Ingersoll-Rand SSR UP5-4, SSR UP5-5.5, SSR UP5-7.5, SSR UP6-10, SSR UP6-7.5 Operation And Maintenance Manual
...
SSR UP5–4, UP5–5.5, UP5–7.5, UP5–11c
50Hz
SSR UP6–5, UP6–7.5, UP6–10, UP6–15c
60Hz
OPERATION AND MAINTENANCE MANUAL
This manual contains
important safety information
and must be made available
to personnel who operate and
maintain this machine.
C.C.N. : 22451884
REV. : A
DATE : JUNE 2004
AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in
material and workmanship for a period of twelve months from the date of placing the Equipment in operation or eighteen
months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be obligated to
promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the
Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement
part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment
in accordance with good industry practices and has complied with specific recommendations of the Company.
Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the
manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall
not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the
Purchaser or others without Company‘s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance
warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period
of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company
in writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.
Note that this is Ingersoll–Rand standard warranty. Any warranty in force at the time of purchase of the compressor
or negotiated as part of the purchase order may take precedence over this warranty.
Register on–line at air.irco.com
Ingersoll–Rand
Industrial Air Solutions
Swan Lane
Hindley Green
Wigan WN2 4EZ
Ingersoll Rand Asia Pacific
C/O Ingersoll–Rand South East Asia (Pte) Ltd.
42 Benoi Road
Singapore 629903
Ingersoll–Rand
Industrial Air Solutions
P.O. Box 1840
800–D Beaty Street
Davidson, NC 28036
CONTENTS & ABBREVIATIONS
1
CONTENTS
1 CONTENTS
2 FOREWORD
3 DECALS
8 SAFETY
10 GENERAL INFORMATION
13 INSTALLATION / HANDLING
21 OPERATING INSTRUCTIONS
24 MAINTENANCE
29 TROUBLE SHOOTING
ABBREVIATIONS & SYMBOLS
#### Contact Ingersoll–Rand for serial number
–>#### Up to Serial No.
####–> From Serial No.
* Not illustrated
{ Option
NR Not required
AR As required
SM Sitemaster/Sitepack
HA High ambient machine
WC Watercooled machine
AC Aircooled machine
ERS Energy recovery system
T.E.F.C. Totally enclosed fan cooled motor (IP55)
O.D.P. Open drip proof motor (IP23)
ppm parts per million
cs Czech
da Danish
de German
el Greek
en English
es Spanish
et Estonian
fi Finnish
fr French
hu Hungarian
it Italian
lt Lithuanian
lv Latvian, Lettish
mt Maltese
nl Dutch
no Norwegian
pl Polish
pt Portuguese
sk Slovak
sl Slovenian
sv Swedish
zh Chinese
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en
2
FOREWORD
The contents of this manual are considered to be proprietary and
confidential to Ingersoll–Rand and should not be reproduced without
the prior written permission of Ingersoll–Rand.
Nothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied, regarding
the Ingersoll–Rand products described herein. Any such warranties or
other terms and conditions of sale of products shall be in accordance
with the standard terms and conditions of sale for such products, which
are available upon request.
This manual contains instructions and technical data to cover
routine operation and scheduled maintenance tasks by operation and
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised Ingersoll–Rand service
department.
The design specification of this machine has been certified as
complying with E.C. directives. Any modification to any part is
absolutely prohibited and would result in the CE certification and
marking being rendered invalid.
All components, accessories, pipes and connectors added to the
compressed air system should be:
. of good quality, procured from a reputable manufacturer and,
wherever possible, be of a type approved by Ingersoll–Rand.
. clearly rated for a pressure at least equal to the machine maximum
allowable working pressure.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation, operation and
maintenance.
Details of approved equipment are available from Ingersoll–Rand
Service departments.
The use of non–genuine spare repair parts other than those
included within the Ingersoll–Rand approved parts list may create
hazardous conditions over which Ingersoll–Rand has no control.
Therefore Ingersoll–Rand does not accept any liability for losses
caused by equipment in which non–approved repair parts are installed.
Standard warranty conditions may be affected.
The intended uses of this machine are outlined below and examples
of unapproved usage are also given, however Ingersoll–Rand cannot
anticipate every application or work situation that may arise.
IF IN DOUBT CONSULT SUPERVISION.
This machine has been designed and supplied for use only in the
following specified conditions and applications:
. Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.
The use of the machine in any of the situation types listed in
table 1:–
a) Is not approved by Ingersoll–Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll–Rand.
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
checks.
Use of the machine outside the ambient temperature range
specified in the GENERAL INFORMATION SECTION of this manual.
Use of the machine where there is any actual or foreseeable risk of
hazardous levels of flammable gases or vapours.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE
USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR
VAPOURS MAY BE PRESENT.
