Ingersoll-Rand Sierra H 125 Operation and Maintenance Manual

Type
Operation and Maintenance Manual
SL, SM & SH 90, 110, 132, 150, 200, 250 & 300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
This manual contains
important safety information
and must be made available
to personnel who operate and
maintain this machine.
OPERATION AND MAINTENANCE MANUAL
LIBRO D’USO E MANUTENZIONE
MANUAL DE MANEJO Y MANTENIMIENTO
MANUAL DE OPERAÇAO E CONSERVAÇAO
C.C.N. : 80441306
REV. : D
DATE : JANUARY 2010
en pt it es
ENGLISH
PRINT LANGUAGE
PORTUGUESE
SPANISH
ITALIAN
U.K. PRESSURE SYSTEM REGULATIONS FINAL IMPLEMENTATION 1 JULY 1994
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
COMPONENT CURRENT
INFORMATION
REVISED
INFORMATION
COMMENT
Pressure vessel. F59 form (U.K. only)
As required, detailed
examination by local /
national legislation.
As required, detailed
examination by local /
national legislation.
1 year Fully inspect
all external surfaces,
welds and fittings;
. report any excessive
corrosion, mechanical
or impact damage.
. report any leakage
or other deterioration.
6 year Remove lid
and any necessary
fittings.
. Fully clean out.
. Fully inspect all
internal surfaces and
welds.
F59 regulation ended
1 July 1994.
Change.
Not applicable to this
compressor unless for
special order.
Pressure gauge. 2 year Remove and
calibrate.
1 year Remove and
calibrate.
Not applicable to this
compressor
Pressure regulator. 1 year Check correct
function.
Not applicable to this
compressor
Filters, valves and
hoses.
6 months No change (Maximum
recommended 1 year.
CONTENTS & ABBREVIATIONS
1
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
CONTENTS
1 CONTENTS
2 FOREWORD
3 DECALS
11 SAFETY
13 GENERAL INFORMATION
26 INSTALLATION / HANDLING
54 OPERATING INSTRUCTIONS
63 MAINTENANCE
66 TROUBLE SHOOTING
ABBREVIATIONS & SYMBOLS
#### Contact IngersollRand 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 (IP55)
O.D.P. Open drip proof motor (IP23)
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
FOREWORD
2
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
The contents of this manual are considered to be proprietary and
confidential to IngersollRand and should not be reproduced without
the prior written permission of IngersollRand.
Nothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied, regarding
the IngersollRand 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
routine operation and scheduled maintenance tasks by operation and
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised IngersollRand service
department.
The design specification of this machine has been certified as
complying with E.C. directives. Any modification to any part is
absolutely prohibited and would result in the CE certification and
marking being rendered invalid.
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 IngersollRand.
. 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.
Details of approved equipment are available from Ingersoll–Rand
Service departments.
The use of nongenuine spare repair parts other than those
included within the IngersollRand approved parts list may create
hazardous conditions over which IngersollRand has no control.
Therefore IngersollRand does not accept any liability for losses
caused by equipment in which nonapproved repair parts are installed.
Standard warranty conditions may be affected.
IngersollRand 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.
The intended uses of this machine are outlined below and examples
of unapproved usage are also given, however IngersollRand cannot
anticipate every application or work situation that may arise.
IF IN DOUBT CONSULT SUPERVISION.
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, vapours. or particles
. Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.
The use of the machine in any of the situation types listed in
table 1:
a) Is not approved by IngersollRand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against IngersollRand.
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
checks.
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 vapours.
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.
The company accepts no responsibility for errors in translation of
this manual from the original English version.
COPYRIGHT 2010
INGERSOLL RAND COMPANY
DECALS 3
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
ISO SYMBOLS
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory Information / Instructions Warning
Use fork lift truck from this side only. RESET Do not use fork lift truck from this side.
Emergency stop. On (power). Off (power).
AUTOMATIC RESTART MAINTENANCE MAINTENANCE PROHIBITED
FRAGILE KEEP DRY THIS WAY UP
USE NO HOOKS NO SIDE CLAMPS HOURS
POWER INSPECT
Every X months, if sooner than required by
operating hours
DECALS4
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
CHANGE / REPLACE CLEAN POWER INLET (AC)
Pinch point hazard.
