Ingersoll-Rand ARO EVO EP20 Series Operator'S Manual Download Page 2

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EP20-XXXXX-XXX-XXX (en)

TABLE OF CONTENTS

1. TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3

1.1. Pump Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2. Variable Frequency Drive (VFD) Data . . . . . . 3

1.3. Electric Motor Data . . . . . . . . . . . . . . . . . . . . . . . 4

1.4. Nameplate Details . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4.1. Standard Nameplate . . . . . . . . . . . . . . . . 5

2. MODEL DESCRIPTION CHART. . . . . . . . . . . . . . . . . . . 6

2.1. Model Code Explanation. . . . . . . . . . . . . . . . . . 6

2.2. Encoder Cable Assembly for

Ordinary Motors . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. OPERATING AND SAFETY PRECAUTIONS . . . . . . . . 7

4. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8

4.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.2. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.3. Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5. MECHANICAL INSTALLATION . . . . . . . . . . . . . . . . . . . 9

5.1. Pump and Motor Installation . . . . . . . . . . . . . 9

5.2. Pump and Gearbox Breather Installation . . 9

5.3. VFD Mechanical installation. . . . . . . . . . . . . . . 10

6. ELECTRICAL INSTALLATION FOR

ORDINARY LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.1. VFD-Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . 11

6.2. General Wiring Practice for VFD . . . . . . . . . . . 11

6.3. VFD AC Mains – Input Power

Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6.4. Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6.4.1 VFD - Input Power Wiring . . . . . . . . . . . . 12

6.4.2. VFD - Output Motor Wiring . . . . . . . . . . 12

6.4.3. Motor - Input Power Wiring . . . . . . . . . . 13

6.5. Control Wiring (Required) . . . . . . . . . . . . . . . . . 13

6.5.1. Leak detector wiring diagram . . . . . . . 13

6.5.2. Thermal protection – Ordinary motor 15

6.5.3. Encoder Wiring – Ordinary Motor . . . . 15

6.6. Control Wiring (Recommended) . . . . . . . . . . 16

6.6.1. Safe Stop wiring diagram . . . . . . . . . . . . 16

6.7. Control Wiring (Optional) . . . . . . . . . . . . . . . . . 16

6.7.1. Digital start / stop control . . . . . . . . . . . 16

6.7.2. Analog Input – Speed control . . . . . . . 17

6.7.3. Analog Inputs – Torque (Pressure)

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.7.4. Additional available

Input / output (Optional) . . . . . . . . . . . . 18

6.8. Configured Input / Output

Summary - Ordinary . . . . . . . . . . . . . . . . . . . . . . 18

6.9. VFD serial communication . . . . . . . . . . . . . . . . 18

6.10. User defined readout . . . . . . . . . . . . . . . . . . . . 19

7. ELECTRICAL INSTALLATION FOR

HAZARDOUS LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 20

7.1. General Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.2. Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.3. Control Wiring (Required) . . . . . . . . . . . . . . . . . 20

7.3.1 Leak Detector Wiring . . . . . . . . . . . . . . . . 20

7.3.2 Thermal Protection - Hazardous

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.3.3 Encoder Wiring - Hazardous Motor . . . 22

7.4. Control Wiring (Optional) . . . . . . . . . . . . . . . . . 22

7.5. Configured Input/Output

Summary - Hazardous . . . . . . . . . . . . . . . . . . . . 22

7.6. VFD Serial Communication - Hazardous . . . 22

8. GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

8.1. Pump Grounding . . . . . . . . . . . . . . . . . . . . . . . . . 23

8.2. VFD Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

8.3. Electric Motor Grounding . . . . . . . . . . . . . . . . . 23

9. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

9.1. Pre Operation Checklist . . . . . . . . . . . . . . . . . . . 24

9.2. Personal Menu Settings . . . . . . . . . . . . . . . . . . 24

9.3. VFD Smart Setup . . . . . . . . . . . . . . . . . . . . . . . . . 25

10. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

10.1. Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

11. SUBSYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . 27

11.1. Fluid section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

11.2. PRV section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

11.3. Crankcase section . . . . . . . . . . . . . . . . . . . . . . . 32

11.4. Oil Piston pump section . . . . . . . . . . . . . . . . . 35

12. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 37

13. DIMENSIONAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 38

13.1 Pump With Motor . . . . . . . . . . . . . . . . . . . . . . . . 38

13.2. Variable Frequency Drive (VFD) . . . . . . . . . . 39

14. PERFORMANCE CURVE. . . . . . . . . . . . . . . . . . . . . . . . 40

15. CERTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

16. WARRANTY DECLARATION . . . . . . . . . . . . . . . . . . . . 42

Summary of Contents for ARO EVO EP20 Series

Page 1: ...PANY INC 209 NORTH MAIN STREET BRYAN OHIO 43506 800 495 0276 FAX 800 892 6276 2022 arozone com OPERATOR S MANUAL EP20 XXXXX XXX XXX INCLUDING OPERATION INSTALLATION AND MAINTENANCE 2 EVO SERIES ELECTR...

