Motor Full Load Power Package Full Load Amps Drive Motor Full Load Amps Fan Motor (Aircooled) Full Load Amps Fan Motor (Watercooled) Full Load Amps Package (Aircooled) Full Load Amps Package (Watercooled) Fan Motor Horsepower (Watercooled) Drive Motor RPM Drive Motor Frame Size: IP55 (IEC 60034) Drive Motor Locked Rotor Amps (5) Drive Motor Efficiency Drive Motor Power Factor NOTES: (1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996. Amps % kW (bhp) kW (bhp) kW (bhp) Amps Amps Amps Amps Amps kW (bhp) RPM mm (Inch) Inch Inch 2600 (102.5) 2.5 1.5 380V 99.0 (132.8) 5.5 (7.4) 104.5 (140.2) 177.5 10.7 1.9 188.2 179.4 0.75 (1.0) 1485 280M1 1,278 93.9 0.85 1661 (65.5) 2.5 1.5 400V 99.0 (132.8) 5.5 (7.4) 104.5 (140.2) 172.9 10.7 1.9 183.6 174.8 0.75 (1.0) 1485 280M1 1,245 93.9 0.87

212.5 1.5 415V

2330 (92)

99.0 (132.8) 5.5 (7.4) 104.5 (140.2) 164.6 10.7 1.9 175.3 166.5 0.75 (1.0) 1485 280M1 1,186 93.9 0.84


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R 90160 IU

22


ENHANCED ROTARY 90 kW 50 Hz GENERAL COMPRESSOR DATA Capacity FAD (1) Compressor Power Full Load Rated Package Discharge Pressure Maximum Off Line Pressure Minimum Reload Pressure Rotor Diameter Male Rotor Speed COOLING DATA GENERAL 46_C MAXIMUM AMBIENT Operating Temperature Airend Injection Temperature Heat Removal Oil Cooler Oil Cooler and After Cooler Oil Flow AFTERCOOLED DATA Aftercooler CTD (2) Fan Air Flow Maximum Added Static Pressure WATERCOOLED DATA Aftercooler CTD (2) Cooling Water Required (recommend 95227 litres / min (2560 GPM)) @ 50_F (10_C) @ 70_F (21_C) @ 90_F (32_C) @ 115_F (46_C) Water Temperature Rise Water Pressure Drop @ max flow rate condition (10 deg C water) Oil Cooler Oil Cooler and After Cooler Fan Air Flow Maximum Added Static Pressure LUBRICATION DATA Sump Capacity Total Lubrication System Capacity SOUND LEVELS Aircooled Watercooled dB(A) dB(A) litres (USgal) litres (USgal) bar (psid) bar (psid) m3/min (CFM) mm (in) H2O litres / min (GPM) litres / min (GPM) litres / min (GPM) litres / min (GPM) _C (_F) _C (_F) _C (_F) m3/min (CFM) mm (in) H2O 1000 kJ/h (1000 BTU/h) 1000 kJ/h (1000 BTU/h) litres / min (GPM) _C (_F) _C (_F) m3/min (CFM) kW (bhp) barg (psig) barg (psig) barg (psig) mm RPM

16.7 (590) 99 (133) 7.5 (109) 7.7 (112) 4.5 (65) 226 1,693

15.3 (540) 99 (133) 8.5 (123) 8.7 (126) 4.5 (65) 226 1,513

14.0 (495) 99 (133) 10.0 (145) 10.2 (148) 4.5 (65) 226 1,404

95 (203) 78 (172) 315 (299) 399 (378) 151 (40)

93 (200) 78 (172) 324 (307) 398 (377) 151 (45)

93 (200) 78 (172) 328 (311) 398 (377) 151 (47)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

14 (25)

14 (25)

14 (25)

125 (33) 121 (32) 114 (30) 102 (27) 14 (25)

129 (34) 121 (32) 114 (30) 106 (28) 14 (25)

129 (34) 117 (31) 114 (30) 106 (28) 14 (25)

0.12 (1.7) 0.02 (.33) 113 (4,000) 6.4 (0.25)

0.13 (1.9) 0.02 (.32) 113 (4,000) 6.4 (0.25)

0.13 (1.9) 0.02 (.32) 113 (4,000) 6.4 (0.25)

