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
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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.
•
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FOREWORD
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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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80448608 Rev B 11
EN
Fuse Type 1,2 Fuse Selection Criteria 3
Class − J, Class − T, or Semiconductor fuses
Note:
Fuse size >= 150% Total Package Amps 4
Fuse size <= 175% Total Package Amps 4
Note:
Fuse must be Fast acting, current limiting with interrupt
rating of 200,000 amps RMS SYM.
Alternate fuse type may be used if the time vs. current
characteristics are faster then fuse types recommended.
1)
2)
This is only a recommendation and installer must follow
local and/or national codes prior to installation.
Total package current (amps) can be obtained from
IR Sales Library (Engineering data sheets) for any
pre−install inquiries, and from actual Compressor
Nameplate (contact your local IR Distributor for more
information).
1)
2)
CIRCUIT BREAKERS are NOT recommended for branch
circuit protection, due to their slow response, resulting into
inadequate protection in event of a fault.
Example of voltage imbalance calculation
U> V 462v
V > W 459v
W > U 453v
V(m) = (462 + 459 + 453) / 3 = 458v
V max = 462 − 453 = 9v
= (9 / 458) x 100 = 1.97%
SPECIAL ELECTRICAL CONSIDERATIONS FOR
VARIABLE SPEED DRIVE VSD COMPRESSORS
Primary Input Power Supply
The primary input power for the compressor can come from
dierent transformer sources and congurations. The most
typical sources and congurations are a wye secondary and a
delta secondary.
Wye and Delta Congurations
Wye Delta
HOW TO GROUND
In most conditions, you must ground a wye system. Refer
to local electrical codes. When you ground a wye system,
the voltage to ground becomes stable and controlled. This
prevents a system from damage by conditions that cause
high voltage to ground. It is typical to ground the neutral
(center) point of a wye source.
It is not necessary to ground a delta system. If you ground a
delta system, ground it to one phase. You can also ground it
to a center tap on one phase.
•
Wye and Delta Grounding
Grounded wye
(typical) Corner grounded delta (not typical)
Ungrounded delta
(typical) Center grounded delta (not typical)
Refer to electrical codes to ground the compressor to a
permanent protective ground connection. The compressor
electrical enclosure contains an electrical power ground
terminal that has the identication of “PE”. The typical primary
input power is a four-wire connection with three power wires
and a ground wire. Connect the ground wire to the ground
terminal.
NOTICE
if there are only three power wires and no ground
wire, connect the ground terminal to a correct building
ground. Do not let the enclosure frame oat without an
electrical connection to a power ground source.
HOW TO FIND WHICH SYSTEM IS USED
NOTICE
Use a multimeter to measure the voltage. All voltage
indications can change plus or minus 10%.
In a grounded wye connected 480-volt network:
Each phase to ground (neutral) voltage is approximately
277 volts (480/sqrt3).
277 volts is a nominal indication for 480-volt systems.
Other voltage indications are possible for 380, 415, 440
and 575-volt systems. See Table 2.
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INSTALLATION

EN
12 80448608 Rev B
INSTALLATION
The phase-to-phase voltage is the same as the primary
supply voltage (575, 480, 460, 440, 415, or 380 volts).
NOTICE
You must disconnect the two electro-magnetic
compatibility (EMC) lters in a wye network that has a
high resistance neutral connection more than 30 ohms.
See “Disconnecting the Electro-Magnetic Compatibility
(EMC) Filters” .
In an ungrounded delta connected network:
The network is capacitively grounded.
Stray capacitances are connected between each phase
conductor to ground.
All phase voltages to ground are approximately 277 volts
for a 480-volt network.
There can be many dierent indications because of the
capacitive ground.
The phase-to-phase voltage is the same as the primary
supply voltage (575, 480, 440, or 380 volts).
The primary function of an ungrounded delta network is
to let uninterrupted power occur during a ground fault. At
this time, the ungrounded network is referenced to ground.
