Ingersoll-Rand SSR-EP20 Air Compressor Manual

XF 20/25/30
EP 20/25/30
HP 20/25/30
HXP 20/25
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 DATA and should be kept with the air compressor at all times.
More Than Air. Answers.

Online answers: http://www.air.ingersoll-rand.com
APDD 739B
July 2001
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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
Companys 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 Companys proposal. Unless responsibility for meeting such performance warranties are limited to specified tests, the Companys obligation shall be to correct in the manner and for
the period of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based
on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such
Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company
in writing of its intention to do so. Any such use of Equipment will be at Purchasers sole risk and liability.
Limitation of 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.
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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.
INGERSOLL-RAND COMPANY
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
1
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 (OPTIONAL)
4.1 emergency stop switch
4.2 power indicator light
4.3 push buttons
4.4 setpoint procedure
4.5 warnings
4.6 alarms
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
inlet air filter element

coolant filter
coolant change
coolant hoses
airend discharge hose
coolant separator filter element
separator tank scavenge
check valve/orifice
cooler cores
motor lubrication
Intellisys controller (optional) removal
receiver tank drain trap inspection/cleaning
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 SERVICE AND OPTIONS KITS
10.0 MAINTENANCE RECORD
GENERAL INFORMATION
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 replacement
5.7 belt tension
5.8 belt tension gas spring replacement
5.9 shaft seal replacement
Cooling Air Flow:

20/25 HP: 1710 cfm (2905m3/hr.)
30 HP: 2060 cfm (3500m3/hr.)
Ambient Temperature Limit: 35F to 115F (2C to 46C)
Coolant:
Factory Filled ULTRA COOLANT
Coolant Change: 8,000 hours or two years, whichever comes
first, when using ULTRA COOLANT
Coolant Capacity:
3.2 GAL (12L)
Discharge Temperature Limit:
228F (109C)
Tools: U.S. Standard and metric are required to perform
maintenance
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.
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:
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.
D! DANGER
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
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
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
Notice is used to notify people of installation, operation, or maintenance information

which is important but not hazard-related.
0.2 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
COMPRESSOR OR PERFORMING ANY MAINTENANCE
WARNING
COMPRESSED AIR AND ELECTRICITY
ARE DANGEROUS.
BEFORE DOING ANY WORK ON THIS
UNIT, BE SURE THE ELECTRICAL SUPPLY HAS BEEN CUT OFFLOCKED &
TAGGED AND THE ENTIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF
ALL PRESSURE.
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.
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.
4. Use only safety solvent for cleaning

the compressor and auxiliary equipment.
Air line separators, properly selected

and installed, will minimize any liquid
carry-over.
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.
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).
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.
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.
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.
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.
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.
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.
7. Before doing any mechanical work on

the compressor:
a.) Shut the unit down.
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.
SAFETY SHUTDOWN
CHECK HIGH AIR TEMPERATURE
There is a high discharge air temperature shutdown function built into each compressor. It is factory preset at 228F (109C). 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.
WARNING
Failure to adhere to these recommendations can result in mechanical failure, property damage and serious
injury or death.
All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must take into account vibration, pulsations, temperature, maximum pressure applied, corrosion
and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some
oil into the air stream; therefore, compatibility between discharge piping, system accessories and software
must be assured.
For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge
piping is not recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the operating parameters of the system.
It is the responsibility of the installer and owner to provide the appropriate service pipework to and from
the machine.
WARNING
Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications.
Ingersoll-Rand does not approve specialized equipment for breathing air application and assumes no
responsibility or liability for compressors used for breathing air services.
0.3 DECALS
This section contains representative examples of
decals which will be appearing throughout this manual
and are applied to the compressor unit.
If for some reason a decal is defaced, parts are

replaced or painted over, we recommend that you
obtain a replacement.
39264734
REV A
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.
CAUTION
Incorrect lifting of
machine can cause injury
or property damage.
Lift only from base
channels.
INGERSOLLrAND
INGERSOLLrAND
39540158
DANGER
Discharge air.
Can contain carbon monoxide or
other contaminants. Will cause
Do not breathe this air.
INGERSOLLrAND
39540232
High pressure air.

Can cause severe injury or death.
Relieve pressure before removing filter
plugs / caps, fittings or covers.
INGERSOLLrAND
39540166*
WARNING
39540240
WARNING
NOTICE
Air discharge.
INGERSOLLrAND
Hazardous voltage. Can cause
39540257*
Disconnect power before servicing.

Lockout/Tagout machine.
INGERSOLLrAND
39540174
CAUTION
Use of incorrect coolant can cause

system contamination.
Use only SSR ULTRA COOLANT.
INGERSOLLrAND
WARNING
39540265
NOTICE
Exposed fan blade. Can cause severe
injury.
Do not operate with covers removed.
Disconnect power. Lock and tag.
INGERSOLLrAND
Lift here.
INGERSOLLrAND
39540273
3954190
* - THESE DECALS ARE LOCATED ON THE END OF THE RECEIVER TANK ON TANK MOUNTED UNITS
10
WARNING
! WARNING
15
Exposed moving belts and sheaves.

Hot surface.
Can cause severe injury.
Do not touch. Allow to cool before

servicing.
Do not operate with guards removed.

Disconnect power, lock and tag out
machine before servicing.
39859236
INGERSOLLrAND
39541362
11
NOTICE
Filler Cap.
Use only recommended
coolant.
Read instruction book
before servicing.
39543921
39540281
12
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
39544143
13
39859236
INGERSOLLrAND
NOTICE
NOTICE
Before installing, operating, or
performing any maintenance on
this unit, read and understand
the instructions in the
Operators/Instruction Manual.
16
Before Starting
1. Check coolant level and add
coolant if necessary.
2. Verify that main isolation
valve is open.
3. Close main disconnect switch.
Starting
1. Push START button. Compressor
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
Rotation.
INGERSOLLrAND
39544150
14
Rotation
17
Rotation
54372719
39557095
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 mans signed agreement to any noted damages will facilitate any future insurance claims.
IMPORTANT
READ THIS
LOST OR DAMAGED GOODS
THOROUGHLY INSPECT THIS SHIPMENT
IMMEDIATELY UPON ARRIVAL
OUR RESPONSIBILITY FOR THIS SHIPMENT
CEASED WHEN THE CARRIER SIGNED
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, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE
MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THE
WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE
FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL.
THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR
RESPONSIBILITY.
Ingersoll-Rand Company
Davidson, North Carolina
APDDGFO-99-79
1.2 UNPACKING AND HANDLING

