Ingersoll-Rand ARO EVO Series Operator's Manual
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Ingersoll-Rand ARO EVO Series Operator's Manual

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OPERATOR'S MANUAL
INCLUDING: OPERATION, INSTALLATION AND MAINTENANCE
2" EVO SERIES  ELECTRIC DIAPHRAGM PUMP
INGERSOLL RAND COMPANY INC
209 NORTH MAIN STREET – BRYAN, OHIO 43506
(800) 495-0276
FAX (800) 892-6276
arozone.com
(METALLIC FLUID SECTIONS)
© 2022
EP20-XXXXX-XXX-XXX
RELEASED:
1-28-22
REVISED:
9-30-22
(REV: B)

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  • Page 1 OPERATOR’S MANUAL EP20-XXXXX-XXX-XXX INCLUDING: OPERATION, INSTALLATION AND MAINTENANCE RELEASED: 1-28-22 REVISED: 9-30-22 (REV: B) 2” EVO SERIES  ELECTRIC DIAPHRAGM PUMP (METALLIC FLUID SECTIONS) INGERSOLL RAND COMPANY INC 209 NORTH MAIN STREET – BRYAN, OHIO 43506   (800) 495-0276 FAX (800) 892-6276 ©...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. TECHNICAL SPECIFICATIONS ....3 8. GROUNDING ........24 1.1.

  • Page 3: Technical Specifications

    1. TECHNICAL SPECIFICATIONS 1.1. Pump Data Models ..See Model Description Chart for “-XXXXX”. Maximum Temperature Limits Pump Type . . Electric Diaphragm Pump Material ..See Model Description Chart   ...

  • Page 4: Variable Frequency Drive (Vfd) Data

    1.2. Variable Frequency Drive (VFD) Data Ordinary Hazardous Part Number 132L0263 132L0262 Power 7.5 kw 7.5 kw Input Voltage 200-240 VAC +/- 10%, 3 Phase, 50/60 Hz 200-240 VAC +/- 10%, 3 Phase, 50/60 Hz Frame Size Ingress Protection NEMA 4X / IP66 NEMA 4X / IP66 Option A Slot N/A - Available for Fieldbus Card Options...

  • Page 5: Electric Motor Data

    1.3. Electric Motor Data ORDINARY LOCATION MOTOR HAZARDOUS LOCATION MOTOR (Black) (Red) Figure 1 ORDINARY HAZARDOUS Part Number 67559 67560-3 Rated Power 5.5 kw 5.5 kw Rated Torque 36 Nm 36 Nm Efficiency Number Of Phases Polarity Voltage 230 VD / 400 VY 230 VD / 400 VY Frequency 50 Hz...

  • Page 6: Nameplate Details

     Viton® is a registered trademarks of the Chemours Company Loctite® is a registered trademark of Henkel Corporation   Santoprene® is a registered trademark of Celanese  ARO® is a registered trademark of Ingersoll-Rand Company  Page 6 of 44...

  • Page 7: Model Description Chart

    2. MODEL DESCRIPTION CHART 2.1. Model Code Explanation Wetted Parts Aluminum C - Cast Iron S - Stainless Steel Port F - ANSI / DIN Hybrid Flange Seat A - Santoprene® F - Aluminum H - 440 SST S - 316 SST Ball A - Santoprene®...

  • Page 8: Operating And Safety Precautions

    3. OPERATING AND SAFETY PRECAUTIONS READ, UNDERSTAND, AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE. All electrical wiring must be done by a qualified elec-  EXCESSIVE FLUID PRESSURE HAZARDOUS MATERIALS trician and comply with all local codes and regula- STATIC SPARK HAZARDOUS PRESSURE tions.

  • Page 9: General Description

    Maximum temperatures are based on Prevent unnecessary damage to the CAUTION CAUTION mechanical stress only. Certain chemicals will signifi- pump. Do not allow pump to operate when out of ma- cantly reduce maximum safe operating temperature. terial for long periods of time. Disconnect power supply from motor when system Consult the chemical manufacturer for chemical com- ...

  • Page 10: Mechanical Installation

    5. MECHANICAL INSTALLATION 5.1. Pump and Motor Installation WARNING Pump and motors are industrial products. They must therefore be installed by qualified, experienced and autho- rized personnel. The safety of people, animals and property must be ensured when fitting the motors into pump. CAUTION Prior to commissioning for all motors, rotate the motor at no load (no mechanical load) for 2 to 5 minutes, checking that there is no abnormal noise.

  • Page 11: Vfd Mechanical Installation

    5.3. VFD Mechanical installation The ordinary motor gearbox will also need to have a breather installed after installation to the pump. Refer to section 3 of VFD manual for detailed mechanical  Remove the temporary metallic plug from breather port. installation.

