Rotary Screw Air Compressors100-500 HP / 75-350 kW Single & 2-Stage

Delivering Compressed Air Solutions For More Than 125 YearsFor more than a century, Ingersoll-Rand air compressors have helped build dams, bridges and tunnels, produce cars, appliances and electrical equipment, and package foods and pharmaceuticals. As more and more companies chose Ingersoll-Rand air compressors, we answered the call for new technologies and updated designs, ensuring that our customers would get the maximum benefits from their compressed air.

MORE THAN

125KNOWLEDGEABLE SALES STAFF

Focused on Our CustomersIngersoll-Rand strives to deliver value to our customers in everything we do. We stay focused on what you need, remaining true to our goal: to help you achieve the best results possible with your compressed air supply. By maintaining solid relationships with our customers, our dedicated sales staff and distributor network relay changing requirements to our engineering team. With this information, our engineers make design improvements that ensure that our customers get the quality compressed air theyve asked for. If you want a single source supplier, you can count on Ingersoll-Rand. Whether you need compressed air systems, parts and service, or technical support, we will be there to help your system run at peak efficiency now and in the future.

2

TECHNOLOGY LEADERSHIP

Ingersoll-Rand: Your Compressed Air ResourceIf you need compressed air, Ingersoll-Rand is here to help. Well listen to what you need. Then well use our decades of leadership in the air systems market to help you design the best compressed air system for your application. Today, were the only manufacturer that can supply you with energy-efficient compressors in all three available technologies: rotary screw, reciprocating and centrifugal. And since each technology has its benefits, we can help you select the one that works best for your application.

TECHNICAL ASSISTANCE

3

Digital ControlOur exclusive digitally controlled stepper motor inlet valve system precisely matches the airflow to the system demand. Just set the preferred system pressure and the builtin Intellisys microprocessor controller takes care of the rest. To further reliability the inlet control system requires no maintenance. There are no pressure switches to manually recalibrate and no valves that can stick open - and, as a matter of fact, there are no manual adjustments required during the course of normal operation.

100 Straight Modulation Control

% FULL LOAD POWER

Energy Saving Control SystemWe equip each compressor with not one, but three separate control modes: On-line/Off-line, Upper Range Modulation, and Auto Control Select. Simply set the Intellisys controller to the desired control method, and the microprocessor does the rest. For the best overall efficiency, choose IRs patented Auto Control Select (ACS) system. ACS constantly monitors the compressors operation and automatically adjusts the control system to the mode that best suits your systems needs: On-line/Off-line or Upper Range Modulation.

70

Geometry Controller Intellisys Control On Line/Off Line

50

20

0 20 40 60 80 100

% CAPACITY

4

SSR: Unparalleled ReliabilityOur time-proven integral gear drive is the only maintenance-free drive system in the industry. The airend and motor are permanently aligned, so during the course of normal operation no adjustments are ever required. The drive train is totally enclosed so that no dust or dirt can get in, and our triple-lip shaft seal prevents leakage of coolant to the motor.

Advanced Airend DesignAt the core of the SSR is our rugged and reliable airend. Used in thousands of compressors worldwide, our airend is known for trouble-free operation and minimal maintenance. Our airends utilize only the highest quality duplex tapered roller bearings. Roller bearings provide line contact for thrust loads, and dramatically improve the life of the airend. The SSR airend also incorporates a bearing coolant dam that traps coolant in the bearing during shutdown. This ensures proper bearing lubrication during the critical start-up phase, and a longer bearing life.

Energy Efficient MotorEvery SSR compressor incorporates a durable high efficiency motor. SSR motors operate at peak efficiency under full load conditions, ensuring maximum energy savings.I-R High Efficiency Motor Design Point 100 95 90 Percent Efficiency 85 80 75 70 Applied Point

"Off the Shelf" Competitive Motor Design Point

100

105

110 115 Percent Load

120

125

5

Reduced Bearing LoadsA lower compression ratio in each stage reduces bearing loads and increases airend life. Our use of the highest quality bearings available assures you of years of reliable, efficient service.

Energy Efficient AirendIf youre looking for the greatest efficiency possible from a rotary screw then check out our two-stage compressors. The heart of the compressor is our time-proven two-stage airend. By compressing the air in two steps instead of one, energy savings of up to 15% are realized. Our rotors are precision machined in a twenty-step process, ensuring unmatched rotor profile accuracy, repeatability, and efficiency.

Coolant CurtainOne of the keys to the efficiency of the two-stage is the coolant curtain. Significant cooling of the air is achieved by injecting atomized oil into the compressed air stream leaving the first stage. Lowering the air temperature prior to entering the second stage significantly lowers the energy required for compression. The coolant curtain also eliminates the need for an intercooler.

Energy Cost/Year

Single-Stage 15% Energy Savings Two-Stage

06

2000

4000

6000

8000

Operating Hours/Year

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SSR AIR-COOLED PACKAGE (FRONT VIEW)

The SSR PackageTo fit the needs of your compressed air system, we offer you the choice of an air-cooled or water-cooled design.

End-to-End CoolingThe aftercooler is located at the inlet end of the package. This allows cool compressed air only 15F/8C above the ambient temperature to pass downstream to the air system.

115F/46C AmbientSSR compressors operate in high ambient conditions, making them suitable for locations around the world. Even if the compressor is not operated in sweltering climates, the high temperature rating ensures fewer nuisance shutdowns caused by fouled coolers.

Star-Delta Starter Inherent Leak-Free DesignBy using SAE O-ring fittings on all connections 1/4" and larger, weve significantly reduced potential leakage problems associated with conventional threaded connections. This advanced starter gives the compressor a controlled, cushioned start, eliminating current surges and extending component life for increased system reliability.

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SSR AIR-COOLED PACKAGE (BACK VIEW)

8000 Hour/2-Year LubricantUltraCoolant reduces maintenance costs by going longer between changes. Also, because of UltraCoolants superior separating properties, less coolant is passed downstream to the air system, further minimizing coolant costs.

Rugged MotorThe extra toughness built into the SSR motor means it will run when other motors quit. Maintenance and repair of the SSR motor are just like any other motor you own.

Factory-TestedEvery SSR compressor undergoes state-ofthe-art computerized testing to ensure that you get the best possible performance under varying conditions.

Quiet EnclosureA low sound enclosure is standard and keeps sound levels to a minimum.

Easy ServiceabilityThe SSR package is remarkably uncluttered, making servicing easy. All components are readily accessible behind easily removable panels.

Easy ConnectivityThe SSR is fully piped and wired, resulting in simple external connection of all utilities.

Convenient Top ExhaustThe cooling air flow discharges from the top of the package facilitating easy ducting for removal and/or recovery of exhaust heat.

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Intellisys Gives You Total Control of Your Compressed Air DeliveryWhether you need eight hours of continuous duty compressed air or an intermittent supply over a 24 hour period, Intellisys puts you in complete control. TOTAL CONTROL AT YOUR FINGERTIPS With finger-touch control, the Intellisys controller provides quick, comprehensive access to your compressed air system. EASY OPERATION Intellisys is easy to learn and easy to operate. ADJUSTABLE OPERATING PARAMETERS To satisfy your system requirements, you can change your operating parameters quickly and easily.

BUILT-IN SEQUENCER You can sequence up to four similarly equipped Intellisys compressors. The lead machine automatically rotates among the compressors based on accumulated hours, so maintenance levels are kept equal. TIMESAVING DIAGNOSTICS Intellisys provides fast diagnosis of system demand and displays a warning and/or stops the compressor if it exceeds operating parameters. This will keep troubleshooting expenses and downtime to a minimum. COMPREHENSIVE DATA DISPLAY An easy-to-read, liquid crystal display provides you with critical details of your compressors operation, allowing you to make fast adjustments when necessary. GIVING YOU COMPLETE FLEXIBILITY With Intellisys, you are always in control. You can change your operating parameters to maintain the best performance level.

SSR OptionsThe SSR compressor comes with several options to ensure that you get the right machine for your application. If there are any special options or requirements you need, well work with you to find a solution. Just contact your local Ingersoll-Rand distributor. Multiple unit sequencer Remote communications capability Automatic power outage restart option Remote starter/no starter10

Variable frequency drive Air-cooled or water-cooled TEFC motors Premium efficiency motors (60Hz only) High-dust inlet filter No aftercooler Power phase monitor NEMA 4 electrical option Outdoor modification Low-ambient temperature option

60Hz SSR 125-450 HP PerformanceFree Air Delivery - CFM Nominal HP 125 150 200 250 300 300E 350 400 450 XF 100 psig 655 739 993 1213 1359 1506 1695 1899 2050 EP 125 psig 571 670 892 1066 1252 1363 1537 1719 1866 HP 140 psig 519 610 812 979 1150 1285 1451 1626 1833 XP 165 psig 558 739 864 L (in) 123 123 123 148 148 148 160 160 160 W (in) 63 63 63 76 76 76 82 82 82 H (in) 75 75 75 86 86 86 95 95 95 Weight (lbs) 5770 5820 6020 10840 11440 11440 12815 12815 12815

60Hz SSR 2-Stage 100-500 HP PerformanceFree Air Delivery - CFM Nominal HP 100 125 150 200 250 300 350 400 450 500 XFE 100 psig 560 690 825 1100 1380 1685 1899 2200 2405 2600 EPE 125 psig 504 621 743 990 1249 1476 1740 1991 2245 2425 HPE 140 psig 470 580 693 924 1167 1428 1669 1924 2099 2266 HXPE 200 psig 443 548 735 960 1185 1366 1543 1739 1879 L (in) 123 123 123 123 148 148 160 160 160 160 W (in) 63 63 63 63 76 76 82 82 82 82 H (in) 75 75 75 75 85 85 96 96 96 96 Weight (lbs) 6050 6770 6820 7020 13080 13080 14685 14685 14685 14685

50Hz SSR 90-300kW PerformanceFree Air Delivery - M3/min Nominal kW 90 110 132 160 Nominal HP 250 300 350 MLD 7.5 barg 17.1 20.0 23.5 28.0 XF 7.5 barg 33.8 38.2 46.9 MMD 8.5 barg 15.3 19.2 22.3 26.0 EP 8.5 barg 29.6 35.0 43.8 MHD 10.0 barg 14.0 17.5 21.0 25.0 HP 10.0 barg 27.1 32.1 41.3 L (mm) 3124 3124 3124 3124 L (mm) 3759 4064 4064 W (mm) 1587 1587 1587 1587 W (mm) 1930 2083 2083 H (mm) 1905 1905 1905 1905 H (mm) 2191 2416 2416 Weight (kg) 2617 2640 2731 2731 Weight (kg) 5189 5813 5813

