Ingersoll-Rand R30 - User Manual

80447162
Revision B
June 2014
Save These Instructions
Contact-Cooled Rotary Screw Air Compressor
R30, R37, R45, R55, R75, R90, R110, R132, R160
Product Information
Information produit
FR
Información del producto
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Product Information
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Informações do produto
PT
93014.15.06
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Summary

About This Manual

Product Manuals Table

Lists product manuals and their part numbers by region.

Compressor Safety Guidelines

General Safety Precautions

Follow all instructions, warnings, and labels for safe operation.

Transportation and Handling Procedures

Transportation and Securing

Ensure the machine is secured against movement during transport.

Receipt and Inspection

Inspect for damage and missing parts before signing receipt.

Unpacking and Handling

Remove protective covers carefully, use designated lifting points.

Long Term Storage

Procedures for storing the product if not commissioned within six months.

Installation Overview

Location in Plant Requirements

Install in a level, dry, well-ventilated area free of contaminants.

Discharge and Condensate Piping

Guidelines for discharge piping, filters, and condensate drainage.

Electrical Installation Requirements

Primary Input Power Supply

Information on power supply configurations like Wye and Delta.

Grounding Procedures

How to properly ground the compressor according to electrical codes.

VSD Specific Electrical Requirements

Cable sizing, connections, and rotation checks for VSD compressors.

Identify Electrical System Type

Grounded Wye and Ungrounded Delta Networks

Explains how to identify system types and voltage indications.

High Voltage and Protection

Measures for protecting against very high voltage conditions.

Power Factor Compensation

Guidelines for connecting compressors with compensation capacitors.

EMC Filter and Grounding Procedures

Disconnecting EMC Filters

Procedures for disconnecting EMC filters in specific electrical systems.

Power Source Considerations

Guidelines for using dedicated transformers or generators.

Control Power Transformer Connections

Instructions for setting control circuit transformer voltage taps.

Water-Cooled Compressor Piping and Venting

Cooling Water Piping Installation

Requirements for water piping size, isolation valves, and strainers.

Venting the Water System

Procedures for venting air from fresh and harsh water cooling systems.

Draining the Water System

Steps for completely draining both fresh and harsh water cooling systems.

Water Quality Recommendations

Guidelines for water quality to ensure effective heat transfer and system life.

Cooling Water Constituent Limits

Acceptable Limits Table

Table of acceptable maximum limits for cooling water constituents.

Compressor Environmental Operating Limits

Standard Operating Conditions

Conditions for standard package design (indoors, dust, temp).

Extended Environmental Options

Options for outdoor use, low/high ambient conditions, and dust filters.

General Compressor Information

Compressor Description and Operation

Description of electric motor, contact cooled screw compressor, and auto restart.

Fixed Speed Compressor Notes

Notes regarding fixed speed compressors and inverter duty conversion.

Integrated Dryer Operation

Information on the integrated dryer's cycling and energy-efficient modes.

Variable Speed Drive (VSD) Operating Instructions

Basic Operation and Startup

Checking coolant, isolation valve, and initial check sequence.

Start and Stop Sequences

Procedures for starting, stopping, and emergency stopping the compressor.

Warm Up and Blower Control

Details on warm-up mode and how blower speed is controlled.

XE-90 M Controller Interface and Controls

User Interface Components

Description of membrane, LCD display, command keys, and LED icons.

Navigation Key Functions

Explanation of how to use the UP, DOWN, LEFT, RIGHT keys for navigation.

Display Layout Elements

Description of the display layout components: Folder Bar, Title Bar, Page Content, Dashboard.

Controller Navigation and Parameter Access

Folder Navigation and Icons

How to move between folders and understand folder icons.

Page Navigation within Folders

How to select and navigate through pages within a folder.

Accessing and Modifying Parameters

Steps for selecting, changing, and confirming parameter values.

Controller Data Displays: Counters and Analog Inputs

Counter Data Overview

Explanation of Run Hours, Hour Meters, and Starts.

Analog Input Data

Details on displayed analog inputs like pressure and temperature.

Operator Settings and Sensor Calibration

Operator Options Configuration

Configuration of options like auto-restart, remote control, and scheduling.

Sensor Calibration Procedure

Steps for calibrating sensors when the compressor is stopped.

