Ingersoll-Rand XF 20, XF 30, EP 20, EP 30, HP 25 Operator's Instruction Manual
...
APDD 739
June 1999
XF 20 - 30
EP 20 - 30
HP 20 - 30
HXP 20 - 30
OPERATORS/
INSTRUCTION MANUAL
OPTIONS
Before installation or starting the compressor for
the first time, this manual should be studied carefully to obtain a clear knowledge of the unit and of the
duties to be performed while operating and maintaining the unit.
RETAIN THIS MANUAL WITH UNIT.
This Technical manual contains IMPORTANT SAFETY DATAand should be kept with the air compres-
®
©INGERSOLL-RAND COMPANY
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 (see extended airend warranty) from the date of placing
the Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from
Davidson, NC, 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 APARTICULAR 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 Equipment will be at Purchaser’s sole risk and liability.
Limitation or Liability
The remedies of the Purchaser set forth herein are exclusive, and the total liability of the Company with respect to
this contract or the Equipment and services furnished hereunder, in connection with the performance or breach
thereof, or from the manufacture, sale, delivery, installation, repair or technical direction covered by or furnished
under this contract, whether passed on contract, warranty negligence, indemnity, strict liability or otherwise, shall
not exceed the purchase price of the unit of Equipment upon which such liability is based.
The Company and its suppliers shall in no event be liable to the Purchaser, any successors in interest or any beneficiary or assignee of this contract for any consequential, incidental, indirect, special or punitive damages arising
out of this contract or any breach thereof, or any defect in, or failure of, or malfunction of the Equipment hereunder,
whether based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other
goods, loss by reason of shutdown or non-operation, increased expenses of operation, cost of purchase of replacement power or claims of Purchaser or customers of Purchaser for service interruption whether or not such loss or
damage is based on contract, warranty, negligence, indemnity, strict liability or otherwise.
EXTENDED AIREND WARRANTY
The Ingersoll-Rand Company Rotary Screw Air Compressor that has been
filled prior to its original shipment from Ingersoll-Rand Company with ULTRA
COOLANT and which has been operated solely on ULTRA COOLANT thereafter shall have its AIREND warranted for twenty four (24) months from the
date of placing the COMPRESSOR in operation or thirty (30) months from the
date of shipment, whichever occurs first.
Except for the above warranty period, the standard warranty provisions shall
apply and the conditions outlined herein are understood to be a supplement to
the standard Ingersoll-Rand Company warranty.
1
ROTARY SCREW AIR COMPRESSOR
This unit was purchased from
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Ingersoll-Rand Company reserves the right to make changes or add
improvements without notice and without incurring any obligation to make
such changes or add such improvements to products sold previously.
No. of units on order:
Customer Order No:
Ingersoll-Rand Co. Order No.:
For ready reference:
Record the serial number and model number of your unit here.
Serial Number:
Model Number:
TYPICAL UNIT
2
TABLE OF CONTENTS
0.0 SAFETY AND WARNINGS
0.1 safety instructions
0.2 safety precautions
0.3 decals
1.0 RECEIPT OF EQUIPMENT
1.1 inspection
1.2 unpacking and handling
1.3 tools
2.0 INSTALLATION
2.1 ventilation
2.2 foundation requirements
2.3 piping
2.4 electrical installation
2.5 voltage conversion
2.6 rotation check
2.7 before starting - starting - stopping
2.8 outdoor sheltered installation
3.0 SYSTEMS
3.1 general system information
3.2 aircooled compressors
3.3 coolant system
3.4 air system
3.5 electrical system
3.6 capacity control
3.7 pressure switch adjustment
3.8 modulation control (optional)
3.9 ACS control (intellisys modulation option only)
3.10 modulate control valve adjustment (optional)
4.0 INTELLISYS
4.1 emergency stop switch
4.2 power indicator light
4.3 push buttons
4.4 setpoint procedure
4.5 warnings
4.6 alarms
5.0 MAINTENANCE
5.1 maintenance schedule
5.2 maintenance records
5.3 maintenance procedures
5.4 pressure relief valve check
5.5 sheave alignment
5.6 drive belt
5.7 belt tension
5.8 belt tension spring replacement
5.9 shaft seal replacement
5.10 inlet air filter element
5.11 coolant filter
5.12 coolant change
5.13 coolant hoses
5.14 airend discharge hose
5.15 coolant separator filter element
5.16 separator tank scavenge
check valve/screen/orifice
4.17 cooler cores
4.18 motor lubrication
4.19 intellisys removal
6.0 TROUBLE SHOOTING
6.1 standard control
6.2 intellisys control
7.0 OPTIONS
7.1 remote start/stop
7.2 remote start/stop and power outage restart option
7.3 sequencer control
8.0 REFERENCE DRAWING
8.1 electrical schematic - full voltage - standard control
8.2 electrical schematic - star delta - standard control
8.3 electrical schematic - full voltage - intellisys control
8.4 electrical schematic - star delta - intellisys control
8.5 foundation plan - base mounted - unenclosed
8.6 foundation plan - base mounted -enclosed
8.7 foundation plan - 120 gal. tank mounted - unenclosed
8.8 foundation plan - 120 gal. tank mounted - enclosed
8.9 foundation plan - 240 gal. tank mounted - unenclosed
8.10 foundation plan - 240 gal. tank mounted - enclosed
8.11 basic flow schematic - standard control
8.12 basic flow schematic - intellisys control
8.13 typical system flow diagrams
9.0 MAINTENANCE RECORD
GENERAL INFORMATION
Cooling Air Flow:
60 Hz: 2060 cfm (3500m
3
/hr.)
50 Hz: 1710 cfm (2905m
3
/hr.)
