80441454en Compresor Nirv
80441454en Compresor Nirv
80441454en Compresor Nirv
C.C.N. : 80441454
REV. : A
en pt it es DATE : MAY 2004
Machine models represented in this manual may be used in various locations world–wide. Machines sold and
shipped into European Union Territories require that the machine display the EC Mark and conform to various
directives. In such cases, the design specification of this machine has been certified as complying with EC directives.
Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being
rendered invalid. A declaration of that conformity follows:
WE,
DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY,
THE PRODUCT(S)
H. SEDDON
01/04
U.K. PRESSURE SYSTEM REGULATIONS – FINAL IMPLEMENTATION 1 JULY 1994
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 of unapproved usage are also given, however Ingersoll–Rand cannot
the prior written permission of Ingersoll–Rand. anticipate every application or work situation that may arise.
Nothing contained in this document is intended to extend any IF IN DOUBT CONSULT SUPERVISION.
promise, warranty or representation, expressed or implied, regarding
the Ingersoll–Rand products described herein. Any such warranties or
other terms and conditions of sale of products shall be in accordance This machine has been designed and supplied for use only in the
with the standard terms and conditions of sale for such products, which following specified conditions and applications:
are available upon request. . Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
This manual contains instructions and technical data to cover GENERAL INFORMATION section of this manual.
routine operation and scheduled maintenance tasks by operation and
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised Ingersoll–Rand service The use of the machine in any of the situation types listed in
department. table 1:–
a) Is not approved by Ingersoll–Rand,
b) May impair the safety of users and other persons, and
The design specification of this machine has been certified as c) May prejudice any claims made against Ingersoll–Rand.
complying with E.C. directives. Any modification to any part is
absolutely prohibited and would result in the CE certification and
marking being rendered invalid. TABLE 1
Use of the machine to produce compressed air for:
All components, accessories, pipes and connectors added to the a) direct human consumption
compressed air system should be: b) indirect human consumption, without suitable filtration and purity
. of good quality, procured from a reputable manufacturer and, checks.
wherever possible, be of a type approved by Ingersoll–Rand.
. clearly rated for a pressure at least equal to the machine maximum Use of the machine outside the ambient temperature range
allowable working pressure. specified in the GENERAL INFORMATION SECTION of this manual.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation, operation and Use of the machine where there is any actual or foreseeable risk of
maintenance. hazardous levels of flammable gases or vapours.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED
Details of approved equipment are available from Ingersoll–Rand IN POTENTIALLY EXPLOSIVE ATMOSPHERES, INCLUDING
Service departments. SITUATIONS WHERE FLAMMABLE GASES OR VAPOURS MAY BE
PRESENT.
The use of non–genuine spare repair parts other than those Use of the machine fitted with non Ingersoll–Rand approved
included within the Ingersoll–Rand approved parts list may create components.
hazardous conditions over which Ingersoll–Rand has no control.
Therefore Ingersoll–Rand does not accept any liability for losses Use of the machine with safety or control components missing or
caused by equipment in which non–approved repair parts are installed. disabled.
Standard warranty conditions may be affected.
2_C
WARNING: Electrical shock risk. WARNING – Hot surface. WARNING – Corrosion risk.
WARNING – Pressure control. WARNING – Air/gas flow or Air discharge. WARNING – Flammable liquid.
Do not stand on any service valve or other Do not remove the Operating and Maintenance
parts of the pressure system. Do not use fork lift truck from this side. manual and manual holder from this machine.
Do not operate the machine without the guard Do not operate with the doors or enclosure Do not open the service valve before the
being fitted. open. airhose is attached
No naked lights. Use fork lift truck from this side only. Tie down point
WATER OUT
WARNING! Compressed air must not be used for a direct feed to any form of
Hazard that CAN cause DEATH, SEVERE INJURY or substantial breathing apparatus or mask.
property damage if ignored. Instructions which must be followed
If the discharged air is to be ultimately released into a confined
precisely to avoid injury or death. space, adequate ventilation must be provided.
CAUTIONS! When using compressed air always use appropriate personal
Cautions call attention to instructions which must be followed protective equipment.
precisely to avoid damaging the product, process or its surroundings.
