ESH/V INSTALLATION INSTRUCTIONS INGERSOLL-RAND AIR COMPRESSORS

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP02-06298R000900030006-6
• Release Decision: RIFPUB
• Original Classification: K
• Document Page Count: 20
• Document Creation Date: December 20, 2016
• Document Release Date: September 8, 2007
• Sequence Number: 6
• Publication Date: September 1, 1977
• Content Type: MISC

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rin
Installation
I listructions
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INGERSOLIAAND?
AIR COMPRESSORS
Form AP 0250-C
September 1977
Supercedes AP-0250 B
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PREFACE
This Manual is being forwarded to assist the
new ESH/ESV owner in the successful installation
prior to start-up of his machine and to acquaint him
with some of its features. This manual should be
studied thoroughly before the arrival of the machine.
This manual covers general information applying
to all sizes of ESH/ESV Compressors. Additional
material in the form of drawings and an instruction
book with material applying specifically to your
machine will be forwarded later.
Should you have any questions concerning this
book or the equipment furnished, contact your
nearest Ingersoll-Rand Representative.
This manual has been prepared by Ingersoll-Rand, Air Power
Compressor Division, Technical Publications, Department
Painted Post, New York 14870
?Copyright Ingersoll-Rand Company 1976
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CONTENTS
SECTION I - AIR SYSTEM PREINSTALLATION
Product Description . . . . . . . . . . . 5
Receiving . . . . . . . . . . . . . . 5
Handling . . . . . . . . . . . . . . 5
Storage . . . . . . . . . . . . . . . 5
Location and System Layout . . . . . . . . 5
SECTION II - FOUNDATION AND MOUNTING
General . . . . . . . . . . . . . . . 7
Foundation Building . . . . . . . . . . 7
Setting the Compressor . . . . . . . . . . 9
Grouting . . . . . . . . . . . . . . 10
Foundation Finishing . . . . . . . . . . 11
SECTION III - AIR SYSTEM INSTALLATION
Pipe Cleaning . . . . . . . . . . . . . 13
Inlet Piping . . . . . . . . . . . . . . 13
Discharge Piping . . . . . . . . . . . . 15
Cooling Water . . . . . . . . . . . . . 16
V-Belt . . . . . . . . . . . . . . . 16
SECTION IV - GENERAL INFORMATION
Compressor Accessories . . . . . . . . . 17
Package Unit Installation . . . . . . . . . 17
Typical Air Piping Schematic for Single Stage
Compressor . . . . . . . . . . . . 18
Typical Air Piping Schematic for Two Stage
Compressor ... . . . . . . . . . . 19
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SAFETY PRECAUTIONS
BEFORE DOING ANY WORK INVOLVING MAINTENANCE, OR ADJUSTMENT - BE SURE THE ELEC-
TRICAL SUPPLY HAS BEEN DISCONNECTED, AND THE COMPRESSOR'S ENTIRE SYSTEM HAS BEEN
VENTED OF ALL PRESSURE.
WHERE LUBRICATING OIL IS PRESENT IN COMPRESSOR DISCHARGE, AN AFTERCOOLER SHOULD
BE INSTALLED IN THE FINAL COMPRESSOR DISCHARGE LINE MOUNTED AS CLOSE AS POSSIBLE
TO THE COMPRESSOR:
APRESSURE RELIEF VALVE MUST BE INSTALLED IN THE DISCHARGE PIPING BETWEEN THE COM-
PRESSOR AND ANY POSSIBLE RESTRICTION, SUCH AS BLOCK VALVE, CHECK VALVE, AFTER-
COOLER, OR AIR DRYER. FAILURE TO INSTALL A PRESSURE RELIEF VALVE-COULD RESULT IN
OVERPRESSURE, PIPE RUPTURE, DAMAGE TO COMPRESSOR AND PERSONAL INJURY. REFER TO
THE INSTRUCTIONS BOOK FOR SPECIFIC INFORMATION.
ON BELT DRIVEN COMPRESSORS, A BELT GUARD, CONFORMING TO O.S.H.A., STATE AND/OR
LOCAL STANDARDS/CODES SHALL BE INSTALLED BY THE USER.
THOSE RESPONSIBLE FOR INSTALLATION OF THIS EQUIPMENT MUST PROVIDE SUITABLE
GROUNDS, MAINTENANCE CLEARANCE AND LIGHTNING ARRESTORS FOR ALL ELECTRICAL COM-
PONENTS AS STIPULATED IN O.S.H.A. 1910.308 THROUGH 1910.329.
WHEN A RECEIVER IS INSTALLED, IT IS RECOMMENDED THAT OCCUPATIONAL SAFETY AND
HEALTH STANDARDS AS COVERED IN THE FEDERAL REGISTER, VOLUME 36 NUMBER 105
PART 11 PARAGRAPH 1910.169 BE ADHERED TO IN THE INSTALLATION AND MAINTENANCE OF
THIS RECEIVER'
BEFORE STARTING THE COMPRESSOR, ITS MAINTENANCE INSTRUCTIONS SHOULD BE THOR-
OUGHLY READ AND UNDERSTOOD.
