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Before installation or starting the compressor for the
first time, this manual should be studied carefully to
obtain a clear knowledge of the unit and of the duties
to be performed while operating and 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
100-200 HP/75-160 KW
TWO STAGE UNITS

OPERATORS/
INSTRUCTION MANUAL
OPTIONS

FORM: APDD 738B

November 2002

More Than Air. Answers.

Online answers: http://www.air.irco.com
Phone: 1-800-526-3615

CCN: 80440415 REV: B

Содержание 100-200

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 53: ...51...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 71: ...69...

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

Страница 73: ...71...

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

Страница 75: ...73...

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

Страница 77: ...75...

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

Страница 79: ...77...

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

Страница 81: ...79...

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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