EP/HP/HXP 30 SE

EP/HP/HXP 40 SE
ML/MM/MH/MU 22SE
ML/MM/MH/MU 30SE
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.

More Than Air. Answers. APDD 556C

Online answers: http://www.air.ingersoll-rand.com
November 1999
 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 conform 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 furnished by the
Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyed 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 performance
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 MERCHANTABILITY
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
beneficiary 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 replacement
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.

EXTENDED AIREND WARRANTY

The Ingersoll-Rand Company Rotary Screw Air Compressor that has been filled prior to
its original shipment from Ingersoll-Rand Company with ULTRA COOLANT and which
has been operated solely on ULTRA COOLANT thereafter shall have its AIREND
warranted for twenty four (24) months from the date of placing the COMPRESSOR in
operation or thirty (30) months from the date of shipment, whichever occurs first.

Except for the above warranty period, the standard warranty provisions shall apply and the
conditions outlined herein are understood to be a supplement to the standard Ingersoll-
Rand Company warranty.

©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.

Number of units on order: __________________________

Customer Order Number: __________________________

Ingersoll-Rand Company Order Number: ______________

For ready reference, record the serial number and

model number of your unit here:

Serial Number: ___________________________________

Model Number:___________________________________

TYPICAL UNIT

1
 TABLE OF CONTENTS
0.0 SAFETY AND WARNINGS 5.13 cooler cores: cleaning
0.1 safety instructions 5.14 motor lubrication
0.2 safety precautions 5.15 long term storage
0.3 decals 5.16 coolant/lubricant changeout
5.17 intellisys removal
1.0 RECEIPT OF EQUIPMENT 5.18 coolant hoses
1.1 inspection 5.19 airend discharge hose
1.2 unpacking and handling
1.3 tools 6.0 TROUBLE SHOOTING

2.0 INSTALLATION 7.0 OPTIONS

2.1 ventilation
2.2 foundation requirements
2.3 piping
2.4 electrical installation
2.5 outdoor sheltered installation
3.0 INTELLISYS
3.1 emergency stop switch
3.2 power on light
3.3 power indicator light
3.4 push buttons
3.5 set point procedure
3.6 warnings
3.7 alarms
4.0 SYSTEMS
4.1 general systems
4.2 aircooled compressors
4.3 coolant system
4.4 compressed air system
4.5 coolant/air separation system
4.6 electrical system
4.7 capacity control
5.0 MAINTENANCE
5.1 maintenance schedule
5.2 maintenance records
5.3 maintenance procedures
5.4 sheave alignment
5.5 drive belt and gas spring replacement
5.6 shaft seal replacement
5.7 inlet air filter
5.8 coolant filter element
5.9 coolant
5.10 separator tank scavenge
check valve/orifice/screen
5.11 temperature control valve element
replacement
5.12 coolant separator element
7.1 remote start/stop
7.2 remote start/stop, PORO
7.3 sequencer control
8.0 REFERENCE DRAWINGS
8.1 electrical schematic - full voltage
8.2 electrical schematic - star-delta
8.3 foundation plan - enclosed
8.4 foundation plan - unenclosed
8.5 foundation plan - outdoor modification
8.6 basic flow schematic - full voltage
8.7 basic flow schematic - full voltage with
modulation
8.8 basic flow schematic - star-delta
8.9 basic flow schematic - star-delta with
modulation
8.10 typical system flow diagrams
9.0 MAINTENANCE RECORD
GENERAL INFORMATION
Weight: See foundation plan, Section 8.0
Cooling Air Flow: See foundation plan, Section 8.0
Ambient Temperature Limit: 35°F to 115°F (2°C to 46°C)
Coolant: Factory Filled SSR Ultra Coolant
Coolant Change: 8000 hours or two years, whichever
comes first
Coolant Capacity: 30-40 HP (3.2 gal) (12.1 liters)
22-30 KW (3.2 gal) (12.1 liters)
DischargeTemperature Limit: 228°F (109°C)
Power Inlet Wiring: Recommended conduit: metallic
flexible Greenfield, or equivalent,
Tools: U.S. Standard and metric are required

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
time to carefully read all the instructions contained in this as follows:
manual.

Electricity and compressed air have the potential to cause
severe personal injury or property damage.
Before installing, wiring, starting, operating or making any
adjustments, identify the components of the air
compressor using this manual as a guide.
The operator should use common sense and good
working practices while operating and maintaining this
unit. Follow all codes, pipe adequately, understand the
starting and stopping sequence. Check the safety devices
by following the procedure contained in this manual.
Maintenance should be done by qualified pers o n n e l ,
a d e q u a t e ly equipped with proper tools. F o l l ow the
maintenance schedules as outlined in the operators
manual to ensure problem free operation after start up.
0.2 SAFETY PRECAUTIONS
Danger is used to indicate the presence of
D! DANGER a hazard which will cause severe personal
i n j u ry, death, or substantial pro p e rt y
damage if the warning is ignored.
Warning is used to indicate the presence of
! WARNING a hazard which can cause severe personal
i n j u ry, death, or substantial pro p e rt y
damage if the warning is ignored.
Caution is used to indicate the presence of
! CAUTION a hazard which will or can cause minor
personal injury or property damage if the
warning is ignored.
Notice is used to notify people of
NOTICE installation, operation, or maintenance
i n formation which is important but not
hazard-related.

BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
COMPRESSOR OR PERFORMING ANY MAINTENANCE
WARNING
COMPRESSED AIR AND ELECTRICITY
ARE DANGEROUS.
BEFORE DOING ANY WORK ON THIS
UNIT,BE SURE THE ELECTRICAL SUPPLY
HAS BEEN CUT OFF–LOCKED & TAGGED
AND THE ENTIRE COMPRESSOR SYSTEM
HAS BEEN VENTED OF ALL PRESSURE.
1. Do not remove the covers, loosen or
r e m ove any fittings, connections or
devices when this unit is in operation.Hot
liquid and air under pressure that are
contained within this unit can cause
severe injury or death.
2. The compressor has high and
dangerous voltage in the motor starter and
control box. All installations must be in
a c c o rdance with recognized electrical
codes. Before working on the electrical
system, be sure to remove voltage from
the system by use of a manu a l -
disconnect-switch. A circuit breaker or
fuse safety switch must be provided in the
electrical supply line leading to the
compressor.
Those responsible for installation of this
equipment must provide suitable grounds,
maintenance clearance and lightning
arrestors for all electrical components as
stipulated in O.S.H.A. 1910.308 through
1910.329.
SAFETY PRECAUTIONS
3.Do not operate the compressor at higher
discharge pressure than those specified
on the Compressor Nameplate or motor
overload will occur. This condition will
result in compressor motor shutdown.
4. Use only safety solvent for cleaning the
compressor and auxiliary equipment.
5. Install a manual shut off valve (isolation
type) in the discharge line.When a safety
valve is installed between the isolation
valve and the compressor, it must have
sufficient capacity to relieve the full
capacity of the compressor(s).
6.Whenever pressure is released through
the pressure relief va l v e, it is due to
excessive pressure in the system. The
cause for the excessive pressure should
be investigated immediately.
7. Before doing any mechanical work on
the compressor:
a.) Shut the unit down.
b.) Electrically isolate the compressor by
use of the manual disconnect switch in the
power line to the unit. Lock and tag the
switch so that it cannot be operated.
c.) Vent pressure from the compressor and
isolate the unit from any other source of
air.
8. There can be adv e rse effects if
compressor lubricants are allowed to enter
plant air systems.
Air line separators, properly selected and
installed, will minimize any liquid carry-
over.
The use of plastic bowls on line filters
without metal guards can be hazardous.
F rom a safety standpoint, metal bow l s
should be used on any pressurize d
system. R ev i ew of your plant air line
system is recommended.
9. When a receiver is installed, it is
recommended that occupational safe t y
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.
10. B e fore starting the compressor, its
maintenance instructions should be
thoroughly read and understood.
11. After maintenance functions are
completed, covers and guards must be
replaced.

3
 SAFETY SHUTDOWN
CHECK HIGH AIR TEMPERATURE
There is a high discharge air temperature shutdown function built into the Intellisys on each compressor.It is fa c t o ry pre-set
at 228°F (109°C).This function should be checked at regular intervals for proper operation, once a month is recommended.
The procedure is:

1. B l o ck off the cooling air discharge.

2. The compressor discharge temperature will rise at a rapid ra t e.S h u t d own should occur when the discharge
t e m p e rature reaches the pre-set maximum discharge air temperature setting of the Intellisys.The display should
indicate “HIGH AIREND T E M P ” and the alarm light will be illuminated.

The actual temperature at which shutdown occurs should be recorded for comparison to the Intellisys set point and with
similar future test results.

WARNING
Failure to adhere to these recommendations can result in mechanical fa i l u r e, property damage and serious injury or death.

All air and water inlet, and air and water discharge pipewo rk to and from the inlet and discharge port connections must take
into account vibration, pulsations, tempera t u r e, maximum pressure applied, corrosion and chemical resistance.In addition, it
should be noted that lubricated compressors will discharge some oil into the air stream;t h e r e fo r e, compatibility betwe e n
discharge piping, system accessories and software must be assured.

For the foregoing reasons, the use of plastic piping, soldered copper fittings and ru bber hose as discharge piping is not
r e c o m m e n d e d .In addition, flex i ble joints and/or flex lines can only be considered for such purposes if their specifications fit
the operating parameters of the system.

It is the responsibility of the installer and owner to provide the appropriate service pipewo rk to and from the machine.

WARNING
“Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications.Ingersoll-Rand does
not approve specialized equipment for breathing air application and assumes no responsibility or liability for compressors
used for breathing air serv i c e s.”

4
0.3 DECALS

This section contains representative examples of decals recommend that you obtain a replacement kit as listed in
which will be appearing throughout this manual and are the spare parts section of the Parts List Manual (Form
applied to the compressor unit. If for some reason a APDD 750).
decal is defaced, painted over, or parts are replaced, we

39543764

39540224

39559646

39540265

39540182

39541362

39540158

39540240

39570098

39544143

39543921

5
6
7
 39543764 39540174

m3/MIN
BARG
BARG
BARG
KW
KW

39557095 54425996
(30/40 HP) (22/30 KW)

39541354

DOOR REMOVED FOR CLARITY

39540174

39540174

8
1.0 RECEIPT OF EQU I P M E N T
1.1 INSPECTION
When you receive the compressor please inspect it
closely. A ny indication of careless handling by the carri e r
should be noted on the delive ry receipt especially if the
compressor will not be immediately uncra t e d .O b t a i n i n g
the delive ry man’s signed agreement to any noted
damages will facilitate any future insurance claims.