The compressor package has been mounted on a base
which provides for forklifting between the two side channels to facilitate handling during shipment. Care in positioning the forklifts is important because the location of
the center of gravity is strongly affected by the location of
the compression module and drive motor.
Slings can be used to lift the crates, but spreader bars
must be used to prevent the slings from exerting a force
against the sides of the crates.
1.3 TOOLS
Remove compressor unit from wooden skid. A crowbar
and hammer will be needed.
8
FORKLIFT PADDING
WILL REDUCE SCRATCHES
AND MARS
SPREADER
BARS
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. A room 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 door.
Ambient temperatures higher than 115F (46C)
should be avoided as well as areas of high humidity.
Consider also the environment surrounding or near
the compressor. The area selected for the location of
the compressor should be free of dust, chemicals,
metal filings, paint fumes and overspray.
DUST
CHEMICALS
METAL
FILINGS
PAINT
SPRAY
36
(.9 m)
36 (.9 m)
42 (1.06 m) OR
CODE MINIMUM
AIR INTAKE
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.
! WARNING
Do not use plastic pipe, soldered copper
fittings or rubber hose for discharge piping.
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, tank mounted compressors
with built-in aftercoolers are furnished with a combination
condensate separator/trap.
9
2.3 PIPING (Continued)

A dripleg assembly and isolation valve should be mounted near the compressor discharge. A drain line should be
connected to the condensate drain in the base.
ISOLATION
VAVLE
IMPORTANT: 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.
DRIP LEG
DISCHARGE PIPING WITH AFTERCOOLER

SAFETY
VALVE
IMPORTANT: Discharge piping should be at least as

large as the discharge connection at the compressor
enclosure. All piping and fittings must be suitable for the
maximum operating temperature of the unit and, at a
minimum, rated for the same pressure as the compressor
sump tank.
NOTICE
ISOLATION
VALVE
SAFETY
VALVE
PRESSURE
GAUGE
RECIPROCATING
COMPRESSOR
DRIP
LEG
TRAP
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.
MOISTURE
SEPARATOR/
DRAIN TRAP
ISOLATION
VALVE
STRAINER
ISOLATION
VALVE
NOTE:
SEPARATE LINES
GOING TO THE
RECEIVER
ROTARYROTARY
COMPRESSOR
COMPRESSOR
DRIP
LEG
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.
MOISTURE
SEPARATOR/
DRAIN TRAP
ROTARY-RECIP IN PARALLEL
200
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.
160
Gallons of Water/24
hours/1000 acfm
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.
120
80
40
DEW POINT
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.
without
Aftercooling
100F/38C
(with
Aftercooler)
35F /1.7C
(Refrigerated
Dryer)
-40F/-40C
(Desiccant
Dryer)
MOISTURE CONTENT OF COMPRESSED AIR

10
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 33F (1C) to
39F (4C) are adequate. Desiccant dryers are required
where pressure dew points must be below 33F (1C).
SAFETY
VALVE
PRESSURE
GAUGE
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.
MOISTURE
SEPARATOR/
DRAIN TRAP
TRAP
STRAINER
Before proceeding further, we recommend that you

review the safety data in the front of this manual.
ROTARY
COMPRESSOR
DRIP
LEG
When two rotary units are operated in parallel, provide an

isolation valve and drain trap for each compressor before
the common receiver.
2.4 ELECTRICAL INSTALLATION
ISOLATION
VALVE
ISOLATION
VALVE
ROTARY
COMPRESSOR
ISOLATION
VALVE
MOISTURE
SEPARATOR/
DRAIN TRAP
DRIP
LEG
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.
ROTARY TWO COMPRESSOR SYSTEM
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.
11
2.5 VOLTAGE CONVERSION (230V TO 460V)

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 compressor data
plate and motor nameplate must indicate multiple voltages.
LINE VOLTS
200
HZ
60
LINE
H4-H5
SEC VOLTS
120
LINE
X1-X2
REFERENCE
Quad Type
220/230
50/60
H1-H2
110-120
X1-X4
Universal Type
380
50/60
H1-H3
110-120
X1-X4
Universal Type
415
50
H1-H3
110-120
X1-X4
Universal Type
440/460
50/60
H1-H4
110-120
X1-X4
Universal Type
550/575
60
H1-H5
110-120
X1-X4
Universal Type
*TYPICAL CONTROL TRANSFORMER

(ELECTRO - PNEUMATIC)
LINE VOLTS
200
HZ
60
LINE
H4-H5
SEC VOLTS
120
8
8
LINE
X1-X2
X3-X4
X4-X5
220/230
60
H3-H5
120
8
8
X1-X2
X3-X4
X4-X5
380
60
H3-H5
120
8
8
X1-X2
X3-X4
X4-X5
440/460
60
H2-H5
120
8
8
X1-X2
X3-X4
X4-X5
575
60
H1-H5
120
8
8
X1-X2
X3-X4
X4-X5
LINE VOLTS
HZ
LINE
SEC VOLTS
LINE
220
50
H5-H6
110
8
8
X1-X2
X3-X4
X4-X5
380
50
H4-H6
110
8
8
X1-X2
X3-X4
X4-X5
415
50
H2-H6
110
8
8
X1-X2
X3-X4
X4-X5
110
8
8
X1-X2
X3-X4
X4-X5
550
50
H1-H6
HIGH
VOLTAGE
PRIMARY
SIDE
LOW
VOLTAGE
SECONDARY
SIDE
QUAD TYPE TRANSFORMER (200V/60 HZ)

HIGH
VOLTAGE
PRIMARY
SIDE
LOW
VOLTAGE
SECONDARY
SIDE
UNIVERSAL TYPE TRANSFORMER

(ALL VOLTAGES EXCEPT 200V/60 HZ)
*TYPICAL 60 HZ
CONTROL TRANSFORMER
(INTELLISYS OPTION)
H4
110V
*TYPICAL 50 HZ
CONTROL TRANSFORMER
(INTELLISYS OPTION)
FIGURE 2.5-1 TYPICAL CONTROL TRANSFORMER WIRING

12
H5
H6
FIGURE 2.5-2 FAN WIRING DIAGRAM
13
Procedure:
Put main disconnect in the OFF position, lock and tag
(See Figure 2.5-3).
2.6 ROTATION CHECK

Locate the rotation decals on the motor and fan (s) and
check for correct rotation. The correct motor rotation
when viewed from the non-drive end of the motor is
clockwise (See Figure 2.6-1).
! CAUTION
DANGER
HIGH VOLTAGE
HASP
If the compressor is operated in the

opposite direction of rotation, airend damage
can result and is not warrantable.
LEVER
TAG
GER
DAN
KEY LOCK
For the compressor motor and fan rotation check, the

motors should be jogged for as short a time as possible.
1. Ensure that the Emergency Stop button is in the
open (depressed) position.
FIGURE 2.5-3 MAIN DISCONNECT