Use of the machine fitted with non Ingersoll–Rand approved
components.
Use of the machine with safety or control components missing or
disabled.
Ingersoll–Rand reserves the right to make changes and
improvements to products without notice and without incurring any
obligation to make such changes or add such improvements to
products sold previously.
The company accepts no responsibility for errors in translation of
this manual from the original English version.
© COPYRIGHT 2004
INGERSOLL–RAND COMPANY
en
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DECALS 3
ISO SYMBOLS
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory Information / Instructions Warning
WARNING: Electrical shock risk. WARNING – Pressurised vessel. WARNING – Hot surface.
WARNING – Pressurised component or
system.
Use fork lift truck from this side only. RESET Do not use fork lift truck from this side.
Emergency stop. On (power). Off (power).
Read the Operation and Maintenance manual
before operation or maintenance of this
machine is undertaken.
WARNING – Air/gas flow or Air discharge. Do not breathe the compressed air from this
Do not operate the machine without the guard
being fitted.
machine.
Lifting point.
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ROTATION AIR DISCHARGE COOLANT FILTER
en
DECALS4
AUTOMATIC RESTART MAINTENANCE MAINTENANCE PROHIBITED
COOLANT DRAIN CONDENSATE DRAIN FILTER
FRAGILE KEEP DRY THIS WAY UP
USE NO HOOKS NO SIDE CLAMPS HOURS
Use ULTRA–Plus Coolant only
Failure to use the specified coolant may
result in damage to the machine
POWER
INSPECT
Every X months, if sooner than required by
operating hours
POWER INLET (AC)
en
CHANGE / REPLACE CLEAN
Pinch point hazard.
Keep hands clear.
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DECALS 5
ANSI SYMBOLS
GRAPHIC FORM AND MEANING OF ANSI SYMBOLS
DANGER
INTAKE AIR. Can contain carbon monoxide or other contaminants. Will cause serious injury or death. Ingersoll–Rand
air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for
breathing air applications unless treated in accordance with all applicable codes and regulations.
WARNING
HAZARDOUS VOLTAGE. Can cause serious injury or death. Disconnect power and bleed pressure from tank before
servicing. Lockout/Tagout machine. Compressor must be connected to properly grounded circuit. See Grounding
Instructions in manual. Do not operate compressor in wet conditions. Store indoors.
RISK OF FIRE OR EXPLOSION. Electrical arcing from compressor components can ignite flammable liquids and
vapors which can result in serious injury. Never operate the compressor near flammable liquids or vapors. If used to
spray flammable materials, keep compressor at least 20ft away from the spray area.
HIGH PRESSURE AIR. Rusted tanks can cause explosion and severe injury or death. Receiver under pressure.
Operator should relieve tank pressure before performing maintenance. In addition to automatic drain, operate manual
drain valve weekly. Manual drain valve located at bottom of the tank.
MOVING PARTS. Can cause serious injury. Do not operate with guards removed. Machine may start automatically.
Disconnect power before servicing. Lockout/Tagout machine.
HOT SURFACES. Can cause serious injury. Do not touch. Allow to cool before servicing. Do not touch hot
compressor or tubing.
EXPOSED MOVING BELTS AND SHEAVES.
Can cause severe injury or death.
Do not operate without guard in place. Disconnect power before servicing.
Lockout/Tagout machine.
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Air flow exhaust may contain flying debris.
Safety protection should be worn at all times.
Pinch point hazard.
Keep hands clear.
en
6
INSIDE STARTER DOOR
DECALS
INSIDE PACKAGE
VIEW TOP VIEW LEFT VIEW FRONT
VIEW BACK
VIEW LEFT
Item ccn Qty. Description Item ccn Qty. Description
1 93166502 1 Decal, replacement element
2 32343584 1 Decal, warning hot surface
Base mount only
3 32343907 1 Decal, lock and tag out
4 93166460 1 Decal, coolant drain
5 32343568 2 Decal, warning hazardous voltage
6 32343527 1 Decal, warning high pressure
7 30286686 1 Decal, notice rotation
8 32343584 1 Decal, warning hot surface
9 32343899 1 Decal, warning flying debris
10 32343543 1 Decal, notice air discharge
Receiver mount only
†11 32343576 1 Decal, auto drain (EDV option)
12 32343519 1 Decal, warning contaminated air
Receiver mount only
13 22050611 1 Decal, I–R logo
Receiver mount only
VIEW FRONT VIEW RIGHT
14 32343543 1 Decal, notice air discharge
Non–dryer only
Base mount only
15 32343519 1 Decal, warning contaminated air
Base mount only
16 SPEC 1 Specifications, compressor package
17 32343493 1 Decal, overload setting IEC starter
18 32343550 2 Decal, rotating fan
19 22455687 1 Tag, rotation
20 81295990 1 Decal, air shield
21 93171262 2 Decal, notice lift here
Base mount only
22 22425557 1 Decal, I–R logo
Base mount only
22435713 1 Decal, I–R logo
Receiver mount only
23 22417109 1 Decal, starter box
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INSIDE STARTER DOOR
DECALS
INSIDE PACKAGE
VIEW TOP VIEW LEFT VIEW FRONT
7
VIEW BACK
VIEW LEFT
Item ccn Qty. Description Item ccn Qty. Description
24 22064562 1 Decal, air care
25 32343535 1 Decal, warning moving belts
26 22417117 1 Decal, maintenance parts
27 32343543 1 Decal, notice air discharge
Dryer only
VIEW FRONT VIEW RIGHT
28 92867530 1 Decal, warning hot surface
Option
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en
8
SAFETY
DANGER!