61 (16) 95 (25)

61 (16) 95 (25)

61 (16) 95 (25)

75 70

75 70

75 70

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R 90160 IU


232.5 1.5 415V

2330 (92)

99.0 (132.8) 5.5 (7.4) 104.5 (140.2) 163.2 10.7 1.9 173.9 165.1 0.75 (1.0) 1485 280M1 1,309 95.1 0.84


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R 90160 IU

24



20.0 (706) 121 (162) 7.5 (109) 7.7 (112) 4.5 (65) 226 1,969

19.2 (678) 121 (162) 8.5 (123) 8.7 (126) 4.5 (65) 226 1,896

17.5 (618) 121 (162) 10.0 (145) 10.2 (148) 4.5 (65) 226 1,758

101 (214) 80 (176) 379 (359) 483 (458) 151 (40)

99 (210) 80 (176) 384 (364) 484 (459) 170 (45)

98 (209) 80 (176) 391 (371) 484 (459) 178 (47)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

14 (25)

14 (25)

14 (25)

151 (40) 148 (39) 140 (37) 125 (33) 14 (25)

151 (40) 144 (38) 140 (37) 129 (34) 14 (25)

151 (40) 144 (38) 140 (37) 129 (34) 14 (25)

0.18 (2.6) 0.03 (.46) 113 (4,000) 6.4 (0.25)

0.19 (2.7) 0.03 (.46) 113 (4,000) 6.4 (0.25)

0.19 (2.8) 0.03 (.46) 113 (4,000) 6.4 (0.25)

61 (16) 95 (25)

61 (16) 95 (25)

61 (16) 95 (25)

75 70

75 70

75 70

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R 90160 IU


252.5 1.5 415V

2330 (92)

121.0 (162.3) 5.5 (7.4) 126.5 (169.7) 201.4 10.7 1.9 212.1 203.3 0.75 (1.0) 1485 280M2 1,390 94.5 0.84


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R 90160 IU

26



20.0 (706) 121 (162) 7.5 (109) 7.7 (112) 4.5 (65) 226 1,969

19.2 (678) 121 (162) 8.5 (123) 8.7 (126) 4.5 (65) 226 1,896

17.5 (618) 121 (162) 10.0 (145) 10.2 (148) 4.5 (65) 226 1,758

101 (214) 80 (176) 379 (359) 483 (458) 151 (40)

99 (210) 80 (176) 384 (364) 484 (459) 170 (45)

98 (209) 80 (176) 391 (371) 484 (459) 178 (47)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

14 (25)

14 (25)

14 (25)

151 (40) 148 (39) 140 (37) 125 (33) 14 (25)

151 (40) 144 (38) 140 (37) 129 (34) 14 (25)

151 (40) 144 (38) 140 (37) 129 (34) 14 (25)

0.18 (2.6) 0.03 (.46) 113 (4,000) 6.4 (0.25)

0.19 (2.7) 0.03 (.46) 113 (4,000) 6.4 (0.25)

0.19 (2.8) 0.03 (.46) 113 (4,000) 6.4 (0.25)

61 (16) 95 (25)

61 (16) 95 (25)

61 (16) 95 (25)

75 70

75 70

75 70

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R 90160 IU


272.5 1.5 415V

2330 (92)

121.0 (162.3) 5.5 (7.4) 126.5 (169.7) 194.6 10.7 1.9 205.3 196.5 0.75 (1.0) 1485 280M2 1,565 95.1 0.87


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R 90160 IU

28



23.5 (830) 145 (194) 7.5 (109) 7.7 (112) 4.5 (65) 226 2,290

22.3 (788) 145 (194) 8.5 (123) 8.7 (126) 4.5 (65) 226 2,203

21.0 (742) 145 (194) 10.0 (145) 10.2 (148) 4.5 (65) 226 2,039

100 (212) 80 (176) 459 (435) 581 (551) 189 (50)

98 (209) 80 (176) 466 (442) 582 (552) 212 (56)

98 (208) 80 (176) 472 (447) 582 (552) 223 (59)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

14 (25)

14 (25)

14 (25)

182 (48) 174 (46) 167 (44) 151 (40) 14 (25)

182 (48) 174 (46) 167 (44) 155 (41) 14 (25)

182 (48) 174 (46) 167 (44) 155 (41) 14 (25)

