Ingersoll Rand UP6-7.5 Owners Manual

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Page 1

SSR UP5-4, UP5-5.5, UP5-7.5, UP5-11c

50 Hz

SSR UP6-5, UP6-7.5, UP6-10, UP6-15c

60 Hz

OPERATION AND MAINTENANCE MANUAL

This manual contains important safety information and must be made available to personnel who operate and maintain this machine.

Refer all communications to the nearest Ingersoll Rand Full Service Distributor.

C.C.N. : 80445273 REV. : A DATE :

OCTOBER 2008

Page 2

AIR COMPRESSOR GROUP

BONDED WARRANTY & REGISTERED START UP

Warranty

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.

Ingersoll Rand

Industrial Air Solutions

Swan Lane

Hindley Green

Wigan WN2 4EZ

Ingersoll Rand Asia Pacic

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

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 rst 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 specic 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 eects of corrosion, erosion and normal wear and tear are specically excluded. Performance warranties are limited to those specically stated within the Company‘s proposal. Unless responsibility for meeting such performance warranties are limited to specied 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 fullment 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 rst 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.

Page 3

Operation and Maintenance Manual Contents

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

DECALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ISO SYMBOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GRAPHIC FORM AND MEANING OF ISO SYMBOLS . . . . . . . . . . . . . . . . . . . 6

ANSI SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

GRAPHIC FORM AND MEANING OF ANSI SYMBOLS . . . . . . . . . . . . . . . . . . 8

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General Information Compressed air Materials Transport

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Condensate disposal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

PIPING AND INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SCHEMATIC, ELECTRICAL UP6 5–15HP FV 3PH 60Hz DOL – U.S.A. . . . . . . . . . . . 15

SCHEMATIC, ELECTRICAL UP6 5–15HP SD 3PH 60Hz . . . . . . . . . . . . . . . . . . . 16

SCHEMATIC, ELECTRICAL UP6 5–15HP FV 1PH 60Hz - U.S.A. . . . . . . . . . . . . . . 17

SCHEMATIC, ELECTRICAL UP5 5–15HP FV 3PH 50Hz DOL . . . . . . . . . . . . . . . . 18

SCHEMATIC, ELECTRICAL UP5 5–15HP SD 3PH 50Hz . . . . . . . . . . . . . . . . . . . 19

INSTALLATION/HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

UP-SERIES TANK MOUNTED (80 GAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

UP-SERIES TANK MOUNTED (120 GAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

UP-SERIES TANK MOUNTED (272 LITRES) . . . . . . . . . . . . . . . . . . . . . . . . . . 26

UP-SERIES TANK MOUNTED (500 LITRES) . . . . . . . . . . . . . . . . . . . . . . . . . . 28

LOCATION IN THE PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

COMPRESSOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

AUTOMATIC START & STOP CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

DUAL CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

PRIOR TO STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

NORMAL/EMERGENCY STOPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Contents Operation and Maintenance Manual

TOP UP COOLANT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

COOLANT CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

COOLANT FILTER CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

AIR FILTER ELEMENT CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 41

SEPARATOR ELEMENT CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 42

COOLER CLEANING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

BELT CHECKING AND ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . 42

ELECTRIC DRAIN VALVE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

TIMER SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

MOISTURE SEPARATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

AIR FILTER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

DISASSEMBLING THE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

REFRIGERANT LEAKS IN THE REFRIGERATION CIRCUIT . . . . . . . . . . . . . . . . . . 45

REFRIGERANT CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

CHARACTERISTICS OF REFRIGERANT R134A . . . . . . . . . . . . . . . . . . . . . . . . 45

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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 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

High ambient machine

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OPERATION AND MAINTENANCE MANUAL FOREWORD

FOREWORD

The contents of this manual are considered to be proprietary and condential 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 sta. Major overhauls are outside the scope of this manual and should be referred to an authorised Ingersoll Rand service department.

The design specication of this machine has been certied as complying with E.C. directives. Any modication to any part is absolutely prohibited and would result in the CE certication 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 aected.

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.

IF IN DOUBT CONSULT SUPERVISION.

This machine has been designed and supplied for use only in the following specied conditions and applications:

Compression of normal ambient air containing

•

no known or detectable additional gases, vapours. or particles

•

Operation within the ambient temperature range specied in the GENERAL INFORMATION section of this manual.

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

Is not approved by Ingersoll Rand,

May impair the safety of users and other

persons, and

May prejudice any claims made against

Ingersoll Rand.

TABLE 1

Use of the machine to produce compressed air for:

direct human consumption

indirect human consumption, without

suitable ltration and purity checks.

Use of the machine outside the ambient temperature range specied in the GENERAL INFORMATION SECTION of this manual.

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.

INGERSOLL RAND

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DECALS OPERATION AND MAINTENANCE MANUAL

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk WARNING − Pressurised vessel. WARNING − Hot surface.

WARNING − Pressurised component or system. WARNING − Air/gas ow or Air discharge. Do not breathe the compressed air from this

machine.

Use fork lift truck from this side only. RESET Do not use fork lift truck from this side.

O (power).On (power).Emergency Stop.

Read the Operation and Maintenance manual

before operation or maintenance of this

machine is undertaken.

Do not operate the machine without the guard

being tted.

Lifting point.

ROTATION AIR DISCHARGE COOLANT FILTER

DECALS

ISO SYMBOLS

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

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OPERATION AND MAINTENANCE MANUAL DECALS

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DECALS OPERATION AND MAINTENANCE MANUAL

DANGER

WARNING

ANSI SYMBOLS

GRAPHIC FORM AND MEANING OF ANSI SYMBOLS

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.

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 ammable liquids and vapors which can result in serious injury. Never operate the compressor near ammable liquids or vapors. If used to spray ammable materials, keep compressor at least 20ft (6m) away from the spray area.

HIGH PRESSURE AIR. Rusted tanks can cause explosion and severe injury or death. Receiver under pressure. Operator should relieve tank pressure before performing maintenance. In addition to automatic drain, operate manual drain valve weekly. Manual drain valve located at bottom of the tank.

MOVING PARTS. Can cause serious injury. Do not operate with guards removed. Machine may start automatically. Disconnect power before servicing. Lockout/Tagout machine.

HOT SURFACES. Can cause serious injury. Do not touch. Allow to cool before servicing. Do not touch hot compressor or tubing.

EXPOSED MOVING BELTS AND SHEAVES. Can cause severe injury or death. Do not operate without guard in place. Disconnect power before servicing. Lockout/Tagout machine.

Air ow exhaust may contain ying debris. Safety protection should be worn at all times.

Pinch point hazard. Keep hands clear.

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OPERATION AND MAINTENANCE MANUAL DECALS

Item ccn Qty. Description Item ccn Qty. Description

1 93166502 1 Decal, replacement element 12 92867498 1 2 92867530 1 Decal, warning hot surface 3 3 Decal, voltage 13 22547145 1 Decal, total air system 4 93166460 1 Decal, coolant drain Dryer packages only 5 92960593 2 Decal, warning hazardous 14 22459200 1 Tag, rotation

voltage 15 SPEC 1 Specications, compressor 6 93166478 1 Decal, condensate drain package 7 22530331 1 Decal, dryer bypass instruction 16 93166486 1 Decal, power inlet 8 23353196 1 Decal, maintenance parts 17 22141311 1 Decal, place to cover hole 9 92930585 1 Decal, pressurized vessel 18 22604276 1 Decal, multiple wiring circuit

10 93165983 1 Decal, rotation direction Dryer packages only 11 92867407 2 Decal, do not inhale 19 93493641 1 Decal, start up warning

Decal, notice air discharge Base mount only

Contd....

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DECALS OPERATION AND MAINTENANCE MANUAL

Item ccn Qty. Description Item ccn Qty. Description

20 93165959 1 Decal, use guards when

running

21 1 Decal, wiring schematic

diagram

22 93171262 1 Decal, lift here both sides

Base mount only

23 22913032 1 Decal, Ingersoll Rand logo

Base mount only

22435713 1 Decal, Ingersoll Rand logo

Receiver mount only

24 92930668 1 Decal, no maintenance before

referring to manual

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25 22417109 1 Decal, facia

Rectangular hourmeter

22529291 1 Decal, facia

Round hourmeter

26 23038474 1 Decal, Ingersoll Rand logo

27 22454060 1 Decal, belt

28 Tank mount option

29 54618681 1 Decal, condensate drain

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OPERATION AND MAINTENANCE MANUAL SAFETY

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.

CAUTION

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 specication of this machine is such that the machine is not suitable for use in ammable 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 lters can be hazardous. Their safety can be aected by either synthetic lubricants, or the additives used in mineral oils. Ingersoll Rand recommends that only lters 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.

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, eective isolation valves must be tted 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 conned space, adequate ventilation must be provided.

When using compressed air always use appropriate personal protective equipment.

All pressure containing parts, especially exible 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.

