Ingersoll-Rand SSR UP5-4 Operation And Maintenance Manual
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Ingersoll-Rand SSR UP5-4 Operation And Maintenance Manual

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See also: Operation & Maintenance Manual
This manual contains
important safety information
and must be made available
to personnel who operate
and maintain this machine.
Refer all communications to the nearest Ingersoll Rand Full Service Distributor.
SSR UP5-4, UP5-5.5, UP5-7.5, UP5-11c
SSR UP6-5, UP6-7.5, UP6-10, UP6-15c
OPERATION AND MAINTENANCE MANUAL
50 Hz
60 Hz
C.C.N. : 80445273
REV. : A
DATE : OCTOBER 2008

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Summary of Contents for Ingersoll-Rand SSR UP5-4

  • Page 1 SSR UP5-4, UP5-5.5, UP5-7.5, UP5-11c 50 Hz SSR UP6-5, UP6-7.5, UP6-10, UP6-15c 60 Hz OPERATION AND MAINTENANCE MANUAL This manual contains important safety information and must be made available to personnel who operate and maintain this machine. C.C.N. : 80445273 REV. : A DATE : OCTOBER 2008 Refer all communications to the nearest Ingersoll Rand Full Service Distributor.
  • Page 2 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 from the date of placing the Equipment in operation or eighteen months from the date of shipment from the factory, whichever shall first occur.

  • Page 3: Table Of Contents

    Operation and Maintenance Manual Contents COnTenTS FORewORD ..........5 DeCALS.
  • Page 4 Contents Operation and Maintenance Manual TOP UP COOLAnT PROCeDURe ....... . . 41 COOLAnT CHAnGe PROCeDURe .

  • Page 5: Foreword

    OPeRATIOn AnD MAInTenAnCe MAnUAL FORewORD FORewORD The intended uses of this machine are outlined below and examples of unapproved usage are also given, The contents of this manual are considered to be however Ingersoll Rand cannot anticipate every proprietary and confidential to Ingersoll Rand and application or work situation that may arise. should not be reproduced without the prior written permission of Ingersoll Rand. IF In DOUBT COnSULT SUPeRVISIOn. Nothing contained in this document is intended to This machine has been designed and supplied for extend any promise, warranty or representation, use only in the following specified conditions and expressed or implied, regarding the Ingersoll Rand applications: products described herein. Any such warranties or other • Compression of normal ambient air containing terms and conditions of sale of products shall be in no known or detectable additional gases, accordance with the standard terms and conditions of vapours. or particles sale for such products, which are available upon request. • Operation within the ambient temperature This manual contains instructions and technical data to range specified in the GENERAL INFORMATION cover routine operation and scheduled maintenance section of this manual.

  • Page 6: Decals

    DeCALS OPeRATIOn AnD MAInTenAnCe MAnUAL DeCALS 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 − Pressurised component or system. WARNING −...
  • Page 7 OPeRATIOn AnD MAInTenAnCe MAnUAL DeCALS http://air.ingersollrand.com...

