Ep 20esp

INGERSOLLrAND ®
EP 20/25/30 - ESP
OPERATORS/
INSTRUCTION MANUAL
PARTS LIST
RECOMMENDED SPARES
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.
APDD 655B
September 1996
AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in
material and workmanship for a period of twelve months (see extended airend warranty) from the date of placing
the Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from
Davidson, NC, whichever shall first occur. The Purchaser shall be obligated to promptly report any failure to con-
form to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct
such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. point of shipment,
provided the Purchaser has stored, installed maintained and operated such Equipment in accordance with good
industry practices and has complied with specific recommendations of the Company. Accessories or equipment fur-
nished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have con-
veyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any
repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser or others
without Company’s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company’s proposal. Unless responsibility for meeting such perfor-
mance warranties are limited to specified tests, the Company’s obligation shall be to correct in the manner and for
the period of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED 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 time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based
on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such
Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company
in writing of its intention to do so. Any such Equipment will be at Purchaser’s sole risk and liability.
Limitation or Liability
The remedies of the Purchaser set forth herein are exclusive, and the total liability of the Company with respect to
this contract or the Equipment and services furnished hereunder, in connection with the performance or breach
thereof, or from the manufacture, sale, delivery, installation, repair or technical direction covered by or furnished
under this contract, whether passed on contract, warranty negligence, indemnity, strict liability or otherwise, shall
not exceed the purchase price of the unit of Equipment upon which such liability is based.
The Company and its suppliers shall in no event be liable to the Purchaser, any successors in interest or any ben-
eficiary or assignee of this contract for any consequential, incidental, indirect, special or punitive damages arising
out of this contract or any breach thereof, or any defect in, or failure of, or malfunction of the Equipment hereunder,
whether based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other
goods, loss by reason of shutdown or non-operation, increased expenses of operation, cost of purchase of replace-
ment power or claims of Purchaser or customers of Purchaser for service interruption whether or not such loss or
damage is based on contract, warranty, negligence, indemnity, strict liability or otherwise.
©INGERSOLL-RAND COMPANY
ROTARY SCREW AIR COMPRESSOR
This unit was purchased from
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Ingersoll-Rand Company reserves the right to make changes or add

improvements without notice and without incurring any obligation to 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 of your unit here.
Serial Number:
Model Number:
BELT
PRESSURE GUARD MOTOR
SWITCH
AIR FILTER
CONTROL
BOX
TUBE SEPARATOR
PRESSURE
AIREND
GAUGE
FINAL
RECEIVER DISCHARGE
TANK
TYPICAL ESP UNIT
1
TABLE OF CONTENTS
0.0 SAFETY AND WARNINGS 6.0 REFERENCE DRAWINGS
0.1 safety instructions 6.1 electrical schematic - full voltage
0.2 safety precautions 6.2 electrical schematic - star delta
0.3 decals 6.3 piping diagram
6.4 foundation plan - tank mounted
1.0 RECEIPT OF EQUIPMENT 6.5 foundation plan - base mounted
1.1 inspection 6.6 typical system flow diagram
1.2 unpacking and handling
7.0 PARTS LIST
2.0 INSTALLATION 7.1 introduction
2.1 ventilation 7.2 parts listing
2.2 foundation requirements starter assembly - full voltage
2.3 outdoor installations starter assembly - star delta
2.4 piping major components
2.5 electrical installation starter box with pressure switch
assembly
2.6 voltage conversion
piping assembly
2.7 shipping bolt removal
table - O-rings
2.8 rotation check
7.3 recommended spare parts
2.9 before starting / starting / stopping
8.0 MAINTENANCE RECORD

3.0 SYSTEMS
3.1 general system information
3.2 coolant system
3.3 air systems
GENERAL INFORMATION
3.4 capacity control
Cooling Air Flow:
3.5 pressure switch adjustment
60 Hz: 1800 cfm (51.0 m3/min.)
50 Hz: 1500 cfm (42.6 m3/min.)
4.0 MAINTENANCE
4.1 maintenance schedule
Ambient Temperature Limit: 35°F to 115°F (2°C to 46°C)
4.2 maintenance records
4.3 maintenance procedures
Coolant: Factory Filled ROTALUBETM 1000
4.4 pressure relief valve check
COOLANT
4.5 sheave alignment
4.6 drive belts
Coolant Change: 1,000 hours or one year, whichever
4.7 belt tension
comes first, when using ROTALUBETM 1000 COOLANT
4.8 shaft seal replacement
4.9 inlet air filter element
Coolant Capacity: 1.6 GAL (6L)
4.10 coolant filter
4.11 coolant change
Discharge Temperature Limit: 228°F (109°C)
4.12 coolant type change
4.13 coolant separator filter element
Tools: U.S. Standard and metric are required to perform
4.14 separator tank scavenge
maintenance
check valve/screen/orifice
4.15 cooler cores
4.16 motor greasing
*This product is produced under license from Cash
Engineering Research Pty. Ltd. United States and foreign
5.0 TROUBLE SHOOTING
patents pending.
2
0.0 SAFETY AND WARNINGS Safety instructions in the operators manual are bold-faced
0.1 SAFETY INSTRUCTIONS for emphasis. The signal words DANGER, WARNING and
Before you install this air compressor you should take the CAUTION are used to indicate hazard seriousness levels as
time to carefully read all the instructions contained in this follows:
manual.
Electricity and compressed air have the potential to cause Danger is used to indicate the presence of
severe personal injury or property damage. D! DANGER a hazard which will cause severe personal
injury, death, or substantial property dam-
Before installing, wiring, starting, operating or making any age if the warning is ignored.
adjustments, identify the components of the air compressor
using this manual as a guide. Warning is used to indicate the presence of
! WARNING a hazard which can cause severe personal
The operator should use common sense and good working injury, death, or substantial property dam-
practices while operating and maintaining this unit. Follow age if the warning is ignored.
all codes, pipe adequately, understand the starting and
stopping sequence. Check the safety devices by following Caution is used to indicate the presence of
the procedure contained in this manual. ! CAUTION a hazard which will or can cause minor per-
sonal injury or property damage if the warn-
Maintenance should be done by qualified personnel, ade- ing is ignored.
quately equipped with proper tools. Follow the maintenance
schedules as outlined in the operators manual to ensure Notice is used to notify people of installa-
problem free operation after start up. NOTICE tion, operation, or maintenance information
which is important but not hazard-related.
0.2 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
COMPRESSOR OR PERFORMING ANY MAINTENANCE
WARNING 3. Do not operate the compressor at high- 8. There can be adverse effects if com-
er discharge pressure than those specified pressor lubricants are allowed to enter
COMPRESSED AIR AND ELECTRICITY on the Compressor Nameplate or motor plant air systems.
ARE DANGEROUS. overload will occur. This condition will
result in compressor motor shutdown. Air line separators, properly selected and
BEFORE DOING ANY WORK ON THIS installed, will minimize any liquid carry-
UNIT, BE SURE THE ELECTRICAL SUPPLY 4. Use only safety solvent for cleaning the over.
HAS BEEN CUT OFF–LOCKED & TAGGED compressor and auxiliary equipment.
AND THE ENTIRE COMPRESSOR SYSTEM The use of plastic bowls on line filters
HAS BEEN VENTED OF ALL PRESSURE. 5. Install a manual shut off valve (isolation without metal guards can be hazardous.
type) in the discharge line. A pressure From a safety standpoint, metal bowls
1. Do not remove the covers, loosen or relief valve, with sufficient capacity to should be used on any pressurized sys-
remove any fittings, connections or relieve full compressor capacity, must be tem. Review of your plant air line system is
devices when this unit is in operation. Hot installed between the compressor and the recommended.
liquid and air under pressure that are con- isolation valve.
tained within this unit can cause severe 9. When a receiver is installed, it is recom-
injury or death. 6. Whenever pressure is released through mended that occupational safety and
the pressure relief valve, it is due to exces- health standards as covered in the Federal
2. The compressor has high and danger- sive pressure in the system. The cause for Register, Volume 36, number 105, part 11,
ous voltage in the motor starter and con- the excessive pressure should be investi- paragraph 1910.169 be adhered to in the
trol box. All installations must be in accor- gated immediately. installation and maintenance of this
dance with recognized electrical codes. receiver.
Before working on the electrical system, 7. Before doing any mechanical work on
be sure to remove voltage from the system the compressor: 10. Before starting the compressor, its
by use of a manual-disconnect-switch. A maintenance instructions should be thor-
circuit breaker or fuse safety switch must a.) Shut the unit down. oughly read and understood.
be provided in the electrical supply line
leading to the compressor. b.) Electrically isolate the compressor by 11. After maintenance functions are com-
use of the manual disconnect switch in the pleted, covers and guards must be
Those responsible for installation of this power line to the unit. Lock and tag the replaced.
equipment must provide suitable grounds, switch so that it cannot be operated.
maintenance clearance and lightning
arrestors for all electrical components as c.) Vent pressure from the compressor and
stipulated in O.S.H.A. 1910.308 through isolate the unit from any other source of
1910.329. air.
3
! SAFETY SHUTDOWN CHECK HIGH AIR TEMPERATURE
There is a high discharge air temperature shutdown function built into the control on each compressor. It
is factory pre-set at 228°F (109°C). This function should be checked at regular intervals for proper opera-
tion, once a month Is recommended.
PROCEDURE:
1. Block off the cooling air discharge.
2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the dis-
charge temperature reaches the pre-set maximum discharge air temperature setting.
! WARNING
Failure to adhere to these recommendations can result in mechanical failure, property damage and serious
injury or death.
All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port con-
nections must take into account vibration, pulsations, temperature, maximum pressure applied, corrosion
and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some
oil into the air stream; therefore, compatibility between discharge piping, system accessories and software
must be assured.
For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge
piping is not recommended. In addition, flexible joints and/or flex lines can only be considered for such pur-
poses if their specifications fit the operating parameters of the system.
It is the responsibility of the installer and owner to provide the appropriate service pipework 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 capa-
ble of producing air of breathing quality. For a compressor to be capable of use In breathing air services It
must be fitted with additional specialized equipment to property filter and/or purify the air to meet all applic-
able federal, state and local laws, rules, regulations and codes, such as, but not limited to, OSHA 29 CFR
1910.134, Compressed Gas Association 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 include the above provision in any agreement for any resale of this compressor.
! WARNING
STATEMENT CONCERNING THE INADVERTENT BREATHING OF COMPRESSED AIR EXHAUST
“The purchaser/user shall insure that adequate ventilation and make up air are provided if a non BAP des-
ignated compressor supplies air in a confined area to air consuming devices such as air motors, air tools,
solenoids, air cylinders, air guns, nozzles, etc. The compressed air discharge stream may contain residual
coolants/lubricants/carbon monoxide/condensable hydrocarbons or other materials which may be haz-
ardous to health with prolonged inhalation.”
4
0.3 DECALS
This section contains representative examples of If for some reason a decal is defaced, parts are
decals which will be appearing throughout this manual replaced or painted over, we recommend that you
and are applied to the compressor unit. obtain a replacement (See Recommended Spare
Parts List for Decal Kit Number).
NOTICE
! WARNING
Rotation.
INGERSOLLrAND ®
39544150
Exposed fan blade. Can cause severe

injury.
Do not operate with covers removed.

