Ingersoll-Rand SM132, SH90, SH132, SL110, SM150 Installation, Operation And Maintenance Manual
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80448574
Revision A
May 2015
Save These Instructions
Oil-Free Rotary Screw Air Compressor
Installation, Operation and Maintenance
SL90, SM90, SH90, SL110, SM110, SH110
SL132, SM132, SH132, SL150, SM150, SH150
SL200, SM200, SH200, SL250, SM250, SH250, SH300
L125, H125, HH125, L150, H150, HH150
L200, H200, HH200, L250, H250, HH250
L300, H300, HH300, L350, H350, HH350, HH400
61115.10.33
2 80448574 Rev A
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 6
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESIGN PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
DESIGN TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPRESSED AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
CONDENSATE REMOVAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .6
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
COOLING SYSTEM (AIRCOOLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COOLING SYSTEM (WATERCOOLED) . . . . . . . . . . . . . . . . . . . . . . . .7
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
CAPACITY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
AUTOMATIC START/STOP CONTROL OPTION . . . . . . . . . . . . . . .7
REMOTE LOAD/UNLOAD OPTION . . . . . . . . . . . . . . . . . . . . . . . . . .8
REMOTE START/STOP OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
POWER OUTAGE RESTART OPTION . . . . . . . . . . . . . . . . . . . . . . . . .8
SEQUENCER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TIMED LEAD/LAG OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SCHEDULED START/STOP OPTION . . . . . . . . . . . . . . . . . . . . . . . . .8
HIGH CONDENSATE LEVEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . .8
RECEIPT / HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RECEIPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
UNPACKING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOCATION IN THE PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DISCHARGE AND CONDENSATE PIPING . . . . . . . . . . . . . . . . . . 10
PRIOR TO STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COOLING WATER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VENTING THE WATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DRAINING THE WATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WATER QUALITY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 12
ROTATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 14
BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
PRIOR TO STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INITIAL CHECK SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
START SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STOP SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EMERGENCY STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RESTARTING AFTER EMERGENCY STOPPING . . . . . . . . . . . . . . 14
INTERFACE DATA AND KEYS . . . . . . . . . . . . . . . . . . . . . . . 15
Xe–90M/145M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LED STATUS ICONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
COMMAND KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
NAVIGATION KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DISPLAY LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SIERRA COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HOME FOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATOR SETTINGS FOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EVENTS FOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WARNING EVENTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TRIP EVENTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TRIP HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GRAPHING FOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MAINTENANCE FOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERAL SETTINGS FOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INTEGRAL SEQUENCING FOLDER . . . . . . . . . . . . . . . . . . . . . . . . . 26
STATUS FOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FACTORY SETTINGS FOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
WEB ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
COMMISSIONING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CONNECTING TO A PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ETHERNET CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
LOGIN PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DEFAULT ACCOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
NAVIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TAB NAVIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
COMMAND BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DASHBOARD ICONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
HOME PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
EVENT LOG UTILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
PERFORMANCE LOG UTILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
GRAPHING UTILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
MAINTENANCE UTILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSPECTION LOG UTILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
COMPRESSOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
COMPRESSOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 51
EMAIL (SMTP) SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CONTENTS
61115.10.33
80448574 Rev A 3
COMPRESSOR DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
UNIT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ACCOUNT MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ADD ACCOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
MODIFY THE ACCESS LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
AIR FILTER CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 58
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
GEARCASE BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CONDENSATE DRAIN FUNCTIONALITY . . . . . . . . . . . . . . . . . . . 58
CONDENSATE STRAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
AIREND BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
COMPRESSOR MODULE INPUT SHAFT SEAL REPLACEMENT 58
MOTOR BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
MOTOR BEARING LUBRICANT SPECIFICATION . . . . . . . . . . . . . 59
CLEANING/INSTALLING PACKAGE PRE-FILTER [90-160Kw(125-
200Hp)NEW ENCLOSURE ONLY] . . . . . . . . . . . . . . . . . . . . . . . . . . 59
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CONTENTS
61115.10.33
4 80448574 Rev.A
FOREWORD
The contents of this manual are considered to be
proprietary and condential 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 to cover all routine
operation and scheduled maintenance tasks by operation
and maintenance sta. Major overhauls are outside
the scope of this manual and should be referred to an
authorised Ingersoll Rand service department.
Any modication to any part is absolutely prohibited and
would result in the CE Certication and marking being
rendered invalid.
All components, accessories, pipes and connectors added
to the compressed air system should be:
of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved
by Ingersoll Rand.
clearly rated for a pressure at least equal to the machine maximum allowable working pressure.
compatible with the compressor lubricant/coolant.
accompanied with instructions for safe installation,
operation and maintenance.
Details of approved equipment are available from
Ingersoll Rand Service departments.
The use of non-genuine spare repair parts other than
those included within the Ingersoll Rand approved parts
list may create hazardous conditions over which
Ingersoll Rand has no control. Therefore
Ingersoll Rand does not accept any liability for losses
caused by equipment in which non-approved repair
parts are installed. Standard warranty conditions may be
aected.
Ingersoll Rand reserves the right to make changes and
improvements to products without notice and without
incurring any obligation to make such changes or add
such improvements to products sold previously.
The intended uses of this machine are outlined below and
examples of unapproved usage are also given, however
Ingersoll Rand cannot anticipate every application or
work situation that may arise.
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IF IN DOUBT CONSULT SUPERVISION.
This machine has been designed and supplied for
use only in the following specied conditions and
applications:
Compression of normal ambient air containing no
known or detectable additional gases, vapours. or
particles.
Operation within the ambient temperature range
specied in the PRODUCT SPECIFICATION SHEET.
The use of the machine in any of the situation types
listed in table 1:−
a) Is not approved by Ingersoll Rand,
b) May impair the safety of users and other persons,
and
c) May prejudice any claims made against
Ingersoll Rand.
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption.
b) indirect human consumption, without suitable
ltration and purity checks.
