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

18

3.0  INTELLISYS

3.1 EMERGENCY STOP SWITCH

Pressing this switch stops the compressor
immediately.  Compressor cannot be restarted until
switch is manually reset.  Turn clockwise to reset.

3.2  POWER ON LIGHT (Inside Starter Box)

Indicates control voltage is available to the control
circuit and line voltage is available for starting.

POWER ON

3.3  POWER INDICATOR LIGHT

Indicates voltage is available to the intellisys
controller.

3.4  PUSH BUTTONS

START

If the display shows READY TO START, pressing
this button will start the compressor.  The
compressor will start and load automatically if there
is a demand for air.

If in the display table press this button to exit the
display table.  Display will show “CHECKING
MACHINE” then “READY TO START”.

POWER ON

EMEG

STOP

UNLOAD

/LOAD

START

STOP

UNLOADED

DISPLAY

SELECT

SET

POWER

POWER ON

EMEG

STOP

UNLOAD

/LOAD

START

STOP

UNLOADED

DISPLAY

SELECT

SET

POWER

UNLOAD STOP

Pressing this button will activate the unload stop.  If
the compressor is running loaded, it will unload.
Seven seconds later it will stop.  if the compressor is
running unloaded, it will stop immediately. Pressing
this button with the unit stopped will flash all L.E.D.’s
for a light check and flash the software version
number in the display.

UNLOAD/LOAD

If the unit is running loaded, pressing this button will
cause the unit to unload, the unload indicator light
will be on.  The unit will not load until the button is
pressed again.  If the unit is running unloaded,
pressing this button will load the unit in the ON/OFF
LINE or MOD/ACS control mode previously
operating.

POWER ON

EMEG

STOP

UNLOAD

/LOAD

START

STOP

UNLOADED

DISPLAY

SELECT

SET

POWER

POWER ON

EMEG

STOP

UNLOAD

/LOAD

START

STOP

UNLOADED

DISPLAY

SELECT

SET

POWER

POWER ON

EMEG

STOP

UNLOAD

/LOAD

START

STOP

UNLOADED

DISPLAY

SELECT

SET

POWER

Summary of Contents for EP 20 SE

Page 1: ...irst 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 APDD 567A September 1998 ...

Page 2: ...h 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 Equipment will be at Purchaser s sole risk and liability Limitation or Liability The re...

Page 3: ...ements without notice and without incurring any obligation to make such changes or add such improvements to products sold previously Number of units on order __________________________ Customer Order Number __________________________ Ingersoll Rand Company Order Number ______________ For ready reference record the serial number and model number of your unit here Serial Number _____________________...

Page 4: ...al 2 8 liters Complete System 1 70 gal 6 4 liters Discharge Temperature Limit 228 F 109 C Power Inlet Wiring Recommended conduit metallic flexible Greenfield or equivalent Tools U S Standard and metric are required to perform maintenance 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 1 3 tools 2 0...

Page 5: ...ecognized 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 grounds maintenance clearance and lightning arrestors for all elec...

Page 6: ...he appropriate service pipework to and from the machine WARNING CHECK HIGH AIR TEMPERATURE There is a high discharge air temperature shutdown function built into the Intellisys on each compressor It is factory pre set at 228 F 109 C This function should be checked at regular intervals for proper operation once a month is recommended The procedure is 1 Block off the cooling air discharge 2 The comp...

Page 7: ...ed fan blade Can cause severe injury Do not operate with covers removed Disconnect power Lock and tag INGERSOLLrAND 39558788 39559646 39544150 WARNING Exposed moving parts Can cause severe injury or death Stay clear or moving parts when machine is operating INGERSOLLrAND WARNING Hazardous voltage Can cause severe injury or death Disconnect power before servicing Lockout Tagout machine INGERSOLLrAN...

Page 8: ...ressor operation and maintenance a minimum of 3 feet clearance on 3 sides is required 3 1 2 feet is required in front of the control panel or minimum required by latest National Electrical code or applicable local codes Refer to the Instruction Operators Manual before performing any maintenance INGERSOLLrAND 39540158 Condensate drain NOTICE INGERSOLLrAND 39541081 6 DANGER Discharge air Can contain...

