Ingersoll-Rand Nirvana SGNe V2.5 User manual

Nirvana SGNe V2.5

Troubleshooting Guide

Rev 1.0; May 2009

SGNe

Troubleshooting Guide

SGNe Troubleshooting Guide Page 1

Revision 1.0; Davidson, May 2009. ©Ingersoll Rand Proprietary Information

Proprietary Notices and Disclaimer

PROPRIETARY NOTICES

CONFIDENTIAL AND TRADE SECRET INFORMATION. This manual contains confidential and trade

secret information owned by Ingersoll-Rand Company (hereinafter referred to as "Proprietary Matter"). In

consideration of the disclosure of the Proprietary Matter herein to the authorized recipient hereof, the

recipient shall treat the Proprietary Matter as secret and confidential; shall not disclose or give such

Proprietary Matter to third parties without the express written authorization of INGERSOLL RAND; shall

not use the Proprietary Matter except to the extent necessary to use or service the equipment disclosed

herein; and shall disclose such Proprietary Matter only to those of its employees whose use or

knowledge of the Proprietary Matter is necessary. This manual shall be returned upon request by

Ingersoll Rand Company. The unauthorized use of this manual may be punishable by law.

DISCLAIMERS

PROVIDED "AS IS". THIS MANUAL AND THE CONTENTS THEREOF ARE PROVIDED "AS IS"

AND WITHOUT ANY IMPLIED WARRANTIES.

SGNe Troubleshooting Guide Page 3

Revision 1.0; Davidson, May 2009. ©Ingersoll Rand Proprietary Information

SGNe

Troubleshooting Guide

Danger

Please utilize extreme caution when performing work within the compressor cabinet.

When opening the cabinet: be certain to wear appropriate PPE (Personal Protective Equipment),

follow lock out-tag out procedures, and ensure all safety procedures are followed.

Compressed air and electricity can be dangerous. Before undertaking any work on the

compressor, ensure that the electrical supply has been isolated and the compressor

has been relieved of all pressure. Use proper Lock Out Tag Out procedures to ensure

you and your coworkers safety.

Keep all parts of the body and any hand-held tools or other conductive objects, away

from exposed live parts of the compressor electrical system. Maintain dry footing,

stand on insulating surfaces and do not contact any other portion of the compressor

when making adjustments or repairs to exposed live parts of the compressor electrical

system. Close and lock all access doors when the compressor is left unattended.

Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use

only extinguishers suitable for class BC or class ABC fires. Attempt repairs only in

clean, dry, well lighted and ventilated areas. Connect the compressor only to electrical

systems that are compatible with its electrical characteristics and that are within it’s

rated capacity.

WARNING

Imposing a normal or emergency stop on the compressor will only relieve pressure up-

stream of the minimum pressure valve on top of the separator tank. If maintenance

work is required downstream of this valve, ensure that all pressure is relieved at the

process vent point external to the compressor.

This state is advised by selecting PACKAGE DISCHARGE PRESSURE on the control

panel.

Caution!!!

SGNe Troubleshooting Guide Page 4

Revision 1.0; Davidson, May 2009. ©Ingersoll Rand Proprietary Information

SGNe

Troubleshooting Guide

Danger

Please utilize extreme caution when performing work within the compressor cabinet.

When opening the cabinet: be certain to wear appropriate PPE (Personal Protective Equipment),

follow lock out-tag out procedures, and ensure all safety procedures are followed.

Current Status Messages

While the compressor has power (started or stopped), a current status screen will be

displayed by the controller. This current status screen will be considered the “normal”

display that the controller shows.

% Energy Savings

This displays the percent of energy saved by a Nirvana compressor, as compared to a

comparable fixed speed compressor that is operating in one of three modes.

% Capacity

Displays the compressor’s current percent capacity. This value will be determined by

the actual speed vs. the maximum speed.

Package kW

Displays the compressor’s kilowatt usage. This value includes the blower’s kW usage.

