SSR UP5-4, UP5-5.5, UP5-7.5, UP5-11c 50 Hz SSR UP6-5, · PDF fileOPERATION AND MAINTENANCE MANUAL. This manual contains important safety information. and must be made available to

C.C.N. :80445273REV. : ADATE : OCTOBER2008

SSR UP5-4, UP5-5.5, UP5-7.5, UP5-11c 50 Hz

SSR UP6-5, UP6-7.5, UP6-10, UP6-15c 60 Hz

OPERATION AND MAINTENANCE MANUAL

This manual containsimportant safety informationand must be made availableto personnel who operate and maintain this machine.

Refer all communications to the nearest Ingersoll Rand Full Service Distributor.

AIR COMPRESSOR GROUPBONDED WARRANTY & REGISTERED START UP

Warranty

Note that this is Ingersoll Rand standard warranty. Any warranty in force at the time of purchase of the compressor or negotiated as part of the purchase order may take precedence over this warranty.

Register on-line at http://air.ingersollrand.com

Ingersoll Rand Industrial Air Solutions

Swan LaneHindley Green

Wigan WN2 4EZ

Ingersoll Rand Asia PacificC/O Ingersoll Rand South East Asia (Pte) Ltd.

42 Benoi Road Singapore 629903

Ingersoll RandIndustrial Air Solutions

P.O. Box 1840800−D Beaty StreetDavidson, NC 28036

The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve months from the date of placing the Equipment in operation or eighteen months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment in accordance with good industry practices and has complied with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufac-tured by others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser or others without Company‘s prior written approval.

The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.

Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time provided above, shall constitute fulfilment of all liabilities of the Company for such nonconformities whether based on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.

The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.

http://air.ingersollrand.com �

Operation and Maintenance Manual Contents

COnTenTSFORewORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5DeCALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ISO SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6GRAPHIC FORM AnD MeAnInG OF ISO SYMBOLS . . . . . . . . . . . . . . . . . . . 6

AnSI SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8GRAPHIC FORM AnD MeAnInG OF AnSI SYMBOLS . . . . . . . . . . . . . . . . . . 8

SAFeTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Condensate disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

GeneRAL InFORMATIOn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13PIPInG AnD InSTRUMenTATIOn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13SCHeMATIC, eLeCTRICAL UP6 5–15HP FV 3PH 60Hz DOL – U.S.A. . . . . . . . . . . . 15SCHeMATIC, eLeCTRICAL UP6 5–15HP SD 3PH 60Hz . . . . . . . . . . . . . . . . . . . 16SCHeMATIC, eLeCTRICAL UP6 5–15HP FV 1PH 60Hz - U.S.A. . . . . . . . . . . . . . . 17SCHeMATIC, eLeCTRICAL UP5 5–15HP FV 3PH 50Hz DOL . . . . . . . . . . . . . . . . 18SCHeMATIC, eLeCTRICAL UP5 5–15HP SD 3PH 50Hz . . . . . . . . . . . . . . . . . . . 19

InSTALLATIOn/HAnDLInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20UnPACKInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21UP-SeRIeS TAnK MOUnTeD (80 GAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22UP-SeRIeS TAnK MOUnTeD (120 GAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24UP-SeRIeS TAnK MOUnTeD (272 LITReS) . . . . . . . . . . . . . . . . . . . . . . . . . . 26UP-SeRIeS TAnK MOUnTeD (500 LITReS) . . . . . . . . . . . . . . . . . . . . . . . . . . 28LOCATIOn In THe PLAnT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30DISCHARGe PIPInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30eLeCTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

OPeRATInG InSTRUCTIOnS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36GeneRAL OPeRATIOn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36COMPReSSOR COnTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37AUTOMATIC START & STOP COnTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37DUAL COnTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37PRIOR TO STARTInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 STARTInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 nORMAL/eMeRGenCY STOPPInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

MAInTenAnCe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39MAInTenAnCe SCHeDULe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39ROUTIne MAInTenAnCe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

� http://air.ingersollrand.com

Contents Operation and Maintenance Manual

TOP UP COOLAnT PROCeDURe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41COOLAnT CHAnGe PROCeDURe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41COOLAnT FILTeR CHAnGe PROCeDURe . . . . . . . . . . . . . . . . . . . . . . . . . . . 41AIR FILTeR eLeMenT CHAnGe PROCeDURe . . . . . . . . . . . . . . . . . . . . . . . . . 41SePARATOR eLeMenT CHAnGe PROCeDURe . . . . . . . . . . . . . . . . . . . . . . . . 42COOLeR CLeAnInG PROCeDURe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42BeLT CHeCKInG AnD ADJUSTMenT PROCeDURe . . . . . . . . . . . . . . . . . . . . . 42eLeCTRIC DRAIn VALVe (OPTIOnAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

PRODUCT DeSCRIPTIOn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43OPeRATIOn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43TIMeR SeTTInGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43TROUBLeSHOOTInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43MAInTenAnCe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

MOISTURe SePARATOR MAInTenAnCe . . . . . . . . . . . . . . . . . . . . . . . . . . . 44AIR FILTeR MAInTenAnCe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44DISASSeMBLInG THe UnIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45ReFRIGeRAnT LeAKS In THe ReFRIGeRATIOn CIRCUIT . . . . . . . . . . . . . . . . . . 45ReFRIGeRAnT CHARGInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45CHARACTeRISTICS OF ReFRIGeRAnT R134A . . . . . . . . . . . . . . . . . . . . . . . . 45TROUBLeSHOOTInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45MAInTenAnCe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

TROUBLe SHOOTInG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

ABBReVIATIOnS & SYMBOLS#### ContactIngersoll Randforserialnumber->#### UptoSerialNo.####-> FromSerialNo.* Notillustrated† OptionnR NotrequiredAR AsrequiredSM Sitemaster/SitepackHA HighambientmachinewC WatercooledmachineAC AircooledmachineeRS EnergyrecoverysystemT.e.F.C. Totallyenclosedfancooledmotor(IP5�)O.D.P. Opendripproof(motor)ppm partspermillion

http://air.ingersollrand.com 5

OPeRATIOn AnD MAInTenAnCe MAnUAL FORewORD

FORewORD

ThecontentsofthismanualareconsideredtobeproprietaryandconfidentialtoIngersoll RandandshouldnotbereproducedwithoutthepriorwrittenpermissionofIngersoll Rand.

Nothingcontainedinthisdocumentisintendedtoextendanypromise,warrantyorrepresentation,expressedorimplied,regardingtheIngersoll Randproductsdescribedherein.Anysuchwarrantiesorothertermsandconditionsofsaleofproductsshallbeinaccordancewiththestandardtermsandconditionsofsaleforsuchproducts,whichareavailableuponrequest.

Thismanualcontainsinstructionsandtechnicaldatatocoverroutineoperationandscheduledmaintenancetasksbyoperationandmaintenancestaff.MajoroverhaulsareoutsidethescopeofthismanualandshouldbereferredtoanauthorisedIngersoll Randservicedepartment.

ThedesignspecificationofthismachinehasbeencertifiedascomplyingwithE.C.directives.AnymodificationtoanypartisabsolutelyprohibitedandwouldresultintheCEcertificationandmarkingbeingrenderedinvalid.

Allcomponents,accessories,pipesandconnectorsaddedtothecompressedairsystemshouldbe:

ofgoodquality,procuredfromareputablemanufacturerand,whereverpossible,beofatypeapprovedbyIngersoll Rand.

clearlyratedforapressureatleastequaltothemachinemaximumallowableworkingpressure.

compatiblewiththecompressorlubricant/coolant.

accompaniedwithinstructionsforsafeinstallation,operationandmaintenance.

Details of approved equipment are available from Ingersoll Rand Service departments.

Theuseofnon-genuinesparerepairpartsotherthanthoseincludedwithintheIngersoll RandapprovedpartslistmaycreatehazardousconditionsoverwhichIngersoll Randhasnocontrol.ThereforeIngersoll Randdoesnotacceptanyliabilityforlossescausedbyequipmentinwhichnon-approvedrepairpartsareinstalled.Standardwarrantyconditionsmaybeaffected.

Ingersoll Randreservestherighttomakechangesandimprovementstoproductswithoutnoticeandwithoutincurringanyobligationtomakesuchchangesoraddsuchimprovementstoproductssoldpreviously.

•

•

•

•

Theintendedusesofthismachineareoutlinedbelowandexamplesofunapprovedusagearealsogiven,howeverIngersoll Randcannotanticipateeveryapplicationorworksituationthatmayarise.

IF In DOUBT COnSULT SUPeRVISIOn.

Thismachinehasbeendesignedandsuppliedforuseonlyinthefollowingspecifiedconditionsandapplications:

Compressionofnormalambientaircontainingnoknownordetectableadditionalgases,vapours.orparticles

OperationwithintheambienttemperaturerangespecifiedintheGENERALINFORMATIONsectionofthismanual.

The use of the machine in any of the situation types listed in table 1:-

IsnotapprovedbyIngersoll Rand,

Mayimpairthesafetyofusersandotherpersons,and

MayprejudiceanyclaimsmadeagainstIngersoll Rand.

•

•

a.

b.

c.

TABLe 1

Useofthemachinetoproducecompressedairfor:

directhumanconsumption

indirecthumanconsumption,withoutsuitablefiltrationandpuritychecks.

a.

b.

UseofthemachineoutsidetheambienttemperaturerangespecifiedintheGENERALINFORMATIONSECTIONofthismanual.

Useofthemachinewherethereisanyactualorforeseeableriskofhazardouslevelsofflammablegasesorvapours.

THISMACHINEISNOTINTENDEDANDMUSTNOTBEUSEDINPOTENTIALLYEXPLOSIVEATMOSPHERES,INCLUDINGSITUATIONSWHEREFLAMMABLEGASESORVAPOURSMAYBEPRESENT.

UseofthemachinefittedwithnonIngersoll Randapprovedcomponents.

Useofthemachinewithsafetyorcontrolcomponentsmissingordisabled.

ThecompanyacceptsnoresponsibilityforerrorsintranslationofthismanualfromtheoriginalEnglishversion.

© COPYRIGHT 2008

InGeRSOLL RAnD


DeCALS OPeRATIOn AnD MAInTenAnCe MAnUAL

DeCALS

ISO SYMBOLS

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk WARNING − Pressurised vessel. WARNING − Hot surface.

WARNING − Pressurised component or system. WARNING − Air/gas �ow or Air discharge. Do not breathe the compressed air from this machine.

Use fork lift truck from this side only. RESET Do not use fork lift truck from this side.

O� (power).On (power).Emergency Stop.

Read the Operation and Maintenance manualbefore operation or maintenance of this

machine is undertaken.

Do not operate the machine without the guardbeing �tted.

Lifting point.

