Nirvana Operators Manual

8/17/2019 Nirvana Operators Manual

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OPERATION AND MAINTENANCE MANUALwith parts catalogue

MANUEL D’UTILISATION ET D’ENTRETIENavec catalogue de pièces détachées

BEDIENINGS EN ONDERHOUDSHANDBOEKonderdelenkatalogusBEDIENUNGS–UND WARTUNGSANLEITUNG

mit ersatzteillisteLIBRO D’USO E MANUTENZIONE

con lista ricambiMANUAL DE MANEJO Y MANTENIMIENTO

con lista de repuestosMANUAL DE OPERAÇAO E CONSERVAÇAO

com lista de peçasDRIFTS– OG VEDLIGEHOLDELSE MANUAL

med reservedelskatalog

DRIFTS– OCH UNDERHÅLLSINSTRUKTIONERmed reservdelskatalog

DRIFTS– OG VEDLIKEHOLDSINSTRUKSJONERmed reservedelskatalog

KÄYTTÖ– JA HUOLTO–OHJEKIRJAsekä varaosaluettelo

54719083JULY 2001

IRN37K–CC IRN45K–CCIRN50H–CC IRN60H–CC

Incomplete manual,Pre–Production Units Only


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3/67

OPERATION AND MAINTENANCE MANUALwith parts catalogue

MANUEL D’UTILISATION ET D’ENTRETIENavec catalogue de pièces détachées

BEDIENINGS EN ONDERHOUDSHANDBOEKonderdelenkatalogusBEDIENUNGS–UND WARTUNGSANLEITUNG

mit ersatzteillisteLIBRO D’USO E MANUTENZIONE

con lista ricambiMANUAL DE MANEJO Y MANTENIMIENTO

con lista de repuestosMANUAL DE OPERAÇAO E CONSERVAÇAO

com lista de peçasDRIFTS– OG VEDLIGEHOLDELSE MANUAL

med reservedelskatalog

DRIFTS– OCH UNDERHÅLLSINSTRUKTIONERmed reservdelskatalog

DRIFTS– OG VEDLIKEHOLDSINSTRUKSJONERmed reservedelskatalog

KÄYTTÖ– JA HUOLTO–OHJEKIRJAsekä varaosaluettelo

54719117JULY 2001

IRN55K–CC IRN75K–CCIRN75H–CC IRN100H–CC

Incomplete manual,Pre–Production Units Only


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5/67

OPERATION AND MAINTENANCE MANUAL

XXXXXXN60H –>

XXXXXXN50H –>

C.C.N. : 54719091 DATE : JULY 2001

SERIAL No :

SERIAL No :Ensure that the operator reads and understands the decals andconsults the manuals before maintenance or operation.

Ensure that maintenance personnel are adequately trained,competent and have read the Maintenance Manuals.

XXXXXXN75K –>

XXXXXXN55K –>

SERIAL No :

SERIAL No :

IRN37/75K –CCIRN50/100H –CC

Ensure that the Operation and Maintenance manual is not

removed permanently from the machine.

XXXXXXN45K –>

XXXXXXN37K –>

SERIAL No :

SERIAL No :

XXXXXXN100H –>

XXXXXXN75H –>

SERIAL No :

SERIAL No :


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Machine models represented in this manual may be used in various locations worldwide. Machines sold andshipped into European common market countries requires that the machine display the EC Mark and conformto various directives. In such cases, the design specification of this machine has been certified as complyingwith EC directives. Any modification to any part is absolutely prohibited and would result in the CE certificationand marking being rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

98/37/EC, 93/68/EEC, 89/336/EEC

WE,

INGERSOLL –RAND COMPANY LIMITEDSWAN LANE

HINDLEY GREENWIGAN WN2 4EZ

UNITED KINGDOM

DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY,THE PRODUCT(S)

IRN37K –CC IRN45K –CC IRN50H –CC IRN60H –CC

TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONSOF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

EN29001, EN292, EN60204 –1, EN1012 –1, EN50081, EN50082

ISSUED AT HINDLEY GREEN ON 01/01/2001 BY H.SEDDON, QUALITY ASSURANCEMANAGER.

H. SEDDON

THIS DECLARATION APPLIES TO UNITS WITH SERIAL NUMBERS OF THE FORMAT

27XXXXX.

UNITS WITH SERIAL NUMBERS OF THE FORMAT NV1XXX MAY NOT CONFORM TO CEREGULATIONS AND ARE INTENDED FOR USE SOLELY OUTSIDE OF THE EUROPEAN

COMMUNITY.


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AIR COMPRESSOR GROUPBONDED WARRANTY & REGISTERED START UP

WarrantyThe Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects inmaterial and workmanship for a period of twelve months (see extended airend warranty) from the date of placing theEquipment in operation or eighteen months (see extended airend warranty) from the date of shipment, whichever shallfirst occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to theCompany in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repairto such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored,installed, maintained and operated such Equipment in accordance with good industry practices and has complied withspecific recommendations of the Company. Accessories or equipment furnished by the Company, but manufacturedby others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passedon to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipmentor 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 arelimited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performancewarranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the periodof 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 MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.

Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of timeprovided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based oncontract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.

The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Companyin writing of its intention to do so.Any such use of Equipment will be at Purchaser ‘s sole risk and liability.

Limitation of LiabilityThe remedies of the Purchaser set forth herein are exclusive, and the total liability of the Company with respect to thiscontract or the Equipment and services furnished hereunder, in connection with the performance or breach thereof,or from the manufacture, sale, delivery, installation, repair or technical direction covered by or furnished under this

contract, whether passed on contract, warranty negligence, indemnity, strict liability or otherwise, shall not exceed thepurchase price of the unit of Equipment upon which such liability is based.

The Company and its suppliers shall in no event be liable to the Purchaser, any successors in interest or any beneficiaryor assignee of this contract for any consequential, incidental, indirect, special or punitive damages arising out of thiscontract or any breach thereof, or any defect in, or failure of, or malfunction of the Equipment hereunder, whether basedupon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other goods, loss byreason of shutdown or non – operation, increased expenses of operation, cost of purchase of replacement power orclaims of Purchaser or customers of Purchaser for service interruption whether or not such loss or damage is basedon contract, warranty, negligence, indemnity, strict liability or otherwise.

EXTENDED AIREND WARRANTY

The Ingersoll – Rand Company Rotary Screw Air Compressor that has been filled prior to its original shipment fromIngersoll – Rand Company with ULTRA COOLANT and which has been operated solely on ULTRA COOLANTthere – after shall have its AIREND warranted for twenty four (24) months from the date of placing the COMPRESSORin operation or thirty (30) months from the date of shipment, whichever occurs first.

Except for the above warranty period, the standard warranty provisions shall apply and the conditions outlined hereinare understood to be a supplement to the standard Ingersoll – Rand Company warranty.

Note that this is Ingersoll – Rand standard warranty. Any warranty in force at the time of purchase of the compressoror negotiated as part of the purchase order may take precedence over this warranty


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AIRCARE PLAN

Superior Service Solutions for Air Systems

AirCare is a responsive and flexible contract maintenance program custom designed for the owner who requiresplanned maintenance for increased system reliability.

The AirCare program provides you with reduced maintenance costs, reduced energy usage through optimization andefficiency, and reduced production losses through fewer unexpected maintenance requirements and downtime. Anoptional feature, Intelliguard is used to reduce downtime by remote monitoring.

Air Care Options

Unit Status Coverage Service Level

Sign up for AirCare within thewarranty period

Five Year Drivetrain or Packagecoverage

Inspection and diagnostic serviceonly or Preventative maintenance

and diagnostic service

To enroll in AirCare or Intelliguard, contact your local Ingersoll – Rand representative today.