Package Discharge Temp

Displays the reading from temperature sensor 4ATT. There is no logic associated with

the package discharge temperature.

Airend Discharge Temp

Displaysthereadingfromtemperaturesensor2ATT

Injected Coolant Temp

Displays the reading from temperature sensor 2CTT.

Sump Pressure

Displays the reading from pressure sensor 3APT.

Separator Pressure Drop

Displays the value of the pressure drop across the separator. This value is determined

by subtracting the dry side sump pressure from the wet side sump pressure.

SGNe Troubleshooting Guide Page 5

Revision 1.0; Davidson, May 2009. ©Ingersoll Rand Proprietary Information

SGNe

Troubleshooting Guide

Danger

Please utilize extreme caution when performing work within the compressor cabinet.

When opening the cabinet: be certain to wear appropriate PPE (Personal Protective Equipment),

follow lock out-tag out procedures, and ensure all safety procedures are followed.

Coolant Filter

Displays the status of the coolant filter.

This status is determined by a coolant filter switch, that is read by the controller.

Inlet Filter

Displays the status of the inlet filter as determined by the air filter delta-p switch.

Total Hours

Displays the total running hours.

Motor Speed

This value is read from the variable speed drive controller and displayed.

Remote Pressure

If the compressor has the remote pressure sensor option, this value is read from the

variable speed drive controller and displayed.

If the compressor doesn’t have the remote pressure sensor option, Not Installed will

bedisplayed.

Time & Date

Displays the current time and date.

Program Name

Displays the program name, version number, and software part number.

VSD

Displays the version number of the drive software.

Factory Set Points

The factory set point sequence is accessed with the hidden function button sequence

of Main Menu, followed by upper middle, then F2, and then F1.

The sequence contains the following settings:

Language

The language selections are:

English, Spanish, Portuguese, French, Italian, German,

Dutch, Danish,Norwegian, Swedish, Finnish, Turkish, Lithuanian, Latvian, Estonian,

Maltese, Slovenian, Slovakian,Czech, Hungarian, and Polish.

SGNe Troubleshooting Guide Page 6

Revision 1.0; Davidson, May 2009. ©Ingersoll Rand Proprietary Information

SGNe

Troubleshooting Guide

Danger

Please utilize extreme caution when performing work within the compressor cabinet.

When opening the cabinet: be certain to wear appropriate PPE (Personal Protective Equipment),

follow lock out-tag out procedures, and ensure all safety procedures are followed.

Units of Measure

The units of measure selections are PSI & Deg F, PSI & Deg C, BAR & Deg C, kPa &

Deg C, and KGCM2 & Deg C.

Whenever the units of measure are changed, the Intellisys will transmit a new

target pressure to the VSD. Along with the target pressure, the Intellisys will also

transmit new minimum and maximum speeds to the VSD. The minimum and

maximum speed is determined from a table, based on the compressor model

and the target pressure.

Compressor Type

The type of compressor will be selected here. The choices are listed below.

Compressor Type and Target Pressure will be used to determine the

compressor’s maximum speed once the speed curves have been generated.

Whenever the compressor type is changed, the Intellisys will transmit new

minimum and maximum speeds to the VSD. The minimum and maximum

speed is determined from a table, based on the compressor model and the

target pressure.

Single Stage 2-Stage, Low Pressure 2-Stage, High Pressure

37 kW/50 HP 1-S 75 kW/100 HP 2-S 90 kW 2-S

45 kW/60 HP 1-S 90 kW 2-S 125 HP 2-S

55 kW/75 HP 1-S 125 HP 2-S 110 kW 2-S

75kW/100HP 1-S 110 kW 2-S 150 HP 2-S

90 kW 1-S 150 HP 2-S 132 kW 2-S

125 HP 1-S 132 kW 2-S 200 HP 2-S

110 kW 1-S 200 HP 2-S 160 kW 2-S

150 HP 1-S 160 kW 2-S

132 kW 1-S 250 HP 2-S

200 HP 1-S 200 kW 2-S

160kW 1-S 300 HP 2-S

250 kW 2-S

SGNe Troubleshooting Guide Page 7

Revision 1.0; Davidson, May 2009. ©Ingersoll Rand Proprietary Information

SGNe

Troubleshooting Guide

Danger

Please utilize extreme caution when performing work within the compressor cabinet.

