Ingersoll-Rand IRN100-200H-2S Operation And Maintenance Manual Download Page 97

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IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & R190-225NE

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11.0 FAULT FINDING

SYMPTOM

FAULT

REMEDY

Pressure produced by

compressor is too high

compressor is too high due to

speed not reducing as demand

reduces

Intellisys set incorrectly

Check and modify settings

Pressure transducer may be

faulty, incorrectly calibrated or

not receiving pressure signal

Recalibrate or replace

Drive settings fault

Contact your local IR representative

Compressor discharge air too

hot

High ambient temperature

Review installation and system parameters

Insufficient cooling air

Check ducting and cooling air path, check

direction of blower rotation

Blocked aftercooler matrix

Clean or replace

Compressor package produces

excessive noise

Panels or doors are not closed

properly

Rectify fault

Air leaks from internal pipework /

components

Overhaul or replace

Blower or blower motor bearings

worn

Overhaul or replace

Loose debris impacting on

blower during rotation

Remove and rectify any damage

Blowdown valve stuck open

Overhaul or replace

Pressure relief valve not seating

correctly

Overhaul or replace

Vibration due to motor, airend or

blower imbalance

Overhaul or replace

Airend requires overhaul

Contact your local IR representative

Discharge air is contaminated

with coolant

Scavenge pipe is blocked, broken

or o-ring is not sealing

Clean or replace

Separator element is punctured,

or incorrect, or requires changing,

or not sealing correctly

Replace

Incorrect coolant has been added Drain system, check for damage. Clean, refill

with correct coolant

System has been overfilled with

coolant

Check for damage, drain excess

111213.14.59

Summary of Contents for IRN100-200H-2S

Page 1: ...75 160K 2S IRN100 200H 2S R190 225NE Operation and Maintenance Manual 111213 14 59 ENGLISH CZECH DANISH BULGARIAN PRINT LANGUAGE DUTCH FINNISH ESTONIAN FRENCH GERMAN HUNGARIAN ITALIAN LATVIAN LITHUANIAN MALTESE NORWEGIAN POLISH PORTUGUESE ROMANIAN SLOVAKIAN SLOVENIAN SPANISH SWEDISH TURKISH ...

Page 2: ...Company s prior written approval The effects of corrosion erosion and normal wear and tear are specifically excluded Performance warranties are limited to those specifically stated within the Company s proposal Unless responsibility for meeting such performance warranties are limited to specified tests the Company s obligation shall be to correct in the manner and for the period of time provided a...

Page 3: ...ION 29 8 1 TECHNICAL INFORMATION 33 8 2 INSTALLATION DRAWING 36 8 3 PROCESS AND INSTRUMENTATION DIAGRAM 46 8 4 ELECTRICAL SCHEMATIC 54 8 5 GENERAL DESCRIPTION 68 9 0 OPERATING INSTRUCTIONS 69 9 1 BASIC OPERATION 69 9 2 INTELLISYS CONTROLS 71 9 3 DISPLAY SCREEN 72 9 4 CURRENT STATUS SCREEN 73 9 5 MAIN MENU 74 9 6 OPERATOR SETPOINTS 75 9 7 OPTIONS 77 9 8 SENSOR CALIBRATION 78 9 9 ALARM HISTORY 79 9 ...

Page 4: ...onents accessories pipes and connectors added to the compressed air system should be of good quality procured from a reputable manufac turer and wherever possible be of a type approved by Ingersoll Rand clearly rated for a pressure at least equal to the ma chine maximum allowable working pressure compatible with the compressor lubricant coolant accompanied with instructions for safe installation o...

Page 5: ...e hazardous conditions over which Ingersoll Rand has no control Therefore Ingersoll Rand cannot be held responsible for equipment in which non approved repair parts are installed warning The motor rotor contains a powerful magnetic field This field can effect the operation of digital devices such as watches mobile phones etc Assembly or handling of the rotor should not be attempted by personnel wi...

Page 6: ...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 Open drip proof motor ppm parts per million cs Czech da Danish de German el Greek en English es Spanish et Estonian fi Finnish fr French hu Hungarian it Italian lt Lithuanian lv Latvian Lettish mt Maltese nl Dutch no Norwegian pl Polish pt Por...

Page 7: ...erves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously No of units on order ____________________________________________ Customer Order No _____________________________________________ Ingersoll Rand Co Order No______________________________________ For ready reference Record ...

Page 8: ...e sure that all protective covers are in place and that the canopy doors are closed during operation Installation of this compressor must be in accordance with recognized electrical codes and any local Health and Safety Codes Use only safety solvent for cleaning the compressor and auxiliary equipment Compressed air Ensure that the machine is operating at the rated pressure and that the rated press...

Page 9: ...s or induce vomiting if the patient is unconscious or having convulsions The above information contains data supplied in support of United Kingdom Control of Substances Hazardous to Health C O S H H regulations Transport When loading or transporting machines ensure that the specified lifting and tie down points are used It is recommended that the machine be moved using the fork lift slots in the m...

