Ingersoll-Rand IRN75-160K-2S, IRN37-160K-CC, IRN250-300H-2S, IRN100-200H-2S, IRN50-200H-CC User Manual

IRN37−160K−CC

IRN50−200H−CC

IRN75−160K−2S IRN100−200H−2S IRN250−300H−2S

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. : 54731245 DATE : DECEMBER 2007 REV. : J

AIR COMPRESSOR GROUP

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 fulﬁllment of all liabilities of the Company for such non conformities 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.

1.0 CONTENTS

CONTENTS PAGE CONTENTS PAGE

1.0 CONTENTS 1

2.0 FOREWORD 2

3.0 ABBREVIATIONS & SYMBOLS 4

4.0 PURCHASE ORDER DETAILS 5

5.0 SAFETY 6

5.1 SAFETY INSTRUCTIONS 6

5.2 SAFETY PRECAUTIONS 6

5.3 TEXT DECALS 9

5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS 13

6.0 RECEIPT / HANDLING 18

6.1 RECEIPT 18

6.2 UNPACKING AND HANDLING 18

7.0 INSTALLATION 19

7.1 LOCATION IN PLANT 19

7.2 DISCHARGE AND CONDENSATE PIPING 20

9.6 OPERATOR SETPOINTS 71

9.7 OPTIONS 73

9.8 SENSOR CALIBRATION 74

9.9 ALARM HISTORY 75

9.10 CLOCK FUNCTIONS 75

9.11 ENERGY STATUS MESSAGES 76

9.12 WARNINGS 77

9.13 SERVICE WARNINGS 77

9.14 INITIAL CHECK ALARMS: 77

9.15 ALARMS 78

10.0 MAINTENANCE 79

10.1 MAINTENANCE PROMPTS 79

10.2 MAINTENANCE CHART 80

10.3 MAINTENANCE PROCEDURES 81

10.4 ROUTINE MAINTENANCE 83

11.0 FAULT FINDING 91

7.3 ELECTRICAL 21

7.4 WATERCOOLED UNITS 23

7.5 SEA WATERCOOLED UNITS SELECTED UNITS ONLY 25

7.6 OUTDOOR SHELTERED INSTALLATION 26

8.0 GENERAL INFORMATION 27

8.1 TECHNICAL INFORMATION 27

8.2 INSTALLATION DRAWING 33

8.3 PROCESS AND INSTRUMENTATION DIAGRAM 42

8.4 ELECTRICAL SCHEMATIC 50

8.5 GENERAL DESCRIPTION 64

9.0 OPERATING INSTRUCTIONS 65

9.1 BASIC OPERATION 65

9.2 INTELLISYS CONTROLS 67

9.3 DISPLAY SCREEN 68

9.4 CURRENT STATUS SCREEN 69

9.5 MAIN MENU 70

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2.0 FOREWORD

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

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 all routine operation and scheduled maintenance tasks by operation and maintenance staﬀ.

Majoroverhauls are outside the scope of this manual and should be referred to an authorized Ingersoll Rand service department.

All components, accessories, pipes and connectors added to the compressed air system should be:

of good quality, procured from a reputable manufac-

•

turer and, wherever possible, be of a type approved by Ingersoll Rand.

clearly rated for a pressure at least equal to the ma-

•

chine maximum allowable working pressure. compatible with the compressor lubricant/coolant.

•

accompanied with instructions for safe

•

installation,operation and maintenance.

Ingersoll Rand reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.

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

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, vapors or particles

Operation within the ambient temperature range

•

speciﬁed in the GENERAL INFORMATION section of this manual.

IF IN DOUBT CONSULT SUPERVISION.

The company accepts no responsibility for errors in translation of this manual from the original English version.

The design of this Compressor package and certain features within it are covered by patents held by Ingersoll Rand and patents pending

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

INTELLISYS is a registered trademark of Ingersoll Rand Company USA.

HPM™, HYBRID PERMANENT MAGNET™ and HPM Logo are trade marks registered by MOTEURS LE-ROYSOMER

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2.0 FOREWORD

WARNING

The use of the machine in any of the situation types listed in table 1:−

Is not approved by Ingersoll Rand,

May impair the safety of users and other persons, and

May prejudice any claims made against Ingersoll Rand.