Page 9: ...et for incoming power See Operators Instruction manual INGERSOLLrAND 39543764 39543921 NOTICE Filler Cap Use only recommended coolant Read instruction book before servicing 39543921 WARNING High pressure air Can cause severe injury or death Relieve pressure before removing filter plugs caps fittings or covers INGERSOLLrAND 39541354 Lift here NOTICE INGERSOLLrAND Lift here NOTICE INGERSOLLrAND CAUT...

Page 10: ...r before servicing Lockout Tagout machine INGERSOLLrAND 39540174 39838396 UNITS W FV STARTER 39838412 UNITS W SD STARTER 39845037 UNITS W REMOTE FV STARTER 39539127 S 2 FV 39539135 S 2 3 S 3 FV 39539150 S 4 FV 39567656 S 2 SD 39539143 S 2 3 S 3 SD UNITS W BUILT ON STARTER ONLY ...

Page 11: ...SPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNED BILL OF LADING If goods are received short or in damaged condition it is important that you notify the carrier and insist on a notation of the loss or damage across the face of the freight bill Otherwise no claim can be enforced against the transportation company If concealed loss or da...

Page 12: ...undation plan for the particular model compressor to be installed See Section 8 0 The compressor can be installed on any level floor that is capable of supporting it Compressor weights are listed on the foundation plans When sound transmission is of particular importance it is often helpful to install a sheet of rubber fabric matting or cork under the compressor to reduce the possibility of resona...

Page 13: ... Any of these could result in partial or total plant shutdown Compressed air dryers reduce the water vapor con centration 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 NOTICE 2 3 PIPING Continued A dripleg assembly and isolation valve should be mounted...

Page 14: ...gerated dryers are normally specified where compressed air pressure dew points of 33 F 1 C to 39 F 4 C are adequate Desiccant dryers are required where pressure dew points must be below 33 F 1 C Contact your local Ingersoll Rand distributor for assistance in selecting correct Ingersoll Rand filtration or drying products NOTE Screw type compressors should not be installed in air systems with recipr...

Page 15: ...d of the motor See Figure 2 4 2 FIGURE 2 4 2 DRIVE MOTOR ROTATION FIGURE 2 4 1 TYPICAL CONTROL TRANSFORMER WIRING DRIVE END NON DRIVE END 110V LINE VOLTS HZ LINE SEC VOLTS LINE 200 60 H4 H5 120 X1 X2 8 X3 X4 8 X4 X5 220 230 60 H3 H5 120 X1 X2 8 X3 X4 8 X4 X5 380 60 H3 H5 120 X1 X2 8 X3 X4 8 X4 X5 440 460 60 H2 H5 120 X1 X2 8 X3 X4 8 X4 X5 575 60 H1 H5 120 X1 X2 8 X3 X4 8 X4 X5 LINE VOLTS HZ LINE S...

Page 16: ...N Continued The Intellisys will automatically shut the unit down if the compressor rotation is incorrect and CHK MTR ROTATION will appear in the display also the alarm light will be on See Section 6 For the compressor motor rotation check the motor jogging time must be as short as possible After depressing the start button IMMEDIATELY depress the EMERGENCY STOP button Should the motor rotation be ...

Page 17: ...ir 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 1 7 C Arrange the machine with the Intellisys con troller starter enclosure facing away from the sun as radiant heat can affect starter lntellisys performance Also direct sunlight and UV rays will degrade the membrane touch panel This is not a warrantable...

Page 18: ...16 FIGURE 2 5 1 TYPICAL OUTDOOR SHELTERED INSTALLATION ...

Page 19: ...MODE SET DISPLAY TIME SELECT OPTIONS PACKAGE DISCHARGE PRESSURE AIREND DISCHARGE TEMPERATURE SUMP PRESSURE SEPARATE PRESSURE DROP TOTAL HOURS LOADED HOURS UNLOAD POWER START UNLOAD LOAD DISPLAY SELECT STOP UNLOADED SET AUTOMATIC RESTART 3 0 INTELLISYS INTELLISYS CONTROLLER INGERSOLLrAND INTELLISYS ...

Page 20: ... READY TO START POWER ON EMEG STOP STOP UNLOADED SET POWER ER ON MEG TOP OAD AD START LAY ECT T POWER UNLOAD STOP Pressing this button will activate the unload stop If the compressor is running loaded it will unload Seven seconds later it will stop if the compressor is running unloaded it will stop immediately Pressing this button with the unit stopped will flash all L E D s for a light check and ...

