- INGERSOLL-RAND. AIR COMPRESSORS SP’ SSR XFE/EPE 25 EP/HP/XP 30 EP/HP/XP 40 U 25 LE/HE SP U 30 H/HH SP U 40 H/HH X SP OPERATORS/ INSTRUCTION MANUAL @ OPTIONS PARTS LIST RECOMMENDED SPARES Before installation or starting the compressor for the first time, this manual should be studied carefully to obtain a clear knowledge of the unit and of the duties to be performed while operating and maintaining the unit. RETAIN THIS MANUAL WITH UNIT. This Technical manual contains IMPORTANT SAFETY DATA and should be kept with the air compressor at all times. AIR SYSTEMS SURVEY Ingersoll-Rand recommends that the compressed air system have sufficient storage volume to prevent the ‘compressor from cycling rapidly. Rapid cycling is more than one complete load-unload cycle per minute. If the system's piping runs do not have sufficient volume, an air receiver should be installed, ‘APDD 2998-90 © Ingersoll Rand Company 1990 Third Edition November 1990,ONDINE roe eg ‘AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UP “he Cerny oe eh ca ‘paseo ind Porch econ ry ahaa Sate on ete esse ie a "ihe COueAn Manes NOG HER Wanmanty On SEPAESENTATIGN OF Any RIND WaT EOEUER BXPEESSED OR MPL EACEET TWAT Ge KE: AN Aik IMPLIED WARRANTIES OF MERCHANTABITY aN FNESS FON A Sarat econo rencvtmie mete ua re marr ant epg tne ey srl kbuy or oars wh arp mer of seh Ean ‘asian a Sb: Any such ve t Equip wa be at Porches 8 mahing ie Company Raines Srnec te hal esermasiem macta oe ree one EXTENDED AIREND WARRANTY ‘The Ingersoll-Rand Company Rotary Serew Air Compressor that has been filled prior to its original shipment from Ingersoll-Rand Company with ULTRA COOLANT and which has been operated solely on ULTRA COOLANT there- after shall have its ATREND warranted for wenty-four(24) months from the date ‘of placing the COMPRESSOR in operation or thirty(30) months from the date of shipment, whichever occurs First. Except for the above warranty period, the standard warranty provisions shall apply and the conditions outlined herein are understood to be a supplement tothe standard Ingersoll-Rand Company warranty ‘This EXTENDED AIREND WARRANTY applies to all COMPRESSORS ‘operating on ULTRA COOLANT after February 1. 1987,a) ROTARY SCREW AIR COMPRESSOR ‘This unit was purchased from Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. Model No. of units on order; Customer Order No Ingersoll-Rand Co. Order No. For ready reference: Record the serial number and model number of your unit here. Serial Number: Model Number:TABLE OF CONTENTS (0.0 SAFETY AND WARNINGS 0.3 DECALS 1.0 RECEIPT OF EQUIPMENT 1.1 inspection 1.2 unpacking and handling 13 tools 2.0 INSTALLATION 2.1 ventilation 2.2 foundation requirements 2.3 piping 2.4 electrical installation 3.0 INTELLISYS 3.1 emergency stop switch 13.2 power light 3.3 automatic restart indicator light ‘3.4 start button 3.5 unloaded stop button 3.6 display select button 3.7 unload button 3.8 load button 3.9 set button 3.10 increase decrease set points 3.11 recalibrate 3.12 alarm indicator light 4.0 SCHEDULED PREVENTATIVE MAINTENANCE. 4.1 maintenance schedule 4.2 maintenance records 4.3 maintenance procedures. 4.4 belt tension adjustment 4,5 to change inlet air filter element 4.8 coolant filter element 4.7 coolant change time 4.8 coolant separator element 4.9 replace separator cover 4.10 cooler cores: cleaning outside faces 4.11 separator scavenge orifice/screen 4.12 SSR motor greasing instructions (Reliance) 4.13 SSR motor greasing instructions (Marathon) 5.0 MAINTENANCE 5.1 enclosure 5.2V-belts 5.3 shaft seal replacement 5.4 idler 5.5 coolant hoses 5.6 control tubing 5.7 intellisys replacement 5.8 starter maintenance schedule 5.9 motor change-out 5.10 compression module change 5.11 cooler replacement 5.12 coolantlubricant change-out 5.13 sheave alignment 5.14 interface board replacement TABLE OF CONTENTS (Continued) 6.0SYSTEMS ‘general system information coolant system air system 6.4 capacity control 7.0 TROUBLE SHOOTING 7.1 intelisys fault signals 72 starter failure 7.3 motor overioad 74 high discharge air temperature 75 high discharge air pressure 7.6 temperature sensor failure 77 pressure sensor talure 7.8 emergency stop 7.9 emergency stop button engaged 7.40 microprocessor fallure 7.11 remote stop engaged 72 low voltage 7.13 incorrect compressor rotation 8.0 OPTIONS 8.1 automatic startstop 8.2 remote startistop 8.3 automatic startistop with remote startistop 9.0 REFERENCE DRAWINGS ‘9:1 wiring diagram ‘9.2 foundation plan ‘9.3 foundation plan ‘9.4 foundation plan ‘95 foundation plan ‘96 alr system flow 9.7 typical system flow 10.0 PARTS LIST 10.1 instructions for ordering 10.2 illustrated parts list 10.3 recommended spare parts list GENERAL INFORMATION Weight: ‘See foundation plan, Section 9.0 Cooling Air Flow: ‘See foundation plan, Section 9.0 Ambient Temperature Limits: 35°F to 100°F (2°C to 38°C) Coolant: Factory Filled SSR Ultra Coolant Coolant Change: 8000 hours or two years whichever ‘comes first Coolant Capacity: (8.0 gal (11.4 titers) Discharge Temperature Limit: 28°F Option: ‘On Line/Off Line Modulation Power Inlet Wiring: Recommended conduit: metallic flexible Greenfield, or equi ‘maximum trade size 25" Tools: US. Standard and metric are required to perform maintenance0 G) 0.0 SAFETY AND WARNINGS O41 Before you install this air compressor you should take the time to carefully read all the instructions contained in this manual. Electricity and compressed air have the potential to ‘cause severe personal injury or property damage. Before installing, wiring, starting, operating or ‘making any adjustments, identify the components of the air compressor using this manual as a guide. ‘The operator should use common sense and good working practices while operating and mai 9 this unit. Follow all codes, pipe adequately, under- stand the starting and stopping sequence. Check the safety devices following the procedures contained in this manual. Maintenance should be done by qualified personnel, adequately equipped with proper tools. Follow the maintenance schedules as outlined in the manual to 02 insure problem free operation atter start up. WARNING COMPRESSED AIR AND ELECTRIC- ITY ARE DANGEROUS. BEFORE DOING ANY WORK ON ‘THIS UNIT, BE SURE THE ELECTRI- CALSUPPLY HAS BEEN CUT OFF— LOCKED & TAGGED AND THE EN- TIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF ALL PRESSURE. 1. Donot remove the covers, loosen or remove any fittings, connections or devices when this unit i 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, the start- fer and control box. All installations ‘must be in accordance with recog- nized electrical codes. Before working ‘on the electrical system, be sure to remove voltage from the system by use of a manual-disconnect-switch. A circuit breaker or fuse safety switch must be provided in the electrical ‘supply line leading to the compressor. ‘Those responsible for tion of this equipment must provide suitable ‘grounds, maintenance clearance and lighting arrestors forall electrical com- ponents as stipulated in O.S.H.A. 1910.308 through 1910.29. SAFETY PRECAUTIONS BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE ‘COMPRESSOR OR PERFORMING ANY MAINTENANCE 3, Do not operate the compressor at higher discharge pressure than those specified on the Compressor Name- plate or motor overload will occur. ‘This condition willresultin motor com- pressor shutdown. 4, Use only safely solvent for cleaning the compressor and auxiliary ‘equipment. ‘5. Install a manual shut oft valve (Isola- tion type) in the discharge line. A ‘safety valve, with sufficient capacity to lieve full compressor capacity, must installed between the compressor and the isolation valve. 6. Whenever pressure is released through the safety vane, itis due to excessive pressure in the system. The cause for the excessive pressure should be investigated immediately. 7. Betore doing any mechanical work fon the compressor: ‘Shut the unit down. .) Electrically isolate the compressor byuse of the manual disconnect switch inthe power line to the unit Lock and tag the switch so that it cannot be operated. Blow down the compressor and isolate the unit from any other source of ir. 8. There canbe badetfectsif compres- sor lubricants are allowed to enter plant air systems. line separators, properly selected ‘and installed, can reduce any liquid carryover close to zero, The use of plastic bowls on line filters without metal guards can be hazard- ‘ous. Their safety can be affected by elther synthetic lubricants or the adi- tives used in mineral oils. From a safety standpoint, metal bowis should bbe used on any pressurized system. Review of your plant airline system is recommended. 9. When a receiver is installed, it is recommended that occupational safe- ty and health standards as covered in the Federal Register, Volume 36, num- ber 105, part 11, paragraph 1910.169 bbe adhered to in the installation and ‘maintenance of this receiver. 10. Before starting the compressor, its ‘maintenance instructions should be thoroughly read and understood. 11. After maintenance functions are completed, covers and guards must bbe replaced.ANY a AUD cence ets There is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory pre-set at 228°F and is user adjustable between 200°F and 28°F. This function should be checked at regular intervals for proper operation, once a month is recommended. Procedu 1. Block off the cooling air discharge. 2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge temperature reaches the pre-set maximum discharge air temperature setting of the Intellisys. The display should indicate — 04 — and the alarm light will be illuminated. The actual temperature at which shutdown occurs should be recorded for comparison to the Intellisys set point and with similar future test results. AWARNING Failure to adhere to these recommendations can result in mechanical failure, property damage and serious injury or death. “All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must take into account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility between discharge piping, system accessories and software must be assured.” “For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is not recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the operating parameters of the system. “It is the responsiblity of the installer and owner to provide the appropriate service pipework to and from the machine.” STATEMENT CONCERNING THE USE OF THIS EQUIPMENT FOR BREATHING AIR AND/OR AQUA LUNG SERVICE If the model number on this air compressor contains the letters “BAP”, the compressor is suitable for use in breathing air services. In the absence of such a designation, the compressor is NOT considered as capable of producing air of breathing quality. For a compressor to be capable of use in breathing air services it must be fitted with additional specialized equipment to properly titer and/or purity the air to meet all applicable federal, state and local laws, rules, regulations and codes, such as, but not limited to, OSHA 29 CFR 1910.134, Compressed Gas Association Commodity Specification G-7, 1-1966, Grade D Breathing Air and/or Canadian Standards Association. Should the Purchaser and/or User fail to add such specialized equipment and proceeds to use the compressor for breathing air service, the Purchaser/User assumes all liability resulting therefrom without any responsil or liability being assumed by Ingersoll-Rand Company. ‘The Purchaser is urged to include the above provision in any agreement for any resale of this compressor.0.3 DECALS e@ This section contains representative examples of _ If for some reason a decal is detaced, parts are decals which will be appearing throughout this replaced or painted over we recommend that you manual and are applied to the compressor unit. obtain a replacement kit (found in section 10.0 recommended for spares) and reapply the decals in WARNING the locations illustrated [WARNING > A\WARNING seca ee AWARNING| an YK | (Gwmwne) | EE ‘gn moving pt ‘erga furs nen aching Sonata xen ran ote, seen fo ASCAUTION| Eig oe |Z\WARNING [Acaurion | [e278] * Decal Kit 39789953, ee ony SSR Ute0.3 DECALS (Continued)0 1.0 RECEIPT OF EQUIPMENT 1.1 INSPECTION When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier should be noted on the delivery receipt espe- cially if the compressor will not be immediately uncrated. Obtaining the delivery man’s signed agreement to any noted damages will facilitate any future insurance claims, IMPORTANT READ THIS LOST OR DAMAGED GOODS THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL ‘OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN ‘THE CARRIER SIGNED BILL OF LADING gst nec ter cn amged cnn ipa al oye Serine an rr a ingen an rt Seacoast emptor concent ‘no nom Stes FORKLIFT PADDING. WILL REDUCE SCRATCHES AND MARS ‘SPREADER 4.2 UNPACKING AND HANDLING The compressor package has been mounted on a base which provides for forklfting between the two side channels to facilitate handling during shipment. Care in positioning the forklifts is important because the location of the center of gravity is strongly affected by the location of the compression module and drive motor. Slings can be used to lft the crates but spreader bars must be used to prevent the slings from exerting a force against the sides of the crate. 