Ingersoll-Rand IRN 20HP Operation And Maintenance Manual
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Ingersoll-Rand IRN 20HP 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.
IRN 15 − 18.5 kW (20 − 25 HP)
IRN 22 − 30 kW (30 − 40 HP)
OPERATION AND MAINTENANCE MANUAL
C.C.N. : 22791511
REV.
DATE
: A
: AUGUST 2006

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Summary of Contents for Ingersoll-Rand IRN 20HP

  • Page 1 IRN 15 − 18.5 kW (20 − 25 HP) IRN 22 − 30 kW (30 − 40 HP) 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.
  • Page 2 Register on−line at air.irco.com/registration.htm Ingersoll−Rand Industrial Air Solutions Swan Lane Hindley Green Wigan WN2 4EZ Ingersoll Rand Asia Pacific C/O Ingersoll−Rand South East Asia (Pte) Ltd. 42 Benoi Road Singapore 629903 Ingersoll−Rand Industrial Air Solutions P.O. Box 1840 800−D Beaty Street...
  • Page 3 CONTENTS & ABBREVIATIONS CONTENTS ABBREVIATIONS & SYMBOLS CONTENTS #### Contact Ingersoll Rand for serial number −>#### Up to Serial No. FOREWORD ####−> From Serial No. Not illustrated Option DECALS Not required As required SAFETY Sitemaster/Sitepack High ambient machine Watercooled machine...
  • Page 4 The contents of this manual are considered to be proprietary and The intended uses of this machine are outlined below and examples confidential to Ingersoll Rand and should not be reproduced without the of unapproved usage are also given, however Ingersoll Rand cannot prior written permission of Ingersoll Rand.
  • Page 5 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 WARNING − Air/gas flow or Air discharge. Do not breathe the compressed air from this system.
  • Page 6 DECALS AUTOMATIC RESTART MAINTENANCE MAINTENANCE PROHIBITED COOLANT DRAIN CONDENSATE DRAIN FILTER FRAGILE KEEP DRY THIS WAY UP USE NO HOOKS NO SIDE CLAMPS HOURS Use ULTRA−Plus Coolant only POWER INSPECT Failure to use the specified coolant may result in damage to the machine Every X months, if sooner than required by CHANGE / REPLACE CLEAN...
  • Page 7 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.
  • Page 8 Decal, coolant drain 32343899 Decal, warning flying debris 32343519 Decal, danger contaminated air 22181663 Decal, drain 22806897 Decal, Ingersoll Rand logo 92930593 Decal, electric shock 22066302 Decal, fifteen minutes before service 32276321 Decal, california safety order decal 22814545 Decal, dryer bypass valve...
  • Page 9 22816797 Decal, maintenance schedule 22539431 Decal, control panel 93166478 Decal, condensate drain Non−dryer packages 92930668 Decal, no maintenance before 16543464 Decal, Ingersoll Rand logo referring manual − Decal, model number 22923015 Tag, shipping 92867498 Decal, air discharge − Decal, voltage...
  • Page 10 When loading or transporting machines ensure that the specified used in mineral oils. Ingersoll Rand recommends that only filters with lifting and tie down points are used. metal bowls should be used on a pressurised system.
  • Page 11 As waste water regulations vary by country and region it is the responsibility of the user to establish the limitations and regulations in their particular area. Ingersoll Rand and its associated distributors are happy to advise and assist in these matters.