Page 2: ...6 6 1 Safe Stop wiring diagram 16 6 7 Control Wiring Optional 16 6 7 1 Digital start stop control 16 6 7 2 Analog Input Speed control 17 6 7 3 Analog Inputs Torque Pressure Control 17 6 7 4 Additiona...

Page 3: ...mber 136Z7170 136Z7171 Power 7 5 kw 7 5 kw InputVoltage 380 500 VAC 10 3 Phase 50 60 Hz 380 500 VAC 10 3 Phase 50 60 Hz Frame Size A5 A5 Ingress Protection NEMA 4X IP66 NEMA 4X IP66 Option A Slot N A...

Page 4: ...PTS IP66 67 Encoder Connection 12 Pin connector 10 m cable flying leads Drain Plug Position Drive end with plug N A Thermal Protection 2 Pto sensors in series 3 Ptc sensors in series Approx Weight 236...

Page 5: ...DEL 18 C TO 40 C Definitions 1 Pump Model Configured Pump Model Number 2 Assembled In Country of Assembly 3 Serial Number Serial Identification Number 4 MGFR Date Date of Manufacture 5 AVG W P Average...

Page 6: ...luminum Seat A Santoprene Pump Crank case C Cast Iron S Integrated Spline Shaft Pump Input Shaft F Aluminum H 440 SST S 316 SST S 316 SST T PTFE V Viton T PTFE 2 2 Encoder Cable Assembly for Ordinary...

Page 7: ...y Connect only to grounded power source y All electrical wiring must be done by a qualified elec trician and comply with all local codes and regula tions For North America hazardous locations NEC CEC...

Page 8: ...range of material compatibility options high volume delivery secondary containment the ability to fully deadhead and is efficient and intelligent The pump works on the principle of converting rotary m...

Page 9: ...vel surface Secure pump legs to floor with M14 anchors y Refer to section 13 1 for bolt circle spacing y Pump must be positioned such that fluid inlet and fluid outlet port are easily accessible Insta...

Page 10: ...f oil supplied with the gearmo tor to adjust the oil level between the two marks on the dip stick y Replace the cap on the oil expansion tank and retighten the air vent port NOTE Regularly check the o...

Page 11: ...2 Ground Ground 1 Ground 2 COM RS485 612 RS485 interface OFF 0 10 V DC to 10 V DC A Analog D Digital 1 Terminal 37 optional is used for Safe Torque Off STO 2 Do not connect cable shield 6 2 General Wi...

Page 12: ...Grounding the Cable Shield in VFD manual y When supplied from an isolated mains source IT mains or floating delta or TT TN S mains with a grounded leg ground ed delta ensure that parameter 14 50 RFI...

Page 13: ...ng from improper installation of components or hardware y Do not attempt any service without disconnecting all electrical supply source 6 4 3 Motor Input Power Wiring y The cables must be fitted with...

Page 14: ...ensor is used for both ordinary and hazardous applications y The Leak Detection Sensor comes with 2m of cable length with flying lead connections It is recommended to combine leak sensor cables into a...

Page 15: ...igital Input 6 5 3 Encoder Wiring Ordinary Motor y Motor is installed with a 1024 ptsTTL encoder with a 12 pin connector on the outside of the motor terminal box y Encoder extension cables with solder...

Page 16: ...analog or digital control methods in the Auto On mode then a Start Stop command will be re quired to run y To configure the VFD for a digital Start Stop command install a switch between pin 20 common...

Page 17: ...High Voltage 10 00 V 622 Terminal 54 Low Current 0 14 A 623 Terminal 54 High Current 20 00 A 6 7 2 Analog Input Speed control y A 0 10 V or 4 20 mA signal can be used to control VFD speed from 0 100...

Page 18: ...Terminal GroundTerminal 24VDCTerminal Diaphragm 1 Leak Detect AA1 Diaphragm 1 Leak 18 20 39 or 55 12 or 13 Diaphragm 2 Leak Detect AA2 Diaphragm 2 Leak 19 20 39 or 55 12 or 13 Diaphragm 3 Leak Detect...

Page 19: ...menu screen By default these values are set to scale motor frequency to actual pump rpm To update the User Defined Readout refer to the following parameter descriptions 1 Select the unit to be displa...

Page 20: ...nsors have a set point of 150 C on the motor windings to ensure rated surface temperatures Ensure the hazardous motor is painted red to indicate haz ardous duty model Ensure the VFD is placed in a saf...

Page 21: ...series It is required to wire the PTC sensors to terminals T1 and T2 on the MCB 112 PTC thermistor card installed in the option A slot of the VFD This card comes pre installed when the hazardous VFD...

Page 22: ...ndTerminal 24VDCTerminal Diaphragm 1 Leak Detect AA1 Diaphragm 1 Leak 18 20 39 or 55 12 or 13 Diaphragm 2 Leak Detect AA2 Diaphragm 2 Leak 19 20 39 or 55 12 or 13 Diaphragm 3 Leak Detect AA3 Diaphragm...

Page 23: ...Ground the variable frequency drive through a proper connection to a power source y Ground the drive in accordance with applicable standards and directives y Use a dedicated ground wire for input pow...

