IRN37−160K−CC IRN50−200H−CC IRN75−160K−2S IRN100−200H−2S IRN250−300H−2S OPERATION AND MAINTENANCE MANUAL 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. TM C.C.N. : 54731245 DATE : DECEMBER 2007 REV.
Warranty AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UP The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve months from the date of placing the Equipment in operation or eighteen months from the date of shipment from the factory, whichever shall first occur.
1.0 contents contents PAGE contents PAGE 1.0 contents 1 9.6 OPERATOR SETPOINTS 71 2.0 FOREWORD 2 9.7 OPTIONS 73 3.0 ABBREVIATIONS & SYMBOLS 4 9.8 SENSOR CALIBRATION 74 4.0 PURCHASE ORDER DETAILS 5 9.9 ALARM HISTORY 75 5.0 SAFETY 6 9.10 CLOCK FUNCTIONS 75 5.1 SAFETY INSTRUCTIONS 6 9.11 ENERGY STATUS MESSAGES 76 5.2 SAFETY PRECAUTIONS 6 9.12 WARNINGS 77 5.3 TEXT DECALS 9 9.13 SERVICE WARNINGS 77 5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS 13 9.
2.0 FOREWORD Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European community countries requiresthat the machine display the EC Mark and conform tovarious directives. In such cases, the design specification of this machine has been certified ascomplying with EC directives. Any modification to any part is absolutely prohibited and would result in the CEcertification and marking being rendered invalid.
2.0 fOREWORD warning The use of the machine in any of the situation types listed in table 1:− a) Is not approved by Ingersoll Rand, b) May impair the safety of users and other persons, and c) May prejudice any claims made against Ingersoll Rand. TABLE 1 warning − NOT PERMITTED Use of the machine to produce compressed air for: a) direct human consumption b) indirect human consumption. Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION of this manual.
3.0 ABBREVIATIONS & SYMBOLS #### Contact Ingersoll Rand for serial number −>#### Up to Serial No. ####−> From Serial No. * Not illustrated † Option NR Not required AR As required SM Sitemaster/Sitepack HA High ambient machine WC Watercooled machine AC Aircooled machine ERS Energy recovery system T.E.F.C. Totally enclosed fan cooled motor (IP54) O.D.P.
4.0 PURCHASE ORDER DETAILS 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.
5.0 SAFETY 5.1 SAFETY INSTRUCTIONS Safety instructions in the operators manual are bold−faced for emphasis. The signal words DANGER, WARNING and CAUTION are used to indicate hazard seriousness levels as follows. Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. danger Indicates the presence of a hazard which WILL cause serious injury, death or property damage, if ignored.
5.0 SAFETY When using compressed air always use appropriate personal protective equipment. All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions. Compressed air can be dangerous if incorrectlyhandled. 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.
5.0 SAFETY Condensate disposal Coolant disposal Condensate cannot be discharged into fresh/surface water drains. In some regions compressor condensate containing ULTRA COOLANT can be fed directly into a drainage system that has downstream sewage treatment. Steps to be taken in the case of spillage: Soak up with a suitable absorbent material, then sweep into a plastic bag for disposal.
5.0 SAFETY Depending on point of manufacture and point of use, the compressor and this manual will show symbols from the following sections. Compressors for use within the European Community must be equipped with symbols from section 5.4. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor. 5.3 TEXT DECALS NOTICE WARNING To obtain satisfactory compressor operation and maintenance, a minimum of 3 feet clearance on 3 sides is required.
5.0 SAFETY CAUTION WARNING Incorrect lifting of machine can cause injury or property damage. Lift only from base channels WARNING Food contaminant. Can cause severe injury or death. Use only Ingersoll Rand SSR H-1F food grade coolant. 39568464 Rev. 03 NOTICE High pressure air. Can cause severe injury or death. Compressor can operate in a pressurized shutdown mode. Lift here Relieve pressure before removing filter plugs/caps, fittings or covers. 22061915 Rev.
