Ingersoll-Rand R37-160 Product Maintenance Information

Brand: Ingersoll-Rand

Model: R37-160

Type: Product Maintenance Information

80446354

Revision D

November 2014

Save These Instructions

Contact-Cooled Rotary Screw Air Compressor

Product Maintenance Information

R37-160

121714.07.03

PRINT LANGUAGE

ENGLISH

SPANISH

FRENCH

PORTUGUESE

80446354 Rev D EN-2

ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

AIR COMPRESSOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . .3

Maintenance Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Analyzing Food-Grade Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Sampling Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Changing Coolant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Checking Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Changing Separator Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Inspecting Separator Tank / Pressure System . . . . . . . . . . . . . . . . . . . . 5

Cleaning / Checking Scavenge Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Replacing Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Checking Minimum Pressure Check Valve (MPCV) . . . . . . . . . . . . . . . 6

Changing Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Regreasing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cleaning Air Cooled Sequential Cooling System . . . . . . . . . . . . . . . . . 6

Removing / Installing Air Cooled Cooler. . . . . . . . . . . . . . . . . . . . . . . . . 6

Cleaning Water Cooled Cooler (for both Clean & Harsh

Water Options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Checking High Airend Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . 7

Cleaning Motor Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.

121714.07.03

EN-3 80446354 Rev D

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.

121714.07.03

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.



121714.07.03

EN-5 80446354 Rev D

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

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

80446354 Rev D EN-6

Cleaning / Checking Scavenge Screen

The screen/orice assemblies are similar in appearance to a straight tubing

connector and will be located between two pieces of 6 mm (0.25 in)

O.D. scavenge line tubing.

The main body is made from 17 mm hexagon shaped metal and the diameter

of the orice and a direction-of-ow arrow is stamped in at areas of the

hexagon.

A removable screen and orice will require clearing as outlined in the

maintenance chart.

To remove the screen/orice:

1. Disconnect the scavenge line tubing from each end.

2. Hold the center section rmly and use a pair of pliers to gently

grasp the exit end of the assembly that seals against the scavenge

line tubing. The exit end is the end toward which the arrow is

pointing.

3. Pull the end out of the center section while using care to prevent

damage to the screen or sealing surfaces.

4. Clean and inspect all parts prior to reinstallation.

5. When the assembly is installed, conrm the direction of ow to

be correct. Observe the small arrow stamped in the center section

and ensure the direction ow to be from the separator tank to the

airend.

Replacing Coolant Hoses

The exible hoses that carry coolant through the cooling system may

become brittle with age and will require replacement. Replace them as

needed or every four years.

1. Depending on the location of the hose, it may contain compressor

coolant. It is recommended to drain the coolant into a clean

container. Cover the container to prevent contamination. If the

coolant is contaminated, replace with new coolant.

2. Remove the hose.

3. Install the new hose and rell the compressor with coolant.

4. Start the compressor, check for leaks and check coolant level. Rell

as necessary.

Checking Minimum Pressure Check Valve (MPCV)

The minimum pressure check valve (MPCV) shall be frequently tested and

regularly maintained. Remove it from the compressor for testing. If operating

conditions are particularly severe, the frequency of testing and maintenance

shall be increased accordingly. The user shall establish the frequency of

such tests as it is inuenced by such factors as the severity of the operating

environment.

The minimum pressure check valve (MPCV) should be tested and re-

calibrated in accordance with any national or local codes that may exist. If

no code exists, Ingersoll Rand recommends that the valve is recalibrated at

intervals of one year by a licensed contractor or qualied service personnel.

Changing Air Filter

1. Check the retaining cap for dirt and debris and wipe clean.

2. Unclip the retaining cap and withdraw the old element.

3. Fit the new element and ret the retaining cap.

Regreasing Motor

The blower motor contains pre-greased, sealed bearings. They cannot be

re-greased and do not require re-greasing. For the main motor, consult the

motor manufacturer to conrm that the motor may be greased and to obtain

instructions for regreasing.

Cleaning Air Cooled Sequential Cooling System

Air compressor operating temperatures will be higher than normal if the

external passages between the ns of the cooler cores become restricted

with foreign material. Regular cleaning of the cooler surfaces will support

the reliable operation of the air compressor system, improve the life of

the compressor coolant and improve overall compressor eciency. When



performed frequently as determined by site conditions and airborne

contamination, more signicant cleaning or replacement may not be

necessary.

1. Stop the compressor.

2. Isolate the compressor from the 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. Ensure that the main power disconnect switch is locked o and

tagged.

NOTICE

For any required lifting of air compressor parts or required tools,

always use the proper certied lifting equipment, and employ sound

working principles.