  • Page 8: Ansi Symbols

    DeCALS OPeRATIOn AnD MAInTenAnCe MAnUAL AnSI SYMBOLS GRAPHIC FORM AND MEANING OF ANSI SYMBOLS DANGER INTAKE AIR. Can contain carbon monoxide or other contaminants. Will cause serious injury or death. Ingersoll Rand air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for breathing air applications unless treated in accordance with all applicable codes and regulations. WARNING HAZARDOUS VOLTAGE. Can cause serious injury or death. Disconnect power and bleed pressure from tank before servicing. Lockout/Tagout machine. Compressor must be connected to properly grounded circuit. See Grounding Instructions in manual. Do not operate compressor in wet conditions. Store indoors. RISK OF FIRE OR EXPLOSION. Electrical arcing from compressor components can ignite flammable liquids and vapors which can result in serious injury. Never operate the compressor near flammable liquids or vapors. If used to spray flammable materials, keep compressor at least 20ft (m) away from the spray area. HIGH PRESSURE AIR. Rusted tanks can cause explosion and severe injury or death. Receiver under pressure. Operator should relieve tank pressure before performing maintenance. In addition to automatic drain, operate manual drain valve weekly. Manual drain valve located at bottom of the tank. MOVING PARTS. Can cause serious injury. Do not operate with guards removed. Machine may start automatically. Disconnect power before servicing. Lockout/Tagout machine. HOT SURFACES. Can cause serious injury. Do not touch. Allow to cool before servicing. Do not touch hot compressor or tubing. EXPOSED MOVING BELTS AND SHEAVES. Can cause severe injury or death. Do not operate without guard in place. Disconnect power before servicing. Lockout/Tagout machine.
  • Page 9 OPeRATIOn AnD MAInTenAnCe MAnUAL DeCALS Item Qty. Description Item Qty. Description 1502 Decal, replacement element 2 Decal, notice air discharge Base mount only 250 Decal, warning hot surface Decal, voltage 22515 Decal, total air system 10 Decal, coolant drain Dryer packages only 205 Decal, warning hazardous 225200 Tag, rotation voltage SPEC Specifications, compressor 1 Decal, condensate drain package 22501 Decal, dryer bypass instruction 1 Decal, power inlet 251 Decal, maintenance parts 221111 Decal, place to cover hole 2055...
  • Page 10 DeCALS OPeRATIOn AnD MAInTenAnCe MAnUAL Item Qty. Description Item Qty. Description 155 Decal, use guards when 22110 Decal, facia running Rectangular hourmeter Decal, wiring schematic 225221 Decal, facia diagram Round hourmeter Decal, Ingersoll Rand logo 1122 Decal, lift here both sides 20 Base mount only Decal, Ingersoll Rand logo 22102 22500 Decal, belt Base mount only 2251 Decal, Ingersoll Rand logo Tank mount option Receiver mount only 20 Decal, no maintenance before 511 Decal, condensate drain...

  • Page 11: Safety

    OPeRATIOn AnD MAInTenAnCe MAnUAL SAFeTY SAFeTY The use of plastic bowls on line filters can be hazardous. Their safety can be affected by either synthetic DAnGeR lubricants, or the additives used in mineral oils. Hazard that wILL cause DeATH, SeVeRe InJURY or Ingersoll Rand recommends that only filters with metal substantial property damage if ignored. Instructions bowls should be used on a pressurised system. must be followed precisely to avoid injury or death. COMPReSSeD AIR wARnInG Hazard that CAn cause DeATH, SeVeRe InJURY or Compressed air can be dangerous if incorrectly substantial property damage if ignored. Instructions handled. Before doing any work on the unit, ensure which must be followed precisely to avoid injury or that all pressure is vented from the system and that the death. machine cannot be started accidentally. CAUTIOn wARnInG Cautions call attention to instructions which must be Imposing a normal or emergency stop on followed precisely to avoid damaging the product, the compressor will only relieve pressure process or its surroundings.

  • Page 12: Materials

    SAFeTY OPeRATIOn AnD MAInTenAnCe MAnUAL Do not over-pressurize the receiver tank or similar wARnInG vessels beyond design limits. Any electrical connections or adjustments Do not use a receiver tank or similar vessels that fail should only be made by a suitably qualified to meet the design requirements of the compressor. electrician Contact your distributor for assistance. Close and lock all access doors when the compressor is Do not drill into, weld or otherwise alter the receiver left unattended. tank or similar vessels. Do not use extinguishers intended for Class A or Class B Before servicing the unit, vent pressure before removing fires on electrical fires. Use only extinguishers suitable the power to ensure that the gauge reads zero pressure. for class BC or class ABC fires. MATeRIALS Attempt repairs only in clean, dry, well lighted and ventilated areas. The following substances are used in the manufacture of this machine and may be hazardous to health if used Connect the compressor only to electrical systems that incorrectly: are compatible with its electrical characteristics and that •...

