ML/MM/MH 45

ML/MM/MH/MJ 55
ML/MM/MH/MJ 75

OPERATORS/INSTRUCTION MANUAL
AND PARTS BOOK

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.

EFFECTIVE
Ingersoll Rand (I) Ltd.,
FROM 70715149IBPL
Peenya Industrial Area,
BANGALORE 560 058 New Release
TO
June, 2002
INDIA
1
2
 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

3
 TABLE OF CONTENTS
0.0 SAFETY AND WARNINGS
0.1 safety instructions 6.0 TROUBLE SHOOTING
0.2 safety precautions
0.3 decals 7.0 REFERENCE DRAWINGS
7.1 electrical schematic - full voltage
1.0 RECEIPT OF EQUIPMENT 7.2 electrical schematic - star delta
1.1 inspection 7.3 foundation plan - air cooled
1.2 unpacking and handling 7.4 foundation plan - water cooled
1.3 tools 7.5 foundation plan - outdoor mod
7.6 basic flow schematic - air cooled
2.0 INSTALLATION 7.7 basic flow schematic - water cooled
2.1 ventilation 7.8 typical system flow diagrams
2.2 foundation requirements
2.3 piping 8.0 WATER QUALITY RECOMMENDATIONS
2.4 electrical installation
2.5 outdoor sheltered installation 9.0 MAINTENANCE RECORD

3.0 INTELLISYS
3.1 emergency stop switch GENERAL INFORMATION
3.2 power on light
3.3 power indicator light Weight: See foundation plan, Section 7.0
3.4 push buttons
Cooling Air Flow: See foundation plan, Section 7.0
3.5 set point procedure
3.6 warnings Ambient Temperature Limit: 2°C to 46°C (35°F to 115°F)
3.7 alarms
Coolant: Factory Filled SSR Ultra Coolant
4.0 SYSTEMS
4.1 general systems Coolant Change: 8000 hours or two years, whichever
comes first
4.2 aircooled compressors
4.3 coolant system Coolant Capacity: 18.9 liters
4.4 compressed air system
4.5 coolant/air separation system Discharge Temperature Limit: 109°C (228°F )
4.6 electrical system
4.7 compressor control system Power Inlet Wiring: Recommended conduit: metallic
4.8 options flexible Greenfield, or equivalent,

5.0 MAINTENANCE Tools: Standard Tools are required

5.1 maintenance schedule to perform maintenance
5.2 maintenance records
5.3 maintenance procedures
5.4 inlet air filter
5.5 coolant filter
5.6 coolant
5.7 separator tank scavenge orifice/screen
5.8 coolant separator element
5.9 cooler cores
5.10 drive motor lubrication
5.11 long term storage
5.12 coolant/lubricant changeout
5.13 intellisys removal
5.14 coolant hoses
5.15 airend discharge hose

4
 faced for emphasis. The signal words DANGER,
0.0 SAFETY AND WARNINGS WARNING and CAUTION are used to indicate hazard
0.1 SAFETY INSTRUCTIONS seriousness levels as follows:
Before you install this air compressor you should
take the time to carefully read all the instructions
contained in this manual. Danger is used to indicate the
Electricity and compressed air have the potential to presence of a hazard which will
! DANGER cause severe personal injury, death,
cause severe personal injury or property damage.
or substantial property damage if the
Before installing, wiring, starting, operating or warning is ignored.
making any adjustments, identify the components of
the air compressor using this manual as a guide. Warning is used to indicate the
The operator should use common sense and good presence of a hazard which can
working practices while operating and maintaining
! WARNING cause severe personal injury, death,
this unit. Follow all codes, pipe adequately, or substantial property damage if the
understand the starting and stopping sequence. warning is ignored.
Check the safety devices by following the procedure
contained in this manual. Caution is used to indicate the
presence of a hazard which will or
Maintenance should be done by qualified personnel, ! CAUTION can cause minor personal injury or
adequately equipped with proper tools. Follow the property damage if the warning is
maintenance schedules as outlined in the operators ignored.
manual to ensure problem free operation after start
up. Notice is used to notify people of
installation, operation, or
Safety instructions in the operators manual are bold- NOTICE maintenance information which is
important but not hazard-related.
0.2 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
COMPRESSOR OR PERFORMING ANY MAINTENANCE
WARNING

COMPRESSED AIR AND ELECTRICITY 3. Do not operate the compressor at

higher discharge pressure than those 8. There can be adverse effects if
ARE DANGEROUS.
specified on the Compressor Nameplate compressor lubricants are
or motor overload will occur. This allowed to enter plant air
BEFORE DOING ANY WORK ON THIS
condition will result in compressor motor systems.
UNIT, BE SURE THE ELECTRICAL
SUPPLY HAS BEEN CUT OFF–LOCKED & shutdown.
Air line separators, properly
TAGGED AND THE ENTIRE
4. Use only safety solvent for cleaning the selected and installed, will
COMPRESSOR SYSTEM HAS BEEN
compressor and auxiliary equipment. minimize any liquid carry-over.
VENTED OF ALL PRESSURE.

5. Install a manual shut off valve (isolation The use of plastic bowls on line
1. Do not remove the covers, loosen or
type) in the discharge line. When a safety filters without metal guards can
remove any fittings, connections or
valve is installed between the isolation be hazardous. From a safety
devices when this unit is in operation. Hot
valve and the compressor, it must have standpoint, metal bowls should
liquid and air under pressure that are
sufficient capacity to relieve the full be used on any pressurized
contained within this unit can cause
capacity of the compressor(s). system. Review of your plant air
severe injury or death.
line system is recommended.
2. The compressor has high and 6. Whenever pressure is released through
the pressure relief valve, it is due to 9. When a receiver is installed, it
dangerous voltage in the motor starter
excessive pressure in the system. The is recommended that
and control box. All installations must be
cause for the excessive pressure should occupational safety and health
in accordance with recognized electrical
be investigated immediately. standards be adhered to in the
codes. Before working on the electrical
installation and maintenance of
system, be sure to remove voltage from
7. Before doing any mechanical work on this receiver.
the system by use of a manual-
disconnect-switch. A circuit breaker or the compressor:
10. Before starting the
fuse safety switch must be provided in
a.) Shut the unit down. compressor, its maintenance
the electrical supply line leading to the
instructions should be
compressor.
b.) Electrically isolate the compressor by thoroughly read and understood.
Those responsible for installation of this use of the manual disconnect switch in the
power line to the unit. Lock and tag the 11. After maintenance functions
equipment must provide suitable
switch so that it cannot be operated. are completed, covers and
grounds, maintenance clearance and
guards must be replaced.
lightning arrestors for all electrical
components as stipulated in Indian c.) Vent pressure from the compressor and
Electricity Rules. isolate the unit from any other source of
air.

5
 SAFETY SHUTDOWN
CHECK-HIGH-AIR-TEMPERATURE
There is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory 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. Block off the cooling air discharge.

2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge
temperature reaches the pre-set maximum discharge air temperature setting of the Intellisys. The display should
indicate “HIGH AIREND TEMP” and the alarm light will glow.

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 failure, property damage and serious injury or death.

All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must
take into account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In
addition, it should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility
between discharge piping, system accessories and software must be assured.

For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is not
recommended. In addition, flexible 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 pipework 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 services.”
0.3 DECALS

This section contains representative examples of

decals which will be appearing throughout this manual
and are applied to the compressor unit. If for some
reason a decal is defaced, painted over, or parts are
replaced, we recommend that you obtain a
replacement kit as listed in the spare parts section.

39879762
(3 REQUIRED)

39905443

70559018

39540257

39540273
(4) 2 EACH END

39541081
39540166
39905203
 70559026

39540240

39541362
39540265

3 REQUIRED - ONE ON LEFT PLENUM WALL

 39540174

39541354
39540174 39899950

10
39543764
39543764

39868419
1.0 RECEIPT OF EQUIPMENT
1.1 INSPECTION
When you receive the compressor please inspect it
closely. Any indication of careless handling by the carrier
should be noted on the delivery receipt especially if the
compressor will not be immediately uncrated. Obtaining
the delivery man’s signed agreement to any noted
damages will facilitate any future insurance claims.

IMPORTANT
READ THIS
LOST OR DAMAGED GOODS

THOROUGHLY INSPECT THIS SHIPMENT

IMMEDIATELY UPON ARRIVAL

OUR RESPONSIBILITY FOR THIS SHIPMENT

CEASED WHEN THE CARRIER SIGNED FORKLIFT PADDING
BILL OF LADING WILL REDUCE SCRATCHES
AND MARS
If goods are received short or in damaged condition, it is important that
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 enforced
against the transportation 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 will
make an inspection and grant a concealed damage notation. If you give
the transportation company a clear receipt for goods that have been
damaged or lost in transit, you do so at your own risk and expense.

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

MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THE
WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE
FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL.
THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR
RESPONSIBILITY.

Ingersoll-Rand Company
Bangalore

1.2 UNPACKING AND HANDLING

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

Slings can be used to lift the crates, but spreader bars

must be used to prevent the slings from exerting a force
against the sides of the crates.

1.3 TOOLS
Remove compressor unit from wooden skid. A crowbar
and hammer will be needed.

11
2.0 INSTALLATION
2.1 VENTILATION
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 ventilation.

If heated air from the compressor exhaust is allowed to

recirculate back to the compressor, the compressor will
overheat and shut down. This heat must be
exhausted from the room. You should take this into
consideration when you decide where to place the
compressor within your plant. Consider that the required
maintenance clearance is 3 ft (.9 m) all around the
compressor.
However 42” (1.06m), or minimum required by
applicable local codes, must be maintained in front of
starter box door.

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

should be avoided as well as areas of high
humidity.

Consider also the environment surrounding or near

the compressor. The area selected for the location
of the compressor should be free of dust,
chemicals, metal filings, paint fumes and overspray.

DUST CHEMICALS

METAL PAINT
FILINGS SPRAY

OVERSPRAY
2.3 PIPING
2.2 FOUNDATION REQUIREMENTS The use of plastic bowls on line filters without metal
Refer to the foundation plan for the particular model guards can be hazardous. Their safety can be affected
compressor to be installed. See Section 7.0. by either synthetic lubricants or the additives used in
mineral oil. From a safety standpoint, metal bowls
The compressor can be installed on any level floor that should be used on any pressurized system. Review of
is capable of supporting it. Compressor weights are your plant air line system is recommended.
listed on the foundation plans.

When sound transmission is of particular importance it WARNING

is often helpful to install a sheet of rubber-fabric-matting,
or cork under the compressor to reduce the possibility
of resonant sounds being transmitted or amplified Do not use plastic pipe, soldered copper
through the floor. fittings or rubber hose for discharge piping.

NOTICE The built-in aftercooler reduces the discharge air

temperature well below the dew point (for most ambient
Never elevate the compressor unit conditions), therefore, considerable water vapor is
above the floor level. This may allow air condensed. To remove this condensation, each
to enter the cabinet under the base. compressor with built-in aftercooler is furnished with a
Performance will be affected. combination condensate separator/trap.

12
2.3 PIPING (Continued)
A dripleg assembly and isolation valve should be
mounted near the compressor discharge. A drain line
should be connected to the condensate drain.

IMPORTANT: The drain line must slope downward from

the compressor to work properly.

NOTE: For ease of inspection of the automatic drain

trap operation, the drain piping should include an open
funnel.

