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OPERATION and MAINTENANCE
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this compressor.
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
DoosanPortablePower.com
Book: 23015142 (9/2013) Rev D
MANUAL
COMPRESSOR MODELS
NHP1500WCU-T3 (C18)
NHP10-425WCU-T3 (C67)
NHP1500WCU-FX-T3 (E07)
NHP1500WCU-EX-T3 (E08)
NHP1500WC-EU-FX-T3 (E76)
NHP10-425WCU-EU-FX-T3 (E87)
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Summary of Contents for Doosan NHP1500WCU-T3
- Page 1 NHP10-425WCU-EU-FX-T3 (E87) This manual contains important safety information. Do not destroy this manual. This manual must be available to the personnel who operate and maintain this compressor. Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 DoosanPortablePower.com Book: 23015142 (9/2013) Rev D...
- Page 3 Ingersoll-Rand Company in this manual is historical or nom- inative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Doosan Infracore Portable Power or the products of either. Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C.
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Page 5: Table Of Contents
TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE FOREWORD ............5 SAFETY . - Page 6 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE MAINTENANCE ............39 General .
- Page 7 TABLE OF CONTENTS Operation & Maintenance Manual TITLE PAGE SYSTEM DIAGRAMS ........... . 73...
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Page 9: Foreword
Foreword... - Page 10 Noise Emission Directive 2000/14/EC. Ric Lunsford Quality Control Manager Issued at Statesville, N.C. Date The technical documentation for the machinery is available from: Doosan Infracore Portable Power, 1293 Glenway Drive, Statesville, N.C. 28625 9218 USA CPN 46553504 Rev A CPN 46552201 re...
- Page 11 Foreword Operating & Maintenance Manual The contents of this manual are considered to be proprietary and confidential to Doosan Infracore Portable Power (herein referred to as “Portable Power” and should not be reproduced without the prior written permission of Portable Power.
- Page 12 Operating & Maintenance Manual Foreword D. With other than Portable Power approved components. E. With guards, or controls or switches missing or disabled. F. For storage or transportation of materials inside or on the enclosure. This company accepts no responsibility for errors in translation of this manual from the original English version.
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Page 13: Safety
Safety... -
Page 14: General Information
Operating & Maintenance Manual Safety Safety Indicates the presence of a hazard which WILL DANGER cause serious injury, death or property damage, if ignored. (Red Background) Indicates the presence of a hazard which CAN WARNING cause serious injury, death or property damage, if ignored. -
Page 15: Compressed Air
Safety Operating & Maintenance Manual Compressed Air Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started accidentally. Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel. -
Page 16: Avoid Inhalation
Operating & Maintenance Manual Safety Avoid Inhalation Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times. The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: •... -
Page 17: Engine Starting Fluid (Ether)
Safety Operating & Maintenance Manual Engine Starting Fluid (Ether) Use and recharge system only with suppliers instructions and replacement parts. Some machines are fitted with an ether cold starting aid. Do NOT use on engines which are provided with inlet heaters. AVOID INGESTION, INHALATION, HOT SURFACES AND NAKED LIGHTS Transport When loading or transporting machines ensure that the specified lifting and tie down points are... -
Page 18: Iso Symbols
Operating & Maintenance Manual Safety ISO Symbols GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition / Mandatory Information / Instructions Warning WARNING - Pressurised component WARNING - Hot surface. WARNING: Electrical shock risk or system WARNING - Corrosion risk. WARNING - Pessure control. WARNING - Air/gas flow or Air discharge. - Page 19 Safety Operating & Maintenance Manual WARNING - Do not undertake any WARNING - Consult the operation Do not breathe the compressed air from this maintenance on this machine until the and maintenance manual before machine. electrical supply is disconnected and the air commencin g any maintenance .
- Page 20 Operating & Maintenance Manual Safety Lifting point. On (power). Off (power). Pro-Tec™ Read the Operation and Maintenance manua l When parking use prop stand, handbrake and Compressor oil filling before operation or maintenance of thi s wheel chocks. machine is undertaken. Keep door closed when engine is running.