Page 10: ...o the air stream therefore compatibility between discharge piping system accessories and software must be assured For the foregoing reasons the use of plastic piping and rubber hose as discharge piping is not recommended In addition flexible joints and or flex lines can only be considered for such purposes if their specifications fit the operating parameters of the system It is the responsibility ...

Page 11: ...n satisfactory compressor operation and maintenance a minimum of 3 feet clearance on 3 sides is required 3 1 2 feet is required in front of the control panel or minimum required by latest National Electrical code or applicable local codes Refer to the Instruction Operators Manual before performing any maintenance air Can contain carbon monoxide or other contaminants Will cause severe injury or dea...

Page 12: ... can operate in a pressurized shutdown mode Relieve pressure before removing filter plugs caps fittings or covers NOTICE Air discharge CAUTION Use of incorrect coolant can cause system contamination Use only SSR ULTRA COOLANT WARNING Food contaminant Can cause severe injury or death Use only Ingersoll Rand SSR H 1F food grade coolant NOTICE Lift here WARNING Hot surface Can cause severe injury Do ...

Page 13: ... 2000 hours thereafter or when coolant is changed NOTICE Rotation Rotation Rotation WARNING 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 Service only with machine blocked to prevent turn over Air Disc...

Page 14: ... de cuivre 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 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 IMPORTANT 39481130 Rev 02 39540158 Rev 05 To obtain satisfactory compressor operati...

Page 15: ...F 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 Pressurized vessel Do not remove the Operating and Maintenance manual from this machine WARNING Flammable liquid 111213 14 59 ...

Page 16: ...ating 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 Do not operate the machine without the guard being in place Do not stand on any service valve or other parts of the pressure system Do not operate with the doors or enclosure open Do not use fork lift truck fro...

Page 17: ... 5 0 SAFETY Use fork lift truck from this side only Emergency stop Tie down point Lifting point On 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 111213 14 59 ...

Page 18: ...ATOR 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 111213 14 59 ...

Page 19: ...ersollrandproducts com 19 EN 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 Kg mm 0v c d SERVICE 15 Min 111213 14 59 ...

Page 20: ...grant a concealed damage notation If you give the transportation company a clear receipt for goods that have been damaged or lost in transit you do so at your own risk and expense WE AT lR ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL THE ACTUAL...

Page 21: ...de for lifting heavy components during major overhaul Use only lifting points provided Minimum space in front of control panel door as required by National or Local codes must be maintained The compressor can be installed on any level floor capable of supporting it A dry well ventilated area where the atmosphere is as clean as possible is recommended Sufficient space all round and above the compre...

Page 22: ...ould be taken to ensure that downstream equipment is compatible When two rotary units are operated in parallel provide an isolation valve and drain trap for each compressor before the common receiver The built in aftercooler reduces the discharge air temperature below the dew point for most ambient conditions therefore considerable water vapor is condensed To remove this condensation each compress...

Page 23: ...or incoming power connection If it is necessary to make a hole in the control box in a different location care should be taken to not allow metal shavings to enter the starter and other electrical components within the box If another hole is used the original hole must be blocked off The feeder cable must be suitably glanded into the power drive module P D M electrical box to ensure that dirty air...

Page 24: ...drive due to voltage spikes line notching harmonics or other power quality related problems will not be covered by the standard compressor warranty The correct type and rating of line input fuse MUST BE fitted onto the customers isolator or breaker close to the compressor For Amp rating see technical information in Section 8 1 Product Identification Class J Class T or Semiconductor Fuse Type Fast ...

Page 25: ...5 and 72 5 psi but must not be above 10 bar 145 psi Water cleanliness is also extremely important Cleaning of coolers as a result of fouling is a customer responsibility Therefore it is highly recommended that proper water quality must meet the requirements listed in WATER QUALITY RECOMMENDATIONS later in this section Venting the water system At the initial installation or for start up after drain...

Page 26: ...arbonate 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 controlled with water treatment Corrosion In contrast to scale formation is the problem of corrosion Chlorides cause problems because of their size and conductivity Low pH levels promote corrosion as well as high levels of dissolved oxygen Fouling Biologi...

Page 27: ... the sea water flow rate through the cooler may be several times the recommended maximum which will lead to rapid failure Sea Water Pressure Bar psi Orifice diameter in mm inch to give a maximum sea water flow of 90 l min 23 76 US gall min 3 43 5 12 0 472 4 58 11 0 433 5 72 5 10 0 394 6 87 9 6 0 378 7 101 5 9 2 0 362 8 116 8 9 0 35 9 130 5 8 7 0 343 10 145 8 4 0 33 No oil cooler manufacturer can g...

Page 28: ...ot suitable for use outdoors If the Outdoor Modification Option is fitted to a machine which will be operated within the EU the machine is not intended to be used as hire equipment or moved from place to place It must be installed as fixed machinery which is not intended to be moved during its operational life For example a compressor permanently fixed outside of buildings and is therefore exclude...

