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SSR·1000 OPERATORS MANUAL

OPTIONS

MAINTENANCE

PARTS LISTS

RECOMMENDED SPARE PARTS LISTS

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INGERSOLL-RAND_, AIR COMPRESSORS

APDD 60-8 February 1982

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OPERATORS MANUAL ALL SSR·1000 MODELS

TABLE OF CONTENTS

ROTARY SCREW AIR COMPRESSOR

General Information 6

Lubricant Circulation System 8

Installation Details 11

Electrical Systems 13

Instrumentation 18

Capacity Control 20

Operation 22

Lubrication 23

Trouble Investigation 24

Section I Options 26

Section II Maintenance 27

Section III Parts List 53

Section IV Spare Parts 61

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.

Model: _

No. of units on order:

Customer order no.: _

Ingersoll-Rand Co. Order No.:

For ready reference:

Record the serial number and model number of your unit here.

Serial number:

Model number: _

APDD 60-B

FEBRUARY 1982

©Ingersoll Rand Company

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SAFETY PRECAUTIONS

READ CAREFULLY BEFORE INSTALLING THE COMPRESSOR.

WARNING

COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS.

BEFORE DOING ANY WORK ON THIS UNIT, BE SURE THE ELECTRICAL SUPPLY HAS BEEN CUT OFF AND THE ENTIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF ALL PRESSURE.

6. A safety valve is located on the receiver-separator. Whenever pressure is released through this valve, it is due to excessive pressure in the system. The cause for the ex· cessive 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.) Make sure the unit has blown down, and close the unit isolation valve to prevent possible backflow into the unit from the air system.

SAFETY PRECAUTIONS

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.

2. The compressor has high and dangerous voltage in both the motor, the 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 fused 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.

8. There can be bad effects if cornpressor lubricants are allowed to enter plant air systems.

Air line separators, properly selected and installed, can reduce any liquid carryover close to zero.

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 oils. 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 II, paragraph 1910.169 be adhered to in the installation and maintenance of this receiver.

3. Do not operate the compressor at higher discharge pressures than those specified on the Compressor Name-plate, or motor overload will occur. This condition will result in motor and compressor shutdown.

4. Use only safety solvent for cleaning the compressor and auxiliary equipment.

10. Before starti ng the compressor, its maintenance instructions should be thoroughly read and understood.

5. Install a manual shut off valve (isolation type) in the discharge line as close to the compressor as possible.

FAILURE TO HEED THIS WARNING MAY RESULT IN AN ACCIDENT CAUSING PERSONAL INJURY OR PROPERTY DAMAGE.

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FORWARD

The SSR-1000 data plate on the enclosed unit is affixed to the compressor housing inside the cabinet.

The data plate on the unenclosed unit is located on the left side of the control box. See Figure 1.

It lists the rated operating pressure and the maximum discharge pressure along with the cornpressor capacity, the electric

motor characteristics and power.

Information has been prepared in this manual to assist an operator to understand, maintain and operate this compressor within the power limits shown on the data plate.

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.

To facilitate maintenance, refer to the "Recommended list of spare parts" included in this manual.

Normal maintenance requires the replacement of parts - and these parts should be kept on hand in convenient quantities.

Take pride in your compressor keep it clean and in good mechanical condition.

Figure 1 Compressor Data

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COMPRESSOR DAtA

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Domestic

COMPRESSOR MODEL NO ~~~~~~~~;

CAPACITY CFM

RATED OPERATING PRESSURE PSIG

MAXIMUM DISCHARGE PRESSURE ~~~~~~~ PS/G

PACKAGE DATA HP

VOLTS HZ PHASE

CONTROL VOLTAGE ::1 ==="::5::AC====--_., SERIAL NO

MADE IN USA BY INGERSOLL·RAND COMPANY AIR POWER COMPRESSOR DIVISION DAVIDSON NORTH CAROLINA 28036

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COMPRESSOR DATA

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International

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WARNING

STATEMENT CONCERNING THE USE OF THIS EQUIPMENT FOR BREATHING AIR AND/OR AQUA LUNG SERVICE

If the model number on this air compressor contains the letters "BAP". the compressor is suitable for use in breathing air services. In the absence of such a desiqnetion, the compressor is NOT considered as capable of producing air of breathing quality. For a compressor to be capable of use in breathing air services. it must be fitted with additional specialized equipment to properly filter and/or purify the air to meet al/ applicable federal. state and local laws, rules, regulations and codes. such as, but not limited to. OSHA 29 CFR 1910.134. Compressed Gas Association Commodity Specification G· 7.1-1966. Grade 0 Breathing Air. and/or Canadian Standards Association. Should the Purchaser and/or User /ailto add such specialized equipment and proceeds to use the compressor for breathing air service, the Purchaser/User assumes all liability resulting therefrom without any responsibility or liability being assumed by Ingersoll·Rand Company.

The Purchaser is urged to include the above provision in any agreement for any resale of this compressor.

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C INGERSOU .. RAND

Figure 2

Typical SSR·1000 Compressor

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INSTRUMENT PANEL SEPARATOR TANK

_____ \ __ a_

CONTROL~

BOX I'

MINIMUM PRESSURE VALVE

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FILTER

STARTER BOX

PRESSURE RELIEF VALVE

THERMOSTATIC OIL CONTROL VALVE

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COOLER·AFTERCOOLER

INLET CONTROL VALVE MODULATOR

INLET AIR CLEANER

FAN

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HIGH AIR TEMPERATURE SWITCH

MOISTURE SEPARATOR

AIREND

CONDENSATE TRAP

Figure 3

Typical SSR·1000 Assembly

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GENERAL INFORMATION

The SSR-1000 compressor is an electric motor driven, single stage, screw compressor - complete with accessories piped, wired and baseplate mounted. It is a totally self-contained air compressor package.

A standard compressor is composed of the following:

Inlet air filtration

Compressor and motor assembly Pressured lubricant system

with cooler Separation system Load control system

Motor starting control system Instrumentation

Safety provisions

Air cooled aftercooler

(Moisture separator and drain trap)

Compression in the screw-type air compressor is created by the meshing of two helical rotors (male and female) on parallel shafts, enclosed in a heavy-duty cast iron housing, with air inlet and outlet ports located on opposite ends. The male rotor has four lobes 90 degrees apart, and the female rotor has six grooves 60 degrees apart. The grooves of the female rotor mesh with, and are driven by, the male rotor. Tapered roller bearings at the discharge end prevent axial movement of the rotors.

The air-lubrication mixture discharges from the compressor into the separation system. This system, self-contained in the receiver tank, removes all but a

few PPM of the lubricant from the discharge air. The lubricant is returned to the system and the air passes to the aftercooler.

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The lubricant system consists of a sump, a cooler, thermostatic lubricant control valve and a filter. When the unit is operating the lubricant is pressurized and forced to the compressor bearings. The lubricant filter indicator is mounted on the filter housing.

Panel instrumentation is provided to indicate the compressor operating conditions, control

power availability, load control mode, a push-button start-stop station.

Safety of operation is provided for excessive discharge temperature, electrical overload and excessive motor winding temperature, by causing the compressor to shut down.

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Effective lubricant filtration is provided by use of a heavy duty hydraulic type filter.

All of the above features are described in greater detail and discussed in the pertinent sections of this manual.

All service connections are on the back of the unit to. provide ease of connection and a clean looking installation.

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Important:

Reference to the available options will be made throughout the general text of this manual, however. the reader should refer to the options section of this manual for specific information,

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COMPRESSION

If one thinks of the female rotor grooves and the compressor housing acting as a conventional cylinder, and the sliding action of the male rotor lobe as a piston, the positive displacement nature of a rotary screw compressor becomes apparent.

As rotation of the compressor begins, air is drawn into the pockets opened between the male rotor lobes and the female rotor grooves at the intake end of the compressor. This is illustrated in Figure 4-1. (A mating male-lobe and female-groove are marked with dots to show the relative positions of the rotors.)

With further rotation, the leading strip of the male lobe reaches the contour of the female groove, and traps the ai r in the pocket previously formed. This air is moved down the female rotor groove and is compressed.

Lubricant is injected during the compression phase and takes up heat of compression, lubricates the rotors, and seals the rotorclearances against leakage. This phase is illustrated in Figure 4-2.

When the male rotor lobe reaches the end of the groove, the trapped air is discharged along with the lubricant Figure 4-3. The mixture

is piped through a check valve to the receiver. In the receiver, the lubricant will be separated from

the air and returned to the system. The air will flow to the aftercooler and the moisture separator, and then to the plant system.

1 - Intake

Inlet air flow

Female rotor

2 - Compression

Discharge port

3 - Discharge

Figure 4 Rotor Compression

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LUBRICANT CIRCULATION SYSTEM

AIR COOLED UNIT. Refer to the Circulation System Schematic, Figure 5.

Lubricant is forced by pressure from the receiver-separator to the inlet port of the thermostatic oil control valve.

SEPARATOR ELEMENT

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The thermostatic oil control valve controls the quantity of lubricant necessary to provide a suitable compressor injection temperature. When the compressor starts cold, part of the lubricant will by-pass the cooler. As the system temperature rises above the valve setting, the lubricant will be directed to the cooler. During periods of operation in higher ambient temperatures, all the lubrlcant flow will be directed through the cooler.

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THERMOSTATIC OIL CONTROL VALVE

Figure 5 Circulation System Schematic

The compressor-injection minimum temperature is controlled to

preclude the possibility of water • vapor condensing in the receiver.

By injecting lubricant at a suffi-

ciently high temperature, the

discharge air and lubricant mixture-temperature will be kept

above the dew point.

The controlled-temperature lubricant passes through a filter to the air end under constant pressure.