  • Page 12: Electrical Installation For Ordinary Locations

    6. ELECTRICAL INSTALLATION FOR ORDINARY LOCATIONS 6.1. VFD-Wiring Diagram 3-phase 91 (L1) (U) 96 power (V) 97 92 (L2) input 93 (L3) (W) 98 (PE) 99 Motor Switch mode 88 (-) power supply DC bus 89 (+) 10 V DC 24 V DC Brake (R+) 82...

  • Page 13: Vfd Ac Mains - Input Power Requirements

    Recommended VFD Cable Entry Positions (B1 Frame Size) 2 plcs - Optional Glands Encoder Cable 1/2" NPT or M20 (22.5 mm) 3/4" NPT or M25 (28.4 mm) Low Voltage Bundled Cable *Leak Detects (3x) *Motor Thermistor Incoming *Safe Stop (E-Stop) Mains Cable 1"...

  • Page 14: Motor - Input Power Wiring

    Position the stripped wire under the cable clamp to establish mechanical fixation and electrical contact between the cable  shield and ground. Connect the ground wire to the nearest grounding terminal in accordance with the grounding instructions, Refer to sec- ...

  • Page 15: Control Wiring (Required)

    6.5. Control Wiring (Required) 6.5.1. Leak detector wiring diagram General Description: An ARO Diaphragm pump equipped with the ARO Leak Detection Sensor warns of a Diaphragm failure by sensing the pres- ence of liquid in the air cap of the pump. This system uses a liquid sensor in each of the three air caps which will send an out- put signal to the VFD to shut down the motor when fluid is detected.

  • Page 16: Thermal Protection - Ordinary Motor

    6.5.2. Thermal protection – Ordinary motor Motor is installed with 2 normally closed contact sensors (PTO) in series for ordinary motors and will need to be wired from  the motor terminal box to the VFD as per below wiring diagram. Cable extension and cable glands are not provided. It is recommended to use the M16 cable gland on the motor terminal box for the PTO control cable.

  • Page 17: Control Wiring (Recommended)

    6.6. Control Wiring (Recommended) 6.6.1. Safe Stop wiring diagram It is recommended to install an external Emergency Stop (Safe Stop). Referred to in VFD manual as Safe Torque Off (STO).  The VFD will come with pin 37 (E-stop digital input) wired to 24V (pin 12 or 13). This jumper will need to be removed when ...

  • Page 18: Analog Input - Speed Control

    6.7.2. Analog Input – Speed control A 0 - 10 V or 4 - 20 mA signal can be used to control VFD speed from 0 - 100% using analog input 53.  The VFD is set to receive a 0-10 V input signal as configured from the factory. To change to 4-20 mA input signal, toggle the ...

  • Page 19: Additional Available Input/Output (Optional)

    6.7.4. Additional available Input/output (Optional) 1. T27 and T29 are configurable for digital input or output. Digital output can be either digital or pulse output. The options for parameters 530 and 531 are all digital, however,  to enable pulse output the parameters in the table below should be set as shown. The pulse output variable can then be selected using parameters 560 and 563.

  • Page 20: User Defined Readout

    Fieldbus Communication Option A Cards: These are available for aftermarket installation only and should be installed in the VFD option A slot. Please note this is only available for ordinary applications. Part Number Description 130B1200 Profibus DP VI MCA 101, coated 130B1202 DeviceNet MCA 104, coated 130B1205...

  • Page 21: Electrical Installation For Hazardous Locations

    7. ELECTRICAL INSTALLATION FOR HAZARDOUS LOCATIONS 7.1. General Wiring Cable glands and plugs shall be selected in accordance with IEC 60079-0, IEC 60079-14 Table 10 and EPL Gb/Db at Before commissioning verify that the information shown on the minimum. They must be correctly sized, tightened, and the nameplate is compatible with explosive atmosphere that gripped and account for any coldflow characteristics of the is present and with the zone where used.

  • Page 22: Hazardous Motor

    Leak Detector Safe Loop Calculations Leak Detector Cable Zener Barrier IR Part Number 96270-2 Alpha Wire 1173C IR Part Number 97414 Ui = 32 VDC Uo = 25.2 VDC Ii = 87 mA Io = 74 mA Pi = 0.616 W Po = 0.464 W Ci = 0.052 uF Cc 0.055uF...

  • Page 23: Encoder Wiring - Hazardous Motor

    7.3.3 Encoder Wiring - Hazardous Motor The hazardous duty motor will come with a 1024pt TTL encoder with 10 meters of cable lengths and flying lead connec-  tions. The motor will ship without the encoder installed to minimize the chance of damage during shipping and installa- tion since the encoder is installed on top of the rain canopy.