  • Page 13: General Information

    OPeRATIOn AnD MAInTenAnCe MAnUAL GeneRAL InFORMATIOn GeneRAL InFORMATIOn PIPInG AnD InSTRUMenTATIOn http://air.ingersollrand.com...
  • Page 14 GeneRAL InFORMATIOn OPeRATIOn AnD MAInTenAnCe MAnUAL Filter, air 21 Gauge, pressure Valve, air inlet 22 Valve, relief (sirc) 23 Filter, general purpose air Air end assembly Motor 24 Filter, high efficiency air Relay, motor overload 25 Valve, check Tank, separator - coarse 26 Recuperator 27 Valve, isolation (option) Tank, separator - fine 28 Moisture separator Valve, minimum pressure 29 Valve, check Aftercooler 10 Valve, blowdown 30 Evaporator 11 Switch, pressure 31 Indicator, dew point 12 Switch, temperature 32 Valve, condensate 13 Filter, coolant...

  • Page 15: Schematic, Electrical Up6 5-15Hp Fv 3Ph 60Hz Dol - U.s.a

    OPeRATIOn AnD MAInTenAnCe MAnUAL GeneRAL InFORMATIOn SCHeMATIC, eLeCTRICAL UP6 5–15HP FV 3PH 60Hz DOL – U.S.A. 1FU, Fuse control circuit HATS Switch, high air temperature 2FU, FU FU, 5FU Fuse Coil motor starter Contact, auxiliary starter Indicator, maintenance option (Instead of standard hourmeter) Contact, auxiliary starter MOT Motor Transformer, control Overload, motor starter 120/1/50–0 See transformer nameplate for wiring connection requirements Relay, control Switch, pressure Contact, control relay Push button, start Customer supplied 115v / 1 / 0hz Terminal points Dryer option To supply...

  • Page 16: Schematic, Electrical Up6 5-15Hp Sd 3Ph 60Hz

    GeneRAL InFORMATIOn OPeRATIOn AnD MAInTenAnCe MAnUAL SCHeMATIC, eLeCTRICAL UP6 5–15HP SD 3PH 60Hz 1FU, 2FU Fuse, primary HATS Switch, high air temperature Fuse, secondary Hourmeter FU, 5FU Fuse, dryer Indicator, maintenance Light, power on indicator (green) Indicator, maintenance option (Instead of standard hourmeter) Light, auto restart indicator (white) Motor, compressor Contactor, main Overload, main motor 1Ma, b, c Contacts, auxiliary. Main contactor Contact, main motor overload Contactor, delta Switch, pressure 2Ma, b Contacts, auxiliary. Delta contactor Push button, start Contactor, star Relay, delta starting (10sec) 1Sa, b Contacts, auxiliary. Star contactor Relay, delay off, contact Valve, solenoid (nc)

  • Page 17: Schematic, Electrical Up6 5-15Hp Fv 1Ph 60Hz - U.s.a

    OPeRATIOn AnD MAInTenAnCe MAnUAL GeneRAL InFORMATIOn SCHeMATIC, eLeCTRICAL UP6 5–15HP FV 1PH 60Hz - U.S.A. 1FU, Fuse control circuit Coil motor starter 2FU, FU FU, 5FU Fuse, dryer Indicator, maintenance option Contact, auxiliary starter (Instead of standard hourmeter) Contact, auxiliary starter Motor,compressor Transformer, control 120/1/50–0 see Overload, motor starter Transformer nameplate for wiring Switch, pressure Connection requirements Push button, start Relay, control Terminal points Contact, control relay To supply Customer supplied 115v / 1 / 0hz Standby light nOTeS Motor, dryer Dryer option (*) Furnished, mounted and wired outside of control panel, if required by order.

  • Page 18: Schematic, Electrical Up5 5-15Hp Fv 3Ph 50Hz Dol

    GeneRAL InFORMATIOn OPeRATIOn AnD MAInTenAnCe MAnUAL SCHeMATIC, eLeCTRICAL UP5 5–15HP FV 3PH 50Hz DOL Fuse, secondary Indicator, maintenance option (Instead of standard hourmeter) 2FU, FU Fuse, primary Motor, compressor FU, 5FU Fuse, dryer Overload, main motor Relay, control MOL-1 Contact, main motor overload Customer supplied 20v / 1 / 50hz Switch, pressure Motor, dryer Push button, start Dryer option Transformer, control Valve, electric drain Terminal points Switch, emergency stop To supply HATS Switch, high air temperature Hourmeter nOTeS Indicator, maintenance Contactor, main (*) Furnished, mounted and wired outside of...

