contact-cooled rotary screw air...

80447212Revision DApril 2015

Save These Instructions

Contact-Cooled Rotary Screw Air Compressor

Product Maintenance Information

R30, R37, R45, R55, R75, R90, R110, R132, R160

42915.12.22

EN

EN-2 80447212 Rev D

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

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

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

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

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

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

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Sampling Coolant for Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Changing Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Checking Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Changing Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Inspecting Separator Tank / Pressure System . . . . . . . . . . . . . . . . . . . . 7

Cleaning / Checking Scavenge Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Replacing Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Checking Minimum Pressure Check Valve (MPCV) . . . . . . . . . . . . . . . 7

Changing Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Regreasing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cleaning Air Cooled Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Removing / Installing Air Cooled Cooler (combination cooler for R30-37) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Removing / Installing Air Cooled Cooler (Sequential cooler for R37e-160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Cleaning Water Cooled Cooler (for both Clean & Harsh Water Options) . . . . . . . . . . . . . . . . . . . . . . . . . 8

Checking High Airend Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . 8

Cleaning Motor Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Removing / Replacing Starter Box Power Drive Module (PDM) Filter Element (For VSD only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cleaning / Checking Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cleaning / Installing Package Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . 9

Checking / Cleaning No Loss Drain Trap (where fitted) . . . . . . . . . . . 9

Monitoring Fluid and Performing Shock Pulse Bearing Analysis . . 9

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INTEGRATED DRYER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cleaning Condensate Drains (Timed Drains Only) . . . . . . . . . . . . . . . 14

Testing Condensate Drains (No-Loss Drains Only) . . . . . . . . . . . . . . . 14

Troubleshooting Condensate Drains (Electronic Drains Only) . . . . 14

Disassembling the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . 14

Decommissioning the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . 14

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 and remote start/stop function is not enabled, locked off, 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 specifically 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 ProductPart/Document Number by Region

Americas EMEA * Asia PacificProduct Safety Information Manual All 80446313 80446156 80446321Product Information Manual All 80447162 80447188 80447204

Product Parts Information Manual

R30-37 kW 24342156R37-45 kW 80448095R55-75 kW 80446271R132-160 kW Single-Stage 80446057R90-160 kW Two-Stage 80446065

* Europe, Middle East and Africa

Product specification sheets and reference drawings are also available.

42915.12.22

80447212 Rev D EN-3

EN

AIR COMPRESSOR MAINTENANCE

Maintenance PromptsThe service warning and flashing LED will appear at intervals dependent on the service level selected. Refer to the Product Information manual for information about service level settings.

Maintenance ChartMaintenance 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 (R30 - 37 kW)

Period Action Maintenance ItemFirst 150 hours Replace Coolant filter

When indicated by controller

Replace Air filter elementReplace Coolant filter elementReplace Separator element

Daily

Check Connections and hoses for leaksCheck Coolant levelCheck Condensate drain operationCheck Controller for service indicatorsCheck Package pre-filter for blockageCheck Air filter indicator condition to ensure air filter operation

MonthlyInspect Air-cooled cooling system for blockageInspect Starter box power drive module filter element

Every 1000 hours Analysis Food-grade Lubricant (Ultra FG)

Every 2000 hours or annually (whichever occurs first)

Replace Air filter elementReplace Coolant filterReplace Separator cartridgesInspect Starter box power drive filter elementReplace Food-grade Filter ModuleAnalysis Shock pulse bearingAnalysis Premium Coolant (Ultra/Ultra EL)Grease All motors (as required)

Every 4000 hours or annually (whichever occurs first)

Inspect Scavenge screen for blockageReplace Starter box power drive filter elementReplace Package pre-filter elementClean Air-cooled cooling systemCalibrate Pressure transducers

Every 6000 hours Replace Food-grade Lubricant (Ultra FG)

Every 8000 hours or annually

Replace No-loss condensate drain service module

Replace Premium Coolant (Ultra) [8000 hours or every 2 years]

Service Minimum pressure check valve (MPCV) service kitClean Drains with all their components (TIMED DRAINS ONLY)Service Inlet valve service kit

16000 hoursReplace Coolant hosesReplace Contact tipsReplace Extended-life Premium Coolant (Ultra EL) [16000 hours or every 3 years]

NOTICE

Inspect and replace coolant filter elements and separator elements more frequently in dirty operating environments .

NOTICE

Continuously running machine not above 5 bar package pressure will cause oil carryover rise and more frequency to inspect and replace separator elements .

NOTICE

Read the motor data plate(s) or call the motor manufacturer(s) to determine specific greasing requirements . For motors that require greasing, grease them more frequently in harsh environments or higher ambient conditions .

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EN-4 80447212 Rev D

Table 3: Maintenance Chart (R37e - 160 kW)

Period Action Maintenance Item

When indicated by controller

Replace Air filter elementReplace Coolant filter elementReplace Separator element

Daily

Check Connections and hoses for leaksCheck Coolant levelCheck Condensate drain operationCheck Controller for service indicatorsCheck Package pre-filter for blockage

Monthly

Inspect Air-cooled sequential cooling system for blockageInspect Water-cooled sequential cooling system screensInspect Starter box power drive module (PDM) filter elementAnalysis Water from water-cooled sequential cooling system

Every 1000 hours Analysis Food-grade Lubricant (Ultra FG)

Every 2000 hours or 3 months

Inspect Air filter elementInspect Coolant filter elementInspect Starter box power drive module (PDM) filter elementReplace Food-grade Filter ModuleAnalysis Shock pulse bearingAnalysis Premium Coolant (Ultra/Ultra EL)