  • Page 24: Grounding

    8. GROUNDING 8.2. VFD Grounding Before operating the pump, ground the system as explained below. LEAKAGE CURRENT HAZARD WARNING Leakage currents exceed 3.5 mA. Failure to ground the drive 8.1. Pump Grounding properly can result in death or serious injury. All pumps have a ground screw installed in Crankcase ...

  • Page 25: Operation

    9. OPERATION 9.1. Pre Operation Checklist VFD is configured according to the motor requirement. The outlet material volume is governed not only by the   Close the safety cover properly and check that all cable Fluid pressure but also by the material supply available ...

  • Page 26: Vfd Smart Setup

    Parameter Description Function Set the maximum frequency for terminal 29, corresponding to the output variable selected in Pulse Output Max Freq #29 parameter 563. Function Relay Define relay functions using 540.0 and 540.1 (2 relays available). Enter the low voltage value (Default 0.07V). This corresponds to the minimum reference value of 0 Terminal 53 Low Voltage Enter the high voltage value (Default 10V).

  • Page 27: Maintenance

    10. MAINTENANCE Refer to the part views and descriptions as provided on page 28 through 37 for parts identification and Service Kit information. Service kits are divided to service four separate section: 1. Before disassembling   CRANKCASE SECTION, 2. FLUID SECTION, 3. PRV SECTION, Empty oil from Crankcase housing through drain port.

  • Page 28: Subsystem Overview

    11. SUBSYSTEM OVERVIEW PARTS LIST / FLUID SECTION EP20-XXXXX-XXX-XXXX Fluid Section Service Kits:  637555-XX Fluid Section Service Kits include: Balls (see BALL Option, refer to -XX in chart below), Diaphragms (see DIAPHRAGM Op- tion, refer to -XX in chart below), and items 3, 4, 12 and 13 (listed below). EXTERNAL HARDWARE OPTIONS EP20-XXXXX-XXX-XXX COMMON PARTS Aluminum /...
  • Page 29 PARTS LIST / FLUID SECTION EP20-XXXXXX-XXX-XXX COLOR CODE )ASSEMBLY TORQUE REQUIREMENTS( NOTE: DO NOT OVERTIGHTEN FASTENERS. Material Diaphragm Ball Color Color (14) Screw, tighten to 55 - 60 ft lbs (75 - 81 Nm). Santoprene® (26, 68) Screws, 20 - 25 ft lbs (27 - 34 Nm). Santoprene®...
  • Page 30 FLUID SECTION DISASSEMBLY FLUID SECTION REASSEMBLY Remove inlet Manifolds (60, 64, 65) and outlet Manifolds Reassemble parts in reverse order from the sequence in   (61, 62, 63) together. which they were removed. Refer to the torque require- Separate inlet wye Manifold (60), Inlet PRV Manifold (65) ments on page 29.

  • Page 31: Prv Section

    PARTS LIST / PRV EP20-XXXXX-XXX-XXX MANIFOLD / HOUSING MATERIAL OPTIONS EP20-XXXXX-XXX-XXX Aluminum Cast Iron Stainless Steel Item Description Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] (size) PRV ASSY 67557-1 67557-2 67557-3  44 Housing, PRV 97971 98073 [CI] 98087 [SS] Manifold, PRV Return...
  • Page 32 PARTS LIST / PRV EP20-XXXXX-XXX-XXX See Detail A )ASSEMBLY TORQUE REQUIREMENTS( NOTE: DO NOT OVERTIGHTEN FASTENERS. (53) Nut, tighten to 7 - 10 ft lbs (10 - 14 Nm). (55) Bolt, tighten to 20 - 25 ft lbs (27 - 34 Nm). DETAIL A Figure 14 Page 32 of 44...

  • Page 33: Crankcase Section

    PARTS LIST / CRANKCASE EP20-XXXXX-XXX-XXX Pump Crankcase Replacement Assembly EP20-CSVX-00-A : Includes all Items shown in the Crankcase parts list (below) except for  item 283. Includes all items shown in the oil pump parts list (page 36). Includes items 13, 16 and 17 shown on page 28. Note: Crankcase components are designed for the intended life of the pump.
  • Page 34 PARTS LIST / CRANKCASE EP20-XXXXX-XXX-XXX Grease inner diameter of seal only )ASSEMBLY TORQUE REQUIREMENTS( NOTE: DO NOT OVERTIGHTEN FASTENERS. (104) Screw, tighten to 20 - 23 ft lbs (27 - 31 Nm). (106) Screw, tighten to 30 - 35 ft lbs (40 - 47 Nm). (115) Screws, 8 - 12 ft lbs (11 - 16 Nm).
  • Page 35 Remove internal snap ring (136) and the wrist pin (135). Lower Crankshaft assembly vertically inside Crankcase   Remove the piston rod (134) and rider band (133).  housing (101) and allow inner race of lower bearing to Journal Bearing (139) is press fitted in to the connecting ...