Hazard that WILL cause DEATH, SEVERE INJURY or substantial
property damage if ignored. Instructions must be followed precisely to
avoid injury or death.
WARNING!
Hazard that CAN cause DEATH, SEVERE INJURY or substantial
property damage if ignored. Instructions which must be followed
precisely to avoid injury or death.
CAUTIONS!
Cautions call attention to instructions which must be followed
precisely to avoid damaging the product, process or its surroundings.
NOTES
Notes are used for supplementary information.
BREATHING AIR PRECAUTION
Ingersoll–Rand air compressors are not designed, intended or
approved for breathing air. Compressed air should not be used for
breathing air applications unless treated in accordance with all
applicable codes and regulations.
General Information
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation.
Ensure that the Operation and Maintenance manual is not removed
permanently from the machine.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
Do not point air nozzles or sprayers toward anyone.
Compressed air and electricity can be dangerous. Before
undertaking any work on the compressor, ensure that the electrical
supply has been isolated and the compressor has been relieved of all
pressure.
Wear eye protection when operating or servicing compressor.
All persons positioned near to operating machinery should be
equipped with hearing protection and given instructions on its use in
accordance with workplace safety legislation.
Make sure that all protective covers are in place and that the
canopy/doors are closed during operation.
The specification of this machine is such that the machine is not
suitable for use in flammable gas risk areas.
Installation of this compressor must be in accordance with
recognised electrical codes and any local Health and Safety Codes.
The use of plastic bowls on line filters can be hazardous. Their
safety can be affected by either synthetic lubricants, or the additives
used in mineral oils. Ingersoll –Rand recommends that only filters with
metal bowls should be used on a pressurised system.
Compressed air
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
WARNING
Imposing a normal or emergency stop on the compressor will
only relieve pressure upstream of the minimum pressure valve on
top of the separator tank.
If maintenance work is required downstream of this valve, ensure
that all pressure is relieved at the process vent point external to
the compressor
If more than one compressor is connected to one common
downstream plant, effective isolation valves must be fitted and
controlled by work procedures, so that one machine cannot
accidentally be pressurised / over pressurised by another.
Compressed air must not be used for a direct feed to any form of
breathing apparatus or mask.
The discharged air contains a very small percentage of compressor
lubricant and care should be taken to ensure that downstream
equipment is compatible.
If the discharged air is to be ultimately released into a confined
space, adequate ventilation must be provided.
When using compressed air always use appropriate personal
protective equipment.
All pressure containing parts, especially flexible hoses and their
couplings, must be regularly inspected, be free from defects and be
replaced according to the Manual instructions.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
Avoid bodily contact with compressed air.
All safety valves located in the separator tank must be checked
periodically for correct operation.
Do not over–pressurize the receiver tank or similar vessels beyond
design limits.
Do not use a receiver tank or similar vessels that fail to meet the
design requirements of the compressor. Contact your distributor for
assistance.
Do not drill into, weld or otherwise alter the receiver tank or similar
vessels.
Before servicing the unit, vent pressure before removing the power
to ensure that the gauge reads zero pressure.
Materials
The following substances are used in the manufacture of this
machine and may be hazardous to health if used incorrectly:
. preservative grease
. rust preventative
. compressor coolant
AVOID INGESTION, SKIN CONTACT AND INHALATION OF
FUMES
Transport
When loading or transporting machines ensure that the specified
lifting and tie down points are used.
Lifting equipment must be properly rated for the weight of the
compressor.
Do not work on or walk under the compressor while it is suspended.
Electrical
Keep all parts of the body and any hand–held tools or other
conductive objects, away from exposed live parts of the 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.
WARNING
Any electrical connections or adjustments should only be
made by a suitably qualified electrician
Ensure that the machine is operating at the rated pressure and that
the rated pressure is known to all relevant personnel.
All air pressure equipment installed in or connected to the machine
must have safe working pressure ratings of at least the machine rated
pressure.
en
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.
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