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Hamilton Beach 44304 Coffeemaker User Manual

1. 2 JILVLSOWYSHL 31 114 1 1002 43113 3un553Hd 3A WA X23H2 3855384 3A7VA 23 2 9 5 IOHINOD 131 4317113 uIV 31 4 3 3 13 XNVI 435 NYI HuOlvUvd3S QN3HIV 114142539 QN3531 5901 5 Livh 1122 1979 lavt 055 81213 813 ASS ASh q oaSE ADL 32 Au A2dH av 315 45 3 v 71 1 335 S54 IZ ee E A a NOILDSNNOD 131100 H31vM lt p 5 m r a T ASS 310N 335 i 45 O NOI123NNO2 LINI H31VM gt T T gt NIVHO MNVl 435 iu E E a sivi O d Tm J 2 4299315 M a yv 1 0 NOTIS NND Avia 52 ix x avul 3unisION 055 5 5 310N 335 NOII23NNOO Y v 394 2510 19 CEPI 11 310N 335 QASE V Add 196 979 8 12 FLOW SCHEMATIC WATERCOOLED 115 F 46 SINGLE STAGE 72 9NIdId 8 4 ONIdId 39N3AV25 5 9NIdid 1 1002 1041 02 T 22 9NIdId MIV 081 2 V 414 H31VM M 1 1002 gt
2. Main Menu Main Menu Main Menu Main Menu OPERATOR Main Menu e SETPOINTS SENSOR CALIBRATION ALARM CLOCK HISTORY FUNCTIONS INTEGRAL SEQUENCING OPTIONS Status Status Status Status lt OPERATOR SENSOR Main Menu ALARM Main Menu PTION SETPOINTS Pree CALIBRATION HISTORY ITEM Main Menu INTEGRAL SEQUENCING Status ITEM Status ITEM Status Cancel or Set Cancel or Set Cancel or Calibrate Alarm Hist Cancel ot Set Cancel ot Set NOTE Use the UP and DOWN arrows to move between selections Items will be highlighted in inverse display mode kkk Selecting the highlighted item will display the corresponding menu Selecting the highlighted item will place the value in edit mode This is indicated by only the value being displayed in inverse display mode The UP and DOWN arrows will alter the value Depressing Cancel will exit the edit mode and leave the value unchanged Depressing Set will save the new value and flash the value to indicate acceptance Depressing Cancel will exit calibration mode Depressing Calibrate will calibrate selected sensor Use UP and DOWN arrows to scroll through list of status items 3 4 MAIN MENU 100 Jesi Ready To
3. WOlLOG 6961 00 81796 00 09 8 8 FOUNDATION PLAN WATERCOOLED g m 6 19796 uv3u NI H31VM 06571 100 1 0571 100 150 HP 75 110 KW TWO STAGE 39925326 REV 65 496 ns8 00786 622 00 6 622 00 6 LH9lN 1 404 25019328 e eo co N s061 00 61 aIv 2N11009 zest 06 29 521 00 32NViSISJH HIV YSLVM 30 9 5 6270 3HOW QQV LON 05538405 OL Q3711V15NI 481314 721 CLSh 00 8 SI LINN 40 401 Q3HInO3H 2 WAWINIW 1 1N3H313 uHO1VUVd3S 711 NI SI LINN s8 8314 Q311V1SNI 38 LSNW SH3A02 330H 1341118034 701 h WY3H1SNMOG SINIT 0351 HO LINN SIHL Q3HDV11V 2115 14 ON 38 GINOHS 3H3H1 76 LINN 532803 5 3 Q3A1053uUNn ANY 183X3 LON TIVHS 5NIdld 1VNUJIX3 8 53002 1 201 3189 21199 MO 53002 1 21812313 11 1531 1 A8 Q3uIno3u SV 13 4 1041 02 JO LNOHJ NI 490 00728 816 00 9 53015 338 1 NO 12 Q3QN3MHOD3U 71 5 9672 W4 0005 79 00 09 Y3BLYVLS LV DNINSdO LI INI u3MOd 3MIM JO HLONZT
4. 211 5 3ufisS3Hd 1YI1N3H34410 H31114 Sad HDLIAS 3H 1YH3dH31 VIY HOTH 51 i HOSN3S 3univH3dW31 uIV 39HYH2SIQ 35v 5vd Live ONIdId q WOSN3S 3HuniVH3dW3i HIY 35HVHOSIQO QN3HIY YOSNAS 3Hn1VH3dW31 1122 9NIdId 39N3AV25 5 3 3unss3ud HIY 3415 AYA YOLVEVdIS 14 9 1081 02 0200 UENOSNVYL 3155384 Hiv 39HYH2SIQ MZ NGSNVYL 3unSS3Hd MIV 3015 13M 35 Ldve HIV 081 2 v2 USONASNVHL 3UhsS3Hd WNNIVA 137NI 9NIdId INV 1002 gt 3214180 39N3AV2S 36 oss YOLVEVdIS 3unlSIOHW SH oni dtd HIY Y 13 1002431 4 uT1213V QN3931 431002 1 1002 010 3105 015 LNV100 gt ASS BATA QION330S NMOGAO18 Q oAS 3A1VA 2 Q 081 2 IILVLSONYSHL ADL 831113 02 42 331134 3 65384 323H 0653 4 ANO dHOShH OSE NO 03810038 ASE 2 23H 39uYH2SIQ 3A1YA 1 2 LIINI MIY A48 LINNA 40 NOILVONNOS 431114 131 335 5 01123 02 YSWOLSND 80371 IN3H313 NVA HOlYuVd3S 315 X NYi1 01 435 15 S310N 114142530 QN3531 69 310N 335 pete E sz NOI123NNO2 131100 831VM I eee eee as
5. 4 z 055 XQ MMC ERA 310N 335 NOIL23NNO2 Y v HIV 7 7 liVh V Add 96 9 9 8 13 FLOW SCHEMATIC AIR COOLED TWO STAGE 74 9NIdid 8 9NIdId 39N3AV2S 5 9NIdId 1002 10H1NO2 r 22 XIV 1081802 T Y 9NIdid 1NV1005 2 XIV QN3931 IN34313 831113 JNO SLINN dHOO 72 LINN 30 NY d 11 4 335 5 01123 02 YSWOLSND 80471 5210 211 5 3ufi5S3Hd 1 3833310 131 113 1 7002 21 115 3unlvHidW3l HIV HDIH uOSN3S 3804 34 31 HIY 358VH2SIQ WOSN35 3UniYM3dW31 HIY 39UYHOSIG QN3UIY u32nqgSNYUL 3unSS3dd 1 1002 03123 MOSN3S 3unlVH3dW3l 1 002 32 30055339 HIV 3015 AYG 1 HNOl1VUVg35 u32nasNvui 3unsSS3ud uiv 35uvH2SIQ 2 3u05S3Hd HIY 3915 13M ANVIL HOLVYVdaS H3 ndSNvui 34055384 WNNIVA 131 1 3314180 39 3 725 uOivuvdiS 35 38015100 8310025841 dV 43700 1 100 QION3105 4015 1 1002 010 3105 NMOGHO18 1 1002 2 21 1 831113 002 BATA 431134 38 55384 SATIVA 23 2 3unS53Hd WOWINIW BAWA X23H2 39uvH2SIG TO81NO2 HIV 831113 UIV A1N3H313 01
6. lt DRIP LEG gt TRAP ISOLATION VALVE ISOLATION STRAINER VALVE DRIP LEG ROTARY TWO COMPRESSOR SYSTEM Ingersoll Rand Compressor Package Data COMPRESSOR MODEL RATED OPERATING PRESSURE MAX DISCHARGE PRESSURE MAX MODULATE PRESSURE NOMINAL DRIVE MOTOR NOMINAL FAN MOTOR TOTAL PACKAG ASSEMBL LOCKED ROTO AIR SOLUTIONS GROUP DAVIDSON NORTH CAROLINA 28036 WWW AIR INGERSOLL RAND COM 54425996 Rev C 54425996 Rev C 75 160 KW Ingersoll Rand Compressor Package Data COMPRESSOR MODEL RATED OPERATING PRESSURE MAX DISCHARGE PRESSURE MAX MODULATE PRESSURE NOMINAL DRIVE MOTOR NOMINAL FAN MOTOR TOTAL PACKAGE AMP VOLTS PHASE CONTROL VOLT SERIAL NUMBER CONTACTOR AMP RATING ASSEMBLY AMP RATING LOCKED ROTOR AMP RATING OF ASSY AIR SOLUTIONS GROUP DAVIDSON NORTH CAROLINA 28036 WWW AIR INGERSOLL RAND COM 39557095 Rev 05 39557095 Rev 05 100 200 HP 11 Primary Secondary Secondary Hz Line Volts Line 60 H4 H5 120 X1 X2 24 X3 X4 H3 H5 120 X1 X2 24 X3 X4 H2 H5 120 X1 X2 24 X3 X4 H1 H5 120 X1 X2 24 X3 X4 CONTROL TRANSFORMER T1 CONNECTIONS 60 HZ H1 H2 H3 H4 H5 HIGH VOLTAGE PRIMARY SIDE LOW VOLTAGE Af x4 2 1 SECONDARY SIDE TRANSFORMER 1 TERMINALS 60 HZ TYPICAL 6
7. 8 3 FOUNDATION PLAN 200 HP 132 160 KW AIRCOOLED SINGLE STAGE 54622931 REV 55 QN3 1 1851 JONVISISAY HIV 1 40 HH 9 S3HONI 5270 NVHi 3HOH QAY LON 05538405 01 9NII2nQ0 Q3T11V1SNI 1314 00 81 SI LINN 30 401 3AOBV TWAOWSY Q3HIDO3H 32 3 1 1N3H313 HO1VHVdiS 32Vld NI SI LINN u3ldV QATIVISNI 38 15 SH3AOD 3 OH 14111803 HYV3H1SNMOQO SANIT ANY Q3sn HO LINN 5 G3HDVLIV 9NIdId 2I1SV d ON 38 QINOHS 3H3Hl LINN NO 532804 Q3A1053uNn 183 3 LON TIVHS 5NIdId 753402 1 201 318 21 HO 300 1 21812313 1531 1 A8 Q3uInOdH SV WAWINIW HO 713NVd 10H1NOD 40 4 NI 1901 00 2h C 516 00 9 53015 33HH1 NO 12 CS EW 9672 W4D 0005 1 15 LV 9NIN3dO 13 NI 43MOd WOH3 30 H15N3 WOAWINIW hi6 00796 S3HONI NI SNOISN3HIQ TIV CWWEF Zl SNOISN3JHIQ T1V NO 32NVH3101 119 1 9 91 AINO 1 1 18 199 Z Aud C31VMIXOHddV ALO 1113 1 1002 53 0592 81 0286 4 061 93 1192 81 OLLS 6 4 921 CALVWIXOUddv 1 596 00 01 310N 335 14111804 803 59 40 s061 00 uIV 9NI 1002 gd 701 6 65 6 1 MJA
8. 435 WVL UOIVuYd35 ON3HIV 418253 0 39 3 540 51 Live 1826 22 1879 lave 14 oss 5 1213 812 56 ASE AQ ADL EP 420 315 15 75 CIH 310N 335 555 ee 1123 02 131100 H31VM I M LS DEOS di jy 0 M M o RR 4 ASS d 310N 33 32 ASh 1 uin 310N 335 _ 2 lt 2 NOI123NNO2 13181 7 T oj 2 NIVHQ XNVL 435 igse 1152 O O 0 1 f EO 344315 ILON 3352 1123 02 Nivud avl aunisiow 7 7 1 SW 310N 335 NOTI33NNO v 39HVH2SIQ HIV ldV h Llyr V Add 6696 9 9 WATERCOOLED 90 F 32 8 14 FLOW SCHEMATIC TWO STAGE 76 9NIdId 9 9NIdIid JONZAVIS 5 9NIdId 1 1002 TOHLNOD 22 9NIdId HIV 1081 02 v2 ONIdId H31VM M 1NV 1002 2 9NIdId HIV 3931 5NIdId 1 343132 821113 1 1002 JNO 3AVH SLINN dHOO 72 LINN 30 NOTLYONNOS 33S 5 01123 02 YAWOLSND 804 5310 211 5 3455384 1 11838343310 317114 1NY OOD 211 6 1139431 HIV HJIH MOSN35 3 1 3931 BIY 39UYHOSIQO HOSN3S 3ufhivuddH3i 39UYHOS
9. XIV v QN35931 5NIdId A INO dHOSh OSE NO Q34InO3M ASE 2 1IN 40 NOILVONNOS 335 5 01123 02 YAWOLSND 80471 5310 H31VM HOLIAS 38 553 44 IWILNSH34410 831113 1 1002 HOLIAS 3univHddW31 HIY 35 3uUniVvH3dW31 NIV 35H8YHOSIQ 30 4 05 35 3univu3dH3l HIV 19 QN3UIY WOSN3S 3unlYH3dW3l 1 1002 2 34155349 1 3915 Aud ANVL 8 35 uaon SNvul 3unss3ud HIV 35uvHOSIQ d3onQsNvui 3unSS3ud 1 3015 13 XNYL HOlVHVd3S u3onqsSNvul 38055384 WONIVA L3 NI 3214180 35N3AYOS 01 435 01 4 5 3uniSIOWM 431002431 831002 1NY1002 QION3105 4015 1 1002 QION3105 440 1 5 H31VM 01083105 NIVHG 1 1002 1081 02 JILVLSOWSHL 831114 1 1002 BATA 431138 35155399 JANYA 23 2 38 553 23 39 2514 081 137 HIY 831113 131 1 1N3W43713 XNYI uOlYHYd35 1 35 QN3HIYV 114182539 QN3531 ALM 54 5171 11v2 1122 18 9 id a idVE 14 055 SH 8121 4 wD ASS ASS 494656 ADL 32 Au Aag iv 315 15 a v 73 2H 310N 335 32 NIVHQ 4 435 1426 1122 sivi O Q 1041 02 4344315 IH 310N 335 01123 02 NIVHQ Au 34un1SIOM
10. 3HIM 40 H19N31 016 00 9 S lt gt OWH S3H2NI NI SNOISN3HIQ 11 w CHWEF 217 SNOISN34IQ 11 NO 32NVH3701 gt 119 199 91 AINO _ 1 18 1v9 aya Fada 31VHIXOMddV ALO 7714 INVOIME T 72 hga lt S 2 5 0h92 81 0286 011 dH OSI 340 10761 gt 9 1192 81 0116 MX 06 dH lt 21 2out 31VHIXOuddV 71 52 S3LON iD z 52 3 1431 0616 NIVYG 31VSN3QNO5 05 256 OS LE 216 LO LE NOILV201 91 907E P see J94YH SIQ YIV 18796 ldN 0072 601 10 h Dil MIA WOLLO 1 596 00 9251 81794 3 5281 00709 8 2 FOUNDATION PLAN 125 150 HP 90 110 KW AIRCOOLED SINGLE STAGE 54622865 REV 53 LH9IY 60611 00764 1861 05 29 32NY1SIS3H XIV H31VM 40 9 53 560 380 QAY LON HOSS3HdHO2 ONY ONILING Q3T1V15NI 41314 C 1S5 0078 SI LINN 40 901 803 12 WNWINIW 1N34313 HO1VHVd3S 11 32 14 NI SI LINN 83143V Q3717V1SNI 38 LSAW SH3AOD 310 13179043 701 WV3HiSNM OQ S3NIT ANY YO LINN SIHL 01 GAHDVLIV 9NIdId 2145 14 ON 38 9110 5 3H3H1 76 NO 532804 HO SIN3HOM Q34A1053uNn 1H3X3 L
11. 516 00796 CHH 93 2 NI SNOISN3WIQ 11 h 217 SNOISN3MIG 11 NO 32NVHU3701 19 199 91 C1 htt 1 9 0 Aud hsh ILYWIXONddY A10 T1114 LNVIOOD 0 61 53 LBIE 81 0204 091 2 1 002 31VMIXOuddV 1 1 S310N 35uvH25IQ OS Z 8 9 FOUNDATION PLAN WATERCOOLED CONTINUED 200 HP 132 160 KW TWO STAGE 66 1431 0951 06716 821 NIVYd 31VSN3Q0NO2 0071 05 8981 Lit he NOI1V201 91 54 5 22762 39 uIV LdN 0672 s0 0 1 2176 09 6 11 92 Sh 9 WOLLOS 11 ll 00 09 g s96 00 9251 81796 056 19 9E MIA s 897 NI H31VM 0871 110 H31VM 0871 200 HP 132 160 KW TWO STAGE 8 9 FOUNDATION PLAN WATERCOOLED e ceo co N 67 CIN 310N 335 01123 02 NIVUQ 3unisION 77 SW 310N 335 xd NOIL23NNO2 v v 3594vH2sIQ 310 335 idVh qASE V Add L8067SvS THERE OM NIVHQO 435 TEE Sivi 1081 02 5399315 add 3 i live 5 oss eut eL v2 8 10 FLOW SCHEMATIC AIRCOOLED SINGLE STAGE 68
12. COOLANT COOLER The cooler is an integral assembly of core fan and fan motor all mounted in the end section of the compressor enclosure The cooling air flows in through the left end of the enclosure through the vertically mounted cooler core and discharges upward through the right end of the enclosure 40 COOLING FAN MOTOR In a standard compressor the cooling fan motor is wired at the factory It is a three phase motor protected by a suitable circuit breaker and overload relay The fan motor is energized at the same time the compressor drive motor is energized The fan motor overload is wired in series with the compressor drive motor overload If an overload occurs in the fan motor circuit both the fan motor and compressor drive motor will stop AFTERCOOLER The discharge air aftercooling system consists of a heat exchanger located at the cooling air entrance of the machine a condensate separator and an automatic drain trap By cooling the discharge air much of the water vapor naturally contained in the air is condensed and eliminated from the downstream plant piping and equipment 5 3 COOLANT SYSTEM Coolant is forced by pressure from the receiver separator sump to the inlet port of the coolant cooler and the bypass port of the thermostatic control valve The thermostatic control valve controls the quantity of coolant necessary to provide a suitable compressor injection temperature When the compressor starts cold
13. 75 psig 5 2 bar or below Coolant system leak Defective moisture separator drain trap Trap drain or drain piping plugged Aftercooler core dirty Enclosure panels not in place No aftercooler on unit Drain line drip leg incorrectly installed No refrigerated or desiccant dryer in air system Compressor defective Bearing or gear failure or rotor contact Enclosure panels not in place Loose component mounting Loose components Motor or compressor bearing failure External sources Compressor operating over pressure Defective valve WHAT TO DO Press LOAD button Press STOP button Set off line set point at a higher value Check filter condition Replace as required Check air system piping Inspect and repair Inspect and repair Check control system operation Install larger or an additional compressor Check level lower if necessary by draining Check separator pressure drop Check separator pressure drop If low replace element Remove and inspect screen orifice Clean if required Operate at rated pressure Reduce system load Inspect and repair leaks Inspect and clean if required Replace separator trap if defective Inspect and clean Inspect and clean Install enclosure panels Install aftercooler Slope drain line away from trap Install drip leg Contact local Ingersoll Rand distributor Contact authorized distributor immediately Do not operate unit
14. 8 15 FLOW SCHEMATIC TWO STAGE 78 ONIdId NIVUQ q 9NIdId 9 3 25 5 9NIdid 1 1002 1OHINOD 3 22 9NIdId 1 2 V 9Nidid M 9 1414 1002 2 XIV v 3931 5NIdId iN3W3l3 841114 1 1002 JNO 3AVH SLINA dHOO 72 LINN 30 NOTLVONNOS 335 5 01123 02 H3WOl15n25 803 I 5310 H31VM 211 5 351553454 1 11 3833310 831113 211 5 3HnlVH3dW3l MIV 05 35 3ufivuidWi3l XIV 3 25 8058325 3univu3dH3 XIV 394YHOSIG H32nQSNvul 3unSS3ud 1 1002 4 1 8 5 35 3H ivH3dH3i 2 3 5 38056304 AIV 3015 AHG ANVIL uO1YuUvd3iS 32 05 340553184 uIV JSYVHISIA ua nasNvul 340553899 1 3015 13 ANVIL uO1Vuvd3S 32 38155384 2 LIMNI 3214180 39N3AV25 uOlvuvd3S 1 35 5 31002831 3V 431005 002 GIONSIOS 4015 1 1002 010 3105 430 10 6 H31VM JAVA QION310S NMOQMO18 2 211V1SOUH3HL 831113 1 1002 431738 34055384 23 3unSS38d WNWINIW X23H2 39uVH2SIQ JANYA 7081802 1 1 NIV 31 113 137NI 1N34313 35 ANVL 1 5 QON3UI
15. Call factory representative Check for defective sensor bad sensor connection or broken sensor wires Interchange any two line connections L1 L2 L3 at the starter Check for loose wires Check supply voltage Check heater setting Check for loose wires Check supply voltage Check heater setting Check for dirty cooler cores Inspect starter connectors Check for loose wires Reset to clear Calibrate sensors Check all set points Check fuses Check transformer and wiring connections Call factory representative Check Remote Stop Switch and wiring Check Remote Start Switch and wiring Disengage emergency stop button Press reset button twice See LOW UNLOAD SUMP PRESS Check for air leaks at inlet valve Check for slipping or broken stepper motor coupling 6 0 TROUBLESHOOTING CHART Continued TROUBLE Low system air pressure High coolant consumption coolant in air system Water in air system Excessive noise level Excessive vibration Pressure relief valve opens CAUSE amp OR DISPLAY Compressor running in UNLOAD Mode Controller off line set point too low Dirty air filter element Air leak Moisture separator trap drain stuck open Inlet valve not fully open System demand exceeds compressor delivery Excessive coolant level Plugged separator element Separator element leak Plugged separator scavenge screen orifice Compressor operating at low pressure
16. condition is an indication of the plant air demand Intellisys controller is sensing and awaiting a sufficient line pressure decrease before signaling a shift to the on line mode If the off line time period is relatively short thereby indicating a high demand for air it is preferable to shift the control system to upper range modulation The Intellisys does this and does it automatically if the compressor unloads 3 times within a 3 minute time period If later the plant demand decreases and even under modulate control the line pressure reaches the setting of the Intellisys controller and the control shifts to the off line mode the time in this mode will still be monitored A long off line time period indicates a low plant air demand indicating the desirability of operating in the on off line mode The Intellisys then does this and does it automatically if the compressor operates unloaded for more than 3 minutes MODULATION ONLY If MODULATION ONLY is turned on in the set point routine the unit will shift to Modulation control mode immediately when the unit is running The 3 cycles within 3 minutes time period required for ACS to change to Modulation mode is bypassed The unit will stay in Modulation mode until the UNLOAD button is pressed or the Mode of Operation set point is changed 5 9 AUTOMATIC START STOP CONTROL Many plant air systems have widely varying air demands or large air storage capacity whic
17. part of the coolant will bypass the cooler As the system temperature rises above the valve setting the coolant will be directed to the cooler During periods of operation in higher ambient temperatures all the coolant flow will be directed through the cooler The compressor injection minimum temperature is controlled to preclude the possibility of water vapor condensing in the receiver By injecting coolant at a sufficiently high temperature temperature of the discharge air and lubricant mixture will be kept above the dew point The controlled temperature coolant passes through a filter to the airend under constant pressure 5 4 COMPRESSED AIR SYSTEM The air system is composed of Inlet air filter Inlet valve stepper motor Rotors Coolant air separator Minimum pressure check valve Aftercooler Moisture separator drain trap oO UE NS Air enters the compressor passing through the inlet air filter and butterfly inlet valve Compression in the screw type air compressor is created by the meshing of two helical rotors male and female on parallel shafts enclosed in a heavy duty cast iron housing with air inlet and outlet ports located on opposite ends The grooves of the female rotor mesh with and are driven by the male rotor Tapered roller bearings at the discharge end prevent axial movement of the rotors The air coolant mixture discharges from the compressor thru a discharge check valve into the separation system
