Ingersoll-Rand IRN75-160K-2S, IRN37-160K-CC, IRN250-300H-2S, IRN50-200H-CC Maintenance Procedures

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10.0 MAINTENANCE

Note:

On some sea watercooled models the oil cooler and aftercooler are fitted with sacrificial zinc anodes (pencils) that are located in the end bonnets of the coolers. These sacrificial zinc anodes should be checked after the first 50 hoursof operation to determine if corrosive conditions exist. If satisfactory this interval may be extended to 500 hours.

NOTE:

1.If sacrificial zinc anode is 50% corroded it should be replaced.

2.Coastal/harbor waters can contain corrosive chemicals from pollution and may reduce anode/cooler life.

3.Effects of corrosion or erosion are specifically excluded from warranty considerations.

10.3 MAINTENANCE PROCEDURES

caution

Before beginning any work on the compressor, read and understand the safety instructions earlier on in this manual. Open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Do not under any circumstances open any drain valve or remove components from the compres- sor until this has been carried out. Ensure that all pressure has been vented from the compressor. Verify this by slowly unscrewing the coolant fill cap one turn. Unscrewing the fill cap opens a vent hole, drilled in the cap, allowing pressure to release to atmosphere. Do not remove the fill cap until all pressure has vented from the unit. Note that pipework downstream of the separator tank may still contain pressure that must also be vented to atmosphere before beginning any work.

caution

When using any form of liquid for cleaning, ensure that all electrical components are protected or covered to prevent ingress of liquid.

warning

This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any work on the drive unless trained. There are no user serviceable items behind the cover.

danger

This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the internal capacitors store a potentially lethal high voltage electric charge which gradually falls to zero over time. After switching off the machine at its local isolator WAIT AT LEAST 15 MINUTES for the capacitors to fully discharge before opening the power drive module doors.

warning

The compressor can operate in a pressurised shutdown mode. If the compressor stops automatically, the airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through which any residual pressure will be vented. Downstream of the separator tank may still contain system pres- sure which must also be vented.

warning

Use suitable equipment for lifting heavy items and ensure loose components are adequately supported to eliminate risk of dropping.

warning

The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with cardiac pacemakers, defibrillators or other implanted electronic medical device.

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S

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Contents Operation and Maintenance Manual AIR Compressor Group Bonded Warranty & Registered Start UP Contents Somer ForewordIf in Doubt Consult Supervision FOREWORD F.C Abbreviations & SymbolsEnergy recovery system ERSThis unit was purchased from Purchase Order DetailsRotary Screw AIR Compressor Compressed air SafetyGeneral Information Electrical MaterialsAvoid INGESTION, Skin Contact Inhalation of Fumes TransportCoolant 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 Unpacking and Handling Receipt / HandlingReceipt Ingersoll Rand CompanyEnsure that the correct tie down points are used InstallationLocation in Plant For technical information see sectionInstallation Discharge and Condensate Piping Installation Electrical Example of voltage imbalance calculation Installation Very ImportantFuse Type 50F 70F Adjusting the Aftercooler Trim ValveCooling Water Piping Model Minimum cooling water requirement vs RangeWater quality recommendations Psi Installation SEA Watercooled Units Selected Units onlyOrifice diameter in mm Outdoor Sheltered Installation Technical INFORMATION-SINGLE Stage General InformationFlow at 7.5 Barg m3/min Minimum ambient temperature C F Weight Kg lbsCooling clean water flow l/min US 51/38 95/46 Sound pressure level dBAMax fuse size @ 550V − 575V a Cooling clean water flow l/min US 84/65 95/72Max fuse size @ 380V − 415V a Max fuse size @ 440V − 480V aN132K N160K N200H General Information Technical Information − TWO Stage 1527 5933Flow at 100 psig cfm 1100 1690KEY 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 Revision M Wiring schematic n75-160k-cc / n125-200h-cc A/c22093058 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 procedureDrain sequence for N250/300H−2S Coolant filter change procedureSeparator element checking procedure Separator element change procedureSeparator tank / Pressure system Separator element change procedure for N250/ 300H−2SScavenge screen clean/check procedure Start the compressor and check for leaks and coolant levelBlower motor Re−Grease Air filter change procedureAir filter change procedure N250/300H−2S Aircooled Cooler CleaningN50/100H N37/75K Aftercooler Watercooled Cooler CleaningHigh Airend Temperature Sensor checking procedure Coolant CoolersMoisture Separator Check / Cleaning Blower / fan Motor Bearing Maintenance Stored unitsMotor cowl cleaning N75−160 units only Drive Box Filter Removal / ReplacementFluid and Vibration Monitoring No Loss Drain Trap where fitted Check / CleaningCoolant Sampling Procedure Compressor will not No power supply to package Fault FindingGeneral Faults Symptom Fault RemedyCheck and modify settings With correct coolant Or not sealing correctlyRemove blockage, repair or replace damaged See aboveWith coolant’ Pressure transducer Fault Cause RemedyIndicated on the INTELhYS Controller Drive FaultsFault Cause Action