Ingersoll-Rand 100-200 HP/75-160 KW manual

Before installation or starting the compressor for the first time, this manual should be studied carefully to obtain a clear kno wledge of the unit and of the duties to be performed while operating and maintaining the unit. RET AIN THIS MANU AL WITH UNIT . This T ec hnical manual contains IMPORT ANT SAFETY D A T A and should be kept with the air co[...]

AIR COMPRESSOR GROUP BONDED W ARRANTY & REGISTERED ST ART UP W arranty The Company warr ants that the equipment manuf actured b y it and deliv ered hereunder will be free of def ects in material and workmanship for a period of twelv e months (see extended airend w arranty) from the date of placing the Equipment in operation or eighteen months ([...]

1 RO T AR Y SCREW AIR COMPRESSOR This unit was purc hased from: _______________________________________________ _______________________________________________ _______________________________________________ Ingersoll-Rand Company reserves the right to make changes or add improv ements without notice and without incurring any obligation to mak e su[...]

2 T ABLE OF CONTENTS 0.0 SAFETY AND W ARNINGS 0.1 safety instructions 0.2 safety precautions 0.3 decals 1.0 RECEIPT OF EQUIPMENT 1.1 inspection 1.2 unpacking and handling 1.3 tools 2.0 INST ALLA TION 2.1 ventilation 2.2 foundation requirements 2.3 piping 2.4 electrical installation 2.5 outdoor sheltered 3.0 INTELLISYS ® 3.1 intellisys controls 3.2[...]

3 0.0 SAFETY AND W ARNINGS 0.1 SAFETY INSTRUCTIONS Before y ou install this air compressor you should take the time to carefully read all the instructions contained in this manual. Electricity and compressed air have the potential to cause severe per sonal injury or property damage . Before installing, wiring, starting, operating or making any adju[...]

4 W ARNING F ailure to adhere to these recommendations can result in mechanical failure , proper ty damage and ser ious injur y or death. All air and water inlet, and air and w ater discharge pipew ork to and from the inlet and discharge por t connections must take into account vibration, pulsations, temper ature, maximum pressure applied, corrosio[...]

39540174 Rev . 05 5 0.3 DECALS This section contains representative e xamples of decals which will be appearing throughout this manual and are applied to the compressor unit. If f or some reason a decal is def aced, painted over , or par ts are replaced, we recommend that you obtain a replacement kit as listed in the spare par ts section of the Par[...]

0.3 DECALS (continued) 6 W ARNING ! Hot surface. Can cause severe injury . Do not touch. Allow to cool before servicing. W ater out. W ater in. Lift Here Condensate drain. Air Dischar ge Electrical power inlet. D ANGER ! Discharge air . Can contain carbon monoxide or other contaminants. Will cause severe injury or death. Do not breathe this air . W[...]

0.3 DECALS (continued) 7 W ARNING ! Hazardous v oltage . Can cause severe injury or death. Only use factory supplied inlet for incoming power . See Operators/ Instruction manual. W ARNING ! Hazardous v oltage . Can cause severe injury or death. Disconnect power bef ore ser vicing. Lockout/T agout machine. Electrical power inlet. V OL T AGE DECAL OP[...]

8 1.0 RECEIPT OF EQUIPMENT 1.1 INSPECTION When you receiv e the compressor please inspect it closely . Any indication of careless handling by the carrier should be noted on the deliv er y receipt especially if the compressor will not be immediately uncrated. Obtaining the delivery man’ s signed agreement to any noted damages will f acilitate any [...]

2.0 INST ALLA TION 2.1 VENTILA TION Oil flooded rotar y air compressors produce large amounts of heat. Because of this large heat production, the compressor must be placed in a room with adequate ventilation. If heated air from the compressor e xhaust is allowed to recirculate back to the compressor , the compressor will ov erheat and shut down. Th[...]

