Page 4 - TABLE OF CONTENTS
2 TABLE OF CONTENTS 0.0 SAFETY AND WARNINGS0.1 safety instructions0.2 safety precautions0.3 decals 1.0 RECEIPT OF EQUIPMENT1.1 inspection1.2 unpacking and handling1.3 tools 2.0 INSTALLATION2.1 ventilation2.2 foundation requirements2.3 piping2.4 electrical installation2.5 outdoor sheltered 3.0 INTELL...
Page 5 - SAFETY AND WARNINGS; identify the components of the air; NOTICE; SAFETY PRECAUTIONS; BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
3 0.0 SAFETY AND WARNINGS 0.1 SAFETY INSTRUCTIONSBefore you install this air compressor you should take thetime to carefully read all the instructions contained in thismanual. Electricity and compressed air have the potential to causesevere personal injury or property damage. Before installing, wiri...
Page 6 - CHECK HIGH AIR TEMPERATURE; Block off the cooling air discharge.; SAFETY SHUTDOWN
4 WARNING Failure to adhere to these recommendations can result in mechanical failure, property damage and serious injury or death. All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must takeinto account vibration, pulsations, temperat...
Page 7 - Lift Here; VIEWED
39540174 Rev. 05 5 0.3 DECALS This section contains representative examples of decalswhich will be appearing throughout this manual and areapplied to the compressor unit. If for some reason adecal is defaced, painted over, or parts are replaced, we recommend that you obtain a replacement kit as list...
Page 8 - WARNING
0.3 DECALS (continued) 6 WARNING ! Hot surface.Can cause severe injury. Do not touch. Allow to cool beforeservicing. Water out. Water in. Lift Here Condensate drain. Air Discharge Electrical power inlet. DANGER ! Discharge air.Can contain carbon monoxide orother contaminants. Will causesevere injury...
Page 9 - Electrical; SCHEMATIC DECAL
0.3 DECALS (continued) 7 WARNING ! Hazardous voltage. Can causesevere injury or death. Only use factory supplied inlet forincoming power. See Operators/Instruction manual. WARNING ! Hazardous voltage. Can causesevere injury or death. Disconnect power before servicing.Lockout/Tagout machine. Electric...
Page 10 - IMPORTANT
8 1.0 RECEIPT OF EQUIPMENT 1.1 INSPECTIONWhen you receive the compressor please inspect itclosely. Any indication of careless handling by the carriershould be noted on the delivery receipt especially if thecompressor will not be immediately uncrated. Obtainingthe delivery man’s signed agreement to a...
Page 12 - MOISTURE CONTENT OF COMPRESSED AIR; DEW POINT
10 DISCHARGE PIPING WITH AFTERCOOLER ROTARY-RECIP IN PARALLEL Do not use the compressor to support the discharge pipe. Careful review of piping size from the compressorconnection point is essential. Length of pipe, size of pipe,number and type of fittings and valves must beconsidered for optimum eff...
Page 14 - CAUTION; Close and fasten the starter box door.; FIGURE 2.4-1 TYPICAL CONTROL TRANSFORMER WIRING
If the compressor is operated in the opposite direction of rotation, airend damage can result and is not warrantable. CAUTION 12 ELECTRICAL INSTALLATION (Continued)Inspect the motor and control wiring for tightness. Close and fasten the starter box door. ROTATION CHECKLocate the rotation decal on ea...
Page 15 - Open the starter box door.
13 ELECTRICAL INSTALLATION (Continued)The Intellisys will automatically shut the unit down if thecompressor rotation is incorrect, and the display willindicate “CHECK MOTOR ROTATION” and will flash“ALARM”. For the compressor motor rotation check, the motorjogging time must be as short as possible. A...
