Brother 1800 Network Card User Manual

IRN37−160K−CC
IRN50−200H−CC
IRN75−160K−2S
IRN100−200H−2S
IRN250−300H−2S
OPERATION AND MAINTENANCE MANUAL
Ensure that the operator reads and understands the
decals and consults the manuals before maintenance
or operation.
Ensure that the Operation and Maintenance manual
is not removed permanently from the machine.
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance
Manuals.
TM
C.C.N. : 54731245
DATE : DECEMBER 2007
REV. : J
Warranty
AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
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 months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall
be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period,
whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or,
furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and
operated such Equipment in accordance with good industry practices and has complied with specific recommendations
of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever
warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company
shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the
Purchaser or others without Company‘s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance
warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period of
time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR
IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such non conformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in
writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.
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.
1.0 contents
contents
PAGE
contents
PAGE
1.0 contents 1
9.6 OPERATOR SETPOINTS
71
2.0 FOREWORD
2
9.7 OPTIONS
73
3.0 ABBREVIATIONS & SYMBOLS
4
9.8 SENSOR CALIBRATION
74
4.0 PURCHASE ORDER DETAILS
5
9.9 ALARM HISTORY
75
5.0 SAFETY
6
9.10 CLOCK FUNCTIONS
75
5.1 SAFETY INSTRUCTIONS
6
9.11 ENERGY STATUS MESSAGES
76
5.2 SAFETY PRECAUTIONS
6
9.12 WARNINGS
77
5.3 TEXT DECALS
9
9.13 SERVICE WARNINGS
77
5.4 GRAPHIC FORM AND MEANING OF ISO
SYMBOLS
13
9.14 INITIAL CHECK ALARMS:
77
9.15 ALARMS
78
6.0 RECEIPT / HANDLING
18
10.0 MAINTENANCE
79
6.1 RECEIPT
18
10.1 MAINTENANCE PROMPTS
79
6.2 UNPACKING AND HANDLING
18
10.2 MAINTENANCE CHART
80
7.0 INSTALLATION
19
10.3 MAINTENANCE PROCEDURES
81
7.1 LOCATION IN PLANT
19
10.4 ROUTINE MAINTENANCE
83
11.0 FAULT FINDING
91
7.2 DISCHARGE AND CONDENSATE PIPING
20
7.3 ELECTRICAL
21
7.4 WATERCOOLED UNITS
23
7.5 SEA WATERCOOLED UNITS (SELECTED
UNITS ONLY)
25
7.6 OUTDOOR SHELTERED INSTALLATION26
8.0 GENERAL INFORMATION
27
8.1 TECHNICAL INFORMATION
27
8.2 INSTALLATION DRAWING 33
8.3 PROCESS AND INSTRUMENTATION
DIAGRAM
42
8.4 ELECTRICAL SCHEMATIC
50
8.5 GENERAL DESCRIPTION
64
9.0 OPERATING INSTRUCTIONS
65
9.1 BASIC OPERATION
65
9.2 INTELLISYS CONTROLS
67
9.3 DISPLAY SCREEN
68
9.4 CURRENT STATUS SCREEN
69
9.5 MAIN MENU
70
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2.0 FOREWORD
Machine models represented in this manual may be
used in various locations worldwide. Machines sold and
shipped into European community countries requiresthat
the machine display the EC Mark and conform tovarious
directives. In such cases, the design specification of
this machine has been certified ascomplying with EC
directives. Any modification to any part is absolutely
prohibited and would result in the CEcertification and
marking being rendered invalid.
The contents of this manual are considered to be
proprietary and confidential to Ingersoll Rand and should
not be reproduced without the prior written permission
of Ingersoll Rand.
Nothing contained in this document is
intended to extend any promise, warranty or
representation,expressed or implied, regarding the
Ingersoll Rand products described herein. Any such
warranties or other terms and conditions of sale of
products shall be in accordance with the standard terms
and conditions of sale for such products, which are
available upon request.
This manual contains instructions and technical
data to cover all routine operation and scheduled
maintenance tasks by operation and maintenance staff.
Majoroverhauls are outside the scope of this manual
and should be referred to an authorized
Ingersoll Rand service department.
All components, accessories, pipes and connectors added
to the compressed air system should be:
• of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved
by Ingersoll Rand.
• clearly rated for a pressure at least equal to the machine maximum allowable working pressure.
• compatible with the compressor lubricant/coolant.
• accompanied with instructions for safe
installation,operation and maintenance.
Ingersoll Rand reserves the right to make changes and
improvements to products without notice and without
incurring any obligation to make such changes or add
such improvements to products sold previously.
Details of approved equipment are available from Ingersoll
Rand Service departments.
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, vapors or
particles
• Operation within the ambient temperature range
specified in the GENERAL INFORMATION section of
this manual.
IF IN DOUBT CONSULT SUPERVISION.
The company accepts no responsibility for errors in
translation of this manual from the original English
version.
The design of this Compressor package and certain
features within it are covered by patents held by
Ingersoll Rand and patents pending
SSR ULTRA COOLANT is a registered trademark of
Ingersoll Rand Company USA.
INTELLISYS is a registered trademark of Ingersoll Rand
Company USA.
HPM™, HYBRID PERMANENT MAGNET™ and HPM
Logo are trade marks registered by MOTEURS LE-ROYSOMER
© COPYRIGHT 2007
INGERSOLL RAND COMPANY
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2.0 fOREWORD
warning
The use of the machine in any of the situation types listed in table 1:−
a) Is not approved by Ingersoll Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll Rand.
TABLE 1
warning − NOT PERMITTED
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption.
Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION
of this manual.
Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or
vapors.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR VAPOURS MAY BE PRESENT.
Use of the machine fitted with non Ingersoll Rand approved components.
Use of the machine with safety or control components missing or disabled.
Connection to an electrical supply of incorrect voltage and/or frequency.
warning
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.
warning
The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such
as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with
cardiac pacemakers, defibrillators or other implanted electronic medical device.
warning
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the
internal capacitors store a potentialy lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any
work on the drive unless trained. There are no user serviceable items behind the cover.
warning
The compressor can operate in a pressurised shutdown mode. If the compressor stops automatically, the
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through
which any residual pressure will be vented. Downstream of the separator tank may still contain system
pressure which must also be vented.
notice
The manual is intended for worldwide use and contains both metric and imperial data where required.
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3.0 ABBREVIATIONS & SYMBOLS
#### Contact Ingersoll Rand for serial number
−>#### Up to Serial No.
####−> From Serial No.
* Not illustrated
† Option
NR Not required
AR As required
SM Sitemaster/Sitepack
HA High ambient machine
WC Watercooled machine
AC Aircooled machine
ERS Energy recovery system
T.E.F.C.
Totally enclosed fan cooled motor (IP54)
O.D.P. Open drip proof (motor)
ppm parts per million
cs Czech
da Danish
de German
el Greek
en English
es Spanish
et Estonian
fi Finnish
fr French
hu Hungarian
it Italian
lt Lithuanian
lv Latvian, Lettish
mt Maltese
nl Dutch
no
Norwegian
pl Polish
pt Portuguese
sk Slovak
sl Slovenian
sv Swedish
zh Chinese
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4.0 PURCHASE ORDER DETAILS
ROTARY SCREW AIR COMPRESSOR
This unit was purchased from
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
Ingersoll Rand Company reserves the right to make changes or add
improvements without notice and without incurring any obligation
to make such changes or add such improvements to products sold
previously.
No. of units on order:____________________________________________
Customer Order No:_____________________________________________
Ingersoll Rand Co. Order No_ _____________________________________
For ready reference:
Record the serial number and model number of your unit here.
Serial Number:_ ________________________________________________
Model Number:_ _______________________________________________
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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 to indicate hazard seriousness levels as follows.
Ensure that the operator reads and understands the
decals and consults the manuals before maintenance or
operation.
danger
Indicates the presence of a hazard which WILL
cause serious injury, death or property damage, if
ignored.
warning
Indicates the presence of a hazard which CAN
cause serious injury, death or property damage, if
ignored.
Ensure that the Operation and Maintenance manual, and
the manual holder, are not permanently removed from
the machine.
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance
Manuals.
caution
Indicates the presence of a hazard which WILL or
can cause injury or property damage, if ignored.
NOTICE
Indicates important set–up, operating or
maintenance information.
5.2 SAFETY PRECAUTIONS
General Information
Compressed air and electricity can be dangerous. Before
undertaking any work on the compressor, ensure that the
electrical supply has been isolated, locked off, tagged and
the compressor has been relieved of all pressure.
Make sure that all protective covers are in place and that
the canopy/doors are closed during operation.
Installation of this compressor must be in accordance with
recognized electrical codes and any local Health and Safety
Codes.
Use only safety solvent for cleaning the compressor and
auxiliary equipment.
Compressed air
Ensure that the machine is operating at the rated pressure
and that the rated pressure is known to all relevant
personnel.
All air pressure equipment installed in or connected to
the machine must have safe working pressure ratings of
at least the machine rated pressure.
If more than one compressor is connected to one
common downstream plant, effective check valves and
isolation valves must be fitted and controlled by work
procedures, so that one machine cannot accidentally be
pressurized / over pressurized by another.
If a safety valve is installed between the isolation valve
and the compressor, it must have sufficient capacity to
relieve the full capacity of the compressor(s).
The discharged air contains a very small percentage of
compressor lubricating oil and care should be taken to
ensure that downstream equipment is compatible.
If the discharged air is to be ultimately released into a
confined space, adequate ventilation must be provided.
The use of plastic bowls on line filters without metal
guards can be hazardous. Their safety can be affected
by either synthetic lubricants, or the additives used in
mineral oils. Metal bowls should be used on a pressurized
system.
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5.0 SAFETY
When using compressed air always use appropriate
personal protective equipment.
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.
Compressed air can be dangerous if incorrectlyhandled.
Before doing any work on the unit, ensure that all
pressure is vented from the system and that the machine
cannot be started accidentally.
Avoid bodily contact with compressed air.
The safety valve located in the separator tank must be
checked periodically for correct operation.
Whenever pressure is released through the pressure relief
valve, it is due to excessive pressure in the system. The
cause for the excessive pressure should be investigated
immediately.
Materials
The following substances are used in the manufacture
of this machine and may be hazardous to health if used
incorrectly:
• preservative grease
• rust preventative
• compressor coolant
warning
AVOID INGESTION, SKIN CONTACT AND
INHALATION OF FUMES
For further information, request and consult the coolant
Material Data Sheet (UK ACGP 011/96 −ULTRA COOLANT
ACGP 029/90−food grade coolant. For USA served areas,
use MSDS sheet APDD 236) from your local IR office,
Distributor or Air Center.
Should compressor lubricant come into contact with the
eyes, then irrigate with water for at least 5 minutes.
Should compressor lubricant come into contact with the
skin, then wash off immediately.
Consult a physician if large amounts of compressor
lubricant are ingested.
The above information contains data supplied in support
of United Kingdom Control of Substances Hazardous to
Health (C.O.S.H.H.) regulations
Transport
When loading or transporting machines ensure that the
specified lifting and tie down points are used.
It is recommended that the machine be moved using the
fork lift slots in the machine base.
Refer to section 8-General Information for reference
information.
Electrical
The compressor has high and dangerous voltage in the
motor starter and control box. All installations must be
in accordance with recognized electrical codes. Before
working on the electrical system, be sure to remove
voltage from the system by using a manual disconnect
switch. A circuit breaker or fuse safety switch must be
provided in the electrical supply line leading to the
compressor.
Those responsible for installation of this equipment
must provide suitable grounds, maintenance clearance
and lightning arrestors for all electrical components in
accordance with National and Local code requirements.
Keep all parts of the body and any hand−held tools or
other conductive objects, away from exposed live parts
of the compressor electrical system. Maintain dry footing,
stand on insulating surfaces and do not contact any other
portion of the compressor when making adjustments or
repairs to exposed live parts of the compressor electrical
system.
Close and lock all access doors when the compressor is
left unattended.
Do not use extinguishers intended for Class A or Class B
fires on electrical fires. Use only extinguishers suitable for
class BC or class ABC fires.
Attempt repairs only in clean, dry, well lighted and
ventilated areas.
Connect the compressor only to electrical systems that
are compatible with its electrical characteristics and that
are within it’s rated capacity.
Consult a physician if compressor lubricant is inhaled.
Never give fluids or induce vomiting if the patient is
unconscious or having convulsions.
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5.0 SAFETY
Condensate disposal
Coolant 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 sewage treatment.
Steps to be taken in the case of spillage: Soak up with a
suitable absorbent material, then sweep into a plastic bag
for disposal.
As waste water regulations vary by country and region it
is the responsibility of the user to establish the limitations
and regulations in their particular area. Ingersoll Rand
and its associated distributors are happy to advise and
assist in these matters.
Burn in an approved incinerator, or according to local area
or country regulations.
For further information, consult ULTRA COOLANT Material
Data Sheets ACGP 011/96 or APDD 236. FOOD GRADE
COOLANT Material Data Sheets IRACA145 or APDD190.
warning
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the
internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any
work on the drive unless trained. There are no user serviceable items behind the cover.
warning
There is a high discharge air temperature shutdown function built into each compressor. lt is factory preset
at 109 °C (228° F).This function should be checked at regular intervals for proper operation, once a month is
recommended. Refer to maintenance section.
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 take into account vibration, pulsations, temperature, maximum pressure applied,
corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will
discharge some oil into the air stream; therefore, compatibility between discharge piping, system
accessories and software must be assured.
• For the foregoing reasons, the use of plastic piping and rubber hose as discharge piping is not
recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if
their specifications fit the operating parameters of the system.
• It is the responsibility of the installer and owner to provide the appropriate service pipework to and from
the machine.
warning
“Ingersoll Rand air compressors are not designed, intended, or approved for breathing air applications.
Ingersoll Rand does not approve specialized equipment for breathing air application and assumes no
responsibility or liability for compressors used for breathing air services.”
warning
No portable communication devices emitting more than 7.5 volts per metre in the frequency range from 250
MHz to 280 MHz should be operated within 5m (16.5ft) of the unit.
warning
The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such
as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with
cardiac pacemakers, defibrillators or other implanted electronic medical device.
warning
The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas.
If such an application is required then all local regulations, codes of practice and site rules must be observed.
To ensure that the machine can operate in a safe and reliable manner, additional equipment such as gas
detection and intake (shut−off) valves may be required, dependant on local regulations or the degree of risk
involved.
warning
The compressor can operate in a pressurized shutdown mode. If the compressor stops automatically, the
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through
which any residual pressure will be vented. Downstream of the separator tank may still contain system
pressure which must also be vented
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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 within the European Community must be equipped with symbols from section
5.4. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your
supervisor.
5.3 TEXT DECALS
NOTICE
WARNING
To obtain satisfactory compressor operation and
maintenance, a minimum of 3 feet clearance on 3
sides is required. 3 1/2 feet is required in front of
the control panel (or minimum required by latest
National Electrical code or applicable local codes.)
Refer to the Instruction / Operators Manual before
performing any maintenance.
Hazardous voltage. Can cause severe injury or
death.
DANGER
Disconnect power before servicing.
Lockout/Tagout machine.
WARNING
Discharge air.
Can contain carbon monoxide or other
contaminants. Will cause severe injury or death.
Do not breathe this air.
Rotating fan blade. Can cause severe injury.
Do not operate with covers removed.
Disconnect power. Lock/out and tag out machine.
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5.0 SAFETY
CAUTION
WARNING
Incorrect lifting of machine can cause injury or
property damage.
Lift only from base channels
WARNING
Food contaminant.
Can cause severe injury or death.
Use only Ingersoll Rand SSR H-1F food grade coolant.
39568464 Rev. 03
NOTICE
High pressure air.
Can cause severe injury or death.
Compressor can operate in a pressurized
shutdown mode.
Lift here
Relieve pressure before removing filter plugs/caps,
fittings or covers.
22061915 Rev. A
NOTICE
WARNING
Air discharge
CAUTION
Use of incorrect coolant can cause system
contamination.
Use only SSR ULTRA COOLANT
10
Hot surface.
Can cause severe injury.
Do not touch. Allow to cool before servicing.
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5.0 SAFETY
CAUTION
Rotation
Improper coolant filter replacement will cause
compressor damage.
Rotation
Replace filter element after first 150 hours of
operation and every 2000 hours thereafter or when
coolant is changed.
NOTICE
WARNING
Rotation
HIGH VOLTAGE
Do not attempt any work.
Read manual.
Trained service personnel only.
Remove electrical supply.
Wait 15 minutes.
Check for zero voltage.
Proceed with caution.
WARNING
Moving parts. Can cause severe injury.
Do not operate with covers removed.
Service only with machine blocked to prevent turn over.
39540224 Rev. 04
Air
Discharge
39540257 Rev. 04
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11
5.0 SAFETY
Condensate
drain.
Use 75˚C copper wire only.
Nur 75˚C kupferdraht verwenden.
Utilisez 75˚C uniquement fil de cuivre.
Usar solamente cable de cobre para 75˚ C.
usare 75˚C solamente cavi di rame.
Electrical
power inlet.
WARNING
Use somente fio de cobre de 75˚.
39492384 Rev. 03
Use 75°C copper wire only.
IMPORTANT
Before starting this air compressor unit
the shipping brace(s) must be removed.
Save the brace(s) for future use. Refer to
Operators/Instruction Manual.
39481130 Rev. 02
Hazardous voltage. Can cause severe injury or
death.
IMPORTANT
Before starting this air compressor unit the shipping
brace(s) must be removed.
Save the brace(s) for future use.
Refer to Operators / Instruction Manual.
Disconnect power before servicing.
Lockout/Tagout machine.
NOTICE
To obtain satisfactory compressor operation and
maintenance, a minimum of 3 feet clearance on 3
sides is required. 3 1/2 feet is required in front of
the control panel (or minimum required by latest
National Electrical code or applicable local codes.)
Refer to the Instruction / Operators Manual before
performing any maintenance.
12
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5.0 SAFETY
5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory
Information / Instructions
Warning
WARNING: Electrical shock risk.
WARNING − Pressurized component or
system.
WARNING − Hot surface.
WARNING − Pressure control.
WARNING − Corrosion risk.
WARNING − Air/gas flow or Air discharge.
WARNING − Pressurized vessel.
Do not remove the Operating and
Maintenance manual from this machine.
WARNING − Flammable liquid.
WARNING − Rotor magnetic field
can affect pacemakers.
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13
5.0 SAFETY
0° C
WARNING − Do not undertake any
maintenance on this machine until the
electrical supply is disconnected and the
air pressure is totally relieved.
WARNING − Consult the Operation
and Maintenance manual before
commencing any maintenance.
WARNING − For operating temperature
below 0°C, consult the Operation and
Maintenance manual.
Read the Operation and Maintenance
manual before operation or maintenance
of this machine is undertaken.
Do not stack.
Do not operate the machine without the
guard being in place.
Do not stand on any service valve or
other parts of the pressure system.
Do not operate with the doors or
enclosure open.
Do not use fork lift truck from this side.
Do not breathe the compressed air from
this machine.
No naked lights.
Do not open the service valve before the
air hose is attached.
14
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5.0 SAFETY
Use fork lift truck from this side only.
Emergency stop.
Tie down point
Lifting point.
On (power).
Off (power).
SET
SEQUENCER STATUS
LOAD
SEQUENCER (AUTOMATIC CONTROL)
COMPRESSOR
OFF LOAD (UNLOADED)
RESET
COMPRESSOR STATUS
MODULATE
MALFUNCTION
POWER
FOULED FILTER
POWER INLET
ELECTRIC MOTOR
HOURS
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15
5.0 SAFETY
16
COOLANT SEPARATOR
PRESSURE
AIR DISCHARGE
PRESSURIZED TANK
ON / OFF CYCLE
COOLANT FILTER
AIR FILTER
ON / OFF PUSH BUTTON
COOLANT PRESSURE
AIR PRESSURE
STAR DELTA IEC 617−7
AUTOMATIC RESTART
HEAT EXCHANGER
MAINTENANCE
MAINTENANCE PROHIBITED
COOLANT DRAIN
CONDENSATE DRAIN
PRESSURE CONTROL
MANUAL (SELECT)
TEMPERATURE
HIGH TEMPERATURE
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5.0 SAFETY
BELT TENSION
FILTER
MOTOR LUBRICATION
FRAGILE
KEEP DRY
THIS WAY UP
USE NO HOOKS
NO SIDE CLAMPS
ROTATION
POWER INLET (AC)
WATER IN
WATER OUT
TRAINED SERVICE PERSONNEL
WAIT TIME
CHECK ZERO VOLTS
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17
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 on the delivery receipt especially if the compressor will not be immediately unpacked. Obtaining the deIivery
persons signed agreement to any noted damages will facilitate any future insurance claims.
IMPORTANT
READ THIS
LOST OR DAMAGED GOODS
THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL
OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNED
BILL OF LADING
If goods are received short or in damaged condition, it is important that you notify the carrier and insist on a
notation of the loss or damage across the face of the freight bill. Otherwise no claim can be enforced against the
transportation company.
If concealed loss or damage is discovered, notify your carrier at once and request an inspection. This is absolutely
necessary. Unless you do this the carrier will not entertain any claim for loss or damage. The agent will make an
inspection and grant a concealed damage notation. If you give the transportation company a clear receipt for
goods that have been damaged or lost in transit, you do so at your own risk and expense.
WE, AT lR, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSS
OR DAMAGE, BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR
COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL. THE ACTUAL FILING AND PROCESSING OF
THE CLAIM IS YOUR RESPONSIBILITY.
Ingersoll Rand Company
6.2 UNPACKING AND HANDLING
The compressor will normally be delivered with a polyethylene or other cover. If a knife has to be used to remove this
cover, ensure that the exterior paintwork of the compressor is not damaged.
Incorporated within the base of the compressor are slots to enable a fork lift truck to move the machine. Ensure truck
forks are fully engaged on both sides. Alternatively a special lifting frame can be utilized to enable a crane or hoist to
move the compressor. Use only marked lifting points.
Once the packaging and pallet are discarded and the unit is in its final position, remove the transit brackets from the
resilient mounts and store for future use or discard.
On N75−160 units remove the screw in the base and slide the separator tank service bracket into the upper position on
the slots and tighten screws.
18
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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 removal) position the
machine to obtain lifting access e.g. fork lift truck.
See diagram in reference section for minimum space
requirements for normal operation and maintenance.
Ambient temperatures higher than 46° C (115° F) must be
avoided as well as areas of high humidity.
Consider also the environment surrounding or near the
compressor. The area selected for the location of the
compressor should be free of dust, chemicals, metal
filings, paint fumes and overspray.
It is recommended that provision be made for lifting
heavy components during major overhaul. Use only
lifting points provided.
Minimum space in front of control panel door as required
by National or Local codes must be maintained.
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.
Sufficient space all round and above the compressor must
be allowed, to enable the effective removal of the cooling
air which, in turn, will reduce the risk of recirculating the
cooling air back through the compressor.
Hard surfaces may reflect noise with an apparent
increase in the decibel level. When sound transmission
is important, a sheet of rubber or cork can be installed
beneath the machine to reduce noise. Flexible piping
may be required.
caution
A minimum of 1 m (3.3ft) all round the compressor is recommended. If headroom is restricted, then the exhaust should be ducted or deflected away from the machine.
Screw type compressors [1] should not be installed in air systems with reciprocating compressors without
means of isolation such as a common receiver tank. It is recommended that both types of compressor be
piped to a common receiver using individual air lines.
