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.
EP/HP/HXP 20 SE
EP/HP/HXP 25 SE
OPERATORS/
INSTRUCTION MANUAL
OPTIONS
®
APDD 567A
September 1998
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Table of Contents
Related Manuals for Ingersoll-Rand EP 25 SE
Summarization of Contents
Warranty Information
Bonded Warranty & Registered Start Up
Details standard warranty terms and conditions for the compressor unit.
Limitation or Liability
Outlines limitations on the company's liability regarding product performance and defects.
Extended Airend Warranty
Specifies terms for the extended warranty applicable to the airend component.
Safety and Warnings
Safety Instructions
General guidelines for safe operation and maintenance of the air compressor.
Safety Precautions
Specific safety measures to be taken before operating or performing maintenance.
Safety Shutdown Procedures and Warnings
Critical safety alerts and shutdown procedures for operation, including high temperature.
Decals and Labels
Decal Identification
Shows examples of safety and warning decals applied to the compressor unit.
Intellisys Controller Operations
Intellisys Operating Instructions
Explains how to start, stop, and operate the Intellisys controller.
Equipment Receipt and Handling
Inspection Upon Arrival
Procedure for checking shipment for damages or discrepancies.
Unpacking and Handling
Guidelines for safely unpacking and moving the compressor unit.
Required Tools for Unpacking
Lists essential tools needed for unpacking the compressor.
Installation Procedures
Ventilation Requirements
Specifies air flow and clearance needs for proper compressor operation.
Foundation Requirements
Guidance on selecting and preparing the installation base for the compressor.
Piping Guidelines
Recommendations for air and coolant piping installation to ensure efficiency and safety.
Electrical Installation
Details connecting power, wiring, and checks for the starter box.
Outdoor Installation Guidelines
Sheltered Outdoor Installation
Specific requirements for outdoor placement and protection of the unit.
Intellisys Control Functions
Controller Display and Buttons
Overview of the Intellisys controller's layout, display, and primary buttons.
Emergency Stop Switch
How to use the emergency stop button for immediate shutdown.
Power Indicators
Description of power on and indicator lights for system status.
Push Buttons Overview
Explanation of START, UNLOAD/LOAD, and UNLOADED STOP buttons.
Display Select and Set Buttons
Functionality of display select, set, and arrow buttons for navigation.
Pressure Sensor Calibration
Procedure for zeroing the pressure sensor for accurate readings.
Controller Settings and Warnings
Set Point Procedure
Guide to modifying controller variables and operating parameters.
System Warnings
Explanation of common system warnings and their potential causes.
System Alarms and Faults
Alarm Messages
List and description of various alarm conditions for troubleshooting.
Emergency Stop Alarm
Specific handling and reset procedure for the emergency stop alarm.
System Components and Design
General System Overview
Description of the compressor package and its main functional parts.
Air-Cooled Compressor Details
Design temperatures and information on the coolant cooler.
Coolant System Function
Explains how the coolant system operates to maintain optimal temperatures.
Compressed Air System
Components and function of the air processing system.
Coolant/Air Separation
Details how coolant is removed from the compressed air stream.
System Operation and Control
Electrical System and Controls
Description of electrical components and Intellisys controller integration.
Capacity Control Modes
Explanation of different operating modes like On-Off Line and Modulation.
Control Valve Adjustments
Modulate Control Valve Adjustment
Procedure for setting the modulation control valve for optimal performance.
Scheduled Preventative Maintenance
Maintenance Schedule
Recommended service intervals and tasks for keeping the compressor in good condition.
Maintenance Records
Importance of keeping accurate logs of all maintenance performed.
Maintenance Procedures
General guidelines to follow before commencing any maintenance work.
Drive System Maintenance
Sheave Alignment
Procedure for ensuring proper sheave alignment to prevent belt wear.
Belt System Maintenance
V-Belt Replacement
Steps for replacing and installing V-belts for the compressor drive.
Belt Tensioning
Belt Tension Adjustment
Method for setting correct belt tension to ensure proper efficiency.
Seal Maintenance
Shaft Seal Replacement
Procedure for replacing compressor shaft seals.
Filtration System Maintenance
Inlet Air Filter Replacement
How and when to replace the inlet air filter for optimal performance.
Coolant Filter Element Replacement
Procedure for changing the coolant filter element.
Coolant and Separator Maintenance
Coolant Management
Information on coolant types, change intervals, and filling procedures.
Separator Tank Scavenge Maintenance
Servicing the check valve, screen, and orifice in the separator tank.
Component Replacements
Temperature Control Valve Replacement
Procedure for replacing the temperature control valve element.
Coolant Separator Element Replacement
Steps to replace the coolant separator element.
Cooling System Cleaning
Cooler Cores Cleaning
Instructions for cleaning the coolant cooler and aftercooler cores.
Motor Maintenance
Motor Lubrication
Guidelines for lubricating motor bearings, including intervals and amounts.
Special Procedures
Long Term Storage
Procedures for preparing units for extended storage.
Coolant/Lubricant Changeout
Guidance on changing coolant and lubricants if necessary.
Intellisys Controller Removal
Steps for safely removing the Intellisys controller from the unit.
Hose System Maintenance
Coolant Hose Replacement
Instructions for replacing coolant hoses that may become brittle.
Airend Discharge Hose Replacement
Procedure for replacing the hose from the airend discharge to the separator tank.
Troubleshooting Guide
Troubleshooting Chart
Common problems, their causes, and recommended solutions.
Optional Features and Accessories
Remote Start/Stop Option
How to use remote start/stop functionality with the Intellisys system.
Remote Start/Stop and Power Outage Restart
Combined option for remote control and automatic restart after power interruptions.
Sequencer Control Option
Adding sequencer capability to manage multiple compressors.
Reference Drawings and Schematics
Full Voltage Electrical Schematic
Wiring diagram for systems using a full voltage starter.
Star-Delta Electrical Schematic
Wiring diagram for systems using a star-delta starter.
Remote Mounted Starter Schematic
Wiring diagram for systems with a remote mounted starter.
Foundation Plans
Enclosed Unit Foundation Plan
Dimensional drawings for the base of an enclosed compressor unit.
Unenclosed Unit Foundation Plan
Dimensional drawings for the base of an unenclosed compressor unit.
Outdoor Modification Foundation Plan
Dimensional drawings for the base of an outdoor modified compressor unit.
System Flow Diagrams
Full Voltage Basic Flow Schematic
Diagram showing air and coolant flow paths for full voltage systems.
Full Voltage with Modulation Schematic
Diagram illustrating modulated flow paths for full voltage systems.
Star-Delta Basic Flow Schematic
Diagram showing air and coolant flow for star-delta systems.
Star-Delta with Modulation Schematic
Diagram illustrating modulated flow for star-delta systems.
Receiver and Dryer Integration
Diagrams illustrating system integration with receivers and dryers.
Dryer Types and Air Quality Monitoring
Diagrams for specialized dryers and air quality monitoring devices.
Pre-filter and Bypass Configurations
Diagrams showing pre-filter and bypass arrangements in the air system.
Dry Receiver and Monitoring Devices
Diagrams for dry receivers and air quality sensors.
Pipeline Aftercooler System Diagram
Diagram of a system incorporating a pipeline aftercooler.
Maintenance Records
Maintenance Log
Forms provided for recording service history and maintenance activities.
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