Ingersoll-Rand NIRVANA IRN37K–OF Operation And Maintenance Manual
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Ingersoll-Rand NIRVANA IRN37K–OF Operation And Maintenance Manual

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Ensure that the operator reads and understands the
decals and consults the manuals before maintenance or
operation.
Ensure that the Operation and Maintenance manual is
not removed permanently from the machine.
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance
Manuals.
IRN37–160K–OF
IRN50–200H–OF
OPERATION AND MAINTENANCE MANUAL
C.C.N. : 22310387
DATE
REV.
: AUGUST 2005
: D
TM

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  • Page 1 IRN37–160K–OF IRN50–200H–OF OPERATION AND MAINTENANCE MANUAL Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation. Ensure that the Operation and Maintenance manual is not removed permanently from the machine. C.C.N. : 22310387 Ensure that maintenance personnel are adequately DATE : AUGUST 2005...
  • 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 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 twenty four months from the date of placing the Equipment in operation or thirty months from the date of shipment from the factory, whichever shall first occur (see extended airend warranty).

  • Page 5: Table Of Contents

    CONTENTS CONTENTS PAGE CONTENTS PAGE CONTENTS GENERAL INFORMATION 26 FOREWORD Technical information ABBREVIATIONS & Installation drawing SYMBOLS Process and PURCHASE ORDER instrumentation diagram DETAILS Electrical schematic SAFETY General description Safety instructions OPERATING INSTRUCTIONS Safety precautions Text decals Basic operation Graphic form and meaning Intellisys controls of ISO symbols Display screen...

  • Page 6: Foreword

    2.0 FOREWORD Machine models represented in this manual may be Details of approved equipment are available from Ingersoll–Rand Service departments. used in various locations worldwide. Machines sold and shipped into European community countries requires that the machine display the EC Mark and conform to This machine has been designed and supplied for use various directives.

  • Page 7: Foreword 2

    2.0 FOREWORD WARNING The use of the machine in any of the situation types listed in table 1:– a) Is not approved by Ingersoll–Rand, b) May impair the safety of users and other persons, and c) May prejudice any claims made against Ingersoll–Rand. TABLE 1 WARNING –...

  • Page 8: Symbols

    3.0 ABBREVIATIONS & SYMBOLS #### Contact Ingersoll–Rand for serial number –>#### Up to Serial No. ####–> From Serial No. Not illustrated Option † Not required As required Sitemaster/Sitepack High ambient machine Watercooled machine Aircooled machine Energy recovery system Totally enclosed fan cooled motor (IP54) T.E.F.C.

  • Page 9: Purchase Order

    4.0 PURCHASE ORDER DETAILS 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. No.

  • Page 10: Safety

    5.0 SAFETY 5.1 SAFETY INSTRUCTIONS Safety instructions in the operators manual are Ensure that the Operation and Maintenance manual, bold–faced for emphasis. The signal words DANGER, and the manual holder, are not permanently removed WARNING and CAUTION are used to indicate hazard from the machine.
  • Page 11 5.0 SAFETY All pressure containing parts, especially flexible hoses Electrical and their couplings, must be regularly inspected, be The compressor has high and dangerous voltage in the free from defects and be replaced according to the motor starter and control box. All installations must be Manual instructions.
  • Page 12 5.0 SAFETY WARNING This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any work on the drive unless trained. There are no user serviceable items behind the cover. WARNING There is a high discharge air temperature shutdown function built into each compressor.

  • Page 13: Text Decals

    5.0 SAFETY Depending on point of manufacture and point of use, the compressor and this manual will show symbols from the following sections. Compressors for use within the European Community must be equipped with symbols from section 5.4. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your supervisor.
  • Page 14 5.0 SAFETY CAUTION CAUTION Incorrect lifting of machine can cause injury or Use of incorrect coolant can cause system property damage. contamination. Lift only from base channels Use only SSR ULTRA COOLANT NOTICE WARNING Lift here WARNING High pressure air. Can cause severe injury or death.