18. 4 15 FLUID AND VIBRATION MONITORING Ingersoll Rand recommends incorporating predictive maintenance specifically the use of coolant and vibration analysis into all Preventative Maintenance programs Predictive Maintenance is designed to increase system reliability and prevent costly downtime Through the use of sophisticated diagnostic tools including fluid vibration and optional air analysis IRA Certified Service Technicians can identify and correct potential problems BEFORE they can cause expensive unscheduled downtime How does predictive analysis work By establishing an initial baseline for normal operation and then regularly monitoring fluid and vibration conditions any sudden deviation or significant increase from this baseline can be identified and investigated to pinpoint the cause More quickly diagnosing potential problems can directly save money by preventing costly failures and reducing or eliminating downtime In addition regular condition monitoring also helps to maximize the time between expensive preventative maintenance intervals such as component rebuilds and coolant changes 4 16 COOLANT SAMPLING PROCEDURE Bring unit up to operating temperature Draw sample using pump kit from separator tank port DO NOT draw sample from drain port or oil filter Use new hose on pump for each sample failure to do this can give false readings 5 0 SYSTEMS 5 1 GENERAL SYSTEM INFORMATION The SSR compressor is an elec
19. A has been met but the compressor must continue to run unloaded an additional 10 minutes to satisfy timer B After 10 minutes of unloaded run time the compressor is stopped automatically and the total run time was 22 minutes 5 10 REMOTE START STOP The remote start stop option allows the operator to control the compressor from a remote mounted start stop station Two different switches can be wired to the controller for remote start stop Refer to Electrical Schematic 8 1 for wiring locations The switches are customer supplied and must be of momentary type The stop switch contacts are normally closed and the start switch contacts are normally open When starting the compressor from the remote location the Start button must be held depressed for approximately 2 seconds to activate the remote start function and then released within a maximum of 7 seconds or a Remote Start Failure alarm will occur N WARNING Disconnect power before servicing This machine is remote start and stop equipped May start or stop at Lock and tag out anytime See Operators Instruction Manual Can cause severe injury or death 45 46 TROUBLE Compressor fails to start Compressor shuts down NOTE If a shutdown occurs press the Status button once to activate the display table Using the adjacent up and down arrows the values displayed will be those immediately preceding shutdown Use these values when t
20. If the lead compressor s mode of operation is Mod ACS or Modulation Only it will modulate when it is loaded Once loaded if pressure falls to its online set point the lead compressor will transmit a load command to the next compressor in sequence The lead compressor will then wait for a period of time for the line pressure to rise This time period is determined by the load delay time set point At the end of this time period if line pressure is not rising the lead compressor will transmit a load command to the next compressor in sequence This will be repeated until the line pressure starts to rise When line pressure rises to the lead compressor offline set point it will transmit an unload command to the last loaded compressor in the sequence The lead compressor will do this every 10 seconds until the line pressure starts to fall After a certain amount of time or at a certain time the lead compressor can change the sequence by transferring the lead to the next compressor in the sequence If the set point Lead Change Hours is set to a value greater than 0 the unit will operate as the lead compressor for that number of hours before transferring the lead If Lead Change Hours is set to 0 the set points Lead Change Day and Lead Change Time will be used to determine when the lead will be transferred The Lead Change Day set point will contain the day of the week the lead will be transferred The time of the day will be cont
21. LOCATED OUTSIDE FUTURE C SIZE MANIFOLD HEADER CLAMP amp BOLT THE TO HANDLE FLOW OF RECEIVER TO A CONCRETE A B amp C AT FULL LOAD BASE OR FLOOR WITH LESS THAN 1 2 PSIO TO RECEIVER 8 16 TYPICAL SYSTEM FLOW DIAGRAMS 81 RECEIVER AND NLM CLEANUP PIPING CONTROL AIR LINE INSTALL UNION HERE ON NLM 1 AND NLM 2 NOT NECESSARY ON NLM 3 4 5 AND 6 WHICH HAVE FLANGED CONNECTIONS PRE FILTER BEFORE REFRIGERATED OR DESICCANT DRYER DO NOT PIPE TRAPS UP HILL OR TOGETHER PRE FILTER amp DRYER WITH BLOCK amp BYPASS AIR FLOW NL MODULE PREFILTER SOME REFRIGERATED DRYER HAVE A CONDENSATE sty DRAIN ON AIR TO AIR rans PRECOOLER REHEATER 4 CONDENSATE DRAIN EXCHANGER TOO po IF DRYER IS TS REFRIGERATED TYPE 8 16 TYPICAL SYSTEM FLOW DIAGRAMS 82 DRYER WITH POLISHING NLM OR IR C SERIES OR PARTICULATE IR SERIES FOR DESICCANT DRYERS AFTER FILTER NL MODULE OR IR C SERIES ON LUBE APPL OR IR P SERIES ON NON LUBE APPL DRY RECEIVER AND MONITORING DEVICES ON AIR QUALITY TAKE DOWN COMMER LINES OFF TOP OF HEADER X SLOPE HEADER TO LOW POINT AFTER DRAIN FILTER DRY RECEIVER DOWN TO POINTS IF USED OF USE DEWPOINT HYGROMETER E LUBRICANT INDICATOR FALSE LOADER IF THE POINT OF USE PIPE OUTSIDE AIR QUALITY IS STRICTLY TO SILENCER REQUIRED TO BE VERY CLEAN THE RECEIVER INTERNALS SHOU
22. cc may be used or a 35mm film canister can give a close approximation for 2 cubic inches when filled 3 Add the recommended volume of the recommended lubricant Do not expect grease to appear at the outlet but if it does discontinue greasing at once 4 Run motor for about 30 minutes before replacing out let plugs or reliefs BE SURE TO SHUT MOTOR DOWN DISCONNECT POWER LOCK OUT AND TAG AND REPLACE THESE DRAIN FITTINGS TO PRECLUDE LOSS OF NEW GREASE AND ENTRANCE OF CONTAMINANTS Recommended Motor Grease 60 Hz motors require Mobilith SHC 220 39218193 Use the grease as indicated on a special grease information nameplate on the motor Use of alternative greases can result in shortened motor life due to incompatibility of greases If there is not a grease nameplate on the motor use Chevron Black Pearl 2 39204292 Preferred Chevron SRI 2 39161641 50 Hz motors require Esso Unirex N3 92844729 N WARNING Hazardous voltage Can cause severe injury or death Disconnect power before servicing Lockout Tagout machine MOTOR BEARING MAINTENANCE STORED UNITS To ensure that complete contact is maintained between the motor bearings and the bearing grease on units to be placed in storage for extended intervals the following motor maintenance procedure should be adhered to 1 Prior to placing a unit in storage rotate the motor several revolutions by hand in the proper direction of rotation
23. 2 Thereafter rotate the motor as described in Step 1 at three month intervals until such time as the unit is placed in service 3 If the storage time is to exceed a total of nine 9 months duration the compressor must be ordered with long term storage option 37 4 11 LONG TERM STORAGE GENERAL The factory upon special request prepares compressor units for long term storage In such cases a special bulletin is supplied for storage and start up procedures The bulletin provides special procedures for rotation and lubrication of compressors during storage Before actual start up of the compressor the unit must be drained of coolant containing vapor space inhibitors Procedure for long term storage start up is covered in the special bulletin APDD 339 4 12 COOLANT LUBRICANT CHANGEOUT Ingersoll Rand does not recommend changeout of coolant lubricants however if a coolant lubricant change cannot be avoided procedure APDD 106E 87 should be obtained from your Ingersoll Rand representative 4 13 INTELLISYS REMOVAL Ensure the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg Ensure the main power disconnect switch is locked open and tagged See Figure 4 13 1 HASP KEY LOCK FIGURE 4 13 1 MAIN DISCONNECT LOCKED AND TAGGED 38 Follow these precautions to minimize damage from static electricity Static can cause severe damage to micro
24. FAIL 1 or 2 4 This warning will occur if the compressor is the lead unit while using integral sequencing and is unable to communicate with another compressor SERVICED REQUIRED The Intellisys has 2 levels of service The service level can be set at the factory or by an Ingersoll Rand service representative Either service level will issue a SERVICE REQUIRED warning at 150 hours This warning is a reminder for initial service and can be cleared by the operator Level 1 If service level 1 default is selected a SERVICE REQUIRED warning will be issued every 2000 operating hours This warning is to serve as a reminder to have the unit serviced and can be cleared by the operator Level 2 If service level 2 is selected service warnings will be issued every 2000 operating hours default or in 3 6 9 or 12 month intervals as selected at the factory or by an I R service 3 12 ALARMS 100 psi STOPPED BY ALARM Mode MOD ACS representative Service warnings at level 2 are issued in 3 stages First a 100 HOURS TO SERVICE or 14 DAYS TO SERVICE depending on the service interval type warning will be issued This warning will let the operator know that the time for service is approaching and can be cleared by the operator Following that 100 hours or 14 days later a SERVICE REQUIRED warning will be issued This warning can be temporarily cleared by the operator however it will return 24 hours later if s
25. LON NYD 2 WO44 5NII2nQ 4311 15 1 01314 CASh 00781 SI LINN 40 401 3AO8V 1vAOM3U N03 438 1 538 12 1N3W313 1 435 32 14 NI SI LINN 8314 0311 15 38 5 SH3AO0D 310 1417X404 2115 14 ON 38 Q InOHS 3H3Hi 1INQ NO 532803 HO 5 053uNn LON TIVHS 5NIdId JVNH31X3 53002 1 201 318 21144 53002 1 21412313 1531V1 A8 4381938 Sv WNWINIW HO T3NVd TONLNOD 40 LNOUS NI 19012 00728 516 00796 53015 33 8 1 NO 31 CNIM E W S25 32 000 61 MHOTI 06 dHOSI S2I CNIW EW 62 00 01 MNSL Z dHOO MOTI MIV H31HV1S 1 5NIN3dO L3 NI 3 SHIM 30 19 31 C416 00796 S3H2NI NI SNOISN3HIQ 11 CWHEF 21 SNOISNSWIG 11 NO 32NVYU3101 Mx3011 SL dH0S1 001 8034 1 19 199 91 3NV1 M3011 06 dHO0S1 S21 804 hii 1 9 OE MNSL dHOO T 8 1 9 ZZ AUG 31VMIXOMddV ALO 1114 1 1002 93 60 81 0289 011 dH OSI 53 1106 H1 0119 Mx 06 dH 921 93 hh 2 81 0509 SL dH 001 31VWIXOHddV 1HOI3M 84 596 00 Ol 310N 335 14113804 803 59 340 so6i 00 SZ MOTA uIv 9NIT1005 sz h6 2 el 8676611 0676 8 MIIA 401 HIV 0072 8261 5NIN340
26. OPTIONS Section 3 6 A setpoint s value can be changed by first highlighting the item and its value and pressing the SELECT button to highlight just the value When the value line is highlighted by itself the value can be adjusted using the up and down arrow buttons The CANCEL and SET buttons appear at this time Press the SET button to enter the new value or press the CANCEL button to return to the value of the setpoint prior to using the arrows The displayed value will flash twice to indicate it has been entered into the setpoint and the pair of setpoint item and value display lines will again be highlighted together Operator set points can be exited by pressing the STATUS or MAIN MENU buttons If no buttons are pressed within 30 seconds the display will return to the CURRENT STATUS screen 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 lower pressure range 3 5 2 Offline Pressure This setpoint is the pressure the compressor will unload at if it is operating in on off line mode 3 5 3 Online Pressure This setpoint is the pressure the compressor will load at 3 5 4 Lag Offset This setpoint is used with the lead lag operation If the lead lag set point
27. SUN AROUND UNIT 4 FEET 1 2 METERS OVERHANG ALL SIDES AREA SHOULD BE SECURED WITH A FENCE OR SECURITY SYSTEM LEVEL AND SLOPING SEAL ALL CONCRETE AROUND BASE PAD OF UNIT FIGURE 2 5 1 TYPICAL OUTDOOR SHELTERED INSTALLATION e z m r E o lt o INTELLISYS CONTROLLER 3 0 INTELLISYS 3 1 INTELLISYS CONTROLS EMERGENCY STOP Pressing this switch stops the compressor immediately The compressor can not be restarted until the switch is manually reset Turn the switch knob clockwise to reset POWER ON LIGHT This indicates the control voltage and the line voltage are available for starting POWER ON The operator panel is divided into two areas The bottom row of four buttons provides direct control over the starting stopping unloading and loading of the compressor These are defined by the symbols printed on the buttons themselves as shown here START Pressing this button will start the compressor if the display shows Ready To Start The compressor will start and load if there is sufficient demand for air STOP Pressing this button will activate the unloaded stop sequence If the compressor is running loaded it will unload and continue to run unloaded for an adjustable 10 to 30 seconds and then stop If the compressor is running unloaded it will stop immediately UNLOAD Pressing this button will cause the compressor to unload and remain unloaded The display will indicate
28. This system self contained in the separator tank removes all but a few PPM of the coolant from the discharge air The coolant is returned to the system and the air passes to the aftercooler The aftercooling system consists of a heat exchanger a condensate separator and a drain trap By cooling the discharge air much of the water vapor naturally contained in the air is condensed and eliminated from the downstream plant piping and equipment During unloaded operation the butterfly inlet valve closes via stepper motor and the blowdown solenoid valve opens expelling any compressed air back to the compressor inlet 5 5 COOLANT AIR SEPARATION SYSTEM The coolant air separation system is composed of a separator with specially designed internals a two stage coalescing type separator element and provision for return of the separated fluid back to the compressor OPERATION The coolant and air discharging from the compressor flow into the separator through a tangential discharge outlet This outlet directs the mixture along the inner circumference of the separator allowing the coolant stream to collect and drop to the separator sump Internal baffles maintain the circumferential flow of remaining coolant droplets and air In an almost continuous change of direction of flow more and more droplets are removed from the air by inertial action and then returned to the sump The air stream now essentially a very fine mist is directed t
29. alarm history 3 9 warnings 3 10 alarms SCHEDULED PREVENTATIVE MAINTENANCE 4 1 maintenance schedule 4 2 maintenance records 4 3 maintenance procedures 4 4 inlet air filter 4 5 coolant filter 4 6 coolant 4 7 separator tank scavenge screen orifice 4 8 coolant separator element 4 9 cooler cores cleaning 4 10 motor lubrication 4 11 long term storage 4 12 coolant lubricant changeout 4 13 intellisys removal 4 14 coolant hoses 4 15 fluid and vibration monitoring 4 16 coolant sampling procedure SYSTEMS 5 1 general system information 5 2 air cooled compressors 5 3 coolant system 5 4 compressed air system 5 5 coolant air separation system 5 6 electrical system 5 7 stepper motor inlet control 5 8 capacity control system 5 9 automatic start stop control 5 10 remote start sto TROUBLESHOOTING 7 0 8 0 9 0 10 0 OPTIONS 7 1 power outage restart option 7 2 sequencer 7 3 low ambient 7 4 separator delta p solenoid 7 5 separator delta p sensor 7 6 high dust filter 7 7 lead lag cycle length 7 8 schedule start stop 7 9 remote load unload 7 10 modbus 7 11 integral sequencing REFERENCE DRAWINGS 8 1 electrical schematic star delta 8 2 foundation plan 125 150 HP A C Single Stage 8 3 foundation plan 200 HP A C Single Stage 8 4 foundation plan 125 150 HP W C Single Stage 8 5 foundation plan 200 HP W C Single Stage 8 6 foundation plan 125 150 HP A C Two Stage 8 7 foundation pla
30. controlled by an external device such as an ISC or sequencer using the communications port P7 on the Intellisys 7 3 LOW AMBIENT The low ambient option is turned on by enabling it through the OPTIONS set point routine Also temperature sensor is added to the compressor and connected at P6 7 amp 8 on the Intellisys The options set point minimum cooler out temperature is set to the minimum temperature at which the unit can load When this option is enabled the compressor after being started will not load until the Intellisys reads a temperature from 3CTT at or higher than the value of the minimum cooler out temperature set point If this option is enabled without installing 3CTT a SENSOR FAILURE 3CTT alarm will occur 7 4 SEPARATOR DELTA P SOLENOID The separator delta p solenoid option is turned on by enabling it through the OPTIONS set point routine When this option is enabled the Intellisys will measure the pressure drop across the separator element by 48 first reading the wet side sump pressure Next the Intellisys will momentarily energize solenoid that will switch the dry side sump pressure to the sump pressure sensor The Intellisys will then read the dry side sump pressure and subtract it from the wet side sump pressure to measure the pressure drop across the separator element Do not enable this option if the separator delta p solenoid is not installed This will result in an incorrect measur