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CONTENTS

1IRN37/75K – CC & IRN50/100H – CC (DRAFT COPY ONLY)

CONTENTS PAGE CONTENTS PAGE

1.0 CONTENTS 1

2.0 FOREWORD 2

3.0 ABBREVIATIONS &SYMBOLS

3

4.0 PURCHASE ORDERDETAILS

4

5.0 SAFETY 6

5.1 Safety instructions

5.2 Safety precautions5.3 Text decals

5.4 Graphic form and meaningof ISO symbols

6.0 RECEIPT ANDHANDLING

13

6.1 Receipt

6.2 Unpacking and handling

7.0 INSTALLATION 14

7.1 Location in plant

7.2 Discharge and condensatepiping

7.3 Electrical

7.4 Watercooled units

7.5 Sea watercooled units

7.6 Outdoor sheltered installa-

tion

8.0 GENERAL INFORMATION 24

8.1 Technical information

8.2 Installation drawing

8.3 Process andinstrumentation diagram

8.4 Electrical schematic

8.5 General operation

9.0 OPERATINGINSTRUCTIONS

33

9.1 Basic operation

9.2 Intellisys controls

9.3 Display screen

9.4 Current status screen

9.5 Main menu

9.6 Operator setpoints

9.7 Options

9.8 Sensor calibration

9.9 Alarm history

9.10 Warnings

9.11 Service warnings

9.11 Initial check alarms

9.13 Alarms

10.0 MAINTENANCE 43

10.1 SSR care programs

10.2 Maintenance prompts10.3 Maintenance chart

10.4 Maintenance procedures

10.5 Routine maintenance

11.0 FAULT FINDING 51


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3

2.0 FOREWORD

2 IRN37/75K – CC & IRN50/100H – CC (DRAFT COPY ONLY)

Machine models represented in this manual may beused in various locations worldwide. Machines sold andshipped into European community countries requiresthat the machine display the EC Mark and conform tovarious directives. In such cases, the designspecification of this machine has been certified ascomplying with EC directives. Any modification to anypart is absolutely prohibited and would result in the CEcertification and marking being rendered invalid.

The contents of this manual are considered to beproprietary and confidential to Ingersoll – Rand andshould not be reproduced without the prior writtenpermission of Ingersoll – Rand.

Nothing contained in this document is intended toextend any promise, warranty or representation,expressed or implied, regarding the Ingersoll – Randproducts described herein. Any such warranties orother terms and conditions of sale of products shall be

in accordance with the standard terms and conditionsof sale for such products, which are available uponrequest.

This manual contains instructions and technical data tocover all routine operation and scheduled maintenancetasks by operation and maintenance staff. Majoroverhauls are outside the scope of this manual andshould be referred to an authorized Ingersoll – Randservice department.

All components, accessories, pipes and connectorsadded to the compressed air system should be:. of good quality, procured from a reputablemanufacturer and, wherever possible, be of a typeapproved by Ingersoll – Rand.. clearly rated for a pressure at least equal to themachine maximum allowable working pressure.. compatible with the compressor lubricant/coolant.. accompanied with instructions for safe installation,operation and maintenance.

Ingersoll – Rand reserves the right to make changes andimprovements to products without notice and withoutincurring any obligation to make such changes or addsuch improvements to products sold previously.

Details of approved equipment are available from Ingersoll–Rand Service departments.

This machine has been designed and supplied for useonly in the following specified conditions andapplications:. Compression of normal ambient air containing no

known or detectable additional gases, vapors orparticles. Operation within the ambient temperature rangespecified in the GENERAL INFORMATION section ofthis manual.

IF IN DOUBT CONSULT SUPERVISION.

The company accepts no responsibility for errors intranslation of this manual from the original Englishversion.

The design of this Compressor package andcertain features within it are covered by patentsheld by Ingersoll –Rand and patents pending

SSR ULTRA COOLANT is a registered trademark of Ingersoll–Rand Company USA.

INTELLISYS is a registered trademark of Ingersoll–Rand Company USA.

© COPYRIGHT 2001INGERSOLL –RAND COMPANY


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2.0 FOREWORD


WARNINGThe use of the machine in any of the situation types listed in table 1: –a) Is not approved by Ingersoll –Rand,b) May impair the safety of users and other persons, andc) May prejudice any claims made against Ingersoll –Rand.

TABLE 1

WARNING – NOT PERMITTEDUse of the machine to produce compressed air for:a) direct human consumptionb) indirect human consumption.

Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION

SECTION of this manual.

Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or

vapors.

Use of the machine fitted with non Ingersoll – Rand approved components.

Use of the machine with safety or control components missing or disabled.

Connection to an electrical supply of incorrect voltage and/or frequency.

WARNINGThe use of repair parts other than those included within the Ingersoll –Rand approved parts list may createhazardous conditions over which Ingersoll –Rand has no control. Therefore Ingersoll –Rand cannot be heldresponsible for equipment in which non –approved repair parts are installed.

WARNINGThe motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices suchas watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel withcardiac pacemakers, defibulators or other implanted electronic medical device.

DANGERThis compressor contains a variable frequency drive. When it is switched off and the motor is stopped, theinternal capacitors store a potentialy lethal high voltage electric charge which gradually falls to zero overtime. After switching off the machine at its local isolator WAIT AT LEAST 5 MINUTES for the capacitors to fullydischarge before opening the power drive module doors.

WARNINGThe compressor can operate in a pressurised shutdown mode. If the compressor stops automatically, theairend, separator tank and oil system can contain high pressure air. This can be relieved by pressing theemergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole throughwhich any residual pressure will be vented. Downstream of the separator tank may still contain systempressure which must also be vented.

NOTICEThe manual is intended for worldwide use and contains both metric and imperial data where required.


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54.0 PURCHASE ORDER DETAILS


ROTARY SCREW AIR COMPRESSOR

This unit was purchased from

Ingersoll – Rand Company reserves the right tomake changes or add improvements withoutnotice and without incurring any obligation tomake such changes or add such improvementsto products sold previously.

No. of units on order:

Customer Order No:

Ingersoll – Rand Co. Order No.:For ready reference:

Record the serial number and model number ofyour unit here.

Serial Number:

Model Number:


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5.0 SAFETY


5.1 SAFETY INSTRUCTIONS

Safety instructions in the operators manual arebold – faced for emphasis. The signal words DANGER,WARNING and CAUTION are used to indicate hazardseriousness levels as follows.

Ensure that the operator reads and understands thedecals and consults the manuals before maintenanceor operation.

Ensure that the Operation and Maintenance manual,and the manual holder, are not removed permanentlyfrom the machine.

Ensure that maintenance personnel are adequatelytrained, competent and have read the MaintenanceManuals.

DANGERIndicates the presence of a hazard which WILL causeserious injury, death or property damage, if ignored.

WARNINGIndicates the presence of a hazard which CAN causeserious injury, death or property damage, if ignored.

CAUTIONIndicates the presence of a hazard which WILL or cancause injury or property damage, if ignored.

NOTICEIndicates important set – up, operating or maintenanceinformation.

5.2 SAFETY PRECAUTIONS

General Information

Compressed air and electricity can be dangerous.Before undertaking any work on the compressor,ensure that the electrical supply has been isolated,locked off, tagged and the compressor has beenrelieved of all pressure.

Make sure that all protective covers are in place and

that the canopy/doors are closed during operation.

Installation of this compressor must be in accordance with recognized electrical codes and any local Health and Safety Codes.

Use only safety solvent for cleaning the compressorand auxillary equipment.

Compressed air

Ensure that the machine is operating at the ratedpressure and that the rated pressure is known to allrelevant personnel.

All air pressure equipment installed in or connected tothe machine must have safe working pressure ratingsof at least the machine rated pressure.

If more than one compressor is connected to onecommon downstream plant, effective check valves andisolation valves must be fitted and controlled by workprocedures, so that one machine cannot accidently bepressurized / over pressurized by another.

If a safety valve is installed between the isolation valveand the compressor, it must have sufficient capacity torelieve the full capacity of the compressor(s).

The discharged air contains a very small percentage ofcompressor lubricating oil and care should be taken toensure that downstream equipment is compatible.

If the discharged air is to be ultimately released into aconfined space, adequate ventilation must be provided.

The use of plastic bowls on line filters without metalguards can be hazardous. Their safety can be affectedby either synthetic lubricants, or the additives used inmineral oils. Metal bowls should be used on apressurized system.

When using compressed air always use appropriatepersonal protective equipment.


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5.0 SAFETY


All pressure containing parts, especially flexible hosesand their couplings, must be regularly inspected, befree from defects and be replaced according to theManual instructions.

Compressed air can be dangerous if incorrectlyhandled. Before doing any work on the unit, ensure thatall pressure is vented from the system and that the

machine cannot be started accidentally.Avoid bodily contact with compressed air.

The safety valve located in the separator tank must bechecked periodically for correct operation.

Whenever pressure is released through the pressurerelief valve, it is due to excessive pressure in thesystem. The cause for the excessive pressure shouldbe investigated immediately.

