Ingersoll-Rand XF 7.5, EP 15, HP 7.5, HP 15, XF 15 Operators/instruction Manual And Parts List

...

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.

XF 7.5 - 15 EP 7.5 - 15 HP 7.5 - 15 XP 7.5 - 15

OPERATORS/ INSTRUCTION MANUAL PARTS LIST RECOMMENDED SPARES

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.ingersoll-rand.com

APDD 702B

June 2000

BONDED WARRANTY & REGISTERED START UP

AIR COMPRESSOR GROUP

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.The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B.point of shipment, provided the Purchaser has stored, installed maintained 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 the Purchaser.The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of 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 performance warranties are limited to specified tests, the Company’s obligation shall be to correct in the manner and for the period of time 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 MERCHANTABILITY AND 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 time provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on contract, 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

in writing of its intention to do so.Any such use of Equipment will be at Purchaser’s sole risk and liability.

Limitation of Liability

The 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, or from 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 purchase price 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 this contract or any breach thereof, or any defect in, or failure of, or malfunction of the Equipment hereunder, whether based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other goods, loss by reason of shutdown or non-operation, increased expenses of operation, cost of purchase of replacement power or claims of 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.

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 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.

©INGERSOLL-RAND COMPANY

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.

No.of units on order: Customer Order No: Ingersoll-Rand Co. Order No.:

For ready reference:

Record the serial number and model number of your unit here.

Serial Number: Model Number:

TABLE OF CONTENTS

0.0 SAFETY AND WARNINGS

0.1 safety instructions

0.2 safety precautions

0.3 decals

1.0 RECEIPT OF EQUIPMENT

1.1 inspection

1.2 unpacking and handling

6.0 REFERENCE DRAWINGS

6.1 electrical schematic - full voltage

6.2 electrical schematic - star-delta

6.3 piping diagram

6.4 found. plan - 80 gal tank mounted - enclosed

6.5 found. plan - 80 gal tank mounted - unenclosed

6.6 found. plan - 120 gal tank mounted - enclosed

6.7 found. plan - 120 gal tank mounted - unenclosed

6.8 found. plan - base mounted - enclosed

6.9 found. plan - base mounted - unenclosed

6.10 typical system flow diagram

2.0 INSTALLATION

2.1 ventilation

2.2 foundation requirements

2.3 outdoor installations

2.4 piping

2.5 electrical installation

2.6 voltage conversion

2.7 rotation check

2.8 before starting - starting - stopping

3.0 SYSTEMS

3.1 general system information

3.2 coolant system

3.3 air systems

3.4 capacity control

3.5 pressure switch adjustment

4.0 MAINTENANCE

4.1 maintenance schedule

4.2 maintenance records

4.3 maintenance procedures

4.4 pressure relief valve check

4.5 sheave alignment

4.6 drive belt

4.7 belt tension

4.8 shaft seal replacement

4.9 inlet air filter element

4.10 coolant filter element

4.11 coolant change

4.12 coolant hose

4.13 coolant separator element

4.14 separator tank scavenge check valve/screen/orifice

4.15 cooler cores/cleaning

4.16 motor bearing maintenance-stored units

7.0 PARTS LIST

7.1 introduction

7.2 parts listing starter box assembly starter assembly - full voltage starter assembly - star-delta major components assembly drive components control piping assembly cooler box assembly with aftercooler cooler box assembly without aftercooler 80 gallon receiver tank assembly 120 gallon receiver tank assembly canopy assembly option table - O-rings

7.3 service and option kits

7.4 recommended spare parts

8.0 MAINTENANCE RECORD

GENERAL INFORMATION

Cooling Air Flow:

60 Hz: 1800 cfm (0.85 m3/sec) 50 Hz: 1500 cfm (0.71 m3/sec)

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

Coolant: Factory Filled ULTRA COOLANT

Coolant Change: 8,000 hours or two years, whichever comes first, when using ULTRA COOLANT

Coolant Capacity: 1.5 GAL (5.75L)

5.0 TROUBLE SHOOTING

DischargeTemperature Limit: 228°F (109°C)

Tools:U.S. Standard and metric are required to perform maintenance

0.0 SAFETY AND WARNINGS

0.1 SAFETY INSTRUCTIONS Before you install this air compressor you should take the time to carefully read all the instructions contained in this manual.

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

Before installing, wiring, starting, operating or making any adjustments, identify the components of the air compressor using this manual as a guide.