The primary circuit breaker opens only when two phases are
connected to ground. Thus, it is possible to have one of the
three phases of an ungrounded delta network connected
to ground or the network be ungrounded at the time of
compressor installation, but have a grounded phase at a
future time.
NOTICE
You must disconnect the two electro-magnetic
compatibility (EMC) lters in a delta network that is
not grounded. If you do not do this, damage will occur
to the lter and to the VSD. This voids the factory
warranties. See “Disconnecting the Electro-Magnetic
Compatibility (EMC) Filters”.
In a delta connected network:
Only two phases to ground have a voltage, while the
third phase has zero volts. The phase with zero volts is
grounded.
The two ungrounded phase voltages are the same as
the primary supply (480 volts to ground for a 480-volt
system).
The phase-to-phase voltage is the same as the primary
supply voltage (480, 440, or 380 volts).
NOTICE
With all compressors that have a variable speed drive
for the primary drive, connect the ground to the
L2 input of the compressor. If you do not obey this
procedure, the compressor does not operate.
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NOTICE
If you nd a grounded phase during installation, it is
important to know if the grounded phase is intentional
(grounded) or accidental (ungrounded with a ground
fault condition present).
Table 2: Input Voltage Rating
Nominal voltage rating (VAC) 380-460
Phase 3
Hertz 50/60
Min./Max. Voltage Tolerance(%) 400-460 V ± 10
380 V +10, -6
Min. /Max. Voltage Imbalance Between Phases
(%)
3
Min./Max. Frequency Tolerance (%) ± 5
NOTICE
Ratings that do not fall in these limits can cause damage
to the compressor and make all factory warranties void.
High Voltage Conditions and Secondary
Protection
A compressor with a variable speed drive contains metal
oxide varistors (MOV). The MOV prevent damage to the VSD
from typical voltage conditions. Very high voltage conditions
can cause damage to the MOV and the VSD. These are
examples of very high voltage conditions:
lightning storms
switching of power factor capacitors
welders
thyristors
If there are very high voltage conditions, you must add
secondary protection to prevent damage to the compressor.
NOTICE
Damage to the MOV shows that the compressor was
exposed to very high voltage conditions.
Damage to the MOV because of very high voltage
makes the factory warranty and the extended contract
warranty void.
Power Factor Compensation Capacitors
Power factor compensation is not necessary for a compressor
that contains a variable speed drive. Nevertheless, if
you connect the compressor to a system that includes
compensation capacitors, obey these instructions:
Do not connect a high-power capacitor to the power
line while the compressor is connected to the primary
power. High voltage conditions can open the compressor
protection circuits or they can cause damage to the
compressor.
If you increase or decrease the capacitor load gradually
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EN
when the compressor is connected to the power line,
make sure the connection steps are suciently low not
to cause voltage transients that can open the compressor
protection circuits or cause damage to the compressor.
Check that the power factor compensation unit is correct
for use in systems with AC drives. The compensation unit
must typically have a blocking reactor or harmonic lter.
Do not connect any devices to the output of the AC drive
in the compressor.
NOTICE
If you do not obey the electrical installation
instructions, the factory warranty and any extended
contract warranty is void.
Disconnecting the Electro-magnetic
Compatibility (EMC) Filters
On some types of electrical power systems, you must
disconnect the internal electro-magnetic compatibility (EMC)
lters. If you do not do this, the electrical power system
is connected to ground potential through the EMC lter
capacitors. This can cause a dangerous situation and it can
cause damage to the variable speed drive. Disconnect the
two EMC lters if the electrical power system is:
ungrounded (oating)
a high-resistance ground system (greater than 30 ohms)
a corner- grounded delta system
NOTICE
Do not try to install or remove the EMC lters and
jumpers while power is applied to the compressors
input terminals.
