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
800−D Beaty Street
Davidson, NC 28036
CONTENTS & ABBREVIATIONS
1
CONTENTS
1CONTENTS
2FOREWORD
3DECALS
8SAFETY
10GENERAL INFORMATION
16INSTALLATION / HANDLING
28OPERATING INSTRUCTIONS
33MAINTENANCE
37TROUBLE SHOOTING
ABBREVIATIONS & SYMBOLS
####Contact Ingersoll Rand for serial number
−>#### Up to Serial No.
####−> From Serial No.
*Not illustrated
{Option
NRNot required
ARAs required
SMSitemaster/Sitepack
HAHigh ambient machine
WCWatercooled machine
ACAircooled machine
ERSEnergy recovery system
T.E.F.C. Totally enclosed fan cooled motor (IP54)
O.D.P.Open drip proof (motor)
ppmparts 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 non−genuine 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 non−approved 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
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.)
ItemccnQty.DescriptionItemccnQty.Description
1323435842Decal, warning hot surface
2323439071Decal, lock and tag out
3931712622Decal, lift here
4812959901Decal, air shield USA
5220645621Decal, aircare
6931664601Decal, coolant drain
7323435192Decal, danger contaminated air
8228068971Decal, Ingersoll Rand logo
9220663021Decal, fifteen minutes before service
10228145451Decal, dryer bypass valve
11−1Decal, model number
12228068711Decal, facia
13323435432Decal, notice air discharge
14233532381Decal, maintenance schedule
15931665021Decal, replacement filter element
16302866861Decal, rotation arrow notice
17227947391Decal, electric schematic
18323435271Decal, warning high pressure
19323435502Decal, warning exposed fan
20323435682Decal, warning hazardous voltage
21323438991Decal, warning flying debris
22221816631Decal, drain
23929305931Decal, electric shock
24322763211Decal, california safety order decal
25223943811Decal, power inlet
26323435761Decal, auto drain (Tank mount only)
27225471451Decal, total air system (Dryer models
28229230151Tag, shipping
29−1
only)
Decal, voltage
DECALS (I.S.O.)
7
ItemccnQty.DescriptionItemccnQty.Description
1928675302Decal, hot surface
2931712622Decal, lift here
(Base mount only)
3220623191Tag, air care do you know
4931664601Decal, coolant drain
5928674072Decal, do not inhale
6220663021Decal, fifteen minutes before service
7228145451Decal, dryer bypass valve
225394311Decal, control panel
Non−dryer packages
8165434641Decal, Ingersoll Rand logo
9−1Decal, model number
10928674982Decal, air discharge
11931664781Decal, auto drain
12931665021Decal, replacement filter element
13931659831Decal, rotation arrow notice
14228068711Decal, facia
15929305851Decal, warning pressurized vessel
16931659592Decal, use guards when running
17929305932Decal, electric shock
18228167971Decal, maintenance schedule
19931664781Decal, condensate drain
20929306681Decal, no maintenance before
21229230151Tag, 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 over−pressurize 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 hand−held 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 classABC 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. 380−460V, 50Hz/60Hz.
KEY
XS1Main terminals
QF1Fan motor starter
QF1.1Auxiliary contact
FU3Transformer secondary fuse
FU1, 2Transformer primary fuses
FR1Solid state relay
FR2Solid state relay
FR3Solid state relay
EDVElectric drain valve
DRVariable speed drive
MMMain motor
FMBlower motor
MCDryer motor
ESEmergency stop
1ATSHigh air temperature switch
1RPSDryer refrigeration pressure switch
PTOThermistor, motor winding temp.
P1, P2Pressure transducer
EDVOElectronic drain valve option
DODryer option
CACommon alarm
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 CLASS−J, 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. 200−230V, 60Hz. 380−460V, 50Hz/60Hz.
