Ingersoll-Rand R37-160 Setup guide

80446354
Revision D
November 2014
Save These Instructions
Contact-Cooled Rotary Screw Air Compressor
Product Maintenance Information
R37-160
121714.07.03
PRINT LANGUAGE
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SPANISH
FRENCH
PORTUGUESE

EN
80446354 Rev D EN-2
ABOUTTHISMANUAL ......................................2
PERSONNEL................................................2
SAFETY ....................................................2
AIR COMPRESSOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CheckingCoolantLevel........................................ 4
AddingCoolant ............................................... 4
Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AnalyzingFood-GradeCoolant ................................ 4
SamplingCoolant............................................. 4
ChangingCoolantFilter........................................ 5
CheckingSeparatorElement................................... 5
ChangingSeparatorElement................................... 5
Inspecting Separator Tank / Pressure System . . . . . . . . . . . . . . . . . . . . 5
Cleaning / Checking Scavenge Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ReplacingCoolantHoses....................................... 6
Checking Minimum Pressure Check Valve (MPCV) . . . . . . . . . . . . . . . 6
ChangingAirFilter ............................................ 6
RegreasingMotor............................................. 6
Cleaning Air Cooled Sequential Cooling System . . . . . . . . . . . . . . . . . 6
Removing / Installing Air Cooled Cooler. . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning Water Cooled Cooler (for both Clean & Harsh
WaterOptions)................................................ 7
Checking High Airend Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . 7
CleaningMotorCowl .......................................... 7
Removing / Replacing Starter Box Power Drive Module (PDM) Filter
Element (For VSD only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning / Checking Condensate Drain. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning / Installing Package Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking / Cleaning No Loss Drain Trap (where tted) . . . . . . . . . . . 8
Monitoring Fluid and Performing Shock Pulse Bearing Analysis . . 8
TROUBLESHOOTING........................................9
R3775 INTEGRATED DRYER MAINTENANCE . . . . . . . . . . . . . . . 13
Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cleaning Condensate Drains (Timed Drains Only). . . . . . . . . . . . . . . 13
Testing Condensate Drains (No-Loss Drains Only). . . . . . . . . . . . . . . 13
Troubleshooting Condensate Drains (Electronic
Drains Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembling the Integrated Dryer. . . . . . . . . . . . . . . . . . . . . . . . 13
Decommissioning the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . 13
CONTENTS
ABOUT THIS MANUAL
PERSONNEL
SAFETY
Proper use, inspections and maintenance increases the life and usefulness
of the compressor. It is extremely important that anyone involved with
maintaining the compressor be familiar with the servicing procedures of
these compressors and be physically capable of conducting the procedures.
These personnel shall have skills that include:
1. Proper and safe use and application of mechanics common hand
tools as well as special Ingersoll Rand or recommended tools.
2. Safety procedures, precautions and work habits established by
accepted industry standards.
Some maintenance procedures are technical in nature and require
specialized tools, equipment, training and experience to accomplish
correctly. In such situations, only allow Ingersoll Rand trained technicians
to perform maintenance on this compressor. Service or inspections beyond
the procedures given in this manual shall not be attempted by operating
personnel.
For additional information contact the Ingersoll Rand factory or the nearest
service provider.
Before undertaking any work on the compressor, ensure that the electrical
supply has been isolated, locked o, tagged and the compressor has been
relieved of all pressure. Ensure the compressor is electrically isolated for at
least 15 minutes before commencing any maintenance work. See the Product
Safety Information manual for additional information.
Ingersoll Rand cannot know of or provide all the procedures by which
repairs may be conducted and the hazards and/or results of each method. If
maintenance procedures not specically recommended by the manufacturer
are conducted, ensure that safety is not endangered by the actions taken.
If you are unsure of a maintenance procedure or step, place the compressor
in a safe condition before consulting technical assistance.
The use of other than genuine Ingersoll Rand replacement parts may result
in safety hazards, decreased performance and increased maintenance and
may invalidate all warranties.
For additional information contact the Ingersoll Rand factory or the nearest
service provider.
The purpose of this manual is to provide maintenance and troubleshooting guidelines for the compressor.
For supporting documentation refer to Table 1.
Table 1: Product Manuals
Publication Product Part/Document Number by Region
Americas EMEA * Asia Pacic
Product Safety Information Manual All 80446313 80446156 80446321
Product Information Manual All 80446339 80446164 80446347
Product Parts Information Manual
R37-45 kW 80448095
R55-75 kW 80446271
R132-160 kW Single-Stage 80446057
R90-160 kW Two-Stage 80446065
* Europe, Middle East and Africa
Product specication sheets and reference drawings are also available.
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EN-3 80446354 Rev D
EN
AIR COMPRESSOR MAINTENANCE
Maintenance Prompts
The service warning and ashing LED will appear at intervals dependent
on the service level selected. Refer to the Product Information manual for
information about service level settings.
Maintenance Chart
Maintenance should be performed per the recommendations below in the
following priority: (1) Perform maintenance when indicated by the controller;
(2) Perform maintenance through either hourly intervals or scheduled
maintenance intervals, or (3) Annually.