5.0 SAFETY CAUTION Rotation Improper coolant filter replacement will cause compressor damage. Rotation Replace filter element after first 150 hours of operation and every 2000 hours thereafter or when coolant is changed. NOTICE WARNING Rotation HIGH VOLTAGE Do not attempt any work. Read manual. Trained service personnel only. Remove electrical supply. Wait 15 minutes. Check for zero voltage. Proceed with caution. WARNING Moving parts. Can cause severe injury. Do not operate with covers removed.
5.0 SAFETY Condensate drain. Use 75˚C copper wire only. Nur 75˚C kupferdraht verwenden. Utilisez 75˚C uniquement fil de cuivre. Usar solamente cable de cobre para 75˚ C. usare 75˚C solamente cavi di rame. Electrical power inlet. WARNING Use somente fio de cobre de 75˚. 39492384 Rev. 03 Use 75°C copper wire only. IMPORTANT Before starting this air compressor unit the shipping brace(s) must be removed. Save the brace(s) for future use. Refer to Operators/Instruction Manual. 39481130 Rev.
5.0 SAFETY 5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition / Mandatory Information / Instructions Warning WARNING: Electrical shock risk. WARNING − Pressurized component or system. WARNING − Hot surface. WARNING − Pressure control. WARNING − Corrosion risk. WARNING − Air/gas flow or Air discharge. WARNING − Pressurized vessel. Do not remove the Operating and Maintenance manual from this machine. WARNING − Flammable liquid. WARNING − Rotor magnetic field can affect pacemakers.
5.0 SAFETY 0° C WARNING − Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved. WARNING − Consult the Operation and Maintenance manual before commencing any maintenance. WARNING − For operating temperature below 0°C, consult the Operation and Maintenance manual. Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken. Do not stack.
5.0 SAFETY Use fork lift truck from this side only. Emergency stop. Tie down point Lifting point. On (power). Off (power). SET SEQUENCER STATUS LOAD SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED) RESET COMPRESSOR STATUS MODULATE MALFUNCTION POWER FOULED FILTER POWER INLET ELECTRIC MOTOR HOURS IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.
5.0 SAFETY 16 COOLANT SEPARATOR PRESSURE AIR DISCHARGE PRESSURIZED TANK ON / OFF CYCLE COOLANT FILTER AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE AIR PRESSURE STAR DELTA IEC 617−7 AUTOMATIC RESTART HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.
5.0 SAFETY BELT TENSION FILTER MOTOR LUBRICATION FRAGILE KEEP DRY THIS WAY UP USE NO HOOKS NO SIDE CLAMPS ROTATION POWER INLET (AC) WATER IN WATER OUT TRAINED SERVICE PERSONNEL WAIT TIME CHECK ZERO VOLTS IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.
6.0 RECEIPT / HANDLING 6.1 RECEIPT When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier should be noted on the delivery receipt especially if the compressor will not be immediately unpacked. Obtaining the deIivery persons signed agreement to any noted damages will facilitate any future insurance claims.
7.0 INSTALLATION For technical information see section 8.0. 7.1 LOCATION IN PLANT Ensure that the correct tie down points are used. For major overhaul (i.e. motor removal) position the machine to obtain lifting access e.g. fork lift truck. See diagram in reference section for minimum space requirements for normal operation and maintenance. Ambient temperatures higher than 46° C (115° F) must be avoided as well as areas of high humidity. Consider also the environment surrounding or near the compressor.
7.0 INSTALLATION 7.2 DISCHARGE AND CONDENSATE PIPING It is essential when installing a new compressor [1], to review the total air system. This is to ensure a safe and effective total system. One item which should be considered is liquid carryover. Installation of air dryers [3] is always good practice since properly selected and installed they can reduce any liquid carryover to zero. A receiver [2] may be necessary to ensure that the total system volume is not less than 2.0 U.S. Gal. per rated delivery C.
