Ingersoll-rand 100-200 HP/75-160 KW Bedienungsanleitung

Before installation or starting the compressor for thefirst time, this manual should be studied carefully toobtain a clear knowledge of the unit and o

81.0 RECEIPT OF EQUIPMENT1.1 INSPECTIONWhen you receive the compressor please inspect itclosely. Any indication of careless handling by the carriersho

2.0 INSTALLATION2.1 VENTILATION Oil flooded rotary air compressors produce largeamounts of heat. Because of this large heat production,the compressor

10DISCHARGE PIPING WITH AFTERCOOLERROTARY-RECIP IN PARALLELDo not use the compressor to support the discharge pipe.Careful review of piping size from

112.4 ELECTRICAL INSTALLATIONBefore proceeding further, we recommend that youreview the safety data in the front of this manual.Locate the compressor

If the compressor is operated in theopposite direction of rotation, airend damagecan result and is not warrantable.CAUTION12ELECTRICAL INSTALLATION (C

13ELECTRICAL INSTALLATION (Continued)The Intellisys will automatically shut the unit down if thecompressor rotation is incorrect, and the display will

142.5 OUTDOOR SHELTERED INSTALLATIONMany times a compressor must be installed outside dueto jobsite conditions or limited space within amanufacturing

FIGURE 2.5-1 TYPICAL OUTDOOR SHELTERED INSTALLATION15

163.0 INTELLISYSINTELLISYS CONTROLLERINGERSOLLrANDINTELLISYS

3.0 INTELLISYS3.1 INTELLISYS CONTROLSEMERGENCY STOP Pressing this switch stops the compressor immediately.The compressor can not be restarted until th

AIR COMPRESSOR GROUPBONDED WARRANTY & REGISTERED START UPWarrantyThe Company warrants that the equipment manufactured by it and delivered hereunde

The display screen is divided into three functionalareas, as seen in the typical CURRENT STATUSscreen shown here.The left side continuously shows the

19NOTE - Use the UP and DOWN arrows to move between selections. Items will be highlighted in inverse display mode.* - Selecting the highlighted item

1 0 0P S I3.4 MAIN MENUThe MAIN MENU screen is the point from whichvarious operator functions can be accessed. Refer tothe reference diagram in Figure

3.5.1 Lead/Lag- This setpoint is used for setting leador lag operation. If set to lead, the controller will loadand unload the compressor by the onli

223.6.1 Auto Restart- This setpoint is used to enable ordisable the auto restart option.3.6.2 Auto Restart Time- This setpoint is the minimumtime peri

3.7 SENSOR CALIBRATION1 0 0P S I-SENSOR CALIBRATION-Sensor 1AVPTCALIBRATESensor 3APTCALIBRATESTATUSMAIN MENUSELECTReady To StartPressure sensor calibr

241 0 0P S I-ALARM HISTORY 1-Package Disch Pressure199 PSIPackage Discharge Temp103°FSTATUSMAIN MENUALARM HISTORYReady To StartThe name and value of e

251 0 0P S I-INTEGRAL SEQUENCING-Lead CompressorOffTotal Compressors23.10 INTEGRAL SEQUENCINGIntegral Sequencing is set up using the INTEGRALSEQUENCIN

1 0 0P S IChange Inlet FilterPress RESET Twice3.11 WARNINGSSTATUSMAIN MENURESETRunning UnloadedMode: MOD/ACS1 0 0P S I-CURRENT STATUS-Package Discharg

1 0 0P S IHigh Airend Disch Temp229°FPress RESET Twice3.12 ALARMSSTATUSMAIN MENURESETSTOPPED BY ALARMMode: MOD/ACS1 0 0P S I-ALARM STATUS-Package Disc

1ROTARY SCREW AIR COMPRESSORThis unit was purchased from:_____________________________________________________________________________________________

28The possible Alarm messages are as follows.CHECK INLET CONTROL- This will occur if themachine is unloaded and the inlet vacuum is less than3 psig (.

4.0 SCHEDULED PREVENTATIVE MAINTENANCE4.1 MAINTENANCE SCHEDULETHE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THECOMPR

4.4 INLET AIR FILTERTo check condition of the inlet filter, run compressor inthe LOADED mode and observe “Inlet Filter” on theCURRENT STATUS display s

31COOLANT DRAIN4.6 COOLANT SSR Ultra Coolant (Standard Factory Fill) SSR H1-F Food Grade (Optional)SSR Ultra Coolant is a polyglycol base coolant.

