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ENGLISH
M300–2S–HV
FRENCH
DUTCH
M350–2S–HV
OPERATION AND MAINTENANCE MANUAL
GERMAN
PORTUGUESE
ITALIAN
SPANISH
DANISH
SWEDISH
NORWEGIAN
FINNISH
ESTONIAN
LATVIAN
LITHUANIAN
POLISH
SLOVAK
CZECH
SLOVENIAN
HUNGARIAN
MALTESE
C.C.N. : 22076400 en
A REV. :B
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2 FOREWORD
TABLE 1
The contents of this manual are considered to be proprietary and
confidential to Ingersoll–Rand and should not be reproduced without Use of the machine to produce compressed air for:
the prior written permission of Ingersoll–Rand. a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
checks.
Nothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied, regarding Use of the machine outside the ambient temperature range
the Ingersoll–Rand products described herein. Any such warranties or specified in the GENERAL INFORMATION SECTION of this manual.
other terms and conditions of sale of products shall be in accordance
with the standard terms and conditions of sale for such products, which Use of the machine where there is any actual or foreseeable risk of
are available upon request. hazardous levels of flammable gases or vapours.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE
This manual contains instructions and technical data to cover all USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
routine operation and scheduled maintenance tasks by operation and INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR
maintenance staff. Major overhauls are outside the scope of this VAPOURS MAY BE PRESENT.
manual and should be referred to an authorised Ingersoll–Rand service
department. Use of the machine fitted with non Ingersoll–Rand approved
components.
The design specification of this machine has been certified as Use of the machine with safety or control components missing or
complying with E.C. directives. Any modification to any part is
disabled.
absolutely prohibited and would result in the CE certification and
marking being rendered invalid. Connection to an electrical supply of incorrect voltage and/or
frequency.
All components, accessories, pipes and connectors added to the
compressed air system should be:
. of good quality, procured from a reputable manufacturer and, The company accepts no responsibility for errors in translation of
wherever possible, be of a type approved by Ingersoll–Rand. this manual from the original English version.
. clearly rated for a pressure at least equal to the machine maximum
allowable working pressure.
. compatible with the compressor lubricant/coolant. SSR ULTRA COOLANT is a registered trademark of
. accompanied with instructions for safe installation, operation and Ingersoll–Rand Company USA.
maintenance.
INTELLISYS is a registered trademark of Ingersoll–Rand
Details of approved equipment are available from Ingersoll–Rand Company USA.
Service departments.
COPYRIGHT 2004
The use of repair parts other than those included within the INGERSOLL–RAND COMPANY
Ingersoll–Rand approved parts list may create hazardous conditions
over which Ingersoll–Rand has no control. Therefore Ingersoll–Rand
cannot be held responsible for equipment in which non–approved
repair parts are installed.
The intended uses of this machine are outlined below and examples
of unapproved usage are also given, however Ingersoll–Rand cannot
anticipate every application or work situation that may arise.
This machine has been designed and supplied for use only in the
following specified conditions and applications:
. Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.
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ISO SYMBOLS 3
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
WARNING: Electrical shock risk. WARNING – Pressurised vessel. WARNING – Hot surface.
WARNING – Pressure control. WARNING – Corrosion risk. WARNING – Air/gas flow or Air discharge.
X,X BAR
0_C
WARNING – Before connecting the tow bar WARNING – For operating temperature
WARNING – Flammable liquid. or commencing to tow consult the below 0_C, consult the operation and
4 ISO SYMBOLS
Do not remove the Operating and Maintenance Do not operate the machine without the guard
Do not stack.
manual and manual holder from this machine. being fitted.
Do not stand on any service valve or other Do not operate with the doors or enclosure
Do not use fork lift truck from this side.
parts of the pressure system. open.
XX
km/h
Do not open the service valve before the
Do not exceed the trailer speed limit. No naked lights.
airhose is attached.
Use fork lift truck from this side only. Emergency stop. Tie down point
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ISO SYMBOLS 5
a
Read the Operation and Maintenance manual
When parking use prop stand, handrake and
before operation or maintenance of this Contains asbestos.
wheel chocks.
machine is undertaken.
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6 ISO SYMBOLS
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ISO SYMBOLS 7
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8 SAFETY
The discharged air contains a very small percentage of compressor
WARNINGS
lubricating oil and care should be taken to ensure that downstream
Warnings call attention to instructions which must be followed
equipment is compatible.
precisely to avoid injury or death.
Installation of this compressor must be in accordance with Should compressor lubricant come into contact with the skin, then
recognised electrical codes and any local Health and Safety Codes. wash off immediately.