IMPORTANT
READ T H I S
LOST OR DA M AGED GOODS

T H O RO U G H LY INSPECT THIS SHIPMENT

I M M E D I AT E LY UPON ARRIVA L

OUR RESPONSIBILITY FOR THIS SHIPMENT

CEASED WHEN THE CARRIER SIGNED
FORKLIFT PADDING
BILL OF LADING WILL REDUCE SCRATCHES
If goods are received short or in damaged condition, it is important that AND MARS
you notify the carrier and insist on a notation of the loss or damage
across the face of the freight bill.Otherwise no claim can be enfo r c e d
against the tra n s p o rtation company.

If concealed loss or damage is discovered, notify your carrier at once

and request an inspection.This is absolutely necessary.Unless you do
this the carrier will not entertain any claim for loss or damage.The agent SPREADER
will make an inspection and grant a concealed damage notation.If yo u BARS
g i ve the tra n s p o rtation company a clear receipt for goods that have been
damaged or lost in transit, you do so at your own risk and ex p e n s e.

WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE

MANNER TO COLLECT CLAIMS FOR LOSS OR DA M AGE, BUT T H E
WILLINGNESS ON OUR PA RT DOES NOT MAKE US RESPONSIBLE
FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MAT E R I A L .
THE AC T UAL FILING AND PROCESSING OF THE CLAIM IS YO U R
RESPONSIBILITY.

I n ge rs o l l-Rand Company
Davidson, N o rth Caro l i n a
A P D D G F O-9 9-7 9

1.2 UNPACKING AND HANDLING

The compressor package has been mounted on a base
which provides for fo rklifting between the two side
channels to facilitate handling during shipment. Care in
positioning the fo rklifts is important because the location
of the center of gravity is strongly affected by the location
of the compression module and dri ve motor.

Slings can be used to lift the cra t e s, but spreader bars

must be used to prevent the slings from exe rting a fo r c e
against the sides of the cra t e s.

1.3 TO O L S
R e m ove compressor unit from wooden skid. A crow b a r
and hammer will be needed.

9
2.0 INSTA L L AT I O N
2.1 V E N T I L ATION
Oil flooded rotary air compressors produce large
amounts of heat. Because of this large heat production,
the compressor must be placed in a room with adequate
ve n t i l a t i o n .A room in which the amount of air that is
d rawn in and exhausted is equal to or greater than the
cooling fan air flow requirement for the compressor that is
installed.

If heated air from the compressor exhaust is allowed to

recirculate back to the compressor, the compressor will
overheat and shut dow n . This heat must be ex h a u s t e d
f rom the ro o m . You should take this into considera t i o n
when you decide where to place the compressor within
your plant. Consider that the required maintenance
c l e a rance is 3 ft (.9 m) all around the compressor.
H owever 42” (1.06m), or minimum required by latest NEC
or applicable local codes, must be maintained in front of
control panel.

Ambient temperatures higher than 115°F (46°C)

should be avoided as well as areas of high humidity.
42”(1.06 m) OR
Consider also the env i ronment surrounding or near 36”
CODE MINIMUM
(.9 m)
the compressor.The area selected for the location of
the compressor should be free of dust, chemicals,
metal filings, paint fumes and ov e rs p r ay.
36”(.9 m)
DUST CHEMICALS

METAL PAINT
FILINGS SPRAY

OVERSPRAY
2.2 FOUNDATION REQU I R E M E N T S
R e fer to the foundation plan for the particular model
compressor to be installed. See Section 8.0.
The compressor can be installed on any level floor that is
c a p a ble of supporting it. Compressor weights are listed
on the foundation plans.
2.3 PIPING
The use of plastic bowls on line filters without metal
guards can be hazardous.Their safety can be affected by
either synthetic lubricants or the additives used in minera l
oil. From a safety standpoint, metal bowls should be used
on any pressuri zed system. R ev i ew of your plant air line
system is recommended.

When sound transmission is of particular importance it is WARNING

often helpful to install a sheet of ru bb e r - fa b ri c-matting, or
c o rk under the compressor to reduce the possibility of Do not use plastic pipe, soldered copper
resonant sounds being transmitted or amplified through fittings or rubber hose for disch a rge piping.
the floor.

NOTICE The bu i l t-in aftercooler reduces the discharge air

N ever elevate the compressor unit
a b ove the floor lev e l .This may allow air
to enter the cabinet under the base.
Pe r formance will be affe c t e d .
t e m p e rature well below the dew point (for most ambient
conditions), therefo r e, considera ble water vapor is
c o n d e n s e d .To remove this condensation, each
compressor with built-in aftercooler is furnished with a
combination condensate separa t o r / t ra p.

10
2.3 PIPING (Continu e d )
A dripleg assembly and isolation va l ve should be
mounted near the compressor discharge. A drain line
should be connected to the condensate drain in the
base.

IMPORTANT: The drain line must slope dow n ward from

the base to wo rk properl y.

NOTE: For ease of inspection of the automatic drain tra p

o p e ration, the drain piping should include an open funnel.

It is possible that additional condensation can occur if the

d ownstream piping cools the air even further and low DISCHARGE PIPING WITH AFTERCOOLER
points in the piping systems should be provided with
d riplegs and tra p s.

IMPORTANT: Discharge piping should be at least as

large as the discharge connection at the compressor
enclosure. All piping and fittings must be suitable for the
m a x i mum operating temperature of the unit and, at a
m i n i mum, rated for the same pressure as the compressor
sump tank.

NOTICE
Do not use the compressor
to support the disch a rge pipe.

Careful rev i ew of piping size from the compressor

connection point is essential. Length of pipe, size of pipe,
number and type of fittings and va l ves must be ROTARY
considered for optimum efficiency of your compressor. COMPRESSOR

It is essential when installing a new compressor to rev i ew

the total plant air system.This is to ensure a safe and ROTA RY-RECIP IN PA R A L L E L
e f fe c t i ve total system.
200
Liquid water occurs naturally in air lines as a result of
compression. Moisture vapor in ambient air is 160
c o n c e n t rated when pressuri zed and condenses when
cooled in downstream air piping.
120
Moisture in compressed air is responsible for costly
p r o blems in almost eve ry application that relies on 80
compressed air. Some common problems caused by
moisture are rusting and scaling in pipelines, clogging of 40
i n s t ru m e n t s, sticking of control va l ve s, and freezing of
outdoor compressed air lines. A ny of these could result in
p a rtial or total plant shutdow n . 0

DEW POINT
Compressed air dryers reduce the water vapor con-
without 100°F/38°C 35°F /1.7°C -40°F/-40°C
c e n t ration and prevent liquid water fo rmation in (with
Aftercooling (Refrigerated (Desiccant
compressed air lines.D ryers are a necessary companion Aftercooler) Dryer) Dryer)
to filters, aftercoolers, and automatic drains for improv i n g
the productivity of compressed air systems.
MOISTURE CONTENT OF COMPRESSED AIR
11
Two types of drye r s, refri g e rated or desiccant, are used
to correct moisture related problems in a compressed air
system. R e f ri g e rated dryers are normally specified where
compressed air pressure dew points of 33°F (1°C) to
39°F (4°C) are adequate. Desiccant dryers are required
where pressure dew points must be below 33°F (1°C).

Contact your local Ingersoll-Rand distri butor fo r

assistance in selecting correct Ingersoll-Rand filtration or
d rying products.

NOTE: S c r ew type compressors should not be installed

in air systems with reciprocating compressors without a
means of pulsation isolation, such as a common receive r
t a n k .We recommend both types of compressor units be
piped to a common receiver utilizing individual air lines.

When two rotary units are operated in parallel, provide an

isolation va l ve and drain trap for each compressor befo r e
the common receive r.

2.4 ELECTRICAL INSTALLATION

B e fore proceeding furt h e r, we recommend that yo u

r ev i ew the safety data in the front of this manu a l .

Locate the compressor data plate on the left rear corn e r

of the enclosed unit or on the right starter support on the ROTA RY T WO COMPRESSOR SYSTEM
unenclosed unit.

The data plate lists the rated operating pressure, the

m a x i mum discharge pressure and the electric motor
c h a ra c t e ristics and powe r.

C o n f i rm that the line voltage and compressor nameplate

voltage are the same and that the standard starter box
meets the intent of NEMA 1 guidelines.

R e m ove the screws and door from the front of the start e r
box. C o n f i rm that all electrical connections are made and
tightened. C o n f i rm that the control tra n s fo rmer is wired
39557095 (30/40 SE)
correctly for supply vo l t a g e.See Figure 2.4-1 on nex t
page for typical control tra n s fo rmer wiri n g .

m 3/MIN
BARG
BARG
BARG
KW
KW

54425996 (22/30 KW)

12
 LINE VOLTS HZ LINE SEC VOLTS LINE
200 60 H4-H5 120 X1-X2
8 X3-X4
8 X4-X5
220/230 60 H3-H5 120 X1-X2
8 X3-X4
8 X4-X5
380 60 H3-H5 120 X1-X2
8 X3-X4
8 X4-X5
440/460 60 H2-H5 120 X1-X2
8 X3-X4
8 X4-X5
575 60 H1-H5 120 X1-X2
8 X3-X4
8 X4-X5

LINE VOLTS HZ LINE SEC VOLTS LINE

220 50 H5-H6 110 X1-X2 H4 H5 H6
8 X3-X4
8 X4-X5
380 50 H4-H6 110 X1-X2
8 X3-X4
8 X4-X5
415 50 H2-H6 110 X1-X2
8 X3-X4 110V
8 X4-X5
550 50 H1-H6 110 X1-X2
8 X3-X4
8 X4-X5

FIGURE 2.4-1 T Y P I C A L CONTROLTRANSFORMER WIRING

ELECTRICAL I N S TA L L ATION (Continu e d )

Inspect the motor and control wiring for tightness.

Replace the starter box door.

Rotation Check
Locate the rotation decal on each motor.
DRIVE
Drive Motor END
The correct compressor drive motor rotation is
cl o ckwise when viewed from the rear or non-d r i v e
end of the motor. See Figure 2.4-2.

