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Ingersoll-Rand EP 20-ESP, Руководство оператора/инструкция по эксплуатации и перечень запасных частей

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Ingersoll-Rand EP 20-ESP Скачать руководство пользователя страница 34

32

5.0 TROUBLE SHOOTING

TROUBLE

CHECK POINT NUMBERS

Compressor Fails to Start

1,2,3

Repeat Shutdowns

3,4,5,2

High Amp Draw

8,9,6,7

Low Amp Draw

1,10,12

High Discharge Pressure

13,15,18

Low Air System Pressure

21,19,16,17,13,15,14,18,7

Unit Running Hot

21,20,22,23,6

High Coolant Consumption

27,26,24,25

Excessive Noise Level

16,17,30,29,28

Shaft Seal Leak

31

Pressure Relief Valve Opens

6,13,15,14,18

Black Residue on Belt

16,32,33

Guard/Cooler Box

CHECK POINT NUMBERS

TROUBLE CAUSE

1.

Control Voltage Not Available

2.

Defective Starter

3.

Motor Overload

4.

Incorrect Overload Heater Size

5.

Line Voltage Variation

6.

Compressor Operating Above Rated Pressure

7.

Dirty Separator Filter Element

8.

Low Voltage

9.

Unbalanced Voltage

10.

Dirty Air Filter

11.

Compressor Operating Unloaded

12.

High Voltage

13.

Incorrect Pressure Switch Setting

14.

Faulty Minimum Pressure Valve

15.

Load Solenoid Valve Defective

16.

Drive Belt Slipping

17.

Air System Leaks

18.

Inlet Valve Malfunction

29.

System Demand Exceeds Compressor Delivery

20.

Coolant Cooler Core Dirty

21.

Low Coolant Level

22.

High Ambient Temperature

23.

Restricted Cooling Air Flow

24.

Separator Filter Element Leak

25.

Plugged Separator Filter Drain

26.

Compressor Operating Below Rated Pressure

27.

Coolant System Leak

28.

Airend Defective

29.

Motor Defective

30.

Loose Components

31.

Worn or Defective Shaft Seal

32.

Sheaves Misaligned

33.

Worn Sheaves

Содержание EP 20-ESP

Страница 1: ...tain 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 shou...

Страница 2: ...WARRANTIES OF MERCHANTABILI TY 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 tim...

Страница 3: ...o 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...

Страница 4: ...ge check valve screen orifice 4 15 cooler cores 4 16 motor greasing 5 0 TROUBLE SHOOTING 6 0 REFERENCE DRAWINGS 6 1 electrical schematic full voltage 6 2 electrical schematic star delta 6 3 piping dia...

Страница 5: ...sor has high and danger ous voltage in the motor starter and con trol box All installations must be in accor dance with recognized electrical codes Before working on the electrical system be sure to r...

Страница 6: ...ENT FOR BREATHING AIR AND OR AQUA LUNG SERVICE If the model number on this air compressor contains letters BAP the compressor is suitable for use in breathIng air services In the absence of such a des...

Страница 7: ...IEW RIGHT SIDE VIEW NOTICE Rotation INGERSOLLrAND WARNING Hot surface Can cause severe injury Do not touch Allow to cool before servicing INGERSOLLrAND 39541362 39861810 39544150 CAUTION Incorrect lif...

Страница 8: ...e instructions in the Operators Instruction Manual Before Starting 1 Check Coolant level and add coolant if necessary 2 Verify that main isolation valve is open 3 Close main disconnect switch Starting...

Страница 9: ...Cap Use only recommended coolant Read instruction book before servicing 39540281 39540257 39540240 39541362 39540166 CAUTION Use of incorrect coolant can cause system contamination Use only ROTALUBETM...

Страница 10: ...of the compressor 2 2 FOUNDATION REQUIREMENTS The compressor can be installed on any level floor that is capable of supporting the weight When sound transmission is of particular importance it is oft...

Страница 11: ...n such as a fence or security system should be provided to prevent unauthorized access FIGURE 2 3 1 TYPICAL OUTDOOR SHELTERED INSTALLATION 35 F 2 C AND ABOVE DISCHARGE PIPE STEEL POWER DISCONNECT SWIT...

Страница 12: ...the drain piping should include an open funnel or some type of sight flow indicator It is possible that additional condensation can occur if the downstream piping cools the air even further Therefore...

Страница 13: ...ressor 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 eno...

Страница 14: ...nel front 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 NOTE This p...

Страница 15: ...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 remo...

