° GP Ingersoll Rand. XF 7.5-15 EP 7.5 - 15 HP 7.5 - 15 XP 7.5 - 15 e OPERATORS/ INSTRUCTION MANUAL PARTS LIST RECOMMENDED SPARES Before installation oF starting the compressor for the first time, this manual should be studied careful- ly to obtain a clear knowledge of the unit and of the duties to be performed while operating and main- taining the unit. RETAIN THIS MANUAL WITH UNIT. This Technical manual contains IMPORTANT SAFE- TY DATA and should be kept wit the air compres- or at all times. More Than Air. Answers. @ _ Lane answers: tp smwvaiires.com Phone: 1-800-526-9615 CCN: 80440720 Rev. C ‘PDD 702C sty 2002PBB oe eee occas AIR COMPRESSOR GROUP. BONDED WARRANTY & REGISTERED START UP Warranty "The Company warrants ha the acumen! manvtactured by and delored hereunder wl be fo of dacs in rmaltel and workranah fr a perod o wave mont (see exandod aend warranty) rom te dae of placing the Equipe in operaon or eghen mont (se estended sand waranty) trom tw cate 9 ship om Davidson, NC, whichever shal fest occu. The Purchaser shale oigatea to prompt report an fare to conor tote waren wing tho Company n sad pots, whoreupen te Company sala ts opin, crac uh ronontarmy, by sutaberapar fo such squpmert or tunis a fplacerent pant FO. pobi al shipment pov (3 the Purchase has slot. taleg martared and operated sch Equipnent in ccorcance win god indy [racioes ane nas eompled win epost resonmonaatione of he Company, Accesses equipment unshod BY {ho Company, tut manuacured by sthare, hal cary helever waranty the manufoturers have coweyed othe ‘Company at ich can be passed ono te Purchseer The Company sal not be sl fo ay fepa, pace ‘manta, ar ssusrments toto Equpmonl or shy cose of bor perma by the Puchasor or omers wiNout ‘Companys ptr writen approval Tha eats of cose, erosion and nomal wen and ear ae spctieally excluded. Petrmance waranies are lites fo ese spoctealy sated witnn the Company’ proposal Uness responsbily for meting such per Trance waranes are ee fo specie test. tha Campsnys cbigaton shale fo camel nthe manne’ sid or {ha pei cf tne proved above. “The COMPRA MAKES NO.OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OF IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABIL "TV AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED. ‘Gonston ty the Company of nencertrmites whee paton orator n the manner snd for the ptiod of ine promod abow, shal caste atime atl tatates of he Company fr such noncorores whether based ica naar rapper, ony be ny sherase wih espana Ot Ssh ‘uipmen “The purchaser shal nl operate Equpment which is considered obe detective, tout et noting the Company ln wg ts terion todo so. ry such use of Equpment wil beat Purchaser's sole sk and aby Limitation of Lsbitty Note that his is Ingersotands slandard watranty. Any waranty in force atthe fie of purchase of the compres sore ngotated oo par of he purchase over ayia precedence over hs waa PETE TE TEEPE weeAeeeS) Pree ooo eae [A Ae INGERSOLL-RAND COMPANYROTARY SCREW AIR COMPRESSOR This unit was purchased from Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make ‘such changes or add such improvements to products sold previously. No. of units on order: Customer Order No: a Ingersoll-Rand Co, Order No: — For ready reference: Record the serial number and model number of your unit here. Serial Number: se Model Number: —_ rereTABLE OF CONTENTS 0.0 SAFETY AND WARNINGS 0.1 safety instructions 0.2 safety precautions 03 decals 1.0 RECEIPT OF EQUIPMENT 1.1 inspection 1.2 unpacking and handling 2.0 INSTALLATION 2.1 ventilation 2.2 foundation requirements. 2.3 outdoor installations 24 piping 2.8 electrical installation 2.6 voltage conversion 2.7 rotation check 2.8 before starting - starting - stopping 3.0 SYSTEMS 3.1 general syster 3.2 coolant system 3.3 air systems, 3.4 capacity control 43.5 pressure switch adjustment 4.0 MAINTENANCE. 4.1 maintenance schedule 4.2 maintenance records 4.3 maintenance procedures 4A pressure relief valve check 4.5 sheave alignment 4.6 drive belt 4.7 belt tension 4.8 shaft seal replacement 4.9 inlet air filter element 4.10 coolant filter element 4.11 coolant change 4.12 coolant hose 4.13 coolant separator element 4.14 separator tank scavenge check valve/screen/orifice 4.18 cooler cores/cleaning 4.16 motor bearing maintenance-stored units 4.17 fluid and vibration monitoring 4.18 coolant sampling procedure 5.0 TROUBLE SHOOTING 6.0 REFERENCE DRAWINGS 6.1 electrical schematic - full voltage 6.2 electrical schematic - star-delta 6.3 piping diagram 6.4 found, plan - 80 gal tank mounted - enclosed 6.5 found. plan - 80 gal tank mounted - unenclosed 6.6 found. plan - 120 gal tank mounted - enclosed 6.7 found. plan - 120 gal tank mounted - unenclosed 6.8 found. plan - base mounted - enclosed 6.9 found. plan - base mounted - unenclosed 6.10 typical system flow diagram 7.9 PARTS LIST 7.1 introduction 7.2 parts listing starter box assembly starter assembly - full voltage starter assembly - star-delta major components assembly drive components control piping assembly cooler box assembly with aftercooler cooler box assembly without aftercooler 80 gallon receiver tank assembly 120 gallon receiver tank assembly canopy assembly option table - O-rings. 7.3 service and option kits 7.4 recommended spare parts 8.0 MAINTENANCE RECORD. GENERAL INFORMATION Cooling ‘Ambient Temperature Limit Coolant: 60 Hz: 1800 cfm 50 Hz: 1500 cfm (0.85 msec) (0.71 msec) 35°F to 115°F (2°C to 46°C) Factory Filled ULTRA COOLANT Coolant Change: 8,000 hours or two years, whichever comes first, when using ULTRA COOLANT Coolant Capacity: Discharge Temperature Limit: Too! 1.5 GAL (5.75L) 28°F (109°C) U.S. Standard and metric are required to perform ‘maintenance0.0 SAFETY AND WARNINGS 0.1 SAFETY INSTRUCTIONS Before you install tis air compressor you should take the time to carefully read all the instructions contained inthis manual. Electricity and compressed air have the potential to cause Severe personal injury or property damage. Before installing, witing, starting, operating or making any Adjustments, identity the components of the air compressor Using this manual a8 a guide. ‘The operator should use common sense and good working practices while operating and maintaining this unit. Follow all odes, pipe adequately, understand the starting and stopping Sequence, Check the safety devices by following the proce: ‘dure contained inthis manda. Maintenance should be done by qualified personnel, ade- quately equipped with proper tools. Follow the maintenance schedules as outlined in the operators manual to ensure prob- lem free operation after start up. 0.2 SAFETY PRECAUTIONS, Safety instructions in the operators manual are bold-taced for femphasis. The signal words DANGER, WARNING and CAU- TION are used to indicate hazard seriousness levels as fol- lows: Danger is wed to inate he presence of MINTS IY taco wich wit couse severe persovel nr, doth, or substan property dam: ge the warnings ignore Warning is used to indicate the presence of a hazard which ean cause severe personal injury, death, or substantial property dam- ‘age the waming is ignored. [AAWARNING Caution is used to indicate the presence of WINTON sort shwitor cons ins p injury or property damage ifthe warn= Notice i tion, operation, oF maintenance information which is important but not hazard-related. NOTICE SAFETY PRECAUTIONS WARNING COMPRESSED AIR AND ELECTRICITY [ARE DANGEROUS, BEFORE DOING ANY WORK ON THIS UNIT, BE SURE THE ELECTRICAL SUP- Ply HAS BEEN CUT OFF-LOCKED & TAGGED AND THE ENTIRE COMPRES- SOR SYSTEM HAS BEEN VENTED OF ALL PRESSURE. 