EP20-25 ingersoll rand manuel

8/19/2019 EP20-25 ingersoll rand manuel

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EP/HP/HXP 20 SEEP/HP/HXP 25 SE

OPERATORS/INSTRUCTION MANUALOPTIONS

Before installation or starting the compressor for thefirst time, this manual should be studied carefully to

obtain a clear knowledge of the unit and of the dutiesto be performed while operating and maintaining theunit.

RETAIN THIS MANUAL WITH UNIT.This Technical manual contains IMPORTANT SAFETYDATA and should be kept with the air compressor at alltimes.

APDD 567A

September 1998

®


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©INGERSOLL-RAND COMPANY

AIR COMPRESSOR GROUPBONDED WARRANTY & REGISTERED START UP

WarrantyThe Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material

and workmanship for a period of twelve months (see extended airend warranty) from the date of placing the Equipmentin operation or eighteen months (see extended airend warranty) f rom the date of shipment from Davidson, NC, whichevershall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing tothe Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repairto such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installedmaintained and operated such Equipment in accordance with good industry practices and has complied with specific

recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others,shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to thePurchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costsof labor performed by the Purchaser or others without Company’s prior written approval.The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are limited

to those specifically stated within the Company’s proposal. Unless responsibility for meeting such performancewarranties are limited to specified tests, the Company’s obligation shall be to correct in the manner and for the period oftime provided above.

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.

Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of timeprovided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based oncontract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.

The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company inwriting of its intention to do so. Any such Equipment will be at Purchaser’s sole risk and liability.

Limitation or LiabilityThe remedies of the Purchaser set forth herein are exclusive, and the total liability of the Company with respect to this

contract or the Equipment and services furnished hereunder, in connection with the performance or breach thereof, orfrom the manufacture, sale, delivery, installation, repair or technical direction covered by or furnished under this contract,whether passed on contract, warranty negligence, indemnity, strict liability or otherwise, shall not exceed the purchaseprice of the unit of Equipment upon which such liability is based.The Company and its suppliers shall in no event be liable to the Purchaser, any successors in interest or any beneficiary

or assignee of this contract for any consequential, incidental, indirect, special or punitive damages arising out of thiscontract or any breach thereof, or any defect in, or failure of, or malfunction of the Equipment hereunder, whether basedupon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other goods, loss by reasonof shutdown or non-operation, increased expenses of operation, cost of purchase of replacement power or claims ofPurchaser or customers of Purchaser for service interruption whether or not such loss or damage is based on contract,warranty, negligence, indemnity, strict liability or otherwise.

EXTENDED AIREND WARRANTYThe Ingersoll-Rand Company Rotary Screw Air Compressor that has been filled

prior to its original shipment from Ingersoll-Rand Company with ULTRA

COOLANT and which has been operated solely on ULTRA COOLANT

thereafter shall have its AIREND warranted for twenty four (24) months from the

date of placing the COMPRESSOR in operation or thirty (30) months from the

date of shipment, whichever occurs first.

Except for the above warranty period, the standard warranty provisions shall

apply and the conditions outlined herein are understood to be a supplement to the

standard Ingersoll-Rand Company warranty.


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1

ROTARY SCREW AIR COMPRESSOR

This unit was purchased from:

_______________________________________________

_______________________________________________

_______________________________________________

Ingersoll-Rand Company reserves the right to make

changes or add improvements without notice and withoutincurring any obligation to make such changes or add suchimprovements to products sold previously.

Number of units on order: __________________________

Customer Order Number: __________________________

Ingersoll-Rand Company Order Number: ______________

For ready reference, record the serial number andmodel number of your unit here:

Serial Number: ___________________________________

Model Number:___________________________________

TYPICAL UNIT


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2

TABLE OF CONTENTS

5.15 motor lubrication

5.16 long term storage

5.17 coolant/lubricant changeout

5.18 intellisys removal

5.19 coolant hoses

5.20 airend discharge hose

6.0 TROUBLE SHOOTING

7.0 OPTIONS

7.1 remote start/stop

7.2 remote start/stop, PORO

7.3 sequencer control

8.0 REFERENCE DRAWINGS

8.1 electrical schematic - full voltage

8.2 electrical schematic - star-delta

8.3 electrical schematic - full voltageremote mounted starter

8.4 foundation plan - enclosed

8.5 foundation plan - unenclosed

8.6 foundation plan - outdoor modification

8.7 basic flow schematic - full voltage

8.8 basic flow schematic - full voltage with

modulation

8.9 basic flow schematic - star-delta

8.10 basic flow schematic - star-delta with

modulation

8.11 typical system flow diagrams

9.0 MAINTENANCE RECORD

GENERAL INFORMATION

Weight: See foundation plan, Section 8.0

Cooling Air Flow: See foundation plan, Section 8.0

Ambient Temperature Limit: 35°F to 115°F (2°C to 46°C)

Coolant: Factory Filled SSR Ultra Coolant

Coolant Change: 8000 hours or two years, whichever

comes first

Coolant Capacity: Tank only: 0.75 gal. (2.8 liters)

Complete System: 1.70 gal. (6.4 liters)

Discharge Temperature Limit: 228°F (109°C)

Power Inlet Wiring: Recommended conduit: metallic

flexible Greenfield, or equivalent,

Tools: U.S. Standard and metric are required

to perform maintenance

0.0 SAFETY AND WARNINGS

0.1 safety instructions

0.2 safety precautions

0.3 decals

1.0 RECEIPT OF EQUIPMENT1.1 inspection

1.2 unpacking and handling

1.3 tools

2.0 INSTALLATION

2.1 ventilation

2.2 foundation requirements

2.3 piping

2.4 electrical installation

2.5 outdoor sheltered installation

3.0 INTELLISYS3.1 emergency stop switch

3.2 power on light

3.3 power indicator light

3.4 push buttons

3.5 setpoint procedure

3.6 warnings

3.7 alarms

4.0 SYSTEMS

4.1 general systems

4.2 aircooled compressors

4.3 coolant system4.4 compressed air system

4.5 coolant/air separation system

4.6 electrical system

4.7 capacity control

5.0 MAINTENANCE

5.1 maintenance schedule

5.2 maintenance records

5.3 maintenance procedures

5.4 sheave alignment

5.5 v-belts

5.6 belt tension adjustment

5.7 shaft seal replacement

5.8 inlet air filter

5.9 coolant filter element

5.10 coolant

5.11 separator tank scavenge

check valve/orifice/screen

5.12 temperature control valve element

replacement

5.13 coolant separator element

5.14 cooler cores: cleaning


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3

0.0 SAFETY AND WARNINGS0.1 SAFETY INSTRUCTIONSBefore you install this air compressor you should take thetime to carefully read all the instructions contained in thismanual.

Electricity and compressed air have the potential to causesevere personal injury or property damage.

Before installing, wiring, starting, operating or making anyadjustments, identify the components of the aircompressor using this manual as a guide.

The operator should use common sense and goodworking practices while operating and maintaining thisunit. Follow all codes, pipe adequately, understand thestarting and stopping sequence. Check the safety devicesby following the procedure contained in this manual.

Maintenance should be done by qualified personnel,adequately equipped with proper tools. Follow themaintenance schedules as outlined in the operatorsmanual to ensure problem free operation after start up.

Safety instructions in the operators manual are bold-facedfor emphasis. The signal words DANGER, WARNING andCAUTION are used to indicate hazard seriousness levelsas follows:

Danger is used to indicate the presence of

a hazard which will cause severe personal

injury, death, or substantial property

damage if the warning is ignored.

Warning is used to indicate the presence of

a hazard which can cause severe personal

injury, death, or substantial property

damage if the warning is ignored.

Caution is used to indicate the presence of

a hazard which will or can cause minor

personal injury or property damage if the

warning is ignored.