Table 2: Maintenance Chart
Period Action Maintenance Item
When indicated by
controller
Replace Air lter element
Replace Coolant lter element
Replace Separator element
Daily Check Connections and hoses for leaks
Check Coolant level
Check Condensate drain operation
Check Controller for service indicators
Check Package pre-lter for blockage
Monthly Inspect Air-cooled sequential cooling system for blockage
Inspect Water-cooled sequential cooling system screens
Inspect Starter box power drive module (PDM) lter element
Analysis Water from water-cooled sequential cooling system
Every 500 hours Analysis Food-grade coolant
Every 1000 hours Replace Food-grade coolant (if not using food-grade lter module)
Replace Food-grade coolant lter (if not using food-grade lter module)
Every 2000 hours or
3 months
Inspect Air lter element
Inspect Coolant lter element
Inspect Starter box power drive module (PDM) lter element
Replace Food-grade coolant (if using food-grade lter module)
Replace Food-grade lter module
Analysis Shock pulse bearing
Analysis Coolant
Every 4000 hours or
6 months
Inspect Scavenge screen for blockage
Replace Air lter element
Replace Coolant lter element
Replace Starter box power drive module (PDM) lter element
Replace Package pre-lter element
Clean Air-cooled sequential cooling system
Inspect / Clean Water-cooled sequential cooling system
Grease All motors (as required)
Calibrate Pressure transducers
Analysis Coolant
Analysis Shock pulse bearing
Every 8000 hours or
annually
Replace Standard coolant [8000 hours or every 2 years]
Replace Separator element
Replace No-loss condensate drain service module
Service Minimum pressure check valve (MPCV) service kit
Service Inlet valve service kit
16000 hours Replace Coolant hoses
Replace Contact tips
NOTICE
Inspect and replace coolant lter elements and separator elements more frequently in dirty operating environments.
NOTICE
Read the motor data plate(s) or call the motor manufacturer(s) to determine specic greasing requirements. For motors that require greasing,
grease them more frequently in harsh environments or higher ambient conditions.
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EN
80446354 Rev D EN-4
Routine Maintenance
This section refers to the various components which require periodic
maintenance and replacement.
Refer to safety information and maintenance procedures prior to carrying out
any of the maintenance in the following sections.
Checking Coolant Level
The coolant level should be checked daily. A coolant level sight glass is
located on the side of the separator tank. While the compressor is running
under load, coolant should always be visible in the sight glass. The normal
position is half way. The compressor should be running for at least 40 seconds
for this check.
Stop the compressor, ensure the sump pressure is 0 psig and ensure the
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:
1. Stop the compressor.
2. Isolate the compressor from the external air system.
3. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.
4. Slowly unscrew the coolant ll plug to verify all pressure has been
released.
5. Add coolant.
6. Replace the coolant ll plug and restart the compressor.
7. Recheck the coolant level.
8. Repeat the above steps until the coolant level is visible in the sight
glass with the compressor both running and stopped.
NOTICE
Do not add coolant through the intake of the compressor, as this can
result in overlling, saturation of the separator lter element, and
coolant carry-over downstream.
Draining Coolant
It is better to drain the coolant immediately after the compressor has been
operating as the coolant will drain faster and any contaminant will still be in
suspension.
See Figure 1.
1. Place the straight end of the drain hose in a suitable container.
Install the other end of the drain hose in the drain valve. The
coolant ows through the drain hose automatically.
2. After drainage, remove the hose and close the valve.
NOTICE
On air cooled compressors, you may also drain coolant from the
coolant cooler by removing the plug.
You should also drain additional coolant from the airend by removing
the plug in the airend discharge elbow.




