Ingersoll-Rand R90 - 160I Page 30 Operation And Maintenance Manual Download

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R90 - 160N / R90 - 160I / R90 - 160NE / R90 - 160IE

http://www.ingersollrandproducts.com

8.0 GENERAL INFORMATION

8.1 GENERAL ARRANGEMENT, WATER COOLED (R90-110I / R90-110N)

23539844

Revision B

Summary of Contents for R90 - 160I

Page 1: ...eads 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 mainte...

Page 2: ...thout 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 Co...

Page 3: ...C 90 160 KW FS 47 8 2 PROCESS AND INSTRUMENTATION DIAGRAM ENERGY RECOVERY SYSTEM 50 8 3 SCHEMATIC ELECTRICAL WIRING VSD Single st age 52 8 3 SCHEMATIC ELECTRICAL WIRING VSD two stage 55 8 3 SCHEMATIC...

Page 4: ...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 clea...

Page 5: ...Rand approved parts list may Create hazardous conditions over which Ingersoll Rand has no control Therefore Ingersoll Rand cannot be held responsible Decrease compressor performance Increase maintenan...

Page 6: ...le Starter Box for VSD Units 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 p...

Page 7: ...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 ______...

Page 8: ...eration 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 e...

Page 9: ...dom 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 tha...

Page 10: ...il into 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...

Page 11: ...will show symbols from the following sections Compressors for use within the European Community must be equipped with symbols from section 5 4 Read and understand thoroughly Heed warnings and follow i...

Page 12: ...160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 10 5 0 SAFETY Pressure Vessel Coolant Cap X Tend Coolant Cap Ultra Coolant Drain Remove shipping brace High Voltage Condensate Dra...

Page 13: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 11 5 0 SAFETY Compressed Air Don t breath Customer Power Motor rotation 15 min warning...

Page 14: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 12 5 0 SAFETY 5 4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS...

Page 15: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 13 5 0 SAFETY...

Page 16: ...ssor are slots to enable a fork lift truck to move the machine Ensure truck forks are fully engaged on both sides Alternatively a special lifting frame can be utilized to enable a crane or hoist to mo...

Page 17: ...d It is recommended that provision be made 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 L...

Page 18: ...be taken to ensure that downstream equipment is compatible When two rotary units are operated in parallel provide an isolation vaIve 7 and drain trap 6 for each compressor before the common receiver...

Page 19: ...glanded in to the starter box to maintain proper ingress protection Fixed speed starter boxes are rated for NEMA4 IP65 and VSD starter boxes are rated for NEMA12 IP54 For VSD starter boxes the feeder...

Page 20: ...oltage 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...

Page 21: ...lts are very abrasive and their ability to erode the heat exchanger tubes increase significantly as the water velocity flow increases It is recommended that the pipe fitter or engineer responsible for...

Page 22: ...ration corrosion chemical and temperature changes aeration scale and biological formations affect the water makeup Most problems in a cooling system first appear as a reduction in the heat transfer ra...

Page 23: ...following conditions Indoors only Area not considered to be a high dust area Ambient temperature range 2 to 46o C 35 115o F Ingersoll Rand offers the following options for fixed speed units that exte...

Page 24: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 22 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110I R90 110N 23539836 Revision B...

Page 25: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 23 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110I R90 110N 23539836 Revision B...

Page 26: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 24 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110I R90 110N 23539836 Revision B...

Page 27: ...R90 160IE http www ingersollrandproducts com 25 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110I R90 110N 23539836 Revision B GENERAL ARRANGEMENT WITH OPTIONAL OUTDOOR MODIFICATION...

Page 28: ...R90 160IE http www ingersollrandproducts com 26 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110I R90 110N 23539836 Revision B GENERAL ARRANGEMENT WITH OPTIONAL HIGH DUST PRE FILTER...

Page 29: ...160I R90 160NE R90 160IE http www ingersollrandproducts com 27 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110I R90 110N 23539836 Revision B GENERAL ARRANGEMENT WITH OPTIONAL CONTA...

