Phụ tùng máy nén khí Ingersoll Rand V Series 5-11kW

2 FOREWORD

The intended uses of this machine are outlined below and examples of unapproved usage are also given, however Ingersoll Rand cannot anticipate every application or work situation that may arise.

IF IN DOUBT CONSULT SUPERVISION.

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

. Compression of normal ambient air containing no known or detectable additional gases, vapours. or particles

. Operation within the ambient temperature range specified in the

GENERAL INFORMATION section of this manual.

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

a) Is not approved by Ingersoll Rand,

b) May impair the safety of users and other persons, and

c) May prejudice any claims made against Ingersoll Rand.

TABLE 1

Use of the machine to produce compressed air for:

a) direct human consumption

b) indirect human consumption, without suitable filtration and purity checks.

Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION of this manual.

Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or vapours.

THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES, INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR VAPOURS MAY BE PRESENT.

Use of the machine fitted with non Ingersoll Rand approved components.

Use of the machine with safety or control components missing or disabled.

The contents of this manual are considered to be proprietary and confidential to Ingersoll Rand and should not be reproduced without the prior written permission of Ingersoll Rand.

Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll Rand products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and conditions of sale for such products, which are available upon request.

This manual contains instructions and technical data to cover routine operation and scheduled maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this manual and should be referred to an authorised Ingersoll Rand service department.

All components, accessories, pipes and connectors added to the compressed air system should be:

. of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Ingersoll Rand.

. clearly rated for a pressure at least equal to the machine maximum allowable working pressure.

. compatible with the compressor lubricant/coolant.

. accompanied with instructions for safe installation, operation and maintenance

Details of approved equipment are available from Ingersoll Rand Service departments.

The use of non−genuine spare repair parts other than those included within the Ingersoll Rand approved parts list may create hazardous conditions over which Ingersoll Rand has no control. Therefore Ingersoll Rand does not accept any liability for losses caused by equipment in which non−approved repair parts are installed. Standard warranty conditions may be affected.

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

The company accepts no responsibility for errors in translation ofthis manual from the original English version.

DECALS 3

ISO SYMBOLS

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory

Information / Instructions

Warning

WARNING: Electrical shock risk.

WARNING − Pressurised component or system.

WARNING − Hot surface.

WARNING − Pressurised vessel.

WARNING − Air/gas flow or Air discharge.

Do not breathe the compressed air from this machine.

Use fork lift truck from this side only.

RESET

Do not use fork lift truck from this side.

Emergency stop.

On (power).

Off (power).

Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken.

Do not operate the machine without the guard being fitted.

Lifting point.

ROTATION

AIR DISCHARGE

COOLANT FILTER

4 DECALS

AUTOMATIC RESTART

MAINTENANCE

MAINTENANCE PROHIBITED

COOLANT DRAIN

CONDENSATE DRAIN

FILTER

FRAGILE

KEEP DRY

THIS WAY UP

USE NO HOOKS

NO SIDE CLAMPS

HOURS

Pinch point hazard. Keep hands clear.

POWER

INSPECT

Every X months, if sooner than required by operating hours

CHANGE / REPLACE

CLEAN

POWER INLET (AC)

ANSI SYMBOLS

GRAPHIC FORM AND MEANING OF ANSI SYMBOLS

DECALS 5

INTAKE AIR. Can contain carbon monoxide or other contaminants. Will cause serious injury or death. Ingersoll Rand air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for breathing air applications unless treated in accordance with all applicable codes and regulations.

HAZARDOUS VOLTAGE. Can cause serious injury or death. Disconnect power and bleed pressure from tank before servicing. Lockout/Tagout machine. Compressor must be connected to properly grounded circuit. See Grounding Instructions in manual. Do not operate compressor in wet conditions. Store indoors

RISK OF FIRE OR EXPLOSION. Electrical arcing from compressor components can ignite flammable liquids and vapors which can result in serious injury. Never operate the compressor near flammable liquids or vapors. If used to spray flammable materials, keep compressor at least 20ft away from the spray area.