Page 29: ... outlet ΔT C F 8 15 8 15 8 15 8 15 Water Cooling System Cooling clean water flow l min US gallon min 10 C 50 F 32 C 90 F 23 38 6 10 27 49 7 13 23 38 6 10 27 49 7 13 Maximum ΔP in air ducts Pa inch WG 62 0 25 62 0 25 62 0 25 62 0 25 Compressed air outlet ΔT C F 14 25 14 25 14 25 14 25 Main Power Circuit A C W C Package full load current at 220V A 140 131 168 159 140 131 168 159 Package full load cu...

Page 30: ...5 8 15 8 15 8 15 Water Cooling System Cooling clean water flow l min US gallon min 10 C 50 F 32 C 90 F 51 38 13 5 10 95 46 25 12 51 38 13 5 10 95 46 25 12 Maximum ΔP in air ducts Pa inch WG 62 0 25 62 0 25 62 0 25 62 0 25 Compressed air outlet ΔT C F 14 25 14 25 14 25 14 25 Main Power Circuit A C W C Package full load current at 220V A 208 196 208 196 Package full load current at 400V A 110 104 14...

Page 31: ...05 124 05 124 05 Compressed air outlet ΔT C F 8 15 8 15 8 15 8 15 Water Cooling System Cooling clean water flow l min US gallon min 10 C 50 F 32 C 90 F 84 65 22 17 95 72 25 19 84 65 22 17 95 72 25 19 Maximum ΔP in air ducts Pa inch WG 62 0 25 62 0 25 62 0 25 62 0 25 Compressed air outlet ΔT C F 14 25 14 25 14 25 14 25 Main Power Circuit A C W C Package full load current at 400V A 182 170 218 206 P...

Page 32: ...5 Compressed air outlet ΔT C F 8 15 8 15 8 15 Water Cooling System Cooling clean water flow l min US gallon min 10 C 50 F 32 C 90 F 110 87 29 23 125 106 33 28 125 106 33 28 Maximum ΔP in air ducts Pa inch WG 62 0 25 62 0 25 62 0 25 Compressed air outlet ΔT C F 14 25 14 25 14 25 Main Power Circuit A C W C Package full load current at 400V A 251 239 301 289 Package full load current at 460V A 255 24...

Page 33: ...P in air ducts Pa inch WG 124 0 5 124 0 5 124 0 5 124 0 5 124 0 5 124 0 5 Compressed air outlet ΔT C F 8 15 8 15 8 15 8 15 8 15 8 15 Water Cooling System Cooling clean water flow l min US gallon min 10 C 50 F 32 C 90 F 175 106 46 28 84 65 22 17 95 72 25 19 175 106 46 28 84 65 22 17 95 72 25 19 Maximum ΔP in air ducts Pa inch WG 62 0 25 62 0 25 62 0 25 62 0 25 62 0 25 62 0 25 Compressed air outlet ...

Page 34: ... F 8 15 8 15 8 15 Water Cooling System Cooling clean water flow l min US gallon min 10 C 50 F 32 C 90 F 110 87 29 23 125 106 33 28 125 106 33 28 Maximum ΔP in air ducts Pa inch WG 62 0 25 62 0 25 62 0 25 Compressed air outlet ΔT C F 14 25 14 25 14 25 Main Power Circuit A C W C Package full load current at 400V A 251 239 301 289 Package full load current at 460V A 255 245 Package full load current ...

Page 35: ...IRN37 160K CC IRN50 200H IRN75 160K 2S IRN 100 200H 2S R190 225NE ingersollrandproducts com 35 EN 8 0 GENERAL INFORMATION For R190 225NE data please refer to engineering data pages 111213 14 59 ...

Page 36: ...e 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 G 4 x Ø 13 0mm 0 5 Compressor should be bolted to the floor with four M10 0 38 bolts using holes shown Seal base to floor with cork or...

Page 37: ...rences 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 G 4 x Ø 13 0mm 0 5 Compressor should be bolted to the floor with four M10 0 38 bolts using holes shown Seal base to floor with cork or rubber H INTELLISYS Controller J 1 NPT Water inlet Female 60Hz units 1 BSP...

Page 38: ...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 G 4 x Ø 13 0mm 0 5 Compressor should be bolted to the floor with four M10 0 38 bolts using holes shown Seal base to floor with cork or r...

Page 39: ...nces 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 G 4 x Ø 13 0mm 0 5 Compressor should be bolted to the floor with four M10 0 38 bolts using holes shown Seal base to floor with cork or rubber H INTELLISYS Controller J 1 NPT Water inlet Female 60Hz units 1 BSP W...

Page 40: ... CC IRN50 200H CC IRN75 160K 2S IRN100 200H 2S R190 225NE ingersollrandproducts com 40 EN 8 0 GENERAL INFORMATION 8 2 INSTALLATION DRAWING N90 160K CC SINGLE STAGE N90 160K CC TWO STAGE Water Cooled 111213 14 59 ...

Page 41: ...parately 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 G 4 x Ø 13 0mm 0 5 Compressor should be bolted to the floor with four M10 0 38 bolts using holes shown Seal base to floor with cork or rubber H INTELLISYS Controller J 1 5...