  • Page 15: Power Inlet

    5.0 SAFETY Rotation Discharge 39540257 Rev. 04 Condensate drain. 39541081 Rev. 04 Electrical power inlet. 39541354 Rev. 03 WARNING WARNING – HIGH VOLTAGE Do not attempt any work. Read manual. Trained service personnel only. Remove electrical supply. Wait 15 minutes. Check for zero voltage.
  • Page 16 5.0 SAFETY IMPORTANT Use 75°C copper wire only. Before starting this air compressor unit the shipping brace(s) must be removed. Save the brace(s) for future use. Refer to Operators / Instruction Manual. IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...

  • Page 17: Graphic Form And Meaning

    5.0 SAFETY 5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition / Mandatory Information / Instructions Warning WARNING: Electrical shock risk. WARNING – Pressurized WARNING – Hot surface. component or system. WARNING – Air/gas flow or Air WARNING – Pressure control. WARNING –...
  • Page 18 5.0 SAFETY WARNING – Do not undertake any WARNING – Consult the WARNING – For operating maintenance on this machine Operation and Maintenance temperature below 0_C, consult until the electrical supply is manual before commencing any the Operation and Maintenance disconnected and the air pressure maintenance.
  • Page 19 5.0 SAFETY Use fork lift truck from this side only. Emergency stop. Tie down point Lifting point. On (power). Off (power). SEQUENCER STATUS LOAD SEQUENCER (AUTOMATIC COMPRESSOR OFF LOAD (UNLOADED) CONTROL) RESET COMPRESSOR STATUS MODULATE MALFUNCTION POWER FOULED FILTER POWER INLET ELECTRIC MOTOR HOURS IRN37–160K–OF &...
  • Page 20 5.0 SAFETY OIL SEPARATOR PRESSURE AIR 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 OIL DRAIN CONDENSATE DRAIN PRESSURE CONTROL MANUAL (SELECT) TEMPERATURE...
  • Page 21 5.0 SAFETY 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 WAIT TIME CHECK ZERO VOLTS PERSONNEL IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...

  • Page 22: Receipt And Handling

    6.0 RECEIPT / HANDLING 6.1 RECEIPT 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 unpacked. Obtaining the deIivery persons signed agreement to any noted damages will facilitate any future insurance claims.

  • Page 23: Installation

    7.0 INSTALLATION For technical information see section 8.0. 7.1 LOCATION IN PLANT Ensure that the correct tie down points are used. It is recommended that provision be made for lifting heavy components during major overhaul. Use only For major overhaul (i.e. motor removal) position the lifting points provided.

  • Page 24: Discharge And Condensate

    7.0 INSTALLATION 7.2 DISCHARGE AND CONDENSATE PIPING It is essential when installing a new compressor [1], to The built–in intercooler and aftercooler reduce the discharge air temperature below the dew point (for most review the total air system. This is to ensure a safe and ambient conditions), therefore, considerable water effective total system.
  • Page 25 7.0 INSTALLATION 7.3 ELECTRICAL CAUTION This procedure should only be carried out by a qualified electrician, electrical contractor or your local Ingersoll–Rand Distributor or Air Center. The compressor and drive should be properly grounded The feeder cable must be suitably glanded into the / earthed in accordance with Local and National Code power drive module (P.D.M.) electrical box to ensure requirements.

  • Page 26: Installation 19

    7.0 INSTALLATION CAUTION VERY IMPORTANT Supply voltage must be kept to a maximum imbalance of 2% on 50Hz and 3% on 60Hz applications. Voltage imbalances greater than these levels can cause permanent damage to the drive. Compressor must not be subjected to any voltage spikes or surges in excess of 575V. Exposure to spikes/surges in excess of 575V can permanently damage the drive.

  • Page 27: Watercooled Units

    7.0 INSTALLATION 7.4 WATERCOOLED UNITS Cooling Water Piping Water temperature and pressure gauges should be installed in the water piping for use in any fault finding Water piping to and from the compressor package of the water system. Water pressure should ideally be must be at least the size of the water connections on between 3 and 5 bar (43.5 and 72.5 psi) but must not the machine.
  • Page 28 7.0 INSTALLATION Water quality recommendations Cooling Water Analysis Chart Water quality is often overlooked when the cooling system of a water–cooled air compressor is examined. Substances Test interval Acceptable Water quality determines how effective the heat concentration transfer rate, as well as the flow rate will remain during Corrosivity Monthly —...

