AP NirvanaOF Manual v3

Nirvana
Oil Free
Training
Manual
Overview
Airend
Drive
Airflow Circuit
Lubricant Circuit
SG Intellysis
VSD Troubleshooting
Commissiong
Service and Maintenance
Integration
Diagnostics
Copyright Notice
© 2001 Ingersoll-Rand Company
Proprietary Notices and Disclaimer
PROPRIETARY NOTICES
Copyright 2001 INGERSOLL-RAND COMPANY
CONFIDENTIAL AND TRADE SECRET INFORMATION. This manual contains confidential and
trade secret information owned by Ingersoll-Rand Company (hereinafter referred to as
“Proprietary Matter”). In consideration of the disclosure of the Proprietary Matter herein to the
authorised recipient hereof, the recipient shall treat the Proprietary Matter as secret and
confidential; shall not disclose or give such Proprietary Matter to third parties without the express
written authorisation of INGERSOLL-RAND; shall not use the Proprietary Matter except to the
extent necessary to sue or service the equipment disclosed herein; and shall disclose such
Proprietary Matter only to those of its employees whose use or knowledge of the Proprietary
Matter is necessary. This manual shall be returned upon request by Ingersoll-Rand Company.
The unauthorised use of this manual may be punishable by law.
DISCLAIMERS
PROVIDED “AS IS”. THIS MANUAL AND THE CONTENTS THEREOF ARE PROVIDED “AS
IS” AND WITHOUT ANY IMPLIED WARRANTIES.
Nirvana Oil Free Compressors
Index
Introduction SGNe Intelllisys

This Manual has been designed to provide you with Controller Description ........................ 1, 3-14
fundamental knowledge about Ingersoll Rand Intellisys Controller Button
Nirvana Oil Free Compressors. Its purpose is to give Functions .............................................2
you an understanding of operation, construction and Alarms .................................................. 15-18
service requirements of these units. It will also Pressure Sensor
provide engineering data, service procedures and Calibration Routine ...................... 19-21
prepare you for the hands-on practical training that Alarm History & Clock Function .................22
you will receive on the Training Course. PORO—Power Outage Restart Option .....23
Sensors ................................................ 24-25
RTD Sensors ....................................... 26-27
Index RTD Sensors—Temperature
Overview Vs Resistance Charts .................. 28-29
How to Identify the Sensors ................................................ 30-31
Nirvana Oil Free compressor ..............1 Electrical............................................... 32-35
Compressor Model Number.........................2 Short Test............................................. 36-37
General Description ................................. 3-4
Design Pressures.........................................5 VSD Introduction & Troubleshooting
Design Temperatures ..................................5 HPM VSD Troubleshooting Manual
Compressed Air System ..............................5 (Modular Drive)
Condensate Removal System .....................7 VSD Fault Diagnostic Guide
Lubrication System ......................................7
Cooling System (Air-cooled) ........................8 Commissioning
Cooling System (Water cooled) ...................9 Power Off Pre-start Checks ..................... 1-2
Short Test ..................................................10 Running Check ............................................3
Maintenance & Start-up Checklist ...............4
Airend
Compression Process..................................1 Service & Maintenance
Typical Components ....................................2 Service Overview .........................................1
Protection & Performance............................3 Maintenance Schedule ................................1
Airend Sizes and Modules ....................... 3-4 3P Service Philosophy .................................2
Bearings ................................................... 3-6 Preventive Maintenance ..............................2
Short Test ....................................................7 Predictive Maintenance................................2
Proactive Maintenance ................................3
Drive Maintenance Chart.......................................4
Main Drive Motor...................................... 1-2 Maintenance Procedures .............................5
Routine Maintenance ............................. 6-12
Airflow Circuit CD Module Rebuild.............................. 13-18
Introduction ..................................................1 Short Test...................................................19
Airflow Circuit Drawing.................................2
Component Descriptions.......................... 4-5 Nirvana Integration
Check Valve.................................................6 Nirvana Integration.......................................1
Compressor Cooling “System .................. 7-9 Pre-Engineered Systems .............................2
Short Test ..................................................10 Nirvana Control Setpoints ........................ 3-4
Power Off Pre-start Checks ..................... 5-6
Lubricant Circuit
Lubricant Circuit Diagram ............................1 Engineering Data
Component Descriptions.......................... 2-4
Short Test ....................................................5 Diagnostics
Overview ......................................................1
Electrical System Testing .................................................... 2-5
Safety First...................................................1 Five Steps of fluid analysis ..........................6
Electrical System ..................................... 2-7 Fluid Sampling Procedure............................7
Basic Hardware Relationship................. 8-13 Sample Description Sheet (SDS) .......... 8-10
Short Test ..................................................14 Test Report Results ............................. 11-15
Fluid Sampling Instructions........................16
Short Test...................................................17
Nirvana Oil Free Training Manual Page 5

IR Global Service Education Team
Issue: 01/Australia, June, 2004. ÓIngersoll-Rand Proprietary Information
Index
Fluid Analysis for Rotary Compressors

Ultracoolant Guide................................18-21
Short Test .................................................. 22
IR30 and Condmaster Pro
Introduction...........................................23-27
SPM Data Acquisition General Rules........ 28
dBm/dBc Interpretation for
Rotary Compressors ....................29-30
Vibration Severity Monitoring (VSM) ......... 31
IR30—Trending ....................................32-33
Condmaster Pro Software ......................... 34
IR30—Success Stories.............................. 35
Short Test .................................................. 36
SPM Measuring Points for Sierra compressors
General Guide ........................................... 37
CD8 Air End..........................................38-44
........................................................... 45
Operation and Maintenance Manual
FSM (Davidson)
Drawings & Electrical Schematics

Nirvana Oil Free Training Manual
Overview
Overview
How to Identify the Nirvana Oil Free compressor .............................. 1
Compressor Model Number ................................................................ 2
General Description.......................................................................... 3-4
Design Pressures ................................................................................ 5
Design Temperatures.......................................................................... 5
Compressed Air System...................................................................... 5
Condensate Removal System............................................................. 7
Lubrication System.............................................................................. 7
Cooling System (Air-cooled)................................................................ 8
Cooling System (Water cooled) .......................................................... 9
Short Test ............................................................................. 10

Issue: 01/Australia, June, 2004. ©Ingersoll-Rand Proprietary Information
Overview
In this section, you will learn about:

• How to identify Nirvana Oil Free compressors
• The rated operating pressures
• What information is provided on compressor
nameplates
• Cooling System configurations
• Condensate Removal System
• Lubrication System
How to identify the Nirvana Oil Free

compressor
Each Nirvana Oil Free unit worldwide can be
identified by the unique serial number. You need to
look at the compressor nameplate to find the
identification information.
The following identification explanation applies to

units built in the USA.
European built units have different identification

system.
Nirvana Oil Free compressors are designed for the

maximum ambient temperature of
46°C (115°F)
Compressor Model Number

The following diagram depicts Ingersoll Rand
Nirvana (IRN) Oil Free (OF) 125 Horsepower
compressor model number
IRN 125 H - OF
IR Nominal Power Oil Free
H—stands for
Horsepower
K—stands for
Kilowatts
Therefore 132KW unit will have the following Model

Number: IRN 132 K OF !
Note
Remember
Nominal Power is shown on the Nameplate

Overview
60 Hz NIRVANA OIL FREE 125-200 HP Specifications

Free Air Delivery - CFM
Highest Pres-
Lowest pressure L W H Weight
Nominal HP sure
65 psig (in) (in) (in) (lbs)
150 psig
125 646 444 100.4 72 96 7088
150 681 555 100.4 72 96 7088
200 904 751 100.4 72 96 7088
50 Hz NIRVANA OIL FREE 90-160 kW Specifications

Free Air Delivery - M3/min
Lowest pressure Highest Pressure L W H Weight

Nominal kW
4.5 barg 10.4 barg (mm) (mm) (mm) (kg)
90 17.8 12.1 2550 1826 2438 3215
110 19.3 15.4 2550 1826 2438 3215
132 24.9 18.6 2550 1826 2438 3215
160 25.6 22.8 2550 1826 2438 3215
FAD (Free Air Delivery) CFM and M3/min. are full package performance ratings in accordance with CAGI/Pneurop
acceptance test standard
PN2CPTC2 or ISO 1217.
**Specification given with air-cooled value. Maximum temperature 46ºC (115ºF)

Overview
Nirvana Oil Free General Description The profile is of such a configuration that a small,
Nirvana Oil Free two stage variable speed precisely defined gap (clearance) is maintained over
compressors operate on the positive air the full meshing line between male and female rotor
displacement principle in a similar way as Nirvana lobes even in heated condition inside the
contact cooled rotary permissible limits of application. Any contact
compressors do.
However, there is no First Stage
coolant injected into the
Male rotor 3 Female rotor 4
compression chamber
and the female rotor is Second Stage
powered by the timing
gear. Male rotor 4 Female rotor 6
Inside the screw
compressor casing between the rotors is excluded by a pair of timing
there are two rotors gears arranged outside the compression chamber,
which rotate in opposite as shown in the following picture.
directions. The radial and axial clearances between the rotors
The following picture shows a typical configuration. and the casing are also very low. Therefore, for
The rotors have specially shaped profile lobes which increased safety, small projections have been
provided on the profile diameter and on the
discharge-side face ends of the rotors to ensure
Inlet
Timing
Gears
2nd stage
1st stage
Airend
Airend perfect running.
Discharge
are helically twisted in an axial direction, comparable

to a helically toothed pair of gearwheels.
Number of Lobes :
Small
Projection

Overview
Should there be any fouling, these projections will The Nirvana Oil Free two stage variable speed
be ground down to such an extent that there is clear compressor is driven by Hybrid Permanent Magnet
running with optimum clearances during continued Motor® ( HPM®) and comes as totally self–contained
operation. package.
The intake opening is connected to the suction A standard Nirvana Oil Free package will have the
nozzle by an appropriate configuration of the following components:
casing, as shown on the following picture displaying • Inlet air filtration
a cross-cut 1st stage airend. • Compressor and Hybrid Permanent Magnet
Motor®
The shaft sealing elements fitted • Modular Variable Frequency Drive
between the compression chamber and Inlet • Oil system
the suction/discharge-side bearings are • Intellisys Controller
• Instrumentation
• Safety provisions
• Intercooler
• Aftercooler
• Moisture separation first and second stage.
• Automatic condensate removal first and
second stage.
• Acoustic enclosure
The motor and airend are integrally mounted and

there are no bearings in the HPM® motor.
Discharge
used for minimising air leakages from the
compression chamber, while the fitted oil sealing
rings prevent any bearing oil from penetrating into
the compression chamber.
Pressure balancing pockets with discharge to the

atmosphere are provided.
This assembly is isolated from the base by rubber

isolation mounts. Flexible pipe connections are
utilised where necessary to isolate the main base
and customer connections

Overview
Operating Pressures Compressed Air System

The normal operating pressure range for Ingersoll–
The compressor air enters the compressor through
Rand Nirvana Oil Free compressors is between 4.5
an opening at the enclosure. It travels through a
to 10.3 barg
passageway lined with sound–absorbing material to
the air filter. Via a round flexible hoses and ductwork,
There are two pressure safety valves, one per each
the air passes through to the first stage of the
stage located at the discharge of each air cooler
compressor. There is no inlet valve on the unit.
• The design of the pressurised
system is well above the safety The 1st stage helical rotors compress the air to a
valve settings. pressure of between 1.7 to 2.4 barg (25 – 38psig).
The air is discharged into a venturi, which dampens
Safety Valve Settings any pressure pulsations that may be present.
1st Stage 2nd Stage
The intercooler then reduces the air temperature
90-150kW 3.4barg 11.6barg before it enters into the second stage. A safety relief
125-200 HP 50 psig 165psig valve is also positioned in this system to guard
against an abnormally high interstage pressure. A
moisture separator is supplied immediately following
the intercooler to remove any condensation that may
occur under certain conditions of ambient humidity
Design Temperatures and temperature.
An expansion joint is utilised between the moisture

The standard compressor is separator and the second stage.
designed for operation in an
ambient range of 1.7°C to 46°C The second stage further compresses the air to the
(35°F – 115°F) desired pressure. The pressure pulsations are
dampened in a venturi. An expansion joint prevents
transmitted vibrations. The aftercooler cools the air
When conditions other than the design levels to a suitable temperature, while the discharge
described are encountered, we recommend to moisture separator removes significant amounts of
contact your nearest Ingersoll–Rand Distributor for condensation.
additional information.
A wafer type check valve is provided to prevent any
backflow of air into the compressor.
2nd Stage Venturi

Overview
Condensate Removal System supplied loose inside the compressor enclosure and
A moisture separator is located immediately after the need to be connected to the ports as indicated in
intercooler and aftercooler to collect any the general arrangement drawing.
condensation from the compressed air.
• To check operation of solenoid
Moisture valves, open the manual bypass
Separator valves momentarily once per day.
• For extended shutdown periods,
the manual valves should be
opened and left open.
Strainers are provided upstream of the condensate

valves to prevent any particles from plugging the
Expansion
Joint solenoid valves.
• Before any maintenance is

performed on the strainers or
solenoid valves, the strainer
service valves should be closed, in
order to isolate from possible high
pressure.
The condensate is drained through electrically
operated solenoid valves.
Solenoid Valves
Strainers
The opening duration is preset at three (3) seconds

and is adjustable on the SG Controller, between 2
and 20 seconds, the interval between openings may
be altered between 60 and 360 seconds, depending
on ambient conditions. If the environment consists of
high temperature and/or high humidity, then the
interval may have to be reduced. The factory set
interval is 180 seconds.
The manual bypass valves are located on the

outside and rear of the sub–base These valves are

Overview
Lubrication System
The oil sump is integral within the gearcase. An oil
strainer is located in the oil pump suction line. The oil
pump is a positive displacement gear–type pump,
and is driven by the compressor driven shaft. There-
fore, it rotates at the same speed as the HPM® mo-
tor.
Nirvana Oil Free compressors are factory filled

with SSR Ultra Coolant which is designed to op-
erate for 8000 hours providing there is no exter-
nal influence that might require more frequent
changes.
From the pump, the oil travels past a pressure relief

valve set at 35 psig to the oil cooler.
The pressure relief valve’s function is to prevent
over–pressure of the system. It may divert some oil
flow back to the sump.
At the discharge side of the oil cooler is a thermo-

static valve. This valve mixes the cold oil with hot oil
that bypasses the cooler to provide oil at the opti-
mum temperature to the bearings, gears, airends
and inlet valve hydraulic cylinder.
The oil then passes through a filter to a distribution

manifold. A non-return spring loaded variable orifice,
calibrated to 25psig determines the oil pressure in
the system. The SGNe controller will issue a high oil
pressure alarm if the pressure reaches 2.4barg (35
psig) at a temperature above 57 °C, and a low pres-
sure alarm if the oil pressure falls below 1.1barg
(17psig)
The gearcase is vented to the atmosphere through a

breather. The breather prevents oil vapour from es-
caping the sump area. The breather exhaust is piped
to the top of the package
! Note:
If the inlet and exhaust ducting is used on the
package, the breather exhaust will need to be
vented outside the package

Overview
Cooling System (Aircooled) A cooling blower and TEFC blower motor are also
Efficient and reliable after-cooling is especially included as part of the module.
critical within an “oil free” compressor as the
compressed air does not have a fluid coolant The complete module is then installed as in integral
medium to absorb heat of compression. part of the Nirvana Oil-Free package. This
Consequently, compressed air entering the after- innovative design yields impressive cooling results.
cooler may be more than twice the temperature of a In fact, all Nirvana Oil-Free compressors will run
contact cooled compressor. continuously and efficiently in ambient temperatures
as high as 46oC (115oF) and will provide an
The heat exchanger and impressive 11oC (20oF) after-cooler CTD.
variable speed blower are
mounted above the compressor Pre-cooling and the three-sectioned after-
assembly. Cooling air flows cooler provide efficient cooling, minimal
through the end of the pressure drop and protection from thermal
enclosure, through the heat stress as applied to the after-cooler. All
exchangers and discharges coolers are constructed with aluminum for
through the top of the package. efficient heat rejection and reliable
service. The external fins, turbulators,
The standard Nirvana Oil-Free
and brazed sheets are structured with
design features our three part air
grade 3003 aluminum; the tanks
cooler module. This module
(manifolds) are composed of grade
contains the compressor
Triple Inlet Cooler Module 6061T6 aluminum.
intercooler, after-cooler and oil
cooler.
Oil Cooler This diagram shows

a typical interstage
pipework
Intercooler
Interstage
blowdown
valve
1st Stage
Venturi
Silencer
(Muffler)
Intercooler
Moisture
Separator
From 1st Stage
To 2nd Stage
Safety Valve
Expansion Joint

Overview
The Nirvana Oil Free utilizes a Triple Inlet After-

Cooler design that includes three large diameter
tubes for pre-cooling second stage discharge air,
and a three-sectioned after-cooler. This initial pre-
cooling (between the second stage discharge and
after-cooler) reduces the compressed air tempera-
ture by 16°C (30° F.).
Aftercooler
Pre-cooling
Tubes
2nd Stage
Valve
2nd Stage
Discharge
Maniforld 2nd Stage
Venturi
Check Valve
From 2nd Stage,

see page 8
2nd Stage
Moisture
Separator Blowdown Valve
This diagram shows a typical 2nd stage discharge pipeworks
Cooling System (Water Cooled)

The intercooler, aftercooler and oilcooler are shell
and tube type heat exchangers. The intercooler and
aftercooler are ”water in the shell” design. the oil
cooler employs ”water in the tube”.
Cooling water flows through each of the three com-

ponents in parallel. A water solenoid shut off valve
is provided in the water discharge line from the
package. The tube bundles are removable for easy
cleaning.

Short Test
Short Test
Answer each question as fully as you can, or tick the best option.
When you finish, check your answers by reading through the section again.
1 What are the maximum operating ambient temperatures for the Nirvana Oil Free
compressors?
2 List three important pieces of information about the compressor that can be
obtained from the compressor model number.
3 Explain the following Model Number: IRH 160 K OF
4 What is the horsepower and maximum/minimum operating pressure of an

IRN 125H OF?

Airend
Compression Process................................................... 1
Typical Components ..................................................... 2
Protection and Performance ......................................... 3
Airend Sizes and Modules ......................................... 3-4
Bearings..................................................................... 3-6
Short Test ..................................................................... 7

Nirvana Oil Free Airend
Compression Process
In this section, you will learn

• How to define the Airend size for Nirvana Oil
Free Compressors
• The typical components of a Nirvana Oil Free
Airend Inlet
• The types of bearings used on Nirvana Oil
f
ion o
Free airends Di
tat on
r
Ro ecti
ro recti
ta on
tio o
Di
n f
Compression Process
As rotation of the compressor begins, air is drawn Tip
into the pockets between the male rotor lobes and
the female rotor grooves.
The compression process for the positive

displacement group of compressors depends upon
reducing the volume of a given amount of air, which
thereby increases the air pressure. With further
rotation, the leading strip of the male lobe reaches Tip
the contour of the female groove and traps the air in
Outlet
the pocket previously formed. The air is moved
down the female rotor groove and is compressed as
the volume is reduced.
Inlet
When the male rotor lobe reaches the end of the
groove, the trapped air is discharged from the
airend.
Outlet

Typical Components
Airend--Typical Components
Radial
Compressor Outlet casing bearings
Radial bearings Female Cover
Timing gear
Sealing Male Rotor Sealing Axial
Radial
Bearings
Cover
Compressor Outlet
casing casing Radial bearing

Identification & Sizes
Airend precision ground, and assembled to ensure that

The airend is a fundamental component in any tolerances are kept within the designed
rotary screw compressor package. Reliability, specifications. This is essential to producing airends
performance and efficiency are determined, for the and compression modules with required
most part, by the design, manufacturing tolerances performance and durability.
and assembly of the airend itself. All other elements
in the compressor system are essentially support Both the rotors and the internal surfaces of the cast
and monitoring devices, included to ensure iron compression chambers receive a special
dependable service and performance. Ultracoat™ treatment to eliminate corrosion.
Ultracoat™ is a patented process that robotically
The pair of rotors in the Nirvana Oil Free applies a micro coating of organic, high temperature
compressors fit into a combined airend assembly. resins, with PTFE and Molybdenumdisulfide, to
specially prepared surfaces.
This process creates a mechanical bond of coating

to metal. Additionally, this mechanically bonded
coating increases airend efficiency by precisely
limiting the clearances with the airend (rotor to
rotor / rotor to housing). Since the rotors are pinion
gear driven, no rotor contact can occur;
consequently, this precisely applied coating should
last the life of the airend.
End view of Rotors Rotor timing and power transmission to the primary
and secondary rotors are accomplished with high
quality, helical cut gears. Bull gear specification:
Compression Module 30CRMOV9, DIN 17200, 1.7707. Pinion gear
specification: 16 MNCR5, DIN 17210, 1.7131.
The airends and bull gear represent the heart of the
oil-free rotary screw package. For efficient and The bearing system used on the Nirvana Oil-Free
reliable operation, both the first and second stage airends has been designed to handle all of the
airends, along with the bull gear are designed and expected radial and thrust loads. Four (4) roller
manufactured to the highest quality standards. bearings are used on each airend to absorb radial
loads, while two (2) ball bearings per airend are
provided to absorb thrust loads.
Since these airends are designed to deliver a

continuous flow of oil-free air it is essential that only
the finest quality oil and air seals be used. All air
seals are constructed of stainless steel and all oil
seals are of a time proven labyrinth design. One set
of air seals on each rotor is also vented to further
eliminate any chance of oil leakage into the
compression chamber.
HPM® Motor / Airend / Gearcase
The rotors are manufactured from high quality

forged steel and stainless steel. First-stage rotors
are machined from E35 steel and second-stage
rotors from X20CR13 stainless steel (400 series).
Rotor housings are cast iron: GG20 (DIN 1691)
material no. 0.6020. Components are machined,

UltraCoat Protection and Performance
Figure 2: Bearings / Seals
After a great deal of research, Ingersoll-Rand found

that inferior rotor coatings wear away over time,
leaving the rotors unprotected and susceptible to
impurities in the air and to the Rotor Surface
effects of temperature variation.
Eventually, this leads to reduced
performance or even compressor
failure.
Ingersoll-Rand solved this

problem by choosing UltraCoat,
the coating that consistently
outperformed all others in
adhesion and durability tests, to
protect every Nirvana Oil Free
airend.
Rotor Coating
(UltraCoat)
The first step to full UltraCoat protection
is the superior surface preparation of our rotors and
housings.
Surface preparation creates minute crevices in our

rotors that tightly grip the UltraCoat coating. The
result is the most durable performance on the
market, lowering our customers energy costs and
increasing the life of the airend in their Sierra
compressor.
As the image shows, IR’s component surface

treatment allows for the tightest possible grip for the
coating. In the next step, UltraCoat is applied using
robotics for the thinnest, most even coat available.
Then the rotors and housings are heat-cured to
solidify the bond between the coating and the rotor
or housing surface.

Bearings
Bearings
The airend bearings position the rotor in the centre
of the airend housing and prevent rotor movement
due to thrust.
Nirvana Oil Free Bearing types include:
• Four roller bearings at Inlet and Thrust Bearing Radial Bearing

Discharge
Radial Load
Bearing
• Two 4 point aircraft type thrust
bearings at the Discharge. Bearing
Shaft
Thrust Load
Shaft
Male and Female Rotors Front Inlet Bearings

(Suction)
• Absorb Axial Side Loads
• Allow for Longitudinal Rotor Expansion
Male and Female Rear Bearings (Thrust)

(Discharge)
• One Roller bearings per Rotor to absorb Axial Side
Loads
• One Ball Bearing per rotor to absorb Discharge
Pressure Gas Loads

Short Test
Short Test
1 What are typical components of a Nirvana Oil Free Airend?
2 Why does an Airend have bearings?
3 What types of bearings are used on Nirvana Oil Free Airends?

DE :
NDE :

Drive
Main Drive Motor ............................................................ 1-2

Short Test ....................................................................... 3

Nirvana Oil Free Drive
Main Drive Motor
Contrary to induction wound motors, the HPM®
In this section, you will learn motor has constant torque, efficiency, and power
• What HPM stands for factor at all applied loads. Also, generous service
factors are available:
• Advantages of HPM over conventional
motors
• HPM motor insulation on the Module Efficiency Power Service
Factor Factor
• HPM efficiency, service and power factors
90kW 96.0 90.3 1.25
110kW 96.0 90.3 1.25

The Nirvana Oil Free compressor utilizes an HPM®
(Hybrid Permanent Magnet®) motor to control the 160kW 97.0 91.3 1.21
speed of the compression module. The advanced
technology incorporated into this motor (including
salient coils in the stator and permanent magnets in
The inherent strengths of the motor provide a
the rotor laminations) produces three times the
smooth, “ramp-up”, soft start which results in the
magnetic flux found in a traditional induction motors
drive motor never requiring inrush current greater
with one-third the motor frame size.
than 100% FLA compared with six to nine times
inrush current when the start button is pushed on
There are twelve poles in the 90-160kW motors.
the conventional star delta or direct on line starters.
Generally speaking: the greater the number of poles,
the greater the size and strength of the magnetic
Since this motor is applied with an inverter to
field. This is important as the motor is 33% the size
produce a VFD system, motor cooling is very
of an induction motor of equal horsepower but has
important. The HPM® motor cooling air gap is
300% of the magnetic flux. Magnetic flux is defined
nearly twice than found in a traditional motor. This
as the transfer of energy across a given surface
results in a rise of approximately 70° C (158°F) at
without touching that surface. The strength of flux is
full load in a package designed for 46°C (115°F).
measured by the closeness of the magnetic flux lines
(magnets align along magnetic flux lines).
This is much cooler
than the 89°-115° C
rise design of
typical “F” class
insulation motor.
Note that this

increased air gap
does not diminish
the strength of the
magnetic flux as
the twelve poles/
permanent Typical Rotor of HPM motor
Typical arrangement of HPM motor with IR airend. magnets/salient
coils provide an
extremely powerful
magnetic field.
This motor is
conservatively
applied within the
Nirvana Oil Free as
the maximum full
load rpm never
exceeds 75% of the
motor’s designed
speed.
Front view of typical 8 pole HPM motor. Typical stator of HPM motor.

Main Drive Motor
The HPM® rotor: provides the HPM® motor with the capability of
75Kw (100HP) weighs 34Kg (75 lbs) and 160Kw unlimited starts and stops per hour. Unlimited starts/
(200HP) weighs 125Kg (275lbs) respectively stops and the low inrush characteristic of the motor
The motor mounts directly to the bull gear jackshaft. provide the energy savings opportunity of simply
This eliminates the need for motor bearings and, stopping the motor during periods of light loading.
consequently, the inherent friction and maintenance
associated with these bearings. The HPM® motors carry the following approvals:
The combination of motor components and air gap CSA Certified
CE Marked
UL Recognized (Canada and U.S.)
HPM®, Hybrid Permanent Magnet® and the HPM

logo are trademarks registered by MOTEURS
LEROY-SOMER
Gap
Minimum
gap .030"

Short Test
Short Test
1 What does HPM Stand for?
2 What are the advantages of an HPM motor over a conventional motor?
3 What is the minimum motor-stater air gap?
4 What is the maximum inrush current on an HPM motor with a variable speed
drive?

Airflow
Introduction .......................................................................... 1
Airflow Circuit Drawing ......................................................... 2
Component Descriptions................................................... 4-5
Check Valve......................................................................... 6
Compressor Cooling System ............................................ 7-9
Short Test .......................................................................... 10

Nirvana Oil Free Airflow Circuit
Introduction

• The major components of the airflow circuit
• Purpose of each component of the airflow
circuit
• Coolers performance
The following picture shows the direction of cooling

air through Nirvana Oil Free 90-160 kW air and
water cooled packages .
Atmospheric air is drawn in from the outside through

the side wall and discharged through the roof panel.
!
Note:
Nirvana Compressors are not suitable for outdoor
installation
Installing Nirvana Compressors outside voids the
warranty of the compressor.

Description & Drawing
Airflow Circuit Drawing Airflow Circuit Drawing Legend

Next page, (page 3) 1AVPT Inlet Air Vacuum Pressure Transducer
Atmospheric air is drawn in from the right end of the
1AAT Inlet Temperature Thermistors
cabinet via internal sound attenuating ducting. The
following is a typical diagram applicable to all units. 1DS First Stage Discharge Silencer
However instrumentation might vary slightly. Refer 1EJ Interstage Expansion Joint
to Controller sections for details. 1MCV Interstage Manual Condensate Valve
1MS Interstage Moisture Separator
1RV Interstage Safety Relief Valve
1SSV Interstage Strainer Service Valve
2ATT LP Discharge Temperature (RTD)
Range 18oC - 266oC
2APT HP Inlet Pressure Transducer
2CS Discharge Condensate Strainer
2DS Second Stage Discharge Silencer
2MCV Discharge Manual Condensate Valve
2MS Discharge Moisture Separator
2RV Discharge Safety Relief Valve
2SSV Discharge Strainer Service Valve
3ATT Air Temperature (Thermistor)
Range 18oC - 120oC
3SV Discharge Blowdown Solenoid Valve
4APT System Air Pressure Transducer
4ATT HP Discharge Air Temperature Transducer
(RTD)
Range 18oC - 266oC
6SV Interstage Condensate Solenoid Valve
7ATT Discharge Air Temperature Transducer
(Thermistor)
Range 18oC - 120oC
9SV Discharge Condensate Solenoid Valve
AC Aftercooler
AF Air Filter
5SV Interstage Blowdown Solenoid Valve
CCV Condensate Check Valve
DCV Discharge Check Valve
IC Intercooler
ICS Interstage Condensate Strainer
S1 First Compressor Stage
S2 Second Compressor Stage

Blowdown Silencer
Air enters through the 11 reduces noise levels Discharge
1 Inlet Filter to the first air discharges from
2 The
the airend via a venturi during unloaded operation. Blowdown
stage airend where it is Discharge Silencer
compressed to 26 - 31 used to dissipate pressure Relief Valve
pulsation. (3DS)
PSIG (1.8 - 2.1 Bar). Air moves from the (2RV) 3SV
3 10 The air
venturi through the 1st flows to
stage expansion joint and the customer
Air Filter enters the intercooler where systems.
7ATT
it is cooled to approximately
(AF) 11°C above ambient
1st Stage
temperature. 4APT
Disc Venturi
1ATT
(IDS) Discharge

Moisture

1st Stage Expansion
1st 2ATT Separator
Joint (IEJ) (2MS) Discharge
Stage
Airend Check Valve
(S1) (DCV)
A check valve
7 prevents the air re-
3ATT entering the 2nd Stage
exits the Airend. It is fitted on the
(AC)
(IC)
4 Air
intercooler Interstage aftercooler outlet.
2APT
through stainless steel Relief
Oil Cooler
Aftercooler
Intercooler
piping to a moisture Valve
separator. epoxy Any moisture that
(IRV) 9 has condensed due
coated internals).

Page 3
to the lowering of the
Interstage
temperature is removed
Moisture
in the separator.
Separator
(MS)
9SV
2CS
6SV 2MCV 2SSV
1CS
1MC 1SS CC
Blowdown Condensate is
Silencer
5 removed
(3DS) Interstage Expansion Joint (IEJ) before the air goes
to the 2nd Stage
5S Airend. The air temperature is
2nd Stage
8 lowered to within
Disc Venturi approximately 11°C of the
2nd Stage ambient air temperature
(2DS) before exiting through a
2nd 4ATT 3APT Expansion
stainless steel pipe, into a
Stage Joint (IEJ) moisture separator.
Airend
(S2)
The air exits the 2nd Stage Airend into a silencer

6 bottle (venturi), then through an expansion joint
and into the aftercooler.
Introduction
Component Descriptions
Inlet Air Filer

Inlet air filtration for the Nirvana Oil Free compressor
is accomplished by a large 99.9% efficient at 3
micron or, dry type, air filter (efficiency testing to
SEA J726 fine dust standard). This filter will provide
effective filtration for the majority of industrial
applications.
Package air
direction
Sound
Attenuators
Intake
Air Drive
Filter Ventilation
Blower

1st Stage Airend Intercooler

• Compresses air to 26-31 PSIG (1.8 - 2.1 Bar) • Cools the air prior to the inlet of the 2nd stage
airend
1st Stage Discharge Venturi • Normal ΔT temp is 11 °C above ambient on
• Provides pulsation dampening aircooled and 8.5°C above inlet water
temperature on water cooled units at design
• Air is carried via hose into inlet valve on 1st condition of 38ºC ambient and 40% relative
stage humidity and water 26ºC
• Relief valve set at 50 PSIG (3.4 bar)
First Stage Airend Venturi Intercooler Moisture Separator

• Collects any moisture prior to 2nd stage airend
• Specially designed with epoxy coating on the
interior to prevent rust
2nd Stage Airend

• Compresses 1st stage pressure from 26 31
PSIG (1.8 2.1 Bar), up to rated package
discharge pressure
2nd Stage Discharge Venturi

• Provide pulsation dampening and silencing
Check Valve
• Isolates customers system from compressor
• Twin flap butterfly type
Aftercooler
• Cools the air from the 2nd stage airend prior to
Venturi 2nd Stage package discharge
Venturi 1st Stage
• Normal CTD is 11°C above ambient on aircooled
and 8.5°C above inlet water temperature on
Interstage Blowdown Valve water cooled units. Same as for Intercooler
This valve will open whenever the compressor is
ramping up to minimum speed during starts and will
open when compressor stops. Discharge Moisture Separator
Removes condensed water from air stream prior to
Intercooler Blowdown Silencer discharging into customer plant
Provides silencing during Start up//Unloaded
Package Blowdown Solenoid Valve
This valve is open at the start until the compressor
reaches minimum speed and will open when the
compressor stops
Discharge Silencer
• Provides silencing during starting, stopping and
unloaded operation

Check Valve
Check Valve Nirvana Oil Free Check Valve Installation

• Isolates customers system from compressor It is imperative that the Package Discharge Check
• Twin flap butterfly type Valve is installed with the valve shaft in the vertical
orientation.
The pipe plugs in the body of the check valve should

be in the 12 o’ clock & 6 o’ Clock positions, as per
the diagram below:-
12 o’ Clock
Moisture
Separator
6 o’ Clock
Discharge
Check Valve
Discharge
Blowdown
Valve

Compressor Cooling System
Compressor Cooling System—Aircooled

The standard Nirvana Oil-Free design features our Inlet
three part air cooler module. This module contains Manifold
the compressor intercooler, after-cooler and oil
cooler. A cooling blower and TEFC blower motor are
also included as part of the module.
Aftercooler
Oil Cooler
Intercooler
Discharge
Separator
The complete module is then installed as in integral Element
part of the Nirvana Oil-Free package. This
innovative design yields impressive cooling results.
In fact, all Nirvana Oil-Free compressors will run Efficient and reliable after-cooling is especially critical
continuously and efficiently in ambient temperatures within an “oil free” compressor as the compressed air
as high as 46oC (115oF) and will provide an does not have a fluid coolant medium to absorb heat
impressive 11oC (20oF) after-cooler CTD, at the of compression.
design condition of 38ºC ambient and 40% Relative
Humidity Consequently, compressed air entering the after-
cooler may be more than twice the temperature of a
contact cooled compressor.
The Nirvana Oil Free utilizes a Triple Inlet After-

Cooler design that includes three large diameter
tubes for pre-cooling second stage discharge air, and
a three-sectioned after-cooler. This initial pre-cooling
(between the second stage discharge and after-
3 Section cooler) reduces the compressed air temperature by
Aftercooler 16°C (30° F.). Pre-cooling and the three-sectioned
after-cooler provide efficient cooling, minimal
pressure drop and protection from thermal stress as
applied to the after-cooler.
All coolers are constructed with aluminum for efficient

heat rejection and reliable service. The external fins,
turbulators, and brazed sheets are structured with
Oil Cooler grade 3003 aluminum; the tanks (manifolds) are
composed of grade 6061T6 aluminum.
Intercooler

Package design is separated into a “cold’ side / “hot”

side configuration to ensure that the compression
module receives the coolest, cleanest air available.
While the hot side contains the compression module,
coolers, and HPM® drive motor, the cold side
provides cooling air to the drive motor, blower motor
for the coolers, inverter fan motor, and heat sinks.
Again, this method of cooling the components
provides a package rated for 46° C (115°F) ambient.
Another feature of the cooling system is the VSD

controlled centrifugal blower motor. Utilizing a
centrifugal blower provides better distribution of
cooling airflow across the coolers and allows the
addition of 0.50”H20 static head to the cooling air
discharge. Utilizing an inverter controlled blower
motor and varying the blower speed by “Intelligently”
evaluating discharge and ambient temperatures
results in:
a) prolonged bearing life by providing stable

lubricant temperatures;
b) maximized energy efficiency with effective
cooling;
c) reduced sound levels at traditional demand
loading.