LOCKED AND TAGGED
Open the motor junctoion box on the side of the motor.
Reconnect the motor to the desired voltage. Use the
connection diagram proviced on the motor as a guide.
Adjust motor overload setting as outlined below in
Figure 2.5.4.
NOTICE
IEC STARTER OVERLOAD SETTING
1. Full-Voltage Starter (Main or Fan Motor):
Multiply MOTOR nameplate amps by 1.11.
Star-Delta Starter (Main motors only):
Multiply MOTOR nameplate amps by 0.64.
2. Set corresponding overload relay at this value.
2. Verify that coolant level is in the middle (green)

range of the sight tube.
3. Verify that the main isolation valve is open.
4. Open the enclosure canopy if machine is so
equipped. Disengage Emergency Stop button by turning pushbutton clockwise. 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).
CAUTION: 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.
3. Never exceed the following limits:

Full-Voltage Starter: 125% of MOTOR nameplate amps.
Star-Delta Starter: 72% of MOTOR nameplate amps.
FIGURE 2.5-4 MOTOR OVERLOAD SETTING

Reconnect the promary side of the control transformer
for the desired voltage, as shown on the control transformer wiring decal.
Reconnect the fan motor (s) wiring to the desired voltage (See fan wiring diagram Figure 2.5-2).
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.
14
5. 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 fan(s) should be in accordance with the
direction arrow adjacent to each fan. (See Figures 2.62 and 2.6-3.
6. 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 component that is rotating incorrectly. Close the control box cover. Recheck
for correct rotation.
DRIVE
END
NON-DRIVE
END
FIGURE 2.6-1 DRIVE MOTOR ROTATION

CORRECT ROTATION
FIGURE 2.6-2 MAIN FAN (ALL MODELS)
CORRECT ROTATION
FIGURE 2.6-3 AUXILIARY FAN (S) (25, 30 HP ONLY)
2.7 BEFORE STARTING - STARTING - STOPPING
Starting
Read and understand the following instructions

before operating or performing any maintenance
on this unit
1. Push the Unloaded Stop/Reset button (red fault indicator light will go out).
Before Starting:
2. Push the Start button and release. The compressor

will start and then load automatically if line pressure is
below the lower set point of the pressure switch.
1. Ensure that Emergency Stop push button is in the

OFF (depressed) position (See Figure 2.7-1).
Stopping
2. Verify that coolant level is in the middle (green)
range in the sight tube.
3. Close the main disconnect switch (ON position).
1. Depress the Unloaded Stop/Reset button.

Compressor will unload for approximately 7 seconds
and then stop.
4. Verify that the main isolation valve is open.
2. Open the main disconnect switch (OFF position).
15
EMERGENCY
CONTROL
STOP
PANEL
BUTTON
HOUR
METER
AUTO
UNLOADED POWER ON
STOP/RESET INDICATOR RESTART
INDICATOR
BUTTON
LIGHT
LIGHT
START
BUTTON
PRESSURE
GAUGE
FAULT/
ALARM
INDICATOR
LIGHT
TEMP.
GAUGE
FIGURE 2.7-1 STANDARD CONTROL PANEL
If a standard machine is to be installed outside, the

ambient temperature must never drop below 35F
(1.7C).
Arrange the machine with the Control Panel facing

away from the sun as radiant heat can affect 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 drain must never be allowed to drain 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 connectors 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 door.
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 airborne 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.
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.
16
CONTROL
PANEL FACING
AWAY FROM
SUN
17
FIGURE 2.8-1 TYPICAL OUTDOOR SHELTERED INSTALLATION
3.0 SYSTEMS
(tank mounted unit only).
3.1 GENERAL SYSTEM INFORMATION
A moisture separator and automatic drain trap

assembly is available through your Ingersoll-Rand
Representative.
The compressor is an electric motor driven, single

stage, rotary screw compressor, complete with supporting components to make a fully functional unit. A standard 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 35F to 115F (1.7C to 46C).
When conditions other than design levels described
are encountered, we recommend you contact your
nearest Ingersoll-Rand representative for additional
information.
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 control valve, 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, 228F (109C). Effective coolant filtration is provided by the use of a screw on, heavy
duty coolant filter.
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 amounts used for lubrication and sealing.
The standard maximum temperature 115F (46C)

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.
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.
Coolant Cooler
Circulation of Coolant
The cooler is an integral assembly of core, fan and

fan-motor, mounted in the compressor. The cooling
air flows in through the front of the enclosure, through
the vertically mounted cooler core, and discharges
upward and downward through the rear sound box.
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.
Aftercooler
The compressed air aftercooling system consists of a
heat exchanger (located at the cooling air discharge
of the machine) and an automatic drain trap
18
Before being injected into the airend, all coolant flows

through the coolant filter. It is 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 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.
Coolant/Air Separation System

The coolant/air separation system is composed of a
separator tank with specially designed internals and a
coaslescing type separator element located inside the
tank.
The air-coolant mixture discharges from the airend into
the separator tank. The majority of coolant is separated while in the separator tank and the coalescing separator filter element is used for final cleaning of the air
prior to the customers 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 valve
Airend (rotors)
Coolant/Air separator
Minimum pressure check valve (MPCV)
Aftercooler
Moisture separator/drain trap (remote mounted)
The direction of flow is from the inlet filter to the aftercooler. Refer to process 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 operation. 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 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 control as standard, or with the
micro-processor based Intellisys controller as an
option.
The standard electrical/electronic components are
enclosed in a readily accessible enclosure and
include:
1. Push button controls w/analog gauges
2. Indicator lights
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. Refer to the electrical schematic,
Section 8.0 schematic 8.1 (Standard control) or 8.3
(Intellisys option).
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. Refer
to the electrical schematic, Section 8.0 schematic 8.2
(Standard control) or 8.4 (Intellisys option).
The standard machine is equipped with a red shutdown alarm indicator. This indicator will illuminate upon
machine shutdown as a result of main motor overload,
high discharge air temperature, or emergency stop
activation.
Options such as remote start/stop or power outage
restart can be added.
The separator tank removes most of the coolant from

the air.
The separator element performs the final separation of
19
3.6 CAPACITY CONTROL
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.
The SSR compressor is supplied with on-line/off-line

with automatic start/stop control 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.
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).
On-Line/Off-Line With Automatic Start/Stop

Control (Electro-Pneumatic Control)
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).
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.
CAUTION:
DO NOT EXCEED MAXIMUM DISCHARGE PRESSURE (LOCATED ON COMPRESSOR DATA
PLATE)
When the compressor starts and line pressure is

below the lower setting of the line pressure switch,
control solenoid 1SV will be energized (closed), inlet
valve will open, and the compressor will load. When
the line pressure reaches the upper setting of the
pressure switch, the compressor will unload by deenergizing (closing) 1SV and closing the inlet valve.
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 on the pressure switch.
Adjusting the Auto Restart timer below the 10
minute factory setting may shorten the life of the
compressor drive motor.
5. Turn power back on, start compressor and test

adjustment(s) made. If necessary, readjust according
to steps 1-4 above.
5
2
3.7 PRESSURE SWITCH ADJUSTMENT