NOTICE
If you disconnect the internal EMC lters, the
variable speed drive does not agree to the European
requirements for electro-magnetic compatibility. If
you operate the compressor without the EMC lters,
the compressor can cause unwanted interference with
electronic devices. You can continue to operate the
compressor without the EMC lters only if electro-
magnetic compatibility is not necessary in your area.
NOTICE
You must remove the two jumpers. One jumper is in the
MOV/EMC metal box at the bottom of the compressor.
The other jumper is on the printed circuit board (PCB)
found on the input buss bars to the drive.
Location of First Jumper
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A First jumper
Location of Second Jumper
A Power interface board (located underneath)
B DC Bus sensing board
C Control board
D EMC board
E Cooling fan
F Second jumper
Power Supplied By Dedicated Transformer or
Generator
High Impedance Power Source
The compressor can operate in industrial electrical networks
that have a short-circuit power 15 times greater than the
rated power of the drive (line impedance less than seven
percent). Make sure that the network is correct if you
operate the compressor on a generator set or on a dedicated
transformer.
We recommend that you open the link that connects the
electro-magnetic compatibility lter capacitors to the ground
point if the installation has the following characteristics:
the distribution power network has no connection to
ground and
the short-circuit current at the drive connection point
and its rated current has a ratio lower than 30.
Low Impedance Power Source
The variable speed drive can experience low impedance if the
installation has the following characteristics:
the compressor is installed near to the medium voltage/
low voltage (MV/LV) power supply transformer, and
a bank of power factor correction capacitors are
connected in parallel at the secondary side of the
transformer.
The risk of a high voltage surge at the equipment terminals
is high in the condition that the voltage decrease > at the
primary side of the transformer.
Example of line impedance calculation in percent
For a compressor with a rated input current of 100 amps and
a line power supply with short-circuit current capacity of 5000
amps, the line impedance is two percent (100 A/5000).
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INSTALLATION
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INSTALLATION
Control Power Transformer Connections
The control circuit transformer has dierent voltage primary
taps for dierent power line voltage levels. Make sure that the
taps are set for the correct applied voltage before you start
the compressor.
Control Power Transformer Connections
WATERCOOLED UNITS
Cooling Water Piping
Water piping to and from the compressor package must be
at least the size of the water connections on the machine.
Refer to the installation drawing section for this size. 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. The strainers will connect to the water
manifold on all units, but also requires a pipe nipple. The list
below shows the required parts for each unit.
IRN37−45K−OF & IRN50−60H−OF:
Strainer − CCN 39157433
Nipple − CCN 95946117
IRN55−75K−OF & IRN75−100H−OF:
Strainer − CCN 39116389
Nipple − CCN 95928032
IRN90−160K−OF & IRN125−200H−OF:
Strainer − CCN 39116397
Nipple − CCN 95960662
Note: KW rated units will be supplied with an NPT to BSPT
adaptor
Carefully inspect your water system before installing the
compressor package. Ensure that the piping is free of scale
and deposits that may restrict water ow to the compressor
package.
Proper operation of your compressor requires that the water
ow listed in Section 8.1 be provided at a maximum supply
temperature of 46 °C (115 °F).
Water temperature and pressure gauges should be installed
in the water piping for use in any fault nding 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).
Water cleanliness is also extremely important. Cleaning of
coolers as a result of fouling is a customer responsibility.
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Therefore, it is highly recommended that proper water
quality must meet the requirements listed in WATER QUALITY
RECOMMENDATIONS later in this section.
Venting the water system
At the initial installation or for start−up after draining the
water system proceed to vent the system as follows.
Locate the water system vent cocks on top of the
intercooler , aftercooler, and oil cooler.
Open the water valve(s) allowing water to ow to the
package.
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.
Disconnect the inlet and discharge water lines from the
connections located at the rear of the unit.
Locate the intercooler, aftercooler, and oil coolers.
Disconnect the water inlet connections to drain each
cooler. Also, drain any piping between the coolers and the
water shut o solenoid valve (it is normally closed).