  • Page 19: Schematic, Electrical Up5 5-15Hp Sd 3Ph 50Hz

    OPeRATIOn AnD MAInTenAnCe MAnUAL GeneRAL InFORMATIOn SCHeMATIC, eLeCTRICAL UP5 5–15HP SD 3PH 50Hz Valve, solenoid (nc) KM2-1,2 Contacts, auxiliary. Delta contactor Relay, control Contactor, star CR-1 Contact, control relay KM-1,2 Contacts, auxiliary. Star contactor Customer supplied 20v / 1 / 50hz Light, power on indicator (green) Motor, dryer Light, auto restart indicator (white) Dryer option Indicator, maintenance option Valve, electric drain (Instead of standard hourmeter) HATS Switch, high air temperature Overload, main motor Hourmeter MOL-1 Contact, main motor overload Indicator, maintenance Push button, start Motor, compressor Transformer, control Switch, pressure Relay, delta starting (10sec) Switch, emergency stop...

  • Page 20: Installation/Handling

    InSTALLATIOn / HAnDLInG OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn/HAnDLInG VIEW TOP VIEW RIGHT VIEW FRONT VIEW LEFT http://air.ingersollrand.com...

  • Page 21: Unpacking

    OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn / HAnDLInG Package pre-filler Motor Hole, incoming power supply conduit Integrated dryer (Optional) Gauge, pressure Compressor and cooling air intake Yellow stand–by light Filter, coolant Green power–on light Cartridge, coolant separator Green start push button Valve, airend relief Emergency stop button Plug, coolant filler Hourmeter Sight–glass Starter box Plug, coolant drain Lifting points Valve, pilot Mounting holes ( x 1.0mm [0.550”] diameter) w Switch, pressure Filter, air inlet Cooling air exhaust nOTeS nOTe 1. Foundation or floor must be level and support all mounting bolt locations equally. If necessary, shim All dimensions are in millimetres (inches) unless or grout the fourth bolt location.

  • Page 22: Up-Series Tank Mounted (80 Gal)

    InSTALLATIOn / HAnDLInG OPeRATIOn AnD MAInTenAnCe MAnUAL UP-SeRIeS TAnK MOUnTeD (80 GAL) http://air.ingersollrand.com...
  • Page 23 OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn / HAnDLInG Package pre-filler Filter, coolant Hole, incoming power supply conduit Cartridge, coolant separator Gauge, pressure Valve, airend relief Yellow stand–by light Plug, coolant filler Green power–on light Sight–glass Green start push button Plug, coolant drain Emergency stop button Valve, pilot Hourmeter Switch, pressure Starter box Cooling air exhaust Lifting points Valve, ball 0.5” N.P.T. Mounting holes ( x 1.5mm [0.”] x .5mm Air receiver (Ø 20.0mm x 11.mm LG) ( Ø 2.0” [1.5”] slots) x .00” LG) Filter, air inlet Location for manual receiver drain Motor Valve, receiver relief Integrated dryer (Optional) 0.25” discharge port for optional electric drain valve Compressor and cooling air intake nOTeS nOTe 1.

