Ingersoll-Rand IRN37-160K - CC Operation And Maintenance Manual
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Ingersoll-Rand IRN37-160K - CC Operation And Maintenance Manual

Ingersoll-Rand IRN37-160K - CC Operation And Maintenance Manual

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111213.14.59
IRN37-160K - CC, IRN50-200H-CC,
IRN75-160K-2S, IRN100-200H-2S,
R190-225NE
Operation and Maintenance Manual
Save These Instructions
November 2013
PRINT LANGUAGE
ENGLISH
POLISH
BULGARIAN
PORTUGUESE
CZECH
ROMANIAN
DANISH
SLOVAKIAN
DUTCH
SLOVENIAN
ESTONIAN
SPANISH
FINNISH
SWEDISH
FRENCH
TURKISH
GERMAN
HUNGARIAN
ITALIAN
LATVIAN
LITHUANIAN
MALTESE
NORWEGIAN
54719091
Revision K

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Summary of Contents for Ingersoll-Rand IRN37-160K - CC

  • Page 1 111213.14.59 54719091 Revision K November 2013 PRINT LANGUAGE ENGLISH POLISH BULGARIAN PORTUGUESE CZECH IRN37-160K - CC, IRN50-200H-CC, ROMANIAN DANISH SLOVAKIAN IRN75-160K-2S, IRN100-200H-2S, DUTCH SLOVENIAN R190-225NE ESTONIAN SPANISH FINNISH SWEDISH FRENCH TURKISH GERMAN HUNGARIAN ITALIAN LATVIAN LITHUANIAN MALTESE NORWEGIAN Operation and Maintenance Manual...
  • Page 2 111213.14.59 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

    111213.14.59 1.0 CONTENTS CONTENTS PAGE CONTENTS PAGE 1.0 CONTENTS 9.0 OPERATING INSTRUCTIONS 2.0 FOREWORD 9.1 BASIC OPERATION 3.0 ABBREVIATIONS & SYMBOLS 9.2 INTELLISYS CONTROLS 4.0 PURCHASE ORDER DETAILS 9.3 DISPLAY SCREEN 5.0 SAFETY 9.4 CURRENT STATUS SCREEN 5.1 SAFETY INSTRUCTIONS 9.5 MAIN MENU 5.2 SAFETY PRECAUTIONS 9.6 OPERATOR SETPOINTS...

  • Page 4: Foreword

    111213.14.59 2.0 FOREWORD Machine models represented in this manual may be Details of approved equipment are available from Ingersoll used in various locations worldwide. Machines sold and Rand Service departments. shipped into European community countries requires This machine has been designed and supplied for that the machine display the EC Mark and conform to use only in the following specified conditions and various directives.
  • Page 5 111213.14.59 2.0 FOREWORD WARNING The use of the machine in any of the situation types listed in table 1:- Is not approved by Ingersoll Rand, May impair the safety of users and other persons, and May prejudice any claims made against Ingersoll Rand. TABLE 1 WARNING - NOT PERMITTED Use of the machine to produce compressed air for:...

  • Page 6: Abbreviations & Symbols

    111213.14.59 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 T.E.F.C.

  • Page 7: Purchase Order Details

    111213.14.59 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.

  • Page 8: Safety

    111213.14.59 5.0 SAFETY 5.1 SAFETY INSTRUCTIONS Safety instructions in the operators manual are bold- Ensure that the Operation and Maintenance manual, and faced for emphasis. The signal words DANGER, WARNING the manual holder, are not permanently removed from and CAUTION are used to indicate hazard seriousness the machine.
  • Page 9 111213.14.59 5.0 SAFETY When using compressed air always use appropriate The above information contains data supplied in support personal protective equipment. of United Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.) regulations. All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free Transport from defects and be replaced according to the Manual When loading or transporting machines ensure that the...
  • Page 10 111213.14.59 5.0 SAFETY Condensate disposal Coolant disposal Condensate cannot be discharged into fresh/surface Steps to be taken in the case of spillage: Soak up with a water drains. In some regions compressor condensate suitable absorbent material, then sweep into a plastic bag containing ULTRA COOLANT can be fed directly into a for disposal.