Use of the machine outside the ambient temperature
range specied in the PRODUCT SPECIFICATION SHEET.
Use of the machine where there is any actual or
foreseeable risk of hazardous levels of ammable gases
or vapours.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE
USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR
VAPOURS MAY BE PRESENT.
Use of the machine tted with non Ingersoll Rand
approved components.
Use of the machine with safety or control components
missing or disabled.
The company accepts no responsibility for errors in
translation of this manual from the original English
version.
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61115.10.33
80448574 Rev.A 5
SAFETY
Locate, read, understand and follow all Danger, Warning,
Caution, and Operating Instructions on the product and
in all Manuals. Failure to comply with safety precautions
described in the manuals supplied with the product,
this manual or any of the labels and tags attached to the
product may result in death, serious injury or property
damage.
Check that all labels, tags and data (name) plates are in
place and legible.
It is your responsibility to make this information available
to others.
If you have any questions about safety or procedures not
included in this manual, ask your supervisor or contact
any Ingersoll Rand oce or qualied
Ingersoll Rand distributor.
61115.10.33
6 80448574 Rev A
GENERAL INFORMATION
GENERAL OPERATION
The Sierra compressor is an electric motor driven, two stage,
dry screw compressor complete with accessories piped, wired
and baseplate mounted. It is a totally self–contained oil free
air compressor package. A standard compressor is composed
of the following:
Inlet air ltration
Compressor and motor assembly
Pressurised oil system with cooler
ON/OFF line capacity control system
Motor starting control system
Instrumentation
Safety provisions
Intercooler
Aftercooler
Moisture separation rst and second stage
Automatic condensate removal rst and second stage.
The motor and airend are integrally mounted. This assembly
is isolated from the base by rubber isolation mounts. Flexible
pipe connections are utilised where necessary to isolate the
main base and customer connections.
DESIGN PRESSURES
The normal operating pressures for Ingersoll Rand Sierra
compressors are 7.0 bar, 8.5 bar and 10.0 bar (100 psi, 125 psi
and 150 psi). The maximum allowable pressure is 0.2 bar (3
psi) above the normal operating pressure and is shown on the
compressor name plate.
The inter–stage safety valve is set at 3.1 barg (45 psi)
90–150 kW, 125–200 hp or 3.8 barg (55 psi) 200–300 kW,
250–400 hp. The second stage safety valve is set at
11.4 barg (165 psi) max. The design of the pressurised system
is well above the safety valve settings.
DESIGN TEMPERATURES
The standard compressor is designed for operation in
an ambient range of 2 °C to 46 °C (35 °F to 115 °F). When
conditions other than the design levels described are
encountered, we recommend you contact your nearest
Ingersoll Rand Distributor or Air Centre for additional
information.
COMPRESSED AIR SYSTEM
The compressor air enters the compressor through an
opening at the right end of the enclosure. It travels through
a passageway lined with sound–absorbing material to the
air lter. Via a round exible hose, the air passes through the
inlet/unloading valve into the rst stage of the compressor.
The helical rotors compress the air to a pressure of between
1.7 to 2.6 barg (25 to 38 psig). It is discharged into a venturi,
which dampens any pressure pulsations that may be present.
The intercooler then reduces the air temperature before it
enters the second stage. A safety relief valve is also positioned
in this system to guard against an abnormally high interstage pressure. A moisture separator is supplied immediately
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following the intercooler to remove any condensation that
may occur under certain conditions of ambient humidity and
temperature.
An expansion joint is utilised between the moisture separator
and the second stage.
The second stage further compresses the air to the desired
pressure. The pressure pulsations being dampened in a
venturi. An expansion joint prevents transmitted vibrations. A
poppet type check valve is provided to prevent any backow
of air into the compressor. The aftercooler cools the air to a
suitable temperature, while the discharge moisture separator
removes signicant amounts of condensation.
During unloaded operation, the inlet/unloading valve closes,
via mechanical linkage, the blowdown valve opens, expelling
any compressed air from the package.
CONDENSATE REMOVAL SYSTEM
A moisture separator is located immediately after the
intercooler and aftercooler to collect and eject any
condensation formed from the compressed air.
The condensate is drained through electrically operated
solenoid valves. The opening duration is preset at three (3)
adjustable between 2 and 20 seconds, the interval between
openings may be altered between 60 and 360 seconds,
depending on ambient conditions. If the environment
consists of high temperature and/or high humidity, then the
interval may have to be reduced. The factory set interval is
180 seconds.
The bosses for the manual valves are located on the outside
and rear of the sub–base. These valves are supplied loose
inside the compressor enclosure and need to be connected to
the ports as indicated in the general arrangement drawing. To
check operation of solenoid valves, open the manual bypass
valves momentarily once per day. For extended shutdown
periods, the manual valves should be opened and left open.
Strainers are provided upstream of the condensate valves
to prevent any particles from plugging the solenoid valves.
Before any maintenance is performed on the strainers or
solenoid valves, the strainer service valves should be closed,
in order to isolate from possible high pressure.
LUBRICATION SYSTEM
The oil sump is integral within the gearcase. The oil pump is
a positive displacement gear–type pump, and is driven by
the compressor driven shaft. Therefore, it rotates at the main
motor speed.
See MAINTENANCE section for lubricant specication.
From the pump, the oil travels past a pressure relief valve to
the oil cooler. The pressure relief valve’s function is to prevent
over–pressure of the system. It also regulates oil pressure and
may divert some oil ow back to sump.
At the discharge side of the oil cooler is a thermostatic valve.
This valve mixes the cold oil with hot oil that bypasses the
cooler to provide oil at the optimum temperature to the
bearings and gears.
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61115.10.33
80448574 Rev A 7
The oil then passes through a lter to a distribution manifold.
An orice from the manifold determines the oil pressure (2.8
to 3.5 barg) (40 to 50 psig), at normal operating temperature
(54 °C to 68 °C) (129 °F to 154 °F).
