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.

EP 20/25/30 - ESP

OPERATORS/ INSTRUCTION MANUAL PARTS RECOMMENDED SPARES

APDD 6558 September 1996

AIR COMPRESSOR GROUP BONDED WARRANTY & REGISTERED START UP

SP<ecilicallv excluded. Performance warraniies are resoor1sibililv for meeling such perfor-

to wrrect in the manner !or

EXPRESSED OR TY AND FITNESS FOR A

Correction by the or latent, in the manner and for the of time provided above. shall fulfillment oi all liabilities !he Company for such nonconformities based on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such

is considered to be defective, withoui: first notifying tl1e Company such Equipment will be at Purchaser's sole risk and liability.

limitation or The remedies of the

this contract or the thereof, or from the sale, under this contract, whether passed on not exceed the purchase price of the unit of rn111nmArn

The and its shall in no of contract !or any m1nsF!f11J,Rnti~i

out or any breach thereof. or any in, or failure or malfunction whether based upon loss of use, lost profits or revenue. interest, lost goodwill, work goods, loss by reason of shutdown or increased expenses of operation, ment power or claims of Purchaser or customers for service whether or not such damage is based on contract, warranty, negligence, indemnity, strict liability or

or

lfil•lfil

©INGERSOLL-RAND COMPANY

CONTROL BOX

PRESSURE GAUGE

ROTARY SCREW AIR COMPRESSOR

This unit was

reserves the omo~mHrn·~=m0 without notice and without

f'n:"nr"'"" or add such to

No. of units on order: __________ .... ____ _

Customer Order No: _

Co. Order No.: ________ ··---·-·--··--·_

For reference:

Record the serial number and model number of your unit here.

Serial Number: ______ --··------·-· _____ .. ______ -··--------

Model Number: ....... ______ ····-· __ .---·

PRESSURE SWITCH

BELT GUARD MOTOR

RECEIVER

TANK~

TYPICAL ESP UNIT

AIR FILTER

TUBE SEPARATOR

AIRElllD

FINAL DISCHARGE

TABLE OF CONTENTS

0.0 SAFETY AND WARNINGS

0.1 safety instructions

0.2 safety

0.3 decals

1.0 RECEIPT OF EQUIPMENT

1.1 inspection 1.2 and h::>1ra.-llinn

2.0 INSTALLATION

2.1 ventilation

2.2 foundation

2.3 outdoor installations

2.4

2.5 electrical installation

2.6 voltage conversion

2. 7 bolt removal

2.8 rotation check

2.9 before !

3.0 SYSTEMS

3.1 general information 3.2 coolant system

3.3 air systems

3.4 control

3.5 pressure switch "rn'""""''""

4.0 MAINTENANCE

4.1 maintenance schedule

4.2 maintenance records

4.3 maintenance

4.4 pressure relief valve check

4.5 sheave

4.6 drive belts

4.7 belt tension

4.8 shaft seal 4.9 inlet air filter element 4.10 coolant filter

4.11 coolant change

4.12 coolant

4.13 coolant separator filter element

4.14 separator tank scavenge check valve/screen/orifice

4.15 cooler cores 4.16 motor greasing

5.0 TROUBLE SHOOTING

2

6.0 REFERENCE DRAWINGS

6:1 electrical schematic - full

6.2 electrical schematic - star delta

6.3

6.4 foundation plan - tank mounted

6.5 foundation - base mounted

6.6 flow

7.0 PARTS LIST

7.1 introduction

7.2 parts

starter

starter

- full

- star delta

components

starter box with pressure switch

7.3 recommended spare parts

8.0 MAINTENANCE RECORD

GENERAL I FORMATION

Co1olir1a Air Flow:

60 1-lz: 1800 cfm

50 Hz: 1500 cfm

limit: 35°F to 115°F to

Coolant: Filled ROTALUBE™ 1000

COOLANT

Coolant 1,000 hours or one year, whichever

comes when ROTALUBE™ 1000 COOLANT

Tools: U.S. Standard and metric are maintenance

228°F

to perform

under license from Cash

Ltd. United States and

patents pending.

0.0 SAFETY AND WARNINGS 0.1 SAFETY INSTRUCTIONS Before you install this air compressor you should take the time to carefully read all the instructions contained in this follows: manual.

co1rnore~;sed air have the po1tential to cause or property damage. ~DANGER

nnPr~otrnr<> manual are bold-faced words DANGER, WARNING and

hazard seriousness levels as

Danger is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property dam­age if the warning is ignored. Before installing, wiring, nn,or'""'nn or any

adjustments, identify the components of air compressor using this manual as a guide. ..-.,.--------. Warning is used to indicate the presence of

nn,"'r'""'r should use common sense and good nr:•"t'""'"'" while operating and maintaining this unit. Follow

codes, pipe adequately, understand the and stopping sequence. Check the devices the procedure contained in this manual.

Maintenance should be done ade-quately equipped with proper Follow maintenance schedules as outlined in the operators manual to ensure problem free operation after start up.

0.2 SAFETY PRECAUTIONS

~CAUTION

NOTICE

a hazard which can cause severe personal injury, death, or substantial property dam­age if the warning is ignored.

Caution is used to indicate the presence of a hazard which will or can cause minor per­sonal injury or property damage if the warn­ing is ignored.

Notice is used to notify people of installa­tion, operation, or maintenance information which is important but not hazard-related.

SAFETY PRECAUTIONS BEFORE PROCEEDING, READ CAREFULLY BEFORE

COMPRESSOR OR PERFORMING WARNING

COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS.

BEFORE DOING ANY WORK ON THIS UNIT, BE SURE THE ELECTRICAL SUPPLY HAS BEEN CUT OFF-LOCKED & TAGGED AND THE ENTIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF ALL PRESSURE.

1. Do not remove the covers, loosen or remove any fittings, connections or devices when this unit is in operation. Hot liquid and air under pressure that are con­tained within this unit can cause severe injury or death.

2. The compressor has high and danger­ous voltage in the motor starter and con­trol box. All installations must be in accor­dance with recognized 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 electrical components as stipulated in O.S.HA 1910.308 through 1910.329.

3. Do not operate the compressor at high­er discharge pressure than those specified on the Compressor Nameplate or motor overload will occur. This condition will result in compressor motor shutdown.

4. Use only safety solvent for cleaning the compressor and auxiliary equipment.

5. Install a manual shut off valve (isolation type) in the discharge line. A pressure relief valve, with sufficient capacity to relieve full compressor capacity, must be installed between the compressor and the isolation valve.

6. Whenever pressure is released through the pressure relief valve, it is due to exces­sive pressure in the system. The cause for the excessive pressure should be investi­gated immediately.

7. Before doing any mechanical work on the compressor:

a.) Shut the unit down.

b.) Electrically isolate the compressor by use of the manual disconnect switch in the power line to the unit. lock and tag the switch so that it cannot be operated.

c.) Vent pressure from the compressor and isolate the unit from any other source of air.

8. There can be adverse effects if com­pressor lubricants are allowed to enter plant air systems.

Air line separators, properly selected and installed, will minimize any liquid carry­over.

The use of plastic bowls on line filters without metal guards can be hazardous. From a safety standpoint, metal bowls should be used on any pressurized sys­tem. Review of your plant air line system is recommended.

9. When a receiver is installed, it is recom­mended that occupational safety and health standards as covered in the Federal Register, Volume 36, number 105, part 11, paragraph 1910.169 be adhered to in the installation and maintenance of this receiver.

10. Before starting the compressor, its maintenance instructions should be thor­oughly read and understood.

11. After maintenance functions are com­pleted, covers and guards must be replaced.

3

& SAFETY SHUTDOWN CHECKHIGHAIRTEMPERATURE

There is a high discharge air temperature shutdown function built into the control on each compressor. it is factory pre-set at 228°F This function should be checked at regular intervals for proper opera­tion, once a month Is recommended. PROCEDURE:

2. The compressor rate. Shutdown should occur when the dis-charge temperature reaches the pre-set maximum 111.::r:h::.rn"'' air temperature

Failure to adhere to these recommendations can result in mechanical failure, property n"'m~1a"' and serious or death.

All air and water inlet, and air and water pipework to and from the inlet and "'"·•:n:;orn: ...

nections must take into account vibration, pulsations, temperature, maximum pressure and chemical resistance. In addition, it should be noted that lubricated compressors will some oil into the air stream; therefore, between system accessories and software must be assured.

For the foregoing reasons, the use of soldered copper piping is not recommended. In addition, and/or flex: lines can be considered for such pur-poses if their specifications fit the nn,or~•tin .... parameters of the

It is the responsibility of the installer and owner to nrc1vic12 the "'n11"1ro,nri,,.t2 service oic1e11m1'k to and from the machine.

~ WARNING

STATEMENT CONCERNING THE USE OF THIS EQUIPMENT 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 designation, the compressor is NOT considered as capa­ble of producing air of breathing quality. For a compressor to be capable of use In air services It must be fitted with additional specialized to filter and/or the air to meet all applic­able federal, state and local laws, rules, regulations and codes, such as, but not limited to, OSHA 29 CFR 1910.134, Compressed Gas Association G-7, 1-1966, Grade D Air and/or Canadian Standards Association. Should the purchaser and/or User fail to add such and proceeds to use the compressor for air service, the resulting therefrom without any responsibility or liability assumed

STATEMENT CONCERNING THE INADVERTENT BREATHING OF COMPRESSED AIR EXHAUST

"The purchaser/user shall insure that adequate ventilation and make air are provided if a non BAP des-ignated compressor supplies air in a confined area to air consuming such as air air tools, solenoids, air cylinders, air guns, nozzles, etc. The compressed air discharge stream residual coolants/lubricants/carbon monoxide/condensable hydrocarbons or other materials may be haz-ardous to health with inhalation."

4

0.3 DECALS

This section contains r"''""''"'"'nr<a11,,i::.

decals which will be and are applied to the compressor unit.