  • Page 11: Text Decals

    111213.14.59 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 12 111213.14.59 5.0 SAFETY WARNING CAUTION Incorrect lifting of machine can cause injury or property damage. Lift only from base channels WARNING Food contaminant. Can cause severe injury or death. Use only Ingersoll Rand SSR H-1F food grade coolan t. 39568464 Rev. 03 NOTICE High pressure air.
  • Page 13 111213.14.59 5.0 SAFETY CAUTION Rotation Improper coolant filter replacement will cause compressor damage. Replace filter element after first 150 hours of operation and every 2000 hours thereafter or when coolant is changed. NOTICE WARNING HIGH VOLTAGE Do not attempt any work. Rotation Read manual.
  • Page 14 111213.14.59 5.0 SAFETY Condensate drain. Use 75˚C copper wire only. Nur 75˚C kupferdraht verwenden. Utilisez 75˚C uniquement fil de cuivre. Usar solamente cable de cobre para 75˚ C. usare 75˚C solamente cavi di rame. Use somente fio de cobre de 75˚ . Electrical 39492384 Rev.

  • Page 15: Graphic Form And Meaning Of Iso Symbols

    111213.14.59 5.0 SAFETY 5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition / Mandatory Information / Instructions Warning WARNING: Electrical shock risk. WARNING − Pressurized component or WARNING − Hot surface. system. WARNING − Pressure control. WARNING − Corrosion risk. WARNING −...
  • Page 16 111213.14.59 5.0 SAFETY WARNING − Do not undertake any WARNING − Consult the Operation WARNING − For operating temperature maintenance on this machine until the and Maintenance manual before below 0°C, consult the Operation and electrical supply is disconnected and the commencing any maintenance.
  • Page 17 111213.14.59 5.0 SAFETY Use fork lift truck from this side only. Emergency stop. Tie down point Lifting point. On (power). SEQUENCER STATUS LOAD SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED) RESET COMPRESSOR STATUS MODULATE MALFUNCTION POWER FOULED FILTER POWER INLET ELECTRIC MOTOR HOURS IRN37 - 160K - CC &...
  • Page 18 111213.14.59 5.0 SAFETY COOLANT SEPARATOR PRESSURE AIR DISCHARGE PRESSURIZED TANK ON / OFF CYCLE COOLANT FILTER AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE AIR PRESSURE STAR DELTA IEC 617−7 AUTOMATIC RESTART HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL MANUAL (SELECT)
  • Page 19 111213.14.59 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 SERVICE 15 Min TRAINED SERVICE PERSONNEL WAIT TIME CHECK ZERO VOLTS IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & R190-225NE ingersollrandproducts.com...

  • Page 20: Receipt / Handling

    111213.14.59 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 delivery persons signed agreement to any noted damages will facilitate any future insurance claims.

  • Page 21: Installation

    111213.14.59 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 22: Discharge And Condensate

    111213.14.59 7.0 INSTALLATION 7.2 DISCHARGE AND CONDENSATE PIPING It is essential when installing a new compressor [1], When two rotary units are operated in parallel, provide an to review the total air system. This is to ensure a safe isolation valve and drain trap for each compressor before and effective total system.

  • Page 23: Electrical

    111213.14.59 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 The feeder cable must be suitably glanded into the power grounded / earthed in accordance with Local and drive module (P.D.M.) electrical box to ensure that dirty air National Code requirements.
  • Page 24 111213.14.59 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/surg- es in excess of 575V can permanently damage the drive.

  • Page 25: Watercooled Units

    111213.14.59 7.0 INSTALLATION 7.4 WATERCOOLED UNITS Cooling Water Piping Venting the water system Water piping to and from the compressor package must At the initial installation or for start-up after draining the be 1” diameter or larger for N37/75K (N50/100H), 11/2” water system proceed to vent the system as follows: diameter or larger for N75/160K (N100H/200H) and 2.0”...
  • Page 26 111213.14.59 7.0 INSTALLATION Water quality recommendations Cooling Water Analysis Chart Water quality recommendations Water quality is often Substances Test interval Acceptable overlooked when the cooling system of a water-cooled air concentration compressor is examined. Water quality determines how Corrosivity Monthly - if stable Langelier Index effective the heat transfer rate, as well as the flow rate (Hardness,...