0.25 (3.6) 0.04 (.60) 113 (4,000) 6.4 (0.25)

0.26 (3.7) 0.04 (.55) 113 (4,000) 6.4 (0.25)

0.26 (3.8) 0.04 (.51) 113 (4,000) 6.4 (0.25)

61 (16) 95 (25)

61 (16) 95 (25)

61 (16) 95 (25)

75 70

75 70

75 70

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R 90160 IU


292.5 1.5 415V

2330 (92)

145.2 (194.7) 5.5 (7.4) 150.7 (202.1) 236.3 10.7 1.9 247.0 238.2 0.75 (1.0) 1485 315M1 1,631 94.8 0.85


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R 90160 IU

30



23.5 (830) 145 (194) 7.5 (109) 7.7 (112) 4.5 (65) 226 2,290

22.3 (788) 145 (194) 8.5 (123) 8.7 (126) 4.5 (65) 226 2,203

21.0 (742) 145 (194) 10.0 (145) 10.2 (148) 4.5 (65) 226 2,039

100 (212) 80 (176) 459 (435) 581 (551) 189 (50)

98 (209) 80 (176) 466 (442) 582 (552) 212 (56)

98 (208) 80 (176) 472 (447) 582 (552) 223 (59)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

14 (25)

14 (25)

14 (25)

182 (48) 174 (46) 167 (44) 151 (40) 14 (25)

182 (48) 174 (46) 167 (44) 155 (41) 14 (25)

182 (48) 174 (46) 167 (44) 155 (41) 14 (25)

0.25 (3.6) 0.04 (.60) 113 (4,000) 6.4 (0.25)

0.26 (3.7) 0.04 (.55) 113 (4,000) 6.4 (0.25)

0.26 (3.8) 0.04 (.51) 113 (4,000) 6.4 (0.25)

61 (16) 95 (25)

61 (16) 95 (25)

61 (16) 95 (25)

75 70

75 70

75 70

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R 90160 IU


312.5 1.5 415V

2330 (92)

145.2 (194.7) 5.5 (7.4) 150.7 (202.1) 235.2 10.7 1.9 245.9 237.1 0.75 (1.0) 1485 315M1 1,491 95.8 0.86


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R 90160 IU

32



28.5 (1006) 176 (236) 7.5 (109) 7.7 (112) 4.5 (65) 226 2,809

26.0 (918) 176 (236) 8.5 (123) 8.7 (126) 4.5 (65) 226 2,589

25.0 (883) 176 (236) 10.0 (145) 10.2 (148) 4.5 (65) 226 2,487

102 (215) 80 (176) 552 (523) 705 (668) 189 (50)

102 (215) 80 (176) 563 (534) 705 (668) 212 (56)

101 (214) 80 (176) 569 (539) 707 (670) 223 (59)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

14 (25)

14 (25)

14 (25)

220 (58) 212 (56) 201 (53) 185 (49) 14 (25)

220 (58) 212 (56) 201 (53) 185 (49) 14 (25)

220 (58) 212 (56) 201 (53) 189 (50) 14 (25)

0.34 (4.9) 0.05 (.79) 113 (4,000) 6.4 (0.25)

0.34 (5.0) 0.05 (.72) 113 (4,000) 6.4 (0.25)

0.35 (5.1) 0.05 (.69) 113 (4,000) 6.4 (0.25)

61 (16) 95 (25)

61 (16) 95 (25)

61 (16) 95 (25)

75 70

75 70

75 70

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R 90160 IU


332.5 1.5 415V

2330 (92)

176.0 (236.0) 5.5 (7.4) 181.5 (243.4) 279.5 10.7 1.9 290.2 281.4 0.75 (1.0) 1485 315M2 1,929 94.9 0.88


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R 90160 IU

34



28.5 (1006) 176 (236) 7.5 (109) 7.7 (112) 4.5 (65) 226 2,809

26.0 (918) 176 (236) 8.5 (123) 8.7 (126) 4.5 (65) 226 2,589

25.0 (883) 176 (236) 10.0 (145) 10.2 (148) 4.5 (65) 226 2,487

102 (215) 80 (176) 552 (523) 705 (668) 189 (50)

102 (215) 80 (176) 563 (534) 705 (668) 212 (56)

