PROYECTO LA ARENA

MANUAL DE OPERACIONES
PLANTA ADR FASE I

PROCESOS Y FACILIDADES

MANUAL DE OPERACIÓN

COMPRESOR DE AIRE
TAG 110-AC-001
SSR UP6 40, SSR UP6 50PE, SSR UP6 50PEI
HF50–PE, EP50–PE, HP50–PE, HXP50–PE
60Hz
OPERATION AND MAINTENANCE MANUAL

This manual contains

important safety information
and must be made available
to personnel who operate and
maintain this machine.
C.C.N. : 80445190
REV. : A
DATE : OCTOBER 2008
 AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in
material and workmanship for a period of twelve months from the date of placing the Equipment in operation or eighteen
months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be obligated to
promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the
Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement
part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment
in accordance with good industry practices and has complied with specific recommendations of the Company.
Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the
manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall
not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the
Purchaser or others without Company‘s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance
warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period
of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company
in writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.

Note that this is Ingersoll Rand standard warranty. Any warranty in force at the time of purchase of the compressor
or negotiated as part of the purchase order may take precedence over this warranty.

Register on–line at http://air.ingersollrand.com

Ingersoll Rand Air Solutions Group

Global Aftermarket Division
800–B Beaty Street
Davidson, NC 28036

1–800–526–3615
 CONTENTS & ABBREVIATIONS 1
CONTENTS ABBREVIATIONS & SYMBOLS
1 CONTENTS #### Contact Ingersoll Rand for serial number
–>#### Up to Serial No.
2 FOREWORD ####–> From Serial No.
* Not illustrated
3 DECALS { Option
NR Not required
AR As required
8 SAFETY SM Sitemaster/Sitepack
HA High ambient machine
10 GENERAL INFORMATION WC Watercooled machine
AC Aircooled machine
ERS Energy recovery system
12 INSTALLATION / HANDLING T.E.F.C. Totally enclosed fan cooled motor (IP55)
O.D.P. Open drip proof (motor)
OPERATING INSTRUCTIONS
21 – GENERAL
22 – ELECTRO–PNEUMATIC
29 – INTELLISYS
40 MAINTENANCE

47 TROUBLE SHOOTING

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2 FOREWORD

The contents of this manual are considered to be proprietary and The intended uses of this machine are outlined below and examples
confidential to Ingersoll Rand and should not be reproduced without of unapproved usage are also given, however Ingersoll Rand cannot
the prior written permission of Ingersoll Rand. anticipate every application or work situation that may arise.

Nothing contained in this document is intended to extend any IF IN DOUBT CONSULT SUPERVISION.
promise, warranty or representation, expressed or implied, regarding
the Ingersoll Rand products described herein. Any such warranties or
other terms and conditions of sale of products shall be in accordance This machine has been designed and supplied for use only in the
with the standard terms and conditions of sale for such products, which following specified conditions and applications:
are available upon request. . Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
This manual contains instructions and technical data to cover GENERAL INFORMATION section of this manual.
routine operation and scheduled maintenance tasks by operation and
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised Ingersoll Rand service The use of the machine in any of the situation types listed in
department. table 1:–
a) Is not approved by Ingersoll Rand,
b) May impair the safety of users and other persons, and
The design specification of this machine has been certified as c) May prejudice any claims made against Ingersoll Rand.
complying with E.C. directives. Any modification to any part is
absolutely prohibited and would result in the CE certification and
marking being rendered invalid. TABLE 1
Use of the machine to produce compressed air for:
All components, accessories, pipes and connectors added to the a) direct human consumption
compressed air system should be: b) indirect human consumption, without suitable filtration and purity
. of good quality, procured from a reputable manufacturer and, checks.
wherever possible, be of a type approved by Ingersoll Rand.
. clearly rated for a pressure at least equal to the machine maximum Use of the machine outside the ambient temperature range
allowable working pressure. specified in the GENERAL INFORMATION SECTION of this manual.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation, operation and Use of the machine where there is any actual or foreseeable risk of
maintenance. hazardous levels of flammable gases or vapours.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE
Details of approved equipment are available from Ingersoll Rand USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
Service departments. INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR
VAPOURS MAY BE PRESENT.

The use of non–genuine spare repair parts other than those Use of the machine fitted with non Ingersoll Rand approved
included within the Ingersoll Rand approved parts list may create components.
hazardous conditions over which Ingersoll Rand has no control.
Therefore Ingersoll Rand does not accept any liabilitity for losses Use of the machine with safety or control components missing or
caused by equipment in which non–approved repair parts are installed. disabled.
Standard warranty conditions may be affected.

The company accepts no responsibility for errors in translation of

Ingersoll Rand reserves the right to make changes and this manual from the original English version.
improvements to products without notice and without incurring any
obligation to make such changes or add such improvements to
products sold previously. © COPYRIGHT 2008
INGERSOLL RAND COMPANY

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 DECALS 3
ISO SYMBOLS
GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

Use fork lift truck from this side only. RESET Do not use fork lift truck from this side.

Emergency stop. On (power). Off (power).

AUTOMATIC RESTART MAINTENANCE MAINTENANCE PROHIBITED

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS HOURS

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4 DECALS

POWER INSPECT CLEAN

Every X months, if sooner than required by CHANGE / REPLACE

operating hours

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 DECALS 5
ANSI SYMBOLS
GRAPHIC FORM AND MEANING OF ANSI SYMBOLS

DANGER
INTAKE AIR. Can contain carbon monoxide or other contaminants. Will cause serious injury or death. Ingersoll Rand
air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for
breathing air applications unless treated in accordance with all applicable codes and regulations.

WARNING

HAZARDOUS VOLTAGE. Can cause serious injury or death. Disconnect power and bleed pressure from tank before
servicing. Lockout/Tagout machine. Compressor must be connected to properly grounded circuit. See Grounding
Instructions in manual. Do not operate compressor in wet conditions. Store indoors.

RISK OF FIRE OR EXPLOSION. Electrical arcing from compressor components can ignite flammable liquids and
vapors which can result in serious injury. Never operate the compressor near flammable liquids or vapors. If used to
spray flammable materials, keep compressor at least 20ft away from the spray area.

HIGH PRESSURE AIR. Rusted tanks can cause explosion and severe injury or death. Receiver under perssure.
Operator should relieve tank pressure before performing maintenance. In addition to automatic drain, operate manual
drain valve weekly. Manual drain valve located at bottom of the tank.

MOVING PARTS. Can cause serious injury. Do not operate with guards removed. Machine may start automatically.
Disconnect power before servicing. Lockout/Tagout machine.

HOT SURFACES. Can cause serious injury. Do not touch. Allow to cool before servicing. Do not touch hot
compressor or tubing.

EXPOSED MOVING BELTS AND SHEAVES.

Can cause severe injury or death.
Do not operate without guard in place. Disconnect power before servicing.
Lockout/Tagout machine.

Air flow exhaust may contain flying debris.

Safety protection should be worn at all times.

Pinch point hazard.

Keep hands clear.

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6 DECALS – ANSI
60 Hz Units

VIEW BACK VIEW LEFT

INSIDE PACKAGE

INSIDE STARTER DOOR

VIEW FRONT VIEW RIGHT

VIEW TOP

Item ccn Qty. Description Item ccn Qty. Description

1 32343519 1 Decal, warning contaminated air 10 93171262 2 Decal, notice lift here
2 93166502 1 Decal, replacement filter element 11 32343493 1 Decal, overload setting IEC starter
3 93166460 1 Decal, coolant drain 12 SPEC 1 Specifications, compressor package
4 32343501 1 Decal, dual voltage (if needed) 13 81295883 1 Decal, facia – Electro–Pneumatic

5 22248538 2 Decal, pinch hazard 81295891 1 Decal, facia – Intellisys

6 23038474 1 Decal, Ingersoll Rand signature 14 32017469 1 Decal, voltage 120/1/60

horizontal 27.5“
15 32017436 1 Decal, voltage 230/3/60
7 23353170 1 Decal, maintenance parts 32018475 1 Decal, voltage 200/3/60
8 30286686 1 Decal, notice rotation 32236481 1 Decal, voltage 380/3/60
9 32343543 1 Decal, notice air discharge

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 DECALS – ANSI 7
60 Hz Units

VIEW BACK VIEW LEFT

INSIDE PACKAGE

INSIDE STARTER DOOR

VIEW FRONT VIEW RIGHT

VIEW TOP

Item ccn Qty. Description Item ccn Qty. Description

32017444 1 Decal, voltage 460/3/60 22182356 1 Decal, wiring schematic

Star Delta Intellisys 60Hz
32177305 1 Decal, voltage 575/3/60
22 32343907 1 Decal, lock and tag out
16 32343527 1 Decal, warning high pressure
23 32343899 1 Decal, warning flying debris
17 32343535 3 Decal, warning moving belts
24 22115703 1 Tag, rotation 60Hz
18 32343550 4 Decal, warning exposed fan
25 22436760 4 Tag, shipping bracket
19 32343568 2 Decal, warning hazardous voltage
26 22064562 1 Decal, aircare
20 32343584 1 Decal, warning hot surface
27 30286686 1 Decal, rotation arrow
21 22182372 1 Decal, wiring schematic
Full Voltage 60Hz 28 22181663 1 Decal, condensate drain
22182349 1 Decal, wiring schematic 29 81296196 1 Decal, maintenance schedule
Star Delta 60Hz
22182364 1 Decal, wiring schematic
Full Voltage Intellisys 60Hz
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8 SAFETY

DANGER! If more than one compressor is connected to one common

Hazard that WILL cause DEATH, SEVERE INJURY or substantial downstream plant, effective isolation valves must be fitted and
property damage if ignored. Instructions must be followed precisely to controlled by work procedures, so that one machine cannot accidently
avoid injury or death. be pressurised / over pressurised by another.

WARNING! Compressed air must not be used for a direct feed to any form of
Hazard that CAN cause DEATH, SEVERE INJURY or substantial breathing apparatus or mask.
property damage if ignored. Instructions which must be followed
The discharged air contains a very small percentage of compressor
precisely to avoid injury or death. lubricant and care should be taken to ensure that downstream
CAUTIONS! equipment is compatible.
Cautions call attention to instructions which must be followed If the discharged air is to be ultimately released into a confined
precisely to avoid damaging the product, process or its surroundings. space, adequate ventilation must be provided.
NOTES When using compressed air always use appropriate personal
Notes are used for supplementary information. protective equipment.
BREATHING AIR PRECAUTION All pressure containing parts, especially flexible hoses and their
Ingersoll Rand air compressors are not designed, intended or couplings, must be regularly inspected, be free from defects and be
approved for breathing air. Compressed air should not be used for replaced according to the Manual instructions.
breathing air applications unless treated in accordance with all
applicable codes and regulations. Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.

General Information Avoid bodily contact with compressed air.

Ensure that the operator reads and understands the decals and All safety valves located in the separator tank must be checked
consults the manuals before maintenance or operation. periodically for correct operation.

Ensure that the Operation and Maintenance manual is not removed Do not over–pressurize the receiver tank or similar vessels beyond
permanently from the machine. design limits.

