This Information For : SL, SM & SH 90, 110, 132, 150, 200, 250 &300 (50Hz) L, H & HH 125,

150,
200, 250, 300, 350 & 400 (60Hz)

GENERAL OPERATION

The Sierra compressor is an electric motor driven, two stage, dry screw compressor complete with accessories
piped, wired and baseplate mounted. It is a totally self–contained oil free air compressor package .A standard
compressor is composed of the following:

 . Inlet air filtration

and second stage. The motor and airend are integrally mounted. This assembly is isolated from the base by rubber
isolation mounts. Flexible pipe connections are utilised where necessary to isolate the main base and customer
connections.

DESIGN PRESSURES

The normal operating pressures for Ingersoll–Rand Sierra compressors are 7,0 bar, 8,5 bar and 10,0 bar
(100psi,125psi & 150psi). The maximum allowable pressure is 0,2 bar (3psi) above the normal operating pressure
and is shown on the compressor name plate. The inter–stage safety valve is set at 3,1 barg (45psi) 90–150kW,
125–200HP or 3,8 barg (55psi) 200–300kW, 250–400HP. The second stage safety valve is set at 11,4 barg (165psi)
max. The design of the pressurised system is well above the safety valve settings.

DESIGN TEMPERATURES

The standard compressor is designed for operation in an ambient range of 2C to 46C (35F – 115F). When
conditions other than the design levels described are encountered, we recommend you contact your nearest
Ingersoll–Rand Distributor for additional information.

COMPRESSED AIR SYSTEM

The compressor air enters the compressor through an opening at the right end of the enclosure. It ravels through a
passageway lined with sound–absorbing material to the air filter. Via a round flexible hose, the air passes through
the inlet/unloading valve into the first stage of the compressor. The helical rotors compress the air to a pressure of
between 1,7 to 2,4 barg (25 – 38psig). It is discharged into a venturi, which dampens any pressure pulsations that
may be present. The intercooler then reduces the air temperature before it enters the second stage. A safety relief
valve is also positioned in this system to guard against an abnormally high interstage pressure. A moisture
separator is supplied immediately following the intercooler to remove any condensation that may occur under
certain conditions of ambient humidity and temperature. An expansion joint is utilized between the moisture
separator and the second stage. The second stage further compresses the air to the desired pressure. The pressure
pulsations being dampened in a venturi. An expansion joint prevents transmitted vibrations. A wafer type check
valve is provided to prevent any backflow of air into the compressor. The aftercooler cools the air to a suitable
temperature, while the discharge moisture separator removes significant amounts of condensation. During
unloaded operation, the inlet/unloading valve closes, via mechanical linkage, the blowdown valve opens, expelling
any compressed air from the package.

CONDENSATE REMOVAL SYSTEM

A moisture separator is located immediately after the intercooler and aftercooler to collect and eject any
condensation formed from the compressed air. The condensate is drained through electrically operated solenoid
valves. The opening duration is preset at three (3) adjustable between 2 and 20 seconds, the interval between
openings may be altered between 60 and 360 seconds, depending on ambient conditions. If the environment
consists of high temperature and/or high humidity, then the interval may have to be reduced. The factory set
interval is 180 seconds. The bosses for the manual valves are located on the outside and rear of the sub–base These
valves are supplied loose inside the compressor enclosure and need to be connected to the ports as indicated in the
general arrangement drawing. To check operation of solenoid valves, open the manual bypass valves momentarily
once per day. For extended shutdown periods, the manual valves should be opened and left open. Strainers are
provided upstream of the condensate valves to prevent any particles from plugging the solenoid valves. Before any
maintenance is performed on the strainers or solenoid valves, the strainer service valves should be closed, in order
to isolate from possible high pressure.

LUBRICATION SYSTEM

The oil sump is integral within the gearcase. An oil strainer is located in the oil pump suction line. The oil pump is a
positive displacement gear–type pump, and is driven by the compressor driven shaft. Therefore, it rotates at the
main motor speed. See MAINTENANCE section for lubricant specification. From the pump, the oil travels past a
pressure relief valve to the oil cooler. The pressure relief valve’s function is to prevent over–pressure of the
system. It may divert some oil flow back to sump. At the discharge side of the oil cooler is a thermostatic valve. This
valve mixes the cold oil with hot oil that bypasses the cooler to provide oil at the optimum temperature to the
bearings and gears. The oil then passes through a filter to a distribution manifold. An orifice from the manifold
determines the oil pressure (2,8 – 3,5 barg) (40 – 50 psig), at normal operating temperature 54C– 68C) 129F –
154F). The gearcase is vented to a mounted breather. The breather prevents oil vapour from escaping the sump
area. The breather exhaust is piped to the plenum area of the package.

COOLING SYSTEM (AIRCOOLED)

The intercooler, aftercooler, oil cooler, fan and motor are an integral assembly. The heat exchanger and fan are
mounted directly above the compressor assembly. Cooling air flows through the end of the enclosure, through the
heat exchangers and discharges through the top of the package.

COOLING SYSTEM (WATERCOOLED)

The intercooler, aftercooler and oilcooler are shell and tube type heat exchangers. The intercooler and aftercooler
are ”water in the shell”design. the oil cooler employs ”water in the tube”. Cooling water flows through each of the
three components in parallel. A water solenoid shut off valve is provided in the water discharge line from the
package. The tube bundles are removable for ease of cleaning.

