Ingersoll-Rand XF 20, XF 30, EP 20, EP 30, HP 25 Operator's Instruction Manual

APDD 739

June 1999

XF 20 - 30
EP 20 - 30
HP 20 - 30
HXP 20 - 30

OPERATORS/
INSTRUCTION MANUAL
OPTIONS

Before installation or starting the compressor for
the first time, this manual should be studied careful­ly to obtain a clear knowledge of the unit and of the
duties to be performed while operating and main­taining the unit.

RETAIN THIS MANUAL WITH UNIT.
This Technical manual contains IMPORTANT SAFE­TY DATAand should be kept with the air compres-

®

©INGERSOLL-RAND COMPANY

AIR COMPRESSOR GROUP

BONDED WARRANTY & REGISTERED START UP

Warranty

The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in
material and workmanship for a period of twelve months (see extended airend warranty) from the date of placing
the Equipment in operation or eighteen months (see extended airend warranty) from the date of shipment from
Davidson, NC, whichever shall first occur. The Purchaser shall be obligated to promptly report any failure to con­form to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct
such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. point of shipment,
provided the Purchaser has stored, installed maintained and operated such Equipment in accordance with good
industry practices and has complied with specific recommendations of the Company. Accessories or equipment fur­nished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have con­veyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any
repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser or others
without Company’s prior written approval.

The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company’s proposal. Unless responsibility for meeting such perfor­mance warranties are limited to specified tests, the Company’s obligation shall be to correct in the manner and for
the period of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILI­TY AND FITNESS FOR APARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.

Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based
on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such
Equipment.

The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company

in writing of its intention to do so. Any such Equipment will be at Purchaser’s sole risk and liability.

Limitation or Liability

The remedies of the Purchaser set forth herein are exclusive, and the total liability of the Company with respect to
this contract or the Equipment and services furnished hereunder, in connection with the performance or breach
thereof, or from the manufacture, sale, delivery, installation, repair or technical direction covered by or furnished
under this contract, whether passed on contract, warranty negligence, indemnity, strict liability or otherwise, shall
not exceed the purchase price of the unit of Equipment upon which such liability is based.

The Company and its suppliers shall in no event be liable to the Purchaser, any successors in interest or any ben­eficiary or assignee of this contract for any consequential, incidental, indirect, special or punitive damages arising
out of this contract or any breach thereof, or any defect in, or failure of, or malfunction of the Equipment hereunder,
whether based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other
goods, loss by reason of shutdown or non-operation, increased expenses of operation, cost of purchase of replace­ment power or claims of Purchaser or customers of Purchaser for service interruption whether or not such loss or
damage is based on contract, warranty, negligence, indemnity, strict liability or otherwise.

EXTENDED AIREND WARRANTY

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

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

1

ROTARY SCREW AIR COMPRESSOR
This unit was purchased from

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Ingersoll-Rand Company reserves the right to make changes or add
improvements without notice and without incurring any obligation to make
such changes or add such improvements to products sold previously.

No. of units on order:
Customer Order No:
Ingersoll-Rand Co. Order No.:

For ready reference:

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

Serial Number:
Model Number:

TYPICAL UNIT

2

TABLE OF CONTENTS

0.0 SAFETY AND WARNINGS

0.1 safety instructions

0.2 safety precautions

0.3 decals

1.0 RECEIPT OF EQUIPMENT

1.1 inspection

1.2 unpacking and handling

1.3 tools

2.0 INSTALLATION

2.1 ventilation

2.2 foundation requirements

2.3 piping

2.4 electrical installation

2.5 voltage conversion

2.6 rotation check

2.7 before starting - starting - stopping

2.8 outdoor sheltered installation

3.0 SYSTEMS

3.1 general system information

3.2 aircooled compressors

3.3 coolant system

3.4 air system

3.5 electrical system

3.6 capacity control

3.7 pressure switch adjustment

3.8 modulation control (optional)

3.9 ACS control (intellisys modulation option only)

3.10 modulate control valve adjustment (optional)

4.0 INTELLISYS

4.1 emergency stop switch

4.2 power indicator light

4.3 push buttons

4.4 setpoint procedure

4.5 warnings

4.6 alarms

5.0 MAINTENANCE

5.1 maintenance schedule

5.2 maintenance records

5.3 maintenance procedures

5.4 pressure relief valve check

5.5 sheave alignment

5.6 drive belt

5.7 belt tension

5.8 belt tension spring replacement

5.9 shaft seal replacement

5.10 inlet air filter element

5.11 coolant filter

5.12 coolant change

5.13 coolant hoses

5.14 airend discharge hose

5.15 coolant separator filter element

5.16 separator tank scavenge
check valve/screen/orifice

4.17 cooler cores

4.18 motor lubrication

4.19 intellisys removal

6.0 TROUBLE SHOOTING

6.1 standard control

6.2 intellisys control

7.0 OPTIONS

7.1 remote start/stop

7.2 remote start/stop and power outage restart option

7.3 sequencer control

8.0 REFERENCE DRAWING

8.1 electrical schematic - full voltage - standard control

8.2 electrical schematic - star delta - standard control

8.3 electrical schematic - full voltage - intellisys control

8.4 electrical schematic - star delta - intellisys control

8.5 foundation plan - base mounted - unenclosed

8.6 foundation plan - base mounted -enclosed

8.7 foundation plan - 120 gal. tank mounted - unenclosed

8.8 foundation plan - 120 gal. tank mounted - enclosed

8.9 foundation plan - 240 gal. tank mounted - unenclosed

8.10 foundation plan - 240 gal. tank mounted - enclosed

8.11 basic flow schematic - standard control

8.12 basic flow schematic - intellisys control

8.13 typical system flow diagrams

9.0 MAINTENANCE RECORD

GENERAL INFORMATION

Cooling Air Flow:

60 Hz: 2060 cfm (3500m

3

/hr.)

50 Hz: 1710 cfm (2905m

3

/hr.)
Ambient Temperature Limit: 35°F to 115°F (2°C to 46°C)
Coolant: Factory Filled ULTRACOOLANT
Coolant Change: 8,000 hours or two years, whichever
comes first, when using ULTRACOOLANT
Coolant Capacity: 3.2 GAL (12L)
Discharge Temperature Limit: 228°F (109°C)

Tools: U.S. Standard and metric are required to perform
maintenance

3

0.0 SAFETY AND WARNINGS

0.1 SAFETY INSTRUCTIONS Before you install this air compressor you should take the time to carefully read all the instructions contained in this manual.

Electricity and compressed air have the potential to cause
severe personal injury or property damage.

Before installing, wiring, starting, operating or making any
adjustments, identify the components of the air compressor
using this manual as a guide.

The operator should use common sense and good working
practices while operating and maintaining this unit. Follow all
codes, pipe adequately, understand the starting and stopping
sequence. Check the safety devices by following the proce­dure contained in this manual.

Maintenance should be done by qualified personnel, ade­quately equipped with proper tools. Follow the maintenance
schedules as outlined in the operators manual to ensure prob­lem free operation after start up.

Safety instructions in the operators manual are bold-faced for
emphasis. The signal words DANGER, WARNING and CAU­TION are used to indicate hazard seriousness levels as fol­lows:

Danger is used to indicate the presence of
a hazard which will cause severe personal
injury, death, or substantial property dam­age if the warning is ignored.

Warning is used to indicate the presence of
a hazard which can cause severe personal
injury, death, or substantial property dam­age if the warning is ignored.

Caution is used to indicate the presence of
a hazard which will or can cause minor per­sonal injury or property damage if the warn­ing is ignored.

Notice is used to notify people of installa­tion, operation, or maintenance information
which is important but not hazard-related.

D! DANGER

! WARNING

! CAUTION

NOTICE

SAFETY PRECAUTIONS

BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE

COMPRESSOR OR PERFORMING ANY MAINTENANCE

WARNING
COMPRESSED AIR AND ELECTRICITY

ARE DANGEROUS.
BEFORE DOING ANY WORK ON THIS

UNIT, BE SURE THE ELECTRICAL SUP­PLY HAS BEEN CUT OFF–LOCKED &
TAGGED AND THE ENTIRE COMPRES­SOR SYSTEM HAS BEEN VENTED OF
ALL PRESSURE.

1. Do not remove the covers, loosen or
remove any fittings, connections or
devices when this unit is in operation.
Hot liquid and air under pressure that
are contained within this unit can cause
severe injury or death.

2. The compressor has high and dan­gerous voltage in the motor starter and
control box. All installations must be in
accordance with recognized electrical
codes. Before working on the electrical
system, be sure to remove voltage from
the system by use of a manual-discon­nect-switch. A circuit breaker or fuse
safety switch must be provided in the
electrical supply line leading to the
compressor.

Those responsible for installation of
this equipment must provide suitable
grounds, maintenance clearance and
lightning arrestors for all electrical com­ponents as stipulated in O.S.H.A.

1910.308 through 1910.329.

3. Do not operate the compressor at
higher discharge pressure than those
specified on the Compressor Nameplate
or motor overload will occur. This con­dition will result in compressor motor
shutdown.

4. Use only safety solvent for cleaning
the compressor and auxiliary equip­ment.

5. Install a manual shut off valve (isola­tion type) in the discharge line. When a
safety valve is installed between the iso­lation valve and the compressor, it must
have sufficient capacity to relieve the
full capacity of the compressor(s).

6. Whenever pressure is released
through the pressure relief valve, it is
due to excessive pressure in the sys­tem. The cause for the excessive pres­sure should be investigated immediate­ly.

7. Before doing any mechanical work on
the compressor:

a.) Shut the unit down.
b.) Electrically isolate the compressor

by use of the manual disconnect switch
in the power line to the unit. Lock and
tag the switch so that it cannot be oper­ated.

c.) Vent pressure from the compressor
and isolate the unit from any other
source of air.

8. There can be adverse effects if com­pressor lubricants are allowed to enter
plant air systems.

Air line separators, properly selected
and installed, will minimize any liquid
carry-over.

The use of plastic bowls on line filters
without metal guards can be hazardous.
From a safety standpoint, metal bowls
should be used on any pressurized sys­tem. Review of your plant air line sys­tem is recommended.

9. When a receiver is installed, it is rec­ommended that occupational safety and
health standards as covered in the
Federal Register, Volume 36, number
105, part 11, paragraph 1910.169 be
adhered to in the installation and main­tenance of this receiver.

10. Before starting the compressor, its
maintenance instructions should be
thoroughly read and understood.

11. After maintenance functions are
completed, covers and guards must be
replaced.

0.2 SAFETY PRECAUTIONS

4

There is a high discharge air temperature shutdown function built into the Intellisys on each compressor.
It is factory pre-set at 228°F (109°C). This function should be checked at regular intervals for proper oper­ation, once a month is recommended.
PROCEDURE:

1. Block off the cooling air discharge.

2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the dis­charge temperature reaches the pre-set maximum discharge air temperature setting.

Failure to adhere to these recommendations can result in mechanical failure, property damage and serious
injury or death.

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

For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge
piping is not recommended. In addition, flexible joints and/or flex lines can only be considered for such pur­poses if their specifications fit the operating parameters of the system.

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

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

! WARNING

! WARNING

! SAFETY SHUTDOWN CHECK HIGH AIR TEMPERATURE

5

0.3 DECALS

This section contains representative examples of
decals which will be appearing throughout this manual
and are applied to the compressor unit.

If for some reason a decal is defaced, parts are
replaced or painted over, we recommend that you
obtain a replacement (See Parts manual APDD 742
for Decal Kit Number).