FAILURE TO HEED THIS WARNING MAY RESULT IN AN ACCIDENT CAUSING PERSONAL INJURY
OR PROPERTY DAMAGE.
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SECTION I
AIR SYSTEM PREINSTALLATION
PRODUCT DESCRIPTION
The Ingersoll-Rand ESH (Horizontal) and ESV (Vertical)
Compressors are straight-line, single stage, double acting,
water cooled, heavy duty, crosshead type units in the 15 to
125 horsepower range. Both ESH and ESV Compressors
are available with either Lubricated or Non-Lubricated
cylinders. Multi-Stage and Vacuum Pump units are also
available.
The rugged design of the ESH-ESV incorporates such
features as "A" Channel Valves, Full Floating Aluminum
Alloy Bearings, Filtered Pressure Lubrication, and Sealed
Frame. All running gear parts are precision made and
adjustment free. The sealed frame prevents contamination
and waste of lube oil and due to low frame oil temperatures,
oil changes are infrequent. The cylinder and heads are
water jacketed for efficient cooling. Easy access to wiper
rings and cylinder packing is gained through removal of
bolted, sealed covers in the distance piece.
ESH-ESV Compressors require only a simple mounting
with easy hook-up. These units are more compact than
other compressors of their type and the ESV is especially
suitable where floor space is tight. ESV Packaged Plants
are also available.
RECEIVING
For shipment the compressor has been adequately
packed. Immediately upon receiving, the unit should be
carefully inspected. If shipping damage is noticed it should
be reported to the carrier immediately. Generally, the
compressor and its standard components are shipped fully
assembled. Accessories may be shipped separately and
assembly will be required. Packaged Plants will be fully
assembled and required only placement and hook-up of
water and air lines.
HANDLING
The wood packing skid used for most domestic shipping
of bare units is designed for fork lift truck use. Packaged
units are assembled on a permanent steel skid and may be
handled in the same manner.
General-Both Lubricated and Non-Lubricated units
have been prepared at the factory with an anti-corrosive
material to retard rust and deterioration during shipment.
While this preparation is adequate for shipment and short-
term storage in a warm, dry environment; it will not
sufficiently protect the unit for any extended period. If
there is to be a delay in erection and putting into service,
special precautions may be necessary. Your nearest Ingersoll-
Rand Distributor or representative should be contacted.
Non-Lubricated Compressors-Upon inspection, it may
be noted that the cylinder is protected by Vapor Phase
Inhibitor (VPI) Crystals. Though similar to a light, colored
sand in appearance; VPI is non-abrasive and will vaporize
when the machine is started.
If after receiving, it is noticed that the protective seals
are damaged and/or covers opened, or if after use the unit
is to be stored, shipped, or otherwise inoperative; your local
Ingersoll-Rand Representative should be contacted for
proper reprocessing procedures.
LOCATION AND SYSTEM LAYOUT
It is recommended that the unit be located in an enclosed
building. In cold climates the area should be heated. The
location should be well ventilated, lighted, and most impor-
tantly, clean and free of dampness, and corrosive vapors.
A crane or hoist is helpful for both erection and main-
tenance and should be provided when machine parts are
heavy. Enough room should be left around the compressor
to allow for maintenance.
The dimensions given on the general arrangement drawing
for removal of pistons and rods are based on the normal
amount of dismantling. The space required can usually be
reduced by further dismantling should floor space be
limited. Contact your nearest Ingersoll-Rand Branch Office
or Distributor for further information.
When selecting a location, equal consideration must be
given to the physical needs of both the compressor and its
system's components. The final location will be influenced
by the continuing cost of operating supervision at that
point. An automatic control system may make possible the
use of an area which otherwise might require costly
supervision. Positive outside ventilation is recommended
for any area where ambient temperature may exceed
104?F (40?C). A good water supply and drainage will
be required by both the compressor cylinder and an
aftercooler. The air compressor plant should always include
an aftercooler/separator, followed by a receiver. As com-
pressed air within the system cools substantial amounts of
water vapor entering the system will condense. Therefore,
the aftercooler/separator, receiver, and various points within
the distribution system must be kept drained. The use of
automatic traps is usually the best method. When dry air
is mandatory or maximum efficiency is required at the
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point of usage serious consideration should be given to the
use of an air dryer.
Matched components in any system are important for
efficient performance. For highest efficiency and lowest
overall cost per cubic foot of air you need an air power
system that is properly engineered. The following standard
components are available for your system:
1. Ingersoll-Rand slide base.
2. Motor - Standard T-Frame, nema design.
3. Motor starter - Standard - Full voltage magnetic across -
the line starter.
4. Inlet filter silencer - Purpose of this filter is to prevent
harmful particles from entering the compressor cylinder
and minimize noise.