Locate the pressure switch (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.
20
FIGURE 3.7-1 PRESSURE SWITCH
3.8 MODULATION 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).
Capacity control of machines supplied with electropneumatic control and the modulation option can be
manually switched from on-line/off-line to modulation
(MOD) via the control mode switch (S1) located adjacent to the pressure switch.
3.9 ACS CONTROL (INTELLISYS w/ MODULATION

OPTION ONLY)
For compressors supplied with Intellisys control and
modulation option, ACS control will allow the compressor to automatically switch between on-line/off-line 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.
FIGURE 3.8-1
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 off-line 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.
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 3.8-1
21
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 thereby reducing power costs.
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. A long "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.
22
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.
3.10 MODULATE CONTROL VALVE ADJUSTMENT

(MODULATION OPTION)
WARNING
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. Put the compressor in the MODULATION mode
by placing control selector switch S1 in the
MODULATION position. Refer to Section 4.4 for
instructions (Intellisys option).
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.

O
WARNING
4. Put the main power disconnect switch in the ON

position.
5. Open the isolation valve and start the compressor.
6. Adjust the isolation valve to bring the discharge air
pressure to the rated discharge pressure (100, 125,
140, or 200 psig).
7. While maintaining the rated discharge
pressure, turn the adjustment screw on the modulation valve (see Figure 3.9-1) so that the test pressure gauge reads:
High pressure air.

Relieve pressure before removing filter
plugs / caps, fittings or covers.
30 psig for modulate 60% cfm (star-delta units)

Tighten the adjustment screw locknut.
8. Press UNLOADED STOP. Wait for sump pressure
to go 0 psig. Close the isolation valve or vent off all
system air.
9. Put the compressor in the desired control mode.
10. Remove the test pressure gauge and replace the
1/8" NPT plug using Loctite PST or similar thread
sealant.
LOCKNUT
LOCKNUT
*Loctite is a registered trademark.

ADJUSTING
SCREW
ADJUSTING
SCREW
FIGURE 3.9-1 MODULATION VALVE

23
4.0 INTELLISYS
(OPTIONAL)
24
PACKAGE DISCHARGE PRESSURE
AIREND DISCHARGE TEMPERATURE
SUMP PRESSURE
SEPARATE PRESSURE DROP
TOTAL HOURS
LOADED HOURS
INGERSOLLrAND
INGERSOLrAND
INTELLISYS
INTELLISYS
POWER
AUTOMATIC
RESTART
DISPLAY
SELECT
UNLOAD
SET OFFLINE AIR PRESURE
SET ONLINE AIR PRESSURE
SELECT CONTROL MODE
SET DISPLAY TIME
SELECT OPTIONS
SET
START
UNLOAD
/LOAD
ALARM
UNLOADED
FIGURE 4.0-1 INTELLISYS CONTROLLER
STOP
4.0 INTELLISYS (OPTIONAL)

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.
Unloaded 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.
EMEG
STOP
UNLOADED
STOP
4.2 POWER INDICATOR LIGHT
Unload/load
Indicates voltage is available to the Intellisys controller.
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.
POWER
4.3 PUSH BUTTONS
UNLOAD
/LOAD
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.
START
If in the display table press this button to exit the display table. Display will show CHECKING
MACHINE then READY TO START.
25
4.3 PUSH BUTTONS (Continued)

Pressure Sensor Calibration (Zeroing) Routine
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.
DISPLAY
SELECT
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.
SET
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.
26
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.
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:
** 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 compressors 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.
4.5 WARNINGS
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 seconds.
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
PSI
ONLINE PRESSURE
65
OFFLINE - 10
PSI
CONTROL MODE
DISPLAY TIME
AUTO RESTART
AUTO RESTART TIME
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 221F (105C).
MOD/ACS - MODULATION - ON/OFF LINE

10
600
10
OFF
ON
---
SEC
---
60
MIN
SEQUENCER
OFF
ON
---
---
REMOTE START/STOP *
OFF
ON
---
---
POWER OUT/RESTART*
OFF
ON
---
---
POWER OUT RESTART

TIME *
10
120
SEC
DELAY LOAD TIME
60
SEC
LEAD/LAG**
---
---
---
---
LAG OFFSET
45
PSI
*Optional
27
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.
9) CK MTR ROTATION
This alarm will occur if a unit is started and compressor has incorrect rotation.
10) CALIBRATION FAIL
This alarm will occur if the sensor calibration routine
is executed and the sensor reading exceeds 10% of
scale.
11) NO CONTROL POWER
This alarm will occur when the controller senses a
loss of control power.
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 228F (109C).
12) PRES SENSOR FAIL

Whenever the pressure sensor is recognized as
missing or broken, a pressure sensor failure alarm
will occur.
13) HIGH AIREND TEMP
This will occur if airend discharge temperature is
greater than 217F (103C).
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.
14) EMERGENCY STOP
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.
This will occur when the EMERGENCY STOP button

is engaged. The alarm indicator will light and display
will show:
EMERGENCY STOP
5) MAIN MTR OVERLD

This will occur if a motor overload is sensed.
6) TEMP SENSOR FAIL
This will occur when the temperature sensor is
recognized as missing or broken.
7) REMT STOP FAIL
This will occur if the momentary remote stop switch
does not disengage by the time the unit attempts to
start.
8) REMT START FAIL
This will occur if the momentary remote start switch
does not disengage by the end of preset time.
28
Disengage the EMERGENCY STOP button and

press the SET button twice to reset this alarm.
5.0 SCHEDULED PREVENTATIVE MAINTENANCE

5.1 MAINTENANCE SCHEDULE
THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE
COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST.
Running
Hours
Action
Part or Item
Inspect
Inspect
Inspect
Inspect
Inspect
Replace
Check
Replace
Inspect
Replace
Inspect
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Inspect
Clean
Service
Coolant level
Weekly
Discharge temperature (air)
Weekly
Separator element differential pressure Weekly
Air filter Delta P (at full load)
Weekly
Drain trap (optional)
Weekly
Coolant filter*
150
Temperature sensor (Intellisys option)
1000
Food grade coolant (when used)
1000
Hoses
1200
Coolant filter*
2000
Drive belt
2000
Separator scavenge orifice
4000
Cooler cores**
4000
Air filter*
4000
Separator element*
4000
SSR Coolant
6000
Ultra Coolant*
8000
Drive belt
8000
Gas Spring (Belt Tensioner)
8000
Shaft seals
8000
Starter contactors
8000
Drain trap (optional)
Yearly
Drive motor lubrication
Time Interval (whichever comes first)