The use of plastic bowls on line filters without metal guards can be Consult a physician if large amounts of compressor lubricant are
hazardous. Their safety can be affected by either synthetic lubricants, ingested.
or the additives used in mineral oils. Metal bowls should be used on a
pressurised system.
Consult a physician if compressor lubricant is inhaled.
Ensure that the machine is operating at the rated pressure and that When loading or transporting machines ensure that the specified
the rated pressure is known to all relevant personnel. lifting and tie down points are used.
All air pressure equipment installed in or connected to the machine When refitting any enclosure panels or doors, it is essential to
must have safe working pressure ratings of at least the machine rated ensure that no persons or equipment remain inside the compressor.
pressure.
Compressed air must not be used for a direct feed to any form of
breathing apparatus or mask.
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SAFETY 9
Electrical Coolant disposal
Keep all parts of the body and any hand–held tools or other Steps to be taken in the case of spillage: Soak up with a suitable
conductive objects, away from exposed live parts of the compressor absorbent material, then sweep into a plastic bag for disposal.
electrical system. Maintain dry footing, stand on insulating surfaces
and do not contact any other portion of the compressor when making
adjustments or repairs to exposed live parts of the compressor Method of disposal
electrical system. Burn in an approved incinerator, or according to local area or
Before removing high voltage motor terminal box cover, ensure that country regulations.
high voltage supply to motor is isolated and earthed.
The above information contains data supplied in support of United
Close and lock all access doors when the compressor is left Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.)
unattended. regulations.
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10 GENERAL INFORMATION
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12 GENERAL INFORMATION
AC
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GENERAL INFORMATION 13
WC
AIR PIPING & WATER PIPING: WATER COOLED MACHINES GENERAL OPERATION
KEY The compressor is an electric motor driven, two stage screw
compressor, complete with accessories piped, wired and baseplate
mounted. The high voltage starter is a remote device, controlled from
A. AIR the compressor instrument / control panel. A low voltage electrical
supply is required for the instrument / control panel.
B. LUBRICANT / AIR
1. AFTERCOOLER The standard compressor is designed to operate in an ambient
range of 1,7_C to 46_C. The standard maximum temperature of 46_C
2. SEPARATOR TANK is applicable up to an elevation of 1000m (3280ft) above sea level.
3. COMPRESSOR Above this altitude significant reductions in ambient temperature are
required if a standard motor is to be used.
4. CHECK VALVE
5. BLOWDOWN VALVE (3SV) Compression in the screw type air compressor is created by the
meshing of two in–line pairs of helical rotors.
6. PRESSURE TRANSDUCER
7. MOISTURE SEPARATOR (OPTIONAL)
Air is drawn through the air inlet filter into the first stage where it is
8. COOLER compressed to the interstage pressure. It then passes through a
curtain of coolant on its way to the second stage, and through contact
9. MINIMUM PRESSURE VALVE cooling significantly lowers the second stage inlet temperature. The
compressed air enters the second stage to be compressed to the final
10.SAFETY VALVE
discharge pressure, and exits the two stage airend through the
11.TO WATER DISCHARGE SOCKET discharge flange. The compressed air enters the separator where the
coolant is separated from the air. Coolant is then cooled and returned
12.FROM WATER INLET SOCKET to the compressor inlet. The air exits the separator, enters the
aftercooler to be cooled down to final discharge temperature.
13.TO AIR DISCHARGE SOCKET
Condensate is separated in the moisture separator and discharged
through a drain. Quality air is discharged out of the package at the
desired discharge pressure.
Air is pulled into the compressor by the cooling fan and is pushed
through the coolers.
D R A removed.
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14 GENERAL INFORMATION
The coolant system consists of a sump, cooler, thermostatic valve The modulation system extends the control types to Modulation
and a filter. When the unit is operating, the coolant is pressurised and (capacity control) and Automatic Control System when the compressor
forced to the compressor bearings. switches between ’On–Off line’ and modulation as demand varies.
The compressor load control system is automatic On–Off line. The The electrical components are housed in a readily accessible sheet
compressor will operate to maintain a set discharge line pressure and metal cabinet.
is provided with an autorestart system for use in plants where the air
demand varies widely.
Safety of operation is provided for as the compressor will shut down
if excessive temperatures, electrical overload conditions, or system
Panel instrumentation is provided to indicate the compressor over pressure should occur.
operating conditions and general status.