10 DISCHARGE PIPING WITH AFTERCOOLER RO T AR Y-RECIP IN P ARALLEL Do not use the compressor to support the discharge pipe. Careful re view of piping size from the compressor connection point is essential. Length of pipe, siz e of pipe, number and type of fittings and v alves must be considered f or optimum efficiency of your compressor . It is esse[...]

11 2.4 ELECTRICAL INST ALLA TION Before pr oceeding fur ther , we recommend that you revie w the safety data in the front of this manual. Locate the compressor data plate on the side of the cooler bo x or end of the unit. The data plate lists the rated operating pressure , the maximum discharge pressure and the electric motor characteristics and po[...]

If the compressor is operated in the opposite direction of rotation, airend damage can result and is not warrantable. CA UTION 12 ELECTRICAL INST ALLA TION (Continued) Inspect the motor and control wiring for tightness . Close and f asten the star ter bo x door . RO T A TION CHECK Locate the rotation decal on each motor . DRIVE MO T OR The correct [...]

13 ELECTRICAL INST ALLA TION (Continued) The Intellisys will automatically shut the unit down if the compressor rotation is incorrect, and the displa y will indicate “CHECK MOT OR RO T A TION” and will flash “ALARM”. F or the compressor motor rotation check, the motor jogging time must be as shor t as possible. After depressing the start bu[...]

14 2.5 OUTDOOR SHEL TERED INST ALLA TION Many times a compressor must be installed outside due to jobsite conditions or limited space within a manuf actur ing facility . When this occurs there are cer tain items that should be incor porated into the installation to help ensure trouble free oper ation. These items hav e been listed below plus Figure[...]

FIGURE 2.5-1 TYPICAL OUTDOOR SHEL TERED INST ALLA TION 15[...]

16 3.0 INTELLISYS INTELLISYS CONTROLLER INGERSOLLrAND INTELLISYS[...]

3.0 INTELLISYS 3.1 INTELLISYS CONTROLS EMERGENCY ST OP Pressing this s witch stops the compressor immediately . The compressor can not be restar ted until the switch is manually reset. T urn the switch knob cloc kwise to reset. PO WER ON LIGHT This indicates the control v oltage and the line voltage are av ailable f or star ting. The operator panel[...]

The displa y screen is divided into three functional areas, as seen in the typical CURRENT ST A TUS screen shown here . The left side continuously shows the pac kage discharge pressure in large numbers, with the line directly below the numbers sho wing the r unning condition of the machine, and the line belo w that showing the present mode of oper [...]

19 NO TE - Use the UP and DOWN arrows to mo ve between selections . Items will be highlighted in inv erse displa y mode. * - Selecting the highlighted item will displa y the corresponding menu. ** - Selecting the highlighted item will place the value in edit mode . This is indicated by only the v alue being displa yed in in verse displa y mode. ***[...]

1 0 0 P S I 3.4 MAIN MENU The MAIN MENU screen is the point from which various operator functions can be accessed. Refer to the ref erence diagram in Figure 3.2.1. Each of the functions can be chosen by using the up and down arro ws to highlight it on the screen. The controller will go to the highlighted function if the SELECT button is pressed or [...]

3.5.1 Lead/Lag- This setpoint is used for setting lead or lag operation. If set to lead, the controller will load and unload the compressor by the online and offline setpoints. If set to lag, the controller will subtract the lag offset (see 3.5.4) from the online and offline set points and operate the compressor at the lo wer pressure range. 3.5.2 [...]

22 3.6.1 A uto Restar t- This setpoint is used to enable or disable the auto restart option. 3.6.2 A uto Restar t Time- This setpoint is the minimum time period the compressor must run unloaded before it can stop in the auto restar t mode. 3.6.3 A uto Restar t Delay Time- If the compressor is stopped in auto restar t, this setpoint is the number of[...]

3.7 SENSOR CALIBRA TION 1 0 0 P S I -SENSOR CALIBRA TION- Sensor 1A VPT CALIBRA TE Sensor 3APT CALIBRA TE ST A TUS MAIN MENU SELECT Ready T o Star t Pressure sensor calibration is done through the SENSOR CALIBRA TION screen. Sensor calibration can only take place when the machine is stopped. Calibration needs to be done only after a sensor has been[...]

