Ingersoll-Rand 80445364 User Manual

IRN 15 18.5 kW (20 25 HP)
IRN 22 30 kW (30 40 HP)
OPERATION AND MAINTENANCE MANUAL
Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.
Ensure that the Operation and Maintenance manual is not removed permanently from the machine.
Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.
C.C.N. : 80445364 REV. : A DATE : OCTOBER 2008
AIR COMPRESSOR GROUP
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BONDED WARRANTY & 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 from the date of placing the Equipment in operation or eighteen months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment in accordance with good industry practices and has complied with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the
Purchaser or others without 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 fulfilment of all liabilities of the Company for such nonconformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment. The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company
in writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.
Note that this is Ingersoll Rand standard warranty. Any warranty in force at the time of purchase of the compressor or negotiated as part of the purchase order may take precedence over this warranty.
Register on−line at http://air.ingersollrand.com
Ingersoll Rand
Industrial Air Solutions
Swan Lane
Hindley Green
Wigan WN2 4EZ
Ingersoll Rand Asia Pacific
C/O Ingersoll Rand South East Asia (Pte) Ltd.
42 Benoi Road
Singapore 629903
Ingersoll Rand
Industrial Air Solutions
P.O. Box 1840
800D Beaty Street
Davidson, NC 28036
CONTENTS & ABBREVIATIONS
1
CONTENTS 1 CONTENTS
2 FOREWORD
3 DECALS
8 SAFETY
10 GENERAL INFORMATION
16 INSTALLATION / HANDLING
28 OPERATING INSTRUCTIONS
33 MAINTENANCE
37 TROUBLE SHOOTING
ABBREVIATIONS & SYMBOLS
#### Contact Ingersoll Rand for serial number
>#### Up to Serial No. ####> From Serial No. * Not illustrated
{ Option
NR Not required AR As required SM Sitemaster/Sitepack HA High ambient machine WC Watercooled machine AC Aircooled machine ERS Energy recovery system T.E.F.C. Totally enclosed fan cooled motor (IP54) O.D.P. Open drip proof (motor)
ppm parts per million
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FOREWORD
The contents of this manual are considered to be proprietary and confidential to Ingersoll Rand and should not be reproduced without the prior written permission of Ingersoll Rand.
Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll Rand products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such products, which are available upon request.
This manual contains instructions and technical data to cover routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be referred to an authorised Ingersoll Rand service department.
The design specification of this machine has been certified as complying with E.C. directives. Any modification to any part is absolutely prohibited and would result in the CE certification and marking being rendered invalid.
All components, accessories, pipes and connectors added to the compressed air system should be: . of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Ingersoll Rand. . clearly rated for a pressure at least equal to the machine maximum allowable working pressure. . compatible with the compressor lubricant/coolant. . accompanied with instructions for safe installation, operation and maintenance.
Details of approved equipment are available from Ingersoll Rand Service departments.
The use of nongenuine spare repair parts other than those included within the Ingersoll Rand approved parts list may create hazardous conditions over which Ingersoll Rand has no control. Therefore Ingersoll Rand does not accept any liability for losses caused by equipment in which nonapproved repair parts are installed. Standard warranty conditions may be affected.
The intended uses of this machine are outlined below and examples of unapproved usage are also given, however Ingersoll Rand cannot anticipate every application or work situation that may arise.
IF IN DOUBT CONSULT SUPERVISION.
This machine has been designed and supplied for use only in the following specified conditions and applications: . Compression of normal ambient air containing no known or detectable additional gases, vapours. or particles . Operation within the ambient temperature range specified in the GENERAL INFORMATION section of this manual.
The use of the machine in any of the situation types listed in table 1: a) Is not approved by Ingersoll Rand, b) May impair the safety of users and other persons, and c) May prejudice any claims made against Ingersoll Rand.
TABLE 1
Use of the machine to produce compressed air for: a) direct human consumption b) indirect human consumption, without suitable filtration and purity checks.
Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION of this manual.
Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or vapours.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES, INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR VAPOURS MAY BE PRESENT.
Use of the machine fitted with non Ingersoll Rand approved
components.
Use of the machine with safety or control components missing or disabled.
Ingersoll Rand reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.
The company accepts no responsibility for errors in translation of
this manual from the original English version.
COPYRIGHT 2008 INGERSOLL RAND COMPANY LIMITED
DECALS 3
ISO SYMBOLS
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory Information / Instructions Warning
WARNING: Electrical shock risk. WARNING Pressurised vessel. WARNING Hot surface.
WARNING Pressurised component or
system.
Use fork lift truck from this side only. RESET Do not use fork lift truck from this side.
Emergency stop. On (power). Off (power).
Read the Operation and Maintenance manual
before operation or maintenance of this
machine is undertaken.
WARNING Air/gas flow or Air discharge. Do not breathe the compressed air from this
Do not operate the machine without the guard
being fitted.
machine.
Lifting point.
ROTATION AIR DISCHARGE COOLANT FILTER
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DECALS4
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AUTOMATIC RESTART MAINTENANCE MAINTENANCE PROHIBITED
COOLANT DRAIN CONDENSATE DRAIN FILTER
FRAGILE KEEP DRY THIS WAY UP
USE NO HOOKS NO SIDE CLAMPS HOURS
POWER
INSPECT
CLEAN
Every X months, if sooner than required by
operating hours
POWER INLET (AC)
CHANGE / REPLACE
Pinch point hazard.
Keep hands clear.