39264734

REV A

6

3954190

39540232

39540174

39540166*

39540257*

3

1

2

7

5

6

4

8

9

39540158

39540240

39540265

39540273

NOTICE

To obtain satisfactory compressor
operation and maintenance a
minimum of 3 feet clearance on 3
sides is required 3-1/2 feet is
required in front of the control panel
(or minimum required by latest
National Electrical code or applicable
local codes).

Refer to the Instruction / Operators
Manual before performing any
maintenance.

INGERSOLLrAND ®

!

DANGER

!

CAUTION

Incorrect lifting of
machine can cause injury
or property damage.

Lift only from base
channels.

I

!

WARNING

Discharge air.
Can contain carbon monoxide or
other contaminants.Will cause
severe injury or death.

Do not breathe this air.

INGERSOLLrAND ®

!

WARNING

Hazardous voltage. Can cause
severe injury or death.

Disconnect power before servicing.
Lockout/Tagout machine.

INGERSOLLrAND ®

!

WARNING

High pressure air.
Can cause severe injury or death.

Relieve pressure before removing filter
plugs / caps, fittings or covers.

INGERSOLLrAND ®

NOTICE

Air discharge.

INGERSOLLrAND®

!

CAUTION

Use of incorrect coolant can cause
system contamination.

Use only SSR ULTRA COOLANT.

INGERSOLLrAND ®

Exposed fan blade. Can cause severe
injury.

Do not operate with covers removed.
Disconnect power.Lock and tag.

INGERSOLLrAND ®

NOTICE

Lift here.

INGERSOLLrAND®

7

39859236

39541362

39544143

39557095

INGERSOLLrAND®

39544150

NOTICE

Filler Cap.

Use only recommended

coolant.

Read instruction book

before servicing.

39543921

39540281

12

10

11

16

14

15

13

!

WARNING

Hot surface.
Can cause severe injury.

Do not touch. Allow to cool before
servicing.

INGERSOLLrAND ®

!

CAUTION

Improper coolant filter replacement
will cause compressor damage.

Replace filter element after first 150
hours of operation and every 2000
hours thereafter or when coolant is
changed.

INGERSOLLrAND ®

! WARNING

Exposed moving belts and sheaves.

Can cause severe injury or death.

Do not operate with guards removed.
Disconnect power, lock and tag out
machine before servicing.

NOTICE

Before installing, operating, or
performing any maintenance on
this unit, read and understand
the instructions in the
Operators/Instruction Manual.

Before Starting

1. Check coolant level and add
coolant if necessary.

2. Verify that main isolation
valve is open.

3. Close main disconnect switch.

39859236

NOTICE

Rotation.

INGERSOLLrAND ®

Starting

1. Push START button. Compresor
will start and load automatically.

2. Air Pressure will rise if
there is sufficient demand
for air.

Stopping

1. Pushing STOP button.
Compressor will stop
after 7-10 seconds.

2. Open main disconnect switch.

INGERSOLLrAND ®

39919246

1.0 RECEIPT OF EQUIPMENT

1.1 INSPECTION

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

1.2 UNPACKING AND HANDLING

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

Slings can be used to lift the crates, but spreader bars
must be used to prevent the slings from exerting a force
against the sides of the crates.

1.3 TOOLS

Remove compressor unit from wooden skid. Acrowbar
and hammer will be needed.

IMPORT ANT

READ THIS

LOST OR DAMAGED GOODS

THOROUGHLY INSPECT THIS SHIPMENT

IMMEDIA TELY UPON ARRIV AL

OUR RESPONSIBILITY FOR THIS SHIPMENT

CEASED WHEN THE CARRIER SIGNED

BILL OF LADING

If goods are received short or in damaged condition, it is important that
you notify the carrier and insist on a notation of the loss or damage
across the face of the freight bill. Otherwise no claim can be enforced
against the transportation company.

If concealed loss or damage is discovered, notify your carrier at once
and request an inspection. This is absolutely necessary. Unless you do
this the carrier will not entertain any claim for loss or damage. The agent
will make an inspection and grant a concealed damage notation. If you
give the transportation company a clear receipt for goods that have been
damaged or lost in transit, you do so at your own risk and expense.

WE, ATI-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE
MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THE
WILLINGNESS ON OUR PARTDOES NOT MAKE US RESPONSIBLE
FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL.
THE ACTUALFILING AND PROCESSING OF THE CLAIM IS YOUR
RESPONSIBILITY.

Ingersoll-Rand Company
Davidson, North Carolina

APDDGFO-99-79

FORKLIFT PADDING

WILL REDUCE SCRATCHES

AND MARS

SPREADER
BARS

8

2.0 INSTALLATION

2.1 VENTILATION

Oil flooded rotary air compressors produce large
amounts of heat. Because of this large heat production,
the compressor must be placed in a room with adequate
ventilation. Aroom in which the amount of air that is
drawn in and exhausted is equal to or greater than the
cooling fan air flow requirement for the compressor that
is installed.

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

Ambient temperatures higher than 115°F (46°C)
should be avoided as well as areas of high humidity.

Consider also the environment surrounding or near
the compressor. The area selected for the location of
the compressor should be free of dust, chemicals,
metal filings, paint fumes and overspray.

2.2 FOUNDATION REQUIREMENTS

Refer to the foundation plan for the particular model com­pressor to be installed. See Section 8.0.

The compressor can be installed on any level floor that is
capable of supporting it. Compressor weights are listed
on the foundation plans.

When sound transmission is of particular importance it is
often helpful to install a sheet of rubber-fabric-matting, or
cork under the compressor to reduce the possibility of
resonant sounds being transmitted or amplified through
the floor.

2.3 PIPING

The use of plastic bowls on line filters without metal
guards can be hazardous. Their safety can be affected
by either synthetic lubricants or the additives used in min­eral oil. From a safety standpoint, metal bowls should be
used on any pressurized system. Review of your plant air
line system is recommended.

The built-in aftercooler reduces the discharge air temper­ature well below the dew point (for most ambient condi­tions), therefore, considerable water vapor is condensed.
To remove this condensation, each compressor with
built-in aftercooler is furnished with a combination con­densate separator/trap.

DUST

CHEMICALS

METAL

FILINGS

PAINT

SPRAY

OVERSPRAY

Do not use plastic pipe, soldered copper

fittings or rubber hose for discharge piping.

WARNING

Never elevate the compressor unit

above the floor level. This may allow air

to enter the cabinet under the base.

Performance will be affected.

NOTICE

!

!

36”

(.9 m)

36” (.9 m)

42” (1.06 m) OR

CODE MINIMUM

9

AIR INTAKE

10

DISCHARGE PIPING WITH AFTERCOOLER

ROTARY-RECIP IN PARALLEL

Do not use the compressor

to support the discharge pipe.

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

It is essential when installing a new compressor to review
the total plant air system. This is to ensure a safe and
effective total system.

Liquid water occurs naturally in air lines as a result of
compression. Moisture vapor in ambient air is concentrat­ed when pressurized and condenses when cooled in
downstream air piping.

Moisture in compressed air is responsible for costly prob­lems in almost every application that relies on com­pressed air. Some common problems caused by mois­ture are rusting and scaling in pipelines, clogging of
instruments, sticking of control valves, and freezing of
outdoor compressed air lines. Any of these could result in
partial or total plant shutdown.

Compressed air dryers reduce the water vapor con­centration and prevent liquid water formation in com­pressed air lines. Dryers are a necessary companion to
filters, aftercoolers, and automatic drains for improving
the productivity of compressed air systems.

NOTICE

!

2.3 PIPING (Continued)

A dripleg assembly and isolation valve should be mount­ed near the compressor discharge. Adrain line should be
connected to the condensate drain in the base.

IMPORT ANT: The drain line must slope downward from
the base to work properly.

NOTE: For ease of inspection of the automatic drain trap
operation, the drain piping should include an open funnel.

It is possible that additional condensation can occur if the
downstream piping cools the air even further and low
points in the piping systems should be provided with dri­plegs and traps.

IMPORT ANT: Discharge piping should be at least as
large as the discharge connection at the compressor
enclosure. All piping and fittings must be suitable for the
maximum operating temperature of the unit and, at a
minimum, rated for the same pressure as the compres­sor sump tank.

MOISTURE CONTENT OF COMPRESSED AIR

200

160

120

80

40

0

DEW POINT

without
Aftercooling

100°F/38°C
(with
Aftercooler)

35°F /1.7°C
(Refrigerated
Dryer)

-40°F/-40°C
(Desiccant
Dryer)

Gallons of Water/24

hours/1000 acfm

ROTARY

COMPRESSOR

ISOLATION

VALVE

DRIP LEG

SAFETY

VALVE

PRESSURE

GAUGE

ISOLATION

VALVE

DRIP

LEG

SAFETY

VALVE

RECIPROCATING

COMPRESSOR

TRAP

ISOLATION

VALVE

ISOLATION

STRAINER

NOTE:
SEPARATE LINES
GOING TO THE
RECEIVER

VALVE

DRIP

LEG

ROTARY

COMPRESSOR

11

2.4 ELECTRICAL INSTALLATION

Before proceeding further, we recommend that you
review the safety data in the front of this manual.

Locate the compressor data plate on the left end of the
cooler box next to the control box.

The data plate lists the rated operating pressure, the
maximum discharge pressure and the electric motor
characteristics and power.

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

A hole is provided for incoming power connection. If it is
necessary to make a hole in the control box in a different
location, care should be taken to not allow metal shav­ings to enter the starter and other electrical components
within the box. After making the power inlet hole, all
shavings and debris must be removed from inside of
control box before power is turned on.

Incoming power should be connected per the electrical
schematic on the starter box door. Confirm that all electri­cal connections are made and tightened. Confirm that
the control transformer is wired correctly for supply volt­age (See Figure 2.5-1).

Inspect the motor and control wiring for tightness. Close
the panel front.

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

Contact your local Ingersoll-Rand distributor for assis­tance in selecting correct Ingersoll-Rand filtration or dry­ing products.

NOTE: Screw type compressors should not be installed
in air systems with reciprocating compressors without a
means of pulsation isolation, such as a common receiver
tank. We recommend both types of compressor units be
piped to a common receiver utilizing individual air lines.

When two rotary units are operated in parallel, provide
an isolation valve and drain trap for each compressor
before the common receiver.

ROT ARY TWO COMPRESSOR SYSTEM

SAFETY

VALVE

PRESSURE

GAUGE

ISOLATION

VALVE

ROTARY

COMPRESSOR

TRAP

DRIP

LEG

ISOLATION

STRAINER

VALVE

ISOLATION

VALVE

DRIP

LEG

COMPRESSOR

ROTARY

12

2.5 VOLTAGE CONVERSION

IMPORTANT: This procedure should only be carried
out by a qualified electrician, electrical contractor or
your local Ingersoll Rand Distributor or Air Center

NOTE: This procedure applies only to units manufac­tured to multi-voltage specifications. Motor nameplate
must indicate multiple voltatges.

