Product Maintenance Information: Contact-Cooled Rotary Screw Air Compressor

RELEASED 11/Feb/2019 01:43:20 GMT
47612267
Revision B
January 2019
Contact-Cooled Rotary Screw Air Compressor

RS45i, RS55i, RS75i
Product Maintenance Information
Save These Instructions

EN
CONTENTS
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . .3 CLEANING/ CHECKING CONDENSATE DRAIN (WHERE
FITTED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CLEANING / INSTALING PACKAGE PRE-FILTER (COOLING
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AIR COMPRESSOR MAINTENANCE. . . . . . . . . . . . . . . .4 CHECKING / CLEANING NO LOSS DRAIN TRAP (WHERE
FITTED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE PROMPTS . . . . . . . . . . . . . . . . . . . . . . . . .4
MONITORING FLUID AND PERFORMING SHOCK PULSE
MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 BEARING ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CHECKING COOLANT LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INTEGRATED DRYER MAINTENANCE. . . . . . . . . . . . 13
ADDING COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLEANING CONDENSATE DRAINS (TIMED
DRAINING COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DRAINS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SAMPLING COOLANT FOR ANALYSIS . . . . . . . . . . . . . . . . . . 6 TESTING CONDENSATE DRAINS (NO-LOSS DRAINS
CHANGING COOLANT FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . 6 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CHECKING SEPARATOR ELEMENT. . . . . . . . . . . . . . . . . . . . . . 6 TROUBLESHOOTING CONDENSATE DRAINS
CHANGING SEPARATOR ELEMENT . . . . . . . . . . . . . . . . . . . . . 6 (ELECTRONIC DRAINS ONLY) . . . . . . . . . . . . . . . . . . 13
INSPECTING SEPARATOR TANK / PRESSURE SYSTEM . . . 7 DISASSEMBLING THE INTEGRATED DRYER . . . . . . . . . . 13
CLEANING / CHECKING SCAVENGE SCREEN . . . . . . . . . . . 7 DECOMMISSIONING THE INTEGRATED DRYER . . . . . . . 14
CHECKING MINIMUM PRESSURE CHECK VALVE (MPCV) 7
CHANGING AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REGREASING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CLEANING AIR COOLED COOLING SYSTEM . . . . . . . . . . . . 7
REMOVING / INSTALLING AIR COOLED COOLER . . . . . . . 8
CLEANING WATER COOLED COOLER (FOR BOTH CLEAN
& HARSH WATER OPTIONS). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING MOTOR COWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EN-2 47612267 Rev B

EN
ABOUT THIS MANUAL

The purpose of this manual is to provide maintenance and troubleshooting guidelines for the compressor.
For supporting documentation refer to Table 1.
Table 1: Product Manuals
Part/Document Number by Region
Publication Product
Americas EMEA * Asia Pacific
Product Safety Information Manual All 80446313 80446156 80446321
Product Information Manual RS 45-75i 47612264 47612265 47612266
Product Maintenance Manual RS 45-75i 47612267 47612268 47612269
Product Parts Information Manual RS 45-75I 47612270
* Europe, Middle East and Africa
Product specification sheets and reference drawings are also available.
PERSONNEL
Proper use, inspections and maintenance increases the life and usefulness of the compressor. It is extremely important that
anyone involved with maintaining the compressor be familiar with the servicing procedures of these compressors and be
physically capable of conducting the procedures. These personnel shall have skills that include:
1. Proper and safe use and application of mechanics common hand tools as well as special Ingersoll Rand or
recommended tools.
2. Safety procedures, precautions and work habits established by accepted industry standards.
Some maintenance procedures are technical in nature and require specialized tools, equipment, training and experience
to accomplish correctly. In such situations, only allow Ingersoll Rand trained technicians to perform maintenance on this
compressor. Service or inspections beyond the procedures given in this manual shall not be attempted by operating personnel.
For additional information contact the Ingersoll Rand factory or the nearest service provider.
SAFETY
Before undertaking any work on the compressor, ensure that the electrical supply has been isolated, and remote start/stop
function is not enabled, locked off, tagged and the compressor has been relieved of all pressure. Ensure the compressor is
electrically isolated for at least 15 minutes before commencing any maintenance work. See the Product Safety Information
manual for additional information.
Ingersoll Rand cannot know of or provide all the procedures by which repairs may be conducted and the hazards and/or
results of each method. If maintenance procedures not specifically recommended by the manufacturer are conducted, ensure
that safety is not endangered by the actions taken.
If you are unsure of a maintenance procedure or step, place the compressor in a safe condition before consulting technical
assistance.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and
increased maintenance and may invalidate all warranties.
For additional information contact the Ingersoll Rand factory or the nearest service provider.
47612267 Rev B EN-3