7.0 INSTALLATION 7.3 ELECTRICAL caution This procedure should only be carried out by a qualified electrician, electrical contractor or your local Ingersoll Rand Distributor or Air Center. The compressor and drive should be properly grounded / earthed in accordance with Local and National Code requirements. Installation of this compressor must be in accordance with recognized electrical codes and any local Health and Safety Codes. The compressor must have its own isolator situated adjacent to it.
7.0 INSTALLATION caution VERY IMPORTANT Supply voltage must be kept to a maximum imbalance of 2% on 50Hz and 3% on 60Hz applications. Voltage imbalances greater than these levels can cause permanent damage to the drive. Compressor must not be subjected to any voltage spikes or surges in excess of 575V. Exposure to spikes/surges in excess of 575V can permanently damage the drive.
7.0 INSTALLATION 7.4 WATERCOOLED UNITS Cooling Water Piping Venting the water system Water piping to and from the compressor package must be 1”diameter or larger for N37/75K (N50/100H), 11/2” diameter or larger for N75/160K (N100H/200H) and 2.0” diameter or larger for N250/300H−2S. Isolation valves with side drains should be installed on both the inlet and outlet lines. Also a strainer of 2mm−mesh size should be installed on the inlet line. Strainers are available from Ingersoll Rand.
7.0 INSTALLATION Water quality recommendations Water quality recommendations Water quality is often overlooked when the cooling system of a water−cooled air compressor is examined. Water quality determines how effective the heat transfer rate, as well as the flow rate will remain during the life of the unit. It should be noted that the quality of water used in any cooling system does not remain constant during the operation of the system.
7.0 INSTALLATION 7.5 SEA WATERCOOLED UNITS (SELECTED UNITS ONLY) Water cleanliness is extremely important. Strainers are available from Ingersoll Rand. Cleaning of coolers as a result of fouling is a customer responsibility. Isolation valves with side drains should be installed on both the inlet and outlet lines. A normally closed solenoid valve is fitted to the water outlet side of the compressor package. It is important to ensure that the recommended flow rate cannot be exceeded.
7.0 INSTALLATION 7.6 OUTDOOR SHELTERED INSTALLATION Nirvana compressors are not suitable for outdoor installation. Installing a Nirvana compressor outside voids the warranty of the compressor. 26 IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.
8.0 GENERAL INFORMATION TECHNICAL INFORMATION-SINGLE STAGE General Sound pressure level dB(A) * Maximum ambient temperature ° C (° F) Minimum ambient temperature ° C (° F) Weight Kg (lbs) Maximum pressure barg (psig) Minimum pressure barg (psig) Coolant capacity litres (US gal) HAT switch setting ° C (° F) Performance ** Flow at 7.5 Barg (m³/min) Flow at 8.
8.0 GENERAL INFORMATION N55K N75K N75H N100H 75 75 75 75 Maximum ambient temperature ° C (° F) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature ° C (° F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35) 1531 (3374) 1531 (3374) 1531 (3374) 1531 (3374) Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) 10 (145) Minimum pressure barg (psig) 4.5 (65) 4.5 (65) 4.5 (65) 4.
8.0 GENERAL INFORMATION N90K N110K N125H N150H 75 75 75 75 Maximum ambient temperature ° C (° F) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature ° C (° F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35) 3175 (6985) 3175 (6985) 3175 (6985) 3175 (6985) Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) 10 (145) Minimum pressure barg (psig) 4.5 (65) 4.5 (65) 4.5 (65) 4.
8.0 GENERAL INFORMATION N132K N160K N200H 75 75 75 Maximum ambient temperature ° C (° F) 46 (115) 46 (115) 46 (115) Minimum ambient temperature ° C (° F) 1.7 (35) 1.7 (35) 1.7 (35) General Sound pressure level dB(A) * Weight Kg (lbs) 3175 (6985) 3175 (6985) 3175 (6985) Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) Minimum pressure barg (psig) 4.5 (65) 4.5 (65) 4.