  • Page 27: Sea Watercooled Units (Selected Units Only)

    111213.14.59 7.0 INSTALLATION 7.5 SEA WATERCOOLED UNITS (SELECTED UNITS ONLY) Water cleanliness is extremely important. Strainers are No oil cooler manufacturer can guarantee that its available from Ingersoll Rand. Cleaning of coolers as a products will have an indefinite life and for this reason, we result of fouling is a customer responsibility.

  • Page 28: Outdoor Sheltered Installation

    111213.14.59 7.0 INSTALLATION 7.6 OUTDOOR SHELTERED INSTALLATION Nirvana compressors are not suitable for outdoor Installing a Nirvana compressor outside voids the installation. warranty of the compressor. 7.7 OUTDOOR MODIFICATION OPTION EU Directive 2000/14/EC. Noise Emission By Equipment This exclusion is on the basis that the machine forms For Use Outdoors.

  • Page 29: General Information

    111213.14.59 8.0 GENERAL INFORMATION TECHNICAL INFORMATION-SINGLE STAGE N37K N45K N50H N60H General Sound pressure level dB(A) * Maximum ambient temperature °C (°F) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature °C (°F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35) Weight Kg (lbs) 1048 (2310)
  • Page 30 111213.14.59 8.0 GENERAL INFORMATION N55K N75K N75H N100H General Sound pressure level dB(A) * Maximum ambient temperature °C (°F) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature °C (°F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35) Weight Kg (lbs) 1531 (3374) 1531 (3374)
  • Page 31 111213.14.59 8.0 GENERAL INFORMATION N90K N110K N125H N150H General Sound pressure level dB(A) * Maximum ambient temperature °C (°F) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature °C (°F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35) Weight Kg (lbs) 3175 (6985) 3175 (6985)
  • Page 32 111213.14.59 8.0 GENERAL INFORMATION N132K N160K N200H General Sound pressure level dB(A) * 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) Weight Kg (lbs) 3175 (6985) 3175 (6985) 3175 (6985) Maximum pressure barg (psig)

  • Page 33: Technical Information

    111213.14.59 8.0 GENERAL INFORMATION 8.1 TECHNICAL INFORMATION - TWO STAGE N75K N90K N110K N100H N125H N150H General Sound pressure level dB(A) * Maximum ambient temperature °C (°F) 46 (115) 46 (115) 46 (115) 46 (115) 46 (115) 46 (115) Minimum ambient temperature °C (°F) 1.7 (35) 1.7 (35) 1.7 (35)
  • Page 34 111213.14.59 8.0 GENERAL INFORMATION N132K N160K N200H General Sound pressure level dB(A) * 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) Weight Kg (lbs) 3650 3650 3650 (8030) (8030)
  • Page 35 111213.14.59 8.0 GENERAL INFORMATION “FOR R190-225NE DATA, PLEASE REFER TO ENGINEERING DATA PAGES.” IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & R190-225NE ingersollrandproducts.com...

