SSR UP6 15, UP6 20, UP6 25, UP6 30 60Hz OPERATION AND MAINTENANCE MANUAL This manual contains important safety information and must be made available to personnel who operate and maintain this machine. SERIAL No : 0110190126 –> C.C.N.
CONTENTS & ABBREVIATIONS CONTENTS ABBREVIATIONS & SYMBOLS 1 AIRCARE WARRANTY #### Contact Ingersoll–Rand for serial number 2 CONTENTS 3 FOREWORD 4 DECALS 9 SAFETY 10 GENERAL INFORMATION –>#### ####–> * { NR AR SM HA WC AC ERS T.E.F.C. O.D.P. Up to Serial No. From Serial No.
FOREWORD 3 The contents of this manual are considered to be proprietary and confidential to Ingersoll–Rand and should not be reproduced without the prior written permission of Ingersoll–Rand. 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.
DECALS ISO SYMBOLS GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition / Mandatory Information / Instructions Warning Use fork lift truck from this side only. RESET Do not use fork lift truck from this side. Emergency stop. On (power). Off (power).
DECALS 5 Use ULTRA–Plus Coolant only Failure to use the specified coolant may result in damage to the machine Every X months, if sooner than required by operating hours POWER INSPECT CHANGE / REPLACE CLEAN SSR UP6 15, UP6 20, UP6 25, UP6 30
DECALS ANSI SYMBOLS GRAPHIC FORM AND MEANING OF ANSI SYMBOLS DANGER INTAKE AIR. Can contain carbon monoxide or other contaminants. Will cause serious injury or death. Ingersoll–Rand air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for breathing air applications unless treated in accordance with all applicable codes and regulations. WARNING HAZARDOUS VOLTAGE. Can cause serious injury or death.
DECALS 7 60 Hz Units INSIDE PACKAGE VIEW LEFT VIEW BACK INSIDE STARTER DOOR VIEW TOP VIEW FRONT Item 1 ccn 32343519 Qty. 1 VIEW RIGHT Description Item Decal, warning contaminated air 9 ccn 32343543 Qty.
DECALS 60 Hz Units INSIDE PACKAGE VIEW LEFT VIEW BACK INSIDE STARTER DOOR VIEW TOP VIEW FRONT Item 15 ccn Qty. VIEW RIGHT Description Item ccn Qty.
SAFETY DANGER! Hazard that WILL cause DEATH, SEVERE INJURY or substantial property damage if ignored. Instructions must be followed precisely to avoid injury or death. WARNING! Hazard that CAN cause DEATH, SEVERE INJURY or substantial property damage if ignored. Instructions which must be followed precisely to avoid injury or death. CAUTIONS! Cautions call attention to instructions which must be followed precisely to avoid damaging the product, process or its surroundings.
GENERAL INFORMATION TO SUPPLY SEE NOTES 1 & 2 * WYE (STAR) DELTA MOTOR (OPEN TRANSITION) LINE NUMBER SEE TRANSFORMER NAMEPLATE FOR WIRING CONNECTION REQUIREMENTS. “POWER ON” OFF ON “STAND BY” *RESET “HI TEMP SHUTDOWN” 85583417 Rev.
GENERAL INFORMATION 11 TO SUPPLY SEE NOTES 1 & 2 COMPRESSOR * MOTOR SEE TRANSFORMER NAMEPLATE FOR WIRING CONNECTION REQUIREMENTS. LINE NUMBER “POWER ON” OFF ON “STAND BY” *RESET “HI TEMP SHUTDOWN” 85583409 Rev. B LEGEND CPT Transformer, control n EDV Valve, electric drain * E–STOP Button, emergency stop FU Fuse HM Hourmeter HATR Relay, high air temperature * TR Relay, time delay (6 min) Terminal points Light, transformer type * NOTES 1.