M300AC l D M300WC l D
PRESSURE 7,5 bar 8,5 bar 10 bar 14 bar 7,5 bar 8,5 bar 10 bar 14 bar
(L) (M) (H) (XU) (L) (M) (H) (XU)
CAPACITY 60,2 m3/min 56 m3/min 52,1 m3/min 44,3 m3/min 60,2 m3/min 56 m3/min 52,1 m3/min 44,3 m3/min
2126 ft3/min 1978 ft3/min. 1845 ft3/min. 1564 ft3/min. 2126 ft3/min 1978 ft3/min. 1845 ft3/min. 1564 ft3/min.
FULL LOAD CURRENT 29.6 2.6
(MAXIMUM) – FAN
380V
FULL LOAD CURRENT 29.2 2.5
(MAXIMUM) – FAN
415V
STARTING CURRENT 207.2 18.2
(MAXIMUM) – FAN
380V
STARTING CURRENT 204.4 17.5
(MAXIMUM) – FAN
415V
FULL LOAD CURRENT 38.6 38.6
(MAXIMUM) – MAIN
6000V
STARTING CURRENT 270 270
(MAXIMUM) – MAIN
6000V
*NOISE LEVEL 84+/– 3 dB(A) 84+/– 3 dB(A)
* Equivalent continuous sound pressure level (workstation) (rated load)
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M350AC l D M350WC l D
PRESSURE 7,5 bar 8,5 bar 10 bar 14 bar 7,5 bar 8,5 bar 10 bar 14 bar
(L) (M) (H) (XU) (L) (M) (H) (XU)
CAPACITY 69,2 64,1 59,5 50,2 69,2 64,1 59,5 50,2
m3/min m3/min m3/min m3/min m3/min m3/min m3/min m3/min
FULL LOAD CURRENT 29.6 2.6
(MAXIMUM) – FAN
380V
FULL LOAD CURRENT 29.2 2.5
(MAXIMUM) – FAN
415V
STARTING CURRENT 207.2 18.2
(MAXIMUM) – FAN
380V
STARTING CURRENT 204.4 17.5
(MAXIMUM) – FAN
415V
FULL LOAD CURRENT 45 45
(MAXIMUM) – MAIN
6000V
STARTING CURRENT 315 315
(MAXIMUM) – MAIN
6000V
*NOISE LEVEL 84+/– 3 dB(A) 84+/– 3 dB(A)
CAGI PNEUROP 1m
* Equivalent continuous sound pressure level (workstation) (rated load)
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16 GENERAL INFORMATION
AC
89246060
Revision D
KEY
D R A
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GENERAL INFORMATION 17
WC
22090450
Revision A
KEY
D
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R A Earth lead, motor WHI White
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18 INSTALLATION / HANDLING
KEY
NOTE
A Electrical cable entry All dimensions are in millimetres unless otherwise stated.
B 1/2” BSPP Condensate drain
C 4” ASA Flange – Air discharge UNPACKING
D 1/4”BSPP Coolant drain The compressor will normally be delivered with a polythene cover.
If a knife has to be used to remove this cover ensure that the exterior
E 2” BSPP Water in (WC) paintwork of the compressor is not damaged.
F 2” BSPP Water out (WC)
G Cooling air intake Incorporated within the base of the compressor are slots to enable
a fork lift truck (5,000 kg minimum) to move the machine. Alternatively
H Cooling air exhaust a special lifting frame can be supplied to enable a crane or hoist to move
the compressor.
J Access panels
K Control panel
LOCATION IN THE PLANT
L Control cabinet door
The compressor can be installed on any level floor capable of
supporting it. A dry, well ventilated area where the atmosphere is as
clean as possible is recommended.
INSTALLATION / HANDLING 19
KEY NOTE
After the machine has been sited, remove the four transportation
1. Compressor bolts and spacers which are marked with fluorescent tags. Two are
2. Air Receiver situated on the airend support and the other two on the motor support.
3. Air Dryer
4. Compressed air filters
ELECTRICAL DATA
5. System demand points
The main drive motor is supplied from a remote high voltage starter.
An independent low voltage supply is required and an electrical isolator
should be installed adjacent to the compressor.
NOTE
Items [2] to [5] are optional or may be existing items of plant. Refer An independent electrical isolator should be installed adjacent to the
to your Ingersoll–Rand distributor / representative for specific compressor.
recommendations.
CAUTION
CAUTION
Never test the insulation resistance of any part of the machines
The use of plastic bowls on line filters and other plastic air line
electrical circuits, including the motor without completely disconnecting
components without metal guards can be hazardous. Their safety can
the intellisys controller.
be affected by either synthetic coolants or the additives used in mineral
oils. From a safety standpoint, metal bowls should be used on any
pressurised system.