13 TOOLS Remove compressor unit from wooden skid. A crowbar and hammer will be needed.2.0 INSTALLATION 2.1 VENTILATION Oil flooded rotary air compressor produce large amounts of heat. Because of this large heat production, the compressor must be placed in a room with adequate ventilation If heated air from the compressor exhaust is allowed to recirculate back to the compressor, the compressor will overheat and shutdown. This heat must be exhausted from the room. You should take this into consideration when you decide where to place the compressor within your plant. Consider that the required maintenance clearance is three feet all around the compressor. Ambient temperatures higher than 100° should be avoided as well as areas of high humidity. Consider also the environment surrounding or near the compressor. [ec] Boxes] CARRE) [Cédies | usone 2.2 FOUNDATION REQUIREMENTS Refer to the foundation plan for the particular model compressor to be installed. See Section 9.0. ‘The compressor can be installed on any level floor that is capable of supporting it. Compressor weights are listed on the foundation plans. When sound transmission is of particular importance it is often helpful to install a sheet of rubber-fabric-matting, or cork under the compressor to reduce the possibility of resonant sounds being transmitted or amplified through the floor. 2.3 PIPING The use of plastic bowls on line filters without metal guards can be hazardous. Their safety can be affected by either synthetic lubricants or the additives used in mineral oils. From a safety standpoint, metal bowis should be used on any pressurized system. Review of your plant air line system is recommended The built-in aftercooler reduces the discharge air temperature well below the dew point (for most ambient conditions), therefore, considerable water vapor is condensed. To remove this condensation, each compressor with built-in aftercooler is furnished with a combination condensate separator/trap. 8 36 el be z AIR INLET fa oa io masnsoumane 5 in nl Les3 2.3 PIPING (Continued) ‘The separator/trap must be installed as shown. A dripleg assembly, condensate separator/trap and isolation valve should be mounted near the compressor discharge. 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. It is possible that additional condensation can occur if the downstream piping cools the air even further. Therefore low points in the piping systems should be provided with driplegs and traps. IMPORTANT: Discharge Piping should be at least as large as the discharge connection at the ‘compressor enclosure. All piping and fittings must be suitably rated for the discharge pressure. Careful review of piping size from the compressor connection point is essential. Length of pipe, size of pipe, number and type of fittings and valves must be considered for optimum efficiency of your compressor. See Section 9.0 system. It is essential when installing a new compressor to review the total plant air system. This is to insure a safe and effective total system. An item which must bbe considered is liquid water carryover into the plant air line. Installation of aftercoolers, air dryers and line separators is always a good practice. See Section 9.0 system, Water condensation can affect the operation of pneumatic devices. Aftercoolers and the addition of air dryers can eliminate this hazard. Similarly, there can be negative effects it compressor coolant is allowed to enter plant air systems. Air line separators, properly selected and installed, can reduce any liquid carryover. NOTE: Screw type compressors should not be installed in air systems with reciprocating compressors without a means of isolation, such as a common receiver tank. We recommend both types of compressor units be piped to a common receiver utilizing individual airlines, When two rotary units are operated in parallel, provide an isolation valve and drain trap for each compressor before the common receiver. IsotaTion VALVE SEPARATORTRAP | ts ‘TO OPEN DRAN DISCHARGE PIPING WITH AFTERCOOLER (CY ROTARY-RECIP IN PARALLEL, = Ee ROTARY TWO COMPRESSOR SYSTEM2.4 ELECTRICAL INSTALLATION A\WARNING Ihr or cea ‘See Operators! Before proceeding further, we recommend that you review the safety data in the front of this manual. ELECTRICAL POWER INLET: The recommended power inlet conduitis, metallic, flexible, Greenfield, or equivalent, maximum trade size 2.5 inches. Locate the compressor data plate on the side of the cooler box (open units) or on the end of the enclosure. The data plate lists the rated operating pressure, the maximum discharge pressure, the electric motor characteristics, and power. Confirm that the line voltage and compressor name- plate voltage are the same. The standard SSR starter box meets the intent of NEMA 1 guidelines. Remove the starter box front panel. Confirm that all electrical connections are made and tightened. Confirm that the control transformer is wired cor- rectly for supply voltage. TNE Set va [wz [ume | aumrers | SEC, | sec 200 | 30 | HBHT | NONE % | Ox 20) a | HeHT | NONE mo | x38 je | so] HEH? | NONE | xox as | 3 | HoH | None % | 2x3 460 | 6 | HoH? | NONE wo | x38 sr | s0 | Rt? | NONE mo | x33 aa | a | HaH? | NONE mo | x38 as2_| 60 | HoH? | None vo | x3 Control Transformer Connections Inspect the motor and control wiring for tightness. Replace the starter box front panel, 10 G INGERSOLL-RAND. Compressor Data to oes ras i —pes HIGH VOLTAGE SIDE-PRIMARY WeoHo He HS He Ww ca mom LOW VOLTAGE SECONDARY SIDE TRANSFORMER TERMINALSELECTRICAL INSTALLATION (Continued) Before Starting — Starting — Stopping — Emergency Stopping. See instructions below. ROTATION CHECK. LOCATE THE ROTATION DECAL ON THE MOTOR. WARNING: If compressor is operated in the opposite direction of rotation this can result in ‘end damage and is not warrantable. The correct fan rotation is clockwise when viewed from the rear or non-drive end of the motor. For the compressor motor rotation check, the motor jogging must be as short a time as possible. After depressing the start button IMMEDIATELY depress the EMERGENCY STOP button. Observe the compressor cooling fan. The rotation should be in accordance with the directional arrow decal affixed to the motor. For units built after 7/89 the Intellisys will automatically shut the unit down if the compressor rotation is incorrect, and fault code - 12 - will appear in the display. See Section 7.13. Should the motor rotation not be correct put the main disconnect in the OFF position, lock and tag. Remove the starter box cover. Interchange any two line connections (L1, L2 or 3) at the starter. Replace the starter box cover. Recheck for correct rotation. BEFORE STARTING — STARTING — STOPPING — EMERGENCY STOPPING. NOTE: These instructions are also contained on the decal near the Intellisys panel of the unit. ROTATION DECAL A\WARNING ‘ue > ect ‘jy orden ces ‘isconneet power Defoe ering. Cocca tag out machine, See Operators Inston Manus Before Startin Check coolant level. Add coolant it necessary. Verify that main isolation valve is open. Close Main disconnect switch. Display window will show O. Power and unload indicator lights will be on. Push and hold “unloaded stop” for lamp check. All in- dicator lights will be on and “8886” will show in the display until “unloaded stop” is released. Startin Push "START" to start compressor. Compressor will operate unloaded, Allow compressor to warm up for 2 minutes in the unload mode. Push "LOAD" once for ON/OFF LINE, twice for MODULATE/ACS. The air pressure will rise if there is sufficient demand for air. Stopping: Push “UNLOADED STOP”. Compressor will immediately unload and continue to run unloaded approximately seven seconds. Compressor will then stop. If compressor is running unloaded when "UNLOADED STOP" is pushed, compressor will stop immediately. Open main disconnect switch ‘Stopping — Emergency: If there is a need to stop the compressor immediately or if the ‘UNLOADED STOP” does not stop the compressor, push “EMERG STOP” Compressor will stop immediately. Display window will show -07- and the alarm light will be on, Open main disconnect switch. "3.0 INTELLISYS © La en ora DISPLAY SELECT ed TaN A J) CR Oe ay SRC aa aaa) ST ulaseua eo) Sua a Ra tet Pere aR ty ery area Petry See ‘© SET ON LINE AIR PRESSURE eae arc Pee eRe Beaune) Lo ( INGERSOLL-RAND INTELLISYS..3.0 INTELLISYS Close the main power disconnect. The Intellisys Panel is activated. Line power is available to the starter. Inteliisys is continuously scanning sensors of the ‘compressor unit. Display window will indicate (0) ready to start. 3.1 EMERGENCY STOP SWITCH — COMPRESSOR STOPS IMMEDIATELY (33) Power still on to Intellisys. Prevents re-starting until switch is manually re-set. Turn clockwise to re-set. 3.2 POWER LIGHT Indicates 115 volt contro! voltage is available to the control circuit, and into the intellisys, and line voltage is available at the motor starter main contacts. POWER Never use this light to determine if starter power is available. 3.8 AUTOMATIC RESTART INDICATOR LIGHT Indicates the compressor has shut down. AUTOMATIC RESTART Auto restart is selected. Compressor will restart automatically when line pressure drops below preset on-line pressure. 3.4 START BUTTON Energizes starter coil to start compressor. Intellisys begins scanning compressor system. B3.5 UNLOADED STOP BUTTON Button activates unloaded stop. When pressed, unit unloads and continues to run approximately 7 seconds, then stops. if unit is in unloaded condition compressor stops immediately. ‘UNLOADED | STOP 3.6 DISPLAY SELECT BUTTON Selects function which is displayed in the numeric display window, Each time display select is pressed the indicator light moves down one position. Display functions will be displayed, DISPLAY ‘SELECT DISCHARGE AIR PRESSURE (PSIG) DISCHARGE AIR TEMPERATURE (°F) SUMP AIR PRESSURE (PSIG) SEPARATOR PRESSURE DROP (PSI) TOTAL TIME RUNNING (HOURS) TOTAL TIME LOADED (HOURS) decimal point appears. 