All pressure containing parts, especially flexible hoses and their
NOTES couplings, must be regularly inspected, be free from defects and be
Notes are used for supplementary information. replaced according to the Manual instructions.
BREATHING AIR PRECAUTION Avoid bodily contact with compressed air.
Ingersoll–Rand air compressors are not designed, intended or
approved for breathing air. Compressed air should not be used for All safety valves must be checked periodically for correct operation.
breathing air applications unless treated in accordance with all
Do not over–pressurize the receiver tank or similar vessels beyond
applicable codes and regulations.
design limits.
Do not use a receiver tank or similar vessels that fail to meet the
General Information design requirements of the compressor. Contact your distributor for
assistance.
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation. Do not drill into, weld or otherwise alter the receiver tank or similar
vessels.
Ensure that the Operation and Maintenance manual is not removed
permanently from the machine.
Ensure that maintenance personnel are adequately trained, Materials
competent and have read the Maintenance Manuals.
The following substances are used in the manufacture of this
Do not point air nozzles or sprayers toward anyone. machine and may be hazardous to health if used incorrectly:
. preservative grease
Compressed air and electricity can be dangerous. Before . rust preventative
undertaking any work on the compressor, ensure that the electrical . compressor coolant
supply has been isolated and the compressor has been relieved of all
pressure. For further information, consult Material Data Sheet 80440043
(LUBE OIL)
Wear eye protection when operating or servicing compressor.
AVOID INGESTION, SKIN CONTACT AND INHALATION OF
All persons positioned near to operating machinery should be FUMES
equipped with hearing protection and given instructions on its use in
accordance with workplace safety legislation.
Make sure that all protective covers are in place and that the Transport
canopy/doors are closed during operation.
When loading or transporting machines ensure that the specified
The specification of this machine is such that the machine is not lifting and tie down points are used.
suitable for use in flammable gas risk areas.
Lifting equipment must be properly rated for the weight of the
Installation of this compressor must be in accordance with compressor.
recognised electrical codes and any local Health and Safety Codes.
Do not work on or walk under the compressor while it is suspended.
The use of plastic bowls on line filters can be hazardous. Their
safety can be affected by either synthetic lubricants, or the additives
used in mineral oils. Ingersoll –Rand recommends that only filters with
Electrical
metal bowls should be used on a pressurised system.
Keep all parts of the body and any hand–held tools or other
conductive objects, away from exposed live parts of the compressor
Compressed air electrical system. Maintain dry footing, stand on insulating surfaces
and do not contact any other portion of the compressor when making
Compressed air can be dangerous if incorrectly handled. Before adjustments or repairs to exposed live parts of the compressor
doing any work on the unit, ensure that all pressure is vented from the electrical system.
system and that the machine cannot be started accidentally.
WARNING
WARNING Any electrical connections or adjustments should only be
Imposing a normal or emergency stop on the compressor will made by a suitably qualified electrician
only relieve pressure upstream of the discharge check valve.
If maintenance work is required downstream of this valve, ensure
that all pressure is relieved at the process vent point external to Close and lock all access doors when the compressor is left
the compressor. unattended.
Do not use extinguishers intended for Class A or Class B fires on
electrical fires. Use only extinguishers suitable for class BC or class
ABC fires.
Ensure that the machine is operating at the rated pressure and that
the rated pressure is known to all relevant personnel. Attempt repairs only in clean, dry, well lighted and ventilated areas.
All air pressure equipment installed in or connected to the machine Connect the compressor only to electrical systems that are
must have safe working pressure ratings of at least the machine rated compatible with its electrical characteristics and that are within it’s rated
pressure. capacity.
SL & SM 37 & 45 SL, SM & SH 55 & 75
L & H 50 & 60 L, H & HH 75 &100
SAFETY 11
Mobile Telephones
The correct operation of this machine may be affected by the nearby
use of a mobile telephone. Ensure that such telephones, when in use,
are kept at least 5 metres from the perimeter of a machine which is
operating or is being worked on whilst connected to its power supply.
Condensate disposal
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.