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Page 21: General Information
General Information... -
Page 22: Unit Models
Operating & Maintenance Manual General Information General Information Unit Models Unit Models NHP1500WCU ......................10/425 Air Delivery - cfm (litres/sec) ..................1500 (708) Compressor Rated Operating Pressure - psi (kPa) ................60-150 (41-1050) Engine (Diesel) Manufacturer ........................Cummins Model ..........................QSX-15 Rated Horsepower at 1800 rpm .................. -
Page 23: Units Measurements/Weights (Feet (Meters)
General Information Operating & Maintenance Manual Units Measurements/Weights (feet (meters) Overall Length ........................ 19.6 (5.97) Overall Height ......................... 8 (2.44) Overall Width ........................7.4 (2.25) Gross Weight - pounds (kg) (all fluids) ................22,040 (9995) Running Gear Tire Size (turntable running gear) ..................16x5 Tire Size (standard running gear) .................. -
Page 25: Operating Instructions
Operating Instructions... -
Page 26: Operating Controls And Instruments
Operating & Maintenance Manual Operating Instructions Operating Instructions INGERSOLL RAND INTELLISYS 13 13 Operating Controls and Instruments The operating controls and instruments are arranged on the control panel as shown above. A description of each panel device is as follows: 1. - Page 27 Operating Instructions Operating & Maintenance Manual 8. Unload Button: Press this button to “unload” machine prior to stopping. NOTE: Pressing this button will close air intake and decrease engine speed to idle condition. 9. Stop Button: Press this button to initiate a controlled stop to the machine following “unload”.
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Page 28: Lifting Unit
Operating & Maintenance Manual Operating Instructions Lifting Unit Fork Tubes — drawbar vertical stowing position. — fork truck lifting capacity per gross weight (see general data). Four Corner Lifting Pockets — Use 2 spreader bars. — Hoist/crane per machines gross weight (see general data). Wheel Chock —... -
Page 29: Compressor Mounting
Operating Instructions Operating & Maintenance Manual Compressor Mounting Portable compressors, which are modified to remove the running gear and mount the machine direct to trailers, truck beds or frames, etc. may experience failure of the enclosure, frame, and/or other components. It is necessary to isolate the compressor package from the carrier base with a flexible mounting system. -
Page 30: Air Hose Restraining Cable Installation
Operating & Maintenance Manual Operating Instructions Air Hose Restraining Cable Installation: Secure hose restraining cable at each end to prevent accidental hose whipping. At the machine-side of the air hose, install and secure one end of the hose restraining cable on the 3”... -
Page 31: Setting Up Multiple Units
Operating Instructions Operating & Maintenance Manual Setting up Multiple Units Many applications will require multiple machines operating in parallel in order to meet the flow requirements of the application. Use the following guidelines in setting up multiple machines. 1. Position each unit in an open, well-ventilated area. Position and space each unit sufficiently apart from each other so that doors can be opened fully for service and maintenance. -
Page 32: Setting Up The Plant Air Pressure Signal
Operating & Maintenance Manual Operating Instructions 9. If a check valve is installed at the customer header, an additional pressure signal line must be used to provide the unit control system with air pressure on the plant-side of the check valve. One pressure signal line must be plumbed to each machine. -
Page 33: Before Starting
Operating Instructions Operating & Maintenance Manual Before Starting Open service valves. Inspect the complete installation including remote fuel lines (if any) and air hose routing and connections. Check battery for proper connections and condition. WARNING Combustible gas can cause severe burns, blindness or death. Keep sparks and open flame away from battery. - Page 34 Operating & Maintenance Manual Operating Instructions NOTE: This machine will not allow engine starting if engine coolant is low. NOTICE If the appropriate mixture of antifreeze is not used during freezing temperatures, failure to drain the engine may cause costly engine damage.