The machine is shipped with the shipping restraints in place. Ensure that these are removed to allow free
movement of the drive assembly during operation. Each restraint is painted yellow.
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19
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 safe
and effective total system. One item which should be
considered is liquid carryover. Installation of air dryers
[3] is always good practice since properly selected and
installed they can reduce any liquid carryover to zero.
A receiver [2] may be necessary to ensure that the total
system volume is not less than 2.0 U.S. Gal. per rated
delivery C.F.M.
Discharge piping should be at least as large as the
discharge connection of the compressor. All piping
and fittings should be suitably rated for the discharge
pressure.
It is good practice to locate an isolation valve close to the
compressor and to install line filters [4].
Include a means [6] to vent the discharge pipework
downstream from the minimum pressure check valve
located on the separator tank. Upstream of the first
system isolation valve [7].
The discharged air contains a very small percentage of
compressor lubricating oil and care should be taken to
ensure that downstream equipment is compatible.
When two rotary units are operated in parallel, provide an
isolation vaIve and drain trap for each compressor before
the common receiver.
The built−in aftercooler reduces the discharge air
temperature below the dew point (for most ambient
conditions), therefore, considerable water vapor
is condensed. To remove this condensation, each
compressor with built−in aftercooler is furnished with a
combination condensate separator/trap.
A dripleg assembly and isolation valve should be
mounted near the compressor discharge. A drain line
should be connected to the condensate drain in the base.
IMPORTANT: The drain line must slope downward from
the base to work properly. For ease of inspection of the
automatic drain trap operation, the drain piping should
include an open funnel.
NOTICE
For low volume systems that may not include a
receiver [2], compressor response time may need
adjusting. Contact your local IR service agent.
caution
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 oils. From
a safety standpoint, metal bowls should be used on any pressurized system.
NOTICE
Do not use the compressor to support the discharge pipe.
20
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7.0 INSTALLATION
7.3 ELECTRICAL
caution
This procedure should only be carried out by a qualified electrician, electrical contractor or your local Ingersoll Rand Distributor or Air Center.
The compressor and drive should be properly grounded
/ earthed in accordance with Local and National Code
requirements.
Installation of this compressor must be in accordance
with recognized electrical codes and any local Health and
Safety Codes.
The compressor must have its own isolator situated
adjacent to it. The fuse protecting the circuit and the
compressor must be selected in accordance with local
and national code requirements on the basis of the data
provided in the general information section
Feeder cables should be sized by the customer/electrical
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 performance of the
compressor.
Cable sizes may vary considerably so the mains
terminals will accept up to 50mm2 (1awg) (37/45k
& 50/60H) and up to 90mm2 (3/0awg) (55/75k &
75/100H) cable. The N75K−160K and N100H−200H
machines mains terminals will accept 2 x 120mm2 (4/0
AWG) cables. The N250H−300H−2S machines main
terminals will accept 2 x 400 MCM cables.
Feeder cable connections to incoming terminals
L1−L2−L3 should be tight and clean.
The applied voltage must be compatible with the motor
and compressor data plate ratings.
The control circuit transformer has different voltage
tappings. Ensure that these are set for the specific applied
voltage prior to starting.
The feeder cable must be suitably glanded into the power
drive module (P.D.M.) electrical box to ensure that dirty air
does not by−pass the filter pads or degrade the cooling
air flow.
On completion of electrical installation, check that blower
motor rotation is correct. N250H−300H utilizes a fan.
This machine is designed for use in heavy industrial
environments, where the electricity supply is separated
from nearby residential and commercial areas. If the
machine is to be used in the light industrial, residential or
commercial environment where the local supply network
is shared, further radio frequency (RF) screening measures
may be required. Consult your local distributor/supplier
for details of the optional RF filter. RF filter supplied as
standard on N250−300H−2S
The compressor has a anti−condensation heater and
thermostat in the electrical box. This circuit can be
connected to an independent electrical supply of either
110V or 230V single phase, dependant on the country
of installation. The supply should be suitable fused
and an independent isolator installed adjacent to the
compressor.
This should be done in accordance with local and national
codes. It is good practice and sometimes mandatory, to
display suitable signs warning that the machine has two
separate electrical supplies which both must be isolated
before any work is attempted.
Alternately it can be supplied from the 110V tapping
of the control transformer and connected as shown on
schematic wiring diagram.
A hole is provided for incoming power connection. If it is
necessary to make a hole in the control box in a different
location, care should be taken to not allow metal shavings
to enter the starter and other electrical components
within the box. If another hole is used, the original hole
must be blocked off.
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21
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 than these levels can cause permanent damage to the drive.
Compressor must not be subjected to any voltage spikes or surges in excess of 575V. Exposure to spikes/surges in excess of 575V can permanently damage the drive. If the possibility of such exists it is recommended
that adequate surge protection is fitted such as an Ingersoll Rand line reactor. See your local Ingersoll Rand
representative.
Failure of the drive due to voltage spikes, line notching, harmonics or other power quality related problems,
will not be covered by the standard compressor warranty.
The correct type and rating of line input fuse MUST BE fitted onto the customers isolator or breaker close to
the compressor. For Amp rating see technical information in Section 8.1.
Product Identification
Class − J, Class − T, or
Semiconductor
Fuse Type
Fast Acting Class−J, T or Semiconductor type,
Current limiting, Interrupt Rating − 200,000 Amps
RMS SYM.
Alternate fuse may be used if the time current
characteristics are faster than fuses recommended
in this section.
See your local Ingersoll Rand representative for a range of fuses and disconnect isolators matched to your particular
machine.
Example of voltage imbalance calculation
U →V 462v
V → W 459v
W → U 453v
V(m) = (462 + 459 + 453) / 3 = 458v
VΔ max = 462 − 453 = 9v
= (9 / 458) x 100 = 1.97%
22
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7.0 INSTALLATION
7.4 WATERCOOLED UNITS
Cooling Water Piping
Venting the water system
Water piping to and from the compressor package must
be 1”diameter or larger for N37/75K (N50/100H), 11/2”
diameter or larger for N75/160K (N100H/200H) and 2.0”
diameter or larger for N250/300H−2S. Isolation valves
with side drains should be installed on both the inlet and
outlet lines. Also a strainer of 2mm−mesh size should
be installed on the inlet line. Strainers are available from
Ingersoll Rand. Ingersoll Rand CPN 54689997 (N37/45K &
N50/60H) or CPN 54690029 (N55/75K & N75/100H)
At the initial installation or for start−up after draining the
water system proceed to vent the system as follows.
A normally closed solenoid valve is fitted to the water
outlet side of the compressor package. This is wired
into the compressor control circuit and closes when the
compressor stops.
Carefully inspect your water system before installing
the compressor package. Ensure that the piping is free
of scale and deposits that may restrict water flow to the
compressor package.
Proper operation of your compressor requires that the
water flow listed below be provided at a maximum supply
temperature of 46° C (115° F).
Model
Range
Minimum cooling water requirement vs
water inlet temperatures, in litres per
minute (US gallons per minute)
10°F /
50°F
21°F /
70°F
32°C /
90°F
46°C /
115°F
N37
23(6.0)
23 (6.0)
38 (10.0)
57(15.0)
N45
27(7.0)
30(8.0)
49(13.0)
76(20.0)
N55
51(13.5)
46(12.0)
38(10.0)
38(10.0)
N75
95(25.0)
68(18.0)
46(12.0)
53(14.0)
N75-2S 175(46.0)
133(35.0)
106(28.0)
76(20.0)
N90
84(22.0)
72(19.0)
65(17.0)
72(19.0)
N110
95(25.0)
80(21.0)
72(19.0)
87(23.0)
N132
110(29.0)
91(24.0)
87(23.0)
106(28.0)
N160
125(33.0)
118(31.0)
106(28.0)
125(33.0)
N250
91(24.0)
110(29.0)
179(47.0)
N300
95(25.0)
133(35.0)
220(58.0)
Water temperature and pressure gauges should be
installed in the water piping for use in any fault finding
of the water system. Water pressure should ideally be
between 3 and 5 bar (43.5 and 72.5 psi) but must not be
above 10 Bar (145 psi)
1. Locate the water system vent cocks on top of the
aftercooler and lubricant cooler.
2. Open the water valve(s) allowing water to flow to the
package.
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.
Draining the water system
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.
N75−160k, N100−200H Watercooled
See piping and instrumentation diagram (Section
8.3). The coolers are piped in a ”parallel” water flow
arrangement with a manual trim valve controlling the
flow through the aftercooler. An additional automatic
anti−condensation thermal valve controls the flow of
water to the oilcooler. It has a sensor in the separator
tank and capillary to signal the valve to open and close in
order to avoid water condensing in the tank.
Adjusting the Aftercooler Trim Valve
The anti−condensation valve has no adjustment. The
Aftercooler Trim Valve is factory set and should not need
adjusting but if disturbed use following procedure.
Close valve fully clockwise and then open 1/4 turn. With
machine running loaded observe the package discharge
temperature Intellisys display. It should be be approx 15°
F (8° C) above the water inlet temperature. If it is higher,
open the valve a little more. Put a ’Warning − Do Not
Adjust’ label on the valve or fit a lock.
Water cleanliness is also extremely important. Cleaning of
coolers as 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.
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23
7.0 INSTALLATION
Water quality recommendations
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 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.
Scale: Scale formation inhibits effective heat transfer, yet
it does help prevent corrosion. Therefore, a thin uniform
coating of calcium carbonate is desired on the inner
surface. Perhaps the largest contributor to scale formation
is the precipitation of calcium carbonate out of the water.
This is dependent on temperature and pH. The higher the
pH value, the greater the chance of scale formation. Scale
can be controlled with water treatment.
Cooling Water Analysis Chart
Substances
Test interval
Acceptable
concentration
Corrosivity
(Hardness,
pH, Total
Dissolved Solids,
Temperature at
inlet Alkalinity)
Monthly - if stable Langelier Index
for 3 to 4 months, 0 to 1
analyse quarterly.
Iron
Monthly
<2 ppm
Sulphate
Monthly
<50 ppm
Chloride
Monthly
<50 ppm
Nitrate
Monthly
<2 ppm
Silica
Monthly
< 100 ppm
Desolated
Oxygen
Daily - if stable,
analyse weekly
0 ppm (as low
as possible)
Oil & Grease
Monthly
<5 ppm
Ammonia
Monthly
<1 ppm
Corrosion: In contrast to scale formation is the problem
of corrosion. Chlorides cause problems because of their
size and conductivity. Low pH levels promote corrosion,
as well as high levels of dissolved oxygen.
Fouling: Biological and organic substances (slime)
can also cause problems, but in elevated temperature
environments such as cooling processes they are not a
major concern. If they create problems with clogging,
commercial shock treatment are available.
To ensure good operation life and performance of
the compressor cooling system, the recommended
acceptable ranges for different water constituents are
included below:
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7.0 INSTALLATION
7.5 SEA WATERCOOLED UNITS (SELECTED UNITS ONLY)
Water cleanliness is extremely important. Strainers are
available from Ingersoll Rand. Cleaning of coolers as a
result of fouling is a customer responsibility.
Isolation valves with side drains should be installed on
both the inlet and outlet lines.
A normally closed solenoid valve is fitted to the water
outlet side of the compressor package.
It is important to ensure that the recommended flow
rate cannot be exceeded. This will normally mean that an
orifice plate must be fitted in the pipework at least 1m
(3.3ft) before the cooler, with the orifice size calculated to
ensure that the maximum sea water flow rate cannot be
exceeded. If these precautions are not taken, it is possible
that the sea water flow rate through the cooler may be
several times the recommended maximum, which will
lead to rapid failure.
Sea Water Pressure Bar
(psi)
Orifice diameter in mm
(inch) to give a maximum
sea water flow of 90l/min
(23.76 US gall/min)
3 (43.5)
12 (0.472)
4 (58)
11 (0.433)
5 (72.5)
10 (0.394)
6 (87)
9.6 (0.378)
7 (101.5)
9.2 (0.362)
8 (116)
8.9 (0.35)
9 (130.5)
8.7 (0.343)
10 (145)
8.4 (0.33)
No oil cooler manufacturer can guarantee that its
products will have an indefinite life and for this reason, we
suggest that the cooling system is designed to minimize
any damage caused by a leaking oil cooler. This can be
achieved as follows ;
1. The oil pressure should be higher than the sea water
pressure, so that in the event of a leak occurring, the
oil will not be contaminated.
2. If the sea water pressure is 100PSIG (7BARG) or above
it is recommended that the water solenoid valve is
changed to the water inlet side. This will protect the
system from high pressure surges when not in use.
3. The sea water outlet pipe from the cooler should
have a free run to waste.
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25
7.0 INSTALLATION
7.6 OUTDOOR SHELTERED INSTALLATION
Nirvana compressors are not suitable for outdoor
installation.
Installing a Nirvana compressor outside voids the
warranty of the compressor.
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8.0 GENERAL INFORMATION
TECHNICAL INFORMATION-SINGLE STAGE
General
Sound pressure level dB(A) *
Maximum ambient temperature ° C (° F)
Minimum ambient temperature ° C (° F)
Weight Kg (lbs)
Maximum pressure barg (psig)
Minimum pressure barg (psig)
Coolant capacity litres (US gal)
HAT switch setting ° C (° F)
Performance **
Flow at 7.5 Barg (m³/min)
Flow at 8.5 Barg (m³/min)
Flow at 10 Barg (m³/min)
Flow at 100 psig (cfm)
Flow at 125 psig (cfm)
Flow at 140 psig (cfm)
Air Cooling System
Cooling air flow m3/min (cfm)
Maximum ΔP in air ducts Pa (inch WG)
Compressed air outlet ΔT ° C (° F)
Water Cooling System
Cooling (clean) water flow l/min (US
gallon/min) @ 10 ° C (50 ° F) / 32 ° C
(90 ° F)
Maximum ΔP in air ducts Pa (inch WG)
Compressed air outlet ΔT ° C (° F)
Main Power Circuit A/C (W/C) ***
Package full load current at 220V (A) **
Package full load current at 400V (A) **
Package full load current at 460V (A) **
Package full load current at 575V (A) **
Max fuse size @ 220V (A)
Max fuse size @ 400V (A)
Max fuse size @ 460V (A)
Max fuse size @ 575V (A)
Fuse type
Heater Circuit
110V Single Phase Rating (A)
230V Single Phase Rating (A)
Fuse type
N37K
N45K
N50H
N60H
75
46 (115)
1.7 (35)
1048 (2310)
10 (145)
4.5 (65)
18 (4.8)
120 (248)
75
46 (115)
1.7 (35)
1048 (2310)
10 (145)
4.5 (65)
18 (4.8)
120 (248)
75
46 (115)
1.7 (35)
1048 (2310)
10 (145)
4.5 (65)
18 (4.8)
120 (248)
75
46 (115)
1.7 (35)
1048 (2310)
10 (145)
4.5 (65)
18 (4.8)
120 (248)
6.43
6.12
5.83
−
−
−
7.39
7.02
6.46
−
−
−
−
−
−
235
216
209
−
−
−
262
248
233
184 (6500)
124 (0.5)
8 (15)
184 (6500)
124 (0.5)
8 (15)
184 (6500)
124 (0.5)
8 (15)
184 (6500)
124 (0.5)
8 (15)
23/38 (6/10)
27/49 (7/13)
23/38 (6 /10)
27 /49 (7 /13)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
140 (131)
168 (159)
140 (131)
168 (159)
75 (70 )
90 (85)
−
−
−
−
68 (63)
81 (77)
−
−
56 (52)
67 (63)
250
250
250
250
125
125
125
125
125
125
125
125
100
100
100
100
Fast acting class J, T or semiconductor type, current limiting interrupt
rating 200, 000 Amps RMS SYM.
4
4
4
4
4
4
General purpose
4
4
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)
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8.0 GENERAL INFORMATION
N55K
N75K
N75H
N100H
75
75
75
75
Maximum ambient temperature ° C (° F)
46 (115)
46 (115)
46 (115)
46 (115)
Minimum ambient temperature ° C (° F)
1.7 (35)
1.7 (35)
1.7 (35)
1.7 (35)
1531 (3374)
1531 (3374)
1531 (3374)
1531 (3374)
Maximum pressure barg (psig)
10 (145)
10 (145)
10 (145)
10 (145)
Minimum pressure barg (psig)
4.5 (65)
4.5 (65)
4.5 (65)
4.5 (65)
Coolant capacity litres (US gal)
30 (8)
30 (8)
30 (8)
30 (8)
120 (248)
120 (248)
120 (248)
120 (248)
Flow at 7.5 Barg (m3/min)
10.11
12.94
−
−
Flow at 8.5 Barg (m3/min)
9.29
12.15
−
−
Flow at 10 Barg (m3/min)
8.49
11.50
−
−
Flow at 100 psig (cfm)
−
−
372
479
Flow at 125 psig (cfm)
−
−
328
429
Flow at 140 psig (cfm)
−
−
306
413
241 (8500)
241 (8500)
241 (8500)
241 (8500)
124 (0.5)
124 (0.5)
124 (0.5)
124 (0.5)
8 (15)
8 (15)
8 (15)
8 (15)
Cooling (clean) water flow l/min (US
gallon/min) @ 10 ° C (50 ° F) / 32 ° C (90
° F)
51/38
(13.5 /10)
95/46
(25 /12)
51/38
(13.5/10)
95/46
(25/12)
Maximum ΔP in air ducts Pa (inch WG)
62 (0.25)
62 (0.25)
62 (0.25)
62 (0.25)
14 (25)
14 (25)
14 (25)
14 (25)
Package full load current at 220V (A) **
208 (196)
−
208 (196)
−
Package full load current at 400V (A) **
110 (104)
144 (138)
−
−
Package full load current at 460V (A) **
−
−
100 (94)
131 (125)
Package full load current at 575V (A) **
−
−
82 (78)
108 (103)
Max fuse size @ 220V (A)
300
400
300
400
Max fuse size @ 400V (A)
150
200
150
200
Max fuse size @ 460V (A)
150
200
150
200
Max fuse size @ 575V (A)
125
150
125
150
Fuse type
Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.
General
Sound pressure level dB(A) *
Weight Kg (lbs)
HAT switch setting ° C (° F)
Performance
Air Cooling System
Cooling air flow m3/min (cfm)
Maximum ΔP in air ducts Pa (inch WG)
Compressed air outlet ΔT° C (° F)
Water Cooling System
Compressed air outlet ΔT ° C (° F)
Main Power Circuit A/C (W/C) ***
Heater Circuit
110V Single Phase Rating (A)
4
4
4
4
230V Single Phase Rating (A)
4
4
4
4
Fuse type
General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)
28
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
8.0 GENERAL INFORMATION
N90K
N110K
N125H
N150H
75
75
75
75
Maximum ambient temperature ° C (° F)
46 (115)
46 (115)
46 (115)
46 (115)
Minimum ambient temperature ° C (° F)
1.7 (35)
1.7 (35)
1.7 (35)
1.7 (35)
3175 (6985)
3175 (6985)
3175 (6985)
3175 (6985)
Maximum pressure barg (psig)
10 (145)
10 (145)
10 (145)
10 (145)
Minimum pressure barg (psig)
4.5 (65)
4.5 (65)
4.5 (65)
4.5 (65)
Coolant capacity litres (US gal)
91 (24)
91 (24)
91 (24)
91 (24)
120 (248)
120 (248)
120 (248)
120 (248)
Flow at 7.5 Barg (m3/min)
17.1
20.0
−
−
Flow at 8.5 Barg (m3/min)
15.3
19.2
−
−
Flow at 10 Barg (m3/min)
14.0
17.5
−
−
Flow at 100 psig (cfm)
−
−
655
739
Flow at 125 psig (cfm)
−
−
571
670
Flow at 140 psig (cfm)
−
−
524
610
382 (13500)
382 (13500)
382 (13500)
382 (13500)
124 (05)
124 (05)
124 (05)
124 (05)
8 (15)
8 (15)
8 (15)
8 (15)
Cooling (clean) water flow l/min (US
gallon/min) @ 10° C (50° F) / 32° C (90° F)
84/65
(22/17)
95/72
(25/19)
84/65
(22/17)
95/72
(25/19)
Maximum ΔP in air ducts Pa (inch WG)
62 (0.25)
62 (0.25)
62 (0.25)
62 (0.25)
14 (25)
14 (25)
14 (25)
14 (25)
Package full load current at 400V (A) **
182 (170)
218 (206)
−
−
Package full load current at 460V (A) **
−
−
170 (160)
200 (190)
Package full load current at 575V (A) **
−
−
140 (132)
165 (157)
Max fuse size @ 380V − 415V (A)
250
350
−
−
Max fuse size @ 440V − 480V (A)
−
−
250
250
Max fuse size @ 550V − 575V (A)
−
−
200
200
General
Sound pressure level dB(A) *
Weight Kg (lbs)
HAT switch setting ° C (° F)
Performance **
Air Cooling System
Cooling air flow m3/min (cfm)
Maximum ΔP in air ducts Pa (inch WG)
Compressed air outlet ΔT ° C (° F)
Water Cooling System
Compressed air outlet ΔT ° C (° F)
Main Power Circuit A/C (W/C) ***
Fuse type
Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.
Heater Circuit
110V Single Phase Rating (A)
4
4
4
4
230V Single Phase Rating (A)
4
4
4
4
Fuse type
General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable
size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
29
8.0 GENERAL INFORMATION
N132K
N160K
N200H
75
75
75
Maximum ambient temperature ° C (° F)
46 (115)
46 (115)
46 (115)
Minimum ambient temperature ° C (° F)
1.7 (35)
1.7 (35)
1.7 (35)
General
Sound pressure level dB(A) *
Weight Kg (lbs)
3175 (6985)
3175 (6985)
3175 (6985)
Maximum pressure barg (psig)
10 (145)
10 (145)
10 (145)
Minimum pressure barg (psig)
4.5 (65)
4.5 (65)
4.5 (65)
Coolant capacity litres (US gal)
91 (24)
91 (24)
91 (24)
120 (248)
120 (248)
120 (248)
Flow at 7.5 Barg (m3/min)
23.5
28.0
−
Flow at 8.5 Barg (m3/min)
22.3
26.0
−
Flow at 10 Barg (m3/min)
HAT switch setting ° C (° F)
Performance **
21.0
25.0
−
Flow at 100 psig (cfm)
−
−
993
Flow at 125 psig (cfm)
−
−
892
Flow at 140 psig (cfm)
−
−
819
382 (13500)
382 (13500)
382 (13500)
124 (0.5)
124 (0.5)
124 (0.5)
8 (15)
8 (15)
8 (15)
Cooling (clean) water flow l/min (US gallon/
min) @ 10° C (50° F) / 32° C (90° F)
110/87
(29/23)
125/106
(33/28)
125/106
(33/28)
Maximum ΔP in air ducts Pa (inch WG)
62 (0.25)
62 (0.25)
62 (0.25)
14 (25)
14 (25)
14 (25)
Package full load current at 400V (A) **
251 (239)
301(289)
−
Package full load current at 460V (A) **
−
−
255 (245)
Package full load current at 575V (A) **
−
−
210 (202)
Max fuse size @ 380V − 415V (A)
350
450
−
Max fuse size @ 440V − 480V (A)
−
−
350
−
−
300
Air Cooling System
Cooling air flow m3/min (cfm)
Maximum ΔP in air ducts Pa (inch WG)
Compressed air outlet ΔT ° C (° F)
Water Cooling System
Compressed air outlet ΔT ° C (° F)
Main Power Circuit A/C (W/C) ***
Max fuse size @ 550V − 575V (A)
Fuse type
Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.