  • Page 36: Oil Piston Pump Section

    PARTS LIST / OIL PISTON PUMP ASSEMBLY SECTION EP20-XXXXX-XXX-XXX Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl] 128 Plug Y17-52-S [SS] (3/8” - 18 NPT)  164 Plug Y17-50-S [SS] (1/8” -18 NPT ) (not shown) 129 Fitting 98059 (9/16”-18 STOR x 3/8”, 90°)
  • Page 37 PARTS LIST / OIL FILTER EP20-XXXXX-XXX-XXX )ASSEMBLY TORQUE REQUIREMENTS( NOTE: DO NOT OVERTIGHTEN FASTENERS. (129, 176) Straight Thread O-Ring, tighten to 20-25 ft lbs (27-34 Nm) (150) Screws, tighten to 8-12 ft lbs (11-16 Nm) (174, 175) Screws, tighten to 20-30 in lbs (2.2-3.4 Nm) )129 (158) Plug, tighten to 45-50 ft lbs (61-68 Nm) (179) Fitting Body, tighten to 45-50 ft lbs (61-68 Nm)

  • Page 38: Troubleshooting

    12. TROUBLESHOOTING Issue Possible Cause Action See manual section 6 and 7 for proper wiring instruc- Improper power wiring: Mains to VFD, VFD to Motor. tions. Improper sensor wiring: Leak detects, e-stop, motor thermal See manual section 6 and 7 for proper wiring instruc- sensor, motor encoder.

  • Page 39: Dimensional Data

    13. DIMENSIONAL DATA 13.1 Pump With Motor (Dimensions shown are for reference only, they are displayed in inches and millimeters (mm)). 51.79” (1315.4 mm) Ordinary pump height 3.31” 1.81” Outlet (84 mm) (46 mm) 2" ANSI / DIN Flange 39.27” (997.6 mm) 1/8”...

  • Page 40: Variable Frequency Drive (Vfd)

    13.2. Variable Frequency Drive (VFD) VARIABLE FREQUENCY DRIVE (VFD) - A5 Frame Size SEE DETAIL 9.53” 0.25” (242 mm) (6.42 mm) 16.54” (420.2 mm) 15.81” (401.7 mm) 0.39” 8.46” (10 mm) 0.53” DRIVE DISCONNECT (215 mm) (13.5 mm) SEE DETAIL 5.40”...
  • Page 41 VARIABLE FREQUENCY DRIVE (VFD) - B1 Frame Size SEE DETAIL F 9.53” 0.35” (242 mm) (9 mm) 17.87” 18.92” (454 mm) (480.8 mm) DRIVE DISCONNECT 0.35” 8.26” 0.55” (9 mm) (210 mm) (14 mm) 8.07” SEE DETAIL G (205 mm) 6.37”...

  • Page 42: Performance Curve

    14. PERFORMANCE CURVE EP20-XXXXX-XXX-XXA 2" EVO ELECTRIC DIAPHRAGM PUMP (METALLIC FLUID SECTION) Performance based on water at ambient temperature. CAPACITY IN U.S. GALLONS PER MINUTE Performance based on water at ambient temperature. FLOW RATE (LITERS / MIN.) Drive Controls: Motor Frequency ≈ Flow Torque limit ≈...

  • Page 43: Certification

    15. CERTIFICATION 15.1 Certification Standards and Markings Description Directive Applicable Standards Marking EN 61000 - 6 - 2:2005/AC:2005 EN 61000 - 4 - [2,3,4,5,6,8,11] EN 55011:2016/A1:2017/A11:2020 Group 1 Class A EMC Directive 2014/30/EU FCC Part 15 Subpart B ICES-001:Issue 5:2020 Chinese National Standard 13438 (2006) AS/NZS CISPR 11:2017 EN ISO 12100:2010...

  • Page 44: Warranty Declaration

    Internet sites and unauthorized storefronts on online marketplaces. Ingersoll-Rand / ARO will provide a new part or repaired part, at its election, in place of any part which is found upon its inspec- tion to be defective in material and workmanship during the period described above. Such part will be repaired or replaced without charge to the initial end customer during normal working hours at the place of business of a Reseller authorized to sell the type of Product involved or other establishment authorized by Company.

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