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SAFETY OPERATION AND MAINTENANCE MANUAL

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

WARNING

Any electrical connections or adjustments should only be made by a suitably qualied electrician

Close and lock all access doors when the compressor is left unattended.

Do not use extinguishers intended for Class A or Class B res on electrical res. Use only extinguishers suitable for class BC or class ABC res.

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.

When loading or transporting machines ensure that the specied 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.

For further information, consult Material Data Sheets for ULTRA.

The above information contains data supplied in support of United Kingdom Control of Substances

Hazardous to Health (C.O.S.H.H.) regulations.

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OPERATION AND MAINTENANCE MANUAL GENERAL INFORMATION

22426035

REV F

GENERAL INFORMATION

PIPING AND INSTRUMENTATION

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Page 14

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GENERAL INFORMATION OPERATION AND MAINTENANCE MANUAL

KEY

1 Filter, air 21 Gauge, pressure 2 Valve, air inlet 22 Valve, relief (sirc) 3 Air end assembly 23 Filter, general purpose air

4 Motor 24 Filter, high eciency air 5 Relay, motor overload 25 Valve, check 6 Tank, separator - coarse 26 Recuperator 7 Tank, separator - ne 27 Valve, isolation (option) 8 Valve, minimum pressure 28 Moisture separator 9 Aftercooler 29 Valve, check 10 Valve, blowdown 30 Evaporator 11 Switch, pressure 31 Indicator, dew point 12 Switch, temperature 32 Valve, condensate 13 Filter, coolant 33 Tube, capillary 14 Thermostat 34 Filter drier, refrigerant 15 Cooler, oil 35 Condenser 16 Valve, pilot 36 Valve, hot gas bypass 17 Valve, relief 37 Compressor, refrigerant

18 Valve, drain 38 Valve, auto drain 19 Screen, scavenge 39 Receiver, air 20 Valve, solenoid 40 Filter

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OPERATION AND MAINTENANCE MANUAL GENERAL INFORMATION

SCHEMATIC, ELECTRICAL UP6 5–15HP FV 3PH 60Hz DOL – U.S.A.

KEY

1FU, 2FU, 3FU

4FU, 5FU Fuse M Coil motor starter 1Ma Contact, auxiliary starter MIO Indicator, maintenance option

1Mb Contact, auxiliary starter MOT Motor CPT Transformer, control

CR Relay, control PS Switch, pressure CRa Contact, control relay ST Push button, start CS Customer supplied 115v / 1 / 60hz TP Terminal points DO Dryer option TS To supply DM Motor, dryer W Standby light EDV Valve, electric drain 120/1/50–60 E-STOP Button, emergency stop 1. (*) Furnished, mounted and wired outside of control

G Power on light 2. Circuit shown in normal position de–energized. HM Hourmeter 3. All wiring to be marked in accordance with this

HM1

Fuse control circuit HATS Switch, high air temperature

(Instead of standard hourmeter)

OL Overload, motor starter 120/1/50–60 See transformer nameplate for wiring connection requirements

NOTES

panel, if required by order.

schematic.

Indicator, maintenance 4. All wiring to be in accordance with NEC.

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Page 16

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GENERAL INFORMATION OPERATION AND MAINTENANCE MANUAL

SCHEMATIC, ELECTRICAL UP6 5–15HP SD 3PH 60Hz

KEY

1FU, 2FU Fuse, primary HATS Switch, high air temperature 3FU Fuse, secondary HM Hourmeter 4FU, 5FU Fuse, dryer HM1 Indicator, maintenance 1LT Light, power on indicator (green) MIO Indicator, maintenance option

(Instead of standard hourmeter) 2LT Light, auto restart indicator (white) MTR Motor, compressor 1M Contactor, main OL Overload, main motor 1Ma, b, c Contacts, auxiliary. Main contactor OLa Contact, main motor overload 2M Contactor, delta PS Switch, pressure 2Ma, b Contacts, auxiliary. Delta contactor ST Push button, start 1S Contactor, star T D Relay, delta starting (10sec) 1Sa, b Contacts, auxiliary. Star contactor TDc Relay, delay o, contact 1SV Valve, solenoid (nc) CPT Transformer, control CR Relay, control 1. (*) Furnished, mounted and wired outside of control

CRa Contact, control relay 2. Circuit shown in normal position de–energized. CS Customer supplied 115v / 1 / 60hz 3. All wiring to be marked in accordance with this

DM Motor, dryer 4. All wiring to be in accordance with NEC. DO Dryer option EDV Valve, electric drain (optional) E–STOP Switch, emergency stop

NOTES

panel, if required by order.

schematic.

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OPERATION AND MAINTENANCE MANUAL GENERAL INFORMATION

SCHEMATIC, ELECTRICAL UP6 5–15HP FV 1PH 60Hz - U.S.A.

KEY

1FU, 2FU, 3FU

4FU, 5FU Fuse, dryer MIO Indicator, maintenance option 1Ma Contact, auxiliary starter (Instead of standard hourmeter)

1Mb Contact, auxiliary starter MTR Motor,compressor CPT Transformer, control 120/1/50–60 see OL Overload, motor starter

CR Relay, control TP Terminal points CRa Contact, control relay TS To supply CS Customer supplied 115v / 1 / 60hz W Standby light DM Motor, dryer DO Dryer option 1. (*) Furnished, mounted and wired outside of control

EDV Valve, electric drain 2. Circuit shown in normal position de–energized. E-STOP Switch, emergency stop 3. All wiring to be marked in accordance with this

G HM Hourmeter HM1 Indicator, maintenance

Fuse control circuit M Coil motor starter

Transformer nameplate for wiring PS Switch, pressure Connection requirements ST Push button, start

NOTES

panel, if required by order.

schematic.

Power on light 4. All wiring to be in accordance with NEC.

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Page 18

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GENERAL INFORMATION OPERATION AND MAINTENANCE MANUAL

SCHEMATIC, ELECTRICAL UP5 5–15HP FV 3PH 50Hz DOL

KEY

1FU Fuse, secondary MIO Indicator, maintenance option

(Instead of standard hourmeter) 2FU, 3FU Fuse, primary MM Motor, compressor 4FU, 5FU Fuse, dryer MOL Overload, main motor CR Relay, control MOL-1 Contact, main motor overload CS Customer supplied 230v / 1 / 50hz PS Switch, pressure DM Motor, dryer ST Push button, start DO Dryer option T1 Transformer, control EDV Valve, electric drain TP Terminal points ES Switch, emergency stop TS To supply HATS Switch, high air temperature HM Hourmeter HM1 KM Contactor, main 1. (*) Furnished, mounted and wired outside of

KM–1,2 Contacts, auxiliary. Main contactor 2. Circuit shown in normal position de–energized. LT1 Light, power on indicator (green) 3. All wiring to be marked in accordance with this

LT2

Indicator, maintenance

NOTES

control panel, if required by order.

schematic.

Light, auto restart indicator (white) 4. All wiring to be in accordance with NEC.

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OPERATION AND MAINTENANCE MANUAL GENERAL INFORMATION

SCHEMATIC, ELECTRICAL UP5 5–15HP SD 3PH 50Hz

KEY

1SV Valve, solenoid (nc) KM2-1,2 Contacts, auxiliary. Delta contactor CR Relay, control KM3 Contactor, star CR-1 Contact, control relay KM3-1,2 Contacts, auxiliary. Star contactor CS Customer supplied 230v / 1 / 50hz LT1 Light, power on indicator (green) DM Motor, dryer LT2 Light, auto restart indicator (white) DO Dryer option MIO Indicator, maintenance option EDV Valve, electric drain (Instead of standard hourmeter) HATS Switch, high air temperature MOL Overload, main motor HM Hourmeter MOL-1 Contact, main motor overload HM1 Indicator, maintenance ST Push button, start MM Motor, compressor T1 Transformer, control P Switch, pressure TM1 Relay, delta starting (10sec) ES Switch, emergency stop TM1-1 Relay, delay o, contact FU1, FU2 Fuse, primary FU3 Fuse, secondary FU4, FU5 Fuse, dryer 1. (*) Furnished, mounted and wired outside of

KM1 Contactor, main 2. Circuit shown in normal position de–energized. KM-1,2,3 Contacts, auxiliary. Main contactor 3. All wiring to be marked in accordance with this

KM2

Contactor, delta 4. All wiring to be in accordance with NEC.

NOTES

control panel, if required by order.

schematic.

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INSTALLATION / HANDLING OPERATION AND MAINTENANCE MANUAL

WITH

OPTIONAL

OUTDOOR MOD.

WITH

OPTIONAL

OUTDOOR MOD.