  • Page 29: Outdoor Sheltered Installation

    7.0 INSTALLATION 7.6 OUTDOOR SHELTERED INSTALLATION Nirvana compressors are not suitable for outdoor installation. Installing a Nirvana compressor outside voids the warranty of the compressor. IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...

  • Page 30: General Information

    8.0 GENERAL INFORMATION 8.1 TECHNICAL INFORMATION N37K N45K N50H N60H General Sound pressure level dB(A) – AC 65–74 65–74 65–74 65–74 Sound pressure level dB(A) – WC 63–69 63–69 63–69 63–69 Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature _C (_F)
  • Page 31 8.0 GENERAL INFORMATION N75H N100H N55K N75K General Sound pressure level dB(A) – AC 73–84 73–84 73–84 73–84 Sound pressure level dB(A) – WC 73–84 73–84 73–84 73–84 Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature _C (_F) 2 (35) 2 (35)
  • Page 32 8.0 GENERAL INFORMATION N90K N110K N132K N160K General Sound pressure level dB(A) – AC 72–79 72–79 72–79 72–79 Sound pressure level dB(A) – WC 69–73 69–73 69–78 69–78 Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature _C (_F) 1.7 (35) 1.7 (35)
  • Page 33 8.0 GENERAL INFORMATION N125H N150H N200H General Sound pressure level dB(A) – AC 72–79 72–79 72–79 Sound pressure level dB(A) – WC 69–73 69–73 69–78 Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115) Minimum ambient temperature _C (_F) 1.7 (35) 1.7 (35) 1.7 (35)
  • Page 34 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING – N37/45k OIL FREE AIR COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 35 8.0 GENERAL INFORMATION A Air discharge 5 All dimensions in millimeters (inches). 1.5” N.P.T. – 60Hz 6 Tolerance on all dimensions: ±6 mm (± .25 inch). 1.5” B.S.P.T. – 50Hz 7 Recommended clearance on three sides 915mm B Power inlet location for conduit (36 inches).
  • Page 36 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING – N37/45k OIL FREE WATER COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 37 8.0 GENERAL INFORMATION A Air discharge 3 Pipe condensate drain lines separately to an open 1.5” N.P.T. – 60Hz drain due to difference in drain pressures. Check local 1.5” B.S.P.T. – 50Hz regulations. B Power inlet location for conduit 4 Lube oil fill quantity: 53 litres (14 US gallons) ∅...

  • Page 38: Installation Drawing

    8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING – N55/75K OIL FREE AIR COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 39 8.0 GENERAL INFORMATION A Air discharge 7 Recommended clearance on three sides 915mm 1.5” N.P.T. – 60Hz (36 inches). Side with electrical box 1067mm (42 1.5” B.S.P.T. – 50Hz inches) or minimum as required by latest national electrical code or applicable local codes. B Power inlet location for conduit ∅...
  • Page 40 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING – N55/75K OIL FREE WATER COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 41 8.0 GENERAL INFORMATION A Air discharge 5 All dimensions in millimeters (inches). 1.5” N.P.T. – 60Hz 6 Tolerance on all dimensions: ±6 mm (± .25 inch). 1.5” B.S.P.T. – 50Hz 7 Recommended clearance on three sides 915mm B Power inlet location for conduit (36 inches).
  • Page 42 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING – N90/160K, N125/200H OIL FREE AIR COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 43 8.0 GENERAL INFORMATION A Air discharge 5 All dimensions in millimeters (inches). 2” N.P.T. – 60Hz 6 Tolerance on all dimensions: ±6 mm (± .25 inch). 2” B.S.P.T. – 50Hz 7 Recommended clearance on three sides 915mm B Power inlet location for conduit (36 inches).
  • Page 44 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING – N90/160K, N125/200H OIL FREE WATER COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 45 8.0 GENERAL INFORMATION Air discharge 3 Pipe condensate drain lines separately to an open 2” N.P.T. – 60Hz drain due to difference in drain pressures. Check local 2” B.S.P.T. – 50Hz regulations. Power inlet location for conduit 4 Lube oil fill quantity: 64 litres (17 US gallons) ∅...