31. instructions in the Operators Instruction Manual Before Starting Check coolant lever Add coolant i necessary 2 that the mam isolation valve 1s open 3 If watercooled turn on water 4 Close main disconnect switch An acte screen indicates voltage s available to Ihe Intellisys controller The POWER ON lights indicate that iine and control voltages are available for starting Starting 1 Push START The compressor wil start and load automatically there is sullicient demand for Stopping 1 Push STOP Compressor will immediately unload and continue to run unioaded an adjustable 10 30 seconds Compressor will then stop 1 the compressor does not stop running after the set depress the EMERGENCY STOP if compressor is running unioaded when STOP is pushed compressor wili stop immediately Open main disconnect switch Stopping Emergency 1 If there is a need to stop the compressor immediately depress the EMF RGFNCY STOP Open main disconnect switch Push Button Functions QD SIART s unioan Loan 39878657 Rev 03 PORO OPTION 39584529 REMOTE START STOP OPTION 39547708 FOOD GRADE COOLANT OPTION 39568803 Lift Here dm N WARNING Hazardous voltage Can cause severe injury or death Disconnect power before servicing Lockout Tagout machine 39540174 Rev 05 VIEWED FROM FRONT am 39540273 Rev 04 2 REQUIRED BASE F
32. this alarm to occur after changing controller software 28 REMOTE START FAILURE This will occur if the Remote Start button is pressed after the machine is running or if the Remote Start button remains closed REMOTE STOP FAILURE This will occur if the Remote Stop button remains open and either Start button is pressed SENSOR FAILURE 1AVPT or 3APT 4APT 5 2 2 This will occur if a sensor is recognized as missing or broken This does not apply to sensor 4ATT STARTER FAULT 1SL 2SL This will occur if the starter contacts open while the machine is running It will also occur if the machine is given the stop command and the starter contacts do not open 1SL refers to the auxiliary circuit on starter contact 1M 2SL refers to the auxiliary circuit on starter contacts 2M and 15 STEPPER LIMIT SWITCH This will occur if both limit switches are activated at the same time INVALID CALIBRATION This will occur during the calibration process if the sensor reads greater than 20 of scale LOW COOLANT PRESSURE This will occur if the compressor is running and the following conditions are met The coolant must be less than 1 psi and either the sump pressure is greater than 10 psi or the inlet vacuum is less than 12 psi 4 0 SCHEDULED PREVENTATIVE MAINTENANCE 4 1 MAINTENANCE SCHEDULE THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE COMPRESSOR IN GOOD OPERATING CONDI
33. used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored CAUTION Notice is used to notify people of installation operation or maintenance information which is important but not hazard related NOTICE SAFETY PRECAUTIONS BEFORE PROCEEDING READ CAREFULLY BEFORE INSTALLING THE COMPRESSOR OR PERFORMING ANY MAINTENANCE WARNING COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS BEFORE DOING ANY WORK ON THIS UNIT BE SURE THE ELECTRICAL SUPPLY HAS BEEN CUT OFF LOCKED amp TAGGED AND THE ENTIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF ALL PRESSURE 1 Do not remove the covers loosen or remove any fittings connections or devices when this unit is in operation Hot liquid and air under pressure that are contained within this unit can cause severe injury or death 2 The compressor has high and dangerous voltage in the motor starter and control box All installations must be in accordance with recognized electrical codes Before working on the electrical system be sure to remove voltage from the system by use of a manual disconnect switch A circuit breaker or fuse safety switch must be provided in the electrical supply line leading to the compressor Those responsible for installation of this equipment must provide suitable grounds maintenance clearance and lightning arrestors for all electrical components as stipulated in O S H A 1910 308 throug
34. 0 HZ CONTROL TRANSFORMER Primary Secondary Secondary Line Volts Line H3 H4 110 X1 X2 24 X3 X4 H2 H4 110 X1 X2 24 X3 X4 H1 H4 110 X1 X2 24 X3 X4 CONTROL TRANSFORMER T1 CONNECTIONS 50HZ H1 H2 H3 H4 HIGH VOLTAGE PRIMARY SIDE LOW VOLTAGE I 24V 110V x4 X3 x2 1 SIDE TRANSFORMER 1 TERMINALS 50 HZ TYPICAL 50 HZ CONTROL TRANSFORMER THESE DIAGRAMS ARE FOR REFERENCE ONLY LOCATE THE WIRING DIAGRAM AFFIXED TO THE TOP OF THE CONTROL TRANSFORMER TO DETERMINE PROPER WIRE CONNECTIONS FIGURE 2 4 1 TYPICAL CONTROL TRANSFORMER WIRING ELECTRICAL INSTALLATION Continued Inspect the motor and control wiring for tightness Close and fasten the starter box door ROTATION CHECK Locate the rotation decal on each motor DRIVE MOTOR The correct compressor drive motor rotation is clockwise when viewed from the rear or non drive end of the motor See Figure 2 4 2 CAUTION If the compressor is operated in the opposite direction of rotation airend damage can result and is not warrantable 12 NON DRIVE END FIGURE 2 4 2 DRIVE MOTOR ROTATION ELECTRICAL INSTALLATION Continued The Intellisys will automatically shut the unit down if the compressor rotation is incorrect and the display will indicate CHECK MOTOR ROTATION and will flash ALARM For the compressor motor rotation check the motor jogging time must be as short as po
35. 00 09 hga ONIN3dO 10761 521 sz z 00 21 6 2 15310N 8 6 FOUNDATION PLAN AIRCOOLED CONTINUED 100 150 HP 75 110 KW TWO STAGE o N N co LO 60 1331 0951 05726 i 31VSN3QNO2 ari 06 011 201 137 1 92 00 14 HIY 18796 1 0072 n601 10 ni WOLLOG 00709 9251 81796 38 8 6 FOUNDATION PLAN AIRCOOLED 100 150 HP 75 110 KW TWO STAGE 54622980 REV B 61 MJA LNOUS 596 00 622 00 6 LO co N LO MJA QN3 lH9 13 s061 006 MO14 uly 9 110052 861 0529 sz 00 z 672 33NVISIS38 XIV H31VM 40 C WWI 5 6270 00 10 NV 5 2 WOUS ONILING Q3TIVISNI 81313 721 168 00781 ST LINN 30 901 IWAOWSY 438 1938 32NVHY3O WOWINIW 1N34313 6 711 327719 NI SI 8314 Q311V1SNI 38 15 SH3AO2 310 1417X404 01 58 h Q3HD3V11V 2115 4 ON 38 GINOHS 383 1 6 LINN NO 532404 HO SLNAWOW Q3A10S33Nn ANY 183 3 LON 11VHS 9NIdId TVNH31X3 78 53002 1 201 318 21144 53002 1v21H12313 JVNOILVN 1531 1 4381031 Sv HO 13NVd 30 1NONJ NI 290 00 2 tChl6 00 9 53015
36. 03 F STATUS MAIN MENU ALARM HISTORY The name and value of each of the items listed below can be seen by moving the list up and down using the arrow buttons Pressing the ALARM HIST button will return the display to the ALARM HISTORY screen ALARM HISTORY Items Discharge Pressure Coolant Filter Discharge Temperature Inlet Vacuum Airend Discharge Temperature Inlet Filter Injected Temperature Total Hours Loaded Hours Load Modulation Unloaded Inlet Vacuum Coolant Pressure Time amp Date Sump Pressure Separator Press Drop 3 9 CLOCK FUNCTIONS Ready To Start Alarm histories can be exited by pressing either the STATUS or MAIN MENU buttons If no buttons are pressed within 30 seconds the display will return to the CURRENT STATUS screen CLOCK FUNCTIONS Time 01 15 Date Jan 01 00 STATUS MAIN MENU SELECT The date and time for the real time clock is set through the CLOCK FUNCTIONS screen Use the up and down arrows to highlight either TIME or DATE Select the highlighted setting by pressing SELECT If TIME is selected first the hours will be highlighted Adjust the hours 00 23 hour clock by using the up and down arrows Once the correct time is in the display press SET to highlight the minutes Adjust the minutes 00 59 and then press SET to complete setting the time If DATE is selected first the month will be highlighted Adjust the month by using the up and down arrows and then press SET t
37. 20 F 49 C a separator sump pressure of 45 50 psig 3 1 3 4 bar will be maintained When the injected coolant temperature is above 120 F 49 C a receiver pressure of 24 33 psig 1 7 2 3 bar will be maintained The minimum pressure check valve will prevent any backflow of air from the plant air system during unloaded operation 42 ON OFF LINE CONTROL For those plants which have a widely varying air demand on off line control will deliver air at full capacity compressor maximum efficiency condition or will operate at zero capacity compressor minimum power condition The compressor is controlled by the Intellisys responding to changes in plant air pressure The Intellisys stepper motor opens the inlet valve and closes the blowdown valve 3SV whenever plant air pressure drops below the on line pressure set point The compressor will then operate to deliver full capacity air to the plant system If the plant air system pressure rises to the off line set point of the Intellisys the inlet valve closes and the blowdown solenoid valve opens the separator vent line allowing separator pressure to drop The compressor will continue to run with minimum power draw MODULATION ACS CONTROL For those plants which have relatively high constant air demand relative to the compressor capacity the recommended control mode is modulation The modulation control system retains the features of on off line control but provides for thro
38. 338H1 NO Q3Q0N3HHOD3U 71 3ouvH sIQ HIV 06572 Hd 00081 HIV 79 1 hesi u3iHViS LV ONIN3dO 13 NI M3MOd 3HIM 30 19 31 WAWINIW 16 00796 S 5 NI SNOISN3MIQ TV WHE 217 SNOISN3WIQ NO 32NVH3701 19 7 9 91 AINO C1 511 199 ANd hga 3LYWIXOYddY ALO 7714 1INYJIY NI 2 72 x ONIN3dO 10761 1 sz COM ABIE 81 0201 091 261 dH 002 00 1 6 2 31VMIXONddV 1 9 71 25310 8 7 FOUNDATION PLAN AIRCOOLED CONTINUED 200 HP 132 160 KW TWO STAGE 62 3 1431 0951 1 2 05 NOILV201 131 H3MOd 91 0o e 2 lt 6 35uvH2SIQ NIV 18796 14 0672 1601 LO EA nest 00 09 59 1 M3l 38 200 HP 132 160 KW TWO STAGE 8 7 FOUNDATION PLAN AIRCOOLED 54623053 REV B 63 LNO3J s96 ns8 00 8 LH9IY L31404 H03 S5NIN340 92 09 6 1 32NV1SIS3H YIV H31VM 40 WW9 S3HONI amp 2 0 NVHL 340W QOY LON NV HOSS3HdHO Ol ONTLINGA Q311V1SNI 1313 Z 168 00781 SI LINN 40 401 3408Y 803 1N34313 711 NI SI LINN 38 1
39. 3unss3ud u32noSNvul 1uVIS 310W3u 4015 340838 S12VINOD WYVIV 310038 43110H1NO2 SASITT3INI 54055384406 3univd3dW31 HIV HOIH HOLIMS LINN 031002 310W3H 331138 34055359 JATYA 4 3 05 CdWNd 110 HLIM SLINA NO LON 9015 1NV1002 GION310S LINN 931002 U31VM 340 1 5 H31VM 3ANVA 910 3105 LINN dHOOS OSE NO Q3YINOAY MASE 3A1YA 41 3105 9015 LIMIT 8344316 QuvOH 1112412 Q31NIHd 14405 u3MOd 08708 1112812 O31NIUd 13 4 LNSWNYISNI NO H3MOd T3NVdXOVG NO H3MOd dWv 1 431114 138 8318115 YOLOW AV134 GVOTHSAO HOIOW NIVW 40104 394315 yOLOW HOLOW 3AIHQ NIVW 612 1 02 AUVITIXNY YOLDIVINOD YVLS YOLIVINOD 15 SLOVINOD YOLIVLNOD V113Q YOLIVLNOD 1139 612 1 02 YOLIVINOD NIVW 012 1 02 NIVW 39 16 OML 1 1002 083123 1 3016 0 01 435 394 2610 39 3015 13M 1 uOiVuVd3S 131 079 o s S E 829 076 075 S e 085 o s 5 2 08 046 0 2 871 0682 4 CVADIL 21715 3Sf4 H34HO JSNVHI 09 1 021 YO 06 1 011 H3WHOd35NVHl 3513 588 ONILIV 15 1 v 38 iSNW 036 3503 SIVNIWHSL NIVW 43114405 15 L23NNODSIQ NIVW QNnOu5 H1uV3 NIVW QV31 114182534 1
40. 401 05 amp 39 25 19 XIV n251 00 2 S 00 09 n8 9 40 10761 21 00 21 5310 8 4 FOUNDATION PLAN 125 150 HP 90 110 KW WATERCOOLED SINGLE STAGE CONTINUED 56 LO N M3IA 1431 0951 EUM i511 811 16 hh NIVHQ 31VSN3QNO2 OS NO11V201 137NI 91 00 6 JOYMVHISIO HIV 1 0072 06111 92 Sh WOLLOd nest 00 09 9 1 81796 h6 NI XJLYM 14 09 1 065 150 31 OS 8 4 FOUNDATION PLAN 125 150 HP 90 110 KW WATERCOOLED SINGLE STAGE 39925300 REV 57 4 s96 s18 00 01 26 622 622 310N 336 0076 00 6 1341118034 YOS 59 40 60611 00764 Iv 9N1100 gt 1851 02769 00 21 32NV1SIS3H XIV H31VM 10 HH 9 53 2 5270 3NOH 00 LON HOSS3HdMO2 OL ONILING 4311 15 1 61314 CLSh 00781 SI LINN 20 401 3AO8V WAOWSY 804 381 538 12 WAWINIW 1N34313 1 435 11 1 NI 51 LINN 4 Q371V1SNI 38 15 SH3AOD 370H 1341118034 701 WY3HISNMOQ SINIT MO4 9351 HO LINN 5 93 2 11 2115 ON 38 3H3Hl 6 LINN NO 532803 HO SIN3HOMW Q3A 0S3uNn 1H3X3
41. 425 1979 idVh 1dAVI 158 58 v5 2 158 51 ASL ASS ASh Q 0ASE 53 2824 1824 112 171 348 SWW 81 3 051 St P ON2 92 941 WI 11 n3e n4i 61 11 510 ad A3ugav QN3931 51 4 5961 si8 00 8 3 1 Hod 2203222 LO N N LO s061 00 MOTA ulv 9 100 I 611 05753 00 21 6 2 32NVISISJU XIV 40 HH 9 53 2 6270 380 QQV LON HOSS3HdWOD ONTLING 4311 15 01314 721 C Sh 00781 SI LINN 40 dOL 3AO8V IVAOW3H 804 Q3HInO3H 32NYHV3O WNWINIW 1 3 3 13 HOLIVUVd3S 711 32vVld NI SI LINN 83134 Q3711V15NI 38 150 5 3 310 143113804 WV381SNMOQ SINIT ANY 0351 YO LINN SIHL OL Q3HDV1l1V 1414 2115 14 38 GINOHS 383 1 6 401 532804 SIN3WOW 1343X3 LON 11 5 VNH31X3 8 353002 1 201 J18V gt IIddv HO 300 192105123713 1VNOILVN 1531YV 0311831 SV WOWINIW YO TANVd TONLNOD 30 4 NI 1901 00 2 5 816 00 9 53015 33UH1 NO 12 74 8 6 1 0576 39 25 19 uIV CNIW EW SZh 000 51 MIV 9 0072 1 5251 9 31 16 LV 9NIN3dO 13NI NIN3dO 00 09 lt H3MOd
42. 50H SH3A02 310H 34111804 701 SINIT ANY 4350 40 LINN SIMI 01 Q3HOVLIY 2115 14 ON 38 3H3Hl 6 401 85 6 1 LINN 532804 HO SLNAWOW Q3A7053HNn ANY 1H3X3 LON TIVHS JVNH31X3 78 53002 1 201 318 211144 53402 1 21 412313 1 11 1531 1 A8 4381 38 SV HO 13 4 10 1 02 40 1NOuH3 NI 1901 00728 116 00796 53415 338 1 NO 32 3712 Q3QN3HHOD238 71 S M 9672 42 0005 79 U31HV1S LV 9NIN3dO 1371 1 WOH4 30 H19N31 16 00 96 n251 Hane T 00796753 00 09 F 06576 9 2514 0072 6 NI SNOISN3HIQ CHWEF 217 SNOISNSWIG 11V NO 101 76 061 001 803 7 19 7V9 91 YNVL 4 061 621 1 hil 192 OE dHOO 804 11 8 IVD 22 AUG gt A10 1114 2 88 1 1 1002 72 hga 960 81 0289 dH OS 0 10761 0 81 0419 06 dH 621 53 9512 81 0509 dH 001 3LVHIXOHddV LHOTSM 71 5310 8 8 FOUNDATION PLAN WATERCOOLED CONTINUED 100 150 HP 75 110 KW TWO STAGE N LO N 64 M3l 1431 0951 NIVHQ 31VSN3QNO2 1 05 NOI1V201 1 1 39 519 NIV 0072 05111 hi 96
43. ATUS display screen If the display says xxPSI then no maintenance is required If is flashing on the screen and the display says CHANGE SEPR ELEMENT then the separator element should be replaced Disconnect the scavenge tube at the airend Loosen the fitting that holds the scavenge tube into the tank and withdraw the tube assembly Disconnect the piping from the tank cover Tag the lines if required Use a suitable wrench and remove the bolts that hold the tank cover in position Remove cover by lifting up and away Carefully lift the separator element up and out of the tank Discard the faulty element Clean the gasket surface on both the tank and its cover Exercise care to prevent pieces of the old gasket from falling down into the tank Check the tank to be absolutely certain that no foreign objects such as rags or tools have been allowed to fall into the tank Install replacement element down into the tank after checking the new element gaskets for possible damage Center the element up within the tank Place the tank cover in its correct position and install bolts Tighten the bolts in a cross pattern to prevent over tightening one side of the cover An improperly tightened cover will likely result in a leak Tank cover bolt torque values 100 200 HP 75 160 KW 5 8 11 UNC 150 ft lb 203 Inspect tank scavenge screen and orifice Clean if necessary following instructions in Section 4 7 Inst
44. BEST 1 COOLEST BECAUSE PEOPLE 2 CLEANEST DO NOT KEEP 3 DRYEST AWAY FROM STEAM VENTS OR COOLING TOWERS IN THE BATH gt 4 FUME GAS FREE TYPE FILTER 5 EASILY ACCESSIBLE WITHOUT OIL IT DOES 6 GENERALLY THIS WILL BE OUTDOORS amp UP ON THE ROOF NOT FILTER WELL BRACE INLET PIPE WELL AT ROOF OR AT WALL PHOTO HELIC MAGNAHELIC OR MANOMETER TO MONITOR AP COMPRESSOR WEIGHT OF PING 0 TEMPORARY INLET SCREEN OFF THE COMPRESSOR TO REMOVE WELD BEADS amp SCALE LOW POINT DRAIN ALWAYS FABRICATE INLET PtPING FROM 1 SCHEDULE 40 ON ROTARY PVC 2 STEEL PIPE FABRICATED AND FLANGED IN SECTIONS CLEAN amp EPOXY PAINT INSIDE PREVENT RUST 3 STAINLESS STEEL 4 ALUMINUM 5 ALWAYS CLEAN INTAKE PIPE THOROUGHLY WELD BEADS SCALE RUST DIRT ETC TYPICAL ROTARY rer OUTSIDE MOTORIZED LOUVERS TO REMOVE ROOM HEAT ecto IGNAL FR SEFARATOR OF THE RECEIVER ISOLATION VALVE xU TO CLEAN UP PORTION OF AIR SYSTEM AIR LINE COPPER OR STAINLESS STEEL PIPE OUT OF RECEIVER AT THE TOP FLANGED UNION FOR EASY REMOVAL DIRECT OUTLET OF ALL SAFETY VALVES UP amp AWAY SWEPT FROM PERSONNEL ALWAYS PIPE IN TO RECEIVER AT gt BOTTOM OUTSIDE AIR WATCH OUT FOR FREEZING CONTROL AIR LINES amp AFTERCOOLER CONDENSATE IN WINTERTIME HEAT TRACE IF RECEIVER IS