EN
AIR COMPRESSOR MAINTENANCE

MAINTENANCE PROMPTS MAINTENANCE CHART
The service warning and flashing LED will appear at intervals Maintenance should be performed per the recommendations
dependent on the service level selected. Refer to the Product below in the following priority: (1) Perform maintenance
Information manual for information about service level when indicated by the controller; (2) Perform maintenance
settings. through either hourly intervals or scheduled maintenance
intervals, or (3) Annually.
Table 2: Maintenance Chart
Period Action Maintenance Item
Replace Air filter element
When indicated by
controller Replace Coolant filter element
Replace Separator element
Check Connections and hoses for leaks
Check Coolant level
Daily Check Condensate drain operation
Check Controller for service indicators
Check Package pre-filters for blockage
Inspect Air-cooled cooling system for blockage
Inspect Water-cooled cooling system screens
Monthly
Inspect Starter box power drive module (PDM) filter element*
Analysis Water from water-cooled cooling system
Every 1000 hours Analysis Food-grade Lubricant (Ultra FG)
Inspect Air filter element
Inspect Coolant filter element
Every 2000 hours Inspect Starter box power drive module (PDM) filter element*
Analysis Shock pulse bearing
Analysis Premium Coolant (Ultra/Ultra EL)
Inspect Scavenge screen for blockage
Replace Air filter element
Replace Coolant filter element
Replace Starter box power drive module (PDM) filter element*
Every 4000 hours Replace Package pre-filter elements
Inspect / Clean Air-cooled cooling system
Inspect / Clean Water-cooled cooling system
Calibrate Pressure transducers
Grease Drive motors (as required)
Replace Separator element
Replace No-loss condensate drain service module
Every 8000 hours Replace Premium Coolant (Ultra) / Food-grade Lubricant (Ultra FG) [8000 hours]
Clean Drains with all their components (TIMED DRAINS ONLY)
Service Lubricate inlet valve cylinders (modulation packages only)
Service Inlet valve service kit
Replace Extended-life Premium Coolant (Ultra EL) [16000 hours]
16000 hours
Replace Rubber hoses
Service Minimum pressure check valve (MPCV) service kit
Replace Stainless Steel/PTFE hoses
Replace Blowdown Valve(s)
Replace Oil Stop Valve
40000 hours Replace Water Stop Valve
Replace Discharge Check Valve
Replace Inlet Valve
Service Shaft Seal
EN-4 47612267 Rev B

EN
NOTICE
Inspect and replace coolant filter elements and separator elements more frequently in dirty operating environments.
ROUTINE MAINTENANCE DRAINING COOLANT

This section refers to the various components which require It is better to drain the coolant immediately after the
periodic maintenance and replacement. compressor has been operating as the coolant will drain
faster and any contaminant will still be in suspension.
Refer to safety information and maintenance procedures
prior to carrying out any of the maintenance in the following See Figure 1.
sections. 1. Place the straight end of the drain hose in a suitable
container. Install the other end of the drain hose in
NOTICE
the drain valve. The coolant flows through the drain
Prior to opening or removing panels or covers to work hose automatically.
inside a machine, ensure that anyone entering the 2. After drainage, remove the hose and close the valve.
machine is aware of the reduced level of protection
and the additional hazards, including hot surfaces and NOTICE
intermittently moving parts.
You may also drain coolant from the coolant cooler by
removing the plug.
CHECKING COOLANT LEVEL
You should also drain additional coolant from the
A coolant level sight glass is located on the side of the
airend by using drain hose.
separator tank. While the compressor is running under load,
coolant should always be visible in the sight glass. The normal
position is half way. The compressor should be running for at Figure 1: Coolant Drain
least 40 seconds for this check.
Stop the compressor, ensure the sump pressure is 0 psig and
ensure the coolant is still visible in the sight glass.
ADDING COOLANT
Run the compressor for a minimum of 40 seconds. The
coolant level should be visible in the sight glass. If not: 1 2
1. Stop the compressor.