The operator should use common sense and good working practices while operating and maintaining this unit. Follow all codes, pipe adequately, understand the starting and stopping sequence. Check the safety devices by following the procedure contained in this manual.

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

0.2 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE

COMPRESSOR OR PERFORMING ANY MAINTENANCE

Safety instructions in the operators manual are bold-faced for emphasis. The signal words DANGER, WARNING and CAUTION are used to indicate hazard seriousness levels as follows:

Danger is used to indicate the presence of

D! DANGER

! WARNING

! CAUTION

NOTICE

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 whichwill 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.

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 SYSTEM HAS BEEN VENTED OF ALL PRESSURE.

1. Do not remove the covers, loosen or r e m ove 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 from the 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 g ro u n d s , 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 . W h e n ever 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 on the 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, nu m b e r 1 0 5 , p a rt 11, p a r agraph 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.

1 1 . After maintenance functions are completed, covers and guards must be replaced.

! SAFETY SHUTDOWN CHECK HIGH AIR TEMPERATURE

There is a high discharge air temperature shutdown function built into each compressor. It is factory preset at 228°F (109°C).This function should be checked at regular intervals for proper operation,once a month is recommended. PROCEDURE:

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.

! WARNING

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 take into 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 between discharge 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 not recommended.In addition,flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the 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

“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 used for breathing air services.”

0.3 DECALS

This section contains representative examples of decals which will be appearing throughout this manual and are applied to the compressor unit.

If for some reason a decal is defaced, parts are replaced or painted over, we recommend that you obtain a replacement (See Recommended Spare Parts List for Decal Kit Number).

39541362

39921804

39879762 I-R LOGO ON RECEIVER TANK

39868419 IR LOGO ON CANOPY (ENCLOSED UNITS)

39540265

39540273

39540240

39540174

39540232

INGERSOLLrAND®

39859236

3954190

39544143

39540281

39544150

*THESE DECALS ARE LOCATED ON THE END OF THE

RECEIVER TANK ON TANK MOUNTED UNITS.

39540166*

39540257*

1.0 RECEIPT OF EQUIPMENT

1.1 INSPECTION

2.2 FOUNDATION REQUIREMENTS

The compressor can be installed on any level floor that is capable of supporting the weight.

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 un-crated. Obtaining the delivery man’s signed agreement to any noted damages will facilitate any future insurance claims.

1.2 UNPACKING AND HANDLING

The compressor package has been mounted on a wooden shipping base which will allow fork lifting under the compressor base to facilitate handling during shipment. Care in positioning the forklift is important because the location of the center of gravity is strongly affected by the location of the airend and drive motor.

The wooden base must be removed prior to installation.

2.0 INSTALLATION

2.1 VENTILATION

Air cooled 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 re-circulate back to the compressor, the compressor will overheat and shut down.This heat must be exhausted from the room.You should take this into consideration when deciding where to place the compressor within the building. Sufficient clearance must be allowed around the compressor to perform the required maintenance.

Ambient temperatures higher than 115°F (46°C) should be avoided as well as areas of high humidity. Also consider the environment near the compressor.

DUST, CHEMICALS, METAL FILINGS, PAINT FUMES, and OVERSPRAY should be avoided as well as any other conditions which might be detrimental to the proper operation of the compressor.

When sound transmission is of particular importance, it is often helpful to install a sheet of rubber-fabric-matting, under the compressor baseplate or receiver tank feet to reduce the possibility of resonant sounds being transmitted or amplified through the floor.

2.3 OUTDOOR INSTALLATIONS

When a compressor must be installed outside, there are certain items that should be incorporated into the installation to help assure trouble free operation.These items have been listed below plus Figure 2.3-1 has been included to show a typical outdoor protected installation.The unit must be purchased with the NEMA 4 option to provide watertight electrics, and a TEFC motor.

• The compressor should be on a concrete pad designed to drain water away.If the concrete pad is sloped, then the compressor must be leveled.

• The roof of the shelter should overhang the compressor a minimum of 4 feet (1.2m) on all sides to prevent direct rain and snow from falling on the unit.

• The unit must be arranged under the shelter in a way that prevents air recirculation (i.e. hot exhaust 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 (2°C) or freezing of condensate will result.

• Power disconnect switch must be within the compressor operator’s line of sight and should be in close proximity to the unit.