COOLER

CONDENSATE TRAP

CLEAN

DRY AIR DISCHARGING

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LUBRICANT I AIR SEPARATION SYSTEM

The lubricant/air-separation-system is composed of a receiver with specially designed internals, a twostage, coalescing-type separatorelement, and provision for return of the separated fluid back to the compressor. See Figure 6.

OPERATION

The lubricant and air discharging from the compressor flow into a tangential separator tank inlet. This inlet directs the mixture along the inner circumference of the receiver, allowing the lubricant stream to collect and drop to the receiver sump.

The internal baffle maintains the circumferential flow of remaining lubricant droplets and air. In an almost continuous change of direction of flow, more and more droplets are removed from the air by inertial action and then returned to the sump.

The air stream, now a very fine mist, is directed to the separator element.

The separator element is constructed with two concentriccylindrical-sections of closely packed fibers, each held in steel mesh. It is flange-mounted at the receiver-outlet-cover.

The air stream enters the separator element and the mist coalesces to form droplets. The droplets collected on the outer first stage fall to the receiver sump. Those collected on the inner second stage collect on the bottom of the element, and are drawn back to the compressor inlet through a filterscreen and orifice-fitting installed in the separator scavenge line.

The air stream, now essentially

free of lubricant, flows from the separator to the aftercooler, then

to the condensate separator, and on to the plant air system .

SCAVENGE -

BACK TO COMPRESSOR INLET

CLEAN AIR TO PLANT SYSTEM

DISCHARGE AIR

AND LUBRICANT ENTER SEPARATOR

Figure 6

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AIR COOLED COMPRESSORS

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DESIGN TEMPERATURES

The standard compressor is designed for operation in an ambient range of 35°F. to 100°F. (1.7°C. to 38°C.).

The standard maximum temperature (100°F.) is applicable up to an elevation of 7500 ft. (2300 meters) above sea level. Above this altitude. significant reductions in ambient temperature are reo quired if a standard drive motor is to be used.

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LUBRICANT COOLERS

The cooler is an integral assembly of the compressor unit. The cooting air flows into the housing through the left end of the unit and exits out the right end of the unit.

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AFTERCOOLER

The discharge air aftercooling system consists of a heat exchanger, a condensate separator, and a drain trap. The after-

cooler is mounted in front of the lubricant cooler. By cooling the discharged air, much of the water vapor naturally contained in the

air is condensed and eliminated from the downstream ptant-pipino and equipment.

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INSTALLATION DETAILS

GENERAL

The condition of the arriving compressor should be carefully inspected. 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 man's signed agreement to any noted damages will facilitate any future insurance claims.

UNPACKING AND HANDLING

The compressor package has been mounted on a heavy duty structural steel base which includes protective forklift channel guides 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 inline assembly of the compressor air

end and drive motor.

SI ings can be used to I ift the crates but spreader bars must be used to prevent the slings from exerting a force against the sides of the crates. After uncrating, the above handling precautions should still be observed. Holes are furnished in the base channels of the unit for lifting. If slings are used. spreader bars must be used. Placing protective material between the slings and the compressor enclosure should not be attempted .

FOUNDATION REQUIREMENTS

Refer to the foundation plan for the particular model compressor to be installed. Foundation plans are furnished as part of the Technical Publications packet when the unit is shipped.

LOCATION IN PLANT

The compressor should be installed in a dry, well-ventilated area where the air is as clean as possible. We recommend the compressor unit with enclosure, have three feet of clearance on the intake and exhaust end of the unit. Air cooled units. in particular, require a free flow of cooling air. Cooling air enters at the left end of the enclosure and exits at the right end. The possibility of excessive recycling of cooling air must be avoided.

Consideration must be given to the need for clearances around the compressor for ease of maintenance. The foundation plan shows the minimum clearances required.

NOTE: 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.

CONDENSATE DRAIN PIPING

Condensate (condensed water vapor). is removed from the compressor system through an automatic drain trap, and piped to the plant drains. The location of the condensate drain of the compressor is shown on the foundation plans. The drain piping and lower half of condensate separator must not be subject to freezing. Important: The drain line must slope downward from the trap to work properly.

For ease of inspection of the automatic drain trap operation. the drain piping should include an open funnel.

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CAUTION

Screw type compressors should not be installed in air systems with reciprocating compressors without a means of isolation, such as a common receiver tank. We recornmend both types of compressor units be piped to a common receiver utilizing individual air lines.

It is essential in installing a new compressor to review the total plant air system. This is to insure a safe and effective total system. One item which must be considered is liquid carryover into the plant air line. Installation of after· coolers. air dryers and line separators is always good practice.

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Water condensation can affect the operation of pneumatic devices. Aftercoolers and the addition of air dryers can eliminate this hazard.

Similarly, there can be bad effects if compressor lubricants are allowed to enter plant air systems. Air line separators, properly selected and installed, can reduce any Ii· quid carryover close to zero.

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CAUTION

The use of plastic bowls on line filters without metal guards can be hazardous. Their safety can be atfected by either synthetic lubricants, or the additives used in mineral oils. From a safety standpoint, metal bowls should be used on any pressurized system.

Review of your plant air line system is recommended.

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ELECTRICAL SYSTEM

GENERAL

The electrical system of each SSR-1000 is built with dependable components. Optional control modules allow variations and additions to the standard control circuit.

The Compressor Motor Starter with auxiliary contacts and overload relays, the control transformer and its fuse are standard electrical components enclosed in a readily accessible sheet metal box. The top portion of this box is made up of the instrument panel which holds the start and stop pushbuttons, capacity control selector switches, various indicating lights, and hourmeter.

FULL VOLTAGE TYPE STARTER (ACROSS THE LINE, MAGNETIC)

Refer to the electrical schematic wiring drawing, Figure 9.

The starter coil is controlled by the start button and an interlocking switch. Provided all protective temperature switches and motor overload relays are closed, when the start button (2PB) is closed the starter coil ls energized. An interlock switch on the starter holds the starter energized. The cornpressor motor will start and the Normal-Unload Selector Switch should then be moved to the Normal position and the compressor will load.

UNLOADED START CONTROL

The SSR·1000 incorporates into the control system the following components to provide a self-unloading start:

Refer to the electric wiring schematic, Figure 9 or 10 or one applicable to the type of motor starter being used.

A self-unloading start is achieved by closing the inlet valve with pressure created by the compressor.

The mode switch should be set to the normal position after the unit starts. Air pressure will rise to the preset pressure.

The Normal-Unload Selector Switch, mounted on the Instrument Panel is used to control the Load Solenoid Valve (1SV). When the selector switch is in the Unload position, the Load Solenoid valve can not be energized thus keeping the compressor in the Unload Mode. Moving the selector to "Normal" position will allow the Load Solenoid valve to be energized, closing off air pressure to the inlet valve causing it to open and begin compression.

OPTIONAL

STAR-DELTA UNLOADED START

The use of the interlocking switch (2Ma) in the optional Star-Delta Starter provides for an automatic self-unloading start. The switch is connected to ensure that during

the starting cycle of the Star-Delta Starter, the Load Solenoid valve is - de-energized. When the starter transfers to the run position, the switch contacts close; arming the Load Solenoid valve circuit. The compressor will now load: provided the NORMAL-UNLOAD Selector Switch is in the NORMAL position on the compressor panel.

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STAR-DELTA TYPE STARTERS

By use of the optional Star-Delta type starter, the compressor motor can be started and accelerated using a greatly reduced "inrush" electric current. The starter is completely automatic and controlled by a push button station mounted in the compressor panel. The sequence of operation of the starter is explained in the fOllowing section.

Refer to the electrical schematic wiring drawing, Figure 10, and note that the starter coils and time delay relay are controlled by the normally open contact of either the starter interlock switch or automatic control module. Note if all protective temperature switches and motor overload relays are erosed, this normally-open, contact will be energized when the start button is closed.

When start button (2PB) is closed, the following sequence takes place automatically in the Star-Delta Type Starter:

1. Control voltage is available across the start contactor coil (1 S) because the timer contact (HR) and auxiliary contact (2Mb) are

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both closed. The start contactor coil (1S) will be energized and auxiliary contacts (1Sa) will close and (1Sb) will open.

2. The action of auxiliary contacts (1Sa) and (1Sb) will put control voltage across the start-run contactor coil (1 M), and will prevent the run contactor coil (2M) from being energized. Auxiliary contacts

(1 Ma) will then close to provide an interlock to hold the coil (1 M) in an energized state. The time delay relay (HR) will be energized and begin to time out. Contactors (1S) and (1 M) are now energized and

the compressor motor will start and run in the "star connected" mode.

3. When the time delay relay (HR) runs out its time, contact (HR) opens. This breaks the circuit to the start contactor (1 S), and energizes the run contactor coil (2M) through the auxiliary contact (1 Sb). Contactors (1 M) and (2M) are now energized and the compressor is running in the "delta" mode and the auxiliary contacts (2Ma), (used as the unloaded start automatic control) are closed permitting the compressor to be loaded.

* ISO * 2Mb -II- I Sa -II- 2Ma

-II- I Ma

Figure 7 Star-Delta Contactors

4. A mechanical interlock exists between contactors (1S) and (2M),

which prevents both these contac- •

tors "pulling in" at the same time. Additional electrical, interlock, ex-

ists; auxiliary contact, (2Mb), when contactor (2M) is energized. This

auxiliary contact opens, preventing

any possible energization of the

start contactor (1 S).

STAR-DELTA STARTER AUXILIARY CONTACTS

The auxiliary contacts which control the starter sequencing are located on the upper rear section of the contactor which bears its number. The auxiliary contacts on the Star-Delta starter are shown below. See Figure 7.