Ambient Temperature Limit: 35°F to 115°F (2°C to 46°C)
Coolant: Factory Filled ULTRACOOLANT
Coolant Change: 8,000 hours or two years, whichever
comes first, when using ULTRACOOLANT
Coolant Capacity: 3.2 GAL (12L)
Discharge Temperature Limit: 228°F (109°C)
Tools: U.S. Standard and metric are required to perform
maintenance
3
0.0 SAFETY AND WARNINGS
0.1 SAFETY INSTRUCTIONS Before you install this air compressor you should take the time to carefully read all the instructions contained in this manual.
Electricity and compressed air have the potential to cause
severe personal injury or property damage.
Before installing, wiring, starting, operating or making any
adjustments, identify the components of the air compressor
using this manual as a guide.
The operator should use common sense and good working
practices while operating and maintaining this unit. Follow all
codes, pipe adequately, understand the starting and stopping
sequence. Check the safety devices by following the procedure contained in this manual.
Maintenance should be done by qualified personnel, adequately equipped with proper tools. Follow the maintenance
schedules as outlined in the operators manual to ensure problem free operation after start up.
Safety instructions in the operators manual are bold-faced for
emphasis. The signal words DANGER, WARNING and CAUTION are used to indicate hazard seriousness levels as follows:
Danger is used to indicate the presence of
a hazard which will cause severe personal
injury, death, or substantial property damage if the warning is ignored.
Warning is used to indicate the presence of
a hazard which can cause severe personal
injury, death, or substantial property damage if the warning is ignored.
Caution is used to indicate the presence of
a hazard which will or can cause minor personal injury or property damage if the warning is ignored.
Notice is used to notify people of installation, operation, or maintenance information
which is important but not hazard-related.
D! DANGER
! WARNING
! CAUTION
NOTICE
SAFETY PRECAUTIONS
BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
COMPRESSOR OR PERFORMING ANY MAINTENANCE
WARNING
COMPRESSED AIR AND ELECTRICITY
ARE DANGEROUS.
BEFORE DOING ANY WORK ON THIS
UNIT, BE SURE THE ELECTRICAL SUPPLY HAS BEEN CUT OFF–LOCKED &
TAGGED AND THE ENTIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF
ALL PRESSURE.
1. Do not remove the covers, loosen or
remove any fittings, connections or
devices when this unit is in operation.
Hot liquid and air under pressure that
are contained within this unit can cause
severe injury or death.
2. The compressor has high and dangerous voltage in the motor starter and
control box. All installations must be in
accordance with recognized electrical
codes. Before working on the electrical
system, be sure to remove voltage from
the system by use of a manual-disconnect-switch. A circuit breaker or fuse
safety switch must be provided in the
electrical supply line leading to the
compressor.
Those responsible for installation of
this equipment must provide suitable
grounds, maintenance clearance and
lightning arrestors for all electrical components as stipulated in O.S.H.A.
1910.308 through 1910.329.
3. Do not operate the compressor at
higher discharge pressure than those
specified on the Compressor Nameplate
or motor overload will occur. This condition will result in compressor motor
shutdown.
4. Use only safety solvent for cleaning
the compressor and auxiliary equipment.
5. Install a manual shut off valve (isolation type) in the discharge line. When a
safety valve is installed between the isolation valve and the compressor, it must
have sufficient capacity to relieve the
full capacity of the compressor(s).
6. Whenever pressure is released
through the pressure relief valve, it is
due to excessive pressure in the system. The cause for the excessive pressure should be investigated immediately.
7. Before doing any mechanical work on
the compressor:
a.) Shut the unit down.
b.) Electrically isolate the compressor
by use of the manual disconnect switch
in the power line to the unit. Lock and
tag the switch so that it cannot be operated.
c.) Vent pressure from the compressor
and isolate the unit from any other
source of air.
8. There can be adverse effects if compressor lubricants are allowed to enter
plant air systems.
Air line separators, properly selected
and installed, will minimize any liquid
carry-over.
The use of plastic bowls on line filters
without metal guards can be hazardous.
From a safety standpoint, metal bowls
should be used on any pressurized system. Review of your plant air line system is recommended.
9. When a receiver is installed, it is recommended that occupational safety and
health standards as covered in the
Federal Register, Volume 36, number
105, part 11, paragraph 1910.169 be
adhered to in the installation and maintenance of this receiver.
10. Before starting the compressor, its
maintenance instructions should be
thoroughly read and understood.
11. After maintenance functions are
completed, covers and guards must be
replaced.
0.2 SAFETY PRECAUTIONS
4
There is a high discharge air temperature shutdown function built into the Intellisys on each compressor.
It is factory pre-set at 228°F (109°C). This function should be checked at regular intervals for proper operation, once a month is recommended.
PROCEDURE:
1. Block off the cooling air discharge.
2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge temperature reaches the pre-set maximum discharge air temperature setting.
Failure to adhere to these recommendations can result in mechanical failure, property damage and serious
injury or death.
All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must take into account vibration, pulsations, temperature, maximum pressure applied, corrosion
and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some
oil into the air stream; therefore, compatibility between discharge piping, system accessories and software
must be assured.
For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge
piping is not recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the operating parameters of the system.
It is the responsibility of the installer and owner to provide the appropriate service pipework to and from
the machine.
“Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications.
Ingersoll-Rand does not approve specialized equipment for breathing air application and assumes no
responsibility or liability for compressors used for breathing air services.”
! WARNING
! WARNING
! SAFETY SHUTDOWN CHECK HIGH AIR TEMPERATURE
5
0.3 DECALS
This section contains representative examples of
decals which will be appearing throughout this manual
and are applied to the compressor unit.
If for some reason a decal is defaced, parts are
replaced or painted over, we recommend that you
obtain a replacement (See Parts manual APDD 742
for Decal Kit Number).