Rotation.

INGERSOU. -RAND @

39544150

Exposed moving belts and sheaves.

Can cause severe injury or death.

111\!GERSOl.lflAND ®

ffi WARNING

Disconnect power before servicing. LockouVTagout machine.

INGERSOLLflAND ® 39540174

LOCATED INSIDE

CONTROL BOX

of

TOP VIEW

RIGHT SIDE VIEW 39861810

are over, we recommend that you

Recommended

WARN IN

fan blade. Can cause severe

Do not operate with covers removed D1sconnecl power. Lock and tag.

iNGERSOl.LflAND ®

CAUTION

Incorrect lifting of machine can cause injury or property damage.

il\IGERSOLHIAND m.

39540232

:39540190

WARN IN

Hol surface. Can cause severe injury.

Do not touch. Allow to cool before servicing.

INGERSOLLflAND ®

39541362

5

O'J

39875463

WARNING

14. Hot surface. Can cause severe injury.

Do not touch. Allow to cool before servicing.

INGa!SOl.I. i'IAl\IO •• 39541362

l~lc~~l!L~J:~_·> I

LEFT SIDE VIEW

@

This product is produced under license from Cash Engineering Research Pty, Ltd, United St• and foreign patents pending

INGERSOLL -RAND&

WARNING

@±® Exposed moving baits and sheaves.

Can -cause severe injury or death.

39859236

INGERSOLL-RANIJ.;,

39871991

39859228

FRONT VIEW

m1.INGERSOll-RAND. Compressor Package Data

COMPRESSOR YODEL .. -· ........ _ .•

39557095

N8TIDi Dual Voltage Unit l-<>1'1·n1rv

Wired 230 Volts

!NGERSOLL-f!Al\IO w

39569140

Disconnect power before servicing. Lockout.'Tagout (nach1ne.

INGERSOl..l -f!AND ,, 39540174

""l

CAUTION maintenance of coolant cause compressor damage.

Change coolant filter after first 150 hours of operation and 1000 hours thereafter when is changed.

INGERSOU.-RAND ® 39871462

39540216 (OPTIONAL ULTRA COOLANT)

Filler Cap. Use only recommended

coolant. Read instruction book

before servicing.

39540281

NCi>!Fl~E

Air discharge.

INGEf!SOLL i'IANDB>

39540257

WARNING

~ High pressure air. Can cause severe injury or death.

Relieve pressure before removing filter plugs I caps, iittings or covers.

39540240

REAR VIEW

&CAUTION Use of incorrect coolant can cause system contamination.

Use only ROTALUBE"' 1000 COOLANT.

INGERSOLL-RAN!l ® 39871454

39540265 (OPTIONAL ULTRA COOLANT)

WARNING

~ Hot surface. Can cause severe injury.

Do not touch. Allow lo cool before servicing.

INGERSOU.-RAND ® 39541362

ffiDANOIR

air. Can contain carbon monoxide or other contaminants, Will cause severe injury or death,

Do not breathe this air.

INGERSOLL-RAND 39540166

NOTE: DECALS 39540257 AND 39540166 ARE LOCATED ON THE END OF THE COOLER BOX ON BASE MOUNTED UNITS.

1.0 RECEIPT OF EQUIPMENT 1.1 INSPECTION

When you receive the compressor indication of careless

rier should be noted on the if the compressor will not be 1m1ne<:11a1te111 Obtaining the man's to any noted damages will facilitate any future insurance claims.

1.2 UNPACKING AND HANDLING The compressor has been mounted on a wooden base which will allow fork under the compressor base to facilitate

shipment Care in the forklift is tant because the location of the center of is

affected by the location of the airend and motor.

The wooden base must be removed tion.

2.0 INSTALLATION 2.1 VENTILATION

Air cooled air compressors heat. Because of this heat pressor must be lation.

to installa-

If heated air from the compressor exhaust is allowed to re-circulate back to the compressor, the compressor will overheat and shut down. This heat must be exhausted from the room. You should take this into consideration when where to the com-pressor within the clearance must be allowed around the compressor to the

maintenance.

Ambient temperatures higher than 115"F should be avoided as well as areas of

External ducting, to and from the compressor, that is installed in the field must be sized so that no

as any other conditions which be detrimental to the proper of the compressor.

2.2 FOUNDATION REQUIREMENTS

The compressor can be installed on any level floor that is of the

When sound transmission is of it is often to install a sheet of rubber-fabric-mat-

under the compressor ua.,:,,,,u,a or receiver tank feet to reduce the of resonant sounds being transmitted or the floor.

2.3 OUTDOOR INSTALLATIONS

When a compressor must be installed~~·~·~·~. are certain items that should be installation to assure trouble free nr.£>r<ll'lf"\n

These items have been listed below been included to show a

The unit must be to ~M'"'~'~

• The compressor should be on a concrete pad to drain water away. If the concrete is

then the compressor must be leveled.

• The roof of the shelter should sor a minimum of 4 feet (1 direct rain and snow from

the compres­on all Sides to nrO•\/l'>ll1t

on the unit.

• The unit must be under the shelter in a way that air recirculation hot exhaust back to the

• If the installation includes more than one compressor, the hot air exhaust should not be directed towards the fresh air intake of the second unit or an Air

• If a standard machine is to be installed outside, the ambient must never below 35°F

or of condensate will result.

• Power disconnect switch must be within the com­and should be in close

• Condensate drains must never be allowed to to a suitable sump for future col­c''"""'"'m of lubricant and water

excessive back pressure is exerted on the fan. mixture. Maximum allowable is 0.25 inches of water column air resistance total for inlet and exhaust ducting.

Also consider the environment near the compres­sor.

mr>.nminn power connections must use suitable con-nectors for outdoor weather service.

• Sufficient clearance must be allowed on all four sides of the unit for service access. If access a fork lift and/or an overhead beam hoist should be

CHEMICALS, METAL PAINT in mind eventual service to airend or and OVERSPRAY should be avoided as well

8

• If the area around the installation contains fine air­borne dust or lint and fibers etc., then the unit should be with the TEFC motor

AREA SHOULD BE SECURED WITH A FENCE

OR SECURITY SYSTEM

SLOPING CONCRETE

PAD

. -o .

access.

POWER DISCONNECT

SWITCH (LOCKABLE)

FIGURE 2.3·1 TYPICAL OUTDOOR SHELTERED INSTALLATION 35°F AND ABOVE

4'

9

2.4 PIPING

It is essential when review the total and effective total

a new compressor to This is to insure a safe

The use of bowls on line filters without metal can be hazardous. Their can be affected

either lubricants or the additives used in mineral oils. From a metal bowls should be used on any

_6WARNING Do not use plastic pipe, soldered copper fittings or rubber hose for discharge piping.

Condensed water occurs in air lines as a result of Moisture vapor in ambient air is con-centrated when and condenses when

Moisture in compressed air is r<=>c::nnn<t1n1

problems in almost every ap1)l1caticm nro,cct:•rt air. Some common nr,,,n,.,,mc

ture are: and in instruments, sticking of control outdoor air lines. in or total shutdown of the tern.

The air from this compressor will be at some elevated and will therefore contain amounts of water vapor. As this air cools the vapor will condense within the

IMPORTANT: The drain line must downward from the to work nrr,no,rht

NOTE: For ease of of the automatic drain should include an open

flow indicator.

It is that additional condensation can occur if the downstream cools the air even further.

low in the should be """"'"""" • with and

reduce the water vapor concen­water formation in ,...,..,,.,,..,,.,,,"',"""

air lines. are a necessary aftercoolers. and automatic drains for mnnrn·nlfl

of Two

Refrigerated dryers are normally specified where com-nr"""'"''""' air pressure dew of 33°F to 39°F to

are Desiccant are pressure dew points must be below 33°F to

10

are Desiccant are where pressure dew must be below 33°F 2.4-1 indicates the mate moisture content in

Contact your local 1nn.:>rc.n11-H

Center for assistance in Rand filtration or

Distributor or Air correct

Moisture Content of Compressed Air

200

160 -

120 -80 ,_

. ·.· 40 ..._

0 :•1•:

DEW POINT

FIGURE 2.4-1 MOISTURE CONTENT OF COMPRESSED AIR

IMPORTANT: should be at least as connection at the compressor.

and fillings must be rated for the pressure and ti:>rnn,c.r,:,1t1

A careful review of size from the compressor connection is essential. of size of

number and of and valves must be considered for minimum air pressure and mum of your compressor.

NOTE: Screw compressors should not be installed in air systems with rnr,;..,.,.,....,.. . .,t;.,,.,

sors without a means of such as a common receiver tank. We recommend both of compressor units be to a common receiver uti-

individual air lines. See 2.4-2.

When two units are in pro-vide an isolation valve and drain for each com-pressor before the common receiver. See 2.4-3

To assure trouble free of a compressor with On-line/ Off-line and Auto

the volume must be the load/unload to a minimum. This may

the installation of a receiver down stream of the compressor. mounted units must be

to a receiver if installed in a with insuffi-cient volume to mum. If such as filters or air is installed in the main system, must be sized to handle the entire flow of the compressor and an air receiver must be in the between the compressor discharge and the

of volume.

This will prevent quick of the compressor which results in fluctuations in pressure.

ISOU\TION PRESSURE

RELIEF VALVE RECIPROCATING

COMPRESSOR

NOTE: SEPARATE LINES GOING TO THE RECEIVER

DRIP LEG

t DRIP LEG

ISOLATION VALVE '

ROTARY COMPRESSOR

FIGURE 2.4-2 ROTARY-RECIP IN PARALLEL

PRESSURE RELIEF VALVE

STRAINER

f DRIP LEG

DRIP LEG

FIGURE 2.4-3 ROTARY-TWO COMPRESSOR SYSTEM

11

2.5 ELECTRICAL INSTALLATION

Before proceeding we recommend that you review the safety data in the front of this manual.