The gearcase is vented to a mounted breather. The breather
prevents oil vapour from escaping the sump area. The
breather exhaust is piped to the plenum area of the package.
COOLING SYSTEM (AIRCOOLED)
The intercooler, aftercooler, oil-cooler, fan and motor are
an integral assembly. The heat exchanger and fan are
mounted directly above the compressor assembly. Cooling
air ows through the end of the enclosure, through the heat
exchangers and discharges through the top of the package.
COOLING SYSTEM (WATERCOOLED)
The intercooler, aftercooler and oil-cooler are shell and tube
type heat exchangers. The intercooler and aftercooler are
”water in the shell” design. The oil-cooler employs ”water in
the tube”.
Cooling water ows through each of the three components
in parallel. A water solenoid shut o valve is provided in the
water discharge line from the package.
The tube bundles are removable for ease of cleaning.
ELECTRICAL SYSTEM
The electrical system of the compressor utilises the
microprocessor–based Xe controller. The standard electrical/
electronic components, contained within a readily accessible
enclosure include:
Xe controller
Star–Delta compressor motor starter, with auxiliary
contacts and overload relays
Cooling fan manual motor starter and circuit breaker or
fuses
Power supply board
Main motor overload relay
Control relay control transformer, and fuses.
Star–Delta type starter
By use of the Star–Delta type starter, the compressor motor
can be started and accelerated using a greatly reduced
”inrush” electric current. The starter is completely automatic
and controlled by the Xe controller. Refer to the electrical
schematic.
CAPACITY CONTROL
Automatic unloaded start
The compressor will always start in the unload mode. When
unloaded, the inlet valve is nearly closed, the blowdown valve
is open and the compressor is operating at minimum power.
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On–O line control
On–O line control will deliver air at full capacity (compressor
maximum eciency condition) or will operate at zero
capacity (compressor minimum power condition). The
compressor is controlled by the Xe controller responding to
changes in plant air pressure. The Xe controller energises the
load solenoid valve (1SV) to actuate the hydraulic cylinder
and load the compressor whenever plant air pressure drops
below the online pressure set point. The compressor will then
operate to deliver full capacity air to the plant system. If the
plant air system pressure rises to the o line set point of the
Xe, the load solenoid valve is de–energised, the hydraulic
cylinder is de–actuated allowing the machine to unload. The
compressor will continue to run with minimum power draw.
AUTOMATIC START/STOP CONTROL OPTION
Many plant air systems have widely varying air demands or
large air storage capacity which allows for automatic standby
air capacity control.
The Xe system has been designed to carry out this function
utilising a software module. Automatic Start–Stop is standard
on all Sierra compressors.
During periods of low air demand, if the line pressure rises
to the oine set point, the Xe controller begins to time out.
If the line pressure remains above the online set point for as
long as the set time, the compressor will stop. At the same
time, the Automatic Restart warning message will appear
in the display to indicate the comdpressor has shut down
automatically and will restart automatically. An automatic
restart will occur when the line pressure drops to the online
set point.
The oine and online set points and shutdown delay time
are set on the control panel. There is a 10 second delay after
shutdown during which the compressor will not restart even
if line air pressure drops below the online set point. This
is to allow the motor to come to a complete stop and the
controller to collect current data of operating condition. If line
air pressure is below the online set point at the end of
10 seconds, the unit will start unless the load delay timer is set
greater than 10 seconds.
Delay load time
This is the amount of time the line pressure must remain
below the online set point before the compressor will load
or start (if the unit was stopped due to an auto start/stop
situation). This timer will not delay loading after a start or
if the time is set to 0. When the delay load timer becomes
active, the display will switch to line pressure (if not displaying
line pressure at that time) and then display the delay load
countdown. Once the countdown reaches 0, the unit will load
or start and the display will return to line pressure. The display
select arrows are inactive during the delay load countdown.
•
•
•
GENERAL INFORMATION
61115.10.33
8 80448574 Rev A
Automatic start/stop operation
When in operation, the compressor must meet two specic
timing intervals before the Xe controller will stop the unit in
an Automatic Start/Stop situation.
A timer prevents the compressor from automatically starting
more than 6 times an hour by requiring the unit to run at least
10 minutes after each automatic start.
This 10 minute run period can be loaded, unloaded or a
combination of the two and allows dissipation of heat
generated within the motor windings at start.
When the compressor has completed the settings of the
timer, the controller stops the compressor, turns on the
automatic restart light and displays AUTO-RESTART in the
message display.
Pressure sensor 4APT continues to monitor the package
discharge pressure and sends information to the controller
which automatically restarts the compressor when the
pressure falls to the online setting.
REMOTE LOAD/UNLOAD OPTION
This option allows the operator to remotely load and unload
the machine.
With the option enabled, two dierent switches can be wired
(refer to the electrical schematic for wiring locations). The
switches are customer supplied.
REMOTE START/STOP OPTION
The remote start/stop option allows the operator to control
the compressor from a remote mounted start/stop station.
This option may be selected from the customer set–up
routine.
With the option enabled, two dierent switches can be
wired to the Xe for remote start/stop. (Refer to the electrical
schematic for wiring locations.) The switches are customer
supplied and must be of momentary type. The stop switch
contacts are normally closed / the start switch contacts are
normally open.
The following notice must be permanently xed to the unit in
a prominent position.
(Factory tted on 60Hz machines).
WARNING
This machine is remote start and stop equipped.
Disconnect power before servicing.
May start or stop at any time.
Lock and tag out.
Can cause severe injury or death.
See Operators / Instruction Manual.
•
•
•
POWER OUTAGE RESTART OPTION
The Power Outage Restart option is for installations that
have interruptions in their incoming power supply to the
compressor and must maintain an uninterrupted supply
of compressed air. When turned on, the option allows the
compressor to automatically restart and load
10 seconds after incoming power is restored after a power
interruption. Suitable visible and audible warnings are given
before restart.
SEQUENCER CONTROL
Sequencer control capability can be added to the electronic
control system by utilising a sequencer interface. This option
is available as a eld installation kit.