50Hz SSR 2-Stage 90-350kW PerformanceFree Air Delivery - M3/min Nominal kW 75 90 110 132 160 Nominal HP 250 300 350 400 450 500 MLD 7.5 barg 15.7 18.0 22.1 26.2 31.1 XFE 7.5 barg 38.1 46.5 53.2 59.0 65.6 72.0 MMD 8.5 barg 14.2 17.5 20.4 24.2 29.6 EPE 8.5 barg 34.5 40.7 48.1 55.0 61.1 67.0 MHD 10.0 barg 13.1 15.4 18.9 23.1 27.2 HPE 10.0 barg 32.3 39.4 46.5 51.4 57.0 62.0 MXUD 14.0 barg 12.5 15.4 18.4 22.2 HXPE 14.0 barg 26.9 34.1 39.2 43.3 48.2 52.5 L (mm) 3124 3124 3124 3124 3124 L (mm) 3759 4064 4064 4064 4064 4064 W (mm) 1587 1587 1587 1587 1587 W (mm) 1930 2083 2083 2083 2083 2083 H (mm) 1905 1905 1905 1905 1905 H (mm) 2146 2416 2416 2416 2416 2416 Weight (kg) 2744 3071 3094 3184 3184 Weight (kg) 5933 6665 6665 6665 6665 6665

Notes: 1) FAD (Free Air Delivery) CFM and M3/min. are ratings of full package performance in accordance with CAGI-PNEUROP acceptance test standard PN2CPTC2 or ISO1217: 1996 Appendix C. Product improvement is a continuing goal at Ingersoll-Rand. Designs and specifications are subject to change without notice or obligation.

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More Than Air. Solutions.Online solutions: www.air.ingersoll-rand.com

Ingersoll-Rand air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for breathing air applications unless treated in accordance with all applicable codes and regulations. Nothing contained in this brochure is intended to extend any warranty or representation, expressed or implied, regarding the products described herein. Any such warranties or other terms and conditions of sale shall be in accordance with Ingersoll-Rands standard terms and conditions of sale for such products which are available upon request. Product improvement is a continuing goal at Ingersoll-Rand. Designs and specifications are subject to change without notice or obligation.

Ingersoll-Rand Company Air Solutions 800-D Beaty Street P.O. Box 1840 Davidson, NC 28036 2001 Ingersoll-Rand Company Form 3193-A Printed in USA

SSR 2-Stage 300 HPXFE300-2S GENERAL COMPRESSOR DATA Capacity FAD (1) Compressor Power Full Load Package Discharge Pressure Maximum Operating Pressure Minimum Operating Pressure Rotor Diameters - 1st/2nd Male Rotor Speed - 1st Stage Male Rotor Speed - 2nd Stage COOLING DATA - GENERAL 115F MAXIMUM AMBIENT Operating Temperature Airend Injection Temperature Heat Removal - Oil Cooler Oil Cooler and After Cooler Oil Flow AIRCOOLED DATA Aftercooler CTD (4) Fan Air Flow Maximum Added Static Pressure WATERCOOLED DATA Aftercooler CTD (4) Cooling Water Required @ 50F 70F 90F Water Temperature Rise @ 90F Water Pressure Drop @ 90F Oil Cooler Oil Cooler and After Cooler Fan Air Flow Maximum Added Static Pressure LUBRICATION DATA Sump Capacity Total Lubrication System Capacity SOUND LEVELS (5) Standard Enclosure Low Sound Enclosure ELECTRICAL DATA (2) Full Load BHP -Driver Full Load BHP -Fan Full Load BHP -Package Full Load Amps - Driver Full Load Amps - Fan Full Load Amps - Package Fan Horsepower (Watercooled) Drive Motor RPM Drive Motor Frame: ODP TEFC Driver (FV) Locked Rotor Amps (3) Driver Efficiency/Power Factor - % of Load AMPS 100% 75% 50% Starter Size: Star Delta Full Voltage BHP BHP BHP AMPS AMPS AMPS BHP RPM dBA dBA 80 N/A 460V 330 16.5 346.5 381.7 22.6 404.3 1.1 1780 447T 449T 2180 95.0 / 86.0 95.0 / 85.0 94.0 / 79.0 D250 N/A 80 N/A 575V 330 16.5 346.5 308.0 17.6 325.6 1.1 1780 447T 449T 1744 95.0 / 86.0 95.0 / 85.0 94.0 / 79.0 D180 N/A Gal Gal 16 33 16 33 PSID PSID CFM In. Water 6 10 5000 0.25 6 10 5000 0.25 F GPM GPM GPM F 25 26 35 58 32 25 26 35 58 31 F CFM In. Water 15 24,000 .25 15 24,000 .25 F F 1000 BTU/Hr 1000 BTU/Hr GPM 209 160 714 931 68 205 160 714 896 79 CFM BHP PSIG PSIG PSIG MM RPM RPM 1685 330 100 110 65 297/250 1860 1593 1476 330 125 135 65 297/250 1630 1406 EPE300-2S

Revision: January 2006 Cancels: February 2000 Davidson, NC 28036HPE300-2S HXPE300-2S

1428 330 140 150 65 297/250 1576 1363

1185 330 200 210 65 297/250 1334 1165

201 160 714 880 83

195 160 714 865 98

15 24,000 .25

15 24,000 .25

25 26 35 58 31 6 10 5000 0.25

25 26 35 58 31 6 10 5000 0.25

16 33

16 33

80 N/A 2300V 330 16.5 346.5 83.6 22.6 (7) 1.1 1781 449T 5010 425 94.0 / 88.0 95.0 / 86.0 96.0 / 80.0 N/A (8)

80 N/A 4160V 330 16.5 346.5 41.8 22.6 (7) 1.1 1781 449T 5010 249 94.4 / 86.6 94.5 / 84.5 96.0 / 80.0 N/A (8)

NOTES: (1) FAD (Free Air Delivery) is full package performance including all losses per CAGI / PNEUROP PN2CPTC2. (2) Electrical data based on Reliance ODP motors, consult factory for others. (3) Star Delta starting current inrush is 33% of full voltage KVA inrush. (4) CTD (Cold Temperature Difference) based on 100 F / 38 C inlet air at 40% relative humidity. (5) Sound levels are "Free field conditions" per CAGI / PNEUROP S5.1 (6) For weights, dimensions, and piping connections see general arrangement drawings. (7) 460V Fan Motor. (8) Remote Full Voltage IEC starter.

SSR 2-Stage7550.02 Ref: 9 July 2003 Date: Cancels: 15 May 1999

100 - 500 HP QUIET ENCLOSEDDavidson, NC 28036Point of ManufactureDavidson, NC, USA

GENERAL INFORMATION 60 HZThe SSR 2-Stage compressor is an electric motor driven, two stage, screw compressor complete with accessories piped, wired and baseplate mounted. It is a totally self-contained air compressor package. The compressor is available at the following horsepower sizes and full load pressure ratings. Horsepower 100 HP 125 HP 150 HP 200 HP 250 HP 300 HP 350 HP 400 HP 450 HP 500 HP Standard Equipment 100 PSIG (CFM) 560 690 825 1100 1380 1685 1899 2200 2405 2600 125 PSIG (CFM) 504 621 743 990 1249 1476 1740 1991 2245 2425 140 PSIG (CFM) 470 580 693 924 1167 1428 1669 1924 2099 2266 200 PSIG (CFM) N/A 443 548 735 960 1185 1366 1543 1739 1879

Two-stage, oil-lubricated airend with tapered roller bearing High Efficiency motor, Class F insulation, 115F ambient rated Rugged, proven integral three gear drive with vibration isolation system Efficient coolant separation system (less than 2 ppm carryover) Factory fill of exclusive SSR Ultra Coolant Choice of integral aircooled coolers (Remote on 500) or watercooled design Aircooled or watercooled aftercooler Mounted (remote on 400, 450 and 500) Star Delta motor starter Intellisys Microprocessor control system with Stepper Motor Power-saving Intellisys ACS Control with on-line/off-line and upper range modulation Intellisys LCD Display and Membrane Touch Panel - 12 Normal Operation Information Displays - 6 Fault Warning - 16 Fault Shutdowns Protective Controls - Air pressure relief - Minimum pressure/check valve - High temperature shutdown Quiet Enclosure Equipment Coolants

control

Optional

Alternate

Power Outage Restart Option Thermostatic Water Valve (watercooled) TEFC motor Premium Efficiency Motors (ODP and TEFC) High voltage motors High dust inlet filter Low ambient package Outdoor modification NEMA 4 electrics Phase monitor

SSR 2-Stage100 - 500 HP QUIET ENCLOSEDDavidson, NC 28036Point of ManufactureDavidson, NC, USA