Locate the compressor data on the left end of the cooler box next to the control box.

The data plate lists the rated pressure, the maximum discharge pressure. the electric motor char­acteristics and power.

Confirm that the line " .... 'T""'"' and compressor name­are the same.

The standard control box meets the intent of NEMA 1

It will be necessary to make a hole in the control box for the power connection. Care should be taken to not allow metal to enter the starter and other electrical within the box. After

the power inlet and debris must be removed from inside of control box before power is turned on.

power should be connected per the electrical schematic at the rear of this manual Section Confirm that all electrical connections are made and

Confirm that the control transformer is wired for supply voltage 2.6-1 I

Inspect the motor and control Close the front.

2.6 VOLTAGE CONVERSION

PRIMARY

should be carried electrical contractor or

Rand Distributor or Air Center.

PRIMARY

I

~-·-· · ·---1 '1

SECONDARY

FIGURE 2.6-1 CONTROL TRANSFORMER

CONNECTIONS - 60HZ

FIGURE 2.6-2 CONTROL TRANSFORMER

CONNECTIONS - 50 HZ

12

tured to

PROCEDURE:

Put main disconnect in the OFF

to units manufac­Motor n'.:l•man•

lock and

FIGURE 2.6·3 MAIN DISCONNECT LOCKED AND TAGGED

the motor box on the side of the motor.

Reconnect the motor to the desired Use the

Reconnect the side of the control transformer for the desired as shown on the control trans-former decal.

rott>rr;,,..., to the heater chart decal located in the heater heater

Make sure all connections are

Put main disconnect in the ON and check motor as outlined in Section 2. 7 of this manu-al.

2.7 SHIPPING BOLT REMOVAL

The unit is shipped with a bolt in the motor sup-to prevent possible belt damage caused

bouncing during shipment. This bolt must be removed prior to motor rotation or oper-ating the unit.

In addition, a jackscrew is located under the base and offers support to the motor during shipment. This jackscrew must be loosened as far as ble without removing it to operating unit A locknut is provided to keep the jackscrew in place.

Locate the shipping bolt and in the motor as shown in 2.7-1 and remove the

shipping bolt.

FIGURE 2.7-1 SHIPPING BOLT LOCATION

2.8 ROTATION CHECK

Locate the rotation on the motor and check for correct rotation. The correct rotation when viewed from the drive end on the motor is clockwise.

If compressor is operated in the opposite direc­tion of rotation, airend damage can result and is not warrantable.

For the compressor motor rotation jogging should be as short a time as µu::;:::.11.;11::.

2. Check coolant level. To check coolant loosen the fill plug one turn. As the fill

is unscrewed approximately one tum, a small amount of pressure may be released. Do not remove the fill

until all pressure has been vented. Once pressure is finish the fill The proper coolant level is when the coolant is at the of the fill Add coolant if necessary.

fill

4. Close the main disconnect switch position.

5. that the main isolation valve is open.

button to start the unit and the button to stop the

unit

Observe the compressor drive motor shaft. The rota­tion should be in accordance with the directional arrow decal on the motor.

Should the motor rotation not be the main disconnect in the OFF lock and tag.

any two line connections or at the starter. Close U1e control box cover. Recheck for correct rotation.

2.9 BEFORE STARTING I STARTING I STOPPING

before "'""'°''T1n1n or nQlrl"nirmi

on this unit.

instructions

button is in the OFF 2.9-1).

POWER ON START/STOP AUTO RESTART CONTROL LIGHT BUTTON LIGHT BOX

HOUR METER

PRESSURE GAUGE

FIGURE 2.9-1 CONTROL BOX 13

2. Check coolant level. To check coolant loosen the fill one tum. As the fill is unscrewed approximately one a small amount of pressure may be released. Do not remove the fill until all pressure has been vented. Once pressure is

finish removing the fill The proper coolant level is when the coolant is at the of the fill Add coolant if necessary.

the fill

4. Close the main disconnect switch

5. that the main isolation valve is open.

Starting

1 . Pull the button to the ON and release. The compressor will start and then load auto-

if line pressure is below the lower of the pressure switch.

Stopping

1 . Depress the Start/Stop button to the OFF Compressor will

2. the main disconnect switch (OFF

3.0 SYSTEMS

3.1 GENERAL SYSTEM INFORMATION

compressor is an electric motor stage, rotary screw compressor, rnrnn1ota with sup-

components to make a functional unit. A standard compressor is of the tn11."'"'"""

Inlet air filter Drive motor Ai rend Pressurized coolant Separation system

control Instruments

devices

with cooler & filter

Compression in rotary screw air compressor is created the of two helical rotors and female) on parallel enclosed in a

iron housing, with air inlet and outlet located on opposite ends. The grooves of the female rotor mesh with and are driven the male rotor. on both ends of the rotors are used to rotor both laterally and

14

3.2 COOLANT SYSTEM

consists of a "L" tube sep-thermostatic coolant coolant

cooler with element. When the unit is the coolant is pressurized and forced to the compressor The compressor is ed with a switch which will shut the unit down in case of excessive 228°F (1 Effective coolant filtration is the use of a screw on, automotive coolant filter.

The compressor is £1,,,.,,,.,,~,,rl ent range of 35°F to 115°F

COOLANT

in an ambi-

screw compressor fluids have a triple function lubricate the bearings and ""''"~·~"r·~

seal internal clearances within and for the of the

process. The bulk of the fluid is actually with small amounts used for

ESP air compressors are filled with 1000 ROTALUBE™ 1000 COOLANT. ROTALUBE™ 1000 COOLANT is to for 1,000 hours or one year, whichever comes first. The coolant must be changed at these intervals to avoid break­down and

CIRCULATION OF COOLANT

Coolant is forced air pressure from the tube separa-tor to the thermostatic element. The temperature of the element will determine whether the coolant cir-culates the the mixes the two

air coolant mixture above the dew

Before into the all coolant flows the coolant filter. It is an automotive

flow filter with a rated at 10 micron. There is a .-Mt·~.,,~.,;~

valve set to open in the event that the pres­across the filter rises to as high as 35 psi which indicates an fouled ele­

ment as well as poor maintenance ~-~~ .. ~.~

COOLANT/AIR SEPARATION SYSTEM

coolant/air

in a airend.

The air-coolant mixture the tube The while in the tube

removes air. The

separated coolant is returned to the coolant and the air passes to the air

3.3 AIR SYSTEM

COMPONENTS AND FLOW

The air is of: Inlet air filter Inlet control valve Ai rend Coolant/ Air Minimum pressure valve Non-return check valve Aftercooler

The direction of flow is from the inlet filter to the after­cooler.

FUNCTIONS OF COMPONENTS

Inlet air particles 10 micron and

Inlet valve opens full for on-line

The valve closes in the off-line mode and at shutdown which prevents back flow of the air.

The airend compresses the air.

The tube ''"'"'"'''"'tr" removes most of the coolant from the air.

of

compressor.

The minimum pressure check valve keeps the tube and element at a minimum pres-

sure to ensure adequate oil flow and proper coolant/air

The non-return check valve prevents line pressure from

exhausting back the airend at shutdown and periods of unloaded

The aftercooler cools the air age.

to the

3.4 CAPACITY CONTROL

ON LINE/OFF LINE WITH AUTOMATIC START/STOP CONTROL

The compressor will deliver air at full capacity, compressor maximum or will oper-ate at zero with compressor minimum power continues to run.

When the compressor starts and line pressure is below the lower of the line pressure switch, control solenoid 1 SV will be inlet control valve ICV will open, and the compressor will load. When the line pressure reaches the upper setting of the pressure the compressor will unload by de-

SV and ICV. Solenoid 1 SV relieves the internal pressure of the compressor back to the inlet filter. The only is

of the pressure switch.

When the compressor a time is on."''""7

"',... and to time out The mounted in the control set at 10 minutes. It will

nn<>r::11·., for as as its time after which a contact opens to pressor starter coil. At the same an amber (1 on the control box is lit to indicate the compres­sor has shut down and will restart auto­

The automatic restart will take place when the line pressure to the lower of the pres-sure switch.

Adjusting the adjustable timer below the 10 minute Tar·tnrv setting may shorten the life of the com­pressor drive motor.

15

3.5 SETTING NEMA 1 PRESSURE SWITCH

1. control to sense "line"

2. Start the compressor.

The compressor should load it the line pressure is lower than then the maximum pressure stat-ed on the compressor data It may be necessary to vent air from customer load unit

3. Slowly close the isolation valve pressure to rise to the maximum or of the pressure switch.

4. Remove cover from pressure switch 3.5-1). as range

the air line pressure

screw clockwise to increase and counterclockwise to decrease trip setting When 1 PS trips, the compressor will unload. When the line pres-sure falls to the reset of 1 PS 12

the unit should reload. The pressure switch dif-ferential is adjustable and set at about 12

bar) to meet the of the average cation.

Limited receiver and line may differential. Sufficient receiver and line accept a narrow differential. If adjustment is turn differential screw clockwise to decrease the differential and counter-clockwise to

CAUTION When adjusting differential, adjust switch so that maximum discharge pressure does not exceed maximum discharge pressure stated on the compressor data plate.

increase the differential.

5. Vent air from customer operation is satisfactory.

16

to confirm switch

unit in service.

PRESSURE SWITCH

FIGURE 3.5-1 LOCATION OF PRESSURE SWITCH

RANGE ADJUSTMENT

SCREW

DIFFERENTIAL ADJUSTMENT

SCREW

FIGURE 3.5-2 NEMA 1 PRESSURE SWITCH (1 PS)

3.6 SETTING NEMA 4 PRESSURE SWITCH

1 . to sense "line" pressure.