39264734
REV A
6
3954190
39540232
39540174
39540166*
39540257*
3
1
2
7
5
6
4
8
9
39540158
39540240
39540265
39540273
NOTICE
To obtain satisfactory compressor
operation and maintenance a
minimum of 3 feet clearance on 3
sides is required 3-1/2 feet is
required in front of the control panel
(or minimum required by latest
National Electrical code or applicable
local codes).
Refer to the Instruction / Operators
Manual before performing any
maintenance.
INGERSOLLrAND ®
!
DANGER
!
CAUTION
Incorrect lifting of
machine can cause injury
or property damage.
Lift only from base
channels.
I
!
WARNING
Discharge air.
Can contain carbon monoxide or
other contaminants.Will cause
severe injury or death.
Do not breathe this air.
INGERSOLLrAND ®
!
WARNING
Hazardous voltage. Can cause
severe injury or death.
Disconnect power before servicing.
Lockout/Tagout machine.
INGERSOLLrAND ®
!
WARNING
High pressure air.
Can cause severe injury or death.
Relieve pressure before removing filter
plugs / caps, fittings or covers.
INGERSOLLrAND ®
NOTICE
Air discharge.
INGERSOLLrAND®
!
CAUTION
Use of incorrect coolant can cause
system contamination.
Use only SSR ULTRA COOLANT.
INGERSOLLrAND ®
Exposed fan blade. Can cause severe
injury.
Do not operate with covers removed.
Disconnect power.Lock and tag.
INGERSOLLrAND ®
NOTICE
Lift here.
INGERSOLLrAND®
7
39859236
39541362
39544143
39557095
INGERSOLLrAND®
39544150
NOTICE
Filler Cap.
Use only recommended
coolant.
Read instruction book
before servicing.
39543921
39540281
12
10
11
16
14
15
13
!
WARNING
Hot surface.
Can cause severe injury.
Do not touch. Allow to cool before
servicing.
INGERSOLLrAND ®
!
CAUTION
Improper coolant filter replacement
will cause compressor damage.
Replace filter element after first 150
hours of operation and every 2000
hours thereafter or when coolant is
changed.
INGERSOLLrAND ®
! WARNING
Exposed moving belts and sheaves.
Can cause severe injury or death.
Do not operate with guards removed.
Disconnect power, lock and tag out
machine before servicing.
NOTICE
Before installing, operating, or
performing any maintenance on
this unit, read and understand
the instructions in the
Operators/Instruction Manual.
Before Starting
1. Check coolant level and add
coolant if necessary.
2. Verify that main isolation
valve is open.
3. Close main disconnect switch.
39859236
NOTICE
Rotation.
INGERSOLLrAND ®
Starting
1. Push START button. Compresor
will start and load automatically.
2. Air Pressure will rise if
there is sufficient demand
for air.
Stopping
1. Pushing STOP button.
Compressor will stop
after 7-10 seconds.
2. Open main disconnect switch.
INGERSOLLrAND ®
39919246
1.0 RECEIPT OF EQUIPMENT
1.1 INSPECTION
When you receive the compressor please inspect it
closely. Any indication of careless handling by the carrier
should be noted on the delivery receipt especially if the
compressor will not be immediately uncrated. Obtaining
the delivery man’s signed agreement to any noted damages will facilitate any future insurance claims.
1.2 UNPACKING AND HANDLING
The compressor package has been mounted on a base
which provides for forklifting between the two side channels to facilitate handling during shipment. Care in positioning the forklifts is important because the location of
the center of gravity is strongly affected by the location of
the compression module and drive motor.
Slings can be used to lift the crates, but spreader bars
must be used to prevent the slings from exerting a force
against the sides of the crates.
1.3 TOOLS
Remove compressor unit from wooden skid. Acrowbar
and hammer will be needed.
IMPORT ANT
READ THIS
LOST OR DAMAGED GOODS
THOROUGHLY INSPECT THIS SHIPMENT
IMMEDIA TELY UPON ARRIV AL
OUR RESPONSIBILITY FOR THIS SHIPMENT
CEASED WHEN THE CARRIER SIGNED
BILL OF LADING
If goods are received short or in damaged condition, it is important that
you notify the carrier and insist on a notation of the loss or damage
across the face of the freight bill. Otherwise no claim can be enforced
against the transportation company.
If concealed loss or damage is discovered, notify your carrier at once
and request an inspection. This is absolutely necessary. Unless you do
this the carrier will not entertain any claim for loss or damage. The agent
will make an inspection and grant a concealed damage notation. If you
give the transportation company a clear receipt for goods that have been
damaged or lost in transit, you do so at your own risk and expense.
WE, ATI-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE
MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THE
WILLINGNESS ON OUR PARTDOES NOT MAKE US RESPONSIBLE
FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL.
THE ACTUALFILING AND PROCESSING OF THE CLAIM IS YOUR
RESPONSIBILITY.
Ingersoll-Rand Company
Davidson, North Carolina
APDDGFO-99-79
FORKLIFT PADDING
WILL REDUCE SCRATCHES
AND MARS
SPREADER
BARS
8
2.0 INSTALLATION
2.1 VENTILATION
Oil flooded rotary air compressors produce large
amounts of heat. Because of this large heat production,
the compressor must be placed in a room with adequate
ventilation. Aroom in which the amount of air that is
drawn in and exhausted is equal to or greater than the
cooling fan air flow requirement for the compressor that
is installed.
If heated air from the compressor exhaust is allowed to
recirculate back to the compressor, the compressor will
overheat and shut down. This heat must be exhausted
from the room. You should take this into consideration
when you decide where to place the compressor within
your plant. Consider that the required maintenance clearance is 3 ft (.9 m) all around the compressor.
However 42” (1.06m), or minimum required by latest
NEC or applicable local codes, must be maintained in
front of control panel.
Ambient temperatures higher than 115°F (46°C)
should be avoided as well as areas of high humidity.
