Ingersoll-Rand XFE 50 Operators/Instruction Manual Options
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Ingersoll-Rand XFE 50 Operators/Instruction Manual Options

Ingersoll-Rand XFE 50 Operators/Instruction Manual Options

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Before installation or starting the compressor for the
first time, this manual should be studied carefully to
obtain a clear knowledge of the unit and of the duties
to be performed while operating and maintaining the
unit.
RETAIN THIS MANUAL WITH UNIT.
This Technical manual contains IMPORTANT SAFETY
DATA and should be kept with the air compressor at all
times.
More Than Air. Answers.
Online answers: http://www.air.irco.com
Phone: 1-800-526-3615
CCN: 80440332 REV: C
XFE/EPE/HPE 50
XF/EP/HP 60
XF/EP/HP/XP 75-100
ML/MM/MH 37-75
OPERATORS/
INSTRUCTION MANUAL
OPTIONS
FORM: APDD 696C
July 2002

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Summary of Contents for Ingersoll-Rand XFE 50

  • Page 1 XFE/EPE/HPE 50 XF/EP/HP 60 XF/EP/HP/XP 75-100 ML/MM/MH 37-75 OPERATORS/ INSTRUCTION MANUAL OPTIONS Before installation or starting the compressor for the first time, this manual should be studied carefully to obtain a clear knowledge of the unit and of the duties to be performed while operating and maintaining the unit.
  • Page 2 AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UP Warranty The 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 Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from Davidson, NC, whichever shall first occur.
  • Page 3 ROTARY SCREW AIR COMPRESSOR This unit was purchased from: _______________________________________________ _______________________________________________ _______________________________________________ Ingersoll-Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously. Number of units on order: __________________________ Customer Order Number: __________________________ Ingersoll-Rand Company Order Number: ______________...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 0.0 SAFETY AND WARNINGS 5.12 coolant/lubricant changeout 0.1 safety instructions 5.13 intellisys removal 0.2 safety precautions 5.14 coolant hoses 0.3 decals 5.15 airend discharge hose 5.16 fluid and vibration monitoring 1.0 RECEIPT OF EQUIPMENT 5.17 coolant sampling procedure inspection unpacking and handling 6.0 TROUBLE SHOOTING...

  • Page 5: Safety And Warnings

    0.0 SAFETY AND WARNINGS Safety instructions in the operators manual are bold-faced 0.1 SAFETY INSTRUCTIONS for emphasis. The signal words DANGER, WARNING and Before you install this air compressor you should take the CAUTION are used to indicate hazard seriousness levels as follows: time to carefully read all the instructions contained in this manual.
  • Page 6 SAFETY SHUTDOWN CHECK HIGH AIR TEMPERATURE There is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory pre-set at 228°F (109°C). This function should be checked at regular intervals for proper operation, once a month is recommended. The procedure is: Block off the cooling air discharge.

  • Page 7: Decals

    0.3 DECALS This section contains representative examples of decals recommend that you obtain a replacement kit as listed in which will be appearing throughout this manual and are the spare parts section of the Parts List Manual (Form applied to the compressor unit. If for some reason a APDD 751).
  • Page 8 WARNING WARNING Moving parts. Can cause severe injury. Exposed fan blade. Can cause severe injury. Do not operate with covers removed. Service only with machine blocked to Do not operate with covers removed. prevent turn over. Disconnect power. Lock and tag. INGERSOLLrAND ®...
  • Page 9 NOTICE CAUTION Improper coolant filter replacement will cause compressor damage. Replace filter element after first 150 hours of operation and every 2000 hours thereafter or when coolant is Rotation. changed. INGERSOLLrAND ® 39540182 39544143 INGERSOLLrAND ® WARNING High pressure air. Can cause severe injury or death.
  • Page 10 WARNING WARNING WARNING Hazardous voltage. Can cause Moving parts. severe injury or death. Can cause severe injury. Hazardous voltage. Can cause severe injury or death. Only use factory supplied inlet for Do not operate with covers removed. incoming power. See Operators/ Service only with machine blocked to Disconnect power before servicing.

  • Page 11: Receipt Of Equipment

    1.0 RECEIPT OF EQUIPMENT 1.1 INSPECTION When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier should be noted on the delivery receipt especially if the compressor will not be immediately uncrated. Obtaining the delivery man’s signed agreement to any noted damages will facilitate any future insurance claims.