2. Start the compressor.

The compressor should load if the line pressure is lower than then the maximum pressure stat-ed on the compressor data It may be necessary to vent air from customer load unit

3. Slowly close the isolation valve pressure to rise to the maximum

of the pressure switch.

the air line pressure or

4. OPERATING RANGE ADJUSTMENT: Turn lock nut on adjustment screw "A" counterclockwise to loosen. Turn adjustment screw "A" clockwise to raise upper and lower pressure settings. To decrease the upper pres­sure settings, tum "A" counterclockwise. The mate upper pressure is shown an indicator in the left window between the calibration scales on the nameplate. When the setting is r.o:::i,...ni:•r1

the lock nut on screw clockwise.

5. DIFFERENTIAL ADJUSTMENT: Remove the front cover. When the differential screw "B" is flush with the enclosure base. the control will function at minimum dif-ferential. To increase the turn screw "B" clockwise. This will decrease the lower set­

The higher setting will not ,.,n,,n,.,10

to decrease the differential turn the differential rnent screw "B" counterclockwise. This will raise the lower setting

Condensed instructions can be found on the inside of the front cover of the switch.

NOTE: The use of a pressure gauge is desirable when setting the control.

CAUTION The adjustment screw "A" should not be forced beyond the range of the control indicated on the calibrated scale. The adjustment screw "B" should never extend above the base of the enclo­sure nor be adjusted beyond the maximum speci­fied differential of the control.

6. After the desired setting has been """''""'''"''''"hc•n mount the cover and tighten the four cover screws 6-8 in. lbs. the seal.

7. Vent air from customer to confirm switch nn<>r::>1ronn is <><ltocr"'"tn

8. Place unit in service.

in.o«<>tonn variables in a may cause changing It is recommended that a

odic of the gauge pressure be made and the pressure control to when necessary for these

OPERATING RANGE

ADJUSTMENT SCREW"A"

UPPER PRESSURE SETTING INDICATOR

DIFFERENTIAL PRESSURE

ADJUSTMENT SCREW "B"

FIGURE 3.6-1 NEMA 4 PRESSURE SWITCH (1

17

4.0 MAINTENANCE 4.1 MAINTENANCE SCHEDULE

THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE COM­PRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT NUMBER OF HOURS, WHICHEVER OCCURS FIRST.

TIME INTERVAL (WHICHEVER COMES FIRST)

ACTION PART OR ITEM HOURS 1WK 1 MO 6MO 9MO YEARLY 2YR

INSPECT COOLANT LEVEL VISIBLE IN FILL PORT WEEKLY x (WHEN COLD)

INSPECT AIR FILTER WEEKLY x REPLACE COOLANT FILTER' 150 x (INITIAL CHANGE ONLY)

REPLACE COOLANT FILTER* 1000 (SUBSEQUENT CHANGES)

INSPECT HOSES 1000

INSPECT DRIVE BELTS 500

REPLACE DRIVE BELTS YEARLY x CHECK HIGH AIR TEMP. SWITCH 1000 x CHECK OPERATE PRESSURE RELIEF VALVES 1000 x CLEAN SEPARATOR SCAVENGE ORIFICE 1000 x

CLEAN COOLERS CORES** 4000

REPLACE AIR FILTER 2500

REPLACE SEPARATOR FILTER ELEMENT' 1000 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

ROTALUBE TM 1000 COOLANT IS A 1000 HOUR FLUID FOR ROTARY SCREW COMPRESSORS. THE COOLANT MUST BE CHANGED AT RECOMMENDED INTERVALS TO AVOID BREAKDOWN AND EQUIPMENT DAMAGE.

'IN VERY CLEAN OPERATING ENVIRONMENTS AND WHERE INLET AIR FILTER IS CHANGED AT THE ABOVE PRESCRIBED INTERVALS. IN EXTREME DIRTY ENVIRONMENT CHl\NGE COOLANT. FILTERS AND SEPARATOR ELEMENTS MORE FREOUENTL Y.

"CLEAN COOLER CORES IF UNIT SHUTDOWN OCCURS ON HIGH AIR TEMPERATURE.

4.2 MAINTENANCE RECORDS

It is very important that you, the owner, keep accurate and detailed records of all maintenance work you or the Ingersoll-Rand Distributor or Air Center on your compressor. but is not limited to, coolant, coolant inlet air drive belts, shaft seals and so forth. This information must be by you, the owner, should you warranty service work your Distributor or Air Center. Maintenance record sheets are located at the back of this manual.

4.3 MAINTENANCE PROCEDURES

18

is heeded.

Read Instructions. ""4'J'l.JfJt::u mechanic's tool box with

..,..,.V""'"' tools when needed will be

.,.,...'""'·""r1 air nozzle and compressed air. - local codes may Have recommended spare on hand in back of this

When the unit is residual pressure can be trapped within the compressor system. This pressure must be vented from the system

to beginning any service work.

Before any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor

Wait 2 minutes after to allow internal pressure to sure from the unit coolant fill opens a vent pressure to release to "'"nnn•>nh

A slight mist or oil may be visible Do not remove fill until all

pressure has vented from the unit. Also vent the leg valve . When

the drain valve or the coolant fill stand clear of the valve discharge, wear work

VENT HOLE

and

0-RING

FIGURE 4.3-1 FILL PLUG WITH VENT HOLE

4.4 MANUAL PRESSURE RELIEF VALVE CHECK

condition a lever test" every month . Under severe ser­

vice or if corrosion and/or are noticed within the valve must be per-formed more often. A lever test" must also be per-formed at the end of any non-service CAU-TION! pressure air will

of the valve

maximum pressure open for at least 5 seconds to flush the valve seat

free of debris. Then release lever and the valve to snap shut. If lift lever does not activate, or there is no evidence of discontinue use of ment and contact a licensed contractor or

4.5 SHEAVE ALIGNMENT

of sheave reduction of belt life. not exceed 1 /16 in.

will result in a of belt drive should

11nr1m.cnt occurs when the drive and dri­but the two sheaves lie in dif-

4.5-1 ).

1116" MAX

Al REND

STRAIGHTEDGE

MOTOR

FIGURE 4.5-1 PARALLEL MISALIGNMENT

1116" MAX

STRAIGHTEDGE

FIGURE 4.5-2 ANGULAR MISALIGNMENT

19

ALIGN SHEAVES

Insure that the compressor is isolated from the compressed air system the isolation valve and pressure from the drip leg. Insure that the main power disconnect switch is locked and tagged.

An easy and effective method of in both directions between the driver and driven sheaves utilizes an accurate

across the face of the driver sheave and check of the driven sheave. Then the across the

driven sheave and check that the driver sheave is

/ .. rnrmm1onT should be within 1/16" (1.6 when the gap between the <>tr<>1nt,t<=>11no

and the rim of the sheave in each direction.

is set and should '"'''"'"'n" if the drive motor or airend is removed.

1 . Remove the cooler corners and air deflector.

2. the front of the airend measure the amount of mic,<>li,nninoint

seen on the motor sheave. If 1/16" (1.6 then reinstall cooler box outer

to unit.

3. If "'"''nmonT is more than 1/16" (1.6 must be loosened for

To re[>osmc1n the motor sheave:

1. Remove drive belts Section

2. Remove the three hex head screws that hold motor sheave to sheave See 4.5-3.

3. Lubricate the thread and end of screws that were removed.

4. Reinstall all three screws in the holes of the that are threaded.

5.

may assist

6. Remove the screws from the holes.

20

on

ALLEN HEAD SCREW

"A" Clearance Holes "B" - Threaded Holes

FIGURE 4.5-3 MOTOR SHEAVE BUSHING

7. Loosen alien screw in sheave

8. Move the either in or out on the motor shaft 0 .-..,,nr1i • .-. .... upon the measurement taken earlier.

9. alien screw in sheave

careful to not move the on the sheave so that the three threaded holes in

the sheave line up with the three clearance holes in the

11. Insert all three screws clearance holes in the and thread into sheave.

13. and block or sleeve to avoid

screws until the no turns the screw after '"'r""""'

14. Install belts as shown in Section 4.6.

15. Recheck for proper

16. Reinstall cooler box air deflector and corners.

4.6 DRIVE BELTS

Insure that the compressor is isolated from the compressor air system dosing the isolation valve and venting pressure from the Insure that the main power disconnect switch is locked open and ta~me~a

If or the belts on a new unit at start-up, the motor bolt must first be removed. This bolt is used to brace the motor dur-

"''"'""'""" ..... and will not be reinstalled once the belts Locate the motor

2.7-1 and remove. Locate the motor on the underside of the base. Loosen the locknut and tum the counter-clockwise to set the motor down onto the belts. Be sure to back the belt will

REPLACEMENT PARTS

3. Lower the motor '""'"'"'ra"' locknut and the clockwise. Be sure to back the as since the belts will stretch after initial run-

and the motor will be lowered as a result. the locknut

4.7 BELT TENSION

This unit has been with a self ten-for the drive belts. There is no

to insure proper belt Be Genuine to

assure correct belt tension.

4.8 SHAFT SEAL REPLACEMENT

There are two seals on the compressor. are wearable and should be replaced at

hour intervals. While it is advisable to have your local Distributor or Air Center per -form this the task can be a

mechanic these instructions.

Before any work on the compressor, Belts Recommended Parts Be open, lock and the main electrical disconnect sure to use Rand Genuine assure proper belt size and belts can lead to '"""'"'''"',.., airend or motor failure.

DISASSEMBLY

Belt tension is maintained due to a motor sup-The of the motor holds the belt

1 . Remove the cooler box corner from the airend side of the machine.

2. Lift the back of the motor '"""'""'"' on the underside of the

uoiiirih,ton the locknut.

3. Remove belts from the airend sheave and the motor sheave.

INSTALLATION/INSPECTION

material or rubber n&>,rm=•:::ic:A sheaves before

drive belts to insure belt life.

1 . Lift the back of the motor '"''"'!<"'~'"''" "'~"'"''~'"' on the underside of the

~.::.1·•.-.htt:\ln the locknut.