45. CALIBRATION Items Sensor 1AVPT Sensor 3APT Sensor 4APT Sensor 5CPT Sensor 6APT 3 8 ALARM HISTORY 100 esi Ready To Start Select the highlighted sensor by pressing the SELECT button Press the CALIBRATE button to start the automatic calibration procedure or press the CANCEL button to not calibrate it and return to the sensor list The calibration screen can be exited by pressing either the STATUS or MAIN MENU buttons If no buttons are pressed within 30 seconds the display will return to the CURRENT STATUS screen ALARM HISTORY Alarm History 1 MOTOR OVERLOAD Alarm History 2 HIGH AIREND DISCH TEMP STATUS MAIN MENU SELECT Alarm History displays each of the Alarm messages for the last 15 Alarms experienced by the machine It also gives access to displaying the machine operating conditions that existed at the time of each Alarm The first one shown Alarm History 1 was the most recent Alarm to occur Note that multiple consecutive EMERGENCY STOP Alarms are not recorded as separate Alarms only the first one will be shown Each of the last 15 Alarm messages can be seen by moving the Alarm History list up and down using the arrow buttons Pressing the SELECT button when one of the Alarms is highlighted will display the list of machine values that existed at the time that particular Alarm occurred 23 24 Ready To Start ALARM HISTORY 1 Package Disch Pressure 199 PSI Package Discharge Temp 1
46. EN ORIFICE TOOLS REQUIRED m Open end wrench m Pliers PROCEDURE The screen orifice assemblies are similar in appearance to a straight tubing connector and will be located between two pieces of 1 4 inch O D scavenge line tubing The main body is made from 1 2 inch hexagon shaped steel 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 end of the assembly See Figure 4 7 1 and will require cleaning as outlined in the Maintenance Schedule Section 4 1 To remove the screen orifice disconnect the scavenge line tubing from each end Hold the center section firmly and use a pair of pliers to gently grasp the exit end of the assembly that seals against the scavenge line tubing Pull the end out of the center section while using care to prevent damage to the screen or sealing surfaces Clean and inspect all parts prior to reinstallation When the assembly is installed confirm the direction of flow to be correct Observe the small arrow stamped in the center section and ensure the direction flow to be from the separator tank to the airend 32 SCREW O RING HOUSING SCREEN ORIFICE FIGURE 4 7 1 SEPARATOR TANK SCAVENGE SCREEN ORIFICE 4 8 COOLANT SEPARATOR ELEMENT To check condition of separator element run compressor in full load mode and at rated pressure and observe Separator Pressure Drop on the CURRENT ST
47. FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNED BILL OF LADING If goods are received short or in damaged condition it is important that you notify the carrier and insist on a notation of the loss or damage across the face of the freight bill Otherwise no claim can be enforced against the transportation company If concealed loss or damage is discovered notify your carrier at once and request an inspection This is absolutely necessary Unless you do this the carrier will not entertain any claim for loss or damage The agent will make an inspection and grant a concealed damage notation If you give the transportation company a clear receipt for goods that have been damaged or lost in transit you do so at your own risk and expense WE AT ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR RESPONSIBILITY Ingersoll Rand Company Davidson North Carolina APDDGFO 99 79 1 2 UNPACKING AND HANDLING The compressor package has been mounted on a base which provides for forklifting between the two side channels to facilitate handling during shipment Care in positioning the forklifts is important because the location of the center of gravity is strongly affected by the location of the compression module and drive motor Slings c
48. IO ONGHIV u3onaSNvHi 3unSS3Hd 1 1002 023123 1 MOSN3S 3HniVH3dH31 1 1002 u3onosNvHl 3unsS3ud HIV 3016 NVI HOIVHVd35 uaonasNvui 3aunSs3ud HIV 39uvH2SIQ uaonagsNvui 553 YIV 3915 13 1 HOlVuvd3S Wu35nasNvul 3unsS3usd WnnovA 13 1NI 3213140 39 3 25 HOlVHVd3S 1 435 38 151 437002431 831002 1 1002 010 3105 4015 1 1002 010837105 440 1 5 H31VM GION3 10S NAOQMO NIVHQ OUINCO JILVLSONUSHL 831114 2 331138 55 X23H2 3unSS3Hud 23 2 30uYH25IQ JANYA 1041102 31 1 ULV 831113 NIV LINI 1N3H313 XNYL YOLVUVdSS NNV HOIYUYd3S QN3UIY NOI Ld H2S 3 0N3931 5401 51 L1vh Live 1425 1122 14 9 LdVE 055 5 u1213Y 12 ASS ASh ASE aq 21 32 Addi A2Q A38 av 315 15 a v 77 310N 335 23 133100 H31VM IH ALON 335 1123 02 131 1 H3iVM T NIVHO 435 5455 icm 4 DK sivt O O t n 344315 14 3 18 310N 335 T 01123 02 1 JYNLSIOW 310N 335 01123 02 Y 39 19 ulv 812140 idVh 11 5 t t X oss EE V Add LeL6LGVS WATERCOOLED 115 46 C
49. Ingersoll Rand 125 200 HP 90 160 KW SINGLE STAGE AND 100 200 HP 75 160 KW TWO STAGE UNITS 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 More Than Air Answers Online answers http www air irco com Phone 1 800 526 3615 CCN 80440415 REV B FORM APDD 738B November 2002 AIR COMPRESSOR GROUP BONDED WARRANTY amp REGISTERED START UP Warranty The 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 see extended airend warranty from the date of placing the Equipment in operation or eighteen months see extended airend warranty from the date of shipment from Davidson NC 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 su
50. Install enclosure panels Inspect and tighten Inspect and tighten Contact authorized distributor immediately Do not operate unit Inspect area for other equipment Adjust Intellisys set points Replace valve 47 7 0 OTIONS 7 1 POWER OUTAGE RESTART OPTION For customers that have interruptions in their incoming power supply to the compressor and must maintain an uninterrupted supply of compressed air the Power Outage Restart Option allows an Intellisys compressor to restart automatically 10 120 seconds adjustable after incoming power is restored The Power Outage Restart Option is turned on by plugging in the required option module and enabling it thru the OPTION S set point routine The restart time delay which is adjustable from 10 600 seconds can also be adjusted while in the option s set routine on the Intellisys controller Any time power is restored to the compressor after a power interruption a horn located on the side of the starter box will sound during the restart time delay 10 600 seconds after which the compressor will automatically start After starting the compressor will return to the mode of operation that the compressor was in prior to the power interruption This option may be factory installed or a field installation kit is available 7 2 SEQUENCER The sequencer option is turned on by enabling it through the OPTIONS set point routine Enabling this option will allow the compressor to be
51. LD BE GALVANIZED STAINLESS STEEL WALL OR VINYL COATED ETC 8 16 TYPICAL SYSTEM FLOW DIAGRAMS 83 TYPICAL RECIP OR ROTARY BE SURE YOU HAVE FITTINGS TO ADAPT THE GLADHAND THREAD CONNECTION TO THE STANDARD HOSE SIZES USED BY THE RENTAL AIR COMPANIES YOU WOULD USE IF YOU NEEDED RENTAL AIR INCREASE INLET gt x 2S PIPE 1 2 PIPE T SIZES ABOVE I x LANGE INTAKE ane FACE EXHAUST OF ALL SAFETY VALVES v UP AND AWAY So FROM PERSONNEL Ho SERS 1 25 BRACE THE PIPING WELL 8 16 TYPICAL SYSTEM FLOW DIAGRAMS 84 GLAD HAND SUPPORT FOOT Cc a OVERSIZE THIS AFTERCOOLER AND PIPING TO HANDLE 2X FLOW AT 1 16 to 1 8 INCH PER FOOT ON THE LINEAL LENGTH OF THE AFTERCOOLER INSULATE OR GUARD HOT DISCHARGE AIR PIPE LOCATE AFTERCOOLER support AS CLOSE TO THE FOOT COMPRESSOR DISCHARGE AS POSSIBLE s SLOPE THE AFTERCOOLER WITH PIPELINE AFTERCOOLER RENTAL UNIT UNION HERE TO AID IN AFTER COOLER REMOVAL CONTROL AIR SIGNAL TAKEN FROM HEADER OR PREFERABLY FROM RECEIVER TO CLEANUP PORTION OF AIR SYSTEM 9 0 WATER QUALITY RECOMMENDATIONS Water quality is often overlooked when the cooling system of a water cooled 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 quali
52. LON TIVHS TVN831X3 78 53002 1 201 318 21144 3902 1921412313 TVNOILVN 1531 1 Q34inO3H SV WOAWINIW YO 10 1 02 30 84 NI 490 00 2 816 00 9 53015 338 1 NO Q30N3HWOD3H 71 5 9672 W4 0005 Xiv 79 n251 u3iuviS LV 5NIN3dO LZ INI M3MOd HOH4 3HIM 40 HI9N31 WOWINIW 16 00 9 9 DyINTHG 00 09 S3HONI NI SNOISN3HIQ 11 21 SNOISN3HIQ NO 32 3 76 1 19 199 91 AINO 7 18 1 9 C31VMIXOHuddV ALD 1113 21 81 1 1 00 59 401 39uvH2sId LdN 0672 n8 COM 1 L2 81 0209 MNO9I ZEI dH 002 ONIN3dO 10761 1 1H9I3M 5310N 00 2 8 5 FOUNDATION PLAN 200 HP 132 160 KW WATERCOOLED SINGLE STAGE CONTINUED 58 N O co MIA 08 4 3 1331 6 11 NI BEI 14 0571 31VSN3QNOD 05 9 1 8981 91 6 256 91 hE 05746 eh 110 H31VM db 0671 NOI1V201 137NI 92 00 399 5 19 MIV 14 06 2 05111 92 Sh 8 5 FOUNDATION PLAN SINGLE STAGE 59 200 HP 132 160 KW WATERCOOLED 39926191 REV 06 29 32NViSIS3H HIV H31VM 30 HH9 S3HONI 5270 NVHL 3HOW QAY
53. NO 811 01 6 81 WOUS V HAIM 03271435 SI 541 9300 1v2IH12313 1 201 TWNOILVYN 3iV id Viva HOSS3UdWOD 3H NO JHI HLIM JINVGYOD SV NI 38 Q InOHS ANY 53801512 AHL 40 ALITIGISNOdS3H 3 SI QNVH 110S835NI A8 03114415 LON SIN3NOdWOD 1 21412313 30 931215 743801502 9 1N353Hd3U SINIT G3HSVG 2 u3W01Sn2 8 38 01 0112310 4 1112812 123 02519 NIVM 1 S310N 4891938 39Vi1nO NHOH YOLINOW 35V170 WAT SNOI1d0 0113 3389 1 9 NMOUS NH8 M01134 7134 31IHM 031 031 3 18 5v18 QN3531 NOIidIH553Q 5NINUVM Mev 01120 HDLIMS 310838 nta TWNOILdO 211 5 318VN3 QVO JLOW3Y 318 211 5 9 1 0 31 310W3H 118 5 01190 6d 1804 5 2 2 4 S IWNIWH31 81 38 55384 134 1 1002 HOLIMS 542 AINO LINN 35V1S OML 38 5538 39V1Su3INI HOLIMS SdI SDYVHISIO 39 YOSN3S 1 005 03123P NI 3801793 31 HOSN3S 1122 39 25 19 QN3HIV 3ufnivuddW3i 05 5 11v2 NOI1dIH5S3Q QN3531 3unss3ud 4320nQSNYHl 38055344 4J35naSNvui 3unss34Hd u3ongasNvul 3unss3ud u3ongsNvui
54. ON TIVHS 5NIdId 1 8 53402 1 201 3il8v2IlddV MO 3002 7V2IH123 3 1531 1 8 43818341 SV WAWINIW 13NYd 08 1 2 40 NI 1901 O0 2h 816 00796 53015 338H1 NO 12 71 CNIW EW 682 000 61 79 H431HV15 1V ONIN3dO 137 NI H3MOd SHIM 30 H15N37 WAWINIW 16 00 9 S S3H NI NI SNOISN3MIQ 11 8 WWE 21 F SNOISNSWIG 77 NO 32NVH33101 C1 19 199 91 AINO 1 18 31vMIXOBUddV ALO 1114 INVOIH8Q01 1 7002 93 1512 81 0209 Mx 091 261 dH 002 C31VHIXOHddV LHOI3M 71 S310N ONIN3d0 60 09 DN IN340 10761 MJA 84 s96 00 622 01 310N 335 1311388903 804 SONIN3dO uIv 9 1 1002 sz n6 Z 58 ne 401 9 UIV LdN 0672 n251 58 8 3 FOUNDATION PLAN 200 HP 132 160 KW AIRCOOLED SINGLE STAGE CONTINUED 54 co o N N LO ni WOLLOG IE 11 00 09 596 00 9251 81796 1331 0951 38 167 h 256 065746 256 10 1t NOI1V201 137NI H3MOd 94 00 E 6 39HYHDSIQ 18 9 00 2 n601 10 h NIVHQ 31VSN3QNO2 05
55. S 0 1 SAFETY INSTRUCTIONS Before you 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 personal injury or property damage Before installing wiring starting operating or making any adjustments identify the components of air compressor using this manual as a guide The operator should use common sense and good working practices while operating and maintaining this unit Follow all codes pipe adequately understand the starting and stopping sequence Check the safety devices by following the procedure contained in this manual Maintenance should be done by qualified personnel adequately equipped with proper tools Follow the maintenance schedules as outlined in the operators manual to ensure problem free operation after start up 0 2 SAFETY PRECAUTIONS Safety instructions the operators manual bold faced for emphasis The signal words DANGER WARNING and CAUTION are used to indicate hazard seriousness levels as follows Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored DANGER Warning is used to indicate the presence of WARNING a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored Caution is
56. Start MAIN MENU Operator Setpoints Options Sensor Calibration Alarm History Clock Functions STATUS jp SELECT The MAIN MENU screen is the point from which various operator functions can be accessed Refer to the reference diagram in Figure 3 2 1 Each of the functions can be chosen by using the up and down arrows to highlight it on the screen 3 5 OPERATOR SETPOINTS 100 Ready To Start The controller will go to the highlighted function if the SELECT button is pressed or will return to the CURRENT STATUS screen if the STATUS button is pressed OPERATOR SETPOINTS Offline Pressure 103 PSI Online Pressure 93 PSI STATUS MAIN MENU SELECT Setpoints are user adjustable variables in the controller logic that can be set using the OPERATOR SETPOINTS screen The name and value of each of the setpoints listed below can be seen on the screen by moving the list up and down using the arrow buttons OPERATOR SETPOINTS RANGE STEP UNIT Lead Lag Lead or Lag Offline Pressure 75 to RATED 3 1 PSIG Online Pressure 65 to OFFLINE 10 1 PSIG Lag Offset 0 to 45 1 PSIG Mode of Operation MOD ACS ON OFF LINE MODULATION ONLY Max Modulation Pressure Online 10 to Offline 7 1 PSIG Stop Delay Time 10 to 60 1 SEC Star Delta Time 5 to 20 1 SEC Screen Contrast 10 1 Does not apply to automatic across the line starters 20 Setpoints associated with options are described in the
57. TION SERVICE AT THE INTERVAL LISTED OR AFTER THAT NUMBER OF RUNNING HOURS WHICHEVER OCCURS FIRST Running Time Interval ee comes first Part or Item Hours 1Week 1 6Mo Yearly 2 Years inspect Coolantievel level Weekly We x inspect Discharge temperate x inspect Separator element differential Weekly x After Dota P x SSS 10 Replace Ultra Coolant 8000 Service Drive motor lubrication See Section 4 10 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 4 2 MAINTENANCE RECORDS 4 3 MAINTENANCE PROCEDURES It is very important that you the owner keep accurate Before starting any maintenance be certain the following and detailed records of all maintenance work you or the is heeded Ingersoll Rand Distributor or Air Center perform on your compressor This includes but is not limited to coolant 1 Read Safety Instructions filter separator inlet air filter and so forth This 2 Use correct tools information must be kept by you the owner should you 3 Have recommended spares on hand require warranty service work by your Ingersoll Rand Dis
58. Y 41832534 ALA 54 51 117 11 1424 1122 199 14 idAVI oss 5 81213 ut ASS ASh ASE AQ ADL 42 Au 20 18 dv 315 15 a v 79 000 SNS SAAS 4 T ili U u 7 J FUTURE dS DL lt lii W COMP D COMP O M Z v X 4 DL 7 t A y MD Ji X 3 o L TYPICAL SYSTEM FLOW DIAGRAM GLADHAND Emergency Standby Air Hook Up Complete with Necessary Fitting for Portable or 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 DIFFERENTIAL PRESSURE INDICATOR I R AUTOMATIC DRAIN VALVE FALSE LOADER Blows off Air Outside of Compressor Room SYSTEM INSTRUMENTATION INCLUDES Nephelometer Hygrometer Pressure Temperature VENTILATION Motorized Louvers Exhaust Fans AFTERCOOLER SEPARATOR ISOLATION VALVE UNION STRAINER AND TRAP 8 16 TYPICAL SYSTEM FLOW DIAGRAMS 80 TO SYSTEM O d EE DRY X 7 e X RECEIVER BOTTOM BOTTOM X V eb b TU 2222272 2222222 OUTSIDE COMPRESSOR SYMBOLS ROOM REMOTE INLET FILTER AND PIPING LOCATE AT DRY TYPE IS
59. ained in the Lead Change Time set point The lead will be transferred when the real time clock matches these 2 set points To connect the compressors for integral sequencing put the 4 position connector into port P8 One connector I R part number 39186101 will be needed for each compressor The total length of cable for an integral sequencing system is not to exceed 1000 feet For the cable use I R part number 39204508 or equivalent This is a 4 wire twisted pair cable Use one pair for pins 1 and 2 and the other pair for pins 3 and 4 The connection on port P8 is a one to one connection The wire on pin 1 on the first compressor will connect to pin 1 on the second compressor and so on This is true for all 4 wires 49 n m gt I N Tee L Bl i z 2 NELST a COPTIONAL COPTIONAL u gt z 1 2 amp amp a Ld 8 E 6 1 r t lt 1 1 1 1 t t 1 fee fea COPTIONAL IPS sb Mb OPTIONAL AT x ON ON m 1 1 1 T m 2 a a m 2 2 1 0 120v 2 OPTIONAL 3 8 0 REFERENCE DRAWINGS 8 1 ELECTRICAL SCHEMATIC STAR DELTA 50 54418074 REV B 54418074 REV B 211 5 8 55344 39V1SH31NI NV ONIYINOAY LON INN
60. air piping Moisture in compressed air is responsible for costly problems in almost every application that relies on compressed air Some common problems caused by moisture are rusting and scaling in pipelines clogging of instruments sticking of control valves and freezing of outdoor compressed air lines Any of these could result in partial or total plant shutdown Compressed air dryers reduce the water vapor con centration and prevent liquid water formation in compressed air lines Dryers are a necessary companion to filters aftercoolers and automatic drains for improving the productivity of compressed air systems 10 ISOLATION VALVE DRIP LEG DISCHARGE PIPING WITH AFTERCOOLER PRESSURE ISOLATION RELIEF VALVE RECIPROCATING COMPRESSOR PRESSURE GAUGE ISOLATION VALVE STRAINER SEPARATE LINES ROTARY GOING TO THE COMPRESSOR RECEIVER 1 DRIP LEG ROTARY RECIP IN PARALLEL 200 120 hours 1000 acfm 80 Gallons of Water 24 40 DEW POINT without 100 8 35 F 1 7 40 40 Aftercooling with Refrigerated Desiccant Aftercooler Dryer Dryer MOISTURE CONTENT OF COMPRESSED AIR Two types of dryers refrigerated or desiccant are used to correct moisture related problems in a compressed air system Refrigerated dryers are normally specified where compressed air pressure dew points of 33 F 1 C to 39 F 4 C are adequate Desicc