Materials

The following substances are used in the manufactureof this machine and may be hazardous to health if usedincorrectly:. preservative grease. rust preventative. compressor coolant

WARNINGAVOID INGESTION, SKIN CONTACT ANDINHALATION OF FUMES

For further information, request and consult the coolantMaterial Data Sheet (UK ACGP 011/89 – ULTRACOOLANT ACGP 029/90 – food grade coolant. ForUSA served areas, use MSDS sheet APDD 236) fromyour local IR office, Distributor or Air Center.

Should compressor lubricant come into contact with theeyes, then irrigate with water for at least 5 minutes.

Should compressor lubricant come into contact with theskin, then wash off immediately.

Consult a physician if large amounts of compressorlubricant are ingested.

Consult a physician if compressor lubricant is inhaled.

Never give fluids or induce vomiting if the patient isunconscious or having convulsions.

The above information contains data supplied insupport of United Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.) regulations.

Transport

When loading or transporting machines ensure that thespecified lifting and tie down points are used.

It is recommended that the machine be moved usingthe fork lift slots in the machine base.

Refer to section 8 for reference information.

Electrical

The compressor has high and dangerous voltage in themotor starter and control box. All installations must be

in accordance with recognized electrical codes. Beforeworking on the electrical system, be sure to removevoltage from the system by using a manual disconnectswitch. A circuit breaker or fuse safety switch must beprovided in the electrical supply line leading to thecompressor.

Those responsible for installation of this equipmentmust provide suitable grounds, maintenance clearanceand lightning arrestors for all electrical components inaccordance with National and Local coderequirements.

Keep all parts of the body and any hand – held tools orother conductive objects, away from exposed live parts

of the compressor electrical system. Maintain dryfooting, stand on insulating surfaces and do not contactany other portion of the compressor when makingadjustments or repairs to exposed live parts of thecompressor electrical system.

Close and lock all access doors when the compressoris left unattended.

Do not use extinguishers intended for Class A or ClassB fires on electrical fires. Use only extinguisherssuitable for class BC or class ABC fires.

Attempt repairs only in clean, dry, well lighted andventilated areas.

Connect the compressor only to electrical systems thatare compatible with its electrical characteristics andthat are within it’s rated capacity.


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5.0 SAFETY


Condensate disposal

Condensate cannot be discharged into fresh/surfacewater drains. In some regions compressor condensatecontaining ULTRA COOLANT can be fed directly into adrainage system that has downstream seweragetreatment.

As waste water regulations vary by country and regionit is the responsibility of the user to establish thelimitations and regulations in their particular area.Ingersoll – Rand and its associated distributors arehappy to advise and assist in these matters.

Coolant disposal

Steps to be taken in the case of spillage: Soak up witha suitable absorbent material, then sweep into a plasticbag for disposal.

Burn in an approved incinerator, or according to localarea or country regulations.

For further information, consult Material Data SheetsACGP 011/96 (ULTRA COOLANT) or APDD 236.

DANGERThis compressor contains a variable frequency drive. When it is switched off and the motor is stopped, theinternal capacitors store a potentialy lethal high voltage electric charge which gradually falls to zero overtime. After switching off the machine at its local isolator WAIT AT LEAST 5 MINUTES for the capacitors to fullydischarge before opening the power drive module doors.

WARNINGThere is a high discharge air temperature shutdown function built into each compressor. lt is factory presetat 109C (228F).This function should be checked at regular intervals for proper operation, once a month isrecommended. Refer to maintenance section.

Failure to adhere to these recommendations can result in mechanical failure,property damage and seriousinjury or death.

All air and water inlet, and air and water discharge pipework to and from the inlet and discharge portconnections must take into account vibration, pulsations, temperature, maximum pressure applied,corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will dischargesome 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 dischargepiping is not recommended. In addition,flexible joints and/or flex lines can only be considered for suchpurposes 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 fromthe machine.

WARNING“Ingersoll –Rand air compressors are not designed, intended, or approved for breathing air applications.Ingersoll –Rand does not approve specialized equipment for breathing air application and assumes noresponsibility or liability for compressors used for breathing air services.”

WARNINGThe motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices suchas watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel withcardiac pacemakers.

WARNINGNo portable communication devices emitting more than 7.5 volts per metre in the frequency range from 250MHz to 280 MHz should be operated within 5m (16.5ft) of the unit.

WARNINGThe motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices suchas watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel withcardiac pacemakers, defibulators or other implanted electronic medical device.

WARNINGThe specification of this machine is such that the machine is not suitable for use in flammable gas risk areas.If such an application is required then all local regulations, codes of practice and site rules must be observed.To ensure that the machine can operate in a safe and reliable manner, additional equipment such as gasdetection and intake (shut – off ) valves may be required, dependant on local regulations or the degree of riskinvolved.


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5.0 SAFETY


Depending on point of manufacture and point of use, the compressor and this manual will show symbolsfrom the following sections. Compressors for use within the European Community must be equipped withsymbols from section 5.4. Read and understand thoroughly. Heed warnings and follow instructions. If youdo not understand, inform your supervisor.

5.3 TEXT DECALS

NOTICETo obtain satisfactory compressor operation andmaintenance a minimum of 3 feet clearance on 3 sides

is required 3 – 1/2 feet is required in front of the controlpanel (or minimum required by latest National Electricalcode or applicable local codes).

Refer to the Instruction / Operators Manual Manualbefore performing any maintenance.

DANGER

Discharge air.Can contain carbon monoxide or othercontaminants. Will cause severe injury or death.

Do not breathe this air.

WARNING

Hazardous voltage. Can cause severe injury ordeath.

Disconnect power before servicing.

Lockout/Tagout machine.

WARNING

Exposed blower blade. Can cause severe injury.

Do not operate with covers removed.Disconnect power. Lock and tag.

CAUTIONIncorrect lifting of machine can cause injury or

property damage.

Lift only from base channels


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5.0 SAFETY


WARNING

High pressure air.Can cause severe injury or death.

Relieve pressure before removing filter plugs/caps,fittings or covers.

NOTICE

Air discharge

CAUTIONUse of incorrect coolant can cause systemcontamination.

Use only SSR ULTRA COOLANT

NOTICE

Lift here

WARNING

Hot surface.Can cause severe injury.

Do not touch. Allow to cool before servicing.

NOTICE

Filler Cap.Use only recommended

coolant

Read instruction bookbefore servicing.

39543921

CAUTIONImproper coolant filter replacement will causecompressor damage.

Replace filter element after first 150 hours of operationand every 2000 hours thereafter or when coolant ischanged.


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5.0 SAFETY


NOTICE

Rotation

WARNING

Exposed moving belts sheaves.

Can cause severe injury or death.

Do not operate with guards removed.Disconnect power, lock and tag out machine beforeservicing. 39859236

NOTICEBefore installing, operating, or performing anymaintenance on this unit, read and understand theinstructions in the Operators Instruction Manual.

Before Starting

1. Check coolant level and add coolant ifnecessary.

2. Verify that main isolation valve is open.

3. Close main disconnect switch

Starting

1. Push START button. Compressor will start andload automatically.

2. Air pressure will rise if there is sufficientdemand for air.

Stopping

1. Push STOP button.Compressor will stop after 7 –10 seconds.

2. Open main disconnect switch.

89919246

Rotation

R o t a t i o n


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5.0 SAFETY


5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING – Pressurized vessel. WARNING – Hot surface.

WARNING – Pressure control. WARNING – Corrosion risk.WARNING – Air/gas flow or Air

discharge.

WARNING – Pressurizedcomponent or system.

Do not remove the Operating andMaintenance manual from this

machine.

WARNING – Flammable liquid.

WARNING – Rotor magnetic fieldcan affect pacemakers.


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5.0 SAFETY


0C

WARNING – Do not undertake anymaintenance on this machineuntil the electrical supply is

disconnected and the air pressureis totally relieved.

WARNING – Consult the

Operation and Maintenancemanual before commencing any

maintenance.

WARNING – For operating

temperature below 0C, consultthe Operation and Maintenance

manual.

Read the Operation andMaintenance manual before

operation or maintenance of thismachine is undertaken.

Do not stack.Do not operate the machine without

the guard being in place.

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

Do not operate with the doors orenclosure open.

Do not use fork lift truck from thisside.

Do not breathe the compressed airfrom this machine.

No naked lights.Do not open the service valve before

the air hose is attached.


23/67

5.0 SAFETY


Use fork lift truck from this side only. Emergency stop. Tie down point

Lifting point. On (power). Off (power).