FIGURE 2.5-1 TYPICAL CONTROL TRANSFORMER WIRING

110V

LINE VOLTS HZ LINE SEC VOLTS LINE

200 60 H4-H5 120 X1-X2

8 X3-X4
8 X4-X5

220/230 60 H3-H5 120 X1-X2

8 X3-X4
8 X4-X5

380 60 H3-H5 120 X1-X2

8 X3-X4
8 X4-X5

440/460 60 H2-H5 120 X1-X2

8 X3-X4
8 X4-X5

575 60 H1-H5 120 X1-X2

8 X3-X4
8 X4-X5

LINE VOLTS HZ LINE SEC VOLTS LINE

220 50 H5-H6 110 X1-X2

8 X3-X4
8 X4-X5

380 50 H4-H6 110 X1-X2

8 X3-X4
8 X4-X5

415 50 H2-H6 110 X1-X2

8 X3-X4
8 X4-X5

550 50 H1-H6 110 X1-X2

8 X3-X4
8 X4-X5

LINE VOLTS HZ LINE SEC VOLTS LINE REFERENCE

200 60 H4-H5 120 X1-X2 Quad Type

220/230 50/60 H1-H2 120 X1-X4 Universal Type

380 50/60 H1-H3 120 X1-X4 Universal Type

415 50 H1-H3 120 X1-X4 Universal Type

440/460 50/60 H1-H4 120 X1-X4 Universal Type

550/575 60 H1-H5 120 X1-X4 Universal Type

*TYPICAL 60 HZ

CONTROL TRANSFORMER

(INTELLISYS OPTION)

*TYPICAL 50 HZ

CONTROL TRANSFORMER

(INTELLISYS OPTION)

H4

H5

H6

HIGH
VOLTAGE
PRIMARY

SIDE

HIGH

VOLTAGE

PRIMARY

SIDE

LOW

VOLTAGE

SECONDARY

SIDE

LOW

VOLTAGE

SECONDARY

SIDE

UNIVERSAL TYPE TRANSFORMER

(ALL VOLTAGES EXCEPT 200V/60 HZ)

QUAD TYPE TRANSFORMER (200V/60 HZ)

*TYPICAL CONTROL TRANSFORMER

(STANDARD OPTION)

If the compressor is operated in the

opposite direction of rotation, airend damage

can result and is not warrantable.

CAUTION

Open the motor junction box on the side of the motor.
Reconnect the motor to the desired voltage. Use the con-

nection decal provided on the motor as a guide.
Reconnect the primary side of the control transformer for

the desired voltage, as shown on the control transformer
wiring decal.

Refer to the motor nameplate for full load amps. Set
main fan the dial position of the overload relay to the cor­responding setting.

Make sure all wiring connections are tight.
Put main disconnect in the ON position and check main

motor and fan motor rotation, as outlined in Section 2.6
of this manual.

2.6 ROTATION CHECK

Locate the rotation decal on the motor and check for cor­rect rotation. The correct rotation when viewed from the
non-drive end of the motor is clockwise (See Figure 2.6-

1).

!

FIGURE 2.6-1 DRIVE MOTOR ROTATION

NON-DRIVE

END

DRIVE

END

FIGURE 2.5-2 MAIN DISCONNECT

LOCKED AND TAGGED

DANGER

Procedure:

Put main disconnect in the OFF position, lock and tag
(See Figure 2.5-2).

For the compressor motor and fan rotation check, the
motor jogging should be as short a time as possible.

1. Assure that the Emergency Stop button is in the
stop (depressed) position.

2. Check coolant level. To check coolant level, slowly
loosen the fill plug one complete turn. As the fill plug is
unscrewed approximately one complete turn, a small
amount of pressure may be released. Do not remove
the fill plug until all pressure has been vented. Once
pressure is vented, finish removing the fill plug. The
proper coolant level is when the coolant is even with
the top of the fill port. Add coolant if necessary.

3. Replace and tighten fill plug.

4. Close the main disconnect switch (ON position).

5. Verify that the main isolation valve is open.

6. Open the canopy enclosure if machine is so
equipped. Push the red unloaded Stop/Reset Button.
Push the Start button to start the unit and immediately
depress (push) the Emergency Stop button to stop
the unit (See Figure 2.7-1 for Control Panel layout).

NOTE: Do not use the Unloaded Stop Button for this
procedure; it is equipped with a time delayed stop cir­cuit and damage may occur to the compression mod­ule if operated in wrong direction.

Observe the compressor drive motor shaft. The rota­tion should be in accordance with the directional arrow
decal on the motor. Observe the cooling fan (s). The
rotation of the main fan should be counter-clockwise.
The auxiliary fan rotation should be clockwise. (See
Figures 2.6-2 and 2.6-3.

Should the main motor or fan rotation be incorrect, put
the main disconnect in the OFF position, lock and tag.

Interchange any two line connections (L1, L2, or L3) at
the starter panel for the appropriate component. Close
the control box cover. Recheck for correction rotation.

13

DANGER

HASP

KEY LOCK

HIGH VOLTAGE

LEVER

DANGER

TAG

14

2.7 BEFORE STARTING - STARTING - STOPPING Read and understand the following instructions

before operating or performing any maintenance
on this unit

Before Starting:

1. Ensure that Emergency Stop push button is in the
OFF (depressed) position (See Figure 2.7-1).

2. Check coolant level. To check coolant level, slowly
loosen the fill plug one complete turn. As the fill plug is
unscrewed approximately one turn, a small amount of
pressure may be released. Do not remove the fill plug
until all pressure has been vented. Once pressure is
vented, finish removing the fill plug. The proper
coolant level is when the coolant is even with the top
of the fill port. Add coolant if necessary.

3. Replace and tighten fill plug.

4. Close the main disconnect switch (ON position).

5. Verify that the main isolation valve is open.

Starting

1. Push the unloaded Stop/Reset Button (red fault
indicator will go out).

2. Push the Start button and release. The compressor­will start and then load automatically if line pressure is
below the lower setting of the pressure switch.

FIGURE 2.6-2 MAIN FAN

FIGURE 2.6-3 AUXILIARY FAN

CORRECT ROTATION CORRECT ROTATION

Stopping

1. Depress the Stop button to the OFF position.
Compressor will unload for approximately 7 seconds
and then stop.

2. Open the main disconnect switch (OFF position).

FIGURE 2.7-1 CONTROL PANEL

EMERGENCY

STOP

BUTTON

CONTROL

PANEL

HOUR

METER

START

BUTTON

PRESSURE

GAUGE

UNLOADED

STOP/RESET

BUTTON

POWER ON

INDICATOR

AUTO

RESTART

INDICATOR

FAULT

ALARM

INDICATOR

TEMP

GAUGE

15

2.8 OUTDOOR SHELTERED INSTALLATION

Many times a compressor must be installed outside due
to jobsite conditions or limited space within a manufactur­ing facility. When this occurs there are certain items that
should be incorporated into the installation to help ensure
trouble free operation. These items have been listed
below plus Figure 2.8-1 has been included to show a typ­ical outdoor sheltered installation. The unit must be pur­chased with the Outdoor Modification Option to provide
watertight electrics and a TEFC motor.

■ The compressor should be on a concrete pad

designed to drain water away. If the concrete pad is
sloped, then the compressor must be leveled. In order
to properly pull cooling air through the aftercooler, the
base/skid must be sealed to the concrete pad.

■ The roof of the shelter should extend a minimum of

4 ft (1.2 m) around all sides of the compressor to pre­vent direct rain and snow from falling on the unit.

■ Air-cooled machines must be arranged under the

shelter in a way that prevents air recirculation (i.e. hot
exhaust back to the package inlet).

■ If the installation includes more than one compressor,

the hot air exhaust should not be directed towards the
fresh air intake of the second unit or an Air Dryer.

■ If a standard machine is to be installed outside, the

ambient temperature must never drop below 35°F
(1.7°C).

■ Arrange the machine with the Intellisys con-

troller/starter enclosure facing away from the sun as
radiant heat can affect starter/lntellisys performance.
Also direct sunlight and UV rays will degrade the
membrane touch panel. This is not a warrantable situ­ation.

■ Power disconnect switch should be within line of sight

and in close proximity to the unit. N.E.C. and local
electrical codes must be followed when installing the
power disconnect switch.

■ Condensate drains must never be allowed to dump on

the ground. Run to a suitable sump for future collec­tion and disposal or separation of lubricant and water
mixture.

■ Incoming power connections must use suitable con-

nectors for outdoor weather tight service.

■ A minimum of 3 ft (.9 m) clearance must be allowed

on all four sides of the unit for service access.
However 42” (1.06m), or minimum required by latest
NEC or applicable local code, must be maintained in
front of control panel.

■ If possible, access by a forklift and/or an overhead

beam hoist should be kept in mind (for eventual ser­vice to airend or motor).

■ If the area around the installation contains fine air-

borne dust or lint and fibers etc., then the unit should
be purchased with the High Dust Filter Option and
TEFC motor option.

■ Some type of protection such as a fence or security

system, should be provided to prevent unauthorized
access.

16

FIGURE 2.8-1 TYPICAL OUTDOOR SHELTERED INSTALLATION

17

3.0 SYSTEMS

3.1 GENERAL SYSTEM INFORMATION

The compressor is an electric motor driven, single
stage, rotary screw compressor, complete with support­ing components to make a fully functional unit. Astan­dard compressor is composed of the following:
Inlet air filter
Drive motor
Airend
Pressurized coolant system with cooler & filter
Cooling fan (s)
Capacity control
Instruments
Safety devices

Compression in the rotary screw type air compressor is
created by the meshing of two helical rotors (male and
female) on parallel shafts, enclosed in a heavy duty
iron housing, with air inlet and outlet ports located on
opposite ends. The grooves of the female rotor mesh
with and are driven by the male rotor. Bearings on both
ends of the rotors are used to support the rotor both
laterally and axially.

3.2 AIRCOOLED COMPRESSORS

Design Temperatures

The standard compressor is designed for operation in
an ambient range of 35°F. to 115°F. (1.7°C. to 46°C.).
When conditions other than design levels described
are encountered, we recommend you contact your
nearest Ingersoll-Rand representative for additional
information.

The standard maximum temperature 115°F. (46°C)
is applicable up to an elevation of 3300 ft. (1000
meters) above sea level. Above this altitude, signifi­cant reductions in ambient temperature are required if
a standard drive motor is to be used.

Coolant Cooler

The cooler is an integral assembly of core, fan and
fan-motor, mounted in the compressor. The cooling
air flows in through the front corners of the enclosure,
through the vertically mounted cooler core, and dis­charges upward through the top of the enclosure.

Aftercooler

The discharge air aftercooling system consists of a
heat exchanger (located at the cooling air discharge
of the machine), a condensate separator, and an
automatic drain trap.

By cooling the discharge air, much of the water
vapor naturally contained in the air is condensed
and eliminated from the downstream plant-piping
and equipment.

3.3 COOLANT SYSTEM

The coolant system consists of a separator tank,
thermostatic element, coolant filter, coolant cooler
with fans, and a separator element. When the unit
is operating, the coolant is pressurized and forced
to the compressor bearings. The compressor is
provided with a temperature switch which will shut
the unit down in case of excessive temperature,
228°F (109°C). Effective coolant filtration is provid­ed by the use of a screw on, automotive type,
heavy duty coolant filter.

The compressor is designed for operation in an
ambient range of 35°F to 115°F (2°C to 46°C).

Coolant

Rotary screw compressor fluids have a triple func­tion to perform. They lubricate the bearings and
contacting surfaces of the rotors, seal internal
clearances within the rotor chamber, and provide
for the cooling of the compression process. The
bulk of the fluid is actually used for cooling, with
only small amouts used for lubrication and sealing.

SSR air compressors are factory filled with
SSR ULTRA COOLANT which is designed to
operate for 8,000 hours or two years, whichev­er comes first. The coolant must be changed at
these intervals to avoid breakdown and equip­ment damage.

Circulation of Coolant

Coolant is forced by air pressure from the separa­tor tank to the thermostatic element. The position
of the element (a direct result of coolant tempera­ture) will determine whether the coolant circulates
through the cooler, bypasses the cooler, or mixes
the two paths together to maintain an optimum
compressor injection temperature. This tempera­ture is controlled to preclude the possibility of
water vapor condensing. By injecting coolant at a
sufficiently high temperature, the discharge air
coolant mixture temperature will be kept above the
dew point.

