60513.08.

02

80446362
Revision C
June 2013

Contact-Cooled Rotary Screw Air Compressor

R37-160

Product Maintenance Information

PRINT LANGUAGE

ENGLISH

CHINESE

Save These Instructions

60513.08.02

EN

Contents
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cleaning Air Cooled Sequential Cooling System . . . . . . . . . . . . . . . . . . 6

PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removing / Installing Air Cooled Cooler . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cleaning Water Cooled Cooler (for both Clean & Harsh
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Water Options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AIR COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Checking High Airend Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning Motor Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removing / Replacing Starter Box Power Drive Module (PDM) Filter
Element (For VSD only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning / Checking Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning / Installing Package Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Checking / Cleaning No Loss Drain Trap (where fitted) . . . . . . . . . . . . 8
Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Monitoring Fluid and Performing Shock Pulse Bearing Analysis . . . 8
Analyzing Food Grade Coolant Option . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING (VARIABLE SPEED DRIVE
Sampling Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSORS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Changing Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
R37-75 INTEGRATED DRYER MAINTENANCE . . . . . . . . . . . . . . . . 13
Checking Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Changing Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Inspecting Separator Tank / Pressure System . . . . . . . . . . . . . . . . . . . . 5 Cleaning Condensate Drains (Timed Drains Only) . . . . . . . . . . . . . . . 13

Cleaning / Checking Scavenge Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Testing Condensate Drains (No-Loss Drains Only) . . . . . . . . . . . . . . . 13

Replacing Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting Condensate Drains (Electronic

Drains Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Checking Minimum Pressure Check Valve (MPCV) . . . . . . . . . . . . . . . . 6
Disassembling the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . 13
Changing Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Regreasing Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Decommissioning the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . 13

ABOUT THIS MANUAL

The purpose of this manual is to provide maintenance and troubleshooting guidelines for the compressor.
For supporting documentation refer to Table 1.
Table 1: Product Manuals
Part/Document Number by Region
Publication Product
Americas EMEA * Asia Pacific
Product Safety Information Manual All 80446313 80446156 80446321
Product Information Manual All 80446339 80446164 80446347
R37-45 kW 80448095
R55-75 kW 80446271
Product Parts Information Manual
R132-160 kW Single-Stage 80446057
R90-160 kW Two-Stage 80446065
* Europe, Middle East and Africa
Product specification sheets and reference drawings are also available.

PERSONNEL
Proper use, inspections and maintenance increases the life and usefulness Some maintenance procedures are technical in nature and require
of the compressor. It is extremely important that anyone involved with specialized tools, equipment, training and experience to accomplish
maintaining the compressor be familiar with the servicing procedures of correctly. In such situations, only allow Ingersoll Rand trained technicians
these compressors and be physically capable of conducting the procedures. to perform maintenance on this compressor. Service or inspections beyond
These personnel shall have skills that include: the procedures given in this manual shall not be attempted by operating
personnel.
1. Proper and safe use and application of mechanics common hand
tools as well as special Ingersoll Rand or recommended tools. For additional information contact the Ingersoll Rand factory or the nearest
service provider.
2. Safety procedures, precautions and work habits established by
accepted industry standards.

SAFETY
Before undertaking any work on the compressor, ensure that the electrical If you are unsure of a maintenance procedure or step, place the compressor
supply has been isolated, locked off, tagged and the compressor has been in a safe condition before consulting technical assistance.
relieved of all pressure. Ensure the compressor is electrically isolated for at
least 15 minutes before commencing any maintenance work. See the Product The use of other than genuine Ingersoll Rand replacement parts may result
Safety Information manual for additional information. in safety hazards, decreased performance and increased maintenance and
may invalidate all warranties.
Ingersoll Rand cannot know of or provide all the procedures by which
repairs may be conducted and the hazards and/or results of each method. If For additional information contact the Ingersoll Rand factory or the nearest
maintenance procedures not specifically recommended by the manufacturer service provider.
are conducted, ensure that safety is not endangered by the actions taken.

80446362 Rev C EN-

60513.08.02

EN

AIR COMPRESSOR MAINTENANCE

 Maintenance Prompts
The service warning and flashing LED will appear at intervals dependent
on the service level selected. Refer to the Product Information manual for
information about service level settings.
 Maintenance Chart
Maintenance should be performed per the recommendations below in the
following priority: (1) Perform maintenance when indicated by the controller;
(2) Perform maintenance through either hourly intervals or scheduled
maintenance intervals, or (3) Annually.

Table 2: Maintenance Chart

Period Action Maintenance Item
When indicated by Replace Air filter element
controller Replace Coolant filter element
Replace Separator element
Daily Check Connections and hoses for leaks
Check Coolant level
Check Condensate drain operation
Check Controller for service indicators
Check Package pre-filter for blockage
Monthly Inspect Air-cooled sequential cooling system for blockage
Inspect Water-cooled sequential cooling system screens
Inspect Starter box power drive module (PDM) filter element
Analysis Water from water-cooled sequential cooling system
Every 500 hours Analysis Food grade coolant
Every 1000 hours Replace Food grade coolant (if not using food grade filter module)
Replace Food grade coolant filter (if not using food grade filter module)
Every 2000 hours or Inspect Air filter element
3 months Inspect Coolant filter element
Inspect Starter box power drive module (PDM) filter element
Replace Food grade coolant (if using food grade filter module)
Replace Food grade filter module
Analysis Shock pulse bearing
Analysis Coolant
Every 4000 hours or 6 Inspect Scavenge screen for blockage
months Replace Air filter element
Replace Coolant filter element
Replace Starter box power drive module (PDM) filter element
Replace Package pre-filter element
Clean Air-cooled sequential cooling system
Inspect / Clean Water-cooled sequential cooling system
Grease All motors (as required)
Calibrate Pressure transducers
Analysis Coolant
Analysis Shock pulse bearing
Every 8000 hours or Replace Standard coolant (8000 hours or every two years)
annually Replace Separator element
Replace No-loss condensate drain service module
Service Minimum pressure check valve (MPCV) service kit
Service Inlet valve service kit
16000 hours Replace Coolant hoses
Replace Contact tips

NOTICE

Inspect and replace coolant filter elements and separator elements more frequently in dirty operating environments.

NOTICE

Read the motor data plate(s) or call the motor manufacturer(s) to determine specific greasing requirements. For motors that require greasing,
grease them more frequently in harsh environments or higher ambient conditions.

EN- 80446362 Rev C

60513.08.02

EN

 Routine Maintenance Figure 1: Coolant Drain

This section refers to the various components which require periodic

maintenance and replacement.
Refer to safety information and maintenance procedures prior to carrying out
any of the maintenance in the following sections.

 Checking Coolant Level

The coolant level should be checked daily. A coolant level sight glass is
located on the side of the separator tank. While the compressor is running 1 2
under load, coolant should always be visible in the sight glass. The normal
position is half way. The compressor should be running for at least 40 seconds
for this check.
Stop the compressor, ensure the sump pressure is 0 psig and ensure the
coolant is still visible in the sight glass.

 Adding Coolant
Run the compressor for a minimum of 40 seconds. The coolant level should
be visible in the sight glass. If not:
1. Stop the compressor.
2. Isolate the compressor from the external air system.
3. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.
4. Slowly unscrew the coolant fill plug to verify all pressure has been
released.
5. Add coolant.
6. Replace the coolant fill plug and restart the compressor.
3 4
3. Dispose of waste coolant in accordance with local and
governmental regulations.
It is recommended to perform a coolant analysis every 2000 hours or three
months to monitor its condition and determine when to change the coolant.
If analysis is not performed, the recommended coolant change interval is
8000 hours or two years, whichever comes first.
NOTICE
Shorter coolant change intervals may be necessary if the compressor
is operated in adverse conditions.

7. Recheck the coolant level.

8. Repeat the above steps until the coolant level is visible in the sight
glass with the compressor both running and stopped.
NOTICE
Do not add coolant through the intake of the compressor, as this can
result in overfilling, saturation of the separator filter element, and
coolant carry-over downstream.
 Draining Coolant
It is better to drain the coolant immediately after the compressor has been
operating as the coolant will drain faster and any contaminant will still be in
suspension.
See Figure 1.
1. Place the straight end of the drain hose in a suitable container.
Install the other end of the drain hose in the drain valve. The
coolant flows through the drain hose automatically.
2. After drainage, remove the hose and close the valve.
NOTICE
On air cooled compressors, you may also drain coolant from the
coolant cooler by removing the plug.
You should also drain additional coolant from the airend by removing
the plug in the airend discharge elbow.
 Analyzing Food Grade Coolant
It is highly recommended to have samples of the coolant analyzed every
500 hours or each month to determine when coolant should be changed.
If analysis is not performed, coolant should be changed after 2000 hours
or every six months when utilizing the food grade filter supplied with the
compressor.
For compressors running food grade coolant without the food grade filter,
the change interval should be 1000 hours or six months, whichever comes
first.
 Sampling Coolant
1. Bring the compressor up to operating temperature.
2. Stop the compressor.
3. Isolate the compressor from the external air system.
4. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.
5. Draw a sample from the separator tank port using a pump kit. DO
NOT draw a sample from the drain port or oil filter.
Use a new hose on the pump for each sample. Failure to do this can give
false readings.
See Figure 2.