Ensure that maintenance personnel are adequately trained, Do not use a receiver tank or similar vessels that fail to meet the
competent and have read the Maintenance Manuals. design requirements of the compressor. Contact your distributor for
assistance.
Do not point air nozzles or sprayers toward anyone.
Do not drill into, weld or otherwise alter the receiver tank or similar
Compressed air and electricity can be dangerous. Before vessels.
undertaking any work on the compressor, ensure that the electrical
supply has been isolated and the compressor has been relieved of all
pressure.
Materials
Wear eye protection when operating or servicing compressor. The following substances are used in the manufacture of this
All persons positioned near to operating machinery should be machine and may be hazardous to health if used incorrectly:
equipped with hearing protection and given instructions on its use in . preservative grease
accordance with workplace safety legislation. . rust preventative
. compressor coolant
Make sure that all protective covers are in place and that the
canopy/doors are closed during operation. AVOID INGESTION, SKIN CONTACT AND INHALATION OF
FUMES
The specification of this machine is such that the machine is not
suitable for use in flammable gas risk areas.
Installation of this compressor must be in accordance with Transport
recognised electrical codes and any local Health and Safety Codes. When loading or transporting machines ensure that the specified
The use of plastic bowls on line filters can be hazardous. Their lifting and tie down points are used.
safety can be affected by either synthetic lubricants, or the additives Lifting equipment must be properly rated for the weight of the
used in mineral oils. Ingersoll –Rand recommends that only filters with
metal bowls should be used on a pressurised system. compressor.

Do not work on or walk under the compressor while it is suspended.

Compressed air
Compressed air can be dangerous if incorrectly handled. Before Electrical
doing any work on the unit, ensure that all pressure is vented from the Keep all parts of the body and any hand–held tools or other
system and that the machine cannot be started accidentally. conductive objects, away from exposed live parts of the compressor
electrical system. Maintain dry footing, stand on insulating surfaces
and do not contact any other portion of the compressor when making
WARNING adjustments or repairs to exposed live parts of the compressor
Imposing a normal or emergency stop on the compressor will electrical system.
only relieve presure upstream of the minimum pressure valve on
top of the separator tank.
If maintenance work is required downstream of this valve, ensure WARNING
that all pressure is relieved at the process vent point external to Any electrical connections or adjustments should only be
the compressor made by a suitably qualified electrician

Ensure that the machine is operating at the rated pressure and that Close and lock all access doors when the compressor is left
the rated pressure is known to all relevant personnel. unattended.
All air pressure equipment installed in or connected to the machine Do not use extinguishers intended for Class A or Class B fires on
must have safe working pressure ratings of at least the machine rated electrical fires. Use only extinguishers suitable for class BC or class
pressure. ABC fires.
SSR UP6 40, SSR UP6 50PE, SSR UP6 50PEI, HF50–PE, EP50–PE, HP50–PE, HXP50–PE http://air.ingersollrand.com
 SAFETY 9
Attempt repairs only in clean, dry, well lighted and ventilated areas.
Connect the compressor only to electrical systems that are
compatible with its electrical characteristics and that are within it’s rated
capacity.

Condensate disposal
As waste water regulations vary by country and region it is the
responsibility of the user to establish the limitations and regulations in
their particular area. Ingersoll Rand and its associated distributors are
happy to advise and assist in these matters.
For further information, consult Material Data Sheets
for ULTRA Coolant.

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10 GENERAL INFORMATION

PIPING AND INSTRUMENTATION – Electro–pneumatic and Intellisys Units

37 36

41

M
38 40 39
11
28 27
27 9
35

20 DRYER 10 P 29
OPTION 23 34

31
8

3
19
33
22 17
21 7
12

16 24 32
2 5M 25
T
30
4 6
1 MODULATION (OPTION)
26
INTELLISYS (OPTION)
REPLACES ITEM 12 INTELLISYS (OPTION) PIPING LEGEND
REPLACES ITEMS 10 & 11 A
18 B
13 C
14 T D
E
F
G
15

22292783
Rev F

KEY

1. Filter, air 20 Valve, solenoid (blowdown)

2. Valve, inlet 21.Orifice
3. Valve, solenoid (load) 22 Indicator, air restriction
4. Airend assembly 23.Electric drain valve (EDV – condensate)
5. Motor 24.Valve solenoid (line/sump), Intellisys Option
6. Tank, separator 25.Transducer pressure, Intellisys Option, replaces 10 and 11
7. Separator elements 26.Sensor temperature, Intellisys Option, replaces 12
8. Valve, minimum pressure 27.Moisture separator
9. Aftercooler 28.Compressor air discharge
10.Gauge, pressure 29.Condensate discharge
11.Switch, discharge pressure 30.Compressor air inlet
12.Switch, temperature 31.Valve, solenoid, (modulation option)
13.Filter, coolant 32.Valve, solenoid, (modulation option)
14.Thermostat 33.Valve, shuttle, (modulation option)
15.Cooler 34.Valve, modulation (modulation option)
16 Relay, overload, Motor 35.Sensor, temperature, dryer (option) thermometer or
17.Valve, safety thermistor–Intellisys

18.Valve, drain 36.Valve, expansion, dryer (option)

19.Screen, scavenge 37.Filter, refrigerant, dryer (option)

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HP50–PE, HXP50–PE
 GENERAL INFORMATION 11
38.Condenser, dryer (option) A Air/Coolant
39.Evaporator, dryer (option) B Air
40.Refrigerant compressor, dryer (option) C Coolant
41.Hot gas bypass valve, dryer (option) D Condensate
E Component boundary
F Refrigerant
G Option

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12 INSTALLATION / HANDLING

ROTATION

VIEW LEFT

VIEW REAR

VIEW FRONT VIEW RIGHT

DRYER
ROTATION

VIEW BOTTOM VIEW TOP

Note: Dimensions are mm (inches)

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HP50–PE, HXP50–PE
 INSTALLATION / HANDLING 13
KEY

A Pre filter H .25 Inch female NPT moisture separator drain.

B Compressor and cooling air intake J Emergency stop button
C Starter box K Primary compressor service door
D Cooling air exhaust L 4 holes, 0.67 Inch (17mm) diameter
E 1.5” NPT air discharge M 4 holes, 0.47 Inch (12mm) diameter
F Customer power inlet N Dryer cooling air intake
G Fork lift openings
(Fork lift hole covers must be installed after unit is in place to
reduce noise and ensure proper cooling of package)

NOTES

1. Coolant (lubricant) fill quantity (approximate) 5.5 US gallons NOTE

(21 litres). All dimensions are in millimetres (inches) unless otherwise stated.
2. Recommended clearance in front of control panel door 42 inches
(1067 mm) or minimum as required by the latest national electrical
codes (NEC) or applicable local codes.
3. Recommended clearances on left and right sides 36 inches Ensure that the correct fork lift truck slots or marked lifting points are
(914mm). used whenever the machine is lifted or transported.
4. Minimum recommended clearance for the rear of the compressor
is to be 6 inches (152mm).
5. External piping shall not exert any unresolved moments or forces
on the unit. Use pipe size as large or larger at discharge connection. UNPACKING
6. There should be no plastic or pvc piping attached to this unit or used The compressor will normally be delivered with a polythene cover.
for any lines downstream. If a knife has to be used to remove this cover ensure that the exterior
paintwork of the compressor is not damaged.
7. Any field installed ducting to and from the compressor cannot add
more than 1/2 inch (12.5mm) water gauge total air resistance.
Ensure that all transport and packing materials are discarded in a
Ducting is not recommended for the dryer cooling air inlet and outlet manner prescribed by local codes.
openings.
8. Do not pipe into a common header with a reciprocating compressor,
unless the reciprocating compressor utilizes a discharge pulsation
damper. NOTE
9. Sizing of electrical components not supplied by Ingersoll Rand is Units are shipped with transit locking bolt in place. Prior to
the responsibility of the customer and should be done in accordance running the unit the shipping bolt must be removed and the belt
tension checked. Loosen, remove and discard 10mm shipping
with the information on the compressor data plate and national and bolt. For belt tensioning procedure refer to Maintenance section.
local electrical codes.

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14 INSTALLATION / HANDLING

4 4

2 3 5

T5750
Revision 02
07/04

KEY CAUTION
The use of plastic bowls on line filters and other plastic air line
1. Compressor components can be hazardous. Their safety can be affected by
2. Air Dryer either synthetic coolants or the additives used in mineral oils.
Ingersoll Rand recommends that only filters with metal bowls
3. Air Receiver should be used on any pressurised system.
4. Compressed air filters
5. System demand points

NOTE CAUTION
Items [2] to [5] are optional or may be existing items of plant. Refer Before starting machine remove shipping bolt and discard
to your Ingersoll Rand distributor / representative for specific
recommendations.

CAUTION
LOCATION IN THE PLANT The standard compressor unit is not suitable for operation in
temperatures liable to cause freezing as Condensate water is
liable to be produced in the after cooler and receiver where fitted.
Note:
Ensure that the unit is wired for proper voltage before installation. Refer to your Ingersoll Rand distributor for further information.

The compressor can be installed on any level floor capable of

supporting it. A dry, well ventilated area where the atmosphere is clean
is recommended. A minimum of 6 inches (150mm) should be left at the
DISCHARGE PIPING
rear and 3ft (1m) at the sides of the machine for adequate service
access and ventilation. Discharge piping should be at least as large as the discharge
connection of the compressor. All piping and fittings should be suitably
Adequate clearance needs to be allowed around and above the
rated for the discharge pressure.
machine to permit safe access for specified maintenance tasks.

It is essential when installing a new compressor [1], to review the

Ensure that the machine is positioned securely and on a stable
total air system. This is to ensure a safe and effective total system. One
foundation. Any risk of movement should be removed by suitable
item which should be considered is liquid carryover. Installation of air
means, especially to avoid strain on any rigid discharge piping.
dryers [3] is always good practice since properly selected and installed
they can reduce any liquid carryover to zero.

CAUTION It is good practice to locate an isolation valve close to the

Screw type compressors [1] should not be installed in air compressor and to install line filters [4].
systems with reciprocating compressors without means of
isolation such as a common receiver tank. It is recommended that
both types of compressor be piped to a common receiver using It is a requirement for air dryers covered under Aircare that correctly
individual air lines. sized Ingersoll Rand pre and afterfilters are installed.

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HP50–PE, HXP50–PE
 INSTALLATION / HANDLING 15
UP6 50PE
60Hz UP6 40 UP6 50PEI
HF50–PE EP50–PE HP50–PE HXP50–PE

COMPRESSOR 115 125 150 200 115 125 150 200

Maximum operating pressure 115 125 150 200 115 125 150 200
psig (barg) (8.0) (8.5) (10.3) (13.8) (8.0) (8.5) (10.3) (13.8)
Factory set reload pressure 105 115 140 190 105 115 140 190
psig (barg) (7.2) (7.9) (9.6) (13.1) (7.2) (7.9) (9.6) (13.1)
Flow rate 188 185 170 143 212 208 201 167
cfm (m3/min) (5.32) (5.24) (4.81) (4.05) (6.02) (5.89) (5.70) (4.73)

Maximum airend discharge 216 F (102 C)

temperature
Ambient operating 36 F(+2 C ) ? 105 F(+40 C) 36 F(+2 C ) ? 115 F(+46 C)
temperature
min. max.

