This Information For :SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz) L, H & HH 125, 150, 200, 250, 300

, 350 & 400 (60Hz)
GENERAL OPERATION The Sierra compressor is an electricmotor driven, two stage, dry screwcompressor complete with accessoriespiped, wired and baseplate mounted. Itis a totally self contained oil free aircompressor package .A standardcompressor is composed of thefollowing: y y y y y y y y y y y y y . Inlet air filtration . Compressor and motor assembly . Pressurised oil system with cooler . ON/OFF line capacity control system . Motor starting control system . Instrumentation . Safety provisions . Intercooler . Aftercooler . Moisture separation first and second stage. . Automatic condensate removal first

and second stage.The motor and airend are integrallymounted. This assembly is isolatedfrom the base by rubber isolationmounts. Flexible pipe connections areutilised where necessary to isolate themain base and customer connections. DESIGN PRESSURES The normal operating pressures forIngersoll Rand Sierra compressors are7,0 bar, 8,5 bar and 10,0 bar (100psi,125psi & 150psi). The maximumallowable pressure is 0,2 bar (3psi)above the normal operating pressureand is shown on the compressor nameplate.The inter stage safety valve is set at3,1barg (45psi) 90 150kW,125 200HP or 3,8 barg (55psi)200 300kW, 250 400HP. The secondstage safety valve is set at 11,4barg(165psi) max. The design of thepressurised system is well above thesafety valve settings. DESIGN TEMPERATURES The standard compressor isdesigned for operation in an ambientrange of 2C to 46C (35F 115F).When conditions other than the designlevels described are encountered, werecommend you contact your nearestIngersoll Rand Distributor foradditional information. COMPRESSED AIR SYSTEM The compressor air enters thecompressor through an opening at theright end of the enclosure. It ravelsthrough a passageway lined withsound absorbing material to the airfilter. Via a round flexible hose, the airpasses through the inlet/unloadingvalve into the first stage of thecompressor.The helical rotors compress the airto a pressure of between 1,7 to 2,4 barg(25 38psig). It is discharged into aventuri, which dampens any pressurepulsations that may be present.The intercooler then reduces the airtemperature before it enters the secondstage. A safety relief valve is alsopositioned in this system to guardagainst an abnormally high interstagepressure. A moisture separator issupplied immediately following theintercooler to remove any condensationthat may occur under certain conditionsof ambient humidity and temperature.An expansion joint is utilized between the moisture separator and