1 Week 1 Mo. 3 Mo. 6 Mo. Yearly 2 Years
x
x
x
x
x
x (initial change only)
x
x
x
x (subsequent changes)
x
x
x
x
(*See special note below)
x
x
x
x
x
x
x
x
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.
SPECIAL NOTE:
Replace separator element when the separator differential pressure ( P) reaches three times the initial pressure drop or a maximum pressure differential of 12 psi (.8 bar) at full load. See Section 5.15.
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 mechanics 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.
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.
5.5 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).
1/16 (1.6mm) MAX
1/16" MAX
MOTOR
O-RING
VENT
HOLE
FIGURE 5.3-1 COOLANT FILL PLUG WITH

VENT HOLE
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. CAUTION! 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 compressor 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.
30
STRAIGHT
EDGE
STRAIGHTEDGE
AIREND
FIGURE 5.5-1 PARALLEL MISALIGNMENT
1/16 (1.6mm)
MAX
1/16" MAX
MOTO
STRAIGHT EDGE
STRAIGHTEDGE
AIREND
FIGURE 5.5-2 ANGULAR MISALIGNMENT
Align Sheaves
locked and tagged.
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.
ALLEN HEAD SCREW
SHEAVE RETAINING SCREWS
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.
B
A
A
B
The following steps should be taken to insure proper

alignment of all components.
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. 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 be repositioned (parallel
alignment) or the motor must be repositioned (angular
alignment).
To reposition the motor sheave:
1. Remove drive belt (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.
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 belt as shown in Section 5.6.
15. Recheck for proper alignment.
16. Reinstall belt/fan safety panel.
31
5.6 DRIVE BELT REPLACEMENT

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.
The belt should be removed, discarded, and a new
belt and gas spring installed at the 8000 hour (or 1
year, whichever comes first) interval. To replace the
belts and gas spring, the following procedure should
be followed:
Replacement Parts
4. Remove gas 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 a belt tension gas 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 belt to ensure 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.
Belt (See Table In Parts Manual APDD 742). Be sure

to use only Ingersoll-Rand Genuine parts to ensure
proper belt size and length.
3. Replace cooler, piping and safety panel.
Removal
This unit has been designed with a unique self tensioning system for the drive belt. There is no adjustment required to ensure proper belt tension. Be sure to
use only Ingersoll-Rand Genuine parts to ensure correct belt tension.
1. Remove the belt/fan safety panel from the cooler

box.
hose.
3. Remove screws which fasten the left hand side of
5.7 BELT TENSION
5.8 BELT TENSION GAS SPRING REPLACEMENT

1. With the spring tension relieved as described in step
4 of drive belt removal (Section 5.6), remove gas
spring by lifting clips at each end of the spring rod
ends with a flat blade screw driver.
2. Pull spring from ball studs.
3. Install new gas spring by snapping into place with
the rod end (smaller diameter) toward the larger motor
sheave.
4. Reinstall clips in spring rod ends.
OVERCENTER
TOGGLE
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
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).
DANGER
HIGH VOLTAGE
HASP
LEVER
TAG
KEY LOCK
GER
DAN

LOCKED AND TAGGED
opens a vent hole, drilled In the plug, allowing the
pressure to release to atmosphere (See Figure 5.31). 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
Special Tools
A clean work bench
Replacement Parts
Shaft seal kit (42466409)
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 assembly. The term "out board" side will refer to the face
closest to the sheave.
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 included in the shaft
seal kit, 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.
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.
33
16. Install the plug in the bottom of the seal housing.
5.10 INLET AIR FILTER ELEMENT
17. Install the large o-ring onto the seal housing.

Place the seal housing assembly aside for later use.
The inlet air filter element should be changed when the

air filter maintenance indicator shows red.
18. Heat the new wear sleeve to 275 F (135 C) in

hot oil or oven. (Do not allow the sleeve to come into
direct contact with the oil container or the oven.)
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 valve.
Remove and discard the filter element. Install a new filter element. Replace cap (See Figure 5.10-1).
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.
INLET AIR FILTER
CAP
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 216 in. Ibs. (24.4 N.m.) torque.
34
FIGURE 5.10-1 INLET AIR FILTER
5.11 COOLANT FILTER
! CAUTION
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.
The coolant filter and coolant may be hot!
1. Place a clean pan under the coolant filter drain

spout.
DANGER
HIGH VOLTAGE
HASP
2. Using a filter wrench, remove the coolant filter (See

Figure 5.11-3).
LEVER
3. Discard the old filter.
TAG
KEY LOCK
GER
DAN

LOCKED AND TAGGED
opening the drain valve or removing the coolant
fill plug, stand clear of the valve discharge, wear
work gloves and appropriate eye protection.
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 its protective
package.
6. Apply a small amount of clean coolant on the gasket of the filter.
7. Screw filter on until the gasket makes contact with
the seat on the filter head. Tighten approximately one
half turn additional.
8. Remove coolant fill plug (See Figure 5.11-2).
COOLANT FILL PLUG
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.
FIGURE 5.11-2 SEPARATOR TANK
35
9. Fill unit with new coolant as follows:

a. Fill tank to the bottom of the threads of the
coolant fill port.
b. Replace fill plug.
c. Run compressor 15-20 seconds.
d. Stop compressor and relieve pressure by
slowly unscrewing the coolant fill plug one
turn. Do not remove fill plug
until all pressure has vented.
e. Add more coolant up to the bottom of the
threads of the coolant fill port.
f. Replace fill plug.
g. Start the compressor and verify coolant
level is in the middle (green) range of the
sight tube (See Figure 5.11-3) when the
compressor is running unloaded. Check
for leaks.
5.12 COOLANT CHANGE

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.
DANGER
HIGH VOLTAGE
HASP
NOTICE
LEVER
UNDER NO CIRCUMSTANCE SHOULD

