Ingersoll-Rand XF250 Operator's Manual
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Ingersoll-Rand XF250 Operator's Manual

Ingersoll-Rand XF250 Operator's Manual

Contact-cooled rotary screw air compressor
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RELEASED 06/Dec/2018 22:26:36 GMT
Contact-Cooled Rotary Screw Air Compressor
XF250, HP250, EP250, XP250
XF300, HP300, EP300
XFE300, EPE300, HPE300
XF350, EP350, HP350
XF400, EP400, HP400
XF450, EP450, HP450
EPE250-2S, XFE250-2S, HPE250-2S, HXPE250-2S
EPE300-2S, XFE300-2S, HPE300-2S, HXPE300-2S
EPE350-2S, XFE350-2S, HPE350-2S, HXPE350-2S
EPE400-2S, XFE400-2S, HPE400-2S, HXPE400-2S
EPE450-2S, XFE450-2S, HPE450-2S, HXPE450-2S
EPE500-2S, XFE500-2S, HPE500-2S, HXPE500-2S
Operators Manual/Options
Operators Manual/Options
EN
Manual del operador/Opciones
ES
FR
Manuel de l'opérateur/Options
PT
Opções/Manual de operadores
Save These Instructions
80447097
Revision B
November 2018

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Summary of Contents for Ingersoll-Rand XF250

  • Page 1 RELEASED 06/Dec/2018 22:26:36 GMT 80447097 Revision B November 2018 Contact-Cooled Rotary Screw Air Compressor XF250, HP250, EP250, XP250 XF300, HP300, EP300 XFE300, EPE300, HPE300 XF350, EP350, HP350 XF400, EP400, HP400 XF450, EP450, HP450 EPE250-2S, XFE250-2S, HPE250-2S, HXPE250-2S EPE300-2S, XFE300-2S, HPE300-2S, HXPE300-2S...

  • Page 2: Table Of Contents

    RELEASED 06/Dec/2018 22:26:36 GMT CONTENTS CONTENTS ........2 COOLANT/AIR SEPARATION SYSTEM .

  • Page 3: Foreword

    RELEASED 06/Dec/2018 22:26:36 GMT FOREWORD The contents of this manual are considered to be proprietary The use of the machine in any of the situation types listed and confidential to Ingersoll Rand and should not be in table 1:− reproduced without the prior written permission of Is not approved by Ingersoll Rand, Ingersoll Rand.

  • Page 4: Safety

    RELEASED 06/Dec/2018 22:26:36 GMT SAFETY Locate, read, understand and follow all Danger, Warning, It is your responsibility to make this information available to Caution, and Operating Instructions on the product and in all others. Manuals. Failure to comply with safety precautions described If you have any questions about safety or procedures not in the manuals supplied with the product, this manual or any included in this manual, ask your supervisor or contact any...

  • Page 5: Receipt Of Equipment

    RELEASED 06/Dec/2018 22:26:36 GMT RECEIPT OF EQUIPMENT INSPECTION TOOLS When you receive the compressor please inspect it closely. Remove compressor unit from wooden skid. A crowbar and Any indication of careless handling by the carrier should be hammer will be needed. noted on the delivery receipt especially if the compressor will not be immediately uncrated.

  • Page 6: Installation

    RELEASED 06/Dec/2018 22:26:36 GMT INSTALLATION 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.
  • Page 7 RELEASED 06/Dec/2018 22:26:36 GMT INSTALLATION NOTE For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel. It is possible that additional condensation can occur if the downstream piping cools the air even further and low points in the piping systems should be provided with driplegs and traps.

  • Page 8: Electrical Installation

    RELEASED 06/Dec/2018 22:26:36 GMT INSTALLATION When two rotary units are operated in parallel, provide an isolation valve and drain trap for each compressor before the common receiver. PRESSURE RELIEF VALVE ELECTRICAL INSTALLATION PRESSURE GAUGE Locate the compressor data plate on the side of the cooler box or end of the unit.
  • Page 9 RELEASED 06/Dec/2018 22:26:36 GMT INSTALLATION Inspect the motor and control wiring for tightness. Close and Open the starter box door. fasten the starter box door. Interchange any two line connections (L1, L2 or L3) at the ROTATION CHECK starter. Close and fasten the starter box door. Recheck for correct rotation.

  • Page 10: Outdoor Sheltered Installation

    RELEASED 06/Dec/2018 22:26:36 GMT INSTALLATION OUTDOOR SHELTERED INSTALLATION Option requires a separate power source to operate internal heaters. Many times a compressor must be installed outside due to • Arrange the machine with the Intellisys controller/ jobsite conditions or limited space within a manufacturing starter enclosure facing away from the sun as radiant facility.

  • Page 11: Intellisys

    RELEASED 06/Dec/2018 22:26:36 GMT INTELLISYS INTELLISYS CONTROLLER INTELLISYS CONTROLS EMERGENCY STOP there is sufficient demand for air. Pressing this switch stops the compressor immediately. The compressor can not be restarted until the switch is manually reset. Turn the switch knob clockwise to reset. STOP EMEG Pressing this button will activate the unloaded stop...

