80235740

Edition1
June 2007

Starter Relay Valve

RR100

Installation and Maintenance

Information

Save These Instructions

Description
The RR100-F30-D includes air valve and regulator functions. The slave regulator using the pressure signal on top of the upper
The RR100-F30-D is made of three main components: piston will force the valve piston off its seat. That allows air to flow
1. The master regulator which sets the pilot pressure. into the control chamber below the upper piston, through the
2. The solenoid valve which will open or close the system when the outlet port of the RR100 valve to the starter motor. Outlet pressure
operator actuates the switch key. increases in the downstream system and sensing chamber (under
3. The slave regulator which is the main body. the upper piston) and applies an upward force on the bottom of
the upper piston. The upper piston and valve piston move upward.
The slave regulator will receive the signal from the master regulator
Upward movement stops when the forces below the upper piston
through the solenoid valve. For pre-engage starters the signal
balance the force above the upper piston.
pressure will come from the master regulator through the solenoid
valve to the pilot “In” port of the air starter drive housing, giving the WARNING
signal to engage the drive pinion into the ring gear. After engaging
the drive pinion, air will come out through the “Out” port of the drive Do not use this starter relay valve with natural gas or other
housing and will go to the cap of the slave regulator. flammable gases.

(Dwg. 45532504) (Dwg. 45533866)

Operation
Clockwise rotation of screw (1) will open the seat in the master The master pressure regulator is designed as a relieving regulator.
regulator and will increase the pressure between the master When the pressure below the diaphragm reaches 1.5 bars over the
regulator and solenoid valve (2). Do not try to exceed 11 bar or 160 adjusted pressure, the regulator exhausts the excess pressure.
psig (or slightly higher than the working pressure of the starter).
The pressure you adjust at the slave regulator will be slightly higher
than the working pressure at the starter. In order to easily adjust the
working pressure install a gauge on the gauge port.
1
2

(Dwg. 45534005)

 80235740_ed1
Dimensions

(75.8) [2.99]

1.00” SAE J518C Flange Head

(73.0) [2.88] Outlet Inlet

(52.4) [2.06] (68.1) [2.68]

4X 3/8 - 16 UNC Screws

(50.3) [1.98]

(76.3) [3.00]

4X (9.8) [.39]
(127.5) [5.02]

(50.8) [2.00]
(26.2) [1.03] 91-279

(43.7) [1.72]

(15.2) [.60]

(25.7) [1.01] (110.0) [4.33] (35.2) [1.39]

Ø (54.3) [2.14]

(Dwg. 45534021)

Schematics Piping Diagram

For Inertia Drive Applications

Gage Solenoid Valve

Master Regulator (Optional)
This line must be diverted if the
valve is used with pre engaged
air starter

Safety Valve (Optional)

In
Out

Slave Regulator

For Pre-Engaged Drive Applications

Gage Solenoid Valve

Master Regulator (Optional)

In Safety Valve
(Optional) In Out
M
Air Pre-engaged
Slave Regulator Air Starter

(Dwg. 80177223)

80235740_ed1 
Installation

The RR100-F30 is specially designed and manufactured by 2. For industrial or Marine applications the valve can be installed on
Ingersoll Rand for use on air starter installations. Install it in a steel pipe in a remote location. Apply SMB-441
accordance with the following instructions. Ingersoll Rand Sealant to the tapped inlet of Flange ST400-18.
Tighten the ST400-18 flange on the steel pipe to 80 Nm torque .
For installation of the valve on the starter 3. If desired, connect an outlet pressure gauge to the gauge port.
1. Install a 50 micron or 300 mesh compressed air Strainer upstream Gauge ports can also be used as additional outlets. Make sure
of the RR100-F30. If possible install the RR100-F30 directly on unused gauge ports are plugged.
the Starter. The valve is delivered with the flange and 4 captive 4. Mount the RR100-F30 valve to flange ST400-18 with supplied
screws. Using a 14 mm wrench, tighten the 4 captive screws to flange fittings. Tighten the four flange bolts to 40 Nm Torque.
40 Nm torque. 5. Attach a 1 inch hose to the outlet side of the valve with the
2. Install the O-Ring in the Inlet Flange groove. Attach a 1 inch hose ST400-16 4-bolt split-flange. Tighten bolts to 40 Nm torque.
to the inlet of the valve with a ST400-16 4-bolt split-flange. Using 6. Attach the 1 inch hose to the Starter Inlet flange. Tighten the 4
a 14mm wrench, tighten the four flange bolts to 40 Nm torque. bolts to 40 Nm torque.
3. If desired, connect an outlet pressure gauge to the gauge port. 7. Pressurize the complete starting system. Using a soap solution,
The gauge ports can also be used as additional outlets. Make sure check for leaks.
unused gauge ports are plugged.
For installation of the valve in a different location than
on the starter
1. Install a 50 micron or 300 mesh compressed air Strainer upstream
of the RR100-F30.