Page 24: ...Select Disabled 0 to avoid accidental start of the drive in Hand mode Select Password 2 to avoid unauthorized start in Hand mode 042 Auto On key on LCP Select Disabled 0 to avoid accidental start of t...

Page 25: ...s comparator It allows to optimize dead head settings or leak detect filter time 1502 KWH Counter Read only display of KWh Counter 2310 Maintenance Item 0 5 Set the item to be associated with the prev...

Page 26: ...air cap directly below the PRV This will trip the corresponding leak detect and VFD will display AA1 Diaphragm 1 Leak if wired per recommen dations NOTE Frequency of maintenance fluid section maintena...

Page 27: ...6 4 6 T XXFXX 95892 6 A XXSXX 95877 6 SS XXXSX 95878 6 SS XXXVX 95826 3 6 V NOTE Seat Option XXAXX does not require item 19 O ring DIAPHRAGM OPTIONS EP20 XXXXX XXX XXX Item Description QTY Santoprene...

Page 28: ...14 22 61 21 19 26 28 15 26 28 27 28 60 67 68 69 22 21 19 64 62 NOTE DO NOT OVERTIGHTEN FASTENERS ASSEMBLY TORQUE REQUIREMENTS 14 Screw tighten to 55 60 ft lbs 75 81 Nm 26 68 Screws 20 25 ft lbs 27 34...

Page 29: ...worn or damaged parts with new parts as required y Install Bellows 13 Bellows plate 16 and secure with socket head screw 17 y Diaphragms should be installed as marked and should be concave towards Flu...

Page 30: ...ISASSEMBLY y Disconnect 3 8 OD tube 184 between PRV housing 44 and air cap 147 y Loosen clam shell 37 between PRV return Manifold 66 and PRV housing 44 Remove PRV return Manifold 66 from inlet PRV Man...

Page 31: ...57 38 37 39 66 41 40 See Detail A 59 55 56 39 58 37 37 41 38 44 46 50 52 54 42 43 45 47 49 48 51 53 DETAIL A NOTE DO NOT OVERTIGHTEN FASTENERS ASSEMBLY TORQUE REQUIREMENTS 53 Nut tighten to 7 10 ft l...

Page 32: ...7 25M13EA467 C 180 Drain Plug 3 8 18 NPT 1 98062 SS 181 Fitting 3 8 ODTube x 1 4 NPT 90 Elbow 3 59756 160 Ny 182 Fitting 3 8 ODTube x 1 4 NPT 45 Elbow 3 98060 Ny 183 Fitting 1 2 ODTube x 3 8 NPT 6 98...

Page 33: ...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 125 Screw 55 65 in lbs 6 7 Nm 141 Screws 18 20 ft lbs 24 27 Nm 192 Screws 25 30 ft...

Page 34: ...ing rod 140 y To replace Journal 139 arbor press need to be use to press new Journal while simultaneously pushing out the old journal y Install lower shaft seal 112 into Crankcase housing 101 Ensure O...

Page 35: ...Item 180 from Crankcase housing below lowest cylinder y Clean all foreign particles from the drain plug y Allow oil to drain from pump Crankcase to an approved oil container for disposal y Unscrew Fil...

Page 36: ...161 DETAIL C NOTE DO NOT OVERTIGHTEN FASTENERS ASSEMBLY TORQUE REQUIREMENTS 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 ti...

Page 37: ...ow Missing ball check or excessive ball check wear or failure Ensure ball checks are all installed intact and in place Excessive back pressure is causing pump to go into torque limit and reducing spee...

Page 38: ...mm Outlet 2 ANSI DIN Flange Inlet 2 ANSI DIN Flange Dimensions shown are for reference only they are displayed in inches and millimeters mm 34 34 872 2 mm 18 02 457 8 mm 2 PLCS 10 37 263 3 mm 21 83 5...

Page 39: ...75 146 mm 0 73 18 5 mm 1 03 26 3 mm 3 PLCS 9 53 242 mm 16 54 420 2 mm 9 11 231 3 mm 7 92 201 2 mm DRIVE DISCONNECT DETAIL E 2 PLCS 2 PLCS 15 81 401 7 mm 0 53 13 5 mm 8 46 215 mm 0 39 10 mm 0 25 6 42 m...

Page 40: ...limit the pressure in the system the torque limit can be set less than 100 When backpressure builds the pump will begin to de rate its speed at a lower pressure where it intersects its respective curv...

Page 41: ...EP20 XXXXX XXX XXX en Page 41 of 44 15 CERTIFICATION See PN 97999 1972 S 1639 Declaration of Conformity for details...

Page 42: ...made to the Products without express written consent of Ingersoll Rand ARO or failure to follow the recommended operating practices and maintenance procedures as provided in the product s operating a...

Page 43: ...EP20 XXXXX XXX XXX en Page 43 of 44...

Page 44: ...ur employees develop customers for life through their daily commitment to expertise productivity and efficiency For more information visit www IRCO com In order to see updated information about ARO or...

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