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R 90-160 IU Operation & Maintenance July 2007 Rev.A
R 90-160 IU Operation & Maintenance July 2007 Rev.A
Note that this is Ingersoll−Rand standard warranty. Any warranty in force at the time of purchase of the compressor
or negotiated as part of the purchase order may take precedence over this warranty.
Ingersoll−Rand
Industrial Air Solutions
Swan Lane
Hindley Green
Wigan WN2 4EZ
Ingersoll−Rand
Industrial Air Solutions
P.O. Box 1840
800−D Beaty Street
Davidson, NC 28036
CONTENTS & ABBREVIATIONS 1
CONTENTS ABBREVIATIONS & SYMBOLS
49 MAINTENANCE
52 FAULT FINDING
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2 FOREWORD
TABLE 1
The contents of this manual are considered to be proprietary and
confidential to Ingersoll Rand and should not be reproduced without the Use of the machine to produce compressed air for:
prior written permission of Ingersoll Rand. a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
checks.
Nothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied, regarding Use of the machine outside the ambient temperature range
the Ingersoll Rand products described herein. Any such warranties or specified in the GENERAL INFORMATION SECTION of this manual.
other terms and conditions of sale of products shall be in accordance
with the standard terms and conditions of sale for such products, which Use of the machine where there is any actual or foreseeable risk of
are available upon request. hazardous levels of flammable gases or vapours.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE
This manual contains instructions and technical data to cover all USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
routine operation and scheduled maintenance tasks by operation and INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR
maintenance staff. Major overhauls are outside the scope of this VAPOURS MAY BE PRESENT.
manual and should be referred to an authorised Ingersoll Rand service
department. Use of the machine fitted with non Ingersoll Rand approved
components.
Machine models represented in this manual may be used in various Use of the machine with safety or control components missing or
locations world−wide. Machines sold and shipped into European disabled.
Union Territories require that the machine display the EC Mark and
conform to various directives. In such cases, the design specification Connection to an electrical supply of incorrect voltage and/or
of this machine has been certified as complying with EC directives. Any
frequency.
modification to any part is absolutely prohibited and would result in the
CE Certification and marking being rendered invalid.
The company accepts no responsibility for errors in translation of
All components, accessories, pipes and connectors added to the this manual from the original English version.
compressed air system should be:
. of good quality, procured from a reputable manufacturer and,
wherever possible, be of a type approved by Ingersoll Rand. ULTRA COOLANT is a registered trademark of Ingersoll−Rand
. clearly rated for a pressure at least equal to the machine maximum Company USA.
allowable working pressure.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation, operation and INTELLISYS is a registered trademark of Ingersoll−Rand
maintenance. Company USA.
The use of repair parts other than those included within the Ingersoll
Rand approved parts list may create hazardous conditions over which
Ingersoll Rand has no control. Therefore Ingersoll Rand cannot be held
responsible for equipment in which non−approved repair parts are
installed.
The intended uses of this machine are outlined below and examples
of unapproved usage are also given, however Ingersoll Rand cannot
anticipate every application or work situation that may arise.
This machine has been designed and supplied for use only in the
following specified conditions and applications:
. Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.
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ISO SYMBOLS 3
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
WARNING − Pressure control. WARNING − Corrosion risk. WARNING − Air/gas flow or Air discharge.
X,X BAR
0_C
WARNING − Before connecting the tow bar WARNING − For operating temperature
WARNING − Flammable liquid. or commencing to tow consult the below 0_C, consult the operation and
operation and maintenance manual. maintenance manual.
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4 ISO SYMBOLS
Do not remove the Operating and Maintenance Do not operate the machine without the guard
Do not stack.
manual and manual holder from this machine. being fitted.
Do not stand on any service valve or other Do not operate with the doors or enclosure
Do not use fork lift truck from this side.
parts of the pressure system. open.
XX
km/h
Use fork lift truck from this side only. Emergency stop. Tie down point
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ISO SYMBOLS 5
a
Read the Operation and Maintenance manual
When parking use prop stand, handrake and
before operation or maintenance of this Contains asbestos.
wheel chocks.
machine is undertaken.
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6 ISO SYMBOLS
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ISO SYMBOLS 7
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8 DECALS (I.S.O.)
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SAFETY 9
WARNING
WARNINGS
Imposing a normal or emergency stop on the compressor will
Warnings call attention to instructions which must be followed
only relieve pressure upstream of the minimum pressure valve on
precisely to avoid injury or death.
top of the separator tank.
If maintenance work is required downstream of this valve, ensure
CAUTIONS
that all pressure is relieved at the process vent point external to
Cautions call attention to instructions which must be followed
the compressor
precisely to avoid damaging the product, process or its surroundings.
This state is advised by selecting PACKAGE DISCHARGE
NOTES PRESSURE on the control panel.
Notes are used for supplementary information.
Ensure that the Operation and Maintenance manual, and the Materials
manual holder, are not removed permanently from the machine.
The following substances are used in the manufacture of this
machine and may be hazardous to health if used incorrectly:
Ensure that maintenance personnel are adequately trained, . preservative grease
competent and have read the Maintenance Manuals. . rust preventative
. compressor coolant
Compressed air
Consult a physician if compressor lubricant is inhaled.
Ensure that the machine is operating at the rated pressure and that
the rated pressure is known to all relevant personnel.
Never give fluids or induce vomiting if the patient is unconscious or
having convulsions.
All air pressure equipment installed in or connected to the machine
must have safe working pressure ratings of at least the machine rated
pressure. Transport
When loading or transporting machines ensure that the specified
If more than one compressor is connected to one common lifting and tie down points are used.
downstream plant, effective check valves and isolation valves must be
fitted and controlled by work procedures, so that one machine cannot
Electrical
accidentally be pressurised / over pressurised by another.
Keep all parts of the body and any hand−held tools or other
conductive objects, away from exposed live parts of the compressor
Compressed air must not be used for a direct feed to any form of
electrical system. Maintain dry footing, stand on insulating surfaces
breathing apparatus or mask.
and do not contact any other portion of the compressor when making
adjustments or repairs to exposed live parts of the compressor
The discharged air contains a very small percentage of compressor electrical system.
lubricating oil and care should be taken to ensure that downstream
Close and lock all access doors when the compressor is left
equipment is compatible.
unattended.
If the discharged air is to be ultimately released into a confined Do not use extinguishers intended for Class A or Class B fires on
space, adequate ventilation must be provided. electrical fires. Use only extinguishers suitable for class BC or class
ABC fires.
When using compressed air always use appropriate personal Attempt repairs only in clean, dry, well lighted and ventilated areas.
protective equipment. Connect the compressor only to electrical systems that are
compatible with its electrical characteristics and that are within it’s rated
capacity.
All pressure containing parts, especially flexible hoses and their
couplings, must be regularly inspected, be free from defects and be
replaced according to the Manual instructions.
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10 SAFETY
Condensate disposal
Condensate cannot be discharged into fresh/surface water drains.
In some regions compressor condensate containing ULTRA
COOLANT can be fed directly into a drainage system that has
downstream sewerage treatment.
Coolant disposal
Steps to be taken in the case of spillage: Soak up with a suitable
absorbent material, then sweep into a plastic bag for disposal.