Keep hands clear.
DECALS 50Hz 5
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
2_C
WARNING Before starting the machine
consult the operation and maintenance
manual.
WARNING For operating temperature
below 2_C, consult the operation and
maintenance manual.
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: Electrical shock risk. WARNING Pressurised vessel.
WARNING Hot surface. WARNING Pressure control. WARNING Corrosion risk.
WARNING Air/gas flow or Air discharge.
WARNING Pressurised component or
system.
WARNING Flammable liquid.
DECALS 50Hz6
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
WARNING WARNING EXHAUST GAS
Do not breathe the compressed air from this
machine.
Do not remove the Operating and Maintenance
manual and manual holder from this machine.
Do not stack.
Do not operate the machine without the guard
being fitted.
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 open the service valve before the
airhose is attached
No naked lights.
Read the Operation and Maintenance manual
before operation or maintenance of this
machine is undertaken.
Use fork lift truck from this side only. Emergency stop. Tie down point
Lifting point. On (power). Off (power).
DECALS 50Hz 7
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
Air intake. Minimum clearance to walls.
Use only IngersollRand ULTRA COOLANT
lubricating oil.
Oil pressure Air pressure Filter condition
DECALS 60Hz8
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
DECALS 60Hz 9
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
DECALS 60Hz10
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
SAFETY
11
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
DANGER!
Hazard that WILL cause DEATH, SEVERE INJURY or substantial
property damage if ignored. Instructions must be followed precisely to
avoid injury or death.
WARNING!
Hazard that CAN cause DEATH, SEVERE INJURY or substantial
property damage if ignored. Instructions which must be followed
precisely to avoid injury or death.
CAUTIONS!
Cautions call attention to instructions which must be followed
precisely to avoid damaging the product, process or its surroundings.
NOTES
Notes are used for supplementary information.
BREATHING AIR PRECAUTION
IngersollRand air compressors are not designed, intended or
approved for breathing air. Compressed air should not be used for
breathing air applications unless treated in accordance with all
applicable codes and regulations.
General Information
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.
Do not point air nozzles or sprayers toward anyone.
Compressed air and electricity can be dangerous. Before
undertaking any work on the compressor, ensure that the electrical
supply has been isolated and the compressor has been relieved of all
pressure.
Wear eye protection when operating or servicing compressor.
All persons positioned near to operating machinery should be
equipped with hearing protection and given instructions on its use in
accordance with workplace safety legislation.
Make sure that all protective covers are in place and that the
canopy/doors are closed during operation.
The specification of this machine is such that the machine is not
suitable for use in flammable gas risk areas.
Installation of this compressor must be in accordance with
recognised electrical codes and any local Health and Safety Codes.
The use of plastic bowls on line filters can be hazardous. Their
safety can be affected by either synthetic lubricants, or the additives
used in mineral oils. Ingersoll Rand recommends that only filters with
metal bowls should be used on a pressurised system.
Compressed air
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.
WARNING
Imposing a normal or emergency stop on the compressor will
only relieve pressure upstream of the discharge check valve.
If maintenance work is required downstream of this valve, ensure
that all pressure is relieved at the process vent point external to
the compressor.
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 isolation valves must be fitted and
controlled by work procedures, so that one machine cannot
accidentaly be pressurised / over pressurised by another.
Compressed air must not be used for a direct feed to any form of
breathing apparatus or mask.
If the discharged air is to be ultimately released into a confined
space, adequate ventilation must be provided.
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.
Avoid bodily contact with compressed air.
All safety valves must be checked periodically for correct operation.
Do not overpressurize the receiver tank or similar vessels beyond
design limits.
Do not use a receiver tank or similar vessels that fail to meet the
design requirements of the compressor. Contact your distributor for
assistance.
Do not drill into, weld or otherwise alter the receiver tank or similar
vessels.
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
For further information, consult Material Data Sheet 80440043
(LUBE OIL)
AVOID INGESTION, SKIN CONTACT AND INHALATION OF
FUMES
Transport
When loading or transporting machines ensure that the specified
lifting and tie down points are used.