  • Page 46: Process And

    8.0 GENERAL INFORMATION 8.3 PROCESS AND INSTRUMENTATION DIAGRAM N37/160K & N50/200H AIR COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 47 8.0 GENERAL INFORMATION Air filter 35 Oil bypass check valve – 25 PSIG LP Airend 36 Gear case breather LP Discharge silencer 37 1ATT–LP Inlet temperature thermistor Intercooler 38 1AVPT–LP Inlet vacuum transducer Interstage moisture separator 39 2ATT–LP Discharge temperature RTD HP Airend 40 2APT–HP Inlet pressure transducer HP Discharge silencer...
  • Page 48 8.0 GENERAL INFORMATION 8.3 PROCESS AND INSTRUMENTATION DIAGRAM N37/160K & N50/200H WATER COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 49 8.0 GENERAL INFORMATION Air filter 36 Gear case breather LP Airend 37 1ATT–LP Inlet temperature thermistor LP Discharge silencer 38 1AVPT–LP Inlet vacuum transducer Intercooler 39 2ATT–LP Discharge temperature RTD Interstage moisture separator 40 2APT–HP Inlet pressure transducer HP Airend 41 3ATT–HP Inlet temperature thermistor HP Discharge silencer 42 3APT–HP Discharge pressure transducer...

  • Page 50: Electrical Schematic

    8.0 GENERAL INFORMATION 8.4 ELECTRICAL SCHEMATIC N37–75K, N50–100H AIR COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 51 8.0 GENERAL INFORMATION 1ATT Sensor, LP inlet temperature. Drive, blower. 1AVPT Transducer, LP inlet vacuum. Motor, blower. Backplate 2APT Transducer, interstage pressure. Cabinet 2ATT Sensor, LP discharge temperature. Common fault output 3APT Transducer, HP discharge pressure. Choke 3ATT Sensor, HP inlet temperature. Drive Valve, package discharge blowdown solenoid.
  • Page 52 8.0 GENERAL INFORMATION Heater circuit SS1–3 Relay, solid state HTR1 Heater 125 watts Service tool HTR2 Heater 125 watts Transformer, control Relay, run Thermostat Relay fault True running relay Contactor, main motor General warning Contactor, heatsink blower Notes: MCB1 Breaker, miniature circuit, transformer Alternatively the supply may be taken from an MCB2 Breaker, miniature circuit, control circuit independent source: in that case, factory supplied...
  • Page 53 8.0 GENERAL INFORMATION 8.4 ELECTRICAL SCHEMATIC N37–75K, N50–100H WATER COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 54 8.0 GENERAL INFORMATION Auxiliary warning 2 1ATT Sensor, LP inlet temperature. Drive, blower. 1AVPT Transducer, LP inlet vacuum. Motor, blower. 2APT Transducer, interstage pressure. Backplate 2ATT Sensor, LP discharge temperature. Cabinet 3APT Transducer, HP discharge pressure. Common fault output 3ATT Sensor, HP inlet temperature.
  • Page 55 8.0 GENERAL INFORMATION Alternative heater connection for external Serial link 220/230V supply. SS1–3 Relay, solid state Heatsink blower Service tool Heater circuit Transformer, control HTR1 Heater 125 watts Thermostat HTR2 Heater 125 watts True running relay Relay, run General warning Relay fault Contactor, main motor Notes:...
  • Page 56 8.0 GENERAL INFORMATION 8.4 ELECTRICAL SCHEMATIC N90–160K, N125–200H AIR COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 57 8.0 GENERAL INFORMATION 1ATT Sensor, LP inlet temperature. Drive Blower Motor, Blower 1AVPT Transducer, LP inlet vacuum. Backplate 2APT Transducer, interstage pressure. Cabinet 2ATT Sensor, LP discharge temperature. Common fault output 3APT Transducer, HP discharge pressure. Choke 3ATT Sensor, HP inlet temperature. Drive Valve, package discharge blowdown Earth bar...
  • Page 58 8.0 GENERAL INFORMATION HTR2 Heater 125 watts Transformer, control Relay, run Thermostat Relay fault True running relay Contactor, main motor General warning Contactor, heatsink blower Notes: MCB1 Breaker, miniature circuit, transformer Alternatively the supply may be taken from an MCB2 Breaker, miniature circuit, control circuits independent source: in that case, factory supplied MCB3 Breaker miniature circuits, drive connection must be disconnected.
  • Page 59 8.0 GENERAL INFORMATION 8.4 ELECTRICAL SCHEMATIC N90–160K, N125–200H WATER COOLED IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...
  • Page 60 8.0 GENERAL INFORMATION Auxiliary warning 2 1ATT Sensor, LP inlet temperature. Drive, blower. 1AVPT Transducer, LP inlet vacuum. Motor, blower. 2APT Transducer, interstage pressure. Backplate 2ATT Sensor, LP discharge temperature. Cabinet 3APT Transducer, HP discharge pressure. Common fault output 3ATT Sensor, HP inlet temperature.
  • Page 61 8.0 GENERAL INFORMATION Heater circuit SS1–3 Relay, solid state HTR1 Heater 125 watts Service tool HTR2 Heater 125 watts Transformer, control Relay, run Thermostat Relay fault True running relay Contactor, main motor General warning Contactor, heatsink blower Notes: MCB1 Breaker, miniature circuit, transformer Alternatively the supply may be taken from an MCB2 Breaker, miniature circuit, control circuit independent source: in that case, factory supplied...