  • Page 12: General Information

    Dryer refrigeration pressure switch SECTION Thermistor, motor winding temp. 2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER P1, P2 Pressure transducer AND SHOULD BE DONE IN ACCORDANCE WITH THE INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND...
  • Page 13 SECTION P1, P2 Pressure transducer 2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER Capacitor AND SHOULD BE DONE IN ACCORDANCE WITH THE Dryer option INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND LOCAL ELECTRICAL CODES.
  • Page 14 Pressure transducer SECTION Capacitor 2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER Dryer option AND SHOULD BE DONE IN ACCORDANCE WITH THE Dryer discharge pressure (Dryer option) INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND LOCAL ELECTRICAL CODES.
  • Page 15 2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY 1RPS Dryer refrigeration pressure switch INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER AND SHOULD BE DONE IN ACCORDANCE WITH THE Thermistor, motor winding temp. INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND LOCAL ELECTRICAL CODES.
  • Page 16 1RPS Dryer refrigeration pressure switch 2. SIZING OF ELECTRICAL COMPONENTS NOT SUPPLIED BY Thermistor, motor winding temp. INGERSOLL RAND IS THE RESPONSIBILITY OF THE CUSTOMER AND SHOULD BE DONE IN ACCORDANCE WITH THE P1, P2 Pressure transducer INFORMATION ON THE COMPRESSOR DATA PLATE, N.E.C., AND LOCAL ELECTRICAL CODES.
  • Page 17 GENERAL INFORMATION PIPING AND INSTRUMENTATION AR Air receiver (option) 24. Valve, blowdown Integral dryer (option) 25. Filter, air − High efficiency Filter, air 26. Valve, check Valve, inlet 27. Recuperator Airend assembly 28. Valve, isolation Motor 29. Moisture separator Tank, separator − coarse 30.
  • Page 18 INSTALLATION / HANDLING 20−40HP 120 GALLON BASEPLATE A Blower rotation O Drive motor rotation B Air discharge location P Coolant filter C Drain location Q Incoming power connections D Emergency stop button R Electrical controls/fuses access panel E Dryer dewpoint indicator S Bypass valve F Drive location T Integrated dryer (Optional)
  • Page 19 INSTALLATION / HANDLING 20−40HP 120 GALLON A Blower rotation P Coolant filter B Air discharge location Q Incoming power connections C Drain location R Electrical controls/fuses access panel D Emergency stop button S Bypass valve E Dryer dewpoint indicator T Integrated dryer (Optional) F Drive location U Package pre−filter G Air inlet...
  • Page 20 INSTALLATION / HANDLING 20−40HP 240 GALLON A Blower rotation P Coolant filter B Air discharge location Q Incoming power connections C Drain location R Electrical controls/fuses access panel D Emergency stop button S Bypass valve E Dryer dewpoint indicator T Integrated dryer (Optional) F Drive location U Package pre−filter G Air inlet...
  • Page 21 INSTALLATION / HANDLING 15−30kW 500 LITRE A Blower rotation P Coolant filter B Air discharge location Q Incoming power connections C Drain location R Electrical controls/fuses access panel D Emergency stop button S Bypass valve E Dryer dewpoint indicator T Integrated dryer (Optional) F Drive location U Package pre−filter G Air inlet...
  • Page 22 INSTALLATION / HANDLING 15−30kW 750 LITRE A Blower rotation P Coolant filter B Air discharge location Q Incoming power connections C Drain location R Electrical controls/fuses access panel D Emergency stop button S Bypass valve E Dryer dewpoint indicator T Integrated dryer (Optional) F Drive location U Package pre−filter G Air inlet...
  • Page 23 For further advice or assistance consult your The compressor will normally be delivered with a polythene cover. local Ingersoll Rand representative. If a knife has to be used to remove this cover ensure that the exterior paintwork of the compressor is not damaged.
  • Page 24 Their safety can be affected by either synthetic coolants or the additives used in mineral oils. 2. Air Receiver Ingersoll Rand recommends that only filters with metal bowls 3. Air Dryer should be used on any pressurised system.
  • Page 25 INSTALLATION / HANDLING 60/50Hz IRN 20HP/ 15 kW IRN 25HP / 18.5 kW non−TAS non−TAS COMPRESSOR Nominal pressure PSIG (bar) (10.34) (10.34) Flow rate @ 150 PSIG (10.3 bar) 1, 4 ACFM (m /MIN) (2.12) (2.18) (2.61) (2.66) Flow rate @ 125 PSIG (8.6 bar)
  • Page 26 INSTALLATION / HANDLING ELECTRICAL DATA − ALL UNITS IRN 20HP / 15kW Standard voltage Low Voltage High Voltage 208V 230V 380V 400V 460V Drive motor Motor enclosure IP65 Power 20HP / 15kW Full load current (maximum) 58.3 52.7 31.9 30.3 26.3...
  • Page 27 INSTALLATION / HANDLING 60/50Hz IRN 30HP/ 22 kW IRN 40HP / 30 kW non−TAS non−TAS COMPRESSOR Nominal pressure PSIG (bar) (10.34) (10.34) Flow rate @ 150 PSIG (10.3 bar) 1, 4 ACFM (m /MIN) (3.09) (3.17) (4.02) (4.14) Flow rate @ 125 PSIG (8.6 bar) 2, 4 ACFM (m /MIN)
  • Page 28 INSTALLATION / HANDLING ELECTRICAL DATA − ALL UNITS IRN 30HP / 22kW Standard voltage Low Voltage High Voltage 208V 230V 380V 400V 460V Drive motor Motor enclosure IP65 Power 20HP / 15kW Full load current (maximum) Starts per hour (maximum) ELECTRICAL DATA Control voltage 24VDC...
  • Page 29 INSTALLATION / HANDLING ELECTRICAL DATA CAUTION Do not verify cooling simply by air flow direction, but ensure An independent electrical isolator or disconnect should be installed that the fan rotates in the correct direction as indicated by adjacent to the compressor. direction arrows Feeder cables/wires should be sized by the customer/electrical NOTE...

