Ingersoll-Rand 100-200 Page 90 Operator'S Instruction Manual Download

Page: 90 / 93

DATE

RUN TIME

WORK DONE

QTY.

UNIT

WORK

(HOURS)

MEASURE

10.0 MAINTENANCE RECORD

Summary of Contents for 100-200

Page 1: ...maintaining the unit RETAIN THIS MANUAL WITH UNIT This Technical manual contains IMPORTANT SAFETY DATA and should be kept with the air compressor at all times 125 200 HP 90 160 KW SINGLE STAGE AND 10...

Page 2: ...rchaser 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...

Page 3: ...mprovements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously Number of units on order __________________________ Customer O...

Page 4: ...a p solenoid 7 5 separator delta p sensor 7 6 high dust filter 7 7 lead lag cycle length 7 8 schedule start stop 7 9 remote load unload 7 10 modbus 7 11 integral sequencing 8 0 REFERENCE DRAWINGS 8 1...

Page 5: ...cognized 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 provide...

Page 6: ...er to provide the appropriate service pipework to and from the machine WARNING CHECK HIGH AIR TEMPERATURE There is a high discharge air temperature shutdown function built into the Intellisys on each...

Page 7: ...filter plugs caps fittings or covers CAUTION Improper maintenance of coolant filter can cause compressor damage Change coolant filter after first 150 hours of operation and every 2000 hours thereafter...

Page 8: ...cedure 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 late...

Page 9: ...L VOLTAGE SERIAL NUMBER CONTACTOR AMP RATING ASSEMBLY AMP RATING LOCKED ROTOR AMP RATING OF ASSY AIR SOLUTIONS GROUP DAVIDSON NORTH CAROLINA 28036 WWW AIR INGERSOLL RAND COM 54425996 Rev C m3 MIN BARG...

Page 10: ...HIS 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 damag...

Page 11: ...pressor 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 helpf...

Page 12: ...on centration 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...

Page 13: ...ts 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 co...

Page 14: ...ntrol wiring for tightness Close and fasten the starter box door ROTATION CHECK Locate the rotation decal on each motor DRIVE MOTOR The correct compressor drive motor rotation is clockwise when viewed...

Page 15: ...See Figure 2 4 4 prior to operating the unit NOTE These instructions are also contained on the decal near the Intellisys panel of the unit FIGURE 2 4 3 MAIN DISCONNECT LOCKED AND TAGGED Open the start...

Page 16: ...f ambient temperature drops below 35 F 1 7 C to as low as 10 F 23 C the unit must be supplied with the Low Ambient Option Installations below 10 F 23 C ambient are not recommended The Low Ambient Opti...

Page 17: ...FIGURE 2 5 1 TYPICAL OUTDOOR SHELTERED INSTALLATION 15...

Page 18: ...16 3 0 INTELLISYS INTELLISYS CONTROLLER INGERSOLLrAND INTELLISYS...

Page 19: ...s button will cause the compressor to load if the compressor is running and if the Discharge Pressure is less than the Online Pressure This also returns the machine to the operating mode that is speci...

Page 20: ...ions are permitted at any particular time The action resulting from pressing each of these buttons is indicated in Figure 3 2 1 which can be used as a quick reference of how to step the controller scr...

Page 21: ...essing Calibrate will calibrate selected sensor Use UP and DOWN arrows to scroll through list of status items INTELLISYS Operator Panel Flow Diagram Figure 3 2 1 CURRENT STATUS MAIN MENU OPERATOR SETP...

Page 22: ...on 3 6 A setpoint s value can be changed by first highlighting the item and its value and pressing the SELECT button to highlight just the value When the value line is highlighted by itself the value...

Page 23: ...ssor will run unloaded before stopping This period does not apply to alarms shutdowns 3 5 8 Star Delta Time This setpoint is only used with star delta starters It is not used if the starter is full vo...

Page 24: ...ta P Solenoid This setpoint enables or disables the separator delta p solenoid option Enabling this option will automatically disable the Separator Delta P Sensor option 3 6 11 Separator Delta P Senso...

Page 25: ...bration screen can be exited by pressing either the STATUS or MAIN MENU buttons If no buttons are pressed within 30 seconds the display will return to the CURRENT STATUS screen 0 23 1 0 0 P S I ALARM...

Page 26: ...n 30 seconds the display will return to the CURRENT STATUS screen 1 0 0 P S I CLOCK FUNCTIONS Time 01 15 Date Jan 01 00 3 9 CLOCK FUNCTIONS The date and time for the real time clock is set through the...

Page 27: ...seconds the lead compressor will wait for the package discharge pressure to start rising after issuing a load command to another compressor If the package discharge pressure has not started rising at...

Page 28: ...ers as shown above The display message will indicate what caused the warning If multiple Warnings exist the small up down arrows will appear in the upper right corner of the display screen The multipl...