MOTOR
Motor enclosure ODP TEFC ODP TEFC
Nominal power 40HP 50HP
Speed 1775 RPM 1775 RPM
Frame 324T 324T 326T 326T
Insulation class F

COOLING SYSTEM – Air cooled

Cooling air flow 3100 ft3/min (87.8m3/min) 3900 ft3/min (110m3/min)
Dryer cooling air flow 1200 ft3/min (34m3/min)
Maximum ∆P in air ducts 0.5 inWg (12.7mmH2O) (not recommended for dryer openings)
Compressed air outlet ∆T 15 F (8.3 C) 15 F (8.3 C)
Cooling air outlet ∆T 40 F (22 C) 42 F (23 C)
Dryer cooling air outlet ∆T 11 F (6 C)
GENERAL DATA
Residual coolant content 3ppm (3 mg/m3)
Separator vessel capacity 3.7 US gallons (14 liters)
Coolant capacity 5.5 US gallons (21 liters)
Sound pressure level to 69 dB(A) 69 dB(A)
CAGI–PNEUROP
(Non–dryer unit)
Weight – base mount unit 2326 lbs 2436 lbs 2384 lbs 2476 lbs
(1055 kg) (1105 kg) (1081 kg) (1123 kg)
Weight – dryer option unit 2576 lbs 2686 lbs 2634 lbs 2726 lbs
(1168 kg) (1218 kg) (1194 kg) (1236 kg)

CAUTION
230/460 Dual voltage machines are fitted with a decal to advise
the correct supply voltage as connected from the factory.
Factory units wired for 230V supply can be re–wired to 460V
supply voltage by re–wiring the main drive motor and the fan
motor as shown on the electrical schematic AND by replacing
the fan motor starter CCN 22395800 - 50HP with CCN 22395792
- 50 HP (shipped loose). The main motor overload and the fan
motor starter overload settings should be adjusted accordingly –
reference the IEC decal mounted inside the starter door. Also,
the transformer primary voltage connections will need to be
re–wired for the new supply voltage.
Re–wiring should only be effected by a competent Electrician.

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HP50–PE, HXP50–PE
16 INSTALLATION / HANDLING
60Hz UP6 30E–HA UP6 40–HA

COMPRESSOR 115 125 150 200 115 125 150 200

Maximum operating pressure 125 150 200 115 125 150 200
psig (barg) (8.5) (10.3) (13.8) (8.0) (8.5) (10.3) (13.8)
Factory set reload pressure 115 140 190 105 115 140 190
psig (barg) (7.9) (9.6) (13.1) (7.2) (7.9) (9.6) (13.1)
Flow rate 125 112 92 188 185 170 143
cfm (m3/min) (3.54) (3.17) (2.61) (5.32) (5.24) (4.81) (4.05)

Maximum airend discharge 216_F (102_C)

temperature
Ambient operating 36_F(+2_C ) → 122_F(+50_C)
temperature
min. → max.

MOTOR
Motor enclosure ODP TEFC ODP TEFC
Nominal power 30HP 40HP
Speed 1775 RPM
Frame 324T 324T 326T 326T
Insulation class F

COOLING SYSTEM – Air cooled

Cooling air flow 3100 ft3/min (87.8m3/min) 3900 ft3/min (110m3/min)
Dryer cooling air flow 1200 ft3/min (34m3/min)
Maximum ∆P in air ducts 0.5 inWg (12.7mmH2O) (not recommended for dryer openings)
Compressed air outlet ∆T 15_F (8.3_C)
Cooling air outlet ∆T 40_F (22_C) 42_F (23_C)
Dryer cooling air outlet ∆T 11_F (6_C)
GENERAL DATA
Residual coolant content 3ppm (3 mg/m3)
Separator vessel capacity 3.7 US gallons (14 liters)
Coolant capacity 5.5 US gallons (21 liters)
Sound pressure level to 69 dB(A) 69 dB(A)
CAGI–PNEUROP
(Non–dryer unit)
Weight – base mount unit 2326 lbs 2436 lbs 2384 lbs 2476 lbs
(1055 kg) (1105 kg) (1081 kg) (1123 kg)
Weight – dryer option unit 2576 lbs 2686 lbs 2634 lbs 2726 lbs
(1167 kg) (1218 kg) (1194 kg) (1236 kg)

CAUTION
230/460 Dual voltage machines are fitted with a decal to advise
the correct supply voltage as connected from the factory.
Factory units wired for 230V supply can be re–wired to 460V
supply voltage by re–wiring the main drive motor and the fan
motor as shown on the electrical schematic AND by replacing
the fan motor starter CCN 22395800 - 50 HP with CCN 22395792 -
50 HP (shipped loose). The main motor overload and the fan
motor starter overload settings should be adjusted accordingly –
reference the IEC decal mounted inside the starter door. Also,
the transformer primary voltage connections will need to be
re–wired for the new supply voltage.
Re–wiring should only be effected by a competent Electrician.

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HP50–PE, HXP50–PE
 INSTALLATION / HANDLING 17
DRYER OPTION TECHNICAL INFORMATION 60Hz
General
Refrigerant type R404A
Refrigerant charge 1.8 (0.84)
kg (lbs)
Refrigerant oil Emkarate RL32CF or Texaco Capella HFC32

Control settings
Hot gas setting 72 – 74 (5.0 – 5.1)
barg (psig)
High pressure switch setting 425 (29.3)
barg (psig)
Fan pressure switch setting 225 / 175 (15.5 / 12.1)
on/off
barg (psig)
Performance 30 / 40HP 50HP
(2) (3)

Dew point temperature at rated 41_F (5_C)(4) 50_F (10_C)

conditions and flow
(3)

Maximum ∆P across dryer 2.2 (0.15) 3.0 (0.21)

barg (psig)

(1) In accordance with PNEUROP PN8NTC2.3

(2) In accordance with ISO 7183 at the modified rated conditions.
(3) 60Hz machines: 85_F ambient, 125 psig inlet.
(4) 40hp 200v unit dewpoint is 50_F (10_C)

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18 INSTALLATION / HANDLING
ELECTRICAL DATA – ALL UNITS SSR UP6–40
Standard voltage 200V 230V 380V 460V 575V
PACKAGE
Motor enclosure ODP TEFC ODP TEFC ODP TEFC ODP TEFC ODP TEFC
Power (nominal) 40HP
Full load current at maximum 136.0A 125.6A 118.3A 109.2A 71.6A 66.1A 59.2A 54.6A 47.3A 43.7A
pressure
Full load current at maximum 143.7A 133.3A 125.2A 116.1A – – 62.5A 57.9A – –
pressure with dryer option
Starting current FV (STAR) 706.1 (264.5) 614 (230) 367 (135.2) 307 (115) 245.6 (92)
Starting current FV (STAR) 744.4 (302.5) 652 (268) – 323 (131) –
with dryer option
Starting time FV (STAR) 3–5 Sec (7–10 Sec)
Starts per hour (maximum) 6
ELECTRICAL DATA – FV / Star Delta
Control voltage 120VAC
Minimum fuse rating 175A 150A 100A 90A 75A 60A
See note 1
Minimum fuse rating with dryer 200A 175A 175A 150A – – 80A 75A – –
option
See note 1
Minimum wire size AWG 4/0 3/0 2 3 4
See note 2

ELECTRICAL DATA – ALL UNITS SSR UP6 50PE, UP6 50PEI, HF50–PE, EP50–PE, HP50–PE and HXP50–PE
Standard voltage 200V 230V 380V 460V 575V
PACKAGE
Motor enclosure ODP TEFC ODP TEFC ODP TEFC ODP TEFC ODP TEFC
Power (nominal) 50HP
Full load current at maximum 170.8A 160.0A 148.5A 139.1A 89.8A 82.2A 74.2A 67.9A 59.4A 55.7A
pressure
Full load current at maximum – – 155.4A 146.0A – – 77.5A 71.2A – –
pressure with dryer option
Starting current FV (STAR) 876.3 (321.2) 762 (279.3) 461 (169.0) 381 (139.7) 304.8 (111.7)
Starting current FV (STAR) – 800 (317) – 397 (156) –
with dryer option
Starting time FV (STAR) 3–5 Sec (7–10 Sec)
Starts per hour (maximum) 6
ELECTRICAL DATA – FV / Star Delta
Control voltage 120VAC
Minimum fuse rating 225A 200A 200A 175A 110A 110A 100A 90A 75A 70A
See note 1
Minimum fuse rating with dryer – – 200A 200A – – 100A 90A – –
option
See note 1
Minimum wire size AWG 250 4/0 1 2 3
See note 2

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HP50–PE, HXP50–PE
 INSTALLATION / HANDLING 19
ELECTRICAL DATA – ALL UNITS SSR UP6–40–HA
Standard voltage 200V 230V 380V 460V 575V
PACKAGE
Motor enclosure ODP TEFC ODP TEFC ODP TEFC ODP TEFC ODP TEFC
Power (nominal) 40HP
Full load current at maximum 136.0A 128.3A 119.0A 111.5A 71.6A 65.1A 59.5A 56.9A 47.6A 44.7A
pressure
Full load current at maximum – – 123.5A 116.0A – – 61.7A 58.1A – –
pressure with dryer option
Starting current FV (STAR) 706 (265) 617 (231) 374 (140) 309 (115) 247 (93)
Starting current FV (STAR) – 652 (268) – 323 (131) –
with dryer option
Starting time FV (STAR) 3–5 Sec (7–10 Sec)
Starts per hour (maximum) 6
ELECTRICAL DATA – FV / Star Delta
Control voltage 120VAC
Minimum fuse rating 175A 150A 90A 75A 60A
See note 1
Minimum fuse rating with dryer – – 175A 150A – – 80A 75A – –
option
See note 1
Minimum wire size AWG 4/0 3/0 2 3 4
See note 2

ELECTRICAL DATA – ALL UNITS SSR 30E–HA

Standard voltage 200V 230V 380V 460V 575V
PACKAGE
Motor enclosure ODP TEFC ODP TEFC ODP TEFC ODP TEFC ODP TEFC
Power (nominal) 30HP
Full load current at maximum 109.2A 100.9A 95.0A 87.8A 57.5A 53.1A 47.5A 43.9A 38.0A 38.3A
pressure
Full load current at maximum – – 99.5A 92.3A – – 49.7A 46.1A – –
pressure with dryer option
Starting current FV (STAR) 567 (212.4) 493.2 (184.8) 298.5 (111.8) 246.6 (92.4) 197.3 (73.9)
Starting current FV (STAR) – 516.6 (193.5) – 258 (96.7) –
with dryer option
Starting time FV (STAR) 3–5 Sec (7–10 Sec)
Starts per hour (maximum) 6
ELECTRICAL DATA – FV / Star Delta
Control voltage 120VAC
Minimum fuse rating 150A 125A 125A 125A 75A 75A 60A 60A 50A 50A
See note 1
Minimum fuse rating with dryer – – 150A 150A – – 75A 75A – –
option
See note 1
Minimum wire size AWG 3/0 1/0 3 4 6
See note 2

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20 INSTALLATION / HANDLING
1. If a circuit breaker is selected it should only be a magnetic trip type, Feeder cables/wires should be sized by the customer/electrical
set above the anticipated starting current of the machine, but below the contractor to ensure that the circuit is balanced and not overloaded by
maximum prospective fault current for the circuit. The circuit breaker other electrical equipment. The length of wiring from a suitable
or fuseable disconnect must be capable of breaking the prospective electrical feed point is critical as voltage drops may impair the
fault current at its terminals. performance of the compressor.

2. PVC/PVC Type Calculated using the following conditions:

Feeder cables / wires connections to isolator or disconnect should
be tight and clean.
i) PVC insulated cable, armoured, copper conductors.
ii) Cable clipped to a wall, in free air. The applied voltage must be compatible with the motor and
iii) Ambient temperature of 104_F (40_C) and relative humidity of 40%. compressor data plate ratings.
iv) 65ft (20m) cable run.
v) Volt drop limited to –10% during starting, –5% during normal
running. The control circuit transformer has different voltage tappings.
vi) Protected by the circuit breaker listed above. Ensure that these are set for the specific applied voltage prior to
starting.