20 INSTALLATION / HANDLING
Minimum cooling water requirement at ambient Cooling Water Analyses Chart
temperatures, in litres per minute (UK gallons per
Model minute)
Range
90_F /
115_F / 46_C
32_C
Substances Test interval Acceptable
M300–2s 273(60) 303(67) concentration
Scale: Scale formation inhibits effective heat transfer, yet it does help 6 bar 19
prevent corrosion. Therefore, a thin uniform coating of calcium
carbonate is desired on the inner surface. Perhaps the largest 7 bar 18
contributor to scale formation is the precipitation of calcium carbonate
out of the water. This is dependent on temperature and pH. The higher 8 bar 17
the pH value, the greater the chance of scale formation. Scale can be 9 bar 17
controlled with water treatment.
10 bar 16
Corrosion: In contrast to scale formation is the problem of corrosion.
Chlorides cause problems because of their size and conductivity. Low
pH levels promote corrosion, as well as high levels of dissolved
oxygen.
Water cleanliness is also extremely important. Strainers are available
Fouling: Biological and organic substances (slime) can also cause from Ingersoll–Rand. Cleaning of coolers as a result of fouling is a
problems, but in elevated temperature environments such as cooling customer responsibility.
processes they are not a major concern. If they create problems with
clogging, commercial shock treatment are available. Isolation valves with side drains should be installed on both the inlet and
outlet lines.
To ensure good operation life and performance of the compressor
cooling system, the recommended acceptable ranges for different It is recommended that a normally closed solenoid valve be fitted to the
water constituents are included below: water outlet side of the compressor package.
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OPERATING INSTRUCTIONS 21
FOR INTELLISYS REFER TO XE145 MANUAL
The controller display will illuminate, indicating that the line and The other five buttons provide access to various
control voltages are available. operator–selectable functions and machine operating conditions. The
purpose of each of these buttons is defined by the display screen and
2. START the particular function being performed at that time.
Pressing this button will start the compressor if the display shows
READY TO START. the compressor will start and load if there is 6. ARROWS
sufficient demand for air. These up and down buttons have multiple functions relating to the
right half of the display screen. When lists are presented, the buttons
3. STOP are used to move up or down through the items on the list. The small
arrow(s) displayed in the upper right hand corner of the display screen
Pressing this button will activate the unloaded stop sequence. If the indicate when you can move up (designated by arrow head pointing up)
compressor is running loaded, it will unload and continue to run and/or down (designated by arrow head pointing down) through the list.
unloaded for an adjustable 10 to 30 seconds and then stop. If the
compressor is running unloaded, it will stop immediately.
When the value of a specific machine operating parameter is
highlighted on the display screen for the purpose of changing that
4. UNLOAD value, the buttons are used to change the value itself.
Pressing this button will cause the compressor to unload and
remain unloaded. The display will indicate that the machine is 7. DISPLAY BUTTONS
RUNNING UNLOADED and MODE:UNLOAD.
The functions of the three buttons below the display screen change
and are defined by the words immediately above them in the bottom line
22 OPERATING INSTRUCTIONS
DISPLAY SCREEN
The display screen is divided into three functional areas, as seen
in the typical CURRENT STATUS screen shown here.
The right side shows various items or lists such as the machine’s
CURRENT STATUS readings, the MAIN MENU, the OPERATOR
SETPOINTS list, etc. Any of the lists can be moved up or down by
pressing the arrow buttons to the right of the screen. The small arrow(s)
displayed in the upper right corner of the screen indicate when you can
move up and/or down through a list. The arrow buttons are also used
to change an individual item’s value. At certain times, items and/or their
values are “highlighted”. This means that they are displayed as light
characters on a dark background.
The bottom of the screen is divided into thirds with the words in each CURRENT STATUS items
small box showing the function of the button directly beneath it. The
words will change in these boxes depending on what actions are Package Discharge Temperature
permitted at any particular time. The action resulting from pressing Airend Discharge Temperature
each of these buttons is indicated in the Operator Panel Flow Diagram
later in this section. This can be used as a quick reference of how to Injected Temperature
step the controller screen through any desired function.
Sump Pressure
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OPERATING INSTRUCTIONS 23
CURRENT
STATUS
MAIN MENU
(1)
The controller automatically returns the display to this CURRENT (3) The UP and DOWN arrows will alter the value.
STATUS screen from other screens if no buttons are pressed within 30 Depressing “Cancel” will exit the edit mode and leave the value
seconds. unchanged.
