IR Ingersoll Rand ESH Operation And Maintenance Instructions Download

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Summary of Contents for ESH

Page 1: ...ESV ESH Operadon II IIICI lnstrucdons 70457080 Rev 00 March 2003 lij lngersollfland IIIII IB inalB ...

Page 2: ...f OR the confidential OR trade secret information therein 2 NOT copy the manual OR part of it 3 NOT disclose to others either the manual OR any copy thereof OR the confidential OR trade secret information therein and 4 upon completion of the need to retain the manual OR upon demand return the manual all copies thereof and all material copied therefrom You may not modify copy reproduce republish up...

Page 3: ...TION COMMODITY SPECIFICATION G 7 1 1966 GRADE D BREATHING AIR AND OR CANADIAN STANDARDS ASSOCIATION SHOULD THE PURCHASER AND OR USER FAIL TO ADD SUCH SPECIALIZED EQUIPMENT AND PROCEEDS TO USE THE COMPRESSOR FOR BREATHING AIR SERVICE THE PURCHASER USER ASSUMES ALL LIABILITY RESULTING THEREFROM WITHOUT ANY RESPONSIBILITY OR LIABILITY BEING ASSUMED BY INGERSOLL RAND COMPANY THE PURCHASER IS URGED TO ...

Page 4: ...DERAL REGISTER VOLUME 36 NUMBER 105 PART II PARAGRAPH 1910 169 BE ADHERED TO IN THE INSTALLATION AND MAINTENANCE OF THIS RE CEIVER ALL ELECTRICAL INSTALLATION MUST BE IN ACCORDANCE WITH RECOGNIZED ELECTRICAL CODES BEFORE WORKING ON THE ELECTRICAL SYSTEM BE SURE TO CUT OFF THE ELECTRICAL SUPPLY FROM THE SYSTEM BY USE OF A MANUAL DISCONNECT SWITCH DO NOT RELY ON THE STARTER TO CU T OFF THE ELECTR IC...

Page 5: ...res have been applied to all openings NOTE Oo nor remove tile protective uvt rlllg unttl yllu arc ready to assemble tlte pipi tg or vessels on the compressor RECOMMENDATIONS This is particularly importan t wtth mult i tag high pressure compressors where special metallic packings are required and in N L Nonlubricatcd compressors where special carbon or Teflon rings and packagings are required These...

Page 6: ...ME OIL PUMP OIL DRAIN TWO PIECE CONNECTING ROD DISTANCE PIECE Figure 1 Cross Section View of Typical FR AM E LOW OIL PRESSURE SWITCH FRAME DISTANCE PIECE V BELT SHEAVE ESH Lubricated Compressor Figure 2 Horizontal Nonlubricated Compressor CYLINDE R OUTER HEAD CYLINDER OUTER HEAD ...

Page 7: ...essor 2 Remove the frame top cover and distance piece side covers and clean out with safety solvent every portion of the interior and the crankcase oil sump to insure a clean interio r free from dust and dirt which may have entered during shipping and installation Use a cellulose sponge only NEVER use waste or a linty cloth to clean the interio r of the machine You cannot ge t these portions too c...

Page 8: ...s need be done only as found necessary 4 Start the motor in accordance with instructions fur nished with the electrical equipment If oil pressurt 8 does not build up tht machine with manual starting nloading will shut down automatically when the start button is released On full auto start units if the oil pressure does not build up the unit will shut down when the oil pressure shunt timer times ou...

Page 9: ...After the compressor has run for the first two or three hours under load and has thoroug ly warmed up under operating conditions it should be shut down and checked out in compliance with the maintenance chart above CAUTION BEFORE DOING ANY INSPECTION OR SERVIC ING ON THIS COMPRESSOR 1 SHUT THE MACHINE DOWN 2 CUT OFF THE ELECTRICAL SUPPLY FROM THE MOTOR BY OPENING A MANUAL DIS CONNECT SWITCH IN THE...