If there are any deviations from the above, or special regulations

apply, the installation must be planned by a competent, qualified
engineer.

CAUTION
Never test the insulation resistance of any part of the machines
NOTE electrical circuits, including the motor without completely
All data applies to standard product only. disconnecting the electronic controller (where fitted).

ELECTRICAL DATA
CAUTION
An independent electrical isolator or disconnect should be installed Ensure that the motor, blower and dryer fan rotate in the
adjacent to the compressor. correct direction as indicated by direction arrows, and on
drawing.

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 OPERATING INSTRUCTIONS – GENERAL 21
GENERAL OPERATION CAUTION
Cooling air is drawn in at the end of the machine package
The compressor is an electric motor driven, single stage screw passing through the filter and cooler before being discharged
compressor, complete with accessories piped, wired and baseplate from the top of the machine. Care should be taken to avoid
mounted. It is a totally self contained air compressor package. blocking the airflow, or causing any restriction in excess of the
maximum backpressure allowed for ducting.
The 40hp compressor packages are designed to operate in an Do not direct the airflow at face or eyes.
ambient range of 35.6_F – 104_F (2_C to 40_C) with a special
option package available to operate in ambient temperatures ranges
from 35.6_F up to 124_F (2_C up to 50_C). The maximum The power transmission from the drive motor to the airend male
temperature is applicable to either version up to a maximum rotor is by pulley and belts. The constant auto tensioning system, using
elevation of 3280ft (1000m) above sea level. Above this altitude airend mass torque and gas arm, ensures that the belts are always
significant reduction in maximum allowable ambient temperature is under the correct tension, eliminating the need for adjustment and
required. maximizing the life of the belts.

The 50 hp package is designed for a 115_F (46_C) maximum By cooling the discharge air, much of the water vapour naturally
ambient. contained in the air is condensed and may be drained from the
downstream piping and equipment.
Compression in the screw type air compressor is created by the
meshing of two (male & female) helical rotors. The coolant system consists of a sump, cooler, thermostatic valve
and a filter. When the unit is operating, the coolant is pressurized and
forced to the compressor bearings.
The air/coolant mixture discharges from the compressor into the
separation system. This system removes all but a few PPM of the
coolant from the discharge air. The coolant is returned to the cooling The compressor load control system is automatic on–off line. The
system and the air passes through the aftercooler and out of the compressor will operate to maintain a set discharge line pressure and
compressor. is provided with an auto restart system for use in plants where the air
demand varies sufficiently to allow a compressor to shut down and
save power. Significant system volume will assist this and is
Cooling air is moved through the coolers by the cooling fan and recommended.
discharged from the machine.

With the dryer option, the dryer will run continuously when the
compressor is automatically off line.

WARNING
When the unit stops running as the result of low air demand,
normally indicated by auto restart light, it may restart and return
to load at any time.

Safety of operation is provided as the compressor will shut down if

excessive temperatures or electrical overload conditions should occur.

CAUTION
This unit is not designed or intended to operate when
contaminated with silicone. Lubricants, greases or other items
containing silicone should not be used on this unit.

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22 OPERATING INSTRUCTIONS – ELECTRO–PNEUMATIC

1. PRESSURE GAUGE 8. RESET BUTTON

Indicates the system pressure. Press button to reset the control system following compressor trip.

9. DEW POINT INDICATOR (Dryer Option)

WARNING Green indicates good dew point. Red indicates dew point above
DO NOT operate the compressor at discharge pressures 65_F (18_C) and blue indicates freezing.
exceeding the maximum operating pressure.

PRIOR TO STARTING
2. HOURMETER
Records the total running time of the compressor. 1. Make visual check of the machine, ensure that all guards secure
and that nothing is obstructing the proper ventilation of, or free access
to the machine.
3. EMERGENCY STOP
When depressed will stop the compressor immediately. The ’Power
on’ indicator will remain illuminated. The emergency stop button must 2. Check coolant level. Add if necessary.
be released before the compressor can be restarted.
3. Make sure main discharge valve is open.
4. START/STOP
When switched to the ON position will cause the unit to start and run
in a loaded condition if there is a demand for air. If there is no demand, 4. Turn on electrical isolator or disconnect. The Power on (5) indicator
the machine will run unloaded before stopping automatically. will light, indicating that line and control voltages are available.
When switched to the OFF position, will unload and stop the unit if
it is running. If the unit is in auto restart it will prevent the unit from
5. Check direction of rotation at initial start or following interruption in
re–starting when there is a demand for air.
power supply.

5. POWER ON (Green) WARNING

Indicates the presence of control voltage at the controller. Make sure that all protective covers are in place.
Cooling air flow exhaust may contain flying debris. Safety
6. AUTO RESTART (White) Protection should be worn at all times to avoid injury.
Will illuminate when the machine has shut-down due to low air
demand. The machine will restart and load automatically as soon as the
demand for air returns. STARTING
1. Push the RESET button (8). The fault indicator (7) will extinguish.
7. FAULT / HIGH AIR TEMPERATURE ALARM (Red) Switch the ON/OFF switch (4) to the ON position. The compressor will
Turn off electrical Isolator or disconnect. Investigate cause of fault. start and then load automatically.

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EP50–PE, HP50–PE, HXP50–PE
 OPERATING INSTRUCTIONS – ELECTRO–PNEUMATIC 23
NORMAL/EMERGENCY STOPPING For customers that have interruptions in their incoming power supply
to the compressor and must maintain an uninterrupted supply of
1. Switch the ON/OFF switch (4) to the OFF position. The compressor compressed air, the Power Outage Restart Option allows a
will unload and stop. compressor to restart automatically 10 seconds (adjustable) after
incoming power is restored.
2. Press EMERGENCY STOP button (3) and the compressor will stop
immediately. FUNCTION TEST
To test the operation of the Power Outage Restart Option:
3. Turn off electrical isolator or disconnect. 1. Slowly open the main isolation valve.
2. Start the compressor.

CAUTION 3 The compressor will load automatically if there is sufficient demand

After shutdown never allow unit to stand idle with pressure in for air. Allow the compressor to load.
receiver/separator system. 4. Open the main disconnect to remove power from the compressor.
5. Close the main disconnect to reapply power to the compressor.
The horn will sound for ten seconds; then the compressor will start
automatically.

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24 OPERATING INSTRUCTIONS – ELECTRO–PNEUMATIC

FULL VOLTAGE WIRING SCHEMATIC

DRYER OPTION

SEE NOTES 1 & 2

DRYER OPTION

LEGEND
CPT Transformer 1M Contactor, main
EDV Valve, electric drain 1Ma, b Contacts, aux. main contactor
ES Switch, emergency stop 3M Contactor, dryer compressor (option)
FOL Overload, internal fan (option) 4M Contactor, dryer fan (option)
1FU Fuse, secondary voltage MMS Starter & overload, fan motor
2FU, 3FU Fuses, primary voltage MMSa Contact, fan motor overload
4FU, Fuses, dryer fan (option) MOD Modulation control option
5FU, 6FU
1MTR Motor, compressor
HATR Relay, high air temperature
2MTR Motor, fan
HATR Contacts, relay – HATR
1,2,3 3MTR Motor, dryer compressor (option)
4MTR Motor, dryer fan (option)
HATS Switch, high air temperature.
OL Overload, main motor
HM Hourmeter
OLa Contact, main motor overload
1LT Light, power on indicator (Green)
2LT Light, auto restart indicator (White) 3OL Overload, dryer compressor (option)

3LT Fault indicator light (Red)

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HP50–PE, HXP50–PE
 OPERATING INSTRUCTIONS – ELECTRO–PNEUMATIC 25
LEGEND
1PS Switch, pressure VAR Varistor
1RPS Switch, high refrigerant pressure (option) Barrier terminal strip
2RPS Switch, fan pressure (option)
RST Switch, reset
1SV Valve, solenoid (load) N.C. NOTES
3SV Valve, solenoid (blowdown) N.O. 1. Approved fused disconnect or circuit breaker per N.E.C.
5SV Valve, solenoid (modulation option) requirements must be provided by customer.
6SV Valve, solenoid (modulation option) 2. Dashed lines represent wiring by customer.
S1 Switch, selector (modulation option) 3. Sizing of electrical components not supplied by Ingersoll Rand is
SS Switch, selector Off/On the responsibility of the customer and should be done in
accordance with the information on the compressor data plate
TDR1 Relay timed delay (10 sec.)
N.E.C. and local electrical codes.
TDR1a Contact, relay – timed
4.. When changing the supply voltage, ensure that:
TDR1b Contact, relay – instant a) The motor and the transformer are rewired for the new voltage
TR Relay, restart, time delay (6 min) b) The motor overload is adjusted to the proper setting.

TRa Contact, relay 5. Verify actual motor conditions with motor schematic.

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26 OPERATING INSTRUCTIONS – ELECTRO–PNEUMATIC
STAR – DELTA WIRING SCHEMATIC

DRYER OPTION

SEE NOTES 1 & 2

DRYER OPTION

LEGEND
CPT Transformer 1Ma, b, c Contacts, aux. main contactor
EDV Valve, electric drain 2M Contactor, delta
ES Switch, emergency stop 2Ma, b Contacts, aux. delta contactor
FOL Overload, internal fan (option) 3M Contactor, dryer compressor (option)
1FU Fuse, secondary voltage 4M Contactor, dryer fan (option)
2FU, 3FU Fuses, primary voltage MMS Starter & overload, fan motor
4FU, Fuses, dryer fan (option) MMSa Contact, fan motor overload
5FU, 6FU
MOD Modulation control option
HATR Relay, high air temperature
1MTR Motor, compressor
HATR Contacts, relay – HATR
1,2,3 2MTR Motor, fan

HATS Switch, high air temperature. 3MTR Motor, dryer compressor (option)
4MTR Motor, dryer fan (option)
HM Hourmeter
1LT Light, power on indicator (Green) 3OL Overload, dryer compressor (option)

2LT Light, auto restart indicator (White) OL Overload, main motor

3LT Fault indicator light (Red) OLa Contact, main motor overload

1M Contactor, main
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 OPERATING INSTRUCTIONS – ELECTRO–PNEUMATIC 27
LEGEND
1PS Switch, pressure TDR1b Contact, relay – instant
1RPS Switch, high refrigerant pressure (option) TR Relay, restart, time delay (6 min)
2RPS Switch, fan pressure (option) TRa Contact, relay
RST Switch, reset VAR Varistor
S1 Switch, selector (modulation option) Barrier terminal strip
1S Contactor, star
1Sa, b Contacts, aux. star contactor NOTES
SS Switch, selector Off/On 1. Approved fused disconnect or circuit breaker per N.E.C.
1SV Valve, solenoid (load) N.C. requirements must be provided by customer.

3SV Valve, solenoid (blowdown) N.O. 2. Dashed lines represent wiring by customer.
5SV Valve, solenoid (modulation option) 3. Sizing of electrical components not supplied by Ingersoll Rand is
the responsibility of the customer and should be done in
6SV Valve, solenoid (modulation option)
accordance with the information on the compressor data plate
N.E.C. and local electrical codes.
TD Relay, delta starting (10 sec.)
4.. When changing the supply voltage, ensure that:
TDa Relay, delay off contact
a) The motor and the transformer are rewired for the new voltage
TDR1 Relay timed delay (10 sec.) b) The motor overload is adjusted to the proper setting.