Every 4000 hours or 6 months

Inspect Scavenge screen for blockage

Replace Air filter element

Replace Coolant filter elementReplace Starter box power drive module (PDM) filter elementReplace Package pre-filter elementClean Air-cooled sequential cooling systemInspect / Clean Water-cooled sequential cooling systemCalibrate Pressure transducersGrease All motors (as required)

Every 6000 hours

Replace Food-grade Lubricant (Ultra FG)Replace Separator element (if using Food-grade Lubricant)Inspect Air filter elementInspect Coolant filter element

Every 8000 hours or annually

Replace Separator elementReplace No-loss condensate drain service module

Replace Premium Coolant (Ultra) [8000 hours or every 2 years]

Service Minimum pressure check valve (MPCV) service kitClean Drains with all their components (TIMED DRAINS ONLY)Service Inlet valve service kit

16000 hoursReplace Coolant hosesReplace Contact tipsReplace Extended-life Premium Coolant (Ultra EL) [16000 hours or every 3 years]

NOTICE

Inspect and replace coolant filter elements and separator elements more frequently in dirty operating environments .

NOTICE

Continuously running machine not above 5 bar package pressure will cause oil carryover rise and more frequency to inspect and replace separator elements .

NOTICE

Read the motor data plate(s) or call the motor manufacturer(s) to determine specific greasing requirements . For motors that require greasing, grease them more frequently in harsh environments or higher ambient conditions .

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80447212 Rev D EN-5

EN

Routine MaintenanceThis 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

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 fill plug to verify all pressure has been released.

5. Add coolant.

6. Replace the coolant fill 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 overfilling, saturation of the separator filter 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 flows 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.

NOTICE

Shorter coolant change intervals may be necessary if the compressor is operated in adverse conditions .

Sampling Coolant for Analysis

1. Bring the compressor up to operating temperature.


3. Isolate the compressor from the external air system.


5. Draw a sample from the separator tank port using a pump kit. DO NOT draw a sample from the drain port or oil filter.

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-6 80447212 Rev D

Figure 2: Coolant Sampling

Changing Coolant Filter

1. Remove drain plug from bottom of filter housing and drain coolant.

2. Loosen the filter 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 filter housing.

8. Screw the housing to the filter head and tighten to the torque specified 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 differential pressure via the controller. It will be necessary to change the element if the differential pressure equals zero or exceeds 1 bar (15 psig).

Changing Separator Element

For R30-37, separator cartridges change procedure is as follows,

1. Stop the machine, electrically isolate and vent all trapped pressure.

2. Loosen separator cartridges with the correct tool.

3. Remove the cartridges from the housing; place in a sealed bag and dispose of safely.

4. Clean the mating faces of the housing.

5. Remove the new Ingersoll Rand replacement cartridges from protective package.

6. Apply a small amount of lubricant to the cartridge seal.

7. Screw the new cartridges down until the seal makes contact with the housing, then hand tighten a further half turn.

8. Start the compressor and check for leaks.

For R37e-160, separator element change procedure is as follows,

1. Remove the fitting 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 off 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. Lubricate a thin layer of coolant on the separator gasket top and bottom before installing 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 sufficiently 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 orifice. 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 fittings.

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 Pattern3

5

1

9

74

6

2

10

83

11

5

1

9

74

12

6

2

10

8

R37, R45, R55, R75R90, R110, R132, R160

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 .

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80447212 Rev D EN-7

EN

Inspecting Separator Tank / Pressure System

Inspect the external surfaces of the airend and separator tank, including all fittings, 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.

Cleaning / Checking Scavenge Screen

The screen/orifice 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 orifice and a direction-of-flow arrow is stamped in flat areas of the hexagon.

A removable screen and orifice will require clearing as outlined in the maintenance chart.

To remove the screen/orifice:

1. Disconnect the scavenge line tubing from each end.

2. Hold the center section firmly 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, confirm the direction of flow to be correct. Observe the small arrow stamped in the center section and ensure the direction flow to be from the separator tank to the airend.

Replacing Coolant Hoses

The flexible 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 refill the compressor with coolant.

4. Start the compressor, check for leaks and check coolant level. Refill 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 influenced by such factors as the severity of the operating environment. For R30-37, the MPCV is installed as part of combination block.

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 qualified 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 refit 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 confirm that the motor may be greased and to obtain instructions for regreasing.

Cleaning Air Cooled Cooling System

Air compressor operating temperatures will be higher than normal if the external passages between the fins 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 efficiency. When performed frequently as determined by site conditions and airborne contamination, more significant cleaning or replacement may not be necessary.


2. Isolate the compressor from the system.


4. Ensure that the main power disconnect switch is locked off and tagged.

NOTICE

For any required lifting of air compressor parts or required tools, always use the proper certified 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 panel on the cooler plenum. For R30-37, gently blow compressed air across the cooler surface. For R37e-160, gently blow compressed air across the coolant cooler surface, then use a vacuum hose with a soft brush to clean the exposed face of the air aftercooler. Repeat the process until the coolers are sufficiently 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 (combination cooler for R30-37)

To remove:





5. Drain the coolant from the coolant cooler by removing the hex plug located at the lower side of the coolant cooler.

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

7. Remove the external sheet metal panels.

8. Properly secure the coolant cooler and remove the six nuts from the three bolts at the upper side of the cooler.

9. Remove the nuts from the bolts at the bottom of the cooler.

10. Re-install the coolant drain plug to 65 N m (48 ft lb).

42915.12.22

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EN-8 80447212 Rev D

To install:





5. Carefully place the cooler in its proper location and install the three sets of lower nuts and bolts tightly.

6. Install the three sets of upper side nuts and bolts, finger tight + ¼ turn. Next, add the second nut to each tightly. This second nut is used to lock the first in place. It is important the first nut is not too tight so it can allow the cooler to expand and contract without stressing the cooler’s brazed joints.