Disconnect power. Lock and tag.
INGERSOLLrAND ®
39540190
! WARNING TOP VIEW
! CAUTION
Incorrect lifting of
machine can cause injury
or property damage.
Exposed moving belts and sheaves.
Lift only from base
Can cause severe injury or death. channels.
Do not operate with guards removed. INGERSOLLrAND ®

Disconnect power, lock and tag out
machine before servicing. 39540232
INGERSOLLrAND ®
! WARNING
! WARNING
Hazardous voltage. Can cause

severe injury or death.
Disconnect power before servicing.

Lockout/Tagout machine. Hot surface.
Can cause severe injury.
INGERSOLLrAND ®
Do not touch. Allow to cool before
39540174 servicing.
LOCATED INGERSOLLrAND ®
INSIDE 39541362
CONTROL BOX
RIGHT SIDE VIEW 39861810
5
! WARNING
6
NOTICE
This product is produced under
license from Cash Engineering
Research Pty. Ltd. United States
and foreign patents pending
Hot surface. INGERSOLLrAND®

INGERSOLLrAND®

39859228
servicing.
39875463
INGERSOLLrAND ®
39541362 ! WARNING 39557095
NOTICE
Exposed moving belts and sheaves. Dual Voltage
Can cause severe injury or death. Unit Factory
Do not operate with guards removed. Wired 230 Volts
Disconnect power, lock and tag out
machine before servicing.
INGERSOLLrAND ®
Apply 460V overlay
39859236 over 230V if unit
field wired to 460V.
Dual Voltage
Unit Field
Wired 460 Volts
NOTICE INGERSOLLrAND ®
39569140
Before installing, operating, or
performing amy maintenance on this
unit, read and understand the
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.
! WARNING
LEFT SIDE VIEW 3. Close main disconnect switch. FRONT VIEW
Starting
1. Pull START/STOP button to the
START position. Compressor will
start and load automatically.
2. Air pressure will rise if there is
sufficient demand for air.
Stopping
1. Push START/STOP button to the
STOP position. Compressor will stop
automatically.
2. Open main disconnect switch.
39871991
Hazardous voltage. Can cause
INGERSOLLrAND®
Disconnect power before servicing.
39871991
Lockout/Tagout machine.
INGERSOLLrAND ®
39540174
! CAUTION ! WARNING ! CAUTION
Use of incorrect coolant can cause
Improper maintenance of coolant system contamination.
filter can cause compressor damage.
Use only ROTALUBETM 1000 COOLANT.
Change coolant filter after first 150 hours
of operation and every 1000 hours
thereafter when coolant is changed.
INGERSOLLrAND ®
39871454
INGERSOLLrAND ® High pressure air. 39540265 (OPTIONAL ULTRA COOLANT)

39871462
Can cause severe injury or death.
39540216 (OPTIONAL ULTRA COOLANT) Relieve pressure before removing filter
plugs / caps, fittings or covers.
INGERSOLLrAND ®
39540240 ! WARNING
Hot surface.

Filler Cap. servicing.
Use only recommended
INGERSOLLrAND ®
coolant. 39541362
Read instruction book
before servicing.
39540281
! DANGER
NOTICE
Air discharge. Discharge air.
Can contain carbon monoxide or
REAR VIEW
other contaminants. Will cause
INGERSOLLrAND®
INGERSOLLrAND®
Do not breathe this air.
39540257
INGERSOLLrAND ®
39540166
NOTE: DECALS 39540257 AND 39540166 ARE LOCATED ON THE END OF THE COOLER BOX ON BASE MOUNTED UNITS.
7
as any other conditions which might be detrimental to
1.0 RECEIPT OF EQUIPMENT the proper operation of the compressor.
1.1 INSPECTION 2.2 FOUNDATION REQUIREMENTS

When you receive the compressor please inspect it The compressor can be installed on any level floor that
closely. Any indication of careless handling by the car- is capable of supporting the weight.
rier should be noted on the delivery receipt especially
if the compressor will not be immediately un-crated. When sound transmission is of particular importance, it
Obtaining the delivery man’s signed agreement to any is often helpful to install a sheet of rubber-fabric-mat-
noted damages will facilitate any future insurance ting, under the compressor baseplate or receiver tank
claims. feet to reduce the possibility of resonant sounds being
transmitted or amplified through the floor.
1.2 UNPACKING AND HANDLING
The compressor package has been mounted on a 2.3 OUTDOOR INSTALLATIONS
wooden shipping base which will allow fork lifting
under the compressor base to facilitate handling dur- When a compressor must be installed outside, there
ing shipment. Care in positioning the forklift is impor- are certain items that should be incorporated into the
tant because the location of the center of gravity is installation to help assure trouble free operation.
strongly affected by the location of the airend and These items have been listed below plus Figure 2.31
drive motor. has been included to show a typical outdoor protected
installation. The unit must be purchased with
The wooden base must be removed prior to installa- NEMA 4 option to provide watertight electric’s.
tion.
• The compressor should be on a concrete pad
designed to drain water away. If the concrete pad is
2.0 INSTALLATION sloped, then the compressor must be leveled.
2.1 VENTILATION • The roof of the shelter should overhang the compres-
sor a minimum of 4 feet (1.2m) on all sides to prevent
Air cooled air compressors produce large amounts of direct rain and snow from falling on the unit.
heat. Because of this large heat production, the com-
pressor must be placed in a room with adequate venti- • The unit must be arranged under the shelter in a way
lation. that prevents air recirculation (i.e. hot exhaust back to
the package inlet).
If heated air from the compressor exhaust is allowed
to re-circulate back to the compressor, the compressor • If the installation includes more than one compressor,
will overheat and shut down. This heat must be the hot air exhaust should not be directed towards the
exhausted from the room. You should take this into fresh air intake of the second unit or an Air Dryer.
consideration when deciding where to place the com- • If a standard machine is to be installed outside, the
pressor within the building. Sufficient clearance must ambient temperature must never drop below 35°F
be allowed around the compressor to perform the (2°C) or freezing of condensate will result.
required maintenance.
• Power disconnect switch must be within the com-
Ambient temperatures higher than 115°F (46°C) pressor operator’s line of sight and should be in close
should be avoided as well as areas of high humidi- proximity to the unit.
ty.
• Condensate drains must never be allowed to dump
External ducting, to and from the compressor, that on the ground. Pipe to a suitable sump for future col-
is installed in the field must be sized so that no lection, disposal or separation of lubricant and water
excessive back pressure is exerted on the fan. mixture.
Maximum allowable is 0.25 inches (6.4mm) of
water column air resistance total for inlet and • Incoming power connections must use suitable con-
exhaust ducting. nectors for outdoor weather tight service.
Also consider the environment near the compres- • Sufficient clearance must be allowed on all four sides
sor. of the unit for service access. If possible, access by a
fork lift and/or an overhead beam hoist should be kept
DUST, CHEMICALS, METAL FILINGS, PAINT in mind (for eventual service to airend or motor).
FUMES, and OVERSPRAY should be avoided as well
8
• If the area around the installation contains fine air- • Some type of protection such as a fence or security
borne dust or lint and fibers etc., then the unit should system, should be provided to prevent unauthorized
be purchased with the TEFC motor option. access.
POWER
DISCONNECT
SWITCH DISCHARGE
(LOCKABLE) PIPE
(STEEL)
AREA SHOULD BE 4’
SECURED WITH A FENCE (1.2m)
OR SECURITY SYSTEM OVER-
HANG
(ALL
SIDES)
ISOLATION
VALVE
PRESSURE DRIP
TREATED LEG
TIMBER TO
LEVEL
SLOPING
CONCRETE
PAD
FIGURE 2.3-1 TYPICAL OUTDOOR SHELTERED INSTALLATION

35°F (2°C) AND ABOVE
9
2.4 PIPING 39°F (.5°C to 4°C) are adequate. Desiccant dryers
are required where pressure dew points must be
It is essential when installing a new compressor to below 33°F (.5°C). Figure 2.4-1 indicates the approxi-
review the total plant air system. This is to insure a safe mate moisture content in compressed air at various
and effective total system. operating points.
The use of plastic bowls on line filters without metal Contact your local Ingersoll-Rand Distributor or Air
guards can be hazardous. Their safety can be affected Center for assistance in selecting correct Ingersoll-
by either synthetic lubricants or the additives used in Rand filtration or drying products.
mineral oils. From a safety standpoint, metal bowls
should be used on any pressurized system.
! WARNING
Do not use plastic pipe, soldered copper fittings
or rubber hose for discharge piping. Moisture Content of Compressed Air
200
Condensed water occurs naturally in air lines as a result 160

of compression. Moisture vapor in ambient air is con-
120
centrated when pressurized and condenses when
cooled in downstream air piping. 80
Moisture in compressed air is responsible for costly 40

problems in almost every application that relies on com-
pressed air. Some common problems caused by mois- 0
ture are: rusting and scaling in pipelines, clogging of DEW POINT
instruments, sticking of control valves, and freezing of
outdoor compressed air lines. Any of these could result ❏ without ■ 100°F/38°C ■ 35°F/2°C ■ -40°F/ -40°C
Aftercooling (with Aftercooler) (Refrigerated (Desiccant Dryer)
in partial or total shutdown of the compressed air sys- Dryer)
tem.
The compressed air discharging from this compressor FIGURE 2.4-1 MOISTURE CONTENT OF
will be at some elevated temperature and will therefore COMPRESSED AIR
contain amounts of water vapor. As this air cools the
vapor will condense within the piping system.
IMPORTANT: The drain line must slope downward from

the trap to work properly.
NOTE: For ease of inspection of the automatic drain

trap operation, 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, low points in the piping system should be
provided with driplegs and traps.
Compressed air dryers reduce the water vapor concen-

tration and prevent liquid water formation in compressed
air lines. Dryers are a necessary companion to filters,
aftercoolers, and automatic drains for improving the pro-
ductivity of compressed air systems. Two types of dry-
ers, refrigerated or desiccant , are used to correct mois-
ture related problems in a compressed air system.
Refrigerated dryers are normally specified where com-
pressed air pressure dew points of 33°F to 39°F (.5°C to
4°C) are adequate. Desiccant dryers are required where
pressure dew points must be below 33°F to
10
IMPORTANT: Discharge piping should be at least as
large as the discharge connection at the compressor.
All piping and fillings must be suitably rated for the PRESSURE
discharge pressure and temperature. RELIEF
VALVE
A careful review of piping size from the compressor PRESSURE

connection point is essential. Length of pipe, size of GAUGE
pipe, number and type of fittings and valves must be

considered for minimum air pressure drop and opti-
mum efficiency of your compressor.
NOTE: Screw type compressors should not be

installed in air systems with reciprocating compres-
sors without a means of pulsation isolation, such as a
common receiver tank. We recommend both types of
compressor units be piped to a common receiver uti-
lizing individual air lines. See Figure 2.4-2.
When two rotary units are operated in parallel, pro-

vide an isolation valve and drain trap for each com-
pressor before the common receiver.
See Figure 2.4-3 ISOLATION
VALVE
TRAP
To assure long trouble free operation of a compressor STRAINER
operating with On-line/ Off-line and Auto Stop/Start
control, the system volume must be large enough to
keep the load/unload cycles to a minimum. This may
require the installation of a receiver down stream of
the compressor. Baseplate mounted units must be
piped to a receiver if installed in a system with insuffi- FIGURE 2.4-2 ROTARY-RECIP IN PARALLEL
cient volume to keep compressor cycling to a mini-
mum. If equipment such as filters or air dryers, is
installed in the main piping system, they must be PRESSURE
sized to handle the entire flow of the compressor and RELIEF
VALVE
an air receiver must be placed in the system between
the compressor discharge and the equipment, PRESSURE
regardless of system volume. GAUGE
This will prevent quick cycling of the compressor