Ref: 7551.01 Date: 15 May 1999 Cancels: 10 November 1995

DETAILED

SPECIFICATIONS

INLET AIR FILTER: Inlet air filtration is accomplished by a large 99.9% efficiency at 3 micron and above, dry type air cleaner. This is more than suitable for the vast majority of applications; however, where high dust and dirt contamination is present, optional filtration systems are available. AIREND Since the airend is the fundamental component in any rotary screw compressor package, reliability, performance and efficiency are determined, for the most part, by the design, manufacturing tolerances and assembly of the airend itself. All other elements in the compressor system are essentially support and monitoring devices, included to insure dependable service and performance. The pairs of rotors in SSR 2-stage compressors fit into a combined airend assembly. Compression is shared between the 1st and 2nd stages, flowing in series, which increases overall compression efficiency up to 15% of the total full load kilowatt consumption. To achieve peak efficiency, our two stage, rotary screw airend uses different Ingersoll-Rand profile rotor sets, because the two compression stages have different objectives. Our first stage rotors utilize a profile for high displacement, and discharge at relatively low pressure. The second stage profile achieves high efficiency compression to final package pressure. The rotors are manufactured from AISI-C-1141 forged steel, rotor housings are made of close grain high quality cast iron. After machining, all components are dimensionally checked to insure accuracy. Air enters into the inlet of the 1st stage and is compressed as the male and female high displacement rotors rotate and mesh with each other. To further enhance airend efficiency, coolant is injected into a channel at the 1st stage discharge port. A precisely machined liquid orifice in the channel creates a curtain of coolant in the interstage passage. Air passes through the curtain on its way to the 2nd stage, and through contact cooling, significantly lowers the 2nd stage inlet temperature. This patented process eliminates expensive non-contact cooling devices such as air or water to coolant heat exchangers. Cooled air from the interstage enters the inlet of the 2nd stage and is compressed by the high efficiency 2nd stage male and female rotors. The compressed air passes through the 2nd stage discharge port, now at desired system pressure, and exits the 2-stage airend through the discharge flange. DUPLEX TAPERED ROLLER BEARINGS The bearing configuration used is the tapered roller bearing. The tapered roller bearing essentially consists of constructing the roller elements, as well as the raceways, so that lines drawn coincide with the working surfaces of the rollers and races will all meet at a common point on the axis of the bearing. This allows the bearing to handle all loads, radial, thrust or both. With this bearing configuration, the discharge end of the male and female rotors are each equipped with a pair of tapered roller bearings offset at opposing axis for maximum absorption of thrust and radial loads. High quality cylindrical roller bearings are used to carry the radial loads on the inlet end of the rotors. All bearings, whether thrust or radial, are premium cost, vacuum degassed, which provide truer, harder running surfaces for both inner and outer bearing races. Coolant dams are machined at the duplex taper roller bearing locations. The coolant dam provides an area for coolant to collect or pond when the compressor is shut off. Upon startup the taper roller bearing which is resting in coolant ponded by the coolant dam begins to rotate and is immediately lubricated. Airends without coolant dams have bearing systems that operate dry for approximately six seconds on start up.

Ingersoll-Rand Company 1999 Printed in U.S.A.

SSR 2-Stage7551.02 Ref: 15 May 1999 Date: Cancels: 10 November 1995

100 - 500 HP QUIET ENCLOSEDDavidson, NC 28036Point of ManufactureDavidson, NC, USA

DETAILED SPECIFICATIONS (Continued)THREE GEAR INTEGRAL DRIVE In order to utilize the inherent efficiency advantage of the SSR motor and airend, it was necessary to develop a means of efficiently transmitting power from the driver to the compressor. The integral gear drive system was chosen because it is an efficient, reliable and rugged design. The drive gear (center) is mounted directly on the motor shaft, and the driven gears are mounted on the shafts of each male rotor, eliminating maintenance prone and mis-aligned coupling or power robbing belts. The loads generated by the driven gears help to offset the load on the drive gear, further enhancing reliability and life. The flanged motor is doweled for permanent alignment to the airend. The use of optimizing (AGMA Class 11) gears allow the rotors to rotate at a specific speed, which allows maximum airend efficiency. The gear housing is completely sealed against atmospheric contaminants to insure life-time trouble-free power transmission. A self-centering Teflon impregnated motor shaft seal provides a positive system against leakage to the motor windings. The entire assembly is vibration isolated from the package. HIGH EFFICIENCY MOTOR The main drive motor is exactly matched to the requirements of the SSR 2-Stage. Torque and load requirements of the compressor were matched to specific design criteria that enabled the SSR motor to develop peak efficiency and power factor at full load. This stated efficiency advantage is illustrated if one were to compare SSR motor efficiencies with typical NEMA motor efficiencies; generally this advantage is 5%. A. FRAME: Motor frame and end brackets are of cast iron with integrally cast feet. This provides maximum strength and rigidity for bearing support, uniform stator/rotor gap and flanged permanent alignment of all mating parts. B. ELECTRICAL DESIGN:

Speed, torque and operating characteristics have been designed to match the load of the compressor. Motor efficiency and power factor have been optimized to cover the entire capacity range of the SSR 2-Stage and are all rated at a 115F ambient. C. BEARINGS: Vacuum degassed ball bearings for the drive end and roller bearings for the discharge end provide dependable and reliable service. Both bearings are grease lubricated with bearing housings having inlet and relief fittings to simplify the lubrication procedures. D. INSULATION: The SSR high efficiency motor has class F insulation as standard. That means it is rated at continuous duty for up to a 115C temperature rise. However, no SSR motor is ever applied for a temperature rise over 95C, a difference of 20C. The extra conservatism built into every SSR motor means more reliability, increased life, and a much more forgiving motor under adverse conditions. And even with all these unique features, the SSR motor still utilizes NEMA design standards. E. WIRING: All windings and leads are copper with triple coats of insulating varnish to add extra margins of protection to the driver.

SSR 2-Stage100 - 500 HP QUIET ENCLOSEDDavidson, NC 28036Point of ManufactureDavidson, NC, USA

7551.03 Ref: 15 May 1999 Date: Cancels: 10 November 1995

DETAILED SPECIFICATIONS (Continued)LUBRICATION A. COOLANT SYSTEM FILTRATION:

The full capacity coolant filters are 4 micron, spin-on, replaceable elements with pressure bypass. B. COOLANT/LUBRICANT HEAT EXCHANGERS:

Integrally mounted (remote on 500 HP) aircooled heat exchangers are designed for ambient temperatures to 115F. The core, fan and fan motor are all mounted and prewired within the compressor package. Watercooled coolers are shell and tube type designed to use fresh cooling water at inlet temperature up to 90F. Other materials of construction and higher temperature ratings are also available. C. COOLANT/LUBRICANT TEMPERATURE CONTROL (AIRCOOLED AND WATERCOOLED UNITS): The thermostatic control valve with three ports, (1) for the coolant from the cooler, (2) for the coolant from the pressurized receiver/separator, and (3) for the coolant to the airend, is mounted in the piping system. The temperature sensitive element controls the quantity of coolant from each source, cooled and uncooled, necessary to provide the proper injection temperature and assure fast warm-up. D. COOLANT INJECTION:

Coolant is injected internally to the 1st stage female rotor and the male and female rotors in the 2nd stage. This insures the best possible presealing of the rotors. Coolant is also sprayed into an interstage coolant curtain to cool the interstage air and improve efficiency. E. COOLANT/AIR Ingersoll-Rand Company 1999 Printed in U.S.A.

SEPARATION:

After compression and discharge from the airend, the air heavily laden with coolant travels to the receiver/separator. Entering through a tangential inlet, the air coolant mixture is directed in a circular motion around the inside of the tank. The vortex or circular motion separates a major portion of the coolant from the air through centrifugal force. The air is then directed through baffles, which further reduces the coolant content. The vortex action and baffling results in a precleaning of the compressed air, prior to entering the separator element. The separator element is a molded fiberglass two-stage reinforced separator. On all size SSR compressors, the carryover, after the separator element is 3-5 ppm. Compressed air then enters the optional aircooled or watercooled aftercooler, where the carryover of 3-5 ppm will be further reduced by the aftercooler and condensate separator to a final carryover figure of 2 ppm. Hence, when calculating coolant makeup for SSR compressors, always use 3-5 ppm by weight. MICROPROCESSOR CONTROL

The SSR 2-Stage compressor includes a microprocessor based control module which provides for starting, capacity control, operating control, and safety control of the unit. A. COMPRESSOR/CAPACITY CONTROLS:

The Intellisys microprocessor controls Ingersoll-Rand's innovative stepper motor inlet-control for precise inlet throttling to match system requirements. This advanced control system will automatically throttle the compressor to match pressure to load through our exclusive stepper motor.

SSR 2-Stage7551.04 Ref: 9 July 2003 Date: Cancels: 15 May 1999

100 - 500 HP QUIET ENCLOSEDDavidson, NC 28036Point of ManufactureDavidson, NC, USA

DETAILED SPECIFICATIONS (Continued)Intellisys auto control selector (ACS), for the first time offers the user a microprocessor based, automated system to deliver efficient, real time energy management. Intellisys ACS control operates the compressor in on-line, off-line during low (0-60% capacity) demand periods, or in upper range modulation during medium to high (60-100% capacity) demand periods. Realizing pressure is a function of volume, Intellisys control continuously monitors pressure and its rate of decay or increase. Intellisys automatically selects the operating mode which will best fulfill the system's compressed air needs, while operating the compressor in its most efficient control mode.

B. ADJUSTABLE

OPERATING

PARAMETERS:

D. FAULT WARNINGS:

Off-line pressure On-line pressure Control mode selection - Intellisys Control, ACS - Modulation only - On-line/off-line Load/unload delay time Star Delta transition time Stop delay time Available as options - Power Outage Rstart Option Auto start and stop shutdown time Sequencer control Power outage restart Power outage restart time

Change inlet filter Change coolant filter Change separator element High airend discharge temperature High airend discharge pressure Sensor failure 4ATT

E. FAULT

SHUTDOWNS:

C. DISPLAY

STANDARDS:

Package discharge pressure Package discharge temperature Airend discharge temperature Injection coolant temperature Sump pressure Inlet filter condition Inlet vacuum Coolant filter condition Separator element pressure drop Modulation % load Total hours/loaded hours

High airend discharge temperature Low unloaded sump pressure Low loaded sump pressure Starter fault Inlet control Main motor overload Fan motor overload Reverse rotation Pressure transducer failure Temperature sensor failure Microprocessor failure memory fault Control power loss

F. PROTECTIVE

CONTROLS:

Air pressure relief Minimum pressure/check valve High temperature shutdown

STAR DELTA STARTER As a complete package, the SSR includes a Star Delta starter integrally mounted (Remote on 400, 450, and 500 HP) and wired to the compressor package. Incoming line terminals are clearly marked and conveniently located for ease of installation. Starter overload protection is designed and sized specifically for SSR motor characteristics. A separate breaker and overload relay is mounted and wired on the starter for the fan motor (not included on 400, 450, and 500 HP). The main starter and fan motor protection circuit are electrically interlocked and wired for proper sequencing. The Star Delta reduced voltage starter is thoroughly tested as a part of the compressor package prior to shipment.

ROTARYDavidson, NC 28036Point of ManufactureDavidson, N.C., U.S.A .

Ref: 7002.01 Date: 19 November 2003 Cancels: 1 February 2001

125-500 HP MATERIALS OF CONSTRUCTION AND SPECIFICATIONSAIREND: Housing Rotors Radial Bearings Tapered Roller Bearings DRIVE TRAIN: Speed Optimizing Gears Motor Shaft Seal Gear Housing MOTOR: Frame Windings Insulation Bearings BASE: RESERVOIR: Receiver/separator tank Separator element TEMPERATURE CONTROL: Aircooled Watercooled Ingersoll-Rand Company 2001 Printed in U.S.A.