8.0 GENERAL INFORMATION 8.1 TECHNICAL INFORMATION − TWO STAGE General Sound pressure level dB(A) * Maximum ambient temperature ° C (° F) Minimum ambient temperature ° C (° F) Weight Kg (lbs) Maximum pressure barg (psig) Minimum pressure barg (psig) Coolant capacity litres (US gal) HAT switch setting ° C (° F) Performance ** Flow at 7.5 Barg (m3/min) Flow at 8.
8.0 GENERAL INFORMATION General Sound pressure level dB(A) * Maximum ambient temperature ° C (° F) Minimum ambient temperature ° C (° F) Weight Kg (lbs) Maximum pressure barg (psig) Minimum pressure barg (psig) Coolant capacity litres (US gal) HAT switch setting ° C (° F) Performance ** Flow at 7.5 Barg (m3/min) Flow at 8.
8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING−N37/45K−CC & N50/60H−CC − Air Cooled KEY A 11/2” NPT Air discharge (Female) 60Hz units 11/2” BSP Air discharge (Female) 50Hz units B Ø63mm (2.48”) Electrical inlet C 0.38“ NPT (Female) Note: Pipe condensate drain lines separately to an open drain due to differences in drain pressures. Use drain lines at least as large as the connection.
8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING− N37/45K−CC & N50/60H−CC − Water Cooled KEY A B C Note: D E F G 34 11/2” NPT Air discharge (Female) 60Hz units 11/2” BSP Air discharge (Female) 50Hz units Ø63mm (2.48”) Electrical inlet 0.38“ NPT (Female) Pipe condensate drain lines separately to an open drain due to differences in drain pressures. Use drain lines at least as large as the connection.
8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING − N55/75K−CC & N75/100H−CC − Air Cooled KEY G A 2” NPT Air discharge (Female) 60Hz units 2” BSP Air discharge (Female) 50Hz units B Ø63mm (2.48”) Electrical inlet C 0.38“ NPT (Female) Note: Pipe condensate drain lines separately to an open drain due to differences in drain pressures. Use drain lines at least as large as the connection.
8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING−N55/75K−CC & N75/100H−CC−Water Cooled KEY A B C Note: D E F G 36 2” NPT Air discharge (Female) 60Hz units 2” BSP Air discharge (Female) 50Hz units Ø63mm (2.48”) Electrical inlet 0.38“ NPT (Female) Pipe condensate drain lines separately to an open drain due to differences in drain pressures. Use drain lines at least as large as the connection.
8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING − N90/160K − CC SINGLE STAGE & N90/160K − CC TWO STAGE − Water Cooled IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.
8.0 GENERAL INFORMATION KEY A 2” NPT Air discharge (Female) 60Hz units (N100H−N150H) 2” BSP Air discharge (Female) 50Hz units (N75K−N110K) 2 1/2” NPT Air discharge (Female) 60Hz units (N200H) 2 1/2” BSP Air discharge (Female) 50Hz units (N132K and N160K units) B Electrical inlet − Ø75mm (3”) Ø64mm 575V (Option) C 0.38“ NPT (Female) Note: Pipe condensate drain lines separately to an open drain due to differences in drain pressures. Use drain lines at least as large as the connection.
8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING − N90/160K, N125/200H SINGLE STAGE & N75/160K, N100/200H TWO STAGE − Air Cooled IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.
8.0 GENERAL INFORMATION KEY A 2” NPT Air discharge (Female) 60Hz units (N100H−N150H) 2” BSP Air discharge (Female) 50Hz units (N75K−N110K) 2 1/2” NPT Air discharge (Female) 60Hz units (N200H) 2 1/2” BSP Air discharge (Female) 50Hz units (N132K and N160K units) B Electrical inlet − Ø75mm (3”) Ø64mm 575V (Option) C 0.38“ NPT (Female) Note: Pipe condensate drain lines separately to an open drain due to differences in drain pressures. Use drain lines at least as large as the connection.