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GENERAL INFORMATION 11
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12 GENERAL INFORMATION
18. Scavenge filter / orifice / check PIPING LEGEND
19. Separator tank (primary/secondary) A. Air/coolant
20. Oil temperature control valve B. Air
21. Temperature thermistor 2ATT C. Coolant
22. 3SV blowdown solenoid valve D. Condensate
23. Drive motor E. Cooling water (W.C. only)
24. Fan motor F. Compressor enclosure
25. Cooling fan G. Sensor connection
26. Cooling water inlet (W.C. only) H. Modulation
27. Cooling water outlet (W.C. only)
28. Pressure transducer 3APT NOTES
29. Water stop valve 4SV 1. For customer connection sizes and locations see foundation plan
of unit.
30. Modulation valve 6SV
2. Post filter must be supplied by customer.
31. Modulation valve 5SV
32. Regulator
33. Shuttle valve
34. Ball valve
M(o)Modulation (optional)
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GENERAL INFORMATION 13
GENERAL OPERATION OPTIONAL FEATURES
The compressor is an electric motor driven, single stage screw Modulation hardware extends the control types to Modulation
compressor, complete with accessories piped, wired and baseplate (capacity control) and Automatic Control System when the compressor
mounted. It is a totally self contained air compressor package. switches between ’On−Off line’ and modulation as demand varies.
The standard compressor is designed to operate in an ambient Safety of operation is provided for as the compressor will shut down
range of 2_C to 46_C (35_F to 115_F). The standard maximum if excessive temperatures, electrical overload conditions, or system
temperature of 46_C (115_F) is applicable up to an elevation of 1000m over pressure should occur.
(3280ft) above sea level. Above this altitude significant reductions in
ambient temperature are required if a standard motor is to be used. Low Ambient Option (Standard & Enhanced Compressors)
Compression in the screw type air compressor is created by the When the low ambient option is installed and selected and the A/E
meshing of two (male & female) helical rotors. Discharge Temperature is measured to be at or below 2_C (35_F), the
The air/coolant mixture discharges from the compressor into the compressor will be started when commanded but will delay to load a
separation system. This system removes all but a few PPM of the period of time defined by the Low Ambient Delay Time. This will allow
coolant from the discharge air. The coolant is returned to the cooling the coolant temperature to rise above an allowable level before loading
system and the air passes to the aftercooler and out of the compressor the compressor in cold environments.
through the moisture separator (optional). When the low ambient option is not installed, the machine will not start
Air is pulled into the machine by the cooling fan and is pushed if the A/E Discharge Temperature is below 2_C (35_F).
through the combined cooler / aftercooler.
CAUTION
By cooling the discharge air and passing it through the separator, If PORO or Scheduled Start / Stop are installed, additional
much of the water vapour which is naturally present in the air, can be hardware is required to provide an audible warning of pending
removed. re−start.
The coolant system consists of a sump, cooler, thermostatic valve Contact IR for details.
and a filter. When the unit is operating, the coolant is pressurised and
forced to the compressor bearings. Power Out Restart Option (PORO)
(Dependant on installed options and/or installed controls)
The compressor load control system is automatic ’On−Off line’. The
compressor will operate to maintain a set discharge line pressure and For PORO to execute, the PORO option must be installed and the
is provided with an auto restart system for use in plants where the air PORO set point must be set to ON. If power is lost to the compressor
demand varies widely. while the unit is running or is stopped in auto start/stop, the controller
will store the current operating conditions in memory.
Panel instrumentation is provided to indicate the compressor
operating conditions and general status. When power is restored, the controller will energize the horn and start
a countdown on the display. The red LED will flash indicating a warning
condition and the horn will blow for the number of seconds set in the
CAUTION PORO time set point. At the end of the countdown, the horn will stop
LOW DEMAND APPLICATIONS blowing and the compressor will start.
During periods of low demand, the compressor may not
reach its normal operating temperature. Sustained operation at The PORO countdown may be stopped at any time by pressing the
low demand can result in the build up of condensate in the Stop / Reset button on the user interface. Pressing any button will
coolant. If this situation occurs, the lubricating characteristics cause the horn to stop blowing and the countdown to stop. The control
of the coolant can be impaired which may lead to damage of the will power up normally in a ready to start mode.
compressor.
THE COMPRESSOR SHOULD BE ALLOWED AMPLE LOADED Scheduled Start / Stop
RUNNING TIME. (Dependant on installed options and/or installed controls)
The scheduled start / stop option enables starting and stopping the
compressor at specified times. This mode of operation can be turned
on and off by selecting the desired mode in the Scheduled Start Stop
On / Off Setpoint.
When enabled, the horn will blow for 10 seconds to warn anyone in the
surrounding area that the compressor is about to start. The display
screen will display the warning message ”Scheduled Start in X
seconds”, where ”X” is a countdown from 10 to 0 seconds. After 10
seconds, the compressor will automatically start as long as the
compressor is not in a fault condition or manually stopped by pressing
the stop / reset button.
When a scheduled stop occurs, the compressor can be manually
re−started by pressing the control panel start button or closing the
remote start signal.
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14 GENERAL INFORMATION
ROTARY 125 HP 60 Hz R90IU−100 R90IU−125 R90IU−140
AFTERCOOLED DATA
Aftercooler CTD (2) _F (_C) 15 (8) 15 (8) 15 (8)
Fan Air Flow CFM (m3/min) 13,000 (368) 13,000 (368) 13,000 (368)
Maximum Added Static Pressure in (mm) H2O 0.25 (6.4) 0.25 (6.4) 0.25 (6.4)
WATERCOOLED DATA
Aftercooler CTD (2) _F (_C) 25 (14) 25 (14) 25 (14)
Cooling Water Required
(recommend 25−60 GPM (95−227 litres / min))
@ 50_F (10_C) GPM (litres / min) 35 (132) 34 (129) 35 (132)
@ 70_F (21_C) GPM (litres / min) 33 (125) 33 (125) 32 (121)
@ 90_F (32_C) GPM (litres / min) 31 (117) 31 (117) 31 (117)
@ 115_F (46_C) GPM (litres / min) 28 (106) 29 (110) 29 (110)
Water Temperature Rise _F (_C) 25 (14) 25 (14) 25 (14)
Water Pressure Drop @ max flow rate condition
(50 deg F water)
Oil Cooler psid(bar) 1.9 (0.13) 2.0 (0.14) 2.1 (0.14)