Normally Ooeo

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CONTROL TRANSFORMER

Connections
Line Volts Line Control Jumper Secondary
Primary HZ Primary Secondary Across Voltage
575 60 Hl·H5 Xl·X3 H2·H3 115
460 60 Hl·H4 Xl·X3 H2·H3 115
415 50 Hl·H4 Xl·X3 H2·H3 104
380 50 Hl·H4 Xl·X3 H2·H3 95
230 60 Hl·H4 Xl·X3 Hl·H3 115
H2·H4
220 50 Hl·H4 X1-X2 Hl·H3 91
H2·H4
200 60 Hl·H4 Xl·X3 Hl·H3 100
H2·H4 The control transformer, mounted in the electrical control box, is a universal type. It is suitable for use with various primary voltages and frequencies and is connected according to the rated voltage of the compressor: up to 575 volts. See Figure 8A.

The transformer primary-secondary connections should be confirmed prior to initial start-up on the compressor. The primary-secondary connections for various primary voltages are as follows:

The electrical terminals at the transformer are as shown in the following schematic: See Figure 8.

Figure 8A

Control Transformer Connections

Hl

H3

H2

H4

H5

fOOOOOTOOOOOOOOOOOOOOOOOOOOOl X3 X2 Xl

Figure 8 Transformer Terminals

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"APPROVED FUSED DISCONNECT OR CIRCUIT BREAKER PER NEC REQUIREMENTS MUST BE PROVIDED BY INSTALLER."

LI-J:I'l)._-- ----~---=

L2 --"', '.'.- - -- ----+--------4

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L3 - i.' :'L - - - - - - -_-----~------_I

1M IOL
: : o..X'o TI
"
aJ'O T2 8 •

o..X'o T~ / T8-1

T
~
IFU r 115V 11- G
----
- "- /
ILT
,,- ,
S~ START
ITAS 2TS XB-A TB-9 IOL
. ......, I T8-3 2 1 ...r.
T8-2 .~ T8-182 1T8-4 ""-1
1"'0
T8-11 T8-12 1
4SV
1M

T8-8 HM

NO T8-13
COM IPS ISV
NC "
UNLOAD v
T9-16 TB-15 RSI
LOAD TB·21
3SV TB-7

Figure 9 Typical SSR-1000

Full Voltage Wiring Schematic

LEGEND

1 MTR COMPRESSOR MOTOR

1M lMTR START·RUN CONTACTOR

10L 1 MTR OVERCURRENT RELAY

lMa AUXILIARY INTERLOCK SWITCH

T CONTROL POWER TRANSFORMER

lFU CONTROL FUSE 3 AMP

HM HOURMETER

1 PB STOP PUSH BUTTON

2PB·a START PUSH BUTTON

lTAS HIGH AIR TEMPERATURE SWITCH

1 PS LINE PRESSURE SWITCH

1 SV LOAD SOLENOID VALVE. N .0.

2SV MODULATE CONTROL SOLENOID VALVE. NO

3SV SLOWDOWN SOLENOID VALVE. NO.

RS 1 NO'LOAD-NORMAL ROCKER SWITCH

4SV OIL STOP SOLENOID VALVE. N C.

1Li POWER ON INDICATOR LAMP

18-5

T8-5

TB-5

TB-6

T8-5

T8-17

TB-17

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"APPROVED FUSED DISCONNECT OR CIRCUIT BREAKER PER NEC REQUIREMENTS MUST BE PROVIDED BY INSTALLER."

IFU

T8-1 .--I:J--------------_J

/

}-------------------+ T B-~

TB-~

TB-6

TB-S

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Figure 10

Typical SSR·1000 Star-Delta Wiring Diagram

LEGEND

lMTR COMPRESSOR MOTOR MOR MODULAR OVERLOAD RELAY
1M 1 MiR ST ~Ri ·RUN CONTACTOR lDS LINE PRESSURE SWITCH
IS H.1TR START CONTACiOR 2PS fOULED AIR FillER PRESSURE SWITCH
1M IMTR Ruri CONTACTOR ISV LO':'O SOLEriOiO VALVE. NO
IOL 1~ITR OV,RCURRENT RELAY :5" MODULATE CONTROL SOLENOID VAL VE NO
t Sa :J AUXllI"RY irnERLOCK SWITCH 3Sv SLOWDOWN SOLENOID VALVE NO
iMc AUI .. U.1RY :::rERlOCK SWlTCI-i RS' NO'LOAD-NORMAL ROCKER SWITCH
:?r.12 D ~UXILI.lQ'" l'HERlOCE SwnCH PS2 MODULATE-ON·OFF litlE ROCKER SWITCH
CONTROL POWER TRANSFORMER. liP STAR·DELlA TIME DELAY RELAY 10 SEC
lFU COliTROL FUSE 3 AMR "CM STOPPED·AUTO RESTART TIME DELAY 10 MIN
HM HOURMETER lU PDVlER ON INDICATOR LAMP
ID8 STOP PUSH BUTTON 1L7 STORPED·AUTO RESTART INDICATOR LAMP
2PB·, ST~RT PUSH BUTTON 3Ll FOULEQ AIR FILTER INDICA TOR LAMP
2PB'D FOULED A'R 'IllER LAMP T,ST PUSH BUTTON oSV OIL STOP SOLENOIO VA.lVE. N C
iT AS HIG." AIR TEMPERAiUR(SVilTCH •

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INSTRUMENTATION

CONTROL PANEL

DISCHARGE TEMPERATURE GAUGE - indicates temperature of air leaving the compressor. The temperature sensing bulb is located in the coolant reservoir.

AIR PRESSURE GAUGE - reads sump pressure and line pressure. The difference in the two readings is the pressure drop across the separator element.

POWER ON LIGHT - indicates that control voltage is available to the control circuit and that the line voltage is available at the motorstarter main-contacts.

WARNING

The power on light must never be used as a positive indication that power has been shut off. A burned out bulb can give a false indication.

START -STOP-PUSH BUTTONS-

energize or de-energize the main contactor on the standard starter • or the Auto Control Module w/op-

tional Automatic Start-Stop.

NOTE: On the 50 hertz only. The

start push-button (2PB) has in-

terlocked to it an Air Filter In-

dicator Lamp test switch. Pushing

the start button will start the compressor and light the optional Air

Filter Indicator Lamp (3L 1").

Releasing the start button will

cause the light to extinguish until

the optional vacuum switch (2PS)

signals that the filter needs replac-

ing.

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Figure 11

60 Hz ONLY. :<

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HOUR METER - reads the total time of operation of the compressor. It runs only when the motor starter coils are energized. It should be used to schedule maintenance functions such as lubricant and lubricant filter changes.

NORMAL-UNLOAD SELECTORcontrols the ability of the compressor to "load up". When the selector is in the Normal mode, the Load-Solenoid-Valve can be energized, and the Inlet Valve can open. When the selector is in the Unload mode, the Load-SolenoidValve cannot be energized. This

selector position is used when the compressor is started rnanually.

AIR FILTER (MAINTENANCE INDICATOR) - senses the pressure drop across the inlet air filter element and indicates the element cleanliness. As the filter element traps dust, the pressure drop increases.

In addition to the pressure and temperature indicators and other instruments on the control panel, each compressor is equipped with:

LUBRICANT FILTER (MAINTENANCE INDICATOR) - located on the filter housing.

FILTER MAINTENANCE INDICATOR

Figure 12

Senses the pressure drop across the filter, and indicates when the filter element must be replaced. See Figure 12. However, the indicator showing "RED" when the compressor starts cold is a normal condition. After operating for a short period of time the indicator must change to show green. Refer to the lubrication section for specific details.

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CAPACITY CONTROL

The SSR-1000 compressor is available with two types of capacity control - each designed to suit the individual plant requirements.

These controls are:

A. Standard

On tine-Ott line

B. Optional

Modulation

... and either is available by operation of the selector switch on the compressor panel.

ON LINE-OFF LINE CONTROL

For those plants which have a widely varying air demand, the On line-Off line control will deliver air

20

at full capacity, (the compressor maximum efficiency condition) or will operate at zero capacity with low receiver pressure (the compressor minimum power condition).

When the solenoid valves are energized, pressurized air is removed from the inlet valve allowing it to fully open. The Blowdown Valve closes the atmospheric vent.

The compressor will then operate to deliver full capacity air to the plant system. If the plant air system pressure rises to that of the pressure switch upper set point, both solenoids will be deenergized.

The Load Solenoid valve will open allowing pressurized air to be fed to the inlet valve, causing it to close.

Line pressure increases

110 when compressor output r is greater than plant

105 air demand. ' P

I I' l\ ressure switch (1 PSI

100 If+-H-H-i ;..! [;' ~per set point.

95 I

I I 1 Compressor rated

1!- 90 1H-++.J-;.t++++1 ++++~-H++ J--+ discharge pressure.

·13 C II Ii

l1 om pressor

~ 85 capacity increases +t+f+t+t+

when line pressure ,

al 80 drops to resel~'...J....l.++++++++~

~ po;n,' ~f,' ;~'I I I ~Z::'a~~~:~~~ps

"0 75 IH-...!.,...!.+ ttt L"':"';'M4-++++++++~ tl+ to zero when

<fl. 70 IH-+++I++ ~I++ 1 1++++++1++++++-1 line pressure

I ~es~t pre~~u~e. II I I ~~~Cph~~tU~f~~s.

65 I ~ I t III I I! I • f

60 1~U+~++++++++-4++++...!.-

Ilj I I Line, pressure deCrteam~eSt i

H-\~as a" consR~mpltlotn, I

I I f.J T cont'"u~s, 1 J

~~ I N..' II '..L'

o

90

100 105

95

% of rated line pressure

Figure 13 Operating Sequence Using On-Off Line Control

The compressor will continue to run, but since pressure levels have

reduced, it will do so with a •

minimum power draw.