which results in large fluctuations in system pressure.
FIGURE 2.4-3 ROTARY-TWO

COMPRESSOR SYSTEM
11
NOTE: This procedure applies only to units manufac-
2.5 ELECTRICAL INSTALLATION tured to multi-voltage specifications. Motor nameplate
must indicate multiple voltages.
Before proceeding further, we recommend that you
review the safety data in the front of this manual. PROCEDURE:
Locate the compressor data plate on the left end of Put main disconnect in the OFF position, lock and tag
the cooler box next to the control box. (See Figure 2.6-3).
The data plate lists the rated operating pressure, the
maximum discharge pressure, the electric motor char-
acteristics and power.
Confirm that the line voltage and compressor name-

plate voltage are the same.
The standard control box meets the intent of NEMA 1

guidelines. HASP
It will be necessary to make a hole in the control box
for the incoming power connection. Care should be
LEVER
taken to not allow metal shavings to enter the starter
and other electrical components within the box. After
making the power inlet hole, all shavings and debris
must be removed from inside of control box before TAG
power is turned on.
KEY LOCK
Incoming power should be connected per the electrical
schematic at the rear of this manual (See Section 6.0).
Confirm that all electrical connections are made and
tightened. Confirm that the control transformer is wired FIGURE 2.6-3 MAIN DISCONNECT
correctly for supply voltage (See Figures 2.6-1 / 2.6-2). LOCKED AND TAGGED
Inspect the motor and control wiring for tightness.
Close the panel front. Open the motor junction box on the side of the motor.
2.6 VOLTAGE CONVERSION Reconnect the motor to the desired voltage. Use the
connection decal provided on the motor as a guide.
IMPORTANT: This procedure should only be carried
out by a qualified electrician, electrical contractor or Reconnect the primary side of the control transformer
your local Ingersoll Rand Distributor or Air Center. for the desired voltage, as shown on the control trans-
former wiring decal.
PRIMARY PRIMARY After referring to the heater chart decal located in the
starter box panel, remove the original heater packs
and replace them with the appropriate heater packs
based on horsepower and voltage.
Again referring to the heater chart, set the dial position

200V
of the overload relay to the appropriate setting.
Make sure all wiring connections are tight.
Put main disconnect in the ON position and check

motor rotation, as outlined in Section 2.7 of this manu-
SECONDARY SECONDARY al.
115V
FIGURE 2.6-1 CONTROL FIGURE 2.6-2 CONTROL

TRANSFORMER TRANSFORMER
CONNECTIONS - 60HZ CONNECTIONS - 50 HZ
12
2.7 SHIPPING BOLT REMOVAL 3. Replace and tighten fill plug.
The unit is shipped with a bolt in the motor sup- 4. Close the main disconnect switch (ON) position.
port to prevent possible belt damage caused by
bouncing during shipment. This bolt must be 5. Verify that the main isolation valve is open.
removed prior to checking motor rotation or oper-
ating the unit. 6. Pull the Start/Stop button to start the unit and
immediately depress (push) the button to stop the
In addition, a jackscrew is located under the base unit.
and offers support to the motor during shipment.
This jackscrew must be loosened as far as possi- Observe the compressor drive motor shaft. The rota-
ble without removing it prior to operating unit. A tion should be in accordance with the directional arrow
locknut is provided to keep the jackscrew in decal on the motor.
place.
Should the motor rotation not be correct, put the main
Locate the shipping bolt and jackscrew in the motor disconnect in the OFF position, lock and tag.
support as shown in Figure 2.7-1 and remove the
shipping bolt. Interchange any two line connections (L1, L2, or L3)
at the starter. Close the control box cover. Recheck
for correct rotation.
2.9 BEFORE STARTING / STARTING / STOPPING

SHIPPING BOLT
Read and understand the following instructions
before operating or performing any maintenance
on this unit.
Before Starting:
JACKSCREW 1. Assure that Start/Stop push button is in the OFF
(depressed) position (See Figure 2.9-1).
FIGURE 2.7-1 SHIPPING BOLT LOCATION

POWER ON START/STOP AUTO RESTART CONTROL
LIGHT BUTTON LIGHT BOX
2.8 ROTATION CHECK
Locate the rotation decal on the motor and check for

correct rotation. The correct rotation when viewed
from opposite the drive end on the motor is clockwise.
If compressor is operated in the opposite direc-

tion of rotation, airend damage can result and is
not warrantable.
For the compressor motor rotation check, the motor

jogging should be as short a time as possible.
1. Assure that the Start/Stop button is in the stop

(depressed) position.
2. Check coolant level. To check coolant level, slowly

loosen the fill plug one complete turn. As the fill plug
is unscrewed approximately one turn, a small amount
of pressure may be released. Do not remove the fill HOUR PRESSURE GAUGE PRESSURE SWITCH
plug until all pressure has been vented. Once METER
pressure is vented, finish removing the fill plug. The
FIGURE 2.9-1 CONTROL BOX
proper coolant level is when the coolant is at the top 13
of the fill port. Add coolant if necessary.
2. Check coolant level. To check coolant level, slowly 3.2 COOLANT SYSTEM
loosen the fill plug one complete turn. As the fill plug is
unscrewed approximately one turn, a small amount of The coolant system consists of a “L” shaped tube sep-
pressure may be released. Do not remove the fill plug arator, thermostatic element, coolant filter, coolant
until all pressure has been vented. Once pressure is cooler with fans, and a separator element. When the
vented, finish removing the fill plug. The proper coolant unit is operating, the coolant is pressurized and forced
level is when the coolant is at the top of the fill port. to the compressor bearings. The compressor is provid-
Add coolant if necessary. ed with a temperature switch which will shut the unit
down in case of excessive temperature, 228°F
3. Replace and tighten the fill plug. (109°C). Effective coolant filtration is provided by the
use of a screw on, automotive type, heavy duty
4. Close the main disconnect switch (ON position). coolant filter.
The compressor is designed for operation in an ambi-

5. Verify that the main isolation valve is open. ent range of 35°F to 115°F (2°C to 46°C).
Starting COOLANT
1. Pull the Start/Stop button to the ON position and Rotary screw compressor fluids have a triple function
release. The compressor will start and then load auto- to perform. They lubricate the bearings and contacting
matically if line pressure is below the lower setting of surfaces of the rotors, seal internal clearances within
the pressure switch. the rotor chamber, and provide for the cooling of the
compression process. The bulk of the fluid is actually
Stopping used for cooling, with only small amounts used for
1. Depress the Start/Stop button to the OFF position. lubrication and sealing.
Compressor will stop immediately. ESP air compressors are factory filled with 1000
2. Open the main disconnect switch (OFF position). ROTALUBETM 1000 COOLANT. ROTALUBETM 1000
COOLANT is designed to operate for 1,000 hours
or one year, whichever comes first. The coolant
3.0 SYSTEMS must be changed at these intervals to avoid break-
down and equipment damage.
3.1 GENERAL SYSTEM INFORMATION
The compressor is an electric motor driven, single CIRCULATION OF COOLANT

stage, rotary screw compressor, complete with sup-
porting components to make a fully functional unit. A Coolant is forced by air pressure from the tube separa-
standard compressor is composed of the following: tor to the thermostatic element. The temperature rating
Inlet air filter of the element will determine whether the coolant cir-
Drive motor culates through the cooler, bypasses the cooler, or
Airend mixes the two paths together to maintain an optimum
Pressurized coolant system with cooler & filter compressor injection temperature. This temperature is
Separation system controlled to preclude the possibility of water vapor
Capacity control condensing. By injecting coolant at a sufficiently high
Instruments temperature, the discharge air coolant mixture temper-
Safety devices ature will be kept above the dew point.
Before being injected into the airend, all coolant flows

Compression in the rotary screw type air compressor through the coolant filter. It is an automotive type full-
is created by the meshing of two helical rotors (male flow filter with a single replacement spin-on element,
and female) on parallel shafts, enclosed in a heavy rated at 10 micron. There is a differential-pressure
duty iron housing, with air inlet and outlet ports located bypass valve set to open in the event that the pres-
on opposite ends. The grooves of the female rotor sure drop across the filter rises to as high as 35 psi
mesh with and are driven by the male rotor. Bearings (2.5 bar), which indicates an excessively fouled ele-
on both ends of the rotors are used to support the ment as well as poor maintenance practice.
rotor both laterally and axially.
14
COOLANT/AIR SEPARATION SYSTEM 3.4 CAPACITY CONTROL
The coolant/air separation system is composed of a ON LINE/OFF LINE WITH AUTOMATIC START/STOP
tube separator with specially designed internals and a CONTROL
two stage, coalescing type separator element located
in a housing above the inlet control valve on the The compressor will deliver air at full capacity, (the
airend. compressor maximum efficiency condition) or will oper-
ate at zero capacity with high receiver pressure (the
The air-coolant mixture discharges from the airend into compressor minimum power condition), while the unit
the tube separator. The majority of coolant is separated continues to run.
while in the tube separator and the coalescing separa-
tor filter element is used for final polishing of the air When the compressor starts and line pressure is below
prior to the customer’s system. The system removes the lower setting of the line pressure switch, control
nearly all of the coolant from the discharge air. The solenoid 1SV will be energized (close), inlet control
separated coolant is returned to the coolant system valve ICV will open, and the compressor will load.
and the air passes to the compressed air system. When the line pressure reaches the upper setting of
the pressure switch, the compressor will unload by de-
3.3 AIR SYSTEM energizing (opening) 1SV and closing ICV. Solenoid
1SV relieves the internal pressure of the compressor
COMPONENTS AND FLOW back to the inlet filter. The only adjustment required is
setting of the pressure switch.
The air system is composed of:
Inlet air filter When the compressor unloads, a time delay relay is
Inlet control valve (lCV) energized and begins to time out. The timer, mounted
Airend in the control box, is factory set at 10 minutes. It will
Coolant/Air separator continue to operate for as long as its time setting, after
Minimum pressure valve (MPV) which a relay contact opens to de-energize the com-
Non-return check valve (NRV) pressor starter coil. At the same time, an amber light
Aftercooler (1LT) on the control box is lit to indicate the compres-
sor has shut down automatically and will restart auto-
The direction of flow is from the inlet filter to the after- matically. The automatic restart will take place when
cooler. the line pressure drops to the lower setting of the pres-
sure switch.
FUNCTIONS OF COMPONENTS
Inlet air filter, filters the incoming air, trapping 99% of Adjusting the adjustable timer below the 10 minute
particles 10 micron and larger. factory setting may shorten the life of the com-
pressor drive motor.
Inlet valve opens full for on-line operation.
The valve closes in the off-line mode and at shutdown

which prevents back flow of the compressed air.
The airend compresses the air.
The tube separator removes most of the coolant from

the air.
The separator element performs the final separation of

coolant and polishing of the air prior to leaving the
compressor.
The minimum pressure check valve keeps the tube

separator and separator element at a minimum pres-
sure to ensure 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 aftercooler cools the air prior to leaving the pack-

age. 15
3.5 SETTING NEMA 1 PRESSURE SWITCH
PRESSURE SWITCH
1. Open isolation valve, allowing control system to

sense “line” pressure.
2. Start the compressor.
The compressor should load if the line pressure is

lower than then the maximum discharge pressure stat-
ed on the compressor data plate. It may be necessary
to vent air from customer system load unit.
3. Slowly close the isolation valve allowing the air line

pressure to rise to the maximum discharge pressure
or “trip” setting of the pressure switch.
4. Remove cover from pressure switch (See Figure