Oil Cooler and After Cooler psid(bar) 0.36 (0.02) 0.30 (0.02) 0.32 (0.02)
Fan Air Flow CFM (m3/min) 4,000 (113) 4,000 (113) 4,000 (113)
Maximum Added Static Pressure in (mm) H2O 0.25 (6.4) 0.25 (6.4) 0.25 (6.4)
LUBRICATION DATA
Sump Capacity USgal (litres) 16 (61) 16 (61) 16 (61)
Total Lubrication System Capacity USgal (litres) 25 (95) 25 (95) 25 (95)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 15
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H Inch (mm) 102.5 (2600) 65.5 (1661) 92 (2330)
Discharge Air Connection NPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet NPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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16 GENERAL INFORMATION
ROTARY 150 HP 60 Hz R110IU−100 R110IU−125 R110IU−140
AFTERCOOLED DATA
Aftercooler CTD (2) _F (_C) 15 (8) 15 (8) 15 (8)
Fan Air Flow CFM (m3/min) 13,000 (368) 13,000 (368) 13,000 (368)
Maximum Added Static Pressure in (mm) H2O 0.25 (6.4) 0.25 (6.4) 0.25 (6.4)
WATERCOOLED DATA
Aftercooler CTD (2) _F (_C) 25 (14) 25 (14) 25 (14)
Cooling Water Required
(recommend 25−60 GPM (95−227 litres / min))
@ 50_F (10_C) GPM (litres / min) 41 (155) 41 (155) 40 (151)
@ 70_F (21_C) GPM (litres / min) 40 (151) 39 (148) 39 (148)
@ 90_F (32_C) GPM (litres / min) 37 (140) 37 (140) 37 (140)
@ 115_F (46_C) GPM (litres / min) 34 (129) 34 (129) 35 (132)
Water Temperature Rise _F (_C) 25 (14) 25 (14) 25 (14)
Water Pressure Drop @ max flow rate condition
(50 deg F water)
Oil Cooler psid(bar) 2.6 (0.18) 2.8 (0.19) 2.9 (0.20)
Oil Cooler and After Cooler psid(bar) 0.52 (0.04) 0.45 (0.03) 0.39 (0.03)
Fan Air Flow CFM (m3/min) 4,000 (113) 4,000 (113) 4,000 (113)
Maximum Added Static Pressure in (mm) H2O 0.25 (6.4) 0.25 (6.4) 0.25 (6.4)
LUBRICATION DATA
Sump Capacity USgal (litres) 16 (61) 16 (61) 16 (61)
Total Lubrication System Capacity USgal (litres) 25 (95) 25 (95) 25 (95)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 17
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H Inch (mm) 102.5 (2600) 65.5 (1661) 92 (2330)
Discharge Air Connection NPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet NPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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18 GENERAL INFORMATION
ROTARY 200 HP 60 Hz R150IU−100 R150IU−125 R150IU−140
AFTERCOOLED DATA
Aftercooler CTD (2) _F (_C) 15 (8) 15 (8) 15 (8)
Fan Air Flow CFM (m3/min) 13,000 (368) 13,000 (368) 13,000 (368)
Maximum Added Static Pressure in (mm) H2O 0.25 (6.4) 0.25 (6.4) 0.25 (6.4)
WATERCOOLED DATA
Aftercooler CTD (2) _F (_C) 25 (14) 25 (14) 25 (14)
Cooling Water Required
(recommend 25−60 GPM (95−227 litres / min))
@ 50_F (10_C) GPM (litres / min) 55 (208) 54 (204) 54 (204)
@ 70_F (21_C) GPM (litres / min) 53 (201) 52 (197) 52 (197)
@ 90_F (32_C) GPM (litres / min) 50 (189) 50 (189) 50 (189)
@ 115_F (46_C) GPM (litres / min) 46 (174) 46 (174) 46 (174)
Water Temperature Rise _F (_C) 25 (14) 25 (14) 25 (14)
Water Pressure Drop @ max flow rate condition
(50 deg F water)
Oil Cooler psid(bar) 4.3 (0.30) 4.5 (0.31) 4.6 (0.32)
Oil Cooler and After Cooler psid(bar) 0.77 (0.05) 0.66 (0.05) 0.63 (0.04)
Fan Air Flow CFM (m3/min) 4,000 (113) 4,000 (113) 4,000 (113)
Maximum Added Static Pressure in (mm) H2O 0.25 (6.4) 0.25 (6.4) 0.25 (6.4)
LUBRICATION DATA
Sump Capacity USgal (litres) 16 (61) 16 (61) 16 (61)
Total Lubrication System Capacity USgal (litres) 25 (95) 25 (95) 25 (95)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 19
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H Inch (mm) 102.5 (2600) 65.5 (1661) 92 (2330)
Discharge Air Connection NPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet NPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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20 GENERAL INFORMATION
ROTARY 90 kW 50 Hz R90IU−7.5 R90IU−8.5 R90IU−10
AFTERCOOLED DATA
Aftercooler CTD (2) _C (_F) 8 (15) 8 (15) 8 (15)
Fan Air Flow m3/min (CFM) 368 (13,000) 368 (13,000) 368 (13,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
WATERCOOLED DATA
Aftercooler CTD (2) _C (_F) 14 (25) 14 (25) 14 (25)
Cooling Water Required
(recommend 95−227 litres / min (25−60 GPM))
@ 50_F (10_C) litres / min (GPM) 125 (33) 129 (34) 129 (34)
@ 70_F (21_C) litres / min (GPM) 121 (32) 121 (32) 117 (31)
@ 90_F (32_C) litres / min (GPM) 114 (30) 114 (30) 114 (30)
@ 115_F (46_C) litres / min (GPM) 102 (27) 106 (28) 106 (28)
Water Temperature Rise _C (_F) 14 (25) 14 (25) 14 (25)
Water Pressure Drop @ max flow rate condition
(10 deg C water)
Oil Cooler bar (psid) 0.12 (1.7) 0.13 (1.9) 0.13 (1.9)
Oil Cooler and After Cooler bar (psid) 0.02 (.33) 0.02 (.32) 0.02 (.32)
Fan Air Flow m3/min (CFM) 113 (4,000) 113 (4,000) 113 (4,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
LUBRICATION DATA
Sump Capacity litres (USgal) 61 (16) 61 (16) 61 (16)
Total Lubrication System Capacity litres (USgal) 95 (25) 95 (25) 95 (25)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 21
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H mm (Inch) 2600 (102.5) 1661 (65.5) 2330 (92)
Discharge Air Connection BSPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet BSPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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22 GENERAL INFORMATION
ENHANCED ROTARY 90 kW 50 Hz R90IU−7.5 R90IU−8.5 R90IU−10
AFTERCOOLED DATA
Aftercooler CTD (2) _C (_F) 8 (15) 8 (15) 8 (15)
Fan Air Flow m3/min (CFM) 368 (13,000) 368 (13,000) 368 (13,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
WATERCOOLED DATA
Aftercooler CTD (2) _C (_F) 14 (25) 14 (25) 14 (25)
Cooling Water Required
(recommend 95−227 litres / min (25−60 GPM))
@ 50_F (10_C) litres / min (GPM) 125 (33) 129 (34) 129 (34)
@ 70_F (21_C) litres / min (GPM) 121 (32) 121 (32) 117 (31)
@ 90_F (32_C) litres / min (GPM) 114 (30) 114 (30) 114 (30)
@ 115_F (46_C) litres / min (GPM) 102 (27) 106 (28) 106 (28)
Water Temperature Rise _C (_F) 14 (25) 14 (25) 14 (25)
Water Pressure Drop @ max flow rate condition
(10 deg C water)
Oil Cooler bar (psid) 0.12 (1.7) 0.13 (1.9) 0.13 (1.9)
Oil Cooler and After Cooler bar (psid) 0.02 (.33) 0.02 (.32) 0.02 (.32)
Fan Air Flow m3/min (CFM) 113 (4,000) 113 (4,000) 113 (4,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
LUBRICATION DATA
Sump Capacity litres (USgal) 61 (16) 61 (16) 61 (16)
Total Lubrication System Capacity litres (USgal) 95 (25) 95 (25) 95 (25)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 23
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H mm (Inch) 2600 (102.5) 1661 (65.5) 2330 (92)
Discharge Air Connection BSPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet BSPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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24 GENERAL INFORMATION
ROTARY 110 kW 50 Hz R110IU−7.5 R110IU−8.5 R110IU−10
AFTERCOOLED DATA
Aftercooler CTD (2) _C (_F) 8 (15) 8 (15) 8 (15)