The pressure switch has an adjustable differential which is factory set at 12 psi (0.83 Bar) range between its upper and lower setpoint pressures. The upper setpoint pressure is factory set at slightly above the compressor

rated discharge pressure. The correct upper-set-point pressures are listed in the Regulation Adjustment Section of this manual.

A graph indicating the relationships between the compressor output, the line pressure. and the pressure switch (1 PS) setting is shown in Figure 13.

•

•

.'

•

MODULATION CONTROL

For those plants which have a relatively high and constant al_r demand, relative to the compressor capacity, the recommended control mode is Modulation.

The modulation control system retains the features of the On line-Off line control, but provides for throttling of the inlet air flow as the line pressure rises to the upper set point of the pressure switch (1 PS).

By applying line pressure to an adjustable regulating valve, this is, the Modulator Valve, the throttling position of the inlet valve is controlled, thus allowing the modulator to "trim" the inlet valve position as dictated by the line pressure.

The modulating pressure range is about 4 psig (0.3 BAR) and the modulator is factory set to straddle the compressor rated pressure. Modulation begins when the line pressure reaches about 99 percent of the compressor rated pressure and continues as/if the line pressure rises. Modulation becomes stable when the com-

pressor output equals the plant air demand. When the modulation is at the factory setting as shown on Figure 14 the maximum capacity reduction will be down to approximately 60 percent of the compressor rated capacity.

If the air demand has decreased to a level below the 60 percent modulated output, the line pressure will increase slightly to actuate the pressure switch (1 PS). The compressor will then shift to the Off-line control position, and operate unloaded with the receiver vented.

It is sometimes desirable to begin modulation at a higher pressure than the standard factory setting, thereby increasing the modulated capacity at the time the pressure switch (1 PS) is actuated. Reference to Figure 14 will indicate the typical modulated capacities available when this is done.

Factory setting

of mcdutstor

Optional field sellings of rnonutator

Pressure switch (' PSI upper set point

105
100
95
:: 90
u
to 85
c.
to
c 80
'C
'"
~ 75
'0
,,0 70
65
60 I /
I I~ 4K 1\ II
" T H ~, I-<
I r\
I ~ I \I
I 1\ I ~
I 1 \
I I I II \
I I I I
I
~ I I i II! I I
I I I I
I I
ib I I Modulate 10 60% capacity

Modulate to 94% capacity

Modulate to 85c/o capacity

Modulate to 72°.0 capacity

99 100101 102103

'" of rated line pressure

Figure 14 Modulation Capacity

AUTOMATIC START-STOP CONTROL (OPTION)

For those plants which have a widely varying plant air demand, large air storage capacity and/or want automatically available standby air capacity, Automatic Start-Stop Control, is available.

During periods of low demand, if the line pressure rises to the upper set point of pressure switch (1 PS), a time delay relay automatic control module is energized and

begins to time out. The module, mounted in the starter box, is set at 10 minutes and will continue to operate as long as the plant linepressure remains above the lower set-point of the pressure switch.

If the module continues to operate for as long as its time setting a relay contact in the control module opens to de-energize the compressor motor coil. At the same time, an amber light (2L 1) on the instrument panel is lit to indicate the compressor has shut down automatically and will restart automatically.

The automatic restart will take place when the line pressure drops to the lower set point of pressure switch (1 PS).

21

OPERATION

INITIAL PREPARATIONS AND START·UP

1. Inspect and confirm that all piping and electrical work is tight and that the main disconnect switch is in the OFF position.

2. Confirm that line voltage and compressor Name plate voltage are the same. Confirm that the control transformer is connected correctly. Refer to the electrical section of this manual for transformer hook-up.

3. Open the panel on the starter box. Confirm that all electrical connections are made and tightened.

4. Inspect the motor and control wiring for tightness and safety.

5. Place the main disconnect switch in the ON position. Note whether the white "power on" light on the panel is lit, indicating control voltage is available to the control circuit.

6. Place the normal-unload selector switch in the unload position.

Note: This switch should always be placed in the unload position when starting the unit manually. Provisions have been made to automatically perform this function on Auto/Start-Stop units as they restart under automatic conditions.

7. Rotation check.

..

'''I

;. ','1 .,

CAUTION

For the compressor motor rotation check, the motor jogging must be for as short a time as possible. After depressing the start

button, immediately depress the stop button.

22

Observe a blade of the compressor cooling fan. The rotation must be in accordance with the directionalarrow-decal affixed to the motor and fan shroud. Note: The correct motor rotation is clockwise when the motor is viewed from the end opposite the drive end.

WARNING

After putting the main disconnect in the off position, if the rotation is not correct, interchange any two line connections (L 1, L2, or L3) at the starter,

8.Check to determine that the lubricant level is at the mid-point of the sight glass provided.

9. Prime the condensate trap as outlined in the Maintenance section of this manual.

10. Close the isolation valve leading to the customers plant air system.

11. Start the compressor and allow it to run unloaded for a few moments to circulate the lubricant. Check for any leaks and correct

as required.

12. Set the mode selector switch to the "NORMAL" position and allow the pressure to rise to the maximum discharge pressure as indicated on the unit data plate. Adjust as required; details are in the Maintenance section of this manual.

13. Check for tightness of all fittings, particularly in the lubrication system. After a few minutes of operation, place the mode selector switch in the "UNLOAD" position and shut the unit down.

14. Check the lubricant level in the separator tank.

WARNING

Confirm all pressure is relieved from the compressor system and that the main electric disconnect switch is open and tagged to remain open.

Because some lubricant will remain in the piping and accessories, it may be necessary to add lubricant to bring the level back to the mid-point of the sight glass. Tighten the fill plug securely.

15. Re-start the compressor and place the mode selector switch in the "NORMAL" position. Open the isolation valve and allow the compressed air to enter the customers system.

Note: For air cooled units, the discharge temperature should rise to near 190 OF. (88 ·C.) and may rise to as high as 210°F. (99°C) at full load if the ambient cooling air is as high as 10QoF. (38°C.).

•

•

•

LUBRICATION

GENERAL

LUBRICANT (SSR-COOLANn Rotary screw compressor fluids have a triple function to perform in that they lubricate the bearings and contacting surfaces of the rotors, they seal internal clearances within the rotor chamber, and they provide for the cooling of the compression process. The bulk of the fluid is actually used for cooling, with only small amounts used for lubrication and sealing.

The coolant lubricant used in the SSR-1000 compressor has been specially blended and formulated to perform the above three functions exceptionally well. Its lubricating qualities exceed those of standard petroleum oils as well as those of previously available synthetic-lubricants. Its viscosity characteristics are such as to provide excellent sealing of internal clearances over broad ranges of operating temperatures. In fact, the viscosity change with temperature is small enough to permit the coolant-lubricant to be used over the entire range of ambients from 35 of. to 100 of. (1.7 °C. to 38°C.) without significant loss of its qualitites, or the cause of problems of any kind.

Most important is the performance of the fluid as a coolant. In this function the SSR-Coolant demonstrates its outstanding abilities. It has exceptional

oxidat ion-stabi lity at systemoperating-temperatures so as to provide long life. Advanced-rustinhibitors assure clean piping. clean cooler tubes, and clean separator tanks.

Due to the large volume of coolant circulated and its direct contact with the air being compressed foaming at blowdown or other

pressure change conditions is often a problem with rotary compressors. The SSR-Coolant has quick air release characteristics and minimal air-entrainment, such that foaming has been largely eliminated as an operating concern.

In addition, the coolant has little affinity for water as well as quick, effective water release at shutdown. These characteristics provide for maximum bearing lubrication integrity. as even small amounts of water in the lubricant can be highly detrimental. These factors also provide for easy draining of condensation from the vertical-separator-receiver-tank.

Readily available but normally ordered and shipped with the unit is a service kit which includes air and lubricant filter elements and make-up lubricant for approximately one year's operation.

If a situation arises where, for some reason this fluid cannot be used. consult Ingersoll-Rand for specifications and recommendations on possible substitutes.

LUBRICANT FILTRATION

Each compressor has a hydraulictype-full-flow-filter with a single replacement spin-on element.

The filter is mounted downstream of the cooler and the thermostatic coolant control valve.

It is rated at 10 microns.

It has a differential-pressurebypass-valve set to open in the event that the pressure drop across the filter element rises to as high as 25 psi, which indicates an excessively fouled element, as well as poor maintenance practice.

To eliminate this latter possibility, a maintenance indicator which senses pressure on each side of the filter element is mounted on the compressor oil filter housing. This indicator will signal that a dif-

ferential pressure of 15 psi has been reached when the floating piston passes entirely into the RED. See Figure 15.

Figure 15

During some start-ups, if the lubricant is cold the indicator may rise entirely into the RED. This is normal. If the filter element is serviceable, the floating piston will drop back into the green as the compressor temperature rises.

Regardless of the maintenance indicator reading, the filter element should be changed after the first 150 hours of operation and again after each 2000 hours of operation. The element should be replaced when the annual lubricant change is made.

The procedure for renewing the filter element is outlined in the maintenance section of this manual. Spare elements should be kept in stock at the installation to facilitate regular replacement.

The procedure for change out of the lubricant is outlined in the maintenance section. Make-up for use between annual changes should also be kept in plant stock.

23

TROUBLE INVESTIGATION

COMPRESSOR FAILS TO START

1. If the main disconnect switch is closed and the "power on" light bulb is good but does not light up, the control voltage is probably not available. Check the transformer secondary for control voltage and check the fuse 1 FU for continuity. If the fuse is blown, check for the fault.

