Ingersoll-Rand EP 60 Operators/Instruction Manual Options Download Page 1

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XFE/EPE/HPE 50
XF/EP/HP 60
XF/EP/HP/XP 75-100
ML/MM/MH 37-75

OPERATORS/
INSTRUCTION MANUAL
OPTIONS

Before installation or starting the compressor for the
first time, this manual should be studied carefully to
obtain a clear knowledge of the unit and of the duties
to be performed while operating and maintaining the
unit.

RETAIN THIS MANUAL WITH UNIT.
This Technical manual contains IMPORTANT SAFETY
DATA and should be kept with the air compressor at all
times.

FORM: APDD 696C

July 2002

More Than Air. Answers.

Online answers: http://www.air.irco.com
Phone: 1-800-526-3615

CCN: 80440332 REV: C

Summary of Contents for EP 60

Page 1: ...died 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 FORM APDD 696C July 2002 More Than Air Answers Online answers http www air irco com Phone 1 800 526 3615 CCN 80440332 REV C ...

Page 2: ...abor 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 i...

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: ...F CONTENTS 5 12 coolant lubricant changeout 5 13 intellisys removal 5 14 coolant hoses 5 15 airend discharge hose 5 16 fluid and vibration monitoring 5 17 coolant sampling procedure 6 0 TROUBLE SHOOTING 7 0 REFERENCE DRAWINGS 7 1 electrical schematic full voltage 7 2 electrical schematic star delta 7 3 foundation plan air cooled 7 4 foundation plan water cooled 7 5 foundation plan outdoor mod 7 6 ...

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: ...priate 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 compressor d...

Page 7: ...D Lift here NOTICE INGERSOLLrAND Condensate drain NOTICE INGERSOLLrAND 39557095 50 100 HP 39540257 39540166 39540273 4 2 EACH END 39541081 54425996 37 75 KW NOTICE NOTICE NOTICE To obtain satisfactory compressor 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 o...

Page 8: ...ved Service only with machine blocked to prevent turn over INGERSOLLrAND WARNING Exposed moving parts Can cause severe injury or death Stay clear or moving parts when machine is operating INGERSOLLrAND CAUTION Incorrect lifting of machine can cause injury or property damage Lift only from base channels INGERSOLLrAND 39540190 39540224 39558788 39540232 NOTICE NOTICE Rotation Rotation INGERSOLLrAND ...

Page 9: ...000 hours thereafter or when coolant is changed INGERSOLLrAND WARNING Hot surface Can cause severe injury Do not touch Allow to cool before servicing INGERSOLLrAND CAUTION Use of incorrect coolant can cause system contamination Use only SSR ULTRA COOLANT INGERSOLLrAND Filler Cap Use only recommended coolant Read instruction book before servicing INGERSOLLrAND 39543921 NOTICE Rotation INGERSOLLrAND...

Page 10: ...ardous voltage Can cause severe injury or death Disconnect power before servicing Lockout Tagout machine INGERSOLLrAND WARNING This machine is remote start and stop equipped May start or stop at any time Can cause severe injury or death Disconnect power before servicing Lock and tag out See Operators Instruction Manual INGERSOLLrAND 39543764 39540174 39543764 39540174 39899950 39541354 39547708 39...

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: ... 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 resonant sounds being transmitted or amplified through the floor 2 3 PIPING The use o...

Page 13: ...ed air lines 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 shoul...

Page 14: ... compressed air system Refrigerated 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 installe...

Page 15: ...ear or non drive end of the motor See Figure 2 4 2 FIGURE 2 4 2 DRIVE MOTOR ROTATION DRIVE END NON DRIVE END FIGURE 2 4 1 TYPICAL CONTROL TRANSFORMER WIRING 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 L...

Page 16: ...closure Should the motor rotation not be correct put the main disconnect in the OFF position lock and tag Interchange any two fan motor leads at the fan motor overload relay FMS OL Close and fasten the starter box door Recheck for correct rotation DANGER HIGHVOLTAGE DANGER DANGER LEVER HASP TAG KEY LOCK FIGURE 2 4 4 INTELLISYS OPERATING INSTRUCTIONS NOTICE Intellisys Operating Instructions Before ...

Page 17: ...never drop below 35 F 1 7 C If ambient temperature drops below 35 F 1 7 C to as low as 10 F 23 C the unit must be supplied with the Low Ambient Option Installations below 10 F 23 C ambient are not recommended The Low Ambient Option requires a separate power source to operate internal heaters Arrange the machine with the Intellisys con troller starter enclosure facing away from the sun as radiant h...