5. Visually check the outside of the cooler cores to determine the

appropriate cleaning method detailed as follows:

a. For loose dirt, dust and other light foreign material, open the

access panels on the sides of the cooler plenum and gently

blow compressed air across the coolant cooler surface. Use a

vacuum hose with a soft brush to clean the exposed face of the

air aftercooler. Repeat the process until the coolers are suciently

clean. Replace the access panels before returning the compressor to

service.

b. For thick, packed dirt, coolant or grease, or other heavy material,

the coolers will need to be removed from the compressor for

pressure washing. Ingersoll Rand does NOT support pressure

washing coolers when they are installed in the compressor due

to the dangers of spraying water in or around potential electrical

power sources. Follow the steps below for cooler removal.

Removing / Installing Air Cooled Cooler

To remove:

1. Stop the compressor.

2. Isolate the compressor from the 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. Ensure that the main power disconnect switch is locked o and

tagged.

NOTICE

For any required lifting of air compressor parts or required tools,

always use the proper certied lifting equipment, and employ sound

working principles.

5. Drain the coolant from the coolant cooler by removing the hex plug

located at the front of the air cooler, and lower side of the coolant

cooler.

6. Remove all hoses, pipes, and sensors from the coolers.

7. Remove the external sheet metal panels.

8. Remove the access panels on the sides of the cooler plenum.

9. Properly secure the air aftercooler and remove the four nuts from

the two bolts at the upper sides of the cooler.

10. Remove the two nuts from the bolts at the bottom of the cooler.

11. Carefully remove the air aftercooler.

12. Properly secure the coolant cooler and remove the four nuts from

the two bolts at the upper sides of the cooler.

13. Remove the two nuts from the bolts at the bottom of the cooler.

14. Carefully remove the coolant cooler.



121714.07.03

EN-7 80446354 Rev D

15. Re-install the coolant drain plug to 23 N m (17 ft lb) for compressors

75 kW and smaller or 65 N m (48 ft lb) for compressors 90 kW and

larger.

To install:

1. Stop the compressor.

2. Isolate the compressor from the 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. Ensure that the main power disconnect switch is locked o and

tagged.

NOTICE

For any required lifting of air compressor parts or required tools,

always use the proper certied lifting equipment, and employ sound

working principles.

5. Carefully place the coolant cooler in its proper location and install

the two sets of lower nuts and bolts, tightly.

6. Install the two sets of upper side nuts and bolts, nger tight + ¼

turn. Next, add the second nut to each tightly. This second nut is

used to lock the rst in place. It is important the rst nut is not too

tight so it can allow the cooler to expand and contract without

stressing the cooler’s brazed joints.

7. Ensure the rubber seal on the air aftercooler is in place on the

cooler and in good condition.

8. Carefully place the air aftercooler cooler in its proper location and

install the two sets of lower nuts and bolts tightly.

9. Install the two sets of upper side nuts and bolts nger tight + ¼

turn. Next add the second nut to each tightly. This second nut is

used to lock the rst in place. It is important the rst nut is not too

tight so it can allow the cooler to expand and contract without

stressing the cooler’s brazed joints.

10. Re-attach all hoses, pipes and sensors, and properly torque

according to the Parts Information manual.

11. Replace the access panels on the sides of the cooler plenum.

12. Rell the compressor with coolant to the proper level, following the

process outlined in the “Adding Coolant” procedure.

Cleaning Water Cooled Cooler (for both Clean & Harsh Water

Options)

A periodic inspection and maintenance program should be implemented for

water cooled heat exchangers. It is recommended that you contact

Ingersoll Rand for cleaning services should you not have experience and

equipment to do this work.



If water inlet lines have strainers, inspect them and replace or clean as

required.

Mineral scale may be removed with a suitable de-scaling agent containing

amidosulphuric acid + citric acid and Neutralit solutions for cleaning the

coolers. As an alternative, any weak acid mixed with water in the ratio of 1:4

may be used.

Fouling should be removed with a suitable detergent in hot water.

Back ush the cooler with a ow rate at least 1.5 times the normal ow rate.

After using any cleaning solution, thoroughly ush out all chemicals with

clean water before returning the cooler to service.

Mechanical cleaning methods are not recommended as damage to the

internal passages may occur.

After cleaning, examine the cooler for erosion or corrosion.

Checking High Airend Temperature Sensor

It is recommended that the discharge temperature sensor (2ATT) is checked

regularly as follows:

a. For air cooled compressors, stop the cooling blower by opening the

blower / fan motor circuit breaker.

b. For water cooled compressors, shut o the cooling water.

The compressor should trip at 109 °C (228 °F). A trip warning will appear on

the controller display.

Cleaning Motor Cowl

1. Ensure the compressor is electrically isolated for at least 15 minutes

before commencing any maintenance work.

2. Remove the panels from the compressor.

3. Using a clean dry cloth, remove dust from the surface of the motor

cowl and ensure all ventilation slots are free of obstructions.

4. Replace the panels.

Removing / Replacing Starter Box Power Drive Module (PDM)

Filter Element (For VSD only)

See Figure 4.

