o INGERSOLL-RAND. AIR COMPRESS SORS SSP’ 50-200 HP ALL UNITS 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. APDD 321C-90 ‘©Ingersoll Rand Company 1990 September 1990‘AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UP cers i tee sev ues Prem cre EXTENDED DRIVETRAIN WARRANTY ‘The Ingersoll-Rand Company Rotary Screw Air Compressor that has been filled prior tots original shipment from Ingersoll-Rand Company with ULTRA COOLANT and which has been operated solely on ULTRA (COOLANT thereafter shall have its DRIVETRAIN 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 frst, 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. ‘This EXTENDED DRIVETRAIN WARRANTY applies to all COMPRES. ‘SORS operating on ULTRA COOLANT alter February 1. 1990,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. Model: 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: I ! INGERSOU agTABLE OF CONTENTS 0.0 SAFETY AND WARNINGS 0.3 DECALS 1.0 RECEIPT OF EQUIPMENT 1.1 inspection 1.2 unpacking and handling 13 tools 2.0 INSTALLATION 21 ventilation 2.2 foundation requirements 23 piping 3.0 INTELLISYS 3.4 emergency stop switch 3.2 power on light 3.3 power indicator light 34 push buttons 3.5 set point procedure 3.6 warnings 3.7 alarms 4.0 SCHEDULED PREVENTATIVE MAINTENANCE 4.1 maintenance schedul 4.2 maintenance records 4.3 maintenance procedures 4.4 inlet air filter 45 coolant fitter 46 coolant 4,7 separator tank scavenge orificeiscreen 4.8 coolant separator element 49 cooler cores, 4.10 drive motor lubrication 4.11 long term storage 4.12 coolantlubricant changeout 4.13 intellisys removal 4.14 coolant hoses. 5.0 SYSTEMS 5.1 general systems 5.2 aircooled compressors 5.3 coolant system 5.4 compressed air system 5.5 coolantiair separation system 5.6 electrical system 5.7 stepper motor inlet control 5.8 capacity control system TABLE OF CONTENTS (Continued) 6.0 TROUBLE SHOOTING e 7.0 OPTIONS 7.1 automatic start’stop contro! 7.2 modulation % load 7.3 remote startistop 7.4 sequencer control ‘8.0 REFERENCE DRAWINGS 8.1 electrical schematic 28.2 foundation plan - 50/60 HP, AIC, Enclosed {8.3 foundation plan - 50/60 HP, WIC, Enclosed {8.4 foundation plan - 50 HP, A/C, Unenciosed 8.5 foundation plan - 60 HP, A/C, Unenciosed {8.6 foundation plan - 50 HP, WIC, Unenclosed 8.7 foundation plan - 60 HP, WIC, Unenclosed {8.8 foundation plan - 75/100 HP, A/C, Unenclosed {8.9 foundation plan - 75/100 HP, WIC, Unenclosed 8.10 foundation plan - 75/100 HP, AVC, Enclosed 8.11 foundation plan - 75/100 HP, WIC, Enclosed 8.12 foundation plan - 125-200 HP, A/C, Enclosed 8.13 foundation plan - 125-200 HP, WIC, Enclosed 8.14 basic flow schematic. 8.15 typical system flow 9.0 WATER QUALITY GENERAL INFORMATION Weight: ‘See foundation plan, Section Cooling Air Flow: See foundation plan, Section 8.0 Ambient Temperature Limits: 95°F to 115°F (2°C to 46°C) Coolant: Factory Filled SSR Ultra Coolant Coolant Change: 8000 hours or two years whichever, ‘comes first Coolant Capacity 50H. - (4.0 gal) (18.2 liters) 60 HP. - (5.0 gal) (19. liters) 75/100 HP. - (9.0 gal) (34.2 liters) 125-200 HP. - (30.0 gal) (114 liters) Discharge Temperature Limit: 28°F Recommended conduit: metallic flexible Greenfield, or equivalent, maximum trade size 2.5" Tools: US. Standard and metric are required to perform maintenance . Power inlet Wiring:0.0 SAFETY AND WARNINGS on Before you install this air compressor you should take the time to carefully read all the instructions contained in this manual. Electricity and compressed air have the potential to cause severe personal injury or property damage. Before installing, wiring, starting, operating or making any adjustments, identity 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, under- stand the starting and stopping sequence. Check the safety devices following the procedures contained in, this manual. Maintenance should be done by qualified personnel, adequately equipped with proper tools. Follow the maintenance schedules as outlined in the manual to insure problem free operation after start up. oz SAFETY PRECAUTIONS BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE ‘COMPRESSOR OR PERFORMING ANY MAINTENANCE WARNING 4,0 not pul te compet a! Threcanbabad aie compre ignerischergepressrethaninose sor hiocons ate allowed fo ener COMPRESSEDARANDELECTAIC: Od on the Comprestor Name: plantaiaystems BEFORE DOING ANY WORK ON ‘THIS UNIT, BE SURE THE ELECTRI- CAL SUPPLY HAS BEEN CUT OFF— LOGKED & TAGGED AND THE EN- TIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF ALL PRESSURE. 1.Donotremove the covers, loosen or remove any fittings, connections or devices when this units in operation. Hot liquid and air under pressure that are contained within this unit can Ccause severe injury or death. 2. The compressor has high and dan- {gerous voltage in the motor, the start- fer and control box. All installations ‘must be in accordance with recog- nized electrical codes. Before working fon the electrical system, be sure 10 remove voltage trom the system by Use of a manual-disconnect-switch. A circuit breaker or fuse safety switch must be provided in the electrical supply ine leading othe compressor. Those responsible for installation of this equipment must provide sul grounds, maintenance cl lighting arrestors fora ponents as stipulated 1910-308 through 1910.323, plate or motor overload will occur. ‘This condition willresultin motorcom- pressor shutdown, 4. Use only safety solvent for cleaning the compressor and auxiliary equipment. 5. Install a manual shutot valve (isola tion type) in the discharge line. A safety valve, with sufficient capacity to relieve full compressor capacity, must be installed between the compressor and the isolation valve. 6. Whenever pressure is released through the safety valve, itis due to excessive pressure in the system. The cause for the excessive pressure should be investigated immediately 7. Before doing any mechanical work fon the compressor, 2.) Shut the unit down. .) Electrically isolate the compressor byuse ofthe manual disconnect switch in the powerline to the unit. Lock and tag the switch so that it cannot be operated. .) Blow down the compressor and isolate the unit rom any other source ot Air line separators, properly selected ‘and installed, can reduce any liquid ‘carryover close to zero. ‘The use of plastic bowls on line filters. without metal guards can be hazard- safety standpoint, metal bowls should be used on any pressurized system. Review of your plant airline system is. commended. 9. When a receiver is installed, itis recommended that occupational safe- ty and health standards as covered in the Federal Register, Volume 36, num- ber 106, part 11, paragraph 1910.169, be adhered to in the installation and. ‘maintenance of this receiver. 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.PNY \ eA Oe) a meetin Gk There is a high discharge air temperature shutdown function built into the Intellisys on “@ compressor. It is factory pre-set at 228°F. This function should be checked at regular intervals f 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 of the. Intellisys. The display should indicate “HIGH A/E DISCH TEMP" and the alarm light will be illuminated. The actual temperature at which shutdown occurs should be recorded for comparison to the Intellisys set point and with similar future test results. PNY EG ils 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 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 responsiblity of the installer and owner to provide the appropriate service pipework to and from the machine,’ AWARNING ‘STATEMENT CONCERNING THE USE OF THIS EQUIPMENT FOR BREATHING AIR AND/OR AQUA LUNG SERVICE If the model number on this air compressor contains the letters “BAP”, the compressor is suitable for use in breathing air services. In the absence of such a designation, the compressor is NOT considered as capable of producing air of breathing quality. For a compressor to be capable of use in breathing air services it must be fitted with additional specialized equipment to properly filter and/or purity the air to, meet all applicable federal, state and local laws, rules, regulations and codes, such as, but not limited’ to, OSHA 29 CFR 1910.134, Compressed Gas Association Commodity Specification G-7, 1-1966, Grade D Breathing Air and/or Canadian Standards Association. Should the Purchaser and/or User fail |° to add such specialized equipment and proceeds to use the compressor for breathing air service, the Purchaser/User assumes all liability resulting therefrom without any responsiblity or liability being assumed by Ingersoll-Rand Company. The Purchaser is urged to include the above provision in any agreement for any resale of t compressor.0.3 DECALS This section contains representative examples of _If for some reason a decal is defaced, parts are decals which will be appearing throughout this replaced or painted over we recommend that you manual and are applied to the compressor unit. WARNING [AWARNING| obtain a replacement kit. NOTICE t ROTATION. Ingersot-Rana Rotary: Rec Compressor Division Davidson. NC ces ASWARNING A\CAUTION0.3 DECALS (Continued) |e AXCAUTION ELECTRICAL POWER INLET. AIR DISCHARGE.1.0 RECEIPT OF EQUIPMENT 1.4 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 espe- cially 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 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. FORKLIFT PADDING WILL REDUCE SCRATCHES AND MARS SPREADER IMPORTANT. BEFORE STARTING THIS AIR COM- PRESSOR UNIT THE SHIPPING BRACE(S) MUST BE REMOVED. SAVE THE BRACE(S) FOR FUTURE USE. SEE TAG IN UNIT2.0 INSTALLATION 2.1 VENTILATION iil 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. It heated air from the compressor exhaust is. allowed to recirculate back to the compressor, the compressor will overheat and shutdown. 