TDR1a Contact, relay – timed 5. Verify actual motor conditions with motor schematic.

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 28 OPERATING INSTRUCTIONS – ELECTRO–PNEUMATIC
CONTROL PIPING DIAGRAM

11
10

1
R
14
P A 12

13

2 6
6

18

4
13

7
8

ADAPTER INTO
THIS PORT
15
PLUG INTO
5
THIS PORT

22250039
Revision F A
09/06 B
A

KEY

1. Pressure gauge 12.Nipple

2. Pressure switch 13.Adaptor
3. Tee 14.Intake valve assembly
4. Connector 15.Separator tank
5. Moisture separator 16.Tee
6. Elbow 17.Valve
7. Tee, male run 18.Plug

8. Reducer bushing 17.Valve

9. Blow down solenoid valve NOTES:
10.Load solenoid valve A. Tubing 3/8 inch
11.Indicator air filter B. Tubing 1/4 inch

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 OPERATING INSTRUCTIONS – INTELLISYS OPTION 29

INTELLISYS CONTROL AND INSTRUMENTATION

PRIOR TO STARTING POWER OUT RESTART (Optional)
1. Check coolant level. Add if necessary. If this setting is set to ON, the compressor will automatically restart
when power is returned to the compressor if it was operating when
power was removed.
2. Make sure main discharge valve is open.
POWER OUT RESTART TIME
3. Turn on electrical isolator. The power L.E.D. will illuminate and the If the power out restart setting is set to ON, this is the number of
display will indicate ‘Ready to start’. seconds from the time power is restored until the compressor starts.
The power out restart horn will sound during this time.

WARNING NORMAL STOPPING

Make sure that all protective covers are in place.
1. Press ‘Unloaded Stop’[25]. The compressor will unload then stop.

STARTING
2. Turn off electrical isolator.
Press ‘Start’ [24]. The compressor will start and then load
automatically.

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30 OPERATING INSTRUCTIONS – INTELLISYS OPTION
EMERGENCY STOP 16 L.E.D.–Select options.
1. Press ‘Emergency stop button’ [26] and the compressor will stop
immediately. 17 L.E.D.–Not used.

2. Turn off electrical isolator. 18 L.E.D.–Not used.

INSTRUMENT PANEL FUNCTION

1 PACKAGE DISCHARGE PRESSURE L.E.D. 19 DISPLAY SELECT BUTTON
This will illuminate when the display indicates the package Press to index through compressor operating conditions. The
discharge pressure. corresponding L.E.D. will illuminate adjacent to display.
This is used to select alternative status displays (after
approximately 5 minutes, the display defaults to the package discharge
2 AIREND DISCHARGE TEMPERATURE L.E.D. pressure). Depressing this button in the set point routine will cause exit
This will illuminate when the display indicates the airend discharge to checking machine for 2 seconds, then ready to start.
temperature.
20 LOAD/UNLOAD BUTTON
3 SUMP PRESSURE L.E.D. These are used to manually switch the compressor between a
This will illuminate when the display indicates the sump pressure. loaded control mode (e.g. on/off line) and unloaded running.
See L.E.D.
4 SEPARATOR PRESSURE DROP L.E.D.
This will illuminate when the display indicates the separator 21 SET BUTTON
pressure drop. Depressing this button when the compressor is stopped will enable
entry into the set point routine. When in the set point routine, depressing
this button will cause the controller to move on to the next set point
5 TOTAL HOURS L.E.D. setting, saving the new value if one has been entered.
This will illuminate when the display indicates the total compressor A warning reset is obtained by depressing this button (while the
running hours. machine is running). An alarm reset is obtained by depressing this
button twice within 3 seconds (the alarm condition will remain if the
6 LOADED HOURS L.E.D. indicated fault has not been rectified).
This will illuminate when the display indicates the total loaded
compressor hours. 22 LIQUID CRYSTAL DISPLAY
This indicates the status of the compressor, set up parameters and
7 LOAD/UNLOAD L.E.D. warning/alarm messages. When the compressor is running, the
This will illuminate when the compressor is running onload. display will normally show the package discharge pressure.

8 MODULATION L.E.D. 23 ARROW KEYS

This will illuminate when the compressor is running in modulation These are used to index through warning and alarm messages. In
mode. (Note: capacity modulation will occur only if the appropriate the set point routine, these buttons are used to increase/decrease set
regulation pneumatics are fitted to the compressor). point values and enable/disable some operation conditions.

9 UNLOAD L.E.D. The arrow keys are also used to select pressure bands 1 (Y) or 2
This will illuminate when the compressor is running in unload mode. (B) during normal operation of the compressor.

10 ALARM L.E.D. 24 START BUTTON

This will flash when a warning condition exists. The warning This button when depressed will cause the compressor to start and
detected will be displayed and the compressor will continue to run. The load automatically, provided that the controller detects a demand for air.
warning can be reset by depressing set [21]. When pressed in the display mode, it will cause exit to checking
It will illuminate when an alarm condition has occurred. The machine for 2 seconds, then ready to start.
compressor will shutdown immediately. The alarm can be reset by
depressing set [21] twice within 3 seconds. 25 UNLOADED STOP
This button when depressed while the compressor is running, will
OTHER L.E.D.s unload the compressor (if not already unloaded) for 10 seconds and
These will illuminate during the set point routine to indicate which then stop. This is the normal method for stopping the compressor. If the
function is being adjusted. compressor is already stopped, it will execute an L.E.D. check (all the
L.E.D.s should illuminate) and display the controller software revision.

11 L.E.D.–Set off line pressure.

26 EMERGENCY STOP
This button when depressed will stop the compressor immediately
12 L.E.D.–Set on line pressure. and display an emergency stop alarm message.

13 L.E.D.–Select control mode.

14 L.E.D.–Set star delta time.

15 L.E.D.–Set auto restart time.

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 OPERATING INSTRUCTIONS – INTELLISYS OPTION 31
27 POWER L.E.D. CONTROLLER WARNING MESSAGES
This will illuminate when the 8V controller supply is available. In the event of a warning, the controller will display a message and
the alarm L.E.D. [10] will flash. The warning message will alternate with
the normal display every 4 seconds, the compressor will continue to run
28 AUTOMATIC RESTART L.E.D. but the fault should be rectified as soon as possible. The arrow keys
This will illuminate when the machine has shutdown due to low air [23] should be used to index the display for any additional warning
demand. The compressor will restart and load automatically as soon messages. A warning message may be reset by depressing set [21]
as the demand for air resumes. once.

DISPLAY MESSAGES NOTE:

When the compressor is running normally, the display will indicate The warning will recur if the fault has not been rectified. The
the package discharge pressure and illuminate the corresponding following warning messages may be displayed:
L.E.D. [1]. An arrow will also appear in the far right of the display
indicating pressure band selection. Pressing display select [19] will COOLANT FILTER (OPTIONAL)
change the display value and the corresponding L.E.D. will illuminate. The pressure differential across the coolant filter exceeds 15 psi (1
The controller monitors all aspects of the compressor while running and bar)
will display warnings or in severe conditions execute an emergency .
stop and display alarm conditions.
AIR FILTER
The air filter is dirty or blocked and should be replaced.
MACHINE CONTROL MODES
CAPACITY CONTROL SEPARATOR ELEMENT
The compressor is designed to work with two types of capacity The separator element is dirty or blocked and should be replaced.
control, to suit the individual plant requirements. These controls are:–
A. On line – Off line. (Fitted as standard)
B. On line – Off line, with Upper Range Modulation. (Optional extra) AIREND TEMPERATURE
Either is available by selection at the control panel. The airend temperature reaches 97% of the high airend
temperature set point (i.e. 223°F (106°C)).
ON LINE – OFF LINE CONTROL
For applications that require a widely varying air demand, this mode CONTROLLER ALARMS
of control will deliver air at full capacity or zero capacity with low In the event of an alarm, the controller will execute an emergency
receiver pressure. stop, the alarm L.E.D. [10] will illuminate and an alarm message will be
displayed. The arrow keys [23] should be used to index the display for
any additional alarm messages. An alarm is reset by depressing set
This mode of operation is controlled by the pressure transducer [21] twice within a 3 second period after the fault has been rectified. The
responding to changes in plant air pressure. This sensor energizes compressor will restart only when all alarm conditions have been
the load solenoid valve which in turn operates the venting valve rectified. The following alarm messages may be displayed (For fault
(blowdown) and the closing of the atmospheric vent opening in the correction see the Fault Finding section):
air inlet valve.

STARTER FAULT
The compressor then delivers full capacity air to the plant system. The contactor sequence during start or stop is incorrect.
If the air pressure in this system rises to the upper set point of the
pressure setting, the load solenoid valve is de–energized allowing the
inlet valve to close. At the same time, the venting valve opens allowing AIREND TEMPERATURE
the receiver pressure to drop. The airend discharge temperature is above the high temperature
set point.
The pressure setting has a range of 12 psi (0.83 bar) between its
upper and lower set points.The upper set point is set at 3 psi (0.2 bar) MOTOR OVERLOAD
above the compressor rated discharge pressure. The motor overload contacts are open. The motor overload must be
reset before the controller can be reset.
UPPER RANGE MODULATION CONTROL (Optional Extra)
For plants having a relatively high and constant air demand, Upper REVERSE ROTATION
Range Modulation is the recommended mode of control. No sump pressure is detected after the first 2 seconds of running.
Isolate the machine and reverse the mains supply connections before
resuming.
Upper range modulation retains the features of On line – Off line
control but provides the throttling of the inlet air flow as the line pressure
rises to the upper set point of the off–line pressure setting. OVER PRESSURE
The line pressure is 15 psi (1 bar) greater than the rated discharge
pressure.
By bleeding off a small amount from the regulator valve, which
energises the Modulate Solenoid Valve, a reduction in the air signal to
the pneumatic cylinder on the inlet valve allows the cylinder to ‘trim’ the TEMPERATURE SENSOR 1
inlet valve position as dictated by changing line pressure. Modulation The airend temperature sensor/ connecting cable has failed.
begins when the compressor reaches about 94% of the rated line
pressure and is factory set to modulate down to approximately 70% of
rated capacity. TEMPERATURE SENSOR 2
The separator tank temperature sensor/connecting cable has
failed.
If the air demand decreases to a level below the 70% modulated
output, the line pressure will increase slightly to the upper limit of the
pressure setting, when the compressor then changes to the Off line PRESSURE SENSOR
control position and operates with the receiver vented. Indicates pressure transducer failure / connecting cable fault.

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32 OPERATING INSTRUCTIONS – INTELLISYS OPTION
FAILED CALIBRATION EMERGENCY STOP
During calibration routine, a 10% of scale error has been detected. The emergency stop button is engaged.
Ensure that the separator is completely blowndown and repeat
calibration.
LOW SUMP PRESSURE
The sump pressure drops below 15 psi (1 bar) during normal
CONTROL POWER LOSS operation.
The 48Vac signal is not present at the controller.
HIGH DEW POINT (Dryer Option)
REMOTE START FAILURE The dew point indication is above 65_F (18_C).
Momentary remote start has not disengaged before star–delta Ensure that the dryer is running properly and that maximum ambient
transition. This alarm is active only if the remote start/stop is enabled. conditions are not exceeded.

REMOTE STOP FAILURE

The momentary remote stop switch has not disengaged when the
start signal is received. This alarm is active only if the remote start/stop
is enabled.