• Condensate drains must never be allowed to dump on the ground. Pipe to a suitable sump for future collection, disposal or separation of lubricant and water mixture.

• Incoming power connections must use suitable connectors for outdoor weather tight service.

• Sufficient clearance must be allowed on all four sides of the unit for service access. If possible, access by a fork lift and/or an overhead beam hoist should be kept in mind (for eventual service to airend or motor).

• If the area around the installation contains fine airborne dust or lint and fibers etc., then the unit should be purchased with the TEFC motor option.

• Some type of protection such as a fence or security system, should be provided to prevent unauthorized access.

POWER DISCONNECT SWITCH

DISCHARGE

PIPE

(STEEL)

AREA SHOULD BE

SECURED WITH A FENCE

OR SECURITY SYSTEM

SLOPING

CONCRETE

PAD

FIGURE 2.3-1 TYPICAL OUTDOOR SHELTERED INSTALLATION

PRESSURE

TREATED

TIMBER TO

LEVEL

4’

(1.2m) OVERHANG

(ALL

SIDES)

ISOLATION

VALVE

DRIP

LEG

35°F (2°C) AND ABOVE

2.4 PIPING

It is essential when installing a new compressor to review the total plant air system.This is to insure a safe and effective total system.

The use of plastic bowls on line filters without metal guards can be hazardous.Their safety can be affected by either synthetic lubricants or the additives used in mineral oils. From a safety standpoint, metal bowls should be used on any pressurized system.

! WARNING

Do not use plastic pipe, soldered copper fittings or rubber hose for discharge piping.

Figure 2.4-1 indicates the approximate moisture content in compressed air at various operating points.

Contact your local Ingersoll-Rand Distributor or Air Center for assistance in selecting correct IngersollRand filtration or drying products.

200

Moisture Content of Compressed Air

Condensed water occurs naturally in air lines as a result of compression. Moisture vapor in ambient air is concentrated 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 by moisture are: rusting and scaling in pipelines, clogging of instruments, sticking of control valves, and freezing of outdoor compressed air lines. Any of these could result in partial or total shutdown of the compressed air system.

The compressed air discharging from this compressor will be at some elevated temperature and will therefore contain amounts of water vapor. As this air cools, the vapor will condense within the piping system.

IMPORTANT:The drain line must slope downward from the trap to work properly.

NOTE: For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel or some type of sight flow indicator.

160

120

DEW POINT

❏ without 100°F (with 35°F -40°F (Desiccant

Aftercooling Aftercooler) (Refrigerated Dryer)

Dryer)

FIGURE 2.4-1 MOISTURE CONTENT OF

COMPRESSED AIR

It is possible that additional condensation can occur if the downstream piping cools the air even further. Therefore, low points in the piping system should be provided with driplegs and traps.

Compressed air dryers reduce the water vapor concentration and prevent liquid water formation in compressed air lines. Dryers are a necessary companion to filters, aftercoolers, and automatic drains for improving the productivity of compressed air systems.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 to 39°F (.5°C to 4°C) are adequate. Desiccant dryers are required where pressure dew points must be below 33°F (.5°C).

IMPORTANT: Discharge piping should be at least as large as the discharge connection at the compressor. All piping and fittings must be suitably rated for the discharge pressure and temperature.

A 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 minimum air pressure drop and optimum efficiency of your compressor.

NOTE: Screw type compressors should not be installed in air systems with reciprocating compressors without a means of pulsation isolation, such as a common receiver tank.We recommend both types of compressor units be piped to a common receiver utilizing individual air lines. See Figure 2.4-2.

When two rotary units are operated in parallel, provide an isolation valve and drain trap for each compressor before the common receiver. See Figure 2.4-3

To assure long trouble free operation of a compressor operating with On-line/ Off-line and Auto Stop/Start control, the system volume must be large enough to keep the load/unload cycles to a minimum.This may require the installation of a receiver down stream of the compressor. Baseplate mounted units must be piped to a receiver if installed in a system with insufficient volume to keep compressor cycling to a minimum. If equipment such as filters or air dryers, is installed in the main piping system, they must be sized to handle the entire flow of the compressor and an air receiver must be placed in the system between the compressor discharge and the equipment, regardless of system volume.

This will prevent quick cycling of the compressor which results in large fluctuations in system pressure.