24 1 0 0 P S I -ALARM HIST OR Y 1- P ackage Disch Pressure 199 PSI P ackage Discharge T emp 103°F ST A TUS MAIN MENU ALARM HIST OR Y Ready T o Star t The name and v alue of each of the items listed below can be seen by mo ving the list up and down using the arrow b uttons. Pressing the ALARM HIST . button will return the display to the ALARM HIST [...]

25 1 0 0 P S I -INTEGRAL SEQUENCING- Lead Compressor Off T otal Compressors 2 3.10 INTEGRAL SEQUENCING Integral Sequencing is set up using the INTEGRAL SEQUENCING screen. A description of integral is in section 7.0. The name and value of each of the integral sequencing setpoints as listed in the right hand column can be seen by mo ving the list up [...]

1 0 0 P S I Change Inlet Filter Press RESET T wice 3.11 W ARNINGS ST A TUS MAIN MENU RESET Running Unloaded Mode: MOD/A CS 1 0 0 P S I -CURRENT ST A TUS- P ackage Discharge T emp 103°F Airend Discharge T emp 193°F W ARNING MAIN MENU Running Unloaded Mode: MOD/A CS Pressing the W ARNING button will return the display to the W ARNING screen and the[...]

1 0 0 P S I High Airend Disch T emp 229°F Press RESET T wice 3.12 ALARMS ST A TUS MAIN MENU RESET ST OPPED BY ALARM Mode: MOD/A CS 1 0 0 P S I -ALARM ST A TUS- P ackage Disch Pressure 100 PSI P ackage Discharge T emp 103°F ALARM MAIN MENU ST OPPED BY ALARM Mode: MOD/A CS The name and v alue of each of the items listed can be seen by mo ving the l[...]

28 The possible Alarm messages are as f ollows . CHECK INLET CONTROL- This will occur if the machine is unloaded and the inlet v acuum is less than 3 psig (.2 bar). CHECK INLET CTRL SYS 1 (2) - This will occur if the inlet butterfly v alve f ails to open or close properly . A 1 means the inlet v alve f ailed to closer properly . A 2 means the inlet[...]

4.0 SCHEDULED PREVENT A TIVE MAINTENANCE 4.1 MAINTENANCE SCHEDULE THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE COMPRESSOR IN GOOD OPERA TING CONDITION. SER VICE A T THE INTER V AL LISTED OR AFTER THA T NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST . 4.2 MAINTENANCE RECORDS It is very impor tant that you, the[...]

4.4 INLET AIR FIL TER T o check condition of the inlet filter , run compressor in the LOADED mode and observe “Inlet Filter” on the CURRENT ST A TUS display screen. If the display sa ys “Inlet Filter OK”, then no maintenance is required. If “ ? ” is flashing on the screen and the displa y says “CHANGE INLET FIL TER”, then the inlet [...]

31 COOLANT DRAIN 4.6 COOLANT ■ SSR Ultra Coolant (Standard F actor y Fill) ■ SSR H1-F F ood Grade (Optional) SSR Ultra Coolant is a polyglycol base coolant. Change Ultra Coolant after e very 8000 hours or ev er y two years , whiche ver comes first. SSR F ood Grade Coolant is a polyalphaolefin base coolant. Change after e ver y 1000 hours or ev [...]

32 4.6 COOLANT (Continued) After the unit is drained and a ne w coolant filter element is installed, refill the system with fresh coolant. Bring the receiver le v el of coolant up to the midpoint of the sight glass. Replace the fill cap. Star t the compressor and run it f or a shor t time. The correct coolant lev el is at the midpoint of the sight [...]