thesecond stage.The second stage furthercompresses the air to the desiredpressure. The pressure pulsationsbeing dampened in a venturi. Anexpansion joint prevents transmittedvibrations. A wafer type check valve isprovided to prevent any backflow of airinto the compressor. The aftercoolercools the air to a suitable temperature,while the discharge moisture separatorremoves significant amounts ofcondensation. During unloaded operation, theinlet/unloading valve closes, viamechanical linkage, the blowdownvalve opens, expelling any compressedair from the package. CONDENSATE REMOVAL SYSTEM A moisture separator is locatedimmediately after the intercooler andaftercooler to collect and eject anycondensation formed from thecompressed air.The condensate is drained throughelectrically operated solenoid valves.The opening duration is preset at three(3) adjustable between 2 and 20seconds, the interval between openingsmay be altered between 60 and 360seconds, depending on ambientconditions. If the environment consistsof high temperature and/or highhumidity, then the interval may have tobe reduced. The factory set interval is180 seconds.The bosses for the manual valvesare located on the outside and rear ofthe sub base These valves aresupplied loose inside the compressorenclosure and need to be connected tothe ports as indicated in the generalarrangement drawing. To checkoperation of solenoid valves, open themanual bypass valves momentarilyonce per day. For extended shutdownperiods, the manual valves should beopened and left open.Strainers are provided upstream ofthe condensate valves to prevent anyparticles from plugging the solenoidvalves. Before any maintenance isperformed on the strainers or solenoidvalves, the strainer service valvesshould be closed, in order to isolatefrom possible high pressure. LUBRICATION SYSTEM The oil sump is integral within thegearcase. An oil strainer is located inthe oil pump suction line. The oil pumpis a positive displacement gear typepump, and is driven by the compressordriven shaft. Therefore, it rotates at themain motor speed.See MAINTENANCE section forlubricant specification.From the pump, the oil travels past apressure relief valve to the oil cooler.The pressure relief valve s function is toprevent over pressure of the system. Itmay divert some oil flow back to sump.At the discharge side of the oil cooleris a thermostatic valve. This valvemixes the cold oil with hot oil thatbypasses the cooler to provide oil at theoptimum temperature to the bearingsand gears.The oil then passes through a filter toa distribution manifold. An orifice fromthe manifold determines the oilpressure (2,8 3,5 barg) (40 50 psig),at normal operating temperature 54C 68C) 129F 154F).The gearcase is vented to amounted breather. The breatherprevents oil vapour from escaping thesump area. The breather exhaust ispiped to the plenum area of thepackage. COOLING SYSTEM (AIRCOOLED) The intercooler, aftercooler, oilcooler, fan and motor are an integralassembly. The heat exchanger and fanare mounted directly above thecompressor assembly. Cooling air flowsthrough the end of the enclosure,through the heat exchangers anddischarges through the top of thepackage. COOLING SYSTEM(WATERCOOLED) The intercooler, aftercooler andoilcooler are shell and tube type heatexchangers. The intercooler andaftercoolerare water in the shell design. the oil cooler employs water inthe tube .Cooling water flows through each ofthe three components in parallel. Awater solenoid shut off valve is providedin the water discharge line from thepackage.The tube bundles are removable forease of cleaning. ELECTRICAL SYSTEM

The electrical system of thecompressor utilises themicroprocessor based INTELLISYScontroller.The standardelectrical/electronic components,contained within a readily accessibleenclosure include: 1. 2. 3. 4. 5. 6. INTELLISYS controller Star Delta compressor motor starter, with auxiliary contacts and overload relays Cooling fan manual motor starter and circuitbreaker or fuses 4. Power supply board 5. Main motor overload relay 6. Control relay control transformers, and fusesStar delta type starterBy use of the Star Delta type starter,

the compressor motor can be startedand accelerated using a greatlyreduced inrush electric current. Thestarter is completely automatic andcontrolled by the INTELLISYScontroller. Refer to the electricalschematic. CAPACITY CONTROL Automatic unloaded startThe compressor will always start inthe unload mode. When unloaded, theinlet valve is nearly closed, theblowdown valve is open and thecompressor is operating at minimumpower.On off line controlOn off line control will deliver air atfull capacity (compressor maximumefficiency condition) or will operate atzero capacity (compressor minimumpower condition). The compressor iscontrolled by the INTELLISYScontroller responding to changes inplant air pressure. The INTELLISYScontroller energises the load solenoidvalve (1SV) to actuate the hydrauliccylinder and load the compressorwhenever plant air pressure dropsbelow the on line pressure set point.The compressor will then operate todeliver full capacity air to the plantsystem. If the plant air system pressurerises to the off line set point of theINTELLISYS, the load solenoid valve isde energised, the hydraulic cylinder isde actuated allowing the machine tounload. The compressor will continue torun with minimum power draw.If there is no demand for air, thecompressor will stop in a standby mode after a run on time period whichis set on the controller. AUTOMATIC START/STOP (CONTROL OPTION) Many plant air systems have widelyvarying air demands or large air storagecapacity which allows for automaticstandby air capacity control.The INTELLISYS system has beendesigned to carry out this functionutilising a software module. AutomaticStart Stop is standard on all oil freecompressors.During periods of low air demand, ifthe line pressure rises to the upper setpoint, the INTELLISYS controllerbegins to time out. If the line pressureremains above the lower set point for aslong as the set time, the compressor willstop. At the same time, the AutomaticRestart warning message will appear inthe display to indicate the compressorhas shut down automatically and willrestart automatically. An automaticrestart will occur when the line pressuredrops to the lower set point.The upper and lower set points andshutdown delay time are set on thecontrol panel. There is a 10 seconddelay after shutdown during which thecompressor will not restart even if lineair pressure drops below the lower setpoint. This is to allow the motor to cometo a complete stop and the controller tocollect current data of operatingcondition. If line air pressure is belowthe lower set point at the end of 10seconds, the unit will start unless theload delay timer is set greater than 10seconds. Delay load time This is the amount of time the linepressure must remain below the onlineset point before the compressor willload or start (if the unit was stopped dueto an auto start/stop situation). Thistimer will not delay loading after a startor if the time is set to 0. When the delayload timer becomes active, the displaywill switch to line pressure (if notdisplaying line pressure at that time)and then display the delay loadcountdown. Once the countdownreaches 0, the unit will load or start andthe display will return to line pressure.The display select arrows are inactiveduring the delay load countdown.Automatic start/stop operation When in operation, the compressormust meet a specific timing intervalbefore the INTELLISYS controller willstop the unit in an Automatic Start/Stopsituation.A timer