Page 10: ... minimize the condensation of oil vapors on the outside of the compressor CAUTION WE RECOMMEND THE USE OF SAFETY SOL VENT FOR CLEANING NEVER USE GASOLINE KEROSENE OR SIMILAR FLUIDS TO CLEAN THE AIR INLET MUFFLER AND CLEANER SHUT DOWNS Routine To shut down the compressor during regular service push the stop button Immediately after the com pressor has stopped shut off the cooling water so that the ...

Page 11: ...el on the discharge This fills the syphon leg with water 2 Close the inlet valve and remove the pipe plug vent in the outer head This admits atmospheric air pres sure to the water surface in the outer head and starts the syphon operating 3 Allow the discharge line to drain the outer head 4 Open the drain valve connected to the water inlet This drains the compressor cylinder 5 Remove two pipe plugs...

Page 12: ...JACKETS REFER TO SECTION 2 3 2 CROSSHEAD Figure 3 1 The crosshead is of one piece aluminum construc tion No adjustment is necessary 3 3 REMOVAL OF CROSSHEAD I On vert ical units blnck the belt wheel to prevent rotation and block the crosshead prior to removal of the con necting roJ Remove connecting rod refer to Section J 6 Lower the crosshead to bottom or the stroke and reblock 2 Loosen the pisto...

Page 13: ... ring out of the pin groove The ring can now be unwound by hand NOT Removal will be sur pler if lht pry 111 1vol IS held trl the left hand while the righ t hand is used to prevent rotating of the ring while prying The ring may be held by t he right hand by reaching th rough the open ing in the distance piece 7 The crosshead pin is now free to be removed Refer to CAUTION note A B and C 8 To reassem...

Page 14: ...the frame oil pump If excess clearance causes the rod to become noisy it is necessary to replace the bushing The crankpin bushing can be replaced by removing the connecting rod cap and rotating the crankshaft free of the con necting rod CAUTION THE BELT WHEEL AND THE CROSSHEAD MUST BE BLOCKED TO PREVENT ROTATION WHILE THE CRANKPIN BUSHING IS BEING REPLACED FAILURE TO DO SO CAN RESULT IN PERSONAL I...

Page 15: ... the main bearing housing 5 Support the crankshaft in a horizontal position and re move it from the frame by pulling straight out through the main bearing housing opening 3 10 CRANKSHAFT OIL SEALS figure 3 61 A double oil seal is provided on the drive side of the frame to prevent t he escape of oil along the crankshaft Each seal is of the lip type and is normally composed of a neoprene base materi...

Page 16: ... rotary screw motion be used while pushing it over the shaft 5 Stroke Units Force the inner seal into position such that there will be 1 4 6 35 mm to 5 16 7 935 mm between the inner seal and the outer seal when the outer seal is flush with the I 8 3 I74 mm counterbore 7 Stroke Units Force the inner seal into the bore as far as it will go using a block of wood and a hammer or an extreme ly blunt in...

Page 17: ...CATION When starting for the first time the oil pump must be primed Remove the pipe plug in the pump cover Sec Figure I 0 and pour oil down the hole into the pump Priming is necessary only before the initial start up or after the machine has been idle for several days Frame Oil Pump The oil pump is an internal gear pump with two rotating gears The pump drive shaft is driven directly off the compre...

Page 18: ...ine always contains some dirt and foreign matter which is washed out by the flow of oil through the system This is collected by the ftlter before it can get into bearings When the filter becomes clogged the pressure at the bearings will decrease until the oil pressure failure protection switch automatically shuts down the compressor at 5 psig 0 34 bar oil pressure The filter should be replaced bef...

Page 19: ...icnt temperatures encountered to permit proper lubrica tion in the crankcase at starting The following recommended limits on laboratory test characteristics arc generally satisfactory Flash Point Open Cup Viscosity at I00 F 38 C SSU Viscosity at 210 F 99 C SSU Carbon Residue Conradson Strong Acid Number 380 F 193 C Min 780 Max 60 Min 0 45 Max 0 00 Max All tests shall be conducted in accordance wit...