S. Aftercooler - Purpose is to cool the compressed air after
the final compression stage. It is also recommended that
a moisture separator and condensate trap be furnished.
6. Receiver - Manufactured to ASME codes. Standard fittings
include inspection opening, safety valve, pressure gauge.
A receiver is recommended to efficiently control load
cycle and minimize air piping pulsation. An automatic
condensate trap is recommended.
7. Air Dryer - In a fully-enclosed cabinet with temperature
switch and moisture separator. Purpose is to reduce cost
of instrumentation failure, piping corrosion, maintenance
traps and drains due to water and oil compressed air sup-
ply lines.
8. Control System - To regulate the operation of the com-
pressor to the customers fullest advantage.
9. Belt Guards - (Fully enclosed) is used to cover the rotating
sheaves and v-belts and is recommended as a means of
preventing persons or objects from coming in contact with
these moving parts of the compressor.
For additional information refer to the air flow diagrams
in Section 4.
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r
L
SECTION I I
FOUNDATION AND MOUNTING
Since the responsibility for a successful foundation
rests with the customer, he should carefully check the
following points which are suggested in the interest of
securing a satisfactory installation:
The foundation drawing furnished shows the minimum
size recommended for hard, firm ground such as well ce-
mented sand and gravel or hard clay, always dry. If the soil
is wet or less firm, solid boring or deflection test should be
made to determine whether to increase the foundation size.
Alluvial solid, unconfined sand or gravel, soft clay, silt or
filled ground do not furnish satisfactory support for founda-
tion of large reciprocating machines-When these soils are
encountered, the foundation should be extended or placed
on a reinforced mat so as the increase the total mass, provide
a large surface in contact with the ground and reduce the
soil bearing pressure.
Foundations for reciprocating machines differ from foun-
dations for buildings or similar structures since dynamic
rather than static loads are involved. Consequently much
lower solid bearing pressure should be used than permitted
by municipal ordinances; usually 1 /4 to 1 /6 in (6.4 to
4.2 mm). Low soil bearing pressures keep the natural
frequency of the foundation high and prevent resonance,
also reduce the possibility of transmitted vibration.
When the soil is soft, piling may be necessary to provide
vertical support and to compact the sub-soil. In some cases
spur or batter piles are desirable to absorb horizontal forces.
If necessary to make the foundation deeper than shown
in the foundation drawing, the area of the base should be in-
creased. likewise when it is necessary to set the machine
higher above the floor level than shown on the foundation
drawing, or where the soil is not tamped back around the
sides of the foundation, the area of the base of the founda-
tion must be increased to compensate. This is especially im-
portant if the soil is not the very best, as failure to provide
an adequate base will promote rocking.
When several units are installed, they should either be
placed on a common foundation, or, if separate foundation
blocks are desired, they should be joined by a mat of ade-
quate thickness. The mat thickness will vary from 18" (457
mm) minimum to 36" (914 mm) or more, depending on the
ground characteristics, the size of machine, and the spacing
between the machines.
Frequently it is possible to observe neighboring Installa-
tions on similar soil. Such observations will greatly aid in
determining whether or not additional soil contact area,
additional mass or piling will be required.
When conditions are at all doubtful or if the founda-
tion site is located where transmitted vibration might be
objectionable, a foundation specialist should be consulted.
The Ingersoll-Rand Company is prepared to supply informa-
tion on the unbalanced forces for the use of the specialist
in analyzing the problem.
THE FOUNDATION IS A POOR PLACE TO ECONOMIZE.
THE EXTRA COST FOR AN ADEQUATE FOUNDATION
IS USUALLY SMALL, AND IS ALWAYS WELL JUSTI-
FIED.
FOUNDATION BUILDING
The following instructions apply not only to frame
grouted compressors but also to sub-base grouted com-
pressors. Reference is given to frame grouted compressors,
and if there is any variation in the sub-base terminology, it
will follow immediately in parentheses ().
1. Template (See Figure 2.)
a. Build a firmly supported wooden template so that the
foundation can be built below it. This template should
be made in one piece to include compressor frame
bolts, motor bolts, and distance piece bolting, where
applicable. (In the case of a package unit, the tem-
plate will be made to the sub-base dimensions.)
b. Locate the template in the exact position to be occu-
pied by the compressor. The bottom of the template
should be level and approximately 3/4" (19 mm)
lower than the desired height of the compressor bed-
plated or (subbase).
DO NOT MOVE TEMPLATE
WHILE POURING FOUNDATION
OBTAIN EXACT LOCATION
OF FOUNDATION BOLTS
FROM CERTIFIED FOUNDA-
TION PLAN
Figure 2. Template Used for Locating Foundation Bolts
2. Foundation Bolting (See Figure 3.)
a. Slip a 1-1/2" (38 mm) minimum diameter pipe over
each foundation bolt and hang the bolts from the tem-
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BOLT PROJECTION
ABOVE ROUGH
FOUNDATION, SEE
FOUNDATION PLAN
WHICH ALLOWS
FOR GROUT.