101 (214) 80 (176) 569 (539) 707 (670) 223 (59)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

8 (15) 368 (13,000) 6.4 (0.25)

14 (25)

14 (25)

14 (25)

220 (58) 212 (56) 201 (53) 185 (49) 14 (25)

220 (58) 212 (56) 201 (53) 185 (49) 14 (25)

220 (58) 212 (56) 201 (53) 189 (50) 14 (25)

0.34 (4.9) 0.05 (.79) 113 (4,000) 6.4 (0.25)

0.34 (5.0) 0.05 (.72) 113 (4,000) 6.4 (0.25)

0.35 (5.1) 0.05 (.69) 113 (4,000) 6.4 (0.25)

61 (16) 95 (25)

61 (16) 95 (25)

61 (16) 95 (25)

75 70

75 70

75 70

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R 90160 IU


352.5 1.5 415V

2330 (92)

176.0 (236.0) 5.5 (7.4) 181.5 (243.4) 286.1 10.7 1.9 296.8 288.0 0.75 (1.0) 1485 315M2 2,102 95.9 0.86


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R 90160 IU

36

GENERAL INFORMATION

KEY 0V 1DPS 1SV 1VAC 2ATT 3APT 3SV 4APT 4SV 6SV 9SV AL CAB CON ES FM FMS FRI FUA HTRS IP IS KM1 KM2 Zero voltage Switch, oil filter condition Load valve Switch, inlet filter condition Airend discharge temperature Sump pressure Blowdown valve Package discharge pressure Valve, water stop Modulation valve Valve, condensate drain Alarm Cabinet Controller Emergency stop Fan motor Fan motor overload relay Poro solid state relay Fuse alternative Heaters Inst. panel Isolator if fitted Main contactor Delta contactoren R 90160 IU

KM3 KM4 MCB MM MOL MS PE PM PTC RLE RL/U RS RS/S SFUA SP T1

Star contactor Fan contactor Circuit breakers Motor, main Main motor overload relay Mains supply, ensure correct phase rotation Protected earth Phase monitor Motor winding thermistor Remote load enable Remote load/unload Running signal Remote start/stop See fuse alternative Starter panel Transformer, control

PORO Power outage restart option (optional)

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GENERAL INFORMATIONColors BLK BLU BRO GRE PIN RED SCR VIO WHI YEL Black Blue Brown Green Pink Red Screened Violet White Yellow Wires Numbers 199 100199 200299 Function Power AC Control DC Control Wire color Black Red Blue

37

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R 90160 IU

38

INSTALLATION / HANDLING

ACKEY A 2.5 NPT Air discharge (Female) 60Hz units 2.5 BSPT Air discharge (Female) 50Hz units B Electrical inlet: Blank plate supplied C Cooling air intake D Cooling air exhaust E 0.5 NPT Condensate drain 60Hz units 0.5 BSPT Condensate drain 50Hz units F 4 x 23,0mm (0.9) Compressor should be bolted to the floor with four M20 (0.75) bolts using holes shown. Seal base to floor with cork or rubber. V Bottom view W Front view XX1 Part section through XX showing customer air discharge with moisture seperator XX2 Part section through XX showing customer air discharge without moisture seperator Y Left view Z Plan view NOTES: All dimensions are in millimetres unless otherwise stated. Weights (approximate): R90IU 2703 kg (5957 lbs) R110IU 2833 kg (6244 lbs) R132IU 3160 kg (6965 lbs) R150IU 3230 kg (7119 lbs) R160IU 3230 kg (7119 lbs) Denotes center of gravity.

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R 90160 IU

INSTALLATION / HANDLING

39

WCKEY A 2.5 NPT Air discharge (Female) 60Hz units 2.5 BSPT Air discharge (Female) 50Hz units B Electrical inlet: Blank plate supplied C Cooling air intake D Cooling air exhaust E Water out 1.5 NPT on 60Hz units 1.5 BSPT on 50Hz units F Water in 1.5 NPT on 60Hz units 1.5 BSPT on 50Hz units G 0.5 NPT Condensate drain 60Hz units 0.5 BSPT Condensate drain 50Hz units H 4 x 23,0mm (0.9) Compressor should be bolted to the floor with four M20 (0.75) bolts using holes shown. Seal base to floor with cork or rubber. U Rear view V Bottom view W Front viewhttp://air.irco.com en