TABLE 1

WARNING − NOT PERMITTED

Use of the machine to produce compressed air for:

direct human consumption

indirect human consumption.

Use of the machine outside the ambient temperature range speciﬁed in the GENERAL INFORMATION SECTION of this manual.

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

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.

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

WARNING

The use of 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 cannot be held responsible for equipment in which non−approved repair parts are installed.

WARNING

The motor rotor contains a powerful magnetic ﬁeld. This ﬁeld can eﬀect the operation of digital devices such as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with cardiac pacemakers, deﬁbrillators or other implanted electronic medical device.

WARNING

This compressor contains a variable frequency drive. When it is switched oﬀ and the motor is stopped, the internal capacitors store a potentialy lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any work on the drive unless trained. There are no user serviceable items behind the cover.

WARNING

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

NOTICE

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

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3.0 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

cs Czech

da Danish

de German

el Greek

en English

es Spanish

et Estonian

ﬁ Finnish

fr French

hu Hungarian

it Italian

lt Lithuanian

lv Latvian, Lettish

mt Maltese

nl Dutch

no Norwegian

pl Polish

pt Portuguese

sk Slovak

sl Slovenian

sv Swedish

zh Chinese

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4.0 PURCHASE ORDER DETAILS

ROTARY SCREW AIR COMPRESSOR

This unit was purchased from

_____________________________________________________________

Ingersoll Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously.

No. of units on order: ___________________________________________

Customer Order No: ____________________________________________

Ingersoll Rand Co. Order No _____________________________________

For ready reference:

Record the serial number and model number of your unit here.

Serial Number: ________________________________________________

Model Number: _______________________________________________

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5.0 SAFETY

5.1 SAFETY INSTRUCTIONS

Safety instructions in the operators manual are bold−faced for emphasis. The signal words DANGER, WARNING and CAUTION are used to indicate hazard seriousness levels as follows.

Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

DANGER

Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored.

WARNING

Indicates the presence of a hazard which CAN cause serious injury, death or property damage, if ignored.

5.2 SAFETY PRECAUTIONS

General Information

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

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

CAUTION

Indicates the presence of a hazard which WILL or can cause injury or property damage, if ignored.

NOTICE

Indicates important set–up, operating or maintenance information.

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

Make sure that all protective covers are in place and that the canopy/doors are closed during operation.

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

Use only safety solvent for cleaning the compressor and auxiliary equipment.

Compressed air

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.

If more than one compressor is connected to one common downstream plant, eﬀective check valves and isolation valves must be ﬁtted and controlled by work procedures, so that one machine cannot accidentally be pressurized / over pressurized by another.

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

The discharged air contains a very small percentage of compressor lubricating oil 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.

The use of plastic bowls on line ﬁlters without metal guards can be hazardous. Their safety can be aﬀected by either synthetic lubricants, or the additives used in mineral oils. Metal bowls should be used on a pressurized system.

5.0 SAFETY

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 incorrectlyhandled. 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.

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

Whenever pressure is released through the pressure relief valve, it is due to excessive pressure in the system. The cause for the excessive pressure should be investigated immediately.

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

•

WARNING

AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES

For further information, request and consult the coolant Material Data Sheet (UK ACGP 011/96 −ULTRA COOLANT ACGP 029/90−food grade coolant. For USA served areas, use MSDS sheet APDD 236) from your local IR oﬃce, Distributor or Air Center.

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

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

Consult a physician if large amounts of compressor lubricant are ingested.

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

Transport

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

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

Refer to section 8-General Information for reference information.

Electrical

The compressor has high and dangerous voltage in the motor starter and control box. All installations must be in accordance with recognized electrical codes. Before working on the electrical system, be sure to remove voltage from the system by using a manual disconnect switch. A circuit breaker or fuse safety switch must be provided in the electrical supply line leading to the compressor.

Those responsible for installation of this equipment must provide suitable grounds, maintenance clearance and lightning arrestors for all electrical components in accordance with National and Local code requirements.

Keep all parts of the body and any hand−held tools or other conductive objects, away from exposed live parts of the compressor 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 compressor electrical system.

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.

Consult a physician if compressor lubricant is inhaled.

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

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Condensate disposal

5.0 SAFETY

Coolant disposal

Condensate cannot be discharged into fresh/surface water drains. In some regions compressor condensate containing ULTRA COOLANT can be fed directly into a drainage system that has downstream sewage treatment.