18

Before being injected into the airend, all coolant flows
through the coolant filter. If tis an aubomotive type full
flow filter with a single replacement spin-on element,
rated at 4 micron. There is a differential-pressure
bypass valve set to open in the event that the pres­sure drop across the filter rises to as high as 15 psi (1
bar), which indicates an excessively fouled element as
well as poor maintenance practice.

Coolant/Air Separation System

The coolant/air separation system is composed of a
separator tank with specially designed internals and a
coslescing type separator element located inside the
tank.

The air-coolant mixture discharges from the airend into
the separator tank. The majority of coolant is separted
while in the separator tank and the coalescing separa­tor filter element is used for final cleaning of the air
prior to the customer’s system. The system removes
nearly all of the coolant from the discharge air. The
separated coolant is returned to the coolant system
and the air passes to the compressed air system.

3.4 AIR SYSTEM

Components and Flow

The air system is composed of:
Inlet air filter
Inlet control valve (ICV)
Airend (rotors)
Coolant/Air separator
Minimum pressure check valve (MPCV)
Aftercooler
Moisture separator/drain trap (optional)

The direction of flow is from the inlet filter to the after­cooler. Refer to procedure and instrumentation dia­grams in Section 8.0.

Functions of Components

Inlet air filter, filters the incoming air, trapping 99.9% of
particles 3 micron and larger.

Inlet valve opens full for on-line opeation.
The valve closes in the off-line mode and at shutdown

which prevents back flow of the compressed air.
The airend compresses the air.
The separator tank removes most of the coolant from

the air.

The separator element performs the final separation of
coolant and cleaning of the air prior to leaving the
compressor.

The minimum pressure check valve keeps the separa­tor tank and separator element at a minimum pressure
to ensure adequate oil flow and proper coolant/air sep­aration. It also prevents line pressure from exhausting
back through the airend at shutdown and during peri­ods of unloaded operation.

The aftercooler cools the air prior to leaving the pack­age.

3.5 ELECTRICAL SYSTEM

The electrical system of each SSR compressor is built
with electro-pneumatic controls as standard, or with
the micro-processor based Intellisys controller as an
option.

The standard electrical/electronic components,
enclosed in a readily accessible enclosure include:

1. Push buttons control w/analog gauges

2. Neon indicators

3. Switching relays/timers

4. Control transformers and fuses

5. Compressor motor starter, with auxiliary contacts
and overload relays

6. Optional Intellisys controller in place of #1, 2, and 3

By use of a built-in Automatic Across-The-Line type
starter, the compressor can be started using full volt­age electric current. The starter is completely automat­ic and controlled by the Intellisys controller. Refer to
the electrical schematic, Section 8.0 schematic 8.1
(Standard controller) or 8.3 (Intellisys controller).

By use of an optional built-in Star-Delta type starter,
the compressor motor can be started and accelerated
using a greatly reduced “inrush” electric current. The
starter is completely automatic and controlled by the
Intellisys controller. Refer to the electrical schematic,
Section 8.0 schematic 8.2 (Standard control) or 8.4
(Intellisys control).

Options such as remote start/stop or power outage
restart with remote start/stop can be added by
installing a plug-in module in the controller.

3.6 CAPACITY CONTROL

The SSR compressor is supplied with on-line/off-line
and automatic start/stop controls as standard.
Optional modulation control enables the compressor
to operate with a throttled inlet flow for air systems
which have a relatively high constant demand relative
to compressor capacity.

On-Line/Off-Line With Automatic Start/Stop
Control

The compressor will deliver air at full capacity, (the
compressor maximum efficiency condition) or will
operate at zero capacity with high receiver pressure
(the compressor minimum power condition), while the
unit continues to run.

When the compressor starts and line pressure is
below the lower setting of the line pressure switch,
control solenoid 1SV will be energized (close), inlet
control valve ICV will open, and the compressor will
load. When the line pressure reaches the upper set­ting of the pressure switch, the compressor will
unload by de-energizing (opening) 1SV and closing
ICV. Solenoid 1SV relieves the internal pressure of
the compressor back to the inlet filter. The only
adjustment required is setting of the pressure switch.

A time delay relay is energized and begins to time
out. The timer, mounted in the control box, is factory
set at 10 minutes. It will continue to operate for as
long as its time setting, after which a relay contact
opens to de-energize the compressor starter coil. At
the same time, an amber light (1LT) on the control
box is lit to indicate the compressor has shut down
automatically and will restart automatically. The auto­matic restart will take place when the line pressure
drops to the lower setting of the pressure switch.

Adjusting the adjustable timer below the 10
minute factory setting may shorten the life of the
compressor drive motor.

3.7 PRESSURE SWITCH ADJUSTMENT

Locate the pressure switch as shown in Figure 3.7-1.
The pressure switch can be adjusted using the follow­ing procedure:

1. Open, lock and tag the main electrical disconnect.
Do not adjust the pressure switch with power on or
machine operating.

FIGURE 3.7-1 PRESSURE SWITCH ADJUSTMENT

5

2

3

4

2. Remove pressure switch cover by turning the cover
screw counterclockwise.
NOTE: It is required that the load or on-line pressure
be set first, before the unload or off-line pressure is
set.

3. Set the on-line pressure by turning screw 5 (See
Figure 3.7-1). Turn clockwise to increase setting or
counter-clockwise to decrease setting (indicated by
pointer 4).

4. Set the off-line pressure by turning screw 2. Turn
screw counter-clockwise to increase setting or clock­wise to decrease setting (indicated by pointer 3).

CAUTION:
DO NOT EXCEED NAMEPLATE RATING OF THE
COMPRESSOR.

5. Start compressor and test adjustment(s) made. If
necessary, readjust according to steps 1-4 above.

19

3.8 MODULATION/ACS CONTROL (OPTIONAL)

For those plants which have relatively high constant
air demand, relative to the compressor capacity, the
recommended control mode is modulation.

The modulation control system retains the features
of the on-line/off-line control, but also provides for
throttling of the inlet flow up to the off-line air pres­sure setpoint value.

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

The modulating pressure range is about 4 psig (0.3
BAR) and the modulator is factory set to straddle the
compressor rated pressure. Modulation begins when
the line pressure reaches about 99 percent of the
compressor rated pressure and continues as/if the
line pressure rises. Modulation becomes stable
when the compressor output equals the plant air
demand. When the modulation is at the factory set­ting, the maximum capacity reduction will be approx­imately 60 percent of the compressor rated capacity
(as indicated in Figure 3.8-1).

FIGURE 3.8-1

Capacity control of machines supplied with standard
electro-pneumatic controls and the modulation option
can be manually switched from on-line/off-line with
auto start/stop to modulation via a rotary selector
switch located adjacent to the pressure switch.

3.9 ACS CONTROL (INTELLISYS MODULATION
OPTION ONLY)

For compressors supplied with Intellisys control and
modulation options, ACS control will allow the com­pressor to automatically switch between on-line/off­line and modulation control, depending on air
demand.

If the air demand has decreased to a level below
the 60 percent modulated output, the line pressure
will increase slightly to actuate the Intellisys. The
compressor will then shift to the off-line control
position, and operate unloaded with the compressor
vented.

20

It is sometimes desirable to begin modulation at a
higher pressure than the standard factory setting,
thereby increasing the modulated capacity at the
time the Intellisys is actuated. Refer to Figure 3.8­1 for modulated capacities available when this is
done.

The compressor will then operate to deliver full
capacity air to the plant system. If the plant air
system pressure rises to that of the Intellisys off­line set point, pressurized air will be sent to the
inlet valve causing it to close, and to the blow­down valve, causing it to open.

The compressor will continue to run unloaded, but
since pressure levels have reduced, it will do so
with a minimum power draw.

The Intellisys®has a fixed minimum differential of 10
psi between the off-line air pressure setting and the
on-line air pressure setting. The differential may be
increased by adjusting the on-line air pressure set­ting of the Intellisys

®

.
Refer to Section 4.4 for instructions.
The automatic control selector (ACS) is designed to

continuously monitor the plant air demand and
select either the on-line/off-line, or the modulate
control mode - whichever is most desirable at any­time during an operating day.

It allows the compressor to operate in its most
efficient mode without attendance, thereby reducing
power costs to a minimum.

When the compressor operates in the on-line/off-line
control mode, the length of time the compressor
remains in the "off-line" condition is an indication of
the plant air demand. Intellisys controller is sensing
and awaiting a sufficient line pressure decrease
before signaling a shift to the on-line mode. If the
"off-line" time period is relatively short, thereby indi­cating a high demand for air, it is preferable to shift
the control system to upper range modulation.

The Intellisys

®

does this, and does it automatically if
the compressor unloads 3 times within a 3 minute
time period.

If later, the plant demand decreases, and even
under modulate control the line pressure reaches
the setting of the Intellisys

®

controller, and the
control shifts to the "off-line" mode, the time in this
mode will still be monitored. Along "off-line" time­period indicates a low plant air demand, indicating
the desirability of operating in the on-line/off-line
mode.

The Intellisys

®

then does this, and does it
automatically if the compressor operates unloaded
for more than 3 minutes.

Modulation Only

If MODULATION ONLY is turned on in the setpoint
routine, the unit will shift to Modulation control mode
immediately when the unit is running. The 3 cycles
within 3 minutes time period required for ACS to
change to Modulation mode is bypassed. The unit
will stay in Modulation mode until the unit runs
unloaded for 3 minutes (the unit then returns to ACS
control) or MODULATION ONLY is turned off via the
set routine.

Delay Load Time

This is the amount of time the line pressure must
remain below the 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.

21

3.10 Modulate Control Valve Adjustment (Optional)

Ensure that the compressor is isolated from the
compressed air system by closing the isolation
valve and venting pressure from the drip leg.

Ensure that the main power disconnect switch is
locked open and tagged.

1. Enter the setpoint routine and put the compressor
in the MODULATION mode. Refer to Section 4.4 for
instructions.

2. Remove 1/8" NPT plug from the tee in the control
piping on the side of the airend support. Connect a
pressure gauge to this port.

3. Loosen the adjustment screw locknut and back
out adjusting screw 3 turns. See Figure 3.9-1.

4. Open the isolation valve and start the compressor.

5. Adjust the isolation valve to bring the discharge
air pressure to the rated discharge pressure (100,
125, 140, or 200 psig).

6. While MAINTAINING the rated discharge
pressure, turn the adjustment screw on the modula­tion valve (see Figure 3.9-1) so that the test pres­sure gauge reads:

30 psig for modulate 60% cfm (star-delta units)

Tighten the adjustment screw locknut.

7. Press UNLOADED STOP. Wait for sump pressure
to go 0 psig. Close the isolation valve or bleed off all
system air.

8. Enter the setpoint routine and put the compressor
in the desired control mode (Intellisys units only).

9. Remove the test pressure gauge and replace the
1/8" NPT plug using Loctite

®

PST or similar thread

sealant.
*Loctite is a registered trademark.

FIGURE 3.9-1 MODULATION VALVE

22

!

WARNING

Hazardous voltage. Can cause
severe injury or death.

Disconnect power before servicing.
Lockout/Tagout machine.

!

WARNING

High pressure air.
Can cause severe injury or death.

Relieve pressure before removing filter
plugs / caps, fittings or covers.