7. Re-attach all hoses and pipes, and properly torque according to the Parts Information manual.

8. Replace the access panels on the side of the cooler plenum.

9. Refill the compressor with coolant to the proper level, following the process outlined in the “Adding Coolant” procedure.

Removing / Installing Air Cooled Cooler (Sequential cooler for R37e-160)

To remove:





NOTICE


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.

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:



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.


NOTICE


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, finger tight + ¼ turn. Next, add the second nut to each tightly. This second nut is used to lock the first in place. It is important the first 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 finger tight + ¼ turn. Next add the second nut to each tightly. This second nut is used to lock the first in place. It is important the first 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. Refill 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 flush the cooler with a flow rate at least 1.5 times the normal flow rate.

After using any cleaning solution, thoroughly flush 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 off the cooling water.

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

42915.12.22

80447212 Rev D EN-9

EN

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 filter housing.

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

4. Replace the front grill.

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

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 fitting 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 flat washers.

3. Remove the filter grill.

4. Pull out the filter element.

5. Center the new element over the package intake opening. Also note that the filter is washable with mild detergent.

6. Push the filter over the grill studs so that the studs poke through the filter media.

7. Install the filter grill.

8. Install the six wing nuts and flat washers.

9. Close the intake panel and latch.

Checking / Cleaning No Loss Drain Trap (where fitted)

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 first.

Monitoring Fluid and Performing Shock Pulse Bearing Analysis

Ingersoll Rand recommends incorporating predictive maintenance, specifically the use of coolant and shock pulse bearing analysis, into all preventative maintenance programs. Contact Ingersoll Rand for details.

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EN-10 80447212 Rev D

TROUBLESHOOTINGThis section provides basic troubleshooting information. Determination of specific causes to problems are best identified 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 4: General Faults

SYMPTOM CAUSE REMEDY

Compressor will not start. No power supply to compressor. Check supply is switched on. If so, contact a qualified electrician.

Controller failure. Check supply to controller. Replace controller.

Starter failure. Isolate supply, lock off and tag. Replace failed component or contact your local Ingersoll Rand representative.

Compressor stops and will not restart.

Drive controller has tripped. See Tables 4 and 5.

Controller has tripped the compressor. See Tables 4 and 5.

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 4 and 5.

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 5.

Controller fault. Repair or replace.

Drive motor fault. See Table 5.

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 filter 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.

Insufficient cooling air. Check ducting and cooling air path, check direction of blower rotation.

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

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80447212 Rev D EN-11

EN

Table 4: 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, refill with correct coolant.

System has been overfilled 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 filter element dirty or blocked. Replace.

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

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

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.

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EN-12 80447212 Rev D

Table 5: 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.

Insufficient 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.

Insufficient cooling taking place. If compressor is watercooled or sea watercooled, check that the cooling water is flowing. 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 4: Troubleshooting Chart.

Separator element dirty or blocked. Change separator element.

Change HE filter (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 4: Troubleshooting Chart.

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

Dryer HE filter dirty or blocked. Change HE filter.

Machine stops but no alarm message Loss of outputs of control power. Check controller outputs (110V AC) power supply (fuses/mini circuit breaker).

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EN

FAULT CAUSE REMEDY

Motor current fault(R30-37 only) Loss of control power.

Sump pressure too high.

Faulty motor or Airend.

Check control power circuit and breaker.

Check separator element pressure drop.


CT failure Fault CT, wiring or loss of control power. Check wiring and control power circuit.

Table 6: 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.

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 filter, replace if necessary. Check drive cooling fan circuit breaker. Check wiring.

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


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


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EN-14 80447212 Rev D

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 ChartFor optimum performance from your dryer, follow the periodic maintenance schedule described below.

Table 7: 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 fins.

EVERY 6 MONTHS AIR FILTER

Replace air filter 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 flying 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 filter screen and clean it. Remove any debris that may be in the strainer body before replacing the filter screen.

5. Replace plug and tighten with wrench.

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

Testing Condensate Drains (No-Loss Drains Only)

Press the TEST button to confirm proper function.

Troubleshooting Condensate Drains (Electronic Drains Only)This section provides basic troubleshooting information. Determination of specific causes to problems are best identified 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 8: 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 identified 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 classification) .

Decommissioning the Integrated DryerDecommission 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 9: 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

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ingersollrandproducts .com© 2015 Ingersoll-Rand

42915.12.22

80447212修订版 D

2015年4月

保存这些说明

螺杆式空气压缩机

产品维护信息

R30, R37, R45, R55, R75, R90, R110, R132, R160

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ZH-� 80447�1� Rev D

关于本手册 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

人员 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

安全 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

空气压缩机的维护 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

维护提示 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

空气压缩机维护表 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

日常维护 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

检查冷却剂水平 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

添加冷却剂 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

排放冷却剂 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

采样进行分析的冷却剂 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

更换冷却剂过滤器 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

检查分离器芯 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

更换分离器芯 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

检查分离筒/压力系统 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

清洗 / 检查排滤网 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

更换冷却剂软管 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

检查最小压力止回阀（MPCV） . . . . . . . . . . . . . . . . . . . . . . . . . . 7

更换空气过滤器 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

再润滑风扇电机 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

清洁空气冷却系统 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

拆卸 / 安装空气冷却器 (组合冷却器R30-37） . . . . . . . . . . . . . . . . 7

拆卸 / 安装空气冷却器 (顺序冷却器R37e-160) . . . . . . . . . . . . . . 7

清洗水冷冷却器（用于清洁水和生水选择） . . . . . . . . . . . . . . . . 8

检查空气端高温传感器 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

清洗电机外壳 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

拆卸 / 更换起动箱动力驱动模块（PDM）的 . . . . . . . . . . . . . . . . . . 滤芯（仅 VSD 适用） . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