SET SEQUENCER STATUS LOAD

SEQUENCER (AUTOMATIC

CONTROL)

COMPRESSOR OFF LOAD (UNLOADED)

RESET COMPRESSOR STATUS MODULATE

MALFUNCTION POWER FOULED FILTER

POWER INLET ELECTRIC MOTOR HOURS


24/67

5.0 SAFETY


COOLANT SEPARATOR PRESSURE AIR DISCHARGE

PRESSURIZED TANK ON / OFF CYCLE COOLANT FILTER

AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE

AIR PRESSURE STAR DELTA IEC 617 –7 AUTOMATIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE


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5.0 SAFETY


BELT TENSION FILTER MOTOR LUBRICATION

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS ROTATION

POWER INLET (AC) WATER IN WATER OUT


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6.0 RECEIPT / HANDLING


6.1 RECEIPT

When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier shouldbe noted on the delivery receipt especially if the compressor will not be immediately unpacked. Obtaining the deIiverypersons signed agreement to any noted damages will facilitate any future insurance claims.

IMPORTANTREAD THIS

LOST OR DAMAGED GOODS

THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL

OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNEDBILL OF LADING

If goods are received short or in damaged condition, it is important that you notify the carrier and insist on anotation 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 absolutelynecessary. 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 forgoods that have been damaged or lost in transit, you do so at your own risk and expense.

WE, AT lR, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSSOR DAMAGE, BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FORCOLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL. THE ACTUAL FILING AND PROCESSING OFTHE CLAIM IS YOUR RESPONSIBILITY.

Ingersoll –Rand Company

6.2 UNPACKING AND HANDLING

The compressor will normally be delivered with a polythene cover. If a knife has to be used to remove this cover, ensurethat the exterior paintwork of the compressor is not damaged.

Incorporated within the base of the compressor are slots to enable a fork lift truck to move the machine. Ensure truckforks are fully engaged on both sides. Alternatively a special lifting frame can be utilized to enable a crane or hoist tomove the compressor. Use only marked lifting points.


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7.0 INSTALLATION / HANDLING


For technical information see reference section.

7.1 LOCATION IN PLANT

Ensure that the correct tie down points are used.

For major overhaul (i.e. motor removal) position themachine to obtain lifting access e.g. fork lift truck.

See diagram in reference section for minimum spacerequirements for normal operation and maintenance.

Ambient temperatures higher than 46C (115F) mustbe avoided as well as areas of high humidity.

Consider also the environment surrounding or near thecompressor. The area selected for the location of thecompressor should be free of dust, chemicals, metal

filings, paint fumes and overspray.

Hard surfaces may reflect noise with an apparentincrease in the decibel level. When sound transmissionis important, a sheet of rubber or cork can be installedbeneath the machine to reduce noise. Flexible pipingmay be required.

It is recommended that provision be made for liftingheavy components during major overhaul. Use onlylifting points provided.

Minimum space in front of control panel door asrequired by National or Local codes must bemaintained.

The compressor can be installed on any level floorcapable of supporting it. A dry, well ventilated areawhere the atmosphere is as clean as possible isrecommended.

Sufficient space all round and above the compressormust be allowed, to enable the effective removal of thecooling air which, in turn, will reduce the risk ofrecirculating the cooling air back through thecompressor.

CAUTIONA minimum of 1 m (3.3ft) all round the compressor is recommended. If headroom is restricted, then theexhaust should be ducted or deflected away from the machine.

Screw type compressors [1] should not be installed in air systems with reciprocating compressors withoutmeans of isolation such as a common receiver tank. It is recommended that both types of compressor bepiped to a common receiver using individual air lines.

The machine is shipped with the shipping restraints in place. Ensure that these are removed to allow freemovement of the drive assembly during operation. Each restraint is painted yellow.


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7.2 DISCHARGE AND CONDENSATE PIPING

It is essential when installing a new compressor [1], toreview the total air system. This is to ensure a safe andeffective total system. One item which should be

considered is liquid carryover. Installation of air dryers[3] is always good practice since properly selected andinstalled they can reduce any liquid carryover to zero.

Discharge piping should be at least as large as thedischarge connection of the compressor. All piping andfittings should be suitably rated for the dischargepressure.

It is good practice to locate an isolation valve close tothe compressor and to install line filters [4].

Include a means [6] to vent the discharge pipeworkdownstream from the minimum pressure check valvelocated on the separator tank. Upstream of the first

system isolation valve [7].The discharged air contains a very small percentage ofcompressor lubricating oil and care should be taken toensure that downstream equipment is compatible.

When two rotary units are operated in parallel, providean isolation vaIve and drain trap for each compressorbefore the common receiver.

The built – in aftercooler reduces the discharge airtemperature below the dew point (for most ambientconditions), therefore, considerable water vapor is

condensed. To remove this condensation, eachcompressor with built in aftercooler is furnished with acombination condensate separator/trap.

A dripleg assembly and isolation valve should bemounted near the compressor discharge. A drain lineshould be connected to the condensate drain in thebase.

IMPORTANT: The drain line must slope downwardfrom the base to work properly. For ease of inspectionof the automatic drain trap operation, the drain pipingshould include an open funnel.

NOTICEFor low volume systems that may not include a receiver[2], compressor response time may need adjusting.Contact your local IR service agent.

CAUTIONThe use of plastic bowls on line filters and other plastic air line components without metal guards can behazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils.From a safety standpoint, metal bowls should be used on any pressurised system.

NOTICEDo not use the compressor to support the discharge pipe.


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7.3 ELECTRICAL

CAUTIONThis procedure should only be carried out by a qualified electrician, electrical contractor or your localIngersoll –Rand Distributor or Air Center.

The compressor and drive should be properly grounded / earthed in accordance with Local and National Coderequirements.

Installation of this compressor must be in accordancewith recognized electrical codes and any local Healthand Safety Codes.

The compressor must have its own isolator situatedadjacent to it. The fuse protecting the circuit and thecompressor must be selected in accordance with thedata provided in the general information section

Feeder cables should be sized by thecustomer/electrical contractor to ensure that the circuitis balanced and not overloaded by other electricalequipment. The length of wiring from a suitableelectrical feed point is critical as voltage drops mayimpair the performance of the compressor. Cable sizesmay vary considerably so the mains terminals willaccept up to 50mm2 (1awg) (37/45k & 50/60H) andup to 90mm2 (3/0awg) (55/75k & 75/100H) cable

Feeder cable connections to incoming terminalsL1 – L2 – L3 should be tight and clean.

The applied voltage must be compatible with the motorand compressor data plate ratings.

The control circuit transformer has different voltagetappings. Ensure that these are set for the specificapplied voltage prior to starting.

A hole is provided for incoming power connection. If itis necessary to make a hole in the control box in adifferent location, care should be taken to not allowmetal shavings to enter the starter and other electricalcomponents within the box. If another hole is used, theoriginal hole must be blocked off.

On completion of electrical installation, check thatblower motor rotation is correct.

This machine is designed for use in heavy industrialenvironments, where the electricity supply is separatedfrom nearby residential and commercial areas. If the

machine is to be used in the light industrial, residentialor commercial environment where the local supplynetwork is shared, further radio frequency (RF)screening measures may be required. Consult yourlocal distributor/supplier for details of the optional RFfilter.

The compressor has an anti – condensation heater fittedin the control panel. This must be connected to anindependent electrical supply of either 110V or 230Vsingle phase, dependant on the country of installation.The supply should be suitable fused and an indepenentisolator installed adjacent to the compressor.

7.4 WATERCOOLED UNITS

Cooling Water Piping

Water piping to and from the compressor package mustbe 1”diameter or larger. Isolation valves with side drainsshould be installed on both the inlet and outlet lines.Also a strainer of 2mm – mesh size should be installedon the inlet line. Strainers are available fromIngersoll – Rand. Ingersoll – Rand CPN 54689997(N37/45K & N50/60H) or CPN 54690029 (N55/75K &N75/100H)

It is recommended that a normally closed solenoidvalve be fitted to the water outlet side of the compressorpackage. This is to be wired into the compressor controlcircuit. This option detail is available fromIngersoll – Rand.

Carefully inspect your water system before installing

the compressor package. Ensure that the piping is freeof scale and deposits that may restrict water flow to thecompressor package.

Proper operation of your compressor requires that thewater flow listed below be provided at a maximumsupply temperature of 46C (115F).