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 three feet all around the compressor. Ambient temperatures higher than 115° should be avoided as well as areas of high humidity. Consider also the environment surrounding or né the compressor. Co] (ae) 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 oils. From a safety standpoint, metal bowls should be used on any pressurized system. Review of your plant air line system is recommended. 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, each compressor with built-in aftercooler is furnished with a combination condensate separator/trap. NEVER ELEVATE THE i 36" 36" AIR INTAKE ACAUTION COMPRESSOR UNIT ‘ABOVE THE FLOOR LEVEL WHICH MAY ALLOW AIR TO ENTER, ‘THE CABINET UNDER ‘THE BASE. PERFORMANCE WILL BE AFFECTED.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, 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. IMPORTANT: Discharge Piping should be at least as large as the discharge connection at the compressor enclosure. All piping and fittings must be suitably rated for the discharge pressure. A\CAUTION 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. See Section 8.5. Itis essential when installing a new compressor to review the total plant air system. This is to insure a safe and effective total system. An item which must be considered is liquid water carryover into the plant air line. Installation of aftercoolers, air dryers. and line separators is always a good practice. See Section 8.5. Water condensation can affect the operation of pneumatic devices. Aftercoolers and the addition of air dryers can eliminate this hazard. Similarly, there can be negative effects if compressor coolant is allowed to enter plant air systems. Air line separators, properly selected and installed, can reduce any liquid carryover. NOTE: Screw type compressors should not be installed in air systems with reciprocating compressors without a means of isolation, such as a common receiver tank, We recommend both types of compressor units be piped to a common receiver utilizing individual air lines. ‘When two rotary units are operated in parallel, provide an isolation valve and drain trap for each compressor before the common receiver, ISOLATION VALVE ORIP LEG DISCHARGE PIPING WITH AFTERCOOLER, recenvts | sareryyave ==) ROTARY-RECIP IN PARALLEL ROTARY TWO COMPRESSOR SYSTEM2.4 ELECTRICAL INSTALLATION AWARNING Inyo dot Detore serving Before proceeding further, we recommend that you review the safety data in the front of this manual. ELECTRICAL POWERINLET: The recommended power inlet conduit is, metallic, flexible, Greenfield, or equivalent, maximum trade size 2.5 inches. G INGERSOLLRAND. Compressor Data sven ‘genet am ‘aren erasing Pi ar tua essa ee bene Teta ct wi Pa ‘Guin LT SERIAL NO. Locate the compressor data plate on the side of the cooler box or end of unit The data plate lists the rated operating pressure the maximum discharge pressure and the electric motor characteristics and power. Confirm that the line voltage and compressor name- plate voltage are the same. ‘The standard starter box meets the intent of NEMA 1 guidelines. Open the starter box door. Contirm that all electri- cal connections are made and tightened. Confirm that the control transformer is wired correctly for supply voltage. Unevorrs | W ] UNe | SeovOUTs | UNE 20 eo | Has 120 Xrx2 24 woxt 230 | Hass 2 xix 24 wax 60 | HHS 120 xix 24 wax 575 Cs 12 xg 24 ox ‘Contra! Transformer (T1) Connections 10 TE BU] ois Ew EE BE | aR en | ie Jarl] ah viene | mina | sa WA) (AMP (AMP) " peep 3 asf s0 spose CONTROL TRANSFORMER CONNECTIONS HGH VOLTAGE SIDE-PRMMARY Low vouTace, seconoany sie |!) Loy :ELECTRICAL INSTALLATION (Continued) Inspect the motor and control wiring for tightness. Close and fasten the starter box door. Before Starting — Starting — ‘Stopping — Emergency Stop See instructions below. ROTATION CHECK. LOCATE THE ROTATION DECAL ON EACH MOTOR. ‘CAUTION: If the compressor is operated in the ‘opposite direction of rotation, airend damage can result and is not warrantable. DRIVE MOTOR: The correct motor rotation is clockwise when viewed from the rear or non-crive end of the motor. ‘The Intellisys will automatically shut the unit down if the compressor rotation is incorrect, and "CK MOTOR ROTATION” will appear in the display, also the alarm light will be on. See Section 6. For the compressor motor rotation check, the motor jogging must be as short a time as possible. After depressing the start button IMMEDIATELY depress the “EMERGENCY STOP" button. Should the motor rotation be incorrect, put main disconnect in the OFF position, lock and tag. Open the starter box door. Interchange any two line connections (L1, L2 or L3) at the starter. Close and fasten the starter box door. Recheck for correct rotation FAN MOTOR: Observe the compressor cooling fan. The rotation should be in accordance with the fan rotation decal affixed to the fan motor. Cooling air should exhaust through fan end of compressor enclosure. Should the motor rotation not be correct put the ‘main disconnect in the OFF position, lock and tag. Interchange any two fan motor leads at the fan motor overload relay (2OL). Close and fasten the starter box door. Recheck for correct rotation. BEFORE STARTING — STARTING — STOPPING — EMERGENCY STOPPING. NOTE: These instructions are also contained on the decal near the Intellisys panel of the unit. NOTICE [AWARNING | . | roan oemnaer NOTICE NOTE FAN MOTOR ROTATION ON 50 AND 60 HP COMPRESSORS IS COUNTER-CLOCKWISE WHEN VIEWED FROM THE FAN MOTOR SIDE. FAN MOTOR ROTATION ON 75 THROUGH 200 HP COMPRESSORS IS CLOCKWISE WHEN VIEWED FROM THE FAN MOTOR SIDE. nerlearere OR 3.0 INTELLISYS3.0 INTELLISYS 3.1 EMERGENCY STOP SWITCH Pressing this switch stops the compressor immediately. Compressor cannot be restarted until switch is manually reset. Turn clockwise to reset. 3.2 POWER ON LIGHT Indicates control voltage is available to the control circuit and line voltage is available for starting. 3.3 POWER INDICATOR LIGHT Indicates voltage is available to the Intellisys controller. POWER 3.4 PUSH BUTTONS START If the display shows READY TO START. Pressing this button will start the compressor. The compressor will start in an unloaded state. UNLOADED STOP Pressing this button will activate the unloaded stop. If the compressor is running loadeg, it will unload. Seven seconds later it will stop. If the compressor is running unloadeg, it will stop immediately. ‘STOP RESET This button lights when compressor is in alarm mode. This button is only functional when lit, Pressing this button twice will clear an alarm RESET UNLOAD Pressing this button will cause the unit to unload. The unload indicator light will be on. UNLOAD ON/OFF LINE If unit is running, pressing this button will put the unit into on/off line mode and light the on/off line light. If LINE PRESSURE is less than ON LINE PRESSURE, the unit will load. If LINE PRESSURE is greater than OFF LINE PRESSURE, the unit will not load 33.4 PUSH BUTTONS (Continued) MoD/Acs I unit is running, pressing this button will allow unit to operate the ACS function. When this mode is in operation, the inlet valve will open and close in order to keep a stable line pressure. moo. DISPLAY SELECT Pressing these buttons will change the information selected for the displays. The display table will be incremented, If the button is held, the display table will scroll DISPLAY SELECT NOTE: For readings less than 1 hr., hourmeter displays minutes. After 1 hr. hourmeter displays hours. TEST ‘The TEST button is only active when lit. This button has more than one function. © If the SET/TEST mode is selected, pressing the TEST button will initiate a lamp test. Ifthe unitis in an alarm state, pressing the TEST button will allow viewing of the display table. Press the TEST button again to allow use of the RESET button. Test “4 SET ‘The SET button is used to select the SET/TEST mode and then the set point mode. Once selecte; the SET button is used to enter the set point procedure. The SET button is also used in the calibration