ROTATION

VIEW TOP

VIEW LEFT

VIEW RIGHT

VIEW FRONT

INSTALLATION/HANDLING

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OPERATION AND MAINTENANCE MANUAL INSTALLATION / HANDLING

KEY

A Package pre-ller M Motor B Hole, incoming power supply conduit N Integrated dryer (Optional) C Gauge, pressure O Compressor and cooling air intake D Yellow stand–by light P Filter, coolant E Green power–on light Q Cartridge, coolant separator F Green start push button R Valve, airend relief G Emergency stop button S Plug, coolant ller H Hourmeter T Sight–glass I Starter box U Plug, coolant drain J Lifting points V Valve, pilot K Mounting holes (4 x 14.0mm [0.550”] diameter) W Switch, pressure L Filter, air inlet X Cooling air exhaust

NOTES

1. Foundation or oor must be level and support all mounting bolt locations equally. If necessary, shim or grout the fourth bolt location.

2. Foundation bolts should protect thru nuts a minimum of 13mm (0.50”) to allow for levelling.

3. Allow a minimum clearance of 1100mm (42”) on the front and 920mm (36”) on the top, left right and rear of the package for proper air circulation and serviceability.

4. Approximate package weight: 298kg (655lbs).

5. External piping shall not exert any unresolved moments or forces on the unit. Use pipe size as large or larger at discharge connection.

6. There should be no plastic or pvc piping attached to this unit or used for any lines downstream.

7. Do not pipe into a common header with a reciprocating compressor, unless the reciprocating compressor utilizes a discharge pulsation damper.

8. Sizing of electrical components not supplied by Ingersoll Rand is the responsibility of the customer and should be done in accordance with the information on the compressor data plate and national and local electrical codes.

All dimensions are in millimetres (inches) unless otherwise stated.

Ensure that the correct fork lift truck slots or marked lifting points are used whenever the machine is lifted or transported.

UNPACKING

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

Ensure that all transport and packing materials are discarded in a manner prescribed by local codes.

NOTE

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INSTALLATION / HANDLING OPERATION AND MAINTENANCE MANUAL

UP-SERIES TANK MOUNTED (80 GAL)

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OPERATION AND MAINTENANCE MANUAL INSTALLATION / HANDLING

KEY

A Package pre-ller P Filter, coolant B Hole, incoming power supply conduit Q Cartridge, coolant separator C Gauge, pressure R Valve, airend relief D Yellow stand–by light S Plug, coolant ller E Green power–on light T Sight–glass F Green start push button U Plug, coolant drain G Emergency stop button V Valve, pilot H Hourmeter W Switch, pressure I Starter box X Cooling air exhaust J Lifting points 1A Valve, ball 0.75” N.P.T. K Mounting holes (4 x 17.5mm [0.68”] x 44.5mm

[1.75”] slots)

L Filter, air inlet 1C Location for manual receiver drain M Motor 1D Valve, receiver relief N Integrated dryer (Optional) 1E 0.25” discharge port for optional electric drain valve O Compressor and cooling air intake

1B Air receiver (Ø 620.0mm x 1168.4mm LG) ( Ø 24.40”

x 46.00” LG)

NOTES

1. Foundation or oor must be level and support all mounting bolt locations equally. If necessary, shim or grout the fourth bolt location.

2. Foundation bolts should protect thru nuts a minimum of 13mm (0.50”) to allow for levelling.

3. Allow a minimum clearance of 1100mm (42”) on the front and 920mm (36”) on the top, left right and rear of the package for proper air circulation and serviceability.

4. Approximate package weight: 420kg (925lbs).

5. External piping shall not exert any unresolved moments or forces on the unit. Use pipe size as large or larger at discharge connection.

6. There should be no plastic or pvc piping attached to this unit or used for any lines downstream.

7. Do not pipe into a common header with a reciprocating compressor, unless the reciprocating compressor utilizes a discharge pulsation damper.

NOTE

All dimensions are in millimetres (inches) unless otherwise stated.

Ensure that the correct fork lift truck slots or marked lifting points are used whenever the machine is lifted or transported.

UNPACKING

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

Ensure that all transport and packing materials are discarded in a manner prescribed by local codes.

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INSTALLATION / HANDLING OPERATION AND MAINTENANCE MANUAL

UP-SERIES TANK MOUNTED (120 GAL)

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OPERATION AND MAINTENANCE MANUAL INSTALLATION / HANDLING

KEY

[1.75”] slots)

1B Air receiver (Ø 618.0mm x 1701.0mm LG) ( Ø 24.33”

x 67.00” LG)

NOTES

1. Foundation or oor must be level and support all mounting bolt locations equally. If necessary, shim or grout the fourth bolt location.

2. Foundation bolts should protect thru nuts a minimum of 13mm (0.50”) to allow for levelling.

3. Allow a minimum clearance of 1100mm (42”) on the front and 920mm (36”) on the top, left right and rear of the package for proper air circulation and serviceability.

4. Approximate package weight: 430kg (946lbs).

5. External piping shall not exert any unresolved moments or forces on the unit. Use pipe size as large or larger at discharge connection.

6. There should be no plastic or pvc piping attached to this unit or used for any lines downstream.

7. Do not pipe into a common header with a reciprocating compressor, unless the reciprocating compressor utilizes a discharge pulsation damper.

NOTE

All dimensions are in millimetres (inches) unless otherwise stated.

Ensure that the correct fork lift truck slots or marked lifting points are used whenever the machine is lifted or transported.

UNPACKING

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

Ensure that all transport and packing materials are discarded in a manner prescribed by local codes.

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INSTALLATION / HANDLING OPERATION AND MAINTENANCE MANUAL

UP-SERIES TANK MOUNTED (272 LITRES)

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OPERATION AND MAINTENANCE MANUAL INSTALLATION / HANDLING

KEY

[1.75”] slots)

1B Air receiver ( Ø 600.0mm x 1111.0mm LG) ( Ø 23.62”

x 43.74” LG)

NOTES

1. Foundation or oor must be level and support all mounting bolt locations equally. If necessary, shim or grout the fourth bolt location.

2. Foundation bolts should protect thru nuts a minimum of 13mm (0.50”) to allow for levelling.

3. Allow a minimum clearance of 1100mm (42”) on the front and 920mm (36”) on the top, left right and rear of the package for proper air circulation and serviceability.

4. Approximate package weight: 400kg (880lbs).

5. External piping shall not exert any unresolved moments or forces on the unit. Use pipe size as large or larger at discharge connection.

6. There should be no plastic or pvc piping attached to this unit or used for any lines downstream.

7. Do not pipe into a common header with a reciprocating compressor, unless the reciprocating compressor utilizes a discharge pulsation damper.

NOTE

All dimensions are in millimetres (inches) unless otherwise stated.

Ensure that the correct fork lift truck slots or marked lifting points are used whenever the machine is lifted or transported.

UNPACKING

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

Ensure that all transport and packing materials are discarded in a manner prescribed by local codes.

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INSTALLATION / HANDLING OPERATION AND MAINTENANCE MANUAL

UP-SERIES TANK MOUNTED (500 LITRES)

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OPERATION AND MAINTENANCE MANUAL INSTALLATION / HANDLING

KEY

[1.75”] slots)

L Filter, air inlet 1C Location for manual receiver drain M Motor 1D Valve, receiver relief N Integrated dryer (Optional) 1E 0.25” discharge port for optional electric drain

O Compressor and cooling air intake

1B Air receiver (Ø 610.0mm x 1866.0mm LG) ( Ø 24.02”

x 73.46” LG)

valve

NOTES

1. Foundation or oor must be level and support all mounting bolt locations equally. If necessary, shim or grout the fourth bolt location.

2. Foundation bolts should protect thru nuts a minimum of 13mm (0.50”) to allow for levelling.

3. Allow a minimum clearance of 1100mm (42”) on the front and 920mm (36”) on the top, left right and rear of the package for proper air circulation and serviceability.

4. Approximate package weight: 455kg (1000lbs).

5. External piping shall not exert any unresolved moments or forces on the unit. Use pipe size as large or larger at discharge connection.

6. There should be no plastic or pvc piping attached to this unit or used for any lines downstream.

7. Do not pipe into a common header with a reciprocating compressor, unless the reciprocating compressor utilizes a discharge pulsation damper.

NOTE

All dimensions are in millimetres (inches) unless otherwise stated.

Ensure that the correct fork lift truck slots or marked lifting points are used whenever the machine is lifted or transported.

UNPACKING

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

Ensure that all transport and packing materials are discarded in a manner prescribed by local codes.

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INSTALLATION / HANDLING OPERATION AND MAINTENANCE MANUAL

KEY

Compressor

CAUTION

The use of plastic bowls on line lters and other

Air Receiver

Air Dryer

plastic air line components can be hazardous. Their safety can be aected by either synthetic coolants or the additives used in mineral oils.

Compressed air lters

System demand points

Ingersoll Rand recommends that only lters with metal bowls should be used on any pressurised system.

NOTE

Items [2] to [5] are optional or may be existing items of plant. Refer to your Ingersoll Rand distributor / representative for specic recommendations.