Model

Minimum cooling water requirement atambient temperatures, in litres perminute (US gallons per minute)

Range 50F / 10C

70F / 21C

90F / 32C

N37 – 45 15 (4) 23 (6.1) 38 (10)

N55 19 (5) 27 (7.1) 45 (11.9)

N75 30 (7.7) 42 (11.1) 68 (18)


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Water temperature and pressure gauges should beinstalled in the water piping for use in any fault findingof the water system. Water pressure should ideally bebetween 3 and 5 bar (43.5 and 72.5 psi) but must notbe above 10 Bar (145 psi)

Water cleanliness is also extremely important. Cleaningof coolers as a result of fouling is a customer

responsibility. Therefore, it is highly recommended thatproper water quality must meet the requirements listedin WATER QUALITY RECOMMENDATIONS later inthis section.

Venting the water system

At the initial installation or for start – up after draining thewater system proceed to vent the system as follows

1 Locate the water system vent cocks on top of theaftercooler and lubricant cooler.

2 Open the water valve(s) allowing water to flow to thepackage.

3 Open the vent cocks and allow all air to escape fromthe system. When water is observed at the vent cocks,close them

The system is now vented.

Draining the water system

Should it become necessary to completely drain thewater system, proceed as follows.

1 Disconnect the inlet and discharge water lines fromthe connections located at the rear of the unit.

2 Locate the aftercooler and lubricant cooler. Removethe drain plugs located at the bottom of the coolers.

Allow the system to completely drain.Water quality recommendations

Water quality is often overlooked when the coolingsystem of a water – cooled air compressor is examined.Water quality determines how effective the heattransfer rate, as well as the flow rate will remain duringthe operation life of the unit. It should be noted that thequality of water used in any cooling system does notremain constant during the operation of the system.Evaporation, corrosion, chemical and temperaturechanges, aeration, scale and biological formationseffect the water makeup. Most problems in a coolingsystem show up first in a reduction in the heat transfer

rate, then in a reduced flow rate and finally with damageto the system.

Scale: Scale formation inhibits effective heat transfer,yet it does help prevent corrosion. Therefore, a thinuniform coating of calcium carbonate is desired on theinner surface. Perhaps the largest contributor to scaleformation is the precipitation of calcium carbonate outof the water. This is dependent on temperature and pH.The higher the pH value, the greater the chance of scaleformation. Scale can be controlled with watertreatment.

Corrosion: In contrast to scale formation is theproblem of corrosion. Chlorides cause problemsbecause of their size and conductivity. Low pH levelspromote corrosion, as well as high levels of dissolvedoxygen.

Fouling: Biological and organic substances (slime)can also cause problems, but in elevated temperatureenvironments such as cooling processes they are nota major concern. If they create problems with clogging,commercial shock treatment are available.

To ensure good operation life and performance of the

compressor cooling system, the recommendedacceptable ranges for different water constituents areincluded below:

Cooling Water Analysis Chart

Substances Test interval Acceptableconcentration

Corrosivity(Hardness, pH,Total DissolvedSolids,Temperature at

inlet Alkalinity)

Monthly — ifstable for 3 to 4months, analysequarterly.

Langelier Index0 to 1

Iron Monthly


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7.5 SEA WATERCOOLED UNITS

Water cleanliness is extremely important. Strainers areavailable from Ingersoll – Rand. Cleaning of coolers asa result of fouling is a customer responsibility.

Isolation valves with side drains should be installed on

both the inlet and outlet lines.

It is recommended that a normally closed solenoidvalve be fitted to the water outlet side of the compressorpackage.

It is important to ensure that the recommended flow ratecannot be exceeded. This will normally mean that anorifice plate must be fitted in the pipework at least 1m(3.3ft) before the cooler, with the orifice size calculatedto ensure that the maximum sea water flow rate cannotbe exceeded. If these precautions are not taken, it ispossible that the sea water flow rate through the coolermay be several times the recommended maximum,

which will lead to rapid failure.

Sea Water PressureBar (psi)

Orifice diameter in mm(inch) to give a maximumsea water flow of 90l/min

(23.76 US gall/min)

3 (43.5) 12 (0.472)

4 (58) 11 (0.433)

5 (72.5) 10 (0.394)

6 (87) 9.6 (0.378)

7 (101.5) 9.2 (0.362)

8 (116) 8.9 (0.35)

9 (130.5) 8.7 (0.343)

10 (145) 8.4 (0.33)

No oil cooler manufacturer can guarantee that itsproducts will have an indefinite life and for this reason,we suggest that the cooling system is designed tominimize any damage caused by a leaking oil cooler.This can be achieved as follows ;

1. The oil pressure should be higher than the sea waterpressure, so that in the event of a leak occurring, theoil will not be contaminated.

2. When the hydraulic system is not being used, thecoolers should be isolated from sea water pressure.

3. The sea water outlet pipe from the cooler should

have a free run to waste.


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7.6 OUTDOOR SHELTERED INSTALLATION

Many times a compressor must be installed outside dueto jobsite conditions or limited space within amanufacturing facility. When this occurs there arecertain items that should be incorporated into theinstallation to help ensure trouble free operation. These

items are listed below. The unit must be purchased withthe Outdoor Modification Option to provide water tightelectrics and a TETC motor.

The compressor should be on a concrete pad designedto drain water away. If the concrete pad is sloped, thenthe compressor must be levelled. The base/skid mustbe sealed to the concrete pad.

The roof of the shelter should extend a minimum of 1.2m (4 ft) around all sides of the compressor to preventdirect rain and snow from falling on the unit.

Aircooled machines must be arranged under the shelterin a way that prevents air recirculation (i.e. hot exhaustback to the package inlet).

If the installation includes more than one compressor,the hot air exhaust should not be directed towards thefresh air intake of the second unit or an Air Dryer.

If a standard machine is to be installed outside, it mustnot be started or run if the ambient temperature, bothin and around the compressor drops or is likely to dropbelow 1.7C (35F).

Arrange the machine with the control panel facing awayfrom the sun as radiant heat can affect performance.Also direct sunlight and UV rays will degrade themembrane touch panel. This is not a warrantable

situation.

Power disconnect switch should be within line of sightand in close proximity to the unit. National and Localelectrical codes must be foIIowed when installing thepower disconnect switch.

Condensate drain must never be allowed to drain on the

ground. Run to a suitable sump for future collection anddisposal or separation of lubricant and water mixture.

Incoming power connections must use suitableconnectors for outdoor weather tight service.

A minimum of 1m (3.3ft) clearance must be allowed onall four sides of the unit for service access. HoweverNational or Local codes may require a minimumdistance be maintained in front of control panel door.

If possible, access by a forklift and/or an overheadbeam hoist should be kept in mind (for eventual serviceto airend or motor).

If the area around the installation contains fine airbornedust or lint and fibers etc., then the unit should bepurchased with the High Dust Filter Option, packageprefilter and TETC motor option.

Some type of protection such as a fence or securitysystem should be provided to prevent unauthorizedaccess.


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8.0 GENERAL INFORMATION

IRN37/75K – CC & IRN50/100H – CC (DRAFT COPY ONLY)24

8.1 TECHNICAL INFORMATION

N37K N45K N50H N60H

General

Sound pressure level dB(A) * 75 75 75 75

Maximum ambient temperature C (F) 46 (115) 46 (115) 46 (115) 46 (115)

Minimum ambient temperature C (F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35)

Weight Kg (lbs) 1048 (2310) 1048 (2310) 1048 (2310) 1048 (2310)

Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) 10 (145)

Minimum pressure barg (psig) 4.5 (65.25) 4.5 (65.25) 4.5 (65.25) 4.5 (65.25)

Coolant capacity litres (US gall) 18 (4.75) 18 (4.75) 18 (4.75) 18 (4.75)

HAT switch setting C (F) 109 (228) 109 (228) 109 (228) 109 (228)

Performance

Flow at 7.5 Barg (m3 /min) 6.43 7.42

Flow at 8.5 Barg (m3 /min) 6.12 7.05

Flow at 10 Barg (m3 /min) 5.75 6.46

Flow at 100 psig (cfm) 235 262



Air Cooling System

Cooling air flow m3 /min (cfm) 184 (6500) 184 (6500) 184 (6500) 184 (6500)

Maximum ∆P in air ducts Pa (inch WG) 62 (0.25) 62 (0.25) 62 (0.25) 62 (0.25)