Fan Air Flow m3/min (CFM) 368 (13,000) 368 (13,000) 368 (13,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
WATERCOOLED DATA
Aftercooler CTD (2) _C (_F) 14 (25) 14 (25) 14 (25)
Cooling Water Required
(recommend 95−227 litres / min (25−60 GPM))
@ 50_F (10_C) litres / min (GPM) 151 (40) 151 (40) 151 (40)
@ 70_F (21_C) litres / min (GPM) 148 (39) 144 (38) 144 (38)
@ 90_F (32_C) litres / min (GPM) 140 (37) 140 (37) 140 (37)
@ 115_F (46_C) litres / min (GPM) 125 (33) 129 (34) 129 (34)
Water Temperature Rise _C (_F) 14 (25) 14 (25) 14 (25)
Water Pressure Drop @ max flow rate condition
(10 deg C water)
Oil Cooler bar (psid) 0.18 (2.6) 0.19 (2.7) 0.19 (2.8)
Oil Cooler and After Cooler bar (psid) 0.03 (.46) 0.03 (.46) 0.03 (.46)
Fan Air Flow m3/min (CFM) 113 (4,000) 113 (4,000) 113 (4,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
LUBRICATION DATA
Sump Capacity litres (USgal) 61 (16) 61 (16) 61 (16)
Total Lubrication System Capacity litres (USgal) 95 (25) 95 (25) 95 (25)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 25
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H mm (Inch) 2600 (102.5) 1661 (65.5) 2330 (92)
Discharge Air Connection BSPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet BSPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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26 GENERAL INFORMATION
ENHANCED ROTARY 110 kW 50 Hz R110IU−7.5 R110IU−8.5 R110IU−10
AFTERCOOLED DATA
Aftercooler CTD (2) _C (_F) 8 (15) 8 (15) 8 (15)
Fan Air Flow m3/min (CFM) 368 (13,000) 368 (13,000) 368 (13,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
WATERCOOLED DATA
Aftercooler CTD (2) _C (_F) 14 (25) 14 (25) 14 (25)
Cooling Water Required
(recommend 95−227 litres / min (25−60 GPM))
@ 50_F (10_C) litres / min (GPM) 151 (40) 151 (40) 151 (40)
@ 70_F (21_C) litres / min (GPM) 148 (39) 144 (38) 144 (38)
@ 90_F (32_C) litres / min (GPM) 140 (37) 140 (37) 140 (37)
@ 115_F (46_C) litres / min (GPM) 125 (33) 129 (34) 129 (34)
Water Temperature Rise _C (_F) 14 (25) 14 (25) 14 (25)
Water Pressure Drop @ max flow rate condition
(10 deg C water)
Oil Cooler bar (psid) 0.18 (2.6) 0.19 (2.7) 0.19 (2.8)
Oil Cooler and After Cooler bar (psid) 0.03 (.46) 0.03 (.46) 0.03 (.46)
Fan Air Flow m3/min (CFM) 113 (4,000) 113 (4,000) 113 (4,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
LUBRICATION DATA
Sump Capacity litres (USgal) 61 (16) 61 (16) 61 (16)
Total Lubrication System Capacity litres (USgal) 95 (25) 95 (25) 95 (25)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 27
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H mm (Inch) 2600 (102.5) 1661 (65.5) 2330 (92)
Discharge Air Connection BSPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet BSPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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28 GENERAL INFORMATION
ROTARY 132 kW 50 Hz R132IU−7.5 R132IU−8.5 R132IU−10
AFTERCOOLED DATA
Aftercooler CTD (2) _C (_F) 8 (15) 8 (15) 8 (15)
Fan Air Flow m3/min (CFM) 368 (13,000) 368 (13,000) 368 (13,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
WATERCOOLED DATA
Aftercooler CTD (2) _C (_F) 14 (25) 14 (25) 14 (25)
Cooling Water Required
(recommend 95−227 litres / min (25−60 GPM))
@ 50_F (10_C) litres / min (GPM) 182 (48) 182 (48) 182 (48)
@ 70_F (21_C) litres / min (GPM) 174 (46) 174 (46) 174 (46)
@ 90_F (32_C) litres / min (GPM) 167 (44) 167 (44) 167 (44)
@ 115_F (46_C) litres / min (GPM) 151 (40) 155 (41) 155 (41)
Water Temperature Rise _C (_F) 14 (25) 14 (25) 14 (25)
Water Pressure Drop @ max flow rate condition
(10 deg C water)
Oil Cooler bar (psid) 0.25 (3.6) 0.26 (3.7) 0.26 (3.8)
Oil Cooler and After Cooler bar (psid) 0.04 (.60) 0.04 (.55) 0.04 (.51)
Fan Air Flow m3/min (CFM) 113 (4,000) 113 (4,000) 113 (4,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
LUBRICATION DATA
Sump Capacity litres (USgal) 61 (16) 61 (16) 61 (16)
Total Lubrication System Capacity litres (USgal) 95 (25) 95 (25) 95 (25)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 29
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H mm (Inch) 2600 (102.5) 1661 (65.5) 2330 (92)
Discharge Air Connection BSPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet BSPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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30 GENERAL INFORMATION
ENHANCED ROTARY 132 kW 50 Hz R132IU−7.5 R132IU−8.5 R132IU−10
AFTERCOOLED DATA
Aftercooler CTD (2) _C (_F) 8 (15) 8 (15) 8 (15)
Fan Air Flow m3/min (CFM) 368 (13,000) 368 (13,000) 368 (13,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
WATERCOOLED DATA
Aftercooler CTD (2) _C (_F) 14 (25) 14 (25) 14 (25)
Cooling Water Required
(recommend 95−227 litres / min (25−60 GPM))
@ 50_F (10_C) litres / min (GPM) 182 (48) 182 (48) 182 (48)
@ 70_F (21_C) litres / min (GPM) 174 (46) 174 (46) 174 (46)
@ 90_F (32_C) litres / min (GPM) 167 (44) 167 (44) 167 (44)
@ 115_F (46_C) litres / min (GPM) 151 (40) 155 (41) 155 (41)
Water Temperature Rise _C (_F) 14 (25) 14 (25) 14 (25)
Water Pressure Drop @ max flow rate condition
(10 deg C water)
Oil Cooler bar (psid) 0.25 (3.6) 0.26 (3.7) 0.26 (3.8)
Oil Cooler and After Cooler bar (psid) 0.04 (.60) 0.04 (.55) 0.04 (.51)
Fan Air Flow m3/min (CFM) 113 (4,000) 113 (4,000) 113 (4,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
LUBRICATION DATA
Sump Capacity litres (USgal) 61 (16) 61 (16) 61 (16)
Total Lubrication System Capacity litres (USgal) 95 (25) 95 (25) 95 (25)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 31
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H mm (Inch) 2600 (102.5) 1661 (65.5) 2330 (92)
Discharge Air Connection BSPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet BSPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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32 GENERAL INFORMATION
ROTARY 160 kW 50 Hz R160IU−7.5 R160IU−8.5 R160IU−10
AFTERCOOLED DATA
Aftercooler CTD (2) _C (_F) 8 (15) 8 (15) 8 (15)
Fan Air Flow m3/min (CFM) 368 (13,000) 368 (13,000) 368 (13,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
WATERCOOLED DATA
Aftercooler CTD (2) _C (_F) 14 (25) 14 (25) 14 (25)
Cooling Water Required
(recommend 95−227 litres / min (25−60 GPM))
@ 50_F (10_C) litres / min (GPM) 220 (58) 220 (58) 220 (58)
@ 70_F (21_C) litres / min (GPM) 212 (56) 212 (56) 212 (56)
@ 90_F (32_C) litres / min (GPM) 201 (53) 201 (53) 201 (53)
@ 115_F (46_C) litres / min (GPM) 185 (49) 185 (49) 189 (50)
Water Temperature Rise _C (_F) 14 (25) 14 (25) 14 (25)
Water Pressure Drop @ max flow rate condition
(10 deg C water)
Oil Cooler bar (psid) 0.34 (4.9) 0.34 (5.0) 0.35 (5.1)
Oil Cooler and After Cooler bar (psid) 0.05 (.79) 0.05 (.72) 0.05 (.69)
Fan Air Flow m3/min (CFM) 113 (4,000) 113 (4,000) 113 (4,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
LUBRICATION DATA
Sump Capacity litres (USgal) 61 (16) 61 (16) 61 (16)
Total Lubrication System Capacity litres (USgal) 95 (25) 95 (25) 95 (25)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 33