Page 42: ...N50 200H CC IRN75 160K 2S IRN100 200H 2S R190 225NE ingersollrandproducts com 42 EN 8 0 GENERAL INFORMATION 8 2 INSTALLATION DRAWING N90 160K N125 200H SINGLE STAGE N75 160K N100 200H TWO STAGE Air Cooled 111213 14 59 ...

Page 43: ...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 Read operations manual and check local regulations D Cooling airflow E Exhaust airflow F Cabinet cooling airflow G 4 x Ø 13 0mm 0 5 Compressor should be bolted to the floor with four M10 0 38 bolts using h...

Page 44: ...4 0 65 91 4X 14 0 0 55 25 5 1 00 G W V X I Y Z 23442510 Rev A KEY A Discharge Air 3 0 Asa 150 Flange B Electrical connections Ø75mm 3 C Condensate drain 0 5 BSPT 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 Inlet airflow E Exhaust...

Page 45: ... 37 99 1674 0 65 91 1879 0 73 98 25 5 1 00 B H F I G A C D E W V Y X Z 23442502 Rev A KEY A Discharge Air 3 0 Asa 150 Flange B Electrical connections Ø75mm 3 C Condensate drain 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 Read operations manual and check local regulations D Inl...

Page 46: ...ATION 8 3 PROCESS AND INSTRUMENTATION DIAGRAM N37 45K CC N50 60h CC 1 2 3 4 5 6 7 9 10 11 12 14 15 16 17 18 19 20 22 23 24 25 26 27 T 28 21 D F F 33 7 30 31 34 35 32 36 8 P 39 P P 37 T P 13 T V M M T 41 T T 42 29 P 38 44 40 43 21 T 21 R 45 T 7 46 2nd 23 M 1st 47 48 P 2 TWO STAGE ONLY 49 22381206 Revision B 111213 14 59 ...

Page 47: ...ater outlet W C only 28 Pressure transducer 3APT 29 Pressure transducer 6APT 30 Dryer customer supply equipment 31 Line filters customer equipment 32 Receivers customer equipment 33 Dryer AUX warning 34 Line filter AUX warning 35 Receiver trap AUX warning 36 Remote pressure transducer 9APT optional 37 Water stop valve 4SV 38 Typical customer downstream air treatment 39 Anti condensation valve 11SV...

Page 48: ...4 5 6 7 9 10 11 12 14 15 16 17 18 19 20 22 23 24 25 26 27 PIPING LEGEND AIR COOLANT AIR COOLANT COOLING WATER W C ONLY CONDENSATE T 28 21 D F F 33 7 30 31 34 35 32 36 8 P 39 P P 37 T COMPRESSOR ENCLOSURE P 13 T V M M SENSOR CONNECTION T 41 T T 42 29 P 38 EQUIPMENT DOWNSTREAM OF COMPRESSOR 44 40 43 21 T 21 R 45 T 7 46 2nd 23 M 1st 48 P 2 TWO STAGE ONLY 49 T 50 23128994 Revision A 111213 14 59 ...

Page 49: ...essure transducer 3APT WET 29 Pressure transducer 6APT DRY 30 Dryer customer equipment 31 Line filters customer equipment 32 Receivers customer equipment 33 Dryer aux warning 34 Line filter aux warning AW1 Wire in series 35 Receiver trap aux warning 36 Remote air pressure transducer 9APT Optional 37 Water shutoff valve 4SV W C only 38 Typical customer downstream air treatment 39 Anti condensation ...

Page 50: ...RUMENTATION DIAGRAM N90 160K N125 200H SINGLE STAGE AND N75 160K N100 200H TWO STAGE 1 2 3 4 5 6 7 9 10 11 12 14 15 16 17 18 19 20 22 23 24 25 26 27 T 28 21 D F F 33 7 30 31 34 35 32 36 8 P 39 P P 37 T P 13 T V M M T 41 T T 42 29 P 38 44 40 43 21 T 21 R 45 T 7 46 2nd 23 M 1st 47 48 P 2 TWO STAGE ONLY 49 50 T 51 22099006 Revision C 111213 14 59 ...

Page 51: ...28 Pressure transducer 3APT 29 Pressure transducer 6APT 30 Dryer customer supply equipment 31 Line filters customer equipment 32 Receivers customer equipment 33 Dryer AUX warning 34 Line filter AUX warning 35 Receiver trap AUX warning 36 Remote pressure transducer 9APT optional 37 Water stop valve 4SV W C only 38 Typical customer downstream air treatment 39 Anti condensation valve 11SV 40 Cooling ...