ROTARY

COMPRESSOR

FIGURE 2.4-2 ROTARY-RECIP IN PARALLEL

ROTARY

COMPRESSOR

FIGURE 2.4-3 ROTARY-TWO

COMPRESSOR SYSTEM

ROTARY

COMPRESSOR

2.5 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 left end of the cooler box next to the control box (See Figure

2.5-1). The data plate lists the rated operating pressure, the

maximum discharge pressure, the electric motor characteristics and power.

Confirm that the line voltage and compressor nameplate voltage are the same.

The standard control box meets the intent of NEMA 1 guidelines. It will be necessary to make a hole in the control box for the incoming power connection. Care should be taken to not allow metal shavings to enter the starter and other electrical components within the box. After making the power inlet hole, all shavings and debris must be removed from inside of control box before power is turned on.

Inspect the motor and control wiring for tightness. Replace control box door.

2.6 VOLTAGE CONVERSION

IMPORTANT:This procedure should only be carried out by a qualified electrician, electrical contractor or your local Ingersoll Rand Distributor or Air Center.

PRIMARY

Incoming power should be connected per the electrical schematic at the rear of this manual (See Section

6.0). Confirm that all electrical connections are made and tightened. Confirm that the control transformer is wired correctly for supply voltage (See Figure 2.6-1).

SECONDARY

FIGURE 2.6-1 CONTROL TRANSFORMER

CONNECTIONS

NOTE:This procedure applies only to units manufactured to multi-voltage specifications. Compressor data plate and motor nameplate must indicate multiple voltages.

FIGURE 2.5-1 COMPRESSOR DATA PLATE

PROCEDURE:

2.7 ROTATION CHECK.

Put main disconnect in the OFF position, lock and tag (See Figure 2.6-2).

FIGURE 2.6-2 MAIN DISCONNECT

LOCKED AND TAGGED

Open the motor junction box on the side of the motor.

Locate the rotation decal on the motor and check for correct rotation.The correct rotation when viewed from the opposite drive end of the motor is clockwise.

If compressor is operated in the opposite direction of rotation, airend damage can result and is not warrantable.

The unit is shipped with a bolt in the motor support to prevent possible belt damage caused by bouncing during shipment.This bolt must be remove prior to checking motor rotation or operating the unit.

Locate the shipping bolt in the motor support as shown in Figure 2.7-1. and remove.

SHIPPING BOLT

Reconnect the motor to the desired voltage. Use the connection diagram provided on the motor as a guide.

Reconnect the primary side of the control transformer for the desired voltage, as shown on the control transformer wiring decal.

Adjust motor overload setting as outlined below in Figure 2.6-3.

FIGURE 2.6-3 MOTOR OVERLOAD SETTING

FIGURE 2.7-1 SHIPPING BOLT LOCATION

For the compressor motor rotation check, the motor jogging should be as short a time as possible.

1. Ensure that the Stop button is in the stop (depressed) position.

2. Check coolant level.To check coolant level, slowly loosen the fill plug one complete turn. As the fill plug is unscrewed approximately one turn, a small amount of pressure may be released. Do not remove the fill plug until all pressure has been vented. Once pressure is vented, finish removing the fill plug.The proper coolant level is when the coolant is even with the top of the fill port. Add coolant if necessary.

3. Replace and tighten fill plug.

4. Close the main disconnect switch (ON position).

Make sure all wiring connections are tight. Put main disconnect in the ON position and check

motor rotation, as outlined in Section 2.7 of this manual.

5.Verify that the main isolation valve is open.

6. Open the canopy enclosure if machine is so

equipped. Push the Start button to start the unit and immediately depress (push) the Stop button to stop the unit. Observe the compressor drive motor shaft. The rotation should be in accordance with the directional arrow decal on the motor.

Should the motor rotation not be correct, put the main disconnect in the OFF position, lock and tag.

Interchange any two line connections (L1 ,L2, or L3) at the starter. Close the control box cover. Recheck for correct rotation.

Starting

1. Push the Start button and release.The compressor will start and then load automatically if line pressure is below the lower set point of the pressure switch.

Stopping

1. Depress the Stop button to the OFF position. Compressor will stop immediately.

2. Open the main disconnect switch (OFF position).

2.8 BEFORE STARTING - STARTING - STOPPING Read and understand the following instructions

before operating or performing any maintenance on this unit.