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 OPERATING INSTRUCTIONS – INTELLISYS w/ MODULATION CONTROL 33
MODULATION CONTROL ACS CONTROL (INTELLISYS w/ MODULATION OPTION ONLY)
For those plants which have relatively high constant air demand For compressors supplied with IntellisysR control and modulation
relative to the compressor capacity, the recommended control mode is option, ACS control will allow the compressor to automatically switch
modulation. between on–line/off–line and modulation control, depending on air
demand.
The modulation control system retains the features of the on–line /
off–line control, but also provides for throttling of the inlet flow up to the If the air demand has decreased to a level below the 60 percent
off–line air pressure setpoint value. modulated output, the line pressure will increase slightly to actuate the
IntellisysR. The compressor will then shift to the off–line control
By applying line pressure to an adjustable modulator valve, the position, and operate unloaded with the compressor vented.
throttling position of the inlet valve is controlled, thus allowing the
modulator to ”trim” the inlet valve position as dictated by the line It is sometimes desirable to begin modulation at a higher pressure than
pressure. the standard factory setting, thereby increasing the modulated capacity
at the time the IntellisysR is actuated. Refer to Figure 1 for modulated
The modulating pressure range is about 4 psig (0.3 BAR) and the capacities available when this is done.
modulator normally should be set to straddle the compressor rated
pressure. Modulation begins when the line pressure reaches about 99 The compressor will then operate to deliver full capacity air to the plant
percent of the compressor rated pressure and continues as/if the line system. If the plant air system pressure rises to that of the IntellisysR
pressure rises. Modulation becomes stable when the compressor off–line set point, pressurized air will be sent to the inlet valve causing
output equals the plant air demand. When the modulation is at the it to close, and to the blowdown valve, causing it to open.
factory setting, the flow will be reduced to 60 percent of the
compressor rated capacity (as indicated in Figure 1). The compressor will continue to run unloaded, but since pressure
levels have reduced, it will do so with a minimum power draw.
Capacity control of machines supplied with electro–pneumatic control
and the modulation option can be manually switched from The IntellisysR has a fixed minimum differential of 10 psi between the
on–line/off–line to modulation (MOD) via the control mode switch (SS) off–line air pressure setting and the on–line air pressure setting. The
located adjacent to the pressure switch. differential may be increased by adjusting the on–line air pressure
setting of the IntellisysR.
The automatic control selector (ACS) is designed to continuously
monitor the plant air demand and select either the on–line/off–line, or
the modulate control mode – whichever is most desirable at any time
during an operating day.
It allows the compressor to operate in its most efficient mode thereby
reducing power costs.
MODULATE TO
94% CAPACITY When the compressor operates in the on–line/off–line control mode,
the length of time the compressor remains in the ”off–line” condition is
MODULATE TO
% OF RATED FLOW

an indication of the plant air demand. IntellisysR controller is sensing

85% CAPACITY and awaiting a sufficient line pressure decrease before signalling a shift
to the on–line mode. If the ”off–line” time period is relatively short,
thereby indicating a high demand for air, it is preferable to shift the
MODULATE TO control system to upper range modulation.
72% CAPACITY The IntellisysR does this, and does it automatically if the compressor
unloads 3 times within a 3 minute time period.
If later, the plant demand decreases, and even under modulate control
MODULATE TO
the line pressure reaches the setting of the IntellisysR controller, and
60% CAPACITY
the control shifts to the ”off–line” mode, the time in this mode will still be
monitored. A long ”off–line” time period indicates a low plant air
demand, indicating the desirability of operating in the on–line/off–line
mode.

% OF RATED LINE PRESSURE The IntellisysR then does this, and does it automatically if the
compressor operates unloaded for more than 3 minutes.

KEY Modulation Only

A Normal settings of modulator If MODULATION ONLY is turned on in the setpoint routine, the unit will
shift to Modulation control mode immediately when the unit is running.
B Optional field settings of modulator The 3 cycles within 3 minutes time period required for ACS to change
C IntellisysR off–line set point to Modulation mode is bypassed. The unit will stay in Modulation mode
until the unit runs unloaded for 3 minutes (the unit then returns to ACS
FIGURE 1 control) or MODULATION ONLY is turned off via the set routine.
Delay Load Time
This is the amount of time the line pressure must remain below the
on–line setpoint before the compressor will load or start (if the unit was
stopped due to an auto start/stop situation). Setting the load delay time
to 0 will cause no delay. When the delay load timer becomes active, the
display will switch to package discharge pressure (if not displaying
package discharge pressure at that time) and then display the delay
load count down. Once the count down reaches 0, the unit will load or
start and the display will return to line pressure. The display select
button is inactive during the delay load count down.

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34 OPERATING INSTRUCTIONS – INTELLISYS w/ PORO OPTION

OPERATION 6. Use the up or down arrows to select the desired delay time (10–120
sec.).
POWER OUTAGE RESTART OPTION
7. Press SET and the display will flash twice indicating the change has
For customers that have interruptions in their incoming power supply been made.
to the compressor and must maintain an uninterrupted supply of
compressed air, the Power Outage Restart Option allows an Intellisys 8. Push the DISPLAY SELECT BUTTON or wait 30 seconds for the
compressor to restart automatically 10–120 seconds (adjustable) after controller to automatically exit the set routine. The display returns to
incoming power is restored. READY TO START.
The Power Outage Restart Option is turned on by using the customer Function test
set routine on the IntellisysR controller. The restart time delay, which
is adjustable from 10–120 seconds, can also be adjusted while in the To test the operation of the Power Outage Restart Option:
set routine on the IntellisysR controller. Any time power is restored to
1. Slowly open the main isolation valve.
the compressor after a power interruption and if the compressor was
running when power was lost, a horn located on the side of the starter 2. Push the green START button on the IntellisysR display to start the
box will sound during the restart time delay (10–120 seconds), after compressor.
which the compressor will automatically start. After starting, the
compressor will return to the mode of operation that the compressor 3. The compressor will load automatically if there is a sufficient
was in prior to the power interruption. demand for air. Allow the compressor to load.
To operate in the power outage restart mode, proceed with 4. Open the main disconnect to remove power from the compressor.
following steps:
1. Power up the unit and wait for the IntellisysR display to read READY 5. Close the main disconnect to reapply power to the compressor.The
TO START. horn will sound and the IntellisysR display will read START IN
___SEC.The display will count down the time until the compressor
2. Press the SET button once to enter the customer set point starts automatically and the horn stops. After starting, the compressor
routine. The Set Offline Air Pressure indicator will light and the will automatically return to the same mode of operation as prior to the
display will show the set point pressure. power interruption.
3. Press and release the SET button multiple times until the message Fault Analysis
PWR OUT RSTR OFF is displayed.
1. If the IntellisysR display indicates the count down message and the
4. Push the up or down arrows to change to the desired condition. ON horn does not sound, check the wiring of the horn.
in the display indicates Power Outage Restart is turned on and OFF in
the display indicates Power Outage Restart is turned off. 2. If the IntellisysR display does not indicate the count down message,
the horn does not sound and the unit does not restart automatically,
5. Once the selection has been made, press SET button to put the verify that the Option has been turned on.
selection into IntellisysR memory. The display will flash twice and the
message will change to STR DELAY 10 Sec if the option was turned
on. This message will only display if the Power Outage Restart Option
is turned on.

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 OPERATING INSTRUCTIONS – INTELLISYS OPTION 35
FULL VOLTAGE WIRING SCHEMATIC

DRYER OPTION

SEE NOTES 1 & 2

PORO OPTION

DRYER OPTION

LEGEND
3APT Sensor, presure, line/sump 3M Contactor, dryer compressor (option)
2ATT Sensor, temperature, airend discharge 4M Contactor, dryer fan (option)
3ATT Sensor, temperature dryer air (option) MMS Starter & overload, fan motor
COM Port, communications / test / service / sequencer MMSa Contact, fan motor overload
CPT Transformer MOD Option, modulation control
EDV Valve, electric drain 1MTR Motor, compressor
ES Switch, emergency stop 2MTR Motor, fan
FOL Overload, internal fan (option) 3MTR Motor, dryer compressor (option)
1FU, 2FU Fuses, primary voltage 4MTR Motor, dryer fan (option)
3FU Fuse, secondary voltage OL Overload, main motor
4FU, 5FU Fuses, low voltage OLa Contact, main motor overload
6FU, Fuses, dryer fan (option) 3OL Overload, dryer compressor (option)
7FU, 8FU
OM Module, option
1M Contactor, main
1Ma Contact, aux. main contactor
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36 OPERATING INSTRUCTIONS – INTELLISYS OPTION
LEGEND NOTES

PORO Horn, power outage (option) 1. Approved fused disconnect or circuit breaker per N.E.C.
requirements must be provided by customer.
RAC Contacts, remote alarm, (option)
1RPS Switch, high refrigerant pressure (option) 2. Dashed lines represent wiring by customer.

2RPS Switch, fan pressure (option) 3. Sizing of electrical components not supplied by Ingersoll Rand is
the responsibility of the customer and should be done in
RS1 Switch, remote start (option)
accordance with the information on the compressor data plate
RS2 Switch, remote stop (option) N.E.C. and local electrical codes.
1SV Valve. solenoid (load) N.C. 4.. When changing the supply voltage, ensure that:
3SV Valve, solenoid (blowdown) N.O. a) The motor and the transformer are rewired for the new voltage
5SV Valve, solenoid (modulation option) b) The motor overload is adjusted to the proper setting.

6SV Valve, solenoid (modulation option) 5. Blue wire – 16volts A.C.

10SV Valve, solenoid (line/sump) 6. Verify actual motor connections with motor schematic.
Barrier terminal strip

BLK Black
BLU Blue
GRN Green
RED Red
WHI White

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 OPERATING INSTRUCTIONS – INTELLISYS OPTION 37
STAR – DELTA WIRING SCHEMATIC

DRYER OPTION

SEE NOTES 1 & 2

PORO OPTION

DRYER OPTION

LEGEND
3APT Sensor, presure, line/sump 3M Contactor, dryer compressor (option)
2ATT Sensor, temperature, airend discharge 4M Contactor, dryer fan (option)
3ATT Sensor, temperature dryer air (option) MMS Starter & overload, fan motor
COM Port, communications / test / service / sequencer MMSa Contact, fan motor overload
CPT Transformer MOD Option, modulation control
EDV Valve, electric drain 1MTR Motor, compressor
ES Switch, emergency stop 2MTR Motor, fan
FOL Overload, internal fan (option) 3MTR Motor, dryer compressor (option)
1FU, 2FU Fuses, primary voltage 4MTR Motor, dryer fan (option)
3FU Fuse, secondary voltage OL Overload, main motor
4FU, 5FU Fuses, low voltage OLa Contact, main motor overload
6FU, Fuses, dryer fan (option) 3OL Overload, dryer compressor (option)
7FU, 8FU
OM Module, option
HATS Switch, high air temperature.
PORO Horn, power outage (option)
1M Contactor, main
RAC Contacts, remote alarm, (option)
1Ma Contact, aux. main contactor
RCI Supressor
2M Contact, delta
1RPS Switch, high refrigerant pressure (option)
2Ma Contact, aux. delta contactor

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38 OPERATING INSTRUCTIONS – INTELLISYS OPTION
LEGEND NOTES

2RPS Switch, fan pressure (option) 1. Approved fused disconnect or circuit breaker per N.E.C.
requirements must be provided by customer.
RS1 Switch, remote start (option)
RS2 Switch, remote stop (option) 2. Dashed lines represent wiring by customer.