THE COMPRESSOR BE OPERATED WITH
THE COOLANT FILL PLUG REMOVED.
TAG
KEY LOCK
GER
DAN
COOLANT SIGHT TUBE

LOCKED AND TAGGED
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.
FIGURE 5.11-3 COOLANT SIGHT TUBE

36
COOLANT SIGHT TUBE
OIL DRAIN VALVE
COOLANT FILTER
FIGURE 5.12-2 OIL DRAIN VALVE AND

COOLANT SIGHT TUBE
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 coolant drain valve.
2. Remove the cap from the coolant drain valve
(See Figure 5.12-2).
3. Thread the coolant drain fitting (supplied with compressor), with hose attached, onto the coolant drain
valve. The valve will open as the fitting is threaded
completely, allowing the coolant to drain.
4. Using a filter wrench, remove the coolant filter.
Remember that the coolant filter may be hot (See
Figure 5.12-3).
FIGURE 5.12-3 COOLANT 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
gasket of the filter.
9. Screw element on until the gasket makes contact
with the seat on the filter head. Tighten approximately
one half turn additional.
10. Remove drain fitting with hose and replace drain
valve cap.
11. Remove coolant fill plug (See Figure 5.11-2).
5. Discard the old filter.
37
12. Fill unit with new coolant as follows:

a. Fill tank to the bottom of the threads of the
coolant fill port.
b. Replace fill plug.
c. Run compressor 15-20 seconds.
d. Stop compressor and relieve pressure by
slowly unscrewing the coolant fill plug one
turn. Do not remove fill plug
until all pressure has vented.
e. Add more coolant up to the bottom of the
threads of the coolant fill port.
f. Replace fill plug.
g. Start the compressor and verify coolant
level is in the middle (green) range of the
sight tube (See Figure 5.11-3) when the
compressor is running unloaded. Check
for leaks.
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.
NOTICE
UNDER NO CIRCUMSTANCE SHOULD
THE COMPRESSOR BE OPERATED WITH
THE COOLANT FILL PLUG REMOVED.
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 inspect them every 3 months and replace
them as needed or every 2 years.
38
DANGER
HIGH VOLTAGE
HASP
LEVER
TAG
KEY LOCK
GER
DAN

LOCKED AND TAGGED
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.
5.14 AIREND DISCHARGE HOSE

The flexible hose from the airend discharge to separator tank may become brittle with age and require
replacement. Inspect or replace this hose as per the
maintenance schedule in Section 5.1.
Replacement
locked and tagged.
Disconnect hose nut from piping at each end of discharge hose and remove. Hold fittings securely while
removing hose. Install new hose.
5.15 COOLANT SEPARATOR ELEMENT
Procedure:
The separator element should be replaced after 4000

hours of operation, whichever comes first, to prevent
excessive coolant carryover into the plant air piping
system.
1. Disconnect tank-aftercooler tube, inlet valve control

tube, and scavenge tube.
The element is located inside the separator tank (See

Figure 5.15-1).
SEPARATOR ELEMENT (INSIDE)
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.
TANK COVER BOLT
FIGURE 5.15-1 SEPARATOR ELEMENT LOCATION

opening the drain valve or removing the coolant
fill plug, stand clear of the valve discharge, wear
work gloves and appropriate eye protection.
FIGURE 5.15-2 TANK COVER REMOVAL
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.
39
5.16 SEPARATOR TANK SCAVENGE

CHECK VALVE/ORIFICE
7. Start unit and verify proper operation.
Tools Required
5.18 MOTOR LUBRICATION
Open end wrench

Screwdriver
The induction-type squirrel cage ODP motors have

antifriction ball or roller bearings front and rear. At
periodic intervals they require relubrication.
Procedure
Relubrication Interval
(or 9 months, whichever comes first)
Disconnect tubing at each end of check

valve/screen/ orfice assembly.
Check orifice and clean if required. Use suitable
tool and remove orifice from its housing (See Figure
5.16-1). Be careful not to damage flared end of fitting or O-ring. Wash housing in safety solvent and
blow dry.
ODP DRIVE MOTOR . . . . . . . . . . . . . .2000 hours

TEFC DRIVE MOTOR . . . . . . . .*NOT REQUIRED
* No greasing required (permanently lubricated bearings)
Press the check valve/orifice into fitting block.

Assemble the check valve/orifice assembly to the
tubing lines. The fitting must be re-installed with the
check valve on the upstream side of the orifice as
indicated by the flow arrow (See Figure 5.16-1).
INLET
CHECK
VALVE
HOUSING
SPRING
Relubrication amount
in3
Lubricant Amount
cc
oz.
grams
1.0
16
23
.8
ORIFICE
NOTICE
VITON
O-RING
FIGURE 5.16-1 SEPARATOR TANK SCAVENGE

CHECK VALVE/ORIFICE
5.17 COOLER CORES/CLEANING

Inspection
Motors MUST be greased

periodically. See Operators
Manual for procedure.
1. Remove the cooler box rear panel.

39570098

hose.
3. Remove screws which fasten the left hand side of
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.
40
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.
! CAUTION
WARNING
Overgreasing can be a cause of bearing and

motor failure. Make sure dirt and contaminants
are not introduced when adding grease.
Procedure for relubrication
! CAUTION

INGERSOLLrAND
Grease should be added when the motor

is stopped and power disconnected.
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 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 oclock 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!
Recommended Motor Grease

Most motors require:
Mobilith SHC 220 (39218193)
Use the grease as indicated on a special grease information 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 (39204292)
(Preferred)
Chevron SRI 2 (39161641)
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, the compressor must be ordered
with long term storage option.
41
2) Discharge potential static electricity by touching

(grounding) yourself to the starter box.
5.19 INTELLISYS CONTROLLER REMOVAL

(OPTIONAL)
3) Handle circuit boards only by their edges.

compressed air system by closing the isolation valve
4) Do not place the Intellisys Controller on any metal
and venting pressure from the drip leg.
surface.
5) Leave the replacement parts in their protective bags
locked open and tagged. (See Figure 5.19-1).
until ready for installation.
Controller Removal:
1) Remove the starter box door.
DANGER
HIGH VOLTAGE
HASP
2) Check all wiring for tightness.

3) Remove clamp rods and nuts which fasten the controller in place.
LEVER
TAG
KEY LOCK
GER
DAN
4) Pull the Intellisys controller down off of the mounting

studs.
5) Remove the five plug-in connectors from the top of
the controller.
6) Remove the controller. Remove any option modules
which must be installed in the new controller.