80446362 Rev C EN-

60513.08.02
Figure 2: Coolant Sampling
 Changing Coolant Filter
1. Remove drain plug from bottom of filter housing and drain coolant.
2. Loosen the filter housing.
3. Remove the element from the housing.
4. Place the old element in a sealed bag and dispose of in a safe way.
5. Remove the new replacement element from its protective package.
6. Apply a small amount of coolant to the element seal.
7. Install new replacement element into the filter housing.
8. Screw the housing to the filter head and tighten to the torque
specified on the housing.
9. Reinstall drain plug.
10. Start the compressor, check for leaks and check the coolant level.
 Checking Separator Element
With the compressor running on load, check the separator differential
pressure via the controller. It will be necessary to change the element if the
differential pressure equals zero or exceeds 1 bar (15 psig).
 Changing Separator Element
1. Remove the fitting that holds the scavenge tube into the tank and
withdraw the tube assembly.
2. Disconnect the piping from the tank cover. Tag the lines if required.
Remove all the bolts securing the cover to the tank except the
bolt opposite the pivot bolt which should be left engaged by 2-3
threads with at least 6.5 mm (0.25 in) clearance from the screw
head to the cover. Rotate the jacking bolt clockwise until the cover
lifts off the tank at least 2 mm (0.08 in) all the way around the tank.
Remove the remaining bolt. The cover can now be rotated to allow
access to inside the tank.
3. Carefully lift the separator element up and out of the tank. Discard
the faulty element.
4. Clean the sealing surface on both the tank and its cover. Check the
EN- 80446362 Rev C
EN
tank to be absolutely certain that no foreign objects such as rags or
tools have been allowed to fall into the tank. Install a replacement
element down into the tank after checking the new element seal
for possible damage. Center the element within the tank ensuring
that it is fully seated in the sealing groove. Rotate the tank cover
back into position taking care not to damage the seal, and locate
the cover using two bolts but do not tighten down.
5. Loosen the jacking bolt to fully disengage the threads and tighten
the cover bolts in a cross-pattern to prevent over-tightening one
side of the cover. An improperly tightened cover will likely result in
a leak.
NOTICE
Unscrew the jacking bolt sufficiently to ensure that the cover can be
fully tightened down without imparting any stress onto the jacking
points. Tighten down the cover bolt to 81 N m (60 ft lb) for 75 kW
and smaller compressors or 200 N m (150 ft lb) for 90 kW and larger
compressors. Refer to Figure 3 for the tightening sequence of the
bolts.
6. Inspect the tank scavenge screen and orifice. Clean if necessary
following the instructions below.
7. Install the scavenge tube down into the tank until the tube just
touches the separator element and then raise it 3 mm (0.125 in).
Tighten fittings.
NOTICE
Take extreme caution to not force the scavenge tube into the tank.
This could potentially damage the separator element.
8. Install the piping in the original position.
Figure 3: Recommended Bolt Tightening Cross Pattern
3 3
11 8 8
5
5 10
10
2 1
1
2
9 9
6
6
7 12 7
4 4
90-160 kW 55-75 kW
9. Start the compressor and check for leaks.
NOTICE
Do not use any form of sealant on either the separator tank or the
separator tank cover faces.
 Inspecting Separator Tank / Pressure System
At 2000 hour intervals, inspect the external surfaces of the airend and
separator tank, including all fittings, for visible signs of impact damage,
excessive corrosion and abrasions. When changing the separator element,
inspect the internal components and surfaces. Any suspect parts shall be
replaced before the compressor is put back into service.
The separator tank should also be tested and inspected in accordance with
any national or local codes that may exist.
 Cleaning / Checking Scavenge Screen
The screen/orifice assemblies are similar in appearance to a straight tubing
connector and will be located between two pieces of 6 mm (0.25 in) O.D.
scavenge line tubing.
The main body is made from 17 mm hexagon shaped metal and the diameter
of the orifice and a direction-of-flow arrow is stamped in flat areas of the
hexagon.
60513.08.02

EN

A removable screen and orifice will require clearing as outlined in the 4. Ensure that the main power disconnect switch is locked off and
maintenance chart. tagged.
To remove the screen/orifice:
NOTICE
1. Disconnect the scavenge line tubing from each end.
For any required lifting of air compressor parts or required tools,
2. Hold the center section firmly and use a pair of pliers to gently
always use the proper certified lifting equipment, and employ sound
grasp the exit end of the assembly that seals against the scavenge
working principles.
line tubing. The exit end is the end toward which the arrow is
pointing.
3. Pull the end out of the center section while using care to prevent 5. Visually check the outside of the cooler cores to determine the
damage to the screen or sealing surfaces. appropriate cleaning method detailed as follows:

4. Clean and inspect all parts prior to reinstallation. a. For loose dirt, dust and other light foreign material, open the
access panels on the sides of the cooler plenum and gently
5. When the assembly is installed, confirm the direction of flow to blow compressed air across the coolant cooler surface. Use a
be correct. Observe the small arrow stamped in the center section vacuum hose with a soft brush to clean the exposed face of the
and ensure the direction flow to be from the separator tank to the air aftercooler. Repeat the process until the coolers are sufficiently
airend. clean. Replace the access panels before returning the compressor to
service.
 Replacing Coolant Hoses
b. For thick, packed dirt, coolant or grease, or other heavy material,
The flexible hoses that carry coolant through the cooling system may the coolers will need to be removed from the compressor for
become brittle with age and will require replacement. Replace them as pressure washing. Ingersoll Rand does NOT support pressure
needed or every four years. washing coolers when they are installed in the compressor due
1. Depending on the location of the hose, it may contain compressor to the dangers of spraying water in or around potential electrical
coolant. It is recommended to drain the coolant into a clean power sources. Follow the steps below for cooler removal.
container. Cover the container to prevent contamination. If the
 Removing / Installing Air Cooled Cooler
coolant is contaminated, replace with new coolant.
To remove:
2. Remove the hose.
1. Stop the compressor.
3. Install the new hose and refill the compressor with coolant.
2. Isolate the compressor from the system.
4. Start the compressor, check for leaks and check coolant level. Refill
as necessary. 3. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
 Checking Minimum Pressure Check Valve (MPCV) de-pressurize once stopped.
The minimum pressure check valve (MPCV) shall be frequently tested and 4. Ensure that the main power disconnect switch is locked off and
regularly maintained. Remove it from the compressor for testing. If operating tagged.
conditions are particularly severe, the frequency of testing and maintenance
shall be increased accordingly. The user shall establish the frequency of
such tests as it is influenced by such factors as the severity of the operating NOTICE
environment.
For any required lifting of air compressor parts or required tools,
The minimum pressure check valve (MPCV) should be tested and re- always use the proper certified lifting equipment, and employ sound
calibrated in accordance with any national or local codes that may exist. If working principles.
no code exists, Ingersoll Rand recommends that the valve is recalibrated at
intervals of one year by a licensed contractor or qualified service personnel.
5. Drain the coolant from the coolant cooler by removing the hex plug
 Changing Air Filter located at the front of the air cooler, and lower side of the coolant
cooler.
1. Check the retaining cap for dirt and debris and wipe clean.
6. Remove all hoses, pipes, and sensors from the coolers.
2. Unclip the retaining cap and withdraw the old element.
7. Remove the external sheet metal panels.
3. Fit the new element and refit the retaining cap.
8. Remove the access panels on the sides of the cooler plenum.
 Regreasing Motor
9. Properly secure the air aftercooler and remove the four nuts from
The blower motor contains pre-greased, sealed bearings. They cannot be the two bolts at the upper sides of the cooler.
re-greased and do not require re-greasing. For the main motor, consult the
motor manufacturer to confirm that the motor may be greased and to obtain 10. Remove the two nuts from the bolts at the bottom of the cooler.
instructions for regreasing.
11. Carefully remove the air aftercooler.
 Cleaning Air Cooled Sequential Cooling System 12. Properly secure the coolant cooler and remove the four nuts from
Air compressor operating temperatures will be higher than normal if the the two bolts at the upper sides of the cooler.
external passages between the fins of the cooler cores become restricted 13. Remove the two nuts from the bolts at the bottom of the cooler.
with foreign material. Regular cleaning of the cooler surfaces will support
the reliable operation of the air compressor system, improve the life of 14. Carefully remove the coolant cooler.
the compressor coolant and improve overall compressor efficiency. When
15. Re-install the coolant drain plug to 23 N m (17 ft lb) for compressors
performed frequently as determined by site conditions and airborne
75 kW and smaller or 65 N m (48 ft lb) for compressors 90 kW and
contamination, more significant cleaning or replacement may not be
larger.
necessary.
1. Stop the compressor.
2. Isolate the compressor from the system.
3. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.