ROTATION AIR DISCHARGE COOLANT FILTER


OPeRATIOn AnD MAInTenAnCe MAnUAL DeCALS



AnSI SYMBOLS

GRAPHIC FORM AND MEANING OF ANSI SYMBOLS

DANGERINTAKEAIR.Cancontaincarbonmonoxideorothercontaminants.Willcauseseriousinjuryordeath.Ingersoll Randaircompressorsarenotdesigned,intendedorapprovedforbreathingair.Compressedairshouldnotbeusedforbreathingairapplicationsunlesstreatedinaccordancewithallapplicablecodesandregulations.

WARNINGHAZARDOUSVOLTAGE.Cancauseseriousinjuryordeath.Disconnectpowerandbleedpressurefromtankbeforeservicing.Lockout/Tagoutmachine.Compressormustbeconnectedtoproperlygroundedcircuit.SeeGroundingInstructionsinmanual.Donotoperatecompressorinwetconditions.Storeindoors.

RISKOFFIREOREXPLOSION.Electricalarcingfromcompressorcomponentscanigniteflammableliquidsandvaporswhichcanresultinseriousinjury.Neveroperatethecompressornearflammableliquidsorvapors.Ifusedtosprayflammablematerials,keepcompressoratleast20ft(�m)awayfromthesprayarea.

HIGHPRESSUREAIR.Rustedtankscancauseexplosionandsevereinjuryordeath.Receiverunderpressure.Operatorshouldrelievetankpressurebeforeperformingmaintenance.Inadditiontoautomaticdrain,operatemanualdrainvalveweekly.Manualdrainvalvelocatedatbottomofthetank.

MOVINGPARTS.Cancauseseriousinjury.Donotoperatewithguardsremoved.Machinemaystartautomatically.Disconnectpowerbeforeservicing.Lockout/Tagoutmachine.

HOTSURFACES.Cancauseseriousinjury.Donottouch.Allowtocoolbeforeservicing.Donottouchhotcompressorortubing.

EXPOSEDMOVINGBELTSANDSHEAVES.Cancausesevereinjuryordeath.Donotoperatewithoutguardinplace.Disconnectpowerbeforeservicing.Lockout/Tagoutmachine.

Airflowexhaustmaycontainflyingdebris.Safetyprotectionshouldbewornatalltimes.

Pinchpointhazard.Keephandsclear.


OPeRATIOn AnD MAInTenAnCe MAnUAL DeCALS

29

Item ccn Qty. Description Item ccn Qty. Description1 ��1��502 1 Decal,replacementelement 12 �2�� 1 Decal,noticeairdischarge

Basemountonly2 �2��5�0 1 Decal,warninghotsurface

� � Decal,voltage 1� 225��1�5 1 Decal,totalairsystem

� ��1��0 1 Decal,coolantdrain Dryerpackagesonly

5 �2��05�� 2 Decal,warninghazardous 1� 22�5�200 1 Tag,rotation

voltage 15 SPEC 1 Specifications,compressor

� ��1�� 1 Decal,condensatedrain package

� 225�0��1 1 Decal,dryerbypassinstruction 1� ��1�� 1 Decal,powerinlet

� 2��5�1�� 1 Decal,maintenanceparts 1� 221�1�11 1 Decal,placetocoverhole

� �2��05�5 1 Decal,pressurizedvessel 1� 22�0�2�� 1 Decal,multiplewiringcircuit

10 ��1�5�� 1 Decal,rotationdirection Dryerpackagesonly

11 �2��0� 2 Decal,donotinhale 1� ��1 1 Decal,startupwarning

Contd....

10 http://air.ingersollrand.com


29

Item ccn Qty. Description Item ccn Qty. Description20 ��1�5�5� 1 Decal,useguardswhen

running25 22�1�10� 1 Decal,facia

Rectangularhourmeter

21 1 Decal,wiringschematicdiagram

2252�2�1 1 Decal,faciaRoundhourmeter

22 ��1�12�2 1 Decal,liftherebothsidesBasemountonly

2� 2�0�� 1 Decal,Ingersoll Randlogo

2� 22�1�0�2 1 Decal,Ingersoll RandlogoBasemountonly

2� 22�5�0�0 1 Decal,belt

22��5�1� 1 Decal,Ingersoll RandlogoReceivermountonly

2� Tankmountoption

2� �2��0�� 1 Decal,nomaintenancebeforereferringtomanual

2� 5��1��1 1 Decal,condensatedrain


OPeRATIOn AnD MAInTenAnCe MAnUAL SAFeTY

SAFeTY

DAnGeRHazardthatwILLcauseDeATH,SeVeReInJURYorsubstantialpropertydamageifignored.Instructionsmustbefollowedpreciselytoavoidinjuryordeath.

wARnInGHazardthatCAncauseDeATH,SeVeReInJURYorsubstantialpropertydamageifignored.Instructionswhichmustbefollowedpreciselytoavoidinjuryordeath.

CAUTIOnCautionscallattentiontoinstructionswhichmustbefollowedpreciselytoavoiddamagingtheproduct,processoritssurroundings.

nOTeSNotesareusedforsupplementaryinformation.

BReATHInG AIR PReCAUTIOnIngersoll Randaircompressorsarenotdesigned,intendedorapprovedforbreathingair.Compressedairshouldnotbeusedforbreathingairapplicationsunlesstreatedinaccordancewithallapplicablecodesandregulations.

GeneRAL InFORMATIOn

Ensurethattheoperatorreadsandunderstandsthedecalsandconsultsthemanualsbeforemaintenanceoroperation.

EnsurethattheOperationandMaintenancemanualisnotremovedpermanentlyfromthemachine.

Ensurethatmaintenancepersonnelareadequatelytrained,competentandhavereadtheMaintenanceManuals.

Donotpointairnozzlesorsprayerstowardanyone.

Compressedairandelectricitycanbedangerous.Beforeundertakinganyworkonthecompressor,ensurethattheelectricalsupplyhasbeenisolatedandthecompressorhasbeenrelievedofallpressure.

Weareyeprotectionwhenoperatingorservicingcompressor.

Allpersonspositionedneartooperatingmachineryshouldbeequippedwithhearingprotectionandgiveninstructionsonitsuseinaccordancewithworkplacesafetylegislation.

Makesurethatallprotectivecoversareinplaceandthatthecanopy/doorsareclosedduringoperation.

Thespecificationofthismachineissuchthatthemachineisnotsuitableforuseinflammablegasriskareas.

Installation of this compressor must be in accordance with recognised electrical codes and any local Health and Safety Codes.

Theuseofplasticbowlsonlinefilterscanbehazardous.Theirsafetycanbeaffectedbyeithersyntheticlubricants,ortheadditivesusedinmineraloils.Ingersoll Randrecommendsthatonlyfilterswithmetalbowlsshouldbeusedonapressurisedsystem.

COMPReSSeD AIR

Compressedaircanbedangerousifincorrectlyhandled.Beforedoinganyworkontheunit,ensurethatallpressureisventedfromthesystemandthatthemachinecannotbestartedaccidentally.

wARnInGImposing a normal or emergency stop on the compressor will only relieve pressure upstream of the minimum pressure valve on top of the separator tank. If maintenance work is required downstream of this valve, ensure that all pressure is relieved at the process vent point external to the compressor.

Ensurethatthemachineisoperatingattheratedpressureandthattheratedpressureisknowntoallrelevantpersonnel.

Allairpressureequipmentinstalledinorconnectedtothemachinemusthavesafeworkingpressureratingsofatleastthemachineratedpressure.

Ifmorethanonecompressorisconnectedtoonecommondownstreamplant,effectiveisolationvalvesmustbefittedandcontrolledbyworkprocedures,sothatonemachinecannotaccidentallybepressurised/overpressurisedbyanother.

Compressedairmustnotbeusedforadirectfeedtoanyformofbreathingapparatusormask.

Thedischargedaircontainsaverysmallpercentageofcompressorlubricantandcareshouldbetakentoensurethatdownstreamequipmentiscompatible.

Ifthedischargedairistobeultimatelyreleasedintoaconfinedspace,adequateventilationmustbeprovided.

Whenusingcompressedairalwaysuseappropriatepersonalprotectiveequipment.

Allpressurecontainingparts,especiallyflexiblehosesandtheircouplings,mustberegularlyinspected,befreefromdefectsandbereplacedaccordingtotheManualinstructions.


Avoidbodilycontactwithcompressedair.

Allsafetyvalveslocatedintheseparatortankmustbecheckedperiodicallyforcorrectoperation.


SAFeTY OPeRATIOn AnD MAInTenAnCe MAnUAL

Donotover-pressurizethereceivertankorsimilarvesselsbeyonddesignlimits.

Donotuseareceivertankorsimilarvesselsthatfailtomeetthedesignrequirementsofthecompressor.Contactyourdistributorforassistance.

Donotdrillinto,weldorotherwisealterthereceivertankorsimilarvessels.

Beforeservicingtheunit,ventpressurebeforeremovingthepowertoensurethatthegaugereadszeropressure.

MATeRIALS

Thefollowingsubstancesareusedinthemanufactureofthismachineandmaybehazardoustohealthifusedincorrectly:

preservativegrease

rustpreventative

compressorcoolant

AVOID InGeSTIOn, SKIn COnTACT AnD InHALATIOn OF FUMeS

TRAnSPORT

Whenloadingortransportingmachinesensurethatthespecifiedliftingandtiedownpointsareused.

Liftingequipmentmustbeproperlyratedfortheweightofthecompressor.

Donotworkonorwalkunderthecompressorwhileitissuspended.

eLeCTRICAL

Keepallpartsofthebodyandanyhand-heldtoolsorotherconductiveobjects,awayfromexposedlivepartsofthecompressorelectricalsystem.Maintaindryfooting,standoninsulatingsurfacesanddonotcontactanyotherportionofthecompressorwhenmakingadjustmentsorrepairstoexposedlivepartsofthecompressorelectricalsystem.

•••

wARnInGAny electrical connections or adjustments should only be made by a suitably qualified electrician

Closeandlockallaccessdoorswhenthecompressorisleftunattended.

DonotuseextinguishersintendedforClassAorClassBfiresonelectricalfires.UseonlyextinguisherssuitableforclassBCorclassABCfires.

Attemptrepairsonlyinclean,dry,welllightedandventilatedareas.

Connectthecompressoronlytoelectricalsystemsthatarecompatiblewithitselectricalcharacteristicsandthatarewithinit’sratedcapacity.

COnDenSATe DISPOSAL

Aswastewaterregulationsvarybycountryandregionitistheresponsibilityoftheusertoestablishthelimitationsandregulationsintheirparticulararea.Ingersoll Randanditsassociateddistributorsarehappytoadviseandassistinthesematters.

Forfurtherinformation,consultMaterialDataSheetsforULTRA.