Notice is used to notify people of

installation, operation, or maintenance

information which is important but not

hazard-related.

D! DANGER

! WARNING

! CAUTION

NOTICE

WARNING

COMPRESSED AIR AND ELECTRICITY

ARE DANGEROUS.

BEFORE DOING ANY WORK ON THIS

UNIT, BE SURE THE ELECTRICAL SUPPLY

HAS BEEN CUT OFF–LOCKED & TAGGED

AND THE ENTIRE COMPRESSOR SYSTEMHAS BEEN VENTED OF ALL PRESSURE.

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 or death.

2. The compressor has high and

dangerous voltage in the motor 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 fromthe system by use of a manual-

disconnect-switch. A circuit breaker or

fuse 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.

3. Do not operate the compressor at higher

discharge pressure than those specified

on the Compressor Nameplate or motor

overload will occur. This condition will

result in compressor motor shutdown.

4. Use only safety solvent for cleaning the

compressor and auxiliary equipment.

5. Install a manual shut off valve (isolation

type) in the discharge line. When a safety

valve is installed between the isolation

valve and the compressor, it must have

sufficient capacity to relieve the full

capacity of the compressor(s).

6. Whenever pressure is released through

the pressure relief valve, it is due to

excessive pressure in the system. The

cause for the excessive pressure should

be investigated immediately.

7. Before doing any mechanical work onthe 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.) Vent pressure from the compressor and

isolate the unit from any other source of

air.

8. There can be adverse effects if

compressor lubricants are allowed to

enter plant air systems.

Air line separators, properly selected and

installed, will minimize any liquid carry-

over.

The use of plastic bowls on line filters

without metal guards can be hazardous.

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 11, paragraph 1910.169 be adhered to

in the installation and maintenance of this

receiver.

10. Before starting the compressor, its

maintenance instructions should be

thoroughly read and understood.

11. After maintenance functions are

completed, covers and guards must be

replaced.

0.2 SAFETY PRECAUTIONS

SAFETY PRECAUTIONSBEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE

COMPRESSOR OR PERFORMING ANY MAINTENANCE


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WARNING

4

Failure to adhere to these recommendations can result in mechanical failure, property damage and serious injury or death.

All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must takeinto account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In addition,it should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility betweendischarge piping, system accessories and software must be assured.

For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is notrecommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fitthe operating parameters of the system.

It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine.

WARNING

CHECK HIGH AIR TEMPERATUREThere is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory pre-setat 228°F (109°C). This function should be checked at regular intervals for proper operation, once a month is recommended.The procedure is:

1. Block off the cooling air discharge.2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge

temperature reaches the pre-set maximum discharge air temperature setting of the Intellisys. The display shouldindicate “HIGH AIREND TEMP” and the alarm light will be illuminated.

The actual temperature at which shutdown occurs should be recorded for comparison to the Intellisys set point and withsimilar future test results.

SAFETY SHUTDOWN!

!

!

“Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll-Rand doesnot approve specialized equipment for breathing air application and assumes no responsibility or liability for compressorsused for breathing air services.”


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5

0.3 DECALS

This section contains representative examples of decals

which will be appearing throughout this manual and areapplied to the compressor unit. If for some reason a

decal is defaced, painted over, or parts are replaced, we

recommend that you obtain a replacement kit as listed in

the spare parts section of the Parts List Manual (FormAPDD 568).

WARNING!

Exposed fan blade.Can cause severeinjury.

Do not operate with covers removed.Disconnect power. Lock and tag.

INGERSOLLr AND ®

39558788

39559646

39544150

WARNING!

Exposed moving parts.Can cause severeinjury or death.

Stay clear or movingparts when machine is operating.

INGERSOLLr AND ®

WARNING!

Hazardous voltage.Can causesevere injury or death.

Disconnect power before servicing.Lockout/Tagout machine.

INGERSOLLr AND ®

39540174

CAUTION!

Incorrect lifting ofmachine can cause injuryor property damage.

Lift only from basechannels.

INGERSOLLr AND ®

NOTICE

Rotation.

INGERSOLLr AND ®

39540232


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C o n d e n s a t e d r a i n

.

N O T I C E

I N G E R S O

L L r

A

N D ®

L

i f t h e r e .

N O

T I C E

I N G E R S O

L L

r

A

N D ®

N O T I C E

M o t o r s M U S T

b e g r e a s e d

p e r i o d i c a l l y . S

e e O p e r a t o r s

M a n u a l f o r p r o

c e d u r e .

3 9 5 7 0 0 9 8

3 9 5 4 0 2 7 3

N O T I C E

F o r d e t a i l e d

r e g u l a t i o n a d j u s t m e n t

i n s t r u c t i o n s r e f e r

t o O p e r a t o r s /

I n s t r u c t i o n M a n u a l .

I N G E R S O

L L r

A

N D ®

3 9 5 4 0 2 0 8

3 9 5 4 1 0 8 1

3 9 5 7 0 0 9 8

N O T I C E

T o o b t a i n s a t i s f a c t o r y c o m p r e s s o r

o p e r a t i o n a n d m a i n t e n a n c e a

m i n i m u m o f 3 f e e t c l e a r a n c e o n 3

s i d e s i s r e q u i r e d 3 - 1 / 2 f e e t i s

r e q u i r e d i n f r o n t o f t h e c o n t r o l p a n e l

( o r m i n i m u m r e q u i r e d b y l a t e s t

N a t i o n a l E l e c t r i c a l c o d e o r a p p l i c a b l e

l o c a l c o d e s ) .

R e f e r t o t h e I n s t r u c t i o n / O p e r a t o r s

M a n u a l b e f o r e p e r f o r m i n g a n y

m a i n t e n a n c e .

I N G E R S O

L L r

A

N D ®

3 9 5 4 0 1 5 8

C o n d e n s a t e d r a i n .

N O T I C E

I N G E R S O

L L r

A

N D ®

3 9 5 4 1 0 8 1

6

D A N G E R

!

D i s c h a r g e a i r .

C a n c o n t a i n c a r b o n m o n o x i d e o r

o t h e r c o n t a m i n a

n t s . W i l l c a u s e

s e v e r e i n j u r y o r

d e a t h .

D o n o t b r e a t h e t h

i s a i r .

I N G E R S O

L L r

A

N D ®

3 9 5 5 7 2 3 6

R I G H T S I D E V I E W


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C A U T I O N

! U s e o f i n c o r r e c t c o o l a n t c a n c a u s e

s y s t e m c o n t a m i n a t i o n .

U s e o n l y S S R U L T R A C O O L A N T .

I N G E R S O

L L r

A

N D ®

3 9 5 4 0 2 6 5

E l e c t r i c a l p o w e r i n l e t .

N O T I C E

I N G E R S O

L L r

A

N D ®

3 9 5 4 0 2 4 0

3 9 5 4 4 1 5 0

N O T I C E

R o t a t i o n .

I N G E R S O

L L r

A N D ®

W A R N I N G

! H o t s u r f a c e .

C a n c a u s e s e v e r e i n j u r y .

D o n o t t o u c h . A l l o w t o c o o l b e f o r e

s e r v i c i n g .

I N G E R S O

L L r

A

N D ®

3 9 5 4 1 3 6 2

3 9 5 4 0 2 7 3

W A R N I N G

! H a z a r d o u s v o l t a g e . C a n c a u s e

s e v e r e i n j u r y o r d e a t h .

O n l y u s e f a c t o r y s u p p l i e d i n l e t f o r

i n c o m i n g p o w e r . S e e O p e r a t o r s /

I n s t r u c t i o n m a n u a l .

I N G E R S O

L L r

A

N D ®

3 9 5 4 3 7 6 4

3 9 5 4 3 9 2 1

N O T I C E

F i l l e r C a p .