  • Page 36: Installation Drawing

    111213.14.59 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING - N37/45K-CC & N50/60H-CC - AIR COOLED 11/2” NPT Air discharge (Female) 60Hz units 4 x Ø 13.0mm (0,5”) Compressor should be 11/2” BSP Air discharge (Female) 50Hz units bolted to the floor with four M10 (0.38”) bolts using holes shown.
  • Page 37 111213.14.59 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING- N37/45K-CC & N50/60H-CC - WATER COOLED 11/2” NPT Air discharge (Female) 60Hz units INTELLISYS Controller 11/2” BSP Air discharge (Female) 50Hz units 1” NPT Water inlet (Female) 60Hz units Ø63mm (2.48”) Electrical inlet 1”...
  • Page 38 111213.14.59 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING - N55/75K-CC & N75/100H-CC - AIR COOLED 2” NPT Air discharge (Female) 60Hz units 4 x Ø 13.0mm (0,5”) 2” BSP Air discharge (Female) 50Hz units Compressor should be bolted to the floor with four M10 (0.38”) bolts using holes shown.
  • Page 39 111213.14.59 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING-N55/75K-CC & N75/100H-CC-WATER COOLED INTELLISYS Controller 2” NPT Air discharge (Female) 60Hz units 1” NPT Water inlet (Female) 60Hz units 2” BSP Air discharge (Female) 50Hz units 1” BSP Water inlet (Female) 50Hz units Ø63mm (2.48”) Electrical inlet 1”...
  • Page 40 111213.14.59 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING - N90/160K - CC SINGLE STAGE & N90/160K - CC TWO STAGE - WATER COOLED IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & R190-225NE ingersollrandproducts.com...
  • Page 41 111213.14.59 8.0 GENERAL INFORMATION 2” NPT Air discharge (Female) 60Hz units Cabinet cooling airflow (N100H-N150H) 4 x Ø 13.0mm (0,5”) 2” BSP Air discharge (Female) 50Hz units Compressor should be bolted to the floor with (N75K-N110K) four M10 (0.38”) bolts using holes shown. Seal 2 1/2”...
  • Page 42 111213.14.59 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING - N90/160K, N125/200H SINGLE STAGE & N75/160K, N100/ 200H TWO STAGE - AIR COOLED IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & R190-225NE ingersollrandproducts.com...
  • Page 43 111213.14.59 8.0 GENERAL INFORMATION 2” NPT Air discharge (Female) 60Hz units Exhaust airflow (N100H-N150H) Cabinet cooling airflow 2” BSP Air discharge (Female) 50Hz units 4 x Ø 13.0mm (0,5”) (N75K-N110K) Compressor should be bolted to the floor with 2 1/2” NPT Air discharge (Female) 60Hz units four M10 (0.38”) bolts using holes shown.
  • Page 44 111213.14.59 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING - R190-225NE 22.4 OPENING 1830 72.0 OPENING 1930 [76.0] 4000 1289 83,6 [157.5] 50.8 [6.0] [3.29] [12.6] OPENING 31.4 OPENING 1376 [54.2] 2146 [84.5] 1273 [50.1] 664,7 [28.6] [26.17] [19.0] 1296 [3.0] 63,1 [51.0] [1.3] [9.1]...
  • Page 45 111213.14.59 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING - R190-225NE 22.4 OPENING 1830 72.0 OPENING 198,0 [7.80] 203,2 [8.00] 3015,0 [118.70] 1930 [76.0] 4000 1108 [157.5] 43.6 83,6 [11.5] OPENING [3.29] [12.6] 15.5 1376 OPENING 2146 [54.2] [84.5] 1278 [50.3] 664,7 [28.6] [26.17] [19.0]...

  • Page 46: Process And Instrumentation Diagram

    111213.14.59 8.0 GENERAL INFORMATION 8.3 PROCESS AND INSTRUMENTATION DIAGRAM N37/45K-CC & N50/60H-CC IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & R190-225NE ingersollrandproducts.com...
  • Page 47 111213.14.59 8.0 GENERAL INFORMATION Air discharge Dryer AUX warning Compressor Line filter AUX warning Air filter Receiver trap AUX warning Vacuum switch 1VAC Remote pressure transducer 9APT (optional) Cooler, air Water stop valve 4SV Cooler, coolant Typical customer downstream air treatment Condensate discharge Anti - condensation valve 11SV Coolant filter...
  • Page 48 111213.14.59 8.0 GENERAL INFORMATION 8.3 PROCESS AND INSTRUMENTATION DIAGRAM N55/75K-CC & N75/100H-CC IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & R190-225NE ingersollrandproducts.com...
  • Page 49 111213.14.59 8.0 GENERAL INFORMATION Air discharge Water shutoff valve 4SV (W.C. only) Compressor Typical customer downstream air treatment Air filter Anti-condensation valve 11SV Vacuum switch 1VAC Cooling air exhaust box Cooler, air Package discharge air temperature sensor 4ATT Cooler, coolant Injected coolant temperature sensor 2CTT Condensate discharge Orifice, seal scavenge air supply...
  • Page 50 111213.14.59 8.0 GENERAL INFORMATION 8.3 PROCESS AND INSTRUMENTATION DIAGRAM N90/160K & N125/200H SINGLE STAGE AND N75/160K & N100/200H TWO STAGE IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & R190-225NE ingersollrandproducts.com...
  • Page 51 111213.14.59 8.0 GENERAL INFORMATION Air discharge Remote pressure transducer 9APT (optional) Compressor Water stop valve 4SV (W.C. only) Air filter Typical customer downstream air treatment Vacuum switch 1VAC Anti - condensation valve 11SV Cooler, air Cooling air exhaust box Cooler, coolant Package discharge temperature transducer 4ATT Condensate discharge Injection temperature, transducer 2CTT...
  • Page 52 111213.14.59 8.0 GENERAL INFORMATION 8.3 PIPING AND INSTRUMENTATION DIAGRAM R190-225NE TWO STAGE IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & R190-225NE ingersollrandproducts.com...
  • Page 53 111213.14.59 8.0 GENERAL INFORMATION Air discharge Dryer aux warning Compressor Line filter aux warning AW1 (wire in series) Air filter Receiver trap aux warning Vacuum switch 1VAC Remote air pressure transducer 9APT (optional) Cooler, air Water shutoff valve 4SV (W.C. only) Cooler, coolant Typical customer downstream air treatment Condensate discharge...