2. Isolate the compressor from the external air system.
3. Press the emergency stop. Compressors can take
more than two minutes to fully de-pressurize once
stopped.
3 4
4. Slowly unscrew the coolant fill plug to verify all
pressure has been released.
3. Dispose of waste coolant in accordance with local and
5. Add coolant. governmental regulations.
6. Replace the coolant fill plug and restart the
NOTICE
compressor.
7. Recheck the coolant level. Shorter coolant change intervals may be necessary if
the compressor is operated in adverse conditions.
8. Repeat the above steps until the coolant level is
visible in the sight glass with the compressor both
running and stopped.
NOTICE
Do not add coolant through the intake of the

compressor, as this can result in overfilling, saturation
of the separator filter element, and coolant carry-over
downstream.
47612267 Rev B EN-5

EN
SAMPLING COOLANT FOR ANALYSIS CHECKING SEPARATOR ELEMENT

1. Bring the compressor up to operating temperature. With the compressor running on load, check the separator
differential pressure via the controller. It will be necessary to
2. Stop the compressor.
change the element if the differential pressure equals zero or
3. Isolate the compressor from the external air system. exceeds 1 bar (15 psig).
4. Press the emergency stop. Fixed speed compressors CHANGING SEPARATOR ELEMENT
can take more than two minutes to fully de-pressurize
1. Remove the fitting that holds the scavenge tube into
once stopped.
the tank and withdraw the tube assembly.
5. Draw a sample from the separator tank port using a
2. Disconnect the piping from the tank cover. Tag the
pump kit. DO NOT draw a sample from the drain port
lines if required. Remove all the bolts securing the
or oil filter.
over to the tank except the bolt opposite the pivot
Use a new hose on the pump for each sample. Failure to do bolt which should be left engaged by 2-3 threads
this can give false readings. with at least 6.5 mm (0.25 in) clearance from the screw
head to the cover. Rotate the jacking bolt clockwise
See Figure 2.
until the cover lifts off the tank at least 2 mm (0.08 in)
Figure 2: Coolant Sampling all the way around the tank. Remove the remaining
bolt. The cover can now be rotated to allow access to
inside the tank.
3. Carefully lift the separator element up and out of the
tank. Discard the faulty element.
4. Clean the sealing surface on both the tank and its
cover. Check the tank to be absolutely certain that
no foreign objects such as rags or tools have been
allowed to fall into the tank. Lubricate a thin layer of
coolant on the separator seal top and bottom before
installing a replacement element down into the tank
after checking the new element seal for possible
damage. Center the element within the tank ensuring
that it is fully seated in the sealing groove. Rotate
the tank cover back into position taking care not to
damage the seal, and locate the cover using two bolts
but do not tighten down.
5. Loosen the jacking bolt to fully disengage the threads
and tighten the cover bolts in a cross-pattern to
prevent over-tightening one side of the cover. An
improperly tightened cover will likely result in a leak.
See Figure 3
CHANGING COOLANT FILTER 6. Inspect the tank scavenge screen and orifice. Clean if
1. Loosen filter with the correct tool. necessary following the instructions below.
2. Remove the filter from the housing. 7. Install the scavenge tube down into the tank until the
tube just touches the separator element and then
3. Place the old filter in a sealed bag and dispose of in a
raise it 2 mm (0.10 in). Ensure tube is not raised less
safe way.
than 2 mm (0.10 in) or more than 3 mm (0.125 in).
4. Clean the mating face of the housing taking care to Tighten fittings.
avoid any particles entering the machine.
NOTICE
5. Remove the new Ingersoll Rand replacement filter
from its protective package. Take extreme caution to not force the scavenge tube
6. Apply a small amount of lubricant to the filter seal. into the tank. This could potentially damage the
Screw the new filter down until the seal makes separator element.
contact with the housing, then hand tighten a further
half turn. 8. Install the piping in the original position.
7. Start the compressor and check for leaks.
EN-6 47612267 Rev B

