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125-200 HP/90-160 KW SINGLE STAGE 100-200 HP/75-160 KW TWO STAGE UNITS OPERATORS/ INSTRUCTION MANUAL OPTIONS Before installation or starting the compressor for the first time, this manual should be studied carefully to obtain a clear knowledge of the unit and of the duties to be performed while operating and maintaining the unit.
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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 (see extended airend warranty) from the date of placing the Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from Davidson, NC, whichever shall first occur.
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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. Number of units on order: __________________________ Customer Order Number: __________________________ Ingersoll-Rand Company Order Number: ______________...
100 HP (75 KW) - 5.2 air cooled compressors Two Stage ........22.0 gallons (83.3 liters) 5.3 coolant system 125-200 HP (90-160 KW) - 5.4 compressed air system Two Stage ........30.0 gallons (113.6 liters) 5.5 coolant/air separation system 5.6 electrical system Discharge Temperature Limit ......228°F (109°C)
0.0 SAFETY AND WARNINGS Safety instructions in the operators manual are bold-faced 0.1 SAFETY INSTRUCTIONS for emphasis. The signal words DANGER, WARNING and Before you install this air compressor you should take the CAUTION are used to indicate hazard seriousness levels as follows: time to carefully read all the instructions contained in this manual.
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SAFETY SHUTDOWN CHECK HIGH AIR TEMPERATURE There is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory pre-set at 228°F (109°C). This function should be checked at regular intervals for proper operation, once a month is recommended. The procedure is: Block off the cooling air discharge.
0.3 DECALS This section contains representative examples of decals recommend that you obtain a replacement kit as listed in which will be appearing throughout this manual and are the spare parts section of the Parts List Manual Form applied to the compressor unit. If for some reason a APDD 735 for single stage and Form APDD 736 for two decal is defaced, painted over, or parts are replaced, we stage units.
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0.3 DECALS (continued) Compressor Package Data COMPRESSOR MODEL....... m 3 /MIN CAPACITY............RATED OPERATING PRESSURE....BARG MAX. DISCHARGE PRESSURE....BARG WARNING MAX. MODULATE PRESSURE..... BARG WARNING NOMINAL DRIVE MOTOR......NOMINAL FAN MOTOR........ TOTAL PACKAGE AMPS....... VOLTS............PHASE / HERTZ..........CONTROL VOLTAGE........SERIAL NUMBER..........
1.0 RECEIPT OF EQUIPMENT 1.1 INSPECTION 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 uncrated. Obtaining the delivery man’s signed agreement to any noted damages will facilitate any future insurance claims.
2.0 INSTALLATION 2.1 VENTILATION Oil flooded rotary air compressors produce large amounts of heat. Because of this large heat production, the compressor must be placed in a room with adequate ventilation. If heated air from the compressor exhaust is allowed to recirculate back to the compressor, the compressor will overheat and shut down.
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2.3 PIPING (Continued) A dripleg assembly and isolation valve should be mounted near the compressor discharge. A drain line should be connected to the condensate drain in the base. IMPORTANT: The drain line must slope downward from the base to work properly. NOTE: For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel.
Two types of dryers, refrigerated or desiccant, are used to correct moisture related problems in a compressed air system. Refrigerated dryers are normally specified where compressed air pressure dew points of 33°F (1°C) to 39°F (4°C) are adequate. Desiccant dryers are required PRESSURE RELIEF where pressure dew points must be below 33°F (1°C).
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110V FIGURE 2.4-1 TYPICAL CONTROL TRANSFORMER WIRING ELECTRICAL INSTALLATION (Continued) Inspect the motor and control wiring for tightness. Close and fasten the starter box door. ROTATION CHECK Locate the rotation decal on each motor. DRIVE DRIVE MOTOR The correct compressor drive motor rotation is clockwise when viewed from the rear or non-drive end of the motor.
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ELECTRICAL INSTALLATION (Continued) Fan motor rotation is clockwise when viewed from The Intellisys will automatically shut the unit down if the the fan motor side. compressor rotation is incorrect, and the display will indicate “CHECK MOTOR ROTATION” and will flash INTELLISYS OPERATING INSTRUCTIONS “ALARM”.
2.5 OUTDOOR SHELTERED INSTALLATION Condensate drains must never be allowed to dump on Many times a compressor must be installed outside due the ground. Run to a suitable sump for future to jobsite conditions or limited space within a collection and disposal or separation of lubricant and manufacturing facility.
3.0 INTELLISYS UNLOAD Pressing this button will cause the compressor to unload and remain unloaded. The display will indicate INTELLISYS CONTROLS the machine is “Running Unloaded”, and “Mode: UNLOAD”. EMERGENCY STOP Pressing this switch stops the compressor immediately. The compressor can not be restarted until the switch is manually reset.
3.2 DISPLAY SCREEN - CURRENT STATUS- Package Discharge Temp 1 0 0 103°F P S I Running Loaded Airend Discharge Temp Mode: MOD/ACS 193°F MAIN MENU The display screen is divided into three functional arrow head pointing up) and/or down (designated by areas, as seen in the typical CURRENT STATUS arrow head pointing down) through a list.
