Ingersoll-Rand SSR M11, Operation And Maintenance Manual

Page 1: ... This manual contains important safety information and must be made available to personnel who operate and maintain this machine 2161200 M11 2141800 M7 5 2121300 M5 5 2101200 M4 SERIAL No SERIAL No SERIAL No SERIAL No C C N 89270334 GB DATE NOVEMBER 2002 ...

Page 2: ...INGERSOLL RAND COMPANY LIMITED SWAN LANE HINDLEY GREEN WIGAN WN2 4EZ UNITED KINGDOM DECLARE THAT UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY THE PRODUCT S M4 M5 5 M7 5 M11 TO WHICH THIS DECLARATION RELATES IS ARE IN CONFORMITY WITH THE PROVISIONS OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS EN29001 EN292 EN60204 1 EN1012 EN50081 EN50082 ISSUED AT HINDLEY GREEN ON 01...

Page 3: ...or serial number Up to Serial No From Serial No Not illustrated Option NR Not required AR As required SM Sitemaster Sitepack HA High ambient machine WC Watercooled machine AC Aircooled machine ERS Energy recovery system T E F C Totally enclosed fan cooled motor IP54 O D P Open drip proof motor ppm parts per million BR Brazil CN China DE Germany DK Denmark ES Spain FI Finland FR France GB Great Bri...

Page 4: ...ous conditions over which Ingersoll Rand has no control Therefore Ingersoll Rand cannot be held responsible for equipment in which non approved repair parts are installed Ingersoll Rand reserves the right to make changes and improvements to products without notice and without incurring any obligation to make such changes or add such improvements to products sold previously The intended uses of thi...

Page 5: ...on risk WARNING Air gas flow or Air discharge X XBAR WARNING Pressurised component or system WARNING Hot and harmful exhaust gas WARNING Maintain correct tyre pressure Refer to the GENERAL INFORMATION section of this manual 0_C WARNING Flammable liquid WARNING Before connecting the tow bar or commencing to tow consult the operation and maintenance manual WARNING For operating temperature below 0_C...

Page 6: ... Do not remove the Operating and Maintenance manual and manual holder from this machine Do not stack Do not operate the machine without the guard being fitted Do not stand on any service valve or other parts of the pressure system Do not operate with the doors or enclosure open Do not use fork lift truck from this side XX km h Do not exceed the trailer speed limit No naked lights Do not open the s...

Page 7: ...fore operation or maintenance of this machine is undertaken When parking use prop stand handrake and wheel chocks Contains asbestos SET SEQUENCER STATUS LOAD SEQUENCER AUTOMATIC CONTROL COMPRESSOR OFF LOAD UNLOADED RESET COMPRESSOR STATUS MODULATE MALFUNCTION POWER SOILED FILTER POWER INLET ELECTRIC MOTOR HOURS ...

Page 8: ...URISED TANK ON OFF CYCLE COOLANT FILTER AIR FILTER ON OFF PUSH BUTTON COOLANT PRESSURE AIR PRESSURE STAR DELTA IEC 617 7 AUTOMATIC RESTART HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL MANUAL SELECT TEMPERATURE HIGH TEMPERATURE ...

Page 9: ...ISO SYMBOLS 7 M4 M5 5 M7 5 M11 BELT TENSION FILTER MOTOR LUBRICATION FRAGILE KEEP DRY THIS WAY UP USE NO HOOKS NO SIDE CLAMPS ROTATION POWER INLET AC WATER IN WATER OUT ...

Page 10: ...l and care should be taken to ensure that downstream equipmentis compatible If the discharged air is to be ultimately released into a confined space adequate ventilation must be provided When using compressed air always use appropriate personal protective equipment All pressure containing parts especially flexible hoses and their couplings must be regularly inspected be free from defects and be re...

Page 11: ...onsibility of the user to establish the limitations and regulations in their particular area Ingersoll Rand and its associated distributors are happy to advise and assist in these matters Coolant disposal Steps to be taken in the case of spillage Soak up with a suitable absorbent material then sweep into a plastic bag for disposal Burn in an approved incinerator or according to local area or count...