It is possible that additional condensation can occur if

the downstream piping cools the air even further and
low points in the piping systems should be provided with
driplegs and traps.

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
maximum operating temperature of the unit and, at a
minimum, rated for the same pressure as the
compressor sump tank.

NOTICE

Do not use the compressor

to support the discharge pipe.

Careful review of piping size from the compressor

connection point is essential. Length of pipe, size of
pipe, number and type of fittings and valves must be
considered for optimum efficiency of your compressor.

It is essential when installing a new compressor to

review the total plant air system. This is to ensure a
safe and effective total system. 200

Liquid water occurs naturally in air lines as a result of 160

compression. Moisture vapor in ambient air is
concentrated when pressurized and condenses when
Gallons of Water/24

120
hours/1000 acfm

cooled in downstream air piping.

Moisture in compressed air is responsible for costly 80

problems in almost every application that relies on
compressed air. Some common problems caused by 40
moisture are rusting and scaling in pipelines, clogging of
instruments, sticking of control valves, and freezing of
outdoor compressed air lines. Any of these could result 0
in partial or total plant shutdown.
DEW POINT
Compressed air dryers reduce the water vapor con-
centration and prevent liquid water formation in without 100°F/38°C 35°F /1.7°C -40°F/-40°C
compressed air lines. Dryers are a necessary com- Aftercooling (with (Refrigerated (Desiccant
Aftercooler) Dryer) Dryer)
panion to filters, aftercoolers, and automatic drains for
improving the productivity of compressed air systems.
MOISTURE CONTENT OF COMPRESSED AIR

13
Two types of dryers, refrigerated or desiccant, are used
to correct moisture related problems in a compressed
air system. Refrigerated dryers are normally specified
where compressed air pressure dew points of 1°C
(33°F) to 4°C (39°F) are adequate. Desiccant dryers
are required where pressure dew points must be below
1°C (33°F).

Contact your local Ingersoll-Rand distributor for

assistance in selecting correct Ingersoll-Rand filtration
or drying products.

NOTE: Screw type compressors should not be installed

in air systems with reciprocating compressors without a
means of pulsation isolation, such as a common
receiver tank. 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 valve and drain trap for each compressor
before the common receiver.

2.4 ELECTRICAL-INSTALLATION

Before proceeding further, we recommend that you

review the safety data in the front of this manual.

Locate the compressor data plate on the left rear corner

of the unit.

The data plate lists the rated operating pressure, the

maximum discharge pressure and the electric motor
characteristics and power.

Confirm that the line voltage and compressor nameplate

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

Open the starter box door. Confirm that all electrical

connections are made and tightened. Confirm that the
control transformer is wired correctly for supply voltage.
See Figure 2.4-1 on next page for typical control
transformer wiring.

FUSE TABLE
Starter Size Control Transformer 1FU & 2FU 4FU & 5FU 3FU
(T1) Size Primary Fuse Secondary Fuse
( Amp ) ( Amp )

C70SD 350VA 6A 2A 6A

14
ELECTRICAL-INSTALLATION (Continued)
Inspect the motor and control wiring for tightness.

Close and fasten the starter box door.

Rotation Check
Locate the rotation decal on each motor.

Drive Motor
The correct compressor drive motor rotation is
clockwise when viewed from the rear or non-drive
end of the motor. See Figure 2.4-2.

CAUTION

If the compressor is operated in the

opposite direction of rotation, airend damage
can result and is not warrantable.

15
ELECTRICAL-INSTALLATION (Continued)
Open the starter box door.
The Intellisys will automatically shut the unit down if the
compressor rotation is incorrect, and “CHK MTR Interchange any two line connections (L1, L2 or L3) at
ROTATION” will appear in the display, also the alarm the starter. Close and fasten the starter box door.
light will be on. See Section 6. Recheck for correct rotation.

For the compressor motor rotation check, the motor Fan Motor
jogging time must be as short as possible. Observe the compressor cooling fan. The rotation
should be in accordance with the fan rotation decal
After depressing the start button, IMMEDIATELY affixed to the fan motor. Cooling air should exhaust
depress the “EMERGENCY STOP” button. Should through fan end of compressor enclosure.
the motor rotation be incorrect, put main
disconnect in the OFF position, lock and tag. See Should the motor rotation not be correct, put the main
Figure 2.4-3. disconnect in the OFF position, lock and tag.

Interchange any two fan motor leads at the fan motor

overload relay (FMS/OL). Close and fasten the starter
box door. Recheck for correct rotation.

Fan motor rotation is clockwise when viewed from

the fan motor side.

Intellisys Operating Instructions

Read and understand the following Intellisys Operating
Instructions (See Figure 2.4-4) prior to operating the
unit.

NOTE: These instructions are also contained on

the decal near the Intellisys panel of the unit.

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
Stopping
1. Check coolant level. Add voltages are available for will stop immediately.
1. Push “UNLOADED STOP”.
coolant if necessary. starting.“UNLOAD” indicator 2. Open main disconnect switch.
Compressorwill immediately
2. Verify that main isolation light will be on. Stopping - Emergency
unload and continue to run
valve is open. Starting 1. If there is a need to stop the
unloaded roximately 7
3. If water-cooled, turn on 1. Push “START”. Compressor compressor immediately or if the
seconds.Compressor will then
water. will load automatically and the “UNLOADED STOP” does not stop
stop. If compressor is running
4. Close main disconnect air pressure will riseif there is the compressor after 7seconds,
unloaded when “UNLOADED
switch. The“POWER” light sufficient demand for air. push “EMERGENCY STOP”
STOP” is pushed, compressor
indicates that line and control 2. Open main disconnect switch.

FIGURE 2.4-4 INTELLISYS OPERATING INSTRUCTIONS

16
2.5 OUTDOOR SHELTERED INSTALLATION
n Incoming power connections must use
Many times a compressor must be installed outside suitable connectors for outdoor weather
due to jobsite conditions or limited space within a tight service.
manufacturing facility. When this occurs there are
certain items that should be incorporated into the
n A minimum of 3 ft (.9 m) clearance must be
installation to help ensure trouble free operation. allowed on all four sides of the unit for
These items have been listed below plus Figure service access. If possible, access by a
2.5-1 has been included to show a typical outdoor forklift and/or an overhead beam hoist
sheltered installation.The unit must be purchased should be kept in mind (for eventual
with the Outdoor Modification Option to provide service to airend or motor).
NEMA 4 electrics and a cabinet exhaust on the end n If the area around the installation contains
of the unit rather than the top to prevent recir- fine airborne dust or lint and fibers etc.,
culation of cooling air. then the unit should be purchased with the
n The compressor should be on a concrete High Dust Filter Option and TEFC motors.
pad designed to drain water away. If the n If larger debris, such as leaves or trash,
concrete pad is sloped, then the compres- are blowing in the area, the Cabinet Pre-
sor must be leveled . In order to properly filter Accessory should be purchased and
pull cooling air through the aftercooler, the added to the unit (ship loose item).
base/skid must be sealed to the concrete
pad. n Some type of protection such as a fence or
security system, should be provided to
n The roof of the shelter should extend a prevent unauthorized access.
minimum of 4 ft (1.2 m) around all sides of
the compressor to prevent direct rain and
snow from falling on the unit.
n Air-cooled machines must be arranged
under the shelter in a way that prevents air
recirculation (i.e. hot exhaust back to the
package inlet).
n 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 Dryer.
n If a standard machine is to be installed
outside, the ambient temperature must
never drop below 35°F (1.7°C).
n Arrange the machine with the Intellisys
controller/starter enclosure facing away
from the sun as radiant heat can affect
starter/lntellisys performance. Also direct
sunlight and UV rays will degrade the
membrane touch panel.This is not a
warrantable situation.
n Power disconnect switch should be within
line of sight and in close proximity to the
unit. Local electrical codes must be fol-
lowed when installing the power disconnect
switch.
n Condensate drains must never be allowed
to dump on the ground. Run to a suitable
sump for future collection and disposal or
separation of lubricant and water mixture.

17
18
19
INTELLISYS CONTROLLER
3.0 INTELLISYS
3.0 INTELLISYS UNLOAD STOP

3.1 EMERGENCY STOP SWITCH Pressing this button will activate the unload stop. -If
the compressor is running loaded, it will unload.
Pressing this switch stops the compressor Seven seconds later it will stop. -if the compressor is
immediately. Compressor cannot be restarted until running unloaded, it will stop immediately. Pressing
switch is manually reset. Turn clockwise to reset. 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”.

20
3.4 PUSH BUTTONS (Continued)
PRESSURE SENSOR CALIBRATION (ZEROING)
DISPLAY SELECT ROUTINE

Pressing this button will change the information This routine is entered if the unit is not running and
selected for the display. The display table will be both the up and down arrows button are pressed at
incremented. If the button is held, this display table the same time. -Make sure all pressure is relieved
will scroll. This button can also be used to exit the from the compressor before calibration. The display
set point procedure. 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.

21
 ** The lead/lag feature allows the customer to choose
3.5 SET POINT PROCEDURE
one compressor as the “lead” compressor and any
others as the “lag” compressor (simulates the mode of a
This procedure allows the customer to modify 11
sequencer). The lag compressor’s on-line and off-line
variables in the controller logic.
pressures are determined by subtracting the lag offset
set-point from the on-line and off-line pressure set-
At this time, press the SET button to enter the set points of the lead compressor.
point routine. The SET OFFLINE AIR PRESSURE
indicator will light and the display will show:

XXXX PSI 3.6 WARNINGS

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

*Optional
3.7 ALARMS 10) CK MTR ROTATION
When an alarm occurs, the alarm indicator will light This alarm will occur if a unit is started and
and display will show actual alarm message. If compressor has incorrect rotation.
alternately multiple alarms have occurred the display
will show SCROLL FOR ALARM. In this situation the 11) CALIBRATION FAIL
up and down arrows will be used to view the alarm This alarm will occur if the sensor calibration routine
messages. All alarms (with the exception of the is executed and the sensor reading exceeds 10% of
emergency stop) will be reset by twice pressing the scale.
SET button. Any exceptions to the above will be
explained in the alarm description. 12) NO CONTROL POWER
This alarm will occur when the controller senses a
The following is a list of the alarm messages. loss of control power.