  • Page 54: Electrical Schematic

    111213.14.59 8.0 GENERAL INFORMATION 8.4 WIRING SCHEMATIC N37K - N45K-CC / N50-60H-CC A/C BLOWER VFD KM5-1 SG-NE 1DPS 1DPS MCB2 ES-2 DVF3 GRN/YEL 1VAC 1VAC 230V ES-1 1ATS 1ATS 200/230V-3ph-50/60Hz K2-1 K2-1 400/460V-3ph-50/60Hz 110V MCB3 CDE (OPT) MCB1 200V 105 (110V) 16 17 18 L1 L2 +24V...
  • Page 55 111213.14.59 8.0 GENERAL INFORMATION 1ATS Switch, high airend discharge temperature PORO Power outage restart option (optional) 1DPS Switch, fouled oil filter Power supply unit 1VAC Switch, fouled air filter Filter, radio frequency interference 1ATT Sensor, airend inlet Remote stop 2ATT Sensor, airend discharge temperature Remote start 2CTT...
  • Page 56 111213.14.59 8.0 GENERAL INFORMATION 8.4 WIRING SCHEMATIC - N55-75K-CC / N75-100H-CC A/C BLOWER VFD KM5-1 SGNE 1DPS 1DPS MCB2 DVF3 ES-2 GRN/YEL 1VAC 1VAC 230V ES-1 1ATS 1ATS 200/230V-3ph-50/60Hz K2-1 K2-1 400/460V-3ph-50/60Hz 110V MCB3 CDE (OPT) MCB1 200V 105 (110V) 16 17 18 L1 L2 +24V...
  • Page 57 111213.14.59 8.0 GENERAL INFORMATION Valve, water stop solenoid (W.C. only) Service tool 6APT Transducer, sump air pressure, dry side Transformer, control 9APT Transmitter, remote air pressure Thermostat (optional) True running Valve, condensate drain General warning 11SV Valve, anti-condensation solenoid Auto transformer (if fitted) Colors Auxiliary warning 1 Black...
  • Page 58 111213.14.59 8.0 GENERAL INFORMATION 8.4 WIRING SCHEMATIC - N37/45K-CC/N50/60H-CC W/C KM5-1 MCB5 DVF3 GRN/YEL SGNE 1DPS 1DPS ES-2 MMS-1 230V 1VAC 1VAC 200/230V-3ph-50/60Hz 400/460V-3ph-50/60Hz ES-1 1ATS 1ATS 110V MCB3 K2-1 K2-1 MCB1 200V CDE (OPT) 16 17 18 105 (110V) MCB4 PORO 11SV...
  • Page 59 111213.14.59 8.0 GENERAL INFORMATION 1ATS Switch, high air end discharge Zero voltage temperature Protected earth 1DPS Switch, fouled oil filter PORO Power outage restart option (optional) 1VAC Switch, fouled air filter Power supply unit 1ATT Sensor, airend inlet Filter, radio frequency interference 2ATT Sensor, airend discharge temperature Remote stop...
  • Page 60 111213.14.59 8.0 GENERAL INFORMATION 8.4 WIRING SCHEMATIC - N55-75K-CC / N75-100H-CC W/C KM5-1 MCB5 DVF3 GRN/YEL SGNE 1DPS 1DPS ES-2 MMS-1 230V 1VAC 1VAC 200/230V-3ph-50/60Hz 400/460V-3ph-50/60Hz ES-1 1ATS 1ATS 110V MCB3 K2-1 K2-1 MCB1 200V CDE (OPT) 16 17 18 105 (110V) MCB4 PORO...
  • Page 61 111213.14.59 8.0 GENERAL INFORMATION 1ATS Switch, high air end discharge temperature Zero voltage 1DPS Switch, fouled oil filter Protected earth 1VAC Switch, fouled air filter PORO Power outage restart option (optional) 1ATT Sensor, airend inlet Power supply unit 2ATT Sensor, airend discharge temperature Filter, radio frequency interference 2CTT Sensor, injected coolent temperature...
  • Page 62 111213.14.59 8.0 GENERAL INFORMATION 8.4 WIRING SCHEMATIC - N75-160K-CC / N125-200H-CC A/C 380-480V SG-Ne 50/60 Hz 3ph + PE 1DPS ES-2 214A 214B MCB1 MMS1-1 MMS2-1 1VAC ES-1 1ATS SHT 2 K2-1 MMS2 110v MCB2 14 15 (OPT) 200v 105 (110V) 11SV MCB3 PORO...
  • Page 63 111213.14.59 8.0 GENERAL INFORMATION 1ATS Switch, high air end discharge temperature Zero voltage 1ATT Sensor, inlet temperature Protective earth 1DPS Switch, fouled oil filter PORO Power outage restart option (optional) 1VAC Switch, fouled air filter Power supply unit 2APT Sensor, interstage pressure (2 stage only) Filter, radio frequency interference 2ATT Sensor, airend discharge temperature...
  • Page 64 111213.14.59 8.0 GENERAL INFORMATION 8.4 WIRING SCHEMATIC - N75-160K-CC / N125-200H-CC W/C 380-480V 50/60 Hz 3ph + PE SG-Ne MCB1 1DPS ES-2 214A MMS1-1 MMS2-1 1VAC SHT 2 ES-1 1ATS 110v MCB2 K2-1 (OPT) MMS2 MMS1 200v MCB3 102 (110V) PORO 11SV 4-20 mA...
  • Page 65 111213.14.59 8.0 GENERAL INFORMATION 1ATS Switch, high air end discharge temperature Protective earth 1ATT Sensor, inlet temperature PORO Power outage restart option (optional) 1DPS Switch, fouled oil filter Power supply unit 1VAC Switch, fouled air filter Filter, radio frequency interference 2APT Sensor, interstage pressure (2 stage only) Remote stop...
  • Page 66 111213.14.59 8.0 GENERAL INFORMATION 8.4 WIRING SCHEMATIC - R190-225NE A/C & W/C SGNe 1DPS 16 17 18 ES-2 214A 214B MCB1 MMS1 FD 11 MMS1-1 MMS2-1 FD 12 230v 1VAC K1-3 MCB5 KM5-1 ES-1 1ATS SHT 2 K2-1 110v MCB2 (OPT) 200v 105 (110V)
  • Page 67 111213.14.59 8.0 GENERAL INFORMATION 1ATT Sensor, inlet temperature MCB10 Breaker, miniature circuit, heater (external) 1DPS Switch, fouled oil filter Mains filter 1VAC Switch, fouled air filter Motor, main 2APT Sensor, interstage pressure MMS1 Breaker, fan motor 2ATT Sensor, airend discharge temperature Optional 2CTT Sensor, injected coolent temperature...