DECALS 5
ANSI SYMBOLS
GRAPHIC FORM AND MEANING OF ANSI SYMBOLS
DANGER
INTAKE AIR. Can contain carbon monoxide or other contaminants. Will cause serious injury or death. Ingersoll Rand air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for
breathing air applications unless treated in accordance with all applicable codes and regulations.
WARNING
HAZARDOUS VOLTAGE. Can cause serious injury or death. Disconnect power and bleed pressure from tank before servicing. Lockout/Tagout machine. Compressor must be connected to properly grounded circuit. See Grounding
Instructions in manual. Do not operate compressor in wet conditions. Store indoors.
RISK OF FIRE OR EXPLOSION. Electrical arcing from compressor components can ignite flammable liquids and vapors which can result in serious injury. Never operate the compressor near flammable liquids or vapors. If used to
spray flammable materials, keep compressor at least 20ft (6m) away from the spray area.
HIGH PRESSURE AIR. Rusted tanks can cause explosion and severe injury or death. Receiver under pressure. Operator should relieve tank pressure before performing maintenance. In addition to automatic drain, operate manual
drain valve weekly. Manual drain valve located at bottom of the tank.
MOVING PARTS. Can cause serious injury. Do not operate with guards removed. Machine may start automatically. Disconnect power before servicing. Lockout/Tagout machine.
HOT SURFACES. Can cause serious injury. Do not touch. Allow to cool before servicing. Do not touch hot compressor or tubing.
EXPOSED MOVING BELTS AND SHEAVES. Can cause severe injury or death. Do not operate without guard in place. Disconnect power before servicing. Lockout/Tagout machine.
Air flow exhaust may contain flying debris. Safety protection should be worn at all times.
Pinch point hazard. Keep hands clear.
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DECALS (A.N.S.I.)
Item ccn Qty. Description Item ccn Qty. Description
1 32343584 2 Decal, warning hot surface 2 32343907 1 Decal, lock and tag out 3 93171262 2 Decal, lift here 4 81295990 1 Decal, air shield USA 5 22064562 1 Decal, aircare 6 93166460 1 Decal, coolant drain 7 32343519 2 Decal, danger contaminated air 8 22806897 1 Decal, Ingersoll Rand logo 9 22066302 1 Decal, fifteen minutes before service
10 22814545 1 Decal, dryer bypass valve
11 1 Decal, model number 12 22806871 1 Decal, facia 13 32343543 2 Decal, notice air discharge 14 23353238 1 Decal, maintenance schedule 15 93166502 1 Decal, replacement filter element
16 30286686 1 Decal, rotation arrow notice 17 22794739 1 Decal, electric schematic 18 32343527 1 Decal, warning high pressure 19 32343550 2 Decal, warning exposed fan 20 32343568 2 Decal, warning hazardous voltage 21 32343899 1 Decal, warning flying debris 22 22181663 1 Decal, drain 23 92930593 1 Decal, electric shock 24 32276321 1 Decal, california safety order decal 25 22394381 1 Decal, power inlet 26 32343576 1 Decal, auto drain (Tank mount only) 27 22547145 1 Decal, total air system (Dryer models
28 22923015 1 Tag, shipping 29 1
only)
Decal, voltage
DECALS (I.S.O.)
7
Item ccn Qty. Description Item ccn Qty. Description
1 92867530 2 Decal, hot surface 2 93171262 2 Decal, lift here
(Base mount only) 3 22062319 1 Tag, air care do you know 4 93166460 1 Decal, coolant drain 5 92867407 2 Decal, do not inhale 6 22066302 1 Decal, fifteen minutes before service 7 22814545 1 Decal, dryer bypass valve
22539431 1 Decal, control panel
Nondryer packages
8 16543464 1 Decal, Ingersoll Rand logo 9 1 Decal, model number
10 92867498 2 Decal, air discharge
11 93166478 1 Decal, auto drain 12 93166502 1 Decal, replacement filter element 13 93165983 1 Decal, rotation arrow notice 14 22806871 1 Decal, facia 15 92930585 1 Decal, warning pressurized vessel 16 93165959 2 Decal, use guards when running 17 92930593 2 Decal, electric shock 18 22816797 1 Decal, maintenance schedule 19 93166478 1 Decal, condensate drain 20 92930668 1 Decal, no maintenance before
21 22923015 1 Tag, shipping 22 1
referring manual
Decal, voltage
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SAFETY
DANGER!
Hazard that WILL cause DEATH, SEVERE INJURY or substantial
property damage if ignored. Instructions must be followed precisely to avoid injury or death.
WARNING!
Hazard that CAN cause DEATH, SEVERE INJURY or substantial
property damage if ignored. Instructions which must be followed precisely to avoid injury or death.
CAUTIONS!
Cautions call attention to instructions which must be followed
precisely to avoid damaging the product, process or its surroundings.
NOTES
Notes are used for supplementary information.
BREATHING AIR PRECAUTION
Ingersoll Rand air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for breathing air applications unless treated in accordance with all
applicable codes and regulations.
General Information
Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.
Ensure that the Operation and Maintenance manual is not removed permanently from the machine.
Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.
Do not point air nozzles or sprayers toward anyone.
Compressed air and electricity can be dangerous. Before undertaking any work on the compressor, ensure that the electrical supply has been isolated and the compressor has been relieved of all pressure.
Wear eye protection when operating or servicing compressor.
All persons positioned near to operating machinery should be equipped with hearing protection and given instructions on its use in accordance with workplace safety legislation.