  • Page 30: Operating Instructions

    OPERATING INSTRUCTIONS GENERAL OPERATION The power transmission from the drive motor to the airend male rotor is by direct drive. The compressor is an electric motor driven, single stage screw compressor, complete with accessories piped, wired and baseplate mounted. It is a totally self contained air compressor package. By cooling the discharge air, much of the water vapour naturally contained in the air is condensed and may be drained from the downstream piping and equipment.
  • Page 31 OPERATING INSTRUCTIONS 9. LCD DISPLAY SCREEN The LCD contrast is adjusted by pressing and holding the Status button and pressing the Up and Down navigation keys. 10.DEWPOINT INDICATOR (DRYER ONLY) Green indicates an acceptable dewpoint, red indicates a dewpoint above 50_F(10_C), and blue indicates a freezing risk. PRIOR TO STARTING 1.
  • Page 32 OPERATING INSTRUCTIONS S Energy Saving − a cumulative total, calculated hourly, and can be DEWPOINT ADJUSTMENT (DRYER ONLY) reset by selecting Reset Energy Savings in the Operator Setpoints. The dewpoint may be adjusted by the Hot Gas Bypass Valve (HGBV). This is calculated the same as Lifetime Energy Savings but this To reduce the dewpoint turn the HGBV adjustment counter−clockwise.
  • Page 33 OPERATING INSTRUCTIONS Change a value by highlighting the item and its value and pressing the SCHEDULED START TIME SELECT button to highlight just the value. When the value line is This is the Scheduled Start Time entry used for the Scheduled Start of highlighted by itself, the value can be adjusted using the up and down the compressor.
  • Page 34 OPERATING INSTRUCTIONS Modbus Address Service Soon − Warning text ”Service Soon” should appear in the This parameter is used to adjust the Modbus address to the desired warning display area above the bar graph when 20% or less time is value.

  • Page 35: Maintenance Schedule

    Check the operation of the high operation necessary. 3000 hours temperature protection switch (109_C). Visual check of Report immediately, contact Ingersoll Rand Change the coolant filter. machine for any authorized distributor for assistance if in Check scavenge orifice for blockage, clean leaks, dust build up doubt if required.
  • Page 36 National environmental protection 6. Remove the new Ingersoll Rand replacement filter from its codes. protective package. WARNING 7.
  • Page 37 (Used filter elements must be disposed of in accordance with local regulations.) • Adjustable time off (0.5 − 45 minutes) Use only genuine Ingersoll Rand replacement elements. • Stainless steel operator • LED to indicate electrical power is on •...
  • Page 38 MAINTENANCE 1. Stop compressor, lock and tag out machine. REFRIGERANT LEAKS IN THE REFRIGERATION CIRCUIT The unit is despatched in perfect working order, already charged. Refrigerant leaks may be identified by tripping of the refrigeration overload protector . IF A LEAK IS DETECTED IN THE REFRIGERANT CIRCUIT, SEEK TECHNICAL ASSISTANCE.

  • Page 39: Trouble Shooting

    Ice formation in dryer Low evaporator pressure. Check hot gas valve setting. NOTES: § Must be carried out by a competent electrician. † This work is recommended to be carried out only by an Ingersoll Rand authorized service technician. http://air.irco.com...
  • Page 40 Check hot gas bypass valve. Ensure ambient temperature is greater than 35_F (2_C). NOTES: § Must be carried out by a competent electrician. † This work is recommended to be carried out only by an Ingersoll Rand authorized service technician. http://air.irco.com...

This manual is also suitable for:

Irn 25hpIrn 30hpIrn 40hp

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