AC
39898960
Revision 03
KEY
WC
39898978
Revision 02
KEY
The gearcase is vented to a mounted breather. The breather The Intellisys system has been designed to carry out this function
prevents oil vapour from escaping the sump area. The breather utilising a software module. Automatic Start–Stop is standard on all
exhaust is piped to the plenum area of the package. Sierra compressors.
COOLING SYSTEM During periods of low air demand, if the line pressure rises to the
upper set point, the Intellisys controller begins to time out. If the line
The intercooler, aftercooler, oil cooler, fan and motor are an integral pressure remains above the lower set point for as long as the set time,
assembly. The heat exchanger and fan are mounted vertically. Cooling the compressor will stop. At the same time, the Automatic Restart light
air flows through the left side of the enclosure, through the heat on the display panel will be lit to indicate the compressor has shut down
exchangers and discharges through the top of the package. automatically and will restart automatically. An automatic restart will
occur when the line pressure drops to the lower set point.
COOLING SYSTEM (WATERCOOLED)
The intercooler, aftercooler and oilcooler are shell and tube type The upper and lower set points and shutdown delay time are set on
heat exchangers. The intercooler and aftercooler are ”water in the the control panel. There is a 10 second delay after shutdown during
shell” design. the oil cooler employs ”water in the tube”. which the compressor will not restart even if line air pressure drops
Cooling water flows through each of the three components in below the lower set point. This is to allow the motor to come to a
parallel. A water solenoid shut off valve is provided in the water complete stop and the controller to collect current data of operating
discharge line from the package. condition. If line air pressure is below the lower set point at the end of
10 seconds, the unit will start unless the load delay timer is set greater
than 10 seconds.
The tube bundles are removable for ease of cleaning.
Delay load time
ELECTRICAL SYSTEM
This is the amount of time the line pressure must remain below the
The electrical system of the compressor utilises the online set point before the compressor will load or start (if the unit was
microprocessor–based INTELLISYS controller.The standard stopped due to an auto start/stop situation). This timer will not delay
electrical/electronic components, contained within a readily accessible loading after a start or if the time is set to 0. When the delay load timer
enclosure include: becomes active, the display will switch to line pressure (if not displaying
line pressure at that time) and then display the delay load countdown.
Once the countdown reaches 0, the unit will load or start and the display
1. INTELLISYS controller will return to line pressure. The display select arrows are inactive during
2. Star–Delta compressor motor starter, with auxiliary contacts and the delay load countdown.
overload relays.
3. Cooling fan manual motor starter and circuitbreaker or fuses.
Automatic start/stop operation
Star–delta type starter When in operation, the compressor must meet two specific timing
intervals before the Intellisys controller will stop the unit in an Automatic
By use of the Star–Delta type starter, the compressor motor can be Start/Stop situation.
started and accelerated using a greatly reduced ”inrush” electric
current. The starter is completely automatic and controlled by the
INTELLISYS controller. Refer to the electrical schematic. For this discussion, the timers will be called timer ”A” and timer ”B”.
SECOND: After the compressor has started and reached the off–line
setting and has unloaded, timer ”B” requires the unit to run unloaded for
a period of time that the operator can adjust between 2 and 20 minutes. WARNING
This machine is remote start and
The setting of timer ”B” is part of the customer set–point routine and stop equipped.
the timer cancels any accumulated time if the compressor reloads Disconnect power before servicing.
before the timer cycle has finished. May start or stop at any time.
Lock and tag out.
Can cause severe injury or death.
NOTE This unloaded run time may, or may not, be included in the
See Operators / Instruction Manual.
mandatory 10 minute run time used to cool the motor windings.
When the compressor has completed the settings of both timer ”A”
and timer ”B”, the controller stops the compressor, turns on the
automatic restart light and displays AUTOMATIC RESTART in the
message display.
POWER OUTAGE RESTART OPTION
Pressure sensor 4APT continues to monitor the package discharge The Power Outage Restart option is for installations that have
pressure and sends information to the controller which automatically interruptions in their incoming power supply to the compressor and
restarts the compressor when the pressure falls to the on–line setting. must maintain an uninterrupted supply of compressed air. When turned
on, the option allows the compressor to automatically restart and load
10 seconds after incoming power is restored after a power interruption.
