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OPERATION AND MAINTENANCE MANUAL

C.C.N.

22310387

DATE

AUGUST

2005

REV.

: D

Ensure that the operator reads and

understands

the

decals and consults the manuals before maintenance or

operation.

Ensure that maintenance personnel are adequately

trained, competent and have read the Maintenance

Manuals.

IRN37–160K–OF

IRN50–200H–OF

Ensure that the Operation and Maintenance manual is
not removed permanently from the machine.

Содержание NIRVANA IRN110K-OF

Страница 1: ...nderstands the decals and consults the manuals before maintenance or operation Ensure that maintenance personnel are adequately trained competent and have read the Maintenance Manuals IRN37 160K OF IR...

Страница 2: ...WAN LANE HINDLEY GREEN WIGAN WN2 4EZ UNITED KINGDOM DECLARE THAT UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY THE PRODUCT S IRN37K OF IRN45K OF IRN55K OF IRN75K OF IRN90K OF IRN110K OF IRN...

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: ......

Страница 5: ...ed installation 8 0 GENERAL INFORMATION 26 8 1 Technical information 8 2 Installation drawing 8 3 Process and instrumentation diagram 8 4 Electrical schematic 8 5 General description 9 0 OPERATING INS...

Страница 6: ...ssories 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 r...

Страница 7: ...ntrol components missing or disabled Connection to an electrical supply of incorrect voltage and or frequency WARNING The use of repair parts other than those included within the Ingersoll Rand approv...

Страница 8: ...bient 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...

Страница 9: ...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 on ord...

Страница 10: ...of all pressure Make 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 electrica...

Страница 11: ...that the machine be moved using the fork lift slots in the machine base Refer to section 8 for reference information Electrical The compressor has high and dangerous voltage in the motor starter and c...

Страница 12: ...d for such purposes if their specifications fit the operating parameters of the system S It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the...

Страница 13: ...nd 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 code...

Страница 14: ...High pressure air Can cause severe injury or death Relieve pressure before removing filter plugs caps fittings or covers 39540240 Rev 04 NOTICE Air discharge CAUTION Use of incorrect coolant can cause...

Страница 15: ...r Discharge 39540257 Rev 04 Condensate drain 39541081 Rev 04 Electrical power inlet 39541354 Rev 03 WARNING Hazardous voltage Can cause severe injury or death Only use factory supplied inlet for incom...

Страница 16: ...OF IRN50 200H OF http air irco com 12 Use 75 C copper wire only IMPORTANT Before starting this air compressor unit the shipping brace s must be removed Save the brace s for future use Refer to Operato...

Страница 17: ...rning 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 Pressurize...

Страница 18: ...e 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...

Страница 19: ...t 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 STATUS MO...

Страница 20: ...R DISCHARGE PRESSURIZED TANK ON OFF CYCLE OIL FILTER AIR FILTER ON OFF PUSH BUTTON OIL PRESSURE AIR PRESSURE STAR DELTA IEC 617 7 AUTOMATIC RESTART HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED OI...

Страница 21: ...IRN50 200H OF http air irco com 17 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 W...

Страница 22: ...for loss or damage The agent will make an inspection and grant a concealed damage notation If you give the transportation company a clear receipt for goods that have been damaged or lost in transit y...

Страница 23: ...ce 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...

Страница 24: ...ain trap for each compressor before the common receiver The built in intercooler and aftercooler reduce the discharge air temperature below the dew point for most ambient conditions therefore consider...

Страница 25: ...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 metal shavings to enter the...

Страница 26: ...nized Local and National electrical equipment installation codes and any other related local Health and Safety Codes The compressor input power supply branch circuit protection shall be made by utiliz...

Страница 27: ...m supply temperature of 46_C 115_F Water temperature and pressure gauges should be installed in the water piping for use in any fault finding of the water system Water pressure should ideally be betwe...

Страница 28: ...ependent 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...

Страница 29: ...37 160K OF IRN50 200H OF http air irco com 25 7 6 OUTDOOR SHELTERED INSTALLATION Nirvana compressors are not suitable for outdoor installation Installing a Nirvana compressor outside voids the warrant...

Страница 30: ...76 2700 76 2700 76 2700 Maximum P in air ducts Pa inch WG 125 0 5 125 0 5 125 0 5 125 0 5 Compressed air outlet T _C _F 2 8 15 8 15 8 15 8 15 Main Power Circuit AC WC Package full load current at 200V...

Страница 31: ...19 90 8 24 Cooling air flow m3 min cfm 76 2700 76 2700 76 2700 76 2700 Maximum P in air ducts Pa inch WG 125 0 5 125 0 5 125 0 5 125 0 5 Compressed air outlet T _C _F 2 8 15 8 15 8 15 8 15 Main Power...