Make sure that all protective covers are in place and that the canopy/doors are closed during operation.
The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas.
Installation of this compressor must be in accordance with recognised electrical codes and any local Health and Safety Codes.
The use of plastic bowls on line filters can be hazardous. Their safety can be affected by either synthetic lubricants, or the additives used in mineral oils. Ingersoll Rand recommends that only filters with metal bowls should be used on a pressurised system.
Compressed air
Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.
WARNING
Imposing a normal or emergency stop on the compressor will only relieve pressure upstream of the minimum pressure valve on top of the separator tank. If maintenance work is required downstream of this valve, ensure that all pressure is relieved at the process vent point external to the compressor
If more than one compressor is connected to one common downstream plant, effective isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidentally be pressurised / over pressurised by another.
Compressed air must not be used for a direct feed to any form of breathing apparatus or mask.
The discharged air contains a very small percentage of compressor lubricant and care should be taken to ensure that downstream equipment is compatible.
If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided.
When using compressed air always use appropriate personal protective equipment.
All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions.
Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.
Avoid bodily contact with compressed air.
All safety valves located in the separator tank must be checked periodically for correct operation.
Do not overpressurize the receiver tank or similar vessels beyond design limits.
Do not use a receiver tank or similar vessels that fail to meet the design requirements of the compressor. Contact your distributor for
assistance.
Do not drill into, weld or otherwise alter the receiver tank or similar vessels.
Before servicing the unit, vent pressure before removing the power to ensure that the gauge reads zero pressure.
Materials
The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: . preservative grease . rust preventative . compressor coolant . refridgerant
AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES
Transport
When loading or transporting machines ensure that the specified lifting and tie down points are used.
Lifting equipment must be properly rated for the weight of the compressor.
Do not work on or walk under the compressor while it is suspended.
Electrical
Keep all parts of the body and any handheld tools or other conductive objects, away from exposed live parts of the electrical system. Maintain dry footing, stand on insulating surfaces and do not contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system.
WARNING
Any electrical connections or adjustments should only be made by a suitably qualified electrician
Ensure that the machine is operating at the rated pressure and that
the rated pressure is known to all relevant personnel.
All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine rated pressure.
Close and lock all access doors when the compressor is left
unattended.
Do not use extinguishers intended for Class A or Class B fires on
electrical fires. Use only extinguishers suitable for class BC or class ABC fires.
Attempt repairs only in clean, dry, well lighted and ventilated areas.
Connect the compressor only to electrical systems that are compatible with its electrical characteristics and that are within it’s rated capacity.
Condensate disposal
As waste water regulations vary by country and region it is the responsibility of the user to establish the limitations and regulations in their particular area. Ingersoll Rand and its associated distributors are happy to advise and assist in these matters.
For further information, consult Material Data Sheets CPN 88303979 for ULTRA Coolant.
The above information contains data supplied in support of United Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.) regulations.
SAFETY
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GENERAL INFORMATION
TN, TT, IT 3+PE. 380460V, 50Hz/60Hz.
KEY
XS1 Main terminals QF1 Fan motor starter QF1.1 Auxiliary contact FU3 Transformer secondary fuse FU1, 2 Transformer primary fuses FR1 Solid state relay FR2 Solid state relay FR3 Solid state relay EDV Electric drain valve DR Variable speed drive MM Main motor FM Blower motor MC Dryer motor ES Emergency stop 1ATS High air temperature switch 1RPS Dryer refrigeration pressure switch PTO Thermistor, motor winding temp. P1, P2 Pressure transducer EDVO Electronic drain valve option DO Dryer option CA Common alarm
WHT White RED Red DDP Dryer discharge pressure (Dryer option) ADP Aftercooler discharge pressure
WIRES
POWER Black DC CONTROL Blue NEUTRAL Light blue PROTECTIVE EARTH − Green / Yellow
NOTES
1. THE CORRECT TYPE AND RATING OF LINE INPUT FUSE
MUST BE FITTED ONTO THE CUSTOMER’S ISOLATOR OR BREAKER CLOSE TO THE COMPRESSOR.
FAST ACTING CLASSJ, T OR SEMICONDUCTOR TYPE, CURRENT LIMITING, INTERRUPT RATING − 200,000 AMPS RMS
SECTION
2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER AND SHOULD BE DONE IN ACCORDANCE WITH THE INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND LOCAL ELECTRICAL CODES.
3. DECAL MUST CONFORM TO THE LATEST REVISION OF IR SPECIFICATION 92−8.95.
GENERAL INFORMATION
TN, TT, IT 3+PE. 200230V, 60Hz. 380460V, 50Hz/60Hz.
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KEY
XS1 Main terminals QF1 Fan motor starter QF1.1 Auxiliary contact FU3 Transformer secondary fuse FU1, 2 Transformer primary fuses FR1 Solid state relay FR2 Solid state relay FR3 Solid state relay EDV Electric drain valve DR Variable speed drive MM Main motor FM1 Blower motor
FM2 Main blower motor fan MC Dryer motor ES Emergency stop 1ATS High air temperature switch 1RPS Dryer refrigeration pressure switch PTO Thermistor, motor winding temp. P1, P2 Pressure transducer
C Capacitor DO Dryer option DDP Dryer discharge pressure (Dryer option) ADP Aftercooler discharge pressure EDVO Electronic drain valve option CA Common alarm
BLK Black BLU Blue BRO Brown WHT White RED Red
WIRES
POWER Black DC CONTROL Blue NEUTRAL Light blue PROTECTIVE EARTH − Green / Yellow
NOTES
1. THE CORRECT TYPE AND RATING OF LINE INPUT FUSE
MUST BE FITTED ONTO THE CUSTOMER’S ISOLATOR OR BREAKER CLOSE TO THE COMPRESSOR.