8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING − N250/300H TWO STAGE KEY G A B 4” NPT Air discharge (Female) Electrical inlet − Ø75mm (3”) C 0.50“ NPT (Female) Note: Pipe condensate drain lines separately to an open drain due to differences in drain pressures. Use drain lines at least as large as the connection. Read operations manual and check local regulations D Cooling airflow E Exhaust airflow F Cabinet cooling airflow H U V W X Y Z 4 x Ø 14.
8.0 GENERAL INFORMATION 22381206 Revision B P 35 32 36 46 31 27 7 30 13 T21 M T 10 P 42 4 3 T 45 V 9 42 T21 12 39 44 T 2 M 23 8 11 T T 21 20 18 22 17 19 P 28 6 49 P 25 29 14 24 40 5 37 15 T 41 43 P 16 1 26 33 D 7 34 F 1st M 23 38 F 47 7 R 2nd P 48 2 TWO STAGE ONLY 8.
8.0 GENERAL INFORMATION KEY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Air discharge Compressor Air filter Vacuum switch 1VAC Cooler, air Cooler, coolant Condensate discharge Coolant filter Pressure switch, coolant filter 1DPS Drain valve, coolant Temperature switch 1ATS Air inlet check valve Timed solenoid condensate drain.
44 4 3 T V 45 9 T 12 42 21 23128994 Revision A P 39 44 T 2 M 23 8 T 21 T 11 20 18 22 T 10 17 19 P 28 6 49 T 25 P 29 T21 M 24 14 50 40 5 41 15 37 T 43 13 P 16 27 1 26 7 30 33 D 7 34 F 46 31 1st M 23 F 38 7 R 32 48 35 P 2nd 2 P IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.
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22099006 Revision C P 35 32 36 46 31 27 7 30 15 T 51 T21 M T T 10 46 P 4 3 T 45 V 9 42 T 21 12 39 44 T 2 M 23 8 11 T T 21 20 18 22 17 19 P 28 6 49 25 P 29 24 14 40 5 50 41 43 37 13 P 16 1 26 33 D 7 34 F 1st M 23 38 F 47 7 R 2nd P 48 2 TWO STAGE ONLY 8.0 GENERAL INFORMATION 8.
8.0 GENERAL INFORMATION KEY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Air discharge Compressor Air filter Vacuum switch 1VAC Cooler, air Cooler, coolant Condensate discharge Coolant filter Pressure switch, coolant filter 1DPS Drain valve, coolant Temperature switch 1ATS Air inlet check valve Timed solenoid condensate drain.
8.0 GENERAL INFORMATION 27 7 30 15 T 40 T21 M 20 T 48 P 13 V 4 48 IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 9 T21 12 3 T 45 42 39 T 1st M 44 23 47 2nd 8 2 P 52 21 T T 11 22 18 10 19 P 17 28 6 49 25 P 29 14 24 T 51 5 50 41 43 37 46 P 16 1 26 33 D 7 34 F 31 38 F R 35 32 36 P 22402135 Revision C 8.
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8.0 GENERAL INFORMATION KEY 1ATS Switch, high airend discharge temperature 1DPS Switch, fouled oil filter 1VAC Switch, fouled air filter 1ATT Sensor, airend inlet.
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8.0 GENERAL INFORMATION 8.5 GENERAL DESCRIPTION The compressor is an electric motor driven, contact cooled screw compressor, complete with all necessary components piped, wired and baseplate mounted. It is a totally self contained air compressor package. The standard compressor is designed to operate in an ambient range of 1.7° C to 46° C (35° F to 115° F). The standard maximum temperature of 46° C (115° F) is applicable up to an elevation of 1000m (3280ft) above sea level.
9.0 OPERATING INSTRUCTIONS 9.1 BASIC OPERATION Prior to starting warning Ensure that all protective covers/guards are in place before attempting to start the machine. warning The compressor can operate in a pressurized shutdown mode. If the compressor stops automatically, the airend, separator tank and oil system can contain high pressure air.
