Page 2 - WARRANTY
AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UP WARRANTY The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve months from the date of placing the Equipment in operation or eighteen...
Page 4 - IF IN DOUBT CONSULT SUPERVISION.
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 2 2.0 FOREWORD Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European community countries req...
Page 5 - TABLE 1; GENERAL INFORMATION SECTION
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 3 WARNING The use of the machine in any of the situation types listed in table 1:− Is not approved by Ingersoll Rand, May impair the safety of users and other person...
Page 7 - PURCHASE ORDER DETAILS; ROTARY SCREW AIR COMPRESSOR; Record the serial number and model number of your unit here.
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 5 4.0 PURCHASE ORDER DETAILS ROTARY SCREW AIR COMPRESSOR This unit was purchased from _____________________________________________________________ _________________...
Page 8 - SAFETY INSTRUCTIONS; DANGER; SAFETY PRECAUTIONS
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 6 5.0 SAFETY 5.1 SAFETY INSTRUCTIONS Safety instructions in the operators manual are bold−faced for emphasis. The signal words DANGER, WARNING and CAUTION are used ...
Page 9 - Avoid bodily contact with compressed air.; Materials; WARNING; AVOID INGESTION, SKIN CONTACT AND; Consult a physician if compressor lubricant is inhaled.; Transport
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 7 When using compressed air always use appropriate personal protective equipment. All pressure containing parts, especially flexible hoses and their couplings, must ...
Page 11 - NOTICE; To obtain satisfactory compressor operation and; Refer to the Instruction / Operators Manual before; Can contain carbon monoxide or other; Do not breathe this air.; Hazardous voltage. Can cause severe injury or; Disconnect power before servicing.; Rotating fan blade. Can cause severe injury.; Do not operate with covers removed.
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 5.0 SAFETY Depending on point of manufacture and point of use, the compressor and this manual will show symbols from the following sections. Compressors for use with...
Page 12 - Lift only from base channels; Relieve pressure before removing filter plugs/caps,; Air discharge; CAUTION; Use only SSR ULTRA COOLANT; Use only Ingersoll Rand SSR H-1F food grade coolant.; Lift here; Do not touch. Allow to cool before servicing.
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 10 5.0 SAFETY CAUTION Incorrect lifting of machine can cause injury or property damage. Lift only from base channels WARNING High pressure air. Can cause severe inj...
Page 13 - Replace filter element after first 150 hours of; Rotation; WARNING HIGH VOLTAGE; Air
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 11 5.0 SAFETY CAUTION Improper coolant filter replacement will cause compressor damage. Replace filter element after first 150 hours of operation and every 2000 hour...
Page 14 - Before starting this air compressor unit the shipping; IMPORTANT
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 12 5.0 SAFETY Condensate drain. Electrical power inlet. WARNING Hazardous voltage. Can cause severe injury or death. Disconnect power before servicing. Lockout/Tago...
Page 15 - GRAPHIC FORM AND MEANING OF ISO SYMBOLS; Prohibition / Mandatory
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 13 5.0 SAFETY 5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS Prohibition / Mandatory Information / Instructions Warning WARNING: Electrical shock risk. WARNING − Pressu...
Page 20 - READ THIS; transportation company.; Ingersoll Rand Company; UNPACKING AND HANDLING
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 1 6.0 RECEIPT / HANDLING 6.1 RECEIPT When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier should be noted o...
Page 21 - For technical information see section 8.0.; LOCATION IN PLANT; Ensure that the correct tie down points are used.
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 1 7.0 INSTALLATION For technical information see section 8.0. 7.1 LOCATION IN PLANT Ensure that the correct tie down points are used. For major overhaul (i.e. motor ...
Page 22 - DISCHARGE AND CONDENSATE PIPING; The drain line must slope downward from; For low volume systems that may not include a; Do not use the compressor to support the discharge pipe.
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 20 7.0 INSTALLATION 7.2 DISCHARGE AND CONDENSATE PIPING It is essential when installing a new compressor [1], to review the total air system. This is to ensure a sa...
Page 23 - soll Rand Distributor or Air Center.; The compressor and drive should be properly grounded
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 21 7.0 INSTALLATION 7.3 ELECTRICAL CAUTION This procedure should only be carried out by a qualified electrician, electrical contractor or your local Inger- soll Rand...
Page 24 - Fuse Type; Fast Acting Class−J, T or Semiconductor type,; Example of voltage imbalance calculation
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 22 7.0 INSTALLATION CAUTION VERY IMPORTANT Supply voltage must be kept to a maximum imbalance of 2% on 50Hz and 3% on 60Hz applications. Voltage imbalances greater ...