TheaboveinformationcontainsdatasuppliedinsupportofUnitedKingdomControl of Substances Hazardous to Health (C.O.S.H.H.) regulations.

http://air.ingersollrand.com 1�

OPeRATIOn AnD MAInTenAnCe MAnUAL GeneRAL InFORMATIOn

GeneRAL InFORMATIOn

PIPInG AnD InSTRUMenTATIOn

2242

6035

REV

F

1� http://air.ingersollrand.com

GeneRAL InFORMATIOn OPeRATIOn AnD MAInTenAnCe MAnUAL

KeY1 Filter,air 21 Gauge,pressure2 Valve,airinlet 22 Valve,relief(sirc)3 Airendassembly 23 Filter,generalpurposeair

4 Motor 24 Filter,highefficiencyair

5 Relay,motoroverload 25 Valve,check

6 Tank,separator-coarse 26 Recuperator

7 Tank,separator-fine 27 Valve,isolation(option)

8 Valve,minimumpressure 28 Moistureseparator

9 Aftercooler 29 Valve,check

10 Valve,blowdown 30 Evaporator

11 Switch,pressure 31 Indicator,dewpoint

12 Switch,temperature 32 Valve,condensate

13 Filter,coolant 33 Tube,capillary

14 Thermostat 34 Filterdrier,refrigerant

15 Cooler,oil 35 Condenser

16 Valve,pilot 36 Valve,hotgasbypass

17 Valve,relief 37 Compressor,refrigerant18 Valve,drain 38 Valve,autodrain19 Screen,scavenge 39 Receiver,air20 Valve,solenoid 40 Filter


OPeRATIOn AnD MAInTenAnCe MAnUAL GeneRAL InFORMATIOnSCHeMATIC, eLeCTRICAL UP6 5–15HP FV 3PH 60Hz DOL – U.S.A.

KeY1FU,2FU,�FU

Fusecontrolcircuit HATS Switch,highairtemperature

�FU,5FU Fuse M Coilmotorstarter1Ma Contact,auxiliarystarter MIO Indicator,maintenanceoption

(Insteadofstandardhourmeter)1Mb Contact,auxiliarystarter MOT Motor

CPT Transformer,control120/1/50–�0Seetransformernameplateforwiringconnectionrequirements

OL Overload,motorstarter

CR Relay,control PS Switch,pressure

CRa Contact,controlrelay ST Pushbutton,start

CS Customersupplied115v/1/�0hz TP Terminalpoints

DO Dryeroption TS Tosupply

DM Motor,dryer W Standbylight

EDV Valve,electricdrain120/1/50–�0 nOTeSE-STOP Button,emergencystop 1. (*)Furnished,mountedandwiredoutsideofcontrol

panel,ifrequiredbyorder.G Poweronlight 2. Circuitshowninnormalpositionde–energized.

HM Hourmeter �. Allwiringtobemarkedinaccordancewiththisschematic.

HM1 Indicator,maintenance �. AllwiringtobeinaccordancewithNEC.


GeneRAL InFORMATIOn OPeRATIOn AnD MAInTenAnCe MAnUALSCHeMATIC, eLeCTRICAL UP6 5–15HP SD 3PH 60Hz

KeY1FU,2FU Fuse,primary HATS Switch,highairtemperature�FU Fuse,secondary HM Hourmeter�FU,5FU Fuse,dryer HM1 Indicator,maintenance1LT Light,poweronindicator(green) MIO Indicator,maintenanceoption

(Insteadofstandardhourmeter)2LT Light,autorestartindicator(white) MTR Motor,compressor1M Contactor,main OL Overload,mainmotor1Ma,b,c Contacts,auxiliary.Maincontactor OLa Contact,mainmotoroverload2M Contactor,delta PS Switch,pressure2Ma,b Contacts,auxiliary.Deltacontactor ST Pushbutton,start1S Contactor,star TD Relay,deltastarting(10sec)1Sa,b Contacts,auxiliary.Starcontactor TDc Relay,delayoff,contact1SV Valve,solenoid(nc)CPT Transformer,control nOTeSCR Relay,control 1. (*)Furnished,mountedandwiredoutsideofcontrol

panel,ifrequiredbyorder.CRa Contact,controlrelay 2. Circuitshowninnormalpositionde–energized.CS Customersupplied115v/1/�0hz �. Allwiringtobemarkedinaccordancewiththis

schematic.DM Motor,dryer �. AllwiringtobeinaccordancewithNEC.DO DryeroptionEDV Valve,electricdrain(optional)E–STOP Switch,emergencystop


OPeRATIOn AnD MAInTenAnCe MAnUAL GeneRAL InFORMATIOnSCHeMATIC, eLeCTRICAL UP6 5–15HP FV 1PH 60Hz - U.S.A.

KeY1FU,2FU,�FU

Fusecontrolcircuit M Coilmotorstarter

�FU,5FU Fuse,dryer MIO Indicator,maintenanceoption1Ma Contact,auxiliarystarter (Insteadofstandardhourmeter)

1Mb Contact,auxiliarystarter MTR Motor,compressor

CPT Transformer,control120/1/50–�0see OL Overload,motorstarter

Transformernameplateforwiring PS Switch,pressure

Connectionrequirements ST Pushbutton,start

CR Relay,control TP Terminalpoints

CRa Contact,controlrelay TS Tosupply

CS Customersupplied115v/1/�0hz W Standbylight

DM Motor,dryer nOTeSDO Dryeroption 1. (*)Furnished,mountedandwiredoutsideofcontrol

panel,ifrequiredbyorder.EDV Valve,electricdrain 2. Circuitshowninnormalpositionde–energized.

E-STOP Switch,emergencystop �. Allwiringtobemarkedinaccordancewiththisschematic.

G Poweronlight �. AllwiringtobeinaccordancewithNEC.

HM Hourmeter

HM1 Indicator,maintenance


GeneRAL InFORMATIOn OPeRATIOn AnD MAInTenAnCe MAnUALSCHeMATIC, eLeCTRICAL UP5 5–15HP FV 3PH 50Hz DOL

KeY1FU Fuse,secondary MIO Indicator,maintenanceoption

(Insteadofstandardhourmeter)2FU,�FU Fuse,primary MM Motor,compressor�FU,5FU Fuse,dryer MOL Overload,mainmotor

CR Relay,control MOL-1 Contact,mainmotoroverloadCS Customersupplied2�0v/1/50hz PS Switch,pressureDM Motor,dryer ST Pushbutton,startDO Dryeroption T1 Transformer,controlEDV Valve,electricdrain TP TerminalpointsES Switch,emergencystop TS TosupplyHATS Switch,highairtemperatureHM HourmeterHM1 Indicator,maintenance nOTeSKM Contactor,main 1. (*)Furnished,mountedandwiredoutsideof

controlpanel,ifrequiredbyorder.KM–1,2 Contacts,auxiliary.Maincontactor 2. Circuitshowninnormalpositionde–energized.LT1 Light,poweronindicator(green) �. Allwiringtobemarkedinaccordancewiththis

schematic.

LT2 Light,autorestartindicator(white) �. AllwiringtobeinaccordancewithNEC.


OPeRATIOn AnD MAInTenAnCe MAnUAL GeneRAL InFORMATIOnSCHeMATIC, eLeCTRICAL UP5 5–15HP SD 3PH 50Hz

KeY1SV Valve,solenoid(nc) KM2-1,2 Contacts,auxiliary.DeltacontactorCR Relay,control KM� Contactor,starCR-1 Contact,controlrelay KM�-1,2 Contacts,auxiliary.StarcontactorCS Customersupplied2�0v/1/50hz LT1 Light,poweronindicator(green)DM Motor,dryer LT2 Light,autorestartindicator(white)DO Dryeroption MIO Indicator,maintenanceoptionEDV Valve,electricdrain (Insteadofstandardhourmeter)HATS Switch,highairtemperature MOL Overload,mainmotorHM Hourmeter MOL-1 Contact,mainmotoroverloadHM1 Indicator,maintenance ST Pushbutton,startMM Motor,compressor T1 Transformer,controlP Switch,pressure TM1 Relay,deltastarting(10sec)ES Switch,emergencystop TM1-1 Relay,delayoff,contactFU1,FU2 Fuse,primaryFU� Fuse,secondary nOTeSFU�,FU5 Fuse,dryer 1. (*)Furnished,mountedandwiredoutsideof

controlpanel,ifrequiredbyorder.KM1 Contactor,main 2. Circuitshowninnormalpositionde–energized.KM-1,2,� Contacts,auxiliary.Maincontactor �. Allwiringtobemarkedinaccordancewiththis

schematic.KM2 Contactor,delta �. AllwiringtobeinaccordancewithNEC.


InSTALLATIOn / HAnDLInG OPeRATIOn AnD MAInTenAnCe MAnUAL

InSTALLATIOn/HAnDLInGW

ITH

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PTIO

NA

LO

UTD

OO

R M

OD

.

WIT

H

OPT

ION

AL

OU

TDO

OR

MO

D.

ROTA

TIO

N

VIEW TOP

VIEW LEFT

VIEW RIGHT

VIEW FRONT


OPeRATIOn AnD MAInTenAnCe MAnUAL InSTALLATIOn / HAnDLInG

KeYA Packagepre-filler M Motor

B Hole,incomingpowersupplyconduit n Integrateddryer(Optional)

C Gauge,pressure O Compressorandcoolingairintake

D Yellowstand–bylight P Filter,coolant

e Greenpower–onlight Q Cartridge,coolantseparator

F Greenstartpushbutton R Valve,airendrelief

G Emergencystopbutton S Plug,coolantfiller

H Hourmeter T Sight–glass

I Starterbox U Plug,coolantdrain

J Liftingpoints V Valve,pilot

K Mountingholes(�x1�.0mm[0.550”]diameter) w Switch,pressure

L Filter,airinlet X Coolingairexhaust

nOTeS1. Foundationorfloormustbelevelandsupportall

mountingboltlocationsequally.Ifnecessary,shimorgroutthefourthboltlocation.

2. Foundationboltsshouldprotectthrunutsaminimumof1�mm(0.50”)toallowforlevelling.

�. Allowaminimumclearanceof1100mm(�2”)onthefrontand�20mm(��”)onthetop,leftrightandrearofthepackageforproperaircirculationandserviceability.

�. Approximatepackageweight:2��kg(�55lbs).

5. Externalpipingshallnotexertanyunresolvedmomentsorforcesontheunit.Usepipesizeaslargeorlargeratdischargeconnection.

�. Thereshouldbenoplasticorpvcpipingattachedtothisunitorusedforanylinesdownstream.

�. Donotpipeintoacommonheaderwithareciprocatingcompressor,unlessthereciprocatingcompressorutilizesadischargepulsationdamper.

�. SizingofelectricalcomponentsnotsuppliedbyIngersoll Randistheresponsibilityofthecustomerandshouldbedoneinaccordancewiththeinformationonthecompressordataplateandnationalandlocalelectricalcodes.

nOTeAll dimensions are in millimetres (inches) unless otherwise stated.