3.5-1). Adjust as required by turning range adjustment
screw clockwise to increase and counterclockwise to
decrease trip setting (See Figure 3.5-2). When 1PS
trips, the compressor will unload. When the line pres-
sure falls to the reset point of 1PS (about 12 psig/.8
bar), the unit should reload. The pressure switch dif- FIGURE 3.5-1 LOCATION OF PRESSURE SWITCH
ferential is adjustable and factory set at about 12 psig
(.8 bar) to meet the requirements of the average appli-
cation.
Limited receiver and line storage may require a wider

differential. Sufficient receiver and line storage can RANGE
accept a narrow differential. If adjustment is required, ADJUSTMENT
turn differential adjustment screw clockwise to SCREW
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 system to confirm switch

operation is satisfactory.
DIFFERENTIAL
6. Replace switch cover and place unit in service.
ADJUSTMENT
SCREW
FIGURE 3.5-2 NEMA 1 PRESSURE SWITCH (1PS)
16
3.6 SETTING NEMA 4 PRESSURE SWITCH 7. Vent air from customer system to confirm switch
operation is satisfactory.
1. Open isolation valve, allowing control system to
sense “line” pressure. 8. Place unit in service.
2. Start the compressor. Operating variables in a system may cause changing

pressure requirements. It is recommended that a peri-
The compressor should load if the line pressure is odic inspection of the gauge pressure be made and
lower than then the maximum discharge pressure stat- the pressure control adjusted to compensate when
ed on the compressor data plate. It may be necessary necessary for these changes.
to vent air from customer system load unit.
OPERATING
3. Slowly close the isolation valve allowing the air line RANGE
ADJUSTMENT
pressure to rise to the maximum discharge pressure or SCREW “A”
“trip” setting of the pressure switch.
CONTACT
BLOCK LOCKING NUT
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 pres-
sure settings, turn “A” counterclockwise. The approxi-
mate upper pressure setting is shown by an indicator in
the left window between the calibration scales on the
nameplate. When the proper setting is reached, tighten
the lock nut on screw “A” clockwise.
5. DIFFERENTIAL ADJUSTMENT: Remove the front DIFFERENTIAL

PRESSURE
cover. When the differential screw “B” is flush with the GROUND
ADJUSTMENT
SCREW
enclosure base, the control will function at minimum dif- SCREW “B”
ferential. To increase the differential, turn adjustment
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-
UPPER PRESSURE
ment screw “B” counterclockwise. This will raise the SETTING INDICATOR
lower setting only.
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 enclo-
sure nor be adjusted beyond the maximum speci-
fied differential of the control.
6. After the desired setting has been accomplished,

mount the cover and tighten the four cover screws 6-8
in. lbs. thereby compressing the gasket seal.
FIGURE 3.6-1 NEMA 4 PRESSURE SWITCH (1PS)
17
4.0 MAINTENANCE
4.1 MAINTENANCE SCHEDULE
THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE COM-
PRESSOR 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 1 WK 1 MO 6 MO 9 MO YEARLY 2 YR
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 X (SUBSEQUENT CHANGES)
INSPECT HOSES 1000 X
INSPECT DRIVE BELTS 500 X
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 X
REPLACE AIR FILTER 2500 X
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
ROTALUBETM 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 CHANGE COOLANT, FILTERS AND SEPARATOR ELEMENTS MORE FREQUENTLY.
**CLEAN COOLER CORES IF UNIT SHUTDOWN OCCURS ON HIGH AIR TEMPERATURE.
4.2 MAINTENANCE RECORDS ing is heeded.
It is very important that you, the owner, keep accurate Read Safety Instructions.
and detailed records of all maintenance work you or Have a well equipped mechanic’s tool box with English
the Ingersoll-Rand Distributor or Air Center perform on and Metric sockets. (Special tools when needed will be
your compressor. This includes, but is not limited to, listed under each appropriate procedure).
coolant, coolant filter, separator element, inlet air filter, Have an OSHA approved air nozzle and compressed
drive belts, shaft seals and so forth. This information air. (International - local codes may apply).
must be kept by you, the owner, should you require Have recommended spare parts on hand (See listing
warranty service work by your Ingersoll-Rand in back of this manual).
Distributor or Air Center. Maintenance record sheets
are located at the back of this manual. ! WARNING
4.3 MAINTENANCE PROCEDURES
When the unit is shutdown, residual pressure
Before starting any maintenance, be certain the follow- can be trapped within the compressor system.
This pressure must be vented from the system
18 prior to beginning any service work.
Before beginning any work on the compressor, 4.5 SHEAVE ALIGNMENT
open, lock and tag the main electrical disconnect
and close the isolation valve on the compressor Any degree of sheave misalignment will result in a
discharge. Wait 2 minutes after stopping to allow reduction of belt life. Misalignment of belt drive should
internal pressure to dissipate. Vent residual pres- not exceed 1/16 in. (1.6 mm).
sure from the unit by slowly unscrewing the Parallel misalignment occurs when the drive and dri-
coolant fill plug one turn. Unscrewing the fill plug ven shafts are parallel, but the two sheaves lie in dif-
opens a vent hole, drilled in the plug, allowing the ferent planes (See Figure 4.5-1).
pressure to release to atmosphere (See Figure
4.31). A slight mist or oil droplets may be visible Angular misalignment occurs when the two shafts are
during venting. Do not remove fill plug until all not parallel (See Figure 4.5-2).
pressure has vented from the unit. Also vent pip-
ing by slightly opening the drip leg valve . When
opening the drain valve or removing the coolant fill
plug, stand clear of the valve discharge, wear work
1/16” MAX
gloves and appropriate eye protection.
AIREND
O-RING
STRAIGHTEDGE
VENT MOTOR
HOLE
FIGURE 4.5-1 PARALLEL MISALIGNMENT
FIGURE 4.3-1 FILL PLUG WITH VENT HOLE
1/16” MAX
4.4 MANUAL PRESSURE RELIEF VALVE CHECK
Under normal operating condition a “try lever test”
must be performed every month . Under severe ser-
vice conditions, or if corrosion and/or deposits are
noticed within the valve body, testing must be per-
formed more often. A “try lever test” must also be per- D
AIREN
formed at the 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 during valve testing. Run the compressor for STRAIGHTEDGE
about 10 minutes by venting air from the system to let
the unit warm up. With the unit running, test at or near
maximum operating pressure by holding the test lever MOTOR
fully open for at least 5 seconds to flush the valve seat
free of debris. Then release lever and permit the valve
to snap shut. If lift lever does not activate, or there is
no evidence of discharge, discontinue use of equip- FIGURE 4.5-2 ANGULAR MISALIGNMENT
ment immediately and contact a licensed contractor or
qualified service personnel.
19
ALIGN SHEAVES ALLEN HEAD SCREW SHEAVE RETAINING SCREWS
Insure that the compressor is isolated from the
compressed air system by closing the isolation
valve and venting pressure from the drip leg.
Insure that the main power disconnect switch is A
locked and tagged.
An easy and effective method of checking alignment in B

both directions between the driver and driven sheaves
utilizes an accurate straightedge.
B
Lay the straightedge across the face of the driver A
(motor) sheave and check alignment of the driven
(airend) sheave. Then lay the straightedge across the
driven sheave and check that the driver sheave is A
aligned.
B
Alignment should be within 1/16” (1.6 mm) maximum
when measuring the gap between the straightedge
and the rim of the opposite sheave in each direction.
This alignment is factory set and should only require

“A” - Clearance Holes
resetting if the drive motor or airend is removed.
“B” - Threaded Holes
The following steps should be taken to insure proper
alignment of all components. FIGURE 4.5-3 MOTOR SHEAVE BUSHING
1. Remove the cooler corners and air deflector.
2. Holding the straightedge against the front of the