Heater Circuit
110V Single Phase Rating (A)
4
4
4
230V Single Phase Rating (A)
4
4
4
Fuse type
General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)
30
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
8.0 GENERAL INFORMATION
8.1 TECHNICAL INFORMATION − TWO STAGE
General
Sound pressure level dB(A) *
Maximum ambient temperature ° C (° F)
Minimum ambient temperature ° C (° F)
Weight Kg (lbs)
Maximum pressure barg (psig)
Minimum pressure barg (psig)
Coolant capacity litres (US gal)
HAT switch setting ° C (° F)
Performance **
Flow at 7.5 Barg (m3/min)
Flow at 8.5 Barg (m3/min)
Flow at 10 Barg (m3/min)
Flow at 14 Barg (m3/min)
Flow at 100 psig (cfm)
Flow at 125 psig (cfm)
Flow at 140 psig (cfm)
Flow at 200 psig (cfm)
Air Cooling System
Cooling air flow m3/min (cfm)
Maximum ΔP in air ducts Pa (inch WG)
Compressed air outlet ΔT ° C (° F)
Water Cooling System
Cooling (clean) water flow l/min (US
gallon/min) @ 10° C (50° F) / 32° C (90°
F)
Maximum ΔP in air ducts Pa (inch WG)
Compressed air outlet ΔT ° C (° F)
Main Power Circuit A/C (W/C)***
Package full load current at 400V (A) **
Package full load current at 460V (A) **
Package full load current at 575V (A) **
Max fuse size @ 380V − 415V (A)
Max fuse size @ 440V − 480V (A)
Max fuse size @ 550V − 575V (A)
Fuse type
N75K
N90K
N110K
N100H
N125H
N150H
75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)
75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)
75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)
75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)
75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)
75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)
15.7
14.2
13.1
−
−
−
−
−
18.0
17.5
15.4
12.5
−
−
−
−
22.1
20.4
18.9
15.4
−
−
−
−
−
−
−
−
560
504
470
−
−
−
−
−
690
621
580
443
−
−
−
−
825
743
693
548
382
(13500)
124 (0.5)
8 (15)
382
(13500)
124 (0.5)
8 (15)
382
(13500)
124 (0.5)
8 (15)
382
(13500)
124 (0.5)
8 (15)
382
(13500)
124 (0.5)
8 (15)
382
(13500)
124 (0.5)
8 (15)
175/106
(46/28)
84/65
(22/17)
95/72
(25/19)
175/106
(46/28)
84/65
(22/17)
95/72
(25/19)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
153 (142)
−
−
250
−
−
182 (170) 218 (206)
−
−
−
−
−
139 (129) 170 (160) 200 (190)
−
−
114 (106) 140 (132) 165 (157)
250
350
−
−
−
−
−
200
250
250
−
−
200
200
200
Fast acting class J, T or semiconductor type, current
limiting interrupt rating 200, 000 Amps RMS SYM.
Heater Circuit
110V Single Phase Rating (A)
4
4
4
4
4
4
230V Single Phase Rating (A)
4
4
4
4
4
4
4Fuse type
General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated onbasis of mean package full load current X1.25 (i.e. 25% margin)
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
General
Sound pressure level dB(A) *
Maximum ambient temperature ° C (° F)
Minimum ambient temperature ° C (° F)
Weight Kg (lbs)
Maximum pressure barg (psig)
Minimum pressure barg (psig)
Coolant capacity litres (US gal)
HAT switch setting ° C (° F)
Performance **
Flow at 7.5 Barg (m3/min)
Flow at 8.5 Barg (m3/min)
Flow at 10 Barg (m3/min)
Flow at 14 Barg (m3/min)
Flow at 100 psig (cfm)
Flow at 125 psig (cfm)
Flow at 140 psig (cfm)
Flow at 200 psig (cfm)
Air Cooling System
Cooling air flow m3/min (cfm)
Maximum ΔP in air ducts Pa (inch WG)
Compressed air outlet ΔT ° C (° F)
Water Cooling System
Cooling (clean) water flow l/min (US gallon/
min) @
10° C (50° F) / 32° C (90° F) ****
Maximum ΔP in air ducts Pa (inch WG)
Compressed air outlet ΔT ° C (° F)
Main Power Circuit A/C (W/C) ***
Package full load current at 400V (A) **
Package full load current at 460V (A) **
Package full load current at 575V (A) **
Max fuse size @ 380V − 415V (A)
Max fuse size @ 440V − 480V (A)
Max fuse size @ 550V − 575V (A)
Fuse type
Heater Circuit
110V Single Phase Rating (A)
230V Single Phase Rating (A)
Fuse type
N132K
N160K
N200H
N250H
N300H
75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)
75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)
75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)
80
46 (115)
1.7 (35)
5933
(13,080)
10 (145)
4.5 (65)
152 (40)
120 (248)
80
46 (115)
1.7 (35)
5933
(13,080)
10 (145)
4.5 (65)
152 (40)
120 (248)
26.2
24.2
23.1
18.4
−
−
−
−
31.1
29.6
27.2
22.2
−
−
−
−
−
−
−
−
1100
990
924
735
−
−
−
−
1380
1249
1167
−
−
−
−
−
1690
1527
1430
−
382
(13500)
124 (0.5)
8 (15)
382
(13500)
124 (0.5)
8 (15)
382
(13500)
124 (0.5)
8 (15)
679
(24000)
62 (0.25)
8 (15)
679
(24000)
62 (0.25)
8 (15)
110/87
(29/23)
125/106
(33/28)
125/106
(33/28)
352
(93)
352
(93)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
62 (0.25)
14 (25)
251 (239)
301 (289)
−
−
−
−
−
255 (245)
335 (313)
406 (384)
−
−
210 (202)
267 (250)
324 (307)
350
450
−
−
−
−
−
350
−
600
−
−
300
−
500
Fast acting class J, T or semiconductor type, current limiting interrupt
rating 200, 000 Amps RMS SYM.
4
4
4
4
4
4
General purpose
4
4
4
4
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)
**** Cooling water flow for N250H and N300H are @ 46 deg C (115 deg F)
32
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
8.0 GENERAL INFORMATION
8.2 INSTALLATION DRAWING−N37/45K−CC & N50/60H−CC − Air Cooled
KEY
A
11/2” NPT Air discharge (Female) 60Hz units
11/2” BSP Air discharge (Female) 50Hz units
B
Ø63mm (2.48”) Electrical inlet
C
0.38“ NPT (Female)
Note: Pipe condensate drain lines separately to an open drain due to differences in drain pressures. Use drain lines at least as large as the connection. Read operations manual and check local regulations
D
Cooling airflow
E
Exhaust airflow
F
Cabinet cooling airflow
G
4 x Ø 13.0mm (0,5”) Compressor should be
bolted to the floor with fourM10 (0.38”) bolts using holes
shown. Seal base tofloor with cork or rubber.
H
INTELLISYS Controller
U
Right
V
Bottom
W
Front
X−X Section through X−X
Y
Rear view
Z
Plan view
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 − Water Cooled
KEY
A
B
C
Note: D
E
F
G
34
11/2” NPT Air discharge (Female) 60Hz units 11/2” BSP Air discharge (Female) 50Hz units
Ø63mm (2.48”) Electrical inlet
0.38“ NPT (Female)
Pipe condensate drain lines separately to an open drain due to differences in drain pressures. Use drain lines at least as large as the connection.
Read operations manual and check local regulations
Cooling airflow
Exhaust airflow
Cabinet cooling airflow
4 x Ø 13.0mm (0,5”) Compressor should be bolted to the floor with four M10 (0.38”) bolts using holes shown. Seal base to floor with cork or rubber.
H
J
K
U
V
W
X−X Y
Z
INTELLISYS Controller
1” NPT Water inlet (Female) 60Hz units
1” BSP Water inlet (Female) 50Hz units
1” NPT Water outlet (Female) 60Hz units
1” BSP Water outlet (Female) 50Hz units
Right
Bottom
Front
Section through X−X
Rear view
Plan view
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
8.0 GENERAL INFORMATION
8.2 INSTALLATION DRAWING − N55/75K−CC & N75/100H−CC − Air Cooled
KEY
A
2” NPT Air discharge (Female) 60Hz units
2” BSP Air discharge (Female) 50Hz units
B
Ø63mm (2.48”) Electrical inlet
C
0.38“ NPT (Female)
Note: Pipe condensate drain lines separately to an open
drain due to differences in drain pressures. Use drain
lines at least as large as the connection. Read operations
manual and check local regulations
D
Cooling airflow
E
Exhaust airflow
F
Cabinet cooling airflow
G
H
U
V
W
X−X Y
Z
4 x Ø 13.0mm (0,5”)
Compressor should be bolted to the floor with four M10 (0.38”) bolts using holes shown. Seal base to floor with cork or rubber.
INTELLISYS Controller
Right
Bottom
Front
Section through X−X
Rear view
Plan view
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
35
8.0 GENERAL INFORMATION
8.2 INSTALLATION DRAWING−N55/75K−CC & N75/100H−CC−Water Cooled
KEY
H
J
A
2” NPT Air discharge (Female) 60Hz units
2” BSP Air discharge (Female) 50Hz units
K
B
Ø63mm (2.48”) Electrical inlet
C
0.38“ NPT (Female)
U
Note: Pipe condensate drain lines separately to an open drain due to differences in drain pressures. V Use drain lines at least as large as the connection.
W
Read operations manual and check local X−X regulations
Y
D
Cooling airflow
Z
E
Exhaust airflow
F
G
36
INTELLISYS Controller
1” NPT Water inlet (Female) 60Hz units
1” BSP Water inlet (Female) 50Hz units
1” NPT Water outlet (Female) 60Hz units
1” BSP Water outlet (Female) 50Hz units
Right
Bottom
Front
Section through X−X
Rear view
Plan view
Cabinet cooling airflow
4 x Ø 13.0mm (0,5”)
Compressor should be bolted to the floor with four M10 (0.38”) bolts using holes shown. Seal base to floor with cork or rubber.
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
8.0 GENERAL INFORMATION
8.2 INSTALLATION DRAWING − N90/160K − CC SINGLE STAGE & N90/160K −
CC TWO STAGE − Water Cooled
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
37
8.0 GENERAL INFORMATION
KEY
A
2” NPT Air discharge (Female) 60Hz units
(N100H−N150H)
2” BSP Air discharge (Female) 50Hz units
(N75K−N110K)
2 1/2” NPT Air discharge (Female) 60Hz units
(N200H)
2 1/2” BSP Air discharge (Female) 50Hz units
(N132K and N160K units)
B
Electrical inlet −
Ø75mm (3”)
Ø64mm 575V (Option)
C
0.38“ NPT (Female)
Note: Pipe condensate drain lines separately to an open
drain due to differences in drain pressures. Use drain
lines at least as large as the connection. Read operations
manual and check local regulations
D
Cooling airflow
E
Exhaust airflow
38
F
G
H
J
K
U
V
W
X−X Y
Z
Cabinet cooling airflow
4 x Ø 13.0mm (0,5”)
Compressor should be bolted to the floor with four M10 (0.38”) bolts using holes shown. Seal base to floor with cork or rubber.
INTELLISYS Controller
1.5” NPT Water inlet (Female) 60Hz units
1.5” BSP Water inlet (Female) 50Hz units
1.5” NPT Water outlet (Female) 60Hz units
1.5” BSP Water outlet (Female) 50Hz units
Right
Bottom
Front
Section through X−X
Rear view
Plan view
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
8.0 GENERAL INFORMATION
8.2 INSTALLATION DRAWING − N90/160K, N125/200H SINGLE STAGE &
N75/160K, N100/200H TWO STAGE − Air Cooled
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
39
8.0 GENERAL INFORMATION
KEY
A
2” NPT Air discharge (Female) 60Hz units
(N100H−N150H)
2” BSP Air discharge (Female) 50Hz units
(N75K−N110K)
2 1/2” NPT Air discharge (Female) 60Hz units
(N200H)
2 1/2” BSP Air discharge (Female) 50Hz units
(N132K and N160K units)
B
Electrical inlet − Ø75mm (3”)
Ø64mm 575V (Option)
C
0.38“ NPT (Female)
Note: Pipe condensate drain lines separately to an
open drain due to differences in drain pressures. Use drain
lines at least as large as the connection. Read operations
manual and check local regulations
D
Cooling airflow
40
E
F
G
H
U
V
W
X−X
Y
Z
Exhaust airflow
Cabinet cooling airflow
4 x Ø 13.0mm (0,5”)
Compressor should be bolted to the floor with four M10 (0.38”) bolts using holes shown. Seal base to floor with cork or rubber.
INTELLISYS Controller
Right
Bottom
Front
Section through X−X
Rear view
Plan view
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
8.0 GENERAL INFORMATION
8.2 INSTALLATION DRAWING − N250/300H TWO STAGE
KEY
A
4” NPT Air discharge (Female)
B
Electrical inlet −
Ø75mm (3”)
C
0.50“ NPT (Female)
Note: Pipe condensate drain lines separately to an
open drain due to differences in drain pressures. Use drain
lines at least as large as the connection. Read operations
manual and check local regulations
D
Cooling airflow
E
Exhaust airflow
F
Cabinet cooling airflow
G
H
U
V
W
X
Y
Z
4 x Ø 14.2mm (0,6”)
Compressor should be bolted to the floor with four M12 (0.5”) bolts using holes shown. Seal base to floor with cork or rubber.
INTELLISYS Controller
Right
Bottom
Front
Left view
Rear view
Plan view
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
41
8.0 GENERAL INFORMATION
22381206
Revision B
P
35
32
36
46
31
27
7
30
13
T21
M
T
10
P
42
4
3
T
45
V
9
42
T21
12
39
44
T
2
M
23
8
11
T
T
21
20
18
22
17
19
P
28
6
49
P
25
29
14
24
40
5
37
15
T
41
43
P
16
1
26
33
D
7
34
F
1st
M
23
38
F
47
7
R
2nd
P
48
2
TWO STAGE ONLY
8.3 PROCESS AND INSTRUMENTATION DIAGRAM N37/45K-CC & N50/60H-CC
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
8.0 GENERAL INFORMATION
KEY
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 Air discharge
Compressor
Air filter
Vacuum switch 1VAC
Cooler, air
Cooler, coolant
Condensate discharge
Coolant filter
Pressure switch, coolant filter 1DPS
Drain valve, coolant
Temperature switch 1ATS
Air inlet check valve
Timed solenoid condensate drain.
(single stage)
Minimum pressure check valve
Moisture separator
Pressure transducer 4APT
Pressure relief valve
Scavenge filter / orifice / check
Separator tank (primary/secondary)
Oil temperature control valve
Temperature transducer 2ATT
3SV blowdown solenoid valve
Drive motor
Blower motor
Cooling air blower
Cooling water inlet (W.C. only)
Cooling water outlet (W.C. only)
Pressure transducer 3APT
Pressure transducer 6APT
Dryer (customer supply equipment)
Line filters (customer equipment)
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 45 46 49 Receivers (customer equipment)
Dryer AUX warning
Line filter AUX warning
Receiver trap AUX warning
Remote pressure transducer 9APT (optional)
Water stop valve 4SV
Typical customer downstream air treatment
Anti − condensation valve 11SV
Cooling air exhaust box
Package discharge temperature transducer 4ATT
Injected coolant temperature sensor
Seal scavenge air supply
Seal scavenge line
Air intake temperature sensor. 1ATT
Electronic drain trap. Alternative to item 13. (Standard equipment on 2 stage. Optional on single stage).
Interstage pressure relief valve. (2 stage.)
Interstage pressure transducer. (2 stage)
Air/Coolant separator element
Air/coolant
Air
Coolant
Condensate
Cooling water (W.C. only)
Compressor enclosure
Sensor connection
Equipment downstream of
compressor
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
43
44
4
3
T
V
45
9
T
12
42
21
23128994
Revision A
P
39
44
T
2
M
23
8
T
21
T
11
20
18
22
T
10
17
19
P
28
6
49
T
25
P
29
T21
M
24
14
50
40
5
41
15
37
T
43
13
P
16
27
1
26
7
30
33
D
7
34
F
46
31
1st
M
23
F
38
7
R
32
48
35
P
2nd
2
P
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
EQUIPMENT
DOWNSTREAM
OF COMPRESSOR
SENSOR
CONNECTION
COMPRESSOR
ENCLOSURE
COOLING WATER
(W.C. ONLY)
CONDENSATE
COOLANT
AIR
AIR/COOLANT
PIPING LEGEND
36
TWO STAGE ONLY
8.0 GENERAL INFORMATION
8.3 PROCESS AND INSTRUMENTATION DIAGRAM N55/75K-CC & N75/100H-CC
8.0 GENERAL INFORMATION
KEY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
AIR DISCHARGE
COMPRESSOR
AIR FILTER
VACUUM SWITCH 1VAC
COOLER, AIR
COOLER, COOLANT
CONDENSATE DISCHARGE
COOLANT FILTER (S)
PRESSURE SWITCH, COOLANT FILTER 1DPS
DRAIN VALVE, COOLANT
HIGH AIR TEMPERATURE SWITCH 1ATS
AIR INLET/CHECK VALVE
TIMED SOLENOID CONDENSATE DRAIN SINGLE
STAGE UNITS ONLY)
MINIMUM PRESSURE CHECK VALVE
MOISTURE SEPARATOR
PRESSURE TRANSDUCER 4APT
PRESSURE RELIEF VALVE
SCAVENGE FILTER / ORIFICE / CHECK VALVE
SEPARATOR TANK (PRIMARY/SECONDARY)
OIL TEMPERATURE CONTROL VALVE
TEMPERATURE SENSOR 2ATT
BLOWDOWN SOLENOID VALVE 3SV
DRIVE MOTOR - VARIABLE SPEED
MOTOR, BLOWER - VARIABLE SPEED
COOLING AIR BLOWER
COOLING WATER INLET (W.C. ONLY)
COOLING WATER OUTLET (W.C. ONLY)
PRESSURE TRANSDUCER 3APT (WET)
PRESSURE TRANSDUCER 6APT (DRY)
DRYER (CUSTOMER EQUIPMENT)
LINE FILTERS (CUSTOMER EQUIPMENT)
RECEIVERS (CUSTOMER EQUIPMENT)
DRYER AUX WARNING |
LINE FILTER AUX WARNING | AW1 (WIRE IN
SERIES)
RECEIVER TRAP AUX WARNING |
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
REMOTE AIR PRESSURE TRANSDUCER 9APT
(OPTIONAL)
WATER SHUTOFF VALVE 4SV (W.C.ONLY)
TYPICAL CUSTOMER DOWNSTREAM AIR
TREATMENT
ANTI-CONDENSATION VALVE 11SV
COOLING AIR EXHAUST BOX
PACKAGE DISCHARGE AIR TEMPERATURE SENSOR
4ATT
INJECTED COOLANT TEMPERATURE SENSOR
2CTT
ORIFICE, SEAL SCAVENGE AIR SUPPLY
SEAL SCAVENGE LINE DRAIN
PACKAGE INTAKE AIR TEMPERATURE SENSOR
1ATT
ELECTRONIC DRAIN TRAP-ALTERNATIVE TO ITEM
13 (STANDARD EQUIPMENT ON 2 STAGE
OPTIONAL ON SINGLE STAGE)
INTERSTAGE PRESSURE RELIEF VALVE (TWO
STAGE)
INTERSTAGE PRESSURE TRANSDUCER (TWO
STAGE)
AIR/COOLANT SEPARATOR ELEMENT
OIL COOLER OUT TEMPERATURE SENSOR 4CTT
Air/coolant
Air
Coolant
Condensate
Cooling water (W.C. only)
Compressor enclosure
Sensor connection
Equipment downstream of
compressor
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
45
22099006
Revision C
P
35
32
36
46
31
27
7
30
15
T
51
T21
M
T
T
10
46
P
4
3
T
45
V
9
42
T
21
12
39
44
T
2
M
23
8
11
T
T
21
20
18
22
17
19
P
28
6
49
25
P
29
24
14
40
5
50
41
43
37
13
P
16
1
26
33
D
7
34
F
1st
M
23
38
F
47
7
R
2nd
P
48
2
TWO STAGE ONLY
8.0 GENERAL INFORMATION
8.3 PROCESS AND INSTRUMENTATION DIAGRAM N90/160K &
N125/200H SINGLE STAGE AND N75/160K & N100/200H 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
KEY
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Air discharge
Compressor
Air filter
Vacuum switch 1VAC
Cooler, air
Cooler, coolant
Condensate discharge
Coolant filter
Pressure switch, coolant filter 1DPS
Drain valve, coolant
Temperature switch 1ATS
Air inlet check valve
Timed solenoid condensate drain.
(single stage only)
Minimum pressure check valve
Moisture separator
Pressure transducer 4APT
Pressure relief valve
Scavenge filter / orifice / check
Separator tank (primary/secondary)
Oil temperature control valve
Temperature transducer 2ATT
3SV blowdown solenoid valve
Drive motor
Blower motor
Cooling air blower
Cooling water inlet (W.C. only)
Cooling water outlet (W.C. only)
Pressure transducer 3APT
Pressure transducer 6APT
Dryer (customer supply equipment)
Line filters (customer equipment)
Receivers (customer equipment)
33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 49
50 51 Dryer AUX warning
Line filter AUX warning
Receiver trap AUX warning
Remote pressure transducer 9APT (optional)
Water stop valve 4SV (W.C. only)
Typical customer downstream air treatment
Anti − condensation valve 11SV
Cooling air exhaust box
Package discharge temperature transducer 4ATT
Injection temperature, transducer 2CTT
Seal scavenge air supply
Seal scavenge line
Temperature sensor 1ATT
Electronic drain trap. Alternative to item 13
(Optional on single stage)
Interstage pressure relief valve. 2 stage.
Interstage pressure transducer. 2 stage
Element, separator
Valve, aftercooler trim (W.C. only)
Valve, airend discharge temperature control
(W.C. only)
Air/coolant
Air
Coolant
Condensate
Cooling water (W.C. only)
Compressor enclosure
Sensor connection
Equipment downstream of
compressor
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
47
8.0 GENERAL INFORMATION
27
7
30
15
T
40
T21
M
20
T
48
P
13
V
4
48
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
9
T21
12
3
T
45
42
39
T
1st
M
44
23
47
2nd
8
2
P
52
21
T
T
11
22
18
10
19
P
17
28
6
49
25
P
29
14
24
T
51
5
50
41
43
37
46
P
16
1
26
33
D
7
34
F
31
38
F
R
35
32
36
P
22402135
Revision C
8.3 PROCESS AND INSTRUMENTATION DIAGRAM N250−300H TWO STAGE
8.0 GENERAL INFORMATION
KEY
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Air discharge
Compressor
Air filter
Vacuum switch 1VAC
Cooler, air
Cooler, coolant
Condensate discharge
Coolant filter
Pressure switch, coolant filter 1DPS
Drain valve, coolant
Temperature switch 1ATS
Air inlet/adaptor
Coolant stop solenoid valve 5SV
Minimum pressure check valve
Moisture separator
Pressure transducer 4APT
Pressure relief valve
Scavenge filter / orifice / check
Separator tank (primary/secondary)
Oil temperature control valve
Temperature transducer 2ATT
3SV blowdown solenoid valve
Drive motor
Blower motor
Cooling air blower
Cooling water inlet (W.C. only)
Cooling water outlet (W.C. only)
Pressure transducer 3APT
Pressure transducer 6APT
Dryer (customer supply equipment)
Line filters (customer equipment)
Receivers (customer equipment)
33 34 35 36 37
38 39 40 41 42 43 44 45 46 47 48 49
50 51 52 Dryer AUX warning
Line filter AUX warning
Receiver trap AUX warning
Remote pressure transducer 9APT (optional)
Water stop valve 4SV (W.C. only)
Typical customer downstream air treatment
Anti − condensation valve 11SV
Cooling air exhaust box
Package discharge temperature transducer 4ATT
Injection temperature, transducer 2CTT
Orifice, seal scavenge air supply
Seal scavenge line
Temperature sensor 1ATT
Electronic drain trap
Interstage pressure relief valve. 2 stage.