ELECTRICAL SYSTEM

The electrical system of the compressor utilises the microprocessor–based INTELLISYS controller.The standard
electrical/electronic components, contained within a readily accessible enclosure include:
 1. INTELLISYS controller
2. Star–Delta compressor motor starter, with auxiliary contacts and overload relays
3. Cooling fan manual motor starter and circuitbreaker or fuses
4. 4. Power supply board
5. 5. Main motor overload relay
6. 6. Control relay control transformers, and fuses Star–delta type starter By use of the 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 the INTELLISYS controller. Refer to the electrical schematic.

CAPACITY CONTROL

Automatic unloaded start The compressor will always start in the unload mode. When unloaded, the inlet valve is
nearly closed, the blowdown valve is open and the compressor is operating at minimum power. On–off line control
On–off line control will deliver air at full capacity (compressor maximum efficiency condition) or will operate at
zero capacity (compressor minimum power condition). The compressor is controlled by the INTELLISYS controller
responding to changes in plant air pressure. The INTELLISYS controller energises the load solenoid valve (1SV) to
actuate the hydraulic cylinder and load the compressor whenever plant air pressure drops below the on–line
pressure set point. The compressor will then operate to deliver full capacity air to the plant system. If the plant air
system pressure rises to the off line set point of the INTELLISYS, the load solenoid valve is de–energised, the
hydraulic cylinder is de–actuated allowing the machine to unload. The compressor will continue to run with
minimum power draw. If there is no demand for air, the compressor will stop in a ”standby” mode after a ”run on
time” period which is set on the controller.

AUTOMATIC START/STOP (CONTROL OPTION)

Many plant air systems have widely varying air demands or large air storage capacity which allows for automatic
standby air capacity control. The INTELLISYS system has been designed to carry out this function utilising a
software module. Automatic Start–Stop is standard on all oil free compressors. During periods of low air demand, if
the line pressure rises to the upper set point, the INTELLISYS controller begins to time out. If the line pressure
remains above the lower set point for as long as the set time, the compressor will stop. At the same time, the
Automatic Restart warning message will appear in the display to indicate the compressor has shut down
automatically and will restart automatically. An automatic restart will occur when the line pressure drops to the
lower set point. The upper and lower set points and shutdown delay time are set on the control panel. There is a 10
second delay after shutdown during which the compressor will not restart even if line air pressure drops below the
lower set point. This is to allow the motor to come to a complete stop and the controller to collect current data of
operating condition. If line air pressure is below the lower set point at the end of 10 seconds, the unit will start
unless the load delay timer is set greater than 10 seconds.

Delay load time

This is the amount of time the line pressure must remain below the online set point before the compressor will
load or start (if the unit was stopped due to an auto start/stop situation). This timer will not delay loading after a
start or if the time is set to 0. When the delay load timer becomes active, the display will switch to line pressure (if
not displaying line pressure at that time) and then display the delay load countdown. Once the countdown reaches
0, the unit will load or start and the display will return to line pressure. The display select arrows are inactive
during the delay load countdown. Automatic start/stop operation When in operation, the compressor must meet a
specific timing interval before the INTELLISYS controller will stop the unit in an Automatic Start/Stop situation. A
timer prevents the compressor from automatically starting more than 6 times an hour by requiring the unit to run
at least 10 minutes after each automatic start. This 10 minute run period can be loaded, unloaded or a combination
of the two and allows dissipation of heat generated within the motor windings at start. When the compressor has
completed the settings of the timer, the controller stops the compressor, turns on the automatic restart light and
displays AUTOMATIC RESTART in the message display. Pressure sensor 4APT continues to monitor the package
discharge pressure and sends information to the controller which automatically restarts the compressor when the
pressure falls to the on–line setting.

REMOTE LOAD / UNLOAD OPTION

This option allows the operator to remotely load and unload the machine. With the option enabled, two different
switches can be wired (refer to the electrical schematic for wiring locations). The switches are customer supplied.

General Information

Ensure that the operator reads and understands the decals and consults the manuals before aintenance or
operation. Ensure that the Operation and Maintenance manual, and the manual holder, are not removed
permanently from the machine. Ensure that maintenance personnel are adequately trained, competent and have
read the Maintenance Manuals. 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. Make sure that all protective covers are in place and that the canopy/doors are closed during operation.
The specification of this machine is such that the machine is not suitable for use in flammable gas risk
areas.Installation of this compressor must be in accordance with recognized electrical codes and any local Health
and Safety Codes. The use of plastic bowls on line filters without metal guards can be hazardous. Metal bowls
should be used on a pressurised system. Compressed air can be dangerous if incorrectly handled. Before doing any
work on the unit, ensure that all pressure is vented from the system and that the machine cannot be started
accidentally.Compressed air Ensure that the machine is operating at the rated pressure and that the rated pressure
is known to all relevant personnel. All air pressure equipment installed in or connected to the machine must have
safe working pressure ratings of at least the machine rated pressure. If more than one compressor is connected to
one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work
procedures, so that one machine cannot accidently be pressurised / over pressurised by another. Compressed air
must not be used for a direct feed to any form of breathing apparatus or mask.If the discharged air is to be
ultimately released into a confined space, adequate ventilation must be provided. When using compressed air
always use appropriate personal protective equipment. All pressure containing parts, especially flexible hoses and
their couplings, must be regularly inspected, be free from defects and be replaced according to the Manual
instructions.Compressed air can be dangerous if incorrectly handled. Before doing any work on the unit, ensure
that all pressure is vented from the system and that the machine cannot be started accidentally. Avoid bodily
contact with compressed air.