3.7 UNLOAD BUTTON Untoads unit Unload indicator light is on Auto re-start will not function when this button is depressed UNLOAD 14 3.8 LOAD BUTTON Loads unit. There are two different operational modes. Press once to select on-line off line control On/off line indicator light is on. Press again to select modulation/ACS control, Modulate/ACS indicator light is on. Each press alternates between on/off line and modulate. If you are utilizing on line/off line and. due to limited usage or lack of storage, the unit, unloads three times in three minutes, the Intellisys will automatically shift to modulate. If the unit is in modulate/ACS and runs unloaded for 3 minutes, the Intellisys will automatically shift to on/off line. Modulate/ACS indicator light will remain on 3.9 SET BUTTON Adjust set points only when unit is stopped. ‘The Operator selects set points of adjustable func- tions. (Check display window). Each time set button is depressed the indicator light moves down one position. When a set point is changed press set button and the Intellisys stores the new point, blinks twice, then automatically moves to next parameter, ‘Step arrows are used to change value of the Intellisys parameter. Set point is indicated at each lighted function. set9.10 INCREASE DECREASE SET POINTS LAN STEP VW To change a value press set button, until desired parameter indicator is lighted. Then press step arrow to either increase or decrease the displayed value. If the Intellisys is allowed to remain in the Set Point mode with no change for more than fifteen seconds (15) the system will return to a (0) and is ready to start. (Check numeric display window for value of set point.) FUNCTIONS After parameters are re-set you must either wait ten seconds (10) or depress display select to re-set the unit. 3.11 RECALIBRATE ‘Also used to auto-zero calibrate the pressure sensor after replacement. Stop machine, relieve pressure, push both step arrows at same time. aX STEP WY CAUTION DO NOT ADD ANY ELECTRICAL RELAYS THAT ALLOW THE COMPRESSOR TO AUTOMATICALLY RESET SHOULD A POWER OUTAGE OCCUR. 3.12 ALARM INDICATOR LIGHT When lighted indicates abnormal shutdown or operating conditions. A blinking alarm light indicates discharge air ‘temperature is 3% below max. discharge temperature set point or 97% of set point. A lighted non-blinking alarm light indicates an abnormal shutdown The error message code is shown in the numeric display window. The error messages are: O1.STARTER FAILURE 02.MOTOR OVERLOAD. 03.HIGH DISCHARGE AIR TEMPERATURE 04.DISCHARGE AIR PRESSURE 05. TEMPERATURE SENSOR FAILURE 06, PRESSURE SENSOR FAILURE *07.EMERGENCY STOP-MANUAL, **08.RESET EMERGENCY STOP-MANUAL RESET 09.MICROPROCESSOR FAILURE 10.REMOTE STOP 11.LOW VOLTAGE 12.INCORRECT COMPRESSOR ROTATION —OPTION NOT INSTALLED For clearing the display and repairing abnormal conditions see Trouble Shooting Section 7.0. *07-BUTTON IS PRESSED **08-BUTTON MUST BE RESET BY TWISTING CLOCKWISE, ZA\WARNING ‘This equipment generates, uses, and can radiate radio frequency energy andif not usedin accordance with the instructions manual, may cause interference to radi communications. It'has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart Jof Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environ- ment. Operation of this equipment in a residential area {s likely to cause interference in which. his own expense will be required to t ‘measures may be required to correct th 54.0 SCHEDULED PREVENTATIVE MAINTENANCE 4.1 MAINTENANCE SCHEDULE ‘THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED ‘OR AFTER THAT NUMBER OF HOURS, WHICHEVER OCCURS FIRST. RUNNING] TIME INTERVAL (WHICHEVER COMES FIRST) a panes ee HOURS "DAILY WK. IMO. 3MO. 6MO. YEARLY 2¥A, INSPECT | COOLANT LEVEL 8 INSPECT | DISCHARGE TEMPERATURE (AIR) 8 | x INSPECT | SEPARATOR ELEMENT DIFFERENTIAL ea INSPECT | AIR FILTER DELTA P (AT FULL LOAD) 8 | x REPLACE | COOLANT FILTER* 180 X {INITIAL CHANGE ONLY) inspect | V-BELTS, V-BELT TENSION 500 x CHECK | HIGH AlR TEMP. SiVITCH/SENSOR ‘000 x REPLACE | COOLANT FILTER* 200 X (SUBSEQUENT CHANGES) CLEAN | SEPARATOR SCAVENGE SCREENS ORIFICE | 1000 x cuEAN_ | COOLER coRES** 4000 x ePLACE | aR FILTER 2500 x CLEAN [SEPARATOR ELEMENT SEE SPECIAL NOTE REPLACE |V-BELTS YEARLY x rnePLace |COOLANT* 2000 x REPLACE | SHAFT SEAL 2000 x INSPECT | STARTER CONTACTORS 3000 x REPLACE [IDLER SHEAVE ASSEMBLY 16.000 “INVERY CLEAN OPERATING ENVIRONMENTS AND WHERE INLET AIR FILTER IS CHANGED AT THE ABOVE PRESCRIBED INTERVALS. IN EXTREMELY DIRTY ENVIRONMENTS CHANGE COOLANT, FILTERS AND SEPARATOR ELEMENTS MORE FREQUENTLY. *“CLEAN COOLER CORES iF DISCHARGE AIR TEMPERATURE IS EXCESSIVE OR IF UNIT SHUTDOWN OGCURS ON HIGH AIR TEMPERATURE, 4.2 MAINTENANCE RECORDS Itis very important that you, the owner, keep accurate and detailed records of all maintenance work you or the Ingersoll-Rand distributor perform on your compressor. This includes but is not limited to coolant, coolant filter, separator, inlet air filter, V-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. Maintenance record sheets are located at the back of this manual. 4,3 MAINTENANCE PROCEDURES. Before starting any maintenance, be certain the following is heeded. 1, Read Safety Instructions. 2. Use correct tools. 3. Have recommended spares on hand. 16 SPECIAL NOTE: REPLACE SEPARATOR ELEMENT WHEN THE SEPARATOR DIFFERENTIAL PRESSURE (2\ P) REACHES THREE TIMES THE INITIAL PRESSURE DROP OR A MAXIMUM OF 12 PSID AT FULL LOAD.4.4 BELT TENSION ADJUSTMENT A belt that is too loose will slip, causing overheating, reduction in belt life, and a loss of compressor efficiency. Conversely, a belt that is too tight may cause a reduction in belt life and may overload bearings. The proper tensioning method is described as follows: 1. Remove belt access cover, loosen idler shaft (NOTE: Shaft has Left Hand thread). Turn idler adjusting screw until idler sheave contacts belt, 2. At the center of the sheave span, apply a force (perpendicular to the span) by use of a tension tester or other calibrated spring. The adjacent belt can be used as a reference for measuring deflection. At the appropriate deflection measurement, the applied force should fall within the 4 and 6 Ibs/belt for the given unit. New belts should be set at the 7 Ibs. deflection force. 3. If the deflection force is less than required, the idler sheave should be moved downward. If the deflection force is greater than required, the.idler sheave should be moved upward. 4, Tighten idler shaft, note Shatt has Left Hand thread. 5, Tighten adjusting screw locknut. 6, Replace belt access cover. 7. There will normally be a rapid drop in belt tension during the run-in period. Tension new belts with the initial deflection force as indicated. Check tension frequently during the first 24 hours of unit operation, then every 500 hours thereafter. 8, The idler is pre-greased at the factory with a special hi-temp grease and does not require re- greasing as itis prelubricated for its intended service lif 4.5 TO CHANGE INLET AIR FILTER ELEMENT Loosen wing nut on top of inlet filter. Remove cover and filter. Install new element and inspect to insure that it has seated properly, Replace cover and tighten service, The filter should be changed when the filter indicator shows red. The filter should be changed every 2500 hours and more frequently in dirty environments, because coolant, coolant filter, separator and airend life are a direct function of how well you maintain and replace the inlet air filter. \g nut. Place unit in SPANLENGTH DEFLECTION SHEAVE SHAFT HAS LEFT HAND THREAD BELT DEFLECTION 5/16 IN. DEFLECTION FORCE: NEW - 7 LBS. AFTER RUN IN BETWEEN 4-6 LBS. CAUTION DO NOT OVERTIGHTEN BELTS. MAY CAUSE DAMAGE TO BEARINGS, SHAFT OR SEAL RETAINER ASSEMBLY. FILTER AIR FILTER AP INDICATOR INLET AIR FILTER, v74.6 COOLANT FILTER ELEMENT Time of change — after the first 150 hours and every 1,200 hours thereafter, or when the coolant is being changed. In dirty operating environments the filter should be changed more frequently Use a fiter wrench to loosen the old element. Use drain pan to catch any leakage during removal Discard old element. Wipe the sealing surface of the compressor with a clean, lint-free rag to prevent the entry of dirt into the system, Remove the replacement element from its protective package. Apply a small amount of clean Coolant on the rubber seal and install element. ‘Screw element on until the seal makes contact with the seat on the compressor housing. Tighten approximately one half to three quarter turns. additional, Start unit and check for leaks 4.7 COOLANT CHANGE TIME After every 8000 hours or every two years, whichever comes first (SSR ULTRA). Items Required In addition to the tools normally found in any reasonably equipped serviceman’s toolbox, the following items should be available at the work site: 1. Suitable drain pan and container to hold lubricant drained from unit. 2. A quantity of proper lubricant sufficient to refill the compressor. 3. A minimum of one replacement lubricant filter element of the proper type for the unit to be worked on There is a coolant drain hose on each compressor. Itis located on the end of the compressor module. The coolant should be drained soon after the compressor has been shut down. When the coolant is hot, the drainage will be more complete and any particles in suspension in the coolant will be carried out with the coolant. After the unit is drained and a new coolant filter element is installed, refill the system with fresh coolant. Bring the sump level of coolant up to the midpoint of the sight glass. Replace the fill cap. Approximate coolant fill capacity is 3.0 Gal/11.4 Liters. 8 A\CAUTION e SPIN ON TYPE FILTER Coolant Fill Quantity 3.0 Gal. (11.4 Liters) A\WARNING HOTCOOLANT USE CARE. CAN CAUSE WHEN SEVERE INJURY DRAINING Sena sry tcotnences~ — 4.7 COOLANT CHANGE TIME (Continued) 4, Start the compressor and run it for a short while. Shut it down and check the coolant level in the sump. Add enough coolant to bring the level back to the gauge midpoint. Replace the fill cap. Correct oil level is between bottom and midpoint of sight glass with unit running unloaded. Do not overfill the compressor. Do not add coolant through the intake of the compressor as this can result in overfilling saturation of the separator and coolant carry-over downstream. 8 COOLANT SEPARATOR ELEMENT ‘The separator element must be replaced when the differential pressure across the element reaches 3 times the initial pressure drop or a maximum of 15 psi (1.0 BAR). The unit must be fully loaded and at its rated pressure when the differential is checked. NOTE: A drop to zero differential also indicates a failing or bypassing element that must be replaced. 1. Shut the unit down. Open the main disconnect, lock and tag 2, Disconnect the discharge air tube between the separator cover and aftercooler. 3, Disconnect the control air lines after noting their original connection points, 4, Tag the control lines to insure they can be reassembled correctly. 5, Remove the bolts that hold the separator cover in position. 6, Remove cover by lifting up and away. 7, Remove bolts retaining separator clamp, 8. Carefully lift the separator element up and out of the receiver portion of compression module. Discard the old element. Check to assure element ‘O-Ring is removed from bottom of separator cavity. 9. Clean the gasket surface on both the compressor module and its cover. Exercise care to prevent pieces of the old gasket from falling down into the receiver area. Replace separator cover gasket if damaged. 410. Check the receiver area to be absolutely certain no foreign objects such as rags or tools have fallen into the receiver area. 11. Place the new O-Ring onto replacement separator element. Install and center the element in the receiver area COoLaNT ‘a FILL CAP. ‘cootaNT LeveL onal Hose SIGHT GLASS GAUGE AXWARNING \ | Sacre or danth ‘ine oe tela rmorng cape tose totaion vue Soe Operators O-RING NOTICE While tightening the separator clamp bolts, adjust element to ensure proper alignment and seating of O-Ring, Failure to do so may result in improper coolant separation. Torque separator clamp bolts t07 ft. Ibs, Care should’ be exercised to prevent excessive clamp bending. 94.9 REPLACE SEPARATOR COVER Replace cover gasket if damaged. Since an improperly tightened cover may result in a leak, following the recommended procedure for reinstalling the separator cover is important. Utilizing the cross pattern tightening procedure as illustrated. Begin by using the number one bolt and tighten all bolts hand tight. Start again with the number one bolt and torque to 80 ft-lbs, again using the cross pattern sequence. See Figure 1 Once all eight bolts have been torqued, recheck each bolt, in sequence, to insure all bolts are at 80 ftlbs. Install the discharge air tube that connects the separator cover and aftercooler. Install the control air lines in their original position. Start unit, check for leaks, place in service. 