80446362 Rev C EN-

60513.08.02
To install:
1. Stop the compressor.
2. Isolate the compressor from the system.
3. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.
4. Ensure that the main power disconnect switch is locked off and
tagged.
NOTICE
For any required lifting of air compressor parts or required tools,
always use the proper certified lifting equipment, and employ sound
working principles.
5. Carefully place the coolant cooler in its proper location and install
the two sets of lower nuts and bolts, tightly.
6. Install the two sets of upper side nuts and bolts, finger tight + ¼
turn. Next, add the second nut to each tightly. This second nut is
used to lock the first in place. It is important the first nut is not too
tight so it can allow the cooler to expand and contract without
stressing the cooler’s brazed joints.
7. Ensure the rubber seal on the air aftercooler is in place on the
cooler and in good condition.
8. Carefully place the air aftercooler cooler in its proper location and
install the two sets of lower nuts and bolts tightly.
9. Install the two sets of upper side nuts and bolts finger tight + ¼
turn. Next add the second nut to each tightly. This second nut is
used to lock the first in place. It is important the first nut is not too
tight so it can allow the cooler to expand and contract without
stressing the cooler’s brazed joints.
10. Re-attach all hoses, pipes and sensors, and properly torque
according to the Parts Information manual.
11. Replace the access panels on the sides of the cooler plenum.
12. Refill the compressor with coolant to the proper level, following the
process outlined in the “Adding Coolant” procedure.
 Cleaning Water Cooled Cooler (for both Clean & Harsh Water
Options)
A periodic inspection and maintenance program should be implemented for
water cooled heat exchangers. It is recommended that you contact
Ingersoll Rand for cleaning services should you not have experience and
equipment to do this work.
Figure 4: Starter Box Power Drive Module (PDM) Filter Element Replacement
EN- 80446362 Rev C
EN
If water inlet lines have strainers, inspect them and replace or clean as
required.
Mineral scale may be removed with a suitable de-scaling agent containing
amidosulphuric acid + citric acid and Neutralit solutions for cleaning the
coolers. As an alternative, any weak acid mixed with water in the ratio of 1:4
may be used.
Fouling should be removed with a suitable detergent in hot water.
Back flush the cooler with a flow rate at least 1.5 times the normal flow rate.
After using any cleaning solution, thoroughly flush out all chemicals with
clean water before returning the cooler to service.
Mechanical cleaning methods are not recommended as damage to the
internal passages may occur.
After cleaning, examine the cooler for erosion or corrosion.
 Checking High Airend Temperature Sensor
It is recommended that the discharge temperature sensor (2ATT) is checked
regularly as follows:
a. For air cooled compressors, stop the cooling blower by opening the
blower / fan motor circuit breaker.
b. For water cooled compressors, shut off the cooling water.
The compressor should trip at 109° C (228° F). A trip warning will appear on
the controller display.
 Cleaning Motor Cowl
1. Ensure the compressor is electrically isolated for at least 15 minutes
before commencing any maintenance work.
2. Remove the panels from the compressor.
3. Using a clean dry cloth, remove dust from the surface of the motor
cowl and ensure all ventilation slots are free of obstructions.
4. Replace the panels.
 Removing / Replacing Starter Box Power Drive Module (PDM)
Filter Element (For VSD only)
See Figure 4.
1. Ensure compressor is electrically isolated for at least 15 minutes
before commencing any maintenance work.
2. Unclip the front grill of the starter box filter housing.
3. Remove the filter element from the housing and replace with a new
filter element.
4. Replace the front grill.
60513.08.02

EN

 Cleaning / Checking Condensate Drain
1. Ensure the compressor is electrically isolated for at least 15 minutes,
before commencing any maintenance work.
2. Isolate the compressor from the system and fully discharge the
compressed air within the compressor.
3. Remove the tube from the fitting located on the bottom of the
moisture separator.
4. Remove the bowl of the moisture trap, clean and replace.
 Cleaning / Installing Package Pre-Filter
1. Unlatch the two 1/4 turn latches and open the intake panel (panel
is hinged)
2. Remove the six wing nuts and flat washers.
3. Remove the filter grill.
4. Pull out the filter element.
5. Center the new element over the package intake opening. Also
note that the filter is washable with mild detergent.
6. Push the filter over the grill studs so that the studs poke through
the filter media.
7. Install the filter grill.
8. Install the six wing nuts and flat washers.
9. Close the intake panel and latch.
 Checking / Cleaning No Loss Drain Trap (where fitted)
It is recommended to check the no loss drain trap daily to ensure that
condensate is draining from the moisture separator system. To check for
correct function:
1. Press the test button on the drain and listen for condensate / air
passing through the drain.
2. If the drain is clogged, replace the no loss drain valve service
module. The service module consists of the lower portion of the
drain trap and is not serviceable.
Additionally, it is recommended to replace the service module every 8000
hours or once per year, whichever comes first.
 Monitoring Fluid and Performing Shock Pulse Bearing
Analysis
Ingersoll Rand recommends incorporating predictive maintenance,
specifically the use of coolant and shock pulse bearing analysis, into all
preventative maintenance programs. Contact Ingersoll Rand for details.

80446362 Rev C EN-

60513.08.02
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed
by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common symptoms, probable
causes and remedies.
SYMPTOM
Compressor will not start.
Compressor stops and will not
restart.
Compressor is stopped and will not
restart.
Compressor will not meet pressure
required by system.
Compressor will not meet pressure
required by system.
Pressure produced by compressor is
too high due to speed not reducing
as demand reduces.
Compressor discharge air too hot.
EN- 80446362 Rev C
EN
TROUBLESHOOTING
Table 3: General Faults
CAUSE REMEDY
No power supply to compressor. Check supply is switched on. If so, contact a qualified
electrician.
Controller failure. Check supply to controller. Replace controller.
Starter failure. Isolate supply, lock off and tag. Replace failed component
or contact your local Ingersoll Rand representative.
Drive controller has tripped. See Tables 3 and 4.
Controller has tripped the compressor. See Tables 3 and 4.
Maximum number of starts per hour exceeded.
Controller has tripped the compressor and has not See Tables 3 and 4.
been reset.
Emergency stop has been pressed and not released. Identify reason why, repair fault, disengage button and
reset controller.
Emergency stop has been pressed and released but Repair fault and reset controller.
controller has not been reset.
Compressor not sized to meet system requirements Contact your local Ingersoll Rand representative.
or requirements have been changed.
Air loss due to pipe, hose, joint or seal failure. Repair or replace.
Air loss due to blowdown valve stuck open. Repair or replace.
Air loss through pressure relief valve not seating or Repair or replace.
set incorrectly.
Air loss due to moisture separator drain trap stuck Repair or replace.
open.
Motor speed too low caused by drive incorrectly set. Contact your local Ingersoll Rand representative.
Motor speed too low caused by fault in drive settings. See Table 4.
Controller fault. Repair or replace.
Drive motor fault. See Table 4.
Pressure transducer faulty, incorrectly calibrated or Recalibrate or replace.
EMF interference.
Incorrect controller settings. Check and modify settings.
Inlet grill or ducting is blocked. Check and clean.
Air filter dirty or collapsed. Replace.
Inlet valve not opening fully. Repair or replace.
Separator element dirty or collapsed. Replace.
Pipe / Hoses blocked or collapsed. Clean or replace.
Cooler core blocked. Clean or replace.
Minimum pressure check valve not functioning Repair or replace.
correctly.
Equipment between compressor and customer Review system requirements.
measuring point causing pressure drop / pressure
loss.
Controller set incorrectly. Check and modify settings.
Pressure transducer may be faulty, incorrectly Recalibrate or replace.
calibrated or not receiving pressure signal.
Drive settings fault. Contact your local Ingersoll Rand representative.
High ambient temperature. Review installation and system parameters.
Insufficient cooling air. Check ducting and cooling air path, check direction of
blower rotation.
Dirty, blocked aftercooler (cooling air side). Clean or replace.
60513.08.02

EN

Table 3: General Faults (cont.)

SYMPTOM
Compressor package produces
excessive noise.
Discharge air is contaminated with
coolant.
Discharge air is contaminated with
condensate.
Compressor package draws too much
current.
Excessive coolant consumption.
High dewpoint.
Ice formation in dryer.
Solenoid condensate valve will not
close
CAUSE REMEDY
Panels or doors are not closed properly. Rectify fault.
Air leaks from internal pipework / components. Repair or replace.
Blower or blower motor bearings worn. Repair or replace.
Loose debris impacting on blower during rotation. Remove and rectify any damage.
Blowdown valve stuck open. Repair or replace.
Pressure relief valve not seating correctly. Repair or replace.
Vibration due to motor, airend or blower imbalance. Repair or replace.
Airend requires repair. Contact your local Ingersoll Rand representative.
Scavenge pipe is blocked, broken or o-ring is not Clean or replace.
sealing.
Separator element is punctured, or incorrect, or Replace.
requires changing, or not sealing correctly.
Incorrect coolant has been added. Drain system, check for damage. Clean, refill with correct
coolant.
System has been overfilled with coolant. Check for damage, drain excess.
Aftercooler not functioning correctly. Clean or replace.
Moisture separator drain trap faulty. Repair or replace.
Continuous low speed / low ambient operation Review system requirements and contact your local
causing condensate build up. Ingersoll Rand representative.
Compressor operating above rated pressure. Check and modify settings. Review system requirements
and contact your local Ingersoll Rand representative.
Separator filter element dirty or blocked. Replace.
Voltage supply is low or unbalanced. Contact your local Ingersoll Rand representative or a
qualified electrician.
Airend is damaged. Contact your local Ingersoll Rand representative.
Coolant system leak. Repair or replace.
See also ‘discharge air is contaminated with coolant’. See above.
Refrigeration compressor not supplied power. Check incoming power supply.
Check the dryer protection fuse.
Check auxiliary contact on main motor contactor.
Condensate system malfunction. Check operation of drain valve.
Check operation of condensate check valves.
Condenser dirty. Clean condenser and replace panel filter element.
Low evaporator pressure. Check hot gas valve setting.
Debris in solenoid valve prevents diaphragm from Remove solenoid valve, disassemble, clean and
seating reassemble
Short in electrical component Check and replace power cord or timer as needed