PIPE. SUPPORTED SO
THAT TOP IS AGAINST
TEMPLATE WHEN FOUNDATION
IS POURED LENGTH OF PIPE.
TOP OF ROUGH
FOUNDATION
STUFF WASTE AROUND BOLT
BEFORE POURING FOUNDATION
DO NOT REMOVE UNTIL TOP
OF FOUNDATION HAS BEEN
CLEANED AND COMPRESSOR
READY TO PUT ON.
plate. This pipe is used to correct any variation in
bolting and should be long enough to extend from the
template. to within a few inches of the bottom of the
bolts.
b. To insure proper height of the bolts above the frame
(sub-base), place blocks of wood on top of the tem-:
plate board to make the thickness of the template
equal to the thickness of the. compressor flange (sub-
base). See foundation plan for this dimension. The top
of the foundation bolts will then be the required dis-
tance above the frame (sub-base) holes. Screw down
the foundation bolt nuts so that the bolts project
above the nuts, see foundation plan for dimensions.
c. Place waste around top of the foundation bolts to pre-
vent concrete from falling into the pipe while pouring.
d. By means of wire, fasten the pipe in position so that its
upper end is against the bottom of the template.
NOTE: Foundation bolts for these compressors usually
have a small right-angle bend at their lower end
to prevent them from turning when the nut is
pulled down.
3. Alternative Foundation Bolting
(See Figure 4.)
To mount the compressor to an existing foundation the
concrete must be of an equivalent mass to that on the found-
ation plan and comply with sub-soil requirements. To
fasten the compressor base to the existing foundation a
non-shrinking or epoxy type cement should be used with
the following procedure. -
NOTE: It should be pointed out that an existing founda-
tion which is oil soaked should not be used.
Foundation bolts cannot be sufficiently bonded
in oil soaked concrete..
a. To locate the hold down bolts, set the compressor
in the desired location and mark or scribe the
bolt's locations.
b. Remove the compressor and drill 2 inch (51 mm)
diameter holes at least 6 inches (152 mm) deep.
When the hole is drilled to the desired depth, tip
and rotate the drill in such a manner to widen the
bottom of the hole. Avoid drilling through the con-
crete. If the bottom breaks out of the hole it must be
plugged to prevent wasting of cement.
c. Blow all loose particles from the holes and thor-
oughly wet the hole's surface. Blow out any excess
water.
d. Lift the compressor and place the hold down bolts
in its base with about 1/8 inch (3.2 mm) of bolt
projecting above the nut. Set the compressor in place
with the bolts hanging in the holes (see Figure 4).
e. Level the compressor using metal wedges or plates to
provide approximately 3/4 inch (19 mm) of grout
between it and the foundation. Remove the com-
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Figure 4. Alternate Foundation Bolting
pressor frame top cover and place a level on the
finished surface for leveling in both directions. ?
f. Mix a small quantity of the non-shrink or epoxy type
cement to pouring consistance. Carefully follow the
mixing instructions on the package. Thoroughly mix
the cement and pour it into the holes, filling them
flush to the floor. Most cements of this type set
quickly and care should be taken not to mix more
than can be used within a given period.
g. Generally the compressor can be grouted an hour
after the cement has set (see grouting instructions
on Page 10). However, it is best to follow the pack-
age instructions for setting and hardening time. The
mounting bolts should not be tightened until the
cement and grout have thoroughly hardened.
5. Pouring the Foundation
a. Check the lodation and height of all foundation bolts
before pouring your foundation.
b. Pour concrete to bottom of template and leave top
surface rought to accomodate grout.
c. Cover the foundation with burlap and wet it down
twice a day until forms are removed at the end of the
thrid or fourth day.
There should be a total elapsed time of twenty-one days
between the pouring of the foundation and the starting
of the compressor, using the mixture above. If it is desired
to reduce this time through the use of a quick drying
cement, the cement manufacture should be consulted as
to the possible saving.
4. Foundation Mixture
Concrete-A good strength mixture for the foundation
consists of:
Cement 1 part
Sand (clean & sharp) 2 parts
Crushed Stone or Gravel 4 parts
SETTING THE COMPRESSOR
(See Figure 5.)
1. Roughen the foundation with a star chisel and thoroughly
clean the surface.
2. Remove waste from around the foundation bolts.
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SEE FOUNDATION PLAN FOR
DISTANCE FROM TOP OF ROUGH
FOUNDATION TO TOP OF BOLT.
FINISH
LINE
STUFF WASTE IN PIPE AROUND
BOLT WHEN POURING ROUGH
FOUNDATION. REMOVE WASTE
AFTER SETTING COMPRESSOR
AND FILL PIPE WITH GROUT.