WARNING

Care must be exercised during any trouble shooting checks and/or adjustments because of the electrical hazards that are present when the electrical panel box is open.

The operation of the control circuits may be checked without the use of line voltage. For testing purposes, an auxiliary source of 110 volts A.C. can be used to operate the system.

A. Remove wire leading from 1 FU to X1 on control power transformer.

B. Identify "Neutral" and "HOT" leads from auxiliary power source.

C. Connect "HOT" side to 1 FU where previous wire was removed.

D. Connect "Neutral" side to X3 or ground lug.

The control system can now be checked without the dangers of high line voltage.

2. If "power on" light (1 L n is lit and starter button is depressed, check the voltage across the hour meter terminals (T85) and (T88). If full control voltage exists across the hour meter, the trouble is in the motor starter. If full voltage does not exist across the hour meter, check the protective control circuit from (TB1) to (T85) for an open temperature switch, an open overload relay, an open "stop" push button or a defective control module (ACM).

24

COMPRESSOR FAILS TO DELIVER RATED CAPACITY

A fouled inlet air-filter will reduce the actual weight flow of air which will show up as reduced capacity of the compressor. The filter erement should be changed when the Pressure Drop Indicator shows operation in the RED area. (See Figure 20).

COMPRESSOR WILL NOT BUILD UP RATED PRESSURE

The air demand may be too high. Check for plant air leaks or open service valves.

The pressure switch (1 PS) may be set too low. Check the pressure setting when the unit is operating in "Normal", and the On line-Off line control mode. If the pressure setting is increased, it must not be set higher than the upper set point pressure listed on the compressor Data Plate.

A faulty adjustment of the capacity regulation system could cause modulation of capacity at incorrect pressures.

COMPRESSOR OVERTEMPERA· TURE SHUTDOWN

Insufficient lubricant being circulated.

Check lubricant level in receiver sump.

Insufficient cooling of lubricant. Insufficient cooling can be caused by fouled coolers, usually external fouling on air cooled units, and tubeside fouling on water cooled units.

Operating air cooled units in excessively high ambient air. Insufficient ventilation could be a cause.

Overtemperature can result if the thermal control valve becomes defective. This would show up if the injection temperatures are higher than normal.

Operating above rated discharge pressure can cause overtemperature. It also shortens motor insulation life because of the overload the motor must carry.

SAFETY SHUTDOWN CHECKS

HIGH AIR TEMPERATURE

•

There is a High Air Discharge Temperature shutdown switch furnished on each compressor. It is located at the discharge housing of the compressor. This switch should be checked at regular intervals; about once a month is recommended. Check by:

1. Cover the Air Intake around the coolers with cardboard on the air cooled unit.

2. The discharge temperature will rise at a fairly rapid rate. Shutdown should occur at about 230°F. (110°C.).

The temperature at which the shutdown occurs should be recorded for comparison with similar future test results.

•.. - ..

"

•

EXCESSIVE LUBRICANT CONSUMPTION:

EXCESSIVE LINE CURRENT

•

A ruptured or fouled separator element or a blocked scavenge orifice-screen-assembly will increase lubricant consumption. The orifice-screen-assembly should be checked regularly.

An increase in pressure differential across the separator is the indication of a fouled separator.

A decrease of pressure differential from the previous reading would indicate a ruptured separator.

Differential pressure should be noted and recorded. It should be taken when the compressor is operating at rated capacity and pressure.

If shutdown occurs because of electrical overload, a trip indicator projects from an opening in the lower portion of the relay.

Overload relays can trip if line voltage is excessively low. This condition causes the motor to draw higher current. Unbalanced electrical phase can contribute to this problem.

Operating at pressures above the rated pressure will cause higher motor currents.

All starter contacts must be in good condition. The contacts can be inspected by removing the arc box from the front of the starter.

r=-

~

f

!

r· .....

r

I,: -

I

Figure 16

•

WATER CARRYOVER TO DISCHARGE LINES

A fouled or defective condensate trap that does not drain condensate will allow the condensate to be carried to the plant system. The trap operation must be checked regularly.

Condensate should flow whenever the aftercooler lowers the discharge air temperature below the dew point. Under atmospheric conditions of very low humidity, it is possible that no water vapor is condensed and therefore there will be no flow from the condensate trap.

The use of an open funnel in the drain line has been recommended to make a visual inspection easier.

The condensate trap Figure 16, located next to the air-moisture separator, must be primed before you start up the unit. Remove the plug located on the trap cover. Fill the trap with water; replace the plug.

25

OPTIONAL ACCESSORIES

1. Optional accessories can provide for such things as automatic starting and stopping of the compressor - desirable ir. a plant where the air demand varies widely.

2. The optional motor starting control system includes a Star-Delta type starter (and a Star-Delta motor) which brings the motor up to rated speed without causing excessive electric current draw. Provision is made to allow the compressor to remain unloaded during the starting and warm-up phase.

3. The compressor capacity can be governed by the modulate control option. By panel selection of the control mode, the compressor can operate "On-Off Line", with modulation. The compressor will operate to maintain discharge line pressure at or slightly above the rated pressure.

4. The SSR-1000 unit is available with air storage capability in a

tank mounted configuration.

5. Optional enclosures are available when protection of the unit is necessary or desired. Examples are damage by: impact, corrosion, dirt, leaking, splashing processes or condensation causing problems.

SECTION I OPTIONS

•

Figure 17 Typical SSR-1000 Tank Mounted Unit

_ .. __ .o--'-.--,." ..• _.,.,><~( .~ .• - __

Figure 18·A Typical

Low Sound Enclosed Unit

26

.. :.:~:~~--- ....... '--

.... "" ....

"">, __ --

••

Figure 18 Typical SSR·1000 Standard Enclosed Unit

•

•

MAINTENANCE

GENERAL

The SSR-1000 Compressor requires a minimum of rnaintenance. The major concerns are the air cleanliness, the quality of the lubricant and the lubrication of the electric motors. Over relatively long periods of time, other system accessories will require replacement; items such as the air separator element.

The procedures to follow when servicing the compressor or replacing major accessories are described in the following paragraphs.

SECTION II MAINTENANCE

CHANGING LUBRICANT FILTER ELEMENT

Time of Change-after first 150 hours and every 2000 hours thereafter, or when the filter indicator shows the need for element change, or when the lubricant is being changed.

CAUTION

Hoses should be checked every three months for signs of deterioration. Hairline cracks and hardening are two signs to look for; replace hoses as required, A service life of two to four years is normal.

AIR FILTER ELEMENT

Time of Change-when the panelmounted lamp comes on and or the filter indicator located on the air inlet housing shows RED.

Filter elements should be changed once a year even with no indication.

Before starting any maintenance be certain the following is heeded.

Confirm all pressure is relieved from the compressor system and that the main electric disconnect switch is open and tagged to remain open.

WARNING

27

LUBRICANT CHANGE TIMEAFTER EVERY 8000 HOURS OR ANNUALLY (SSR·COOLANT)

PROCEDURE AND COMMENTS

1. There is a lubricant drainage point on each compressor. It is located on the bottom of the separator tank.

WARNING

No drainage points should be opened until the compressor has been isolated electrically and all air pressure has been relieved from the system.

2. A hand operated transfer pump, connected to the drain valve will be a convenient way to remove the used lubricant.

3. The lubricant should be drained soon after the compressor has been shut down. When the lubrlcant is hot, the drainage will be more complete and any particles in suspension in the lubricant will be carried out with the lubricant.

WARNING

Extreme care should be exercised when draining the hot lubricant so that no possibility of injury to personnel exists.

4. After the unit is drained and a new filter element is installed, close the drain valve and refill the system with fresh lubricant.

RECOMMENDED LUBRICANT

CAPACITY

3 Gal. (11.6 Liters)

Bring the receiver level of lubricant up to the midpoint of the gauge glass. Replace the fill plug.

28

5. Start the compressor and run it for a short while. Shut it down and check the lubricant level in the receiver. Add enough lubricant to bring the level back to the gauge midpoint. Replace the fill plug.

•

LUBRICANT SEPARATOR ELEMENT

The separator element must be replaced when the differential exceeds three times the initial dlfferential as recorded on a new unit or replacement element, or, at a maximum of 15 psig (1.0 BAR), whichever occurs first. The unit must be fully loaded and at its rated pressure when the differential is measured.

••••••

.'

•

. '

.'

•

DRIVE MOTOR LUBRICATION The induction-type squirrel cage motor have anti-friction ball or roller bearings front and rear. At extended intervals they require retubrlcatlon.

The periods between re-greasings of the motor bearings can vary, primari Iy with the severity of the service conditions under which the motor operates, As a general rule the following would apply:

SERVICE CONDITION
OUTDOORS INDOORS
DIRTY CLEAN
ABRASIVE DRY
CORROSIVE INDUSTRIAL
2000 HOURS 4000 HOURS
(OR) (OR)
3-4 MONTHS 6 MONTHS IMPORTANT

A major cause of motor bearing failure is overgreasing. The quantity of grease added should be carefully controlled. The smaller motors must be greased with a lesser amount of grease than the large motors.

WARNING

Grease should only be added when the motor is stopped and power disconnected .

Inlet grease gun fittings and spring-loaded outlets are arranged at each end on the motor housing.

Use a hand lever type grease gun. Determine in advance the quantity of grease delivered with each stroke of the lever. Add grease in the following quantities:

Procedure for Relubrication

When regreasing, stop motor, remove inlet and outlet plugs, and add amount of grease per reference table with hand lever gun only, Do not expect grease to appear at the outlet, but if it does, discontinue' greasing at once. Run for about ten minutes before replacing outlet plug. Certain TEFC motors have a spring relief outlet fitting on the fan end, if the outlet plug is not accessible at surface of hood, it is the spring relief type and need not be removed when regreasing.