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.

WARNING

This compressor contains a variable frequency drive. When it is switched oﬀ and the motor is stopped, the internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any work on the drive unless trained. There are no user serviceable items behind the cover.

WARNING

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

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

All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port

• connections must take into account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility between discharge piping, system accessories and software must be assured.

For the foregoing reasons, the use of plastic piping and rubber hose as discharge piping is not

• recommended. In addition, ﬂexible joints and/or ﬂex lines can only be considered for such purposes if their speciﬁcations ﬁt the operating parameters of the system.

It is the responsibility of the installer and owner to provide the appropriate service pipework to and from

• the machine.

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

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

For further information, consult ULTRA COOLANT Material Data Sheets ACGP 011/96 or APDD 236. FOOD GRADE COOLANT Material Data Sheets IRACA145 or APDD190.

WARNING

“Ingersoll Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll Rand does not approve specialized equipment for breathing air application and assumes no responsibility or liability for compressors used for breathing air services.”

WARNING

No portable communication devices emitting more than 7.5 volts per metre in the frequency range from 250 MHz to 280 MHz should be operated within 5m (16.5ft) of the unit.

WARNING

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

WARNING

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

5.0 SAFETY

NOTICE

To obtain satisfactory compressor operation and maintenance, a minimum of 3 feet clearance on 3 sides is required. 3 1/2 feet is required in front of the control panel (or minimum required by latest National Electrical code or applicable local codes.)

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

DANGER

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

Do not breathe this air.

WARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect power before servicing. Lockout/Tagout machine.

WARNING

Rotating fan blade. Can cause severe injury.

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

Depending on point of manufacture and point of use, the compressor and this manual will show symbols from the following sections. Compressors for use within the European Community must be equipped with symbols from section

5.4. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor.

5.3 TEXT DECALS

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5.0 SAFETY

CAUTION

Incorrect lifting of machine can cause injury or property damage.

Lift only from base channels

WARNING

High pressure air. Can cause severe injury or death.

Compressor can operate in a pressurized shutdown mode.

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

NOTICE

Air discharge

CAUTION

Use of incorrect coolant can cause system contamination.

Use only SSR ULTRA COOLANT

WARNING

Food contaminant. Can cause severe injury or death.

Use only Ingersoll Rand SSR H-1F food grade coolan

NOTICE

Lift here

WARNING

Hot surface. Can cause severe injury.

Do not touch. Allow to cool before servicing.

39568464 Rev. 03

22061915 Rev. A

5.0 SAFETY

CAUTION

Improper coolant filter replacement will cause compressor damage.

Replace filter element after first 150 hours of operation and every 2000 hours thereafter or when coolant is changed.

NOTICE

Rotation

WARNING HIGH VOLTAGE

Do not attempt any work. Read manual. Trained service personnel only. Remove electrical supply. Wait 15 minutes. Check for zero voltage. Proceed with caution.

WARNING

Moving parts. Can cause severe injury.

Do not operate with covers removed. Service only with machine blocked to prevent turn over.

Air

Discharge

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39540224 Rev. 04

39540257 Rev. 04

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5.0 SAFETY

Condensate

drain.

Electrical

power inlet.

WARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect power before servicing. Lockout/Tagout machine.

NOTICE

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

Use 75°C copper wire only.

Use 75˚C copper wire only.

Nur 75˚C kupferdraht verwenden.

Use somente fio de cobre de 75˚.

39492384 Rev. 03

usare 75˚C solamente cavi di rame.

Usar solamente cable de cobre para 75˚ C.

Utilisez 75˚C uniquement fil de cuivre.

IMPORTANT

Before starting this air compressor unit the shipping brace(s) must be removed. Save the brace(s) for future use. Refer to Operators / Instruction Manual.

Before starting this air compressor unit the shipping brace(s) must be removed. Save the brace(s) for future use. Refer to Operators/Instruction Manual.

IMPORTANT

39481130 Rev. 02

5.0 SAFETY

5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING − Pressurized component or

system.

WARNING − Pressure control. WARNING − Corrosion risk. WARNING − Air/gas ﬂow or Air discharge.

WARNING − Pressurized vessel. Do not remove the Operating and

Maintenance manual from this machine.

WARNING − Hot surface.

WARNING − Flammable liquid.