U s e o n l y r e c o m m e n d e d

c o o l a n t .

R e a d i n s t r u c t i o n b o o k

b e f o r e s e r v i c i n g .

3 9 5 4 3 9 2 1

W A R N I N G

! H i g h p r e s s u r e a i r .

C a n c a u s e s e v e r e i n j u r y o r d e a t h .

R e l i e v e p r e s s u r e b e f o r e r e m o v i n g f i l t e r

p l u g s / c a p s , f i t t i n g s o r c o v e r s .

I N G E R S O

L L r

A

N D ®

3 9 5 4 1 3 5 4

L i f t h e r e .

N O T I C E

I N G E R S O

L L r

A

N D ®

L i f t h e r

e .

N O T I C E

I N G E R S O

L L r

A

N D

®

C A U T I O N

!

I M P R O P E R C O O L A N T F I L T E R R E P L A C E M E N T

W I L L C A U S E C O M P R E S S O R D A M A G E .

R E P L A C E F I L T E R E L E M E N T A F T E R F I R S T

1 5 0 H O U R S O F O P E R A T I O N ; A N D E V E R Y 1 2 0 0

H O U R S T H E R E A F T E R O R W H E N C O O L A N T I S

C H A N G E D .

I N G E R S O

L L r

A N D ®

3 9 5 4 0 2 7 3

3 9 5 5 7 2 4 4


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8

W A R N I N G

! H a z a r d o u s v o l t a g e . C a n c a u s e

s e v e r e i n j u r y o r d e a t h .

D i s c o n n e c t p o w e r b e f o r e s e r v i c i n g .

L o c k o u t / T a g o u t m a c h i n e .

I N G E R S O

L L r

A

N D ®

3 9 5 4 0 1 7 4

3 9 8 3 8 3 9 6 ( U N I T S W / F V S T A R T E

R )

3 9 8 3 8 4 1 2 ( U N I T S W / S D S T A R T E

R )

3 9 8 4 5 0 3 7 ( U N I T S W / R E M O T E F V S T A R T E R )

3 9 5 3 9 1 2 7 ( S / 2 F V )

3 9 5 3 9 1 3 5 ( S / 2 . 3 , S / 3 F V )

3 9 5 3 9 1 5 0 ( S / 4 F V )

3 9 5 6 7 6 5 6 ( S / 2 S D )

3 9 5 3 9 1 4 3 ( S / 2 . 3 , S / 3 S D )

U N I T S W / B U I L T - O N S T A R T E R

O N L Y


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9

1.0 RECEIPT OF EQUIPMENT

1.1 INSPECTION

When you receive the compressor please inspect itclosely. Any indication of careless handling by the carriershould be noted on the delivery receipt especially if the

compressor will not be immediately uncrated. Obtainingthe delivery man’s signed agreement to any noted

damages will facilitate any future insurance claims.

1.2 UNPACKING AND HANDLINGThe compressor package has been mounted on a basewhich provides for forklifting between the two side

channels to facilitate handling during shipment. Care inpositioning the forklifts is important because the location

of the center of gravity is strongly affected by the locationof the compression module and drive motor.

Slings can be used to lift the crates, but spreader barsmust be used to prevent the slings from exerting a force

against the sides of the crates.

1.3 TOOLSRemove compressor unit from wooden skid. A crowbar

and hammer will be needed.

IMPORTANTREAD THIS

LOST OR DAMAGED GOODS

THOROUGHLY INSPECT THIS SHIPMENT

IMMEDIATELY UPON ARRIVAL

OUR RESPONSIBILITY FOR THIS SHIPMENT

CEASED WHEN THE CARRIER SIGNEDBILL OF LADING

If goods are received short or in damaged condition, it is important thatyou notify the carrier and insist on a notation of the loss or damageacross the face of the freight bill. Otherwise no claim can be enforcedagainst the transportation company.

If concealed loss or damage is discovered, notify your carrier at onceand request an inspection. This is absolutely necessary. Unless you dothis the carrier will not entertain any claim for loss or damage. The agentwill make an inspection and grant a concealed damage notation. If yougive the transportation company a clear receipt for goods that have beendamaged or lost in transit, you do so at your own risk and expense.

WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLEMANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THEWILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLEFOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL.

THE ACTUALFILING AND PROCESSING OF THE CLAIM IS YOURRESPONSIBILITY.

Ingersoll-Rand CompanyDavidson, North Carolina

APDDGFO-99-79

FORKLIFT PADDINGWILL REDUCE SCRATCHES

AND MARS

SPREADERBARS


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2.0 INSTALLATION

2.1 VENTILATIONOil flooded rotary air compressors produce large

amounts of heat. Because of this large heat production,the compressor must be placed in a room with adequate

ventilation. A room in which the amount of air that isdrawn in and exhausted is equal to or greater than the

cooling fan air flow requirement for the compressor thatis installed.

If heated air from the compressor exhaust is allowed torecirculate back to the compressor, the compressor will

overheat and shut down. This heat must be exhaustedfrom the room. You should take this into considerationwhen you decide where to place the compressor within

your plant. Consider that the required maintenanceclearance is 3 ft (.9 m) all around the compressor.

However 42” (1.06m), or minimum required by latestNEC or applicable local codes, must be maintained in

front of control panel.

Ambient temperatures higher than 115°F (46°C)

should be avoided as well as areas of high humidity.

Consider also the environment surrounding or nearthe compressor. The area selected for the location of

the compressor should be free of dust, chemicals,metal filings, paint fumes and overspray.

AIR INTAKE

2.2 FOUNDATION REQUIREMENTS

Refer to the foundation plan for the particular modelcompressor to be installed. See Section 8.0.

The compressor can be installed on any level floor that is

capable of supporting it. Compressor weights are listedon the foundation plans.

When sound transmission is of particular importance it isoften helpful to install a sheet of rubber-fabric-matting, or

cork under the compressor to reduce the possibility ofresonant sounds being transmitted or amplified through

the floor.

2.3 PIPINGThe use of plastic bowls on line filters without metal

guards can be hazardous. Their safety can be affectedby either synthetic lubricants or the additives used in

mineral oil. From a safety standpoint, metal bowls shouldbe used on any pressurized system. Review of your plant

air line system is recommended.

The built-in aftercooler reduces the discharge airtemperature well below the dew point (for most ambient

conditions), therefore, considerable water vapor iscondensed. To remove this condensation, each

compressor with built-in aftercooler is furnished with acombination condensate separator/trap.

DUST CHEMICALS

METALFILINGS

PAINTSPRAY

OVERSPRAY

Do not use plastic pipe, soldered copper

fittings or rubber hose for discharge piping.

WARNING

Never elevate the compressor unitabove the floor level. This may allow air

to enter the cabinet under the base.Performance will be affected.

NOTICE!

!

36”(.9 m)

36” (.9 m)

42” (1.06 m) ORCODE MINIMUM

10


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1

ISOLATION

VALVE

DRIP LEG

DISCHARGE PIPING WITH AFTERCOOLER

ISOLATION

VALVE

ISOLATION

VALVESTRAINER

TRAP

NOTE:

SEPARATE LINES

GOING TO THERECEIVER

DRIP

LEG

ROTARY

COMPRESSOR

PRESSURE

GAUGE

SAFETY

VALVE

ISOLATION

VALVE

RECIPROCATING

COMPRESSOR

DRIPLEG

SAFETY

VALVE

ROTARY-RECIP IN PARALLEL

Do not use the compressor

to support the discharge pipe.

Careful review of piping size from the compressor

connection point is essential. Length of pipe, size of pipe,number and type of fittings and valves must be

considered for optimum efficiency of your compressor.

It is essential when installing a new compressor to review

the total plant air system. This is to ensure a safe andeffective total system.

