Table of Contents
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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.
More Than Air. Answers.
Online answers: http://www.air.irco.com
Phone: 1-800-526-3615
CCN: 80440332 REV: C
XFE/EPE/HPE 50
XF/EP/HP 60
XF/EP/HP/XP 75-100
ML/MM/MH 37-75
OPERATORS/
INSTRUCTION MANUAL
OPTIONS
FORM: APDD 696C
July 2002
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Table of Contents
Related Manuals for Ingersoll-Rand HP 60
Summarization of Contents
SAFETY AND WARNINGS
SAFETY INSTRUCTIONS
General instructions for safe installation, operation, and maintenance.
SAFETY PRECAUTIONS
Specific precautions to prevent injury or damage during operation.
RECEIPT OF EQUIPMENT
INSPECTION
Procedures for inspecting the compressor upon delivery for damage or discrepancies.
UNPACKING AND HANDLING
Guidelines for safely unpacking and moving the compressor unit.
TOOLS
List of tools required for initial setup and unpacking.
INSTALLATION
VENTILATION
Requirements for proper airflow and heat dissipation around the compressor.
FOUNDATION REQUIREMENTS
Guidelines for preparing a stable and level foundation for the compressor.
PIPING
Recommendations and warnings for connecting air and coolant piping.
ELECTRICAL INSTALLATION
Rotation Check
Procedures to verify correct motor rotation direction.
INTELLISYS
EMERGENCY STOP SWITCH
Function and operation of the emergency stop button for immediate shutdown.
POWER ON LIGHT (Inside Starter Box)
Indicates availability of control and line voltage for starting.
POWER INDICATOR LIGHT
Indicates voltage availability to the Intellisys controller.
PUSH BUTTONS
Description of the main control panel buttons (Start, Unload/Stop, etc.).
PRESSURE SENSOR CALIBRATION (ZEROING) ROUTINE
Procedure for calibrating the pressure sensor on the Intellisys controller.
SYSTEMS
GENERAL SYSTEM INFORMATION
Overview of the compressor package and its main components.
AIR COOLED COMPRESSORS
Specifics related to air-cooled compressor design and operation.
COOLANT SYSTEM
Details on the compressor's coolant circulation and temperature control system.
COMPRESSED AIR SYSTEM
Components and operation of the air intake, compression, and discharge system.
COOLANT/AIR SEPARATION SYSTEM
How the coolant is separated from the compressed air.
ELECTRICAL SYSTEM
Overview of the electrical components and controller integration.
COMPRESSOR CONTROL SYSTEM
Automatic Unloaded Start
Procedure for starting the compressor unloaded to ensure proper lubrication.
On/Off Line Control
How the compressor operates at full capacity or unloads based on system pressure.
Delay Load Time
Setting the time delay before the compressor loads or starts.
Unloaded Stop
How the compressor stops after running unloaded for a specified period.
Automatic Start/Stop Control
System for automatically controlling compressor operation based on demand.
OPTIONS
Starter Options
Details on different starter types for the compressor motor.
Remote Start/Stop
How to set up and use remote start/stop functionality.
Power Outage Restart
Functionality for automatic restart after a power interruption.
Sequencer Control
Capability to add sequencer control for multiple compressors.
Modulation
Explanation of modulation control modes for matching system demand.
Modulate Control Valve Adjustment
Step-by-step guide to adjust the modulation control valve.
SCHEDULED PREVENTATIVE MAINTENANCE
MAINTENANCE SCHEDULE
Table outlining required maintenance tasks and intervals.
MAINTENANCE RECORDS
Importance of keeping detailed records of all maintenance performed.
MAINTENANCE PROCEDURES
General procedures and safety checks before performing maintenance.
INLET AIR FILTER
Instructions for inspecting and replacing the inlet air filter.
COOLANT FILTER
Instructions for replacing the coolant filter element.
COOLANT
Information on coolant types, fill quantities, and draining procedures.
SEPARATOR TANK SCAVENGE SCREEN/ORIFICE
Procedure for cleaning the separator tank's scavenge screen and orifice.
COOLANT SEPARATOR ELEMENT
How to check and replace the coolant separator element.
COOLER CORES: CLEANING
Air Cooled Coolers
Procedures for cleaning the air-cooled heat exchangers.
Water Cooled Coolers
Procedures for inspecting and cleaning water-cooled heat exchangers.
MOTOR LUBRICATION
Motor Bearing Maintenance (Stored Units)
Maintenance for motor bearings on units intended for storage.
LONG TERM STORAGE
COOLANT/LUBRICANT CHANGEOUT
Guidance on changing coolant and lubricant, if necessary.
INTELLISYS REMOVAL
Steps for safely removing the Intellisys controller from the unit.
COOLANT HOSES
AIREND DISCHARGE HOSE
Information on inspecting and replacing the airend discharge hose.
FLUID AND VIBRATION MONITORING
Importance of predictive maintenance using fluid and vibration analysis.
COOLANT SAMPLING PROCEDURE
Procedure for drawing and analyzing coolant samples.
REFERENCE DRAWINGS
ELECTRICAL SCHEMATIC-FULL VOLTAGE
Wiring diagram for full voltage electrical systems.
ELECTRICAL SCHEMATIC-STAR-DELTA
Wiring diagram for star-delta electrical systems.
FOUNDATION PLAN (AIR COOLED)
Dimensional drawings and requirements for air-cooled compressor foundations.
FOUNDATION PLAN (WATER COOLED)
Dimensional drawings and requirements for water-cooled compressor foundations.
FOUNDATION PLAN - OUTDOOR MOD
Dimensional drawings for outdoor modification foundation plans.
BASIC FLOW SCHEMATIC - AIR COOLED
Schematic illustrating the air flow paths in an air-cooled compressor.
BASIC FLOW SCHEMATIC - WATER COOLED
Schematic illustrating the fluid and air flow paths in a water-cooled compressor.
TYPICAL SYSTEM FLOW DIAGRAMS
Diagrams illustrating various system configurations and piping.
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