Page 29: ...l will issue a SERVICE REQUIRED warning at 150 hours This warning is a reminder for initial service and can be cleared by the operator Level 1 If service level 1 default is selected a SERVICE REQUIRED...

Page 30: ...TS This will occur if the controller has determined some of the data stored in memory contains unacceptable values When this occurs the sensors should be calibrated and all the set points checked It i...

Page 31: ...sure differential of 12 psi 8 bar at full load or if the Intellisys warning CHANGE SEPARATOR ELEMENT is displayed See Section 3 9 Running Time Interval whichever comes first Action Part or Item Hours...

Page 32: ...e When the temperature is greater than 120 F 49 C observe Coolant Filter on the screen If the display says Coolant Filter OK then the filter does not need service If is flashing on the screen and the...

Page 33: ...arter box when shipped from the factory The coolant should be drained soon after the compressor has been shut down When the coolant is hot drainage will be more complete and any particles in suspensio...

Page 34: ...diameter of the orifice and a direction of flow arrow is stamped in flat areas of the hexagon A removable screen and orifice is located in the exit end of the assembly See Figure 4 7 1 and will requi...

Page 35: ...d away Carefully lift the separator element up and out of the tank Discard the faulty element Clean the gasket surface on both the tank and its cover Exercise care to prevent pieces of the old gasket...

Page 36: ...em by closing the isolation valve and venting pressure from the drip leg Ensure the main power disconnect switch is locked open and tagged See Figure 4 9 1 TOOLS REQUIRED Screwdriver Wrench set Air ho...

Page 37: ...lange Disconnect tube from aftercooler outlet flange Remove aftercooler holding screws from aftercooler support and remove cooler Aftercooler Cleaning It is recommended the cooler be taken to a profes...

Page 38: ...some TEFC motors Grease should be added when the motor is stopped and power disconnected CAUTION Lubricant Amount Motor Frame Size in3 cc oz grams 182 215 5 8 4 11 254 286 1 0 16 8 23 324 365 1 5 25 1...

Page 39: ...POWER LOCK OUT AND TAG AND REPLACE THESE DRAIN FITTINGS TO PRECLUDE LOSS OF NEW GREASE AND ENTRANCE OF CONTAMINANTS Recommended Motor Grease 60 Hz motors require Mobilith SHC 220 39218193 Use the gre...

Page 40: ...e potential static electricity by touching grounding yourself to the starter box 3 Handle circuit boards only by their edges 4 Do not place the controller or power supply assembly on any metal surface...

Page 41: ...check for leaks 4 15 FLUID AND VIBRATION MONITORING Ingersoll Rand recommends incorporating predictive maintenance specifically the use of coolant and vibration analysis into all Preventative Maintena...

Page 42: ...ed temperature coolant passes through a filter to the airend under constant pressure 5 0 SYSTEMS 5 1 GENERAL SYSTEM INFORMATION The SSR compressor is an electric motor driven single stage screw compre...

Page 43: ...affles maintain the circumferential flow of remaining coolant droplets and air In an almost continuous change of direction of flow more and more droplets are removed from the air by inertial action an...

Page 44: ...ng unloaded operation ON OFF LINE CONTROL For those plants which have a widely varying air demand on off line control will deliver air at full capacity compressor maximum efficiency condition or will...

Page 45: ...ration set point is changed 43 5 9 AUTOMATIC START STOP CONTROL Many plant air systems have widely varying air demands or large air storage capacity which allows for automatic standby air capacity con...

Page 46: ...r to stop much sooner in certain situations and timer settings thereby reducing power costs Some Examples of Operation EXAMPLE 1 The operator selects an unloaded run time of 2 minutes in the OPTION ro...

Page 47: ...te mounted start stop station Two different switches can be wired to the controller for remote start stop Refer to Electrical Schematic 8 1 for wiring locations The switches are customer supplied and...

Page 48: ...or fan motor overload relay and press reset button twice Check for defective sensor bad sensor connection or broken sensor wires Call factory representative Check fuses Check wiring Verify 24 VAC is w...

Page 49: ...Loose component mounting Loose components Motor or compressor bearing failure External sources Compressor operating over pressure Defective valve WHAT TO DO Press LOAD button Press STOP button Set of...

Page 50: ...arator delta p solenoid option is turned on by enabling it through the OPTIONS set point routine When this option is enabled the Intellisys will measure the pressure drop across the separator element...

Page 51: ...e line pressure to rise This time period is determined by the load delay time set point At the end of this time period if line pressure is not rising the lead compressor will transmit a load command t...

Page 52: ...50 54418074 REV B 8 0 REFERENCE DRAWINGS 8 1 ELECTRICAL SCHEMATIC STAR DELTA...

Page 53: ...51...

Page 54: ...52 54622865 REV B 8 2 FOUNDATION PLAN 125 150 HP 90 110KW AIRCOOLED SINGLE STAGE CONTINUED...