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Page 35: Starting
Operating Instructions Operating & Maintenance Manual Starting 1. Flip the POWER switch to “ON”. INTELLISYS Controller display will be activated. 2. Insure that the “EMERGENCY STOP” switch is not depressed. Reset this switch by pulling out the knob. 3. Insure that the service valve is open and make sure side doors are closed. 4. -
Page 36: Normal Operation
Operating & Maintenance Manual Operating Instructions Normal Operation The Operator may observe and monitor operating parameters using the STATUS and SCROLL buttons. In the event the machine controller detects a parameter outside normal operating limits, first an ALERT message will appear on the Message Display. In the event the machine controller detects a parameter at a dangerously high or low level, the machine will be automatically unloaded and stopped with the cause of the SHUTDOWN shown on the Message Display and warning lights will flash. -
Page 37: Intellisys Controller Logic
Operating Instructions Operating & Maintenance Manual Intellisys Controller Logic Coolant> 80° F Star t Button RPM >600 Panel STOP Power button Manual Unload Crank Warm Loa d Button Unload Button = Speed Control Auto Unload Setpoint - 10 psi = Idle Only Aut o Reload Unloading Pressure... -
Page 38: Auto Start/Stop Operation
NOTICE Set the line pressure to REMOTE or ONBOARD based on your application prior to using AUTOSTART/STOP. Doosan Portable Power recommends the use of a check valve and REMOTE PRESSURE in all AUTO START/ STOP applications. The compressor has two methods of autostart/stop control. -
Page 39: Stopping
Operating Instructions Operating & Maintenance Manual Stopping Press the STOP button. The unit will unload and begin timed cool down (180 seconds). Once the timed cool down is complete, the engine will shutdown. During a normal “non-emergency” stop, the following stopping procedure should be followed: 1. -
Page 40: Remote Start Stop And Enuciation Kit
Operating & Maintenance Manual Operating Instructions Remote Start Stop and Enuciation Kit The NHP1500 compressor may include an Automatic Start/Stop feature as an option from the factory. This option includes a box which contains 3 terminal blocks. The three blocks are defined as follows: REMOTE CONTACTS - used as part of the Autostart/Stop features if required. -
Page 41: Main Menu
Operating Instructions Operating & Maintenance Manual Main Menu: Displays a link to the following sub-menus: 1. User options: Displays the following options: A. Pressure Setpoint: Press “SELECT” then adjust using the toggle up and down buttons and pressing “SET”. B. Auto ReLoad Pressure: Setpoint-140 psi (default). C. - Page 42 Operating & Maintenance Manual Operating Instructions 8. Stg 2 Disch Temp: Displays the airend stage 2 discharge temperature measured in the stage 2 discharge venturi. 9. Remote Press: Displays the pressure from an external tap measured downstream of the package discharge. If REMOTE PRESS is selected from user menu.
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Page 43: Maintenance
Maintenance... -
Page 44: General
Operating & Maintenance Manual Maintenance Maintenance General In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and post-operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need for repair. -
Page 45: Gauges
Maintenance Operating & Maintenance Manual To service the air cleaners on all units proceed as follows: 1. Loosen outer wing nut and remove with outer element. Inspect red window on special inner wing nut to find small dot. If dot is not visible, remove cotter pin and special wing nut and inner (safety) element. -
Page 46: Battery
Operating & Maintenance Manual Maintenance Battery Heavy-duty, diesel cranking type batteries were installed at the factory and these should be inspected weekly. Keep the battery posts-to-cable connections clean, tight and lightly coated with a grease. Also the electrolyte level in each cell should cover the top of the plates. If necessary, top-up with clean distilled water. -
Page 47: Hoses
Maintenance Operating & Maintenance Manual Hoses Each month it is recommended that all of the intake lines to and from the air cleaners, the engine cooling system hoses and all of the flexible hoses used for air, oil, and fuel be inspected. -
Page 48: Compressor Oil Filters
Operating & Maintenance Manual Maintenance Compressor Oil Filters The compressor lubrication and hydraulic oil systems include spin-on, throw away type oil filters, each with an internal bypass valve. With a clean, new filter element, all of the oil flows through the full element area, from the outside/inside. As each element becomes contaminated with dirt, a pressure differential is created in the filter housing between the oil inlet and outlet ports. -
Page 49: Fasteners
Maintenance Operating & Maintenance Manual 4. Lubricate the new filter gasket with the same oil being used in the machine. 5. Install new filter by turning element clockwise until gasket makes initial contact. Tighten an additional 1/2 to 3/4 turn. 6. - Page 50 Operating & Maintenance Manual Maintenance NOTICE Disregard any maintenance pertaining to components not provided on your machine. NOTICE Drain the frame after power-washing/cleaning or heavy rains.
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Page 51: Maintenance Schedule
Maintenance Operating & Maintenance Manual Maintenance Schedule These time periods should be reduced if operating in extreme conditions (very hot, cold, dusty or wet). Initial Daily Weekly Monthly 3 MOS. 6 MOS. 12 MOS. Miles 850 Km 500 hrs 1000 hrs 2000 hrs Compressor Oil Level Engine Oil Level *Radiator Coolant Level... - Page 52 Operating & Maintenance Manual Maintenance Initial Daily Weekly Monthly 3 MOS. 6 MOS. 12 MOS. 12 MOS. Miles 850 Km 500 hrs 1000 hrs 1500 hrs 2000 hrs *Fuel/Water Separator Element Compressor Oil Filter Element Compressor Oil Engine Oil Change Engine Oil Filter *Water Pump Grease *Wheels (Bearings, Seals, etc.)
- Page 53 Maintenance Operating & Maintenance Manual Initial Daily Weekly Monthly 3 MOS. 6 MOS. 12 MOS. Miles 850 Km 500 hrs 1000 hrs 2000 hrs Pressure system Engine breather element Lubricator (Fill) 2 yrs. 4 yrs. 6 yrs. Safety valve Hoses *Disregard if not appropriate for this particular machine.