FAST ACTING CLASSJ, T OR SEMICONDUCTOR TYPE, CURRENT LIMITING, INTERRUPT RATING − 200,000 AMPS RMS
SECTION
2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER AND SHOULD BE DONE IN ACCORDANCE WITH THE INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND LOCAL ELECTRICAL CODES.
3. DECAL MUST CONFORM TO THE LATEST REVISION OF IR SPECIFICATION 92−8.95.
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GENERAL INFORMATION
TN, TT, IT 3+(N)+PE. 200230V, 380415V, 50Hz.
WIRING FOR 3 PHASE, NEUTRAL AND PROTECTIVE EARTH POWER SUPPLY ( SHOWS ALTERNATE WIRING FOR 230V POWER SUPPLY WITH NO NEUTRAL AVAILABLE)
KEY
XS1 Main terminals QF1 Fan motor starter QF1.1 Auxiliary contact FU3 Transformer secondary fuse FU1, 2 Transformer primary fuses FR1 Solid state relay FR2 Solid state relay FR3 Solid state relay EDV Electric drain valve DR Variable speed drive MM Main motor FM1 Blower motor
FM2 Main blower motor fan MC Dryer motor ES Emergency stop 1ATS High air temperature switch 1RPS Dryer refrigeration pressure switch PTO Thermistor, motor winding temp. P1, P2 Pressure transducer
C Capacitor DO Dryer option DDP Dryer discharge pressure (Dryer option) ADP Aftercooler discharge pressure EDVO Electronic drain valve option CA Common alarm
NN No neutral BLK Black BLU Blue BRO Brown WHT White RED Red
WIRES
POWER Black DC CONTROL Blue NEUTRAL Light blue PROTECTIVE EARTH − Green / Yellow
NOTES
1. THE CORRECT TYPE AND RATING OF LINE INPUT FUSE
MUST BE FITTED ONTO THE CUSTOMER’S ISOLATOR OR BREAKER CLOSE TO THE COMPRESSOR.
FAST ACTING CLASSJ, T OR SEMICONDUCTOR TYPE, CURRENT LIMITING, INTERRUPT RATING − 200,000 AMPS RMS
SECTION
2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER AND SHOULD BE DONE IN ACCORDANCE WITH THE INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND LOCAL ELECTRICAL CODES.
3. DECAL MUST CONFORM TO THE LATEST REVISION OF IR SPECIFICATION 92−8.95.
TN, TT, IT 3+PE. 200V, 60Hz.
GENERAL INFORMATION
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KEY
XS1 Main terminals QF1 Fan motor starter QF1.1 Auxiliary contact FU3 Transformer secondary fuse FU1, 2 Transformer primary fuses FU4, 5 Dryer fuses FR1 Solid state relay FR2 Solid state relay FR3 Solid state relay EDV Electric drain valve DR Variable speed drive MM Main motor FM Blower motor MC Dryer motor ES Emergency stop 1ATS High air temperature switch 1RPS Dryer refrigeration pressure switch PTO Thermistor, motor winding temp. P1, P2 Pressure transducer DO Dryer option CA Common alarm WHT White
RED Red DDP Dryer discharge pressure (Dryer option) ADP Aftercooler discharge pressure
WIRES
POWER Black DC CONTROL Blue NEUTRAL Light blue PROTECTIVE EARTH − Green / Yellow
NOTES
1. THE CORRECT TYPE AND RATING OF LINE INPUT FUSE MUST BE FITTED ONTO THE CUSTOMERS ISOLATOR OR BREAKER CLOSE TO THE COMPRESSOR.
FAST ACTING CLASSJ, T OR SEMICONDUCTOR TYPE, CURRENT LIMITING, INTERRUPT RATING − 200,000 AMPS RMS
SECTION
2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER AND SHOULD BE DONE IN ACCORDANCE WITH THE INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND LOCAL ELECTRICAL CODES.
3. DECAL MUST CONFORM TO THE LATEST REVISION OF IR SPECIFICATION 92−8.95.
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GENERAL INFORMATION
TN, TT, IT 3+PE. 220230V, 60Hz. 380460V, 50Hz.
KEY
Alternative wiring for 3 phase, neutral and protective earth power supply.
XS1 Main terminals QF1 Fan motor starter QF1.1 Auxiliary contact FU4, 5 Dryer fuses FU1, 2 EDV fuses FR1 Solid state relay FR2 Solid state relay FR3 Solid state relay EDV Electric drain valve DR Variable speed drive MM Main motor FM Blower motor MC Dryer motor ES Emergency stop 1ATS High air temperature switch 1RPS Dryer refrigeration pressure switch PTO Thermistor, motor winding temp. P1, P2 Pressure transducer DO Dryer option CA Common alarm WHT White
RED Red DDP Dryer discharge pressure (Dryer option) ADP Aftercooler discharge pressure 220/230 NN Alternate wiring for 230v power supply with no neutral
available.
WIRES
POWER Black DC CONTROL Blue NEUTRAL Light blue PROTECTIVE EARTH − Green / Yellow
NOTES
1. THE CORRECT TYPE AND RATING OF LINE INPUT FUSE MUST BE FITTED ONTO THE CUSTOMERS ISOLATOR OR BREAKER CLOSE TO THE COMPRESSOR.