routine, which will be described later. ARROWS ‘These buttons have several functions. They are only active when lit. If the Intelisys is in the set point mode, the ARROWS are used to change the set point 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. jus, | F, PRESSURE SENSOR CALIBRATION (ZEROING) ROUTINE This routine is entered if the unit is in the SET/TEST mode and the SELECT DOWN and MOD/ACS buttons are pressed at the same time. ‘The ARROWS are used to select the sensors. The SET button is used to execute the calibration procedure. Zeroing should only be done atter a pressure sensor transducer has been replaced or any controller change. DISPLAY MOD/ACS. eieee .3.5 SET POINT PROCEDURE This procedure allows the customer to modify 8 variables in the controller logic. In order to execute this procedure, press the SET button. The display will alternate between PRESS SET — CHANGE VALUES PRESS TEST — LIGHT CHECK ‘At this time, press the set button to enter the set point routine. The display will show: OFFLINE PRESSURE XXX PSIG. ‘The ARROWS will light to show that they are active. Offline pressure is the first set point and XXXX stands for the value of the set point. Press the SET button to select the set point to be adjusted. Press the up and down arrow buttons to raise or lower the set point value. Press the SET button to move to the next set point. If the set point has been adjusted, press the SET button to enter the new value. The display will flash twice to acknowledge. The next set point will then be displayed. ifthe value of the set point was not changed, pressing the SET button will only step to the next set point. The set point routine can be exited by pressing the SELECT UP or SELECT DOWN buttons for the L.E.D. Table or exit will be automatic after 20 sec. The following is a list of the set points. Also included are maximum and minimum limits, step size, and units of measure. FUNCTIONS MIN] MAX _ [STEP] UNIT OFFLINE PRESSURE. 7% | rateo-3| 1 [Psic [ONLINE PRESSURE 65 [orune-10| 1 [Psic DISPLAY TIME ee [STAR DELTA TIME 0 | 2 1 [sec AUTO SHUTDOWN DELAY| 10 | 15 + [aa autostantistop [or] on | — | — sequence contro. _[orr] on | — | — Remote stantistop [orr] on | — | — 63.6 WARNINGS When a warning occurs, the display will alternate between the current message and the warning message. If multiple warnings exist, the message SCROLL FOR WARNINGS 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 RESET button is. pressed once. The following is a list of the warning messages. 1) CHANGE INLET FILTER This will occur if the Inlet Vacuum (1AVPT) is greater than .7 psig and the unit is fully loaded (inlet vaive is completely open). 2) CHG COOLANT FILTER This warning will occur if the high side pressure is 15 psig greater than the low side pressure of (1DPS), and the Injected Coolant temperature (2CTT) is greater than 120 degrees. 3) CHANGE SEPR ELEMENT This warning will occur if the pressure on the Separator (3APT) is 12 psig greater than the pressure at the Package discharge (APT), the unit is fully loaded. 4) CHECK AIR/COOLANT SYSTEM This will occur if the Airend Discharge (2ATT) ‘exceeds 97% of the alarm limit, (228° F) and is not adjustable. nd 163.7 ALARMS When an alarm occurs, the display will alternately ‘show the following messages: the actual alarm message, PRESS TEST - FOR VALUES and PRESS RESET 2x - CLEAR. If alternately multiple alarms have occurred the display will show the following messages: PRESS RESET 2X - CLEAR and SCROLL FOR ALARMS. 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 RESET button. Any exceptions to the above will be explained in the alarm description. ‘The following is a list of the alarm messages. 1)HIGH INLET VACUUM This will occur if the unit is running unloaded and a high inlet vacuum occurs. 2)CK INLET CONTROL This will occur if the unit is running unloaded with too little inlet vacuum. 3)LOW UNLOAD SUMP PRES This will occur if the unit is running unloaded and sump pressure is 100 low. 4) HIGH SUMP AIR PRESS This will occur if the unit is running and sump pressure is greater than unit rated operating pressure plus 23 psig, 8) STARTER DOOR OPEN This alarm will occur if the starter door is not closed and fastened. 6)HIGH A/E DISCH TEMP This will occur if airend discharge temperature is greater than 228 degrees. 7)STARTER FAULT This alarm will occur if the starter contacts open while the unit is running. This alarm will aiso occur if the unit is given the stop command and the starter contacts do not open. 8)MAIN MOTOR OVERLOAD This will occur if a motor overload is sensed 8) FAN MOTOR OVERLOAD This will occur if a fan motor overload is sensed, v73.7 ALARMS (Continued) 10)CK MOTOR ROTATION This alarm will occur if a unit is started and compressor has incorrect rotation. 11)CK INLET CONTROL SYS This alarm will occur if the inlet butterfly valve is in an incorrect position. 12)INLET VALVE ROTATED This alarm will occur if unit is given the start ‘command and the inlet valve is not in the fully closed position. 18)SENSOR FAILURE Whenever a sensor is recognized as missing or broken, a sensor failure alarm will occur. The failed sensor will be displayed along with the sensor failure message. INITIAL CHECK ALARMS This alarm will occur only when the machine is not running, When it occurs, the message WAIT FOR COOL DOWN is added to the alternating group of alarm messages. 14)HIGH A/E DISCH TEMP This will occur if airend discharge temperature is greater than 217°F. EMERGENCY STOP This will occur when the EMERGENCY STOP button is engaged. The display will alternate between: EMERGENCY STOP DISENGAGE BFR START. When the EMERGENCY STOP button is dis- engaged the display will change to: RESET BEFORE START Press the RESET button once to reset this alarm. 84.0 SCHEDULED PREVENTATIVE 4.1 MAINTENANCE SCHEDULE MAINTENANCE ‘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 HOURS, WHICHEVER OCCURS FIRST. RUNNING] TIME INTERVAL (WHICHEVER COMES FIRST) _ bodied ue! HOURS "DAILY 1WK. 1-MO. 3MO. GMO. YEARLY 2YR INSPECT | COOLANT LEVEL INSPECT | DISCHARGE TEMPERATURE (AR) INSPECT | SEPARATOR ELEMENT OIFFERENTIAL INSPECT | AIA FILTER DELTA P (AT FULL LOAD) INSPECT | OIL FILTER DELTA P perce | coma LER a TANT ANGE CRT coon | TeenaTuRE SAGA sj x rence [coma TER = BS cacaw | ScmeaTOR SCAPNEESEENE ORE | atm : cua coven ORES «on : feruce [anecree 00 ri ‘REPLACE | SEPARATOR ELEMENT* *SEE SPECIAL NOTE verse coma a00 r TEPC | STATER COTCTORS a 5 “IN VERY CLEAN OPERATING ENVIRONMENTS AND WHERE INLET AIR FILTER IS CHANGED AT THE ABOVE PRESCRIBED INTERVALS. IN EXTREMELY DIRTY ENVIRONMENTS CHANGE COOLANT, FILTERS AND SEPARATOR ELEMENTS MORE FREQUENT “CLEAN COOLER CORES IF DISCHARGE AIR TEMPERATUR OCCURS ON HIGH AIR TEMPERATURE. LY. |E1S EXCESSIVE OR IF UNIT SHUTDOWN 4.2 MAINTENANCE RECORDS Itis very important that you, the owner, keep accurate and detailed records of all maintenance work you or the Ingersoll-Rand distributor perform ‘on your compressor. This includes but is not limited to coolant, coolant filter, separator, inlet air filter and so forth. This information must be kept by you, the owner, should you require warranty Service work by your Ingersoll-Rand distributor. Maintenance record sheets are located at the back SPECIAL NOTE: REPLACE SEPARATOR ELEMENT WHEN THE SEPARATOR DIFFERENTIAL PRESSURE (Z\ P) REACHES THREE TIMES THE INITIAL PRESSURE DROP OR A MAXIMUM OF 12 PSID ATFULL LOAD OR IF THE INTELLISYS WARNING OCCURS: CHANGE SEPARATOR ELEMENTS IS DISPLAYED. SEE SECTION 3. of this manual, 4.3 MAINTENANCE PROCEDURES Before starting any maintenance, be certain the following is heeded, 1. Read Safety Instructions. 2. Use correct tools. 3, Have recommended spares on hand, 194.4 INLET AIR FILTER To check condition of inlet filter, run compressor in load mode and select “INLET FILTER CONDITION” in L.E.D. Table. If display says “INLET FILTER O.K." then no maintenance is required. If warning light is on and display says “CHANGE INLET FILTER,” then the air filter should be changed. To change inlet filter, loosen wing nut on top of, inlet filter housing. Lift cover up and away to expose element. Carefully remove the old element to prevent dirt from entering the inlet valve. Discard old element. ‘Thoroughly clean the element housing and wipe all surfaces Install new element and inspect to insure that it has seated properly Install top of inlet filter housing. Inspect the rubber seal on the retainer wing nut and replace seal if required. Tighten wing nut. Start machine and run in the load mode to verity filter condition. 