Consider also the environment surrounding or near
the compressor. The area selected for the location of
the compressor should be free of dust, chemicals,
metal filings, paint fumes and overspray.
2.2 FOUNDATION REQUIREMENTS
Refer to the foundation plan for the particular model compressor to be installed. See Section 8.0.
The compressor can be installed on any level floor that is
capable of supporting it. Compressor weights are listed
on the foundation plans.
When sound transmission is of particular importance it is
often helpful to install a sheet of rubber-fabric-matting, or
cork under the compressor to reduce the possibility of
resonant sounds being transmitted or amplified through
the floor.
2.3 PIPING
The use of plastic bowls on line filters without metal
guards can be hazardous. Their safety can be affected
by either synthetic lubricants or the additives used in mineral oil. From a safety standpoint, metal bowls should be
used on any pressurized system. Review of your plant air
line system is recommended.
The built-in aftercooler reduces the discharge air temperature well below the dew point (for most ambient conditions), therefore, considerable water vapor is condensed.
To remove this condensation, each compressor with
built-in aftercooler is furnished with a combination condensate separator/trap.
DUST
CHEMICALS
METAL
FILINGS
PAINT
SPRAY
OVERSPRAY
Do not use plastic pipe, soldered copper
fittings or rubber hose for discharge piping.
WARNING
Never elevate the compressor unit
above the floor level. This may allow air
to enter the cabinet under the base.
Performance will be affected.
NOTICE
!
!
36”
(.9 m)
36” (.9 m)
42” (1.06 m) OR
CODE MINIMUM
9
AIR INTAKE
10
DISCHARGE PIPING WITH AFTERCOOLER
ROTARY-RECIP IN PARALLEL
Do not use the compressor
to support the discharge pipe.
Careful review of piping size from the compressor connection point is essential. Length of pipe, size of pipe,
number and type of fittings and valves must be considered for optimum efficiency of your compressor.
It is essential when installing a new compressor to review
the total plant air system. This is to ensure a safe and
effective total system.
Liquid water occurs naturally in air lines as a result of
compression. Moisture vapor in ambient air is concentrated when pressurized and condenses when cooled in
downstream air piping.
Moisture in compressed air is responsible for costly problems in almost every application that relies on compressed air. Some common problems caused by moisture are rusting and scaling in pipelines, clogging of
instruments, sticking of control valves, and freezing of
outdoor compressed air lines. Any of these could result in
partial or total plant shutdown.
Compressed air dryers reduce the water vapor concentration and prevent liquid water formation in compressed air lines. Dryers are a necessary companion to
filters, aftercoolers, and automatic drains for improving
the productivity of compressed air systems.
NOTICE
!
2.3 PIPING (Continued)
A dripleg assembly and isolation valve should be mounted near the compressor discharge. Adrain line should be
connected to the condensate drain in the base.
IMPORT ANT: The drain line must slope downward from
the base to work properly.
NOTE: For ease of inspection of the automatic drain trap
operation, the drain piping should include an open funnel.
It is possible that additional condensation can occur if the
downstream piping cools the air even further and low
points in the piping systems should be provided with driplegs and traps.
IMPORT ANT: Discharge piping should be at least as
large as the discharge connection at the compressor
enclosure. All piping and fittings must be suitable for the
maximum operating temperature of the unit and, at a
minimum, rated for the same pressure as the compressor sump tank.
MOISTURE CONTENT OF COMPRESSED AIR
200
160
120
80
40
0
DEW POINT
without
Aftercooling
100°F/38°C
(with
Aftercooler)
35°F /1.7°C
(Refrigerated
Dryer)
-40°F/-40°C
(Desiccant
Dryer)
Gallons of Water/24
hours/1000 acfm
ROTARY
COMPRESSOR
ISOLATION
VALVE
DRIP LEG
SAFETY
VALVE
PRESSURE
GAUGE
ISOLATION
VALVE
DRIP
LEG
SAFETY
VALVE
RECIPROCATING
COMPRESSOR
TRAP
ISOLATION
VALVE
ISOLATION
STRAINER
NOTE:
SEPARATE LINES
GOING TO THE
RECEIVER
VALVE
DRIP
LEG
ROTARY
COMPRESSOR
11
2.4 ELECTRICAL INSTALLATION
Before proceeding further, we recommend that you
review the safety data in the front of this manual.
Locate the compressor data plate on the left end of the
cooler box next to the control box.
The data plate lists the rated operating pressure, the
maximum discharge pressure and the electric motor
characteristics and power.
Confirm that the line voltage and compressor nameplate
voltage are the same and that the standard starter box
meets the intent of NEMA 1 guidelines.
A hole is provided for incoming power connection. If it is
necessary to make a hole in the control box in a different
location, care should be taken to not allow metal shavings to enter the starter and other electrical components
within the box. After making the power inlet hole, all
shavings and debris must be removed from inside of
control box before power is turned on.
Incoming power should be connected per the electrical
schematic on the starter box door. Confirm that all electrical connections are made and tightened. Confirm that
the control transformer is wired correctly for supply voltage (See Figure 2.5-1).
Inspect the motor and control wiring for tightness. Close
the panel front.
Two types of dryers, refrigerated or desiccant, are used
to correct moisture related problems in a compressed air
system. Refrigerated dryers are normally specified where
compressed air pressure dew points of 33°F (1°C) to
39°F (4°C) are adequate. Desiccant dryers are required
where pressure dew points must be below 33°F (1°C).
Contact your local Ingersoll-Rand distributor for assistance in selecting correct Ingersoll-Rand filtration or drying products.
NOTE: Screw type compressors should not be installed
in air systems with reciprocating compressors without a
means of pulsation isolation, such as a common receiver
tank. We recommend both types of compressor units be
piped to a common receiver utilizing individual air lines.
When two rotary units are operated in parallel, provide
an isolation valve and drain trap for each compressor
before the common receiver.