61. all scavenge tube down into the tank until the tube just touches the separator element and then raise it 1 8 inch 3 2 mm Tighten fittings Install the regulation lines in their original position Start unit check for leaks place in service WARNING This machine contains high air pressure which can cause severe injury or death from hot oil or flying parts Always relieve pressure before removing caps plugs covers or other parts Blow down pressurized air system Close isolation valve See Operators Instruction Manual RECOMMENDED BOLT TIGHTENING CROSS PATTERN 125 200 HP 33 34 4 9 COOLER CORES CLEANING Ensure the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg Ensure the main power disconnect switch is locked open and tagged See Figure 4 9 1 HASP TAG KEY LOCK FIGURE 4 9 1 MAIN DISCONNECT LOCKED AND TAGGED TOOLS REQUIRED m Screwdriver Wrench set m Air hose equipped with approved O S H A nozzle On units sold outside the U S A consult local codes PROCEDURE Visually check the outside of the cooler cores to be certain that a complete outside cleaning of the cooler is required Frequently dirt dust or other foreign material may only need to be removed with an air hose to remedy the problem When the cooler is covered with a combination of oil grease or other heavy substances that may affec
62. an be used to lift the crates but spreader bars must be used to prevent the slings from exerting a force against the sides of the crates 1 3 TOOLS Remove compressor unit from wooden skid A crowbar and hammer will be needed WILL REDUCE SCRATCHES FORKLIFT PADDING AND MARS SPREADER IMPORTANT Before starting this air compressor unit the shipping brace s must be removed Save the brace s for future use See tag in unit 2 0 INSTALLATION 2 1 VENTILATION Oil flooded rotary 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 exhaust is allowed to recirculate back to the compressor the compressor will overheat and shut down This heat must be exhausted from the room You should take this into consideration when you decide where to place the compressor within your plant Consider that the required maintenance clearance is 3 ft 9 m all around the compressor However 42 1 06m or minimum required by latest NEC or applicable local codes must be maintained in front of control panel Ambient temperatures higher than 115 F 46 C should be avoided as well as areas of high humidity Consider also the environment surrounding or near the compressor The area selected for the location of the compressor should be free of dust chemicals metal filings paint fumes and ov
63. ant dryers are required where pressure dew points must be below 33 F 1 C Contact your local Ingersoll Rand distributor for assistance in selecting correct Ingersoll Rand filtration or drying products NOTE Screw type compressors should not be installed in air systems with reciprocating compressors without a means of pulsation isolation such as a common receiver tank We recommend both types of compressor units be piped to a common receiver utilizing individual air lines When two rotary units are operated in parallel provide an isolation valve and drain trap for each compressor before the common receiver 2 4 ELECTRICAL INSTALLATION Before proceeding further we recommend that you review the safety data in the front of this manual Locate the compressor data plate on the side of the cooler box or end of the unit The data plate lists the rated operating pressure the maximum discharge pressure and the electric motor characteristics and power Confirm that the line voltage and compressor nameplate voltage are the same and that the standard starter box meets the intent of NEMA 1 guidelines Open the starter box door Confirm that all electrical connections are made and tightened Confirm that the control transformer is wired correctly for supply voltage See Figure 2 4 1 on next page for typical control transformer wiring PRESSURE RELIEF VALVE ISOLATION VALVE PRESSURE GAUGE
64. cer This setpoint is used to enable or disable sequencer operation 3 6 5 Remote Start Stpop This setpoint is used to enable or disable the remote start stop option 3 6 6 Power Out Restart This setpoint is used to enable or disable the power out restart option if it is installed 3 7 7 Power Out Restart Time If the power out restart option is installed and enabled this setpoint is time period between power returning to the compressor and the compressor starting 3 6 8 Low Ambient This setpoint enables or disables the low ambient option If the low ambient option is enabled sensor 3CTT must be installed in the compressor 3 6 9 Minimum Cooler Out Temperature When the low ambient option is installed this setpoint is the minimum temperature to which the coolant must rise before the compressor will load 3 6 10 Separator Delta P Solenoid This setpoint enables or disables the separator delta p solenoid option Enabling this option will automatically disable the Separator Delta P Sensor option 22 3 6 11 Separator Delta P Sensor This setpoint enables or disables the separator delta p sensor option Enabling this option will automatically disable the Separator Delta P Solenoid option 3 6 12 Lead Lag Cycle Length This setpoint enables the automatic cycling between lead and lag operation If it is set to a value greater than 0 the controller will cycle between lead and lag operation The value of this set point is the c
65. ch 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 Company 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 warranties are limited to specified tests the Company s 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 fulfillment 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
66. circuits 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 flathead 3 8 inch hex driver Before removing any components open the starter box door and check all wiring for tightness A loose wire or bad connection may be the cause of problems This section gives guidelines for removing replacing the Intellisys Controller assembly and the Intellisys Power Supply assembly The controller is mounted in the starter box door and the power supply is mounted on the upper right corner of the starter backpanel on the inside rear of the starter box Controller Removal 1 Open the starter box door 2 Remove each plug in connector labeled P1 P10 from the sides of the controller If any of the cables are not labeled label them with the appropriate plug designator P1 P10 These must be plugged into the correct sockets in the replacement controller 3 Remove and save the Option Module if one is plugged into P9 This must be installed in the replacement controller Note that it is keyed to plug into P9 only one way 4 Remove the six holding sc
67. duled start and scheduled stop times to the same value will disable this option 7 9 REMOTE LOAD UNLOAD The remote load unload option gives the operator the ability to control the loading and unloading of the compressor This option is enabled when two switches are wired to the Intellisys to perform this function The firstswitch is the master local input P3 25 amp 26 and the second switch is the load unload input P3 27 amp 28 If the master local switch is closed the Intellisys will read the load unload switch for loading and unloading the compressor If the load unload switch is closed the Intellisys will load the compressor If the load unload switch is open the Intellisys will unload the compressor If the master local switch is open the Intellisys will ignore the load unload switch and operate the compressor normally 7 10 MODBUS The Modbus option uses the Modbus protocol and modbus address set points in the OPTIONS menu This is used by the Ingersoll Rand service organization 7 11 INTEGRAL SEQUENCING Integral sequencing allows one compressor the lead to sequence up to 3 other compressors The compressors are daisy chained together using port P8 on the Intellisys Each compressor has a unique address and the lead compressor will sequence the other units in numerical order based on that address The lead compressor will be the first to load and the last to unload It is also the only compressor that can modulate
68. e day that the compressor will transfer the lead 25 3 11 WARNINGS Running Unloaded Mode MOD ACS Change Inlet Filter Press RESET Twice STATUS MAIN MENU RESET When a Warning occurs a question mark will flash on the display screen and appear in large letters as shown above The display message will indicate what caused the warning If multiple Warnings exist the small up down arrows Running Unloaded Mode MOD ACS WARNING VANWEND SSS Pressing the WARNING button will return the display to the WARNING screen and the RESET button A Warning needs to be reset by the operator by pressing the RESET button twice The possible Warning messages are as follows AIREND DISCHARGE TEMP This will occur if the Airend Discharge 2ATT exceeds 97 of the alarm limit 228 F 109 C and is not adjustable CHANGE COOLANT FILTER This warning will occur if the high side pressure is 20 psig 1 4 bar greater than the low side pressure of 1 DPS and the Injected Coolant temperature 2CTT is greater than 120 F 49 C CHANGE INLET FILTER This will occur if the Inlet Vacuum 1AVPT is greater than 0 7 psig 05 bar and the machine is fully loaded inlet valve is completely open CHANGE SEPR ELEMENT This warning will occur if the pressure on the Separator is 12 psig 8 bar greater than the pressure at the Package Discharge 4APT and the machine is fully loaded 26 will appear in the upper r
69. ement of the pressure drop across the separator element 7 5 SEPARATOR DELTA P SENSOR The separator delta p sensor option is turned on by enabling it through the OPTIONS set point routine When this option is enabled the Intellisys will measure the pressure drop across the separator element by subtracting the dry side sump pressure GAPT from the wet side sump pressure 3APT Do not enable this option if the separator delta p sensor is not installed This will result in an incorrect measurement of the pressure drop across the separator element and a 6APT sensor failure warning 7 6 HIGH DUST FILTER The high dust filter option is turned on by enabling it through the OPTIONS set point routine If this option is enabled the Intellisys will change its measurement of the inlet filter Do not enable this option unless a high dust filter is installed 7 7 LEAD LAG CYCLE LENGTH The lead lag cycle length option allows the Intellisys to automatically switch the online and offline pressure settings to the lead or lag values after a programmed number of hours This option is enabled by selecting a number of hours greater than 0 in the OPTIONS set point routine 7 8 SCHEDULEDSTART STOP The scheduled start stop option allows the customer to automatically start and stop the compressor once each day based on the real time clock This is an installed option and is enabled by selecting a scheduled start and scheduled stop time Setting the sche
70. erspray 2 2 FOUNDATION REQUIREMENTS Refer to the foundation plan for the particular model compressor to be installed See Section 8 0 The compressor can be installed on any level floor that is capable of supporting it Compressor weights are listed on the foundation plans When sound transmission is of particular importance it is often helpful to install a sheet of rubber fabric matting or cork under the compressor to reduce the possibility of resonant sounds being transmitted or amplified through the floor NOTICE Never elevate the compressor unit above the floor level This may allow air to enter the cabinet under the base Performance will be affected 42 1 06m OR CODE MINIMUM AIR INTAKE 2 3 PIPING 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 oil From a safety standpoint metal bowls should be used on any pressurized system Review of your plant air line system is recommended WARNING Do not use plastic pipe soldered copper fittings or rubber hose for discharge piping The built in aftercooler reduces the discharge air temperature well below the dew point for most ambient conditions therefore considerable water vapor is condensed To remove this condensation each compressor with built in aftercooler is furnished with a combination condensate separator
71. ervice has not been performed by an I R service representative A new service period will start when service is performed If another 100 hours or 14 days elapses and service has not been performed an ALARM SERVICE REQUIRED warning will be issued This warning can only be cleared by an I R service representative SENSOR FAILURE 6APT This warning will occur if the separator delta p sensor option is installed and sensor 6APT is recognized as missing or broken High Airend Disch Temp 209 Press RESET Twice STATUS MAIN MENU RESET When an Alarm occurs an exclamation mark will flash on the display screen as shown above The display message will indicate what caused the Alarm 100 Psi STOPPED BY ALARM Mode MOD ACS The name and value of each of the items listed can be seen by moving the list up and down using the arrow buttons Pressing the ALARM button will return the display to the Alarm screen and the RESET button Pressing the STATUS button will display the ALARM STATUS screen with the ALARM button indicating an Alarm still exists Alarm Status is the list of machine operating conditions that existed at the time of the Alarm ALARM STATUS Package Disch Pressure 100 PSI Package Discharge Temp 103 F ALARM The Alarm needs to be reset by the operator by pressing the RESET button twice Any exceptions to this are explained in the alarm descriptions 27 The possible Alarm messages are as f
72. h 4 ALON 335 Lu 1123 02 137 NI H31VM 25 i 2 NIVHQO JNYL d3S 511 J 081N02 E 83441315 0 v x hbk aa r 1 ADG EL Live 18 310N 335 NO1123NNO NIVHO 38015106 SW 5 JLON 335 NOTL3NNO v 81213 LdVh 11 28 310N 335 AASE v2 V 0S6 SvS WATERCOOLED 90 F 32 C SINGLE STAGE 8 11 FLOW SCHEMATIC 70 9NIdId 39N3AV25 6 9NIdId 1 002 081 2 52 5NIdld MIV 0HINO2 v gt Q 9ONIdId H31VM 9NIdId 1 1002 gt 9NIdId HIV v QN3531 5NIdId AINO dHOSh OSE NO Q3HIDnO3H ASE 72 LINN 340 NOTLVQNNOS 135 5 01123 02 Y3BWOLSND 80371 S310N HOLIAS 3ufSS3Hd WIIN3H344IQ 8317142 1 1002 211 5 3univH3dW3l HIV HJIH HOSN35 34ni1vH3dW31 HIY 35HVH2SIQ 35vxovd 05 15 3uniVu3dH31 HIY 39 2510 QN3UIV HOSN3S 3801193631 1 1002 32 95 1 34155344 HIV JAIS AYO WNYL HOlVuvd3S 3 1553 9 MIY 39HvYH2SIQ ua nasNvul 38055344 3915 13 1 HOLViHVd3S u3 naSNvuli 3unssS3ud WONIVA LIWII 32134180 9 25 35 1 35 380151080 u31002u3L4v 431002 1NY 002 010837105 4015 I1NY 005 910 3105 330 1 5 H3lV 1 010 3105
73. h 1910 329 3 Do not operate the compressor at higher discharge pressure than those specified on the Compressor Nameplate or motor overload will occur This condition will result in compressor motor shutdown 4 Use only safety solvent for cleaning the compressor and auxiliary equipment 5 Install a manual shut off valve isolation type in the discharge line When a safety valve is installed between the isolation valve and the compressor it must have sufficient capacity to relieve the full capacity of the compressor s 6 Whenever pressure is released through the pressure relief valve it is due to excessive pressure in the system The cause for the excessive pressure should be investigated immediately 7 Before doing any mechanical work on the compressor a Shut the unit down b Electrically isolate the compressor by use of the manual disconnect switch in the power line to the unit Lock and tag the Switch so that it cannot be operated C Vent pressure from the compressor and isolate the unit from any other source of air 8 There can be adverse effects if compressor lubricants are allowed to enter plant air systems Air line separators properly selected and installed will minimize any liquid carry over The use of plastic bowls on line filters without metal guards can be hazardous From a safety standpoint metal bowls should be used on any pressurized system Review of your plant air line system
74. h allows for automatic standby air capacity control During periods of low air demand if the line pressure rises to the upper set point the Intellisys begins to time out If the line pressure remains above the lower set point for as long as the set time the compressor will stop At the same time the display will indicate the compressor has shut down automatically and will restart automatically An automatic restart will occur when the line pressure drops to the lower set point The upper and lower set points and shutdown delay time are set on the Intellisys control panel There is a 10 second delay after shutdown during which the compressor will not restart even if line air pressure drops below the lower set point This is to allow the motor to come to a complete stop and the Intellisys controller to collect current data of operating condition If line air pressure is below the lower set point at the end of 10 seconds the unit will start unless the load delay timer is set greater than 10 seconds Auto Restart Delay This is the number of seconds the line pressure must remain below the online set point before the compressor will start if it was stopped due to an auto start stop situation This timer will not delay an auto restart if the time is set to 0 Automatic Start Stop Operation When in operation the compressor must meet two specific timing intervals before the Intellisys controller will stop the unit in an Automatic Start Stop