Page 21: ...es If the unit has multiple alarms or warnings the ARROWS are used to scroll through these conditions The ARROWS have a function in the calibration routine which will be described later PRESSURE SENSOR CALIBRATION ZEROING ROUTINE This routine is entered if the unit is not running and both the up and down arrows button are pressed at the same time Make sure all pressure is relieved from the compres...

Page 22: ... flash to acknowledge The next set point will then be displayed If the value of the set point was not changed pressing the SET button will only step to the next set point When the SELECT OPTIONS set point is entered the SELECT OPTIONS indicator will light and the setpoints for options Auto Start Stop or Remote Start Stop will only be accessible and displayed if the option module is installed in th...

Page 23: ...ur if a motor overload is sensed 6 TEMP SENSOR FAIL This will occur when the sensor temperature is recognized as missing or broken 7 REMT STOP FAIL This will occur if the momentary remote stop switch does not disengage by the time the unit attempts to start 8 REMT START FAIL This will occur if the momentary remote start switch does not disengage by the time star delta transition occurs 9 CK MTR RO...

Page 24: ...er with a single replacement spin on element The filter is mounted on the oil filter thermal valve housing It is rated at 4 microns 22 4 0 SYSTEMS 4 1 GENERAL SYSTEM INFORMATION The SE compressor is an electric motor driven single stage screw compressor complete with accessories piped wired and baseplate mounted It is a totally self contained air compressor package A standard compressor is compose...

Page 25: ...rovision for return of the separator fluid back to the compressor Operation The coolant and air discharging from the compressor flow into the receiver through a tangential discharge outlet This outlet directs the mixture along the inner circumference of the receiver allowing the coolant stream to collect and drop to the receiver sump Internal baffles maintain the circumferential flow of remaining ...

Page 26: ...rol For those plants which have a widely varying air demand on off line control will deliver air at full capacity compressor maximum efficiency condition or will operate at zero capacity compressor minimum power condition The compressor is controlled by the Intellisys responding to changes in plant air pressure The Intellisys opens the inlet valve and closes the blowdown valve 3SV whenever plant a...

Page 27: ...ins when the line pressure reaches about 99 percent of the compressor rated pressure and continues as if the line pressure rises Modulation becomes stable when the compressor output equals the plant air demand When the modulation is at the factory setting the maximum capacity reduction will be approximately 60 percent of the compressor rated capacity as indicated in Figure 4 7 1 If the air demand ...

Page 28: ...ion The Intellisys does this and does it automatically if the compressor unloads 3 times within a 3 minute time period If later the plant demand decreases and even under modulate control the line pressure reaches the setting of the Intellisys controller and the control shifts to the off line mode the time in this mode will still be monitored A long off line time period indicates a low plant air de...

Page 29: ...ure turn the adjustment screw on the modulation valve see Figure 4 7 2 so that the test pressure gauge reads 22 psig for modulate 60 cfm full voltage units 16 psig for modulate 60 cfm star delta units 20 psig for modulate 70 cfm full voltage units 18 psig for modulate 70 cfm star delta units Tighten the adjustment screw locknut 7 Press UNLOADED STOP Wait for sump pressure to go 0 psig Close the is...

Page 30: ...imes the initial pressure drop or a maximum pressure differential of 12 psi 8 bar at full load or if the Intellisys warning CHG SEPR ELEMENT is displayed See Section 3 9 Running Time Interval whichever comes first Action Part or Item Hours 1 Week 1 Mo 3 Mo 6 Mo Yearly 2 Years Inspect Coolant level Weekly x Inspect Discharge temperature air Weekly x Inspect Separator element differential Weekly x I...

Page 31: ...ht edge 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 6mm maximum when measuring the gap between the straightedge and the rim of the opposite sheave in each direction This alignment is factory set and shou...

Page 32: ...he 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 new belts to insure long belt life Install new belts in the reverse order of disassembly When installing a new belt do not pry or force the belt over the sheave grooves See Section 5 6 to tension the belt properly W...

