Ingersoll-Rand SL90 Installation, Operation And Maintenance Manual
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Ingersoll-Rand SL90 Installation, Operation And Maintenance Manual

Ingersoll-Rand SL90 Installation, Operation And Maintenance Manual

Oil-free rotary screw
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61115.10.33
80448574
Revision A
May 2015
Oil-Free Rotary Screw Air Compressor
SL90, SM90, SH90, SL110, SM110, SH110
SL132, SM132, SH132, SL150, SM150, SH150
SL200, SM200, SH200, SL250, SM250, SH250, SH300
L125, H125, HH125, L150, H150, HH150
L200, H200, HH200, L250, H250, HH250
L300, H300, HH300, L350, H350, HH350, HH400
Installation, Operation and Maintenance
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Summary of Contents for Ingersoll-Rand SL90

  • Page 1 80448574 Revision A May 2015 Oil-Free Rotary Screw Air Compressor SL90, SM90, SH90, SL110, SM110, SH110 SL132, SM132, SH132, SL150, SM150, SH150 SL200, SM200, SH200, SL250, SM250, SH250, SH300 L125, H125, HH125, L150, H150, HH150 L200, H200, HH200, L250, H250, HH250...

  • Page 2: Table Of Contents

    61115.10.33 CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 START SEQUENCE .
  • Page 3 61115.10.33 CONTENTS COMPRESSOR DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 COMPRESSOR MODULE INPUT SHAFT SEAL REPLACEMENT 58 UNIT TYPE .

  • Page 4: Foreword

    61115.10.33 FOREWORD IF IN DOUBT CONSULT SUPERVISION . The contents of this manual are considered to be proprietary and confidential to Ingersoll Rand and This machine has been designed and supplied for should not be reproduced without the prior written use only in the following specified conditions and permission of Ingersoll Rand .

  • Page 5: Safety

    61115.10.33 SAFETY Locate, read, understand and follow all Danger, Warning, It is your responsibility to make this information available Caution, and Operating Instructions on the product and to others . in all Manuals . Failure to comply with safety precautions If you have any questions about safety or procedures not described in the manuals supplied with the product, included in this manual, ask your supervisor or contact...

  • Page 6: General Information

    61115.10.33 GENERAL INFORMATION • GENERAL OPERATION following the intercooler to remove any condensation that may occur under certain conditions of ambient humidity and The Sierra compressor is an electric motor driven, two stage, temperature . dry screw compressor complete with accessories piped, wired An expansion joint is utilised between the moisture separator and baseplate mounted .

  • Page 7: Cooling System (Aircooled)

    61115.10.33 GENERAL INFORMATION On–Off line control The oil then passes through a filter to a distribution manifold . • An orifice from the manifold determines the oil pressure (2 .8 On–Off line control will deliver air at full capacity (compressor to 3 .5 barg) (40 to 50 psig), at normal operating temperature maximum efficiency condition) or will operate at zero (54 °C to 68 °C) (129 °F to 154 °F) .

  • Page 8: Remote Load/Unload Option

    61115.10.33 GENERAL INFORMATION Automatic start/stop operation • POWER OUTAGE RESTART OPTION • When in operation, the compressor must meet two specific The Power Outage Restart option is for installations that timing intervals before the Xe controller will stop the unit in have interruptions in their incoming power supply to the an Automatic Start/Stop situation .

  • Page 9: Receipt / Handling

    61115.10.33 RECEIPT / HANDLING • RECEIPT • UNPACKING AND HANDLING Before signing the delivery receipt, inspect for damage and The compressor will normally be delivered with a missing parts . If damage or missing parts are apparent, make polyethylene or other cover . If a knife has to be used to the appropriate notation on the delivery receipt, then sign remove this cover, ensure that the exterior paintwork of the the receipt .

  • Page 10: Installation

    61115.10.33 INSTALLATION • LOCATION IN THE PLANT • The area selected for the location of the compressor should be free of dust, chemicals, metal filings, paint Compressor fumes and overspray . • Air Receiver Dry Tank Hard surfaces may reflect noise with an apparent increase in the decibel level .

  • Page 11: Prior To Starting

    61115.10.33 INSTALLATION at different pressures, it is extremely important that they IMPORTANT: The drain line must slope downward from the are piped separately into an open drain . base to work properly . For ease of inspection of the automatic drain trap operation, the drain piping should include an open A dripleg assembly and isolation valve should be mounted funnel .