WARNING − Rotor magnetic ﬁeld

can aﬀect pacemakers.

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5.0 SAFETY

0°

WARNING − Do not undertake any

maintenance on this machine until the

electrical supply is disconnected and the

air pressure is totally relieved.

Read the Operation and Maintenance

manual before operation or maintenance

of this machine is undertaken.

Do not stand on any service valve or

other parts of the pressure system.

WARNING − Consult the Operation

and Maintenance manual before

commencing any maintenance.

Do not stack. Do not operate the machine without the

Do not operate with the doors or

enclosure open.

WARNING − For operating temperature

below 0°C, consult the Operation and

Maintenance manual.

guard being in place.

Do not use fork lift truck from this side.

Do not breathe the compressed air from

this machine.

No naked lights. Do not open the service valve before the

air hose is attached.

5.0 SAFETY

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

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

SET SEQUENCER STATUS LOAD

SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED)

RESET COMPRESSOR STATUS MODULATE

MALFUNCTION POWER FOULED FILTER

POWER INLET ELECTRIC MOTOR HOURS

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5.0 SAFETY

COOLANT SEPARATOR PRESSURE AIR DISCHARGE

PRESSURIZED TANK ON / OFF CYCLE COOLANT FILTER

AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE

AIR PRESSURE STAR DELTA IEC 617−7 AUTOMATIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE

5.0 SAFETY

BELT TENSION FILTER MOTOR LUBRICATION

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS ROTATION

POWER INLET (AC) WATER IN WATER OUT

TRAINED SERVICE PERSONNEL WAIT TIME CHECK ZERO VOLTS

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6.0 RECEIPT / HANDLING

IMPORTANT

READ THIS

LOST OR DAMAGED GOODS

THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL

OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNED

BILL OF LADING

If goods are received short or in damaged condition, it is important that you notify the carrier and insist on a

notation of the loss or damage across the face of the freight bill. Otherwise no claim can be enforced against the

transportation company.

If concealed loss or damage is discovered, notify your carrier at once and request an inspection. This is absolutely

necessary. Unless you do this the carrier will not entertain any claim for loss or damage. The agent will make an

inspection and grant a concealed damage notation. If you give the transportation company a clear receipt for

goods that have been damaged or lost in transit, you do so at your own risk and expense.

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

Ingersoll Rand Company

6.1 RECEIPT

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

6.2 UNPACKING AND HANDLING

The compressor will normally be delivered with a polyethylene or other cover. If a knife has to be used to remove this cover, ensure that the exterior paintwork of the compressor is not damaged.

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

Once the packaging and pallet are discarded and the unit is in its ﬁnal position, remove the transit brackets from the resilient mounts and store for future use or discard.

On N75−160 units remove the screw in the base and slide the separator tank service bracket into the upper position on the slots and tighten screws.

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For technical information see section 8.0.

7.1 LOCATION IN PLANT

7.0 INSTALLATION

Ensure that the correct tie down points are used.

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

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

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

Consider also the environment surrounding or near the compressor. The area selected for the location of the compressor should be free of dust, chemicals, metal ﬁlings, paint fumes and overspray.

Hard surfaces may reﬂect noise with an apparent increase in the decibel level. When sound transmission is important, a sheet of rubber or cork can be installed beneath the machine to reduce noise. Flexible piping may be required.

CAUTION

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

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.

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

It is recommended that provision be made for lifting heavy components during major overhaul. Use only lifting points provided.

Minimum space in front of control panel door as required by National or Local codes must be maintained.

The compressor can be installed on any level ﬂoor capable of supporting it. A dry, well ventilated area where the atmosphere is as clean as possible is recommended.

Suﬃcient space all round and above the compressor must be allowed, to enable the eﬀective removal of the cooling air which, in turn, will reduce the risk of recirculating the cooling air back through the compressor.

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7.0 INSTALLATION

7.2 DISCHARGE AND CONDENSATE PIPING

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.

A receiver [2] may be necessary to ensure that the total system volume is not less than 2.0 U.S. Gal. per rated delivery C.F.M.

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

Include a means [6] to vent the discharge pipework downstream from the minimum pressure check valve located on the separator tank. Upstream of the ﬁrst system isolation valve [7].

The discharged air contains a very small percentage of compressor lubricating oil and care should be taken to ensure that downstream equipment is compatible.