Interstage pressure transducer. 2 stage
Element, separator
Valve, aftercooler trim (W.C. only)
Valve, airend discharge temperature control
(W.C. only)
Airend discharge check valve.
Piping legend
Air/coolant
Air
Coolant
Condensate
Cooling water (W.C. only)
Compressor enclosure
Sensor connection
Equipment downstream of
compressor
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
49
8.0 GENERAL INFORMATION
8.4 WIRING SCHEMATIC N37K − N45K-CC / N50-60h−cc a/c
blower vfd
P
MF
124
AT
KM5-1
106
MCB2
BLU
BLK
BRN
GRN/YEL
107
122
DVF3
OPT
FM
L1
T1
L2
4
DVF
CAB
SC-
7
P7
P3
SD+
230V
BP
200/230V-3ph-50/60Hz
FD
400/460V-3ph-50/60Hz
ES-1
104
103
1ATS
L1
11
L3
12
110V 100
101
121
215
216
RSP
RST
AW1
14
15
2
111
AW2
112
KM5
17
3
CDE (OPT)
18
1
4
2
P4
KM1
SS1 -
3
+
4
SS2 +
5
16 17 18
120
L1 L2 L3
241
214
215
252
253
01
02
60
55
L2
116
PX6
PE
DR
FD
FAULT
+
-
BLK
2
RED
3
4
BRO
V
115
1
RED
108
3
2
MCB5
BLK
2
3
3
V
S
1
CK
+ RECTIFIER
OUT
2
E
7
8
W
PX2
AO1
A11+
A11A12
OV
+24VDC
D11
D12
ENABLE
OV
P1
1
P2
2
3
4
5
9
10
200
201
1
12V DC
2
1
RED
BLK
P5
3
P10
4
2
5
P5
12
BLK
RED
CFO
1
2
1
P8
2
3
P6
2
3
RED 4-20mA
+
WHI
P
7 230
8
K1-1
9 231
10
BLK
V
P
WHI
P2
9APT
4
5
6
7
8
OPT
BLK
V
P
WHI
BLK
WHI
V
P
BLK
T 2CTT
WHI
BLK
T 2ATT
WHI
BLK
WHI
BLK
T 4ATT
T 1ATT
110/120V
50/60 HZ
23
T
KM5-1 22
21
HTR1
CDV
HTR2
OPT
121
25
24
MCB9
T1
PE
TH
L
22775738
Revision B
20
KM5-1 22
21
220/230 V
50/60 HZ
T
23
HTR1
CDV
HTR2
OPT
N
25
24
MCB9
PE
50
6APT
WHI
TH
20
3APT
RED
GND
GND
100
4APT
RED
11
BLK
WHI
BLK
RED
RED
10
1
WHI
7
9
BLK
WHI
6
8
BLK
WHI
6
+252
-253
BLK
RED
ST
SL
1
4-20 mA 9
OUTPUT
WHI
2
U
PORO
1
7
+ DC-BUS
105 (110V)
1
2
6
PSU
4
GND
116
9SV
6
WR
2
+
120
K2
7
FM
MM
102
2
SS3 -
TRR
2
1
120
6
VIO
114
11SV
5
BLU
W
DR
1
GRE
U
2
126
-
6
5
1
MCB4
GND
YEL
U V W
125
123
1
113
3SV
L3
PX1
242
L1
PE
PX3
K1-2
+24V
18 START
27 STOP
12
PX4
240
1VAC
217
9
16
200V
MMS
214
13
P1
K1
120
T1
MCB1
ES-2
213
12
102
MCB3
R
FI
DVF
1DPS
212
11
1
110
8
210
211
10
SD105
K2-1
KM1
EB
3SV
6
BSC+
EXC
MM
SGN
5
A+
C
L3
OV
RFI
2
3
PE
PSU
1
SG-NE
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
OPT
8.0 GENERAL INFORMATION
KEY
1ATS Switch, high airend discharge temperature
1DPS Switch, fouled oil filter
1VAC Switch, fouled air filter
1ATT Sensor, airend inlet.
2ATT Sensor, airend discharge temperature
2CTT Sensor, injected coolant temperature
3APT Transducer, sump pressure, wet side
3SV Valve, blowdown solenoid
4APT Transducer, package air discharge pressure
4ATT Sensor, package discharge temperature
4SV Valve, water stop solenoid (W/C only)
6APT Transducer, sump air pressure, dry side
9APT Transmitter, remote air pressure (optional)
9SV Valve, condensate drain
11SV Valve, anti − condensation solenoid
AT Autotransformer (if fitted)
AW1 Auxiliary warning 1
AW2 Auxiliary warning 2
BP Backplate
C
Capacitor
CAB Cabinet
CDE Condensate drain error
CDV Condensate drain valve. (if fitted)
CFO Common fault output
CK Choke
EXC External communications
DR Drive
DVF Fan, drive box ventilation
EB Earth bar
ES Switch, emergency stop
FD Drive, blower
FM Motor, blower
GND Ground
HC Heater circuit
HTR1 Heater, spacer 25 Watts
HTR2 Heater, spacer 25 Watts
K1 Relay, run
K2 Relay fault
KM1 Contactor, main motor
KM5 Contactor, Drive ventilation fan.
MCB1 Breaker, miniature circuit, transformer
MCB2 Breaker, miniature circuit, DVFMCB3 Breaker, miniature circuit, control circuits
MCB4 Breaker, miniature circuit, VFD supply
MCB5 Breaker, miniature circuit, PSU
MCB9 Breaker, miniature circuit, heater
MF Mains filter (if fitted)
MM Motor, main
MMS Breaker, blower motor
OPT Optional
OV Zero voltage
PE Protected earth
PORO Power outage restart option (optional)
PSU RFI RSP RST SGNE SL SS1−3 ST T1 TH TRR WR BLK BLU BRO GRE PIN RED SCR VIO WHI YEL Wires
Power supply unit
Filter, radio frequency interference
Remote stop
Remote start
Controller, Intellisys
Serial link
Relay, solid state
Service tool
Transformer, control
Thermostat
True running relay
General warning
Colors
Black
Blue
Brown
Green
Pink
Red
Screened
Violet
White
Yellow
Numbers
Function
Wire color
1−99
100−199
200−299
300−399
Power
AC Control
DC Control
Auxiliary
Black
Red
Blue
Orange
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
51
8.0 GENERAL INFORMATION
8.4 Wiring schematic - n55-75k-cc / n75-100h-cc a/c
blower vfd
P
MF
124
AT
KM5-1
106
BLU
BLK
BRN
GRN/YEL
107
122
MCB2
DVF3
OPT
1
SG-NE
2
3
4
DVF
5
A+
C
6
BSC+
EXC
FM
L1
T1
L2
SC-
L3
OV
230V
PSU
ES-1
MM
104
103
RFI
BP
200/230V-3ph-50/60Hz
SGN
FD
400/460V-3ph-50/60Hz
CAB
1ATS
P3
L1
11
L3
12
110V 100
DVF
101
SD-
RF
I
216
RSP
RST
AW1
14
15
111
K1
120
AW2
T1
CDE (OPT)
18
1
112
KM5
17
3
4
2
P4
KM1
SS1
3
17
18
120
L1 L2 L3
SS2
241
214
215
252
253
27
01
55
L3
116
FD
1
2
+
U V
W
RED
4
116
9SV
1
2
6
108
MCB5
BLK
WHI
1
2
7
3
1
P1
1
P2
2
200
12V DC
3
201
4
2
5
P5
RED
1
CK
1
2
3
4
5
6
1
2
1
P8
2
3
1
P6
2
CFO
WHI
3
BLK
RED 4-20mA
+
WHI
P
RED
V
P
WHI
4APT
RED
BLK
V
P
WHI
3APT
RED
BLK
WHI
V
P
6APT
12
BLK
RED
WHI
7 230
8
K1-1
9 231
10
BLK
11
BLK
WHI
ST
SL
RED
10
WHI
8
W
7
9
BLK
7
6
8
BLK
2
E
PX2
3
P10
S
+ RECTIFIER
OUT
AO1
A11+
A11A12
OV
+24VDC
D11
D12
ENABLE
OV
2
1
RED
BLK
P5
+ DC-BUS
-253
BLK
U
V
9
OPT
+252
10
PSU
RED
4
GND
MM
4-20 mA 9
OUTPUT
7
FM
6
120
K2
6
VIO
105 (110V)
120
5
BLU
WR
1
2
PORO
114
11SV
3
3
BRO
W
V
126
115
2
2
GRE
U
DR
1
BLK
-
2
MCB4
102
GND
YEL
SS3
5
TRR
2
1
+
125
123
PE
DR
FAULT
02
60
L2
PX6
18
L1
PE
PX1
242
+24V
START
STOP
PX3
K1-2
12
PX4
240
+
-
6
113
3SV
1
+
4
5
16
1VAC
217
9
13
2
200V
MMS
215
16
MCB3
MCB1
214
12
P1
102
121
ES-2
213
11
1
110
8
1DPS
212
10
105
K2-1
KM1
EB
3SV
7
P7
SD+
PE
210
211
5
6
P2
9APT
4
7
8
OPT
9
10
WHI
BLK
T 2CTT
WHI
BLK
T 2ATT
WHI
BLK
T 4ATT
WHI
BLK
T 1ATT
WHI
BLK
T 4CTT
GND
GND
TH
100
20
KM5-1
21
110/120V
50/60 HZ
23
T
22
HTR1
CDV
HTR2
OPT
121
25
24
MCB9
T1
PE
TH
20
KM5-1
21
22
T
23
L
220/230 V
50/60 HZ
HTR1
CDV
HTR2
OPT
23131337
Revision A
LABEL
1ATS
1DPS
1VAC
1ATT
2ATT
2CTT
52
N
25
24
MCB9
PE
DESCRIPTION
SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
SWITCH, FOULED OIL FILTER
SWITCH, FOULED AIR FILTER
SENSOR, AIREND INLET
SENSOR, AIREND DISCHARGE TEMPERATURE
SENSOR, INJECTED COOLENT TEMPERATURE
LABEL
3APT
3SV
4APT
4ATT
4CTT
DESCRIPTION
TRANSDUCER, SUMP PRESSURE, WET SIDE
VALVE, BLOWDOWN SOLENOID
TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
SENSOR, OIL COOLER OUT TEMPERATURE
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
8.0 GENERAL INFORMATION
KEY
4SV
6APT
9APT
9SV
11SV
AT
AW1
AW2
BP
C
CAB
CDE
CDV
CFO
CK
EXC
DR
DVF
EB
ES
FD
FM
GND
HTR1
HTR2
K1
K2
KM1
KM5
MCB1
MCB2
MCB3
MCB4
MCB5
MCB9
MF
MM
MMS
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNE
SL
SS1-3
ST
VALVE, WATER STOP SOLENOID (W/C ONLY)
TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
TRANSMITTER, REMOTE AIR PRESSURE
(OPTIONAL)
VALVE, CONDENSATE DRAIN
VALVE, ANTI-CONDENSATION SOLENOID
AUTOTRANSFORMER (IF FITTED)
AUXILIARY WARNING 1
AUXILIARY WARNING 2
BACKPLATE
CAPACITOR
CABINET
CONDENSATE DRAIN ERROR
CONDENSATE DRAIN VALVE (IF FITTED)
COMMON FAULT OUTPUT
CHOKE
EXTERNAL COMMUNICATIONS
DRIVE
FAN, DRIVE BOX VENTILATION
EARTH BAR
SWITCH, EMERGENCY STOP
DRIVE, BLOWER
MOTOR, BLOWER
GROUND
HEATER, SPACER 25 WATTS
HEATER, SPACER 25 WATTS
RELAY, RUN
RELAY, FAULT
CONTACTOR, MAIN MOTOR
CONTACTOR, DRIVE VENTILATION FAN
BREAKER, MINIATURE CIRCUIT, TRANSFORMER
BREAKER, MINIATURE CIRCUIT, DVF
BREAKER, MINIATURE CIRCUIT, CONTROL
CIRCUITS
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINATURE CIRCUIT, PSU
BREAKER, MINIATURE CIRCUIT, HEATERS
MAINS FILTER (IF FITTED)
MOTOR, MAIN
BREAKER, FAN MOTOR
OPTIONAL
ZERO VOLTAGE
PROTECTED EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
T1
TH
TRR
WR
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
GENERAL WARNING
COLORS
BLK
BLACK
BLU
BLUE
BRO
BROWN
GRE
GREEN
PIN
PINK
RED
RED
SCR
SCREEN
VIO
VIOLET
WHI
WHITE
YEL
YELLOW
Wires
Numbers
Function
Wire color
1−99
Power
Black
100−199
AC Control
Red
200−299
DC Control
Blue
300−399
Auxiliary
Orange
NOTES:
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER
100 & 121.
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN
INDEPENDENT SOURCE: IN THAT CASE, FACTORY
SUPPLIED CONNECTION MUST BE DISCONNECTED.
3. ENSURE PARALLEL CONNECTION OF HEATERS.
NOTES:
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE
DISCONNECTED.
2. ENSURE SERIES CONNECTION OF HEATERS.
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
8.4 Wiring schematic - n37/45k-cc/n50/60h-cc w/c
124
KM5-1
106
MF
BLU
BLK
BRN
GRN/YEL
107
122
MCB5
DVF3
AT
DVF
C
P
OPT
1
SGNE
2
3
4
FM
L1
T1
L2
L3
OV
MM
RFI
BP
SC-
200/230V-3ph-50/60Hz
ES-1
EB
L1
11
L3
12
110V 100
4SV
101
102
DVF
P3
I
RF
110
KM1
MMS
17
PX6
1
PX1
W
FM
YEL
125
102
115
RED
2
GRE
3
4
K2
120
2
S
116
1
P2
2
200
PORO
6
4-20 mA 9
OUTPUT
10
RED
201
1
WHI
2
3
WHI
4
BLK
5
RED
RED 4-20mA
+
WHI
P
1
2
CFO
OPT
BLK
WHI
2
3
P6
2
4
T 2CTT
WHI
BLK
T 2ATT
BLK
7
TH
KM5-1
23
T
22
HTR1
CDV
HTR2
OPT
25
24
MCB9
T1
PE
TH
20
KM5-1
21
22
T
23
L
220/230 V
50/60 HZ
HTR1
CDV
HTR2
OPT
N
25
24
MCB9
PE
54
6APT
BLK
8
121
P
WHI
5
6
P2
110/120V
50/60 HZ
V
WHI
1
P8
3
K1-1
21
3APT
RED
7
12
BLK
RED
1
20
4APT
11
BLK
WHI
9APT
100
P
WHI
6
9
ST
SL
V
10
WHI
8
BLK
8
BLK
P
RED
5
BLK
V
WHI
4
2
RED
7
BLK
3
P10
P5
2
RED
2
1
GND
GND
22776520
Revision B
105 (110V)
2
120
BLK
P5
1
7
230
8
9
231
10
WR
2
1
5
9
12V DC
E
6
-
TRR
2
1
WHI
P1
4
W
AO1
A11+
A11A12
OV
+24VDC
D11
D12
ENABLE
OV
-
SS3
1
CK
+ RECTIFIER
OUT
+
BLK
3
2
3
5
1
MCB5
U
V
SS2
PSU
108
GND
114
9SV
BLK
7
1
113
3SV
11SV
7
+ DC-BUS
1
+
4
+
3
6
4
SS1
3
KM5
120
6
VIO
2
P4
6
5
BLU
112
KM4
RED
2
DR
PX3
1
AW2
CDE (OPT)
1
3
126
MCB4
GND
BLK
BRO
MM
2
PX2
V
PX4
U
111
K1
PE
DR
AW1
18
4SV
116
123
RST
15
2
L3
KM4
RSP
17
KM1
L1
1VAC
217
9
16
18
L2
216
14
200V
16
MMS-1
215
13
P1
T1
MCB1
214
12
1
120
ES-2
213
11
105
K2-1
121
8
1DPS
212
10
SD-
1ATS
104
103
MCB3
9SV
7
P7
SD+
400/460V-3ph-50/60Hz
CAB
3SV
SC+
EXC
SGN
6
B-
230V
PSU
5
A+
PE
210
211
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
T 4ATT
OPT
8.0 GENERAL INFORMATION
KEY
1ATS
1DPS
1VAC
1ATT
2ATT
2CTT
3APT
3SV
4APT
4ATT
4SV
6APT
9APT
9SV
11SV
AT
AW1
AW2
BP
C
CAB
CDE
CDV
CFO
CK
EXC
DR
DVF
EB
ES
FD
FM
GND
HTR1
HTR2
K1
K2
KM1
KM4
KM5
MCB1
MCB2
MCB3
MCB4
MCB5
MCB9
MF
MM
SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
SWITCH, FOULED OIL FILTER
SWITCH, FOULED AIR FILTER
SENSOR, AIREND INLET
SENSOR, AIREND DISCHARGE TEMPERATURE
SENSOR, INJECTED COOLENT TEMPERATURE
TRANSDUCER, SUMP PRESSURE, WET SIDE
VALVE, BLOWDOWN SOLENOID
TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
VALVE, WATER STOP SOLENOID (W/C ONLY)
TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
TRANSMITTER, REMOTE AIR PRESSURE
(OPTIONAL)
VALVE, CONDENSATE DRAIN
VALVE, ANTI-CONDENSATION SOLENOID
AUTOTRANSFORMER (IF FITTED)
AUXILIARY WARNING 1
AUXILIARY WARNING 2
BACKPLATE
CAPACITOR
CABINET
CONDENSATE DRAIN ERROR
CONDENSATE DRAIN VALVE (IF FITTED)
COMMON FAULT OUTPUT
CHOKE
EXTERNAL COMMUNICATIONS
DRIVE
FAN, DRIVE BOX VENTILATION
EARTH BAR
SWITCH, EMERGENCY STOP
DRIVE, BLOWER (A/C ONLY)
MOTOR, BLOWER
GROUND
HEATER, SPACER 25 WATTS
HEATER, SPACER 25 WATTS
RELAY, RUN
RELAY, FAULT
CONTACTOR, MAIN MOTOR
CONTACTOR, FAN MOTOR (W/C ONLY)
CONTACTOR, DRIVE VENTILATION FAN
BREAKER, MINIATURE CIRCUIT, TRANSFORMER
BREAKER, MINIATURE CIRCUIT, DVF
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINIATURE CIRCUIT, PSU
BREAKER, MINIATURE CIRCUIT, HEATERS
MAINS FILTER (IF FITTED)
MOTOR, MAIN
MMS
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNE
SL
SS1-3
ST
T1
TH
TRR
WR
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires
BREAKER, FAN MOTOR
OPTIONAL
ZERO VOLTAGE
PROTECTED EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
GENERAL WARNING
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW
Numbers
Function
Wire color
1−99
Power
Black
100−199
AC Control
Red
200−299
DC Control
Blue
300−399
Auxiliary
Orange
NOTES:
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER
100 & 121.
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN
INDEPENDENT SOURCE: IN THAT CASE, FACTORY
SUPPLIED CONNECTION MUST BE DISCONNECTED.
3. ENSURE PARALLEL CONNECTION OF HEATERS.
NOTES:
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE
DISCONNECTED.
2. ENSURE SERIES CONNECTION OF HEATERS.
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
8.4 Wiring schematic - n55-75k-cc / n75-100h-cc W/c
124
KM5-1
106
MF
BLU
BLK
BRN
GRN/YEL
107
122
MCB5
DVF3
AT
DVF
C
P
OPT
1
SGNE
2
3
4
FM
L1
T1
L2
L3
OV
MM
RFI
BP
SC-
200/230V-3ph-50/60Hz
ES-1
EB
L1
11
L3
12
110V 100
4SV
101
102
DVF
104
103
RF
I
121
P3
110
MMS
17
PX6
PE
DR
1
PX1
W
FM
YEL
125
102
115
RED
2
GRE
3
4
120
3
4-20 mA 9
OUTPUT
9
2
3
WHI
P1
1
4
P2
2
200
12V DC
RED
201
3
P10
4
2
5
P5
RED
1
1
WHI
2
3
WHI
4
BLK
5
RED 4-20mA
+
WHI
P
RED
BLK
1
2
1
P8
2
3
1
CFO
OPT
P6
2
3
K1-1
4
5
6
P2
BLK
8
9
10
110/120V
50/60 HZ
BLK
WHI
T 2ATT
WHI
BLK
HTR1
T
BLK
HTR2
23
L
23131345
Revision A
220/230 V
50/60 HZ
HTR1
CDV
HTR2
OPT
N
25
24
MCB9
PE
56
T 4ATT
WHI
TH
22
6APT
T 2CTT
24
KM5-1
21
P
WHI
BLK
PE
20
V
BLK
MCB9
T1
3APT
WHI
OPT
25
4APT
RED
23
T
22
CDV
121
P
WHI
TH
KM5-1
21
V
7
GND
GND
20
P
RED
12
BLK
RED
9APT
100
V
WHI
11
BLK
WHI
ST
SL
RED
10
WHI
8
7
9
BLK
7
6
8
BLK
2
7
230
8
9
231
10
2
1
BLK
P5
W
6
105 (110V)
2
10
1
CK
AO1
A11+
A11A12
OV
+24VDC
D11
D12
ENABLE
OV
6
116
E
+ RECTIFIER
OUT
-
WR
2
1
BLK
S
2
+
-
SS3
TRR
2
1
PORO
1
MCB5
+ DC-BUS
1
+
SS2
120
PSU
U
V
5
SS1
5
114
9SV
BLK
7
108
GND
113
3SV
11SV
7
1
4
+
6
VIO
4
3
KM5
120
5
BLU
2
P4
112
3
6
AW2
CDE (OPT)
1
3
6
RED
2
DR
PX3
1
AW1
18
111
KM4
K2
RST
15
126
MCB4
GND
BLK
BRO
MM
2
PX2
V
PX4
U
RSP
14
2
L3
116
123
1VAC
217
9
13
4SV
K1
L2
216
17
KM1
L1
MMS-1
215
16
18
KM4
214
12
200V
16
ES-2
213
11
P1
KM1
8
1DPS
212
10
SD105
1
120
T1
MCB1
1ATS
K2-1
MCB3
9SV
7
P7
SD+
400/460V-3ph-50/60Hz
CAB
3SV
SC+
EXC
SGN
6
B-
230V
PSU
5
A+
PE
210
211
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
T 4CTT
OPT
8.0 GENERAL INFORMATION
KEY
1ATS
1DPS
1VAC
1ATT
2ATT
2CTT
3APT
3SV
4APT
4ATT
4CTT
4SV
6APT
9APT
9SV
11SV
AT
AW1
AW2
BP
C
CAB
CDE
CDV
CFO
CK
EXC
DR
DVF
EB
ES
FD
FM
GND
HTR1
HTR2
K1
K2
KM1
KM4
KM5
MCB1
MCB2
MCB3
MCB4
MCB5
MCB9
MF
SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
SWITCH, FOULED OIL FILTER
SWITCH, FOULED AIR FILTER
SENSOR, AIREND INLET
SENSOR, AIREND DISCHARGE TEMPERATURE
SENSOR, INJECTED COOLENT TEMPERATURE
TRANSDUCER, SUMP PRESSURE, WET SIDE
VALVE, BLOWDOWN SOLENOID
TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
SENSOR, OIL COOLER OUT TEMPERATURE
VALVE, WATER STOP SOLENOID (W/C ONLY)
TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
TRANSMITTER, REMOTE AIR PRESSURE
(OPTIONAL)
VALVE, CONDENSATE DRAIN
VALVE, ANTI-CONDENSATION SOLENOID
AUTOTRANSFORMER (IF FITTED)
AUXILIARY WARNING 1
AUXILIARY WARNING 2
BACKPLATE
CAPACITOR
CABINET
CONDENSATE DRAIN ERROR
CONDENSATE DRAIN VALVE (IF FITTED)
COMMON FAULT OUTPUT
CHOKE
EXTERNAL COMMUNICATIONS
DRIVE
FAN, DRIVE BOX VENTILATION
EARTH BAR
SWITCH, EMERGENCY STOP
DRIVE, BLOWER (A/C ONLY)
MOTOR, BLOWER
GROUND
HEATER, SPACER 25 WATTS
HEATER, SPACER 25 WATTS
RELAY, RUN
RELAY, FAULT
CONTACTOR, MAIN MOTOR
CONTACTOR, FAN MOTOR (W/C ONLY)
CONTACTOR, DRIVE VENTILATION FAN
BREAKER, MINIATURE CIRCUIT, TRANSFORMER
BREAKER, MINIATURE CIRCUIT, DVF
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINIATURE CIRCUIT, PSU
BREAKER, MINIATURE CIRCUIT, HEATERS
MAINS FILTER (IF FITTED)
MM
MMS
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNE
SL
SS1-3
ST
T1
TH
TRR
WR
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires
MOTOR, MAIN
BREAKER, FAN MOTOR
OPTIONAL
ZERO VOLTAGE
PROTECTED EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
GENERAL WARNING
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW
Numbers
Function
Wire color
1−99
Power
Black
100−199
AC Control
Red
200−299
DC Control
Blue
300−399
Auxiliary
Orange
NOTES:
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER
100 & 121.