1) LOW SUMP PRESS 13) PRES SENSOR FAIL

This will occur if the unit is running and sump Whenever the pressure sensor is recognized as
pressure is too low. missing or broken, a pressure sensor failure alarm
will occur.
2) HIGH AIR PRESS
This will occur if the unit is running and sump
pressure is greater than unit rated operating INITIAL CHECK ALARMS
pressure plus 1.4 bar (20 psig), plus the separator
pressure drop, or the line pressure is 1.0 bar (15 14) HIGH AIREND TEMP
psig) above the rated pressure.
This will occur if airend discharge temperature is
3) HIGH AIREND TEMP greater than 103°C (217°F).
This will occur if airend discharge temperature is
greater than 109°C(228°F ). This alarm will only occur when the machine is not
running. When it occurs, the message MUST COOL
4) STARTER FAULT DOWN is added to the alternating group of alarm
This alarm will occur if the starter contacts open messages.
while the unit is running. This alarm will also occur if
the unit is given the stop command and the starter EMERGENCY STOP
contacts do not open.
This will occur when the EMERGENCY STOP
5) MAIN MTR OVERLD button is engaged. The alarm indicator will light and
This will occur if a motor overload is sensed. display will show:

6) FAN MTR OVERLOAD EMERGENCY STOP

This will occur if a fan motor overload is sensed.
Disengage the EMERGENCY STOP button and
7) TEMP SENSOR FAIL press the SET button twice to reset this alarm.
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.
 Cooling Fan Motor
4.0 SYSTEMS
In a standard compressor, the cooling fan motors
4.1 GENERAL SYSTEM INFORMATION are wired at the factory. They are three-phase-
motors. Each is protected by a fan motor starter/
The SSR compressor is an electric motor driven, overload. The fan motor is energized at the same
single stage, screw compressor—complete with time the compressor drive motor is energized. The
accessories piped, wired and baseplate mounted. It fan motor starter/overload is wired in series with the
is a totally self-contained air compressor package. compressor drive motor overload. If an overload
occurs in the fan motor circuit, both the fan motor
A standard compressor is composed of the and compressor drive motor will stop.
following:
Aftercooler
Inlet air filtration
Compressor and motor assembly The discharge air aftercooling system consists of a
Pressurized coolant system with cooler heat exchanger (located at the cooling air discharge
Separation system of the machine), a condensate separator, and an
Capacity control system automatic drain trap.
Motor starting control system
Instrumentation By cooling the discharge air, much of the water
Safety provisions vapor naturally contained in the air is condensed
Aftercooler and eliminated from the downstream plant-piping
Moisture separator and drain trap and equipment.

Optional accessories can provide for such things as 4.3 COOLANT SYSTEM
remote starting or stopping and sequencer.
Coolant is forced by pressure from the receiver-
4.2 AIR COOLED COMPRESSORS separator sump to the inlet port of the coolant cooler
and the bypass port of the thermostatic control
Design Temperatures valve.

The standard compressor is designed for operation The thermostatic control valve controls the quantity
in an ambient range of 1.7°C to 46°C(35°F to 15°F of coolant necessary to provide a suitable
). When conditions other than design levels compressor injection temperature. When the
described are encountered, we recommend you compressor starts cold, part of the coolant will
contact your nearest Ingersoll-Rand representative bypass the cooler. As the system temperature rises
for additional information. above the valve setting, the coolant will be directed
to the cooler. During periods of operation in higher
The standard maximum temperature 46°C (115°F) is ambient temperatures, all the coolant flow will be
applicable up to an elevation of 3300 ft. (1000 directed through the cooler.
meters) above sea level. Above this altitude,
significant reductions in ambient temperature are The compressor injection minimum temperature is
required if a standard drive motor is to be used. controlled to preclude the possibility of water vapor
condensing in the receiver. By injecting coolant at a
Coolant Cooler sufficiently high temperature, temperature of the
discharge air and lubricant mixture will be kept
The cooler is an integral assembly of core, fan and above the dew point.
fan-motor, mounted in the compressor. The cooling
air flows in through the left side of the enclosure, The controlled temperature coolant passes through
through the vertically mounted cooler core, and a filter to the airend under constant pressure.
discharges upward through the top of the enclosure.
4.4 COMPRESSED AIR SYSTEM Operation

The air system is composed of: The coolant and air discharging from the
compressor flow into the separator tank through a
tangential inlet. This inlet directs the mixture along
1. Inlet air filter the inner circumference of the separator tank,
2. Inlet valve allowing the coolant stream to collect and drop to
3. Rotors the separator tank sump.
4. Coolant/air separator
5. Minimum pressure/check valve Internal baffles maintain the circumferential flow of
6. Aftercooler remaining coolant droplets and air. In an almost
7. Moisture separator/drain trap continuous change of direction of flow, more and
more droplets are removed from the air by inertial
action and then returned to the sump.
Air enters the compressor, passing through the inlet
air filter and inlet valve. The air stream, now essentially a very fine mist, is
directed to the separator element.
Compression in the screw-type air compressor is
created by the meshing of two helical rotors (male The separator element is constructed with two
and female) on parallel shafts, enclosed in a heavy- concentric, cylindrical sections of closely packed
duty cast iron housing, with air inlet and outlet ports fibers, each held in steel mesh. It is flange-mounted
at the receiver-outlet-cover.
located on opposite ends. The grooves of the female
rotor mesh with, and are driven by, the male rotor. The air stream enters the separator element radially
Tapered roller bearings at the discharge end prevent and the mist coalesces to form droplets. The
axial movement of the rotors. droplets collected on the outer first stage fall to the
receiver sump. Those collected on the inner second
The air-coolant mixture discharges from the stage collect near the outlet of the element, and are
compressor into the separation system. This system, drawn back to the compressor inlet through a filter-
self-contained in the receiver tank, removes all but a screen and orifice fitting installed in the separator
scavenge line.
few PPM of the coolant from the discharge air. The
coolant is returned to the system and the air passes The air stream, now essentially free of coolant,
to the aftercooler. The aftercooling system consists flows from the separator to the aftercooler, then to
of a heat exchanger, a condensate separator, and a the condensate separator, and on to the plant air
drain trap. By cooling the discharge air, much of the system.
water vapor naturally contained in the air is
condensed and eliminated from the downstream 4.6 ELECTRICAL SYSTEM
plant-piping and equipment.
The electrical system of each SSR compressor is
built around the microprocessor-based Intellisys
During unloaded operation, the inlet valve closes controller.
and the blowdown solenoid valve opens, expelling
any compressed air back to the compressor inlet. The standard electrical/electronic components,
enclosed in a readily accessible enclosure include:
4.5 COOLANT/AIR SEPARATION SYSTEM
1. SSR Intellisys controller
The coolant/air-separation-system is composed of a 2. Control transformers and fuses
3. Compressor motor starter, with auxiliary contacts
separator tank with specially designed internals, a
two-stage, coalescing-type separator-element, and and overload relays
provision for return of the coolant back to the 4. Cooling fan motor starter/overload
compressor.
4.7 COMPRESSOR CONTROL SYSTEM
Tools Required
The Intellisys® controls the various operating modes
of the compressor, monitors key compressor • 1/2" open end wrench.
operating parameters, and shuts the compressor • 9/16" open end wrench.
down in the case of an operating problem. The • Loctite® 242 or equivalent.
control system has customer adjustable inputs as
With the compressor shut down remove the nut that
described in the Intellisys® section 3.0. The
fastens the inlet valve pivot anchor to the bracket on
compressor control system has the following
the inlet valve. Apply Loctite® 242 or equivalent to
standard features.
threads on spacer and loosely install nut. Start
compressor and press the unload button so that the
• Automatic Unloaded Start. compressor will not load. Use the display select button
• On/Off Line Capacity Control. to indicate sump pressure on the display. Move the
• Unloaded Stop. position of the pivot anchor to alter the sump pressure
• Automatic Start/Stop. until the sump pressure is between 25-35 psig (1.7-2.4
• Compressor Fault Warning. bar). Moving the pivot towards the inlet valve will raise
• Compressor Fault Alarm Shutdown. the sump pressure. Moving the pivot away from the
inlet valve will lower the sump pressure. Once the
The following paragraphs provide a description of position is correct, fully tighten the nut.
the standard features. Please also refer to the flow
schematic in section 7.0. On/Off Line Control

Automatic Unloaded Start The standard control system provides for either full
compressor capacity flow or zero flow based on the
Pushing the start button signals the Intellisys® to system pressure. If the system pressure falls below
engage the starter coils and opens the oil stop valve the on line set point, the Intellisys® energizes the
(5SV). The compressor will always start in the load/unload solenoid (1SV) and the blowdown
unloaded mode, with the inlet valve in the closed solenoid (3SV). This causes the inlet valve to open
position and the blowdown valve open to vent the and the blowdown valve to close. Compressed air
pressure from the separator tank. The unloaded flows into the system.
start ensures that the compressor has a low starting
torque requirement and that proper oil flow is If system pressure reaches the off line setting, the
established before the compressor loads. compressor unloads to minimize power demands.
Compressors with full voltage starters will not load The Intellisys® de-energizes the load/unload
for seven seconds after the starter button is solenoid
pressed. Compressors with optional star-delta (1SV) and the blowdown solenoid (3SV). This
starters will not load until two seconds after star- causes the inlet valve to close and vents the
delta transition. If system pressure is below the on separator tank. The minimum pressure check valve
line set point pressure, the compressor will (MPCV) closes to prevent back flow from the
automatically load at this time. Press the load/unload compressed air system. The compressor operates at
button to prevent the compressor from loading. minimum power until the system pressure falls to the
on-line pressure setting.
Adjustment Of Unloaded Sump Pressure.
Delay Load Time
During unloaded operation, the inlet valve must allow
some air flow past it to maintain sump pressure for This is the amount of time the line pressure must
proper lubricant flow. This air is compressed by the remain below the on line set point before the
compression module and vented through the compressor will load or start (if the unit was stopped
blowdown valve (3SV). By adjusting the closed due to an auto start/stop situation). This timer will
position of the inlet valve plate, the unloaded sump not delay loading after a start or if the time is set to
pressure can be varied. The unloaded sump pressure
zero. The delay load time feature is useful if the
is set at the factory and should not need adjustment
compressor is operating as a backup to another
under most circumstances. If adjustment is required
compressor and is normally stopped in auto start/
use the following procedure.
stop mode. The delay load time prevents the
compressor from starting and loading if the system
air pressure momentarily drops below the on line
setting of the backup compressor. If no delay is
desired the delay load time setting should be set to
zero.
26
Unloaded Stop
Automatic Start/Stop Operation
If the compressor is running at full load and the
unloaded stop button is depressed, the compressor When in operation, the compressor must meet two
will unload and stop only after running unloaded for specific timing intervals before the Intellisys controller
seven seconds. If the compressor is already unloaded, will stop the unit in an Automatic Start/Stop situation.
the compressor will stop immediately. Use of the
unloaded stop button is the preferred method of For this discussion, the timers will be called timer "A"
stopping the compressor. If an immediate shutdown is and timer "B".
required the EMERGENCY STOP button should be
used. FIRST
Timer "A" prevents the compressor from automatically
Automatic Start/Stop Control starting more than 6 times an hour by requiring the
unit to run at least 10 minutes after each automatic
Many plant air systems have widely varying air start.
demands or large air storage capacity which allows for
automatic standby air capacity control. This 10 minute run period can be loaded, unloaded or
a combination of the two and allows dissipation of
The Intellisys system has been designed to carry out heat generated within the motor windings at start.
this function utilizing a software option module.
Automatic Start/Stop is available as a factory instailed SECOND
option or as a field installation kit. After the compressor has started and reached the off-
line setting and has unloaded, timer "B" requires the
During penods of low air demand, if the line pressure unit to run unloaded for a period of time that the
rises to the upper set point, the Intellisys begins to operator can adjust between 2 and 60 minutes.
time out. If the line pressure remains above the lower
set point for as long as the set time, the compressor The setting of timer "B" is part of the options setpoint
will stop. At the same time the display will indicate the routine and the timer cancels any accumulated time if
compressor has shut down automatically and will the compressor reloads before the timer cycle has
restart automatically. An automatic restart will occur finished.
when the line pressure drops to the lower set point.
An important point... This unloaded run time may, or
The upper and lower set points and shutdown delay may not, be included in the mandatory 10 minute run
time are set on the Intellisys control panel. There is a time used to cool the motor windings.
10 second delay after shutdown during which the
compressor will not restart even if line air pressure When the compressor has completed the settings of
drops below the lower set point. This is to allow the both timer "A" and timer "B", the Intellisys controller
motor to come to a complete stop and the Intellisys stops the compressor and displays "STOPPED IN
controller to collect current data of operating condition. AUTO RESTART."
If line air pressure is below the lower set point at the
end of 10 seconds, the unit will start unless the load Pressure sensor 3APT continues to monitor the
delay timer is set greater than 10 seconds. package discharge pressure and sends information to
the controller which automatically restarts the
Delay Load Time compressor when the pressure falls to the on-line
setting.
This is the amount of time the line pressure must
remain below the online set point before the An advantage to this method of automatic start/stop
compressor will load or start (if the unit was stopped control is allowing the compressor to stop much
due to an auto start/stop situation). This timer will not sooner in certain situations and timer settings,
delay loading after a start or if the time is set to 0. thereby reducing power costs.
When the delay load timer becomes active, the display
will show the delay load countdown. Once the
countdown reaches 0, the unit will load or start.