Page 52: ...1 3 4 5 6 9 10 11 12 14 15 16 17 18 19 20 22 24 25 26 27 PIPING LEGEND AIR COOLANT AIR COOLANT COOLING WATER W C ONLY CONDENSATE T 28 21 D F F 33 7 30 31 34 35 32 36 8 P 39 P P 37 T COMPRESSOR ENCLOSURE P T V M SENSOR CONNECTION T 41 T T 42 29 P 38 EQUIPMENT DOWNSTREAM OF COMPRESSOR 40 43 21 T 21 R 45 T 7 46 2nd 23 M 1st 47 48 P 2 49 50 T 52 51 13 44 23487978 Revision B 111213 14 59 ...

Page 53: ... Cooling water inlet W C only 27 Cooling water outlet W C only 28 Pressure transducer 3APT WET 29 Pressure transducer 6APT DRY 30 Dryer customer equipment 31 Line filters customer equipment 32 Receivers customer equipment 33 Dryer aux warning 34 Line filter aux warning AW1 wire in series 35 Receiver trap aux warning 36 Remote air pressure transducer 9APT optional 37 Water shutoff valve 4SV W C onl...

Page 54: ... EB 1 2 RST RSP BLK RED 1 2 3 4 5 6 P4 SS1 SS3 TRR WR 1 2 7 8 RED BLK BLK WHI BLK WHI RED BLK ST AT MF OPT 400 460V 3ph 50 60Hz 3SV 11SV 1 2 SS2 A B SC SC SD SD 1 2 1 2 K1 230V 200V FM MMS U V W L1 L2 12 18 27 U V W 16 17 18 K1 2 242 FD 240 241 01 02 60 55 214 215 252 253 L3 P5 P5 T P6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 P5 T T P P P 2CTT 2ATT 4ATT 4APT 3APT 6APT WHI BLK WHI WHI BLK WHI BLK...

Page 55: ...ansformer MCB2 Breaker miniature circuit DVF MCB3 Breaker miniature circuit control circuits MCB4 Breaker miniature circuit VFD supply MCB5 Breaker miniature circuit PSU MCB9 Breaker miniature circuit heater MF Mains filter if fitted MM Motor main MMS Breaker blower motor OPT Optional OV Zero voltage PE Protected earth PORO Power outage restart option optional PSU Power supply unit RFI Filter radi...

Page 56: ...HI BLK WHI BLK BLK RED WHI BLK RED WHI BLK RED V V V T P6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 P5 T T P P P 2CTT 2ATT 4ATT 4APT 3APT 6APT WHI BLK 4 20 mA 10 FAULT PORO OPT 105 110V 120 126 9SV 9 T 1ATT WHI BLK 24V START STOP 1 M K 1 M K 116 OUTPUT 252 253 16 17 18 CDE OPT PE FD 4CTT WHI BLK T 9 10 L1 L2 L3 PX6 1 2 PX1 102 115 L1 L2 L3 127 123 PE DR DR PX3 2 3 6 7 GND RED BLK PX4 3 7 2 5 1 4 ...

Page 57: ...r miniature circuit heaters MF Mains filter if fitted MM Motor main MMS Breaker fan motor OPT Optional OV Zero voltage PE Protected earth PORO Power outage restart option optional PSU Power supply unit RFI Filter radio frequency interference RSP Remote stop RST Remote start SGNE Controller intellisys SL Serial link SS1 3 Relay solid state ST Service tool T1 Transformer control TH Thermostat TRR Tr...

Page 58: ... 460V 3ph 50 60Hz 3SV 11SV 1 2 SS2 A B SC SC SD SD 1 2 1 2 K1 230V 200V FM MMS U V W 16 17 18 5 P5 P T P6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 P5 T T P P P 2CTT 2ATT 4ATT 4APT 3APT 6APT WHI BLK WHI WHI BLK WHI BLK BLK RED WHI BLK RED WHI BLK RED V V V T P6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 P5 T T P P P 2CTT 2ATT 4ATT 4APT 3APT 6APT WHI BLK 4 20 mA 10 PORO OPT 105 110V 120 126 9SV 9 ...

Page 59: ...1 Breaker miniature circuit transformer MCB2 Breaker miniature circuit DVF MCB3 Breaker miniature circuit VFD supply MCB4 Breaker miniature circuit VFD supply MCB5 Breaker miniature circuit PSU MCB9 Breaker miniature circuit heaters MF Mains filter if fitted MM Motor main MMS Breaker fan motor OPT Optional OV Zero voltage PE Protected earth PORO Power outage restart option optional PSU Power suppl...

Page 60: ... MF OPT 400 460V 3ph 50 60Hz 3SV 11SV 1 2 SS2 A B SC SC SD SD 1 2 1 2 K1 230V 200V FM MMS U V W 16 17 18 5 P5 P T P6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 P5 T T P P P 2CTT 2ATT 4ATT 4APT 3APT 6APT WHI BLK WHI WHI BLK WHI BLK BLK RED WHI BLK RED WHI BLK RED V V V T P6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 P5 T T P P P 2CTT 2ATT 4ATT 4APT 3APT 6APT WHI BLK 4 20 mA 10 PORO OPT 105 110V 120...