2. Install belts on the airend sheave and the motor

the

sheave. When a new do not pry or force the belt over the sheave grooves.

and close the isolation valve on the compressor Wait 2 minutes after stopping to allow

internal pressure to Vent residual pres-sure from the unit the coolant fill opens a vent pressure to release to atrnosp!he1re 4.3-1). A

pressure has vented from the unit. Also vent the valve. When

mn,uiniN the COOiant stand clear of the valve discharge, wear

and eye prc)teic:t1cm

SPECIAL TOOLS

A clean work bench

REPLACEMENT PARTS

20-25 HP Units Shaft seal kit Loctite® 242 Loctite® 609 Loctite® 515

30 HP Units Shaft seal kit Seal retainer Loctite® 609

21

INSTALLATION

1 . Remove both doors and the of the so

2. and

to remove.

3. Remove seal

(if

11. The term "inboard side'" will refer to the machined face of the seal The term "out-board side" will refer to the unmachined side next to the sheave.

12. Be certain to install the seals from the proper side and in the proper orieintation. follow instruc-tions for seal Protect seal elements from inadvertent installation. Be sure all tools are free of contaminants before installation.

4. Drive both seals out of seal careful 13. Put a thin continuous coat of Loctite® 609 on the not to seal bore. outer diameter of the double seal.

5. Discard seals. 14. Remove the seal from the sleeve and it in the seal from the inboard side.

6. Remove check valve ball and from seal hous- The seal should be oriented such that the of the of the seal is toward the installer.

wear sleeve. If ex~::eE:S1'llre wear is a bar or than the seal

a wide bladed scraper, remove all traces of sealant from the seal and rotor

careful not to scratch the surfaces.

9. clean and rlor1n::.''"'"'

and wear sleeve on the rotor.

10. Clean scavenge holes in seal rotor 4.8-1 ).

WEAR SLEEVE

SCAVENGE HOLES

4.8-1 SHAFT SEAL ASSEMBLY

22

and in the

LIP EDGE OF SEAL INWARD

press the double seal into the seal until it locates the shoulder.

16. Remove any excess Loctite® 609 with a clean cloth.

17. Put a thin continuous coat of Loctite® 609 on the outer diameter of the seal.

18. Remove the seal from the sleeve. From the outboard the seal such that the

of the seal is inserted first.

19. a bar or bore press the seal into the seal from the outboard side. The seal will in the hous-

in the flush To avoid enge the seal should never be flush ~~'""r·~

20. Remove any excess Loctite® 609 from the seals, from the seal and from the seal scav-enge holes.

21. Install the in the bottom of the seal

22. Place a surface of the seal Do not over

Loc:t1te1Bl 515 on the machined 32. Reinstall belts.

FIGURE 4.8-2 SEAL HOUSING

23. lubricate the coolant.

24. Slide the sleeve into the seal from the outboard side of the

a new check valve ball in the seal

4.8-2.

with clean

25. Lubricate the wear sleeve coolant.

with clean

26. Slide the seal with the installed over the shaft until it locates sleeve.

sleeve the wear

27. Make sure the check valve ball is in and slide the seal off the sleeve and onto the wear sleeve on the

rotor. amount of grease can be to hold the check valve ball in for

28. Push the rotor seal rotor

30. Attach the seal nine screws and

31 . Reinstall sheave and Loctite® 242 to

lbs. ft.

the

33. Reinstall belt and enclosure.

2. Remove V-belts and airend sheave. Note airend sheave is heat shrink fit to shaft and is to remove.

3. Remove seal

4. Drive both seals out of seal careful not to seal bore.

5. Discard seals.

6. Remove and save from seal

7. Remove check valve ball and from seal hous-

8. wear sleeve. if or excessive wear is nr"''""'""'t the wear sleeve must be

9. clean and and wear sleeve on the rotor.

10. Clean scavenge holes in seal rotor

LIP EDGE OF SEAL INWARD

and in the

WEAR SLEEVE

FIGURE 4.8-3 SHAFT SEAL ASSEMBLY

23

11. The term "inboard side" will refer to the 23. Lubricate the wear sleeve with clean coolant. machined face of the seal The term "outboard side" will refer to the unmachined side next to the sheave.

12. Be certain to install the seals from the proper side and in the proper orientation. follow instruc-tions for seal Protect seal elements from inadvertent damage installation. Be sure all tools are free of contaminants before installation.

13. Install in seal

14. Put a thin continuous coat of Loctite® 609 on the outer diameter of the double seal.

15. Remove the seal from the the Seal Installation

press the double seal into the seal inboard side until it "locates" the rnT'e>oninn

The seal should be oriented such that the of the seal is toward the installer

16. Remove any excess Loctite® 609.

17. Put a thin continuous coat of Loctite® 609 on the outer diameter of the seal.

18. Remove the seal from the sleeve the Seal Installation press the seal into the

seal from the outboard side until the seal is flush with the surface of the seal Do not the seal the flush The seal should be oriented such that the of the of the seal is inserted first

19. Remove any excess Loctite® 609 from the from the seal and from the seal scav-enge holes.

20. Install the

21. Lubricate the coolant.

in the bottom of the seal

sleeve with clean

22. Slide the sleeve into the seal from the outboard side of the Install

and a new check valve ball in the seal

24

"locates" sleeve over the shaft until it

the wear sleeve.

25. Make sure the and check valve ball are in slide the seal assembly off

""'"'"'m'rn" sleeve and onto the wear sleeve on the rotor.

26. Push the seal

27. Remove

four screws and

TO 2.08 DIA.

TO 1.85 DIA.

MATERIAL: STEEL

the rotor

with

REMOVE BURS

1" MINIMUM

FIGURE 4.8-4 SEAL INSTALLATION TOOL

4.9 INLET AIR FILTER ELEMENT

The inlet air filter should be at the interval shown in the maintenance chart or any time the filter becomes

The filter element is not washable and must be Remove the filter the on

the filter located on the Inlet Control Valve. Remove and discard the old filter element Install a new filter element. 4.9-1).

CLAMP

FIGURE 4.9·1 INLET AIR FILTER

4.10 COOLANT FILTER

- after the first 150 hours and every '"""'"'"'""'' or when the coolant is

the filter

Before any work on the compressor, open, lock and tag the main electrical disconnect and close the isolation valve on the compressor Wait 2 minutes after to allow internal pressure to u1;:,:::.1u.:w:::. Vent residual pressure from the unit slow-

•n~.n•~ ... •r·~ the coolant fill one turn. the fill opens a vent drilled in

the pressure to release to atmos-4.3-1 ). A mist or oil

may be visible Do not remove fill until all pressure has vented from the unit. Also vent

the valve . When the drain valve or the coolant fill

stand clear of the valve wear work and ,;,nr\rnr>ri"1t<>

SPECIAL TOOLS

Suitable clean drain pan or container to hold coolant drained from unit.

A of proper coolant sufficient to off the coolant level in the compressor.

1. Place a clean pan under the coolant filter.

2. a filter wrench, remove the coolant filter. Remember that the filter and coolant may be hot!

3. Discard the old filter.

4. the surface of the filter head with a clean lint-free rag to rm='""''m entry of dirt into the sys­tem.

5. Remove the

6. a small amount of clean coolant on the rubber seal of the filter.

7. Screw filter on until the seal makes contact with the seat on the filter header. one half to three tum additional.

8. Remove coolant fill 4.10-1).

FILL PLUG

FIGURE 4.10-1 FILL PLUG

25

9. a off the level with new coolant The proper level is at the of the fill

11. Start unit and check for leaks.

Do not add coolant sor, as this can result in saturation of the

filter element. and coolant carry-over down-stream.

4.11 COOLANT CHANGE

Before beginning any work on the compressor, open, lock and the main electrical disconnect and close the isolation valve on the compressor

Wait 2 minutes after stopping to allow internal pressure to dissipate. Vent residual pres­sure from the unit by unscrewing the coolant fill plug one turn. Unscrewing the fill opens a vent hole, drilled in the plug, pressure to release to atmosphere {See

A slight mist or oil droplets may be visible dur-venting. Do not remove fill until all pres-

sure has vented from the unit. Also vent slightly opening the drip valve . When the drain valve or removing the coolant fill stand clear of the valve wear work

SPECIAL TOOLS

Suitable clean drain pan or container to hold 3.6 {13.5 L) of coolant drained from unit

A of proper coolant sufficient to refill the coolant level in the compressor.

coolant filter of the prop-

The coolant should be drained soon after the com­pressor has been shut down. When the coolant is warm, the will be more and any

in in the coolant will be carried out with the coolant.

1. Place a clean pan under the drain

2. Remove drain coolant to drain from the tube "'"'r1::.r~•rnr

3. a filter remove the coolant filter. Remember that the filter and coolant may be hot!

4. Discard the old filter.

5. the clean lint-free rag to tern.

26

surface of the filter head with a of dirt into the sys-

7. a small amount of clean coolant on the rubber seal of the filter.

DRAIN PLUG

8. Screw element on until the seal makes contact with the seat on the filter header. one half to three turns additional.

9. Install and the coolant drain

10. Remove coolant fill 4.10-1).

11. a fill unit with new coolant. The prop-er level is even with the of the fill

13. Start unit and check for leaks.

Do not add coolant the intake of the compres-sor as this can result in saturation of the on~•r'><,r..r filter element and coolant carry-over down-

stream.

4.12 COOLANT TYPE CHANGE

OBJECTIVE 3. Place drain pan under coolant drain

To drain coolant from compressor as as and allow coolant to drain from om;s101e when of coolant to avoid cont-amination or dilution of new fluid.

5. Remove coolant filter.

CAUTION

If it is not compati-ble with certain Conditioner" fluids

from ~ machines running on Addition ~g of these products to Ultra Coolant can lead to -plugged filters and lead-

to severe mechanical problems. do not flush the compressor system with a "Compressor Conditioner" to with Ultra 6. Allow to drain Coolant.