Page 25 - WATERCOOLED UNITS; should
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 23 7.0 INSTALLATION 7.4 WATERCOOLED UNITS Cooling Water Piping Water piping to and from the compressor package must be 1”diameter or larger for N37/75K (N50/100H), 1...
Page 28 - OUTDOOR SHELTERED INSTALLATION
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 26 7.0 INSTALLATION 7.6 OUTDOOR SHELTERED INSTALLATION Nirvana compressors are not suitable for outdoor installation. Installing a Nirvana compressor outside voids ...
Page 29 - GENERAL INFORMATION; TECHNICAL INFORMATION-SINGLE STAGE; Heater Circuit; Fuse type
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 27 8.0 GENERAL INFORMATION TECHNICAL INFORMATION-SINGLE STAGE N37K N45K N50H N60H General Sound pressure level dB(A) * 75 75 75 75 Maximum ambient temperature ° C (°...
Page 30 - General
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 2 8.0 GENERAL INFORMATION N55K N75K N75H N100H General Sound pressure level dB(A) * 75 75 75 75 Maximum ambient temperature ° C (° F) 46 (115) 46 (115) 46 (115) 46 ...
Page 33 - Fuse type
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 31 8.0 GENERAL INFORMATION 8.1 TECHNICAL INFORMATION − TWO STAGE N75K N90K N110K N100H N125H N150H General Sound pressure level dB(A) * 75 75 75 75 75 75 Maximum amb...
Page 35 - KEY
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 33 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING−N37/45K−CC & N50/60H−CC − AIR COOLED KEY A 11/2” NPT Air discharge (Female) 60Hz units 11/2” BSP Air discharg...
Page 36 - X−X
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 3 8.0 GENERAL INFORMATION 8.2 INSTALLATION DRAWING− N37/45K−CC & N50/60H−CC − WATER COOLED KEY A 11/2” NPT Air discharge (Female) 60Hz units 11/2” BSP Air disch...
Page 44 - Revision B
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 2 8.0 GENERAL INFORMATION 8.3 PROCESS AND INSTRUMENTATION DIAGRAM N37/45K-CC & N50/60H-CC 1 2 3 4 5 6 7 9 10 11 12 14 15 16 17 18 19 20 22 23 24 25 26 27 T 28 2...
Page 46 - Revision A
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 8.0 GENERAL INFORMATION 8.3 PROCESS AND INSTRUMENTATION DIAGRAM N55/75K-CC & N75/100H-CC 1 2 3 4 5 6 7 9 10 11 12 14 15 16 17 18 19 20 22 23 24 25 26 27 PIPING ...
Page 48 - Revision C
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 6 8.0 GENERAL INFORMATION 8.3 PROCESS AND INSTRUMENTATION DIAGRAM N90/160K & N125/200H SINGLE STAGE AND N75/160K & N100/200H TWO STAGE 1 2 3 4 5 6 7 9 10 11...
Page 50 - PROCESS AND INSTRUMENTATION DIAGRAM N250−300H TWO STAGE
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 8.0 GENERAL INFORMATION 8.3 PROCESS AND INSTRUMENTATION DIAGRAM N250−300H TWO STAGE 1 3 4 5 6 9 10 11 12 14 15 16 17 18 19 20 22 24 25 26 27 T 28 21 D F F 33 7 30 3...
Page 54 - LABEL
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 52 8.0 GENERAL INFORMATION 8.4 WIRING SCHEMATIC - N55-75K-CC / N75-100H-CC A/C BLOWER VFD KM5 1ATS PSU MCB1 MCB3 MCB5 CFO 110V SG-NE 123456789 101112131415 P3 1 2 1...
Page 55 - COLORS
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 53 8.0 GENERAL INFORMATION KEY 4SV VALVE, WATER STOP SOLENOID (W/C ONLY) 6APT TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE 9APT TRANSMITTER, REMOTE AIR PRESSURE (OPTIONAL...
Page 57 - COLOR
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 55 8.0 GENERAL INFORMATION KEY 1ATS SWITCH, HIGH AIR END DISCHARGE TEMPERATURE 1DPS SWITCH, FOULED OIL FILTER 1VAC SWITCH, FOULED AIR FILTER 1ATT SENSOR, AIREND INLE...
Page 67 - OPERATING INSTRUCTIONS; Prior to starting; Refer to diagram T5716 above.; Initial check sequence
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 65 9.0 OPERATING INSTRUCTIONS 9.1 BASIC OPERATION WARNING Ensure that all protective covers/guards are in place before attempting to start the machine. WARNING The c...
