Ingersoll-Rand 125-200 HP/90-160 KW, 100-200 HP/75-160 KW Coolant Hoses, Removal, Installation

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Power Supply Removal:

1)Open the starter box door.

2)Remove each plug-in connector, labeled J1 - J4, from the circuit board. If any of the cables are not labeled, label them with the appro- priate plug designator, J1-J4. These must be plugged into the correct sockets in the replacement power supply.

3)Remove the four screws holding the power supply to the starter plate, save them for mounting the replacement board, and remove the power supply.

4.14 COOLANT HOSES

The flexible hoses that carry coolant to and from the oil cooler may become brittle with age and will require replacement. Have your local Ingersoll-Rand distributor check them every 2 years.

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.

REMOVAL

Remove enclosure panels.

Drain coolant into a clean container. Cover the container to prevent contamination. If the coolant is contaminated, a new charge of coolant must be used.

Hold fitting securely while removing hose.

INSTALLATION

Install the new hoses and reassemble the package by reversing the disassembly procedure. Start the compressor and check for leaks.

4.15 FLUID AND VIBRATION MONITORING

Ingersoll-Rand recommends incorporating predictive maintenance, specifically the use of coolant and vibration analysis, into all Preventative Maintenance programs. Predictive Maintenance is designed to increase system reliability and prevent costly downtime. Through the use of sophisticated diagnostic tools, including fluid, vibration, and optional air analysis, IRA Certified Service Technicians can identify and correct potential problems BEFORE they can cause expensive unscheduled downtime.

How does predictive analysis work? By establishing an initial baseline for normal operation, and then regularly monitoring fluid and vibration conditions, any sudden deviation or significant increase from this baseline can be identified and investigated to pinpoint the cause. More quickly diagnosing potential problems can directly save money by preventing costly failures and reducing or eliminating downtime. In addition, regular condition monitoring also helps to maximize the time between expensive preventative maintenance intervals, such as component rebuilds and coolant changes.

4.16 COOLANT SAMPLING PROCEDURE

Bring unit up to operating temperature. Draw sample, using pump kit, from separator tank port. DO NOT draw sample from drain port or oil filter. Use new hose on pump for each sample, failure to do this can give false readings.

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Contents Form Apdd 738B Phone CCN 80440415 REV BAIR Compressor Group Bonded Warranty & Registered Start UP This unit was purchased from Rotary Screw AIR CompressorTable of Contents Safety and Warnings Safety Shutdown Decals Lift HereViewed From Rear DecalsCompressor Package Data Ingersoll-Rand Company Davidson, North Carolina InspectionUnpacking and Handling ToolsFoundation Requirements VentilationNever elevate the compressor unit Performance will be affectedPiping Moisture Content of Compressed AIRDo not use the compressor to support the discharge pipe Discharge Piping with Aftercooler ROTARY-RECIP in ParallelRotary TWO Compressor System Electrical InstallationDrive Motor Rotation CheckHasp Lever TAG KEY Lock Electrical InstallationFAN Motor Intellisys Operating InstructionsOutdoor Sheltered Installation 1 Typical Outdoor Sheltered Installation Intellisys Controller IntellisysIntellisys Controls Emergency Stop Power on LightStart StopCurrent Status Items Display ScreenCurrent Status Operator DiagramPanel Flow Figure IntellisysOperator Setpoints Main MenuOptions Items Range Step Unit OptionsOptions Sensor Calibration Items Alarm HistorySensor Calibration Clock Functions Alarm History ItemsIntegral Sequencing Range Step Unit Integral SequencingStatus Main Menu Reset Alarm Main Menu AlarmsPage Maintenance Records Maintenance ScheduleMaintenance Procedures Number of Running HOURS, Whichever Occurs FirstCoolant Filter Inlet AIR Filter200 HP/132-160 KW Requires 2 Elements ElementsItems Required CoolantCoolant Drain Hot coolant can cause severe injurySeparator Tank Scavenge SCREEN/ORIFICE Tools Required ProcedureCoolant Tank cover bolt torque values Coolant Separator ElementRecommended Bolt Tightening Cross Pattern 125/200 HPCoolant Coolers Cooler Cores CleaningAftercooler Aftercooler CleaningAftercooler Relubrication amount Lubricant Amount Motor Frame Size Grams Motor LubricationMotor Lubrication Motor Bearing Maintenance Stored UnitsRecommended Motor Grease Hazardous voltage. Can cause severe injury or deathIntellisys Removal Long Term Storage GeneralTools Controller RemovalCoolant Sampling Procedure InstallationCoolant Hoses RemovalGeneral System Information AIR Cooled Compressors Design TemperaturesCoolant Cooler Cooling FAN MotorCOOLANT/AIR Separation System Compressed AIR System The air system is composedOperation Electrical SystemStepper Motor Inlet Control STAR-DELTA Type StarterCapacity Control Automatic Unloaded StartFirst Modulation onlyAutomatic START/STOP Control Example SecondSome Examples of Operation Remote START/STOP Troubleshooting Chart Troubleshooting Chart Sequencer Power Outage Restart OptionLOW Ambient Separator DELTA-P SolenoidModbus Remote LOAD/UNLOADReference Drawings Electrical Schematic Star DeltaPage 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 100-150 HP/75-110 KW TWO Stage Foundation Plan AircooledFoundation 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 Diagrams Typical System Flow DiagramTypical System Flow Diagrams Typical System Flow Diagrams Typical System Flow Diagrams Typical System Flow Diagrams Corrosion ScaleFouling Parameter Concentration Frequency of AnalysisPage Total dissolved solids ppm Temperature FHardness ppm Alkalinity ppmMaintenance Record Maintenance Record Maintenance Record Maintenance Record