Page 20: ...linder with its valves frame and outer heads piston and rod and the stuffing box and packing The following is a brief explanation of these major assemblies making up the cylinder end Refer to the cross section Figure 12 and become familiar with the parts and their functions PISTON ROD FRA MEHEAD PRESSURE PACKING A The cylinder is a single piece cast iron construction with easily removable valves a...

Page 21: ...e plate by four cap screws Alignment For raising or lowering the cylinder for alignment on the compressor frame the bottom flange of the foot elbow is provided with two additional holes tapped for the sole plate cap screws When first installing and aligning a cylinder two of the cap screws are inserted in these holes and used as ja ks by tigh ening hem agamst the upper face of the sole plate After...

Page 22: ... be bumped loose by inserting approxi mately 1 8 3 rnm metal strips between the piston and the framehead on each side of the piston rod Back the piston rod nut off approximately one turn and slowly rotate the compressor by hand so that the piston moves toward the framehead Do not use power for bumping As the piston presses against the metal strips it will be pushed loose on the rod To remove the p...

Page 23: ...A INGS Figure 14 Lubricated Cast Iron Piston and Rod f o ION 0 0 NUl Figure 15 Non lubricated Cast Iron Piston and Rod Be sure that the partition plate stuffing box is properly installed The oil drain should be at the bottom and the vent hole at the top to allow proper drainage oroil tl the frame Sec Figure 13 PISTON There are two types of pistons used on the 5 7 inch stroke ESH ESV type compresso...

Page 24: ...e considerably narrower in width at the outside circumference 24 5 Rotate the crankshaft by hand so that when the piston have moved to the end of its stroke the taper or wire will flatten to the exact amount of clearance which exists between the piston and the head NOTE The rod can be tu rned by using a socket wrench on the nut on the face of the riston NEVER USE A PIPE WRENCH ON THE PISTON ROD 6 ...

Page 25: ...ir and piping and surface finish of the bore The piston rings should be replaced when worn approx imately I 4 to 1 2 of their original thickness Figure 18 Piston Rider Ring 005 INCH MIN 0 127 mm WEAR RING CUT AWAY __ WOODEN M WEDGE rT Tl j Figure 19 Checking the Rider Ring for Wear Rider Ring Wear The rider ring carries the weight of the piston on the cylinder The cylinder bore has a fine honed su...

Page 26: ...it Therefore it is desirable to replace the rings with new ones after they have worn approximately 1 4 to 1 2 their original thickness PISTON ROD AND SPRINGS COMPRESSOR PROTECTION FOR STORAGE General The unit has been prepared at the factory with an an ti corrosive material to retard rust However it is important that the unit be stored in a warm dry environ ment Inspection Upon inspection it may b...

Page 27: ...ame head where the rings and case can be separated on the rod Carefully observe the order in which the rings come out of the case It is necessary to replace the rings in the same order as they were removed to insure tha t the packing A DOWE L l GART ER SPRING A TANGENTIAL CUT RING SECTION A A SECT ION OF RINGS DOWELED TOGETHER Figure 21 Tangential Cut Packing Rings rings maintain their original se...

Page 28: ...laced In AN EMERGENCY the clearance between the ends of the segments can be adjusted by cutting them off The original opening was 125 inch 3 18 mm at the step of the tangent joint Figure 22 After making this emergency adjustment it may be necessary to shorten the spring slightly to maintain sufficient tension to hold the ring segments to the rod The tension should never be any more than enough to ...

Page 29: ... should also be checked for leakage into the line Long intake lines between the filter anti the compressor cylinder can cause pipe scale to form and therefore they should be avoided lns uctions regarding air intake piping arc given in Section I of this manual and Se tion 3 of yuur ESH V Installation Manual Ingersoll Rand 1 orm AP 0250 CYLINDER OIL FEED RATES Break In The initial break in of a comp...