Depressing “Set” will save the new value and flash the value to
indicate acceptance.
The MAIN MENU screen can be accessed from the CURRENT
STATUS screen by pressing the MAIN MENU button, identified by the
words “MAIN MENU” in the bottom line of the screen directly above the (4) Depressing “Cancel” will exit the calibration mode.
centre button. Depressing “Calibrate” will calibrate the selected sensor.
(2) Selecting the highlighted item will place the value in edit mode. This
is indicated by only the value being displayed in inverse display mode.
–MAIN MENU–
7,5 barg
OPERATOR SETPOINTS
OPTIONS
READY TO START SENSOR CALIBRATION
ALARM HISTORY
D R A STATUS SELECT
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24 OPERATING INSTRUCTIONS
MAIN MENU OPERATOR RANGE STEP UNIT
SETPOINTS
The MAIN MENU screen is the point from which various operator
functions can be accessed. Refer to the Operator Panel Flow Diagram. Offline Pressure 75 to RATED +3 1 PSIG
Online Pressure 65 to OFFLINE 1 PSIG
Each of the functions can be chosen by using the up and down – 10
arrows to highlight it on the screen.
Mode of MOD/ACS, ON/OFF LINE, MODULATION
Operation ONLY
The controller will go to the highlighted function if the SELECT Load Delay Time 0 to 60 1 SEC
button is pressed or will return to the CURRENT STATUS screen if the
STATUS button is pressed. Stop Delay Time 10 to 30 1 SEC
Star–Delta Time* 10 to 20 1 SEC
OPERATOR SETPOINTS
(Screen) Contrast 0 to 10 1 –––
Setpoints are user–adjustable variables in the controller logic that
can be set using the OPERATOR SETPOINTS screen.
*Does not apply to automatic across the line starters.
The name and value of each of the setpoints listed below can be
seen on the screen by moving the list up and down using the arrow
buttons.
–OPERATOR SETPOINTS–
7,5 barg
OFFLINE PRESSURE
7,6 barg
READY TO START ONLINE PRESSURE
6,9 barg
STATUS MAIN MENU SELECT
–OPTIONS–
7,5 barg
AUTO RESTART
Off
READY TO START AUTO RESTART TIME
10 MINUTES
STATUS MAIN MENU SELECT
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OPERATING INSTRUCTIONS 25
OPTIONS OPTIONS Range Step Unit
Items
Options are turned on or off and their associated values are set
using the OPTION screen. Power Out ON/OFF – –
Restart
Some options require additional machine hardware and the correct Power Out 10 to 120 1 SEC
“Option Module” to plug into the Intellisys controller. Descriptions of the Restart Time
options operations can be found later in this section. The name and
Low Ambient ON/OFF – –
value of each of the following options can be seen by moving the list up
and down using the arrow buttons. Min. Cooler 30 to 150 1 Deg.F
Out Temp.
–SENSOR CALIBRATION–
7,5 barg
SENSOR 1AVPT
CALIBRATE
READY TO START SENSOR 3APT
CALIBRATE
STATUS MAIN MENU SELECT
SENSOR CALIBRATION Select the highlighted sensor by pressing the SELECT button.
Press the CALIBRATE button to start the automatic calibration
Pressure sensor calibration is done through the SENSOR procedure, or press the CANCEL button to not calibrate it and return
CALIBRATION screen. Sensor calibration can only take place when to the sensor list.
the machine is stopped. Calibration needs to be done only after a
sensor has been replaced or the Intellisys controller has been
replaced. The calibration screen can be exited by pressing either the STATUS
or MAIN MENU buttons. If no buttons are pressed within 30 seconds,
the display will return to the CURRENT STATUS screen.
Each of the sensors listed below can be chosen by using the up and
down arrow buttons to highlight it on the screen.
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26 OPERATING INSTRUCTIONS
–ALARM HISTORY–
7,5 barg
ALARM HISTORY 1
MAIN MOTOR OVERLOAD
READY TO START ALARM HISTORY 2
HIGH AIREND DISCH TEMP
STATUS MAIN MENU SELECT
ALARM HISTORY Each of the last 15 Alarm messages can be seen by moving the
Alarm History list up and down using the arrow buttons. Pressing the
Alarm History displays each of the Alarm messages for the last 15 SELECT button when one of the Alarms is highlighted will display the
Alarms experienced by the machine. It also gives access to displaying list of machine values that existed at the time that particular Alarm
the machine operating conditions that existed at the time of each Alarm. occurred.
