Ingersoll-Rand IRN250-300H-2S, IRN37-160K-CC manual Operation and Maintenance Manual

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IRN37−160K−CC

IRN50−200H−CC

IRN75−160K−2S

IRN100−200H−2S

IRN250−300H−2S

OPERATION AND MAINTENANCE MANUAL

Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

Ensure that the Operation and Maintenance manual is not removed permanently from the machine. Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

TM

C.C.N. : 54731245

DATE : DECEMBER 2007

REV. : J

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Contents Operation and Maintenance Manual AIR Compressor Group Bonded Warranty & Registered Start UP Contents If in Doubt Consult Supervision ForewordSomer FOREWORD Energy recovery system Abbreviations & SymbolsERS F.CRotary Screw AIR Compressor Purchase Order DetailsThis unit was purchased from General Information SafetyCompressed air Avoid INGESTION, Skin Contact Inhalation of Fumes MaterialsTransport ElectricalCoolant disposal Condensate disposalDischarge air Text DecalsLift here 39540257 Rev RotationCondensate Drain Electrical power inlet Prohibition / Mandatory Information / Instructions Safety Graphic Form and Meaning of ISO SymbolsDo not stand on any service valve or Safety Coolant Separator Pressure AIR Discharge Belt Tension Filter Motor Lubrication Receipt Receipt / HandlingIngersoll Rand Company Unpacking and HandlingLocation in Plant InstallationFor technical information see section Ensure that the correct tie down points are usedInstallation Discharge and Condensate Piping Installation Electrical Fuse Type Installation Very ImportantExample of voltage imbalance calculation Cooling Water Piping Adjusting the Aftercooler Trim ValveModel Minimum cooling water requirement vs Range 50F 70FWater quality recommendations Orifice diameter in mm Installation SEA Watercooled Units Selected Units onlyPsi Outdoor Sheltered Installation Technical INFORMATION-SINGLE Stage General InformationCooling clean water flow l/min US 51/38 95/46 Minimum ambient temperature C F Weight Kg lbsSound pressure level dBA Flow at 7.5 Barg m3/minMax fuse size @ 380V − 415V a Cooling clean water flow l/min US 84/65 95/72Max fuse size @ 440V − 480V a Max fuse size @ 550V − 575V aN132K N160K N200H General Information Technical Information − TWO Stage Flow at 100 psig cfm 1100 59331690 1527KEY Installation DRAWING−N37/45K−CC & N50/60H−CC − Air CooledInstallation DRAWING− N37/45K−CC & N50/60H−CC − Water Cooled Installation Drawing − N55/75K−CC & N75/100H−CC − Air Cooled Installation DRAWING−N55/75K−CC & N75/100H−CC−Water Cooled General Information General Information General Information General Information KEY 22381206 Revision B Equipment downstream of compressor Stage only 23128994 Revision aAir/coolant Coolant Condensate Cooling water W.C. only 22099006 Revision C General Information 22402135 Revision C Process and Instrumentation Diagram N250−300H TWO StagePiping legend Stop FD Wiring Schematic N37K − N45K-CC / N50-60h−cc a/c blower vfdNumbers Function Wire color WiresLabel Description Wiring schematic n55-75k-cc / n75-100h-cc a/c Blower vfdSS1-3 Wires Numbers Function Wire colorSgne Wiring schematic n37/45k-cc/n50/60h-cc w/cColor 23131345 Revision a Wiring schematic n55-75k-cc / n75-100h-cc W/c4ATT SENSOR, Package AIR Discharge Temperature 4CTT 22093058 Wiring schematic n75-160k-cc / n125-200h-cc A/cRevision M SGNe F10Revision E Wiring schematic n75-160k-cc / n125-200h-cc W/c4SV VALVE, Water Stop 6APT 380-480V SG-Ne Wiring schematic n250-300H4ATT SENSOR, Package AIR Discharge Temperature 6APT General Information General Description Basic Operation Operating InstructionsStopping the machine in an emergency Arrows Intellisys ControlsMain Menu Display ScreenCurrent Status items Current Status ScreenReady to Start Main MenuOperator Setpoints Operator Setpoints Default MIN MAX Step UnitCondensate Interval Selection MIN MAX OptionsScheduled start Sensor CalibrationClock Functions Alarm HistoryEnergy Status Messages Initial Check Alarms Service WarningsAlarm Main Menu AlarmsMaintenance Ultra Coolant Maintenance Procedures Prior to attempting any maintenance work, ensure that− Adding coolant Prior to starting Coolant level checking procedureSeparator element checking procedure Coolant filter change procedureSeparator element change procedure Drain sequence for N250/300H−2SScavenge screen clean/check procedure Separator element change procedure for N250/ 300H−2SStart the compressor and check for leaks and coolant level Separator tank / Pressure systemAir filter change procedure N250/300H−2S Air filter change procedureAircooled Cooler Cleaning Blower motor Re−GreaseN50/100H N37/75K High Airend Temperature Sensor checking procedure Watercooled Cooler CleaningCoolant Coolers AftercoolerMotor cowl cleaning N75−160 units only Blower / fan Motor Bearing Maintenance Stored unitsDrive Box Filter Removal / Replacement Moisture Separator Check / CleaningCoolant Sampling Procedure No Loss Drain Trap where fitted Check / CleaningFluid and Vibration Monitoring General Faults Fault FindingSymptom Fault Remedy Compressor will not No power supply to packageCheck and modify settings With correct coolant Or not sealing correctlyWith coolant’ See aboveRemove blockage, repair or replace damaged Pressure transducer Fault Cause RemedyFault Cause Action Drive FaultsIndicated on the INTELhYS Controller