INSTALLATION / HANDLING BASE MOUNTED UNITS ROTATION VIEW REAR VIEW LEFT VIEW RIGHT VIEW FRONT VIEW TOP VIEW BOTTOM KEY A Pre filter B Compressor and cooling air intake C Starter box D Cooling air exhaust E 1.00” NPT air discharge F Customer power inlet SSR UP6 15, UP6 20, UP6 25, UP6 30 G Fork lift openings Fork lift hole covers must be installed after unit is in place to reduce noise and ensure proper cooling of package) H 4 slots 15 (0.6) x 25 (1.
INSTALLATION / HANDLING 13 TANK MOUNTED (120 GALLON) 60 Hz UNITS ROTATION VIEW RIGHT VIEW FRONT VIEW LEFT VIEW TOP VIEW REAR VIEW BOTTOM KEY A Pre filter H Air receiver (120 gallons) B Compressor and cooling air intake I Automatic drain valve C Starter box J 0.25 inch coondensate drain D Cooling air exhaust K 4 slots 17 (0.7) x 44 (1.8) E 1.
INSTALLATION / HANDLING TANK MOUNTED (240 GALLON) 60 Hz UNITS ROTATION VIEW RIGHT VIEW FRONT VIEW LEFT VIEW TOP VIEW REAR VIEW BOTTOM KEY A Pre filter H Air receiver (240 gallons) B Compressor and cooling air intake I Automatic drain valve C Starter box J 0.25 inch coondensate drain D Cooling air exhaust K 4 slots 17 (0.7) x 44 (1.8) E 1.
INSTALLATION / HANDLING 15 NOTES 1. Coolant (lubricant) fill quantity (approximate) 13 litres (3.4 gallons). NOTE All dimensions are in millimetres (inches) unless otherwise stated. 2. Recommended clearance in front of control panel door 1067 mm (42 inches) or minimum as required by the latest national electrical codes (NEC) or applicable local codes. 3. Recommended clearances on left and right sides 914mm (36 inches).
INSTALLATION / HANDLING KEY 1. Compressor 2. Air Receiver 3. Air Dryer CAUTION The use of plastic bowls on line filters and other plastic air line components can be hazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils. Ingersoll –Rand recommends that only filters with metal bowls should be used on any pressurised system. 4. Compressed air filters 5. System demand points NOTE Items [2] to [5] are optional or may be existing items of plant.
INSTALLATION / HANDLING 60Hz COMPRESSOR UP6 20 UP6 25 UP6 30 125 150 200 125 150 200 125 150 200 Maximum operating pressure PSIG (bar) 125 (8.62) 150 (10.34) 200 (13.79) 125 (8.62) 150 (10.34) 200 (13.79) 125 (8.62) 150 (10.34) 200 (13.79) Factory set reload pressure PSIG (bar) 115 (7.93) 140 (9.66) 190 (13.10) 115 (7.93) 140 (9.66) 190 (13.10) 115 (7.93) 140 (9.66) 190 (13.10) Flow rate CFM (m3/MIN) 83 (2.35) 75 (2.12) 58 (1.64) 102 (2.89) 92 (2.61) 75 (2.
INSTALLATION / HANDLING ELECTRICAL DATA – ALL UNITS SSR UP6–20 Standard voltage 200V 230V 460V 575V Drive motor Motor enclosure ODP TEFC ODP TEFC Power Full load current (maximum) ODP TEFC ODP TEFC 28.2A 27.5A 22.6A 22A 20HP 65A Starting current DOL (STAR) 63.1A 56.4A 336 (150) 54.
INSTALLATION / HANDLING If there are any deviations from the above, or special regulations apply, the installation must be planned by a competent, qualified engineer. 19 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. NOTE All data applies to standard product only. The control circuit transformer has different voltage tappings.
OPERATING INSTRUCTIONS GENERAL OPERATION The compressor is an electric motor driven, single stage screw compressor, complete with accessories 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 2_C to 40_C (35.6_F – 104_F) with a special option package available to operate in ambient temperatures ranges from 2_C up to 50_C (35.6_F up to 124_F).