Page 33: ...ioning bolt located on the right side of the airend See Figure 5 6 3 4 Rotate the belt tensioning bolt clockwise until the proper belt tension is achieved as measured by a belt tension gauge This gauge can be obtained from your Ingersoll Rand Distributor or Air Center Tighten the belt tensioning locknut Do not overtighten belts It may cause damage to bearings shaft or seal retainer assembly 5 Rein...

Page 34: ...lugs caps fittings or covers INGERSOLLrAND Special Tools A clean work bench Replacement Parts Shaft seal kit 42370353 Loctite 609 Loctite 515 Loctite 242 Installation Remove both doors and the top of the enclosure if so equipped Remove both guards V belts and airend sheave Note Airend sheave is heat shrink fit to shaft and a puller is required to remove Remove seal housing from airend assembly Dri...

Page 35: ...op in the housing in the flush position To avoid blocking the scavenge hole the seal should never be pushed beyond flush position Remove any excess Loctite 609 from the seals from the seal housing bore and from the seal scavenge holes Install the plug in the bottom of the seal housing Place a thin continuous bead of Loctite 515 on the machined surface of the seal housing as shown in Figure 5 7 2 D...

Page 36: ...r or when the coolant is being changed In dirty operation environments the filter should be changed more frequently Use a suitable device and loosen the old element Use drain pan to catch any leakage during removal Discard old element Wipe the sealing surface of the filter housing with a clean lint free rag to prevent the entry of dirt into the system Remove the replacement element from its protec...

Page 37: ...uspension in the coolant will be carried out with the coolant Hot coolant can cause severe injury Use care when draining separator tank To drain the unit place drain pan under drain valve Open drain valve to start drainage After draining is complete close drain valve After the unit is drained and a new coolant filter element is installed refill the system with fresh coolant through the filler cap ...

Page 38: ...le the check vavle screen orifice assembly to the tubing lines The fitting must be re installed with the screen on the upstream side of the orifice as indicated by the flow arrow See Figure 5 11 1 5 12 TEMPERATURE CONTROL VALVE ELEMENT REPLACEMENT Tools Required Open end wrench Procedure Use suitable wrench to loosen temperature control valve element Ensure that excess stress is not exerted on oil...

Page 39: ...th the tank and its cover Exercise care to prevent pieces of the old gasket from falling down into the tank Check the tank to be absolutely certain that no foreign objects such as rags or tools have been allowed to fall into the tank Install replacement element down into the tank after checking the new element gaskets for possible damage Center the element up within the tank Place the tank cover i...

Page 40: ...e cooler cores be thoroughly cleaned on the outside Strong cleaners can harm aluminum cooler parts Follow cleaner manufacturer s instructions for use Wear appropriate safety equipment CAUTION DANGER HIGHVOLTAGE DANGER LEVER HASP TAG KEY LOCK FIGURE 5 14 1 MAIN DISCONNECT LOCKED AND TAGGED Reassemble in reverse order Make sure guards are replaced Refill the compressor with coolant If contamination ...

Page 41: ...se of motor bearing failure The quantity of grease added should be carefully controlled The smaller motors must be greased with a lesser amount of grease than larger motors When regreasing stop motor Disconnect power lock out and tag Remove outlet plugs or spring loaded grease relief plugs if present The outlet plug may not be accessible on the fan end of some TEFC motors Grease should be added wh...

Page 42: ... POWER LOCK OUT AND TAG AND REPLACE THESE DRAIN FITTINGS TO PRECLUDE LOSS OF NEW GREASE AND ENTRANCE OF CONTAMINANTS Recommended Motor Grease Most motors require Mobilith SHC 220 Mobil Use the grease as indicated on a special grease information nameplate on the motor Use of alternative greases can result in shortened motor life due to incompatibility of greases If there is not a grease nameplate o...

Page 43: ...switch is locked open and tagged See Figure 5 18 1 FIGURE 5 18 1 MAIN DISCONNECT LOCKED AND TAGGED Tools Screwdriver Size 1 flathead 3 8 inch hex driver Follow these precautions to minimize damage from static electricity Static can cause severe damage to microcircuits 1 Make the least possible movement to avoid build ing up static electricity from your clothing or tools 2 Discharge potential stati...