1. Ensure compressor is electrically isolated for at least 15 minutes

before commencing any maintenance work.

2. Unclip the front grill of the starter box lter housing.

3. Remove the lter element from the housing and replace with a new

lter element.

4. Replace the front grill.



Figure 4: Starter Box Power Drive Module (PDM) Filter Element Replacement

121714.07.03

80446354 Rev D EN-8

Cleaning / Checking Condensate Drain

1. Ensure the compressor is electrically isolated for at least 15 minutes,

before commencing any maintenance work.

2. Isolate the compressor from the system and fully discharge the

compressed air within the compressor.

3. Remove the tube from the tting located on the bottom of the

moisture separator.

4. Remove the bowl of the moisture trap, clean and replace.

Cleaning / Installing Package Pre-Filter

1. Unlatch the two 1/4 turn latches and open the intake panel (panel

is hinged)

2. Remove the six wing nuts and at washers.

3. Remove the lter grill.

4. Pull out the lter element.

5. Center the new element over the package intake opening. Also

note that the lter is washable with mild detergent.

6. Push the lter over the grill studs so that the studs poke through

the lter media.

7. Install the lter grill.

8. Install the six wing nuts and at washers.

9. Close the intake panel and latch.



Checking / Cleaning No Loss Drain Trap (where tted)

It is recommended to check the no loss drain trap daily to ensure that

condensate is draining from the moisture separator system. To check for

correct function:

1. Press the test button on the drain and listen for condensate / air

passing through the drain.

2. If the drain is clogged, replace the no loss drain valve service

module. The service module consists of the lower portion of the

drain trap and is not serviceable.

Additionally, it is recommended to replace the service module every

8000 hours or once per year, whichever comes rst.

Monitoring Fluid and Performing Shock Pulse Bearing

Analysis

Ingersoll Rand recommends incorporating predictive maintenance,

specically the use of coolant and shock pulse bearing analysis, into all

preventative maintenance programs. Contact Ingersoll Rand for details.



121714.07.03

EN-9 80446354 Rev D

TROUBLESHOOTING

This section provides basic troubleshooting information. Determination of specic causes to problems are best identied by thorough inspections performed

by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common symptoms, probable

causes and remedies.

Table 3: General Faults

SYMPTOM CAUSE REMEDY

Compressor will not start. No power supply to compressor. Check supply is switched on. If so, contact a qualied

electrician.

Controller failure. Check supply to controller. Replace controller.

Starter failure. Isolate supply, lock o and tag. Replace failed component

or contact your local Ingersoll Rand representative.

Compressor stops and will not

restart.

Drive controller has tripped. See Tables 3 and 4.

Controller has tripped the compressor. See Tables 3 and 4.

Maximum number of starts per hour exceeded.

Compressor is stopped and will not

restart.

Controller has tripped the compressor and has not

been reset.

See Tables 3 and 4.

Emergency stop has been pressed and not released. Identify reason why, repair fault, disengage button and

reset controller.

Emergency stop has been pressed and released but

controller has not been reset.

Repair fault and reset controller.

Compressor will not meet pressure

required by system.

Compressor not sized to meet system requirements

or requirements have been changed.

Contact your local Ingersoll Rand representative.

Air loss due to pipe, hose, joint or seal failure. Repair or replace.

Air loss due to blowdown valve stuck open. Repair or replace.

Air loss through pressure relief valve not seating or

set incorrectly.

Repair or replace.

Air loss due to moisture separator drain trap stuck

open.

Repair or replace.

Motor speed too low caused by drive incorrectly set. Contact your local Ingersoll Rand representative.

Motor speed too low caused by fault in drive settings. See Table 4.

Controller fault. Repair or replace.

Drive motor fault. See Table 4.

Pressure transducer faulty, incorrectly calibrated or

EMF interference.

Recalibrate or replace.

Incorrect controller settings. Check and modify settings.

Inlet grill or ducting is blocked. Check and clean.

Air lter dirty or collapsed. Replace.

Compressor will not meet pressure

required by system.

Inlet valve not opening fully. Repair or replace.

Separator element dirty or collapsed. Replace.

Pipe / Hoses blocked or collapsed. Clean or replace.

Cooler core blocked. Clean or replace.

Minimum pressure check valve not functioning

correctly.

Repair or replace.

Equipment between compressor and customer

measuring point causing pressure drop / pressure

loss.

Review system requirements.

Pressure produced by compressor is

too high due to speed not reducing

as demand reduces.

Controller set incorrectly. Check and modify settings.

Pressure transducer may be faulty, incorrectly

calibrated or not receiving pressure signal.

Recalibrate or replace.

Drive settings fault. Contact your local Ingersoll Rand representative.

Compressor discharge air too hot. High ambient temperature. Review installation and system parameters.

Insucient cooling air. Check ducting and cooling air path, check direction of

blower rotation.

Dirty, blocked aftercooler (cooling air side). Clean or replace.

