Ingersoll-Rand EP 20-ESP Operators/Instruction Manual And Parts List
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Ingersoll-Rand EP 20-ESP Operators/Instruction Manual And Parts List

Ingersoll-Rand EP 20-ESP Operators/Instruction Manual And Parts List

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INGERSOLLrAND
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 20/25/30 - ESP
OPERATORS/
INSTRUCTION MANUAL
PARTS LIST
RECOMMENDED SPARES
®
APDD 655B
September 1996

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  • Page 1 INGERSOLLrAND ® EP 20/25/30 - ESP OPERATORS/ INSTRUCTION MANUAL PARTS LIST RECOMMENDED SPARES 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 Purchaser 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. ©INGERSOLL-RAND COMPANY...
  • 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. No. of units on order: Customer Order No: Ingersoll-Rand Co.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.0 REFERENCE DRAWINGS 0.0 SAFETY AND WARNINGS 6.1 electrical schematic - full voltage 0.1 safety instructions 6.2 electrical schematic - star delta 0.2 safety precautions 6.3 piping diagram 0.3 decals 6.4 foundation plan - tank mounted 6.5 foundation plan - base mounted 1.0 RECEIPT OF EQUIPMENT 6.6 typical system flow diagram 1.1 inspection...

  • Page 5: Safety And Warnings

    0.0 SAFETY AND WARNINGS Safety instructions in the operators manual are bold-faced for emphasis. The signal words DANGER, WARNING and 0.1 SAFETY INSTRUCTIONS Before you install this air compressor you should take the CAUTION are used to indicate hazard seriousness levels as time to carefully read all the instructions contained in this follows: manual.
  • Page 6 Ingersoll-Rand Company. The Purchaser is urged to include the above provision in any agreement for any resale of this compressor.

  • Page 7: Decals

    0.3 DECALS This section contains representative examples of If for some reason a decal is defaced, parts are decals which will be appearing throughout this manual replaced or painted over, we recommend that you and are applied to the compressor unit. obtain a replacement (See Recommended Spare Parts List for Decal Kit Number).
  • Page 8 WARNING NOTICE This product is produced under license from Cash Engineering Research Pty. Ltd. United States and foreign patents pending INGERSOLLrAND® Hot surface. INGERSOLLrAND® Can cause severe injury. 39859228 Do not touch. Allow to cool before servicing. INGERSOLLrAND ® WARNING 39541362 39875463 39557095...
  • Page 9 WARNING CAUTION CAUTION Use of incorrect coolant can cause Improper maintenance of coolant system contamination. filter can cause compressor damage. Use only ROTALUBE 1000 COOLANT. Change coolant filter after first 150 hours of operation and every 1000 hours thereafter when coolant is changed. INGERSOLLrAND ®...

  • Page 10: Receipt Of Equipment

    as any other conditions which might be detrimental to 1.0 RECEIPT OF EQUIPMENT the proper operation of the compressor. 1.1 INSPECTION 2.2 FOUNDATION REQUIREMENTS When you receive the compressor please inspect it The compressor can be installed on any level floor that closely.
  • Page 11 • If the area around the installation contains fine air- • Some type of protection such as a fence or security borne dust or lint and fibers etc., then the unit should system, should be provided to prevent unauthorized be purchased with the TEFC motor option. access.

  • Page 12: Piping

    The use of plastic bowls on line filters without metal Contact your local Ingersoll-Rand Distributor or Air guards can be hazardous. Their safety can be affected Center for assistance in selecting correct Ingersoll- by either synthetic lubricants or the additives used in Rand filtration or drying products.
  • Page 13 IMPORTANT: Discharge piping should be at least as large as the discharge connection at the compressor. All piping and fillings must be suitably rated for the PRESSURE discharge pressure and temperature. RELIEF VALVE A careful review of piping size from the compressor PRESSURE connection point is essential.

  • Page 14: Electrical Installation

    NOTE: This procedure applies only to units manufac- 2.5 ELECTRICAL INSTALLATION tured to multi-voltage specifications. Motor nameplate must indicate multiple voltages. Before proceeding further, we recommend that you review the safety data in the front of this manual. PROCEDURE: Locate the compressor data plate on the left end of Put main disconnect in the OFF position, lock and tag the cooler box next to the control box.

  • Page 15: Shipping Bolt Removal

    2.7 SHIPPING BOLT REMOVAL 3. Replace and tighten fill plug. The unit is shipped with a bolt in the motor sup- 4. Close the main disconnect switch (ON) position. port to prevent possible belt damage caused by bouncing during shipment. This bolt must be 5.