NON-DRIVE
END
CAUTION

If the compressor is operated in the

opposite direction of ro t a t i o n , airend damage
can result and is not warrantabl e. FIGURE 2.4-2 DRIVE MOTOR ROTAT I O N

13
ELECTRICAL I N S TA L L ATION (Continu e d ) R e m ove the starter box door.

The Intellisys will automatically shut the unit down if the Interchange any two line connections (L1, L2 or L3) at
compressor rotation is incorrect, and “CHK MTR the start e r. Close and fasten the starter box door.
ROTATION” will appear in the display, also the alarm light R e c h e ck for correct rotation.
will be on. See Section 6.
Intellisys Operating Instructions
For the compressor motor rotation check, the motor
Read and understand the fo l l owing Intellisys Opera t i n g
jogging time must be as short as possibl e.
I n s t ructions (See Figure 2.4-4) prior to operating the unit.
After depressing the start bu t t o n , IMMEDIATELY
NOTE: These instructions are also contained on
depress the “EMERGENCY STO P ”bu t t o n . Should the
the decal near the Intellisys panel of the unit.
motor rotation be incorrect, put main disconnect in
the OFF position, l o ck and tag . See Figure 2.4-3.

NOTICE
Intellisys
Operating Instructions

BEFORE INSTALLING,OPERATING,OR PERFORMING ANY

MAINTENANCE ON THIS UNIT,READ AND UNDERSTAND
THE INSTRUCTIONS IN THE OPERATORS / INSTRUCTION
MANUAL

Before Starting
1.Check coolant level.Add coolant if necessary.
2.Verify that main isolation valve is open.
3.Close main disconnect switch.The “ POWER”light
indicates that line and control voltages are available
for starting. “UNLOAD”indicator light will be on.

Starting
1.Push “START”.Compressor will start.The compressor
will load automatically and the air pressure will rise
if there is sufficient demand for air.

Stopping
1.Push “UNLOADED STOP”.Compressor will immediately
unload and continue to run unloaded approximately
7 seconds.Compressor will then stop.If compressor
is running unloaded when “UNLOADED STOP”is
FIGURE 2.4-3 MAIN DISCONNECT pushed, compressor will stop immediately.
2.Open main disconnect switch.
LOCKED AND TAGGED
Stopping - Emergency
1.If there is a need to stop the compressor immediately
or if the “UNLOADED STOP” does not stop the com-
pressor after 7 seconds, push “EMERGENCY STOP”
Compressor will stop immediately.
2.Open main disconnect switch.

FIGURE 2.4-4 INTELLISYS OPERATING

INSTRUCTIONS

14
2.5 OUTDOOR SHELTERED INSTA L L AT I O N
M a ny times a compressor must be installed outside due
to jobsite conditions or limited space within a
m a nu fa c t u ring fa c i l i t y.When this occurs there are cert a i n
items that should be incorp o rated into the installation to
help ensure trouble free opera t i o n .These items have
been listed below plus Figure 2.5-1 has been included to
s h ow a typical outdoor sheltered installation.The unit
must be purchased with the Outdoor Modification Option
to provide NEMA 4 electrics and a cabinet exhaust on
the rear of the unit rather than the top to prevent recir-
culation of cooling air.
■ The compressor should be on a concrete pad
designed to drain water away.If the concrete pad is
sloped, then the compressor must be leve l e d . In order
to properly pull cooling air through the aftercooler, the
base/skid must be sealed to the concrete pad.
■ The roof of the shelter should extend a minimum of
4 ft (1.2 m) around all sides of the compressor to pre-
vent direct rain and snow from falling on the unit.
■ A i r-cooled machines must be arranged under the
shelter in a way that prevents air recirculation (i.e.h o t
exhaust back to the package inlet).
■ If the installation includes more than one compressor,
the hot air exhaust should not be directed towards the
fresh air intake of the second unit or an Air Drye r.
■ If a standard machine is to be installed outside, the
ambient temperature must never drop below 35°F
(1.7°C).
■ A r range the machine with the Intellisys con-
t r o l l e r / s t a rter enclosure facing away from the sun as
radiant heat can affect starter/lntellisys perfo rm a n c e.
Also direct sunlight and UV rays will degrade the
m e m b rane touch panel.This is not a wa r ra n t a bl e
situation.
■ Power disconnect switch should be within line of sight
and in close proximity to the unit. N.E.C. and local
e l e c t rical codes must be fo l l owed when installing the
p ower disconnect sw i t c h .
■ Condensate drains must never be allowed to dump on
the gr o u n d . Run to a suitable sump for future
collection and disposal or separation of lubricant and
water mixture.
■ Incoming power connections must use suitabl e
connectors for outdoor weather tight serv i c e.
■ A minimum of 3 ft (.9 m) clearance must be allowe d
on all four sides of the unit for service access.
H owever 42” (1.06m), or minimum required by latest
NEC or applicable local code, must be maintained in
front of control panel.
■ If possibl e, access by a fo rklift and/or an ove r h e a d
beam hoist should be kept in mind (for eve n t u a l
s e rvice to airend or motor).
■ If the area around the installation contains fine
a i r b o rne dust or lint and fibers etc., then the unit
should be purchased with the High Dust Filter Option
and TEFC motor.
■ Some type of protection such as a fence or securi t y
system, should be provided to prevent unauthori ze d
access.
15
16
3.0 INTELLISYS

17
3.0 INTELLISYS UNLOAD STOP

3.1 EMERGENCY STOP SWITCH
Pressing this switch stops the compressor
immediately. Compressor cannot be restarted until
switch is manually reset. Turn clockwise to reset.
Pressing this button will activate the unload stop. If
the compressor is running loaded, it will unload.
Seven seconds later it will stop. if the compressor is
running unloaded, it will stop immediately. Pressing
this button with the unit stopped will flash all L.E.D.’s
for a light check and flash the software version
number in the display.

3.2 POWER ON LIGHT (Inside Starter Box)

Indicates control voltage is available to the control UNLOAD/LOAD

circuit and line voltage is available for starting.
If the unit is running loaded, pressing this button will
cause the unit to unload, the unload indicator light
will be on. The unit will not load until the button is
POWER ON pressed again. If the unit is running unloaded,
pressing this button will load the unit in the ON/OFF
LINE or MOD/ACS control mode previously
3.3 POWER INDICATOR LIGHT operating.

Indicates voltage is available to the intellisys

controller.

3.4 PUSH BUTTONS

START

If the display shows READY TO START, pressing this

button will start the compressor. The compressor
will start and load automatically if there is a demand
for air.

If in the display table press this button to exit the

display table. Display will show “CHECKING
MACHINE” then “READY TO START”.

18
3.4 PUSH BUTTONS (Continued)
DISPLAY SELECT
Pressing this button will change the information
selected for the display. The display table will be
incremented. If the button is held, this display table
will scroll. This button can also be used to exit the
set point procedure.
PRESSURE SENSOR CALIBRATION (ZEROING)
ROUTINE
This routine is entered if the unit is not running and
both the up and down arrows button are pressed at
the same time. Make sure all pressure is relieved
from the compressor before calibration. The display
will flash the message “CALIBRATING”. After
calibration is completed the display will indicate
“READY TO START”. Zeroing should only be done
after a pressure sensor has been replaced or any
controller change.

NOTE: For readings less than 1 hr., hourmeter

display minutes. After 1 hr. the hourmeter displays
hours.

SET

The SET button is used to enter the set point

procedure. The set button is also used to reset
warnings and alarms. Pressing this button once will
reset a warning, twice will clear an alarm.

ARROWS

These buttons have several functions. If the

Intellisys is in the set point mode, the ARROWS are
used to change the set point values. If the unit has
multiple alarms or warnings, the ARROWS are used
to scroll through these conditions. The ARROWS
have a function in the calibration routine, which will
be described later.

19
3.5 SET POINT PROCEDURE
This procedure allows the customer to modify 14
variables in the controller logic.
At this time, press the SET button to enter the
setpoint routine.The SET OFFLINE AIR
PRESSURE indicator will light and the display will
show:
** The lead/lag feature allows the customer to choose
one compressor as the “lead” compressor and any
others as the “lag” compressor (simulates the mode of a
sequencer).The lag compressor’s on-line and off-line
pressures are determined by subtracting the lag offset
set-point from the on-line and off-line pressure set-
points of the lead compressor.
3.6 WARNINGS

XXXX PSI When a warning occurs, the alarm indicator will flash
and the display will alternate between the current
OFFLINE AIR PRESSURE is the first set point and message and the warning message. If multiple
XXXX stands for the value of the set point. Press the warnings exist, the message
SET button to select the set point to be adjusted.
Press the up or down arrow buttons to raise or lower SCROLL FOR WARN
the set point value. Press the SET button to move to
the next set point. If the set point value has been will be substituted for the warning messages. The up
adjusted, press the SET button to enter the new and down arrows can be used to obtain the
value. The display will flash to acknowledge.The next warnings
set point will then be displayed. If the value of the set
point was not changed, pressing the SET button will A warning needs to be reset by an operator.The
only step to the next set point.When the SELECT warning will clear when the SET button is pressed
OPTIONS set point is entered, the SELECT once. The following is a list of the warning
OPTIONS indicator will light, and the setpoints for messages.
options Auto Start/Stop or Remote Start/Stop will
only be accessible and displayed if the option 1) CHG SEPR ELEMENT
module is installed in the unit. The Power Outage This warning will occur if the pressure on the
Restart setpoints will only be accessible and Separator is 12 psig (.8 bar) greater than the
displayed if the combination Auto/Remote pressure at the Package discharge and the unit is
Start/Stop/Power Outage Restart option module is fully loaded.
installed in the unit.The set point routine can be
exited by pressing the DISPLAY/SELECT button or 2) HIGH AIREND TEMP
exit will be automatic after 30 sec. This will occur if the Airend Discharge Temperature
(2ATT) exceeds 221°F (105°C).
The following is a list of the set points. Also included
are maximum and minimum limits, step size, and 3) HIGH AIR PRESS
units of measure. This will occur if the unit is connected to an ISC
(sequencer), and the line pressure exceeds the max.
MIN MAX STEP UNIT offline pressure for 3 seconds.
OFFLINE PRESSURE 75 RATED + 3 1 PSI
ONLINE PRESSURE 65 OFFLINE - 10 1 PSI
4) T2 SENSOR FAILURE (Not Applicable)
CONTROL MODE MOD/ACS - MODULATION - ON/OFF LINE
DISPLAYTIME 10 600 10 SEC
This will occur when the Low Ambient Option is
AUTO RESTART OFF ON --- --- turned on and either the low ambient sensor is not
AUTO RESTARTTIME 2 60 1 MIN installed or is broken.
SEQUENCER OFF ON --- ---
REMOTE START/STOP * OFF ON --- ---
POWER OUT/RESTART* OFF ON --- ---
POWER OUT RESTART 10 120 1 SEC
TIME *
DELAY LOAD TIME 0 60 1 SEC
LEAD/LAG** --- --- --- ---
LAG OFFSET 0 45 1 PSI
LOW AMBIENT OFF ON --- ---