ROT ARY TWO COMPRESSOR SYSTEM
SAFETY
VALVE
PRESSURE
GAUGE
ISOLATION
VALVE
ROTARY
COMPRESSOR
TRAP
DRIP
LEG
ISOLATION
STRAINER
VALVE
ISOLATION
VALVE
DRIP
LEG
COMPRESSOR
ROTARY
12
2.5 VOLTAGE CONVERSION
IMPORTANT: This procedure should only be carried
out by a qualified electrician, electrical contractor or
your local Ingersoll Rand Distributor or Air Center
NOTE: This procedure applies only to units manufactured to multi-voltage specifications. Motor nameplate
must indicate multiple voltatges.
FIGURE 2.5-1 TYPICAL CONTROL TRANSFORMER WIRING
110V
LINE VOLTS HZ LINE SEC VOLTS LINE
200 60 H4-H5 120 X1-X2
8 X3-X4
8 X4-X5
220/230 60 H3-H5 120 X1-X2
8 X3-X4
8 X4-X5
380 60 H3-H5 120 X1-X2
8 X3-X4
8 X4-X5
440/460 60 H2-H5 120 X1-X2
8 X3-X4
8 X4-X5
575 60 H1-H5 120 X1-X2
8 X3-X4
8 X4-X5
LINE VOLTS HZ LINE SEC VOLTS LINE
220 50 H5-H6 110 X1-X2
8 X3-X4
8 X4-X5
380 50 H4-H6 110 X1-X2
8 X3-X4
8 X4-X5
415 50 H2-H6 110 X1-X2
8 X3-X4
8 X4-X5
550 50 H1-H6 110 X1-X2
8 X3-X4
8 X4-X5
LINE VOLTS HZ LINE SEC VOLTS LINE REFERENCE
200 60 H4-H5 120 X1-X2 Quad Type
220/230 50/60 H1-H2 120 X1-X4 Universal Type
380 50/60 H1-H3 120 X1-X4 Universal Type
415 50 H1-H3 120 X1-X4 Universal Type
440/460 50/60 H1-H4 120 X1-X4 Universal Type
550/575 60 H1-H5 120 X1-X4 Universal Type
*TYPICAL 60 HZ
CONTROL TRANSFORMER
(INTELLISYS OPTION)
*TYPICAL 50 HZ
CONTROL TRANSFORMER
(INTELLISYS OPTION)
H4
H5
H6
HIGH
VOLTAGE
PRIMARY
SIDE
HIGH
VOLTAGE
PRIMARY
SIDE
LOW
VOLTAGE
SECONDARY
SIDE
LOW
VOLTAGE
SECONDARY
SIDE
UNIVERSAL TYPE TRANSFORMER
(ALL VOLTAGES EXCEPT 200V/60 HZ)
QUAD TYPE TRANSFORMER (200V/60 HZ)
*TYPICAL CONTROL TRANSFORMER
(STANDARD OPTION)
If the compressor is operated in the
opposite direction of rotation, airend damage
can result and is not warrantable.
CAUTION
Open the motor junction box on the side of the motor.
Reconnect the motor to the desired voltage. Use the con-
nection decal provided on the motor as a guide.
Reconnect the primary side of the control transformer for
the desired voltage, as shown on the control transformer
wiring decal.
Refer to the motor nameplate for full load amps. Set
main fan the dial position of the overload relay to the corresponding setting.
Make sure all wiring connections are tight.
Put main disconnect in the ON position and check main
motor and fan motor rotation, as outlined in Section 2.6
of this manual.
2.6 ROTATION CHECK
Locate the rotation decal on the motor and check for correct rotation. The correct rotation when viewed from the
non-drive end of the motor is clockwise (See Figure 2.6-
1).
!
FIGURE 2.6-1 DRIVE MOTOR ROTATION
NON-DRIVE
END
DRIVE
END
FIGURE 2.5-2 MAIN DISCONNECT
LOCKED AND TAGGED
DANGER
Procedure:
Put main disconnect in the OFF position, lock and tag
(See Figure 2.5-2).
For the compressor motor and fan rotation check, the
motor jogging should be as short a time as possible.
1. Assure that the Emergency Stop button is in the
stop (depressed) position.
2. Check coolant level. To check coolant level, slowly
loosen the fill plug one complete turn. As the fill plug is
unscrewed approximately one complete turn, a small
amount of pressure may be released. Do not remove
the fill plug until all pressure has been vented. Once
pressure is vented, finish removing the fill plug. The
proper coolant level is when the coolant is even with
the top of the fill port. Add coolant if necessary.
3. Replace and tighten fill plug.
4. Close the main disconnect switch (ON position).
5. Verify that the main isolation valve is open.
6. Open the canopy enclosure if machine is so
equipped. Push the red unloaded Stop/Reset Button.
Push the Start button to start the unit and immediately
depress (push) the Emergency Stop button to stop
the unit (See Figure 2.7-1 for Control Panel layout).
NOTE: Do not use the Unloaded Stop Button for this
procedure; it is equipped with a time delayed stop circuit and damage may occur to the compression module if operated in wrong direction.
Observe the compressor drive motor shaft. The rotation should be in accordance with the directional arrow
decal on the motor. Observe the cooling fan (s). The
rotation of the main fan should be counter-clockwise.
The auxiliary fan rotation should be clockwise. (See
Figures 2.6-2 and 2.6-3.
Should the main motor or fan rotation be incorrect, put
the main disconnect in the OFF position, lock and tag.
Interchange any two line connections (L1, L2, or L3) at
the starter panel for the appropriate component. Close
the control box cover. Recheck for correction rotation.
13
DANGER
HASP
KEY LOCK
HIGH VOLTAGE
LEVER
DANGER
TAG
14
2.7 BEFORE STARTING - STARTING - STOPPING Read and understand the following instructions
before operating or performing any maintenance
on this unit
Before Starting:
1. Ensure that Emergency Stop push button is in the
OFF (depressed) position (See Figure 2.7-1).