  • Page 24: Up-Series Tank Mounted (120 Gal)

    InSTALLATIOn / HAnDLInG OPeRATIOn AnD MAInTenAnCe MAnUAL UP-SeRIeS TAnK MOUnTeD (120 GAL) http://air.ingersollrand.com...
  • Page 25 OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn / HAnDLInG Package pre-filler Filter, coolant Hole, incoming power supply conduit Cartridge, coolant separator Gauge, pressure Valve, airend relief Yellow stand–by light Plug, coolant filler Green power–on light Sight–glass Green start push button Plug, coolant drain Emergency stop button Valve, pilot Hourmeter Switch, pressure Starter box Cooling air exhaust Lifting points Valve, ball 0.5” N.P.T. Mounting holes ( x 1.5mm [0.”] x .5mm Air receiver (Ø 1.0mm x 101.0mm LG) ( Ø 2.” [1.5”] slots) x .00” LG) Filter, air inlet Location for manual receiver drain Motor Valve, receiver relief Integrated dryer (Optional) 0.25” discharge port for optional electric drain valve Compressor and cooling air intake nOTeS nOTe 1.

  • Page 26: Up-Series Tank Mounted (272 Litres)

    InSTALLATIOn / HAnDLInG OPeRATIOn AnD MAInTenAnCe MAnUAL UP-SeRIeS TAnK MOUnTeD (272 LITReS) http://air.ingersollrand.com...
  • Page 27 OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn / HAnDLInG Package pre-filler Filter, coolant Hole, incoming power supply conduit Cartridge, coolant separator Gauge, pressure Valve, airend relief Yellow stand–by light Plug, coolant filler Green power–on light Sight–glass Green start push button Plug, coolant drain Emergency stop button Valve, pilot Hourmeter Switch, pressure Starter box Cooling air exhaust Lifting points Valve, ball 0.5” N.P.T. Mounting holes ( x 1.5mm [0.”] x .5mm Air receiver ( Ø 00.0mm x 1111.0mm LG) ( Ø 2.2” [1.5”] slots) x .” LG) Filter, air inlet Location for manual receiver drain Motor Valve, receiver relief Integrated dryer (Optional) 0.25” discharge port for optional electric drain valve Compressor and cooling air intake nOTeS nOTe 1.

  • Page 28: Up-Series Tank Mounted (500 Litres)

    InSTALLATIOn / HAnDLInG OPeRATIOn AnD MAInTenAnCe MAnUAL UP-SeRIeS TAnK MOUnTeD (500 LITReS) http://air.ingersollrand.com...
  • Page 29 OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn / HAnDLInG Package pre-filler Filter, coolant Hole, incoming power supply conduit Cartridge, coolant separator Gauge, pressure Valve, airend relief Yellow stand–by light Plug, coolant filler Green power–on light Sight–glass Green start push button Plug, coolant drain Emergency stop button Valve, pilot Hourmeter Switch, pressure Starter box Cooling air exhaust Lifting points Valve, ball 0.5” N.P.T. Mounting holes ( x 1.5mm [0.”] x .5mm Air receiver (Ø 10.0mm x 1.0mm LG) ( Ø 2.02” [1.5”] slots) x .” LG) Filter, air inlet Location for manual receiver drain Motor Valve, receiver relief Integrated dryer (Optional) 0.25” discharge port for optional electric drain valve Compressor and cooling air intake nOTeS 1.

