SSR UP5 22E, UP5 30, SSR M37PE

50Hz

OPERATION AND MAINTENANCE MANUAL

This manual contains important safety information and must be made available to personnel who operate and maintain this machine.

50Hz UP5 22E

 

 

50Hz UP5 30

50Hz M37PE 37

SERIAL No : SERIAL No : SERIAL No  :

2235000  –>

2245000  –>

2274000  –>

C.C.N.:   22255426  en REV.    :    D

DATE :   JUNE 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:

DECLARATION OF CONFORMITY WITH EC DIRECTIVES

 

 

98/37/EC, 97/23/EC, 93/68/EEC, 89/336/EEC

 

 

WE,

 

 

INGERSOLL–RAND COMPANY LIMITED SWAN LANE

HINDLEY GREEN WIGAN WN2 4EZ UNITED KINGDOM

 

 

 

DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY, THE PRODUCT(S)

 

 

SSR UP5 22E, UP5 30, SSR M37PE

 

 

TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

 

 

EN29001, EN292, EN60204–1, EN1012, EN50081, EN50082

 

 

ISSUED AT HINDLEY GREEN ON 01/01/2004 BY H.SEDDON, QUALITY ASSURANCE MANAGER.

 

 

 

 

1. H. SEDDON

 

 

 

 

 

 

 

 

 

 

 

 

 

 

03/04

 

 

 

 

 

Warranty

AIR COMPRESSOR GROUP

BONDED WARRANTY & REGISTERED START UP

 

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. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment in accordance with good industry practices and has complied with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the

Purchaser or others without Company‘s prior written approval.

 

The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period of time provided above.

 

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.

 

Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.

 

The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.

 

Note that this is Ingersoll–Rand standard warranty. Any warranty in force at the time of purchase of the compressor or negotiated as part of the purchase order may take precedence over this warranty.

 

Register on–line at air.irco.com

 

 

Ingersoll–Rand European Sales Company Swan Lane

Hindley Green Wigan WN2 4EZ

United Kingdom Phone: +44 (0)1942 257 171

 

Ingersoll Rand Asia Pacific C/O Ingersoll–Rand SEA (Pte) Ltd.

42 Benoi Road

Singapore 629903

Phone: +65 8611555

 

air.irco.com

 

 

 

CONTENTS & ABBREVIATIONS      1

 

 

 

CONTENTS

 

• CONTENTS

 

• FOREWORD

 

• DECALS

 

6             SAFETY

 

8             GENERAL INFORMATION

10           INSTALLATION / HANDLING OPERATING INSTRUCTIONS

 

• – GENERAL

 

19               – ELECTRO–PNEUMATIC

 

24           – INTELLISYS

 

32           MAINTENANCE

 

 

39           TROUBLE SHOOTING

 

ABBREVIATIONS & SYMBOLS

 

####       Contact Ingersoll–Rand for serial number

 

–>####   Up to Serial No.

####–>   From Serial No.

*             Not illustrated

t             Option

NR          Not required

AR          As required

SM         Sitemaster/Sitepack

HA          High ambient machine WC     Watercooled machine AC           Aircooled machine

ERS        Energy recovery system

T.E.F.C.  Totally enclosed fan cooled motor (IP55)

O.D.P.     Open drip proof (motor)

 

 

cs           Czech

da           Danish

de           German

el            Greek

en           English

es           Spanish

et            Estonian

fi            Finnish

fr            French

hu          Hungarian

it            Italian

lt            Lithuanian

lv            Latvian, Lettish

mt          Maltese

nl           Dutch

no          Norwegian

pl           Polish

pt           Portuguese

sk           Slovak

sl            Slovenian

sv           Swedish

zh           Chinese

 

2        FOREWORD

 

The intended uses of this machine are outlined below and examples of unapproved usage are also given, however Ingersoll–Rand cannot anticipate every application or work situation that may arise.     IF IN DOUBT CONSULT SUPERVISION.     This machine has been designed and supplied for use only in the following specified conditions and applications: .    Compression of  normal  ambient  air  containing  no  known  or detectable additional gases, vapours. or particles .    Operation within the ambient temperature range specified in the GENERAL INFORMATION section of this manual.     The use of the machine in any of the situation types listed in table 1:– a)  Is not approved by Ingersoll–Rand, b)  May impair the safety of users and other persons, and c)  May prejudice any claims made against Ingersoll–Rand. TABLE 1 Use of the machine to produce compressed air for: a)  direct human consumption b)  indirect human consumption, without suitable filtration and purity checks. Use of  the  machine  outside  the  ambient  temperature  range specified in the GENERAL INFORMATION SECTION of this manual. Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or vapours. THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES, INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR VAPOURS MAY BE PRESENT. Use of the machine fitted with non Ingersoll–Rand approved components. Use of the machine with safety or control components missing or disabled.

The contents of this manual are considered to be proprietary and confidential to Ingersoll–Rand and should not be reproduced without the prior written permission of Ingersoll–Rand.

 

 

Nothing contained in this document is intended to extend any 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 with the standard terms and conditions of sale for such products, which are available upon request.

 

 

This manual contains instructions and technical data to cover 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 department.

 

 

The design specification of this machine has been certified as 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.

 

All components, accessories, pipes and connectors added to the compressed air system should be:

.    of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved by Ingersoll–Rand.

.    clearly rated for a pressure at least equal to the machine maximum allowable working pressure.

.    compatible with the compressor lubricant/coolant.

.    accompanied with instructions for safe installation, operation and maintenance.

 

 

Details of approved equipment are available from Ingersoll–Rand Service departments.

 

 

The use of non–genuine spare repair parts other than those included within the Ingersoll–Rand approved parts list may create hazardous conditions over which Ingersoll–Rand has no control. Therefore Ingersoll–Rand does not accept any liabilitity for losses caused by equipment in which non–approved repair parts are installed. Standard warranty conditions may be affected.

 

 

 

Ingersoll–Rand  reserves   the   right   to   make   changes   and improvements to products without notice and without incurring any

The company accepts no responsibility for errors in translation of this manual from the original English version.

 

obligation to make such changes or add such improvements to                                                                                                               

 

products sold previously.

© COPYRIGHT 2004 INGERSOLL–RAND COMPANY

 

DECALS        3

ISO SYMBOLS

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

 

Prohibition / Mandatory	Information / Instructions	Warning

 

WARNING: Electrical shock risk.	WARNING – Pressurised vessel.	WARNING – Hot surface.
WARNING – Pressurised component or system.	WARNING – Air/gas flow or Air discharge.	Do not breathe the compressed air from this machine.
Use fork lift truck from this side only.	RESET	Do not use fork lift truck from this side.
Emergency stop.	On (power).	Off (power).
Read the Operation and Maintenance manual before operation or maintenance of this machine is undertaken.	Do not operate the machine without the guard being fitted.	Lifting point.
ROTATION	AIR DISCHARGE	COOLANT FILTER

 

4        DECALS

 

AUTOMATIC RESTART	MAINTENANCE	MAINTENANCE PROHIBITED
COOLANT DRAIN	CONDENSATE DRAIN	FILTER
FRAGILE	KEEP DRY	THIS WAY UP
USE NO HOOKS	NO SIDE CLAMPS	HOURS
Use ULTRA–Plus Coolant only Failure to use the specified coolant may result in damage to the machine	POWER	INSPECT
Every X months, if sooner than required by operating hours	CHANGE / REPLACE	CLEAN
POWER INLET (AC)	Pinch point hazard. Keep hands clear.Riesgo de punto de aplastamiento. Mantener las manos alejadas.

 

DECALS – ISO      5

 

 

 

 

VIEW BACK                                                   VIEW LEFT   INSIDE PACKAGE                       INSIDE STARTER DOOR     VIEW RIGHT VIEW FRONT

VIEW TOP

 

 

Item           ccn          Qty.                       Description                               Item            ccn          Qty.                   Description

 

1	92867498	1	Decal, air discharge	13	93165983	2	Decal, rotation
2	93166478	1	Decal, condensate drain	14	81295883	1	Decal, facia – Electro–Pneumatic
3	93166460	1	Decal, coolant drain		81295891	1	Decal, facia – Intellisys
4	92867407	1	Decal: Do not inhale	15	93165959	6	Decal, use guards when running
5	92930593	3	Decal, electric shock	16	32343097	1	Decal, voltage 380– 415/3/50
6	22248538	2	Decal, pinch hazard		32343105	1	Decal, voltage 220/3/50
7	92867530	2	Decal, Hot surface		32343113	1	Decal, voltage 550/3/50
8	22050611	1	Decal, Ingersoll–Rand signature	17	32343089	1	Decal, wiring schematic Star Delta 50Hz
horizontal 27.5“ 18					22062319	1	Tag, Air Care do you know
9       92930668         1      Decal, no maintenance before referring manual                                              19					22115661	1	Tag, rotation 50Hz
10      93171262         2      Decal, notice lift here                                      20					32344095	2	Tag, shipping bracket
11       92930585         1      Decal, Pressurised vessel                              21					93166502	1	Decal, replacement filter element

 

12      SPEC               1      Specifications, compressor package

 

6        SAFETY

 

 

DANGER!

Hazard that WILL cause DEATH, SEVERE INJURY or substantial property damage if ignored. Instructions must be followed precisely to

avoid injury or death.

 

WARNING!

Hazard that CAN cause DEATH, SEVERE INJURY or substantial property damage if ignored.   Instructions which must be followed

precisely to avoid injury or death.

 

CAUTIONS!

Cautions call attention to instructions which must be followed precisely to avoid damaging the product, process or its surroundings.

 

NOTES

Notes are used for supplementary information.

 

BREATHING AIR PRECAUTION

Ingersoll–Rand air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for breathing air  applications  unless  treated  in  accordance  with  all

applicable codes and regulations.

 

 

General Information

 

Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

 

Ensure that the Operation and Maintenance manual is not removed permanently from the machine.

 

Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

 

Do not point air nozzles or sprayers toward anyone.

 

Compressed air and electricity can be dangerous. Before undertaking any work on the compressor, ensure that the electrical supply has been isolated and the compressor has been relieved of all pressure.

 

Wear eye protection when operating or servicing compressor.

 

All persons positioned near to operating machinery should be 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 canopy/doors are closed during operation.

 

The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas.

 

Installation of this compressor must be in accordance with recognised electrical codes and any local Health and Safety Codes.

 

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 metal bowls should be used on a pressurised system.

 

 

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.

 

 

WARNING

Imposing a normal or emergency stop on the compressor will only relieve presure upstream of the minimum pressure valve on top of the separator tank.

If maintenance work is required downstream of this valve, ensure that all pressure is relieved at the process vent point external to the compressor

If more than one compressor is  connected  to  one  common downstream plant, effective isolation valves must be fitted and controlled by work procedures, so that one machine cannot accidently be pressurised / over pressurised by another.

 

Compressed air must not be used for a direct feed to any form of breathing apparatus or mask.

 

The discharged air contains a very small percentage of compressor lubricant and care should be taken to ensure that downstream equipment is compatible.

 

If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided.

 

When using compressed air always use appropriate personal protective equipment.

 

All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual instructions.

 

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.

 

Avoid bodily contact with compressed air.

 

All safety valves located in the separator tank must be checked periodically for correct operation.

 

Do not over–pressurize the receiver tank or similar vessels beyond design limits.

Do not use a receiver tank or similar vessels that fail to meet the design requirements of the compressor. Contact your distributor for assistance.

Do not drill into, weld or otherwise alter the receiver tank or similar vessels.

 

 

Materials

 

The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly:

.    preservative grease

.    rust preventative

.    compressor coolant

 

AVOID  INGESTION,  SKIN  CONTACT  AND  INHALATION  OF FUMES

 

 

Transport

 

When loading or transporting machines ensure that the specified lifting and tie down points are used.

 

Lifting equipment must be properly rated for the weight of the compressor.

 

Do not work on or walk under the compressor while it is suspended.

 

 

Electrical

 

Keep all parts of the body and any hand–held tools or other conductive objects, away from exposed live parts of the compressor electrical system. Maintain dry footing, stand on insulating surfaces and do not contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the compressor electrical system.

 

 

WARNING

Any electrical connections or adjustments should only be made by a suitably qualified electrician

 

 

 

 

Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all relevant personnel.

 

All air pressure equipment installed in or connected to the machine must have safe working pressure ratings of at least the machine rated pressure.

Close and lock all access doors when the compressor is left 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.

 

SAFETY       7

 

Attempt repairs only in clean, dry, well lighted and ventilated areas. Connect the  compressor  only  to  electrical  systems  that  are

compatible with its electrical characteristics and that are within it’s rated capacity.

 

 

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.

 

For further information, consult Material Data Sheets CPN 88303979 for ULTRA–Plus Coolant.

 

The above information contains data supplied in support of United Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.) regulations.

 

8        GENERAL INFORMATION

 

 

PIPING AND INSTRUMENTATION – Electro–pneumatic and Intellisys Units

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

22292783

Rev C

 

 

KEY

 

 

1. Filter, air

 

2. Valve, inlet

 

3. Valve, solenoid (load) (1SV)

 

4. Airend assembly

 

5. Motor

 

6. Tank, separator

 

7. Separator elements

 

8. Valve, minimum pressure

 

9. Aftercooler 10.Gauge, pressure
10. 1 Switch, discharge pressure 12.Switch, temperature 13.Filter, coolant 14.Thermostat

15.Cooler

 

16 Relay, overload, Motor 17.Valve, safety

18.Valve, drain 19.Screen, scavenge

20 Valve, solenoid (blowdown) (3SV)

 

21.Orifice

 

22 Indicator, air restriction

23.Electric drain valve (EDV – condensate) 24.Valve solenoid (line/sump), Intellisys Option

(10SV)

 

25.Transducer pressure, Intellisys Option, replaces 10 and 11 26.Sensor temperature, Intellisys Option, replaces 12 27.Moisture separator

28.Compressor air discharge 29.Condensate discharge 30.Compressor air inlet

• Valve, solenoid (5SV)

 

• Valve, solenoid (6SV)

 

GENERAL INFORMATION      9

 

 

 

• Valve, shuttle

 

• Valve, modulation

 

• Sensor, temperature, Intellisys option 36 Valve, expansion

37 Filter, refrigerant 38.Condenser

• Evaporator

 

• Refrigerant compressor 41 Hot gas bypass valve

 

• Air/Coolant

 

• Air

 

• Coolant

 

• Condensate

 

• Component boundary F Refrigerant

G       Option

 

 

 

 

 

 

 

 

 

ROTATION

 

 

 

 

 

 

 

 

VIEW LEFT

 

VIEW REAR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VIEW FRONT                                                                                              VIEW RIGHT

 

 

 

 

 

 

 

 

 

 

DRYER ROTATION

 

 

 

 

 

 

 

 

 

 

 

VIEW BOTTOM

 

Note: Dimensions are mm (inches)

VIEW TOP

 

 

KEY

 

 

• Pre filter

 

• Compressor and cooling air intake C Starter box
• Cooling air exhaust

 

• 00” BSPT air discharge F Customer power inlet
• Fork lift openings

(Fork lift hole covers must be installed after unit is in place to reduce noise and ensure proper cooling of package)

• .25 Inch female NPT moisture separator J  Emergency stop button
• Primary compressor service door

 

• 4 holes, 17 (0.67) diameter

 

• 4 holes, 12 (0.47) diameter N Dryer cooling air intake

 

 

See notes – Page 12

 

 

 

NOTES

 

 

1. Coolant (lubricant) fill quantity (approximate) 21 litres (4,6 UK gallons).
2. Recommended clearance in front of control panel door 1067 mm (42 inches) or minimum as required by the latest national electrical codes (NEC) or applicable local
3. Recommended clearances on left and right sides 914mm (36 inches).
4. Minimum recommended clearance for the rear of the compressor is to be 152mm (6 inches).
5. External piping shall not exert any unresolved moments or forces on the unit. Use pipe size as large or larger at discharge
6. There should be no plastic or pvc piping attached to this unit or used for any lines
7. Any field installed ducting to and from the compressor cannot add more than 5mm (1/2 inch) water gauge total air resistance.

Ducting is not recommended for the dryer cooling air inlet and outlet openings.

 

8. Do not pipe into a common header with a reciprocating compressor, unless the reciprocating compressor utilizes a discharge pulsation damper.
9. 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 and national and

local electrical codes.

NOTE

All dimensions are in millimetres (inches) unless otherwise stated.

 

 

 

 

 

Ensure that the correct fork lift truck slots or marked lifting points are used whenever the machine is lifted or transported.

 

 

 

 

 

UNPACKING

 

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 paintwork of the compressor is not damaged.

 

 

Ensure that all transport and packing materials are discarded in a manner prescribed by local codes.

 

 

 

 

 

NOTE

Units are shipped with transit locking bolt in place. Prior to running the unit the shipping bolt must be removed and the belt tension checked. Loosen, remove and discard 10mm shipping bolt. For belt tensioning procedure refer to Maintenance section.

 

 

 

 

KEY

 

1. Compressor

 

2. Air Dryer

 

3. Air Receiver

 

4. Compressed air filters

 

5. System demand points

CAUTION

The use of plastic bowls on line filters and other plastic air line components can be hazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils. Ingersoll–Rand recommends that only filters with metal bowls should be used on any pressurised system.

 

 

 

 

NOTE

Items [2] to [5] are optional or may be existing items of plant. Refer to your Ingersoll–Rand distributor / representative for specific recommendations.

 

 

 

LOCATION IN THE PLANT

 

 

The compressor can be installed on any level floor capable of supporting it. A dry, well ventilated area where the atmosphere is clean is recommended. A minimum of 150mm (6 inches) should be left at the rear and 1m (3ft) at the sides of the machine for adequate service access and ventilation.

 

 

Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks.

 

 

Ensure that the machine is positioned securely and on a stable foundation. Any risk of movement should be removed by suitable means, especially to avoid strain on any rigid discharge piping.

 

 

 

CAUTION

Screw type compressors [1] should not be installed in air systems with reciprocating compressors without means of isolation such as a common receiver tank. It is recommended that both types of compressor be piped to a common receiver using individual air lines.

CAUTION

Before starting machine remove shipping bolt and discard

 

 

 

CAUTION

The standard compressor unit is not suitable for operation in temperatures liable to cause freezing as Condensate water is liable to be produced in the after cooler and receiver where fitted.

 

Refer to your Ingersoll–Rand distributor for further information.

 

 

 

DISCHARGE PIPING

 

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.

 

It is essential when installing a new compressor [1], to review the total air system. This is to ensure a safe and effective total system. One item which should be considered is liquid carryover. Installation of air dryers [3] is always good practice since properly selected and installed they can reduce any liquid carryover to zero.

 

 

It is good practice to locate an isolation valve close to the compressor and to install line filters [4].

 

 

It is a requirement for air dryers covered under Aircare that correctly sized Ingersoll–Rand pre and afterfilters are installed.

 

 

50Hz

UP5–22E

UP5–30

M37PE

 

COMPRESSOR	7	8	10	14	7	8	10	14	7	8	10	14
Maximum operating pressure	7,5	8,5	10,0	14,0	7,5	8,5	10,0	14,0	7,5	8,5	10,0	14,0
barg (psig)	(109)	(123)	(145)	(203)	(109)	(123)	(145)	(203)	(109)	(123)	(145)	(203)
Factory set reload pressure	6,8	7,8	9,3	13,3	6,8	7,8	9,3	13,3	6,8	7,8	9,3	13,3
barg(psig)	(99)	(113)	(135)	(193)	(99)	(113)	(135)	(193)	(99)	(113)	(135)	(193)
Flow rate m3/min (cfm)	3,9	3,7	3,4	2,8	5,6	5,0	4,7	3,9	6,2	6,0	5,7	4,8
	(139,5)	(130,7)	(118,3)	(97,1)	(197,8)	(176,6)	(166)	(137,7)	(219)	(212)	(201)	(170)

 

Maximum   airend   discharge temperature	102 C (216 F)
Ambient operating temperature (min.) → (max.)	+2 C (36 F) → +40 C (105 F)	+2 C (36 F) → +46 C (115 F)

 

MOTOR
Drive motor protection	IP55
Nominal power	22kW	30kW	37kW
Speed	1475 RPM
Frame	LSES180L–T	LSES200L–T	LSES225SR–T
Insulation class	F

 

COOLING SYSTEM – Air cooled
Cooling air flow	87.8m3/min (3100 ft3/min)		110.4m3/min (3900 ft3/min)
Dryer cooling air flow	1200 ft3/min (34m3/min)
Maximum ∆P in air ducts	12.7mmH2O (0.5 inWg) (not recommended for dryer openings)
Compressed air outlet ∆T	8.3 C (15 F)
Cooling air outlet ∆T	15 C (27 F)	22 C (40 F)	23 C (42 F)
Dryer cooling air outlet ∆T	11 F (6 C)

 

GENERAL DATA
Residual coolant content	3 mg/m3 (3ppm)
Separator vessel capacity	14 Litres (3.1 UK gallons)
Coolant capacity	21 Litres (4.6 UK gallons)
Sound pressure level to CAGI–PNEUROP	69 dB(A)
Weight – base mount unit	992 kg (2187 lbs)	1028 kg (2266 lbs)	1064 kg (2346 lbs)
Weight – dryer option unit	1101 kg (2427 lbs)	1137 kg (2506 lbs)	1173 kg (2586 lbs)

 

 

ELECTRICAL DATA – ALL UNITS SSR UP5–22E
Standard voltage	220V	380V	400V
PACKAGE
Power (nominal)	22kW
Full load current at maximum pressure	87.4A	50.6A	48.1A
Full load current at maximum pressure with dryer option	–	–	50.5A
Starting current – Star Delta	197.5A	114.4A	108.6A
Starting current – Star Delta with dryer option	–	–	124.6A
Starting time – Star Delta	7–10 Sec
Starts per hour (maximum)	6
ELECTRICAL DATA – Star Delta
Control voltage	120VAC
Minimum fuse rating See note 1	110A	60A	60A
Minimum fuse rating with dryer option See note 1	–	–	60A
Minimum wire size mm2/Cu See note 2	50	25	25

 

ELECTRICAL DATA – ALL UNITS SSR UP5–30
Standard voltage	220V	380V	400V
PACKAGE
Power (nominal)	30kW
Full load current at maximum pressure	116.7A	67.6A	64.2A
Full load current at maximum pressure with dryer option	–	–	66.6A
Starting current – Star Delta	264.8A	153.3A	145.6A
Starting current – Star Delta with dryer option	–	–	161.6A
Starting time – Star Delta	7–10 Sec
Starts per hour (maximum)	6
ELECTRICAL DATA – Star Delta
Control voltage	120VAC
Minimum fuse rating See note 1	150A	90A	90A
Minimum fuse rating with dryer option See note 1	–	–	90A
Minimum wire size mm2/Cu See note 2	70	25	25

 

ELECTRICAL DATA – ALL UNITS SSR M37PE
Standard voltage	220V	380V	400V
PACKAGE
Power (nominal)	37kW
Full load current at maximum pressure	142.5A	82.5A	78.4A
Full load current at maximum pressure with dryer option	–	–	80.8A
Starting current – Star Delta	325.6A	188.6A	179.1A
Starting current – Star Delta with dryer option	–	–	195.1A
Starting time – Star Delta	7–10 Sec
Starts per hour (maximum)	6

 

 

ELECTRICAL DATA – Star Delta
Control voltage	120VAC
Minimum fuse rating See note 1	200A	100A	100A
Minimum fuse rating with dryer option See note 1	–	–	100A
Minimum wire size mm2/Cu See note 2	95	50	50

 

DRYER OPTION TECHNICAL INFORMATION 50Hz
General
Refrigerant type	R404A
Refrigerant charge kg (lbs)	0.84 (1.8)
Refrigerant oil	Emkarate RL32CF or Texaco Capella HFC32
Control settings
Hot gas setting barg (psig)	5.0 – 5.1 (72 – 74)
High pressure switch setting barg (psig)	29.3 (425)
Fan pressure switch setting on/off barg (psig)	15.5 / 12.1 (225 / 175)
Performance                                                               25 / 30kW (2) (3)		37kW
Dew point temperature at rated conditions and flow (3)	7 C (45 F)	10 C (50 F)
Maximum ∆P across dryer barg (psig)	0.15 (2.2)	0.21 (3.0)

 

• In accordance with PNEUROP 3
• In accordance with ISO 7183 at the modified rated
• 50Hz machines: 25 C ambient, 7 barg

 

 

 

1. If a circuit breaker is selected it should only be a magnetic trip type, set above the anticipated starting current of the machine, but below the maximum prospective fault current for the circuit. The circuit breaker or fuseable disconnect must be capable of breaking the prospective

fault current at its terminals.

 

2. PVC/PVC Type Calculated using the following conditions:

 

 

1. PVC insulated cable, armoured, copper
2. Cable clipped to a wall, in free air.

• Ambient temperature of 40 C (104 F) and relative humidity of 40%.

1. 20m (65ft) cable
2. Volt drop limited to –10% during starting, –5% during normal running.
3. Protected by the circuit breaker listed

 

 

If there are any deviations from the above, or special regulations apply, the installation must be planned by a competent, qualified engineer.

 

 

 

NOTE

All data applies to standard product only.

Feeder cables/wires should be sized by the customer/electrical contractor to ensure that the circuit is balanced and not overloaded by other electrical equipment. The length of wiring from a suitable electrical feed point is critical as voltage drops may impair the performance of the compressor.

 

 

Feeder cables / wires connections to isolator or disconnect should be tight and clean.

 

 

The applied voltage must be compatible with the motor and compressor data plate ratings.

 

 

The control circuit transformer has different voltage tappings. Ensure that these are set for the specific applied voltage prior to starting.

 

 

 

 

CAUTION

Never test the insulation resistance of any part of the machines electrical  circuits,  including  the  motor  without  completely

disconnecting the electronic controller (where fitted).

 

 

 

 

ELECTRICAL DATA

 

An independent electrical isolator or disconnect should be installed adjacent to the compressor.

CAUTION

Ensure that the motor, blower and dryer fan rotate in the correct direction as indicated by direction arrows, and on drawing.

 

18      OPERATING INSTRUCTIONS – GENERAL

 

 

GENERAL OPERATION

 

The compressor is an electric motor driven, single stage screw compressor, complete with accessories piped, wired and baseplate mounted. It is a totally self contained air compressor package.

 

The 22kW & 30kW units are designed to operate in an ambient range of 2 C to 40 C (35.6 F – 104 F) with a special option package available to operate in ambient temperatures ranges from 2 C up to 50 C (35.6 F up to 124 F). The maximum temperature is applicable to either version up to a maximum elevation of 1000m (3280ft) above sea level. Above this altitude significant reduction in maximum allowable ambient temperature is required.

 

 

The 37kW packages are designed for a 46 C (115 F) maximum ambient.

 

 

Compression in the screw type air compressor is created by the meshing of two (male & female) helical rotors.

 

 

The air/coolant mixture discharges from the compressor into the separation system. This system removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the cooling system and the air passes through the aftercooler and out of the compressor.

 

 

Cooling air is moved through the coolers by the cooling fan and discharged from the machine.

CAUTION

Cooling air is drawn in at the end of the machine package passing through the filter and cooler before being discharged from the top of the machine. Care should be taken to avoid blocking the airflow, or causing any restriction in excess of the maximum backpressure allowed for ducting.

Do not direct the airflow at face or eyes.

 

 

The power transmission from the drive motor to the airend male rotor is by pulley and belts. The constant auto tensioning system, using airend mass torque and gas arm, ensures that the belts are always under the correct tension, eliminating the need for adjustment and maximizing the life of the belts.

 

 

By cooling the discharge air, much of the water vapour naturally contained in the air is condensed and may be drained from the downstream piping and equipment.

 

 

The coolant system consists of a sump, cooler, thermostatic valve and a filter. When the unit is operating, the coolant is pressurized and forced to the compressor bearings.

 

The compressor load control system is automatic on–off line. The compressor will operate to maintain a set discharge line pressure and is provided with an auto restart system for use in plants where the air demand varies sufficiently to allow a compressor to shut down and save power. Significant system volume will assist this and is recommended.

 

 

With the dryer option, the dryer will run continuously when the compressor is automatically off line.

 

WARNING

When the unit stops running as the result of low air demand, normally indicated by auto restart light, it may restart and return to load at any time.

 

 

 

Safety of operation is provided as the compressor will shut down if excessive temperatures or electrical overload conditions should occur.

 

 

CAUTION

This unit is not designed or intended to operate when contaminated with silicone. Lubricants, greases or other items containing silicone should not be used on this unit.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.  PRESSURE GAUGE

Indicates the system pressure.

 

 

WARNING

DO NOT operate the compressor at discharge pressures exceeding the maximum operating pressure.

 

 

2. HOURMETER

Records the total running time of the compressor.

 

 

3.  EMERGENCY STOP

When depressed will stop the compressor immediately. The ’Power on’ indicator will remain illuminated. The emergency stop button must be released before the compressor can be restarted.

 

 

4.  START/STOP

When switched to the ON position will cause the unit to start and run in a loaded condition if there is a demand for air. If there is no demand, the machine will run unloaded before stopping automatically.

When switched to the OFF position, will unload and stop the unit if it is running. If the unit is in auto restart it will prevent the unit from re–starting when there is a demand for air.

 

 

5.  POWER ON (Green)

Indicates the presence of control voltage at the controller.

 

 

6.  AUTO RESTART (White)

Will illuminate when the machine has shut-down due to low air demand. The machine will restart and load automatically as soon as the demand for air returns.

 

7.  FAULT / HIGH AIR TEMPERATURE ALARM (Red)

Turn off electrical Isolator or disconnect. Investigate cause of fault.

8.  RESET BUTTON

Press button to reset the control system following compressor trip.

 

 

9.  DEW POINT INDICATOR (Dryer Option)

Green indicates good dew point. Red indicates dew point above 18 C (65 F) and blue indicates freezing.

 

 

PRIOR TO STARTING

 

1. Make visual check of the machine, ensure that all guards secure and that nothing is obstructing the proper ventilation of, or free access to the

 

 

2. Check coolant level. Add if necessary.

 

 

3. Make sure main discharge valve is

 

 

4. Turn on electrical isolator or disconnect. The Power on (5) indicator will light, indicating that line and control voltages are

 

 

5. Check direction of rotation at initial start or following interruption in power supply.

 

WARNING

Make sure that all protective covers are in place.

Cooling air flow exhaust may contain flying debris. Safety Protection should be worn at all times to avoid injury.

 

STARTING

 

1. Push the RESET button (8). The fault indicator (7) will extinguish. Switch the ON/OFF switch (4) to the ON position. The compressor will start and then load automatically.

 

 

NORMAL/EMERGENCY STOPPING

 

1. Switch the ON/OFF switch (4) to the OFF position. The compressor will unload and

 

2. Press EMERGENCY STOP button (3) and the compressor will stop immediately.

 

3. Turn off electrical isolator or

 

 

 

CAUTION

After shutdown never allow unit to stand idle with pressure in

receiver/separatorsystem.

 

 

 

STAR – DELTA WIRING SCHEMATIC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPTION

 

 

DRYER OPTION

 

 

 

LEGEND

 

DMF           Motor, dryer fan (option)

 

EDV           Valve, electric drain

 

HATR 1,2,3

 

Contacts, relay – HATR

 

 

FM             Motor, fan

 

FOL           Overload, internal fan (option) HATS          Switch, high air temperature. MM        Motor, compressor

MOD          Modulation control option P         Switch, pressure

RCM          Motor, dryer compressor (option)

 

1RPS         Switch, high refrigerant pressure (option) 2RPS        Switch, fan pressure (option)

1SV            Valve, solenoid (load) N.C.

 

3SV            Valve, solenoid (blowdown) N.O. 5SV         Valve, solenoid (modulation option) 6SV           Valve, solenoid (modulation option) ES              Switch, emergency stop

1FU, 2FU   Fuses, primary voltage 3FU         Fuse, secondary voltage 7FU, 8FU   Fuses, dryer fan (option) HATR            Relay, high air temperature

HM             Hourmeter

 

KM1           Contactor, main

 

KM1–1,2,3   Contacts, aux. main contactor KM2           Contactor, delta

KM2–1,2    Contacts, aux. delta contactor KM3              Contactor, star

KM3–1,2    Contacts, aux. star contactor

 

KM4           Contactor, dryer compressor (option) KM5                Contactor, dryer fan (option)

1LT             Light, power on indicator (Green) 2LT        Light, auto restart indicator (White) 3LT             Fault indicator light (Red)

MOL           Overload, main motor MOL–1       Contact, main motor overload MMS    Starter & overload, fan motor MMS–1      Contact, fan motor overload

ROL           Overload, dryer compressor (option)

 

RST           Switch, reset

 

SS              Switch, selector Off/On

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPTION

 

 

DRYER OPTION

 

 

LEGEND

 

T1              Transformer

 

TM1           Relay, delta starting (10 sec.) TM1–1           Contact, relay – delay off

TM2           Relay, restart, time delay (6 min)

 

TM2–1       Contact, relay – timed

 

TM3           Relay timed delay (10 sec.) TM3–1               Contact, relay – timed TM3–2               Contact, relay – instant

 

 

CONTROL PIPING DIAGRAM

 

 

 

 

 

 

 

 

KEY

 

 

1. Pressure gauge

 

2. Pressure switch

 

3. Tee

 

4. Connector

 

5. Moisture separator

 

6. Elbow

 

7. Tee, male run

 

8. Reducer bushing

 

9. Blow down solenoid valve 10.Load solenoid valve

11. 1 Indicator air filter 12.Nipple 13.Adaptor

• Intake valve assembly 15.Line / Sump solenoid valve

 

NOTES:

 

1. Tubing 3/8 inch

 

1. Tubing 1/4 inch

 

 

 

 

 

 

 

 

 

INTELLISYS CONTROL AND INSTRUMENTATION PRIOR TO STARTING

1. Check coolant level. Add if necessary.

 

 

2. Make sure main discharge valve is

 

 

3. Turn on electrical isolator. The power E.D. will illuminate and the display will indicate ‘Ready to start’.

 

WARNING

Make sure that all protective covers are in place.

 

STARTING

 

Press    ‘Start’  [24].  The  compressor  will  start  and  then  load automatically.

 

POWER OUT RESTART (Optional)

 

If this setting is set to ON, the compressor will automatically restart when power is returned to the compressor if it was operating when power was removed.

 

POWER OUT RESTART TIME

 

If the power out restart setting is set to ON, this is the number of seconds from the time power is restored until the compressor starts. The power out restart horn will sound during this time.

 

NORMAL STOPPING

 

1. Press ‘Unloaded Stop’[25]. The compressor will unload then

 

 

2. Turn off electrical isolator.

 

 

 

EMERGENCY STOP

 

1. Press ‘Emergency stop button’ [26] and the compressor will stop immediately.

 

2. Turn off electrical isolator.

 

 

INSTRUMENT PANEL FUNCTION

 

• PACKAGE DISCHARGE PRESSURE E.D.

This will illuminate when the display indicates the package discharge pressure.

 

2   AIREND DISCHARGE TEMPERATURE L.E.D.

This will illuminate when the display indicates the airend discharge temperature.

 

3   SUMP PRESSURE L.E.D.

This will illuminate when the display indicates the sump pressure.

 

 

4   SEPARATOR PRESSURE DROP L.E.D.

This will illuminate when the display indicates the separator pressure drop.

 

5   TOTAL HOURS L.E.D.

This will illuminate when the display indicates the total compressor running hours.

 

6   LOADED HOURS L.E.D.

This will illuminate when the display indicates the total loaded compressor hours.

 

7   LOAD/UNLOAD L.E.D.

This will illuminate when the compressor is running onload.

 

 

8   MODULATION L.E.D.

This will illuminate when the compressor is running in modulation mode. (Note: capacity modulation will occur only if the appropriate regulation pneumatics are fitted to the compressor).

 

9   UNLOAD L.E.D.

This will illuminate when the compressor is running in unload mode.

 

 

10 ALARM L.E.D.

This will flash when a warning condition exists. The warning detected will be displayed and the compressor will continue to run. The warning can be reset by depressing set [21].

It will illuminate when an alarm condition has occurred. The compressor will shutdown immediately. The alarm can be reset by depressing set [21] twice within 3 seconds.

 

OTHER L.E.D.s

These will illuminate during the set point routine to indicate which function is being adjusted.

 

• E.D.–Set off line pressure. 12 L.E.D.–Set on line pressure. 13 L.E.D.–Select control mode. 14 L.E.D.–Set star delta time. 15 L.E.D.–Set auto restart time.

• E.D.–Select options.

 

 

• E.D.–Not used.

 

 

• E.D.–Not used.

 

 

 

19 DISPLAY SELECT BUTTON

Press to index through compressor operating conditions. The corresponding L.E.D. will illuminate adjacent to display.

This is used to select alternative status displays (after approximately 5 minutes, the display defaults to the package discharge pressure). Depressing this button in the set point routine will cause exit to checking machine for 2 seconds, then ready to start.

 

20  LOAD/UNLOAD BUTTON

These are used to manually switch the compressor between a loaded control mode (e.g. on/off line) and unloaded running.

See L.E.D.

 

21 SET BUTTON

Depressing this button when the compressor is stopped will enable entry into the set point routine. When in the set point routine, depressing this button will cause the controller to move on to the next set point setting, saving the new value if one has been entered.