LOCATION IN THE PLANT

The compressor can be installed on any level oor capable of supporting it. A dry, well ventilated area where the atmosphere is clean is recommended. A minimum of 1m (3ft) should be left all around machine for adequate service access and ventilation.

Adequate clearance needs to be allowed around and above the machine to permit safe access for specied maintenance tasks.

The standard compressor unit is not suitable for operation in temperatures liable to cause freezing as Condensate water is liable to be produced in the after cooler and receiver where tted.

Refer to your Ingersoll Rand distributor for further information.

DISCHARGE PIPING

Discharge piping should be at least as large as the discharge connection of the compressor. All piping and ttings should be suitably rated for the discharge pressure.

CAUTION

Ensure that the machine is positioned securely and on a stable foundation. Any risk of movement should be removed by suitable means, especially to avoid strain on any rigid discharge piping.

It is essential when installing a new compressor [1], to review the total air system. This is to ensure a safe and eective total system. One item which should be considered is liquid carryover. Installation of air dryers [3] is always good practice since properly selected

CAUTION

Screw type compressors [1] should not be installed in air systems with reciprocating compressors without means of isolation such

and installed they can reduce any liquid carryover to zero.

It is good practice to locate an isolation valve close to the compressor and to install line lters [4].

as a common receiver tank. It is recommended that both types of compressor be piped to a common receiver using individual air lines.

It is a requirement for air dryers covered under AirCare that correctly sized Ingersoll Rand pre and afterlters are installed.

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OPERATION AND MAINTENANCE MANUAL INSTALLATION / HANDLING

60Hz UP6 5 UP6 7 UP6 10 UP6 15c

COMPRESSOR 125 150 210 125 150 210 125 150 210 125 150 210

Operating pressure PSIG (bar)

Factory set reload pressure PSIG (bar)

Flow rate CFM (m3/MIN)

Airend discharge temperature trip point.

Ambient operating temperature (min.) →(max.)

MOTOR

Motor enclosure ODP TEFC ODP TEFC ODP TEFC ODP TEFC Nominal power 5HP 7.5HP 10HP 15HP Speed 3500 RPM Insulation class F

GENERAL DATA

Residual coolant content

Separator vessel capacity

Coolant capacity 1.2 gallons (4.5 Litres) Sound pressure

level to CAGI-PNEUROP

Weight-base mount unit

Weight-80 gallon Receiver mounted

Weight-120 gallon Receiver mounted

CAUTION

230/460 Dual voltage machines are tted with a decal to advise the correct voltage as connected from the factory. There is a decal tted to the starter door describing the procedure to change the connections for the alternative

voltage. Rewiring should only be eected by a competent Electrician.

125

(8.6)

110

(7.58)

18.5

(0.52)

150

(10.3)

130

(8.96)

16.0

(0.45)

-- 125 (8.6)

-- 110

(7.58)

-- 28.0 (0.79)

150

(10.3)

130

(8.96)

25.0

(0.71)

210

(14.5)

180

(12.41)

17.5

(0.50)

125

(8.6)

110

(7.58)

38.0

(1.08)

150

(10.3)

130

(8.96)

(0.96)

210

(14.5)

180

(12.41)

24.0

(0.68)

(7.58)

(1.55)

228°F (109°C)

36°F (+2°C) → 105°F (+40°C)

3ppm (3 mg/m3)

0.8 gallons (3 Litres)

65 dB(A) 65 dB(A) 68 dB(A) 69 dB(A)

295kg (650lb)

420kg (925lb)

436kg (960lb)

125

(8.6)

110

55.0

150

(10.3)

130

(8.96)

50.0

(1.42)

210

(14.5)

180

(12.41)

38.0

(1.08)

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INSTALLATION / HANDLING OPERATION AND MAINTENANCE MANUAL

50Hz UP5 4 UP5 5 UP5 7 UP5 11c

COMPRESSOR 8 10 14.5 8 10 14.5 8 10 14.5 8 10 14.5

Operating pressure PSIG (bar)

Factory set reload pressure PSIG (bar)

Flow rate CFM (m3/MIN)

Airend discharge temperature trip point.

Ambient operating temperature (min.) →(max.)

MOTOR

Motor enclosure TEFC Nominal power 4KW 5.5KW 7.5KW 11KW Speed Insulation class F

GENERAL DATA

Residual coolant content

Separator vessel capacity

Coolant capacity 1.2 gallons (4.5 Litres) Sound pressure

level to CAGI-PNEUROP

Weight-base mount unit

Weight-272 LitresReceiver mounted

Weight-500 Litres Receiver mounted

115

(8)

100

(7.58)

19.5

(0.55)

145 (10)

125

(8.96)

16.0

(0.45)

210

(14.5)

-- 100

-- 29.0

115

(8)

(7.93)

(0.82)

145 (10)

125

(9.66)

26.0

(0.74)

(13.10)

210

(14.5)

180

18.0

(0.51)

115

(8)

100

(7.93)

38.0

(1.08)

228°F (109°C)

36°F (+2°C) → 105°F (+40°C)

2900 RPM

3ppm (3 mg/m3)

0.8 gallons (3 Litres)

65 dB(A) 65 dB(A) 68 dB(A) 69 dB(A)

295kg (650lb)

420kg (925lb)

454kg (1000lb)

145 (10)

125

(9.66)

(0.96)

210

(14.5)

180

(13.10)

24.0

(0.68)

115

(8)

100

(7.93)

56.5

(1.60)

145 (10)

125

(9.66)

50.0

(1.92)

210

(14.5)

180

(13.1)

38.0 (8.6)

DRYER ENGINEERING DATA 60Hz 50Hz

Electrical supply 115V - 1ph - 60Hz 230V - 1ph - 50Hz L.R.A. current (Amps) 30.0 12.6 F.L.A. current (Amps) 5.0 2.7

Total installed power (kW) 0.46 0.47 Electrical protection class (std) NEMA 1

(IP 20)

Factory refrigerant charge (lb/g) 0.78 lb

354 g

Regeration type 134 A

CAUTION

voltage. Rewiring should only be eected by a competent Electrician.

ELECTRICAL DATA-UP6 5

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OPERATION AND MAINTENANCE MANUAL INSTALLATION / HANDLING

Standard voltage 230V/1PH 200V 230V/3PH 460V 575V Full load current (maximum) 23.5A 15.5A 13.5A 6.8A 5.4A Starting current DOL (Star Delta) - - - - Starting time DOL (Star Delta) 3–5 Sec (7–10 Sec) Starts per hour (maximum) 6 Control voltage 120VAC Recommended fuse rating See note 1 40A 25A 20A 10A 8A Recommended wire size AWG See note 2 8 10 12 14 14

ELECTRICAL DATA-UP6 7.5

Standard voltage 230V/1PH 200V 230V/3PH 460V 575V Full load current (maximum) 34.1A 22.7A 19.7A 9.9A 7.9A Starting current DOL (Star Delta) - - - - Starting time DOL (Star Delta) 3–5 Sec (7–10 Sec) Starts per hour (maximum) 6 Control voltage 120VAC Recommended fuse rating See note 1 50A 35A 35A 15A 12A Recommended wire size AWG See note 2 6 8 10 14 14

ELECTRICAL DATA-UP6 10

Standard voltage 230V/1PH 200V 230V/3PH 460V 575V Full load current (maximum) - 29.8A 26.0A 13.0A 10.3A Starting current DOL (Star Delta) - - - - Starting time DOL (Star Delta) 3–5 Sec (7–10 Sec) Starts per hour (maximum) 6 Control voltage 120VAC Recommended fuse rating See note 1 - 50A 45A 20A 15A Recommended wire size AWG See note 2 - 8 8 12 14

ELECTRICAL DATA-UP6 15c

Standard voltage 230V/1PH 200V 230V/3PH 460V 575V Full load current (maximum) - 43.2A 37.6A 18.8A 15.1A Starting current DOL (Star Delta) - - - - Starting time DOL (Star Delta) 3–5 Sec (7–10 Sec) Starts per hour (maximum) 6 Control voltage 120VAC Recommended fuse rating See note 1 - 75A 65A 30A 25A Recommended wire size AWG See note 2 - 4 6 10 10

1. If a circuit breaker is selected it should only be a magnetic trip type, set above the anticipated starting current of the machine, but below the maximum prospective fault current for the circuit. The circuit breaker or fuseable disconnect must be capable of breaking the prospective fault current at its terminals.

2. PVC/PVC Type Calculated using the following conditions:

PVC insulated cable, armoured, copper

conductors.

Cable clipped to a wall, in free air.

ii)

Ambient temperature of 40°C (104°F) and relative

iii)

20m (65ft) cable run.

iv)

Volt drop limited to –10% during starting, –4%

during normal running.

Protected by the circuit breaker listed above.

vi)

humidity of 40%.