324.6 COOLANT (Continued)After the unit is drained and a new coolant filter elementis installed, refill the system with fresh coolant. Bring thereceiv

WARNING125/200 HPThis machine contains high air pressurewhich can cause severe injury or deathfrom hot oil or flying parts.Always relieve pressure bef

34COOLANT COOLERSFollowing are instructions for removal and internalcleaning of coolant coolers.Coolant Cooler Remove panels and top cover. Drain t

35AFTERCOOLERFollowing are instructions for the removal and internalcleaning of aftercoolers.Aftercooler Disconnect hose from aftercooler inlet flan

36Overgreasing can be a cause of bearing and motor failure. Make sure dirt and contaminants are not introduced when adding grease.CAUTION4.10 MOTOR LU

374.10 MOTOR LUBRICATION (Continued)Grease relief along shaft can occur, precluding necessityof removing this plug if inaccessible. The inlet grease g

2TABLE OF CONTENTS0.0 SAFETY AND WARNINGS0.1 safety instructions0.2 safety precautions0.3 decals1.0 RECEIPT OF EQUIPMENT1.1 inspection1.2 unpacking an

384.11 LONG TERM STORAGEGENERALThe factory, upon special request, prepares compressorunits for long term storage. In such cases, a specialbulletin is

39Power Supply Removal:1) Open the starter box door.2) Remove each plug-in connector, labeled J1 -J4, from the circuit board. If any of the cables are

40COOLING FAN MOTORIn a standard compressor, the cooling fan motor is wiredat the factory. It is a three-phase motor, protected by asuitable circuit b

5.4 COMPRESSED AIR SYSTEMThe air system is composed of:1) Inlet air filter2) Inlet valve/stepper motor 3) Rotors 4) Coolant/air separator5) Minimum pr

5.6 ELECTRICAL SYSTEM (Continued)STAR-DELTA TYPE STARTERBy use of the Star-Delta type starter, the compressormotor can be started and accelerated usin

5.8 CAPACITY CONTROL (Continued)MODULATION/ACS CONTROL (Continued)The automatic control selector (ACS) is designed tocontinuously monitor the plant ai

44SECONDAfter the compressor has started and reached the off-linesetting and has unloaded, timer “B” requires the unit torun unloaded for a period of

45EXAMPLE 3The operator selects an unloaded run time of 10 minutesin the OPTION routine and starts the compressor. Theunit runs loaded 12 minutes and

466.0 TROUBLESHOOTING CHARTTROUBLECompressor fails to start.Compressor shuts down.NOTE: If a shutdownoccurs, press the Statusbutton once to activateth

6.0 TROUBLESHOOTING CHART (Continued)TROUBLELow system air pressureHigh coolantconsumption/coolant inair systemWater in air systemExcessive noise leve

30.0 SAFETY AND WARNINGS0.1 SAFETY INSTRUCTIONSBefore you install this air compressor you should take thetime to carefully read all the instructions c

487.0 OTIONS7.1 POWER OUTAGE RESTART OPTIONFor customers that have interruptions in their incomingpower supply to the compressor and must maintain anu

7.9 REMOTE LOAD/UNLOADThe remote load/unload option gives the operator theability to control the loading and unloading of thecompressor. This option i

5054418074REV B8.0 REFERENCE DRAWINGS8.1 ELECTRICAL SCHEMATICSTAR DELTA

51

5254622865REV B8.2 FOUNDATION PLAN125-150 HP/90-110KW AIRCOOLEDSINGLE STAGE(CONTINUED)

5354622865REV B8.2 FOUNDATION PLAN125-150 HP/90-110 KW AIRCOOLEDSINGLE STAGE

8.3 FOUNDATION PLAN200 HP/132-160 KW AIRCOOLEDSINGLE STAGE(CONTINUED)54622931REV B54

8.3 FOUNDATION PLAN200 HP/132-160 KW AIRCOOLEDSINGLE STAGE54622931REV B55

568.4 FOUNDATION PLAN125-150 HP/90-110 KW WATERCOOLEDSINGLE STAGE(CONTINUED)39925300REV C

578.4 FOUNDATION PLAN125-150 HP/90-110 KW WATERCOOLEDSINGLE STAGE39925300REV C

4WARNINGFailure to adhere to these recommendations can result in mechanical failure, property damage and serious injury or death.All air and water inl