  • Page 30: Location In The Plant

    InSTALLATIOn / HAnDLInG OPeRATIOn AnD MAInTenAnCe MAnUAL CAUTIOn Compressor The use of plastic bowls on line filters and other Air Receiver plastic air line components can be hazardous. Their safety can be affected by either synthetic Air Dryer coolants or the additives used in mineral oils. Compressed air filters Ingersoll Rand recommends that only filters with metal bowls should be used on any...
  • Page 31 OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn / HAnDLInG 60Hz UP6 5 UP6 7 UP6 10 UP6 15c COMPReSSOR Operating pres- 125 150 125 150 210 125 150 210 125 150 210 sure PSIG (bar) (.) (10.) (.) (10.) (1.5) (.) (10.) (1.5) (.) (10.) (1.5) Factory set reload 110...
  • Page 32 InSTALLATIOn / HAnDLInG OPeRATIOn AnD MAInTenAnCe MAnUAL 50Hz UP5 4 UP5 5 UP5 7 UP5 11c COMPReSSOR 1.5 1.5 1.5 1.5 Operating pressure 115 15 210 115 15 210 115 15 210 115 15 210 PSIG (bar) (10) (1.5) (10) (1.5) (10) (1.5) (10) (1.5)
  • Page 33 OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn / HAnDLInG Standard voltage 20V/1PH 200V 20V/PH 0V 55V Full load current (maximum) 2.5A 15.5A 1.5A .A 5.A Starting current DOL (Star Delta) Starting time DOL (Star Delta) –5 Sec (–10 Sec) Starts per hour (maximum) Control voltage 120VAC Recommended fuse rating See note 1 Recommended wire size AWG See note 2 eLeCTRICAL DATA-UP6 7.5 Standard voltage 20V/1PH 200V 20V/PH 0V 55V Full load current (maximum) .1A 22.A 1.A .A .A Starting current DOL (Star Delta)
  • Page 34 InSTALLATIOn / HAnDLInG OPeRATIOn AnD MAInTenAnCe MAnUAL eLeCTRICAL DATA-UP5 4 Standard voltage 0V 00V Full load current (maximum) .A .5A Starting current DOL (Star Delta) Starting time DOL (Star Delta) –5 Sec (–10 Sec) Starts per hour (maximum) Control voltage 120VAC Recommended fuse rating See note 1 Recommended wire size See note 2  mm  mm C u eLeCTRICAL DATA-UP5 5.5 Standard voltage 0V 00V Full load current (maximum) 11.A 11.2A Starting current DOL (Star Delta) Starting time DOL (Star Delta) –5 Sec (–10 Sec) Starts per hour (maximum) Control voltage 120VAC...

  • Page 35: Electrical Data

    OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn / HAnDLInG If there are any deviations from the above, or special The applied voltage must be compatible with the motor regulations apply, the installation must be planned by a and compressor data plate ratings. competent, qualified engineer. The control circuit transformer has different voltage tappings. Ensure that these are set for the specific nOTe applied voltage prior to starting. All data applies to standard product only. CAUTIOn eLeCTRICAL DATA never test the insulation resistance of any part of the machines electrical circuits, including the An independent electrical isolator or disconnect should motor without completely disconnecting the be installed adjacent to the compressor.

  • Page 36: Operating Instructions

    OPeRATInG InSTRUCTIOnS OPeRATIOn AnD MAInTenAnCe MAnUAL OPeRATInG InSTRUCTIOnS wARnInG when the unit stops running as the result of low GeneRAL OPeRATIOn air demand, it may restart and return to load at The compressor is an electric motor driven, single any time. stage screw compressor, complete with accessories piped, wired and base plate mounted. It is a totally self Safety of operation is provided as the compressor contained air compressor package. will shut down if excessive temperatures or electrical The standard compressor is designed to operate in overload conditions should occur.

  • Page 37: Compressor Controls

    OPeRATIOn AnD MAInTenAnCe MAnUAL OPeRATInG InSTRUCTIOnS COMPReSSOR COnTROLS AUTOMATIC START & STOP COnTROL nOTe Direct online starting: Automatic Start & Stop Control is intended for The compressor is equipped for Automatic Start & Stop use when the motor will start no more than 6 Control. When the receiver tank pressure reaches the factory pre–set maximum pressure, the pressure switch times per hour. stops the unit. When the receiver tank pressure drops When the receiver tank pressure reaches the factory below the factory pre–set minimum. The pressure...

  • Page 38: Prior To Starting

    OPeRATInG InSTRUCTIOnS OPeRATIOn AnD MAInTenAnCe MAnUAL PRIOR TO STARTInG 1. PReSSURe GAUGe Indicates the system pressure. 1. Make visual check of the machine, ensure that wARnInG all guards secure and that nothing is obstructing the proper ventilation of, or free access to the DO nOT operate the compressor at discharge machine. pressures exceeding the maximum operating 2. Check coolant level. Add if necessary. pressure. . Make sure air discharge valve is open. 2. HOURMeTeR Records the total running time of the compressor. . Turn on electrical isolator or disconnect. The Power on (5) indicator will light, indicating that 3. STOP BUTTOn / eMeRGenCY STOP line and control voltages are available.