清洗 / 检查冷凝水的排放 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

清洗 / 安装机组预滤器 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

检查 / 清洗无损排放弯管（如果装有） . . . . . . . . . . . . . . . . . . . . 9

监测液体并进行轴承冲击脉冲分析 . . . . . . . . . . . . . . . . . . . . . . . 9

故障排除 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

集成式干燥机的维护 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

维修表 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

清洗冷凝水的排放件（仅定时排放） . . . . . . . . . . . . . . . . . . . . . .14

测试冷凝水的排放（仅无损排放）) . . . . . . . . . . . . . . . . . . . . . . .14

拆开集成式干燥机 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

将集成式干燥机退役 . . . . . . . . . . . . . . . . . . . . . . . . . . 14

目录

关于本手册

人员

安全

正确使用、检查和维修将增加空压机的使用寿命和有效性。极为重要的是涉及空压机维护的任何人员都必须熟悉空压机的维修程序并有能力执行这些程序。这些人员应具有以下技能：

1. 常用机械手动工具以及Ingersoll Rand 专用或推荐工具的正确与安全使用。

2. 由公认行业标准确立的安全程序、预防措施和工作惯例。

有些维修程序具有较强的技术性，需要专门的工具、设备、培训和经验才能正确完成。在这种情况下，只允许Ingersoll Rand培训的技术人员来执行空压机的维护。操作人员不应尝试超出本手册程序范围之外的维修或检查。

有关其他信息请联系Ingersoll Rand 工厂或就近的服务提供商。

在压缩机承担任务之前，确保切断供电，不启用远程启动/停止功能，并进行锁闭和标定，而且压缩机已解除所有的压力。在进行任何维护工作前，应确保空压机至少断电 15 分钟。请见产品安全信息手册的其他信息。

Ingersoll Rand 无法知道或指出进行维修时的所有程序和每种方法可能导致的危害和/或后果。如果进行非由制造商特别推荐的维护程序，则应确保所采取的行为不会危及安全。

如果您不了解维护程序或步骤，则请将空压机置于安全环境下再进行技

术咨询。

使用非Ingersoll Rand原厂更换部件可能导致安全危险、降低性能、增加维护工作并可能导致丧失所有保修权利。

有关其他信息请联系Ingersoll Rand工厂或就近的服务提供商。

本手册的目的是旨在提供空压机的维修和故障排除指南。

有关支持文件请参考表 1。

表 1：产品手册

出版产品按地区分类的部件/文件号

美洲 EMEA * 亚太区

产品安全信息手册全部 80446313 80446156 80446321

产品信息手册全部 80447162 80447188 80447204

产品部件信息手册

R30-37 kW 24342156

R37-45 kW 80448095

R55-75 kW 80447592

R90-160 kW Single-Stage 80446057

R90-160 kW Two-Stage 80446065

* 欧洲、中东和非洲

还可提供产品规格表及参考图。

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空气压缩机的维护

维护提示

根据所选的维修级别，维修警告和闪光 LED 将交替出现。请参考产品信息手册以了解维修级别设置的信息。

空气压缩机维护表

应遵循下列维护建议及优先次序：（1）控制器有指示时应进行维护；（2）到达小时间隔或预定维护间隔时间后应进行维护，（3）应进行年度维护。

表 2: 维修表 (R30 - 37 kW)

周期操作维护项目

最初的 150 小时更换冷却剂过滤器

当控制器有指示时

更换空气过滤器芯

更换冷却剂滤芯

更换分离器芯

每天

检查防漏连接和软管

检查冷却剂水平

检查冷凝水排放操作

检查维修指示控制器

检查防堵塞机组预滤器

检查空气过滤器真空指示状态以确保空气过滤器运作

每月检测风冷冷却系统堵塞

检测起动箱动力驱动模块滤芯

每 1000 小时分析食品级润滑剂 (Ultra FG)

每 2000 小时或每年以先到为准


更换冷却剂过滤器

更换油气分离器

检测起动箱动力驱动模块滤芯

更换食品级过滤器模块

分析轴承冲击脉冲

分析优质冷却剂 (Ultra/Ultra EL)

润滑脂所有电机（按需要）

每 4000 小时或每年以先到为准

检测回油滤网是否堵塞

更换起动箱动力驱动滤芯

更换机组预滤器芯

清洗风冷系统

校准压力传感器

每 6000 小时更换食品级润滑剂 (Ultra FG)

每 8000 小时或每年

更换无损冷凝水排放维修模块

更换优质冷却剂 (ULTRA) [8000 小时或每两年]

维修最小压力止回阀（MPCV）维修套件

清洗排水阀及组件（仅限定时排水）

维修进气阀维修配件包

16000 小时

更换冷却剂软管

更换接触滑片

更换长效优质冷却剂 (ULTRA EL) [16000小时或每3 年]