TIMED LEAD/LAG OPTION
When two or more machines are set up in a Lead/Lag
situation. This option allows the machines to be switched
from Lead to Lag at certain time of day.
SCHEDULED START/STOP OPTION
Allows the machine to be started or stopped at certain times
of the day.
HIGH CONDENSATE LEVEL SWITCH
This option prevents high condensate levels in the interstage moisture separator, providing added protection against
condensate carryover into the second stage compression
module. If the condensate drain system becomes clogged
or inoperative, this switch would signal the controller to
shut the unit down and display a HIGH I/C CONDENSATE
trip. The option may be factory installed or ordered as a eld
installation kit.
•
•
•
•
•
GENERAL INFORMATION
61115.10.33
80448574 Rev A 9
RECEIPT / HANDLING
RECEIPT
Before signing the delivery receipt, inspect for damage and
missing parts. If damage or missing parts are apparent, make
the appropriate notation on the delivery receipt, then sign
the receipt. Immediately contact the carrier for an inspection.
All material shall be held in the receiving location for the
carrier’s inspection.
Delivery receipts that have been signed without a notation
of damage or missing parts are considered to be delivered
“clear.” Subsequent claims are then considered to be
concealed damage claims. Settle damage claims directly with
the transportation company.
If you discover damage after receiving the compressor
(concealed damage), the carrier shall be notied within
15 days of receipt and an inspection shall be requested
by telephone with conrmation in writing. On concealed
damage claims, the burden of establishing that the
compressor was damaged in transit reverts back to the
claimant.
Read the compressor nameplate to verify it is the model
ordered, and read the motor nameplate to verify it is
compatible with your electrical conditions.
Make sure electrical enclosures and components are
appropriate for the installation environment.
• 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 compressor. Ensure truck
forks are fully engaged on both sides. Alternatively a special
lifting frame can be used to enable a crane or hoist to move
the compressor. Use only marked lifting points.
Once the packaging and pallet are discarded and the
compressor is in its nal position, remove the yellow painted
transit brackets from the resilient mounts and store for future
use or discard.
IMPORTANT
Remove any shipping brackets particularly the soft
mount transit braces painted in yellow.
LONG TERM STORAGE
If the product will not be commissioned within six months of
receipt, it should be prepared for long term storage. Please
contact Ingersoll Rand for details.
•
•
61115.10.33
10 80448574 Rev A
INSTALLATION
LOCATION IN THE PLANT•
Key
1. Compressor
2. Air Receiver Dry Tank
3. Air Dryer
4. Compressed Air Filters
5. System Demand Points
6. Vent/Drain Trap
7. Isolation Valve
8. Air Receiver (“Wet Tank”)
The compressor can be installed on any level oor
capable of supporting it. A dry, well ventilated area
where the atmosphere is as clean as possible is
recommended.
•
The area selected for the location of the compressor
should be free of dust, chemicals, metal lings, paint
fumes and overspray.
Hard surfaces may reect 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 compressor to reduce noise. Flexible piping
may be required.
See the general arrangement drawing for minimum
space requirements for normal operation and
maintenance.
Minimum space in front of the control panel door as
required by national or local codes shall be maintained.
Ambient temperatures higher than 46 °C (115 °F) shall be
avoided, as well as areas of high humidity.
•
•
•
•
•
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 deected 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.
NOTICE
If ducting is tted, the sump breather needs to be piped outside the enclosure to avoid back pressure into the
compression module.
1
5
4
2
3
4
6
7
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 eective
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.
To assure long trouble free operation of a compressor
operating with ON-LINE OFF-LINE control, the system volume
must be large enough to keep the load/unload cycles to a
minimum (greater than 2 minutes).
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 ttings 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 lters [4].
Include a means [6] to vent the discharge pipework
downstream from the machine’s check valve and upstream of
the rst 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
61115.10.33
80448574 Rev A 11
at dierent 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.
CAUTION
The use of plastic bowls on line lters and other plastic air line components without metal guards can be hazardous.
Their safety can be aected 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.
PRIOR TO STARTING
If the electric motor/control wiring should become exposed
or saturated with moisture/water deposits, it must be safely
dried o before attempting to make any part or conductor
electrically live.
Ensure all persons concerned are suitably competent with
electrical installations.
Ensure that there is a safe working procedure which has been
issued by supervisory personnel, and that it is understood by
all persons concerned with the operation of the compressor.
Ensure that the safety procedure to be applied is based on the
appropriate national regulations.
Ensure that the safety procedure is followed at all times.
ELECTRICAL CONNECTION
Feeder cables should be sized by a competent electrical
engineer to meet all power requirements.
IMPORTANT
Ensure that the control circuit is connected to the
transformer tapping that matches the supply voltage.
COOLING WATER PIPING
NOTICE
Water piping to and from the compressor package shall
be atleast as large as the package connection size. Do
not undersize the water piping.
Isolation valves with side drains should be installed on both
the inlet and outlet lines. To maintain cooler cleanliness and
reliability, it is important to install a strainer of 2 mm mesh
size on the inlet line. Strainers are available from
Ingersoll Rand.
•
•
•
The air compressor has a normally closed solenoid valve that
is tted to the water outlet side within the package. The valve
is wired into the air compressor control circuit and closes
when the compressor stops.
Carefully inspect the water system before installing the
air compressor package. Ensure that the piping is free of
scale and deposits that may restrict water ow to the air
compressor package. If water cleanliness is poor, ltration
installed on the water inlet pipe line is recommended.
Proper operation of the compressor requires that the cooling
water ow be provided at a maximum supply temperature of
46 °C (115 °F). See the compressor engineering data sheets for
cooling water ow rates.
Water temperature and pressure gauges should be installed
in the water piping for use in any fault nding of the water
system. Water pressure should ideally be between 3 and 5 bar
(43.5 and 72.5 psi) but shall 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 shall meet the requirements listed in WATER QUALITY
RECOMMENDATIONS later in this section.