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Page 54: Torque Values
Operating & Maintenance Manual Maintenance Torque Values TABL E 1 INCH FASTENERS NOMINAL DESIGN TORQUE 8AE J249 8AE J249 GRADE 5 GRADE 8 (HEAD MARK ING) TYPICAL RECTANGULAR TORQUE (HEAD MARKETING) PATTERN CAPSCREW OR NUT THREAD SIZE AND PITCH TYPICAL SQUARE TORQUE PATTERN (Nm.) (Nm.) - Page 55 Maintenance Operating & Maintenance Manual TABL E 2 METRIC FASTENERS NOMINAL DESIGN TORQUE PROPERTY PROPERTY PROPERTY GRADE 8.8 GRADE 10.9 GRADE 12.9 TYPICAL RECTANGULAR TORQUE (HEAD MARKING) (HEAD MARKING) (HEAD MARKING) PATTERN 10.9 12.9 CAPSCREW OR NUT THREAD SIZE AND PITCH 10.9 12.9 TYPICAL SQUARE TORQUE...
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Page 57: Lubrication
Lubrication... -
Page 58: General Information
Operating & Maintenance Manual Lubrication Lubrication General Information Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit require more frequent lubrication than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency of their application be explicitly followed. - Page 59 Lubrication Operating & Maintenance Manual If the unit has been operated for the time/ hours mentioned above, it should be completely drained of oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier change period may be necessary as oil deteriorates with time as well as by operating conditions.
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Page 61: Fault Finding
Fault Finding... -
Page 62: Introduction
Operating & Maintenance Manual Fault Finding Fault Finding Introduction Troubleshooting for a portable air compressor is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The troubleshooting chart that follows includes some of the problems that an operator may encounter during the operation of a portable compressor. -
Page 63: Double Check Before Disassembly
Fault Finding Operating & Maintenance Manual C. Double Check Before Disassembly The source of most compressor troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a compressor can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly. -
Page 64: Fault Finding Chart
Operating & Maintenance Manual Fault Finding Fault Finding Chart Bold Headings depict the COMPLAINT - Subheadings suggest the CAUSE NOTE: Subheadings suggest sequence to follow troubleshooting. 1. Unit Shutdown: Corrective Action Out of Fuel Add CLEAN diesel Fuel Compressor Oil Temp. Too High See Complaint 10 Engine Water Temp. - Page 65 Fault Finding Operating & Maintenance Manual Loose Wire Connection. Repair or replace. 5. Alternator Low Volltage: Corrective Action Loose or Broken Belts Tighten or replace belt set. Loose Wire Connection Repair or replace connection. Low Battery Voltage Check electrolyte level. Add if necessary. Check connectors.
- Page 66 Operating & Maintenance Manual Fault Finding 10. Low CFM: Corrective Action Dirty Air Filter Clean or replace elements. Incorrect Linkage Adjustment Make adjustment per Section 6. Malfunctioning Inlet Unloader/Butterfly Inspect valve. Make adjustment per Section 6. Valve Malfunctioning Hydraulic Cylinder Replace hydraulic cylinder.
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Page 67: Alerts And Shutdowns
Fault Finding Operating & Maintenance Manual Alerts and Shutdowns Software V3.02 ALERT SHUTDOWN AIREND Parameters Units Value Type Value Type High Inlet Restriction psiv (bar) 0.69 (0.05) >3.05 (0.21) >13.5 (0,93) Hi Stg 2 Inlet Press psig (bar) >43 (3) & >5 (0,34) &... -
Page 69: Electrical
Electrical... -
Page 70: Intellisys Controller
Operating & Maintenance Manual Electrical Electrical Intellisys Controller The INTELLISYS Controller is the heart of the NHP1500 machine monitor and control system. It provides data collection, alarming and control functions for compressor operations. It is an Intel microcontroller based unit with analog and digital inputs and outputs. The first function of the INTELLISYS Controller is to scan all analog and digital inputs at a given time interval. -
Page 71: Controller Outputs
Electrical Operating & Maintenance Manual Controller Outputs The INTELLISYS Controller has three different types of outputs: frequency, pulse width modulated (PWM) and 24 VDC digital (ON / OFF). The frequency output is used as a throttle signal for the engine (software revisions less than 2.0). The INTELLISYS Controller varies the frequency from 150 Hz to 375 Hz, corresponding to 1200 to 1800 RPM. -
Page 72: Electrical System
Operating & Maintenance Manual Electrical Electrical System The electrical system consists of the wiring harness and associated electrical devices such as relays, switches, lights, solenoids and alarm horn. There are two wiring harnesses in the NHP1500 machine. They are as follows: 23047020 W1 Chassis Main Wiring Harness 54633003 W3 Fuse Box Wiring Harness The schematic diagrams show the connections for these harnesses. -
Page 73: Electronic Control Systems
Electrical Operating & Maintenance Manual Electronic Control Systems... - Page 74 **Always use Ingersoll Rand Replacement parts!**...