27
Some Examples of Operation 4.8 OPTIONS

EXAMPLE 1 Several options are available with the Intellisys®

The operator selects an unloaded run time of 2 control. These include starter options, remote start/stop
minutes in the OPTION routine and starts the option, power outage restart, sequencer control, and
compressor. The unit runs loaded for 8 minutes, modulation control.
unloads and then runs unloaded for two more minutes.
4.8.1 Starter Options
The total running time is 10 minutes which satisfies
timer “A” plus the unit ran two minutes unloaded which The standard compressor is supplied with a reduced
also satisfies timer “B,” therefore, the unit stops voltage (star delta) starting fully installed at the factory
automatically. and is also controlled by the Intellisys. This starter
initially provides a reduced voltage to the compressor
This example shows how timer “B” can sometimes be motor to reduce starting current spike. After the
included within the timer “A” interval. Think of the two compressor motor is at full speed, the starter transitions
timers as running parallel. to supply full line voltage to the compressor motor.

EXAMPLE 2
The operator selects an unloaded run time of 3 4.8.2 Remote Start/Stop
minutes in the OPTION routine and starts the
compressor. The unit runs loaded for 10 minutes and The remote start/stop option allows the operator to
then unloads. control the compressor from a remote mounted start/
stop station. This option may be factory installed or a
At this point, timer “A” has been satisfied but timer “B” field installation kit is available. This feature requires a
still wants the compressor to run unloaded 3 more software option module.
minutes before allowing an automatic stop.
With the optional plug-in module installed, two different
The total run time for this example will be 13 minutes. switches can be wired to the controller for remote start/
stop. (Refer to Electrical Schematics 7.1 or 7.2 for
Remember.... If the unit reloads before timer “B” wiring locations). The switches are customer supplied
finishes the 3 minute setting, the partial time is and must be of momentary type. The stop switch
canceled and timer “B” must restart the 3 minute cycle contacts are normally closed and the start switch
when the compressor unloads again. contacts are normally open.

EXAMPLE 3 When starting the compressor from the remote location,

The operator selects an unloaded run time of 10 the Start button must be held depressed for
minutes in the OPTION routine and starts the approximately 2 seconds to activate the remote start
compressor. The unit runs loaded 12 minutes and then function and then released within a maximum of 7
unloads. seconds or a Remote Start Failure alarm will occur.

After 12 minutes of running, the 10 minute mandatory 4.8.3 Power Outage Restart
run-time for timer “A” has been met but the
compressor must continue to run unloaded an For customers that have interruption in their incoming
additional 10 minutes to satisfy timer “B”. power supply to the compressor and must maintain an
uninterrupted supply of compressor air, the Power
After 10 minutes of unloaded run time, the compressor Outage Restart Option allows an Intellisys®
is stopped automatically and the total run time was 22 compressor to automatically restart after incoming
minutes. power is restored.
 Modulation Only
The Power Outage Restart Option is turned on by
plugging in the required option module and enabling it
The "MODULATlON" control mode can be selected
through the set point routine. The restart time delay, during the set point procedure on a compressor that
which is adjustable from 10-120 seconds, can also be has the modulation option installed. To load, the
adjusted while in the set point routine on the Intellisys® energizes the load solenoid (1SV) and
Intellisys® controller. Any time power is restored to the blowdown solenoid (3SV) as in on line/off line
compressor after a power interruption, a horn located control. The Intellisys® also energizes the
on the side of the starter box will sound during the modulation solenoids (2SV and 6SV). This connects
restart time delay (10-120 seconds) , after which the regulated pressure from the modulator valve (MV) to
compressor will automatically start. After starting, the the air cylinder. The regulated pressure decreases
compressor will return to the mode of operation that with increasing system pressure near the set point
the compressor was in prior to the power interruption. of the modulation valve. This causes the inlet valve
to throttle the compressor flow. The modulator valve
This option may be installed at the factory or in the is factory set such that the compressor will modulate
field by using an available kit. The remote start/stop to approximately 60% of rated capacity before the
option is included with this option. off line pressure is reached. If the system pressure
continues to increase, the compressor will unload at
4.8.4 Sequencer Control the off line pressure setting. If the system pressure
falls below the on line set point, the compressor will
Sequencer control capability can be added to the load in the modulation control mode.
Intellisys® system by using a sequencer interface.
This option is available as a field installation kit. Modulate/ACS Control

In compressors equipped with the modulation option

4.8.5 Modulation
the "MOD/ACS" control mode allows the Intellisys®
to select the most appropriate control mode to
On/Off Line control is the most efficient mode of match system demands. This eliminates the need for
operation for the compressor. For compressed air manual selection of the control mode to
systems that have a continuous demand near the full accommodate various compressed air demand
capacity of the compressor, modulation control will cycles.
prevent excessive cycling of the compressor and
provide a more constant supply pressure. Modulation When operating in the MOD/ACS" control mode, the
control will also prevent excessive cycling if the compressor automatically defaults to the on line/off
compressed air system volume is small. An air line control mode. If the compressor completes three
compressor should never be installed in a compressed load/unload cycles within a three minute time period
air system volume with a ratio of receiver volume (in the Intellisys® determines that there is a high
gallons) to total compressor capacity (in cubic feet per demand for compressed air. The Intellisys® switches
minute) of less than one. to modulation control in an attempt to match the
compressed air demand by regulating the flow. The
On/Off Line Control compressor continues to operate in the modulation
control mode until the compressor operates
The modulation control system retains all the unloaded for three minutes. This is an indication that
features of on-line/off-line control but provides for compressed air usage has fallen off and that on/off
throttling of the compressed air flow to match line is a more appropriate control mode. The
system demand. The compressor can be set to Intellisys® changes the control mode to on/off line
operate in "ON/OFF LINE" control using the set and continues to operate in this manner until three
point procedure even if the compressor has the load/unload cycles occur within three minutes.
modulation option. If the compressor is set in the on
line/off line control mode, it operates as described in Modulate Control Valve Adjustment
section 4.7.
Tools Required

• 7/16" open end wrench.

• Pressure Gauge 0-100 PSIG.
• Loctite® PST or equivalent.
The modulator valve is set at the factory to modulate
at the compressor's rated pressure. For example a
compressor with a 125 psig (8.6 bar) pressure rating
will modulate up to 60% capacity when the system
pressure is near the default off line setting of 128
psig. (8.8 bar). The following procedure describes
the method of setting the modulation valve. The
desired pressure should never be more than 3 psig
(.2 bar) below the off line pressure entered during
the set point routine. For example if the off line
pressure is set at 96 psig (6.6 bar), the desired set
point pressure should be 93 psig (6.4 bar).

Ensure that the compressor is isolated from the

compressed air system by closing the isolation valve
and venting pressure from the system.

Ensure that the main power disconnect switch is

locked open and tagged.

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

control piping and connect a pressure gauge to this
port.

2. Reconnect power to the compressor. When

display reads "READY TO START," enter the set
points routine and set control mode to
"MODULATION".

3. Start the compressor and elevate system

pressure to desired set point pressure. This
pressure must be maintained while adjusting the
modulator valve.

4. Loosen the lock nut on the bottom of the

modulator valve and turn the adjusting screw to
modify the modulation valve set pressure. Turning
the screw counterclockwise (as viewed from the top)
raises the set point pressure. Turning the screw
clockwise lowers the set point pressure.

5. Adjust the screw while maintaining system

pressure at the desired value until the output
pressure of the modulator valve is 30 psig (2.1 bar).
Tighten the locknut.

6. Stop the compressor and lock open the main

disconnect. Insure that all pressure is bled from the
system.

7. Remove pressure gauge from modulation valve

and re-install 1/8" NPT plug in tee in control piping
using Loctite® PST or equivalent to seal threads.

30
NOTES:

31
 5.0 SCHEDULED PREVENTATIVE MAINTENANCE
5.1 MAINTENANCE SCHEDULE
THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE
COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT
NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST.

Running Time Interval (whichever comes first)

Action Part or Item Hours 1 Week 1 Mo. 3 Mo. 6 Mo. Yearly 2 Years

Inspect Coolant level Weekly x

Inspect Discharge temperature (air) Weekly x
Inspect Separator element differential Weekly x
Inspect Air filter Delta P (at full load) Weekly x
Replace Coolant filter* 150 x(initial change only)
Check Temperature sensor 1000 x
Replace Food grade coolant (when used) 1000 x
Inspect Hoses 1200 x
Replace Coolant filter* 2000 x (subsequent changes)
Clean Separator scavenge screen and orifice 4000 x
Clean Cooler cores** 4000 x
Replace Air filter* 2000 x
Replace Separator element* *See special note.
Replace Ultra Coolant* 8000 x
Inspect Starter contactors 8000 x
Service Drive/Fan motor lubrication See Section 5.10.

* In very clean operating environments and where inlet filter is changed at the above prescribed intervals.
In extremely dirty environments change coolant, filters, and separator elements more frequently.

** Clean cooler cores if discharge air temperature is excessive or if unit shutdown occurs on high air temperature.

5.3 MAINTENANCE PROCEDURES

5.2 MAINTENANCE RECORDS Before starting any maintenance, be certain the
It is very important that you, the owner, keep accurate following is heeded.
and detailed records of all maintenance work you, or the
Ingersoll-Rand Distributor or Air Center perform on your 1. Read Safety Instructions.
compressor. This includes but is not limited to coolant 2. Use correct tools.
filter, separator, inlet air filter and so forth. This information 3. Have recommended spares on hand.
must be kept by you, the owner, should you require
warranty service work by your Ingersoll-Rand Distributor
or Air Center. Maintenance record sheets are located at
the back of this manual.

SPECIAL-NOTE:
Replace separator element when the separator
differential pressure ( V P) reaches three times the
initial pressure drop or a maximum pressure
differential of 12 psi (.8 bar) at full load or if the
Intellisys warning CHANGE-SEPARATOR-ELEMENT is
displayed. See Section 3.6.

32
5.4 INLET AIR FILTER

The filter should be changed when the filter indicator

shows red.

The filter should be changed every 2000 hours and

more frequently in dirty environments because coolant,
coolant filter, separator element, and airend life are a
direct function of how well you maintain and replace the
inlet air filter.

To change inlet filter elements, loosen wing nut on top of

inlet filter housing. Lift cover up and away to expose
INLET AIR FILTER
element.