7. Drain all hoses and low within the

ITEMS REQUIRED 8. Install a new coolant filter Section 4.1

In addition to the tools Section 4.1 serviceman's •~r·•'"'~·v

items should be available at the work site: 10. Install and

Suitable clean drain pan or container to hold 11. Remove coolant fill 4.10-1). 3.6 (13.5 L) of coolant drained from unit

12. a refill unit with the new coolant to be A of new coolant sufficient to refill the com-pressor.

A minimum of one '"'"'"'""·"'"'"'nt coolant filter. One sep­arator element.

PROCEDURE

used. Exercise care to of any contami-nants.

13. fill

14. Start unit and check for leaks.

15. Install proper decals for the fluid now installed in

the up to the compressor.

2. Shut compressor down button to the OFF ~~'""r·~

the

Before beginning any work on the compressor, open, 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 from the unit slowly the coolant fill plug one turn. the fill opens a vent drilled in the pressure to release to

A mist or oil may be visible dur-venting. Do not remove fill until all pres·

sure has vented from the unit. Also vent opening the valve . When

the drain valve or the coolant fill stand clear of the valve

and appropriate eye orc>te!C:tlC>n

27

4.13 COOLANT SEPARATOR FILTER ELEMENT

The filter element should be every year or after 1 000 hours of whichever comes

'"''"'"'""cu excessive coolant carryover into the

The element is located in the """1'n"1"""'1 on of the inlet Control Valve

Before beginning any work on the compressor, open, 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 pres­sure from the unit by slowly unscrewing the coolant fill plug one tum. Unscrewing the fill opens a vent hole, drilled in the allowing the pressure to release to atmosphere (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 slightly opening the drip valve. When the drain valve or the coolant fill stand clear of the valve discharge, wear work gloves and appropriate eye

SEPARATOR ELEMENT (INSIDE)

FIGURE 4.13-1 SEPARATOR ELEMENT LOCATION

28

BOLT

APPLY DOWNWARD FORCE ON TOP OF COVER

FIGURE 4.13~2 COVER REMOVAL

Procedure:

1 . The cover has a the element in so be careful when lnn .. :,onin the bolts. Place

downward on the cover while rcm,nuon

bolts and then release the force cover to be removed 4.1

2. cover from the of element.

the 6 the

3. Remove the cover and discard.

4. Remove the from the of the element

ELEMENT

FIGURE 4.13-3 ELEMENT REMOVAL

5. Lift element from 4.1

6. Remove element

and discard

8. Install new element in sure is seated in groove.

9. Install new element.

10. Install new cover seated in groove.

11. Place retainer cover.

on

Make sure

Make

is

12. Insert and start bolts.

13. Place downward force on cover and finish screw­bolts in

14. bolts to 220 in-lbs. ).

15. Start unit and check for leaks.

DRAIN HOLE

FIGURE 4.13-4 DRAIN HOLE LOCATION

29

4.14 SEPARATOR TANK SCAVENGE CHECK VALVE/SCREEN/ORIFICE

TOOLS REQUIRED

end wrench Screwdriver

PROCEDURE

at each end of check valve/screen/

Check orifice and clean if Use suitable small screwdriver or knife and press screen retainer orifice from its mating 4.14-1 }. Be careful not to flared end of Wash

Press the check valve/screen/orifice into block.

Assemble the check valve/screen/orifice to the tubing lines. The must be re-installed with the screen on the side of the orifice as indi-cated the flow arrow 4.15-1

CHECK

~JJruNG :'11--H-O_U_S~IN-G--Jr

30

VITRON 0-RING

FIGURE 4.14-1 SEPARATOR TANK SCAVENGE CHECK VALVE/SCREEN/ORIFICE

4.15 COOLER CORES

INSPECTION

check the cooler cores for build up of dust, lint or other material.

an OSHA "'"'""'''""" air gun, blow air through the omios1te direction of normal air

Remove cooler box outer and clean all loose material that blew from the coolers into the fans.

Reinstall the cooler box outer

Start unit and proper

4.16 MOTOR GREASING

cage motor has antifriction "~"'"n'~~ front and rear. At intervals

re-lubrication.

Re-lubrication Interval 9 mos., whichever comes

1000 hours all TEFC drive motors 2000 hours all ODP drive motors

Re-lubrication Amount:

Motor frame Size

Lubricant Amount cu in cc oz grams

254-286 1.0 16 .8 23

lubrication can be a cause of motor failure. The of grease added should be care-

controlled. The smaller motors must be '"''"''"'"<'rl with a lesser amount of grease than motors.

When motor. Disconnect power: lock out and Remove outlet grease relief if may not be accessible on the fan end of some TEFC motors. Grease relief shaft can occur, neces-

of this if inaccessible. Remove the of the on each end of the

The inlet grease gun

i. Clean drain hole of any hard grease wire if ne1::es:sa1

are

of

grease gun. Determine in advance the of grease delivered with each stroke of the lever. A cubic centimeters may be used. or a 35mm film canister can give a close for 2 cubic inches of volume when filled.

3. Add the recommended volume of the recommended lubricant. Do not at the

4. Run motor for about 30 minutes before outlet or reliefs. BE SURE TO SHUT MOTOR DOWN, DISCONNECT POWER, LOCK OUT AND

AND REPLACE THESE DRAIN FITTINGS TO PRECLUDE LOSS Of NEW GREASE AND ENTRANCE OF CONTAMINANTS!

Most motors

Mobilith SHC 220 . . . . . . ................ Mobil

Use the grease as indicated on a grease infor-mation on the motor. Use of alternative greases can result in shortened motor life due to

of greases. If there is not a grease on the motor use:

Chevron Black Pearl #2 ............. Standard Oil of California

Chevron SRI 2 ..... ,, .... Standard Oil of California

MOTOR BEARING MAINTENANCE-STORED UNITS To ensure that ""'""'"'''"'

on units to be the motor maintenance adhered to:

1. Prior to a unit in rotate the motor several revolutions hand in the proper direction of rotation.

2. rotate the motor as described in at three month intervals until such time as the unit is

in service.

3. The time should not exceed a total of nine months duration.

31

5.0 TROUBLE SHOOTING

32

TROUBLE

Coolant Excessive Noise Level Shaft Seal Leak Pressure Relief Valve Black Residue on Belt Guard/Cooler Box

CHECK POINT NUMBERS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 29. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.

CHECK POINT NUMBERS 1

TROUBLE CAUSE Control Not Available Defective Starter Motor Incorrect Overload Heater Size Line

Above Rated Pressure Filter Element

Unloaded

Incorrect Pressure Switch Minimum Pressure Valve

Load Solenoid Valve Defective Drive Belt ""r'no"'" Air Leaks Inlet Valve Malfunction

Demand Exceeds Coolant Core Low Coolant Level

Ambient Restricted Air Flow "'"''~"'"'tnr Filter Element Leak

"'"''"'"'r'~uw Filter Drain

Airend Defective Motor Defective Loose

Below Rated Pressure

Worn or Defective Shaft Seal Sheaves Worn Sheaves

SEE llOTE I

LI ~-----'10""'-~---------------1 L.2 .. -----~- ... ~----L3 ------1Q""'-""';;, ____ ,1 \...---------

_________ J \,.. ____________ J

IFl.I

llTSl-1

1(111> l(llo

IHSl-7

11'5

US1-11

NOTES:

I. APPROVED FUSED OISCON~E(T OR CIRCUIT BREAKER PER ~.E.C. REQUIREHEHTS HUST BE PROVIDED BY CUSTOMER.

2. DASHED ll~ES REPRESE~T WIRI~G BY CuSTOHER.

3. SIZING OF ELECTRICAL COMPO~E~TS ~OT SUPPLIED BY INGERSOll-RA~D 15 THE RESPO~SlBlllTY OF THE CUSTOMER AND SHOULD BE DOllE I~ ACCORDA~CE WITH THE l~FORHATIO~ O~ THE COMPRESSOR DATA PLATE. N.E.C. A~O LOCAL ELECTRICAL CODES.

C0Ml'OllEl>jT5 SUl'PLIEll Altll WIRED ilY l·R:

----- COHPRE55011 MOTOR ---- HIGH AIR TEMPERATURE SWITCH

------ l'llESSURE SW! TCH ------ SOLEHOID VALVE ------ FAii MOTOR! 5 l

COHl'OltEMT5 SUPl'llEO AMD WIRED av SlARTER MFG.l

2FU - PRIMARY yOLTAGE FUSES ------ SECO~DAllY VOLTAGE fUSE (I 15VAC l

------- HOTOR STARTER COil ------ HOUllHETEll ------ HOTOll OVER LOAD RELAY ------ START/STOP SWITCH

------- TRA~SFORMER ----- IAl!R!ER TERHl~l STRIP

------ AUTO l!E5TART l!CHT ( AMBHI) ------ POWER OH l~OlCATOR LlGH. ------ COllTllOl REI.AV

---- (OljTROL RELAY (~TACTS ------ AUTO RESTART ilHE DELAY RELAY ----- AUTO RESTART T!HE DELAY RELAY CO~TACT ----- STARTER AUXILIARY CO!iTA:Ts

3FU SECO~OAl!r

FUSE (AMPS l

8.D

6.0 REFERENCE DRAWINGS 6.1 ELECTRICAL SCHEMATIC - FULL VOLTAGE

33

l '.3 ~-----~- ... ;;;: ____ ,; '------

_.,.. _______ .,!

HI

XF

STS 1-6

STSl-8 ,._-------o

l!OTE5:

'· PER ~.E.C.