Page 17 - FIGURE 2.5-1 TYPICAL OUTDOOR SHELTERED INSTALLATION
FIGURE 2.5-1 TYPICAL OUTDOOR SHELTERED INSTALLATION 15
Page 18 - INTELLISYS CONTROLLER
16 3.0 INTELLISYS INTELLISYS CONTROLLER INGERSOLLrANDINTELLISYS
Page 19 - INTELLISYS CONTROLS; EMEG
3.0 INTELLISYS 3.1 INTELLISYS CONTROLS EMERGENCY STOP Pressing this switch stops the compressor immediately.The compressor can not be restarted until the switch ismanually reset. Turn the switch knob clockwise toreset. POWER ON LIGHTThis indicates the control voltage and the line voltageare availabl...
Page 21 - - Use UP and DOWN arrows to scroll through list of status items.; INTELLISYS
19 NOTE - Use the UP and DOWN arrows to move between selections. Items will be highlighted in inverse display mode. * - Selecting the highlighted item will display the corresponding menu. ** - Selecting the highlighted item will place the value in edit mode. This is indicated by only the value being...
Page 23 - P S I
3.5.1 Lead/Lag- This setpoint is used for setting leador lag operation. If set to lead, the controller will loadand unload the compressor by the online and offlinesetpoints. If set to lag, the controller will subtract thelag offset (see 3.5.4) from the online and offline setpoints and operate the co...
Page 25 - SENSOR CALIBRATION
3.7 SENSOR CALIBRATION 1 0 0 P S I -SENSOR CALIBRATION- Sensor 1AVPT CALIBRATE Sensor 3APT CALIBRATE STATUS MAIN MENU SELECT Ready To Start Pressure sensor calibration is done through theSENSOR CALIBRATION screen. Sensor calibrationcan only take place when the machine is stopped.Calibration needs to...
Page 30 - The possible Alarm messages are as follows.
28 The possible Alarm messages are as follows. CHECK INLET CONTROL- This will occur if themachine is unloaded and the inlet vacuum is less than3 psig (.2 bar). CHECK INLET CTRL SYS 1 (2) - This will occur if theinlet butterfly valve fails to open or close properly. A 1means the inlet valve failed to...
Page 31 - SCHEDULED PREVENTATIVE MAINTENANCE; Read Safety Instructions.; P) reaches three times the; Running
4.0 SCHEDULED PREVENTATIVE MAINTENANCE 4.1 MAINTENANCE SCHEDULETHE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THECOMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THATNUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST. 4.2 MAINTENANCE RECOR...
Page 32 - INLET AIR FILTER
4.4 INLET AIR FILTERTo check condition of the inlet filter, run compressor inthe LOADED mode and observe “Inlet Filter” on theCURRENT STATUS display screen. If the display says“Inlet Filter OK”, then no maintenance is required. If “ ? ”is flashing on the screen and the display says “CHANGEINLET FILT...
Page 34 - TOOLS REQUIRED; Open end wrench
32 4.6 COOLANT (Continued) After the unit is drained and a new coolant filter elementis installed, refill the system with fresh coolant. Bring thereceiver level of coolant up to the midpoint of the sightglass. Replace the fill cap. Start the compressor and runit for a short time. The correct coolant...
Page 35 - Disconnect the scavenge tube at the airend.; Tank cover bolt torque values
WARNING 125/200 HP This machine contains high air pressurewhich can cause severe injury or deathfrom hot oil or flying parts. Always relieve pressure before removing caps,plugs, covers or other parts. Blow downpressurized air system. Close isolation valve.See Operator’s Instruction Manual. 4.8 COOLA...
Page 37 - Aftercooler; Disconnect hose from aftercooler inlet flange.; Aftercooler Cleaning; Reassemble in reverse order.
35 AFTERCOOLERFollowing are instructions for the removal and internalcleaning of aftercoolers. Aftercooler ■ Disconnect hose from aftercooler inlet flange. ■ Disconnect tube from aftercooler outlet flange. ■ Remove aftercooler holding screws from aftercoolersupport and remove cooler. Aftercooler Cle...
Page 38 - M75-160 As indicated on motor
36 Overgreasing can be a cause of bearing and motor failure. Make sure dirt and contaminants are not introduced when adding grease. CAUTION 4.10 MOTOR LUBRICATIONThe induction-type squirrel cage motors have antifrictionball or roller bearings front and rear. At periodic intervalsthey require relubri...