Compressor Cooling Systems—

Watercooled
In order to provide the best cooling, the Nirvana Oil-
Free compressors are suited with copper tube
coolers with carbon steel shell. Stainless steel (304)
tubes are available as an option for applications
where cooling water, or inlet air is corrosive.
The coolers have been oversized to allow for a

maximum of 46oC (115oF) Inlet air.
The coolers are shell and tube design. The design

CTD is 8ºC at 38ºC, 40% RH of inlet air and inlet
water temperature of 26ºC. To protect the intercooler
and after-cooler from damage due to compressed air
pulsations, the compressed air is passed in the
tubes, and cooling water in the shell. The oil cooler,
on the other hand, is water in the tube/oil in the shell.
All standard coolers utilize copper tubes (the oil
cooler has admiralty brass tubes). To protect the
bonnets, which are made of cast iron on the hot side
and cast aluminum on the cold side, they have been
coated with high temperature corrosion resistant
coating (cast iron) or have been hard anodized
(aluminum)

Short Test
Short Test
1 List the major components of the Airflow Circuit.
2 What is the CTD value on the intercooler and the aftercooler, on air cooled and
water cooled units?
3 Where is the Discharge Check Valve located on Nirvana Oil Free Units?
4 What is the orientation of the Air Discharge Check Valve on the Nirvana Oil
Free Units?

Lubricant Circuit
Lubrication Circuit Diagram ..................................................1

Component Descriptions .................................................. 2-4
Short Test .............................................................................5

Nirvana Oil Free Lubricant Circuit
Lubrication Circuit Diagram
The oil pump provides oil for the following

In this section, you will learn purposes:
• Major components of Lubrication System
1) Lubrication of Bearings
• Purpose of each component
2) Housing cooling of 2nd stage airends 90-160kw
• Ultracoolant units
The following diagram provides a description of the 1 The oil is drawn

through a
Lubricant Circuit suction strainer,
8 The oil pressure is used to filter out
2 An integral gear controlled by the use
large contaminants, 7 The oil that has been
type, positive of a non-adjustable fed to the bearings, is
check valve/ orifice, set and then passes drained from the airends
displacement oil through a suction
pump is provided at 25psig, sized by the via oversized drain ports
factory, located in the oil tube that connects located on the bottom
within the gearcase to the oil pump.
housing. The pump is out piping. side of the airends.
direct driven off the
bullgear shaft,
providing positive
lubrication to all gears
and bearings. The oil Breather
proceeds to the
suction port on the oil Gearcase 5OTT
pump and is then
elevated in pressure
to 2.4 bar
Sump
1st Stage
6OPT Airend
(S1)
Oil Oil
Pump filter
Relief Valve 2nd Stage
5OPT Airend
(S2)
Thermal
Valve
6 The oil leaves the thermal
mixing valve and proceeds
through a 4 micron oil filter and is
Oil Cooler then diverted to multiple oil feed
points on the two airends.
3 There is a pressure 4 The oil is discharged to 5 A thermally controlled mixing valve is located on the
relief valve on the pump the oil cooler, where it cooler outlet. This valve mixes hot oil, (which
discharge piping, to relieve is cooled to approximately bypasses the cooler) and cool oil, from the oil cooler, to
oil to the sump. This is 54-60°C. maintain the optimum oil temperature of +/- 54-60°C.
factory set at 2.4barg.
(35psig).
! Note:
The oil pump is not shown in the gearcase for
clarity of the diagram

Oil Cooler Pressure Check Valve/Variable Orifice

Cools oil prior to lubricating bearings and airend Maintains the oil pressure at 1.7—2.4 barg (25-
jackets. Designed for 65°C in and 59°C out (+6°C 35psig) during normal operation.
∆T) The oil cooler is placed between the intercooler
and aftercooler as per the following picture: The variable orifice is not adjustable and is factory
set
3 Section Oil Fill Port

Aftercooler
Oil Cooler
Intercooler
Orifice Location
Pressure & Temperature Sensors

Refer to SG Sections in this Manual for more details
on these devices.
Location of oil temperature sensor

Oil Pump
This is a positive displacement gear type oil pump,
driven by the Bull gear shaft.
A A
A—A
Discharge connection is on the top of the gearcase

and ‘T’ is provided to direct oil to thermal valve and
cooler as per the following picture.
To Thermal Valve To the Oil

Cooler

Pump Relief Valve Sump

This valve prevents the oil system from being over The oil level should be maintained at three quarters
pressurised. The valve is Factory set at 35 PSIG (7 full with the compressor running.
Bar
Thermostatic Control Valve
Regulates oil temperature to around 54 - 60°C
Oil Filter
This component filters contaminants from the lubri- The oil used is Ultracoolant, the specification for the
cation system and is Rated at 4 microns. There is a oil is provided in the Diagnostic section of this man-
built in bypass set at 15 PSIG (1.0 Bar). ual.
Oil Filter & Manifolds Oil supply

From the thermostatic control valve, the oil passes
the cartridge type 4mm oil filter and is directed to
bearings and airends as per the following picture
Seal
vents
Thermal Control Valve

Gearcase Breather Connection to the top of

Replaceable cartridge separates gearcase oil mist acoustic enclosure
from gearcase vapour.
Vents into plenum area of enclosure to prevent va-

pour from being drawn directly into the inlet Oil breather housing
of the first stage.
The cartridge is constructed from a wire wool type

filter material and is to be cleaned every
2000 hrs.

Short Test
Short Test
1 Name three purposes for which oil is used on Nirvana Oil Free Compressors
2 What is the proper level of oil on Nirvana Oil Free Compressors?
3 What is the maximum oil pressure on Nirvana Oil Free Compressors?
4 What is the purpose of the oil pressure control orifice?
5 How often should the Gearcase breather be cleared?

Electrical System
Safety First ...........................................................................1

Electrical System ...............................................................2-7
Basic Hardware Relationship ..........................................8-13
Short Test........................................................................... 14

Nirvana Oil Free Electrical System
Safety First
Safety First
• Electrical Hardware Relationship
• Electrical Schematics
• Explanation of major electrical components
Δ! WARNING • Operation of Relay and Contactors
Hazardous voltage. Can cause severe injury or

death
Electrical System
The diagrams on the following pages provide the main
Only use factory supplied inlet for incoming components of a typical Nirvana Oil Free electrical
power. See Operators/Instruction Manual. control system.
Δ! WARNING
Variable frequency drive to be serviced by trained person-
nel only.
After switching off the machine at its local isolator. WAIT
AT LEAST 15 MINUTES for the capacitors to fully dis-
charge before removing the drive cover. With caution,
verify DC bus voltage is zero before servicing. Proceed
Δ! WARNING—HIGH VOLTAGE
Do not attempt any work.
Read manual.
Trained service personnel only.
Remove electrical supply.
Wait 15 minutes.
Check for zero voltage.
Proceed with caution.

Nirvana Electrical System Section 6
Electrical System

Issue: 01/Australia, June, 2004. Ingersoll-Rand Proprietary Information
Electrical System
Legend
1ATT Sensor, LP inlet temperature. CAB Cabinet
1AVPT Transducer, LP inlet vacuum. CFO Common fault output
2APT Transducer, interstage pressure. CK Choke
2ATT Sensor, LP discharge temperature. DR Drive
3APT Transducer, HP discharge pressure. EB Earth bar
3ATT Sensor, HP inlet temperature. ES Switch, emergency stop
3SV Valve, package discharge blowdown sole- EXC External communications
noid. F10 Fuse, external heater supply
4APT Transducer, package discharge pressure. GND Ground
4ATT Sensor, HP discharge temperature. H1 110/120V, 50/60Hz From SHT 1
5OPT Transducer, oil filter in pressure. H2 110/120V, 50/60Hz From SHT 1
5OTT Sensor, bearing oil temperature. H3 110/120V, 50/60Hz External supply
5SV Valve, interstage blowdown solenoid. H4 220/230V, 50/60Hz External supply
6OPT Transducer, oil filter out pressure. H5 Alternative heater connection for external
6SV Valve, interstage condensate drain/solenoid 110/120V supply.
7ATT Sensor, package discharge temperature. H6 Alternative heater connection for external
9SV Valve, package discharge condensate drain/ 220/230V supply.
solenoid. HB Heatsink blower
AT Autotransformer (if fitted) HTR1 Heater 125 watts
AW1 Auxiliary warning 1 HTR2 Heater 125 watts
AW2 Auxiliary warning 2 K1 Relay, run
BD Drive Blower K2 Relay fault
BM Motor, Blower KM1 Contactor, main motor
BP Backplate Continued page 5

Electrical System
Legend Colours
BLK Black
BLU Blue
Continued from page 4 BRO Brown
KM5 Contactor, heatsink blower GRE Green
MCB1 Breaker, miniature circuit, transformer PIN Pink
MCB2 Breaker, miniature circuit, control circuits RED Red
MCB3 Breaker miniature circuits, drive SCR Screened
MCB4 Breaker, miniature circuit, PSU VIO Violet
MCB9 Breaker, miniature circuit, heater WHI White
MCB10 Breaker, miniature circuit, heater (external) YEL Yellow
MF Mains filter (if fitted)
MI Main input terminals options Wires
MM Motor, main
MMS1 Breaker, fan motor
MMS2 Breaker, heatsink blower motor Numbers Function Wire colour
OPT Optional
OV Zero voltage 1–99 Power Black
PE Protected earth
PORO Power outage restart option (optional) 100–199 AC Control Red
PSU Power supply unit
RFI Filter, radio frequency interference
200–299 DC Control Blue
RSP Remote stop
RST Remote start
SBC Supplied by customer 300–399 Auxiliary Orange
SGN Controller, Intellisys
SH Standard heater connections as delivered
SL Serial link
SS1–3 Relay, solid state
ST Service tool
T1 Transformer, control
TH Thermostat
TRR True running relay
WR General warning
! Notes:
Alternatively the supply may be taken from an
independent source: in that case, factory supplied
connection must be disconnected.

Electrical System
5 16 4 15
14
12
11
7
10
9
2
8 6 13
Item Description Item
1 Contactor (KM1)
2 Transformer T1
3 Circuit board PSU
4 Radio Frequency Interference Filter RFI
5 Thermostat TH
6 Breaker, motor starter MMS2
7 Circuit breaker MCB1
8 Breaker, motor starter MMS1
13 ContactorKM5
14 Contactor K1, K2
15 Terminal, contact block
16 Terminal, earth EB

Electrical System
Item Description Item Description

1 Cable DC Choke 17 Heater
2 Pin, hinge 18 Nut
3 Hinge 19 Washer
4 Choke DC 20 Back panel assembly
5 Gland, cable 21 Busbar L2
Gland, cable 22 Busbar L1
6 Plate, cover 23 Cable DC Choke
7 Door
8 Screw
9 Washer
10 Gasket
11 Controller, INTELLISYS
12 Switch, emergency stop
13 Key
14 Latch
15 Busbar L3
16 Drive assembly A/C
16a Plate, cover W/C

Basic Hardware Relationship
POWER
SUPPLY UNIT
PRESSURE
CONTACTORS
TEMPERATURE
SOLENOIDS
SENSORS
BLOWER MAIN MOTOR

VFD VFD

Power Supply Unit

A printed circuit board is located in the electrical
cabinet to supply power to the SGN Intellisys con-
troller.
110V AC is brought into the board from the control

transformer T1 via MCB4 for protection. On the
power supply unit is another transformer to reduce
the 110V AC down to lower value which can be rec-
tified to DC voltage and regulated to provide an out-
put of 12V DC.
The 12V DC is then taken to the SGN Intellisys

were it is used for all internal control power and as a
power supply to pressure and temperature sensors
Power Supply Diagram

Transformer Miniature Circuit Breakers

Transformer T1 receives its primary input voltage Miniature circuit breakers provide protection against
from feeder cables taken from the incoming power over current situations within the control circuit.
supply. The input voltage to the primary tapping of Each circuit has it’s own individual protection device
the transformer is protected by MCB1 - miniature which is labelled accordingly.
circuit breaker.
The advantage of the circuit breaker
protection, compared to a fuse protec-
tion, is that the circuit breaker is a re-
settable device and does not require
the service engineer to carry various
sizes of fuses to cover a range of
units. A list of the MCB's follows:
The 110 VAC power from T1 is used to energise the MCB1 - 415 VAC T1 Transformer
Contactors and Solenoid valves via the SGN Intelli- MCB2 - 110 VAC SGN Intellisys
sys outputs. MCB3 - 200 VAC VFD
MCB4 - 110 VAC SG Power Supply
MCB9 - 110 VAC Temperature
MCB 10 - 110 VAC Heater

KM1 - Isolation Contactor

KM1 contactor is used to apply and removing the
incoming power supply to the drive, whenever the
SGN Intellisys displays a healthy condition the KM1
contactor will be energised and the VSD will have
power.
! Note: -
The drive will still retain voltage and should not
be worked on until the correct amount of time has
passed since incoming power was removed. Please
refer to the relevant safety notes within this manual.
KM1 contactor will de-energise whenever an alarm

condition occurs removing the incoming power sup-
ply from the drive.
Excessive power ups of the VSD can cause compo-

nent failure within the drive, care should be taken
that repetitive alarm condition are reset after a suit-
able time has passed i.e. 5 minutes.

K1 & K2 - Control Relays

K1 (VSD Start Relay) is used to control the VSD and
therefore the HPM motor. When the start button is
pressed on the SGN Intellisys the controller will sup-
ply 110VAC control voltage to K1.
K1 will then energise and close its contacts thus

signalling the VSD to start the HPM motor and con-
trol the speed of HPM motor based on the pressure
input generated by 4APT to the VSD. (P x 2 Termi-
nals 6 & 7)
At the same time, K1-2 contact will provide a signal

to start cooling blower VFD. The cooling blower
speed is controlled by 4-20mA signal, generated by
SG (Terminal P4 Pin 9 and 10)
The VSD will control the speed of the HPM motor to
achieve the Target Pressure which is set in the SGN
through Operator Setpoints, if the pressure in-
creases, the VSD will reduce the HPM Motor until

MMS1 Blower Motor Circuit MMS1 Circuit Breaker

Protection
This device provides both Overload and Short Cir-
cuit protection for the blower VFD.
The device amperage setting should be set correctly

for the site voltage present, refer to the commission-
ing section for further details.

Short Test
Short Test
1 Which MCB protects the PSU?
2 What are the secondary tappings on T!?
3 What does “CK” stand for?
4 Explain how the speed of the fan motor is controlled.
5 Explain how HPM start signal is generated.

SGNe Intellisys
Controller Description ................................................. 1, 3-14

Intellisys Controller Button Functions....................................2
Alarms .......................................................................... 15-18
Pressure Sensor Calibration Routine............................ 19-21
Alarm History and Clock Function.......................................22
PORO—Power Outage Restart Option...............................23
Sensors .............................................................24-25, 30, 31
RTD Sensors ................................................................ 26-27
RTD Sensors—Temperature Vs Resistance Charts..... 28-29
Electrical ....................................................................... 32-35
Short Test ..................................................................... 36-37

Nirvana Oil Free SGNe Intellisys Controller
Controller Description
In this section, you will learn Major Components

The major logic components of the Intellisys
• SGNe Controller major Function controller are depicted in the following diagram
• SGNe Major Components
• SGNe Electrical Diagram
• SGNe Input and Outputs Contains operating INPUTS
instructions called
software. Central Processing
Unit—the brain.
! CPU
Note: EPROM
The Electrical Schematics are located at the end
of this section, Pages 32-34 for your reference RAM
Random Access
The SGNe Intellisys control system is an exclusive Memory, where values
and customer set points
Ingersoll-Rand design, developed for reliable are stored, like a
compressor operation. The controller display can OUTPUTS
be programmed in nine languages and various
units of measure for the pressure and temperature
readings.
The microprocessor- Software

based controller uses a The term software refers to the program or set of
finger touch membrane instructions which the central processing unit
for operation of the (C.P.U.) requires and will obey for all of the
compressor and setting compressors operating functions.
control parameters.
Information about the The software is programmed (or written) into a 32
current operating status pin chip called an Eprom (electronically
is available on a Liquid programmed, read only memory) which is located in
Crystal Display (LCD) the controller.
from a list of
temperature, pressure From time to time, software is updated to
and filter condition readings. incorporate improvements or additional features.
In this case, we say that the new software is a new
revision and it would move up one level, e.g.,
original software Revsion 1.0 may become Revision
The Intellisys monitors the compressor and should 1.1 etc.
any pre-programmed limit be exceeded, the
controller automatically displays a warning or The new revision would be programmed into a new
issues an alarm to shut the compressor down. Eprom and the original would have to be replaced.
A group of pressure and temperature sensors, There is a danger when doing this as static
relays and switches support the decision making electricity from your body, could discharge into the
process. Eprom, causing actual or potential damage.
For this reason you should always use anti-static kit
Operation of the control system will be easy after CPN 93457596.
the following explanation of the control system
components is read and understood

Button Functions
Arrows.
These up and down buttons have multiple
Three Display buttons. functions relating to the right half of the
The functions of the three buttons, screen. When lists are presented, the
below the display screen, change and buttons are used to move up and down
are defined by the words immediately through the items on the list.
above them in the bottom line of the
screen. The small arrow(s) displayed in the upper
right corner of the display screen indicate
Each function, such as MAIN MENU, when you can move up (designated by
STATUS, SET etc..., is described in arrow head pointing up) and/or down
appropriate sections in this manual. (designated by arrow head pointing down)
through the list.
Start button.
Pressing this button will Stop button.
start the compressor if Pressing this button will
the display shows activate the unloaded stop
Ready To Start. The sequence. The
compressor will start compressor will start to
and increase speed to decelerate. The blowdown
maintain the Target valves and solenoid
Pressure. condensate valves will be
de-energised. Then the
start output will be de-
energised.
F1 button. F2 button.
This button is used to gain This button is used to gain
access to the factory set access to the factory set
points. Refer to points. Refer to program-
programming section for ming section for access t
access the factory set factory set points.
Emergency Stop Button

Pressing this switch stops the compressor
immediately. This switch should only be pressed in
emergency situations. The discharge blowdown
valve will open to vent pressure downstream of the
check valve to atmosphere.
Note: the system downstream of the check valve

may still contain pressure. The compressors can
not be restarted until the switch is manually reset.
Turn the switch knob clockwise and press the reset
button twice to reset. On reset the controller will
display a message, indicating that the compressor
is ready to start.

Initial Check Sequence ramp up the motor speed to its minimum speed.
The controller will perform an initial check sequence
if the compressor (1) receives initial power to the Once the minimum speed has been achieved, The
controller or (2) has experienced an alarm reset. Intellisys will energize the blowdown valves and
While the initial check sequence occurs, the the VSD will start to control pressure by using its
controller will display a “Checking Machine” speed regulation. When the system pressure
message. approaches the target pressure, the VSD will start
to slow the motor.
During the initial check sequence, the controller will
purge its memory buffer of false or alarm related If the system pressure rises to the immediate stop
data and replenish it with new readings from all pressure set point, the Intellisys will perform stop
sensors. During this time, if a sensor is found sequence immediately.
inoperative and is required for a shutdown, a sensor
failure (alarm) will occur. If the Intellisys reaches its auto-stop pressure it will
wait until the drive is running at minimum speed
In addition to the sensor update, sensors 2ATT, and if pressure is maintained above the auto-stop
4ATT, and 5OTT will also be checked for correct pressure the Intellisys will perform is stop
temperature readouts. If sensor 2ATT’s measured sequence.
value is greater than 95% of its maximum value, the
controller will issue an alarm and not allow the unit Immediate stop and auto-stop conditions will leave
to start. the compressor in an auto-start state where it will
automatically start if the compressor’s discharge
During the initial check sequence, the Intellisys pressure falls below the target pressure. This
will transmit initialization settings to the VSD. process will continue until the Intellisys receives a
stop command or has an alarm.
Once the sensors are checked and the drive is
initialized, the controller will then check all warnings. Stop Sequence
After completion of the initial check sequence, the The compressor can be stopped by a local or
controller will then display “READY TO START”. remote stop, a shutdown due to alarm, an
This process should be completed within 5 seconds. emergency stop, or a VSD failure. Any of these
conditions will cause the start output to de-
Isolation Contact (KM1) energize and the compressor will not automatically
The isolation contact (KM1) will close at power up restart.
once VSD status is verified. The isolation contact
will only open on: The compressor will first de-energize the
blowdown valves, de-energize the condensate
• Loss of power,
solenoid valves, and then de-energize the start
• Emergency stop, output. The compressor will stop if the system
• HAT switch, pressure reaches the automatic stop pressure set
• Drive failure. point and running at minimum speed or immediate
Drive failure is determined by reading status stop pressure set point. However, if the
information from the drive. The isolation contact will compressor stops for either of these reasons, it will
re-close once the drive status is verified and a automatically restart when the system pressure
minimum time period has expired. The minimum falls below the target pressure.
time period is determined by the following.
According to Leroy Somer, the drive can be powered Blowdown Valves
up 5 times consecutively. After that, the equation The package blowdown valve shall be open
(60 – (# of minutes for 5 power ups)) / 15 will be whenever the compressor starts until the
used. compressor reaches minimum speed at which time
it will close. This valve will re-open any time the
Start Sequence compressor unloads before stops. The Interstage
Blowdown valve will open whenever the
The compressor will initially start by pressing the
compressor is ramping up to minimum speed
local start button or receiving a remote start
during starts and it will open when the compressor
command. The Intellisys will energize the start
stops.
output to start the VSD, and both blowdown valves
de-energize to start the unit unloaded. The VSD will

Condensate Valves
The condensate valves shall open at intervals set
by the user using the Condensate interval setpoint
and shall remain open for the interval defined by
the user in the condensate release setpoint . In
addition, the condensate valves shall be opened
each time the machine stops and remain open until
a time period defined by the condensate realese
setpoint after the machine has reached minimum
speed.
Variable Speed Blower

The fan will operate anytime the compressor is
running. If the fan is stopped, it will start with the
compressor. The fan will always run for at least 4
minutes even if the compressor has stopped. This
will be done to limit the number of fan starts to 15
per hour. If the compressor stops due to an alarm
(shutdown) or a stop button (local or remote), the
fan will stop with the compressor regardless of its
operating time.
The variable speed blower is trying to maintain a

CTD of 8.3ºC—10ºC (15º-18ºF), between the First
Stage inlet temperature and either the second
stage discharge temperature or the package
discharge temperature (whichever is higher). The
fan will run from 20% to 100% of full speed,
slowing down when the CTD is below the target
band and speeding up any time the CTD is above
the target band or if the VSD speeds up to
maintain pressure.

Information Display AREA 1

When power is first applied to the compressor, the The left side continuously shows the package
Intellisys makes a check of the required inputs and discharge pressure in large numbers, with the line
displays "Checking Machine" and during this time if directly below the numbers showing the running
all inputs are correct during the three second check, condition of the machine, and the line below that
the display changes to "Ready To Start". Information showing the present mode of operation.
concerning line pressure (if any) and the software
revision level is also shown. The STATUS, MAIN AREA 2
MENU and START buttons are now active. The right side shows various items or lists such as
the machine's CURRENT STATUS readings, the
This display appears once, each time power is MAIN MENU, the OPERATOR SETPOINTS list, etc.
applied and remains until either the STATUS, MAIN Any of the lists can be moved up or down by
MENU or START button is pressed. Pressing either pressing the arrow buttons to the right of the screen.
of these buttons will perform the normal function of
the button pressed. No other buttons are active at A small arrow(s) is displayed in the upper right
this time. corner of the screen. This arrow(s) indicates when
the operator can move up (designated by arrow
A separate display continuously shows Package head pointing up) and/or down (designated by arrow
Discharge Pressure. head pointing down) through a list. The arrow
buttons are also used to change an individual item's
Any of the Current Status readings selected will value.
remain on the display until another status item is
chosen. Use the Up or Down buttons at the right of At certain times, items and/or their values are
the display to change the selection. "highlighted". This means they are displayed as
light characters on a dark background. When the
The display does not scroll through the list and highlighted item is selected (using the select button),
automatically return to the start. When either the first the menu for that item is displayed.
or last item on the current status list as been
reached, use the Up or Down button to reverse the AREA 3
scrolling direction. There is a small arrow prompt The bottom of the screen is divided into thirds with
within the display indicating which of the two buttons the words in each small box showing the function of
to use. The LCD Screen is divided into three areas the button directly beneath it. The words change in
these boxes depending on what actions are
permitted at any particular time.
AREA 2
AREA 1
- CURRENT STATUS -
6.2 Bar Package Discharge Temp
32º C
1st Stage Temperature

Running Loaded 165ºC
AREA 3
MAIN MENU

Current Status Messages Second Stage Airend Inlet Temp

While the compressor has power (started or Displays the reading for temperature sensor 3ATT
stopped), a current status screen will be displayed
by the controller. This current status screen will be Second Stage Airend Discharge Press
considered the “normal” display that the controller Displays the reading for pressure sensor 3APT
shows.
Second Stage Airend Discharge Temp
The following items and their present values will be Displays the reading for temperature sensor 4ATT
displayed on the right side (area 2) of the screen by
pressing the UP and DOWN arrows. Bearing Oil Press
Displays the reading for pressure sensor 6OPT
% Energy Savings
This displays the percent of energy saved by a Bearing Oil Temp
Nirvana compressor, as compared to a comparable Displays the reading for temperature sensor 5OTT
fixed speed compressor.
Motor Speed
% Capacity Displays the speed of the variable speed drive in
Displays the compressor’s load percentage. This RPM.
value will be determined by the actual speed vs. the
maximum speed. Motor Current
This value is read from the variable speed drive
Package KW controller and displayed.
Displays the compressor’s kilowatt usage. This
value includes the blower’s kW usage. Input Voltage
Package Discharge Temp controller and displayed.
Displays the reading from temperature sensor 7ATT.
There is no logic associated with the package DC bus Voltage
discharge temperature. This value is read from the variable speed drive
controller and displayed.
Package Discharge Press
Displays the reading from pressure sensor 4APT. Time & Date
This sensor is used for Auto stop and immediate Displays the current time and date.
stop.
Program Date
Inlet Vacuum Displays the program name, version number, and
Displays the reading from pressure sensor 1AVPT. software part number.
Inlet Filter VSD

Displays current status of the inlet filter. There are 3 Displays the software version number of the
Possible status values here: software in the VSD.
• OK
The controller automatically returns the display to
• Alarm indicating 1AVPT Sensor Failure
the CURRENT STATUS screen showing Package
• Warning, Change Inlet Filter. Discharge Temperature and 1st Stage Temperature
from other MAIN MENU screens if no other buttons
Oil Pressure Filter Drop are pressed within 30 seconds.
Displays pressure drop across the oil filter.
First Stage Inlet Temperature

Displays the reading for temperature sensor 1ATT
First Stage Airend Discharge Temperature

Displays the reading for temperature sensor 2ATT
Second Stage Airend Inlet Press

Displays the reading for pressure sensor 2APT

Main Menu Compressor Type and Target Pressure will be used

The MAIN MENU screen will be accessible from the to determine the compressor’s maximum speed
CURRENT STATUS screen by pressing the MAIN once the speed curves have been generated.
MENU button (identified by the words “MAIN MENU”
in the bottom line of the screen directly above the Whenever the compressor type is changed, the
center button). The MAIN MENU screen is the point Intellisys will transmit new minimum and
from which various operator functions can be maximum speeds to the VSD. The minimum and
accessed. maximum speed is determined from a table,
based on the compressor model and the target
pressure.
Each of the functions shall be chosen by using the
UP and DOWN arrows to highlight them on the Total Hours
screen. The controller should go to the highlighted The total hours selection is used to adjust the total
function if the SELECT button is pressed or should operating hours display.
return to the CURRENT STATUS screen if the
STATUS button is pressed.
Service Level
This set point is used to select a service level of 1 or
Factory Setpoints 2 for maintenance warnings.
The factory set point sequence is accessed with the
hidden function button sequence of Main Menu, Service Interval Type
followed by upper middle, then “F1”, and then “F2”. This set point is used to select hours or months for
The sequence contains the following settings. measuring the service interval. This set point is not
used if the service level is 1.
Language
The language selections are English, Spanish, Service Interval
Portuguese, French, Italian, German, Dutch, Danish, This set point is used to select the number of
Norwegian, Swedish, Finnish, and Turkish. Future months for measuring the service interval. The
software upgrades will include Mandarin, Korean, selections are 3, 6, 9, or 12 months. This set point
Russian, Polish, Czech, and Hungarian. These is not used if the service level is 1 or the service
languages will not be in the initial release of the interval type is hours.
software.
Units of Measure Service Complete

The units of measure selections are PSI & Deg F, This set point is used to indicate to the controller that
PSI & Deg C, BAR & Deg C, kPa & Deg C, and service has been completed. This set point is not
kgcm2 & Deg C. used if the service level is 1.
Whenever the units of measure are changed, the Service Menu

Intellisys will transmit a new target pressure to the This set point is used by IR service to gain access to
VSD. Along with the target pressure, the Intellisys a set of service set points, the field interface, and the
will also transmit new minimum and maximum direct read from the VSD function. IR service will
speeds to the VSD. The minimum and maximum enter a code number to gain access to these items.
speed is determined from a table, based on the An incorrect code will send the user back to the
compressor model and the target pressure. current status display. These set points are
described in later sections.
Compressor Type
The type of compressor will be selected here. The
choices are:
22kW /30HP
30kW/ 40 HP
37kW/ 50HP
45kW/ 60HP
55kW/ 75HP AC 55kW/ 75HP WC
75kW/100HP AC 75kW/100HP WC
90kW/125HP
110kW/150HP
132kW/200HP
160kw

Operator Setpoints
OPERATOR SETPOINTS Default MIN. MAX. STEP UNIT
Target Pressure 100 65 150 1 Psi
Automatic Stop Pressure 105 Target+1 Target+10 1 Psi
Immediate Stop Pressure 115 Auto Auto+10 1 Psi
Condensate Release 10 2 10 1 Sec
Condensate Interval 360 60 360 1 Sec
Energy Rate 0 0 9999.999 --- ---
Reset Averaging Blank --- --- --- Date
Service Menu 1 1 25535 1 ---
The operator set point screen contains the name Immediate Stop Pressure
and value of each user-adjustable set point. These The compressor will stop if the system pressure
points shall be adjustable without stopping the rises to this pressure. The range for this set point
compressor. The following set points can be seen will be the automatic stop pressure to automatic
on this screen by moving the list up and down with stop pressure+5 psi or 160psi—whichever is less.
the arrow buttons.
Condensate Release
Target Pressure This Set Point allows the operator to set the
The compressor will try to operate at this pressure amount of time the condensate release valves (see
setting. The target pressure ranges and step sizes section 2.3) are opened when the time interval
for each unit of measure are listed in the table between openings is reached.
below.
Condensate Interval
This Set Point allows the operator to set the
Unit Min Max Step interval at which the condensate valves (see
section 2.3) are opened.
PSI 65 150 1
BAR 4.4 10.3 0.1 Energy Rate
This set point is used to enter the cost per kilowatt
kPa 440 1034 10 hour into the Intellisys. This value is used for
kgcm2 4.5 10.5 0.1 calculating energy cost and energy savings in the
energy status menu.
Whenever the target pressure is changed, the Reset Averaging

Intellisys will transmit the new target pressure to the This set point is to reset the time period that the
VSD. Along with the target pressure, the Intellisys energy status information will be calculated over.
will also transmit new minimum and maximum When this set point has been selected and set, the
speeds to the VSD. The minimum and maximum date that is was last set will be displayed.
speed is determined from a table, based on the
compressor model and the target pressure. Service Menu
This set point is used by IR service to gain access
Automatic Stop Pressure to a set of service set points and to the direct read
The compressor will stop once the system pressure from the VSD function. IR service will enter a code
rises to this pressure and the compressor is number to gain access. An incorrect code will
operating at the minimum speed. The range for this send the user back to the current status display.
set point will be target pressure+1 to target
pressure+5 psi or 155psi—whichever is less.

Options
OPTION ITEMS SELECTION MIN. MAX. STEP UNIT Installed
Option
Required
Remote Sensor ON/OFF --- --- --- --- No
Sequencer ON/OFF --- --- --- --- No
Remote Start/Stop ON/OFF --- --- --- --- Yes

Power Out Restart ON/OFF --- --- --- --- Yes
Power Out Restart Time --- 10 600 1 Sec Yes
Scheduled Start Day --- Day Day 1 Day Yes

Scheduled Start --- 00:00 23:59 1 Time Yes
Scheduled Stop Day --- Day Day 1 Day Yes
Scheduled Stop --- 00:00 23:59 1 Time Yes

Modbus Protocol ON/OFF/ICU --- --- --- --- No
Modbus Address --- 1 247 1 --- No
Condensate Level Installed Yes/No --- --- --- --- No
receives an unload command, the Intellisys will

The options screen is similar to the operator set
respond as if it were executing an immediate stop.
point screen in terms of step intervals and units.
However, the range section allows the operator to
Remote Start/Stop
turn the options “ON” or “OFF”. The following are
If the remote start/stop option is installed and this
the names and values of each option. They are
setting is set to yes, the compressor will be able to
viewed by moving up and down with the arrow
be started and stopped from a remote device.
buttons
Power Out Restart
If an option has not been purchased and installed in
If this setting is set to yes, the compressor will
the unit, the message “Not Installed” will be shown
automatically restart when power is returned to the
on the selection display screen. Installation of
compressor if it was operating when power was
options is done using the IR service tool.
removed.
Remote Pressure Transducer
Power Out Restart Time
If this setting is set to on, the compressor will use
If the power out restart setting is set to yes, this is
the remote sensor for pressure control, except for
the number of seconds from the time power is
the immediate stop. The remote sensor is
restored until the compressor starts.
connected directly to the VSD and measures the
pressure after the discharge of the package. The
Scheduled Start Day
Intellisys will read the remote sensor pressure value
This option is the selection for the day that a
from the drive and display it in the current status
scheduled start will take place. The selections are
menu under remote pressure. The VSD will
Sunday, Monday, Tuesday, Wednesday, Thursday,
determine the speed directly from the remote
Friday, Saturday, Daily (Su – Sa), Weekdays (M –
sensor. The local discharge pressure sensor
F), or Weekends. This option set point will work with
(4APT) will still be used by the Intellisys for all
the scheduled start set point.
alarms, warnings, and immediate stop.
Scheduled Start
Sequencer
This option will cause the unit to start on the
If this setting is set to yes, the compressor will be
scheduled start day at the time stored in this set
able to receive commands from a host device, such
point. To disable this option, set the value of
as an ISC. When the Intellisys receives a load
scheduled start equal to the value of scheduled
command from the host device, the compressor will
stop.
start and ramp up to speed. When the Intellisys

Scheduled Stop Day Alarm History

This option is the selection for the day that a The ALARM HISTORY screen gives the operator
scheduled stop will take place. The selections are the capability to scroll through the stored alarms
Sunday, Monday, Tuesday, Wednesday, (15 most current) experienced by the machine.
Thursday, Friday, Saturday, Daily (Su – Sa), Each alarm is labeled by number (i.e. “Alarm
Weekdays (M – F), or Weekends. This option set History 1”) and listed in the order of most recent
point will work with the scheduled stop (3.3.3.8) set alarm being first. Pressing the SELECT button
point. when one of the alarms is highlighted will display
the list of machine values that existed at the time
Scheduled Stop that particular alarm occurred.
This option will cause the unit to stop on the
scheduled stop day (3.3.3.7), at the time stored in
this set point. To disable this option, set the value Clock Functions
of scheduled stop equal to the value of scheduled The clock functions screen is used for setting the
start (3.3.3.6). time and date for the real time clock.
Modbus Protocol Time

The Modbus communications will be disabled if This is used for setting the hours (0 - 23) and
this is set to OFF. If set to ON or ICU, Modbus minutes (0 - 59).
communications will be enabled using RTU Date
protocol. If set to ICU, the Intellisys will call out if This is used for setting the month, day, and year.
an alarm or warning occurs. See the Modbus
manual for information on RTU protocol. Service Menu
The following are set points that are only set by IR
Modbus Address service.
The Modbus address can be set from 1 to 247.
Service Menu Default MIN. MAX. Step Unit
Condensate Level Installed Idle Mode Off Off On --- ---
This option should be set to yes only when the
High Condensate Level switch is installed. This will Proportional Gain 30 0 999 1 ---
enable the High I/C Condensate alarm. Integral Gain 600 0 999 1 ---
Sensor Calibration Derivative Gain 1 0 10 1 ---
Pressure transducers are calibrated by using the Maximum Speed 5400 1600 5400* 50 ---
SENSOR CALIBRATION screen. Calibration can
Minimum Speed 1286 900 1500 50 ---
only take place when the unit is not running. The
following sensors are displayed for calibration Fixed Speed Control Off Off On --- ---
(chosen by using the UP and DOWN arrow
buttons): Memory Test Result 0 0 2 --- ---
Sensor Calibration Items

Sensor 1AVPT ................(Inlet Pressure) These set points are accessed by entering a code
Sensor 2APT...................(First Stage Discharge) number in the service menu set point. The
Sensor 3APT...................(Second Stage maximum speed maximum limit will change
Discharge) whenever the compressor type or target pressure
Sensor 4APT...................(Package Discharge) is changed. The above is the initialization value.
Sensor 5OPT ..................(Bearing Oil Pressure)
Sensor 6OPT ..................(Bearing Oil Pressure) Idle Mode
If this is set to ON, the compressor will only run at
If a zero value is +/- 10% of the scale then the slowest (65 psi) minimum speed with the
calibration should not be allowed. If this occurs, blowdown valve open. A ‘replace coolant filter’
the following message will be displayed: Invalid alarm will be issued when this mode is set to ON.
Calibration This alarm is a reminder to only operate in this
mode if a new coolant filter is installed. Once the
alarm is reset, the unit can be started in idle mode.
When this is turned OFF, the compressor will

automatically return to VSD operation. If idle mode The compressor must be stopped to conduct this
is not turned off by IR service, it will automatically set test and this will only be used by IR service.
itself to OFF after 10 minutes of operation and the
compressor will stop at that time. This will only be
used by IR service.
Field Interface
The field interface can only be accessed from the
Proportional Gain service menu, in the factory set points. A code
This set point is sent to the VSD when it is changed. number is entered to access the field interface. The
This is used for the PID proportional gain. field interface will only be accessed by IR service
personnel and is only for use with the IR field service
Integral Gain tool.
This set point is sent to the VSD when it is changed.
This is used for the PID integral gain. Read from VSD
The direct read from the VSD function can only be
Derivative Gain accessed from the service menu. A code number is
This set point is sent to the VSD when it is changed. entered to access this function. The direct read from
This is used for the PID derivative gain. the VSD will only be accessed by IR service. This
function will allow IR service personnel to read
Maximum Speed parameters directly from the VSD.
This set point is sent to the VSD when the target Service Display
pressure is changed. This set point can be used to This Display will contain data points necessary for
lower the maximum speed for the VSD as set by the service personnel but not displayed on the current
target pressure. This is the maximum speed the status display. This function can only be accessed
motor will operate at after it has started. The speed from the service menu. A code number is entered to
of the motor will not exceed this value during access this function.
operation.
First Stage Inlet Temp
Minimum Speed Displays the reading for temperature sensor 1ATT
This set point as described in section 3.3.2.1, is sent
to the VSD when the target pressure is changed. First Stage Airend Discharge Temp
This set point can be used to raise the minimum Displays the reading for temperature sensor 2ATT
speed for the VSD as set by the target pressure.
This is the minimum speed the motor will operate at Second Stage Airend Inlet Press
after it has started. Displays the reading for pressure sensor 2APT
Fixed Speed Control Second Stage Airend Inlet Temp
If this is set to ON, the compressor will only run at Displays the reading for temperature sensor 3ATT
the slowest (150 psi) maximum speed. When this is
turned OFF, the compressor will automatically return Second Stage Airend Discharge Press
to VSD operation. If fixed speed control is not turned Displays the reading for pressure sensor 3APT
off by IR service, it will automatically set itself to OFF
after 10 minutes of operation and the compressor Second Stage Airend Discharge Temp
will stop at that time. This will only be used by IR Displays the reading for temperature sensor 4ATT
service.
Bearing Oil Press
Memory Test Result Displays the reading for pressure sensor 6OPT
If this is selected and set, the Intellisys will conduct a
memory test on its RAM and ROM. At completion of Bearing Oil Temp
the test the Intellisys will display the result. Displays the reading for temperature sensor 5OTT
• 0 will mean that both the RAM and ROM passed
the test. Motor Speed
• 1, 2, or 3 will mean that the RAM failed the Displays the speed of the variable speed drive in
memory test, but the ROM passed. RPM.
• 4 will mean that the RAM passed, but the ROM
failed the memory test. Motor Current
• Greater than 4 will mean that both the RAM and
ROM failed the memory test.