Ensurethatthecorrectforklifttruckslotsormarkedliftingpointsareusedwheneverthemachineisliftedortransported.

UnPACKInG

Thecompressorwillnormallybedeliveredwithapolythenecover.Ifaknifehastobeusedtoremovethiscoverensurethattheexteriorpaintworkofthecompressorisnotdamaged.

Ensurethatalltransportandpackingmaterialsarediscardedinamannerprescribedbylocalcodes.



UP-SeRIeS TAnK MOUnTeD (80 GAL)



KeYA Packagepre-filler P Filter,coolant

B Hole,incomingpowersupplyconduit Q Cartridge,coolantseparator

C Gauge,pressure R Valve,airendrelief

D Yellowstand–bylight S Plug,coolantfiller

e Greenpower–onlight T Sight–glass

F Greenstartpushbutton U Plug,coolantdrain

G Emergencystopbutton V Valve,pilot

H Hourmeter w Switch,pressure

I Starterbox X Coolingairexhaust

J Liftingpoints 1A Valve,ball0.�5”N.P.T.

K Mountingholes(�x1�.5mm[0.��”]x��.5mm[1.�5”]slots)

1B Airreceiver(Ø�20.0mmx11��.�mmLG)(Ø2�.�0”x��.00”LG)

L Filter,airinlet 1C Locationformanualreceiverdrain

M Motor 1D Valve,receiverrelief

n Integrateddryer(Optional) 1e 0.25”dischargeportforoptionalelectricdrainvalve

O Compressorandcoolingairintake





�. Approximatepackageweight:�20kg(�25lbs).







UnPACKInG





UP-SeRIeS TAnK MOUnTeD (120 GAL)














1B Airreceiver(Ø�1�.0mmx1�01.0mmLG)(Ø2�.��”x��.00”LG)









�. Approximatepackageweight:��0kg(��lbs).







UnPACKInG





UP-SeRIeS TAnK MOUnTeD (272 LITReS)














1B Airreceiver(Ø�00.0mmx1111.0mmLG)(Ø2�.�2”x��.��”LG)









�. Approximatepackageweight:�00kg(��0lbs).







UnPACKInG





UP-SeRIeS TAnK MOUnTeD (500 LITReS)














1B Airreceiver(Ø�10.0mmx1��.0mmLG)(Ø2�.02”x��.��”LG)









�. Approximatepackageweight:�55kg(1000lbs).







UnPACKInG



�0 http://air.ingersollrand.com


KeYCompressor

AirReceiver

AirDryer

Compressedairfilters

Systemdemandpoints

1.

2.

�.

�.

5.

nOTeItems [2] to [5] are optional or may be existing items of plant. Refer to your Ingersoll Rand distributor / representative for specific recommendations.

LOCATIOn In THe PLAnT

Thecompressorcanbeinstalledonanylevelfloorcapableofsupportingit.Adry,wellventilatedareawheretheatmosphereiscleanisrecommended.Aminimumof1m(�ft)shouldbeleftallaroundmachineforadequateserviceaccessandventilation.

Adequateclearanceneedstobeallowedaroundandabovethemachinetopermitsafeaccessforspecifiedmaintenancetasks.

Ensurethatthemachineispositionedsecurelyandonastablefoundation.Anyriskofmovementshouldberemovedbysuitablemeans,especiallytoavoidstrainonanyrigiddischargepiping.

CAUTIOnScrew type compressors [1] should not be installed in air systems with reciprocating compressors without means of isolation such as a common receiver tank. It is recommended that both types of compressor be piped to a common receiver using individual air lines.

CAUTIOnThe use of plastic bowls on line filters and other plastic air line components can be hazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils. Ingersoll Rand recommends that only filters with metal bowls should be used on any pressurised system.

CAUTIOnThe standard compressor unit is not suitable for operation in temperatures liable to cause freezing as Condensate water is liable to be produced in the after cooler and receiver where fitted.

Refer to your Ingersoll Rand distributor for further information.

DISCHARGe PIPInG

Dischargepipingshouldbeatleastaslargeasthedischargeconnectionofthecompressor.Allpipingandfittingsshouldbesuitablyratedforthedischargepressure.

Itisessentialwheninstallinganewcompressor[1],toreviewthetotalairsystem.Thisistoensureasafeandeffectivetotalsystem.Oneitemwhichshouldbeconsideredisliquidcarryover.Installationofairdryers[�]isalwaysgoodpracticesinceproperlyselectedandinstalledtheycanreduceanyliquidcarryovertozero.

Itisgoodpracticetolocateanisolationvalveclosetothecompressorandtoinstalllinefilters[�].

ItisarequirementforairdryerscoveredunderAirCarethatcorrectlysizedIngersoll Randpreandafterfiltersareinstalled.

http://air.ingersollrand.com �1


60Hz UP6 5 UP6 7 UP6 10 UP6 15c

COMPReSSOR 125 150 210 125 150 210 125 150 210 125 150 210

Operatingpres-surePSIG(bar)

125(�.�)

150(10.�)

-- 125(�.�)

150(10.�)

210(1�.5)

125(�.�)

150(10.�)

210(1�.5)

125(�.�)

150(10.�)

210(1�.5)

FactorysetreloadpressurePSIG(bar)

110(�.5�)

1�0(�.��)

-- 110(�.5�)

1�0(�.��)

1�0(12.�1)

110(�.5�)

1�0(�.��)

1�0(12.�1)

110(�.5�)

1�0(�.��)

1�0(12.�1)

FlowrateCFM(m�/MIN)

1�.5(0.52)

1�.0(0.�5)

-- 2�.0(0.��)

25.0(0.�1)

1�.5(0.50)

��.0(1.0�)

��(0.��)

2�.0(0.��)

55.0(1.55)

50.0(1.�2)

��.0(1.0�)

Airenddischargetemperaturetrippoint.

22�°F(10�°C)

Ambientoperatingtemperature(min.)→(max.)

��°F(+2°C)→105°F(+�0°C)

MOTOR

Motorenclosure ODP TEFC ODP TEFC ODP TEFC ODP TEFC

Nominalpower 5HP �.5HP 10HP 15HP

Speed �500RPM

Insulationclass F

GeneRAL DATA

Residualcoolantcontent

�ppm(�mg/m�)

Separatorvesselcapacity

0.�gallons(�Litres)

Coolantcapacity 1.2gallons(�.5Litres)

SoundpressureleveltoCAGI-PNEUROP

�5dB(A) �5dB(A) ��dB(A) ��dB(A)

Weight-basemountunit

2�5kg(�50lb)

Weight-�0gallonReceivermounted

�20kg(�25lb)

Weight-120gallonReceivermounted

��kg(��0lb)

CAUTIOn

2�0/��0Dualvoltagemachinesarefittedwithadecaltoadvisethecorrectvoltageasconnectedfromthefactory.

Thereisadecalfittedtothestarterdoordescribingtheproceduretochangetheconnectionsforthealternativevoltage.

RewiringshouldonlybeeffectedbyacompetentElectrician.



50Hz UP5 4 UP5 5 UP5 7 UP5 11c

COMPReSSOR � 10 1�.5 � 10 1�.5 � 10 1�.5 � 10 1�.5

OperatingpressurePSIG(bar)

115(�)

1�5(10)

210(1�.5)

115(�)

1�5(10)

210(1�.5)

115(�)

1�5(10)

210(1�.5)

115(�)

1�5(10)

210(1�.5)

FactorysetreloadpressurePSIG(bar)

100(�.5�)

125(�.��)

-- 100(�.��)

125(�.��)

1�0(1�.10)

100(�.��)

125(�.��)

1�0(1�.10)

100(�.��)

125(�.��)

1�0(1�.1)

FlowrateCFM(m�/MIN)

1�.5(0.55)

1�.0(0.�5)

-- 2�.0(0.�2)

2�.0(0.��)

1�.0(0.51)

��.0(1.0�)

��(0.��)

2�.0(0.��)

5�.5(1.�0)

50.0(1.�2)

��.0(�.�)

Airenddischargetemperaturetrippoint.

22�°F(10�°C)

Ambientoperatingtemperature(min.)→(max.)

��°F(+2°C)→105°F(+�0°C)

MOTORMotorenclosure TEFCNominalpower �KW 5.5KW �.5KW 11KWSpeed 2�00RPMInsulationclass F

GeneRAL DATAResidualcoolantcontent

�ppm(�mg/m�)

Separatorvesselcapacity

0.�gallons(�Litres)

Coolantcapacity 1.2gallons(�.5Litres)SoundpressureleveltoCAGI-PNEUROP

�5dB(A) �5dB(A) ��dB(A) ��dB(A)

Weight-basemountunit

2�5kg(�50lb)

Weight-2�2Litres-Receivermounted

�20kg(�25lb)

Weight-500LitresReceivermounted

�5�kg(1000lb)

DRYeR enGIneeRInG DATA 60Hz 50Hz

Electricalsupply 115V-1ph-�0Hz 2�0V-1ph-50HzL.R.A.current(Amps) �0.0 12.�F.L.A.current(Amps) 5.0 2.�

Totalinstalledpower(kW) 0.�� 0.��Electricalprotectionclass(std) NEMA1

(IP20)Factoryrefrigerantcharge(lb/g) 0.��lb

�5�gRefigerationtype 1��A

CAUTIOn2�0/��0Dualvoltagemachinesarefittedwithadecaltoadvisethecorrectvoltageasconnectedfromthefactory.Thereisadecalfittedtothestarterdoordescribingtheproceduretochangetheconnectionsforthealternativevoltage.RewiringshouldonlybeeffectedbyacompetentElectrician.

eLeCTRICAL DATA-UP6 5

http://air.ingersollrand.com ��


Standardvoltage 2�0V/1PH 200V 2�0V/�PH ��0V 5�5VFullloadcurrent(maximum) 2�.5A 15.5A 1�.5A �.�A 5.�AStartingcurrentDOL(StarDelta) - - - - -StartingtimeDOL(StarDelta) �–5Sec(�–10Sec)Startsperhour(maximum) �Controlvoltage 120VACRecommendedfuseratingSeenote1 �0A 25A 20A 10A �ARecommendedwiresizeAWGSeenote2 � 10 12 1� 1�

eLeCTRICAL DATA-UP6 7.5Standardvoltage 2�0V/1PH 200V 2�0V/�PH ��0V 5�5VFullloadcurrent(maximum) ��.1A 22.�A 1�.�A �.�A �.�AStartingcurrentDOL(StarDelta) - - - - -StartingtimeDOL(StarDelta) �–5Sec(�–10Sec)Startsperhour(maximum) �Controlvoltage 120VACRecommendedfuseratingSeenote1 50A �5A �5A 15A 12ARecommendedwiresizeAWGSeenote2 � � 10 1� 1�

eLeCTRICAL DATA-UP6 10Standardvoltage 2�0V/1PH 200V 2�0V/�PH ��0V 5�5VFullloadcurrent(maximum) - 2�.�A 2�.0A 1�.0A 10.�AStartingcurrentDOL(StarDelta) - - - - -StartingtimeDOL(StarDelta) �–5Sec(�–10Sec)Startsperhour(maximum) �Controlvoltage 120VACRecommendedfuseratingSeenote1 - 50A �5A 20A 15ARecommendedwiresizeAWGSeenote2 - � � 12 1�

eLeCTRICAL DATA-UP6 15cStandardvoltage 2�0V/1PH 200V 2�0V/�PH ��0V 5�5VFullloadcurrent(maximum) - ��.2A ��.�A 1�.�A 15.1AStartingcurrentDOL(StarDelta) - - - - -StartingtimeDOL(StarDelta) �–5Sec(�–10Sec)Startsperhour(maximum) �Controlvoltage 120VACRecommendedfuseratingSeenote1 - �5A �5A �0A 25ARecommendedwiresizeAWGSeenote2 - � � 10 10

1.Ifacircuitbreakerisselecteditshouldonlybeamagnetictriptype,setabovetheanticipatedstartingcurrentofthemachine,butbelowthemaximumprospectivefaultcurrentforthecircuit.Thecircuitbreakerorfuseabledisconnectmustbecapableofbreakingtheprospectivefaultcurrentatitsterminals.