LOCKNUT

ADJUSTING SCREW

•

ALARM

•

•

•

•

•

•

AIREND DISCHARGE TEMPERATURE •

SUMP PRESSURE •

SEPARATE PRESSURE DROP •

TOTAL HOURS •

LOADED HOURS •

UNLOAD •

POWER

START

UNLOAD

/LOAD

DISPLAY

SELECT

STOP

SET

4.0 INTELLISYS

INTELLISYS CONTROLLER

INGERSOLLrAND

INTELLISYS

(OPTIONAL)

23

•

•

SET OFFLINE AIR PRESURE

SET ONLINE AIR PRESSURE

SELECT CONTROL MODE

SET DISPLAY TIME

SELECT OPTIONS

•

•

•

•

•

•

•

INGERSOLrAND

INTELLISYS

RESTART

AUTOMATIC

SET

DISPLAY

POWER

•

SELECT

•

STOP

UNLOADED

/LOAD

UNLOAD

START

TOTAL HOURS •

SUMP PRESSURE •

PACKAGE DISCHARGE PRESSURE •

AIREND DISCHARGE TEMPERATURE •

LOADED HOURS •

SEPARATE PRESSURE DROP •

UNLOAD •

4.0 INTELLISYS

4.1 EMERGENCY STOP SWITCH

Pressing this switch stops the compressor immedi­ately. Compressor cannot be restarted until switch
is manually reset. Turn clockwise to reset.

4.2 POWER INDICATOR LIGHT

Indicates voltage is available to the intellisys con­troller.

4.3 PUSH BUTTONS

Start

If the display shows READY TO START, pressing
this button will start the compressor. The compres­sor will start and load automatically if there is a
demand for air.

If in the display table press this button to exit the dis­play table. Display will show “CHECKING
MACHINE” then “READY TO START”.

Unload Stop

Pressing this button will activate the unload stop. If
the compressor is running loaded, it will unload.
Seven seconds later it will stop. if the compressor is
running unloaded, it will stop immediately. Pressing
this button with the unit stopped will flash all L.E.D.’s
for a light check and flash the software version num­ber in the display.

Unload/load

If the unit is running loaded, pressing this button will
cause the unit to unload, the unload indicator light
will be on. The unit will not load until the button is
pressed again. If the unit is running unloaded,
pressing this button will load the unit in the ON/OFF
LINE or MOD/ACS control mode previously operat­ing.

24

EMEG

STOP

UNLOADED

STOP

POWER

START

UNLOAD

/LOAD

4.3 PUSH BUTTONS (Continued)

Display Select

Pressing this button will change the information
selected for the display. The display table will be
incremented. If the button is held, this display table
will scroll. This button can also be used to exit the
set point procedure.

NOTE: For readings less than 1 hr., hourmeter
display minutes. After 1 hr. the hourmeter displays
hours.

Set

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

Arrows

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

Pressure Sensor Calibration (Zeroing) Routine

This routine is entered if the unit is not running and
both the up and down arrows button are pressed at
the same time. Make sure all pressure is relieved
from the compressor before calibration. The display
will flash the message “CALIBRATING”. After cali­bration is completed the display will indicate
“READY TO START”. Zeroing should only be done
after a pressure sensor has been replaced or any
controller change.

25

DISPLAY

SELECT

SET

4.5 WARNINGS

When a warning occurs, the alarm indicator will flash
and the display will alternate between the current
message and the warning message. If multiple
warnings exist, the message

SCROLL FOR WARN

will be substituted for the warning messages. The up
and down arrows can be used to obtain the warn­ings

A warning needs to be reset by an operator. The
warning will clear when the SET button is pressed
once. The following is a list of the warning mes­sages.

1) CHG SEPR ELEMENT

This warning will occur if the pressure on the
Separator is 12 psig (.8 bar) greater than the pres­sure at the Package discharge and the unit is fully
loaded.

2) HIGH AIREND TEMP

This will occur if the Airend Discharge Temperature
(2ATT) exceeds 221°F (105°C).

4.4 SETPOINT PROCEDURE

This procedure allows the customer to modify 11
variables in the controller logic.

At this time, press the SET button to enter the set­point routine. The SET OFFLINE AIR PRESSURE
indicator will light and the display will show:

XXXX PSI

OFFLINE AIR PRESSURE is the first setpoint and
XXXX stands for the value of the setpoint. Press the
SET button to select the setpoint to be adjusted.
Press the up or down arrow buttons to raise or lower
the setpoint value. Press the SET button to move to
the next setpoint. If the setpoint value has been
adjusted, press the SET button to enter the new
value. The display will flash to acknowledge.The
next setpoint will then be displayed. If the value of
the setpoint was not changed, pressing the SET but­ton will only step to the next setpoint. When the
SELECT OPTIONS setpoint is entered, the SELECT
OPTIONS indicator will light, and the setpoints for
options Auto Start/Stop or Remote Start/Stop will
only be accessible and displayed if the option mod­ule is installed in the unit. The Power Outage Restart
setpoints will only be accessible and displayed if the
combination Auto/Remote Start/Stop/Power Outage
Restart option module is installed in the unit. The
setpoint routine can be exited by pressing the DIS­PLAY/SELECT button or exit will be automatic after
30 sec.

The following is a list of the setpoints. Also included
are maximum and minimum limits, step size, and
units of measure.

MIN MAX STEP UNIT

OFFLINE PRESSURE 75 RATED + 3 1 PSI
ONLINE PRESSURE 65 OFFLINE - 10 1 PSI
CONTROL MODE MOD/ACS - MODULATION - ON/OFF LINE
DISPLAYTIME 10 600 10 SEC
AUTO RESTART OFF ON --- --­AUTO RESTART TIME 2 60 1 MIN
SEQUENCER OFF ON --- --­REMOTE START/STOP * OFF ON --- --­POWER OUT/RESTART* OFF ON --- --­POWER OUT RESTART 10 120 1 SEC

TIME *
DELAY LOAD TIME 0 60 1 SEC
LEAD/LAG** --- --- --- --­LAG OFFSET 0 45 1 PSI

*Optional

** The lead/lag feature allows the customer to choose
one compressor as the “lead” compressor and any oth­ers as the “lag” compressor (simulates the mode of a
sequencer). The lag compressor’s on-line and off-line
pressures are determined by subtracting the lag offset
setpoint from the on-line and off-line pressure set-points
of the lead compressor.

26

4.6 ALARMS

When an alarm occurs, the alarm indicator will light
and display will show actual alarm message. If alter­nately multiple alarms have occurred the display will
show SCROLL FOR ALARM. In this situation the up
and down arrows will be used to view the alarm
messages. All alarms (with the exception of the
emergency stop) will be reset by twice pressing the
SET button. Any exceptions to the above will be
explained in the alarm description.

The following is a list of the alarm messages.

1) LOW SUMP PRESS

This will occur if the unit is running and sump pres­sure is too low.

2) HIGH AIR PRESS

This will occur if the unit is running and sump pres­sure is greater than unit rated operating pressure
plus 20 psig (1.4 bar), plus the separator pressure
drop, or the line pressure is 15 psig (1.0 bar) above
the rated pressure.

3) HIGH AIREND TEMP

This will occur if airend discharge temperature is
greater than 228°F (109°C).

4) STARTER FAULT

This alarm will occur if the starter contacts open
while the unit is running. This alarm will also occur if
the unit is given the stop command and the starter
contacts do not open.

5) MAIN MTR OVERLD

This will occur if a motor overload is sensed.

6) FAN MTR OVERLOAD

This will occur if a fan motor overload is sensed.

7) TEMP SENSOR FAIL

This will occur when the sensor temperature is
recognized as missing or broken.

8) REMT STOP FAIL

This will occur if the momentary remote stop switch
does not disengage by the time the unit attempts to
start.

9) REMT START FAIL

This will occur if the momentary remote start switch
does not disengage by the time star-delta transition
occurs.

10) CK MTR ROTATION

This alarm will occur if a unit is started and compres­sor has incorrect rotation.

11) CALIBRATION FAIL

This alarm will occur if the sensor calibration routine
is executed and the sensor reading exceeds 10% of
scale.

12) NO CONTROL POWER

This alarm will occur when the controller senses a
loss of control power.

13) PRES SENSOR FAIL

Whenever the pressure sensor is recognized as
missing or broken, a pressure sensor failure alarm
will occur.

INITIAL CHECK ALARMS

14) HIGH AIREND TEMP

This will occur if airend discharge temperature is
greater than 217°F (103°C).

This alarm will only occur when the machine is not
running. When it occurs, the message MUST COOL
DOWN is added to the alternating group of alarm
messages.

Emergency Stop

This will occur when the EMERGENCY STOP button
is engaged. The alarm indicator will light and display
will show:

EMERGENCY STOP

Disengage the EMERGENCY STOP button and
press the SET button twice to reset this alarm.

27

28

5.2 MAINTENANCE RECORDS

It is very important that you, the owner, keep accurate
and detailed records of all maintenance work you or the
Ingersoll-Rand Distributor or Air Center perform on your
compressor. This includes, but is not limited to, coolant,
coolant filter, separator element, inlet air filter, drive
belts, shaft seals and so forth. This information must be

kept by you, the owner, should you require warranty
service work by your Ingersoll-Rand Distributor or Air
Center. Maintenance record sheets are located at the
back of this manual.

5.3 MAINTENANCE PROCEDURES

Before starting any maintenance, be certain the follow­ing is heeded.
Read Safety Instructions.
Have a well equipped mechanic’s tool box with English
and Metric sockets. (Special tools when needed will be
listed under each appropriate procedure).
Have an OSHA approved air nozzle and compressed
air. (International - local codes may apply).
Have spare parts on hand (See Parts Manual APDD

742.

5.0 SCHEDULED PREVENTATIVE MAINTENANCE

5.1 MAINTENANCE SCHEDULE

THE MAINTENANCE SCHEDULE SPECIFIES ALLRECOMMENDED MAINTENANCE REQUIRED TO KEEP THE
COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT

NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST.

SPECIAL NOTE:
Replace separator element when the separator dif­ferential pressure ( ▲▲ P) reaches three times the ini-
tial pressure drop or a maximum pressure differen­tial of 12 psi (.8 bar) at full load or if the Intellisys
warning “CHG SEPR ELEMENT” is displayed. See
Section 5.15.

Running Time Interval (whichever comes first)

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

Inspect Coolant level Weekly x
Inspect Discharge temperature (air) Weekly x
Inspect Separator element differential Weekly x
Inspect Air filter Delta P (at full load) Weekly x
Replace Coolant filter* 150 x (initial change only)
Check Temperature sensor (intellisys option) 1000 x
Replace Food grade coolant (when used) 1000 x
Inspect Hoses 1200 x
Replace Coolant filter* 2000 x (subsequent changes)
Inspect Drive belt 2000 x
Clean Separator scavenge screen and orifice 4000 x
Clean Cooler cores** 4000 x
Replace Air filter* 4000 x
Replace Separator element* *See special note
Replace SSR Coolant 6000 x
Replace Ultra Coolant* 8000 x
Inspect Starter contactors 8000 x
Service Drive Motor Lubrication See Section 5.18

* In very clean operating environments and where inlet filter is changed at the above prescribed intervals.

In extremely dirty environments change V-belts, coolant, filters, and separator elements more frequently.

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

29

Before beginning any work on the compressor,
open, lock and tag the main electrical disconnect
and close the isolation valve on the compressor
discharge. Wait 2 minutes after stopping to allow
internal pressure to dissipate. Vent residual pres­sure from the unit by slowly unscrewing the
coolant fill plug one turn. Unscrewing the fill plug
opens a vent hole, drilled in the plug, allowing the
pressure to release to atmosphere (See Figure

5.3-1). A slight mist or oil droplets may be visible
during venting. Do not remove fill plug until all
pressure has vented from the unit. Also vent pip­ing by slightly opening the drip leg valve. When
opening the drain valve or removing the coolant fill
plug, stand clear of the valve discharge, wear work
gloves and appropriate eye protection.