Water quality recommendations
Water quality is often overlooked when the cooling system
of a water−cooled air compressor is examined. Water quality
determines how eective the heat transfer rate, as well as the
ow 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 eect the water
makeup. Most problems in a cooling system show up rst in a
reduction in the heat transfer rate, then in a reduced ow rate
and nally with damage to the system.
Scale: Scale formation inhibits eective 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.
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
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EN
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 dierent water constituents are included below:
Cooling Water Analysis Chart
Substances Test interval Acceptable
concentration
Corrosivity
(Hardness, pH, Total
Dissolved Solids,
Temperature at inlet
Alkalinity)
Monthly — if
stable for 3 to 4
months, analyse
quarterly.
Langelier Index
0 to 1
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
OUTDOOR SHELTERED INSTALLATION
Nirvana compressors are not suitable for outdoor installation.
Installing a Nirvana compressor outside voids the warranty of
the compressor.
INSTALLATION

EN
16 80448608 Rev B
GENERAL INFORMATION
GENERAL DESCRIPTION
The compressor is an electric motor driven, oil free, two stage
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 signicant reductions in ambient temperature are
required if a standard motor is to be used. Some models have
more strict limitations on the maximum altitude/ambient
at higher operating pressures. Consult engineering or the
engineering data pages for specic guidance.
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. Air is pulled into
the machine by the cooling blower and through the heat
exchangers (for air cooled).
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 separators and drains.
The oil sump and pump are integral within the gearcase. The
oil pump is a positive displacement gear−type pump, and is
driven by the motor/bullgear shaft. The gearcase is vented to
a mounted breather. The breather exhaust is piped to the top
of the package.
The compressor is provided with temperature sensors
which will shut the unit down in case of excessive oil or air
temperatures.
Eective oil ltration is provided by the use of a screw on,
heavy duty oil lter.
NOTICE
Nirvana air compressors are factory lled with
Ingersoll rand premium coolant which is designed to
operate for 8,000 hours or two years, whichever comes
rst.
The oil must be changed at these intervals to avoid
breakdown and equipment damage.
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80448608 Rev B 17
INTERFACE DATA & KEYS
Xe-90M / 145M
The standard user interface conguration of the controller
consists of the membrane and the LCD display. The
membrane consists of ve command keys (Start, Stop, Load,
Unload, and Reset), four navigation keys (Up, Right, Left and
Down), and an Edit mode selection key (Enter). These keys,
in conjunction with the color graphics display and the LED
icons, make up the user interface to the compressor.
Figure : Xe-90M /145M
LED STATUS ICONS
Three LED icons are used to indicate the current status of the
control system from a distance and are located on the upper
left side of the user interface.
Icon Name Function
OK
Illuminates when no
Warnings or Trips are sensed.
Can be in a Ready or Not
Ready state. This icon will
ash when the machine is
Running Unloaded
Alert
Illuminates when an Warning
(ashes) or Trip (constant on)
is sensed. Can be in a Ready
(Warning) or Tripped state.
Auto
Illuminates when the
compressor stops in auto
restart.
COMMAND KEYS
These keys command the controller to perform actions as
specied in the following table. When any of these keys are
pressed the action below will be initiated and logged in the
event log.
Key Name Function
--- None
Load
The Load button is not used
with the variable speed
application.
Unload
The Unload button is not
used with the variable speed
application.
Reset
Clears Warnings and Trips
once the condition is
corrected.
Start Starts the compressor.
Stop
Stops the compressor. This
button should be pressed
instead of the E-Stop for
normal stopping operation.
Enter
Toggles the display between
the Navigation mode and the
Edit mode.
Xe-90M / 145M Command Keys
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NAVIGATION KEYS
There are four navigation keys (UP, RIGHT, DOWN and LEFT).
While the ENTER key is not considered a navigation key, it
is used in conjunction with the navigation keys to make or
conrm a selection.