VENTING THE WATER SYSTEM
At the initial installation, or for startup after draining the
water system, proceed to vent the system as follows:
Locate the water system vent cock on top of the
intercooler.
Open the water valve(s) allowing water to ow to the
package.
Open the vent cock and allow all air to escape from the
system. When water is observed at the vent cock, close it.
The system is now properly vented.
•
1.
2.
3.
INSTALLATION
61115.10.33
12 80448574 Rev A
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 the
connections located at the rear of the unit.
Locate the oil cooler by removing the left and centre rear
panels. Remove the two drain plugs located at the end of
the cooler.
Allow the system to completely drain.
WATER QUALITY RECOMMENDATIONS
Water quality is often overlooked when the cooling system
of a water-cooled air compressor is examined. Water quality
determines how eective the heat transfer rate, as well as the
ow rate will remain during the operation 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. The water make–up is eected by evaporation,
corrosion, chemical and temperature changes, aeration, scale
and biological formations. Most problems in a cooling system
show up rst in a reduction in the heat transfer rate, then in a
reduced ow rate and nally with damage to the system.
There are many constituents in the water system that must be
balanced to have a good, stable system. The following major
components should be monitored:
SCALE: Scale formation inhibits eective heat transfer, yet it
does help prevent corrosion. Therefore, a thin uniform coating
of calcium carbonate is desired in the inner surfaces. 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
treatments are available.
To ensure good operation life and performance of the
compressor cooling system, the recommended acceptable
ranges for dierent water constituents are included below:
Corrosivity (Hardness, pH, Total dissolved solids, Temperature
at inlet and Alkalinity should be analysed monthly, or if stable
for 3 to 4 months, analysed quarterly.
Acceptable concentration:
Langelier Index 0 to 1
•
1.
2.
•
Iron content should be analysed monthly.
Acceptable concentration:
2 mg/l (2 ppm)
Sulphate content should be analysed monthly.
Acceptable concentration:
50 mg/l (50 ppm)
Chloride content should be analysed monthly.
Acceptable concentration:
50 mg/l (50 ppm)
Nitrate content should be analysed monthly.
Acceptable concentration:
2 mg/l (2 ppm)
Silica content should be analysed monthly.
Acceptable concentration:
100 mg/l (100 ppm)
Dissolved Oxygen content should be analysed daily, or if
stable, analysed weekly.
Acceptable concentration:
0 mg/l (0 ppm) (as low as possible)
Oil and Grease content should be analysed monthly.
Acceptable concentration:
5 mg/l (5 ppm)
Ammonia content should be analysed monthly. Acceptable
concentration:
1 mg/l (1 ppm).
ROTATION CHECK
CAUTION
If the compressor is operated in the opposite direction
of rotation, airend damage may result and is not
warrantable.
Locate the rotation decal on each motor.
DRIVE MOTOR
The correct motor rotation is clockwise when viewed from the
rear or non–drive end of the motor.
For the compressor motor rotation check, the running of the
motor must be as short a time as possible.
After depressing the start button, IMMEDIATELY depress
the ”EMERGENCY STOP” BUTTON. Should the motor
rotation be incorrect, put the main isolator in the OFF
position.
Open the starter box door.
Interchange any two line connections (L1, L2 or L3) at the
starter. Close and fasten the starter box door. Recheck for
correct rotation.
•
•
INSTALLATION
61115.10.33
80448574 Rev A 13
FAN MOTOR
Observe the compressor cooling fan. The rotation should
be in accordance with the fan rotation decal axed to the
fan motor. Cooling air should exhaust from the top of the
compressor enclosure.
Should the motor rotation not be correct, put the main
isolator in the OFF position.
Interchange any two fan motor leads at the fan manual motor
starter (MMS). Close and fasten the starter box door. Recheck
for correct rotation.
CAUTION
Do not operate the machine with the panels removed
as this may cause overheating and operators to be
exposed to high noise levels.
Do not start or operate the machine in temperatures below
or approaching 0 °C (32 °F), because the operation of the
regulation system, the unloader valve, the safety valve, will be
compromised. Your Ingersoll Rand distributor will advise on
low ambient modications.
• ELECTRICAL DATA
An independent electrical isolator should be installed
adjacent to the compressor.
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.
Feeder cable connections to studs L1–L2–L3 on isolator
should be tight and clean.
The applied voltage must be compatible with the motor and
compressor data plate ratings.
The control circuit transformer has dierent voltage tappings.
Ensure that these are set for the specic applied voltage prior
to starting.
CAUTION
Never test the insulation resistance of any part of
the machines electrical circuits, including the motor
without completely disconnecting the Xe controller.
•
INSTALLATION
61115.10.33
14 80448574 Rev A
OPERATING INSTRUCTIONS
BASIC OPERATION
NOTICE
The language and compressors of measure displayed on
the controller will be preset before leaving the factory.
If these are required to be changed, contact your local
Ingersoll Rand service provider.
PRIOR TO STARTING
Check that the lubricant level is at least visible in the center
of the sight glass and add lubricant if necessary. Refer to the
maintenance procedures for setting the correct level.
Ensure that the discharge air isolation valve is open. Switch
on the main electrical isolation switch. The control panel will
illuminate, indicating that the line and control voltages are
available.
INITIAL CHECK SEQUENCE
The controller will perform an initial check sequence if the
compressor receives initial power to the controller or has
experienced an trip reset. While the initial check sequence
occurs, the controller will display a “Checking Machine”
message.
During the initial check sequence, the controller will check
the control system for proper operation. During this time,
if any items are found inoperative, a trip will occur and the
compressor will not start.
After completion of the initial check sequence, the controller
will then display “READY TO START’. This process should be
completed within 10 seconds.
START SEQUENCE
The compressor will initially start by the operator pressing the
local start button or receiving a remote start command. The
compressor will start loaded at the end of star delta transition
period for a star delta starter or wait for a period of time equal
to the starter time set point for a remote starter.