W ARNING 125/200 HP This machine contains high air pressure which can cause severe injury or death from hot oil or flying parts. Alwa ys relieve pressure bef ore removing caps, plugs, cov ers or other par ts. Blow down pressurized air system. Close isolation valve . See Operator’ s Instruction Manual. 4.8 COOLANT SEP ARA T OR ELEMENT T o check co[...]

34 COOLANT COOLERS F ollowing are instructions for remov al and inter nal cleaning of coolant coolers. Coolant Cooler ■ Remov e panels and top cov er . ■ Drain the coolant. See Section 4.6. ■ Remov e side panels from coolant cooler box. ■ Disconnect piping from coolant cooler inlet and outlet por ts. ■ Plug cooler inlet and outlet por ts [...]

35 AFTERCOOLER F ollowing are instructions for the remov al and inter nal cleaning of aftercoolers. Aftercooler ■ Disconnect hose from aftercooler inlet flange. ■ Disconnect tube from aftercooler outlet flange. ■ Remov e aftercooler holding screws from aftercooler suppor t and remove cooler . Aftercooler Cleaning ■ It is recommended the coo[...]

36 Overgreasing can be a cause of bearing and motor failure. Make sure dir t and contaminants are not introduced when ad ding grease . CA UTION 4.10 MO T OR LUBRICA TION The induction-type squirrel cage motors hav e antifriction ball or roller bearings front and rear . At per iodic inter vals they require relubrication. Relubrication Interval - 60 [...]

37 4.10 MO T OR LUBRICA TION (Continued) Grease relief along shaft can occur , precluding necessity of removing this plug if inaccessib le. The inlet grease gun fittings and outlet plugs (or spring-loaded reliefs) are located at each end of the motor housing. The drive end reliefs protrude out the circumference of the lo wer por tion of the end bel[...]

38 4.11 LONG TERM ST ORA GE GENERAL The f actor y , upon special request, prepares compressor units f or long ter m storage. In such cases, a special bulletin is supplied f or storage and star t-up procedures. The bulletin pro vides special procedures for rotation and lubrication of compressors dur ing storage. Bef ore actual star t-up of the compr[...]

39 P ower Supply Remo val: 1) Open the star ter box door . 2) Remov e each plug-in connector , labeled J1 - J4, from the circuit board. If any of the cables are not labeled, label them with the appro- priate plug designator , J1-J4. These must be plugged into the correct sockets in the replacement power suppl y . 3) Remov e the four scre ws holding[...]

40 COOLING F AN MO T OR In a standard compressor , the cooling f an motor is wired at the f actor y . It is a three-phase motor , protected by a suitable circuit break er and ov erload relay . The f an motor is energized at the same time the compressor drive motor is energized. The f an motor ov erload is wired in series with the compressor dr ive [...]

5.4 COMPRESSED AIR SYSTEM The air system is composed of: 1) Inlet air filter 2) Inlet v alve/stepper motor 3) Rotors 4) Coolant/air separ ator 5) Minim um pressure/check v alve 6) Aftercooler 7) Moisture separ ator/drain trap Air enters the compressor , passing through the inlet air filter and butterfly inlet v alve . Compression in the screw-type [...]

5.6 ELECTRICAL SYSTEM (Continued) ST AR-DEL T A TYPE ST ARTER By use of the Star-Delta type star ter , the compressor motor can be star ted and accelerated using a greatly reduced “inr ush” electr ic current. The star ter is completely automatic and controlled by the Intellisys controller . Refer to the Electrical Schematic 8.1 in Section 8.0. [...]

5.8 CAP A CITY CONTROL (Contin ued) MODULA TION/ACS CONTR OL (Continued) The automatic control selector (A CS) is designed to continuously monitor the plant air demand and select either the on-off line, or the modulate control mode - whiche ver is most desirab le at any time during an operating da y . It allows the compressor to oper ate in its mos[...]

44 SECOND After the compressor has star ted and reached the off-line setting and has unloaded, timer “B” requires the unit to run unloaded for a period of time that the operator can adjust between 2 and 60 minutes . The setting of timer “B” is par t of the options setpoint routine and the timer cancels any accum ulated time if the compresso[...]