5.4 PRESSURE RELIEF VALVE CHECK

Under normal operating condition a “try lever test”
must be performed every month . Under severe ser­vice conditions, or if corrosion and/or deposits are
noticed within the valve body, testing must be per­formed more often. A“try lever test” must also be per­formed at the end of any non-service period. CAU-

TION! High pressure air will discharge through the
discharge ports of the valve during “try lever test”.
Wear ample clothing, gloves, safety glasses and
ear protection during valve testing. Run the com-

pressor for about 10 minutes by venting air from the
system to let the unit warm up. With the unit running,
test at or near maximum operating pressure by holding
the test lever fully open for at least 5 seconds to flush
the valve seat free of debris. Then release lever and
permit the valve to snap shut. If lift lever does not acti­vate, or there is no evidence of discharge, discontinue
use of equipment immediately and contact a licensed
contractor or qualified service personnel.

5.5 SHEAVE ALIGNMENT

Any degree of sheave misalignment will result in a
reduction of belt life. Misalignment of belt drive should
not exceed 1/16 in. (1.6 mm).

Parallel misalignment occurs when the drive and dri­ven shafts are parallel, but the two sheaves lie in dif­ferent planes (See Figure 5.5-1).

Angular misalignment occurs when the two shafts are
not parallel (See Figure 5.5-2).

FIGURE 5.3-1 FILL PLUG WITH VENT HOLE

FIGURE 5.5-1 PARALLEL MISALIGNMENT

FIGURE 5.5-2 ANGULAR MISALIGNMENT

VENT

O-RING

1/16” (1.6mm) MAX

1/16” (1.6mm) MAX

STRAIGHTEDGE

STRAIGHTEDGE

1/16" MAX

AIREND

STRAIGHT EDGE

MOTOR

1/16" MAX

AIREND

STRAIGHT EDGE

MOTOR

30

Align Sheaves
Ensure that the compressor is isolated from the

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

An easy and effective method of checking alignment in
both directions between the driver and driven sheaves
utilizes an accurate straightedge.

Lay the straightedge across the face of the driver
(motor) sheave and check alignment of the driven
(airend) sheave. Then lay the straightedge across the
driven sheave and check that the driver sheave is
aligned.

Alignment should be within 1/16” (1.6 mm) maximum
when measuring the gap between the straightedge
and the rim of the opposite sheave in each direction.

This alignment is factory set and should only require
resetting if the drive motor or airend is removed.

The following steps should be taken to insure proper
alignment of all components.

1. Remove the belt/sheave safety panel from the cool­er box.

2. Disconnect aftercooler inlet tube and discharge
hose.

3. Remove screws which fasten the left-hand side of
the cooler; swing cooler outward.

4. Holding the straightedge against the front of the
airend sheave, measure the amount of misalignment
seen on the motor sheave. If misalignment is less than
1/16” (1.6 mm) then reinstall cooler box panel prior to
operating unit.

5. If misalignment is more than 1/16” (1.6 mm), the
motor sheave bushing must berepositioned (parallel
alignment) or the motor must be repositioned (angular
alignment).

To reposition the motor sheave:

1. Remove drive belts (See Section 5.6).

2. Remove the three hex head screws that hold the
sheave to the sheave bushing. See Figure 5.5-3.

3. Lubricate the thread and end of screws that were
just removed.

4. Reinstall all three screws in the holes of the bushing
that are threaded.

5. Slowly tighten the three screws evenly until the
sheave is pressed from the bushing. (Light tapping on
bushing may assist removal.)

6. Remove the screws from the holes.

“A” - Clearance Holes
“B” - Threaded Holes

FIGURE 5.5-3 MOTOR SHEAVE BUSHING

7. Loosen allen screw in sheave bushing.

8. Move the bushing either in or out on the motor shaft
depending upon the measurement taken earlier.

9. Tighten allen screw in sheave bushing.

10. Being careful to not move the bushing on the
shaft, align sheave so that the three threaded holes in
the sheave line up with the three clearance holes in
the bushing.

11. Insert all three screws through clearance holes in
the bushing and thread into sheave.

12. Slowly and evenly tighten all sheave retaining
screws. Torque to 180 lb-in. (2.1 kg-m).

13. Tap against large end of bushing using hammer
and block or sleeve to avoid damage. Continue to
torque screws until the specified wrench torque no
longer turns the screw after tapping.

14. Install belts as shown in Section 5.6.

15. Recheck for proper alignment.

16. Reinstall belt/sheave safety panel.

ALLEN HEAD SCREW

SHEAVE RETAINING SCREWS

B

B

B

A

A

A

31

5.6 DRIVE BELT

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

Belt tension is maintained using airend mass and drive
torque about a pivoting airend support in conjunction
with a gas spring. Belt is automatically held under the
correct tension and requires no periodic adjustment.

Replacement Parts

Belts (See Parts Manual APDD 742). Be sure to use
only Ingersoll-Rand Genuine parts to assure proper
belt size and length. Incorrectly sized belts can lead to
overloading of bearings and eventual airend or motor
failure.

Disassembly

1. Remove the belt/fan safety panel from the cooler
box.

2. Disconnect aftercooler inlet tube and discharge
hose.

3. Remove screws which fasten the left hand side of
the cooler; swing cooler outward.

4. Remove spring tension on drive belt by rotating
overcenter toggle clockwise with a 1/2 in. drive ratchet
(See Figure 5.6-1).

5. Remove belt.

6. If belt tension spring replacement is required, see
Section 5.8.

Installation / Inspection

Inspect sheave grooves for foreign material or rubber
build-up. Clean and degrease sheaves before
installing drive belts to insure long belt life.

1. Install new belt on motor and airend sheaves. Do
not pry or force the belt over the sheave grooves.

2. Re-apply spring tension by slowly rotating over­center toggle counter clockwise until it hits the stop.

3. Replace cooler, piping and safety panel.

5.7 BELT TENSION

This unit has been designed with a unique self ten­sioning system for the drive belts. There is no adjust­ment required to insure proper belt tensioning. Be sure
to use only Ingersoll-Rand Genuine parts to assure
correct belt tension.

5.8 BELT TENSION SPRING REPLACEMENT

1. With the spring tension relieved as described in step
4 of drive belt disassembly (Section 5.6), remove ten­sioning spring by lifting clips at each end of the spring
with a flat blade screw driver.

2. Pull spring from ball studs.

3. Install new spring by snapping into place with the
rod end (smaller diameter) toward the larger motor
sheave.

5.9 SHAFT SEAL REPLACEMENT

There are two lip type seals on the compressor. They
are wearable parts and should be replaced at 8,000
hour intervals. While it is advisable to have your local
Ingersoll-Rand Distributor or Air Center perform this
work, the task can be accomplished by a good
mechanic following these instructions.

FIGURE 5.6-1 DRIVE BELT ASSEMBLY

32

FIGURE 5.9-1 SEAL INSTALLATION TOOL

Before beginning any work on the compressor,
open, lock and tag the main electrical disconnect
and close the isolation valve on the compressor
discharge. Wait 2 minutes after stopping to allow
internal pressure to dissipate. Vent residual pres­sure from the unit by slowly unscrewing the
coolant fill plug one turn. Unscrewing the fill plug
opens a vent hole, drilled In the plug, allowing the
pressure to release to atmosphere (See Figure 5.3-

1). A slight mist or oil droplets may be visible dur­ing venting. Do not remove fill plug until all pres­sure has vented from the unit. Also vent piping by
slightly opening the drip leg valve. When opening
the drain valve or removing the coolant fill plug,
stand clear of the valve discharge, wear work
gloves and appropriate eye protection.

Special Tools

A clean work bench
Seal installation tool

Replacement Parts

Shaft seal kit
Seal retainer O-Ring
Loctite® 609
Loctite® 515

Installation

1. Remove seal housing from
airend assembly.

2. Drive each seal out of the housing. Be careful not to
damage the surface of the housing bore. The larger
double lip seal must be driven out toward the inboard
side. The term "inboard" side of the seal housing will
refer to the face that is mounted to the airend assem-

bly. The term "out board" side will refer to the face
closest to the sheave.

3. Remove check valve ball and plug from seal hous­ing.

4. If the service technician determines replacement of
the wear sleeve is necessary, remove the wear sleeve
from the shaft,
being careful not to damage the shaft. (If wear sleeve
is not replaced, skip steps 18 and 19).

5. Thoroughly clean the holes, bore surfaces, face of
the seal housing, wear sleeve journal on the shaft, and
the face of the airend assembly. Be careful not to dam
age any of the surfaces, and ensure that no particles
are allowed to enter the bearings.

6. Be certain to install seals from the proper side and
in the proper orientation, as described in following
steps. Carefully follow directions for seal assembly.
Protect seal elements from inadvertent damage during
installation. Be sure all tools are free of contaminants
before installation.

7. Put a thin continuous coat of Loctite 609 on the
outer diameter of the double lip seal.

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

9. Using the seal installation tool (machined according
to Figure 5.9-1), press the double lip seal into the seal
housing until it locates against the shoulder.

10. Remove any excess Loctite 609 with a clean cloth.

33

11. Put a thin continuous coat of Loctite 609 on the
outer diameter of the single lip seal.

12. Position the seal in the seal housing from the out­board side. The seal should be oriented such that the
edge of the lip is installed first.

13. Using a clean flat tool press the single lip seal into
the seal housing until it is flush or below flush with the
surface of the housing.

14. Remove any excess Loctite 609 from the seals,
the seal housing and from the seal scavenge holes in
the seal housing between the seals.

15. Insert the supplied seal installation tool into the
seals. Starting with the tapered end, insert the tool into
the seals from the inboard side of the seal housing.
Insert the tool until all three lips of the seals are on the
nontapered portion of the tool.

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

17. Install the large o-ring onto the seal housing. Place
the seal housing assembly aside for later use.

18. Heat the new wear sleeve to 135˚ C. (275˚ F.) in
hot oil or oven. (Do not allow the sleeve to come into
direct contact with the oil container or the oven.)

19. Install the heated sleeve onto the shaft, seated
against the bearing.

20. Install the new, small o-ring, around the oil scav­enge hole and a new check valve ball in the oil scav­enge hole in the airend assembly. A small amount of
grease can be used to hold
the o-ring and ball in place, in the airend assembly, for
assembly.

21. Lubricate the outside diameter of the wear sleeve
with compressor coolant.

22. Retrieve the seal assembly.

23. Making sure that the check valve ball and o-rings
remain in place, assemble the seal housing to the
airend assembly. As you slide the seal housing along
the drive shaft the seal installation tool will come in
contact with the wear sleeve and will be pushed from
the seals and allow the seal lips to glide onto the wear
sleeve. Using the four bolts removed earlier, attach the
seal housing to the airend. Tighten the bolts to 24.4
N.m (216 in. Ibs.) torque.

34

5.10 INLET AIR FILTER ELEMENT

The inlet air filter should be changed at the interval
shown in the maintenance chart or any time the filter
becomes dirty.

The filter element is not washable and must be
replaced. Remove the filter element by removing the
cap on the filter assembly located on the Inlet Control
Valve. Remove and discard the old filter element.
Install a new filter element. Replace cap (See Figure

5.10-1).

FIGURE 5.10-1 INLET AIR FILTER

5.11 COOLANT FILTER

Time of change - after the first 150 hours and every
2000 hours thereafter, or when the coolant is being
changed. In dirty operating environments, the filter
should be changed more frequently.

Before beginning any work on the compressor,
open, lock and tag the main electrical disconnect
and close the isolation valve on the compressor
discharge. Wait 2 minutes after stopping to allow
internal pressure to dissipate. Vent residual pres­sure from the unit by slowly unscrewing the
coolant fill plug one turn. Unscrewing the fill plug
opens a vent hole, drilled in the plug, allowing the
pressure to release to atmosphere (See Figure 5.3-

1). A slight mist or oil droplets may be visible dur­ing venting. Do not remove fill plug until all pres­sure has vented from the unit. Also vent piping by
slightly opening the drip leg valve. When opening
the drain valve or removing the coolant fill plug,
stand clear of the valve discharge, wear work
gloves and appropriate eye protection.