4.5 COOLANT FILTER To check condition of coolant filter, compressor must be running. Select "INJECTED COOLANT TEMP" in L.E.D. Table. If coolant temperature is less than 120°F, continue to run machine, When coolant temperature is greater than 120°F, select “COOLANT FILTER CONDITION’ in L-E.D. Table. I the display says “COOLANT FILTER O.K." then, the filter does not need service. If the warning light is on and the display says "CHG COOLANT FILTER” then the filter should be replaced. Use a suitable device and loosen the old element. Use drain pan to catch any leakage during removal. Discard old element. Wipe the sealing surface of the filter with a clean, lint-free rag to prevent the entry of dirt into the system. Remove the replace element from its protective package. Apply a smatl amount of clean lubricant on the rubber seal and install element, ‘Screw element on until the seal makes contact with the head of the filter assembly. Tighten approximately one-half turn additional ‘Start unit and check for leaks. 20 INLET AIR FILTER 75, 100, 200 HP REQUIRE (2) ELEMENTS ASCAUTION COOLANT FILTER 50-100 HP (125-200 HP REQUIRES 2 ELEMENTS)4.6 COOLANT Change after every 8000 hours or every two years, whichever comes first (SSR ULTRA) lems Required: In addition to the tools normally found in any reasonably equipped serviceman's toolbox, the following items should be available at the work site: 1, Suitable drain pan and container to hold lubricant drained from unit, 2. A quantity of proper lubricant sutticient to refill the compressor. 3. A minimum of one replacement coolant filter, element of the proper type for the unit to be worked on There is a coolant drain hose on each compressor. It is located on the bottom of the separator tank. The coolant should be drained soon after the ‘compressor has been shut down. When the coolant ig hot, the drainage will be more complete and any particles in suspension in the coolant will be carried out with the coolant, COOLANT DRAIN To drain unit, remove drain plug in end of drain Ce eniitbi hose. Place end of hose in suitable drain pan. Open HOT COOLANT USE CARE drain valve to start drainage. After draining is CAN CAUSE WHEN complete, close drain valve. Replace plug in end of SEVERE INJURY DRAINING hose after drain valve is closed. After the unit is drained and a new coolant filter element is installed, refill the system with fresh coolant, Bring the receiver level of coolant up to the midpoint of the sight glass. Replace the fill cap. Start the compressor and run it for a short time, The correct coolant level is at the midpoint of the ‘sight glass with the unit running in the "UNLOADED" mode. Coolant Fill Quantity 50 HP. 4.0 GAL. (15.2 liters) = 60 HP. 5.0 GAL. (19.0 liters) 75 /A00H.P. 9.0 GAL. (34.2 liters) 125-200 H.P. 23 GAL. (114 liters) 214,7 SEPARATOR TANK SCAVENGE ORIFICE/SCREEN TOOLS REQUIRED (Open end wrench Screwdriver PROCEDURE Disconnect tubing at each end of screen assembly. Remove the screen housing from the orifice block. Check orifice and clean if required. Use suitable screwdriver and remove screen retainer from its housing. Wash screen and housing in safety solvent and blow dry. Re-assemble the screen into the housing using care not to overtighten the screen retainer. ‘Assemble screen housing into orifice block ‘Assemble the orifice and screen to the tubing lines. ‘The screen must be re-installed with the screen on the upstream side of the orifice 22 serew Screen Screen Housing Orifice8 COOLANT SEPARATOR ELEMENT To check condition of separator element, run ‘compressor in full load mode and at rated pressure and select "SEPARATOR PRESSURE DROP” in LED. Table. If display says "SEPARATOR ELEMENT XX PSI,” then no maintenance is required. If warning light is on and display says “CHANGE SEPR ELEMENT” then the separator should be replaced. Disconnect the scavenge tube at the airend, Loosen the fitting that holds the scavenge tube into the tank and withdraw the tube assembly. Disconnect the piping from the receiver cover. Tag the lines if required, Use a suitable wrench and remove the bolts that hold the tank cover in position. Remove cover by lifting up and away. Carefully lift the separator element up and out of the tank. Discard the faulty element. Clean the gasket surface on both the tank and its cover. Exercise care to prevent pieces of the old gasket from falling down into the tank. ‘Check the tank to be absolutely certain that no foreign objects such as rags or tools have been allowed to fall into the tank. Install replacement element down into the tank after checking the new element gaskets for possible damage. Center the element up within the tank Place the tank cover in its correct position and install bolts. Tighten the bolts in a cross-pattern to prevent over-tightening one side of the cover. An improperly tightened cover will ikely result in a leak. Tank Cover Bolt Torque Values 30 HP UNG 80 fb 60 HP UNG 150 fb 7sooHP | UNG | ison. | 125-200 HP %@ UNC 150 ft. Ib. Inspect tank scavenge screen and orifice, Clean if necessary following instructions in Section 4,7, Install scavenge tube down into the tank until the tube just touches the separator element, Tighten fittings, Install the regulation lines in their original position Start unit, check for leaks, place in service. WARNING) RECOMMENDED BOLT TIGHTENING CROSS PATTERN SEPARATOR TANK 234.9 COOLER CORES: CLEANING OUTSIDE FACES SAFETY Insure that the compressor is isolated from the compressed air system by closing the isolation valve and bleeding pressure from the drip leg. Insure that the main power disconnect switch is locked open and tagged. TOOLS REQUIRED Screwdriver Wrench set Air hose equipped with approved O.S.H.A. nozzle. On units sold outside the U.S.A. consult local codes. PROCEDURE Visually check the outside of the cooler cores to be certain that a complete outside cleaning of the cooler is required. Frequently dirt, dust or other foreign material, may only need to be removed to remedy the problem. ‘When the cooler is covered with a combination of oll, grease or other heavy substances that may affect the unit's cooling, then it is recommended that the cooler cores be thoroughly cleaned on the outside, OIL COOLER 50-100 HORSEPOWER Remove panels and top cover. Drain the coolant, See Section 4.6. Remove fan guard. Disconnect piping from oil cooler inlet and outlet ports. Plug oil cooler inlet and outlet ports to prevent possible contamination. Mark fan motor support location on base. Remove bolts that attach fan motor support to base. Move fan motor assembly away from cooler. Remove oil cooler shroud from exhaust box. Remove oil cooler holding screws from exhaust box and remove oil cooler. 244.9 COOLER CORES: CLEANING OUTSIDE FACES (Continued) OIL COOLER 125-200 HORSEPOWER Remove panels and top cover. Drain the coolant. See Section 4.6. Remove side panels from oil cooler box. Disconnect piping from oil cooler inlet and outlet ports. Plug oil cooler inlet and outlet ports to prevent possible contamination. Remove oil cooler holding screws from sides of oil cooler and remove cooler through side of cooler shroud. AFTERCOOLER 50-100 HORSEPOWER Disconnect hose from aftercooler inlet Disconnect tube from aftercooler outlet. Remove aftercooler holding screws from aftercooler support and remove cooler. AFTERCOOLER 125-200 HORSEPOWER Disconnect hose from aftercooler inlet flange. Disconnect tube from aftercooler outlet flange. Remove aftercooler holding screws from aftercooler support and remove cooler. COOLER CLEANING Flush the outside cooler core using a safety sol- vent. Follow solvent manufacturer's directions. For proper use. Reassemble in reverse order. Make sure fan guards are replaced. Refill the compressor with coolant. If ‘contamination is suspected, replace with new coolant, Run compressor for ten minutes. Check for possible leaks, Check coolant level. Replace enclosure panels. ZAXCAUTION STRONG CLEANERS CAN HARM ALUMINUM AFTERCOOLER PARTS. FOLLOW CLEANER MANUFACTURERS INSTRUC- TIONS FOR USE. WEAR APPROPRIATE SAFETY EQUIPMENT. 