2. DASHED Ll~ES REPRESENT W!Fl~G BY CUSTOMER.

l.

osv

8TSl-l &TSl-1 I

6.2 ELECTRICAL SCHEMATIC - STAR DELTA

34

w (J1

a> (.,.) .,, =ii z (;)

0 ;; (;)

~ :5::

ABBR AF

!CV

ME RCVTNK

MATS

RV

AFTCLR

LEGEND DESCRIPTI

DRY TYPE. DISPOSABLE ELEMENT

HULT! PURPOSE INLET VALVE

ROTARY S<REW AiRENO AIR RECEIVER TANK

r------------A --

f,

3) A---1-

3) AF --(LR

CF .._ ___ _;:;:::::;_ ___ _J;;::!_<A-----

RV lSV

Of!TRP ------A---SE

SSCVl'O

TS COOLANT SUMP 6 PRE-SEPARATION

l HHER~Al TO l <V)

TCV COOLANT MIXING VALVE PIPING 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 TO RECEIVER TANK ON TANK-MOUNTED UNITS.

w (J)

CJ)

"" .,, 0 c::: z c ~ 5 z "ti

~ z . ~ z ,:::; i::: 0 c: :z -I m c

1069 [42.07]

1625 [6 3. 96]

71 [2. 79]

N

1980 [77 .95]

TOP VIEW

LEFT SIDE VIEW

612 (24. I 0]

NOTES: I , WEIGHT 2.

(APPROXIMATELY): 684 KG,. ( 1504 LBJ -l FILL QUANTITY (APPROX.):

I 3, 6 L, ( J, 3. TOLERANCE ON ALL DIMENSIONS: 3 MM ( •.12 INCH l 4, ALL DlMENSIONS IN MILLIMETERS (INCH J, 5. A!R FLOW: 1800 CFM. 6, REC OMMENDEC

7 •

8'

586 [23. 07]

892 [35. I 3]

FRONT VIEW

'IX i2) 25 Cl [. 98] j:..

-n l 73 CG 0

[6. al] c:: z c

I ?!! 5

546 z .,, [21. 50]

I r-610 > z [24. oo] .

~ 32 J z

" [I. 25] s:: 0 c.: :z -! m w c "'I

RIGHT SIDE VlEW

'>l l ( G i.,.

I [ 16. l 9]

----

--- . ---

I 0<; I [4 I . 00)

I 7 27 [6 7. 97]

f--- 542 [2 l. 32]

342 [I 3 • 118]

I 271

[I 0. 75]

198 [7. 80)

68 [2. 68]

REAR VIEW

en iJ1 "!'I 0 c: z c ~ 0 z .,, ' )> z . OJ > (ft m i:: 0 c: z -I m c

1069 [4 2' 0 7]

1005 [39. 58] II~

~ 0

IO

lori I 1' 1-..,_ ___i_

TOP VIEW

1628 (64 .08]

I

610 [24 '00]

LEFT SIDE VIEW

I Ill

I [6.6

l 680

[26. 77]

33 I, 30)

NOTES: I, \/El GHT 2,

(APPROX!MATELYJ: 502 KG. ( 1104 LB.), FILL QUANTITY (APPROX.):

L. l. 3, TOLERANCE ON ALL DIMENSIONS~ ±3 MM (1,12).

". DIMENSIONS IN MILLIMETERS< !NCH J, 5. 6,

7,

8,

586 [23.07]

273 [I 0, 76]

800 CFM.

33 [I . 30]

II

!

II

FRONT VIEW

4 7 0 CG [I 8, 50]

i

3:: Ul 5 "' v

w "'"' Cl NO'

iJ.i N~

I-:J: Cl

0:::

'N II'"' 0

.., "' ~

"' v

':;:;' :;::o ~"' N

"'00 "'"' ,__:,

'";;:J roo

"' k - :;:: "' w

> :::::;: 0 I-I-0 CD

6.5 FOUNDATION PLAN - BASE MOUNTED

39

.--1 I FUTURE

PRE FILTER

l _ - - ..l..L..f:*'I-

-!I·

-0

+

GLADHAND with Necessary Fitting For Portable

VALVE Water, Or Ball Type Valve

UNION Aids in Disconnecting Compressor From The System

PRESSURE GAUGE

THERMOMETER

DRIP LEG

MANOMETER

DIFFERENTIAL PRESSURE INDICATOR

1-R AUTOMATIC DRAIN VALVE

FALSE LOADER Blows Oli Air Outside 01 Compressor Room

SYSTEM INSTRUMENTATION INCLUDES Nephelometer: Hygrometer; Pressure; Temperature

VENTILATION Moisture Louvers, Exhaust Fans

AFTERCOOLER/SEPARATOR, ISOLATION VALVE, UNION, STRAINER AND TRAP

6.6 TYPICAL SYSTEM FLOW DIAGRAM BASE PLATED MOUNTED

40

OUTSIDE COMPRESSOR

ROOM

PARTS LIST

7.1 INTRODUCTION

nrc.n".'.>;rnrl as an aid in ono1nrn·•·'-

for the ESP compressor. All of the compressor parts, listed in the parts are manufactured with the same

as the

service facilities and are available worldwide. There are Rand Branch Offices and authorized distributors located in the principle cities of the United States. In our customers

the Canadian Co1mo;anv. Limited.

There are also ,,.,,..,...,.,,..,

subsidiaries and autho­rized distributors located in the

cities the world.

DESCRIPTION

The illustrated breakdown illustrates the various sub-assemblies and detailed which make up this

ANOOOO

MANUFACTURED IN U.S.

YEAR OF MANUFACTURE

"'"'<,,,,.,,..,h1" Items

of Ref. indicate that the item is located elsewhere in the list

HOW TO USE THIS PARTS MANUAL

1. Tum to the Parts Section to locate desired illustrations.

2. Locate the on the illustration visual identification and the mf­

erence number.

3. Find the reference number on the Tabulated page, with the Part Number and

95 102

JULIAN DATE OF MANUFACTURE -----------...l

SERIAL NUMBER BREAK

U95102 indicates part is used on units up to and serial number in U95102.

U95103 is used on units with serial number in U95103 or

HOW TO ORDER PARTS

In order that all avoidable errors be eliminated when rwrl~•"'~

the tn11,..,,.,.;n,.,

1. The model number of the unit as shown on the Data Plate.

2. The serial number of the unit as shown on the Data Plate.

3. The form number of this manual.

4. The reference

'"'"'""'"'"'"'" and as listed.

5. The motor data code shown on the motor data

41

0

0

42

..,. w

Starter

Ref. Part No. Number

39881032 39881040

2 39237193 39237219

2A 39240064 39245337

3 39190939 4 39403290 5 39125091 6 35258508 7 35245224 8 39242268 9 39219332 10 39239983 11 39180898 12 39318845

39318852

13 39231915 14 39231899

39244751

·NOT ILLUSTRATED

1 ENCLOSURE, STARTER BOX (NEMA 1) 1 ENCLOSURE, STARTER BOX (NEMA 4) 1 ·1 1 1 1 1 1 1 1 1 1 1 1 1

2 i i

0

0 0

44

.;:. (.)1

Starter

Ref. Part No. Number

39881032 39881040

2 39243597 39237193

2A 39240064 39240064

3 39239868 39237227

4 39239975 5 39190939 6 39403290 7 39125091 8 35258508 9 35245224 10 35249754 11 39242268 12 39219332 13 39239983 14 39180898 15 39318845

39318852

16 39231915 17 39231899 x 39244751

- NOT ILLUSTRATED

- Star Delta

1 ENCLOSURE, STARTER BOX (NEMA 1) 1 ENCLOSURE, STARTER BOX (NEMA 4) i CONTACTOR STARTER 1 CONTACTOR, STARTER 1 CONTACTS, AUXILIARY 1 CONTACTS, AUXILIARY 2NO 1 CONTACTS, REVERSING i CONTACTS, REVERSING 1 BLOCK, TERMINAL 1 LUG, GROUND 1 RELAY, CONTROL 2 i AUTO RESTART TIME DELAY 1 TIMER RELAY 1 RELAY, STAR-DELTA TIMER 1 LIGHT, AMBER INDICATOR 1 SWITCH, START/STOP 1 i 1

2 i

46

Ref. Part Ref. Part No. Number Qty. Description No. Number Qty. Description

1 39862222 1 ASSEMBLY, SEPARATOR TUBE 2 39313184 4 CLAMP, TUBE 23A 39133145 4 SCREW 2A 95953204 8 SCREW 24 39878913 1 FAN, 50/60HZ 28 39128541 8 NUT 24A 96705082 4 SCREW 3 39876453 1 BASE, OPEN 25 39872049 1 RING, FAN INLET 4 39246335 1 SCREW, JACK 25A 39133145 4 SCREW 4A 95922910 1 NUT, JACK SCREW 26 39869805 1 BOX, FAN/RING 5 39310792 1 SHAFT, MOTOR PIVOT 26A 39133145 4 5A 95231494 2 PIN, COTTER 27 39302260 1 BLOCK, TERMINAL DOUBLE 3 POSITION 58 39224209 2 WASHER, NYLON 27A 35249721 2 6 39879150 1 SUPPORT, MOTOR PIVOT) 28 39317268 1

39879168 1 SUPPORT, MOTOR PIVOT) 28A 35249721 2 39879176 1 SUPPORT, MOTOR PIVOT) 29 39580857 39879184 1 SUPPORT, MOTOR PIVOT) 29A 39236534 2

6A 39133152 1 SCREW 30 39879812 1 REF. NO 30A 39133145 8 SCREW

7 xxxxxxxx 1 MOTOR. (FRAME 31 1 7A 39128517 4 SCREW 31A 96702279 3 78 39116348 4 NUT 39177167 2 7 xxxxxxxx 1 MOTOR, (FRAME SIZE: 324TS) 31B 39183538 2 7A 95930723 4 SCREW 31C 39110309 2 78 95929188 4 WASHER 310 39128566 2 7C 95423687 4 NUT 32 39870241 1 8 xxxxxxxx 1 ASSEMBLY, STARTERBOX 39870233 1 8A 39141809 4 SCREW 32A 39178678 4 SCREW 88 95379392 1 STAR 33 39121256 1 PRESSURE RELIEF (165 PSIG) 9 39879820 1 GUARD, (38MM 34 39128624 1 TUBE