Page 30: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 28 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110I R90 110N 23539844 Revision B...

Page 31: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 29 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110I R90 110N 23539844 Revision B...

Page 32: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 30 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110I R90 110N 23539844 Revision B...

Page 33: ...R90 160IE http www ingersollrandproducts com 31 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110I R90 110N 23539844 Revision B GENERAL ARRANGEMENT WITH OPTIONAL HIGH DUST PRE FILTE...

Page 34: ...160I R90 160NE R90 160IE http www ingersollrandproducts com 32 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110I R90 110N 23539844 Revision B GENERAL ARRANGEMENT WITH OPTIONAL CONT...

Page 35: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 33 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110IE R90 110NE R132 R150 R160 23570609 Revision A...

Page 36: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 34 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110IE R90 110NE R132 R150 R160 23570609 Revision A...

Page 37: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 35 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110IE R90 110NE R132 R150 R160 23570609 Revision A...

Page 38: ...E http www ingersollrandproducts com 36 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110IE R90 110NE R132 R150 R160 23570609 Revision A GENERAL ARRANGEMENT WITH OPTIONAL OUTDOOR MODI...

Page 39: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 37 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110IE R90 110NE R132 R150 R160 23570609 Revision A...

Page 40: ...0 160NE R90 160IE http www ingersollrandproducts com 38 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT AIR COOLED R90 110IE R90 110NE R132 R150 R160 23570609 Revision A GENERAL ARRANGEMENT WITH OPTIO...

Page 41: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 39 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110IE R90 110NE R132 R150 R160 23570617 Revision A...

Page 42: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 40 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110IE R90 110NE R132 R150 R160 23570617 Revision A...

Page 43: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 41 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110IE R90 110NE R132 R150 R160 23570617 Revision A...

Page 44: ...http www ingersollrandproducts com 42 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110IE R90 110NE R13 2 R150 R160 23570617 Revision A GENERAL ARRANGEMENT WITH OPTIONAL OUTDOOR MO...

Page 45: ...http www ingersollrandproducts com 43 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110IE R90 110NE R132 R150 R160 23570617 Revision A GENERAL ARRANGEMENT WITH OPTIONAL HIGH DUST P...

Page 46: ...160NE R90 160IE http www ingersollrandproducts com 44 8 0 GENERAL INFORMATION 8 1 GENERAL ARRANGEMENT WATER COOLED R90 110IE R90 110NE R132 R150 R160 23570617 Revision A GENERAL ARRANGEMENT WITH OPTI...

Page 47: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 45 8 0 GENERAL INFORMATION 8 2 PROCESS AND INSTRUMENTATION DIAGRAM AC WC 90 160 KW VSD 23371677 Revision E...

Page 48: ...e airend discharge 2ATT 22 Blowdown solenoid valve 3SV 23 Drive motor variable speed 24 Motor blower variable speed 25 Cooling air blower 26 Cooling water inlet W C ONLY 27 Cooling water outlet W C ON...

Page 49: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 47 8 0 GENERAL INFORMATION 8 2 PROCESS AND INSTRUMENTATION DIAGRAM A C W C 90 160 KW FS 23371669 Revision C...

Page 50: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 48 8 0 GENERAL INFORMATION 8 2 PROCESS AND INSTRUMENTATION DIAGRAM A C W C 90 160 KW FS 23371669 Revision C...

Page 51: ...0 Oil temperature control valve 21 Temperature thermistor airend discharge 2ATT 22 Drive motor 23 Motor fan 24 Cooling fan 25 Cooling water inlet W C ONLY 26 Cooling water outlet W C ONLY 27 Pressure...

Page 52: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 50 8 0 GENERAL INFORMATION 8 2 PROCESS AND INSTRUMENTATION DIAGRAM ENERGY RECOVERY SYSTEM 23498108 Revision B...

Page 53: ...or 2 Cooler coolant package 3 Coolant filter 4 Separator tank primary secondary 5 Oil temperature control valve package 6 Cooler coolant ERS 7 Oil temperature control valve ERS 8 Cooling water inlet E...