121714.07.03

80446354 Rev D EN-10

Table 3: General Faults (cont.)

SYMPTOM CAUSE REMEDY

Compressor package produces

excessive noise.

Panels or doors are not closed properly. Rectify fault.

Air leaks from internal pipework / components. Repair or replace.

Blower or blower motor bearings worn. Repair or replace.

Loose debris impacting on blower during rotation. Remove and rectify any damage.

Blowdown valve stuck open. Repair or replace.

Pressure relief valve not seating correctly. Repair or replace.

Vibration due to motor, airend or blower imbalance. Repair or replace.

Airend requires repair. Contact your local Ingersoll Rand representative.

Discharge air is contaminated with

coolant.

Scavenge pipe is blocked, broken or o-ring is not

sealing.

Clean or replace.

Separator element is punctured, or incorrect, or

requires changing, or not sealing correctly.

Replace.

Incorrect coolant has been added. Drain system, check for damage. Clean, rell with correct

coolant.

System has been overlled with coolant. Check for damage, drain excess.

Discharge air is contaminated with

condensate.

Aftercooler not functioning correctly. Clean or replace.

Moisture separator drain trap faulty. Repair or replace.

Continuous low speed / low ambient operation

causing condensate build up.

Review system requirements and contact your local

Ingersoll Rand representative.

Compressor package draws too much

current.

Compressor operating above rated pressure. Check and modify settings. Review system requirements

and contact your local Ingersoll Rand representative.

Separator lter element dirty or blocked. Replace.

Voltage supply is low or unbalanced. Contact your local Ingersoll Rand representative or a

qualied electrician.

Airend is damaged. Contact your local Ingersoll Rand representative.

Excessive coolant consumption. Coolant system leak. Repair or replace.

See also ‘discharge air is contaminated with coolant’. See above.

High dewpoint. Refrigeration compressor not supplied power. Check incoming power supply.

Check the dryer protection fuse.

Check auxiliary contact on main motor contactor.

Condensate system malfunction. Check operation of drain valve.

Check operation of condensate check valves.

Condenser dirty. Clean condenser and replace panel lter element.

Ice formation in dryer. Low evaporator pressure. Check hot gas valve setting.

Solenoid condensate valve will not

Debris in solenoid valve prevents diaphragm from

seating.

Remove solenoid valve, disassemble, clean and

reassemble.

Short in electrical component. Check and replace power cord or timer as needed.

121714.07.03

EN-11 80446354 Rev D

Table 4: Controller Faults (indicated on the controller)

FAULT CAUSE REMEDY

Emergency stop. Emergency stop button has been

pressed.

Identify reason why, repair fault, disengage button and reset controller.

Blower motor overload. Blower is blocked, damaged or blower

motor is faulty.

Remove blockage, repair or replace damaged components.

High airend discharge temperature. Compressor operating above rated

pressure.

Check and modify settings. Review system requirements and contact

your local Ingersoll Rand representative.

Low coolant level. Check for leaks. See also ‘discharge air is contaminated with coolant’.

Top up coolant.

High ambient temperature. Review installation and system parameters.

Insucient cooling air. Check ducting and cooling air path.

Dirty, blocked coolant cooler (cooling

air side).

Clean or replace.

Blower motor direction of rotation

incorrect.

Wire correctly.

Check setpoints. Controller software has been changed. Recalibrate all sensors and check setpoints.

Remote start failure. Remote start button is pressed after

compressor is running or remote start

button remains closed.

Check operation of buttons or operating procedures.

Remote stop failure. Remote stop button remains open and

either start button is pressed.

Check operation of buttons or operating procedures.

Sensor failure. Sensor is missing or faulty. Install, repair or replace faulty sensor.

Compressor trips indicating a high

compressor temperature.

Insucient cooling taking place. If compressor is watercooled or sea watercooled, check that the cooling

water is owing. Check that there is no air in the water cooling system.

Check that the strainer is not blocked.

Controller has tripped the

compressor.

A fault has occurred. Repair fault / reset controller.

Invalid calibration. Calibration done with pressure in

compressor.

Depressurize and re calibrate with pressure pipe to sensor

disconnected. If fault still exists, replace pressure transducer.

Low sump pressure. System leak. Located and repair.

Minimum pressure check valve faulty. Repair with service kit.

Blowdown valve faulty. Repair with service kit.

Loss of control power. Check 110V circuit breaker.

Check wiring.

Check contactor KM1.

Check motor rotation. Drive system fault. Contact your local Ingersoll Rand representative.

VSD communication failure. Communication wiring faulty. Check and replace if required.

Drive faulty. Contact your local Ingersoll Rand representative.

Controller faulty. Contact your local Ingersoll Rand representative.

VSD initialization fault. Communication wiring faulty. Check and replace if required.

Drive faulty. Contact your local Ingersoll Rand representative.