When two rotary units are operated in parallel, provide an isolation vaIve and drain trap for each compressor before the common receiver.

The built−in aftercooler reduces the discharge air temperature below the dew point (for most ambient conditions), therefore, considerable water vapor is condensed. To remove this condensation, each compressor with built−in aftercooler is furnished with a combination condensate separator/trap.

A dripleg assembly and isolation valve should be mounted near the compressor discharge. A drain line should be connected to the condensate drain in the base.

IMPORTANT: The drain line must slope downward from the base to work properly. For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel.

NOTICE

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

CAUTION

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

NOTICE

Do not use the compressor to support the discharge pipe.

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7.0 INSTALLATION

7.3 ELECTRICAL

CAUTION

This procedure should only be carried out by a qualiﬁed electrician, electrical contractor or your local Ingersoll Rand Distributor or Air Center.

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

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

The compressor must have its own isolator situated adjacent to it. The fuse protecting the circuit and the compressor must be selected in accordance with local and national code requirements on the basis of the data provided in the general information section

Feeder cables 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.

Cable sizes may vary considerably so the mains terminals will accept up to 50mm2 (1awg) (37/45k & 50/60H) and up to 90mm2 (3/0awg) (55/75k & 75/100H) cable. The N75K−160K and N100H−200H machines mains terminals will accept 2 x 120mm2 (4/0 AWG) cables. The N250H−300H−2S machines main terminals will accept 2 x 400 MCM cables.

Feeder cable connections to incoming terminals L1−L2−L3 should be tight and clean.

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

The control circuit transformer has diﬀerent voltage tappings. Ensure that these are set for the speciﬁc applied voltage prior to starting.

The feeder cable must be suitably glanded into the power drive module (P.D.M.) electrical box to ensure that dirty air does not by−pass the ﬁlter pads or degrade the cooling air ﬂow.

On completion of electrical installation, check that blower motor rotation is correct. N250H−300H utilizes a fan.

This machine is designed for use in heavy industrial environments, where the electricity supply is separated from nearby residential and commercial areas. If the machine is to be used in the light industrial, residential or commercial environment where the local supply network is shared, further radio frequency (RF) screening measures may be required. Consult your local distributor/supplier for details of the optional RF ﬁlter. RF ﬁlter supplied as standard on N250−300H−2S

The compressor has a anti−condensation heater and thermostat in the electrical box. This circuit can be connected to an independent electrical supply of either 110V or 230V single phase, dependant on the country of installation. The supply should be suitable fused and an independent isolator installed adjacent to the compressor.

This should be done in accordance with local and national codes. It is good practice and sometimes mandatory, to display suitable signs warning that the machine has two separate electrical supplies which both must be isolated before any work is attempted.

Alternately it can be supplied from the 110V tapping of the control transformer and connected as shown on schematic wiring diagram.

A hole is provided for incoming power connection. If it is necessary to make a hole in the control box in a diﬀerent location, care should be taken to not allow metal shavings to enter the starter and other electrical components within the box. If another hole is used, the original hole must be blocked oﬀ.

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7.0 INSTALLATION

CAUTION

VERY IMPORTANT

Supply voltage must be kept to a maximum imbalance of 2% on 50Hz and 3% on 60Hz applications. Voltage imbalances greater than these levels can cause permanent damage to the drive.

Compressor must not be subjected to any voltage spikes or surges in excess of 575V. Exposure to spikes/surges in excess of 575V can permanently damage the drive. If the possibility of such exists it is recommended that adequate surge protection is ﬁtted such as an Ingersoll Rand line reactor. See your local Ingersoll Rand representative.

Failure of the drive due to voltage spikes, line notching, harmonics or other power quality related problems, will not be covered by the standard compressor warranty.

The correct type and rating of line input fuse MUST BE ﬁtted onto the customers isolator or breaker close to the compressor. For Amp rating see technical information in Section 8.1.

Product Identiﬁcation Class − J, Class − T, or Semiconductor

See your local Ingersoll Rand representative for a range of fuses and disconnect isolators matched to your particular machine.

Example of voltage imbalance calculation

U →V 462v V → W 459v W → U 453v

Fuse Type 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.