Input Voltage Energy Savings
This value is read from the variable speed drive While the compressor has power (started or
controller and displayed. stopped), an energy status screen can be displayed
by the controller. The energy status display can be
DC Bus Voltage selected by the operator by pressing the energy
This value is read from the variable speed drive status button. The operator can return the display to
controller and displayed. the current status by pressing the status button.
IGBT U Temperature The following items and their present values will be
This value is read from the variable speed drive displayed on the right side (area 2) of the screen by
controller and displayed. pressing the UP and DOWN arrows.
IGBT V Temperature Average Package kW-hours
This value is read from the variable speed drive This displays the average package kW per hour for
controller and displayed. the time period that was started by selecting the
reset averaging set point. This value includes the
IGBT W Temperature blower power usage.
controller and displayed. Average % Capacity
Displays the compressor’s average percent capacity
Input Rectifier Temperature for the time period that was started by selecting the
This value is read from the variable speed drive reset averaging set point. This value is determined
controller and displayed. by taking the average package kW per hour
removing the blower power usage, and then dividing
VSD Ambient Temperature that number by the motor kW per hour for that size
This value is read from the variable speed drive of compressor at 100% capacity.
Average Capacity
Remote Pressure Displays the compressor’s average capacity in cfm
If the compressor has the remote pressure sensor or M3/min for the time period that was started by
option, this value is read from the variable speed selecting the reset averaging (set point.
drive controller and displayed. If the compressor
dosen’t have the remote pressure sensor option, Not Energy Cost
Installed will be displayed. Displays the energy cost of the compressor for the
time period that was started by selecting the reset
IEO Target Pressure averaging set point. This is calculated by multiplying
When the Nirvana is being controlled by an IEO, this the kW hours of the motor and the blower by the
display will show the target pressure the IEO is energy rate.
trying to control the unit at.
Energy Savings
Displays the energy savings of the compressor for
the time period that was started by selecting the
reset averaging set point as compared to a
conventional compressor. This value is determined
by calculating how much a conventional compressor
motor would cost to operate at the same average
capacity and then subtracting the motor energy cost
of the Nirvana compressor from it. It is assumed
that the blower cost is the same in both packages.
Lifetime Energy Savings

Displays the lifetime energy savings of the
compressor at the existing energy rate and at the
average percent capacity as compared to a
conventional compressor

SG Intellisys Warning Messages Initial Service Required At 150 Hours

When a warning occurs, a All units will issue a “SERVICE REQUIRED” warning
large question mark will when the total hours reaches 150. This warning can
flash on the display be reset the same as any other warning.
screen.
Service Level 1
A warning will not cause If service level 1 (3.3.1.5) has been selected for the
the unit to shutdown. The unit, a “SERVICE REQUIRED” warning will be
unit will continue to run in issued every 2000 operating hours. This warning
its normal operation and can be reset the same as any other warning.
the warning will remain
displayed until reset, by Service Level 2
pressing the RESET If service level 2 has been selected for the unit,
button twice. factory set points service interval type, service
interval, and service complete will be used for
If multiple warnings exist, the small up/down arrows determining when service is required and resetting
will appear in the upper right corner of the display the service warning. The service complete factory
screen. The multiple warnings can be seen by set point (3.3.1.8) will be used to clear a level 2
pressing the UP and DOWN arrow buttons. service warning and reset the service time or date.
Pressing the STATUS button will display the The service complete can be reset before a service
CURRENT STATUS screen with the WARNING warning occurs.
button indicating a warning exists.
Service Interval Type – Hours
Warning messages are as follows: If hours has been selected for service interval type
(3.3.1.6), the service warnings will be activated by
Change Inlet Filter the operating hours of the compressor. After the
Will occur if the unit is loaded and 1AVPT indicates initial 150 hours “SERVICE REQUIRED” warning,
a reading greater than 0.7 psi. the next “SERVICE REQUIRED” warning will occur
at 2000 total hours. However, 100 hours before this
Sensor Failure a “100 HOURS TO SERVICE” warning will occur.
Will occur whenever sensors 5OPT or 7ATT are This warning can be reset the same as any other
recognized as missing or broken. The sensor failure warning. One hundred hours later, at 2000 total
message shall follow the following format: SENSOR hours, the “SERVICE REQUIRED” warning will
FAILURE 5OPT. occur. This warning can be reset the same as any
other warning, however this warning will return in 24
Change Oil Filter hours if the service complete through factory set
Will occur if 5OPT-6OPT is greater than 13 psi and point routine has not be set. If the service complete
5OTT is greater than 48ºC (120°F). has not been set, 100 hours later, at 2100 total
hours, the “ALARM – SERVICE REQUIRED”
High Discharge Press warning will be issued. This warning can only be
Will occur if the unit is under the control of an cleared by the service complete factory set point.
external device, such as an ISC, and the discharge Once the service complete factory set point is set,
pressure is greater than the immediate stop indicating the service is completed, the time for the
pressure. next “SERVICE REQUIRED” warning will be
calculated by adding 2000 to the total hours value,
Auxiliary Warning 1(2) with the “100 HOURS TO SERVICE” warning
Will occur if the auxiliary warning input closes. occurring 100 hours before and the “ALARM –
SERVICE REQUIRED” warning occurring 100 hours
Service after that time.
Service warnings occur when the unit has operated
a certain number of hours, based on the total hours, Service Interval Type – Months
or has operated for a certain number of months, If months has been selected for service interval
based on the real time clock. Service warnings can type, the service warnings will be activated by the
have multiple levels, depending on the service level real time clock of the compressor. After the initial
selection. 150 hours “SERVICE REQUIRED” warning, the next
service date will be calculated by adding the value
(number of months) of the Service Interval factory
set point to the current value of the real time clock.

However, 14 days before the service date a “14
DAYS TO SERVICE” warning will occur. This
warning can be reset the same as any other
warning. On the service date, the “SERVICE
REQUIRED” warning will occur. This warning can be
reset the same as any other warning, however this
warning will return in 24 hours if the service
complete factory set point has not be set. If the
service complete has not been set, 14 days after the
service date, the “ALARM – SERVICE REQUIRED”
warning will be issued. This warning can only be
cleared by the service complete factory set point.
Once the service complete factory set point is set,
indicating the service is completed, the next service
date will be calculated by adding the value (number
of months) of the Service Interval factory set point to
the current value of the real time clock.

Nirvana Oil Free SG Intellisys Controller
Alarms
Alarms displayed along with the sensor failure message.

If a critical value is exceeded (during any mode of The sensor failure message shall follow the
operation; i.e. loaded, unloaded, stopped, etc.), an following format: SENSOR FAILURE 4APT.
alarm sequence shall take place. In this sequence,
the controller shall flash a large exclamation mark in Emergency Stop
a triangle on the display screen while removing Will occur when the EMERGENCY STOP button is
power from the starter contactor. The display should engaged.
also indicate what caused the alarm in addition to its
recorded measurement. VSD Fault
The VSD fault is read from the drive. The Intellisys
Power shall not be issued back to the starter until will read the status menu of the variable speed
the alarm message has been reset and the alarm drive. If a fault condition is returned in the status
parameters have returned to normal range. The information, the Intellisys will issue a VSD FAULT
operator resets the alarm by pressing the RESET alarm and display the number of the fault condition.
twice. These alarms are archived in the controller
memory for future reference (up to 15 alarms total). VSD Fault 1 - Over-Current
Each stored alarm will be referred to as an “Alarm
History.” Multiple, consecutive EMERGENCY STOP VSD Fault 2 - Current Imbalance
Alarms will not be recorded as separate alarms; only
the first one will be shown. VSD Fault 3 - Drive Temperature Too High
.
An ALARM STATUS screen (reached by depressing
the STATUS button) should allow the operator to VSD Fault 4 - Not Activated
view the list of machine operating conditions that
existed at the time of the Alarm. VSD Fault 5 - Internal Power Supply
The name and value of each of the items listed VSD Fault 6 - Microprocessor
should be available for viewing through the use of .
the UP and DOWN buttons. The operator should
then be able to return to the Alarm screen by VSD Fault 7 - Encoder (Hall Effect Sensors)
pressing the ALARM button.
VSD Fault 8 - Encoder Loss
The following sections describe each alarm
message and the conditions associated with each VSD Fault 9 - Not Active.
(the controller logic must be de-bounced for each
alarm). VSD Fault 10 - Bus Oscillation
Fan Motor Overload VSD Fault 11 - Not Active

Will occur if a fan motor overload relay contact
opens. VSD Fault 12 - Mains Failure (Loss of Incoming
Power)
Remote Stop Failure
Will occur if the REMOTE START/STOP option is VSD Fault 13 - Phase Missing
enabled, the remote stop button remains open and
either start button is pressed. VSD Fault 14 - Mains Under Voltage
Remote Start Failure VSD Fault 15 – Mains Over Voltage

Will occur if the unit is started by the remote start
button and the button stays closed for 7 seconds VSD Fault 16 – DC Bus Under Voltage
after the unit starts.
VSD Fault 17 – Not Active
Sensor Failure
Will occur when a sensor is recognized as missing VSD Fault 18 – Motor PTC Probe
or broken. The sensors affected by this alarm are
1AVPT, 2APT, 3APT, 4APT, 6OPT, 1ATT, 2ATT, VSD Fault 19 – Not Active
3ATT, 4ATT, 5OTT. The sensor should be

Alarms
VSD Fault 21 – Not Active Check Motor Rotation

This will occur if the Intellisys reads a negative speed
VSD Fault 22 - Current Overload from the VSD when starting.
VSD Fault 23 - Motor Underspeed VSD Communication Failure

This will occur if the Intellisys does not receive a
VSD Fault 24 – Not Active response from the VSD when requesting information.
This alarm will take about 8 seconds to occur.
VSD Initialization Fault
VSD Fault 26 – Motor Overspeed Will occur if the Intellisys is unable to establish
communications with the VSD after a power up.
High I/C Condensate
This will occur if COND LEVEL INSTALLED is YES
and the High Condensate Level switch remains on
for 1 minute.
VSD Fault 29 – IGBT
VSD Fault 30 – Not Active High Intercooler Pressure

Will occur if 2APT is greater than 47 psig and the unit
VSD Fault 31 – Motor Phase is running or 5 psig while the unit is stopped.
VSD Fault 32 – Not Active High 2nd Stage Pressure

Will occur if 3APT is greater than the rated discharge
VSD Fault 33 – Rectifier Temperature pressure plus 15 psig.
VSD Fault 34 – Inverter Temperature, Phase U. High Line Air Pressure

This will occur if the discharge pressure (from 4APT)
VSD Fault 35 - Inverter Temperature, Phase V. is greater than the rated discharge pressure plus 15
psig.
VSD Fault 36 - Inverter Temperature, Phase W.
Low Bearing Oil Pressure
VSD Fault 37 – Loss of +15 volts power supply This will occur if 6OPT is less than 1.1barg (17 psig
for Hall Effect Sensors. and the unit is running.
VSD Fault 38 – Loss of +24 volts DC power High 1st Stage Temperature
supply. This will occur if 2ATT is greater than 250ºC (482°F)
VSD Fault 39 – IGBT Fault Phase U High 2nd Stage Temperature

Will occur when 4ATT is greater than 255ºC (492°F)
VSD Fault 40 – IGBT Fault Phase V for CD4D, 255ºC (492°F) for CD8D or 271ºC (520°F)
for CD14D.
VSD Fault 41 – IGBT Fault Phase W
High I/C Air Temperature
VSD Fault 42 – Rectifier Fault This will occur if temperature sensor 3ATT is greater
than 60ºC (140°F)
VSD Fault 43 – Ambient Temperature
High Bearing Oil Temperature
VSD Fault 44 – Diagnostic Fault This will occur if temperature sensor 5OTT is greater
than 77ºC (170°F)
! Note: 2nd Stage Over Ration

For Information on the above alarms, refer to This alarm will occur if (3APT+14.5psig)/(2APT +
Modular Drive Troubleshooting Guide, Section 12. 14.5psig) is greater than 5.
Inlet Restriction
This will occur if the unit is running and 1AVPT is
greater than 1.45 psig.

Alarms
High Bearing Oil Pressure I/O

This will occur if 6OPT is greater than 2.4 barg (35 The following sections will describe the I/O (used
psig) and the 5OTT is greater than 37.2ºC (135°F) and available) for the Nirvana oil-free SGNe con-
troller.
Control Power Loss
This will occur if the compressor should be running Sensors
and the AC input voltage, as read from the VSD, The following sensors are used. All unused inputs
falls below 100 VAC. There is a delay of 2 seconds can be read through the serial port (P7) using Mod-
on this alarm in case the power quickly returns. bus.
Open HAT switches or phase monitors are 2 things
that can cause this alarm. Pressure
Sensor Range Description Location

Initial Check Alarms:
The following alarms will only occur when the 1AVPT 0-15 psig Inlet Pressure P5-1,2,3
machine is not running. These alarms are related to 0-100 Second Stage Inlet
high temperature, power loss, and sensor 2APT P5-4,5,6
psig Pressure
calibration. They will have the same display mode Second Stage
0-225
as other alarms. 3APT Discharge Pres- P5 – 7,8,9
psig
sure
Check Setpoints 0-225 Package Dis-
4APT P5 – 10,11,12
Will occur if the controller has determined that some psig charge Pressure
of the data stored in memory contains unacceptable 0-100 Oil Pressure Differ-
5OPT P5 – 13,14,15
psig ential
values.
0-100
6OPT Oil Pressure P5 – 16,17,18
psig
Invalid Calibration
--- --- Unused P5 – 19,20,21
Will occur if the sensor zero value is +/- 10% of its
scale. --- --- Unused P5 – 22,23,24
For units equipped with the remote pressure sensor
High Bearing Oil Temperature
option, the remote pressure sensor (9APT) will not
Will occur if 5OTT is greater than 95% of the high
be connected to the Intellisys controller. The re-
bearing oil temperature set point.
mote pressure sensor will be connected to the vari-
able speed drive controller. The Intellisys will re-
trieve the remote pressure sensor reading from the
variable speed drive controller.
Temperature
Sensor Range Description Location
1ATT 0-246 °F First Stage Inlet Tem- P6 – 1&2
perature
2ATT 0-525 °F First Stage Discharge P6 – 3&4
Temperature
3ATT 0-246 °F Second Stage Inlet P6 – 5&6
Temperature
4ATT 0-525 °F Second Stage Dis- P6 – 7&8
charge Temperature
5OTT 0-246 °F Oil Temperature P6 – 9&10
7ATT 0-246 °F Package Discharge P6 – 11&12

Temperature
--- --- Unused P6 – 13&14
--- --- Unused P6 – 15&16

Alarms
Digital Inputs Digital Outputs (Low Voltage)
Input # Description Location Output # Description Location
1 High Condensate Level P3 - 1&2 1 Unused P4 - 1&2
2 Emergency Stop P3 - 3&4 2 True Running P4 - 3&2
3 Fan Motor Overload P3 - 5&6 3 Warning Output P4 - 4&5
4 Unused P3 - 7&8 4 PORO Horn P4 - 6&5
5 Remote Stop P3 - 9&10
6 Remote Start P3 - 11&12

Analog Outputs (4-20Ma)
7 Auxiliary Warning 1 P3 - 13&14 Output # Description Location

8 Auxiliary Warning 2 P3 - 15&16 1 Package Variable P4 - 9&10
Speed Blower
9 Unused P3 - 17&18
2 Unused P4 - 11&12
10 Unused P3 - 19&20
11 Unused P3 – 21,22
12 Unused P3 – 23,24
13 Unused P3 – 25,26
14 Unused P3 – 27,28
15 Unused P3 – 29,30
16 Unused P3 – 31,32
TRIAC Outputs
Output
Description Location
#
TX1 Isolation Contact P1 – 2
TX2 Motor Drive – Run P1 – 3
TX3 Fan Starter P1 – 4

TX4 Package Blowdown Solenoid P1 – 5
TX5 Condensate Valve P1 – 6
TX6 Interstage Blowdown Solenoid P1 – 7
TX7 Unused P1 – 8
TX8 Unused P1 – 9

Pressure Sensor Calibration Routine
Sensor Calibrations The calibration routine can be exited by pressing

Pressure sensor calibration is done through the the STATUS or MAIN MENU button. If no buttons
SENSOR CALIBRATION screen. Sensor calibration are pressed within 30 seconds, the display will
can only take place when the compressor is stopped. automatically return to the CURRENT STATUS
Calibration needs to be done only after a sensor has screen showing Package Discharge Pressure and
been replaced or the Intellisys controller has been Airend Discharge Temperature.
replaced.
SENSOR CALIBRATION items

Sensor 1AVPT
Sensor 2APT
Sensor 3APT
Sensor 4APT
Sensor 5OPT
Sensor 6OPT
MAIN MENU - c
2.1 Operator Set Points
Options
Sensor Calibration
Running Loaded Alarm History
Mode : ON/ OFF Clock Function
STATU SELE
To Calibrate
The compressor must be stopped with "Ready To
Start showing in the display. All pressure must be
vented by disconnecting the tubing at the sensor.
This is very important or the calibration will be
incorrect and an Invalid Calibration alarm will be
issued if the sensor output signal is greater than
10% of the range during calibration.
Press the MAIN MENU button and then use the

down arrow to highlight SENSOR CALIBRATION.
One of the three pressure sensors will appear in the
display and be highlighted with the word
"CALIBRATE". Use the up or down arrow to choose
the sensor to be calibrated. Press the SELECT
button to highlight CALI B RATE. At this time, the
SELECT button changes to a CALIBRATE button.
Press the CALIBRATE button. The displayed
sensor flashes twice to indicate it has been entered
into the controller, and the sensor name and
CALIBRATE will again be highlighted together.

SG Intellisys
Calibration Example of 1AVPT Transducer
1. Unit stopped displaying ready to start.
Low Pressure Conversion Table (Inlet Vacuum)
2. Select “Main Menu”.
3. Move cursor to highlight the sub-menu PSIG kPa BARG
“Calibration”, and then press the “Select”
button to enter the calibration routine. 0.1 0.689 0.006
0.2 1.378 0.0137
4. Move cursor to highlight the sensor “1AVPT”,
and then press the “Select” button. 0.3 2.067 0.0206
5. Remove the 6mm nylon tube at its connection 0.4 2.756 0.0275
to the 1 AVPT transducer and press the
“Calibrate” button. 0.5 3.445 0.0344
6. After the Intellisys has calibrated the sensor,
0.6 4.134 0.0413
replace the pipe.
0.7 4.823 0.0482
0.8 50512 0.0551
0.9 60201 0.062
1 6.894 0.0689
2 13.79 0.1379
3 20.686 0.2069
4 27.582 0.2758
5 34.478 0.3448
6 41.374 0.4137
7 48.27 0.4827
8 55.166 0.5517
9 62.062 0.6206
Remove pipe to sensor 1AVPT to 10 68.958 0.6896
ensure that the sensor is
measuring atmospheric pressure. 11 75.854 0.7585
12 82.75 0.8275
13 89.646 0.8965

SG Intellisys Sensor 1 AVPT Calibration

Routine

Alarm History and Clock Function
Clock Functions
The Clock Function allows the controller to perform
real time control functions. Scheduled Start / Stop.

PORO—Power Outage Restart Option
Power Outage Restart Option (PORO)

The purpose of the PORO option is to automatically
restart the compressor after a mains power
interruption has occurred.
Additional hardware is required to install this feature
(Kit available) Refer to Intellisys Option Manual for
details

Sensors
Sensor Location
Pressure Sensors 1AVPT, 2APT, 3APT, 4APT, 5OPT & 6OPT Mounted on the side of
the Starter Panel
Sensor Identification.
The 6 sensors can be identified by checking the amount. The result is a variable output signal that
bracket for the ID number of the sensor, which is ranges from 0.5 to 4.5 volts DC.
stamped into the metal bracket near the brass fitting
of the sensor. The output signal is processed by an analogue to
digital converter within the Intellisys controller.
Pressure transducers used to convert air pressure Depending on the voltage level, decisions are made
signals to a voltage signal between 0.5 and 4.5 volts by the Intellisys that may cause a change in the
DC. pressure reading on the display panel, unload the
compressor or possibly shut the compressor down if
The transducer contains a metal diaphragm conditions dictate.
connected to a small piece of steel called the beam
which in turn has a strain gauge attached. As If a pressure sensor is replaced, it is important to
pressure pushes the diaphragm, the beam flexes calibrate the new sensor. Basically, calibration allows
and bends the strain gauge. the controller to read the sensor's output signal with
the diaphragm in a totally relaxed state and then
A continuous 5 volt DC supply is attached to the correct for any minor deviations from 0.5V.
strain gauge assembly.
As the strain gauge bends due to the changing

pressure on the diaphragm, the resistance value
through the strain gauge changes a corresponding

Sensors
Pressure Sensor Description stops in an alarm condition.

1AVPT - Inlet Vacuum
A pressure sensor having a range between 0 and 15 4APT- Package Discharge Pressure
psig vacuum connected to the airend inlet to provide A pressure sensor used to provide information
vacuum information for the controller. The output about the discharge pressure just prior to the
voltage is .05 volts DC at 0 psig vacuum and 4.5 compressed air leaving the package. The
volts DC at 15 psig vacuum. connection is downstream of the aftercooler and in
the top of the moisture separator.
The controller uses inlet vacuum information to
indicate the condition of the inlet air filter for the Package discharge pressure provides logic to load
Intellisys to monitor and warn when necessary. or unload the compressor.
2APT - 1st Stage Discharge Pressure & 3APT - 5OPT - Oil Filter Inlet Pressure & 6OPT - Oil
2nd Stage Discharge Pressure Filter Outlet Pressure
The airend discharge is monitored. Two pressure sensors are used to monitored the
lubricant filter differential and the lubricant pressure
The normal unloaded intercooler pressure is is monitored continually to ensure that the bearings
maintained at 0 psig and loaded within a range of 26 have a continually feed of lubricant.
to 31 psig to ensure adequate inlet pressure to the
2nd stage to prevent over-ratio of the 2nd stage
airend.
The normal unloaded 2nd stage discharge pressure
is maintained at 0 psig and loaded to the rated
pressure of the machine. This pressure is monitored
as the unit unloads to ensure the 2nd stage airend
discharge has blown down to atmosphere ensuring
that any over ratio situation is detected and the unit
Pressure Sensor Input/Output Information

Pressure Millivolt Output Relationship 2APT
3APT
4APT
5OPT &
+4.5V 6OPT
13.8 barg
7.0 barg
(200
(100
+0.5V
Vacuum Pressure (bar)
1 barg
(15
- 4.5V
1AVPT
RTD Sensors
Temperature Sensors Description NTC Thermistor Input/Output Information
Temperature Sensors -
TEMPERATURE ºC RESISTANCE (ohms)
1AAT, 2ATT, 3ATT, 4ATT, 5OTT & 7ATT
Temperature sensors are used to monitor 0 33631.0
temperature changes at various points within the 5 25988.0
compressor package. 10 20244.0
15 15889.0
As the temperature of the sensor changes, either 20 12562.0
higher or lower, the resistance through the sensor 25 10000.0
changes a corresponding amount. 30 8013.0
35 6461.0
As the output voltage varies due to the temperature 40 5241.0
changes, the voltage strength is processed by an 45 4276.0
analogue to digital converter within the controller.
50 3507.0
Depending on the output voltage from the various 55 2894.0
sensors, the controller makes decisions that may 60 2400.0
change a number on the panel display, delay a 65 2001.0
pressure reading until the compressor warms up, or 70 1677.0
could possibly shut the compressor down with an 75 1412.0
Alarm if operating conditions dictate. 80 1194.0
85 1014.0
Temperature Sensors - 90 865.2
There are five RTD type temperature sensors. 95 741.0
The term RTD means Resistance Temperature 100 636.9
Device and it will change its resistance value as it 105 549.7
changes in temperature. The thermistor is made
110 476.1
from a mixture of sintered metal oxides such as
manganese, cobalt or nickel sealed within a glass 115 413.9
bead. Two wires are attached to the thermistor - a
black wire IN and a white wire OUT.
The resistance will DECREASE as the temperature

INCREASES, therefore these devices are called
Negative Temperature coefficient NTC Thermistors
The DC voltage from the thermistor is processed by

an analogue to digital converter and then forwarded
to the CPU. Depending on the voltage level,
decisions will be made that could change a number
on the message display or shut the compressor
down on ALARM.
These devices are neither adjustable nor repairable

and must be replaced should one fail.
The thermistor housing is made of stainless steel

and requires loctite to seal the S.A.E. area of the
housing to its installed location.
These are:
1 ATT - First Stage Inlet Thermistor
3 ATT - 2nd stage inlet temperature Thermistor
7 ATT - Package discharge temperature Thermistor
5 OTT - Bearing oil temperature Thermistor

Alarms
RTD’s Temperature Sensors Checking

All RTD’s are identical. There are two RTD’s and
neither are adjustable or repairable. AMBIENT
25°C
2 ATT - 1st stage discharge temperature RTD
4 ATT - 2nd stage discharge temperature RTD
BLACK
General SIG
The RTD’s are used to convert a temperature value
into a resistance value, i.e. as the temperature WHITE
increases the resistance value will increase (PTC).
The resistance of the RTD varies linearly at a rate of
0.385 ohms per °C, with an initial resistance of 100 SCREEN
ohms at 0°C. (GROUND)
Therefore: -
0°C 100.00 ohms
10°C 103.85 ohms 10000
25°C 109.62 ohms
50°C 119.25 ohms CONTINUITY
75°C 128.87 ohms METER
100°C 138.50 ohms
150°C 157.30 ohms
175°C 166.60 ohms
200°C 175.80 ohms
250°C 194.07
The temperature range of the RTD is: - 50°C to

+260°C

Temperature vs. Resistance Charts
ºC ºF OHMS ºC ºF OHMS ºC ºF OHMS
-18 -0.4 92.95 35 95.00 113.61 90 194.00 134.70
-17 1.40 93.34 36 96.80 113.99
91 195.80 135.08
-16 3.20 93.73 37 98.60 114.38
92 197.60 135.46
-15 5.00 94.12 38 100.40 114.77
93 199.40 135.84
-14 6.80 94.52 39 102.20 115.15
40 104.00 115.54 94 201.20 136.22
-13 8.609 4.91
-12 10.40 95.30 41 105.80 115.93 95 203.00 136.60
-11 12.20 95.69 42 107.60 116.31 96 204.80 136.98
-10 14.00 96.09 43 109.40 116.70 97 206.60 137.36
-9 15.80 96.48 44 111.20 117.08 98 208.40 137.74
-8 17.60 96.87 45 113.00 117.47 99 210.20 138.12
-7 19.40 97.26 46 114.80 117.85
100 212.00 138.50
-6 21.20 97.65 47 116.60 118.24
110 230.00 142.29
-5 23.00 98.04 48 118.40 118.62
49 120.20 119.01 111 231.80 142.66
-4 24.80 98.44
50 122.00 119.40 112 233.60 143.04
-3 26.60 98.83
51 123.80 119.78 113 235.40 143.42
-2 28.40 99.22
52 125.60 120.16 114 237.20 143.80
-1 30.20 99.61
53 127.40 120.55 115 239.00 144.17
0 32.00 100.00
54 129.20 120.93 116 240.80 144.55
1 33.80 100.39
55 131.00 121.32
2 35.60 100.78 117 242.60 144.93
56 132.80 121.70
3 37.40 101.17 118 244.40 145.31
57 134.60 122.09
4 39.20 101.56 119 246.20 145.68
58 136.40 122.47
5 41.00 101.95 120 248.00 146.06
59 138.20 122.86
6 42.80 102.34 60 140.00 123.24 121 249.80 146.44
7 44.60 102.73 61 141.80 123.62 122 251.60 146.81
8 46.40 103.12 62 143.60 124.01 123 253.40 147.19
9 48.20 103.51 65 149.00 125.16 124 255.20 147.57
10 50.00 103.90 66 150.80 125.54
11 51.80 104.29 125 257.00 147.94
67 152.60 125.92
12 53.60 104.68 126 258.80 148.32
68 154.40 126.31
13 55.40 105.07 69 156.20 126.69 127 260.60 148.70
14 57.20 105.46 70 158.00 127.07 128 262.40 149.07
15 59.00 105.85 71 159.80 127.45 129 264.20 149.45
16 60.80 106.24 72 161.60 127.84 130 266.00 149.82
17 62.60 106.63 73 163.40 128.22 131 267.80 150.20
18 64.40 107.02 74 165.20 128.60 132 269.60 150.57
19 66.20 107.40 75 167.00 128.98
133 271.40 150.95
20 68.00 107.79 76 168.80 129.37
134 273.20 151.33
21 69.80 108.18 77 170.60 129.75
78 172.40 130.13 135 275.00 151.70
22 71.60 108.57
23 73.40 108.96 79 174.20 130.51 136 276.80 152.08
24 75.20 109.35 80 176.00 130.89 137 278.60 152.45
25 77.00 109.73 81 177.80 131.27 138 280.40 152.83
26 78.80 110.12 82 179.60 131.66 139 282.20 153.20
27 80.60 110.51 83 181.40 132.04 140 284.00 153.58
28 82.40 110.90 84 183.20 132.42
141 285.80 153.95
29 84.20 111.28 85 185.00 132.80
142 287.60 154.32
30 86.00 111.67 86 186.80 133.18
143 289.40 154.70
31 87.80 112.06 87 188.60 133.56
88 190.40 133.94 144 291.20 155.07
32 89.60 112.45
33 91.40 112.83 89 192.20 134.32 145 293.00 155.45
34 93.20 113.22

Temperature vs. Resistance Charts
ºC ºF OHMS ºC ºF OHMS C ºF OHMS
146 294.80 155.82 19 374.00 172.16 231 447.80 187.18
147 296.60 156.19 0 232 449.60 187.54
191 375.80 172.53
148 298.40 156.57 233 451.40 187.91
192 377.60 172.90
149 300.20 156.94 234 453.20 188.27
193 379.40 173.26 235 455.00 188.63
150 302.00 157.31
194 381.20 173.63 236 456.80 189.00
151 303.80 157.69
195 383.00 174.00 237 458.60 189.36
152 305.60 158.06
196 384.80 174.37 238 460.40 189.72
155 311.00 159.18
197 386.60 174.74 239 462.20 190.09
156 312.80 159.55
200 392.00 175.84 240 464.00 190.45
157 314.60 159.93
201 393.80 176.21 241 465.80 190.81
158 316.40 160.30
202 395.60 176.57 242 467.60 191.18
159 318.20 160.67
160 320.00 161.04 203 397.40 176.94 245 473.00 192.26
161 321.80 161.42 204 399.20 177.31 246 474.80 192.63
162 323.60 161.79 205 401.00 177.68 247 476.60 192.99
163 325.40 162.16 206 402.80 178.04 248 478.40 193.35
164 327.20 162.53 207 404.60 178.41 249 480.20 193.71
165 329.00 162.90 208 406.40 178.78 250 482.00 194.07
166 330.80 163.27 209 408.20 179.14 251 483.80 194.44
167 332.60 163.65 210 410.00 179.51 252 485.60 194.80
168 334.40 164.02 211 411.80 179.88 253 487.40 195.16
169 336.20 164.39 212 413.60 180.24 254 489.20 195.52
170 338.00 164.76 213 415.40 180.61 255 491.00 195.88
171 339.80 165.13 214 417.20 180.97 256 492.80 196.24
172 341.60 165.50 215 419.00 181.34 257 494.60 196.60
173 343.40 165.87 216 420.80 181.71 258 496.40 196.96
174 345.20 166.24 217 422.60 182.07 259 498.20 197.33
175 347.00 166.61 218 424.40 182.44 260 500.00 197.69
176 348.80 166.98 219 426.20 182.80 261 501.80 198.05
177 350.60 167.35 220 428.00 183.17 262 503.60 198.41
178 352.40 167.72 221 429.80 183.53 263 505.40 198.77
179 354.20 168.09 222 431.60 183.90 264 507.20 199.13
180 356.00 168.46 223 433.40 184.26 265 509.00 199.49
181 357.80 168.83 224 435.20 184.63 266 510.80 199.85
182 359.60 169.20 225 437.00 184.99 267 512.60 200.21
183 361.40 169.57 226 438.80 185.36 268 514.40 200.57
184 363.20 169.94 227 440.60 185.72 269 516.20 200.93
185 365.00 170.31 270 518.00 201.29
228 442.40 186.09
186 366.80 170.68 271 519.80 201.65
229 444.20 186.45
187 368.60 171.05 272 521.60 202.01
230 446.00 186.82
188 370.40 171.42 273 523.40 202.36
189 372.20 171.79

RTD Sensors
Sensor Failure Inaccurate Display
The Intellisys panel will display SENSOR FAILURE if If the RTD is displaying a temperature reading, but
an open circuit occurs on the following Sensors; this is thought to be inaccurate, the best course of
action is to remove the RTD from the machine for
2ATT first stage discharge testing purposes.
4ATT second stage discharge
• Remove the sensor and place in a
5OTT bearing oil
pre-heated oil bath at a temperature of
±50°C
This is an ALARM condition and the machine will
• Connect a good quality digital test
shutdown. The display will indicate the specific
meter across white and black wires,
sensor in an alternating message with whatever
set at ohms
message was on the display at the moment of
ALARM. • Place a good quality digital
temperature probe in the oil and check
The RESET button will allow the controller to initiate the temperature value versus the
a restart after the problem has been corrected. resistance in ohms via the chart
A 2% variance is the maximum permitted.
An open circuit on Sensors;
3ATT second stage inlet Sensor Checking and Replacement
7ATT package discharge On occasion, an operator could make an easy
comparison check of the three temperature sensors
Will not shutdown on ALARM, but display WARN, by merely scrolling through the current status after
RESET and SENSOR FAILURE. the compressor has been shut down for several
hours. As an example, make the comparison check
Short Circuits on Monday morning after a weekend shutdown.
White wire to ground or black wire short
circuited to White wire causes the particular If any reading seems abnormal from the others,
temperature sensor to display "O DEG" or "1 DEG" further checks can be made as follows.
on the Intellisys panel if that display has been
selected. To remove any of the three sensors, disconnect the
incoming power from the unit and vent all pressure
This problem will not cause any Alarm or from the system. In the case of the Bearing Oil
Warnings to occur. Temperature Sensor (5OTT), small amounts of
Coolant could drain from the unit when the sensor is
As an example, if the Black and White wires for removed from its location. A small drain pan might
Package Discharge Temperature sensor 4ATT be handy here.
become short circuited, the compressor will continue
to run and "O DEG” or "1 DEG" will come up on the Locate a high quality thermometer, a suitable
display for 2nd Stage Airend Discharge Temperature container of liquid (Oil will do nicely), a high quality
when selected. ohmmeter that has a digital read-out and a heating
device such as an electric hot plate.
The short circuit is individual to the affected sensor
and will not cause multiple displays on the panel. Place the sensor and the thermometer into the liquid
filled container.
Black wire to Ground will not cause any change in
the Intellisys readings because the black wire is Heat the liquid to a temperature somewhere
connected to board ground when wired to the between 100ºC and 150ºC to bring the sensor into
terminal strip. its normal operating range. Stir the liquid to ensure
even heating allowing ample time for the sensor and
After the short circuit is corrected, the Intellisys can the thermometer to stabilise with each other in the
be cleared in the normal manner. liquid.
In summation, wire damage is the most likely cause Connect a good quality digital read-out ohmmeter to
of temperature sensor failures. These failures are the Black and White wires.
usually "cut wires“ or "short circuits" either to ground
or between wires. A careful investigation will quickly Carefully record the thermometer and ohmmeter
identify your problem area. readings and compare them with the chart in the
previous section.