The first one shown, “Alarm History 1”, was the most recent Alarm to
occur. Note that multiple, consecutive EMERGENCY STOP Alarms
are not recorded as separate Alarms, only the first one will be shown.
–ALARM HISTORY 1–
7,5 barg
PACKAGE DISCH PRESSURE
13,7 barg
READY TO START PACKAGE DISCHARGE TEMP
54_C
STATUS MAIN MENU ALARM HIST.
The name and value of each of the items listed below can be seen Inlet Filter
by moving the list up and down using the arrow buttons. Pressing the
ALARM HIST. button will return the display to the ALARM HISTORY Injected Temperature
screen. Total Hours
Sump Pressure
ALARM HISTORY Items
Loaded Hours
Package Discharge Pressure
Separator Press. Drop
Coolant Filter
% Load Modulation
Package Discharge Temperature
Alarm histories can be exited by pressing either the STATUS or
Inlet Vacuum MAIN MENU buttons. If no buttons are pressed within 30 seconds, the
Airend Discharge Temperature display will return to the CURRENT STATUS screen.
WARNING
7,5 barg
CHANGE INLET FILTER
OPERATING INSTRUCTIONS 27
–CURRENT STATUS–
7,5 barg
PACKAGE DISCHARGE TEMP
39,4_C
RUNNING UNLOADED AIREND DISCHARGE TEMP
MODE: MOD/ACS 89,4_C
WARNING MAIN MENU
Pressing the WARNING button will return the display to the CHANGE COOLANT FILTER – This warning will occur if the high side
WARNING screen and the RESET button. pressure is 20 psig (1,4 bar) greater than the low side pressure of 1
DPS and the Injected Coolant temperature (2CTT) is greater than
120_F (49_C).
A Warning needs to be reset by the operator by pressing the RESET
button twice.
CHANGE INLET FILTER – This will occur if the Inlet Vacuum (1AVPT)
is greater than 0,7 psig (0,05 bar) and the machine is fully loaded (inlet
The possible Warning messages are as follows; valve is completely open).
AIREND DISCHARGE TEMP – This will occur if the Airend Discharge CHANGE SEPR ELEMENT – This warning will occur if the pressure
(2ATT) exceeds 97% of the alarm limit, 228_F (109_C) and is not on the Separator (3APT) is 15 psig (1,0 bar) greater than the pressure
adjustable. at the Package Discharge (4APT) and the machine is fully loaded.
ALARM
7,5 barg
HIGH AIREND DISCH TEMP
109,4_C
STOPPED BY ALARM
MODE: MOD/ACS PRESS RESET TWICE
STATUS MAIN MENU RESET
HIGH DISCHARGE PRESS – This can occur if the machine’s loading ALARMS
function is being controlled by a host device such as a sequencer or an
ISC. This warning will occur when the package discharge pressure is When an Alarm occurs, the word ALARM will flash on the display
above the maximum offline pressure (rated pressure plus 3 psig (0,2 screen and appear in large letters as shown above. The display
bar)) for more than 3 seconds. This warning will cause the compressor message will indicate what caused the Alarm.
to unload. The host device will not be able to load the compressor until
the package discharge pressure falls to the rated pressure of the Pressing the STATUS button will display the STATUS screen. The
machine. presence of the ALARM button indicates that an Alarm condition still
exists. Alarm Status is the list of machine operating conditions that
SENSOR FAILURE 4ATT – This will occur if the Package Discharge existed at the time of the Alarm.
Temperature Sensor (4ATT) is missing or broken.
–ALARM STATUS–
7,5 barg
PACKAGE DISCH PRESSURE
7,0 barg
STOPPED BY ALARM PACKAGE DISCHARGE TEMP
MODE: MOD/ACS 39,4_C
ALARM MAIN MENU
The name and value of each of the items listed can be seen by The possible Alarm messages are as follows;
moving the list up and down using the arrow buttons. Pressing the
ALARM button will return the display to the Alarm screen and the
RESET button. CHECK INLET CONTROL – This will occur if the machine is unloaded
and the inlet vacuum is less than 3 psig (0,2 bar).
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28 OPERATING INSTRUCTIONS
CHECK INLET CTRL SYS – This will occur if the inlet butterfly valve MAIN MOTOR OVERLOAD– This will occur if a drive motor overload
is in an incorrect position. is sensed.
CHECK MOTOR ROTATION – This will occur if the machine is started MEMORY FAULT– This will occur if the controller has determined
and the compressor has incorrect rotation. some of the data stored in memory contains unacceptable values.