4. Do not remove the covers, loosen or remove any fittings, connections. or devices when this unit ia in operation. Hot liquid and air under pressure that are contained within this unit can cause severe injury or death, 2. The compressor has high and dan- {gerous voltage in the motor starter and Control box. All installations must be in accordance with recognized electrical codes. Before working on the electrical be sure to remove voltage from jstom by use of a manual-discon- nect-ewitch. A circuit breaker or fuse Safety switch must be provided in the ‘electrical supply line leading to the compressor. ‘Those responsible for installation of this equipment must provide suitable ‘grounds, ‘maintenance clearance and lightning arrestors forall electrical com- ponents as. stipulated in O.S.HA. 910.308 through 1910.229. Do not operate the compressor at higher discharge pressure than those specified on the Compressor Nameplate (of motor overload will occur. This condi- tion will result in compressor motor shutdown. 4. Use only safety solvent for cleaning the compressor and aun 5. Install a manual shut off valve tion type) in the discharge line. When safety valve is installed between the iso- lation valve and the compressor, it must have sufficient capacity to relieve the full capacity of the compressor(s). 6. Whenever pressure is released through the pressure relief valve, it is due to excessive pressure in the sys- tem. The cause for the excessive pres- sure should be investigated immediate- Wy 7. Before doing any mechanical work on the compresso 12) Shut the unit down. ,) Electrically isolate the compressor by use of the manual disconnect switch in the power line to the unit. Lock and tag the switch so that it cannot be oper- ated, BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE COMPRESSOR OR PERFORMING ANY MAINTENANCE 2) Vent pressure from the compressor fand isolate the unit from any other source of {8 There can be adverse effects if com- pressor lubricants are allowed to enter Plant air systems. Air line separators, properly selected ‘and installed, will minimize any tiquid ‘carry-over, ‘The use of plastic bowls on line filters without metal guards can be hazardous. From a safety standpoint, metal bowls ‘should be used on any pressurized sys tom. Fleview of your plant ai Is recommended, 9..When a receiver ‘ommended that occupational safety and health standards as covered in the Federal Register, Volume 36, number 105, part 11, paragraph 1910.169 sdhered to in the installation and main: tenance of this receive 10. Before starting the compressor, its maintenance instructions should be thoroughly road and understood. 11, After maintenance functions a completed, covers and guards must be roplaced.UNS ana ye eet nt There is a high discharge air temperature shutdown function built into each compressor. It is factory pre- set at 226°F (109°C). This function should be checked at regular intervals for proper operation, once a month is recommended. PROCEDURE: 1. Block off the cooling air discharge. 2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the dis- charge temperature reaches the pre-set maximum discharge alr temperature setting. 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 con- nections must take into account vibration, pulsations, temperature, maximum pressure applied, corrosion ‘and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility between discharge piping, system accessories and software must be assured. For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is not recommended. In addition, flexible joints andor flex lines can only be considered for such pur- poses if their specifications fit the operating parameters of the system. Itis the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine. “Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll-Rand does not approve specialized equipment for breathing air application and assumes no responsibility or liability for compressors used for breathing air services’ Z\_ WARNING0.3 DECALS This section contains representative examples of I for some reason a decal is detaced, parts are decals which will be appearing throughout this manual replaced or painted over, we recommend that you and are applied to the compressor unit. ‘obtain a replacement (See Recommended Spare Parts List for Decal Kit Number). NOTICE eyes Z\WARNING Fi 0st1062 ZA\CAUTION ‘9540s 39921004 sess0ors 39858419 IR LOGO ON CANOPY (ENCLOSED UNITS) Z\ WARNING Me sston40[A\ WARNING ZA WARNING B : ‘0850096 “ a ‘ Z\ WARNING AXcaution 2 984160 NOTICE 9540261 se i x A\CAUTION wee Se No} alos = ssoas7* ae) “THESE DECALS ARE LOCATED ON THE ENO OF THE RECEIVER TANK ON TANK MOUNTED UNTS,SNINYYM Vi SDNINYVM \// SNINYYM \j1.0 RECEIPT OF EQUIPMENT 1.1 INSPECTION When you receive the compressor please inspect it closely. Any indication of careless handling by the car- rier should be noted on the delivery receipt especially if the compressor will not be immediately un-crated. Obtaining the delivery man’s signed agreement to any noted damages will facilitate any future insurance claims. 1.2 UNPACKING AND HANDLING The compressor package has been mounted on a wooden shipping base which will allow fork lifting under the compressor base to facilitate handling dur- ing shipment. Care in positioning the forklift is impor- tant because the location of the center of gravity is strongly affected by the location of the airend and drive motor ‘The wooden base must be removed prior to installa- tion, 2.0 INSTALLATION 2.1 VENTILATION Air cooled air compressors produce large amounts of heat. Because of this large heat production, the com- pressor must be placed in a room with adequate venti- tation It heated air from the compressor exhaust is allowed to re-circulate back to the compressor, the compressor will overheat and shut down. This heat must be exhausted from the room. You should take this into consideration when deciding where to place the com- pressor within the building. Sufficient clearance must be allowed around the compressor to perform the required maintenance. Ambient temperatures higher than 115°F (46°C) should be avoided as well as areas of high humidi ty. Also consider the environment near the com- pressor. DUST, CHEMICALS, METAL FILINGS, PAINT FUMES, and OVERSPRAY should be avoided as well as any other conditions which might be detrimental to the proper operation of the compressor. 2.2 FOUNDATION REQUIREMENTS, ‘The compressor can be installed on any level floor that is capable of supporting the weight. When sound transmission is of particular importance, itis often helpful to install a sheet of rubber-fabric-mat- ting, under the compressor baseplate or receiver tank feet to reduce the possibilty of resonant sounds being transmitted or amplified through the floor. 