Special Tools

Suitable clean drain pan or container to hold coolant
drained from unit.

A quantity of proper coolant sufficient to top off the
coolant level in the compressor.

One genuine IR replacement coolant filter of the prop­er type for the unit.

1. Place a clean pan under the coolant filter drain
spout.

2. Using a filter wrench, remove the coolant filter.
Remember that the filter and coolant may be hot!

3. Discard the old filter.

4. Wipe the sealing surface of the filter head with a
clean lint-free rag to prevent entry of dirt into the sys­tem.

5. Remove the replacement filter from it’s protective
package.

6. Apply a small amount of clean coolant on the rubber
seal of the filter.

7. Screw filter on until the seal makes contact with the
seat on the filter head. Tighten approximately one half
to three quarters turn additional.

8. Remove coolant fill plug (See Figure 5.11-1).

FIGURE 5.11-1 SEPARATOR TANK

CAP

INLET AIR FILTER

FILL PLUG

35

9. Fill unit with new coolant as follows:

a. Fill tank to just below the threads of the fill

port.

b. Restart machine and verify that coolant level

is in the green operating zone as viewed
through the sight tube (See Figure 5.11-2).

10. Replace fill plug.

11. Start unit and check for leaks.
Do not add coolant through the intake of the compres-

sor, as this can result in overfilling, saturation of the
separator filter element, and coolant carry-over down­stream.

4.12 COOLANT CHANGE Before beginning any work on the compressor,

open, lock and tag the main electrical disconnect
and close the isolation valve on the compressor
discharge. Wait 2 minutes after stopping to allow
internal pressure to dissipate. Vent residual pres­sure from the unit by slowly unscrewing the coolant
fill plug one turn. Unscrewing the fill plug opens a
vent hole, drilled in the plug, allowing the pressure
to release to atmosphere (See Figure 5.3-1). A slight
mist or oil droplets may be visible during venting.
Do not remove fill plug until all pressure has vented
from the unit. Also vent piping by slightly opening
the drip leg valve. When opening the drain valve or
removing the coolant fill plug, stand clear of the
valve discharge, wear work gloves and appropriate
eye protection.

FIGURE 5.12-1 OIL DRAIN VALVE

OIL DRAIN VALVE

FIGURE 5.11-2 COOLANT SIGHT TUBE

Special Tools

Suitable clean drain pan or container to hold approxi­mately 3.2gal. (12L) of coolant drained from unit.

A quantity of proper coolant sufficient to refill the
coolant level in the compressor.

One genuine IR replacement coolant filter of the prop­er type for the unit.

The coolant should be drained soon after the com­pressor has been shut down. When the coolant is
warm, the drainage will be more complete and any
particles in suspension in the coolant will be carried
out with the coolant.

1. Place a clean pan under the oil drain valve.

2. Remove the cap from the oil drain valve
(See Figure 5.12-1).

3. Thread the oil drain fitting (supplied with compres­sor), with hose attached, onto the oil drain valve. The
valve will open as the fitting is threaded completely,
allowing the oil to drain.

COOLANT SIGHT TUBE

36

13. Replace fill plug.

14. Start unit and check for leaks.
Do not add coolant through the intake of the compres-

sor as this can result in overfilling, saturation of the
separator filter element and coolant carry-over down­stream.

5.13 COOLANT HOSES

The flexible hoses that carry coolant through the cool­ing system may become brittle with age and will
require replacement. Have your local Ingersoll-Rand
Distributor or Air Center check them every year and
replace them as needed or every 2 years.

Before beginning any work on the compressor,
open, lock and tag the main electrical disconnect
and close the isolation valve on the compressor
discharge. Wait 2 minutes after stopping to allow
internal pressure to dissipate. Vent residual pres­sure from the unit by slowly unscrewing the
coolant fill plug one turn. Unscrewing the fill plug
opens a vent hole, drilled in the plug, allowing the
pressure to release to atmosphere (See Figure 5.3-

1). A slight mist or oil droplets may be visible dur­ing venting. Do not remove fill plug until all pres­sure has vented from the unit. Also vent piping by
slightly opening the drip leg valve. When opening
the drain valve or removing the coolant fill plug,
stand clear of the valve discharge, wear work
gloves and appropriate eye protection.

Removal

Drain coolant into a clean container. Cover the con­tainer to prevent contamination. If the coolant is conta­minated, a new charge of coolant must be used.

Remove the hose.

Installation

Install the new hose. Refill the unit with coolant. Start
the compressor and check for leaks. Stop unit and
check coolant level in the coolant sight tube on the
separator tank.

FIGURE 5.12-2 COOLANT FILTER

4. Using a filter wrench, remove the coolant filter.
Remember that the coolant filter may be hot (See
Figure 5.12-2).

5. Discard the old filter.

6. Wipe the sealing surface of the filter head with a
clean lint-free rag to prevent entry of dirt into the sys­tem.

7. Remove the replacement filter from its protective
package.

8. Apply a small amount of clean coolant on the rubber
seal of the filter.

9. Screw element on until the seal makes contact with
the seat on the filter header. Tighten approximately one
half to three quarters turns additional.

10. Remove drain fitting and replace drain valve cap.

11. Remove coolant fill plug (See Figure 5.11-1).

12. Fill unit with new coolant as follows:
a. Fill tank to the threads of the coolant

fill port.

b. Run machine 15-20 seconds and relieve

pressure.

c. Add more coolant up to the threads of the

coolant fill port.

d. Restart machine and verify that coolant

level is in the middle (green) range of the
sight tube when the unit is running loaded.

COLLANT FILTER

37

Before beginning any work on the compressor,
open, lock and tag the main electrical disconnect
and close the isolation valve on the compressor
discharge. Wait 2 minutes after stopping to allow
internal pressure to dissipate. Vent residual pres­sure from the unit by slowly unscrewing the
coolant fill plug one turn. Unscrewing the fill plug
opens a vent hole, drilled in the plug, allowing the
pressure to release to atmosphere (See Figure 5.3-

1). A slight mist or oil droplets may be visible dur­ing venting. Do not remove fill plug until all pres­sure has vented from the unit. Also vent piping by
slightly opening the drip leg valve. When opening
the drain valve or removing the coolant fill plug,
stand clear of the valve discharge, wear work
gloves and appropriate eye protection.

Procedure:

1. Disconnect tank discharge fitting, inlet valve control
tube, and scavenge tube.

2. Remove tank cover bolts and cover (See Figure

5.15-2).

3. Remove separator element.

4. Clean all tank flange surfaces of dirt and residual
gasket material.

5.Install new separator element, making sure that the
ground staple comes in contact with the flange materi­al.

FIGURE 5.15-2 TANK COVER REMOVAL

TANK COVER BOLT

5.14 AIREND DISCHARGE HOSE

The flexible hose from the airend discharge to sepa­rator tank may become brittle with age and require
replacement. Check this hose as per the mainte­nance schedule in Section 5.1.

Removal

Ensure that the compressor is isolated from the
compressed air system by closing the isolation
valve and venting pressure from the drip leg.

Ensure that the main power disconnect switch is
locked and tagged.

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

5.15 COOLANT SEPARATOR FILTER ELEMENT

The separator filter element should be replaced
every year or after 4000 hours of operation, whichev­er comes first, to prevent excessive coolant carryover
into the plant’s air piping system.

The element is located inside the separator tank
(See Figure 5.15-1).

FIGURE 5.15-1 SEPARATOR ELEMENT LOCATION

SEPARATOR ELEMENT (INSIDE)

38

6. Replace cover and start the retaining bolts.

7. Torque bolts evenly to 80 ft.-lb (109 N-m).

8. Replace connections removed in step 1.

9. Start unit and check for leaks.

5.16 SEPARATOR TANK SCAVENGE

CHECK VALVE/SCREEN/ORIFICE

Tools Required

Open end wrench
Screwdriver

Procedure

Disconnect tubing at each end of check valve/screen/
orfice assembly.

Check orifice and clean if required. Use suitable small
screwdriver or knife and press screen retainer orifice
from its mating fitting (See Figure 5.16-1). Be careful
not to damage flared end of fitting or O-ring. Wash
screen and housing in safety solvent and blow dry.

Press the check valve/screen/orifice into fitting block.
Assemble the check valve/screen/orifice assembly to

the tubing lines. The fitting must be re-installed with
the screen on the upstream side of the orifice as indi­cated by the flow arrow (See Figure 5.16-1).

5.17 COOLER CORES

Inspection

1. Remove the cooler box rear panel.

2. Disconnect aftercooler inlet tube and discharge

hose.

3. Remove screws which fasten the left hand side of

the cooler; swing cooler outward.

4. Visually check the cooler cores for build up of dirt,
dust, lint or other foreign material.

5. Using an OSHA approved air gun, blow air through
the cooler cores in the opposite direction of normal air
flow.

6. Re-install cooler assembly.

7. Start unit and verify proper operation.

5.18 MOTOR LUBRICATION

The induction-type squirrel cage motors have antifriction
ball or roller bearings front and rear. At periodic intervals
they require relubrication.

Relubrication Interval
(or 9 months, whichever comes first)

ODP DRIVE MOTOR......................................2000 hours

TEFC DRIVE MOTOR .........................NON-REQUIRED

Relubrication amount

* No greasing required (permanently lubricated bear­ings)

Improper
lubrication can be a cause of motor bearing failure. The
quantity of grease added should be carefully controlled.
The smaller motors must be greased with a lesser
amount of grease than larger motors.

FIGURE 5.16-1 SEPARATOR TANK SCAVENGE

CHECK VALVE/SCREEN/ORIFICE

INLET

SPRING

HOUSING

CHECK

VALVE

SCREEN

ORIFICE

VITON

O-RING

Lubricant Amount

Motor Frame Size in

3

cc oz. grams

254-286 1.0 1 6 .8 23

NOTICE

Motors MUST be greased
periodically. See Operators
Manual for procedure.

39570098

Recommended Motor Grease

Most motors require:

Mobilith SHC 220..............................................................

Mobil
Use the grease as indicated on a special grease infor-

mation nameplate on the motor. Use of alternative
greases can result in shortened motor life due to incom­patibility of greases. If there is not a grease nameplate
on the motor use:

Chevron Black Pearl #2

(Preferred) ................................................Standard Oil of

California

Chevron SRI 2..........................................Standard Oil of

California

Motor Bearing Maintenance (Stored Units)

To ensure that complete contact is maintained between
the motor bearings and the bearing grease on units to
be placed in storage for extended intervals, the follow­ing motor maintenance procedure should be adhered
to:

1) Prior to placing a unit in storage, rotate the motor
several revolutions by hand in the proper direction
of rotation.

2) Thereafter, rotate the motor as described in Step 1
at three month intervals until such time as the unit
is placed in service.

3) If the storage time is to exceed a total of nine (9)
months duration.

Overgreasing can be a cause of bearing and

motor failure. Make sure dirt and contaminants

are not introduced when adding grease.

CAUTION

!

When regreasing, stop motor. Disconnect power; lock out
and tag. Remove outlet plugs (or spring-loaded grease
relief plugs if present). The outlet plug may not be acces­sible on some motors.

Grease should be added when the motor

is stopped and power disconnected.

CAUTION

!

Procedure for relubrication

Grease relief along shaft can occur, precluding necessity
of removing this plug if inaccessible. The inlet grease
gun fittings and outlet plugs (or spring-loaded reliefs) are
located at each end of the motor housing. The drive end
reliefs protrude out the circumference of the lower por­tion of the end bell. The non-drive end outlet plugs are
located just behind the flange in the air intake area at
about the 5 or 6 o’clock position.