  • Page 62: General Description

    8.0 GENERAL INFORMATION 8.5 GENERAL DESCRIPTION The compressor is an electric motor driven, oil free, two Air is pulled into the machine by the cooling blower and stage screw compressor, complete with all necessary through the heat exchangers (for air cooled). components piped, wired and baseplate mounted.

  • Page 63: Operating Instructions

    9.0 OPERATING INSTRUCTIONS 9.1 BASIC OPERATION WARNING Switch on the main electrical isolation switch. The control panel will illuminate, indicating that the line and Ensure that all protective covers/guards are in control voltages are available. place before attempting to start the machine. The contrast of the display may be adjusted by turning the small screw which is on the right hand side of the NOTICE...
  • Page 64 9.0 OPERATING INSTRUCTIONS Start sequence Blower control The compressor will initially start by pressing the local The blower speed varies to minimize energy start button or receiving a remote start command. The consumption while optimizing cooler performance. The Intellisys will energize the start output to start the blower motor has its own variable speed drive and will compressor.

  • Page 65: Intellisys Controls

    9.0 OPERATING INSTRUCTIONS 9.2 INTELLISYS CONTROLS 1. Emergency stop 5. F2 Pressing this switch stops the compressor immediately. Not used. This switch should only be pressed in emergency situations. The discharge blowdown valve will open to 6. Arrows vent pressure downstream of the check valve to atmosphere.

  • Page 66: Display Screen

    9.0 OPERATING INSTRUCTIONS 9.3 DISPLAY SCREEN The display screen is divided into three functional The right side shows various items or lists such as the areas, as seen in the typical CURRENT STATUS machine’s CURRENT STATUS readings, the MAIN screen shown here. MENU, the OPERATOR SETPOINTS list, etc.

  • Page 67: Current Status Screen

    9.0 OPERATING INSTRUCTIONS 9.4 CURRENT STATUS SCREEN The CURRENT STATUS screen is considered to be the 14 SECOND STAGE AIREND DISCHARGE TEMP “normal” display that the controller shows. 15 BEARING OIL PRESS The following items and their present values can be 16 BEARING OIL TEMP displayed on the right side of the screen by pressing the up and down arrow buttons.

  • Page 68: Main Menu

    9.0 OPERATING INSTRUCTIONS 9.5 MAIN MENU The MAIN MENU screen can be accessed from the The language and units of measure are pre–set prior to CURRENT STATUS screen by pressing the MAIN the compressor leaving the factory. MENU button, identified by the words “MAIN MENU” in the bottom line of the screen directly above the center –MAIN MENU–...