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

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

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

EXPOSED MOVING BELTS AND SHEAVES.

Can cause severe injury or death.

Do not operate without guard in place. Disconnect power before servicing. Lockout/Tagout machine.

Air flow exhaust may contain flying debris. Safety protection should be worn at all times.

Pinch point hazard. Keep hands clear.

6 DECALS

Item ccn Qty. Description Item ccn Qty. Description

SAFETY 7

General Information

Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

Ensure that the Operation and Maintenance manual is not removed permanently from the machine.

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

Do not point air nozzles or sprayers toward anyone.

Compressed air and electricity can be dangerous. Before undertaking any work on the compressor, ensure that the electrical supply has been isolated and the compressor has been relieved of all pressure.

Wear eye protection when operating or servicing compressor.

All persons positioned near to operating machinery should be equipped with hearing protection and given instructions on its use in accordance with workplace safety legislation.

Make sure that all protective covers are in place and that the canopy/doors are closed during operation.

The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas.

Installation of this compressor must be in accordance with recognised electrical codes and any local Health and Safety Codes.

The use of plastic bowls on line filters can be hazardous. Their safety can be affected by either synthetic lubricants, or the additives used in mineral oils. Ingersoll Rand recommends that only filters with metal bowls should be used on a pressurised system.

Compressed air

Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.

DANGER!

Hazard that WILL cause DEATH, SEVERE INJURY or substantial property damage if ignored. Instructions must be followed precisely to avoid injury or death.

WARNING!

Hazard that CAN cause DEATH, SEVERE INJURY or substantial property damage if ignored. Instructions which must be followed precisely to avoid injury or death.

CAUTIONS!

Cautions call attention to instructions which must be followed precisely to avoid damaging the product, process or its surroundings.

NOTES

Notes are used for supplementary information.

BREATHING AIR PRECAUTION

Ingersoll Rand air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for breathing air applications unless treated in accordance with all

applicable codes and regulations.

If more than one compressor is connected to one common downstream plant, effective isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidentally be pressurised / over pressurised by another.

Compressed air must not be used for a direct feed to any form of breathing apparatus or mask.

The discharged air contains a very small percentage of compressor lubricant and care should be taken to ensure that downstream equipment is compatible.

If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided.

When using compressed air always use appropriate personal protective equipment.

All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions.

Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.

Avoid bodily contact with compressed air.

All safety valves located in the separator tank must be checked periodically for correct operation.

Do not over−pressurize the receiver tank or similar vessels beyond design limits.

Do not use a receiver tank or similar vessels that fail to meet the design requirements of the compressor. Contact your distributor for assistance.

Do not drill into, weld or otherwise alter the receiver tank or similar vessels.

Before servicing the unit, vent pressure before removing the power to ensure that the gauge reads zero pressure.

Materials

The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly:

. preservative grease

. rust preventative

. compressor coolant

AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES

Transport

When loading or transporting machines ensure that the specified lifting and tie down points are used.

Lifting equipment must be properly rated for the weight of the compressor.

Do not work on or walk under the compressor while it is suspended.

Electrical

WARNING

Imposing a normal or emergency stop on the compressor will only relieve pressure upstream of the minimum pressure valve on top of the separator tank.

If maintenance work is required downstream of this valve, ensure that all pressure is relieved at the process vent point external to the compressor

Keep all parts of the body and any hand−held tools or other conductive objects, away from exposed live parts of the compressor electrical system. Maintain dry footing, stand on insulating surfaces and do not contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the compressor electrical system.

Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel.

All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine rated pressure.

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

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

8 SAFETY

Attempt repairs only in clean, dry, well lighted and ventilated areas.

Connect the compressor only to electrical systems that are compatible with its electrical characteristics and that are within it’s rated capacity.

Condensate disposal

As waste water regulations vary by country and region it is the responsibility of the user to establish the limitations and regulations in their particular area. Ingersoll Rand and its associated distributors are happy to advise and assist in these matters.

For further information, consult Material Data Sheets for ULTRA Coolant.

The above information contains data supplied in support of United Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.) regulations.