RECOMMENDED UNIT OF MEASURE:

Model SSR-1000 - % cu. in. or 0.2 oz .

Recommended Motor Greases (or equals)

Chevron SRI Standard Oil of

California

Premium RB Texaco

Unirex N2 Exxon

Dolium R Shell

Rykon Premium American Oil

Figure M1

29

TO REPLACE THE H.A.T.S, HIGH AIR TEMPERATURE SWITCH

Disconnect the two wires that connect the H.A.T. switch electrically to the terminal strips within the starter box. Note wire location prior to disconnection. See Figure M1a.

Loosen the conduit fitting on the conduit adjacent to the H.A.T. switch. Gently pull the wires out of the conduit. See Figures M1b and M1c.

30

•

Figure M1a

\

.. .•

. ' .

Figure M1b

III 'I ;!. : ! II i i r-'''";7 ,"' I !

I I

•

. __ --_

Figure M1c

•

•'_

.. :"!.

•

Use a suitable wrench and remove the faulty switch. Catch any drainage that may come from the port. Install new "0" ring on replacement switch and install in port. Do not over-tighten as this may alter switch setting. Install conduit fitting on replacement switch. Place the wires back into the protective conduit. Tighten the conduit into the fitting. See Figure M1d_

Connect switch wire in proper terminal strip location as noted earlier. See Figure M1a.

Start unit and check for leaks. Determine that switch functions properly by restricting the air flow across the coolers to cause a rise in discharge temperature. The unit should shut down on the HATS at 220·F. - 230·F. (104 ·C. - no·c.) as indicated on the instrument panel discharge temperature gauge.

Figure M1d

31

TO REPLACE ELECTRicAL COMPONENTS IN INSTRUMENT PANEL

Remove screws that secure panel face to housing.

Note location of wires and position of component. Draw sketch if required.

Disconnect appropriate wires.

Loosen or disengage component retainers. Remove component and discard.

Install replacement device. Connect wires as recorded earlier.

Replace panel. Put unit in service. See Figure M2.

Figure M2

TO REPLACE PRESSURE SWITCH (1 PS), TO ADJUST (1 PS), AND ADJUST MODULATION.

Note location of the three wires connected to the switch. Disconnect wires. Disconnect

the air pressure signal line and remove the fitting from the switch. Retain the fitting. See Figure M3a.

32

Figure M3a

•

•

Remove the screws that hold the switch to the back of the starter box. Discard the faulty switch. Install new switch by placing back in position and tighten the two retaining screws. Install wires in positions noted earlier. See Figure M3b.

Inspect the indicator on the side of the switch assembly and preadjust the switch to a pressure level considerably lower than the rated pressure of the unit. Use the pointer and scale on the switch as a guide. To determine rated pressure- Refer to unit Data Plate. See Figures M4a and M4b.

To adjust 1 PS, proceed' as follows:

a. Open the isolation valve at the unit to allow the regulation to sense the line pressure, Failure to do so may cause the regulation to be erratic and difficult to set accurately.

b. Place the rocker type switches (RS·1) and the optional (RS·2) in the "Unload" and "On/Off Line" position, See Figure M5a,

c. Start the compressor. Place the Untoad/Normal rocker switch in the "Normal" position. The compressor should load if the line pressure is lower than the lower reset point of 1 PS,

••

•

Figure M4b

Figure M3b

Figure M4a

Figure M5a

33

d. Allow the line pressure to rise to the upper trip point of 1 PS as indicated by the Chart below.

60 HZ 50 HZ
Model .. L" Compressor 103 PSIG 7.2 BAR
Model .. H" Compressor 128 PSIG 8.7 BAR
: Model .. H H" Compressor 150 PSIG 10.0 BAR WARNING

Care must be exercised during any trouble shooting checks and or adjustments because of the electrical hazards that are present.

e. Adjust as required. Specific adjustment in· structions are shown on the switch cover.

t. When 1 PS opens, the compressor should unload and vent the Receiver/Separator tank. When the line pressure falls to the reset poi nt of 1 PS (about 12 psig). the unit should reload. The pressure switch reset differential is adjustable and factory set at about 12 psig to meet the requirements of the average application.

Limited receiver and line storage may reo quire a wider reset differential. Sufficient receiver and I ine storage can accept a narrower reset differential. If adjustment is reo quired, turn the differential adjustment clockwise to narrow the differential and counter clockwise to widen the differential. See Figure M5b.

g. It will be necessary to bleed a slight amount of air from the air line system to cycle the control system to insure that the switch repeats.

h. Replace switch cover and put unit in ser· vice. See Figure M5c.

34

:,.. •

.-

Figure MSb

•

Figure MSc

•

•

•

•

TO ADJUST MODULATION CONTROL

Open the isolation valve at the unit to allow the regulation to sense the line pressure. Failure to do so may cause the regulation to be erratic and difficult to set accurately.

Place the rocker type switch (RS-1) and the optional (RS-2) in the "Unload" and "On/Off Line" positions. See Figure M5d.

Remove the small plug and connect a pressure gauge to the fitting provided in the inlet control valve modulator. See Figures M5e and M5f.

Figure MSd

Figure MSe

.I

\

Figure MSf

35

Loosen lock-nut "A". Turn adjusting screw "8" counter clockwise 3 full turns. See Figure M5g.

Start the compressor. Place the "Normal! Unload" (RS-1) rocker switch in the "Normal" position. The compressor should load if the line pressure is lower than the lower reset point of 1 PS. Allow the line pressure to rise to the rated pressure level as shown in chart, page 34.

While maintaining rated pressure, set adjustment screw "8" until the signal pressure reaches 25 psig (1.7 BAR) as indicated by the test gauge installed earlier. See Figures M5h and M5i.

Tighten lock-nut "A" to complete adjustment.

36

•

Figure MSg

•

Figure M5h

•

Figure M5i

•

•

,.

•

TO CHANGE OIL FILTER ELEMENT

Use a suitable device and loosen the old element. Use drain pan to catch any leakage during removal. Discard old element. See Figure M7a.

Wipe the sealing surface of the filter with a clean, lint-free rag to prevent the entry of dirt into the system. See Figure M7b.

Remove the replacement element from its protective package. Apply a small amount of clean lubricant on the rubber seal and install element.

Screw element on until the seal makes contact with the head of the filter assembly. Tighten approximately one-quarter turn additional.

Start unit and check for leaks.

Figure M7a

Figure M7b

37

TO CHANGE TEMPERATURE CONTROL VALVE ELEMENTS

Remove tubing on valve that is connected from "C" Port to the cooler. Use a suitable pan to catch any leakage. See Figure M8a. Remove the four bolts that retain the cover of the valve to the main body.

Remove the element after noting its position. Inspect and replace as required. See Figure M8b.

Inspect the "0" rings (3 each) for hardness or damage. Replace as required. See Figure M8c.

Install replacement element in correct posltion. Replace the cover plate and tighten the retainer bolts.

Install tubing, start unit and check for leaks. Load unit and check for proper discharge temperature control.

Figure M8a

Figure M8b

Figure Mac

38

•

••••••••

. .

. ,.~,

•

•

•

•

TO CHANGE INLET AIR FILTER ELEMENT

Loosen wing nut on top of inlet filter housing. Lift cover up and away to expose element. See Figure M9a.

Carefully remove the old element to prevent dirt from entering the inlet valve. Discard old element.

Thoroughly clean the element housing and wipe all surfaces. See Figure M9b.

Install new element and inspect to insure that it has seated properly.

Install top of inlet filter housing.

Inspect the rubber seal on the retainer wing nut and replace seal if required.

Tighten wing nut. Reset inlet filter indicator if required.

Place unit in service.

Figure M9a

':-";--: . ~,' __ ._

~ .it .. " "1iI!!!I~

Figure M9b

39

TO CLEAN SCAVENGE ORIFICE SCREEN

Disconnect tubing at each end of screen assembly. See Figure M10a.

Remove the screen housing from the orifice block. Check orifice and clean if required. Use suitable screwdriver and remove screen retainer from its housing. Wash screen and housing in safety solvent and blow dry. See Figure M10b.

He-assemble the screen into the housing using care not to overtighten the screen retainer.

Assemble the orifice and screen to the tubing lines. Be certain the screen is on the upstream side of the orifice. See Figure M10c.

Place unit back in service.

40

•

Figure M10a

•

Figure M10b

I

~ SCREEN

"L;!\7 ~ROM

TA .. ~OVER

•

Figure M10c

TO REPLACE THE SEPARATOR ELEMENT

•

Disconnect the scavenge screen assembly after carefully noting the position of the screen and orifice in the line. See Figure M11a.

Loosen the fitting that holds the scavenge tube into the tank and withdraw the tube assembly. See Figure M11 b.

Disconnect the two control air lines after noting their original connection points. Tag the lines if required. See Figure M11c.

.-

•

Figure M11a

Figure M11b

Figure M11 c

41

Use a suitable wrench and remove the bolts that hold the tank cover in position. Remove cover by lifting up and away. See Figure M11f.

Carefully lift the separator element up and out of the tank. Discard the faulty element. See Figure M11g.

Clean the gasket surface on both the tank and its cover. Exercise care to prevent pieces of the old gasket from falling down into the tank. See Figure M11 h.

Check the tank to be absolutely certain that no foreign objects such as rags or tools have been allowed to fall into the tank. Install replacement element down into the tank after checking the new element gaskets for possible damage. Center the element up within the tank.

Figure M11g

42

•

Figure M11f

e-

Figure M11h

•

•

•

•

Place the tank cover in its correct position and install bolts. Tighten the bolts in a crosspattern to prevent over-tightening one side of the cover. An improperly tightened cover will likely result in a leak. See Figure M11 i.