FAST ACTING CLASSJ, T OR SEMICONDUCTOR TYPE, CURRENT LIMITING, INTERRUPT RATING − 200,000 AMPS RMS
SECTION
2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER AND SHOULD BE DONE IN ACCORDANCE WITH THE INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND LOCAL ELECTRICAL CODES.
3. DECAL MUST CONFORM TO THE LATEST REVISION OF IR SPECIFICATION 92−8.95.
PIPING AND INSTRUMENTATION
GENERAL INFORMATION
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KEY
AR Air receiver (option) ID Integral dryer (option)
1. Filter, air
2. Valve, inlet
3. Airend assembly
4. Motor
5. Tank, separator coarse
6. Tank, separator fine
7. Valve, minimum pressure
8. Aftercooler
9. Transducer, pressure
10. Switch, temperature
11. Filter, coolant
12. Thermostat
13. Cooler, oil
14. Controller, drive
15. Valve, safety
16. Valve, drain
17. Screen, scavenge
18. Receiver, air
19. Moisture separator (Option)
20. Transducer, pressure Line
21. Condensate discharge
22. Filter, air General purpose
23. Orifice
24. Valve, blowdown
25. Filter, air High efficiency
26. Valve, check
27. Recuperator
28. Valve, isolation
29. Moisture separator
30. Valve, check
31. Evaporator
32. Indicator, dew point
33. Valve, condensate
34. Valve, thermal expansion
35. Filter, dryer refrigerant
36. Condenser
37. Valve, hot gas bypass
38. Refrigerant compressor
39. Valve, auto drain
40. Valve, minimum pressure
A Air/Coolant B Air C Coolant D Condensate E Component boundary F Refrigerant
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INSTALLATION / HANDLING
KEY 2040HP 120 GALLON BASEPLATE
A Blower rotation B Air discharge location C Drain location D Emergency stop button E Dryer dewpoint indicator F Drive location G Air inlet H Air exhaust I Air inlet filter J Coolant separator element K Separator tank relief valve L Coolant fill M Coolant level sight glass N Separator tank
O Drive motor rotation P Coolant filter Q Incoming power connections R Electrical controls/fuses access panel S Bypass valve T Integrated dryer (Optional) U Package prefilter V Drive W Dryer general purpose filter X Electric drain valve Y Dryer high efficiency filter
Center of gravity
INSTALLATION / HANDLING
17
KEY 2040HP 120 GALLON
A Blower rotation B Air discharge location C Drain location D Emergency stop button E Dryer dewpoint indicator F Drive location G Air inlet H Air exhaust I Air inlet filter J Coolant separator element K Separator tank relief valve L Coolant fill M Coolant level sight glass N Separator tank O Drive motor rotation
P Coolant filter Q Incoming power connections R Electrical controls/fuses access panel S Bypass valve T Integrated dryer (Optional) U Package prefilter V Drive W Dryer general purpose filter X Electric drain valve Y Dryer high efficiency filter Z Receiver relief valve AAPackage lifting points
Center of gravity
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INSTALLATION / HANDLING
KEY 2040HP 240 GALLON
A Blower rotation B Air discharge location C Drain location D Emergency stop button E Dryer dewpoint indicator F Drive location G Air inlet H Air exhaust I Air inlet filter J Coolant separator element K Separator tank relief valve L Coolant fill M Coolant level sight glass N Separator tank O Drive motor rotation
P Coolant filter Q Incoming power connections R Electrical controls/fuses access panel S Bypass valve T Integrated dryer (Optional) U Package prefilter V Drive W Dryer general purpose filter X Electric drain valve Y Dryer high efficiency filter Z Receiver relief valve AAPackage lifting points
Center of gravity
INSTALLATION / HANDLING
19
KEY 1530kW 500 LITRE
A Blower rotation B Air discharge location C Drain location D Emergency stop button E Dryer dewpoint indicator F Drive location G Air inlet H Air exhaust I Air inlet filter J Coolant separator element K Separator tank relief valve L Coolant fill M Coolant level sight glass N Separator tank O Drive motor rotation
P Coolant filter Q Incoming power connections R Electrical controls/fuses access panel S Bypass valve T Integrated dryer (Optional) U Package prefilter V Drive W Dryer general purpose filter X Electric drain valve Y Dryer high efficiency filter Z Receiver relief valve AAPackage lifting points
Center of gravity
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INSTALLATION / HANDLING
KEY 1530kW 750 LITRE
A Blower rotation B Air discharge location C Drain location D Emergency stop button E Dryer dewpoint indicator F Drive location G Air inlet H Air exhaust I Air inlet filter J Coolant separator element K Separator tank relief valve L Coolant fill M Coolant level sight glass N Separator tank O Drive motor rotation
P Coolant filter Q Incoming power connections R Electrical controls/fuses access panel S Bypass valve T Integrated dryer (Optional) U Package prefilter V Drive W Dryer general purpose filter X Electric drain valve Y Dryer high efficiency filter Z Receiver relief valve AAPackage lifting points
Center of gravity
INSTALLATION / HANDLING
21
NOTES
1 Foundation or floor must be level, and support all feet equally. If necessary, shim or grout the fourth foot.
2 Foundation bolts should project thru nuts a minimum of 13mm [0.50”] to allow for levelling.
3 Allow a minimum clearance of 1100mm [42”] on the front and 920mm [36”] on the top, left, right and the rear of the package for proper air circulation and serviceability.