处于肮脏运行环境中的冷却剂滤芯和分离器芯应更频繁地进行更换。

若压缩机长时间在5bar及以下压力下运行，将影响您的空气质量以及油分芯的更换频率。

阅读电机数据铭牌或致电电机制造商以了解具体的润滑要求。对于需要润滑的电机，在恶劣的环境或要求较高的环境条件下应对其进行更频繁的润滑。

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表 3: 维修表 (R37e - 160 kW)

周期操作维护项目

当控制器有指示时



更换分离器芯

每天

检查防漏连接和软管


检查冷凝水排放操作

检查维修指示控制器

检查防堵塞机组预滤器

每月

检测防堵塞气冷步序冷却系统

检测水冷步序冷却系统滤网

检测起动箱动力驱动模块（PDM）滤芯

分析水冷步序冷却系统水

每 1000 小时分析食品级润滑剂 (ULTRA FG)

每 2000 小时或3个月

检测空气过滤器芯

检测冷却剂滤芯

检测起动箱动力驱动模块（PDM）滤芯

更换食品级过滤器模块

分析轴承冲击脉冲

分析优质冷却剂 (Ultra/Ultra EL)

每 4000 小时或 6 个月

检测回油滤网是否堵塞



更换起动箱动力驱动模块（PDM）滤芯

更换机组预滤器芯

清洗气冷步序冷却系统

检测 / 清洗水冷步序冷却系统

校准压力传感器

润滑脂所有电机（按需要）

每 6000 小时

更换食品级润滑剂 (Ultra FG)

更换分离器元件（若采用 Ultra FG 食品级冷却剂）

检测空气过滤器芯

检测冷却剂滤芯

每 8000 小时或每年

更换分离器芯

更换无损冷凝水排放维修模块

更换优质冷却剂 (Ultra) [8000 小时或每两年]

维修最小压力止回阀（MPCV）维修套件

清洗排水阀及组件（仅限定时排水）

维修进气阀维修配件包

16000小时


更换接触滑片

更换长效优质冷却剂 (Ultra EL) [16000小时或每3 年]

处于肮脏运行环境中的冷却剂滤芯和分离器芯应更频繁地进行更换。

若压缩机长时间在5bar及以下压力下运行，将影响您的空气质量以及油分芯的更换频率。

阅读电机数据铭牌或致电电机制造商以了解具体的润滑要求。对于需要润滑的电机，在恶劣的环境或要求较高的环境条件下应对其进行更频繁的润滑。

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日常维护

本节涉及到要求定期维护并替换的各种部件。

进行任何维护工作之前，请参考下列各节中的安全信息和维护步骤。.


