Ingersoll-Rand EP 20 SE Operators/Instruction Manual Options
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Ingersoll-Rand EP 20 SE Operators/Instruction Manual Options

Rotary screw air compressor
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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.
EP/HP/HXP 20 SE
EP/HP/HXP 25 SE
OPERATORS/
INSTRUCTION MANUAL
OPTIONS
®
APDD 567A
September 1998

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  • Page 1 ® EP/HP/HXP 20 SE EP/HP/HXP 25 SE 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 EXTENDED AIREND WARRANTY The 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...
  • Page 3 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: __________________________...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 0.0 SAFETY AND WARNINGS 5.15 motor lubrication 0.1 safety instructions 5.16 long term storage 0.2 safety precautions 5.17 coolant/lubricant changeout 0.3 decals 5.18 intellisys removal 5.19 coolant hoses 1.0 RECEIPT OF EQUIPMENT 5.20 airend discharge hose inspection unpacking and handling 6.0 TROUBLE SHOOTING tools...

  • 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 CAUTION are used to indicate hazard seriousness levels Before you install this air compressor you should take the time to carefully read all the instructions contained in this as follows: manual.
  • Page 6 It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine. WARNING “Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll-Rand does not approve specialized equipment for breathing air application and assumes no responsibility or liability for compressors...

  • 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 568).

  • Page 11: Receipt Of Equipment

    WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL. THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR RESPONSIBILITY. Ingersoll-Rand Company Davidson, North Carolina APDDGFO-99-79 1.2 UNPACKING AND HANDLING The compressor package has been mounted on a base which provides for forklifting between the two side channels to facilitate handling during shipment.

  • 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. A room in which the amount of air that is drawn in and exhausted is equal to or greater than the cooling fan air flow requirement for the compressor that is installed.
  • 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 in the VALVE base. 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.

  • Page 14: Electrical Installation

    33°F (1°C). SAFETY ISOLATION VALVE VALVE Contact your local Ingersoll-Rand distributor for PRESSURE assistance in selecting correct Ingersoll-Rand filtration or GAUGE ROTARY drying products. COMPRESSOR NOTE: Screw type compressors should not be installed in air systems with reciprocating compressors without a...
  • 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 C.T. 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...
  • Page 16 ELECTRICAL INSTALLATION (Continued) Remove 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 “CHK MTR the starter. Close and fasten the starter box door. ROTATION”...

  • Page 17: Outdoor Sheltered Installation

    2.5 OUTDOOR SHELTERED INSTALLATION Many times a compressor must be installed outside due Power disconnect switch should be within line of sight to jobsite conditions or limited space within a and in close proximity to the unit. N.E.C. and local manufacturing facility.

  • Page 19: Intellisys

    3.0 INTELLISYS...

  • Page 20: Emergency Stop Switch

    START 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 POWER Seven seconds later it will stop. if the compressor is UNLOADED STOP immediately.
  • Page 21 UNLOADED STOP PRESSURE SENSOR CALIBRATION (ZEROING) 3.4 PUSH BUTTONS (Continued) ROUTINE EMEG DISPLAY DISPLAY SELECT This routine is entered if the unit is not running and SELECT STOP both the up and down arrows button are pressed at Pressing this button will change the information the same time.

  • Page 22: Setpoint 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 This procedure allows the customer to modify 11 a sequencer). The lag compressor’s on-line and off-line variables in the controller logic.

  • Page 23: Alarms

    9) CK MTR ROTATION 3.7 ALARMS This alarm will occur if a unit is started and compressor has incorrect rotation. When an alarm occurs, the alarm indicator will light and display will show actual alarm message. If 10) CALIBRATION FAIL alternately multiple alarms have occurred the display This alarm will occur if the sensor calibration routine will show SCROLL FOR ALARM.

  • Page 24: Systems

    Ingersoll-Rand representative for additional information. The controlled temperature coolant passes through a filter to the airend under constant pressure.

  • Page 25: Compressed Air System

    4.3 COOLANT SYSTEM (Continued) Operation The coolant and air discharging from the There is a differential-pressure-bypass-valve set to compressor flow into the receiver through a open in the event that the pressure drop across the tangential discharge outlet. This outlet directs the filter element rises to as high as 25 psi (1.8 BAR), mixture along the inner circumference of the which indicates an excessively fouled element, as...