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

2) Use a hand lever type grease gun. Determine in
advance the quantity of grease delivered with each
stroke of the lever. A graduated cylinder showing
cubic centimeters (cc) may be used, or a 35mm film
canister can give a close approximation for 2 cubic
inches when filled.

3) Add the recommended volume of the recommended
lubricant. Do not expect grease to appear at the

outlet, but if it does, discontinue greasing at
once.

4) Run motor for about 30 minutes before replacing out­let plugs or reliefs. BE SURE TO SHUT MOTOR

DOWN, DISCONNECT POWER, LOCK OUT AND
TAG, AND REPLACE THESE DRAIN FITTINGS TO
PRECLUDE LOSS OF NEW GREASE AND
ENTRANCE OF CONTAMINANTS!

39

!

WARNING

Hazardous voltage. Can cause
severe injury or death.

Disconnect power before servicing.
Lockout/Tagout machine.

INGERSOLLrAND ®

40

5.19 COOLER CORES: CLEANING

Ensure that the compressor is isolated from the
compressed air system by closing the isolation valve
and venting pressure from the drip leg.

Ensure that the main power disconnect switch is
locked open and tagged. (See Figure 5.19-1).

Tools Required

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

DANGER

FIGURE 5.19-1 MAIN DISCONNECT

LOCKED AND TAGGED

Follow these precautions to minimize damage from
static electricity. Static can cause severe damage to
microcircuits.

1) Make the least possible movement to avoid building
up static electricity from your clothing or tools.

2) Discharge potential static electricty by touching
(grounding) yourself to the starter box.

3) Handle circuit boards only by their edges.

4) Do not place the Intellisys® Controller on any metal
surface.

5) Leave the replacement parts in their protective bags
until ready for installation.

Before removing any components, remove the starter
box door and check all wiring for tightness. Aloose
wire or bad connection may be the cause of problems.

Controller Removal:

1) Remove the starter box door.

2) Remove clamp rods and nuts which fasten the con­troller in place.

3) Pull the Intellisys controller down off of the mounting
studs.

4) Remove the five wire connectors from the top of the
controller.

5) Remove the controller. Remove any option modules
which must be installed in the new controller.

DANGER

HASP

KEY LOCK

HIGH VOLTAGE

DANGER

LEVER

TAG

41

TROUBLE CHECK POINT NUMBERS

Compressor Fails to Start 1,2,3
Repeat Shutdowns 3,4,5,2
High Amp Draw 8,9,6,7
Low Amp Draw 1,10,12
High Discharge Pressure 13,15,16,19
Low Air System Pressure 22, 20,17,18,13,15,14,19,7
Unit Running Hot 22,21,23,24,6
High Coolant Consumption 28,27,25,26
Excessive Noise Level 17,18,31,30,29
Shaft Seal Leak 32
Pressure Relief Valve Opens 6,13,15,14,16,19
Black Residue on Belt 17,33,34
Guard/Cooler Box

CHECK POINT NUMBERS TROUBLE CAUSE

1. Control Voltage Not Available

2. Defective Starter

3. Motor Overload

4. Incorrect Overload Size

5. Line Voltage Variation

6. Compressor Operating Above Rated Pressure

7. Dirty Separator Filter Element

8. Low Voltage

9. Unbalanced Voltage

10. Dirty Air Filter

11. Compressor Operating Unloaded

12. High Voltage

13. Incorrect Pressure Switch Setting

14. Faulty Minimum Pressure Valve

15. Load Solenoid Valve Defective

16. Blowdown Valve Defective

17. Drive Belt Slipping

18. Air System Leaks

19. Inlet Valve Malfunction

20. System Demand Exceeds Compressor Delivery

21. Coolant Cooler Core Dirty

22. Low Coolant Level

23. High Ambient T emperature

24. Restricted Cooling Air Flow

25. Separator Filter Element Leak

26. Plugged Separator Filter Drain

27. Compressor Operating Below Rated Pressure

28. Coolant System Leak

29. Airend Defective

30. Motor Defective
31 Loose Components
32 Worn or Defective Shaft Seal
33 Sheaves Misaligned
34 Worn Sheaves

6.0 TROUBLE SHOOTING

6.1 TROUBLE SHOOTING CHART (STANDARD CONTROL)

6.2 TROUBLE SHOOTING CHART - INTELLISYS CONTROL (CONTINUED)

TROUBLE CAUSE &/OR DISPLAY WHAT TO DO

Compressor fails to start. 110/120V control voltage not available. — Check fuses. Check transformers and

wiring connections.
"STARTER FAULT". — Inspect contactors.
"EMERGENCY STOP". — Rotate emergency stop button to

disengage, and press"SET" button twice.
"MAIN MTR OVER LD" — Manually reset main overload relay, and

press "SET"button twice.
"PRES SENSOR FAIL" or — Check for defective sensor, bad sensor
"TEMP SENSOR FAIL" connection, or broken sensor wires.
“NO CONTROL POWER”—Check fuses and HAT switch

Compressor shuts down. "HIGH AIREND TEMP." — Insure that installation area has

adequate ventilation.

— Insure that cooling fan is operating. If

not reset circuit breaker inside starter

box.

— Check coolant level. Add if required.
— Cooler cores dirty. Clean coolers.

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

— Check supply voltage.
— Check heater size.

"STARTER FAULT." — Inspect starter contactors.

— Check for loose wires.

“NO CONTROL POWER”—Check fuses and HAT switch

Low system air pressure Compressor running in "Unload" Mode. — Press "UNLOAD/LOAD" button.

Controller off-line set point too low. — Press "UNLOAD/STOP" button, set off-

line set point at a higher value.
Dirty air filter element. — Check filter condition. Replace

as required.
V-Belts slipping. — Adjust belt tension.
Air leak. — Check air system piping.
Moisture separator trap drain stuck open. — Inspect and repair.
Inlet valve not fully open. — Inspect and repair. Check control

system operation.
System demand exceeds compressor — Install larger or an additional

delivery. compressor.

42

6.2 TROUBLE SHOOTING CHART - INTELLISYS CONTROL

TROUBLE CAUSE &/OR DISPLAY WHAT TO DO

High coolant Excessive coolant level. — Check level, lower if necessary by
consumption/coolant draining.
in air system Plugged separator element. — Check separator pressure drop.

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

replace element.

Plugged separator scavenge orifice/ — Remove and inspect orifice/screen.
screen. Clean if required.

Compressor operating at low pressure — Operate at rated pressure.
(75 psig or below). — Reduce system load.

Coolant system leak. — Inspect and repair leaks.

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

separator/trap if defective.
Trap drain or drain piping plugged. — Inspect and clean.
Aftercooler core dirty. — Inspect and clean.
Enclosure panels not in place. — Install enclosure panels.

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

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

air system. Distributor or Air Center.
V-belts slipping. — Adjust belt tension or replace belts.

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

failure or rotor contact.) Center immediately, do not operate

unit.
Enclosure panels not in place. — Install enclosure panels.
Loose component mounting. Inspect and tighten.

Excessive vibration Loose components — Inspect and tighten.

Motor or compressor bearing failure. — Contact authorized Distributor or Air

Center immediately, do not operate

unit.
External sources. — Inspect area for other equipment.

Shaft Seal leak Defective shaft seal. — Replace per this manual or contact

authorized Distributor or Air Center

Black residue on belt guards V-belts loose. — Adjust belt tension.

Sheaves mis-aligned. — Align sheaves.
Excessive belt wear — Replace belts.

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

Defective valve. — Replace valve.

43

7.0 OPTIONS

7.1 REMOTE START/STOP

The remote start/stop option allows the operator to
control the compressor from a remote mounted
start/stop station. This option may be factory
installed or a field installation kit is available. This
option is a plug-in module for machines supplied
with the Intellisys option.

With the remote start/stop option installed, two differ­ent switches can be wired to the Intellisys

®

for
remote start/stop. Refer to electrical schematics in
section 8.0 for wiring locations. The switches are
customer supplied and must be of the momentary
type. The stop switch contacts are normally closed
and start switch contacts are normally open.

7.2 REMOTE START/STOP AND POWER OUTAGE RESTART OPTION

When the Power Outage Restart Option is desired, a
field installation kit that contains this feature is avail­able. The option includes a logic controller for
machines supplied with standard controls, or a plug­in module for machines supplied with Intellisys con­trol. All of the hardware necessary for installation is
included.

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

7.3 SEQUENCER CONTROL

Sequencer control capability can be added to the
Intellisys

®

System by utilizing a sequencer interface.

This option is available as a field installation kit.

44

!

WARNING

This machine is remote
start and stop equipped.

May start or stop at
anytime.

Can cause severe injury or
death.

Disconnect power before
servicing.

Lock and tag out.
See Operators / Instruction

Manual.

NOTE:

45

46

8.0 REFERENCE DRAWINGS

54364062

REV A

8.1 ELECTRICAL SCHEMATIC-FULL VOLTAGE STANDARD CONTROL

47

8.2 ELECTRICAL SCHEMATIC-STAR DELTA STANDARD CONTROL

54364088

REV A

8.3 ELECTRICAL SCHEMATIC-FULL VOLTAGE WITH INTELLISY OPTION

48

39932397

REV C

49

39932405

REV B

8.4 ELECTRICAL SCHEMATIC-STAR DELTA WITH INTELLISYS OPTION

50

39263066

REV A

8.5 FOUNDATION PLAN–BASE MOUNTED-UNENCLOSED (CONTINUED)

51

8.5 FOUNDATION PLAN–BASE MOUNTED-UNENCLOSED

39263066

REV A

52

39929518

REV A

8.6 FOUNDATION PLAN–BASE MOUNTED-ENCLOSED (CONTINUED)

53

8.6 FOUNDATION PLAN–BASE MOUNTED-ENCLOSED

39929518

REV A

54

39932777

REV A

8.7 FOUNDATION PLAN–120 GAL. TANK MOUNTED-UNENCLOSED (CONTINUED)

55

8.7 FOUNDATION PLAN–120 GAL. TANK MOUNTED-UNENCLOSED

39932777

REV A

56

39263082

REV A

8.8 FOUNDATION PLAN–120 GAL. TANK MOUNTED-ENCLOSED (CONTINUED)

57

8.8 FOUNDATION PLAN–120 GAL. TANK MOUNTED-ENCLOSED

39263082

REV A

58

39932785

REV A

8.9 FOUNDATION PLAN–240 GAL. TANK MOUNTED-UNENCLOSED (CONTINUED)

59

8.9 FOUNDATION PLAN–240 GAL. TANK MOUNTED-UNENCLOSED

39932785

REV A

60

39929401

REV A

8.10 FOUNDATION PLAN–240 GAL. TANK MOUNTED-ENCLOSED (CONTINUED)

61

8.10 FOUNDATION PLAN–240 GAL. TANK MOUNTED-ENCLOSED

39929401

REV A

54363650

REV A

62

8.11 BASIC FLOW SCHEMATIC-STANDARD CONTROL

5436376

REV A

63

8.12 BASIC FLOW SCHEMATIC-INTELLISYS CONTROL

64

8.13 TYPICAL SYSTEM FLOW DIAGRAMS

TYPICAL SYSTEM FLOW

DIAGRAM

65

8.13 TYPICAL SYSTEM FLOW DIAGRAMS

66

8.13 TYPICAL SYSTEM FLOW DIAGRAMS

67

8.13 TYPICAL SYSTEM FLOW DIAGRAMS

68

8.10 TYPICAL SYSTEM FLOW DIAGRAMS

69

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

9.0 MAINTENANCE RECORD

70

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

MAINTENANCE RECORD

71

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

MAINTENANCE RECORD

72

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

MAINTENANCE RECORD