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN
INDEPENDENT SOURCE: IN THAT CASE, FACTORY
SUPPLIED CONNECTION MUST BE DISCONNECTED.
3. ENSURE PARALLEL CONNECTION OF HEATERS.
NOTES:
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE
DISCONNECTED.
2. ENSURE SERIES CONNECTION OF HEATERS.
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
57
8.0 GENERAL INFORMATION
8.4 Wiring schematic - n75-160k-cc / n125-200h-cc A/c
L1
L2
L3
PE
P
MCB1
HB
HTR
CDV
3SV
9SV
CAB
KM1
ES-1
104
103
SHT 2
1ATS
101
121
15
B-
3
SC+
120
4
SC-
5
SD+
6
SD-
5
P7
6
7
P3
105
110
T1
17
120
113
3SV
P4
5
242
214
215
252
253
DR
FD
8
21
9SV
102
1
123
2
K2
1
2 P1
P2
1
RECTIFIER
1
2
7
YEL
2
RED
3
1
4
RED
201
P10
BLU
0V
7
2
MM
3
U
1
2
DI2
3
DI1
4
+24Vdc
5
0V
AI2
V
W
P5
BLK
BLK
RED
1
2
230
K1-1 1-STG ONLY
230
K1-1 2-STG ONLY
8
9
21
CFO
9APT
3
2
4
P2
BLK
WHI
P
V
WHI
WHI
3APT
P
V
P
6APT
2APT
2 STG
ONLY
WHI
BLK
T 2CTT
WHI
BLK
T 2ATT
WHI
5
BLK
6
T 4ATT
WHI
BLK
8
T 1ATT
WHI
9
BLK
10
T 4CTT
WHI
10
MAIN INPUT
TERMINALS
OPTIONS
TH
KM5-2
22
T
23
MAINS FILTER
L1
CDV
BLK
RED
BLK
7
MCB9
110/120 V
50/60 HZ
FROM SHT 1
P6
3
OPT
RED
7
AI1-
WHI 4-20mA
RED
+
P
1
4APT
RED
7
11
12
P8
V
WHI
6
10
231
HEATER CIRCUITS:100
BLK
9
BLK
WHI
WHI
P
RED
8
BLK
V
WHI
2
6
AI1+
AO1
BLK
1
ENABLE
GND
1
RED
ST
SL
BLK
6
BLK
RED
3
4
7
6
VIO
3
SIGNAL
2
2
GND
5
PX2
BRO
PX3
1
BLK
8
RED
2
252
5
-
W
GRE
WR
105 (110V)
253
1
CK
W
FM
12V DC
+
PX4
V
2
200
BLK
GND
U
1
2
WHI
1
3
+ DC-BUS
+12V
PSU
MCB4
+
9
116
9
10
4-20 mA
OUTPUT
120
FAULT
U V
-
TRR
2
120
108
11
20
-
SS3
2
1
PORO
9
12
+
+
18
2
7
SS2
151
PX1
K1-2
241
+
4
6
6
1
SS1
3
5
114
11SV
MCB3
L1 L2 L3
240
CDE (OPT)
1
4
152
PX6
17
AW1
AW2
L3
MMS1
16
RST
16
153
L2
RSP
2
151
200v 150
L1
1VAC
217
9
15
2
W
OPT
HTR1
STANDARD HEATER
CONNECTIONS AS
DELIVERED
HTR2
L2
LINE
AUTO - TRANSFORMER
L3
MF
OR
LOAD
L2
L1
L1
L2
AT
L3
L3
L1
L2
L3
121
SUPPLIED BY CUSTOMER
TH
MCB10
OR
KM5-2
22
T
23
F10
110/120 V
50/60 HZ
EXTERNAL SUPPLY
100
MCB9
110/120 V
50/60 HZ
FROM SHT 1
HTR1
HTR2
ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
110 / 120 V SUPPLY
HTR2
ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
220 / 230 V SUPPLY
21
CDV
OPT
SUPPLIED BY CUSTOMER
TH
121
MCB10
OR
121
KM5-2
22
T
23
F10
22093058
Revision M
58
214B
MMS2-1
216
14
3
112
KM5
HB
214A
MMS1-1
215
18
KM5
V
214
13
1
U
ES-2
213
12
2
111
K1
8
1DPS
212
11
P1
KM1
102
RF
I
14
2
4
1
MCB2
13
3
210
211
10
K2-1
110v
2
A+
1
EXC
MMS2
1
SG-Ne
11SV
SGNe
OV
RFI
T1
PSU
2
FM
L3
EB
DR
1
FD
L1
MM
380-480V
50/60 Hz 3ph + PE
220/230 V
50/60 HZ
EXTERNAL SUPPLY
HTR1
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
OPT
8.0 GENERAL INFORMATION
KEY
1ATS SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
1ATT SENSOR, INLET TEMPERATURE
1DPS SWITCH, FOULED OIL FILTER
1VAC SWITCH, FOULED AIR FILTER
2APT SENSOR, INTERSTAGE PRESSURE (2STG ONLY)
2ATT SENSOR, AIREND DISCHARGE TEMPERATURE
2CTT SENSOR, INJECTED COOLENT TEMPERATURE
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE
3SV
VALVE, BLOWDOWN SOLENOID
4APT TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
4ATT SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
4CTT SENSOR, OIL COOLER OUT TEMPERATURE
6APT TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
9APT TRANSDUCER, REMOTE AIR PRESSURE
(OPTIONAL)
9SV
VALVE, CONDENSATE DRAIN
11SV VALVE, ANTI-CONDENSATION SOLENOID 1
AT
AUTOTRANSFORMER (IF FITTED)
AW1 AUXILIARY WARNING 1
AW2 AUXILIARY WARNING 2
BP
BACKPLATE
C
CAPACITOR
CAB
CABINET
CDE
CONDENSATE DRAIN ERROR (OPTIONAL)
CDV
CONDENSATE DRAIN VALVE (IF FITTED)
CFO
COMMON FAULT OUTPUT
CK
CHOKE
DR
DRIVE
EB
EARTH BAR
ES
SWITCH, EMERGENCY STOP
EXC
EXTERNAL COMMUNICATIONS
F10
FUSE, EXTERNAL HEATER SUPPLY
FD
FAN DRIVE
FM
MOTOR, BLOWER
GND GROUND
HB
HEATSINK BLOWER
HTR1 HEATER, 125 WATTS
K1
RELAY, RUN
K2
RELAY, FAULT
KM1
CONTACTOR, MAIN MOTOR
KM5
CONTACTOR, HEATSINK BLOWER
MCB1 BREAKER, MINIATURE CIRCUIT, TRANSFORMER
MCB2 BREAKER, MINIATURE CIRCUIT, CONTROL
CIRCUITS
MCB3 BREAKER, MINIATURE CIRCUIT, DR
MCB4 BREAKER, MINIATURE CIRCUIT, PSU
MCB9 BREAKER, MINIATURE CIRCUIT, HEATER
MCB10 BREAKER, MINIATURE CIRCUIT, HEATER
(EXTERNAL)
MF
MAINS FILTER (IF FITTED)
MM
MMS1
MMS2
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNe
SL
SS1-3
ST
T1
TH
TRR
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires
MOTOR, MAIN
BREAKER, FAN MOTOR
BREAKER, HEATSINK BLOWER
OPTIONAL
ZERO VOLTAGE
PROTECTIVE EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW
Numbers
Function
Wire color
1−99
Power
Black
100−199
AC Control
Red
200−299
DC Control
Blue
300−399
Auxiliary
Orange
NOTES:
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER
100 & 121.
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN
INDEPENDENT SOURCE: IN THAT CASE, FACTORY
SUPPLIED CONNECTION MUST BE DISCONNECTED.
3. ENSURE PARALLEL CONNECTION OF HEATERS.
NOTES:
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE
DISCONNECTED.
2. ENSURE SERIES CONNECTION OF HEATERS.
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
59
8.0 GENERAL INFORMATION
8.4 Wiring schematic - n75-160k-cc / n125-200h-cc W/c
MCB1
HB
CDV
HTR
3SV
9SV
SGNe
OV
RFI
T1
PSU
FM
2
L3
CAB
EB
1
L1
FD
380-480V
50/60 Hz 3ph + PE
PE
11SV
L3
MM
L2
DR
L1
P
1
KM1
EXC
SHT 2
ES-1
KM5
101
110v
1ATS
104
103
102
RF
I
121
2
3
A+
4
2
B-
3
SC+
4
SC-
5
SD+
7
6
SD-
8
5
P7
6
P3
110
KM1
ES-2
213
214
215
214A
MMS1-1
MMS2-1
216
1VAC
217
9
RSP
RST
12
P1
14
1DPS
212
11
1
120
210
211
10
105
K2-1
MCB2
15
13
1
SG-Ne
13
AW1
14
2
15
1
AW2
16
2
MMS2
U
V
MMS1
W
U
V
151
200v 150
17
3
1
153
2
4SV
MCB3
P4
FM
L1
L2
L3
112
KM5
PX6
PX1
1
2
120
102
123
114
11SV
120
K2
113
3SV
SS2
108
+
MCB4
CK
1
1
2 P1
P2
3
-
2
116
200
12V DC
BLK
4-20 mA
OUTPUT
9
WHI
0V
6
VIO
7
2
MM
3
U
1
ENABLE
2
DI2
3
DI1
4
+24Vdc
5
GND
1
BLK
0V
AI2
V
W
AI1-
8
AI1+
9
AO1
K1-1 1-STG ONLY
230
K1-1 2-STG ONLY
21
WHI 4-20mA
RED
+
P
2
OPT
CFO
1
3
2
4
P6
3
BLK
WHI
P2
T 2CTT
WHI
BLK
T 2ATT
BLK
T 4ATT
T 1ATT
WHI
BLK
T 4CTT
MAIN INPUT
TERMINALS
OPTIONS
TH
23
MAINS FILTER
L1
L2
LINE
AUTO - TRANSFORMER
L3
MF
CDV
OPT
HTR1
STANDARD HEATER
CONNECTIONS AS
DELIVERED
HTR2
OR
LOAD
L2
L1
L1
L2
AT
L3
L3
L1
L2
121
SUPPLIED BY CUSTOMER
TH
MCB10
OR
KM5-2
22
T
23
F10
110/120 V
50/60 HZ
EXTERNAL SUPPLY
100
MCB9
110/120 V
50/60 HZ
FROM SHT 1
HTR1
HTR2
ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
110 / 120 V SUPPLY
HTR2
ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
220 / 230 V SUPPLY
21
CDV
OPT
SUPPLIED BY CUSTOMER
TH
121
MCB10
OR
121
KM5-2
22
T
23
F10
22258891
Revision E
60
220/230 V
50/60 HZ
EXTERNAL SUPPLY
2APT
2 STG
ONLY
WHI
10
MCB9
110/120 V
50/60 HZ
FROM SHT 1
P
BLK
BLK
9
T
6APT
WHI
5
8
22
P
V
WHI
7
WHI
V
WHI
6
10
KM5-2
BLK
2
9APT
3APT
RED
12
P8
P
WHI
11
RED
HEATER CIRCUITS:100
BLK
9
1
4APT
RED
7
10
BLK
RED
V
WHI
6
1
230
7
BLK
5
8
ST
P
RED
4
BLK
WHI
V
WHI
3
2
231
6
BLK
2
P10
P5
WHI
8
RED
1
1
RED
201
GND
5
BLU
PORO
9
BLK
7
SL
PX2
BRO
4
102 (110V)
1
2
120
6
BLK
2
7
3
1
PX4
GRE
PX3
2
RED
RED
3
6
WR
2
+
RED
1
2
1
BLK
-
5
BLK
GND
YEL
-
TRR
2
1
10
9SV
RECTIFIER
+
SS3
PSU
+ DC-BUS
+
4
6
151
1
SS1
3
5
4
152
DR
CDE (OPT)
18
W
T1
HB
111
K1
HTR1
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
L3
OPT
8.0 GENERAL INFORMATION
KEY
1ATS
1ATT
1DPS
1VAC
2APT
2ATT
2CTT
3APT
3SV
4APT
4ATT
4CTT
4SV
6APT
9APT
9SV
11SV
AT
AW1
AW2
BP
C
CAB
CDE
CDV
CFO
CK
DR
EB
ES
EXC
F10
FM
GND
HB
HTR1
K1
K2
KM1
KM5
MCB1
MCB2
MCB3
MCB4
MCB9
MCB10
MF
SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
SENSOR, INLET TEMPERATURE
SWITCH, FOULED OIL FILTER
SWITCH, FOULED AIR FILTER
SENSOR, INTERSTAGE PRESSURE (2STG ONLY)
SENSOR, AIREND DISCHARGE TEMPERATURE
SENSOR, INJECTED COOLENT TEMPERATURE
TRANSDUCER, SUMP PRESSURE, WET SIDE
VALVE, BLOWDOWN SOLENOID
TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
SENSOR, OIL COOLER OUT TEMPERATURE
VALVE, WATER STOP
TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
TRANSMITTER, REMOTE AIR PRESSURE
(OPTIONAL)
VALVE, CONDENSATE DRAIN
VALVE, ANTI-CONDENSATION SOLENOID 1
AUTOTRANSFORMER (IF FITTED)
AUXILIARY WARNING 1
AUXILIARY WARNING 2
BACKPLATE
CAPACITOR
CABINET
CONDENSATE DRAIN ERROR (OPTIONAL)
CONDENSATE DRAIN VALVE (IF FITTED)
COMMON FAULT OUTPUT
CHOKE
DRIVE
EARTH BAR
SWITCH, EMERGENCY STOP
EXTERNAL COMMUNICATIONS
FUSE, EXTERNAL HEATER SUPPLY
MOTOR, BLOWER
GROUND
HEATSINK BLOWER
HEATER, 125 WATTS
RELAY, RUN
RELAY, FAULT
CONTACTOR, MAIN MOTOR
CONTACTOR, HEATSINK BLOWER
BREAKER, MINIATURE CIRCUIT, TRANSFORMER
BREAKER, MINIATURE CIRCUIT, CONTROL
CIRCUITS
BREAKER, MINIATURE CIRCUIT, DR
BREAKER, MINIATURE CIRCUIT, PSU
BREAKER, MINIATURE CIRCUIT, HEATER
BREAKER, MINIATURE CIRCUIT, HEATER
(EXTERNAL)
MAINS FILTER (IF FITTED)
MM
MMS1
MMS2
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNe
SL
SS1-3
ST
T1
TH
TRR
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires
MOTOR, MAIN
BREAKER, FAN MOTOR
BREAKER, HEATSINK BLOWER
OPTIONAL
ZERO VOLTAGE
PROTECTED EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW
Numbers
Function
Wire color
1−99
Power
Black
100−199
AC Control
Red
200−299
DC Control
Blue
300−399
Auxiliary
Orange
NOTES:
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER
100 & 121.
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN
INDEPENDENT SOURCE: IN THAT CASE, FACTORY
SUPPLIED CONNECTION MUST BE DISCONNECTED.
3. ENSURE PARALLEL CONNECTION OF HEATERS.
NOTES:
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE
DISCONNECTED.
2. ENSURE SERIES CONNECTION OF HEATERS.
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
61
8.0 GENERAL INFORMATION
8.4 Wiring schematic - n250-300H
L1
L2
L3
PE
P
EB
MCB1
HB
CDV
HTR
3SV
9SV
CAB
EXC
KM1
230v
124 MCB5
115
107
106
5SV
K1-3
KM5-1
DVF
ES-1
122
1ATS
104
103
SHT 2
101
I
RF
120
A+
3
2
B-
4
3
SC+
4
SC-
5
SD+
6
SD-
5
P7
6
7
105
112
17
151
120
113
3SV
214
215
252
253
20
21
PX6
1
PX1
DR
2
9SV
102
123
K2
1
2 P1
P2
1
RECTIFIER
PX3
1
BLK
2
RED
3
1
4
RED
201
P10
0V
VIO
7
GND
1
U
2
MM
ENABLE
2
DI2
3
DI1
4
+24Vdc
5
0V
AI2
V
3
1
PX2
6
AI1AI1+
W
AO1
HEATER CIRCUITS:21
100
ST
SL
BLK
1
230
K1-1 1-STG ONLY
230
K1-1 2-STG ONLY
WHI 4-20mA
RED
+
P
9APT
22
P6
3
OPT
P2
T 2CTT
T 2ATT
BLK
MAINS FILTER
L2
LINE
BLK
AUTO - TRANSFORMER
L3
MF
OPT
HTR1
STANDARD HEATER
CONNECTIONS AS
DELIVERED
HTR2
OR
LOAD
L2
L1
L1
L2
AT
L3
L3
L1
L2
L3
121
SUPPLIED BY CUSTOMER
TH
MCB10
OR
KM5-2
22
T
23
F10
110/120 V
50/60 HZ
EXTERNAL SUPPLY
100
MCB9
110/120 V
50/60 HZ
FROM SHT 1
HTR1
HTR2
ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
110 / 120 V SUPPLY
HTR2
ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
220 / 230 V SUPPLY
21
CDV
OPT
SUPPLIED BY CUSTOMER
TH
121
MCB10
OR
121
KM5-2
22
T
23
F10
22407100
Revision C
62
220/230 V
50/60 HZ
EXTERNAL SUPPLY
HTR1
T 4ATT
WHI
MAIN INPUT
TERMINALS
OPTIONS
23
2APT
2 STG
ONLY
WHI
BLK
WHI
T
P
6APT
BLK
10
L1
CDV
P
V
WHI
5
8
MCB9
110/120 V
50/60 HZ
FROM SHT 1
4
7
BLK
WHI
3APT
WHI
6
RED
V
WHI
3
2
CFO
P
WHI
2
TH
KM5-2
BLK
RED
BLK
1
1
4APT
RED
11
12
P8
2
V
WHI
9
231
7
9
BLK
10
BLK
RED
P
RED
8
BLK
WHI
WHI
8
V
WHI
7
BLK
7
6
8
BLK
6
P5
GND
5
BLU
RED
4
BLK
2
RED
6
BLK
3
RED
1
3
SIGNAL
2
2
7
PX4
BRO
2
252
5
-
2
YEL
GRE
WR
105 (110V)
253
1
BLK
GND
FM
2
12V DC
+
W
V
1
WHI
1
200
CK
W
+12V
PSU
3
+ DC-BUS
9
116
9
10
4-20 mA
OUTPUT
120
MCB4
+
U
-
TRR
2
120
FAULT
U V
-
SS3
2
1
PORO
108
12
+
151
9
11
SS2
6
6
1
+
4
5
114
11SV
MCB3
SS1
3
P4
5
+
18
FD
8
CDE (OPT)
1
4
152
2
7
AW1
AW2
16
L1 L2 L3
242
RST
L3
MMS1
K1-2
RSP
2
T1
241
1VAC
217
15
3
214B
MMS2-1
216
14
153
240
214A
MMS1-1
215
18
200v 150
17
214
9
2
16
ES-2
213
13
2
111
KM5
L2
1DPS
212
12
1
L1
210
211
11
110
K1
8
P3
P1
MCB2
121
1
1
KM1
102
2
10
K2-1
110v
1
SG-Ne
11SV
SGNe
OV
RFI
T1
PSU
FD
2
L3
DR
FM
1
L1
MM
380-480V
50/60 Hz 3ph + PE
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T 1ATT
OPT
8.0 GENERAL INFORMATION
KEY
1ATS
1ATT
1DPS
1VAC
2APT
2ATT
2CTT
3APT
3SV
4APT
4ATT
6APT
9APT
9SV
11SV
AT
AW1
AW2
BP
C
CAB
CDE
CDV
CFO
CK
DR
EB
ES
EXC
F10
FD
FM
GND
HTR1
K1
K2
KM1
KM5
MCB1
MCB2
MCB3
MCB4
MCB9
MCB10
MF
MM
SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
SENSOR, INLET TEMPERATURE
SWITCH, FOULED OIL FILTER
SWITCH, FOULED AIR FILTER
SENSOR, INTERSTAGE PRESSURE (2STG ONLY)
SENSOR, AIREND DISCHARGE TEMPERATURE
SENSOR, INJECTED COOLENT TEMPERATURE
TRANSDUCER, SUMP PRESSURE, WET SIDE
VALVE, BLOWDOWN SOLENOID
TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
TRANSDUCER, REMOTE AIR PRESSURE
(OPTIONAL)
VALVE, CONDENSATE DRAIN
VALVE, ANTI-CONDENSATION SOLENOID 1
AUTOTRANSFORMER (IF FITTED)
AUXILIARY WARNING 1
AUXILIARY WARNING 2
BACKPLATE
CAPACITOR
CABINET
CONDENSATE DRAIN ERROR (OPTIONAL)
CONDENSATE DRAIN VALVE (IF FITTED)
COMMON FAULT OUTPUT
CHOKE
DRIVE
EARTH BAR
SWITCH, EMERGENCY STOP
EXTERNAL COMMUNICATIONS
FUSE, EXTERNAL HEATER SUPPLY
FAN DRIVE
MOTOR, BLOWER
GROUND
HEATER, 125 WATTS
RELAY, RUN
RELAY, FAULT
CONTACTOR, MAIN MOTOR
CONTACTOR, HEATSINK BLOWER
BREAKER, MINIATURE CIRCUIT, TRANSFORMER
BREAKER, MINIATURE CIRCUIT, CONTROL
CIRCUITS
BREAKER, MINIATURE CIRCUIT, DR
BREAKER, MINIATURE CIRCUIT, PSU
BREAKER, MINIATURE CIRCUIT, HEATER
BREAKER, MINIATURE CIRCUIT, HEATER
(EXTERNAL)
MAINS FILTER
MOTOR, MAIN
MMS1
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNe
SL
SS1-3
ST
T1
TH
TRR
DVF
5SV
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires
BREAKER, FAN MOTOR
OPTIONAL
ZERO VOLTAGE
PROTECTIVE EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
FAN, DRIVE VENTILATION
VALVE, COOLANT STOP
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW
Numbers
Function
Wire color
1−99
Power
Black
100−199
AC Control
Red
200−299
DC Control
Blue
300−399
Auxiliary
Orange
NOTES:
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER
100 & 121.