2.3 OUTDOOR INSTALLATIONS, When a compressor must be installed outside, there are certain items that should be incorporated into the installation to help assure trouble free operation. These items have been listed below plus Figure 2.9-1 has been included to show a typical outdoor protected installation. The unit must be purchased with the NEMA 4 option to provide watertight electrics, and a TEFC motor. + The compressor should be on a conerete pad designed to drain water away. If the concrete pad is. sloped, then the compressor must be leveled. ‘+ The roof of the shelter should overhang the compres- ‘sor a minimum of 4 feet (1.2m) on all sides to prevent direct rain and snow from falling on the unit. ‘The unit must be arranged under the shelter in a way that prevents air recirculation (i.e. hot exhaust back to the package inlet). + If the installation includes more than one compressor, the hot air exhaust should not be directed towards the fresh air intake of the second unit or an Air Dryer. + Ifa standard machine is to be installed outside, the ambient temperature must never drop below 35°F (2°C) oF freezing of condensate will result. * Power disconnect switch must be within the compres- sor operator's line of sight and should be in close prox- imity to the unit * Condensate drains must never be allowed to dump ‘on the ground. Pipe to a suitable sump for future col- lection, disposal or separation of lubricant and water mixture. * Incoming power connections must use suitable con- nectors for outdoor weather tight service. + Sufficient clearance must be allowed on all four sides of the unit for service access. If possible, access by a fork lit and/or an overhead beam hoist should be kept in mind (for eventual service to airend or motor).+ If the area around the installation contains fine air- + Some type of protection such as a fence or security borne dust or lint and fibers etc., then the unit should system, should be provided to prevent unauthorized be purchased with the TEFC motor option. access. SESSA = 0 PIPE (STEEL) i Cd AREA SHOULD BE O S|. a Sat 25 sie sae a e { © TneareD one FIGURE 2.3-1 TYPICAL OUTDOOR SHELTERED INSTALLATION 35°F (2°C) AND ABOVE2.4 PIPING Figure 2.4-1 indicates the approximate moisture con- tent in compressed air at various operating points. Itis essential when installing a new compressor to tevin te tal para yom Tis fo naute 4 Sl6 Contact your lca goo and Ditbvtororar Ss @) and effective total system. Center for assistance in selecting correct Ingersoll- Rang filtration or drying products. ‘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 olls. From a safety standpoint, metal bowls should be used on any pressurized system. Do not use plastic pipe, soldered copper fi or rubber hose for discharge piping. Moisture Content of Compressed Air Condensed water occurs naturally in air lines as a result Cf compression. Moisture vapor in ambient air is concen trated when pressurized and condenses when cooled in downstream air piping Moisture in compressed air is responsible for costly problems in almost every application that relies on com- pressed air. Some common problems caused by mois- ture are: rusting and scaling in pipelines, clogging of DEW POINT instruments, sticking of control valves, and freezing of outdoor compressed air lines. Any of these could result [~C)waoa Ei wor om ay in partial or total shutdown of the compressed air sys- ‘iweooing ———'Atercln) tigated Oe) e tem. nen ‘The compressed air discharging from this compressor FIGURE 2.4-1 MOISTURE CONTENT OF will be at some elevated temperature and will therefore COMPRESSED AIR contain amounts of water vapor. As this air cools, the vapor will condense within the piping system, IMPORTANT: The drain line must slope downward from the trap to work properly. NOTE: For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel or some type of sight flow indicator. Itis possible that additional condensation can occur if the downstream piping cools the air even further. Therefore, low points in the piping system should be provided with driplegs and traps. Compressed air dryers reduce the water vapor concen- tration and prevent liquid water formation in compressed airlines. Dryers are a necessary companion to fiers, attercoolers, and automatic drains for improving the pro- ductivity of compressed air systems. Two types of dry- ers, refrigerated or desiccant , are used to correct mois- ture related problems in a compressed air system. Refrigerated dryers are normally specified where com- pressed air pressure dew points of 33°F to 39°F (.5°C to @ 4°C) are adequate. Desiccant dryers are required where pressure dew points must be below 33°F (.5°C). 10IMPORTANT: Discharge piping should be at least as swe large as the discharge connection at the compressor. va wae Sve All piping and fittings must be suitably rated for the aessune sccerccames discharge pressure and temperature. ‘oumeesoon A careful review of piping size from the compressor connection point is essential. Length of pipe, size of pipe, number and type of fitings and valves must be considered for minimum air pressure drop and opti- mum efficiency of your compressor. NOTE: Screw type compressors should not be installed in air systems with reciprocating compres- sors without a means of pulsation isolation, such as a common receiver tank. We recommend both types of eS compressor units be piped to a common receiver uti- lizing individual air lines. See Figure 2.4-2. ‘When two rotary units are operated in parallel, pro- Vide an isolation valve and drain trap for each com- aon pressor belo the common reser ae J | See Figure 243 aye lin To assure long trouble free operation of a compressor operating with On-line/ Off-line and Auto Stop/Start ‘onto, the system volume must be large enough to keep the load/unioad cycles to a minimum. This may FIGURE 2.4-2 ROTARY-RECIP IN PARALLEL require the installation ofa receiver down stream of the compressor. Baseplate mounted units must be piped to a receiver if installed in a system with insuffi- Cient volume to keep compressor cycling to a mini- mum. If equipment such as fters of air dryers, is installed in the main piping system, they must be sized to handle the entire flow of the compressor and an air receiver must be placed in the system between the compressor discharge and the equipment, regardless of system volume. This wi prevent quick cyting ofthe compressor scl cotmion wich esuts in large fatuons in system pressure tS FIGURE 2.4-3 ROTARY-TWO COMPRESSOR SYSTEM n2.5 ELECTRICAL INSTALLATION Before proceeding further, we recommend that you review the safety data in the front of this manual. Locate the compressor data plate on the left end of the cooler box next to the control box (See Figure 25-1). The data plate lists the rated operating pressure, the maximum discharge pressure, the electric motor char- acteristics and power. Confirm that the line voltage and compressor name- plate voltage are the same. ‘The standard control box meets the intent of NEMA 1 ‘guidelines. Iwill be necessary to make a hole in the control box for the incoming power connection. Care should be taken to not allow metal shavings to enter the starter ‘and other electrical components within the box. After making the power inlet hole, all shavings and debris, must be removed from inside of control box before power is turned on. Incoming power should be connected per the electri- cal schematic at the rear of this manual (See Section 6.0). Confirm that all electrical connections are made and tightened. Confirm that the control transformer is wired correctly for supply voltage (See Figure 2.6-1). GBINGERSOLL-RAND. Compressor Package Data COMPRESSOR MODEL—~—- GaPacity. = RATED OPERATING PRESSURE - MAX. DISCHARGE PRESSURE — Max. MODULATE PRESSURE — NOMINAL DRIVE MOTOR. NOMINAL FAN MOTOR ———— TOTAL PACKAGE AMPS———— vous — PHASEIMERTZ meme CONTROL VOLTAGE-———— SERIAL NUMBER CONTACTOR AMP. RATING ——- ASSEMBLY AMP. RATING. = LOCKED ROTOR AMP. RATING OF ASSY. ~ AMoEON wom EANCUNA SE FIGURE 2.5-1 COMPRESSOR DATA PLATE 12 Inspect the motor and control wiring for tightness. Replace control box door. 2.6 VOLTAGE CONVERSION IMPORTANT: This