Lifting equipment must be properly rated for the weight of the
compressor.
Do not work on or walk under the compressor while it is suspended.
Electrical
Keep all parts of the body and any handheld 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.
WARNING
Any electrical connections or adjustments should only be
made by a suitably qualified electrician
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 its rated
capacity.
SAFETY
12
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
Mobile Telephones
The correct operation of this machine may be affected by the nearby
use of a mobile telephone. Ensure that such telephones, when in use,
are kept at least 5 metres from the perimeter of a machine which is
operating or is being worked on whilst connected to its power supply.
Condensate 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. IngersollRand and its associated distributors are
happy to advise and assist in these matters.
GENERAL INFORMATION
13
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
Revision 02
10/98
39899000
125–200HP
(90–150kW)
AC
KEY
A AIR PIPING
O OIL PIPING
CP CONDENSATE PIPING
B BLOWDOWN PIPING
S1 FIRST COMPRESSOR STAGE
S2 SECOND COMPRESSOR STAGE
GC GEARCASE
SU SUMP
AF AIRFILTER
BFV BUTTERFLY THROTTLE VALVE
HC HYDRAULIC CYLINDER
IC INTERCOOLER
AC AFTERCOOLER
OC OIL COOLER
OM OIL MANIFOLD
OF OIL FILTER
OTCV OIL TEMP CONTROL VALVE
OP OIL PUMP
ODV OIL DRAIN VALVE
1OR ORIFICE BLOWDOWN
2OR ORIFICE OIL FLOW
OS OIL STRAINER
BR BREATHER
BDV BLOWDOWN VALVE
DCV DISCHARGE CHECK VALVE
CA COMPRESSED AIR
C CONDENSATE
1DS FIRST STAGE DISCHARGE SILENCER
2DS SECOND STAGE DISCHARGE SILENCER
3DS DISCHARGE BLOWDOWN SILENCER
1EJ INTERSTAGE EXPANSION JOINT
2EJ DISCHARGE EXPANSION JOINT
GENERAL INFORMATION
14
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
3EJ DISCHARGE EXPANSION JOINT
4EJ SECOND STAGE EXPANSION JOINT
1RV INTERSTAGE SAFETY RELIEF VALVE
2RV DISCHARGE SAFETY RELIEF VALVE
3RV OIL PRESSURE RELIEF VALVE
1MS INTERSTAGE MOISTURE SEPARATOR
2MS DISCHARGE MOISTURE SEPARATOR
1MCV INTERSTAGE MANUAL CONDENSATE VALVE
2MCV DISCHARGE MANUAL CONDENSATE VALVE
1SSV INTERSTAGE STRAINER SERVICE VALVE
2SSV DISCHARGE STRAINER SERVICE VALVE
1CS INTERSTAGE CONDENSATE STRAINER
2CS DISCHARGE CONDENSATE STRAINER
CCV CONDENSATE CHECK VALVE
1SV LOAD SOLENOID VALVE
6SV INTERSTAGE CONDENSATE SOLENOID VALVE
9SV DISCHARGE CONDENSATE SOLENOID VALVE
CLS CONDENSATE LEVEL SWITCH (OPTIONAL)
1AVPT VACUUM PRESSURE TRANSDUCER RANGE : 01 BAR
(015psi)
2APT AIR PRESSURE TRANSDUCER RANGE : 06.9 BAR
(0100psi)
3APT AIR PRESSURE TRANSDUCER RANGE : 013.8 BAR
(0200psi)
4APT AIR PRESSURE TRANSDUCER RANGE : 013.8 BAR
(0200psi)
50PT OIL PRESSURE TRANSDUCER RANGE : 06.9 BAR
(0100psi)
60PT OIL PRESSURE TRANSDUCER RANGE : 06.9 BAR
(0100psi)