80446362 Rev C EN-10

60513.08.02
FAULT
Emergency stop.
Blower motor overload.
High airend discharge temperature.
Check setpoints.
Remote start failure.
Remote stop failure.
Sensor failure.
Compressor trips indicating a high
compressor temperature.
Controller has tripped the
compressor.
Invalid calibration.
Low sump pressure.
Check motor rotation.
VSD communication failure.
VSD initialization fault.
Change separator element and/or
high sump pressure
Change HE filter (integrated dryer
models only)
EN-11 80446362 Rev C
Table 4: Controller Faults (indicated on the controller)
CAUSE
Emergency stop button has been
pressed.
Blower is blocked, damaged or blower
motor is faulty.
Compressor operating above rated
pressure.
Low coolant level.
High ambient temperature.
Insufficient cooling air.
Dirty, blocked coolant cooler (cooling
air side).
Blower motor direction of rotation
incorrect.
Controller software has been changed.
Remote start button is pressed after
compressor is running or remote start
button remains closed.
Remote stop button remains open and
either start button is pressed.
Sensor is missing or faulty.
Insufficient cooling taking place.
A fault has occurred.
Calibration done with pressure in
compressor.
System leak.
Minimum pressure check valve faulty.
Blowdown valve faulty.
Loss of control power.
Drive system fault.
Communication wiring faulty.
Drive faulty.
Controller faulty.
Communication wiring faulty.
Drive faulty.
Controller faulty.
Faulty pressure transducer measurement
Moisture separator condensate drain
trap faulty
Separator element dirty or blocked
Faulty pressure transducer measurement
Moisture separator condensate drain
trap faulty
Blockage in dryer
Dryer HE filter dirty or blocked
EN
REMEDY
Identify reason why, repair fault, disengage button and reset controller.
Remove blockage, repair or replace damaged components.
Check and modify settings. Review system requirements and contact
your local Ingersoll Rand representative.
Check for leaks. See also ‘discharge air is contaminated with coolant’.
Top up coolant.
Review installation and system parameters.
Check ducting and cooling air path.
Clean or replace.
Wire correctly.
Recalibrate all sensors and check setpoints.
Check operation of buttons or operating procedures.
Check operation of buttons or operating procedures.
Install, repair or replace faulty sensor.
If compressor is watercooled or sea watercooled, check that the cooling
water is flowing. Check that there is no air in the water cooling system.
Check that the strainer is not blocked.
Repair fault / reset controller.
Depressurize and re calibrate with pressure pipe to sensor
disconnected. If fault still exists, replace pressure transducer.
Located and repair.
Repair with service kit.
Repair with service kit.
Check 110V circuit breaker.
Check wiring.
Check contactor KM1.
Contact your local Ingersoll Rand representative.
Check and replace if required.
Contact your local Ingersoll Rand representative.
Contact your local Ingersoll Rand representative.
Check and replace if required.
Contact your local Ingersoll Rand representative.
Contact your local Ingersoll Rand representative.
Calibrate and validate the wet sump and package discharge
transducers
Ensure condensate drain system is functioning properly, and
condensate is being drained. See Table 3: Troubleshooting Chart
Change separator element
Calibrate and validate the after cooler discharge and package
discharge transducers
Ensure condensate drain system is functioning properly, and
condensate is being drained. See Table 3: Troubleshooting Chart
Ensure dryer blockage is not due to freeze up from refrigerant leaks
Change HE filter
60513.08.02

EN

Table 5: Drive Faults (indicated on the controller)

The drive controller is directly linked to the controller. Faults in the drive controller will be displayed on the controller as ‘VSD fault 0, VSD fault 1’ etc.
The following VSD faults may be investigated and remedied at source. For all other VSD faults, contact your local Ingersoll Rand customer support
representative.

FAULT CAUSE ACTION

VSD Fault 1 Over-current. Check separator element.
Check cooler, pipework and moisture separator for blockages.
Check operation of minimum pressure check valve (MPCV).
VSD Fault 3 Drive temperature too high. Check drive filter, replace if necessary.
Check drive cooling fan circuit breaker.
Check wiring.

80446362 Rev C EN-12

60513.08.02

EN

R37-75 INTEGRATED DRYER MAINTENANCE

Table 7: Condensate Drain Troubleshooting Chart
! WARNING
TROUBLE CAUSE ACTION
Before accessing live electrical parts, disconnect the power supply Solenoid Debris in solenoid valve Remove solenoid valve,
to the dryer using the disconnect switch or disconnecting the cable condensate valve prevents diaphragm disassemble, clean and
connections.
will not close. from seating. reassemble.
Short in electrical Check and replace power
 Maintenance Chart component. cord or timer as needed.
For optimum performance from your dryer, follow the periodic maintenance
schedule described below.  Disassembling the Integrated Dryer
Table 6: Maintenance Chart
NOTICE
WEEKLY CONDENSATE DRAINS (TIMED AND NO-LOSS
DRAINS) The dryer shall be disassembled, charged or repaired by a refrigerant
specialist.
Verify that the condensate drains are operating
correctly by pressing the TEST button. Refrigerant liquid and lubricating oil inside the refrigeration circuit
shall be recovered in compliance with current norms in the country
EVERY 4 MONTHS CONDENSER where the dryer is installed.
Remove any dust from the condenser fins.
EVERY 6 MONTHS AIR FILTER NOTICE

Replace air filter element. Refrigerant leaks may be identified by tripping of the refrigeration
overload protector.
YEARLY (TIMED DRAINS ONLY)
If a leak is detected in the refrigerant circuit, seek technical assistance.
Completely disassemble the drains and clean all
their components. If a refrigerant leak occurs, thoroughly air the room before
commencing work.
 Cleaning Condensate Drains (Timed Drains Only)
Periodically clean the screen inside the valve to keep the drain functioning at NOTICE
maximum capacity. To do this, perform the following steps:
In normal temperature and pressure conditions, the R-404A
1. Close the strainer ball valve completely to isolate it from the air refrigerant is a colorless, class A1/A1 gas with TVL value of 1000 ppm
receiver tank. (ASHRAE classification).
2. Press the TEST button on the timer to vent the pressure remaining
in the valve. Repeat until all pressure is removed.
 Decommissioning the Integrated Dryer
! WARNING Decommission the dryer and the relevant packaging in compliance with the
rules locally in force.
High pressure air can cause injury from flying debris. Ensure the
strainer ball valve is completely closed and pressure is released from Pay particular attention to the refrigerant, as it contains part of the
the valve prior to cleaning. refrigerating compressor lubricating oil.
Contact a waste disposal and recycling utility.
3. Remove the plug from the strainer with a suitable wrench. If you
Table 8: Integrated Dryer Materials of Construction
hear air escaping from the cleaning port, STOP IMMEDIATELY and
repeat steps 1 and 2. RECYCLING DISASSEMBLY
4. Remove the stainless steel filter screen and clean it. Remove any Frame and panels Steel / epoxy resin polyester
debris that may be in the strainer body before replacing the filter
screen. Heat exchanger (cooler) Stainless steel / aluminum
Pipes Copper
5. Replace plug and tighten with wrench.
Insulation Gum synthetic
6. When putting the valve back into service, press the TEST button to
confirm proper function. Compressor Steel / copper / aluminum / oil
Condenser Aluminum
 Testing Condensate Drains (No-Loss Drains Only)
Refrigerant R-404A
Press the TEST button to confirm proper function.
Valve Steel
 Troubleshooting Condensate Drains (Electronic
Drains Only)
This section provides basic troubleshooting information. Determination
of specific causes to problems are best identified by thorough inspections
performed by personnel instructed in safety, operation and maintenance
of this equipment. The chart below provides a brief guide to common
symptoms, probable causes and remedies.