GENERAL INFORMATION 9

PIPING AND INSTRUMENTATION

KEY

SD For SD only

DA Discharge air

Filter, air
Valve, inlet
Airend assembly
Motor
Relay, overload Motor
Tank, separator − coarse
Tank, separator − fine
Valve, minimum pressure
Aftercooler
Valve, blowdown
Switch, discharge pressure
Switch, temperature
Filter, coolant
Thermostat
Cooler, oil
Valve, pilot
Valve, safety
Valve, drain
Screen, scavenge
Valve, solenoid
Gauge, pressure
Air/Coolant
Air
Coolant
Condensate
Component boundary
Refrigerant

10 GENERAL INFORMATION

SCHEMATIC, ELECTRICAL − SD 50Hz

19004555-B

KEY

1SV Valve, solenoid (NC) MOL – 1 Contact, main motor overload relay

CR1 Relay, control PS Switch, pressure

CR1 – 1 Contact, control relay S1 Switch, off (red, maintained)

CR2 Relay, fault S2 Switch, on (green, momentary)

CR2 – 1 Contact, fault relay TM1 Relay, star-delta timer (7-10 seconds)

FU1, FU2 Fuse, primary TM1 – 1 Contact, star-delta timer relay

FU3 Fuse, secondary TR Transformer, control HATS Switch, high airend temperature

HM Meter, hour

NOTES

1. Approved fused disconnect or circuit breaker per IEC requirements must be provided by customer.

2. Sizing of electrical components not supplied by Ingersoll−Rand is the responsibility of the customer and should be done in accordance with the information on the compressor data plate, IEC and local electrical code.

KM1 Contactor, main KM1 – 1 Contact, Aux. main contactor KM2 Contactor, delta KM2 – 1 Contact, Aux. delta contactor KM3 Contactor, star KM3 – 1, 2 Contact, Aux. star contactor

LT1 Light, power on indicator (green)

LT2 Light, fault indicator (red)

MOL Overload, main motor

GENERAL INFORMATION 11

SCHEMATIC, ELECTRICAL − DOL 50Hz

19004548-B

KEY

NOTES

1. Approved fused disconnect or circuit breaker per IEC requirements must be provided by customer.

2. If separate single phase control power is used, remove jumper between terminal L3 and L.

3. Sizing of electrical components not supplied by Ingersoll−Rand is the responsibility of the customer and should be done in accordance with the information on the compressor data plate, IEC and local electrical code.

CR1 Relay, control

CR1 – 1 Contact, control relay

CR2 Relay, fault

CR2 – 1 Contact, fault relay

FU1 Fuse, control circuit

HATS Switch, high airend temperature

HM Meter, hour

KM1 Contactor, main

LT1 Light, power on indicator (green)

LT2 Light, fault indicator (red)

MOL Overload, main motor MOL – 1 Contact, main motor overload relay PS Switch, pressure

S1 Switch, off (red, maintained)

S2 Switch, on (green, momentary)

12 INSTALLATION / HANDLING

KEY

Cooler
Oil separator C Filter, air inlet D Oil filter
Motor
Gauge, pressure
Green power−on light H Green start push button J Stop, red button
Fault indicator, red light

Hourmeter
Valve, safety
Switch, pressure
Valve, pilot
Sight−glass
Plug, coolant drain S Plug, coolant filler T Airend

U Transformer

INSTALLATION / HANDLING 13

NOTES

Foundation or floor must be level and support all mounting bolt locations If necessary, shim or grout the fourth bolt location.
Foundation bolts should protect thru nuts a minimum of 13mm (0.50”) to allow for
Allow a minimum clearance of 1100mm (42”) on the front and 920mm (36”) on the top, left right and rear of the package for proper air circulation and
External piping shall not exert any unresolved moments or forces on the Use pipe size as large or larger at discharge connection.
There should be no plastic or pvc piping attached to this unit or used for any lines
Do not pipe into a common header with a reciprocating compressor, unless the reciprocating compressor utilizes a discharge pulsation damper.
Sizing of electrical components not supplied by Ingersoll Rand is the responsibility of the customer and should be done in accordance with the information on the compressor data plate and national and local

electrical codes.