Страница 16: ...ator element When the unit is operating the coolant is pressurized and forced to the compressor bearings The compressor is provid ed with a temperature switch which will shut the unit down in case of...

Страница 17: ...adequate oil flow and proper coolant air separation The non return check valve prevents line pressure from exhausting back through the airend at shutdown and during periods of unloaded operation The...

Страница 18: ...s to the reset point of 1PS about 12 psig 8 bar the unit should reload The pressure switch dif ferential is adjustable and factory set at about 12 psig 8 bar to meet the requirements of the average ap...

Страница 19: ...ent screw B clockwise This will decrease the lower set ting only The higher setting will not change Similarly to decrease the differential turn the differential adjust ment screw B counterclockwise Th...

Страница 20: ...0 X REPLACE ROTALUBE TM 1000 COOLANT 1000 X REPLACE ULTRA COOLANT OPTIONAL 8000 X REPLACE SHAFT SEAL 8000 X GREASE ODP MOTOR 2000 X GREASE TEFC MOTOR 1000 X TIME INTERVAL WHICHEVER COMES FIRST INITIAL...

Страница 21: ...end of any non service period CAU TION 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 dur...

Страница 22: ...st be loosened for reposi tioning To reposition the motor sheave 1 Remove drive belts See Section 4 6 2 Remove the three hex head screws that hold motor sheave to sheave bushing See Figure 4 5 3 3 Lub...

Страница 23: ...8024 Loctite 609 4 6 DRIVE BELTS Insure that the compressor is isolated from the compressor air system by closing the isolation valve and venting pressure from the drip leg Insure that the main power...

Страница 24: ...inadvertent damage during installation Be sure all tools are free of contaminants before installation 13 Put a thin continuous coat of Loctite 609 on the outer diameter of the double lip seal 14 Remo...

Страница 25: ...ttach the seal housing to the rotor housing with nine screws and tighten to 18 Ibs ft 2 5 kg m 31 Reinstall sheave and sheave retaining hardware apply Loctite 242 to clamp screw and tighten to 32 Ibs...

Страница 26: ...lation Tool press the seal into the seal housing from the outboard side until the seal is flush with the surface of the seal housing Do not push the seal beyond the flush position The seal should be o...

Страница 27: ...o atmos phere 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...

Страница 28: ...olant sufficient to refill the coolant level in the compressor One genuine IR replacement coolant filter of the prop er type for the unit The coolant should be drained soon after the com pressor has b...

Страница 29: ...en 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 pres sure f...

Страница 30: ...ing the pressure to release to atmosphere See Figure 4 3 1 A slight mist or oil droplets may be visible dur ing venting Do not remove fill plug until all pres sure has vented from the unit Also vent p...

Страница 31: ...nt sealing o ring from the housing 7 Verify that the drain hole in the inlet control valve is clean See Figure 4 3 4 8 Install new element sealing o ring in housing Make sure o ring is properly seated...

Страница 32: ...k valve screen orifice assembly to the tubing lines The fitting must be re installed with the screen on the upstream side of the orifice as indi cated by the flow arrow See Figure 4 15 1 FIGURE 4 14 1...

Страница 33: ...cylinder showing cubic centimeters cc may be used or a 35mm film canister can give a close approximation for 2 cubic inches of volume when filled 3 Add the recommended volume of the recommended lubri...

Страница 34: ...Voltage Variation 6 Compressor Operating Above Rated Pressure 7 Dirty Separator Filter Element 8 Low Voltage 9 Unbalanced Voltage 10 Dirty Air Filter 11 Compressor Operating Unloaded 12 High Voltage...

Страница 35: ...33 6 0 REFERENCE DRAWINGS 6 1 ELECTRICAL SCHEMATIC FULL VOLTAGE 39884143 REV 01...

Страница 36: ...34 6 2 ELECTRICAL SCHEMATIC STAR DELTA 39884150 REV 01...

Страница 37: ...IPING LEGEND A AIR PIPING C COOLANT PIPING CA CONTROL AIR PIPING NOTES 1 FOR CUSTOMER CONNECTIONS SEE FOUNDATION PLAN OF UNIT 2 DASHED ITEMS ARE OPTIONAL 3 PRESSURE SWITCH PRESSURE GAUGE ARE CONNECTED...

Страница 38: ...36 6 4 FOUNDATION PLAN TANK MOUNTED CONTINUED 39871975 REV 03...

Страница 39: ...37 6 4 FOUNDATION PLAN TANK MOUNTED 39871975 REV 03...