LOCKED AND TAGGED
5.20 RECEIVER TANK DRAIN TRAP

INSPECTION/CLEANING
Tools Required
Inspection
Screwdriver Size #1, flathead
3/8 inch hex driver
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.
42
Open (unscrew) the discharge valve on the trap and let

water flow out until compressed air blows through for a
few seconds. If a significant amount of water (more
than 0.5 litre) exits the valve, then the drain must be
thoroughly cleaned.
Cleaning
Dismantle the drain and clean all components. Do not
use solvents to clean rubber components.
6.0 TROUBLE SHOOTING

6.1 TROUBLE SHOOTING CHART (STANDARD CONTROL)
TROUBLE
Compressor Fails to Start
Repeat Shutdowns
High Amp Draw
Low Amp Draw
High Discharge Pressure
Low Air System Pressure
Unit Running Hot
High Coolant Consumption
Excessive Noise Level
Shaft Seal Leak
Pressure Relief Valve Opens
Black Residue on Belt
Guard/Cooler Box
CHECK POINT NUMBERS

1,2,3
3,4,5,2
8,9,6,7
1,10,12
13,15,16,19
22, 20,17,18,13,15,14,19,7
22,21,23,24,6, 35
28,27,25,26
17,18,31,30,29
32
6,13,15,14,16,19
17,33,34
CHECK POINT NUMBERS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31
32
33
34
35
TROUBLE CAUSE
Control Voltage Not Available
Defective Starter
Motor Overload
Incorrect Overload Size
Line Voltage Variation
Compressor Operating Above Rated Pressure
Dirty Separator Filter Element
Low Voltage
Unbalanced Voltage
Dirty Air Filter
Compressor Operating Unloaded
High Voltage
Incorrect Pressure Switch Setting
Faulty Minimum Pressure Valve
Load Solenoid Valve Defective
Blowdown Valve Defective
Drive Belt Slipping/Worn Belt Tension Gas Spring
Air System Leaks
Inlet Valve Malfunction
System Demand Exceeds Compressor Delivery
Coolant Cooler Core Dirty
Low Coolant Level
High Ambient Temperature
Restricted Cooling Air Flow
Separator Filter Element Leak
Plugged Scavenge Orifice
Compressor Operating Below Rated Pressure
Coolant System Leak
Airend Defective
Motor Defective
Loose Components
Worn or Defective Shaft Seal
Sheaves Misaligned
Worn Sheaves
Incorrect Fan Rotation/Blown Fan Fuse
43
6.2 TROUBLE SHOOTING CHART - INTELLISYS CONTROL (CONTINUED)
TROUBLE
Compressor fails to start.
CAUSE &/OR DISPLAY
WHAT TO DO
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.
Manually reset main overload relay, and
press "SET"button twice.
Check for defective sensor, bad sensor
connection, or broken sensor wires.
Check fuses and HAT switch
"MAIN MTR OVER LD"

"PRES SENSOR FAIL" or
"TEMP SENSOR FAIL"
NO CONTROL POWER
Compressor shuts down.
"HIGH AIREND TEMP."
Ensure that installation area has

adequate ventilation.
Ensure that cooling fan is operating.
Check fan fuses inside starter box.
Check coolant level. Add if required.
Cooler cores dirty. Clean coolers.
NOTE: If a shutdown occurs, press the DISPLAY

SELECT button once to
activate the L.E.D. display
table. Using the adjacent up
and down arrows, the values
displayed will be those immediately preceding shutdown. Use these values
when trouble shooting a
problem.
Low system air pressure
44
"HIGH AIR PRESS."

"LOW SUMP PRESS."
"PRES SENSOR FAIL" or
"TEMP SENSOR FAIL"
"CK MOTOR ROTATION."
"MAIN MTR OVERLD"
Check for restricted or malfunctioning

blowdown valve or minimum pressure
check valve.
Check for air leak from tank or
blowdown piping.
Check for defective sensor, bad sensor
connection, or broken sensor wires.
Interchange any two line connections
(L1,L2,L3) at the starter.
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
Compressor running in "Unload" Mode.
Press "UNLOAD/LOAD" button.
Controller off-line set point too low.
Press "UNLOAD/STOP" button, set offline set point at a higher value.
Dirty air filter element.
Check filter condition. Replace

as required.
Drive belt slipping.
Replace drive belt/gas spring.
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

delivery.
Install larger or an additional

compressor.
6.2 TROUBLE SHOOTING CHART - INTELLISYS CONTROL
TROUBLE
High coolant
consumption/coolant
in air system
CAUSE &/OR DISPLAY
WHAT TO DO
Excessive coolant level.
Check level, lower if necessary by

draining.
Check separator pressure drop.
Plugged separator element.

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

replace element.
Plugged separator scavenge orifice.
Remove and inspect orifice.

Clean if required.
Compressor operating at low pressure

(75 psig or below).
Operate at rated pressure.

Reduce system load.
Coolant system leak.
Inspect and repair leaks.
Defective or missing moisture

separator/drain trap
Inspect and clean if required. Replace

separator if defective/missing.
Drain trap or drain piping plugged.
Inspect and clean.
Aftercooler core dirty.
Inspect and clean.
Drain line/drip leg incorrectly installed.
Slope drain line away from trap. Install

drip leg.
No refrigerated or desiccant dryer in

air system.
Contact local Ingersoll-Rand

Distributor or Air Center.
Drive belt slipping.
Compressor defective. (Bearing

failure or rotor contact.)
Contact authorized Distributor or Air

Center immediately, do not operate
unit.
Loose component mounting.
Inspect and tighten.
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
Drive belt loose.

Sheaves mis-aligned.

Align sheaves.
Excessive belt wear
Replace belt.
Compressor operating over pressure.
Adjust Intellisys setpoints.
Defective valve.
Replace valve.
Water in Air System
Excessive noise level
Excessive vibration
Pressure relief valve opens
45
7.0 OPTIONS
7.1 REMOTE START/STOP (STD. CONTROL)
The remote start/stop option on the Intellisys
Controller 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 compressor 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 (INTELLISYS CONTROL)
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 control, or a plug-in
module for machines supplied with Intellisys control
option. 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.
46
WARNING
This machine is remote

start and stop equipped.
Disconnect power before

servicing.
May start or stop at

anytime.
any time.
Lock and tag out.
Can cause severe injury or

death.
See Operators / Instruction

Manual.
NOTE:
47
8.1 ELECTRICAL SCHEMATIC-FULL VOLTAGE WITH STANDARD CONTROL
8.0 REFERENCE DRAWINGS
48
54422704
REV B
54422712
REV B
8.2 ELECTRICAL SCHEMATIC-STAR DELTA WITH STANDARD CONTROL

49
54374665
REV C
8.3 ELECTRICAL SCHEMATIC-FULL VOLTAGE WITH INTELLISYS OPTION

50
54374673
REV C
8.4 ELECTRICAL SCHEMATIC-STAR DELTA WITH INTELLISYS OPTION

51
39263066
REV B
8.5 FOUNDATION PLANBASE MOUNTED-UNENCLOSED

52
39263066
REV B
8.5 FOUNDATION PLANBASE MOUNTED-UNENCLOSED

53
8.6 FOUNDATION PLANBASE MOUNTED-ENCLOSED (CONTINUED)

54
39929518
REV B
39929518
REV B
8.6 FOUNDATION PLANBASE MOUNTED-ENCLOSED

55
56
39932777
REV B
8.7 FOUNDATION PLAN120 GAL. TANK MOUNTED-UNENCLOSED (CONTINUED)
39932777
REV B
8.7 FOUNDATION PLAN120 GAL. TANK MOUNTED-UNENCLOSED