V(m) = (462 + 459 + 453) / 3 = 458v V∆ max = 462 − 453 = 9v = (9 / 458) x 100 = 1.97%

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7.4 WATERCOOLED UNITS

Cooling Water Piping

7.0 INSTALLATION

Venting the water system

Water piping to and from the compressor package must be 1”diameter or larger for N37/75K (N50/100H), 11/2” diameter or larger for N75/160K (N100H/200H) and 2.0” diameter or larger for N250/300H−2S. Isolation valves with side drains should be installed on both the inlet and outlet lines. Also a strainer of 2mm−mesh size should be installed on the inlet line. Strainers are available from Ingersoll Rand. Ingersoll Rand CPN 54689997 (N37/45K & N50/60H) or CPN 54690029 (N55/75K & N75/100H)

A normally closed solenoid valve is ﬁtted to the water outlet side of the compressor package. This is wired into the compressor control circuit and closes when the compressor stops.

Carefully inspect your water system before installing the compressor package. Ensure that the piping is free of scale and deposits that may restrict water ﬂow to the compressor package.

Proper operation of your compressor requires that the water ﬂow listed below be provided at a maximum supply temperature of 46° C (115° F).

Model Range

Minimum cooling water requirement vs

water inlet temperatures, in litres per

minute (US gallons per minute)

10°F /

50°F

21°F /

70°F

32°C /

90°F

46°C / 115°F

N37 23(6.0) 23 (6.0) 38 (10.0) 57(15.0) N45 27(7.0) 30(8.0) 49(13.0) 76(20.0) N55 51(13.5) 46(12.0) 38(10.0) 38(10.0) N75 95(25.0) 68(18.0) 46(12.0) 53(14.0)

N75-2S 175(46.0) 133(35.0) 106(28.0) 76(20.0)

N90 84(22.0) 72(19.0) 65(17.0) 72(19.0) N110 95(25.0) 80(21.0) 72(19.0) 87(23.0) N132 110(29.0) 91(24.0) 87(23.0) 106(28.0) N160 125(33.0) 118(31.0) 106(28.0) 125(33.0) N250 91(24.0) 110(29.0) 179(47.0) N300 95(25.0) 133(35.0) 220(58.0)

Water temperature and pressure gauges should be installed in the water piping for use in any fault ﬁnding of the water system. Water pressure should ideally be between 3 and 5 bar (43.5 and 72.5 psi) but must not be above 10 Bar (145 psi)

At the initial installation or for start−up after draining the water system proceed to vent the system as follows.

Locate the water system vent cocks on top of the

1. aftercooler and lubricant cooler.

Open the water valve(s) allowing water to ﬂow to the

2. package.

Open the vent cocks and allow all air to escape from

3. the system. When water is observed at the vent cocks, close them.

The system is now vented.

Draining the water system

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

Disconnect the inlet and discharge water lines from

1. the connections located at the rear of the unit.

Locate the aftercooler and lubricant cooler. Remove

2. the drain plugs located at the bottom of the coolers. Allow the system to completely drain.

N75−160k, N100−200H Watercooled

See piping and instrumentation diagram (Section

8.3). The coolers are piped in a ”parallel” water ﬂow arrangement with a manual trim valve controlling the ﬂow through the aftercooler. An additional automatic anti−condensation thermal valve controls the ﬂow of water to the oilcooler. It has a sensor in the separator tank and capillary to signal the valve to open and close in order to avoid water condensing in the tank.

Adjusting the Aftercooler Trim Valve

The anti−condensation valve has no adjustment. The Aftercooler Trim Valve is factory set and should not need adjusting but if disturbed use following procedure. Close valve fully clockwise and then open 1/4 turn. With machine running loaded observe the package discharge temperature Intellisys display. It should be be approx 15° F (8° C) above the water inlet temperature. If it is higher, open the valve a little more. Put a ’Warning − Do Not Adjust’ label on the valve or ﬁt a lock.

Water cleanliness is also extremely important. Cleaning of coolers as a result of fouling is a customer responsibility. Therefore, it is highly recommended that proper water quality must meet the requirements listed in WATER QUALITY RECOMMENDATIONS later in this section.