XX1 Part section through XX showing customer air discharge with moisture seperator XX2 Part section through XX showing customer air discharge without moisture seperator Y Left view Z Plan view

NOTES: All dimensions are in millimetres unless otherwise stated. Weights (approximate): R90IU 2510 kg (5532 lbs) R110IU 2640 kg (5819 lbs) R132IU 2945 kg (6491 lbs) R150IU 3015 kg (6645 lbs) R160IU 3015 kg (6645 lbs)

Denotes center of gravity.R 90160 IU

40

INSTALLATION / HANDLINGUNPACKING Incorporated within the base of the compressor are slots to enable a fork lift truck (2 ton minimum) to move the machine. Alternatively a special lifting frame can be supplied to enable a crane or hoist to move the compressor. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the position of the emergency stop device is known and recognised by its markings. Ensure that it is functioning correctly and that the method of operation is known.

UNPACKING / SHIPPING STRAP Remove the yellow shipping strap (identified by two red identification tags) as follows; 1. Remove any covering from the compressor. 2. Remove the two access panels from the right hand side of the compressor. 3. Remove the two screws from the front of the airend / separator support. 4. Remove the two remaining screws via the support access holes. 5. Straps and tags can be discarded or retained for future transportation purposes. 6. Replace the access panels.

KEY 1. Compressor 2. Air Receiver 3. Air Dryer 4. Compressed air filters 5. System demand points LOCATION IN THE PLANT The compressor can be installed on any level floor capable of supporting it. A dry, well ventilated area where the atmosphere is as clean as possible is recommended. Sufficient space all round and above the compressor must be allowed, to enable the effective removal of the cooling air which, in turn, will reduce the risk of recirculating the cooling air back through the compressor. CAUTION: A minimum of 1 metre all round the compressor is recommended. If headroom is restricted, then the exhaust should be ducted or deflected away from the machine. Field installed ducting to and from compressor cannot add more than 6mm (0.25 inches) of water total air resistance. Hard surfaces may reflect noise with an apparent increase in the decibel level. When sound transmission is important, a sheet of rubber or cork can be installed beneath the machine to reduce noise. It is recommended that provision be made for lifting heavy components during major overhaul.

CAUTION Screw type compressors [1] should not be installed in air systems with reciprocating compressors without means of isolation such as a common receiver tank. It is recommended that both types of compressor be piped to a common receiver using individual air lines. CAUTION The use of plastic bowls on line filters and other plastic air line components without metal guards can be hazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils. From a safety standpoint, metal bowls should be used on any pressurised system.

DISCHARGE PIPING Discharge piping should be at least as large as the discharge connection of the compressor. All piping and fittings should be suitably rated for the discharge pressure. External piping shall not exert any unresolved moments or forces on unit. It is essential when installing a new compressor [1], to review the total air system. This is to ensure a safe and effective total system. One item which should be considered is liquid carryover. Installation of air dryers [3] is always good practice since properly selected and installed they can reduce any liquid carryover to zero. Unit has an internal discharge check valve, external check valve not required. Isolation valve required within 1m (36 inches) of the compressor discharge. There should be no plastic or PVC piping attached to this unit or used for any lines downstream with the exception of condensate removal lines.

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INSTALLATION / HANDLINGELECTRICAL DATA An independent electrical isolator should be installed adjacent to the compressor. Feeder cables should be sized by the customer/electrical contractor to ensure that the circuit is balanced and not overloaded by other electrical equipment. The length of wiring from a suitable electrical feed point is critical as voltage drops may impair the performance of the compressor. Feeder cable connections to studs L1L2L3 on isolator should be tight and clean.

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The applied voltage must be compatible with the motor and compressor data plate ratings. The control circuit transformer has different voltage tappings. Ensure that these are set for the specific applied voltage prior to starting. CAUTION Never test the insulation resistance of any part of the machines electrical circuits, including the motor without completely disconnecting the intellisys controller. NOTE: Main and fan motor insulation must be tested by a competent electrician prior to initial startup or following an extended shutdown period in cold damp conditions.