Carefully remove the old element to prevent dirt from

entering the inlet valve. Discard old element.

Thoroughly clean the element housing and wipe all NOTICE

surfaces.

Install new element and inspect to ensure that they

have seated properly. Improper coolant filter replacement
will cause compressor damage.
Install top of inlet filter housing.
Replace filter element after first 150
Inspect the rubber seal on the retainer wing nut and hours of operation and every 2000 hours
replace seal if required. thereafter or when coolant is changed.
Tighten wing nut.

Start machine and run in the load mode to verify filter

condition.

5.5 COOLANT FILTER

The coolant filter should be changed after the first 150

hours of operation and every 2000 hours thereafter, or
when the coolant is being changed. In dirty operating
environments the filter should be changed more
frequently.

Use a suitable device and loosen the old element. Use

drain pan to catch any leakage during removal. Discard
old element.

Wipe the sealing surface of the filter with a clean, lint-

free rag to prevent the entry of dirt into the system.

Remove the replacement element from its protective

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

Screw element on until the seal makes contact with the

head of the filter assembly. Tighten approximately one-
half turn additional.

Start unit and check for leaks. COOLANT FILTER (45-75 KW)

33
5.6 COOLANT

Q SSR Ultra Coolant (Standard Factory Fill) Coolant fill quantity

SSR Ultra Coolant is a polyglycol base coolant. Change 60 hp (45KW) .................. 19 liters (5 gallons)
Ultra Coolant after every 8000 hours or every two years,
75-100 hp (55-75KW)...... 34.2 liters (9 gallons)
whichever comes first.

Items Required
In addition to the tools normally found in any reasonably
equipped serviceman’s toolbox, the following items
should be available at the work site:

1) Suitable drain pan and container to hold lubricant

drained from unit.
2) A quantity of proper lubricant sufficient to refill the
compressor.
3) A minimum of one replacement coolant filter ele-
ment of the proper type for the unit to be worked on.

There is a coolant drain hose supplied with each

compressor. The drain hose is placed in the starter box
when shipped from the factory.

The coolant should be drained soon after the

compressor has been shut down. When the coolant is
hot, drainage will be more complete and any particles in
suspension in the coolant will be carried out with the
coolant.

Hot coolant can cause severe injury. Use care when

draining separator tank.

To drain the unit, remove plug from drain valve located

on the bottom of the separator tank. Install supplied
drain hose and fitting assembly in end of drain valve
and place end of hose in a suitable pan. Open drain NOTICE
valve to start drainage. After draining is complete, close
Filler Cap.
valve, remove hose and fitting assembly from valve, Use only recommended
and store in a suitable location for future use. Replace coolant.
plug in end of drain valve.
Read instruction book before
servicing.
Do not store drain hose in starter box after it has
been used to drain the separator tank.

34
5.6 COOLANT (Continued)

After the unit is drained and a new coolant filter element

is installed, refill the system with fresh coolant. Bring the
receiver level of coolant up to the midpoint of the sight
glass. Replace the fill cap. Start the compressor and run it
for a short time. The correct coolant level is at the
midpoint of the sight glass with the unit running in the
‘UNLOADED” mode.

5.7 SEPARATOR TANK

SCAVENGE SCREEN/ORIFICE

Tools Required
Q Open end wrench
Q Pliers

Procedure
The screen/orifice assemblies are similar in appearance
to a straight tubing connector and will be located between
two pieces of 1/4 inch O.D. scavenge line tubing.

The main body is made from 1/2 inch hexagon shaped

steel and the diameter of the orifice and a direction-of-
flow arrow is stamped in flat areas of the hexagon.

A removable screen and orifice is located in the exit end FIGURE 5.7-1 SEPARATOR TANK SCAVENGE
of the assembly (See Figure 5.7-1) and will require SCREEN/ORIFICE
cleaning as outlined in the Maintenance Schedule,
Section 5.1.

To remove the screen/orifice, disconnect the scavenge

line tubing from each end. Hold the center section firmly
and use a pair of pliers to gently grasp the exit end of the
assembly that seals against the scavenge line tubing. Pull
the end out of the center section while using care to
prevent damage to the screen or sealing surfaces.

Clean and inspect all parts prior to reinstallation.

When the assembly is installed, confirm the direction of

flow to be correct. Observe the small arrow stamped in
the center section and ensure the direction flow to be
from the separator tank to the airend.

35
5.8 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 display 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 RECOMMENDED BOLT TIGHTENING
element up within the tank. CROSS PATTERN

Place the tank cover in its correct position and

install bolts. Tighten the bolts in a cross-pattern
(Reference Figure 5.8-1) to prevent over-
tightening one side of the cover. An improperly
tightened cover will likely result in a leak.

Tank Cover Bolt Torque Values

5/8 UNC 150 ft. Ib.(203 N-M)

Inspect tank scavenge screen and orifice. Clean if

necessary following instructions in Section 5.7.

Install scavenge tube down into the tank until the

tube just touches the separator element. Tighten FIGURE 5.8-1
fittings.

Install the regulation lines in their original position.

Start unit, check for leaks, place in service.

36
5.9 COOLER CORES: CLEANING Coolant Coolers
Following are instructions for removal and internal
Ensure that the compressor is isolated from the cleaning of coolant/aftercooler.
compressed air system by closing the isolation
valve and venting pressure from the drip leg.
1) Remove right side panel.
Ensure that the main power disconnect switch is 2) Remove 6 screws in right side plenum wall and
locked open and tagged. (See Figure 5.9-1). remove plenum wall.
3) Remove 8 screws in left side plenum wall and
remove plenum wall.
4) Remove hose from aftercooler discharge (right side)
and plug hole.
5) Disconnect tube from aftercooler inlet (left side).
Loosen tube nut on opposite end of tube and rotate
tube away. Plug hole in aftercooler.
6) Loosen hose nuts 1/4 turn on oil cooler inlet and
outlet hoses. This will allow hose fittings to swivel
without causing kink in hose.
7) Remove 6 screws in cooler support panel to allow
cooler to swing out on hinges.
8) Cover opening that exposes fan and fan motor to
ensure water does not spray onto motors.
9) Before cleaning coolers, check to ensure all
connections are plugged to prevent contamination of
compressor system.

CAUTION
FIGURE 5.9-1 MAIN DISCONNECT
LOCKED AND TAGGED Strong cleaners can harm
Tools Required aluminum cooler parts. Follow cleaner
Q Screwdriver manufacturer’s instructions for use.
Q Wrench set Wear appropriate safety equipment.
Q Air hose equipped with approved local codes.

5.9-1 Air Cooled Coolers

Procedure 10) After cleaning is complete, reassemble in reverse

Visually check the outside of the cooler cores to be order.
certain that a complete outside cleaning of the cooler is 11) Replace enclosure panels.
required. Frequently, dirt, dust or other foreign material,
may only need to be removed with an air hose to 5.9-2 Water Cooled Coolers
remedy the problem.
Procedure
When the cooler is covered with a combination of
oil, grease or other heavy substances that may A periodic inspection and maintenance program
affect the unit’s cooling, then it is recommended should be implemented for water cooled heat
that the cooler cores be thoroughly cleaned on the exchangers. The following steps should be taken.
outside.
1. Inspect filters in system and replace or clean as
If it is determined that the compressor operating required.
temperature is higher than normal due to the internal
passages of the cooler cores being restricted with 2. Carefully examine tubes for scale and clean if
deposits or foreign material, then the cooler should be necessary. If a cleaning solution is used, be sure to
removed for internal cleaning. wash out all chemicals thoroughly with clean water
before returning the compressor to service. After
cleaning, examine the cooler for erosion or corrosion.

37
5.9-2 Water Cooled Coolers (Continued)

Cleaning Improper lubrication can be a cause of motor bearing

failure. The quantity of grease added should be carefully
The interior tube surfaces can be cleaned by several controlled. The smaller motors must be greased with a
methods. Flushing a high velocity stream of water lesser amount of grease than larger motors.
through the tubes will remove many forms of deposits.
More severe deposits may require running wire
brushes or rods through the tubes. Also, rubber plugs
can be forced through the tubes if a special air or
water gun is available for this procedure.

A qualified cleaning service should be used for the

cleaning process. These organizations can evaluate
the type of deposit to be removed and supply the
appropriate solution and method for a complete
cleaning job.

Precautions

When re-installing bonnets to cooler shell, tighten bolts

uniformly in a cross-pattern. Overtightening can result
in cracking of bonnet.

Cleaning solutions must be compatible with metallurgy

of cooler.

Care must be taken to avoid damaging tubes if

mechanical cleaning procedure is used.

CAUTION
5.10 MOTOR LUBRICATION

The induction-type squirrel cage motors have antifriction

Overgreasing can be a cause of bearing and
ball or roller bearings front and rear. At periodic intervals
motor failure. Make sure dirt and contaminants
they require relubrication.
are not introduced when adding grease.
Relubrication Interval
2000 hours..........................................Drive end bearing
2500 hours...................................Non drive end bearing
Procedure for relubrication

CAUTION
Relubrication amount Grease should be added when the motor
Lubricant Amount is stopped and power disconnected.
Motor Frame Size in3 cc oz. grams

200L 0.9 14.3 0.7 20

When regreasing, stop motor. Disconnect power; lock
404-449L 1.15 18.5 0.92 26 (NDE)
1.6 26.4 1.3 37 (DE) out and tag. Remove outlet plugs (or spring-loaded
grease relief plugs if present). The outlet plug may not
be accessible on the fan end of some TEFC-motors.

38
5.10 MOTOR LUBRICATION (Continued)

Grease relief along shaft can occur, precluding

necessity of removing this plug if inaccessible. The inlet
grease gun fittings and outlet plugs (or spring-loaded
reliefs) are located at each end of the motor housing.
The drive end reliefs protrude out the circumference of
the lower portion of the end bell near a flange bolt. The
drive 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. Determine in

advance the quantity of grease delivered with each
stroke of the lever. A graduated cylinder showing
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, discontinue
greasing at once.

4) Run motor for about 30 minutes before replacing

outlet plugs or reliefs. BE SURE TO SHUT MOTOR
DOWN, DISCONNECT POWER, LOCK OUT AND
TAG, AND REPLACE THESE DRAIN FITTINGS Motor Bearing Maintenance (Stored Units)
TO PRECLUDE LOSS OF NEW GREASE AND
ENTRANCE OF CONTAMINANTS! To ensure that complete contact is maintained between
the motor bearings and the bearing grease on units to
be placed in storage for extended intervals, the following
Recommended Motor Grease motor maintenance procedure should be adhered to:

Most motors require: 1) Prior to placing a unit in storage, rotate the motor
several revolutions by hand in the proper direction
Mobilith SHC 220.................................................Mobil of rotation.
Unrex N2........................................................... ESSO
2) Thereafter, rotate the motor as described in Step 1
Use the grease as indicated on a special grease at three month intervals until such time as the unit is
information nameplate on the motor. Use of alternative placed in service.
greases can result in shortened motor life due to
incompatibility of greases.

39
 Follow these precautions to minimize damage from
5.11 INTELLISYS REMOVAL static electricity. Static can cause severe damage to
microcircuits.
Ensure that the compressor is isolated from the
compressed air system by closing the isolation 1) Make the least possible movement to avoid build-
valve and venting pressure from the drip leg. ing up static electricity from your clothing or tools.