Page 12: ... totally self contained air compressor package The standard compressor is designed to operate in an ambient range of 1 7_C to 46_C The standard maximum temperature of 46_C is applicable up to an elevation of 1000m 3280ft above sea level Above this altitude significant reductions in ambient temperature are required if a standard motor is to be used Compression in the screw type air compressor is cr...

Page 13: ...ar 9 5 bar 12 5 bar 7 0 bar 8 0 bar 9 5 bar 12 5 bar 7 0 bar 8 0 bar 9 5 bar 12 5 bar 7 0 bar 8 0 bar 9 5 bar 12 5 bar Maximum Pressure ratio 8 5 1 9 5 1 11 0 1 14 0 1 8 5 1 9 5 1 11 0 1 14 0 1 8 5 1 9 5 1 11 0 1 14 0 1 8 5 1 9 5 1 11 0 1 14 0 1 Maximum airend discharge temperature 109 _C 109 _C 109 _C 109 _C Ambient operating temperature 2_C 46_C 2_C 46_C 2_C 46_C 2_C 46_C MOTOR Nominal power 4 0...

Page 14: ...r 20 IP23 54 20 IP23 54 20 IP23 54 10 IP23 54 Fan motor Power 80 W 160 W 160 W 240 kW Control voltage Control 110 VAC 110 VAC 110 VAC 110 VAC Mains supply cable cross section 1 PVC PVC 4 mm2Cu 4 mm2Cu 4 mm2Cu 6 mm2Cu Fuse rating 2 16 A 16 A 20 A 32 A 1 Local Regulations apply if stricter than above The voltage drop must not exceed 5 of the nominal voltage It may be necessary to use cables with a l...

Page 15: ...GENERAL INFORMATION 13 M4 M5 5 M7 5 M11 ...

Page 16: ...t breaker T1 Transformer control supply T2 Transformer dryer supply MAXT Temperature switch MOL Motor overload ES Switch emergency stop 1SV Load solenoid P Pressure switch TM Star Delta Timer TM1 Run on Timer HR Hourmeter R1 R2Relay control Terminal control Option S1 Pushbutton start S2 Pushbutton dryer on S3 Pushbutton dryer off DR1 Supply to dryer supply has neutral Option DR2 Supply to dryer su...

Page 17: ...ded A minimum of 0 5m should be left around all sides of the machine for adequate service access and ventilation Ensure that the correct fork lift truck slots or marked lifting tie down points are used whenever the machine is lifted or transported CAUTION Screw type compressors 1 should not be installed in air systems with reciprocating compressors without means of isolation such as a common recei...

Page 18: ...se of plastic bowls on line filters and other plastic air line components without metal guards can be hazardous Their safety can be affected by either synthetic coolants or the additives used in mineral oils From a safety standpoint metal bowls should be used on any pressurised system ...

Page 19: ... clamps the pivoted table to the main chassis before running the compressor ELECTRICAL DATA An independent electrical isolator should be installed adjacent to the compressor CAUTION Do not remove the motor table transit bolt until the electrical connection and correct rotation have been completed Feeder cables should be sized by the customer electrical contractor to ensure that the circuit is bala...

Page 20: ...off electrical isolator CAUTION After shutdown never allow unit to stand idle with pressure in receiver separatorsystem KEY 1 PRESSURE GAUGE Indicates the pressure immediately after the aftercooler DO NOT operate the compressor at discharge pressures over the rated pressure 2 HOURMETER Records the total running time of the compressor 3 EMERGENCY STOP STOP When depressed will stop the compressor im...

Page 21: ...rough optimization and efficiency and reduced produc tion losses through fewer unexpected maintenance requirements and downtime An optional feature Intelliguard is used to reduce downtime by remote monitoring Air Care Options Unit Status Coverage Service Level Sign up for AirCare within the warranty period Five Year Drivetrain or Package coverage Inspection and diagnostic service only or Preventat...

Page 22: ...ed competent and have read the Maintenance Manuals Prior to attempting any maintenance work ensure that all air pressure is fully discharged and isolated from the system If the automatic blowdown valve is used for this purpose then allow enough time for it to complete the operation the machine cannot be started accidently or otherwise by posting warning signs and or fitting appropriate anti start ...