STOP SEQUENCE
The compressor can be stopped by a local or remote
stop, a shutdown due to a trip, or an emergency stop.
All of the above conditions will cause the compressor to
stop immediately, except the local or remote stop. A local
or remote stop will open the blowdown valve and the
compressor will run for up to 10 seconds. The compressor
will stop if the system pressure reaches the oine pressure
setpoint. However, if the compressor stops for this reason,
it will automatically restart when the system pressure falls
below the online pressure set point.
NOTICE
If the compressor has to be stopped in an emergency
depress the emergency stop button located underneath
the instrument panel.
•
•
•
•
EMERGENCY STOPPING
If the compressor has to be stopped in an emergency
press the emergency stop button located underneath the
instrument panel.
This will over-ride the normal unload/stop button and will
immediately stop the compressor.
RESTARTING AFTER EMERGENCY STOPPING
If the compressor has been switched o because of a
compressor malfunction, identify and correct the fault before
attempting to restart.
If the compressor has been switched o for reasons of safety,
ensure that the compressor can be operated safely before
restarting.
Refer to the PRIOR TO STARTING and START SEQUENCE
instructions earlier in this section before restarting the
compressor.
•
•
61115.10.33
80448574 Rev A 15
INTERFACE DATA AND KEYS
Xe–90M/145M
The standard user interface conguration of the controller
consists of the membrane and the LCD display. The
membrane consists of ve command keys (Start, Stop, Load,
Unload, and Reset), four navigation keys (Up, Right, Left and
Down), and an Edit mode selection key (Enter). These keys,
in conjunction with the color graphics display and the LED
icons, make up the user interface to the compressor.
Xe–90M/145M
LED STATUS ICONS
Three LED icons are used to indicate the current status of the
control system from a distance and are located on the upper
left side of the user interface.
Icon Name Function
OK
Illuminates when no
Warnings or Trips are sensed.
Can be in a Ready or Not
Ready state.
This icon will ash when
the machine is Running
Unloaded.
Alert
Illuminates when a Warning
(ashes) or Trip (constant on)
is sensed.
Can be in a Ready (Warning)
or Tripped state.
Auto
Illuminates when the
compressor stops in auto
restart.
COMMAND KEYS
These keys command the controller to perform actions as
specied in the following table. When any of these keys are
pressed the action below will be initiated and logged in the
event log.
•
•
•
Key Name Function
--- None
Load
Puts the compressor into the
selected mode of operation.
Unit will load if the pressure
conditions are right.
Unload
Puts the compressor into an
unloaded state. Unit will run
unloaded indenitely.
Reset
Clears Warnings and Trips
once the condition is
corrected.
Start Starts the compressor.
Stop
Stops the compressor. This
button should be pressed
instead of the E-Stop for
normal stopping operation.
Enter
Toggles the display between
the Navigation mode and the
Edit mode.
Xe–90M/145M Command Keys
NAVIGATION KEYS
There are four navigation keys (UP, RIGHT, DOWN and LEFT).
While the ENTER key is not considered a navigation key, it
is used in conjunction with the navigation keys to make or
conrm a selection.
Xe–90M/145M’s Navigation Keys
•
OPERATING INSTRUCTIONS
61115.10.33
16 80448574 Rev A
The navigation keys roll over. Pressing one of the navigation
keys will lead the user down a navigation path. Each time
the key is pressed, another step in the path is taken. Once
the end of a navigation path is reached, pressing the key one
more time will bring the user back to the beginning of the
path. Pressing the opposite key will move the user through
the navigation path in the opposite direction. Once the
beginning is reached, pressing the opposite key will take the
user to the end of the path.
DISPLAY LAYOUT
Xe–90M/145M’s Display Layout
Folder Bar: Uses tabs to graphically identify each
folder.
Title Bar: Identies current folder and page
(underlined).
Page Content: Content of the current page.
Dashboard: Displays system status.
FOLDER NAVIGATION AND ICONS
To move among the tabbed folders shown on the LCD display,
press the RIGHT and LEFT keys. The navigation rolls over from
the last to the rst folder and vice-versa.
Folder
Name
Icon Description
Home
System performance and status
main information. The rst page
of this folder is the default page
when the controller rst powers
up.
Operator
Settings
System options and conguration
settings.
Events System events log.
Trip History Details on the most recent trips.
Graphing
On-board graphing of system
data (Xe–145M Only).
Maintenance
Status and notication setup for
compressor maintenance items.
•
•
Folder
Name
Icon Description
General
Settings
General settings such as
Language, Time, and Units of
Measure.
Integral
Sequencing
Intergral Sequencing
communication status and
conguration.
Status
Measurements or status from/of
all analog and digital I/O.
Factory
Settings
Compressor tuning parameters.
Also displays hardware and
software versions.
Folder Bar Icons
PAGE NAVIGATION
Once the desired folder is selected, press the DOWN key to
move to the page selection area and then use the RIGHT and
LEFT keys to select the desired page. Use the UP key to get
back to the folder tabs.
Icon Description
Start of the page selection area.
Indicates that there are more pages available
by navigating right.
Indicates that there are more pages available
by navigating left.
Title Bar Page Icons
ACCESSING PARAMETERS
After the desired page is selected, the page’s parameters can
be selected by using the DOWN key. The cursor will move to
the next parameter each time the DOWN key is pressed. Use
the UP key to go back to the previous one.
The cursor rolls over, so once the last parameter is selected,
pressing the DOWN key will navigate the cursor to the Folder
Bar. If the rst parameter is selected, pressing the UP key will
move the cursor to the page selection area.
Once selected, access parameters by pressing the ENTER key.
Make changes using the NAVIGATION keys and then enter the
setting by pressing the ENTER key again. After a parameter
is accessed, pressing the ENTER key will enter the current
setting into the control program and navigate the cursor back
to the selected parameter on the page.
When the cursor is on a parameter that has an enabled/
disabled box, pressing the ENTER key will cause the setting to
toggle.