Page 44: ...minated a new charge of coolant must be used Hold fitting securely while removing hose Installation Install the new hoses and reassemble the package by reversing the disassembly procedure Start the compressor and check for leaks 5 20 AIREND DISCHARGE HOSE The flexible hose from the airend discharge to separator tank may become brittle with age and require replacement Check this hose as per the mai...

Page 45: ... air leak from tank or table Using the adjacent up blowdown piping and down arrows the values PRES SENSOR FAIL or Check for defective sensor bad sensor displayed will be those im TEMP SENSOR FAIL connection or broken sensor wires mediately preceding shut down Use these values CK MOTOR ROTATION Interchange any two line connections when trouble shooting a L1 L2 L3 at the starter problem MAIN MTR OVE...

Page 46: ...rectly installed Slope drain line away from trap Install drip leg No refrigerated or desiccant dryer in Contact local Ingersoll Rand air system Distributor or Air Center V belts slipping Adjust belt tension or replace belts Excessive noise level Compressor defective Bearing Contact authorized Distributor or Air failure or rotor contact Center immediately do not operate unit Enclosure panels not in...

Page 47: ...t Option is desired a combination field installation kit that contains these features is available The option includes a plug in module and all of the hardware necessary The Power Outage Restart portion of the option is for plants that have interruptions in their incoming power supply to the compressor and must maintain an uninterrupted supply of compressed air When turned on the option allows the...

Page 48: ...46 8 0 REFERENCE DRAWINGS 8 1 ELECTRICAL SCHEMATIC FULL VOLTAGE 39838388 REV 01 ...

Page 49: ...47 8 2 ELECTRICAL SCHEMATIC STAR DELTA 39851985 REV 01 ...

Page 50: ...48 8 3 ELECTRICAL SCHEMATIC FULL VOLTAGE REMOTE MOUNTED STARTER 39845029 REV 01 ...

Page 51: ...49 NOTES ...

Page 52: ...50 8 4 FOUNDATION PLAN ENCLOSED Continued 39838750 REV 02 ...

Page 53: ...51 8 4 FOUNDATION PLAN ENCLOSED 39838750 REV 02 ...

Page 54: ...52 8 4 FOUNDATION PLAN UNENCLOSED Continued 39848171 REV 02 ...

Page 55: ...53 8 4 FOUNDATION PLAN UNENCLOSED 39848171 REV 02 ...

Page 56: ...54 8 6 FOUNDATION PLAN OUTDOOR MODIFICATION Continued 39848189 REV 02 ...

Page 57: ...55 8 6 FOUNDATION PLAN OUTDOOR MODIFICATION 39848189 REV 02 ...

Page 58: ...56 8 7 BASIC FLOW SCHEMATIC FULL VOLTAGE 39589437 REV 01 NOTE FOR CUSTOMER CONNECTIONS SEE FOUNDATION PLAN OF UNIT ...

Page 59: ...57 8 8 BASIC FLOW SCHEMATIC FULL VOLTAGE WITH MODULATION 39557251 REV 05 NOTE FOR CUSTOMER CONNECTIONS SEE FOUNDATION PLAN OF UNIT ...

Page 60: ...58 8 9 BASIC FLOW SCHEMATIC STAR DELTA 39589429 REV 01 NOTE FOR CUSTOMER CONNECTIONS SEE FOUNDATION PLAN OF UNIT ...

Page 61: ...59 8 10 BASIC FLOW SCHEMATIC STAR DELTA WITH MODULATION 39568159 REV 02 NOTE FOR CUSTOMER CONNECTIONS SEE FOUNDATION PLAN OF UNIT ...

Page 62: ...60 8 11 TYPICAL SYSTEM FLOW DIAGRAMS TYPICAL SYSTEM FLOW DIAGRAM ...

Page 63: ...61 8 11 TYPICAL SYSTEM FLOW DIAGRAMS ...

Page 64: ...62 8 11 TYPICAL SYSTEM FLOW DIAGRAMS ...

Page 65: ...63 8 11 TYPICAL SYSTEM FLOW DIAGRAMS ...

Page 66: ...64 8 11 TYPICAL SYSTEM FLOW DIAGRAMS ...

Page 67: ...65 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY 9 0 MAINTENANCE RECORD ...

Page 68: ...66 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD ...

Page 69: ...67 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD ...

Page 70: ...68 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD ...

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