  • Page 68: General Description

    111213.14.59 8.0 GENERAL INFORMATION 8.5 GENERAL DESCRIPTION The compressor is an electric motor driven, contact The coolant system consists of a sump, cooler, cooled screw compressor, complete with all necessary thermostatic valve, anti-condensation valve and a filter. components piped, wired and baseplate mounted. It is a When the unit is operating, coolant is forced by air totally self contained air compressor package.

  • Page 69: Operating Instructions

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.1 BASIC OPERATION Prior to starting WARNING Refer to diagram T5716 above. Ensure that all protective covers/guards are in place Check that the coolant level is at least visible in the before attempting to start the machine. center of the sight glass, add coolant if necessary.
  • Page 70 111213.14.59 9.0 OPERATING INSTRUCTIONS Start sequence Blowdown mode The compressor will initially start by the operator All two stage compressors will blowdown when pressing the local start button or receiving a remote start compressor is signalled to stop. Intellisys indicates that command.

  • Page 71: Intellisys Controls

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.2 INTELLISYS CONTROLS 1. Emergency stop 5. F2 Pressing this switch stops the compressor immediately. Not used. The blowdown valve will open to vent pressure in 6. Arrows the separator tank to atmosphere. Note: the system These up and down buttons have multiple functions downstream of the separator tank may still contain relating to the right half of the display screen.