75. h the coolant Hot coolant can cause severe injury Use care when draining separator tank To drain the unit remove plug from drain valve located on the bottom of the separator tank Install supplied drain hose and fitting assembly in end of drain valve and place end of hose in a suitable pan Open drain valve to start drainage After draining is complete close valve remove hose and fitting assembly from valve and store in a suitable location for future use Replace plug in end of drain valve Do not store drain hose in starter box after it has been used to drain the separator tank Coolant fill quantity 125 200 HP 90 160 KW Single Stage 23 gallons 87 4 liters 100 HP 75 KW 2 Stage 22 gallons 83 3 liters 125 200 HP 90 160 KW 2 stage 30 gallons 113 6 liters COOLANT DRAIN N WARNING Hot coolant can cause severe injury Use care when near this area Filler Cap Use only recommended coolant Read instruction book before servicing 39543921 31 4 6 COOLANT Continued After the unit is drained and a new coolant filter element is installed refill the system with fresh coolant Bring the receiver level of coolant up to the midpoint of the sight glass Replace the fill cap Start the compressor and run it for a short time The correct coolant level is at the midpoint of the sight glass with the unit running in the UNLOADED mode 4 7 SEPARATOR TANK SCAVENGE SCRE
76. ight corner of the display screen The multiple Warnings can be seen by pressing the up and down arrow buttons Pressing the STATUS button will display the CURRENT STATUS screen with the WARNING button indicating a Warning still exists CURRENT STATUS Package Discharge Temp 103 F Airend Discharge Temp 193 F HIGH DISCHARGE PRESS This can occur if the machine s loading function is being controlled by a host device such as a sequencer or an ISC This warning will occur when the package discharge pressure is above the maximum offline pressure rated pressure plus 3 psig 2 bar for more than 3 seconds This warning will cause the compressor to unload The host device will not be able to load the compressor until the package discharge pressure falls to the rated pressure of the machine SENSOR FAILURE 4ATT This will occur if the Package Discharge Temperature Sensor 4ATT is recognized as missing or broken AUXILIARY 1 OR 2 This warning will occur if either of the auxiliary contacts closes HIGH SUMP LINE DIF This warning will occur if the compressor is running loaded the injected coolant temperature is greater than or equal to 120 deg F 49 C the package discharge pressure is greater than 90 psig 6 3 bar the sump pressure is greater than the compressor s rated pressure and the sump pressure is 25 psig 1 8 bar or more above the package discharge pressure 3 11 WARNINGS CONTINUED COMMUNICATION
77. iller Cap Use only recommended coolant Read instruction book before servicing 39543921 39543921 Rev 03 FOOD GRADE COOLANT OPTION ONLY TEMS MARKED WITH ARE OPTIONS THAT ARE AVAILABLE recommend that you obtain a replacement kit as listed in the spare parts section of the Parts List Manual Form APDD 735 for single stage and Form APDD 736 for two stage units al Hot surface Can cause severe injury Do not touch Allow to cool before servicing 39541362 Rev 04 N CAUTION Use of incorrect coolant can cause system contamination Use only SSR ULTRA COOLANT 39540265 Rev 05 FOOD GRADE COOLANT OPTION 39568464 N WARNING M High pressure air Can cause severe injury or death Relieve pressure before removing filter plugs caps fittings or covers 39540240 Rev 04 CAUTION Improper maintenance of coolant filter can cause compressor damage Change coolant filter after first 150 hours of operation and every 2000 hours thereafter or when coolant is changed 39544143 03 N WARNING iw Moving parts Can cause severe injury Do not operate with covers removed Service only with machine blocked to prevent turn over 39540224 Rev 04 am 0 3 DECALS continued Moving parts Can cause severe injury Do not operate with covers removed Service only with machine blocked t
78. ilures 3 10 4 Load Delay Time This is the number of seconds the lead compressor will wait for the package discharge pressure to start rising after issuing a load command to another compressor If the package discharge pressure has not started rising at the end of this time period the lead compressor will load the next compressor in the sequencer INTEGRAL SEQUENCING Lead Compressor Total Compressors Compressor Address Load Delay Time Lead Change Hours RANGE On Off Always Never 2 to 4 1 to Total Compressors 10 to 60 0 to 750 Sun to Sat Daily Week Day Week End 00 00 to 23 59 STEP Lead Change Day Lead Change Time 3 10 5 Lead Change Hours This is the number of hours the compressor will operate as the lead unit Once a compressor has operated as the lead for this number of hours it will transfer the lead to the next compressor in the sequence This setpoint does not apply to a unit where the lead compressor is set to always or never If this setpoint is set to 0 the next 2 setpoints will determine when the lead is transferred 3 10 6 Lead Change Day amp Lead Change Time These two setpoints are used together If the Lead Change Hours setpoint is set to 0 these two setpoints will be used to determine when the compressor will transfer the lead to the next compressor in sequence Lead Change Day is the day of the week that the compressor will transfer the lead Lead Change Time is the time of th
79. in certain situations and timer settings thereby reducing power costs 44 Some Examples of Operation EXAMPLE 1 The operator selects an unloaded run time of 2 minutes in the OPTION routine and starts the compressor The unit runs loaded for 8 minutes unloads and then runs unloaded for two more minutes The total running time is 10 minutes which satisfies timer plus the unit ran two minutes unloaded which also satisfies timer B therefore the unit stops automatically This example shows how timer B can sometimes be included within the timer A interval Think of the two timers as running parallel EXAMPLE 2 The operator selects an unloaded run time of 3 minutes in the OPTION routine and starts the compressor The unit 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 more minutes 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 is canceled and timer B must restart the 3 minute cycle when the compressor unloads again EXAMPLE 3 The operator selects an unloaded run time of 10 minutes in the OPTION routine and starts the compressor The unit runs loaded 12 minutes and then unloads After 12 minutes of running the 10 minute mandatory run time for timer
80. irect sunlight and UV rays will degrade the membrane touch panel This is not a warrantable situation m Power disconnect switch should be within line of sight and in close proximity to the unit N E C and local electrical codes must be followed when installing the power disconnect switch 14 Condensate drains must never be allowed to dump on the ground Run to a suitable sump for future collection and disposal or separation of lubricant and water mixture Incoming power connections must use suitable connectors for outdoor weather tight service A minimum of 3 ft 9 m clearance must be allowed on all four sides of the unit for service access If possible access by a forklift and or an overhead beam hoist should be kept in mind for eventual service to airend or motor If the area around the installation contains fine airborne dust or lint and fibers etc then the unit should be purchased with the High Dust Filter Option and TEFC motors If larger debris such as leaves or trash are blowing in the area the Inlet Panel Filter Accessory should be purchased and added to the unit ship loose item Some type of protection such as a fence or security system should be provided to prevent unauthorized access SL SS POWER DISCHARGE DISCONNECT PIPE SWITCH STEEL LOCKABLE INTELLISYS ZS FEET 9 METERS CONTROLLER MINIMUM FACING AWAY CLEARANCE ALL FROM
81. is recommended 9 When a receiver is installed it is recommended that occupational safety and health standards as covered in the Federal Register Volume 36 number 105 part 11 paragraph 1910 169 be adhered to in the installation and maintenance of this receiver 10 Before starting the compressor its maintenance instructions should be thoroughly read and understood 11 After maintenance functions are completed covers and guards must be replaced N SAFETY SHUTDOWN CHECK HIGH AIR TEMPERATURE There is a high discharge air temperature shutdown function built into the Intellisys on each compressor It is factory pre set at 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 should indicate HIGH AIREND DISCH TEMP and flash ALARM The actual temperature at which shutdown occurs should be recorded for comparison to the Intellisys set point and with similar future test results N WARNING 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
82. is set to lag see 3 5 1 the value of the lag offset will be subtracted from the online and offline setpoints 3 5 5 Mode of Operation This setpoint is used to select the operating mode of the compressor The choices are MOD ACS ON OFF LINE and MODULATION ONLY See section 5 8 for more information on these operating modes 3 6 OPTIONS 100 esi Ready To Start 3 5 6 Max Modulation Pressure This setpoint is the pressure the compressor will unload at if it is modulating As the package discharge pressure rises toward this value the inlet valve will start to close The compressor will unload once the package discharge reaches this value See section 5 8 for more information on modulation 3 5 7 Stop Delay Time This setpoint is the minimum amount of time the compressor will run unloaded before stopping This period does not apply to alarms shutdowns 3 5 8 Star Delta Time This setpoint is only used with star delta starters It is not used if the starter is full voltage or a remote starter This is the time period between starting and star delta transition 3 5 9 Contrast This setpoint is used to improve the display on the Intellisys OPTIONS Auto Restart Off Auto Restart Time 10 MINUTES STATUS MAIN MENU SELECT Options are turned on or off and their associated values are set using the OPTION screen Some options require additional machine hardware and the proper Option Module to pl
83. ll affect performance Lift only from base channels am 39540232 Rev 03 Discharge air ie Can contain carbon monoxide or Motors must be greased periodically other contaminants Will cause severe injury or death Do not breathe this air am 39857552 Rev 04 See Operators Manual for procedure WATERCOOLED UNITS ONLY 39540166 06 0 3 DECALS continued Ingersoll Rand Compressor Package Data GFP Ingersoll Rand Compressor Package Data COMPRESSOR MODE COMPRESSOR MODEL RATED OPERATING PRESSURI RATED OPERATING PRESSURE PSIG MAX DISCHARGE PRESSURE PSIG W A R N G MAX MODULATE PRESSURE PSIG NOMINAL DRIVE MOTOR HP NOMINAL FAN MOTOR NOMINAL FAN MOTOR TOTAL PACKAGE TOTAL PACKAGE AMPS SERIAL NUMBER CONTACTOR AMP RATING ASSEMBLY RATING LOCKED ROTOR AMP RATING OF ASSY AIR SOLUTIONS GROUP DAVIDSON NORTH CAROLINA 28036 WWW AIRINGERSOLL RAND COM 39557095 05 SERIAL NUMBER CONTACTOR AMP RATING ASSEMBLY AMP RATING LOCKED ROTOR AMP AIR SOLUTIONS GROUP DAVIDSON NORTH CAROLINA 28036 WWW AIR INGERSOLL RAND COM 54425996 Hazardous voltage Can cause 39557095 Rev 05 100 200 HP 2 REQUIRED 54425996 Rev 75 160 KW 2 REQUIRED Only
84. mitted at any particular time The action resulting from pressing each of these buttons is indicated in Figure 3 2 1 which can be used as a quick reference of how to step the controller screen through any desired function CURRENT STATUS Package Discharge Temp 103 F Airend Discharge Temp 193 F x MAIN MENU ee The CURRENT STATUS screen is considered the normal display that the controller shows The following items and their present values can be displayed on the right side of the screen by pressing the up and down arrow buttons CURRENT STATUS Items Discharge Temperature Inlet Vacuum Airend Discharge Temperature Inlet Filter Injected Temperature Total Hours Loaded Hours Load Modulation Unloaded Inlet Vacuum Coolant Pressure Time amp Date Software Title and Version Sump Pressure Separator Pressure Drop Coolant Filter 18 The controller automatically returns the display to this CURRENT STATUS screen from other screens if no buttons are pressed within 30 seconds The MAIN MENU screen can be accessed from the CURRENT STATUS screen by pressing the MAIN MENU button identified by the words MAIN MENU in the bottom line of the screen directly above the center button 61 SASITTALNI Main Menu Status Status gt CURRENT STATUS Main Menu Status MAIN MENU Main Menu
85. n 200 HP A C Two Stage 8 8 foundation plan 125 150 HP W C Two Stage 8 9 foundation plan 200 HP W C Two Stage 8 10 flow schematic A C Single Stage 8 11 flow schematic W C 90 F 32 C Single Stage 8 12 flow schematic W C 115 46 C Single Stage 8 13 flow schematic A C Two Stage 8 14 flow schematic W C 90 F 32 C Two Stage 8 15 flow schematic W C 115 46 C Two Stage 8 16 typical system flow diagrams WATER QUALITY RECOMMENDATIONS MAINTENANCE RECORD See foundation plan Section 8 0 Cooling Air Flow See foundation plan Section 8 0 Ambient Temperature Limits 35 F to 115 F 2 C to 46 Coolant Factory Filled SSR Ultra Coolant Coolant Change 8000 hours or two years whichever comes first Coolant Capacity 125 200 HP 90 160 KW Single Stage 23 0 gallons 87 4 liters 100 HP 75 KW Two Stages 22 0 gallons 83 3 liters 125 200 HP 90 160 KW Two Stages 30 0 gallons 113 6 liters Discharge Temperature Limit 228 F 109 C Power Inlet Wiring Recommended conduit metallic flexible Greenfield or equivalent EDI U S standard and metric are required to perform maintenance 0 0 SAFETY AND WARNING
86. n this manual 17 3 2 DISPLAY SCREEN 100 Running Loaded Mode MOD ACS CURRENT STATUS Package Discharge Temp 103 F Airend Discharge Temp 193 F SS MAINMENU The display screen is divided into three functional areas as seen in the typical CURRENT STATUS screen shown here The left side continuously shows the package discharge pressure in large numbers with the line directly below the numbers showing the running condition of the machine and the line below that showing the present mode of operation The right side shows various items or lists such as the machine s CURRENT STATUS readings the MAIN MENU the OPERATOR SETPOINTS list etc Any of the lists can be moved up or down by pressing the arrow buttons to the right of the screen The small arrow s displayed in the upper right corner of the screen indicate when you can move up designated by 3 3 CURRENT STATUS Running Loaded Mode MOD ACS arrow head pointing up and or down designated by arrow head pointing down through a list The arrow buttons are also used to change an individual item s value At certain times items and or their values are highlighted This means they are displayed as light characters on a dark background The bottom of the screen is divided into thirds with the words in each small box showing the function of the button directly beneath it The words will change in these boxes depending on what actions are per
87. necessary Verify that the main isolation valve is open If watercooled turn on water Close main disconnect switch An active screen indicates voltage 15 available to the Intellisys controller The POWER lights indicate that line and control voltages are available for starting Starting Push START The compressor will start and load automatically if there is sufficient demand for air Stopping 1 Push STOP Compressor will immediately unioad and continue to run unloaded an adjustable 10 30 seconds Compressor will then stop If the compressor does not stop running after the set time depress the EMERGENCY STOP If compressor is running unloaded when STOP 15 pushed compressor will stop immediately Open main disconnect switch Stopping Emergency 1 there is a need to stop the compressor immediately depress the EMERGENCY STOP 2 Open main disconnect switch Push Button Functions CJI START STOP UNLOAD 33 LOAD FIGURE 2 4 4 INTELLISYS OPERATING INSTRUCTIONS 13 2 5 OUTDOOR SHELTERED INSTALLATION Many times a compressor must be installed outside due to jobsite conditions or limited space within a manufacturing facility When this occurs there are certain items that should be incorporated into the installation to help ensure trouble free operation These items have been listed below plus Figure 2 5 1 has been included to show a typical outdoor sheltered installation The unit must be purchased with the Outdo
88. o prevent turn over 39540224 04 Do not operate with covers removed Disconnect power Lock and tag 39557095 Rev 05 100 200 HP J 39540190 Rev 04 Rotation N WARNING 2 2 Hot surface Can cause severe injury Do not touch Allow to cool before servicing Water out 39541321 Rev 04 Water in 39541339 Rev 03 Lift Here 39540273 Rev 04 N WARNING 22 Rotation GD ingersoll Rand 39541362 Rev 04 dm Ingersoll Rand Compressor Package Data COMPRESSOR MODEL 39540182 04 Exposed fan blade Can cause severe injury ASSEMBLY AMP RATING LOCKED ROTOR RATING OF ASSY IR 39540257 Rev 04 39544150 Rev 03 Electrical power inlet 39541354 03 Condensate drain qm 39541081 Rev 04 NOTICE To obtain satisfactory compressor operation and maintenance a minimum of 3 feet clearance on 3 sides is VI EWED required 3 1 2 feet is required in front of the control panel or minimum required by FROM latest National Electrical code or applicable local codes REAR Refer to the Instruction Operators Manual before any maintenance DANGER Incorrect lifting of machine Do not operate without enclosure can cause injury or property panels and forklift covers in place damage Enclosure panels wi
