Ingersoll-Rand IRN160K–OF, IRN45K–OF, IRN132K–OF, IRN110K–OF, IRN75K–OF Operation And Maintenance Manual

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OPERATION AND MAINTENANCE MANUAL

C.C.N. : 22310387

DATE : AUGUST 2005

REV. : D

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

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

IRN37–160K–OF IRN50–200H–OF

Ensure that the Operation and Maintenance manual is not removed permanently from the machine.

01/05

Machine models represented in this manual may be used in various locations world–wide. Machines sold and shipped into European Union Territories require that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

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

WE,

INGERSOLL–RAND COMPANY LIMITED

SWAN LANE

HINDLEY GREEN

WIGAN WN2 4EZ

UNITED KINGDOM

DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY,

THE PRODUCT(S)

IRN37K–OF IRN45K–OF IRN55K–OF IRN75K–OF

IRN90K–OF IRN110K–OF IRN132K–OF IRN160K–OF

TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS

OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

EN29001, EN292, EN60204–1, EN1012–1, EN61000–6

ISSUED AT HINDLEY GREEN ON 01/01/2005 BY H.SEDDON, QUALITY ASSURANCE

MANAGER.

H. SEDDON

EC Pressure Equipment Directive and Related Regulations

We declare that this product has been assessed according to the Pressure Equipment Directive (97/23/EC) and, in accordance with the terms of this Directive, has been excluded from the scope of this Directive. It may carry ”CE” marking in compliance with other applicable EC Directives.

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 twenty four months from the date of placing the Equipment in operation or thirty months from the date of shipment from the factory, whichever shall first occur (see extended airend warranty). 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 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.

CONTENTS

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

CONTENTS PAGE CONTENTS PAGE

1.0 CONTENTS 1

2.0 FOREWORD 2

3.0 ABBREVIATIONS & SYMBOLS

4.0 PURCHASE ORDER DETAILS

5.0 SAFETY 6

5.1 Safety instructions

5.2 Safety precautions

5.3 Text decals

5.4 Graphic form and meaning of ISO symbols

6.0 RECEIPT AND HANDLING

6.1 Receipt

6.2 Unpacking and handling

7.0 INSTALLATION 19

7.1 Location in plant

7.2 Discharge and condensate piping

7.3 Electrical

7.4 Watercooled units

7.5 Sea watercooled units

7.6 Outdoor sheltered installation

8.0 GENERAL INFORMATION 26

8.1 Technical information

8.2 Installation drawing

8.3 Process and instrumentation diagram

8.4 Electrical schematic

8.5 General description

9.0 OPERATING INSTRUCTIONS

9.1 Basic operation

9.2 Intellisys controls

9.3 Display screen

9.4 Current status screen

9.5 Main menu

9.6 Operator setpoints

9.7 Options

9.8 Sensor calibration

9.9 Alarm history

9.10 Clock functions

9.11

Energy status messages

9.12 Warnings

9.13 Service warnings

9.14 Initial check alarms

9.15 Alarms

10.0 MAINTENANCE 74

10.1 Maintenance prompts

10.2 Maintenance chart

10.3 Maintenance procedures

10.4 Routine maintenance

11.0 FAULT FINDING 82

11.1

General faults

11.2 Intellisys faults

11.3

Drive faults

2.0 FOREWORD

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European community countries requires that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE certification 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. Major

overhauls 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 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 oil. . 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.

HPMT, HYBRID PERMANENT MAGNETT and HPM Logo are trade marks registered by MOTEURS LEROY–SOMER

2005

INGERSOLL–RAND COMPANY

2.0 FOREWORD

IRN37–160K–OF & IRN50–200H–OF

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WARNING

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

WARNING – NOT PERMITTED

Use of the machine to produce compressed air for: a) direct human consumption b) 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.

NOTICE

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

3.0 ABBREVIATIONS & SYMBOLS

IRN37–160K–OF & IRN50–200H–OF

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#### 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

4.0 PURCHASE ORDER DETAILS

IRN37–160K–OF & IRN50–200H–OF

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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:

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

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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.

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.

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.

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.

5.2 SAFETY PRECAUTIONS

General Information

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

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.

When using compressed air always use appropriate personal protective equipment.

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

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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.

The safety valve located in the interstage and aftercooler 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 oil

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

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

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

Consult a physician if compressor oil is inhaled.

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

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 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.

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.

Oil disposal

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.

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

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. It is factory preset. Refer to the operation section for shutdown temperatures. 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.

S 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.

S For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge

piping is not recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the operating parameters of the system.

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

the machine.

WARNING

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

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

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

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 without guard in place Disconnect power before servicing Lockout/Tagout machine

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

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.

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

39540240 Rev.04

NOTICE

Air discharge

CAUTION

Use of incorrect coolant can cause system contamination.

Use only SSR ULTRA COOLANT

NOTICE

Lift here

WARNING

Hot surface. Can cause severe injury.

Do not touch. Allow to cool before servicing.

NOTICE

Rotation

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

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.

39540224 Rev. 04

Air

Discharge

39540257 Rev. 04

Condensate

drain.

39541081 Rev. 04

Electrical

power inlet.

39541354 Rev. 03

WARNING

Hazardous voltage. Can cause severe injury or death.

Only use factory supplied inlet for incoming power. See Operators / Instruction Manual.

39543764 Rev. 03

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.

39540158 Rev.05

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

Use 75°C copper wire only.

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.

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING – Pressurized

component or system.