2. Check coolant level. To check coolant level, slowly
loosen the fill plug one complete turn. As the fill plug is
unscrewed approximately one turn, a small amount of
pressure may be released. Do not remove the fill plug
until all pressure has been vented. Once pressure is
vented, finish removing the fill plug. The proper
coolant level is when the coolant is even with the top
of the fill port. Add coolant if necessary.
3. Replace and tighten fill plug.
4. Close the main disconnect switch (ON position).
5. Verify that the main isolation valve is open.
Starting
1. Push the unloaded Stop/Reset Button (red fault
indicator will go out).
2. Push the Start button and release. The compressorwill start and then load automatically if line pressure is
below the lower setting of the pressure switch.
FIGURE 2.6-2 MAIN FAN
FIGURE 2.6-3 AUXILIARY FAN
CORRECT ROTATION CORRECT ROTATION
Stopping
1. Depress the Stop button to the OFF position.
Compressor will unload for approximately 7 seconds
and then stop.
2. Open the main disconnect switch (OFF position).
FIGURE 2.7-1 CONTROL PANEL
EMERGENCY
STOP
BUTTON
CONTROL
PANEL
HOUR
METER
START
BUTTON
PRESSURE
GAUGE
UNLOADED
STOP/RESET
BUTTON
POWER ON
INDICATOR
AUTO
RESTART
INDICATOR
FAULT
ALARM
INDICATOR
TEMP
GAUGE
15
2.8 OUTDOOR SHELTERED INSTALLATION
Many times a compressor must be installed outside due
to jobsite conditions or limited space within a manufacturing facility. When this occurs there are certain items that
should be incorporated into the installation to help ensure
trouble free operation. These items have been listed
below plus Figure 2.8-1 has been included to show a typical outdoor sheltered installation. The unit must be purchased with the Outdoor Modification Option to provide
watertight electrics and a TEFC motor.
■ The compressor should be on a concrete pad
designed to drain water away. If the concrete pad is
sloped, then the compressor must be leveled. In order
to properly pull cooling air through the aftercooler, the
base/skid must be sealed to the concrete pad.
■ The roof of the shelter should extend a minimum of
4 ft (1.2 m) around all sides of the compressor to prevent direct rain and snow from falling on the unit.
■ Air-cooled machines must be arranged under the
shelter in a way that prevents air recirculation (i.e. hot
exhaust back to the package inlet).
■ If the installation includes more than one compressor,
the hot air exhaust should not be directed towards the
fresh air intake of the second unit or an Air Dryer.
■ If a standard machine is to be installed outside, the
ambient temperature must never drop below 35°F
(1.7°C).
■ Arrange the machine with the Intellisys con-
troller/starter enclosure facing away from the sun as
radiant heat can affect starter/lntellisys performance.
Also direct sunlight and UV rays will degrade the
membrane touch panel. This is not a warrantable situation.
■ Power disconnect switch should be within line of sight
and in close proximity to the unit. N.E.C. and local
electrical codes must be followed when installing the
power disconnect switch.
■ Condensate drains must never be allowed to dump on
the ground. Run to a suitable sump for future collection and disposal or separation of lubricant and water
mixture.
■ Incoming power connections must use suitable con-
nectors for outdoor weather tight service.
■ A minimum of 3 ft (.9 m) clearance must be allowed
on all four sides of the unit for service access.
However 42” (1.06m), or minimum required by latest
NEC or applicable local code, must be maintained in
front of control panel.
■ If possible, access by a forklift and/or an overhead
beam hoist should be kept in mind (for eventual service to airend or motor).
■ If the area around the installation contains fine air-
borne dust or lint and fibers etc., then the unit should
be purchased with the High Dust Filter Option and
TEFC motor option.
■ Some type of protection such as a fence or security
system, should be provided to prevent unauthorized
access.
16
FIGURE 2.8-1 TYPICAL OUTDOOR SHELTERED INSTALLATION
17
3.0 SYSTEMS
3.1 GENERAL SYSTEM INFORMATION
The compressor is an electric motor driven, single
stage, rotary screw compressor, complete with supporting components to make a fully functional unit. Astandard compressor is composed of the following:
Inlet air filter
Drive motor
Airend
Pressurized coolant system with cooler & filter
Cooling fan (s)
Capacity control
Instruments
Safety devices
Compression in the rotary screw type air compressor is
created by the meshing of two helical rotors (male and
female) on parallel shafts, enclosed in a heavy duty
iron housing, with air inlet and outlet ports located on
opposite ends. The grooves of the female rotor mesh
with and are driven by the male rotor. Bearings on both
ends of the rotors are used to support the rotor both
laterally and axially.
3.2 AIRCOOLED COMPRESSORS
Design Temperatures
The standard compressor is designed for operation in
an ambient range of 35°F. to 115°F. (1.7°C. to 46°C.).
When conditions other than design levels described
are encountered, we recommend you contact your
nearest Ingersoll-Rand representative for additional
information.
The standard maximum temperature 115°F. (46°C)
is applicable up to an elevation of 3300 ft. (1000
meters) above sea level. Above this altitude, significant reductions in ambient temperature are required if
a standard drive motor is to be used.
Coolant Cooler
The cooler is an integral assembly of core, fan and
fan-motor, mounted in the compressor. The cooling
air flows in through the front corners of the enclosure,
through the vertically mounted cooler core, and discharges upward through the top of the enclosure.
Aftercooler
The discharge air aftercooling system consists of a
heat exchanger (located at the cooling air discharge
of the machine), a condensate separator, and an
automatic drain trap.
By cooling the discharge air, much of the water
vapor naturally contained in the air is condensed
and eliminated from the downstream plant-piping
and equipment.