4.10 COOLER CORES: CLEANING OUTSIDE FACES ‘SAFETY Insure that the compressor is isolated from the compressed air system by closing the isolation valve and bleeding pressure from the drip leg. Insure that the main power disconnect switch is locked open and tagged. TOOLS REQUIRED Screwdriver Allen wrench set Wrench set Air hose equipped with approved O.S.H.A. nozzle. On units sold outside the U.S.A. consult local codes. 20 ‘SEPARATOR COVER BOLT TORQUE PATTERN FIG.1REMOVE ENCLOSURE Remove enclosure. See ENCLOSURE. Visually check the outside of the cooler cores to be certain that a complete outside cleaning of the cooler is required. Frequently dirt, dust or other foreign material, may only need to be removed to remedy the problem. When the cooler is covered with a combination of oil, grease or other heavy substances that may affect the unit's cooling, then it is recommended that the cooler cores be thoroughly cleaned on the outside. PROCEDURE Remove the fan guard and belt guards. Drain the coolant. See Section 47. Remove the tubing from the top of aftercooler to the separator cover. Disconnect the coolant hoses from the oil cooler. Tag and mark for re-assembly. Plug the inlet and outlet fittings in the coolers to prevent possible contamination. Remove the holding screws at the bottom of the cooler box. Remove the cooler box from the base. Flush the outside cooler cores using a safety solvent. Follow solvent manufacturer's directions. Wear appropriate safety equipment. Reassemble in reverse. Make sure all fan guards and belt guards are replaced. Refill the compressor with coolant. If contamination is suspected, replace with new coolant. Run unit for ten minutes. Check for possible leaks. Check the coolant level. Replace the enclosure. 2a4.11 SEPARATOR SCAVENGE ORIFICE/SCREEN TOOLS REQUIRED 7/8” box wrench or socket wrench 1/4" hex allen socket wrench PROCEDURE Remove hex plug and O-Ring from rear bearing housing on rear of compressor module. ‘Asmail amount of coolant will be left in the bottom of the separator cavity when the unit is shutdown, This coolant drains from the separator element. The separator orifice and screen contain a small amount of coolant. When the orifice screen is removed, expect a small amount of coolant drainage. Remove scavenge orifice/screen, located in area under hex plug, using 1/4” hex allen socket wrench. Inspect orifice and screen: clean if dirty or plugged. Re-install scavenge orifice. Re-install hex plug/O-Ring and tighten 22 SCAVENGE ORIFICE/SCREEN LOCATED UNDER, HEX PLUG DO NOT LocTITE* HEX PLUG TRADE NAME4.12 SSR MOTOR GREASING INSTRUCTIONS (RELIANCE) *TRADE NAME @ “RELIANCE ODP MOTORS KIT P/N 39654140 FRAME] GREASE | GREASE Nomina HP) FRAME | CrING P/N | RELIEF P/N INSTALLATION INSTRUCTIONS MOTORS HAVE SEALED BEARINGS a) 213 na __NA__|NOGREASING REQUIRED: 5 2187 N/A N/A T REMOVE GREASE INLET PLUGS ON TOP OF BOTH ENDS OF THE 20 | _asat | eszorsa7 | soreses1 | Moron meTait GHEAGE-ReLicr IN Tre INLET PORTS. INSTALL Be} ager | eszotsa7 | aereseer | S*ASE FITTING INTO TOP OF Grease RELIEF. 30 eeaTs | 95201547 | 30165881 40 zests | 95201547 | 39165881 LUBRICATION LUBRICATION PROCEDURE Cteeninesisimportantin treatin. Any grease uedto eres ‘sings soul be ash andre tom contamination Sima. tuner fo propety els ta genes niet aea ot be mater to re Relance antiton Besings may be lubricstd wih the motor Fanning or statonary.Statanary ih the motor warms peled + Locate the gost et an lean me tg {sng ahand operated grease gun Grosse sy sscherge out ofthe SERVICE CONDITIONS - Table 1 rosin ree Siti, [am 0 Garnet RECOMMENDED LUBRICANT SSratom [osama trtan ormatorcot 850% ‘oS ens areagymnrerertonn deve [Rees Ser eon Fa sos or saTon oS oPenarinG YeuP 1610 oNF a [eo erertonte Saing2 wv = sore? LUBRICATION FREQUENCY (Ball Bearings) - Table 2 Setloxco Set rane iain | SE Eee eatery To 00 RE Sones | ton the anne LUBRICATION VOLUME - Table 3 ‘Shar apaneans we hve een Com oe he — = site ir eu ee on PARTS LIST LUBRICATION INSTRUCTIONS 1, Select stvic condition rom tba [aise PERT WO, erence DEC RSTONs 2 Sac oreaton requeney tom abe? sz01547 GREASE FITTING 5 Sect ubcaten volume Hom abe 3. Sarees (Grease RELY {uur wtume in aocordance wit th Solow 0 234.13 SSR MOTOR GREASING INSTRUCTIONS (MARATHON) *TRADE NAME *MARATHON ODP MOTORS KIT P/N 39654157 LUBRICATION ‘earings should een ae tao rom contra, slay. eae anode taker © propery aan the greave let res ofthe moor forever grass ‘SERVICE CONDITIONS - Table 1 aad [Eight Roeper cy, poral or ah dog, oraitons San 0° (00°F mentmumambsn Severe “en fur Pou par dy operation or sock onatons eaaing mtaton or nator aust @ 400°C (Geng amber Heavy shock or raion, dart LUBRICATION FREQUENCY (Ball Bearings) - Table 2 Horsepower craton | condi ilove 1600 | 6Montne | _ a Monts LUBRICATION INSTRUCTIONS. LUBRICATION PROCEDURE + Lect the grate lt and clan the iting 2 gpy Chowron SA1-2 rate (or equal fo net grease ting win low tau grave gun 3: a ease un the ease bain fo ext he grease 24 PARTS LIST PART NO. DESCRIPTION ‘GREASE FITTING REDUCING BUSHING serosa? 016708 Fame | —GneNGE aR omar we] "BARE |, GREASE | ,GRERSE, INSTALLATION NSTRUCTIONS a 21ST | 95201547 _| 95705547 _| MOTOR. INSTALL GREASE FITTING INTHE FILLER (TOP) PORTS 2} 2st |_ssamise:_|_osrsse?_ Hea Saree enc an Sorta ae 2) _254T | 95201547 | 95705547 _| Moron. INSTALL GREASE FITTING IN THE FICLER PORTS. INSTALL So | BAT. | SRE | Se _ RRL CSUN A ET WARES aeers | aezee7 | esos co [aaers [sears | sree5.0 MAINTENANCE 5.1 ENCLOSURE Removal of Enclosure - All maintenance procedures require that the enclosure be removed. SAFETY Before beginning any work on the compressor, open, lock and tag the main electrical disconnect, and close the isolation valve on the compressor discharge. Vent pressure from the aftercooler and piping by slightly opening the drip leg valve. When. opening the drain valve, stand clear of the valve discharge and wear appropriate eye protection. TOOLS 4%" wrench or rachet. REMOVAL You will note that the SSR enclosure was designed to ease maintenance. ” socket and 6” extension with Both the hinged top cover and the front panel are equipped with quick release push button latches. The rear or back panel may be removed, if necessary, by using a socket wrench to remove the holding screws. To gain access to the starter box and the Intellisys module, remove the four holding screws on the starter box panel and lift the panel off the baseplate, IMPORTANT: There are no repairable parts inside the Intellisys module. See Section 5.2 Intellisys Replacement. If for any reason the starter box panel is removed, be certain to replace this panel to prevent potential electrical hazard exposure. Since the compressor unit's performance will be affected, replace all panels and close the hinged access panel before starting the unit. TOP PANEL ‘SCREWS LATCHES: FRONT VIEW REAR COVER SCREWS CORNER COVER SCREWS REAR VIEW 255.2 V-BELTS [WARNING SAFETY Insure that the compressor is isolated fromthe compressor air system by closing the isolation valve and bleeding pressure from the drip leg Insure that the main power disconnect switch is: locked open and tagged. TOOLS REQUIRED Screwdriver Wrench 9", %" Belt tension gauge REPLACEMENT PARTS Belts (See Recommended Spares section.) DISASSEMBLY Remove enclosure. (See ENCLOSURE.) Remove belt guards and fan guard, Remove air discharge tube between compressor. housing and aftercooler. Remove fan/belt guards. Loosen idler adjusting screw to top of idler bracket. See Figure 1 Loosen idler center shaft (Left Hand thread), turn clockwise and slide idler sheave assembly. to top of bracket —re-tighten to hold in place. See Figure 2, Remove screws attaching fan orifice to cooler box Slide orifice over fan toward the drive motor. This will allow belt removal without disturbing-the drive motor location or fan removal. Examine the sheaves and idler for wear and possible replacement. If replacement is necessary, see IDLER REPLACEMENT. 26 Stay cae of movingINSTALLATION/INSPECTION Install new belts and reattach fan orifice to cooler box. When installing a new belt, do not pry or force the belts over the sheave grooves. The proper method of removing and installing a new belt is as follows: Tighten idler adjusting screw, loosen idler center shaft (Left Hand thread) and adjust belts to proper tension. See Figure 3 and Figure 4. See Section 4 for belt tension specs, Once proper belt tension is set, re-tighten idler shaft Torque to 65 ft-lbs. and tighten adjustment screw lock nut. 5.3 SHAFT SEAL REPLACEMENT The shaft seal on the drive side of the compressor ‘module is a mechanical type carbon face seal. It is a wearable part and should be inspected for wear and cracks every 12-14 months. It should be replaced at 6000 hours. While itis advisable to have your local Ingersoll-Rand distributor perform this work, the task can be accomplished by a good ‘mechanic following these instructions. ‘SAFETY Before beginning any work on the compressor, ensure the main electrical disconnect is locked and tagged open and that all air pressure is relieved from the system. See Section 5.1 for procedure to relieve pressure and other warnings. TOOLS ‘Awell equipped mechanic’s tool box with English and Metric sockets will have all tools required for this procedure. Additional supplies required are: - A clean work bench = Clean shop rags, = 1 pint clean SAE 20 wt. petroleum base oil in pump can’ ~ 42mm socket and ratchet ~ Torque wrench - OSHA approved air nozzle and compressed air. International-local codes may apply. REPLACEMENT PARTS - Shaft seal ~ Seal retainer gasket ~ Assembly sleeve thing ba. See Operators! 27INSTALLATION NOTICE THE MATING RING IS VERY BRITTLE. IT IS EASILY DAMAGED AND MUST BE HANDLED WITH CARE AND KEPT EXTREMELY CLEAN, CARE SHOULD BE EXERCISED WHEN INSTALLING SEALS AND RINGS. EXTREME CARE SHOULD BE TAKEN TO KEEP PARTS CLEAN AND FREE OF DIRT AND GRIT. Remove enclosure. See Section 5.1 Move starter box to give ample access to seal retainer. Remove half of belt guard over driven sheave. Remove belts by loosening idler shaft (Left Hand thread).and raising idler adjusting screw. Place belts out of way. Remove sheave from rotor shaft. Remove seal seavenge tubing Remove seal retainer from compression module using seal retainer bolts as jack screws. Press out old mating ring from seal retainer. Use a file to remove paint from dowel pin holes in seal retainer plate and scrape paint from edges. Check oil injection hole for blockage. Blow through with blast of air to insure passage way Is clear. See Figure 5 Thoroughly clean mating ring cavity and wipe with clean shop cloth. Lubricate seal retainer bore using a pump-type oil dispenser can. (GAE 20 weight petroleum base oil) Remove seal from package and place on a clean surface. Visually inspect sealing surfaces without touching them, 28 AWARNING A\WARNING e a ‘arya eat tetaadiag ot alee ee Operator tata norng sabe Sart Blow down dutus RbTGa SHAFT e_ e eg 3B a ‘SHAFT SEAL COMPONENTS FIG. 5:INSTALLATION (Continued) Hold mating ring with two fingers. The faces should not be touched at any time during the installation. See Figure 6. Lubricate the O-Ring with oil from pump can, being careful not to touch the face of the mating ring. Note: An“X" is marked on the seal face which goes into seal retainer cavity. The other face, which contacts with the primary sealing ring, has no markings. Place the round cardboard disc, furnished with the seal on the mating ring. Push mating ring onto bore using thumbs and fingers to seat ring squarely into cavity. See Figure 7. Remove cardboard disc, lubricate mating ring face with oil from pump can. Do not use fingers, brush, cloth, nor anything other than pump can. to lubricate faces. Use 200 to 400 grit emery paper to slightly dull the finish on the large diameter of the male rotor shaft. Use emery paper in a radial motion only, perpendicular to the shaft as shown in Figure 8. FIG.7 FIG.8 29INSTALLATION (Continued) Inspect shaft surface and wipe with a clean shop Cloth. See Figure 9. Lubricate the shaft lightly with coolant. Slide seal onto shaft as shown until spring is, slightly compressed. Note: Existing spacer between