OPERATING INSTRUCTIONS 21 ELECTRO–PNEUMATIC CONTROL AND INSTRUMENTATION KEY 1. Pressure gauge 10.Load solenoid valve 2. Pressure switch 11.Indicator air filter 3. Tee 12.Nipple 4. Connector 13.Adaptor 5. Combination block 14.Intake valve assembly 6. Elbow 7. Tee, male run NOTES: 8. Reducer bushing A. Tubing 3/8 inch 9. Blow down solenoid valve B.
OPERATING INSTRUCTIONS 1. PRESSURE GAUGE Indicates the system pressure. WARNING DO NOT operate the compressor at discharge pressures over the rated pressure. 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. 2. HOURMETER Records the total running time of the compressor. 3.
OPERATING INSTRUCTIONS 23 NORMAL/EMERGENCY STOPPING 1. Switch the ON/OFF switch (4) to the OFF position. The compressor will unload and stop. 2. Press EMERGENCY STOP button (3) and the compressor will stop immediately. 3. Turn off electrical isolator or disconnect. CAUTION After shutdown never allow unit to stand idle with pressure in receiver/separator system.
MAINTENANCE ROUTINE MAINTENANCE SSR UP Series Maintenance Schedule This section refers to the various components which require periodic maintenance and replacement. PERIOD Each 24 operation MAINTENANCE hours Check the coolant level and replenish if necessary.
MAINTENANCE 25 . all hazards present are known (e.g. pressurised components, electrically live components, removed panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving parts, safety valve discharge etc.). 8. Refill the machine following the ”top up coolant” procedure above. After initial fill, 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. .
MAINTENANCE SEPARATOR CARTRIDGE CHANGE PROCEDURE 7. Screw the new cartridge down until the seal makes contact with the housing, then hand tighten a further half turn. 1. Stop the machine, electrically isolate and vent all trapped pressure. 2. Loosen separator cartridge with the correct tool. 3. Remove the cartridge from the housing; place it in a sealed bag and dispose of it safely. 8. Start the compressor and check for leaks.
MAINTENANCE 27 SETTING THE PRESSURE SWITCH (1PS) TO CHECK THE LOWER SET POINT TO CHECK THE MAXIMUM DISCHARGE PRESSURE (Pressure switch upper trip point) Observe the line pressure fall and note the point at which the pressure switch closes (and loads the compressor). Slowly close the isolation valve located adjacent to the compressor. Observe the rise in pressure and ensure that the pressure switch opens (and unloads the compressor) at the correct Maximum discharge pressure.
MAINTENANCE BELT CHANGE / GAS STRUT CHANGE PROCEDURE 1. Stop the machine, electrically isolate and vent all trapped pressure. 2. Remove the side cover from the machine. 3. Fit a 1/2” square drive wrench in the tension cam located above the airend (access from front door). Turn clockwise 1/4 turn to Position 2 to release gas strut tension on the belts. 4. Using a small screwdriver under the spring clip, ease the ball ends off the spherical studs at the ends of the gas strut. 5.
TROUBLE SHOOTING 29 PROBLEM CAUSE REMEDY Compressor fails to start Mains power or Control voltage not available. § Check incoming power supply. § Check the control circuit fuse. § Check the transformer secondary windings for the control voltage. § Change Star / Delta timer. Defective Star / Delta timer. Machine shutsdown periodically High airend temperature. Motor overload. Top up coolant. § Belt stretch protection (when fitted). Line voltage variation. High current draw Change belt.
TROUBLE SHOOTING PROBLEM CAUSE REMEDY Compressor trips due to Compressor operating above rated pressure. over temperature Package pre–filter blocked. Excessive coolant consumption Set pressure to correct rating for machine. Clean / replace package pre–filter. Cooler blocked. Clean cooler. Missing or incorrectly fitted enclosure panels Ensure that all enclosure panels are correctly fitted Low coolant level. Top up coolant and check for leaks. High ambient temperature. Re–site compressor.