3.3 COOLANT SYSTEM
The coolant system consists of a separator tank,
thermostatic element, coolant filter, coolant cooler
with fans, and a separator element. When the unit
is operating, the coolant is pressurized and forced
to the compressor bearings. The compressor is
provided with a temperature switch which will shut
the unit down in case of excessive temperature,
228°F (109°C). Effective coolant filtration is provided by the use of a screw on, automotive type,
heavy duty coolant filter.
The compressor is designed for operation in an
ambient range of 35°F to 115°F (2°C to 46°C).
Coolant
Rotary screw compressor fluids have a triple function to perform. They lubricate the bearings and
contacting surfaces of the rotors, seal internal
clearances within the rotor chamber, and provide
for the cooling of the compression process. The
bulk of the fluid is actually used for cooling, with
only small amouts used for lubrication and sealing.
SSR air compressors are factory filled with
SSR ULTRA COOLANT which is designed to
operate for 8,000 hours or two years, whichever comes first. The coolant must be changed at
these intervals to avoid breakdown and equipment damage.
Circulation of Coolant
Coolant is forced by air pressure from the separator tank to the thermostatic element. The position
of the element (a direct result of coolant temperature) will determine whether the coolant circulates
through the cooler, bypasses the cooler, or mixes
the two paths together to maintain an optimum
compressor injection temperature. This temperature is controlled to preclude the possibility of
water vapor condensing. By injecting coolant at a
sufficiently high temperature, the discharge air
coolant mixture temperature will be kept above the
dew point.
18
Before being injected into the airend, all coolant flows
through the coolant filter. If tis an aubomotive type full
flow filter with a single replacement spin-on element,
rated at 4 micron. There is a differential-pressure
bypass valve set to open in the event that the pressure drop across the filter rises to as high as 15 psi (1
bar), which indicates an excessively fouled element as
well as poor maintenance practice.
Coolant/Air Separation System
The coolant/air separation system is composed of a
separator tank with specially designed internals and a
coslescing type separator element located inside the
tank.
The air-coolant mixture discharges from the airend into
the separator tank. The majority of coolant is separted
while in the separator tank and the coalescing separator filter element is used for final cleaning of the air
prior to the customer’s system. The system removes
nearly all of the coolant from the discharge air. The
separated coolant is returned to the coolant system
and the air passes to the compressed air system.
3.4 AIR SYSTEM
Components and Flow
The air system is composed of:
Inlet air filter
Inlet control valve (ICV)
Airend (rotors)
Coolant/Air separator
Minimum pressure check valve (MPCV)
Aftercooler
Moisture separator/drain trap (optional)
The direction of flow is from the inlet filter to the aftercooler. Refer to procedure and instrumentation diagrams in Section 8.0.
Functions of Components
Inlet air filter, filters the incoming air, trapping 99.9% of
particles 3 micron and larger.
Inlet valve opens full for on-line opeation.
The valve closes in the off-line mode and at shutdown
which prevents back flow of the compressed air.
The airend compresses the air.
The separator tank removes most of the coolant from
the air.
The separator element performs the final separation of
coolant and cleaning of the air prior to leaving the
compressor.
The minimum pressure check valve keeps the separator tank and separator element at a minimum pressure
to ensure adequate oil flow and proper coolant/air separation. It also prevents line pressure from exhausting
back through the airend at shutdown and during periods of unloaded operation.
The aftercooler cools the air prior to leaving the package.
3.5 ELECTRICAL SYSTEM
The electrical system of each SSR compressor is built
with electro-pneumatic controls as standard, or with
the micro-processor based Intellisys controller as an
option.
The standard electrical/electronic components,
enclosed in a readily accessible enclosure include:
1. Push buttons control w/analog gauges
2. Neon indicators
3. Switching relays/timers
4. Control transformers and fuses
5. Compressor motor starter, with auxiliary contacts
and overload relays
6. Optional Intellisys controller in place of #1, 2, and 3
By use of a built-in Automatic Across-The-Line type
starter, the compressor can be started using full voltage electric current. The starter is completely automatic and controlled by the Intellisys controller. Refer to
the electrical schematic, Section 8.0 schematic 8.1
(Standard controller) or 8.3 (Intellisys controller).
By use of an optional built-in Star-Delta type starter,
the compressor motor can be started and accelerated
using a greatly reduced “inrush” electric current. The
starter is completely automatic and controlled by the
Intellisys controller. Refer to the electrical schematic,
Section 8.0 schematic 8.2 (Standard control) or 8.4
(Intellisys control).
Options such as remote start/stop or power outage
restart with remote start/stop can be added by
installing a plug-in module in the controller.
3.6 CAPACITY CONTROL
The SSR compressor is supplied with on-line/off-line
and automatic start/stop controls as standard.
Optional modulation control enables the compressor
to operate with a throttled inlet flow for air systems
which have a relatively high constant demand relative
to compressor capacity.
On-Line/Off-Line With Automatic Start/Stop
Control
The compressor will deliver air at full capacity, (the
compressor maximum efficiency condition) or will
operate at zero capacity with high receiver pressure
(the compressor minimum power condition), while the
unit continues to run.
When the compressor starts and line pressure is
below the lower setting of the line pressure switch,
control solenoid 1SV will be energized (close), inlet
control valve ICV will open, and the compressor will
load. When the line pressure reaches the upper setting of the pressure switch, the compressor will
unload by de-energizing (opening) 1SV and closing
ICV. Solenoid 1SV relieves the internal pressure of
the compressor back to the inlet filter. The only
adjustment required is setting of the pressure switch.
A time delay relay is energized and begins to time
out. The timer, mounted in the control box, is factory
set at 10 minutes. It will continue to operate for as
long as its time setting, after which a relay contact
opens to de-energize the compressor starter coil. At
the same time, an amber light (1LT) on the control
box is lit to indicate the compressor has shut down
automatically and will restart automatically. The automatic restart will take place when the line pressure
drops to the lower setting of the pressure switch.