254.10 DRIVE MOTOR LUBRICATION ‘The induction-type squirrel cage motors have anti- friction ball or roller bearings front and rear. At extended intervals they require relubrication. ‘The periods between re-greasings of the motor, bearings can vary, primarily with the severity of the service conditions under which the motor operates. As a general rule the following would apply: Frequency of Lubrication-Normal Environments ‘Wotor Relubrication Size Interval 0-60 HP ‘3 Months {or 1000 hrs) 75HP 6 Months and Larger (or 2000 hrs) NOTE: For severe duty - Dusty locations - High Ambients Reduce time intervals in table above to 1/2 the listed value. Grease lubricated bearings as furnished are adequate for a long period of operation without relubrication. A good maintenance schedule for regreasing will vary widely depending on motor size, speed, duty and environment. Procedure for Relubrication — ASCAUTION Grease should be added when the motor is stopped and power disconnected. When regreasing, stop motor and remove inlet and outlet plugs. Inlet grease gun fittings and spring- loaded outlets are arranged at each end on the motor housing. Use a hand lever type grease gun. Determine in advance the quantity of grease delivered with each stroke of the lever. Add grease in the following quantity: Motor Lubricant Amount Frame int | cc | oz. [grams 286 10 | 16 | oe | 23 326-365 Fiera) |reoue acttous | boa) 404 & Larger 25 | 40 | 20 | 57 Do not expect grease to appear at the outlet, but if it does, discontinue greasing at once. 264.10 DRIVE MOTOR LUBRICATION (Continued) Run for about ten minutes before replacing outlet plug. Certain TEFC motors have a spring relief outlet fitting on the fan end. If the outlet plug is not accessible at surface of hood, it is the spring relief type and need not be removed when regreasing. ‘A major cause of motor bearing failure is overgreasing, The quantity of grease added should be carefully controlied. The smaller motors must be greased with a lesser amount of grease than the larger motors. Recommended Motor Greases (or equals) Chevron SRI... Standard Oil of California Premium RB - Texaco Unirex N2 . Exxon Dolium R -+ Shell Rykon Premium ‘American Oil DRIVE 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 procedures should be adhered to: 284T THRU 449TDZ FRAME DRIVE MOTORS 1. Prior to placing a unit in storage, rotate the drive motor several revolutions by hand in the proper direction of rotation. This can be accomplished by carefully turning the rotor with the fan biades located at each end of the rotor. 2, Thereatter, rotate the motor as described in Step ‘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 six (6) months duration, the compressor must be ordered with long term storage option (See Section 4.11) AXCAUTION ‘Overgreasing is a major cause of bearing and motor failure. Make sure dirt and contaminants are not introduced when adding grease. ACAUTION Never mix greases. Can cause motor failure. 274.11 LONG TERM STORAGE GENERAL The factory upon special request prepares ‘compressor units for long term storage. In such cases, a special bulletin is supplied for storage and start-up procedures. The bulletin provides special procedures for rotation and lubrication of compressors during storage. Before actual start-up of the compressor, the unit must be Grained of coolant containing vapor space inhibitors. Procedure for long term storage start-up is covered in the special bulletin APDD 333. 4,12 COOLANT/LUBRICANT CHANGEOUT PROCEDURE RECOMMENDATION Instructions Covering Field Changeout of Coolant/Lubricants. SSR Ultra Coolant (Standard Factory Fill) SSR Coolant (Optional) SSR HIF Food Grade (Optional] IMPORTANT: To eliminate confusion concerning the type of fluid to be added as make up coolant/lubricant use the correct decal as outlined in this instruction procedure for SSR Ultra Coolant and SSR H-1F Food Grade Coolant. (COMPRESSOR COOLANT/LUBRICANT CHANGE PROCEDURE OBJECTIVE To drain coolant/lubricant from compressor as completely as possible when changing types of coolant/lubricant to avoid contamination or dilution of new fluid ‘CAUTION: Ultra Coolant is not compatible with certain “Compressor Conditioner” fluids often utilized to remove varnish deposits from ‘machines running on petroleum oll products. Addition of these products to Ultra Coolant can lead to plugged filters and bearing lines, potentially leading to severe mechanical problems. Therefore, do not flush the compressor system with a “Compressor Conditioner” prior to filling with Ultra Coolant. WARNING Zt Hot surface can injury. Use cate when rear this area, 284.12 COOLANT/LUBRICANT CHANGEOUT (Continued) NOTE: If changing to food grade coolant/lubricant SSR H-1F, the following procedure is mandatory. The initia! fill of SSR H-1F should be run a few hours (2-10 hours) at NO LOAD and then drained. A fresh change of SSR H-1F is then added and the unit is placed in normal service. ‘CAUTION: (SYSTEM CONTAMINATION) The factory does not recommend field changes from ‘SSR Coolant to SSR H-1F based on tests and experience as of January 1986, We believe that in @ majority of applications it may be impractical and undesirable to follow this course of action The residual dye from SSR Coolant will tint the replacement coolant after the double flush procedure has been completed. The factory recommends that the customer take this fact into consideration before decision is made to make a chargeout utilizing SSR H-1F Food Grade coolant. ITEMS REQUIRED In addition to the tools normally found in any reasonably equipped serviceman’s toolbox, the following items should be available at the work site A suitable drain pan and container to hold coolant drained from unit A quantity of proper coolant sufficient to refill the compressor. ‘A minimum of one replacement coolant filter, element. PROCEDURE Operate the unit to bring the complete system up to operating temperature. Shut compressor down, Initiate remainder of change procedure while system is still warm, Drain the receiver-separator tank, lubricant cooler, and any low points in the lubricant piping system. Change the coolant filter element. Refill the unit with proper type coolant. Exercise care to prevent entry of any contamination. Start unit and check coolant level. Add additional Coolant if required. Check for any leaks. WARNING > a rm met. 294,12 COOLANT/LUBRICANT CHANGEOUT (Continued) ‘Thoroughly clean a suitable area of the separator tank near the coolant fill connection. install the correct decal, as shown, for the fluid now installed in the compressor. NOTE: 1. Tank area must be dry and completely free of dirt prior to applying decal NOTE: 2. Decals in sufficient quantities must be ordered from Piscataway Parts Center, contact, your Ingersoll-Rand distributor. NOTE: 3. Units running on Food Grade Coolant ‘SSR H-1F must have the coolant changed at least every 3000 hours or more frequently under dirty environmental conditions. 4.13 INTELLISYS REMOVAL Removal - Replacement Instructions Covering: Intellisys Controller Starter Interface Board Analog Barrier Terminal Board TOOLS: Screwdriver Size #1 Open the starter box door. Check all the wiring for tightness before replacing either board. A loose wire or bad connection may be the cause of the problem. ‘TO PREVENT STATIC ELECTRIC DAMAGE Static can cause severe damage to microcircuits. Below are steps to minimize damage to the Intellisys Controller and boards. 1. Make the least possible movement to avoid building up static electricity trom your clothing or tools. 2. Discharge potential static electricity by touching = grounding yourself on the Starter Box. 3. Handle the boards by the edges only. 4. Do not place the Intellisys Controller or boards on any metal surtace. 5. Leave the replacement Intellisys Controller or the board in its protective bag until ready for installation, 30 AXCAUTION AXWARNING ae \ | tt e Teer sno ap Oo See daerators4.13 INTELLISYS REMOVAL (Continued) INTELLISYS CONTROLLER REMOVAL SAFETY Insure that the compressor is isolated from the ‘compressed air system by closing the isolation valve and bleeding pressure from the drip leg Insure that the main power disconnect switch is locked open and tagged Open starter box door. Remove the two different ribbon cables from the analog barrier interface board and the starter interface board. Remove the (12) twelve holding screws from the Intelisys controller box at the back of the panel Remove the controller box through the front of the starter box door Be careful and do not damage the gasket between the panel display assembly frame and the Inteliisys. STARTER INTERFACE BOARD Locate the two intellisys ribbon cables. Remove the cable from the board, note that each cable connector is of a different size to ensure correct re- connections, The connectors also have (keys) to help in locating the pins correctly. The holding snaps, located at each end of the connector; when released, force the male connector upwards making for easier removal Remove the cable transformer cable holder. IMPORTANT Mark or tag each wire that is removed from the board. Refer to the wiring schematic for details. Remove the wires one by one. Remember to mark or tag. After all the wires are removed, loosen and remove the six holding screws. Hold the board by the edge and remove the optional proms which must be installed on the new board. To ensure proper re-installation of the prom(s) note the key at bottom left corner. Use extreme care when removing this part since the holding legs are easily damaged, Use extreme care and insert the prom chip from the old board into the holding socket of the new interface board. By using the key on the option module and the board as a guide a correct matchup will be made. Holding Screws Intelsys. Socket for Ribbon Option Prom Modules Key 314.13 INTELLISYS REMOVAL (Continued) ANALOG BARRIER TERMINAL BOARD Located in the upper center of starter box. This board is not removed from the backing plate. 1, Remove the Intellisys ribbon cable from the board. 2. Loosen eight holding nuts on the backing plate, 8. Disconnect the wire connectors, three pressure transducers and the three temperature sensors quick disconnect. 