Install scavenge tube down into the tank until the tube just touches the separator element. Tighten the fitting. Install the scavenge orifice assembly after noting the position of the screen and orifice. Remember: The screen is upstream of the orifice.

Install .the main air line that connects the tank cover to the minimum pressure valve.

Install the regulation lines in their original position.

Start unit, check for leaks, place in service.

Figure M11i

43

TO REPLACE DISCHARGE AIR TEMPERATURE GAUGE

Remove the screws that hold the panel face in position. See Figure M12.

Remove the screws holding the gauge to the panel face.

Loosen the retainer nut that holds the temperature sensing bulb into the tank.

Use suitable container to collect drainage as you remove the sensing bulb from tank. Remove bulb.

Pull gauge and capilliary tube through panel face.

Install replacement gauge through panel and install bulb in tank. Use care to prevent damage to the capilliary tube.

Secure capilliary tube, tighten gauge in panel face, install panel, tighten sensing bulb in tank.

Start unit, check for leaks. Place unit in service.

'/

.'

.,

Figure M12

44

•

•

•

•

•

REPLACEMENT OF CONTROL VOLTAGE TRANSFORMER

Determine and record on paper the exact wire location on transformer. Use the schematic on transformer as a guide.

Disconnect wires and loosen screws holding transformer in position.

Install replacement transformer and connect wires as recorded earlier.

Check all connections for proper tightness. Place unit in service. See Figure M13.

. -- __

DANGER'l

WARNING

Care must be exercised during any trouble shooting checks and or adjustments because of the electrical hazards that are present when the electrical panel box is open.

Figure M13

45

REPLACEMENT OF CONTACTS IN CONTACTOR ASSEMBLY

NOTE: Replace all contacts as a set. Remove the two screws that hold the contact cover in position. Remove cover. See Figure M14a.

Remove the screws that hold the stationary contacts in position. Remove contacts and replace. See Figure M14b.

Carefully observe how the moving contacts are held in position by a spring. See Figure M14c. Remove the contacts and replace as a set.

Assemble cover back in position.

,',

J

" _j

• ·1

'!

Figure M14b

46

•

Figure M14a

Figure M14c

.'

•

.-

•

~-~~ ----~-------

REPLACEMENT OF CONTACTOR HOLDING COIL

Remove the two screws that hold the cover in position. Set cover aside. See Figure M15a.

Disconnect the wires connected to the holding coil. See Figure M15b.

Figure M15a

Figure M15b

47

Remove the screws that hold the main contact assembly in position. Lift assembly away to expose the holding coil. See Figures M15c and M15d.

Pull coil gently towards you to disengage the locating pins. Replace the coil. See Figure M15e.

Reassemble contactor in reverse order of teardown.

Figure M1Sc

Figure M15d

Figure M1Se

48

•

•

•

••••

•

REPLACEMENT OF HEATER ELEMENT IN OVERLOAD RELAY

Remove the two screws that hold each heater element in position.

Pull each heater gently toward you to remove. Discard old heater.

Observe the relieved areas on the corner of the replacement elements. Align these areas so that they match the guides on the overload relay.

Put replacement element into proper position and install screws. See Figure M16.

Figure M16

49

ADJUSTMENT OF OVERLOAD RELAY TRIP SETTING

NOTE: This relay has a range adjustment of 85% to 115% of the nominal setting of the heater element.

On the lower side of the over-current relay can be found a small dial with the numbers 85-100-115. This indicates the variance in percent from the nominal setting of the heater element. See Figure M17a.

To adjust, rotate the dial in the direction desired until the number selected is in alignment with the painter. See Figure M17b.

50

Figure M17a

\

v .'. ,~ ....... ~ ".

,Al.,

".>:!~;ilC·-

·l~~

Figure M17b

•

•

•

REPLACEMENT OF THE AUXILIARY CONTACT ASSEMBLY

Locate auxiliary contact on main contactor assembly.

Disconnect the wires after carefully noting their position. Draw a sketch if required.

Use a suitable device to depress the small retainer spring on the front of the auxiliary contact. Lift the contact up and out of its position.

Install new contact.

Connect wires in positions as noted earlier. See Figure M18.

Figure M18

REPLACEMENT OF CONTROL VOLTAGE FUSE

Use suitable fuse puller to remove faulty fuse from snap type fuse holder.

Check metal clips for adequate tension. Install replacement fuse by pushing fuse slowly and evenly into position. See Figure M19.

Figure M19

51

INTRODUCTION GENERAL

This manual, which contains an illustrated parts breakdown, has been prepared as an aid in identifying and ordering parts in the SSR-l000 compressor. All of the compressor parts, listed in the parts breakdown, are manufactured with the same precision as the original equipment.

lnqersoll-Hand Company service facilities and parts are available worldwide. There are Ingersoll-Rand Company Branch Offices and authorized distributors located in the principal cities of the United States. In Canada, our customers are serviced by the Canadian Ingersoll-Rand Company, Limited. There are also Ingersoll-Rand Company subsidiaries and authorized distributors located in the principal cities throughout the world.

DESCRIPTION

The illustrated parts breakdown illustrates the various assemblies. subassemblies and detailed parts which make up this particular SSR-1000 compressor. A series of illustrations show each part clearly and in its correct location relative to the other parts in the illustration. Each part on an illustration is referenced with a number. The number. description and quantity needed per assembly is listed in numerical order on the following

pages.

RECOMMENDED SPARE PARTS

A selection of spare parts have been prepared as insurance against prolonqed shutdown periods. These parts are shown itemized in the rear of this publication. The contents of the list gives the part name, part number. the quantity of parts used on the compressor and the recommended quantity to keep on hand so as to provide maximum protection for a compressor with a minimum number of parts. The recommended quantity to keep on hand is broken down into three

SECTION III PARTS LIST

classes. The Class I recommendation is for installations that have a local distributor. The Class II recommendation is for installations that have a nearby distributor. The Class III recommendations is for installations where the distributor is remote.

OPTIONAL EQUIPMENT

Several optional accessory items are available for convenience or special application. These accessories have

been selected as being particularly suitable for use on the SSR-1000 compressor.

For complete details on Optional Equipment, contact your Sales Representative.

HOW TO USE THIS PARTS MANUAL

1. Refer to the Index and find the Section pertaining to the system of the compressor. in which the desired part is used.

2. Turn to the Section and refer to the Table of Contents to locate the desired illustrations.

3. Locate the part on the illustration by visual identification and the reference number.

4. Find the referenced number on the following Tabulated page.

HOW TO ORDER PARTS

In order that all avoidable errors be eliminated when ordering parts, please specify the following:

1. The model number of the unit as shown ori the Compressor Data Plate.

• 2. The serial number of the unit as shown on the Compressor Data Plate.

*0300

U 81 A S

MANUFACTURED IN U.S. J I YEAR OF MANUFACTURE _j

REVISION LEVEL ---------'

DESIGNATION FOR SPECIAL UNITS

52

3_ The form number of this manual.

4. The reference number, part number, description and quantity needed exactly as listed.

• *5. The motor data code shown on the motor data plate.

•

CAUTION

The use of repair parts other than those included within the Ingersoll-Rand Company approved parts list may create hazardous conditions over which the Ingersoll-Rand Company has no control. Such hazardous conditions can lead to accidents that may be life threatening, cause substantial bodily injury, or result in damage to the equipment. Therefore, Ingersoll-Rand Company can bear no responsibility for equipment in which non-approved repair parts are installed.

••

.'

•

C INGERSOlLilAND

•

9

ILLUSTRATION 1 (PARTS)

Item
No. Part No. Qty. Description
1. 39105739 Valve, Ball (Under Tank)
2. 39422944 Valve, Thermostatic
Oil Control
3. 39105911 Valve, Check
4. 39726328 Filter,
Lubricant-Complete
5. 39125828 Kit Element
6. 39124847 Valve, Minimum Pressure
7. 39125562 Valve, Solenoid (SV4 Oil
Shut·Off)
8. 39726286 Element, Separator
9. 39124698 Safety Valve
(100H, 2.3H, 3.0H)
9A. 39111356 Safety Valve
(4.3L, 125L, 150L, 3.0L)
9B. 39124896 Safety Valve
(2.3L, 100L)
9C. 35254952 Safety Valve
(4.3H. 125H, 150H)
90. 39124888 Safety Valve
• (2.3HH, 3.0HH, 100HH)
9E. 39121256 Safety Valve (125HH) 4,5

3

2

53

--::--.~-,. .

54

8

6,7

5

4

•

~

- ~-':_'r, "",_ .

~~_~_'-L_

Ir .__~=-\:~==

~

I. r--

I~

t

f

II

••

1,1A

2

3

ILLUSTRATION 2 (PARTS)

Item No.

Part No.

Qty. Description

1. 1A. 2. 3. 4. 5. 6. 7. 8. 9.

10.

39416128 39419668 39416144 39124755 39125547 39124722 39120563 35271865 39016712

1 High Air Temp. Switch

1 High Air Temp. Switch

1 Separator Moisture

1 Trap, Moisture Element, Air Cleaner Indicator, Air Cleaner Screen, Scavenge Orifice

Valve, Inlet

Motor

Gear Set

'INCLUDE MOTOR DATA CODE WHEN RE·ORDERING.

•

•

8

9

3

4, 5

50 HZ ONLY

2

7

1A

18

6

•'':''

-c.