1S Contactor, star 3. Sizing of electrical components not supplied by Ingersoll Rand is

the responsibility of the customer and should be done in
1Sa, b Contact, aux. star contactor
accordance with the information on the compressor data plate
1SV Valve, solenoid (load) N.C. N.E.C. and local electrical codes.
3SV Valve, solenoid (blowdown) N.O. 4.. When changing the supply voltage, ensure that:
5SV Valve, solenoid (modulation option) a) The motor and the transformer are rewired for the new voltage

6SV Valve, solenoid (modulation option) b) The motor overload is adjusted to the proper setting.

10SV Valve, solenoid (line/sump) 5. Blue wire – 16volts A.C.

Barrier terminal strip 6. Verify actual motor connections with motor schematic.

BLK Black
BLU Blue
GRN Green
RED Red
WHI White

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 OPERATING INSTRUCTIONS – INTELLISYS OPTION 39
CONTROL PIPING DIAGRAM

11
10
6 3

15 R
P A
12
14
2

R
13
P A 6
6
1 6
4
18

8 9
4

6
13

4
6
7 8

NOTES:
B
A

A
ADAPTER INTO
THIS PORT

5
22250047
Revision E
11/04

KEY

1. Separator tank 12.Nipple

2. Pressure transducer 13.Adaptor
3. Adaptor 14.Intake valve assembly
4. Connector 15.Line / Sump solenoid valve
5. Moisture separator 16.Tee
6. Elbow 17.Valve
7. Tee, male run 18.Plug
8. Reducer bushing
NOTES:
9. Valve, solenoid (blowdown)
A Tubing 3/8 inch
10.Valve, solenoid (load)
B Tubing 1/4 inch
11.Indicator air filter

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40 MAINTENANCE

SSR UP Series Maintenance Schedule

PERIOD MAINTENANCE Every 4 years or Replace all hoses.
16000 hours
Each 24 hours Check the coolant level and replenish if Strip, clean and re–Grease motor bearings
operation necessary. of ODP motors.

Visual check of Report immediately, contact Ingersoll Rand Replace sealed bearing on IP55 motors.
machine for any authorized distributor for assistance if in Fit replacement electrical contactor tips.
leaks, dust build up doubt
or unusual noise or 6 years/16000 hours Separator tank.
vibration or as defined by Remove the cover plate and any necessary
local or national fittings. Clean the interior thoroughly and
When compressor Drain air receiver of condensate, or check legislation. inspect all internal surfaces.
is receiver mounted that automatic drain is operating
Visual check Blow clean if needed
condition of
ROUTINE MAINTENANCE
package pre–filter
This section refers to the various components which require
If the air filter Check the Condition of filter. Change the air
periodic maintenance and replacement.
indicator locks into filter if needed. Dusty environments require
red position before more frequent replacement.
the 2000 hour/1 year (Indicator should be checked with unit . It should be noted that the intervals between service requirement
change out period stopped) may be significantly reduced as a consequence of poor operating
First 150 hours Change the coolant filter. environment. This would include effects of atmospheric contamination
and extremes of temperature.
Each month or 100 Remove and clean package pre–filter,
hours replace if needed
The SERVICE/MAINTENANCE CHART indicates the various
Check the cooler(s) for build up of foreign components’ descriptions and the intervals when maintenance has to
matter. Clean if necessary by blowing out take place. Oil capacities, etc., can be found in the GENERAL
with air or by pressure washing. INFORMATION section of this manual.
Check hoses and fittings for leaks – tighten
as required. Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
Each 2000 hours / 6 Take coolant sample for fluid analysis. system and that the machine cannot be started accidentally.
months
Check scavenge screen for blockage, clean
if required.
Each year or Change the coolant filter.
2000 hours CAUTION: Before beginning any work on the compressor, open,
lock and tag the main electrical disconnect and close the isolation
Change the separator cartridges. valve on the compressor discharge. Vent pressure from the unit
Change the package pre–filter. by slowly unscrewing the coolant fill cap one turn. Unscrewing
the fill cap opens a vent hole, drilled in the cap, allowing pressure
Visual Check of Drive Belt and tensioning to release to atmosphere. Do not remove the fill cap until all
gas spring. pressure has vented from the unit. Also vent piping by slightly
opening the drain valve. When opening the drain valve or the
Take Coolant sample for Fluid Analysis coolant fill cap, stand clear of the valve discharge and wear
Change the Air Filter element. appropriate eye protection.

Check inlet valve flapper – re–condition as

needed. Ensure that maintenance personnel are properly trained,
Check refrigerant compressor oil level. competent and have read the Maintenance Manuals.

Pressure vessel Separator vessel and air receiver when Prior to attempting any maintenance work, ensure that:–
inspection fitted.
frequency may be Fully inspect all external surfaces, and . all air pressure is fully discharged and isolated from the system. If
otherwise defined fittings. Report any excessive corrosion, the automatic blowdown valve is used for this purpose, then allow
by local or national mechanical or impact damage, leakage or enough time for it to complete the operation.
legislation. other deterioration.
Every two years or Change drive belt and gas spring. . the machine cannot be started accidently or otherwise.
8000 hours
Replace the Ultra Coolant at whichever
interval occurs first. . all residual electrical power sources (mains and battery) are
isolated.
Check and replace all items included within
2000 hour service
Prior to opening or removing panels or covers to work inside
Fit the following reconditioning parts as a machine, ensure that:–
appropriate:

Solenoid valves . anyone entering the machine is aware of the reduced level of
Inlet valve kit protection and the additional hazards, including hot surfaces and
Minimum Pressure valve insert intermittently moving parts.
Thermostatic Valve actuator
Strip, clean and re–Grease motor bearings
of ODP motors.

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 MAINTENANCE 41
. the machine cannot be started accidently or otherwise. 1. Stop the machine, electrically isolate and vent all trapped pressure.

Prior to attempting any maintenance work on a running 2. Place a suitable container close to the drain valve.
machine, ensure that:–

3. Slowly remove fill/vent cap.

DANGER
Only properly trained and competent persons should 4. Remove plug from drain valve.
undertake any maintanence tasks with the compressor running or
with electrical power connected.
5. Open the drain valve and drain coolant into container.

. the work carried out is limited to only those tasks which require the
6. Close the drain valve.
machine to run.

. the work carried out with safety protection devices disabled or 7. Replace plug in drain valve.
removed is limited to only those tasks which require the machine to be
running with safety protection devices disabled or removed.
8. Refill the machine following the ”top up coolant” procedure above.
After initial fill, to purge any airlocks, the machine should be run for a
. all hazards present are known (e.g. pressurised components, few minutes cycling between load and no load, before checking that the
electrically live components, removed panels, covers and guards, level is correct.
extreme temperatures, inflow and outflow of air, intermittently moving
parts, safety valve discharge etc.). 9. Replace and tighten oil fill cap.

. appropriate personal protective equipment is worn.

. loose clothing, jewellery, long hair etc. is made safe.

COOLANT FILTER CHANGE PROCEDURE
. warning signs indicating that Maintenance Work is in Progress are 1. Stop the machine, electrically isolate and vent all trapped pressure.
posted in a position that can be clearly seen.

2. Loosen filter with the correct tool.

Upon completion of maintenance tasks and prior to returning
the machine into service, ensure that:–
3. Remove the filter from the housing.
. the machine is suitably tested.
. all guards and safety protection devices are refitted and correctly
4. Place the old filter in a sealed bag and dispose of in a safe way.
working.
. all panels are replaced, canopy and doors closed.
5. Clean the mating face of the housing taking care to avoid any
. hazardous materials are effectively contained and disposed of in a particles entering the machine.
manner compliant with local or National environmental protection
codes.
6. Remove the new Ingersoll Rand replacement filter from its
protective package.
WARNING
Do not under any circumstances open any drain valve or
7. Apply a small amount of lubricant to the filter seal.
remove components from the compressor without first ensuring
that the compressor is FULLY SHUT– DOWN, power isolated and
all air pressure relieved from the system. 8. Screw the new filter down until the seal makes contact with the
housing, then hand tighten a further half turn.

TOP UP COOLANT PROCEDURE 9. Start the compressor and check for leaks.
The reservoir is designed to prevent overfill. With warm unit
stopped in the normal way, coolant should be at the top of the sight
glass. The level should not drop beyond the bottom of the sight glass
when running with steady load.
AIR FILTER ELEMENT CHANGE PROCEDURE
CAUTION 1. Stop the machine, electrically isolate and vent all trapped pressure.
Ensure that SSR ULTRA coolant is used. Failure to do
so will void manufacturers warranty.
2. Unclip the retaining cap and withdraw the old element.

COOLANT CHANGE PROCEDURE

3. Fit the new element.
It is better to drain the coolant immediately after the compressor has
been operating as the liquid will drain more easily and any contaminant
will still be in suspension. 4. Replace the retaining cap.

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42 MAINTENANCE
SEPARATOR CARTRIDGES CHANGE PROCEDURE Oil level checking procedure
1. Stop the machine, electrically isolate and vent all trapped pressure. The oil level should be checked regularly. An oil level sight glass is
located at the bottom of the refrigeration compressor and while the
machine is running on load, oil should always be visible in the sight
2. Loosen separator cartridges with the correct tool.
glass. The normal position is half way.

3. Remove the cartridges from the housing; place in a sealed bag

and dispose of safely.
Adding oil
4. Clean the mating faces of the housing.
The refrigeration circuit is hermetically sealed so adding oil should
never be necessary unless the system is leaking or has been pumped
5. Remove the new Ingersoll Rand replacement cartridges from down or recharged.
protective package.
If adding oil is necessary, do the following.

6. Apply a small amount of lubricant to the cartridge seal. Run the dryer for a minimum of 2 minutes, the oil level should be
visible in the sight glass. If not, slowly add the proper oil, using the
appropriate pump, to the Schradert valve on the suction connector
7. Screw the new cartridges down until the seal makes contact with
of the compressor. Continue until the oil level is visible in the sight
the housing, then hand tighten a further half turn.
glass with the compressor running.

8. Start the compressor and check for leaks.

CAUTION
CAUTION
This unit is not designed or intended to operate when Do not mix oil types. Use only oil specified by IR
contaminated with silicone. Lubricants, greases or other items
containing silicone should not be used on this unit.

COOLER CLEANING PROCEDURE

DRYER MAINTENANCE (DRYER OPTION) 1. Stop the machine, electrically isolate and vent all trapped pressure.

WARNING 2. Remove the top cover to obtain access to the cooler.

The dryer’s refrigeration system operates in a pressurised
shutdown mode. If the compressor stops, the system will 3. Clean the cooler.
contain high pressure refrigerant. The refrigeration system
must only be opened by a qualified technician certified in
handling refrigerants. Never adjust thermal expansion valve. It 4. Rebuild in reverse order.
has been factory set.

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HP50–PE, HXP50–PE
 MAINTENANCE 43

1
2

SETTING THE PRESSURE SWITCH (where used) TO CHECK THE LOWER SET POINT
TO CHECK THE MAXIMUM DISCHARGE PRESSURE Observe the line pressure fall and note the point at which the
(Pressure switch upper trip point) pressure switch closes (and loads the compressor).
Slowly close the isolation valve located adjacent to the compressor.
Observe the rise in pressure and ensure that the pressure switch TO ADJUST THE UPPER SET POINT
opens (and unloads the compressor) at the correct Maximum
discharge pressure. Remove the transparent cover and turn the adjuster [1]. The red
pointer will move. Turn the adjuster anti–clockwise to increase the set
point or clockwise to decrease it.
The maximum discharge pressure is shown on the machine data plate.
TO ADJUST THE LOWER SET POINT
DO NOT exceed these figures.
Remove the transparent cover and turn the adjuster [2]. The green
pointer will move. Turn the adjuster anti–clockwise to increase the set
point or clockwise to decrease it.

