Ingersoll-Rand 100-200 HP/75-160 KW, 125-200 HP/90-160 KW Cooler Cores Cleaning, Coolant Coolers

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4.9 COOLER CORES: CLEANING

Ensure the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg.

Ensure the main power disconnect switch is locked open and tagged. (See Figure 4.9-1).

HASP

LEVER

TAG

KEY LOCK

FIGURE 4.9-1 MAIN DISCONNECT

LOCKED AND TAGGED

TOOLS REQUIRED

Screwdriver

Wrench set

Air hose equipped with approved O.S.H.A. nozzle.

On units sold outside the U.S.A. consult local codes.

PROCEDURE

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 with an air hose 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.

If it is determined that the compressor operating temperature is higher than normal due to the internal passages of the cooler cores being restricted with deposits or foreign material, then the cooler should be removed for internal cleaning.

COOLANT COOLERS

Following are instructions for removal and internal cleaning of coolant coolers.

Coolant Cooler

Remove panels and top cover.

Drain the coolant. See Section 4.6.

Remove side panels from coolant cooler box.

Disconnect piping from coolant cooler inlet and outlet ports.

Plug cooler inlet and outlet ports to prevent possible contamination.

Remove coolant cooler holding screws from sides of coolant cooler and remove cooler through side of cooler shroud.

Coolant Cooler Cleaning

It is recommended the cooler be taken to a professional cooler service shop for flushing with an appropriate environmentally safe cleaning agent.

Reassemble in reverse order.

Make sure fan guards are replaced.

Refill the compressor with coolant. If contamination is suspected, replace with new coolant.

Replace fill plug.

Run compressor for ten minutes. Check for possible leaks. Check coolant level.

Replace enclosure panels.

CAUTION

Strong cleaners can harm

aluminum cooler parts. Follow cleaner manufacturer’s instructions for use.

Wear appropriate safety equipment.

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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 Inspection Ingersoll-Rand Company Davidson, North CarolinaUnpacking and Handling ToolsVentilation Foundation RequirementsNever elevate the compressor unit Performance will be affectedMoisture Content of Compressed AIR PipingDo not use the compressor to support the discharge pipe Discharge Piping with Aftercooler ROTARY-RECIP in ParallelElectrical Installation Rotary TWO Compressor SystemRotation Check Drive MotorElectrical Installation Hasp Lever TAG KEY LockFAN Motor Intellisys Operating InstructionsOutdoor Sheltered Installation 1 Typical Outdoor Sheltered Installation Intellisys Intellisys ControllerPower on Light Intellisys Controls Emergency StopStart StopDisplay Screen Current StatusCurrent Status Items Diagram OperatorPanel Flow Figure 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 Schedule Maintenance RecordsMaintenance Procedures Number of Running HOURS, Whichever Occurs FirstInlet AIR Filter Coolant Filter200 HP/132-160 KW Requires 2 Elements ElementsCoolant Items RequiredCoolant Drain Hot coolant can cause severe injuryProcedure CoolantSeparator Tank Scavenge SCREEN/ORIFICE Tools Required Coolant Separator Element Tank cover bolt torque valuesRecommended Bolt Tightening Cross Pattern 125/200 HPCooler Cores Cleaning Coolant CoolersAftercooler Cleaning AftercoolerAftercooler Motor Lubrication Relubrication amount Lubricant Amount Motor Frame Size GramsMotor Bearing Maintenance Stored Units Motor LubricationRecommended Motor Grease Hazardous voltage. Can cause severe injury or deathLong Term Storage General Intellisys RemovalTools Controller RemovalInstallation Coolant Sampling ProcedureCoolant Hoses RemovalAIR Cooled Compressors Design Temperatures General System InformationCoolant Cooler Cooling FAN MotorCompressed AIR System The air system is composed COOLANT/AIR Separation SystemOperation Electrical SystemSTAR-DELTA Type Starter Stepper Motor Inlet ControlCapacity Control Automatic Unloaded StartModulation only Automatic START/STOP ControlFirst Second Some Examples of OperationExample Remote START/STOP Troubleshooting Chart Troubleshooting Chart Power Outage Restart Option SequencerLOW Ambient 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 Scale CorrosionFouling Parameter Concentration Frequency of AnalysisPage Temperature F Total dissolved solids ppmHardness ppm Alkalinity ppmMaintenance Record Maintenance Record Maintenance Record Maintenance Record