EN-13 80446362 Rev C

60513.08.02
60513.08.02
60513.08.02

ingersollrandproducts.com
© 2013 Ingersoll-Rand, plc
60513.08.02

80446362
修订版 C
2013年6月

螺杆式空气压缩机
R37-160

产品维护信息

保存这些说明
60513.08.02

ZH

目录
关于本手册 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 再润滑风扇电机 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

人员 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
安全 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
空气压缩机的维护 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
维护提示 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
空气压缩机维护表 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
日常维护 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
清洗气冷步序冷却系统 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
拆卸 / 安装空气冷却器 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
清洗水冷冷却器（用于清洁水和生水选择） . . . . . . . . . . . . . . . . . 6
检查空气端高温传感器 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
清洗电机外壳 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
拆卸 / 更换起动箱动力驱动模块（PDM）的 . . . . . . . . . . . . . . . . . .
滤芯（仅 VSD 适用） . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

检查冷却剂水平 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 清洗 / 检查冷凝水的排放 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

添加冷却剂 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 清洗 / 安装机组预滤器 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

排放冷却剂 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 检查 / 清洗无损排放弯管（如果装有） . . . . . . . . . . . . . . . . . . . . 7

分析食品级冷却剂 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 监测液体并进行轴承冲击脉冲 分析 . . . . . . . . . . . . . . . . . . . . . . . 7

冷却剂抽样 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 故障排除 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
更换冷却剂过滤器 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 R37-75 集成式干燥机的维护 . . . . . . . . . . . . . . . . . . . . . . . . . 11
检查分离器芯 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 维修表 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
更换分离器芯 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 清洗冷凝水的排放件（仅定时排放） . . . . . . . . . . . . . . . . . . . . . 11
检查分离筒/压力系统 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 测试冷凝水的排放（仅无损排放）) . . . . . . . . . . . . . . . . . . . . . . 11
清洗 / 检查排滤网 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
故障排除冷凝水排放（仅用于电子排放） . . . . . . . . . . . . . . . 11
更换冷却剂软管 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
拆开集成式干燥机 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
检查最小压力止回阀（MPCV） . . . . . . . . . . . . . . . . . . . . . . . . . . 6
将集成式干燥机退役 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
更换空气过滤器 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

关于本手册
本手册的目的是旨在提供空压机的维修和故障排除指南。
有关支持文件请参考表 1。
表 1：产品手册
按地区分类的部件/文件号
出版 产品
美洲 EMEA * 亚太区
产品安全信息手册 全部 80446313 80446156 80446321
产品信息手册 全部 80446339 80446164 80446347
R37-45 kW 80448095
R55-75 kW 80446271
产品部件信息手册
R132-160 kW 单级 80446057
R90-160 kW 双级 80446065
* 欧洲、中东和非洲
还可提供产品规格表及参考图。

人员
正确使用、检查和维修将增加空压机的使用寿命和有效性。极为重要的是 有些维修程序具有较强的技术性，需要专门的工具、设备、培训和经验
涉及空压机维护的任何人员都必须熟悉空压机的维修程序并有能力执行这 才能正确完成。在这种情况下，只允许Ingersoll Rand培训的技术人员来执
些程序。这些人员应具有以下技能： 行空压机的维护。操作人员不应尝试超出本手册程序范围之外的维修或
检查。
1. 常用机械手动工具以及Ingersoll Rand 专用或推荐工具的正确与安
全使用。 有关其他信息请联系Ingersoll Rand 工厂或就近的服务提供商。
2. 由公认行业标准确立的安全程序、预防措施和工作惯例。

安全
在对空压机进行任何维修之前，一定要切断、锁住和标记电源并将空压机 使用非Ingersoll-Rand原厂更换部件可能导致安全危险、降低性能、增加维
中的压力全部释放。在进行任何维护工作前，应确保空压机至少断电 15 护工作并可能导致丧失所有保修权利。
分钟。请见产品安全信息手册的其他信息。
有关其他信息请联系Ingersoll Rand工厂或就近的服务提供商。
Ingersoll Rand 无法知道或指出进行维修时的所有程序和每种方法可能导致
的危害和/或后果。如果进行非由制造商特别推荐的维护程序，则应确保
所采取的行为不会危及安全。
如果您不了解维护程序或步骤，则请将空压机置于安全环境下再进行技
术咨询。

80446362 Rev. C ZH-

60513.08.02

ZH

空气压缩机的维护
 维护提示  空气压缩机维护表
根据所选的维修级别，维修警告和闪光 LED 将交替出现。请参考产品信 应遵循下列维护建议及优先次序：（1）控制器有指示时应进行维护；
息手册以了解维修级别设置的信息。 （2）到达小时间隔或预定维护间隔时间后应进行维护，（3）应进行年
度维护。

表 1：空气压缩机维护表
周期 操作 维护项目
当控制器有指示时 更换 空气滤芯
更换 冷却剂滤芯
更换 分离器芯
每天 检查 防漏连接和软管
检查 冷却剂液位
检查 冷凝水排放操作
检查 维修指示控制器
检查 防堵塞机组预滤器
每月 检测 防堵塞气冷步序冷却系统
检测 水冷步序冷却系统滤网
检测 起动箱动力驱动模块（PDM）滤芯
分析 水冷步序冷却系统水
每 500 小时 分析 食品级冷却剂
每 1000 小时 更换 食品级冷却剂（如果没有使用食品级过滤器模块）
更换 食品级冷却剂过滤器（如果没有使用食品级过滤器模块）
每 2000 小时或 3 个月 检测 空气滤芯
检测 冷却剂滤芯
检测 起动箱动力驱动模块（PDM）滤芯
更换 食品级冷却剂（如果使用食品级过滤器模块）
更换 食品级过滤器模块
分析 轴承冲击脉冲
分析 冷却剂
每 4000 小时或 6 个月 检测 防堵塞回油滤网
更换 空气滤芯
更换 冷却剂滤芯
更换 起动箱动力驱动模块（PDM）滤芯
更换 机组预滤器芯
清洁 气冷步序冷却系统
检查 / 清洗 水冷步序冷却系统
润滑脂 所有电机（按需要）
CALIBRATE （校准） 压力传感器
分析 冷却剂
分析 轴承冲击脉冲
每 8000 小时或每年一次 更换 标准冷却剂（8000 小时或每两年）
更换 分离器芯
更换 无损冷凝水排放维修模块
维修 最小压力止回阀（MPCV）维修套件
维修 进气阀维修套件
16000 小时 更换 冷却剂软管
更换 接触滑片

注意
处于肮脏运行环境中的冷却剂滤芯和分离器芯应更频繁地进行更换。

注意
阅读电机数据铭牌或致电电机制造商以了解具体的润滑要求。对于需要润滑的电机，在恶劣的环境或要求较高的环境条件下应对其进行更频繁的润
滑。

ZH- 80446362 Rev. C

60513.08.02

ZH

 日常维护 图 1：冷却剂排放口

本节涉及到要求定期维护并替换的各种部件。
进行任何维护工作之前，请参考下列各节中的安全信息和维护步骤。.

 检查冷却剂水平
每天都应检查冷却剂水平。油分离筒体的侧面有一个油窥镜，当机组在有
负载情况下运行时，应始终能在油窥镜中看到冷却剂水平。正常位置为一
半刻度。设备应至少运行 40 秒以进行该项检查。
1 2
停止设备运行，应确保油槽压力为 0 psig，且可从油窥镜中看到冷却剂。

 添加冷却剂
使空压机至少运行 40 秒，此时应该可以在油窥镜看到冷却剂。如果没
有：
1. 关闭压缩机。
2. 将压缩机与系统隔离。
3 4
3. 按下紧急按钮以使分离筒和空气端排气。FS 设备在停止后需要
两分钟以上才能完全将气排净。
3. 应按照当地和政府规定处理废冷却剂。
4. 缓慢地拧开冷却剂加料塞以验证是否已释放所有压力。
建议每 2000 小时或 3 个月进行一次冷却剂分析，以了解其状况并决定何
5. 添加冷却剂。 时需要更换冷却剂，如果没有进行分析，则建议每 8000 小时或每两年更
换冷却剂，以先到为准。
6. 盖上冷却剂加料塞并重新启动压缩机。
7. 再次检查冷却剂水平。 注意
8. 重复以上步骤，直到当压缩机运行和停止时都可在油窥镜中看见 如果在不利状况下操作压缩机，可能需要更频繁地更换冷却剂。
冷却剂水平为止。

注意
 分析食品级冷却剂
请勿通过空压机的进口添加冷却剂，因为这会导致添加过量、分离器过
建议采用冷却剂试样，每 500 小时或每月分析一次，以便确定更换冷却
滤芯浸透，并使冷却剂进入下游系统中。
剂的适宜时间。
如果没有进行分析，则应在使用设备配套的食品级过滤器的情况下，每
 排放冷却剂
2000 小时或每 6 个月更换冷却剂。
最好在空压机运行后立即排放冷却剂，因为这样可更快地排放冷却剂，且
对使用食品级冷却剂但没有安装食品级过滤器的设备而言，更换间隔应为
污染物仍然处于悬浮状态。
1000 小时或 6 个月，以先到为准。
请参见图 1。
 冷却剂抽样
1. 将排放软管末端置于合适的容器内。 将排放软管的另一端安装
于排放阀。 冷却剂通过排放软管自动流出。 1. 使空压机达到工作温度。

2. 排放后，卸下软管并关闭阀门。 2. 关闭空压机。
3. 将空压机与外部空气系统隔离。
注意 4. 按下紧急关机按钮以对分离槽和空气端进行排气。稳定速度的空
压机在停止后还需要两分钟以上才能将气压完全排出。
如果是气冷空压机，还可以通过卸下插塞将冷却剂从冷却器中排出。
5. 从分离器油箱口用泵套件中抽取样本 。不要从排放口或机油过
您还应该卸下空气端排放弯管中的插塞来排放空气端更多的冷却剂。
滤器中抽取样品。