Controller faulty. Contact your local Ingersoll Rand representative.

Change separator element and/or

high sump pressure.

Faulty pressure transducer measurement. Calibrate and validate the wet sump and package discharge

transducers.

Moisture separator condensate drain

trap faulty.

Ensure condensate drain system is functioning properly, and

condensate is being drained. See Table 3: Troubleshooting Chart.

Separator element dirty or blocked. Change separator element.

Change HE lter (integrated dryer

models only).

Faulty pressure transducer measurement. Calibrate and validate the after cooler discharge and package

discharge transducers.

Moisture separator condensate drain

trap faulty.

Ensure condensate drain system is functioning properly, and

condensate is being drained. See Table 3: Troubleshooting Chart.

Blockage in dryer. Ensure dryer blockage is not due to freeze up from refrigerant leaks.

Dryer HE lter dirty or blocked. Change HE lter.

121714.07.03

80446354 Rev D EN-12

Table 5: Drive Faults (indicated on the controller)

The drive controller is directly linked to the controller. Faults in the drive controller will be displayed on the controller as ‘VSD fault 0, VSD fault 1’ etc.

The following VSD faults may be investigated and remedied at source. For all other VSD faults, contact your local Ingersoll Rand customer support

representative.

FAULT CAUSE ACTION

VSD Fault 1 Over-current. Check separator element.

Check cooler, pipework and moisture separator for blockages.

Check operation of minimum pressure check valve (MPCV).

VSD Fault 3 Drive temperature too high. Check drive lter, replace if necessary.

Check drive cooling fan circuit breaker.

Check wiring.

VSD Fault 22 Current overload. Check oil level and add oil as needed.

Contact your local Ingersoll Rand representative.

VSD Fault 23 Motor underspeed. Check oil level and add oil as needed.

Contact your local Ingersoll Rand representative.

121714.07.03

EN-13 80446354 Rev D

R37-75 INTEGRATED DRYER MAINTENANCE

WARNING

Before accessing live electrical parts, disconnect the power supply

to the dryer using the disconnect switch or disconnecting the cable

connections.

Maintenance Chart

For optimum performance from your dryer, follow the periodic maintenance

schedule described below.

Table 6: Maintenance Chart

WEEKLY CONDENSATE DRAINS (TIMED AND NO-LOSS

DRAINS)

Verify that the condensate drains are operating

correctly by pressing the TEST button.

EVERY 4 MONTHS CONDENSER

Remove any dust from the condenser ns.

EVERY 6 MONTHS AIR FILTER

Replace air lter element.

YEARLY (TIMED DRAINS ONLY)

Completely disassemble the drains and clean all

their components.

Cleaning Condensate Drains (Timed Drains Only)

Periodically clean the screen inside the valve to keep the drain functioning at

maximum capacity. To do this, perform the following steps:

1. Close the strainer ball valve completely to isolate it from the air

receiver tank.

2. Press the TEST button on the timer to vent the pressure remaining

in the valve. Repeat until all pressure is removed.

WARNING

High pressure air can cause injury from ying debris. Ensure the

strainer ball valve is completely closed and pressure is released from

the valve prior to cleaning.

3. Remove the plug from the strainer with a suitable wrench. If you

hear air escaping from the cleaning port, STOP IMMEDIATELY and

repeat steps 1 and 2.

4. Remove the stainless steel lter screen and clean it. Remove any

debris that may be in the strainer body before replacing the lter

screen.

5. Replace plug and tighten with wrench.

6. When putting the valve back into service, press the TEST button to

conrm proper function.

Testing Condensate Drains (No-Loss Drains Only)

Press the TEST button to conrm proper function.

Troubleshooting Condensate Drains (Electronic

Drains Only)

This section provides basic troubleshooting information. Determination

of specic causes to problems are best identied by thorough inspections

performed by personnel instructed in safety, operation and maintenance

of this equipment. The chart below provides a brief guide to common

symptoms, probable causes and remedies.



Table 7: Condensate Drain Troubleshooting Chart

TROUBLE CAUSE ACTION

Solenoid

condensate valve

will not close.

Debris in solenoid valve

prevents diaphragm

from seating.

Remove solenoid valve,

disassemble, clean and

reassemble.

Short in electrical

component.

Check and replace power

cord or timer as needed.

Disassembling the Integrated Dryer

NOTICE

The dryer shall be disassembled, charged or repaired by a refrigerant

specialist.

Refrigerant liquid and lubricating oil inside the refrigeration circuit

shall be recovered in compliance with current norms in the country

where the dryer is installed.

NOTICE

Refrigerant leaks may be identied by tripping of the refrigeration

overload protector.

If a leak is detected in the refrigerant circuit, seek technical assistance.

If a refrigerant leak occurs, thoroughly air the room before

commencing work.

NOTICE

In normal temperature and pressure conditions, the R-404A

refrigerant is a colorless, class A1/A1 gas with TVL value of 1000 ppm

(ASHRAE classication).