*Optional

20
3.7 ALARMS
When an alarm occurs, the alarm indicator will light
and display will show actual alarm message. If
alternately multiple alarms have occurred the display
will show SCROLL FOR ALARM. In this situation the
up and down arrows will be used to view the alarm
messages. All alarms (with the exception of the
emergency stop) will be reset by twice pressing the
SET button. Any exceptions to the above will be
explained in the alarm description.
The following is a list of the alarm messages.
1) LOW SUMP PRESS
This will occur if the unit is running and sump
pressure is too low.
2) HIGH AIR PRESS
This will occur if the unit is running and sump
pressure is greater than unit rated operating
pressure plus 20 psig (1.4 bar), plus the separator
pressure drop, or the line pressure is 15 psig (1.0
bar) above the rated pressure.
3) HIGH AIREND TEMP
This will occur if airend discharge temperature is
greater than 228°F (109°C).
4) STARTER FAULT 1SL (2SL)
This alarm will occur if the starter contacts open
while the unit is running.This alarm will also occur if
the unit is given the stop command and the starter
contacts do not open. 1SL refers to the auxiliary
circuit on starter contactor 1M. 2SL refers to the
auxiliary circuit on starter contacts 2M and 1S.
5) MAIN MTR OVERLD
This will occur if a motor overload is sensed.
6) FAN MTR OVERLOAD (Not Applicable)
This will occur if a fan motor overload is sensed.
7) TEMP SENSOR FAIL
This will occur when the sensor temperature is
recognized as missing or broken.
8) REMT STOP FAIL
This will occur if the momentary remote stop switch
does not disengage by the time the unit attempts to
start.
9) REMT START FAIL
This will occur if the momentary remote start switch
does not disengage by the time star-delta transition
occurs.
10) CK MTR ROTATION
This alarm will occur if a unit is started and
compressor has incorrect rotation.
11) CALIBRATION FAIL
This alarm will occur if the sensor calibration routine
is executed and the sensor reading exceeds 10% of
scale.
12) NO CONTROL POWER
This alarm will occur when the controller senses a
loss of control power.
13) PRES SENSOR FAIL
Whenever the pressure sensor is recognized as
missing or broken, a pressure sensor failure alarm
will occur.
14) LOW UNLOAD SUMP
This alarm will occur if the unit is running unloaded
and sump pressure is less than 15 psig (1.0 bar).
INITIAL CHECK ALARMS
15) HIGH AIREND TEMP
This will occur if airend discharge temperature is
greater than 217°F (103°C).
This alarm will only occur when the machine is not
running. When it occurs, the message MUST COOL
DOWN is added to the alternating group of alarm
messages.
EMERGENCY STOP
This will occur when the EMERGENCY STOP button
is engaged.The alarm indicator will light and display
will show:
21

4.0 SYSTEMS
4.1 GENERAL SYSTEM INFORMATION
The SSR compressor is an electric motor driven,
single stage, screw compressor—complete with
accessories piped, wired and baseplate mounted. It
is a totally self-contained air compressor package.
A standard compressor is composed of the
following:
Inlet air filtration
Compressor and motor
Pressurized coolant system with cooler
Separation system
Capacity control system
Motor starting control system
Instrumentation
Safety provisions
Aftercooler
Moisture separator and drain trap
Optional accessories can provide for such things as
remote starting or stopping and sequencer.
4.2 AIRCOOLED COMPRESSORS
Design Temperatures
The standard compressor is designed for operation
in an ambient range of 35°F. to 115°F. (1.7°C. to
46°C.). When conditions other than design levels
described are encountered, we recommend you
contact your nearest Ingersoll-Rand representative
for additional information.
The standard maximum temperature 115°F. (46°C)
is applicable up to an elevation of 3300 ft. (1000
meters) above sea level. Above this altitude,
significant reductions in ambient temperature are
required if a standard drive motor is to be used.
Coolant Cooler
The cooler is an integral assembly of core, fan and
fan-motor, mounted in the compressor. The cooling
air flows in through the front corners of the
enclosure, through the vertically mounted cooler
core, and discharges upward through the top of the
enclosure.
22
Aftercooler
The discharge air aftercooling system consists of a
heat exchanger (located at the cooling air discharge
of the machine), a condensate separator, and an
automatic drain trap.
By cooling the discharge air, much of the water
vapor naturally contained in the air is condensed
and eliminated from the downstream plant-piping
and equipment.
4.3 COOLANT SYSTEM
Coolant is forced by pressure from the receiver-
separator sump to the inlet port of the coolant cooler
and the bypass port of the thermostatic control
valve.
The thermostatic control valve controls the quantity
of coolant necessary to provide a suitable
compressor injection temperature.When the
compressor starts cold, part of the coolant will
bypass the cooler. As the system temperature rises
above the valve setting, the coolant will be directed
to the cooler. During periods of operation in higher
ambient temperatures, all the coolant flow will be
directed through the cooler.
The compressor injection minimum temperature is
controlled to preclude the possibility of water vapor
condensing in the receiver. By injecting coolant at a
sufficiently high temperature, temperature of the
discharge air and lubricant mixture will be kept
above the dew point.
The controlled temperature coolant passes through
a filter to the airend under constant pressure.
Each compressor has a hydraulic-type-full-flow filter
with a single replacement spin-on element.The filter
is mounted on the oil filter/thermal valve housing. It
is rated at 4 microns.
4.3 COOLANT SYSTEM (Continued)
There is a differential-pressure-bypass-valve set to
open in the event that the pressure drop across the
filter element rises to as high as 25 psi (1.8 BAR),
which indicates an excessively fouled element, as
well as poor maintenance practice.
4.4 COMPRESSED AIR SYSTEM
The air system is composed of:
1. Inlet air filter
2. Inlet valve
3. Rotors
4. Coolant/air separator
5. Minimum pressure/check valve
6. Aftercooler
7. Moisture separator/drain trap
Air enters the compressor, passing through the inlet
air filter and inlet valve.
Compression in the screw-type air compressor is
created by the meshing of two helical rotors (male
and female) on parallel shafts, enclosed in a heavy-
duty cast iron housing, with air inlet and outlet ports
located on opposite ends.The grooves of the female
rotor mesh with, and are driven by, the male rotor.
Tapered roller bearings at the discharge end prevent
axial movement of the rotors.
The air-coolant mixture discharges from the
compressor into the separation system. This system,
self-contained in the receiver tank, removes all but a
few PPM of the coolant from the discharge air. The
coolant is returned to the system and the air passes
to the aftercooler. The optional aftercooling system
consists of a heat exchanger, a condensate
separator, and a drain trap. By cooling the discharge
air, much of the water vapor naturally contained in
the air is condensed and eliminated from the
downstream plant-piping and equipment.
During unloaded operation, the inlet valve closes
and the blowdown solenoid valve opens, expelling
any compressed air back to the compressor inlet.
4.5 COOLANT/AIR SEPARATION SYSTEM
The coolant/air-separation-system is composed of a
receiver with specially designed internals, a two-
stage, coalescing-type separator-element, and
provision for return of the separator fluid back to the
compressor.
Operation
The coolant and air discharging from the
compressor flow into the receiver through a
tangential discharge outlet.This outlet directs the
mixture along the inner circumference of the
receiver, allowing the coolant stream to collect and
drop to the receiver sump.
Internal baffles maintain the circumferential flow of
remaining coolant droplets and air. In an almost
continuous change of direction of flow, more and
more droplets are removed from the air by inertial
action and then returned to the sump.
The air stream, now essentially a very fine mist, is
directed to the separator element.
The separator element is constructed with two
concentric, cylindrical sections of closely packed
fibers, each held in steel mesh. It is flange-mounted
at the receiver-outlet-cover.
The air stream enters the separator element radially
and the mist coalesces to form droplets.The
droplets collected on the outer first stage fall to the
receiver sump. Those collected on the inner second
stage collect near the outlet of the element, and are
drawn back to the compressor inlet through a filter-
screen and orifice fitting installed in the separator
scavenge line.
The air stream, now essentially free of coolant, flows
from the separator to the aftercooler, then to the
condensate separator, and on to the plant air
system.
4.6 ELECTRICAL SYSTEM
The electrical system of each SE compressor is built
around the microprocessor-based Intellisys
controller.
The standard electrical/electronic components,
enclosed in a readily accessible enclosure include:
1. SE Intellisys controller
2. Control transformers and fuses
3. Compressor motor starter, with auxiliary contacts
and overload relays
By use of a built-in Automatic Across-The-Line type
starter, the compressor can be started using full
voltage electric current.The starter is completely
automatic and controlled by the Intellisys controller.
Refer to the electrical schematic, Section 8.0
schematic 8.1.
23
4.6 ELECTRICAL SYSTEM (Continued)
By use of an optional built-in Star-Delta type starter,
the compressor motor can be started and accelerated
using a greatly reduced “inrush” electric current.The
starter is completely automatic and controlled by the
Intellisys controller. Refer to the electrical schematic,
Section 8.0 schematic 8.2.
Options such as remote start/stop or power outage
restart with remote start/stop can be added by
installing a plug-in module in the controller.
4.7 CAPACITY CONTROL
The SE compressor is supplied with on-off line
control equipment.
Optional modulation control enables the compressor
to function with three operator selectable capacity
control systems, each designed for different plant air
requirements.
- Mod/ACS (modulation/automatic control sector)
- Modulation
- On-Off Line
The desired control is selected at the Intellisys
control panel (See Section 3.0).
Automatic Unloaded Start
The compressor will always start in the unload
mode.When unloaded, the inlet valve is nearly
closed, the blowdown solenoid valve is open (tank
vented), and the compressor is operating at
minimum power. The Intellisys will open the inlet
valve slightly to maintain the proper sump pressure
to insure positive oil flow and smooth, quiet
operation.
The minimum pressure check valve will prevent any
backflow of air from the plant air system during
unloaded operation.
24
On-Off Line Control
For those plants which have a widely varying air
demand, on-off line control will deliver air at full
capacity (compressor maximum efficiency condition)
or will operate at zero capacity (compressor minimum
power condition).The compressor is controlled by the
Intellisys, responding to changes in plant air pressure.
The Intellisys opens the inlet valve and closes the
blowdown valve (3SV) whenever plant air pressure
drops below the on-line pressure set point.The
compressor will then operate to deliver full capacity air
to the plant system. If the plant air system pressure
rises to the off-line set point of the Intellisys, the inlet
valve closes and the blowdown solenoid valve opens
the receiver vent line, allowing receiver pressure to
drop. The compressor will continue to run with
minimum power draw.
Automatic Start-Stop
Many plant air systems have widely varying air
demands or large air storage capacity which allows for
automatic standby air capacity control.
During periods of low air demand, if the line pressure
rises to the offline set point, the Intellisys begins to time
out. If the line pressure remains above the online set
point for as long as the set time, the compressor will
stop. At the same time the Automatic Restart light on
the display panel will be lit to indicate the compressor
has shut down automatically and will restart
automatically, and the display will show “AUTO
RESTART”. An automatic restart will occur when the line
pressure drops to the online set point.
The offline and online set points and shut down delay
time are set on the Intellisys control panel.
Modulation/ACS Control (Optional)