每个样品都要使用新软管从泵中取样。不按照该程序操作将得到错误的
读数。
参见图 2。

80446362 Rev. C ZH-

60513.08.02

ZH

图 2：冷却剂采样 片，并使用两个螺栓将罐盖定位，但不要拧紧。
5. 松开定位螺栓以完全脱离螺纹，并以交叉方式拧紧罐盖螺栓以防
止将罐盖一侧拧得太紧。机盖紧固不当很可能会导致渗漏。

注意
完全旋松定位螺栓，确保在没有向支撑点施加任何压力的情况下机盖可
以完全紧固。如果是 75 kW 和更小的空压机，则将罐盖螺栓拧紧至 81
牛米（60 磅英尺），如果是 90 kW 和更大的空压机，则拧紧至 200 牛
米（150 磅英尺）。螺栓的拧紧顺序请参见图 3。

6. 检查冷却剂罐的回油滤网和滤孔。根据需要按照以下说明进行清
洁。
7. 将回油管道向下装入分离槽内，管道一接触分离器元件即向上提
起1/8 英寸（3 毫米）。旋紧接头。

注意
应特别小心不要将回油管道压入罐内。这可能会损坏分隔器芯。

8. 将管道安装在原位置。
图 3：推荐螺栓交叉拧紧方式
3 3
11 8 8
5
5 10
10

2 1
1
2

9 6 9
6
7 12 7
4 4

90-160 kW 55-75 kW
 更换冷却剂过滤器
1. 从过滤器壳底部卸下放油螺塞，排放冷却剂。 9. 启动压缩机并检查是否泄漏

2. 松开过滤器壳 。 注意
3. 从机体上卸下滤芯 。
切勿在分离槽或分离槽盖面上使用任何形式的密封胶。
4. 将旧的滤芯放到密封袋中，然后以安全的方式进行处理 。
5 . 从保护包装上卸下新滤芯 。  检查分离筒/压力系统
6. 在滤芯密封上涂少许冷却剂 。 每隔 2000 小时检测一次主机和油分离筒体（包括所有配件）的外表面上
是否有严重破坏、过度腐蚀和磨损的可见痕迹。在更换分离器芯时，应检
7. 将新的更换元件安装到过滤器外壳内 。
查内部组件和表面。在重新使用空压机之前，应当更换所有怀疑可能有问
8. 将外壳拧到过滤头上，根据外壳上规定的扭力拧紧 。 题的部件。

9. 重新安装放油螺塞 。 分离槽也应当根据国家或当地规定进行测试和检查。

10. 启动空压机，检查有无泄漏及冷却剂的含量 。  清洗 / 检查排滤网

 检查分离器芯
在空压机带负载运行时，通过微控制器检查分离器差压。如果压力差等于
零或超过 1 bar (15 psig)，就必须更换元件。
 更换分离器芯
1. 旋松回油管道与油分离筒体之间的接头，卸下管道部件。
2. 断开罐盖上的管道。如有必要，请在管道上贴上标签。卸下将罐
盖固定在罐体上的所有螺栓，只留下与枢轴螺栓相对的螺栓，
保留 2-3 圈螺纹，且螺丝的头部与机盖的间隙至少应为 6.5 mm
(0.25 英寸)。顺时针旋转定位螺栓，直到罐盖与罐体的间隙至少
达到 2 mm（0.08 英寸）。卸下剩余的螺栓。现在可旋转机盖，
以便手部伸入分离槽内。
3. 小心地提起分离器芯并将其拿出筒体。丢弃有故障的滤芯。丢弃
有故障的滤芯。
4. 清洗冷却剂罐和罐盖的密封表面。检查油分离筒体，完全确定没
有异物（如布片或工具等）掉入油分离筒体内。在检查新的滤芯
垫片并确定没有损坏后将其装入罐内。应确保滤芯在罐内对中并
完全安装在密封槽中。将罐盖旋回正常位置，注意不要损坏垫
排滤网/滤孔配件在外观上与直线管道接头相似，它们安装在两根外径为
1/4 英寸的回油管之间。
配件的主体由17毫米的六角形黄铜制成，滤孔直径和液体的流动方向箭头
压印在六角形钢的平面上。
应按照维护计划表中的规定清洗可拆卸滤芯和滤孔。
要卸下滤芯/孔板:
1. 断开各端的回油管道。
2. 紧紧握住配件的中心部分，使用钳子轻轻夹住组件的出口端，该
出口端密封了回油管道。出口端是朝外的一端，即箭头指向的一
端。
3. 将出口端从中心部分拉出，在操作中注意不要损坏滤网或密封表
面。
4. 在重新安装之前应清洗并检查所有零件。
5. 配件安装好后，应确认液体流动方向正确。观察压印在中心部分
的小箭头，确保流动方向为从油分离筒体到主机 。

