Ingersoll-Rand NIRVANA IRN37K-OF Installation and operating instructions

80448608
Revision B
January 2018
Save These Instructions
Oil-Free Rotary Screw Air Compressor
Installation, Operation and Maintenance
IRN37K-OF, IRN45K-OF, IRN55K-OF, IRN75K-OF
IRN90K-OF, IRN110K-OF, IRN132K-OF, IRN160K-OF
IRN50H-OF, IRN60H-OF, IRN75H-OF, IRN100H-OF
IRN125H-OF, IRN150H-OF, IRN200H-OF
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EN
2 80448608 Rev B
FOREWORD.......................................... 3
PURCHASE ORDER DETAILS .......................... 5
SAFETY .............................................. 6
RECEIPT / HANDLING ................................ 7
RECEIPT................................................7
UNPACKING AND HANDLING...........................7
INSTALLATION ....................................... 8
LOCATION IN THE PLANT ...............................8
DISCHARGE AND CONDENSATE PIPING ................9
SPECIAL ELECTRICAL CONSIDERATIONS FOR VARIABLE
SPEED DRIVE VSD COMPRESSORS....................11
WATERCOOLED UNITS.................................14
OUTDOOR SHELTERED INSTALLATION.................15
GENERAL INFORMATION ............................16
GENERAL DESCRIPTION ...............................16
INTERFACE DATA & KEYS ............................17
XE90M/145M........................................17
LEDSTATUSICONS....................................17
COMMANDKEYS......................................17
NAVIGATION KEYS ....................................18
DISPLAY LAYOUT......................................18
NIRVANA OILFREE COMPRESSOR ...................20
HOME FOLDER ........................................20
OPERATOR SETTINGS FOLDER.........................22
EVENTS FOLDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
SERVICE...............................................24
TRIP EVENTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
TRIP HISTORY .........................................27
GRAPHING FOLDER ...................................27
MAINTENANCE FOLDER ...............................28
GENERAL SETTINGS FOLDER ..........................28
INTEGRAL SEQUENCING FOLDER......................31
STATUS FOLDER.......................................32
FACTORY SETTINGS FOLDER ..........................34
WEB ACCESS ........................................38
COMMISSIONING PROCEDURES .......................38
CONNECTING TO A PC.................................39
ETHERNET CONFIGURATION ..........................43
LOGIN PROCESS.......................................44
DEFAULT ACCOUNTS ..................................46
NAVIGATION ..........................................47
TAB NAVIGATION......................................47
COMMANDBUTTONS.................................47
DASHBOARD ICONS...................................48
HOME PAGE...........................................49
EVENT LOG UTILITY ...................................50
PERFORMANCE LOG UTILITY ..........................52
GRAPHING UTILITY....................................54
INSPECTION LOG UTILITY .............................57
COMPRESSOR INFORMATION .........................59
COMPRESSOR IDENTIFICATION........................59
EMAIL SMTP SETTINGS ..............................60
COMPRESSOR DETAILS ................................61
UNITTYPE.............................................61
ACCOUNT MANAGEMENT .............................62
MODBUS ...........................................66
MAINTENANCE .....................................70
MAINTENANCE PROMPTS .............................70
MAINTENANCE CHART ................................70
MAINTENANCE PROCEDURES .........................71
ROUTINE MAINTENANCE..............................71
PRIOR TO STARTING ...................................72
FAULT FINDING .....................................76
GENERAL FAULTS......................................76
XE FAULTS INDICATED ON THE XE CONTROLLER .....77
DRIVE FAULTS INDICATED ON THE XE CONTROLLER . .79
CONTENTS
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80448608 Rev B 3
EN
Machine models represented in this manual may be used in
various locations worldwide. Machines sold and shipped into
European community countries requires that the machine
display the EC Mark and conform to various directives. In
such cases, the design specication of this machine has been
certied as complying with EC directives. Any modication to
any part is absolutely prohibited and would result in the CE
certication and marking being rendered invalid.
The contents of this manual are considered to be proprietary
and condential 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 sta. Major overhauls 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 oil.
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 specied conditions and applications:
Compression of normal ambient air containing no
known or detectable additional gases, vapors or particles
Operation within the ambient temperature range
specied 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.
HPM™, HYBRID PERMANENT MAGNET™ and HPM Logo are
trade marks registered by MOTEURS LEROY−SOMER.