  • Page 39: Maintenance

    OPeRATIOn AnD MAInTenAnCe MAnUAL MAInTenAnCe MAInTenAnCe MAInTenAnCe SCHeDULe UP Series Maintenance Schedule PeRIOD MAInTenAnCe Each 2 hours operation Check the coolant level and replenish if necessary. Report immediately, contact Ingersoll Rand authorized distributor for Visual check of machine for any leaks, dust build up or unusual noise or assistance if in doubt. vibration When compressor is receiver mounted Drain air receiver of condensate, or check that automatic drain is operating. Visual check condition of package pre- Blow clean if needed. filter First 150 hours Change the coolant filter. Each month or 100 hours Remove and clean package pre-filter, replace if needed Check the cooler(s) for build up of foreign matter. Clean if necessary by blowing out with air or by pressure washing. Each year or 2000 hours Check the operation of the high temperature protection switch (10˚C). Replace elements in IRGP and IRHE filters. Change the coolant filter. Check scavenge screen for blockage, clean if required. Change the separator element. Change the Air Filter element.

  • Page 40: Routine Maintenance

    MAInTenAnCe OPeRATIOn AnD MAInTenAnCe MAnUAL ROUTIne MAInTenAnCe Prior to opening or removing panels or covers to work inside a machine, ensure that:- This section refers to the various components which • anyone entering the machine is aware of the require periodic maintenance and replacement. reduced level of protection and the additional It should be noted that the intervals between service hazards, including hot surfaces and intermittently requirement may be significantly reduced as a moving parts. consequence of poor operating environment. This • the machine cannot be started accidentally or would include effects of atmospheric contamination otherwise. and extremes of temperature. Prior to attempting any maintenance work on a The SERVICE/MAINTENANCE CHART indicates the various running machine, ensure that:- components’ descriptions and the intervals when...

  • Page 41: Top Up Coolant Procedure

    OPeRATIOn AnD MAInTenAnCe MAnUAL MAInTenAnCe COOLAnT CHAnGe PROCeDURe wARnInG It is better to drain the coolant immediately after Do not under any circumstances open any the compressor has been operating as the liquid will drain valve or remove components from the drain more easily and any contaminant will still be in compressor without first ensuring that the suspension. compressor is FULLY SHUT- DOwn, power isolated and all air pressure relieved from the Stop the machine, electrically isolate and vent all system.

  • Page 42: Separator Element Change Procedure

    MAInTenAnCe OPeRATIOn AnD MAInTenAnCe MAnUAL SePARATOR eLeMenT CHAnGe PROCeDURe Clean the cooler. Rebuild in reverse order. Stop the machine, electrically isolate and vent all trapped pressure. BeLT CHeCKInG AnD ADJUSTMenT PROCeDURe Loosen separator element with the correct tool. Check belt tension occasionally, especially if looseness Remove the element from the housing; place it in is suspected. A quick check to determine if adjustment a sealed bag and dispose of it safely. is proper may be made by observing the slack side of the belt for a slight bow when the unit is in operation. Clean the mating face of the housing. If a slight bow is evident, the belt is usually adjusted Remove the new Ingersoll Rand replacement satisfactorily. element from its protective package. A belt tension measurement device can be used to Apply a small amount of lubricant to the element determine the tension of the belt. seal. Belt tensioning can be achieved by loosening the airend Screw the new element down until the seal anchor screws, a belt tensioning bolt is provided to aid makes contact with the housing, then hand in moving the airend. tighten a further half turn.

  • Page 43: Electric Drain Valve (Optional)

    OPeRATIOn AnD MAInTenAnCe MAnUAL MAInTenAnCe Ensure the pulley and sheave are properly aligned and cycles from 0 seconds to 5 minutes. The “time on” the motor anchor screws are adequately retightened setting determines the actual time the compressor prior to restarting the compressor. drains condensate. CAUTIOn The timer’s cycle rate and drain opening time should be adjusted to open just long enough to discharge the Improper pulley/sheave alignment and belt condensate. The timer is properly set when it opens tension can result in motor overload, excessive and discharges condensate and then vents air for vibration, and premature belt and/or bearing approximately one second before closing. Adjustments failure. may be made depending on many factors, including To prevent these problems from occurring, humidity and duty cycle.