11
KEY
XS1Main terminals
QF1Fan motor starter
QF1.1Auxiliary contact
FU3Transformer secondary fuse
FU1, 2Transformer primary fuses
FR1Solid state relay
FR2Solid state relay
FR3Solid state relay
EDVElectric drain valve
DRVariable speed drive
MMMain motor
FM1Blower motor
FM2Main blower motor fan
MCDryer motor
ESEmergency stop
1ATSHigh air temperature switch
1RPSDryer refrigeration pressure switch
PTOThermistor, motor winding temp.
P1, P2Pressure transducer
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 CLASS−J, 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. 200−230V, 380−415V, 50Hz.
WIRING FOR 3 PHASE, NEUTRAL AND PROTECTIVE EARTH POWER SUPPLY
(−−−− SHOWS ALTERNATE WIRING FOR 230V POWER SUPPLY WITH NO NEUTRAL AVAILABLE)
KEY
XS1Main terminals
QF1Fan motor starter
QF1.1Auxiliary contact
FU3Transformer secondary fuse
FU1, 2Transformer primary fuses
FR1Solid state relay
FR2Solid state relay
FR3Solid state relay
EDVElectric drain valve
DRVariable speed drive
MMMain motor
FM1Blower motor
FM2Main blower motor fan
MCDryer motor
ESEmergency stop
1ATSHigh air temperature switch
1RPSDryer refrigeration pressure switch
PTOThermistor, motor winding temp.
P1, P2Pressure transducer
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 CLASS−J, 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
13
KEY
XS1Main terminals
QF1Fan motor starter
QF1.1Auxiliary contact
FU3Transformer secondary fuse
FU1, 2Transformer primary fuses
FU4, 5Dryer fuses
FR1Solid state relay
FR2Solid state relay
FR3Solid state relay
EDVElectric drain valve
DRVariable speed drive
MMMain motor
FMBlower motor
MCDryer motor
ESEmergency stop
1ATSHigh air temperature switch
1RPSDryer refrigeration pressure switch
PTOThermistor, motor winding temp.
P1, P2Pressure transducer
DODryer option
CACommon alarm
WHTWhite
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 CLASS−J, 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. 220−230V, 60Hz. 380−460V, 50Hz.
KEY
Alternative wiring for 3 phase, neutral and protective earth power
supply.
XS1Main terminals
QF1Fan motor starter
QF1.1Auxiliary contact
FU4, 5Dryer fuses
FU1, 2EDV fuses
FR1Solid state relay
FR2Solid state relay
FR3Solid state relay
EDVElectric drain valve
DRVariable speed drive
MMMain motor
FMBlower motor
MCDryer motor
ESEmergency stop
1ATSHigh air temperature switch
1RPSDryer refrigeration pressure switch
PTOThermistor, motor winding temp.
P1, P2Pressure transducer
DODryer option
CACommon alarm
WHTWhite
REDRed
DDPDryer discharge pressure (Dryer option)
ADPAftercooler 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 CLASS−J, 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
15
KEY
AR Air receiver (option)
ID Integral dryer (option)
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 pre−filter
V Drive
W Dryer general purpose filter
X Electric drain valve
Y Dryer high efficiency filter
Center of gravity
INSTALLATION / HANDLING
17
KEY
20−40HP 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 pre−filter
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
20−40HP 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 pre−filter
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
15−30kW 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 pre−filter
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
15−30kW 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 pre−filter
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
60/50HzIRN 20HP/ 15 kWIRN 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
Cooling air flow1900ft3/min (53.8m3/min)