Cast Iron AISI-C-1141 Forged Steel Vacuum Degassed Cylindrical Roller Cages are High Quality Carbon Steel

Alloy Steel FLUOROCARBON LIP Cast iron

Cast Iron 100% Copper F or H Vacuum Degassed roller and/or ball Fabricated Steel

Welded steel, ASME Section VIII, Division 1, unfired pressure vessel code Two Stage, molded fiberglass, 99.9% efficient, .3 micron

Thermostatic control valve Thermostatic control valve (Water conservation valve optional)

OIL COOLERS: Aircooled Watercooled shell Tubes Tube sheets Tube bundles OIL FILTER: Oil filter Pressure relief valve LUBRICATION: PIPING SPECIFICATIONS: (Welded pipe assemblies 3" and larger) Materials piping Materials fittings Welding

Aluminum Steel 1/4 or 3/8 Admiralty brass Steel Fixed

Spin-on, single element paper 4 micron nominal 25 psi differential Pressure differential system

ASME SA 53-73 and SA53-73 E&F ASTM A234 grade WPB ANSI B31.1

Screwed Pipe Assemblies (2" and smaller) Materials piping ASME SA 106-73 Grade B; SA53-73 Type E&F Materials fittings American Standard Black Mallable Iron Pressure Limitations Schedule 40 Schedule 80

150 psi max working 300 psi max working

ROTARYRef: 7002.02 Date: 19 November 2003 Cancels: 1 February 2001Point of ManufactureDavidson, N.C., U.S.A .

Davidson, NC 28036

125-500 HP MATERIALS OF CONSTRUCTION AND SPECIFICATIONS (CONTINUED)TUBE ASSEMBLIES: Size 1/4" and 3/8" Material Flares Fittings Size 1/2" and larger Material Flares Fittings ELECTRICAL COMPONENTS: Listed by SAE J5225 SAE J533 37 degree double flare SAE J514; Sec I & II

SAE J524, J525 SAE J533 37 degree single flare SAE J514; Sec I & II

Underwriters Laboratories Recognized of Canadian Standards Association National Electrical Manufacturing Association National Electric Code

AFTERCOOLERS: Watercooled shell Tubes Tube Sheet Tube Bundles PAINT SPECIFICATIONS: Primer Top coat requirements Viscosity Weight/gallon Solid/weight Solid/volume Reduction

Steel 3/8" Admiralty brass Steel Fixed

TTP-664 Type resin Meet or exceed ASTM-D523-67, D870-54, D-117-73, D-22-7-68 69-65-KU 9.37 plus/minus .1 LB/gal 45% 30% 5/1

SSR 2-Stage 250-300HP Aircooled Foundation Plan

SSR 2-Stage 250-300HP Aircooled Foundation Plan

SSR 100-500HP 1-Stage & 2-Stage Wiring Schematic

SSR 100-500HP 1-Stage & 2-Stage Wiring Schematic

SSR 100-500HP 1-Stage & 2-Stage Wiring Schematic

SSR 100-500HP 1-Stage & 2-Stage Wiring Schematic

SSR 2-Stage 250-450HP Air Cooled Process & Instrumentation Diagram

Desiccant Air DryersHeatless, Heated and Heated Blower

Desiccant Dryers...

Desiccant Our reliable high strength, non-acidic desiccant provides maximum performance and is easily stored and handled. Environmentally friendly, it eliminates worries associated with other types of dryers, such as refrigerant leaks, spills and disposal.

2 Desiccant Dryers

Designed for ReliabilityWhen we designed the Ingersoll Rand heatless, heated and heated blower desiccant dryers we set our sights on creating the most reliable desiccant dryers you can purchase and operate. And our success was extraordinary. We set a new standard, and, in fact, re-wrote the book.

One look tells you that these dryers are like no othersextremely low silhouette manifolds and valves within an arm's reach of the operatorreadily accessible fill and drain portsjust a few of the differences apparent on the outside. Both externally and internally, each model combines innovative engineering and technically advanced, highly durable components, to provide easy installation, operation, maintenance, and, simply, the most reliable desiccant dryers available. Low Profile Design Our easy access design places key maintenance points at operator level for faster servicing and less downtime. The lower silhouette also allows upright shipment and facilitates installation.New Low Profile Design Traditional Design

Easy to Maintain High Performance Valves With manifolds angled toward the center at operator level, the valves are easily accessed for maintenance. A typical diaphragm valve in a heatless dryer can be rebuilt in less than ten minutes, without removing the valve from the manifold. State of the Art Controller The advanced microprocessor-controller maintains dryer performance at optimum levels. It constantly monitors dryer functions and provides alert when maintenance is required so that downtime is held to a minimum.

Desiccant Dryers 3

Selecting An Ingersoll Rand Desiccant DryerAll three technologies heatless, heated and heated blower use twin desiccant towers and strategically positioned valves for the process of drying compressed air. Each Ingersoll Rand model incorporates high-strength desiccant and durable, easily maintained valves for unsurpassed reliability, performance and customer value. Whether using a heatless, heated or heated blower dryer, the compressed air produced is thoroughly dried as it is directed through the on-line desiccant-filled tower of the dryer. As the desiccant in this tower adsorbs moisture from the air, the desiccant in the dryers off-line tower is purged of moisture and readied for use. The basic difference in the three technologies is the manner in which moisture is desorbed from the desiccant, also known as regeneration.

To air system

Heatless Dryers Simplest of the three technologies, the heatless dryer diverts a portion of the dried compressed air to the off-line tower. This dry air then flows through and regenerates the desiccant. The purge air, now moisture laden, is harmlessly exhausted through a muffler to the atmosphere. Lowest in capital investment, this technology may be more expensive to operate because it requires a portion of the dried compressed air to be diverted from the air system for desiccant regeneration.HL heatless desiccant dryer Heatless dryers offer the lowest capital investment. From air compressor

4 Desiccant Dryers

From air compressor

Heated These dryers operate similarly to heatless dryers, with a big exception. Dried air diverted from the air system is first passed through a high efficiency external heater before entering the off-line tank to regenerate the desiccant. Since this heated air can hold considerably more moisture than unheated air, only about half the amount of dried compressed air is needed for regeneration. Although the addition of the heater and associated components raises the initial capital investment for a heated dryer, less diverted compressed air means lower operating costs.EH heated desiccant dryer Heated dryers offer a compromise between operating efficiency and capital investment. To air system

Heated Blower This type of dryer does not divert dried compressed air from the air system to remove moisture from the desiccant in the off-line tank. Rather, it employs its own high performance centrifugal blower to direct ambient air through a heater and then through the off-line tank. There the stream of heated air regenerates the desiccant. Heated blower technology requires the highest initial capital investment, but with no or little diversion of compressed air from the system for regeneration, it offers significantly lower operating costs than the other two desiccant dryer technologies.From air compressor

So, how do you select the right desiccant dryer technology? That depends on the variables, such as system demand, compressed air capacity, air quality requirements, and applicable life cycle costs, that are unique to your compressed air system.HB heated blower desiccant dryer Heated blower dryers offer the lowest operating cost. To air system

Desiccant Dryers 5

Ingersoll Rand HL Heatless Desiccant Dryerentering the dryer, and an after-filter to make sure that only clean dried air exits the dryer. As an additional design precaution, the dryers switching valves are normally open and purge valves normally closed, to allow air flow through the dryer in case of power loss.

A standard feature of every Ingersoll Rand heatless desiccant dryer is its NEMA 4 package, providing increased protection of electrical components, as well as advanced digital dryer controls and displays. It includes a NEMA 4 electrical enclosure to protect against water and condensation, a UL/ULC panel, and an advanced digital electronic controller. In addition, every HL comes standard with a compressor interlock feature. This substantially prolongs compressor life and improves reliability.

While reliability has been a key focus of its design, the Ingersoll Rand HL heatless desiccantHL heatless desiccant dryer

dryer is also a leader in its class for energy efficiency and the health and safety of operating personnel and the environment.

Available in flows ranging from 120 SCFM (3.4 nm /min.) to 1800 SCFM (51.0 nm /min.), Ingersoll Rand HL heatless desiccant dryers are designed to ensure a constant 40F (-40C) or optionally 100F (-70C) pressure dew point, virtually eliminating costly interruption of production due to moisture. Clean air is further assured by use of strategically placed filters: a pre-filter to remove oil andcontaminants in air3 3

6 Desiccant Dryers

Ingersoll Rand EH Heated and HB Heated Blower Desiccant DryersThe EH and HB dryers use high performance ball or butterfly valves for switching and purge operations. These non-lubricated valves are designed specifically for high temperature applications and feature stainless steel internals, filled PTFE seats, and include double-acting pneumatic actuators.EH heated desiccant dryer

Both EH heated and HB heated blower models Ingersoll Rand EH heated desiccant dryers incorporate an external heater to heat dry purge air. This allows EH dryers to divert significantly less dry air from the air system for regenerating desiccant than is required by heatless dryers. Available in sizes ranging from 400 SCFM (11.3 nm /min.) to 2100 SCFM (59.5 nm /min.), Ingersoll Rand EH dryers deliver 40F (-40C) pressure dew point air for critical applications.3 3

provide the reliability and safety features of heatless dryers, with increased energy efficiency. These features include heatless backup mode in the event of heater or blower malfunction, and an innovative solid-state relay heater control to extend valve and heater life. NEMA 4 electrical enclosures are standard and include an advanced multi-function digital controller.

Ingersoll Rand HB heated blower desiccant dryers are equipped with dedicated durable centrifugal blowers to provide purge air for regeneration, eliminating the need to divert dry compressed air from the air system. Instead, the blower directs ambient air through an external heater and then through the off-line tower to regenerate the desiccant. This means more compressed air is available for critical downstream applications. Available in sizes from 1000 SCFM (28.3 nm3/min.) to 8000 SCFM (226.5 nm3/min.), Ingersoll Rand HB dryers deliver 40F (-40C) pressure dew point air.

HB heated blower desiccant dryer

Desiccant Dryers 7

Benefits Of Desiccant Dryers

All of our desiccant dryers are designed with energy efficiency, reliability, productivity and safety in mind: Engineered for low pressure drop through valve selection, tower size and filter design Optional Energy Management System (EMS) reduces purge consumption while maintaining a constant dew point, monitors the dew point and extends the dryer cycle, greatlyHigh efficiency heater reduces air needed to regenerate desiccant.