  • Page 44: Moisture Separator Maintenance

    MAInTenAnCe OPeRATIOn AnD MAInTenAnCe MAnUAL AIR FILTeR MAInTenAnCe Before accessing live electrical parts, disconnect the power supply to the dryer using disconnect switch or In order to ensure optimum compressed air quality the disconnect the cable connections. filter element should be replaced as follows. (Used filter Preventive maintenance elements must be disposed of in accordance with local regulations.) For optimum performance from your dryer, follow the periodic maintenance schedule described below. Use only genuine Ingersoll Rand replacement elements. weeKLY COnDenSATe DRAInS Verify that the condensate drains are operating correctly. eVeRY 4 MOnTHS COnDenSeR Remove any dust from the con- denser fins. COMPReSSOR Make sure compressor power > 30s consumption complies with data plate specifications. YeARLY COnDenSATe DRAInS Completely disassemble the drains and clean all their compo-...

  • Page 45: Disassembling The Unit

    OPeRATIOn AnD MAInTenAnCe MAnUAL MAInTenAnCe DISASSeMBLInG THe UnIT TROUBLeSHOOTInG The unit has been designed and constructed to TROUBLe CAUSe ACTIOn guarantee continuous operation. Solenoid Debris in solenoid Remove The long service life of some components such as the condensate valve prevents solenoid valve, fan and compressor depends on good maintenance. valve will diaphragm from disassemble, not close. seating. clean and The unit must only be disassembled by a refrigerant reassemble. specialist. Refrigerant liquid and lubricating oil inside the Short in electrical Check and refrigeration circuit must be recovered in compliance component. replace power with current norms in the country where the machine is cord or timer as installed.

  • Page 46: Trouble Shooting

    TROUBLe SHOOTInG OPeRATIOn AnD MAInTenAnCe MAnUAL TROUBLe SHOOTInG PROBLeM CAUSe ReMeDY Compressor fails to Mains power or Control voltage not § Check incoming power supply. start available. § Check the control circuit fuse. § Check the transformer secondary windings for the control voltage. Defective Star / Delta timer. § Change Star / Delta timer. Machine shuts down High airend temperature. Top up coolant. periodically Motor overload. § Set overload to correct value and switch to manual reset. Line voltage variation. § Ensure voltage does not drop below 10% on start up and % running.
  • Page 47 OPeRATIOn AnD MAInTenAnCe MAnUAL TROUBLe SHOOTInG PROBLeM CAUSe ReMeDY Compressor trips Compressor operating above rated pres- Set pressure to correct rating for machine. due to over tem- sure. perature Package pre–filter blocked. Clean / replace package pre–filter. Cooler blocked. Clean cooler. Missing or incorrectly fitted enclosure Ensure that all enclosure panels are correctly panels fitted. Low coolant level. Top up coolant and check for leaks. High ambient temperature. Re–site compressor. Restricted cooling air flow. Ensure correct air flow to compressor. excessive coolant Separator element leak. Fit new Separator element. consumption Blocked separator element drain. † Remove fittings and clean. Compressor operating below rated pres- Set pressure to correct rating for machine.
  • Page 48 LOOK wHAT InGeRSOLL RAnD CAn DO FOR YOU! efficient Field Service We maintain a highly trained staff of technicians to service your equipment for preventive maintenance, or to assist you should emergencies ever occur. Complete Repair Service Our trained technicians will repair or overhaul your equipment to factory specifications, using only genuine Ingersoll Rand parts. Special engineering Service We can help you identify and solve your problems by evaluating your needs and recommending theproper equipment to give your maximum efficiency. Spare Parts By stocking genuine Ingersoll Rand spare parts, we can help you avoid costly delays or substituting inferior parts. Using genuine Ingersoll Rand parts on you Ingersoll Rand equipment will help to keep even older equipment running in good-as-new Complete Stock of equipment condition.

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