•
•
OPERATING INSTRUCTIONS
61115.10.33
80448574 Rev A 17
The icon appears on numeric entry windows (see gure
below). Placing the cursor on it and then pressing the ENTER
key will cancel the entry and any changes that were made.
Not all pages have adjustable parameters. Some just
have read-only information.
DASHBOARD ICONS
The dashboard is intended to be a quick at-a-glance view of
system status. The following table lists standard dashboard
icons and their denition. Note that the color of these icons
changes based on the state set by the application while
running.
Name Icon Description
Remote
Control
Remote control is enabled. This
can be Remote Start/Stop, COM
Control, Integral Sequencing or
Web Control.
Service
Required
A service reminder is nearing or
has expired (i.e.: an air or oil lter
needs to be changed).
Unloaded
or
Loaded
Compressor is in the unloaded
state.
Compressor is in the loaded state.
Xe–90M/145M’s Dashboard Icons
DASHBOARD STATUS MESSAGES
The dashboard also displays the current operating state of the
compressor. The following states can be encountered during
machine operation:
Ready to Start – The compressor currently has no trip
or start inhibit conditions present. The machine can be
started by pressing the start button at any time.
•
•
•
Starting – A start command has been given to the
compressor and the start sequence is being performed.
The time period for this state can vary depending on the
starter type of the machine.
Load Delay – The compressor is waiting for a small
period of time after starting before allowing the machine
to load. This ensures the machine is at operating
conditions before loading
Running Loaded – The compressor is operating and
producing air. The inlet valve is open and the blowo
valve is closed.
Running Unloaded – The compressor is operating,
but not producing air. The inlet valve is closed and the
blowo valve is open.
Auto-Restart – The compressor has stopped due to
pressure rising above the oine or auto-stop setpoints
and auto-restart being enabled. The compressor will
automatically restart when pressure falls to the online or
target pressure setpoint.
Stopping – The compressor has received a stop
command and the stop sequence is being performed.
Blowdown – The compressor must wait for a brief period
of time after stopping its motor before it is allowed to
start again.
Not Ready – The compressor has detected a condition
that will not allow the compressor to start. The condition
must be cleared before a start is allowed, but does not
need to be acknowledged.
Tripped – The compressor has detected an abnormal
operational condition that has stopped the machine. A
trip must be acknowledged by hitting the reset button
before the compressor can start.
Processor Init – The controller is being initialized.
•
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•
•
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OPERATING INSTRUCTIONS
61115.10.33
18 80448574 Rev A
SIERRA COMPRESSOR
HOME FOLDER
PAGE 1 – SYSTEM OVERVIEW
This is the factory default display after powering up the
system.
Load Pressure – indicated in the white box and by the
white arrow, which is always left of center on the gauge. The
compressor will load when package discharge pressure falls
below this value.
Unload Pressure – indicated in the white box and by the
white arrow, which is always right of center on the gauge. The
compressor will unload when package discharge pressure
rises above this value.
Package Discharge Pressure – indicated by the large
numbers centred below the gauge and by the red arrow. This
is the air pressure that the compressor is supplying to the
plant.
Pressure Unit of Measure – indicated below the Package
Discharge Pressure. This is selectable from the GENERAL
SETTINGS folder.
Package Discharge Temperature – indicated by the
numbers in the lower right of the display. This is the
temperature of the compressed air/at the discharge of the
compression module. The Package Discharge Temperature is
only displayed if the Hot Discharge option is disabled.
Second Stage Discharge Temperature – indicated by
the numbers in the lower right of the display. This is the
temperature of the compressed air at the discharge of the
2nd stage compression module.
Temperature Unit of Measure – indicated to the right of the
Airend Discharge Temperature. This is selectable from the
GENERAL SETTINGS folder.
Run Hours – indicate the number of hours the compressor
has been running.
All information on this page is read only.
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PAGE 2 – COUNTERS
Hour Meters – Indicates the hours that: the controller has
been powered up, the compressor has been running, and the
compressor has running loaded.
Starts – Indicates the number of times a start is attempted on
the compressor.
Date and Time – Indicates the current date and time. This is
adjustable and congurable in the GENERAL SETTINGS folder.
All information on this page is read only.
PAGES 3 THRU 4 – ANALOG INPUTS
Pressure is indicated by this icon.
Temperature is indicated by this icon.
Any sensor that is not installed or is reporting a failure will
show an X symbol.
All information on these pages is read only.
The following analog inputs are displayed in this section:
Package Discharge Pressure – The pressure the compressor
is delivering to the plant.
Package Discharge Temperature – The temperature of the
air after passing through the After-cooler.
1st Stage Discharge Temperature – The temperature of
the air at the discharge of the 1st stage of the compression
module.
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OPERATING INSTRUCTIONS
61115.10.33
80448574 Rev A 19
2nd Stage Inlet Pressure – The pressure of the air at the
intake of the 2nd stage of the compression module.
2nd Stage Inlet Temperature – The temperature of the air at
the intake of the 2nd stage of the compression module.
2nd Stage Discharge Pressure – The pressure of the air at
the discharge of the 2nd stage of the compression module.
2nd Stage Discharge Temperature – The temperature of
the air at the discharge of the 2nd stage of the compression
module.
Bearing Oil Temperature – The temperature of the coolant
oil at the bearings of the compression module shaft.
Bearing Oil Pressure – The pressure of the coolant oil at the
bearings of the compression module shaft.
Inlet Vacuum – Vacuum reading at the inlet valve.
Remote Pressure (optional) – An optional pressure sensor
that reads pressure at a point outside of the compressor
package. Usually this would be on a common tank.
Oil Filter Pressure Drop – Dierential pressure across the
lter. Higher values indicate an older or clogged lter.
OPERATOR SETTINGS FOLDER
PAGE 1–2 OPERATOR SETTINGS
The below values are all setpoints:
Oine Pressure – The compressor will unload when package
discharge pressure rises above this value.
Range (in PSI): 75 to Rated Pressure +3.
Online Pressure – The compressor will load when the
package discharge pressure falls below this value.