Warning Events and Service Notifications

Common Warning Events

Details on warnings like Inlet Filter, Coolant Filter, and Sensor Failure.

Service Warnings and Levels

Explanation of service warnings, levels, and reset procedures.

Trip Events and History Logging

Trip Events List and Descriptions

List and explanation of various trip events like High Discharge Press, Overload.

Trip History Functionality

How to navigate and view recorded trip history entries.

Maintenance Folder: Filter and Status Checks

Filter Status Display

Displays the status of filters, indicating if they need changing.

Maintenance Status and Configuration

Setting service intervals and resetting maintenance counters.

General Settings: Units, Home Page, and Time;Date

Units of Measure Settings

Selectable units for temperature, pressure, and power.

Home Page Selection

Configuring the display to return to a selected Home Page after inactivity.

Time and Date Settings

Setting the current time, date, and date format.

Backlight and Ethernet Network Configuration

Backlight Settings

Adjusting backlight brightness and auto-off delay time.

Ethernet Settings Configuration

Configuring IP address, gateway, and DHCP for network connection.

Digital Inputs and Outputs Status

Digital Input Status Interpretation

How to interpret the status of digital inputs (OPEN/CLOSED).

Digital Output Status Interpretation

How to interpret the status of digital outputs (OPEN/CLOSED).

Factory Settings and Password Management

Factory Settings Folder Access

Accessing parameters specific to compressor setup and software info.

Password Entry and Timeout

Setting and managing passwords for protected parameters.

Factory Settings for Compressor Configuration

Compressor Type and Options

Selecting compressor type, PAC, dryer, and modulation options.

Software Information Display

Displays software versions and names for the controller.

Compressor Configuration and Operator Settings

Operator Settings: Pressure and Savings

Setting target pressure, auto stop, and savings comparison.

Operator Options Configuration

Configuring COM control, remote start/stop, PORO, and scheduled operations.

Operator Options and Sensor Calibration

Operator Options Details

Details on options like PORO, scheduled start/stop, and low ambient temperature.

Sensor Calibration Procedure

Steps to calibrate sensors when the compressor is stopped.

Warning Events List and Descriptions

Specific Warning Event Details

Explanations for warnings like High Airend Discharge Temp, High Sump Pressure.

Service Warning Logic

How service warnings are triggered and reset based on service levels.

Trip Events and Fault Handling

Emergency Stop and VSD Faults

Procedures for Emergency Stop and troubleshooting VSD faults.

Common Trip Event Causes

Explanations for trips like Low Sump Pressure, Check Motor Rotation, and VSD errors.

Trip History and Maintenance Status

Trip History Log Navigation

How to navigate and view recorded trip history entries.

Maintenance Status and Configuration

Setting service intervals and resetting maintenance counters.

General Settings: Language, Time, Date, and Backlight

Language and Units Selection

Selecting language and units of measure for the controller display.

Time and Date Configuration

Setting the controller's time, date, and date format.

Backlight and Ethernet Network Configuration

Backlight Brightness Control

Adjusting the display's backlight brightness and auto-off delay.

Ethernet Settings Configuration

Configuring IP address, gateway, and DHCP for network connection.

Compressor Data, Digital Inputs, and Outputs

Compressor Data Overview

Displays energy savings, capacity, power, hours, and motor speed.

Digital Input Status

Interpreting the status of digital inputs like Emergency Stop and Overload.

Digital Output Status

Interpreting the status of digital outputs like Starter Contacts and Solenoids.

Analog Outputs and Factory Settings Management

Analog Output Values

Displays analog output values in mA for VSD blower and other outputs.

Factory Password Protection

Accessing and securing factory-specific parameters with a password.

VSD Diagnostics and Service Menus

Software Information Display

Displays controller software versions and names for the controller.

Maximum Values Recording and Reset

Recording and resetting highest seen values for motor speed, current, etc.

VSD Diagnostics and Service Menus

Screens for troubleshooting drive problems and setting up VSD for optimal operation.

XE-70 M Controller Operating Instructions

XE-70 M Controller Interface

Description of the controller's membrane, display, LEDs, and command keys.

Navigation Key Functions

How to use the navigation keys (UP, DOWN, LEFT, RIGHT) to move through menus.