Xe-90M /145M’s Navigation Keys
The navigation keys roll over. Pressing one of the navigation
keys will lead the user down a navigation path. Each time
the key is pressed, another step in the path is taken. Once
the end of a navigation path is reached, pressing the key one
more time will bring the user back to the beginning of the
path. Pressing the opposite key will move the user through
the navigation path in the opposite direction. Once the
beginning is reached, pressing the opposite key will take the
user to the end of the path.
DISPLAY LAYOUT
Xe-90M /145M’s Display Layout
Folder Bar: Uses tabs to graphically identify each
folder.
Title Bar: Identies current folder and page
(underlined).
Page
Content:
Content of the current page.
Dashboard: Displays system status.
FOLDER NAVIGATION & ICONS
To move among the tabbed folders shown on the LCD display,
press the RIGHT and LEFT keys. The navigation rolls over from
the last to the rst folder and vice-versa.
Folder
Name Icon Description
Home
System performance and status
main information. The rst page
of this folder is the default page
when the controller rst powers
up.
Operator
Settings
System options and conguration
settings.
Events System events log.
Trip History Details on the most recent trips.
Graphing On-board graphing of system
data. (Xe-145M Only)
Maintenance Status and notication setup for
compressor maintenance items.
General
Settings
General settings such as
Language, Time, and Units of
Measure.
Integral
Sequencing
Intergral Sequencing
communication status and
conguration.
Status Measurements or status from/of
all analog and digital I/O.
Factory
Settings
Compressor tuning parameters.
Also displays hardware and
software versions.
Folder Bar Icons
PAGE NAVIGATION
Once the desired folder is selected, press the DOWN key to
move to the page selection area and then use the RIGHT and
LEFT keys to select the desired page. Use the UP key to get
back to the folder tabs.
Icon Description
Start of the page selection area.
Indicates that there are more pages available
by navigating right.
Indicates that there are more pages available
by navigating left.
Title Bar Page Icons
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INTERFACE DATA & KEYS
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INTERFACE DATA & KEYS
ACCESSING PARAMETERS
After the desired page is selected, the page’s parameters can
be selected by using the DOWN key. The cursor will move to
the next parameter each time the DOWN key is pressed. Use
the UP key to go back to the previous one.
The cursor rolls over, so once the last parameter is selected,
pressing the DOWN key will navigate the cursor to the Folder
Bar. If the rst parameter is selected, pressing the UP key will
move the cursor to the page selection area.
Once selected, access parameters by pressing the ENTER
key. Make changes by using the NAVIGATION keys. The LEFT
key can be used to move the cursor under the digit to be
changed. Use the UP or DOWN keys to change the value.
Once all digits have been changed, enter the setting by
pressing the ENTER key again. After a parameter is accessed,
pressing the ENTER key will enter the current setting into the
control program and navigate the cursor back to the selected
parameter on the page.
When the cursor is on a parameter that has an enabled/
disabled box, pressing the ENTER key will cause the setting to
toggle.
The icon appears on numeric entry windows (see gure
below). Placing the cursor on it and then pressing the ENTER
key will cancel the entry and any changes that were made.
Press the RIGHT key to place the cursor on the icon.
Not all pages have adjustable parameters. Some just
have read-only information.
DASHBOARD ICONS
The dashboard is intended to be a quick at-a-glance view of
system status. The following table lists standard dashboard
icons and their denition. Note that the color of these icons
changes based on the state set by the application while
running.
Name Icon Description
Remote
Control
Remote control is enabled. This
can be Remote Start/Stop, COM
Control, Integral Sequencing or
Web Control.
Service
Required
A service reminder is nearing or
has expired (i.e.: an air or oil lter
needs to be changed).
Unloaded
or
Loaded
Compressor is in the unloaded
state.
Compressor is in the loaded state.