WARNING – Hot surface.

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 – Flammable liquid.

WARNING – Rotor magnetic field

can affect pacemakers.

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

0_C

WARNING – Do not undertake any

maintenance on this machine

until the electrical supply is

disconnected and the air pressure

is totally relieved.

WARNING – Consult the

Operation and Maintenance

manual before commencing any

maintenance.

WARNING – For operating

temperature below 0_C, consult

the Operation and Maintenance

manual.

Read the Operation and

Maintenance manual before

operation or maintenance of this

machine is undertaken.

Do not stack.

Do not operate the machine without

the guard being in place.

Do not stand on any service valve or

other parts of the pressure system.

Do not operate with the doors or

enclosure open.

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

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

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

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

OIL SEPARATOR PRESSURE AIR DISCHARGE

PRESSURIZED TANK ON / OFF CYCLE OIL FILTER

AIR FILTER ON / OFF PUSH BUTTON OIL PRESSURE

AIR PRESSURE STAR DELTA IEC 617–7 AUTOMATIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

OIL DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE

5.0 SAFETY

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

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

6.0 RECEIPT / HANDLING

IRN37–160K–OF & IRN50–200H–OF

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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.

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

6.2 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.

7.0 INSTALLATION

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

For technical information see section 8.0.

7.1 LOCATION IN PLANT

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.

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.

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.

NOTICE

If ducting is fitted to the machine, the sump breather needs to be piped outside the enclosure to avoid back pressure into the compression module.

7.0 INSTALLATION

IRN37–160K–OF & IRN50–200H–OF

http://air.irco.com

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], installed before the feeder lines [5], may be necessary to ensure that the total system volume is not less than 2.0 U.S.Gallons 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 important to install an isolation valve [7] within 3 feet (1 meter) of the compressor.

It is good practice to install line filters [4].

Include a means [6] to vent the discharge pipework downstream from the machine’s check valve and upstream of the first system isolation valve [7].

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 intercooler and aftercooler reduce 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 two moisture separator/solenoid valve combinations. Since these solenoid valves discharge at different pressures, it is extremely important that they are piped separately into an open drain.

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, 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 oils 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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7.3 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 50mm

(1 AWG)

(37/45k & 50/60H) and up to 90mm

(3/0 AWG) (55/75k & 75/100H) cable. The N75K–160K and N100H–200H machines mains terminals will accept 2 x 120mm2 (4/0 AWG) 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.

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.

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 both the main blower motor and heat sink blower motor rotations are correct.

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.

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.

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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.

CAUTION

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

The compressor installation must be properly installed in accordance with recognized Local and National electrical equipment installation codes and any other related local Health and Safety Codes.

The compressor input power supply (branch circuit) protection shall be made by utilizing an Isolator switch (Disconnect switch). The input power supply branch circuit shall only be protected using “FAST ACTING (FAST BLOWING)”

fuses as defined below, and NOT using “Time Delay” (slow acting or dual element type) fuses.

Fuse Type

1,2

Fuse Selection Criteria

Class – J, Class – T, or Semiconductor fuses Fuse size  150% Total Package Amps

Fuse size  175% Total Package Amps

Note: Note:

1. Fuse must be Fast acting, current limiting with

interrupt rating of 200,000 amps RMS SYM

3. This is only a recommendation and installer must follow local and/or national codes prior to installation

2. Alternate fuse type may be used if the time vs. current characteristics are faster then fuse types recommended

4. Total package current (amps) can be obtained from IR Sales Library (Engineering data sheets) for any pre–install inquiries, and from actual Compressor Nameplate (contact your local IR Distributor for more information)

CIRCUIT BREAKERS are NOT recommended for branch circuit protection, due to their slow response, resulting into inadequate protection in event of a fault.

Example of voltage imbalance calculation

U → V 462v

V → W 459v

W → U 453v

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

Water piping to and from the compressor package must be at least the size of the water connections on the machine. Refer to the installation drawing section for this size. 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. The strainers will connect to the water manifold on all units, but also requires a pipe nipple. The list below shows the required parts for each unit.

IRN37–45K–OF & IRN50–60H–OF: Strainer – CCN 39157433 Nipple – CCN 95946117

IRN55–75K–OF & IRN75–100H–OF: Strainer – CCN 39116389 Nipple – CCN 95928032

IRN90–160K–OF & IRN125–200H–OF: Strainer – CCN 39116397 Nipple – CCN 95960662

Note: KW rated units will be supplied with an NPT to BSPT adaptor

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 in Section 8.1 be provided at a maximum supply temperature of 46_C (115_F).

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)

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.

Venting the water system

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

1 Locate the water system vent cocks on top of the intercooler , aftercooler, and oil cooler.

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

3 Open the vent cocks and allow all air to escape from 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.

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

2 Locate the intercooler, aftercooler, and oil coolers. Disconnect the water inlet connections to drain each cooler. Also, drain any piping between the coolers and the water shut off solenoid valve (it is normally closed).

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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.

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:

Cooling Water Analysis Chart

Substances Test interval Acceptable

concentration

Corrosivity (Hardness, pH, Total Dissolved Solids, Temperature at inlet Alkalinity)

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

Langelier Index 0 to 1

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

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7.6 OUTDOOR SHELTERED INSTALLATION

Nirvana compressors are not suitable for outdoor installation.

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

+ 65 hidden pages

Ingersoll-Rand IRN160K–OF, IRN45K–OF, IRN132K–OF, IRN110K–OF, IRN75K–OF Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual