Ingersoll-Rand SSR-EP20 Air Compressor Manual

XF 20/25/30EP 20/25/30 HP 20/25/30 HXP 20/25 OPERATORS/ INSTRUCTION MANUAL OPTIONS Before installation or starting the compressor for the first time, this manual should be studied carefully to obtain a clear knowledge of the unit and of the duties to be performed while operating and maintaining the unit. RETAIN THIS MANUAL WITH UNIT. This Technical manual contains IMPORTANT SAFETY DATA and should be kept with the air compressor at all times. More Than Air. Answers. Online answers: http://www.air.ingersoll-rand.com APDD 739B July 2001 @@@@@@@@@@@@@@ @?h@?e@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ @?h@ @?@@@@@@@?@?@@ @?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?f@?@?@?@@@@@@@?@ @?@?f@?@?@?@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@ @?@?f@?@ 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?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f?@?@f@@?@?@@@@@@@?@ ?@?@?@f?@?@ @?@@@@@@@?@ @@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@@@?@@@@@ @?h@ ?@h?@ @@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@ AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UP Warranty The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve months (see extended airend warranty) from the date of placing the Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from Davidson, NC, 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. Limitation of Liability The remedies of the Purchaser set forth herein are exclusive, and the total liability of the Company with respect to this contract or the Equipment and services furnished hereunder, in connection with the performance or breach thereof, or from the manufacture, sale, delivery, installation, repair or technical direction covered by or furnished under this contract, whether passed on contract, warranty negligence, indemnity, strict liability or otherwise, shall not exceed the purchase price of the unit of Equipment upon which such liability is based. The Company and its suppliers shall in no event be liable to the Purchaser, any successors in interest or any beneficiary or assignee of this contract for any consequential, incidental, indirect, special or punitive damages arising out of this contract or any breach thereof, or any defect in, or failure of, or malfunction of the Equipment hereunder, whether based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other goods, loss by reason of shutdown or non-operation, increased expenses of operation, cost of purchase of replacement power or claims of Purchaser or customers of Purchaser for service interruption whether or not such loss or damage is based on contract, warranty, negligence, indemnity, strict liability or otherwise. 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V+Y?hg ?V+Y EXTENDED AIREND WARRANTY The Ingersoll-Rand Company Rotary Screw Air Compressor that has been filled prior to its original shipment from Ingersoll-Rand Company with ULTRA COOLANT and which has been operated solely on ULTRA COOLANT thereafter shall have its AIREND warranted for twenty four (24) months from the date of placing the COMPRESSOR in operation or thirty (30) months from the date of shipment, whichever occurs first. Except for the above warranty period, the standard warranty provisions shall apply and the conditions outlined herein are understood to be a supplement to the standard Ingersoll-Rand Company warranty. ©INGERSOLL-RAND COMPANY ROTARY SCREW AIR COMPRESSOR This unit was purchased from ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– ––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. No. of units on order: Customer Order No: Ingersoll-Rand Co. Order No.: For ready reference: Record the serial number and model number of your unit here. Serial Number: Model Number: TYPICAL UNIT 1 TABLE OF CONTENTS 0.0 SAFETY AND WARNINGS 0.1 safety instructions 0.2 safety precautions 0.3 decals 1.0 RECEIPT OF EQUIPMENT 1.1 inspection 1.2 unpacking and handling 1.3 tools 2.0 INSTALLATION 2.1 ventilation 2.2 foundation requirements 2.3 piping 2.4 electrical installation 2.5 voltage conversion 2.6 rotation check 2.7 before starting - starting - stopping 2.8 outdoor sheltered installation 3.0 SYSTEMS 3.1 general system information 3.2 aircooled compressors 3.3 coolant system 3.4 air system 3.5 electrical system 3.6 capacity control 3.7 pressure switch adjustment 3.8 modulation control (optional) 3.9 ACS control (intellisys modulation option only) 3.10 modulate control valve adjustment (optional) 4.0 INTELLISYS (OPTIONAL) 4.1 emergency stop switch 4.2 power indicator light 4.3 push buttons 4.4 setpoint procedure 4.5 warnings 4.6 alarms 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 inlet air filter element coolant filter coolant change coolant hoses airend discharge hose coolant separator filter element separator tank scavenge check valve/orifice cooler cores motor lubrication Intellisys controller (optional) removal receiver tank drain trap inspection/cleaning 6.0 TROUBLE SHOOTING 6.1 standard control 6.2 Intellisys control 7.0 OPTIONS 7.1 remote start/stop 7.2 remote start/stop and power outage restart option 7.3 sequencer control 8.0 REFERENCE DRAWING 8.1 electrical schematic - full voltage - standard control 8.2 electrical schematic - star delta - standard control 8.3 electrical schematic - full voltage - Intellisys control 8.4 electrical schematic - star delta - Intellisys control 8.5 foundation plan - base mounted - unenclosed 8.6 foundation plan - base mounted - enclosed 8.7 foundation plan - 120 gal. tank mounted - unenclosed 8.8 foundation plan - 120 gal. tank mounted - enclosed 8.9 foundation plan - 240 gal. tank mounted - unenclosed 8.10 foundation plan - 240 gal. tank mounted - enclosed 8.11 basic flow schematic - standard control 8.12 basic flow schematic - Intellisys control 8.13 typical system flow diagrams 9.0 SERVICE AND OPTIONS KITS 10.0 MAINTENANCE RECORD GENERAL INFORMATION 5.0 MAINTENANCE 5.1 maintenance schedule 5.2 maintenance records 5.3 maintenance procedures 5.4 pressure relief valve check 5.5 sheave alignment 5.6 drive belt replacement 5.7 belt tension 5.8 belt tension gas spring replacement 5.9 shaft seal replacement 2 Cooling Air Flow: 20/25 HP: 1710 cfm (2905m3/hr.) 30 HP: 2060 cfm (3500m3/hr.) Ambient Temperature Limit: 35°F to 115°F (2°C to 46°C) Coolant: Factory Filled ULTRA COOLANT Coolant Change: 8,000 hours or two years, whichever comes first, when using ULTRA COOLANT Coolant Capacity: 3.2 GAL (12L) Discharge Temperature Limit: 228°F (109°C) Tools: U.S. Standard and metric are required to perform maintenance 0.0 SAFETY AND WARNINGS 0.1 SAFETY INSTRUCTIONS Before you install this air compressor you should take the time to carefully read all the instructions contained in this manual. Safety instructions in the operators manual are bold-faced for emphasis. The signal words DANGER, WARNING and CAUTION are used to indicate hazard seriousness levels as follows: Electricity and compressed air have the potential to cause severe personal injury or property damage. Before installing, wiring, starting, operating or making any adjustments, identify the components of the air compressor using this manual as a guide. The operator should use common sense and good working practices while operating and maintaining this unit. Follow all codes, pipe adequately, understand the starting and stopping sequence. Check the safety devices by following the procedure contained in this manual. Maintenance should be done by qualified personnel, adequately equipped with proper tools. Follow the maintenance schedules as outlined in the operators manual to ensure problem free operation after start up. D! DANGER Danger is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored. ! WARNING Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored. ! CAUTION Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored. NOTICE Notice is used to notify people of installation, operation, or maintenance information which is important but not hazard-related. 0.2 SAFETY PRECAUTIONS SAFETY PRECAUTIONS BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE COMPRESSOR OR PERFORMING ANY MAINTENANCE WARNING COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS. BEFORE DOING ANY WORK ON THIS UNIT, BE SURE THE ELECTRICAL SUPPLY HAS BEEN CUT OFF–LOCKED & TAGGED AND THE ENTIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF ALL PRESSURE. 3. Do not operate the compressor at higher discharge pressure than those specified on the Compressor Nameplate or motor overload will occur. This condition will result in compressor motor shutdown. c.) Vent pressure from the compressor and isolate the unit from any other source of air. 8. There can be adverse effects if compressor lubricants are allowed to enter plant air systems. 4. Use only safety solvent for cleaning the compressor and auxiliary equipment. Air line separators, properly selected and installed, will minimize any liquid carry-over. 1. Do not remove the covers, loosen or remove any fittings, connections or devices when this unit is in operation. Hot liquid and air under pressure that are contained within this unit can cause severe injury or death. 5. Install a manual shut off valve (isolation type) in the discharge line. When a safety valve is installed between the isolation valve and the compressor, it must have sufficient capacity to relieve the full capacity of the compressor(s). The use of plastic bowls on line filters without metal guards can be hazardous. From a safety standpoint, metal bowls should be used on any pressurized system. Review of your plant air line system is recommended. 2. The compressor has high and dangerous voltage in the motor starter and control box. All installations must be in accordance with recognized electrical codes. Before working on the electrical system, be sure to remove voltage from the system by use of a manual-disconnect-switch. A circuit breaker or fuse safety switch must be provided in the electrical supply line leading to the compressor. 6. Whenever pressure is released through the pressure relief valve, it is due to excessive pressure in the system. The cause for the excessive pressure should be investigated immediately. 9. When a receiver is installed, it is recommended that occupational safety and health standards as covered in the Federal Register, Volume 36, number 105, part 11, paragraph 1910.169 be adhered to in the installation and maintenance of this receiver. Those responsible for installation of this equipment must provide suitable grounds, maintenance clearance and lightning arrestors for all electrical components as stipulated in O.S.H.A. 1910.308 through 1910.329. b.) Electrically isolate the compressor by use of the manual disconnect switch in the power line to the unit. Lock and tag the switch so that it cannot be operated. 7. Before doing any mechanical work on the compressor: a.) Shut the unit down. 10. Before starting the compressor, its maintenance instructions should be thoroughly read and understood. 11. After maintenance functions are completed, covers and guards must be replaced. 3 ! SAFETY SHUTDOWN CHECK HIGH AIR TEMPERATURE There is a high discharge air temperature shutdown function built into each compressor. It is factory preset at 228°F (109°C). This function should be checked at regular intervals for proper operation, once a month is recommended. PROCEDURE: 1. Block off the cooling air discharge. 2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge temperature reaches the pre-set maximum discharge air temperature setting. ! WARNING Failure to adhere to these recommendations can result in mechanical failure, property damage and serious injury or death. All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must take into account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility between discharge piping, system accessories and software must be assured. For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is not recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the operating parameters of the system. It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine. ! WARNING “Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll-Rand does not approve specialized equipment for breathing air application and assumes no responsibility or liability for compressors used for breathing air services.” 4 0.3 DECALS This section contains representative examples of decals which will be appearing throughout this manual and are applied to the compressor unit. If for some reason a decal is defaced, parts are replaced or painted over, we recommend that you obtain a replacement. 39264734 REV A 5 1 NOTICE To obtain satisfactory compressor operation and maintenance a minimum of 3 feet clearance on 3 sides is required 3-1/2 feet is required in front of the control panel (or minimum required by latest National Electrical code or applicable local codes). Refer to the Instruction / Operators Manual before performing any maintenance. ! CAUTION 5 Incorrect lifting of machine can cause injury or property damage. Lift only from base channels. INGERSOLLrAND ® INGERSOLLrAND ® 39540158 2 ! DANGER Discharge air. Can contain carbon monoxide or other contaminants. Will cause severe injury or death. Do not breathe this air. INGERSOLLrAND ® 39540232 ! ! 6 High pressure air. Can cause severe injury or death. Relieve pressure before removing filter plugs / caps, fittings or covers. INGERSOLLrAND ® 39540166* 3 WARNING 39540240 WARNING NOTICE Air discharge. 7 INGERSOLLrAND® Hazardous voltage. Can cause severe injury or death. 39540257* Disconnect power before servicing. Lockout/Tagout machine. INGERSOLLrAND ® 39540174 ! CAUTION 8 Use of incorrect coolant can cause system contamination. Use only SSR ULTRA COOLANT. INGERSOLLrAND ® 4 ! WARNING 39540265 NOTICE Exposed fan blade. Can cause severe injury. Do not operate with covers removed. Disconnect power. Lock and tag. INGERSOLLrAND ® Lift here. INGERSOLLrAND® 39540273 3954190 6 * - THESE DECALS ARE LOCATED ON THE END OF THE RECEIVER TANK ON TANK MOUNTED UNITS 9 10 WARNING ! ! WARNING 15 Exposed moving belts and sheaves. Hot surface. Can cause severe injury. Can cause severe injury or death. Do not touch. Allow to cool before servicing. Do not operate with guards removed. Disconnect power, lock and tag out machine before servicing. 39859236 INGERSOLLrAND ® 39541362 11 NOTICE Filler Cap. Use only recommended coolant. Read instruction book before servicing. 39543921 39540281 12 ! CAUTION Improper coolant filter replacement will cause compressor damage. Replace filter element after first 150 hours of operation and every 2000 hours thereafter or when coolant is changed. INGERSOLLrAND ® 39544143 13 39859236 INGERSOLLrAND® NOTICE NOTICE Before installing, operating, or performing any maintenance on this unit, read and understand the instructions in the Operators/Instruction Manual. 16 Before Starting 1. Check coolant level and add coolant if necessary. 2. Verify that main isolation valve is open. 3. Close main disconnect switch. Starting 1. Push START button. Compressor will start and load automatically. 2. Air Pressure will rise if there is sufficient demand for air. Stopping 1. Pushing STOP button. Compressor will stop after 7-10 seconds. 2. Open main disconnect switch. INGERSOLLrAND ® 39919246 Rotation. INGERSOLLrAND ® 39544150 14 Rotation 17 Rotation 54372719 39557095 7 1.0 RECEIPT OF EQUIPMENT 1.1 INSPECTION When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier should be noted on the delivery receipt especially if the compressor will not be immediately uncrated. Obtaining the delivery man’s signed agreement to any noted damages will facilitate any future insurance claims. IMPORTANT READ THIS LOST OR DAMAGED GOODS THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNED BILL OF LADING If goods are received short or in damaged condition, it is important that you notify the carrier and insist on a notation of the loss or damage across the face of the freight bill. Otherwise no claim can be enforced against the transportation company. If concealed loss or damage is discovered, notify your carrier at once and request an inspection. This is absolutely necessary. Unless you do this the carrier will not entertain any claim for loss or damage. The agent will make an inspection and grant a concealed damage notation. If you give the transportation company a clear receipt for goods that have been damaged or lost in transit, you do so at your own risk and expense. WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL. THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR RESPONSIBILITY. Ingersoll-Rand Company Davidson, North Carolina APDDGFO-99-79 1.2 UNPACKING AND HANDLING The compressor package has been mounted on a base which provides for forklifting between the two side channels to facilitate handling during shipment. Care in positioning the forklifts is important because the location of the center of gravity is strongly affected by the location of the compression module and drive motor. Slings can be used to lift the crates, but spreader bars must be used to prevent the slings from exerting a force against the sides of the crates. 1.3 TOOLS Remove compressor unit from wooden skid. A crowbar and hammer will be needed. 8 FORKLIFT PADDING WILL REDUCE SCRATCHES AND MARS SPREADER BARS 2.0 INSTALLATION 2.1 VENTILATION Oil flooded rotary air compressors produce large amounts of heat. Because of this large heat production, the compressor must be placed in a room with adequate ventilation. A room in which the amount of air that is drawn in and exhausted is equal to or greater than the cooling fan air flow requirement for the compressor that is installed. If heated air from the compressor exhaust is allowed to recirculate back to the compressor, the compressor will overheat and shut down. This heat must be exhausted from the room. You should take this into consideration when you decide where to place the compressor within your plant. Consider that the required maintenance clearance is 3 ft (.9 m) all around the compressor. However 42” (1.06m), or minimum required by latest NEC or applicable local codes, must be maintained in front of control panel door. Ambient temperatures higher than 115°F (46°C) should be avoided as well as areas of high humidity. Consider also the environment surrounding or near the compressor. The area selected for the location of the compressor should be free of dust, chemicals, metal filings, paint fumes and overspray. DUST CHEMICALS METAL FILINGS PAINT SPRAY 36” (.9 m) 36” (.9 m) 42” (1.06 m) OR CODE MINIMUM AIR INTAKE OVERSPRAY 2.2 FOUNDATION REQUIREMENTS Refer to the foundation plan for the particular model compressor to be installed. See Section 8.0. The compressor can be installed on any level floor that is capable of supporting it. Compressor weights are listed on the foundation plans. When sound transmission is of particular importance it is often helpful to install a sheet of rubber-fabric-matting, or cork under the compressor to reduce the possibility of resonant sounds being transmitted or amplified through the floor. 2.3 PIPING The use of plastic bowls on line filters without metal guards can be hazardous. Their safety can be affected by either synthetic lubricants or the additives used in mineral oil. From a safety standpoint, metal bowls should be used on any pressurized system. Review of your plant air line system is recommended. ! WARNING Do not use plastic pipe, soldered copper fittings or rubber hose for discharge piping. The built-in aftercooler reduces the discharge air temperature well below the dew point (for most ambient conditions), therefore, considerable water vapor is condensed. To remove this condensation, tank mounted compressors with built-in aftercoolers are furnished with a combination condensate separator/trap. 9 2.3 PIPING (Continued) A dripleg assembly and isolation valve should be mounted near the compressor discharge. A drain line should be connected to the condensate drain in the base. ISOLATION VAVLE IMPORTANT: The drain line must slope downward from the base to work properly. NOTE: For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel. It is possible that additional condensation can occur if the downstream piping cools the air even further and low points in the piping systems should be provided with driplegs and traps. DRIP LEG DISCHARGE PIPING WITH AFTERCOOLER SAFETY VALVE IMPORTANT: Discharge piping should be at least as large as the discharge connection at the compressor enclosure. All piping and fittings must be suitable for the maximum operating temperature of the unit and, at a minimum, rated for the same pressure as the compressor sump tank. ! NOTICE ISOLATION VALVE SAFETY VALVE PRESSURE GAUGE RECIPROCATING COMPRESSOR DRIP LEG TRAP Do not use the compressor to support the discharge pipe. Careful review of piping size from the compressor connection point is essential. Length of pipe, size of pipe, number and type of fittings and valves must be considered for optimum efficiency of your compressor. MOISTURE SEPARATOR/ DRAIN TRAP ISOLATION VALVE STRAINER ISOLATION VALVE NOTE: SEPARATE LINES GOING TO THE RECEIVER ROTARYROTARY COMPRESSOR COMPRESSOR DRIP LEG It is essential when installing a new compressor to review the total plant air system. This is to ensure a safe and effective total system. MOISTURE SEPARATOR/ DRAIN TRAP ROTARY-RECIP IN PARALLEL 200 Moisture in compressed air is responsible for costly problems in almost every application that relies on compressed air. Some common problems caused by moisture are rusting and scaling in pipelines, clogging of instruments, sticking of control valves, and freezing of outdoor compressed air lines. Any of these could result in partial or total plant shutdown. 160 Gallons of Water/24 hours/1000 acfm Liquid water occurs naturally in air lines as a result of compression. Moisture vapor in ambient air is concentrated when pressurized and condenses when cooled in downstream air piping. 120 80 40 0 DEW POINT Compressed air dryers reduce the water vapor concentration and prevent liquid water formation in compressed air lines. Dryers are a necessary companion to filters, aftercoolers, and automatic drains for improving the productivity of compressed air systems. without Aftercooling 100°F/38°C (with Aftercooler) 35°F /1.7°C (Refrigerated Dryer) -40°F/-40°C (Desiccant Dryer) MOISTURE CONTENT OF COMPRESSED AIR 10 Two types of dryers, refrigerated or desiccant, are used to correct moisture related problems in a compressed air system. Refrigerated dryers are normally specified where compressed air pressure dew points of 33°F (1°C) to 39°F (4°C) are adequate. Desiccant dryers are required where pressure dew points must be below 33°F (1°C). SAFETY VALVE PRESSURE GAUGE Contact your local Ingersoll-Rand distributor for assistance in selecting correct Ingersoll-Rand filtration or drying products. NOTE: Screw type compressors should not be installed in air systems with reciprocating compressors without a means of pulsation isolation, such as a common receiver tank. We recommend both types of compressor units be piped to a common receiver utilizing individual air lines. MOISTURE SEPARATOR/ DRAIN TRAP TRAP STRAINER Before proceeding further, we recommend that you review the safety data in the front of this manual. ROTARY COMPRESSOR DRIP LEG When two rotary units are operated in parallel, provide an isolation valve and drain trap for each compressor before the common receiver. 2.4 ELECTRICAL INSTALLATION ISOLATION VALVE ISOLATION VALVE ROTARY COMPRESSOR ISOLATION VALVE MOISTURE SEPARATOR/ DRAIN TRAP DRIP LEG Locate the compressor data plate on the left end of the cooler box next to the control box. The data plate lists the rated operating pressure, the maximum discharge pressure and the electric motor characteristics and power. ROTARY TWO COMPRESSOR SYSTEM Confirm that the line voltage and compressor nameplate voltage are the same and that the standard starter box meets the intent of NEMA 1 guidelines. A hole is provided for incoming power connection. If it is necessary to make a hole in the control box in a different location, care should be taken to not allow metal shavings to enter the starter and other electrical components within the box. After making the power inlet hole, all shavings and debris must be removed from inside of control box before power is turned on. Incoming power should be connected per the electrical schematic on the starter box door. Confirm that all electrical connections are made and tightened. Confirm that the control transformer is wired correctly for supply voltage (See Figure 2.5-1). Inspect the motor and control wiring for tightness. Close the panel front. 11 2.5 VOLTAGE CONVERSION (230V TO 460V) IMPORTANT: This procedure should only be carried out by a qualified electrician, electrical contractor or your local Ingersoll Rand Distributor or Air Center NOTE: This procedure applies only to units manufactured to multi-voltage specifications compressor data plate and motor nameplate must indicate multiple voltages. LINE VOLTS 200 HZ 60 LINE H4-H5 SEC VOLTS 120 LINE X1-X2 REFERENCE Quad Type 220/230 50/60 H1-H2 110-120 X1-X4 Universal Type 380 50/60 H1-H3 110-120 X1-X4 Universal Type 415 50 H1-H3 110-120 X1-X4 Universal Type 440/460 50/60 H1-H4 110-120 X1-X4 Universal Type 550/575 60 H1-H5 110-120 X1-X4 Universal Type *TYPICAL CONTROL TRANSFORMER (ELECTRO - PNEUMATIC) LINE VOLTS 200 HZ 60 LINE H4-H5 SEC VOLTS 120 8 8 LINE X1-X2 X3-X4 X4-X5 220/230 60 H3-H5 120 8 8 X1-X2 X3-X4 X4-X5 380 60 H3-H5 120 8 8 X1-X2 X3-X4 X4-X5 440/460 60 H2-H5 120 8 8 X1-X2 X3-X4 X4-X5 575 60 H1-H5 120 8 8 X1-X2 X3-X4 X4-X5 LINE VOLTS HZ LINE SEC VOLTS LINE 220 50 H5-H6 110 8 8 X1-X2 X3-X4 X4-X5 380 50 H4-H6 110 8 8 X1-X2 X3-X4 X4-X5 415 50 H2-H6 110 8 8 X1-X2 X3-X4 X4-X5 110 8 8 X1-X2 X3-X4 X4-X5 550 50 H1-H6 HIGH VOLTAGE PRIMARY SIDE LOW VOLTAGE SECONDARY SIDE QUAD TYPE TRANSFORMER (200V/60 HZ) HIGH VOLTAGE PRIMARY SIDE LOW VOLTAGE SECONDARY SIDE UNIVERSAL TYPE TRANSFORMER (ALL VOLTAGES EXCEPT 200V/60 HZ) *TYPICAL 60 HZ CONTROL TRANSFORMER (INTELLISYS OPTION) H4 110V *TYPICAL 50 HZ CONTROL TRANSFORMER (INTELLISYS OPTION) FIGURE 2.5-1 TYPICAL CONTROL TRANSFORMER WIRING 12 H5 H6 FIGURE 2.5-2 FAN WIRING DIAGRAM 13 Procedure: Put main disconnect in the OFF position, lock and tag (See Figure 2.5-3). 2.6 ROTATION CHECK Locate the rotation decals on the motor and fan (s) and check for correct rotation. The correct motor rotation when viewed from the non-drive end of the motor is clockwise (See Figure 2.6-1). ! CAUTION DANGER HIGH VOLTAGE HASP If the compressor is operated in the opposite direction of rotation, airend damage can result and is not warrantable. LEVER TAG GER DAN KEY LOCK For the compressor motor and fan rotation check, the motors should be jogged for as short a time as possible. 1. Ensure that the Emergency Stop button is in the open (depressed) position. FIGURE 2.5-3 MAIN DISCONNECT LOCKED AND TAGGED Open the motor junctoion box on the side of the motor. Reconnect the motor to the desired voltage. Use the connection diagram proviced on the motor as a guide. Adjust motor overload setting as outlined below in Figure 2.5.4. NOTICE IEC STARTER OVERLOAD SETTING 1. Full-Voltage Starter (Main or Fan Motor): Multiply MOTOR nameplate amps by 1.11. Star-Delta Starter (Main motors only): Multiply MOTOR nameplate amps by 0.64. 2. Set corresponding overload relay at this value. 2. Verify that coolant level is in the middle (green) range of the sight tube. 3. Verify that the main isolation valve is open. 4. Open the enclosure canopy if machine is so equipped. Disengage Emergency Stop button by turning pushbutton clockwise. Push the red Unloaded Stop/Reset button. Push the Start button to start the unit and immediately depress (push) the Emergency Stop button to stop the unit (See Figure 2.7-1 for Control Panel layout). CAUTION: Do not use the Unloaded Stop button for this procedure; it is equipped with a time delayed stop circuit and damage may occur to the compression module if operated in wrong direction. 3. Never exceed the following limits: Full-Voltage Starter: 125% of MOTOR nameplate amps. Star-Delta Starter: 72% of MOTOR nameplate amps. FIGURE 2.5-4 MOTOR OVERLOAD SETTING Reconnect the promary side of the control transformer for the desired voltage, as shown on the control transformer wiring decal. Reconnect the fan motor (s) wiring to the desired voltage (See fan wiring diagram Figure 2.5-2). Make sure all wiring connections are tight. Put main disconnect in the ON position and check main motor and fan motor rotation, as outlined in Section 2.6 of this manual. 14 5. Observe the compressor drive motor shaft. The rotation should be in accordance with the directional arrow decal on the motor. Observe the cooling fan (s). The rotation of the fan(s) should be in accordance with the direction arrow adjacent to each fan. (See Figures 2.62 and 2.6-3. 6. Should the main motor or fan rotation be incorrect, put the main disconnect in the OFF position, lock and tag. Interchange any two line connections (L1, L2, or L3) at the starter panel for the component that is rotating incorrectly. Close the control box cover. Recheck for correct rotation. DRIVE END NON-DRIVE END FIGURE 2.6-1 DRIVE MOTOR ROTATION CORRECT ROTATION FIGURE 2.6-2 MAIN FAN (ALL MODELS) CORRECT ROTATION FIGURE 2.6-3 AUXILIARY FAN (S) (25, 30 HP ONLY) 2.7 BEFORE STARTING - STARTING - STOPPING Starting Read and understand the following instructions before operating or performing any maintenance on this unit 1. Push the Unloaded Stop/Reset button (red fault indicator light will go out). Before Starting: 2. Push the Start button and release. The compressor will start and then load automatically if line pressure is below the lower set point of the pressure switch. 1. Ensure that Emergency Stop push button is in the OFF (depressed) position (See Figure 2.7-1). Stopping 2. Verify that coolant level is in the middle (green) range in the sight tube. 3. Close the main disconnect switch (ON position). 1. Depress the Unloaded Stop/Reset button. Compressor will unload for approximately 7 seconds and then stop. 4. Verify that the main isolation valve is open. 2. Open the main disconnect switch (OFF position). 15 EMERGENCY CONTROL STOP PANEL BUTTON HOUR METER AUTO UNLOADED POWER ON STOP/RESET INDICATOR RESTART INDICATOR BUTTON LIGHT LIGHT START BUTTON PRESSURE GAUGE FAULT/ ALARM INDICATOR LIGHT TEMP. GAUGE FIGURE 2.7-1 STANDARD CONTROL PANEL ■ If a standard machine is to be installed outside, the ambient temperature must never drop below 35°F (1.7°C). ■ Arrange the machine with the Control Panel facing away from the sun as radiant heat can affect performance. Also direct sunlight and UV rays will degrade the membrane touch panel. This is not a warrantable situation. ■ Power disconnect switch should be within line of sight and in close proximity to the unit. N.E.C. and local electrical codes must be followed when installing the power disconnect switch. ■ Condensate drain must never be allowed to drain on the ground. Run to a suitable sump for future collection and disposal or separation of lubricant and water mixture. ■ Incoming power connections must use suitable connectors for outdoor weather tight service. ■ A minimum of 3 ft (.9 m) clearance must be allowed on all four sides of the unit for service access. However 42” (1.06m), or minimum required by latest NEC or applicable local code, must be maintained in front of control panel door. ■ If possible, access by a forklift and/or an overhead beam hoist should be kept in mind (for eventual service to airend or motor). ■ If the area around the installation contains fine airborne dust or lint and fibers etc., then the unit should be purchased with the High Dust Filter Option and TEFC motor option. ■ Some type of protection such as a fence or security system, should be provided to prevent unauthorized access. 2.8 OUTDOOR SHELTERED INSTALLATION Many times a compressor must be installed outside due to jobsite conditions or limited space within a manufacturing facility. When this occurs there are certain items that should be incorporated into the installation to help ensure trouble free operation. These items have been listed below plus Figure 2.8-1 has been included to show a typical outdoor sheltered installation. The unit must be purchased with the Outdoor Modification Option to provide watertight electrics and a TEFC motor. ■ The compressor should be on a concrete pad designed to drain water away. If the concrete pad is sloped, then the compressor must be leveled. In order to properly pull cooling air through the aftercooler, the base/skid must be sealed to the concrete pad. ■ The roof of the shelter should extend a minimum of 4 ft (1.2 m) around all sides of the compressor to prevent direct rain and snow from falling on the unit. ■ Air-cooled machines must be arranged under the shelter in a way that prevents air recirculation (i.e. hot exhaust back to the package inlet). ■ If the installation includes more than one compressor, the hot air exhaust should not be directed towards the fresh air intake of the second unit or an Air Dryer. 16 CONTROL PANEL FACING AWAY FROM SUN 17 FIGURE 2.8-1 TYPICAL OUTDOOR SHELTERED INSTALLATION 3.0 SYSTEMS (tank mounted unit only). 3.1 GENERAL SYSTEM INFORMATION A moisture separator and automatic drain trap assembly is available through your Ingersoll-Rand Representative. The compressor is an electric motor driven, single stage, rotary screw compressor, complete with supporting components to make a fully functional unit. A standard compressor is composed of the following: Inlet air filter Drive motor Airend Pressurized coolant system with cooler & filter Cooling fan (s) Capacity control Instruments Safety devices Compression in the rotary screw type air compressor is created by the meshing of two helical rotors (male and female) on parallel shafts, enclosed in a heavy duty iron housing, with air inlet and outlet ports located on opposite ends. The grooves of the female rotor mesh with and are driven by the male rotor. Bearings on both ends of the rotors are used to support the rotor both laterally and axially. 3.2 AIRCOOLED COMPRESSORS Design Temperatures The standard compressor is designed for operation in an ambient range of 35°F to 115°F (1.7°C to 46°C). When conditions other than design levels described are encountered, we recommend you contact your nearest Ingersoll-Rand representative for additional information. By cooling the discharge air, much of the water vapor naturally contained in the air is condensed and eliminated from the downstream plant-piping and equipment. 3.3 COOLANT SYSTEM The coolant system consists of a separator tank, thermostatic control valve, coolant filter, coolant cooler with fans, and a separator element. When the unit is operating, the coolant is pressurized and forced to the compressor bearings. The compressor is provided with a temperature switch which will shut the unit down in case of excessive temperature, 228°F (109°C). Effective coolant filtration is provided by the use of a screw on, heavy duty coolant filter. Coolant Rotary screw compressor fluids have a triple function to perform. They lubricate the bearings and contacting surfaces of the rotors, seal internal clearances within the rotor chamber, and provide for the cooling of the compression process. The bulk of the fluid is actually used for cooling, with only small amounts used for lubrication and sealing. The standard maximum temperature 115°F (46°C) is applicable up to an elevation of 3300 ft. (1000 meters) above sea level. Above this altitude, significant reductions in ambient temperature are required if a standard drive motor is to be used. SSR air compressors are factory filled with SSR ULTRA COOLANT which is designed to operate for 8,000 hours or two years, whichever comes first. The coolant must be changed at these intervals to avoid breakdown and equipment damage. Coolant Cooler Circulation of Coolant The cooler is an integral assembly of core, fan and fan-motor, mounted in the compressor. The cooling air flows in through the front of the enclosure, through the vertically mounted cooler core, and discharges upward and downward through the rear sound box. Coolant is forced by air pressure from the separator tank to the thermostatic element. The position of the element (a direct result of coolant temperature) will determine whether the coolant circulates through the cooler, bypasses the cooler, or mixes the two paths together to maintain an optimum compressor injection temperature. This temperature is controlled to preclude the possibility of water vapor condensing. By injecting coolant at a sufficiently high temperature, the discharge air coolant mixture temperature will be kept above the dew point. Aftercooler The compressed air aftercooling system consists of a heat exchanger (located at the cooling air discharge of the machine) and an automatic drain trap 18 Before being injected into the airend, all coolant flows through the coolant filter. It is full flow filter with a single replacement spin-on element, rated at 4 micron. There is a differential-pressure bypass valve set to open in the event that the pressure drop across the filter rises to as high as 15 psi (1 bar), which indicates an excessively fouled element as well as poor maintenance practice. coolant and cleaning of the air prior to leaving the compressor. The minimum pressure check valve keeps the separator tank and separator element at a minimum pressure to ensure adequate oil flow and proper coolant/air separation. It also prevents line pressure from exhausting back through the airend at shutdown and during periods of unloaded operation. Coolant/Air Separation System The coolant/air separation system is composed of a separator tank with specially designed internals and a coaslescing type separator element located inside the tank. The air-coolant mixture discharges from the airend into the separator tank. The majority of coolant is separated while in the separator tank and the coalescing separator filter element is used for final cleaning of the air prior to the customer’s system. The system removes nearly all of the coolant from the discharge air. The separated coolant is returned to the coolant system and the air passes to the compressed air system. 3.4 AIR SYSTEM Components and Flow The air system is composed of: Inlet air filter Inlet valve Airend (rotors) Coolant/Air separator Minimum pressure check valve (MPCV) Aftercooler Moisture separator/drain trap (remote mounted) The direction of flow is from the inlet filter to the aftercooler. Refer to process and instrumentation diagrams in Section 8.0. Functions of Components Inlet air filter, filters the incoming air, trapping 99.9% of particles 3 micron and larger. Inlet valve opens full for on-line operation. The valve closes in the off-line mode and at shutdown which prevents back flow of the compressed air. The airend compresses the air. The aftercooler cools the air prior to leaving the package. 3.5 ELECTRICAL SYSTEM The electrical system of each SSR compressor is built with electro-pneumatic control as standard, or with the micro-processor based Intellisys controller as an option. The standard electrical/electronic components are enclosed in a readily accessible enclosure and include: 1. Push button controls w/analog gauges 2. Indicator lights 3. Switching relays/timers 4. Control transformers and fuses 5. Compressor motor starter, with auxiliary contacts and overload relays 6. Optional Intellisys controller in place of #1, 2, and 3 By use of a built-in automatic Across-The-Line type starter, the compressor can be started using full voltage electric current. Refer to the electrical schematic, Section 8.0 schematic 8.1 (Standard control) or 8.3 (Intellisys option). By use of an optional built-in Star-Delta type starter, the compressor motor can be started and accelerated using a greatly reduced “inrush” electric current. Refer to the electrical schematic, Section 8.0 schematic 8.2 (Standard control) or 8.4 (Intellisys option). The standard machine is equipped with a red shutdown alarm indicator. This indicator will illuminate upon machine shutdown as a result of main motor overload, high discharge air temperature, or emergency stop activation. Options such as remote start/stop or power outage restart can be added. The separator tank removes most of the coolant from the air. The separator element performs the final separation of 19 3.6 CAPACITY CONTROL 2. Remove pressure switch cover by turning the cover screw counterclockwise. NOTE: It is required that the load or on-line pressure be set first, before the unload or off-line pressure is set. The SSR compressor is supplied with on-line/off-line with automatic start/stop control as standard. Optional modulation control enables the compressor to operate with a throttled inlet flow for air systems which have a relatively high constant demand relative to compressor capacity. 3. Set the on-line pressure by turning screw 5 (See Figure 3.7-1). Turn clockwise to increase setting or counter-clockwise to decrease setting (indicated by pointer 4). On-Line/Off-Line With Automatic Start/Stop Control (Electro-Pneumatic Control) 4. Set the off-line pressure by turning screw 2. Turn screw counter-clockwise to increase setting or clockwise to decrease setting (indicated by pointer 3). The compressor will deliver air at full capacity, (the compressor maximum efficiency condition) or will operate at zero capacity with high receiver pressure (the compressor minimum power condition), while the unit continues to run. CAUTION: DO NOT EXCEED MAXIMUM DISCHARGE PRESSURE (LOCATED ON COMPRESSOR DATA PLATE) When the compressor starts and line pressure is below the lower setting of the line pressure switch, control solenoid 1SV will be energized (closed), inlet valve will open, and the compressor will load. When the line pressure reaches the upper setting of the pressure switch, the compressor will unload by deenergizing (closing) 1SV and closing the inlet valve. Solenoid 1SV relieves the internal pressure of the compressor back to the inlet filter. The only adjustment required is setting of the pressure switch. A time delay relay is energized and begins to time out. The timer, mounted in the control box, is factory set at 10 minutes. It will continue to operate for as long as its time setting, after which a relay contact opens to de-energize the compressor starter coil. At the same time, an amber light (1LT) on the control box is lit to indicate the compressor has shut down automatically and will restart automatically. The automatic restart will take place when the line pressure drops to the lower setting on the pressure switch. Adjusting the Auto Restart timer below the 10 minute factory setting may shorten the life of the compressor drive motor. 5. Turn power back on, start compressor and test adjustment(s) made. If necessary, readjust according to steps 1-4 above. 5 2 3 4 3.7 PRESSURE SWITCH ADJUSTMENT Locate the pressure switch (shown in Figure 3.7-1). The pressure switch can be adjusted using the following procedure: 1. Open, lock and tag the main electrical disconnect. Do not adjust the pressure switch with power on or machine operating. 20 FIGURE 3.7-1 PRESSURE SWITCH 3.8 MODULATION CONTROL (OPTIONAL) 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 is factory 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 3.8-1). Capacity control of machines supplied with electropneumatic control and the modulation option can be manually switched from on-line/off-line to modulation (MOD) via the control mode switch (S1) located adjacent to the pressure switch. 3.9 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. FIGURE 3.8-1 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. 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 3.8-1 21 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®. Refer to Section 4.4 for instructions. 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 anytime 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 signaling 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" timeperiod 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. 22 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. 3.10 MODULATE CONTROL VALVE ADJUSTMENT (MODULATION OPTION) WARNING ! 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 S1 in the “MODULATION” position. Refer to Section 4.4 for instructions (Intellisys option). 2. Remove 1/8" NPT plug from the tee in the control piping on the side of the airend support. Connect a pressure gauge to this port. 3. Loosen the adjustment screw locknut and back out adjusting screw 3 turns. See Figure 3.9-1. Hazardous voltage. Can cause severe injury or death. Disconnect power before servicing. Lockout/Tagout machine. O ! WARNING 4. Put the main power disconnect switch in the ON position. 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 3.9-1) so that the test pressure gauge reads: High pressure air. Can cause severe injury or death. Relieve pressure before removing filter plugs / caps, fittings or covers. 30 psig for modulate 60% cfm (star-delta units) Tighten the adjustment screw locknut. 8. Press UNLOADED STOP. Wait for sump pressure to go 0 psig. Close the isolation valve or vent off all system air. 9. Put the compressor in the desired control mode. 10. Remove the test pressure gauge and replace the 1/8" NPT plug using Loctite® PST or similar thread sealant. LOCKNUT LOCKNUT *Loctite is a registered trademark. ADJUSTING SCREW ADJUSTING SCREW FIGURE 3.9-1 MODULATION VALVE 23 4.0 INTELLISYS (OPTIONAL) 24 PACKAGE DISCHARGE PRESSURE • AIREND DISCHARGE TEMPERATURE • SUMP PRESSURE • SEPARATE PRESSURE DROP • TOTAL HOURS • LOADED HOURS • • INGERSOLLrAND INGERSOLrAND • INTELLISYS INTELLISYS POWER AUTOMATIC RESTART • DISPLAY SELECT • UNLOAD • SET OFFLINE AIR PRESURE • SET ONLINE AIR PRESSURE • SELECT CONTROL MODE • SET DISPLAY TIME • SELECT OPTIONS • SET • • START UNLOAD /LOAD ALARM UNLOADED FIGURE 4.0-1 INTELLISYS CONTROLLER STOP 4.0 INTELLISYS (OPTIONAL) 4.1 EMERGENCY STOP SWITCH Pressing this switch stops the compressor immediately. Compressor cannot be restarted until switch is manually reset. Turn clockwise to reset. Unloaded Stop Pressing this button will activate the unload stop. If the compressor is running loaded, it will unload. Seven seconds later it will stop. if the compressor is running unloaded, it will stop immediately. Pressing this button with the unit stopped will flash all L.E.D.’s for a light check and flash the software version number in the display. EMEG STOP UNLOADED STOP 4.2 POWER INDICATOR LIGHT Unload/load Indicates voltage is available to the Intellisys controller. If the unit is running loaded, pressing this button will cause the unit to unload, the unload indicator light will be on. The unit will not load until the button is pressed again. If the unit is running unloaded, pressing this button will load the unit in the ON/OFF LINE or MOD/ACS control mode previously operating. POWER 4.3 PUSH BUTTONS UNLOAD /LOAD Start If the display shows “READY TO START”, pressing this button will start the compressor. The compressor will start and load automatically if there is a demand for air. START If in the display table press this button to exit the display table. Display will show “CHECKING MACHINE” then “READY TO START”. 25 4.3 PUSH BUTTONS (Continued) Pressure Sensor Calibration (Zeroing) Routine Display Select Pressing this button will change the information selected for the display. The display table will be incremented. If the button is held, this display table will scroll. This button can also be used to exit the set point procedure. DISPLAY SELECT NOTE: For readings less than 1 hr., hourmeter display minutes. After 1 hr. the hourmeter displays hours. Set The SET button is used to enter the setpoint procedure. The set button is also used to reset warnings and alarms. Pressing this button once will reset a warning, twice will clear an alarm. SET Arrows These buttons have several functions. If the Intellisys is in the setpoint mode, the ARROWS are used to change the setpoint values. If the unit has multiple alarms or warnings, the ARROWS are used to scroll through these conditions. The ARROWS have a function in the calibration routine, which will be described later. 26 This routine is entered if the unit is not running and both the up and down arrows button are pressed at the same time. Make sure all pressure is relieved from the compressor before calibration. The display will flash the message “CALIBRATING”. After calibration is completed the display will indicate “READY TO START”. Zeroing should only be done after a pressure sensor has been replaced or any controller change. 4.4 SETPOINT PROCEDURE This procedure allows the customer to modify 11 variables in the controller logic. At this time, press the SET button to enter the setpoint routine. The SET OFFLINE AIR PRESSURE indicator will light and the display will show: ** The lead/lag feature allows the customer to choose one compressor as the “lead” compressor and any others as the “lag” compressor (simulates the mode of a sequencer). The lag compressor’s on-line and off-line pressures are determined by subtracting the lag offset setpoint from the on-line and off-line pressure set-points of the lead compressor. 4.5 WARNINGS XXXX PSI OFFLINE AIR PRESSURE is the first setpoint and XXXX stands for the value of the setpoint. Press the SET button to select the setpoint to be adjusted. Press the up or down arrow buttons to raise or lower the setpoint value. Press the SET button to move to the next setpoint. If the setpoint value has been adjusted, press the SET button to enter the new value. The display will flash to acknowledge.The next setpoint will then be displayed. If the value of the setpoint was not changed, pressing the SET button will only step to the next setpoint. When the SELECT OPTIONS setpoint is entered, the SELECT OPTIONS indicator will light, and the setpoints for options Auto Start/Stop or Remote Start/Stop will only be accessible and displayed if the option module is installed in the unit. The Power Outage Restart setpoints will only be accessible and displayed if the combination Auto/Remote Start/Stop/Power Outage Restart option module is installed in the unit. The setpoint routine can be exited by pressing the DISPLAY/SELECT button or exit will be automatic after 30 seconds. The following is a list of the setpoints. Also included are maximum and minimum limits, step size, and units of measure. MIN MAX STEP UNIT OFFLINE PRESSURE 75 RATED + 3 1 PSI ONLINE PRESSURE 65 OFFLINE - 10 1 PSI CONTROL MODE DISPLAY TIME AUTO RESTART AUTO RESTART TIME When a warning occurs, the alarm indicator will flash and the display will alternate between the current message and the warning message. If multiple warnings exist, the message SCROLL FOR WARN will be substituted for the warning messages. The up and down arrows can be used to obtain the warnings A warning needs to be reset by an operator. The warning will clear when the SET button is pressed once. The following is a list of the warning messages. 1) CHG SEPR ELEMENT This warning will occur if the pressure on the Separator is 12 psig (.8 bar) greater than the pressure at the Package discharge and the unit is fully loaded. 2) HIGH AIREND TEMP This will occur if the Airend Discharge Temperature (2ATT) exceeds 221°F (105°C). MOD/ACS - MODULATION - ON/OFF LINE 10 600 10 OFF ON --- SEC --- 2 60 1 MIN SEQUENCER OFF ON --- --- REMOTE START/STOP * OFF ON --- --- POWER OUT/RESTART* OFF ON --- --- POWER OUT RESTART TIME * 10 120 1 SEC DELAY LOAD TIME 0 60 1 SEC LEAD/LAG** --- --- --- --- LAG OFFSET 0 45 1 PSI *Optional 27 4.6 ALARMS When an alarm occurs, the alarm indicator will light and display will show actual alarm message. If alternately multiple alarms have occurred the display will show SCROLL FOR ALARM. In this situation the up and down arrows will be used to view the alarm messages. All alarms (with the exception of the emergency stop) will be reset by twice pressing the SET button. Any exceptions to the above will be explained in the alarm description. 9) CK MTR ROTATION This alarm will occur if a unit is started and compressor has incorrect rotation. 10) CALIBRATION FAIL This alarm will occur if the sensor calibration routine is executed and the sensor reading exceeds 10% of scale. 11) NO CONTROL POWER This alarm will occur when the controller senses a loss of control power. The following is a list of the alarm messages. 1) LOW SUMP PRESS This will occur if the unit is running and sump pressure is too low. 2) HIGH AIR PRESS This will occur if the unit is running and sump pressure is greater than unit rated operating pressure plus 20 psig (1.4 bar), plus the separator pressure drop, or the line pressure is 15 psig (1.0 bar) above the rated pressure. 3) HIGH AIREND TEMP This will occur if airend discharge temperature is greater than 228°F (109°C). 12) PRES SENSOR FAIL Whenever the pressure sensor is recognized as missing or broken, a pressure sensor failure alarm will occur. 13) HIGH AIREND TEMP This will occur if airend discharge temperature is greater than 217°F (103°C). This alarm will only occur when the machine is not running. When it occurs, the message MUST COOL DOWN is added to the alternating group of alarm messages. 14) EMERGENCY STOP 4) STARTER FAULT This alarm will occur if the starter contacts open while the unit is running. This alarm will also occur if the unit is given the stop command and the starter contacts do not open. This will occur when the EMERGENCY STOP button is engaged. The alarm indicator will light and display will show: EMERGENCY STOP 5) MAIN MTR OVERLD This will occur if a motor overload is sensed. 6) TEMP SENSOR FAIL This will occur when the temperature sensor is recognized as missing or broken. 7) REMT STOP FAIL This will occur if the momentary remote stop switch does not disengage by the time the unit attempts to start. 8) REMT START FAIL This will occur if the momentary remote start switch does not disengage by the end of preset time. 28 Disengage the EMERGENCY STOP button and press the SET button twice to reset this alarm. 5.0 SCHEDULED PREVENTATIVE MAINTENANCE 5.1 MAINTENANCE SCHEDULE THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST. Running Hours Action Part or Item Inspect Inspect Inspect Inspect Inspect Replace Check Replace Inspect Replace Inspect Clean Clean Replace Replace Replace Replace Replace Replace Replace Inspect Clean Service Coolant level Weekly Discharge temperature (air) Weekly Separator element differential pressure Weekly Air filter Delta P (at full load) Weekly Drain trap (optional) Weekly Coolant filter* 150 Temperature sensor (Intellisys option) 1000 Food grade coolant (when used) 1000 Hoses 1200 Coolant filter* 2000 Drive belt 2000 Separator scavenge orifice 4000 Cooler cores** 4000 Air filter* 4000 Separator element* 4000 SSR Coolant 6000 Ultra Coolant* 8000 Drive belt 8000 Gas Spring (Belt Tensioner) 8000 Shaft seals 8000 Starter contactors 8000 Drain trap (optional) Yearly Drive motor lubrication Time Interval (whichever comes first) 1 Week 1 Mo. 3 Mo. 6 Mo. Yearly 2 Years x x x x x x (initial change only) x x x x (subsequent changes) x x x x (*See special note below) x x x x x x x x See Section 5.18 * In very clean operating environments and where inlet filter is changed at the above prescribed intervals. In extremely dirty environments change V-belts, coolant, filters, and separator elements more frequently. ** Clean cooler cores if discharge air temperature is excessive or if unit shutdown occurs on high air temperature. SPECIAL NOTE: Replace separator element when the separator differential pressure ( ▲ P) reaches three times the initial pressure drop or a maximum pressure differential of 12 psi (.8 bar) at full load. See Section 5.15. 5.2 MAINTENANCE RECORDS It is very important that you, the owner, keep accurate and detailed records of all maintenance work you or the Ingersoll-Rand Distributor or Air Center perform on your compressor. This includes, but is not limited to, coolant, coolant filter, separator element, inlet air filter, drive belts, shaft seals and so forth. This information must be kept by you, the owner, should you require warranty service work by your Ingersoll-Rand Distributor or Air Center. Maintenance record sheets are located at the back of this manual. 5.3 MAINTENANCE PROCEDURES Before starting any maintenance, be certain the following is heeded. Read Safety Instructions. Have a well equipped mechanic’s tool box with English and Metric sockets. (Special tools when needed will be listed under each appropriate procedure). Have an OSHA approved air nozzle and compressed air. (International - local codes may apply). Have spare parts on hand (See Parts Manual APDD 742. 29 Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pressure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled in the plug, allowing the pressure to release to atmosphere (See Figure 5.3-1). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pressure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. 5.5 SHEAVE ALIGNMENT Any degree of sheave misalignment will result in a reduction of belt life. Misalignment of belt drive should not exceed 1/16 in. (1.6 mm). Parallel misalignment occurs when the drive and driven shafts are parallel, but the two sheaves lie in different planes (See Figure 5.5-1). Angular misalignment occurs when the two shafts are not parallel (See Figure 5.5-2). 1/16” (1.6mm) MAX 1/16" MAX MOTOR O-RING VENT HOLE FIGURE 5.3-1 COOLANT FILL PLUG WITH VENT HOLE 5.4 PRESSURE RELIEF VALVE CHECK Under normal operating condition a “try lever test” must be performed every month . Under severe service conditions, or if corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be performed at the end of any non-service period. CAUTION! High pressure air will discharge through the discharge ports of the valve during “try lever test”. Wear ample clothing, gloves, safety glasses and ear protection during valve testing. Run the compressor for about 10 minutes by venting air from the system to let the unit warm up. With the unit running, test at or near maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of debris. Then release lever and permit the valve to snap shut. If lift lever does not activate, or there is no evidence of discharge, discontinue use of equipment immediately and contact a licensed contractor or qualified service personnel. 30 STRAIGHT EDGE STRAIGHTEDGE AIREND FIGURE 5.5-1 PARALLEL MISALIGNMENT 1/16” (1.6mm) MAX 1/16" MAX R MOTO STRAIGHT EDGE STRAIGHTEDGE AIREND FIGURE 5.5-2 ANGULAR MISALIGNMENT Align Sheaves 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 and tagged. 5. Slowly tighten the three screws evenly until the sheave is pressed from the bushing. (Light tapping on bushing may assist removal.) 6. Remove the screws from the holes. ALLEN HEAD SCREW SHEAVE RETAINING SCREWS An easy and effective method of checking alignment in both directions between the driver and driven sheaves utilizes an accurate straightedge. A Lay the straightedge across the face of the driver (motor) sheave and check alignment of the driven (airend) sheave. Then lay the straightedge across the driven sheave and check that the driver sheave is aligned. Alignment should be within 1/16” (1.6 mm) maximum when measuring the gap between the straightedge and the rim of the opposite sheave in each direction. This alignment is factory set and should only require resetting if the drive motor or airend is removed. B B A A B The following steps should be taken to insure proper alignment of all components. 1. Remove the belt/fan safety panel from the cooler box. 2. Disconnect aftercooler inlet tube and discharge hose. 3. Remove screws which fasten the left-hand side of the cooler; swing cooler outward. 4. Holding the straightedge against the front of the airend sheave, measure the amount of misalignment seen on the motor sheave. If misalignment is less than 1/16” (1.6 mm) then reinstall cooler box panel prior to operating unit. 5. If misalignment is more than 1/16” (1.6 mm), the motor sheave bushing must be repositioned (parallel alignment) or the motor must be repositioned (angular alignment). To reposition the motor sheave: 1. Remove drive belt (See Section 5.6). 2. Remove the three hex head screws that hold the sheave to the sheave bushing. See Figure 5.5-3. 3. Lubricate the thread and end of screws that were just removed. 4. Reinstall all three screws in the holes of the bushing that are threaded. “A” - Clearance Holes “B” - Threaded Holes FIGURE 5.5-3 MOTOR SHEAVE BUSHING 7. Loosen allen screw in sheave bushing. 8. Move the bushing either in or out on the motor shaft depending upon the measurement taken earlier. 9. Tighten allen screw in sheave bushing. 10. Being careful to not move the bushing on the shaft, align sheave so that the three threaded holes in the sheave line up with the three clearance holes in the bushing. 11. Insert all three screws through clearance holes in the bushing and thread into sheave. 12. Slowly and evenly tighten all sheave retaining screws. Torque to 180 lb-in. (2.1 kg-m). 13. Tap against large end of bushing using hammer and block or sleeve to avoid damage. Continue to torque screws until the specified wrench torque no longer turns the screw after tapping. 14. Install belt as shown in Section 5.6. 15. Recheck for proper alignment. 16. Reinstall belt/fan safety panel. 31 5.6 DRIVE BELT REPLACEMENT 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. Belt tension is maintained using airend mass and drive torque about a pivoting airend support in conjunction with a gas spring. Belt is automatically held under the correct tension and requires no periodic adjustment. The belt should be removed, discarded, and a new belt and gas spring installed at the 8000 hour (or 1 year, whichever comes first) interval. To replace the belts and gas spring, the following procedure should be followed: Replacement Parts 4. Remove gas spring tension on drive belt by rotating overcenter toggle clockwise with a 1/2 in. drive ratchet (See Figure 5.6-1). 5. Remove belt. 6. If a belt tension gas spring replacement is required, see Section 5.8. Installation / Inspection Inspect sheave grooves for foreign material or rubber build-up. Clean and degrease sheaves before installing drive belt to ensure long belt life. 1. Install new belt on motor and airend sheaves. Do not pry or force the belt over the sheave grooves. 2. Re-apply spring tension by slowly rotating overcenter toggle counter clockwise until it hits the stop. Belt (See Table In Parts Manual APDD 742). Be sure to use only Ingersoll-Rand Genuine parts to ensure proper belt size and length. 3. Replace cooler, piping and safety panel. Removal This unit has been designed with a unique self tensioning system for the drive belt. There is no adjustment required to ensure proper belt tension. Be sure to use only Ingersoll-Rand Genuine parts to ensure correct belt tension. 1. Remove the belt/fan safety panel from the cooler box. 2. Disconnect aftercooler inlet tube and discharge hose. 3. Remove screws which fasten the left hand side of the cooler; swing cooler outward. 5.7 BELT TENSION 5.8 BELT TENSION GAS SPRING REPLACEMENT 1. With the spring tension relieved as described in step 4 of drive belt removal (Section 5.6), remove gas spring by lifting clips at each end of the spring rod ends with a flat blade screw driver. 2. Pull spring from ball studs. 3. Install new gas spring by snapping into place with the rod end (smaller diameter) toward the larger motor sheave. 4. Reinstall clips in spring rod ends. OVERCENTER TOGGLE 5.9 SHAFT SEAL REPLACEMENT There are two lip type seals on the compressor. They are wearable parts and should be replaced at 8,000 hour intervals. While it is advisable to have your local Ingersoll-Rand Distributor or Air Center perform this work, the task can be accomplished by a good mechanic following these instructions. FIGURE 5.6-1 DRIVE BELT ASSEMBLY 32 3. Remove check valve ball and plug from seal housing. 4. If the service technician determines replacement of the wear sleeve is necessary, remove the wear sleeve from the shaft, being careful not to damage the shaft. (If wear sleeve is not replaced, skip steps 18 and 19). DANGER HIGH VOLTAGE HASP LEVER TAG KEY LOCK GER DAN FIGURE 5.9-1 MAIN DISCONNECT LOCKED AND TAGGED Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pressure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled In the plug, allowing the pressure to release to atmosphere (See Figure 5.31). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pressure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. Special Tools A clean work bench Replacement Parts Shaft seal kit (42466409) Installation 1. Remove seal housing from airend assembly. 2. Drive each seal out of the housing. Be careful not to damage the surface of the housing bore. The larger double lip seal must be driven out toward the inboard side. The term "inboard" side of the seal housing will refer to the face that is mounted to the airend assembly. The term "out board" side will refer to the face closest to the sheave. 5. Thoroughly clean the holes, bore surfaces, face of the seal housing, wear sleeve journal on the shaft, and the face of the airend assembly. Be careful not to dam age any of the surfaces, and ensure that no particles are allowed to enter the bearings. 6. Be certain to install seals from the proper side and in the proper orientation, as described in following steps. Carefully follow directions for seal assembly. Protect seal elements from inadvertent damage during installation. Be sure all tools are free of contaminants before installation. 7. Put a thin continuous coat of Loctite 609 on the outer diameter of the double lip seal. 8. Position the seal in the seal housing from the inboard side. The seal should be oriented such that the edge of the lip is toward the installer. 9. Using the seal installation tool included in the shaft seal kit, press the double lip seal into the seal housing until it locates against the shoulder. 10. Remove any excess Loctite 609 with a clean cloth. 11. Put a thin continuous coat of Loctite 609 on the outer diameter of the single lip seal. 12. Position the seal in the seal housing from the outboard side. The seal should be oriented such that the edge of the lip is installed first. 13. Using a clean flat tool press the single lip seal into the seal housing until it is flush or below flush with the surface of the housing. 14. Remove any excess Loctite 609 from the seals, the seal housing and from the seal scavenge holes in the seal housing between the seals. 15. Insert the supplied seal installation tool into the seals. Starting with the tapered end, insert the tool into the seals from the inboard side of the seal housing. Insert the tool until all three lips of the seals are on the nontapered portion of the tool. 33 16. Install the plug in the bottom of the seal housing. 5.10 INLET AIR FILTER ELEMENT 17. Install the large o-ring onto the seal housing. Place the seal housing assembly aside for later use. The inlet air filter element should be changed when the air filter maintenance indicator shows red. 18. Heat the new wear sleeve to 275˚ F (135˚ C) in hot oil or oven. (Do not allow the sleeve to come into direct contact with the oil container or the oven.) The filter element is not washable and must be replaced. Remove the filter element by removing the cap on the filter assembly located on the inlet valve. Remove and discard the filter element. Install a new filter element. Replace cap (See Figure 5.10-1). 19. Install the heated sleeve onto the shaft, seated against the bearing. 20. Install the new, small o-ring, around the oil scavenge hole and a new check valve ball in the oil scavenge hole in the airend assembly. A small amount of grease can be used to hold the o-ring and ball in place, in the airend assembly, for assembly. INLET AIR FILTER CAP 21. Lubricate the outside diameter of the wear sleeve with compressor coolant. 22. Retrieve the seal assembly. 23. Making sure that the check valve ball and o-rings remain in place, assemble the seal housing to the airend assembly. As you slide the seal housing along the drive shaft the seal installation tool will come in contact with the wear sleeve and will be pushed from the seals and allow the seal lips to glide onto the wear sleeve. Using the four bolts removed earlier, attach the seal housing to the airend. Tighten the bolts to 216 in. Ibs. (24.4 N.m.) torque. 34 FIGURE 5.10-1 INLET AIR FILTER 5.11 COOLANT FILTER ! CAUTION Time of change - after the first 150 hours and every 2000 hours thereafter, or when the coolant is being changed. In dirty operating environments, the filter should be changed more frequently. The coolant filter and coolant may be hot! 1. Place a clean pan under the coolant filter drain spout. DANGER HIGH VOLTAGE HASP 2. Using a filter wrench, remove the coolant filter (See Figure 5.11-3). LEVER 3. Discard the old filter. TAG KEY LOCK GER DAN FIGURE 5.11-1 MAIN DISCONNECT LOCKED AND TAGGED Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pressure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled in the plug, allowing the pressure to release to atmosphere (See Figure 5.3-1). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pressure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. 4. Wipe the sealing surface of the filter head with a clean lint-free rag to prevent entry of dirt into the system. 5. Remove the replacement filter from it’s protective package. 6. Apply a small amount of clean coolant on the gasket of the filter. 7. Screw filter on until the gasket makes contact with the seat on the filter head. Tighten approximately one half turn additional. 8. Remove coolant fill plug (See Figure 5.11-2). COOLANT FILL PLUG Special Tools Suitable clean drain pan or container to hold coolant drained from unit. A quantity of proper coolant sufficient to top off the coolant level in the compressor. One genuine IR replacement coolant filter of the proper type for the unit. FIGURE 5.11-2 SEPARATOR TANK 35 9. Fill unit with new coolant as follows: a. Fill tank to the bottom of the threads of the coolant fill port. b. Replace fill plug. c. Run compressor 15-20 seconds. d. Stop compressor and relieve pressure by slowly unscrewing the coolant fill plug one turn. Do not remove fill plug until all pressure has vented. e. Add more coolant up to the bottom of the threads of the coolant fill port. f. Replace fill plug. g. Start the compressor and verify coolant level is in the middle (green) range of the sight tube (See Figure 5.11-3) when the compressor is running unloaded. Check for leaks. 5.12 COOLANT CHANGE Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pressure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled in the plug, allowing the pressure to release to atmosphere (See Figure 5.31). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pressure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. Do not add coolant through the intake of the compressor, as this can result in overfilling, saturation of the separator filter element, and coolant carry-over downstream. DANGER HIGH VOLTAGE HASP NOTICE LEVER UNDER NO CIRCUMSTANCE SHOULD THE COMPRESSOR BE OPERATED WITH THE COOLANT FILL PLUG REMOVED. TAG KEY LOCK GER DAN COOLANT SIGHT TUBE FIGURE 5.12-1 MAIN DISCONNECT LOCKED AND TAGGED Special Tools Suitable clean drain pan or container to hold approximately 3.2gal. (12L) of coolant drained from unit. A quantity of proper coolant sufficient to refill the coolant level in the compressor. One genuine IR replacement coolant filter of the proper type for the unit. FIGURE 5.11-3 COOLANT SIGHT TUBE 36 COOLANT SIGHT TUBE OIL DRAIN VALVE COOLANT FILTER FIGURE 5.12-2 OIL DRAIN VALVE AND COOLANT SIGHT TUBE The coolant should be drained soon after the compressor has been shut down. When the coolant is warm, the drainage will be more complete and any particles in suspension in the coolant will be carried out with the coolant. 1. Place a clean pan under the coolant drain valve. 2. Remove the cap from the coolant drain valve (See Figure 5.12-2). 3. Thread the coolant drain fitting (supplied with compressor), with hose attached, onto the coolant drain valve. The valve will open as the fitting is threaded completely, allowing the coolant to drain. 4. Using a filter wrench, remove the coolant filter. Remember that the coolant filter may be hot (See Figure 5.12-3). FIGURE 5.12-3 COOLANT FILTER 6. Wipe the sealing surface of the filter head with a clean lint-free rag to prevent entry of dirt into the system. 7. Remove the replacement filter from its protective package. 8. Apply a small amount of clean coolant on the rubber gasket of the filter. 9. Screw element on until the gasket makes contact with the seat on the filter head. Tighten approximately one half turn additional. 10. Remove drain fitting with hose and replace drain valve cap. 11. Remove coolant fill plug (See Figure 5.11-2). 5. Discard the old filter. 37 12. Fill unit with new coolant as follows: a. Fill tank to the bottom of the threads of the coolant fill port. b. Replace fill plug. c. Run compressor 15-20 seconds. d. Stop compressor and relieve pressure by slowly unscrewing the coolant fill plug one turn. Do not remove fill plug until all pressure has vented. e. Add more coolant up to the bottom of the threads of the coolant fill port. f. Replace fill plug. g. Start the compressor and verify coolant level is in the middle (green) range of the sight tube (See Figure 5.11-3) when the compressor is running unloaded. Check for leaks. Do not add coolant through the intake of the compressor, as this can result in overfilling, saturation of the separator filter element, and coolant carry-over downstream. NOTICE UNDER NO CIRCUMSTANCE SHOULD THE COMPRESSOR BE OPERATED WITH THE COOLANT FILL PLUG REMOVED. 5.13 COOLANT HOSES The flexible hoses that carry coolant through the cooling system may become brittle with age and will require replacement. Have your local Ingersoll-Rand Distributor or Air Center inspect them every 3 months and replace them as needed or every 2 years. Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pressure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled in the plug, allowing the pressure to release to atmosphere (See Figure 5.31). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pressure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. 38 DANGER HIGH VOLTAGE HASP LEVER TAG KEY LOCK GER DAN FIGURE 5.13-1 MAIN DISCONNECT LOCKED AND TAGGED Removal Drain coolant into a clean container. Cover the container to prevent contamination. If the coolant is contaminated, a new charge of coolant must be used. Remove the hose. Installation Install the new hose. Refill the unit with coolant. Start the compressor and check for leaks. Stop unit and check coolant level in the coolant sight tube on the separator tank. 5.14 AIREND DISCHARGE HOSE The flexible hose from the airend discharge to separator tank may become brittle with age and require replacement. Inspect or replace this hose as per the maintenance schedule in Section 5.1. Replacement 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 and tagged. Disconnect hose nut from piping at each end of discharge hose and remove. Hold fittings securely while removing hose. Install new hose. 5.15 COOLANT SEPARATOR ELEMENT Procedure: The separator element should be replaced after 4000 hours of operation, whichever comes first, to prevent excessive coolant carryover into the plant air piping system. 1. Disconnect tank-aftercooler tube, inlet valve control tube, and scavenge tube. The element is located inside the separator tank (See Figure 5.15-1). SEPARATOR ELEMENT (INSIDE) 2. Remove tank cover bolts and cover (See Figure 5.15-2). 3. Remove separator element. 4. Clean all tank flange surfaces of dirt and residual gasket material. 5. Install new separator element, making sure that the ground staple comes in contact with the flange material. TANK COVER BOLT FIGURE 5.15-1 SEPARATOR ELEMENT LOCATION Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pressure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled in the plug, allowing the pressure to release to atmosphere (See Figure 5.3-1). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pressure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. FIGURE 5.15-2 TANK COVER REMOVAL 6. Replace cover and start the retaining bolts. 7. Torque bolts evenly to 80 ft.-lb (109 N-m). 8. Replace connections removed in step 1. 9. Start unit and check for leaks. 39 5.16 SEPARATOR TANK SCAVENGE CHECK VALVE/ORIFICE 7. Start unit and verify proper operation. Tools Required 5.18 MOTOR LUBRICATION Open end wrench Screwdriver The induction-type squirrel cage ODP motors have antifriction ball or roller bearings front and rear. At periodic intervals they require relubrication. Procedure Relubrication Interval (or 9 months, whichever comes first) Disconnect tubing at each end of check valve/screen/ orfice assembly. Check orifice and clean if required. Use suitable tool and remove orifice from its housing (See Figure 5.16-1). Be careful not to damage flared end of fitting or O-ring. Wash housing in safety solvent and blow dry. ODP DRIVE MOTOR . . . . . . . . . . . . . .2000 hours TEFC DRIVE MOTOR . . . . . . . .*NOT REQUIRED * No greasing required (permanently lubricated bearings) Press the check valve/orifice into fitting block. Assemble the check valve/orifice assembly to the tubing lines. The fitting must be re-installed with the check valve on the upstream side of the orifice as indicated by the flow arrow (See Figure 5.16-1). INLET CHECK VALVE HOUSING SPRING Relubrication amount in3 Lubricant Amount cc oz. grams 1.0 16 23 .8 ORIFICE NOTICE VITON O-RING FIGURE 5.16-1 SEPARATOR TANK SCAVENGE CHECK VALVE/ORIFICE 5.17 COOLER CORES/CLEANING Inspection Motors MUST be greased periodically. See Operators Manual for procedure. 1. Remove the cooler box rear panel. 39570098 2. Disconnect aftercooler inlet tube and discharge hose. 3. Remove screws which fasten the left hand side of the cooler; swing cooler outward. 4. Visually check the cooler cores for build up of dirt, dust, lint or other foreign material. 5. Using an OSHA approved air gun, blow air through the cooler cores in the opposite direction of normal air flow. 6. Re-install cooler assembly. 40 Improper lubrication can be a cause of motor bearing failure. The quantity of grease added should be carefully controlled. The smaller motors must be greased with a lesser amount of grease than larger motors. ! CAUTION ! WARNING Overgreasing can be a cause of bearing and motor failure. Make sure dirt and contaminants are not introduced when adding grease. Procedure for relubrication ! CAUTION Hazardous voltage. Can cause severe injury or death. Disconnect power before servicing. Lockout/Tagout machine. INGERSOLLrAND ® Grease should be added when the motor is stopped and power disconnected. When regreasing, stop motor. Disconnect power; lock out and tag. Remove outlet plugs (or spring-loaded grease relief plugs if present). The outlet plug may not be accessible on some motors. Grease relief along shaft can occur, precluding necessity of removing this plug if inaccessible. The inlet grease gun fittings and outlet plugs (or spring-loaded reliefs) are located at each end of the motor housing. The drive end reliefs protrude out the circumference of the lower portion of the end bell. The non-drive end outlet plugs are located just behind the flange in the air intake area at about the 5 or 6 o’clock position. 1) Free drain hole of any hard grease (use piece of wire if necessary). 2) Use a hand lever type grease gun. Determine in advance the quantity of grease delivered with each stroke of the lever. A graduated cylinder showing cubic centimeters (cc) may be used, or a 35mm film canister can give a close approximation for 2 cubic inches when filled. 3) Add the recommended volume of the recommended lubricant. Do not expect grease to appear at the outlet, but if it does, discontinue greasing at once. 4) Run motor for about 30 minutes before replacing outlet plugs or reliefs. BE SURE TO SHUT MOTOR DOWN, DISCONNECT POWER, LOCK OUT AND TAG, AND REPLACE THESE DRAIN FITTINGS TO PRECLUDE LOSS OF NEW GREASE AND ENTRANCE OF CONTAMINANTS! Recommended Motor Grease Most motors require: Mobilith SHC 220 (39218193) Use the grease as indicated on a special grease information nameplate on the motor. Use of alternative greases can result in shortened motor life due to incompatibility of greases. If there is not a grease nameplate on the motor use: Chevron Black Pearl #2 (39204292) (Preferred) Chevron SRI 2 (39161641) Motor Bearing Maintenance (Stored Units) To ensure that complete contact is maintained between the motor bearings and the bearing grease on units to be placed in storage for extended intervals, the following motor maintenance procedure should be adhered to: 1) Prior to placing a unit in storage, rotate the motor several revolutions by hand in the proper direction of rotation. 2) Thereafter, rotate the motor as described in Step 1 at three month intervals until such time as the unit is placed in service. 3) If the storage time is to exceed a total of nine (9) months duration, the compressor must be ordered with long term storage option. 41 2) Discharge potential static electricity by touching (grounding) yourself to the starter box. 5.19 INTELLISYS CONTROLLER REMOVAL (OPTIONAL) 3) Handle circuit boards only by their edges. Ensure that the compressor is isolated from the compressed air system by closing the isolation valve 4) Do not place the Intellisys® Controller on any metal and venting pressure from the drip leg. surface. Ensure that the main power disconnect switch is 5) Leave the replacement parts in their protective bags locked open and tagged. (See Figure 5.19-1). until ready for installation. Controller Removal: 1) Remove the starter box door. DANGER HIGH VOLTAGE HASP 2) Check all wiring for tightness. 3) Remove clamp rods and nuts which fasten the controller in place. LEVER TAG KEY LOCK GER DAN 4) Pull the Intellisys controller down off of the mounting studs. 5) Remove the five plug-in connectors from the top of the controller. 6) Remove the controller. Remove any option modules which must be installed in the new controller. FIGURE 5.19-1 MAIN DISCONNECT LOCKED AND TAGGED 5.20 RECEIVER TANK DRAIN TRAP INSPECTION/CLEANING Tools Required Inspection Screwdriver Size #1, flathead 3/8 inch hex driver Follow these precautions to minimize damage from static electricity. Static can cause severe damage to microcircuits. 1) Make the least possible movement to avoid building up static electricity from your clothing or tools. 42 Open (unscrew) the discharge valve on the trap and let water flow out until compressed air blows through for a few seconds. If a significant amount of water (more than 0.5 litre) exits the valve, then the drain must be thoroughly cleaned. Cleaning Dismantle the drain and clean all components. Do not use solvents to clean rubber components. 6.0 TROUBLE SHOOTING 6.1 TROUBLE SHOOTING CHART (STANDARD CONTROL) TROUBLE Compressor Fails to Start Repeat Shutdowns High Amp Draw Low Amp Draw High Discharge Pressure Low Air System Pressure Unit Running Hot High Coolant Consumption Excessive Noise Level Shaft Seal Leak Pressure Relief Valve Opens Black Residue on Belt Guard/Cooler Box CHECK POINT NUMBERS 1,2,3 3,4,5,2 8,9,6,7 1,10,12 13,15,16,19 22, 20,17,18,13,15,14,19,7 22,21,23,24,6, 35 28,27,25,26 17,18,31,30,29 32 6,13,15,14,16,19 17,33,34 CHECK POINT NUMBERS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31 32 33 34 35 TROUBLE CAUSE Control Voltage Not Available Defective Starter Motor Overload Incorrect Overload Size Line Voltage Variation Compressor Operating Above Rated Pressure Dirty Separator Filter Element Low Voltage Unbalanced Voltage Dirty Air Filter Compressor Operating Unloaded High Voltage Incorrect Pressure Switch Setting Faulty Minimum Pressure Valve Load Solenoid Valve Defective Blowdown Valve Defective Drive Belt Slipping/Worn Belt Tension Gas Spring Air System Leaks Inlet Valve Malfunction System Demand Exceeds Compressor Delivery Coolant Cooler Core Dirty Low Coolant Level High Ambient Temperature Restricted Cooling Air Flow Separator Filter Element Leak Plugged Scavenge Orifice Compressor Operating Below Rated Pressure Coolant System Leak Airend Defective Motor Defective Loose Components Worn or Defective Shaft Seal Sheaves Misaligned Worn Sheaves Incorrect Fan Rotation/Blown Fan Fuse 43 6.2 TROUBLE SHOOTING CHART - INTELLISYS CONTROL (CONTINUED) TROUBLE Compressor fails to start. CAUSE &/OR DISPLAY WHAT TO DO 110/120V control voltage not available. — Check fuses. Check transformers and wiring connections. "STARTER FAULT". — Inspect contactors. "EMERGENCY STOP". — Rotate emergency stop button to disengage, and press"SET" button twice. — Manually reset main overload relay, and press "SET"button twice. — Check for defective sensor, bad sensor connection, or broken sensor wires. — Check fuses and HAT switch "MAIN MTR OVER LD" "PRES SENSOR FAIL" or "TEMP SENSOR FAIL" “NO CONTROL POWER” Compressor shuts down. "HIGH AIREND TEMP." — Ensure that installation area has adequate ventilation. — Ensure that cooling fan is operating. Check fan fuses inside starter box. — Check coolant level. Add if required. — Cooler cores dirty. Clean coolers. NOTE: If a shutdown occurs, press the DISPLAY SELECT button once to activate the L.E.D. display table. Using the adjacent up and down arrows, the values displayed will be those immediately preceding shutdown. Use these values when trouble shooting a problem. Low system air pressure 44 "HIGH AIR PRESS." "LOW SUMP PRESS." "PRES SENSOR FAIL" or "TEMP SENSOR FAIL" "CK MOTOR ROTATION." "MAIN MTR OVERLD" — Check for restricted or malfunctioning blowdown valve or minimum pressure check valve. — Check for air leak from tank or blowdown piping. — Check for defective sensor, bad sensor connection, or broken sensor wires. — Interchange any two line connections (L1,L2,L3) at the starter. — Check for loose wires. — Check supply voltage. — Check heater size. "STARTER FAULT." — Inspect starter contactors. — Check for loose wires. “NO CONTROL POWER” — Check fuses and HAT switch Compressor running in "Unload" Mode. — Press "UNLOAD/LOAD" button. Controller off-line set point too low. — Press "UNLOAD/STOP" button, set offline set point at a higher value. Dirty air filter element. — Check filter condition. Replace as required. Drive belt slipping. — Replace drive belt/gas spring. Air leak. — Check air system piping. Moisture separator trap drain stuck open. — Inspect and repair. Inlet valve not fully open. — Inspect and repair. Check control system operation. System demand exceeds compressor delivery. — Install larger or an additional compressor. 6.2 TROUBLE SHOOTING CHART - INTELLISYS CONTROL TROUBLE High coolant consumption/coolant in air system CAUSE &/OR DISPLAY WHAT TO DO Excessive coolant level. — Check level, lower if necessary by draining. — Check separator pressure drop. Plugged separator element. Separator element leak. — Check separator pressure drop. If low, replace element. Plugged separator scavenge orifice. — Remove and inspect orifice. Clean if required. Compressor operating at low pressure (75 psig or below). — Operate at rated pressure. — Reduce system load. Coolant system leak. — Inspect and repair leaks. Defective or missing moisture separator/drain trap — Inspect and clean if required. Replace separator if defective/missing. Drain trap or drain piping plugged. — Inspect and clean. Aftercooler core dirty. — Inspect and clean. Drain line/drip leg incorrectly installed. — Slope drain line away from trap. Install drip leg. No refrigerated or desiccant dryer in air system. — Contact local Ingersoll-Rand Distributor or Air Center. Drive belt slipping. — Replace drive belt/gas spring. Compressor defective. (Bearing failure or rotor contact.) — Contact authorized Distributor or Air Center immediately, do not operate unit. Loose component mounting. — Inspect and tighten. Loose components — Inspect and tighten. Motor or compressor bearing failure. — Contact authorized Distributor or Air Center immediately, do not operate unit. External sources. — Inspect area for other equipment. Shaft Seal leak Defective shaft seal. — Replace per this manual or contact authorized Distributor or Air Center Black residue on belt guards Drive belt loose. Sheaves mis-aligned. — Replace drive belt/gas spring. — Align sheaves. Excessive belt wear — Replace belt. Compressor operating over pressure. — Adjust Intellisys setpoints. Defective valve. — Replace valve. Water in Air System Excessive noise level Excessive vibration Pressure relief valve opens 45 7.0 OPTIONS 7.1 REMOTE START/STOP (STD. CONTROL) The remote start/stop option on the Intellisys Controller allows the operator to control the 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 plug-in module for machines supplied with the Intellisys option. With the remote start/stop option installed, two different switches can be wired to the compressor for remote start/stop. Refer to electrical schematics in section 8.0 for wiring locations. The switches are customer supplied and must be of the momentary type. The stop switch contacts are normally closed and start switch contacts are normally open. 7.2 REMOTE START/STOP AND POWER OUTAGE RESTART OPTION (INTELLISYS CONTROL) When the Power Outage Restart Option is desired, a field installation kit that contains this feature is available. The option includes a logic controller for machines supplied with standard control, or a plug-in module for machines supplied with Intellisys control option. All of the hardware necessary for installation is included. The Power Outage Restart Option is for plants that have interruptions in their incoming power supply to the compressor and 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. 7.3 SEQUENCER CONTROL Sequencer control capability can be added to the Intellisys® System by utilizing a sequencer interface. This option is available as a field installation kit. 46 ! WARNING This machine is remote start and stop equipped. Disconnect power before servicing. May start or stop at anytime. any time. Lock and tag out. Can cause severe injury or death. See Operators / Instruction Manual. NOTE: 47 8.1 ELECTRICAL SCHEMATIC-FULL VOLTAGE WITH STANDARD CONTROL 8.0 REFERENCE DRAWINGS 48 54422704 REV B 54422712 REV B 8.2 ELECTRICAL SCHEMATIC-STAR DELTA WITH STANDARD CONTROL 49 54374665 REV C 8.3 ELECTRICAL SCHEMATIC-FULL VOLTAGE WITH INTELLISYS OPTION 50 54374673 REV C 8.4 ELECTRICAL SCHEMATIC-STAR DELTA WITH INTELLISYS OPTION 51 39263066 REV B 8.5 FOUNDATION PLAN–BASE MOUNTED-UNENCLOSED 52 39263066 REV B 8.5 FOUNDATION PLAN–BASE MOUNTED-UNENCLOSED 53 8.6 FOUNDATION PLAN–BASE MOUNTED-ENCLOSED (CONTINUED) 54 39929518 REV B 39929518 REV B 8.6 FOUNDATION PLAN–BASE MOUNTED-ENCLOSED 55 56 39932777 REV B 8.7 FOUNDATION PLAN–120 GAL. TANK MOUNTED-UNENCLOSED (CONTINUED) 39932777 REV B 8.7 FOUNDATION PLAN–120 GAL. TANK MOUNTED-UNENCLOSED 57 8.8 FOUNDATION PLAN–120 GAL. TANK MOUNTED-ENCLOSED (CONTINUED) 58 39263082 REV B 39263082 REV B 8.8 FOUNDATION PLAN–120 GAL. TANK MOUNTED-ENCLOSED 59 8.9 FOUNDATION PLAN–240 GAL. TANK MOUNTED-UNENCLOSED (CONTINUED) 60 39932785 REV B 39932785 REV B 8.9 FOUNDATION PLAN–240 GAL. TANK MOUNTED-UNENCLOSED 61 8.10 FOUNDATION PLAN–240 GAL. TANK MOUNTED-ENCLOSED (CONTINUED) 62 39929401 REV B 39929401 REV B 8.10 FOUNDATION PLAN–240 GAL. TANK MOUNTED-ENCLOSED 63 54363650 REV A 8.11 BASIC FLOW SCHEMATIC-STANDARD CONTROL 64 5336676 REV A 8.12 BASIC FLOW SCHEMATIC-INTELLISYS CONTROL 65 TYPICAL SYSTEM FLOW DIAGRAM 8.13 TYPICAL SYSTEM FLOW DIAGRAMS 66 8.13 TYPICAL SYSTEM FLOW DIAGRAMS 67 8.13 TYPICAL SYSTEM FLOW DIAGRAMS 68 8.13 TYPICAL SYSTEM FLOW DIAGRAMS 69 8.10 TYPICAL SYSTEM FLOW DIAGRAMS 70 9.0 SERVICE AND OPTION KITS SERVICE KITS: Part Number Description Models 37993870 *Kit, 4000 Hr. Maintenance All 20HP/60Hz 37993888 *Kit, 4000 Hr. Maintenance 37993896 *Kit, 4000 Hr. Maintenance All 20HP/50Hz All 25 & 30HP/60Hz All 30HP/50Hz 42491688 Kit, Service (Gas Spring & 54” Drive Belt) XF20, EP20,/HXP25/60Hz HXP20/50 Hz 42491696 Kit, Service (Gas Spring & 1397mm Drive Belt) HP20/60Hz 42496216 Kit, Service (Gas Spring & 51” Drive Belt) HXP20/60 Hz 42491704 Kit, Service (Gas Spring & 56.26” Drive Belt) XF/EP/HP20/50Hz XF/EP25/60Hz XF/EP/HP25/50Hz XF/EP/HP30/60Hz 42496224 Kit, Service (Gas Spring & 1460mm Drive Belt) HP25/60Hz 42496232 Kit, Service (Gas Spring & 1420mm Drive Belt) HXP25/50Hz 42491712 Kit, Service (Gas Spring & 58.26” Drive Belt) XF/EP/HP30/50Hz *Contains (1) oil filter, (1) air filter, (1) separator element, and (1) gallon of UItracoolant OPTION KITS: Part Number 42474619 Description Kit, Field - High Dust Filter 42475293 Kit, Field - Power Outage Restart (PORO) (Units with Std. Control) Kit, Field - Power Outage Restart (PORO) and Remote Start / Stop (Intellisys Option) 42475285 42472886 42488593 Kit, Field - Standard Enclosure (20/25HP, 30HP/60Hz) Kit, Field - Standard Enclosure (30HP/50Hz) 42474817 42474924 42474791 42474932 Kit, Kit, Kit, Kit, 42489526 42489534 Kit, Field - 120 Gallon Receiver Tank Kit, Field - 240 Gallon Receiver Tank Field Field Field Field - Modulation Modulation Modulation Modulation (XF/EP/HP Units with Std. Control) (HXP Units with Std. Control) (XF/EP/HP Units with Intellisys Control) (HXP Units with Intellisys Control) 71 10.0 MAINTENANCE RECORD DATE 72 RUN TIME (HOURS) WORK DONE QTY. UNIT MEASURE WORK BY MAINTENANCE RECORD DATE RUN TIME (HOURS) WORK DONE QTY. UNIT MEASURE WORK BY 73 MAINTENANCE RECORD DATE 74 RUN TIME (HOURS) WORK DONE QTY. UNIT MEASURE WORK BY MAINTENANCE RECORD DATE RUN TIME (HOURS) WORK DONE QTY. UNIT MEASURE WORK BY 75