Air Compressor

Air Compressor
Name	Air Compressor
Zone	Infrastructure
Owner	i3Detroit
Make Model	Ingersoll Rand rotary screw compressor model R7.5i-TAS-135 with nodemcu (ESP-12)
Part Number	Serial Number: CBV365001
Date Acquired	2015-01-04
Storage Location	west side of machine shop, next to wood shop
Authorization Required	No
Status	Running
Value	$8000
IP Address	10.13.107.45, 10.13.107.195
MAC Address	2C:3A:E8:1D:2B:50, 5c:cf:7f:bd:72:ae
Hostname	air-compressor.i3detroit.local, infrastructure-compressor-valve
Power Requirements	240vac 3ph 30a
Documentation	File:Product Safety 80446313.PDF File:Product Information 80448483.pdf File:Product Maintenance 80448517.pdf One of the files (the parts manual) is too big to fit on the wiki, find it at [1]
Other References	https://github.com/i3detroit/custom-mqtt-programs/tree/master/air-compressor

Instructions

Turn on

1. Press green button
2. Wait for PSI reading to go above 75
3. Open valve on wall behind compressor (towards wood shop) really fast
4. Receive air

Turn Off

1. Press red button
2. Close valve on wall behind compressor (towards wood shop)
3. Stop receiving air

MQTT

• cmnd/i3/inside/machineShop/air-compressor/POWER ON/OFF/QUERY
• start/i3/inside/machineShop/air-compressor/POWER
• tele/i3/inside/machineShop/air-compressor/INFO2

Maintenance Info

• admin password: 0121

• Coolant: INGERSOLL RAND Ultra Coolant. Like 250USD/5L
• Coolant filter: INGERSOLL RAND 39329602
• Air filter: 2 16x20x1 filters

the coolant should be at this level, after running for 10 minutes

ToDo

Maintenance History

Task	Date completed	Cost	Done by	Next scheduled
Coolant and Filters checked	??-05-02	??	AGM	300 hr
Coolant Filter Changed	??-06-27	??	AGM	??
Belt	2019-11-04	??	Tom N	??
Coolant filter changed	2019-11-04	??	Tom N	12,500 hr
Air, Coolant, and Separator filters changed	2022-09-15	??	Roger S	16,000 hrs
Drained and replaced coolant	2022-09-15	??	Roger S	21,000 hrs
Replaced MPCV (23694938) and thermal valve kit and 47518605001, lost some oil and topped back up	2022-11-20	??	Mark F	?

Error Codes

per Table 5 in File:Product Maintenance 80448517.pdf

Type	Error Code	Meaning	Cause	Remedy
Warning	A:2040	Freeze Warning (Dryer Package Only)	Dryer low temperature warning.	This serves as a log that the compressor is running in low-ambient conditions
	A:2050	Dryer High Pressure (Dryer Pressure Only)	Dryer high pressure warning.	This is a locking switch and the dryer high pressure switch must be reset (contact closed) before this warning can be reset.
	A:2118	High Airend Discharge Pressure	Discharge pressure is greater than offline pressure by 1.45 psi for a period of 3 seconds or longer	Discharge pressure must fall to the rated pressure value before the unit is available for reload.
	A:2128	High Airend Discharge Temperature (above 105°C)	Compressor operating above rated pressure.	Check and modify settings. Review system requirements and contact your local Ingersoll Rand representative.
			Low coolant level.	Check for leaks. See also if discharge air is contaminated with coolant. Top off coolant.
			High ambient temperature.	Review installation and system parameters.
			Insufficient cooling air.	Check ducting and cooling air path.
			Dirty, blocked coolant cooler (cooling air side).	Clean or replace.
			Fan motor direction of rotation incorrect.	Wire correctly.
	A:2816	Power Failure Detected	If power supply to controller is inconsistent.	Check power supply.
	A:4804	Service Due	Service interval hours counter has reduced to zero	Service compressor.
Trip	E:0010	Emergency Stop	24Vac input not being detected on terminal R1C (emergency stop button pressed)	Identify reason why, repair fault, disengage button (if pressed) and reset controller.
	E:0020	Main or Blower Motor Overload	Will occur if the fan or main motor overload relays open for three seconds. Fan is blocked, damaged or blower fan is faulty.	Remove blockage, repair or replace damaged components. So far at i3Detroit, we have been able to bypass this by opening the side panel (square panel key is in the infrastructure cabinet) and resetting FA1 breaker
	E:0115	Pressure Sensor Fault	4-20mA signal out-of-range (<3.8mA or >20.8mA)	Install, repair or replace faulty sensor.
	E:0119	High Airend Discharge Pressure	Discharge pressure is greater than offline pressure by 4.35 psi	Check and modify settings. Review system requirements and contact your local Ingersoll Rand representative.
	E:0125	Temperature Sensor Fault	Signal out of range (<-50°C or >250°C)	Install, repair or replace faulty sensor.
	E:0129	Excess Temperature	Shutdown limit exceeded	Can be reset only when airend discharge temperature is lower than 107°C.
	E:0866	Power Supply 24V DC Low	24V DC power supply to controller is low.	Check controller power supply and call your local Ingersoll Rand representative.
	E:0821	Power Supply Analog Inputs Low	Analog input power supply to controller is low.	Check controller power supply and call your local Ingersoll Rand representative.
Start Inhibit	A:3129	High Airend Discharge Temperature (above 103°C)	Airend discharge temperature above 103°C.	Abnormal operating condition which is self-clearing.
	A:3123	Run Inhibited	Temperature is below set low temperture run inhibit limit.	Will self-reset when temperature increases above the temperature limit; cannot be manually reset.
	A:3423	Load Inhibited	Temperature is below set low temperature load inhibit limit.	Will self-reset when temperature increases above the temperature limit; cannot be manually reset.

Misc Notes

Ingersoll Rand Thermal Valve Kit Replacement - 47518605001

> The thermal valve actuator sits on the inside of the manifold connected to the bottom of the cooler. This valve opens when the oil gets hot to let coolant flow through the cooler/radiator before the oil is sent back into the sump tank. Typically if your compressor is shutting down on a high temperature, the thermal valve needs to be replaced. It's common for this valve to be replaced every 2-3 years depending on run hours and operating conditions.

Exerpt from https://www.portlandcompressor.com/store/ingersoll-rand-thermal-valve-22463368

This kit contains

• Ingersoll Rand Thermal Valve 22463368
• Ingersoll Rand Thermal Valve Spring 22186696
• some housing thingy
• an o-ring

https://www.youtube.com/watch?v=nBP_SRtLpxM