2.PVC/PVCTypeCalculatedusingthefollowingconditions:

PVCinsulatedcable,armoured,copperconductors.

Cableclippedtoawall,infreeair.

Ambienttemperatureof�0°C(10�°F)andrelativehumidityof�0%.

i)

ii)

iii)

20m(�5ft)cablerun.

Voltdroplimitedto–10%duringstarting,–�%duringnormalrunning.

Protectedbythecircuitbreakerlistedabove.

iv)

v)

vi)

�� http://air.ingersollrand.com


eLeCTRICAL DATA-UP5 4Standardvoltage ��0V �00VFullloadcurrent(maximum) �.�A �.5AStartingcurrentDOL(StarDelta) �� StartingtimeDOL(StarDelta) �–5Sec(�–10Sec)Startsperhour(maximum) �Controlvoltage 120VACRecommendedfuseratingSeenote1 1�A 1�ARecommendedwiresizeSeenote2 �mm2Cu �mm2Cu

eLeCTRICAL DATA-UP5 5.5Standardvoltage ��0V �00VFullloadcurrent(maximum) 11.�A 11.2AStartingcurrentDOL(StarDelta) 100 �5StartingtimeDOL(StarDelta) �–5Sec(�–10Sec)Startsperhour(maximum) �Controlvoltage 120VACRecommendedfuseratingSeenote1 1�A 1�ARecommendedwiresizeSeenote2 �mm2Cu �mm2Cu

eLeCTRICAL DATA-UP5 7.5Standardvoltage ��0V �00VFullloadcurrent(maximum) 1�.�A 15.�AStartingcurrentDOL(StarDelta) 121(��) 11�(52)StartingtimeDOL(StarDelta) �–5Sec(�–10Sec)Startsperhour(maximum) �Controlvoltage 120VACRecommendedfuseratingSeenote1 20A 20ARecommendedwiresizeSeenote2 �mm2Cu �mm2Cu

eLeCTRICAL DATA-UP5 11cStandardvoltage ��0V �00VFullloadcurrent(maximum) 2�.0A 21.�AStartingcurrentDOL(StarDelta) (��) (�5)StartingtimeDOL(StarDelta) �–5Sec(�–10Sec)Startsperhour(maximum) �Controlvoltage 120VACRecommendedfuseratingSeenote1 �2A �2ARecommendedwiresizeSeenote2 �mm2Cu �mm2Cu

1.Ifacircuitbreakerisselecteditshouldonlybeamagnetictriptype,setabovetheanticipatedstartingcurrentofthemachine,butbelowthemaximumprospectivefaultcurrentforthecircuit.Thecircuitbreakerorfuseabledisconnectmustbecapableofbreakingtheprospectivefaultcurrentatitsterminals.

2.PVC/PVCTypeCalculatedusingthefollowingconditions:

PVCinsulatedcable,armoured,copperconductors.

i)

Cableclippedtoawall,infreeair.

Ambienttemperatureof�0°C(10�°F)andrelativehumidityof�0%.

20m(�5ft)cablerun.

Voltdroplimitedto–10%duringstarting,–�%duringnormalrunning.

Protectedbythecircuitbreakerlistedabove.

ii)

iii)

iv)

v)

vi)



Ifthereareanydeviationsfromtheabove,orspecialregulationsapply,theinstallationmustbeplannedbyacompetent,qualifiedengineer.

nOTeAll data applies to standard product only.

eLeCTRICAL DATA

Anindependentelectricalisolatorordisconnectshouldbeinstalledadjacenttothecompressor.

Feedercables/wiresshouldbesizedbythecustomer/electricalcontractortoensurethatthecircuitisbalancedandnotoverloadedbyotherelectricalequipment.Thelengthofwiringfromasuitableelectricalfeedpointiscriticalasvoltagedropsmayimpairtheperformanceofthecompressor.

Feedercables/wiresconnectionstoisolatorordisconnectshouldbetightandclean.

Theappliedvoltagemustbecompatiblewiththemotorandcompressordataplateratings.

Thecontrolcircuittransformerhasdifferentvoltagetappings.Ensurethatthesearesetforthespecificappliedvoltagepriortostarting.

CAUTIOnnever test the insulation resistance of any part of the machines electrical circuits, including the motor without completely disconnecting the electronic controller (where fitted).

CAUTIOnensure that the motor rotates in the correct direction as indicated by direction arrows.


OPeRATInG InSTRUCTIOnS OPeRATIOn AnD MAInTenAnCe MAnUAL

OPeRATInG InSTRUCTIOnS

GeneRAL OPeRATIOn

Thecompressorisanelectricmotordriven,singlestagescrewcompressor,completewithaccessoriespiped,wiredandbaseplatemounted.Itisatotallyselfcontainedaircompressorpackage.

Thestandardcompressorisdesignedtooperateinanambientrangeof�5.�°F-10�°F(2°Cto�0°C).Themaximumtemperatureisapplicableuptoamaximumelevationof�2�0ft(1000m)abovesealevel.Abovethisaltitudesignificantreductioninmaximumallowableambienttemperatureisrequired.

Compressioninthescrewtypeaircompressoriscreatedbythemeshingoftwo(male&female)helicalrotors.

Theair/coolantmixturedischargesfromthecompressorintotheseparationsystem.ThissystemremovesallbutafewPPMofthecoolantfromthedischargeair.Thecoolantisreturnedtothecoolingsystemandtheairpassesthroughtheaftercoolerandoutofthecompressor.

Coolingairismovedthroughthecoolersbythecoolingfananddischargedfromthemachine.

CAUTIOnCooling air is drawn in at the rear of the machine package passing through the filter and cooler before being discharged from the top of the machine. Care should be taken to avoid blocking the airflow, or causing any restriction in excess of the maximum backpressure allowed for ducting.

Do not direct the airflow at face or eyes.

Bycoolingthedischargeair,muchofthewatervapournaturallycontainedintheairiscondensedandmaybedrainedfromthedownstreampipingandequipment.

Thecoolantsystemconsistsofasump,cooler,thermostaticvalveandafilter.Whentheunitisoperating,thecoolantispressurizedandforcedtothecompressorbearings.

Thecompressorloadcontrolsystemisautomaticon-off line.Thisallowsthecompressortomaintainasetdischargelinepressurebyvaryingoutputcapacitytomatchthesystemdemand.Theunitisprovidedwithanautomaticstopandrestartsystemforuseinplantswheretheairdemandvariessufficientlytoallowacompressortoshutdownandsavepower.Significantsystemvolumewillassistthisandisrecommended.

Whenthecompressorisequippedwiththeoptionaldryer,thedryerwillcycleonandoffwiththecompressor.

wARnInGwhen the unit stops running as the result of low air demand, it may restart and return to load at any time.

Safetyofoperationisprovidedasthecompressorwillshutdownifexcessivetemperaturesorelectricaloverloadconditionsshouldoccur.

CAUTIOnThis unit is not designed or intended to operate when contaminated with silicone. Lubricants, greases or other items containing silicone should not be used on this unit.

CAUTIOnLOw DeMAnD APPLICATIOnS During periods of low demand, the compressor may not reach its normal operating temperature. Sustained operation at low demand can result in the build up of condensate in the coolant. If this situation occurs, the lubricating characteristics of the coolant can be impaired which may lead to damage of the compressor.

THe COMPReSSOR SHOULD Be ALLOweD AMPLe LOADeD RUnnInG TIMe OF AT LeAST 10 MInUTeS PeR HOUR DURInG nORMAL DAILY USe.


OPeRATIOn AnD MAInTenAnCe MAnUAL OPeRATInG InSTRUCTIOnSCOMPReSSOR COnTROLS

Direct online starting:

ThecompressorisequippedforAutomaticStart&StopControl.Whenthereceivertankpressurereachesthefactorypre–setmaximumpressure,thepressureswitchstopstheunit.Whenthereceivertankpressuredropsbelowthefactorypre–setminimum.Thepressureswitchresetsandrestartstheunit.

Thepressureswitchcovercanberemovedbyunscrewingthetwoscrewsholdingthecover.

Pressure switch adjustment:

Thecompressorpackagewillcut–inandcut–outatfactorypresetpressuresettings.Adjustthepressureswitchonlyifabsolutelynecessary.

Adjustmentsaretobecarriedoutonlywhentheswitchismounted,underpressureandvoltage–free.

wARnInGHigh voltage is present at the pressure switch contacts when the power supply is connected. Disconnect, lock and tag main power supply before making adjustments.

wARnInGDo not adjust the pressure switch to exceed the maximum discharge pressure of the unit.

nOTewhen replacing the pressure switch cover, ensure the selector knob on the cover and the lever on the switch are both in the ”OFF” position.

nOTewhen the compressor is equipped with the optional dryer and filters, the pressure switch differential should be increased 10psi to account for the added pressure drop of the filters and dryer.

A. Upper Pressure Setting

B. Pressure Differential

AUTOMATIC START & STOP COnTROL

nOTeAutomatic Start & Stop Control is intended for use when the motor will start no more than 6 times per hour.

Whenthereceivertankpressurereachesthefactorypre–setmaximumpressure,thepressureswitchstopstheunit.Whenthereceivertankpressuredropsbelowthefactorypre–setminimum,thepressureswitchresetsandrestartstheunit.