An advantage to this method of automatic start/stop control is Suitable visible and audible warnings are given before restart.
allowing the compressor to stop much sooner in certain situations and
timer settings, thereby reducing power costs.
SEQUENCER CONTROL
REMOTE START/STOP OPTION Sequencer control capability can be added to the electronic
control system by utilising a sequencer interface. This option is
The remote start/stop option allows the operator to control the available as a field installation kit.
compressor from a remote mounted start/stop station. This option may
be factory installed or a field installation kit is available. This option is
a plugin PROM module. HIGH CONDENSATE LEVEL SWITCH
This option prevents high condensate levels in the interstage
With the optional plug–in PROM installed, two different switches moisture separator, providing added protection against condensate
can be wired to the starter interface board for remote start/stop. (Refer carryover into the second stage compression module. If the
to the electrical schematic for wiring locations). The switches are condensate drain system becomes clogged or inoperative, this switch
customer supplied and must be of momentary type. The stop switch would signal the controller to shut the unit down and display a HIGH
contacts are normally closed / the start switch contacts are normally COND LEVEL alarm. The option may be factory installed or ordered as
open. a field installation kit.
AC/WC
39892302
Revision 07
04/04
Note:
1. Main disconnect and branch circuit protection to be provided by the customer.
2. Dashed lines represent wiring by customer.
3. Sizing of electrical components, not supplied by Ingersoll–Rand, is the responsibility of the customer and should be done in accordance with the
information on the compressor data plate, national and local electrical codes.
KEY
AC 50Hz
AC (50Hz)
39898903
Revision 02
Sheet 1
KEY
A Starter box door clearance area J 1/4” BSPT Intercooler manual condensate drain
B Cooling air exhaust K 1/2” BSPT Aftercooler condensate drain
C Air intake L 1/2” BSPT Intercooler condensate drain
D Starter box M Seal vent opening – do not plug
E Compressor air intake N 1/4” BSPT Shaft seal drain. Do not plug.
F 1” BSPT Breather piping connection P Base drains
G 11/2” BSPT Air discharge S Fork lift truck channels
H 1/ ” BSPT Aftercooler manual condensate drain T Power inlet location for conduit
4
AC (50Hz)
39898903
Revision 02
Sheet 2
WC (50Hz)
39898895
Revision 02
Sheet 1
KEY
A Starter box door clearance area K 1/2” BSPT Aftercooler condensate drain
B Cooling air exhaust L 1/2” BSPT Intercooler condensate drain
C Air intake M Seal vent opening – do not plug
D Starter box N 1/4” BSPT Shaft seal drain. Do not plug.
E Compressor air intake P Base drains
F 1” BSPT Breather piping connection S Fork lift truck channels
G 11/2” BSPT Air discharge T Power inlet location for conduit
H 1/ ” BSPT Aftercooler manual condensate drain X 11/2” BSPT Water out
4
J 1/4” BSPT Intercooler manual condensate drain Y 11/2” BSPT Water in
WC (50Hz)
39898895
Revision 02
Sheet 2
AC (60Hz)
39902275
Revision 03
Sheet 1
KEY
A Starter box door clearance area J 1/4” NPT Intercooler manual condensate drain
B Cooling air exhaust K 1/2” BSPT Aftercooler condensate drain
C Air intake L 1/2” BSPT Intercooler condensate drain
D Starter box M Seal vent opening – do not plug
E Compressor air intake N 1/4” NPT Shaft seal drain. Do not plug.
F 1” NPT Breather piping connection S Fork lift truck channels
G 11/2” NPT Air discharge T Power inlet location for conduit
H 1/ ” NPT Aftercooler manual condensate drain
4
AC (60Hz)
39902275
Revision 03
Sheet 2
WC (60Hz)
39902325
Revision 03
Sheet 1
KEY
A Starter box door clearance area K 1/2” BSPT Aftercooler condensate drain
B Cooling air exhaust L 1/2” BSPT Intercooler condensate drain
C Air intake M Seal vent opening – do not plug
D Starter box N 1/4” NPT Shaft seal drain. Do not plug.