EN
Figure 3: Recommended Bolt Tightening Cross Pattern CHECKING MINIMUM PRESSURE CHECK VALVE
(MPCV)
The minimum pressure check valve (MPCV) shall be
frequently tested and regularly maintained. Remove it
from the compressor for testing. If operating conditions are
particularly severe, the frequency of testing and maintenance
shall be increased accordingly. The user shall establish the
frequency of such tests as it is influenced by such factors as
the severity of the operating environment including, but not
limited to, cycles.
9. Start the compressor and check for leaks. The minimum pressure check valve (MPCV) should be
tested and re-calibrated in accordance with any national or
NOTICE local codes that may exist. If no code exists, Ingersoll Rand
recommends that the valve is recalibrated at intervals of one
Do not use any form of sealant on either the separator year by a licensed contractor or qualified service personnel.
tank or the separator tank cover faces.
CHANGING AIR FILTER
INSPECTING SEPARATOR TANK / PRESSURE SYSTEM 1. Check the retaining cap for dirt and debris and wipe
clean.
Inspect the external surfaces of the airend and separator
tank, including all fittings, for visible signs of impact damage, 2. Unclip the retaining cap and withdraw the old
excessive corrosion and abrasions. When changing the element.
separator element, inspect the internal components and 3. Fit the new element and refit the retaining cap.
surfaces. Any suspect parts shall be replaced before the
compressor is put back into service. REGREASING MOTOR
The separator tank should also be tested and inspected in The blower motor contains pre-greased, sealed bearings.
accordance with any national or local codes that may exist. They cannot be re-greased and do not require re-greasing.
CLEANING / CHECKING SCAVENGE SCREEN Motor bearings - Clean the area around the inlet and outlet
plugs before removing the plugs. Add the specified quantity
The screen/orifice assemblies are similar in appearance to a of recommended grease using a hand lever gun. Replace the
straight tubing connector and will be located between 0.25 inlet plug, run the machine for 10 minutes and then replace
inch hose and 6mm (0.25 in) O.D. scavenge line tubing. the outlet plug
The main body is made from 19 mm hexagon shaped metal NOTICE
and the diameter of the orifice and a direction-of-flow arrow
is stamped in flat areas of the hexagon. Read the motor data plate(s). For motors that require
A removable screen and orifice will require clearing as greasing, grease them more frequently in harsh
outlined in the maintenance chart. environments or higher ambient conditions.
To remove the screen/orifice:

CLEANING AIR COOLED COOLING SYSTEM
1. Disconnect the scavenge line tubing from each end.
Air compressor operating temperatures will be higher than
2. Hold the center section firmly and use a pair of pliers normal if the external passages between the fins of the
to gently grasp the exit end of the assembly that seals cooler cores become restricted with foreign material. Regular
against the scavenge line tubing. The exit end is the cleaning of the cooler surfaces will support the reliable
end toward which the arrow is pointing. operation of the air compressor system, improve the life of
the compressor coolant and improve overall compressor
3. Pull the end out of the center section while using care
efficiency. When performed frequently as determined by
to prevent damage to the screen or sealing surfaces.
site conditions and airborne contamination, more significant
4. Clean and inspect all parts prior to reinstallation. cleaning or replacement may not be necessary.
5. When the assembly is installed, confirm the 1. Stop the compressor.
direction of flow to be correct. Observe the small
2. Isolate the compressor from the system.
arrow stamped in the center section and ensure the
direction flow to be from the separator tank to the 3. Press the emergency stop. Fixed speed compressors
airend. can take more than two minutes to fully de-pressurize
once stopped.
4. Ensure that the main power disconnect switch is
locked off and tagged.
47612267 Rev B EN-7