A warning reset is obtained by depressing this button (whilst the machine is running). An alarm reset is obtained by depressing this button twice within 3 seconds (the alarm condition will remain if the indicated fault has not been rectified).

 

22 LIQUID CRYSTAL DISPLAY

This indicates the status of the compressor, set up parameters and warning/alarm messages. When the compressor is running, the display will normally show the package discharge pressure.

 

23 ARROW KEYS

These are used to index through warning and alarm messages. In the set point routine, these buttons are used to increase/decrease set point values and enable/disable some operation conditions.

 

The arrow keys are also used to select pressure bands 1 (•) or 2

(T) during normal operation of the compressor.

 

 

24 START BUTTON

This button when depressed will cause the compressor to start and load automatically, provided that the controller detects a demand for air. When pressed in the display mode, it will cause exit to checking machine for 2 seconds, then ready to start.

 

25  UNLOADED STOP

This button when depressed while the compressor is running, will unload the compressor (if not already unloaded) for 10 seconds and then stop. This is the normal method for stopping the compressor. If the compressor is already stopped, it will execute an L.E.D. check (all the

L.E.D.s should illuminate) and display the controller software revision.

 

 

26 EMERGENCY STOP

This button when depressed will stop the compressor immediately and display an emergency stop alarm message.

 

 

 

27 POWER L.E.D.

This will illuminate when the 8V controller supply is available.

 

 

28 AUTOMATIC RESTART L.E.D.

This will illuminate when the machine has shutdown due to low air demand. The compressor will restart and load automatically as soon as the demand for air resumes.

 

 

DISPLAY MESSAGES

When the compressor is running normally, the display will indicate the package discharge pressure and illuminate the corresponding

L.E.D. [1]. An arrow will also appear in the far right of the display indicating pressure band selection. Pressing display select [19] will change the display value and the corresponding L.E.D. will illuminate. The controller monitors all aspects of the compressor whilst running and will display warnings or in severe conditions execute an emergency stop and display alarm conditions.

 

MACHINE CONTROL MODES CAPACITY CONTROL

The compressor is designed to work with two types of capacity control, to suit the individual plant requirements. These controls are:–

CONTROLLER WARNING MESSAGES

In the event of a warning, the controller will display a message and the alarm L.E.D. [10] will flash. The warning message will alternate with the normal display every 4 seconds, the compressor will continue to run but the fault should be rectified as soon as possible. The arrow keys [23] should be used to index the display for any additional warning messages. A warning message may be reset by depressing set [21] once.

 

NOTE:

The warning will recur if the fault has not been rectified. The following warning messages may be displayed:

 

COOLANT FILTER (OPTIONAL)

The pressure differential across the coolant filter exceeds 1 bar (15 psi).

 

AIR FILTER

The air filter is dirty or blocked and should be replaced.

 

 

SEPARATOR ELEMENT

The separator element is dirty or blocked and should be replaced.

 

1. On line – Off line. (Fitted as standard)

AIREND TEMPERATURE

 

1. On line – Off line, with Upper Range Modulation. (Optional extra)

Either is available by selection at the control panel.

 

 

ON LINE – OFF LINE CONTROL

For applications that require a widely varying air demand, this mode of control will deliver air at full capacity or zero capacity with low receiver pressure.

 

This mode of operation is controlled by the pressure transducer responding to changes in plant air pressure. This sensor energises the load solenoid valve which in turn operates the venting valve (blowdown) and the closing of the atmospheric vent opening in the air inlet valve.

 

 

The compressor then delivers full capacity air to the plant system. If the air pressure in this system rises to the upper set point of the pressure setting, the load solenoid valve is de–energised allowing the inlet valve to close. At the same time, the venting valve opens allowing the receiver pressure to drop.

 

 

The pressure setting has a range of 0,83 bar (12 psi) between its upper and lower set points.The upper set point is set at 0,2 bar (3 psi) above the compressor rated discharge pressure.

 

UPPER RANGE MODULATION CONTROL (Optional Extra)

For plants having a relatively high and constant air demand, Upper Range Modulation is the recommended mode of control.

 

 

Upper range modulation retains the features of On line – Off line control but provides the throttling of the inlet air flow as the line pressure rises to the upper set point of the off–line pressure setting.

 

By bleeding off a small amount from the regulator valve, which energises the Modulate Solenoid Valve, a reduction in the air signal to the pneumatic cylinder on the inlet valve allows the cylinder to ‘trim’ the inlet valve position as dictated by changing line pressure. Modulation begins when the compressor reaches about 94% of the rated line pressure and is factory set to modulate down to approximately 70% of rated capacity.

 

 

If the air demand decreases to a level below the 70% modulated output, the line pressure will increase slightly to the upper limit of the pressure setting, when the compressor then changes to the Off line control position and operates with the receiver vented.

The airend temperature reaches 97% of the high airend temperature set point (i.e. 106 C (223 F)).

 

CONTROLLER ALARMS

In the event of an alarm, the controller will execute an emergency stop, the alarm L.E.D. [10] will illuminate and an alarm message will be displayed. The arrow keys [23] should be used to index the display for any additional alarm messages. An alarm is reset by depressing set [21] twice within a 3 second period after the fault has been rectified. The compressor will restart only when all alarm conditions have been rectified. The following alarm messages may be displayed (For fault correction see the Fault Finding section):

 

 

STARTER FAULT

The contactor sequence during start or stop is incorrect.

 

 

AIREND TEMPERATURE

The airend discharge temperature is above the high temperature set point.

 

MOTOR OVERLOAD

The motor overload contacts are open. The motor overload must be reset before the controller can be reset.

 

REVERSE ROTATION

No sump pressure is detected after the first 2 seconds of running. Isolate the machine and reverse the mains supply connections before resuming.

 

OVER PRESSURE

The line pressure is 1 bar (15 psi) greater than the rated discharge pressure.

 

TEMPERATURE SENSOR 1

The airend temperature sensor/ connecting cable has failed.

 

 

TEMPERATURE SENSOR 2

The separator tank temperature sensor/connecting cable has failed.

 

PRESSURE SENSOR

Indicates pressure transducer failure / connecting cable fault.

 

 

 

FAILED CALIBRATION

During calibration routine, a 10% of scale error has been detected. Ensure that the separator is completely blowndown and repeat calibration.

 

CONTROL POWER LOSS

The 48Vac signal is not present at the controller.

 

REMOTE START FAILURE

Momentary remote start has not disengaged before star–delta transition. This alarm is active only if the remote start/stop is enabled.

 

REMOTE STOP FAILURE

The momentary remote stop switch has not disengaged when the start signal is received. This alarm is active only if the remote start/stop is enabled.

EMERGENCY STOP

The emergency stop button is engaged.

 

 

LOW SUMP PRESSURE

The sump pressure drops below 1 bar (15 psi) during normal operation.

 

HIGH DEW POINT (Dryer Option)

The dew point indication is above 65 F (18 C).

Ensure that the dryer is running properly and that maximum ambient conditions are not exceeded.

 

28   OPERATING INSTRUCTIONS – INTELLISYS w/ MODULATION CONTROL

 

 

MODULATION CONTROL

 

For those plants which have relatively high constant air demand relative to the compressor capacity, the recommended control mode is modulation.

 

The modulation control system retains the features of the on–line / off–line control, but also provides for throttling of the inlet flow up to the off–line air pressure setpoint value.

 

By applying line pressure to an adjustable modulator valve, the throttling position of the inlet valve is controlled, thus allowing the modulator to ”trim” the inlet valve position as dictated by the line pressure.

 

The modulating pressure range is about 4 psig (0.3 BAR) and the modulator normally should be set to straddle the compressor rated pressure. Modulation begins when the line pressure reaches about 99 percent of the compressor rated pressure and continues as/if the line pressure rises. Modulation becomes stable when the compressor output equals the plant air demand. When the modulation is at the factory setting, the maximum capacity reduction will be approximately 60 percent of the compressor rated capacity (as indicated in Figure 1).

 

Capacity control of machines supplied with electro–pneumatic control and the modulation option can be manually switched from on–line/off–line to modulation (MOD) via the control mode switch (SS) located adjacent to the pressure switch.

 

 

 

 

 

 

 

MODULATE TO 94% CAPACITY

 

MODULATE TO 85% CAPACITY

 

 

MODULATE TO 72% CAPACITY

 

 

MODULATE TO 60% CAPACITY

 

 

 

 

% OF RATED LINE PRESSURE

 

KEY

 

• Normal settings of modulator

 

• Optional field settings of modulator C Intellisys® off–line set point FIGURE 1

ACS CONTROL (INTELLISYS w/ MODULATION OPTION ONLY)

 

For compressors supplied with Intellisys® control and modulation option, ACS control will allow the compressor to automatically switch between on–line/off–line and modulation control, depending on air demand.

 

If the air demand has decreased to a level below the 60 percent modulated output, the line pressure will increase slightly to actuate the Intellisys®. The compressor will then shift to the off–line control position, and operate unloaded with the compressor vented.

 

It is sometimes desirable to begin modulation at a higher pressure than the standard factory setting, thereby increasing the modulated capacity at the time the Intellisys® is actuated. Refer to Figure 1 for modulated capacities available when this is done.

 

The compressor will then operate to deliver full capacity air to the plant system. If the plant air system pressure rises to that of the Intellisys® off–line set point, pressurized air will be sent to the inlet valve causing it to close, and to the blowdown valve, causing it to open.

 

The compressor will continue to run unloaded, but since pressure levels have reduced, it will do so with a minimum power draw.