油分离筒体的侧面有一个油窥镜，当机组在有负载情况下运行时，应始终能在油窥镜中看到冷却剂水平。正常位置为一半刻度。设备应至少运行 40 秒以进行该项检查。

停止设备运行，应确保油槽压力为 0 psig，且可从油窥镜中看到冷却剂。

添加冷却剂

使空压机至少运行 40 秒，此时应该可以在油窥镜看到冷却剂。如果没有：

1. 关闭压缩机。

2. 将压缩机与系统隔离。

3. 按下紧急按钮以使分离筒和空气端排气。FS 设备在停止后需要两分钟以上才能完全将气排净。

4. 缓慢地拧开冷却剂加料塞以验证是否已释放所有压力。

5. 添加冷却剂。

6. 盖上冷却剂加料塞并重新启动压缩机。

7. 再次检查冷却剂水平。

8. 重复以上步骤，直到当压缩机运行和停止时都可在油窥镜中看见冷却剂水平为止。

请勿通过空压机的进口添加冷却剂，因为这会导致添加过量、分离器过滤芯浸透，并使冷却剂进入下游系统中。

排放冷却剂

最好在空压机运行后立即排放冷却剂，因为这样可更快地排放冷却剂，且污染物仍然处于悬浮状态。

请参见图 1。

1. 将排放软管末端置于合适的容器内。将排放软管的另一端安装于排放阀。冷却剂通过排放软管自动流出。

2. 排放后，卸下软管并关闭阀门。

如果是气冷空压机，还可以通过卸下插塞将冷却剂从冷却器中排出。

您还应该卸下空气端排放弯管中的插塞来排放空气端更多的冷却剂。

图 1：冷却剂排放口

1 2

3 4

3. 应按照当地和政府规定处理废冷却剂。

如果在不利状况下操作压缩机，可能需要更频繁地更换冷却剂。

采样进行分析的冷却剂

1. 使空压机达到工作温度。

2. 关闭空压机。

3. 将空压机与外部空气系统隔离。

4. 按下紧急关机按钮以对分离槽和空气端进行排气。稳定速度的空压机在停止后还需要两分钟以上才能将气压完全排出。

5. 从分离器油箱口用泵套件中抽取样本。不要从排放口或机油过滤器中抽取样品。

每个样品都要使用新软管从泵中取样。不按照该程序操作将得到错误的读数。

参见图 2。

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图 2：冷却剂采样

更换冷却剂过滤器

1. 从过滤器壳底部卸下放油螺塞，排放冷却剂。

2. 松开过滤器壳。

3. 从机体上卸下滤芯。

4. 将旧的滤芯放到密封袋中，然后以安全的方式进行处理。

5 . 从保护包装上卸下新滤芯。

6. 在滤芯密封上涂少许冷却剂。

7. 将新的更换元件安装到过滤器外壳内。

8. 将外壳拧到过滤头上，根据外壳上规定的扭力拧紧。

9. 重新安装放油螺塞。

10. 启动空压机，检查有无泄漏及冷却剂的含量。

检查分离器芯

在空压机带负载运行时，通过微控制器检查分离器差压。如果压力差等于零或超过 1 bar (15 psig)，就必须更换元件。

更换分离器芯

R30-37 分离器滤芯更换步骤

1. 停止机器, 隔离电源, 然后排出所有积聚的压力。

2. 使用适当的工具松开分离器芯。

3. 从机体上卸下分离器芯, 将其放到密封袋中, 然后以安全的方式进行处理。

4. 清理机体的啮合面。

5. 将 Ingersoll Rand 备用分离器芯从其保护包装中取出。

6. 在分离器芯密封处涂少许润滑油。

7. 向下旋紧新分离器芯直到密封与机体接触，然后用手再转半圈将其拧紧。

8. 启动压缩机并检查有无泄漏。

R37e-160 分离器滤芯更换步骤

1. 旋松回油管道与油分离筒体之间的接头，卸下管道部件。

2. 断开罐盖上的管道。如有必要，请在管道上贴上标签。卸下将罐盖固定在罐体上的所有螺栓，只留下与枢轴螺栓相对的螺栓，保留 2-3 圈螺纹，且螺丝的头部与机盖的间隙至少应为 6.5 mm (0.25 英寸)。顺时针旋转定位螺栓，直到罐盖与罐体的间隙至少达到 2 mm（0.08 英寸）。卸下剩余的螺栓。现在可旋转机盖，以便手部伸入分离槽内。

3. 小心地提起分离器芯并将其拿出筒体。丢弃有故障的滤芯。丢弃有故障的滤芯。

4. 清洁分离槽及槽盖的密封表面。检查油分离筒体，完全确定没有异物（如布片或工具等）掉入油分离筒体内。在检查完新元件密封是否存在可能的损坏之后，在将替换元件安装到分离槽之前，在分离器垫圈顶部和底部涂抹一薄层冷却剂。应确保滤芯在罐内对中并完全安装在密封槽中。将罐盖旋回正常位置，注意不要损坏垫片，并使用两个螺栓将罐盖定位，但不要拧紧。

5. 松开定位螺栓以完全脱离螺纹，并以交叉方式拧紧罐盖螺栓以防止将罐盖一侧拧得太紧。机盖紧固不当很可能会导致渗漏。

完全旋松定位螺栓，确保在没有向支撑点施加任何压力的情况下机盖可以完全紧固。如果是 75 kW 和更小的空压机，则将罐盖螺栓拧紧至 81 牛米（60 磅英尺），如果是 90 kW 和更大的空压机，则拧紧至 200 牛米（150 磅英尺）。螺栓的拧紧顺序请参见图 3。

6. 检查冷却剂罐的回油滤网和滤孔。根据需要按照以下说明进行清洁。

7. 将回油管道向下装入分离槽内，管道一接触分离器元件即向上提起1/8 英寸（3 毫米）。旋紧接头。

应特别小心不要将回油管道压入罐内。这可能会损坏分隔器芯。

8. 将管道安装在原位置。

图 3：推荐螺栓交叉拧紧方式

3

5

1

9

74

6

2

10

83

11

5

1

9

74

12

6

2

10

8

R37, R45, R55, R75R90, R110, R132, R160

9. 启动压缩机并检查是否泄漏

切勿在分离槽或分离槽盖面上使用任何形式的密封胶。

检查分离筒/压力系统

每隔 2000 小时检测一次主机和油分离筒体（包括所有配件）的外表面上是否有严重破坏、过度腐蚀和磨损的可见痕迹。在更换分离器芯时，应检查内部组件和表面。在重新使用空压机之前，应当更换所有怀疑可能有问题的部件。

分离槽也应当根据国家或当地规定进行测试和检查。

清洗 / 检查排滤网

排滤网/滤孔配件在外观上与直线管道接头相似，它们安装在两根外径为 1/4 英寸的回油管之间。

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配件的主体由17毫米的六角形黄铜制成，滤孔直径和液体的流动方向箭头压印在六角形钢的平面上。

应按照维护计划表中的规定清洗可拆卸滤芯和滤孔。

要卸下滤芯/孔板:

1. 断开各端的回油管道。

2. 紧紧握住配件的中心部分，使用钳子轻轻夹住组件的出口端，该出口端密封了回油管道。出口端是朝外的一端，即箭头指向的一端。

3. 将出口端从中心部分拉出，在操作中注意不要损坏滤网或密封表面。

4. 在重新安装之前应清洗并检查所有零件。

5. 配件安装好后，应确认液体流动方向正确。观察压印在中心部分的小箭头，确保流动方向为从油分离筒体到主机。


冷却系统中输送冷却剂的弹性软管因年久可能变脆，此时将需要更换。更换它们需要或根据维护图表。

1. 因软管位置不同，软管可能含有压缩机冷却剂。我们建议将冷却剂排到干净的容器中。盖上容器以免内部零件受污染。如冷却剂受到污染，必须更换新的冷却剂。则用新冷却剂进行更换。

2. 卸下软管。

3. 安装新软管并用冷却剂充满设备。

4. 启动空压机，检查有无泄漏及冷却剂的水平。按需重新注入冷却剂。

检查最小压力止回阀（MPCV）

应经常测试和定期维护最小压力止回阀（MPCV）。将其从空压机上拆下以进行测试。如果工作条件非常差，则必须相应地增加测试和维护频率。由于受诸如不良操作环境等因素的影响，因此用户必须确定此类测试的频率。对于 R30-37，MPCV 作为组合组件的一部分进行安装。