Decommissioning the Integrated Dryer

Decommission the dryer and the relevant packaging in compliance with the

rules locally in force.

Pay particular attention to the refrigerant, as it contains part of the

refrigerating compressor lubricating oil.

Contact a waste disposal and recycling utility.

Table 8: Integrated Dryer Materials of Construction

RECYCLING DISASSEMBLY

Frame and panels Steel / epoxy resin polyester

Heat exchanger (cooler) Stainless steel / aluminum

Pipes Copper

Insulation Gum synthetic

Compressor Steel / copper / aluminum / oil

Condenser Aluminum

Refrigerant R-404A

Valve Steel



121714.07.03

ingersollrandproducts.com

121714.07.03

80446354

Revisión D

Noviembre 2014

Conserve estas instrucciones

Compresor de aire de tornillo giratorio

Información de mantenimiento del

producto

R37-160

121714.07.03

80446354 Rev D ES-2

ACERCA DE ESTE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PERSONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SEGURIDAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MANTENIMIENTO DEL COMPRESOR DE AIRE. . . . . . . . . . . . . . . . .3

Mensajes de Mantenimiento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Tabla de Mantenimiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Mantenimiento Periódico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Vericando el nivel de refrigerante . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Añadir refrigerante. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Drenado de refrigerante . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Analizando el refrigerante de grado alimentario . . . . . . . . . . . . . . . . 4

Muestras de refrigerante. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cambio del ltro del refrigerante. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Controlar el elemento del separador. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Cambio del elemento separador. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Inspección del tanque del separador / sistema de presión . . . . . . . . 5

Limpieza / control de la pantalla de purga. . . . . . . . . . . . . . . . . . . . . . . 6

Cambio de manguitos del refrigerante. . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vericación de la válvula de control de la presión mínima (MPCV) 6

Cambio del ltro de aire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Reengrasado del motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Limpieza del sistema de refrigeración secuencial de aire . . . . . . . . . 6

Retirar/instalar el refrigerante de aire. . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Limpieza del refrigerador de agua (para versiones de agua limpia y

dura) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Control del sensor de temperatura del extremo del compresor alto 7

Limpieza del capó del motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Retirar / sustituir el módulo de conducción de la caja de arranque

(PDM) elemento de ltro (solo para VSD) . . . . . . . . . . . . . . . . . . . . . . . 7

Limpieza/control del drenaje de condensado. . . . . . . . . . . . . . . . . . . . 8

Limpieza/instalación del preltro del paquete .. . . . . . . . . . . . . . . . . . 8

Vericación/limpieza de la trampilla de drenaje sin pérdida (si hay)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Control del análisis de uido y cojinetes de “Shock Pulse” . . . . . . . . 8

RESOLUCIÓN DE PROBLEMAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

R3775 MANTENIMIENTO DEL SECADOR INTEGRADO . . . . . . 14

Tabla de Mantenimiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Limpieza de los drenajes de condensado (solo drenajes

planicados) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Prueba de drenajes de condensado (sólo drenajes sin pérdida) . . 14

Resolución de problemas Drenajes de condensado (sólo drenajes

electrónicos). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Desmonte el secador integrado . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Retirada del servicio del secador integrado . . . . . . . . . . . . . . . . . . 14

CONTENIDO

ACERCA DE ESTE MANUAL

PERSONAL

SEGURIDAD

El uso, inspecciones y mantenimiento adecuados aumentan la vida y la

utilidad del compresor. Es extremadamente importante que todos los

involucrados en el mantenimiento del compresor estén familiarizados con

los procedimientos de mantenimiento y reparaciones de estos compresores

y que sean físicamente capaces de realizar los procedimientos. Este personal

debe ser capaz de realizar lo siguiente:

1. Manejo seguro y adecuado de herramientas mecánicas comunes,

así como de herramientas especiales o recomendadas por

Ingersoll Rand.

2. Procedimientos de seguridad, precauciones y hábitos de trabajo

establecidos por normas industriales aceptadas.

Algunos procedimientos de mantenimiento son técnicos en su naturaleza

y exigen herramientas especiales, maquinaria, formación y experiencia

para ser realizados correctamente. En dichas situaciones, sólo permita

que técnicos formados de Ingersoll Rand realicen el mantenimiento del

compresor. El personal operativo no debe intentar llevar a cabo el servicio o

las inspecciones más allá de los procedimientos indicados en este manual.

Para más información, póngase en contacto con la planta de Ingersoll Rand

o el técnico más cercano.

Antes de realizar cualquier trabajo en el compresor, asegúrese de haber

aíslado, bloqueado y marcado la alimentación eléctrica y de que el compresor

haya sido liberado de toda presión. Asegúrese de que el compresor está

aislado eléctricamente durante al menos 15 minutos antes de comenzar todo

trabajo de mantenimiento. Consulte el manual de información de seguridad

del producto para más información.