3.4 MAIN MENU -MAIN MENU- Operator Setpoints 1 0 0 Options P S I Sensor Calibration Alarm History Ready To Start Clock Functions SELECT STATUS The MAIN MENU screen is the point from which The controller will go to the highlighted function if the various operator functions can be accessed.
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3.5.1 Lead/Lag- This setpoint is used for setting lead 3.5.6 Max Modulation Pressure- This setpoint is the or lag operation. If set to lead, the controller will load pressure the compressor will unload at if it is and unload the compressor by the online and offline modulating.
3.6 OPTIONS (CONTINUED) 3.6.1 Auto Restart- This setpoint is used to enable or 3.6.11 Separator Delta-P Sensor- This setpoint disable the auto restart option. enables or disables the separator delta-p sensor option. Enabling this option will automatically disable 3.6.2 Auto Restart Time- This setpoint is the minimum the Separator Delta-P Solenoid option.
3.7 SENSOR CALIBRATION -SENSOR CALIBRATION- Sensor 1AVPT 1 0 0 P S I CALIBRATE Sensor 3APT Ready To Start CALIBRATE STATUS MAIN MENU SELECT Pressure sensor calibration is done through the SENSOR CALIBRATION screen. Sensor calibration Select the highlighted sensor by pressing the SELECT can only take place when the machine is stopped.
-ALARM HISTORY 1- Package Disch Pressure 1 0 0 P S I 199 PSI Package Discharge Temp Ready To Start 103°F STATUS MAIN MENU ALARM HISTORY The name and value of each of the items listed below can be seen by moving the list up and down using the arrow buttons.
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3.10 INTEGRAL SEQUENCING -INTEGRAL SEQUENCING- Lead Compressor 1 0 0 P S I Total Compressors Ready To Start STATUS MAIN MENU SELECT Integral Sequencing is set up using the INTEGRAL INTEGRAL SEQUENCING RANGE STEP UNIT SEQUENCING screen. A description of integral is in Lead Compressor On/Off/Always/Never section 7.0.
3.11 WARNINGS 1 0 0 P S I Change Inlet Filter Running Unloaded Press RESET Twice Mode: MOD/ACS RESET STATUS MAIN MENU When a Warning occurs, a question mark will flash on will appear in the upper right corner of the display the display screen and appear in large letters as screen.
3.11 WARNINGS (CONTINUED) COMMUNICATION FAIL 1 (or 2 - 4) - This warning representative. Service warnings at level 2 are issued will occur if the compressor is the lead unit while using in 3 stages. First a “100 HOURS TO SERVICE” or 14 integral sequencing and is unable to communicate with DAYS TO SERVICE”...
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The possible Alarm messages are as follows. REMOTE START FAILURE- This will occur if the Remote Start button is pressed after the machine is CHECK INLET CONTROL- This will occur if the running or if the Remote Start button remains closed. machine is unloaded and the inlet vacuum is less than 3 psig (.2 bar).
4.0 SCHEDULED PREVENTATIVE MAINTENANCE 4.1 MAINTENANCE SCHEDULE THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST. Running Time Interval (whichever comes first) Action Part or Item Hours...
200 HP/132-160 KW REQUIRES (2) ELEMENTS entering the inlet valve. Discard old element/s. 100 HP/75 KW-2S REQUIRES (1) ELEMENT Thoroughly clean the element housing and wipe all 125-200 HP/110-160 KW - 2S REQUIRES (2) surfaces. ELEMENTS Install new element/s and inspect to ensure that they have seated properly.
100 HP/75 KW - 2 Stage .......22 gallons (83.3 liters) SSR Ultra Coolant is a polyglycol base coolant. Change 125-200 HP/90-160 KW - 2 stage ....30 gallons (113.6 liters) Ultra Coolant after every 8000 hours or every two years, whichever comes first.
4.6 COOLANT (Continued) After the unit is drained and a new coolant filter element is installed, refill the system with fresh coolant. Bring the receiver level of coolant up to the midpoint of the sight glass. Replace the fill cap. Start the compressor and run it for a short time.
4.8 COOLANT SEPARATOR ELEMENT WARNING To check condition of separator element, run compressor in full load mode and at rated pressure and observe “Separator Pressure Drop” on the CURRENT STATUS display screen. If the display says “xxPSI”, then no maintenance is required. If “ ? ” is flashing on the screen and the display says “CHANGE SEPR ELEMENT”, then the separator element should be replaced.
4.9 COOLER CORES: CLEANING COOLANT COOLERS Following are instructions for removal and internal Ensure the compressor is isolated from the cleaning of coolant coolers. compressed air system by closing the isolation valve and venting pressure from the drip leg. Coolant Cooler Remove panels and top cover.
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AFTERCOOLER Following are instructions for the removal and internal cleaning of aftercoolers. Aftercooler Disconnect hose from aftercooler inlet flange. Disconnect tube from aftercooler outlet flange. Remove aftercooler holding screws from aftercooler support and remove cooler. Aftercooler Cleaning It is recommended the cooler be taken to a professional cooler service shop for flushing with an appropriate environmentally safe cleaning agent.