I
TOP OF ROUGH
FOUNDATION
SEE FOUNDATION PLAN
FOR DISTANCE FROM TOP
OF ROUGH FOUNDATION
TO TOP OF BOLT.
ff~~ D
17a~o0
STUFF WASTE IN PIPE AROUND
BOLT WHEN POURING ROUGH
FOUNDATION. REMOVE WASTE
AFTER SETTING COMPRESSOR
AND FILL PIPE WITH GROUT.
TOP OF ROUGH
Fn1IrvnATION
do o
3. Prepare enough metal wedges to allow one to be placed
near each foundation bolt. The wedges must be thick
enough to allow approximately 3/4" (i9 mm) of
grout between the bottom of the : Unessor frame
(sub-base) and the top of the fount: . when the unit
is in its final level position.
4. Wedges should be placed so the bottom of the frame
(sub-base) is about 1/4" (6 mm) below its final setting.
5. Drive in the wedge a little at a time and in rotation until
the frame (sub-base) is up to the desired height and level
in both directions.
6. On skid mounted units loosen all bolts between the
compressor frame and its skid. All frame feet should be
probed with feelers to assure the frame is sitting flat
on the skid. If it is not sitting flat, adjust by driving
wedges between the skid and the foundation top until
the compressor is flat and uniformly supported by all
feet and the top of the skid. The object is to make the
unit sit flat on top of the skid. The skid should be com-
pletely filled grout to provide firm support and max-
imum rigidity.
7. When the unit is level, place washers and nuts over the
foundation bolts and tighten them down a little at a time
in rotation. At the same time, check with the level to
make sure the compressor does not shift on the wedges.
8. On frame grouted units check the alignment of the
motor sheave with the compressor sheave; they must
be parallel. The motor location, with respect to the
base, should allow sufficient movement to install and
adjust the V-belts.
1. A non-shrinking or epoxy type grout is strongly rec-
ommended for grouting the compressor frame (sub-base)
to the foundation. In either case it is important that the
manufacturor's instructions be followed. In the event
that non-shrinking grout is not available, prepare a mix-
ture of two parts clean sharp sand to one part cement,
thoroughly mixed with water so that it will just flow
freely. Do not use any more water than necessary to
avoid excessive shrinkage.
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2. Before grouting make a final check on level and align-
ment or compressor.
3. Build a temporary dam of boards around the top of the
foundation about 2" or 3" (50 mm or 76 mm) higher
than the bottom of the frame (sub-base). The gout will
be carried up under the compressor to the full height.of
the dam. Mark the location of the wedges so they can be
removed after the grout has started to set. Prepare a
sufficient amount of grout.
4. Wet the top of the foundation thoroughly, but avoid leav-
ing puddles. Blow any water out of the foundation bolt
holes with an air hose. Puddle the grout continuously as
it is poured to remove any air pockets. Be sure to work
the grout into the holes around the foundation bolts.
5. As soon as the grout has started to set, remove the forms,
cut off the grout flush with the bottom edge of the
frame (sub-base), trowel smooth and point up the
foundation. After the initial set of the grout, (not
less than 24 hours), PULL OUT THE ADJUSTING
WEDGES AND PATCH. After the grout has thoroughly
set, (three or four days), check the foundation bolts to
see that they are tight.
FOUNDATION FINISHING
(See Figure 6.)
If non-shrinking grout is used, remove th? grout down to
the foundation on all surfaces that extend beyond the
frame. This area should be filled in with regular cement and
grouts, they must not be used in places where they are not
sand grout. Because of the expanding ability of non-shrink
confined by the frame. Non-shrink grouts will ravel and
provide a bad appearance, and will sometimes fail physi-
cally when applied to an open area.
After the concrete work is finished, the foundation should
be painted with a good water proof and oil proof cement
paint, to prevent oil from softing the foundation.
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NOTES
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SECTION I I I
AIR SYSTEM INSTALLATION
Although the use of clean piping is important on any
compressor, it is vital in "NL" service. Dirt, scale, welding
beads, or any type of foreign matter from piping that has
not been properly cleaned will promote wear and failures
with resultant expensive shutdowns and replacement of
parts. If practical, use a rust resistant material for the piping.
If steel piping is desired, pickle and clean. Coat with a rust
preventative..
Compressor-Whenever possible the intake of an air
compressor should be piped to the outside of the building
where the coolest and cleanest air is available. In certain
cases, such ,as package units, an alternate system may be
utilized having the intake filter mounted right at the
cylinder.
Where piping is used the following precautions should be
followed. Locate the end of the intake pipe so that waste
being discharged from pipes near it can not be drawn into
the compressor intake. The piping should be well supported
and slope away from the compressor cylinder thus pre-
venting any condensation from draining into the cylinder.
Moisture in the cylinder will cause accelerated wear of rub-
bing parts.
Piping should be fabricated with sufficient joints so that
it can be dismantled easily for cleaning and testing. It is
better to clean and test piping in sections before actual
erection than after it is in place. If iron piping is used on
the inlet piping we recommend the pipe be pickled. Non-
lubricated compressor's inlet pipe should be of non-corrosive
material such as aluminum, stainless steel, or plastic.