Adjusting the adjustable timer below the 10
minute factory setting may shorten the life of the
compressor drive motor.
3.7 PRESSURE SWITCH ADJUSTMENT
Locate the pressure switch as shown in Figure 3.7-1.
The pressure switch can be adjusted using the following procedure:
1. Open, lock and tag the main electrical disconnect.
Do not adjust the pressure switch with power on or
machine operating.
FIGURE 3.7-1 PRESSURE SWITCH ADJUSTMENT
5
2
3
4
2. Remove pressure switch cover by turning the cover
screw counterclockwise.
NOTE: It is required that the load or on-line pressure
be set first, before the unload or off-line pressure is
set.
3. Set the on-line pressure by turning screw 5 (See
Figure 3.7-1). Turn clockwise to increase setting or
counter-clockwise to decrease setting (indicated by
pointer 4).
4. Set the off-line pressure by turning screw 2. Turn
screw counter-clockwise to increase setting or clockwise to decrease setting (indicated by pointer 3).
CAUTION:
DO NOT EXCEED NAMEPLATE RATING OF THE
COMPRESSOR.
5. Start compressor and test adjustment(s) made. If
necessary, readjust according to steps 1-4 above.
19
3.8 MODULATION/ACS CONTROL (OPTIONAL)
For those plants which have relatively high constant
air demand, relative to the compressor capacity, the
recommended control mode is modulation.
The modulation control system retains the features
of the on-line/off-line control, but also provides for
throttling of the inlet flow up to the off-line air pressure setpoint value.
By applying line pressure to an adjustable modulator
valve, the throttling position of the inlet valve is controlled, thus allowing the modulator to "trim" the inlet
valve position as dictated by the line pressure.
The modulating pressure range is about 4 psig (0.3
BAR) and the modulator is factory set to straddle the
compressor rated pressure. Modulation begins when
the line pressure reaches about 99 percent of the
compressor rated pressure and continues as/if the
line pressure rises. Modulation becomes stable
when the compressor output equals the plant air
demand. When the modulation is at the factory setting, the maximum capacity reduction will be approximately 60 percent of the compressor rated capacity
(as indicated in Figure 3.8-1).
FIGURE 3.8-1
Capacity control of machines supplied with standard
electro-pneumatic controls and the modulation option
can be manually switched from on-line/off-line with
auto start/stop to modulation via a rotary selector
switch located adjacent to the pressure switch.
3.9 ACS CONTROL (INTELLISYS MODULATION
OPTION ONLY)
For compressors supplied with Intellisys control and
modulation options, ACS control will allow the compressor to automatically switch between on-line/offline and modulation control, depending on air
demand.
If the air demand has decreased to a level below
the 60 percent modulated output, the line pressure
will increase slightly to actuate the Intellisys. The
compressor will then shift to the off-line control
position, and operate unloaded with the compressor
vented.
20
It is sometimes desirable to begin modulation at a
higher pressure than the standard factory setting,
thereby increasing the modulated capacity at the
time the Intellisys is actuated. Refer to Figure 3.81 for modulated capacities available when this is
done.
The compressor will then operate to deliver full
capacity air to the plant system. If the plant air
system pressure rises to that of the Intellisys offline set point, pressurized air will be sent to the
inlet valve causing it to close, and to the blowdown valve, causing it to open.
The compressor will continue to run unloaded, but
since pressure levels have reduced, it will do so
with a minimum power draw.
The Intellisys®has a fixed minimum differential of 10
psi between the off-line air pressure setting and the
on-line air pressure setting. The differential may be
increased by adjusting the on-line air pressure setting of the Intellisys
®
.
Refer to Section 4.4 for instructions.
The automatic control selector (ACS) is designed to
continuously monitor the plant air demand and
select either the on-line/off-line, or the modulate
control mode - whichever is most desirable at anytime during an operating day.
It allows the compressor to operate in its most
efficient mode without attendance, thereby reducing
power costs to a minimum.
When the compressor operates in the on-line/off-line
control mode, the length of time the compressor
remains in the "off-line" condition is an indication of
the plant air demand. Intellisys controller is sensing
and awaiting a sufficient line pressure decrease
before signaling a shift to the on-line mode. If the
"off-line" time period is relatively short, thereby indicating a high demand for air, it is preferable to shift
the control system to upper range modulation.
The Intellisys
®
does this, and does it automatically if
the compressor unloads 3 times within a 3 minute
time period.
If later, the plant demand decreases, and even
under modulate control the line pressure reaches
the setting of the Intellisys
®
controller, and the
control shifts to the "off-line" mode, the time in this
mode will still be monitored. Along "off-line" timeperiod indicates a low plant air demand, indicating
the desirability of operating in the on-line/off-line
mode.
The Intellisys
®
then does this, and does it
automatically if the compressor operates unloaded
for more than 3 minutes.
Modulation Only
If MODULATION ONLY is turned on in the setpoint
routine, the unit will shift to Modulation control mode
immediately when the unit is running. The 3 cycles
within 3 minutes time period required for ACS to
change to Modulation mode is bypassed. The unit
will stay in Modulation mode until the unit runs
unloaded for 3 minutes (the unit then returns to ACS
control) or MODULATION ONLY is turned off via the
set routine.
Delay Load Time
This is the amount of time the line pressure must
remain below the on-line setpoint before the compressor will load or start (if the unit was stopped due
to an auto start/stop situation). Setting the load delay
time to 0 will cause no delay. When the delay load
timer becomes active, the display will switch to package discharge pressure (if not displaying package
discharge pressure at that time) and then display the
delay load count down. Once the count down reaches 0, the unit will load or start and the display will
return to line pressure. The display select button is
inactive during the delay load count down.
21
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