Page 54: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 52 8 0 GENERAL INFORMATION 8 3 SCHEMATIC ELECTRICAL WIRING VSD Single stage 23382245 Revision L...

Page 55: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 53 8 0 GENERAL INFORMATION 8 3 SCHEMATIC ELECTRICAL WIRING VSD Single stage 23382245 Revision L...

Page 56: ...lter board ES Emergency stop button EXC External communications FD Drive blower motor FM Fan motor FMP Fan motor protector FU Fuses GND Ground HTR Panel space heater K1 Run relay K2 Drive fault relay...

Page 57: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 55 8 0 GENERAL INFORMATION 8 3 SCHEMATIC ELECTRICAL WIRING VSD two stage 23587652 Revision C...

Page 58: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 56 8 0 GENERAL INFORMATION 8 3 SCHEMATIC ELECTRICAL WIRING VSD two stage 23587652 Revision C...

Page 59: ...EMC Filter board ES Emergency stop button EXC External communications FD Drive blower motor FM Fan motor FMP Fan motor protector FU Fuses GND Ground HTR Panel space heater K1 Run relay K2 Drive fault...

Page 60: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 58 8 0 GENERAL INFORMATION 8 3 SCHEMATIC ELECTRICAL WIRING FIXED SPEED Y D STANDARD 23771933 Revision G...

Page 61: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 59 8 0 GENERAL INFORMATION 8 3 SCHEMATIC ELECTRICAL WIRING FIXED SPEED Y D STANDARD 23771933 Revision G...

Page 62: ...top button FM Fan motor FMH Fan motor heater FMP Fan motor protector FR1 Main motor overload FU Fuses K2 Phase monitor relay K3 Blower drive control relay KM1 Main contactor KM2 Delta contactor KM3 St...

Page 63: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 61 8 0 GENERAL INFORMATION 8 3 SCHEMATIC ELECTRICAL WIRING FIXED SPEED SOFT STARTER OPTION 23378540 Revision E...

Page 64: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 62 8 0 GENERAL INFORMATION 8 3 SCHEMATIC ELECTRICAL WIRING FIXED SPEED SOFT STARTER OPTION 23378540 Revision E...

Page 65: ...DMH Drive motor heater EB Earthing bar ES Emergency stop button FM Fan motor FM Fan motor FMH Fan motor heater FMP Fan motor protector FR1 Main motor overload FU Fuses K1 Start control relay K2 Starte...

Page 66: ...es the cooler or mixes the two paths together to maintain an optimum compressor injection temperature This temperature is controlled to preclude the possibility of water vapor condensing By injecting...

Page 67: ...g Refer to diagram 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 Ensu...

Page 68: ...However if the compressor stops for this reason it will automatically restart when the system pressure falls below the target pressure Important Depress the emergency stop button when the compressor...

Page 69: ...e 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...

Page 70: ...t 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 ite...

Page 71: ...apacity 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 Pressure Drop 10 Inlet Vac...

Page 72: ...ove the center button The MAIN MENU screen is the point from which various operator functions can be accessed Refer to the Operator Panel Flow Diagram Each of the functions can be chosen by using the...

Page 73: ...anged 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 do...

Page 74: ...or stops due to an automatic stop Blowdown mode is set on at all times for 2 stage models Blowdown mode will be shown as Not Installed at the controller display savings compared to This setpoint is to...

Page 75: ...easured 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 Trip conditions and...

Page 76: ...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...

Page 77: ...d down using the arrow buttons Pressing the TRIP HIST button will return the display to the TRIP HISTORY screen Trip histories can be exited by pressing either the STATUS or MAIN MENU buttons If no bu...

Page 78: ...ze of compressor at 100 capacity AVERAGE CAPACITY Displays the compressor s average capacity in cfm or m3 for the time period that was started by selecting the reset averaging setpoint ENERGY COST Dis...

Page 79: ...rning 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 me...

Page 80: ...inimum speed 4 seconds after the stop signal is given HIGH START PRESSURE If the sump pressure is above 100 psi 6 9 bar when the compressor starts the Intellisys will open the blowdown valve during th...