Liquid water occurs naturally in air lines as a result of

compression. Moisture vapor in ambient air isconcentrated when pressurized and condenses when

cooled in downstream air piping.

Moisture in compressed air is responsible for costly

problems in almost every application that relies on

compressed air. Some common problems caused bymoisture are rusting and scaling in pipelines, clogging ofinstruments, sticking of control valves, and freezing of

outdoor compressed air lines. Any of these could result inpartial or total plant shutdown.

Compressed air dryers reduce the water vapor con-centration and prevent liquid water formation in

compressed air lines. Dryers are a necessary companionto filters, aftercoolers, and automatic drains for improving

the productivity of compressed air systems.

NOTICE!

2.3 PIPING (Continued)A dripleg assembly and isolation valve should bemounted near the compressor discharge. A drain line

should be connected to the condensate drain in thebase.

IMPORTANT: The drain line must slope downward from

the base to work properly.

NOTE: For ease of inspection of the automatic drain trap

operation, the drain piping should include an open funnel.

It is possible that additional condensation can occur if thedownstream piping cools the air even further and low

points in the piping systems should be provided withdriplegs and traps.

IMPORTANT: Discharge piping should be at least aslarge as the discharge connection at the compressor

enclosure. All piping and fittings must be suitable for the

maximum operating temperature of the unit and, at aminimum, rated for the same pressure as thecompressor sump tank.

MOISTURE CONTENT OF COMPRESSED AIR

200

160

120

80

40

0

DEW POINT

withoutAftercooling

100°F/38°C(withAftercooler)

35°F /1.7°C(RefrigeratedDryer)

-40°F/-40°C(DesiccantDryer)

G

a l l o n s o f W a t e r / 2 4

h o u r s / 1 0 0 0 a c f m

ROTARYCOMPRESSOR


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12

2.4 ELECTRICAL INSTALLATION

Before proceeding further, we recommend that you

review the safety data in the front of this manual.

Locate the compressor data plate on the right side ofstarter box.

The data plate lists the rated operating pressure, themaximum discharge pressure and the electric motor

characteristics and power.

Confirm that the line voltage and compressor nameplatevoltage are the same and that the standard starter box

meets the intent of NEMA 1 guidelines.

Remove the screws and door from the front of the starter

box. Confirm that all electrical connections are made andtightened. Confirm that the control transformer is wired

correctly for supply voltage. See Figure 2.4-1 on nextpage for typical control transformer wiring.

Two types of dryers, refrigerated or desiccant, are usedto correct moisture related problems in a compressed air

system. Refrigerated dryers are normally specified wherecompressed air pressure dew points of 33°F (1°C) to

39°F (4°C) are adequate. Desiccant dryers are requiredwhere pressure dew points must be below 33°F (1°C).

Contact your local Ingersoll-Rand distributor for

assistance in selecting correct Ingersoll-Rand filtration ordrying products.

NOTE: Screw type compressors should not be installedin air systems with reciprocating compressors without ameans of pulsation isolation, such as a common receiver

tank. We recommend both types of compressor units bepiped to a common receiver utilizing individual air lines.

When two rotary units are operated in parallel, provide

an isolation valve and drain trap for each compressorbefore the common receiver.

ISOLATION

VALVE

ISOLATION

VALVESTRAINER

TRAP

DRIP

LEG

ROTARY

COMPRESSOR

PRESSURE

GAUGE

SAFETY

VALVE

ISOLATION

VALVE

ROTARY

COMPRESSOR

DRIP

LEG

ROTARY TWO COMPRESSOR SYSTEM

1FU 2FU 3FU 4FU/5FUTransformer Primary Primary Secondary Secondary

Rating Fuse Fuse Fuse Fuse(VA) (Amp) (Amp) (Amp) (Amp)

230 2.0 2.0 2.0 2.0

330 2.5 2.5 3.2 2.0

FUSE TABLE


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13

If the compressor is operated in theopposite direction of rotation, airend damage

can result and is not warrantable.

CAUTION

ELECTRICAL INSTALLATION (Continued)

Inspect the motor and control wiring for tightness.

Replace the starter box door.

Rotation Check

Locate the rotation decal on the motor.

Drive MotorThe correct compressor drive motor rotation is

clockwise when viewed from the rear or non-driveend of the motor. See Figure 2.4-2.

!

FIGURE 2.4-2 DRIVE MOTOR ROTATION

FIGURE 2.4-1 TYPICAL CONTROL TRANSFORMER WIRING

DRIVEEND

NON-DRIVEEND

110V

LINE VOLTS HZ LINE SEC VOLTS LINE

200 60 H4-H5 120 X1-X28 X3-X48 X4-X5

220/230 60 H3-H5 120 X1-X28 X3-X48 X4-X5

380 60 H3-H5 120 X1-X28 X3-X4

8 X4-X5

440/460 60 H2-H5 120 X1-X28 X3-X48 X4-X5

575 60 H1-H5 120 X1-X28 X3-X48 X4-X5

LINE VOLTS HZ LINE SEC VOLTS LINE

220 50 H5-H6 110 X1-X28 X3-X48 X4-X5

380 50 H4-H6 110 X1-X28 X3-X48 X4-X5

415 50 H2-H6 110 X1-X28 X3-X48 X4-X5

550 50 H1-H6 110 X1-X2

8 X3-X48 X4-X5

H4 H5 H6

X5

X5

X4

16V

C.T.

X416VC.T.


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T

U L

/L

U L E

I L

L C

POWER

Before Starting

1. Check coolant level. Add coolant if necessary.

2. Verify that main isolation valve is open.3. Close main disconnect switch. The “ POWER” light

indicates that line and control voltages are available

for starting. “UNLOAD” indicator light will be on.

Starting

1. Push “START”. Compressor will start. The compressor

will load automatically and the air pressure will riseif there is sufficient demand for air.

Stopping1. Push “UNLOADED STOP”. Compressor will immediately

unload and continue to run unloaded approximately

7 seconds. Compressor will then stop. If compressor

is running unloaded when “UNLOADED STOP” is

pushed, compressor will stop immediately.

2. Open main disconnect switch.

Stopping - Emergency

1. If there is a need to stop the compressor immediately

or if the “UNLOADED STOP” does not stop the com-

pressor after 7 seconds, push “EMERGENCYSTOP”

Compressor will stop immediately.

2. Open main disconnect switch.

14

ELECTRICAL INSTALLATION (Continued)

The Intellisys will automatically shut the unit down if thecompressor rotation is incorrect, and “CHK MTR

ROTATION” will appear in the display, also the alarmlight will be on. See Section 6.

For the compressor motor rotation check, the motor

jogging time must be as short as possible.

After depressing the start button, IMMEDIATELYdepress the “EMERGENCY STOP” button. Should

the motor rotation be incorrect, put main disconnectin the OFF position, lock and tag. See Figure 2.4-3.

Intellisys Operating Instructions

Read and understand the following Intellisys OperatingInstructions (See Figure 2.4-4) prior to operating the unit.

NOTE: These instructions are also contained onthe decal near the Intellisys panel of the unit.

FIGURE 2.4-3 MAIN DISCONNECT

LOCKED AND TAGGED

Remove the starter box door.

Interchange any two line connections (L1, L2 or L3) atthe starter. Close and fasten the starter box door.

Recheck for correct rotation.