ZH- 80446362 Rev. C

60513.08.02
ZH
 更换冷却剂软管
冷却系统中输送冷却剂的弹性软管因年久可能变脆，此时将需要更换。根
据需要或每四年更换一次。
1. 因软管位置不同，软管可能含有压缩机冷却剂。我们建议将冷却
剂排到干净的容器中。盖上容器以免内部零件受污染。如冷却剂
受到污染，必须更换新的冷却剂。 则用新冷却剂进行更换。
2. 卸下软管。
3. 安装新软管并用冷却剂充满设备。
4. 启动空压机，检查有无泄漏及冷却剂的水平。按需重新注入冷却
剂。
 检查最小压力止回阀（MPCV）
应经常测试和定期维护最小压力止回阀（MPCV）。将其从空压机上拆下
以进行测试。如果工作条件非常差，则必须相应地增加测试和维护频率。
由于受诸如不良操作环境等因素的影响，因此用户必须确定此类测试的
频率。
应该对最小压力止回阀（MPCV）进行测试并按照任何现有国家或地区法
规重新校准。如果没有适用的法规，则Ingersoll Rand推荐该阀按一年的间
隔，由授权承包商或合格的维修人员重新校准。
 更换空气过滤器
1. 检查固定盖是否有灰尘和碎片并擦拭干净。
2. 松开固定盖并卸下旧滤芯。
3. 装上新滤芯并重新装上固定盖。
 再润滑风扇电机
风扇电机含有经预先润滑的密封轴承。这些轴承不能再润滑，也不需要再
润滑。对主电机而言，应咨询电机制造商以确认电机是否需要润滑并获得
重新润滑的操作说明。
 清洗气冷步序冷却系统
如冷却器芯散热片之间的外部通道被异物堵塞，则空压机工作温度将高于
正常范围。定期清洗冷却器表面有助于空压机系统的可靠运行，能增加空
压机冷却剂的使用寿命和提高空压机的整体效率。当受现场条件和空气污
染的影响而频繁地进行清洗时，可能就不需要进行更大的清洗或更换。
1. 关闭空压机。
2. 将空压机与系统隔离。
3. 按下紧急关机按钮以对分离槽和空气端排气。稳定速度的空压机
在停止后还需要两分钟以上才能将气压完全排出。
4. 应确保主电源切断开关已锁定且贴上标签。
注意
如果需要吊升空压机零件或使用工具，应始终使用合格的吊升设备并遵
循严格的工作程序。
5. 目视检查冷却器芯外部，以确定适当的清洁方法，详情如下。
a. 对于松散尘土及其它细小异物，请打开冷却器侧面的检修板，并
用压缩空气轻轻吹扫机油冷却器的表面。使用带软刷的真空软管
以清洗空气后冷却器的暴露面。重复该程序，直到冷却器清洗干
净为止。将检修板复位后再返回对设备进行维修。
b. 对于厚重密实的尘土、机油、润滑脂及其他大面积脏污，则需将
冷却器从设备上卸下进行压力冲洗。由于在电源周围喷水十分危
险，因此Ingersoll Rand不建议在冷却器安装在机构系统中时进行
压力清洗。遵循下列步骤，拆除冷却器。
 拆卸 / 安装空气冷却器
要拆卸：
1. 关闭空压机。
2. 将空压机与系统隔离。
3. 按下紧急关机按钮以对分离槽和空气端进行排气。稳定速度的空
压机在停止后还需要两分钟以上才能将气压完全排出。
4. 应确保主电源切断开关已锁定且贴上标签。
80446362 Rev. C ZH-
注意
如果需要吊升空压机零件或使用工具，应始终使用合格的吊升设备并遵
循严格的工作程序。
5. 卸下位于空气冷却器前面和冷却剂冷却器下方的六角插塞以将冷
却剂从冷却器中排出。
6. 从冷却器上卸下所有软管、管道和传感器。
7. 拆卸外金属面板.
8. 卸下冷却器各侧的检修板
9. 正确固定空气后冷却器并卸下冷却器上边 2 个螺栓上的 4 个螺
母。
10. 卸下冷却器底部螺栓上的 2 个螺母。
11. 小心地卸下空气后冷却器。
12. 正确固定机油冷却器并卸下冷却器上边 2 个螺栓上的 4 个螺
母。
13. 卸下冷却器底部螺栓上的 2 个螺母。
14. 小心地卸下机油冷却器。
15. 如果是 75 kW 和更小的空压机，则将冷却剂插塞重新拧紧至 23
牛米（17 磅英尺），如果是 90 kW 和更大的空压机，则拧紧至
65 牛米（48 磅英尺）。
要安装：
1. 关闭空压机。
2. 将空压机与系统隔离。
3. 按下紧急关机按钮以对分离槽和空气端进行排气。稳定速度的空
压机在停止后还需要两分钟以上才能将气压完全排出。
4. 应确保主电源切断开关已锁定且贴上标签。
注意
如果需要吊升空压机零件或使用工具，应始终使用合格的吊升设备并遵
循严格的工作程序。
5. 小心地将机油冷却器放在其正确的位置，安装两组下紧固件并将
其拧紧。
6. 安装两组上紧固件并用手拧紧 - 圈。接下来安装第二个螺母并将
其拧紧。第二个螺母用于将第一个锁定到位。切记第一个螺母不
能过紧，以便冷却器进行膨胀和收缩时不会压迫冷却器的铜焊接
头。
7. 应确保空气后冷却器上的橡胶密封在冷却器上安装到位和状况良
好。
8. 小心地将空气后冷却器的冷却器放在其正确的位置，安装两组下
紧固件并将其拧紧。
9. 安装两组上紧固件并用手拧紧 - 圈。接下来安装第二个螺母并将
其拧紧。第二个螺母用于将第一个锁定到位。切记第一个螺母不
能过紧，以便冷却器进行膨胀和收缩时不会压迫冷却器的铜焊接
头。
10. 重新连接所有的软管、管道和传感器，并根据零部件信息手册用
适当的扭矩拧紧。
11. 重新装上冷却器各边的检修板。
12. 按照“添加冷却剂“中所描述的程序给空压机充填冷却剂到合适
的液位。
 清洗水冷冷却器（用于清洁水和生水选择）
对于水冷式热交换器，应当定期执行检查和维护程序。如果您没有经验或
没有设备进行此项工作，建议您与Ingersoll Rand联系以获得清洗服务。
如果进水管道有滤网，应检查滤网并按要求更换或清洗。
清洁冷却器时，可使用含氨基硫磺酸和柠檬酸的除垢剂及中性溶液清除矿
物积垢。作为一种可选方法，可使用 1:4 的弱酸水。
60513.08.02
应使用适当的清洁剂在热水中去除污垢。
至少使用正常流速的 1.5 倍速度反冲洗冷却器。
在使用任何清洁溶液之后，应使用清水彻底冲洗掉所有的化学品之后再返
回到冷却器的维修。
不推荐使用机械清洗方法，因其可能损坏内部通道。
清洁后，请检查冷却器是否受到腐蚀或磨损。
 检查空气端高温传感器
建议按以下时间定期检查排气温度传感器（2ATT）：
a. 对气冷式设备而言，可打开风扇/风扇电机的断路器使冷却风扇
停止运转。
b. 对水冷式设备而言，应关闭冷却水。
空压机应在109 ℃（228 ° F）跳闸。跳闸警告将出现在控制器的显示器
上。
图 4：起动箱动力驱动模块（PDM）滤芯的更换
 清洗 / 检查冷凝水的排放
1. 进行任何维护工作前，请确保空压机至少断电 15 分钟。
2. 将空压机与系统隔离，并排出机器内的全部压缩空气。
3. 卸下水分离器底部管件上的塑料管。
4. 卸下接水杯，将其清洗并重新安装。
 清洗 / 安装机组预滤器
1. 打开两个 1/4 圈的闩锁并打开进气面板（铰链面板）
2. 卸下六个翼形螺母和平垫圈。
3. 拆下过滤器格板。
4. 拉出滤芯。
5. 将新滤芯在机组进气开口中对中。还要注意过滤器可用温和洗涤
剂清洗。
6. 将过滤器推向格板杆，以使格板杆穿过过滤器介质。
7. 安装过滤器格板。
8. 安装六个翼形螺母和平垫圈。
9. 关闭进气面板和闩锁。
ZH- 80446362 Rev. C
ZH
 清洗电机外壳
1. 在进行任何维护工作前，请确保空压机至少断电 15 分钟。
2. 卸下压缩机的检修板。
3. 使用一块干净的干布擦去电机外壳表面的灰尘，并确保所有通风
孔没有残留任何障碍物。
4. 装上检修板。
 拆卸 / 更换起动箱动力驱动模块（PDM）的
滤芯（仅 VSD 适用）
请见图 4。
1. 在进行任何维护工作前，请确保空压机至少断电 15 分钟。
2. 打开起动箱过滤器外壳的前格板。
3. 卸下外壳上的滤芯并用新滤芯更换。
4. 重新装好前格板。
 检查 / 清洗无损排放弯管（如果装有）
建议每天检查无损耗排放弯管，以确保冷凝水从水分离器系统中排出要检
查功能是否正常。
1. 按下设备上的测试按钮并倾听是否有冷凝水 / 空气通过排放弯
管。
2. 如果排放弯管已堵塞，则应更换无损排放阀维修模块。维修模块
包含排放弯管较底的部分，且无法进行维修。
另外，建议每 8000 小时或每年更换维修模块，以先到为准。
 监测液体并进行轴承冲击脉冲
分析
Ingersoll-Rand建议将推测性维护（尤其是使用冷却剂和轴承冲击脉冲分
析）与所有的预防性维护结合起来。请联系Ingersoll Rand了解详情。
60513.08.02

ZH

故障排除
本节介绍故障排除的基本信息。应按照本设备安全、操作和维修说明，由专业人员进行彻底检查以确定问题的具体原因。以下图表为常见状况、可能
的原因及维修方法提供了简要指南。
表 3：一般故障
状况 故障 维修方法
空压机不启动 机组不通电 检查是否接通电源。如果电源已接通，请与合格的电
工联系。
微控制器故障 检查控制器是否通电。更换控制器。
起动机故障 断开电源，锁定并贴上标签。更换故障部件或与当地
Ingersoll-Rand代表联系
空压机停机后不能重新启动 驱动控制器已切断 请见表 3 和 4。
微控制器使压缩机跳闸 请见表 3 和 4。
已超过每小时的最大允许启动次数
空压机停机后不能重新启动 微控制器使压缩机跳闸和没有复位 请见表 3 和 4。
按下了紧急停机按钮但未放开 找到故障原因并进行修理，松开按钮并将微控制器复位
已按下并释放紧急按钮，但微控制器没有复位 修理故障并复位微控制器
空压机无法满足系统所要求的压力 空压机规格无法满足系统要求或要求已变更。 联系您当地的Ingersoll-Rand代表
因导管、软管、接头或密封损坏而漏气 修理或更换。
因放气阀回路故障而漏气 修理或更换。
因减压安全阀固定不当而漏气 修理或更换。
因水分离器排放弯管回路故障而漏气 修理或更换。
因驱动设置不当而导致电机转速过低 联系您当地的Ingersoll-Rand代表
因驱动设置有误而导致电机转速过低 请见表 4。
微控制器故障 修理或更换。
驱动电机故障 请见表 4。
压力传感器出现故障、校准有误或电磁干扰 重新校准或更换
微控制器设置不正确 检查并修改设置
进气格栅或导管阻塞 检查并清洁
空气过滤器脏污或损坏 更换
空压机无法满足系统所要求的压力 进气阀未完全打开 修理或更换。
分离器元件脏污或损坏 更换
管道/导管阻塞或损坏 清洁或更换
冷却器芯子阻塞 清洁或更换
最小压力止回阀运转不正常 修理或更换。
空压机与客户测点之间的设备导致产生压降/压力 请查看系统要求
损失
因空压机速度在需要降低时没有降 微控制器设置不正确 检查并修改设置
低而导致空压机的压力过高。 压力传感器出现故障、校准有误或不接收压力信号 重新校准或更换
驱动设置故障 联系您当地的Ingersoll-Rand代表
空压机排放空气过热 环境温度高 查看安装及系统参数
冷却空气不足 检查导管及冷却空气管路，检查风扇的旋转方向
后冷却器（冷却空气侧）脏污、阻塞 清洁或更换