Страница 40: ...38 6 5 FOUNDATION PLAN BASE MOUNTED CONTINUED 39872835 REV 03...

Страница 41: ...39 6 5 FOUNDATION PLAN BASE MOUNTED 39872835 REV 03...

Страница 42: ...all Type Valve UNION Aids in Disconnecting Compressor From The System PRESSURE GAUGE DRIP LEG MANOMETER DIFFERENTIAL PRESSURE INDICATOR THERMOMETER I R AUTOMATIC DRAIN VALVE FALSE LOADER Blows Off Air...

Страница 43: ...with a description of NSS are not sold separately and must be purchased as an assembly Items with a description of Ref indicate that the item is located elsewhere in the parts list HOW TO USE THIS PAR...

Страница 44: ...42 39876461 REV 02...

Страница 45: ...939 1 LUG GROUND 4 39403290 1 RELAY CONTROL 1CR 5 39125091 1 SOCKET CONTROL RELAY 6 35258508 1 RELAY AUTO RESTART TIME DELAY 7 35245224 1 SOCKET TIMER RELAY 8 39242268 1 LIGHT AMBER INDICATOR AUTO RES...

Страница 46: ...44 39880844 REV 01...

Страница 47: ...39975 1 BLOCK TERMINAL 5 39190939 1 LUG GROUND 6 39403290 1 RELAY CONTROL 1CR 7 39125091 2 SOCKET CONTROL RELAY 8 35258508 1 RELAY AUTO RESTART TIME DELAY 1TD 9 35245224 1 SOCKET TIMER RELAY 10 352497...

Страница 48: ...46 39872031 REV 01 SEE PIPING ASSEMBLY OPTIONS...

Страница 49: ...1 1 TUBE OIL COOLER SEPARATOR TUBE Ref Part No Number Qty Description 23 39881974 1 DEFECTOR AIR 23A 39133145 4 SCREW 24 39878913 1 FAN 50 60HZ 24A 96705082 4 SCREW 25 39872049 1 RING FAN INLET 25A 39...

Страница 50: ...01 NEMA 1 NEMA 4 TO RECEIVER TANK OR ELBOW IN ICV DISCHARGE BASE MOUNTED UNITS TO RECEIVER TANK OR ELBOW IN ICV DISCHARGE BASE MOUNTED UNITS TO HIGH AIR TEMPERATURE SWITCH AIREND TO HIGH AIR TEMPERATU...

Страница 51: ...Ref Part No Number Qty Description 1 xxxxxxxx 1 ASSEMBLY STARTERBOX 2 95333266 1 CONNECTOR CONDUIT 2A 39135355 1 LOCKNUT CONDUIT SEAL 3 39132303 30 CONDUIT 4 95333373 1 ELBOW CONDUIT 4A 39135355 1 LOC...

Страница 52: ...50 39872023 REV 02 TO AFTERCOOLER TO AFTERCOOLER...

Страница 53: ...UPLING 33 39114079 1 LOCKNUT NEMA 1 39108949 1 LOCKNUT NEMA 4 34 39416128 1 SWITCH HIGH AIR TEMPERATURE 35 39404165 1 O RING 36 39848148 1 TUBE FRONT BEARING FEED 20 25 HP Piping Ref Part No Number Qt...

Страница 54: ...E Tubing No Thread Size Size 39404157 7 16 20 1 4 39404132 9 16 18 3 8 39404165 3 4 16 1 2 39437074 7 8 14 5 8 39407531 1 1 16 12 3 4 39404173 1 5 16 12 1 39404140 1 5 8 12 1 1 4 39406996 1 7 8 12 1 1...

Страница 55: ...NE PRESSURE NEMA 4 39201884 1 CONTACT AUXILIARY 1Ma 2Ma FOR SIZE F K CONTACTORS 39240064 1 CONTACT AUXILIARY 1Ma 2Ma FOR SIZE N CONTACTOR 39245337 1 HOURMETER 60 HZ 39226618 1 HOURMETER 50 HZ 39233382...

Страница 56: ...AD SIZE N 39237367 1 STAR DELTA STARTER PARTS SIZE F CONTACTOR STARTER 1M SIZE F 39239850 1 CONTACTOR STARTER REVERSING 1S 2M 39239868 1 KIT STARTER CONTACT SIZE F 1 COIL STARTER SIZE F 39226592 1 REL...

Страница 57: ...55 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY 8 0 MAINTENANCE RECORD...

Страница 58: ...56 DATE RUN TIME WORK DONE QTY UNIT WORK HOURS MEASURE BY MAINTENANCE RECORD...

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