Ingersoll-Rand IRN100-200H-2S, IRN37-160K-CC, IRN250-300H-2S, IRN50-200H-CC manual N50/100H N37/75K

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10.0 MAINTENANCE

N50/100H (N37/75K)

Following are instructions for tilting the cooler away from the enclosure and cleaning of the cooler.

•Remove 6 screws from lower rear fixed panel and remove panel.

•Remove 10 screws from the rear intake panel and remove panel.

•Loosen clamp and disconnect the air inlet hose from the intake plenum.

•Remove intake plenum. Note, plenum is unsupported, before removing the 8 screws from the intake plenum, block underside of plenum prior to removing screws to prevent plenum from falling.

•Remove hose from elbow in aftercooler inlet. Plug elbow in inlet hole of aftercooler.

•Unscrew the fitting connecting the aftercooler to the discharge tube.

•Loosen mounting bolts on moisture separator to allow moisture separator to slide down in mounting bracket. Once lowered, remove the discharge tube connecting the moisture separator to the aftercooler outlet.

•Plug aftercooler discharge hole.

•To tilt cooler forward, remove 6 screws holding the cooler in place. While removing the last screw, hold the top of the cooler in place to prevent the cooler from tilting. Once the screw is removed, allow the cooler to tilt forward until the pivot brackets touch the pivot stops. The cooler will stop tilting at 45 degrees.

•Cover the main drive motor with plastic sheeting to prevent cleaning solution from entering the motor.

•Before cleaning coolers, check to ensure aftercooler intake and discharge holes are plugged to prevent contamination of compressor system. Clean coolers with a mild cleaning solution.

warning

Strong cleaners can harm aluminium cooler parts. Follow cleaner manufacturers instructions for use. Wear appropriate safety equipment.

•After cleaning is complete, reassemble in reverse order.

N125/200H (N90/160K) SINGLE STAGE and N100/200H (N75K−160K) TWO STAGE

The coolers in these machines can either be cleaned by removing the complete cooler for off site cleaning or ’back flushing’ in place using a high pressure hose and gaining access through the holes in the intermediate plenum.

Instructions for cleaning the coolers while installed in the compressor.

While cleaning coolers, great care must be taken to protect the rest of the machine from moisture and contamination by covering sensitive parts with plastic sheeting.

•Remove 4 screws from enclosure panel below moisture separator and remove panel.

•Remove 4 screws from enclosure panel above moisture separator and remove panel.

•Remove the 16 screws securing the access panels on the cooling plenum and remove covers.

•Cover main drive motor, PDM Heat sink blower motor, drain valve, and cooling motor variable speed drive with plastic sheeting to prevent damage from entrance of cleaning solution.

•Cover inlet of blower wheel with plastic sheeting to prevent entrance of cleaning fluid.

•Cover the inlet grill of the intake panel with plastic sheeting to prevent cleaning solution from exiting the compressor.

•Attach drain hose to the coupling on the bottom of the plenum to allow the cleaning solution to drain outside the compressor. Alternately, place large bucket underneath plenum to collect cleaning fluid.

•Use an extended length nozzle and a mild cleaning solution to clean the coolers.

warning

Strong cleaners can harm aluminium cooler parts. Follow cleaner manufacturers instructions for use. Wear appropriate safety equipment.

• Cleaning fluid will collect on both sides of the cooler core. If required, periodically drain fluid from intake plenum and bucket to prevent them from over flowing.

•After cleaning is complete, dry off plenum, intake, and cooler core. Reassemble parts in reverse order.

If the cooler cores are unable to be cleaned while in- stalled in the compressor, remove cooler as follows:

•Remove 5 screws from panel below the intake panel and remove panel. Be careful not to damage the electrical leads entering the panel.

•Remove 8 screws from the intake panel and remove panel.

•Remove 8 screws from the intake plenum supports and remove the supports.

•Remove the 10 screws securing the intake plenum and remove the plenum

•Disconnect both oil lines and both air lines from the cooler. Plug all 4 inlets to prevent cleaning fluid from entering the cooler cores.

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 Energy recovery system Abbreviations & SymbolsERS F.CThis unit was purchased from Purchase Order DetailsRotary Screw AIR Compressor Compressed air SafetyGeneral Information 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 Example of voltage imbalance calculation Installation Very ImportantFuse Type Cooling Water Piping Adjusting the Aftercooler Trim ValveModel Minimum cooling water requirement vs Range 50F 70FWater quality recommendations Psi Installation SEA Watercooled Units Selected Units onlyOrifice diameter in mm 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 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 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 / CleaningFluid and Vibration Monitoring No Loss Drain Trap where fitted Check / CleaningCoolant Sampling Procedure General Faults Fault FindingSymptom Fault Remedy Compressor will not No power supply to packageCheck 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
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