When opening the cabinet: be certain to wear appropriate PPE (Personal Protective Equipment),

follow lock out-tag out procedures, and ensure all safety procedures are followed.

Water Cooled

This set point is used to select the type of cooling. The selection is water cooled On or

Off. A selection of Off will mean the unit is air cooled.

Hot Side Thermal Valve

This should only be set to on if the compressor is equipped with a hot side thermal

valve. If this is set to On, the Intellisys will focus on CTD when determining the blower

speed. If this is set to Off, the Intellisys will focus on anti-condensation when determin-

ing the blower speed. Hot side thermal valve operation also requires the cooler out

temperature sensor (4CTT). The default value for this set point is On unless

the unit is a 50 HP, 60 HP, or Viper-N. For these units the default value is Off.

Total Hours

The total hours selection is used to adjust the total operating hours display.

Service Level

This set point is used to select a service level of 1 or 2 for maintenance warnings.

Service Interval Type

This set point is used to select hours or months for measuring the service interval.

This set point is not used if the service level is 1. Service warnings occur when the

unit has operated a certain number of hours, based on the total hours, or has

operated for a certain number of months, based on the real time clock. Service

warnings can have multiple levels, depending on the service level selection.

Service Interval

This set point is used to select the number of months for measuring the service inter-

val. The selections are 3, 6, 9, or 12 months. This set point is not used if the service

level is 1 or the service interval type is hours.

Service Complete

This set point is used to indicate to the controller that service has been completed.

This set point is not used if the service level is 1.

Service Menu

This set point is used by IR service to gain access to a set of service set points, the

field interface, and the direct read from the VSD function. IR service will enter a code

number to gain access to these items. An incorrect code will send the user back to the

current status display.

SGNe Troubleshooting Guide Page 8

Revision 1.0; Davidson, May 2009. ©Ingersoll Rand Proprietary Information

SGNe

Troubleshooting Guide

Danger

Please utilize extreme caution when performing work within the compressor cabinet.

When opening the cabinet: be certain to wear appropriate PPE (Personal Protective Equipment),

follow lock out-tag out procedures, and ensure all safety procedures are followed.

Operator Set Points

The operator set point screen contains the name and value of each user-adjustable set

point. These points shall be adjustable without stopping the compressor. The following

set points can be seen on this screen by moving the list up and down with the arrow

buttons.

Target Pressure

The compressor will try to operate at this pressure setting. The target pressure ranges

and step sizes for each unit of measure are listed in the table below. The maximum

pressure range is shown for single and two stage units.

OPERATOR SETPOINTS Default MIN. MAX. STEP UNIT

Immediate Stop Pressure 120 Auto Auto+10 1 1 psi

Condensate Release 5 2 20 1 sec

Condensate Interval 180 90 270 1 sec

Service Menu 1 1 25535 1 —-

% Savings Compared To Modulation —- —- —- —-

Automatic Stop Pressure 110 Target+1 Target+10 1 psi

Target Pressure 100 65 145/203 1 psi

Blowdown Mode Off Off On --- ---

Reset Averaging Blank —- —- —- date

Energy Rate 0.000 0.000 9999.999 —- —-

Unit Min Max (1S/2S) Step

PSI 65 145/203 1

BAR 4.4 10/14 0.1

kPa 4401000/1400 10

KGCM2 4.5 10.2/14. 0.1

SGNe Troubleshooting Guide Page 9

Revision 1.0; Davidson, May 2009. ©Ingersoll Rand Proprietary Information

SGNe

Troubleshooting Guide

Danger

Please utilize extreme caution when performing work within the compressor cabinet.

