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This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
SSR M4 M5,5
M7,5 M11
OPERATION AND MAINTENANCE MANUAL
M4
M5,5
M7,5
M11
C.C.N. : 89270334 GB
DATE
SERIAL No :
2101200
SERIAL No :
2121300
SERIAL No :
2141800
SERIAL No :
2161200
: NOVEMBER 2002
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Table of Contents
Related Manuals for Ingersoll-Rand SSR M4
Summary of Contents for Ingersoll-Rand SSR M4
- Page 1 SSR M4 M5,5 M7,5 M11 OPERATION AND MAINTENANCE MANUAL SERIAL No : 2101200 –> This manual contains important safety information M5,5 SERIAL No : 2121300 –> and must be made available to personnel who operate and M7,5 SERIAL No : 2141800 –>...
- Page 2 Machine models represented in this manual may be used in various locations world–wide. Machines sold and shipped into European Union Territories require that the machine display the EC Mark and conform to various directives. In such cases, the design specification of this machine has been certified as complying with EC directives. Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered invalid.
- Page 3 CONTENTS & ABBREVIATIONS ABBREVIATIONS & SYMBOLS CONTENTS #### Contact Ingersoll–Rand for serial number CONTENTS –>#### Up to Serial No. ####–> From Serial No. FOREWORD Not illustrated ISO SYMBOLS † Option Not required SAFETY As required Sitemaster/Sitepack GENERAL INFORMATION High ambient machine INSTALLATION / HANDLING Watercooled machine Aircooled machine...
- Page 4 FOREWORD The contents of this manual are considered to be proprietary and The intended uses of this machine are outlined below and examples confidential to Ingersoll–Rand and should not be reproduced without of unapproved usage are also given, however Ingersoll–Rand cannot the prior written permission of Ingersoll–Rand.
- Page 5 ISO SYMBOLS GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition / Mandatory Information / Instructions Warning WARNING: Electrical shock risk. WARNING – Pressurised vessel. WARNING – Hot surface. WARNING – Pressure control. WARNING – Corrosion risk. WARNING – Air/gas flow or Air discharge. WARNING –...
- Page 6 ISO SYMBOLS WARNING – Do not undertake any WARNING – Consult the operation and maintenance on this machine until the Do not breathe the compressed air from this maintenance manual before commencing electrical supply is disconnected and the air machine. any maintenance.
- Page 7 ISO SYMBOLS Lifting point. On (power). Off (power). Read the Operation and Maintenance manual When parking use prop stand, handrake and Contains asbestos. before operation or maintenance of this wheel chocks. machine is undertaken. SEQUENCER STATUS LOAD SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED) RESET...
- Page 8 ISO SYMBOLS COOLANT SEPARATOR PRESSURE AIR DISCHARGE PRESSURISED 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 PROHIBITED COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL MANUAL (SELECT) TEMPERATURE...
- Page 9 ISO SYMBOLS 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 M4 M5,5 M7,5 M11...
- Page 10 SAFETY All pressure containing parts, especially flexible hoses and their WARNINGS couplings, must be regularly inspected, be free from defects and be Warnings call attention to instructions which must be followed replaced according to the Manual instructions. precisely to avoid injury or death. CAUTIONS Compressed air can be dangerous if incorrectly handled.
- Page 11 SAFETY Condensate disposal Coolant disposal Condensate cannot be discharged into fresh/surface water drains. Steps to be taken in the case of spillage: Soak up with a suitable In some regions compressor condensate containing ULTRA absorbent material, then sweep into a plastic bag for disposal. COOLANT can be fed directly into a drainage system that has downstream sewerage treatment.
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Page 12: General Information
GENERAL INFORMATION Revision 00 11/97 Condensate 1 Filter, air Air/Coolant 2 Regulator 3 Valve, solenoid Water 4 Airend assembly Regulation 5 Motor Coolant 6 Tank, separator Coarse GENERAL OPERATION 7 Tank, separator The compressor is an electric motor driven, single stage screw Fine compressor, complete with accessories piped, wired and baseplate or 8 Valve, minimum pressure... - Page 13 GENERAL INFORMATION The power transmission from the drive motor to the airend male The compressor load control system is automatic ’On–Off line’. The rotor is by pulley and V–belts. The constant auto tensioning system, compressor will operate to maintain a set discharge line pressure and using motor mass and torque, ensures that the belts are always under is provided with an autorestart system for use in plants where the air the correct tension, eliminating the need for adjustment and maximising...
- Page 14 GENERAL INFORMATION M5,5 M7,5 ELECTRICAL DATA Standard voltage 3 ~ 400V 3 ~ 400V 3 ~ 400V 3 ~ 400V Drive motor Power 4,0 kW 5,5 kW 7,5 kW 11,0 kW Full load current 8,1 A 11,3 A 15,3 A 23,0 A (maximum) Starting current (approx.)
- Page 15 GENERAL INFORMATION M4 M5,5 M7,5 M11...
- Page 16 GENERAL INFORMATION CABLE Switch, emergency stop Supply earth Load solenoid L1–L3 Mains terminals Pressure switch Earth point, Sub–base Star Delta Timer Main contactor Run–on Timer Delta contactor Hourmeter Star contactor R1–R2Relay, control Main motor Terminal, control Fuse, fan motor – – – Option Fan motor Pushbutton, start CB1–5Circuit breaker...