Page 30: ... supplier so that he may select the correct lubricant for your operating conditions DESCRIPTION OF OIL TYPES Type 1 For cylinders Jess than 26 inches in diameter and discharge air temperatures under 350 F handling dry gases that is gases which do not carry suspended liquid but may contain water vapor in the super h eated state throughou t the compression cycle Rust and or oxidation inhibited oil o...

Page 31: ...oided since the film thickness of synthetic lubricant is generally less than wi th mineral oil Specifications It is strongly recommended that the particular grade of synthetic lubricant selected must meet the following physical requirements Viscosity SSU I00 F 38 C Viscosity SSU 2 10 F 99 C Viscosity Index Flash Point F C0 Fire Point F C0 Auto Ignition Point F C Pour Po int F C0 500 maximum 57 min...

Page 32: ...to maximum delivery and then manually operate the pump spindle until clear oil is delivered Replace and tighten the vent screw VENT SCREW 01 L FEED SIGHT GLASS HAND PUMP SPINDLE RESERVOIR FILLER CAP FEED ADJUSTMENT NUT HIGH LEVEL SIGHT GLASS RESERVOIR _ _ _ DRAIN 3 Each lube line connection should be loosened at the check valve Manually operate the pump spindle until oil issues from the loosened f...

Page 33: ...der where it is used to prevent air from blowing back into the lubricator When the check valve leaks it usually gets hot The leakage can usually be corrected by reseating the valve see Figure 25 Sight Feed Liquid The sight feed should be kept full of liquid A mixture of half glycerine and half distilled SIGHT GLASS UPPER Ill COUPLING NUT 0 BODY TAILPIECE ASSEMBLY IN LET TERMINAL CHECK VA LVE PLUG ...

Page 34: ... Type A channel valve each valve spring has two functions The first is to return the valve Figure 27 Lubricated Valve Components 34 Figure 28 Non Lubricated Valve Components channel to the valve seat plate after the air has been pushed through the valve The second is to cushion the opening of the valve channel and prevent it from impacting against the valve stop plate rib The valve spring is fi tt...

Page 35: ...st be taken Lo assure that they will be returned to their proper position Should an inlet valve be mounted in a discharge position or a discharge valve be mounted upside down extreme over pressure can occur It must be clearly unden tuuJ tha l such negligence can result in serious damage to the compressor and serious if not fatal injury to personnel To remove a valve assembly from Lhe cylinder use ...

Page 36: ...mble the valve refer to Figure 31 I Place the valve assembly on a clean flat surface 2 Remove the discharge valve crab or inlet valve free air unloader cage from the valve taking care to note or mark which side of the valve it was attached to 3 Remove the two flat head machine screws which hold the valve seat and stop plate together If you are servicing an inlet valve the entire valve assembly sho...

Page 37: ...ents must be thoroughly dried before reassembly and reinstallation in the compressor cylinder CAUTION USE ONLY SAFETY SOLVENT TO CLEAN VALVES AND COMPRESSOR COMPONENTS USE OF OTHER CHEMICALS CAN BE HAZARD ous Replacement Parts If upon inspection any of the channels have been found broken or the seat plate damaged in the seating area a new set of genuine Ingersoll Rand channels and springs should b...

Page 38: ...removed The valve should rest squarely on the valve seat gasket It is recommended that the valve ports be placed parallel to the axis 0 rthe cylinder 3l S 4 On the lower half ut th cornp1t s o J cylmdet the valve assembly complete is held in the cylinder valve hole by a valve holder Figure 30 while the valve cover is reinstalled A special hollow type cover set screw and a valve holder which is thr...

Page 39: ... an intake filter or scrubber should be installed and properly main rained Expereince will dictate the time length of the filter or scrubber maintenance cycle lubricated Valves On lubricated compressors oil in excess of that amount required to properly lubricate the compressor cylinder bore and valves is detrimental to long valve life The feed rate of the cylinder lubricator may be reduced to elim...