I ILLUSTRATION 3 (PARTS)
:j
1
"
"
Item
No. Part No. Qty. Description
1. 39126883 Light, Yellow 60 HZ
1A. 39127311 Light, Yellow 50 HZ
1 B. 39427067 Vacuum Switch Sending
Unit (50 HZ Units Only)
(Not Shown)
2. 39126891 1 Light, White
3. 39125745 2 Switch
4. 39407150 1 Hourmeter (50 Hz Only)
5. 39406608 1 Hourmeter (60 Hz Only)
6. 39127014 1 Button, Stop
7. 39115910 1 Button, Start
8. 39513544 1 Gauge, Air Pressure
9. 39513536 1 Gauge, Discharge Temp.
• 55

5

8

4

2

1

3

ILLUSTRATION 4 (PARTS) •
Item
No. Part No. aty. Description
1. 39124839 2·Way Solenoid Valve
(2SV) . Optional
2. 39124748 1 3·Way Solenoid Valve (1SV)
3. 35275767 1 Valve. Check
4. 39127261 2 Shuttte-Valve 1 Each Optional
5. 39127279 1 2·Way Solenoid Valve
(3SV)
6. 39100029 Pressure Switch (1 PS)
7. 39124250 Pressure Regulator·
Optional
8. 35116540 Silencer •

56

•

••

4

7

8

1,2

3

5

6

9,10,11,12

ILLUSTRATION 5 (PARTS)

SIZE 1 and 2 STAR·DELTA STARTER

(ITEMS 1 - 8 ARE COMMON FOR ALL STAR·DELTA STARTERS)

Item No.

Part No. Oty.

Description

1. 2. 3. 4. 5. 6. 7. 8.

39108204 1

39113535 1

39111448 1

39127204 1

39729280 1

39729272 1

39111323 1

39129036 1

Fuse Block

Fuse 2 AMP (1 FU) Control Transformer (T) Terminal Block

Time Delay Relay (HR) Automatic Control Module Power Terminal Block

Modular Overload Relay (50 Hertz Only)

SIZE 2 STAR·DELTA

SIZE 1 STAR·DELTA

Item
No. Part No.
9. 39134419
10. 39134200
11. 39134192
12. 39115126
13. 39134101
• 14. 39134200
15. 39134192
16. 39109244
17. 39114509 Oty.

Item
Description No. Part No. Oty. Description
Contactor Size 1 (1 M) 9. 39114418 Contactor Size 2 (1 M)
Coil 10. 39114525. Coil
Contacts· 3 Pole 11. 39114541 Contacts· 3 Pole
Interlock Switch 12. 39115126 Interlock Switch
(N.O.-N.O.) (N.O.-N.O.)
Star-Delta Contactor 13. 39114426 Star-Delta Contactor
Assy. (lS/2M) Assy. (lS/2M)
Coil 14. 39114525 2 Coil
Contacts· 3 Pole 15. 39114541 2 Contacts- 3 Pole
Interlock Switch 16. 39109244 2 Interlock Switch
(N.O.-N.O.) (N.O.-N.O.)
Overload Relay (10l) 17. 39118203 Overload Relay (10l)
(60 Hertz Only) (60 Hertz Only)
57
---- 2 2 2

4

5

•

•••

.

ILLUSTRATION 6 (PARTS)

SIZES 2, 3 & 4 FULL VOLTAGE STARTER

(ITEMS 1 - 5 ARE COMMON FOR ALL FULL VOLTAGE STARTERS)

Description

Item
No. Part No. aty. Description
1. 39108204 Fuse Block
2. 39113535 Fuse 2 AMP (1FU)
3. 39111448 Control Transformer (T)
4. 39127204 Terminal Block
5. 39111323 Power Terminal Block (SIZE 2 FULL VOLTAGE)

Item
No. Part No. aty.
(SIZE 3 FULL VOLTAGE)
7. 39114434
8. 39114533
9. 39114558
10. 39115126
11. 39114517
(SIZE 4 FULL VOLTAGE)
7. 39114442
8. 39114533
9. 39114566
10. 39115126
11. 39121264 7. 39121157 Starter-Size 2 (1 M)
8. 39114525 Coil
9. 39114541 Contacts· 3 Pole
10. 39115126 Interlock Switch
(N.O.-N.O.)
11. 39118203 Overload Relay (SIZE 2 FULL VOLTAGE W/S/3 O.L)

7. 8. 9.

10.

39114418 39114525 39114541 39115126

Contactor (1 M) Coil

r:ontacts . 3 Pole Interlock Switch (N.O.-N.O.)

Overload Relay (10L)

11.

39114517

58

Starter· Size 3 (1 M) Coil

Contacts· 3 Pole Interlock Switch (N.O.-N.O.)

Overload Relay (10L)

Starter - Size 4 (1 M) Coil

Contact - 3 Pole Interlock Switch (N.O.-N.O.)

Overload Relay (10L)

•

•

••••

•

SECTION IV RECOMMENDED SPARE PARTS LIST

HOW TO SELECT RECOMMENDED SPARES

These sheets list spare parts by class:

CLASS I - Recommended where downtime is acceptable.

CLASS II - Recommended where limited downtime is acceptable.

CLASS III - Recommended where any downtime is highly undesirable .

CAUTION

The use of repair parts other than those included within the Ingersoll-Rand Company approved parts list may create hazardous conditions over which the lnqersoll-Rand Company has no control. Such hazardous conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, or result in damage to the equipment. Therefore, Ingersoll-Rand Cornpany can bear no responsibility for equipment in which non-approved repair parts are installed .

59

SPARE PARTS
RECOMMENDED QUANTITY.
QTY. LOCATION KEPT ON HAND
PART PER OR AT INSTALLATION
COMPRESSOR PART NO. UNIT USE CLASS 1 CLASS 2 CLASS 3
Air Cleaner Element 39125547 1 At Air End Inlet 2 3 4
Coolant Filter 39125828 .1 In Coolant Filter 4 4 5
Separator Element 39726286 In Separator Tank 0 0 1
Safety Valve 39124698 1 On Separator Tank 0 0
(100H, 2.3H, 3.0H)
Safety Valve 39111356 1 On Separator Tank 0 0 1
(4.3l, 125l, 150l, 3.0l)
Safety Valve 39124896 On Separator Tank 0 0
(2.3l, 100l)
Safety Valve 35254952 On Separator Tank 0 0
(4.3H, 125H, 150H)
Safety Valve 39124888 On Separator Tank 0 0
(2.3HH, 3.0HH, 100HH)
Safety Valve 39121256 On Separator Tank 0 0
(125HH, 150HH)
Thermostatic Control 39422506 In Thermostatic Control 0 0 0
Valve Element Valve
Thermostatic Control 39422944 1 0 0 1 .:.
Valve "."
Minimum Pressure Valve 39124847 Tank Discharge Line 0 0 1
Shuttle Valve 39127261 2 Behind Control Box 0 0
Inline Check Valve 35275767 Gear Case Vent 0 0 0
Disch Check Valve 39105911 Air End Discharge to 0 0 1
Sep Tank
Solenoid Valve 39125562 In Coolant Filter Line 0 2
(SV4)
Blowdown Valve 39127279 Behind Control Box (SV3) 0 0 0
Blowdown Repair Kit 39137492 For Blowdown Valve 0 2
2-Way Solenoid Valve 39124839 Behind Control Box (SV2) 0 2
3-Way Solenoid Valve 39124748 Behind Control Box (SV1) 0 1
ForSV3
Temp Gauge 39513544 On Control Panel 0 2
Pressure Gauge 39513536 On Control Panel 0
Hourmeter 60 HZ 39406608 On Control Panel 0 0
Hourmeter 5.0 HZ 39407150 On Control Panel 0 0
Start Button 39115910 On Control Panel 0 0
Stop Buttom 39127014 1 On Control Panel 0 0
Normal/Unload Switch 39125745 1 Behind Control Box 0 0 ••
Pressure Switch 39100029 On Airend 0 60

SPARE PARTS (CONTINUED)
• RECOMMENDED QUANTITY
QTY. LOCATION KEPT ON HAND
PART PER OR AT INSTALLATION
COMPRESSOR PART NO. UNIT USE CLASS 1 CLASS 2 CLASS 3
High Temp Switch 39416128 On Separator Tank 1 2
Air Cleaner Indicator 39124722 1 Below Air Cleaner 0 0 1
Scavenge Screen 39120563 Tank Cover 0 0
Coolant (5 Gal. Container) 39118294 Fi II 3 Ga1./11.6 Liters 0 2
Transformer Fuse 39113535 1 In All Starters (2AMP) 1 2
Coil 39114525 3 In Size No.2 Contactor 0 3
Coil 39114533 3 In Size NO.3 & 4 Contactor 0 3
Contact Kit (3 Poles) 39114541 In Size No.2 Contactor 0 3
Contact Kit (3 Poles) 39114558 In Size NO.3 Contactor 0 1 3
1 Contact Kit (3 Poles) 39114566 In Size NO.4 Contactor 0 3
, Star Delta Timer-
:~ 39729280 In Star-Delta Starter (HR) 2
Star-Delta Only
.1
~ Automatic Control 39022546 (Optional) In Starter Box 2TR 0 0 1
.~
~ Module Field Kit
$:
" Modulate Control Kit 39022538 0 0 1
c
"
.,
i •... Overhaul Gasket Set 39134804 1 2
. . .. : . , Shaft Sleeve 39402235 For 150H & L- 0 0 1
200, 230, 460 & 575
125HH-200, 230 & 460
Shaft Sleeve 39422340 All Other Units 0 0 1
Fan (14") 39130265 On Airend Fan Drive Shaft 0 0 0
Fan (17") 39124268 On Airend Fan Drive Shaft 0 0 0
Fan Bushings 39130281 On Airend Fan Drive Shaft 0 0
14" & 17" •

61

NOTES

•

....

••

62

NOTES

•

•

63

NOTES

•

•

64

•

j

•.. ~.~

..

~ .<

•

•

e·

•