XE-70 M Display Layout

Explains the display layout components: Folder Bar, Title Bar, Page Content, Dashboard.

Controller Menu Navigation and Dashboard Status

Folder Navigation and Icons

How to navigate between folders using LEFT and RIGHT keys.

Dashboard Icons and Definitions

Definitions for dashboard icons indicating system status.

Dashboard Status Message Interpretation

Explains various compressor operating states shown on the dashboard.

Fixed Speed Compressor: System Overview and Data

Fixed Speed System Overview

Description of the factory default display after powering up the system.

Fixed Speed Counters and Analog Inputs

Details on counter data and analog inputs for fixed speed models.

Fixed Speed Operator Settings and Options

Operator Settings: Pressure and Timing

Setting online pressure, offline pressure, and startup times.

Operator Options: Control and Scheduling

Configuring COM control, remote start/stop, PORO, and scheduled operations.

Sensor Calibration and Event Logging

Sensor Calibration Procedure

Steps to calibrate sensors when the machine is stopped and pressure is zero.

Events Folder Content

How events are documented, time-stamped, and displayed in the Events folder.

Warning Events List and Descriptions

Specific Warning Event Details

Explanations for warnings like Sensor Failure, High Sump Pressure, Dryer Temp.

Service Warning Logic

How service warnings are triggered and reset based on service levels for Xe-70M.

Trip Events and Fault Handling

Trip Event Descriptions

Explanations for trips like Overload, Sensor Failure, Emergency Stop, High Sump Pressure.

Start Inhibit Conditions

Lists conditions that prevent the compressor from starting.

Maintenance and General Settings Configuration

Filter Status Check

Displays the status of filters, indicating if they need changing.

Maintenance Configuration

Setting service intervals and resetting maintenance counters.

Language and Units Selection

Selecting display language and units of measure for the controller.

Network Communication and Integral Sequencing

Serial Port Address Settings

Setting addresses for RS-485 and Modbus networks.

Ethernet Settings (ECO Module)

Configuring IP address, gateway, and DHCP for ECO module.

Integral Sequencing Setup

Configuring compressors for networked operation to maintain system pressure.

Integral Sequencing and Analog Input Monitoring

Integral Sequencing Parameters

Setting parameters like unload pressure, load pressure, and compressor priority.

Status Folder: Analog Inputs

Displays readings for Package Discharge Pressure, Sump Pressure, and Temperatures.

Digital Inputs and Outputs Status

Digital Input Status Details

Explains the meaning of OPEN/CLOSED states for digital inputs.

Digital Output Status Details

Explains the meaning of OPEN/CLOSED states for digital outputs.

Factory Settings and Password Management

Factory Settings Folder Access

Accessing and securing factory-specific parameters with a password.

Password Protection

Setting and managing passwords for protected parameters.

Factory Settings and Compressor Options

Factory Settings for Compressor Type

Setting compressor type, rated pressure, and enabling features like PAC and Dryer.

Factory Options and Adjustments

Enabling VSD blower, limiting blower speed, and adjusting running/loaded hours.

Variable Speed Compressor: System Overview and Settings

Variable Speed System Overview

Description of the factory default display for VSD models.

Variable Speed Counters

Details on counter data like Power On, Running, and Loaded hours for VSD.

Variable Speed Operator Settings

Setting target pressure, auto stop, and immediate stop pressures for VSD.

Operator Options and Sensor Calibration for VSD

Operator Options for VSD

Configuring COM Control, Remote Start/Stop, PORO, and scheduled operations for VSD.

Sensor Calibration Procedure

Steps to calibrate sensors when the machine is stopped and pressure is zero.

Xe-70 M Events and Warning Details

Xe-70 M Events Folder Content

How events are documented, time-stamped, and displayed for Xe-70M.

Xe-70 M Specific Warning Events

Explanations for warnings like Change Separator Element, High Discharge Press, Dryer Temp.

Xe-70 M Service Warning Logic

How service warnings are triggered and reset based on service levels for Xe-70M.

Xe-70 M Fault and Trip Event Handling

Xe-70 M Trip Event Descriptions

Explanations for trips like Overload, Sensor Failure, Emergency Stop, High Sump Pressure.

Xe-70 M VSD Faults and Communication Errors

Troubleshooting VSD faults, communication failures, and initialization errors.