For those plants which have relatively high constant

air demand, relative to the compressor capacity, the
recommended control mode is modulation.

The modulation control system retains the features

of the on line-off line control, but provides for
throttling of the inlet flow up to the off line air
pressure set point value.

By applying line pressure to an adjustable modulator

valve, the throttling position of the inlet valve is
controlled, thus allowing the modulator to "trim" the
inlet valve position as dictated by the line pressure.

The modulating pressure range is about 4 psig (0.3

BAR) and the modulator is factory set to straddle the
compressor rated pressure. Modulation begins when
the line pressure reaches about 99 percent of the
compressor rated pressure and continues as/if the
line pressure rises. Modulation becomes stable
when the compressor output equals the plant air
demand. When the modulation is at the factory
setting, the maximum capacity reduction will be
approximately 60 percent of the compressor rated
capacity (as indicated in Figure 4.7-1).

If the air demand has decreased to a level below the

60 percent modulated output, the line pressure will
increase slightly to actuate the Intellisys.The
compressor will then shift to the off line control FIGURE 4.7-1
position, and operate unload with the compressor
vented.

It is sometimes desirable to begin modulation at a

higher pressure than the standard factory setting,
thereby increasing the modulated capacity at the
time the Intellisys is actuated. Refer to Figure 4.7-1
for modulated capacities available when this is done.

25
Modulate/ACS Control (Continued)
The compressor will then operate to deliver full
capacity air to the plant system. If the plant air
system pressure rises to that of the Intellisys off line
set point, pressurized air will be sent to the inlet
valve causing it to close, and to the blowdown valve,
causing it to open.
The compressor will continue to run unloaded, but
since pressure levels have reduced, it will do so with
a minimum power draw.
The Intellisys ® has a fixed minimum differential of 10
psi between the off line air pressure setting and the
on line air pressure setting.The differential may be
increased by adjusting the on line air pressure
setting of the Intellisys ®.
Refer to Section 3.5 for instructions.
The automatic control selector (ACS) is designed to
continuously monitor the plant air demand and
select either the on line-off line, or the modulate
control mode - whichever is most desirable at
anytime during an operating day.
It allows the compressor to operate in its most
efficient mode without attendance, thereby reducing
power costs to a minimum.
When the compressor operates in the on line-off line
control mode, the length of time the compressor
remains in the "off line" condition is an indication of
the plant air demand. Intellisys controller is sensing
and awaiting a sufficient line pressure decrease
before signaling a shift to the on line mode. If the "off
line" time period is relatively short, thereby indicating
a high demand for air, it is preferable to shift the
control system to upper range modulation.
The Intellisys® does this, and does it automatically if
the compressor unloads 3 times within a 3 minute
time period.
If later, the plant demand decreases, and even under
modulate control the line pressure reaches the
setting of the Intellisys ® controller, and the
control shifts to the "off line" mode, the time in this
mode will still be monitored. A long "off line" time-
period indicates a low plant air demand, indicating
the desirability of operating in the on line-off line
mode.
The Intellisys® then does this, and does it
automatically if the compressor operates unloaded
for more than 3 minutes.
26
MODEL RATED
OPERATING PRESSURE
EP 125 PSIG (8.6 BAR)
HP 140 PSIG (9.6 BAR)
HXP 200 PSIG (13.8 BAR)
ML 7.5 BAR (109 PSIG)
MM 8.5 BAR (123 PSIG)
MH 10 BAR (145 PSIG)
MU 13 BAR (189 PSIG)
Modulation Only
If MODULATION ONLY is turned on in the set point
routine, the unit will shift to Modulation control mode
immediately when the unit is running.The 3 cycles
within 3 minutes time period required for ACS to
change to Modulation mode is bypassed.The unit
will stay in Modulation mode until the unit runs
unloaded for 3 minutes (the unit then returns to ACS
control) or MODULATION ONLY is turned off via the
set routine.
Delay Load Time
This is the amount of time the line pressure must
remain below the online set point before the
compressor will load or start (if the unit was stopped
due to an auto start/stop situation). Setting the load
delay time to 0 will cause no delay.When the delay
load timer becomes active, the display will switch to
package discharge pressure (if not displaying
package discharge pressure at that time) and then
display the delay load count down. Once the count
down reaches 0, the unit will load or start and the
display will return to line pressure.The display select
button is inactive during the delay load count down.
Modulate Control Valve Adjustment

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

locked open and tagged.

1. Enter the setpoint routine and put the compressor

in the MODULATION mode. Refer to Section 3.5 for
instructions.

2. Remove 1/8" NPT plug from the tee in the control

piping on the side of the airend support. Connect a
pressure gauge to this port.

3. Loosen the adjustment screw locknut and back

out adjusting screw 3 turns. See Figure 4.7-2.

4. Open the isolation valve and start the compressor.

5. Adjust the isolation valve to bring the discharge air

pressure to the rated discharge pressure (125, 140,
200 psig or 7.5, 8.5, 10, 13 bar).

6.While MAINTAINING the rated discharge

pressure, turn the adjustment screw on the
modulation valve (see Figure 4.7-2) so that the test
pressure gauge reads:

22 psig (1.5 bar) for modulate 20% cfm

(full voltage units)
30 psig (2.1 bar) for modulate 60% cfm
(star-delta units)

Tighten the adjustment screw locknut.

7. Press UNLOADED STOP.Wait for sump pressure

to go 0 psig (0 bar). Close the isolation valve or
bleed off all system air.

8. Enter the setpoint routine and put the compressor

in the desired control mode.

9. Remove the test pressure gauge and replace the

1/8" NPT plug using Loctite® PST or similar thread
sealant.

*Loctite is a registered trademark.

FIGURE 4.7-2 MODULATION VALVE

27
5.0 SCHEDULED PREVENTATIVE MAINTENANCE
5.1 MAINTENANCE SCHEDULE
THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP T H E
COMPRESSOR IN GOOD OPERATING CONDITION. S E RVICE AT THE INTERVAL LISTED OR AFTER T H AT
NUMBER OF RUNNING HOURS,WHICHEVER OCCURS FIRST.

Running Time Interval (which ever comes firs t )

Action Pa rt or Item Hours 1 We e k 1 Mo. 3 Mo. 6 Mo. Ye a r ly 2 Ye a rs

Inspect Coolant leve l Weekly x

Inspect Discharge temperature (air) Weekly x
Inspect S e p a rator element diffe r e n t i a l Weekly x
Inspect Air filter Delta P (at full load) Weekly x
Replace Coolant filter* 150 x (initial change only)
Check Te m p e rature sensor 1000 x
Replace Food grade coolant (when used) 1000 x
Inspect Hoses 1200 x
Replace Coolant filter* 2000 x (subsequent changes)
Inspect V-Belt/Belt Te n s i o n 2000 x
Clean S e p a rator scavenge screen and ori f i c e 4000 x
Clean Cooler cores** 4000 x
Replace Air filter* 4000 x
Replace S e p a rator element* *See special note
Replace SSR Coolant 6000 x
Replace Ul t ra Coolant* 8000 x
Inspect S t a rter contactors 8000 x
Service D ri ve Motor Lubri c a t i o n See Section 5.15
Replace V-Belts 8000 x
Replace Gas Spring (Belt Te n s i o n e r ) 8000 x

* In ve ry clean operating environments and where inlet filter is changed at the above prescribed interva l s.
In extremely dirty environments change V- b e l t s, coolant, filters, and separator elements more frequently.

** Clean cooler cores if discharge air temperature is ex c e s s i ve or if unit shutdown occurs on high air tempera t u r e.

5.2 MAINTENANCE RECORDS 5.3 MAINTENANCE PRO C E D U R E S

It is ve ry important that you, the ow n e r, keep accura t e B e fore starting any maintenance, be certain the fo l l ow i n g
and detailed records of all maintenance wo rk you, or the is heeded.
I n g e r s o l l-Rand Distri butor or Air Center perfo rm on yo u r
c o m p r e s s o r.This includes but is not limited to coolant, 1. Read Safety Instru c t i o n s.
coolant filter, separa t o r, inlet air filter, V- b e l t s, shaft seal, 2. Use correct tools.
and so fo rt h .This info rmation must be kept by you, the 3. H ave recommended spares on hand.
ow n e r, should you require wa r ranty service wo rk by yo u r
I n g e r s o l l-Rand Distri butor or Air Center. Maintenance SPECIAL NOTE:
record sheets are located at the back of this manu a l . Replace separator element when the separator
d i f ferential pressure ( P) reaches three times the
initial pressure drop or a maximum pressure
d i f ferential of 12 psi (.8 bar) at full load or if the
Intellisys warning “CHG SEPR ELEMENT”i s
displayed. See Section 3.9.