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

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

Page 20: ...ble press this button to exit the display table Display will show CHECKING MACHINE then READY TO START EMEG STOP 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...

Page 21: ...uttons have several functions If the Intellisys is in the set point mode the ARROWS are used to change the set point values 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 runnin...

Page 22: ...ess the SET button to move to the next set point If the set point value has been adjusted press the SET button to enter the new value The display will 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 ...

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

Page 24: ...ensing in the receiver By injecting coolant at a sufficiently high temperature temperature of the discharge air and lubricant mixture will be kept above the dew point The controlled temperature coolant passes through a filter to the airend under constant pressure 22 4 0 SYSTEMS 4 1 GENERAL SYSTEM INFORMATION The SSR compressor is an electric motor driven single stage screw compressor complete with...

Page 25: ...he separated fluid back to the compressor Operation The coolant and air discharging from the compressor flow into the separator tank through a tangential inlet This inlet directs the mixture along the inner circumference of the separator tank allowing the coolant stream to collect and drop to the separator tank sump Internal baffles maintain the circumferential flow of remaining coolant droplets a...

Page 26: ... end wrench 9 16 open end wrench Loctite 242 or equivalent With the compressor shut down remove the nut that fastens the inlet valve pivot anchor to the bracket on the inlet valve Apply Loctite 242 or equivalent to threads on spacer and loosely install nut Start compressor and press the unload button so that the compressor will not load Use the display select button to indicate sump pressure on th...

Page 27: ...re the compressor will load or start if the unit was stopped due to an auto start stop situation This timer will not delay loading after a start or if the time is set to 0 When the delay load timer becomes active the display will show the delay load countdown Once the countdown reaches 0 the unit will load or start Automatic Start Stop Operation When in operation the compressor must meet two speci...

Page 28: ...ions remote start stop option power outage restart sequencer control and modulation control 4 8 1 Starter Options The standard compressor is supplied with an automatic across the line full voltage starter This starter is fully controlled by the Intellisys and supplies full line voltage to the compressor motor at startup Optional reduced voltage star delta starting is available fully installed at t...

Page 29: ...odulation Only The MODULATlON control mode can be selected during the set point procedure on a compressor that has the modulation option installed To load the Intellisys energizes the load solenoid 1SV and blowdown solenoid 3SV as in on line off line control The Intellisys also energizes the modulation solenoids 2SV and 6SV This connects regulated pressure from the modulator valve MV to the air cy...

Page 30: ... in the control piping and connect a pressure gauge to this port 2 Reconnect power to the compressor When display reads READY TO START enter the set points routine and set control mode to MODULATION 3 Start the compressor and elevate system pressure to desired set point pressure This pressure must be maintained while adjusting the modulator valve 4 Loosen the lock nut on the bottom of the modulato...

Page 31: ...29 NOTES ...

Page 32: ...e 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 6 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 Inspect Air filter Delta ...

Page 33: ... coolant filter should be changed after the first 150 hours of operation and every 2000 hours thereafter or when the coolant is being changed In dirty operating 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 with a clean lint free ...

Page 34: ...The coolant should be drained soon after the compressor has been shut down When the coolant is hot drainage will be more complete and any particles in suspension 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 remove plug from drain valve located on the bottom of the separator tank Install supplied drai...

Page 35: ...e diameter of the orifice and a direction of flow arrow is stamped in flat areas of the hexagon A removable screen and orifice is located in the exit end of the assembly See Figure 5 7 1 and will require cleaning as outlined in the Maintenance Schedule Section 5 1 To remove the screen orifice disconnect the scavenge line tubing from each end Hold the center section firmly and use a pair of pliers ...

Page 36: ...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 in its c...

Page 37: ...e to wash out all chemicals thoroughly with clean water before returning the compressor to service After cleaning examine the cooler for erosion or corrosion 5 9 COOLER CORES CLEANING 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 See F...

Page 38: ...ubricant Amount Motor Frame Size in3 cc oz grams 56 145 182 215 5 8 4 11 254 286 1 0 1 6 8 23 324 365 1 5 25 1 2 34 404 449 2 5 40 2 0 57 Relubrication amount Procedure for relubrication 36 NOTICE Motors MUST be greased periodically See Operators Manual for procedure 39570098 5 9 2 Water Cooled Coolers Continued Cleaning The interior tube surfaces can be cleaned by several methods Flushing a high ...