E Compressor air intake S Fork lift truck channels
F 1” NPT Breather piping connection T Power inlet location for conduit
G 11/2” NPT Air discharge X 11/2” NPT Water out
H 1/ ” NPT Aftercooler manual condensate drain Y 11/2” NPT Water in
4
J 1/4” NPT Intercooler manual condensate drain
WC (60Hz)
39902325
Revision 03
Sheet 2
KEY UNPACKING
1. Compressor The compressor will normally be delivered with a polythene cover.
If a knife has to be used to remove this cover ensure that the exterior
2. Air Receiver paintwork of the compressor is not damaged.
3. Air Dryer
4. Compressed air filters Ensure that all transport and packing materials are discarded.
IMPORTANT
NOTE: Remove any shipping brackets particularly the soft mount
The diagram above shows two typical simple installations. transit braces painted in primer.
Items [2] to [5] are optional or may be existing items of plant. Refer
to your Ingersoll–Rand distributor / representative for specific
recommendations.
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation. LOCATION IN THE PLANT
Ensure that the position of the emergency stop device is known and
recognised by its markings. Ensure that it is functioning correctly and The compressor can be installed on any level floor capable of
that the method of operation is known. supporting it. A dry, well ventilated area where the atmosphere is as
clean as possible is recommended.
NOTICE:
Sufficient space all round and above the compressor must be The drain line must slope downward from the base to work
allowed, to enable the effective removal of the cooling air which, in turn, properly.
will reduce the risk of re–circulating the cooling air back through the
compressor.
Adequate clearance needs to be allowed around and above the It is possible that additional condensation can occur if the
machine to permit safe access for specified maintenance tasks. downstream piping cools the air even further and low points in the
piping systems should be provided with driplegs and traps.
DISCHARGE PIPING Ensure all persons concerned are suitably competent with electrical
installations.
Discharge piping should be at least as large as the discharge
connection of the compressor. All piping and fittings should be suitably
rated for the discharge pressure. Ensure that there is a safe working procedure which has been
issued by supervisory personnel, and that it is understood by all
persons concerned with the operation of the compressor.
Water temperature and pressure gauges should be installed in the FOULING: Biological and organic substances (slime) can also cause
water piping for use in any fault finding of the water system. problems, but in elevated temperature environments such as cooling
processes they are not a major concern. If they create problems with
clogging, commercial shock treatments are available.
Water cleanliness is also extremely important. Strainers are
available from Ingersoll–Rand for units on open evaporative cooling
towers, etc., where precipitates and particulates are present in the To ensure good operation life and performance of the compressor
coolant stream. Cleaning of coolers as a result of fouling is a customer cooling system, the recommended acceptable ranges for different
responsibility. Therefore, it is highly recommended that proper water water constituents are included below:
strainers are utilised. In addition, water quality must meet the
requirements listed in WATER QUALITY RECOMMENDATIONS later
Corrosivity (Hardness, pH, Total dissolved solids, Temperature at inlet
in this section.
and Alkalinity should be analysed monthly, or if stable for 3 to 4 months,
analysed quarterly.
VENTING THE WATER SYSTEM Acceptable concentration:
Langelier Index 0 to 1
At the initial installation, or for startup after draining the water
system, proceed to vent the system as follows.
Iron content should be analysed monthly.
Acceptable concentration:
1. Locate the water system vent cock on top of the intercooler. 2 mg/l (2 ppm)
2. Open the water valve(s) allowing water to flow to the package. Sulphate content should be analysed monthly.
Acceptable concentration:
50 mg/l (50 ppm)
3. Open the vent cock and allow all air to escape from the system.
When water is observed at the vent cock, close it.
Chloride content should be analysed monthly.
Acceptable concentration:
The system is now properly vented.
50 mg/l (50 ppm)
1. Disconnect the inlet and discharge water lines from the connections Silica content should be analysed monthly.
located at the rear of the unit. Acceptable concentration:
100 mg/l (100 ppm)
2. Locate the oil cooler by removing the left and centre rear panels.
Remove the two drain plugs located at the end of the cooler. Dissolved Oxygen content should be analysed daily, or if stable,
analysed weekly.