89. o highlight the date Once the correct date is displayed press SET to highlight the year Once the correct year is displayed press SET to complete setting the date 3 10 INTEGRAL SEQUENCING 100 esi Ready To Start INTEGRAL SEQUENCING Lead Compressor Off Total Compressors 2 STATUS MAIN MENU SELECT 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 moving the list up and down using the arrow buttons 3 10 1 Lead Compressor The choices for this setpoint are On Off Always and Never On means the compressor is the lead unit Off means the compressor is not the lead unit but it could become the lead unit If Always is selected the compressor is the lead unit and it will not transfer the lead to another compressor Never means the compressor is not the lead unit and will never become the lead unit The operator must set one unit and only one to On or Always to start integral sequencing 3 10 2 Total Compressors This is the total number of compressors in the integral sequence This setpoint must be set to the same number on each compressor 3 10 3 Compressor Address This is the address of the compressor in the integral sequence No two compressors can have the same address Two compressors with the same address will cause communication fa
90. o the separator element The separator element is constructed with two concentric cylindrical sections of closely packed fibers each held in steel mesh It is flange mounted at the separator outlet cover The air stream enters the separator element radially and the mist coalesces to form droplets The droplets collected on the outer first stage fall to the separator sump Those collected on the inner second stage collect near the outlet of the element and are drawn back to the compressor inlet through a filter screen and orifice fitting installed in the separator scavenge line The air stream now essentially free of coolant flows from the separator to the aftercooler then to the condensate separator and on to the plant air system 5 6 ELECTRICAL SYSTEM The electrical system of each SSR compressor is built around the microprocessor based Intellisys controller The standard electrical electronic components enclosed in a readily accessible enclosure include 1 Intellisys controller 2 Compressor motor starter with auxiliary contacts and overload relays 3 Cooling fan motor overload relays and circuit breaker or fuses 4 Intellisys Power Supply Board 5 Control transformer and fuses Options such as power outage restart can be enabled by installing plug in option modules in the Intellisys controller 41 5 6 ELECTRICAL SYSTEM Continued STAR DELTA TYPE STARTER By use of the Star Delta type starter the compre
91. ogging commercial shock treatments 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 FREQUENCY OF ANALYSIS Corrosivity hardness temperature at inlet alkalinity Langelier Index pH total dissolved solids 0 to 1 Monthly if stable for 3 to 4 months analyze quarterly Iron 2 ppm Monthly Sulfate 50 ppm Monthly Chloride 50 ppm Monthly Nitrate 2 ppm Monthly Silica 100 ppm Monthly Dissolved oxygen 0 ppm Daily as low as possible if stable analyze weekly Oil and grease 5 ppm Monthly Ammonia 1 ppm Monthly 85 Recommended equipment for on site analysis includes a thermometer pH meter and dissolved oxygen meter Dissolved oxygen 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 professional water quality analyst The Langelier Index LI is calculated using the following equation and the tables found on the following pages LI pH 9 30 Total Dissolved Solids chart value Temperature chart value Hardness chart valve Alkalinity chart value The LI is zero when the water is in chemical balance If the LI is greater than zero there is a tendency to form scale If the LI is less than zero the water tends to be corrosive Dissolved oxygen ma
92. ollows CHECK INLET CONTROL This will occur if the machine is unloaded and the inlet vacuum is less than 3 psig 2 bar CHECK INLET CTRL SYS 1 2 This will occur if the inlet butterfly valve fails to open or close properly A 1 means the inlet valve failed to closer properly A 2 means the inlet valve failed to open properly CHECK MOTOR ROTATION This will occur if the machine is started and the compressor has incorrect rotation CONTROL POWER LOSS This will occur if the controller detects a loss of the 110 VAC or 120 VAC control power EMERGENCY STOP This will occur if the Emergency Stop button is engaged The button must be disengaged before the alarm can be cleared FAN MOTOR OVERLOAD This will occur if a fan motor overload is sensed HIGH AIREND DISCH TEMP This will occur if the airend discharge temperature is greater than 228 F 109 C LOW SUMP AIR PRESSURE This will occur if the machine is running fully loaded and the sump pressure drops below 20 psig 1 4 bar LOW UNLOAD SUMP PRESS This will occur if the machine is running unloaded and the sump pressure is less than 15 psig 1 0 bar for 15 seconds MAIN MOTOR OVERLOAD This will occur if a drive motor overload is sensed CHECK SET POINTS This will occur if the controller has determined some of the data stored in memory contains unacceptable values When this occurs the sensors should be calibrated and all the set points checked It is normal for
93. operation and every 2000 hours thereafter or when coolant is changed VALVE FURNISHED ONLY ON UNITS EQUIPPED WITH LUBRICANT PUMP COOLANT FILTER 100 HP 75 KW REQUIRES 1 ELEMENT 125 200 HP 90 160 KW REQUIRES 2 ELEMENTS 4 6 COOLANT SSR Ultra Coolant Standard Factory Fill m SSR H1 F Food Grade Optional SSR Ultra Coolant is a polyglycol base coolant Change Ultra Coolant after every 8000 hours or every two years whichever comes first SSR Food Grade Coolant is a polyalphaolefin base coolant Change after every 1000 hours or every 6 months whichever comes first Do not operate unit beyond this 1000 hour lubricant change interval as lubricant degradation will occur Items Required In addition to the tools normally found in any reasonably equipped serviceman s toolbox the following items should be available at the work site 1 Suitable drain pan and container to hold lubricant drained from unit 2 Aquantity of proper lubricant sufficient to refill the compressor 3 Aminimum of one replacement coolant filter element of the proper type for the unit to be worked on There is a coolant drain hose supplied with each compressor The drain hose is placed in the starter box when shipped from the factory The coolant should be drained soon after the compressor has been shut down When the coolant is hot drainage will be more complete and any particles in suspension in the coolant will be carried out wit
94. or Modification Option to provide NEMA 4 electrics and a cabinet exhaust on the end of the unit rather than the top to prevent recir culation of cooling air m The compressor should be on a concrete pad designed to drain water away If the concrete pad is sloped then the compressor must be leveled In order to properly pull cooling air through the aftercooler the base skid must be sealed to the concrete pad m 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 m Air cooled machines must be arranged under the shelter in a way that prevents air recirculation i e hot exhaust back to the package inlet m the installation includes more than one compressor the hot air exhaust should not be directed towards the fresh air intake of the second unit or an Air Dryer m standard machine is to be installed outside the ambient temperature must never drop below 35 F 1 70 m lf ambient temperature drops below 35 F 1 7 C to as low as 10 F 23 C the unit must be supplied with the Low Ambient Option Installations below 10 F 23 ambient are not recommended The Low Ambient Option requires a separate power source to operate internal heaters m Arrange the machine with the Intellisys con troller starter enclosure facing away from the sun as radiant heat can affect starter Intellisys performance Also d
95. pment AFTERCOOLER Following are instructions for the removal and internal cleaning of aftercoolers Aftercooler Disconnect hose from aftercooler inlet flange m Disconnect tube from aftercooler outlet flange m Remove aftercooler holding screws from aftercooler support and remove cooler Aftercooler Cleaning m is recommended the cooler be taken to a professional cooler service shop for flushing with an appropriate environmentally safe cleaning agent m Reassemble in reverse order m Replace enclosure panels 35 4 10 MOTOR LUBRICATION The induction type squirrel cage motors have antifriction ball or roller bearings front and rear At periodic intervals they require relubrication Relubrication Interval 60 Hz or 9 months whichever comes first 1000 hours all TEFC drive motors 2000 hours all ODP drive motors and all fan motors Relubrication amount Lubricant Amount Motor Frame Size in cc 02 grams 182 215 5 254 286 1 0 324 365 1 5 404 449 2 5 5000 Frame Series 1 0 Relubrication Interval 50 Hz or 9 months whichever comes first 2000 hours M90 160 KW TEFC drive motors 4000 75 TEFC drive motors Relubrication amount Lubricant Amount Motor Frame Size in oz grams As indicated on motor nameplate M75 160 Improper lubrication can be a cause of motor bearing fail
96. 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 Equipment will be at Purchaser 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 or negotiated as part of the purchase order may take precendence over this warranty INGERSOLL RAND COMPANY ROTARY SCREW AIR COMPRESSOR This unit was purchased from Ingersoll Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously Number of units on order Customer Order Number Ingersoll Rand Company Order Number For ready reference record the serial number and model number of your unit here Serial Number Model Number TABLE OF CONTENTS 0 0 1 0 2 0 3 0 4 0 5 0 6 0 SAFETY AND WARNINGS 0 1 safety instructions 0 2 safety precautions 0 3 decals RECEIPT OF EQUIPMENT 1 1 inspection 1 2 unpacking and handling 1 3 tools INSTALLATION 2 1 ventilation 2 2 foundation requirements 2 3 piping 2 4 electrical installation 2 5 outdoor sheltered INTELLISYS 3 1 intellisys controls 3 2 display screen 3 3 current status 3 4 main menu 3 5 operator setpoints 3 6 options 3 7 sensor calibration 3 8
97. rews from the con troller on the inside of the starter box door 5 Remove the controller through the front of the door being careful to save the gasket that is between the controller and the door Power Supply Removal 1 Open the starter box door 2 Remove 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 supply 3 Remove the four screws holding the power supply to the starter plate save them for mounting the replacement board and remove the power supply 4 14 COOLANT HOSES The flexible hoses that carry coolant to and from the oil cooler may become brittle with age and will require replacement Have your local Ingersoll Rand distributor check them every 2 years Ensure the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg Ensure the main power disconnect switch is locked open and tagged REMOVAL Remove enclosure panels Drain coolant into a clean container Cover the container to 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 by reversing the disassembly procedure Start the compressor and check for leaks
98. roubleshooting a problem 6 0 TROUBLESHOOTING CHART WHAT TO DO CAUSE amp OR DISPLAY 110 120V control voltage not available CONTROL POWER LOSS STARTER FAULT EMERGENCY STOP MAIN OR FAN MOTOR OVERLOAD SENSOR FAILURE XXXX CHECK INLET CTRL SYS Intellisys 24 VAC control voltage not available Display panel and power on light does not illuminate HIGH AIREND DISCH TEMP LOW UNLOAD SUMP PRESS CHECK INLET CTRL SYS SENSOR FAILURE XXXX CHECK MOTOR ROTATION MAIN MOTOR OVERLOAD FAN MOTOR OVERLOAD STARTER FAULT CHECK SET POINTS CONTROL POWER LOSS STEPPER LIMIT SWITCH REMOTE STOP FAILURE REMOTE START FAILURE EMERGENCY STOP LOW SUMP AIR PRESS CHECK INLET CONTROL Check fuses Check transformer and wiring connections Inspect contactors Rotate emergency stop button to disengage and press reset button twice Manually reset main or fan motor overload relay and press reset button twice Check for defective sensor bad sensor connection or broken sensor wires Call factory representative Check fuses Check wiring Verify 24 VAC is within voltage tolerance 15 Ensure that installation area has adequate ventilation Ensure that cooling fan is operating If not reset circuit breaker inside starter box Check coolant level Add if required Cooler cores dirty Clean coolers Check for air leak from tank or blowdown piping Check for slipping or broken stepper motor coupling
99. situation For this discussion the timers will be called timer A and timer B FIRST Timer A prevents the compressor from automatically starting more than 6 times an hour by requiring the unit to run at least 10 minutes after each automatic start This 10 minute run period can be loaded unloaded or a combination of the two and allows dissipation of heat generated within the motor windings at start 43 SECOND After the compressor has started 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 part of the options setpoint routine and the timer cancels any accumulated time if the compressor reloads before the timer cycle has finished An important point This unloaded run time may or may not be included in the mandatory 10 minute run time used to cool the motor windings When the compressor has completed the settings of both timer A and timer B the Intellisys controller stops the compressor and displays STOPPED IN AUTO RESTART Pressure sensor 4APT continues to monitor the package discharge pressure and sends information to the controller which automatically restarts the compressor when the pressure falls to the on line setting An advantage to this method of automatic start stop control is allowing the compressor to stop much sooner
100. ssible After depressing the start button IMMEDIATELY depress the EMERGENCY STOP button Should the motor rotation be incorrect put main disconnect in the OFF position lock and tag See Figure 2 4 3 HASP FIGURE 2 4 3 MAIN DISCONNECT LOCKED AND TAGGED Open the starter box door Interchange any two line connections L1 L2 or L3 at the starter Close and fasten the starter box door Recheck for correct rotation FAN MOTOR Observe the compressor cooling fan The rotation should be in accordance with the fan rotation decal affixed to the fan motor Cooling air should exhaust through fan end of compressor enclosure Should the motor rotation not be correct put the main disconnect in the OFF position lock and tag Interchange any two fan motor leads at the fan motor manual starter MMS Close and fasten the starter box door Recheck for correct rotation Fan motor rotation is clockwise when viewed from the fan motor side INTELLISYS OPERATING INSTRUCTIONS Read and understand the following Intellisys Operating Instructions See Figure 2 4 4 prior to operating the unit NOTE These instructions are also contained on the decal near the Intellisys panel of the unit NOTICE Inteilisys Operating instructions Before installing operating or performing any maintenance on this unit read and understand the instructions in the Operators Instruction Manual Before Starting Check coolant level Add coolant if
101. ssor motor can be started and accelerated using a greatly reduced inrush electric current The starter is completely automatic and controlled by the Intellisys controller Refer to the Electrical Schematic 8 1 in Section 8 0 5 7 STEPPER MOTOR INLET CONTROL The inlet valve is opened and closed by a stepper motor mounted on the inlet valve The Intellisys controller regulates the stepper motor to precisely position the inlet valve based upon the demand of the plant air system See Section 5 8 The stepper motor is maintenance free Bearings are lubricated at the factory and sealed for life No adjustment of the stepper motor inlet valve system is required 5 8 CAPACITY CONTROL The SSR compressor is supplied as standard equipment with three operator selectable capacity control systems each designed for different plant air requirements MOD ACS Modulation Automatic Control Selector On Off Line Modulation Only The desired control is selected at the Intellisys control panel See Section 3 0 AUTOMATIC UNLOADED START The compressor will always start in the unload mode When unloaded the inlet valve is nearly closed the blowdown solenoid valve is open tank vented and the compressor is operating at minimum power The Intellisys will open the inlet valve slightly to maintain the proper sump pressure to ensure positive coolant flow and smooth quiet operation When the injected coolant temperature is less than 1