Page 61: ... ventilation fan MCB1 Breaker miniature circuit transformer MCB2 Breaker miniature circuit DVF MCB3 Breaker miniature circuit VFD supply MCB4 Breaker miniature circuit VFD supply MCB5 Breaker miniature circuit PSU MCB9 Breaker miniature circuit heaters MF Mains filter if fitted MM Motor main MMS Breaker fan motor OPT Optional OV Zero voltage PE Protected earth PORO Power outage restart option opti...

Page 62: ...53 252 CDV 12V SIGNAL AW2 116 9 9SV 1ATT WHI BLK CDE 17 18 OPT 10 11 WHI BLK RED HTR P V P V P V 2APT 2 STG ONLY T T T L1 L2 L3 MM DR FD 13 MMS2 KM5 14 15 U V W PE 380 480V 50 60 Hz 3ph PE 1 1 2 L3 214A MMS1 1 214B MMS2 1 9 10 4CTT WHI BLK T L1 L2 L3 PX6 1 3 K1 1 1 STG ONLY P 4 20mA 1 2 PX1 PX2 102 123 PX3 231 230 5 6 P 4 20mA 152 151 2 WHI BLK 9APT WHI 3 RED 4 2 7 6 7 GND RED BLK OPT RED MM PX4 3...

Page 63: ...iature circuit transformer MCB2 Breaker miniature circuit control circuits MCB3 Breaker miniature circuit DR MCB4 Breaker miniature circuit PSU MCB9 Breaker miniature circuit heater MCB10 Breaker miniature circuit heater external MF Mains filter if fitted MM Motor main MMS1 Breaker fan motor MMS2 Breaker heatsink blower OPT Optional OV Zero voltage PE Protective earth PORO Power outage restart opt...

Page 64: ...TG ONLY T T T L1 L2 L3 MM DR FD PE 380 480V 50 60 Hz 3ph PE 1 1 2 WHI BLK RED P V WHI BLK RED P V WHI BLK RED P V HB MMS2 KM5 KM1 K1 KM5 4SV U V W U V W 13 14 15 MMS1 1 214 215 MMS2 1 214A 9 10 4CTT WHI BLK T L1 L2 L3 PX6 1 2 PX1 102 123 PX3 152 151 2 3 6 7 GND RED BLK MM PX4 3 7 2 5 1 4 6 1 2 3 U V W YEL BLK RED GRE BRO BLU VIO GND DR CK 1 DC BUS RECTIFIER 1 3 K1 1 1 STG ONLY P 4 20mA PX2 231 230...

Page 65: ... miniature circuit transformer MCB2 Breaker miniature circuit control circuits MCB3 Breaker miniature circuit DR MCB4 Breaker miniature circuit PSU MCB9 Breaker miniature circuit heater MCB10 Breaker miniature circuit heater external MF Mains filter if fitted MM Motor main MMS1 Breaker fan motor MMS2 Breaker heatsink blower OPT Optional OV Zero voltage PE Protective earth PORO Power outage restart...

Page 66: ...K CDE 17 18 OPT 10 11 WHI BLK RED HTR P V P V P V 2APT T T T L1 L2 L3 MM DR FD PE 1 1 2 L3 214A MMS1 1 214B MMS2 1 5SV K1 3 MCB5 230v KM5 1 DVF 124 106 107 122 115 FD 21 FD 20 FD 11 FD 12 SGNe P3 5 SGNe P3 6 SGNe P4 10 SGNe P4 9 A C FM MMS1 U V W KM5 16 17 18 W C L1 L2 L3 L1 L2 L3 PX6 1 3 P 4 20mA 1 2 PX1 PX2 102 123 PX3 231 5 6 P 152 151 2 WHI BLK 9APT WHI 3 RED 4 2 7 6 7 GND RED BLK OPT RED MM P...

Page 67: ...r ES Switch emergency stop EXC External communications F10 Fuse external heater supply FD Fan drive FM Motor blower GND Ground HTR1 Heater 125 watts K1 Relay run K2 Relay fault KM1 Contactor main motor KM5 Contactor heatsink blower MCB1 Breaker miniature circuit transformer MCB2 Breaker miniature circuit control circuits MCB3 Breaker miniature circuit DR MCB4 Breaker miniature circuit PSU MCB9 Bre...

Page 68: ... the built in moisture separator and drain The coolant system consists of a sump cooler thermostatic valve anti condensation valve and a filter When the unit is operating coolant is forced by air pressure from the separator tank to the thermostatic element The position of the element a direct result of coolant temperature will determine whether the coolant circulates through the cooler bypasses th...

Page 69: ...ram T5716 above Check that the coolant level is at least visible in the center of the sight glass add coolant if necessary Refer to maintenance procedures for setting correct level Ensure that the discharge air isolation valve is open Switch on the main electrical isolation switch The control panel will illuminate indicating that the line and control voltages are available The contrast of the disp...

Page 70: ...stem pressure falls below the target pressure The R190 225NE compressor will operate for 30 seconds with the blowdown valve open and at reduced speed before stopping This sequence occurs for local or remote stops and when the system pressure reaches the automatic or immediate stop pressure setpoints The compressor will automatically restart when the system pressure falls below the target pressure ...