Acceptable concentration:
Allow the system to completely drain. 0 mg/l (0 ppm) (as low as possible)
PRESSURE L M L M L M H L M H
7,0bar 8,5bar 7,0bar 8,5bar 7,0bar 8,5bar 10,0bar 7,0bar 8,5bar 10,0bar
WC WC
CAPACITY 6,0 5,1 7,6 6,5 9,6 8,6 7,7 12,5 11,6 10,7
m3/min.
CAPACITY 212 180 268 230 339 303 272 442 410 377
ft3/min.
FULL LOAD CURRENT – – – –
(MAXIMUM)
220V
A
STARTING CURRENT – – – –
(MAXIMUM)
220V
A
PRESSURE L 100 H 125 L 100 H 125 L 100 H 125 HH 150 L 100 H 125 HH 150
psig psig psig psig psig psig psig psig psig psig
WC WC
CAPACITY 6,05 5,27 7,60 6,56 9,42 8,14 7,58 11,90 11,50 10,71
m3/min.
CAPACITY 214 186 268 232 333 288 268 419 407 378
ft3/min.
FULL LOAD CURRENT 162 188 223 286
(MAXIMUM)
200V
A
*Equivalent continuous sound pressure level (workstation) (rated load) The applied voltage must be compatible with the motor and
compressor data plate ratings.
ELECTRICAL DATA
The control circuit transformer has different voltage tappings.
An independent electrical isolator should be installed adjacent to the Ensure that these are set for the specific applied voltage prior to
compressor. starting.
EMERGENCY STOP SWITCH (1) NOTE: For readings less than 1 hour, the hourmeter displays minutes.
After 1 hour, the hourmeter displays hours.
Pressing this switch stops the compressor immediately. The
compressor cannot be restarted until the switch is manually reset. Turn
clockwise to reset.
SET (7)
POWER INDICATOR LIGHT (2) The SET button is used to enter the set point procedure. The SET
Indicates that voltage is available to the Intellisys controller. button is also used to reset warnings and alarms. Pressing this button
once will clear a warning, pressing twice will clear an alarm.
START (3)
ARROWS (8)
If the display shows READY TO START, pressing this button will
start the compressor. The compressor will start and load automatically These buttons have several functions. If the Intellisys is in the set
if there is a demand for air. If in the display table, press this button to exit point mode, the ARROWS are used to change the set point values. If
the display table. Display will show ‘CHECKING MACHINE.’then the compressor has multiple alarms or warnings, the ARROWS are
‘READY TO START.’ used to scroll through these conditions. The ARROWS have a function
in the calibration routine, which will be described later.
Offline pressure is the first set point and XXXX stands for the value
of the set point. Press the SET button to select the set point to be A warning needs to be reset by an operator. The warning will clear
adjusted. Press the up and down arrow buttons to raise or lower the set when the RESET button is pressed once. The following is a list of the
point value. Press the SET button to move to the next set point. If the warning messages.
set point has been adjusted, press the SET button to enter the new
value. The display will flash to acknowledge. The next set point will then TEMPERATURE SENSOR FAIL
be displayed. If the value of the set point was not changed, pressing the This warning will occur whenever the Intellisys receives a faulty
SET button will only step to the next set point. value from one of the sensors, indicating that one of the sensors listed
When the SELECT OPTIONS set point is entered, the SELECT below has failed.
OPTIONS indicator will light, and the set points for options ‘AUTO – (3ATT)
STOP/START’ or ‘REMOTE STOP START’ will only be accessible and – (7ATT)
displayed if the option module is installed in the unit.
The ‘POWER FAILURE RESTART’ setpoints will only be displayed
if the combination ‘AUTO START STOP – REMOTE START STOP – HIGH TEMPERATURE
POWER FAILURE RESTART’ option module is installed in the unit. Package discharge temperature exceeds 60_C (140_F). (7ATT).
The set point routine can be exited by pressing the ‘DISPLAY/SELECT’
buttons. Exit will be automatic after 30 seconds.