57
8.8 FOUNDATION PLAN120 GAL. TANK MOUNTED-ENCLOSED (CONTINUED)

58
39263082
REV B
39263082
REV B
8.8 FOUNDATION PLAN120 GAL. TANK MOUNTED-ENCLOSED

59
8.9 FOUNDATION PLAN240 GAL. TANK MOUNTED-UNENCLOSED (CONTINUED)

60
39932785
REV B
39932785
REV B
8.9 FOUNDATION PLAN240 GAL. TANK MOUNTED-UNENCLOSED

61
8.10 FOUNDATION PLAN240 GAL. TANK MOUNTED-ENCLOSED (CONTINUED)

62
39929401
REV B
39929401
REV B
8.10 FOUNDATION PLAN240 GAL. TANK MOUNTED-ENCLOSED

63
54363650
REV A
8.11 BASIC FLOW SCHEMATIC-STANDARD CONTROL

64
5336676
REV A
8.12 BASIC FLOW SCHEMATIC-INTELLISYS CONTROL

65
TYPICAL SYSTEM FLOW

DIAGRAM
8.13 TYPICAL SYSTEM FLOW DIAGRAMS

66

67

68

69
70
9.0 SERVICE AND OPTION KITS

SERVICE KITS:
Part Number
Description
Models
37993870
*Kit, 4000 Hr. Maintenance
All 20HP/60Hz
37993888
37993896
All 20HP/50Hz
All 25 & 30HP/60Hz
All 30HP/50Hz
42491688
Kit, Service (Gas Spring &

54 Drive Belt)
XF20, EP20,/HXP25/60Hz
HXP20/50 Hz
42491696

1397mm Drive Belt)
HP20/60Hz
42496216

51 Drive Belt)
HXP20/60 Hz
42491704

56.26 Drive Belt)
XF/EP/HP20/50Hz
XF/EP25/60Hz
XF/EP/HP25/50Hz
XF/EP/HP30/60Hz
42496224

1460mm Drive Belt)
HP25/60Hz
42496232

1420mm Drive Belt)
HXP25/50Hz
42491712

58.26 Drive Belt)
XF/EP/HP30/50Hz
*Contains (1) oil filter, (1) air filter, (1) separator element, and (1) gallon of UItracoolant
OPTION KITS:
Part Number
42474619
Description
Kit, Field - High Dust Filter
42475293
Kit, Field - Power Outage Restart (PORO)

(Units with Std. Control)
Kit, Field - Power Outage Restart (PORO)
and Remote Start / Stop (Intellisys Option)
42475285
42472886
42488593
Kit, Field - Standard Enclosure (20/25HP, 30HP/60Hz)

Kit, Field - Standard Enclosure (30HP/50Hz)
42474817
42474924
42474791
42474932
Kit,
Kit,
Kit,
Kit,
42489526
42489534
Kit, Field - 120 Gallon Receiver Tank

Kit, Field - 240 Gallon Receiver Tank
Field
Field
Field
Field
Modulation
Modulation
Modulation
Modulation
(XF/EP/HP Units with Std. Control)

(HXP Units with Std. Control)
(XF/EP/HP Units with Intellisys Control)
(HXP Units with Intellisys Control)
71
10.0 MAINTENANCE RECORD

DATE
72
RUN TIME
(HOURS)
WORK DONE
QTY.
UNIT
MEASURE
WORK
BY
MAINTENANCE RECORD
DATE
RUN TIME
(HOURS)
WORK DONE
QTY.
UNIT
MEASURE
WORK
BY
73
MAINTENANCE RECORD
DATE
74
RUN TIME
(HOURS)
WORK DONE
QTY.
UNIT
MEASURE
WORK
BY
MAINTENANCE RECORD
DATE
RUN TIME
(HOURS)
WORK DONE
QTY.
UNIT
MEASURE
WORK
BY
75

Ingersoll-Rand SSR-EP20 Air Compressor Manual

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Ingersoll-Rand SSR-EP20 Air Compressor Manual

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XF 20/25/30

Before installation or starting the compressor for

More Than Air. Answers.

AIR COMPRESSOR GROUP

EXTENDED AIREND WARRANTY

ROTARY SCREW AIR COMPRESSOR

Ingersoll-Rand Company reserves the right to make changes or add

No. of units on order:

For ready reference:

inlet air filter element

6.0 TROUBLE SHOOTING

Cooling Air Flow:

0.0 SAFETY AND WARNINGS

Safety instructions in the operators manual are bold-faced for

Electricity and compressed air have the potential to cause

Danger is used to indicate the presence of

Warning is used to indicate the presence of

Caution is used to indicate the presence of

Notice is used to notify people of installation, operation, or maintenance information

0.2 SAFETY PRECAUTIONS

3. Do not operate the compressor at

c.) Vent pressure from the compressor

4. Use only safety solvent for cleaning

Air line separators, properly selected

1. Do not remove the covers, loosen or

The use of plastic bowls on line filters

6. Whenever pressure is released

9. When a receiver is installed, it is recommended that occupational safety and

Those responsible for installation of

b.) Electrically isolate the compressor

7. Before doing any mechanical work on

10. Before starting the compressor, its

CHECK HIGH AIR TEMPERATURE

If for some reason a decal is defaced, parts are

High pressure air.

Disconnect power before servicing.

Use of incorrect coolant can cause

Exposed moving belts and sheaves.

Can cause severe injury or death.

Do not touch. Allow to cool before

Do not operate with guards removed.

Improper coolant filter replacement

1.0 RECEIPT OF EQUIPMENT

1.2 UNPACKING AND HANDLING

2.3 PIPING (Continued)

IMPORTANT: The drain line must slope downward from

DISCHARGE PIPING WITH AFTERCOOLER

IMPORTANT: Discharge piping should be at least as

Do not use the compressor

It is essential when installing a new compressor to review

Liquid water occurs naturally in air lines as a result of

MOISTURE CONTENT OF COMPRESSED AIR

Two types of dryers, refrigerated or desiccant, are used

Before proceeding further, we recommend that you

When two rotary units are operated in parallel, provide an

2.4 ELECTRICAL INSTALLATION

Locate the compressor data plate on the left end of the

ROTARY TWO COMPRESSOR SYSTEM

Confirm that the line voltage and compressor nameplate

2.5 VOLTAGE CONVERSION (230V TO 460V)

*TYPICAL CONTROL TRANSFORMER

QUAD TYPE TRANSFORMER (200V/60 HZ)

UNIVERSAL TYPE TRANSFORMER

FIGURE 2.5-1 TYPICAL CONTROL TRANSFORMER WIRING