102. t the unit s cooling then it is recommended that the cooler cores be thoroughly cleaned on the outside If it is determined that the compressor operating temperature is higher than normal due to the internal passages of the cooler cores being restricted with deposits or foreign material then the cooler should be removed for internal cleaning COOLANT COOLERS Following are instructions for removal and internal cleaning of coolant coolers Coolant Cooler m Remove panels and top cover m Drain the coolant See Section 4 6 m Remove side panels from coolant cooler box m Disconnect piping from coolant cooler inlet and outlet ports Plug cooler inlet and outlet ports to prevent possible contamination m Remove coolant cooler holding screws from sides of coolant cooler and remove cooler through side of cooler shroud Coolant Cooler Cleaning m is recommended the cooler be taken to a professional cooler service shop for flushing with an appropriate environmentally safe cleaning agent m Reassemble in reverse order m Make sure fan guards are replaced m Refill the compressor with coolant If contamination is suspected replace with new coolant m Replace fill plug m Run compressor for ten minutes Check for possible leaks Check coolant level m Replace enclosure panels CAUTION Strong cleaners can harm aluminum cooler parts Follow cleaner manufacturer s instructions for use Wear appropriate safety equi
103. the CURRENT STATUS display screen If the temperature is less than 120 F 49 C continue to run the machine When the temperature is greater than 120 F 49 observe Coolant Filter on the screen If the display says Coolant Filter OK then the filter does not need service is flashing on the screen and the display says CHANGE COOLANT FILTER then the filter should be replaced Use a suitable device and loosen the old element Use drain pan to catch any leakage during removal Discard old element Wipe the sealing surface of the filter with a clean lint free rag to prevent the entry of dirt into the system Remove the replacement element from its protective package Apply a small amount of clean lubricant on the rubber seal and install the element Screw element s on until the seal makes contact with the head of the filter assembly Tighten approximately one half turn additional Start unit and check for leaks 30 94 VA XX ANY YANAWAN NN 5 WKY X X YY 4 ANI INLET AIR FILTER 125 150 HP 90 110KW REQUIRES 1 ELEMENT 200 HP 132 160 KW REQUIRES 2 ELEMENTS 100 HP 75 KW 2S REQUIRES 1 ELEMENT 125 200 HP 110 160 KW 2S REQUIRES 2 ELEMENTS CAUTION Improper maintenance of coolant filter can cause compressor damage Change coolant filter after first 150 hours of
104. the machine is Running Unloaded and UNLOAD LOAD Pressing this button will cause the compressor to load if the compressor is running and if the Discharge Pressure is less than the Online Pressure This also returns the machine to the operating mode that is specified by the Mode of Operation set point The other five buttons provide access to various operator selectable functions and machine operating conditions The purpose of each of these buttons is defined by the display screen and the particular function being performed at that time ARROWS These up and down buttons have multiple functions relating to the right half of the display screen When lists are presented the buttons are used to move up or down through the items on the list The small arrow s displayed in the upper right corner of the display screen indicate when you can move up designated by arrow head pointing up and or down designated by arrow head pointing down through the list A V When the value of a specific machine operating parameter is highlighted on the display screen for the purpose of changing that value the buttons are used to change the value itself DISPLAY BUTTONS The functions of the three buttons below the display screen change and are defined by the words immediately above them in the bottom line of the screen Each function such as MAIN MENU STATUS SET etc is described in appropriate sections i
105. to and from the inlet and discharge port connections must take into account vibration pulsations temperature maximum pressure applied corrosion and chemical resistance In addition it should be noted that lubricated compressors will discharge some oil into the air stream therefore compatibility between discharge 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 not recommended In addition flexible joints and or flex lines can only be considered for such purposes if their specifications fit the 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 N WARNING Ingersoll Rand air compressors are not designed intended or approved for breathing air Ingersoll Rand does not approve specialized equipment for breathing air application and assumes no responsibility or liability for compressors used for breathing air services 0 3 DECALS This section contains representative examples of decals which will be appearing throughout this manual and are applied to the compressor unit If for some reason a decal is defaced painted over or parts are replaced we NOTICE Intellisys Operating instructions Before installing operating or performing any maintenance on this unit read and understand the
106. trap 2 3 PIPING Continued A dripleg assembly and isolation valve should be mounted near the compressor discharge A drain line should be connected to the condensate drain in the base IMPORTANT The drain line must slope downward from the base to work properly NOTE For ease of inspection of the automatic drain trap operation the drain piping should include an open funnel It is possible that additional condensation can occur if the downstream piping cools the air even further and low points in the piping systems should be provided with driplegs and traps IMPORTANT Discharge piping should be at least as large as the discharge connection at the compressor enclosure All piping and fittings must be suitable for the maximum operating temperature of the unit and at a minimum rated for the same pressure as the compressor sump tank NOTICE Do not use the compressor to support the discharge pipe Careful review of piping size from the compressor connection point is essential Length of pipe size of pipe number and type of fittings and valves must be considered for optimum efficiency of your compressor It is essential when installing a new compressor to review the total plant air system This is to ensure a safe and effective total system Liquid water occurs naturally in air lines as a result of compression Moisture vapor in ambient air is concentrated when pressurized and condenses when cooled in downstream
107. tributor or Air Center Maintenance record sheets are located at the back of this manual SPECIAL NOTE Replace separator element when the separator differential pressure P reaches three times initial pressure drop or a maximum pressure differential of 12 psi 8 bar at full load or if the Intellisys warning CHANGE SEPARATOR ELEMENT is displayed See Section 3 9 29 4 4 INLET AIR FILTER To check condition of the inlet filter run compressor in the LOADED mode and observe Inlet Filter on the CURRENT STATUS display screen If the display says Inlet Filter OK then no maintenance is required If is flashing on the screen and the display says CHANGE INLET FILTER then the inlet filter should be changed To change inlet filter elements loosen wing nut on top of inlet filter housing Lift cover up and away to expose elements Carefully remove the old element s to prevent dirt from entering the inlet valve Discard old element s Thoroughly clean the element housing and wipe all surfaces Install new element s and inspect to ensure that they have seated properly Install top of inlet filter housing Inspect the rubber seal on the retainer wing nut and replace seal if required Tighten wing nut Start machine and run in the load mode to verify filter condition 4 5 COOLANT FILTER To check the condition of the coolant filter the compressor must be running Observe Injected Temperature on
108. tric motor driven single stage screw compressor complete with accessories piped wired and baseplate mounted It is a totally self contained air compressor package A standard compressor is composed of the following m Inlet air filtration Compressor and motor assembly Pressurized coolant system with cooler Separation system Capacity control system with stepper motor inlet Motor starting control system Instrumentation Safety provisions Aftercooler Moisture separator and drain trap Optional accessories can provide for such things as automatic starting and stopping remote starting or stopping and sequencer The motor airend separator tank and piping are mounted on independent supports The supports are isolated from the base by rubber isolation mounts Flexible hoses are utilized on the separator tank coolant out and air discharge to isolate the motor airend tank 5 2 AIR COOLED COMPRESSORS DESIGN TEMPERATURES The standard compressor is designed for operation in an ambient range of 35 F to 115 F 1 7 C to 46 C When conditions other than the design levels described are encountered we recommend you contact your nearest Ingersoll Rand representative for additional information The standard maximum temperature 115 F 46 C is applicable up to an elevation of 3300 ft 1000 m above sea level Above this altitude significant reductions in ambient temperature are required if a standard drive motor is to be used
109. ttling of the inlet flow up to the modulation off line air pressure set point The throttling position of the inlet valve is controlled by the Intellisys allowing the stepper motor to trim the inlet valve position as dictated by the line pressure The modulating pressure range is 10 psig 7 bar Modulation begins when the line pressure reaches the maximum modulation pressure setting minus 10 psig 7 bar and continues as if the line pressure rises Modulation becomes stable when the compressor output equals the plant air demand When the modulation is at the maximum modulation pressure setting the maximum capacity reduction will be down to approximately 60 percent of the compressor rated capacity If the air demand has decreased to a level below the 60 percent modulated output the line pressure will increase slightly to actuate the Intellisys unloading the compressor and venting the separator 5 8 CAPACITY CONTROL Continued MODULATION ACS CONTROL Continued The automatic control selector ACS is designed to continuously monitor the plant air demand and select either the on off line or the modulate control mode whichever is most desirable at any time during an operating day It allows the compressor to operate in its most efficient mode without attendance thereby reducing power costs to a minimum When the compressor operates in the on off line control mode the length of time the compressor remains in the off line
110. ty of water used in any cooling system does not remain constant during the operation of the system The water makeup is affected by evaporation corrosion chemical and temperature changes aeration scale and biological formations 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 There are many constituents in the water system that must be balanced to have a good stable system The following is a list of the major components that should be monitored SCALE 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 surfaces PARAMETER CONCENTRATION 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 major concerns If they create problems with cl
111. ug into the Intellisys controller Descriptions of the options operations are in Section 7 0 The name and value of each of the options listed in the right hand column can be seen by moving the list up and down using the arrow buttons An Option item s value can be changed the same way OPERATOR SETPOINTS values are changed See Section 3 5 for an explanation OPTIONS ITEMS Auto Restart Auto Restart Time Auto Restart Delay Time Sequencer Remote Start Stop Power Out Restart Power Out Restart Time Low Ambient Min Cooler Out Temp Separator Delta P Solenoid Separator Delta P Sensor Lead Lag Cycle Length Scheduled Start Scheduled Stop High Dust Filter Modbus Protocol Modbus Address RANGE On Off 2 to 60 0 to 60 On Off On Off On Off 10 to 600 On Off 30 to 150 On Off On Off 0 750 00 00 to 23 59 00 00 to 23 59 On Off On Off ICU 1 to 247 1 1 1 UNIT MIN SEC SEC Deg HRS TIME TIME 21 3 6 OPTIONS CONTINUED 3 6 1 Auto Restart This setpoint is used to enable or disable the auto restart option 3 6 2 Auto Restart Time This setpoint is the minimum time period the compressor must run unloaded before it can stop in the auto restart mode 3 6 3 Auto Restart Delay Time If the compressor is stopped in auto restart this setpoint is the number of seconds the package discharge pressure must remain below the online pressure setpoint before the compressor will restart 3 6 4 Sequen
112. ure The quantity of grease added should be carefully controlled The smaller motors must be greased with a lesser amount of grease than larger motors 36 CAUTION Overgreasing can be a cause of bearing and motor failure Make sure dirt and contaminants are not introduced when adding grease Procedure for relubrication CAUTION Grease should be added when the motor is stopped and power disconnected When regreasing stop motor Disconnect power lock out and tag Remove outlet plugs or spring loaded grease relief plugs if present The outlet plug may not be accessible on the fan end of some TEFC motors NOTICE Motors must be greased periodically See Operator s Manual for procedure 4 10 MOTOR LUBRICATION Continued Grease relief along shaft can occur precluding necessity of removing this plug if inaccessible 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 lower portion of the end bell near a flange bolt The drive end outlet plugs are located just behind the flange in the air intake area at about the 5 or 6 o clock position 1 Free drain hole of any hard grease use piece of wire if necessary 2 Use a hand lever type grease gun Determine in advance the quantity of grease delivered with each stroke of the lever A graduated cylinder showing cubic centimeters
113. use factory supplied inlet for incoming power See Operators Instruction Manual power inlet 39541354 Rev 03 am 39543764 Rev 04 N WARNING Hazardous voltage Can cause severe injury or death Disconnect power before servicing Lockout Tagout machine Hazardous voltage Can cause inj death T severe injury or dm 39540174 Rev 05 Only use factory supplied inlet for incoming power See Operators Instruction Manual 39543764 Rev 03 NOTICE IEC Starter Overload Setting Full Voltage Starter Main or Fan Motor Multiply MOTOR nameplate amps by 1 11 Star Delta Starter Main motors only Multiply MOTOR nameplate amps by 0 64 SC H EMATI C D ECAL Set corresponding overload relay at this value Never exceed the following limits VOLTAGE DECAL OPTION UMOR INSIDE STARTER BOX Star Delta Starter 72 of MOTOR ON RIGHT SIDE nameplate amps dm 39921804 Rev B 1 0 RECEIPT OF EQUIPMENT 1 1 INSPECTION When you receive the compressor please inspect it closely Any indication of careless handling by the carrier should be noted on the delivery receipt especially if the compressor will not be immediately uncrated Obtaining the delivery man s signed agreement to any noted damages will facilitate any future insurance claims IMPORTANT READ THIS LOST OR DAMAGED GOODS THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL OUR RESPONSIBILITY
114. y be controlled in closed cooling towers Several types of treatments are commercially available to remove dissolved oxygen For open cooling towers dissolved oxygen is not an easily controlled parameter Also a filtration system is recommended for the water going into the air compressor when using an open cooling tower It should be noted that Ingersoll Rand s guidelines and recommendations should be used in evaluating the water Systems and the problems that may occur in the normal operation of our air compressors If water problems persist or are not covered above you should consult a professional 86 TENS HUNDREDS LANGELIER INDEX CHART VALUES Total dissolved solids ppm o a l o a Hardness ppm HUNDREDS Temperature 10 0 MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD gt WORK DONE HOURS E py p p c _ s p un Wasa NEN p y ry p p i f pr Ss 1 SS DATE MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY
115. ycle length in real time hours A value of 0 will disable the automatic cycling between lead and lag 3 6 13 Scheduled Start If the scheduled start stop option is installed this set point is the time of the day hour and minute that the compressor will automatically start To disable this option set it to the same value as the scheduled stop section 3 6 14 3 6 14 Scheduled Stop If the scheduled start stop option is installed this setpoint is the time of the day hour and minute that the compressor will automatically stop To disable this option set it to the same value as the scheduled start section 3 6 13 3 6 15 High Dust Filter This option enables or disables the high dust filter operation 3 6 16 Modbus Protocol This option is for Ingersoll Rand service use only 3 6 17 Modbus Address This feature is used with the Modbus Protocol and is for Ingersoll Rand service use only 3 7 SENSOR CALIBRATION PSI Ready To Start SENSOR CALIBRATION Sensor 1AVPT CALIBRATE Sensor 3APT CALIBRATE STATUS MAIN MENU SELECT Pressure sensor calibration is done through the SENSOR CALIBRATION screen Sensor calibration can only take place when the machine is stopped Calibration needs to be done only after a sensor has been replaced or the Intellisys controller has been replaced Each of the sensors listed below can be chosen by using the up and down arrow buttons to highlight it on the screen SENSOR

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