4, Remove the wire tie wraps. 5. Remove thé eight holding nuts from the terminal board and pull all the wires along with the board from starter box. 4.14 COOLANT HOSES The flexible hoses that carry coolant to and from the oil cooler may become brittle with age and will require replacement. Have your local Ingersol~ Rand distributor check them every 2 years. ‘SAFETY Insure that the compressor is isolated from the compressed air system by closing the isolation valve and bleeding pressure trom the drip leg Insure that the main power disconnect switch is locked open and tagged. REMOVAL Remove enclosure panels, 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. Hold fitting securely while removing hose INSTALLATION Install the new hoses and reassemble the package by reversing the disassembly procedure. Start the ‘compressor and check for leaks. 32 Intelisys Ribbon Cable5.0 SYSTEMS 5.1 GENERAL SYSTEM INFORMATION The SSR compressor is an electric motor driven, single stage, screw compressor — complete with accessories piped, wired and baseplate mounted. It is a totally self-contained air compressor package. A standard compressor is composed of the following Inlet air filtration Compressor and motor assembly Pressurized coolant system with cooler Separation system Capacity control system with stepper motor inlet Motor starting control system Instrumentation Safety provisions Aftercooler Moisture separator and drain trap. Optional accessories can provide for such things as automatic starting and stopping, remote starting or stopping, and sequencer. The motor, airend, separator tank, and piping are mounted on independent supports. The supports are isolated from the base by rubber isolation. mounts. Flexible hoses are utilized on the separator tank oil out and air discharge to isolate the motor/airend/tank 5.2 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 the design levels described are encountered, we recommend you contact your nearest ingersoll-Rand representative for adgitional information. The standard maximum temperature (115°F.) is applicable up to an elevation of 7500 ft. (2300 meters) above sea level. Above this altitude, significant reductions in ambient temperature are required if a standard drive motor is to be used COOLANT COOLER The cooler is an integral assembly of core, fan and fan-motor, all mounted in the end section of the ‘compressor enclosure. The cooling air flows in through the left end of the enclosure, through the vertically mounted cooler core. and discharges upward through the right end of the enclosure, 335.2 AIRCOOLED COMPRESSORS (Continued) COOLING FAN MOTOR Ina standard compressor, the cooling tan motors are wired at the factory. They are three-phase- motors, Each is protected by a suitable circuit breaker and overload relay. The fan motor is energized at the same time the compressor drive motor is energized. The fan motor overload is wired in series with the compressor drive motor overload. If an overload occurs in the fan motor circuit, both the fan motor and compressor drive motor will stop. AFTERCOOLER ‘The discharge air aftercooling system consists of a heat exchanger (located at the cooling air entrance of the machine), a condensate separator, and an automatic drain trap. 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. 5.3 COOLANT SYSTEM Coolant is forced by pressure from the receiver- separator sump to the inlet port of the coolant cooler and the bypass port of the thermostatic control vaive. The thermostatic control valve controls the quantity of coolant necessary to provide a suitable ‘compressor injection temperature. When the compressor starts cold, part of the coolant will bypass the cooler. As the system temperature rises above the valve setting, the coolant will be directed to the cooler. During periods of operation in higher ambient temperatures, all the coolant flow will be directed through the cooler. The compressor injection minimum temperature is controlled to preclude the possibility of water vapor condensing in the receiver. By injecting coolant at a sufficiently high temperature, temperature of the discharge air and lubricant mixture will be kept above the dew point. The controlled temperature coolant passes through a filter to the airend under constant pressure. 345.4 COMPRESSED AIR SYSTEM The air system is composed of: 1. Inlet air filter 2, Inlet valve/stepper motor 3, Rotors 4, Coolant/air separator 5, Minimum pressure/check valve 6. Aftercooler 7. Moisture separator/drain trap Air enters the compressor, passing through the inlet air filter and butterfly inlet valve. Compression in the screw-type air compressor is created by the meshing of two helical rotors (male and female) on parallel shatts, enclosed in a heavy- duty cast 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. Tapered roller bearings at the discharge end prevent axial movement of the rotors. The air-coolant mixture discharges from the ‘compressor thru a discharge check valve into the separation system. This system, self-contained in the receiver tank, removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the system and the air passes to the aftercooler, The aftercooling system consists of a heat exchanger, a condensate separator, and a drain trap. By cooling the discharge air, much of the water vapor naturally contained in the air is condensed and eliminated trom the downstream plant-piping and equipment During unloaded operation, the butterfly iniet valve closes, via stepper motor, and the blowdown solenoid valve opens, expelling any compressed air back to the compressor inlet. 5.5 COOLANT/AIR SEPARATION SYSTEM The coolant/ait-seperation-system is composed of a receiver with specially designed internals, a two- stage, coalescing-type separator-element, and provision for return of the separated fluid back to the compressor. 355.5 COOLANT/AIR SEPARATION SYSTEM (continued) OPERATION The coolant and air discharging from the ‘compressor flow into the receiver through a tangential discharge outlet. This outlet directs the mixture along the inner circumference of the receiver, allowing the coolant stream to collect and rop to the receiver sump. Internal baffles maintain the circumferential flow of remaining coolant droplets and air. In an almost continuous change of direction of flow, more and more droplets are removed from the air by inertial action and then returned to the sump. ‘The air stream, now essentially a very fine mist, is Girected to the separator element. ‘The separator element is constructed with two concentric, cylindrical sections of closely packed fibers, each held in steel mesh. It is flange-mounted at the receiver-outlet-cover. The air stream enters the separator element radially and the mist coalesces to form droplets. The droplets collected on the outer first stage fall to the receiver sump. Those collected on the inner second stage collect near the outlet of the element, and are drawn back to the compressor inlet, through a filter-screen and orifice fitting installed in the separator scavenge line. The air stream, now essentially free of coolant, flows from the separator to the aftercooler, then to the condensate separator, and on to the plant air system 5.6 ELECTRICAL SYSTEM ‘The electrical system of each SSR compressor is built around the microprocessor-based Intellisys controller. The standard electrical/electronic components, enclosed in a readily accessible enclosure include: 1. SSR Intellisys controller 2, Star-Delta compressor motor starter, with auxiliary contacts and overload relays 3, Cooling fan motor overload relays and circuit breaker or fuses Analog barrier terminal board Starter interface board Control, electronic control transformers, and fuses Options, such as automatic start/stop, remote start/stop, modulation % load, and sequencer, can bbe added by installing plug-in (prom) modules in the starter interface board, 36 Separator Tank Internals5.6 ELECTRICAL SYSTEM (Continued) STAR-DELTA TYPE STARTER By use of the Star-Delta type starter, the ‘compressor motor can be started and accelerated using a greatly reduced “inrush’” electric current. ‘The starter is completely automatic and controlied by the Intellisys controller. Refer to the electrical schematic, Section 8.0. 5.7 STEPPER MOTOR INLET CONTROL The inlet valve is opened and closed by a stepper motor mounted on the inlet valve. The Intellisys controller regulates the stepper motor to precisely position the inlet valve based upon the demand of the plant air system (See Section 5.8) The stepper motor is maintenance free. Bearings are lubricated at the factory and sealed for life. No adjustment of the stepper motor/inlet valve system is required A cover protects the stepper motor from damage and contamination. 