DUAL COnTROL

Selecteitherautomaticstartandstopcontrolorconstantspeedcontrolbyadjustingtheknobontheauxiliaryvalve.Forautomaticstartandstopcontrol,turntheknobontheauxiliaryvalvefullyclockwisetodisabletheauxiliaryvalve.Thepressureswitchwillthenstartandstoptheunit.

Auxiliary Valve.

A. Knob

B. Clockwise

C. Counterclockwise

Selectconstantspeedcontroliftheunitrestartsinlessthan10minuteintervalsorrunsmorethan�0minutesperhour.Turntheknobfullycounterclockwisetoruntheunitcontinually.

nOTeThe auxilIary valve is factory pre–set at 5 psig (0,3 bar) lower than the factory pressure switch setting.

CAUTIOnRunning unloaded with no air demand, will cause the unit to be shutoff by the pressure switch.


OPeRATInG InSTRUCTIOnS OPeRATIOn AnD MAInTenAnCe MAnUAL

1. PReSSURe GAUGe

Indicatesthesystempressure.

wARnInGDO nOT operate the compressor at discharge pressures exceeding the maximum operating pressure.

2. HOURMeTeR Recordsthetotalrunningtimeofthecompressor.

3.STOP BUTTOn / eMeRGenCY STOP Whendepressedwillstopthecompressorimmediately.The’Poweron’indicatorwillremainilluminated.TheSTOPbuttonmustbereleasedbeforethecompressorcanberestarted.

4. On PUSH BUTTOn SwITCH Whendepressedwillcausetheunittostartandruninaloadedconditionifthereisademandforair.Ifthereisnodemand,themachinewillstopautomatically.

5. POweR On InDICATOR LIGHT (Green)Indicatesthepresenceofcontrolvoltage.

6. STOPPeD/AUTO ReSTART InDICATOR LIGHT (Amber)Willilluminatewhenthemachinehasshut-downduetolowairdemand.Themachinewillrestartandloadautomaticallyassoonasthedemandforairreturns.

7. Dew POInT InDICATOR (Dryer Option)Greenindicatesgooddewpoint.Redindicatesewpointabove50°F(10°C)Blueindicatesfreezing.

PRIOR TO STARTInG

1.Makevisualcheckofthemachine,ensurethatallguardssecureandthatnothingisobstructingtheproperventilationof,orfreeaccesstothemachine.

2.Checkcoolantlevel.Addifnecessary.

�.Makesureairdischargevalveisopen.

�.Turnonelectricalisolatorordisconnect.ThePower on(5)indicatorwilllight,indicatingthatlineandcontrolvoltagesareavailable.

5.Checkdirectionofrotationatinitialstartorfollowinginterruptioninpowersupply.

wARnInGMake sure that all protective covers are in place.

Cooling air flow exhaust may contain flying debris. Safety protection should be worn at all times to avoid injury.

STARTInG

1.PresstheSTARTbutton.Thecompressorwillstartandthenloadautomatically.

nORMAL/eMeRGenCY STOPPInG

1.PressSTOPbutton(�)andthecompressorwillstopimmediately.

2.Turnoffelectricalisolatorordisconnect.

CAUTIOnAfter shutdown never allow unit to stand idle with pressure in receiver/separator system.


OPeRATIOn AnD MAInTenAnCe MAnUAL MAInTenAnCe

MAInTenAnCe

MAInTenAnCe SCHeDULe

UP Series Maintenance Schedule

PeRIOD MAInTenAnCeEach2�hoursoperation Checkthecoolantlevelandreplenishifnecessary.

Visualcheckofmachineforanyleaks,dustbuilduporunusualnoiseorvibration

Reportimmediately,contactIngersoll Randauthorizeddistributorforassistanceifindoubt.

Whencompressorisreceivermounted Drainairreceiverofcondensate,orcheckthatautomaticdrainisoperating.

Visualcheckconditionofpackagepre-filter

Blowcleanifneeded.

First150hours Changethecoolantfilter.

Eachmonthor100hours Removeandcleanpackagepre-filter,replaceifneededCheckthecooler(s)forbuildupofforeignmatter.Cleanifnecessarybyblowingoutwithairorbypressurewashing.

Eachyearor2000hours Checktheoperationofthehightemperatureprotectionswitch(10�˚C).

ReplaceelementsinIRGPandIRHEfilters.

Changethecoolantfilter.

Checkscavengescreenforblockage,cleanifrequired.

Changetheseparatorelement.

ChangetheAirFilterelement.

Takecoolantsampleforfluidanalysis.

Changethepackagepre–filter.

CheckDriveBelts.

Motorswithoutgreasefittings-Replacesealedbearings

1yearexternaland�yearsinternalpressurevesselinspection.Frequencymaybeotherwisedefinedbylocalornationallegislation.

Separator vessel and air receiver when fitted.

Fullyinspectallexternalsurfaces,andfittings.Reportanyexcessivecorrosion,mechanicalorimpactdamage,leakageorotherdeterioration.

Everytwoyearsor�000hours Changedrivebelts.

ReplacetheUltra atwhicheverintervaloccursfirst.

Checkandreplaceallitemsincludedwithin2000hourservice.

Fitthefollowingreconditioningpartsasappropriate:SolenoidvalvesInletvalvekitMinimumPressurevalvekitThermostaticValveKit

Every�yearsor1�000hours Replaceallhoses.

Checkmotorswithgreasefittingsandgreasepermotordatatag

Fitreplacementelectricalcontactortips.

Motorswithoutgreasefittings-Replacesealedbearings


MAInTenAnCe OPeRATIOn AnD MAInTenAnCe MAnUAL

ROUTIne MAInTenAnCe

Thissectionreferstothevariouscomponentswhichrequireperiodicmaintenanceandreplacement.

Itshouldbenotedthattheintervalsbetweenservicerequirementmaybesignificantlyreducedasaconsequenceofpooroperatingenvironment.Thiswouldincludeeffectsofatmosphericcontaminationandextremesoftemperature.

TheSERVICE/MAINTENANCE CHARTindicatesthevariouscomponents’descriptionsandtheintervalswhenmaintenancehastotakeplace.Oilcapacities,etc.,canbefoundintheGENERAL INFORMATIONsectionofthismanual.


CAUTIOnBefore beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge. Vent pressure from the unit by slowly unscrewing the coolant fill cap one turn. Unscrewing the fill cap opens a vent hole, drilled in the cap, allowing pressure to release to atmosphere. Do not remove the fill cap until all pressure has vented from the unit. Also vent piping by slightly opening the drain valve. when opening the drain valve or the coolant fill cap, stand clear of the valve discharge and wear appropriate eye protection.

Ensurethatmaintenancepersonnelareproperlytrained,competentandhavereadtheMaintenanceManuals.

Prior to attempting any maintenance work, ensure that:-

allairpressureisfullydischargedandisolatedfromthesystem.Iftheautomaticblowdownvalveisusedforthispurpose,thenallowenoughtimeforittocompletetheoperation.

themachinecannotbestartedaccidentallyorotherwise.

allresidualelectricalpowersources(mainsandbattery)areisolated.

•

•

•

Prior to opening or removing panels or covers to work inside a machine, ensure that:-

anyoneenteringthemachineisawareofthereducedlevelofprotectionandtheadditionalhazards,includinghotsurfacesandintermittentlymovingparts.

themachinecannotbestartedaccidentallyorotherwise.

Prior to attempting any maintenance work on a running machine, ensure that:-

DAnGeROnly properly trained and competent persons should undertake any maintenance tasks with the compressor running or with electrical power connected.

theworkcarriedoutislimitedtoonlythosetaskswhichrequirethemachinetorun.

theworkcarriedoutwithsafetyprotectiondevicesdisabledorremovedislimitedtoonlythosetaskswhichrequirethemachinetoberunningwithsafetyprotectiondevicesdisabledorremoved.

allhazardspresentareknown(e.g.pressurisedcomponents,electricallylivecomponents,removedpanels,coversandguards,extremetemperatures,inflowandoutflowofair,intermittentlymovingparts,safetyvalvedischargeetc.).

appropriatepersonalprotectiveequipmentisworn.

looseclothing,jewellery,longhairetc.ismadesafe.

warningsignsindicatingthatMaintenance Work is in Progressarepostedinapositionthatcanbeclearlyseen.

Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:-

themachineissuitablytested.

allguardsandsafetyprotectiondevicesarerefittedandcorrectlyworking.

allpanelsarereplaced,canopyanddoorsclosed.

hazardousmaterialsareeffectivelycontainedanddisposedofinamannercompliantwithlocalorNationalenvironmentalprotectioncodes.

•

•

•

•

•

•

•

•

••

••



wARnInGDo not under any circumstances open any drain valve or remove components from the compressor without first ensuring that the compressor is FULLY SHUT- DOwn, power isolated and all air pressure relieved from the system.

TOP UP COOLAnT PROCeDURe

Slowlyremovefillcap.

Pourcoolantintospoutuntillspoutalmostoverflows.

Replaceandtightenoilfillcap.

Startunitforabout10seconds(untilcoolantdrainsoutthebottomofthesightglass).


Re–fillintospoutuntilspoutalmostoverflows.


Rununit.

nOTeCoolant level is correct when a unit is showing coolant in bottom half of sight glass when up to operating temperature (ten minutes running loaded).

A. Correct at operating temperature

B. Too much

C. OK

D. Too little

Repeatthisproceduretogetcoolanttoproperlevelwhenuptooperatingtemperature.Whentheunitisshutdown,coolantwillusuallyfillupsightglass.Donotadjustlevelbasedonlevelatshutdown.Properlevelisalwayssetforarunningunitatoperatingtemperature.

CAUTIOnensure that SSR ULTRA is used. Failure to do so will void manufacturers warranty.

1.

2.

�.

�.

5.

�.

�.

�.

COOLAnT CHAnGe PROCeDURe

Itisbettertodrainthecoolantimmediatelyafterthecompressorhasbeenoperatingastheliquidwilldrainmoreeasilyandanycontaminantwillstillbeinsuspension.

Stopthemachine,electricallyisolateandventalltrappedpressure.

Placeasuitablecontainerclosetothedrainvalve.


Removeplugfromdrainvalve.

Openthedrainvalveanddraincoolantintocontainer.

Closethedrainvalve.

Replaceplugindrainvalve.

Refillthemachinefollowingthe”topupcoolant”procedureabove.Afterinitialfill,topurgeanyairlocks,themachineshouldberunforafewminutescyclingbetweenloadandnoload,beforecheckingthattheleveliscorrect.


COOLAnT FILTeR CHAnGe PROCeDURe


Loosenfilterwiththecorrecttool.

Removethefilterfromthehousing.

Placetheoldfilterinasealedbaganddisposeofinasafeway.

Cleanthematingfaceofthehousingtakingcaretoavoidanyparticlesenteringthemachine.

RemovethenewIngersoll Randreplacementfilterfromitsprotectivepackage.

Applyasmallamountoflubricanttothefilterseal.