7. Loosen allen screw in sheave bushing.
airend sheave, measure the amount of misalignment
seen on the motor sheave. If misalignment is less than 8. Move the bushing either in or out on the motor shaft
1/16” (1.6 mm) then reinstall cooler box outer panel depending upon the measurement taken earlier.
prior to operating unit.
9. Tighten allen screw in sheave bushing.
3. If misalignment is more than 1/16” (1.6 mm), the
motor sheave bushing must be loosened for reposi- 10. Being careful to not move the bushing on the
tioning. shaft, align sheave so that the three threaded holes in
the sheave line up with the three clearance holes in
To reposition the motor sheave: the bushing.
1. Remove drive belts (See Section 4.6). 11. Insert all three screws through clearance holes in
the bushing and thread into sheave.
2. Remove the three hex head screws that hold motor
sheave to sheave bushing. See Figure 4.5-3. 12. Slowly and evenly tighten all sheave retaining
screws. Torque to 180 lb-in. (2.1 kg-m).
3. Lubricate the thread and end of screws that were
just removed. 13. Tap against large end of bushing using hammer
and block or sleeve to avoid damage. Continue to
4. Reinstall all three screws in the holes of the bushing
torque screws until the specified wrench torque no
that are threaded.
longer turns the screw after tapping.
5. Slowly tighten the three screws evenly until the
14. Install belts as shown in Section 4.6.
sheave is pressed from the bushing. (Light tapping on
bushing may assist removal.) 15. Recheck for proper alignment.
6. Remove the screws from the holes. 16. Reinstall cooler box air deflector and corners.
20
4.6 DRIVE BELTS 3. Lower the motor support plate by loosening the
jackscrew locknut and turning the jackscrew counter-
Insure that the compressor is isolated from the clockwise. Be sure to back the jackscrew down as far
compressor air system by closing the isolation as possible since the belts will stretch after initial run-
valve and venting pressure from the drip leg. in, and the motor support will be lowered as a result.
Insure that the main power disconnect switch is Retighten the locknut.
locked open and tagged.
4.7 BELT TENSION
If installing or removing the belts on a new unit at start-
up, the motor support shipping bolt must first be This unit has been designed with a unique self ten-
removed. This bolt is only used to brace the motor dur- sioning system for the drive belts. There is no adjust-
ing shipment and will not be reinstalled once the belts ment required to insure proper belt tensioning. Be
are put into place. Locate the motor support shipping sure to use only Ingersoll-Rand Genuine parts to
bolt as shown in Figure 2.7-1 and remove. Locate the assure correct belt tension.
motor support jackscrew on the underside of the base.
Loosen the locknut and turn the jackscrew counter- 4.8 SHAFT SEAL REPLACEMENT
clockwise to set the motor down onto the belts. Be sure There are two lip type seals on the compressor. They
to back the jackscrew down as far as possible since the are wearable parts and should be replaced at
belt will stretch after initial run-in, and motor support will 8,000 hour intervals. While it is advisable to have
stretch after initial run-in, and the motor support will be your local Ingersoll-Rand Distributor or Air Center per-
lowered as a result. Retighten the locknut. form this work, the task can be accomplished by a
good mechanic following these instructions.
REPLACEMENT PARTS
Before beginning any work on the compressor,
Belts (See Recommended Spare Parts Section 7.0). Be open, lock and tag the main electrical disconnect
sure to use only Ingersoll Rand Genuine parts to and close the isolation valve on the compressor
assure proper belt size and length. Incorrectly sized discharge. Wait 2 minutes after stopping to allow
belts can lead to overloading of bearings and eventual internal pressure to dissipate. Vent residual pres-
airend or motor failure. sure from the unit by slowly unscrewing the
coolant fill plug one turn. Unscrewing the fill plug
DISASSEMBLY opens a vent hole, drilled In the plug, allowing the
pressure to release to atmosphere (See Figure
Belt tension is maintained due to a pivoting motor sup- 4.3-1). A slight mist or oil droplets may be visible
port. The weight of the motor holds the belt tight. during venting. Do not remove fill plug until all
pressure has vented from the unit. Also vent pip-
1. Remove the cooler box corner from the airend side ing by slightly opening the drip leg valve. When
of the machine. opening the drain valve or removing the coolant
fill plug, stand clear of the valve discharge, wear
2. Lift the back of the motor support plate by turning the work gloves and appropriate eye protection.
jackscrew (located on the underside of the base) clock-
wise. Retighten the locknut. SPECIAL TOOLS
3. Remove belts from the airend sheave and the motor A clean work bench
sheave.
REPLACEMENT PARTS
INSTALLATION/INSPECTION 20-25 HP Units
Shaft seal kit (42370353)
Inspect sheave grooves for foreign material or rubber Loctite® 242
build-up. Clean and degrease sheaves before installing Loctite® 609
drive belts to insure long belt life. Loctite® 515
1. Lift the back of the motor support plate by turning the 30 HP Units
jackscrew (located on the underside of the base) clock- Shaft seal kit (39699418)
wise. Retighten the locknut. Seal retainer O-ring (95358024)
Loctite® 609
2. Install belts on the airend sheave and the motor
sheave. When installing a new belt, do not pry or force
the belt over the sheave grooves.
21
INSTALLATION (20-25 HP) 11. The term “inboard side” will refer to the large
machined face of the seal housing. The term “out-
1. Remove both doors and the top of the enclosure, (if board side” will refer to the unmachined side next to
so equipped). the sheave.
2. Remove both guards, V-belts, and airend sheave. 12. Be certain to install the seals from the proper side
Note airend sheave is heat shrink fit to shaft and puller and in the proper orientation. Carefully follow instruc-
required to remove. tions for seal assembly. Protect seal elements from
inadvertent damage during installation. Be sure all
3. Remove seal housing from airend assembly. tools are free of contaminants before installation.
4. Drive both seals out of seal housing, being careful 13. Put a thin continuous coat of Loctite® 609 on the
not to damage seal housing bore. outer diameter of the double lip seal.
5. Discard seals. 14. Remove the seal from the assembly sleeve and
position it in the seal housing from the inboard side.
6. Remove check valve ball and plug from seal hous- The seal should be oriented such that the edge of the
ing. lip of the seal is toward the installer.
7. Inspect wear sleeve. If damage or excessive wear is 15. Using a bar or plate larger than the seal housing
present the wear sleeve must be replaced. bore diameter, press the double lip seal into the seal
housing until it locates against the shoulder.
8. Using a wide bladed scraper, remove all traces of
flange sealant from the seal housing and rotor housing, 16. Remove any excess Loctite® 609 with a clean
being careful not to scratch the surfaces. cloth.
9. Thoroughly clean and degrease the seal housing 17. Put a thin continuous coat of Loctite® 609 on the
and wear sleeve journal on the rotor. outer diameter of the single lip seal.
10. Clean scavenge holes in seal housing and in the 18. Remove the seal from the assembly sleeve. From
rotor housing (See Figure 4.8-1). the outboard side, position the seal such that the
edge of the seal is inserted first.
LIP EDGE 19. Using a bar or plate larger than the seal housing
OF SEAL bore diameter, press the seal into the seal housing
INWARD
from the outboard side. The seal will stop in the hous-
WEAR ing in the flush position. To avoid blocking the scav-
SLEEVE enge hole, the seal should never be pushed beyond
flush position.
20. Remove any excess Loctite® 609 from the seals,

from the seal housing bore, and from the seal scav-
enge holes.
21. Install the plug in the bottom of the seal housing.
SCAVENGE
HOLES
4.8-1 SHAFT SEAL ASSEMBLY (20-25 HP)

22
22. Place a thin bead of Loctite® 515 on the machined 32. Reinstall belts.
surface of the seal housing as shown in Figure 4.8-2.
Do not over apply. 33. Reinstall belt guards and enclosure.
INSTALLATION(30 HP)
BEAD OF
LOCTITE® 515 1. Remove enclosure, (if so equipped).
2. Remove V-belts and airend sheave. Note airend

sheave is heat shrink fit to shaft and puller is required
to remove.
3. Remove seal housing from airend assembly.
4. Drive both seals out of seal housing, being careful

not to damage seal housing bore.
5. Discard seals.
6. Remove and save retaining ring from seal housing.

FIGURE 4.8-2 SEAL HOUSING (20-25 HP)
7. Remove check valve ball and plug from seal hous-
23. Lubricate the assembly sleeve lightly with clean ing.
coolant.
8. Inspect wear sleeve. If damage or excessive wear
24. Slide the sleeve into the seal housing assembly, is present the wear sleeve must be replaced.
starting from the outboard side of the housing. Install
a new check valve ball in the seal housing. 9. Thoroughly clean and degrease the seal housing
and wear sleeve journal on the rotor.
25. Lubricate the wear sleeve lightly with clean
coolant. 10. Clean scavenge holes in seal housing and in the
rotor housing (See Figure 4.8-3).
26. Slide the seal housing with the assembly sleeve
installed over the shaft until it locates against the wear
sleeve.
27. Make sure the check valve ball is in place and WEAR
carefully slide the seal housing assembly off the SLEEVE
assembly sleeve and onto the wear sleeve on the
rotor. (A small amount of grease can be used to hold
the check valve ball in place for assembly).
28. Push the rotor seal housing assembly against the

rotor housing.
29. Remove assembly sleeve. LIP EDGE

OF SEAL
INWARD ASSEMBLY
30. Attach the seal housing to the rotor housing with SLEEVE
nine screws and tighten to 18 Ibs. ft. (2.5 kg. m).
31. Reinstall sheave and sheave-retaining hardware,

SCAVENGE
apply Loctite® 242 to clamp screw and tighten to 32 HOLES
Ibs. ft. (4.4 kg. m).
FIGURE 4.8-3 SHAFT SEAL ASSEMBLY (30 HP)
23
11. The term “inboard side” will refer to the large 23. Lubricate the wear sleeve lightly with clean coolant.
machined face of the seal housing. The term “outboard
side” will refer to the unmachined side next to the 24. Slide the assembly sleeve over the shaft until it
sheave. “locates” against the wear sleeve.
12. Be certain to install the seals from the proper side 25. Make sure the o-rings and check valve ball are in
and in the proper orientation. Carefully follow instruc- place and carefully slide the seal housing assembly off
tions for seal assembly. Protect seal elements from the assembly sleeve and onto the wear sleeve on the
inadvertent damage during installation. Be sure all rotor.
tools are free of contaminants before installation.
26. Push the seal housing assembly against the rotor
13. Install retaining ring in seal housing. housing.
14. Put a thin continuous coat of Loctite® 609 on the 27. Remove assembly sleeve.
outer diameter of the double lip seal.
28. Attach the seal housing to the rotor housing with
15. Remove the seal from the assembly sleeve, and four screws and tighten to 18 Ibs. ft. (2.5 kg. m).
using the Seal Installation Tool, (See Figure 4.8-4)
press the double lip seal into the seal housing from the
inboard side until it “locates” against the retaining ring. REMOVE BURS
The seal should be oriented such that the edge of the
lip of the seal is toward the installer (See Figure 4.8-3).
16. Remove any excess Loctite® 609.

2.10 1.88
17. Put a thin continuous coat of Loctite® 609 on the TO TO
outer diameter of the single lip seal. 2.08 1.85
DIA. DIA.
18. Remove the seal from the assembly sleeve and,

using the Seal Installation Tool, press the seal into the
seal housing from the outboard side until the seal is 1” MINIMUM
flush with the surface of the seal housing. Do not push
MATERIAL: STEEL
the seal beyond the flush position. The seal should be
oriented such that the edge of the lip of the seal is FIGURE 4.8-4 SEAL INSTALLATION TOOL
inserted first (See Figure 4.8-3).
19. Remove any excess Loctite® 609 from the seals,

from the seal housing bore, and from the seal scav-
enge holes.
20. Install the plug in the bottom of the seal housing.
21. Lubricate the assembly sleeve lightly with clean

coolant.
22. Slide the sleeve into the seal housing assembly,

starting from the outboard side of the housing. Install
new o-rings and a new check valve ball in the seal
housing.
24
4.9 INLET AIR FILTER ELEMENT SPECIAL TOOLS
The inlet air filter should be changed at the interval Suitable clean drain pan or container to hold coolant
shown in the maintenance chart or any time the filter drained from unit.
becomes dirty.
A quantity of proper coolant sufficient to top off the
The filter element is not washable and must be coolant level in the compressor.
replaced. Remove the filter by loosening the clamp on
the filter assembly located on the Inlet Control Valve. One genuine IR replacement coolant filter of the prop-
Remove and discard the old filter element. Install a er type for the unit.
new filter element. Tighten clamp (See Figure 4.9-1). 1. Place a clean pan under the coolant filter.
2. Using a filter wrench, remove the coolant filter.

CLAMP
Remember that the filter and coolant may be hot!
3. Discard the old filter.
4. Wipe the sealing surface of the filter head with a

clean lint-free rag to prevent entry of dirt into the sys-
tem.
5. Remove the replacement filter from its protective

package.
6. Apply 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. Tighten approximately one
half to three quarters turn additional.
8. Remove coolant fill plug (See Figure 4.10-1).
FILL PLUG
FIGURE 4.9-1 INLET AIR FILTER
4.10 COOLANT FILTER
Time of change - after the first 150 hours and every

1000 hours thereafter, or when the coolant is being
changed. In dirty operating environments, the filter
should be changed more frequently.
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 slow-
ly unscrewing the coolant fill plug one turn.
Unscrewing the fill plug opens a vent hole, drilled in
the plug, allowing the pressure to release to atmos-
phere (See Figure 4.3-1). A slight mist or oil droplets
may be visible during venting. Do not remove fill plug FIGURE 4.10-1 FILL PLUG
until all pressure has vented from the unit. Also vent
piping by slightly opening the drip leg valve . When
opening the drain valve or removing the coolant fill
plug, stand clear of the valve discharge, wear work
25
9. Using a funnel, top off the level with new coolant. 6. Remove the replacement filter from its protective
The proper level is at the top of the fill port. package.
10. Replace fill plug. 7. Apply a small amount of clean coolant on the rubber
seal of the filter.
11. Start unit and check for leaks.
Do not add coolant through the intake of the compres-

sor, as this can result in overfilling, saturation of the
separator filter element, and coolant carry-over down-
stream.
4.11 COOLANT CHANGE

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 by slowly unscrewing the
opens a vent hole, drilled in the plug, allowing 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 piping by
slightly opening the drip leg valve . When opening
the drain valve or removing the coolant fill plug,
stand clear of the valve discharge, wear work
DRAIN PLUG
SPECIAL TOOLS FIGURE 4.11-1 DRAIN PLUG
Suitable clean drain pan or container to hold approxi-

mately 3.6 gal. (13.5 L) of coolant drained from unit. 8. Screw element on until the seal makes contact with
the seat on the filter header. Tighten approximately
A quantity of proper coolant sufficient to refill the one half to three quarters turns additional.
coolant level in the compressor.
9. Install and tighten the coolant drain plug.
One genuine IR replacement coolant filter of the prop-
er type for the unit. 10. Remove coolant fill plug (See Figure 4.10-1).
The coolant should be drained soon after the com- 11. Using a funnel, fill unit with new coolant. The prop-
pressor has been shut down. When the coolant is er level is even with the top of the fill port.
warm, the drainage will be more complete and any
particles in suspension in the coolant will be carried 12. Replace fill plug.
out with the coolant.
1. Place a clean pan under the drain plug.
Do not add coolant through the intake of the compres-
2. Remove drain plug (See Figure 4.11-1) and allow sor as this can result in overfilling, saturation of the
coolant to drain from the tube separator. separator filter element and coolant carry-over down-
stream.
3. Using a filter wrench, remove the coolant filter.
Remember that the filter and coolant may be hot!
4. Discard the old filter.