 

The Intellisys® has a fixed minimum differential of 10 psi between the off–line air pressure setting and the on–line air pressure setting. The differential may be increased by adjusting the on–line air pressure setting of the Intellisys®.

 

The automatic control selector (ACS) is designed to continuously monitor the plant air demand and select either the on–line/off–line, or the modulate control mode – whichever is most desirable at any time during an operating day.

 

It allows the compressor to operate in its most efficient mode thereby reducing power costs.

 

When the compressor operates in the on–line/off–line control mode, the length of time the compressor remains in the ”off–line” condition is an indication of the plant air demand. Intellisys® controller is sensing and awaiting a sufficient line pressure decrease before signalling a shift to the on–line mode. If the ”off–line” time period is relatively short, thereby indicating a high demand for air, it is preferable to shift the control system to upper range modulation.

 

The Intellisys® does this, and does it automatically if the compressor unloads 3 times within a 3 minute time period.

 

If later, the plant demand decreases, and even under modulate control the line pressure reaches the setting of the Intellisys® controller, and the control shifts to the ”off–line” mode, the time in this mode will still be monitored. A long ”off–line” time period indicates a low plant air demand, indicating the desirability of operating in the on–line/off–line mode.

 

The Intellisys® then does this, and does it automatically if the compressor operates unloaded for more than 3 minutes.

 

Modulation Only

 

If MODULATION ONLY is turned on in the setpoint routine, the unit will shift to Modulation control mode immediately when the unit is running. The 3 cycles within 3 minutes time period required for ACS to change to Modulation mode is bypassed. The unit will stay in Modulation mode until the unit runs unloaded for 3 minutes (the unit then returns to ACS control) or MODULATION ONLY is turned off via the set routine.

 

Delay Load Time

 

This is the amount of time the line pressure must remain below the on–line setpoint before the compressor will load or start (if the unit was stopped due to an auto start/stop situation). Setting the load delay time to 0 will cause no delay. When the delay load timer becomes active, the display will switch to package discharge pressure (if not displaying package discharge pressure at that time) and then display the delay load count down. Once the count down reaches 0, the unit will load or start and the display will return to line pressure. The display select button is inactive during the delay load count down.

 

OPERATING INSTRUCTIONS – INTELLISYS w/ PORO OPTION  29

 

 

OPERATION

 

POWER OUTAGE RESTART OPTION

 

For customers that have interruptions in their incoming power supply to the compressor and must maintain an uninterrupted supply of compressed air, the Power Outage Restart Option allows an Intellisys compressor to restart automatically 10–120 seconds (adjustable) after incoming power is restored.

 

The Power Outage Restart Option is turned on by using the customer set routine on the Intellisys® controller. The restart time delay, which is adjustable from 10–120 seconds, can also be adjusted while in the set routine on the Intellisys® controller. Any time power is restored to the compressor after a power interruption and if the compressor was running when power was lost, a horn located on the side of the starter box will sound during the restart time delay (10–120 seconds), after which the compressor will automatically start. After starting, the compressor will return to the mode of operation that the compressor was in prior to the power interruption.

 

To operate in the power outage restart mode, proceed with following steps:

 

1. Power up the unit and wait for the Intellisys® display to read READY TO START.

 

2. Press the SET button once to enter the customer set point routine. The Set Offline Air Pressure indicator will light and the display will show the set point

 

3. Press and release the SET button multiple times until the message PWR OUT RSTR OFF is

 

4. Push the up or down arrows to change to the desired condition. ON in the display indicates Power Outage Restart is turned on and OFF in the display indicates Power Outage Restart is turned of

 

5. Once the selection has been made, press SET button to put the selection into Intellisys® memory. The display will flash twice and the message will change to STR DELAY 10 Sec if the option was turned This message will only display if the Power Outage Restart Option is turned on.

6. Use the up or down arrows to select the desired delay time (10–120 ).

 

7. Press SET and the display will flash twice indicating the change has been

 

8. Push the DISPLAY SELECT BUTTON or wait 30 seconds for the controller to automatically exit the set routine. The display returns to READY TO START.

 

Function test

 

To test the operation of the Power Outage Restart Option:

 

1. Slowly open the main isolation

 

2. Push the green START button on the Intellisys® display to start the compressor.

 

3. The compressor will load automatically if there is a sufficient demand for air. Allow the compressor to

 

4. Open the main disconnect to remove power from the compressor.

 

 

5. Close the main disconnect to reapply power to the compressor.The horn will sound and the Intellisys® display will read START IN

      SEC.The display will count down the time until the compressor starts automatically and the horn stops. After starting, the compressor will automatically return to the same mode of operation as prior to the power interruption.

 

Fault Analysis

 

1. If the Intellisys® display indicates the count down message and the horn does not sound, check the wiring of the

 

2. If the Intellisys® display does not indicate the count down message, the horn does not sound and the unit does not restart automatically, verify that the Option has been turned

 

30      OPERATING INSTRUCTIONS – INTELLISYS OPTION

 

STAR – DELTA WIRING SCHEMATIC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPTION

 

 

 

PORO OPTION

 

DRYER OPTION

 

 

 

 

LEGEND

 

FOL           Overload, internal fan (option) EDV            Valve, electric drain

DMF           Motor, dryer fan (option)

 

FM             Motor, fan

 

ES              Switch, emergency stop FU1, FU2   Fuses, primary voltage FU3            Fuse, secondary voltage FU4, FU5   Fuses, low voltage

 

MM             Motor, compressor

 

MOD          Option, modulation control

FU6, FU7, FU8

Fuses, dryer fan (option)

 

OP             Plug, option

 

PORO        Horn, power outage (option) PT  Transducer, pressure

RAC           Contacts, remote alarm (option) RCM         Motor, dryer compressor (option)

1RPS         Switch, high refrigerant pressure (option) 2RPS        Switch, fan pressure (option)

RS1            Switch, remote start (option) RS2 Switch, remote stop (option) 1SV            Valve, solenoid (load) N.C.

3SV            Valve, solenoid (blowdown) N.O. 5SV         Valve, solenoid (modulation option) 6SV           Valve, solenoid (modulation option) 10SV          Valve, solenoid (line/sump)

1TAS          Transducer, air temperature

 

2TAS          Thermistor, dryer coldest air temp. (option)

KM1           Contactor, main

 

KM1–1       Contact, aux. main contactor KM2                Contactor, delta

KM2–1       Contact, aux. delta contactor KM3                Contactor, star

KM3–1,2    Contacts, aux. star contactor

 

KM4           Contactor, dryer compressor (option) KM5                Contactor, dryer fan (option)

MOL           Overload, motor

 

MOL–1       Contact, main motor overload MMS             Starter & overload, fan motor MMS–1  Contact, fan motor overload RC1                   Suppressor

ROL           Overload, dryer compressor (option)

 

T1              Transformer

 

OPERATING INSTRUCTIONS – INTELLISYS OPTION  31

 

CONTROL PIPING DIAGRAM

 

 

 

 

 

 

KEY

 

 

1. Separator tank

 

2. Pressure transducer

 

3. Adaptor

 

4. Connector

 

5. Moisture separator

 

6. Elbow

 

7. Tee, male run

 

8. Reducer bushing

 

9. Valve, solenoid (blowdown) 10.Valve, solenoid (load)

11. 1 Indicator air filter 12.Nipple 13.Adaptor

14.Intake valve assembly 15.Line / Sump solenoid valve

 

NOTES:

 

• Tubing 3/8 inch

 

• Tubing 1/4 inch

 

SSR UP Series Maintenance Schedule

 

Every 4 years or 18000 hours	Replace all hoses.   Strip, clean and re–Grease motor bearings of ODP motors.   Replace sealed bearing on IP55 motors. Fit replacement electrical contactor tips.
6 years/18000 hours or as defined by local or national legislation.	Separator tank. Remove the cover plate and any necessary fittings. Clean the interior thoroughly and inspect all internal surfaces.

 

PERIOD MAINTENANCE Each 24 hours operation   Visual check of machine for any leaks, dust build up or unusual noise or vibration   When compressor is receiver mounted Check the coolant level and replenish if necessary.   Report immediately, contact Ingersoll–Rand authorized distributor for assistance if in doubt     Drain air receiver of condensate, or check that automatic drain is operating Visual check condition of package pre–filter Blow clean if needed If the air filter indicator shows red before the 3000 hour/1 year change out period Check the Condition of filter. Change the air filter if needed. Dusty environments require more frequent replacement. First 150 hours Change the coolant filter. Each month or 100 hours Remove and clean package pre–filter, replace if needed   Check the cooler(s) for build up of foreign matter. Clean if necessary by blowing out with air or by pressure washing.   Check hoses and fittings for leaks – tighten as required. Each 2000 hours / 6 months Take coolant sample for fluid analysis.   Check scavenge screen for blockage, clean if required. Each year or 3000 hours Check the operation of the high temperature shutdown protection (109 C).   Change the coolant filter. Change the separator cartridges. Change the package pre–filter. Visual Check of Drive Belt and tensioning gas spring.   Take Coolant sample for Fluid Analysis Change the Air Filter element. Check refrigerant compressor oil level. Pressure vessel inspection frequency may be otherwise defined by local or national legislation. Separator vessel and air receiver when fitted. Fully inspect all external surfaces, and fittings. Report any excessive corrosion, mechanical or impact damage, leakage or other deterioration. Every two years or 9000 hours Change drive belt and gas spring.   Replace the Ultra Plus Coolant at whichever interval occurs first.   Check and replace all items included within 3000 hour service   Fit  the  following  reconditioning  parts  as appropriate:   Solenoid valves Inlet valve kit Minimum Pressure valve insert Thermostatic Valve actuator

ROUTINE MAINTENANCE

 

This section refers to the various components which require periodic maintenance and replacement.