80446362 Rev. C ZH-

60513.08.02

ZH

表 3：一般故障（续）
状况 故障 维修方法
空压机组噪音过大 护板或门没有完全关闭 矫正故障
内部管道系统／部件漏气 修理或更换。
风扇或风扇电机轴承磨损 修理或更换。
松动的残存物对离心风扇旋转有影响 撤换并矫正任何损坏的部件
放气阀回路故障 修理或更换。
减压安全阀固定有误 修理或更换。
因电机、空气端或风扇不平衡而产生振动 修理或更换。
主机需要检修 联系您当地的Ingersoll-Rand代表
排放空气被冷却剂污染 排滤管道阻塞、破损或 O 形圈没有完全密封 清洁或更换
分离器芯被刺破、型号有误、需要更换或没有正 更换
确密封
添加的冷却剂不正确 检查排放系统有无损坏。清洁该系统，然后重新灌注正
确的冷却剂。
系统内的冷却剂过多 检查系统是否有损坏，是否排出过量的冷却剂。
排放空气被冷凝水污染 后冷却器功能失灵。 清洁或更换
水分离器排放弯管出现故障 修理或更换。
持续的低速/低温操作导致冷凝水淤积 查看系统要求并联系您当地的Ingersoll-Rand代表
空压机组产生的电流过高 空压机超出额定压力运转 检查并修改设置。查看系统要求并联系您当地的
Ingersoll-Rand代表
分离器过滤器元件脏污或阻塞 更换
电压过低或不稳定 联系您当地的Ingersoll-Rand代表或合格电工
空气端损坏 联系您当地的Ingersoll-Rand代表
冷却剂消耗过度 冷却剂系统泄漏 修理或更换。
还请见“排气空气受到冷却剂的污染” 参见上文
露点高 制冷空压机未通电。 检查供电。
检查干燥器保护熔断器。
检查主电机接触器辅助触点。
冷凝水系统功能失灵。 检查排放阀的运行状况。
检查冷凝水止回阀的运行状况。
冷凝器脏了。 清洁冷凝器并更换面板滤芯。
干燥器内结冰了 蒸发器压力过低。 检查热气阀设置。
冷凝水电磁阀不能关闭 电磁阀内的碎屑阻止膜片贴合 卸下并拆开电磁阀，清洗后重新装配
电气部件短路 检查并根据需要更换电源线或计时器

ZH- 80446362 Rev. C

60513.08.02

ZH

表 4：控制器故障（显示在控制器上）
故障 原因 维修方法
EMERGENCY STOP（紧急停机） 紧急停机按钮已按下。 找到故障原因并进行修理，松开按钮并将微控制器复位
BLOWER MOTOR OVERLOAD (风扇 风扇阻塞、损坏或风扇电机出现故障。 清除阻塞物、修理或更换损坏的零部件
电机过载)
高空气喷口排气温度 空压机超出额定压力运转 检查并修改设置。查看系统要求并联系您当地的Ingersoll-Rand代表
冷却剂不够 检查是否有泄漏。还请见“排气空气受到冷却剂的污染”加满冷却
剂。
环境温度高 查看安装及系统参数
冷却空气不足 检查导管及冷却空气管路。
冷却器（冷却空气侧）脏污、阻塞 清洁或更换
风扇电机的旋转方向不正确 正确接线
检查设定点 控制器软件已更改 重新校准所有传感器并检查设定点
REMOTE START FAILURE（远程启 远程启动按钮在设备运转后按下或远程 检查按钮的状况或操作步骤
动失败） 启动按钮处于关闭状态。
REMOTE STOP FAILURE（远程停机 远程停机按钮处于打开状态且启动按 检查按钮的状况或操作步骤
失败） 扭已按下
传感器故障 缺少传感器或传感器故障 安装、修理或更换故障的传感器
压缩机跳闸表示空压机温度过高。 发生冷却剂不足情况 如果机器是用水冷却或用海水冷却，则检查冷却水是否在流动。检
查水冷却系统中是否没有空气。检查滤网是否未阻塞。
微控制器使压缩机跳闸 出现故障 修理故障 / 复位微控制器
校准无效 在空压机中有压力的情况下进行了校准 在压力管道与传感器断开的情况下降压并重新校准。如故障仍然存
在，请更换压力传感器。
LOW SUMP PRESSURE（分离前压力 系统渗漏 找到渗漏处并进行修理
过低） 最小压力止回阀故障 使用维修套件进行修理
放气阀故障 使用维修套件进行修理
控制电源损失 检查110V断路器
检查接线
检查接触器KM1
检查电机旋转 驱动系统故障 联系您当地的Ingersoll-Rand代表
VSD通讯故障 通信连线有误 检查并在必要时更换
驱动故障 联系您当地的Ingersoll-Rand代表
微控制器故障 联系您当地的Ingersoll-Rand代表
VSD初始化故障 通信连线有误 检查并在必要时更换
驱动故障 联系您当地的Ingersoll-Rand代表
微控制器故障 联系您当地的Ingersoll-Rand代表
变更分离器元件和/或高油槽压力 故障压力传感器测量 校准并验证湿油槽和机组排放传感器
水分离器冷凝液排放弯管故障 确保冷凝液排放系统正常工作，冷凝液正在排放。 参见表 3： 故障
排除图表。
分离器元件变脏或堵塞 更换分离器元件。
更换 HE 过滤器 (集成式乾燥機機 故障压力传感器测量 校准并验证后冷却器排放和机组排放传感器
型) 水分离器冷凝液排放弯管故障 确保冷凝液排放系统正常工作，冷凝液正在排放。 参见表 3： 故
障排除图表
干燥机堵塞 确保干燥机不因制冷剂泄漏导致的冻结而堵塞。
干燥机 HE 过滤器变脏或堵塞 更换 HE 过滤器。

表 5：驱动器故障（显示在控制器上）
驱动控制器直接连接到控制器上。驱动控制器的故障将显示在控制器上，如“VSD 故障 0、VSD 故障 1” 等。
下列 VSD 故障会在原产地进行调查并矫正。关于其它VSD故障，请联系您当地的Ingersoll-Rand客户支持代表。

故障 原因 操作
VSD 故障 1 过流 检查分离器芯。
检查冷却器、管道系统和水分离器是否阻塞。
检查最小压力止回阀的运行状况。
VSD故障 3 驱动器温度过高 检查驱动过滤器，如有必要请予以更换
检查驱动冷却风扇的断路器
检查接线

80446362 Rev. C ZH-10

60513.08.02

ZH

R37-75 集成式干燥机的维护
表 7：冷凝水排放故障诊断表
警告
故障 原因 操作
在接近带电部件之前，应使用断路开关或断开电缆连接的办法断开干燥 冷凝水电磁阀不 电磁阀内的碎屑阻止膜 卸下并拆开电磁阀，清
机的电源。 能关闭。 片贴合。 洗后重新装配。
电气部件短路。 检查并根据需要更换电
源线或计时器。
 维修表
为了获得干燥机的最佳性能，应按照下述定期维护计划表进行操作。.  拆开集成式干燥机
表 6：维修表
注意
每周 冷凝水的排放（定时和无损排放）
按下测试按钮以验证冷凝水的排放操作是否正 该设备必须由制冷专业人士拆卸、加料或修理。
确。 制冷环路中的制冷剂和润滑油必须按照安装机器所处国家的当前标准予
每 4 个月 冷凝器 以回收利用。

除去冷凝器冷凝片上的所有灰尘。
注意
每 6 个月 空气过滤器
制冷剂泄漏可以通过启动制冷系统过载保护器来识别。
更换空气过滤器芯。
每年 （仅定时排放） 如果在制冷回路中发现泄漏，应寻求技术帮助。

完全拆开排水部件，清洁所有部件。 一旦发生制冷剂泄漏，首先让房间彻底通风，然后再进行其他作业。

 清洗冷凝水的排放件（仅定时排放） 注意
定期清理阀内部的滤网，以保持最大容量的排放功能。为此，请执行下
在正常的温度和压力条件下，R404 制冷剂为无色，A1/A1 类气体，
列步骤：
TVL 值为 1000 ppm（ASHRAE 分类法）。
1. 完全关闭滤网球阀以使之与储气罐隔离。
2. 按下定时器上的“测试”按钮以便排出阀中的剩余压力。重复此  将集成式干燥机退役
步骤直到排完所有压力。
按照当地现行规定将设备和相关机组退役。
警告 由于制冷剂中含有少量制冷压缩机润滑油，因此须特别注意。
高压空气会导致残存物飞溅£-并造成伤害。请确保在清理前滤网球阀 请与废料处理和回收公共单位联系。
已完全关闭，而且阀中的压力已全部释放。
表 8：集成式干燥机的制造材料。.

3. 用适当的扳手卸下滤网上的插塞。如果您听到空气从清理端口出 回收利用部件
来的声音，请立即停止，并重复步骤 1 和 2。 机壳和面板 钢／环氧树脂聚酯
4. 卸下不锈钢过滤器芯并将其清洗干净。在更换滤网前，请清除滤 热交换器（冷却器） 不锈钢 / 铝
网中的所有残存物。 管道 铜
5. 重新装上插塞并用扳手拧紧。 绝缘体 合成胶
6. 当重新使用电子排水阀时，请按“测试”按钮以确认其具有正常 压缩机 钢／铜／铝／油
的功能。 冷凝器 铝
 测试冷凝水的排放（仅无损排放）) 制冷剂 R-404A

按下测试按钮以确认其具有正常的功能。 阀 钢

 故障排除冷凝水排放（仅用于电子排放）
本节介绍故障排除的基本信息。应按照本设备安全、操作和维修说明，由
专业人员进行彻底检查以确定问题的具体原因。以下图表为常见状况、可
能的原因及维修方法提供了简要指南。

ZH-11 80446362 Rev. C

60513.08.02

ingersollrandproducts.com
© 2013 Ingersoll-Rand, plc