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

UNPACKING

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

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

14 INSTALLATION / HANDLING

CAUTION

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

Refer to your Ingersoll Rand distributor for further information.

NOTE

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

The compressor can be installed on any level floor capable of supporting it. A dry, well ventilated area where the atmosphere is clean is recommended. A minimum of 150mm (6 inches) should be left at the rear and 1m (3ft) at the sides of the machine for adequate service access and ventilation.

LOCATION IN THE PLANT

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

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

DISCHARGE PIPING

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

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.

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

50Hz V5 V7 V11
Operating pressure bar (PSIG)	7 (102)	8 (116)	10 (145)	7 (102)	8 (116)	10 (145)	7 (102)	8 (116)	10 (145)
Factory set reload pressure bar (PSIG)	5.8 (85)	6.8 (100)	8.8 (128)	5.8 (85)	6.8 (100)	8.8 (128)	5.8 (85)	6.8 (100)	8.8 (128)
Flow rate ms/min (CFM)	0.83 (29.3)	0.78 (27.5)	0.70 (24.7)	1.10 (38.8)	1.03 (36.3)	0.91 (32.1)	1.63 (57.5)	1.52 (53.6)	1.35 (47.6)

Airend discharge temperature trip point	109°C (228°F)
Ambient temperature min. -. max.	+2°C (36°F) -.+40°C (104°F)

MOTOR
Motor enclosure	ODP
Nominal power	5.5 kW 7.5 kW 11 kW
Speed	2900 RPM
Insulation class	F

GENERAL DATA
Residual coolant content	15 mg/ms (15 ppm)
Separator vessel capacity	3 L (0.8 G)
Coolant capacity	4.5 L (1.2 G)
Sound pressure level to CAGI-PNEUROP	72 dB(A) + 3 dB(A)
Weight – base mount unit	280 kg (617 lb)
Weight – 272 L Receiver mounted	450 kg (991 lb)

INSTALLATION / HANDLING 15

ELECTRICAL DATA —V5
Standard voltage	380V
Motor enclosure	ODP
Full load current (maximum) [MEPS]	11.8A [N/A]
Starting current DOL (Star Delta) [MEPS]	100A (33A) [N/A]
Starting time DOL (Star Delta)	3-5 sec (7-10 sec)
Starts per hour (maximum)	6
Control voltage	220VAC 110VAC
Recommended fuse rating See note 1	16A
Recommended wire size See note 2	4 mm2 Cu

ELECTRICAL DATA — V7
Standard voltage	380V
Motor enclosure	ODP
Full load current (maximum) [MEPS]	17.1A [N/A]
Starting current DOL (Star Delta) [MEPS]	126A (42A) [N/A]
Starting time DOL (Star Delta)	3-5 sec (7-10 sec)
Starts per hour (maximum)	6
Control voltage	220VAC 110VAC
Recommended fuse rating See note 1	25A
Recommended wire size See note 2	4mm2 Cu

ELECTRICAL DATA — V11
Standard voltage	380V
Motor enclosure	ODP
Full load current (maximum) [MEPS]	24.7A[N/A]
Starting current DOL (Star Delta) [MEPS]	178 (60A)[N/A]
Starting time DOL (Star Delta)	3-5 sec (7-10 sec)
Starts per hour (maximum)	6
Control voltage	220VAC 110VAC
Recommended fuse rating See note 1	32A
Recommended wire size See note 2	6 mm2 Cu

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

PVC/PVC Type Calculated using the following conditions: PVC

insulated cable, armoured, copper conductors.

) Cable clipped to a wall, in free air.

Ambient temperature of 40°C (104°F) and relative humidity of 40%.
20m (65ft) cable

Volt drop limited to -10% during starting, -4% during normal

Protected by the circuit breaker listed

http://air.irco.comen en

16 INSTALLATION / HANDLING

CAUTION

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

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

ELECTRICAL DATA

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

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

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

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

OPERATING INSTRUCTIONS 17

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 35.6°F − 104°F (2°C to 40°C). The maximum temperature is applicable to either version up to a maximum elevation of 3280ft (1000m) above sea level. Above this altitude significant reduction in maximum allowable ambient temperature is required.