Maximum ∆P in air ducts0.25 inWg (6.4mmH2O)
Compressed air outlet ∆TN/A15_F (8.3_C)N/A20_F (11_C)
1, 4
2, 4
3, 4
75
(2.12)
80
(2.27)
84
(2.38)
150
(10.34)
non−TA 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)
non−TA S
150
(10.34)
94
(2.66)
102
(2.89)
108
(3.06)
23
GENERAL DATA
Separation volume1.8 gallons (7 Litres )
Coolant capacity3.4 gallons (13 Litres )
Weight − base mount unit1350 lbs (612 kg)
Weight − 120 gallon Receiver mounted1720 lbs (780 kg)
Weight − 240 gallon Receiver mounted1891 lbs (858 kg)
Weight − 500 Litre Receiver mounted1772 lbs (804 kg)
Weight − 750 Litre Receiver mounted1891 lbs (858 kg)
DRYER ENGINEERING DATA50 / 60Hz
Electrical protection class (std)NEMA 1
Factory refrigerant charge (oz/g)23.5 oz
Refigeration type134 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 voltageLow VoltageHigh Voltage
Drive motor
Motor enclosureIP65
Power20HP / 15kW
Full load current (maximum)58.352.731.930.326.3
Starts per hour (maximum)20
ELECTRICAL DATA
Control voltage24VDC
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 voltageLow VoltageHigh Voltage
Drive motor
Motor enclosureIP65
Power25HP / 18.5kW
Full load current (maximum)73.2A63.7A40.2A38.2A33.2A
Starts per hour (maximum)20
ELECTRICAL DATA
Control voltage24VDC
Maximum fuse rating
See note 1, 3
Minimum wire size AWG
(mm2)
See note 2, 3
INSTALLATION / HANDLING
208V230V380V400V460V
100A90A50A50A45A
4 (25)4 (25)8 (10)8 (10)8 (10)
208V230V380V400V460V
125A100A70A60A50A
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 Class−J, 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
60/50HzIRN 30HP/ 22 kWIRN 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
Cooling air flow2700ft3/min (76.5m3/min)
Maximum ∆P in air ducts0.25 inWg (6.4mmH2O)
Compressed air outlet ∆TN/A15_F (8.3_C)N/A20_F (11_C)
1, 4
2, 4
3, 4
109
(3.09)
120
(3.40)
125
(3.54)
150
(10.34)
non−TA 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)
non−TA S
150
(10.34)
146
(4.14)
158
(4.48)
164
(4.65)
25
GENERAL DATA
Separation volume2.8 gallons (10.7 Litres )
Coolant capacity5.5 gallons (21 Litres )
Weight − base mount unit1350 lbs (612 kg)
Weight − 120 gallon Receiver mounted1720 lbs (780 kg)
Weight − 240 gallon Receiver mounted1891 lbs (858 kg)
Weight − 500 Litre Receiver mounted1772 lbs (804 kg)
Weight − 750 Litre Receiver mounted1891 lbs (858 kg)
DRYER ENGINEERING DATA50 / 60Hz
Electrical protection class (std)NEMA 1
Factory refrigerant charge (oz/g)45 oz
Refigeration type134 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 voltageLow VoltageHigh Voltage
Drive motor
Motor enclosureIP65
Power20HP / 15kW
Full load current (maximum)9182504741
Starts per hour (maximum)20
ELECTRICAL DATA
Control voltage24VDC
Maximum fuse rating
See note 1, 3
Minimum wire size AWG
(mm2)
See note 2, 3
ELECTRICAL DATA − ALL UNITS IRN 40HP / 30kW
Standard voltageLow VoltageHigh Voltage
Drive motor
Motor enclosureIP65
Power25HP / 18.5kW
Full load current (maximum)122A110A66.5A63A55A
Starts per hour (maximum)20
ELECTRICAL DATA
Control voltage24VDC
Maximum fuse rating
See note 1, 3
Minimum wire size AWG
(mm2)
See note 2, 3
INSTALLATION / HANDLING
208V230V380V400V460V
150A125A75A75A70A
2 (32)2 (32)6 (16)6 (16)6 (16)
208V230V380V400V460V
200A200A125A100A80A
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 Class−J, 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
on−off selector switch is in the ’off’ position with the e−stop
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 andrestart, 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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