 

. It should be noted that the intervals between service requirement may be significantly reduced as a consequence of poor operating environment. This would include effects of atmospheric contamination and extremes of temperature.

 

 

The SERVICE/MAINTENANCE CHART indicates  the  various components’ descriptions and the intervals when maintenance has to take place. Oil capacities, etc., can be found in the GENERAL INFORMATION section of this manual.

 

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.

 

 

 

CAUTION: Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Vent pressure from the unit by slowly unscrewing the coolant fill cap one turn. Unscrewing the fill cap opens a vent hole, drilled in the cap, allowing pressure to release to atmosphere. Do not remove the fill cap until all pressure has vented from the unit. Also vent piping by slightly opening the drain valve. When opening the drain valve or the coolant fill cap, stand clear of the valve discharge and wear appropriate eye protection.

 

 

Ensure  that   maintenance   personnel   are   properly  trained, competent and have read the Maintenance Manuals.

 

Prior to attempting any maintenance work, ensure that:–

 

. all air pressure is fully discharged and isolated from the system. If the automatic blowdown valve is used for this purpose, then allow enough time for it to complete the operation.

 

.    the machine cannot be started accidently or otherwise.

 

 

. all residual electrical power sources (mains and battery) are isolated.

 

Prior to opening or removing panels or covers to work inside

a machine, ensure that:–

 

 

. anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts.

 

 

 

.    the machine cannot be started accidently or otherwise.

 

 

Prior to attempting any maintenance work  on  a  running

machine, ensure that:–

 

 

 

DANGER

Only properly trained and competent persons should undertake any maintanence tasks with the compressor running or with electrical power connected.

 

 

.    the work carried out is limited to only those tasks which require the machine to run.

 

 

. the work carried out with safety protection devices disabled or removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed.

 

 

. all hazards present are known (e.g. pressurised components, electrically live components, removed panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving parts, safety valve discharge etc.).

 

.    appropriate personal protective equipment is worn.

 

 

.    loose clothing, jewellery, long hair etc. is made safe.

 

 

.    warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen.

 

 

Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:–

 

.    the machine is suitably tested.

 

.    all guards and safety protection devices are refitted and correctly working.

 

.    all panels are replaced, canopy and doors closed.

 

. hazardous materials are effectively contained and disposed of in a manner compliant with local or National environmental protection codes.

 

 

WARNING

Do not under any circumstances open any drain valve or remove components from the compressor without first ensuring that the compressor is FULLY SHUT– DOWN, power isolated and all air pressure relieved from the system.

 

 

 

TOP UP COOLANT PROCEDURE

 

The reservoir is designed to prevent overfill. With warm unit stopped in the normal way, coolant should be at the top of the sight glass. The level should not drop beyond the bottom of the sight glass when running with steady load.

 

 

CAUTION

Ensure that SSR ULTRA–PLUS coolant is used. Failure to do so will void manufacturers warranty.

 

 

COOLANT CHANGE PROCEDURE

 

It is better to drain the coolant immediately after the compressor has been operating as the liquid will drain more easily and any contaminant will still be in suspension.

1. Stop the machine, electrically isolate and vent all trapped

 

 

2. Place a suitable container close to the drain

 

 

3. Slowly remove fill/vent

 

 

4. Remove plug from drain

 

 

5. Open the drain valve and drain coolant into container.

 

 

6. Close the drain

 

 

7. Replace plug in drain

 

 

8. Refill the machine following the ”top up coolant” procedure After initial fill, to purge any airlocks, the machine should be run for a few minutes cycling between load and no load, before checking that the level is correct.

 

9. Replace and tighten oil fill

 

 

 

 

 

COOLANT FILTER CHANGE PROCEDURE

 

1. Stop the machine, electrically isolate and vent all trapped

 

 

2. Loosen filter with the correct

 

 

3. Remove the filter from the

 

 

4. Place the old filter in a sealed bag and dispose of in a safe way.

 

 

5. Clean the mating face of the housing taking care to avoid any particles entering the

 

 

6. Remove the  new  Ingersoll–Rand  replacement  filter  from  its protective

 

 

7. Apply a small amount of lubricant to the filter

 

 

8. Screw the new filter down until the seal makes contact with the housing, then hand tighten a further half

 

 

9. Start the compressor and check for

 

 

 

 

 

AIR FILTER ELEMENT CHANGE PROCEDURE

 

1. Stop the machine, electrically isolate and vent all trapped

 

 

2. Unclip the retaining cap and withdraw the old

 

 

3. Fit the new

 

 

4. Replace the retaining

 

 

 

SEPARATOR CARTRIDGES CHANGE PROCEDURE

 

1. Stop the machine, electrically isolate and vent all trapped

 

 

2. Loosen separator cartridges with the correct

 

 

3. Remove the cartridges from the housing; place in a sealed bag and dispose of safely.

 

4. Clean the mating faces of the

 

 

5. Remove the new Ingersoll–Rand replacement cartridges from protective

 

6. Apply a small amount of lubricant to the cartridge

 

 

7. Screw the new cartridges down until the seal makes contact with the housing, then hand tighten a further half

 

8. Start the compressor and check for

 

 

 

CAUTION

This unit is not designed or intended to operate when contaminated with silicone. Lubricants, greases or other items containing silicone should not be used on this unit.

Oil level checking procedure

 

The oil level should be checked regularly. An oil level sight glass is located at the bottom of the refrigeration compressor and while the machine is running on load, oil should always be visible in the sight glass. The normal position is half way.

 

 

 

Adding oil

 

The refrigeration circuit is hermetically sealed so adding oil should never be necessary unless the system is leaking or has been pumped down or recharged.

 

If adding oil is necessary, do the following.

 

Run the dryer for a minimum of 2 minutes, the oil level should be visible in the sight glass. If not, slowly add the proper oil, using the appropriate pump, to the SchraderTM valve on the suction connector of the compressor. Continue until the oil level is visible in the sight glass with the compressor running.

 

 

 

CAUTION

 

Do not mix oil types. Use only oil specified by IR

 

 

 

 

 

DRYER MAINTENANCE (DRYER OPTION)

COOLER CLEANING PROCEDURE

 

1. Stop the machine, electrically isolate and vent all trapped

 

 

 

WARNING

 

The dryer’s refrigeration system operates in a pressurised shutdown mode. If the compressor stops, the system will contain high pressure refrigerant. The refrigeration system must only be opened by a qualified technician certified in handling refrigerants. Never adjust thermal expansion valve. It has been factory set.

2. Remove the top cover to obtain access to the cooler.

 

 

3. Clean the cooler.

 

 

4. Rebuild in reverse order.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SETTING THE PRESSURE SWITCH (where used)

 

TO CHECK THE MAXIMUM DISCHARGE PRESSURE

(Pressure switch upper trip point)

 

Slowly close the isolation valve located adjacent to the compressor. Observe the rise in pressure and ensure that the pressure switch opens (and unloads the compressor) at the correct Maximum discharge pressure.

 

The maximum discharge pressure is shown on the machine data plate. DO NOT exceed these figures.

TO CHECK THE LOWER SET POINT

 

Observe the line pressure fall and note the point at which the pressure switch closes (and loads the compressor).

 

TO ADJUST THE UPPER SET POINT

 

Remove the transparent cover and turn the adjuster [1]. The red pointer will move. Turn the adjuster anti–clockwise to increase the set point or clockwise to decrease it.

 

TO ADJUST THE LOWER SET POINT

 

Remove the transparent cover and turn the adjuster [2]. The green pointer will move. Turn the adjuster anti–clockwise to increase the set point or clockwise to decrease it.

 

 

 

NOTE

The pressure switch scale is a guide only. Use the machine pressure gauge to verify the upper and lower set points.

 

 

 

BELT CHANGE / GAS STRUT CHANGE PROCEDURE

 

 

1. Gas

 

1. Support bracket (part of pivoted assembly).

 

1. Tension

 

1. Stop the machine, electrically isolate and vent all trapped

 

 

2. Remove the side cover from the

 

 

3. Fit a 1/2” square drive wrench in the tension cam located above the airend (access from front door). Turn clockwise 1/4 turn to Position II to release gas strut tension on the

 

 

4. Using a small screwdriver under the spring clip, ease the ball ends off the spherical studs at the ends of the gas

 

 

5. Replace the gas strut and the studs at the same time by removing and replacing the studs then pushing the new gas strut firmly onto the studs until it clicks into

 

 

6. Turn the tension cam clockwise 1/4 turn to Position III to raise and support the airend. Place a block of wood or similar under the separator tank for

 

 

7. Replace the belts from the left side of the

 

 

MOISTURE SEPARATOR MAINTENANCE

 

The moisture separator will operate indefinitely under normal working conditions, however at some time it may be necessary to replace the seals should the housing leak.

 

1. Isolate the housing from the air supply.

 

2. Fully depressurise in drain bowl as

 

3. Unscrew bowl and If pressure has not been completely released from the housing, air will escape from the warning hole giving an audible alarm. Screw back bowl and repeat instruction 2 before attempting again. Should resistance to unscrewing be experienced,

provision is made for a ’C’ spanner to fit onto the ribs of the bowl.

 

4. Check condition of bowl seal and replace if necessary. Clean screw

 

5. Refit bowl with ’O’ ring

 

6. Repressurise and check for If leaks occur they will most probably be from the bowl ’O’ ring. Depressurise housing and remove ’O’ ring as stated above and inspect and clean. Ensure that mating

surfaces are clean and then refit ’O’ ring and repressurise.