39879838 1 GUARD, BELT (70MM 35 39184510 1 PLUG 9A 39133145 6 SCREW 36 39152368 1 10 39173927 2 GLAND, WIRE 37 39111752 1 11 39173935 2 LOCKNUT, WIRE GLAND 39111752 2 12 1 BUSHING, SHEAVE 38 391'11752 13 1 DRIVEN 39318613 1 14 xxxxxxxx BELT, 39494976 1

xxxxxxxx BELT, 90 INCHES 39 39310784 2 15 xxxxxxxx 1 BUSHING, SHEAVE 40 39441944 1 16 xxxxxxxx 1 SHEAVE, DRIVER 41 92740950 1 17 39879804 1 CORNER, RIGHT 42 39155759 2 ELBOW, TUBE 17A 39133145 8 SCREW 43 39124821 15" TUBING 18 39870563 1 TUBE, AFTERCOOLER-RECEIVER 44 39137898 1 TRAP, MOISTURE

TANK 45 95279378 1 CONNECTOR, TUBE 19 95938171 4 ELBOW, TUBE (TANK MOUNTED UNITS) 46 39310958 1 TUBE, MOISTURE SEPARATOR

95938171 3 ELBOW, TUBE (BASE MOUNTED UNITS) 47 39316179 1 MANIFOLD 39581715 1 MANIFOLD, CUSTOMER AIR 48 39105754 1 VALVE, BALL

DISCHARGE (BASE MOUNTED UNTS) 49 39862230 1 TANK, RECEIVER 120 GAL 20 39843735 1 COOLER, COMBINED OIL/AFTER (FOR TANK MOUNTED UNITS

..,. 20A 39141809 4 SCREW 39871223 1 BASE, BASE MOUNTED UNITS "'.J 208 39178660 4 WASHER 50 39121256 1 RELIEF

21 39870589 1 TUBE, OIL COOLER-SEPARATOR TUBE TANK MOUNTED UNITS ONLY) 39870571 1 TUBE, OIL COOLER-SEPARATOR TUBE 5·1 39128673 1 TUBE

52 39156435 1 TUBE

-!>­co

TO IHPEU.£1'!

!6

TO HIGH AIR TEMPERATURE SWITCH (AIREND)

TO

NEMA1 NEMA4

.j::. (.0

Ref. No.

1 2 3 4 5 6 7 8 SA 9 10 11 12

13 14 15 16 17 18

18A

NEMA 1

Part Number

39301973 39147186 39301965 39479472 39139332 39479431 39100029 39125133 95952495 39156435 39124813 95295986 39315700 39204490 39173927 39173935 39139332 39243985 39226618 39233382 39127295

Qtv.

i i

30" 1 2

2" 1 1 2 1 1

32" 1 i

90" 2 2

63;; 1 1 1 2

Starter Box With Pressure Switch

NEMA4

Ref. Part Description No. Number Qty.

STARTERBOX 1 xxxxxxxx 1 ASSEMBLY, STARTERBOX CONDUIT 2 95333266 1 CONDUIT

CONDUIT 2A 39135355 1 LOCKNUT. SEAL ELBOW, CONDUIT 3 39132303 30" CONDUIT ELBOW, CONDUIT 4 95333373 1 ELBOW, CONDUIT CONDUIT 4A 39135355 1 LOCKNUT, CONDUIT SEAL

5 95361390 1 ELBOW, CONDUIT SWITCH, 5A 39108949 3 LOCKNUT. SEALING SCREW 6 39132261 28" TEE 7 95245221 1 CONNECTOR 8 39201884 1 SWITCH, TUBING 8A 95952511 2 SCREW, PAN HEAD GAUGE, PRESSURE BB 39192000 2 GROMMET GAUGE, PRESSURE BC 39128541 2 NUT

9 95952495 1 TEE WIRE 10 39156435 1 CONNECTOR

LOCKNUT, WIRE GLAND 11 39124813 32 H TUBING CONDUIT 12 95295986 1 GAUGE, PRESSURE LIGHT, WHITE INDICATOR 39315700 1 GAUGE, PRESSURE HOURMETER HZ 13 39204490 90;; HOURMETER HZ

I 14 39173927 2

SCREW 15 39173935 2 16 39132261 50" 17 39243985 1 8 39226618 1

39233382 1 HOURMETER 18A 39127295 2 SCREW 19 95361390 1 ELBOW, CONDUIT

50

rx w

8 0 er UJ

t:: <1'.

i?

30 HP 20-25 HP

Ref. Part Ref. Part No. Number No. Number

1 xxxxxxxx 1 1 xxxxxxxx i Al REND

2 39317870 2 2 39111745 1 CONNECTOR, TUBE

3 39796479 1 TUBE, INJECTION 3 39871884 i TUBE, SCAVENGE

4 39111703 2 ELBOW, TUBE 4 39171517 1 ELBOW, TUBE

5 39128624 2 CONNECTOR, TUBE 5 39870886 1 TUBE, OIL FEED

6 39871926 1 SCAVENGE 6 39870894 1 TUBE, INLET VALVE·AFTERCOOLER

7 39870795 1 AIREND·SEPARATOR 7 39878053 1 ELBOW, TUBE

8 39870803 1 TUBE, INLET VALVE-AFTERCOOLER 8 39156435 1 CONNECTOR

9 39878053 1 ELBOW, TUBE 39184510 1 PLUG 10 39156435 1 CONNECTOR (BASE MOUNT) 9 42410761 1 VALVE. INLET

39184510 1 PLUG MOUNT) 9A 39139266 7 11 42410761 1 INLET 10 95000089 1 O·RING, ADAPTER PLATE

11A 39139266 7 11 39869045 1 ADAPTER, INLET VALVE TO Al REND

12 95000089 1 ADAPTER PLATE 11A 39185293 6 SCREW

13 39869045 1 INLET VALVE TO AIREND 12 39496591 i GASKET, Al REND

13A 39185293 6 SCREW 13 39304332 1 CLAMP, AIR FILTER

14 39496591 1 Al REND 14 39582721 i FILTER AIR

15 39304332 1 AIR FILTER 15 39128624 1 16 39582721 1 AIR 16 39870878 1 17 39870829 1 TUBE, SEPARATOR TUBE-INLET VALVE 17 39111703 1 18 39316203 1 LOAD SOLENOID 18 39316203 ·1

19 39871876 1 TUBE, 19 39871876 1 TUBE,

20 39303219 1 ORIFICE, CHECK-VALVE-FILTER 20 39303219 i ORIFICE, CHECK-VALVE-FILTER

21 39124813 10" TUBING 21 39124813 10" TUBING

22 39155577 1 TUBE 22 39155577 1 ELBOW, TUBE

23 39156393 1 TUBE 23 39156393 1 CONNECTOR, TUBE

24 39870811 1 24 39139332 60" CONDUIT. FLEX

25 39796453 ., 39132261 60" SEAL

26 39180872 1 CAP 25 39479431 ·1 CONDUIT (NEMA 1)

27 39476817 1 MANIFOLD, OIL FEED 95361390 1 CONNECTOR, CONDUIT (NEMA 4)

28 95938965 1 PLUG 26 95952388 1 COUPLING

29 39477005 1 CONNECTOR 27 39114079 1 LOCKNUT

30 39139332 60" FLEX 1) 39108949 1 LOCKNUT 39132261 60" (NEMA4) 28 39416128 1 SWITCH,

31 39479431 1 CONNECTOR, CONDUIT (NEMA 1) 29 39404165 1 0-RING 95361390 1 CONNECTOR, CONDUIT (NEMA 4) 30 39870902 1 TUBE, AIREND-SEPARATOR TUBE

32 95952388 1 COUPLING 31 39317250 1 CONNECTOR, TUBE

33 39114079 1 39108949 1

34 39416128 1 35 39404165 1 O·RING

01 36 39848148 1 TUBE, FRONT BEARING FEED

52

1 1-1 1-1

2

RECOMMENDED SPARE PARTS

COMPRESSOR PART DESCRIPTION

THERMOSTATIC CONTROL ORIFICE/FILTER/CHECK SWITCH, START I STOP

LINE LINE PRESSURE

AUXILIARY (1 Ma 2Ma - SIZE F & K CONTACT, AUXILIARY (1 Ma & 2Ma - FOR SIZE N ~r""~· HOURMETER HOURMETER

1-R PART NO.

42413114 42420307 39582721 92740950 42412452 39236328 39433735 42410761 42421347 42421354 39316203 39236492 39243894 39416128 39843735 39878913 39441944 39303219 39219332 39100029 39201884 39:240064 39245337 39226618 39233382 39·121256 39121256 95295986 39315700 39316203 39231915 39231899 39318845 39318852 35258508 35245224 39403290 39125091 39242268 39243985 42370353 39699418 39235288 39239447 39239454

*QUANTITY VARIES PER MACHINE. CONTACT YOUR LOCAL DISTRIBUTOR.

PER UNIT

1 1 1 1 1 1 1 1 1 1 1

3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1

53

7.3 RECOMMENDED SPARE PARTS (CONTINUED) lmR QTY

COMPRESSOR PART DESCRIPTION PART PER NO. UNIT

FULL VOLTAGE STARTER PARTS

SIZE K

39237318 39237250 39237292 39237342

SIZE N

39237334 39237276 39237300 39237367

STAR DELTA STARTER PARTS

SIZE F

39239850 1 39239868 1

1 39226592 1 39214986 1 35249754 1 35245224 1

SIZE K

39237318 39237250 39237292 39237342

STARTER OVERLOAD 39237367 STAR-DELTA TIMER (1 35249754

RELAY 1 35245224

**PURCHASE COMPLETE CONTACTOR ASSEMBLY.

54

MAINTENANCE RECORD

llME 110111 TIME Wllllll llOl\IE UllllT WllRK {llllURS) MEASURE BY

55

MAINTENANCE RECORD

om RUN TIME Wlllll!IOlllE UNIT Wiii (HOODS) MEASURE RY

56