DANGER

HIGH VOLTAGE

D A N G E R

LEVER

HASP

TAG

KEY LOCK

FIGURE 2.4-4 INTELLISYS OPERATINGINSTRUCTIONS

NOTICEIntellisys

Operating Instructions

BEFORE INSTALLING, OPERATING, OR PERFORMING ANY

MAINTENANCE ON THIS UNIT, READ AND UNDERSTAND

THE INSTRUCTIONS IN THE OPERATORS / INSTRUCTION

MANUAL


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15

2.5 OUTDOOR SHELTERED INSTALLATION

Many times a compressor must be installed outside dueto jobsite conditions or limited space within a

manufacturing facility. When this occurs there are certainitems that should be incorporated into the installation tohelp ensure trouble free operation. These items have

been listed below plus Figure 2.5-1 has been included to

show a typical outdoor sheltered installation. The unitmust be purchased with the Outdoor Modification Optionto provide NEMA 4 electrics and a cabinet exhaust on

the rear of the unit rather than the top to prevent recir-culation of cooling air.

The compressor should be on a concrete paddesigned to drain water away. If the concrete pad is

sloped, then the compressor must be leveled. In orderto properly pull cooling air through the aftercooler, the

base/skid must be sealed to the concrete pad.

The roof of the shelter should extend a minimum of

4 ft (1.2 m) around all sides of the compressor to pre-vent direct rain and snow from falling on the unit.

Air-cooled machines must be arranged under the

shelter in a way that prevents air recirculation (i.e. hotexhaust back to the package inlet).

If the installation includes more than one compressor,the hot air exhaust should not be directed towards the

fresh air intake of the second unit or an Air Dryer.

If a standard machine is to be installed outside, the

ambient temperature must never drop below 35°F(1.7°C).

Arrange the machine with the Intellisys con-

troller/starter enclosure facing away from the sun asradiant heat can affect starter/lntellisys performance.

Also direct sunlight and UV rays will degrade themembrane touch panel. This is not a warrantablesituation.

Power disconnect switch should be within line of sight

and in close proximity to the unit. N.E.C. and localelectrical codes must be followed when installing the

power disconnect switch.

Condensate drains must never be allowed to dump onthe ground. Run to a suitable sump for futurecollection and disposal or separation of lubricant and

water mixture.

Incoming power connections must use suitableconnectors for outdoor weather tight service.

A minimum of 3 ft (.9 m) clearance must be allowedon all four sides of the unit for service access.

However 42” (1.06m), or minimum required by latestNEC or applicable local code, must be maintained in

front of control panel.

If possible, access by a forklift and/or an overheadbeam hoist should be kept in mind (for eventualservice to airend or motor).

If the area around the installation contains fine

airborne dust or lint and fibers etc., then the unitshould be purchased with the High Dust Filter Option

and TEFC motor.

Some type of protection such as a fence or security

system, should be provided to prevent unauthorizedaccess.


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16

F I G U R E 2 . 5 - 1 T Y P I C A L O U T D O O R S H E L T E R E D I N S

T A L L A T I O N


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17

I N G E R S O

L r

A

N D

I N T E L L I S Y S

•

A L A R M

• •

S E T O F F L I N E A I R

P R E S U R E

•

S E T O N L I N E A I R

P R E S S U R E

•

S E L E C T C O N T R O L M O D E

•

S E T D I S P L A Y T I M E

•

S E L E C T O P T I O N

S

• •

P A C K A G E D I S C H A R G E P R E S S U R E

•

A I R E N D

D I S C H A R G E T E M P E R A T U R E

•

S U M P P R E S S U R E

•

S E P A R A T E P R E S S U R

E D R O P

•

T O T A L

H O U R S

•

L O A D E D

H O U R S

• • •

U N L O A D

•

P O W E R S

T A R T

U N L O A D

/ L O A D

D I S P L A

Y

S E L E C

T

S T O P

U N

L O A D E D

S E T

A U T O M A T I C

R E S T A R T

3.0 INTELLISYS

I N T

E L L I S Y S C O N T R O L L E R

I N G E R S O

L L r

A

N D

I N T E L L I S

Y S


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18

3.0 INTELLISYS

3.1 EMERGENCY STOP SWITCH

Pressing this switch stops the compressorimmediately. Compressor cannot be restarted untilswitch is manually reset. Turn clockwise to reset.

3.2 POWER ON LIGHT (Inside Starter Box)

Indicates control voltage is available to the controlcircuit and line voltage is available for starting.

POWER ON

3.3 POWER INDICATOR LIGHT

Indicates voltage is available to the intellisyscontroller.

3.4 PUSH BUTTONS

START

If the display shows READY TO START, pressingthis button will start the compressor. Thecompressor will start and load automatically if there

is a demand for air.

If in the display table press this button to exit thedisplay table. Display will show “CHECKINGMACHINE” then “READY TO START”.

EMEG

STOP

POWER

UNLOAD STOP

Pressing this button will activate the unload stop. Ifthe compressor is running loaded, it will unload.Seven seconds later it will stop. if the compressor isrunning unloaded, it will stop immediately. Pressing

this button with the unit stopped will flash all L.E.D.’sfor a light check and flash the software versionnumber in the display.

UNLOAD/LOAD

If the unit is running loaded, pressing this button willcause the unit to unload, the unload indicator lightwill be on. The unit will not load until the button ispressed again. If the unit is running unloaded,pressing this button will load the unit in the ON/OFFLINE or MOD/ACS control mode previously

operating.

START

UNLOAD

/LOAD

STOPUNLOADED


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19

3.4 PUSH BUTTONS (Continued)

DISPLAY SELECT

Pressing this button will change the informationselected for the display. The display table will beincremented. If the button is held, this display table

will scroll. This button can also be used to exit theset point procedure.

NOTE: For readings less than 1 hr., hourmeterdisplay minutes. After 1 hr. the hourmeter displayshours.

SET

The SET button is used to enter the set point

procedure. The set button is also used to resetwarnings and alarms. Pressing this button once willreset a warning, twice will clear an alarm.

ARROWS

These buttons have several functions. If theIntellisys is in the set point mode, the ARROWS areused to change the set point values. If the unit hasmultiple alarms or warnings, the ARROWS are usedto scroll through these conditions. The ARROWS

have a function in the calibration routine, which willbe described later.

PRESSURE SENSOR CALIBRATION (ZEROING)ROUTINE

This routine is entered if the unit is not running andboth the up and down arrows button are pressed atthe same time. Make sure all pressure is relievedfrom the compressor before calibration. The displaywill flash the message “CALIBRATING”. Aftercalibration is completed the display will indicate“READY TO START”. Zeroing should only be doneafter a pressure sensor has been replaced or anycontroller change.

DISPLAY

SELECT

SET


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3.6 WARNINGS

When a warning occurs, the alarm indicator will flashand the display will alternate between the currentmessage and the warning message. If multiplewarnings exist, the message

SCROLL FOR WARN

will be substituted for the warning messages. The upand down arrows can be used to obtain thewarnings

A warning needs to be reset by an operator. Thewarning will clear when the SET button is pressedonce. The following is a list of the warningmessages.

1) CHG SEPR ELEMENTThis warning will occur if the pressure on theSeparator is 12 psig (.8 bar) greater than thepressure at the Package discharge and the unit isfully loaded.

2) HIGH AIREND TEMPThis will occur if the Airend Discharge Temperature(2ATT) exceeds 221°F (105°C).

20

3.5 SET POINT PROCEDURE

This procedure allows the customer to modify 11variables in the controller logic.

At this time, press the SET button to enter thesetpoint routine. The SET OFFLINE AIR

PRESSURE indicator will light and the display willshow:XXXX PSI

OFFLINE AIR PRESSURE is the first set point and

XXXX stands for the value of the set point. Press theSET button to select the set point to be adjusted.Press the up or down arrow buttons to raise or lowerthe set point value. Press the SET button to move tothe next set point. If the set point value has beenadjusted, press the SET button to enter the newvalue. The display will flash to acknowledge.Thenext set point will then be displayed. If the value ofthe set point was not changed, pressing the SETbutton will only step to the next set point. When theSELECT OPTIONS set point is entered, theSELECT OPTIONS indicator will light, and thesetpoints for options Auto Start/Stop or Remote

Start/Stop will only be accessible and displayed ifthe option module is installed in the unit. The PowerOutage Restart setpoints will only be accessible anddisplayed if the combination Auto/RemoteStart/Stop/Power Outage Restart option module isinstalled in the unit (See Section 7.0). The set pointroutine can be exited by pressing the

DISPLAY/SELECT button or exit will be automaticafter 30 sec.