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H mm (Inch) 2600 (102.5) 1661 (65.5) 2330 (92)
Discharge Air Connection BSPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet BSPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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34 GENERAL INFORMATION
ENHANCED ROTARY 160 kW 50 Hz R160IU−7.5 R160IU−8.5 R160IU−10
AFTERCOOLED DATA
Aftercooler CTD (2) _C (_F) 8 (15) 8 (15) 8 (15)
Fan Air Flow m3/min (CFM) 368 (13,000) 368 (13,000) 368 (13,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
WATERCOOLED DATA
Aftercooler CTD (2) _C (_F) 14 (25) 14 (25) 14 (25)
Cooling Water Required
(recommend 95−227 litres / min (25−60 GPM))
@ 50_F (10_C) litres / min (GPM) 220 (58) 220 (58) 220 (58)
@ 70_F (21_C) litres / min (GPM) 212 (56) 212 (56) 212 (56)
@ 90_F (32_C) litres / min (GPM) 201 (53) 201 (53) 201 (53)
@ 115_F (46_C) litres / min (GPM) 185 (49) 185 (49) 189 (50)
Water Temperature Rise _C (_F) 14 (25) 14 (25) 14 (25)
Water Pressure Drop @ max flow rate condition
(10 deg C water)
Oil Cooler bar (psid) 0.34 (4.9) 0.34 (5.0) 0.35 (5.1)
Oil Cooler and After Cooler bar (psid) 0.05 (.79) 0.05 (.72) 0.05 (.69)
Fan Air Flow m3/min (CFM) 113 (4,000) 113 (4,000) 113 (4,000)
Maximum Added Static Pressure mm (in) H2O 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)
LUBRICATION DATA
Sump Capacity litres (USgal) 61 (16) 61 (16) 61 (16)
Total Lubrication System Capacity litres (USgal) 95 (25) 95 (25) 95 (25)
SOUND LEVELS
Aircooled dB(A) 75 75 75
Watercooled dB(A) 70 70 70
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GENERAL INFORMATION 35
PACKAGE DATA
PACKAGE DIMENSIONS (3) L x W x H mm (Inch) 2600 (102.5) 1661 (65.5) 2330 (92)
Discharge Air Connection BSPT (Female) Inch 2.5 2.5 2.5
Water Inlet & Outlet BSPT (Female) Inch 1.5 1.5 1.5
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per ISO1217 annex C: 1996.
(2) CTD (Cold Temperature Difference) defined as difference between package discharge and cooling fluid (ambient air or water) inlet temperatures.
− Ambient reference conditions are 100_F / 38_C inlet air at 40% relative humidity.
(3) For weights, and piping connection positions, see general arrangement drawings − 23057581 (aircooled), 23057573 (watercooled).
(4) Electrical data based on Ingersoll Rand IP55 motors, consult factory for others.
(5) Star Delta starting current inrush is 33% of full voltage KVA inrush.
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36 GENERAL INFORMATION
KEY
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GENERAL INFORMATION 37
Colors Wires
BLK Black
Numbers Function Wire color
BLU Blue
1−99 Power Black
BRO Brown
100−199 AC Control Red
GRE Green
200−299 DC Control Blue
PIN Pink
RED Red
SCR Screened
VIO Violet
WHI White
YEL Yellow
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38 INSTALLATION / HANDLING
AC
KEY
A 2.5” NPT Air discharge (Female) 60Hz units X−X2 Part section through X−X showing customer air discharge
2.5” BSPT Air discharge (Female) 50Hz units without moisture seperator
B Electrical inlet: Blank plate supplied Y Left view
C Cooling air intake Z Plan view
D Cooling air exhaust
NOTES:
E 0.5” NPT Condensate drain 60Hz units
0.5” BSPT Condensate drain 50Hz units All dimensions are in millimetres unless otherwise stated.
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INSTALLATION / HANDLING 39
WC
KEY
A 2.5” NPT Air discharge (Female) 60Hz units X−X1 Part section through X−X showing customer air discharge
2.5” BSPT Air discharge (Female) 50Hz units with moisture seperator
B Electrical inlet: Blank plate supplied X−X2 Part section through X−X showing customer air discharge
C Cooling air intake without moisture seperator
D Cooling air exhaust Y Left view
E Water out Z Plan view
1.5” NPT on 60Hz units
1.5” BSPT on 50Hz units
F Water in
NOTES:
1.5” NPT on 60Hz units
1.5” BSPT on 50Hz units All dimensions are in millimetres unless otherwise stated.
G 0.5” NPT Condensate drain 60Hz units Weights (approximate):
0.5” BSPT Condensate drain 50Hz units R90IU − 2510 kg (5532 lbs)
R110IU − 2640 kg (5819 lbs)
H 4 x Ø 23,0mm (0.9”)
R132IU − 2945 kg (6491 lbs)
Compressor should be bolted to the floor with four M20 (0.75”) bolts
R150IU − 3015 kg (6645 lbs)
using holes shown. Seal base to floor with cork or rubber.
R160IU − 3015 kg (6645 lbs)
U Rear view
V Bottom view
W Front view Denotes center of gravity.
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40 INSTALLATION / HANDLING
UNPACKING / SHIPPING STRAP UNPACKING
Remove the yellow shipping strap (identified by two red Incorporated within the base of the compressor are slots to enable
identification tags) as follows; a fork lift truck (2 ton minimum) to move the machine. Alternatively a
special lifting frame can be supplied to enable a crane or hoist to move
1. Remove any covering from the compressor. the compressor.
2. Remove the two access panels from the right hand side of the Ensure that the operator reads and understands the decals and
compressor. consults the manuals before maintenance or operation.
3. Remove the two screws from the front of the airend / separator Ensure that the position of the emergency stop device is known and
support. recognised by its markings. Ensure that it is functioning correctly and
that the method of operation is known.
4. Remove the two remaining screws via the support access holes.
5. Straps and tags can be discarded or retained for future
transportation purposes.
6. Replace the access panels.
KEY CAUTION
Screw type compressors [1] should not be installed in air systems
1. Compressor with reciprocating compressors without means of isolation such as a
2. Air Receiver common receiver tank. It is recommended that both types of
compressor be piped to a common receiver using individual air lines.
3. Air Dryer
4. Compressed air filters
CAUTION
5. System demand points The use of plastic bowls on line filters and other plastic air line
components without metal guards can be hazardous. Their safety can
be affected by either synthetic coolants or the additives used in mineral
LOCATION IN THE PLANT oils. From a safety standpoint, metal bowls should be used on any
pressurised system.
The compressor can be installed on any level floor capable of
supporting it. A dry, well ventilated area where the atmosphere is as
clean as possible is recommended.
DISCHARGE PIPING
Sufficient space all round and above the compressor must be
allowed, to enable the effective removal of the cooling air which, in turn, Discharge piping should be at least as large as the discharge
will reduce the risk of re−circulating the cooling air back through the connection of the compressor. All piping and fittings should be suitably
compressor. rated for the discharge pressure.
External piping shall not exert any unresolved moments or forces
on unit.