spring holder and bearing must be re-used, Flush the face of the primary sealing ring by pumping clean oil from the pump oil can across the sealing surface. The face area must be absolutely clean except for the oil which should be permitted to remain. Place the plastic assembly sleeve on the shaft as shown. The sleeve guides the seal retainer sub- assembly and prevents the mating ring from being damaged as it slides over the shaft shoulder. See Figure 10. Place gasket on seal retainer sub-assembly. Carefully align mating ring with male rotor shaft and slide sub-assembly onto shaft. See Figure 11 Push seal retainer sub-assembly over shaft, being very careful to align dowels with holes in retainer plate. Do not force sub-assembly as any shock to the mating ring will cause it to crack If retainer plate will not go on easily, use a file or emery paper to slightly open up dowel holes in seal retainer plate. Using a hand-held wrench, tighten bolts in the order shown alternating every half turn to draw sub-assembly onto housing. See Figure 12. Torque bolts to 80 ft. Ibs. using the above procedure Remove assembly sleeve. Install driven sheave. Install seal scavenge tubing, Install belts, set tension. See Section 4.4 Install belt guard. Place starter box back in original position Install enclosure. See Section 5.1 Place unit back into operation. ll used during the assembly may be observed at the shaft seal area during the first 1% hour after startup. This oil should not be mistaken for a leaking seal 30 FIG. 9 FIG. 125.4 IDLER SAFETY Insure that the compressor i isdlated from the valve and bleeding presstire from the drip leg insure that! the main, power disconnect Switch i8 locked open and tagged. : compressed air system by closing the isolation, | TOOLS REQUIRED Screwdriver Wrench REPLACEMENT PARTS Idler replacement kit. (See Recommended Spares Section.) DISASSEMBLY Remove enclosure. See ENCLOSURE. Remove belt guard. Loosen the belt tensioner locknut: Loosen the adjusting screw. The idler shaft has Left Handed threads. Reméve the idler shaft and the idler assembly. Inspect the belts for possible replacement. It replacement is necessary, see BELT CHANGE. INSTALLATION/INSPECTION Replace the idler assembly. idler shatt has left handed threads. Tightén to . Do not overtighten as shaft breakage may After assembly, adjust the belts to the cofrect tension arid tighten idler shaft. See Section 4.4 1g sciew ‘inspect the idler shaft and tensiori adj locknut to be sure they are tight. NoTE: IDLER SHAFT HAS. LEFT-HAND THREAD CAUTION ‘THE IDLER ASSEMBLY IS PRE LUBRI- CATED AT THE FACTORY WITH SPECIAL GREASE. NO ADDITIONAL LUBRICATION IS REQUIRED. 35.5 COOLANT HOSES The flexible hoses that carry coolant to and from the oil cooler may become brittle with age and will require replacement. Have your local Ingersoll- Rand distributor check them every 2 years. A\WARNING ‘SAFETY Insure that the compressor is isolated from the compressed air system by closing the isolation valve and bleeding pressure from the drip leg Insure that the main power disconnect switch is locked open and tagged. REMOVAL Remove the enclosure. See Section 5.1. 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. See Section 4.7. Unbott the starter box and belt guard section behind starter box. Position starter box out of the way. Be careful not to damage any conduit or tubing attached to starter. If necessary, remove the contro! tubing; carefully mark each piece so that it may be reassembled correctly. Remove each hose by holding the fitting in compression module (or cooler) stationary and rotating fitting on hose. INSTALLATION Install the new hoses and reassemble the package by reversing the disassembly procedure. Start the compressor and check for leaks. 5.6 CONTROL TUBING 4 ee Seas ye oate Sage, vera ote SAFETY Insure that the compressor is isolated from the compressed air system by closing the isolation valve and bleeding pressure from the drip leg Insure that the main power disconnect switch is locked open and tagged. ZANWARNING Noe > atone Inyo ea Disconnect power See Operators TOOLS REQUIRED Screw driver Wrench REPLACEMENT PARTS Replacement. See Parts List Section. 325.7 INTELLISYS REPLACEMENT NOTE: Record the total running hours as. displayed in the Intellisys panel window display. See display select Section 3.7 SAFETY Lock and tag the main power disconnect in the open position. Isolate the compressor from the compressed air system by closing the isolation valve and bleeding pressure from the drip leg. The Intellisys contains no servicable parts and should never be opened for any reason. TOOLS ‘Screw driver set. ‘Socket wrench set. REPLACEMENT PARTS Intellisys assembly. INTELLISYS REMOVAL FROM THE STARTER BOX MOUNT Record the serial number of the original Intellisys. (Serial number is located on the bottom cover of the Intellisys.) Remove the starter box cover: Locate the two Intellisys ribbon cables. Remove the cables trom the interface board. On the left connector push the locking tabs on the end outward. Plug will move up. Then pull plug straight out. On the right ‘connector rock connector up and down to release. Do not rock sideways. Disconnect the green ground wire trom the back of the Intellisys. (Spade connector.) From the inside of the Intellisys mount or starter box, push the four retainer clips on the Intellisys enclosure inward while exerting upward pressure, Remove the old gasket from the face of the Intellisys mount or starter box. Clean the facing area thoroughly. A\WARNING Sry ordent Soper GROUND WIRE RETAINER CUPS 33INTELLISYS INSTALLATION Record the serial number of the replacement Intelisys. Be sure that the replacement gasket which comes with the replacement Intellisys is applied correctly Clean the surface of the starter box and be sure no objects have fallen into the starter box area Push the new Intellisys into place by exerting force on the long side. Check to be sure that all four clips have gripped enclosure. Reconnect the green ground wire to the back of the Intetlisys, Reconnect the two ribbon cables onto the interface board. Be careful and use only enough pressure to insure a good seating has been made. Re-check all the wiring connections for tightness, on both the Intellisys and the interface board. Remove tools and all foreign objects from the starter box. Replace the starter box cover. Remove the lock and tag from the main disconnect switch. Recalibrate Intellisys. Refer to Section 3.11. Refer to Section 3.0 Inteliisys for starting instructions. 5.8 STARTER MAINTENANCE SCHEDULE ‘SAFETY Insure that the compressor is isolated from the compressed air system by closing the isolation valve and bleeding pressure from the drip leg. Insure that the main power disconnect switch is locked open and tagged. TOOLS REQUIRED Screw driver Allen Wrench Set Wrench Set 34 GROUND WIRE A\WARNING ye fromnot or ‘ing pr. |] Sst Siow down | ‘Gose isolation vaREMOVE ENCLOSURE Remove enclosure. See ENCLOSURE. Remove starter box cover corner panel Check that all wiring connections are tight — transformer — tie block — terminal blocks — intertace board. Look for any indications of electrical arcing. Remove 1M contactor cover. Check for broken or weak springs. Replace it necessary. Check for severe arcing of contactor points. Replace as required. Before the contactor cover is replaced be certain that no wiring particles or other foreign materials, have been left in or on the contactor. Itis also a good practice before the starter panel cover is replaced to re-check all the wiring connections. Remove all tools or other foreign materials from the starter and replace the starter panel cover. 5.9 MOTOR CHANGE-OUT TOP PANEL SCREWS LATCHES: FRONT VIEW REAR COVER SCREWS ‘SAFETY Before beginning any work on compressor, open, lock and tag the main electrical disconnect and close the isolation vaive on the compressor discharge. Vent pressure from the aftercooler and piping by slightly opening the drip leg valve. ‘When opening the drip leg valve, stand clearof the valve discharge and wear appropriate eye protection TOOLS ~ Metric wrench set - English wrench set & socket set. ~ Allen wrench set ~ Machinist rule - Hand operated gear puller ~ 10" adjustable wrench - Loctite 242 CORNER COVER SCREWS REAR VIEW 35DISASSEMBLY A\WARNING: ‘SAFETY Isolate the compressor from the air and electrical systems and remove the-enclosure. See Section 5.1. Remove the aftercooler tubing from the aftercooler. Remove the starter box cover. Disconnect the motor leads from the contactor and tie off block and remove the motor conduit from the starter box. Loosen the idler shatt (Left Hand threads). Turn the idler adjusting screw to loosen the belts. Remove the belts. Remove the fan, fan hub, and driver sheave from the motor shaft. Remove the motor. Remove the conduit and fittings from the motor conduit box and set it aside to be installed on the new motor. Cemenese sve inpryoraact Dsconectgower ‘etre recing. taadog ot EVALUATION When a motor fails, other components could be damaged. Inspect the following parts and replace if, any damage is noted: Fan and orifice plate, belt, drive sheave, idler assembly, conduit, contact and tie off block, control transformer. REASSEMBLE Reverse procedure. 5.10 COMPRESSION MODULE CHANGE ‘SAFETY Insure that the compressor is isolated from the compressed air system by closing the isolation valve and bleeding pressure from the drip leg Insure that the main power disconnect switch is locked open and tagged. TOOLS REQUIRED Screwdriver Wrench Gear puller for sheave 36 See OperatorREPLACEMENT PARTS ‘The airend exchange includes a complete module, filters, hat switch, relief valve and a change of ULTRA COOLANT. Belts, idler assembly and other components should hhave been examined at the time the replacement module was ordered and replace as necessary. DISASSEMBLY Remove the enclosure. See ENCLOSURE. Remove the belt guard. Loosen the locknut and move the belt tensioner adjusting screw to the minimum tension position. Remove the belts from the driven sheave and the idler assembly. Remove the two screws holding the idler assembly to module. Remove the idler assembly and store for reassembly. Remove the screw, retainer plate, spacer, key, and driven sheave from the module. Drain the coolant from the module and the coolant cooler. Tag for future assembly and remove the oil piping, Remove the air piping. Remove the three screws holding the module to the. base. Remove the module from the base. It weighs about 250 pounds. Use appropriate lifting equipment. Examine the replacement module and transfer fittings, valves, gauges, etc. as necessary from the old module to the replacement module. Apply Loctite PST to all threaded NPT connections ‘except SAE O-Ring type fittings INSTALLATION Using appropriate means and equipment place the module on the base. ‘Assemble the three screws to hold the module to the base. Connect the oil piping, ‘Assemble the control piping ‘Assemble the driven sheave, retainer plate, key and screw to the module. 37INSTALLATION (Continued) Assemble the idler assembly to the module. Install the belts. Align sheaves and tension belts. Fill the system with coolant. Do not overfill. Inspect all connections and assemblies. Replace the belt guard. OPERATIONAL INSPECTION ‘A twenty (20) to twenty four (24) hour run in period is recommended to ensure that the replacement module is leak free, after you have completed a ‘module or component changeout. Control adjustments may be necessary during this period. ‘At the end of twenty (20) to twenty four (24) hours elapsed time on the hour meter, check for leaks and operational set points, correcting as necessary. ASSEMBLE ENCLOSURE ‘Assemble the enclosure, See ENCLOSURE. 5.11 COOLER REPLACEMENT ‘SAFETY Insure that the compressor is isolated from the compressed air system by closing the isolation valve and bleeding pressure from the drip leg Insure that the main power disconnect switch is locked open and tagged TOOLS REQUIRED Screwdriver Wrenches (sizes) REPLACEMENT PARTS Oil cooler (see spare parts list.) Altercooler (see spare parts list.) DISASSEMBLY Remove enclosure. See ENCLOSURE. Remove fan belt guard. Remove the front and rear fan guard. 