Before Starting:

1. Ensure that Stop push button is in the OFF (depressed) position (See Figure 2.8-1).

3. Replace and tighten fill plug.

4. Close the main disconnect switch (ON position).

5.Verify that the main isolation valve is open.

STOP

BUTTON

CONTROL

BOX

START

BUTTON

HOUR

METER

3.0 SYSTEMS

3.1 GENERAL SYSTEM INFORMATION

The compressor is an electric motor driven, single stage, rotary screw compressor, complete with supporting components to make a fully functional unit. A standard compressor is composed of the following: Inlet air filter Drive motor Airend Pressurized coolant system with cooler & filter Separation system Capacity control Instruments Safety devices

Compression in the rotary screw type air compressor is created by the meshing of two helical rotors (male and female) on parallel shafts, enclosed in a heavy duty iron housing, with air inlet and outlet ports located on opposite ends.The grooves of the female rotor mesh with and are driven by the male rotor. Bearings on both ends of the rotors are used to support the rotor both laterally and axially.

POWER ON

LIGHT

AUTO RESTART

LIGHT

FIGURE 2.8-1 CONTROL BOX

PRESSURE

GAUGE

3.2 COOLANT SYSTEM

The coolant system consists of a separator tank, thermostatic element, coolant filter, coolant cooler with fans, and a separator element.When the unit is operating, the coolant is pressurized and forced to the compressor bearings.The compressor is provided with a temperature switch which will shut the unit down in case of excessive temperature, 228°F (109°C). Effective coolant filtration is provided by the use of a screw on, automotive type, heavy duty coolant filter.

The compressor is designed for operation in an ambient range of 35°F to 115°F (2°C to 46°C).The standard maximum temperature 115°F (46°) is applicable up to an elevation of 3300 ft. (1000 m).

Coolant

3.3 AIR SYSTEM

Rotary screw compressor fluids have a triple function to perform.They lubricate the bearings and contacting surfaces of the rotors, seal internal clearances within the rotor chamber, and provide for the cooling of the compression process.The bulk of the fluid is actually used for cooling, with only small amounts used for lubrication and sealing.

SSR air compressors are factory filled with SSR ULTRA COOLANT. ULTRA COOLANT is designed to operate for 8,000 hours or two years, whichever comes first.The coolant must be changed at these intervals to avoid breakdown and equipment damage.

Circulation of Coolant

Coolant is forced by air pressure from the separator tank to the thermostatic element.The position of the element (a direct result of coolant temperature) will determine whether the coolant circulates through the cooler, bypasses the cooler, or mixes the two paths together to maintain an optimum compressor injection temperature.This temperature is controlled to preclude the possibility of water vapor condensing. By injecting coolant at a sufficiently high temperature, the discharge air coolant mixture temperature will be kept above the dew point.

Before being injected into the airend, all coolant flows through the coolant filter. It is a full-flow, spin-on element, rated at 4 micron.There is a differential-pressure bypass valve in the element that opens in the event that the pressure drop across the element rises to as high as 15 psi (1 bar), which indicates an excessively fouled element as well as poor maintenance practice.

Coolant/Air Separator System

Components and Flow

The air system is composed of: Inlet air filter Inlet valve Airend Coolant/Air separator Minimum pressure check valve (MPCV)

Aftercooler

The direction of flow is from the inlet filter to the aftercooler.

Functions of Components

Inlet air filter, filters the incoming air, trapping 99.9% of

particles 3 micron and larger.

Inlet valve opens full for on-line operation.The valve closes in the off-line mode and at shutdown which prevents back flow of the compressed air.

The airend compresses the air. The separator tank removes most of the coolant from

the air.

The separator element performs the final separation of coolant and cleaning of the air prior to leaving the

compressor. The minimum pressure check valve keeps the separa-

tor tank and separator element at a minimum pressure

to ensure adequate oil flow and proper coolant/air separation. It also prevents line pressure from exhausting back through the airend at shutdown and during periods of unloaded operation.

The aftercooler cools the air prior to leaving the package.

The coolant/air separation system is composed of a separator tank with specially designed internals and a coalescing type separator element located inside the tank.

The air-coolant mixture discharges from the airend into the separator tank.The majority of coolant is separated while in the separator tank and the coalescing separator filter element is used for final cleaning of the air prior to the customer’s system.The system removes nearly all of the coolant from the discharge air.The separated coolant is returned to the coolant system and the air passes to the compressed air system.