  • Page 72: Display Screen

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.3 DISPLAY SCREEN The display screen is divided into three functional areas, The right side shows various items or lists such as the as seen in the typical CURRENT STATUS screen shown machine’s CURRENT STATUS readings, the MAIN MENU, here.

  • Page 73: Current Status Screen

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.4 CURRENT STATUS SCREEN The CURRENT STATUS screen is considered to be the 12 Motor Speed “normal” display that the controller shows. 13 Remote Pressure (optional) The following items and their present values can be 14 Time and Date displayed on the right side of the screen by pressing the 15 Program Name up and down arrow buttons.

  • Page 74: Main Menu

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.5 MAIN MENU The MAIN MENU screen can be accessed from the The language and units of measure are preset prior to the CURRENT STATUS screen by pressing the MAIN MENU compressor leaving the factory. button, identified by the words “MAIN MENU” in the −MAIN MENU−...

  • Page 75: Operator Setpoints

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.6 OPERATOR SETPOINTS Setpoints are user-adjustable variables in the controller −OPERATOR SETPOINTS− 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 be 105 psi seen on the screen by moving the list up and down using READY TO START...
  • Page 76 111213.14.59 9.0 OPERATING INSTRUCTIONS Automatic stop pressure Condensate Release The compressor will stop once the system pressure rises This is the number of seconds that the condensate to this pressure and the compressor is operating at the solenoid will be open (energized) when blowing out the minimum speed.

  • Page 77: Options

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.7 OPTIONS Options are turned on or off and their associated values −OPTIONS− 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 78: Sensor Calibration

    111213.14.59 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 79: Alarm History

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.9 ALARM HISTORY Alarm History displays each of the Alarm messages for the Each of the last 15 Alarm messages can be seen by last 15 Alarms experienced by the machine. It also gives moving the Alarm History list up and down using the access to displaying the machine operating conditions arrow buttons.

  • Page 80: Energy Status Messages

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.11 ENERGY STATUS MESSAGES AVERAGE CAPACITY - Displays the compressor’s average −ENERGY STATUS− capacity in cfm or m³ for the time period that was started AVERAGE PACKAGE kW by selecting the reset averaging setpoint. ENERGY COST - Displays the energy cost of the AVERAGE % CAPACITY−...

  • Page 81: Warnings

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.12 WARNINGS CHANGE INLET FILTER - This will occur if the Inlet When a WARNING occurs, a large question mark will flash on the display screen. Vacuum is greater than 0.05 bar (0.7 psig). CHANGE SEPR ELEMENT - This will occur if the pressure If multiple WARNINGS exist, the small up/down arrows will appear in the upper right corner of the display screen.

  • Page 82: Alarms

    111213.14.59 9.0 OPERATING INSTRUCTIONS 9.15 ALARMS CONTROL POWER LOSS - This will occur if the control When an Alarm occurs, a large exclamation mark in a triangle will flash on the display screen. The display circuit is broken by a bad connection or safety switch (e.g. message will indicate what caused the Alarm.

  • Page 83: Maintenance

    111213.14.59 10.0 MAINTENANCE 10.1 MAINTENANCE PROMPTS The service warning and flashing LED will appear at The service warning will return each subsequent 2000 intervals, dependant on the service level selected. Refer hours. to operating instructions. The machine will be master reset after service work The customer can only reset the warning for 24 hours by conducted prior to the 2000 hour interval to prevent false pressing the “set”...

  • Page 84: Maintenance Chart

    111213.14.59 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 85: Maintenance Procedures

    111213.14.59 10.0 MAINTENANCE Note: On some sea watercooled models the oil cooler and aftercooler are fitted with sacrificial zinc anodes (pencils) that are located in the end bonnets of the coolers. These sacrificial zinc anodes should be checked after the first 50 hours of operation to determine if corrosive conditions exist.
  • Page 86 111213.14.59 10.0 MAINTENANCE Prior to attempting any maintenance work on a Compressed air can be dangerous if incorrectly handled. running machine, ensure that:- Before doing any work on the unit, ensure that all pressure is vented from the system and that the machine •...