Figure 1: Coolant Drain
1 2
3 4
3. Dispose of waste coolant in accordance with local and
governmental regulations.
It is recommended to perform a coolant analysis every 2000 hours or
three months to monitor its condition and determine when to change the
coolant. If analysis is not performed, the recommended coolant change
interval is 8000 hours or two years, whichever comes rst.
NOTICE
Shorter coolant change intervals may be necessary if the compressor
is operated in adverse conditions.
Analyzing Food-Grade Coolant
It is highly recommended to have samples of the coolant analyzed every
500 hours or each month to determine when coolant should be changed.
If analysis is not performed, coolant should be changed after 2000 hours
or every six months when utilizing the food-grade lter supplied with the
compressor.
For compressors running food-grade coolant without the food-grade lter,
the change interval should be 1000 hours or six months, whichever comes
rst.
Sampling Coolant
1. Bring the compressor up to operating temperature.
2. Stop the compressor.
3. Isolate the compressor from the external air system.
4. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.
5. Draw a sample from the separator tank port using a pump kit. DO
NOT draw a sample from the drain port or oil lter.
Use a new hose on the pump for each sample. Failure to do this can give
false readings.
See Figure 2.


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EN-5 80446354 Rev D
EN
Figure 2: Coolant Sampling
Changing Coolant Filter
1. Remove drain plug from bottom of lter housing and drain coolant.
2. Loosen the lter housing.
3. Remove the element from the housing.
4. Place the old element in a sealed bag and dispose of in a safe way.
5. Remove the new replacement element from its protective package.
6. Apply a small amount of coolant to the element seal.
7. Install new replacement element into the lter housing.
8. Screw the housing to the lter head and tighten to the torque
specied on the housing.
9. Reinstall drain plug.
10. Start the compressor, check for leaks and check the coolant level.
Checking Separator Element
With the compressor running on load, check the separator dierential
pressure via the controller. It will be necessary to change the element if the
dierential pressure equals zero or exceeds 1 bar (15 psig).
Changing Separator Element
1. Remove the tting that holds the scavenge tube into the tank and
withdraw the tube assembly.
2. Disconnect the piping from the tank cover. Tag the lines if required.
Remove all the bolts securing the cover to the tank except the bolt
opposite the pivot bolt which should be left engaged by
2-3 threads with at least 6.5 mm (0.25 in) clearance from the screw
head to the cover. Rotate the jacking bolt clockwise until the cover
lifts o the tank at least 2 mm (0.08 in) all the way around the tank.
Remove the remaining bolt. The cover can now be rotated to allow
access to inside the tank.



3. Carefully lift the separator element up and out of the tank. Discard
the faulty element.
4. Clean the sealing surface on both the tank and its cover. 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 a replacement
element down into the tank after checking the new element seal
for possible damage. Center the element within the tank ensuring
that it is fully seated in the sealing groove. Rotate the tank cover
back into position taking care not to damage the seal, and locate
the cover using two bolts but do not tighten down.
5. Loosen the jacking bolt to fully disengage the threads and tighten
the cover bolts in a cross-pattern to prevent over-tightening one
side of the cover. An improperly tightened cover will likely result in
a leak.
NOTICE
Unscrew the jacking bolt suciently to ensure that the cover can be
fully tightened down without imparting any stress onto the jacking
points. Tighten down the cover bolt to 81 N m (60 ft lb) for 75 kW
and smaller compressors or 200 N m (150 ft lb) for 90 kW and larger
compressors. Refer to Figure 3 for the tightening sequence of the
bolts.
6. Inspect the tank scavenge screen and orice. Clean if necessary
following the instructions below.
7. Install the scavenge tube down into the tank until the tube just
touches the separator element and then raise it 3 mm (0.125 in).
Tighten ttings.
NOTICE
Take extreme caution to not force the scavenge tube into the tank.
This could potentially damage the separator element.
8. Install the piping in the original position.
Figure 3: Recommended Bolt Tightening Cross Pattern
3
5
1
9
7
4
6
2
10
8
3
11
5
1
9
7
4
12
6
2
10
8
55-75 kW90-160 kW
9. Start the compressor and check for leaks.
NOTICE
Do not use any form of sealant on either the separator tank or the
separator tank cover faces.
Inspecting Separator Tank / Pressure System
At 2000 hour intervals, inspect the external surfaces of the airend and
separator tank, including all ttings, for visible signs of impact damage,
excessive corrosion and abrasions. When changing the separator element,
inspect the internal components and surfaces. Any suspect parts shall 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.

121714.07.03