28
5.4 SHEAVE ALIGNMENT

Any degree of sheave misalignment will result in a

reduction of belt life.
1/16”(1.6mm) MAX.
Misalignment of sheaves should not exceed
1/16”(1.6mm).

Parallel misalignment occurs when the driven shafts are

parallel, but the two sheaves lie in different planes.

Angular misalignment occurs when the two shafts are

not parallel.

Align Sheaves STRAIGHTEDGE

An easy and effective method of checking alignment in

both directions between the driver and driven sheaves
utilizes an accurate straight edge.

Lay the straightedge across the face of the driver PARALLEL MISALIGNMENT
(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
aligned. 1/16”(1.6mm) MAX.

Alignment should be within 1/16” (1.6mm) 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

resetting if the drive motor or airend is removed (for
example, motor or airend replacement).
STRAIGHTEDGE

ANGULAR MISALIGNMENT

29
5.5 DRIVE BELT & GAS SPRING
REPLACEMENT

Ensure that the compressor is isolated from the

compressed air system by closing the isolation
valve and venting pressure from the drip leg.
Ensure that the main power disconnect switch is
locked open and tagged.

The belts should be removed, discarded, and new belts

and gas spring installed at the 8000 hour (or 1 year,
whichever comes first) interval. To replace the belts
and gas spring, the following procedure should be
followed:

1. Remove the compressor belt guards. Mark holes

that gas spring ends are in for later identification.

2. Place hook end of installation tool (P/N 39908363)

under the airend support (See Figure 5.5-1). Install 5/8”
flat washer (P/N 95947651) on 5/8” screw (P/N
39246335) and insert end of screw thru slot in top of
mounting bracket on airend. Insert screw in threaded
nut on installation tool and turn screw clockwise to
compress the gas spring. Compress the gas spring
until belts can easily slide over the sheaves. Remove
and discard old belts.

3. Loosen screw on spring installation tool until the gas

spring is fully extended. Remove hex whiz-lock nuts
from spring rod ends. Remove and discard gas spring.

4. Install the new gas spring using hex whiz-lock nuts

with rod end pointing down. Spring ends should be in
same holes as removed spring, marked in step one. If
converting pressure rated (model) See Figure 5.5-2.

5. Turn screw clockwise and compress spring until new

belts easily fit over sheaves. Install new belts.

6.Turn screw counter-clockwise until the gas spring

fully tensions the belts. Remove spring installation tool.
Rotate sheaves to properly seat belts. DO NOT leave
tool in bracket - this may damage the automatic
tensioner or prevent proper operation.

7. Replace compressor belt guards.

TOOLS REQUIRED:

15/16 inch open end wrench

drill
3/8” (10mm) drill bit
1/2 inch open end wrench
9/16 inch open end wrench

30
 FIGURE 5.5-1 GAS SPRING INSTALLATION TOOL

AIREND AIREND
AIREND AIREND BRACKET SUPPORT
BRACKET SUPPORT MODEL HOLE# HOLE#
MODEL HOLE# HOLE# (50 HZ)
(60 HZ)
ML22SE 1 C
XF30SE 1 C MM22SE 1 C
EP30SE 1 C MH22SE 1 C
HP30SE 1 C MU22SE 1 B
HXP30SE 1 B
ML30SE 2 A
XF40SE 2 A MM30SE 2 A
EP40SE 2 A MH30SE 2 A
HP40SE 2 A MU30SE 2 A
HXP40SE 2 A

FIGURE 5.5-2 GAS SPRING ROD END MOUNTING HOLE LOCATIONS

31
5.6 SHAFT SEAL REPLACEMENT

There are two lip type seals on the compressor. They

are wearable parts and should be replaced at 8,000
hours. While it is advisable to have your local Ingersoll-
Rand Distributor or Air Center perform this work, the
task can be accomplished by a good mechanic
following these instructions.

Before beginning any work on the compressor,

ensure the main electrical disconnect is locked and
tagged open and that all air pressure is relieved
from the system.

Special Tools

A clean work bench.

Seal Installation Tool.

Replacement Parts

Shaft seal kit (42412205).

Seal retainer O-ring 95358024.

Loctite® 609.

Loctite® 515.

Installation

1. Remove enclosure, (if so equipped).

2. Remove V-belts and airend sheave. Note: Airend

sheave is heat shrink fit to shaft and a puller is required
to remove.

3. Remove seal housing from airend assembly, using LIP EDGE

the two threaded removal holes provided. OF SEAL
INWARD

4. Drive each seal out of the housing. Be careful not to

damage the surface of the bore.The larger double lip WEAR
seal must be driven toward the inboard side.The SLEEVE
smaller single lip seal should be driven toward the
outboard side.The term “inboard” side of the seal
housing will refer to the face that is mounted to the
airend assembly.The term “outboard” side will refer to
the face closest to the sheave.

5. Remove check valve ball and plug from seal housing. SCAVENGE
HOLES
6. Remove wear sleeve from shaft, being careful not to
damage the shaft.

FIGURE 5.6-1 SHAFT SEAL ASSEMBLY

32
7.Thoroughly clean the scavenge holes, bore surfaces,
face of the seal housing, wear sleeve journal on the
shaft, and the face of the airend assembly. Be careful
not to damage any of the surfaces, and make sure that
no particles are allowed to enter the bearings.
8. Be certain to install the seals from the proper side
and in the proper orientation, as described below.
Carefully follow directions for seal assembly. Protect
seal elements from inadvertent damage during
installation. Be sure all tools are free of contaminants
before installation.
21. Making sure that the check valve ball remains in
place, assemble the seal housing to the rotor housing.
Attach the seal housing to the rotor housing with eight
screws and tighten to 19-21 lb.- ft. (26-29 N-m).
22. Lightly lubricate the inner diameter and the outer
diameter of the new wear sleeve with clean compressor
coolant.
23. Carefully slide the wear sleeve onto the rotor and
through the seals, until the wear sleeve locates against
the bearing.

9. Put a thin continuous coat of Loctite®609 on the

outer diameter of the double lip seal.

10. Position the seal in the seal housing from the REMOVE BURRS
inboard side.The seal should be oriented such that the
edge of the lip is toward the installer.

11. Using the seal installation tool (machined according

to Figure 5.6-2), press the double lip seal into the seal
housing until it locates against the shoulder.
3.13” 2.75”
to to
12. Remove any excess Loctite® 609 with a clean cloth. 3.06” 2.63”
Dia. Dia.
13. Put a thin continuous coat of Loctite® 609 on the
outer diameter of the single lip seal.
1”MINIMUM
14. Position the seal in the seal housing from the
outboard side.The seal should be oriented such that
the edge on the lip is installed first.
FIGURE 5.6-2 SEAL INSTALLATION TOOL
15. Using a clean flat tool that is larger in diameter than
the seal, press the single lip seal into the seal housing
until it is flush with the surface of the housing.The seal
must not be pushed beyond the flush position.

16. Remove any excess Loctite® 609 from the seals,

the seal housing and from the seal scavenge holes in
the seal housing between the seals.

17. Install the plug in the bottom of the seal housing.

18. Lightly lubricate a new O-ring with clean

compressor coolant and install on the rotor shaft.

19. Ensure that the surface of the seal housing is clean

and dry. Put a thin continuous coat of Loctite®515 on
the inboard face of the seal hosing. Do no over-apply.

20. Install a new check valve ball in the seal housing. A

small amount of grease can be used to hold the check
valve ball in place for assembly.

33
5.7 INLET AIR FILT E R

The filter should be changed when the filter indicator

s h ows red.

The filter should be changed eve ry 4000 hours and more

frequently in dirty environments because coolant, coolant
f i l t e r, separator element, and airend life are a direct
function of how well you maintain and replace the inlet air
filter.

To change the air filter, loosen the clamp that attaches

the filter to the inlet va l ve. R e m ove the filter. Install the
clamp on the new filter, attach the filter and tighten the
clamp.

5.8 COOLANT FILTER ELEMENT

CAUTION
I m p roper coolant filter replacement
The coolant filter element should be changed after the
will cause compressor damage.
first 150 hours of operation and eve ry 2000 hours
t h e r e a f t e r, or when the coolant is being changed. In dirt y Replace filter element after first 150
o p e ration environments the filter should be changed hours of operation and eve ry 2000 hours
more frequently. thereafter or when coolant is changed.
Use a suitable device and loosen the old element.U s e
d rain pan to catch any leakage during remova l . Discard
old element.

Wipe the sealing surface of the filter housing with a

clean, lint-free rag to prevent the entry of dirt into the
system.

R e m ove the replacement element from its protective

package. Apply a small amount of clean lubricant on the
ru bber seal and install the element.

S c r ew element on until the seal makes contact with the

head of the filter housing.Tighten approximately one-h a l f
t u rn additional.

S t a rt unit and check for leaks.

34
5.9 COOLANT Replace the fill cap. S t a rt the compressor and allow it to
run unloaded. The coolant level should now be near the
■ SSR Ultra Coolant (Standard Fa c t o ry Fill) midpoint of the sightglass.
■ SSR H1-F Food Grade (Optional)
DO NOT OVERFILL THE MAC H I N E . O ver filling will
SSR Ultra Coolant is a polyglycol base coolant. Change a f fect separation and carryover down stream.
U l t ra Coolant after eve ry 8000 hours or eve ry two ye a r s,
w h i c h ever comes first.
Coolant fill quantity
SSR Food Grade Coolant is a polyalphaolefin base
coolant. Change after eve ry 1000 hours or eve ry 6 30 - 40 hp (22-30kw). . . . . . . . .3.2 gallons (12.1 liters)
months whichever comes first. Do not operate unit
b eyond this 1000 hour lubricant change interval, as
l u b ricant degradation will occur.

Items Required
In addition to the tools normally found in any reasonabl y WARNING
equipped serv i c e m a n ’s toolbox, the fo l l owing items
should be ava i l a ble at the wo rk site:

1) S u i t a ble drain pan and container to hold lubri c a n t

d rained from unit.
2) A quantity of proper lubricant sufficient to refill the
compressor. Hot coolant can cause severe injury.
3) A minimum of one replacement coolant filter element Use care when near this area.
of the proper type for the unit to be wo rked on.

There is a coolant drain va l ve on each compressor. It is

located on the bottom of the separator tank.