  • Page 87: Routine Maintenance

    111213.14.59 10.0 MAINTENANCE 10.4 ROUTINE MAINTENANCE This section refers to the various components which DANGER require periodic maintenance and replacement. Under no circumstance should the compressor be For all other maintenance, contact your local Ingersoll operated with the coolant fill plug removed. Rand office, Distributor or Air Center.
  • Page 88 111213.14.59 10.0 MAINTENANCE Coolant filter change procedure Drain sequence for R190-225NE • Remove plug from drain valve located on the bottom • Loosen filter element with the correct tool. of the separator tank. • Remove the element from the housing. •...
  • Page 89 111213.14.59 10.0 MAINTENANCE Separator element change procedure for R190-225NE The main body is made from 1/2 inch hexagon shaped steel and the diameter of the orifice and a direction-of- • Disconnect the scavenge tube at the airend. flow arrow is stamped in flat areas of the hexagon. •...
  • Page 90 111213.14.59 10.0 MAINTENANCE Blower motor Re-Grease Run the compressor for about 10 minutes by venting air from the system to let the unit warm up. With the (N75-160 Aircooled units) unit running, test at or near the maximum operating 6 Months or 4000 Hrs pressure by opening the valve for the minimum period Apply high melting point grease into the blower motor required to flush the valve seat free of debris.
  • Page 91 111213.14.59 10.0 MAINTENANCE N50/100H (N37/75K) Instructions for cleaning the coolers while installed in the compressor Following are instructions for tilting the cooler away from While cleaning coolers, great care must be taken to the enclosure and cleaning of the cooler. protect the rest of the machine from moisture and •...
  • Page 92 111213.14.59 10.0 MAINTENANCE • Remove 6 screws from top panel above cooler and • Disconnect hose from aftercooler inlet flange. remove panel. • Disconnect tube from aftercooler outlet flange. • Using lifting device from above, attach lifting straps • Remove aftercooler holding screws from aftercooler to lifting supports on each side of cooler.
  • Page 93 111213.14.59 10.0 MAINTENANCE Watercooled machines • Remove the filter pad from the housing and replace Shut off the cooling water. with a new filter pad from Ingersoll Rand. • Replace front grill to the drive box filter. The machine should trip at 109°C (228°F). For the N90-160Kw: CAUTION •...
  • Page 94 111213.14.59 10.0 MAINTENANCE No Loss Drain Trap (where fitted) Check / Cleaning Coolant Sampling Procedure • Remove the four socket head screws then carefully Bring unit up to operating temperature. Draw sample, split the trap. Clean and inspect all internal parts using pump kit, from separator tank port.

  • Page 95: Fault Finding

    111213.14.59 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 person- nel and that the safety and maintenance sections of this manual have been read and are fully understood and followed.
  • Page 96 111213.14.59 11.0 FAULT FINDING SYMPTOM FAULT REMEDY Compressor will not meet Compressor not sized to Contact your local IR representative pressure required by system meet system requirements or requirements have been changed Air loss due to pipe, hose, joint or Overhaul or replace seal failure Air loss due to blowdown valve stuck...
  • Page 97 111213.14.59 11.0 FAULT FINDING SYMPTOM FAULT REMEDY Pressure produced by Intellisys set incorrectly Check and modify settings compressor is too high Pressure transducer may be Recalibrate or replace compressor is too high due to faulty, incorrectly calibrated or speed not reducing as demand not receiving pressure signal reduces Drive settings fault...

  • Page 98: Intellisys Faults

    111213.14.59 11.0 FAULT FINDING SYMPTOM FAULT REMEDY Discharge air is contaminated Aftercooler not functioning correctly Clean or replace with condensate Moisture separator drain trap faulty Overhaul or replace Continuous low speed / low ambient Review system requirements and operation causing condensate build contact your local IR representative Compressor package draws too Compressor operating above rated...
  • Page 99 111213.14.59 11.0 FAULT FINDING FAULT CAUSE REMEDY Remote start failure Remote start button is pressed Check operation of buttons or operating after machine is running or procedures remote start button remains closed Remote stop failure Remote stop button remains Check operation of buttons or operating open and either start button is procedures pressed...

  • Page 100: Drive Faults

    111213.14.59 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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This manual is also suitable for:

Irn50-200h-ccIrn75-160k-2sIrn100-200h-2sR190-225ne

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