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

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

CAUTION

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

CAUTION

LOW DEMAND APPLICATIONS

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

THE COMPRESSOR SHOULD BE ALLOWED AMPLE LOADED RUNNING TIME.

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

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

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

The compressor load control system is automatic on−off line. The compressor will operate to maintain a set discharge line pressure and is provided with an auto restart system for use in plants where the air demand varies sufficiently to allow a compressor to shut down and save power. Significant system volume will assist this and is recommended.

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

18 OPERATING INSTRUCTIONS

COMPRESSOR CONTROLS

Direct online starting:

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

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

Pressure switch adjustment:

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

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

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

DUAL CONTROL

WARNING

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

WARNING

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

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

Auxiliary Valve.

A. Knob

B. Clockwise

C. Counterclockwise


A	Delta pressure setting
B	Pressure setting

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

NOTE

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

AUTOMATIC START & STOP CONTROL

OPERATING INSTRUCTIONS 19

PRESSURE GAUGE

Indicates the system pressure.

PRIOR TO STARTING

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

WARNING

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

Check coolant Add if necessary.

HOURMETER

Records the total running time of the compressor.

STOP BUTTON

When depressed will stop the compressor immediately.

ON PUSH BUTTON SWITCH

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

POWER ON INDICATOR LIGHT (Green)

Indicates the presence of control voltage.

FAULT INDICATOR LIGHT (Red)

Indicates machine is stopped due to fault condition (high temperature or motor overload).

Make sure air discharge valve is

Turn on electrical isolator or The Power on (5) indicator will light, indicating that line and control voltages are available.
Check direction of rotation at initial start or following interruption in power supply.

STARTING

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

NORMAL / EMERGENCY STOPPING

Press STOP button (3) and the compressor will stop
Turn off electrical isolator or

20 MAINTENANCE

Maintenance Schedule

PERIOD	MAINTENANCE
Each 24 hours operation Visual check of machine for any leaks, dust build up or unusual noise or vibration When compressor is receiver mounted	Check the coolant level and replenish if necessary. Report immediately, contact Ingersoll Rand authorized distributor for assistance if in doubt. Drain air receiver of condensate, or check that automatic drain is operating.
Visual check condition of package pre−filter	Blow clean if needed
First 150 hours	Change the coolant filter.
Each month or 100 hours	Remove and clean package pre−filter, replace if needed. Check the cooler(s) for build up of foreign matter. Clean if necessary by blowing out with air or by pressure washing.
Each 3 months	Operate the safety valve manually to verify that the valve mechanism is functioning correctly and that a small amount of air is released.
Each year or 2000 hours	Check the operation of the high temperature protection switch (109°C). Change the coolant filter. Check scavenge screen for blockage, clean if required. Change the separator element. Change the Air Filter element. Take coolant sample for fluid analysis. Change the package pre−filter. Check Drive Belts.
1 year external and 6 years internal pressure vessel inspection. Frequency may be otherwise defined by local or national legislation.	Separator vessel and air receiver when fitted. Fully inspect all external surfaces, and fittings. Report any excessive corrosion, mechanical or impact damage, leakage or other deterioration.
Every1.5 years or 6000 hours	Replace the Ultra Coolant at whichever interval occurs first.
Every two years or 8000 hours	Change drive belts. Check and replace all items included within 2000 hour service. Fit the following reconditioning parts as appropriate: Solenoid valves Inlet valve kit Minimum Pressure valve kit Thermostatic Valve Kit
Every 4 years or 16000 hours	Replace all hoses. Strip, clean and re−Grease motor bearings of ODP motors. Fit replacement electrical contactor tips.

. It should be noted that the intervals between service requirement may be significantly reduced as a consequence of poor operating environment. This would include effects of atmospheric contamination and extremes of temperature.

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

Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally.