  • Page 69: Operator Setpoints

    9.0 OPERATING INSTRUCTIONS 9.6 OPERATOR SETPOINTS Setpoints are user–adjustable variables in the –OPERATOR SETPOINTS– controller logic that can be set using the OPERATOR SETPOINTS screen shown opposite. TARGET PRESSURE The name and value of each of the setpoints listed can 105 psi be seen on the screen by moving the list up and down using the arrow buttons.
  • Page 70 9.0 OPERATING INSTRUCTIONS Automatic stop pressure Condensate Release The compressor will unload once the system pressure This is the number of seconds that the condensate rises to the automatic stop pressure and the solenoid will be open (de–energized) when blowing out compressor is operating at the minimum speed.

  • Page 71: Options

    9.0 OPERATING INSTRUCTIONS 9.7 OPTIONS –OPTIONS– Options are turned on or off and their associated values are set using the OPTION screen shown opposite. Some options are purchased, they require additional REMOTE START/STOP ON machine hardware and must first be enabled by service personnel.

  • Page 72: Sensor Calibration

    9.0 OPERATING INSTRUCTIONS Scheduled start Scheduled stop This option will cause the unit to start on the scheduled This option will cause the unit to stop on the scheduled start day , at the time stored in this setpoint. To disable stop day, at the time stored in this setpoint.

  • Page 73: Alarm History

    9.0 OPERATING INSTRUCTIONS 9.9 ALARM HISTORY Alarm History displays each of the Alarm messages for Each of the last 15 Alarm messages can be seen by the last 15 Alarms experienced by the machine. It also moving the Alarm History list up and down using the gives access to displaying the machine operating arrow buttons.

  • Page 74: Energy Status Messages

    9.0 OPERATING INSTRUCTIONS 9.11 ENERGY STATUS MESSAGES AVERAGE CAPACITY – Displays the compressor’s –ENERGY STATUS– average capacity in cfm or m for the time period that AVERAGE PACKAGE kW was started by selecting the reset averaging setpoint. ENERGY COST – Displays the energy cost of the AVERAGE % CAPACITY–...

  • Page 75: Warnings

    9.0 OPERATING INSTRUCTIONS 9.12 WARNINGS When a WARNING occurs, a large question mark will SENSOR FAILURE – This will occur if a sensor is flash on the display screen. recognized as missing or broken. If multiple WARNINGS exist, the small up/down arrows HIGH DISCHARGE PRESS –...

  • Page 76: Alarms

    9.0 OPERATING INSTRUCTIONS 9.15 ALARMS When an Alarm occurs, a large exclamation mark in a VSD FAULT – The VSD fault is read from the drive. The triangle will flash on the display screen. The display Intellisys will read the status menu of the variable speed drive.
  • Page 77 9.0 OPERATING INSTRUCTIONS 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 1ATT EXCEEDS 125_F / 51.6_C IRN37–160K–OF & IRN50–200H–OF http://air.irco.com...

  • Page 78: Maintenance

    10.0 MAINTENANCE 10.1 MAINTENANCE PROMPTS The service warning will return each subsequent 2000 The service warning and flashing LED will appear at hours. intervals, dependant on the service level selected. Refer to operating instructions. The machine will be master reset after service work conducted prior to the 2000 hour interval to prevent The customer can only reset the warning for 24 hours false indication.

  • Page 79: Maintenance Chart

    10.0 MAINTENANCE 10.2 MAINTENANCE CHART The MAINTENANCE CHART indicates the various components and the intervals when maintenance has to take place. Where a service interval is stated in both hours and months, it is the sooner of the two intervals that must be adhered to.

  • Page 80: Maintenance Procedures

    10.0 MAINTENANCE 10.3 MAINTENANCE PROCEDURES CAUTION Before beginning any work on the compressor, read and understand the safety instructions in this manual. Open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Do not under any circumstances open any drain valve or remove components from the compressor until this has been carried out.