Page 71: ... the stop sequence 4 F1 Not used 5 F2 Not used 6 Arrows These up and down buttons have multiple functions relating to the right half of the display screen When lists are presented the buttons are used to move up or down through the items on the list The small arrow s displayed in the upper right hand corner of the display screen indicate when you can move up designated by arrow head pointing up an...

Page 72: ...e moved up or down by pressing the arrow buttons to the right of the screen The small arrow s displayed in the upper right corner of the screen indicate when you can move up and or down through a list The arrow buttons are also used to change an individual item s value At certain times items and or their values are highlighted This means that they are displayed as light characters on a dark backgr...

Page 73: ...1 Energy Saving 2 Capacity 3 Package kW 4 Package Discharge Temperature 5 Airend Discharge Temperature 6 Injected Coolant Temperature 7 Sump Pressure 8 Separator Pressure Drop 9 Coolant Filter 10 Inlet Filter 11 Total Hours 12 Motor Speed 13 Remote Pressure optional 14 Time and Date 15 Program Name 16 Version of Drive Software When the CURRENT STATUS screen is displayed pressing the ENERGY STATUS ...

Page 74: ... language and units of measure are preset prior to the compressor leaving the factory MAIN MENU 100 PSI 100 PSI OPERATOR SETPOINTS OPTIONS READY TO START SENSOR CALIBRATION ALARM HISTORY STATUS SELECT OPERATOR SETPOINTS OPERATOR SETPOINTS ITEM MAIN MENU CURRENT STATUS ENERGY STATUS OPTIONS OPTIONS ITEM SENSOR CALIBRATION SENSOR CALIBRATION ITEM ALARM HISTORY ALARM HISTORY ITEM CLOCK FUNCTIONS DATE...

Page 75: ...ce menu 1 1 25535 1 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 can be adjusted using the up and down arrow buttons The CANCEL and SET buttons appear at this time Press the SET button to enter the new value or press the CANCEL button to return the val...

Page 76: ...own mode will be shown as Not Installed at the controller display Condensate Release This is the number of seconds that the condensate solenoid will be open energized when blowing out the condensation Condensate Interval This is the time interval between condensation blowdowns savings compared to This setpoint is to determine what Nirvana s percent of savings is compared to The modes of operation ...

Page 77: ...etting and the Auto Stop Pressure setting The pressure measured by this sensor is shown in the CURRENT STATUS display as the Remote Pressure reading The local sensor at the package discharge is still used for Immediate Stop for certain Alarm conditions and for display on the left side of the screen Sequencer If this setting is set to ON the compressor will be able to start and stop by commands fro...

Page 78: ...Modbus manual 9 8 SENSOR CALIBRATION Pressure sensor calibration is done through the SENSOR CALIBRATION screen Sensor calibration can only take place when the machine is stopped Calibration needs to be done only after a sensor has been replaced or the Intellisys controller has been replaced SENSOR CALIBRATION 100 PSI 100 PSI SENSOR 4APT CALIBRATE READY TO START SENSOR 3APT CALIBRATE STATUS MAIN ME...

Page 79: ...be seen by moving the list up and down using the arrow buttons Pressing the ALARM HIST button will return the display to the ALARM HISTORY screen Alarm histories 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 9 10 CLOCK FUNCTIONS CLOCK FUNCTIONS 100 PSI Time 01 15 Date READY TO START ...

Page 80: ...and then dividing that number by the motor kW per hour for that size of compressor at 100 capacity AVERAGE CAPACITY Displays the compressor s average capacity in cfm or m for the time period that was started by selecting the reset averaging setpoint ENERGY COST Displays the energy cost of the compressor for the time period that was started by selecting the reset averaging setpoint This is calculat...

Page 81: ...external device such as an ISC and the discharge pressure is greater than the immediate stop pressure AUXILIARY WARNING 1 or 2 Will occur if the auxiliary warning input closes REMOTE PRESSURE SENSOR FAILURE option This will occur if the remote pressure sensor fails If this happens the lntellisys will start using the package discharge pressure sensor to measure system pressure CONDENSATE DRAIN ERRO...

Page 82: ...ue a VSD FAULT alarm and display the number of the fault condition CONTROL POWER LOSS This will occur if the control circuit is broken by a bad connection or safety switch e g HAT Switch Phase Monitor Any fall of voltage below 100VAC for more than 2 seconds will cause this alarm trip STOP FAILURE This will occur if the compressor should be stopped but the motor is still running above minimum speed...

Page 83: ...the service level selected Refer to operating instructions The customer can only reset the warning for 24 hours by pressing the set button IR service engineers will master reset the warning after completing the service work 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 indica...

Page 84: ...ge Change Change Air filter Check pressure Change Change Separator element Check pressure Change Change ULTRA COOLANT Check Sample Sample Change Power Drive Module filter Check Change Change Change Scavenge screen Check clean Check clean Check clean Hoses Check clean Check clean High Air Temperature sensor Check Check Check Check Pressure relief valve Check Check Check Cooler Core s Check clean Ch...