procedure should only be carried out by a qualified electrician, electrical contractor or your local Ingersoll Rand Distributor or Air Center. Ht Pa a een 20 soy | Hey HB be tiav | >} 1 bat rio wR i SECONDARY FIGURE 2.6-1 CONTROL TRANSFORMER, CONNECTIONS NOTE: This procedure applies only to units manufac tured to mutt-voltage specifications. Compressor data plate and motor nameplate must indicate muttiple volt- ages.PROCEDURE: @ eurmain disconnect in the OFF positon, ok and tag (See Figure 2.6-2) Tas FIGURE 2.6-2 MAIN DISCONNECT LOCKED AND TAGGED (Open the motor junction box on the side of the motor. @ _ecoment the motos to the destod voltage Use the connection diagram provided on the motor as a guide. Reconnect the primary side of the control transformer for the desired voltage, as shown on the control trans- former wiring decal Adjust motor overload setting as outlined below in Figure 2.6-3. NOTICE "attby Mtoe pts eager iota FIGURE 2.6-3 MOTOR OVERLOAD SETTING e Make sure ail wiring connections are tight. Put main disconnect in the ON position and check motor rotation, as outlined in Section 2.7 of this manu: al. 2.7 ROTATION CHECK. Locate the rotation decal on the motor and check for correct rotation. The correct rotation when viewed from the opposite drive end of the motor is clockwise. If compressor is operated in the opposite direction of rotation, airend damage can result and is not war- rantable. ‘The unit is shipped with a bolt in the motor support to prevent possible belt damage caused by bouncing dur- ing shipment. This bolt must be remove prior to check- ing motor rotation or operating the unit. Locate the shipping bolt in the motor support as shown in Figure 2.7-1. and remove. SHIPPING BOLT FIGURE 2.7-1 SHIPPING BOLT LOCATION For the compressor motor rotation check, the motor jogging should be as short a time as possible 41. Ensure that the Stop button is in the stop (depressed) position. 2. Check coolant level. To check coolant level, slowly loosen the fil plug one complete turn. As the fill plug is unscrewed approximately one turn, a small amount of pressure may be released. Do not remove the fil plug until all pressure has been vented. Once pressure is vented, finish removing the fil plug. The proper coolant level is when the coolant is even with the top of the fill port, Add coolant if necessary. 3. Replace and tighten fill plug. 4. Close the main disconnect switch (ON position). 5. Verify that the main isolation valve is open. 6. Open the canopy enclosure if machine is so 8equipped. Push the Start button to start the unit and immediately depress (push) the Stop button to stop the unit Observe the compressor drive motor shaft. The rota- tion should be in accordance with the directional arrow decal on the motor. ‘Should the motor rotation not be correct, put the main disconnect in the OFF position, lock and tag Interchange any two line connections (L1 ,L2, or L3) at the starter. Close the control box cover. Recheck for correct rotation 2.8 BEFORE STARTING - STARTING - STOPPING Read and understand the followi before operating or perfor on this unit. tru 1g any maintenance Before Starting: 1. Ensure that Stop push button is in the OFF (depressed) position (See Figure 2.8-1). 2. Check coolant level. To check coolant level, slowly loosen the fill plug one complete tum. As the fill plug is unscrewed approximately one turn, a small amount of pressure may be released. Do not remove the fill plug until all pressure has been vented. Once pressure is vented, finish removing the fil plug. The proper coolant level is when the coolant is even with the top of the fill port, Add coolant if necessary. 3. Replace and tighten fil plug. 4. Close the main disconnect switch (ON position). 5. Verify that the main isolation valve is open. sToP BUTTON CONTROL, BOX START BUTTON HOUR POWER ON LIGHT AUTORESTART PRESSURE LIGHT GAUGE FIGURE 2.8-1 CONTROL BOX “4 Starting 1. Push the Start button and release. The compressor will start and then load automaticaly if line pressure is below the lower set point of the pressure switch. Stopping 1. Depress the Stop button to the OFF position. Compressor will stop immediately. 2. Open the main disconnect switch (OFF position). 3.0 SYSTEMS 3.1 GENERAL SYSTEM INFORMATION The compressor is an electric motor driven, single stage, rotary screw compressor, complete with sup- porting components to make a fully functional unit. A standard compressor is composed of the following: Inlet air fiter Drive motor Airend Pressurized coolant system with cooler & filter ‘Separation system Capacity control Instruments Safety devices ‘Compression in the rotary screw type air compressor is created by the meshing of two helical rotors (male and female) on parallel shafts, enclosed in a heavy duty iron housing, with air inlet and outlet ports located ‘on opposite ends. The grooves of the female rotor mesh with and are driven by the male rotor. Bearings on both ends of the rotors are used to support the rotor both laterally and axially. 3.2 COOLANT SYSTEM ‘The coolant system consists of a separator tank, ther- mostatic element, coolant filer, coolant cooler with fans, and a separator element. When the unit is operat- ing, the coolant is pressurized and forced to the com- pressor bearings. The compressor is provided with a temperature switch which will shut the unit down in case of excessive temperature, 28°F (109°C). Effective coolant filtration is provided by the use of a screw on, automotive type, heavy duty coolant filter. ‘The compressor is designed for operation in an ambi- ent range of 35°F to 115°F (2°C to 46°C). The stan- dard maximum temperature 11°F (46°) is applicable up to an elevation of 3300 ft. (1000 m)Coolant Rotary screw compressor fluids have a triple function to perform. They lubricate the bearings and contacting surfaces of the rotors, seal internal clearances within the rotor chamber, and provide for the cooling of the compression process. The bulk of the fluid is actually used for cooling, with only small amounts used for lubrication and sealing. SSR air compressors are factory filled with SSR ULTRA COOLANT. ULTRA COOLANT is designed to operate for 8,000 hours or two years, whichever comes first. The coolant must be changed at these intervals to avoid breakdown and equipment dam- age. Circulation of Coolant Coolant is forced by air pressure from the separator tank to the thermostatic element. The position of the element (a direct result of coolant temperature) will determine whether the coolant circulates through the cooler, bypasses the cooler, or mixes the two paths together to maintain an optimum compressor injection temperature. This temperature is controlled to preclude the possibilty of water vapor condensing. By injecting coolant at a sufficiently high temperature, the dis- charge air coolant mixture temperature will be kept above the dew point. Before being injected into the airend, all coolant flows through the cootant fitter. It is a full-flow, spin-on ele- ‘ment, rated at 4 micron. There is a differential-pressure bypass valve in the element that opens in the event that the pressure drop across the element rises to as, high as 15 psi (1 bar), which indicates an excessively fouled element as well as poor maintenance practice. Coolant/Air Separator System The coolanvair separation system is composed of a separator tank with specially designed internals and a coalescing type separator element located inside the tank, ‘The air-cootant mixture discharges from the airend into the separator tank. The majority of coolant is separat- ed while in the separator tank and the coalescing sep- arator filter element is used for final cleaning of the air rior to the customer's system. The system removes ‘nearly all of the coolant from the discharge air. The separated coolant is returned to the ooolant system and the air passes to the compressed air system. 