45 EXAMPLE 3 The operator selects an unloaded run time of 10 minutes in the OPTION routine and star ts the compressor . The unit runs loaded 12 minutes and then unloads. After 12 minutes of running, the 10 minute mandator y run-time for timer “A” has been met but the compressor must continue to run unloaded an additional 10 minutes to satisfy t[...]

46 6.0 TR OUBLESHOO TING CHAR T TROUBLE Compressor fails to start. Compressor shuts down. NO TE: If a shutdown occurs, press the Status button once to activ ate the display tab le. Using the adjacent up and down arrows , the values display ed will be those immediately preceding shutdown. Use these values when troubleshooting a problem. CA USE &[...]

6.0 TR OUBLESHOO TING CHAR T (Continued) TROUBLE Low system air pressure High coolant consumption/coolant in air system W ater in air system Excessive noise le vel Excessive vibr ation Pressure relief valv e opens CA USE &/OR DISPLA Y Compressor running in UNLOAD Mode . Controller off-line set point too low . Dir ty air filter element. Air leak[...]

48 7.0 O TIONS 7.1 PO WER OUT A GE REST ART OPTION F or customers that have interruptions in their incoming power supply to the compressor and m ust maintain an uninterrupted supply of compressed air , the P ower Outage Restar t Option allows an Intellisys compressor to restar t automatically 10-120 seconds (adjustable) after incoming pow er is res[...]

7.9 REMO TE LO AD/UNLO AD The remote load/unload option giv es the operator the ability to control the loading and unloading of the compressor . This option is enabled when two s witches are wired to the Intellisys to perf or m this function. The first s witch is the master/local input (P3, 25 & 26) and the second s witch is the load/unload inp[...]

50 54418074 REV B 8.0 REFERENCE DRA WINGS 8.1 ELECTRICAL SCHEMA TIC ST AR DEL T A[...]

51[...]

52 54622865 REV B 8.2 FOUND A TION PLAN 125-150 HP/90-110KW AIRCOOLED SINGLE ST A GE (CONTINUED)[...]

53 54622865 REV B 8.2 FOUND A TION PLAN 125-150 HP/90-110 KW AIRCOOLED SINGLE ST A GE[...]

8.3 FOUND A TION PLAN 200 HP/132-160 KW AIRCOOLED SINGLE ST A GE (CONTINUED) 54622931 REV B 54[...]

8.3 FOUND A TION PLAN 200 HP/132-160 KW AIRCOOLED SINGLE ST A GE 54622931 REV B 55[...]

56 8.4 FOUND A TION PLAN 125-150 HP/90-110 KW W A TERCOOLED SINGLE ST A GE (CONTINUED) 39925300 REV C[...]

57 8.4 FOUND A TION PLAN 125-150 HP/90-110 KW W A TERCOOLED SINGLE ST A GE 39925300 REV C[...]

58 8.5 FOUND A TION PLAN 200 HP/132-160 KW W A TERCOOLED SINGLE ST A GE (CONTINUED) 39926191 REV C[...]

59 8.5 FOUND A TION PLAN 200 HP/132-160 KW W A TERCOOLED SINGLE ST A GE 39926191 REV C[...]

60 8.6 FOUND A TION PLAN - AIRCOOLED (CONTINUED) 100-150 HP/75-110 KW - TWO ST A GE 54622980 REV B[...]

61 54622980 REV B 8.6 FOUND A TION PLAN - AIRCOOLED 100-150 HP/75-110 KW - TWO ST A GE[...]

62 8.7 FOUND A TION PLAN - AIRCOOLED (CONTINUED) 200 HP/132-160 KW - TWO ST A GE 54623053 REV B[...]

63 54623053 REV B 8.7 FOUND A TION PLAN - AIRCOOLED 200 HP/132-160 KW - TWO ST A GE[...]