ALARMS
When an alarm occurs the controller will shut an operating unit
The following is a list of the set points. Also included are maximum down. The alarm will be on and one of the following messages will be
and minimum limits, step size, and units of measure. displayed:
b) 2nd. stage inlet temperature exceeds 60_C (140_F). (3ATT). 12 ”TEMPERATURE SENSOR FAIL”
Will occur if the Intellisys controller receives an excessive value
from any of the following sensors:
c) 2nd. stage discharge temperature (4ATT) exceeds: . 1st stage discharge Resistance Temperature Detector (2ATT).
. 2nd stage discharge Resistance Temperature Detector (4ATT).
7.0 bar (100psi) – . Bearing oil temperature thermistor (5OTT).
220_C (428_F).
8.5 bar (125psi) –
13.HIGH CONDENSATE LEVEL
249_C (480_F).
Will occur if the condensate level in the intercooler moisture
10.0 bar (150psi) –
separator becomes too high.
254_C (489_F).
This alarm is only activated if a high condensate level switch is
d) Bearing oil temperature exceeds 77_C (170_F). (5OTT). installed.
PRIOR TO STARTING 6: Ensure that the electric motor and electrical equipment has not
become exposed or saturated with moisture / water. (See installation
section)
1: Ensure that the electrical wiring has been inspected and earthed.
. Do not destroy batteries or components containing asbestos
without containing the materials safely.
2: Check the lubricant level in the sight glass. Add lubricant if
necessary.
. Do not dispose of any pressure vessel that is not clearly marked
with its relevant data plate information or rendered unusable by drilling,
3: Ensure that the discharge air isolation valve is open. cutting etc.
4: Switch on the main electrical isolation switch. The power on . Do not allow lubricants or coolants to be released into land surfaces
indicator will illuminate, indicating that the line and control voltages are or drains.
available.
. Do not dispose of a complete machine without documentation
5: Ensure that no persons are in a hazardous position. relating to instructions for its use.
2. Check all power leads for tightness. 1. PRESS UNLOADED STOP. Compressor will immediately unload
and continue to run unloaded for 10 seconds and then stop.
Compressor will stop immediately if UNLOADED STOP is pressed
3. Check lubricating oil level and add as necessary. while unit is running unloaded.
4. Ensure that set points are adjusted appropriately. (See section F). 2. Open main isolator switch.
6. Close the main isolator ( POWER ON light ). STOPPING THE MACHINE IN AN EMERGENCY
Refer to the diagram T5373
7. Verify proper drive motor rotation. (See section E).
If the machine has to be stopped in an emergency DEPRESS THE
EMERGENCY STOP BUTTON (1) LOCATED ON THE
8. Verify proper fan motor rotation. (See section E). INSTRUMENT PANEL.
9. Ensure that all guards and enclosure panels are in place. This will over–ride the normal unload/stop button and will
immediately stop the machine without the 10 second delay.
Check the condensate drain functionality. Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
Change the oil filter element. system and that the machine cannot be started accidentally.
First 150 hours
Clean the condensate strainers. Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
1 month Check the cooler(s) for build–up of foreign Prior to attempting any maintenance work, ensure that:–
matter. Clean if necessary by blowing out . all air pressure is fully discharged and isolated from the system. If
with air. the automatic blowdown valve is used for this purpose, then allow
enough time for it to complete the operation.
Each 3 months Operate the safety valves manually to verify . the machine cannot be started accidentally or otherwise, by posting
that the valve mechanism is functioning warning signs and/or fitting appropriate anti–start devices.
correctly and that a small amount of air is . all residual electrical power sources (mains and battery) are
released. isolated.
Check all hoses for signs of deterioration, Prior to opening or removing panels or covers to work inside
cracks, hardening etc. a machine, ensure that:–
. anyone entering the machine is aware of the reduced level of
protection and the additional hazards, including hot surfaces and
2000 hours Lubricate the main motor drive end bearing. intermittently moving parts.
. the machine cannot be started accidentally or otherwise, by posting
Lubricate the main motor non–drive end
warning signs and/or fitting appropriate anti–start devices.
bearing.