3.3 AIR SYSTEM Components and Flow The air system is composed of: Inlet air fiter Inlet valve Arend CoolantiAir separator Minimum pressure check valve (MPCV) Altercooler ‘The direction of flow is from the inlet filter to the after- cooler, Functions of Components Inlet air fitter, filters the incoming air, trapping 99.9% of particles 3 micron and larger. Inlet valve opens full for on-line operation. The valve closes in the off-line mode and at shutdown which pre- vents back flow of the compressed ai. The airend compresses the air. ‘The separator tank removes most of the coolant from the air. The separator element performs the final separation of coolant and cleaning of the air prior to leaving the compressor. The minimum pressure check valve keeps the separa- tor tank and separator element at a minimum pressure to ensure adequate oil flow and proper coolantiair sep- aration. It also prevents line pressure from exhausting back through the airend at shutdown and during peri- ‘048 of unloaded operation. The aftercooler cools the air prior to leaving the pack- age. 15,3.4 CAPACITY CONTROL 4. Sel the offine pressure by turning screw 2. Turn ’ sorew counter-clockwise to increase setting or clock- On Line!Off Line With Automatic Star/Stop Rise erases eating qaasuisd Gr pone) e@ Control ‘The compressor will deliver air at full capacity, (the e oe CAUTION: compressor maximum efficiency condition) or will operate at zero capacity with high receiver pressure DO. NOT EXCEED MAXIMUM DISCHARGE PRES- (the compressor minimum power condition), while the SURE (LOCATED ON COMPRESSOR DATA unit continues to run. PLATE). When the compressor starts and line pressure is. 5. Turn power back on, start compressor and test below the lower setting of the line pressure switch, adjustment(s) made. If necessary, readjust according control solenoid 1SV will be energized (closed). inlet _ to steps 1-4 above. valve will open, and the compressor will oad. When the line pressure reaches the upper setting of the pressure switch, the compressor will unload by de- PRESSURE SWITCH energizing (opening) 1SV and closing the inlet valve, Solenoid 1SV relieves the internal pressure of the compressor back to the inlet fiter. The only adjustment required is setting of the pressure switch. A time delay relay is energized and begins to time out. The timer, mounted in the control box, is factory set at 410 minutes. It will continue to operate for as long as its time setting, after which a relay contact opens to de- energize the compressor starter coil. At the same time, an amber light (1LT) on the control box is lit to indicate the compressor has shut down automatically and will restart automatically. The automatic restart will take place when the line pressure drops to the lower setting of the pressure switch. Adjusting the Auto/Restart timer below the 10 minute factory setting may shorten the life of the compressor drive motor. 3.5 PRESSURE SWITCH ADJUSTMENT Locate the pressure switch as shown in Figure 3.5-1. ‘The pressure switch can be adjusted using the follow- ing procedure: 1. Open, lock and tag the main electrical disconnect. Do not adjust the pressure switch with power on or ‘machine operating, 2. Remove pressure switch cover by turning the cover screw counterclockwise. NOTE: It is required that the load or on-line pressure be set first, before the unload or off-line pressure is set 3. Set the on-line pressure by tuning sorew 5 (See Figure 3.5-2). Turn clockwise to increase setting or e ‘counter-clockwise to decrease setting (indicated by FIGURE 3.5-2 PRESSURE SWITCH ADJUSTMENT pointer 4). 164.0 MAINTENANCE 4.4 MAINTENANCE SCHEDULE ‘THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMM! (ENDED MAINTENANCE REQUIRED TO KEEP THE COM. PRESSOR IN GOOD OPERATING CONDITION, SERVICE AT THE INTERVAL LISTED OR AFTER THAT NUMBER OF HOURS, WHICHEVER OCCURS FIRST. TIME INTERVAL (WHIGHEVER COMES FIRST) aevion | parr or rem HOURS | 1WK | 1WO_[ _6NO | ONO[YEARIY]2¥R wwarect | cootanr Lever visiaie wu porT | weeKy | x (WnieN COLD) wwspecr | AIR FLTER weeny |x REPLACE | COOLANT ITER 750 x TNITIAL CHANGE ON REPLACE | COOLANT FILTER 7000 % (SUBSEQUENT CHANGES) wwspecr | HOSES +000 x wwspect | OWE BELTS 500 x REPLACE | DRIVE BELTS 2000 x cHECK | HIGH AIR TEMP. SWITCH +000 x HECK | OPERATE PRESSURE RELIEF VALvES | 1000 x CLEAN | SEPARATOR SCAVENGE ORIFICE +000 x Analysis | COOLANT 2000 SEE SECTION 47 x anatysis | vieRATiOn 2000 SEE SECTION 4.17 x curaN_| cooLeRs cores 4000 x REPLACE | AIR FILTER? 2500 REPLACE | SEPARATOR ELEMENT" 4000 REPLAGE | ULTRA COOLANT 3000 REPLACE | SHAFT SEAL 3000 x “NN VERY CLEAN OPERATING ENVIRONMENTS AND WHERE INLET AIR DIRTY ENVIRONMENT CHANGE DRIVE BELTS, COOLANT, FLTERS, AND: “CLEAN COOLER CORES IF UNIT SHUTDOWN OCCURS ON HIGH AIR TE 4.2 MAINTENANCE RECORDS Its very important that you, the owner, keep accurate and detailed records of all maintenance work you or the Ingersoll-Rand Distributor or Air Center perform on your compressor. This includes, but is not limited to, Coolant, coolant fer, separator element, inlet air fitter, drive belts, shaft seals and so forth. This information must be kept by you, the owner, should you require warranty service work by your Ingersoll-Rand Distributor or Air Center. Maintenance record sheets are located at the back of this manual. 4.3 MAINTENANCE PROCEDURES Before starting any maintenance, be certain the follow- IWTER 1S CHANGED AT THE ABOVE PRESCRIBED INTERVALS. IN EXTRENE SEPARATOR ELEMENTS MORE FREQUENTLY. EMPERATURE. ing is heeded. Read Safety Instructions. Have a well equipped mechanic's tool box with English and Metric sockets. (Special tools when needed will be listed under each appropriate procedure). Have an OSHA approved air nozzle and compressed air. (International - local codes may apply). Have recommended spare parts on hand (See listing in back of this manual. ‘AX WARNING When the unit is shut down, residual pressure can be trapped within the compressor system. This pressure must be vented from the system prior to beginning any service work. 7Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor dis- charge. Wait 2 minutes after stopping to allow inter- nal pressure to dissipate. Vent residual pressure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled in the plug, allowing the pressure to release to atmosphere (See Figure 4.3-1). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pres sure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. Norns vent HOLE FIGURE 4.3-1 COOLANT FILL PLUG WITH VENT HOLE 4.4 PRESSURE RELIEF VALVE CHECK Under normal operating condition a “try lever test” must be performed every month . Under severe service condi tions, or if corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be performed at the end of any ‘non-service period. CAUTION! High pressure air will discharge through the discharge ports of the valve during “try lever test”. Wear ample clothing, gloves, safety glasses and ear protection during valve test- ing. Run the compressor for about 10 minutes by vent- ing air from the system to let the unit warm up. With the unit running, test at or near maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of debris. Then release lever and permit the valve to snap shut. If ift lever does not activate, or there is no evidence of discharge, discontin- tue use of equipment immediately and contact a licensed Contractor o qualified service personnel 18 Hazardous voltage. Can cause severe injury or death. Disconnect power before servicing LockoulTagout machine WARNING High pressure air. Can cause severe injury or death. Relieve pressure betore removing titer plugs / caps, fitings or covers. INGERSOLL AND ®4.5 SHEAVE ALIGNMENT ‘Any degree of sheave misalignment will result in a reduction of belt life. Misalignment of belt drive should not exceed 1/16 in. (1.6 mm). Parallel misalignment occurs when the drive and dri- ven shafts are parallel, but the two sheaves lie in dif ferent planes (See Figure 4.5-1). Angular misalignment occurs when the two shafts are not parallel (See Figure 4.5-2). 4/16" (1.6mm) MAX >| FIGURE 4.5-1 PARALLEL MISALIGNMENT 1196 MAX, 4/16" (1.6mm) MAX STRAIGHTEDGE FIGURE 4.5-2 ANGULAR MISALIGNMENT Align Sheaves Ensure that the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg. Ensure that the main power disconnect switch is locked and tagged. ‘An easy and effective method of checking alignment in, both directions between the driver and driven sheaves utilizes an accurate straightedge. Lay the straightedge across the face of the driver (motor) sheave and check alignment of the driven {airend) sheave. Then lay the straightedge across the FIGURE 4.8-2 SEAL INSTALLATION TOOL 19. Remove any excess Loctite® 609 with a clean cloth. 20. Put a thin continuous coat of Loctite® 609 on the outer diameter of the single lip seal 21. Position the seal in the seal housing from the out- board side. The seal should be oriented such that the edge of the lip is installed first. 22 22. Using a clean flat tool that is larger in diameter than the seal, press the single lip seal into the seat housing unti itis flush with the surface of the hous- ing. The seal must not be pushed beyond the flush position. 23. Remove any excess Loctite® 609 from the seals, the seal housing. and from the seal scavenge holes in the seal housing between the seals. 24. Install the plug in the bottom of the seal housing, 28. Lightly lubricate a new O-ring with clean coolant and install on the rotor shaft 26. Insure that the surface of the seal housing is clean and dry. Put a thin continuous coat of Loctite® 515 on the inboard face of the seal housing. Do not over apply. 27. Install a new check valve ball in the seal hous- ing. A small amount of grease can be used to hold the check valve ball in place for assembly. 28. Making sure that the check valve ball remains in place, assemble the seal housing to the rotor hous- ing. Attach the seal housing to the rotor housing with ‘eight screws and tighten to 92-102 Ib-in (1.07-1.19 Kg-m) 29, Lightly lubricate the inner diameter and the outer diameter of the new wear sleeve with clean com- pressor coolant. 30. Carefully slide the wear sleeve onto the rotor and through the seals until the wear sleeve locates, against the bearing, 31. Reinstall the spacer, key, sheave, and bushing, Push the bushing back against the spacer, untiit “locates” against the wear sleeve, when tightening the two bushing alien head screws to 175 Ib-in (2.0, Kg-m). 32. Reinstall belts, and check alignment per Section 45. 33, Reinstall cooler box outer panel4.9 INLET AIR FILTER ELEMENT The inlet air filter element should be changed at the interval shown in the maintenance chart or any time the filter becomes dirty. The filter element is not washable and must be replaced. Remove air filter housing top cover. Remove air filter element. Install new element and replace top cover. (See Figure 4.9-1). ‘TOP COVER FIGURE 4.9-1 INLET AIR FILTER 4.10 COOLANT FILTER Time of change - after the first 150 hours and every 2000 hours thereatter, or when the coolant is being changed. In dirty operating environments, the filter should be changed more frequently. Before beginning any work on the compressor, ‘open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pres- ‘sure from the unit by slowly unscrewing the coolant fill plug one turn. Unserewing the fill plug ‘opens a vent hole, drilled in the plug, allowing the pressure to release to atmosphere (See Figure 4.3- 1). A slight mist or oil droplets may be visible dur- ing venting. Do not remove fill plug until all pres- sure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. Special Tools Suitable clean drain pan or container to hold coolant drained from unit ‘A quantity of proper coolant sufficient to top off the ‘coolant level in the compressor. (One genuine IR replacement coolant fiter of the prop- er type for the unit, Procedure 1. Place a clean pan under the coolant fitter. 2. Using a filter wrench, remove the coolant filter. Remember that the filter and coolant may be hot! 3, Discard the old filter. 4. Wipe the sealing surface of the filter housing with a clean lint-free rag to prevent entry of dirt into the sys: tem. 5. Remove the replacement filter from it's protective package. 6. Apply a small amount of clean coolant on the rubber seal of the filter. 7. Screw filter on until the seal makes contact with the head of the filter housing. Tighten approximately one half to three quarters turn additional. 8, Remove coolant fill plug (See Figure 4.10-1). COOLANT FILL PLUG FIGURE 4.10-1 SEPARATOR TANK 239. Fill unit with new coolant as follows: a. Fill tank to the bottom of the threads in the coolant fill port. b. Replace fill plug. Run compressor 15-20 seconds. . Stop compressor and relieve pressure by slowly unscrewing the coolant fil plug one turn. Do not remove fil plug until all pressure has vented. 8. Add more coolant up to the bottom of the threads of the coolant fil port. {. Replace fil plug 4g. Start the compressor and verify coolant level is in the bottom half of the sight glass (See Figure 4.11-1) when the compressor is running unloaded. Check for leaks. Do not add coolant through the intake of the compres- ‘sor, as this can result in overfilling, saturation of the sep- arator filter element, and coolant carry-over downstream. 4.11 COOLANT CHANGE Before beginning any work on the compressor, ‘open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pres- sure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled in the plug, allowing the pressure to release to atmosphere (See Figure 4.3-1). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pressure has vented from the unit. Also vent pip- ing by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. Special Tools Suitable clean drain pan or container to hold approxi- ‘mately 1.5 gal. (5.75 L) of coolant drained from unit. A quantity of proper coolant sufficient to refil the coolant level in the compressor. One genuine IR replacement coolant filer of the proper type for the unit. Procedure The coolant should be drained soon after the com- pressor has been shut down. When the coolant is warm, the drainage will be more complete and any particles in suspension in the coolant will be carried out with the coolant 24 Z\ WARNING ae yn Hazardous voltage. Can couse Severe injury of death Disconnect poner bere servicing, LeckowTagout machine, Z\ WARNING (Gan cause severe injury or death. Relieve pressure belore removing tier log / aos, ings o over.1. Place a clean pan under the coolant drain valve. 