  • Page 26: Capacity Control

    On-Off Line Control 4.6 ELECTRICAL SYSTEM (Continued) For those plants which have a widely varying air By use of an optional built-in Star-Delta type starter, demand, on-off line control will deliver air at full the compressor motor can be started and accelerated capacity (compressor maximum efficiency condition) using a greatly reduced “inrush”...
  • Page 27 Modulation/ACS Control (Optional) For those plants which have relatively high constant air demand, relative to the compressor capacity, the recommended control mode is modulation. The modulation control system retains the features of the on line-off line control, but provides for throttling of the inlet flow up to the off line air pressure set point value.
  • Page 28 Modulate/ACS Control (Continued) The compressor will then operate to deliver full capacity air to the plant system. If the plant air MODEL RATED system pressure rises to that of the Intellisys off line OPERATING PRESSURE set point, pressurized air will be sent to the inlet valve causing it to close, and to the blowdown valve, 125 PSIG causing it to open.
  • Page 29 Modulate Control Valve Adjustment WARNING Ensure the compressor is isolated from the compressed air system by closing the isolation valve 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 compressor in the MODULATION mode.

  • Page 30: Maintenance Schedule

    Before starting any maintenance, be certain the following and detailed records of all maintenance work you, or the is heeded. Ingersoll-Rand Distributor or Air Center perform on your compressor. This includes but is not limited to coolant, 1. Read Safety Instructions.

  • Page 31: Sheave Alignment

    5.4 SHEAVE ALIGNMENT Any degree of sheave misalignment will result in a reduction of belt life. 1/16” (1.6mm) MAX. Misalignment of sheaves should not exceed 1/16" MAX 1/16”(1.6mm). Parallel misalignment occurs when the driven shafts are parallel, but the two sheaves lie in different planes. AIREND Angular misalignment occurs when the two shafts are not parallel.

  • Page 32: V-Belts

    5.5 V-BELTS WARNING Ensure the compressor is isolated from the compressor air system by closing the isolation valve and venting pressure from the drip leg. Insure the main power disconnect switch is locked open and tagged. Special Tools Belt tension gauge (39199138). Hazardous voltage.

  • Page 33: Belt Tension Adjustment

    Deflection Deflection DEFLECTION FORCE 4 LBS. tension gauge. This gauge can be obtained from your Force Force Ingersoll-Rand Distributor or Air Center. Tighten the belt (New) (After Run-In) tensioning locknut. 5.0 (23N) 3.5 LB (16N) Do not overtighten belts. It may cause damage to 5.5 (25N)

  • Page 34: Shaft Seal Replacement

    5.7 SHAFT SEAL REPLACEMENT Thoroughly clean and degrease the seal housing and wear sleeve journal on the rotor. There are two lip type seals on the compressor. They are wearable parts and should be replace at 8,000 Clean scavenge holes in seal housing and in the rotor hours.
  • Page 35 The term “inboard side” will refer to the large machined grease can be used to hold the check valve ball in place face of the seal housing. The term “out-board side” will for assembly). Push the rotor seal housing assembly refer to the unmachined side next to the sheave.

  • Page 36: Inlet Air Filter

    5.8 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 37: Coolant

    5.10 COOLANT Replace the fill cap. Start the compressor and allow it to run unloaded. The coolant level should now be near the SSR Ultra Coolant (Standard Factory Fill) midpoint of the sightglass. SSR H1-F Food Grade (Optional) DO NOT OVERFILL THE MACHINE. Over filling will SSR Ultra Coolant is a polyglycol base coolant.

  • Page 38: Separator Tank Scavenge

    5.11 SEPARATOR TANK SCAVENGE CHECK VALVE/SCREEN/ORIFICE Tools Required Open end wrench Screwdriver Procedure Disconnect tubing at each end of check valve/screen/orifice asembly. Check orifice and clean if required. Use suitable small screwdriver or knife and press screen retainer FIGURE 5.11-1 SEPARATOR TANK SCAVENGE orifice from its mating fitting (See Figure 5.11-1).

  • Page 39: Coolant Separator Element

    5.13 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 L.E.D. Table. If display says "XX PSI", then no maintenance is required. If warning light is on and display says "CHG SEPR ELEMENT"...

  • Page 40: Cooler Cores: Cleaning

    Coolant Cooler/Aftercooler 5.14 COOLER CORES: CLEANING Remove enclosure. Ensure the compressor is isolated from the compressed air system by closing the isolation valve Drain the coolant. See Section 5.10. and venting pressure from the drip leg. Disconnect piping from cooler inlet and outlet ports. Ensure the main power disconnect switch is locked open and tagged.