  • Page 12: Draining The Water System

    61115.10.33 INSTALLATION • DRAINING THE WATER SYSTEM Iron content should be analysed monthly . Acceptable concentration: Should it become necessary to completely drain the water 2 mg/l (2 ppm) system, proceed as follows: Sulphate content should be analysed monthly . Disconnect the inlet and discharge water lines from the Acceptable concentration: connections located at the rear of the unit .

  • Page 13: Fan Motor

    61115.10.33 INSTALLATION • FAN MOTOR • ELECTRICAL DATA Observe the compressor cooling fan . The rotation should An independent electrical isolator should be installed be in accordance with the fan rotation decal affixed to the adjacent to the compressor . fan motor .

  • Page 14: Operating Instructions

    61115.10.33 OPERATING INSTRUCTIONS BASIC OPERATION • EMERGENCY STOPPING If the compressor has to be stopped in an emergency NOTICE press the emergency stop button located underneath the instrument panel . The language and compressors of measure displayed on the controller will be preset before leaving the factory . This will over-ride the normal unload/stop button and will If these are required to be changed, contact your local immediately stop the compressor .

  • Page 15: Interface Data And Keys

    61115.10.33 OPERATING INSTRUCTIONS INTERFACE DATA AND KEYS Name Function • Xe–90M/145M None The standard user interface configuration of the controller consists of the membrane and the LCD display . The membrane consists of five command keys (Start, Stop, Load, Puts the compressor into the Unload, and Reset), four navigation keys (Up, Right, Left and selected mode of operation .

  • Page 16: Display Layout

    61115.10.33 OPERATING INSTRUCTIONS The navigation keys roll over . Pressing one of the navigation Folder Icon Description keys will lead the user down a navigation path . Each time Name the key is pressed, another step in the path is taken . Once General settings such as the end of a navigation path is reached, pressing the key one General...
  • Page 17 61115.10.33 OPERATING INSTRUCTIONS • Starting – A start command has been given to the The icon appears on numeric entry windows (see figure compressor and the start sequence is being performed . below) . Placing the cursor on it and then pressing the ENTER The time period for this state can vary depending on the key will cancel the entry and any changes that were made .

  • Page 18: Sierra Compressor

    61115.10.33 OPERATING INSTRUCTIONS SIERRA COMPRESSOR PAGE 2 – COUNTERS • • HOME FOLDER Hour Meters – Indicates the hours that: the controller has been powered up, the compressor has been running, and the compressor has running loaded . • PAGE 1 – SYSTEM OVERVIEW Starts –...

  • Page 19: Operator Settings Folder

    61115.10.33 OPERATING INSTRUCTIONS 2nd Stage Inlet Pressure – The pressure of the air at the Condensate Release Time – Time period that determines intake of the 2nd stage of the compression module . how long the condensate drain valve will remain open every cycle .

  • Page 20: Events Folder

    61115.10.33 OPERATING INSTRUCTIONS compressor to automatically restart after a power outage has match exactly . been restored if the compressor was running loaded at the • PAGES 6 CALIBRATE SENSORS time of the outage . PORO is an option and the option module must be purchased and installed before this feature can be turned on .

  • Page 21: Warning Events List

    61115.10.33 OPERATING INSTRUCTIONS the events, with each page displaying up to seven . Page • Auxiliary 2 one displays events one through five, page two displays six On-Screen Text: Auxiliary 2 through ten, and so on . This will occur if auxiliary input 2 closes . The contact must be The following items will generate an event: closed for at least 3 seconds before the warning will occur .

  • Page 22: Trip Events List

    61115.10.33 OPERATING INSTRUCTIONS • Invalid Calibration • 2nd Stage Over Ratio On-Screen Text: Invalid Cal On Screen Text: 2nd Stage Over Ratio Will occur if the sensor zero value is +/-10% of its scale . See Will occur if the compressor is running and the equation (2nd Sensor Calibration .

  • Page 23: Trip History

    61115.10.33 OPERATING INSTRUCTIONS • Remote Start Failure • TRIP HISTORY On-Screen Text: Rem Start Fail • PAGES 1 TO A MAX OF 3 Will occur if the remote start/stop option is enabled, the unit is started by the remote start button, and the button stays closed for 7 seconds after the unit starts .