RTD Sensors
First - locate the temperature on the chart that The panel will not Reset until such time as the
corresponds with the temperature measured with the problem is corrected.
test thermometer in the heated liquid.
B) Black Wire to Ground will not cause any change
Second - observe the resistance value shown on in the Intellisys readings because the black wire
the chart next to the correct temperature. This is connected to board ground when wired to the
resistance value must be within a tolerance of plus/ terminal strip. After the short circuit condition is
minus 2% of your test ohmmeter reading. corrected, the Intellisys can be cleared in the
normal manner.
The sensor will be either good or bad. Replace it, if
required, using loctite on the threads prior to In summation, wire damage is the most likely
installing the sensor back into position. Carefully cause of temperature sensor failures. These
inspect your work at this point to determine no failures are usually cut wires or short circuit either
damage to the wiring has occurred during to ground or between wires.
installation of the sensor.
C) Black Short Circuited to White causes the
Troubleshooting particular temperature sensor to display “0 DEG”
The Intellisys panel has the logic to determine that a on the Intellisys panel if that display has been
“Sensor Failure” has occurred and will indicate the selected.
probable area to check with a message on the
display. This problem will not cause any alarm or
warnings to occur.
As an example, if the compressor has shut down on
an Alarm condition and Sensor Failure 4 APT is on As an example, if the Black and White wires for
display, the problem can be located within the Package Discharge Temperature sensor 7ATT
circuitry for that particular sensor. become short circuited, the compressor will
continue to run and “0 DEG” will come up on the
There can be various types of “Failures” associated display for Package Discharge Temperature”
with the temperature sensors and are easier to when selected.
understand if the failures are placed in different
categories. The short circuit condition is individual to the
affected sensor and will not cause multiple
A) Open Circuit such as a broken wire, displays on the panel.
disconnected cable, loose wire, etc. on either the
Black or the White wire. D) White Wire to Ground will cause a “Warn”
condition for “Package Discharge Air
This type of problem causes the compressor to Temperature” sensor 7ATT while the compressor
shutdown with an Alarm Condition displayed if the continues to operate. The Intellisys display will
open wire is on either 2ATT, 4ATT or 5OTT. The alternate “Sensor Failure 7ATT” with whatever
open circuit reacts the same regardless of which was on the display at the moment the warn
wire (Black or White) is cut. condition began. Remember, the compressor
continues to run with only a “Warn” indication and
The compressor will shut down and the display “Reset” along the lower edge of the panel.
will indicate the specific sensor in an alternating
message with whatever message was on the Again this problem can cause either an Alarm
display at the moment the Alarm condition began. shutdown or a Warn condition depending on the
These messages will continue to alternate until sensor which as failed.
the problem is corrected and “Reset” is pushed.
An investigation of the wires is now indicated.
If an open circuit condition is experienced on the After the short circuit condition is corrected, the
Package Discharge Temperature Sensor (7 ATT) Intellisys can be cleared in the normal manner.
or 2nd stage inlet temperature sensor (3ATT), the
compressor will not shut down but “Warn” and In summation, wire damage is the most likely
“Reset” will appear at the lower edge of the panel cause of temperature sensor failures. These
and message display will show Sensor Failure 7 failures are usually “cut wires” or “short circuits”
ATT or 3ATT alternately with whatever message either to ground or between wires. A careful
was on the display at the moment the “Warn” investigation will quickly identify your problem
condition began. area.

Electrical

Electrical

Electrical

Electrical
Condensate Drains
There are 2 condensate drains used within the Sierra
package which are controlled by the Intellisys.
The purge time of the condensate solenoid valves is

adjustable within the operator set points between the
range of 2 - 10 Seconds.
The unit will purge condensate at the following

intervals: -
• When unit is Started

• When Unit is Stopped
• Whenever unit Loads
• Condensate Interval
(Adjustable) 90 - 270 Seconds
• Whenever unit Unloads
• Every 10 minutes when power is applied and
unit is stopped

Short Test
Short Test
1 What are the three major components of the Intellisys control system?
2 Which sensors issue “sensor failure” warnings?
3 Is “High 1st Stage Temp” alarm adjustable?
4 Which sensors will issue “sensor failure” alarms?
5 What can cause the memory fault alarm?

Short Test
6 Explain the sensor calibration procedure.
7 What is the resistance of TRD at 25oc ambient temperature?
8 Explain how to troubleshoot the four possible faults on RTDs.

Nirvana HPM Motor
Variable Speed Drive
Troubleshooting
Manual
Issue: 09, December, 2008

Copyright Notice
© 2007 Ingersoll Rand Company
PROPRIETARY NOTICES
Copyright 2007 INGERSOLL RAND COMPANY
CONFIDENTIAL AND TRADE SECRET INFORMATION. This manual contains confidential

and trade secret information owned by Ingersoll-Rand Company (hereinafter referred to as
"Proprietary Matter"). In consideration of the disclosure of the Proprietary Matter herein to the
authorized recipient hereof, the recipient shall treat the Proprietary Matter as secret and
confidential; shall not disclose or give such Proprietary Matter to third parties without the
express written authorization of INGERSOLL RAND; shall not use the Proprietary Matter
except to the extent necessary to use or service the equipment disclosed herein; and shall
disclose such Proprietary Matter only to those of its employees whose use or knowledge of the
Proprietary Matter is necessary. This manual shall be returned upon request by Ingersoll Rand
Company. The unauthorized use of this manual may be punishable by law.
DISCLAIMERS
PROVIDED "AS IS". THIS MANUAL AND THE CONTENTS THEREOF ARE PROVIDED
"AS IS" AND WITHOUT ANY IMPLIED WARRANTIES.
HPM VSD Troubleshooting
Index
Introduction
This manual has been designed to provide you with
fundamental knowledge about troubleshooting the
HPM Variable Speed Drive (VSD).
Index Recommended Tools

Safety First................................................... 1
Variable Speed Drive (VSD) Overview........ 2-15 • Volt Meter with a Diode setting
VSD Drive Faults 0—44 .............................. 16-22
Drive Diagnostics—Test .............................. 23-37 • Motor Megger Capable of delivering a
VSD Voltage Checks ................................... 38 1000K volts
Winding Insulation Test ............................... 39-41
Rotor/Stator Torque Settings....................... 42 • Milliohm Meter electrical or battery
Hall Effect Sensor Checks........................... 43-46 operated
Control Board (PL1)..................................... 47-48
Interface Board (PL2) .................................. 49-51 • Hall Effect Senor Checker
I/D Board...................................................... 52
Input Module Parts ID .................................. 53-55 • Stator Installation/Removal Tool
Input Module Replacement.......................... 56
Output Module Parts ID ............................... 57-59 • Rotor Removal Tool
Output Module T1 Old/New Parts ID ........... 60
Output Module Replacement T1/T2 ............ 61-63
• Torex Driver Set
Output Module T1/T2 PL5 Board................. 64
T1 Input (Rectifier) Module Test .................. 65-67
• Lap Top Computer
T1 Output (Inverter) Module Test ................ 68-69
T2 Input (Rectifier) Module Test .................. 70-71
• Nirvana Service Tool
T2 Output (Inverter) Module Test ................ 72-73
Complete Drive Replacement...................... 74
T1 VFD Bolts Torque Settings..................... 75-80
• Nirvana Services Tool Cable
T2 VFD Bolts Torque Settings..................... 81-85
VFD Cooling ................................................ 86-87
Site Log........................................................ 88-90
Revision Updates and History ..................... 91
HPM Variable Speed Drive (VSD) Troubleshooting Manual Page 3

Issue: 08/Davidson, April, 2008. ©Ingersoll Rand Proprietary Information
Safety
Danger
Please utilize extreme caution when performing work within the starter cabinet.
When opening the cabinet: be certain the drive protective shield is in place, wear appropriate PPE (Personal
Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures are followed.
Safety First
Δ! WARNING
Hazardous voltage. Can cause

severe injury or death.
!
Danger
• The drive has various voltages present on the
power terminal blocks and in cables
Δ! WARNING
After switching off the machine at its local isolator.
connected to them that may cause fatal
electrical shocks.
• The drive contains capacitors which remain
WAIT AT LEAST 15 MINUTES for the capacitors
to fully discharge before removing the drive cover. With charged at a fatal voltage for a period of time
caution, verify DC bus voltage is zero before servicing. even after the power supply has been
removed.
• Do not perform operations on the drive
Δ! WARNING—HIGH VOLTAGE
without first manually opening the power
supply circuit to the drive. Lock out and tag
out the fused isolator or circuit breaker to
Do not attempt any work. prevent accidents.
Read manual.
Trained service personnel only. • After performing any operations on the drive,
Remove electrical supply. replace the protective covers before restoring
Wait 15 minutes. power.
Check for zero voltage.
Proceed with caution.
! Note ! Danger
Always use approved electrically insulated A Variable Speed Drive is contained within the
gloves. compressor starter cabinet.

VSD Overview
Danger
2) The intermediate circuits then smoothes and holds

In this section, you will learn the DC voltage at a constant level as the energy
source for the inverter .
• Major components of VSDs and their functions
3) The inverter module, uses the DC Voltage to pulse
• Various terms used for VSDs across the industry the motor with varying levels of voltage and current
• Why VSDs are used in compressed air industry depending upon the control circuit. The pattern of
• Difference between Chassis and Modular drives the pulses going to the motor makes it appear to
• Principle of VSD operation AC sinusoidal waveform voltage of variable
frequency. With the change of frequency the speed
of the motor would also change.
VFD or VSD? Why VSDs are used in compressed air industry?

The following terms are used for the Variable Speed • Over 5 years period energy costs typically make up
Drives (VSD) across the industry: 86% of the overall cost of compressed air
• Variable Frequency Drives (VFD) • With fluctuating air demands VSD saves 20-35%
• Adjustable Frequency Drives (AFD)

on electricity bill
• Reduces maintenance costs
• Adjustable Speed Drives (ASD)
• Lowers the noise levels
• Variable Speed Drives (VSD)
• Better pressure control
• Frequency Inverters
• “Soft starting” -low inrush current enables
• Inverters
‘unlimited’ starts and stops of the motor.
The above list is not exhaustive and different
companies that produce VSD might call their drives Motor speed is directly proportional to frequency and
differently. However, the principle of operations as the VSD changes the speed of the HPM motor by
well as major components of VSDs are similar and using a frequency inverter.
they consist of:
As the motor turns slower, it pulls less power and the
Thyristors often called rectifier bridge with the compressor makes less air. The consumed power and
purpose of phase control and generating “ripple” compressed air flow (capacity) are linear therefore
current later converted to direct current. less flow means that less power is being consumed.
Capacitors or intermediate circuit used to store DC The diagram on the previous page provides typical
Voltage relationship between rotor speed and capacity for
various pressures.
IGBTs (Insulated Gated Bipolar Transistors) often
called Inverter bridge which converts DC to AC of Capacity vs Rotor Spe e d
various frequency depending on system requirements.
300
Capacity
Control System which controls all devices within 250

100psi
200
VSD and communicate with SG controller. 150 125psi
100 150psi
50
In general terms the operation of the VSD drive is as
0
follows. 0 1000 2000 3000 4000 5000 6000
1) Power first go to the rectifier input module, where R ot or S pe e d ( R e v / M in)
the 3 phase AC is converted into a rippling DC

Voltage.

VSD Overview
Danger
Chassis & Modular VSD Drives Drive Type Power Frequency

With the introduction of Nirvana Contact Cooled Chassis 110 / 120 VAC 50 / 60 Hz
compressors Ingersoll Rand used chassis VSD drives Single phase
which later developed to modular type drives for better
spare parts rationalization and more specific T1 Modular 230 VAC 50 / 60 Hz
troubleshooting. Single phase
T2 Modular 460 / 480 VAC 50 / 60 Hz
There are two types of modular drives.
3-phase
• T1 is used on 37kW to 75kW compressors
• T2 is used on 90Kw to 160Kw compressors. The nameplate also indicates the Ingersoll-Rand part
number and serial number of the drive.
The differences between these drives are explained
later in this manual. On chassis drives the drive’s electronic control supply
is a single phase 110/120V, 50/60 Hz circuit. On T1
VSD and T2 modular drives the control voltage is 200 VAC,
The Variable Speed Drive is located in the starter 50/60HZ single phase.
cabinet and has a protective cover to prevent
accidental touching of the drive. Any work performed There is a drive cooling blower which dissipates heat
on the drive should be made competent and qualified generated by the drive components. See chart for
personnel only. blower power ratings:
The drive’s output voltage ranges from 0V to the
The Nirvana drive is an Alternating Current (AC) power supply voltage. On chassis drives the maximum
closed loop flux vector controller particularly adapted number of power-ups is limited to 20 per hour.
for Hybrid Permanent Magnet (HPM) motors. The Modular drives use a formula for the number of power
controller uses an inverter bridge with Insulated Gated ups. Modular drives can be powered up 5 times
Bipolar Transistors consecutively. After that,
(IGBT) which the equation is:
considerably ( 60—number of minutes
diminishes noise and for 5 power ups) ÷ 15.
temperature rise in
variable speed motors. In general, Nirvana’s
ambient operating
There is a nameplate temperature range is 1.6°
on each drive to to 46°C (35° to 115°F),
indicate the rating and with humidity levels
voltage. ranging between 5 to
95%; no condensation
The voltage supply allowed.
must be within 10% ±
of the rated voltage The drive must be
and the frequency protected by fast acting
within ±2%. Class J, Class T or SF
fuses within the main
The phase voltage incoming power supply.
imbalance must not
exceed 2% on 50Hz
units and 3% on 60Hz
units.
Typical Chassis VSD Drive Typical Modular VSD Drive

VSD Overview
Danger
Rectifier Bridge Capacitors Choke Control Board IGBT

PL1 Boards

VSD Overview
Danger
Rectifier
Input (Rectifier) LEM

Capacitors Control Board Output
Module
PL1 (Inverter
1
IGBT)
d PL
Modules
in
Beh
Choke
L1
dP
hin
Be

VSD Overview
Danger
VSD - Operation
The drive receives incoming main voltage through the
Thyristors (Input Rectifier Bridge), the AC voltage is
used to generate a DC voltage which is stored in the
capacitors. The capacitors are mounted on heatsinks
to prevent excess temperatures from occurring within
the capacitors, the heatsinks are cooled by the drive
cooling fan which draws air into the starter cabinet and
upwards across the VSD.
If an alarm condition occurs on the compressor then

the isolation contactor will de-energise and remove
mains power from the drive, an alarm condition should KM1
not be continuously reset as constant powering up of
the drive can cause damage to occur.
The DC voltage generated is directly proportional to

the incoming mains power and can be calculated drive e.g. capacitors remain at the correct
using the following formula: temperature. In the event of an over temperature
situation the drive will shutdown and cause the SGN
Incoming Mains Voltage x 1.4142 (Square Root of 2) Intellisys to stop the compressor and display an Alarm
I.e. 400 v x 1.4142 = 565 Volts DC Condition.
Due to the DC Voltage stored on the capacitors when The temperature of the power components/heat-sinks
incoming mains power is removed via KM1 the drive are monitored by a temperature sensor located on
will retain the charge of DC Voltage for a period of either side of the drive (on chassis drive). The sensors
time after the VSD has been isolated and care should are normally closed and provide a signal to the PL2
be taken to ensure the voltage has been fully circuit board on plug P7, the sensors operate and
discharged before any work on the drive is performed. open at 85ºC (185ºF).
The DC Voltage is then discharged in a controlled and
synchronised manner to create an AC waveform of the
desired frequency to operate the motor at the correct Drive Ventilation Fan
speed required. This is controlled by the IGBT’s which
are controlled and fired by the Interface Board based
on the signals from the Control Board.
When the compressor has power applied and displays

“Ready To Start” the contactor KM1 will energize to
supply main incoming voltage to the drive. An auxiliary
contact designated KM5-1 fitted to the fan contactor
will close and supply 110 V control power to the Drive
Ventilation Blower (Heatsink Blower), as seen below,
when the compressor is started.
The fan ensures that the power components within the
Chassis Drive Cooling arrangement

VSD Overview
Danger
When the isolation contactor KM1 energises, input

Drive Filter voltage will be supplied to the VSD via the terminals
located at the bottom of the drive L1, L2 & L3. Input
voltage is monitored by the VSD and compared to the
internal power, from the transformer located on the
drive, a value is then generated and displayed in the
SGN Intellisys.
The value displayed may not actually represent the

true input voltage to the drive due to the way the drive
generates the values from the voltage comparison.
Example: KM1 Isolation Contactor open due to 1ATS

operating, VSD input voltage is O VAC but the SGN
The cooling air for the VSD is drawn through the inlet Intellisys display will be “Input Voltage - 80 VAC” and
grill located on the side of the starter cabinet at the “DC Bus Voltage - 0VDC” .
bottom.
The HPM motor is connected to terminals U, V & W
The inlet grill also has a filter pad which requires located at the bottom of the drive.
regular checking for excess dirt loading and should be
changed immediately should the filter pad reduce the The HPM Motor has six leads connected as follows:
cooling airflow.
Drive Terminal Pairs
The cooling air should be as free from contamination U 1 and 1
as possible to ensure no cooling problems occur with V 2 and 2
the drive. W 3 and 3
Input Voltage
HPM Motor
Leads

VSD Overview
Danger
There is only one DC Choke:

For T1, it is inserted in —DC bus (not shown)
For T2, it is inserted in +DC bus (shown below)
Input Rectifier Module
+
Thy 1 Thy 2 Thy 3
DC Current
L1 I
L2
L3 r
o
D1 D2 D3
Alternating Voltage
L1 L2 L3
Capacitors
Thyristors are electronic components located in the

input rectifier module, they allow current to flow in only
one direction, converting the 3-phase AC input
voltage to rippling DC voltage as shown above.
The intermediate circuit also known as DC Link can

be seen as a power storage facility for the Invertor
section of the drive. In the diagram at the top of the
right column you will notice that the rippled DC voltage
has been filtered to a constant voltage after passing
through the DC line coil (choke).
The capacitors store the DC current that is generated

by the Thyristors. The capacitors are rated for
400VDC, they are connected in series in order to
handle the DC bus voltage which is generated (560V
during running; 730V maximum, 785 Trip Value).
Choke

VSD Overview
Danger
T1 modular drive
DC Bus EMC PCB : PL5
DC Bus Bar
T2 modular
drive
IGBT
cables
The DC Bus Printed Circuit Board (PCB) (PL5) Interface Board (PL2)
measures the DC Bus Voltage and feeds the
information to the Interface Board (PL2) located
behind the Control Board (PL1) for internal monitoring
and display DC bus voltage by the SGN Intellisys.
The next part of the VSD is the Inverter section. This

section takes the DC voltage from the Intermediate
section ( DC bus) and with the help of the Interface IGBTS
Board (PL2) fires each set of IGBT ( Insulated Gate Circuits
Bipolar Transistors) to the U, V, W terminals of the
motor.
! Note:
Never touch the IGBT driver PCB, or attempt to
remove the IGBT’s from the VSD.

VSD Overview
Danger
The motor current is monitored by 2 Current The drive will automatically stop and will communicate
Transformers (CT) installed on U and V cables to the the drive fault to the SGN Intellisys which will then
motor (T2 drives). There are 3 current transformers display “VSD Fault 3” and stop the compressor in an
on the T1 Drive. The information is provided to the alarm condition.
VSD for motor protection and for display by the SGN
Intellisys (in code 3 on contact cooled). The only thermal probe on a modular drive is the
probe located below the rectifier bridge and directly
connected to the
triggering board. This Temperature Sensor
probe monitors the (Chassis Drive)
temperature of the
rectifier module and is
screwed on its heatsink.
The maximum
temperature allowed is
90 °C (194°F. The
temperature reading is
available from the
Current Transformers (Chassis Drive) Intellisys in code 3.
The temperature probe of

the output module is
The control board (PL1) receives inputs from external internally monitored by the IGBT driver board from the
devices such as the package pressure transducer and transistor chips. The temperature information is then
digital signals to start and stop the motor. Serial forwarded through the interface board to the control
communication with the SGN Intellisys for alarm board with the IGBT firing order cables. Temperature
conditions and programming data for maximum and measurements are accessible from the Intellisys
minimum speeds etc are also controlled by the control controller in code 3 service display. The temperature
board PL1. trip point is 110 °C (230°F).
Control Board PL1
Thermal probe
connector
EMC Board
Triggering Board
The temperature of the power components/heat-sinks

are monitored by a temperature sensor located on
either side of the drive on chassis drives. The sensors
are normally closed and provide a signal to the PL2 Thermal Probe
circuit board.
Modular board

Short Test
Short Test
1 List four major components of VSD.
2 What is the function of Thyristors?
3 What is the function of choke and capacitors?
4 What is the purpose of IGBT?
5 What is estimated DC voltage at busbars if the measured main voltage is 400VAC.

Short Test
Short Test
6 How many times per hour you can isolate capacitors from the main power supply
( KM1 isolator turned on/off)?
7 Which printed circuit board controls the IGBTs?
8 What is the tolerance allowed on the rated voltage, rated frequency and line imbal-
ance?
9 What is the function of the DC Bus PCB PL5?

VSD Overview
Danger
T1 Modular Drive
T1 Drive is the replacement modular drive for
the chassis drive on Nirvana units listed below:
• 37kW (50HP), EMC board
• 45kW (60HP),
• 55kW (75HP) and
• 75kW (100HP)
Input
rectifier
The Control Board and Power Interface Boards are module
installed on the “fold door” mounting plate.
The Control Board is mounted on the front and the
Power Interface Board is behind.
Once the mounting plate is folded down, it exposes

output terminals as per the following picture.
Capacitors
Input power terminals

Power Input voltage :
TL Drives : 3 phase supply
200V to 230V, ±10%, 50Hz or 60Hz ±2%
T Drives : 3 phase supply
380V to 480V, ±10%, 50Hz or 60Hz ±2% DC bus sensing board
The Mounting Plate is in

the closed position so
the Control board (PL1)
L1 is showing.
L2 The Power Interface

Board is located behind
the Control Board and is
L3 not shown.
W
Output motor terminals
V From 0V to power supply voltage
U
Mounting Plate in
open position showing
Power Interface Board

VSD Overview
Danger
T2 Modular Drive
T2 Drive is the modular drive that is installed on
Nirvana units:
• 90kW (125HP),
• 110kW (150HP),
• 132kW and
• 160kW (200HP) single stage and
• 2 Stage Nirvana Oil Free & Contact Cooled
compressors
The following picture points

out the major components
of the drive.

VSD Overview
Danger
Block Diagram of a VSD drive
Power supply
+DC Bus -DC Bus
Rectifier Capacitors Inverter

Current
transformers
Power inteface
Base drive
Microprocessor
Run forward Pre-set Reset Fault indication

reverse speed disable
Intellisys
Pressure sensor

VSD Drive Faults
Danger
! AC voltage is the usual cause for this alarm.

Note:
Prior to beginning any troubleshooting procedures, it is Example: on a 480 volt system, the AC voltage
important to understand that loose terminal must be less than 528 volts (480 + 10%).
connections, blown fuses or improperly engaged plugs
can be a cause for faults to be issued. A thorough Since the relationship between AC and DC is a
inspection and correction, if required, can save time multiplier of 1.4142, the DC voltage is calculated at
and effort lost looking for the wrong thing. 746 volts DC.
The drive has the capability to monitor itself for proper Check the incoming AC voltage to the compressor at
operation and should a problem arise, the drive will the customer disconnect, at the top of drive isolation
issue an alarm that immediately stops the compressor. contactor KM1 or on the Current Status screen of
The cause for the alarm is indicated on the display of the Intellisys display (Input Voltage).
the Intellisys controller. The alarms are listed as a
sequence of letters and numbers.
Examples could be “VSD Fault 0” or “VSD Fault 29”.

A total of 44 faults are possible within the drive; some
of which are not active. VSD indicates Variable Speed
Drive and the number indicates the specific fault.
The following description of active faults is intended to

guide a trained technician during the problem
investigation. The “not active” alarms are merely
listed to maintain the numerical sequence and
therefore have no text or description.
It is assumed the technician has access to, and is

capable of operating, various test devices such as
voltmeters within both AC and DC circuits. Is capable
of checking winding resistance, checking diodes and
reading schematics among other tasks.
Drive Faults
Note:
! The following VSD faults are displayed by the
SGNe FACEPLATE
VSD Fault 0 - DC Bus Over-Voltage

Background: The VSD measures DC voltage on the
bus bars within the drive and should the voltage AC incoming voltage
exceed approximately 785 volts DC, VSD Fault 0 will read by the drive
be issued. The alarm is issued whether the motor is
running or not.
The DC bus voltage is directly proportional to the AC

voltage supplied to the compressor and high incoming

VSD Drive Faults
Danger
The DC bus voltage is also displayed within the with Power Utility suppliers. A Line Reactor may be
Service Menu 3 screen of the Intellisys. required. Refer to IR Line Reactor technical notes and
IR installation instructions.
Service Menu 16 displays the maximum values
registered by the drive and records the date and time Confirm the KM1 contactor is not rapidly closing and
they happened. Values displayed are Motor Speed, opening (chattering) or that there are no loose wire
Motor Current, Input Voltage, DC Bus Voltage and connections to cause voltage spikes.
Motor Voltage. Also confirm that none of the drive motor phases go to
a ground condition.
The high voltage may be transient and monitoring
devices may be required to verify the source. Consult
Input & Output Power Terminals for T1 Drive

Input power terminals
Power Input voltage :
380 to 480 VAC ± 10%, 50 or 60 Hz ± 2% (T Drives)
200 to 230 VAC ± 10%, 50 or 60 Hz ±2% (TL Drives)
L
1
Ouput motor terminals

L From OV to power supply voltage
2

VSD Drive Faults
Danger
VSD Fault 1 - Over-Current • Check all internal connection points, check for
Background: This fault is an instantaneous “do not signs of motor phase arcing, faulty current
exceed” over-current condition. The setting and rapid transformers or chafed motor leads.
response is part of the drive parameter settings and • Confirm drive motor is mechanically able to rotate
pre-programmed. by removing louvre from end of motor and rotating
by hand. Rotation will seem to be unusual as
There are two blue coloured current transformers fitted magnets in rotor pass winding poles in motor
over motor leads U and V on the T2 drive, the T1 drive stator.
has 3 current transformers on U, V and W leads, that • Refer to page 41 and megger motor.
continuously monitor the VSD output current, and in
• Inspect Hall Effect sensor cable wiring and point of
the event that this current exceeds the pre-set
connection at PX4 on the Control Board. A loose
threshold the alarm is activated.
wire or bad connection can cause the drive to
• Confirm incoming power supply voltage is within receive erratic information and possibly accelerate
specifications and stable to avoid over-correction of the motor too fast to create an over-current
the motor speed as the drive responds to the condition.
voltage fluctuation.
• Refer to page 44 for the Hall Effect Sensor
• Confirm I.D. Board is properly plugged into the checking procedure.
Power (Interface) Board. Refer to procedure
• Confirm that the (CT) Current transformers are not
outlined on page 54 for details.
over reading, by viewing the motor current value in
Input & Output Power Terminals for T2 Drive Service menu 3 and use a Current champ meter on
the leads to the motor. The current values on
Output terminals U, V and W service menu 3 and the current clamp meter
• Output voltage 0 to 400V should correspond to each other. If they do not,
• 0 to 300Hz for HPM motor D type then the (CT) Current transformers could be faulty.
• If the problem remains, disconnect the motor leads
U, V and W from the lower terminal block of the
W VSD and attempt to start unit. If Alarm 44 is issued
after turning the power back on, reset Alarm 44
and try to start the motor again,
• If a fault is not issued, conduct a power module
diagnostic test (page 30).
V
• Refer to page 24 and conduct an Electronic boards
internal diagnostic.
U
L
Input terminals
L1, L2 and L3 L
• Input voltage 350 to 520V
L
Flip the control board (PL1) to access the

channel U output terminal and the Power
Interface Board (PL2)

VSD Drive Faults
Danger
VSD Fault 2 - Current Imbalance VSD Fault 3 - Drive Temperature Too High
The measured current to the drive motor on leads U, V Background: A blower located in the bottom rear of
& W should be balanced within 2% or VSD Fault 2 will the T2 drive and at the top of the T1 drive removes
be issued. heat generated by the VSD electrical components
during operation. The blower also removes heat from
This can be caused by improperly tightened U, V & W the heat sinks on the back of the drive modules.
motor leads. • If VSD Fault 3 is experienced, confirm that the
• Check wiring within VSD such as I.D. Board plug in VSD ambient temperature is below 115° (+46°C).
point. See page 54. • Check voltage to blower.
• Confirm I.D. Board is properly plugged into the • Ensure proper operation of KM5 and MMS2 on the
Power (Interface) Board. blower supply voltage.
• Refer to page 30 and conduct a power module • Locate small filter element at lower portion of VSD
diagnostic test enclosure on T1 drive, double filters located on
doors on T2 drive: clean or replace as required.
T1 modular drive
• The temperature of the rectifier is obtained from a
probe attached to the heat sink, just below the
Thyristors. This probe is connected to the
triggering board at connection TH. Check continuity
across terminals, as per the previous picture.
• Ensure the wire connections are tight.
• The IGBT chips measure the temperature of the
IGBT transistors internally. This temperature is
available on Service Menu 3 of the Intellisys
controller. If the temperature of the IGBT exceeds
110°C (230°F) or the Rectifier temperature
Chassis Drive exceeds 90°C (194°F). The VSD fault 3 will be
thermal probes test on P7 issued.
• Check the drive blower is free to rotate.
Connector
removed from P7
of the power VSD Fault 4 - Not Active (reserved)
board
VSD Fault 5 - Internal Power Supply
The Control Board is a self-monitoring device and
should a problem develop on the board, VSD Fault 5
is issued.
• Cycle incoming power to the compressor to see if
the problem clears.
• Refer to page 24 and conduct an electronic board
self-diagnostic test.
VSD Fault 6 - Microprocessor

• Open incoming power supply to compressor at
customer’s disconnect.
• Leave open for approximately 15 minutes to permit
VSD capacitors to fully discharge. Apply power.
• Refer to page 24 and conduct an electronic board
self-diagnostic test.

VSD Drive Faults
Danger
VSD Fault 7 - Encoder (Hall Effect Sensors) VSD Fault 13 - Phase Missing
• Check encoder signals using procedure detailed on Similar to VSD Fault 12 but is calculated using
page 44. parameters at full load conditions.
• Open VSD enclosure and use voltmeter at top of
• Refer to page 24 and conduct a electronic board
self-diagnostic test. Inspect the Hall Effect Sensors KM1 to determine which phase is missing.
for damage, chaffed leads or loose connections. • Identify cause, such as blown fuse and correct as
required.
VSD Fault 8 - Encoder Loss • Ensure KM1 is operating properly
Same procedure as VSD 7.
VSD Fault 14 - Mains Under Voltage
VSD Fault 9 - Not Active (reserved). Confirm incoming voltage supply to compressor is
within -10% of VSD’s rated voltage.
• Verify that KM1 contactor is not chattering.
VSD Fault 10 - Bus Oscillation
This is caused by voltage rapidly rising and falling on
the incoming power supply and is read from the DC
VSD Fault 15 – Mains Over Voltage
bus bar. • Confirm that the incoming voltage supply to
compressor is within +10% of VSD’s rated voltage.
• Check the incoming power supply. Voltage can not
vary more than 3% or an alarm will be issued.
• Ensure proper operation of K2 relay.
VSD Fault 16 – DC Bus Under Voltage
• Check for KM1 contactor chatter. • Confirm incoming voltage supply to compressor is
within -10% of VSD’s rated voltage.
• Refer to page 41 and megger motor.
• Verify that KM1 contactor is not chattering.
• Reset Intellisys controller to permit KM1 to apply
VSD Fault 11 - Not Active (reserved) power to VSD. Confirm AC voltage is correct at
terminals L1, L2 & L3 at bottom left of the T2 Drive.
VSD Fault 12 - Mains Failure (Loss of At the top left of the T1 Drive
Incoming Power) • Multiply the measured AC voltage as read at
Relates to incoming power supply and is read within terminals 1, 2 & 3 at bottom of VSD by 1.4142 to
the VSD. calculate what the DC Bus voltage should be.
• Reset Intellisys controller to permit KM1 to reapply • Check Input Voltage and DC Bus voltage on
power to the VSD. Scroll through Status screen to Intellisys Status screen. The DC voltage in the
Input Voltage. Voltage reading will be Intellisys display should be within 5% of the
approximately half of compressor’s rated voltage if calculation.
all three phases are not available. • Check fuses (2) on small printed circuit board (PL5
• Open VSD enclosure and use voltmeter at top of board), located on bottom of capacitor bank. If
KM1 to determine which phase is missing. either fuse is blown, use instructions on page 41 to
• Identify cause, such as blown fuse and correct as
check drive motor windings (megger test).
required. • Refer to page 24 and conduct an Internal Power
Module diagnostic test.
• If drive motor winding resistance is within
specification, call for assistance.
VSD Fault 17 – Not Active (reserved)

VSD Drive Faults
Danger
•
VSD Fault 18 – Motor PTC Probe Check Hall Effect sensors are properly installed.
• Check the K1 Relay.
• Confirm ambient temperature is within specification
(less than 115°F / 46°C) and airflow is not • Check for locked airend or motor.
restricted. • Check the Hall Effect Sensor for signs of damage
• Reset Intellisys and attempt to start compressor. If or loose connections.
compressor runs, investigate ambient air • Perform the Power Module Test. Refer to Service
temperature and cooling airflow at time alarm was Menu 348.
issued. See Last Alarm Recall.
• If VSD Fault 18 immediately returns after starting VSD Fault 24 – Not Active (reserved)
compressor, use page 44 to check Hall Effect
sensors. Replace as required. VSD Fault 25 – Not Active (reserved)
VSD Fault 19 – Not Active (reserved) VSD Fault 26 – Motor Over Speed
• Use directions detailed on page 44 to check Hall
VSD Fault 20 – Not Active (reserved) Effect sensors.
VSD Fault 21 – Not Active (reserved) VSD Fault 27 – Not Active (reserved)
VSD Fault 22 - Current Overload VSD Fault 28 – Not Active (reserved)

This alarm is issued after the drive motor has been in
an overload condition for a period of time. VSD Fault 29 – IGBT
Reset the Intellisys and check Last Alarm Recall for
• Refer to page 30 and conduct a Power Module
history concerning high drive motor current, airend
discharge temperature, etc. diagnostic
• Refer to page 24 and conduct an internal electronic
• Remove cover from end of drive motor and rotate board’s diagnostic.
by hand to check for hard rotation.
VSD Fault 30 – Not Active (reserved)
!
Note: VSD Fault 31 – Motor Phase
The motor will rotate in an odd way as the
• Check drive motor leads for proper connection at
magnets on the rotor pass the winding poles and will
U, V & W on the right side of the Drive.
feel similar to a large stepper motor.
• Remove cover from end of drive motor and confirm
leads are properly connected to motor windings.
• Attempt restart and observe operation for unusual
noise or vibration. Investigate as required. • Use page 41 to check drive motor windings for
open phase or phase to ground.
• Check the motor current draw (read from service
menu 3 on the Intellisys). • Refer to page 30 and conduct an internal power
module diagnostic test.
VSD Fault 23 - Motor Under Speed
This fault can be the result of the drive not getting the VSD Fault 32 – Not Active (reserved)
start command, which is given by the K1 relay. If
contact is not made when the start command is given,
the SGNe Controller will issue VSD Fault 23.