Ensure that the main power disconnect switch is 2) Discharge potential static electricity by touching
locked open and tagged (See Figure 5.11-1). (grounding) yourself to the starter box.

3) Handle circuit boards only by their edges.

4) Do not place the controller or power supply

assembly on any metal surface.

5) Leave the replacement parts in their protective

bags until ready for installation.

Tools:
Screwdriver Size #1, flathead
3/8 inch hex driver

Before removing any components, open 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) Open the starter box door.

2) Remove the five electrical plug-in connectors from

the top of the controller.
FIGURE 5.11-1 MAIN DISCONNECT
LOCKED AND TAGGED 3) Remove (2) mounting rails that attach the
Intellisys® Controller at the side of the control box.

4) Remove the controller. Remove any option

modules which must be installed in the new
controller.

40
5.12 COOLANT HOSES

The flexible hoses that carry coolant to and from the oil
cooler may become brittle with age and will require
replacement. Have your local Ingersoll-Rand distributor
check them every 2 years.

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.

Removal

Remove enclosure panels.

Drain coolant into a clean container. Cover 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

reversing the disassembly procedure. Start the
compressor and check for leaks.

5.13 AIREND DISCHARGE HOSE

The flexible hose from the airend discharge to separator

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

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 and tagged.

For 45KW (60HP)

Disconnect hose nut from piping at each end of
discharge hose and remove. Hold fittings securely
while removeing hose.

For 55-75KW (75-100HP)

Remove 4 bolts in flange at each end of discharge
hose. Retain flange and bolt for replacement.

41
 6.0 TROUBLE SHOOTING CHART
TROUBLE CAUSE &/OR DISPLAY WHAT TO DO
Compressor fails to start. 110/120V control voltage not available. — Check fuses. Check transformers and
wiring connections.

"STARTER FAULT". — Inspect contactors.

"EMERGENCY STOP". — Rotate emergency stop button to

disengage, and press"SET" button twice.
"MAIN MTR OVER LD" or — Manually reset main or fan motor over-
"FAN MTR OVERLOAD" load relay, and press "SET"button twice.
"PRES SENSOR FAIL" or — Check for defective sensor, bad sensor
"TEMP SENSOR FAIL" connection, or broken sensor wires.

Compressor shuts down. "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.

NOTE: If a shutdown oc- "HIGH AIR PRESS." — Check for restricted or malfunctioning
curs, press the DISPLAY blowdown valve or minimum pressure
SELECT button once to check valve.
activate the L.E.D. display "LOW SUMP PRESS." — Check for air leak from tank or
table. Using the adjacent up blowdown piping.
and down arrows, the values — Adjust sump pressure.
displayed will be those im- "PRES SENSOR FAIL" or — Check for defective sensor, bad sensor
mediately preceding shut- "TEMP SENSOR FAIL" connection, or broken sensor wires.
down. Use these values
when trouble shooting a "CK MOTOR ROTATION." — Interchange any two line connections
problem. (L1,L2,L3) at the starter.
"MAIN MTR OVERLD" — Check for loose wires.
— Check supply voltage.
— Check heater size.

"FAN MTR OVERLOAD" — Check for loose wires.

— Check supply voltage.
— Fan motor overload tripped
— Check for dirty cooler cores.

"STARTER FAULT." — Inspect starter contactors.

— Check for loose wires.

Low system air pressure 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.

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.

42
 TROUBLE SHOOTING CHART (Continued)

TROUBLE CAUSE &/OR DISPLAY WHAT TO DO

High coolant Excessive coolant level. — Check level, lower if necessary by

consumption/coolant draining.
in air system Plugged separator element. — Check separator pressure drop.

Separator element leak. — Check separator pressure drop. If low,

replace element.

Plugged separator scavenge orifice/ — Remove and inspect orifice/screen.

screen. Clean if required.

Compressor operating at low pressure — Operate at rated pressure.

(75 psig or below). — Reduce system load.

Coolant system leak. — Inspect and repair leaks.

Water in Air System Defective moisture separator/drain trap — Inspect and clean if required. Replace
separator/trap if defective.

Trap drain or drain piping plugged. — Inspect and clean.

Aftercooler core dirty. — Inspect and clean.

Enclosure panels not in place. — Install enclosure panels.

Drain line/drip leg incorrectly installed. — Slope drain line away from trap. Install
drip leg.

No refrigerated or desiccant dryer in — Contact local Ingersoll-Rand

air system. Distributor

Excessive noise level Compressor defective. (Bearing — Contact authorized Distributor

failure or rotor contact.) immediately, do not operate
unit.
Enclosure panels not in place. — Install enclosure panels.
Loose component mounting. Inspect and tighten.

Excessive vibration Loose components — Inspect and tighten.

Motor or compressor bearing failure. — Contact authorized Distributor

immediately, do not operate
unit.

External sources. — Inspect area for other equipment.

Pressure relief valve opens Compressor operating over pressure. — Adjust Intellisys set points.

Defective valve. — Replace valve.

43
7.0 REFERENCE DRAWINGS

7.1 ELECTRICAL SCHEMATIC

(Air Cooled)
7.1 ELECTRICAL SCHEMATIC
(Air Cooled)
 7.1 ELECTRICAL SCHEMATIC
(Air Cooled)

46
 7.2 ELECTRICAL SCHEMATIC
(Air Cooled)

47
7.2 FOUNDATION PLAN (WATER COOLED)

48
7.3 ELECTRICAL SCHEMATIC
(Air Cooled)

49
 7.4 BASIC FLOW SCHEMATIC - AIR COOLED

50
 7.5 BASIC FLOW SCHEMATIC - WATER COOLED

51
TYPICAL SYSTEM FLOW
DIAGRAM

52
53
56
8.0 WATER QUALITY
RECOMMENDATIONS
Water quality is often overlooked when the cooling
system of a water cooled air compressor is examined. formation is the precipitation of calcium carbonate out
Water quality determines how effective the heat of the water. This is dependent on temperature and
transfer rate, as well as the flow rate will remain during pH. The higher the pH value, the greater the chance
the operation life of the unit. It should be noted that the of scale formation. Scale can be controlled with water
quality of water used in any cooling system does not treatment.
remain constant during the operation of the system.
The water makeup is affected by evaporation, CORROSION
corrosion, chemical and temperature changes, In contrast to scale formation is the problem of
aeration, scale, and biological formations. Most corrosion. Chlorides cause problems because of their
problems in a cooling system show up first in a size and conductivity. Low pH levels promote
reduction in the heat transfer rate, then in a reduced corrosion, as well as high levels of dissolved oxygen.
flow rate, and finally with damage to the system.
FOULING
There are many constituents in the water system that Biological and organic substances (slime) can also
must be balanced to have a good stable system. The cause problems, but in elevated temperature
following is a list of the major components that should environments such as cooling processes, they are not
be monitored: major concerns. If they create problems with clogging,
commercial shock treatments are available.
SCALE
Scale formation inhibits effective heat transfer, yet it To ensure good operation life and performance of the
does help prevent corrosion. Therefore, a thin uniform compressor cooling system, the recommended
coating of calcium carbonate is desired on the inner acceptable ranges for different water constituents are
surfaces. Perhaps the largest contributor to scale included below:

PARAMETER CONCENTRATION FREQUENCY OF ANALYSIS

Corrosivity (hardness, Langelier Index Monthly

pH, total dissolved solids, 0 to 1 (if stable for 3 to 4 months,
temperature at inlet, analyze quarterly)
alkalinity)

Iron < 2 ppm Monthly

Sulphate < 50 ppm Monthly

Chloride < 50 ppm Monthly

Nitrate < 2 ppm Monthly

Silica < 100 ppm Monthly

Dissolved oxygen 0 ppm Daily

(as low as possible) (if stable, analyze weekly)

Oil and grease < 5 ppm Monthly

Ammonia < 1 ppm Monthly

57
Recommended equipment for on-site analysis in-
cludes a thermometer, pH meter, and dissolved ox-
ygen meter. Dissolved oxygen and temperature must
be measured on-site and it is recommended that pH
be measured on-site. All other analyses should be
performed by a professional water quality analyst. The
Langelier Index (Ll) is calculated using the following
equation and the tables found on the following pages.

Ll = pH - (9.30 + Total Dissolved Solids chart value +

Temperature chart value ) + Hardness chart value +
Alkalinity chart value

The Ll is zero when the water is in chemical balance.

If the Ll is greater than zero, there is a tendency to
form scale. If the Ll is less than zero, the water tends
to be corrosive.

Dissolved oxygen may be controlled in closed cooling

towers. Several types of treatments are commercially
available to remove dissolved oxygen. For open
cooling towers, dissolved oxygen is not an easily
controlled parameter. Also, a filtration system is
recommended for the water going into the air
compressor when using an open cooling tower.

It should be noted that Ingersoll-Rand’s guidelines

and recommendations should be used in evaluating
the water systems and the problems that may occur
in the normal operation of our air compressors. If
water problems persist or are not covered above, you
should consult a professional.

58
 LANGELIER INDEX CHART VALUES

Total dissolved solids (ppm)

Temperature (°F)
UNITS

50 .07 0 2 4 6 8

75 .08 30 2.60 2.67 2.54 2.81

100 .10 40 2.48 2.45 2.43 2.40 2.37
TOTAL-SOLIDS-(PPM)

50 2.34 2.31 2.28 2.25 2.22

150 .11 60 2.20 2.17 2.14 2.11 2.09

70 2.06 2.04 2.03 2.00 1.97
200 .13 80 1.95 1.92 1.90 1.88 1.86
300 .14
90 1.84 1.82 1.80 1.78 1.76

TENS
100 1.74 1.72 1.71 1.09 1.67
400 .16 110 1.05 1.64 1.62 1.60 1.58

600 .18 120 1.67 1.63 1.53 1.51 1.50

800 .19 130 1.48 1.46 1.44 1.43 1.41
140 1.40 1.38 1.37 1.35 1.34

1000 .20 150 1.32 1.31 1.29 1.28 1.27

160 1.26 1.24 1.23 1.22 1.21
170 1.19 1.18 1.17 1.10

Hardness (ppm)
Alkalinity (ppm)

UNITS UNITS

0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

0 0.08 0.20 0.30 0.38 0.43 0.51 0.56 0 0.00 0.30 0.48 0.60 0.70 0.78 0.85 0.90 0.93
10 0.60 0.64 0.68 0.72 0.73 0.78 0.81 0.83 0.86 0.88 10 1.00 1.04 1.08 1.11 1.15 1.18 1.20 1.23 1.26 1.29
20 0.90 0.92 0.94 0.96 0.98 1.00 1.02 1.03 1.05 1.06 20 1.30 1.32 1.34 1.36 1.38 1.40 1.42 1.43 1.45 1.46

30 1.08 1.09 1.11 1.12 1.13 1.15 1.16 1.17 1.18 1.19 30 1.48 1.49 1.51 1.52 1.53 1.54 1.56 1.67 1.58 1.59
40 1.20 1.21 1.23 1.24 1.25 1.26 1.26 1.27 1.28 1.29 40 1.60 1.61 1.62 1.63 1.64 1.65 1.66 1.67 1.68 1.69
50 1.30 1.31 1.32 1.33 1.34 1.34 1.35 1.36 1.37 1.37 50 1.70 1.71 1.72 1.72 1.73 1.74 1.75 1.76 1.76 1.77