•
•
•
•
FOREWORD
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4 80448608 Rev B
WARNING
The use of the machine in any of the situation types listed in table 1:−
Is not approved by Ingersoll Rand,
May impair the safety of users and other persons, and
May prejudice any claims made against Ingersoll Rand.
a)
b)
c)
TABLE 1
WARNING
Use of the machine to produce compressed air for:
direct human consumption
indirect human consumption, without suitable ltration and purity checks
a)
b)
Use of the machine outside the ambient temperature range specied in the PRODUCT INFORMATION SHEET.
Use of the machine where there is any actual or foreseeable risk of hazardous levels of ammable 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 tted 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 eld. This eld can eect 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, debrillators or other implanted electronic medical device.
WARNING
This compressor contains a variable frequency drive. When it is switched o 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.
NOTICE
The manual is intended for worldwide use and contains both metric and imperial data where required.
FOREWORD
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EN
PURCHASE ORDER DETAILS
ROTARY SCREW AIR COMPRESSOR
This unit was purchased from______________________________________________________________________________
Ingersoll Rand Company Limited 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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6 80448608 Rev B
SAFETY
Locate, read, understand and follow all Danger, Warning,
Caution, and Operating Instructions on the product and in all
Manuals. Failure to comply with safety precautions described
in the manuals supplied with the product, this manual or any
of the labels and tags attached to the product may result in
death, serious injury or property damage.
Check that all labels, tags and data (name) plates are in place
and legible.
It is your responsibility to make this information available to
others.
If you have any questions about safety or procedures not
included in this manual, ask your supervisor or contact any
Ingersoll Rand oce or qualied Ingersoll Rand distributor.
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80448608 Rev B 7
EN
RECEIPT / HANDLING
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 Limited
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 nal position, remove the transit brackets from the resilient
mounts and store for future use or discard.
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INSTALLATION
LOCATION IN THE 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 lings,
paint fumes and overspray.
Hard surfaces may reect 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.
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 oor capable
of supporting it. A dry, well ventilated area where the
atmosphere is as clean as possible is recommended.
Sucient space all round and above the compressor must
be allowed, to enable the eective removal of the cooling air
which, in turn, will reduce the risk of recirculating the cooling
air back through the compressor.
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 deected 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.
NOTICE
If ducting is tted to the machine, the sump breather
needs to be piped outside the enclosure to avoid back
pressure into the compression module.
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INSTALLATION
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 eective
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], installed before the feeder lines [5], may be
necessary to ensure that the total system volume is not less
than 2.0 U.S.Gallons per rated delivery C.F.M.
Discharge piping should be at least as large as the discharge
connection of the compressor. All piping and ttings should
be suitably rated for the discharge pressure.
It is important to install an isolation valve [7] within 3 feet (1
meter) of the compressor.
It is good practice to install line lters [4].
Include a means [6] to vent the discharge pipework
downstream from the machine’s check valve and upstream of
the rst system isolation valve [7].
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 intercooler and aftercooler reduce 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 two moisture separator/solenoid
valve combinations. Since these solenoid valves discharge
at dierent pressures, it is extremely important that they are
piped separately into an open drain.
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, compressor response time may
need adjusting. Contact your local IR service agent.
CAUTION
The use of plastic bowls on line lters and other
plastic air line components without metal guards can
behazardous. Their safety can be aected by either
synthetic oils 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.
ELECTRICAL
CAUTION
This procedure should only be carried out by a qualied
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
PRODUCT INFORMATION SHEET.
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
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10 80448608 Rev B
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(1 AWG) (37/45k & 50/60H) and
up to 90mm2(3/0 AWG) (55/75k & 75/100H) cable. The
N75K−160K and N100H−200H machines mains terminals
will accept 2 x 120mm2 (4/0 AWG) 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 dierent voltage tappings.
Ensure that these are set for the specic applied voltage prior
to starting.
A hole is provided for incoming power connection. If it is
necessary to make a hole in the control box in a dierent
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
o.
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 lter pads or degrade the cooling air
ow.
On completion of electrical installation, check that both the
main blower motor and heat sink blower motor rotations are
correct.
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 lter.
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.
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 tted 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
tted onto the customers isolator or breaker close to
the compressor.
CAUTION
This procedure should only be carried out by a qualied
electrician, electrical contractor or your local
Ingersoll Rand Distributor or Air Centre.
The compressor installation must be properly installed in
accordance with recognized Local and National electrical
equipment installation codes and any other related local
Health and Safety Codes.
The compressor input power supply (branch circuit)
protection shall be made by utilizing an Isolator switch
(Disconnect switch). The input power supply branch
circuit shall only be protected using“FAST ACTING (FAST
BLOWING)” fuses as dened below, and NOT using“Time
Delay” (slow acting or dual element type) fuses.
INSTALLATION
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