Ingersoll-Rand Understanding High Sump Pressure Alarms in Air Compressors

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The possible Alarm messages are as follows.

CHECK INLET CONTROL- This will occur if the machine is unloaded and the inlet vacuum is less than 3 psig (.2 bar).

CHECK INLET CTRL SYS 1 (2) - This will occur if the inlet butterfly valve fails to open or close properly. A 1 means the inlet valve failed to closer properly. A 2 means the inlet valve failed to open properly.

CHECK MOTOR ROTATION- This will occur if the machine is started and the compressor has incorrect rotation.

CONTROL POWER LOSS- This will occur if the controller detects a loss of the 110 VAC or 120 VAC control power.

EMERGENCY STOP- This will occur if the Emergency Stop button is engaged. The button must be disengaged before the alarm can be cleared.

FAN MOTOR OVERLOAD- This will occur if a fan motor overload is sensed.

HIGH AIREND DISCH TEMP- This will occur if the airend discharge temperature is greater than 228°F (109°C).

LOW SUMP AIR PRESSURE- This will occur if the machine is running fully loaded and the sump pressure drops below 20 psig (1.4 bar).

LOW UNLOAD SUMP PRESS- This will occur if the machine is running unloaded and the sump pressure is less than 15 psig (1.0 bar) for 15 seconds.

MAIN MOTOR OVERLOAD- This will occur if a drive motor overload is sensed.

CHECK SET POINTS- This will occur if the controller has determined some of the data stored in memory contains unacceptable values. When this occurs, the sensors should be calibrated and all the set points checked. It is normal for this alarm to occur after changing controller software.

REMOTE START FAILURE- This will occur if the Remote Start button is pressed after the machine is running or if the Remote Start button remains closed.

REMOTE STOP FAILURE- This will occur if the Remote Stop button remains open and either Start button is pressed.

SENSOR FAILURE 1AVPT (or 3APT, 4APT, 5CPT,2CTT, 2ATT, 3CTT) - This will occur if a sensor is recognized as missing or broken. This does not apply to sensor 4ATT.

STARTER FAULT 1SL (2SL)- This will occur if the starter contacts open while the machine is running. It will also occur if the machine is given the stop command and the starter contacts do not open. 1SL refers to the auxiliary circuit on starter contact 1M. 2SL refers to the auxiliary circuit on starter contacts 2M and 1S.

STEPPER LIMIT SWITCH- This will occur if both limit switches are activated at the same time.

INVALID CALIBRATION- This will occur during the calibration process if the sensor reads greater than 20% of scale.

LOW COOLANT PRESSURE- This will occur if the compressor is running and the following conditions are met. The coolant must be less than 1 psi and either the sump pressure is greater than 10 psi or the inlet vacuum is less than 12 psi.

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Contents Phone CCN 80440415 REV B Form Apdd 738BAIR Compressor Group Bonded Warranty & Registered Start UP Rotary Screw AIR Compressor This unit was purchased fromTable of Contents Safety and Warnings Safety Shutdown Lift Here DecalsDecals Viewed From RearCompressor Package Data Unpacking and Handling InspectionIngersoll-Rand Company Davidson, North Carolina ToolsNever elevate the compressor unit VentilationFoundation Requirements Performance will be affectedDo not use the compressor to support the discharge pipe Moisture Content of Compressed AIRPiping Discharge Piping with Aftercooler ROTARY-RECIP in ParallelElectrical Installation Rotary TWO Compressor SystemRotation Check Drive MotorFAN Motor Electrical InstallationHasp Lever TAG KEY Lock Intellisys Operating InstructionsOutdoor Sheltered Installation 1 Typical Outdoor Sheltered Installation Intellisys Intellisys ControllerStart Power on LightIntellisys Controls Emergency Stop StopDisplay Screen Current StatusCurrent Status Items Panel Flow Figure DiagramOperator IntellisysMain Menu Operator SetpointsOptions Options Items Range Step UnitOptions Alarm History Sensor CalibrationSensor Calibration Items Alarm History Items Clock FunctionsIntegral Sequencing Integral Sequencing Range Step UnitStatus Main Menu Reset Alarms Alarm Main MenuPage Maintenance Procedures Maintenance ScheduleMaintenance Records Number of Running HOURS, Whichever Occurs First200 HP/132-160 KW Requires 2 Elements Inlet AIR FilterCoolant Filter ElementsCoolant Drain CoolantItems Required Hot coolant can cause severe injuryProcedure CoolantSeparator Tank Scavenge SCREEN/ORIFICE Tools Required Recommended Bolt Tightening Cross Pattern Coolant Separator ElementTank cover bolt torque values 125/200 HPCooler Cores Cleaning Coolant CoolersAftercooler Cleaning AftercoolerAftercooler Motor Lubrication Relubrication amount Lubricant Amount Motor Frame Size GramsRecommended Motor Grease Motor Bearing Maintenance Stored UnitsMotor Lubrication Hazardous voltage. Can cause severe injury or deathTools Long Term Storage GeneralIntellisys Removal Controller RemovalCoolant Hoses InstallationCoolant Sampling Procedure RemovalCoolant Cooler AIR Cooled Compressors Design TemperaturesGeneral System Information Cooling FAN MotorOperation Compressed AIR System The air system is composedCOOLANT/AIR Separation System Electrical SystemCapacity Control STAR-DELTA Type StarterStepper Motor Inlet Control Automatic Unloaded StartModulation only Automatic START/STOP ControlFirst Second Some Examples of OperationExample Remote START/STOP Troubleshooting Chart Troubleshooting Chart LOW Ambient Power Outage Restart OptionSequencer Separator DELTA-P SolenoidRemote LOAD/UNLOAD ModbusElectrical Schematic Star Delta Reference DrawingsPage Foundation Plan 125-150 HP/90-110KW Aircooled Single Stage Foundation Plan 125-150 HP/90-110 KW Aircooled Single Stage Foundation Plan 200 HP/132-160 KW Aircooled Single Stage Foundation Plan 200 HP/132-160 KW Aircooled Single Stage REV C REV C Foundation Plan 200 HP/132-160 KW Watercooled Single Stage Foundation Plan 200 HP/132-160 KW Watercooled Single Stage Foundation Plan Aircooled 100-150 HP/75-110 KW TWO StageFoundation Plan Aircooled 100-150 HP/75-110 KW TWO Stage Foundation Plan Aircooled 200 HP/132-160 KW TWO Stage Foundation Plan Aircooled 200 HP/132-160 KW TWO Stage Foundation Plan -WATERCOOLED Foundation Plan -WATERCOOLED 100-150 HP/75-110 KW TWO Stage Foundation Plan -WATERCOOLED 200 HP/132-160 KW TWO Stage Foundation Plan -WATERCOOLED 200 HP/132-160 KW TWO Stage Flow Schematic Aircooled Single Stage Page Flow Schematic Watercooled 90F 32C Single Stage Page Flow Schematic Watercooled 115F 46 Single Stage Page Flow Schematic AIR-COOLED TWO Stage Page Flow Schematic Watercooled 90F 32C TWO Stage Page Flow Schematic Watercooled 115F 46C TWO Stage Page Typical System Flow Diagram Typical System Flow DiagramsTypical System Flow Diagrams Typical System Flow Diagrams Typical System Flow Diagrams Typical System Flow Diagrams Fouling ScaleCorrosion Parameter Concentration Frequency of AnalysisPage Hardness ppm Temperature FTotal dissolved solids ppm Alkalinity ppmMaintenance Record Maintenance Record Maintenance Record Maintenance Record