5. Wipe the sealing surface of the filter head with a
clean lint-free rag to prevent entry of dirt into the sys-
tem.
26
4.12 COOLANT TYPE CHANGE
3. Place drain pan under coolant drain plug.
OBJECTIVE
To drain coolant from compressor as completely as 4. Remove drain plug and allow coolant to drain from
possible when changing types of coolant to avoid cont- the tube separator.
amination or dilution of new fluid.
5. Remove coolant filter.
CAUTION
If optional Ultra Coolant is used, it is not compati- ! WARNING

ble with certain “Compressor Conditioner” fluids
often utilized to remove varnish deposits from HOT COOLANT USE CARE
machines running on petroleum products. Addition CAN CAUSE WHEN
of these products to Ultra Coolant can lead to SEVERE INJURY DRAINING
plugged filters and bearing lines, potentially lead-
ing to severe mechanical problems. Therefore, do
not flush the compressor system with a
“Compressor Conditioner” prior to filling with Ultra 6. Allow to drain thoroughly.
Coolant.
7. Drain all hoses and low points within the system.
ITEMS REQUIRED 8. Install a new coolant filter (See Section 4.10).
In addition to the tools normally found in any reason- 9. Install a new separator element (See Section 4.14).
ably equipped serviceman’s toolbox, the following
items should be available at the work site: 10. Install and tighten coolant drain plug.
Suitable clean drain pan or container to hold approxi- 11. Remove coolant fill plug (See Figure 4.10-1).
mately 3.6 gal. (13.5 L) of coolant drained from unit.
12. Using a funnel, refill unit with the new coolant to be
A quantity of new coolant sufficient to refill the com- used. Exercise care to prevent entry of any contami-
pressor. nants.
A minimum of one replacement coolant filter. One sep- 13. Replace fill plug.
arator element.
PROCEDURE 15. Install proper decals for the fluid now installed in
1. Operate the unit to bring the complete system up to the compressor.
operating temperature.
2. Shut compressor down by depressing the Start/Stop

push button to the OFF position.

slightly opening the drip leg valve . When opening
the drain valve or removing the coolant fill plug,
27
4.13 COOLANT SEPARATOR FILTER ELEMENT APPLY DOWNWARD
BOLT FORCE ON TOP OF COVER
The separator filter element should be replaced every
year or after 1000 hours of operation, whichever comes
first, to prevent excessive coolant carryover into the
plant’s air piping system.
The element is located in the cylindrical portion on top

of the Inlet Control Valve (See Figure 4.14-1).

slightly opening the drip leg valve. When opening
the drain valve or removing the coolant fill plug, FIGURE 4.13-2 COVER REMOVAL
Procedure:
1. The cover has a spring holding the element in

SEPARATOR ELEMENT (INSIDE) place, so be careful when loosening the bolts. Place
downward force, on the cover while removing the 6
bolts and then carefully release the force allowing the
cover to be removed (See Figure 4.13-2).
2. Lift cover from the top of element.
3. Remove the cover sealing o-ring and discard.
4. Remove the spring from the top of the element.
FIGURE 4.13-1 SEPARATOR ELEMENT LOCATION
28
ELEMENT 12. Insert and start retaining bolts.
13. Place downward force on cover and finish screw-

ing bolts in evenly.
14. Torque bolts evenly to 220 in-lbs. (2.57 kg-m ).
FIGURE 4.13-3 ELEMENT REMOVAL
5. Lift element from housing and discard (See Figure

4.13-3).
6. Remove element 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 in groove. DRAIN HOLE
9. Install new element. FIGURE 4.13-4 DRAIN HOLE LOCATION
10. Install new cover sealing o-ring. Make sure o-ring is

properly seated in groove.
11. Place spring on top of element, followed by the

retainer cover.
29
4.14 SEPARATOR TANK SCAVENGE 4.15 COOLER CORES
CHECK VALVE/SCREEN/ORIFICE
INSPECTION
TOOLS REQUIRED Visually check the cooler cores for build up of dirt,
Open end wrench dust, lint or other foreign material.
Screwdriver Using an OSHA approved air gun, blow air through the
cooler cores in the opposite direction of normal air
PROCEDURE flow.
Disconnect tubing at each end of check valve/screen/ Remove cooler box outer panel and clean all loose
orifice assembly. material that blew from the coolers into the fans.
Check orifice and clean if required. Use suitable small Reinstall the cooler box outer panel.
screwdriver or knife and press screen retainer orifice
from its mating fitting (See Figure 4.14-1). Be careful Start unit and verify proper operation.
not to damage flared end of fitting or o-ring. Wash
screen and housing in safety solvent and blow dry.
Press the check valve/screen/orifice into fitting block.
Assemble the check 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).
CHECK
VALVE
INLET HOUSING
SCREEN
SPRING ORIFICE
VITRON O-RING
FIGURE 4.14-1 SEPARATOR TANK SCAVENGE

CHECK VALVE/SCREEN/ORIFICE
30
4.16 MOTOR GREASING Recommended Motor Grease
The induction-type squirrel cage motor has antifriction Most motors require:
ball bearings, front and rear. At periodic intervals they
require re-lubrication. Mobilith SHC 220 . . . . . . . . . . . . . . . . . . . . . . .Mobil
Re-lubrication Interval (or 9 mos., whichever comes
first) Use the grease as indicated on a special grease infor-
mation nameplate on the motor. Use of alternative
1000 hours all TEFC drive motors greases can result in shortened motor life due to
2000 hours all ODP drive motors incompatibility of greases. If there is not a grease
nameplate on the motor use:
Re-lubrication Amount:
Chevron Black Pearl #2
Motor (Preferred) . . . . . . . . . . . . .Standard Oil of California
Frame Lubricant Amount
Size cu in cc oz grams Chevron SRI 2 . . . . . . . . . .Standard Oil of California
254-286 1.0 16 .8 23
MOTOR BEARING MAINTENANCE-STORED UNITS
Improper lubrication can be a cause of motor bearing To ensure that complete contact is maintained
failure. The quantity of grease added should be care- between the motor bearings and the bearing grease
fully controlled. The smaller motors must be greased on units to be placed in storage for extended intervals,
with a lesser amount of grease than larger motors. the following motor maintenance procedure should be
adhered to:
When re-greasing, stop motor. Disconnect power: lock
out and tag. Remove outlet plugs (or spring-loaded 1. Prior to placing a unit in storage, rotate the motor
grease relief plugs if present). The outlet plug may not several revolutions by hand in the proper direction of
be accessible on the fan end of some TEFC motors. rotation.
Grease relief along shaft can occur, precluding neces-
sity of removing this plug if inaccessible. Remove the 2. Thereafter, rotate the motor as described in Step 1
plug from the top of the housing on each end of the at three month intervals until such time as the unit is
motor and install grease fittings. The inlet grease gun placed in service.
fittings and outlet plugs (or spring-loaded relief’s) are
3. The storage time should not exceed a total of nine
located at each end of the motor housing.
(9) months duration.
1. Clean drain hole of any hard grease (use piece of
wire if necessary).
2. Use a hand lever type grease gun. Determine in

advance the quantity of grease delivered with each
stroke of the lever. A graduated 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
lubricant. Do not expect grease to appear at the outlet,
but if it does, discontinue greasing at once.
4. Run motor for about 30 minutes before replacing

outlet plugs or reliefs. BE SURE TO SHUT MOTOR
DOWN, DISCONNECT POWER, LOCK OUT AND
TAG, AND REPLACE THESE DRAIN FITTINGS TO
PRECLUDE LOSS OF NEW GREASE AND
ENTRANCE OF CONTAMINANTS!
31
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
32
39884143
REV 01
6.0 REFERENCE DRAWINGS

6.1 ELECTRICAL SCHEMATIC - FULL VOLTAGE
33
39884150
REV 01
6.2 ELECTRICAL SCHEMATIC - STAR DELTA
34
39874516
REV 02
PIPING LEGEND
6.3 PIPING DIAGRAM
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.
35
39871975
REV 03
6.4 FOUNDATION PLAN - TANK MOUNTED (CONTINUED)
36
39871975
REV 03
6.4 FOUNDATION PLAN - TANK MOUNTED
37
39872835
REV 03
6.5 FOUNDATION PLAN - BASE MOUNTED (CONTINUED)
38
39872835
REV 03
6.5 FOUNDATION PLAN - BASE MOUNTED
39
PRE FILTER
FUTURE
DRYE
ISOLATION
VALVE
TOP
RECEIVER
COMP.
BOT TO
SYSTEM
AFTER
PRE FILTER FILTER
OUTSIDE
COMPRESSOR
ROOM
GLADHAND Emergency Standby Air Hook Up. Complete with Necessary Fitting For Portable
or IR Rental Air Unit From Local IR Distributor
VALVE Water, Or Ball Type Valve
UNION Aids in Disconnecting Compressor From The System
PRESSURE GAUGE
THERMOMETER
DRIP LEG
MANOMETER
DIFFERENTIAL PRESSURE INDICATOR
I-R AUTOMATIC DRAIN VALVE
FALSE LOADER Blows Off Air Outside Of 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 (TWO BASE PLATED MOUNTED UNITS)
40
7.0 PARTS LIST ESP compressor. A series of illus- SERIAL NUMBER BREAK
trations show each part clearly and
7.1 INTRODUCTION in it’s correct location relative to the When a part is changed and it
other parts in the illustration. Each doesn’t supersede the previous
GENERAL part of an illustration is referenced part, this change must be docu-
This manual, which contains an with a number. The number, mented by a serial number break.
illustrated parts breakdown, has description and quantity needed By using the last six (6) digits of
been prepared as an aid in identify- per assembly are listed in numeri- the serial number, as outlined
ing and ordering parts for the ESP cal order on the following pages. below, this change is recorded in
compressor. All of the compressor the parts list.
parts, listed in the parts breakdown, Items with a description of NSS are
are manufactured with the same not sold separately and must be U95102 indicates part is used
precision as the original equipment. purchased as an assembly. Items on units up to and including serial
with a description of Ref. indicate number ending in U95102.
Ingersoll-Rand Company service that the item is located elsewhere
facilities and parts are available in the parts list. U95103 indicates part is used
worldwide. There are Ingersoll- on units with serial number ending
Rand Company Branch Offices and HOW TO USE THIS in U95103 or higher.
authorized distributors located in PARTS MANUAL
the principle cities of the United HOW TO ORDER PARTS
States. In Canada, our customers 1. Turn to the Parts Section to
are serviced by the Canadian locate desired illustrations. In order that all avoidable errors be
Ingersoll-Rand Company, Limited. eliminated when ordering parts,
There are also Ingersoll-Rand 2. Locate the part on the illustration please specify the following:
Company subsidiaries and autho- by visual identification and the ref-
rized distributors located in the erence number. 1. The model number of the unit as
principle cities throughout the shown on the Compressor Data
world. 3. Find the reference number on Plate.
the Tabulated page, along with the
DESCRIPTION Part Number and Description. 2. The serial number of the unit as
shown on the Compressor Data
The illustrated parts breakdown Plate.
illustrates the various assemblies,
sub-assemblies and detailed parts 3. The form number of this manual.
which make up this particular
4. The reference number, part num-
ber, description and quantity need-
ed exactly as listed.
5. The motor data code shown on

the motor data plate.
AN0000 U 95 102
MANUFACTURED IN U.S.
YEAR OF MANUFACTURE
JULIAN DATE OF MANUFACTURE
41
42
39876461
REV 02
Starter Assembly - Full Voltage
Ref. Part
No. Number Qty. Description
1 39881032 1 ENCLOSURE, STARTER BOX (NEMA 1)