CAUTION: A minimum of 1 metre all round the compressor is
recommended. If headroom is restricted, then the exhaust should be It is essential when installing a new compressor [1], to review the
ducted or deflected away from the machine. total air system. This is to ensure a safe and effective total system. One
item which should be considered is liquid carryover. Installation of air
Field installed ducting to and from compressor cannot add more than dryers [3] is always good practice since properly selected and installed
6mm (0.25 inches) of water total air resistance. they can reduce any liquid carryover to zero.
Unit has an internal discharge check valve, external check valve not
Hard surfaces may reflect noise with an apparent increase in the required. Isolation valve required within 1m (36 inches) of the
decibel level. When sound transmission is important, a sheet of rubber compressor discharge.
or cork can be installed beneath the machine to reduce noise.
There should be no plastic or PVC piping attached to this unit or
It is recommended that provision be made for lifting heavy used for any lines downstream with the exception of condensate
components during major overhaul. removal lines.
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INSTALLATION / HANDLING 41
ELECTRICAL DATA The applied voltage must be compatible with the motor and
compressor data plate ratings.
An independent electrical isolator should be installed adjacent to the
compressor. The control circuit transformer has different voltage tappings.
Ensure that these are set for the specific applied voltage prior to
Feeder cables should be sized by the customer/electrical starting.
contractor to ensure that the circuit is balanced and not overloaded by
other electrical equipment. The length of wiring from a suitable
electrical feed point is critical as voltage drops may impair the CAUTION
performance of the compressor. Never test the insulation resistance of any part of the machines
electrical circuits, including the motor without completely disconnecting
Feeder cable connections to studs L1−L2−L3 on isolator should be the intellisys controller.
tight and clean.
NOTE:
Main and fan motor insulation must be tested by a competent
electrician prior to initial start−up or following an extended shutdown
period in cold damp conditions.
WATERCOOLING SYSTEM
KEY
A WATER IN F. AFTERCOOLER
B WATER OUT G. AIR OUT
C. LUBRICANT OUT H. AIR IN
D. LUBRICANT IN J. WATER
E. LUBRICANT COOLER
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42 INSTALLATION / HANDLING
Cooling Water Piping Scale: Scale formation inhibits effective heat transfer, yet it does help
prevent corrosion. Therefore, a thin uniform coating of calcium
Water piping to and from the compressor package must be 1 1/2” carbonate is desired on the inner surface. Perhaps the largest
diameter or larger. Isolation valves with side drains should be installed contributor to scale formation is the precipitation of calcium carbonate
on both the inlet and outlet lines. Also a strainer of 2mm−mesh size out of the water. This is dependent on temperature and pH. The higher
should be installed on the inlet line. Strainers are available from the pH value, the greater the chance of scale formation. Scale can be
Ingersoll Rand. controlled with water treatment.
A normally closed solenoid valve is fitted to the water inlet side of the Corrosion: In contrast to scale formation is the problem of corrosion.
compressor package. This is wired into the compressor control circuit Chlorides cause problems because of their size and conductivity. Low
and closes when the compressor stops. pH levels promote corrosion, as well as high levels of dissolved
Carefully inspect your water system before installing the compressor oxygen.
package. Ensure that the piping is free of scale and deposits that may Fouling: Biological and organic substances (slime) can also cause
restrict water flow to the compressor package. problems, but in elevated temperature environments such as cooling
Proper operation of your compressor requires that the water flow listed processes they are not a major concern. If they create problems with
in the general information section of this document be provided at a clogging, commercial shock treatment are available.
maximum suppy temperature of 46_C (115_F). To ensure good operation life and performance of the compressor
Water temperature and pressure gauges should be installed in the cooling system, the recommended acceptable ranges for different
water piping for use in any fault finding of the water system. Water water constituents are included below:
pressure should ideally be between 3 and 5 bar.
Water cleanliness is also extremely important. Cleaning of coolers as Cooling Water Analyses Chart
a result of fouling is a customer responsibility. Therefore, it is highly
recommended that proper water quality must meet the requirements
listed in WATER QUALITY RECOMMENDATIONS later in this section. Substances Test interval Acceptable
concentration
Adjusting the Aftercooler Trim Valve
Corrosivity Monthly — if stable Langelier Index 0 to
The coolers are piped in a ”parallel” water flow arrangement with a
(Hardness, pH, Total for 3 to 4 months, 1
manual trim valve controlling the flow through the aftercooler (see
Dissolved Solids, analyse quarterly.
piping and instrumentation diagram in the General Information section
Temperature at inlet
of this document).
Alkalinity)
The Aftercooler Trim Valve is factory set and should not need adjusting
but if disturbed use the following procedure. Close valve fully clockwise Iron Monthly <2 ppm
and then open 1/4 turn. With the machine running loaded, observe the
package discharge temperature on the controller display. It should be Sulphate Monthly <50 ppm
aprrox 8_C (15_F) above the water inlet temperature. If it is higher,
Chloride Monthly <50 ppm
open the valve a little more. Put a ’Warning − Do Not Adjust’ label on
the valve or fit a lock. Nitrate Monthly <2 ppm
Venting the water system
Silica Monthly < 100 ppm
At the initial installation or for start−up after draining the water system
proceed to vent the system as follows Desolated Oxygen Daily — if 0 ppm (as low as
stable,analyse possible)
1 Locate the water system vent cocks on top of the aftercooler and weekly
lubricant cooler.
Oil & Grease Monthly <5 ppm
2 Open the water valve(s) allowing water to flow to the package.
Ammonia Monthly <1 ppm
3 Open the vent cocks and allow all air to escape from the system.
When water is observed at the vent cocks, close them
The system is now vented. The Ingersoll Rand Hydro−check cooling water analysis kit
CPN89223481 provides a sample bottle and pre−addressed return
Draining the water system tube to our laboratory, where a full report on water quality will be issued.
Should it become necessary to completely drain the water system,
proceed as follows.
1 Disconnect the inlet and discharge water lines from the connections
located at the rear of the unit.
2 Locate the aftercooler and lubricant cooler. Remove the drain plugs
located at the bottom of the coolers.
Allow the system to completely drain.
Water quality recommendations
Water quality is often overlooked when the cooling system of a
water−cooled air compressor is examined. Water quality determines
how effective the heat transfer rate, as well as the flow rate will remain
during the operation life of the unit. It should be noted that the quality
of water used in any cooling system does not remain constant during
the operation of the system. Evaporation, corrosion, chemical and
temperature changes, aeration, scale and biological formations effect
the water makeup. Most problems in a cooling system show up first in
a reduction in the heat transfer rate, then in a reduced flow rate and
finally with damage to the system.
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INSTALLATION / HANDLING 43
SEA WATER COOLED UNITS No oil cooler manufacturer can guarantee that its products will have
an indefinite life and for this reason, we suggest that the cooling system
It is important to ensure that the recommended flow rate cannot be is designed to minimise any damage caused by a leaking oil cooler.
exceeded. This will normally mean that an orifice plate must be fitted This can be achieved as follows ;
in the pipework at least 1m before the cooler, with the orifice size
calculated to ensure that the maximum sea water flow rate cannot be 1. The oil pressure should be higher than the sea water pressure, so
exceeded. If these precautions are not taken, it is possible that the sea that in the event of a leak occurring, the oil will not be contaminated.
water flow rate through the cooler may be several times the
recommended maximum, which will lead to rapid failure. 2. When the hydraulic system is not being used, the coolers should be
isolated from sea water pressure.
Sea Water Pressure in Bars Orifice diameter in mm to give a 3. The sea water outlet pipe from the cooler should have a free run to
maximum sea water flow of waste.