Xe-90M /145M’s Dashboard Icons
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DASHBOARD STATUS MESSAGES
The dashboard also displays the current operating state of the
compressor. The following states can be encountered during
machine operation:
Ready to Start - – The compressor currently has no trip
or start inhibit conditions present. The machine can be
started by pressing the start button at any time
Starting – A start command has been given to the
compressor and the start sequence is being performed.
The time period for this state can vary depending on the
starter type of the machine.
Load Delay – The compressor is waiting for a small
period of time after starting before allowing the machine
to load. This ensures the machine is at operating
conditions before loading
Running Loaded – The compressor is operating and
producing air. The blowo valve is closed.
Running Unloaded – The compressor is operating,
but not producing air. The blowo valve is open. This
normally occurs when the compressor is starting or
stopping.
Auto-Restart – The compressor has stopped due to
pressure rising above the oine or auto-stop setpoints
and auto-restart being enabled. The compressor will
automatically restart when pressure falls to the online or
target pressure setpoint.
Stopping – The compressor has received a stop
command and the stop sequence is being performed.
Blowdown – The compressor must wait for a brief period
of time after stopping its motor before it is allowed to
start again.
Not Ready – The compressor has detected a condition
that will not allow the compressor to start. The condition
must be cleared before a start is allowed, but does not
need to be acknowledged.
Tripped – The compressor has detected an abnormal
operational condition that has stopped the machine. A
trip must be acknowledged by hitting the reset button
before the compressor can start.
Processor Init – The controller is being initialized.
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NIRVANA OIL-FREE COMPRESSOR
HOME FOLDER
PAGE 1 – SYSTEM OVERVIEW
This is the factory default display after powering up the
system.
Target Pressure - indicated in the white box and by the
white arrow, which is always in the center of the gauge. The
compressor will adjust the speed of the motor to maintain the
system pressure equal to the target pressure value.
Automatic Stop Pressure - indicated in the white box and
by the white arrow, which is always right of center on the
gauge. The compressor will go into automatic restart if the
system pressure rises above this value and the compressor is
operating at minimum speed.
System Pressure - indicated by the large numbers centred
below the gauge and by the red arrow. This is the air pressure
that the compressor is supplying to the plant. This value is
normally the package discharge pressure. However, if the
compressor is equipped with a remote pressure sensor, this
value will be the remote pressure.
Pressure Unit of Measure - indicated below the System
Pressure. This is selectable from the GENERAL SETTINGS
folder.
Package Discharge Temperature - indicated by the numbers
in the lower right of the display. This is the temperature of the
compressed air/at the discharge of the compression module.
The Package Discharge Temperature is only displayed if the
Hot Discharge option is disabled.
Second Stage Discharge Temperature - indicated by
the numbers in the lower right of the display. This is the
temperature of the compressed air at the discharge of the
2nd stage compression module and is only displayed if the
Hot Discharge option is enabled.
Temperature Unit of Measure - indicated to the right of the
Package Discharge Temperature. This is selectable from the
GENERAL SETTINGS folder.
Capacity - indicates the output of the compressor as
determined by the speed of the motor.
Run Hours indicate the number of hours the compressor has
been running.
All information on this page is read only.
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PAGE 2 - COUNTERS
Hour Meters - Indicates the hours that the controller has
been powered up and the compressor has been running.
Starts - Indicates the number of times a start is attempted on
the compressor.
Date & Time – Indicates the current date and time. This is
adjustable and congurable in the GENERAL SETTINGS folder.
Blower Starts - Indicates the number of times a start is
attempted on the blower.
All information on this page is read only.
PAGES 3 THRU 4 – ANALOG INPUTS
Pressure is indicated by this icon.
Temperature is indicated by this icon.
Any sensor that is not installed or is reporting a failure will
show an X symbol.
All information on these pages is read only.
The following analog inputs are displayed in this section.
Package Discharge Pressure – The pressure the compressor
is delivering to the plant.
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