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Ingersoll Rand 5 to 15 hp Rotary Screw Air Compressor Manual JEC.pdf

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  C.C.N. : 80445273REV. : ADATE : OCTOBER 2008  SSR UP5-4, UP5-5.5, UP5-7.5, UP5-11c 50 Hz SSR UP6-5, UP6-7.5, UP6-10, UP6-15c 60 Hz OPERATION AND MAINTENANCE MANUAL This manual containsimportant safety informationand must be made availableto personnel who operate and maintain this machine.Refer all communications to the nearest Ingersoll Rand Full Service Distributor.  AIR COMPRESSOR GROUPBONDED WARRANTY & REGISTERED START UP Warranty Note that this is Ingersoll Rand standard warranty. Any warranty in orce at the time o purchase o the compressor or negotiated as part o the purchase order may take precedence over this warranty. The Company warrants that the equipment manuactured by it and delivered hereunder will be ree o deects in material and workmanship or a period o twelve months rom the date o placing the Equipment in operation or eighteen months rom the date o shipment rom the actory, whichever shall frst occur. The Purchaser shall be obligated to promptly report any ailure to conorm to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct such nonconormity, by suitable repair to such equipment or, urnish a replacement part F.O.B. point o shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment in accordance with good industry practices and has complied with specifc recommendations o the Company. Accessories or equipment urnished by the Company, but manuac-tured by others, shall carry whatever warranty the manuacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable or any repairs, replacements, or adjustments to the Equipment or any costs o labor perormed by the Purchaser or others without Company‘s prior written approval. The eects o corrosion, erosion and normal wear and tear are specifcally excluded. Perormance warranties are limited to those specifcally stated within the Company‘s proposal. Unless responsibility or meeting such perormance warranties are limited to specifed tests, the Company‘s obligation shall be to correct in the manner and or the period o time provided above. THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.Correction by the Company o nonconormities whether patent or latent, in the manner and or the period o time provided above, shall constitute ulflment o all liabilities o the Company or such nonconormities whether based on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out o such Equipment.  The purchaser shall not operate Equipment which is considered to be deective, without frst notiying the Company in writing o its intention to do so. Any such use o Equipment will be at Purchaser‘s sole risk and liability.  3 Operation and Maintenance Manual ContentsCONTENTSFOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5DECALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6ISO SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6GRAPHIC FORM AND MEANING OF ISO SYMBOLS . . . . . . . . . . . . . . . . . . . 6ANSI SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8GRAPHIC FORM AND MEANING OF ANSI SYMBOLS . . . . . . . . . . . . . . . . . . 8SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Condensate disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13PIPING AND INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13SCHEMATIC, ELECTRICAL UP6 5–15HP FV 3PH 60Hz DOL – U.S.A.. . . . . . . . . . . 15SCHEMATIC, ELECTRICAL UP6 5–15HP SD 3PH 60Hz . . . . . . . . . . . . . . . . . . . 16SCHEMATIC, ELECTRICAL UP6 5–15HP FV 1PH 60Hz - U.S.A. . . . . . . . . . . . . . . 17SCHEMATIC, ELECTRICAL UP5 5–15HP FV 3PH 50Hz DOL . . . . . . . . . . . . . . . . 18SCHEMATIC, ELECTRICAL UP5 5–15HP SD 3PH 50Hz . . . . . . . . . . . . . . . . . . . 19INSTALLATION/HANDLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21UP-SERIES TANK MOUNTED (80 GAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22UP-SERIES TANK MOUNTED (120 GAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24UP-SERIES TANK MOUNTED (272 LITRES) . . . . . . . . . . . . . . . . . . . . . . . . . . 26UP-SERIES TANK MOUNTED (500 LITRES) . . . . . . . . . . . . . . . . . . . . . . . . . . 28LOCATION IN THE PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36COMPRESSOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37AUTOMATIC START & STOP CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37DUAL CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37PRIOR TO STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 NORMAL/EMERGENCY STOPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39ROUTINE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40  4 Contents Operation and Maintenance ManualTOP UP COOLANT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41COOLANT CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41COOLANT FILTER CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 41AIR FILTER ELEMENT CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 41SEPARATOR ELEMENT CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 42COOLER CLEANING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42BELT CHECKING AND ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . 42ELECTRIC DRAIN VALVE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43TIMER SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43MOISTURE SEPARATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 44AIR FILTER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44DISASSEMBLING THE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45REFRIGERANT LEAKS IN THE REFRIGERATION CIRCUIT. . . . . . . . . . . . . . . . . . 45REFRIGERANT CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45CHARACTERISTICS OF REFRIGERANT R134A . . . . . . . . . . . . . . . . . . . . . . . . 45TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 ABBREVIATIONS & SYMBOLS #### Contact Ingersoll Rand  for serial number ->#### Up to Serial No. ####-> From Serial No. * Not illustrated † Option NR Not required AR As required SM Sitemaster/Sitepack  HA High ambient machine WC Watercooled machine AC Aircooled machine ERS Energy recovery system T.E.F.C.  Totally enclosed fan cooled motor (IP54) O.D.P. Open drip proof (motor) ppm parts per million
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