NOTE
The pressure switch scale is a guide only. Use the machine
pressure gauge to verify the upper and lower set points.

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44 MAINTENANCE
BELT CHANGE / GAS STRUT CHANGE PROCEDURE

MOISTURE SEPARATOR MAINTENANCE

The moisture separator will operate indefinitely under normal working
conditions, however at some time it may be necessary to replace the
seals should the housing leak.
1. Isolate the housing from the air supply.

2. Fully depressurize in drain bowl as appropriate.

3. Unscrew bowl and remove. If pressure has not been completely
released from the housing, air will escape from the warning hole giving
an audible alarm. Screw back bowl and repeat instruction 2 before
attempting again. Should resistance to unscrewing be experienced,
provision is made for a ’C’ spanner to fit onto the ribs of the bowl.
4. Check condition of bowl seal and replace if necessary. Clean screw
threads.

5. Refit bowl with ’O’ ring seal.

6. Repressurize and check for leaks. If leaks occur they will most
probably be from the bowl ’O’ ring. Depressurize housing and remove
’O’ ring as stated above and inspect and clean. Ensure that mating
surfaces are clean and then refit ’O’ ring and repressurize.

A. Gas strut.

B. Support bracket (part of pivoted assembly).

C. Tension cam.

1. Stop the machine, electrically isolate and vent all trapped pressure.

2. Remove the side cover from the machine.

3. Fit a 1/2” square drive wrench in the tension cam located above the
airend (access from front door). Turn clockwise 1/4 turn to Position II
to release gas strut tension on the belts.

4. Using a small screwdriver under the spring clip, ease the ball ends
off the spherical studs at the ends of the gas strut.

5. Replace the gas strut and the studs at the same time by removing
and replacing the studs then pushing the new gas strut firmly onto the
studs until it clicks into place.

6. Turn the tension cam clockwise 1/4 turn to Position III to raise and
support the airend. Place a block of wood or similar under the separator
tank for support.

7. Replace the belts from the left side of the machine.

8. Turn the tension cam counter–clockwise 1/2 turn to Position I to

tension the gas strut.

9. Spin the drive to check alignment of the belt ribs on the pulleys
(sheaves).

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HP50–PE, HXP50–PE
 MAINTENANCE 45
ELECTRIC DRAIN VALVE

PRODUCT DESCRIPTION Timer will not 1. No electrical 1. Apply power.

activate supply.
The Electric Drain Valve removes condensed water and oil from the
moisture sepearator. Additional drains may be installed throughout your 2. Timer malfunction 2. Replace timer.
compressed air system, including aftercoolers, filters, drip legs and
dryers. 3. Clogged port. 3. Clean valve.

The Electric Drain Valve operates on a timer which can be set to 4 Solenoid valve 4. Replace solenoid
automatically drain the air receiver tank at operator–determined malfunction. valve.
intervals. 5. Clogged strainer. 5. Clean strainer.
Key features include:
• 100% continuous duty
• NEMA 4 enclosure
MAINTENANCE
• Adjustable time on (0.5 – 10 seconds)
Periodically clean the screen inside the valve to keep the drain
• Adjustable time off (0.5 – 45 minutes) functioning at maximum capacity. To do this, perform the following
steps:
• Stainless steel operator
1. Close the strainer ball valve completely to isolate it from the air
• LED to indicate electrical power is on receiver tank.
• LED to indicate valve is open 2. Press the TEST button on the timer to vent the pressure remaining
• Manual override in the valve. Repeat until all pressure is removed.
CAUTION! High pressure air can cause injury from flying debris.
OPERATION Ensure the strainer ball valve is completely closed and pressure
is released from the valve prior to cleaning.
1. Open the strainer ball valve.
3. Remove the plug from the strainer with a suitable wrench. If you hear
Strainer Ball Valve. air escaping from the cleaning port, STOP IMMEDIATELY and repeat
steps I and 2.
OPEN CLOSED
4. Remove the stainless steel filter screen and clean it. Remove any
debris that may be in the strainer body before replacing the filter screen.
5. Replace plug and tighten with wrench.
6. When putting the Electric Drain Valve back into service, press the
TEST button to confirm proper function.

2. Set the “time off” and “time on” knobs. See TIMER SETTINGS
(below) for an explanation of the settings.
3. During compressor operation, check for air leaks.

TIMER SETTINGS
The “time off” setting determines the interval between cycles from 30
seconds to 45 minutes. The “time on” setting determines the actual time
the compressor drains condensate.
The timer’s cycle rate and drain opening time should be adjusted to
open just long enough to discharge the condensate. The timer is
properly set when it opens and discharges condensate and then vents
air for approximately one second before closing. Adjustments may be
made depending on many factors, including humidity and duty cycle.

TROUBLESHOOTING

TROUBLE CAUSE ACTION

Valve will not 1. Debris in solenoid 1. Remove solenoid

close. valve prevents dia- valve, disassemble,
phragm from seating. clean and reassemble.
2. Short in electrical 2. Check and replace
component. power cord or timer as
needed.

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46 MAINTENANCE
MODULATE CONTROL VALVE ADJUSTMENT 8. Press UNLOADED STOP. Wait for sump pressure to go 0 psig.
Close the isolation valve or vent off all system air.
Ensure that the compressor is isolated from the compressed air system
by closing the isolation valve and venting pressure from the drip leg. 9. Put the compressor in the desired control mode.
Ensure that the main power disconnect switch is locked open and 10.Remove the test pressure gauge and replace 1/4” plastic plug.
tagged.
1. Put the compressor in the MODULATION mode by placing control
selector switch SS in the “MODULATION” position. (Non–(Intellisys
models).
2. Remove 1/4” plastic plug from the tee (18) in the regulator valve.
Connect a pressure gauge to this port.
3. Loosen the adjustment screw locknut and back out adjusting screw
3 turns. See Figure 2
4. Put the main power disconnect switch in the ON position.
5. Open the isolation valve and start the compressor.
LOCKNUT
6. Adjust the isolation valve to bring the discharge air pressure to the
rated discharge pressure (100, 125, 140, or 200 psig).
7. While maintaining the rated discharge pressure, turn the adjustment
screw on the modulation valve (see Figure 2) so that the test pressure
gauge reads: ADJUSTING SCREW
30 psig for modulate 60% cfm.
Tighten the adjustment screw locknut. FIGURE 2 MODULATION VALVE

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 TROUBLE SHOOTING 47
PROBLEM CAUSE REMEDY
Compressor fails to Mains power or Control voltage not available. § Check incoming power supply.
start § Check the control circuit fuse.
§ Check the transformer secondary windings for the
control voltage.
Defective Star / Delta timer. § Change Star / Delta timer.
Machine shuts down High airend temperature. Top up coolant.
periodically
Motor overload. § Set overload to correct value and switch to manual
reset.
Belt stretch protection (when fitted). Change belt.
Line voltage variation. § Ensure voltage does not drop below 10% on start up
and 6% running.
High current draw Compressor operating above rated pressure. Set pressure to correct rating for machine.
Separator cartridge contaminated. Change air filter, and separator cartridge.
Low voltage. § Ensure voltage does not drop below 10% on start up
and 6% running.
Unbalanced voltage. Correct incoming supply voltage.
Damaged airend. † Change Airend.
Low current draw Air filter contaminated. Change air filter.
Compressor operating unloaded. Set pressure to correct rating for machine.
High voltage. Reduce site voltage to correct operating voltage.
Defective inlet valve. † Fit inlet valve service kit.
High discharge Defective or incorrect pressure switch setting. Replace or set pressure to correct rating for machine.
pressure
Load solenoid valve defective. † Fit load solenoid service kit.
Blowdown valve defective. † Fit blowdown solenoid service kit.
Inlet valve malfunction. † Fit inlet valve service kit.
Low system air Separator cartridge contaminated. Fit new Separator cartridge.
pressure
Incorrect pressure switch setting. Set pressure to correct rating for machine.
Minimum pressure valve malfunction. † Fit Minimum pressure valve service kit.
Load solenoid valve defective. † Fit load solenoid service kit.
Blowdown valve defective. † Fit blowdown solenoid service kit.
Drive belt slipping. Fit new belt and tensioner.
Air system leaks. † Fix leaks.
Inlet valve malfunction. † Fit inlet valve service kit.
System demand exceeds compressor delivery. Reduce demand or install additional compressor.

Safety valve blows MPV STUCK CLOSED. Strip MPV, examine and repair if necessary.
when compressor goes
on load. Check the setting of the safety valve and the
SAFETY VALVE FAULTY
rated pressure.

NOTES:
§ Must be carried out by a competent electrician.
† This work is recommended to be carried out only by an Ingersoll Rand authorized service technician.

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48 TROUBLE SHOOTING
PROBLEM CAUSE REMEDY
Compressor trips due to Compressor operating above rated pressure. Set pressure to correct rating for machine.
over temperature
Package pre–filter blocked. Clean / replace package pre–filter.
Cooler blocked. Clean cooler.
Missing or incorrectly fitted enclosure panels Ensure that all enclosure panels are correctly fitted
Low coolant level. Top up coolant and check for leaks.
High ambient temperature. Re–site compressor.
Restricted cooling air flow. Ensure correct air flow to compressor.
Excessive coolant Separator cartridge leak. Fit new Separator cartridge.
consumption
Blocked separator cartridge drain. † Remove fittings and clean.
Compressor operating below rated pressure. Set pressure to correct rating for machine.
Coolant system leak. † Fix leaks.
Excessive noise level Air system leaks. † Fix leaks.
Airend defective. † Change Airend.
Drive belt slipping. Replace belt and tensioner.
Motor defective. † Replace motor.
Loose components. † Retighten loose items.
Shaft seal leaking Defective shaft seal. † Fit Airend shaft seal kit.
Pressure relief valve Defective switch or incorrect pressure switch setting. Replace or set pressure to correct rating for machine.
opens
Minimum pressure valve malfunction. † Fit Minimum pressure valve service kit.
Load solenoid valve defective. † Fit load solenoid service kit.
Blowdown valve defective. † Fit blowdown solenoid service kit.
Inlet valve malfunction. † Fit inlet valve service kit.
Black residue on belt Drive belt slipping. Replace belt and tensioner.
guard/cooler box
Pulleys misaligned. Re–align pulleys.
Worn pulleys. † Replace pulleys and belt.
Gas strut failed. Replace belt and tensioner.
DRYER OPTION
High Dew Point Dryer compressor or fan failed. Check electrical supply and repair as required.
(Indicator Red)
Low refrigerant charge. Check for leaks.
High pressure switch tripped. Check condenser coil for debris. Check fan operation.
Clean / repair as required. Reset manual switch.
Low Dew Point HGBV out of adjustment / defective. Adjust valve or replace as required.
(Indicator Blue)
OR Compressor runs Never adjust thermal expansion valve. It has been
unloaded with no factory set
system pressure
Water Down stream of Restricted / defective drain valve. Clean / replace drain valve.
dryer (Indicator OK) Clean / replace condensate check valves.

NOTES:
§ Must be carried out by a competent electrician.
† This work is recommended to be carried out only by an Ingersoll Rand authorized service technician.

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