The following is a list of the set points. Also includedare maximum and minimum limits, step size, and

units of measure.

MIN MAX STEP UNIT

OFFLINE PRESSURE 75 RATED + 3 1 PSI

ONLINE PRESSURE 65 OFFLINE - 10 1 PSI

CONTROL MODE MOD/ACS - MODULATION - ON/OFF LINE

DISPLAY TIME 10 600 10 SEC

AUTO RESTART OFF ON --- ---

AUTO RESTART TIME 2 60 1 MINSEQUENCER OFF ON --- ---

REMOTE START/STOP * OFF ON --- ---

POWER OUT/RESTART* OFF ON --- ---

POWER OUT RESTART 10 120 1 SECTIME *

DELAY LOAD TIME 0 60 1 SEC

LEAD/LAG** --- --- --- ---

LAG OFFSET 0 45 1 PSI

*Optional (SEE SECTION 7.0)

** The lead/lag feature allows the customer to chooseone compressor as the “lead” compressor and any

others as the “lag” compressor (simulates the mode ofa sequencer). The lag compressor’s on-line and off-line

pressures are determined by subtracting the lag offsetset-point from the on-line and off-line pressure set-points of the lead compressor.


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24/70

Aftercooler

The discharge air aftercooling system consists of aheat exchanger (located at the cooling air dischargeof the machine), a condensate separator, and anautomatic drain trap.

By cooling the discharge air, much of the watervapor naturally contained in the air is condensedand eliminated from the downstream plant-pipingand equipment.

4.3 COOLANT SYSTEM

Coolant is forced by pressure from the receiver-separator sump to the inlet port of the coolant coolerand the bypass port of the thermostatic controlvalve.

The thermostatic control valve controls the quantityof coolant necessary to provide a suitablecompressor injection temperature. When the

compressor starts cold, part of the coolant willbypass the cooler. As the system temperature risesabove the valve setting, the coolant will be directedto the cooler. During periods of operation in higherambient temperatures, all the coolant flow will bedirected through the cooler.

The compressor injection minimum temperature iscontrolled to preclude the possibility of water vaporcondensing in the receiver. By injecting coolant at a

sufficiently high temperature, temperature of thedischarge air and lubricant mixture will be kept

above the dew point.

The controlled temperature coolant passes througha filter to the airend under constant pressure.

Each compressor has a hydraulic-type-full-flow filterwith a single replacement spin-on element. The filteris mounted on the oil filter/thermal valve housing. Itis rated at 4 microns.

22

4.0 SYSTEMS

4.1 GENERAL SYSTEM INFORMATION

The SE compressor is an electric motor driven,

single stage, screw compressor—complete withaccessories piped, wired and baseplate mounted. Itis a totally self-contained air compressor package.

A standard compressor is composed of thefollowing:

Inlet air filtrationCompressor and motorPressurized coolant system with coolerSeparation systemCapacity control system

Motor starting control systemInstrumentation

Safety provisionsAftercoolerMoisture separator and drain trap

Optional accessories can provide for such things asremote starting or stopping and sequencing.

4.2 AIRCOOLED COMPRESSORS

Design Temperatures

The standard compressor is designed for operation

in an ambient range of 35°F. to 115°F. (1.7°C. to46°C.). When conditions other than design levelsdescribed are encountered, we recommend youcontact your nearest Ingersoll-Rand representativefor additional information.

The standard maximum temperature 115°F. (46°C)is applicable up to an elevation of 3300 ft. (1000meters) above sea level. Above this altitude,

significant reductions in ambient temperature arerequired if a standard drive motor is to be used.

Coolant Cooler

The cooler is an integral assembly, mounted in thelower rear section of the compressor. The coolingair flows in through the front corners of theenclosure, through the vertically mounted coolercore, and discharges upward through the top of theenclosure.


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23

4.3 COOLANT SYSTEM (Continued)

There is a differential-pressure-bypass-valve set toopen in the event that the pressure drop across thefilter element rises to as high as 25 psi (1.8 BAR),which indicates an excessively fouled element, aswell as poor maintenance practice.

4.4 COMPRESSED AIR SYSTEM

The air system is composed of:

1. Inlet air filter2. Inlet valve3. Rotors4. Coolant/air separator5. Minimum pressure/check valve6. Aftercooler7. Moisture separator/drain trap

Air enters the compressor, passing through the inletair filter and inlet valve.

Compression in the screw-type air compressor iscreated by the meshing of two helical rotors (maleand female) on parallel shafts, enclosed in a heavy-duty cast iron housing, with air inlet and outlet portslocated on opposite ends. The grooves of the femalerotor mesh with, and are driven by, the male rotor.Tapered roller bearings at the discharge end preventaxial movement of the rotors.

The air-coolant mixture discharges from thecompressor into the separation system. This system,self-contained in the receiver tank, removes all but afew PPM of the coolant from the discharge air. Thecoolant is returned to the system and the air passesto the aftercooler. The optional aftercooling systemconsists of a heat exchanger, a condensateseparator, and a drain trap. By cooling the dischargeair, much of the water vapor naturally contained inthe air is condensed and eliminated from thedownstream plant-piping and equipment.

During unloaded operation, the inlet valve closes

and the blowdown solenoid valve opens, expellingany compressed air back to the compressor inlet.

4.5 COOLANT/AIR SEPARATION SYSTEM

The coolant/air-separation-system is composed of areceiver with specially designed internals, a two-stage, coalescing-type separator-element, andprovision for return of the separator fluid back to thecompressor.

Operation

The coolant and air discharging from thecompressor flow into the receiver through atangential discharge outlet. This outlet directs themixture along the inner circumference of thereceiver, allowing the coolant stream to collect anddrop to the receiver sump.

Internal baffles maintain the circumferential flow ofremaining coolant droplets and air. In an almostcontinuous change of direction of flow, more andmore droplets are removed from the air by inertialaction and then returned to the sump.

The air stream, now essentially a very fine mist, isdirected to the separator element.

The separator element is constructed with twoconcentric, cylindrical sections of closely packedfibers, each held in steel mesh. It is flange-mountedat the receiver-outlet-cover.

The air stream enters the separator element radiallyand the mist coalesces to form droplets. Thedroplets collected on the outer first stage fall to thereceiver sump. Those collected on the inner secondstage collect near the outlet of the element, and aredrawn back to the compressor inlet through a filter-screen and orifice fitting installed in the separatorscavenge line.

The air stream, now essentially free of coolant, flowsfrom the separator to the aftercooler, then to thecondensate separator, and on to the plant airsystem.

4.6 ELECTRICAL SYSTEM

The electrical system of each SE compressor is builtaround the microprocessor-based Intellisyscontroller.

The standard electrical/electronic components,enclosed in a readily accessible enclosure include:

1. SE Intellisys controller2. Control transformers and fuses3. Compressor motor starter, with auxiliary contacts

and overload relays

By use of a built-in Automatic Across-The-Line typestarter, the compressor can be started using fullvoltage electric current. The starter is completelyautomatic and controlled by the Intellisys controller.Refer to the electrical schematic, Section 8.0

schematic 8.1.


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24

4.6 ELECTRICAL SYSTEM (Continued)

By use of an optional built-in Star-Delta type starter,

the compressor motor can be started and acceleratedusing a greatly reduced “inrush” electric current. The

starter is completely automatic and controlled by theIntellisys controller. Refer to the electrical schematic,Section 8.0 schematic 8.2.