VSD Drive Faults
Danger
VSD Fault 33 – Rectifier Temperature VSD Fault 41 – IGBT Fault Phase W

• Check connection wires between probe (located • Refer to pages 30 and 66-72 and conduct a power
under the Thyristor packs) and the triggering module diagnostic test.
board. (Page 58)
VSD Fault 34 – Inverter Temp., Phase U. ! Note

As part of the troubleshooting process on a T2
• Make sure the drive blower is running. Verify the Modular Drive IGBT fault, try swapping over the
ambient is not too high (115°F /46°C). Check the suspected faulty module with another module and see
panel filters and clean or replace as necessary. if the fault then transfers. For example, if the U phase
is faulty and VSD 39 is displayed, swap with the V
VSD Fault 35 - Inverter Temp., Phase V. phase module and see if VSD 40 occurs. If so, then
the U phase is faulty, if not then the suspect fault is
• Make sure the drive blower is running. Verify the related prior to the module.
ambient is not too high (115°F /46°C). Check the
panel filters and clean or replace as necessary.
VSD Fault 42 – Rectifier Fault
VSD Fault 36 - Inverter Temp., Phase W. • Refer to pages 30 and 66-72 and conduct a power
• Make sure the drive blower is running. Verify the module diagnostic test.
ambient is not too high (115°F /46°C). Check the
panel filters and clean or replace as necessary.
VSD Fault 43 – Ambient Temperature
•
This is a high temperature read by the control board
VSD Fault 37 – Loss of +15 volts power inside the drive box.
supply for Hall Effect Sensors. • Ensure the blower is operating properly
• Confirm the voltage on the power interface board • Clean or replace the cabinet filters.
between pin 2 and the board common P16 with the
hall effect sensor disconnected. If the voltage is not VSD Fault 44 – Diagnostic Fault
present change the board. If the voltage drops This indicates that the drive has a fault when power is
every time the Hall Effect sensors are connected, applied and the VSD performs its self diagnostics, the
replace the sensors. latest software will not allow the alarm to be reset as a
problem which exists may cause further damage to
VSD Fault 38 – Loss of +24 volts DC power occur.
supply. • Refer to page 24 and view internal self-diagnostic
results.
• Check for +24 volts on the power board (between
Pin 3 and the board Common P16). If no voltage is
present change the board.
VSD Fault 39 – IGBT Fault Phase U

• Refer to pages 30 and 66-72 and conduct a power
VSD Fault 40 – IGBT Fault Phase V

• Refer to pages 30 and 66-72 and conduct a power

Drive Diagnostics - Test
Danger
VSD self diagnostic test. additional details refer to page 35 of this section of the
The drive automatically conducts a “Auto-Diagnosis” of manual. Error Code 2 is of secondary important.
the power modules every time the drive powers up
VSD manual diagnostic tests through Service
The VSD Fault 44 (Diagnostic Fault) is issued when a
fault occurs. This alarm cannot be reset, as the
Menu 348
Access to the internal drive diagnostics is done
through service Menu 348. Access to this menu is
accomplished with the compressor off in a ready to
start condition. Menu 348 is entered in the service
menu selection in the Factory set points. In the
service menu 348 you will see the following 3 tests.
These three tests must only be done by certified IR

Technicians through Service Menu “348”.
problem which exists may cause further damage.
Whenever Fault 44 is issued, the SGNe Controller will

also display a primary fault which provides additional
information about the possible fault and its location.
This picture shows VSD Fault 44 and Primary Fault 9,
which indicates that the issue is related to the VFD
Drive's component, control or wiring associated with
Phase U or W. Please refer to page 35 for an
explanation of other primary faults.
At this point, the Technician can find additional

information about the fault by accessing Service Menu
348 (Diagnostic Memory), as Error Code 1 and Error
Code 2 will be display there, as shown in the following
picture.
In this picture, the Error Code 1 displays value 2,

which is related to the possible malfunction of U or W
current transformers on T1 and T2 drives. For

Danger
! Note
A Control/Interface Boards test should always be Control board reference
performed even though the fault may be indicating a
power module fault. This test must be carried out
because the Control or Interface board could still be
faulty and could be giving corrupt diagnostic
information. So both tests must always be performed
to make sure the appropriate procedures are followed Remove
when performing these tests.
Keep
1. Control/Interface (Electronic Board) Test.
Starting conditions:
1. Turn off the incoming power supply to the drive,
2. Wait for 15 minutes
3. Then disconnect all the terminals off the control

board except for the SGN Intellysis communication
connector and the Ribbon Cable.
Remove
4.Turn on the incoming power to conduct the test
To select the Control Interface Test, depress the

select key on the SGNE with Control Interface Test Keep
high-lighted. Remove
The high-light will shift to the setting section under the

main parameter heading.
Depress the Set button as the Control Interface test is

being conducted. “0” will be displayed in the setting
section.
Numbers are displayed after the test is completed,

!
If the test passed the value 1 will be displayed.
1 = Pass Note:
Power Module Test takes approximately 5–10 minutes
If the test failed, Primary Faults 2 or 3 will be to do. There is no exit command so, if there is a need to
displayed. exit from the test before completion, it can be done by
2 = Control board failure cycling the incoming power. All connections to the con-
3 = Interface board failure trol board and all electronic components must be prop-
erly connected to do this test.

Danger
Troubleshooting Error Code Values

Error Codes are generated from the Control/Interface Error Code Values 16, 17, 18, 19, 20 or 21
test and are displayed under Error Code 1 and Error PWM (pulse width modulator) is not functional.
Code 2 Replace the control board.
Error Code Value 2 Error Code Value 24

Check the internal voltages (+15 volts and –15 volts) Ensure that no analog outputs from the control board
on the power board (ensure first to disconnect the are shorted to ground. Labelled on the PX2 terminal
IGBT driver cable from the power PCB). If the voltages strip.
are incorrect swap the power board. +15 volts is
measured between pin 2 and the power/Interface Error Code Value 25
board negative. –15 volts is measured between pin 4 Ensure that no analog inputs are shorted to ground.
and the power board neutral (page 53). Labelled on the PX2 terminal strip.
Error Code Value 3 Error Code Value 26 & 27

Check the internal voltage (+28 volts) on the power Not active on this test.
board (ensure first to disconnect the IGBT driver cable
from the power PCB). If the voltage is incorrect swap Error Code Value 28
the power board. +28 volts is measured between pin 5 Check the supply voltage supplied by the control
and the power board neutral (page 53). board to the Hall effect sensor (page 44).
Error Code Value 4 If the voltage test is satisfactory test the Hall effect
If no Errors are issued during the power module test, sensors with the Hall Effect sensor testing tool.
and Error 4 has occurred, then replace the power
Error Code Value 30 Not Active
board.
Error Code Value 31 Not Active
Error Code Value 5
If no Errors are issued during the power module test, Error Code Value 35 Not active on this test.
and Error 5 has occurred, then replace the power
board. Error Code Value 32, 33, 34, 36, 37 or 38
Replace the control board.
Error Code Value 6
Check the +24 volt voltage supplied by the control For additional information, please refer to the Quick
board ( available at PX2 terminal). If the test with Diagnostic Interface Test on pages 27-29.
voltmeter is not conclusive, replace the control board.
Error Code Value 7 Quick Reference Sheets

Confirm the +12/13V voltage is not present on pin1 of The following four pages summarise the Control
the Q8 transistor of the control board ( Q8 is located Interface Test results and can be used as a quick
on the right bottom of the pcb, above PX4 terminal, reference guide during troubleshooting.
and pin1 is the left pin of the chip ).
Page 26
Error Code Values 8, 9, 10, 11, 12 or 13 Control/Interface Board reference picture
If possible, exchange the control board and ribbon Page 27
cable and do the electronic boards test. If one of these Explanation of Control/Interface Test Primary
errors still remains, replace the power board. Fault Numbers and Error Codes
Page 28—29
Error Code Values 14 & 15 Control/Interface Test—Primary Fault Numbers,
Not active on this test. Error Code descriptions and recommended
actions

Danger
Control / Interface Board reference
Pin 1 =7 volts
T2 drive
sharing board
Pin 5
Board negative
Pin 2 +15 volts
Pin 3 +24
Pin 4 –15

Danger
Explanation of Control/Interface Test 25 Problem with analog input 1

Primary Fault Numbers and Error Codes 26 Free
(IR drive firmware : V2.20 and above) 27 Free
Primary Fault - retrievable from Menu 348 -
Problem with control board components related to
0 In progress 28
Hall Effect sensors
1 Passed 29 Free
2 Control board problem
30 Free
3 Power interface problem
31 Free
Explanation of Error code values
- retrievable from Menu 348 - Error Code 1 & 2 Problem with ENABLE digital input when set to
32
negative logic
1 Free
Problem with digital input 0 when set to negative
2 +15v et -15v 33
logic
3 +28V Problem with digital input 1 when set to negative
Mismatch detected on U phase current feedback 34
4 logic
( CT ) 35 Free
Mismatch detected on V phase current feedback Problem with ENABLE digital input when set to
5 36
( CT ) positive logic
6 +24V ref Problem with digital input 0 when set to positive
7 +15V ref 37
logic
8 U1 interface power board ( PWM signals ) Problem with digital input 1 when set to positive
38
9 U2 interface power board ( PWM signals ) logic
39 Free
10 V1 interface power board ( PWM signals )
11 V2 interface power board ( PWM signals )
Error codes associated with the Power
12 W1 interface power board ( PWM signals ) interface board
13 W2 interface power board ( PWM signals )
Error codes associated with the Control
14 Free board
15 Free
U1 control board ( PWM signals from
16
microprocessor )
U2 control board ( PWM signals from
17
microprocessor ) !
V1 control board ( PWM signals from Note
18 A Control/Interface Boards test should always be
microprocessor )
V2 control board ( PWM signals from performed even though the fault may be indicating a
19 power module fault. This test must be carried out
microprocessor )
W1 control board ( PWM signals from because the Control or Interface board could still be
20 faulty and could be giving corrupt diagnostic infor-
microprocessor )
mation. So both tests must always be performed to
W2 control board ( PWM signals from
21 make sure the appropriate procedures are followed
microprocessor )
when performing these tests.
22 Free
23 Free

Danger
Control/Interface Test - Primary Fault Number, Drive firmware : V2.20 & above
14-Sep-2005
Error Code descriptions and recommended actions.
Prima Error Fault Description Check action Drive Fault Location
ry Code
Fault Value
(menu
348)
+24V reference unavailable If VSD fault 38 has been issued while
the drive was running and if Error 6 is
issued by the diagnostic, double check
the +24 volt voltage supplied by the
6
control board ( available at PX2
terminal ). If the test with voltmeter is
not conclusive, replace the control
board.
+15V reference unavailable Check that PX1, PX2 and PX4 are
7 disconnected, if fault persists, replace
the control board
16 to 21 Control board signal faulty Replace control board
Malfunction of analog output Make sure nothing is shorting the

AO1 analog output to the ground ( terminal
24
PX2 ) otherwise replace the control
pcb
(2)
Contr Malfunction of analog input AI1 Make sure nothing is shorting the Control board
ol analog input to the ground ( terminal
Board 25
PX2 ) otherwise replace the control
pcb
Malfunction of Hall Effect If VSD fault 7 or VSD ffault 8 have
Sensor feedback processing been issued while the drive was
28 hardware running and if Error 28 is issued by the
diagnostic, then replace the control
board
Malfunction of digital input Check that PX1, PX2 and PX4 are
32 & 36 Enable ( negative sequence ) disconnected, if fault persists, replace
the control board
Malfunction of digital input 1 Check that PX1, PX2 and PX4 are
33 & 37 ( negative sequence ) disconnected, if fault persists, replace
the control board
Malfunction of digital input 2 Check that PX1, PX2 and PX4 are
34 & 38 ( negative sequence ) disconnected, if fault persists, replace
the control board

Danger
Control/Interface Test—Primary Fault Numbers, Error Code descriptions and recommended actions … cont'd
Primary Error Fault Description Check action Drive Fault Location

Fault Code
Value
(menu
348)
Internal supply +15V and / or - Disconnect IGBT driver board cable Interface power board
15V missing and run the test again. If Error 2
2
persists, replace interface power
board
Internal supply +28V not Check the internal voltage +28 volts
present supplied by the power board ( take
care first to disconnect the ribbon
3 Interface power board
cable between control pcb and power
pcb ). If the voltage is not the one
expected, swap out the power board.
Internal error in processing If no trouble occurs during the
current feedback from U phase diagnostic of the power components
Interface power board, or the
current transformers and if Error 4 is issued, then replace
4 control board if the problem persists
the power board, then the control
or finally the ID board
board if it does not fix and finally the
ID board if the problem persists
Internal error in processing If no trouble occurs during the
current feedback from V phase diagnostic of the power components
current transformer and if Error 5 is issued, then replace Power ( interface ) board, or the
5 the power board, then replace the control board if the problem persists
power board, then the control board if or finally the ID board
(3) it does not fix and finally the ID board
Interface if the problem persists
Disconnect the IGBT driver Replace interface power board or U
board cable and run the test phase power module
again, if Errors 8 or 9 persists,
Interface power board or U phase
8&9 change the interface power
power module
board. If the fault does not
reoccur, then change the U
phase power module
Disconnect the IGBT driver Replace interface power board or V
again, if Errors 10 or 11
Interface power board or V phase
10 & 11 persists, change the interface
power module
power board. If the fault does
not reoccur, then change the V
phase power module
Disconnect the IGBT driver Replace interface power board or W
again, if Errors 12 or 13
Interface power board or W phase
12 & 13 persists, change the interface
power module
power board. If the fault does
not reoccur, then change the W
phase power module

Danger
2. The Power Module Test

Starting conditions:
1. The main power must be applied to KM1 con-
tactor.
2. The motor must be connected to the drive out-
puts.
3. Ensure that terminal PX2 digital input ENABLE
is linked with the circuit common 0 volts.
These connection points are labelled on the
drive control board by terminal strip PX2. If the
input is not correct, the VSD fault 44 will be
issued. There will be additional information indicating Error
Codes 1 and 2. This information is accessible by
The power module test is conducted with the motor scrolling down the Diagnostic Menu screen.
stopped. Once the test begins, the drive reduces its
DC Bus voltage down to 55 volts DC then the Diagno- Error Code 1 is important as it provides additional
sis will start. Depending on the size of the compressor, information to the primary fault code about the
the diagnosis may last a couple of minutes depending
on how long the DC bus takes to reduce to the 55
volts DC.
The selection of the Power Module test is the same as

the Control Interface Test through Service Menu 348.
With the Power Module test high-lighted depress the
select button. The high light will shift to the setting
section under the main parameter heading. Depress
the set button as the Power Module Test is being
conducted, “0” will be displayed.
If the test passed, a “1” will be displayed.
If the test failed, one of the following Primary Fault

Codes will be displayed below the Power Module Test text
on the SGNe Faceplate, as shown in the following picture.
2 = Failure on the U phase module
3 = Failure on the V phase module
4 = Failure on the W phase module
5 = Rectifier Failure
6 = Motor or motor connections failure
7 = U and V phase module failure
8 = V and W phase module failure
9 = U and W phase module failure
10 = Enable logic input not connected to OV

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possible problem and its location within the VSD Error Code Value 4
system. Please refer to pages 7 and 8 for additional Check the connections of the IGBT driver cable.
details.
T1 drive: Only has one IGBT driver cable with a 25
Error Code 2 is of a secondary importance. pin connector on each end. One end connects to the
power card and the other end connects to the driver
The Error Code value numbers, which appears on the board (board with white cover).
SGNe Controller below the text Error Code 1 and Error
Code 2, are explained on the following pages T2 drive: there is a small sharing board plugged
directly into the power PCB. The IGBT driver cables
Troubleshooting Error Code Values plug into this sharing board, then the other end plugs
These are generated from the Power Module test and into the IGBT driver board (page 53).
are displayed under Error Code 1 and Error Code 2
Ensure motor leads are properly connected. With
Error Code Value 1 or 3 particular attention to the V phase lead.
Ensure the DC Bus reading wire (+DC Bus) is properly
connected to board PL5 located on the bottom of the Megger the motor (page 41).
capacitor bank.
Error Code Value 5
Check the connections of the IGBT driver cable. Check the connections of the IGBT driver cable.
T1 drive: Only has one IGBT driver cable with 25-pin T1 drive: Only has one IGBT driver cable with a 25
connector on each end, one end connects to the pin connector on each end. One end connects to the
power card, the other end connects to the driver board power card and the other end connects to the driver
(board with the white cover). board (board with white cover).
T2 drive: There is a small sharing board plugged T2 drive: There is a small sharing board plugged
directly into the power PCB. The IGBT driver cables directly into the power PCB. The IGBT driver cables
plug into this sharing board, then the other end plugs plug into this sharing board then the other end plugs
into the IGBT driver board (page 53). into the IGBT driver board (page 53)
Check the motor lead connections. Check the motor lead connections.
Megger the motor (page 44). Refer to page 41 and megger motor.
Ensure the ENABLE digital input of PX2 is connected Error Code Value 6
to the circuit common 0 volts (PX2 Enable and PX2 0V Check the connections of both ends of the cable
terminals). linking.
Ensure the ID board is properly plugged into the power On the T1 drive the 3 blue current transformers with
PCB. the IGBT driver board (board with white cover)
Error Code Value 2 On the T2 drive the 2 current transformers with the
Make sure ID board is properly plugged into the Power IGBT driver board of the U and V channels.
board.
Make sure the ID board is properly plugged into the
Check connections on both ends of the cable linking power PCB
the upper current transformer with the IGBT driver
board. Refer to page 41 and megger motor.

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Error Code Value 7 T2 drive: the current transformer and the IGBT driver
Check the 2 fuses on PL5 small board mounted on the board on U channel. (Bottom output module hidden by
bottom of the capacitor banks. the white plastic PCB bracket)
Ensure connection between PL5 and the white Ensure ID board is properly plugged in.
connector on the power PCB is correctly tied at both
ends. Ensure the distribution board is properly plugged in.
Check Thyristors according to the Input Power Device Error Code Value 11
test. Check the connections of the leads between the
triggering board and the gate of the thyristor TH1.
Confirm the red wire between the triggering board and
the TH1 thyristor gate is correctly linked at both ends. Ensure the connections on PL5 board are correct.
Megger the motor to ensure that 1 or more motor Verify the 2 fuses on PL5 are good.
phases is not shorted to ground.
Error Code Value 12
Error Code Value 8 Ensure the DC Bus reading wire (- DC Bus) is properly
Check the connections of the IGBT driver cable, tightened to the PL5 board (CCN 22235048). Also
check the fuses on the board.
T1 drive: only has one IGBT driver cable with a 25 pin
connector on each end. One end connects to the T2 drive: Check between motor windings for short
power card and the other end connects to the driver circuit. Refer to the megger motor section.
board (board with white cover).
Error Code Value 13
T2 drive: IGBT driver cable connects between one Ensure the IGBT transistors are fine by carrying out
end into the small sharing board plugged into the the inverter module test. U phase module.
power PCB, the other end to the IGBT driver board U
channel (the bottom output module) Check the connections of the motor leads with a
particular attention to the U phase lead.
Error Code Value 9
Check the connections of the IGBT driver cable, Make sure the distribution board is properly plugged in
the power PCB.
T1 drive: only has one IGBT driver cable with a 25 pin
connector on each end, 1 end connects to the power Check the connections of the IGBT driver cable :
card the other end connects to the driver board (board
with white cover) T1 drive: Only one cable and the 25 pins connector at
each end of the cable plugged in on the one end to the
T2 drive: IGBT driver cable connects between one control board on the other hand to the driver board
end into the small sharing board plugged into the ( white cover ).
power PCB. The other end to the IGBT driver board
on V channel (the middle output module) T2 drive: The end of the IGBT cable connected on
one end to the small distribution board itself plugged in
Error Code Value 10 the power PCB on the other end to the IGBT driver
Check the connections of both ends of the cable board U channel ( the bottom output module ).
connections between
On T1 drive Ensure there is no short circuit between U
T1 drive: the upper blue current transformer with the phase and W phase of the motor. Megger the motor.
IGBT driver board (board with white cover).

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Error Code Value 14 T1 drive: Ensure there is no short circuit between V

Ensure the IGBT transistors are fine by carrying out phase and W phase of the motor
the inverter module test. V phase module (pages 66-
72). Megger the motor.
Check the connections of the motor leads with a par- Error Code Value 16
ticular attention to the U phase lead. Look for a short circuit between one of the motor
phases and the ground (earth)
Make sure the distribution board is properly plugged in Check the 2 fuses on PL5 if not done yet as
the power PCB. recommended at the beginning of this chapter.
Check the connections of the IGBT driver cable : Ensure connection between PL5 and the white
for the T1 drive : only one cable and the 25 pins con- connector on the power PCB is correctly tied at both
nector at each end of the cable plugged in on the one ends.
end to the control board on the other end to the driver
board ( white cover ). Error Code Value 17
Ensure the TH1 thyristor gate is tied to the thyristor
T2 drive: The end of the IGBT cable connected on firing board PL3.
one end to the small distribution board itself plugged in
the power PCB on the other end to the IGBT driver Check the 2 fuses on PL5 if not done yet as
board V channel ( the middle output module ). recommended at the beginning of this chapter.
T1 drive: ensure there is no short circuit between U Ensure connection between PL5 and the white
phase and V phase of the motor. connector on the power PCB is correctly tied at both
ends
Megger the motor.
Ensure the choke leads are properly tied.
Error Code Value 15
Ensure the IGBT transistors are fine by carrying out Error Code Value 18
the inverter module test. W phase module. Verify that on connector PX2 on the drive control
board. The digital input ENABLE is linked with the
T1 frame: Check the connections of the motor leads circuit common 0 volt (terminal PX2, pin # 9).
with a particular attention to the U phase lead.
Make sure the distribution board is properly plugged in

the power PCB.
Check the connections of the IGBT driver cable :
T1 drive: Only one cable and the 25 pins connector at

each end of the cable plugged in on the one end to the
control board on the other end to the driver board !
Note
( white cover ). When the Power Module Fault is generated during
the test, the Control Interface Tests must still be
T2 drive: The end of the IGBT cable connected on performed because these components could have
one end to the small distribution board itself plugged in influenced the results of the Power Module test.
the power PCB on the other end to the IGBT driver
board W channel ( the upper output module ). Both tests must be performed to locate any issues
within the drive.

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Quick Reference Sheets

The following four pages summarise the Power
Module Test results and can be used as a quick
reference guide during troubleshooting. Explanation of Error code values
- retrievable from Menu 348 -
Page 34 Under Error Code 1 & 2
Explanation of Power Module Test Primary Fault
Numbers and Error Codes 0 No fault
Page 35—36
Power Module Test —Primary Fault Numbers, 1 Malfunction of the W phase top transistor
Error Code descriptions and recommended
Malfunction of the U phase current transformer or
actions 2
the W phase current transformer
3 Malfunction of the W phase bottom transistor
Explanation of the Power Module Test
4 Malfunction of the U phase top transistor
Primary Fault Numbers and Error Codes
(IR drive firmware : V2.20 and above) 5 Malfunction of the V phase bottom transistor
Free.
6 If you disconnect CT from V you will get A-6, not
Primary Fault A-10
Displayed as a number below VSD Fault 44 Alarm or 7 Time out of the rectifier for DC Bus discharge
Power Module Test text.
8 Malfunction of the U phase bottom transistor
0 In progress
9 Malfunction of the V phase top transistor
1 Passed
2 U Phase Malfunction of the U phase current transformer or
10
3 V Phase the V phase current transformer
4 W Phase Direct pre-loading ( surge DC Bus voltage at
11
5 Rectifier power up )
6 Motor Motor over current ( fault detected by the
7 Phases U and V 12
hardware )
8 Phases V and W
U phase transistor fault ( fault detected by the
9 Phases U and W 13
hardware )
10 Enable logic input not connected to 0V
V phase transistor fault ( fault detected by the
14
hardware )
W phase transistor fault ( fault detected by the
15
hardware )
16 Motor phase grounded
17 No pre-loading of the DC Bus capacitors
18 Enable logic input not connected

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Power Module Test - Primary Fault Number, Drive firmware : V2.20 & above
14-Sep-2005
Error Code descriptions and recommended actions.
Prima Error Fault Description Check action Drive Fault Location
ry Code
Fault Value
Open circuit or imbalanced Check U and V phase Current T2 frame size : U and V phase
current feedback from current transformers wiring output IGBT modules + Power
10 transformers phase U or V board + distribution board
Check connections between IGBT driver T1 frame size : Power output
board and power pcb module + power board
7 Drive internal supply loss ( 0 Check connectors/cable between driver

(UV) and / or +15V ) or ( white cover ) and power pcb ( T1 drives ) T2 frame size : U and V phase
U phase transistor fault ( fault Check connectors/cable between IGBT output IGBT modules + Power
detected by the hardware ) driver boards and distribution board and board + distribution board
13
connection between power board and
distribution board ( T2 drives ) T1 frame size :
Check IGBT transistors with voltmeter Power output module
( diode setting )
Open circuit or imbalanced Check the W phase current transformers

Output power module
2 current feedback from W wiring
Concerns only T1 frame size drive
phase current transformer
9 Drive internal supply loss ( 0 Check connectors/cable between IGBT

(UW) and/or +15V ) or driver boards and distribution board and U and W phase output IGBT
U phase transistor fault ( fault connection between power board and modules + Power board +
13
detected by the hardware ) distribution board distribution board
Check IGBT transistors with voltmeter Concerns only T2 frame size drive
( diode setting )
Drive internal supply loss ( 0 Check connectors/cable between IGBT
and/or +15V ) or driver boards and distribution board and V and W phase output IGBT
8 v phase transistor fault ( fault connection between power board and modules + Power board +
14
(VW) detected by the hardware ) distribution board distribution board
Check IGBT transistors with voltmeter Concerns only T2 frame size drive
( diode setting )
Short circuit on IGBT module Check connections between IGBT driver
or W phase transistor fault board and power pcb
( fault detected by the Megger the motor ( only T1 drive )
15 hardware ) —No state report Check IGBT transistors with voltmeter
signal from module ( diode setting ) T2 frame size drive :
Short circuit between V and W W output module + power pcb +
4 phases ( only T1 drive ) distribution pcb + motor
(W)
No IGBT command signals to Check connections between IGBT driver T1 frame size drive :
3
module board and power pcb Output module + power pcb
No IGBT command signals to Check connections between IGBT driver
1 module Motor leads not board and power pcb
connected properly Check motor lead connection
Short circuit on IGBT module Check connections between IGBT driver
or —V phase transistor fault board and power pcb
( fault detected by the Megger the motor ( only T1 drive )
14 hardware )—No state report Check IGBT transistors with voltmeter
signal from module ( diode setting ) T2 frame size drive :
Short circuit between U and V V output module + power pcb +
(V)
No IGBT command signals to Check connections between IGBT driver T1 frame size drive :
5 module — Motor leads not board and power pcb Output module + power pcb
connected properly Check motor lead connection
No IGBT command signals to Check connections between IGBT driver

9
module board and power pcb

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Power Module Test—Primary Fault Numbers, Error Code descriptions and recommended actions … cont'd
Primary Error Fault Description Check action Drive Fault Location

Fault Code
Value
Short circuit on IGBT module or Check connections between IGBT

U phase transistor fault ( fault driver board and power pcb
detected by the hardware ) Megger the motor ( only T1 drive )
13 No state report signal from Check IGBT transistors with voltmeter
module ( diode setting ) T2 frame size drive :
Short circuit between U and W U output module + power pcb +
(U)
No IGBT command signals to Check connections between IGBT
T1 frame size drive :
module driver board and power pcb
4 Output module + power pcb
Motor leads not connected Check motor lead connection
properly
No IGBT command signals to Check connections between IGBT
8
module driver board and power pcb
Short circuit between U and V Megger the motor

phases Ensure U, V and W drive power
Short circuit between U and W terminals are not shorted Motor and output modules
12
phases Concerns only T2 frame size drive
Short circuit between V and W
6 phases
(Err Mot) Motor phase U, V or W shorted Megger the motor
to ground Check DC Bus sensing board ( P/N
Motor and DC Bus sensing board
No voltage feedback from DC 15 ) and cable connection at both
16 ( P/N 15 ) located below the drive
Bus sensing board ( P/N 15 ) ends
capacitor bank
Check both fuses on DC Bus sensing
board ( P/N 15 )
Choke leads improperly Check choke lead connections
connected Check DC Bus sensing board ( P/N Choke and drive input rectifier / DC
Pre-loading circuit faulty 15 ) and cable connections at both Bus bar connections
17
ends Rectifier + DC Bus sensing board
5 Check both fuses on DC Bus sensing ( P/N 15 )
(Err board ( P/N 15 )
Rect) DC Bus voltage feedback Check DC Bus sensing board ( P/N
DC Bus sensing board ( P/N 15 )
incorrect 15 ) and cable connection at both
located below the drive capacitor
11 Fault on input rectifier module ends
bank + power pcb + rectifier +
Check thyristors
motor
Megger the motor
10 ENABLE input not or Check wiring to the drive Control board

18
(Enable) improperly linked to 0 volt ref ( pin 9 of the PX2 terminal )

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3. VSD Memory Test.

This is a read only parameter and displays the last
over all results of the Drive Control Board Memory
Test conducted when the last Control Interface test
was accomplished. This parameter can display three
readings. They are.
0 = Test in progress
1 = Test passed
2 = Test failed. There is a problem with
the Drive Control Board memory.

VSD Voltage Checks
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Incoming voltage
Fuses on PL5
T1 modular drive T2 modular drive
Check these 2 fuses in case of DC Bus

Under Voltage Fault
! Note
Power must be isolated before performing
the following checks.

Winding Insulation Test
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! Note ! Note
Power must be isolated before performing Power must be isolated before performing
the following checks. the following checks.
HPM Motor Winding Test Use an Insulation Tester (Megger or other brand)
When the Insulation test is performed, the instrument connecting one of the 2 cables to the earth terminal,
used for this purpose (Megger or other brand) induces the other cable to the motor leads U, V and W one
1000k VDC to motor windings. The high voltage spike after the other ( motor leads are disconnected from the
might affect operation of sophisticated controllers or its drive and the sensors from the control board).
memory cards. Therefore, before the winding
insulation test is carried out, remove Hall Effect
Senor cable connection from the Control Board.
Megger connected
Motor Leads
Megger
connected
Set ≥ 1KV
8. Connect one other cable of the Tester to each of
1. Isolate the compressor from the main incoming the motor leads (one at a time) and test. Set the
voltage supply. Lock and tag the Disconnect Tester to at least 1KV. Each cable should give a
switch in the open position. minimum value of Infinity (20M Ohms)
2. Allow 15 minutes for the VSD to discharge
capacitors. ! Note
3. Open enclosure doors to expose VSD. Contamination of the stator can cause the
4. Remove motor leads protective cover. readings to out of specification.
5. Check with a suitable meter that all voltages have
dissipated before beginning work on the VSD. 9. If the motor tests correctly, reconnect motor
6. Disconnect motor leads from U, V and W on the cables to the VSD in the correct sequence.
bottom of the VSD. 10. If the motor fails the test, replace the stator.
7. Connect one cable of the Insulator Tester to the
main Ground connection of the VSD.

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Motor winding resistance values

The motor can be tested using a Megger to test for a phase to
earth short fault. But if a megger is not available or if additional
trouble shooting is required, a Miliohm meter can be used to
measure the resistance of the motor windings phase to phase.
The table below shows the expected resistance values when

measuring the resistance of the windings phase to phase on the
various types of HPM motors. NOTE: For Chassis drive main
motor combinations, use the larger of the motor type. Example
for a 50HP, use the 60HP motor MIN/MAX resistance values.
Mil Ohms Re-

sistance 20°C
Motor Cross Reference (68°F)
COMPRESSOR
MODEL VOLTAGE DRIVE MOTOR Min Value Max Value
N37kW / 50HP-CC 200 MD60TL A1-200 42554287 6.5 7.2
N37kW / 50HP-CC 400 MD60T A1-400 42554295 23.3 25.7
N45kW / 60HP-CC 200 MD75TL A-200 42531426 3.9 4.4
N45kW / 60HP-CC 400 MD75T A-400 42531434 13.8 15.2
N55kW / 75HP-CC 200 MD75TL C1-200 42554303 5.15 5.75
N55kW / 75HP-CC 400 MD100T C1-400 42554311 18.5 20.5
N75kW / 100HP-CC 400 MD120T C-400 42531459 10 11
N90-110kW-CC
400 MD180T D1 42541797
N125-150HP-CC 10.5 11.5
N132-160kW-CC
400 MD220T D2 42541805
N175-200HP-CC 7 8
N75-110kW-CC-2S
400 MD180T D1 42541797
N100-150HP-CC-2S 10.5 11.5
N132-160kW-CC-2S
400 MD220T D2 42541805
N175-200HP-CC-2S 7 8
N250-300HP-CC-2S 400 MD340T 250L 22282958 5.15 5.75
N37kW / 50HP-OF 200 MD60TL A1-200 42554287 6.5 7.2
N37kW / 50HP-OF 400 MD60T A1-400 42554295 23.3 25.7
N45kW / 60HP-OF 200 MD75TL A-200 42531426 3.9 4.4
N45kW / 60HP-OF 400 MD75T A-400 42531434 13.8 15.2
N55kW / 75HP-OF 400 MD100T B1-400 42556894 14.25 15.75
N75kW / 100HP-OF 400 MD120T B-400 42556902 9 10
N90-110kW-OF
400 MD180T D1 42541797
N125-150HP-OF 10.5 11.5
N132-160kW-OF
400 MD220T D2 42541805
N200HP-OF 7 8
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How to perform a Dielectric Test with an

HIPOT tester (High Potential Tester)
It is highly recommended that the HPM stator is

removed from the compressor package. If failed to
do so, leakage ground during test could damage
other electrical components.
The tester settings should be 1800 VAC–

50/60Hz at (.3 Milliamps)
How to perform Milliohm motor resis-

tance test
For motors 50 to 100 HP, may require that the

individual motor leads labeled 1 to be connected
together. This can be done by using a bolt and nut
to tightly hold them together, and the same for 2
and 3.
A 150 to 200 HP in most cases are connected in

this manner from the factory and should not be
separated for testing. The picture below illustrates
how the test should be performed.
Current reading on Intellisys
The purpose of this test is to look and compare At max load, the motor current must not exceed :
resistance values. The difference in the resistance
values between each phase should be less than 230V mains 400V mains 480V mains
2%.
196 amps for 60TL 100 amps for 97 amps for 60T
A bad reading may result to a possible: 60T
• Cut coil 120 amps for 115 amps for 75T
230 Amps for 75TL
• Short circuit between coil turns 75T
• A defective weld
• A defective wire 145 amps for 140 amps for 100T
100T
190 amps for 185 amps for 120T
120T
180T
220T
340T

Rotor/Stator Torque Settings
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Motor retaining bolts torque settings

This table gives the torque settings the rotor/
stator retaining bolts need to be tightened to when
installing or replacing the rotor/stator.
Model Stator to Stator retaining bolts with Rotor Loctite used on

Airend microencapsulated epoxy coasting Central Bolt Central Rotor
Torque CPN Number Torque Bolt
N47/45 CC and OF 213Nm 22517270 271Nm Loctite 270
N55/75 CC and OF 213Nm 22517270 407Nm Loctite 270
N90-160 CC and OF 213Nm 22517288 679Nm Loctite 270
!
Note
New bolts must be used every time the
Stator and Rotor are removed.
4 Stator Retaining Bolts
Rotor Central Retaining Bolt

Hall Effect Sensor Checks
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Three Hall Effect Sensors are located at the none-

drive end of the HPM Motor, these are embedded in
the Stator windings. They can be easily removed or
installed using three screws.
Location of the
The Hall Effect Sensors provide the speed three Hall Effect
and winding temperature feedback to the Sensors
PL1 Control Board through terminal PX4.
To carry out the test :
1. Isolate the compressor from the main incoming

voltage supply. Lock and tag the isolation
switch in the open position.
capacitors.
3. Open enclosure doors to expose the VSD.
4. Check with a suitable meter that all voltages
have dissipated before beginning work on the
VSD.
5. Remove rear cover of drive motor to permit
rotating by hand.
Test 1—Mechanical Damage

1. Disconnect Hall Effect Cable from PX4 on the
Control Board, plug type is DB9 Type.
2. Inspect cable pins and matching receptacle
connections for damage or bent pins.
3. Remove cover of plug and inspect solder
connection of the wires for damage.
4. Inspect entire length of the cable for damage. If
cable and connections are in good condition,
proceed to Test 2 (refer to page XX).
The three sensors can be

removed. To do this:
1) Remove the screws first
2) Push plastic sensors out
from inside out. as per
the arrow.
When you install new

sensors make sure they are
in the correct order.