Range (in PSI): 65 to Oine Pressure -10.
Lead/Lag – When this box is checked the compressor is
operating as a lead machine. Unchecking the box causes the
machine to run as a lag machine.
Lag Oset – If the machine is running as a lag compressor,
the lag oset will be subtracted from the online and oine
setpoints.
Range (in PSI): 0–45, depending on the online and oine
setpoints. The Lag Oset will never allow you to exceed
the minimum or maximum values of the online and oine
setpoints.
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Condensate Release Time – Time period that determines
how long the condensate drain valve will remain open every
cycle.
Range: 2–20 seconds.
Condensate Interval Time – Time period that determines
how long the condensate drain will remain closed every cycle.
Range: 90–270 seconds.
Starter Time – Time period that the compressor needs in
order to come up to operating speed after a start command
before being able to produce air.
Range (in seconds): 5–30.
Max 1st Stage Temperature – Setting that determines at
what temperature the compressor will trip if the 1st Stage
Discharge Temperature exceeds it.
Range (in °F): 300–440.
Max 2nd Stage Temperature – Setting that determines at
what temperature the compressor will trip if the 2nd Stage
Discharge Temperature exceeds it.
Range (in °F): 328–428.
The parameters on these pages are adjustable any time.
PAGES 3–5 OPERATOR OPTIONS
The below values are all setpoints:
Auto-Restart Time – The time period the compressor must
run unloaded before stopping in auto-restart. This time
period begins the moment that package discharge pressure
rises above the oine setpoint. Both this time period and
the minimum motor run timer (10 minutes) must be satised
before the compressor will stop in auto restart.
Range (in seconds): 120–900.
Auto-Restart Delay – The time period after the package
discharge pressure has fallen below the online setpoint
before the compressor can automatically restart.
Range (in seconds): 0–60.
COM Control – Enabling this setpoint allows the compressor
to be controlled by a serial or Ethernet device, such as an X8I.
This is equivalent to the “Sequencer” option on older Intellisys
controllers.
Remote Start/Stop – Enabling this setpoint allows the
compressor to be started and stopped using the digital inputs
on the controller.
Enable PORO – Enabling this setpoint will allow the
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OPERATING INSTRUCTIONS
61115.10.33
20 80448574 Rev A
compressor to automatically restart after a power outage has
been restored if the compressor was running loaded at the
time of the outage. PORO is an option and the option module
must be purchased and installed before this feature can be
turned on.
PORO Time – Time after the controller power has been
restored and controller has nished booting before the
compressor will perform a PORO start. During this time the
PORO Horn will sound.
Range (in seconds): 10–600.
Condensate Level Installed – Setpoint to enable the level
switch used to detect a blocked condensate drain.
Lead/Lag Cycle Length – The time period that controls how
long the compressor will remain in the lead position before
switching to lag. Setting this to 0 will disable this function.
Range: 0–750 hours.
Scheduled Start Day – Day (or days) of the week for which a
scheduled start will be performed. The compressor will start
when its onboard clock matches the day, hour, and minute
of the scheduled start setpoints. Scheduled Start/Stop is
an option and the option module must be purchased and
installed before this feature can be turned on.
Scheduled Start Hour – Hour of the day for which a
scheduled start will be performed. Scheduled Start/Stop is
an option and the option module must be purchased and
installed before this feature can be turned on.
Scheduled Start Minute – Minute of the hour for which a
scheduled start will be performed. Scheduled Start/Stop is
an option and the option module must be purchased and
installed before this feature can be turned on.
Scheduled Stop Day – Day (or days) of the week for which a
scheduled stop will be performed. The compressor will stop
when its onboard clock matches the day, hour, and minute
of the scheduled stop setpoints. Scheduled Start/Stop is
an option and the option module must be purchased and
installed before this feature can be turned on.
Scheduled Stop Hour – Hour of the day for which a
scheduled stop will be performed. Scheduled Start/Stop is
an option and the option module must be purchased and
installed before this feature can be turned on.
Scheduled Stop Minute – Minute of the hour for which a
scheduled stop will be performed. Scheduled Start/Stop is
an option and the option module must be purchased and
installed before this feature can be turned on.
Enable High Dust Filter – Enabling this when a high dust
lter is installed will adjust the change inlet lter warning and
high inlet vacuum trip thresholds to a higher value.
Enable Remote Pressure Sensor – Enabling this allows the
compressor to load and unload based o a sensor reading
installed in a remote location.
Please note that in order to disable Scheduled Start/Stop,
the Scheduled Start and Stop days, hours, and minutes must
match exactly.
PAGES 6 CALIBRATE SENSORS
Sensor calibration can only take place when the machine is
stopped and there is no pressure on the sensor. Calibration
only needs to take place after a sensor is replaced, the
controller is replaced, the controller software is upgraded, or
the operator suspects the sensor reading is in error. Calibrate
a sensor by selecting the checkbox beside the sensor name.
Each of the sensors listed below can be calibrated:
Inlet Vacuum (1AVPT)
2nd Stage Inlet Pressure (2APT)
2nd Stage Discharge Pressure (3APT)
Package Discharge Pressure (4APT)
Oil Filter Inlet Pressure (5OPT)
Bearing Oil Pressure (6OPT)
Remote Pressure (10APT) – Only on units with the
remote sensor option.
Please note that if a sensor is currently reading a value that is
+/-10% of its range from zero, the sensor will not be able to
be calibrated and an warning will be logged in the event log.
Please make sure the sensor is being exposed to atmosphere
before attempting calibration.
EVENTS FOLDER
PAGES 1 TO A MAX OF 50
The pages in the Events folder document up to the last 250
events that the controller has experienced, with the time and
date of the occurrence. The events are recorded in sequence,
with number one being the newest and 250 being the oldest.
When a new event occurs, it becomes number one and all
others are shifted up in number.
The page numbers in the Title Bar are used to scroll through
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OPERATING INSTRUCTIONS
61115.10.33
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