39881040 1 ENCLOSURE, STARTER BOX (NEMA 4)
2 39237193 1 CONTACTOR, STARTER (SIZE K)
39237219 1 CONTACTOR, STARTER (SIZE N)
2A 39240064 1 CONTACTS, AUXILIARY 2NO (SIZE K)
39245337 1 CONTACTS, AUXILIARY 1NO (SIZE N)
3 39190939 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 RESTART)
9 39219332 1 SWITCH, START/STOP
10 39239983 1 BAR, EARTH
11 39180898 1 BLOCK, TERMINAL
12 39318845 1 TRANSFORMER, CONTROL
(200/230/460/575V 60HZ)
39318852 1 TRANSFORMER, CONTROL
(200/380/415/550V 50/60HZ)
13 39231915 2 FUSE, PRIMARY (6.25 A)
14 39231899 1 FUSE, SECONDARY (8.0 A)
X 39244751 1 DECAL, POWER ON
X - NOT ILLUSTRATED
43
44
39880844
REV 01
Starter Assembly - Star Delta
Ref. Part
No. Number Qty. Description
1 39881032 1 ENCLOSURE, STARTER BOX (NEMA 1)

39881040 1 ENCLOSURE, STARTER BOX (NEMA 4)
2 39243597 1 CONTACTOR, STARTER (SIZE F)
39237193 1 CONTACTOR, STARTER (SIZE K)
2A 39240064 1 CONTACTS, AUXILIARY 2NO (SIZE F)
39240064 1 CONTACTS, AUXILIARY 2NO (SIZE K)
3 39239868 1 CONTACTS, REVERSING (SIZE F)
39237227 1 CONTACTS, REVERSING (SIZE K)
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 35249754 1 RELAY, STAR-DELTA TIMER
11 39242268 1 LIGHT, AMBER INDICATOR (AUTO RESTART)
12 39219332 1 SWITCH, START/STOP
13 39239983 1 BAR, EARTH
15 39318845 1 TRANSFORMER, CONTROL
(200/230/460/575V 60HZ)
39318852 1 TRANSFORMER, CONTROL
(220/380/415/550V 50/60HZ)
16 39231915 2 FUSE, PRIMARY (6.25 A)
17 39231899 1 FUSE, SECONDARY (8.0 A)
X 39244751 1 DECAL, POWER ON
X - NOT ILLUSTRATED
45
46
39872031
REV 01
SEE PIPING
ASSEMBLY
OPTIONS
Major Components
Ref. Part Ref. Part
No. Number Qty. Description No. Number Qty. Description
1 39862222 1 ASSEMBLY, SEPARATOR TUBE 23 39881974 1 DEFECTOR, AIR

2 39313184 4 CLAMP, TUBE 23A 39133145 4 SCREW
2A 95953204 8 SCREW 24 39878913 1 FAN, 50/60HZ
2B 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 SCREW
5A 95231494 2 PIN, COTTER 27 39302260 1 BLOCK, TERMINAL DOUBLE 3 POSITION
5B 39224209 2 WASHER, NYLON 27A 35249721 2 SCREW
6 39879150 1 SUPPORT, MOTOR (440 PIVOT) 28 39317268 1 CLAMP, CAPACITOR
39879168 1 SUPPORT, MOTOR (470 PIVOT) 28A 35249721 2 SCREW
39879176 1 SUPPORT, MOTOR (500 PIVOT) 29 39580857 1 CAPACITOR, FAN
39879184 1 SUPPORT, MOTOR (530 PIVOT) 29A 39236534 2 SCREW, TERMINAL
6A 39133152 1 SCREW 30 39879812 1 CORNER, LEFT
(THRU REF. NO 4, INTO REF. NO. 7) 30A 39133145 8 SCREW
7 xxxxxxxx 1 MOTOR, (FRAME SIZES: 256T-286T) 31 xxxxxxxx 1 ASSEMBLY, PIPING
7A 39128517 4 SCREW 31A 96702279 3 SCREW, (20-25HP AIREND)
7B 39116348 4 NUT 39177167 2 SCREW, (30HP AIREND)
7 xxxxxxxx 1 MOTOR, (FRAME SIZE: 324TS) 31B 39183538 2 WASHER, LOCK (30HP AIREND)
7A 95930723 4 SCREW 31C 39110309 2 SCREW, (30HP AIREND-FRONT FLANGE)
7B 95929188 4 WASHER 31D 39128566 2 NUT, (30HP AIREND-FRONT FLANGE)
7C 95423687 4 NUT 32 39870241 1 SUPPORT, (20-25HP AIREND)
8 xxxxxxxx 1 ASSEMBLY, STARTERBOX 39870233 1 SUPPORT, (30HP AIREND)
8A 39141809 4 SCREW 32A 39178678 4 SCREW
8B 95379392 1 WASHER, STAR 33 39121256 1 VALVE, PRESSURE RELIEF (165 PSIG)
9 39879820 1 GUARD, BELT (38MM TRAVEL) 34 39128624 1 CONNECTOR, TUBE
39879838 1 GUARD, BELT (70MM TRAVEL) 35 39184510 1 PLUG
9A 39133145 6 SCREW 36 39152368 1 ELBOW, TUBE
10 39173927 2 GLAND, WIRE 37 39111752 1 CONNECTOR, TUBE (BASE MOUNT)
11 39173935 2 LOCKNUT, WIRE GLAND 39111752 2 CONNECTOR, TUBE (TANK MOUNT)
12 xxxxxxxx 1 BUSHING, SHEAVE 38 39111752 1 CONNECTOR, TUBE (30HP)
13 xxxxxxxx 1 SHEAVE, DRIVEN 39318613 1 CONNECTOR, ORIFICE TUBE (25HP)
14 xxxxxxxx BELT, 80 INCHES 39494976 1 CONNECTOR, ORIFICE TUBE (20HP)
xxxxxxxx BELT, 90 INCHES 39 39310784 2 PLUG
15 xxxxxxxx 1 BUSHING, SHEAVE 40 39441944 1 ELEMENT, THERMAL WITH WASHER
16 xxxxxxxx 1 SHEAVE, DRIVER 41 92740950 1 FILTER, COOLANT
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 ONLY)
20A 39141809 4 SCREW 39871223 1 BASE, (FOR BASE MOUNTED UNITS ONLY)
47
20B 39178660 4 WASHER 50 39121256 1 VALVE, PRESSURE RELIEF

21 39870589 1 TUBE, OIL COOLER-SEPARATOR TUBE (FOR TANK MOUNTED UNITS ONLY)
22 39870571 1 TUBE, OIL COOLER-SEPARATOR TUBE 51 39128673 1 ELBOW, TUBE
52 39156435 1 CONNECTOR, TUBE
48
39872882
REV 01
TO HIGH AIR
TEMPERATURE
TO HIGH AIR SWITCH (AIREND)
TEMPERATURE
SWITCH (AIREND) TO RECEIVER TANK OR
TO RECEIVER TANK OR ELBOW IN ICV DISCHARGE
ELBOW IN ICV DISCHARGE (BASE MOUNTED UNITS)
(BASE MOUNTED UNITS)
NEMA 1 NEMA 4
Starter Box With Pressure Switch Assembly
NEMA 1 NEMA 4
Ref. Part Ref. Part

1 xxxxxxxx 1 ASSEMBLY, STARTERBOX 1 xxxxxxxx 1 ASSEMBLY, STARTERBOX

2 39301973 1 CONNECTOR, CONDUIT 2 95333266 1 CONNECTOR, CONDUIT
3 39147186 30” CONDUIT 2A 39135355 1 LOCKNUT, CONDUIT SEAL
4 39301965 1 ELBOW, CONDUIT 3 39132303 30 “ CONDUIT
5 39479472 2 ELBOW, CONDUIT 4 95333373 1 ELBOW, CONDUIT
6 39139332 2“ CONDUIT 4A 39135355 1 LOCKNUT, CONDUIT SEAL
7 39479431 1 CONNECTOR, CONDUIT 5 95361390 1 ELBOW, CONDUIT
8 39100029 1 SWITCH, PRESSURE 5A 39108949 3 LOCKNUT, SEALING
8A 39125133 2 SCREW 6 39132261 28 “ CONDUIT
9 95952495 1 TEE 7 95245221 1 CONNECTOR, CONDUIT
10 39156435 1 CONNECTOR 8 39201884 1 SWITCH, PRESSURE
11 39124813 32 “ TUBING 8A 95952511 2 SCREW, PAN HEAD
12 95295986 1 GAUGE, PRESSURE (psig, Kg/CM2) 8B 39192000 2 GROMMET
39315700 1 GAUGE, PRESSURE (psig, KPa) 8C 39128541 2 NUT
13 39204490 90 “ CABLE, 3-CONDUCTOR 9 95952495 1 TEE
14 39173927 2 GLAND, WIRE 10 39156435 1 CONNECTOR
15 39173935 2 LOCKNUT, WIRE GLAND 11 39124813 32 “ TUBING
16 39139332 63 “ CONDUIT 12 95295986 1 GAUGE, PRESSURE (psig, Kg/CM2)
17 39243985 1 LIGHT, WHITE INDICATOR (POWER ON) 39315700 1 GAUGE, PRESSURE (psig, KPa)
18 39226618 1 HOURMETER (60 HZ ONLY) 13 39204490 90 “ CABLE, 3-CONDUCTOR
39233382 1 HOURMETER (50 HZ ONLY) 14 39173927 2 GLAND, WIRE
18A 39127295 2 SCREW 15 39173935 2 LOCKNUT, WIRE GLAND
16 39132261 50 “ CONDUIT
17 39243985 1 LIGHT, WHITE INDICATOR (POWER ON)
18 39226618 1 HOURMETER (60HZ ONLY)
39233382 1 HOURMETER (50HZ ONLY)
18A 39127295 2 SCREW
19 95361390 1 ELBOW, CONDUIT
49
50
39872023
REV 02
TO AFTERCOOLER TO AFTERCOOLER
Piping Assembly
30 HP Piping 20-25 HP Piping

