Ingersoll-Rand Nirvana IRN100-200H-2S Скачать руководство пользователя

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11.0 FAULT FINDING

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

SYMPTOM

FAULT

REMEDY

Compressor will not
meet pressure required
by system

Compressor not sized to meet
system requirements or
requirements have been
changed.

Contact your local IR representative

Air loss due to pipe, hose, joint
or seal failure

Overhaul or replace

Air loss due to blowdown valve
stuck open

Overhaul or replace

Air loss through pressure relief
valve not seating or set
incorrectly

Overhaul or replace

Air loss due to moisture
separator drain trap stuck open

Overhaul or replace

Motor speed too low caused by
drive incorrectly 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 ducting is blocked

Check and clean

Air filter dirty or collapsed

Replace

Inlet valve not opening fully

Overhaul or replace

Separator element dirty or
collapsed

Replace

Pipe / Hoses blocked or
collapsed

Clean or replace

Cooler core blocked

Clean or replace

Minimum pressure check valve
not functioning correctly

Overhaul or replace

Equipment between compressor
and customer measuring point
causing pressure drop /
pressure loss

Review system requirements

Содержание Nirvana IRN100-200H-2S

Страница 1: ...t and have read the Maintenance Manuals IRN37 160K CC IRN50 200H CC IRN75 160K 2S IRN100 200H 2S Ensure that the Operation and Maintenance manual is not removed permanently from the machine TM N37K N4...

Страница 2: ...INGERSOLL RAND COMPANY LIMITED SWAN LANE HINDLEY GREEN WIGAN WN2 4EZ UNITED KINGDOM DECLARE THAT UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY THE PRODUCT S IRN37K CC IRN45K CC IRN55K CC IR...

Страница 3: ...ser 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 stat...

Страница 4: ...atercooled units 7 6 Outdoor sheltered installation 8 0 GENERAL INFORMATION 27 8 1 Technical information 8 2 Installation drawing 8 3 Process and instrumentation diagram 8 4 Electrical schematic 8 5 G...

Страница 5: ...ories pipes and connectors added to the compressed air system should be of good quality procured from a reputable manufacturer and wherever possible be of a type approved by Ingersoll Rand clearly rat...

Страница 6: ...ersoll 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...

Страница 7: ...AR As required SM Sitemaster 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 pro...

Страница 8: ...mpany reserves 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 o...

Страница 9: ...hat 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 fo...

Страница 10: ...ient 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 loadi...

Страница 11: ...ompatibility between discharge piping system accessories and software must be assured S For the foregoing reasons the use of plastic piping soldered copper fittings and rubber hose as discharge piping...

Страница 12: ...eration 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 l...

Страница 13: ...a pressurized shutdown mode Relieve pressure before removing filter plugs caps fittings or covers 22061915 Rev A NOTICE Air discharge CAUTION Use of incorrect coolant can cause system contamination U...

Страница 14: ...hereafter 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...

Страница 15: ...in 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 El...

Страница 16: ...ns Warning WARNING Electrical shock risk WARNING Pressurized component or system WARNING Hot surface WARNING Pressure control WARNING Corrosion risk WARNING Air gas flow or Air discharge WARNING Press...

Страница 17: ...rature 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 ma...

Страница 18: ...rk lift truck from this side only Emergency stop Tie down point Lifting point On power Off power SET SEQUENCER STATUS LOAD SEQUENCER AUTOMATIC CONTROL COMPRESSOR OFF LOAD UNLOADED RESET COMPRESSOR STA...

Страница 19: ...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 PRO...

Страница 20: ...50 200H CC IRN75 160K 2S IRN100 200H 2S 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 PERSON...

Страница 21: ...ncealed 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...

Страница 22: ...avy 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 insta...

Страница 23: ...nsure that downstream equipment is compatible When two rotary units are operated in parallel provide an isolation vaIve and drain trap for each compressor before the common receiver The built in after...

Страница 24: ...fic applied voltage prior to starting A hole is provided for 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 me...

Страница 25: ...ltage 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...

Страница 26: ...38 10 N55 19 5 27 7 1 45 11 9 N75 30 7 7 42 11 1 68 18 N90 34 9 0 45 11 9 77 20 3 N110 41 10 8 59 15 6 95 25 1 N132 64 16 9 82 21 7 123 32 5 N160 73 19 3 95 25 1 150 39 6 Water temperature and pressu...

Страница 27: ...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 probl...

Страница 28: ...er 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...

Страница 29: ...160K CC IRN50 200H CC IRN75 160K 2S IRN100 200H 2S 7 6 OUTDOOR SHELTERED INSTALLATION Nirvana compressors are not suitable for outdoor installation Installing a Nirvana compressor outside voids the w...