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Test 2—Power Supply to the Hall effect 7) Connect the Red probe of the multi-meter to
Pin 3 - Chassis Drive or Pin 1 - Module Drive.
1) On T1 or T2, disconnect terminal strips PX1and
The voltage should be ~ +14 Volts DC.
PX2 (on chassis it is P1 and P2) from the Control
Board. 8) If voltage is not present, replace the Control
Board.
2) Trip and switch off MCB2 and MCB5 (T1 and
chassis drive) to prevent the SGNe Intellisys from
powering up. On T2, MCB2 only.
3) Re-connect main incoming supply voltage to the Modular Drive
unit. Isolation contactor KM1 should remain de-
P5 is 0Volts ( reference
energised and the VSD should only receive con-
for multimeter )
trol power. Caution must be taken as the panel
has voltage present.
4) Set digital multi-meter to DC Volts.
5) Connect Black probe of multi-meter to either of
the 2 pins of P5.
! Note:
P5 is located in the middle of the control Board.
P5 is marked and described as 2 small bare pins.
P5 is the ground connection for the Control Board.
6) Locate the small transistor just to the left of the

PX4 connector. The transistor has 3 pins on the
left side. The pins are numbered
Chassis Drive: 1-top, 2-middle, 3-bottom.
Module Drive: 1-bottom, 2-middle, 3-top.
Chassis
Drive
Pin 1 of the
DC Volt
transistor
P16 is 0 Volts
(reference for
minus of the
multimeter )
Pin 3 of the
transistor

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Test 3—Test Signals from Sensors

1) Connect special adapter CPN 38333332 between
PX4 on the Control Board and the Hall Effect
Sensor Cable.
2) Set digital multi-meter to DC Volts.
3) Connect Black probe of multi-meter to either of
the 2 pins on P5.
4) Connect Red probe of multi-meter to Red wire of
the adapter. Rotate motor by hand and observe
measurement. The meter should read between
+12 and +13 Volts DC alternating to between 0
and +1 volts DC.
5) Repeat the test with the Black wire of the adapter.
The meter should read between +10 and +12
Volts DC alternating to between 0 and +1 volts
DC
6) Repeat the test with the Yellow wire of the
adapter. The meter should read between +10 and
+12 Volts DC alternating to between 0 and +1
volts DC
7) If voltage does not rise to between +10 and +12
Volts DC for any of the 3 sensors, replace the
Hall Effect Sensor Assembly.
The Hall Effect Sensor adaptor has five labels

indicate the following : R, B, Y, P, G which are the
initials of :
-R red wire of the sensor Hall Effect Sensors

-B black wire of the sensor
-Y yellow wire of the sensor
-P purple wire of the motor PTC Motor PTC probe
-G green wire of the motor PTC
From Hall
To the Effect Sensors
control
board PX4
The Hall Effect Sensor Adaptor CPN 3833332

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Test 4—Motor PTC probe

1) Set digital multi-meter to Ohms.
2) Connect multi-meter between Purple and
Green wires of special adapter, the meter
should show a resistance value of
approximately 60 Ohms ± 20% (New Hall Effect
Sensors)* at 70°F (20°C) ambient temperature.
3) If correct value is not confirmed, replace the
P = purple
G = green
Motor cable
P
Set to
Ohm meter
Ohmeter
plugs to
connect

Control Board (PL1)
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The diagnosis is the main addition to the Modular Reconfiguring of the drive Control Board requires
Drive software with a significant improvement of its the use of a Lap Top Computer, Nirvana Service
processing speed. Tool most recent revision and the Service Tool
Cable.
The PCB design has been optimized from the • Locate the Service Port on the compressor
previous version. The modbus interface is exterior. Connect the Service Tool cable
supported by the control board directly, no more between the Lap Top Computer and Service
communication board to plug in. The number of Port. The red LED will blink indicating the
terminals has been reduced to meet the need of connection is good.
Nirvana compressor. • Go to Service Menu 218 in the SGNe
controller from FACTORY SETPOINT, open
Main functions : the Nirvana Service Tool on the Lap Top
• Generates the Pulse Width Modulation (PWM) to Computer. The green LED on the Service
regulate the speed and the torque of the motor Tool Cable should begin to blink to indicate
communication between drive and Lap Top
• Performs the drive diagnosis
Computer is good.
• Controls the rectifier bridge for the pre-loading of • With your tool, select “Configure VSD”, then
the capacitors at power up and allows the select compressor type, and once selection is
diagnosis to be carried out made then select Load VSD Parameters.
• Supports the Modbus interface
Monitors the temperature of the IGBT chips and NOTE: Reconfiguration

the rectifier bridge of the drive Control
Board is required after
Advantages : replacement.
Microprocessor
• Drive auto diagnosis
• Accurate monitoring of temperature
measurement of the IGBT chips as well as the
rectifier
• Integrated Modbus communication interface
• Varnished board
Ribbon cable
connector from
interface PCB
PX1
PX Intellisys Hall effect sensor
communication terminal PX4
terminal PX3

Control Board (PL1)
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Replacement 7) Remove the Hall Effect Sensor plug from PX4

located on side of Control Board.
1) Isolate the compressor from the main incoming
voltage supply. Lock and tag the isolation switch 8) Remove the Communication Plug from PX3
in the open position. located on side of Control Board.
2) Allow 15 minutes for the VSD to discharge 9) Remove ribbon cable from bottom of Control
capacitors. Board.
3) Open enclosure doors to expose VSD. 10) Remove the small mounting screw from each
corner of the Control Board.
4) Remove protective grate from front of VSD.
5) Check with a suitable meter that all voltages have Reverse this procedure to install a new Control
dissipated before beginning work on the VSD. Board.
6) Unplug PX1and PX2 from bottom of the Control
Board. NOTE: Reconfiguration of the drive Control Board
is required after replacement.
Hall Effect
power
transistor.
PX4 Hall
Effect sensor
connector.
PX3
Communication
connection.
P5
board
PX2
Digital inputs
and Analogue
inputs and
outputs.
Green LED to
indicate
power to the PX1
Control Digital output.
Control board reference

Danger
Interface Board
The general task of this board is to interface with the
control board and the power components.
Main functions :
• Makes the PWM signals available by the IGBT
driver boards, signals provided by the control
PCB
• Measures the AC incoming voltage and the DC
Bus voltage to inform the microprocessor about
voltages
• Takes the current information coming from the
IGBT driver boards
• Interfaces the rectifier heatsink thermal sensor
for the control PCB
• Creates different voltages:
+15V & -15V for the IGBT driver boards
+8V for the control board
+24V for the control PCB terminal

Danger
Interface PCB & ID Board (PL2)
Ribbon cable connector from Control PCB

IGBT cable connector
200 V electronic control

supply connector
Connector cable from DC

Bus
ID BOARD plugged in here
Interface PCB & Distribution PC

The duty of this electronic PCB is the same as the T1
or the T2 drive. However, because the T2 is made of 3
modules instead of only 1 for the T1 drive, the IGBT
firing orders must be shared between each module of
the T2. This is the reason an additional PCB must be
used with the T2 drive.
Distribution board
For T2 only.
You must to be sure that the ribbon cables are con-
nected
to the Distribution Board as specified below :
From Output Power Module U to P5 (located at left).
From Output Power Module V to P4 (located at middle).
From Output Power Module W to P3 (located at right).

Danger
PL2 Replacement 8. Remove the small I.D. Board from the Interface
1. Isolate the compressor from the main incoming Board, taking care not to cause damage to pins of
voltage supply. Lock and tag the isolation switch in the plugs. Remove plastic stand-offs. They will be
the open position. needed on new board.
capacitors.
!
3. Open enclosure doors to expose VSD. Note:
4. Remove protective grate from front of VSD. On the T2 drive it will be necessary to remove the
sharing board.
5. Check with a suitable meter that all voltages have
dissipated before beginning work on the VSD.
6. Fold down Control Board power/interface board 9. Install new Interface Board, reversing the above
assembly. procedure.
7. Unplug all cables from the Interface Board.
T2 drive Pin 1 =7 volts

sharing board
Pin 5 28VDC
Board negative
0 Volts P.16
Pin 2 +15 volts

Pin 3 +24 volts
Pin 4 –15 volts
ID Board

I/D Board
Danger
Replacement I/D Board

1. Isolate the compressor from the main incoming
voltage supply. Lock and tag the isolation
2. Allow 15 minutes for the VSD to discharge ca-
pacitors.
3. Open enclosure doors to expose the VSD. ! Note
4. Remove protective grate from front of VSD. Power must be isolated before performing
5. Check with a suitable meter that all voltages the following checks.
have dissipated before beginning work on the
VSD.
6. Fold down Control Board Power / Interface
Board assembly.
7. The I.D. Board is installed on the Interface
Board using 2 plugs and held in position by
plastic stand-offs.
8. Gently remove the I.D. Board from the Interface

Board, taking care not to cause damage to the
plugs.
9. Install new I.D. Board to the Interface Board,
again taking care not to cause damage to pins
of plugs.
10. Re-use plastic stand-offs from original board. ID Board, refer previous page for placement.
11. Fold up into place Control
Board, Power/Interface
Board assembly.
12. Replace the protective grate.
13. Close VSD enclosure doors.
14. Re-apply power to the unit.
15. Run an Internal Electronic
Board Diagnostic Test (page
24)
16. If the test is satisfactory, re-
run the unit.

Input Module Parts ID
Danger
Input (Rectifier) Module ! Note

The Input (Rectifier) Module consists of the Power must be isolated before performing
following major components: the following checks.
• EMC Board
• Thyristor Firing Printed Circuit Board
• Thyristor Packs
Leads of input voltage to feed

the EMC board
L1
Input
power L2
terminals
L3
3 Thyristor packs
TH1, TH2, and TH3

Danger
The EMC board is screwed onto the triggering

board.
Capacitors and MOVs are to comply

international standards regarding emission and MOV
immunity
protection against surge voltages ( MOV )
EMC Printed
Circuit Board
Capacitors
! Note
the following checks. Thyristor
Firing Board
Thyristor Packs
This is the thyristor firing board. The firing is

directly controlled by the microprocessor of the
control board.
No leads are required between the boards and the

thyristors. The links between each PCB are made of
spacers and screws that make the rectifier module ! Note
particularly compact. Power must be isolated before performing
It provides pre loading function of the capacitors
regulation of the DC Bus at 55V during diagnostic
test.
Thyristors firing
command connector
( other end to the
control PCB )
Red wires for the

rectifier firing
connected to the
gate of the
thyristors TH1, TH2
and TH3.
TH3 TH2 TH1

Danger
! Note
Thermal Sensor Power must be isolated before performing
The only visible thermal probe on the modular drive the following checks.
is the probe located below the rectifier bridge and
directly connected to the triggering board. This probe
monitors the temperature of the rectifier module and
is screwed on its heatsink. RECTIFIER PROBE TEMPERATURE CHART, ± 2%.
The max temperature allowed is 90°C (194°F). °C 20 25 30 35 40 45 50 55 60 65 70
Temperature reading is available from the screen of °F 68 77 86 95 104 113 122 131 140 149 158
the Intellisys.
Ω 588 606 624 643 660 678 701 723 746 770 793
The temperature probe of the output modules is

internally monitored by the IGBT driver board from
the transistor ships. The temperature information is
then forwarded through the interface board to the
control board with the IGBT firing order command
cables. Temperature measurements are accessible
from the Intellisys controller. The temperature trip
point is 110°C (230°F).
EMC board Triggering board
Thermal probe
Thermal probe connector
(2 wires, no polarity)

Input Module Replacement
Danger
Replacing the Input rectifier module for T1 Drives 3 This screw must
be unbolted to
2 Remove connector to unplug located on the disconnect the
triggering board, behind the EMC PCB. choke lead.
1 Disconnect
5 Unbolt the 4
the power
screws to release
supply
the complete
leads L1, L2
rectifier module.
and L3
4 This screw must

be unbolted to
disconnect the
choke lead.
Replacing the Input rectifier module for T2 Drives ! Note

Power must be isolated before per-
1 To remove the input rectifier module, the choke leads forming the following checks.
of the DC Bus must be disconnected from the module.
2 Remove the connector located on the triggering board, behind the EMC
4 Unbolt this
screw to
release the DC
Bus lead
6 Unbolt the 4
screws to release
the complete
rectifier module
3 Disconnect the power supply 5 Unbolt this screw to

leads L1, L2 and L3. release the DC Bus lead.

Output Module Parts ID
Danger
! Note
Each Output (Inverter) Module is made of 3 IGBT Power must be isolated before performing
transistors with the included IGBT driver board the following checks.
associated to the transistors.
T1 drive is made of only one IGBT module. Because

of the 3 transistors per module, one module
supports the 3 output phases U,V and W.
T2 drive has 3 IGBT (inverter) modules. Each of

them is dedicated to one output phase U, V or W.
The IGBT module has got its own capacitor bank,

number of capacitors may vary depending on drive
rating.
The IGBT module has got an internal temperature

probe built-into the heart of the IGBT chip.
Output IGBT Power Module for T1

The IGBT transistors are hidden by this white cover
which protects the IGBT driver board. The bars IGBT driver Current
marked U, V and W are connected to each board ( one per information cable
transistor. The 3 current IGBT module )
transformers (in blue) are Capacitor bank
linked to the driver board
that relays the current
information to the
interface board.
Output
V terminals
Holes for module
handling & mounting
U
Connection points
to the DC Bus
Current
Balancing resistor IGBT firing Connector transformers

Danger
! Note
Output IGBT Power Module for T2 the following checks.
IGBT driver board Balancing resistors

( one per module)
Capacitor bank
Current
informatio
Holes for
module
handling
Holes for module
&
handling & mounting
mounting
Connection points
to the DC Bus bars
Current 3 IGBT transistors
transformer ( behind the board )
DC BUS Capacitors
Capacitors are rated for nominal input voltage Advantages :
specified, they are connected in series in order to • Only one balancing resistor within the T1 drive
handle the DC Bus voltage. The DC Bus is app.
• Balancing resistors protected against mechanical
670V during running, 790V maximum for the T type
shocks
drive or 325V running and 360V maximum for the
TL low voltage drives.
Capacitors
22 k Ohms resistors
used to balance the
voltage on the
capacitors.
Only one resistor to T2 modular drive

balance the DC Bus
voltage on the
capacitors.
T1 modular drive

Danger
Current Transformers On the T2 Modular Drive, only 2 current transformers

On the T1 Module Drive there are 3 current (called LEM) installed on the U & V bars. They are
transformers (called LEM) installed on the U, V & W powered by the 2 IGBT driver boards.
bars. They are powered by the IGBT driver board in
white. They give a sine wave image of the outgoing
current used by the microprocessor of the control
board to regulate the current provided to the motor.
T2 modular drive
T1 modular drive
Current
transformers
IGBT driver boards
! Note ! Note

Output Module T1 Old/New Parts ID
Danger
The T1 modular drive has been updated to a new

style output module. This output was introduce to
the field in the beginning of year 2007. The output
module has an additional board that connects to the
Power Interface Board to complete the connection
between the output and Power Interface Board. The
board is referred to as the Intermediate PCB
(Printed Circuit Board).
Intermediate
PCB
NOTE: Do not use PCB with Semikron old style
output module.
OLD
NEW

Output Module Replacement T1/T2
Danger
! Note ! Note
Replacing IGBT power modules for T1 drives 3. Unbolt the 2 screws per metal bracket which
supports the white plastic bracket of the
boards.
1. All the terminals have been removed from the

control board. Disconnect the 3 motor leads
from the drive.
4. Disconnect the IGBT firing cable connector
from the IGBT driver board.
2. Disconnect the 200V supplied from T1 step
down transformer in the SGNe Control Panel.
IGBT firing cable connector

Danger
! Note
5. Take out the complete white plastic bracket Power must be isolated before performing
with its 2 metal supports. the following checks.
Disconnect the DC bus connector from PL5
6. Disconnect the choke leads from the DC Bus

connections of the drive.
power module.
7. Unbolt the 4 screws at each corner of the
Release the module from the PDM
8. Visible location of the module after removing.

Danger
Replacing IGBT power modules for T2 drives

To release at least one module, the 2 bars of the DC
Bus must be removed. This means all the screws
have to be unbolted along the bars to free the choke
leads and the 3 modules.
One pair of screws are used on both sides of the

module. To release the module, unbolt the 4 screws
( 2 per module). For the U phase power IGBT
module, which supports the electronic boards, refer
to the procedure explaining the T1 drive to remove
the plastic support bracket and the electronic These screws must
boards. be unbolted to
release the DC Bus
bars
! Note
This screw must remain because it

holds the entire drive in vertical position
These screws must be unbolted to release

the module. The other screws are located
on the other side of the module, at the
bottom of the capacitor bank.
! Note
This screw must remain because it holds the

entire drive in a vertical position

Output Module T1/T2 PL5 Board
Danger
Replacing PL5 Board for T1 and T2 Output Modules
Uninstall board: remove 3 mounting screws from board and P1

wire connector on PL5 board.
Install board: replace 3 mounting screws and torque according to

chart on page 59. Then connect P1 wire connector to PL5 board.
PL5 P1
Connector
When replacing the T1 and T2 modular drive Output Modules, the PL5 board should be removed and then in-
stalled onto the new Output Module.
Note: New T1 and T2 Output Modules from aftermarket will not have PL5 board attached.

T1 Input (Rectifier) Module Test
Danger
Input and Output Module Tests

1. The Unit must be isolated (locked/Tagged out)
from the power supply
2. Wait at least 15 minutes before removing any
connections
3. Check for 0 voltage
4. Disconnect main cables to the input rectifier
5. Disconnect cables from the HPM motor
The tests for the input rectifier and the output inverter
modules are similar.
The locations to connect the multimeter are

• First probe to : the 2 points ( + DC Bus and - DC
Bus )
• Second probe to : the L1, L2 and L3 terminals to
test the input rectifier bridge and U, V and W
terminals to test the output transistors
• This is shown on the next page
• The Multimeter must be set to Diode setting.

Danger
Input and Output Module Tests

Short Circuit Test The multi-meter must read OL
Test to carry out :
Test one after the other phases L1, L2 and L3 of the
input bridge with the DC Bus bars
Test condition :
• Electronic of UMV switched off.
• Input power bolts L1, L2 and L3 not connected.
• No motor connected
Measuring device needed :

• One multi-meter set on diode test.
Correct Outcome:
.OL
- .OL
-
+ +
.OL = opened .OL = opened

Danger
T1 Input (Rectifier) Module Tests

Diode and Capacitor Test
Test to carry out :
input bridge with the DC Bus bars.
Test condition :
• No motor connected.

Correct outcome:
+ Char
+ 0,34
- -
Char = Capacitor charging

0,34v = Diode threshold

T1 Output (Inverter) Module Test
Danger

Test to carry out :
Test one after the other phases of the output
(inverter) module with DC Bus.
Test condition :

Correct Outcome:
0,29v = IGBT free wheel diode Char = Capacitor charging
threshold
0,29 Char
- + - +

Danger

Test to carry out :
Test one after the other phases of the input bridge
with DC Bus.
Test condition :

Correct Outcome:
0,29v = IGBT free wheel Char = Capacitor charging
diode threshold
Char
0,2
+ -
+ -

Danger

Short Circuit Test
Test to carry out :
Test one after the other phases L1, L2 and L3 of
the input bridge with the DC Bus bars
Test condition :

• One multimeter set on diode test.
Correct Outcome:
.OL .OL
+ +
- -
.OL = opened circuit .OL = opened circuit

Danger

Diode & Capacitor Tests
Test to carry out :
input bridge with the DC Bus bars.
Test condition :

Correct Outcome:
Char
0.3
- -
+ +
Char = Capacitor charging 0,38v = Diode voltage threshold

Danger

Test to carry out :
with DC Bus.
Test condition :

• One multi-meter set on diode test
Correct 0,35v = IGBT free wheel diode

Outcome: Char = Capacitor charging
threshold
0,35v Char
- + - +

Danger

Test to carry out :
with DC Bus.
Test condition :

• One multi-meter set on diode test
Correct Outcome: 0,35v Char = Capacitor char-

= IGBT
0,3 Ch
5v
+ - + -

Complete Drive Replacement
Danger
Replacing the entire T1 drive

To release the entire drive, the choke
leads have to be previously disconnected.
3 screws per side 3 screws per

to release the side to release
entire drive the entire drive
Replacing the entire T2 drive

1) Disconnect the choke leads
2) Disconnect all connections to the terminals
3) Disconnect the 200V electronic supply
4) Disconnect the power leads like L1, L2, L3, U, V
and W
5) Release the entire drive. Undo 5 screws per side.
5 screws per
5 screws per side to
side to release the
release the entire drive
entire drive

T1 VFD Bolts Torque Settings
Danger
T1—VFD Bolts Torque Settings

Connecting power leads to the Drive

Danger

Tightening the output and rectifier modules.
The modules are tied to the main chassis by eight

YR01 nuts (four per module)
YR01
M8 Hex lock nuts (comby S) with attached conical
spring washer.
12 Nm / 106 12 Nm / 106

Danger

Mounting the Electronic Board on the U phase
module
Use TB.9 metallic bracket and TB.10 assembly.
BY07 Hexalobular pan head tapping screw 2.9mm

x 9.5mm
(diam x
length).

Danger

Install TB.9 Metallic bracket on the IGBT output
module and TB.10 board-bracket assembly using
four YR04 nuts.
YR04
M6 hex lock nuts (Comby S) with attached conical
spring washer
Also
connect
TP.1
earth
strap to
the
metallic

Danger

Mounting the PL.5 Board
Connect the PL5 Board using three VS27 screws.
VS27
Hexalobular flange head tapping screw 4mm x
6mm (diam x length)
Mounting the thermal

probe on the rectifier
module.

Danger

Mounting PL4
Use four VS27 screws to mount PL4

Use five VS27 screws to wire PL4
Use three VS27 screws to wire PL3
VS27
Hexalobular flange head tapping screw 4mm x 6mm
(diam x length)

Danger
Connecting the Power Leads to the Drive

Danger
Tightening output and rectifier Modules
Each module is tied to the main chassis by using

four YR01 nuts.
12 Nm / 106 lbf.in 12 Nm / 106 lbf.in
YR01 M8 Hex lock nuts (comby S) with attached conical spring washer

Danger
Tightening DC Bus Bars
Install TB2 and TB3 using twelve ZL02 washers

and twelve HF33 screws.
HF33 M8 hex cap screw fully threaded
ZL02 Conical spring washer for socket head cap screw Diam = 8

Danger
Mounting the Electronic Board on the U phase

Module
Install TB.9 metallic bracket on the U phase Module

and the TB.10 board-bracket assembly using the
four YR04 nuts.
W phase
module
V phase
module
U phase
module
Rectifier
module
Mounting the PL5 Board
Connect the PL5 board using three VS27 screws.
YR04 M6 hex lock nuts (Comby S) with attached conical spring washer
VS27 Hexalobular flange head tapping screw 4mm x 6mm (diam x length)

Danger
Mounting the Thermal Probe
Mounting PL.4
Mount PL4 using four VS27 screws.

Wire PL4 using five VS27 screws.
Wire PL3 using three VS27 screws.
VS27 Hexalobular flange head tapping screw 4mm x 6mm (diam x length)

VFD Cooling
Danger
Cooling System for the T1 Drive
Fan supply Drive fan
DC Choke
Input rectifier
duct
Drive
Output IGBT Air inlet with

duct filter
Air outlet ( air blown into

the compressor enclosure
Cooling System for the T2 Drive and exhausted by the main The 4 heat sinks of
package blower ) the drive
Blower + motor Ducts Air inlet from bottom of the

VFD Cooling
Danger
VFD Cooling
Fan voltage measurement
Fan supply
connector

Site Log
Danger
Nirvana Drive / Motor Investigation Site Log warranty claim. Claims will not be settled until this
form has been completed and returned with the part
This form must be completed in FULL and returned
replaced.
with all Nirvana VFD parts returned as part of a

Site Log
Danger

Site Log
Danger

Revision Updates and History
Danger
Date: August 2007
REV. 05
Comments:
All page references have been changed to section
Milliohm meter test procedure has been added
Motor resistance phase to phase values added to manual
HIPOT testing procedure added to manual
Drive error codes have been removed
New Site Log Sheet added
Date: April 2008
REV. 08
Comments:
Section 4: Instruction added for performing memory test
Section: 6: A notation has been added “NOTE: For Chassis drive main motor combinations, use the large of the motor type. Example for a
50HP, use the 60HP motor MIN/MAX resistance values.
Section 8: Note added regarding required drive configuration requirements fro Control Board after board replacement
Section 11: The section is now have headings labeled Input ID and ID Replacement
Section 12: The sections shows the difference between new and old style output modules,
A note added stating “do not interface old and new output modules with PCB”,
Section: 13: This section now has picture of the PL5 board and a note which states “New T1 and T2 Output Modules from aftermarket will not
have PL5 board attached”
Section 19: Pages 50 through 60 headings have been relabeled to state T1/T2 VFD Bolts Torque Settings
Section 21: Nirvana Site Log Sheet heading corrections “N37KW-50HP And Above, Nirvana, Drive / Motor Investigation Site Log
© 2007 Ingersoll-Rand Company, All rights reserved

Nirvana HPM Motor
Variable Speed Drive
Fault Tree
Manual
Issue: 2 April, 2008

Copyright Notice
2008 Ingersoll Rand Company
PROPRIETARY NOTICES
Copyright 2008 INGERSOLL RAND COMPANY
CONFIDENTIAL AND TRADE SECRET INFORMATION. This manual contains confidential and trade
secret information owned by Ingersoll-Rand Company (hereinafter referred to as "Proprietary Matter"). In
consideration of the disclosure of the Proprietary Matter herein to the authorized recipient hereof, the
recipient shall treat the Proprietary Matter as secret and confidential; shall not disclose or give such
Proprietary Matter to third parties without the express written authorization of INGERSOLL RAND; shall
not use the Proprietary Matter except to the extent necessary to use or service the equipment disclosed
herein; and shall disclose such Proprietary Matter only to those of its employees whose use or
knowledge of the Proprietary Matter is necessary. This manual shall be returned upon request by
Ingersoll Rand Company. The unauthorized use of this manual may be punishable by law.
DISCLAIMERS
THIS MANUAL AND THE CONTENTS ARE PROVIDED "AS IS" AND WITHOUT ANY IMPLIED
WARRANTIES. PRODUCT IMPROVEMENT IS AN ONGOING PROCESS AT IR. DATA IS SUBJECT
TO CHANGE WITHOUT NOTICE.

Nirvana Fault Tree
Index
Introduction
This manual has been designed for you to
use with the Nirvana HPM Motor Variable
Speed Drive Troubleshooting Manual.
Some procures of the Fault Tree Manual
will refer you to sections of this manual
regarding how to test, assemble and
disassemble the Nirvana HPM Variable
Speed Drive.
General Run and Monitor Information ... ..4

VSD Fault 0............................................ ..5
VSD Fault 1............................................ ..6
VSD Fault 2............................................ ..7
VSD Fault 7& 8 ...................................... ..8
VSD Fault 10.......................................... ..9
VSD Fault 12,13 & 14..……………….….10
VSD Fault 16……………………………...11
VSD Fault 18……………………………...12
VSD Fault 23……………………………...13
VSD Fault 26……………………………...14
VSD Fault 31……………………………...15
VSD Fault 33……………………………...16
VSD Fault 34, 35 & 36……………….….17
VSD Fault 37………………………….…..18
VSD Fault 38………………………….…..19
VSD Fault 39, 40 & 41……………….…..20
VSD Fault 42………………………….…..21
VSD Fault 43………………………….…..22
VSD Fault 44-2....................................... 23
VSD Fault 44-3....................................... 24
VSD Fault 44-4....................................... 25
VSD Fault 44-5....................................... 26
VSD Fault 44-6……………………….…...27
VSD Fault 44-7……………………….…...28
VSD Fault 44-8……………………….…...29
VSD Fault 44-9……………………………30
VSD Fault 44-10……………………….….31
VSD Fault Initialization Communication..32
Revision Updates and History………..….33
Nirvana Fault Tree Manual Page

Nirvana Fault Tree
Important Information
IMPORTANT!!
Run and Monitor:

It is necessary to perform the following steps:
¾Power compressor and compare controller display with a volt meter between each phases.
¾Compare DC Bus Voltage display with AC. (See below restrictions regarding the Input and DC Bus voltage)
¾Compare motor current display with clamp on Amp meter with the output reading on the controller
¾Motor current imbalance ( ± 5% max).
¾Power supply current imbalance ( ± 10% max at max speed)
¾Check for unstable motor speed on display etc
¾Pressure displayed (unstable, unable to achieve target pressure)
¾Check for motor noise and /or unusual noises
¾Motor vibration could be a mechanical issue perform checks in this area
If trouble persist record the Alarms History and information from Service Menu 16, onto the Nirvana Trouble Shooting
Log Sheet
INFORMATION
POWER INPUT VOLTAGE :

380 to 480 VAC ± 10%, 50 or 60 Hz ± 2% (T1 and T2 Drives)
200 to 230 VAC ± 10%, 50 or 60 Hz ± 2% (TL Drives)
The phase voltage imbalance must not exceed 2% on 50hz units and 3% on 60Hz units.
DC BUS VOLTAGE :
Approximately equal to AC voltage multiplier by 1.4
Can be lower if running in loaded condition.
CURRENT READING ON INTELLISYS

At max load, the motor current must not exceed the nominal motor current values.
Refer to chart in section: 6.0 Winding

Insulation Test in the Nirvana Trouble
Shooting Manual
Nirvana Fault Tree Manual Page 2

Danger
Please utilize extreme caution when performing work within the drive cabinet.
VSD FAULT 0
DC BUS OVER VOLTAGE
!
Switch Power back Off
and wait for the DC Check and record Alarm History and Menu 16 on Intellisys. If there are recent VSD 10,
voltage to reduce to 0V 12 refer also to corresponding fault trees
before you perform
these steps.
Can the controller be reset and does the compressor run ? Yes
No
Refer to Errors
Code Chart.
Fail Perform Menu 348
board diagnostic. (See procedure in section 4.0)
Pass
Does compressor
Correct Power Supply Fail Incoming power supply within No run on full
specification ? speed range ?
Yes Yes
Fix KM1. Fail Inspect
Does VSD0 always occur
Contactor KM1.
at same condition ?
Pass
Fix Motor. Fail Perform a motor test, inspect hall effect
No Yes
sensor air gap.
Pass
Replace Rectifier.
(See procedure in Fail Perform Diode test Check electrical environment
Input Module. (Power supply failure, etc.) If so,
section 11.0))
(See procedure in section 14.0 fix issue
and 16.0 )
Pass
Switch Power back On / Cycle the Power.
Autotest Fail Autotest Pass

Refer to VSD44 fault trees. Run compressor and monitor
Basic Checks :
- Torque all electrical connections. (See torque procedure)
- Incoming Power Supply - 380 to 480 VAC ± 10%, 50 or 60 Hz ± 2% (T Drives)
- 200 to 230 VAC ± 10%, 50 or 60 Hz ±2% (TL Drives) Page 3
Danger
VSD Fault 1
OVER CURRENT
!
and wait for the DC
voltage to reduce to 0V Check and record Alarm History and Menu 16 on Intellisys. If there are
recent VSD 7,8,10, 12 refer also to corresponding fault trees.
before you perform
these steps.
Can the controller be reset and does the compres- Yes
sor run ?
Fail No Run machine at fixed speed. Monitoring

Refer to Errors Code
Chart. Perform Menu 348 IR30. Increase the speed to find the trip
board diagnostic. (See procedure in section 4.0) point.
Pass
Mechanical investigation. No Does compressor turn Did IR30 show a vibration?
by hand ?
Yes No
Check for bad connection on motor leads. Using a clamp on Amp meter. Does motor
Check internal currents readings correspond to Intellisys
Fix Issue. Fail drive connections display and are well balanced?
Output Power module,
ribbon cable.
Yes No
Pass
Visual inspection
of ID board.
Replace if necessary.
Fix motor. Fail Perform a motor test, inspect hall
effect
sensor air gap. Resolve mechanical issue.
Pass

Basic Checks :
Danger
VSD Fault 2
Current Imbalance
! Check and record Alarm History

and Menu 16 on Intellisys.
and wait for the DC
voltage to reduce to 0V Can reset the controller and does the
before you perform compressor run ? Yes
these steps.
Using a clamp on Amp meter. Does motor
No currents readings correspond to Intellisys
display and are well balanced?
Fail
Perform Menu 348
board diagnostic.
No Yes
Refer to Errors Code
Chart. (See procedure in section 4.0)
Pass
Replace ID board. Fail Visual inspection of ID board.
(See procedure in section (Damaged, or bad soldering…)
10.0)
Pass
Check ID and Distribution board properly plugged.
Fix issue. Fail Visual inspection of
drive ribbon cables
Pass
Fix motor. Fail Perform a motor test
Pass

Basic Checks :
Danger
VSD Fault 7 & 8

Encoder (Hall Effect Sensors)
!
Switch Power back Off Check and record Alarm History
and wait for the DC
voltage to reduce to 0V
before you perform
these steps.
Can reset the Controller and
does the motor run? Yes
No
Perform Menu 348

board diagnostic.
(See procedure in section 4.0)
Pass Fail
Perform HES test Refer to Errors Code Chart.
(See procedure in section 7.0).
Pass Fail
Replace HES.
Switch Power Back On / Cycle the Power
Run compressor and monitor
Basic Checks :
Danger
VSD Fault 10
Bus Oscillation
!
Check and record Alarm History
Switch Power back Off and Menu 16 on Intellisys.
and wait for the DC
before you perform Can the controller be reset and does the compressor
Yes
run ?
these steps.
No Run machine at 50% of the
max speed. Does the
Refer to Errors Code Chart. Fail Perform Menu 348 CURRENT measured
on each phase
board diagnostic.
(See procedure in section 4.0) at the Input Rectifier
Check DC Bus Connections differ more than 15%?
as an additional check.
Pass
Yes No
Fix KM1 Fail Inspect
Contactor KM1. No
Refer to picture in section: Does VOLTAGE imbalance of
11.0 Input (Rectifier) Module Pass Power supply > 3%?
in the Nirvana Trouble
Shooting Manual
Inspect thyresistor gate red wire Yes

Fix issue Fail connections on Input Power
Module. (see section 11.0)
Correct Power
supply
Pass
Replace Rectifier. Perform diode test on Input Module.
(See procedure in section
11.0) Fail (See procedure in section 14.0 and 16.0)
Pass

Basic Checks :
Danger
VSD Fault 12 - Mains Failure

(Loss of Incoming Power)
!
VSD Fault 13 – Phase missing
Switch Power back Off Check and record Alarm History

and wait for the DC
before you perform Incoming Power Supply
these steps. within specifications ?
No Yes
Correct Power Supply. Can reset the Controller?
Fail No Yes
Refer to Errors Perform Menu 348 board Compare AC voltage displayed by
Code Chart. diagnostic. (See procedure in sec- Intellisys with measurements.
tion 4.0)
Fail Pass
Pass Replace Rectifier.
(See procedure)
Fix and tighten at

specified torque.
Fail Check for loose connections.
Ensure KM1 is operating properly
Fix KM1. (including coil)
Pass
Replace Rectifier.
Fail Perform Diode test
Input Power Module.
(See procedure in section 14.0 and 16.0)
Pass
Fix Motor.
Fail Check Motor.
Pass
Autotest Fail Autotest

Basic Checks :
Danger
VSD Fault 16
DC bus Under voltage
!
and wait for the DC and Menu 16 on Intellisys. If there are recent
voltage to reduce to 0V VSD 0, 10, 12 refer also to corresponding fault
tree.
before you perform
these steps.
Can reset the Controller and Yes
does the compressor run?
No
Refer to Errors Perform Menu 348
Code Chart. Fail board diagnostic.
(See procedure)
Pass
Change ID board. No Does DC Bus Voltage displayed by the Intellisys
= 1.4 x AC Voltage ?
Fail Yes Does VSD16 occurs always at

same condition ?
Fix and tighten Check for loose connection (Choke, etc.)
as specified torque.
Pass No Yes
Perform Diode test
Replace Rectifier.
(See procedure in section
Fail Input Power Module.
(See procedure in section 14.0 and
11.0) 16.0)
Pass
Fix Motor. Fail Check Motor.
Pass
Check electrical environment
Switch Power back On / Cycle the Power. ( Power supply failure, etc.)
If so, fix issue

Basic Checks :
Danger
VSD Fault 18
Motor PTC Probe
!
and wait for the DC and Menu 16 on Intellisys
before you perform
these steps. Improve No Check room temperature
Air Flow less than 115°F/ 46°C.
Yes
Yes Can reset the Controller and
does the motor run?
No
Perform Menu 348
board diagnostic.
Fail
Pass Refer to Errors Code Chart.
Perform HES test Replace HES.