EN
6. Carefully place the cooler on its proper location and

NOTICE install mounting hardware. Fully tighten nut against
For any required lifting of air compressor parts or bolt shoulder.
required tools, always use the proper certified lifting 7. Re-attach all hoses and pipes and properly torque
equipment, and employ sound working principles. according part information manual
8. Refill the compressor coolant to proper level,
5. Visually check the outside of the cooler cores to following the process outlined in the “Adding Coolant”
determine the appropriate cleaning method detailed procedure.
as follows:
CLEANING WATER COOLED COOLER (FOR BOTH
a. For loose dirt, dust and other light foreign material, CLEAN & HARSH WATER OPTIONS)
open the access panel on the cooler plenum. Gently
blow compressed air across the cooler surface. A periodic inspection and maintenance program should
Repeat the process until the coolers are sufficiently be implemented for water cooled heat exchangers. It is
clean. Replace the access panels before returning the recommended that you contact Ingersoll Rand for cleaning
compressor to service. services should you not have experience and equipment to
do this work.
b. For thick, packed dirt, coolant or grease, or other
heavy material, the coolers will need to be removed If water inlet lines have strainers, inspect them and replace or
from the compressor for pressure washing. Ingersoll clean as required.
Rand does NOT support pressure washing coolers Mineral scale may be removed with a suitable de-scaling
when they are installed in the compressor due to agent containing amidosulphuric acid + citric acid and
the dangers of spraying water in or around potential Neutralit solutions for cleaning the coolers. As an alternative,
electrical power sources. Follow the steps below for any weak acid mixed with water in the ratio of 1:4 may be
cooler removal. used.
REMOVING / INSTALLING AIR COOLED COOLER Fouling should be removed with a suitable detergent in hot
To remove: water.
1. Stop the compressor. Back flush the cooler with a flow rate at least 1.5 times the
normal flow rate.
After using any cleaning solution, thoroughly flush out all
3. Press the emergency stop. Fixed speed compressors chemicals with clean water before returning the cooler to
can take more than two minutes to fully de-pressurize service.
once stopped.
Mechanical cleaning methods are not recommended as
4. Ensure that the main power disconnect switch is damage to the internal passages may occur.
After cleaning, examine the cooler for erosion or corrosion.
5. Drain the coolant from the coolant cooler.
CLEANING MOTOR COWL
6. Remove all hoses, pipes, and sensors from the coolers.
1. Ensure the compressor is electrically isolated
7. Remove the external sheet metal panels. for at least 15 minutes before commencing any
8. Remove cooler mounting connection at both sides maintenance work.
of the cooler. (support cooler with appropriate lifting 2. Remove the panels from the compressor.
provision prior to removing mounting connection).
3. Using a clean dry cloth, remove dust from the surface
9. Remove cooler out from mounting connection. of the motor cowl and ensure all ventilation slots are
To install: free of obstructions.
1. Stop the compressor. 4. Replace the panels.
3. Press the emergency stop. Compressors can take
more than two minutes to fully de-pressurize once
stopped.
4. Ensure that the main power disconnect switch is
5. Install cooler mounting connection at both sides of
cooling sheet metal plenum and keep it loosen.
EN-8 47612267 Rev B

EN
CLEANING/ CHECKING CONDENSATE DRAIN (WHERE CHECKING / CLEANING NO LOSS DRAIN TRAP (WHERE
FITTED) FITTED)
1. Ensure the compressor is electrically isolated It is recommended to check the no loss drain trap daily
for at least 15 minutes, before commencing any to ensure that condensate is draining from the moisture
maintenance work. separator system. To check for correct function:
2. Isolate the compressor from the system and fully 1. Press the test button on the drain and listen for
discharge the compressed air within the compressor. condensate / air passing through the drain.
3. Disconnect cable plug and tubing. Then remove 2. If the drain is clogged, replace the no loss drain valve
Condensate Drain Valve assembly from base. service module. The service module consists of the
lower portion of the drain trap and is not serviceable.
4. Slowly remove the plug from the strainer with a
suitable tool, ensuring pressure has been completely Additionally, it is recommended to replace the service module
released from valve. every 8000 hours or once per year, whichever comes first.
5. Remove the stainless steel filter screen and clean it. MONITORING FLUID AND PERFORMING SHOCK
Remove any debris that may be in the strainer body PULSE BEARING ANALYSIS
before replacing the filter screen.
Ingersoll Rand recommends incorporating predictive
6. Replace plug and tighten with suitable tool. maintenance, specifically the use of coolant and shock pulse
bearing analysis, into all preventative maintenance programs.
7. Reinstall Condensate Drain Valve assembly, and
Contact Ingersoll Rand for details.
reconnect cable plug and tubing.
8. Confirm Condensate Drain Valve is functioning
properly and check for leaks.
CLEANING / INSTALING PACKAGE PRE-FILTER
(COOLING SUCTION)
1. Unlatch the two 1/4 turn latches and open the intake
panel (panel is hinged)
2. Remove the nuts and flat washer.
3. Remove the filter grill.
4. Pull out the filter element.
5. Center the new element over the package intake
opening. Also note that the filter is washable with
mild detergent.
6. Push the filter over the grill studs so that the studs
poke through the filter media.
7. Install the filter grill.
8. Install the nuts and flat washers.
9. Close the intake panel and latch.
47612267 Rev B EN-9