2. Remove the cap from the coolant drain valve (See Figure 4.11-1) SIGHT GLASS COOLANT DRAIN VALVE FIGURE 4.11-1 COOLANT DRAIN VALVE 3. Thread the coolant drain fiting (supplied with com- pressor), with hose attached, onto the coolant drain valve. The valve will open as the fitting is inserted allowing the coolant to drain. 4. Using a filter wrench, remove the coolant filter Remember that the coolant filter may be hot! 5, Discard the old filter, 6. Wipe the sealing surface of the filter head with a Clean lint-free rag to prevent entry of dirt into the sys- tem, 7. Remove the replacement filter from its protective package. 8. Apply a small amount of clean coolant on the rub- ber seal of the filter. 9. Screw element on until the seal makes contact with the seat on the filter header. Tighten approximately ‘one half to three quarters turn additional 10. Remove drain fiting and replace drain valve cap. 11. Remove coolant fill plug (See Figure 4.10-1). 12. Fill unit with new coolant as follows: a. Fill tank to the bottom of the threads of the coolant fill port. b. Replace fill plug. c. Run compressor 15-20 seconds. d. Stop compressor and relieve pressure by slowly unscrewing the coolant fill plug one tum. Do not remove fill plug until all pressure has vented, . Add more coolant up to the bottom of the threads of the coolant fil port {. Replace fll plug. 9. Start the compressor and verify coolant level is in the bottom half of the sight glass (See Figure 4.11-1) when the compressor is running unloaded. Check for leaks. Do not add coolant through the intake of the compres- sor, as this can result in overfiling, saturation of the sep- arator element, and coolant carry-over downstream. 4.12 COOLANT HOSE The flexible hose that carries coolant to the airend may become brittle with age and will require replacement. Have your local Ingersoll Rand Distributor or Air Center check it every year, and replace as needed or every 2 years. Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor dis- charge. Wait 2 minutes after stopping to allow inter- nal pressure to dissipate. Vent residual pressure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled in the plug, allo release to atmosphere (See Do not remove fill plug until all pressure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. Removal Drain coolant into a clean container. Cover the container to prevent contamination. If the coolant is contaminated, a new charge of coolant must be used. Remove the hose. 25Installation Install the new hose. Refill the unit with coolant. Start the compressor and check for leaks. Stop unit and check coolant level in the sight glass on the separator tank. 4.13 COOLANT SEPARATOR ELEMENT ‘The separator element should be replaced every year or after 4000 hours of operation, whichever comes first, to prevent excessive coolant carryover into the plant's air piping system. The element is located inside the separator tank (See Figure 4.13-1). ‘SEPARATOR ELEMENT (INSIDE) FIGURE 4.13-1 SEPARATOR ELEMENT LOCATION 26 Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pres- sure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled in the plug, allowing the pressure to release to atmosphere (See Figure 4.3- 4). A slight mist or oil droplets may be visible dur- ing venting. Do not remove fill plug until all pres- sure has vented from the unit. Also vent piping by slightly opening the drip leg valve. When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection. Procedure: 1. Disconnect tank discharge fitting, inlet valve control tubing, and scavenge tube. 2. Remove tank cover bolts and cover (See Figure 413-2), BOLT FIGURE 4.13-2 TANK COVER REMOVAL, 3. Remove separator element. 4, Clean all tank flange surfaces of dirt and residual gasket material 5. Install new separator element, making sure that the grounding staple comes in contact with the flange material6. Replace cover and start the retaining bolts. 7. Torque bolts evenly to 80 ft.-Ib (109 N-m).. 8. Replace connections removed in step 1. 9. Start unit and check for leaks. 4.14 SEPARATOR TANK SCAVENGE CHECK VALVE/SCREEN/ORIFICE Tools Required ‘Open end wrench Screwdriver Procedure Disconnect tubing at each end of check valve/screen’ orfice assembly. Check orifice and clean if required. Use suitable tool and remove screenvorifice end from its housing (See Figure 4.14-1). Be careful not to damage flared end of fiting or O-ring. Wash screen and housing in safety solvent and blow dry. Press the check valve/screenioritice into fitting block. ‘Assemble the check valve/screen/orifice assembly to the tubing lines. The fitting must be re-installed with the screen on the upstream side of the orifice as indi- cated by the flow arrow (See Figure 4.14-1) CHECK VALVE wer SCREEN ORIFICE (dalam FIGURE 4.14-1 SEPARATOR TANK SCAVENGE CHECK VALVE/SCREEN/ORIFICE witdn O-RING 4.15 COOLER CORES/CLEANING Inspection Visually check the cooler cores for build up of dirt, dust, lint or other foreign material Using an OSHA approved air gun, blow air through the cooler cores in the opposite direction of normal air flow. Remove cooler box rear panel and clean all loose ‘material that blew from the coolers into the fans. Reinstall the cooler box rear panel. Start unit and verify proper operation. 4.16 MOTOR BEARING MAINTENANCE- STORED UNITS ‘THE MOTOR BEARINGS ARE PERMANTLY LUBRI- CATED AND DO NOT REQUIRE RE-LUBRICATION. To ensure that complete contact is maintained between the motor bearings and the bearing grease ‘on units to be placed in storage for extended intervals, the following motor maintenance procedure should be adhered to: 1. Prior to placing a unit in storage, rotate the motor several revolutions by hand in the proper direction of rotation, 2. Thereafter, rotate the motor as described in Step 1 at three month intervals until such time as the unit is placed in service, a74.17 FLUID AND VIBRATION MONITORING Ingersoll-Rand recommends incorporating predictive ‘maintenance, specifically the use of coolant and vibration analysis, into all Preventative Maintenance programs. Predictive Maintenance is designed to increase system reliability and prevent costly downtime. Through the use of sophisticated diagnostic tools, including fluid, vibration, and optional air analysis, |R Certified Service Technicians can identity and correct potential problems BEFORE they can cause expensive unscheduled downtime, How does predictive analysis work? By establishing an initial baseline for normal operation, and then regularly monitoring fluid and vibration conditions, any sudden deviation or significant increase from this baseline can be identified and investigated to pinpoint the cause. More ‘quickty diagnosing potential problems can directly save money by preventing costly failures and reducing or elii- nating downtime. In addition, regular condition monitoring also helps to maximize the time between expensive pre- ventative maintenance intervals, such as component rebuilds and coolant changes. 4.18 COOLANT SAMPLING PROCEDURE Bring unit up to operating temperature. Draw sample, using pump kit, from separator tank port. DO NOT draw ‘sample from drain port or oi fiter. Use a new hose on pump for each sample, failure to do this can give false readings.NOTE: 295.0 TROUBLE SHOOTING ‘TROUBLE Compressor Fails to Start Repeat Shutdowns High Amp Draw Low Amp Draw High Discharge Pressure Low Air System Pressure Unit Running Hot High Coolant Consumption Excessive Noise Level Shatt Seal Leak Pressure Relief Valve Opens Black Residue on Belt Guard/Cooler Box CHECK POINT NUMBERS. 