(See procedure in section 7.0).
Fail (See procedure)
Pass
Check Motor vents. Fail Fix vents.
Pass
Check Motor. Fail Fix Motor.
Pass
Run compressor and monitor Autotest Pass Switch Power back On / Cycle the Power.
Refer to VSD44 fault trees.

Autotest Fail
Basic Checks :
Danger
VSD Fault 23
Motor Under Speed
!
Switch Power back Off and Menu 16 on Intellisys.
and wait for the DC If there are recent VSD 1 And/ Or VSD 2 trips
refer to VSD 1 fault tree.
before you perform
these steps.
Does the compressor run?
No Yes
Does Motor turn by hand? Is motor current measured at or near
100% of motor nameplate full load?
No Yes No Yes
Mechanical Investigation. Perform Menu 348 Mechanical Investigation.
board diagnostic.
Perform HES test

(See procedure in section 7.0). Fail
Pass Refer to Errors Code Chart.
Pass
Check PL5 board screw
Fail
connections. Replace HES.
Pass
Fail Check K1 relay, and motor
Fail Reconnect as specified
leads
are respectively connected (See information) and tighten
Fix screw as specified torque
at U, V & W on the drive.
connections. or fix K1 relay (wiring).
Pass
T2 only: Check ribbon cable Fail Reconnect as
are respectively connected specified.
on the distribution board T-2 drive (See information)
Pass
Autotest Pass Autotest Fail

Run compressor and monitor Refer to VSD44 fault trees.
Basic Checks :
Danger
VSD Fault 26
Motor Over Speed
!
and wait for the DC
before you perform Check and record Alarm History
these steps.
Yes Can reset the Controller and

No
Perform Menu 348
board diagnostic.
Pass Fail
Check max Speed Refer to Errors Code Chart.
Settings.
Fail Pass
Set the correct
max Speed.
Perform HES test Fail Replace HES.

(See procedure in section 7.0). (See procedure in section 7.0)
Pass
Run compressor and monitor Refer to VSD44 fault trees.
Basic Checks :
Danger
VSD Fault 31
Motor Phase
!
and wait for the DC
voltage to reduce to 0V Check and record Alarm History
before you perform
these steps.
Yes
No
Perform Menu 348
board diagnostic.
Pass Fail
Refer to Errors Code Chart.
Check motor leads
for proper connection Fail
at U, V & W on the drive.
Fix and tighten at

Pass specified torque.
Remove rear cover of motor

for a visual inspection.
Fail
Pass
Megger the Motor. Fail Replace Stator.
Pass

Refer to VSD44 fault trees.
Basic Checks :
Danger
VSD Fault 33
Rectifier Temperature
!
and wait for the DC
before you perform
these steps. Check and record Alarm History and Menu 16 on Intellisys.
Can the Controller reset and

No Yes
Check filters, fan motor rotation,
ambient temperature.
Check in Service Menu 3 for temperature value. Is
value equal to 120°C/ 248°F?
Check the temperature displayed, Does equal to -10°
Fail Pass
C/14°F? Yes Clean or replace filters.
Correct issue with blower.
Improve Air flow.
No
Inspect input rectifier temperature probe connections No Yes

(See section 11.0).
No Yes
Disconnect thermal probe connector from board and measure
resistance and compare No Replace Probe.
values to chart?
Yes Refer to chart in section:

11.0 Input (Rectifier) Module
Replace Rectifier. (See procedure) in the Nirvana Trouble
Shooting Manual
Switch Power Back On.
Basic Checks :
Danger
VSD Fault 34, 35 and 36

Inverter Temperature
!
Phases U, V and W.

and wait for the DC
voltage to reduce to 0V Check and record Alarm History
before you perform
these steps.
No Yes
Check in Menu 3 Check filters, fan motor rotation,
the temperature value. ambient temperature.
Does the Output Module
have fouled heat sink?
Verify that temperatures are stable.

Fail Pass
Clean or replace filters.
Correct issue with blower.
Improve air flow.
Remove the fouling.
No Yes
Replace
Output Module.
Allow the module to cool to room temperature and
check
temperature on display.
Basic Checks :
Danger
VSD Fault 37
Loss of +15 volts power
!
supply for Hall Effect Sensors.

and wait for the DC
before you perform
these steps. Check and record Alarm History
Can reset the Controller and Does the compressor run? Yes
No
Perform Menu 348
Pass Fail
Replace HES. Refer to Errors Code Chart.
Basic Checks :
Danger
VSD Fault 38
Loss of +24 volts DC
! power supply

and wait for the DC
these steps.
Can reset the Controller and does the compressor run? Yes
No
Perform Menu 348
Pass Fail
Is +24VDC present between pin 5 and 6 Refer to Errors Code Chart.
on PX2 Control board?
Yes No
Check wiring.
Fail
Fix issue
Basic Checks :
Danger
VSD Fault 39, 40 and 41

IGBT Fault Phase U, V and W
!
and wait for the DC and Menu 16 on Intellisys.
voltage to reduce to 0V If there are recent VSD0/VSD1/VSD2
or a mix of VSD39/VSD40/VSD41 trips
before you perform refer to VSD 1 fault tree.
these steps.
Can reset the controller and does the compressor run at max speed ?
Yes (intermittent trip)

No
Correct Fail Incoming Power Supply within speci- T2 drive T1 drive
Power Supply. fications ?
Swap 2 output modules.

Yes Run and monitor. Does Trip follows
Module ?
Inspect drive for loose connections
Refer to
Yes No
Error Code. Fail Yes Check electrical environment
Perform Menu 348, ( Power supply failure, ground
Board diagnostic loops, etc.)
( see procedure in section 4.0)
T1 drive
Fail Pass
Fix motor. Replace faulty
Check the motor. Module.
Pass If trip persists, replace

Replace Distribution faulty
board Module.

Basic Checks :
Danger
VSD Fault 42
Rectifier Fault
!
and wait for the DC Check and record Alarm History and Menu 16 on Intellisys.
before you perform
these steps. Yes Can reset the Controller and does the compressor run?
No
Perform Menu 348
board diagnostic.
Pass Fail
Incoming Power Supply Refer to Errors Code Chart.
within specifications?
Yes No
Correct Power Supply.
PL5 fuses blown? Yes Replace fuses.
No
Perform Diode test Fail Replace Rectifier.
Input Power Module. (See procedure in section
(See procedure in section 14.0 11.0)
and 16.0)
Pass
Run compressor and monitor Autotest Pass Switch Power back On.
Cycle the Power.
Run to VSD44 fault trees.

Autotest Fail
Basic Checks :
Danger
VSD Fault 43
Ambient Temperature
!
and wait for the DC
these steps.

Does the compressor turn?
No Yes
Check in Menu 3 for Check filters, fan motor rotation,
the temperature value. ambient temperature.
Fail Pass
Is the temperature displayed stable and Clean or replace filters.
consistent with the ambient temperature? Correct issue with blower.
Improve Air flow.
Yes No
Replace Control board.
Allow the module to cool to room

temperature and check Run compressor and monitor.
temperature on display.
Basic Checks :
Danger
VSD Fault 44 -2 diagnostic Fault

T1 Output module. T2 U Output module
!
Error Code 4, 8, 12 or 13

and wait for the DC
before you perform
these steps.
Perform Menu 348
board diagnostic.
(See procedure section 4.0)
Switch Power back On. Cycle the Power.

Check connections between IGBT drivers board and Interface board.
Record Errors Codes Fail (T-2 and T-1 drives)
on Site Log
Is distribution board well plugged ? (T-2 drive only)
Check all DC BUS connections
Check PL5 board connections (see section 13.0)
Pass
Fix Motor.
Fail Check Motor leads connections.
Megger Motor.
Pass
Replace output module.

(U phase for T2 drive)
Basic Checks :
Danger

T1 Output module. T2 V Output module
! Error Code 5, 9, 12 or 14

and wait for the DC
before you perform
these steps. Perform Menu 348
board diagnostic.

Record Errors Codes (T-2 and T-1 drives)
on Site Log Fail
Is sharing board well plugged ? (T-2 drive only)
Pass
Fix Motor.
Fail Check Motor leads connections.
Megger Motor.
Pass
Replace output module. (V phase for

T2 drive)
Basic Checks :
Danger
VSD Fault 44 - 4 diagnostic Fault

T1 Output module. T2 W Output module
!
Error Code 1, 3, 12 or 15

and wait for the DC
before you perform
these steps.
Perform Menu 348

board diagnostic.

Check connections between IGBT drivers board and Interface
board. (T-2 and T-1 drives)
Fail
Fix issue
Is sharing board well plugged ? (T-2 drive only)
Pass
Check Motor leads connections.
Fix Motor.
Fail
Megger Motor.
Pass
Replace output module. (W phase

on T2 drive)
Basic Checks :
Danger

RECTIFIER
! Error Code 11 or 17

and wait for the DC
before you perform
these steps.
Perform Menu 348

board diagnostic.

Correct Fail Incoming Power Supply
Power Supply
within specifications?
Pass
Check PL5 fuses (See procedure section 13.0),

Fix Issue.
Fail Check DC Choke, Check motor lead connections,
Megger Motor.
Pass
Replace Rectifier
Basic Checks :
Danger

MOTOR

and wait for the DC
before you perform
these steps.
Perform Menu 348
board diagnostic.

Check PL5 fuses.
Fix Issue. Fail Check DC chocks leads connections
Check connection between PL5 and Interface

board.
Ensure the DC bus is not short circuited
Pass
Fix Motor.
Fail Check motor windings resistance values.
Megger Motor (See procedure in section 6.0)
Pass
Switch Power back on with motor leads disconnected. Run compressor and monitor
Autotest Fail with Autotest Fail with

VSD44-4 VSD44-6
Fix Motor.
T1 drive : change output power module
T2 drive : contact Technical Support
Basic Checks :
Danger

T1 Output module. T2 U V Output module

and wait for the DC
before you perform
these steps.
Perform Menu 348
board diagnostic.

Check connections between IGBT drivers
board and Interface board.
Record Errors Fail
Codes on Site Log Is distribution board well plugged ? (T-2
drives only)
Pass (T1 drive) Pass (T2 drive)

Replace output module Replace U phase
output module
T2 drive only.
If error persists, swap the V output power
module with the previous U output power
module
Run compressor and monitor.
Basic Checks :
Danger

T1 Output module. T2 V W Output module
! Error Code 14

and wait for the DC
before you perform
these steps. Perform Menu 348
board diagnostic.

Check connections between IGBT drivers board and
Interface board.
Record Errors Fail
Codes on Site Log Is distribution board well plugged ? (T-2 drives only)

Replace output module Replace V phase output
module
T2 drive only.
If error persists, swap the W output power
module with the previous V output power
module
Basic Checks :
Danger

T1 Output module. T2 U W Output module

and wait for the DC
before you perform
these steps.
Perform Menu 348

board diagnostic.

Record Errors Codes Fail Is distribution board well plugged ? (T-2 drives only)
on Site Log

Replace output module Replace U phase output
module
T2 drive only.
If error persists, swap the W output power
module with the previous U output power
module
Basic Checks :
Danger
VSD Fault 44 - 10
Diagnostic Fault
! Enable

and wait for the DC
before you perform
these steps. Check and record Alarm History
Perform Menu 348

board diagnostic.
Pass
Check Control board Fail Fix Issue.
Wiring. (Pin 9 on PX2)
Pass
Run compressor and monitor. Autotest Pass
Contact Technical Support. Autotest Fail
Basic Checks :
Danger
Initialization
Communication fault
!
and wait for the DC
before you perform
these steps. Is KM1 chattering?
No Yes
Check physically if the 15V DC power supply is present on the Control Fix KM1.
Board. (Led D45, located on left side)
Refer to
Pass Fail
Replace
picture in (See section Interface board
8.0) for LED location and
(See section 9.0) for Check 4 APT and wiring
Interface Board 15 volts.
Pass Fail Fix 4 APT.
Check cable connector

from Intellisys
Pass Fail Replace cable.
Replace Control board.

Autotest Pass
Run compressor and monitor Is DC voltage unstable?
Yes
Refer to
VSD Fault 10.
Basic Checks :
Nirvana Fault Tree
Revision Update History
Date:
REV.1a
Comments: Initial Release
Date: 4/5/2008
REV. 2
Comments:
Updates consist of rewording work instructions for various faults and to ensure that instruction coincide with Nirvana Trouble
Shooting Manual sections for individual component checks.
VSD 0: The tree block references to section (11.0) for diode testing. It should be (Sec and 14.0 and 16.0) in the Nirvana Trou-
ble Shooting Manual
VSD 10:The block that states “Inspect thyresistor gate connections” it has been better refined and now states “ Inspect thyre-
sisitor gate red wires on Input Module”
VSD 23: Added instructions to tree block that states to check PL5 board connections
VSD 33: Reworded tree block instructions, Logic has been changed for trouble shooting fault, “check for unstable temperature
readings” this block has been removed.
VSD 39,40 and 4: Added additional statement to tree block instructions “Inspect for loose connections see section 12.0
through 12.2”
VSD 44/2, 44/3 and 44/4: Added new work instructions to tree block that states “Check PL5 board connections see section
20.0
Added work instructions to tree block that that indicated to check BUS connections states “Check DC BUS connections
see section 12.0 to 12.1
Initialization Communication fault; Rephrased reference block to state “Refer to picture in (See section 8.0) for LED location
and (See section 9.0) for Interface Board 15 volts”.
Nirvana Fault Tree Manual Page 31

VARIABLE
SPEED
DRIVE
FAULT
DIAGNOSTIC
GUIDE
DATE: MARCH 2002

VSD FAULT DIAGNOSTIC GUIDE
NIRVANA DRIVE INTRODUCTION
The Nirvana drive is an Alternating Current (AC) closed loop flux vector controller particularly
adapted for Hybrid Permanent Magnet (HPM) motors. The controller uses an inverter bridge with
Insulated Gated Bipolar Transistors (IGBT) which considerably diminishes noise and temperature
rise in variable speed motors.
There is a nameplate on each drive to indicate the rating and voltage. At present, the rating and
voltages are: 75TL = 55 KW maximum, 3-phase, 200V to 230V, 50 or 60 Hz
75T = 55 KW maximum, 3-phase, 380V to 480V, 50 or 60 Hz
120T = 75 KW maximum, 3-phase, 380V to 480V, 50 or 60 Hz
The voltage supply must be within 10% ± of the rated voltage and the frequency must be within 2% ± .
The nameplate also indicates the Ingersoll-Rand part number and serial number of the drive.
The drive’s electronic control supply is a single phase 110/120V, 50/60 Hz circuit.
There is a cooling fan at the top of the drive operating on a 110/120, 50/60 Hz circuit. The fan
dissipates heat generated by the drive components.
The drive’s output voltage ranges from 0V to the power supply voltage and the maximum number of
power-ups is limited to 20 per hour.
In general, the drive is capable of operating in surrounding temperatures between –10°°C (15°° F) and
+46°° C (115°° F) at humidity levels ranging between 5 to 95%; no condensation allowed.
The drive must be protected by fuses within the main incoming power supply. The fuses are to be
UL 600V Class J. Example: Ferraz Shawmut A4J series or equivalent.
The fuse ratings for various size and voltage Nirvanas are in the General Information section of the
Operation and Maintenance Manual
DANGER
• The drive has various voltages present on the power terminal blocks and in cables connected to
them that may cause fatal electrical shocks.
• The drive contains capacitors which remain charged at a fatal voltage for a period of time even
after the power supply has been removed.
• Do not perform operations on the drive without first manually opening the power supply circuit to
the drive. Lock out and tag out the fused isolator or circuit breaker to prevent accidents.
• After the power has been removed, wait 15 minutes (so the internal circuits can discharge the
capacitors) before removing any protective covers.
• After performing any operations on the drive, replace the protective covers before restoring power.
Basic Troubleshooting
Note: Prior to beginning any troubleshooting procedures, it is important to understand that loose
terminal connections, blown fuses or improperly engaged plugs can be a cause for faults to be
issued. A thorough inspection and correction, if required, can save time and effort lost looking for
the wrong thing.
1 Revision 001 - March, 2002

The drive has the capability to monitor itself for proper operation and should a problem arise, the
drive will issue an alarm that immediately stops the compressor. The cause for the alarm is
indicated on the display of the Intellisys controller. The alarms are listed as a sequence of letters
and numbers.
Examples could be “VSD Fault 0” or “VSD Fault 29”. A total of 32 faults are possible within the
drive; some of which are not active. VSD indicates Variable Speed Drive and the number indicates
the specific fault.
The following description of active faults is intended to guide a trained technician during the
problem investigation. The “not active” alarms are merely listed to maintain the numerical sequence
and therefore have no text or description.
It is assumed the technician has access to, and is capable of operating, various test devices such as
voltmeters within both AC and DC circuits. Is capable of checking winding resistance, checking
diodes and reading schematics among other tasks.

VSD Fault Investigation
VSD Fault 0 - DC Bus Over-Voltage
Background: The VSD measures DC voltage on the bus bars within the drive and should the voltage
exceed approximately 785 volts DC, VSD Fault 0 will be issued. The alarm is issued whether the
motor is running or not.
The DC bus voltage is directly proportional to the AC voltage supplied to the compressor and high
incoming AC voltage is the usual cause for this alarm.
Example: on a 480 volt system, the AC voltage must be less than 528 volts (480 + 10%).
Since the relationship between AC and DC is a multiplier of 1.4142, the DC voltage is calculated at
746 volts DC.
Check the incoming AC voltage to the compressor at the customer disconnect, at the top of motor
isolation contactor KM1 or on the Current Status screen of the Intellisys display (Input Voltage).
The DC bus voltage is also displayed within the Current Status screen of the Intellisys.
The high voltage may be transient and monitoring devices may be required to verify the source.
Consult with Power Utility.
Confirm the KM1 contactor is not rapidly closing and opening or loose wire connections to cause
voltage spikes. Also confirm none of the drive motor phases go to a ground condition.
VSD Fault 1 - Over-Current
Background: This fault is an instantaneous “do not exceed” over-current condition. The setting and
rapid response is part of the drive parameter settings and pre-programmed.
There are two blue colored current transformers fitted over motor leads U and V that cause the VSD
to respond similar in effect to a ground fault interrupter.
Confirm incoming power supply voltage is within specifications and stable to avoid over-correction
of the motor speed as the drive responds to the voltage fluctuation.
Confirm I.D. Board is properly plugged into the Power (Interface) Board. Refer to procedure outlined
in Appendix #3 for details.
Check all internal connection points, check for signs of motor phase arcing, faulty current
transformers or chafed motor leads.
Confirm drive motor is mechanically able to rotate by removing louver from end of motor and
rotating by hand. Normal rotation will seem to be unusual as magnets in rotor pass winding poles in
motor stator.
Inspect hall effect sensor cable wiring and point of connection at P4 Control Board. A loose wire or
bad connection can cause the drive to receive erratic information and possibly accelerate the motor
too fast to create an over-current condition.
If problem remains, disconnect motor leads U, V and W from lower terminal block of VSD attempt to
start unit. If fault is not issued, check motor windings for phase to ground.
If problem persists, change I.D. Board (Appendix #3), Power (Interface) Board (Appendix #2) followed
by the Control Board (Appendix #1) until problem is corrected. When the problem clears, consider
reinstalling previously replaced boards prior to problem clearing.
VSD Fault 2 - Current Imbalance
The measured current to the drive motor on leads U, V & W should be balanced within 2% or VSD
Fault 2 will be issued.

Can be caused by improperly tightened U, V & W motor leads at the VSD or junction box
connections.
Check wiring within VSD such as I.D. Board plug in point. See Appendix #3.
If problem persists, change I.D. Board, Power (Interface) Board followed by the Control Board until
problem is corrected. When problem clears, consider reinstalling previously replaced boards prior
to problem clearing.
VSD Fault 3 - Drive Temperature Too High
Background: A small cooling fan located at the top of the VSD removes heat generated by the VSD
electrical components during operation. The cooling fan is rated at 120 volts AC.
If VSD 3 is experienced, confirm VSD ambient temperature is below 115°° (+46°° C), fan is free to rotate,
check voltage to fan, check circuit breaker MCB2, check timer TDO-1, fan motor windings and
connections.
Locate small filter element at lower portion of VSD enclosure: clean or replace as required.
Confirm wires between P7 of Power (Interface) Board and temperature sensors on each side of the
Power Stack are connected. The sensors are normally closed and continuity can be checked at P7.
The blue wires at P7 terminals 1 & 2 are a circuit and the green wires at P7 terminals 4 & 5 are a
circuit.
If problem persists, change the Power (Interface) Board.
VSD Fault 4 - Not Activated
VSD Fault 5 - Internal Power Supply
The Control Board is a self monitoring device and should a problem develop on the board, VSD Fault
5 is issued.
Cycle incoming power to compressor to see if problem clears. If it doesn’t, change the Control
Board followed by the Power (Interface) Board.
When problem clears, consider reinstalling previously removed board prior to problem clearing.
VSD Fault 6 - Microprocessor
Open incoming power supply to compressor at customer’s disconnect. Leave open for
approximately 15 minutes to permit VSD capacitors to fully discharge. Apply power.
If problem persists, change the Control Board using procedure detailed in Appendix #1.
VSD Fault 7 - Encoder (Hall Effect Sensors)
Check encoder signals using procedure detailed in Appendix #4.
VSD Fault 8 - Encoder Loss
Same procedure as VSD 7.
VSD Fault 9 - Not Active.
VSD Fault 10 - Bus Oscillation
Caused by voltage rapidly rising and falling on the incoming power supply and is read from the DC
bus bar.
Check incoming power supply. Voltage can not vary more than 3% or alarm will be issued.

Call for assistance.
VSD Fault 11 - Not Active
VSD Fault 12 - Mains Failure (Loss of Incoming Power)
Relates to incoming power supply and is read within the VSD.
Reset Intellisys controller to permit KM1 to reapply power to the VSD. Scroll through Status screen
to Input Voltage. Voltage reading will be approximately half of compressor’s rated voltage if all three
phases are not available.
Open VSD enclosure and use voltmeter at top of KM1 to determine which phase is missing.
Identify cause such as blown fuse and correct as required.
VSD Fault 13 - Phase Missing
Similar to VSD Fault 12 but is calculated using parameters at full load conditions.
Open VSD enclosure and use voltmeter at top of KM1 to determine which phase is missing.
Identify cause such as blown fuse and correct as required.
Confirm incoming voltage supply to compressor is within -10% of VSD’s rated voltage.
Check fuse F2 (Item 13 of Parts List) on EMC-Thyristor Triggering Board (Item 3 of Parts List).
VSD Fault 15 – Mains Over Voltage
Confirm incoming voltage supply to compressor is within +10% of VSD’s rated voltage.
VSD Fault 16 – DC Bus Under Voltage
Confirm incoming voltage supply to compressor is within -10% of VSD’s rated voltage.
Reset Intellisys controller to permit KM1 to apply power to VSD. Confirm AC voltage is correct at
terminals 1, 2 & 3 at bottom of VSD.
Multiply the measured AC voltage as read at terminals 1, 2 & 3 at bottom of VSD by 1.4142 to
calculate what the DC Bus voltage should be.
Check Input Voltage and DC Bus voltage on Intellisys Status screen. If the DC voltage in the
Intellisys display isn’t within 5% of the calculation, call for assistance.
Check fuses (2) on small printed circuit board (Item 15 on Parts List) located on bottom of capacitor
bank. If either fuse is blown, use instructions in Appendix #5 to check drive motor windings.
If both fuses are good, check fuse F3 (Item 12 on Parts List) on EMC Thyristor Triggering Board
(Item 3 of Parts List). If F3 is blown, use instructions in Appendix #5 to check drive motor windings.
Change stator if required.
If drive motor winding resistance is within specification, call for assistance.
VSD Fault 18 – Motor PTC Probe
Confirm ambient temperature is within specification (less than 115°° F / 46°° C) and airflow is not
restricted.

Reset Intellisys and attempt to start compressor. If compressor runs, investigate ambient air
temperature and cooling air flow at time alarm was issued. See Last Alarm Recall.
If VSD – 18 immediately returns after starting compressor, replace the Control Board.
If fault persists, use Appendix #4 to check Hall Effect sensors. Replace as required.
If fault clears, consider reinstalling previously removed Control Board.
If fault reoccurs, call for assistance.
VSD Fault 22 – Alarm 1 = Current Overload
This alarm is issued after the drive motor has been in an overload condition for a period of time.
Reset the Intellisys and check Last Alarm Recall for history concerning high drive motor current,
airend discharge temperature, etc,
Remove cover from end of drive motor and rotate by hand the check for hard rotation. Note: the
motor will rotate in an odd way as the magnets on the rotor pass the winding poles and will feel
similar to a large stepper motor.
Attempt restart and observe operation for unusual noise or vibration. Investigate as required.
If compressor appears to run normally, call for assistance.
VSD Fault 23 – Alarm 2 = Motor Underspeed
Check for locked airend or motor.
VSD Fault 26 – Motor Overspeed
Use directions detailed in Appendix # 4 to check Hall Effect sensors.
VSD Fault 29 – IGBT
CAUTION! Confirm power supply to unit has been disconnected and the switch has been locked
and tagged in the open position. Wait 15 minutes for capacitors to discharge completely. Confirm
DC voltage has discharged completely. Remove protective cover from front of VSD.
Inspect all control wiring connections to ensure all are tight and secure with special attention to the
three small circuit boards on the sides of the capacitor bank. One of the cards will be on the left
side and two cards will be on the right side. Confirm both ends of the small red wires are in position
and fully engaged.

Confirm gray colored snap-in cable connectors on same card are in position and fully engaged.
VSD Fault 31 – Motor Phase
Check drive motor leads for proper connection at U, V & W on bottom of VSD.
Check drive motor leads in junction box at back of VSD enclosure for proper connection.
Remove cover from end of drive motor and confirm leads are properly connected to motor windings.
Use Appendix #5 to check drive motor windings for open phase or phase to ground.
If problem persists, call for assistance.
Appendix Section
Appendix 1 – Control Board Replacement

1. Isolate the compressor from the main incoming voltage supply. Lock and tag the isolation
2. Allow 15 minutes for the VSD to discharge capacitors.
3. Open enclosure doors to expose VSD.
4. Remove clear plastic protective cover from front of VSD.
5. Check with a suitable meter that all voltages have dissipated before beginning work on the VSD.
6. Unplug P1, P2 and P3 from bottom of the Control Board.
7. Remove the Hall Effect Sensor plug from P4 located on bottom of Control board.
8. Remove the Modbus Communication Board from the front of Control Board and retain for
installation on new Control Board.
9. Remove ribbon cable from top of Control Board.
10. Remove the small mounting screw from each corner of the Control Board.
Note: Four spacers (3 plastic and 1 metal) are used as a stand-off to support each corner of the
Control Board. When the screws at the corners are removed, the spacers may drop. The metal
spacer also serves as a grounding circuit for the Control Board and must be
reinstalled at the bottom left!
11. Install new Control Board, reversing the above procedure.

Appendix 2 – Interface Board Replacement

1. Isolate the compressor from the main incoming voltage supply. Lock and tag the isolation switch
in the open position.
4. Remove clear plastic protective cover from front of VSD.
6. Loosen the 2 screws at the top corners holding the front metal plate and lower it down.
7. Unplug all cables from the Interface Board.
8. Remove the small I.D. Board from the Interface Board, taking care not to cause damage to pins
of the plugs.
9. Observe the spacers between the Interface Board and the metal plate. Notice the middle spacer
on the left side is made of metal and serves as a ground circuit for the board. Remove the six
small mounting screws holding the Interface Board to the metal plate and carefully remove the
board. See note below.
Note: Six spacers (5 plastic and 1 metal) are used as a stand-off to support the Interface Board
around the perimeter. When the screws are removed, the spacers may drop.
The metal spacer must be correctly located when installing the new board. See
Item 9 above.
10. Install new Interface Board, reversing the above procedure.

Appendix 3 – I.D. Board Replacement

1. Isolate the compressor from the main incoming voltage supply. Lock and tag the
isolation switch in the open position.
4. Remove clear plastic protective cover from the front of the VSD.
5. Check with a suitable meter that all voltages have dissipated before beginning work on
the VSD.
6. Loosen 2 screws at the top corners holding the front metal plate and lower it down.
6. The I.D. Board is installed on the Interface Board using 2 plugs and held in position by a plastic
spacer.
7. Gently remove the I.D. Board from the Interface Board, taking care not to cause damage to the
plugs.
8. Install new I.D. Board to the Interface Board, again taking care not to cause damage to
pins of plugs.
10. Raise the front metal plate and tighten the fixing screws.
11. Replace clear plastic protective cover.
12. Close VSD enclosure doors.
13. Re-apply power to the unit, run and test.

Appendix 4 – Hall Effect Sensor Checks (Four Part)

4. Check with a suitable meter that all voltages have dissipated before beginning work on
the VSD.
5. Remove rear cover of drive motor to permit rotating by hand.
TEST 1
6. Disconnect Hall Effect Cable from P4 on the Control Board, plug type is DB9 Type.
7. Inspect cable pins and matching receptacle connections for damage or bent pins.
Remove cover of plug and inspect solder connection of the wires for damage.
9. Inspect entire length of the cable for damage. If cable and connections are in good condition,
proceed to Test 2.
TEST 2
9. To confirm supply voltage to the Hall Effect Sensor is present using a digital multi-meter go to step 10.
10. Disconnect terminal strips P1, P2 & P3 from the bottom of Control Board.
11. Trip and switch off MCB2 and MCB5 to prevent the SGN Intellisys from powering up.
12. Re-connect main incoming supply voltage to the unit. Isolation contactor KM1 should remain
de-energized and the VSD should only receive control power. Caution must be taken as the
panel has voltage present.
13. Set digital multi-meter to DC Volts.
14. Connect Black probe of multi-meter to either of the 2 pins of P16.
Note: P16 is located on the Control Board, slightly less than half way down and towards the left side.
P16 is marked and described as 2 small bare pins. P16 is the ground connection for the Control
Board.
15. Locate the small transistor just above Pin 3 on terminal strip P1. The transistor has 3 pins on
the left side. The pins are numbered 1 at the top, 2 in the middle and 3 at the bottom.
16. Connect Red probe of multi-meter to Pin 3. The voltage should be between +11 and +14 Volts
DC.
17. If voltage is not present, replace the Control Board.

TEST 3
17. Connect special adapter XXXXXXXX between P4 on the Control Board and the Hall
Effect Sensor Cable.
19. Set digital multi-meter to DC Volts.
20. Connect Black probe of multi-meter to either of the 2 pins on P16.
21. Connect Red probe of multi-meter to Red wire of the adapter. Rotate motor by hand and
observe measurement. The meter should read between +10 and +12 Volts DC.
22. Repeat the test with the Black wire of the adapter. The meter should read between +10 and +12
Volts DC.
23. Repeat the test with the Yellow wire of the adapter. The meter should read between +10 and +12
Volts DC.
24. If voltage does not rise to between +10 and +12 Volts DC for any of the 3 sensors, replace the
TEST 4
25. Set digital multi-meter to Ohms.
25. Connect multi-meter between Purple and Green wires of special adapter XXXXXXXX. The meter
should show a resistance value of approximately 150 Ohms ± 20% (New Hall Effect Sensors)* at
70°° F (20°° C) ambient temperature.
27. If correct value is not confirmed, replace the Hall Effect Sensor Assembly.
Note: Two temperature ranges (130°° C and 150°° C) of Hall Effect Sensor have been used. Typically,
the 50/60hp (37/45kW) units use a 130°° C sensor and the 75/100hp (55/75kW) units use a 150°° C
sensor. All sensors have a small band near the sensor end of the cable.
The 130°° C sensor has four digits such as 6622 on the band. The 150°° C sensor could have either a
four digit number with a star on each side (*6752*) or a four digit number followed by a star and the
letter E (6752*E) or a four digit number followed by an E (7652E).
Appendix 5 – Megger Main Motor Windings
4. Remove clear plastic protective cover from the front of the VSD.
6. Disconnect motor leads from U, V and W on the bottom of the VSD.
7. Connect Black cable of megger to Ground connection of the VSD.
8. Connect Red cable of megger to each of the motor leads (one at a time) and test. Each cable
should give a minimum value of Infinity (20M Ohms)
9. If motor test correctly, reconnect motor cable to the VSD in the correct sequence.

10. If the motor fails the test, replace stator.

Commissioning
Power Off pre-start Checks ..................................................1

Power On pre-start Checks ..................................................2
Running Checks ...................................................................3

Nirvana Oil Free Commissioning
Power Off pre-start Checks
Power Off Pre-Start Checks Subject: Electric Motors Insulation Testing

• Remove all the panels and visually inspect unit All SSR units must have an Insulation test per-
for signs of breakage, oil leakages etc. formed on both Main Motor & Fan Motors, the Insu-
(Any found should be noted on the warranty start lation test should be performed as detailed below:-
up document.)
Insulation Test
Disconnect the main motor leads from the drive and
• Remove all desiccant bags and transportation perform the insulation test.
bolts and spacers (if fitted), normally marked with Replace the main motor leads when the test has
fluorescent cardboard tags. (Any brackets fitted been conducted.
will be painted yellow). Ensure fork lift cover
plates are installed to the unit. Disconnect the fan motor leads from the contactor
and perform the insulation test.
• Check sump coolant level is clearly visible in Replace the fan motor leads when the test has been
sight glass. conducted.
All units are filled via meter control during CAT Phase - Earth = 10 M (Million) Ohms or Greater
test and should not require top up. It is possible
for Ultracoolant to move during transit and not It is essential that an Insulation Test is performed
appear in the sight-glass. If in doubt, remove during the commissioning of the Compressor before
filler cap and check to see if the level is within voltage is applied.
50mm of the sight glass. If so, refit cap and run
unit and recheck level during offload operation. If the compressor has been stored in a damp/cold
(If required, top up with SSR Ultra Coolant only). area and is then transferred into a warmer environ-
ment.
• Spin blower motor by hand to ensure free unre- If the motor has been stored for 6 months or longer
stricted movement. then the check should be performed regardless of
the environmental conditions.
• Ensure unit is isolated before opening the starter
box. Check tightness, good contact of all wiring If the resistance value is less than 10 M Ohms then
connections. the motor requires some time in the warmer environ-
ment or the windings heated and the test repeated
• Check fan motor MMS protection device setting before voltage is applied to the motor.
is correct.
• Check transformer connections are applicable for

site voltage and change as required.
! Note:
Before the Insulation Test is performed the In-
tellisys Controller must be Unplugged; also ensure
• Check motor leads are connected correctly for control circuit fuses are removed and MCB’s are off
site voltage. to prevent any damage from occurring to the Intelli-
sys Controller.
• Check MCB’s are closed.
• Remove all foreign material and contamination

from the starter cabinet.
• All protective covers should be replaced and all

access doors should be closed and locked prior
to applying power to the unit.
• Open main isolation valve into ring main system.

Power On pre-start Checks
Power On Pre-start Checks Input Voltage DC Bus Voltage
! Danger: 380 Volts AC 540 Volts DC

A Variable Speed Drive is contained with the
compressor starter cabinet. 400 Volts AC 565 Volts DC
When it is switched off and the motor is stopped, the

internal capacitors store a potentially lethal high volt- 415 Volts AC 590 Volts DC
age electric charge which gradually falls to zero over
time.
460 Volts AC 690 Volts DC
After switching off the machine at its local isolator,
wait at least 15 minutes for the capacitors to fully
discharge before opening the starter cabinet doors • If “DC Bus Voltage” value displayed is not as
an commencing work within the power drive module. above typical values then refer to troubleshooting
Please utilise extreme caution when performing section for further information.
work within the starter cabinet with power on or off.
Refer to SGN Intellisys section and set as required
• Ensure all protective covers are in place and all the following parameters:-
access doors are closed and locked then apply
power to the unit.
Unit language
Units of measure
• The SGN Intellisys will display “Checking Ma- Compressor Type
chine”. Service Level
Target Pressure
• The VSD will perform a self diagnostic check and Automatic Stop Pressure
if a healthy condition is present the VSD will en-
ergise relay K2 to allow control voltage to the Immediate Stop Pressure
SGN Intellisys. Blowdown Mode
(Plus enable options if relevant.)
• When the SGN Intellisys confirm package is
healthy and displays “Ready to Start” it will then
energise KM1 contactor to supply incoming • Enter the factory set-points and select “Service
mains voltage to the VSD. Menu” Access Code - 33.
• If the SGN Intellisys does not display “Ready to

Start” but shows an alarm condition then press
the reset button to clear the alarm. If the alarm
condition re-occurs then refer to the trouble-
shooting section within this manual.
• Measure and record transformer voltages.
• Measure and record incoming power supply.