  • Page 81: Routine Maintenance

    10.0 MAINTENANCE all hazards present are known (e.g. pressurized Upon completion of maintenance tasks and prior components, electrically live components, removed to returning the machine into service, ensure that:– panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving parts, the machine is suitably tested.
  • Page 82 10.0 MAINTENANCE Start the compressor and check the oil filter and oil Blower motor Re–Grease drain valve for leaks. Select ”BEARING OIL PRESS” (N75–160 Aircooled units) from the current status screen to insure that adequate 6 Months or 4000 Hrs. oil pressure has been attained.
  • Page 83 10.0 MAINTENANCE S Cover the inlet grill of the intake panel with plastic Air filter change procedure sheeting to prevent cleaning solution from exiting Unclip (or unbolt) the retaining cover and remove the the compressor. old element(s). S Remove enclosure intake batts Fit new element(s) and refit the retaining cover.
  • Page 84 10.0 MAINTENANCE S On N90–160K, N125–200H aircooled units, whilst Condensate (Moisture) Drain Valve / Trap rotating the motor, pump grease into the bearing S Ensure compressor is electrically isolated for 15 until grease is seen at the relief port. minutes and all pressure is relieved from system. S Thereafter rotate the motor as described above S Remove all pipes going to and from the valve (or every three months until such time as the unit is...
  • Page 85 10.0 MAINTENANCE Fluid and Vibration Monitoring Oil Sampling Procedure With unit at sump oil temperature of 130 – 140 _F, stop Ingersoll–Rand recommends incorporating predictive the compressor. Wait 5 minutes, or sufficient time until maintenance, specifically the use of oil and vibration oil in sight glass becomes clear, and any entrained air analysis, into all Preventative Maintenance programs.

  • Page 86: Fault Finding

    11.0 FAULT FINDING 11.1 GENERAL FAULTS WARNING When attempting to identify and remedy any fault or failure, ensure it is only attempted by qualified personnel and that the safety and maintenance sections of this manual have been read and are fully understood and followed. Major overhauls should only be carried out by a qualified Ingersoll–Rand representative.
  • Page 87 11.0 FAULT FINDING SYMPTOM FAULT REMEDY Compressor will not Compressor not sized to meet Contact your local IR representative meet pressure required system requirements or by system requirements have been changed. Air loss due to pipe, hose, joint Overhaul or replace or seal failure Air loss due to blowdown valve Overhaul or replace...
  • Page 88 11.0 FAULT FINDING SYMPTOM FAULT REMEDY Pressure produced by Intellisys set incorrectly Check and modify settings compressor is too high compressor is too high Pressure transducer may be Recalibrate or replace due to speed not faulty, incorrectly calibrated or reducing as demand not receiving pressure signal reduces reduces...

  • Page 89: Intellisys Faults

    11.0 FAULT FINDING SYMPTOM FAULT REMEDY Discharge air is Aftercooler not functioning Clean or replace contaminated with correctly condensate condensate Timed solenoids not set properly Adjust the timed solenoid Interval and/or duration for environment. through the Operator Setpoints menu Moisture separator drain lines Clean or replace blocked.
  • Page 90 11.0 FAULT FINDING FAULT CAUSE REMEDY Remote start failure Remote start button is pressed Check operation of buttons or operating procedures after machine is running or remote start button remains closed. Remote stop failure Remote stop button remains Check operation of buttons or operating procedures open and either start button is pressed Sensor failure...
  • Page 91 11.0 FAULT FINDING FAULT CAUSE REMEDY Low bearing oil This will occur if 6OPT is less Check oil level (between 3/4 and full in sightglass), oil pressure than 17 psi / 1.2 bar and the unit leaks, oil filter dirty or plugged, oil relief valve leaking, is running.

  • Page 92: Drive Faults

    11.0 FAULT FINDING 11.3 DRIVE FAULTS (INDICATED ON THE INTELLISYS CONTROLLER) The drive controller is directly linked to the Intellisys controller. Faults in the drive controller will be displayed on the Intellisys controller as ‘VSD fault 0, VSD fault 1’ etc. The following VSD faults may be investigated and remedied at source.

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