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN
INDEPENDENT SOURCE: IN THAT CASE, FACTORY
SUPPLIED CONNECTION MUST BE DISCONNECTED.
3. ENSURE PARALLEL CONNECTION OF HEATERS.
NOTES:
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE
DISCONNECTED.
2. ENSURE SERIES CONNECTION OF HEATERS.
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63
8.0 GENERAL INFORMATION
8.5 GENERAL DESCRIPTION
The compressor is an electric motor driven, contact
cooled screw compressor, complete with all necessary
components piped, wired and baseplate mounted. It is a
totally self contained air compressor package.
The standard compressor is designed to operate in an
ambient range of 1.7° C to 46° C (35° F to 115° F). The
standard maximum temperature of 46° C (115° F) is
applicable up to an elevation of 1000m (3280ft) above
sea level. Above this altitude significant reductions in
ambient temperature are required if a standard motor is
to be used.
The compressor is managed by the onboard electronic
controller. The controller and drive system operate
together to vary the speed of the compressor to deliver
compressed air at the target pressure.
Panel instrumentation is provided to indicate the
compressor operating conditions and general status.
The air/coolant mixture discharges from the compressor
into the separation system. This system removes all
but a few PPM of the coolant from the discharge air.
The coolant is returned to the cooling system and the
air passes to the aftercooler and out of the compressor
through the moisture separator.
Air is pulled into the machine by the cooling blower
(N250−300H use a propeller fan for cooling) and through
the combined cooler / aftercooler.
By cooling the discharge air, much of the water vapor
naturally contained in the air is condensed and is drained
from the built−in moisture separator and drain.
The coolant system consists of a sump, cooler,
thermostatic valve, anti−condensation valve and a
filter. When the unit is operating, coolant is forced by
air pressure from the separator tank to the thermostatic
element. The position of the element (a direct result
of coolant temperature) will determine whether the
coolant circulates through the cooler, bypasses the
cooler, or mixes the two paths together to maintain
an optimum compressor injection temperature. The
two position anti−condensation valve can reduce the
coolant flow and hence the temperature rise of coolant
through the compressor. This temperature is controlled
to preclude the possibility of water vapor condensing. By
injecting coolant at a sufficiently high temperature, the
discharge air coolant mixture temperature will be kept
above the dew point. On the N90/160K, N125/200H−SS,
N75/160K−2S, N100/200H−2S and N250/300H−2S, the
system is enhanced by a control logic that varies the
cooling blower speed dependant on the intake and
discharge temperatures and hence controls the injection
temperature even closer while saving blower motor
energy.
The compressor is provided with a temperature sensor
which will shut the unit down in case of excessive
temperature, 109° C (228° F).
Effective coolant filtration is provided by the use of a
screw on, heavy duty coolant filter.
Notice
Nirvana air comrpessors are factory filled with SSR ULTRA COOLANT which is designed to operate for 8,000
hours or two years, whichever comes first.
Units supplied with optional Food Grade Coolant are designed to operate 1000 hours or 6 months, whichever
comes first.
The coolant must be changed at these intervals to avoid breakdown and equipment damage.
64
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9.0 OPERATING INSTRUCTIONS
9.1 BASIC OPERATION
Prior to starting
warning
Ensure that all protective covers/guards are in place before
attempting to start the machine.
warning
The compressor can operate in a pressurized shutdown
mode. If the compressor stops automatically, the airend,
separator tank and oil system can contain high pressure air.
This can be relieved by pressing the emergency stop button
and can be verified by unscrewing the coolant fill plug which
has a vent hole through which any residual pressure will be
vented. Downstream of the separator tank may still contain
system pressure which must also be vented.
NOTICE
The language and units of measure displayed on the Intellisys
controller will be pre−set before leaving the factory. If these
are required to be changed, contact your local Ingersoll Rand
Service Department, Distributor or Air Center.
Refer to diagram T5716 above.
Check that the coolant level is at least visible in the center of
the sight glass, add coolant if necessary. Refer to maintenance
procedures for setting correct level.
Ensure that the discharge air isolation valve is open. Switch on the
main electrical isolation switch. The control panel will illuminate,
indicating that the line and control voltages are available.
The contrast of the display may be adjusted by turning the small
screw which is on the right hand side of the controller when
accessed through the starter cabinet door.
Initial check sequence
The controller will perform an initial check sequence if the
compressor (1) receives initial power to the controller or (2) has
experienced an alarm reset. While the initial check sequence occurs,
the controller will display a “Checking Machine” message.
During the initial check sequence, the controller will check the
control system for proper operation. During this time, if any items
are found inoperative an alarm will occur and the unit will not start.
After completion of the initial check sequence, the controller will
then display “READY TO START’. This process should be completed
within 10 seconds.
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9.0 OPERATING INSTRUCTIONS
Start sequence
Blowdown mode
The compressor will initially start by the operator pressing the
local start button or receiving a remote start command. The
compressor will start loaded and will ramp up the motor speed to
its minimum speed. Once the minimum speed has been achieved,
the compressor will begin to control pressure by using its speed
regulation. When the system pressure reaches the target pressure,
the compressor will start to slow. If the system pressure rises to
the immediate stop pressure setpoint the compressor will stop.
If the system pressure rises to the auto stop setpoint and the
compressor is at minimum speed, if the blowdown mode is set to
off, the compressor will stop. However if the blowdown mode is set
to on, the compressor will open the blowdown valve for up to 10
seconds or until the pressure in the separator tank falls to 2.4 Bar (35
psi) before stopping. The compressor will restart once the system
pressure falls below the target pressure.
All 2 stage compressors will blowdown when compressor is signaled
to stop. Intellisys indicates that Blowdown Mode is ”not installed”.
Stop sequence
The compressor can be stopped by a local or remote stop, a
shutdown due to an alarm or an emergency stop. All of the above
conditions will cause the compressor to stop immediately, except
the local or remote stop. A local or remote stop will open the
blowdown valve and the compressor will run for up to 10 seconds
or until the pressure in the separator tank falls to 35 psi before
stopping. The compressor will stop if the system pressure reaches
the automatic stop or immediate stop pressure setpoints. However,
if the compressor stops for this reason, it will automatically restart
when the system pressure falls below the target pressure.
The N250/300H − 2S compressor will operate for 30 seconds with
the blowdown valve open and at reduced speed before stopping.
This sequence occurs for local or remote stops and when the
system pressure reaches the automatic or immediate stop pressure
setpoints. The compressor will automatically restart when the
system pressure falls below the target pressure.
If the blowdown mode is set to on, the compressor will open the
blowdown valve anytime that it stops. This will release pressure
from the airend and separator tank. If the blowdown mode is set to
off, the blowdown valve will remain closed when the compressor
stops due to an automatic stop
Blower control N37/160K−1S, N50/200H−1S &
N75/160−2S, N100/200H−2S
Fan control N250/300H−2S
The blower speed varies in some conditions to assist in controlling
the coolant injection temperature. The blower motor has its own
variable speed drive and will ramp up and down as the compressor
starts and stops.
Stopping the machine in an emergency
If the machine has to be stopped in an emergency DEPRESS
THE EMERGENCY STOP BUTTON LOCATED UNDERNEATH THE
INSTRUMENT PANEL.
This will over−ride the normal unload/stop button and will
immediately stop the machine.
Restarting after an emergency
If the unit has been switched off because of a machine malfunction,
identify and correct the fault before attempting to restart.
If the unit has been switched off for reasons of safety, ensure that
the machine can be operated safely before restarting.
Refer to the PRIOR TO STARTING and START SEQUENCE instructions
earlier in this section before restarting the machine.
Important: Depress the emergency stop button when the
compressor must be stopped immediately.
66
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9.0 OPERATING INSTRUCTIONS
9.2 INTELLISYS CONTROLS
1. Emergency stop
5. F2
Pressing this switch stops the compressor immediately. The
blowdown valve will open to vent pressure in the separator tank to
atmosphere. Note: the system downstream of the separator tank
may still contain pressure. The compressors can not be restarted
until the switch is manually reset. Turn the switch knob clockwise
and press the reset button twice to reset.
Not used.
On reset the controller will display a message, indicating that the
compressor is ready to start.
2. Start
Pressing this button will activate the start sequence.
3. Stop
Pressing this button will activate the stop sequence.
4. F1
Not used.
6. Arrows
These up and down buttons have multiple functions relating to
the right half of the display screen. When lists are presented, the
buttons are used to move up or down through the items on the
list. The small arrow(s) displayed in the upper right hand corner of
the display screen indicate when you can move up (designated by
arrow head pointing up) and/or down (designated by arrow head
pointing down) through the list.
When the value of a specific machine operating parameter is
highlighted on the display screen for the purpose of changing that
value, the buttons are used to change the value itself.
7. Display buttons
The functions of the three buttons below the display screen
change and are defined by the words immediately above them in
the bottom line of the screen. Each function, such as MAIN MENU,
STATUS, etc., is described in appropriate sections in this manual.
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9.0 OPERATING INSTRUCTIONS
9.3 DISPLAY SCREEN
The display screen is divided into three functional areas, as seen in
the typical CURRENT STATUS screen shown here.
The left side continuously shows the package discharge pressure
in large numbers with the line directly below showing the running
condition of the machine
100
− CURRENT STATUS −
PACKAGE DISCHARGE
TEMP
102° F
AIREND DISCHARGE
TEMP
192° F
PSI
READY TO START
MAIN MENU
68
The right side shows various items or lists such as the machine’s
CURRENT STATUS readings, the MAIN MENU, the OPERATOR
SETPOINTS list, etc. Any of the lists can be moved up or down by
pressing the arrow buttons to the right of the screen. The small
arrow(s) displayed in the upper right corner of the screen indicate
when you can move up and/or down through a list. The arrow
buttons are also used to change an individual item’s value. At
certain times, items and/or their values are “highlighted”. This means
that they are displayed as light characters on a dark background.
The bottom of the screen is divided into thirds with the words in
each small box showing the function of the button directly beneath
it. The words will change in these boxes depending on what
actions are permitted at any particular time. The action resulting
from pressing each of these buttons is indicated in the Operator
Panel Flow Diagram later in this section. This can be used as a quick
reference of how to step the controller screen through any desired
function.
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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 items and their present values can be displayed on
the right side of the screen by pressing the up and down arrow
buttons
14 Motor Speed
15 Motor Current
16 Motor Voltage
17 Input Voltage
The controller automatically returns the display to this CURRENT
STATUS screen from other screens if no buttons are pressed within
30 seconds.
18 DC Bus Voltage
Use the UP and DOWN arrows to move between selections.
20 Time and Date
CURRENT STATUS items
21 Program Name
1 % Energy Saving
22 Version of Drive Software
2 % Capacity
When the CURRENT STATUS screen is displayed, pressing the
ENERGY STATUS button will toggle the display to the ENERGY
STATUS screen. Likewise, when the ENERGY STATUS screen is
displayed, pressing the STATUS button will toggle the display to the
CURRENT STATUS screen.
3 Package kW
4 Package Discharge Temperature
5 Airend Discharge Temperature
6 Injected Coolant Temperature
7 Inlet Temperature
8 Sump Pressure
9 Separator Pressure Drop
10 Interstage Pressure
11 Coolant Filter
12 Inlet Filter
19 Remote Pressure (optional)
The ENERGY STATUS screen displays the following items.
ENERGY STATUS Items
1 Average Package kW−hr
2 Average % Capacity
3 Average Capacity
4 Energy Cost
5 Energy Savings
6 Lifetime Energy Savings
13 Total Hours
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69
9.0 OPERATING INSTRUCTIONS
9.5 MAIN MENU
The MAIN MENU screen can be accessed from the CURRENT STATUS
screen by pressing the MAIN MENU button, identified by the words
“MAIN MENU” in the bottom line of the screen directly above the
center button.
The language and units of measure are pre−set prior to the
compressor leaving the factory.
100
The MAIN MENU screen is the point from which various operator
functions can be accessed. Refer to the Operator Panel Flow
Diagram.
PSI
−MAIN MENU−
READY TO START
Each of the functions can be chosen by using the up and down
arrows to highlight it on the screen.
The controller will go to the highlighted function if the SELECT
button is pressed or will return to the CURRENT STATUS screen if the
STATUS button is pressed.
“Status”
OPERATOR SETPOINTS
OPTIONS
SENSOR CALIBRATION
ALARM HISTORY
STATUS
CURRENT
STATUS/ENERGY
STATUS
SELECT
Energy
Status
“Main Menu”
“Status”
MAIN MENU
“Main Menu”
“Select”
“Main Menu”
“Main
Menu”
OPERATOR
SETPOINTS
“Status”
“Main Menu”
OPTIONS
“Status”
“Status”
“Select”
“Select”
OPERATOR
SETPOINTS
ITEM
“Main Menu”
“Status”
SENSOR
CALIBRATION
ITEM
“Cancel or set”
ALARM
HISTORY
“Main Menu”
“Status”
ALARM
HISTORY ITEM
“Status”
“Alarm hist”
“Cancel or calibrate”
CLOCK
FUNCTIONS
“Select”
“Select”
“Main Menu”
“Select”
OPTIONS ITEM
“Cancel or set”
“Main
Menu”
“Status”
SENSOR
CALIBRATION
DATE
AND TIME
“Main Menu”
“Status”
ENERGY
STATUS
“Main
Menu”
AVG. PACKAGE kW HRS
AVG. % CAPACITY
AVG. CAPACITY
ENERGY COST
ENERGY SAVINGS
“Status” LIFETIME ENERGY SAVINGS
“Cancel or set”
“Cancel or set”
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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 screen shown opposite.
100
PSI
OPERATOR SETPOINTS−
The name and value of each of the setpoints listed can be seen on
the screen by moving the list up and down using the arrow buttons.
READY TO START
TARGET PRESSURE
105 psi
Setpoints associated with options are described in the OPTIONS
sections.
STATUS
MAIN MENU
SELECT
FACTORY DEFAULTS
DEFAULT
MIN.
MAX.
STEP
UNIT
Target pressure
OPERATOR SETPOINTS
100
65
145 / 203
1
PSI
Automatic stop pressure
110
Target +1
Target +10
1
PSI
Immediate stop pressure
120
Auto
Auto +10
1
PSI
Blowdown mode
Off
Off
On
−
−
Condensate release
5
2
20
1
SEC.
Condensate interval
180
90
270
1
SEC.
Modulation
−
−
−
−
% savings compared to
Energy Rate
0
0
9999.999
−
−
Reset Avg.
--
−
−
Reset Date
−
Service menu
1
1
25535
1
−
A setpoint’s value can be changed by first highlighting the item
and its value and pressing the SELECT button to highlight just the
value. When the value line is highlighted by itself, the value can
be adjusted using the up and down arrow buttons. The CANCEL
and SET buttons appear at this time. Press the SET button to enter
the new value or press the CANCEL button to return the value of
the setpoint prior to using the arrows. The displayed value will
flash twice to indicated that it has been entered into the setpoint
and the pair of setpoint item and value display lines will again be
highlighted together.
Operator setpoints can be exited by pressing the STATUS or MAIN
MENU buttons. If no buttons are pressed within 30 seconds, the
display will return to the CURRENT STATUS screen.
Unit
Min
Max (1S / 2S)
Step
PSI
65
145 / 203
1
BAR
4.4
10 / 14
0.1
kPa
440
1000 / 1400
10
KGCM2
4.5
10.2 / 14.2
0.1
Note: the max target pressure for N250/300H−2S is 145 PSI, 10 BAR ,
1000 kPa, 10.2 KGCM2.
Target pressure
The compressor will try to operate at this pressure setting. The
target pressure ranges and step sizes for each unit of measure are
listed in the table below.
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9.0 OPERATING INSTRUCTIONS
Automatic stop pressure
Condensate Release
The compressor will stop once the system pressure rises to this
pressure and the compressor is operating at the minimum speed.
The range for this setpoint will be the target pressure+1 to target
pressure+10 psi if the target pressure is 145 psi or less, to target
pressure+7 psi if the target pressure is greater than 145, but less
than or equal to 175 psi, or target pressure +5 psi if the target
pressure is greater than 175 psi. If the remote sensor is ’on’, the
maximum automatic stop pressure will always be target pressure
+5 psi.
This is the number of seconds that the condensate solenoid will be
open (energized) when blowing out the condensation.
Immediate stop pressure
The compressor will stop if the system pressure rises to this
pressure. The range for this setpoint will be the automatic stop
pressure to automatic stop pressure+10 psi if the target pressure
is 145 psi or less, to automatic stop pressure+7 psi if the target
pressure is greater than 145, but less than or equal to 175 psi, or
automatic stop pressure +5 psi if the target pressure is greater than
175 psi. If the remote sensor is ’on’, the maximum immediate stop
pressure will always be automatic stop pressure +5 psi.
Blowdown Mode
2 stage compressors will always blowdown when signaled to stop.
If this mode is selected to ON the compressor will open the
blowdown valve anytime that it stops. This will vent pressure from
the airend and the separator tank. If this mode is selected to OFF
the blowdown valve will remain closed when the compressor stops
due to an automatic stop. Blowdown mode is set on at all times for
2 stage models. Blowdown mode will be shown as ”Not Installed” at
the controller display.
72
Condensate Interval
This is the time interval between condensation blowdowns
% savings compared to
This setpoint is to determine what Nirvana’s percent of savings is
compared to. The modes of operation for comparing Nirvana to are
modulation, online/offline, and geometry. The percent savings value
is displayed by the status message, % energy savings
Energy Rate
The energy cost and the energy savings items on the ENERGY
STATUS screen will use this value for their calculations. It is intended
to be a monetary value representing the user’s power cost per
kilowatt hour.
Reset Averaging
When this setpoint is selected and the SET button is pressed, the
items on the ENERGY STATUS screen will be reset, and the date
the reset occurred will be displayed in this setpoint. This selects
the beginning of the time period over which the ENERGY STATUS
information will be calculated. Note that the “Lifetime Energy
Savings” item will not be reset.
Service Menu
For use by IR personnel only.
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9.0 OPERATING INSTRUCTIONS
9.7 OPTIONS
Options are turned on or off and their associated values are set
using the OPTION screen shown opposite.
100
−OPTIONS−
Some options are purchased, they require additional machine
hardware and must first be enabled by service personnel. The name
and value of each of the following options can be seen by moving
the list up and down using the arrow buttons
An Option item’s value can be changed the same way that
OPERATOR SETPOINTS values are changed.
OPTIONS Items
SELECTION
PSI
READY TO START
REMOTE START/STOP ON
STATUS
MIN.
REMOTE START/STOP ON
MAX.
MAIN MENU
Step
Unit
SELECT
Installed
Option
Required
Remote Pressure Sensor
ON/OFF
No
Sequencer
ON/OFF
No
Remote Start/Stop
ON/OFF
Yes
Power Out Restart
ON/OFF
Power Out Restart Time
Scheduled Start Day
Scheduled Start
Scheduled Stop Day
Scheduled Stop
Modbus Protocol
Modbus Address
Yes
10
600
1
SEC
Yes
day
day
1
day
Yes
00:00
23:59
1
time
Yes
day
day
1
day
Yes
00:00
23:59
1
time
Yes
ON/OFF/ICU
No
1
247
1
No
Remote pressure sensor
Power out restart
If this setting is set to ON, the compressor will use a remote
mounted pressure sensor for controlling system pressure by
comparing it to the Target Pressure setting and the Auto Stop
Pressure setting. The pressure measured by this sensor is shown in
the CURRENT STATUS display as the Remote Pressure reading. The
local sensor at the package discharge is still used for Immediate
Stop, for certain Alarm conditions and for display on the left side of
the screen.
If this setting is set to ON, the compressor will automatically restart
when power is returned to the compressor if it was operating when
power was removed.
Sequencer
If this setting is set to ON, the compressor will be able to start and
stop by commands from a host device. When the Intellisys receives
a load command from the host device, the compressor will start.
When the Intellisys receives an unload command the compressor
will respond as though executing an immediate stop.
Remote start/stop
If the remote start/stop option is installed and this setting is set
to ON, the compressor can be started and stopped from a remote
device.
Note:
A kit including instruction manual is required to install this option.
Power out restart time
If the power out restart setting is set to ON, this is the number of
seconds from the time power is restored until the compressor starts.
The power out restart horn will sound during this time.
Scheduled start day
This option is the selection for the day that a scheduled start will
take place. The selections are Sunday, Monday, Tuesday, Wednesday,
Thursday, Friday, Saturday, Daily (Su- Sa), Weekdays (M - F), or
Weekends. This option setpoint will work with the scheduled start
setpoint.
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9.0 OPERATING INSTRUCTIONS
Scheduled start
Scheduled stop
This option will cause the unit to start on the scheduled start day , at
the time stored in this setpoint. To disable this option, set the value
of scheduled start equal to the value of scheduled stop.
This option will cause the unit to stop on the scheduled stop day, at
the time stored in this setpoint. To disable this option, set the value
of scheduled stop equal to the value of scheduled start.
Scheduled stop day
Modbus protocol and address
This option is the selection for the day that a scheduled stop will
take place. The selections are Sunday, Monday, Tuesday, Wednesday,
Thursday, Friday, Saturday, Daily (Su - Sa), Weekdays (M - F), or
Weekends. This option setpoint will work with the scheduled stop
setpoint.
See the Modbus manual.
9.8 SENSOR CALIBRATION
Pressure sensor calibration is done through the SENSOR
CALIBRATION screen. Sensor calibration can only take place when
the machine is stopped. Calibration needs to be done only after
a sensor has been replaced or the Intellisys controller has been
replaced.
100
PSI
−SENSOR CALIBRATION−
READY TO START
STATUS
74
SENSOR 4APT
CALIBRATE
SENSOR 3APT
CALIBRATE
MAIN MENU
SELECT
Each of the sensors listed below can be chosen by using the up and
down arrow buttons to highlight it on the screen.
SENSOR CALIBRATION Items
Sensor 4APT (Package Discharge)
Sensor 3APT (Wet Side Sump)
Sensor 6APT (Dry Side Sump)
Sensor 2APT (Interstage)
Sensor 9APT (Remote Sensor)
Select the highlighted sensor by pressing the SELECT button. Press
the CALIBRATE button to start the automatic calibration procedure,
or press the CANCEL button to not calibrate it and return to the
sensor list.
The calibration screen can be exited by pressing either the STATUS
or MAIN MENU buttons. If no buttons are pressed within 30 seconds,
the display will return to the CURRENT STATUS screen.