应该对最小压力止回阀（MPCV）进行测试并按照任何现有国家或地区法规重新校准。如果没有适用的法规，则Ingersoll Rand建议在阀是根据维护图表校准的。

更换空气过滤器

1. 检查固定盖是否有灰尘和碎片并擦拭干净。

2. 松开固定盖并卸下旧滤芯。

3. 装上新滤芯并重新装上固定盖。

再润滑风扇电机

风扇电机含有经预先润滑的密封轴承。这些轴承不能再润滑，也不需要再润滑。对主电机而言，应咨询电机制造商以确认电机是否需要润滑并获得重新润滑的操作说明。

清洁空气冷却系统

如冷却器芯散热片之间的外部通道被异物堵塞，则空压机工作温度将高于正常范围。定期清洗冷却器表面有助于空压机系统的可靠运行，能增加空压机冷却剂的使用寿命和提高空压机的整体效率。当受现场条件和空气污染的影响而频繁地进行清洗时，可能就不需要进行更大的清洗或更换。


2. 将空压机与系统隔离。

3. 按下紧急关机按钮以对分离槽和空气端排气。稳定速度的空压机在停止后还需要两分钟以上才能将气压完全排出。

4. 应确保主电源切断开关已锁定且贴上标签。

如果需要吊升空压机零件或使用工具，应始终使用合格的吊升设备并遵循严格的工作程序。

5. 目视检查冷却器芯外部，以确定适当的清洁方法，详情如下。

a. 对于松散的灰尘、粉尘和其他轻质异物，打开冷却器静压箱上的检修孔盖板。对于 R30-37，在冷却器表面轻轻吹动压缩空气。

对于 R37e-160，在冷却剂冷却器表面轻轻吹动压缩空气，然后使用带有软刷的真空软管清洁空气后冷却器的暴露表面。重复该程序，直到冷却器清洗干净为止。将检修板复位后再返回对设备进行维修。

b. 对于厚重密实的尘土、机油、润滑脂及其他大面积脏污，则需将冷却器从设备上卸下进行压力冲洗。由于在电源周围喷水十分危险，因此Ingersoll Rand不建议在冷却器安装在机构系统中时进行压力清洗。遵循下列步骤，拆除冷却器。

拆卸 / 安装空气冷却器 (组合冷却器R30-37）

要拆卸:




4. 确保主电源切断开关锁定且贴上标签。

5. 移除位于冷却剂冷却器下部的六角塞子，从冷却剂冷却器排空冷却剂。

6. 从冷却器上卸下所有软管、管道和传感器。

7. 拆卸外金属面板

8. 正确固定冷却剂冷却器，从位于冷却器上部的三个螺栓移除六个螺母。

9. 卸下冷却器底部螺栓上的个螺母。

10. 以 65 N m (48 ft lb) 的扭矩重新安装冷却剂排放塞。

要安装：




4. 确保主电源切断开关锁定且贴上标签。

5. 小心谨慎地将冷却器置于正确位置，并紧固安装三组下方的螺母和螺栓。

6. 小心谨慎地将冷却器置于正确位置，并紧固安装三组下方的螺母和螺栓。接下来安装第二个螺母并将其拧紧。第二个螺母用于将第一个锁定到位。第一只螺母不能过紧，以便冷却器进行膨胀和收缩时不会压迫冷却器的铜焊接头。

7. 重新连接所有的软管、管道和传感器，并根据零部件信息手册用适当的扭矩拧紧。

8. 重新装上冷却器各边的检修板。

9. 按照”添加冷却剂”中所描述的程序给空压机充填冷却剂到合适

的液位。拆卸 / 安装空气冷却器

拆卸 / 安装空气冷却器 (顺序冷却器R37e-160)

要拆卸：






5. 卸下位于空气冷却器前面和冷却剂冷却器下方的六角插塞以将冷却剂从冷却器中排出。

6. 从冷却器上卸下所有软管、管道和传感器。

7. 拆卸外金属面板.

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8. 卸下冷却器各侧的检修板

9. 正确固定空气后冷却器并卸下冷却器上边 2 个螺栓上的 4 个螺母。

10. 卸下冷却器底部螺栓上的 2 个螺母。

11. 小心地卸下空气后冷却器。

12. 正确固定机油冷却器并卸下冷却器上边 2 个螺栓上的 4 个螺母。

13. 卸下冷却器底部螺栓上的 2 个螺母。

14. 小心地卸下机油冷却器。

15. 如果是 75 kW 和更小的空压机，则将冷却剂插塞重新拧紧至 23 牛米（17 磅英尺），如果是 90 kW 和更大的空压机，则拧紧至 65 牛米（48 磅英尺）。

要安装：






5. 小心地将机油冷却器放在其正确的位置，安装两组下紧固件并将其拧紧。

6. 安装两组上紧固件并用手拧紧 - 圈。接下来安装第二个螺母并将其拧紧。第二个螺母用于将第一个锁定到位。切记第一个螺母不能过紧，以便冷却器进行膨胀和收缩时不会压迫冷却器的铜焊接头。

7. 应确保空气后冷却器上的橡胶密封在冷却器上安装到位和状况良好。

8. 小心地将空气后冷却器的冷却器放在其正确的位置，安装两组下紧固件并将其拧紧。

9. 安装两组上紧固件并用手拧紧 - 圈。接下来安装第二个螺母并将其拧紧。第二个螺母用于将第一个锁定到位。切记第一个螺母不能过紧，以便冷却器进行膨胀和收缩时不会压迫冷却器的铜焊接头。