Screwthenewfilterdownuntilthesealmakescontactwiththehousing,thenhandtightenafurtherhalfturn.

Startthecompressorandcheckforleaks.

AIR FILTeR eLeMenT CHAnGe PROCeDURe


Unscrewtheretainingcapandwithdrawtheoldelement.

Fitthenewelement.

Replacetheretainingcap.

1.

2.

�.

�.

5.

�.

�.

�.

�.

1.

2.

�.

�.

5.

�.

�.

�.

�.

1.

2.

�.

�.



SePARATOR eLeMenT CHAnGe PROCeDURe


Loosenseparatorelementwiththecorrecttool.

Removetheelementfromthehousing;placeitinasealedbaganddisposeofitsafely.

Cleanthematingfaceofthehousing.

RemovethenewIngersoll Randreplacementelementfromitsprotectivepackage.

Applyasmallamountoflubricanttotheelementseal.

Screwthenewelementdownuntilthesealmakescontactwiththehousing,thenhandtightenafurtherhalfturn.

Startthecompressorandcheckforleaks.

CAUTIOnThis unit is not designed or intended to operate when contaminated with silicone. Lubricants, greases or other items containing silicone should not be used on this unit.

COOLeR CLeAnInG PROCeDURe


Removethetopcovertoobtainaccesstothecooler.

1.

2.

�.

�.

5.

�.

�.

�.

1.

2.

Cleanthecooler.

Rebuildinreverseorder.

BeLT CHeCKInG AnD ADJUSTMenT PROCeDURe

Checkbelttensionoccasionally,especiallyifloosenessissuspected.Aquickchecktodetermineifadjustmentispropermaybemadebyobservingtheslacksideofthebeltforaslightbowwhentheunitisinoperation.Ifaslightbowisevident,thebeltisusuallyadjustedsatisfactorily.

Abelttensionmeasurementdevicecanbeusedtodeterminethetensionofthebelt.

Belttensioningcanbeachievedbylooseningtheairendanchorscrews,abelttensioningboltisprovidedtoaidinmovingtheairend.

Followtheproceduresoutlinedbelowtocorrectlysetandmeasurebelttension.

1.Layastraightedgeacrossthetopoutersurfaceofthebeltdrivefrompulleytosheave.

2.Atthecenterofthespan,perpendiculartothebelt,applypressuretotheoutersurfaceofthebeltwithatensiongauge.Forcethebelttothedeflectionindicatedinthetablebelow,andcomparethereadingonthetensiongaugetothefiguresshown.

�.

�.

BeLT TenSIOn

5hp/�kw* �.5hp/5.5kw* 10hp/�.5kw* 15hp/11kw**New Used New Used New Used New Used

�0hz125psig �5Lb

(��Kg)�2Lb

(2�Kg)110Lb(50Kg)

�0Lb(�1Kg)

110Lb(50Kg)

�0Lb(�1Kg)

1�0Lb(��Kg)

120Lb(5�Kg)

150psig �5Lb(��Kg)

�2Lb(2�Kg)

�0Lb(�1Kg)

�5Lb(��Kg)

110Lb(50Kg)

�0Lb(�1Kg)

1�0Lb(��Kg)

120Lb(5�Kg)

210psig �5Lb(��Kg)

�2Lb(2�Kg)

�0Lb(�1Kg)

�5Lb(��Kg)

110Lb(50Kg)

�0Lb(�1Kg)

150Lb(��Kg)

125Lb(5�Kg)

50hz�bar �5Lb

(��Kg)�0Lb

(�2Kg)�5Lb

(��Kg)�0Lb

(�2Kg)110Lb(50Kg)

�0Lb(�1Kg)

1�0Lb(��Kg)

120Lb(5�Kg)

10bar �0Lb(�1Kg)

�5Lb(��Kg)

�5Lb(��Kg)

�0Lb(�2Kg)

120Lb(5�Kg)

100Lb(�5Kg)

1�0Lb(��Kg)

120Lb(5�Kg)

1�.5bar �0Lb(�1Kg)

�5Lb(��Kg)

100Lb(�5Kg)

�0Lb(��Kg)

120Lb(5�Kg)

100Lb(�5Kg)

150Lb(��Kg)

125Lb(5�Kg)

*”KrikitI”gaugeorequal**”KrikitII”gaugeorequal


OPeRATIOn AnD MAInTenAnCe MAnUAL MAInTenAnCeEnsurethepulleyandsheaveareproperlyalignedandthemotoranchorscrewsareadequatelyretightenedpriortorestartingthecompressor.

CAUTIOnImproper pulley/sheave alignment and belt tension can result in motor overload, excessive vibration, and premature belt and/or bearing failure. To prevent these problems from occurring, ensure the pulley and sheave are aligned and belt tension is satisfactory after installing new belts or tensioning existing belts.

eLeCTRIC DRAIn VALVe (OPTIOnAL)

PRODUCT DeSCRIPTIOn

TheElectricDrainValveremovescondensedwaterandoilfromtheairreceivertank.Additionaldrainsmaybeinstalledthroughoutyourcompressedairsystem,includingaftercoolers,filters,driplegsanddryers.TheElectricDrainValveoperatesonatimerwhichcanbesettoautomaticallydraintheairreceivertankatoperator-determinedintervals.

Keyfeaturesinclude:

100%continuousduty

NEMA�enclosure

Adjustabletimeon(0.5-10seconds)

Adjustabletimeoff(0.5-�5minutes)

Stainlesssteeloperator

LEDtoindicateelectricalpowerison

LEDtoindicatevalveisopen

Manualoverride

OPeRATIOn

Openthestrainerballvalve.

Strainer Ball Valve.

OPEN CLOSED

2. Setthe“timeoff”and“timeon”knobs.SeeTIMERSETTINGS(below)foranexplanationofthesettings.

�. Duringcompressoroperation,checkforairleaks.

TIMeR SeTTInGS

The“timeoff”settingdeterminestheintervalbetween

••••••••

1.

cyclesfrom�0secondsto�5minutes.The“timeon”settingdeterminestheactualtimethecompressordrainscondensate.

Thetimer’scyclerateanddrainopeningtimeshouldbeadjustedtoopenjustlongenoughtodischargethecondensate.Thetimerisproperlysetwhenitopensanddischargescondensateandthenventsairforapproximatelyonesecondbeforeclosing.Adjustmentsmaybemadedependingonmanyfactors,includinghumidityanddutycycle.

TROUBLeSHOOTInG

TROUBLe CAUSe ACTIOnValve will notclose.

Debrisinsolenoidvalvepreventsdiaphragmfromseating.

Removesolenoidvalve,disassemble,cleanandreas-semble.

Shortinelectricalcomponent.

Checkandreplacepowercordortimerasneeded.

Timer will notactivate

Noelectricalsup-ply.

Applypower.

Timermalfunction Replacetimer.Cloggedport. Cleanvalve.Solenoidvalvemalfunction.

Replacesolenoidvalve.

Cloggedstrainer. Cleanstrainer.

MAInTenAnCe

Periodicallycleanthescreeninsidethevalvetokeepthedrainfunctioningatmaximumcapacity.Todothis,performthefollowingsteps:

Closethestrainerballvalvecompletelytoisolateitfromtheairreceivertank.

PresstheTESTbuttononthetimertoventthepressureremaininginthevalve.Repeatuntilallpressureisremoved.

CAUTIOnHigh 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.

�. Removetheplugfromthestrainerwithasuitablewrench.Ifyouhearairescapingfromthecleaningport,STOPIMMEDIATELYandrepeatsteps1and2.

�. Removethestainlesssteelfilterscreenandcleanit.Removeanydebristhatmaybeinthestrainerbodybeforereplacingthefilterscreen.

5. Replaceplugandtightenwithwrench.

�.WhenputtingtheElectricDrainValvebackintoservice,presstheTESTbuttontoconfirmproperfunction.

1.

2.



Beforeaccessingliveelectricalparts,disconnectthepowersupplytothedryerusingdisconnectswitchordisconnectthecableconnections.

Preventive maintenance

Foroptimumperformancefromyourdryer,followtheperiodicmaintenancescheduledescribedbelow.

weeKLY COnDenSATe DRAInSVerifythatthecondensatedrainsareoperatingcorrectly.

eVeRY 4 MOnTHS COnDenSeRRemoveanydustfromthecon-denserfins.COMPReSSORMakesurecompressorpowerconsumptioncomplieswithdataplatespecifications.

YeARLY COnDenSATe DRAInSCompletelydisassemblethedrainsandcleanalltheircompo-nents.AIR FILTeRReplaceairfilterelement.

MOISTURe SePARATOR MAInTenAnCe

Themoistureseparatorwilloperateindefinitelyundernormalworkingconditions,howeveratsometimeitmaybenecessarytoreplacethesealsshouldthehousingleak.

Isolatethehousingfromtheairsupply.

Fullydepressurizeindrainbowlasappropriate.

Unscrewbowlandremove.Ifpressurehasnotbeencompletelyreleasedfromthehousing,airwillescapefromthewarningholegivinganaudiblealarm.Screwbackbowlandrepeatinstruction2beforeattemptingagain.Shouldresistancetounscrewingbeexperienced,provisionismadefora’C’spannertofitontotheribsofthebowl.

Checkconditionofbowlsealandreplaceifnecessary.Cleanscrewthreads.

Refitbowlwith’O’ringseal.

Repressurizeandcheckforleaks.Ifleaksoccurtheywillmostprobablybefromthebowl’O’ring.Depressurizehousingandremove’O’ringasstatedaboveandinspectandclean.Ensurethatmatingsurfacesarecleanandthenrefit’O’ringandrepressurize.

1.

2.

�.

�.

5.

�.

AIR FILTeR MAInTenAnCe

Inordertoensureoptimumcompressedairqualitythefilterelementshouldbereplacedasfollows.(Usedfilterelementsmustbedisposedofinaccordancewithlocalregulations.)

UseonlygenuineIngersoll Randreplacementelements.

1

2

2

3

> 30s

4 5

0 bar0 psi

1

2

0 bar0 psi

7 8

0 bar0 psi

9 10

2

1

0 bar0 psi

0 bar0 psi

1

2

12

5 6

1



DISASSeMBLInG THe UnIT

Theunithasbeendesignedandconstructedtoguaranteecontinuousoperation.

Thelongservicelifeofsomecomponentssuchasthefanandcompressordependsongoodmaintenance.

Theunitmustonlybedisassembledbyarefrigerantspecialist.

Refrigerantliquidandlubricatingoilinsidetherefrigerationcircuitmustberecoveredincompliancewithcurrentnormsinthecountrywherethemachineisinstalled.