  • Page 16: Systems

    2. Check coolant level. To check coolant level, slowly 3.2 COOLANT SYSTEM loosen the fill plug one complete turn. As the fill plug is The coolant system consists of a “L” shaped tube sep- unscrewed approximately one turn, a small amount of arator, thermostatic element, coolant filter, coolant pressure may be released.

  • Page 17: Air Systems

    COOLANT/AIR SEPARATION SYSTEM 3.4 CAPACITY CONTROL The coolant/air separation system is composed of a ON LINE/OFF LINE WITH AUTOMATIC START/STOP tube separator with specially designed internals and a CONTROL two stage, coalescing type separator element located The compressor will deliver air at full capacity, (the in a housing above the inlet control valve on the compressor maximum efficiency condition) or will oper- airend.
  • Page 18 3.5 SETTING NEMA 1 PRESSURE SWITCH PRESSURE SWITCH 1. Open isolation valve, allowing control system to sense “line” pressure. 2. Start the compressor. The compressor should load if the line pressure is lower than then the maximum discharge pressure stat- ed on the compressor data plate.
  • Page 19 3.6 SETTING NEMA 4 PRESSURE SWITCH 7. Vent air from customer system to confirm switch operation is satisfactory. 1. Open isolation valve, allowing control system to sense “line” pressure. 8. Place unit in service. 2. Start the compressor. Operating variables in a system may cause changing pressure requirements.

  • Page 20: Maintenance

    Have a well equipped mechanic’s tool box with English the Ingersoll-Rand Distributor or Air Center perform on and Metric sockets. (Special tools when needed will be your compressor. This includes, but is not limited to, listed under each appropriate procedure).

  • Page 21: Pressure Relief Valve Check

    Before beginning any work on the compressor, 4.5 SHEAVE ALIGNMENT open, lock and tag the main electrical disconnect Any degree of sheave misalignment will result in a and close the isolation valve on the compressor reduction of belt life. Misalignment of belt drive should discharge.
  • Page 22 ALIGN SHEAVES ALLEN HEAD SCREW SHEAVE RETAINING SCREWS Insure that the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg. Insure that the main power disconnect switch is locked and tagged. An easy and effective method of checking alignment in both directions between the driver and driven sheaves utilizes an accurate straightedge.

  • Page 23: Drive Belts

    This bolt is only used to brace the motor dur- ment required to insure proper belt tensioning. Be ing shipment and will not be reinstalled once the belts sure to use only Ingersoll-Rand Genuine parts to are put into place. Locate the motor support shipping assure correct belt tension.
  • Page 24 INSTALLATION (20-25 HP) 11. The term “inboard side” will refer to the large machined face of the seal housing. The term “out- 1. Remove both doors and the top of the enclosure, (if board side” will refer to the unmachined side next to so equipped).
  • Page 25 22. Place a thin bead of Loctite® 515 on the machined 32. Reinstall belts. surface of the seal housing as shown in Figure 4.8-2. Do not over apply. 33. Reinstall belt guards and enclosure. INSTALLATION(30 HP) BEAD OF 1. Remove enclosure, (if so equipped). LOCTITE®...
  • Page 26 11. The term “inboard side” will refer to the large 23. Lubricate the wear sleeve lightly with clean coolant. machined face of the seal housing. The term “outboard side” will refer to the unmachined side next to the 24. Slide the assembly sleeve over the shaft until it sheave.

  • Page 27: Inlet Air Filter Element

    4.9 INLET AIR FILTER ELEMENT SPECIAL TOOLS The inlet air filter should be changed at the interval Suitable clean drain pan or container to hold coolant shown in the maintenance chart or any time the filter drained from unit. becomes dirty. A quantity of proper coolant sufficient to top off the The filter element is not washable and must be coolant level in the compressor.

  • Page 28: Coolant Change

    9. Using a funnel, top off the level with new coolant. 6. Remove the replacement filter from its protective The proper level is at the top of the fill port. package. 10. Replace fill plug. 7. Apply a small amount of clean coolant on the rubber seal of the filter.

  • Page 29: Coolant Type Change

    4.12 COOLANT TYPE CHANGE 3. Place drain pan under coolant drain plug. OBJECTIVE To drain coolant from compressor as completely as 4. Remove drain plug and allow coolant to drain from possible when changing types of coolant to avoid cont- the tube separator.