When this occurs, the sensors should be calibrated and all the set
points checked. It is normal for this alarm to occur after changing
CONTROL POWER LOSS – This will occur if the controller detects a controller software.
loss of the 110 VAC control power.
REMOTE START FAILURE– This will occur if the Remote Start button
EMERGENCY STOP– This will occur if the Emergency Stop button is is pressed after the machine is running or if the Remote Start button
engaged. The button must be disengaged before the alarm can be remains closed.
cleared.
REMOTE STOP FAILURE– This will occur if the Remote Stop button
FAN MOTOR OVERLOAD– This will occur if a fan motor overload is remains open and either Start button is pressed.
sensed.
SENSOR FAILURE 1AVPT (or 3APT, 4APT, 2CCT, 2ATT)– This will
HIGH AIREND DISCH TEMP– This will occur if the airend discharge occur if a sensor is recognised as missing or broken. This does not
temperature is greater than 228_F (109_C). apply to sensor 4ATT.
LOW SUMP AIR PRESSURE– This will occur if the machine is running STARTER FAULT– This will occur if the starter contacts open while the
fully loaded and the sump pressure drops below 20 psig (1,4 bar). machine is running. It will occur if the machine is given the stop
command and the starter contacts do not open.
LOW UNLOAD SUMP PRESS – This will occur if the machine is
running unloaded and the sump pressure is less than 15 psig (1,0 bar) STEPPER LIMIT SWITCH– This will occur if both limit switches are
for 15 seconds. activated at the same time.
PRIOR TO STARTING 1: Check the coolant level in the sight tube/glass. Add coolant if
necessary.
Refer to the diagram T5461
OPERATING INSTRUCTIONS 29
STARTING THE MACHINE If the machine has to be stopped in an emergency DEPRESS THE
EMERGENCY STOP BUTTON (1) LOCA TED ON THE
Refer to the diagram T5443 INSTRUMENT PANEL.
Upon power up, the Intellisys will carry out a series of checks, and This will over–ride the normal unload/stop button and will
the message CHECKING MACHINE will show on the display. If all the immediately stop the machine without the 10 second delay.
check parameters are satisfactory, the display will then show READY
TO START.
Switch off the main electrical isolation switches for both the high and
low voltage supplies.
Depress the start button (2) on the Intellisys unit. The machine will
start and automatically load.
CAUTION: Never allow the machine to stand idle with pressure in the
STOPPING THE MACHINE system.
Refer to the diagram T5443
RE–STARTING AFTER AN EMERGENCY
Depress the STOP button (3) which will automatically unload the
compressor for 10 seconds before stopping. If the unit has been switched off because of a machine malfunction,
then identify and correct the fault before attempting to re–start.
Switch off the main electrical isolation switches for both the high and
low voltage supplies. If the unit has been switched off for reasons of safety, then ensure
that the machine can be operated safely before re–starting.
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30 AIRCARE WARRANTY
AirCare is a responsive and flexible contract maintenance program custom designed for the owner who requires planned maintenance for increased
system reliability.
The AirCare program provides you with reduced maintenance costs, reduced energy usage through optimization and efficiency, and reduced produc-
tion losses through fewer unexpected maintenance requirements and downtime. An optional feature, Intelliguard is used to reduce downtime by remote
monitoring.
AirCare Options
Unit Status Coverage Service Level
Inspection and diagnostic service only or
Sign up for AirCare within the warranty period Five Year Drivetrain or Package coverage Preventative maintenance and diagnostic
service
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MAINTENANCE 31
PERIOD MAINTENANCE PERIOD MAINTENANCE
After 24 hours Visual check of machine for any leaks, dust Each 2000 hours / 6 Take coolant sample for fluid analysis.
build up or unusual noise/vibration. months
Contact IR authorised distributor if in doubt.
2000 hours / 6 Check scavenge screen for blockage, clean
Daily Check the coolant level and replenish if months if required.
necessary.
1 year Change the air filter element.
When the separator Check the pressure differential. Replace the element sooner if the indicator
element warning is light flashes.
displayed. Change the separator element if the
pressure drop is zero or exceeds 1 bar (15 1 year/1000 hours or Separator tank.
p.s.i.g.) as defined by local Fully inspect all external surfaces, welds and
or national fittings. Report any excessive corrosion,
First 150 hours Change the coolant filter. legislation. mechanical or impact damage, leakage or
1 month Check the operation of the high temperature other deterioration.
protection switch(es) (109_C standard). 4000 hours / 6 Check the operation of the blow down
1 month Check the operation of the discharge months solenoid valve for signs of fatigue. Renew
temperature sensor (109oC standard). The the seals if necessary.
sensor should alert at 106oC. 2000 / 4000 hours Lubricate the main motor bearings according
1 month Check the cooler(s) for build up of foreign to information on the motor data plate.
matter. Clean if necessary by blowing out If in doubt contact Ingersoll–Rand.
with air or by pressure washing.