10. 重新连接所有的软管、管道和传感器，并根据零部件信息手册用适当的扭矩拧紧。

11. 重新装上冷却器各边的检修板。

12. 按照“添加冷却剂“中所描述的程序给空压机充填冷却剂到合适的液位。

清洗水冷冷却器（用于清洁水和生水选择）

对于水冷式热交换器，应当定期执行检查和维护程序。如果您没有经验或没有设备进行此项工作，建议您与Ingersoll Rand联系以获得清洗服务。

如果进水管道有滤网，应检查滤网并按要求更换或清洗。

清洁冷却器时，可使用含氨基硫磺酸和柠檬酸的除垢剂及中性溶液清除矿物积垢。作为一种可选方法，可使用 1:4 的弱酸水。

应使用适当的清洁剂在热水中去除污垢。

至少使用正常流速的 1.5 倍速度反冲洗冷却器。

在使用任何清洁溶液之后，应使用清水彻底冲洗掉所有的化学品之后再返回到冷却器的维修。

不推荐使用机械清洗方法，因其可能损坏内部通道。

清洁后，请检查冷却器是否受到腐蚀或磨损。

检查空气端高温传感器

建议按以下时间定期检查排气温度传感器（2ATT）：

a. 对气冷式设备而言，可打开风扇/风扇电机的断路器使冷却风扇停止运转。

b. 对水冷式设备而言，应关闭冷却水。

空压机应在109 ℃（228 ° F）跳闸。跳闸警告将出现在控制器的显示器上。

清洗电机外壳

1. 在进行任何维护工作前，请确保空压机至少断电 15 分钟。

2. 卸下压缩机的检修板。

3. 使用一块干净的干布擦去电机外壳表面的灰尘，并确保所有通风孔没有残留任何障碍物。

4. 装上检修板。

拆卸 / 更换起动箱动力驱动模块（PDM）的滤芯（仅 VSD 适用）

请见图 4。

1. 在进行任何维护工作前，请确保空压机至少断电 15 分钟。

2. 打开起动箱过滤器外壳的前格板。

3. 卸下外壳上的滤芯并用新滤芯更换。

4. 重新装好前格板。

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图 4：起动箱动力驱动模块（PDM）滤芯的更换

清洗 / 检查冷凝水的排放

1. 进行任何维护工作前，请确保空压机至少断电 15 分钟。

2. 将空压机与系统隔离，并排出机器内的全部压缩空气。

3. 卸下水分离器底部管件上的塑料管。

4. 卸下接水杯，将其清洗并重新安装。

清洗 / 安装机组预滤器

1. 打开两个 1/4 圈的闩锁并打开进气面板（铰链面板）

2. 卸下六个翼形螺母和平垫圈。

3. 拆下过滤器格板。

4. 拉出滤芯。

5. 将新滤芯在机组进气开口中对中。还要注意过滤器可用温和洗涤剂清洗。

6. 将过滤器推向格板杆，以使格板杆穿过过滤器介质。

7. 安装过滤器格板。

8. 安装六个翼形螺母和平垫圈。

9. 关闭进气面板和闩锁。

检查 / 清洗无损排放弯管（如果装有）

建议每天检查无损耗排放弯管，以确保冷凝水从水分离器系统中排出要检查功能是否正常。

1. 按下设备上的测试按钮并倾听是否有冷凝水 / 空气通过排放弯管。

2. 如果排放弯管已堵塞，则应更换无损排放阀维修模块。维修模块包含排放弯管较底的部分，且无法进行维修。

另外，建议每 8000 小时或每年更换维修模块，以先到为准。

监测液体并进行轴承冲击脉冲分析

Ingersoll Rand建议将推测性维护（尤其是使用冷却剂和轴承冲击脉冲分析）与所有的预防性维护结合起来。请联系Ingersoll Rand了解详情。

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故障排除本节介绍故障排除的基本信息。应按照本设备安全、操作和维修说明，由专业人员进行彻底检查以确定问题的具体原因。以下图表为常见状况、可能的原因及维修方法提供了简要指南。

表 3：一般故障

状况故障维修方法

空压机不启动机组不通电检查是否接通电源。如果电源已接通，请与合格的电工联系

微控制器故障检查控制器是否通电。更换控制器

起动机故障断开电源，锁定并贴上标签。更换故障部件或与当地Ingersoll Rand代表联系

空压机停机后不能重新启动驱动控制器已切断请见表 3 和 4

微控制器使压缩机跳闸请见表 3 和 4

已超过每小时的最大允许启动次数

空压机停机后不能重新启动微控制器使压缩机跳闸和没有复位请见表 3 和 4

按下了紧急停机按钮但未放开找到故障原因并进行修理，松开按钮并将微控制器复位

已按下并释放紧急按钮，但微控制器没有复位修理故障并复位微控制器

空压机无法满足系统所要求的压力空压机规格无法满足系统要求或要求已变更。联系您当地的Ingersoll Rand代表

因导管、软管、接头或密封损坏而漏气修理或更换

因放气阀回路故障而漏气修理或更换

因减压安全阀固定不当而漏气修理或更换

因水分离器排放弯管回路故障而漏气修理或更换

因驱动设置不当而导致电机转速过低联系您当地的Ingersoll Rand代表

因驱动设置有误而导致电机转速过低请见表 4

微控制器故障修理或更换

驱动电机故障请见表 4

压力传感器出现故障、校准有误或电磁干扰重新校准或更换

微控制器设置不正确检查并修改设置

进气格栅或导管阻塞检查并清洁

空气过滤器脏污或损坏更换

空压机无法满足系统所要求的压力进气阀未完全打开修理或更换

分离器元件脏污或损坏更换

管道/导管阻塞或损坏清洁或更换

冷却器芯子阻塞清洁或更换

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