4 Approximate package weight: 475 KG. (1045 LBS)
NOTE
All dimensions are in millimetres (inches) unless otherwise stated.
Ensure that the correct fork lift truck slots or marked lifting points are used whenever the machine is lifted or transported.
UNPACKING
The compressor will normally be delivered with a polythene cover. If a knife has to be used to remove this cover ensure that the exterior paintwork of the compressor is not damaged.
Remove shipping bolts on end panel.
Ensure that all transport and packing materials are discarded in a
manner prescribed by local codes.
DRYER INSTALLATION
Do not connect condensate drains common to other pressurised drain lines in a closed circuit. Make sure the outflow from the condensate drains is unimpeded. Connect the condensate piping in such a way to ensure that sound levels are kept to a minimum during drainage. Ensure that all condensate is disposed of in a responsible manner, in accordance with local norms concerning environmental protection.
The ambient air around the dryer and compressor must not contain solid or gaseous contaminants. All compressed and condensed gases can generate acids or chemical products which may damage the compressor or components inside the dryer. Take particular care with sulphur, ammonia, chlorine and installations in marine environments. For further advice or assistance consult your local Ingersoll Rand representative.
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INSTALLATION / HANDLING
KEY
1. Compressor
2. Air Receiver
3. Air Dryer
4. Compressed air filters
5. System demand points
NOTE
Items [2] to [5] are optional or may be existing items of plant. Refer to your Ingersoll Rand distributor / representative for specific recommendations.
LOCATION IN THE PLANT
The compressor can be installed on any level floor capable of supporting it. A dry, well ventilated area where the atmosphere is clean is recommended. A minimum of 1m (3ft) should be left all around machine for adequate service access and ventilation.
Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks.
Ensure that the machine is positioned securely and on a stable foundation. Any risk of movement should be removed by suitable means, especially to avoid strain on any rigid discharge piping.
CAUTION
Screw type compressors [1] should not be installed in air systems with reciprocating compressors without means of isolation such as a common receiver tank. It is recommended that both types of compressor be piped to a common receiver using individual air lines.
CAUTION
The use of plastic bowls on line filters and other plastic air line components can be hazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils. Ingersoll Rand recommends that only filters with metal bowls should be used on any pressurised system.
CAUTION The Basic compressor or Total Air System Package, is not suitable for operation in temperatures liable to cause freezing as Condensate water is liable to be produced in the after cooler and receiver where fitted.
Refer to your Ingersoll Rand distributor for further information
DISCHARGE PIPING
Discharge piping should be at least as large as the discharge connection of the compressor. All piping and fittings should be suitably rated for the discharge pressure.
It is essential when installing a new compressor [1], to review the total air system. This is to ensure a safe and effective total system. One item which should be considered is liquid carryover. Installation of air dryers [3] is always good practice since properly selected and installed they can reduce any liquid carryover to zero.
It is good practice to locate an isolation valve close to the compressor and to install line filters [4].
If you have purchased a TAS model, your compressor package already includes items [1], [3] and [4].
It is a requirement for air dryers covered under Aircare that correctly sized Ingersoll Rand pre and afterfilters are installed.
INSTALLATION / HANDLING
60/50Hz IRN 20HP/ 15 kW IRN 25HP / 18.5 kW
TAS
COMPRESSOR
Nominal pressure PSIG (bar)
Flow rate @ 150 PSIG (10.3 bar) ACFM (m3/MIN)
Flow rate @ 125 PSIG (8.6 bar) ACFM (m3/MIN)
Flow rate @ 115 PSIG (8 bar) ACFM (m3/MIN)
Airend discharge temperature. 228_F (109_C) Trip point Ambient operating temperature
(min.) (max.)
MOTOR
Nominal power 20HP / 15kW 25HP / 18.5kW Insulation class F
COOLING SYSTEM Air cooled
Cooling air flow 1900ft3/min (53.8m3/min) Maximum P in air ducts 0.25 inWg (6.4mmH2O) Compressed air outlet ∆T N/A 15_F (8.3_C) N/A 20_F (11_C)
1, 4
2, 4
3, 4
75
(2.12)
80
(2.27)
84
(2.38)
150
(10.34)
nonTA S
77
(2.18)
83
(2.35)
87
(2.46)
35_F (+2_C) 104_F (+40_C)
TAS
92
(2.61)
99
(2.80)
105
(2.97)
nonTA S
150
(10.34)
94
(2.66)
102
(2.89)
108
(3.06)
23
GENERAL DATA
Separation volume 1.8 gallons (7 Litres ) Coolant capacity 3.4 gallons (13 Litres ) Weight base mount unit 1350 lbs (612 kg) Weight 120 gallon Receiver mounted 1720 lbs (780 kg) Weight 240 gallon Receiver mounted 1891 lbs (858 kg) Weight 500 Litre Receiver mounted 1772 lbs (804 kg) Weight 750 Litre Receiver mounted 1891 lbs (858 kg)
DRYER ENGINEERING DATA 50 / 60Hz
Electrical protection class (std) NEMA 1
Factory refrigerant charge (oz/g) 23.5 oz
Refigeration type 134 A
1 Assuming a 5 psi (0.34 bar) pressure drop through the TAS module. 2 Assuming a 8 psi (0.55 bar) pressure drop through the TAS module. 3 Assuming a 9 psi (0.62 bar) pressure drop through the TAS module. 4 Flow rate will decrease as DP through the TAS module increases.