When opening the cabinet: be certain to wear appropriate PPE (Personal Protective Equipment),

follow lock out-tag out procedures, and ensure all safety procedures are followed.

Automatic Stop Pressure

The compressor will stop once the system pressure rises to this pressure and the

compressor is operating at the minimum speed. The range for this set point will be the

target pressure+1 to target pressure+10 psi if the target pressure is 145 psi or less, to

target pressure+7 psi if the target pressure is greater than 145, but less than or equal

to 175 psi, or to target pressure+5 psi if the target pressure is greater than 175 psi.

Immediate Stop Pressure

The compressor will stop if the system pressure rises to this pressure. The range for

this set point will be the automatic stop pressure to automatic stop pressure+10 psi if

the target pressure is 145 psi or less, to automatic stop pressure+7 psi if the target

pressure is greater than 145, but less than or equal to 175 psi, or to automatic stop

pressure + 5 psi if the target pressure is greater than 175 psi.

Blowdown Mode

If this mode is selected to “ON”, the compressor will de-energize the blowdown sole-

noid anytime that it stops. This will keep the compressor from staying pressurized

when it is stopped. If this mode is selected to “OFF”, the blowdown solenoid will stay

energized when the compressor stops due to an auto stop or an immediate stop. This

set point is only used in single stage compressors. If the compressor is a 2 stage unit,

blowdown mode will be listed as not installed and the compressor will always blow-

down when it stops. Blowdown mode cannot be set to On in 2 stage compressors.

Condensate Release

This is the number of seconds that the condensate solenoid will be open (energized)

when blowing out the condensation

Condensate Interval

This is the time interval between condensation blow downs.

% Savings Compared To

This set point is to determine what Nirvana’s percent of savings is compared to.

The modes of operation for comparing Nirvana to are modulation, online/offline,

and geometry.

The percent savings value is displayed by the status message, % energy savings.

Energy Rate

This set point is used to enter the cost per kilowatt hour into the Intellisys. This value

is used for calculating energy cost and energy savings in the energy status menu.

SGNe Troubleshooting Guide Page 10

Revision 1.0; Davidson, May 2009. ©Ingersoll Rand Proprietary Information

SGNe

Troubleshooting Guide

Danger

Please utilize extreme caution when performing work within the compressor cabinet.

When opening the cabinet: be certain to wear appropriate PPE (Personal Protective Equipment),

follow lock out-tag out procedures, and ensure all safety procedures are followed.

Reset Averaging

This set point is to reset the time period that the energy status information will be

calculated over. When this set point has been selected and set, the date that is

was last set will be displayed.

Options

The options screen is similar to the operator set point screen in terms of step

intervals and units. However, the range section allows the operator to turn the

options “ON” or “OFF”. The following are the names and values of each option.

They are viewed by moving up and down with the arrow buttons.

If an option has not been purchased and installed in the unit, the message “Not

Installed” will be shown on the selection display screen. Installation of options

will be done using the IR service tool.

OPTION ITEMS SELECTION MIN. MAX. STEP UNIT Installed

Option

Required

Remote Sensor ON/OFF --- --- --- --- No

Sequencer ON/OFF --- --- --- --- No

Remote Start/Stop ON/OFF --- --- --- --- No

Power Out Restart ON/OFF --- --- --- --- Yes

Power Out Restart Time --- 10 600 1 sec Yes

Scheduled Start Day --- Day Day 1 day Yes

Scheduled Start --- 00:00 23:59 1 time Yes

Scheduled Stop Day --- Day Day 1 day Yes

Scheduled Stop --- 00:00 23:59 1 time Yes

Modbus Protocol ON/OFF/ICU --- --- --- --- No

Modbus Address --- 1 247 1 --- No

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