38DISASSEMBLY (Continued) Remove the air piping from the aftercooler. Drain oil from the system, Remove the oil piping from the oil cooler. Remove the six cap screws holding the cooler box to the base. Move the cooler box to get to the cooler that needs replacement, Remove the fitings as necessary, from the cooler and remove the cooler. REASSEMBLY Replace the cooler. ‘Assemble the fittings to the cooler. ‘Assemble the cooler box to the base with the four capscrews. ‘Assemble the oil piping to the oil cooler. Fill the system with oil. Do not overfill Assemble the air piping to aftercooler. ‘Assemble the front and rear fan guard. Assemble the belt guard. Check all fittings and connections for tightness. OPERATIONAL INSPECTION Start the compressor and run for twenty (20) seconds. Stop the machine, check the oil and add oil as necessary. Do not overfi Check for and correct leaks as necessary. REPLACE ENCLOSURE Replace enclosure. See ENCLOSURE. 5.12 COOLANT/LUBRICANT CHANGEOUT PROCEDURE RECOMMENDATION Instructions Covering Field Changeout of Coolant/Lubricants. ‘SSR Ultra Coolant (Standard Factory Fill) ‘SSR Coolant (Optional) ‘SSR HIF Food Grade (Optional) IMPORTANT: To eliminate confusion concerning the type of fluid to be added as make up coolant/lubricant use the correct decal as outlined in this instruction procedure for SSR Ultra Coolant and SSR H-1F Food Grade Coolant. 39COMPRESSOR COOLANT/LUBRICANT CHANGE. PROCEDURE OBJECTIVE To drain coolant/lubricant from compressor as completely as possible when changing types of coolant/lubricant to avoid contamination or dilution of new fluid. CAUTION Ultra Coolant is not compatible with certain “Compressor Conditioner” fluids often utilized to remove varnish deposits from machines running on petroleum oil products. Addition of these products to Ultra Coolant can lead to plugged filters and bearing lines, potentially leading to severe mechanical problems. Therefore, do not flush the compressor system with a “Compressor Conditioner” prior to filling with Ultra Coolant. NOTE: If changing to food grade coolant/lubricant SSR H-1F, the following procedure is mandatory. The initial fill of SSR H-1F should be run a few hours (2-10 hours) at NO LOAD and then drained. A fresh change of SSR H-1F is then added and the Unit is placed in normal service. CAUTION (SYSTEM CONTAMINATION) The factory does not recommend field changes from SSR Coolant to SSR H-1F based on tests and experience as of January 1986. We believe thatina majority of applications it may be impractical and undesirable to follow this course of action. The residual dye from SSR Coolant will tint the replacement coolant after the double flush pro- cedure has been completed. The factory recom- mends that the customer take this fact into con- sideration before decision is made to make a chargeout utilizing SSR H-1F Food Grade coolant. ITEMS REQUIRED In addition to the tools normally found in any reasonably equipped serviceman’s toolbox, the following items should be available at the work site: A suitable drain pan and container to hold coolant drained from unit. ‘A quantity of proper coolant sufficient to refill the ‘compressor. ‘A minimum of one replacement coolant filter element. 40 a PGS) HOT COOLANT USE CARE CAN CAUSE WHEN SEVERE INJURY DRAINING A\WARNING arene which en eresPROCEDURE Operate the unit to bring the complete system up to operating temperature. Shut compressor down. Initiate remainder of change procedure while system is still warm. Drain the module, lubricant cooler, and any low points in the lubricant piping system. Change the coolant Refill the unit with proper type coolant. Exercise care to prevent entry of any contamination. Start unit and check coolant level. With unit running unloaded the coolant will be visible between the bottom of the sight glass to midpoint of the sight glass. DO NOT OVERFILL. Add additional coolant if required. Check for any leaks. ‘Thoroughly clean a suitable area of the module near the coolant fill connection. Install the correct decal, as shown, for the fluid now installed in the compressor, NOTE: 1. Module area must be dry and completely {ree of dirt prior to applying decal. NOTE: 2, Decals in sufficient quantities must be ordered from Piscataway Parts Center, contact your Ingersoll-Rand distributor. NOTE: 3. Units running on Food Grade Coolant ‘SSR H-1F must have the coolant changed at least every 3000 hours or more frequently under dirty environmental conditions. er element. [AAWARNING | Compressor unt ‘hoped wih Food ‘Grade Coolant. ‘am contamina food or omer posuct inch ean reat ever inury oF Seam IngersolLnana Som nie Foe Grave cota | (hangs cotent Srey 00 hours Steperation, A\CAUTION Use of incorrect coolant can cause system contamination. Use only IR-SSR Ultra coolant, Dion NC 45.13 SHEAVE ALIGNMENT Any degree of sheave misalignment will result in a reduction of belt life Misalignment of V-belt drives should not exceed (030 inches. Parallel misalignment occurs when the driven. shafts are parallel, but the two sheaves lie in different planes. Angular misalignment occurs when the two shafts. are not parallel. ALIGN SHEAVES: ‘An easy and effective method of checking alignment in both directions between the driver and. driven sheaves utilizes an accurate straight edge and a machinist 6 inch scale. Lay the straight edge across the face of the driver (motor) sheave and check alignment of the driven (compression module) sheave. Then lay the straight edge across the driven sheave and check that the driver sheave is aligned. Alignment should be within .030 inch maximum when measuring the gap between the straight edge. and the rim of the opposite sheave in each direction. This alignment is factory set and should only require resetting if the drive motor or compression module is moved. (For example, motor or ‘compression module replacement.) The following steps should be taken to insure proper alignment of all components. Align motor/fan assembly in center of fan orifice ring (belt must be very loose or removed from units). When fan is centered in orifice ring, check sheave alignment. Adjust as required by moving motor/fan assembly in or out of orifice ring. Slots are provided in motor support to allow for this adjustment. Recheck alignment and adjust as required. Once alignment is obtained, tighten motor support to base and motor to motor support. Re-tension belts 42 iG TE vas mas Fe PARALLEL MISALIGNMENT MoouLe ANGULAR MISALIGNMENT5.14 INTERFACE BOARD REPLACEMENT ‘SAFETY Lock and tag the main power disconnect in the open position. Isolate the compressor from the compressed air system by closing the isolation valve and bleeding pressure from the drip leg Remove the starter box cover. Check all the wiring connections before replacing the interface board. A loose wire or bad connection may be causing the problem. If a loose wire or bad connection is not the problem, proceed as follows. Disconnect the two ribbon cables. Use care and enough pressure to be certain that no damage is sustained by the connector. See Figure 13 On the left connector push the locking tabs on the end outward. Plug will move up. Then pull plug straight out. On the right connector rock connector up and down to release. Do not rock sideways. Disconnect the starter and sensor wires (mark or tag) from the interface board following the wiring diagram contained in Section 9. See Figure 14 Using care, remove the interface board from the retaining track. Slight pressure from a flat screw driver will be required. See Figure 14. Hold the old interface board in your hand and remove the option prom from the board. Use extreme care when removing this part since the pins are easily damaged. Use extreme care and insert the option pro- gramable read only memory (PROM) device from the old board into the holding socket of the new in- terface board. By using the index marks on the op- tion prom and the board as a guide a correct match- Up will be made. Pin #1 on the prom should be in the lower left comer. Exert a slight downward pressure to be certain that the option prom is seated properly in the board Ke Key’ ere 435.14 INTERFACE BOARD REPLACEMENT (Continued) Inspect the snap track holder to be certain that no damage has been sustained while removing the old interface board. Replace if necessary. See Fig. 14. Using extreme care, insert the interface board back into the snap track of the starter box. Reconnect the previously tagged wires and re- insert the two ribbon cables. Check for tightness of all wire, cables and option module. Replace the starter box cover. 446.0 SYSTEMS 6.1 GENERAL SYSTEM INFORMATION The compressor is an elecrtric motor driven, single stage, screw compressor-complete with accessories piped, wired, and baseplate mounted. Itis totally self-contained air compressor package. standard compressor is composed of the following: 4. Inlet air filtration 2. Compressor and motor assembly 3. Pressurized coolant system with cooler 4. Separation system 5. Capacity control system 6. Instrumentation 7. Safety provisions Compression Module-Cutaway side-view 1. Rotors 2. Separator 3. Sump 4. Inlet Valve 5. Temperature Control Valve 6. Minimum Pressure/Check Valve 7. Inlet Filter ‘Compression in the screw-type air compressor is created by the meshing of two helical rotors (male and female) on parallel shafts, enclosed in a heavy- duty east iron housing, with air inlet and outlet ports located on opposite ends. The male rotor has, four lobes 90 degrees apart, and the female rotor has six grooves 60 degrees apart. The grooves of the female rotor mesh with, and are driven by, the male rotor. Tapered roller bearings at the discharge end prevent axial movement of the rotors. 1. Rotors 2. Tapered Roller Beaings 3. Roller Bearings 4. Shaft Seal 5. Compression Module The coolant system consists of a sump, a cooler, temperature control valve and a filter. When the unit is operating the coolant is pressurized and forced to the compressor bearings. Safety of operation is provided for excessive discharge temperature by causing the compressor to shut down. Effective coolant filtration is provided by use of a heavy duty coolant filter. ‘The compressor is designed for operation in an ambient range of 35°F to 100°F (2° to 38°C) vanumun paessuRE CHECK Vauve INUgT FILTER ROTORS SEPARATOR ‘TEMPERATURE ‘CONTROL sume COMPRESSION MODULE—CUTAWAY SIDE-VIEW TAPERED ROLLER SEARINGS oupnession mogul ey Ow rotors le fs ROWER BEARINGS SHAFT SEAL SOREW-TYPE COMPRESSOR 45,6.2 COOLANT SYSTEM COOLANT Rotary screw compressor fluids have a triple function to perform in that they lubricate the bearings and contacting surfaces of the rotors, they seal internal clearances within the rotor chamber, and they 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. AXCAUTION SSR air compressors are factory filled with Ingersoll-Rand ULTRA COOLANT. ULTRA COOLANT is designed to operate for 8,000 hours or two years, whichever comes first. ee of neoret ‘toon can enuen ‘Sytem conaminton se on SSR Uta The coolant used in the compressor has been specially blended and formulated to perform the above three functions exceptionally well. Its lubricating qualities exceeded those of standard petroleum oils as well as those of previously available synthetic lubricants. Its viscosity characteristics are such as to provide excellent sealing of internal clearances over broad ranges of ‘operating temperatures. In fact, the viscosity change with temperature is small enough to permit the coolant-lubricant to be used over the entire range of ambients from 35°F to 100°F (1.7°C to 38°C) without significant loss of its qualities, or the cause of problems of any kind, Most important is the performance of the fluid as a coolant. In this function the coolant demonstrates its outstanding abilities. It has exceptional oxidation-stability at system-operating- temperatures so as to provide long life. Advanced- rust-inhibitors assure clean piping, clean cooler tubes and clean compression module internals. Due to the large volume of coolant circulated and its direct contact with the air being compressed, foaming at blowdown or other pressure change conditions is often a problem with rotary ‘compressors. The SSR-ULTRA Coolant has quick air release characteristics and minimum air- entrainment, such that foaming has been largely eliminated as an operating concern, In addition, the coolant has little affinity for water as well as quick, effective water release at shutdown. These characteristics provide maximum bearing lubrication integrity, as even small amounts of water in the coolant can be highly detrimental. 