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INSTALLATION / HANDLING OPERATION AND MAINTENANCE MANUAL

ELECTRICAL DATA-UP5 4

Standard voltage 380V 400V Full load current (maximum) 8.9A 8.5A Starting current DOL (Star Delta) 66 63 Starting time DOL (Star Delta) 3–5 Sec (7–10 Sec) Starts per hour (maximum) 6 Control voltage 120VAC Recommended fuse rating See note 1 16A 16A Recommended wire size See note 2 4 mm2Cu 4 mm2 Cu

ELECTRICAL DATA-UP5 5.5

Standard voltage 380V 400V Full load current (maximum) 11.8A 11.2A Starting current DOL (Star Delta) 100 95 Starting time DOL (Star Delta) 3–5 Sec (7–10 Sec) Starts per hour (maximum) 6 Control voltage 120VAC Recommended fuse rating See note 1 16A 16A Recommended wire size See note 2 4 mm2Cu 4 mm2 Cu

ELECTRICAL DATA-UP5 7.5

Standard voltage 380V 400V Full load current (maximum) 16.9A 15.6A Starting current DOL (Star Delta) 121 (94) 114 (52) Starting time DOL (Star Delta) 3–5 Sec (7–10 Sec) Starts per hour (maximum) 6 Control voltage 120VAC Recommended fuse rating See note 1 20A 20A Recommended wire size See note 2 4 mm2Cu 4 mm2 Cu

ELECTRICAL DATA-UP5 11c

Standard voltage 380V 400V Full load current (maximum) 23.0A 21.9A Starting current DOL (Star Delta) (79) (75) Starting time DOL (Star Delta) 3–5 Sec (7–10 Sec) Starts per hour (maximum) 6 Control voltage 120VAC Recommended fuse rating See note 1 32A 32A Recommended wire size See note 2 6 mm2Cu 6 mm2 Cu

2. PVC/PVC Type Calculated using the following conditions:

PVC insulated cable, armoured, copper

conductors.

ii)

Cable clipped to a wall, in free air.

iii)

Ambient temperature of 40°C (104°F) and relative humidity of 40%.

iv)

20m (65ft) cable run.

Volt drop limited to –10% during starting, –4% during normal running.

vi)

Protected by the circuit breaker listed above.

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OPERATION AND MAINTENANCE MANUAL INSTALLATION / HANDLING

If there are any deviations from the above, or special regulations apply, the installation must be planned by a competent, qualied engineer.

NOTE

All data applies to standard product only.

ELECTRICAL DATA

An independent electrical isolator or disconnect should be installed adjacent to the compressor.

Feeder cables/wires should be sized by the customer/ electrical contractor to ensure that the circuit is balanced and not overloaded by other electrical equipment. The length of wiring from a suitable electrical feed point is critical as voltage drops may impair the performance of the compressor.

Feeder cables / wires connections to isolator or disconnect should be tight and clean.

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

The control circuit transformer has dierent voltage tappings. Ensure that these are set for the specic 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 electronic controller (where tted).

CAUTION

Ensure that the motor rotates in the correct direction as indicated by direction arrows.

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OPERATING INSTRUCTIONS OPERATION AND MAINTENANCE MANUAL

OPERATING INSTRUCTIONS

GENERAL OPERATION

The compressor is an electric motor driven, single stage screw compressor, complete with accessories piped, wired and base plate mounted. It is a totally self contained air compressor package.

The standard compressor is designed to operate in an ambient range of 35.6°F - 104°F (2°C to 40°C). The maximum temperature is applicable up to a maximum elevation of 3280ft (1000m) above sea level. Above this altitude signicant reduction in maximum allowable ambient temperature is required.

Compression in the screw type air compressor is created by the meshing of two (male & female) helical rotors.

The air/coolant mixture discharges from the compressor into the separation system. This system removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the cooling system and the air passes through the aftercooler and out of the compressor.

Cooling air is moved through the coolers by the cooling fan and discharged from the machine.

CAUTION

Cooling air is drawn in at the rear of the machine package passing through the lter and cooler before being discharged from the top of the machine. Care should be taken to avoid blocking the airow, or causing any restriction in excess of the maximum backpressure allowed for ducting.

WARNING

When the unit stops running as the result of low air demand, it may restart and return to load at any time.

Safety of operation is provided as the compressor will shut down if excessive temperatures or electrical overload conditions should occur.

CAUTION

This unit is not designed or intended to operate when contaminated with silicone. Lubricants, greases or other items containing silicone should not be used on this unit.

CAUTION

LOW DEMAND APPLICATIONS During periods of low demand, the compressor may not reach its normal operating temperature. Sustained operation at low demand can result in the build up of condensate in the coolant. If this situation occurs, the lubricating characteristics of the coolant can be impaired which may lead to damage of the compressor.

THE COMPRESSOR SHOULD BE ALLOWED AMPLE LOADED RUNNING TIME OF AT LEAST 10 MINUTES PER HOUR DURING NORMAL DAILY USE.

Do not direct the airow at face or eyes.

By cooling the discharge air, much of the water vapour naturally contained in the air is condensed and may be drained from the downstream piping and equipment.

The coolant system consists of a sump, cooler, thermostatic valve and a lter. When the unit is operating, the coolant is pressurized and forced to the compressor bearings.

The compressor load control system is automatic on- o line. This allows the compressor to maintain a set discharge line pressure by varying output capacity to match the system demand. The unit is provided with an automatic stop and restart system for use in plants where the air demand varies suciently to allow a compressor to shut down and save power. Signicant system volume will assist this and is recommended.

When the compressor is equipped with the optional dryer, the dryer will cycle on and o with the compressor.

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Page 37

OPERATION AND MAINTENANCE MANUAL OPERATING INSTRUCTIONS

A. Upper Pressure Setting B. Pressure Differential

Auxiliary Valve.

A. Knob B. Clockwise C. Counterclockwise

COMPRESSOR CONTROLS

Direct online starting:

The compressor is equipped for Automatic Start & Stop Control. When the receiver tank pressure reaches the factory pre–set maximum pressure, the pressure switch stops the unit. When the receiver tank pressure drops below the factory pre–set minimum. The pressure switch resets and restarts the unit.

The pressure switch cover can be removed by unscrewing the two screws holding the cover.

Pressure switch adjustment:

The compressor package will cut–in and cut–out at factory preset pressure settings. Adjust the pressure switch only if absolutely necessary.

Adjustments are to be carried out only when the switch is mounted, under pressure and voltage–free.

WARNING

High voltage is present at the pressure switch contacts when the power supply is connected. Disconnect, lock and tag main power supply before making adjustments.

WARNING

AUTOMATIC START & STOP CONTROL

NOTE

Automatic Start & Stop Control is intended for use when the motor will start no more than 6 times per hour.

When the receiver tank pressure reaches the factory pre–set maximum pressure, the pressure switch stops the unit. When the receiver tank pressure drops below the factory pre–set minimum, the pressure switch resets and restarts the unit.

DUAL CONTROL

Select either automatic start and stop control or constant speed control by adjusting the knob on the auxiliary valve. For automatic start and stop control, turn the knob on the auxiliary valve fully clockwise to disable the auxiliary valve. The pressure switch will then start and stop the unit.

Do not adjust the pressure switch to exceed the maximum discharge pressure of the unit.

NOTE

When replacing the pressure switch cover, ensure the selector knob on the cover and the lever on the switch are both in the ”OFF” position.

NOTE

When the compressor is equipped with the optional dryer and lters, the pressure switch dierential should be increased 10psi to account for the added pressure drop of the lters and dryer.

Select constant speed control if the unit restarts in less than 10 minute intervals or runs more than 40 minutes per hour. Turn the knob fully counterclockwise to run the unit continually.

NOTE

The auxilIary valve is factory pre–set at 5 psig (0,3 bar) lower than the factory pressure switch setting.

CAUTION

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Running unloaded with no air demand, will cause the unit to be shuto by the pressure switch.

Page 38

OPERATING INSTRUCTIONS OPERATION AND MAINTENANCE MANUAL

1. PRESSURE GAUGE

Indicates the system pressure.

WARNING

DO NOT operate the compressor at discharge pressures exceeding the maximum operating pressure.

2. HOURMETER

Records the total running time of the compressor.

3. STOP BUTTON / EMERGENCY STOP

When depressed will stop the compressor immediately. The ’Power on’ indicator will remain illuminated. The STOP button must be released before the compressor can be restarted.

4. ON PUSH BUTTON SWITCH

When depressed will cause the unit to start and run in a loaded condition if there is a demand for air. If there is no demand, the machine will stop automatically.

5. POWER ON INDICATOR LIGHT (Green)

Indicates the presence of control voltage.

6. STOPPED/AUTO RESTART INDICATOR LIGHT (Amber)

Will illuminate when the machine has shut-down due to low air demand. The machine will restart and load automatically as soon as the demand for air returns.

7. DEW POINT INDICATOR (Dryer Option) Green indicates good dew point. Red indicates ew point above 50°F (10°C) Blue indicates freezing.