Low profile places valves at operators level and provides ready access to fill and drain ports, increasing operator safety, and ease of maintenance Pre-filter and after-filter protect desiccant and downstream air from oil contamination and particulates to help improve air quality, increasing productivity Easy to replace stainless steel desiccant screen keeps downtime to a minimum Heater and/or blower controlled by outlet regeneration temperature that shuts off to

reducing energy costs Large sound attenuating purge mufflers minimize noise and include built-in relief valves to enhance safety

After-filters help improve air quality, increasing productivity.

save electrical power once desiccant has been thoroughly regenerated (available with EMS on heated dryers)Stainless steel desiccant screens prevent contamination of the downstream air system and are easily removed for cleaning.

Low profile design, with angled manifolds, makes maintenance a snap!

8 Desiccant Dryers

Ingersoll Rand Desiccant Dryer Controls

All Ingersoll Rand desiccant dryers, models HL, EH and HB, are supplied with a digital electronic multi-function controller as standard equipment. This is the dryers command center.

The advanced digital controller is programmed to execute all valve switching functions, as well as to completely monitor dryer operations. Further, it is MODBUS compatible, permitting connection to MODBUS-capable networks, and it makes possible some remarkable enhanced dryer operating functions. The controllers full-featured panel includes: Backlit LCD Display for viewing critical dryer parameters in all lighting conditions Integrated keypad, providing user with access to all internal functions and selectable displays Schematic depiction of dryer, offering visual indication of current operating status Remote alarm contact Failure code storage Multiple displays, from Dryer On/Off Control to Regeneration Sequence Status

Desiccant Dryers 9

Global Reach...

Unsurpassed Local Customer SupportIngersoll Rand provides its products and services directly or through distributors to customers in close to 200 countries. We focus on providing innovation to increase your productivity and profitability. Expect more with Ingersoll Rand. We are your total solutions provider. Ready to Use Desiccant Each dryer is shipped with a desiccant testing kit. This allows the user to easily confirm the condition of the desiccant providing maximum desiccant life and dew point performance. Preventative Maintenance and Warranty Factory training and certified Ingersoll Rand technicians can protect your investment by providing high quality preventative maintenance. In addition we can offer a comprehensive 7 year parts and labor warranty. market channel partnership, mean that friendly Ingersoll Rand support is close at hand. In addition to parts availability, qualified on-site service is available globally.

Replacement Parts Made Easy Ensure that you have all the right parts on hand with our simplified ordering. Ingersoll Rands reputation for dryer parts availability is second to none.

Long Term Value There is more to value than simply price. The commitment of many thousands of dedicated compressed air specialists, either directly employed or members of a select

The best overall value is getting the most out of your investment. Ingersoll Rand customer support teams will help you protect your investment.

10 Desiccant Dryers

Desiccant Dryer SpecificationsModel Capacity Heater 3 SCFM nm /min. kW 120 160 200 250 300 400 500 600 800 1000 1200 1500 1800 3.4 4.5 5.7 7.1 8.5 11.3 14.2 17.0 22.7 28.3 34.0 42.5 51.0 Blower hp/(kW) In/Out Connection in. 1.0 NPT 1.5 NPT 1.5 NPT 1.5 NPT 2.0 NPT 2.0 NPT 2.0 NPT 2.0 NPT 3.0 NPT 3.0 NPT 3.0 NPT 4.0 FLG 4.0 FLG Width 40.5/(1029) 44.5/(1130) 44.5/(1130) 48.5/(1232) 48.5/(1232) 52.5/(1334) 56.5/(1435) 56.5/(1435) 64/(1626) 64/(1626) 64/(1626) 78.5/(1994) 84/(2134) Dimensions in./(mm) Depth Height 30/(762) 32/(813) 32/(813) 32/(813) 32/(813) 32/(813) 34/(864) 34/(864) 42/(1067) 42/(1067) 42/(1067) 55/(1397) 61/(1549) 63/(1600) 66/(1676) 66/(1676) 67/(1702) 67/(1702) 68/(1727) 82/(2083) 82/(2083) 88/(2235) 88/(2235) 88/(2235) 81/(2057) 94/(2388) Weight lbs./(kg) 563/(256) 707/(321) 731/(332) 869/(395) 924/(419) 1115/(506) 1564/(710) 1664/(755) 2017/(916) 2237/(1016) 2424/(1100) 2974/(1350) 3905/(1773) HL120 HL160 HL200 HL250 HL300 HL400 HL500 HL600 HL800 HL1000 HL1200 HL1500 HL1800

EH400 EH500 EH600 EH800 EH1000 EH1200 EH1500 EH1800 EH2100

400 500 600 800 1000 1200 1500 1800 2100

11.3 14.2 17.0 22.7 28.3 34.0 42.5 51.0 59.5

4.5 4.5 6 7.5 9 12 15 18 18

2.0 NPT 2.0 NPT 3.0 NPT 3.0 NPT 3.0 NPT 3.0 NPT 3.0 NPT 4.0 FLG 4.0 FLG

56.5/(1435) 56.5/(1435) 64/(1626) 64/(1626) 78.5/(1994) 78.5/(1994) 84/(2134) 84/(2134) 84/(2134)

34/(864) 34/(864) 47/(1194) 47/(1194) 48/(1219) 48/(1219) 55/(1397) 60/(1524) 60/(1524)

82/(2083) 82/(2083) 86/(2184) 86/(2184) 80/(2032) 80/(2032) 92/(2337) 92/(2337) 92/(2337)

1539/(699) 1707/(775) 2369/(1076) 2681/(1217) 3043/(1382) 3285/(1491) 4480/(2034) 4956/(2250) 5350/(2429)

HB1000 HB1200 HB1500 HB1800 HB2100 HB3000 HB4000 HB5000 HB6000 HB8000

1000 1200 1500 1800 2100 3000 4000 5000 6000 8000

28.3 34.0 42.5 51.0 59.5 84.9 113.3 141.6 169.9 226.5

24 24 30 36 45 60 80 100 125 175

7.5/(5.6) 7.5/(5.6) 15/(11.2) 15/(11.2) 15/(11.2) 20/(14.9) 25/(18.7) 30/(22.4) 30/(22.4) 40/(29.8)

3.0 NPT 3.0 NPT 3.0 NPT 4.0 FLG 4.0 FLG 4.0 FLG 6.0 FLG 6.0 FLG 6.0 FLG 8.0 FLG

78.5/(1994) 78.5/(1994) 84/(2134) 84/(2134) 84/(2134) 96/(2438) 102/(2591) 138/(3505) 150/(3810) 168/(4267)

48/(1219) 48/(1219) 55/(1397) 60/(1524) 60/(1524) 66/(1676) 76/(1930) 87/(2210) 92/(2337) 98/(2489)

80/(2032) 80/(2032) 92/(2337) 92/(2337) 92/(2337) 98/(2489) 90/(2286) 97/(2464) 103/(2616) 105/(2667)

3767/(1710) 4091/(1857) 5515/(2504) 6113/(2775) 6911/(3138) 9730/(4417) 12167/(5524) 13375/(6072) 16000/(7264) 19900/(9035)

Performance data per CAGI Standard 200 ADF 200 Maximum working pressure is 150 psig (10.3 barg) Desiccant is factory installed on all models except HB3000 to HB8000 Dimensions and weights are approximateDesiccant Dryers 11

Ingersoll Rand Industrial Technologies provides products, services and solutions to enhance the efficiency and productivity of our commercial, industrial and process customers. Our innovative products include air compressors, air systems components, tools, pumps, material and fluid handling systems and microturbines. www.air.ingersollrand.comIngersoll Rand compressors are not designed, intended or approved for breathing air applications. Ingersoll Rand does not approve specialized equipment for breathing air applications and assumes no responsibility or liability for compressors used for breathing air service. Nothing contained on these pages is intended to extend any warranty or representation, expressed or implied, regarding the product described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with Ingersoll Rands standard terms and conditions of sale for such products, which are available upon request. Product improvement is a continuing goal at Ingersoll Rand. Designs and specifications are subject to change without notice or obligation.Member ofPR E S S U

RE

K N O W

C MPRESSED AIR CHALLENGE

www.cagi.org

Printed in USA

2006 Ingersoll-Rand Company Limited XXXXXXXX Form 3508

ELECTRICAL INFORMATION

HL, EH & HB DESICCANT AIR DRYERSPoint of Manufacture West Chester, PA, USADate: March 29, 2007 Revision 0

ELECTRICAL DETAILS

MODEL HL @ 115/1/60

MCA (amps) 4

MOP (amps) 5

MODEL (60 Hz) EH300 EH400 EH500 EH600 EH800 EH1000 EH1200 EH1500 EH1800 EH2100

Heater KW 3 4.5 4.5 6 9 9 12 15 18 18

MCA (amps) 5.1 7.5 7.5 9.8 14.5 14.5 19.2 23.9 28.6 28.6

MOP (amps) 6 8 8 10 15 15 20 25 30 30

Model (50Hz) EH300 EH400 EH500 EH600 EH800 EH1000 EH1200 EH1500 EH1800 EH2100

Heater Kw 3 4.5 4.5 6 9 9 12 15 18 18

MCA (amps) 6.1 8.9 8.9 11.8 17.5 17.5 23.1 28.9 34.6 34.6

MOP (amps) 7 10 10 12 20 20 25 30 35 35

MODEL HB1000 HB1200 HB1500 HB1800 HB2100 HB3000 HB4000 HB5000 HB6000 HB8000

Heater KW 24 24 30 36 45 60 80 100 125 175

Blower HP 7.5 7.5 15 15 15 20 25 30 30 40

MCA (amps) 49 49 71 81 93 123 165 199 239 330

MOP (amps) 50 50 80 90 100 125 175 200 250 350

EH HEATED DESICCANT AIR DRYEREH400 EH2100Air Solutions Davidson, NC 28036 Date: 4 December 2006 Cancels: New

ENGINEERING DATA 60HZ

EH400 Inlet Capacity (scfm) Purge (scfm) Desiccant per tower (lbs) Tower Diameter (inches) Electrical Heater Rating (kw) Average Heater kw Air In/Out Connections (inches) Width (inches) Depth (inches) Height (inches) Shipping Weight (lbs) 400 30 302 16 460/3/60 4.5 3.4 2" NPT 56.5 38 82 1539 EH1200 Inlet Capacity (scfm) Purge (scfm) Desiccant per tower (lbs) Tower Diameter (inches) Electrical Heater Rating (kw) Average Heater kw Air In/Out Connections (inches) Width (inches) Depth (inches) Height (inches) 1200 90 800 24 460/3/60 12 9 3" NPT 78 57 80