46SERVICE KIT Readily available and normally ordered and shipped with the unit is a service kit which includes air and coolant filter elements. Make up coolant is ordered separately. See recommended spares list. Ifa situation arises where, for some reason this fiuid cannot be used, consult Ingersoll-Rand for specifications and recommendations on possible substitutes. CIRCULATION OF COOLANT Coolant is forced by pressure from the sump to the inlet port of the temperature control valve. The temperature control valve controls the flow of, coolant necessary to maintain a suitable compressor injection temperature. When the compressor starts cold, most of the coolant will by-pass the cooler. As the system temperature rises above the valve setting, the coolant will be directed to the cooler. During periods of operation in higher ambient temperatures, all the coolant flow will be directed through the cooler. ‘The compressor injection minimum temperature is controlled to preclude the possibilty of water vapor condensing in the receiver. By injecting coolant at a sufficiently high temperature, the discharge air Coolant mixture temperature will be kept above the dew point ‘The controlted-temperature coolant passes through the filter to the airend section of the compression module under constant pressure. See Figure 1 FILTRATION OF COOLANT Each compressor has a hydraulic-type-full-flow filter with a single replacement spin-on element. The filter is mounted at the back of the ‘compression module. It is rated at 10 microns. There is a differential-pressure-bypass-valve set to ‘open in the event that the pressure drop across the filter element rises to as high as 15 psi (1 BAR), which indicates an excessively fouled element, as well as poor maintenance practice. The filter element should be changed after the first 150 hours of operation and again after each 1200 hours of operation. The element should also be replaced when the 8,000 hours or the two year coolant change is made, whichever comes first. creoevaLve Samer ao Save COOLANT CIRCULATION SYSTEM FIG. 1 47COOLANT/AIR SEPARATION SYSTEM ‘The coolant/air separation system is composed of a receiver with specially designed internals, a two- stage, coalescing-type separator-element, and provision for the return of the separated coolant back to the compressor. OPERATION The air-coolant mixture discharges from the ‘compressor into the separation system. The system, self-contained in the compressor housing, removes all but a few parts per million of the coolant from the discharge air. The coolant is. returned to the system and the air passes to the ‘optional aftercooler. 6.3 AIR SYSTEM COMPONENTS AND FLOW The air system is composed of: 1. Inlet air filter 2. Inlet valve 3. Rotors 4. Coolant/air separator 5. Minimum pressure/check valve 6. Aftercooler The direction of flow is from the inlet air filter to the aftercooler. FUNCTIONS OF COMPONENTS Intet air filter filters the incoming air trapping all particles 10 micron and larger. Inlet valve opens full for on line/off line operation. The valve shuts in the off line mode and at shutdown to prevent back flow of the compressed air from the sump. The valve modulates in the modulate mode of operation. The rotors compress the air. The coolant/air separator removes most of the coolant from the air. The minimum pressure check valve keeps the sump at a minimum pressure and keeps line pressure from exhausting back through the module at shutdown ‘The aftercooler cools the air and condenses moisture to improve the air quality to 3-5 parts per million of oil carry-over downstream of the moisture separator. See Figure 2. 48 MINIMUM PRESSURE CHECK VALVE SEPARATOR SEPARATOR: GOOLANT SOAVENGE im (LET FILTER, Inter VALVE: ROTORS COMPRESSOR MODULE CUTAWAY SIDE VIEW FIG. 2 SEPARATOR TERCOOLER6.4 CAPACITY CONTROL (ON LINE-OFF LINE CONTROL For those plants which have a widely varying air demand, the on line-off line contro! will deliver air at full capacity, (the compressor maximum efficiency condition) or will operate at zero capacity with low receiver pressure (the compressor minimum power condition). When the compressor is in the on line-off line mode, pressurized air is removed from the inlet valve allowing it to fully open. The blowdown valve closes the atmospheric vent. MODULATE/ACS CONTROL For those plants which have relatively high constant air demand, relative to the compressor capacity, the recommended control mode is modulation. The modulation control system retains the features of the on line-off line control, but provides for throttling of the inlet flow up to the off line air Pressure set point value. By applying line pressure to an adjustable modulator valve, the throttling position of the inlet valve is controlled, thus allowing the modulator to “trim” the inlet valve position as dictated by the line pressure. The modulating pressure range is about 4 psig (0.3, BAR) and the modulator is factory set to straddle the compressor rated pressure. Modulation be when the line pressure reaches about 99 percent of the compressor rated pressure and continues as/if the line pressure rises. Modulation becomes stable when the compressor output equals the plant air demand. When the modulation is at the factory setting the maximum capacity reduction will be down approximately 60 percent of the compressor rated capacity (as indicated in Figure 3). If the air demand has decreased to a level below the 60 percent modulated output, the line pressure will increase slightly to actuate the Intellisys. The ‘compressor will then shift to the off line control n, and operate unload with the compressor It is sometimes desirable to begin modulation at a higher pressure than the standard factory setting, thereby increasing the modulated capacity at the @ the Intellisys is actuated. Refer to Figure 3 for modulated capacities available when this is done. SOF RATED CAPACITY FACTORY opTIONAL INTELUSYS SETTINGOF FIELOSETTINGS OFF-LINE. MODULATOR GFMODULATOR SETPOINT \ NY wie 10102108 4% OF RATED LINE PRESSURE FIG. 3 IMOoULATE TO, 8 CAPACITY MODULATE TO Bo CAPACITY MODULATE TO TE CAPACITY MooULATE TO 49MODULATE/ACS CONTROL (Continued) The compressor will then operate to deliver full capacity air to the plant system. If the plant air system pressure rises to that of the Intellisys off line set point, pressurized air will be sent to the inlet valve causing it to close, and to the blowdown valve, causing it to open. ‘The compressor will continue to run unloaded, but since pressure levels have reduced, it will do so with a minimum power draw. The Intellisys has a fixed minimum differential of 10, psi between the off line air pressure setting and the ‘on line air pressure setting. The differential may be increased by adjusting the on line air pressure setting of the Intellisys, Refer to Section 3.10 for instructions. ‘The automatic control selector (ACS) is designed to continuously monitor the plant air demand and select either the on line-off line, or the modulate control mode - whichever is most desirable at anytime during an operating day. Itallows the compressor to operate in its most, efficient mode without attendance, thereby reducing power costs to a minimum, When the compressor operates in the on line-off line contro! mode, the length of time the ‘compressor remains in the “off line” condition is an indication of the plant air demand. Intellisys controller is sensing and awaiting a sufficient line pressure decrease before signaling a shift to the on line mode. If the “off line” time period is relatively short, thereby indicating a high demand for air, itis preferable to shift the control system to upper range modulation. The Intellisys does this, and does it automatically if the compressor unloads 3 times within a 3 minute time period. If later, the plant demand decreases, and even under modulate control the line pressure reaches the setting of the Intellisys controller, and the Control shifts to the “off line” mode, the time in this mode will still be monitored. A long “off line” time- period indicates a low plant air demand, indicating the desirability of operating in the on line-off line mode. The Intellisys then does this, and does it automatically if the compressor operates unloaded for more than 3 minutes. 50 RATED MODEL | OPERATING PRESSURE XFE/LE ___ 100 PSIG EPE/HE 125 PSIG HP/HH_ 150 PSIG XPIX 175 PSIGMODULATE CONTROL VALVE ADJUSTMENT SAFETY Insure that the compressor is isolated from the > ‘compressed air system by closing the isolation valve and bleeding ‘pressure from the drip leg. Insure that the main power disconnect switch is locked open and tagged. 1. Remove the 1/8” NPT plug from’the tee on the side of the module. Connect a pressure gage to this port 2. Loosen the adjustment screw locknut and back out adjusting screw 3 turns. See Figure 4. 3. Open the isolation valve and start the compressor. 4. Press LOAD twice to put the compressor in the MODULATION/ACS mode. 5, Make the machine load and unload three times A by closing and opening the isolation valve. This will make the compressor modulate. 6, Adjust the isolation valve to bring the discharge air pressure to the rated discharge pressure (100, 125, 180, or 175 psi). 7. While MAINTAINING the rated discharge Pressure, turn the adjustment screw on the modula- tion valve so that the test pressure gage reads: 34 psig for modulate to 60% cfm 31 psig for modulate to 70% cfm 26 psig for modulate to 80% cfm 22 psig for modulate to 90% cfm Tighten the adjustment screw locknut B ADJUSTING SCREW 8. Press UNLOAD STOP. Wait for sump pressure Fig. 4 to go 0 psig. Close the isolation valve or bleed off MODULATGNIVALTE all system air 9. Remove the test pressure gage and replace the 1/8” NPT plug using Loctite® PST or a similar pipe fitting sealant “Loctite is a registratered trademark. 517.0 TROUBLE SHOOTING 7.4 INTELLISYS FAULT SIGNALS ‘The intellisys is programmed to identity twelve (12) faults, These faults are bracketed by minus signs and are two digits, 01 through 12. ‘The fault must be corrected before trying to clear the fault message and restarting the compressor. ‘Once the fault is cleared, press SET two times, the fault message will clear and the numeric display will show -0- ready to start. It SET is pressed a third time, you will be in the set mode. Press display select to get back to ready to start ‘THE FAULT SIGNALS ARE: 7.2 STARTER FAILURE — defective starter interlock — detective starter coil — no 110 VAC control voltage to starter —_ hat switch defective or open 7.3 MOTOR OVERLOAD — excessive main motor amps — motor overload relay has tripped — motor overload relay defective 52 7.4 HIGH DISCHARGE AIR TEMPERATURE — discharge air temperature has exceeded set point limit — limit is adjustable trom 200°F to 228°F 7.5 HIGH DISCHARGE AIR PRESSURE — the line pressure has exceeded the rated operating pressure by 15 PSIG 7.6 TEMPERATURE SENSOR FAILURE — sensor connections are defective — sensor wires are broken — sensor is defective 7.7 PRESSURE SENSOR FAILURE — sensor connections are defective — sensor wires are broken — pressure connections to line/sump solenoid valve are defective — sensor is defective —_ line/sump solenoid valve is defective — after sensor replacement, see Section 3.11 for recalibration7.8 EMERGENCY STOP — the emergency stop button was depressed — the emergency stop button must be turned to release it from the stop position 7.9 EMERGENCY STOP BUTTON ENGAGED — must be manually re-set 7.10 MICROPROCESSOR FAILURE — contact service representative — replace Intellisys 7.11 REMOTE STOP ENGAGED — remote stop feature is operative and remote stop button is held engaged, defective, or not. 7.12 LOW VOLTAGE — power drop internal external 7.13 INCORRECT COMPRESSOR ROTATION — line voltage connection to starter incorrect — interchange any two line voltage connections (L1, L2, L3) at the starter { the unit is shutdown and displays all 8888's, push the “SET” button. 