Vacuum Pump-Where a vacuum pump is working on a
high vacuum, a very slight leakage either into the pump or
into the system makes all the difference between good and
poor performance. It is, therefore, very important to take
every precaution to eliminate such leakage.
If the vacuum system should contain any dust or other
abrasive material, a filter must be installed. Such materials,
if carried into the cylinder, will cause rapid wear of the
piston and cylinder and will promote the formation of car-
bon on the valves.
It is equally important to safeguard against moisture
being drawn into the cylinder. Moisture will wash away the
cylinder lubricant, and if large quantities should accumulate
in the intake pipe and be drawn into the cylinder, the non-
compressibility of the liquid may cause breakage of parts.
For these reasons, give careful attention to the piping'lay-
out. Arrange the piping so that moisture will not drain
back into the cylinder and provide for draining low spots.
Follow the suggestions shown in Figure 7.
Care should be taken to assure that the inlet piping
slopes away from the cylinder. Should condensate
drain into the cylinder accelerated wear and/or
possible damage may occur.
The size of the intake connection is indicated on the
foundation plan. Do not reduce the size intake pipe from
that shown on the plan. See the foundation plan for crit-
ical lengths to avoid.
CLEAN PIPING CAN NOT BE OVER-EMPHASIZED.
Any dirt, rust, welding beads or scale carried into
the compressor will cause extensive damage.
C The use of backing-up rings for butt welds in piping is
recommended. This will prevent welding beads getting into
the piping and causing damage.
Temporary Line Filter-When first starting, it is ad-
visable to use a temporary line filter in the intake line
near the compressor to catch any dirt, chips, or other
foreign material that may have been left in the pipe. But
clean the pipe first. Do not depend on a temporary line
filter.
Even though the previous cleaning procedure has been
carefully followed on the compressor piping, a temporary
filter should be installed in the suction line to the suction
bottle to remove particles 230 microns (.009 in. [.228
mm]) in diameter or larger. This filter is to be supplied by
the customer.. If the compressor is a non-lubricated design,
the filter should be designed to remove particles 140
microns (.0055 in. [.1397 mm]) in diameter or larger.
Provision must be made in the piping to check the pressure
drop across the filter and to remove the filter cell for
cleaning. If pressure drop across the filter exceeds five
percent of the upstream line pressure, remove the filter,
clean it thoroughly and re-install. The filter cell should be
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. r /
/ " GLOBE VALVE
r= i
GATE VALVE
\ I 1
GLOBE VALVE
-~ L
DISCHARGE
AT
ATMOSPHERE
DRAIN
FREQUENTLY
A TANK CONNECTED TO
THIS TO ACT AS A COL-
LECTING BASIN IS THE
BEST ARRANGEMENT.
DRAIN
LEAVE OPEN TO
SEWER-DO NOT VALVE
WHEN DISCHARGING AT
ATMOSPHERE
removed and left out only when the inlet line is free of
welding beads, pipe scale and other extraneous matter.
THESE FILTERS ARE NOT INTENDED FOR PER-
MANENT INSTALLATIONS. A typical installation with
pressure drop gauge is illustrated in Figure 8.
We recommend that a cone, screen type filter, as illus-
trated, be installed in a horizontal run of piping for ease of
cleaning out dirt on the upstream side of the filter.
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11 I_ - l
GATE VALVE I - -
OPEN TO ATMOSPHERE F- - -~
FIRST STAGE
INTAKE
DRAIN
CONNECTING TO
COLLECTING TANK
IS THE BEST METHOD
1
T-'
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10 G.A. WIRE HOOPS
O;
FILTER SCREEN
EQUALLY SPACED-SEE
~~ /
LL
PERFORATED PLATE
TABLE FOR
QUANTITY "
"
1/8" DIA HOLES
N
3116" STAGGER PITCH
BACKUP SCREEN
SEE TABLE FOR GAGE
STANDARD FILTER-FRAME CARBON STEEL, SCREENS & HOOPS OF BRONZE.
BACK UP SCREEN - .01 7" DIA WIRE 30 MESH - 410 MICRON OPENING
FILTER SCREEN.0075" " " 60 " 230
SPECIAL FILTER-ALL PARTS OF STAINLESS STEEL
BACK UP SCREEN -.017" DIA WIRE 30 MESH - 410 MICRON OPENING
FILTER SCREEN - -0045" " " 100 " 140
NOTE: NECESSARY PROVISION MUST BE MADE
IN PIPING FOR REMOVAL OF FILTER
FOR INSPECTION AND CLEANING.