WATER COOLED UNITS

WATERCOOLING SYSTEM KEY A WATER IN B WATER OUT C. LUBRICANT OUT D. LUBRICANT IN E. LUBRICANT COOLER F. AFTERCOOLER G. AIR OUT H. AIR IN J. WATER

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INSTALLATION / HANDLINGScale: Scale formation inhibits effective heat transfer, yet it does help prevent corrosion. Therefore, a thin uniform coating of calcium carbonate is desired on the inner surface. Perhaps the largest contributor to scale formation is the precipitation of calcium carbonate out of the water. This is dependent on temperature and pH. The higher the pH value, the greater the chance of scale formation. Scale can be controlled with water treatment. Corrosion: In contrast to scale formation is the problem of corrosion. Chlorides cause problems because of their size and conductivity. Low pH levels promote corrosion, as well as high levels of dissolved oxygen. Fouling: Biological and organic substances (slime) can also cause problems, but in elevated temperature environments such as cooling processes they are not a major concern. If they create problems with clogging, commercial shock treatment are available. To ensure good operation life and performance of the compressor cooling system, the recommended acceptable ranges for different water constituents are included below: Cooling Water Analyses Chart Substances Corrosivity (Hardness, pH, Total Dissolved Solids, Temperature at inlet Alkalinity) Iron Sulphate Chloride Nitrate Silica Desolated Oxygen Test interval Monthly if stable for 3 to 4 months, analyse quarterly. Acceptable concentration Langelier Index 0 to 1

Cooling Water Piping Water piping to and from the compressor package must be 1 1/2 diameter or larger. Isolation valves with side drains should be installed on both the inlet and outlet lines. Also a strainer of 2mmmesh size should be installed on the inlet line. Strainers are available from Ingersoll Rand. A normally closed solenoid valve is fitted to the water inlet side of the compressor package. This is wired into the compressor control circuit and closes when the compressor stops. Carefully inspect your water system before installing the compressor package. Ensure that the piping is free of scale and deposits that may restrict water flow to the compressor package. Proper operation of your compressor requires that the water flow listed in the general information section of this document be provided at a maximum suppy temperature of 46_C (115_F). Water temperature and pressure gauges should be installed in the water piping for use in any fault finding of the water system. Water pressure should ideally be between 3 and 5 bar. Water cleanliness is also extremely important. Cleaning of coolers as a result of fouling is a customer responsibility. Therefore, it is highly recommended that proper water quality must meet the requirements listed in WATER QUALITY RECOMMENDATIONS later in this section. Adjusting the Aftercooler Trim Valve The coolers are piped in a parallel water flow arrangement with a manual trim valve controlling the flow through the aftercooler (see piping and instrumentation diagram in the General Information section of this document). The Aftercooler Trim Valve is factory set and should not need adjusting but if disturbed use the following procedure. Close valve fully clockwise and then open 1/4 turn. With the machine running loaded, observe the package discharge temperature on the controller display. It should be aprrox 8_C (15_F) above the water inlet temperature. If it is higher, open the valve a little more. Put a Warning Do Not Adjust label on the valve or fit a lock. Venting the water system At the initial installation or for startup after draining the water system proceed to vent the system as follows 1 Locate the water system vent cocks on top of the aftercooler and lubricant cooler. 2 Open the water valve(s) allowing water to flow to the package. 3 Open the vent cocks and allow all air to escape from the system. When water is observed at the vent cocks, close them The system is now vented. Draining the water system Should it become necessary to completely drain the water system, proceed as follows. 1 Disconnect the inlet and discharge water lines from the connections located at the rear of the unit. 2 Locate the aftercooler and lubricant cooler. Remove the drain plugs located at the bottom of the coolers. Allow the system to completely drain. Water quality recommendations Water quality is often overlooked when the cooling system of a watercooled air compressor is examined. Water quality determines how effective the heat transfer rate, as well as the flow rate will remain during the operation life of the unit. It should be noted that the quality of water used in any cooling system does not remain constant during the operation of the system. Evaporation, corrosion, chemical and temperature changes, aeration, scale and biological formations effect the water makeup. Most problems in a cooling system show up first in a reduction in the heat transfer rate, then in a reduced flow rate and finally with damage to the system.

Monthly Monthly Monthly Monthly Monthly Daily if stable,analyse weekly Monthly Monthly

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R90-150 Manual de Operador

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