 

 

 

/2

• Turn the tension cam counter–clockwise 1

turn to Position I to

 

tension the gas strut.

 

 

9. Spin the drive to check alignment of the belt ribs on the pulleys (sheaves).

 

 

ELECTRIC DRAIN VALVE

 

 

PRODUCT DESCRIPTION

 

The Electric Drain Valve removes condensed water and oil from the moisture sepearator. Additional drains may be installed throughout your compressed air system, including aftercoolers, filters, drip legs and dryers.

 

The Electric Drain Valve operates on a timer which can be set to automatically drain the air receiver tank at operator–determined intervals.

 

Key features include:

 

• 100% continuous duty

 

• NEMA 4 enclosure

 

• Adjustable time on (0.5 – 10 seconds)

 

• Adjustable time off (0.5 – 45 minutes)

 

• Stainless steel operator

 

• LED to indicate electrical power is on

 

• LED to indicate valve is open

 

• Manual override

 

OPERATION

 

1. Open the strainer ball

 

Strainer Ball Valve.

 

OPEN                                  CLOSED

 

 

 

2. Set the “time off” and “time on” See TIMER SETTINGS (below) for an explanation of the settings.

 

3. During compressor operation, check for air

 

TIMER SETTINGS

 

The “time off” setting determines the interval between cycles from 30 seconds to 45 minutes. The “time on” setting determines the actual time the compressor drains condensate.

 

The timer’s cycle rate and drain opening time should be adjusted to open just long enough to discharge the condensate. The timer is properly set when it opens and discharges condensate and then vents air for approximately one second before closing. Adjustments may be made depending on many factors, including humidity and duty cycle.

 

TROUBLESHOOTING

Timer will not activate	1.  No electrical supply.	1.  Apply power.
	2.  Timer malfunction	2.  Replace timer.
	3.  Clogged port.	3.  Clean valve.
	4   Solenoid valve malfunction.	4.  Replace solenoid valve.
	5.  Clogged strainer.	5.  Clean strainer.

 

 

 

MAINTENANCE

 

Periodically clean the screen inside the valve to keep the drain functioning at maximum capacity. To do this, perform the following steps:

 

1. Close the strainer ball valve completely to isolate it from the air receiver

 

2. Press the TEST button on the timer to vent the pressure remaining in the valve. Repeat until all pressure is

 

CAUTION! High pressure air can cause injury from flying debris. Ensure the strainer ball valve is completely closed and pressure is released from the valve prior to cleaning.

 

3. Remove the plug from the strainer with a suitable wrench. If you hear air escaping from the cleaning port, STOP IMMEDIATELY and repeat steps I and 2.

 

4. Remove the stainless steel filter screen and clean it. Remove any debris that may be in the strainer body before replacing the filter

 

5. Replace plug and tighten with

 

6. When putting the Electric Drain Valve back into service, press the TEST button to confirm proper

 

 

TROUBLE	CAUSE	ACTION
Valve will not close.	1.  Debris in solenoid valve prevents dia- phragm from seating.	1.  Remove solenoid valve, disassemble, clean and reassemble.
	2.  Short in electrical component.	2. Check and replace power cord or timer as needed.

 

 

 

MODULATE CONTROL VALVE ADJUSTMENT

 

Ensure that the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg.

 

Ensure that the main power disconnect switch is locked open and tagged.

 

1. Put the compressor in the MODULATION mode by placing control selector switch SS in the “MODULATION” position. (Non–(Intellisys models).

 

2. Remove 1/4” plastic plug from the tee (18) in the regulator Connect a pressure gauge to this port.

 

3. Loosen the adjustment screw locknut and back out adjusting screw 3 turns. See Figure 2

 

4. Put the main power disconnect switch in the ON

 

5. Open the isolation valve and start the compressor.

 

6. Adjust the isolation valve to bring the discharge air pressure to the rated discharge pressure (100, 125, 140, or 200 psig).

 

7. While maintaining the rated discharge pressure, turn the adjustment screw on the modulation valve (see Figure 2) so that the test pressure gauge reads:

 

30 psig for modulate 60% cfm. Tighten the adjustment screw locknut.

8. Press UNLOADED STOP. Wait for sump pressure to go 0 Close the isolation valve or vent off all system air.

 

9. Put the compressor in the desired control

 

• Remove the test pressure gauge and replace 1/4” plastic

 

 

LOCKNUT ADJUSTING SCREW

 

 

FIGURE 2 MODULATION VALVE

 

TROUBLE SHOOTING     39

 

 

PROBLEM	CAUSE	REMEDY
Compressor fails to start	Mains power or Control voltage not available.	§    Check incoming power supply. §    Check the control circuit fuse. §    Check the transformer secondary windings for the control voltage.
	Defective Star / Delta timer.	§    Change Star / Delta timer.
Machine shuts down periodically	High airend temperature.	Top up coolant.
	Motor overload.	§    Set overload to correct value and switch to manual reset.
	Belt stretch protection (when fitted).	Change belt.
	Line voltage variation.	§    Ensure voltage does not drop below 10% on start up and 6% running.
High current draw	Compressor operating above rated pressure.	Set pressure to correct rating for machine.
	Separator cartridge contaminated.	Change air filter, and separator cartridge.
	Low voltage.	§    Ensure voltage does not drop below 10% on start up and 6% running.
	Unbalanced voltage.	Correct incoming supply voltage.
	Damaged airend.	†    Change Airend.
Low current draw	Air filter contaminated.	Change air filter.
	Compressor operating unloaded.	Set pressure to correct rating for machine.
	High voltage.	Reduce site voltage to correct operating voltage.
	Defective inlet valve.	†    Fit inlet valve service kit.
High discharge pressure	Defective or incorrect pressure switch setting.	Replace or set pressure to correct rating for machine.
	Load solenoid valve defective.	†    Fit load solenoid service kit.
	Blowdown valve defective.	†    Fit blowdown solenoid service kit.
	Inlet valve malfunction.	†    Fit inlet valve service kit.
Low system air pressure	Separator cartridge contaminated.	Fit new Separator cartridge.
	Incorrect pressure switch setting.	Set pressure to correct rating for machine.
	Minimum pressure valve malfunction.	†    Fit Minimum pressure valve service kit.
	Load solenoid valve defective.	†    Fit load solenoid service kit.
	Blowdown valve defective.	†    Fit blowdown solenoid service kit.
	Drive belt slipping.	Fit new belt and tensioner.
	Air system leaks.	†    Fix leaks.
	Inlet valve malfunction.	†    Fit inlet valve service kit.
	System demand exceeds compressor delivery.	Reduce demand or install additional compressor.

 

NOTES:

 

• Must be carried out by a competent electrician.

 

†    This work is recommended to be carried out only by an Ingersoll–Rand authorized service technician.

 

40      TROUBLE SHOOTING

 

PROBLEM	CAUSE	REMEDY
Compressor trips due to over temperature	Compressor operating above rated pressure.	Set pressure to correct rating for machine.
	Package pre–filter blocked.	Clean / replace package pre–filter.
	Cooler blocked.	Clean cooler.
	Missing or incorrectly fitted enclosure panels	Ensure that all enclosure panels are correctly fitted
	Low coolant level.	Top up coolant and check for leaks.
	High ambient temperature.	Re–site compressor.
	Restricted cooling air flow.	Ensure correct air flow to compressor.
Excessive coolant consumption	Separator cartridge leak.	Fit new Separator cartridge.
	Blocked separator cartridge drain.	†	Remove fittings and clean.
	Compressor operating below rated pressure.	Set pressure to correct rating for machine.
	Coolant system leak.	†	Fix leaks.
Excessive noise level	Air system leaks.	†	Fix leaks.
	Airend defective.	†	Change Airend.
	Drive belt slipping.	Replace belt and tensioner.
	Motor defective.	†	Replace motor.
	Loose components.	†    Retighten loose items.
Shaft seal leaking	Defective shaft seal.	†	Fit Airend shaft seal kit.
Pressure relief valve opens	Defective switch or incorrect pressure switch setting.	Replace or set pressure to correct rating for machine.
	Minimum pressure valve malfunction.	†    Fit Minimum pressure valve service kit.
	Load solenoid valve defective.	†    Fit load solenoid service kit.
	Blowdown valve defective.	†    Fit blowdown solenoid service kit.
	Inlet valve malfunction.	†    Fit inlet valve service kit.
Black residue on belt guard/cooler box	Drive belt slipping.	Replace belt and tensioner.
	Pulleys misaligned.	Re–align pulleys.
	Worn pulleys.	†	Replace pulleys and belt.
	Gas strut failed.	Replace belt and tensioner.
DRYER OPTION
High Dew Point (Indicator Red)	Dryer compressor or fan failed.	Check electrical supply and repair as required.
	Low refrigerant charge.	Check for leaks.
	High pressure switch tripped.	Check condenser coil for debris. Check fan operation. Clean / repair as required. Reset manual switch.
Low Dew Point (Indicator Blue) OR Compressor runs unloaded with no system pressure	HGBV out of adjustment / defective.	Adjust valve or replace as required.   Never adjust thermal expansion valve. It has been factory set
Water Down stream of dryer (Indicator OK)	Restricted / defective drain valve.	Clean / replace drain valve. Clean / replace condensate check valves.

 

NOTES:

 

• Must be carried out by a competent electrician.

 

†    This work is recommended to be carried out only by an Ingersoll–Rand authorized service technician.