Page 39 - Recommended Motor Grease
37 4.10 MOTOR LUBRICATION (Continued)Grease relief along shaft can occur, precluding necessityof removing this plug if inaccessible. The inlet grease gunfittings and outlet plugs (or spring-loaded reliefs) arelocated at each end of the motor housing. The drive endreliefs protrude out the circumferen...
Page 40 - ) Make the least possible movement to avoid build-
38 4.11 LONG TERM STORAGE GENERALThe factory, upon special request, prepares compressorunits for long term storage. In such cases, a specialbulletin is supplied for storage and start-up procedures. The bulletin provides special procedures for rotation andlubrication of compressors during storage. Be...
Page 41 - Power Supply Removal:; FLUID AND VIBRATION MONITORING
39 Power Supply Removal: 1) Open the starter box door. 2) Remove each plug-in connector, labeled J1 -J4, from the circuit board. If any of the cables are not labeled, label them with the appro-priate plug designator, J1-J4. These must be plugged into the correct sockets in the replacement power supp...
Page 42 - AIR COOLED COMPRESSORS
40 COOLING FAN MOTORIn a standard compressor, the cooling fan motor is wiredat the factory. It is a three-phase motor, protected by asuitable circuit breaker and overload relay. The fan motoris energized at the same time the compressor drivemotor is energized. The fan motor overload is wired inserie...
Page 46 - Some Examples of Operation; The total run time for this example will be 13 minutes.
44 SECONDAfter the compressor has started and reached the off-linesetting and has unloaded, timer “B” requires the unit torun unloaded for a period of time that the operator canadjust between 2 and 60 minutes. The setting of timer “B” is part of the options setpointroutine and the timer cancels any ...
Page 48 - TROUBLESHOOTING CHART
46 6.0 TROUBLESHOOTING CHART TROUBLE Compressor fails to start. Compressor shuts down. NOTE: If a shutdownoccurs, press the Statusbutton once to activatethe display table. Usingthe adjacent up anddown arrows, the valuesdisplayed will be thoseimmediately precedingshutdown. Use thesevalues whentrouble...
Page 52 - REV B; REFERENCE DRAWINGS
50 54418074 REV B 8.0 REFERENCE DRAWINGS 8.1 ELECTRICAL SCHEMATICSTAR DELTA
Page 55 - SINGLE STAGE
53 54622865 REV B 8.2 FOUNDATION PLAN 125-150 HP/90-110 KW AIRCOOLED SINGLE STAGE
Page 58 - REV C
56 8.4 FOUNDATION PLAN125-150 HP/90-110 KW WATERCOOLEDSINGLE STAGE(CONTINUED) 39925300 REV C
Page 70 - REV A
68 8.10 FLOW SCHEMATICAIRCOOLED - SINGLE STAGE 54579081 REV A
Page 82 - TYPICAL SYSTEM FLOW DIAGRAMS; TYPICAL SYSTEM FLOW
80 8.16 TYPICAL SYSTEM FLOW DIAGRAMS TYPICAL SYSTEM FLOW DIAGRAM
Page 89 - LANGELIER INDEX CHART VALUES; AL
87 LANGELIER INDEX CHART VALUES UNITS 0 1 2 3 4 5 6 7 8 9 0 0.00 0.30 0.48 0.60 0.70 0.78 0.85 0.90 0.93 10 1.00 1.04 1.08 1.11 1.15 1.18 1.20 1.23 1.26 1.29 20 1.30 1.32 1.34 1.36 1.38 1.40 1.42 1.43 1.45 1.46 30 1.48 1.49 1.51 1.52 1.53 1.54 1.56 1.67 1.58 1.59 40 1.60 1.61 1.62 1.63 1.64 1.65 1.6...
Page 90 - MAINTENANCE RECORD
88 DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE BY 10.0 MAINTENANCE RECORD
Page 91 - MAINTENANCE RECORD
89 DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE BY MAINTENANCE RECORD