60 1.38 1.39 1.39 1.40 1.41 1.42 1.42 1.43 1.43 1.44 60 1.78 1.79 1.79 1.80 1.81 1.81 1.82 1.83 1.83 1.84
70 1.45 1.45 1.46 1.47 1.47 1.48 1.48 1.49 1.49 1.50 70 1.85 1.85 1.86 1.86 1.87 1.88 1.88 1.89 1.89 1.90
80 1.51 1.51 1.52 1.52 1.53 1.53 1.54 1.54 1.55 1.55 80 1.90 1.91 1.91 1.92 1.92 1.93 1.93 1.94 1.94 1.95

90 1.95 1.96 1.96 1.97 1.97 1.98 1.98 1.99 1.99 2.00
TENS

90 1.56 1.56 1.57 1.57 1.58 1.58 1.58 1.59 1.59 1.60
TENS

100 1.60 1.61 1.61 1.61 1.62 1.62 1.63 1.63 1.64 1.64 100 2.00 2.00 2.01 2.01 2.02 2.02 2.03 2.03 2.03 2.04
110 1.64 1.65 1.65 1.66 1.66 1.66 1.67 1.67 1.67 1.68 110 2.04 2.05 2.05 2.05 2.06 2.06 2.06 2.07 2.07 2.08

120 1.68 1.68 1.69 1.69 1.70 1.70 1.70 1.71 1.71 1.71 120 2.08 2.08 2.09 2.09 2.09 2.10 2.10 2.10 2.11 2 11
130 1.72 1.72 1.72 1.73 1.73 1.73 1.74 1.74 1.74 1.75 130 2.11 2.12 2.12 2.12 2.13 2.13 2.13 2.14 2.14 2.14
140 1.75 1.75 1.75 1.76 1.76 1.76 1.77 1.77 1.77 1.78 140 2.15 2.15 2.15 2.16 2.16 2.16 2.16 2.17 2.17 2.17

150 1.78 1.78 1.78 1.79 1.79 1.79 1.80 1.80 1.80 1.80 150 2.18 2.18 2.18 2.18 2.19 2.19 2.19 2.20 2.20 2.20
160 1.81 1.81 1.81 1.81 1.82 1.82 1.82 1.82 1.83 1.83 160 2.20 2.21 2.21 2.21 2.21 2.22 2.22 2.23 2.23 2.23
170 1.83 1.84 1.84 1.84 1.84 1.85 1.85 1.85 1.85 1.85 170 2.23 2.23 2.23 2.24 2.24 2.24 2.24 2.25 2.25 2.25

180 1.86 1.86 1.86 1.86 1.87 1.87 1.87 1.87 1.88 1.88 180 2.26 2.26 2.26 2.26 2.26 2.27 2.27 2.27 2.27 2.28
190 1.88 1.88 1.89 1.89 1.89 1.89 1.89 1.90 1.90 1.90 190 2.28 2.28 2.28 2.29 2.29 2.29 2.29 2.29 2.30 2.30
200 1.90 1.91 1.91 1.91 1.91 1.91 1.92 1.92 1.92 1.92 200 2.30 2.30 2.30 2.31 2.31 2.31 2.31 2.32 2.32 2.32

TENS TENS
0 10 20 30 40 50 60 70 80 90 0 10 20 30 40 50 60 70 80 90
200 1.92 1.94 1.96 1.98 2.00 2.02 2.03 2.03 2.06 200 2.32 2.34 2.36 2.38 2.40 2.42 2.43 2.43 2.46
300 2.08 2.09 2.11 2.12 2.13 2.13 2.16 2.17 2.18 2.19 300 2.48 2.49 2.51 2.52 2.53 2.54 2.56 2.57 2.58 2.59
400 2.20 2.21 2.23 2.24 2.23 2.26 2.26 2.27 2.28 2.29 400 2.60 2.61 2.62 2.63 2.64 2.65 2.66 2.67 2.68 2.69
HUNDREDS

HUNDREDS

500 2.30 2.31 2.32 2.33 2.34 2.34 2.35 2.36 2.37 2.37 500 2.70 2.71 2.72 2.72 2.73 2.74 2.75 2.76 2.76 2.77
600 2.38 2.39 2.39 2.40 2.41 2.42 2.42 2.43 2.43 2.44 600 2.78 2.79 2.79 2.80 2.81 2.81 2.82 2.83 2.83 2.84
700 2.45 2.45 2.46 2.47 2.47 2.48 2.48 2.49 2.49 2.50 700 2.85 2.85 2.86 2.86 2.87 2.88 2.88 2.89 2.89 2.90
800 2.51 2.51 2.52 2.52 2.53 2.53 2.54 2.54 2.55 2.55 800 2.90 2.91 2.91 2.92 2.92 2.93 2.93 2.94 2.94 2.95
900 2.56 2.56 2.57 2.57 2.58 2.58 2.58 2.59 2.60 2.60 900 2.95 2.96 2.96 2.97 2.97 2.98 2.98 2.99 2.99 3.00

59
60
61
 MAINTENANCE RECORD

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

62
 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
ML/MM/MH 45
ML/MM/MH/MJ 55
ML/MM/MH/MJ 75
PARTS BOOK

65
 TABLE OF CONTENTS
ROTARY SCREW AIR COMPRESSOR

Safety and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 This unit was purchased from

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5 ______________________________________________
Electrical Components - All Units . . . . . . . . . . . . . . . . 6-9
Motor, Gearcase and Gear Set . . . . . . . . . . . . . . . . 10-13 ______________________________________________
Motor Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Airend Piping and Support . . . . . . . . . . . . . . . . . . . 14-15 ______________________________________________
Inlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
Ingersoll-Rand Company reserves the right to make
Air Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19
changes or add improvements without notice and with-
Separator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
out incurring any obligation to make such changes or
Temperature Control Valve and Piping . . . . . . . . . 22-23
add such improvements to products sold previously.
Cooler Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Air Cooled Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27 No. of units on or-
75 HP Moisture Separator . . . . . . . . . . . . . . . . . . . . 28-29 der:___________________________________
100 HP Moisture Separator . . . . . . . . . . . . . . . . . . . 30-31
Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . 32-33 Customer Order
Intake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35 No.:___________________________________
Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . 42-43
Ingersoll-Rand Co. Order
No.:____________________________

For ready reference:

Record the serial number and model number of your
unit here.

Serial Num-
ber:________________________________________

Model Num-
ber:_______________________________________

66
PARTS LIST

INTRODUCTION DESCRIPTION OPTIONAL EQUIPMENT

GENERAL The illustrated parts breakdown Several optional accessories/items
illustrates the various assemblies are available for convenience or
This manual, which contains an
and detailed parts which make up special application. These
illustrated parts breakdown, has
this particular SSR compressor. A accessories have been selected
been prepared as an aid in
series of illustrations show each as being particularly suitable for
identifying and ordering parts in the
part clearly and in it’s correct use on the SSR compressor.
SSR compressor. All of the
location relative to the other parts
compressor parts listed in the parts For complete details on Optional
in the illustration. Each part on an
breakdown are manufactured with Equipment, contact your sales
illustration is referenced with a
the same precision as the original representative.
number, description and quantity
equipment.
needed per assembly is listed in HOW TO USE THIS PARTS
Ingersoll-Rand service facilities numerical order on the following MANUAL
and parts are available worldwide. pages.
1. Turn to the Parts Section
There are Ingersoll-Rand branch
to locate the desired
offices and authorised distributors
illustrations.
located in the principal cities of
India. There are also Ingersoll- 2. Locate the parts on the
Rand subsidiaries and authorised illustration by visual
distributors located in the principal identification and the
cities throughout the world. reference number.
3. Find the referenced
number on the tabulated
page, along with the part
number and description.

HOW TO ORDER PARTS

In order that all avoidable errors be
eliminated when ordering parts,
please specify the following:
1. The model number of the
unit as shown on the
Compressor data plate.
2. The serial number of the
unit as shown on the
Compressor data plate.
3. The form number of this
manual (can be found on
the right bottom corner of
the first page with rev.
level)
4. The reference number,
part number description
and quantity needed ex-
actly as listed.
5. The motor data code
shown on the motor data
plate.

67
 DRAWING NO. REV.
70570015 00

68
 DRAWING NO. REV.
70570015 00

RELAY BASED CONTROLLER ASSEMBLY

REF. PART NO. QTY. DESCRIPTION

NO.
1 39128533 4 NUT, WHIZLOCK #10 ZINC PLATED
2 39249875 1 GASKET, SEALING EDGE 130IN LONG
3 39256318 7 SCREW, KNURL HEAD 0.25 X 1.00 LONG

69
4 39256326 7 RETAINER, BOLT 0.25
5 70561840 1 BOX, STARTER
6 39589007 1 GASKET, CONDUIT PLATE
7 70561725 1 FACIA, CONTROL PANEL
8 70612791 4 GAUGE, PRESSURE 0-16 kg/cm2
9 70539333 4 ADAPTER
10 39155577 4 ELBOW, ADAPTER
11 94203288 8 PLUG
12 70097365 1 GAUGE, OIL TEMP
13 70140801 1 ADAPTER
70
 DRAWING NO. REV.
39908439 02

CONTROLLER ASSEMBLY WITH INTELLYSIS

REF. PART NO. QTY. DESCRIPTION

NO.
1 39128533 4 NUT, WHIZLOCK #10 ZINC PLATED
2 39128541 4 NUT WHIZLOCK .25 ZINC PLATED
3 39186093 1 PLUG 6 POSITION
4 39186101 1 PLUG 4 POSITION
5 39191630 1 PLUG 5 POSITION

71
6 39191648 1 PLUG 11 POSITION
7 39191655 1 PLUG 16 POSITION
8 39249875 1 GASKET SEALING EDGE 130” LONG
9 39256318 7 SCREW KNURL HD .25 X 1 LONG
10 39256326 7 RETAINER BOLT .25
11 39495874 1 GASKET INTELLYSIS STARTER BOX
12* 70195649 1 SWITCH EMERGENCY STOP
13 39589007 1 GASKET CONDUIT PLATE
14 39817655 1 CONTROLLER INTELLYSIS
15 85540144 1 BOX STARTER
16 85540169 2 ANGLE CONTROLLER
 DRAWING NO. REV.
70570023 00

72
 DRAWING NO. REV.
70570023 00
CONTROL PIPING NEMA 1 - NO MODULATION WITH INTELLISYS

REF. PART NO. QTY. DESCRIPTION

NO.

1* 70570205 2 NIPPLE HEX.

3 39140785 2 PLUG, LIQUID TIGHT
4 39155478 3 ELBOW
5 39155577 2 ELBOW
6 39173927 3 GLAND WIRE
7 39418926 1 VALVE
8 39583943 1 VALVE SOLENOID
9 39853809 1 TRANSDUCER PRESSURE

73
** CONTROL PIPING NEMA 1 - NO MODULATION WITH RELAY PANEL

REF. PART NO. QTY. DESCRIPTION

NO.

1* 70570205 1 NIPPLE HEX.