Ref. Part Ref. Part
1 xxxxxxxx 1 AIREND 1 xxxxxxxx 1 AIREND

2 39317870 2 ELBOW, TUBE 2 39111745 1 CONNECTOR, TUBE
3 39796479 1 TUBE, FEMALE INJECTION 3 39871884 1 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 TUBE, SCAVENGE 6 39870894 1 TUBE, INLET VALVE-AFTERCOOLER
7 39870795 1 TUBE, AIREND-SEPARATOR 7 39878053 1 ELBOW, TUBE
8 39870803 1 TUBE, INLET VALVE-AFTERCOOLER 8 39156435 1 CONNECTOR (BASE MOUNT)
9 39878053 1 ELBOW, TUBE 39184510 1 PLUG (TANK MOUNT)
10 39156435 1 CONNECTOR (BASE MOUNT) 9 42410761 1 VALVE, INLET
39184510 1 PLUG (TANK MOUNT) 9A 39139266 7 SCREW
11 42410761 1 VALVE, INLET 10 95000089 1 O-RING, ADAPTER PLATE
11A 39139266 7 SCREW 11 39869045 1 ADAPTER, INLET VALVE TO AIREND
12 95000089 1 O-RING, ADAPTER PLATE 11A 39185293 6 SCREW
13 39869045 1 ADAPTER, INLET VALVE TO AIREND 12 39496591 1 GASKET, AIREND
13A 39185293 6 SCREW 13 39304332 1 CLAMP, AIR FILTER
14 39496591 1 GASKET, AIREND 14 39582721 1 FILTER, AIR
15 39304332 1 CLAMP, AIR FILTER 15 39128624 1 CONNECTOR, TUBE
16 39582721 1 FILTER, AIR 16 39870878 1 TUBE, SEPARATOR TUBE-INLET VALVE
17 39870829 1 TUBE, SEPARATOR TUBE-INLET VALVE 17 39111703 1 ELBOW, TUBE
18 39316203 1 VALVE, LOAD SOLENOID 18 39316203 1 VALVE, LOAD SOLENOID
19 39871876 1 TUBE, SCAVENGE 19 39871876 1 TUBE, SCAVENGE
20 39303219 1 ORIFICE, CHECK-VALVE-FILTER 20 39303219 1 ORIFICE, CHECK-VALVE-FILTER
21 39124813 10” TUBING 21 39124813 10” TUBING
22 39155577 1 ELBOW, TUBE 22 39155577 1 ELBOW, TUBE
23 39156393 1 CONNECTOR, TUBE 23 39156393 1 CONNECTOR, TUBE
24 39870811 1 TUBE, OIL FEED 24 39139332 60” CONDUIT, FLEX (NEMA 1)
25 39796453 1 TUBE, REAR BEARING FEED 39132261 60” CONDUIT, SEALTITE (NEMA 4)
26 39180872 1 CAP 25 39479431 1 CONNECTOR, 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 (NEMA 1)
30 39139332 60” CONDUIT, FLEX (NEMA 1) 39108949 1 LOCKNUT (NEMA 4)
39132261 60” CONDUIT, SEALTITE (NEMA 4) 28 39416128 1 SWITCH, HIGH AIR TEMPERATURE
31 39479431 1 CONNECTOR, CONDUIT (NEMA 1) 29 39404165 1 O-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 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
51
O-Rings
Part For SAE 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 1-1/2
39410279 2-1/2-12 2
52
7.3 RECOMMENDED SPARE PARTS
I-R QTY
COMPRESSOR PART DESCRIPTION PART PER
NO. UNIT
KIT, MAINTENANCE (W/ ROTALUBE 1000 COOLANT) 42413114 1

KIT, MAINTENANCE (W/ ULTRA COOLANT) 42420307 1
FILTER, AIR 39582721 1
FILTER, COOLANT 92740950 1
KIT, COOLANT SEPARATOR ELEMENT 42412452 1
COOLANT, ROTALUBE 1000 (4 X 1 GAL) 39236328 1
ULTRA COOLANT (5 GAL) 39433735 1
VALVE, INLET CONTROL (ICV3) 42410761 1
KIT, COMPLETE REBUILD (ICV3) 42421347 1
KIT, DIAPHRAGM REPLACEMENT (ICV3) 42421354 1
VALVE, LOAD SOLENOID (1SV) 39316203 1
DRIVE BELT, 80” (20,25 30 HP/60Hz; 20,30 HP/50Hz) 39236492 *
DRIVE BELT, 90” (25 HP/50Hz) 39243894 3
SWITCH, HIGH AIR TEMPERATURE (HATS) 39416128 1
COOLER, COOLANT / AFTERCOOLER 39843735 1
FAN, COOLING 39878913 1
ELEMENT, THERMOSTATIC CONTROL (170°F) 39441944 1
ORIFICE/FILTER/CHECK VALVE, SCAVENGE 39303219 1
SWITCH, START / STOP (1SS) 39219332 1
SWITCH, LINE PRESSURE (NEMA 1) 39100029 1
SWITCH, LINE 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 1
VALVE, PRESSURE RELIEF-SEPARATOR TUBE (EP/HP MODELS) 39121256 1
VALVE, PRESSURE RELIEF-RECEIVER TANK (EP/HP MODELS) 39121256 1
GAUGE, PRESSURE(psig, kg/cm2) 95295986 1
GAUGE, PRESSURE(psig, kPa) 39315700 1
VALVE, CONTROL SOLENOID (1SV) 39316203 1
FUSE, 6.25A (1FU/2FU) 39231915 2
FUSE, 8.0A (3FU) 39231899 1
TRANSFORMER, CONTROL CIRCUIT (200/230/460/575V-50/60Hz) 39318845 1
TRANSFORMER, CONTROL CIRCUIT (220/380/415/550V-50/60Hz) 39318852 1
RELAY, AUTO RESTART TIME DELAY (1TD) 35258508 1
SOCKET, RELAY (FOR 1TD) 35245224 1
RELAY, CONTROL(1CR) 39403290 1
SOCKET, RELAY(FOR 1CR) 39125091 1
LIGHT, AMBER INDICATOR (AUTO RESTART) 39242268 1
LIGHT, WHITE INDICATOR (POWER ON) 39243985 1
KIT, SHAFT SEAL REPLACEMENT (20/25 HP) 42370353 1
KIT, SHAFT SEAL REPLACEMENT (30 HP) 39699418 1
SET, DECAL ENGLISH 39235288 1
SPANISH 39239447
PORTUGUESE 39239454
*QUANTITY VARIES PER MACHINE. CONTACT YOUR LOCAL DISTRIBUTOR.
53
7.3 RECOMMENDED SPARE PARTS (CONTINUED)
I-R QTY
COMPRESSOR PART DESCRIPTION PART PER
NO. UNIT
FULL VOLTAGE STARTER PARTS
SIZE K
CONTACTOR, STARTER(1M) - SIZE K 39237318 1

KIT, STARTER CONTACT (SIZE K) 39237250 1
COIL STARTER (SIZE K) 39237292 1
RELAY, STARTER OVERLOAD (SIZE K) 39237342 1
SIZE N
CONTACTOR, STARTER(1M) - SIZE N 39237334 1

KIT, STARTER CONTACT (SIZE N) 39237276 1
COIL STARTER (SIZE N) 39237300 1
RELAY, STARTER OVERLOAD (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
RELAY, STARTER OVERLOAD (SIZE F) 39214986 1
RELAY, STAR-DELTA TIMER(1TR) 35249754 1
SOCKET, RELAY (FOR 1TR) 35245224 1
SIZE K
CONTACTOR, STARTER(1M) - SIZE K 39237318 1

KIT, STARTER CONTACT (SIZE K) 39237250 1
COIL STARTER (SIZE K) 39237292 1
RELAY, STARTER OVERLOAD (SIZE K) 39237342 1
RELAY, STARTER OVERLOAD (SIZE N) 39237367 1
RELAY, STAR-DELTA TIMER (1TR) 35249754 1
SOCKET, RELAY (FOR 1TR) 35245224 1
**PURCHASE COMPLETE CONTACTOR ASSEMBLY.
54
8.0 MAINTENANCE RECORD
DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY
55
MAINTENANCE RECORD
DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY
56

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INGERSOLLrAND ®

Before installation or starting the compressor for the

RETAIN THIS MANUAL WITH UNIT.

Ingersoll-Rand Company reserves the right to make changes or add

No. of units on order:

For ready reference:

TYPICAL ESP UNIT

8.0 MAINTENANCE RECORD

1. Block off the cooling air discharge.

Exposed fan blade. Can cause severe

Do not operate with covers removed.

! WARNING TOP VIEW

Do not operate with guards removed. INGERSOLLrAND ®

Hazardous voltage. Can cause

Disconnect power before servicing.

Hot surface. INGERSOLLrAND®

Can cause severe injury.

INGERSOLLrAND ® High pressure air. 39540265 (OPTIONAL ULTRA COOLANT)

Do not touch. Allow to cool before

1.1 INSPECTION 2.2 FOUNDATION REQUIREMENTS

FIGURE 2.3-1 TYPICAL OUTDOOR SHELTERED INSTALLATION

Condensed water occurs naturally in air lines as a result 160

Moisture in compressed air is responsible for costly 40

IMPORTANT: The drain line must slope downward from

NOTE: For ease of inspection of the automatic drain

It is possible that additional condensation can occur if

Compressed air dryers reduce the water vapor concen-

A careful review of piping size from the compressor PRESSURE

pipe, number and type of fittings and valves must be

NOTE: Screw type compressors should not be

When two rotary units are operated in parallel, pro-

This will prevent quick cycling of the compressor

FIGURE 2.4-3 ROTARY-TWO

Confirm that the line voltage and compressor name-

The standard control box meets the intent of NEMA 1

Again referring to the heater chart, set the dial position

Make sure all wiring connections are tight.

Put main disconnect in the ON position and check

FIGURE 2.6-1 CONTROL FIGURE 2.6-2 CONTROL

2.9 BEFORE STARTING / STARTING / STOPPING

FIGURE 2.7-1 SHIPPING BOLT LOCATION

2.8 ROTATION CHECK

Locate the rotation decal on the motor and check for

If compressor is operated in the opposite direc-

For the compressor motor rotation check, the motor

1. Assure that the Start/Stop button is in the stop

2. Check coolant level. To check coolant level, slowly

The compressor is designed for operation in an ambi-

The compressor is an electric motor driven, single CIRCULATION OF COOLANT

Before being injected into the airend, all coolant flows

The valve closes in the off-line mode and at shutdown

The airend compresses the air.

The tube separator removes most of the coolant from

The separator element performs the final separation of

The minimum pressure check valve keeps the tube

The non-return check valve prevents line pressure from

The aftercooler cools the air prior to leaving the pack-

1. Open isolation valve, allowing control system to

2. Start the compressor.

The compressor should load if the line pressure is

3. Slowly close the isolation valve allowing the air line

4. Remove cover from pressure switch (See Figure

Limited receiver and line storage may require a wider