Compressed air outlet ∆T C (F) 8 (46.4) 8 (46.4) 8 (46.4) 8 (46.4)

Water Cooling System

Cooling (clean) water flow m3 /min (USgallon/min)

0.06 (16) 0.06 (16) 0.06 (16) 0.06 (16)



Main Power Circuit

Package full load current at 220V (A) 170 203 169 202

Package full load current at 400V(A) 88 105 87 104



Max fuse size @ 220V (A)




Fuse type Fast blow semi – conductor

Heater Circuit

110V Single Phase Rating (A)


Fuse type General purpose

* In accordance with PNEUROP PN8NTC2.3


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IRN37/75K – CC & IRN50/100H – CC (DRAFT COPY ONLY) 25

N55K N75K N75H N100H

General

Sound pressure level dB(A) * 75 75 75 75

Maximum ambient temperature C (F) 46 (115) 46 (115) 46 (115) 46 (115)

Minimum ambient temperature C (F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35)

Weight Kg (lbs) 1531 (3374) 1531 (3374) 1531 (3374) 1531 (3374)

Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) 10 (145)

Minimum pressure barg (psig) 4.5 (65.25) 4.5 (65.25) 4.5 (65.25) 4.5 (65.25)

Coolant capacity litres (US gall) 30 (8) 30 (8) 30 (8) 30 (8)

HAT switch setting C (F) 109 (228) 109 (228) 109 (228) 109 (228)

Performance

Flow at 7.5 Barg (m3 /min) 10.14 13.51

Flow at 8.5 Barg (m3 /min) 9.15 12.6

Flow at 10 Barg (m3 /min) 8.44 11.52




Air Cooling System

Cooling air flow m3 /min (cfm) 241 (8500) 241 (8500) 241 (8500) 241 (8500)



Water Cooling System

Cooling (clean) water flow m3 /min (US

gallon/min)

0.13 (35) 0.13 (35) 0.13 (35) 0.13 (35)



Main Power Circuit

Package full load current at 220V (A) 245 330 244 327








Fuse type Fast blow semi – conductor

Heater Circuit



Fuse type General purpose

* In accordance with PNEUROP PN8NTC2.3


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8.2 INSTALLATION DRAWING – N37/45K –CC & N50/60H –CC

A 11 / 2” NPT Air discharge (Female) 60Hz units11 / 2” BSP Air discharge (Female) 50Hz units

B Ø63mm (2.48”) Electrical inlet

C 1 / 4“ NPT (Female) Note: Pipe condensate drain lines separately to anopen drain due to differences in drain pressures.Read operations manual and check local regulations.

D CoolingAirflow

E Exhaust airflow

F Cabinet cooling airflow

G 4 x Ø 13.0mm (1”)Compressor should be bolted to the floor with fourM10 (0.38”) bolts using holes shown. Seal base tofloor with cork or rubber.

H INTELLISYS Controller

U Right

V Bottom

W Front

X –X Section through X – XZ Plan view


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8.2 INSTALLATION DRAWING – N55/75K –CC & N75/100H –CC

A 2” NPT Air discharge (Female) 60Hz units2” BSP Air discharge (Female) 50Hz units

B Ø63mm (2.48”) Electrical inlet

C 1 / 4“ NPT (Female) Note: Pipe condensate drain lines separately to anopen drain due to differences in drain pressures.Read operations manual and check local regulations.

D Cooling airflow

E Exhaust airflow

F Cabinet cooling airflow

G 4 x Ø 13.0mm (1”)Compressor should be bolted to the floor with fourM10 (0.38”) bolts using holes shown. Seal base tofloor with cork or rubber.

H INTELLISYS Controller

U Right

V Bottom

W Front

X –X Section through X – X

Z Plan view


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8.3 PROCESS AND INSTRUMENTATION DIAGRAM


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KEY

1 Air discharge

2 Compressor

3 Air filter

4 Vacuum switch 1VAC

5 Cooler, air

6 Cooler, coolant

7 Condensate discharge

8 Coolant filter

9 Pressure switch, coolant filter 1DPS

10 Drain valve, coolant

11 Temperature switch 1ATS

12 Air inlet check valve

13 Optional electronic drain with alarm

14 Minimum pressure check valve

15 Moisture separator

16 Pressure transducer 4APT

17 Pressure relief valve

18 Scavange filter / orifice / check

19 Separator tank (primary/secondary)

20 Oil temperature control valve

21 Temperature transducer 2ATT

22 3SV blowdown solenoid valve

23 Drive motor

24 Blower motor

25 Cooling air blower

26 Cooling water inlet (W.C. only)

27 Cooling water outlet (W.C. only)



30 Dryer (customer supply equipment)

31 Line filters (customer equipment)

32 Receivers (customer equipment)

33 Dryer AUX warning

34 Line filter AUX warninig

35 Receiver trap AUX warninig

36 Remote pressure transducer 9APT (optional)

37 Water stop valve 4SV

38 Typical customer downstream air treatment

39 Anti – condensation valve 11SV (not on all units)

40 Vent valve

41 Package discharge temperature temperaturetransducer 4ATT

42 Injection temperature, transducer 2CTT (optional)

Piping legend

Air/coolant

Air

Coolant

Condensate

Cooling water (W.C. only)

Compressor enclosure

Sensor connection

Equipment downstream ofcompressor


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8.4 ELECTRICAL SCHEMATIC


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KEY

1ATS Switch, high airend discharge temperature

1DPS Switch, fouled oil filter

1VAC Switch, fouled air filter

2ATT Sensor, airend discharge temperature

2CTT Sensor, injected coolant temperature

3APT Transducer, sump pressure, wet side

3SV Valve. blowdown solenoid

4APT Transducer, package discharge pressure

4ATT Sensor, package discharge temperature

6APT Transducer, sump pressure, dry side

9APT Transmitter, remote pressure

AT Autotransformer (if fitted)

AW1 Auxiliary warning 1

AW2 Auxiliary warning 2

BP Backplate

CAB Cabinet

CFO Common fault output

EXC External communications

DVF Blower, drive ventilation

DR Drive

EB Earth bar

ES Switch, emergency stop

FM Blower motor

GND Ground

K1 Relay, run

K2 Relay fault

KM1 Contactor, main motor

KM4 Contactor, blower motor

MCB1 Breaker, miniature circuit, transformer

MCB2 Breaker, miniature circuit, VFD

MCB3 Breaker, miniature circuit, control circuitsMCB4 Breaker, miniature circuit, VFD supply

MCB5 Breaker, miniature circuit, PSU

MCB9 Breaker, miniature circuit, heaters

MM Main motor

MMS Breaker, blower motor

OPT Optional

PORO Power outage restart option

PSU Power supply unit

RFI Filter, radio frequency interference

RSP Remote stop

RST Remote start

SGN Controller, Intellisys

SL Serial link

SS1 –3 Relay, solid state

ST Service tool

T1 Transformer, control

TH Thermostat

TRR True running

VFD Drive, variable frequency

WR General warning

Colors

BLK Black

BLU Blue

BRO Brown

GRE GreenPIN Pink

RED Red

SCR Screen

WHI White

YEL Yellow

Wires

Numbers Function Wire color

1 – 99 Power Black100 – 199 AC Control Red

200 – 299 DC Control Blue

300 – 399 Auxiliary Orange


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8.5 GENERAL DESCRIPTION

The compressor is an electric motor driven, singlestage screw compressor, complete with all necessarycomponents piped, wired and baseplate mounted. It isa totally self contained air compressor package.

The standard compressor is designed to operate in anambient range of 1.7C to 46C (35F to 115F). Thestandard maximum temperature of 46C (115F) isapplicable up to an elevation of 1000m (3280ft) abovesea level. Above this altitude significant reductions inambient temperature are required if a standard motoris to be used.

The compressor is managed by the onboard electroniccontroller. The controller and drive system operatetogether to vary the speed of the compresor to delivercompressed air at the target pressure.

Panel instrumentation is provided to indicate the

compressor operating conditions and general status.The air/coolant mixture discharges from thecompressor into the separation system. This systemremoves all but a few PPM of the coolant from thedischarge air. The coolant is returned to the coolingsystem and the air passes to the aftercooler and out ofthe compressor through the moisture separator.

Air is pulled into the machine by the cooling blower andthrough the combined cooler / aftercooler.

By cooling the discharge air, much of the water vapornaturally contained in the air is condensed and is

drained from the built – in moisture separator and drain.