3.4 CAPACITY CONTROL On Line/Off Line With Automatic Start/Stop

Control

4. Set the off-line pressure by turning screw 2.Turn screw counter-clockwise to increase setting or clockwise to decrease setting (indicated by pointer 3).

The compressor will deliver air at full capacity, (the compressor maximum efficiency condition) or will operate at zero capacity with high receiver pressure (the compressor minimum power condition), while the unit continues to run.

When the compressor starts and line pressure is below the lower setting of the line pressure switch, control solenoid 1SV will be energized (closed), inlet valve will open, and the compressor will load.When the line pressure reaches the upper setting of the pressure switch, the compressor will unload by deenergizing (opening) 1SV and closing the inlet valve. Solenoid 1SV relieves the internal pressure of the compressor back to the inlet filter.The only adjustment required is setting of the pressure switch.

A time delay relay is energized and begins to time out. The timer, mounted in the control box, is factory set at 10 minutes. It will continue to operate for as long as its time setting, after which a relay contact opens to deenergize the compressor starter coil. At the same time, an amber light (1LT) on the control box is lit to indicate the compressor has shut down automatically and will restart automatically.The automatic restart will take place when the line pressure drops to the lower setting of the pressure switch. Adjusting the

Auto/Restart timer below the 10 minute factory setting may shorten the life of the compressor drive motor.

CAUTION: DO NOT EXCEED MAXIMUM DISCHARGE PRESSURE (LOCATED ON COMPRESSOR DATA PLATE).

5.Turn power back on, start compressor and test adjustment(s) made. If necessary, readjust according to steps 1-4 above.

PRESSURE SWITCH

3.5 PRESSURE SWITCH ADJUSTMENT

Locate the pressure switch as shown in Figure 3.5-1. The pressure switch can be adjusted using the following procedure:

1. Open, lock and tag the main electrical disconnect. Do not adjust the pressure switch with power on or machine operating.

2. Remove pressure switch cover by turning the cover screw counterclockwise. NOTE: It is required that the load or on-line pressure be set first, before the unload or off-line pressure is set.

3. Set the on-line pressure by turning screw 5 (See Figure 3.5-2).Turn clockwise to increase setting or counter-clockwise to decrease setting (indicated by pointer 4).

FIGURE 3.5-1 PRESSURE SWITCH LOCATION

FIGURE 3.5-2 PRESSURE SWITCH ADJUSTMENT

4.0 MAINTENANCE

4.1 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 HOURS, WHICHEVER OCCURS FIRST.

TIME INTERVAL (WHICHEVER COMES FIRST)

ACTION PART OR ITEM HOURS 1WK 1 MO 6 MO 9 MO YEARLY 2YR

INSPECT COOLANT LEVEL VISIBLE IN FILL PORT WEEKLY X

INSPECT AIR FILTER WEEKLY X REPLACE COOLANT FILTER* 150 X REPLACE COOLANT FILTER* 2000 X

INSPECT HOSES 1000 X

INSPECT DRIVE BELTS 500 X REPLACE DRIVE BELTS 8000 X

CHECK HIGH AIR TEMP.SWITCH 1000 X CHECK OPERATE PRESSURE RELIEF VALVES 1000 X

CLEAN SEPARATOR SCAVENGE ORIFICE 1000 X

CLEAN COOLERS CORES** 4000 X REPLACE AIR FILTER* 2500 X REPLACE SEPARATOR ELEMENT* 4000 X REPLACE ULTRA COOLANT 8000 X REPLACE SHAFT SEAL 8000 X

(WHEN COLD)

(INITIAL CHANGE ONLY)

(SUBSEQUENT CHANGES)

*IN VERY CLEAN OPERATING ENVIRONMENTS AND WHERE INLET AIR FILTER IS CHANGED ATTHE ABOVE PRESCRIBED INTERVALS.IN EXTREME DIRTY ENVIRONMENT CHANGE DRIVE BELTS, COOLANT, FILTERS, AND SEPARATOR ELEMENTS MORE FREQUENTLY.

**CLEAN COOLER CORES IF UNIT SHUTDOWN OCCURS ON HIGH AIR TEMPERATURE.

4.2 MAINTENANCE RECORDS

ing is heeded. Read Safety Instructions.