Страница 32: ...n min 125 33 144 38 182 48 193 51 Cooling air flow m3 min cfm 113 4000 113 4000 113 4000 113 4000 Maximum P in air ducts Pa inch WG 62 0 25 62 0 25 62 0 25 62 0 25 Compressed air outlet T _C _F 2 8 15...

Страница 33: ...n US gallon min 125 33 144 38 182 48 Cooling air flow m3 min cfm 113 4000 113 4000 113 4000 Maximum P in air ducts Pa inch WG 62 0 25 62 0 25 62 0 25 Compressed air outlet T _C _F 2 8 15 8 15 8 15 Mai...

Страница 34: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 30 8 2 INSTALLATION DRAWING N37 45k OIL FREE AIR COOLED...

Страница 35: ...charge location 9 There should be no plastic or PVC piping attached to this unit or used for any lines downstream 10 Remove the three isolation mount restraints before the initial start The restraints...

Страница 36: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 32 8 2 INSTALLATION DRAWING N37 45k OIL FREE WATER COOLED...

Страница 37: ...on unit Use pipe size as large or larger at discharge location 9 There should be no plastic or PVC piping attached to this unit or used for any lines downstream 10 Remove the three isolation mount re...

Страница 38: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 34 8 2 INSTALLATION DRAWING N55 75K OIL FREE AIR COOLED...

Страница 39: ...eam 10 Remove the isolation mount restraints before the initial start The two restraints can be discarded 11 Field installed ducting to and from compressor cannot add more than 6mm 0 25 inches of wate...

Страница 40: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 36 8 2 INSTALLATION DRAWING N55 75K OIL FREE WATER COOLED...

Страница 41: ...attached to this unit or used for any lines downstream 10 Remove the isolation mount restraints before the initial start The two restraints can be discarded 11 Field installed ducting to and from comp...

Страница 42: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 38 8 2 INSTALLATION DRAWING N90 160K N125 200H OIL FREE AIR COOLED...

Страница 43: ...location 9 There should be no plastic or PVC piping attached to this unit or used for any lines downstream 10 Remove the isolation mount restraints before the initial start The two restraints can be d...

Страница 44: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 40 8 2 INSTALLATION DRAWING N90 160K N125 200H OIL FREE WATER COOLED...

Страница 45: ...ipe size as large or larger at discharge location 9 There should be no plastic or PVC piping attached to this unit or used for any lines downstream 10 Remove the isolation mount restraints before the...

Страница 46: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 42 8 3 PROCESS AND INSTRUMENTATION DIAGRAM N37 160K N50 200H AIR COOLED...

Страница 47: ...oose 29 Oil sump 30 Oil pump 31 Oil bypass valve 35 PSIG 32 Oil cooler 33 Oil temperature control valve 34 Oil filter 35 Oil bypass check valve 25 PSIG 36 Gear case breather 37 1ATT LP Inlet temperatu...

Страница 48: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 44 8 3 PROCESS AND INSTRUMENTATION DIAGRAM N37 160K N50 200H WATER COOLED...

Страница 49: ...Oil bypass valve 35 PSIG 32 Oil cooler 33 Oil temperature control valve 34 Oil filter 35 Oil bypass check valve 25 PSIG 36 Gear case breather 37 1ATT LP Inlet temperature thermistor 38 1AVPT LP Inlet...

Страница 50: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 46 8 4 ELECTRICAL SCHEMATIC N37 75K N50 100H AIR COOLED...

Страница 51: ...ve interstage condensate drain solenoid 7ATT Sensor package discharge temperature 9ATP Transmitter remote air pressure optional 9SV Valve package discharge condensate drain solenoid AT Autotransformer...

Страница 52: ...er 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 SBC Su...

Страница 53: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 49 8 4 ELECTRICAL SCHEMATIC N37 75K N50 100H WATER COOLED...

Страница 54: ...6OPT Transducer oil filter out pressure 6SV Valve interstage condensate drain solenoid 7ATT Sensor package discharge temperature 9ATP Transmitter remote air pressure optional 9SV Valve package dischar...

Страница 55: ...aker fan motor MMS2 Breaker heatsink blower motor OPT Optional OV Zero voltage PE Protected earth PORO Power outage restart option optional PSU Power supply unit RFI Filter radio frequency interferenc...

Страница 56: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 52 8 4 ELECTRICAL SCHEMATIC N90 160K N125 200H AIR COOLED...

Страница 57: ...terstage condensate drain solenoid 7ATT Sensor package discharge temperature 9ATP Transmitter remote air pressure optional 9SV Valve package discharge condensate drain solenoid AT Autotransformer if f...

Страница 58: ...al 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 SBC Supplied by customer...

Страница 59: ...8 0 GENERAL INFORMATION IRN37 160K OF IRN50 200H OF http air irco com 55 8 4 ELECTRICAL SCHEMATIC N90 160K N125 200H WATER COOLED...

