Ingersoll-Rand HP 60 User Manual

XFE/EPE/HPE 50
XF/EP/HP 60
XF/EP/HP/XP 75-100
ML/MM/MH 37-75
OPERATORS/
INSTRUCTION MANUAL
OPTIONS
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.
FORM: APDD 696C
July 2002
More Than Air. Answers.
Online answers: http://www.air.irco.com
Phone: 1-800-526-3615
CCN: 80440332 REV: C

Ingersoll-Rand HP 60 Specifications

General

Brand	Ingersoll-Rand
Model	HP 60
Category	Air Compressor
Language	English

Summary

0.0 SAFETY AND WARNINGS

0.1 SAFETY INSTRUCTIONS

Reading manual, hazard awareness, common sense, qualified maintenance.

0.2 SAFETY PRECAUTIONS

Explanation of DANGER, WARNING, CAUTION, NOTICE signal words.

SAFETY SHUTDOWN AND GENERAL WARNINGS

HIGH AIR TEMPERATURE SHUTDOWN CHECK

Procedure to check the high discharge air temperature shutdown function.

OPERATIONAL SAFETY WARNINGS

FAN BLADE, MOVING PARTS, AND ROTATION SAFETY

Safety warnings regarding exposed fan blades, moving parts, and correct motor rotation.

ADDITIONAL SAFETY NOTICES

HOT SURFACES AND COOLANT HANDLING SAFETY

Warnings about hot surfaces and safe handling of hot coolant during servicing.

HIGH PRESSURE AIR AND COOLANT FILTER SAFETY

Safety warnings concerning high-pressure air and proper coolant filter replacement.

ELECTRICAL AND CONTROL SYSTEM SAFETY

HAZARDOUS VOLTAGE AND POWER INLET SAFETY

Warnings about hazardous voltage and proper electrical power inlet connections.

2.0 INSTALLATION GUIDELINES

2.1 VENTILATION REQUIREMENTS

Guidelines for ensuring adequate ventilation to prevent overheating.

2.2 FOUNDATION REQUIREMENTS

Instructions for selecting and preparing a suitable foundation for the compressor.

2.3 PIPING AND SYSTEM CONNECTIONS

Recommendations for air discharge piping and filter bowl safety.

2.4 ELECTRICAL INSTALLATION

WIRING, FUSES, AND TRANSFORMER DIAGRAMS

Verifying line voltage, starter box, fuse table, and control transformer wiring.

DRIVE MOTOR ROTATION CHECK

Procedure for checking the correct rotation direction of the drive motor.

ELECTRICAL INSTALLATION AND MOTOR CHECKS

DRIVE MOTOR ROTATION VERIFICATION

Detailed steps for verifying drive motor rotation direction.

INTELLISYS CONTROL SYSTEM OPERATION

EMERGENCY STOP AND MAIN DISCONNECT PROCEDURES

Procedures for using the emergency stop and main disconnect switch safely.

FAN MOTOR ROTATION AND STARTUP INSTRUCTIONS

Checking fan motor rotation and Intellisys startup instructions.

2.5 OUTDOOR SHELTERED INSTALLATION

GUIDELINES FOR OUTDOOR INSTALLATIONS

Procedures for installing the compressor in an outdoor sheltered environment.

3.0 INTELLISYS CONTROLLER

INTELLISYS CONTROLLER LAYOUT AND INDICATORS

Overview of the Intellisys controller display, buttons, and indicators.

INTELLISYS CONTROL FUNCTIONS

EMERGENCY STOP AND POWER INDICATOR LIGHTS

Explanation of the emergency stop switch and power indicator lights.

INTELLISYS PUSH BUTTON OPERATIONS

Description of START, UNLOAD/LOAD, and UNLOADED STOP push buttons.

INTELLISYS NAVIGATION AND CALIBRATION

DISPLAY SELECT, SET, AND ARROW BUTTON FUNCTIONS

Functions of DISPLAY SELECT, SET, and ARROWS buttons for navigation and adjustments.

PRESSURE SENSOR CALIBRATION ROUTINE

INTELLISYS SETTINGS AND WARNINGS

SET POINT PROCEDURE AND VARIABLE ADJUSTMENT

WARNING MESSAGES AND RESET PROCEDURES

INTELLISYS ALARMS

LIST OF ALARM MESSAGES AND CAUSES

List of common alarms, their causes, and reset methods.

4.7 COMPRESSOR CONTROL SYSTEM FEATURES

INTELLISYS STANDARD CONTROL FEATURES

COMPRESSOR OPERATING MODES AND TIMERS

AUTOMATIC UNLOADED START AND ON/OFF LINE CONTROL

DELAY LOAD TIME FUNCTIONALITY

COMPRESSOR START/STOP AND LOAD CONTROL

UNLOADED STOP AND AUTOMATIC START/STOP OPERATION

5.0 SCHEDULED PREVENTATIVE MAINTENANCE

5.1 MAINTENANCE SCHEDULE AND INTERVALS

A detailed schedule of maintenance tasks based on running hours or time.

MAINTENANCE MANAGEMENT AND PROCEDURES

5.2 MAINTENANCE RECORDS AND 5.3 PROCEDURES

5.4 INLET AIR FILTER REPLACEMENT

COOLANT FILTER MAINTENANCE

5.5 COOLANT FILTER REPLACEMENT GUIDELINES

COOLANT AND SEPARATOR SYSTEM MAINTENANCE

5.6 COOLANT SPECIFICATIONS AND FILLING

5.7 SEPARATOR TANK SCAVENGE SCREEN/ORIFICE CLEANING

COOLANT SEPARATOR ELEMENT REPLACEMENT

5.8 SEPARATOR ELEMENT INSPECTION AND REPLACEMENT

CLEANING AND LUBRICATION PROCEDURES

5.9 COOLER CORE CLEANING (AIR & WATER COOLED)

5.10 MOTOR LUBRICATION REQUIREMENTS

MOTOR LUBRICATION AND BEARING MAINTENANCE

5.10 MOTOR LUBRICATION PROCEDURES (GREASE APPLICATION)

MOTOR LUBRICATION AND STORAGE PRECAUTIONS

STORAGE, CHANGEOUT, AND CONTROLLER REMOVAL

HOSE REPLACEMENT AND MONITORING

5.14 COOLANT HOSES AND 5.15 AIREND DISCHARGE HOSE REPLACEMENT

6.0 TROUBLE SHOOTING CHART

COMPRESSOR STARTUP AND SHUTDOWN ISSUES

Troubleshooting common problems related to compressor starting and unexpected shutdowns.

AIR PRESSURE AND AIR LEAK TROUBLESHOOTING

ADVANCED TROUBLESHOOTING

COOLANT CONSUMPTION, NOISE, AND VIBRATION ISSUES

PRESSURE RELIEF VALVE AND SYSTEM RELATED ISSUES