  • Page 12: Installation

    2.0 INSTALLATION 2.1 VENTILATION Oil 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. If heated air from the compressor exhaust is allowed to recirculate back to the compressor, the compressor will overheat and shut down.
  • Page 13 2.3 PIPING (Continued) A dripleg assembly and isolation valve should be mounted near the compressor discharge. A drain line ISOLATION should be connected to the condensate drain. VALVE IMPORTANT: The drain line must slope downward from the compressor to work properly. NOTE: For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel.

  • Page 14: Electrical Installation

    Two types of dryers, refrigerated or desiccant, are used to correct moisture related problems in a compressed air system. Refrigerated dryers are normally specified where compressed air pressure dew points of 33°F (1°C) to SAFETY ISOLATION 39°F (4°C) are adequate. Desiccant dryers are required VALVE VALVE where pressure dew points must be below 33°F (1°C).
  • Page 15 LINE VOLTS LINE SEC VOLTS LINE H4-H5 X1-X2 X3-X4 X4-X5 220/230 H3-H5 X1-X2 X3-X4 X4-X5 H3-H5 X1-X2 X3-X4 X4-X5 440/460 H2-H5 X1-X2 X3-X4 X4-X5 H1-H5 X1-X2 X3-X4 X4-X5 LINE VOLTS LINE SEC VOLTS LINE H5-H6 X1-X2 X3-X4 X4-X5 H4-H6 X1-X2 X3-X4 X4-X5 H2-H6...
  • Page 16 ELECTRICAL INSTALLATION (Continued) Open the starter box door. The Intellisys will automatically shut the unit down if the Interchange any two line connections (L1, L2 or L3) at compressor rotation is incorrect, and “CK MTR the starter. Close and fasten the starter box door. ROTATION”...

  • Page 17: Outdoor Sheltered Installation

    2.5 OUTDOOR SHELTERED INSTALLATION Condensate drains must never be allowed to drain on Many times a compressor must be installed outside due the ground. Run to a suitable sump for future to jobsite conditions or limited space within a collection and disposal or separation of lubricant and manufacturing facility.
  • Page 18 FIGURE 2.5-1 TYPICAL OUTDOOR SHELTERED INSTALLATION...

  • Page 19: Intellisys

    • • ALARM PACKAGE DISCHARGE PRESSURE • • • INGERSOLrAND AIREND DISCHARGE TEMPERATURE AIREND DISCHARGE TEMPERATURE • • • • SET OFFLINE AIR PRESURE INTELLISYS SUMP PRESSURE SUMP PRESSURE • • • • SET ONLINE AIR PRESSURE SEPARATE PRESSURE DROP SEPARATE PRESSURE DROP •...

  • Page 20: Emergency Stop Switch

    3.0 INTELLISYS UNLOAD STOP 3.1 EMERGENCY STOP SWITCH Pressing this button will activate the unload stop. If the compressor is running loaded, it will unload. Pressing this switch stops the compressor Seven seconds later it will stop. if the compressor is immediately.
  • Page 21 PRESSURE SENSOR CALIBRATION (ZEROING) 3.4 PUSH BUTTONS (Continued) ROUTINE DISPLAY SELECT This routine is entered if the unit is not running and both the up and down arrows button are pressed at Pressing this button will change the information the same time. Make sure all pressure is relieved selected for the display.

  • Page 22: Set Point Procedure

    ** The lead/lag feature allows the customer to choose 3.5 SET POINT PROCEDURE one compressor as the “lead” compressor and any others as the “lag” compressor (simulates the mode of a This procedure allows the customer to modify 14 sequencer). The lag compressor’s on-line and off-line variables in the controller logic.

  • Page 23: Alarms

    9) REMT START FAIL 3.7 ALARMS This will occur if the momentary remote start switch does not disengage by the time star-delta transition When an alarm occurs, the alarm indicator will light occurs. and display will show actual alarm message. If alternately multiple alarms have occurred the display 10) CK MTR ROTATION will show SCROLL FOR ALARM.

  • Page 24: Systems

    Cooling Fan Motor 4.0 SYSTEMS In a standard compressor, the cooling fan motors 4.1 GENERAL SYSTEM INFORMATION are wired at the factory. They are three-phase- motors. Each is protected by a fan motor The SSR compressor is an electric motor driven, starter/overload.

  • Page 25: Compressed Air System

    4.4 COMPRESSED AIR SYSTEM Operation The coolant and air discharging from the The air system is composed of: compressor flow into the separator tank through a tangential inlet. This inlet directs the mixture along 1. Inlet air filter the inner circumference of the separator tank, 2.