120l/min
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44 OPERATING INSTRUCTIONS
6: Red LED
Enter Code
11: Escape
High Airend Temperature
12: Enter
Motor Overload
Maintenance Due
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OPERATING INSTRUCTIONS 45
PRIOR TO STARTING NORMAL STOPPING
1. Check coolant level. Add if necessary. 1. Press ‘Unloaded Stop’ . The compressor will unload then stop.
2. Make sure main discharge valve is open. 2. Turn off electrical isolator.
STARTING
1. Press ‘Start’ [1]. The compressor will start and then load CAUTION
automatically. After shutdown never allow unit to stand idle with pressure in
receiver/separator system.
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46 OPERATING INSTRUCTIONS
CONTROLLER MENU NAVIGATION
T4105
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OPERATING INSTRUCTIONS 47
Pass Code Entry 3. Scroll Value to desired selection using the up [8] and down [10]
buttons.
When a pass code is needed, the CD screen will be displayed and the
leftmost character will begin to flash. Select the proper value using the 4. Press enter [12] to store the current value.
up [8] and down [10] buttons and press enter [12] to store this value and
move to the next character. 5. Press escape [11] repeatedly to return to the initial status screen.
Once the right most character is entered, the CD display will be exited
and the first screen available under that password will be displayed. Setup Menu Timeout
The setup menu display will revert to the default status display if any
Changing Parameters controller buttons are not pressed within 30 seconds.
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48 OPERATING INSTRUCTIONS
Screen Display Item Range Pass
Code Code
P03 Advanced Menu Screens 0101
Pd Calibration, Pressure Offset −1.6 — 1.6 bar
Ip Calibration, Pressure Offset (*)
YD Star Delta Time 8 — 20 sec
Sf Soft Starter Time
Cd Condensate Drain Time 2 — 10 sec
Ci Condensate Interval Time 90 — 300sec
Sd Service Due Timer 0 — 2000 hrs
Ss Scheduled Start / Stop (*)
St Scheduled Start Time (*)
Sp Scheduled Stop Time (*)
Po PORO
Pt PORO Time 10 — 360 sec
Lt Low Ambient Load Delay 30 — 300 sec
Rc Remote Control (*)
Is Integral Sequencing Control (*)
Cn Multi 485 compressor (*)
Ad Modbus Address (*)
Bd Modbus Baudrate 1200, 2400, 4800,
9600, 19200, 38400,
57600, 76800, 115200
NOTES
P01 and P02 screens may be entered while the machine is running.
P03 screens may be entered only while the machine is stopped.
* = Dependant on installed options and/or installed controls.
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MAINTENANCE 49
PERIOD MAINTENANCE NOTE:
On some sea water cooled models the oil cooler and after cooler are
After 24 hours Visual check of machine for any leaks, dust fitted with sacrificial zinc anodes (pencils) that are located in the end
build up or unusual noise/vibration. bonnets of the coolers. These sacrificial zinc anodes should be
Contact IR authorised distributor if in doubt. checked after the first 50 hours of operation to determine if corrosive
conditions exist. If satisfactory this interval may be extended to 500
Daily Check the coolant level and replenish if
hours.
necessary.
When the separator Check the pressure differential.
element indicator
light flashes * Change the separator element if the
NOTE
pressure drop is zero or exceeds 1 bar (15
p.s.i.) 1 If sacrificial zinc anode is 50% corroded it should be replaced.
First 150 hours Change the coolant filter. 2 Coastal/harbour waters can contain corrosive chemicals from
pollution and may reduce anode/cooler life.
1 month Check the cooler(s) for build up of foreign
matter. Clean if necessary by blowing out 3 Effects of corrosion or erosion are specifically excluded from
with air or by pressure washing. warranty considerations.
1 monthly intervals. On water cooled and sea water cooled
models check the water input line strainer
for build up of foreign matter, clean if re-
quired WARNING
Do not under any circumstances open any drain valve or remove
Each 3 months Operate the safety valve manually to verify components from the compressor without first ensuring that the
that the valve mechanism is functioning compressor is FULLY SHUT DOWN, power isolated and all air
correctly and that a small amount of air is pressure relieved from the system.
released.
Each 3 months Check all hoses for signs of deterioration,
cracks, hardening etc.
* Caution: The separator tank lid and element are heavy and should
Each 2000 hours Change the coolant filter. only be removed using suitable lifting equipment. Never try to remove
by hand.
2000 hours / 6 Take coolant sample for fluid analysis.
Wear protective gloves due to potential sharp edges/burrs.
months
2000 hours / 6 Check scavenge screen for blockage,
months clean if required.
COOLANT LEVEL CHECKING PROCEDURE
6 months Check the calibration of the pressure
transducer. The coolant level should be checked daily. A coolant level sight
glass is located on the side of the separator tank and while the machine
1 year Change the air filter element. is running on load, coolant should always be visible in the sight glass.
Replace the element sooner if the indicator The normal position is half way, or between the middle and the top of
light flashes. the green section of coloured indicator for sight glass tube.
2000 hours Lubricate the main motor drive end bearing.
90/110kW motors Quantity of grease required: ADDING COOLANT
(125/150hp) 40g
Run the compressor for a minimum of 40 seconds before stopping,
Lubricate the main motor non−drive end then add coolant until the level is up to the mid−point of the sight glass.
bearing.
Quantity of grease required:
35g COOLANT FILTER CHANGE PROCEDURE
2000 hours Lubricate the main motor drive end bearing. . Loosen filter element with the correct tool.
132/160kW motors Quantity of grease required:
. Remove the element from the housing.
(200hp) 40g
. Place the old element in a sealed bag and dispose of in a safe way.
Lubricate the main motor non−drive end
bearing. . Clean the mating face of the housing.
Quantity of grease required:
45g . Remove the new Ingersoll Rand replacement element from its
protective package.
8000 hours / 2 years Replace the ULTRA COOLANT at
whichever interval occurs first. . Apply a small amount of lubricant to the element seal.
Also replace the separator element and . Screw the new element down until the seal makes contact with the
coolant filter. housing, then hand tighten a further half turn.
4 years Replace all hoses. . Start the compressor and check for leaks.
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50 MAINTENANCE
ULTRA COOLANT − CHANGE PROCEDURE CAUTION
Do not use any form of sealant on either the separator tank or the
It is better to drain the coolant immediately after the compressor has separator tank cover faces.
been operating as the liquid will drain more easily and any contaminant
will still be in suspension.
. Position a suitable container under the drain plug. . Re−assemble the components in reverse order.
. Remove the plug and completely drain the coolant. . Start the compressor and check for leaks.
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MAINTENANCE 51
MODULATION CONTROL MODULATE CONTROL VALVE ADJUSTMENT
For those plants which have relatively high constant air demand Ensure that the compressor is isolated from the compressed air system
relative to the compressor capacity, the recommended control mode is by closing the isolation valve and venting pressure from the drip leg.
modulation.
Ensure that the main power disconnect switch is locked open and
The modulation control system retains the features of the on−line / tagged.
off−line control, but also provides for throttling of the inlet flow up to the
off−line air pressure setpoint value. 1. Put the compressor in the MODULATION mode.
By applying line pressure to an adjustable modulator valve, the 2. Connect a pressure gauge to outlet port of modulation valve with
throttling position of the inlet valve is controlled, thus allowing the 1/4” tubing tee.
modulator to ”trim” the inlet valve position as dictated by the line
3. Loosen the adjustment screw locknut and back out adjusting screw
pressure.