Ingersoll Rand no puede saber ni facilitar todos los procedimientos con

los que realizar las reparaciones ni los riesgos/resultados de cada método.

Si se realizan procedimientos de mantenimiento no recomendados

concretamente por el fabricante, asegúrese de que las acciones realizadas no

pongan en peligro la seguridad.

Si no está seguro del procedimiento o pasos para el mantenimiento, coloque

el compresor en una situación segura antes de consultar con un técnico.

El uso de piezas de repuesto que no sean de Ingersoll Rand puede suponer

en riesgo para la seguridad, disminuir el rendimiento, aumentar la necesidad

de mantenimiento e invalidar todas las garantías.

Para más información, póngase en contacto con la planta de Ingersoll Rand

o el técnico más cercano.

El objetivo de este manual es facilitar directrices para el mantenimiento y la resolución de problemas del compresor.

Para ver documentación de apoyo, consulte la Tabla 1.

Tabla 1: Manuales de producto

Publicación Producto

Número de pieza o documento por región

América EMEA * Pacíco asiático

Manual de información de seguridad del

producto

Todos 80446313 80446156 80446321

Manuales de información del producto Todos 80446339 80446164 80446347

Manual de información de piezas de

producto

R37-45 kW 80448095

R55-75 kW 80446271

R132-160 kW Fase individual 80446057

R90-160 kW Bifásico 80446065

* Europa, Oriente Medio y África

También están disponibles las hojas de especicación del producto y los diseños de referencia.

121714.07.03

ES-3 80446354 Rev D

MANTENIMIENTO DEL COMPRESOR DE AIRE

Mensajes de Mantenimiento

La advertencia de servicio y el LED parpadeante aparecerán en intervalos

determinados, dependiendo del nivel de servicio seleccionado. Consulte

el manual de información del producto para más información sobre la

conguración del nivel de servicio.

 Tabla de Mantenimiento

El mantenimiento debe ser realizado según las recomendaciones a

continuación con la siguiente prioridad: (1) Realice el mantenimiento cuando

se lo indique el controlador;(2) Realice el mantenimiento en intervalos

marcados por un número determinado de horas o según el mantenimiento

programado o (3) Anualmente.



Tabla 2: Tabla de mantenimiento

Periodo Acción Artículo de mantenimiento

Cuando lo indique el

controlador

Sustituir Elemento de ltro de aire

Sustituir Elemento de ltro del refrigerante

Diaria Comprobar Conexiones y manguitos para pérdidas

Comprobar Nivel de refrigerante

Comprobar Funcionamiento de drenaje de condensado

Comprobar Controlador de indicadores de servicio

Comprobar Preltro del paquete para bloqueo

Mensual Inspeccionar Sistema de refrigeración secuencial con aire para bloqueo

Inspeccionar Pantallas de sistema de refrigeración secuencial con agua

Inspeccionar Elemento de ltro del módulo de conducción de la caja de arranque (PDM)

Análisis Agua del sistema de refrigeración secuencial con agua

Cada 500 horas Análisis Refrigerante de grado alimentario

Cada 1000 horas Sustituir Refrigerante de grado alimentario (si no utiliza el módulo del ltro de grado alimentario)

Sustituir Filtro del refrigerante de grado alimentario (si no utiliza el módulo del ltro de grado alimentario)

Cada 2000 horas o

3 meses

Inspeccionar Elemento de ltro de aire

Inspeccionar Elemento de ltro del refrigerante

Inspeccionar Elemento de ltro del módulo de conducción de la caja de arranque (PDM)

Sustituir Refrigerante de grado alimentario (si utiliza el módulo del ltro de grado alimentario)

Sustituir Módulo del ltro de grado alimentario

Análisis Cojinete de pulso de choque

Análisis Refrigerante

Cada 4000 horas o

6 meses

Inspeccionar Pantalla de purga para bloqueo

Sustituir Elemento de ltro de aire

Sustituir Elemento de ltro del refrigerante

Sustituir Elemento de ltro del módulo de conducción de la caja de arranque (PDM)

Sustituir Elemento de preltro de paquete

Limpiar Sistema de refrigeración secuencial de aire

Inspeccionar / Limpiar Sistema de refrigeración secuencial de agua

Grasa

Todos los motores (si es necesario)

Calibrar Transductores de presión

Análisis Refrigerante

Análisis Cojinete de pulso de choque

Cada 8000 horas o

anualmente

Sustituir Refrigerante estándar [cada 8000 horas o dos años]

Sustituir Elemento separador

Sustituir Módulo de servicio de drenaje de condensado sin pérdida

Reparación Kit de servicio de la válvula de control de presión mínima (MPCV)

Reparación Kit de servicio de válvula de admisión

16.000 Horas Sustituir Manguitos del refrigerante

Sustituir Puntas de contacto

AVISO

Revise y cambie los elementos de ltro de refrigerante y del separador más frecuentemente en entornos de funcionamiento sucios.