(IP 20)
667 g
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ELECTRICAL DATA − ALL UNITS IRN 20HP / 15kW Standard voltage Low Voltage High Voltage
Drive motor
Motor enclosure IP65 Power 20HP / 15kW Full load current (maximum) 58.3 52.7 31.9 30.3 26.3 Starts per hour (maximum) 20
ELECTRICAL DATA
Control voltage 24VDC Maximum fuse rating
See note 1, 3 Minimum wire size AWG
(mm2) See note 2, 3
ELECTRICAL DATA ALL UNITS IRN 25HP / 18.5kW Standard voltage Low Voltage High Voltage
Drive motor
Motor enclosure IP65 Power 25HP / 18.5kW Full load current (maximum) 73.2A 63.7A 40.2A 38.2A 33.2A Starts per hour (maximum) 20
ELECTRICAL DATA
Control voltage 24VDC Maximum fuse rating
See note 1, 3 Minimum wire size AWG
(mm2) See note 2, 3
INSTALLATION / HANDLING
208V 230V 380V 400V 460V
100A 90A 50A 50A 45A
4 (25) 4 (25) 8 (10) 8 (10) 8 (10)
208V 230V 380V 400V 460V
125A 100A 70A 60A 50A
3 (35) 4 (25) 6 (16) 6 (16) 8 (10)
1. The correct type and rating of line input fuse MUST BE fitted onto the customers isolator or breaker close to the compressor.
Fast Acting ClassJ, T or Semiconductor type, Current limiting, Interrupt Rating 200,000 Amps RMS SYM.
Alternate fuse may be used if the time current characteristics are faster than fuses recommended in this section.
2. PVC/PVC Type Calculated using the following conditions: i) PVC insulated cable, armoured, copper conductors.
ii) Cable clipped to a wall, in free air. iii) Ambient temperature of 40_C (104_F) and relative humidity of 40%. iv) 20m (65ft) cable run. v) Volt drop limited to 10% during starting, 4% during normal running. vi) Protected by the fuse listed above.
3. Always apply local electrical codes for sizing cables and fusing.
If there are any deviations from the above, or special regulations apply, the installation must be planned by a competent, qualified engineer.
NOTE
All data applies to standard product only.
INSTALLATION / HANDLING
60/50Hz IRN 30HP/ 22 kW IRN 40HP / 30 kW
TAS
COMPRESSOR
Nominal pressure PSIG (bar)
Flow rate @ 150 PSIG (10.3 bar) ACFM (m3/MIN)
Flow rate @ 125 PSIG (8.6 bar) ACFM (m3/MIN)
Flow rate @ 115 PSIG (8 bar) ACFM (m3/MIN)
Airend discharge temperature. 228_F (109_C) Trip point Ambient operating temperature
(min.) (max.)
MOTOR
Nominal power 30HP / 22kW 40HP / 30kW Insulation class F
COOLING SYSTEM Air cooled
Cooling air flow 2700ft3/min (76.5m3/min) Maximum P in air ducts 0.25 inWg (6.4mmH2O) Compressed air outlet ∆T N/A 15_F (8.3_C) N/A 20_F (11_C)
1, 4
2, 4
3, 4
109
(3.09)
120
(3.40)
125
(3.54)
150
(10.34)
nonTA S
112
(3.17)
125
(3.54)
130
(3.68)
35_F (+2_C) 104_F (+40_C)
TAS
142
(4.02)
152
(4.31)
158
(4.48)
nonTA S
150
(10.34)
146
(4.14)
158
(4.48)
164
(4.65)
25
GENERAL DATA
Separation volume 2.8 gallons (10.7 Litres ) Coolant capacity 5.5 gallons (21 Litres ) Weight base mount unit 1350 lbs (612 kg) Weight 120 gallon Receiver mounted 1720 lbs (780 kg) Weight 240 gallon Receiver mounted 1891 lbs (858 kg) Weight 500 Litre Receiver mounted 1772 lbs (804 kg) Weight 750 Litre Receiver mounted 1891 lbs (858 kg)
DRYER ENGINEERING DATA 50 / 60Hz
Electrical protection class (std) NEMA 1
Factory refrigerant charge (oz/g) 45 oz
Refigeration type 134 A
1 Assuming a 6 psi (0.4 bar) pressure drop through the TAS module. 2 Assuming a 9 psi (0.62 bar) pressure drop through the TAS module. 3 Assuming a 10 psi (0.69 bar) pressure drop through the TAS module. 4 Flow rate will decrease as DP through the TAS module increases.
(IP 20)
1.27 kg
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ELECTRICAL DATA − ALL UNITS IRN 30HP / 22kW Standard voltage Low Voltage High Voltage
Drive motor
Motor enclosure IP65 Power 20HP / 15kW Full load current (maximum) 91 82 50 47 41 Starts per hour (maximum) 20
ELECTRICAL DATA
Control voltage 24VDC Maximum fuse rating
See note 1, 3 Minimum wire size AWG
(mm2) See note 2, 3
ELECTRICAL DATA ALL UNITS IRN 40HP / 30kW Standard voltage Low Voltage High Voltage
Drive motor
Motor enclosure IP65 Power 25HP / 18.5kW Full load current (maximum) 122A 110A 66.5A 63A 55A Starts per hour (maximum) 20
ELECTRICAL DATA
Control voltage 24VDC Maximum fuse rating
See note 1, 3 Minimum wire size AWG
(mm2) See note 2, 3
INSTALLATION / HANDLING
208V 230V 380V 400V 460V
150A 125A 75A 75A 70A
2 (32) 2 (32) 6 (16) 6 (16) 6 (16)
208V 230V 380V 400V 460V
200A 200A 125A 100A 80A
2/0 (70) 2/0 (70) 4 (25) 4 (25) 4 (25)
1. The correct type and rating of line input fuse MUST BE fitted onto the customers isolator or breaker close to the compressor.