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Water quality recommendations

7.0 INSTALLATION

Cooling Water Analysis Chart

Water quality recommendations Water quality is often overlooked when the cooling system of a water−cooled air compressor is examined. Water quality determines how eﬀective the heat transfer rate, as well as the ﬂow rate will remain during the life of the unit. It should be noted that the quality of water used in any cooling system does not remain constant during the operation of the system. Evaporation, corrosion, chemical and temperature changes, aeration, scale and biological formations eﬀect the water makeup. Most problems in a cooling system show up ﬁrst in a reduction in the heat transfer rate, then in a reduced ﬂow rate and ﬁnally with damage to the system.

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

Corrosion: In contrast to scale formation is the problem of corrosion. Chlorides cause problems because of their size and conductivity. Low pH levels promote corrosion, as well as high levels of dissolved oxygen.

Substances Test interval Acceptable

concentration

Corrosivity (Hardness, pH, Total

Monthly - if stable for 3 to 4 months, analyse quarterly.

Langelier Index 0 to 1

Dissolved Solids, Temperature at inlet Alkalinity)

Iron Monthly <2 ppm Sulphate Monthly <50 ppm Chloride Monthly <50 ppm Nitrate Monthly <2 ppm Silica Monthly < 100 ppm Desolated

Oxygen

Daily - if stable, analyse weekly

0 ppm (as low

as possible) Oil & Grease Monthly <5 ppm Ammonia Monthly <1 ppm

Fouling: Biological and organic substances (slime) can also cause problems, but in elevated temperature environments such as cooling processes they are not a major concern. If they create problems with clogging, commercial shock treatment are available.

To ensure good operation life and performance of the compressor cooling system, the recommended acceptable ranges for diﬀerent water constituents are included below:

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7.0 INSTALLATION

7.5 SEA WATERCOOLED UNITS SELECTED UNITS ONLY

Water cleanliness is extremely important. Strainers are available from Ingersoll Rand. Cleaning of coolers as a result of fouling is a customer responsibility.

Isolation valves with side drains should be installed on both the inlet and outlet lines.

A normally closed solenoid valve is ﬁtted to the water outlet side of the compressor package.

It is important to ensure that the recommended ﬂow rate cannot be exceeded. This will normally mean that an oriﬁce plate must be ﬁtted in the pipework at least 1m (3.3ft) before the cooler, with the oriﬁce size calculated to ensure that the maximum sea water ﬂow rate cannot be exceeded. If these precautions are not taken, it is possible that the sea water ﬂow rate through the cooler may be several times the recommended maximum, which will lead to rapid failure.

Sea Water Pressure Bar

(psi)

3 (43.5) 12 (0.472)

4 (58) 11 (0.433)

5 (72.5) 10 (0.394)

6 (87) 9.6 (0.378)

7 (101.5) 9.2 (0.362)

8 (116) 8.9 (0.35)

9 (130.5) 8.7 (0.343)

10 (145) 8.4 (0.33)

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

(23.76 US gall/min)

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

The oil pressure should be higher than the sea water

1. pressure, so that in the event of a leak occurring, the oil will not be contaminated.

If the sea water pressure is 100PSIG (7BARG) or above

2. it is recommended that the water solenoid valve is changed to the water inlet side. This will protect the system from high pressure surges when not in use.

The sea water outlet pipe from the cooler should

3. have a free run to waste.

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7.0 INSTALLATION

7.6 OUTDOOR SHELTERED INSTALLATION

Nirvana compressors are not suitable for outdoor installation.

Installing a Nirvana compressor outside voids the warranty of the compressor.

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8.0 GENERAL INFORMATION

TECHNICAL INFORMATION-SINGLE STAGE

N37K N45K N50H N60H

General

Performance **

Flow at 7.5 Barg (m³/min) 6.43 7.39 − − Flow at 8.5 Barg (m³/min) 6.12 7.02 − − Flow at 10 Barg (m³/min) 5.83 6.46 − − Flow at 100 psig (cfm) − − 235 262 Flow at 125 psig (cfm) − − 216 248 Flow at 140 psig (cfm) − − 209 233 Air Cooling System Cooling air ﬂow m3/min (cfm) 184 (6500) 184 (6500) 184 (6500) 184 (6500) Maximum ∆P in air ducts Pa (inch WG) 124 (0.5) 124 (0.5) 124 (0.5) 124 (0.5) Compressed air outlet ∆T ° C (° F) 8 (15) 8 (15) 8 (15) 8 (15) Water Cooling System Cooling (clean) water ﬂow l/min (US

gallon/min) @ 10 ° C (50 ° F) / 32 ° C (90 ° F)