5.8 CAPACITY CONTROL, ‘The SSA compressor is supplied, as standard equipment, with two operator selectable capacity control systems, each designed for different plant air requirements: — MOD/ACS (Modulation/Automatic Control Selector) — On-Off Line The desired control is selected at the Intellisys control panel (See Section 3.0) AUTOMATIC UNLOADED START ‘The compressor will always start in the unload mode. When unloaded, the inlet valve is nearly closed, the lowdown solenoid valve is open (tank vented), and the compressor is operating at minimum power. The Intellisys will open the inlet valve slightly to maintain the proper sump pressure to insure positive oil flow and smooth, quiet operation, When the injected coolant temperature is less than 120°F, a receiver (sump) pressure of 45-80 psig will be maintained. When the injected coolant temperature is above 120°F, a receiver pressure of 25-30 psig will be maintained. The ‘minimum pressure check vaive will prevent any backtiow of air from the plant air system during unloaded operation 375.8 CAPACITY CONTROL (Continued) ON-OFF LINE CONTROL For those plants which have a widely varying air demand, on-off line control will deliver air at full capacity (compressor maximum efficiency condition) or will operate at zero capacity (compressor minimum power condition). The ‘compressor is controlled by the Intellisys, responding to changes in plant air pressure. The Intellisys/stepper motor opens the inlet valve and closes the blowdown valve (3SV) whenever plant air pressure drops below the on-line pressure set point. The compressor will then operate to deliver full capacity air to the plant system. If the plant air system pressure rises to the off-line set point of the Intellisys, the inlet valve closes and the blowdown solenoid valve opens the receiver vent line, allowing receiver pressure to drop. The compressor will continue to run with minimum power draw, MODULATION/ACS CONTROL For those plants which have relatively high, constant air-demand relative to the compressor capacity, the recommended control mode is modulation. ‘The modulation control system retains the features of on-off line control, but provides for throttling of the inlet flow up to the modulation off line air pressure set point. The throttling position of the inlet valve is controlled by the Intellisys, allowing the stepper motor to “trim” the inlet valve position as dictated by the line pressure. The modulating pressure range is 10 psig Modulation begins when the line pressure reaches ‘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 down to approximately 60 percent of the compressor rated capacity. 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, unloading the ‘compressor and venting the receiver. 385.8 CAPACITY CONTROL (Continued) MODULATION/ACS CONTROL (Continued) ‘The automatic control selector (ACS) is designed to continuously monitor the plant air demand and select either the on-off line, or the modulate control mode - whichever is most desirable at anytime during an operating day. Itallows the compressor to operate in its most efficient mode without attendance, thereby reducing power costs to a minimum, When the compressor operates in the on-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 shitt to the on line mode. If the “off line” time period is relatively short, thereby indicating a high demand for air, itis 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 I later, the plant demand decreases, and even under modulate control the fine pressure reaches the setting of the Intellisys controller and the control shifts to the “off line” mode, the time in this mode will stl be monitored. A long “off line” time- period indicates a low plant air demand, indicating the desirability of operating in the on-off line mode. The Intellisys then does this, and does it automatically if the compressor operates unloaded for more than 3 minutes 396.0 TROUBLE SHOOTING CHART WHAT TO DO [Compressor fails to start. [115V control voltage not available. —Check fuses. Check transformers and wiring connections. ‘STARTER FAULT.” Inspect contactors. STARTER DOOR OPEN.” — Close and fasten starter box door. EMERGENCY STOP.” Rotate emergency stop button to disengage, and press reset button. MOTOR OVERLOAD.” —Manually reset main or fan motor overload relay, and press reset button ‘SENSOR FAILURE.” |— Check for defective sensor, bad sensor Connection, or broken sensor wires. Ck INLET CONTROL SYS,” |—Call factory representative. } INLET VALVE ROTATED. J—Reset to clear. Inet valve will reset itself [Compressor shuts down. "HIGH A/E DISCH TEMP.” — Insure that installation area has adequate ventilation — Insure that cooling fan is operating. if not reset circuit breaker inside starter box. |—Check coolant level, Add if required. — Cooler cores dirty. Clean coolers. Secu ess etek HIGH INLET VACUUM.” Check for slipping or broken stepper button once to activate motor coupling. Call factory the L.E.D. display table. representative. Using the adjacent up “HIGH SUMP AIR PRESS." |— Check for restricted or malfunction eo NOTE: If a shutdown and down arrows the lowdown valve or minimum pressu values displayed will check valve. be those immediately J—Gheck Yor slipping or broken stepper preceding shutdown, Use motor coupling {hese values when trouble —Cheek for air leak from tank or shooting a problem, lowdown piping J—Check for sipping or broken stepper motor coupling. CK INLET CONTROL SYS.” Call factory representative SENSOR FAILURE” Check for detective sensor, bad sensor Connection, or broken sensor wires, “CK MOTOR ROTATION,” |— Interchange any two line connections (L1, L2, L3) at the starter. MAIN MOTOR OVERLOAD. Check tor loose wires Check supply voltage Check heater size. FAN MOTOR OVERLOAD, —Check for loose wires —Check supply voltage. Check heater size, Check for dirty cooler cores STARTER FAULT” — Inspect starter contactors Greek for loose wires. “STARTER DOOR OPEN.” |— Close and fasten starter box door. 40TROUBLE SHOOTING CHART (Continued) TROUBLE _| CAUSE &/OR DISPLAY WHAT TO DO Low system air pressure |— Press “On/Off Line” button ICompressor running in “Unload” Mode. Controller off-line set point too low. —Press “Unloaded Stop” button, set off- line set point at a higher value —Check filter condition. Replace as required, —Check air system piping. Inspect and repair. —Inspect and repair. Check control system operation. —Install larger or an additional Dirty air filter element. Air teak Moisture separator trap drain stuck open. Iniet valve not fully open. |System demand exceeds compressor delivery. ‘compressor. High coolant JExcessive coolant level. Check level, lower if necessary by Iconsumption/coolant draining, |—Check separator pressure drop. — Check separator pressure drop. If low, replace element. —Remove and inspect orifice/screen. Clean if required. — Operate at rated pressure, /—Reduce system load. /— Inspect and repair leaks. —iInspect and clean if required. Replace separator/trap if defective |— Inspect and clean. |— Inspect and clean. |— Install enclosure panels. |— Install aftercooler. |—Slope drain line away from trap. install Grip leg. —Contact local Ingersoll-Rand distributor. —Contact authorized distributor immediately, do not operate unit. —Install enclosure panels, —Inspect and tighten. Plugged separator element. |Separator element leak. in air system Plugged separator scavenge orifice/ screen, Compressor operating at low pressure (75 psig or below). [Coolant system leak. Defective moisture separator/drain trap Water in Air System Trap drain or drain piping plugged Attercooler core dirty Enclosure panels not in place No aftercooler on unit Drain ine/drip leg incorrectly installed No refrigerated or dessicant dryer in air system, [Compressor defective, (Bearing lor gear failure or rotor contact.) [Enclosure panels not in place. Loose component mountin Excessive noise level — Inspect and tighten. —Contact authorized distributor immediately, do not operate unit. /— Inspect area for other equipment. — Adjust intellisys set points. —Replace valve Loose components. IMotor or compressor bearing failure. [Excessive vibration External sources. [Compressor operating over pressure. Defective valve. Pressure relief valve opens 4a7.0 OPTIONS 7.1 AUTOMATIC START-STOP CONTROL Many plant air systems have widely varying air demands or large air storage capacity which allows for automatic standby air capacity control. The Intellisys system has been designed to carry out this function utilizing a software prom module. Automatic Start-Stop is available as a factory installed option or as a field installation kit. During periods of low air demand, if the line pressure rises to the upper set point, the Intellisys begins to time out. If the line pressure remains above the lower set point for as long as the set time, the compressor will stop. At the same time the Automatic Restart light on the display pane! will bbe lit to indicate the compressor has shut down automatically and will restart automatically. An automatic restart will occur when the line pressure drops to the lower set point. The upper and lower set points and shut down delay time are set on the Inteltisys contro! panel. 