9.0 OPERATING INSTRUCTIONS Start sequence Blowdown mode The compressor will initially start by the operator pressing the local start button or receiving a remote start command. The compressor will start loaded and will ramp up the motor speed to its minimum speed. Once the minimum speed has been achieved, the compressor will begin to control pressure by using its speed regulation. When the system pressure reaches the target pressure, the compressor will start to slow.
9.0 OPERATING INSTRUCTIONS 9.2 INTELLISYS CONTROLS 1. Emergency stop 5. F2 Pressing this switch stops the compressor immediately. The blowdown valve will open to vent pressure in the separator tank to atmosphere. Note: the system downstream of the separator tank may still contain pressure. The compressors can not be restarted until the switch is manually reset. Turn the switch knob clockwise and press the reset button twice to reset. Not used.
9.0 OPERATING INSTRUCTIONS 9.3 DISPLAY SCREEN The display screen is divided into three functional areas, as seen in the typical CURRENT STATUS screen shown here.
9.0 OPERATING INSTRUCTIONS 9.4 CURRENT STATUS SCREEN The CURRENT STATUS screen is considered to be the “normal” display that the controller shows. The following items and their present values can be displayed on the right side of the screen by pressing the up and down arrow buttons 14 Motor Speed 15 Motor Current 16 Motor Voltage 17 Input Voltage The controller automatically returns the display to this CURRENT STATUS screen from other screens if no buttons are pressed within 30 seconds.
9.0 OPERATING INSTRUCTIONS 9.5 MAIN MENU The MAIN MENU screen can be accessed from the CURRENT STATUS screen by pressing the MAIN MENU button, identified by the words “MAIN MENU” in the bottom line of the screen directly above the center button. The language and units of measure are pre−set prior to the compressor leaving the factory. 100 The MAIN MENU screen is the point from which various operator functions can be accessed. Refer to the Operator Panel Flow Diagram.
9.0 OPERATING INSTRUCTIONS 9.6 OPERATOR SETPOINTS Setpoints are user−adjustable variables in the controller logic that can be set using the OPERATOR SETPOINTS screen shown opposite. 100 PSI OPERATOR SETPOINTS− The name and value of each of the setpoints listed can be seen on the screen by moving the list up and down using the arrow buttons. READY TO START TARGET PRESSURE 105 psi Setpoints associated with options are described in the OPTIONS sections.
9.0 OPERATING INSTRUCTIONS Automatic stop pressure Condensate Release The compressor will stop once the system pressure rises to this pressure and the compressor is operating at the minimum speed. The range for this setpoint will be the target pressure+1 to target pressure+10 psi if the target pressure is 145 psi or less, to target pressure+7 psi if the target pressure is greater than 145, but less than or equal to 175 psi, or target pressure +5 psi if the target pressure is greater than 175 psi.
9.0 OPERATING INSTRUCTIONS 9.7 OPTIONS Options are turned on or off and their associated values are set using the OPTION screen shown opposite. 100 −OPTIONS− Some options are purchased, they require additional machine hardware and must first be enabled by service personnel. The name and value of each of the following options can be seen by moving the list up and down using the arrow buttons An Option item’s value can be changed the same way that OPERATOR SETPOINTS values are changed.
9.0 OPERATING INSTRUCTIONS Scheduled start Scheduled stop This option will cause the unit to start on the scheduled start day , at the time stored in this setpoint. To disable this option, set the value of scheduled start equal to the value of scheduled stop. This option will cause the unit to stop on the scheduled stop day, at the time stored in this setpoint. To disable this option, set the value of scheduled stop equal to the value of scheduled start.
9.0 OPERATING INSTRUCTIONS 9.9 ALARM HISTORY Alarm History displays each of the Alarm messages for the last 15 Alarms experienced by the machine. It also gives access to displaying the machine operating conditions that existed at the time of each Alarm. The first one shown, “Alarm History 1”, was the most recent Alarm to occur. Note that multiple, consecutive EMERGENCY STOP Alarms are not recorded as separate Alarms, only the first one will be shown.