The coolant system consists of a sump, cooler,thermostatic valve and a filter. When the unit isoperating, coolant is forced by air pressure from theseparator tank to the thermostatic element. Theposition of the element (a direct result of coolanttemperature) will determine whether the coolantcirculates through the cooler, bypasses the cooler, ormixes the two paths together to maintain an optimumcompressor injection temperature. This temperature iscontrolled to preclude the possibility of water vaporcondensing. By injecting coolant at a sufficiently hightemperature, the discharge air coolant mixture

temperature will be kept above the dew point.

The compressor is provided with a temperature sensorwhich will shut the unit down in case of excessivetemperature, 109C (228F).

Effective coolant filtration is provided by the use of ascrew on, heavy duty coolant filter.

NOTICESSR air compressors are factory filled with SSR ULTRA COOLANT which is designed to operate for 8,000hours or two years, whichever comes first. The coolant must be changed at these intervals to avoid

breakdown and equipment damage.


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9.0 OPERATING INSTRUCTIONS


6

9.1 BASIC OPERATION

WARNINGEnsure that all protective covers/guards are inplace before attempting to start the machine.

WARNINGThe compressor can operate in a pressurisedshutdown mode. If the compressor stopsautomatically, the airend, separator tank and oilsystem can contain high pressure air. This can berelieved by pressing the emergency stop buttonand can be verified by unscrewing the coolant fillplug which has a vent hole through which anyresidual pressure will be vented. Downstream ofthe separator tank may still contain systempressure which must also be vented.

NOTICEThe language and units of measure displayed onthe Intellisys controller will be pre –set beforeleaving the factory. If these are required to bechanged, contact your local Ingersoll –RandService Department, Distributor or Air Center.

Prior to starting

Refer to diagram T5716 above

Check that the coolant level is at least visible in thecentre of the sight glass, add coolant if nescessary.Refer to maintenance procedures for setting correctlevel.

Ensure that the discharge air isolation valve is open.

Switch on the main electrical isolation switch. Thecontrol panel will illuminate, indicating that the line andcontrol voltages are available.

The contrast of the display may be adjusted by turningthe small screw which is on the right hand side of the

controller when accessed through the starter cabinetdoor.

Initial check sequence

The controller will perform an initial check sequence ifthe compressor (1) receives initial power to thecontroller or (2) has experienced an alarm reset. Whilethe initial check sequence occurs, the controller willdisplay a “Checking Machine” message.

During the initial check sequence, the controller willcheck the control system for proper operation. Duringthis time, if any items are found inoperative an alarm willoccur and the unit will not start.

After completion of the initial check sequence, thecontroller will then display “READY TO START’. Thisprocess should be completed within 10 seconds.


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Start sequence

The compressor will initially start by the operatorpressing the local start button or receiving a remotestart command. The compressor will start loaded andwill ramp up the motor speed to its minimum speed.Once the minimum speed has been achieved, thecompressor will begin to control pressure by using its

speed regulation. When the system pressure reachesthe target pressure, the compressor will start to slow. Ifthe system pressure rises to the immediate stoppressure setpoint the compressor will stop. If thesystem pressure rises to the auto stop setpoint and thecompressor is at minimum speed, if the blowdownmode is set to off, the compressor will stop. Howeverif the blowdown mode is set to on, the compressor willopen the blowdown valve for up to 10 seconds or untilthe sump pressure falls to 2.4 Bar (35 psi) beforestopping. The compressor will restart once the systempressure falls below the target pressure.

Stop sequence

The compressor can be stopped by a local or remotestop, a shutdown due to an alarm or an emergencystop. All of the above conditions will cause thecompressor to stop immediately, except the local orremote stop. A local or remote stop will open theblowdown valve and the compressor will run for up to10 seconds or until the sump pressure falls to 35 psibefore stopping. The compressor will stop if the systempressure reaches the automatic stop or immediate stoppressure setpoints. However, if the compressor stopsfor this reason, it will automatically restart when thesystem pressure falls below the target pressure.

Blowdown mode

If the blowdown mode is set to off, the compressor willopen the blowdown valve anytime that it stops. This willrelease pressure from the airend and separator tank.If the blowdown mode is set to on, the blowdown valvewill remain closed when the compressor stops due to anautomatic stop

Blower control

The blower will run when the compressor is running. Ifthe blower is stopped, it will start with the compressor.The blower may run for a period of time after thecompressor stops. This will be done to limit the numberof blower starts to 15 per hour. If the compressor stopsdue to an alarm or a local or remote stop, the blower willstop with the compressor.

Stopping the machine in an emergency

If the machine has to be stopped in an emergencyDEPRESS THE EMERGENCY STOP BUTTONLOCATED UNDERNEATH THE INSTRUMENTPANEL.

This will over – ride the normal unload/stop button andwill immediately stop the machine.

Restarting after an emergency

If the unit has been switched off because of a machinemalfunction, identify and correct the fault beforeattempting to restart.

If the unit has been switched off for reasons of safety,ensure that the machine can be operated safely beforerestarting.

Refer to the PRIOR TO STARTING and START SEQUENCE instructions earlier in this section beforerestarting the machine.


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9.2 INTELLISYS CONTROLS

1. Emergency stop

Pressing this switch stops the compressor immediately.The blowdown valve will open to vent pressure in theseparator tank to atmosphere. Note: the systemdownstream of the separator tank may still containpressure. The compressors can not be restarted untilthe switch is manually reset. Turn the switch knobclockwise and press the reset button twice to reset.

On reset the controller will display a message,indicating that the compressor is ready to start.

2. Start

Pressing this button will activate the start sequence.

3. Stop

Pressing this button will activate the stop sequence.

4. F1

Not used.

5. F2

Not used.

6. Arrows

These up and down buttons have multiple functionsrelating to the right half of the display screen. When listsare presented, the buttons are used to move up or downthrough the items on the list. The small arrow(s)displayed in the upper right hand corner of the displayscreen indicate when you can move up (designated byarrow head pointing up) and/or down (designated by

arrow head pointing down) through the list.When the value of a specific machine operatingparameter is highlighted on the display screen for thepurpose of changing that value, the buttons are used tochange the value itself.

7. Display buttons

The functions of the three buttons below the displayscreen change and are defined by the wordsimmediately above them in the bottom line of thescreen. Each function, such as MAIN MENU, STATUS,etc., is described in appropriate sections in this manual.


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9.3 DISPLAY SCREEN

The display screen is divided into three functionalareas, as seen in the typical CURRENT STATUSscreen shown here.

The left side continuously shows the package

discharge pressure in large numbers with the linedirectly below showing the running condition of themachine

100 – CURRENT STATUS – 100PACKAGE DISCHARGE

TEMP

102F

READY TO START AIREND DISCHARGETEMP

192FMAIN MENU

The right side shows various items or lists such as themachine’s CURRENT STATUS readings, the MAINMENU, the OPERATOR SETPOINTS list, etc. Any ofthe 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 indicatewhen you can move up and/or down through a list. Thearrow buttons are also used to change an individualitem’s value. At certain times, items and/or their valuesare “highlighted”. This means that they are displayed aslight characters on a dark background.

The bottom of the screen is divided into thirds with thewords in each small box showing the function of thebutton directly beneath it. The words will change inthese boxes depending on what actions are permittedat any particular time. The action resulting frompressing each of these buttons is indicated in theOperator Panel Flow Diagram later in this section. Thiscan be used as a quick reference of how to step thecontroller screen through any desired function.

9.4 CURRENT STATUS SCREEN

The CURRENT STATUS screen is considered to be the“normal” display that the controller shows.

The following items and their present values can bedisplayed on the right side of the screen by pressing the

up and down arrow buttons.The controller automatically returns the display to thisCURRENT STATUS screen from other screens if nobuttons are pressed within 30 seconds.

Use the UP and DOWN arrows to move betweenselections.

CURRENT STATUS items

1 % Energy Saving

2 % Load

3 Package Discharge Temperature

4 Airend Discharge Temperature

5 Injected Coolant Temperature (optional)

6 Sump Pressure

7 Separator Pressure Drop

8 Coolant Filter

9 Inlet Filter

10 Total Hours

11 Speed

12 Motor Current

13 Input Voltage

14 DC Bus Voltage

15 Remote Pressure (optional)

16 Time and Date

17 Program Name


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9.5 MAIN MENU

The MAIN MENU screen can be accessed from theCURRENT STATUS screen by pressing the MAINMENU button, identified by the words “MAIN MENU” inthe bottom line of the screen directly above the center

button.