Page 85: ...y work caution When using any form of liquid for cleaning ensure that all electrical components are protected or covered to prevent ingress of liquid warning This compressor contains a variable frequency drive When it is switched off and the motor is stopped the internal capacitors store a potentially lethal high voltage DO NOT REMOVE THE DRIVE COVER or attempt any work on the drive unless trained...

Page 86: ...and intermittently moving parts the machine cannot be started accidentally or otherwise by posting warning signs and or fitting appropriate anti start devices 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...

Page 87: ...he coolant fill plug restart the compressor and recheck the coolant level Repeat until the coolant level is visible in the sight glass with the compressor both running and stopped Do not add coolant through the intake of the compressor as this can result in overfilling saturation of the separator filter element and coolant carry over downstream danger Under no circumstance should the compressor be...

Page 88: ...mall amount of coolant to the element seal Screw the new element down until the seal makes contact with the housing then hand tighten a further half turn Start the compressor and check for leaks and check the coolant level Separator element checking procedure With the compressor running on load check the separator differential pressure via the Intellisys controller It will be necessary to change t...

Page 89: ... straight tubing connector and will be located between two pieces of 1 4 inch O D scavenge line tubing The main body is made from 1 2 inch hexagon shaped steel and the 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 and will require clearing as outlined in the Maintena...

Page 90: ...rom the system to let the unit warm up With the unit running test at or near the maximum operating pressure by opening the valve for the minimum period required to flush the valve seat free of debris This can be accomplished by holding the test lever fully open or unscrewing the spring pressure retaining cap depending on the type of valve installed If there is no evidence of discharge or the valve...

Page 91: ...essure hose and gaining access through the holes in the intermediate plenum Instructions for cleaning the coolers while installed in the compressor While cleaning coolers great care must be taken to protect the rest of the machine from moisture and contamination by covering sensitive parts with plastic sheeting Remove 4 screws from enclosure panel below moisture separator and remove panel Remove 4...

Page 92: ...nnect tube from aftercooler outlet flange Remove aftercooler holding screws from aftercooler support and remove cooler It is recommended the cooler be taken to a professional cooler service shop for flushing with an appropriate environmentally safe cleaning agent Reassemble in reverse order Replace enclosure panels Watercooled Cooler Cleaning A periodic inspection and maintenance program should be...

Page 93: ...e motor cowl and ensure all ventilation slots are free of obstructions Replace panels to the compressor Drive Box Filter Removal Replacement Ensure compressor is electrically isolated for at least 15 minutes before commencing any maintenance work For all but the N90 160KW compressors Unclip the front grill of the drive box filter Remove the filter pad from the housing and replace with a new filter...

Page 94: ...prevent costly downtime Through the use of sophisticated diagnostic tools including fluid vibration and optional air analysis IR Certified Service Technicians can identify and correct potential problems BEFORE they can cause expensive unscheduled downtime How does predictive analysis work By establishing an initial baseline for normal operation and then regularly monitoring fluid and vibration con...

Page 95: ...ly to package Check supply is switched on If so contact a qualified electrician Intellisys controller failure Check supply to unit Replace unit Starter failure Isolate supply lock off and tag Replace failed component or contact your local Ingersoll Rand representative Compressor stops and will not restart Drive controller has tripped See section 11 2 11 3 Intellisys controller has tripped the comp...

Page 96: ...ly set Contact your local IR representative Motor speed too low caused by fault in drive settings See section on drive faults Intellysis controller fault Overhaul or replace Drive motor fault See section on drive faults Pressure transducer faulty incorrectly calibrated or EMF interference Recalibrate or replace Incorrect Intellisys controller settings Check and modify settings Inlet grill or ducti...

Page 97: ... package produces excessive noise Panels or doors are not closed properly Rectify fault Air leaks from internal pipework components Overhaul or replace Blower or blower motor bearings worn Overhaul or replace Loose debris impacting on blower during rotation Remove and rectify any damage Blowdown valve stuck open Overhaul or replace Pressure relief valve not seating correctly Overhaul or replace Vi...

Page 98: ...ant system leak Overhaul or replace See also discharge air is contaminated with coolant See above 11 2 INTELLISYS FAULTS INDICATED ON THE INTELLISYS CONTROLLER FAULT CAUSE REMEDY Emergency Stop Emergency stop button has been pressed Identify reason why repair fault disengage button and reset Intellisys controller Blower motor overload Blower is blocked damaged or blower motor is faulty Remove bloc...

Page 99: ...ellisys controller has tripped the compressor A fault has occurred Repair fault reset Intellisys controller Invalid Calibration Calibration done with pressure in compressor Depressurise and re calibrate with pressure pipe to sensor disconnected If fault still exists replace pressure transducer Low sump pressure System leak Located and repair Minimum pressure check valve faulty Repair with service ...

Page 100: ...ys 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 Check cooler pipework and moisture separator for blockages Check operation of minimum pressure check valve VSD Fault 3 Drive temperature too...

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