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9.0 OPERATING INSTRUCTIONS
9.9 ALARM HISTORY
Alarm History displays each of the Alarm messages for the last
15 Alarms experienced by the machine. It also gives access to
displaying the machine operating conditions that existed at the
time of each Alarm. The first one shown, “Alarm History 1”, was
the most recent Alarm to occur. Note that multiple, consecutive
EMERGENCY STOP Alarms are not recorded as separate Alarms, only
the first one will be shown.
100
PSI
−ALARM HISTORY−
READY TO START
STATUS
ALARM HISTORY 1
BLOWER MOTOR
OVERLOAD
ALARM HISTORY 2
HIGH AIREND DISCH
TEMP
MAIN MENU
Each of the last 15 Alarm messages can be seen by moving the
Alarm History list up and down using the arrow buttons. Pressing
the SELECT button when one of the Alarms is highlighted will
display the list of machine values that existed at the time that
particular Alarm occurred.
The name and value of each of the items can be seen by moving the
list up and down using the arrow buttons. Pressing the ALARM HIST.
button will return the display to the ALARM HISTORY screen.
Alarm histories can be exited by pressing either the STATUS or MAIN
MENU buttons. If no buttons are pressed within 30 seconds, the
display will return to the CURRENT STATUS screen.
SELECT
9.10 CLOCK FUNCTIONS
100
PSI
−CLOCK FUNCTIONS−
READY TO START
Time
01:15
Date
Jan 01, 00
STATUS
MAIN MENU
SELECT
The date and time for the real time clock is set through the CLOCK
FUNCTIONS screen. Use the up and down arrows to highlight either
TIME or DATE. Select the highlighted setting by pressing SELECT.
If TIME is selected, first the hours will be highlighted. Adjust the
hours (00−23 hour clock) by using the up and down arrows. Once
the correct time is in the display, press SET to highlight the minutes.
Adjust the minutes (00−59) and then press SET to complete setting
the time.
If DATE is selected, first the month will be highlighted. Adjust the
month by using the up and down arrows and then press SET to
highlight the date. Once the correct date is displayed, press SET to
highlight the year. Once the correct year is displayed, press SET to
complete setting the date.
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9.0 OPERATING INSTRUCTIONS
9.11 ENERGY STATUS MESSAGES
100
PSI
−ENERGY STATUS−
READY TO START
AVERAGE PACKAGE kW
HRS
AVERAGE % CAPACITY−
−AVERAGE CAPACITY
STATUS
MAIN MENU
SELECT
The Energy Status display can be selected by pressing the ENERGY
STATUS button. The following items and their present values will
be displayed on the right side of the screen by pressing the up and
down arrows.
AVERAGE PACKAGE kW HOURS − This displays the average
package kW per hour for the time period that was started by
selecting the reset averaging setpoint. This value includes the
blower power usage.
AVERAGE CAPACITY − Displays the compressor’s average capacity
in cfm or m3 for the time period that was started by selecting the
reset averaging setpoint.
ENERGY COST − Displays the energy cost of the compressor for
the time period that was started by selecting the reset averaging
setpoint. This is calculated by multiplying the kW hours of the motor
and the blower by the energy rate.
ENERGY SAVINGS − Displays the energy savings of the compressor
for the time period that was started by selecting the reset averaging
setpoint as compared to a conventional compressor. This value is
determined by calculating how much a conventional compressor
motor would cost to operate at the same average capacity and then
subtracting the motor energy cost of the Nirvana compressor from
it. It is assumed that the blower cost is the same in both packages.
LIFETIME ENERGY SAVINGS − Displays the lifetime energy savings
of the compressor at the existing energy rate and at the average
percent capacity as compared to a conventional compressor.
AVERAGE % CAPACITY − Displays the compressor’s average
percent capacity for the time period that was started by selecting
the reset averaging setpoint. The value is determined by taking the
average package kW per hour, removing the blower power usage
and then dividing that number by the motor kW per hour for that
size of compressor at 100% capacity.
76
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9.0 OPERATING INSTRUCTIONS
9.12 WARNINGS
When a WARNING occurs, a large question mark will flash on the
display screen.
CHANGE INLET FILTER − This will occur if the Inlet Vacuum is
greater than 0.05 bar (0.7 psig).
If multiple WARNINGS exist, the small up/down arrows will appear
in the upper right corner of the display screen. The multiple
WARNINGS can be seen by pressing the up and down arrow
buttons. Pressing the STATUS button will display the CURRENT
STATUS screen with the WARNING button indicating that a
WARNING still exists.
CHANGE SEPR ELEMENT − This will occur if the pressure
differential across the separator is 1.0 bar (12 psig).
A WARNING will not cause the unit to shut down. The unit will
continue to run in its normal operation and the WARNING will
remain displayed until reset.
A Warning needs to be reset by the operator by pressing the RESET
button twice.
The possible Warning messages are as follows;
HIGH AIREND DISCHARGE TEMP − This will occur if the Airend
Discharge exceeds 97% of the alarm limit, 109° C (228° F) and is not
adjustable.
SENSOR FAILURE − This will occur if a sensor is recognized as
missing or broken.
HIGH DISCHARGE PRESS − Will occur if the unit is under the
control of an external device, such as an ISC, and the discharge
pressure is greater than the immediate stop pressure.
AUXILIARY WARNING 1 or 2 − Will occur if the auxiliary warning
input closes.
REMOTE PRESSURE SENSOR FAILURE (option) − This will occur
if the remote pressure sensor fails. If this happens, the lntellisys
will start using the package discharge pressure sensor to measure
system pressure.
CONDENSATE DRAIN ERROR − On 2 stage units, this will occur if
the condensate drain error contacts close while the unit is running.
CHANGE COOLANT FILTER − This warning will occur if the high
side pressure is 1.4 bar (20 psig) greater than the low side pressure.
9.13 SERVICE WARNINGS
SERVICE − Service warnings occur when the unit has operated a
certain number of hours, based on the total hours, or has operated
for a certain number of months, based on the real time clock.
Service warnings can have multiple levels, depending on the service
level selection.
This will be set prior to the compressor being shipped from the
factory. When a service warning occurs, contact your local IR service
representative.
9.14 INITIAL CHECK ALARMS:
The following alarms will only occur when the machine is not
running. These alarms are related to high temperature, power loss,
and sensor calibration. They will have the same display mode as
other alarms.
HIGH AIREND DISCH TEMP− Will occur if airend discharge
temperature is greater than 95% of 109° C (228° F).
CHECK SETPOINTS − Will occur if the controller has determined
that some of the data stored in memory contains unacceptable
values.
INVALID CALIBRATION − Will occur if the sensor zero value is
−10% to +1% of its scale. See Sensor Calibration.
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9.0 OPERATING INSTRUCTIONS
9.15 ALARMS
When an Alarm occurs, a large exclamation mark in a triangle will
flash on the display screen. The display message will indicate what
caused the Alarm.
The compressor will stop and cannot be re−started again until the
alarm condition no longer exists and the alarm message reset.
Pressing the STATUS button will display the STATUS screen. The
presence of the ALARM button indicates that an Alarm condition
still exists. Alarm Status is the list of machine operating conditions
that existed at the time of the Alarm.
The name and value of each of the items listed can be seen by
moving the list up and down using the arrow buttons. Pressing the
ALARM button will return the display to the Alarm screen and the
RESET button.
The Alarm needs to be reset by the operator by pressing the RESET
button twice. Any exceptions to this are explained in the alarm
descriptions.
100
PSI
−ALARM STATUS−
STOPPED BY
ALARM
PACKAGE DISCH
PRESSURE
100 psi
PACKAGE DISCHARGE
TEMP
103° F
ALARM
MAIN MENU
The possible Alarm messages are as follows;
EMERGENCY STOP− This will occur if the Emergency Stop button is
engaged. The button must be disengaged before the alarm can be
cleared.
BLOWER FAULT− This will occur if a blower fault is sensed.
HIGH AIREND DISCH TEMP− This will occur if the airend discharge
temperature is greater than 109° C (228° F).
REMOTE START FAILURE− This will occur if the Remote Start
button is pressed after the machine is running or if the Remote Start
button remains closed.
REMOTE STOP FAILURE− This will occur if the Remote Stop button
remains open and either Start button is pressed.
CONTROL POWER LOSS − This will occur if the control circuit is
broken by a bad connection or safety switch (e.g. HAT Switch/ Phase
Monitor). Any fall of voltage below 100VAC for more than 2 seconds
will cause this alarm trip.
STOP FAILURE − This will occur if the compressor should be
stopped but the motor is still running above minimum speed 4
seconds after the stop signal is given.
HIGH START PRESSURE − If the sump pressure is above 100 psi
(6.9 bar) when the compressor starts, the Intellisys will open the
blowdown valve during the first few seconds of starting (3 to 7
seconds). If the sump pressure does not fall to 100 psi (6.9 bar)
during that time period, this shutdown will occur.
CHECK MOTOR ROTATION − This will occur if the Intellisys reads a
negative speed from the VSD when starting .
VSD COMMUNICATION FAILURE − This will occur if the Intellisys
does not receive a response from the VSD when requesting
information. This alarm will take about 8 seconds to occur.
VSD INITIALIZATION FAULT − Will occur if the Intellisys is unable to
establish communications with the VSD after a power up.
LOW SUMP PRESSURE − Will occur if the compressor is operating
at or above the minimum speed and the sump pressure drops
below 15psi (1.03 bar) for 15 seconds.
REPLACE COOLANT FILTER − This will occur if the coolant filter is
blocked and requires changing.
INCORRECT VSD TYPE − Will occur at power up if the VSD type
does not match the size of the compressor
125HP (90kW) machines and above also have the following alarm
messages;
CONTROL POWER LOSS − This will occur if the compressor should
be running and the AC input voltage, as read from the VSD, falls
below 100 VAC. There is a delay of 2 seconds on this alarm in case
the power quickly returns. An open HAT switch or phase monitor are
two things that can cause this alarm.
STOP FAILURE − This will occur if the compressor should be
stopped, but the motor speed has not dropped below the minimum
motor speed setpoint. The Intellisys will wait 4 seconds for the
compressor to stop before issuing this alarm.
HIGH INTERSTAGE PRESSURE − If the interstage pressure is over
100psi while the unit is running and the unit is a 2−stage.
SENSOR FAILURE − This will occur if a sensor is recognized as
missing or broken.
VSD FAULT − The VSD fault is read from the drive. The Intellisys will
read the status menu of the variable speed drive. If a fault condition
is returned in the status information, the Intellisys will issue a VSD
FAULT alarm and display the number of the fault condition.
78
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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 operating instructions.
The customer can only reset the warning for 24 hours by
pressing the “set” button.
The service warning will return each subsequent 2000
hours.
The machine will be master reset after service work
conducted prior to the 2000 hour interval to prevent false
indication.
IR service engineers will master reset the warning after
completing the service work.
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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 service interval is stated in both hours and months, it is the sooner of the two intervals that must be adhered
to. Coolant capacities etc can be found in the GENERAL INFORMATION section of this manual. Note that any Local or
National codes that require specific maintenance that exceeds the requirements of this section must be adhered to.
Maintenance Schedule
Hours:
150
(1st time
only)
™
500
1000
2000
6000
4000
12000
1500
2500
3000
10000
14000
18000
20000
Change
Change
Change
Air filter **
Check
pressure
Change
Change
Separator element ***
Check
pressure
Change
Change
Sample
Sample
Change
Change
Change
Change
Check /
clean
Check /
clean
Check /
clean
Check /
clean
Check /
clean
Check
Check
Check
Check
Check
Check
Daily
Coolant filter
Change
ULTRA COOLANT*
Check
Power Drive Module filter *
Check
Scavenge screen **
Hoses ***
High Air Temperature sensor
Check
Pressure relief valve
8000
16000
Cooler Core(s)
Check /
clean
Check /
clean
Check /
clean
Check /
clean
Moisture separator
Check /
clean
Check /
clean
Check /
clean
Check /
clean
Motor cowl
Check /
clean
Check /
clean
Check /
clean
Check /
clean
Vibration Analysis
Analysis
Analysis
Analysis
Coolant Analysis
Analysis
Analysis
Analysis
Regrease
Regrease
Food Grade Coolant *
Analysis at every 500
Change at every 1000
Blower Motor / Fan Motor
If the compressor is run less than 4,000 hours per year,
HPM 250L motor Regrease at 2000hrs and 4000hrs N250/300H-2S only
* Maintain every 6 months
** Maintain every year
*** Maintain every 2 years
80
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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 bonnets of the coolers. These sacrificial zinc anodes should be checked after the first 50 hours of
operation to determine if corrosive conditions exist. If satisfactory this interval may be extended to 500 hours.
NOTE:
1. If sacrificial zinc anode is 50% corroded it should be replaced.
2. Coastal/harbor waters can contain corrosive chemicals from pollution and may reduce anode/cooler life.
3. Effects of corrosion or erosion are specifically excluded from warranty considerations.
10.3 MAINTENANCE PROCEDURES
caution
Before beginning any work on the compressor, read and understand the safety instructions earlier on in this
manual. Open, lock and tag the main electrical disconnect and close the isolation valve on the compressor
discharge. Do not under any circumstances open any drain valve or remove components from the compressor until this has been carried out. Ensure that all pressure has been vented from the compressor. Verify this
by slowly unscrewing the coolant fill cap one turn. Unscrewing the fill cap opens a vent hole, drilled in the
cap, allowing pressure to release to atmosphere. Do not remove the fill cap until all pressure has vented from
the unit. Note that pipework downstream of the separator tank may still contain pressure that must also be
vented to atmosphere before beginning any work.
caution
When using any form of liquid for cleaning, ensure that all electrical components are protected or
covered to prevent ingress of liquid.
warning
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the
internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any
work on the drive unless trained. There are no user serviceable items behind the cover.
danger
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the
internal capacitors store a potentially lethal high voltage electric charge which gradually falls to zero over
time. After switching off the machine at its local isolator WAIT AT LEAST 15 MINUTES for the capacitors to fully
discharge before opening the power drive module doors.
warning
The compressor can operate in a pressurised shutdown mode. If the compressor stops automatically, the
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through
which any residual pressure will be vented. Downstream of the separator tank may still contain system pressure which must also be vented.
warning
Use suitable equipment for lifting heavy items and ensure loose components are adequately supported to
eliminate risk of dropping.
warning
The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such
as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with
cardiac pacemakers, defibrillators or other implanted electronic medical device.
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10.0 MAINTENANCE
Compressed air can be dangerous if incorrectly handled.
Before doing any work on the unit, ensure that all
pressure is vented from the system and that the machine
cannot be started accidentally.
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance
Manuals.
Prior to attempting any maintenance work, ensure
that:−
• all air pressure is fully discharged and isolated from the
system. If the automatic blowdown valve is used for
this purpose, then allow enough time for it to complete
the operation.
• the machine cannot be started accidentally or
otherwise, by posting warning signs and/or fitting
appropriate anti−start devices.
• all residual electrical power sources (mains and battery)
are isolated.
Prior to opening or removing panels or covers to work
inside a machine, ensure that:−
• anyone entering the machine is aware of the reduced
level of protection and the additional hazards,
including hot surfaces and intermittently moving parts.
• the machine cannot be started accidentally or
otherwise, by posting warning signs and/or fitting
appropriate anti−start devices.
82
Prior to attempting any maintenance work on a
running machine, ensure that:−
• the work carried out is limited to only those tasks
which require the machine to run.
• the work carried out with safety protection devices
disabled or removed is limited to only those tasks
which require the machine to be running with safety
protection devices disabled or removed.
• all hazards present are known (e.g. pressurized
components, electrically live components, removed
panels, covers and guards, extreme temperatures,
inflow and outflow of air, intermittently moving parts,
safety valve discharge etc.).
• appropriate personal protective equipment is worn.
• loose clothing, jewelry, long hair etc. is made safe.
• warning signs indicating that Maintenance Work is in
Progress are posted in a position that can be clearly
seen.
Upon completion of maintenance tasks and prior to
returning the machine into service, ensure that:−
•
•
•
•
the machine is suitably tested.
all guards and safety protection devices are refitted.
all panels are replaced, canopy and doors closed.
hazardous materials are effectively contained and
disposed of.
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10.0 MAINTENANCE
10.4 ROUTINE MAINTENANCE
This section refers to the various components which
require periodic maintenance and replacement.
For all other maintenance, contact your local Ingersoll
Rand office, Distributor or Air Center.
Refer to safety information and maintenance procedures
prior to carrying out any of the maintenance in the
following sections.
Prior to starting
danger
Under no circumstance should the compressor be
operated with the coolant fill plug removed.
Coolant change procedure
warning
The coolant filter and coolant may be hot!
Coolant level checking procedure
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 is running on load, coolant should
always be visible in the sight glass. The normal position is
half way.
Stop the machine and ensure coolant is still visible in the
sight glass.
Adding coolant
Run the compressor for a minimum of 40 seconds, the
coolant level should be visible in the sight glass. If not,
stop the compressor, depressurize by isolating the
compressor from the system, pressing the emergency
stop to vent the separator tank & airend & then slowly
unscrew the coolant fill plug to verify all pressure has
been released and add coolant. Replace the coolant fill
plug, restart the compressor and recheck the coolant
level. Repeat until the coolant level is visible in the sight
glass with the compressor both running and stopped.
Do not add coolant through the intake of the compressor,
as this can result in overfilling, saturation of the separator
filter element, and coolant carry−over downstream.
The compressor features a ’no drip’ coolant drain feature
which requires no special tools and minimizes the risk of
coolant spillage.
It is better to drain the coolant immediately after the
compressor has been operating as the liquid will drain
faster and any contaminant will still be in suspension
• Remove the cap from the drain valve located at the
front of the separator vessel.
• Place a suitable container close to the drain valve.
• Screw the coolant drain hose onto the drain valve.
As the threads engage, the valve will automatically
open and the coolant will drain.
• Remove the drain hose. The valve will automatically
close and seal.
• Replace the cap on the drain valve.
• For a complete drain, remove the plug near the
vessel inlet flange and replace when complete.
• Replace the coolant filter element.
• Refill with correct quantity of coolant.
See 8.0 General Information.
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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 assembly in
end of drain valve and place end of hose in a suitable
pan.
• Open drain valve to start drainage.
• After draining is complete, close valve, remove hose
an fitting assembly from valve, and store in a suitable
location for future use.
• Replace plug in end of drain valve.
• Do not store drain hose in starter box after it has
been used to drain the separator tank.
Coolant fill quantity
250−300 hp − 2 stage
40.0 gallons (152 liters)
Coolant filter change procedure
• Loosen filter element with the correct tool.
• Remove the element from the housing.
• Place the old element in a sealed bag and dispose of
in a safe way.
• Clean the mating face of the housing.
• Remove the new Ingersoll Rand replacement
element from its protective package.
• Apply a small amount of coolant to the element seal.
• Screw the new element down until the seal makes
contact with the housing, then hand tighten a
further half turn.
• Start the compressor and check for leaks and check
the coolant level.
Separator element checking procedure
With the compressor running on load, check the
separator differential pressure via the Intellisys controller.
It will be necessary to change the element if the
differential pressure equals zero or exceeds 1 bar
(12 psig).
Separator element change procedure
COOLANT DRAIN
caution
Do not mix coolant types. Use only coolant specified
by IR
• Start the compressor and check for leaks.
• Check the coolant level, refilling if necessary.
• Dispose of waste coolant in accordance with local
and governmental regulations.
NOTICE
Shorter coolant drain intervals may be necessary if
the compressor is operated in adverse conditions.
Food Grade Coolant option
• SSR Food Grade Coolant is a polyalphaolefin base
coolant. Change after 1000 hours or every 6 months
whichever comes first. Do not operate unit past this
1000 hour change interval, as coolant degradation
will occur.
84
• Remove all the capscrews securing the cover to the
tank except the screw opposite the pivot bolt which
should be left engaged by 2−3 threads with at least
6.5mm (0.25”) clearance from the screw head to the
lid. Rotate the jacking bolt clockwise until the cover
lifts off the tank at least 2mm (0.08”) all the way
around the tank. The cover can now be rotated to
allow access to inside the tank.
• Carefully lift out the element spacer and retain for
reassembly. Do not damage the flat surfaces of the
spacer as this may cause higher oil carryover or leaks.
A hoist is available for 175HP (90kW) machines and
above if required.
• Carefully withdraw the used element, place it in a
sealed bag and dispose of it safely.
• Remove the O−rings from the top of the tank, the
separator element sealing face and the scavenge
tube sealing face.
• Clean the surfaces on both the tank and the cover.
• Install new O−rings
• Install replacement element remembering to fit the
small O−ring on the scavenge tube and positioning
the tube into the matching hole in the Separator
Tank
• Re−fit the separator element spacer with the notch
over the scavenge tube.
• Rotate the tank cover back into position taking care
not to damage the O−ring, and locate the cover
using 2 capscrews but do not tighten down.
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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 into
the tank and withdraw the tube assembly
• Disconnect the piping from the tank cover. Tag the
lines if required.
• Use a suitable wrench and remove the bolts that
hold the tank cover in position. Remove cover by
lifting up and away.
• Carefully lift the separator element up and out of the
tank. Discard the faulty element.
• Clean the gasket surface on both the tank and its
cover. Exercise care to prevent pieces of the old
gasket from falling down into the tank.
• Check the tank to be absolutely certain that no
foreign objects such as rags or tools have been
allowed to fall into the tank. Install replacement
element down into the tank after checking the new
element gaskets for possible damage. Center the
element up within the tank.
• Place the tank cover in its correct position and
install bolts. Tighten the bolts in a cross−pattern to
prevent over−tightening one side of the cover. An
improperly tightened cover will likely result in a leak.
• Tank cover bolt torque values
250−300 HP
3/4−10 UNC
210ft−lb. (285 n−M)
• Inspect tank scavenge screen and orifice. Clean if
necessary following instructions in Section 4.7.
• Install scavenge tube down into the tank until the
tube just touches the separator element and then
raise it 1/8inch (3.2 mm). Tighten fittings.
• Install the regulation lines in their original position.
• Start unit, check for leaks, place in service.
RECOMMENDED BOLT TIGHTENING
CROSS PATTERN
The main body is made from 1/2 inch hexagon
shaped steel and the diameter of the orifice and a
direction−of−flow arrow is stamped in flat areas of the
hexagon.
A removeable screen and orifice is located in the exit end
of the assembly. (see figure) and will require clearing as
outlined in the Maintenance Schedule Section 10.2.
To remove the screen/orifice, disconnect the scavenge
line tubing from each end. Hold the center section firmly
and use a pair of pliers to gently grasp the exit end of
the assembly that seals against the scavenge line tubing.
Pull the end out of the center section while using care to
prevent damage to the screen or sealing surfaces.
Clean and inspect all parts prior to reinstallation.
When the assembly is installed, confirm the direction of
flow to be correct. Observe the small arrow stamped in
the center section and ensure the direction flow to be
from the separator tank to the airend.
SCREW HOUSING
O−RING
SCREEN
ORIFICE
SEPARATOR TANK SCAVENGE SCREEN/ORIFICE
warning
Unscrew the jacking bolt sufficiently to ensure that
the cover can be fully tightened down without imparting any stress onto the jacking points. Tighten
down the cover setscrews.
• Start the compressor and check for leaks and
coolant level.
caution
Do not use any form of sealant on either the separator tank or the separator tank cover faces.
Separator tank / Pressure system
250 − 300 HP
Scavenge screen clean/check procedure
The screen/orifice assemblies are similar in appearance to
a straight tubing connector and will be located between
two pieces of 1/4 inch O.D. scavenge line tubing.