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

Prior to attempting any maintenance work, ensure that:−

. all air pressure is fully discharged and isolated from the system. If the automatic blowdown valve is used for this purpose, then allow enough time for it to complete the operation.

. the machine cannot be started accidentally or otherwise.

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

Prior to opening or removing panels or covers to work inside

a machine, ensure that:−

. anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts.

. the machine cannot be started accidentally or otherwise.

Prior to attempting any maintenance work on a running

machine, ensure that:−

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

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

ROUTINE MAINTENANCE

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

. 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.).

. appropriate personal protective equipment is worn.

MAINTENANCE 21

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

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

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

. the machine is suitably tested.

. all guards and safety protection devices are refitted and correctly working.

. all panels are replaced, canopy and doors closed.

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

Repeat this procedure to get coolant to proper level when up to operating temperature.

When the unit is shut down, coolant will usually fill up sight glass. Do not adjust level based on level at shutdown. Proper level is always set for a running unit at operating temperature.

COOLANT CHANGE PROCEDURE

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

WARNING

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

Stop the machine, electrically isolate and vent all trapped

Place a suitable container close to the drain
Slowly remove fill

TOP UP COOLANT PROCEDURE

Slowly remove fill
Pour coolant into spout until spout almost

Replace and tighten oil fill
Start unit for about 10 seconds (until coolant drains out the bottom of the sight glass).
Slowly remove fill
Re−fill into spout until spout almost
Replace and tighten oil fill
Run
Remove plug from drain
Open the drain valve and drain coolant into
Close the drain
Replace plug in drain
Refill the machine following the ”top up coolant” procedure 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.
Replace and tighten fill

COOLANT FILTER CHANGE PROCEDURE

Stop the machine, electrically isolate and vent all trapped

NOTE

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

Loosen filter with the correct

Remove the filter from the

Place the old filter in a sealed bag and dispose of in a safe way.

Clean the mating face of the housing taking care to avoid any particles entering th

Remove the new Ingersoll Rand replacement filter from its protective

Apply a small amount of lubricant to the filter
Correct at operating temperature
Too much
OK
Too little

Screw the new filter down until the seal makes contact with the housing, then hand tighten a further half
Start the compressor and check for

22 MAINTENANCE

AIR FILTER ELEMENT CHANGE PROCEDURE

Stop the machine, electrically isolate and vent all trapped
Unscrew the retaining cap and withdraw the old
Fit the new
Replace the retaining

SEPARATOR ELEMENT CHANGE PROCEDURE

Stop the machine, electrically isolate and vent all trapped
Loosen separator element with the correct
Remove the element and place it in a sealed bag and dispose of it
Clean the mating face of the
Remove the new Ingersoll Rand replacement element from its protective
Apply a small amount of lubricant to the element
Screw the new element down until the seal makes contact with the housing, then hand tighten a further half
Start the compressor and check for

BELT CHECKING AND ADJUSTMENT PROCEDURE

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

satisfactorily.

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

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

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

Lay a straight edge across the top outer surface of the belt drive from pulley to
At the center of the span, perpendicular to the belt, apply pressure to the outer surface of the belt with a tension Force the belt to the deflection indicated in the table below, and compare the reading on

BELT TENSION

the tension gauge to the figures shown.

CAUTION

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

50Hz

5.5kw

7.5kw

11kw

New

Used

New

Used

New

Used

7 bar

85 lb

(39 kg)

70 lb

(32 kg)

110 lb

(50 kg)

90 lb

(41 kg)

140 lb

(64 kg)

120 lb

(54 kg)

8 bar

90 lb

(41 kg)

75 lb

(34 kg)

120 lb

(54 kg)

100 lb

(45 kg)

140 lb

(64 kg)

120 lb

(54 kg)

10 bar

90 lb

(41 kg)

75 lb

(34 kg)

120 lb

(54 kg)

100 lb

(45 kg)

150 lb

(68 kg)

125 lb

(57 kg)

COOLER CLEANING PROCEDURE

Stop the machine, electrically isolate and vent all trapped

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

CAUTION

Improper pulley/sheave alignment and belt tension can result in motor overload, excessive vibration, and premature belt and/or bearing failure.