  • Page 41: Motor Lubrication

    5.15 MOTOR LUBRICATION The induction-type squirrel cage motors have antifriction ball or roller bearings front and rear. At periodic intervals they require relubrication. Relubrication Interval (or 9 months, whichever comes first) NOTICE 1000 hours ........all TEFC drive motors 2000 hours ..all ODP drive motors and all fan motors Relubrication amount Lubricant Amount Motor Frame Size...
  • Page 42 5.15 MOTOR LUBRICATION (Continued) Grease relief along shaft can occur, precluding necessity 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 WARNING reliefs protrude out the circumference of the lower portion of the end bell near a flange bolt.

  • Page 43: Long Term Storage

    3) Handle circuit boards only by their edges. 5.17 COOLANT/LUBRICANT CHANGEOUT 4) Do not place the Intellisys® Controller on any Ingersoll-Rand does not recommend changeout of metal surface. coolant/lubricants, however, if a coolant/lubricant change cannot be avoided, procedure APDD 106E-87...

  • Page 44: Coolant Hoses

    5.19 COOLANT HOSES The flexible hoses that carry coolant to and from the oil cooler may become brittle with age and will require replacement. Have your local Ingersoll-Rand distributor check them every 2 years. Ensure the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg.

  • Page 45: 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". — Inspect contactors. "EMERGENCY STOP". — Rotate emergency stop button to disengage, and press"SET"...
  • Page 46 Drain line/drip leg incorrectly installed. — Slope drain line away from trap. Install drip leg. No refrigerated or desiccant dryer in — Contact local Ingersoll-Rand air system. Distributor or Air Center. V-belts slipping. — Adjust belt tension or replace belts.

  • Page 47: Options

    7.0 OPTIONS 7.1 REMOTE START/STOP WARNING The remote start/stop option allows the operator to control the compressor from a remote mounted Disconnect power before This machine is remote start/stop station. This option may be factory servicing. start and stop equipped. installed or a field installation kit is available.

  • Page 48: Reference Drawings

    8.0 REFERENCE DRAWINGS 8.1 ELECTRICAL SCHEMATIC-FULL VOLTAGE...

  • Page 49: Electrical Schematic-Star-Delta

    8.2 ELECTRICAL SCHEMATIC-STAR-DELTA...

  • Page 50: Electrical Schematic-Full Voltage Remote Mounted Starter

    8.3 ELECTRICAL SCHEMATIC-FULL VOLTAGE REMOTE MOUNTED STARTER...
  • Page 51 NOTES:...
  • Page 52 39838750 REV 02 8.4 FOUNDATION PLAN - ENCLOSED (Continued)

  • Page 53: Foundation Plan - Enclosed

    39838750 REV 02 8.4 FOUNDATION PLAN - ENCLOSED...
  • Page 54 39848171 REV 02 8.4 FOUNDATION PLAN - UNENCLOSED (Continued)

  • Page 55: Foundation Plan - Unenclosed

    39848171 REV 02 8.4 FOUNDATION PLAN - UNENCLOSED...
  • Page 56 39848189 REV 02 8.6 FOUNDATION PLAN - OUTDOOR MODIFICATION (Continued)

  • Page 57: Foundation Plan - Outdoor Modification

    39848189 REV 02 8.6 FOUNDATION PLAN - OUTDOOR MODIFICATION...

  • Page 58: Basic Flow Schematic - Full Voltage

    8.7 BASIC FLOW SCHEMATIC - FULL VOLTAGE...

  • Page 59: Basic Flow Schematic - Full Voltage With Modulation

    8.8 BASIC FLOW SCHEMATIC - FULL VOLTAGE WITH MODULATION...

  • Page 60: Basic Flow Schematic - Star-Delta

    8.9 BASIC FLOW SCHEMATIC - STAR-DELTA...

  • Page 61: Basic Flow Schematic - Star-Delta With Modulation

    8.10 BASIC FLOW SCHEMATIC - STAR-DELTA WITH MODULATION...

  • Page 62: Typical System Flow Diagrams

    TYPICAL SYSTEM FLOW DIAGRAM 8.11 TYPICAL SYSTEM FLOW DIAGRAMS...
  • Page 63 8.11 TYPICAL SYSTEM FLOW DIAGRAMS...
  • Page 64 8.11 TYPICAL SYSTEM FLOW DIAGRAMS...
  • Page 65 8.11 TYPICAL SYSTEM FLOW DIAGRAMS...
  • Page 66 8.11 TYPICAL SYSTEM FLOW DIAGRAMS...
  • Page 67 9.0 MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...

  • Page 68: Maintenance Record

    MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...
  • Page 69 MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...
  • Page 70 MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...

This manual is also suitable for:

Hxp 25 seHp 20 seHxp 20 seEp 25 seHp 25 se

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