The coolant should be drained soon after the compressor

has been shut dow n .When the coolant is hot, the
d rainage will be more complete and any particles in
suspension in the coolant will be carried out with the
coolant. NOTICE
Filler Cap.
Hot coolant can cause severe injury. Use care when Use only recommended
draining separator tank. coolant.
Read instruction book
To drain the unit, place drain pan under drain va l ve. Open b e fore serv i c i n g .
d rain va l ve to start dra i n a g e.After draining is complete, 39543921
close drain va l ve.

After the unit is drained and a new coolant filter element

is installed, refill the system with fresh coolant through
the filler cap on the side of the separator tank. B ring the
r e c e i ver level of coolant up to the top of the sight glass.
Replace the fill cap. S t a rt the compressor and allow it to
run unloaded for a short time.The correct coolant level is
at the midpoint of the sight glass with the unit running in
the “ U N L OA D E D ” mode. If the level is not near the
midpoint, stop the compressor and allow all pressure to
r e l i eve from the system. Open the fill cap and add more
coolant.

35
5.10 SEPA R ATOR TANK SCAVENGE
CHECKVALVE/SCREEN/ORIFICE

Tools Required

■ Open end wrench

■ S c r ew d ri ve r

Procedure

Disconnect tubing at each end of check

va l ve / s c r e e n / o rifice asembl y.

C h e ck orifice and clean if required. Use suitabl e

small screw d ri ver or knife and press screen retainer FIGURE 5.10-1 SEPA R ATO R TANK SCAVENGE
o rifice from its mating fitting (See Figure 5.10-1). Be CHECKVALVE/SCREEN/ORIFICE
careful not to damage flared end of fitting or O-ri n g .
Wash screen and housing in safety solvent and bl ow
d ry.

Press the check va l ve / s c r e e n / o rifice into fitting bl o ck .

A s s e m ble the check vav l e / s c r e e n / o rifice assembly to

the tubing lines.The fitting must be re-installed with
the screen on the upstream side of the orifice as
indicated by the flow arrow (See Figure 5.10-1).

5.11 T E M P E R ATURE CONTROL VA LVE ELEMENT

REPLACEMENT

Tools Required

Open end wrench

Procedure

Use suitable wrench to loosen temperature control

va l ve element. Ensure that excess stress is not
exe rted on oil piping by holding oil filter/thermal va l ve
housing with appropriate tool while loosening
element.

R e m ove faulty temperature control va l ve element.

Install replacement element. S t a rt and load unit to
c h e ck for proper discharge temperature control.

36
5.12 COOLANT SEPARATOR ELEMENT

To check condition of separator element, run

compressor in full load mode and at rated pressure
and select "SEPARATOR PRESSURE DROP" in
L.E.D.Table. If display says "XX PSI", then no
maintenance is required. If warning light is on and
display says "CHG SEPR ELEMENT" then the
separator should be replaced.

Loosen the fitting that holds the scavenge tube into the
tank and withdraw the tube assembly.

Disconnect blowdown valve from elbow in tank cover.

Disconnect tube from fitting on minimum pressure

check valve. Loosen tube nut on same tube at
aftercooler inlet then swing tube away from tank cover.

Use a suitable wrench and remove the bolts that hold

the tank cover in position. Remove cover by
lifting up and away.

Carefully lift the separator element up and out of the

tank. Discard the faulty element.

Clean the gasket surface on both the tank and its

cover. Exercise care to prevent pieces of the old
gasket from falling down into the tank.

Check the tank to be absolutely certain that no

foreign objects such as rags or tools have been
allowed to fall into the tank. Install replacement
element down into the tank after checking the new
element gaskets for possible damage. Center the
element up within the tank.
RECOMMENDED BOLT TIGHTENING
Place the tank cover in its correct position and install CROSS PATTERN
bolts. Tighten the bolts in a cross-pattern (Reference
Figure 5.12-1) to prevent over-tightening one side of
the cover. An improperly tightened cover will likely
result in a leak.

Tank Cover Bolt Torque Values

30-40HP/ 1/2-13 UNC 80 lb.-ft. (108 N-m)

22-30 KW

Inspect tank scavenge screen and orifice. Clean if

necessary following instructions in Section 5.10.
FIGURE 5.12-1
Install scavenge tube down into the tank until the tube
just touches the separator element. Tighten
fittings.

Install the regulation lines in their original position.

Start unit, check for leaks, place in service.

37
5.13 COOLER CORES: CLEANING Coolant Cooler/Afterc o o l e r

Ensure that the compressor is isolated from the Remove panels and sound box.
compressed air system by closing the isolation va l v e
and venting pressure from the drip leg. Drain the coolant. See Section 4.6.

Ensure that the main power disconnect sw i t ch is Disconnect piping from cooler inlet and outlet ports.
l o cked open and tagge d . (See Figure 5.13-1).
Plug cooler inlet and outlet ports to prevent possible
contamination.

Remove cooler holding screws from cooler box and

remove cooler.

Cooler Cleaning

Flush the outside cooler core using a safety solvent.

Follow solvent manufacturer’s directions for proper use.

CAUTION

S t rong cl e a n e rs can harm

a l u m i num cooler part s . F o l l ow cl e a n e r
m a nu f a c t u r e r ’s instructions for use.
Wear appropriate safety equipment.
FIGURE 5.13-1 MAIN DISCONNECT
LOCKED AND TAGGED
Reassemble in reverse order.

Tools Required Make sure belt/fan guards are replaced.

S c r ew d ri ve r Refill the compressor with coolant. If contamination is

Wrench set suspected, replace with new coolant.
Air hose equipped with approved O. S. H . A . nozzle.
On units sold outside the U. S . A . consult Run compressor for ten minutes. Check for possible
local codes. leaks. Check coolant level.

Inspection Replace enclosure panels.

Visually check the outside of the cooler cores to be

c e rtain that a complete outside cleaning of the cooler is
r e q u i r e d .Frequently dirt, dust or other foreign materi a l ,
m ay only need to be removed to remedy the probl e m .

When the cooler is covered with a combination of oil,

grease or other heavy substances that may affect the
u n i t ’s cooling, then it is recommended that the cooler
cores be thoroughly cleaned on the outside.

38
5.14 MOTOR LUBRICAT I O N

The induction-type squirrel cage motors have antifri c t i o n

ball or roller bearings front and rear. At periodic interva l s
t h ey require relubri c a t i o n .
NOTICE: 50 Hz TEFC Motors have sealed bearings
that do not require relubrication.

Relubrication Interval
(or 9 months, w h i ch ever comes firs t )
1000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . .all 60 Hz TEFC dri ve motors
2000 hours. . . . . . . . . . . . . . . . . . . . . .all 60 Hz ODP dri ve motors and
all fan motors

Relubrication amount

Lubricant Amount
Motor Frame Size in3 cc oz. grams

2 5 4-2 8 6 1.0 16 .8 23
3 2 4-3 6 5 1.5 25 1.2 34

* No greasing required (permanently lubricated beari n g s )

CAUTION
Improper lubrication can be a cause of motor beari n g
fa i l u r e.The quantity of grease added should be carefully
c o n t r o l l e d .The smaller motors must be greased with a O v e rgreasing can be a cause of bearing and
lesser amount of grease than larger motors. motor failure. Make sure dirt and contaminants
are not introduced when adding grease.

P rocedure for relubrication

CAUTION

Grease should be added when the motor

is stopped and power disconnected.

When regreasing, stop motor. Disconnect powe r; l o ck out

and tag.R e m ove outlet plugs (or spring-loaded gr e a s e
relief plugs if present).The outlet plug may not be
a c c e s s i ble on the fan end of some T E F C motors.

39
5.14 MOTOR LUBRICATION (Continu e d )

Grease relief along shaft can occur, precluding necessity

of removing this plug if inaccessibl e.The inlet grease gun
fittings and outlet plugs (or spri n g-loaded reliefs) are
located at each end of the motor housing.The dri ve end
reliefs protrude out the circumference of the lower port i o n
of the end bell near a flange bolt.The dri ve end outlet
plugs are located just behind the flange in the air intake
area at about the 5 or 6 o’clock position.

1) Free drain hole of any hard grease (use piece of wire

if necessary ) .

2) Use a hand lever type grease gun. D e t e rmine in

a d vance the quantity of grease delivered with each
s t r o ke of the leve r. A graduated cylinder show i n g
cubic centimeters (cc) may be used, or a 35mm film
canister can give a close approximation for 2 cubic
inches when filled.

3) Add the recommended volume of the recommended

lubricant. Do not expect grease to appear at the
outlet, but if it does, d i s c o n t i nue greasing at
once.

4) Run motor for about 30 minutes before replacing out-

let plugs or reliefs. BE SURE TO SHUT MOTO R
DOWN, DISCONNECT POW E R , LOCK OUT AND Motor Bearing Maintenance (Stored Units)
TAG , AND REPLACE THESE DRAIN FITTINGS TO
PRECLUDE LOSS OF NEW GREASE AND To ensure that complete contact is maintained betwe e n
ENTRANCE OF CONTA M I N A N T S ! the motor bearings and the bearing grease on units to be
placed in storage for extended interva l s, the fo l l ow i n g
motor maintenance procedure should be adhered to:
Recommended Motor Grease
1) P rior to placing a unit in stora g e, rotate the motor
Most motors require: s eve ral revolutions by hand in the proper direction of
rotation.
MobilithSHC220.......................................................Mobil
2) T h e r e a f t e r, rotate the motor as described in Step 1 at
Use the grease as indicated on a special gr e a s e three month intervals until such time as the unit is
i n fo rmation nameplate on the motor. Use of altern a t i ve placed in serv i c e.
greases can result in shortened motor life due to
incompatibility of gr e a s e s. If there is not a gr e a s e 3) If the storage time is to exceed a total of nine (9)
nameplate on the motor use: months duration, the compressor must be ordered
with long term storage option.
C h evron Black Pe a rl #2
( P r e fe r r e d ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard Oil of Califo rn i a

C h evron SRI 2. . . . . . . . . . . . . . . . . . . . . . . . . . .Standard Oil of Califo rn i a