OIL AND OIL FILTER COMPRESSOR MODULE INPUT SHAFT SEAL REPLACEMENT
Change the oil filter element at 150 hours initially and change the oil 1. Remove the main motor, observing all safety precautions in Section
and filter element every 8000 hours thereafter. A of this manual, utilising appropriate lifting gear as recommended and
following established safe working practices.
To change the oil and filter, the oil should be warm for more effective
drainage. Remove the right end enclosure panel. Remove the pipe plug 2. Loosen the grub screw on the compressor coupling half.
from the oil drain connection in the rear of the baseplate. Place a
suitable drain pan under the drain connection and open the valve.
3. Remove the 4 bolts retaining the seal housing and screw 2 of them
to remove the housing complete with seal.
When the gearcase is empty, close the valve and replace the pipe
plug. Position the empty drain pan under the oil filter. Remove the filter
and allow the oil to drain from the oil cooler as well. Wipe the sealing 4. Remove the old seal from the housing.
surface of the filter adaptor with a clean, lint–free cloth. Remove the
replacement filter from its protective package. Apply a small amount of
clean oil on the rubber seal and install the element. Screw the element 5. Remove the old wear sleeve from the input shaft.
on until the seal makes contact with the seat on the adaptor head.
Tighten the filter a further 1/2 to 3/4 of a turn. 6. Clean the seal housing, input shaft, wear sleeve inside diameter and
seal outside diameter (Absolutely grease free).
Unscrew the oil filler cap and add oil until the level reaches the top
of the gearcase sight glass. 7. Apply Loctite 620 to the sleeve and shaft journal. Install the sleeve
ensuring that the face of the sleeve is 4mm from the shoulder on the
Following oil and filter change start the compressor and run in shaft. Wipe excess Loctite.
unload mode. Check the oil filter and oil drain valve for leaks. Inspect
the gearcase sight glass, the correct oil level for the sump during 8. Apply Loctite 524 to the seal outer diameter and install into the seal
operation is 3/4 to 4/4 full. Some amount of foaming in the sight glass is housing with lip facing towards the compressor.
normal. The oil level is interpreted as the level in the sight glass below
the top foam, where a line of separation can be seen. If additional oil is
required, stop the compressor and add oil as needed. 9. Allow to cure for 2 hours.
Optional oil pressure and temperature gauges are available. 10.Clean the gasket face of the seal housing and gearcase housing
(Absolutely grease free).
Tools required
Wide–blade screwdriver or 3/8” wrench or 3/8” socket with ratchet 11.Apply Loctite 510 to the gasket face on the seal and gearcase
400mm adjustable wrench housings.
600mm adjustable wrench
Oil filter wrench
12.Lubricate the outside diameter of the installation tool with clean oil.
Parts required
Oil filter element. 13.Using the seal installation tool, slide the seal housing into place on
Approximately 42 litres (11 U.S. gall) of ULTRA COOLANT lubricant. the bearing housing, being careful not to tilt the housing and seal. Apply
axial pressure to the end of the installation tool while the seal leaves the
tool and enters the wear sleeve. The seal will slip between the tool and
GEARCASE BREATHER the sleeve if pressure is not applied.
To service the gearcase breather, remove the right end panel.
Remove the breather cover by unscrewing the four retaining screws. 14.Apply Loctite 242 to the 4 seal housing bolt threads and tighten.
Remove all of the breather media and clean with a suitable solvent.
Allow the media to dry. Re–install the media, the cover, and the
enclosure panel.
PROBLEM REMEDY
Compressor fails to start. 110/120V Control voltage not available.
Check the fuse. Check the transformers and wiring connections.
”EMERGENCY STOP”
Rotate emergency stop button to disengage, and press reset button.
”STARTER FAULT”
Inspect contactors. Replace if defective.
”MOTOR OVERLOAD”
Manually reset main or fan motor overload relay, and press reset button.
”STARTER FAULT”
Check for loose wires or faults on the control circuit
”MOTOR OVERLOAD”
Check for loose wires.
Check supply voltage.
Check heater size.
Check for obstructions at machine inlet and outlet openings.
AIR LEAK.
Check air piping system.
Ensure that manual condensate valves are closed.
Also make sure solenoid–operated condensate valves are not stuck open.