  • Page 24: Maintenance Folder

    61115.10.33 OPERATING INSTRUCTIONS X–Axis (Read Only) – The time duration is selectable from PAGE 2 – MAINTENANCE STATUS • page six . The sample rate varies, based on the selected duration . The graph plots a minimum of 255 readings . •...
  • Page 25 61115.10.33 OPERATING INSTRUCTIONS All items are adjustable . Czech Hungarian Polish Thai Hours allows the current hour to be set . The hours format is Danish Italian Portuguese Turkish fixed on 24 hour . Dutch Indonesian Romanian Minutes allows current minutes to be set . Estonian Korean Russian...

  • Page 26: Integral Sequencing Folder

    61115.10.33 OPERATING INSTRUCTIONS PAGE 6 – SERIAL PORT ADDRESS SETTINGS Apply – After editing the desired setpoint navigate to the • accept setting and press enter in order for the values in the setting variables to be confirmed by the controller . Cancel –...

  • Page 27: Status Folder

    61115.10.33 OPERATING INSTRUCTIONS Load Pressure – Determines the pressure at which a • Package Discharge Pressure – The pressure the compressor will be loaded by the system . compressor is delivering to the plant . • Package Discharge Temperature – The temperature of System Pressure –...

  • Page 28: Factory Settings Folder

    61115.10.33 OPERATING INSTRUCTIONS • PAGES 4 THRU 5 – DIGITAL INPUTS • Warning Indication . • FACTORY SETTINGS FOLDER This folder is for Ingersoll Rand factory and service personnel . A password must be entered on page one in order to adjust values in this folder . This folder is used for setting parameters that are specific to that compressor and displaying software information for the controller .
  • Page 29 61115.10.33 OPERATING INSTRUCTIONS Power On Hours (Read Only) . compressor can provide . This setpoint is adjustable from 100–150 psi (6 .9–10 .3 bar) and defaults to 100 psi . Running Hours (adjustable) – Used to adjust the running Starter Type (Star-delta, Remote Starter, Soft Starter) hours counter on the compressor .

  • Page 30: Web Access

    61115.10.33 OPERATING INSTRUCTIONS WEB ACCESS operation, equipment status and setup through an intuitive web-page based user interface . To access this application Ingersoll Rand Xe–90M/145M web pages are a visualization running on the controller, simply connect via a Web Browser application which offers a window using a web browser from any PC using an Ethernet connection .

  • Page 31: Connecting To A Pc

    61115.10.33 OPERATING INSTRUCTIONS • CONNECTING TO A PC In order to configure your computer to communicate point-to-point with the Xe–90M/145M controller, you must first set the IP address range of your computer to the default IP address range of the controller . To do this, please follow the instructions listed below to configure the computer IP address .
  • Page 32 61115.10.33 OPERATING INSTRUCTIONS 2 . Right click on the “Local Area Connection” and select “Properties” . 3 . Scroll down the connection list to find the “Internet Protocol (TCP/IP)” . Select the “Internet Protocol (TCP/IP)” and click on “Properties” . 80448574 Rev A...
  • Page 33 61115.10.33 OPERATING INSTRUCTIONS 4 . Click on the “Alternative Configuration” tab . 5 . Click on “User Configured” Button . 80448574 Rev A...
  • Page 34 61115.10.33 OPERATING INSTRUCTIONS 6 . Enter IP address for the computer (192 .168 .2 .221), Enter the Subnet mask for the computer (255 .255 .255 .0) and leave all other field boxes blank . 7 . Click on “OK” button when it is complete . 80448574 Rev A...

  • Page 35: Ethernet Configuration

    61115.10.33 OPERATING INSTRUCTIONS 8 . Connect an Ethernet cable to your computer and to the controller . Within a minute, the computer will make a connection to the controller . Once connected, you will be able to log into and configure the controller . ETHERNET WIRES Wiring the network is accomplished by connecting the user computer to the controller using Category 5 (or better) cables .

  • Page 36: Login Process

    61115.10.33 OPERATING INSTRUCTIONS • LOGIN PROCESS The server is accessed either by host name or by IP . Accessing by name requires that a router be in the network . During the installation and commissioning process a network address was assigned to the CONTROLLER by your IT department . This address may be a static IP (e .g .
  • Page 37 61115.10.33 OPERATING INSTRUCTIONS The login screen requires the user to enter their username, password and select the language for the web pages . This login screen will authenticate the user against the type of account . After log in the user can view/modify the data as per the available access to the user account .