Страница 60: ...out pressure 6SV Valve interstage condensate drain solenoid 7ATT Sensor package discharge temperature 9ATP Transmitter remote air pressure optional 9SV Valve package discharge condensate drain soleno...

Страница 61: ...er 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 SBC Su...

Страница 62: ...of the compressor to deliver compressed air at the target pressure Panel instrumentation is provided to indicate the compressor operating conditions and general status Air is pulled into the machine...

Страница 63: ...main electrical isolation switch The control panel will illuminate indicating that the line and control voltages are available The contrast of the display may be adjusted by turning the small screw wh...

Страница 64: ...e reset and the alarm must be cleared before the compressor can be restarted If the pressure reaches the automatic stop or immediate stop pressure or if the stop button local or remote is pressed the...

Страница 65: ...tton will activate 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 th...

Страница 66: ...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 67: ...UUM 7 INLET FILTER 8 OIL FILTER PRESSURE DROP 9 FIRST STAGE INLET TEMP 10 FIRST STAGE AIREND DISCHARGE TEMP 11 SECOND STAGE AIREND INLET PRESS 12 SECOND STAGE AIREND INLET TEMP 13 SECOND STAGE AIREND...

Страница 68: ...is pressed The language and units of measure are pre set prior to the compressor leaving the factory MAIN MENU 100 PSI 100 PSI OPERATOR SETPOINTS OPTIONS READY TO START SENSOR CALIBRATION ALARM HISTO...

Страница 69: ...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 valu...

Страница 70: ...atic stop pressure 5 psi Condensate Release This is the number of seconds that the condensate solenoid will be open de energized when blowing out the condensation Condensate Interval This is the time...

Страница 71: ...op 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 Sto...

Страница 72: ...e 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...

Страница 73: ...he 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...

Страница 74: ...t 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 selecting...

Страница 75: ...tellisys will start using the package discharge pressure sensor to measure system pressure FAILED CHECK VALVE Will occur if the 2nd stage discharge pressure exceeds 55 psig when the compressor is runn...

Страница 76: ...3ATT 4ATT 5OTT The sensor should be displayed along with the sensor failure message The sensor failure message shall follow the following format SENSOR FAILURE 4APT EMERGENCY STOP Will occur when the...

Страница 77: ...IRN37 160K OF IRN50 200H OF http air irco com 73 INLET RESTRICTION This will occur if the unit is running and 1AVPT is greater than 1 45 psi 0 1 bar 1ST STAGE INLET TEMPERATURE This will occur if the...

Страница 78: ...elected 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...

Страница 79: ...nge Change Air filter Check pressure Change Change ULTRA COOLANT Check Sample Sample Change Power Drive Module filter Check Change Change Change Hoses Check clean Check clean Check clean Pressure reli...

Страница 80: ...NING 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 attempt...

Страница 81: ...or and slowly unscrew the oil fill plug Add Ultra Coolant and recheck the oil level Repeat until the oil level is visible in the sight glass with the compressor running WARNING Under no circumstance s...

Страница 82: ...N75 160 Aircooled units 6 Months or 4000 Hrs Apply high melting point grease into the blower motor bearings using a grease gun at the nipple provided Stop when excess grease is seen at the relief por...

Страница 83: ...ariable speed drive with plastic sheeting to prevent damage from entrance of cleaning solution S Cover inlet of blower wheel with plastic sheeting to prevent entrance of cleaning fluid S Cover the inl...

Страница 84: ...S Replace front grill to the drive box filter Moisture Separator Check Cleaning S Ensure compressor is electrically isolated for at least 15 minutes before commencing any maintenance work S Isolate th...

Страница 85: ...cause More quickly diagnosing potential problems can directly save money by preventing costly failures and reducing or eliminating downtime In addition regular condition monitoring also helps to maxi...

Страница 86: ...pply 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 Replac...

Страница 87: ...ed 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 o...

Страница 88: ...system parameters air too hot Insufficient cooling air Check ducting and cooling air path check direction of blower rotation Blocked aftercooler matrix Clean or replace Compressor package produces exc...

Страница 89: ...damaged Contact your local IR representative 11 2 INTELLISYS FAULTS INDICATED ON THE INTELLISYS CONTROLLER FAULT CAUSE REMEDY Emergency Stop Emergency stop button has been pressed Identify reason why...

Страница 90: ...essurise and recalibrate with pressure pipe to sensor disconnected If fault still exists replace pressure transducer Check motor rotation This will occur if the Intellisys reads a negative speed from...

Страница 91: ...ntilation ambient temperature is not above 115_F 46_C assure cooling blower is operating coolers are clean High bearing oil temperature This will occur if temperature sensor 5OTT is greater than 170_F...

Страница 92: ...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 CA...

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