2ATT AIR TEMPERATURE TRANSDUCER (RTD) RANGE :
18+266° C (0510°F)
3ATT AIR TEMPERATURE TRANSDUCER (THERMISTOR)
RANGE : 18+121°C (0250°F)
4ATT AIR TEMPERATURE TRANSDUCER (RTD) RANGE :
18+266° C (0510°F)
7ATT AIR TEMPERATURE TRANSDUCER (THERMISTOR)
RANGE : 18+121°C (0250°F)
50TT OIL TEMPERATURE TRANSDUCER (THERMISTOR)
RANGE : 18+121°C (0250°F)
GENERAL INFORMATION
15
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
Revision 02
10/98
39897004
125–200HP
(90–150kW)
WC
KEY
W WATER PIPING
A AIR PIPING
O OIL PIPING
CP CONDENSATE PIPING
B BLOWDOWN PIPING
S1 FIRST COMPRESSOR STAGE
S2 SECOND COMPRESSOR STAGE
GC GEARCASE
SU SUMP
AF AIRFILTER
BFV BUTTERFLY THROTTLE VALVE
HC HYDRAULIC CYLINDER
IC INTERCOOLER
AC AFTERCOOLER
OC OIL COOLER
OM OIL MANIFOLD
OF OIL FILTER
OTCV OIL TEMP CONTROL VALVE
OP OIL PUMP
ODV OIL DRAIN VALVE
1OR ORIFICE BLOWDOWN
2OR ORIFICE OIL FLOW
OS OIL STRAINER
BR BREATHER
BDV BLOWDOWN VALVE
DCV DISCHARGE CHECK VALVE
CW COOLING WATER
CA COMPRESSED AIR
C CONDENSATE
1DS FIRST STAGE DISCHARGE SILENCER
2DS SECOND STAGE DISCHARGE SILENCER
3DS BLOWDOWN DISCHARGE SILENCER
1EJ INTERSTAGE EXPANSION JOINT
3EJ DISCHARGE EXPANSION JOINT
1RV INTERSTAGE SAFETY RELIEF VALVE
2RV DISCHARGE SAFETY RELIEF VALVE
GENERAL INFORMATION
16
SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz)
L, H & HH 125, 150, 200, 250, 300, 350 & 400 (60Hz)
3RV OIL PRESSURE RELIEF VALVE
1MS INTERSTAGE MOISTURE SEPARATOR
2MS DISCHARGE MOISTURE SEPARATOR
1MCV INTERSTAGE MANUAL CONDENSATE VALVE
2MCV DISCHARGE MANUAL CONDENSATE VALVE
1SSV INTERSTAGE STRAINER SERVICE VALVE
2SSV DISCHARGE STRAINER SERVICE VALVE
1CS INTERSTAGE CONDENSATE STRAINER
2CS DISCHARGE CONDENSATE STRAINER
CCV CONDENSATE CHECK VALVE
1SV LOAD SOLENOID VALVE
6SV INTERSTAGE CONDENSATE SOLENOID VALVE
9SV DISCHARGE CONDENSATE SOLENOID VALVE
4SV WATER SOLENOID VALVE
WVV WATER VENT VALVE
CLS CONDENSATE LEVEL SWITCH (OPTIONAL)
1AVPT VACUUM PRESSURE TRANSDUCER RANGE : 01 BAR
(015psi)
2APT AIR PRESSURE TRANSDUCER RANGE : 06.9 BAR
(0100psi)
3APT AIR PRESSURE TRANSDUCER RANGE : 013.8 BAR
(0200psi)
4APT AIR PRESSURE TRANSDUCER RANGE : 013.8 BAR
(0200psi)
50PT OIL PRESSURE TRANSDUCER RANGE : 06.9 BAR
(0100psi)
60PT OIL PRESSURE TRANSDUCER RANGE : 06.9 BAR
(0100psi)
2ATT AIR TEMPERATURE TRANSDUCER (RTD) RANGE :
18+266° C (0510°F)
3ATT AIR TEMPERATURE TRANSDUCER (THERMISTOR)
RANGE : 18+121°C (0250°F)
4ATT AIR TEMPERATURE TRANSDUCER (RTD) RANGE :
18+266° C (0510°F)
7ATT AIR TEMPERATURE TRANSDUCER (THERMISTOR)
RANGE : 18+121°C (0250°F)
50TT OIL TEMPERATURE TRANSDUCER (THERMISTOR)
RANGE : 18+121°C (0250°F)
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Ingersoll-Rand Sierra H 125 Operation and Maintenance Manual

Type
Operation and Maintenance Manual

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