8000 hours / 2 years Replace the ULTRA COOLANT at
1 month Check the operation of the float mechanism whichever interval occurs first.
in the moisture separator and clean if Also replace the separator element and
necessary. coolant filter.
Each 3 months Check all hoses for signs of deterioration, 4 years Replace all hoses.
cracks, hardening etc.
6 years/6000 hours Separator tank.
Each 3 months Operate the safety valve manually to verify or as defined by Remove the cover plate and any necessary
that the valve mechanism is functioning local or national fittings. Clean the interior thoroughly and
correctly and that a small amount of air is legislation. inspect all internal surfaces and welds.
released.
1 monthly intervals. On water cooled and sea water cooled
Each 2000 hours / 6 Change the coolant filter. models check the water input line strainer for
months build up of foreign matter, clean if required
Note:
On some sea water cooled models the oil cooler and after cooler are fitted with sacrificial zinc anodes (pencils) that are located in the end bonnets of
the coolers. These sacrificial zinc anodes should be checked after the first 50 hours of operation to determine if corrosive conditions exist. If satisfactory
this interval may be extended to 500 hours.
NOTE:
1 If sacrificial zinc anode is 50% corroded it should be replaced.
2 Coastal/harbour waters can contain corrosive chemicals from pollution and may reduce anode/cooler life.
3 Effects of corrosion or erosion are specifically excluded from warranty considerations.
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32 MAINTENANCE
ROUTINE MAINTENANCE . all panels are replaced, canopy and doors closed.
This section refers to the various components which require
periodic maintenance and replacement. . hazardous materials are effectively contained and disposed of.
. anyone entering the machine is aware of the reduced level of . Place the old element in a sealed bag and dispose of in a safe way.
protection and the additional hazards, including hot surfaces and
intermittently moving parts.
. Clean the mating face of the housing.
. the machine cannot be started accidently or otherwise, by posting
warning signs and/or fitting appropriate anti–start devices. . Remove the new Ingersoll–Rand replacement element from its
protective package.
Prior to attempting any maintenance work on a running
machine, ensure that:– . Apply a small amount of lubricant to the element seal.
. the work carried out is limited to only those tasks which require the . Screw the new element down until the seal makes contact with the
machine to run. housing, then hand tighten a further half turn.
. the work carried out with safety protection devices disabled or . Check the coolant level, refilling if necessary.
removed is limited to only those tasks which require the machine to be
running with safety protection devices disabled or removed.
. Start the compressor and check for leaks.
. all guards and safety protection devices are refitted. Close the valve and refill the compressor.
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MAINTENANCE 33
CAUTION – DO NOT MIX OILS WITH SSR ULTRA COOLANT. WARNING
Do not remove the staple from the anti–static gasket on the
separator element since it serves to ground any possible static
build–up.
AIREND BEARINGS
Remove the wing-nuts securing the filter cover and remove the
housing lid. CAUTION:
Do not over pack the motor bearings with grease as this may lead
to motor failure.
Fit the new element(s) and re–assemble the components in reverse
order.
CAUTION:
Ensure dirt and/or other contaminants are not introduced into the
SEPARATOR ELEMENT CHANGE PROCEDURE bearing during the greasing process.
Remove the roof panel to gain access to the top of the separator
tank.
H.A.T. SENSOR CHECKING PROCEDURE
Disconnect the scavenge tube from the airend and loosen the fitting It is recommended that the discharge temperature sensor is
that secures the scavenge tube to the separator tank cover and then checked regularly as follows:
remove the scavenge tube.
CAUTION:
. Clean the gasket surface on both the tank and the cover. Under no circumstances should these discharge temperatures be
exceeded. If the machine fails to trip A FAULT EXISTS. Investigate
immediately.
CAUTION
Do not use any form of sealant on either the separator tank or the The temperature at which the machine stops should be recorded for
separator tank cover faces. comparison with future results.
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34 FAULT FINDING
Compressor trips indi- INSUFFICIENT COOLING TAKING If machine is water cooled or seawater cooled, check that the cooling water is
cating a high com- PLACE flowing. Check that there is no air in the water cooling system. Check that the
pressor temperature. strainer is not blocked.
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