EN
TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by
thorough inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart
below provides a brief guide to common symptoms, probable causes and remedies.
Table 3: General Faults
SYMPTOM CAUSE REMEDY
Compressor will not start. No power supply to compressor. Check supply is switched on. If so, contact a
qualified electrician.
Controller failure. Check supply to controller. Replace controller.
Starter failure. Isolate supply, lock off and tag. Replace failed
component or contact your local Ingersoll
Rand representative.
Compressor stops and will not Controller has tripped the compressor. See Table 4
restart.
Maximum number of starts per hour See Table 4
exceeded.
Compressor is stopped and Controller has tripped the compressor and See Table 4
will not restart. has not been reset.
Emergency stop has been pressed and not Identify reason why, repair fault, disengage
released. button and reset controller.
Emergency stop has been pressed and Repair fault and reset controller.
released but controller has not been reset.
Compressor will not meet Compressor not sized to meet system Contact your local Ingersoll Rand
pressure required by system. requirements or requirements have been representative.
changed.
Air loss due to pipe, hose, joint or seal Repair or replace.
failure.
Air loss due to blowdown valve stuck Repair or replace.
open.
Air loss through pressure relief valve not Repair or replace.
seating or set incorrectly.
Air loss due to moisture separator drain Repair or replace.
trap stuck open.
Controller fault. Repair or replace.
Pressure transducer faulty, incorrectly Recalibrate or replace.
calibrated or EMF interference.
Incorrect controller settings. Check and modify settings.
Inlet grill or ducting is blocked. Check and clean.
Air filter dirty or collapsed. Replace.
Compressor will not meet Inlet valve not opening fully. Repair or replace.
pressure required by system.
Separator element dirty or collapsed. Replace.
Pipe / Hoses blocked or collapsed. Clean or replace.
Cooler core blocked. Clean or replace.
Minimum pressure check valve not Repair or replace.
functioning correctly.
Equipment between compressor and Review system requirements.
customer measuring point causing
pressure drop / pressure loss.
Pressure produced by Controller set incorrectly. Check and modify settings.
compressor is too high due Pressure transducer may be faulty, Recalibrate or replace.
to speed not reducing as incorrectly calibrated or not receiving
demand reduces. pressure signal.
Drive settings fault. Contact your local Ingersoll Rand
representative.
EN-10 47612267 Rev B

EN

Compressor discharge air too High ambient temperature. Review installation and system parameters.
hot. Insufficient cooling air. Check ducting and cooling air path, check
direction of blower rotation.
Dirty, blocked aftercooler (cooling air side). Clean or replace.
Table 3: General Faults (cont.)