64 8.8 FOUND A TION PLAN -W A TERCOOLED (CONTINUED) 100-150 HP/75-110 KW - TWO ST A GE 39925326 REV C[...]

65 8.8 FOUND A TION PLAN -W A TERCOOLED 100-150 HP/75-110 KW - TWO ST A GE 39925326 REV C[...]

66 8.9 FOUND A TION PLAN -W A TERCOOLED (CONTINUED) 200 HP/132-160 KW - TWO ST A GE 39926340 REV C[...]

67 8.9 FOUND A TION PLAN -W A TERCOOLED 200 HP/132-160 KW - TWO ST A GE 39926340 REV C[...]

68 8.10 FLO W SCHEMA TIC AIRCOOLED - SINGLE ST A GE 54579081 REV A[...]

69[...]

70 8.11 FLO W SCHEMA TIC W A TERCOOLED - 90 ° F (32 ° C) - SINGLE ST A GE 54579503 REV A[...]

71[...]

72 8.12 FLO W SCHEMA TIC W A TERCOOLED - 115 ° F (46 ° ) - SINGLE ST A GE 54579511 REV A[...]

73[...]

74 8.13 FLO W SCHEMA TIC AIR-COOLED - TWO ST A GE 54579644 REV A[...]

75[...]

76 8.14 FLO W SCHEMA TIC W A TERCOOLED 90 ° F (32 ° C) TWO ST A GE 54579693 REV A[...]

77[...]

78 8.15 FLO W SCHEMA TIC W A TERCOOLED 115 ° F (46 ° C) TWO ST A GE 54579727 REV A[...]

79[...]

80 8.16 TYPICAL SYSTEM FLO W DIA GRAMS TYPICAL SYSTEM FLO W DIA GRAM[...]

81 8.16 TYPICAL SYSTEM FLO W DIA GRAMS[...]

82 8.16 TYPICAL SYSTEM FLO W DIA GRAMS[...]

83 8.16 TYPICAL SYSTEM FLO W DIA GRAMS[...]

84 8.16 TYPICAL SYSTEM FLO W DIA GRAMS[...]

85 9.0 W A TER QU ALITY RECOMMEND A TIONS W ater quality is often ov erlooked when the cooling system of a water cooled air compressor is e xamined. W ater quality deter mines how effectiv e the heat transf er rate, as w ell as the flow rate will remain during the operation lif e of the unit. It should be noted that the quality of water used in an [...]

86 Recommended equipment f or on-site analysis includes a ther mometer , pH meter , and dissolved o xygen meter . Dissolv ed o xygen and temperature must be measured on-site and it is recommended that pH be measured on-site. All other analyses should be performed by a prof essional water quality analyst. The Langelier Index (Ll) is calculated using[...]

87 LANGELIER INDEX CHAR T V ALUES UNITS 0123456789 0 0.00 0.30 0.48 0.60 0.70 0.78 0.85 0.90 0.93 10 1.00 1.04 1.08 1.11 1.15 1.18 1.20 1.23 1.26 1.29 20 1.30 1.32 1.34 1.36 1.38 1.40 1.42 1.43 1.45 1.46 30 1.48 1.49 1.51 1.52 1.53 1.54 1.56 1.67 1.58 1.59 40 1.60 1.61 1.62 1.63 1.64 1.65 1.66 1.67 1.68 1.69 50 1.70 1.71 1.72 1.72 1.73 1.74 1.75 1.[...]

88 DA TE RUN TIME WORK DONE QTY . UNIT WORK (HOURS) MEASURE BY 10.0 MAINTENANCE RECORD[...]

89 DA TE RUN TIME WORK DONE QTY . UNIT WORK (HOURS) MEASURE BY MAINTENANCE RECORD[...]

90 DA TE RUN TIME WORK DONE QTY . UNIT WORK (HOURS) MEASURE BY MAINTENANCE RECORD[...]

91 DA TE RUN TIME WORK DONE QTY . UNIT WORK (HOURS) MEASURE BY MAINTENANCE RECORD[...]