  • Page 30: Coolant Separator Filter Element

    4.13 COOLANT SEPARATOR FILTER ELEMENT APPLY DOWNWARD FORCE ON TOP OF COVER BOLT The separator filter element should be replaced every year or after 1000 hours of operation, whichever comes first, to prevent excessive coolant carryover into the plant’s air piping system. The element is located in the cylindrical portion on top of the Inlet Control Valve (See Figure 4.14-1).
  • Page 31 ELEMENT 12. Insert and start retaining bolts. 13. Place downward force on cover and finish screw- ing bolts in evenly. 14. Torque bolts evenly to 220 in-lbs. (2.57 kg-m ). 15. Start unit and check for leaks. FIGURE 4.13-3 ELEMENT REMOVAL 5.

  • Page 32: Separator Tank Scavenge Check Valve/Screen/Orifice

    4.14 SEPARATOR TANK SCAVENGE 4.15 COOLER CORES CHECK VALVE/SCREEN/ORIFICE INSPECTION TOOLS REQUIRED Visually check the cooler cores for build up of dirt, dust, lint or other foreign material. Open end wrench Screwdriver Using an OSHA approved air gun, blow air through the cooler cores in the opposite direction of normal air PROCEDURE flow.

  • Page 33: Motor Greasing

    4.16 MOTOR GREASING Recommended Motor Grease The induction-type squirrel cage motor has antifriction Most motors require: ball bearings, front and rear. At periodic intervals they require re-lubrication. Mobilith SHC 220 ..... . .Mobil Re-lubrication Interval (or 9 mos., whichever comes Use the grease as indicated on a special grease infor- first)

  • Page 34: Trouble Shooting

    5.0 TROUBLE SHOOTING TROUBLE CHECK POINT NUMBERS Compressor Fails to Start 1,2,3 Repeat Shutdowns 3,4,5,2 High Amp Draw 8,9,6,7 Low Amp Draw 1,10,12 High Discharge Pressure 13,15,18 Low Air System Pressure 21,19,16,17,13,15,14,18,7 Unit Running Hot 21,20,22,23,6 High Coolant Consumption 27,26,24,25 Excessive Noise Level 16,17,30,29,28 Shaft Seal Leak...

  • Page 35: Reference Drawings

    39884143 REV 01 6.0 REFERENCE DRAWINGS 6.1 ELECTRICAL SCHEMATIC - FULL VOLTAGE...

  • Page 36: Electrical Schematic - Star Delta

    39884150 REV 01 6.2 ELECTRICAL SCHEMATIC - STAR DELTA...
  • Page 37 39874516 REV 02 PIPING LEGEND A- AIR PIPING C- COOLANT PIPING CA- CONTROL AIR PIPING NOTES: 1. FOR CUSTOMER CONNECTIONS SEE FOUNDATION PLAN OF UNIT. 2. DASHED ITEMS ARE OPTIONAL. 3. PRESSURE SWITCH & PRESSURE GAUGE ARE CONNECTED TO RECEIVER TANK ON TANK-MOUNTED UNITS.
  • Page 38 39871975 REV 03...
  • Page 39 39871975 REV 03...
  • Page 40 39872835 REV 03...
  • Page 41 39872835 REV 03...

  • Page 42: Typical System Flow Diagram

    PRE FILTER FUTURE DRYE ISOLATION VALVE RECEIVER COMP. SYSTEM AFTER PRE FILTER FILTER OUTSIDE COMPRESSOR ROOM GLADHAND Emergency Standby Air Hook Up. Complete with Necessary Fitting For Portable or IR Rental Air Unit From Local IR Distributor VALVE Water, Or Ball Type Valve UNION Aids in Disconnecting Compressor From The System PRESSURE GAUGE...

  • Page 43: Parts List

    Ingersoll-Rand Company, Limited. 2. Locate the part on the illustration please specify the following: There are also Ingersoll-Rand by visual identification and the ref- Company subsidiaries and autho- erence number. 1. The model number of the unit as...
  • Page 44 39876461 REV 02...

  • Page 45: Starter Assembly - Full Voltage

    Starter Assembly - Full Voltage Ref. Part Number Qty. Description 39881032 ENCLOSURE, STARTER BOX (NEMA 1) 39881040 ENCLOSURE, STARTER BOX (NEMA 4) 39237193 CONTACTOR, STARTER (SIZE K) 39237219 CONTACTOR, STARTER (SIZE N) 39240064 CONTACTS, AUXILIARY 2NO (SIZE K) 39245337 CONTACTS, AUXILIARY 1NO (SIZE N) 39190939 LUG, GROUND 39403290...
  • Page 46 39880844 REV 01...