1.23 3.4.5.2 8.9.6.7 1,10,12 13,15,16,19 22, 20,17,18,13,15,14,19,7 22,21,23,24,6 28,27,25,26 17,18,31,30,29, 32 6,13,15,14,16,19 17,33,34 CHECK POINT NUMBERS ‘TROUBLE CAUSE Control Voltage Not Available Detective Starter Motor Overload Incorrect Overload Size Line Voltage Variation ‘Compressor Operating Above Rated Pressure Dirty Separator Element Low Voltage Unbalanced Voltage Dirty Air Filter ‘Compressor Operating Unloaded High Voltage Incorrect Pressure Switch Setting Faulty Minimum Pressure Valve Load Solenoid Valve Defective Blowdown Valve Defective Drive Betts Slipping Air System Leaks Inlet Valve Malfunction ‘System Demand Exceeds Compressor Delivery Coolant Cooler Core Dirty Low Coolant Level High Ambient Temperature Restricted Cooling Air Flow ‘Separator Element Leak Plugged Separator Scavenge/Orifice ‘Compressor Operating Below Rated Pressure Coolant System Leak Airend Detective Motor Detective Loose Components Worn or Detective Shaft Seal Sheaves Misaligned Worn Sheaves39914643 6.0 REFERENCE DRAWINGS REV O01 6.1 ELECTRICAL SCHEMATIC - FULL VOLTAGE, 3139908884 REV 01 $6°8-26 NOLyDT4ID345 wT 40 NOISIAY Salvi 31-01 weOsNOD SMH W330 “1 15310N 6.2 ELECTRICAL SCHEMATIC - STAR-DELTA 32(39907753 REV 02 Lyn, 40 wy notavonnos as SASHDS Seo Wak isno 80d, 3 s94TwOABLATA/IAINA 330 BBuaAvSe dolvavass | 024358 AWA YOHINOD D1AWISORIIML | 134 jae RAD swwva WaNTR3RN WOLYUVASS eva wv to avi Nina | aia aka LEE Mt aka axowaras wnocno7s | ASE ‘2kiva.cronaves cvown | ASI ous sunkvugavan wry HDIn | SL¥i HOLIRS 34nss3u sa env Sunssava Ef aeowa gains SNNSSaNd | 1837009 INvI00 | 49 THO Saltza 1Nv7009 2 waroopais | waaay aia vom S538 HOMINTH | AD oun | a/v wanna wv gM * WoTLaTws3a | Asweey, GN3937 LNSNOdWOD 9 0 2 AMP RUE. —————5 cave ey rors EES . 104 - VA a & usb 6.3 PIPING DIAGRAM‘39907902 REV 04 6.4 FOUNDATION PLAN - 80 GAL TANK MOUNTED - ENCLOSED (CONTINUED) 34 CENTER OF cRavttY TOP VIEW i FRONT VIEW RIGHT VIEWMIA WOLLOG Ber90 ws-02) poe —— "at? _—_y bye) ( of | j AGIA LAT ea S1015 WONT O6¢1 x SL" am wrvag 2uyena0yo> Tat tSRT Re? io C AGIA UYSU oe nore wy oe aida 70 AS ihe 20620666 6.4 FOUNDATION PLAN - 80 GAL TANK MOUNTED - ENCLOSEDMIA LHO uysysinog s24r7 any vos 0350 yo uIN_ §1H PSTN Snes 3aH “LINN 344 NO_§3>W04 YO SINSHOH e3nnosawin IN TRE USK SSNPS aa “53009 ay201 37ev>1744¥ 149 53002 qworas2373 Tori igsivy Shi ag Osun SY Ngo 08 waluvis Yo" Thavs wticG0-ze> /90t ‘Hera Saunt Siv Ao SSwwlvst> Csovaawod3e 70 ASE (82820666 “ ca 108 AGIA LNOWS [Sao] MNGIA dOL rita 2 wus /~ Sih uno 13538 Rima user) toe G90 ‘ies 6.5 FOUNDATION PLAN - 80 GAL TANK MOUNTED - UNENCLOSED (CONTINUED) 36vane ese MIA L437 yO.ASY 82820666 noua ay mi os MGIA WOLLOG ere ze 2) AGIA UVae noaa ary shes 6.5 FOUNDATION PLAN - 80 GAL TANK MOUNTED - UNENCLOSED 3799906284 REV 04 7a fe} I 8 T y si TOP VIEW oa sa = 6.6 FOUNDATION PLAN - 120 GAL TANK MOUNTED - ENCLOSED (CONTINUED) 38 tea FRONT VIEW RIGHT VIEWMBIA L437 NAIA WOLLOS teen v0 ASU veZs0eee 6.6 FOUNDATION PLAN - 120 GAL TANK MOUNTED - ENCLOSEDla gle = Ss = a 5 Sg 2 = & a = = if & & Zz e 3 2 = 6.7 FOUNDATION PLAN - 120 GAL TANK MOUNTED - UNENCLOSED (CONTINUED) 40MZIA L437 wivag aiyswacyo> Lea SNES? yO AaY 26290866 MIA WOLLOG GIA UVSE a }———- 6.7 FOUNDATION PLAN - 120 GAL TANK MOUNTED - UNENCLOSEDten) AGIA LOT aoumsia sty a aSAE SE yBuIS¥NOQ S2NI7 ANY Od 0350 YO LINN STL 01 GbaDvIIN Suita DTLavie OW 30 OMOHS BEIM “LINN 34 MO g35¥04 40 SINBHOH o3A7OS3uNN Thy WSaGPISt SSvis! 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SH oy Qhbvilw andi stisvia ON 38 CMnOH BEML“ INO 3HL NO_§32¥04 YO SINGHOH C3ATOS3uN Rhy TERUG vis" Share sso “53099 W201 seo TIss¥ eeaiaass IPue Z0u waluvis uo" ikaus Alc Q0-2hy 90) ‘S508 Saud iv AG SbwesysD os@KGKNOIsy “9 (44d) L119 2367qH 14:0 12H 06 (ad 001} 938/4u S8°0 12H OF mon wiv *% CONT) SURLSHITIIM NE SHOISNBKTO TOY» ext faTIW NO BDNVESTOL “€ 6 (xouaaY) ALLAN THEa SNS TE " '38) 420) 9" 12 Sng = nace > tere olay) inbian +1 v0 ASY, 86220666 AGIA LNOWS ene : 4° L ats a 5 e-0e) \D autave 40 wane NSIA dO 6e 1294 y3noe edauiatSSe 6.9 FOUNDATION PLAN - BASE MOUNTED - UNENCLOSED (CONTINUED) 44MZIA WOLLOG t (o0"921 i . seo AGIA L431 ae MIA UVaU vO ABY eezZ0668 45 6.9 FOUNDATION PLAN - BASE MOUNTED - UNENCLOSEDPRE FILTER Coun! | rurure L_-_. ISOLATION esas VALVE E re fo cour ve syste 2 a EEE A _cxrsoe cowpresson roo CGLADIAND Emagen Sac Ar Hook Up Compl wih Necessary Fit For Prato re ‘oF IR ental Ait Unit From Local IF Disinbutor x we ater, OF 8 ype Yabo ae UNON ‘sin Oscomocing Compressor Fon The Sytem PRESSURE GAUGE AIP Les MaNOMETER| DIFFERENTIAL PRESSURE INDICATOR HR AUTOMATIC ORAN VALVE FALSE LOADER Blows Of Air Ouse Of Compressor Room ‘SYSTEM INSTRUMENTATION INCLUDES Nephelometer: Hygrometer, Pressure; Temperature VENTILATION. Moise Lowers, Exteust Fans ° ° ave * 5 x & cp “T AFTERCOOLENSEPARATOR, ISOLATION VALVE, UNION. STAAINER AND TRAP 6.10 TYPICAL SYSTEM FLOW DIAGRAM (TWO BASE PLATE MOUNTED UNITS) 467.0 PARTS LIST 7.4 INTRODUCTION GENERAL This manual, which contains an illustrated parts breakdown, has been prepared as an aid in identity- ing and ordering parts for the SSR compressor. All of the compressor parts, listed in the parts break- down, are manufactured with the same precision as the original equipment. Ingersoll-Rand Company service facilities and parts are available ‘worldwide. There are Ingersoll Rand Company Branch Offices and authorized distributors located in the principle cities of the United States. in Canada, our customers are serviced by the Canadian Ingersoll-Rand Company, Limited There are also Ingersoll-Rand Company subsidiaries and autho- rized distributors located in the principle cities throughout the world. DESCRIPTION The illustrated parts breakdown illustrates the various assemblies, sub-assemblies and detailed parts which make up this particular Lx0000 U MANUFACTURED IN US. YEAR OF MANUFACTURE JULIAN DATE OF MANUFACTURE SSR compressor. A series of illus- trations show each part clearly and in its correct location relative to the other parts in the illustration. Each part of an illustration is referenced with a number. The number, description and quantity needed per assembly are listed in numeri- cal order on the following pages. Items with a description of NSS are not sold separately and must be purchased as an assembly. items with a description of Ret. indicate that the item is located elsewhere in the parts list. HOW TO USE THIS PARTS MANUAL 1. Turn to the Parts Section to locate desired illustrations. 2. Locate the part on the illustration by visual identification and the ref- erence number. 3. Find the reference number on the Tabulated page, along with the Part Number and Description. 99202 SERIAL NUMBER BREAK When a part is changed and it doesn't supersede the previous part, this change must be docu- mented by a serial number break. By using the last six (6) digits of the serial number, as outlined below, this change is recorded in the parts list. > 99202 indicates part is used on units up to and including serial number ending in U99202. U99203 +> indicates part is used on units with serial number ending in U99208 or higher. HOW TO ORDER PARTS In order that all avoidable errors be eliminated when ordering parts, please specify the following: 1. The model number of the unit as shown on the Compressor Data Plate. 2. The serial number of the unit as, shown on the Compressor Data Plate. 3. The form number of this manual. 4, The reference number, part num- ber, description and quantity need- ed exactly as listed. 5. 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