prevents the compressorfrom automatically starting more than 6times an hour by requiring the unit to runat least 10 minutes after each automaticstart.This 10 minute run period can beloaded, unloaded or a combination ofthe two and allows dissipation of heatgenerated within the motor windings atstart.When the compressor hascompleted the settings of the timer, thecontroller stops the compressor, turnson the automatic restart light anddisplays AUTOMATIC RESTART in themessage display.Pressure sensor 4APT continues tomonitor the package dischargepressure and sends information to thecontroller which automatically restartsthe compressor when the pressure fallsto the on line setting. REMOTE LOAD / UNLOAD OPTION This option allows the operator toremotely load and unload the machine.With the option enabled, twodifferent switches can be wired (refer tothe electrical schematic for wiringlocations). The switches are customersupplied.

General Information Ensure that the operator reads andunderstands the decals and consultsthe manuals before aintenance oroperation.Ensure that the Operation andMaintenance manual, and the manualholder, are not removed permanentlyfrom the machine.Ensure that maintenance personnelare adequately trained, competent andhave read the Maintenance Manuals.Compressed air and electricity canbe dangerous. Before undertaking anywork on the compressor, ensure thatthe electrical supply has been isolatedand the compressor has been relievedof all pressure.Make sure that all protective coversare in place and that the canopy/doorsare closed during operation.The specification of this machine issuch that the machine is not suitable foruse in flammable gas risk areas.Installation of this compressor mustbe in accordance with recognized electrical codes and any local Healthand Safety Codes.The use of plastic bowls on linefilters without metal guards can behazardous. Metal bowls should beused on a pressurised system.Compressed air can be dangerous ifincorrectly handled. Before doing anywork on the unit, ensure that allpressure is vented from the system andthat the machine cannot be startedaccidentally.Compressed air Ensure that the machine is operatingat the rated pressure and that the ratedpressure is known to all relevantpersonnel.All air pressure equipment installedin or connected to the machine musthave safe working pressure ratings of atleast the machine rated pressure.If more than one compressor isconnected to one common downstreamplant, effective check valves andisolation valves must be fitted andcontrolled by work procedures, so thatone machine cannot accidently bepressurised / over pressurised byanother.Compressed air must not be usedfor a direct feed to any form of breathingapparatus or mask.If the discharged air is to beultimately released into a confinedspace, adequate ventilation must beprovided.When using compressed air alwaysuse appropriate personal protectiveequipment.All pressure containing parts,especially flexible hoses and theircouplings, must be regularly inspected,be free from defects and be replacedaccording to the Manual instructions.Compressed air can be dangerous ifincorrectly handled. Before doing anywork on the unit, ensure that allpressure is vented from the system andthat the machine cannot be startedaccidentally.Avoid bodily contact withcompressed air.