PERFORATED PLATE
MAX DIFFERENTIAL
PRESS ON FILTJER
NOMINAL
PIPE SIZE
14GA
STL
STEEL
16GA
STL
STEEL
14GA
CARE
STEEL
16GA
CARB
STEEL
24
70
55
55
45
20
85
65
65
50
18
95
70
70
60
16
105
80
80
65
14
120
80
90
75
12
130
100
100
80
10
160
120
120
100
8
200
150
150
120
6
250
190
190
160
4
325
245
245
230
3
400
325
325
300
2ii
500
400
400
350
2
600
500
500
425
NOTE: SPECIAL FILTERS RECOMMENDED FOR ALL NONLUBRICATED
FILTER ELEMENT MAYBE SUBJECTED TO ATMOSPHERES
CORROSIVE TO BRONZE AND CARBON STEEL. ALL OTHER
APPLICATONS USE STANDARD FILTERS.
NOTE: FILTER SCREEN AND EACKUP SCREEN MUST
COVER FULL SLANT HEIGHT OF CONE AND BE
SECURELY WELDED OR BRAZED TO CONE. FILTER
WILL BE SUBJECTED TO PULSATING FLOW AND
MAY ALSO BE SUBJECTED TO FLOW REVERSAL
NOTE: ONLY THE WALL OF THE CONE IS PERFORATED-
END PLATE, BACKING RING AND FLANGE OF THE
FILTER ARE NOT PERFORATED
Inlet Filter-An air intake filter is recommended as an
excellent investment as it will remove harmful dust and
dirt from air that is usually considered clean. Locate the
filter, outside, if possible, in an accessible position to
facilitate cleaning from time to time. The filter element
should be protected from the weather.
Should it be impossible or impractical to run the intake
to the outside of the building, and the ambient temperatures
are not excessive, the air may be taken into the cylinder di-
rectly from the room. However, the room must have ade-
gquate ventilation in order for the compressor to operate
efficiently.
alleviate strain on the compressor cylinder. Flange gaskets
(if applicable) in the discharge line should be of some oil
proof material. Care should be taken to assure that the
piping and aftercooler are sloped away from the compressor
to prevent condensate from draining back and damaging
the cylinder.
CAUTION
DISCHARGE PIPING
Compressor-Discharge piping should be as. large as the
connection on the cylinder and be as short and direct with
as few elbows as possible. It should be well supported to
NEVER INSTALL A SHUT OFF VALVE BETWEEN
THE COMPRESSOR AND AIR RECEIVER OR
AFTERCOOLER UNLESS A SAFETY VALVE IS
PUT IN THE PIPING BETWEEN THE VALVE AND
COMPRESSOR.
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 Approved For Release 2007/09/08: CIA-RDP02-06298R000900030006-6
Vacuum Pump-If the vacuum pump discharges to at-
mosphere, it should be protected so that moisture, dust, or
other waste materials will not carry back into the cylinder.
When the vacuum pump handles saturated air at the inlet,
considerable condensation often occurs in the discharge
pipe. This will eventually 'become a source of trouble un-
less precautions are taken to drain the condensation away
from the cylinder. Figure 7 illustrates how this can be done.
Aftercooler and Separator-An aftercooler is a wise invest-
ment and is recommended for most compressor systems.
It not only lowers the discharge air temperature, but also
used in conjunction with a separator, removes harmful
condensation from the air. The aftercooler should be
located as close to the compressor as possible and acces-
sible for easy cleaning.
Receiver-A receiver is recommended to efficiently
control load cycles and minimize air piping pulsation. The
receiver can be installed inside or outside but should be
placed as close as possible to the aftercooler so as to keep
the discharge pipe short. Installing the receiver outside the
building aids in radiating some additional heat. However, in
colder climates the receiver should be adequately protected
from freezing.
3. Assemble bushing and sheave as shown in Figure 9.
Cap screws should be loosely inserted so that the bush-
ing remains fully expanded to assure a sliding fit on
shaft. Bushing and sheave should be assembled using
mounting style 1 or 2 depending on distance required
from compressor centerline to side of sheave, as shown
on foundation plan.
COMPRESSOR
SIDE
Nm
COMPRESSOR
SIDE
COOLING WATER
Cooling water removes compression heat from the
cylinder and aftercooler. Clean, soft water should be used
in cylinder jackets to permit effective heat transfer,
minimize plugging of water passages and allow for uniform
heat distribution.
Water pressure in the cylinder jacket should not exceed:
Pressure
Cylinder Size (Diameter)
psi (bar)
inch (millimeter)
75
(5.17)
up to 15 (381)
40
(2.76)
16 to 20 (406 to 508)
30
(2.07)
above 20 (508)
Compressor V-Belt drives are often shipped unattached
and must be assembled in the field.
1. Thoroughly clean tapered surface of busing and sheave.
2. Coat the outside of the split tapered bushing, the inside
diameter of the tapered wheel, hub and portion of the
crankshaft where the wheel is assembled, with moly-
bdenum disulfide or white lead and oil to prevent parts
seizing.
N
om
i
Figure 9. Assembly of Sheave and Bushing
4. With the key in position, slide the sheave on to the
crankshaft to the dimension given on the foundation
plan. Tighten bushing screws evenly and progressively.