53TROUBLE SHOOTING CHART [Compressor fails to start. 115V control voltage not available. Intetlisys failure. Defective starter. Intetlisys fault (Check fuses in starter or the disconnect [on the wall. Check control power transformers and wiring connections. Replace Intellisys, Inspect contactor. Replace starter if required, ICheck Intellisys display for error code. [Consult manual for error code explanation land how to correct. [Compressor fails to stop. Intellisys failure. Defective starter. Open disconnect. Replace Intellisys. Inspect starter contacts. Replace [contacts in contactor. Repeated shutdowns. (Alarm light on) High amp draw. Defective starter. }115V control voltage not available. Motor overload. Incorrect overload heater size. Line voltage variation. Compressor operating above rated pressure. V-belts slipping Dirty separator element. Low voltage. Exceeds -10% lof nameplate volts. Low power factor. |Unbalanced line voltage. Unequal voltage in all 3 phases. inspect and replace. ICheck fuse in starter and the disconnect lon the wall. Check contro! power transformers and wiring connections. ICheck intellisys set points. Adjust as required. Check separator delta-p. Replace element it required. Replace with correct size Check supply voltage in all 3 legs. Operate at rated pressure. Adjust belt tension. ICheck separator delta-p. Replace element if pressure drop is 3 times initial pressure drop. ICheck supply voltage from power distribution system, install power factor correction capacitors. Review with power company. ICheck leads and connections to motor. Dirty air filter element. Compressor operating at part load or unloaded. High voltage. Exceeds +10% Jot nameplate volts inspect element. Replace. Adjust Intellisys set points. ICheck control system operation. ICheck supply voltage from power distribution system. Low air system pressure. 54 incorrect Intelisys set points High separator delta-p. Defective minimum pressure check valve intelisys off-line set point too Tow Dirty ar fiter element. V-belts slipping, Air system leaks. Moisture separator trap drain stuck open. Inlet valve not fully open. [System demand exceeds compressor delivery. [Check and adjust as required. ICheck. Replace separator element. inspect and replace ICheck set points. Adjust as required ICheck delta-p indicator. Inspect element. Replace as required. Adjust belt tension. inspect and repair. inspect and repair. inspect and repair. Check control system loperation. Close off block valve on discharge of lcompressors and see if unit pumps up to rated pressure and unloads. if it does, install a larger compressor.TROUBLE SHOOTING CHART (Continued) TROUBLE [CAUSE |__ WHAT TODO Unit running hot. [Unit running cold. lOi/attercooler cores dirty. Compressor operating above rated loperating pressure. Low oil level High ambient temperature, above 100°F. Restricted cooling air flow. fective thermal control valve. [Compressor operating at part load. Inspect and clean. Consider moving com- pressor to cleaner operating conditions. lOperate at rated pressure. Re-adjust set points. ICheck. Add to correct level. Relocate in cooler environment. Provide jadequate ventilation. Provide recommenced clearances around unit, as well as adequate ventilation. Replace. |Adjust capacity control [High oi consumption/oil in air system, Excessive oil level. Plugged separator element. Separator element leak Plugged separator scavenge orifice/screen. ICompressor operating at low pressure (75 PSIG or below). [Coolant system leak. ICheck for proper level. Lower if Inecessary by draining coolant. ICheck separator delta-p. Replace element if pressure drop is 3 times initial pressure drop. ICheck for low separator delta-p. Replace Jelement. Remove and inspect orifice/screen. Clean if required. Operate at rated pressure. Reduce system load, so discharge pressure rises. inspect and repair leaks. Excessive noise level. Defective moisture separator/drain trap. Trap drain or drain piping plugged. JAftercooler core dirty. INo aftercooler on unit, Drain line/drip leg incorrectly installed. No refrigerated or descicant dryer in air system. V-belts slipping, ICompressor detect rotor contact. Enclosure not in place, Loose component mounting . Bearing failure or inspect and clean if required. Replace separator/trap if detective. Inspect and clean. inspect and clean. Install aftercooler. Slope drain line away from trap. Install drip] leg Contact local Ingersoll-Rand distributor for quote. [Adjust belt tension or replace belts, |Contact authorized distributor immediately. [Do not operate unit. Install enclosure. Inspect and tighten. [Excessive vibration [Shaft seal leak Pressure relief valve opens. Loose components. Defective idler assembly. Motor or compressor bearing failure. External sources. Detective shaft seal Compressor operating over pressure. Defective valve. inspect and tighten. inspect and replace parts as necessary. |Contact authorized distributor immediately. [Do not operate unit. Inspect area for other equipment. Replace per this manual or contact, Jauthorized distributor. [Adjust Intellisys set points. Replace, Black residue on belt lguards/cooler box. JV-belts loose. [Sheaves mis-aligned. Excessive belt wear. [Adjust belt tension.8.0 OPTIONS 8.1 AUTOMATIC START-STOP CONTROL Many plant air systems have widely varying air demands and large air storage capacity which allows the operation of the compressor on automatic start and stop. The Intellisys system has been designed to carry out this function utilizing a software prom insert. Automatic start and stop is available from the factory as an option, This option is also available as a field installed kit. Contact your nearest Ingersoll-Rand distributor for details. 8.2 REMOTE START-STOP OPTIONS This option allows for remote operator control of the compressor unit. The option may be factory installed or field installation kits are available. The option software is also a plug in prom. 8.3 AUTO-START-STOP AND REMOTE START-STOP When both auto-start-stop and remote start-stop are desired, a field installation kit is available. This option is a combination piece of software (prom) that is easily installed inside the compressor starter enclosure. With this option both Intellisys functions are activated, 569.0 REFERENCE DRAWINGS 9.1 WIRING DIAGRAMS-ELECTRICAL 87Nvid NOLLWANNOd z'6 MIA LNOS =I =} ONVEFTIOSUSDNI MIA don 58NV1d NolLvaNnod €°6 main WouLOa 8 anveriosuzoni = = /® / j | /G3SOTONSNN NVTd NOLLVGNNOS #°6 a (a0 no > a (eco) Hea wa aT nS Bees sw 008 sOuvNSSIS oy {x09 wausvis Ms a31¥907 °aL0} ‘hd HUIM 3OUVHOSIG UY add LON 00 *L Taaiuoaane 39 10 dV ONY douvirvds 3UMLSIOW) 83003 40 SIN3NOW G3ATOSaUNN, “TWHS SNOILORNOD s3018: aLUVIS OL IZINI HMOW NON uu 40 HONS NIM = oo 60ANNOW YNVL NV1d NOLLVANNO4 $6 a oe] faved 6O14 WALSAS HIV 96 G3SO10 ATIVWHON - ON NaAdO ATIVWHON - ON ONIdld WNUSLNI ONIdId WNYILX3 —— BAIWA YyOLVINGOW M3Y9S oNntisnrav (ASoL) 3a-AVA GIONS 10S ANaw3I3 (AS2) 3AIWA GION 30S dWns/3Nt4 yo lWuvd3s Nol LY IAGO CWNY3END BA WA NModMONd og woo A, ME on NI ; ino YOSN3S ION iy x ze pees TE poo 3AqWA wOLVuVdaS q q DiGi) oan eee dR Lua 100 ou3L av. {| FN BAWA (0) se einos E x ‘ 13WI BAWA 1931 © waits uv BUNSS3Yd WAWININ \e 3AWA 391 4140 | 3TLiAHS ‘_nmoamo 18 (ASL) BAWA GION 3105 avo71Nnn 626 £ B “t TYPICAL SYSTEM FLOW DIAGRAM ‘OUTSIDE ‘COMPRESSOR SYMBOLS aooal GLADHAND Emergency Standby Ar Hook Up. Comp forPonable or Rental Air Un irom Lo VALVE Water Or Ball Type Valve UNION Aids in Dlsconnecting Compressor rom he System ‘THERMOMETER DIFFERENTIAL PRESSURE INDICATOR FALSELOADER lows oll ir Outside of Compressor Room AFTERCOOLER/SEPARATOR, ISOLATION VALVE, UNION, STRAINER AND TRAP. 9.7 TYPICAL SYSTEM FLOW DIAGRAMS 63REMOTE INLET FILTER AND PIPING Day TYPE s Best \ocTeook BECAUSE PEOPLE 2 eveanesr BonorKeer on 33 BhveSt (AWAY FROM STEAM VENTS OR COOLING TOWERS) Were ol gare 3} ume’ ke-rnee piace irngUT Oi pes {8} GENERALLY THis WiLL BE OUTDOORS & UP ON THE ROOF. NOT FILTER WELL 7 5 Brace InceT eet | gerne OR aT WA OR MANOMETER TO MONITOR OP OR AT WALL ‘COMPRESSOR a. TEMPORARY INLET SCREEN ‘TO REMOVE WELD BEADS & SCALE Low POINT DRAIN — ALWAYS FABRICATE INLET PIPING FROM ') SCHEDULE 40 ON ROTARY PVC 2) STEEL PIPE FABRICATED AND FLANGED IN SECTIONS, ‘GLEAN 8 EPOXY PAINT INSIDE ~ PREVENT RUST. a STAINLESS set Sacomnow 5} ALWAYS CLEAN INTAKE PIPE THOROUGHLY {WELD BEADS, SCALE, RUST, DIRT, ETC) ‘TYPICAL ROTARY Ne 9.7 TYPICAL SYSTEM FLOW DIAGRAMS (Continued) 64RECEIVER AND NLM CLEANUI conraot | _sy >t Dt mu rc ® (00 NOT PIPE TRAPS UP-HILL OR TOGETHER @ HAL NUM-1 AND NLM NOT. NECESSARY ON MLMCa/A's [AND 6 wien HAVE. FLANGED CONNECTIONS. PRE FILTER BEFORE REFRIGERATED (Of DESICCANT DRYER ® PRE-FILTER & DRYER WITH BLOCK & BYPASS. Ea ne MODULE PREFILTER| ‘SOME REFRIGERATED ORYERS HAVE A CONDENSATE. DRAIN ON AIR TO AI (PRECOOLERMMEHEATER) ExCHancen Too. 9.7 TYPICAL SYSTEM FLOW DIAGRAMS (Continued) omens REFRIGERATED TYPE. 65DRYER WITH POLISHING (NLM OR I C SERIES) OR PARTICULATE IR P SERIES (FOR DESICCANT DRYERS) oh th @ on — HH iHek kH Lie ; it peu t IAP SERIES OF a eee and Th 3 arten. FIcreR SLOPE HEADER Tortow PONT” ie! | © ne [— DeWeomr HYGROMETER LUBRICANT INDICATOR yTEMP \ PRESS ate FALSE LOADER (IPE OUTSIOE 0 SILENCER) 1 THe POINT OF USE Kin QuaLity \S sTRICTLY REQUIRED TO Be VERY CLEAN. THE RECEIVER INTERNALS SHOULD BE GALVANIZED STAINLESS STeeL WALL SRVINYL COATED ETC. 9.7 TYPICAL SYSTEM FLOW DIAGRAMS (Continued) 66TYPICAL RECIP OR ROTARY e WHR PIBELINE AFTERCOOLER Fe] © 9.7 TYPICAL SYSTEM FLOW DIAGRAMS (Continued)NOTES:10.0 PARTS LIST INTRODUCTION GENERAL This manual, which contains an illustrated parts breakdown, has been prepared as an aid in identify ing and ordering parts in the SSR compressor. All of the compressor parts, listed in the parts breakdown, 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 Com- pany subsidiaries and authorized 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 *0000 U MANUFACTURED IN U.S. I YEAR OF MANUFACTURE REVISION LEVEL, DESIGNATION FOR SPECIAL UNITS SSR compressor. A series of illustrations show each part clearly and in it's correct location relative to the other parts in the illustration. Each part on an illustration is referenced with a number. The number, description and quantity needed per assembly is listed in numerical 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 Ref. indicate that the item is located elsewhere in the parts list. OPTIONAL EQUIPMENT Several optional accessories/ items are available for convenience ‘or special application. These accessories have been selected as being particularly suitable for use on the SSR compressor. For complete details on Optional Equipment, contact your Sales Representative 90 A S HOW TO USE THIS PARTS MANUAL, 1. Turn to the Parts Section to locate the desired illustrations. 2. Locate the part on the illustration. by visual identification and the reference number. 3. Find the referenced number on the Tabulated page, along with the Part Number and Description 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 ‘number, description and quantity needed exactly as listed. 5. The motor data code shown ‘on the motor data plate.soyeigsKsyoqu, 1 einbig 70sousemieIs 6 — Z6E6/8S6 “OZL de1-s19S zo Xoz-v/t'melog 6 G6OBLYIEE “zt Aejoy Peouend | E9EPOLEE “Set CON-O'N) Uolimg YOOWDUL 1 —9zLSLLGE “GZL Plog e-SIORUOD 1 —LPSPLIBE “OL Nod | ppizsiee “Bet Pueng ‘ieued 4 OPOLLYBE “82 (wi)soeuod i oLi2oLee “Wel hq rubrens TO € ZS/M 262NOA Nd 2921S “ZL .9'1 0}98UU09, zozeries 22 . Ad Xei5 GL UMPUOD “ULOS SBLZPLBE “SE JoseMieIS Z686LE96 “OIL UNPUD GL 'MOGIS 1 ZOvELLGE “Sz. 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