7.2 MODULATE % LOAD This option allows the Intellisys controller to display % load when the compressor is operating in the modulate mode. The option may be factory installed oa field installation kit is available. This option is also a plug-in prom module. 7.3 REMOTE START/STOP The remote start/stop option 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 prom module. With the optional plug-in prom installed, two different switches can be wired to the starter intertace board for remote start/stop. (Refer to Electrical Schematic 8.1 for wiring locations) The switches are customer supplied and must be of the momentary type. The stop switch contacts are normally closed/the start switch contacts are normally open. 7.4 SEQUENCER CONTROL ‘Sequencer control capability can be added to the Intellisys System by utilizing a software prom module. This option is available as a factory installed option or as a field installation kit, 42‘OILVWAHOS TOIHL9373 Le SONIMVUG JON3Y343H 0°844 nik Oceana “Bae 8.2 FOUNDATION PLAN - 50/60 HP, AIRCOOLED, ENCLOSEDoy oh RIGHT END VIEW LEFT eno view B0TTOM view 8.3 FOUNDATION PLAN - 50/60 HP, WATERCOOLED, ENCLOSED. 45[sm oscwanae e 8.4 FOUNDATION PLAN - 50 HP, AIRCOOLED, UNENCLOSED 468.5 FOUNDATION PLAN - 60 HP, AIRCOOLED, UNENCLOSED 47BoTTON view s 8.6 FOUNDATION PLAN - 50 HP, WATERCOOLED, UNENCLOSED 48FRONT viEW 22 eorrom view 8.7 FOUNDATION PLAN - 60 HP, WATERCOOLED, UNENCLOSED LEFT ENO vieW 4950 8.8 FOUNDATION PLAN - 75/100 HP, AIRCOOLED, UNENCLOSED51 8.9 FOUNDATION PLAN - 75/100 HP, WATERCOOLED, UNENCLOSED52 fe dae 8.10 FOUNDATION PLAN - 75/100 HP, AIRCOOLED, ENCLOSEDFRONT ww 21 INGERSOMAAK FF sorrow vew 8.11 FOUNDATION PLAN - 75/100 HP, WATERCOOLED, ENCLOSED LeFT eno ew 53were 2 Tor LEFT_END 8.12 FOUNDATION PLAN - 125-200 HP, AIRCOOLED, ENCLOSED 548.13 FOUNDATION PLAN - 125-200 HP, WATERCOOLED, ENCLOSED 55AF STEPPER CONTROL LEGEND ATT Graer MS &) W/TRAP LEGEND DESCRIPTION ABBREVIATION DESCRIPTION TNLET aie FILTER BUTTERFLY INLET VALVE COMPRESSOR SCHARGE CHECK VALVE MINIMUM PRESSURE CONTROL VALVE AFTERCOOLER COOLANT FILTER THERMOSTATIC CONTROL VALVE COOLANT COOLER MOISTURE SEPARATOR SEPARATOR SCAVENGE FILTER SEPARATOR SCAVENGE ORIFICE SEPARATOR TANK RELIEF VALVE ‘COOLANT DRAIN VALVE TavPT 3aPt ant 2crt 2aTT 4atT Tats, 38v 5sv lors VACUUM PRESSURE TRANSDUCER (0-15 PSIG) AIR PRESSURE TRANSDUCER (0-200 PSIG) AIR PRESSURE TRANSDUCER (0-200 Psic) COOLANT TEMPERATURE SENSOR AIR TEMPERATURE SENSOR R TEMPERATURE SENSOR (GH AIR TEMPERATURE SWITCH SLOWDOWN SOLENOID VALVE COOLANT STOP SOLENOID VALVE COOLANT FILTER DELTA-P SWITCH ry 8.14 BASIC FLOW SCHEMATIC 56TYPICAL SYSTEM FLOW DIAGRAM SYSTEM ae X cursive COMPRESSOR SYMBOLS Room GLADHAND Em VALVE Mater, oF UNION Aidain aconnecting Compressor rm he Spat PRESSURE GAUGE ‘THERMOMETER: DIFFERENTIAL PRESSURE INDICATOR FALSE LOADER Blows of Ar Outside of Compressor Room ISTE nsruMenaTioN NCLUDES: VENTILATION Moloied Louvers, Exhaust Fant AFTERCOOLER/SEPARATOR, ISOLATION VALVE, UNION. STRAINER ANO TRAP 8.15 TYPICAL SYSTEM FLOW DIAGRAMS, 5758 REMOTE INLET FILTER AND PIPING WITHOUT Ol rT DOES NOT FILTER welt, Locate at: ‘yeoocest, 2 CLeANeST 3 Grvest (AWAY FROM STEAM VENTS OR COOLING TOWERS) ie ‘GAsrrnee pLAcE? e@ SJ EASILY ACCESSIBLE 3} SENERALLY THiS WILL BE OUTDOORS & UP ON THE ROOF. PHOTO HELIC! Magnanene GR MANOMETER TO MONITOR AP ‘COMPRESSOR ‘TEMPORARY INLET SCREEN TOREMOVE WELD BEADS & SCALE LOW POINT DRAIN — ALWAYS FABRICATE INLET PIPING FROM: 1) SCHEDULE 40 ON ROTARY PYC 2} STEEL PIPE FABRICATED AND FLANGED IN SECTIONS. ‘Lenwa Erony PAINT INSIDE ~ PREVENT RUST 2) STAINLESS STEEL 3) lomo 4} ALWavs CLEAN INTAKE PIPE THORQUGHLY (WELD BEADS, SCALE, RUST. DIRT, ETC) Facraaon | WK Elsi e Sf SEE Sree 8.15 TYPICAL SYSTEM FLOW DIAGRAMS (Continued)[RECEIVER AND NLM CLEANUP PIPING conTRoL SiRUNE K “ © T NY — Se | RE one /*——— PR FILTER BEFORE REFRIGERATED OR DESCICANT DRYER 5 aS (DO NOT PIPE TRAPS UP-HILL OR TOGETHER PRE-FILTER & DRYER WITH BLOCK & BYPASS mobbue lPacricreR 1 ‘SOME REFRIGERATED DRYERS | HAVEA CONDENSATE sss DRAIN ON AIR TO AIR A Prat a : EXCHANGER TOO. omens oA" BG tlle 8.15 TYPICAL SYSTEM FLOW DIAGRAMS (Continued) 59DRYER WITH POLISHING (NLM OR IR € SERIES) OR PARTICULATE IR P SERIES (FOR DESCICANT DRYERS) VALVE eae H 1 K ‘UNION onver L mw moore on Incsenies on LUBE APPL OR Rowtuse arr. Hf ov AECENER No WONTORNG DEMEES ON AM QUAY e@ ‘TAKE-DOWN.COMMER™ ae a, Q oe sa Baa | wie! | he [— Dewromr HyGROMETER [ => LupRicaNT INDICATOR \ PRESS. l ee SERIO 2h wy Sees Peseta j Senses nett SUES aren wa Sees 8.15 TYPICAL SYSTEM FLOW DIAGRAMS (Continued) 608.15 TYPICAL SYSTEM FLOW DIAGRAMS (Continued) 69.0 WATER QUALITY RECOM- MENDATIONS Water quality is often overlooked when the cooling system of a water cooled air compressor is examin- ed. Water quality determines how effective the heat, transfer rate, as well as the flow rate will remain ‘during the operation life of the unit. It should be noted that the quality of water used in any cooling system does not remain constant during the opera- tion of the system. The water makeup is effected by evaporation, corrosion, chemical and temperature changes, aeration, scale, and biological formations. Most problems in a cooling system show up first in @ reduction in the heat transfer rate, then in a reduced flow rate, and finally with damage to the system. There are many constituents in the water system that must be balanced to have a good stable system. The following is a list of the major com- Ponets that should be monitored: SCALE: Scale formation inhibits effective heat transfer, yet it does help prevent corrosion. ‘Therefore, a thin uniform coating of calcium car- bonate is desired on the inner surfaces. Perhaps the largest contributer to scale formation is the Precipitation of calcium carbonate out of the water. This is dependent on temperature and pH. The higher the pH value the greater the chance of scale formation. Scale can be controlled with water treatment, PARAMETER Corrosivity (Hardness, pH, Total Dissolved Solids, Oto1 Temperature at inlet Alkalinity) tron <2 ppm Sulfate <50 ppm Chloride <50 ppm Nitrate <2ppm Silica < 100 ppm Dissolved Oxygen © ppm (as tow as possible) Oil and Grease <5 ppm ‘Ammonia <1 ppm 62 CONCENTRATION Langelier Index CORROSION: In contrast to scale formation is the problem of corrosion. Chiorides cause problems because of their size and conductivity, Low pH levels promote corrosion, as well as high levels dissolved oxygen, FOULING: Biological and organic substances (slime) can also cause problems, but in elevated temperature environments such as cooling pro- cesses they are not major concern. If they create problems with clogging, commercial shock treatments are available, To ensure good operation life and performance of the compressor cooling system, the recommended acceptable ranges for different water constituents are included below: FREQUENCY OF ANALYSIS Monthly - i stable for 3 to 4 months, analyze quarterly Monthly Monthly Monthly Monthly Monthly . Daily - if stable, analyze weekly Monthly MonthlyRecommended equipment for on-site analysis in- cludes a thermometer, pH meter, and dissolved ox- ygen meter. Dissolved oxygen and temperature must be measured on-site and it is recommended that pH be measured on-site. All other analyses should be performed by a professional water quality analyst. The Langelier Index (LI) is calculated using the following equation and the tables found on the following pages. Li=pH - (9.30 + Total Dissolved Solids chart value + ‘Temperature chart value ) + Hardness chart valve + Alkalinity chart value) The LI is zero when the water is in chemical balance. If the LI is greater than zero, there is a tendency to form scale. If the LI is less than zero, the water tends to be corrosive. Dissolved oxygen may be controlled in closed cool ing towers. Several types of treatments are com- mercially available to remove dissolved oxygen. For ‘open cooling towers, dissolved oxygen is not an easily controlled parameter. Also, a fitration system is recommended for the water going into the air compressor when using an open cooiing tower. It should be noted that Ingersoll-Rand’s guidelines and recommendations should be used in evaluating the water systems and the problems that may oc- cur in the normal operation of our air compressors. If water problems persist or are not covered above, you should consult a professional. 63LANGELIER INDEX CHART VALUES e ‘Tempeature (*F) Total Diesoives ‘Solids (ppm) — Alkalinity (ppm)MAINTENANCE RECORD DATE | LOAD TIME [ RUN Time WORK DONE ay. | uw | woax e twours) | (HOURS) measure | BYMAINTENANCE RECORD DATE] LOAD Time | AUN TIME WORK OOKE ory. 7 un 7 work [WOURS) | (HOURS) measure | eyMAINTENANCE RECORD DATE LOAD TIME | RUN TIME WORK DONE oy] uu, | wR i e@ twours) | (HOURS) MEASURE oea