Page 40: ...40 top o f the unloader ptston When the free ai1 unloade1 has been actuated the unloader ptston seals against the unloader cage piston housing seat When the free air unloader is not actuated the unloader piston seals against the unloader cover With zero pressu re on the unloader piston the lifting spring holds the unloader plunger away from the valve channels When pressure is applied the unloader ...

Page 41: ... and unloader cage together 4 Make sure that the two fillister head screws that retain the unloader cover are loose enough to allow some movement of the cover This is necessary for proper centering of the unloader cover with the cover set screw 5 After installation of the cover and its retaining screws insert a screw driver into the slots on the threaded end of the screws and slightly spread them ...

Page 42: ...nlet valve to runction normally and the compressor to operate at full capacity Thus the compressor unloads to maintain the receiver pressure within the pressure range for which the Auxiliary Val ve has heen set To unload the compressor ft r starting when there is p1L ssurc in the receiver screw up on the wing nut at the bottum of the Auxiliary Valve This ac tion will ad mit air or gas to the Free ...

Page 43: ... above the upper valve seat prevents any particles of dust or grit from being carried into the valve chamber Should the Auxiliary Valve fail to work properly at any time it should be dis assembled and cleaned If the pipe from the receiver to the Axuiliary Valve is long it may cause uncertain action and chatter In this case enlarge the pipe Asmall receiver placed in the regulator line close to the ...

Page 44: ...ver By this time oil pressure will have built up a rttl uti pr ure wll ch UPS wtll be do ed holding in the circuit 2 When the contact TOR crosse over the solenoid operated three way valve UNL will become energized allowing the compressor to load Pressure switch PS will now open and close as the discharge pressure rises and falls This action will actuate the solenoid valve UNL loading and unloading...

Page 45: ...l lor lcxallon ol l fCtt Ctl 18 SWitches vatvts EXHAUST FROM DIAGRAMATIC PIPING COM N C EXHAUST R ECElV ER 4 ___ 3 l Y PIPE TO FREE AIR UN LOADERS SOLENOID 3 WAY VALVE CONNECTIONS ASCO 1 2 3 SKINNER 2 I 3 GENERAL C OM NC NO Figure 39 Piping and wiring diagram for Constant Speed Regulation Full Automatic starting unloading Solenoid Val11e The solenoid 3 way air valve is the packless type There is o...

Page 46: ...om the top of the diaphragm the spring will return the lower ball to its seat and lift the upper ball Pressure on the unloading devices will now be exhausted to atmosphere 46 Should the UL58C fail to operate the cause could be a hole in the diaphragm In this event the diaphragm must be replaced Should excessive air leaks occur around the ball seats the balls and their seats should be cleaned If th...

Page 47: ...therwtse indicated on the foun dat ion plan 2 Line up the sheave and tighten each cap screw progress ively See Tightening lnstru tions There should be a gap between the sheave hub and the bushing flange SECTION IX BELT DRIVE Tightening When mounttng a tapered bushing the tightening force on the screws is multiplied m ny times hy the wedging of the tapered surface This actton compresses the bushing...

Page 48: ...djustment of motor position and care should be taken to insure that the grouting of the base does not interfere with the movement of the adjusting screws V BELTS Installation When installing a multiple V belt drive a check should first be made that the motor and compressor sheaves are properly aligned and that the shafts are parallel MOVE the motor toward the compressor as far as the slide base wi...

Page 49: ... place TI1is excessive uneven load will shorten the life of the new belts Keep any of the old belts that appear to be in serviceable conditi on for future emergency use Proper Fit The V belt should saddle in the sheave groove so that the top surface rides above the highest point of the sheave Stresses are then distributed properly throughout the belt section and good contact is assured A low ridin...

Page 50: ...o1ding possible costly delays or the substitution of inferior parts kept in good as new con dition Fast Efficient Field Service We maintain a staff of trained mechanics and service trucks to provide you with preventtve maintenance or meet any em ergenc tes you may have A world of experience at your serviceI Complete Repair Service Trained mechaniCS will repair or overhaul compressors by factory re...

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