It is very important that you, the owner, keep accurate and detailed records of all maintenance work you or the Ingersoll-Rand Distributor or Air Center perform on your compressor.This includes, but is not limited to, coolant, coolant filter, separator element, inlet air filter, drive belts, shaft seals and so forth.This information must be kept by you, the owner, should you require

Have a well equipped mechanic’s tool box with English and Metric sockets. (Special tools when needed will be listed under each appropriate procedure). Have an OSHA approved air nozzle and compressed air.(International - local codes may apply). Have recommended spare parts on hand (See listing

in back of this manual.

warranty service work by your Ingersoll-Rand Distributor or Air Center. Maintenance record sheets

! WARNING

are located at the back of this manual.

When the unit is shut down, residual pressure

4.3 MAINTENANCE PROCEDURES

can be trapped within the compressor system. This pressure must be vented from the system

Before starting any maintenance, be certain the follow-

prior to beginning any service work.

4.3-1). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pressure has vented from the unit. Also vent piping by slightly opening the drip leg valve.When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection.

O-RING

VENT HOLE

FIGURE 4.3-1 COOLANT FILL PLUG WITH

VENT HOLE

4.4 PRESSURE RELIEF VALVE CHECK

Under normal operating condition a “try lever test” must be performed every month . Under severe service conditions, or if corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be performed at the end of any non-service period. CAUTION! High pressure air will

discharge through the discharge ports of the valve during “try lever test”.Wear ample clothing, gloves, safety glasses and ear protection during valve testing. Run the compressor for about 10 minutes by vent-

ing air from the system to let the unit warm up.With the unit running, test at or near maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of debris.Then release lever and permit the valve to snap shut. If lift lever does not activate, or there is no evidence of discharge, discontinue use of equipment immediately and contact a licensed contractor or qualified service personnel.

4.5 SHEAVE ALIGNMENT

Align Sheaves

Any degree of sheave misalignment will result in a reduction of belt life. Misalignment of belt drive should not exceed 1/16 in. (1.6 mm).

Parallel misalignment occurs when the drive and driven shafts are parallel, but the two sheaves lie in different planes (See Figure 4.5-1).

Angular misalignment occurs when the two shafts are not parallel (See Figure 4.5-2).

1/16” (1.6mm) MAX

Ensure that the compressor is isolated from the compressed air system by closing the isolation valve and venting pressure from the drip leg. Ensure 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.

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 is aligned.

Alignment should be within 1/16” (1.6 mm) maximum when measuring the gap between the straightedge and the rim of the opposite sheave in each direction.

This alignment is factory set and should only require resetting if the drive motor or airend is removed.

The following steps should be taken to insure proper alignment of all components.

STRAIGHTEDGE

FIGURE 4.5-1 PARALLEL MISALIGNMENT

1/16” (1.6mm) MAX

STRAIGHTEDGE

1. Remove the cooler box top panel.

2. Holding the straightedge against the front of the airend sheave, measure the amount of misalignment seen on the motor sheave. If misalignment is less than 1/16” (1.6 mm) then reinstall cooler box panel prior to operating unit.

3. If misalignment is more than 1/16” (1.6 mm), the motor sheave bushing must be loosened for repositioning.

To reposition the motor sheave:

1. Remove drive belts (See Section 4.6).

2. Remove the three hex head screws that hold the sheave to the sheave bushing. See Figure 4.5-3.

3. Lubricate the thread and end of screws that were just removed.

4. Reinstall all three screws in the holes of the bushing that are threaded.

5. Slowly tighten the three screws evenly until the sheave is pressed from the bushing. (Light tapping on bushing may assist removal.)

FIGURE 4.5-2 ANGULAR MISALIGNMENT

6. Remove the screws from the holes.

ALLEN HEAD SCREW

SHEAVE RETAINING SCREWS

4.6 DRIVE BELTS Ensure that the compressor is isolated from the

compressed air system by closing the isolation valve and venting pressure from the drip leg. Ensure that the main power disconnect switch is locked open and tagged.

“A” - Clearance Holes “B” - Threaded Holes

FIGURE 4.5-3 MOTOR SHEAVE BUSHING

7. Loosen allen screw in sheave bushing.

8. Move the bushing either in or out on the motor shaft depending upon the measurement taken earlier.

9.Tighten allen screw in sheave bushing.

10. Being careful to not move the bushing on the shaft, align sheave so that the three threaded holes in the sheave line up with the three clearance holes in the bushing.