  • Page 38: Default Accounts

    61115.10.33 OPERATING INSTRUCTIONS • DEFAULT ACCOUNTS The web page software comes with default administrator account . The system administrator can assign users one of three levels of access (view only, user and administrator) which will determine which functions will be available . For example, only users with administrator access will be able to create a new user account and view or modify the configuration overview parameters .

  • Page 39: Command Buttons

    61115.10.33 OPERATING INSTRUCTIONS Clicking this tab will bring the user to the ACCOUNT page . Account See section ACCOUNT MANAGEMENT . • COMMAND BUTTONS All pages show five command buttons (Start, Stop, Reset Alarm, Load and Unload), five dash board icons and current status of the compressor .

  • Page 40: Home Page

    61115.10.33 OPERATING INSTRUCTIONS Compressor Name, User Name, Print Button and Log Out button are always visible on the right side top of the page, regardless of the tab selected . The user can set the “Compressor Name” from the “Compressor Information”...
  • Page 41 61115.10.33 OPERATING INSTRUCTIONS Click on the pressure set point value in the white box, to change the “Pressure Set Point” value . Enter the new pressure set point value and click on “Confirm” button . “Pressure Set Point” is only editable parameter for the “Admin” and “User” type accounts . The user with “View”...

  • Page 42: Event Log Utility

    61115.10.33 OPERATING INSTRUCTIONS • EVENT LOG UTILITY The “EVENT LOG” tab shows the event log from the controller . This tab contains the event log details for the system events, warnings and trips that have occurred and provides first-out indication . It also provides controls for filtering the list of events as shown .
  • Page 43 61115.10.33 OPERATING INSTRUCTIONS The “Event Type” dropdown allows the user to filter the list of events by event type . The user can select the type of event from the list by clicking the dropdown control . The events recorded and placed into one of three categories: Warnings, Trips/ Shutdowns, and System Events .

  • Page 44: Performance Log Utility

    61115.10.33 OPERATING INSTRUCTIONS • PERFORMANCE LOG UTILITY The “PERFORMANCE LOG” tab shows the performance details and system data for the compressor including Average system pressure, hour meters, number of trips and warnings . The Performance log report provides a summary of the compressed air system’s performance for the selected time period .
  • Page 45 61115.10.33 OPERATING INSTRUCTIONS The “PERFORMANCE LOG” provides two dropdown controls that allow the user to select sampling of reporting and reporting settings . The user can change the frequency of reporting and monitoring interval by clicking on the dropdown controls . The time period of the performance report is selected based on the “Frequency of Reporting”...

  • Page 46: Graphing Utility

    61115.10.33 OPERATING INSTRUCTIONS Whenever the user changes the “Frequency of reporting” and/or “Monitoring Interval”, a “Submit” button will appear on the screen . Click on “Submit” button to save the changes . • GRAPHING UTILITY Click on “GRAPHING” tab to view the data in a graphical format for the selected analog input variable and time duration . The GRAPHING UTILITY allows the user to plot a graph on hour, day or week basis .
  • Page 47 61115.10.33 OPERATING INSTRUCTIONS When “Days” has been selected, the X axis will be scaled such that the span on graph represents duration of 1 day . When “Weeks” has been selected, the X axis will be scaled such that the span on graph represents duration of 1 week . 80448574 Rev A...

  • Page 48: Maintenance Utility

    61115.10.33 OPERATING INSTRUCTIONS The drop down menu allows the user to choose a variable to view data on the graph . Click on the dropdown menu and select the variable to monitor on the graph . Variables include all analog inputs as well as some calculated variables . The amount of variables will vary depending on the compressor type and the available options .

  • Page 49: Inspection Log Utility

    61115.10.33 OPERATING INSTRUCTIONS • INSPECTION LOG UTILITY The “INSPECTION LOG” tab is intended to record machine data over a fixed period of time and a fixed rate . Inspection log contains the controller logged data for the variables at the time of download . The controls section of the “INSPECTION LOG” shows the user name currently set to receive inspection logs via email, as per the specified time interval and time of the day for instantaneous data .
  • Page 50 61115.10.33 OPERATING INSTRUCTIONS Click on the dropdown control and select the “Time of day” . It is shown in a 24 hours clock format . Click on the “Submit” button to save the changes into the report settings . The user will receive the INSPECTION LOG as per the selected time interval and time of the day .