40
5.15 LONG TERM STO R AG E
General
The fa c t o ry, upon special request, prepares compressor
units for long term stora g e. In such cases, a special
bulletin is supplied for storage and start-up procedures.
The bulletin provides special procedures for rotation and
l u b rication of compressors during stora g e.
B e fore actual start-up of the compressor, the unit mu s t
be drained of coolant containing vapor space inhibitors.
Procedure for long term storage start-up is covered in the
special bulletin APDD 339.
5.16 COOLANT/LUBRICANT CHANGEOUT
I n ge rsoll-Rand does not recommend ch a n geout of
coolant/lubricants, h ow ev e r, if a coolant/lubricant
ch a n ge cannot be avo i d e d , p rocedure APDD 106E-87
should be obtained from your Inge rs o l l - R a n d
representative.
5.17 INTELLISYS REMOVAL
Ensure that the compressor is isolated from the
compressed air system by closing the isolation
valve and venting pressure from the drip leg.
Ensure that the main power disconnect switch is
locked open and tagged (See Figure 5.17-1).
FIGURE 5.17-1 MAIN DISCONNECT
LOCKED AND TAGGED
Tools:
Screwdriver Size #1, flathead
3/8 inch hex driver
Follow these precautions to minimize damage from
static electricity. Static can cause severe damage to
microcircuits.
1) Make the least possible movement to avoid build-
ing up static electricity from your clothing or tools.
2) Discharge potential static electricity by touching
(grounding) yourself to the starter box.
3) Handle circuit boards only by their edges.
4) Do not place the Intellisys® Controller on any
metal surface.
5) Leave the replacement parts in their protective bags
until ready for installation.
Before removing any components, remove the starter
box door and check all wiring for tightness. A loose wire
or bad connection may be the cause of problems.
Controller Removal:
1) Remove the starter box door.
2) Lift the Intellisys controller out of the starter box.
3) Remove the five wire connectors from the top of the
controller.
4) Remove the controller. Remove any option modules
which must be installed in the new controller.
41
5.18 COOLANT HOSES

The flex i ble hoses that carry coolant to and from the oil
cooler may become brittle with age and will require
replacement. H ave your local Ingersoll-Rand distri bu t o r
c h e ck them eve ry 2 ye a r s.

Ensure that the compressor is isolated from the

compressed air system by closing the isolation va l v e
and venting pressure from the drip leg.

Ensure that the main power disconnect sw i t ch is

l o cked open and tagge d .

R e m ova l

R e m ove enclosure panels.

D rain coolant into a clean container. C over the container

to prevent contamination. If the coolant is contaminated,
a new charge of coolant must be used.

Hold fitting securely while removing hose.

Installation

Install the new hoses and reassemble the package by

r eversing the disassembly procedure. S t a rt the
compressor and check for leaks.

5.19 AIREND DISCHARGE HOSE

The flex i ble hose from the airend discharge to separa t o r

tank may become brittle with age and require
replacement. C h e ck this hose as per the maintenance
schedule in Section 5.1.

R e m ova l

Ensure that the compressor is isolated from the

compressed air system by closing the isolation va l v e
and venting pressure from the drip leg.

Ensure that the main power disconnect sw i t ch is

l o cked and tagge d .

Disconnect hose nut from piping at each end of

discharge hose and remove. Hold fittings securely while
r e m oving hose.

42
 6.0 TROUBLE SHOOTING CHART
TROUBLE
Compressor fails to start.
Compressor shuts down.
NOTE: If a shutdown oc-
curs, press the DISPLAY
SELECT button once to
activate the L.E.D. display
table. Using the adjacent up
and down arrows, the values
displayed will be those im-
mediately preceding shut-
down. Use these values
when trouble shooting a
problem.
Low system air pressure
CAUSE &/OR DISPLAY WHAT TO DO
110/120V control voltage not available. — Check fuses. Check transformers and
wiring connections.
"STARTER FAULT 1SL (2SL)" — Inspect contactors.
"EMERGENCY STOP" — Rotate emergency stop button to
disengage, and press"SET" button twice.
"MAIN MTR OVER LD" — Manually reset main overload relay, and
press "SET"button twice.
"PRES SENSOR FAIL" or — Check for defective sensor, bad sensor
"TEMP SENSOR FAIL" connection, or broken sensor wires.
“NO CONTROL POWER” — Check fuses and HAT switch
"HIGH AIREND TEMP." — Insure that installation area has
adequate ventilation.
— Insure that cooling fan is operating. If
not reset circuit breaker inside starter
box.
— Check coolant level.Add if required.
— Cooler cores dirty. Clean coolers.
"HIGH AIR PRESS" — Check for restricted or malfunctioning
blowdown valve or minimum pressure
check valve.
"LOW SUMP PRESS" — Check for air leak from tank or
blowdown piping.
"PRES SENSOR FAIL" or — Check for defective sensor, bad sensor
"TEMP SENSOR FAIL" connection, or broken sensor wires.
"CK MOTOR ROTATION" — Interchange any two line connections
(L1,L2,L3) at the starter.
"MAIN MTR OVERLD" — Check for loose wires.
— Check supply voltage.
— Check heater size.
"STARTER FAULT 1SL (2SL)" — Inspect starter contactors.
— Check for loose wires.
“NO CONTROL POWER” — Check fuses and HAT switch
Compressor running in "Unload" Mode. — Press "UNLOAD/LOAD" button.
Controller off-line set point too low. — Press "UNLOAD/STOP" button, set off-
line set point at a higher value.
Dirty air filter element. — Check filter condition. Replace
as required.
V-Belts slipping. — Replace belts/gas spring.
Air leak. — Check air system piping.
Moisture separator trap drain stuck open. — Inspect and repair.
Inlet valve not fully open. — Inspect and repair. Check control
system operation.
System demand exceeds compressor — Install larger or an additional
delivery. compressor.
43
 TROUBLE SHOOTING CHART (Continued)
TROUBLE
High coolant
consumption/coolant
in air system
Water in Air System
Excessive noise level
Excessive vibration
Shaft Seal leak
Black residue on belt guards
Pressure relief valve opens
44
CAUSE &/OR DISPLAY
Excessive coolant level.
Plugged separator element.
Separator element leak.
Plugged separator scavenge orifice/
screen.
Compressor operating at low pressure
(75 psig/5bar or below).
Coolant system leak.
Defective moisture separator/drain trap
Trap drain or drain piping plugged.
Aftercooler core dirty.
Enclosure panels not in place.
Drain line/drip leg incorrectly installed.
No refrigerated or desiccant dryer in
air system.
V-belts slipping.
Compressor defective. (Bearing
failure or rotor contact.)
Enclosure panels not in place.
Loose component mounting.
Loose components
Motor or compressor bearing failure.
External sources.
Defective shaft seal.
Sheaves mis-aligned.
Excessive belt wear
Compressor operating over pressure.
Defective valve.
WHAT TO DO
— Check level, lower if necessary by
draining.
— Check separator pressure drop.
— Check separator pressure drop. If low,
replace element.
— Remove and inspect orifice/screen.
Clean if required.
— Operate at rated pressure.
— Reduce system load.
— Inspect and repair leaks.
— Inspect and clean if required.Replace
separator/trap if defective.
— Inspect and clean.
— Inspect and clean.
— Install enclosure panels.
— Slope drain line away from trap. Install
drip leg.
— Contact local Ingersoll-Rand
Distributor or Air Center.
— Replace belts and gas spring.
— Contact authorized Distributor or Air
Center immediately, do not operate
unit.
— Install enclosure panels.
Inspect and tighten.
— Inspect and tighten.
— Contact authorized Distributor or Air
Center immediately, do not operate
unit.
— Inspect area for other equipment.
— Replace per this manual or contact
authorized Distributor or Air Center
— Align sheaves.
— Replace belts and gas spring.
— Adjust Intellisys set points.
— Replace valve.
7.0 OPTIONS
7.1 REMOTE START/STOP

The remote start/stop option allows the operator to

control the compressor from a remote mounted
start/stop station.This option may be factory
installed or a field installation kit is available. This
option is a plug-in module.

With the optional plug-in module installed, two

different switches can be wired to the Intellisys® for
remote start/stop. Refer to (Electrical Schematics 8.1
or 8.2 for wiring locations).The switches are
customer supplied and must be of the momentary
type.The stop switch contacts are normally closed
and start switch contacts are normally open.

7.2 REMOTE START-STOP AND POWER OUTAGE

RESTART OPTION

When remote start-stop and the Power Outage

Restart Option is desired, a combination field
installation kit that contains these features is
available.The option includes a plug-in module and
all of the hardware necessary.

The Power Outage Restart portion of the option is

for plants that have interruptions in their incoming
power supply to the compressor and must maintain
an uninterrupted supply of compressed air.When
turned on, the option allows the compressor to
automatically restart and load 10 seconds after
incoming power is restored after a power
interruption.

7.3 SEQUENCER CONTROL

Sequencer control capability can be added to the

Intellisys® System by utilizing a sequencer interface.
This option is available as a field installation kit.

45
8.0 REFERENCE DRAWINGS

8.1 ELECTRICAL SCHEMATIC-FULL VOLTAGE

46
8.2 ELECTRICAL SCHEMATIC-STAR-DELTA

46
8.3 FOUNDATION PLAN - ENCLOSED (Continued)

48
8.3 FOUNDATION PLAN - ENCLOSED

49
8.4 FOUNDATION PLAN - UNENCLOSED (Continued)

50
8.4 FOUNDATION PLAN - UNENCLOSED

51
8.5 FOUNDATION PLAN - OUTDOOR MODIFICATION (Continued)

52
8.5 FOUNDATION PLAN - OUTDOOR MODIFICATION

53
8.6 BASIC FLOW SCHEMATIC - FULL VOLTAGE

54
8.7 BASIC FLOW SCHEMATIC - FULL VOLTAGE WITH MODULATION

55
 8.8 BASIC FLOW SCHEMATIC - STAR-DELTA

56
8.9 BASIC FLOW SCHEMATIC - STAR-DELTAWITH MODULATION

57
 TYPICAL SYSTEM FLOW
DIAGRAM

8.10 TYPICAL SYSTEM FLOW DIAGRAMS

58
8.10 T Y P I C A L SYSTEM FLOW DIAGRAMS

59
8.10 T Y P I C A L SYSTEM FLOW DIAGRAMS

60
8.10 T Y P I C A L SYSTEM FLOW DIAGRAMS

61
8.10 T Y P I C A L SYSTEM FLOW DIAGRAMS

62
 9.0 MAINTENANCE RECORD

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

63
 MAINTENANCE RECORD

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

64
 MAINTENANCE RECORD

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

65
 MAINTENANCE RECORD

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

66