AVISO

Lea las placas de datos del motor o llame al fabricante del mismo para determinar las necesidades especícas de engrasado. Para motores que

requieran engrasado, engráselos más frecuentemente en ambientes duros o más elevados.

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80446354 Rev D ES-4

Mantenimiento Periódico

Esta sección se reere a los distintos componentes que requieren

mantenimiento y sustitución periódicos.

Consulte la información de seguridad y los procedimientos de

mantenimiento antes de realizar cualquier mantenimiento en las siguientes

secciones.

Vericando el nivel de refrigerante

El nivel de refrigerante debe comprobarse todos los días. En el lado del

tanque del separador se encuentra un cristal de visualización del nivel

de refrigerante y, mientras la máquina funcione con carga, el refrigerante

siempre debe estar visible en el visualizador. La posición normal es a la mitad.

La máquina debe estar funcionando al menos 40 segundos para realizar esta

vericación.

Detenga la máquina, asegúrese de que la presión del colector sea 0 psig y

que se vea bien el refrigerante en el visualizador.

Añadir refrigerante

Al funcionar el compresor durante un mínimo de 40 segundos, el nivel del

refrigerante debe ser visible en el visor de cristal. Si no:

1. Detenga el compresor.

2. Aísle el compresor del sistema.

3. Pulse la parada de emergencia para ventilar el tanque del separador

y el extremo del compresor. Las unidades FS pueden tardar más de

dos minutos para despresurizarse por completo, una vez detenidas.

4. Desatornille lentamente la pieza de relleno del refrigerante para

vericar que toda la presión ha sido liberada.

5. Añada refrigerante.

6. Cambie la pieza de relleno del refrigerante y reinicie el compresor.

7. Vuelva a vericar el nivel de refrigerante.

8. Repita los pasos arriba indicados hasta que el nivel de refrigerante

sea visible en el cristal de visualización con el compresor tanto en

marcha como detenido.

AVISO

No añada refrigerante por la toma del compresor para evitar el relleno

excesivo, la saturación del elemento de ltro del separador y que el

refrigerante pase a otras partes.

Drenado de refrigerante

Es mejor drenar el refrigerante inmediatamente después de que el compresor

haya estado funcionando ya que el líquido drenará más rápidamente y, si

tiene algún contaminante, seguirá en suspensión.

Véase Figura 1.

1. Coloque el extremo derecho de la manguera de drenaje en un

contenedor adecuado. Instale el otro extremo de la manguera de

drenaje en la válvula de drenaje. El refrigerante uye a través de la

manguera de drenaje de forma automática.

2. Tras el drenaje, retire el manguito y cierre la válvula.

AVISO

En compresores refrigerados con aire, puede drenar el refrigerante

desde el refrigerador retirando el tapón.

También debe drenar el refrigerante adicional de la unidad de

compresión retirando el tapón en el codo de descarga de la unidad de

compresión.



Figura 1: Drenaje del refrigerante

1 2

3 4

3. Deshágase de los residuos de refrigerante de acuerdo con las

regulaciones locales y gubernamentales.

Se recomienda realizar un análisis de refrigerante cada 2000 horas o 3 meses

para supervisar la condición y determinar cuándo cambiar el refrigerante. Si

no se realiza un análisis, el intervalo de cambio de refrigerante recomendado

es cada 8000 horas o 2 años, lo que ocurra antes.

AVISO

Puede ser necesario cambiarlo con más frecuencia si el compresor

funciona en condiciones adversas.

Analizando el refrigerante de grado alimentario

Se recomienda analizar muestras del refrigerante cada 500 horas o todos los

meses si se utiliza el ltro de calidad alimenticia incluido con la máquina.

Si no se realiza el análisis, el refrigerante debe cambiarse cada 2000 horas

o cada seis meses si se utiliza el ltro de calidad alimenticia incluido con la

máquina.

Para unidades que funcionen con refrigerante de calidad alimenticia sin el

ltro de calidad alimenticia, el intervalo de cambio debe ser cada 1000 horas

o cada 6 meses, lo que ocurra antes.

Muestras de refrigerante

1. Suba la temperatura del compresor hasta llegar a la temperatura de

funcionamiento.

2. Para el compresor.

3. Aísle el compresor del sistema de aire externo.

4. Pulse el botón de emergencia para ventilar el depósito del

separador y la unidad de compresión. Una vez detenidos, los

compresores de velocidad ja tardarán más de dos minutos en

despresurizarse completamente.

5. Tome una muestra, utilizando el kit de bombeo, del puerto del

tanque del separador. No tome una muestra del puerto de drenaje

ni del ltro de aceite.

Utilice un nuevo manguito en la bomba para cada muestra. No hacerlo

puede falsear la lectura.

Ver Figura 2.



121714.07.03

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