Page 39: ...CONNECT 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 name...

Page 40: ...See Figure 5 13 1 FIGURE 5 13 1 MAIN DISCONNECT LOCKED AND TAGGED 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 static electricity by touching grounding yourself to the starter box 3 Handle circuit boards...

Page 41: ...ly while removing hose 75 100 HP 55 75 KW Machines Remove 4 bolts in flange at each end of discharge hose Retain flanges and bolts for replacement 5 16 FLUID AND VIBRATION MONITORING Ingersoll Rand recommends incorporating predictive maintenance specifically the use of coolant and vibration analysis into all Preventative Maintenance programs Predictive Maintenance is designed to increase system re...

Page 42: ...Check for air leak from tank or table Using the adjacent up blowdown piping and down arrows the values Adjust sump pressure displayed will be those im PRES SENSOR FAIL or Check for defective sensor bad sensor mediately preceding shut TEMP SENSOR FAIL connection or broken sensor wires down Use these values when trouble shooting a CK MOTOR ROTATION Interchange any two line connections problem L1 L2 ...

Page 43: ...plugged Inspect and clean Aftercooler core dirty Inspect and clean Enclosure panels not in place Install enclosure panels Drain line drip leg incorrectly 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 Excessive noise level Compressor defective Bearing Contact authorized Distributor o...

Page 44: ...42 7 0 REFERENCE DRAWINGS 7 1 ELECTRICAL SCHEMATIC FULL VOLTAGE 39899794 REV 02 ...

Page 45: ...43 7 2 ELECTRICAL SCHEMATIC STAR DELTA 39899786 REV 02 ...

Page 46: ...44 7 3 FOUNDATION PLAN AIR COOLED 39894472 REV 03 ...

Page 47: ...45 7 4 FOUNDATION PLAN WATER COOLED 39907894 REV 03 ...

Page 48: ...46 7 5 FOUNDATION PLAN OUTDOOR MOD 39907886 REV 03 ...

Page 49: ...7 6 BASIC FLOW SCHEMATIC AIR COOLED 39899828 REV 02 47 ...

Page 50: ...48 7 7 BASIC FLOW SCHEMATIC WATER COOLED 39899836 REV 02 ...

Page 51: ...49 7 8 TYPICAL SYSTEM FLOW DIAGRAMS TYPICAL SYSTEM FLOW DIAGRAM ...

Page 52: ...50 7 8 TYPICAL SYSTEM FLOW DIAGRAMS ...

Page 53: ...51 7 8 TYPICAL SYSTEM FLOW DIAGRAMS ...

Page 54: ...52 7 8 TYPICAL SYSTEM FLOW DIAGRAMS ...

Page 55: ...53 7 8 TYPICAL SYSTEM FLOW DIAGRAMS ...

Page 56: ...ale formation is the precipitation of calcium carbonate out of the water This is dependent on temperature and pH The higher the pH value the greater the chance of scale formation Scale can be controlled with water treatment CORROSION In contrast to scale formation is the problem of corrosion Chlorides cause problems because of their size and conductivity Low pH levels promote corrosion as well as ...

Page 57: ...ical balance If the Ll is greater than zero there is a tendency to form scale If the Ll is less than zero the water tends to be corrosive Dissolved oxygen may be controlled in closed cooling towers Several types of treatments are commercially available to remove dissolved oxygen For open cooling towers dissolved oxygen is not an easily controlled parameter Also a filtration system is recommended f...

Page 58: ...82 1 80 1 78 1 76 100 1 74 1 72 1 71 1 09 1 67 110 1 05 1 64 1 62 1 60 1 58 120 1 67 1 63 1 53 1 51 1 50 130 1 48 1 46 1 44 1 43 1 41 140 1 40 1 38 1 37 1 35 1 34 150 1 32 1 31 1 29 1 28 1 27 160 1 26 1 24 1 23 1 22 1 21 170 1 19 1 18 1 17 1 10 TENS TENS HUNDREDS Alkalinity ppm Temperature F 50 07 75 08 100 10 150 11 200 13 300 14 400 16 600 18 800 19 1000 20 TOTAL SOLIDS PPM Total dissolved solid...

Page 59: ...57 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY 9 0 MAINTENANCE RECORD ...

Page 60: ...DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD 58 ...

Page 61: ...59 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD ...

Page 62: ...60 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD ...

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