EH500 500 38 374 16 460/3/60 4.5 3.4 2" NPT 56.5 40 82 1707 EH1500 1500 113 1100 30 460/3/60 15 11.3 3" NPT 84 68 92

EH600 600 45 504 20 460/3/60 6 4.5 3" NPT 64 52 88 2369 EH1800 1800 135 1300 30 460/3/60 18 13.5 4" FLG 84 67 92

EH800 800 60 635 20 460/3/60 7.5 5.6 3" NPT 64 52 88 2681 EH2100 2100 158 1464 30 460/3/60 24 18 4" FLG 84 64 92

EH1000 1000 75 700 24 460/3/60 9 6.8 3" NPT 78 57 80 3043

Shipping Weight (lbs) 3285 4480 4956 5350 Capacity on all models is based on 100F, 100 psig. Maximum allowable inlet temperature is 120 F. Maximum inlet pressure is 150 psig. Safety valve set point is 165 psig NEMA cycle time for -40F is8 hours. 3 hours of heating and 1 hour of cooling

8FACE OF AIR INLET & OUTLET (OPTIONAL 3-VALVE BYPASS)

754.00

63.00 (TYP)

5

4CONTROLLER LCD DISPLAY 1) DRYER ON/OFF CONTROL 2) DRYER ALARM 3) HEATER OPERATION & TEMP CONTROL 4) HIGH HEATER TEMP ALARM 5) HEATER FAILURE ALARM 6) LEFT/RIGHT TOWER DRYING 7) LEFT/RIGHT TOWER REGEN 8) FAILURE TO SHIFT ALARM 9) REGEN SEQUENCE STATUS 10) HIGH HUMIDITY ALARM (OPTIONAL) 11) ENERGY MANAGEMENT SYSTEM (EMS) (OPTIONAL)

3POWER ON LIGHT LEFT TOWER REGEN LIGHT LEFT TOWER DRYING LIGHT HEATER ON LIGHT ALARM LIGHT RIGHT TOWER REGEN LIGHT RIGHT TOWER DRYING LIGHTZONE REV ECN

2REVISIONSDESCRIPTION

1DATE DWN APPVD

D54.50 2.00 (TYP) 77.00 67.69 47.00 43.00

D

CONTROLLER PUSH BUTTONS 1) ON 2) OFF 3) RESET 4) TEST 5) SET 6) SELECT DISPLAY 7) ENTER 8) +/-

CONTROLLER & DISPLAY PANEL DETAIL

22.50

2.69

C

OPTIONAL TOWER INSULATION (SHOWN IN THIS VIEW ONLY) (4) .56'' O MOUNTING HOLES DESICCANT FILL PORT PILOT AIR SHUT-OFF VALVE 42.38 FACE OF INLET 12.00 C OF AIR INLET L 3'' NPT AIR INLET CONNECTION PREFILTER INLET FLOW VALVE

C

CONTROLLER AND DISPLAY PANEL (SEE DETAIL) TOWER PRESSURE GAUGE TOWER TEMPERATURE GAUGE

L

C OF AIR INLET L

PURGE VALVE C OF AIR OUTLET L PURGE MUFFLER

B

91.88 RELIEF VALVE ELECTRICAL ENCLOSURE NEMA 4 PURGE PRESSURE GAUGE PURGE ADJUSTMENT VALVE 68.81 3'' NPT AIR OUTLET CONNECTION AFTERFILTER ZTF TYPE ''G'' HEATER

B

48.00

BLUE MOISTURE INDICATOR PILOT AIR FILTER DESICCANT DRAIN PORT

OUTLET FLOW VALVES INLET PURGE CHECK VALVES 84.00 22.50 24.50 42.38 FACE OF OUTLET C OF AIR OUTLET L 54.00 18.00

A

UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS ARE IN INCHES, TOLERANCES ARE: *NOTES: 1) MAXIMUM WORKING PRESSURE - 150 P.S.I. 2) SAFETY RELIEF VALVE SETTING - 165 P.S.I 3) PILOT AIR LINES NOT SHOWN FOR CLARITY 4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE'S LATEST EDITION.FRACTIONS X/XX DECIMALS .50 X.XXX ANGLE X.X

PROPRIETARY NOTICETHIS DRAWING CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION, IS THE PROPERTY OF INGERSOLL-RAND CO., AND IS GIVEN TO THE RECEIVER IN CONFIDENCE. THE RECEIVER BY RECEPTION AND RETENTION OF THE DRAWING ACCEPTS THE DRAWING IN CONFIDENCE AND AGREES THAT, EXCEPT AS AUTHORIZED IN WRITING BY INGERSOLL-RAND CO. IT WILL (1) NOT USE THE DRAWING OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE SECRET INFORMATION THEREIN; (2) NOT COPY THE DRAWING; (3) NOT DISCLOSE TO OTHERS EITHER THE DRAWING OR THE CONFIDENTIAL OF TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE NEED TO RETAIN THE DRAWING, OR UPON DEMAND, RETURN THE DRAWING, ALL COPIES THEREOF, AND ALL MATERIAL COPIED THEREFROM.

REMOVE ALL BURRS AND SHARP CORNERS CAD GENERATED DRAWING, NO MANUAL REVISIONS ALLOWED

NOUN CODE

A

THIRD ANGLE PROJECTION DRAWN DATE

TITLE

SAJCHECKED

10/30/06SIZE ESTIMATED WEIGHT

GENERAL ARRANGEMENT EH 1500DRAWING NO.

D O N OT SCAL E

COPYRIGHT @ 2006 INGERSOLL-RAND COMPANY ALL RIGHTS RESERVED

APPROVED

BCFW 11/20/06SCALE:

NONE

UNIT:

5800121

REVISION

SHEET

1 OF 1

8

7

6

5

4

3

2

250-450 HP SINGLE STAGE UNITS 250-500 HP TWO STAGE UNITSOPERATORS/ INSTRUCTION MANUAL OPTIONS

Before installation or starting the compressor for the first time, this manual should be studied carefully to obtain a clear knowledge of the unit and of the duties to be performed while operating and maintaining the unit. RETAIN THIS MANUAL WITH UNIT. This Technical manual contains IMPORTANT SAFETY DATA and should be kept with the air compressor at all times.

More Than Air. Answers.Online answers: http://www.air.irco.com Phone: 1-800-526-3615 CCN: 80440431 REV: B FORM: APDD 746BNovember 2002

AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UPWarranty 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 (see extended airend warranty) from the date of placing the Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from Davidson, NC, 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 manufactured 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 Companys 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 Companys proposal. Unless responsibility for meeting such performance warranties are limited to specified tests, the Companys 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 fulfillment 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 Equipment will be at Purchasers sole risk and liability. Note that this is Ingersoll-Rands standard warranty. Any warranty in force at the time of purchase of the compressor or negotiated as part of the purchase order may take precendence over this warranty.

GENERAL INFORMATIONWeight ..............................See foundation plan, Section 8.0 Cooling Air Flow .............See foundation plan, Section 8.0 Ambient Temperature Limits ..........................35F to 115F ...........................................................................((2C to 46C) Coolant.............................Factory Filled SSR Ultra Coolant Coolant Change ............................8000 hours or two years ............................................................whichever comes first Coolant Capacity 250-300 HP.......................................33.0 gallons (125 liters) 250-300 HP Two Stage....................40.0 gallons (152 liters) 300E HP............................................33.0 gallons (125 liters) 350-450 HP.......................................38.0 gallons (144 liters) 350-500 HP Two Stage....................42.0 gallons (160 liters) Discharge Temperature Limit .........................228F (109C) Power Inlet Wiring .........................Recommended conduit: ............................metallic flexible Greenfield, or equivalent

Tools ..............................................U.S. standard and metric ...................................are required to perform maintenance

INGERSOLL-RAND COMPANY

ROTARY SCREW AIR COMPRESSOR This unit was purchased from: _______________________________________________ _______________________________________________ _______________________________________________ Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. Number of units on order: __________________________ Customer Order Number: __________________________ Ingersoll-Rand Company Order Number: ______________ For ready reference, record the serial number and model number of your unit here: Serial Number: ___________________________________ Model Number:___________________________________

1

TABLE OF CONTENTS0.0 SAFETY AND WARNINGS 0.1 safety instructions 0.2 safety precautions 0.3 decals RECEIPT OF EQUIPMENT 1.1 inspection 1.2 unpacking and handling 1.3 tools INSTALLATION 2.1 ventilation 2.2 foundation requirements 2.3 piping 2.4 electrical installation 2.5 outdoor sheltered INTELLISYS 3.1 intellisys controls 3.2 display screen 3.3 current status 3.4 main menu 3.5 operator setpoints 3.6 options 3.7 sensor calibration 3.8 alarm history 3.9 warnings 3.10 alarms SCHEDULED PREVENTATIVE MAINTENANCE 4.1 maintenance schedule 4.2 maintenance records 4.3 maintenance procedures 4.4 inlet air filter 4.5 coolant filter 4.6 coolant 4.7 separator tank scavenge screen/orifice 4.8 coolant separator element 4.9 cooler cores (cleaning) 4.10 motor lubrication 4.11 long term storage 4.12 coolant/lubricant changeout 4.13 intellisys removal 4.14 coolant hoses 4.15 fluid and vibration monitoring 4.16 coolant sampling procedure SYSTEMS 5.1 general system information 5.2 air cooled compressors 5.3 coolant system 5.4 compressed air system 5.5 coolant/air separation system 5.6 electrical system 5.7 stepper motor inlet control 5.8 capacity control system 5.9 automatic start/stop control 5.10 remote start/stop