- Page 75 Electrical Operating & Maintenance Manual...
- Page 76 Operating & Maintenance Manual Electrical FAULT FINDING Problem Correction Control Panel Power Switch On, Intellisys Controller Make sure battery disconnect switch is ON Does Not Come On Check Fuse F4 Check Seating of P3 Connector at SGP Battery Voltage too Low Check Control Panel ON / OFF Switch Check Wiring from BAT to SGP Intellisys Controller ON But Start Button does not Work Defective Membrane Panel Switch...
- Page 77 System Diagrams...
- Page 78 Operating & Maintenance Manual System Diagrams Exhaust Out Top IC, AC HC, FC...
- Page 79 System Diagrams Operating & Maintenance Manual Legend: Electrical Components Legend: Mechanical Components Stg 1 Inlet Vacuum Inlet Valve 2nd Stg Inlet Pressure Blowdown Valve 2nd Stg Discharge Pressure Blowdown Muffler Package Discharge Pressure 1st Stage Venturi Oil Filter In Pressure 1st MS 1st Stage Moisture Separator Oil Filter Out Pressure...
- Page 80 Operating & Maintenance Manual System Diagrams Manifold Filter OTCV Stage 2 Pump Stage 1 Breather Lvl Ind Strainer Oil Sump Figure 2: Lube Oil System Schematic Legend: Electrical Components Legend: Mechanical Components PT5 - Oil Filter Inlet Pressure OTCV - Oil Temp Control Valve PT6 - Oil Filter Outlet Pressure PRV - Pressure Relief Valve RT5 - Comp Oil Injection Temp...
- Page 81 System Diagrams Operating & Maintenance Manual Gauge Manifold Motor Stage 2 ENGINE Stage 1 Fill Filter Breather Lvl Ind Strainer Temp Ind Hydraulic Sump Legend: (Electrical Components) Legend: (Mechanical Components) Gauge Oil Pressure Indicator Proportional Valve Input Temp Ind Oil Temperature Indicator Lvl Ind Oil level Indicator Figure 3: Hydraulic System Schematic...
- Page 82 ENGINE 3 way valve QD Out Bypass Return Tank Fill **Always use Ingersoll Rand Replacement parts!** Breather Strainer Supply Tank Fill Breather Strainer Filter Filter QD In Pressure Indicator 3 way valve Valve Figure 4: Fuel System Schematic Legend: Electrical Components Legend: Mechanical Components FL - Fuel Level Gauge - Oil Pressure Indicator...
- Page 83 System Diagrams Operating & Maintenance Manual Exhaust Out Top Radiator IC, AC HC, FC...
- Page 84 Operating & Maintenance Manual System Diagrams ENGINE SIDE COMPRESSOR SIDE Hyd.Sump Coolant Engine Oil Heater Heater Pressure Ether Start Start Injection Oil Pan Pressure Pressure Oil Sump Heater Switch Heater Switch Battery Battery Start Heat Trace Pannel Switch Outlet Outlet (2Lines) IR Model Only Figure 6 : AC Cold Start System Schematic...
- Page 85 System Diagrams Operating & Maintenance Manual Mu ffler Engine CD26 1st MS 2nd MS Save All Base Figure - 7 Condensate Flow Schematic Legend: Electrical Components Legend: Mechanical Components ORFI - IC Orifice Heater IV - Inlet Valve ORF2 - AC Orifice Heater BDV - Blowdown Valve L3 - Hydraulic Fan Motor Speed MUF - Blowdown Muffler...
- Page 86 Operating & Maintenance Manual System Diagrams Legend: Electrical Components Legend: Mechanical Components L4 - Condensate Solenoid Valve (IC) 1st MS - 1st Stage Moisture Separator L5 - Condensate Solenoid Valve (AC) 2nd MS - 2nd Stage Moisture Separator HM - Hydraulic Motor HC - Hydraulic Cooler CAC - Engine Charge Air Cooler FC - Fuel Cooler...
- Page 87 Revision History Rev. EC Number Comments Original release Updates Doosan reference updates CN026601 Added Flex Models to Front Cover CN034865...
- Page 88 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2012 Doosan Infracore Portable Power Printed in the U.S.A.
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