Specifications
Master Regulator Slave Regulator

Specifications Specifications

Flow Capacity 17 I/s (36 scfm) Air Flow Capacity 380 I/s (800 scfm) Air

Maximum Operating Maximum Operating

82°C (180°F) 82°C (180°F)
Temperature Temperature

Maximum Supply Pressure 30 bars (435 psig) Maximum Supply Pressure 30 bars (435 psig)

Adjusting Range Pressure 0 - 11, bars (160 psig) Adjusting Range Pressure 0 - 11, bars (160 psig)

Port Size NPT 1/4 Port Size SAE 1inch

Gauge Port (s) NPT (2) 1/8 Gauge Port (s) BSPT (2) 1/4

Weight kg (lb) 0.2 (0.48) Weight kg (lb) 0.2 (0.48)

 80235740_ed1
Materials of construction

Master Regulator

Materials of Construction

Body Brass

Bonnet Brass

Diaphragm Nitrile /Brass/Zinc-plated steel

Valve Assembly Nitrile

Springs Stainless Steel

Seals Nitrile

Slave Regulator

Materials of Construction

Housing Zinc/Steel

Cap Aluminum

Upper Piston Zinc

Valve Piston Assembly Brass/Polyurethane

Springs Stainless Steel

Seals Nitrile

Solenoid Valve

Valve Normally Closed 3/2 Way

Seat Port Diameter 1.3 mm
Max. Ambient Temperature 82°C
Min Temperature Dry Air -20°C
Kv 1.5
Max. working Pressure 10.5 Bars
Pressure to open plunger 16 Bars
Air Flow rate at 6 Bars 53 l/s
Plunger Stainless Steel
Body Material Zinc
Position Any
Seals Nitrile
Springs Stainless Steel
Connector Din 436540 (PG9)
Port 1/8 bsp
Protection IP 65

80235740_ed1 
Performance

RR100 -F30 Air Flow performance

Secondary Pressure in bars
12

10
4 bars
8 5 bars
6 bars
6 7 bars
8 bars
4 9 bars
10 bars
2

0
0 30 60 90 120 150 180 210 240 270 300 330 360 390 420 450

Liters per second

Nomenclature
RR 100 - F 30

Pressure at inlet
Pressure Regulator (Bar)
Relay Valve

1 inch Flange mounted SAE 1”

Maintenance and Recommendations

CAUTION
• Always wear eye protection when performing any maintenance on this valve.
• Always turn off the air and electrical supply and disconnect the air and electrical supply before installing or removing any
component on this valve, before making any adjustments on this valve or before performing any maintenance on this valve.

Disassembly
General Information Disassembly of the Main Valve Body
1. Do not disassemble the valve any further than necessary to Refer to Dwg. 45534054 and Parts List
replace worn or damaged parts. 1. Disconnect the pilot regulator assembly from the cap (1) of the
2. When grasping a part in a vise jaw, always use copper-covered valve.
vise jaws to protect the surface of the part and help prevent 2. Using a strap wrench, unscrew and remove the housing cover (2).
distortion. This is particularly true of threaded members. 3. Pull the return spring and the piston assembly (4) from the valve
3. Do not remove any part which is a press fit in or on a subassembly housing. Turn the valve housing upside down. Using a retaining
unless the removal of that part is necessary for replacement or ring pliers remove the retaining ring (5).
repairs. 4. Pull cap (1) from the valve housing.
4. Always have a complete set of seals and O-rings on hand before 5. Pull master piston (3) from the valve housing. Remove all the
starting any overhaul of a valve. Never reuse old seals or gaskets. O-rings to be replaced.

Assembly
General Instructions 2. Place O-ring (8) in the groove of the valve housing.
3. Install housing cover (2) in the valve housing. Using a strap
1. Whenever grasping a valve or part in a vise, always use
wrench tighten it enough not to loosen by hand.
copper-covered vise jaws. Take extra care with threaded parts or
4. Hold the valve housing in a vise.
housings.
5. Install O-ring (6) in the master piston groove, lubricate it with an
2. Clean every part before installation.
O-ring lubricant, and slide the master piston (3) into the valve
3. Apply a film of O-ring lubricant to all O-rings before final assembly.
housing.
Assembly of the Valve 6. Install O-ring (7) in the valve housing groove.
7. Install cap (1) in the valve housing. Install retaining ring (5) using
Refer to Dwg. 45534054 and Parts List
retaining ring pliers.
1. Lubricate the valve piston shaft with O-ring lubricant. Slide piston
8. Reconnect the pilot regulator assembly to the cap of the valve.
assembly (4) into the valve housing. Slide the piston spring into
the bottom of the piston.

 80235740_ed1
Valve / Regulator RR100-F30 Parts Diagram
1

5
3
7
6

8 4
2
(Dwg. 45534054)

Valve / Regulator RR100-F30 Parts List

Item Part Description Part Number

1 Cap RR100-616A
2 Housing Cover RR100-338
3 Upper Piston RR100-1
4 Valve Piston Assembly (includes spring, 6, 8) RR100-K618-3
5 Retaining Ring RR100-352
6 Upper Piston O-Ring RR100-341
7 O-Ring RR100-340
8 O-Ring RR100-337
9 Inlet O-Ring RR100-342
Solenoid Valve 24V-DC 5 watt & Override RR100-2450-5P
Solenoid Valve 24V-DC 5 watt & Screw RR100-2450-5S
Solenoid Valve 24V-DC 8 watt & Override RR100-K2450-8P
Pilot Regulator with Solenoid Valve Assembly RR100-K2450-5P
Valve Tune-Up Kit (Includes Items 4,5,6,7,8,9) RR100-TK1-3

Parts and Maintenance

CAUTION
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased motor performance, and
increased maintenance, and may invalidate all warranties.
Ingersoll Rand is not responsible for customer modification of motors for applications on which Ingersoll Rand was not consulted.
Repairs should be made only by authorized trained personnel. Consult your nearest Ingersoll Rand Authorized Service center.
When the life of the Tool has expired, it is recommended that the Tool be disassembled, degreased and parts be separated by material so
that they can be recycled.
Manuals can be downloaded from www.irtools.com.
Refer all communications to the nearest Ingersoll Rand Office or Distributor.

80235740_ed1 
www.irtools.com
© 2007 Ingersoll Rand Company