  • Page 26: Compressor Control System

    Tools Required 4.7 COMPRESSOR CONTROL SYSTEM • 1/2" open end wrench. The Intellisys® controls the various operating modes • 9/16" open end wrench. of the compressor, monitors key compressor operating • Loctite® 242 or equivalent. parameters, and shuts the compressor down in the case of an operating problem.
  • Page 27 Unloaded Stop Automatic Start/Stop Operation If the compressor is running at full load and the When in operation, the compressor must meet two unloaded stop button is depressed, the compressor will specific timing intervals before the Intellisys controller will unload and stop only after running unloaded for seven stop the unit in an Automatic Start/Stop situation.

  • Page 28: Options

    Some Examples of Operation 4.8 OPTIONS EXAMPLE 1 Several options are available with the Intellisys® The operator selects an unloaded run time of 2 minutes control. These include starter options, remote start/stop in the OPTION routine and starts the compressor. The option, power outage restart, sequencer control, and unit runs loaded for 8 minutes, unloads and then runs modulation control.
  • Page 29 The Power Outage Restart Option is turned on by Modulation Only plugging in the required option module and enabling it The "MODULATlON" control mode can be selected through the set point routine. The restart time delay, during the set point procedure on a compressor that which is adjustable from 10-120 seconds, can also be has the modulation option installed.
  • Page 30 The modulator valve is set at the factory to modulate at the compressor's rated pressure. For example a compressor with a 125 psig (8.6 bar) pressure rating will modulate up to 60% capacity when the system pressure is near the default off line setting of 128 psig. (8.8 bar).
  • Page 31 NOTES:...

  • Page 32: Maintenance Schedule

    5.0 SCHEDULED PREVENTATIVE MAINTENANCE 5.1 MAINTENANCE SCHEDULE THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST. Running Time Interval (whichever comes first) Action Part or Item Hours...

  • Page 33: Inlet Air Filter

    5.4 INLET AIR FILTER The filter should be changed when the filter indicator shows red. The filter should be changed every 4000 hours and more frequently in dirty environments because coolant, coolant filter, separator element, and airend life are a direct function of how well you maintain and replace the inlet air filter.

  • Page 34: Coolant

    5.6 COOLANT Coolant fill quantity SSR Ultra Coolant (Standard Factory Fill) 50 hp (37 kw).....5.0 gallons (19.0 liters) SSR H1-F Food Grade (Optional) 60 hp (45 kw).....5.0 gallons (19.0 liters) SSR Ultra Coolant is a polyglycol base coolant. Change 75/100 hp (55-75 kw) ..9.0 gallons (34.2 liters) Ultra Coolant after every 8000 hours or every two years, whichever comes first.

  • Page 35: Separator Tank Scavenge Orifice/Screen

    5.6 COOLANT (Continued) After the unit is drained and a new coolant filter element is installed, refill the system with fresh coolant. Bring the receiver level of coolant up to the midpoint of the sight glass. Replace the fill cap. Start the compressor and run it for a short time.

  • Page 36: Coolant Separator Element

    5.8 COOLANT SEPARATOR ELEMENT WARNING To check condition of separator element, run compressor in full load mode and at rated pressure and select "SEPARATOR PRESSURE DROP" in display table. If display says "XX PSI", then no maintenance is required. If warning light is on and display says "CHG SEPR ELEMENT"...

  • Page 37: Cooler Cores

    5.9 COOLER CORES: CLEANING Coolant Coolers Following are instructions for removal and internal Ensure that the compressor is isolated from the cleaning of coolant/aftercooler. compressed air system by closing the isolation valve and venting pressure from the drip leg. 1) Remove right side panel. Ensure that the main power disconnect switch is 2) Remove 6 screws in right side plenum wall and locked open and tagged.
  • Page 38 5.9-2 Water Cooled Coolers (Continued) Improper lubrication can be a cause of motor bearing failure. The quantity of grease added should be carefully Cleaning controlled. The smaller motors must be greased with a lesser amount of grease than larger motors. The interior tube surfaces can be cleaned by several methods.
  • Page 39 5.10 MOTOR LUBRICATION (Continued) Grease relief along shaft can occur, precluding necessity WARNING of removing this plug if inaccessible. The inlet grease gun fittings and outlet plugs (or spring-loaded reliefs) are located at each end of the motor housing. The drive end reliefs protrude out the circumference of the lower portion of the end bell near a flange bolt.