9.0 OPERATING INSTRUCTIONS 9.11 ENERGY STATUS MESSAGES 100 PSI −ENERGY STATUS− READY TO START AVERAGE PACKAGE kW HRS AVERAGE % CAPACITY− −AVERAGE CAPACITY STATUS MAIN MENU SELECT The Energy Status display can be selected by pressing the ENERGY STATUS button. The following items and their present values will be displayed on the right side of the screen by pressing the up and down arrows.
9.0 OPERATING INSTRUCTIONS 9.12 WARNINGS When a WARNING occurs, a large question mark will flash on the display screen. CHANGE INLET FILTER − This will occur if the Inlet Vacuum is greater than 0.05 bar (0.7 psig). If multiple WARNINGS exist, the small up/down arrows will appear in the upper right corner of the display screen. The multiple WARNINGS can be seen by pressing the up and down arrow buttons.
9.0 OPERATING INSTRUCTIONS 9.15 ALARMS When an Alarm occurs, a large exclamation mark in a triangle will flash on the display screen. The display message will indicate what caused the Alarm. The compressor will stop and cannot be re−started again until the alarm condition no longer exists and the alarm message reset. Pressing the STATUS button will display the STATUS screen. The presence of the ALARM button indicates that an Alarm condition still exists.
10.0 MAINTENANCE 10.1 MAINTENANCE PROMPTS The service warning and flashing LED will appear at intervals, dependant on the service level selected. Refer to operating instructions. The customer can only reset the warning for 24 hours by pressing the “set” button. The service warning will return each subsequent 2000 hours. The machine will be master reset after service work conducted prior to the 2000 hour interval to prevent false indication.
10.0 MAINTENANCE 10.2 MAINTENANCE CHART The MAINTENANCE CHART indicates the various components and the intervals when maintenance has to take place. Where a service interval is stated in both hours and months, it is the sooner of the two intervals that must be adhered to. Coolant capacities etc can be found in the GENERAL INFORMATION section of this manual. Note that any Local or National codes that require specific maintenance that exceeds the requirements of this section must be adhered to.
10.0 MAINTENANCE Note: On some sea watercooled models the oil cooler and aftercooler are fitted with sacrificial zinc anodes (pencils) that are located in the end bonnets of the coolers. These sacrificial zinc anodes should be checked after the first 50 hours of operation to determine if corrosive conditions exist. If satisfactory this interval may be extended to 500 hours. NOTE: 1. If sacrificial zinc anode is 50% corroded it should be replaced. 2.
10.0 MAINTENANCE 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. Ensure that maintenance personnel are adequately 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.
10.0 MAINTENANCE 10.4 ROUTINE MAINTENANCE This section refers to the various components which require periodic maintenance and replacement. For all other maintenance, contact your local Ingersoll Rand office, Distributor or Air Center. Refer to safety information and maintenance procedures prior to carrying out any of the maintenance in the following sections. Prior to starting danger Under no circumstance should the compressor be operated with the coolant fill plug removed.
10.0 MAINTENANCE Drain sequence for N250/300H−2S • Remove plug from drain valve located on the bottom of the separator tank. • Install supplied drain hose and fitting assembly in end of drain valve and place end of hose in a suitable pan. • Open drain valve to start drainage. • After draining is complete, close valve, remove hose an fitting assembly from valve, and store in a suitable location for future use. • Replace plug in end of drain valve.
10.0 MAINTENANCE Separator element change procedure for N250/ 300H−2S • Disconnect the scavenge tube at the airend. • Loosen the fitting that holds the scavenge tube into the tank and withdraw the tube assembly • Disconnect the piping from the tank cover. Tag the lines if required. • Use a suitable wrench and remove the bolts that hold the tank cover in position. Remove cover by lifting up and away. • Carefully lift the separator element up and out of the tank. Discard the faulty element.