588.5 FOUNDATION PLAN200 HP/132-160 KW WATERCOOLEDSINGLE STAGE(CONTINUED)39926191REV C

598.5 FOUNDATION PLAN200 HP/132-160 KW WATERCOOLEDSINGLE STAGE39926191REV C

608.6 FOUNDATION PLAN - AIRCOOLED (CONTINUED)100-150 HP/75-110 KW - TWO STAGE54622980REV B

6154622980REV B8.6 FOUNDATION PLAN - AIRCOOLED100-150 HP/75-110 KW - TWO STAGE

628.7 FOUNDATION PLAN - AIRCOOLED (CONTINUED)200 HP/132-160 KW - TWO STAGE54623053REV B

6354623053REV B8.7 FOUNDATION PLAN - AIRCOOLED 200 HP/132-160 KW - TWO STAGE

648.8 FOUNDATION PLAN -WATERCOOLED (CONTINUED)100-150 HP/75-110 KW - TWO STAGE39925326REV C

658.8 FOUNDATION PLAN -WATERCOOLED100-150 HP/75-110 KW - TWO STAGE39925326REV C

668.9 FOUNDATION PLAN -WATERCOOLED (CONTINUED)200 HP/132-160 KW - TWO STAGE39926340REV C

678.9 FOUNDATION PLAN -WATERCOOLED200 HP/132-160 KW - TWO STAGE39926340REV C

39540174 Rev. 0550.3 DECALSThis section contains representative examples of decalswhich will be appearing throughout this manual and areapplied to the

688.10 FLOW SCHEMATICAIRCOOLED - SINGLE STAGE54579081REV A

69

708.11 FLOW SCHEMATICWATERCOOLED - 90°F (32°C) - SINGLE STAGE54579503REV A

71

728.12 FLOW SCHEMATICWATERCOOLED - 115°F (46°) - SINGLE STAGE54579511REV A

73

748.13 FLOW SCHEMATICAIR-COOLED - TWO STAGE54579644REV A

75

768.14 FLOW SCHEMATICWATERCOOLED 90°F (32°C)TWO STAGE54579693REV A

77

0.3 DECALS (continued)6WARNING!Hot surface.Can cause severe injury.Do not touch. Allow to cool beforeservicing.Water out.Water in.Lift HereCondensated

788.15 FLOW SCHEMATICWATERCOOLED 115°F (46°C)TWO STAGE54579727REV A

79

808.16 TYPICAL SYSTEM FLOW DIAGRAMSTYPICAL SYSTEM FLOWDIAGRAM

818.16 TYPICAL SYSTEM FLOW DIAGRAMS

828.16 TYPICAL SYSTEM FLOW DIAGRAMS

838.16 TYPICAL SYSTEM FLOW DIAGRAMS

848.16 TYPICAL SYSTEM FLOW DIAGRAMS

859.0 WATER QUALITY RECOMMENDATIONSWater quality is often overlooked when the coolingsystem of a water cooled air compressor is examined.Water quality

86Recommended equipment for on-site analysis includes athermometer, pH meter, and dissolved oxygen meter.Dissolved oxygen and temperature must be meas

87LANGELIER INDEX CHART VALUESUNITS01234567890 0.00 0.30 0.48 0.60 0.70 0.78 0.85 0.90 0.9310 1.00 1.04 1.08 1.11 1.15 1.18 1.20 1.23 1.26 1.2920 1.30

0.3 DECALS (continued)7WARNING!Hazardous voltage. Can causesevere injury or death.Only use factory supplied inlet forincoming power. See Operators/Ins

88DATE RUN TIME WORK DONE QTY. UNIT WORK(HOURS) MEASURE BY10.0 MAINTENANCE RECORD

89DATE RUN TIME WORK DONE QTY. UNIT WORK(HOURS) MEASURE BYMAINTENANCE RECORD

90DATE RUN TIME WORK DONE QTY. UNIT WORK(HOURS) MEASURE BYMAINTENANCE RECORD

91DATE RUN TIME WORK DONE QTY. UNIT WORK(HOURS) MEASURE BYMAINTENANCE RECORD