Page 55: ...53 54622865 REV B 8 2 FOUNDATION PLAN 125 150 HP 90 110 KW AIRCOOLED SINGLE STAGE...

Page 56: ...8 3 FOUNDATION PLAN 200 HP 132 160 KW AIRCOOLED SINGLE STAGE CONTINUED 54622931 REV B 54...

Page 57: ...8 3 FOUNDATION PLAN 200 HP 132 160 KW AIRCOOLED SINGLE STAGE 54622931 REV B 55...

Page 58: ...56 8 4 FOUNDATION PLAN 125 150 HP 90 110 KW WATERCOOLED SINGLE STAGE CONTINUED 39925300 REV C...

Page 59: ...57 8 4 FOUNDATION PLAN 125 150 HP 90 110 KW WATERCOOLED SINGLE STAGE 39925300 REV C...

Page 60: ...58 8 5 FOUNDATION PLAN 200 HP 132 160 KW WATERCOOLED SINGLE STAGE CONTINUED 39926191 REV C...

Page 61: ...59 8 5 FOUNDATION PLAN 200 HP 132 160 KW WATERCOOLED SINGLE STAGE 39926191 REV C...

Page 62: ...60 8 6 FOUNDATION PLAN AIRCOOLED CONTINUED 100 150 HP 75 110 KW TWO STAGE 54622980 REV B...

Page 63: ...61 54622980 REV B 8 6 FOUNDATION PLAN AIRCOOLED 100 150 HP 75 110 KW TWO STAGE...

Page 64: ...62 8 7 FOUNDATION PLAN AIRCOOLED CONTINUED 200 HP 132 160 KW TWO STAGE 54623053 REV B...

Page 65: ...63 54623053 REV B 8 7 FOUNDATION PLAN AIRCOOLED 200 HP 132 160 KW TWO STAGE...

Page 66: ...64 8 8 FOUNDATION PLAN WATERCOOLED CONTINUED 100 150 HP 75 110 KW TWO STAGE 39925326 REV C...

Page 67: ...65 8 8 FOUNDATION PLAN WATERCOOLED 100 150 HP 75 110 KW TWO STAGE 39925326 REV C...

Page 68: ...66 8 9 FOUNDATION PLAN WATERCOOLED CONTINUED 200 HP 132 160 KW TWO STAGE 39926340 REV C...

Page 69: ...67 8 9 FOUNDATION PLAN WATERCOOLED 200 HP 132 160 KW TWO STAGE 39926340 REV C...

Page 70: ...68 8 10 FLOW SCHEMATIC AIRCOOLED SINGLE STAGE 54579081 REV A...

Page 71: ...69...

Page 72: ...70 8 11 FLOW SCHEMATIC WATERCOOLED 90 F 32 C SINGLE STAGE 54579503 REV A...

Page 73: ...71...

Page 74: ...72 8 12 FLOW SCHEMATIC WATERCOOLED 115 F 46 SINGLE STAGE 54579511 REV A...

Page 75: ...73...

Page 76: ...74 8 13 FLOW SCHEMATIC AIR COOLED TWO STAGE 54579644 REV A...

Page 77: ...75...

Page 78: ...76 8 14 FLOW SCHEMATIC WATERCOOLED 90 F 32 C TWO STAGE 54579693 REV A...

Page 79: ...77...

Page 80: ...78 8 15 FLOW SCHEMATIC WATERCOOLED 115 F 46 C TWO STAGE 54579727 REV A...

Page 81: ...79...

Page 82: ...80 8 16 TYPICAL SYSTEM FLOW DIAGRAMS TYPICAL SYSTEM FLOW DIAGRAM...

Page 83: ...81 8 16 TYPICAL SYSTEM FLOW DIAGRAMS...

Page 84: ...82 8 16 TYPICAL SYSTEM FLOW DIAGRAMS...

Page 85: ...83 8 16 TYPICAL SYSTEM FLOW DIAGRAMS...

Page 86: ...84 8 16 TYPICAL SYSTEM FLOW DIAGRAMS...

Page 87: ...le formation is the precipitation of calcium carbonate out of the water This is dependent on temperature and pH The higher the pH value the greater the chance of scale formation Scale can be controlle...

Page 88: ...cal balance If the Ll is greater than zero there is a tendency to form scale If the Ll is less than zero the water tends to be corrosive Dissolved oxygen may be controlled in closed cooling towers Sev...

Page 89: ...2 1 80 1 78 1 76 100 1 74 1 72 1 71 1 09 1 67 110 1 05 1 64 1 62 1 60 1 58 120 1 67 1 63 1 53 1 51 1 50 130 1 48 1 46 1 44 1 43 1 41 140 1 40 1 38 1 37 1 35 1 34 150 1 32 1 31 1 29 1 28 1 27 160 1 26...

Page 90: ...88 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY 10 0 MAINTENANCE RECORD...

Page 91: ...89 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD...

Page 92: ...90 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD...

Page 93: ...91 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD...

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