The MAIN MENU screen is the point from which variousoperator functions can be accessed. Refer to theOperator Panel Flow Diagram.

Each of the functions can be chosen by using the upand down arrows to highlight it on the screen.

The controller will go to the highlighted function if theSELECT button is pressed or will return to theCURRENT STATUS screen if the STATUS button ispressed.

The language and units of measure are pre – set prior tothe compressor leaving the factory.

– MAIN MENU –

100OPERATOR SETPOINTS

OPTIONS

READY TO START SENSOR CALIBRATION

ALARM HISTORY

STATUS SELECT

OPERATORSETPOINTS

OPERATOR SETPOINTS

ITEM

MAIN MENU

CURRENTSTATUS

OPTIONS

OPTIONS ITEM

SENSOR CALIBRATION

SENSORCALIBRATION

ITEM

ALARMHISTORY

ALARM HISTORYITEM

CLOCKFUNCTIONS

DATE ANDTIME

“Status”

“Status”

“Main Menu”

“Main Menu”

“Select”

“Status” “Status” “Status”

“Status”“Status”

“Main Menu” “Main Menu” “Main Menu”

“Main Menu” “Main Menu”

“Status”

“Main Menu”

“Status”

“Main Menu”

“Cancel or set” “Cancel or set” “Cancel or calibrate”

“Alarm hist” “Cancel or set”

“Select” “Select” “Select”

“Select” “Select”


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9.6 OPERATOR SETPOINTS

Setpoints are user – adjustable variables in thecontroller logic that can be set using the OPERATORSETPOINTS screen shown opposite.

The name and value of each of the setpoints listed can

be seen on the screen by moving the list up and downusing the arrow buttons.

Setpoints associated with options are described in theOPTIONS sections.

– OPERATOR SETPOINTS –

100TARGET PRESSURE

105 psiREADY TO START

STATUS MAIN MENU SELECT

FACTORY DEFAULTS

OPERATOR SETPOINTS DEFAULT MIN. MAX. STEP UNIT

Target pressure 100 65 145 1 PSI

Automatic stop pressure 110 Target +1 Target +10 1 PSI

Immediate stop pressure 120 Auto Auto +10 1 PSI

Blowdown mode Off Off On – –

% savings compared to Modulation – – – –

Service menu 1 1 25535 1 –

A setpoint’s value can be changed by first highlightingthe item and its value and pressing the SELECT buttonto highlight just the value. When the value line ishighlighted by itself, the value can be adjusted using theup and down arrow buttons. The CANCEL and SETbuttons appear at this time. Press the SET button to

enter the new value or press the CANCEL button toreturn the value of the setpoint prior to using the arrows.The displayed value will flash twice to indicated that ithas been entered into the setpoint and the pair ofsetpoint item and value display lines will again behighlighted together.

Operator setpoints can be exited by pressing theSTATUS or MAIN MENU buttons. If no buttons arepressed within 30 seconds, the display will return to theCURRENT STATUS screen.

Target pressure

The compressor will try to operate at this pressure

setting. The target pressure ranges and step sizes foreach unit of measure are listed in the table below.

Unit Min Max (1S) Step

PSI 65 145 1

BAR 4.4 10 0.1

kPa 440 1000 10

KGCM2 4.5 10.2 0.1

Automatic stop pressure

The compressor will stop once the system pressurerises to this pressure and the compressor is operatingat the minimum speed. The range for this setpoint willbe the target pressure+1 to target pressure+10 psi.

Immediate stop pressureThe compressor will stop if the system pressure risesto this pressure. The range for this setpoint will be theautomatic stop pressure to automatic stop pressure+10psi.

Blowdown Mode

If this mode is selected to ON the compressor will openthe blowdown valve anytime that it stops. This will ventpressure from the airend and the separator tank. If thismode is selected to OFF the blowdown valve willremain closed when the compressor stops due to anautomatic stop.

% savings compared to

This setpoint is to determine what Nirvana’s percent ofsavings is compared to. The modes of operation forcomparing Nirvana to are modulation, online/offline,and geometry. The percent savings value is displayedby the status message, % energy savings


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9.7 OPTIONS

Options are turned on or off and their associated valuesare set using the OPTION screen shown opposite.

Some options are purchased, they require additionalmachine hardware and must first be enabled by service

personnel. The name and value of each of the followingoptions can be seen by moving the list up and downusing the arrow buttons

An Option item’s value can be changed the same waythat OPERATOR SETPOINTS values are changed.

– OPTIONS –

100REMOTE START/STOP ON

READY TO START REMOTE START/STOP ON


OPTIONS Items SELECTION MIN. MAX. Step Unit InstalledOption

Required

Remote Pressure Sensor ON/OFF No

Sequencer ON/OFF No

Remote Start/Stop ON/OFF Yes

Power Out Restart ON/OFF Yes

Power Out Restart Time 10 600 1 SEC Yes

Scheduled Start Day day day 1 day Yes

Scheduled Start 00:00 23:59 1 time Yes

Scheduled Stop Day day day 1 day Yes

Scheduled Stop 00:00 23:59 1 time Yes

Injected coolant temp ON/OFF No

Remote pressure sensor

If this setting is set to YES, the compressor will use aremote mounted pressure sensor for controlling systempressure. This sensor would also provide the readingthat is displayed for system pressure on the controller.The local sensor, would then only be used for alarms.If it is set to NO, the local sensor will be used forcontrolling and displaying the system pressure.

Sequencer

If this setting is set to YES, the compressor will be ableto start and stop by commands from a host device.When the Intellisys receives a load command from thehost device, the compressor will start. When theIntellisys receives an unload command the compressorwill respond as though executing an immediate stop..

Remote start/stop

If the remote start/stop option is installed and thissetting is set to YES, the compressor can be startedand stopped from a remote device.

Power out restart

If this setting is set to YES, the compressor willautomatically restart when power is returned to thecompressor if it was operating when power wasremoved.

Power out restart time

If the power out restart setting is set to YES, this is thenumber of seconds from the time power is restored untilthe compressor starts. The power out restart horn willsound during this time.


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Scheduled start day

This option is the selection for the day that a scheduledstart will take place. The selections are Sunday,Monday, Tuesday, Wednesday, Thursday, Friday,Saturday, Daily (Su — Sa), Weekdays (M — F), orWeekends. This option setpoint will work with thescheduled start setpoint.

Scheduled start

This option will cause the unit to start on the scheduledstart day , at the time stored in this setpoint. To disablethis option, set the value of scheduled start equal to thevalue of scheduled stop.

Scheduled stop day

This option is the selection for the day that a scheduledstop will take place. The selections are Sunday,Monday, Tuesday, Wednesday, Thursday, Friday,Saturday, Daily (Su — Sa), Weekdays (M — F), orWeekends. This option setpoint will work with thescheduled stop setpoint.

Scheduled stop

This option will cause the unit to stop on the scheduledstop day, at the time stored in this setpoint. To disablethis option, set the value of scheduled stop equal to thevalue of scheduled start.

Injected Coolant Temperature

If this option is set to ON, the Intellisys will read theinjected coolant temperature and display its value. Ifthis option is set to OFF, the Intellisys will display “notinstalled”.

9.8 SENSOR CALIBRATION

Pressure sensor calibration is done through theSENSOR CALIBRATION screen. Sensor calibrationcan only take place when the machine is stopped.Calibration needs to be done only after a sensor hasbeen replaced or the Intellisys controller has beenreplaced.

– SENSOR CALIBRATION –

100SENSOR 4APT

CALIBRATE

READY TO START SENSOR 3APT

CALIBRATE


Each of the sensors listed below can be chosen byusing the up and down arrow buttons to highlight it onthe screen.

SENSOR CALIBRATION ItemsSensor 4APT (Package Discharge)Sensor 3APT (Wet Side Sump)Sensor 6APT (Dry Side Sump)Sensor 9APT (Remote Pressure Sensor)

Select the highlighted sensor by pressing the SELECTbutton. Press the CALIBRATE button to start the

automatic calibration procedure, or press the CANCELbutton to not calibrate it and return to the sensor list.

The calibration screen can be exited by pressing eitherthe STATUS or MAIN MENU buttons. If no buttons arepressed within 30 seconds, the display will return to theCURRENT STATUS screen.


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9.9 ALARM HISTORY

Alarm History displays

Nirvana Operators Manual

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