6.0 7.0

TROUBLESHOOTING OPTIONS 7.1 power outage with scheduled start/stop 7.2 sequencer 7.3 low ambient 7.4 separator delta-p solenoid 7.5 separator delta-p sensor 7.6 high dust filter 7.7 lead/lag cycle length 7.8 schedule start/stop 7.9 remote load/unload 7.10 modbus 7.11 integral sequencing REFERENCE DRAWINGS 8.1 electrical schematic - built-in star-delta 8.2 electrical schematic - remote star-delta 8.3 electrical schematic - remote high voltage 8.4 foundation plan - 250-300 hp, 300E; A/C 8.5 foundation plan - 250-300 hp, A/C, two stage 8.6 foundation plan - 250-300 hp, 300E; W/C 8.7 foundation plan - 250-300 hp, W/C, two stage 8.8 foundation plan - 350-450 hp, A/C 8.9 foundation plan - 350-450 hp, A/C, two stage 8.10 foundation plan - 350-450 hp, W/C 8.11 foundation plan - 350-500 hp, W/C, two stage 8.12 foundation plan - 250-300 hp, A/C extended 8.13 foundation plan - 250-300 hp, A/C extended, two stage 8.14 foundation plan - 250-300 hp, W/C extended 8.15 foundation plan - 250-300 hp, W/C extended, two stage 8.16 flow schematic, A/C 8.17 flow schematic, A/C, two stage 8.18 flow schematic, W/C-90F (32C) 8.19 flow schematic, W/C-90F (32C), two stage 8.20 flow schematic, W/C-115F (46C) 8.21 flow schematic, W/C-115F (46C), two stage 8.22 typical system flow diagram WATER QUALITY RECOMMENDATIONS MAINTENANCE RECORD

1.0

2.0

8.0

3.0

4.0

9.0 10.0

5.0

2

0.0 SAFETY AND WARNINGS0.1 SAFETY INSTRUCTIONS Before you install this air compressor you should take the time to carefully read all the instructions contained in this manual. Electricity and compressed air have the potential to cause severe personal injury or property damage. Before installing, wiring, starting, operating or making any adjustments, identify the components of the air compressor using this manual as a guide. The operator should use common sense and good working practices while operating and maintaining this unit. Follow all codes, pipe adequately, understand the starting and stopping sequence. Check the safety devices by following the procedure contained in this manual. Maintenance should be done by qualified personnel, adequately equipped with proper tools. Follow the maintenance schedules as outlined in the operators manual to ensure problem free operation after start up. 0.2 SAFETY PRECAUTIONS

Safety instructions in the operators manual are bold-faced for emphasis. The signal words DANGER, WARNING and CAUTION are used to indicate hazard seriousness levels as follows:Danger is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored. Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored. Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored. Notice is used to notify people of installation, operation, or maintenance information which is important but not hazard-related.

D! DANGER

! WARNING

! CAUTION

NOTICE

SAFETY PRECAUTIONSBEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE COMPRESSOR OR PERFORMING ANY MAINTENANCEWARNING COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS. BEFORE DOING ANY WORK ON THIS UNIT, BE SURE THE ELECTRICAL SUPPLY HAS BEEN CUT OFFLOCKED & TAGGED AND THE ENTIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF ALL PRESSURE. 1. Do not remove the covers, loosen or remove any fittings, connections or devices when this unit is in operation. Hot liquid and air under pressure that are contained within this unit can cause severe injury or death. 2. The compressor has high and dangerous voltage in the motor starter and control box. All installations must be in accordance with recognized electrical codes. Before working on the electrical system, be sure to remove voltage from the system by use of a manualdisconnect-switch. A circuit breaker or fuse safety switch must be provided in the electrical supply line leading to the compressor. Those responsible for installation of this equipment must provide suitable grounds, maintenance clearance and lightning arrestors for all electrical components as stipulated in O.S.H.A. 1910.308 through 1910.329. 3. Do not operate the compressor at higher discharge pressure than those specified on the Compressor Nameplate or motor overload will occur. This condition will result in compressor motor shutdown. 4. Use only safety solvent for cleaning the compressor and auxiliary equipment. 5. Install a manual shut off valve (isolation type) in the discharge line. When a safety valve is installed between the isolation valve and the compressor, it must have sufficient capacity to relieve the full capacity of the compressor(s). 6. Whenever pressure is released through the pressure relief valve, it is due to excessive pressure in the system. The cause for the excessive pressure should be investigated immediately. 7. Before doing any mechanical work on the compressor: a.) Shut the unit down. b.) Electrically isolate the compressor by use of the manual disconnect switch in the power line to the unit. Lock and tag the switch so that it cannot be operated. c.) Vent pressure from the compressor and isolate the unit from any other source of air. 8. There can be adverse effects if compressor lubricants are allowed to enter plant air systems. Air line separators, properly selected and installed, will minimize any liquid carryover. The use of plastic bowls on line filters without metal guards can be hazardous. From a safety standpoint, metal bowls should be used on any pressurized system. Review of your plant air line system is recommended. 9. When a receiver is installed, it is recommended that occupational safety and health standards as covered in the Federal Register, Volume 36, number 105, part 11, paragraph 1910.169 be adhered to in the installation and maintenance of this receiver. 10. Before starting the compressor, its maintenance instructions should be thoroughly read and understood. 11. After maintenance functions are completed, covers and guards must be replaced.

3

SAFETY SHUTDOWNCHECK HIGH AIR TEMPERATURE There is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory pre-set at 228F (109C). This function should be checked at regular intervals for proper operation, once a month is recommended. The procedure is: 1. 2. Block off the cooling air discharge. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge temperature reaches the pre-set maximum discharge air temperature setting of the Intellisys. The display should indicate HIGH AIREND DISCH TEMP and flash ALARM.

The actual temperature at which shutdown occurs should be recorded for comparison to the Intellisys set point and with similar future test results.

WARNINGFailure to adhere to these recommendations can result in mechanical failure, property damage and serious injury or death. All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must take into account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility between discharge piping, system accessories and software must be assured. For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is not recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the operating parameters of the system. It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine.

WARNINGIngersoll-Rand air compressors are not designed, intended, or approved for breathing air. Ingersoll-Rand does not approve specialized equipment for breathing air application and assumes no responsibility or liability for compressors used for breathing air services.

4

0.3 DECALS This section contains representative examples of decals which will be appearing throughout this manual and are applied to the compressor unit. If for some reason a decal is defaced, painted over, or parts are replaced, we recommend that you obtain a replacement kit as listed in the spare parts section of the Parts List Manual Form APDD 735 for single stage and Form APDD 736 for two stage units.

!

WARNING

!

WARNING

!

WARNING

Hazardous voltage. Can cause severe injury or death. Disconnect power before servicing. Lockout/Tagout machine.

Hot surface. Can cause severe injury. Do not touch. Allow to cool before servicing.

High pressure air. Can cause severe injury or death. Relieve pressure before removing filter plugs / caps, fittings or covers.

39540174 Rev. 05

39541362 Rev. 04

39540240 Rev. 04

CAUTION39878657 Rev. 03

*PORO OPTION39584529

Improper maintenance of coolant filter can cause compressor damage. Change coolant filter after first 150 hours of operation and every 2000 hours thereafter or when coolant is changed.39544143 Rev. 03

*REMOTE STARTSTOP OPTION 39547708

*FOOD GRADECOOLANT OPTION 39568803

Lift Here39540273 Rev. 04 2 REQUIRED - BASE

VIEWED FROM FRONT

! !

WARNING

Filler Cap. Use only recommended coolant. Read instruction book before servicing.

CAUTIONMoving parts. Can cause severe injury. Do not operate with covers removed. Service only with machine blocked to prevent turn over.

Use of incorrect coolant can cause system contamination. Use only SSR ULTRA COOLANT.

39543921

39543921 Rev. 03

39540265 Rev. 05

* FOOD GRADE COOLANT OPTION ONLY

* FOOD GRADE COOLANT OPTION 39568464

39540224 Rev. 04

*ITEMS MARKED WITH * ARE OPTIONS THATARE AVAILABLE

5

0.3 DECALS (continued)

!

WARNING

!

WARNINGCompressor Package DataCOMPRESSOR MODEL............................... CAPACITY...................................................... RATED OPERATING PRESSURE................. MAX. DISCHARGE PRESSURE................... MAX. MODULATE PRESSURE..................... NOMINAL DRIVE MOTOR............................ NOMINAL FAN MOTOR................................ TOTAL PACKAGE AMPS............................... VOLTS............................................................ PHASE / HERTZ............................................ CONTROL VOLTAGE..................................... SERIAL NUMBER.......................................... CONTACTOR AMP. RATING..................................... ASSEMBLY AMP. RATING........................................ LOCKED ROTOR AMP. RATING OF ASSY. ............AIR SOLUTIONS GROUP DAVIDSON, NORTH CAROLINA 28036 39557095 Rev.05 WWW.AIR.INGERSOLL-RAND.COM

Rotation.Moving parts. Can cause severe injury. Do not operate with covers removed. Service only with machine blocked to prevent turn over.

CFM PSIG PSIG PSIG H.P. H.P.

39540182 Rev. 04Exposed fan blade. Can cause severe injury. Do not operate with covers removed. Disconnect power. Lock and tag.

39557095 Rev.05

39540224 Rev. 04

39540190 Rev. 04

Rotation.

!

WARNING39544150 Rev. 03

Air Discharge39540257 Rev. 04

Electrical power inlet.39541354 Rev. 03Hot surface. Can cause severe injury. Do not touch. Allow to cool before servicing.

Condensate drain.39541081 Rev. 04

39541362 Rev. 04

*

Water out.39541321 Rev. 04

NOTICEVIEWED FROM REARTo obtain satisfactory compressor operation and maintenance a minimum of 3 feet clearance on 3 sides is required 3-1/2 feet is required in front of the control panel (or minimum required by latest National Electrical code or applicable local codes). Refer to the Instruction / Operators Manual before any maintenance.

*

Water in.39541339 Rev. 03

Lift Here39540273 Rev. 04

!

CAUTION

Incorrect lifting of machine can cause injury or property damage. Lift only from base channels.

!

DANGER

Do not operate without enclosure panels and forklift covers in place. Enclosure panels will affect performance.

39540232 Rev.03

Discharge air. Can contain carbon monoxide or other contaminants. Will cause severe injury or death. Do not breathe this air.

Motors must be greased periodically. See Operators Manual for procedure.

39857552 Rev. 04 39540166 Rev. 06

* WATERCOOLED UNITS ONLY

6

0.3 DECALS (continued)

Compressor Package DataCOMPRESSOR MODEL............................... CAPACITY...................................................... RATED OPERATING PRESSURE................. MAX. DISCHARGE PRESSURE................... MAX. MODULATE PRESSURE..................... NOMINAL DRIVE MOTOR............................ NOMINAL FAN MOTOR................................ TOTAL PACKAGE AMPS............................... VOLTS............................................................ PHASE / HERTZ............................................ CONTROL VOLTAGE..................................... SERIAL NUMBER.......................................... CONTACTOR AMP. RATING..................................... ASSEMBLY AMP. RATING........................................ LOCKED ROTOR AMP. RATING OF ASSY. ............AIR SOLUTIONS GROUP DAVIDSON, NORTH CAROLINA 28036 39557095 Rev.05 WWW.AIR.INGERSOLL-RAND.COM

CFM PSIG PSIG PSIG H.P. H.P.