ReCYCLInG DISASSeMBLYFrameandpanels Steel/epoxyresinpolyester

Heatexchanger(cooler) Stainlesssteel

Pipes Copper

Insulation Gumsynthetic

Compressor Steel/copper/aluminium/oil

Condenser Aluminium

Refrigerant R1��a

Valve Steel

ReFRIGeRAnT LeAKS In THe ReFRIGeRATIOn CIRCUIT

Theunitisdespatchedinperfectworkingorder,alreadycharged.

Refrigerantleaksmaybeidentifiedbytrippingoftherefrigerationoverloadprotector.

IFALEAKISDETECTEDINTHEREFRIGERANTCIRCUIT,SEEKTECHNICALASSISTANCE.

ReFRIGeRAnT CHARGInG

THISOPERATIONMUSTONLYBEPERFORMEDBYAREFRIGERANTSPECIALIST.

wHen RePAIRInG THe ReFRIGeRAnT CIRCUIT, COLLeCT ALL THe ReFRIGeRAnT In A COnTAIneR AnD DISPOSe OF IT In THe APPROPRIATe MAnneR.

CHARACTeRISTICS OF ReFRIGeRAnT R134A

Innormaltemperatureandpressureconditionstheaboverefrigerantisacolorless,classA1/A1gaswithTVLvalueof1000ppm(ASHRAEclassification).

Ifarefrigerantleakoccurs,thoroughlyairtheroombeforecommencingwork.

TROUBLeSHOOTInG

TROUBLe CAUSe ACTIOn

Solenoid condensate valve will not close.

Debrisinsolenoidvalvepreventsdiaphragmfromseating.

Removesolenoidvalve,disassemble,cleanandreassemble.

Shortinelectricalcomponent.

Checkandreplacepowercordortimerasneeded.

Drain timer will not operate.

Noelectricalsupply. Applypower.

Timermalfunction Replacetimer.

Cloggedport. Cleanvalve.

Solenoidvalvemalfunction.

Replacesolenoidvalve.

Cloggedstrainer. Cleanstrainer.

MAInTenAnCe

Periodicallycleanthescreeninsidethevalvetokeepthedrainfunctioningatmaximumcapacity.Todothis,performthefollowingsteps:

Closethestrainerballvalvecompletelytoisolateitfromtheairreceivertank.

PresstheTESTbuttononthetimertoventthepressureremaininginthevalve.Repeatuntilallpressureisremoved.

CAUTIOnHigh 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.

�. Removetheplugfromthestrainerwithasuitablewrench.Ifyouhearairescapingfromthecleaningport,STOPIMMEDIATELYandrepeatsteps1and2.

�. Removethestainlesssteelfilterscreenandcleanit.Removeanydebristhatmaybeinthestrainerbodybeforereplacingthefilterscreen.

5. Replaceplugandtightenwithwrench.

�. WhenputtingtheElectricDrainValvebackintoservice,presstheTESTbuttontoconfirmproperfunction.

1.

2.


TROUBLe SHOOTInG OPeRATIOn AnD MAInTenAnCe MAnUAL

TROUBLe SHOOTInG

PROBLeM CAUSe ReMeDYCompressor fails to start

MainspowerorControlvoltagenotavailable.

§§§

Checkincomingpowersupply.Checkthecontrolcircuitfuse.Checkthetransformersecondarywindingsforthecontrolvoltage.

DefectiveStar/Deltatimer. § ChangeStar/Deltatimer.

Machine shuts down periodically

Highairendtemperature. Topupcoolant.

Motoroverload. § Setoverloadtocorrectvalueandswitchtomanualreset.

Linevoltagevariation. § Ensurevoltagedoesnotdropbelow10%onstartupand�%running.

High current draw Compressoroperatingaboveratedpressure.

Setpressuretocorrectratingformachine.

Separatorcartridgecontaminated. Changeairfilter,andseparatorelement.

Lowvoltage. § Ensurevoltagedoesnotdropbelow10%onstartupand�%running.

Unbalancedvoltage. Correctincomingsupplyvoltage.

Damagedairend. † ChangeAirend.

Low current draw Airfiltercontaminated. Changeairfilter.

Compressoroperatingunloaded. Setpressuretocorrectratingformachine.

Highvoltage. Reducesitevoltagetocorrectoperatingvoltage.

Defectiveinletvalve. † Fitinletvalveservicekit.

High discharge pressure

Defectiveorincorrectpressureswitchsetting.

Replaceorsetpressuretocorrectratingformachine.

Blowdownvalvedefective. † Fitblowdownsolenoidservicekit.

Inletvalvemalfunction. † Fitinletvalveservicekit.

Low system air pressure

Separatorcartridgecontaminated. FitnewSeparatorelement.

Incorrectpressuretransducersetting Setpressuretocorrectratingformachine.

Minimumpressurevalvemalfunction. † FitMinimumpressurevalveservicekit.


Drivebeltslipping. Fitnewbelt.

Airsystemleaks. † Fixleaks.


Systemdemandexceedscompressordelivery.

Reducedemandorinstalladditionalcompressor.

Compressedairfilterscontaminated. Replaceairfilterelements.

High dewpoint Refrigerationcompressornotsuppliedpower.

Checkincomingpowersupply.

Checkthedryerprotectionfuse.

Checkauxiliarycontactonmainmotorcontactor.

Condensatesystemmalfunction. Checkoperationofdrainvalve.

Checkoperationofcondensatecheckvalves.

Condenserdirty. Cleancondenserandreplacepanelfilterelement.

Ice formation in dryer Lowevaporatorpressure. Checkhotgasvalvesetting.


OPeRATIOn AnD MAInTenAnCe MAnUAL TROUBLe SHOOTInG

PROBLeM CAUSe ReMeDYCompressor trips due to over tem-perature

Compressoroperatingaboveratedpres-sure.


Packagepre–filterblocked. Clean/replacepackagepre–filter.

Coolerblocked. Cleancooler.

Missingorincorrectlyfittedenclosurepanels

Ensurethatallenclosurepanelsarecorrectlyfitted.

Lowcoolantlevel. Topupcoolantandcheckforleaks.

Highambienttemperature. Re–sitecompressor.

Restrictedcoolingairflow. Ensurecorrectairflowtocompressor.

excessive coolantconsumption

Separatorelementleak. FitnewSeparatorelement.

Blockedseparatorelementdrain. † Removefittingsandclean.

Compressoroperatingbelowratedpres-sure.


Coolantsystemleak. † Fixleaks.

excessive noise level Airsystemleaks. † Fixleaks.

Airenddefective. † ChangeAirend.

BeltsSlipping. Replacebeltandtensioner.

Motordefective. † Replacemotor.

Loosecomponents. † Retightenlooseitems.

Shaft seal leaking Defectiveshaftseal. † FitAirendshaftsealkit.

Pressure relief valveopens

Defectiveswitchorincorrectpressureswitchsetting.

Replaceorsetpressuretocorrectratingformachine.

Minimumpressurevalvemalfunction. † FitMinimumpressurevalveservicekit.



Pressurereliefvalvedefective. Checkthesettingofthepressurereliefvalveandtheratedpressure.

Black residue on beltguard/cooler box

Drivebeltslipping. Replacebeltandtensioner.

Pulleysmisaligned. Re–alignpulleys.

Wornpulleys. † Replacepulleysandbelt.

Safety valve blowswhen compressor goes on load

Minimumpressurevalvestuckclosed. Stripminimumpressurevalve,examineandrepairifnecessary.

Safetyvalvefaulty Checkthesettingofthesafetyvalveandtheratedpressure.

nOTeS:

§ Mustbecarriedoutbyacompetentelectrician.

† ThisworkisrecommendedtobecarriedoutonlybyanIngersoll Randauthorizedservicetechnician.

CAUTIOn

LOWDEMANDAPPLICATIONS

Duringperiodsoflowdemand,thecompressormaynotreachitsnormaloperatingtemperatureSustainedoperationatlowdemandcanresultinthebuildupofcondensateinthecoolant.Ifthissituationoccurs,thelubricatingcharacteristicsofthecoolantcanbeimpairedwhichmayleadtodamageofthecompressor.

THECOMPRESSORSHOULDBEALLOWEDAMPLELOADEDRUNNINGTIMEOFATLEAST10MINUTESPERHOURDURINGNORMALDAILYUSE.

LOOK wHAT InGeRSOLL RAnD CAn DO FOR YOU!

efficient Field ServiceWemaintainahighlytrainedstaffoftechnicianstoserviceyourequipmentforpreventivemaintenance,ortoassistyoushouldemergencieseveroccur.

Special engineering ServiceWecanhelpyouidentifyandsolveyourproblemsbyevaluatingyourneedsandrecommendingtheproperequipmenttogiveyourmaximumefficiency.

Complete Stock of equipmentWecarryacompletelineofIngersoll Randequipmentandaccessoriesdesignedtomeetanycompressedairapplication.WearebackedbyIngersoll Rand’spromptfactoryshipmenttoensureyouon-timedelivery.

Spare PartsBystockinggenuineIngersoll Randspareparts,wecanhelpyouavoidcostlydelaysorsubstitutinginferiorparts.UsinggenuineIngersoll RandpartsonyouIngersoll Randequipmentwillhelptokeepevenolderequipmentrunningingood-as-newcondition.

Complete Repair ServiceOurtrainedtechnicianswillrepairoroverhaulyourequipmenttofactoryspecifications,usingonlygenuineIngersoll Randparts.

A SUBSTITUTe IS nOT A RePLACeMenT!EnsureyougetpeakperformanceandlongevityoutofyourIngersoll RandproductbyinsistingongenuineIngersoll Randreplacementpartsandmaintenancekits.NotonlyarethereplacementpartsmadetoprecisedimensionsandOEM-specifiedmetallurgy,buteachpartisbackedbytheIngersoll Randwarranty.YourlocalCustomerCenter,Distributor,ordirectIngersoll Randsalespersonwillworkwithyourtoensureyougetthepartsyouneedtodothejobright.EquipyourmachineswithonlythebestIngersoll Randgenuineparts.

nOTe: THe USe OF RePAIR PARTS OTHeR THAn THOSe InCLUDeD wITHIn THe InGeRSOLL RAnD COMPAnY APPROVeD PARTS LIST MAY CReATe UnSAFe COnDITIOnS OR MeCHAnICAL FAILUReS OVeR wHICH InGeRSOLL RAnD COMPAnY HAS nO COnTROL. InGeRSOLL RAnD COMPAnY SHALL BeAR nO ReSPOnSIBILITY FOR eQUIPMenT On wHICH nOn-APPROVeD RePAIR PARTS ARe InSTALLeD.

Themanufacturerreservestherighttomakechangesoraddimprovementswithoutnoticeandwithoutincurringanyobligationtomakesuchchangestoproductspreviouslysold.

Documents

SSR UP5-4, UP5-5.5, UP5-7.5, UP5-11c 50 Hz SSR UP6-5, · PDF fileOPERATION AND MAINTENANCE MANUAL. This manual contains important safety information. and must be made available to