Page 23: ...alf turn Start the compressor and check for leaks AIR FILTER CHANGE PROCEDURE 1 Unscrew the retaining cap and withdraw the old element 2 Fit the new element ensuring that the retaining nut is secured SEPARATOR ELEMENT CHANGE PROCEDURE 1 Disconnect the hose at the top of the separator tank 2 Disconnect the blow down tube 3 Remove the setscrews securing the cover to the tank and remove the complete ...

Page 24: ...and note the point at which the pressure switch closes and loads the compressor The lower set point is factory set 0 85 bar 12psig below the upper set point to suit the average application TO ADJUST THE UPPER SET POINT Remove the transparent cover and turn the adjuster 1 The red pointer will move Turn the adjuster anti clockwise to increase the set point or clockwise to decrease it TO ADJUST THE L...

Page 25: ...and pulley bush 3 Oil the thread and point of the screw 4 Re install one of the screws in the hole that has threads on the bushing side 5 Slowly tighten the screw until the pulley is pressed from the bush Lightly tapping the bush may assist removal 6 Remove the screw from the hole 7 Move the bush either in or out on the motor shaft depending upon the measurement taken earlier 8 Taking care not to ...

Page 26: ...erefore the drive belt requires no manual adjustment Use only genuine Ingersoll Rand replacement parts to ensure the correct belt tension AIREND BEARINGS Airend bearings are lubricated by the compressor coolant and require no maintenance MOTOR BEARINGS Motor bearings are sealed for life and require no maintenance ...

Page 27: ...on Load solenoid valve defective Drive belt slipping Air system leaks Inlet valve malfunction System demand exceeds compressor delivery Low coolant level Compressor overheats Compressor operating above rated pressure Cooler blocked Low coolant level High ambient temperature Restricted cooling air flow Excessive coolant consumption Separator element leak Blocked separator element drain Compressor o...

Page 28: ...tching on the dryer so refrigerant and lubricants can settle in the dryer Start the compressed air compressor The dryer starts with the compressor An acceptable air quality will be reached within minutes During operation Regularly check the position of the dew point indicator The pointer has to be in the green zone If it is in the red zone see the trouble shooting section on page 27 Shut down The ...

Page 29: ...urchasing a second or a larger dryer as a final solution The condenser pressure is too The fan or the fan motor is defective Check and contact the service department high or too low The ambient temperature is too high Check and remedy Move the dryer if required or move the cooling air suction pipe to a cooler location The condenser is dirty on the outside Clean the condenser as described in the ma...

Page 30: ... the dryer These devices need to be replaced when faulty AIR COOLED 4kW 5 5kW 7 5kW 11kW Constant Pressure Valve suction pressure at zero load at the moment of fan motor switch off 2 05 2 05 2 05 2 05 bar g Fan thermostat out 39 39 39 39 _C Fan thermostat in 56 56 56 56 _C Refrigerant R134a R134a R134a R134a Weight 290 420 420 420 g Dangerous Substances The information below is copied completely f...

Page 31: ...arbonyl halides 11 Toxicological information Acute toxicity ALC inhalation 4h rat 567 ml l Local effects Concentrations substancially above the OEL value may cause narcotic effects Inhalation of decomposition products in high concentrationmay cause shortness of breath lung oedema Long term toxicity Did not show carcinogenic teratogenic or mutagenic effects in animal experiments Special effects Rap...

Page 32: ... M11 KEY 1 Condenser 2 Motor fan 3 Exchanger and evaporator 4 Separator water 5 Filter refrigerant 6 Valve constant pressure 7 Dry air out 8 Wet air in 9 Condensate drain M1 Compressor S3 Thermostat fan T1 Indicator dew point ...

Page 33: ...wer live N Main power neutral M1 Compressor M2 Fan M3 Fan PE Main power earthing S0 Mains switch Customer installation S1 On off switch S3 Temperature switch fan S6 Thermal overload switch compressor Options B Level controlled electronic drain K1 Y1 Time controlled electronic drain TR2 Transformer 110V 115V 277V 230V ...

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Page 36: ...Printed in the United Kingdom ...