- Page 17 INSTALLATION / HANDLING 89210074–1 Revision 00 10/97 NOTE CAUTION All dimensions are in millimetres unless otherwise stated. Screw type compressors [1] should not be installed in air systems with reciprocating compressors without means of isolation such as a common receiver tank. It is recommended that both types of compressor be piped to a common receiver using individual air lines.
- Page 18 INSTALLATION / HANDLING 89210074–2 Revision 00 10/97 CAUTION The use of plastic bowls on line filters and other plastic air line components without metal guards can be hazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils.
- Page 19 INSTALLATION / HANDLING 89210074–3 Revision 00 02/98 DISCHARGE PIPING CAUTION: Do not remove the motor table transit bolt until the electrical connection and correct rotation have been completed. Discharge piping should be at least as large as the discharge connection of the compressor. All piping and fittings should be suitably rated for the discharge pressure.
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Page 20: Operating Instructions
OPERATING INSTRUCTIONS PRIOR TO STARTING 1. Check coolant level. Add if necessary. 1: PRESSURE GAUGE Indicates the pressure immediately after the aftercooler. DO NOT The reservoir is designed to prevent overfill. With warm unit stopped operate the compressor at discharge pressures over the rated in the normal way, the sight tube level should be within 15mm of the top pressure. - Page 21 AIRCARE WARRANTY Superior Service Solutions for Air Systems AirCare is a responsive and flexible contract maintenance program custom designed for the owner who requires planned maintenance for increased system reliability. The AirCare program provides you with reduced maintenance costs, reduced energy usage through optimization and efficiency, and reduced produc- tion losses through fewer unexpected maintenance requirements and downtime.
- Page 22 MAINTENANCE PERIOD MAINTENANCE the machine cannot be started accidently or otherwise, by posting warning signs and/or fitting appropriate anti–start devices. Check the coolant level and replenish if Daily necessary. all residual electrical power sources (mains and battery) are Check that the safety valve easing gear isolated.
- Page 23 MAINTENANCE 2. Place a suitable container close to the drain valve. SEPARATOR ELEMENT CHANGE PROCEDURE 1. Disconnect the hose at the top of the separator tank. 3. Screw the coolant drain hose onto the drain valve. As the threads engage, the valve will automatically open and the coolant will drain. 2.
- Page 24 MAINTENANCE SETTING THE PRESSURE SWITCH (1PS) The lower set point is factory set 0.85 bar (12psig) below the upper set point to suit the average application. TO CHECK THE MAXIMUM DISCHARGE PRESSURE (Pressure switch upper trip point) TO ADJUST THE UPPER SET POINT Slowly close the isolation valve located adjacent to the compressor.
- Page 25 MAINTENANCE CAUTION 7. Move the bush either in or out on the motor shaft depending upon Before working on the belt drive system, ensure that the machine the measurement taken earlier. has been stopped and the electrical power supply isolated, as rotating equipment can be dangerous.
- Page 26 MAINTENANCE BELT TENSION AIREND BEARINGS This unit has been designed with a unique self tensioning system, Airend bearings are lubricated by the compressor coolant and therefore, the drive belt requires no manual adjustment. Use only require no maintenance. genuine Ingersoll–Rand replacement parts to ensure the correct belt tension.
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Page 27: Fault Finding
FAULT FINDING FAULT CAUSE Compressor fails to start Control voltage not available. Defective starter. Machine shutsdown periodically Defective starter. Motor overload. Line voltage variation. High current draw Compressor operating above rated pressure. Separator filter element contaminated. Low voltage. Unbalanced voltage. Low current draw Air filter contaminated. - Page 28 OPTIONS The dryer starts with the compressor. SERIAL NO. VALIDITY Refrigerant Compressed Air Dryers covered by this manual: An acceptable air quality will be reached within minutes. BI–1 During operation BI–2 Regularly check the position of the dew point indicator. The pointer has BI–3 to be in the green zone.
- Page 29 OPTIONS Note: With a time or level controlled condensate drain, the float drain Check the trouble–shooting list on page 27 when maintenance shows is not fitted. any irregularities. TROUBLE SHOOTING Before starting maintenance or repair on the dryer, the mains switch and the on/off switch must be turned off. Also, the compressed air must be vented from the system.
- Page 30 OPTIONS RETIREMENT AIR COOLED 5,5kW 7,5kW 11kW Constant Pressure 2,05 2,05 2,05 2,05 At the end of the life cycle of the refrigerant compressed air dryer, there Valve suction pressure are some points that deserve special attention: at zero load at the moment of fan motor 1.
- Page 31 OPTIONS Methods for cleaning up: Evaporates. Special effects: Rapid evaporation of the liquid may cause frostbite. 7. Handling and storage 12.Ecological information Handling: Technical measures / precautions: Provide sufficient air Exotoxicity effects: Halocarbon global warming potential; HGWP; exchange and/or exhaust in work rooms. Safe handling advice: Use (R–11 = 1) = 0.28.
- Page 32 OPTIONS Condenser Dry air (out) Motor, fan Wet air (in) Exchanger and evaporator Condensate drain Separator, water Compressor Filter, refrigerant Thermostat, fan Valve, constant pressure Indicator, dew point M4 M5,5 M7,5 M11...
- Page 33 OPTIONS Options Capacitor compressor Level controlled electronic drain Fuse 16A K1 & Y1 Time controlled electronic drain Customer installation Transformer 110V/115V/277V – 230V Light ’dryer on’ Main power, live Main power, neutral Compressor Main power, earthing Mains switch Customer installation On/off switch Temperature switch fan Thermal overload switch compressor...
- Page 36 Printed in the United Kingdom...