  • Page 51: Compressor Information

    61115.10.33 OPERATING INSTRUCTIONS • COMPRESSOR INFORMATION The “COMPRESSOR INFORMATION” tab contains the compressor name, compressor model number, compressor serial number, rated capacity, rated pressure, rated voltage, running current, starting current, power requirement, motor service factor, measuring units and Email (SMTP) settings . •...

  • Page 52: Email (Smtp) Settings

    61115.10.33 OPERATING INSTRUCTIONS • EMAIL (SMTP) SETTINGS If email notifications are to be used, the SMTP server settings must be obtained from IT and entered in this location . Enter the “SMTP Server” and “SMTP Account” and then click on “Submit” button to save the SMTP settings . User account with access level “Admin”...

  • Page 53: Unit Type

    61115.10.33 OPERATING INSTRUCTIONS • UNIT TYPE Click on the dropdown control and select the measurement unit type for the compressor parameters . Default unit type is “English” . User account with access level “Admin” and “User” can only have an access to change these compressor parameters . User account with access level “VIEW”...
  • Page 54 61115.10.33 OPERATING INSTRUCTIONS To generate a new user account; enter the unique username, password and select the user access rights . Click on “Add Account” button will add the new user account into the list of user accounts . Only a user with “ADMIN” rights will be able to make a new account or remove the existing accounts .

  • Page 55: Modify The Access Level

    61115.10.33 OPERATING INSTRUCTIONS • MODIFY THE ACCESS LEVEL User account with access level “ADMIN” can also change the access level of existing user accounts . To change the access level or password of an existing user account, select the user account from the list and click the Change PW/AL button . Click on the dropdown control and choose the new access level for selected user account .
  • Page 56 61115.10.33 OPERATING INSTRUCTIONS User account with access level “Admin” can only have an access to make a new account or modify the access level of these accounts . User account with access level “User” and “VIEW” can’t have an access to make a new account or modify the user accounts .

  • Page 57: Maintenance

    61115.10.33 MAINTENANCE PERIOD MAINTENANCE PERIOD MAINTENANCE 16000 hours Rebuild hydraulic cylinder using field kit . Daily Check the lubricating oil level and replenish Replace Extended-life Premium Coolant as necessary . (Ultra EL) [16000 hours or every 3 years] . Check the oil filter pressure differential . 4 years Replace all hoses .

  • Page 58: Air Filter Change Procedure

    61115.10.33 MAINTENANCE • OIL FILTER • warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen . Change oil filter after every 8,000 hours or less as required Upon completion of maintenance tasks and prior to (see checking procedure below) .To check the condition of returning the machine into service, ensure that:–...

  • Page 59: Motor Bearings

    61115.10.33 MAINTENANCE Remove the 4 bolts retaining the seal housing and screw removing the plugs . Add the specified quantity of 2 of them to remove the housing complete with seal . recommended grease using a hand lever gun . Replace the inlet plug, run the machine for 10 minutes and then replace Remove the old seal from the housing .

  • Page 60: Troubleshooting

    61115.10.33 TROUBLESHOOTING PROBLEM REMEDY Compressor fails to 110/120V CONTROL VOLTAGE NOT AVAILABLE . start . Check the fuse . Check the transformers and wiring connections . EMERGENCY STOP . Rotate emergency stop button to disengage, and press reset button twice . STARTER FAULT (1SL OR 2SL) .
  • Page 61 61115.10.33 TROUBLESHOOTING PROBLEM REMEDY Compressor shuts HIGH I/C AIR TEMPERATURE . down . Ensure that installation area has adequate ventilation . Fan side of intercooler may be dirty or plugged . Clean as required . HIGH 2ND STAGE PRESSURE HIGH LINE AIR PRESSURE . Check for blockage or obstruction in air side of aftercooler, discharge moisture separator or discharge check valve .
  • Page 62 61115.10.33 TROUBLESHOOTING PROBLEM REMEDY Water in system . DEFECTIVE MOISTURE SEPARATOR/DRAIN TRAP . Inspect and clean if required . Replace separator/trap if defective . TRAP DRAIN OR DRAIN PIPING PLUGGED . Inspect and clean . AFTERCOOLER CORE DIRTY . Inspect and clean . ENCLOSURE PANELS NOT IN PLACE .
  • Page 63 61115.10.33...
  • Page 64 61115.10.33 ingersollrandproducts .com © 2015 Ingersoll-Rand...

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