Never allow the sheave to be drawn in contact with
flange of bushing. This gap should be from 1/8" to
1/4" (3.18 to 6.35 mm).
5. On package units the complete V-belt drive is installed
by the factory. If any of the components have to be re-
moved in the field, care should be taken to reinstall the
parts in their original position.
Electrical-Wiring diagrams may be found in Sections 8A
through 8C of the Maintenance Instructions. All wiring
should be in accordance with sound practice and state and
local codes.
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 Approved For Release 2007/09/08: CIA-RDP02-06298R000900030006-6
C
c
SECTION I V
GENERAL INFORMATION
COMPRESSOR ACCESSORIES
Solenoid Operated Water Valve* *-Automatically shuts
off cooling water when compressor is stopped. Required
with dual control or tendamatic-located in water inlet line.
Safety Valve**-Each compressor discharge line should
have at least one safety valve between the compressor dis-
charge connection and the first air line valve. The standard
air receiver safety valve provides this protection only if no
air line valves are located in the piping between the com-
pressor discharge and the receiver.
High Discharge Air Temperature Shutdown Switch**-
Automatically stops compressor in event of high discharge
air temperature. Located in customer discharge piping as
close to the compressor as possible.
Low Cooling Water Pressure Shutdown Switch-Auto-
matically stops compressor in event of low cooling water
pressure. Located in water inlet line.
Lubricator Line Alert Switch*-Can be wired to motor
shutdown circuit or adapted to visual or audible signal to
indicate loss of cylinder lubricator oil flow.
Thermostatic Water Control Valve-Used to maintain
optimum water flow and constant water temperature con-
sistent with compressor demand.
Lubricator Heater*-Installed in the lubricator reservoir.
Recommended when ambient temperature at compressor
could tesult in poor oil flow.
Crankcase Heater*-Inserted in the crankcase. Recom-
mended when ambient temperature at compressor could
result in poor oil flow.
Cylinder Jacket Water Heater*-To maintain cylinder
wall temperature above ambient during compressor shut
down to prevent moisture condensation and subsequent
corrosion. To prevent cylinder jacket water from freezing on
outdoor installation. Mounted in cylinder or water piping
depending on cylinder desing. Cylinder jacket water heaters
are recommended by Ingersoll-Rand Company for NL
compressors.
Vibration Switch* -Automatically will shut the machine
down when vibration reaches an unsafe level. Cylinder
mounted.
Closed Sight Flow Indicator-A visual check on water
flow in a closed system. Located in water discharge piping.
High Oil Temperature Shutdown Switch*-Automatically
stops compressor in the event of high frame oil temperature
located on the compressor frame.
COMPRESSOR ACCESSORIES WHICH ARE STANDARD
ON PACKAGE UNITS.
THESE ITEMS ARE FACTORY MOUNTED.
Dual Control Regulation* *-Permits the operation of a
compressor with either constant speed regulation or auto-
matic-start and stop regulation.
Tendamatic Control Panel-Is an operator's control panel
also a warning and protection system which provides the
highest possible automatic control of your compressor.
PACKAGE UNIT INSTALLATION
With the purchase of a package air plant, you have all the
advantages of the frame grouted compressor plus the conven-
ience of having the compressor and all its system com-
ponents mounted upon a single sub-base. Follow the in-
stallation instructions from pages 3 to 7 to obtain a suitable
foundation for your package unit. The exact terminology
of the frame grouted compressor and sub-base grouted
compressor may vary slightly. The correct word or phrase
for the installation of a sub-base mounted compressor will
follow immediately in parentheses ( ). Once a suitable
foundation has been erected, connect your package air
plant by completing the following five steps.
1. Electrical wiring of the correct size to carry the voltage
designated on the control panel nameplate must be in-
stalled.
All electrical wiring should be installed to comply with
local and national electrical codes. A disconnect switch
or circuit breaker is required in the electrical supply line
leading to the compressor.
2. Connect cooling water inlet and discharge piping. REFER
TO COMPRESSOR FOUNDATION PLAN FOR PIPING
LOCATIONS.
a. The water inlet connection leads through the water so-
lenoid valve to the aftercooler.
b. The cooling water is discharged from the top of the
compressor cylinder head.
c. A drain line is provided from the condensate trap.
3. An air intake filter and silencer is mounted on the com-
pressor. However, it may be desirable to pipe the air in-
take to an outside source to allow cooler inlet air. If this
is done, a filter adapted for outside use should be pur-
chased and it should be installed within a hood to shelter
it from the weather.
4. The air discharge connection, located in the receiver tank,
is provided for connecting the package unit to the plant
air line.
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 Approved For Release 2007/09/08: CIA-RDP02-06298R000900030006-6
TYPICAL WATER PIPING
SOLENOID
WATER
VALVE
I AFTERCOOLER
OPTIONAL PARALLEL WATER PIPING
DRYER
STANDARD-OPEN FUNNEL
OPTION- CLOSED SIGHT
FLOW INDICATOR
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LEGEND
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