4.10 MOTOR LUBRICATION CAUTION The induction-type squirrel cage motors have antifriction ball or roller bearings front and rear. At periodic intervals they require relubrication. Overgreasing can be a cause of bearing and motor failure. Make sure dirt and contaminants Relubrication Interval - 60 Hz are not introduced when adding grease.
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4.10 MOTOR LUBRICATION (Continued) Grease relief along shaft can occur, precluding necessity WARNING of removing this plug if inaccessible. The inlet grease gun fittings and outlet plugs (or spring-loaded reliefs) are located at each end of the motor housing. The drive end reliefs protrude out the circumference of the lower portion of the end bell near a flange bolt.
4.11 LONG TERM STORAGE Follow these precautions to minimize damage from static electricity. Static can cause severe damage to GENERAL microcircuits. The factory, upon special request, prepares compressor units for long term storage. In such cases, a special 1) Make the least possible movement to avoid build- bulletin is supplied for storage and start-up procedures.
4.15 FLUID AND VIBRATION MONITORING Power Supply Removal: Ingersoll-Rand recommends incorporating predictive 1) Open the starter box door. maintenance, specifically the use of coolant and vibration analysis, into all Preventative Maintenance programs. 2) Remove each plug-in connector, labeled J1 - Predictive Maintenance is designed to increase system J4, from the circuit board.
5.0 SYSTEMS COOLING FAN MOTOR 5.1 GENERAL SYSTEM INFORMATION In a standard compressor, the cooling fan motor is wired The SSR compressor is an electric motor driven, single at the factory. It is a three-phase motor, protected by a stage, screw compressor—complete with accessories suitable circuit breaker and overload relay.
5.4 COMPRESSED AIR SYSTEM Internal baffles maintain the circumferential flow of The air system is composed of: remaining coolant droplets and air. In an almost continuous change of direction of flow, more and more 1) Inlet air filter droplets are removed from the air by inertial action and 2) Inlet valve/stepper motor then returned to the sump.
5.6 ELECTRICAL SYSTEM (Continued) ON-OFF LINE CONTROL For those plants which have a widely varying air demand, STAR-DELTA TYPE STARTER on-off line control will deliver air at full capacity By use of the Star-Delta type starter, the compressor (compressor maximum efficiency condition) or will motor can be started and accelerated using a greatly operate at zero capacity (compressor minimum power reduced “inrush”...
5.8 CAPACITY CONTROL (Continued) 5.9 AUTOMATIC START/STOP CONTROL Many plant air systems have widely varying air demands MODULATION/ACS CONTROL (Continued) or large air storage capacity which allows for automatic The automatic control selector (ACS) is designed to standby air capacity control. continuously monitor the plant air demand and select either the on-off line, or the modulate control mode - During periods of low air demand, if the line pressure...
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SECOND Some Examples of Operation After the compressor has started and reached the off-line setting and has unloaded, timer “B” requires the unit to EXAMPLE 1 run unloaded for a period of time that the operator can The operator selects an unloaded run time of 2 minutes adjust between 2 and 60 minutes.
EXAMPLE 3 When starting the compressor from the remote location, The operator selects an unloaded run time of 10 minutes the Start button must be held depressed for in the OPTION routine and starts the compressor. The approximately 2 seconds to activate the remote start unit runs loaded 12 minutes and then unloads.
6.0 TROUBLESHOOTING CHART WHAT TO DO TROUBLE CAUSE &/OR DISPLAY Check fuses. Check transformer and wiring connections. Compressor fails to start. 110/120V control voltage not available, CONTROL POWER LOSS Inspect contactors. STARTER FAULT Rotate emergency stop button to disengage, and press reset button EMERGENCY STOP twice.
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6.0 TROUBLESHOOTING CHART (Continued) TROUBLE CAUSE &/OR DISPLAY WHAT TO DO Low system air pressure Compressor running in Press LOAD button. UNLOAD Mode. Controller off-line set point too low. Press STOP button. Set off-line set point at a higher value. Dirty air filter element.
7.0 OTIONS first reading the wet side sump pressure. Next the Intellisys will momentarily energize solenoid that will switch the dry side sump pressure to the sump pressure 7.1 POWER OUTAGE RESTART OPTION sensor (3APT). The Intellisys will then read the dry For customers that have interruptions in their incoming side sump pressure and subtract it from the wet side power supply to the compressor and must maintain an...
7.9 REMOTE LOAD/UNLOAD The remote load/unload option gives the operator the When line pressure rises to the lead compressor’s offline ability to control the loading and unloading of the set point, it will transmit an unload command to the last compressor.
9.0 WATER QUALITY RECOMMENDATIONS Perhaps the largest contributor to scale formation is the Water quality is often overlooked when the cooling precipitation of calcium carbonate out of the water. This is system of a water cooled air compressor is examined. dependent on temperature and pH.
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Recommended equipment for on-site analysis includes a thermometer, pH meter, and dissolved oxygen meter. Dissolved oxygen and temperature must be measured on-site and it is recommended that pH be measured on-site. All other analyses should be performed by a professional water quality analyst. The Langelier Index (Ll) is calculated using the following equation and the tables found on the following pages.
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