Trip History and Maintenance Status

Trip History Log Navigation

How to navigate and view recorded trip history entries.

Maintenance Folder: Filter Status

Displays the status of filters, indicating if they need changing.

Maintenance Configuration

Setting service intervals and resetting maintenance counters.

Language and Units Selection

Selecting display language and units of measure for the controller.

Controller Settings and Network Configuration

Time and Date Settings

Setting the current time, date, and date format.

Backlight Brightness Control

Adjusting the display's backlight brightness and auto-off delay.

Serial Port Address Configuration

Setting addresses for RS-485 and Modbus networks.

Ethernet Settings (ECO Module)

Configuring IP address, gateway, and DHCP for ECO module.

Integral Sequencing Setup

Configuring compressors for networked operation to maintain system pressure.

Integral Sequencing and Analog Input Monitoring

Integral Sequencing Parameters

Setting parameters like unload pressure, load pressure, and compressor priority.

Status Folder: Analog Inputs

Displays readings for Package Discharge Pressure, Sump Pressure, and Temperatures.

Compressor Data, Digital Inputs, and Outputs

Compressor Data Details

Displays Power ON Hours, Running Hours, Motor Speed, and Package kW.

Digital Input Status Interpretation

Explains the meaning of OPEN/CLOSED states for digital inputs.

Digital Output Status Interpretation

Explains the meaning of OPEN/CLOSED states for digital outputs.

Analog Outputs and Factory Settings Management

Analog Output Values

Displays analog output values in mA for VSD blower and other outputs.

Factory Password Protection

Accessing and securing factory-specific parameters with a password.

VSD Diagnostics and Service Menus

Maximum Values Recording and Reset

Recording and resetting highest seen values for motor speed, current, etc.

VSD Diagnostics and Service Menus

Screens for troubleshooting drive problems and setting up VSD for optimal operation.

Software Information Display

Displays controller software versions and names for the controller.

Modbus Network Connection and Configuration

Connecting to the Modbus Network

Instructions for connecting the controller to a Modbus RTU network via RS-485.

Modbus Address Selection

Setting the unique Modbus address for each compressor on the network.

RS-485 Network Considerations

Guidelines for routing RS-485 cables to avoid electrical interference.

Modbus Master Settings

Recommended settings for Baud Rate, Stop Bits, Parity, and polling parameters.

R4 to 37 kW Fixed Speed Modbus Table

Modbus Register Definitions

Table listing registers, variables, read/write status, and notes.

Fixed Speed Controller Register Codes and Alarms

Status;Control Register Bits

Explanation of bits within the Status/Control register.

Starter Type and Mode of Operation Codes

Codes for starter types and operating modes.

Trip & Warning Codes

List of codes corresponding to trip and warning events.

R5.5 to 37 kW Variable Speed Modbus Table

VSD Modbus Register Definitions

Table listing registers, variables, read/write status, and notes for VSD.

Variable Speed Controller Register Codes

VSD Status;Control Register Bits

Explanation of bits within the VSD Status/Control register.

VSD Compressor Type and Day Codes

Codes for compressor types and days of the week.

Variable Speed Controller Alarm & Warning Codes

VSD Alarm and Warning Codes

Comprehensive list of alarm and warning codes for VSD controllers.

X-Series System Controls Connection and Configuration

Connecting to X-Series Network

Instructions for connecting the controller to an X-Series network via RS-485.

Enabling System Control Capabilities

Steps to enable COM control and Auto-Restart for system controller integration.

RS-485 Address Selection for X-Series

Setting the RS-485 address for each compressor in an X-Series network.

Notices and Disclaimers

EC Mark and Directives Compliance

Information on EC Mark compliance and prohibited modifications.

Manual Content and Product Information

Manual is proprietary, warranty terms are standard, no implied warranties.

Compressor Warranty Information

Warranty Period and Coverage

Details the warranty period and coverage for defects in material and workmanship.

Warranty Limitations and Exclusions

Excludes corrosion, erosion, normal wear, and labor costs without approval.

Ingersoll-Rand R30 Specifications

General

Model	R30
Type	Reciprocating
Horsepower	3 HP
Max Pressure	175 PSI
Voltage	230V
Maximum Pressure	175 psi
Drive Type	Belt Drive
Phase	Single