Fast Acting ClassJ, T or Semiconductor type, Current limiting, Interrupt Rating 200,000 Amps RMS SYM.
Alternate fuse may be used if the time current characteristics are faster than fuses recommended in this section.
2. PVC/PVC Type Calculated using the following conditions: i) PVC insulated cable, armoured, copper conductors.
ii) Cable clipped to a wall, in free air. iii) Ambient temperature of 40_C (104_F) and relative humidity of 40%. iv) 20m (65ft) cable run. v) Volt drop limited to 10% during starting, 4% during normal running. vi) Protected by the fuse listed above.
3. Always apply local electrical codes for sizing cables and fusing.
If there are any deviations from the above, or special regulations apply, the installation must be planned by a competent, qualified engineer.
NOTE
All data applies to standard product only.
INSTALLATION / HANDLING
27
ELECTRICAL DATA
An independent electrical isolator or disconnect should be installed
adjacent to the compressor.
Feeder cables/wires should be sized by the customer/electrical contractor to ensure that the circuit is balanced and not overloaded by other electrical equipment. The length of wiring from a suitable electrical feed point is critical as voltage drops may impair the performance of the compressor.
Feeder cables / wires connections to isolator or disconnect should be tight and clean.
The applied voltage must be compatible with the motor and compressor data plate ratings.
Do not use a buck and boost transformer.
CAUTION
Never test the insulation resistance of any part of the machines electrical circuits, including the motor without completely
disconnecting the electronic controller (where fitted).
CAUTION
Do not verify cooling simply by air flow direction, but ensure that the fan rotates in the correct direction as indicated by direction arrows
NOTE
If the compressor is installed for 208V 60hz or 380V 60hz applications, the wiring at the primary of the transformer needs to
be changed during installation.
OUTDOOR MODIFICATION OPTION
EU Directive 2000/14/EC. Noise Emission By Equipment For Use Outdoors
The standard compressor packages are not suitable for use outdoors. If the Outdoor Modification Option is fitted to a machine which will be operated within the EU the machine is not intended to be used as hire equipment or moved from place to place. It must be installed as fixed machinery, which is not intended to be moved during its operational life (For example, a compressor permanently fixed outside of buildings) and is therefore excluded from the Directive.
This exclusion is on the basis that the machine forms a permanent part of a factory or plant , and that local Environmental Noise Regulations will apply to this factory / plant, in place of the directive.
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OPERATING INSTRUCTIONS
GENERAL OPERATION
The compressor is an electric motor driven, single stage screw compressor, complete with accessories piped, wired and baseplate mounted. It is a totally self contained air compressor package.
The standard compressor is designed to operate in an ambient range of 35.6_F 104_F (2_C to 40_C). The maximum temperature is applicable up to a maximum elevation of 3280ft (1000m) above sea level. Above this altitude significant reduction in maximum allowable ambient temperature is required.
Compression in the screw type air compressor is created by the meshing of two (male & female) helical rotors.
The air/coolant mixture discharges from the compressor into the separation system. This system removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the cooling system and the air passes through the aftercooler and out of the compressor.
Cooling air is moved through the coolers by the cooling fan and discharged from the machine.
WARNING
This unit is equipped with automatic cooling fan control. The package cooling fan will operate independently of the compression module. The fan may operate when the compressor is stopped in automatic restart mode or when the onoff selector switch is in the ’off’ position with the estop disengaged.
The power transmission from the drive motor to the airend male rotor is by direct drive.
By cooling the discharge air, much of the water vapour naturally contained in the air is condensed and may be drained from the downstream piping and equipment.
The coolant system consists of a sump, cooler, thermostatic valve and a filter. When the unit is operating, the coolant is pressurized and forced to the compressor bearings.
The compressor load control system is automatic stop and restart, with selectable variable speed control. This allows the compressor to maintain a set discharge line pressure by varying output capacity to match the system demand. The unit is provided with an automatic stop and restart system for use in plants where the air demand varies sufficiently to allow a compressor to shut down and save power. Significant system volume will assist this and is recommended.
WARNING
When the unit stops running as the result of low air demand, it may restart and return to load at any time.
CAUTION LOW DEMAND APPLICATIONS
During periods of low demand, the compressor may not reach its normal operating temperature. Sustained operation at low demand can result in the build up of condensate in the coolant. If this situation occurs, the lubricating characteristics of the coolant can be impaired which may lead to damage of the compressor. THE COMPRESSOR SHOULD BE ALLOWED AMPLE LOADED RUNNING TIME.
CAUTION
Cooling air is drawn in at the rear of the machine package passing through the filter and cooler before being discharged from the top of the machine. Care should be taken to avoid blocking the airflow, or causing any restriction in excess of the maximum backpressure allowed for ducting.
Do not direct the airflow at face or eyes.
Safety of operation is provided as the compressor will shut down if
excessive temperatures or electrical overload conditions should occur.
CAUTION
This unit is not designed or intended to operate when contaminated with silicone. Lubricants, greases or other items containing silicone should not be used on this unit.
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