PRIOR TO STARTING

1. Make visual check of the machine, ensure that all guards secure and that nothing is obstructing the proper ventilation of, or free access to the machine.

2. Check coolant level. Add if necessary.

3. Make sure air discharge valve is open.

4. Turn on electrical isolator or disconnect. The Power on (5) indicator will light, indicating that line and control voltages are available.

5. Check direction of rotation at initial start or following interruption in power supply.

WARNING

Make sure that all protective covers are in place.

Cooling air ow exhaust may contain ying debris. Safety protection should be worn at all times to avoid injury.

STARTING

1. Press the START button. The compressor will start and then load automatically.

NORMAL/EMERGENCY STOPPING

1. Press STOP button (3) and the compressor will stop immediately.

2. Turn o electrical isolator or disconnect.

CAUTION

After shutdown never allow unit to stand idle with pressure in receiver/separator system.

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Page 39

OPERATION AND MAINTENANCE MANUAL MAINTENANCE

MAINTENANCE

MAINTENANCE SCHEDULE

UP Series Maintenance Schedule

PERIOD MAINTENANCE

Each 24 hours operation Check the coolant level and replenish if necessary. Visual check of machine for any leaks,

dust build up or unusual noise or vibration

When compressor is receiver mounted Drain air receiver of condensate, or check that automatic drain is

Visual check condition of package prelter

First 150 hours Change the coolant lter. Each month or 100 hours Remove and clean package pre-lter, replace if needed

Each year or 2000 hours Check the operation of the high temperature protection switch (109˚C).

1 year external and 6 years internal pressure vessel inspection. Frequency may be otherwise dened by local or national legislation.

Every two years or 8000 hours Change drive belts.

Every 4 years or 16000 hours Replace all hoses.

Report immediately, contact Ingersoll Rand authorized distributor for assistance if in doubt.

operating. Blow clean if needed.

Check the cooler(s) for build up of foreign matter. Clean if necessary by blowing out with air or by pressure washing.

Replace elements in IRGP and IRHE lters. Change the coolant lter. Check scavenge screen for blockage, clean if required. Change the separator element. Change the Air Filter element. Take coolant sample for uid analysis. Change the package pre–lter. Check Drive Belts. Motors without grease ttings - Replace sealed bearings

Separator vessel and air receiver when tted.

Fully inspect all external surfaces, and ttings. Report any excessive corrosion, mechanical or impact damage, leakage or other deterioration.

Replace the Ultra at whichever interval occurs rst. Check and replace all items included within 2000 hour service. Fit the following reconditioning parts as appropriate:

Solenoid valves Inlet valve kit Minimum Pressure valve kit Thermostatic Valve Kit

Check motors with grease ttings and grease per motor data tag Fit replacement electrical contactor tips. Motors without grease ttings - Replace sealed bearings

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Page 40

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MAINTENANCE OPERATION AND MAINTENANCE MANUAL

ROUTINE MAINTENANCE

This section refers to the various components which require periodic maintenance and replacement.

It should be noted that the intervals between service requirement may be signicantly reduced as a consequence of poor operating environment. This would include eects of atmospheric contamination and extremes of temperature.

The SERVICE/MAINTENANCE CHART indicates the various components’ descriptions and the intervals when maintenance has to take place. Oil capacities, etc., can be found in the GENERAL INFORMATION section of this manual.

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.

CAUTION

Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Vent pressure from the unit by slowly unscrewing the coolant ll cap one turn. Unscrewing the ll cap opens a vent hole, drilled in the cap, allowing pressure to release to atmosphere. Do not remove the ll cap until all pressure has vented from the unit. Also vent piping by slightly opening the drain valve. When opening the drain valve or the coolant ll cap, stand clear of the valve discharge and wear appropriate eye protection.

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

Prior to attempting any maintenance work, ensure that:-

all air pressure is fully discharged and isolated

•

from the system. If the automatic blowdown valve is used for this purpose, then allow enough time for it to complete the operation.

•

the machine cannot be started accidentally or otherwise.

•

all residual electrical power sources (mains and battery) are isolated.

Prior to opening or removing panels or covers to work inside a machine, ensure that:-

anyone entering the machine is aware of the

•

reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts.

•

the machine cannot be started accidentally or otherwise.

Prior to attempting any maintenance work on a running machine, ensure that:-

DANGER

Only properly trained and competent persons should undertake any maintenance tasks with the compressor running or with electrical power connected.

•

the work carried out is limited to only those tasks which require the machine to run.

•

the work carried out with safety protection devices disabled or removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed.

•

all hazards present are known (e.g. pressurised components, electrically live components, removed panels, covers and guards, extreme temperatures, inow and outow of air, intermittently moving parts, safety valve discharge etc.).

•

appropriate personal protective equipment is worn.

•

loose clothing, jewellery, long hair etc. is made safe.

•

warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen.

Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:-

•

the machine is suitably tested.

•

all guards and safety protection devices are retted and correctly working.

•

all panels are replaced, canopy and doors closed.

•

hazardous materials are eectively contained and disposed of in a manner compliant with local or National environmental protection codes.

Page 41

OPERATION AND MAINTENANCE MANUAL MAINTENANCE

A. Correct at operating temperature B. Too much C. OK D. Too little

WARNING

Do not under any circumstances open any drain valve or remove components from the compressor without rst ensuring that the compressor is FULLY SHUT- DOWN, power isolated and all air pressure relieved from the system.

TOP UP COOLANT PROCEDURE

Slowly remove ll cap.

Pour coolant into spout untill spout almost

2. overows.

Replace and tighten oil ll cap.

Start unit for about 10 seconds (until coolant

4. drains out the bottom of the sight glass).

Slowly remove ll cap.

Re–ll into spout until spout almost overows.

Replace and tighten oil ll cap.

Run unit.

NOTE

Coolant level is correct when a unit is showing coolant in bottom half of sight glass when up to operating temperature (ten minutes running loaded).

COOLANT CHANGE PROCEDURE

It is better to drain the coolant immediately after the compressor has been operating as the liquid will drain more easily and any contaminant will still be in suspension.

Stop the machine, electrically isolate and vent all

1. trapped pressure.

Place a suitable container close to the drain valve.

Slowly remove ll cap.

Remove plug from drain valve.

Open the drain valve and drain coolant into

5. container.

Close the drain valve.

Replace plug in drain valve.

Rell the machine following the ”top up coolant”

8. procedure above. After initial ll, to purge any airlocks, the machine should be run for a few minutes cycling between load and no load, before checking that the level is correct.

Replace and tighten oil ll cap.

COOLANT FILTER CHANGE PROCEDURE

Stop the machine, electrically isolate and vent all

1. trapped pressure.

Loosen lter with the correct tool.

Repeat this procedure to get coolant to proper level when up to operating temperature. When the unit is shut down, coolant will usually ll up sight glass. Do not adjust level based on level at shutdown. Proper level is always set for a running unit at operating temperature.

CAUTION

Ensure that SSR ULTRA is used. Failure to do so will void manufacturers warranty.

Remove the lter from the housing.

Place the old lter in a sealed bag and dispose of

4. in a safe way.

Clean the mating face of the housing taking care

5. to avoid any particles entering the machine.

Remove the new Ingersoll Rand replacement

6. lter from its protective package.

Apply a small amount of lubricant to the lter

7. seal.

Screw the new lter down until the seal makes

8. contact with the housing, then hand tighten a further half turn.

Start the compressor and check for leaks.

AIR FILTER ELEMENT CHANGE PROCEDURE

Stop the machine, electrically isolate and vent all

1. trapped pressure.

Unscrew the retaining cap and withdraw the old

2. element.

Fit the new element.

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Replace the retaining cap.

Page 42

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MAINTENANCE OPERATION AND MAINTENANCE MANUAL

Clean the cooler.

SEPARATOR ELEMENT CHANGE PROCEDURE

Stop the machine, electrically isolate and vent all

1. trapped pressure.

Loosen separator element with the correct tool.

Remove the element from the housing; place it in

3. a sealed bag and dispose of it safely.

Clean the mating face of the housing.

Remove the new Ingersoll Rand replacement

5. element from its protective package.

Apply a small amount of lubricant to the element

6. seal.

Screw the new element down until the seal

7. makes contact with the housing, then hand tighten a further half turn.

Start the compressor and check for leaks.

CAUTION

This unit is not designed or intended to operate when contaminated with silicone. Lubricants, greases or other items containing silicone should not be used on this unit.

COOLER CLEANING PROCEDURE

Stop the machine, electrically isolate and vent all

1. trapped pressure.

Rebuild in reverse order.

BELT CHECKING AND ADJUSTMENT PROCEDURE

Check belt tension occasionally, especially if looseness is suspected. A quick check to determine if adjustment is proper may be made by observing the slack side of the belt for a slight bow when the unit is in operation. If a slight bow is evident, the belt is usually adjusted satisfactorily.