!

WARNING

39557095 Rev.05 - 2 REQUIRED

Hazardous voltage. Can cause severe injury or death. Only use factory supplied inlet for incoming power. See Operators/ Instruction manual. Manual.

Electrical power inlet.39541354 Rev 03

39543764 Rev. 04

!

WARNING

!

WARNINGHazardous voltage. Can cause severe injury or death. Disconnect power before servicing. Lockout/Tagout machine.

Hazardous voltage. Can cause severe injury or death. Only use factory supplied inlet for incoming power. See Operators/ Instruction manual. Manual.

39540174 Rev. 05

39543764 Rev. 03

NOTICEIEC Starter Overload Setting 1. Full-Voltage Starter (Main or Fan Motor): Multiply MOTOR nameplate amps by 1.11. Star-Delta Starter (Main motors only): Multiply MOTOR nameplate amps by 0.64. 2. Set corresponding overload relay at this value. 3. Never exceed the following limits: Full-Voltage Starter: 125% of MOTOR nameplate amps. Star-Delta Starter: 72% of MOTOR nameplate amps.

SCHEMATIC DECAL

VOLTAGE DECAL OPTION INSIDE STARTER BOX ON RIGHT SIDE

39921804 Rev. B

7

1.0 RECEIPT OF EQUIPMENT1.1 INSPECTION When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier should be noted on the delivery receipt especially if the compressor will not be immediately uncrated. Obtaining the delivery mans signed agreement to any noted damages will facilitate any future insurance claims.

IMPORTANTREAD THIS LOST OR DAMAGED GOODS THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNED BILL OF LADINGIf goods are received short or in damaged condition, it is important that you notify the carrier and insist on a notation of the loss or damage across the face of the freight bill. Otherwise no claim can be enforced against the transportation company. If concealed loss or damage is discovered, notify your carrier at once and request an inspection. This is absolutely necessary. Unless you do this the carrier will not entertain any claim for loss or damage. The agent will make an inspection and grant a concealed damage notation. If you give the transportation company a clear receipt for goods that have been damaged or lost in transit, you do so at your own risk and expense. WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL. THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR RESPONSIBILITY.

FORKLIFT PADDING WILL REDUCE SCRATCHES AND MARS

SPREADER BARS

Ingersoll-Rand Company Davidson, North CarolinaAPDDGFO-99-79

1.2 UNPACKING AND HANDLING The compressor package has been mounted on a base which provides for forklifting between the two side channels to facilitate handling during shipment. Care in positioning the forklifts is important because the location of the center of gravity is strongly affected by the location of the compression module and drive motor. Slings can be used to lift the crates, but spreader bars must be used to prevent the slings from exerting a force against the sides of the crates. 1.3 TOOLS Remove compressor unit from wooden skid. A crowbar and hammer will be needed. 8

IMPORTANTBefore starting this air compressor unit, the shipping brace(s) must be removed. Save the brace(s) for future use. See tag in unit.

2.0 INSTALLATION2.1 VENTILATION Oil flooded rotary air compressors produce large amounts of heat. Because of this large heat production, the compressor must be placed in a room with adequate ventilation. If heated air from the compressor exhaust is allowed to recirculate back to the compressor, the compressor will overheat and shut down. This heat must be exhausted from the room. You should take this into consideration when you decide where to place the compressor within your plant. Consider that the required maintenance clearance is 3 ft (.9 m) all around the compressor. However 42 (1.06m), or minimum required by latest NEC or applicable local codes, must be maintained in front of control panel. Ambient temperatures higher than 115F (46C) should be avoided as well as areas of high humidity. Consider also the environment surrounding or near the compressor. The area selected for the location of the compressor should be free of dust, chemicals, metal filings, paint fumes and overspray.36 (.9 m) 42 (1.06m) OR CODE MINIMUM

36 (.9 m)

DUST METAL FILINGS

CHEMICALS PAINT SPRAY2.3 PIPING The use of plastic bowls on line filters without metal guards can be hazardous. Their safety can be affected by either synthetic lubricants or the additives used in mineral oil. From a safety standpoint, metal bowls should be used on any pressurized system. Review of your plant air line system is recommended.

OVERSPRAY2.2 FOUNDATION REQUIREMENTS Refer to the foundation plan for the particular model compressor to be installed. See Section 8.0. The compressor can be installed on any level floor that is capable of supporting it. Compressor weights are listed on the foundation plans. When sound transmission is of particular importance it is often helpful to install a sheet of rubber-fabric-matting, or cork under the compressor to reduce the possibility of resonant sounds being transmitted or amplified through the floor.

WARNINGDo not use plastic pipe, soldered copper fittings or rubber hose for discharge piping.

NOTICENever elevate the compressor unit above the floor level. This may allow air to enter the cabinet under the base. Performance will be affected.

The built-in aftercooler reduces the discharge air temperature well below the dew point (for most ambient conditions), therefore, considerable water vapor is condensed. To remove this condensation, each compressor with built-in aftercooler is furnished with a combination condensate separator/trap. 9

2.3 PIPING (Continued) A dripleg assembly and isolation valve should be mounted near the compressor discharge. A drain line should be connected to the condensate drain in the base. IMPORTANT: The drain line must slope downward from the base to work properly. NOTE: For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel. It is possible that additional condensation can occur if the downstream piping cools the air even further and low points in the piping systems should be provided with driplegs and traps. IMPORTANT: Discharge piping should be at least as large as the discharge connection at the compressor enclosure. All piping and fittings must be suitable for the maximum operating temperature of the unit and, at a minimum, rated for the same pressure as the compressor sump tank.

DISCHARGE PIPING WITH AFTERCOOLER

NOTICEDo not use the compressor to support the discharge pipe. Careful review of piping size from the compressor connection point is essential. Length of pipe, size of pipe, number and type of fittings and valves must be considered for optimum efficiency of your compressor. It is essential when installing a new compressor to review the total plant air system. This is to ensure a safe and effective total system.200

ROTARY-RECIP IN PARALLEL

Gallons of Water/24 hours/1000 acfm

Liquid water occurs naturally in air lines as a result of compression. Moisture vapor in ambient air is concentrated when pressurized and condenses when cooled in downstream air piping. Moisture in compressed air is responsible for costly problems in almost every application that relies on compressed air. Some common problems caused by moisture are rusting and scaling in pipelines, clogging of instruments, sticking of control valves, and freezing of outdoor compressed air lines. Any of these could result in partial or total plant shutdown. Compressed air dryers reduce the water vapor concentration and prevent liquid water formation in compressed air lines. Dryers are a necessary companion to filters, aftercoolers, and automatic drains for improving the productivity of compressed air systems. 10

160

120

80

40

0

DEW POINTwithout Aftercooling 100F/38C (with Aftercooler) 35F /1.7C (Refrigerated Dryer) -40F/-40C (Desiccant Dryer)

MOISTURE CONTENT OF COMPRESSED AIR

Two types of dryers, refrigerated or desiccant, are used to correct moisture related problems in a compressed air system. Refrigerated dryers are normally specified where compressed air pressure dew points of 33F (1C) to 39F (4C) are adequate. Desiccant dryers are required where pressure dew points must be below 33F (1C). Contact your local Ingersoll-Rand distributor for assistance in selecting correct Ingersoll-Rand filtration or drying products. NOTE: Screw type compressors should not be installed in air systems with reciprocating compressors without a means of pulsation isolation, such as a common receiver tank. We recommend both types of compressor units be piped to a common receiver utilizing individual air lines. When two rotary units are operated in parallel, provide an isolation valve and drain trap for each compressor before the common receiver.

PRESSURE RELIEF VALVE PRESSURE GAUGE

2.4 ELECTRICAL INSTALLATION Before proceeding further, we recommend that you review the safety data in the front of this manual. Locate the compressor data plate on the side of the cooler box or end of the unit. The data plate lists the rated operating pressure, the maximum discharge pressure and the electric motor characteristics and power. Confirm that the line voltage and compressor nameplate voltage are the same and that the standard starter box meets the intent of NEMA 1 guidelines. Open the starter box door. Confirm that all electrical connections are made and tightened. Confirm that the control transformer is wired correctly for supply voltage. See Figure 2.4-1 on next page for typical control transformer wiring. ROTARY TWO COMPRESSOR SYSTEM

Compressor Package DataCOMPRESSOR MODEL............................... CAPACITY...................................................... RATED OPERATING PRESSURE................. MAX. DISCHARGE PRESSURE................... MAX. MODULATE PRESSURE..................... NOMINAL DRIVE MOTOR............................ NOMINAL FAN MOTOR................................ TOTAL PACKAGE AMPS............................... VOLTS............................................................ PHASE / HERTZ............................................ CONTROL VOLTAGE..................................... SERIAL NUMBER.......................................... CONTACTOR AMP. RATING..................................... ASSEMBLY AMP. RATING........................................ LOCKED ROTOR AMP. RATING OF ASSY. ............AIR SOLUTIONS GROUP DAVIDSON, NORTH CAROLINA 28036 39557095 Rev.05 WWW.AIR.INGERSOLL-RAND.COM

CFM PSIG PSIG PSIG H.P. H.P.

39557095 Rev.05

11

110

110

110

110V

FIGURE 2.4-1 TYPICAL CONTROL TRANSFORMER WIRING ELECTRICAL INSTALLATION (Continued) Inspect the motor and control wiring for tightness. Close and fasten the starter box door. ROTATION CHECK Locate the rotation decal on each motor. DRIVE MOTOR The correct compressor drive motor rotation is clockwise when viewed from the rear or non-drive end of the motor. See Figure 2.4-2.NON-DRIVE END DRIVE END

CAUTIONIf the compressor is operated in the opposite direction of rotation, airend damage can result and is not warrantable.

FIGURE 2.4-2 DRIVE MOTOR ROTATION

12

ELECTRICAL INSTALLATION (Continued) The Intellisys will automatically shut the unit down if the compressor rotation is incorrect, and the display will indicate CHECK MOTOR ROTATION