Options such as remote start/stop or power outage

restart with remote start/stop can be added byinstalling a plug-in module in the controller.

4.7 CAPACITY CONTROL

The SE compressor is supplied with on-off linecontrol equipment.

Optional modulation control enables the compressorto function with three operator selectable capacity

control systems, each designed for different plant airrequirements.

- Mod/ACS (modulation/automatic control sector)- Modulation- On-Off Line

The desired control is selected at the Intellisyscontrol panel (See Section 3.0).

Automatic Unloaded Start

The compressor will always start in the unloadmode. When unloaded, the inlet valve is nearlyclosed, the blowdown solenoid valve is open (tank

vented), and the compressor is operating atminimum power. The Intellisys will open the inletvalve slightly to maintain the proper sump pressureto insure positive oil flow and smooth, quietoperation.

The minimum pressure check valve will prevent anybackflow of air from the plant air system duringunloaded operation.

On-Off Line Control

For those plants which have a widely varying airdemand, on-off line control will deliver air at fullcapacity (compressor maximum efficiency condition)or will operate at zero capacity (compressor minimumpower condition). The compressor is controlled by theIntellisys, responding to changes in plant air pressure.The Intellisys opens the inlet valve and closes the

blowdown valve (3SV) whenever plant air pressuredrops below the on-line pressure set point. Thecompressor will then operate to deliver full capacity airto the plant system. If the plant air system pressurerises to the off-line set point of the Intellisys, the inletvalve closes and the blowdown solenoid valve opensthe receiver vent line, allowing receiver pressure todrop. The compressor will continue to run withminimum power draw.

Automatic Start-Stop

Many plant air systems have widely varying airdemands or large air storage capacity which allows forautomatic standby air capacity control.

During periods of low air demand, if the line pressure

rises to the offline set point, the Intellisys begins to timeout. If the line pressure remains above the online set

point for as long as the set time, the compressor willstop. At the same time the Automatic Restart light onthe display panel will be lit to indicate the compressor

has shut down automatically and will restartautomatically, and the display will show “AUTO

RESTART”. An automatic restart will occur when theline pressure drops to the online set point.

The offline and online set points and shut down delaytime are set on the Intellisys control panel.


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25

Modulation/ACS Control (Optional)

For those plants which have relatively high constantair demand, relative to the compressor capacity, therecommended control mode is modulation.

The modulation control system retains the features

of the on line-off line control, but provides forthrottling of the inlet flow up to the off line airpressure set point value.

By applying line pressure to an adjustable modulator

valve, the throttling position of the inlet valve iscontrolled, thus allowing the modulator to "trim" theinlet valve position as dictated by the line pressure.

The modulating pressure range is about 4 psig (0.3BAR) and the modulator is factory set to straddle thecompressor rated pressure. Modulation begins whenthe line pressure reaches about 99 percent of thecompressor rated pressure and continues as/if theline pressure rises. Modulation becomes stablewhen the compressor output equals the plant airdemand. When the modulation is at the factorysetting, the maximum capacity reduction will be

approximately 60 percent of the compressor ratedcapacity (as indicated in Figure 4.7-1).

If the air demand has decreased to a level below the60 percent modulated output, the line pressure willincrease slightly to actuate the Intellisys. Thecompressor will then shift to the off line control

position, and operate unload with the compressorvented.

It is sometimes desirable to begin modulation at ahigher pressure than the standard factory setting,

thereby increasing the modulated capacity at thetime the Intellisys is actuated. Refer to Figure 4.7-1for modulated capacities available when this is done.

FIGURE 4.7-1


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Modulate/ACS Control (Continued)

The compressor will then operate to deliver fullcapacity air to the plant system. If the plant airsystem pressure rises to that of the Intellisys off lineset point, pressurized air will be sent to the inletvalve causing it to close, and to the blowdown valve,causing it to open.

The compressor will continue to run unloaded, butsince pressure levels have reduced, it will do so witha minimum power draw.

The Intellisys ® has a fixed minimum differential of 10psi between the off line air pressure setting and theon line air pressure setting. The differential may beincreased by adjusting the on line air pressuresetting of the Intellisys ® .

Refer to Section 3.5 for instructions.

The automatic control selector (ACS) is designed tocontinuously monitor the plant air demand andselect either the on line-off line, or the modulatecontrol mode - whichever is most desirable atanytime during an operating day.

It allows the compressor to operate in its mostefficient mode without attendance, thereby reducingpower costs to a minimum.

When the compressor operates in the on line-off linecontrol mode, the length of time the compressorremains in the "off line" condition is an indication of

the plant air demand. Intellisys controller is sensingand awaiting a sufficient line pressure decreasebefore signaling a shift to the on line mode. If the"off line" time period is relatively short, therebyindicating a high demand for air, it is preferable toshift the control system to upper range modulation.

The Intellisys ® does this, and does it automatically ifthe compressor unloads 3 times within a 3 minutetime period.

If later, the plant demand decreases, and evenunder modulate control the line pressure reachesthe setting of the Intellisys ® controller, and thecontrol shifts to the "off line" mode, the time in thismode will still be monitored. A long "off line" time-period indicates a low plant air demand, indicatingthe desirability of operating in the on line-off linemode.

The Intellisys ® then does this, and does itautomatically if the compressor operates unloadedfor more than 3 minutes.

Modulation Only

If MODULATION ONLY is turned on in the set pointroutine, the unit will shift to Modulation control modeimmediately when the unit is running. The 3 cycleswithin 3 minutes time period required for ACS tochange to Modulation mode is bypassed. The unitwill stay in Modulation mode until the unit runsunloaded for 3 minutes (the unit then returns to ACScontrol) or MODULATION ONLY is turned off via theset routine.

Delay Load Time

This is the amount of time the line pressure mustremain below the online set point before thecompressor will load or start (if the unit was stoppeddue to an auto start/stop situation). Setting the loaddelay time to 0 will cause no delay. When the delayload timer becomes active, the display will switch topackage discharge pressure (if not displayingpackage discharge pressure at that time) and thendisplay the delay load count down. Once the countdown reaches 0, the unit will load or start and thedisplay will return to line pressure. The display selectbutton is inactive during the delay load count down.

MODEL RATEDOPERATING PRESSURE

EP 125 PSIG

HP 140 PSIG

HXP 200 PSIG

26


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Modulate Control Valve Adjustment

Ensure the compressor is isolated from thecompressed air system by closing the isolationvalve and venting pressure from the drip leg.

Ensure the main power disconnect switch is

locked open and tagged.

1. Enter the setpoint routine and put the compressorin the MODULATION mode. Refer to Section 3.5 forinstructions.

2. Remove 1/8" NPT plug from the tee in the controlpiping on the side of the airend support. Connect apressure gauge to this port.

3. Loosen the adjustment screw locknut and backout adjusting screw 3 turns. See Figure 4.7-2.

4. Open the isolation valve and start the compressor.

5. Adjust the isolation valve to bring the dischargeair pressure to the rated discharge pressure (125,140, or 200 psig).

6. While MAINTAINING the rated dischargepressure, turn the adjustment screw on themodulation valve (see Figure 4.7-2) so that the testpressure gauge reads:

22 psig for modulate 60% cfm (full voltage units)

16 psig for modulate 60% cfm (star-delta units)20 psig for modulate 70% cfm (full voltage units)18 psig for modulate 70% cfm (star-delta units)

Tighten the adjustment screw locknut.

7. Press UNLOADED STOP. Wait for sump pressureto go 0 psig. Close the isolation valve or bleed off allsystem air.

8. Enter the setpoint routine and put the compressorin the desired control mode.

9. Remove the test pressure gauge and replace the

1/8" NPT plug using Loctite ® PST or similar threadsealant.