11. Insert all three screws through clearance holes in the bushing and thread into sheave.

12. Slowly and evenly tighten all sheave retaining screws.Torque to 108 lb-in. (1.2 kg-m).

13.Tap against large end of bushing using hammer and block or sleeve to avoid damage. Continue to torque screws until the specified wrench torque no longer turns the screw after tapping.

14. Install belts as shown in Section 4.6.

If installing or removing the belts on a new unit at startup, the motor support shipping bolt must first be removed.This bolt is only used to secure the motor support during shipment and will not be reinstalled once the belts are put into place.

Locate the support shipping bolt as shown in Figure

2.7-1 and remove.

Replacement Parts

Belts (See Recommended Spare Parts Section 7.3). Be sure to use only Ingersoll-Rand genuine parts to assure proper belt size and length. Incorrectly sized belts can lead to overloading of bearings and eventual airend or motor failure.

Disassembly

Belt tension is maintained due to a pivoting motor support.The weight of the motor holds the belt tight.

1. Remove the cooler box rear panel.

2. Carefully lift the back of the motor support and place a block of wood underneath the motor support.

3. Remove belts from the airend sheave and the motor sheave.

Installation / Inspection

Inspect sheave grooves for foreign material or rubber build-up.Clean and degrease sheaves before installing drive belts to insure long belt life.

1. Carefully lift the back of the motor support plate and place a block of wood underneath the plate.

2. Install belts on the airend sheave and the motor sheave.When installing a new belt, do not pry or force the belt over the sheave grooves.

3. Remove the block of wood from under the motor support.

15. Recheck for proper alignment.

16. Reinstall cooler box outer panel.

4.7 BELTTENSION

This unit has been designed with a unique self tensioning system for the drive belts.There is no adjustment required to insure proper belt tensioning. Be sure to use only Ingersoll-Rand Genuine parts to assure correct belt tension.

LIP EDGE OF SEAL INWARD

WEAR

SLEEVE

SCAVENGE

HOLES

4.8 SHAFT SEAL REPLACEMENT

There are two lip type seals on the compressor.They are wearable parts and should be replaced at 8,000 hour intervals.While it is advisable to have your local Ingersoll-Rand Distributor or Air Center perform this work, the task can be accomplished by a good mechanic following these instructions.

Before beginning any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge.Wait 2 minutes after stopping to allow internal pressure to dissipate.Vent residual pressure from the unit by slowly unscrewing the coolant fill plug one turn. Unscrewing the fill plug opens a vent hole, drilled In the plug, allowing the pressure to release to atmosphere (See Figure 4.3-1). A slight mist or oil droplets may be visible during venting. Do not remove fill plug until all pressure has vented from the unit. Also vent piping by slightly opening the drip leg valve.When opening the drain valve or removing the coolant fill plug, stand clear of the valve discharge, wear work gloves and appropriate eye protection.

SPECIAL TOOLS A clean work bench

Seal installation tool REPLACEMENT PARTS

Shaft seal kit Seal retainer 0-Ring Loctite® 609 Loctite® 515

Installation

1. Remove the cooler box rear panel.

2. Remove belts (See Section 4.6).

3. Remove the three hex lead screws that hold the sheave to the sheave bushing (See Figure 4.5-3).

4. Lubricate the thread and end of screws that were just removed.

5. Reinstall all three screws in the holes of the bushing that are threaded.

6. Slowly tighten the three screws evenly until the sheave is pressed from the bushing. (Light tapping on bushing may assist removal.)

7. Remove the screws from the holes.

8. Loosen allen screw in sheave bushing.

9. Remove seal housing from airend assembly. Use the removal slots provided to pry the seal housing from the airend. Do not attempt to break the seal housing loose by tapping.

10. Drive each seal out of the housing, being careful not to damage the surface of the bore.The larger double lip seal must be driven out toward the inboard side.The term “inboard” side of the seal housing will refer to the face that is mounted to the airend assembly.The term “outboard” side will refer to the face closest to the sheave.

11. Discard seals.

12. Remove check valve ball and plug from seal housing.

13. Remove wear sleeve from shaft, being careful not to damage the shaft.

14.Thoroughly clean the scavenge holes, (See Figure 4.8-1), bore surfaces of the seal housing, wear sleeve journal on the shaft, and the face of the airend assembly.Be careful not to damage any of the surfaces, and insure that no particles are allowed to enter the bearings.

FIGURE 4.8-1 SHAFT SEAL ASSEMBLY

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