10.0 MAINTENANCE Blower motor Re−Grease (N75−160 Aircooled units) 6 Months or 4000 Hrs Apply high melting point grease into the blower motor drive end bearing using a grease gun at the nipple provided. Stop when excess grease is seen at the relief port. Main motor Re−Grease instructions HPM 250L motor Re-Grease (N250/300N-2S units only) Every 2000 hours Apply Exxon Polyrex - EM or Mobilith - CHC 220 grease into main motor drive end and non-drive end bearings using a grease gun at the nipple provided.
10.0 MAINTENANCE N50/100H (N37/75K) Following are instructions for tilting the cooler away from the enclosure and cleaning of the cooler. • Remove 6 screws from lower rear fixed panel and remove panel. • Remove 10 screws from the rear intake panel and remove panel. • Loosen clamp and disconnect the air inlet hose from the intake plenum. • Remove intake plenum.
10.0 MAINTENANCE • Remove 6 screws from top panel above cooler and remove panel. • Using lifting device from above, attach lifting straps to lifting supports on each side of cooler. • With the weight of the cooler supported by the lifting device, remove the 10 screws securing the cooler and remove the cooler. • Clean coolers with a mild cleaning solution. warning Strong cleaners can harm aluminium cooler parts. Follow cleaner manufacturers instructions for use. Wear appropriate safety equipment.
10.0 MAINTENANCE Watercooled machines Shut off the cooling water. The machine should trip at 109° C (228° F). caution Under no circumstances should these discharge temperatures be exceeded. If the machine fails to trip A FAULT EXISTS. Investigate immediately. Separator tank scavenge check valve/orifice • Disconnect tubing at each end of check valve/ screen/ orifice assembly. • Check orifice and clean if required. Use suitable tool and remove orifice from its housing.
10.0 MAINTENANCE No Loss Drain Trap (where fitted) Check / Cleaning Coolant Sampling Procedure • Remove the four socket head screws then carefully split the trap. Clean and inspect all internal parts with particular attention to the water level sensor(s). • If the stainless steel strainer mesh is blocked, remove it and clean in a weak detergent solution. • Replace any defective parts (see parts manual for repair kit).
11.0 FAULT FINDING 11.1 GENERAL FAULTS warning When attempting to identify and remedy any fault or failure, ensure it is only attempted by qualified personnel and that the safety and maintenance sections of this manual have been read and are fully understood and followed. Major overhauls should only be carried out by a qualified Ingersoll Rand representative.
11.0 FAULT FINDING SYMPTOM FAULT REMEDY Compressor will not meet pressure required by system Compressor not sized to meet system requirements or requirements have been changed.
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11.0 FAULT FINDING SYMPTOM FAULT REMEDY Discharge air is contaminated with condensate Aftercooler not functioning correctly Clean or replace Moisture separator drain trap faulty Overhaul or replace Continuous low speed / low ambient operation causing condensate build up Review system requirements and contact your local IR representative Compressor operating above rated pressure Check and modify settings.
11.0 FAULT FINDING FAULT CAUSE REMEDY Remote start failure Remote start button is pressed after machine is running or remote start button remains closed. Check operation of buttons or operating procedures Remote stop failure Remote stop button remains open and either start button is pressed Check operation of buttons or operating procedures Sensor failure Sensor is missing or faulty Install, repair or replace faulty sensor Compressor trips indicating a high compressor temperature.
11.0 FAULT FINDING 11.3 DRIVE FAULTS (INDICATED ON THE INTELhYS CONTROLLER) The drive controller is directly linked to the Intellisys controller. Faults in the drive controller will be displayed on the Intellisys controller as ‘VSD fault 0, VSD fault 1’ etc. The following VSD faults may be investigated and remedied at source. For all other VSD faults, contact your local IR customer support representative. FAULT CAUSE ACTION VSD Fault 1 Over−current Check separator element.
