Ingersoll-Rand 100-200 HP/75-160 KW Long Term Storage General, Intellisys Removal, Tools

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4.11 LONG TERM STORAGE

GENERAL

The factory, upon special request, prepares compressor units for long term storage. In such cases, a special bulletin is supplied for storage and start-up procedures.

The bulletin provides special procedures for rotation and lubrication of compressors during storage.

Before actual start-up of the compressor, the unit must be drained of coolant containing vapor space inhibitors. Procedure for long term storage start-up is covered in the special bulletin APDD 339.

4.12COOLANT/LUBRICANT CHANGEOUT Ingersoll-Rand does not recommend changeout of coolant/lubricants, however, if a coolant/lubricant change cannot be avoided, procedure APDD 106E-87 should be obtained from your Ingersoll-Rand representative.

4.13INTELLISYS REMOVAL

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 4.13-1).

HASP

LEVER

TAG

KEY LOCK

FIGURE 4.13-1 MAIN DISCONNECT

LOCKED AND TAGGED

Follow these precautions to minimize damage from static electricity. Static can cause severe damage to microcircuits.

1)Make the least possible movement to avoid build- ing up static electricity from your clothing or tools.

2)Discharge potential static electricity by touching (grounding) yourself to the starter box.

3)Handle circuit boards only by their edges.

4)Do not place the controller or power supply assembly on any metal surface.

5)Leave the replacement parts in their protective bags until ready for installation.

Tools:

Screwdriver Size #1, flathead 3/8 inch hex driver

Before removing any components, open the starter box door and check all wiring for tightness. A loose wire or bad connection may be the cause of problems.

This section gives guidelines for removing/replacing the Intellisys Controller assembly and the Intellisys Power Supply assembly. The controller is mounted in the starter box door, and the power supply is mounted on the upper right corner of the starter backpanel on the inside-rear of the starter box.

Controller Removal:

1)Open the starter box door.

2)Remove each plug-in connector, labeled P1-P10, from the sides of the controller. If any of the cables are not labeled, label them with the appropriate plug designator, P1-P10. These must be plugged into the correct sockets in the replacement controller.

3)Remove and save the Option Module if one is plugged into P9. This must be installed in the replacement controller. Note that it is keyed to plug into P9 only one way.

4)Remove the six holding screws from the con- troller on the inside of the starter box door.

5)Remove the controller through the front of the door, being careful to save the gasket that is between the controller and the door.

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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 StopCurrent Status Display ScreenCurrent Status Items Diagram OperatorPanel Flow Figure IntellisysMain Menu Operator SetpointsOptions Options Items Range Step UnitOptions Sensor Calibration Alarm HistorySensor 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 injuryCoolant ProcedureSeparator 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 Aftercooler CleaningAftercooler 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 StartAutomatic START/STOP Control Modulation onlyFirst Some Examples of Operation SecondExample 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