*Loctite is a registered trademark.

FIGURE 4.7-2 MODULATION VALVE

WARNING!

Hazardous voltage. Can causesevere injury or death.


WARNING!

High pressure air.

Can cause severe injury or death.

Relieve pressure before removing filterplugs / caps, fittings or covers.

LOCKNUT

ADJUSTING SCREW


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5.0 SCHEDULED PREVENTATIVE MAINTENANCE

5.1 MAINTENANCE SCHEDULE

THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THECOMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT

NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST.

5.2 MAINTENANCE RECORDS

It is very important that you, the owner, keep accurate

and detailed records of all maintenance work you, or theIngersoll-Rand Distributor or Air Center perform on your

compressor. This includes but is not limited to coolant,

coolant filter, separator, inlet air filter, V-belts, shaft seal,and so forth. This information must be kept by you, the

owner, should you require warranty service work by yourIngersoll-Rand Distributor or Air Center. Maintenance

record sheets are located at the back of this manual.

5.3 MAINTENANCE PROCEDURES

Before starting any maintenance, be certain the following

is heeded.

1. Read Safety Instructions.

2. Use correct tools.3. Have recommended spares on hand.

SPECIAL NOTE:Replace separator element when the separatordifferential pressure ( s P) reaches three times the

initial pressure drop or a maximum pressuredifferential of 12 psi (.8 bar) at full load or if the

Intellisys warning “CHG SEPR ELEMENT” isdisplayed. See Section 3.9.

Running Time Interval (whichever comes first)Action Part or Item Hours 1 Week 1 Mo. 3 Mo. 6 Mo. Yearly 2 Years

Inspect Coolant level Weekly x

Inspect Discharge temperature (air) Weekly x

Inspect Separator element differential Weekly x

Inspect Air filter Delta P (at full load) Weekly x

Replace Coolant filter* 150 x (initial change only)

Check Temperature sensor 1000 x

Replace Food grade coolant (when used) 1000 x

Inspect Hoses 1200 xReplace Coolant filter* 1200 x (subsequent changes)

Inspect V-Belt/Belt Tension 2000 x

Clean Separator scavenge screen and orifice 4000 x

Clean Cooler cores** 4000 x

Replace Air filter* 4000 x

Replace Separator element* *See special note

Replace SSR Coolant 6000 x

Replace Ultra Coolant* 8000 x

Inspect Starter contactors 8000 x

Service Drive Motor Lubrication See Section 5.15

* In very clean operating environments and where inlet filter is changed at the above prescribed intervals.In extremely dirty environments change V-belts, coolant, filters, and separator elements more frequently.

** Clean cooler cores if discharge air temperature is excessive or if unit shutdown occurs on high air temperature.


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5.4 SHEAVE ALIGNMENT

Any degree of sheave misalignment will result in areduction of belt life.

Misalignment of sheaves should not exceed1/16”(1.6mm).

Parallel misalignment occurs when the driven shafts areparallel, but the two sheaves lie in different planes.

Angular misalignment occurs when the two shafts arenot parallel.

Align Sheaves

An easy and effective method of checking alignment inboth directions between the driver and driven sheaves

utilizes an accurate straight edge.

Lay the straightedge across the face of the driver

(motor) sheave and check alignment of the driven(airend) sheave. Then lay the straightedge across the

driven sheave and check that the driver sheave isaligned.

Alignment should be within 1/16” (1.6mm) maximumwhen measuring the gap between the straightedge and

the rim of the opposite sheave in each direction.

This alignment is factory set and should only requireresetting if the drive motor or airend is removed. (For

example, motor or airend replacement).

AIREND

MOTOR

STRAIGHT EDGE

1/16" MAX

A I R E N D

MOTOR

STRAIGHT EDGE

1/16" MAX

PARALLEL MISALIGNMENT

ANGULAR MISALIGNMENT

1/16” (1.6mm) MAX.

1/16” (1.6mm) MAX.

STRAIGHTEDGE

STRAIGHTEDGE


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5.5 V-BELTS

Ensure the compressor is isolated from thecompressor air system by closing the isolationvalve and venting pressure from the drip leg. Insure

the main power disconnect switch is locked openand tagged.

Special Tools

Belt tension gauge (39199138).

Replacement Parts

V-Belts (See Parts Manual APDD-568).

Disassembly

Remove right door of enclosure (if so equipped).

Remove the right belt guard.

Loosen the pivot bolt located on the left side of theairend.

Loosen locknut on tensioning bolt located on right sideof airend.

Screw the belt tensioning bolt away from the airend

cradle by turning counterclockwise.

Remove the belts from the airend sheave and the motor

sheave.

Installation/Inspection

Inspect sheave grooves for foreign material or rubberbuild-up. Clean and degrease sheaves before installing

new belts to insure long belt life.

Install new belts in the reverse order of disassembly.

When installing a new belt, do not pry or force the

belt over the sheave grooves (See Section 5.6 totension the belt properly).

WARNING!

Hazardous voltage. Can causesevere injury or death.


WARNING!

High pressure air.Can cause severe injury or death.

Relieve pressure before removing filterplugs / caps, fittings or covers.

WARNING!

Moving parts.Can cause severe injury.

Do not operate with covers removed.

Service only with machine blocked toprevent turn over.


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5.6 BELT TENSION ADJUSTMENT

Special Tools

Belt tension gauge (39199138).

A belt that is too loose will slip, causing overheating,

reduction in belt life, and a loss of compressor

efficiency.

Conversely, a belt that is too tight may cause a

reduction in belt life and may overload bearings. Theproper tensioning method is described as follows:

1. Remove the right guard.

2. At the center of the sheave span, apply a force(perpendicular to the span) by use of a tension gauge

or other calibrated spring (See Figure 5.6-1). At theappropriate deflection measurement, the applied forceshould be as given in Figure 5.6-1.

3. If the belt tension is incorrect, loosen the nut on the

pivot bolt located on the left side (nearest the separatortank) on the airend (See Figure 5.6-2). Then loosen the

locknut on the tensioning bolt located on the right sideof the airend (See Figure 5.6-3).

4. Rotate the belt tensioning bolt clockwise until theproper belt tension is achieved, as measured by a belt

tension gauge. This gauge can be obtained from yourIngersoll-Rand Distributor or Air Center. Tighten the belt

tensioning locknut.

Do not overtighten belts. It may cause damage to

bearings, shaft or seal retainer assembly.

5. Reinstall right guard.

6. There will normally be a rapid drop in belt tensionduring the run-in period. Tension new belts with the

deflection force as indicated. Check tension frequentlyduring the first 24 hours of unit operation.

FIGURE 5.6-1 BELT DEFLECTION FORCE

DRIVEN

SHEAVE

DRIVE

SHEAVE

DEFLECTION

BELT DEFLECTION 5/16 IN.

DEFLECTION FORCE 4 LBS.

S P A N

L E N G T H

D E F L E C T I O N

F O R C E

BELT DEFLECTION 1/4 IN.

Deflection Deflection

Force ForceHP (New) (After Run-In)

20 5.0 (23N) 3.5 LB (16N)

25 5.5 (25N) 4.0 LB (18N)

FIGURES 5.6-2 PIVOT NUT FIGURES 5.6-3 BELT TENSIONING BOLT

PIVOT NUT LOCKNUT BELT TENSIONING BOLT


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5.7 SHAFT SEAL REPLACEMENT

There are two lip type seals on the compressor. Theyare wearable parts and should be replace at 8,000hours. While it is advisable to have your local Ingersoll-Rand Distributor or Air Center perform this work, thetask can be accomplished by a good mechanic

following these instructions:

Before beginning any work on the compressor,ensure the main elec

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EP20-25 ingersoll rand manuel