  • Page 47: Starter Assembly - Star Delta

    Starter Assembly - Star Delta Ref. Part Number Qty. Description 39881032 ENCLOSURE, STARTER BOX (NEMA 1) 39881040 ENCLOSURE, STARTER BOX (NEMA 4) 39243597 CONTACTOR, STARTER (SIZE F) 39237193 CONTACTOR, STARTER (SIZE K) 39240064 CONTACTS, AUXILIARY 2NO (SIZE F) 39240064 CONTACTS, AUXILIARY 2NO (SIZE K) 39239868 CONTACTS, REVERSING (SIZE F) 39237227...
  • Page 48 39872031 REV 01 SEE PIPING ASSEMBLY OPTIONS...

  • Page 49: Major Components

    Major Components Ref. Part Ref. Part Number Qty. Description Number Qty. Description 39881974 DEFECTOR, AIR 39862222 ASSEMBLY, SEPARATOR TUBE 39133145 SCREW 39313184 CLAMP, TUBE 39878913 FAN, 50/60HZ 95953204 SCREW 96705082 SCREW 39128541 39872049 RING, FAN INLET 39876453 BASE, OPEN 39133145 SCREW 39246335 SCREW, JACK...
  • Page 50 39872882 REV 01 TO HIGH AIR TEMPERATURE TO HIGH AIR SWITCH (AIREND) TEMPERATURE TO RECEIVER TANK OR SWITCH (AIREND) TO RECEIVER TANK OR ELBOW IN ICV DISCHARGE ELBOW IN ICV DISCHARGE (BASE MOUNTED UNITS) (BASE MOUNTED UNITS) NEMA 1 NEMA 4...

  • Page 51: Starter Box With Pressure Switch

    Starter Box With Pressure Switch Assembly NEMA 1 NEMA 4 Ref. Part Ref. Part Number Qty. Description Number Qty. Description xxxxxxxx ASSEMBLY, STARTERBOX xxxxxxxx ASSEMBLY, STARTERBOX 39301973 CONNECTOR, CONDUIT 95333266 CONNECTOR, CONDUIT 39147186 30” CONDUIT 39135355 LOCKNUT, CONDUIT SEAL 39301965 ELBOW, CONDUIT 39132303 30 “...
  • Page 52 39872023 REV 02 TO AFTERCOOLER TO AFTERCOOLER...

  • Page 53: Piping Assembly

    Piping Assembly 30 HP Piping 20-25 HP Piping Ref. Part Ref. Part Number Qty. Description Number Qty. Description xxxxxxxx AIREND xxxxxxxx AIREND 39317870 ELBOW, TUBE 39111745 CONNECTOR, TUBE 39796479 TUBE, FEMALE INJECTION 39871884 TUBE, SCAVENGE 39111703 ELBOW, TUBE 39171517 ELBOW, TUBE 39128624 CONNECTOR, TUBE 39870886...
  • Page 54 O-Rings Part For SAE Tubing Thread Size Size 39404157 7/16-20 39404132 9/16-18 39404165 3/4-16 39437074 7/8-14 39407531 1-1/16-12 39404173 1-5/16-12 39404140 1-5/8-12 1-1/4 39406996 1-7/8-12 1-1/2 39410279 2-1/2-12...

  • Page 55: Recommended Spare Parts

    7.3 RECOMMENDED SPARE PARTS COMPRESSOR PART DESCRIPTION PART UNIT KIT, MAINTENANCE (W/ ROTALUBE 1000 COOLANT) 42413114 KIT, MAINTENANCE (W/ ULTRA COOLANT) 42420307 FILTER, AIR 39582721 FILTER, COOLANT 92740950 KIT, COOLANT SEPARATOR ELEMENT 42412452 COOLANT, ROTALUBE 1000 (4 X 1 GAL) 39236328 ULTRA COOLANT (5 GAL) 39433735...
  • Page 56 7.3 RECOMMENDED SPARE PARTS (CONTINUED) COMPRESSOR PART DESCRIPTION PART UNIT FULL VOLTAGE STARTER PARTS SIZE K CONTACTOR, STARTER(1M) - SIZE K 39237318 KIT, STARTER CONTACT (SIZE K) 39237250 COIL STARTER (SIZE K) 39237292 RELAY, STARTER OVERLOAD (SIZE K) 39237342 SIZE N CONTACTOR, STARTER(1M) - SIZE N 39237334 KIT, STARTER CONTACT (SIZE N)
  • Page 57 8.0 MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...

  • Page 58: Maintenance Record

    MAINTENANCE RECORD DATE RUN TIME WORK DONE QTY. UNIT WORK (HOURS) MEASURE...

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