3 turns. See Figure 2
The modulating pressure range is about 0.3 bar (4.0 psid) and the
4. Put the main power disconnect switch in the ON position.
modulator normally should be set to straddle the compressor rated
pressure. Modulation begins when the line pressure reaches about 99 5. Open the isolation valve and start the compressor.
percent of the compressor rated pressure and continues as/if the line
pressure rises. Modulation becomes stable when the compressor 6. Adjust the isolation valve to bring the discharge air pressure to the
output equals the plant air demand. When the modulation is at the rated discharge pressure (100, 125, or 140 psig).
factory setting, the maximum capacity reduction will be approximately
60 percent of the compressor rated capacity (as indicated in Figure 1). 7. While maintaining the rated discharge pressure, turn the adjustment
screw on the modulation valve (see Figure 2) so that the test pressure
gauge reads:
30 psig for modulate 60% capacity
8. Press UNLOADED STOP. Wait for sump pressure to go 0 psig.
Close the isolation valve or vent off all system air.
9. Put the compressor in the desired control mode.
10.Remove the test pressure gauge and replace 1/4” plastic plug.
MODULATE TO
94% CAPACITY
% OF RATED CAPACITY
MODULATE TO
85% CAPACITY
ADJUSTING SCREW
MODULATE TO
72% CAPACITY
MODULATE TO
60% CAPACITY
KEY
A Normal settings of modulator
B Optional field settings of modulator
C Intellisys − S3 R off−line set point
FIGURE 1 FIGURE 2 MODULATION VALVE
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52 FAULT FINDING
FAULT INDICATORS
−Warning
There are two LED lamps on the controller that indicate operational _ _ _ = reference code (see below)
status.
Green LED:
S ”On” when the compressor is running and no fault conditions are
detected. −Trip
S ”Ready Off” when the compressor is in a shutdown or faulted _ _ _ = reference code (see below)
condition.
S ”Off” when the compressor is not running.
Red LED:
”On” indicates a Shutdown condition.
A trip or warning fault consists of the LED combinations shown below.
Trip Codes:
S Red LED solid
S Green LED off
Warning Codes:
S Red LED flashing
S Green LED on.
When a trip or warning is detected by the controller, the following codes
and icons will be shown on the bottom line of the LCD display.
005 Tr (*) High Sump Air Pressure 005 WA(*) High Sump Air Pressure
012 Tr High Package Discharge Pressure 012 WA High Package Discharge Pressure
013 Tr High Airend Discharge Temperature 013 WA High Airend Discharge Temperature
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FAULT FINDING 53
FAULT CAUSE REMEDY
’Power on’. L.E.D. does CONTROL VOLTAGE NOT Check the control fuses.
not illuminate.
illuminate AVAILABLE
Check the transformer secondary windings for the control voltage.
Controller indicates trip CONTROL CIRCUIT Check machine for indicated fault. Attempt to ’reset’ the controller. If the fault
condition. INTERRUPTED BY A SAFETY persists investigate further.
DEVICE
Compressor trips INSUFFICIENT COOLANT Check the coolant level.
indicating a high CIRCULATION
compressor Check the temperature sensor
temperature. Change coolant filters
T13 W13
T13,
Check the operation of thermostatic valve and oil stop valve
INSUFFICIENT COOLING TAKING Check that the cooling air flow is not obstructed at:
PLACE . The inlet to the package
. The cooler matrix
. The exhaust vents
If machine is water cooled or seawater cooled, 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.
EXCESSIVELY HIGH AMBIENT Improve the ventilation to the compressor room.
TEMPERATURE
(i.e. greater than 46oC (115oF).
Compressor trips and EXCESSIVE CURRENT HAS Check the actual operating pressure and lower the setting if it is too high. Isolate
indicates motor CAUSED THE THERMAL the electrical supply and check that the airend and motor rotate freely. Check the
overload. OVERLOAD (MOL) TO TRIP separator element for excessive pressure drop.
T3
Check supply voltage
Compressor shutdown. ISOLATION VALVE CLOSED. Open the valve and restart.
Display shows
OVERPRESSURE. BLOWDOWN SYSTEM Check the operation of the load solenoid.
T12, W12 INEFFECTIVE
INEFFECTIVE.
Check the operation of the unloader valve − strip and clean if necessary.
Compressor will not DEMAND TOO HIGH Check for leaks, open service valves or exceptionally high demand.
build up rated pressure.
pressure
OFFLINE PRESSURE SET TOO Check the offline pressure setting.
LOW
Compressor will not INLET VALVE NOT OPENING Check that the valve is free to open.
load
load.
Check the operation of the load solenoid valve 1SV.
Compressor fails to − Check the operation of the inlet valve.
deliver rated
capacity. Check the operation of the load solenoid valve 1SV.
Check the offline/online pressure setting.
Check the inlet filter for contamination. The L.E.D. should indicate if it is blocked.
Excessive coolant BLOCKED SCAVENGE LINE Clear the blockage.
consumption
consumption.
RUPTURED OR FOULED Change the element.
SEPARATOR ELEMENT
Rapid cycling or RAPID LOAD/UNLOAD CYCLING Duty cycle too rapid − Increase system capacity.
receiver will not
blow−down to unloaded MINIMUM PRESSURE VALVE Strip the MPV, examine and repair if necessary.
running pressure. (MPV) STUCK OPEN
Safety valve blows MPV STUCK CLOSED Strip MPV, examine and repair if necessary.
when compressor goes
on load. SAFETY VALVE FAULTY Check the setting of the safety valve and the rated pressure.
BLOCKED SEPARATOR ELEMENT Check pressure differential and replace
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54 FAULT FINDING
FAULT CAUSE REMEDY
Motor reverse rotation. INCOMING POWER WIRED TO Review electrical diagram 23002171 in this manual and wire correctly.
T1 PACKAGE INCORRECTLY
Emergency stop. EMERGENCY STOP Please see safety warning message on page 9 of this manual. After all hazards
T2 are cleared, the unit can be restarted by twisting the Emergency Stop button and
restarting.
Low ambient COMPRESSOR WILL NOT START Wait until compressor pacakge air temperature rises above minimum starting
temperature. BELOW 2_C, UNLESS FITTED temp requirement.
T4 WITH LOW AMBIENT OPTION
(−10_C)
High sump air pressure. MPV STUCK CLOSED Strip MPV, examine and repair if necessary.
T5 W5
T5,
BLOCKED SEPARATOR Replace separator element.
ELEMENT
BLOWDOWN SYSTEM Check the operation of the load solenoid valve.
INEFFECTIVE
Check the operation of the unloader valve − strip and clean if necessary.
Low sump air pressure. INCOMING POWER WIRED TO Review electrical diagram 23002171 in this manual and wire correctly.
T6 PACKAGE INCORRECTLY
INLET VALVE NOT OPENING Check that the valve is free to open.
Check the operation of the load solenoid valve.
P1 Sensor calibration Check sensor connection and calibrate if necessary.
failure.
P2 Sensor calibration Check sensor connection and calibrate if necessary.
failure.
Maintenance due soon. TIME SINCE LAST SERVICE IS Schedule Maintenance.
W14 APPROACHING SERVICE
INTERVAL
Maintenance due SERVICE INTERVAL HAS Schedule Maintenance.
immediately. EXPIRED
W15
Change oil filter. CHANGE OIL FILTER Change oil filter.
W16
Change air filter. CHANGE AIR FILTER Change air filter.
W17
Change separator CHANGE SEPARATOR ELEMENT Change separator element.
element.
W18
Integral sequencing WIRING OR COMMUNICATION Check wiring.
communication failure. FAULT
W19
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