Страница 30: ...4 75 HAT switch setting _C _F 120 248 120 248 120 248 120 248 Performance Flow at 7 5 Barg m3 min 6 43 7 42 Flow at 8 5 Barg m3 min 6 17 7 07 Flow at 10 Barg m3 min 5 75 6 46 Flow at 100 psig cfm 235...

Страница 31: ...kage full load current at 575V A 56 63 Max fuse size 220V 230V A 250 250 250 250 Max fuse size 380V 415V A 125 125 125 125 Max fuse size 440V 480V A 125 125 125 125 Max fuse size 550V 575V A 100 100 1...

Страница 32: ..._F 120 248 120 248 120 248 120 248 Performance Flow at 7 5 Barg m3 min 10 18 13 51 Flow at 8 5 Barg m3 min 9 40 12 69 Flow at 10 Barg m3 min 8 51 11 67 Flow at 100 psig cfm 386 490 Flow at 125 psig cf...

Страница 33: ...ackage full load current at 575V A 79 104 Max fuse size 220V 230V A 300 N A 300 N A Max fuse size 380V 415V A 150 200 150 200 Max fuse size 440V 480V A 150 200 150 200 Max fuse size 550V 575V A 125 15...

Страница 34: ..._C _F 120 248 120 248 120 248 120 248 Performance Flow at 7 5 Barg m3 min 17 1 20 0 Flow at 8 5 Barg m3 min 15 3 19 2 Flow at 10 Barg m3 min 14 0 17 5 Flow at 100 psig cfm 655 739 Flow at 125 psig cfm...

Страница 35: ...ent at 460V A 167 197 Mean package full load current at 575V A 134 158 Max fuse size 380V 415V A 250 350 Max fuse size 440V 480V A 200 250 Max fuse size 550V 575V A 200 200 Fuse type Fast acting class...

Страница 36: ...20 248 120 248 120 248 Performance Flow at 7 5 Barg m3 min 23 5 28 0 Flow at 8 5 Barg m3 min 22 3 26 0 Flow at 10 Barg m3 min 21 0 25 0 Flow at 100 psig cfm 993 Flow at 125 psig cfm 892 Flow at 140 ps...

Страница 37: ...t 460V A 256 Mean package full load current at 575V A 205 Max fuse size 380V 415V A 300 400 Max fuse size 440V 480V A 350 Max fuse size 550V 575V A 350 Fuse type Fast acting class J T or semiconductor...

Страница 38: ...20 248 120 248 120 248 120 248 120 248 120 248 Performance Flow at 7 5 Barg m3 min 15 7 18 0 22 1 Flow at 8 5 Barg m3 min 14 2 17 5 20 4 Flow at 10 Barg m3 min 13 1 15 4 18 9 Flow at 14 Barg m3 min 12...

Страница 39: ...package full load current at 460V A 136 167 197 Mean package full load current at 575V A 108 134 158 Max fuse size 380V 415V A 250 250 350 Max fuse size 440V 480V A 200 250 250 Max fuse size 550V 575V...

Страница 40: ...mance Flow at 7 5 Barg m3 min 26 2 31 1 Flow at 8 5 Barg m3 min 24 2 29 6 Flow at 10 Barg m3 min 23 1 27 2 Flow at 14 Barg m3 min 18 4 22 2 Flow at 100 psig cfm 1100 Flow at 125 psig cfm 990 Flow at 1...

Страница 41: ...t 460V A 256 Mean package full load current at 575V A 205 Max fuse size 380V 415V A 300 400 Max fuse size 440V 480V A 350 Max fuse size 550V 575V A 350 Fuse type Fast acting class J T or semiconductor...

Страница 42: ...4 NPT Female Note Pipe condensate drain lines separately to an open drain due to differences in drain pressures Read operations manual and check local regulations D Cooling airflow E Exhaust airflow F...

Страница 43: ...ectrical inlet C 1 4 NPT Female Note Pipe condensate drain lines separately to an open drain due to differences in drain pressures Read operations manual and check local regulations D Cooling airflow...

Страница 44: ...8 0 GENERAL INFORMATION IRN37 160K CC IRN50 200H CC IRN75 160K 2S IRN100 200H 2S 41 8 2 INSTALLATION DRAWING N90 160K N125 200H SINGLE STAGE N75 160K N100 200H TWO STAGE...

Страница 45: ...K units B 63mm 2 48 Electrical inlet C 1 4 NPT Female Note Pipe condensate drain lines separately to an open drain due to differences in drain pressures Read operations manual and check local regulati...

Страница 46: ...8 0 GENERAL INFORMATION IRN37 160K CC IRN50 200H CC IRN75 160K 2S IRN100 200H 2S 43 8 3 PROCESS AND INSTRUMENTATION DIAGRAM N37 75K CC N50 100 CC...