Page 68 - PRIOR TO STARTING
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 66 9.0 OPERATING INSTRUCTIONS Start sequence The compressor will initially start by the operator pressing the local start button or receiving a remote start command...
Page 69 - INTELLISYS CONTROLS; Pressing this button will activate the start sequence.
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 67 9.0 OPERATING INSTRUCTIONS 9.2 INTELLISYS CONTROLS 1. Emergency stop Pressing this switch stops the compressor immediately. The blowdown valve will open to vent p...
Page 71 - CURRENT STATUS SCREEN; CURRENT STATUS items
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 6 9.0 OPERATING INSTRUCTIONS 9.4 CURRENT STATUS SCREEN The CURRENT STATUS screen is considered to be the “normal” display that the controller shows. The following it...
Page 73 - OPERATOR SETPOINTS
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 71 9.0 OPERATING INSTRUCTIONS 9.6 OPERATOR SETPOINTS Setpoints are user−adjustable variables in the controller logic that can be set using the OPERATOR SETPOINTS scr...
Page 74 - stage compressors will always blowdown when signaled to stop.
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 72 9.0 OPERATING INSTRUCTIONS Automatic stop pressure The compressor will stop once the system pressure rises to this pressure and the compressor is operating at th...
Page 76 - Scheduled start; SENSOR CALIBRATION; SENSOR CALIBRATION Items
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 7 9.0 OPERATING INSTRUCTIONS Scheduled start This option will cause the unit to start on the scheduled start day , at the time stored in this setpoint. To disable t...
Page 78 - ENERGY STATUS MESSAGES; AVERAGE PACKAGE kW HOURS −
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 76 9.0 OPERATING INSTRUCTIONS 9.11 ENERGY STATUS MESSAGES 100 PSI READY TO START −ENERGY STATUS− AVERAGE PACKAGE kW HRS AVERAGE % CAPACITY− −AVERAGE CAPACITY STATUS...
Page 79 - SERVICE WARNINGS
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 77 9.0 OPERATING INSTRUCTIONS 9.12 WARNINGS When a WARNING occurs, a large question mark will flash on the display screen. If multiple WARNINGS exist, the small up/d...
Page 81 - MAINTENANCE PROMPTS
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 7 10.0 MAINTENANCE 10.1 MAINTENANCE PROMPTS The service warning and flashing LED will appear at intervals, dependant on the service level selected. Refer to operatin...
Page 82 - MAINTENANCE CHART; Maintenance Schedule
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 0 10.0 MAINTENANCE 10.2 MAINTENANCE CHART The MAINTENANCE CHART indicates the various components and the intervals when maintenance has to take place. Where a servi...
Page 83 - first 50 hours; of; MAINTENANCE PROCEDURES; vented to atmosphere before beginning any work.
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 1 10.0 MAINTENANCE Note: On some sea watercooled models the oil cooler and aftercooler are fitted with sacrificial zinc anodes (pencils) that are located in the end ...
Page 85 - ROUTINE MAINTENANCE
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 3 10.0 MAINTENANCE 10.4 ROUTINE MAINTENANCE This section refers to the various components which require periodic maintenance and replacement. For all other maintenan...
Page 86 - COOLANT DRAIN
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 10.0 MAINTENANCE Drain sequence for N250/300H−2S Remove plug from drain valve located on the bottom of the separator tank.Install supplied drain hose and fitting as...
Page 87 - Clean and inspect all parts prior to reinstallation.; SEPARATOR TANK SCAVENGE SCREEN/ORIFICE
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 5 10.0 MAINTENANCE Separator element change procedure for N250/300H−2S Disconnect the scavenge tube at the airend.Loosen the fitting that holds the scavenge tube int...
Page 89 - Once the screw is removed,
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 7 10.0 MAINTENANCE N50/100H (N37/75K) Following are instructions for tilting the cooler away from the enclosure and cleaning of the cooler. Remove 6 screws from lowe...
Page 90 - Aircooled machines
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 10.0 MAINTENANCE Remove 6 screws from top panel above cooler and remove panel.Using lifting device from above, attach lifting straps to lifting supports on each sid...
Page 93 - not be covered by the terms of any warranty agreement
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S http://air.irco.com 1 11.0 FAULT FINDING 11.1 GENERAL FAULTS WARNING When attempting to identify and remedy any fault or failure, ensure it is only attempted by qualified person- nel an...
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