Compressor package Panels or doors are not closed properly. Rectify fault.
produces excessive noise. Air leaks from internal pipework / Repair or replace.
components.
Blower or blower motor bearings worn. Repair or replace.
Loose debris impacting on blower during Remove and rectify any damage.
rotation.
Blowdown valve stuck open. Repair or replace.
Pressure relief valve not seating correctly. Repair or replace.
Vibration due to motor, airend or blower Repair or replace.
imbalance.
Airend requires repair. Contact your local Ingersoll Rand
representative.
Discharge air is contaminated Scavenge pipe is blocked, broken or o-ring Clean or replace.
with coolant. is not sealing.
Separator element is punctured, or Replace.
incorrect, or requires changing, or not
sealing correctly.
Incorrect coolant has been added. Drain system, check for damage. Clean, refill
with correct coolant.
System has been overfilled with coolant. Check for damage, drain excess.
Discharge air is contaminated Aftercooler not functioning correctly. Clean or replace.
with condensate.
Moisture separator drain trap faulty. Repair or replace.
Continuous low speed / low ambient Review system requirements and contact your
operation causing condensate build up. local Ingersoll Rand representative.
Compressor package draws Compressor operating above rated Check and modify settings. Review system
too much current. pressure. requirements and contact your local Ingersoll
Rand representative.
Separator filter element dirty or blocked. Replace.
Voltage supply is low or unbalanced. Contact your local Ingersoll Rand
representative or a qualified electrician.
Airend is damaged. Contact your local Ingersoll Rand
representative.
Excessive coolant Coolant system leak. Repair or replace.
consumption.
See also ‘discharge air is contaminated See above.
with coolant’.
Solenoid condensate valve Debris in solenoid valve prevents Remove solenoid valve, disassemble, clean
will not close diaphragm from seating. and reassemble.
Short in electrical component. Check and replace power cord or timer as
needed.
47612267 Rev B EN-11

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Table 4: Controller Faults (indicated on the controller)

FAULT CAUSE REMEDY
Emergency stop. Emergency stop button has Identify reason why, repair fault, disengage button and
been pressed. reset controller.
Blower motor overload. Blower is blocked, damaged or Remove blockage, repair or replace damaged
blower motor is faulty. components.
High airend discharge Compressor operating above Check and modify settings. Review system requirements
temperature. rated pressure. and contact your local Ingersoll Rand representative.
Low coolant level. Check for leaks. See also ‘discharge air is contaminated
with coolant’. Top up coolant.
High ambient temperature. Review installation and system parameters.
Insufficient cooling air. Check ducting and cooling air path.
Dirty, blocked coolant cooler Clean or replace.
(cooling air side).
Blower motor direction of Wire correctly.
rotation incorrect.
Check setpoints. Controller software has been Recalibrate all sensors and check setpoints.
changed.
Remote start failure. Remote start button is pressed Check operation of buttons or operating procedures.
after compressor is running or
remote start button remains
closed.
Remote stop failure. Remote stop button remains Check operation of buttons or operating procedures.
open and either start button is
pressed.
Sensor failure. Sensor is missing or faulty. Install, repair or replace faulty sensor.
Compressor trips indicating Insufficient cooling taking place. If compressor is watercooled or sea watercooled, check
a high compressor that the cooling water is flowing. Check that there is no
temperature. air in the water cooling system. Check that the strainer is
not blocked.
Controller has tripped the A fault has occurred. Repair fault / reset controller.
compressor.
Invalid calibration. Calibration done with pressure Depressurize and re calibrate with pressure pipe to
in compressor. sensor disconnected. If fault still exists, replace pressure
transducer.
Low sump pressure. System leak. Located and repair.
Minimum pressure check valve Repair with service kit.
faulty.
Blowdown valve faulty. Repair with service kit.
Loss of control power. Check 110V circuit breaker.
Check wiring.
Check contactor KM1.
Check motor rotation. Drive system fault. Contact your local Ingersoll Rand representative.
Change separator element Faulty pressure transducer Calibrate and validate the wet sump and package
and/or high sump pressure. measurement. discharge transducers.
Moisture separator condensate Ensure condensate drain system is functioning
drain trap faulty. properly, and condensate is being drained. See Table 4:
Troubleshooting Chart.
Separator element dirty or Change separator element.
blocked.
Machine stops but no alarm Loss of outputs of control power. Check controller outputs (110V AC) power supply (fuses/
message mini circuit breaker).
Motor current fault Loss of control power. Check control power circuit and breaker.
Sump pressure too high. Check separator element pressure drop.
Faulty motor or Airend. Contact your local Ingersoll Rand representative.
EN-12 47612267 Rev B