Maximum ∆P in air ducts Pa (inch WG) 62 (0.25) 62 (0.25) 62 (0.25) 62 (0.25) Compressed air outlet ∆T ° C (° F) 14 (25) 14 (25) 14 (25) 14 (25) Main Power Circuit A/C (W/C) *** Package full load current at 220V (A) ** 140 (131) 168 (159) 140 (131) 168 (159) Package full load current at 400V (A) ** 75 (70 ) 90 (85) − − Package full load current at 460V (A) ** − − 68 (63) 81 (77) Package full load current at 575V (A) ** − − 56 (52) 67 (63) Max fuse size @ 220V (A) 250 250 250 250 Max fuse size @ 400V (A) 125 125 125 125 Max fuse size @ 460V (A) 125 125 125 125 Max fuse size @ 575V (A) 100 100 100 100 Fuse type Fast acting class J, T or semiconductor type, current limiting interrupt

Heater Circuit

110V Single Phase Rating (A) 4 4 4 4 230V Single Phase Rating (A) 4 4 4 4 Fuse type General purpose

* In accordance with PNEUROP PN8NTC2.3 ** Tolerances in accordance with ISO 1217 *** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable

size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)

23/38 (6/10) 27/49 (7/13) 23/38 (6 /10) 27 /49 (7 /13)

rating 200, 000 Amps RMS SYM.

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8.0 GENERAL INFORMATION

N55K N75K N75H N100H

General

Sound pressure level dB(A) * 75 75 75 75 Maximum ambient temperature ° C (° F) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature ° C (° F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35) Weight Kg (lbs) 1531 (3374) 1531 (3374) 1531 (3374) 1531 (3374) Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) 10 (145) Minimum pressure barg (psig) 4.5 (65) 4.5 (65) 4.5 (65) 4.5 (65) Coolant capacity litres (US gal) 30 (8) 30 (8) 30 (8) 30 (8) HAT switch setting ° C (° F) 120 (248) 120 (248) 120 (248) 120 (248) Performance Flow at 7.5 Barg (m3/min) 10.11 12.94 − − Flow at 8.5 Barg (m3/min) 9.29 12.15 − − Flow at 10 Barg (m3/min) 8.49 11.50 − − Flow at 100 psig (cfm) − − 372 479 Flow at 125 psig (cfm) − − 328 429 Flow at 140 psig (cfm) − − 306 413 Air Cooling System Cooling air ﬂow m3/min (cfm) 241 (8500) 241 (8500) 241 (8500) 241 (8500) Maximum ∆P in air ducts Pa (inch WG) 124 (0.5) 124 (0.5) 124 (0.5) 124 (0.5) Compressed air outlet ∆T° C (° F) 8 (15) 8 (15) 8 (15) 8 (15) Water Cooling System Cooling (clean) water ﬂow l/min (US

gallon/min) @ 10 ° C (50 ° F) / 32 ° C (90 ° F)

Maximum ∆P in air ducts Pa (inch WG) 62 (0.25) 62 (0.25) 62 (0.25) 62 (0.25) Compressed air outlet ∆T ° C (° F) 14 (25) 14 (25) 14 (25) 14 (25) Main Power Circuit A/C (W/C) *** Package full load current at 220V (A) ** 208 (196) − 208 (196) − Package full load current at 400V (A) ** 110 (104) 144 (138) − − Package full load current at 460V (A) ** − − 100 (94) 131 (125) Package full load current at 575V (A) ** − − 82 (78) 108 (103) Max fuse size @ 220V (A) 300 400 300 400 Max fuse size @ 400V (A) 150 200 150 200 Max fuse size @ 460V (A) 150 200 150 200 Max fuse size @ 575V (A) 125 150 125 150 Fuse type Fast acting class J, T or semiconductor type, current limiting

Heater Circuit 110V Single Phase Rating (A) 4 4 4 4 230V Single Phase Rating (A) 4 4 4 4

Fuse type General purpose * In accordance with PNEUROP PN8NTC2.3 ** Tolerances in accordance with ISO 1217 *** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable

size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)

51/38

(13.5 /10)

95/46

(25 /12)

51/38

(13.5/10)

interrupt rating 200, 000 Amps RMS SYM.

95/46

(25/12)

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