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125-200 HP/90-160 KW
SINGLE STAGE
AND
100-200 HP/75-160 KW
TWO STAGE UNITS
OPERATORS/
INSTRUCTION MANUAL
OPTIONS
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.
More Than Air. Answers
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AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UP Warranty The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve months (see extended airend warranty) from the date of placing the Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from Davidson, NC, whichever shall first occur. The Purchaser shall be obligated to promptly report any fail
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ROTARY SCREW AIR COMPRESSOR This unit was purchased from: _______________________________________________ _______________________________________________ _______________________________________________ Ingersoll-Rand Company 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. Number of units on order: __________________________ Customer Order Number: _________________
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7.0 OPTIONS TABLE OF CONTENTS 7.1 power outage restart option 7.2 sequencer 0.0 SAFETY AND WARNINGS 7.3 low ambient 0.1 safety instructions 7.4 separator delta-p solenoid 0.2 safety precautions 7.5 separator delta-p sensor 0.3 decals 7.6 high dust filter 7.7 lead/lag cycle length 1.0 RECEIPT OF EQUIPMENT 7.8 schedule start/stop 1.1 inspection 7.9 remote load/unload 1.2 unpacking and handling 7.10 modbus 1.3 tools 7.11 integral sequencing 2.0 INSTALLATION 8.0 REFERENCE DRAWINGS 2.1 ventilation 8.
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0.0 SAFETY AND WARNINGS Safety instructions in the operators manual are bold-faced 0.1 SAFETY INSTRUCTIONS for emphasis. The signal words DANGER, WARNING and Before you install this air compressor you should take the CAUTION are used to indicate hazard seriousness levels time to carefully read all the instructions contained in this as follows: manual. Danger is used to indicate the presence of Electricity and compressed air have the potential to cause a hazard which will cause severe personal se
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SAFETY SHUTDOWN CHECK HIGH AIR TEMPERATURE There is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory pre-set at 228°F (109°C). This function should be checked at regular intervals for proper operation, once a month is recommended. The procedure is: 1. Block off the cooling air discharge. 2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge temperature reaches the pre-set maximum d
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0.3 DECALS This section contains representative examples of decals recommend that you obtain a replacement kit as listed in which will be appearing throughout this manual and are the spare parts section of the Parts List Manual Form applied to the compressor unit. If for some reason a APDD 735 for single stage and Form APDD 736 for two decal is defaced, painted over, or parts are replaced, we stage units. ! WARNING ! ! WARNING WARNING Hazardous voltage. Can cause severe injury or death. Hot surf
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0.3 DECALS (continued) Compressor Package Data COMPRESSOR MODEL............................... 3 CAPACITY...................................................... m /MIN RATED OPERATING PRESSURE................. BARG MAX. DISCHARGE PRESSURE................... BARG MAX. MODULATE PRESSURE..................... BARG NOMINAL DRIVE MOTOR............................ KW NOMINAL FAN MOTOR................................ KW TOTAL PACKAGE AMPS............................... ! WARNING ! VOLTS..................
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0.3 DECALS (continued) Compressor Package Data Compressor Package Data COMPRESSOR MODEL............................... COMPRESSOR MODEL............................... 3 CFM CAPACITY...................................................... m /MIN CAPACITY...................................................... PSIG RATED OPERATING PRESSURE................. BARG RATED OPERATING PRESSURE................. PSIG MAX. DISCHARGE PRESSURE................... BARG MAX. DISCHARGE PRESSURE................... PSIG
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1.0 RECEIPT OF EQUIPMENT 1.1 INSPECTION When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier should be noted on the delivery receipt especially if the compressor will not be immediately uncrated. Obtaining the delivery man’s signed agreement to any noted damages will facilitate any future insurance claims. IMPORTANT READ THIS LOST OR DAMAGED GOODS THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL OUR RESPONSIBILITY FOR THIS SHIPMEN
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2.0 INSTALLATION 2.1 VENTILATION Oil flooded rotary air compressors produce large amounts of heat. Because of this large heat production, the compressor must be placed in a room with adequate ventilation. If heated air from the compressor exhaust is allowed to recirculate back to the compressor, the compressor will overheat and shut down. This heat must be exhausted from the room. You should take this into consideration when you decide where to place the compressor within your plant. Consider t
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2.3 PIPING (Continued) A dripleg assembly and isolation valve should be mounted near the compressor discharge. A drain line should be connected to the condensate drain in the base. IMPORTANT: The drain line must slope downward from the base to work properly. NOTE: For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel. It is possible that additional condensation can occur if the downstream piping cools the air even further and low DISCHARGE P
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Two types of dryers, refrigerated or desiccant, are used to correct moisture related problems in a compressed air system. Refrigerated dryers are normally specified where compressed air pressure dew points of 33°F (1°C) to 39°F (4°C) are adequate. Desiccant dryers are required PRESSURE RELIEF where pressure dew points must be below 33°F (1°C). VALVE PRESSURE GAUGE Contact your local Ingersoll-Rand distributor for assistance in selecting correct Ingersoll-Rand filtration or drying products. NOTE
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110 110 110 110V FIGURE 2.4-1 TYPICAL CONTROL TRANSFORMER WIRING ELECTRICAL INSTALLATION (Continued) Inspect the motor and control wiring for tightness. Close and fasten the starter box door. ROTATION CHECK Locate the rotation decal on each motor. DRIVE DRIVE MOTOR END The correct compressor drive motor rotation is clockwise when viewed from the rear or non-drive end of the motor. See Figure 2.4-2. NON-DRIVE END CAUTION If the compressor is operated in the opposite direction of rotation, airend
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ELECTRICAL INSTALLATION (Continued) Fan motor rotation is clockwise when viewed from The Intellisys will automatically shut the unit down if the the fan motor side. compressor rotation is incorrect, and the display will indicate “CHECK MOTOR ROTATION” and will flash INTELLISYS OPERATING INSTRUCTIONS “ALARM”. Read and understand the following Intellisys Operating Instructions (See Figure 2.4-4) prior to operating the unit. For the compressor motor rotation check, the motor jogging time must be as
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2.5 OUTDOOR SHELTERED INSTALLATION Condensate drains must never be allowed to dump on Many times a compressor must be installed outside due the ground. Run to a suitable sump for future to jobsite conditions or limited space within a collection and disposal or separation of lubricant and manufacturing facility. When this occurs there are certain water mixture. items that should be incorporated into the installation to help ensure trouble free operation. These items have Incoming power connec
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15 FIGURE 2.5-1 TYPICAL OUTDOOR SHELTERED INSTALLATION
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3.0 INTELLISYS 16 INGERSOLLrAND INTELLISYS INTELLISYS CONTROLLER
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UNLOAD 3.0 INTELLISYS Pressing this button will cause the compressor to unload and remain unloaded. The display will indicate 3.1 INTELLISYS CONTROLS the machine is “Running Unloaded”, and “Mode: UNLOAD”. EMERGENCY STOP Pressing this switch stops the compressor immediately. The compressor can not be restarted until the switch is manually reset. Turn the switch knob clockwise to reset. LOAD Pressing this button will cause the compressor to load if the compressor is running and if the “Discharge
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3.2 DISPLAY SCREEN - CURRENT STATUS- Package Discharge Temp 103°F P S I 1 0 0 Running Loaded Airend Discharge Temp Mode: MOD/ACS 193°F MAIN MENU The display screen is divided into three functional arrow head pointing up) and/or down (designated by areas, as seen in the typical CURRENT STATUS arrow head pointing down) through a list. The arrow screen shown here. buttons are also used to change an individual item’s value. At certain times, items and/or their values are The left side continuously s