At 2000 hour intervals, inspect the external surfaces of
the airend and separator tank, including all fittings, for
visible signs of impact damage, excessive corrosion and
abrasions. When changing the separator element inspect
the internal components and surfaces. Any suspect parts
should be replaced before the compressor is put back
into service.
The separator tank should also be tested and inspected
in accordance with any national or local codes that may
exist.
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10.0 MAINTENANCE
Blower motor Re−Grease
(N75−160 Aircooled units)
6 Months or 4000 Hrs
Apply high melting point grease into the blower motor
drive end bearing using a grease gun at the nipple
provided.
Stop when excess grease is seen at the relief port.
Main motor Re−Grease instructions
HPM 250L motor Re-Grease (N250/300N-2S units only)
Every 2000 hours
Apply Exxon Polyrex - EM or Mobilith - CHC 220 grease
into main motor drive end and non-drive end bearings
using a grease gun at the nipple provided.
Drive end and non-drive end grease quantity 75 grams.
Stop when excess grease is seen at the relief port.
Coolant hoses
• The flexible hoses that carry coolant through the
cooling system may become brittle with age and
will require replacement. Have your local Ingersoll
Rand Distributor or Air Center inspect them every 3
months and replace them as needed or every 2 years.
• Depending on the location of the hose, it may
contain compressor coolant. It is recommended to
drain the coolant into a clean container. Cover the
container to prevent contamination. If the coolant
is contaminated, a new charge of coolant must be
used.
• Remove the hose.
• Install the new hose and refill the unit with coolant.
Start the compressor, check for leaks and check
coolant level. Refill as necessary
Pressure relief valve check
The pressure relief valve must be frequently tested
and regularly maintained. Remove from the machine
and check for the correct operating pressure. Adjust as
necessary. If operating conditions are particularly severe,
the frequency of testing and maintenance must be
increased accordingly. A pressure relief valve check must
also be performed at the end of any non−service period.
The user must establish the frequency of such tests as it is
influenced by such factors as the severity of the operating
environment.
caution
High pressure air will discharge through the discharge ports of the valve during pressure relief
valve check. Wear ample clothing, gloves, safety
glasses and ear protection during valve testing.
Run the compressor for about 10 minutes by venting
air from the system to let the unit warm up. With the
unit running, test at or near the maximum operating
pressure by opening the valve for the minimum period
required to flush the valve seat free of debris. This can
be accomplished by holding the test lever fully open or
unscrewing the spring pressure retaining cap, depending
on the type of valve installed. If there is no evidence of
discharge or the valve does not fully close, discontinue
use of equipment and contact a licensed contractor or
qualified service personnel.
The pressure relief valve should also be tested and
re−calibrated in accordance with any national or local
codes that may exist. If no code exists, IR recommend that
the pressure relief valve is recalibrated at intervals of one
year.
Air filter change procedure
• Unclip the retaining cap and withdraw the old
element.
• Fit the new element and refit the retaining cap.
Air filter change procedure N250/300H−2S
• Loosen wing nut on top of inlet filter housing. Lift
cover up and away to expose elements.
• Carefully remove the old element to prevent dirt
from entering the the compressor inlet.
• Thoroughly clean the element housing and wipe all
surfaces
• Install new element and inspect to ensure that they
have seated properly.
• Install top of inlet filter housing.
• Inspect the rubber seal on the retainer wing nut and
replace seal if required.
• Tighten wing nuts.
Aircooled Cooler Cleaning
Ensure that the compressor is isolated from the
compressed air system and is vented of all pressure. When
undertaking any work on the compressor always use
certified lifting equipment and employ sound working
principles.
Ensure that the main power disconnect switch is locked
off and tagged.
Visually check the outside of the cooler cores to be
certain that a complete cleaning of the cooler is required.
Frequently, dirt, dust or other foreign material may
only need to be removed with a vacuum to remedy the
problem.
When the cooler is covered with a combination of oil,
grease or other heavy substances that may affect the
unit’s cooling, then it is recommended that the cooler
cores be thoroughly cleaned on the outside.
If it is determined that the compressor operating
temperature is higher than normal due to the external
passages between the fins of the cooler cores being
restricted with deposits of foreign material, then the
cooler should be removed for cleaning.
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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 lower rear fixed panel and
remove panel.
• Remove 10 screws from the rear intake panel and
remove panel.
• Loosen clamp and disconnect the air inlet hose from
the intake plenum.
• Remove intake plenum. Note, plenum is
unsupported, before removing the 8 screws from
the intake plenum, block underside of plenum
prior to removing screws to prevent plenum from
falling.
• Remove hose from elbow in aftercooler inlet. Plug
elbow in inlet hole of aftercooler.
• Unscrew the fitting connecting the aftercooler to the
discharge tube.
• Loosen mounting bolts on moisture separator to
allow moisture separator to slide down in mounting
bracket. Once lowered, remove the discharge tube
connecting the moisture separator to the aftercooler
outlet.
• Plug aftercooler discharge hole.
• To tilt cooler forward, remove 6 screws holding the
cooler in place. While removing the last screw,
hold the top of the cooler in place to prevent the
cooler from tilting. Once the screw is removed,
allow the cooler to tilt forward until the pivot
brackets touch the pivot stops. The cooler will stop
tilting at 45 degrees.
• Cover the main drive motor with plastic sheeting to
prevent cleaning solution from entering the motor.
• Before cleaning coolers, check to ensure aftercooler
intake and discharge holes are plugged to prevent
contamination of compressor system. Clean coolers
with a mild cleaning solution.
warning
Strong cleaners can harm aluminium cooler parts.
Follow cleaner manufacturers instructions for use.
Wear appropriate safety equipment.
• After cleaning is complete, reassemble in reverse
order.
N125/200H (N90/160K) SINGLE STAGE and N100/200H
(N75K−160K) TWO STAGE
The coolers in these machines can either be cleaned by
removing the complete cooler for off site cleaning or
’back flushing’ in place using a high pressure hose and
gaining access through the holes in the intermediate
plenum.
Instructions for cleaning the coolers while installed in
the compressor.
While cleaning coolers, great care must be taken to
protect the rest of the machine from moisture and
contamination by covering sensitive parts with plastic
sheeting.
• Remove 4 screws from enclosure panel below
moisture separator and remove panel.
• Remove 4 screws from enclosure panel above
moisture separator and remove panel.
• Remove the 16 screws securing the access panels on
the cooling plenum and remove covers.
• Cover main drive motor, PDM Heat sink blower
motor, drain valve, and cooling motor variable speed
drive with plastic sheeting to prevent damage from
entrance of cleaning solution.
• Cover inlet of blower wheel with plastic sheeting to
prevent entrance of cleaning fluid.
• Cover the inlet grill of the intake panel with plastic
sheeting to prevent cleaning solution from exiting
the compressor.
• Attach drain hose to the coupling on the bottom of
the plenum to allow the cleaning solution to drain
outside the compressor. Alternately, place large
bucket underneath plenum to collect cleaning fluid.
• Use an extended length nozzle and a mild cleaning
solution to clean the coolers.
warning
Strong cleaners can harm aluminium cooler parts.
Follow cleaner manufacturers instructions for use.
Wear appropriate safety equipment.
• Cleaning fluid will collect on both sides of the cooler
core. If required, periodically drain fluid from intake
plenum and bucket to prevent them from over
flowing.
• After cleaning is complete, dry off plenum, intake,
and cooler core. Reassemble parts in reverse order.
If the cooler cores are unable to be cleaned while installed in the compressor, remove cooler as follows:
• Remove 5 screws from panel below the intake panel
and remove panel. Be careful not to damage the
electrical leads entering the panel.
• Remove 8 screws from the intake panel and remove
panel.
• Remove 8 screws from the intake plenum supports
and remove the supports.
• Remove the 10 screws securing the intake plenum
and remove the plenum
• Disconnect both oil lines and both air lines from the
cooler. Plug all 4 inlets to prevent cleaning fluid from
entering the cooler cores.
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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 side of cooler.
• With the weight of the cooler supported by the
lifting device, remove the 10 screws securing the
cooler and remove the cooler.
• Clean coolers with a mild cleaning solution.
warning
Strong cleaners can harm aluminium cooler parts.
Follow cleaner manufacturers instructions for use.
Wear appropriate safety equipment.
• After cleaning is complete, reassemble in reverse
order.
N250/300H−TWO STAGE
COOLANT COOLERS
• Following are instructions for removal and internal
cleaning of coolant coolers.
• Remove panels and top cover.
• Drain the coolant. See Section 4.6.
• Remove side panels from coolant cooler box.
• Disconnect piping from coolant cooler inlet and
outlet ports.
• Plug cooler inlet and outlet ports to prevent possible
contamination.
• Remove coolant cooler holding screws from sides of
coolant cooler and remove cooler through side of
cooler shroud.
• It is recommended the cooler be taken to a
professional cooler service shop for flushing with an
appropriate environmentally safe cleaning agent.
• Reassemble in reverse order.
• Make sure fan guards are replaced.
• Refill the compressor with coolant. If con tamination
is suspected, replace with new coolant.
• Replace fill plug.
• Run compressor for ten minutes. Check for possible
leaks. Check coolant level.
• Replace enclosure panels.
warning
Strong cleaners can harm aluminum cooler parts.
Follow cleaner manufacturer‘s instructions for use.
Wear appropriate safety equipment.
AFTERCOOLER
• Following are instructions for the removal and
internal cleaning of aftercoolers.
88
• Disconnect hose from aftercooler inlet flange.
• Disconnect tube from aftercooler outlet flange.
• Remove aftercooler holding screws from aftercooler
support and remove cooler.
• It is recommended the cooler be taken to a
professional cooler service shop for flushing with an
appropriate environmentally safe cleaning agent.
• Reassemble in reverse order.
• Replace enclosure panels.
Watercooled Cooler Cleaning
A periodic inspection and maintenance program should
be implemented for watercooled heat exchangers. The
following steps should be taken:
• Inspect filters in system and replace or clean as
required.
• Carefully examine cooler tubes for scale and clean if
necessary. If a cleaning solution is used, be sure to
wash out all chemicals thoroughly with clean water
before returning the compressor to service. After
cleaning, examine the cooler for erosion or corrosion.
• The internal cooler tubes can be cleaned by several
methods. Flushing a high velocity stream of water
through the tubes will remove many forms of
deposits. More severe deposits may require running
wire brushes or rods through the tubes. Also, rubber
plugs can be forced through the tubes if a special air
or water gun is available for this procedure.
• A qualified cleaning service should be used for the
cleaning process. These organizations can evaluate
the type of deposit to be removed and supply the
appropriate solution and method for a complete
cleaning job.
• When reinstalling bonnets to cooler shell, tighten
bolts uniformly in a cross−pattern. Overtightening
can result in cracking of the bonnet.
• Cleaning solutions must be compatible with the
metallurgy of the cooler
• Care must be taken to avoid damaging tubes if
mechanical cleaning procedures are used.
Airend bearings
Airend bearings are lubricated by the compressor coolant
and require no maintenance.
High Airend Temperature Sensor checking procedure
It is recommended that the discharge temperature sensor
(2ATT) is checked regularly as follows:
Aircooled machines
Stop the cooling blower by opening the blower / fan motor circuit breaker.
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10.0 MAINTENANCE
Watercooled machines
Shut off the cooling water.
The machine should trip at 109° C (228° F).
caution
Under no circumstances should these discharge
temperatures be exceeded. If the machine fails to
trip A FAULT EXISTS. Investigate immediately.
Separator tank scavenge check valve/orifice
• Disconnect tubing at each end of check valve/
screen/ orifice assembly.
• Check orifice and clean if required. Use suitable tool
and remove orifice from its housing. Be careful not to
damage flared end of fitting or O−ring.Wash housing
in safety solvent and blow dry.
• Press the check valve/orifice into fitting block.
• Assemble the check valve/orifice assembly to the
tubing lines.The fitting must be re−installed with the
check valve on the upstream side of the orifice as
indicated by the flow arrow.
Blower / fan Motor Bearing Maintenance
(Stored units)
• Prior to placing a unit in storage for extended
intervals, rotate the blower motor several revolutions
by hand in the direction of rotation.
• On N75 − 160, N250 − 300H aircooled units, whilst
rotating the motor, pump grease into the bearing
until grease is seen at the relief port.
• Thereafter rotate the motor as described above
every three months until such time as the unit is
placed in service.
• If the storage time is to exceed a total of nine (9)
months duration, the compressor must be ordered
for long term storage.
Motor cowl cleaning N75−160 units only
• Remove the filter pad from the housing and replace
with a new filter pad from Ingersoll Rand.
• Replace front grill to the drive box filter.
Moisture Separator Check / Cleaning
• Ensure compressor is electrically isolated for at least
15 minutes, before commencing any maintenance
work.
• Isolate the compressor from the system and fully
discharge the compressed air within the unit.
• Remove plastic tube from the fitting located on the
bottom of the moisture separator.
• Remove the bowl of the moisture trap, clean and
replace.
Condensate (Moisture) Drain Valve / Trap
• Ensure compressor is electrically isolated for 15
minutes and all pressure is relieved from system.
• Remove all pipes going to and from the valve (or
trap).
• Disconnect any electrical cables to the valve (or trap).
• Determine the type of condensate drain device and
continue in the appropriate section below:−
Timed Solenoid Drain Valves (where fitted) Check /
Cleaning
• Remove the central nut and then the electrical coil.
• Remove screws holding bonnet of valve and carefully
split the valve. Clean and inspect all internal parts.
• Similarly check and clean the ball valve and needle
valve.
• Replace any defective parts as identified in parts
manual.
• Re−assemble and later, with machine running, check
that condensate and air is expelled at frequency
and duration set into the INTELLISYS controller (see
section 9.6).
• Ensure compressor is electrically isolated for at least
15 minutes before commencing any maintenance
work.
• Remove panels from the compressor.
• Using a clean dry cloth, remove dust from the
surface of the motor cowl and ensure all ventilation
slots are free of obstructions.
• Replace panels to the compressor.
Drive Box Filter Removal / Replacement
• Ensure compressor is electrically isolated for at least
15 minutes before commencing any maintenance
work.
• Unclip the front grill of the drive box filter.
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10.0 MAINTENANCE
No Loss Drain Trap (where fitted) Check / Cleaning
Coolant Sampling Procedure
• Remove the four socket head screws then carefully
split the trap. Clean and inspect all internal parts
with particular attention to the water level sensor(s).
• If the stainless steel strainer mesh is blocked, remove
it and clean in a weak detergent solution.
• Replace any defective parts (see parts manual for
repair kit).
• Re−assemble and later, with machine running, check
that condensate is expelled at regular period and no
alarms are signaled on trap or on INTELLISYS display.
Fluid and Vibration Monitoring
Bring unit up to operating temperature. Draw sample,
using pump kit, from separator tank port. DO NOT draw
sample from drain port or oil filter. Use a new hose on
pump for each sample, failure to do this can give false
readings.
Ingersoll Rand recommends incorporating predictive
maintenance, specifically the use of coolant and vibration
analysis, into all Preventative Maintenance programs.
Predictive Maintenance is designed to increase system
reliability and prevent costly downtime. Through the
use of sophisticated diagnostic tools, including fluid,
vibration, and optional air analysis, IR Certified Service
Technicians can identify and correct potential problems
BEFORE they can cause expensive unscheduled
downtime.
How does predictive analysis work? By establishing an
initial baseline for normal operation, and then regularly
monitoring fluid and vibration conditions, any sudden
deviation or significant increase from this baseline can
be identified and investigated to pinpoint the cause.
More quickly diagnosing potential problems can directly
save money by preventing costly failures and reducing
or eliminating downtime. In addition, regular condition
monitoring also helps to maximize the time between
expensive preventative maintenance intervals, such as
component rebuilds and coolant changes.
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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 personnel and that the safety and maintenance sections of this manual have been read and are fully understood and
followed. Major overhauls should only be carried out by a qualified Ingersoll Rand representative. Failures
caused by fitting parts not recommended by Ingersoll Rand or non−authorized Ingersoll Rand personnel may
not be covered by the terms of any warranty agreement
SYMPTOM
FAULT
REMEDY
Compressor will not
start
No power supply to package
Check supply is switched on. If so, contact a
qualified electrician.
Compressor stops and
will not restart
Intellisys controller failure
Check supply to unit. Replace unit.
Starter failure
Isolate supply, lock off and tag. Replace
failed
component or contact your local
Ingersoll Rand representative
Drive controller has tripped
See section 11.2 & 11.3
Intellisys controller has tripped the
compressor
See section 11.2 & 11.3
Maximum number of starts per hour
exceeded
Compressor is stopped
and will not restart
Intellisys controller has tripped the
compressor and has not been reset
See section 11.2 & 11.3
Emergency stop has been pressed and
not released
Identify reason why, repair fault, disengage
button and reset Intellisys controller
Emergency stop has been pressed and Repair fault and reset Intellisys controller
released but Intellisys controller has not
been reset
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11.0 FAULT FINDING
SYMPTOM
FAULT
REMEDY
Compressor will not meet
pressure required by system
Compressor not sized to
meet system requirements or
requirements have been changed.
Contact your local IR representative
Air loss due to pipe, hose, joint or
seal failure
Overhaul or replace
Air loss due to blowdown valve stuck Overhaul or replace
open
Air loss through pressure relief valve
not seating or set incorrectly
Overhaul or replace
Air loss due to moisture separator
drain trap stuck open
Overhaul or replace
Motor speed too low caused by drive Contact your local IR representative
incorrectly set
Motor speed too low caused by fault See section on drive faults
in drive settings
Intellysis controller fault
Overhaul or replace
Drive motor fault
See section on drive faults
Pressure transducer faulty,
incorrectly calibrated or EMF
interference
Recalibrate or replace
Incorrect Intellisys controller settings Check and modify settings
Inlet grill or ducting is blocked
Check and clean
Air filter dirty or collapsed
Replace
Inlet valve not opening fully
Overhaul or replace
Separator element dirty or collapsed Replace
Pipe / Hoses blocked or collapsed
Clean or replace
Cooler core blocked
Clean or replace
Minimum pressure check valve not
functioning correctly
Overhaul or replace
Equipment between compressor
Review system requirements
and customer measuring point
causing pressure drop / pressure loss
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11.0 FAULT FINDING
SYMPTOM
FAULT
REMEDY
Pressure produced
by compressor is too
highcompressor is too high
due to speed not reducing as
demand reducesreduces
Intellisys set incorrectly
Check and modify settings
Pressure transducer may be
faulty, incorrectly calibrated or
not receiving pressure signal
Recalibrate or replace
Drive settings fault
Contact your local IR representative
Compressor discharge air too
hot
High ambient temperature
Review installation and system parameters
Insufficient cooling air
Check ducting and cooling air path, check
direction of blower rotation
Blocked aftercooler matrix
Clean or replace
Panels or doors are not closed
properly
Rectify fault
Compressor package produces
excessive noise
Air leaks from internal pipework / Overhaul or replace
components
Discharge air is contaminated
with coolantcoolant
Blower or blower motor bearings
worn
Overhaul or replace
Loose debris impacting on
blower during rotation
Remove and rectify any damage
Blowdown valve stuck open
Overhaul or replace
Pressure relief valve not seating
correctly
Overhaul or replace
Vibration due to motor, airend or
blower imbalance
Overhaul or replace
Airend requires overhaul
Contact your local IR representative
Scavenge pipe is blocked, broken Clean or replace
or o−ring is not sealing
Separator element is punctured, Replace
or incorrect, or requires changing,
or not sealing correctly
Incorrect coolant has been added Drain system, check for damage. Clean, refill
with correct coolant.
System has been overfilled with
coolant
Check for damage, drain excess.
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11.0 FAULT FINDING
SYMPTOM
FAULT
REMEDY
Discharge air is contaminated
with condensate
Aftercooler not functioning correctly
Clean or replace
Moisture separator drain trap faulty
Overhaul or replace
Continuous low speed / low ambient
operation causing condensate build
up
Review system requirements and
contact your local IR representative
Compressor operating above rated
pressure
Check and modify settings. Review
system requirements and contact your
local IR representative
Separator filter element dirty or
blocked
Replace
Voltage supply is low or unbalanced
Contact your local IR representative or a
qualified electrician
Airend is damaged
Contact your local IR representative
Coolant system leak
Overhaul or replace
Compressor package draws too
much current
Excessive coolant consumption
See also ‘discharge air is contaminated See above
with coolant’
11.2 INTELLISYS FAULTS
(INDICATED ON THE INTELLISYS CONTROLLER)
FAULT
CAUSE
REMEDY
Emergency Stop
Emergency stop button has
been pressed.
Identify reason why, repair fault, disengage button
and reset Intellisys controller
Blower motor overload
Blower is blocked, damaged or Remove blockage, repair or replace damaged
blower motor is faulty.
components
High airend discharge
temperature
Compressor operating above
rated pressure
Check and modify settings. Review system
requirements and contact your local IR
representative
Low coolant level
Check for leaks. See also ‘discharge air is
contaminated with coolant’. Top up coolant.
High ambient temperature
Review installation and system parameters
Insufficient cooling air
Check ducting and cooling air path.
Blocked coolant cooler matrix
Clean or replace
Blower motor direction of
rotation incorrect
Wire correctly
Controller software has been
changed
Recalibrate all sensors and check setpoints
Check setpoints
94
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
11.0 FAULT FINDING
FAULT
CAUSE
REMEDY
Remote start failure
Remote start button is pressed
after machine is running or
remote start button remains
closed.
Check operation of buttons or operating
procedures
Remote stop failure
Remote stop button remains
open and either start button is
pressed
Check operation of buttons or operating
procedures
Sensor failure
Sensor is missing or faulty
Install, repair or replace faulty sensor
Compressor trips indicating a
high compressor temperature.
Insufficient cooling taking place If machine is watercooled or sea watercooled,
check that the cooling water is flowing. Check
that there is no air in the water cooling system.
Check that the strainer is not blocked.
Intellisys controller has
tripped the compressor
A fault has occurred
Repair fault / reset Intellisys controller
Invalid Calibration
Calibration done with pressure
in compressor.
Depressurise and re calibrate with pressure pipe
to sensor disconnected. If fault still exists, replace
pressure transducer.
Low sump pressure
System leak
Located and repair
Minimum pressure check valve
faulty
Repair with service kit
Blowdown valve faulty
Repair with service kit
Loss of control power
Check 110V circuit breaker
Check wiring
Check contactor KM1
Check motor rotation
Drive system fault
Contact your local IR representative
VSD communication failure
Communication wiring faulty
Check and replace if required
Drive faulty
Contact your local IR representative
Intellisys faulty
Contact your local IR representative
Communication wiring faulty
Check and replace if required
Drive faulty
Contact your local IR representative
Intellisys faulty
Contact your local IR representative
VSD initialisation fault
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
95
11.0 FAULT FINDING
11.3 DRIVE FAULTS
(INDICATED ON THE INTELhYS CONTROLLER)
The drive controller is directly linked to the Intellisys controller. Faults in the drive controller will be displayed on the
Intellisys controller as ‘VSD fault 0, VSD fault 1’ etc.
The following VSD faults may be investigated and remedied at source. For all other VSD faults, contact your local IR
customer support representative.
FAULT
CAUSE
ACTION
VSD Fault 1
Over−current
Check separator element.
Check cooler, pipework and moisture separator for
blockages.
Check operation of minimum pressure check valve.
VSD Fault 3
Drive temperature too high
Check drive filter, replace if necessary
Check drive cooling fan circuit breaker
Check wiring
96
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com