To prevent these problems from occurring, ensure the pulley and sheave are aligned and belt tension is satisfactory after installing new belts or tensioning existing belts.

Remove the top cover to obtain access to the cooler.

Clean the cooler.
Rebuild in reverse order.

TROUBLE SHOOTING 23

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.
Compressor fails to start	Defective Star / Delta timer.	§ Change Star / Delta timer.
Machine shuts down periodically	High airend temperature.	Top up coolant.
	Motor overload.	§ Set overload to correct value and switch to manual reset.
	Line voltage variation.	§ Ensure voltage does not drop below 10% on start up and 6% running.
High current draw	Compressor operating above rated pressure.	Set pressure to correct rating for machine.
	Separator element contaminated	Change air filter, and separator element.
	Low voltage.	§ Ensure voltage does not drop below 10% on start up and 6% running.
	Unbalanced voltage.	Correct incoming supply voltage.
	Damaged airend.	† Change Airend.
Low current draw	Air filter contaminated.	Change air filter.
	Compressor operating unloaded.	Set pressure to correct rating for machine.
	High voltage.	Reduce site voltage to correct operating voltage.
	Defective inlet valve.	† Fit inlet valve service kit.
High discharge pressure	Defective or incorrect pressure switch setting.	Replace or set pressure to correct rating for machine.
	Blowdown valve defective.	† Fit blowdown solenoid service kit.
	Inlet valve malfunction.	† Fit inlet valve service kit.
Low system air pressure	Separator element contaminated.	Fit new Separator element.
	Incorrect pressure switch setting.	Set pressure to correct rating for machine.
	Minimum pressure valve malfunction.	† Fit Minimum pressure valve service kit.
	Blowdown valve defective.	† Fit blowdown solenoid service kit.
	Drive belt slipping.	Fit new belt.
	Air system leaks.	† Fix leaks.
	Inlet valve malfunction.	† Fit inlet valve service kit.
	System demand exceeds compressor delivery.	Reduce demand or install additional compressor.
	Compressed air filters contaminated..	Replace air filter elements.

NOTES:

Must be carried out by a competent electrician.

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

24 TROUBLE SHOOTING

PROBLEM	CAUSE	REMEDY
Compressor trips due to over temperature	Compressor operating above rated pressure.	Set pressure to correct rating for machine.
	Package pre−filter blocked.	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.
	Restricted cooling air flow.	Ensure correct air flow to compressor.
Excessive coolant consumption	Separator element leak.	Fit new Separator element.
	Blocked separator element drain.	† Remove fittings and clean.
	Compressor operating below rated pressure.	Set pressure to correct rating for machine.
	Coolant system leak.	† Fix leaks.
Excessive noise level	Air system leaks.	† Fix leaks.
	Airend defective.	† Change Airend.
	Belts Slipping.	Replace belt and tensioner.
	Motor defective.	† Replace motor.
	Loose components.	† Retighten loose items.
Shaft seal leaking	Defective shaft seal.	† Fit Airend shaft seal kit.
Pressure relief valve opens	Defective switch or incorrect pressure switch setting.	Replace or set pressure to correct rating for machine.
	Minimum pressure valve malfunction.	† Fit Minimum pressure valve service kit.
	Blowdown valve defective.	† Fit blowdown solenoid service kit.
	Inlet valve malfunction.	† Fit inlet valve service kit.
	Pressure relief valve defective.	Check the setting of the pressure relief valve and the rated pressure.
Black residue on belt guard/cooler box	Drive belt slipping.	Replace belt and tensioner.
	Pulleys misaligned.	Re−align pulleys.
	Worn pulleys.	† Replace pulleys and belt.
Safety valve blows when compressor goes on load.	Minimum pressure valve stuck closed.	Strip minimum pressure valve, examine and repair if necessary.
	Safety valve faulty.	Check the setting of the safety valve and the rated pressure.

NOTES:

Must be carried out by a competent electrician.

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