  • Page 40: Long Term Storage

    5.11 LONG TERM STORAGE Follow these precautions to minimize damage from static electricity. Static can cause severe damage to General microcircuits. The factory, upon special request, prepares compressor units for long term storage. In such cases, a special 1) Make the least possible movement to avoid build- bulletin is supplied for storage and start-up procedures.

  • Page 41: Coolant Hoses

    5.14 COOLANT HOSES 5.16 FLUID AND VIBRATION MONITORING The flexible hoses that carry coolant to and from the oil Ingersoll-Rand recommends incorporating predictive cooler may become brittle with age and will require maintenance, specifically the use of coolant and vibration replacement.

  • Page 42: Trouble Shooting

    6.0 TROUBLE SHOOTING CHART TROUBLE CAUSE &/OR DISPLAY WHAT TO DO Compressor fails to start. 110/120V control voltage not available. — Check fuses. Check transformers and wiring connections. "STARTER FAULT 1SL (2SL)" — Inspect contactors. "EMERGENCY STOP" — Rotate emergency stop button to disengage, and press"SET"...
  • Page 43 TROUBLE SHOOTING CHART (Continued) TROUBLE CAUSE &/OR DISPLAY WHAT TO DO High coolant Excessive coolant level. — Check level, lower if necessary by consumption/coolant draining. in air system Plugged separator element. — Check separator pressure drop. Separator element leak. — Check separator pressure drop. If low, replace element.

  • Page 44: Reference Drawings

    7.0 REFERENCE DRAWINGS 7.1 ELECTRICAL SCHEMATIC-FULL VOLTAGE...

  • Page 45: Electrical Schematic-Star-Delta

    7.2 ELECTRICAL SCHEMATIC-STAR-DELTA...

  • Page 46: Foundation Plan - Air Cooled

    7.3 FOUNDATION PLAN (AIR COOLED)

  • Page 47: Foundation Plan - Water Cooled

    7.4 FOUNDATION PLAN (WATER COOLED)

  • Page 48: Foundation Plan - Outdoor Mod

    7.5 FOUNDATION PLAN - OUTDOOR MOD...

  • Page 49: Basic Flow Schematic - Air Cooled

    7.6 BASIC FLOW SCHEMATIC - AIR COOLED...

  • Page 50: Basic Flow Schematic - Water Cooled

    7.7 BASIC FLOW SCHEMATIC - WATER COOLED...

  • Page 51: Typical System Flow Diagrams

    TYPICAL SYSTEM FLOW DIAGRAM 7.8 TYPICAL SYSTEM FLOW DIAGRAMS...
  • Page 52 7.8 TYPICAL SYSTEM FLOW DIAGRAMS...
  • Page 53 7.8 TYPICAL SYSTEM FLOW DIAGRAMS...
  • Page 54 7.8 TYPICAL SYSTEM FLOW DIAGRAMS...
  • Page 55 7.8 TYPICAL SYSTEM FLOW DIAGRAMS...

  • Page 56: Water Quality Recommendations

    8.0 WATER QUALITY RECOMMENDATIONS Perhaps the largest contributor to scale formation is the Water quality is often overlooked when the cooling precipitation of calcium carbonate out of the water. This is system of a water cooled air compressor is examined. dependent on temperature and pH.
  • Page 57 Recommended equipment for on-site analysis includes a thermometer, pH meter, and dissolved oxygen meter. Dissolved oxygen and temperature must be measured on-site and it is recommended that pH be measured on-site. All other analyses should be performed by a professional water quality analyst. The Langelier Index (Ll) is calculated using the following equation and the tables found on the following pages.
  • Page 58 LANGELIER INDEX CHART VALUES Total dissolved solids (ppm) Temperature (°F) UNITS 2.60 2.67 2.54 2.81 2.48 2.45 2.43 2.40 2.37 2.34 2.31 2.28 2.25 2.22 2.20 2.17 2.14 2.11 2.09 2.06 2.04 2.03 2.00 1.97 1.95 1.92 1.90 1.88 1.86 1.84 1.82 1.80...
  • Page 59 9.0 MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...

  • Page 60: Maintenance Record

    MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...
  • Page 61 MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...
  • Page 62 MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...

This manual is also suitable for:

Epe 50Hp 60Xf 75-100Ep 75-100Hp 75-100Xp 75-100 ... Show all

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