  • Page 12: Display Screen

    RELEASED 06/Dec/2018 22:26:36 GMT INTELLISYS Operation” set point. When the value of a specific machine operating parameter is highlighted on the display screen for the purpose of The other five buttons provide access to various operator- changing that value, the buttons are used to change the selectable functions and machine operating conditions.

  • Page 13: Main Menu

    RELEASED 06/Dec/2018 22:26:36 GMT INTELLISYS Separator Pressure Drop CURRENT STATUS screen from other screens if no buttons are % Load Modulation pressed within 30 seconds. Unloaded Inlet Vacuum The MAIN MENU screen can be accessed from the CURRENT Coolant Pressure STATUS screen by pressing the MAIN MENU button, identified Time &...

  • Page 14: Operator Setpoints

    RELEASED 06/Dec/2018 22:26:36 GMT INTELLISYS OPERATOR SETPOINTS -OPERATOR SETPOINTS- Offline Pressure 1 0 0 P S I 103 PSI Online Pressure Ready To Start 93 PSI MAIN MENU SELECT STATUS Setpoints are user-adjustable variables in the controller logic pair of setpoint item and value display lines will again be that can be set using the OPERATOR SETPOINTS screen.

  • Page 15: Options

    RELEASED 06/Dec/2018 22:26:36 GMT INTELLISYS OPTIONS -OPTIONS- Auto Restart 1 0 0 P S I Auto Restart Time Ready To Start 10 MINUTES STATUS SELECT MAIN MENU Options are turned on or off and their associated values are option is installed, this setpoint is the minimum temperature set using the OPTION screen.

  • Page 16: Alarm History

    RELEASED 06/Dec/2018 22:26:36 GMT INTELLISYS Sensor 4APT The calibration screen can be exited by pressing either the Sensor 5CPT STATUS or MAIN MENU buttons. If no buttons are pressed Sensor 6APT within 30 seconds, the display will return to the CURRENT STATUS screen.

  • Page 17: Integral Sequencing

    RELEASED 06/Dec/2018 22:26:36 GMT INTELLISYS INTEGRAL SEQUENCING -INTEGRAL SEQUENCING- Lead Compressor 1 0 0 P S I Total Compressors Ready To Start STATUS SELECT MAIN MENU Integral Sequencing is set up using the INTEGRAL INTEGRAL SEQUENCING RANGE STEP UNIT SEQUENCING screen. A description of integral is in section Lead Compressor On/Off/Always/Never 7.0.
  • Page 18 RELEASED 06/Dec/2018 22:26:36 GMT INTELLISYS -CURRENT STATUS- Package Discharge Temp 1 0 0 P S I 103°F Running Unloaded Airend Discharge Temp Mode: MOD/ACS 193°F WARNING MAIN MENU Pressing the WARNING button will return the display to the the sump pressure is greater than the compressor’s rated WARNING screen and the RESET button.

  • Page 19: Alarms

    RELEASED 06/Dec/2018 22:26:36 GMT INTELLISYS ALARMS High Airend Disch Temp 1 0 0 P S I 229°F STOPPED BY ALARM Press RESET Twice Mode: MOD/ACS MAIN MENU RESET STATUS When an Alarm occurs, an exclamation mark will flash on Pressing the STATUS button will display the ALARM STATUS the display screen as shown above.

  • Page 20: Scheduled Preventative Maintenance

    RELEASED 06/Dec/2018 22:26:36 GMT SCHEDULED PREVENTATIVE MAINTENANCE MAINTENANCE SCHEDULE The maintenance schedule specifies all recommended operating condition. Service at the interval listed or after that maintenance required to keep the compressor in good number of running hours, whichever occurs first. Time Interval (whichever comes first) Action Part or Item...

  • Page 21: Coolant Filter

    RELEASED 06/Dec/2018 22:26:36 GMT SCHEDULED PREVENTATIVE MAINTENANCE COOLANT FILTER ITEMS REQUIRED In addition to the tools normally found in any reasonably To check the condition of the coolant filter, the compressor equipped serviceman’s toolbox, the following items should must be running. Observe “Injected Temperature” on the be available at the work site: CURRENT STATUS display screen.

  • Page 22: Separator Tank Scavenge Screen/Orifice

    RELEASED 06/Dec/2018 22:26:36 GMT SCHEDULED PREVENTATIVE MAINTENANCE SEPARATOR TANK SCAVENGE SCREEN/ORIFICE COOLANT DRAIN COOLANT SEPARATOR ELEMENT To check condition of separator element, run compressor in WARNING full load mode and at rated pressure and observe “Separator Pressure Drop” on the CURRENT STATUS display screen. If the Hot coolant can cause severe injury.