EN
INTEGRATED DRYER MAINTENANCE

TESTING CONDENSATE DRAINS (NO-LOSS DRAINS
WARNING
ONLY)
Before accessing live electrical parts, disconnect the Press the TEST button to confirm proper function.
power supply to the dryer using the disconnect switch
or disconnecting the cable connections. TROUBLESHOOTING CONDENSATE DRAINS
(ELECTRONIC DRAINS ONLY)
MAINTENANCE CHART This section provides basic troubleshooting information.
For optimum performance from your dryer, follow the Determination of specific causes to problems are best
periodic maintenance schedule described below. identified by thorough inspections performed by personnel
instructed in safety, operation and maintenance of this
Table 5: Maintenance Chart
equipment. The chart below provides a brief guide to
WEEKLY CONDENSATE DRAINS (TIMED AND NO- common symptoms, probable causes and remedies.
LOSS DRAINS) Table 6: Condensate Drain Troubleshooting Chart
Verify that the condensate drains are TROUBLE CAUSE ACTION
operating correctly by pressing the TEST
Solenoid Debris in solenoid Remove solenoid
button. condensate valve prevents valve, disassemble,
EVERY 4 CONDENSER valve will not diaphragm from clean and
MONTHS close. seating. reassemble.
Remove any dust from the condenser
Short in electrical Check and replace
fins. component. power cord or timer
EVERY 6 AIR FILTER as needed.
MONTHS
Replace air filter element.
DISASSEMBLING THE INTEGRATED DRYER
YEARLY (TIMED DRAINS ONLY)
NOTICE
Completely disassemble the drains and
clean all their components. The dryer shall be disassembled, charged or repaired by
a refrigerant specialist.
CLEANING CONDENSATE DRAINS (TIMED DRAINS
ONLY) Refrigerant liquid and lubricating oil inside the
refrigeration circuit shall be recovered in compliance
Periodically clean the screen inside the valve to keep the drain
with current norms in the country where the dryer is
functioning at maximum capacity. To do this, perform the
installed.
following steps:
1. Close the strainer ball valve completely to isolate it NOTICE
from the air receiver tank.
Refrigerant leaks may be identified by tripping of the
2. Press the TEST button on the timer to vent the refrigeration overload protector.
pressure remaining in the valve. Repeat until all
pressure is removed. If a leak is detected in the refrigerant circuit, seek
technical assistance.
WARNING If a refrigerant leak occurs, thoroughly air the room
High pressure air can cause injury from flying debris. before commencing work.
Ensure the strainer ball valve is completely closed and
pressure is released from the valve prior to cleaning. NOTICE
In normal temperature and pressure conditions, the

3. Remove the plug from the strainer with a suitable R134a refrigerant is a colorless, class A1/A1 gas with
wrench. If you hear air escaping from the cleaning TVL value of 1000 ppm (ASHRAE classification).
port, STOP IMMEDIATELY and repeat steps 1 and 2.
4. Remove the stainless steel filter screen and clean it.
Remove any debris that may be in the strainer body
before replacing the filter screen.
5. Replace plug and tighten with wrench.
6. When putting the valve back into service, press the
TEST button to confirm proper function.
47612267 Rev B EN-13

EN
DECOMMISSIONING THE INTEGRATED DRYER

Decommission the dryer and the relevant packaging in compliance with the rules locally in force.
Pay particular attention to the refrigerant, as it contains part of the refrigerating compressor lubricating oil.
Contact a waste disposal and recycling utility.
Table 7: Integrated Dryer Materials of Construction
RECYCLING DISASSEMBLY
Frame and panels Steel / epoxy resin polyester
Heat exchanger (cooler) Stainless steel / aluminum
Pipes Copper
Insulation Gum synthetic
Compressor Steel / copper / aluminum
/ oil
Condenser Aluminum
Refrigerant R134a
Valve Steel
EN-14 47612267 Rev B

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Product Maintenance Information: Contact-Cooled Rotary Screw Air Compressor

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Product Maintenance Information: Contact-Cooled Rotary Screw Air Compressor

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Contact-Cooled Rotary Screw Air Compressor