Страница 47: ...solenoid valve 23 Drive motor 24 Blower motor 25 Cooling air blower 26 Cooling water inlet W C only 27 Cooling water outlet W C only 28 Pressure transducer 3APT 29 Pressure transducer 6APT 30 Dryer c...

Страница 48: ...ERAL INFORMATION IRN37 160K CC IRN50 200H CC IRN75 160K 2S IRN100 200H 2S 45 8 3 PROCESS AND INSTRUMENTATION DIAGRAM N90 160K N125 200H SINGLE STAGE AND N75 160K N100 200H TWO STAGE Revision B 10 02 2...

Страница 49: ...ooling water 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...

Страница 50: ...8 0 GENERAL INFORMATION IRN37 160K CC IRN50 200H CC IRN75 160K 2S IRN100 200H 2S 47 8 4 ELECTRICAL SCHEMATIC N37K N75K N50H N100K...

Страница 51: ...heater 25 watts K1 Relay run K2 Relay fault KM1 Contactor main motor KM4 Contactor blower motor MCB1 Breaker miniature circuit transformer MCB2 Breaker miniature circuit VFD MCB3 Breaker miniature ci...

Страница 52: ...8 0 GENERAL INFORMATION IRN37 160K CC IRN50 200H CC IRN75 160K 2S IRN100 200H 2S 49 8 4 ELECTRICAL SCHEMATIC N75K N160K N100H N200H N75H N160H Revision H 12 02 22093058...

Страница 53: ...S Switch emergency stop EXC External communications FD Fan drive FM Motor Blower GND Ground HB Heatsink blower HTRI Heater 125 watts K1 Relay run K2 Relay fault KM1 Contactor main motor KM5 Contactor...

Страница 54: ...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...

Страница 55: ...ove 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 i...

Страница 56: ...s However if the compressor stops for this reason it will automatically restart when the system pressure falls below the target pressure Blowdown mode If the blowdown mode is set to on the compressor...

Страница 57: ...ence 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...

Страница 58: ...n 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 button...

Страница 59: ...re 5 Airend Discharge Temperature 6 Injected Coolant Temperature 7 Inlet Temperature 7 Sump Pressure 8 Separator Pressure Drop 9 Interstage Pressure 9 Coolant Filter 10 Inlet Filter 11 Total Hours 12...

Страница 60: ...ATUS button is pressed The language and units of measure are pre set prior to the compressor leaving the factory MAIN MENU 100 OPERATOR SETPOINTS OPTIONS READY TO START SENSOR CALIBRATION ALARM HISTOR...

Страница 61: ...set Date Service 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 highl...

Страница 62: ...If this mode is selected to ON the compressor will open the blowdown valve anytime that it stops This will vent pressure from the airend and the separator tank If this mode is selected to OFF the blo...

Страница 63: ...sure 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 conditio...

Страница 64: ...BRATION 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 ha...

Страница 65: ...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 MEN...

Страница 66: ...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 m3 for the time period that was started by select...

Страница 67: ...he unit is under the control of an 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 in...

Страница 68: ...ay 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 100...

Страница 69: ...vel 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 ser...

Страница 70: ...18000 Daily Coolant filter Change Change Change Change Air filter Check pressure Change Change Separator element Check pressure Change Change ULTRA COOLANT Check Sample Sample Change Power Drive Modul...

Страница 71: ...TION 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...

Страница 72: ...c S appropriate personal protective equipment is worn S loose clothing jewelry long hair etc is made safe S warning signs indicating that Maintenance Work is in Progress are posted in a position that...

Страница 73: ...Clean the mating face of the housing S Remove the new Ingersoll Rand replacement element from its protective package S Apply a small amount of coolant to the element seal S Screw the new element down...

Страница 74: ...et 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 accompl...

Страница 75: ...cooling plenum and remove covers S Cover main drive motor PDM Heat sink blower motor drain valve and cooling motor variable speed drive with plastic sheeting to prevent damage from entrance of cleani...

Страница 76: ...or tank scavenge check valve orifice S Disconnect tubing at each end of check valve screen orifice assembly S Check orifice and clean if required Use suitable tool and remove orifice from its housing...

Страница 77: ...detergent solution S Replace any defective parts see parts manual for repair kit S Re assemble and later with machine running check that condensate is expelled at regular period and no alarms are sig...

Страница 78: ...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 compone...

Страница 79: ...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 fa...

Страница 80: ...essive Panels or doors are not closed properly Rectify fault noise Air leaks from internal pipework components Overhaul or replace Blower or blower motor bearings worn Overhaul or replace Loose debris...

Страница 81: ...replace consumption 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...

Страница 82: ...oller 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 press...

Страница 83: ...s 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...

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