  • Page 23: Cooler Cores: Cleaning

    RELEASED 06/Dec/2018 22:26:36 GMT SCHEDULED PREVENTATIVE MAINTENANCE Inspect tank scavenge screen and orifice. Clean if necessary TOOLS REQUIRED following instructions in Section SEPARATOR TANK SCAVENGE • Screwdriver SCREEN/ORIFICE. • Wrench set Install scavenge tube down into the tank until the tube just •...
  • Page 24 SCHEDULED PREVENTATIVE MAINTENANCE AFTERCOOLER Grease relief along shaft can occur, precluding necessity of removing this plug if inaccessible. The inlet grease gun Following are instructions for the removal and internal fittings and outlet plugs (or spring-loaded reliefs) are located cleaning of aftercoolers. at each end of the motor housing.

  • Page 25: Coolant/Lubricant Changeout

    RELEASED 06/Dec/2018 22:26:36 GMT SCHEDULED PREVENTATIVE MAINTENANCE The bulletin provides special procedures for rotation and connection may be the cause of problems. lubrication of compressors during storage. This section gives guidelines for removing/replacing the Before actual start-up of the compressor, the unit must Intellisys Controller assembly and the Intellisys Power Supply be drained of coolant containing vapor space inhibitors.
  • Page 26 SCHEDULED PREVENTATIVE MAINTENANCE FLUID AND VIBRATION MONITORING Ingersoll Rand recommends incorporating predictive maintenance, specifically the use of coolant and vibration analysis, into all Preventative Maintenance programs. Predictive Maintenance is designed to increase system reliability and prevent costly downtime. Through the use of sophisticated diagnostic tools, including fluid, vibration, and optional air analysis, IRA Certified Service Technicians can 100%...

  • Page 27: Systems

    RELEASED 06/Dec/2018 22:26:36 GMT SYSTEMS GENERAL SYSTEM INFORMATION machine), a condensate separator, and an automatic drain trap. The compressor is an electric motor driven, single stage, screw compressor—complete with accessories piped, wired By cooling the discharge air, much of the water vapor and baseplate mounted.

  • Page 28: Coolant/Air Separation System

    RELEASED 06/Dec/2018 22:26:36 GMT SYSTEMS During unloaded operation, the butterfly inlet valve closes, STEPPER MOTOR INLET CONTROL via stepper motor, and the blowdown solenoid valve opens, The inlet valve is opened and closed by a stepper motor expelling any compressed air back to the compressor inlet. mounted on the inlet valve.

  • Page 29: Automatic Start/Stop Control

    RELEASED 06/Dec/2018 22:26:36 GMT SYSTEMS the Intellisys, allowing the stepper motor to “trim” the inlet the line pressure remains above the lower set point for as valve position as dictated by the line pressure. long as the set time, the compressor will stop. At the same time the display will indicate the compressor has shut down The modulating pressure range is 10 psig (.7 bar).

  • Page 30: Remote Start/Stop

    RELEASED 06/Dec/2018 22:26:36 GMT SYSTEMS Some Examples of Operation loaded 12 minutes and then unloads. EXAMPLE 1 After 12 minutes of running, the 10 minute mandatory run- time for timer “A” has been met but the compressor must The operator selects an unloaded run time of 2 minutes in continue to run unloaded an additional 10 minutes to satisfy the OPTION routine and starts the compressor.

  • Page 31: Troubleshooting Chart

    RELEASED 06/Dec/2018 22:26:36 GMT TROUBLESHOOTING CHART TROUBLE CAUSE &/OR DISPLAY WHAT TO DO Compressor fails to start. 110/120V control voltage not available, • Check fuses. Check transformer and wiring connections. CONTROL POWER LOSS STARTER FAULT • Inspect contactors. EMERGENCY STOP •...
  • Page 32 RELEASED 06/Dec/2018 22:26:36 GMT TROUBLESHOOTING CHART TROUBLE CAUSE &/OR DISPLAY WHAT TO DO Low system air pressure Compressor running in UNLOAD Mode. • Press LOAD button. Controller off-line set point too low. • Press STOP button. Set off-line set point at a higher value. Dirty air filter element.

  • Page 33: Options

    OPTIONS POWER OUTAGE RESTART WITH SCHEDULED the separator element by subtracting the dry side sump pressure (6APT) from the wet side sump pressure (3APT). Do START/STOP not enable this option if the separator delta-p sensor is not For customers that have interruptions in their incoming installed.
  • Page 34 RELEASED 06/Dec/2018 22:26:36 GMT OPTIONS loaded, if pressure falls to its online set point, the lead before transferring the lead. If Lead Change - Hours is set to compressor will transmit a load command to the next 0, the set points Lead Change - Day and Lead Change - Time compressor in sequence.

  • Page 35: Water Quality Recommendations

    RELEASED 06/Dec/2018 22:26:36 GMT WATER QUALITY RECOMMENDATIONS Water quality is often overlooked when the cooling system precipitation of calcium carbonate out of the water. This of a water cooled air compressor is examined. Water quality is dependent on temperature and pH. The higher the pH determines how effective the heat transfer rate, as well as the value the greater the chance of scale formation.
  • Page 36 RELEASED 06/Dec/2018 22:26:36 GMT ingersollrandproducts.com © 2018 Ingersoll-Rand...

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