Page 81: ...e 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 specified by the MODE OF OPERATION set point The othe...

Page 82: ...values are highlighted This means that they are displayed as light characters on a dark background The bottom of the screen is divided into thirds with the words in each small box showing the functio...

Page 83: ...Items will be highlighted in inverse display mode 1 Selecting the highlighted item will display the cor responding menu 2 Selecting the highlighted item will place the value in edit mode This is indic...

Page 84: ...on MOD ACS ON OFF LINE MODULATION ONLY Condensate Release 2 to 20 1 SEC Condensate Inverter 90 to 270 1 SEC Stop Delay Time 10 to 30 1 SEC Star Delta Time 5 to 30 1 SEC Screen Contrast 0 to 10 1 Does...

Page 85: ...low 2o C 35o F the compressor will be started when commanded but will not load until the airend discharge temperature is above 2o C 35o F After the conditions are met the controller will adjust the fa...

Page 86: ...e 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 SCHEDULED START STOP Dependant on installed...

Page 87: ...by moving the list up and down using the arrow buttons Pressing the TRIP HIST button will return the display to the TRIP HISTORY screen TRIP HISTORY ITEMS Package Discharge Pressure Coolant Filter Pac...

Page 88: ...PT is 15 psig 1 0 bar greater than the pressure at the Package Discharge 4APT and the machine is fully loaded HIGH DISCHARGE PRESS This can occur if the machine s loading function is being controlled...

Page 89: ...psig and sump pressure drop is more than 25 psig Can also occur if sump pressure is above 165 psig LOW SUMP AIR PRESSURE This will occur if the machine is running fully loaded and the sump pressure dr...

Page 90: ...ntellisys unit The machine will start and automatically load STOPPING THE MACHINE Depress the STOP button 3 which will automatically unload the compressor for 10 seconds before stopping Switch off the...

Page 91: ...warning is issued the warning can be reset the same way as any other warning For service level 2 when a Service Required warning is issued the customer can only reset the warning for 24 hours by press...

Page 92: ...r Filter Element Inspect Oil Filter Element Inspect Starter Box Panel Filter VSD Only Replace Food Grade Lubricant when using X Tend Food Grade Filter Module Replace X Tend Food Grade Filter Module An...

Page 93: ...DO NOT REMOVE THE DRIVE COVER or attempt any work on the drive unless trained There are no user serviceable items behind the cover danger For VSD this compressor contains a variable frequency drive W...

Page 94: ...ermittently 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 ru...

Page 95: ...he system pressing the emergency stop to vent the separator tank airend FS units can take more than 2 min to fully de pressurize once stopped slowly unscrew the coolant fill plug to verify all pressur...

Page 96: ...CE Shorter coolant change intervals may be necessary if the compressor is operated in adverse conditions Food Grade Coolant option SSR Food Grade Coolant is a polyalphaolefin base coolant It is recomm...

Page 97: ...tain that no foreign objects such as rags or tools have been allowed to fall into the tank Install replacement element down into the tank after checking the new element seal gasket for possible damage...

Page 98: ...factors as the severity of the operating environment The pressure relief valve should be tested and re calibrated in accordance with any national or local codes that may exist If no code exists Inger...

Page 99: ...This second nut is used to lock the first in place It is 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 important the first nut is not too tight so it can allow the cooler to expand and contract without stre...

Page 100: ...wing nuts Remove filter grill Pull out filter element To Install Pre Filter element Center element over package intake opening Push filter over grill studs so that studs poke through the filter media...

Page 101: ...R90 160N R90 160I R90 160NE R90 160IE http www ingersollrandproducts com 99 10 0 MAINTENANCE 10 5 STARTER BOX PANEL FILTER VSD ONLY...

Page 102: ...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 fai...

Page 103: ...Contact your local Ingersoll Rand 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 Se...

Page 104: ...sor 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...

Page 105: ...Coolant 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 Em...

Page 106: ...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 dis...

Page 107: ...r 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 Ingersoll Rand customer support representative FAULT CA...

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