3 39140785 3 PLUG, LIQUID TIGHT
4 39155478 3 ELBOW
6 39173927 3 GLAND, WIRE
7 39418926 1 VALVE
10 94417938 1 SWITCH, PRESSURE
11 70543624 1 COUPLING
12 39156393 1 ADAPTER, PUSH IN

* PART NUMBER IS DIFFERENT IF USED IN DAVIDSON

** DO NOT APPEAR IN DAVIDSON DRAWING
ALL TUBING IS PART NO 39124813 - 1/4D ,10 MT
74
 DRAWING NO. REV.
39907639 03

INTELLISYS CONTROL PIPING WITH MODULA-

TION
REF. PART NO. QTY. DESCRIPTION
NO.
*1 70570205 4 NIPPLE HEX.
2 37081528 1 ORIFICE
4 39127253 1 NIPPLE
5 39127261 1 VALVE, SHUTTLE
6 39155478 2 ELBOW
7 39155577 4 ELBOW
8 39156385 1 TEE, BRANCH
9 39156393 1 CONNECTOR
10 39156435 1 CONNECTOR
11 39156468 1 TEE, RUN
12 39173927 3 GLAND, WIRE

75
13 39181342 1 TEE, BRANCH
14 39418926 1 VALVE
15 39530852 1 VALVE, SOLENIOD 3WAY
16 39583943 2 VALVE, SOLENOID 3WAY (DC COIL)
17 39853809 1 TRANSDUCER, PRESSURE
18 39905542 1 VALVE, REGULATOR (XF & EP UNITS)
39905682 1 VALVE, REGULATOR (HP & XP UNITS)
19 95343679 1 NIPPLE
20 95837233 1 PLUG, SOCKET
21 95930301 1 BUSHING, REDUCER
22 95940672 1 TEE, BRANCH

* PART NUMBER IS DIFFERENT IF USED IN DAVIDSON

ALL TUBING IS PART NO 39124813 - 1/4D ,10 MT
76
 DRAWING NO. REV.
39907639 03

RELAY PANEL CONTROL PIPING WITH MODU-

LATION
REF. PART NO. QTY. DESCRIPTION
NO.
*1 70570205 3 NIPPLE HEX.
2 37081528 1 ORIFICE
4 39127253 1 NIPPLE
5 39127261 1 VALVE, SHUTTLE
6 39155478 2 ELBOW
7 39155577 2 ELBOW
8 39156385 1 TEE, BRANCH
9 39156393 2 CONNECTOR
10 39156435 1 CONNECTOR
11 39156468 1 TEE, RUN
12 39173927 3 GLAND, WIRE

77
13 39181342 1 TEE, BRANCH
14 39418926 1 VALVE
15 39530852 1 VALVE, SOLENIOD 3WAY
16 39583943 1 VALVE, SOLENOID 3WAY (DC COIL)
17 94417938 1 PRESSURE SWITCH
18 39905542 1 VALVE, REGULATOR (XF & EP UNITS)
39905682 1 VALVE, REGULATOR (HP & XP UNITS)
19 95343679 1 NIPPLE
20 95837233 1 PLUG, SOCKET
21 95930301 1 BUSHING, REDUCER
22 95940672 1 TEE, BRANCH
23 70543624 1 COUPLING

* PART NUMBER IS DIFFERENT IF USED IN DAVIDSON

ALL TUBING IS PART NO 39124813 - 1/4D ,10 MT
78
79
80
81
82
83
84
85
86
87
88
89
92
93
94
95
96
97
100
101
102
103
104
105
106
107
108
109
110
111
112
 DRAWING NO. REV.
REF
39908470 04

55-75KW (75-100HP) WATER COOLED

REF.
PART NO. QTY. DESCRIPTION
NO.

*1 70619325 1 ELBOW
2 39128483 8 SCREW, WHIZLOCK 0.38 X 1 LONG, ZINC PLATED
3 39454525 2 GASKET, FLANGE
4 95992632 2 ELBOW
5 39479845 2 FLANGE
*6 70615018 1 HOSE, HYDRAULIC
*7 70619341 1 HOSE, HYDRAULIC
8 39572276 1 HOSE, HYDRAULIC
9 39572375 1 HOSE, HYDRAULIC
10 39572433 1 HOSE, HYDRAULIC

113
*11 70619333 1 HOSE, HYDRAULIC
12 39577176 1 HOSE, HYDRAULIC
*13 70605530 1 COOLER, OIL
*14 70605548 1 AFTERCOOLER
15 95923355 8 NUT HEX. 0.63
*16 95952354 8 SCREW HEX. 0.63 X 2.75 LONG ZINC PLATED
17 95937645 1 ELBOW
18 95937678 1 ELBOW
19 95939336 2 CONNECTOR
20 95941043 2 BUSHING
21 95950002 1 ELBOW
*22 95376133 2 ELBOW

* PART NUMBER IS DIFFERENT IF USED IN DAVIDSON

114
115
116
117
 @

@ Spares kit, MPCV 45/55 KW 70662424 1 Tank Discharge Line

Spring housing, MPCV 45/55 KW 70662440 1 Tank Discharge Line
Piston MPCV 45/55 KW 70662432 1 Tank Discharge Line

118
119
 SSR 55/75 KW Recommended Spare Parts

Qty.
Part Per
Compressor Part No. Unit Location or Use

Maintenance Kit 39669437 0 Maintenance Kit with Ultra Coolant

Ultra Coolant.(5 Gal. Container) 39433735 2 Fill 9 Gallons
Air Filter Element 39708466 2 At Airend Inlet
Coolant Filter Element 39911631 1 On Coolant Filter
Separator Element 54601513 1 In Separator Tank
Thermostatic Control Valve Element 39902382 1 In Thermostatic Control Valve
Thermostatic Control Valve 39902374 1 Between Cooler and Filter
Blowdown Solenoid Valve (NEMA-1) 39120472 1 On Top of Tank (3SV)
Load Solenoid Valve 1SV (NEMA-1) 39418926 1 Rear of Stanter Box
Line/Sump Solenoid Valve 10SV (NEMA-1) 39583943 1 Rear of Starter Box
Modulate Solenoid valve (NEMA 1) 39530852 1 Rear of Starter Box
Modulate Solenoid Valve (NEMA 1) 39583943 1 Rear of Starter Box
Regulator valve (ML&MM Models) 39905542 1 Rear of Starter Box
Regulator valve (MH&MJ Models) 39905682 1 Rear of Starter Box
Pressure Switch 94417938 1 Rear of Starter Box(Relay Panel)
Pressure Gauge 70612791 4 Inside of Starter Box(Relay Panel)
Oil Temperature Gauge 70097365 1 Inside Starter Box(Relay Panel)
Pressure Transducer 39853809 1 Rear of Starter Box (Intellisys)
Kit, Temperature Sensor 37952439 1 Airend Discharge
Coolant Solenoid Valve (NEMA 1) 39476569 1 In Coolant Filter Line (5SV)
Kit, High Air Temperature Switch 37952264 1 In Airend (1ATS)
Inlet Valve 42527366 1 Under Air Filter
Gasket, Inlet Valve 39476304 1 Under Inlet Valve
Indicator, Air Filter 70180856 1 On Inlet Valve
Cylinder, Pneumatic 42495903 1 At Inlet Valve
Rod End Bearing 39325154 1 On Cylinder
Minimum Pressure Valve, 55 KW 70662416 1 Tank Discharge Line
Spares kit, MPCV 45/55 KW 70662424 1 Tank Discharge Line
Spring housing, MPCV 45/55 KW 70662440 1 Tank Discharge Line
Piston MPCV 45/55 KW 70662432 1 Tank Discharge Line
Minimum Pressure Valve, 75 KW 39475645 1 Tank Discharge Line
Breather Filter 39112362 1 On Gearcase Wall
Discharge Check Valve 39477674 1 Airend Disch. to Sep. Tank
Gasket, Discharge Check Valve 39326228 2 At Discharge Check Valve
Tank Relief Valve 39588116 1 On Separator Tank
Decal Set 70561493 1
Discharge Hose 39905450 1 At Airend Discharge
Hose, Tank Scavenge 39578406 1 Scavenge Orifice to Airend
Hose, Blowdown to Inlet 39575279 1 Blowdown Valve to Inlet
Hose, Coolant Filter to Airend 39572458 1 Oil Filter to Airend
Hose, Aftercooler to Moisture Separator 55 KW 39573100 1 Aftercooler to Moisture Separator
Hose, Aftercooler to Moisture Separator 75 KW 39572219 1 Aftercooler to Moisture Separator
Hoses, Aircooled
Hose, Coolant Cooler Aircooled 75 KW 39572896 1 Thermal Valve to Coolant Cooler
Hose, Coolant Cooler Aircooled 75 KW 39572086 1 Coolant Cooler to Thermal Valve
Hose, Coolant Cooler Aircooled 55 KW 39588884 1 Thermal Valve to Coolant Cooler
Hose, Coolant Cooler Aircooled 55 KW 39577176 1 Coolant Cooler to Thermal Valve
Hoses, Water cooled
Hose, water in 70619341 1 Water into aftercooler
Hose, aftercooler to coolant cooler 39572375 1 Aftercooler to Coolant Cooler
Hose, water out 39577176 1 Coolant cooler to water out
Hose, coolant cooler water cooled 70619333 1 Thermal valve to coolant cooler
Hose, coolant cooler water cooled 39572433 1 Coolant cooler to thermal valve
Hose, separator tank to aftercooler 39572276 1 Tank to aftercooler
Hose, aftercooler to moisture separator 70615018 1 Aftercooler to moisture separator

* Refer to Starter Assembly Section

 SSR 55/75 KW Recommended Spare Parts
Qty.
Per Location of Use
Compressor Part Part No
Unit

FOR INTELLISYS ONLY

Controller 39817655 1 In Control Box

Gasket Controller 39495874 1 Intellisys to Control Box
Transformer 350VA,50Hz 70557830 1 In Control Box
Switch Emergency Stop 70195649 1 In Control Box
Power On Light 70573829 1 In Control Box
Coil for 70A Contactor 70568969 * In 70A Contactor
Coil for 110A Contactor 70571500 * In 110A Contactor
Contact Kit for 110A Contactor 70571518 * In 110A Contactor
Relay Overload 70667449 * For 110A Contactor
Auxiliary Switch 1 NO / 1 NC Contacts 70571526 * For 110A Contactors
Circuit Breaker/Overload 10A 70557848 * Fan Motor Circuit (For Air Cooled)
Circuit breaker/Overload 2.4A 70612072 1 Fan motor circuit, (Warer Cooled)

FOR RELAY PANEL ONLY

Transformer 350A,50Hz-415/110 VAC 70570940 1 In Control Box

Switch Emergency Stop 70195649 1 In Control Box
Power On Light 70573829 1 In Control Box
Coil for 63A Contactor 70568969 * In 63A Contactor
Coil for 110A Contactor 70571500 * In 110A Contactor
Contact Kit for 110A Contactor 70571518 * In 110A Contactor
Relay Overload 70557863 * For 110A Contactor
Circuit Breaker/Overload 10A 70557848 * Fan Motor Circuit (For Air Cooled)
Circuit breaker/Overload 2.4A 70612072 1 Fan motor circuit, (Warer Cooled)
Contactor Auxiliary 70183777 * In Control Box
Assembly Push Button-Red Raised 70561279 * In Control Box
Asembly Push Button-Green Flush 70561261 * In Control Box
Timer Star/Delta 70516141 * In Control Box
Timer On Delay 70183744 * In Control Box
Relay Phase Seq & Under Voltage 70550272 * In Control Box
Selector Switch 70569959 * In Control Box
Meter Hour Run 70197405 1 In Control Box

* Refer to Starter Assembly Section