A belt tension measurement device can be used to determine the tension of the belt.

Belt tensioning can be achieved by loosening the airend anchor screws, a belt tensioning bolt is provided to aid in moving the airend.

Follow the procedures outlined below to correctly set and measure belt tension.

1. Lay a straight edge across the top outer surface of the belt drive from pulley to sheave.

2. At the center of the span, perpendicular to the belt, apply pressure to the outer surface of the belt with a tension gauge. Force the belt to the deection indicated in the table below, and compare the reading on the tension gauge to the gures shown.

Remove the top cover to obtain access to the

2. cooler.

BELT TENSION

New Used New Used New Used New Used 60hz 125 psig 75 Lb

(34 Kg)

150 psig 75 Lb

(34 Kg)

210 psig 75 Lb

(34 Kg) 50hz 8 bar 85 Lb

(39 Kg) 10 bar 90 Lb

(41 Kg)

14.5 bar 90 Lb

(41 Kg)

5hp/4kw * 7.5hp/5.5kw * 10hp/7.5kw * 15hp/11kw **

62 Lb

(28 Kg)

62 Lb

(28 Kg)

62 Lb

(28 Kg)

70 Lb

(32 Kg)

75 Lb

(34 Kg)

75 Lb

(34 Kg)

110 Lb (50 Kg)

90 Lb

(41 Kg)

90 Lb

(41 Kg)

85 Lb

(39 Kg)

85 Lb

(39 Kg) 100 Lb

(45 Kg)

90 Lb

(41 Kg)

75 Lb

(34 Kg)

75 Lb

(34 Kg)

70 Lb

(32 Kg)

70 Lb

(32 Kg)

80 Lb

(36 Kg)

110 Lb

(50 Kg)

110 Lb

(50 Kg)

110 Lb

(50 Kg)

110 Lb

(50 Kg)

120 Lb

(54 Kg)

120 Lb

(54 Kg)

90 Lb

(41 Kg)

90 Lb

(41 Kg)

90 Lb

(41 Kg)

90 Lb

(41 Kg) 100 Lb

(45 Kg) 100 Lb

(45 Kg)

140 Lb (64 Kg)

150 Lb (68 Kg)

140 Lb (64 Kg)

150 Lb (68 Kg)

120 Lb (54 Kg)

125 Lb (57 Kg)

120 Lb (54 Kg)

125 Lb (57 Kg)

* ”Krikit I” gauge or equal ** ”Krikit II” gauge or equal

Page 43

OPERATION AND MAINTENANCE MANUAL MAINTENANCE

Strainer Ball Valve.

OPEN CLOSED

Ensure the pulley and sheave are properly aligned and the motor anchor screws are adequately retightened prior to restarting the compressor.

cycles from 30 seconds to 45 minutes. The “time on” setting determines the actual time the compressor drains condensate.

CAUTION

Improper pulley/sheave alignment and belt tension can result in motor overload, excessive vibration, and premature belt and/or bearing failure. To prevent these problems from occurring, ensure the pulley and sheave are aligned and belt tension is satisfactory after installing new belts or tensioning existing belts.

ELECTRIC DRAIN VALVE (OPTIONAL)

PRODUCT DESCRIPTION

The Electric Drain Valve removes condensed water and oil from the air receiver tank. Additional drains may be installed throughout your compressed air system, including aftercoolers, lters, drip legs and dryers.

The Electric Drain Valve operates on a timer which can be set to automatically drain the air receiver tank at operator-determined intervals.

Key features include:

100% continuous duty

•

NEMA 4 enclosure

The timer’s cycle rate and drain opening time should be adjusted to open just long enough to discharge the condensate. The timer is properly set when it opens and discharges condensate and then vents air for approximately one second before closing. Adjustments may be made depending on many factors, including humidity and duty cycle.

TROUBLESHOOTING

TROUBLE CAUSE ACTION

Valve will not close.

Timer will not activate

MAINTENANCE

Debris in solenoid valve prevents diaphragm from seating. Short in electrical component.

No electrical supply. Timer malfunction Replace timer. Clogged port. Clean valve. Solenoid valve malfunction. Clogged strainer. Clean strainer.

Remove solenoid valve, disassemble, clean and reassemble. Check and replace power cord or timer as needed.

Apply power.

Replace solenoid valve.

•

Adjustable time on (0.5 - 10 seconds)

•

Adjustable time o (0.5 - 45 minutes)

•

Stainless steel operator

•

LED to indicate electrical power is on

•

LED to indicate valve is open

•

Manual override

OPERATION

Open the strainer ball valve.

2. Set the “time o” and “time on” knobs. See TIMER SETTINGS (below) for an explanation of the settings.

3. During compressor operation, check for air leaks.

TIMER SETTINGS

The “time o” setting determines the interval between

Periodically clean the screen inside the valve to keep the drain functioning at maximum capacity. To do this, perform the following steps:

Close the strainer ball valve completely to isolate

1. it from the air receiver tank.

Press the TEST button on the timer to vent the

2. pressure remaining in the valve. Repeat until all pressure is removed.

CAUTION

High pressure air can cause injury from ying debris. Ensure the strainer ball valve is completely closed and pressure is released from the valve prior to cleaning.

3. Remove the plug from the strainer with a suitable wrench. If you hear air escaping from the cleaning port, STOP IMMEDIATELY and repeat steps 1 and 2.

4. Remove the stainless steel lter screen and clean it. Remove any debris that may be in the strainer body before replacing the lter screen.

5. Replace plug and tighten with wrench.

6. When putting the Electric Drain Valve back into service, press the TEST button to conrm proper function.

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MAINTENANCE OPERATION AND MAINTENANCE MANUAL

> 30s

0 bar 0 psi

7 8

0 bar 0 psi

9 10

0 bar

0 psi

0 bar 0 psi

5 6

Before accessing live electrical parts, disconnect the

AIR FILTER MAINTENANCE

power supply to the dryer using disconnect switch or disconnect the cable connections.

In order to ensure optimum compressed air quality the lter element should be replaced as follows. (Used lter

Preventive maintenance

For optimum performance from your dryer, follow the periodic maintenance schedule described below.

WEEKLY CONDENSATE DRAINS

elements must be disposed of in accordance with local regulations.)

Use only genuine Ingersoll Rand replacement elements.

Verify that the condensate drains are operating correctly.

EVERY 4 MONTHS CONDENSER

Remove any dust from the condenser ns.

COMPRESSOR

Make sure compressor power consumption complies with data

YEARLY CONDENSATE DRAINS

plate specications.

Completely disassemble the drains and clean all their components.

AIR FILTER

Replace air lter element.

MOISTURE SEPARATOR MAINTENANCE

The moisture separator will operate indenitely under normal working conditions, however at some time it may be necessary to replace the seals should the housing leak.

Isolate the housing from the air supply.

Fully depressurize in drain bowl as appropriate.

Unscrew bowl and remove. If pressure has not been completely released from the housing, air will escape from the warning hole giving an audible alarm. Screw back bowl and repeat instruction 2 before attempting again. Should resistance to unscrewing be experienced, provision is made for a ’C’ spanner to t onto the ribs of the bowl.

Check condition of bowl seal and replace if

4. necessary. Clean screw threads.

Ret bowl with ’O’ ring seal.

Repressurize and check for leaks. If leaks occur

6. they will most probably be from the bowl ’O’ ring. Depressurize housing and remove ’O’ ring as stated above and inspect and clean. Ensure that mating surfaces are clean and then ret ’O’ ring and repressurize.

Page 45

OPERATION AND MAINTENANCE MANUAL MAINTENANCE

DISASSEMBLING THE UNIT

The unit has been designed and constructed to guarantee continuous operation.

The long service life of some components such as the fan and compressor depends on good maintenance.

The unit must only be disassembled by a refrigerant specialist.

Refrigerant liquid and lubricating oil inside the refrigeration circuit must be recovered in compliance with current norms in the country where the machine is installed.

RECYCLING DISASSEMBLY

Frame and panels Steel / epoxy resin polyester Heat exchanger (cooler) Stainless steel Pipes Copper Insulation Gum synthetic Compressor Steel / copper / aluminium

/ oil Condenser Aluminium Refrigerant R134a Valve Steel

REFRIGERANT LEAKS IN THE REFRIGERATION CIRCUIT

The unit is despatched in perfect working order, already charged.

Refrigerant leaks may be identied by tripping of the refrigeration overload protector.

IF A LEAK IS DETECTED IN THE REFRIGERANT CIRCUIT, SEEK TECHNICAL ASSISTANCE.

REFRIGERANT CHARGING

THIS OPERATION MUST ONLY BE PERFORMED BY A REFRIGERANT SPECIALIST.

WHEN REPAIRING THE REFRIGERANT CIRCUIT, COLLECT ALL THE REFRIGERANT IN A CONTAINER AND DISPOSE OF IT IN THE APPROPRIATE MANNER.

CHARACTERISTICS OF REFRIGERANT R134A

In normal temperature and pressure conditions the above refrigerant is a colorless, class A1/A1 gas with TVL value of 1000 ppm (ASHRAE classication).

If a refrigerant leak occurs, thoroughly air the room before commencing work.

TROUBLESHOOTING

TROUBLE CAUSE ACTION

Solenoid condensate valve will not close.

Drain timer will not operate.

Debris in solenoid valve prevents diaphragm from seating.

Short in electrical component.

No electrical supply. Apply power.

Timer malfunction Replace timer.

Clogged port. Clean valve.

Solenoid valve malfunction.

Clogged strainer. Clean strainer.

Remove solenoid valve, disassemble, clean and reassemble.

Check and replace power cord or timer as needed.

Replace solenoid valve.

MAINTENANCE

Periodically clean the screen inside the valve to keep the drain functioning at maximum capacity. To do this, perform the following steps:

Close the strainer ball valve completely to isolate

1. it from the air receiver tank.

Press the TEST button on the timer to vent the

2. pressure remaining in the valve. Repeat until all pressure is removed.

CAUTION

High pressure air can cause injury from ying debris. Ensure the strainer ball valve is completely closed and pressure is released from the valve prior to cleaning.

3. Remove the plug from the strainer with a suitable wrench. If you hear air escaping from the cleaning port, STOP IMMEDIATELY and repeat steps 1 and 2.

4. Remove the stainless steel lter screen and clean it. Remove any debris that may be in the strainer body before replacing the lter screen.

5. Replace plug and tighten with wrench.

6. When putting the Electric Drain Valve back into service, press the TEST button to conrm proper function.

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Page 46

TROUBLE SHOOTING OPERATION AND MAINTENANCE MANUAL

TROUBLE SHOOTING

PROBLEM CAUSE REMEDY

Compressor fails to start

Machine shuts down periodically

High current draw Compressor operating above rated

Low current draw Air lter contaminated. Change air lter.

High discharge pressure

Low system air pressure

High dewpoint Refrigeration compressor not supplied

Ice formation in dryer Low evaporator pressure. Check hot gas valve setting.

Mains power or Control voltage not available.

Defective Star / Delta timer. § Change Star / Delta timer. High airend temperature. Top up coolant. Motor overload. § Set overload to correct value and switch to

Line voltage variation. § Ensure voltage does not drop below 10% on

pressure. Separator cartridge contaminated. Change air lter, and separator element. Low voltage. § Ensure voltage does not drop below 10% on

Unbalanced voltage. Correct incoming supply voltage. Damaged airend. † Change Airend.

Compressor operating unloaded. Set pressure to correct rating for machine. High voltage. Reduce site voltage to correct operating

Defective inlet valve. † Fit inlet valve service kit. Defective or incorrect pressure switch

setting. Blowdown valve defective. † Fit blowdown solenoid service kit. Inlet valve malfunction. † Fit inlet valve service kit. Separator cartridge contaminated. Fit new Separator element. Incorrect pressure transducer setting Set pressure to correct rating for machine. Minimum pressure valve malfunction. † Fit Minimum pressure valve service kit. Blowdown valve defective. † Fit blowdown solenoid service kit. Drive belt slipping. Fit new belt. Air system leaks. † Fix leaks. Inlet valve malfunction. † Fit inlet valve service kit. System demand exceeds compressor

delivery. Compressed air lters contaminated. Replace air lter elements.

power.

Condensate system malfunction. Check operation of drain valve.

Condenser dirty. Clean condenser and replace panel lter

Check incoming power supply.

Check the control circuit fuse.

Check the transformer secondary windings for the control voltage.

manual reset.

start up and 6% running. Set pressure to correct rating for machine.

start up and 6% running.

voltage.

Replace or set pressure to correct rating for machine.

Reduce demand or install additional compressor.

Check incoming power supply. Check the dryer protection fuse. Check auxiliary contact on main motor

contactor.

Check operation of condensate check valves.

element.

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Page 47

OPERATION AND MAINTENANCE MANUAL TROUBLE SHOOTING

PROBLEM CAUSE REMEDY

Compressor trips due to over temperature

Excessive coolant consumption

Excessive noise level Air system leaks. † Fix leaks.

Shaft seal leaking Defective shaft seal. † Fit Airend shaft seal kit. Pressure relief valve

opens

Black residue on belt guard/cooler box

Safety valve blows when compressor goes on load

Compressor operating above rated pressure.

Package pre–lter blocked. Clean / replace package pre–lter. Cooler blocked. Clean cooler. Missing or incorrectly tted enclosure

panels Low coolant level. Top up coolant and check for leaks. High ambient temperature. Re–site compressor. Restricted cooling air ow. Ensure correct air ow to compressor. Separator element leak. Fit new Separator element. Blocked separator element drain. † Remove ttings and clean. Compressor operating below rated pres-

sure. Coolant system leak. † Fix leaks.

Airend defective. † Change Airend. Belts Slipping. Replace belt and tensioner. Motor defective. † Replace motor. Loose components. † Retighten loose items.

Defective switch or incorrect pressure switch setting.

Minimum pressure valve malfunction. † Fit Minimum pressure valve service kit. Blowdown valve defective. † Fit blowdown solenoid service kit. Inlet valve malfunction. † Fit inlet valve service kit. Pressure relief valve defective. Check the setting of the pressure relief valve

Drive belt slipping. Replace belt and tensioner. Pulleys misaligned. Re–align pulleys. Worn pulleys. † Replace pulleys and belt. Minimum pressure valve stuck closed. Strip minimum pressure valve, examine and

Safety valve faulty Check the setting of the safety valve and the

Set pressure to correct rating for machine.

Ensure that all enclosure panels are correctly tted.

Set pressure to correct rating for machine.

Replace or set pressure to correct rating for machine.

and the rated pressure.

repair if necessary.

rated pressure.

NOTES:

§ Must be carried out by a competent electrician.

† This work is recommended to be carried out only by an Ingersoll Rand authorized service technician.

CAUTION

LOW DEMAND APPLICATIONS

During periods of low demand, the compressor may not reach its normal operating temperature Sustained

operation at low demand can result in the build up of condensate in the coolant. If this situation occurs, the lubricating characteristics of the coolant can be impaired which may lead to damage of the compressor.

THE COMPRESSOR SHOULD BE ALLOWED AMPLE LOADED RUNNING TIME OF ATLEAST 10 MINUTES PER

HOUR DURING NORMAL DAILY USE.

http://air.ingersollrand.com 47

Page 48

LOOK WHAT INGERSOLL RAND CAN DO FOR YOU!

Ecient Field Service

We maintain a highly trained sta of technicians to service your equipment for preventive maintenance, or to assist you should emergencies ever occur.

Complete Repair Service

Our trained technicians will repair or overhaul your equipment to factory specications, using only genuine Ingersoll Rand parts.

Special Engineering Service

We can help you identify and solve your problems by evaluating your needs and recommending theproper equipment to give your maximum eciency.

Spare Parts

By stocking genuine Ingersoll Rand spare parts, we can help you avoid costly delays or substituting inferior parts. Using genuine

Ingersoll Rand parts on you Ingersoll Rand equipment will help to keep even

older equipment running in good-as-new

Complete Stock of Equipment

We carry a complete line of Ingersoll Rand equipment and accessories designed to meet any compressed air application. We are backed by Ingersoll Rand’s prompt factory shipment to ensure you on-time delivery.

condition.

A SUBSTITUTE IS NOT A REPLACEMENT!

Ensure you get peak performance and longevity out of your Ingersoll Rand product by insisting on genuine Ingersoll Rand replacement parts and maintenance kits. Not only are the replacement parts made to precise dimensions and OEM-

specied metallurgy, but each part is backed by the Ingersoll Rand warranty. Your local Customer Center, Distributor, or direct Ingersoll Rand salesperson will work with your to ensure you get the parts you need to do the job right. Equip your machines with only the best Ingersoll Rand genuine parts.

NOTE: THE USE OF REPAIR PARTS OTHER THAN THOSE INCLUDED WITHIN THE INGERSOLL RAND COMPANY APPROVED PARTS LIST MAY CREATE UNSAFE CONDITIONS OR MECHANICAL FAILURES OVER WHICH INGERSOLL RAND COMPANY HAS NO CONTROL. INGERSOLL RAND COMPANY SHALL BEAR NO RESPONSIBILITY FOR EQUIPMENT ON WHICH NON-APPROVED REPAIR PARTS ARE INSTALLED.

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

Ingersoll Rand UP6-7.5 Owners Manual

BONDED WARRANTY & REGISTERED START UP

CONTENTS

ABBREVIATIONS & SYMBOLS

FOREWORD

DECALS

SAFETY

GENERAL INFORMATION

INSTALLATION/HANDLING

OPERATING INSTRUCTIONS

MAINTENANCE

TROUBLE SHOOTING