Check readings against the “Input Voltage” dis-
played in the current status menu on the SGN
Intellisys.
• Check “DC Bus Voltage” display in the current

status menu on the SGN Intellisys is correct, typi-
cal values will be as follows: -

Running Checks
Running Checks • Verify correct operation of all protection devices.
• •Press start button and verify correct rotation of

• Take SPM and Vibration levels
blower motor.
Using display select arrows, check and record cur-

• The motor should rotate CLOCKWISE when
rent status of unit:-
viewed from the Non Drive End.
% Energy Savings
• If the rotation is not correct, disconnect mains % Load
power isolating the unit. Wait at least 15 minutes Interstage Package Discharge
before re-configure L1, L2, L3 connections. Temperature
Airend Discharge Temperature
Injected Coolant Temperature
! Note:- Inlet Filter
Main Motor direction of rotation is controlled by Total Hours
the variable speed drive and is configured to ensure Time & Date
correct direction of rotation occurs irrespective of the Speed
incoming supply cables. Motor Current
Input Voltage
DC Bus Voltage
• As a manual check, verify a positive sump pres- Program Name
sure is generated within 2 seconds of pressing
the start button.
• When all conditions are satisfied, start compres-

sor and run in “Idle Mode” for approximately 5 Stopping
minutes checking for oil leaks etc. • Press Stop Button. The compressor will first
de-energise the blowdown valve and then run for
• Stop the unit and change “Idle Mode” to “Off”. If a maximum of 10 seconds at minimum speed or
“Idle Mode” is not turned off by Ingersoll-Rand until the sump pressure falls to 35 psi before the
Service Representative, it will automatically set motor stops.
itself to “Off” after 10 minutes of operation and
the compressor will stop at that time. • Never use the Emergency Stop unless required.
(Apart from testing function)
• Measure and record voltage drop at start up L1,
L2, L3. • Complete commissioning start up documentation.
(Maximum allowable is -10% from nominal - e.g.
380 - 10% = 342).
• Complete Aircare Registration Card.
• Measure full load voltage drop.

• Ensure Operators Manual received by customer.
(Maximum allowable is -6% from nominal).
• Instruct customer in routine checks and opera-
• Allow unit to operate normally. tion.
• Observe for coolant leaks, air leaks, unusual

sounds etc..
• Check coolant level.
• Measure and record fan motor current.
• Measure and record main motor current.
• Verify condensate drain is purging.

Service &
Maintenance
Service Overview ......................................................................................1-2
3P Service Philosophy ................................................................................. 3
Preventive Maintenance .............................................................................. 3
Predictive Maintenance................................................................................ 3
Proactive Maintenance ................................................................................ 4
Maintenance Schedule ................................................................................ 5
Routine Maintenance ..............................................................................6-12
CD Module Rebuild...............................................................................13-18
Short Test................................................................................................... 19

Nirvana Oil Free Service & Maintenance
Service Overview

• 3P Service Philosophy
• The difference between preventive and
predictive maintenance
• Nirvana Oil Free Maintenance Schedule
• Nirvana Oil Free Routine Maintenance
techniques
Nirvana Oil Free Service Maintenance

Procedures
! Danger
! Caution
This compressor contains a variable frequency
Before beginning any work on the compressor,
read and understand the safety instructions in this drive. When it is switched off and the motor is
manual. stopped, the internal capacitors store a potentially
Open, lock and tag the main electrical disconnect lethal high voltage electric charge which gradually
and close the isolation valve on the compressor falls to zero over time. After switching off the
discharge. machine at its local isolator WAIT AT LEAST 15
Do not under any circumstances open any drain MINUTES for the capacitors to fully discharge
valve or remove components from the compressor before opening the power drive module doors.
until this has been carried out. Note that pipework
downstream of the check valve may still contain
pressure that must also be vented to atmosphere
before beginning any work
! Warning
Use suitable equipment for lifting heavy items
and ensure loose components are adequately
! Caution
supported to eliminate risk of dropping.
When using any form of liquid for cleaning,
ensure that all electrical components are protected
or covered to prevent ingress of liquid.
! ! Warning
Warning
This compressor contains a variable frequency The motor rotor contains a powerful magnetic
drive. When it is switched off and the motor is field. This field can effect the operation of digital
stopped, the internal capacitors store a potentially devices such as watches, mobile phones etc.
lethal high voltage. DO NOT REMOVE THE DRIVE Assembly or handling of the rotor should not be
COVER or attempt any work on the drive unless attempted by personnel with cardiac pacemakers,
trained. There are no user serviceable items behind defibrillators or other implanted electronic medical
the cover device.

Service Overview
Compressed air can be dangerous if incorrectly Upon completion of maintenance tasks and prior
handled. Before doing any work on the unit, ensure to returning the machine into service, ensure that:–
that all pressure is vented from the system and that • the machine is suitably tested.
the machine cannot be started accidentally. • all guards and safety protection devices are
refitted.
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance • all panels are replaced, canopy and doors
Manuals. closed.
• hazardous materials are effectively contained
Prior to attempting any maintenance work, ensure and disposed of.
that:–
• all air pressure is fully discharged and isolated
from the system. If the automatic blowdown valve
is used for this purpose, then allow enough time
for it to complete the operation.
• the machine cannot be started accidentally or
otherwise, by posting warning signs and/or fitting
appropriate anti–start devices.
• all residual electrical power sources (mains and
battery) are isolated.
Prior to opening or removing panels or covers to

work inside a machine, ensure that:–
• anyone entering the machine is aware of the
reduced level of protection and the additional
hazards, including hot surfaces and intermittently
moving parts.
• the machine cannot be started accidentally or
Prior to attempting any maintenance work on a

running machine, ensure that:–
• the work carried out is limited to only those tasks
which require the machine to run.
• the work carried out with safety protection
devices disabled or removed is limited to only
those tasks which require the machine to be
running with safety protection devices disabled or
removed.
• all hazards present are known (e.g. pressurized
components, electrically live components,
removed panels, covers and guards, extreme
temperatures, inflow and outflow of air,
intermittently moving parts, safety valve
discharge etc.)
• appropriate personal protective equipment is
worn.
• loose clothing, jewellery, long hair etc. is made
safe.
• warning signs indicating that Maintenance Work
is in Progress are posted in a position that can
be clearly seen.

Service Overview
3P Service Philosophy Predictive maintenance minimises the possibility of
The objectives of the '3P' service philosophy are to breakdown and loss of production. It provides feed-
maximise plant productivity by using comprehen- back to Preventive Maintenance and gives a quick
sive maintenance techniques and to ensure cus- indication of the condition of the equipment.
tomer satisfaction with Ingersoll Rand products and
services. The way to achieve this objective is to use The collected data is stored in a database and is
the '3P' philosophy of: used for trending to understand where and when
breakdowns can occur. You will also have time to
• Preventive Maintenance order parts needed for the next maintenance visit.
• Predictive Maintenance
• Proactive Maintenance Predictive maintenance tells us about the customer's
operating environment. It improves the image of our
Preventive Maintenance products and services and it reduces Warranty
Claims.
(Time based)
You do this by scheduling regular mainte- What tools are required?
nance programs (as per instruction books Predictive maintenance uses a number of different
and service manuals) such as: tools to analyse the condition of equipment.
• Coolant/Lubricant level checks or re-
placement
• Filter element replacement Bearing Monitoring and Vi-
• Sensor calibration bration Analysis for finite ele-
• Hose inspection ment bearings, use the IR 30
• Clearance checking tools, such as the IR 30 Logger
• Coupling alignment checking
• Contactor inspections, etc.
• Greasing, etc.
CCN 39263009
Please remember that preventive maintenance does
Water and Condensate Analysis
not eliminate machine failure, but it might help you to
uses the
detect the possibility of a failure. You should also be
Water/Condensate
aware of the possibility of over- and under-
Test Kit
maintenance.
What tools are required?

Preventive maintenance can be carried out using
conventional tools.
CCN 91001057
Predictive Maintenance
Fluid Analysis
(Condition based) uses the Fluid Pump
and the
You test the condition of equipment to Fluid Test Kit
discover how healthy it is. The types of
testing done, are:
CCN 91000000 (Pump)
CCN 91002550 (Kit)
• Vibration analysis
• Coolant/Lubricant analysis
• Water analysis
• Condensate analysis
• Air quality audit Air Quality Audits use the
• Power supply audits Air Quality Analysis Kit
• Ultrasonics
• IR Thermography
CCN 68144765

Service Overview
Proactive Maintenance
(Fix the root cause)
Being proactive means that you identify
problems and fix them before they cause
equipment failure. To do this, you review
the data collected by Preventive and
Predictive Maintenance and take the
appropriate action.
This approach will improve your relationship with

customers and vendors, it will enhance IR's image
through superior service and provide opportunities
for additional service revenue.
What tools are required?

You can use the Condmaster
Pro software, in conjunction
with the IR 30 Logger, to
create a sophisticated
database
You can create a customer database, which will

give you information about the location, site
conditions and operating conditions of the unit.
IR's Warranty database allows us to review

problems and to implement changes. This will
improve the product and reduce warranty claims.
IR Asia Pacific Service Management regularly

review the Fluid database and feed information
back to the field.

Maintenance Schedule
Maintenance chart ! Note

The Maintenance chart indicates the various Any Local or National codes that require specific
components and the intervals when maintenance maintenance that exceeds the requirements of this
has to take place. section must be adhered to.
Where a service interval is stated in both hours and

months, it is the sooner of the two intervals that must If the compressor is run less than 4,000 hours per
be adhered to. year,
* Maintain every 6 months
** Maintain every year
*** Maintain every 2 years

Routine Maintenance
Routine Maintenance Dispose of waste oil according to local regulations.

This section refers to the various components which When the gearcase is empty, close the valve and
require periodic maintenance and replacement. For replace the pipe plug. Position the empty drain pan
all other maintenance, contact your local Ingersoll– under the oil filter. Remove the filter and allow the
Rand office, Distributor or Air Centre. Refer to safety oil to drain from the oil cooler as well. Wipe the
information and maintenance procedures prior to sealing surface of the filter adaptor with a clean,
carrying out any of the maintenance in the following lint–free cloth. Remove the replacement filter from
sections. its protective package. Apply a small amount of
clean oil on the rubber seal and install the element.
Screw the element on until the seal makes contact
Prior to starting
with the seat on the adaptor head. Tighten the filter
a further 1/2 to 3/4 of a turn.
Oil level checking procedure.
The oil level should be checked daily. level sight
Unscrew the oil fill plug and add oil until the level
glass is located on the oil sump while the machine is
reaches the top of the gearcase sight glass.
running on load, oil should always be visible in the
Replace the oil fill plug and tighten.
sight glass. The normal position is 3/4 to full
Start the compressor and check the oil filter and oil
Adding oil
drain valve for leaks. Select ”BEARING OIL
Run the compressor for a minimum of 40 seconds,
PRESS” from the current status screen to insure
the oil level should be 3/4 to full as seen in the sight
that adequate oil pressure has been attained.
glass. If not, stop the compressor and slowly
Inspect the gearcase sight glass, the correct oil level
unscrew the oil fill plug. Add Ultra–Coolant and
for the sump during operation is 3/4 to 4/4 full.
recheck the oil level.
Some amount of foaming in the sight glass is
normal. The oil level is interpreted as the level in the
Repeat until the oil level is visible in the sight glass
sight glass below the top foam, where a line of
with the compressor running
separation can be seen. If additional oil is required,
! stop the compressor and add oil as needed.
Warning Tools required

Under no circumstance should the compressor be • Wide–blade screwdriver or M10 wrench or M10
operated with the oil fill plug removed socket with ratchet
• 400mm adjustable wrench
Oil and Filter
Change oil filter after every 8,000 hours or less as • 600mm adjustable wrench
required (see checking procedure below). To check • Oil filter wrench
the condition of the oil filter, the compressor must be
running and the oil temperature must be greater than Parts required
49ºC (120ºF). With these conditions met select “OIL • Oil filter element
FILTER PRESS DROP” from current status screen.
• Approximately 64 litre (17 U.S. gal) of Ultra
If “OIL FILTER PRESS DROP” is less than 0,9 barg
Coolant
(13 psig) then the oil and filter do not need service. If
the warning light is on and “CHANGE OIL FILTER”
warning is displayed, then the oil should be drained Pressure System
and the filter replaced. At 2000 hour intervals, inspect the external surfaces
of the airends and piping, including all fittings, for
To change the oil and filter, the oil should be warm visible signs of impact damage, excessive corrosion
for more effective drainage. Remove the two and abrasions. Any suspect parts should be
enclosure panels at the rear of the machine. remove replaced before the compressor is put back into
the pipe plug from the oil drain connection in the rear service.
of the baseplate. Place a suitable drain pan under
the drain connection and open the valve. Gearcase breather
To service the gearcase breather, remove the
appropriate panel. Remove the breather cover by
unscrewing the four retaining screws. Remove all of
the breather media and clean with a suitable
solvent. Allow the media to dry. Re–install the
media, the cover, and the enclosure panel.

Routine Maintenance
Condensate drain functionality non–service period. The user must establish the
To verify the functionality of the condensate drains, frequency of such tests as it is influenced by such
simply observe the timed operation of each. Each factors as the severity of the operating environment.
drain should open at least every 3 minutes while
the compressor is loaded. (The intercooler drain
exhausts at a much lower pressure than the
aftercooler). Oil free condensate can be disposed
! Caution
High pressure air will discharge through the
of via a sewer drain. discharge ports of the valve during pressure relief
valve check. Wear ample clothing, gloves, safety
Condensate strainers glasses and ear protection during valve testing.
In order to service the condensate strainers (both
interstage and discharge), the strainer service
valves preceding the strainers should be closed. Run the compressor for about 10 minutes by
Remove the screens from the strainers, while venting air from the system to let the unit warm up.
noting the direction. Clean any debris from the With the unit running, test at or near the maximum
screens and reinstall. Open the strainer service operating pressure by opening the valve for the
valves. minimum period required to flush the valve seat free
of debris. This can be accomplished by holding the
Blower motor Re–Grease test lever fully open or unscrewing the spring
(N75–160 Aircooled units) pressure retaining cap, depending on the type of
6 Months or 4000 Hrs. valve installed. If there is no evidence of discharge
or the valve does not fully close, discontinue use of
Apply high melting point grease into the blower equipment and contact a licensed contractor or
motor bearings using a grease gun at the nipple qualified service personnel.
provided.
The pressure relief valve should also be tested and
Stop when excess grease is seen at the relief port. re–calibrated in accordance with any national or
local codes that may exist. If no code exists, IR
Oil hoses recommend that the pressure relief valve is
• The flexible hoses that carry oil through the recalibrated at intervals of one year.
cooling system may become brittle with age and
will require replacement. Have your local
Ingersoll–Rand Distributor or Air Centre inspect
them every 3 months and replace them as
needed or every 2 years.
• Depending on the location of the hose, it may
contain compressor oil. It is recommended to
drain the oil into a clean container. Cover the
container to prevent contamination. If the oil is
contaminated, a new charge of oil must be
used.
• Remove the hose.
• Install the new hose and refill the unit with oil.
Start the compressor, check for leaks and check
coolant level. Refill as necessary.
• Replace the oil fill plug and tighten
Pressure relief valve check

The pressure relief valve must be frequently tested
and regularly maintained. Remove from the
machine and check for the correct operating
pressure. Correct, replace as necessary. If
operating conditions are particularly severe, the
frequency of testing and maintenance must be
increased accordingly. A pressure relief valve
check must also be performed at the end of any

Routine Maintenance
Air filter change procedure • Cover main drive motor, PDM Heat sink blower
motor, drain valve, air filter, and cooling motor
• Unclip the retaining cap and withdraw the old variable speed drive with plastic sheeting to
• element. prevent damage from entrance of cleaning
• Fit the new element and refit the retaining cap. solution.
• Cover inlet of blower wheel with plastic sheeting
Aircooled Cooler Cleaning to prevent entrance of cleaning fluid.
Ensure that the compressor is isolated from the • Cover the inlet grill of the intake panel with
compressed air system and is vented of all pressure. plastic sheeting to prevent cleaning solution from
When undertaking any work on the compressor exiting the compressor.
always use certified lifting equipment and employ
• Remove enclosure intake batts
sound working principles.
• Use an extended length nozzle and a mild
Ensure that the main power disconnect switch is cleaning solution to clean the coolers.
locked off and tagged.
Visually check the outside of the cooler cores to be ! Warning

certain that a complete cleaning of the cooler is Strong cleaners can harm aluminium cooler
required. Frequently, dirt, dust or other foreign parts. Follow cleaner manufacturers instructions for
material may only need to be removed with a use. Wear appropriate safety equipment.
vacuum to remedy the problem.
When the cooler is covered with a combination of oil, • Cleaning fluid will collect on both sides of the
grease or other heavy substances that may affect the cooler core. If required, periodically drain fluid
unit’s cooling, then it is recommended that the cooler from intake plenum and bucket to prevent them
cores be thoroughly cleaned on the outside. from over flowing.
• After cleaning is complete, dry off plenum, intake,
If it is determined that the compressor operating
and cooler core. Reassemble parts in reverse
temperature is higher than normal due to the external
order.
passages between the fins of the cooler cores being
restricted with deposits of foreign material, then the
cooler should be removed for cleaning. Watercooled Cooler Cleaning.
A periodic inspection and maintenance program
should be implemented for watercooled heat
exchangers.
! Warning
Strong cleaners can harm aluminium cooler The following steps should be taken:
parts. Follow cleaner manufacturers instructions for
• Inspect filters in system and replace or clean as
use. Wear appropriate safety equipment.
required.
• Carefully examine cooler shells for scale and
The coolers in these machines can either be cleaned clean if necessary. If a cleaning solution is used,
by removing the complete cooler for off site cleaning be sure to wash out all chemicals thoroughly with
or ’back flushing’ in place using a high pressure hose clean water before returning the compressor to
and gaining access through the holes in the service. After cleaning, examine the cooler for
intermediate plenum. erosion or corrosion.
• A qualified cleaning service should be used for
Instructions for cleaning the coolers the cleaning process. These organizations can
while installed in the compressor. evaluate the type of deposit to be removed and
While cleaning coolers, great care must be taken to supply the appropriate solution and method for a
protect the rest of the machine from moisture and complete cleaning job.
contamination by covering sensitive parts with plastic • When reinstalling bonnets to cooler shell, tighten
sheeting. bolts uniformly in a cross–pattern. Overtightening
• Remove plenum sheet metal to gain access to the
can result in cracking of the bonnet.
coolers from the blower side. • Cleaning solutions must be compatible with the
• Remove the 16 screws securing the access
metallurgy of the cooler
panels on the cooling plenum and remove covers. • Care must be taken to avoid damaging tubes if
mechanical cleaning procedures are used.

Routine Maintenance
Airend bearings Moisture Separator Check/Cleaning
Airend bearings are lubricated by the compressor
• Ensure compressor is electrically isolated for at
oil and require no maintenance.
least 15 minutes, before commencing any
! Caution
maintenance work.
• Isolate the compressor from the system and fully
Under no circumstances should alarm
discharge the compressed air within the unit.
temperatures be exceeded. If the machine fails to
trip A FAULT EXISTS. Investigate immediately. • Remove plastic tube from the fitting located on
the bottom of the moisture separator.
• Remove the bowl of the moisture trap, clean and
Blower Motor Bearing Maintenance replace.
(Stored units)
• Prior to placing a unit in storage for extended
Condensate (Moisture) Drain Valve /
intervals, rotate the blower motor several Trap
revolutions by hand in the direction of rotation. • Ensure compressor is electrically isolated for 15
• On N75 – 160 aircooled units, whilst rotating the minutes and all pressure is relieved from system.
motor, pump grease into the bearing until • Remove all pipes going to and from the valve (or
grease is seen at the relief port. trap).
• Thereafter rotate the motor as described above • Disconnect any electrical cables to the valve (or
every three months until such time as the unit is trap).
placed in service. • Determine the type of condensate drain device
• If the storage time is to exceed a total of nine (9) and continue in the appropriate section below:–
months duration, the compressor must be
ordered for long term storage. Timed Solenoid Drain Valves Check /
Cleaning
Motor Cowl cleaning
• Remove the central nut and then the electrical
• Ensure compressor is electrically isolated for at coil.
least 15 minutes before commencing any
• Remove screws holding bonnet of valve and
maintenance work.
carefully split the valve. Clean and inspect all
• Remove panels from the compressor. internal parts.
• Using a clean dry cloth, remove dust from the • Similarly check and clean the ball valve and
surface of the motor cowl and ensure all needle valve.
ventilation slots are free of obstructions.
• Replace any defective parts as identified in parts
• Replace panels to the compressor. manual.
• Re–assemble and later, with machine running,
Drive Box Filter Removal/Replacement check that condensate and air is expelled at
• Ensure compressor is electrically isolated for at frequency and duration set into the INTELLISYS
least 15 minutes before commencing any controller
maintenance work.
• Unclip the front grill of the drive box filter.
• Remove the filter pad from the housing and
replace with a new filter pad from Ingersoll–
Rand.
• Replace front grill to the drive box filter.

Routine Maintenance
Fluid and Vibration Monitoring

Ingersoll–Rand recommends incorporating
predictive maintenance, specifically the use of oil
and vibration analysis, into all Preventative
Maintenance programs.
Predictive Maintenance is designed to increase

system reliability and prevent costly downtime.
Through the use of sophisticated diagnostic tools,
including fluid, vibration, and optional air analysis, IR
Certified Service Technicians can identify and
correct potential problems BEFORE they can cause
expensive unscheduled downtime.
How does predictive analysis work? By establishing

an initial baseline for normal operation, and then
regularly monitoring fluid and vibration conditions,
any sudden deviation or significant increase from
this baseline can be identified and investigated to
pinpoint the cause. More quickly diagnosing
potential problems can directly save money by
preventing costly failures and reducing or eliminating
downtime. In addition, regular condition monitoring
also helps to maximize the time between expensive
preventative maintenance intervals, such as
component rebuilds and oil changes.

Routine Maintenance
Oil Filter Condensate Drains

Change the oil filter after 150 hours operation and The condensate drains should be checked for
8000 hours thereafter. proper operation on a daily basis.
Air Filter
Replace every 4000 hours / 6 months operation or The condensate drain Y-strainer should be cleaned
as site conditions require. Never change filter while after the first 150 hours operation, inspected once a
unit is running. year, every 4000 hours, or any time that air does not
purge from drain valves when the valve is open.
1)Close the solenoid isolation valve.

2)Crack open the manual valve.
3)Remove the screen from the strainer while noting
the direction.
4)Clean the strainer and reinstall.
5)Close manual bypass valve and open the solenoid
isolation valve.
6)Verify proper operation
Gearcase Breather
Clean gearcase breather every 4000 hours or 6

months operation, whichever occurs first.

Routine Maintenance
Thermal Valve
The thermal valve does not require maintenance
under normal operating conditions. Should the valve
malfunction, follow the procedure listed below.
1) Remove the hose from the oil cooler. (A drain pan
will be required to collect oil)
2) Remove the four bolts holding the valve together
3) Remove the cover and element
4) Replace all o-rings
5) Install new element
6) Install cover and tighten four bolts
7) Reconnect hose from oil cooler
8) Add oil as required to bring level to top of sight
glass
9) Operate compressor until oil temperature is 54-
60°C - note oil level
10) If oil level is less than 3/4 - 7/8 full during
operation, stop compressor and add oil
Oil Pump
There are no serviceable parts within the oil pump
therefore if problems are encountered the pump
must be replaced.

CD Module Rebuild
Recommended Torque Values

Useful CPN’s
Loctite 242 93454452

Loctite 510 93454460
Loctie 7070 93454502
Loctite Chisel
93454536
Loctite 620 Use local
Loctite 542 stockist

CD Module Rebuild—Special Tooling
Gear Removal Tool (CD14 & CD26)
There are two oil injectors available for gear re-

moval one with a 3/8” connector, the other 3/4”.
Oil injector FAG 107640 contains 8cm of oil, and will

give a pressure up to 2500Bar.This injector will
need FAG 107642 which is a connector to the
thread of the airend.
Oil injector FAG 107641 contains 27cm of oil and

will give a pressure up to 1600Bar. This injector will
need FAG 107643 which is a connector to the
thread of the airend.
Drawing 5
Oil Injector
Connector
Connector for gear removal tool CD8
Notes:
1. Material: AISI 4130
2. Unless Otherwise specified
Finish All over N11.
Drawing 6

Gear removal tool CD8 Gear removal tool CD8
Drawing 7
Drawing 8

Gear removal tool CD8 Gear removal tool CD8
Drawing 9 Drawing 10

Locking nut removal socket Locking nut removal socket

Second Stage CD8 First Stage CD 8.
Drawing 11
Drawing 12

Rotor Locking Tool

Short Test
Short Test
1 How often should the gearcase breather be cleaned?
2 How often does an oil filter need to be changed?
3 What is the difference between preventative and predictive maintenance?

Installation instruction for oil pump repair CD14DVSD
CD14DVSD; retrofit of oil pump gear and key

Instruction for application at customer/service shop; Release 13-sep-05
1. Topic
This instruction deals with the failures on CD14DVSD that have occured in the
field, where the oil-pressure of the module went to zero because of a weared key,
which then did not any more drive the oil pump.
It shall enable qualified service personel to repair and eliminate this failure at the
customer or in service shops close to the customer.
2. Preparation
2.a) Parts needed (one of each):
Item CCN Part No. GHH Description Comment

1 Key, hardened
2 Inner gear oil pump with Ø2.5 mm hole
3 22212799 83903645 Grooved ball bearing
4 29517000 22212757 Cylindrical roller bearing For back up only
5 95022299 83903865 O-ring For back up only
6 22558100 83903862 Wear sleeve For back up only
7 22548549 C22548549 Single lip seal For back up only
2.b) Special tools needed:
Item Quantity Description Comment

Tool 1 1 Bar, backside Drawing see chapter 4
Tool 2 1 Bar, frontside Drawing see chapter 4
Tool 3 2 Bars, gearcover Drawing see chapter 4
Tool 4 1 Lifting adapter Drawing see chapter 4
Tool 5 1 Eye bolt; M16
2.c) Drawings needed
Item CCN (Rev) Description

1 22214555 (D) Gearing (assembly)
2 22543953 (D) Screw block (assembly)
3 22542906 (D) Screw block with motor (assembly)
4 22505093 (D) Adhesive/sealing agent application
5 22504872 (G) Tightening torques Screw Blocks/Gearings
2.d) Preparation of module:
• HPM motor to be removed.

• This instruction shows the repair with both airends removed. The procedure
might also work with airends still assembled. Suggestion: Try with assembled
airends. If reassembly (chapter 3.f) is too difficult, one or both airends can
still be removed at that point.
Page 1 (11)
3. Repair of gear box

In addition to this instruction please take care of the drawings named in above
(chapter 2.c) ).
3.a) Remove sub-assembly gear cover
Lifting adapter (Tool 4)

Picture 1 and eye bolt (Tool 5)
assembled to oil-outlet on
gear cover.
Pipe plug (M16) removed.
Backside bar (Tool 1)

screwed into shaft.
Picture 2 Frontside bar (Tool 2)

screwed into shaft.
Gear cover bars (Tools 3)

screwed through gear
cover into gear housing.
Through holes and threads
used, where normally
motor bolts are screwed
in.
Two may be enough, other
than shown in this picture.
Remove gear cover bolts.
Page 2 (11)
Picture 3 Pull away gear cover

assembly.
Be careful with inner ring

of cylindrical roller bearing
(avoid any damage).
Picture 4
Page 3 (11)
3.b) Remove gear cover
Picture 5
Gear cover assembly on

workbench.
Picture 6
Loosen 3 hexagon head
screws.
Picture 7
Lift off gear cover.

Bearing seat could be
tight: Therefore apply
Picture 8 carefully force on shaft, to
slip gearcover off bearing
seat.
Picture 9
Keep spacer
ring!
Page 4 (11)
3.c) Disassemble oil pump
Picture 10
Remove wear sleeve and
o-ring below wear sleeve.
Remove bearing:
Carefully apply heat, to get
it off. If not possible, then
cut bearing for removal
(Use of new bearing
recommended anyway).
Not shown:
Remove retaining ring and
supporting ring.
Oil pump can be slipped

off shaft.
3.d) Oil pump retrofit
Picture 11
Disassemble oil pump (2 bolts).
Page 5 (11)
Picture 12 Replace inner gear of oil pump Picture 13

with new part (with Ø2.5 mm
hole in (one) slot).
Side with chamfer facing

to the bottom.
Slot with hole in same

position as slot in pump
housing.
Picture 14
Picture 15 Reassemble oil pump.
Torque:58 Nm
No Loctite required.
Align both housing parts

„manually“.
Page 6 (11)
3.e) Reassemble oil pump + gear cover
Picture 16
Replace old key with the

new (hardened) one.
1. Oil pump on shaft.
Picture 18
2. Insert (3) bolts.
3. Oil pump down to

Picture 17 shoulder of shaft.
Picture 20
Retaining ring and
supporting ring on
shaft.
Ball bearing on shaft

(bearing needs to
be heated ~100°C).
Picture 19
Page 7 (11)
O-ring Picture 22
Picture 21
Supporting ring
Loctite
Gear cover on shaft.
Picture 23
Gear cover „over“ oil

Picture 24 pump. Picture 25
Carefully provide
correct seat of ball
bearing in gear
cover.
Turn gear cover, until Picture 26

bolts get aligned with
threads in gear cover.
Tighten bolts.
Picture 27 Wear sleeve on shaft.

Make sure, that it is
down till it faces
supporting ring.
Picture 28
Spacer ring
Page 8 (11)
3.f) Reassemby of gearbox

Take gear cover assembly.
Put o-ring in gear cover.
Picture 29 (Grease may help to hold it
better.)
Picture 30
Apply grease on all rollers of

bearing in gear housing, to be
sure, that they stay in position
(with contact to the outer race of
the bearing).
Picture 31
Put bars on gear cover

assembly.
Picture 32 With the aid of those bars
slip carefully gear cover
assembly into gearbox.
Attention: Be sure not to

hit rollers of the cylindrical
roller bearing.
Picture 33 - Gear cover assembly

pushed close to
gearing
- Remove bars
- Reassemble with
bolts
- Screw in pipe plug
M16 (not shown here,
see picture 1)
Gear box is ready!
Page 9 (11)
4. Tools
Tool 1; bar backside
Tool 2; bar frontside
Page 10 (11)
Tool 3; bar gearcover
Tool 4; lifting adapter
M. Besseling 13-september 2005
Page 11 (11)
Lesson Outlay Motor Removal
Secure the drivetrain onto a suitable work

bench and chock the drive train with dunnage
so that it remains level on the bench.
Prepare the motor by removing the hall effect
sensors, cooling ducts, motor rear plate and
cabling conduit.
Using kit cpn 42543967 position the rotor

locking tool as shown in the picture.
Remember to lock the arm off to hold the
rotor securely.
The 34mm socket 6” extension and

torque wrench need to be supplied by the
engineer on site.
A 14mm Hex head socket/spanner can

be used to remove the four stator
retaining bolts.
The socket is to be supplied by the

engineer on site.
With the rotor retaining bolt and stator

retaining bolt removed ensure that the
motor is supported adequately for the
weigh when the motor is removed.
Use Oxy-Acetylene to slowly apply heat

around recess within the rotor and chase
the heat down the bolt hole.
Safety glasses and gauntlets will be
required as hot loctite will emit from the
bolt hole.
Heating times will vary depending on the
motor size being removed.
Approximate times are as follows: -
N37-45 10 mins
N55-75 25 mins
N90-160 35 mins
Once the heating time is completed the

old rotor retaining bolt should be screwed
back into position without the washers and
standing 5-10 mm proud of the rotor.
Place the two 10 mm threaded rods in

position with the blanking cap secured against
the rotor retaining bolt. Tighten using a 24
mm OJ spanner.
If the rotor does not become free by

tightening alone a hammer may be used to
shock the stator off the airend shaft.
If this does not work the assembly will have to
be taken apart heat applied again. Then re-
assembled and tried again.
Once the rotor is free remove the assembly
and unscrew the rotor retaining bolt.
A lever may be needed to pry off the motor
assembly which has been left supported
since the start of the task.
Allow the airend to cool to ambient

temperature.
Using a DTI placed on the airend measure
the run out of the taper of the male rotor
shaft and the shaft lift.
If either or both measurements are greater
than: - 0.003” or 0.0762 mm the airend is
not fit for reuse and corrective action
needs to be taken.
By using the old rotor retaining bolt the

airend shaft can be turned freely and also
used as a lever to measure the shaft lift.
Motor Installation
Ensure that the scavenge pipes and

mating “O” ring between the motor and
airend are in position and secured with
a smear of grease.
The male rotor shaft should be clean
and free of grease and burrs.
Use a new rotor retaining bolt, flat and

bevelled washers in place of the older
stretched one.
Ensure that the bevelled washers go on
first followed by the flat washers then the
spacer.
The number of washers is dependant upon
the size of motor being worked upon and
will vary.
Dress the motor onto the airend and

push into place as far as it will go.
Using the rotor locking tool the rotor
should be torqued down twice. First in a
dry run with no Loctite then the second
time using Loctite 270.
Torque settings are as follows: -
N37-45Kw CC 200lbs/ft 271N/m

N55-75kW CC 300lbs/ft 407N/m
N90-160kW CC 500lbs/ft 679N/m
N75-169kW 2s CC 500lbs/ft 679N/m
CD4 Module 200lbs/ft 271N/m

The four stator retaining screws can now
be screwed lightly into position.
The air gap between rotor and stator can
now be set using a set of non ferrous
feeler gauges.
The gap required is 0.75 mm or 0.030”
Ref: FSB V6 N3
By tightening the four screws into

position the air gap can be set as each
turn of the screws will over come the
magnetic force of the rotor.
If the air gap is not set correctly first time
the process needs to be repeated until
correctly set.
Once set the rotor needs to turned and
the air gap checked in the 12-3-6 and 9
O’clock positions.
Once the airgap is set correctly torque all
four screws to 160lbd/ft 217N-m
The drive train can now be reassembled

and installed into the compressor.
Stator Removal
The stator removal kit can be set up as the

pictures opposite show.
The stator can be jacked off the rotor but care

should be taken when doing this to screw
each side back evenly to protect the
laminations on the rotor.
Two threaded bars are provided in the kit to

draw off the rotor uniformly.
Depending on the size of the stator being

removed it may have to be jacked back three
quarters of the length of the rotor or possibly
more to overcome the magnetic field of the
rotor.
Nirvana Integration
Nirvana Integration ............................................................... 1

Pre-Engineered Systems ..................................................... 2
Nirvana Control Setpoints .................................................3-4
Power Off Pre-start Checks...............................................5-6

Nirvana Oil Free Integration
Introduction
Nirvana Integration
In this section we lay out six different pre-

engineered systems that are designed to minimise
energy consumption. To create these systems we
used the used the following design parameters:
• The minimum acceptable pressure is 100 PSIG

• All Compressors are the same size
• The Nirvana is always the trim unit
In each of the systems we detail the set points, the

system objective and the step by step operation of
the system.

Pre-Engineered Systems
Pre-Engineered Systems Nirvana Operation
System 1 Stand Alone Nirvana Immediate Stop

System 2 One Nirvana, One Fixed Speed Unit
System 3 One Nirvana, Two Fixed Speed Units
Motor Stops
System 4 Two Nirvanas
System 5 Two Nirvanas, Two Fixed Speed Units
Auto Stop
System 6 One Nirvana, Two Fixed Speed Units
on ISC VFD Slows Motor RPM
System 1—Stand Alone Nirvana Target Pressure

Setpoints: VFD Increases Motor RPM
Nirvana:
Target Pressure 100 PSIG Time
Auto Stop 110 PSIG
Immediate Stop 120 PSIG
Operation: This control strategy targets a single

Nirvana Operation
Nirvana unit to maintain 100 PSIG.
Nirvana is manually started with zero pressure in the

air system. Nirvana ramps up in speed. At 100
Immediate Stop
PSIG Nirvana slows to maintain 100 PSIG. In the
event that pressure continues to rise to 110 PSIG
and the Nirvana is operating at minimum speed the Motor Stops
unit will stop. Once system pressure drops to 100
PSIG, Nirvana will automatically restart and ramp up Auto Stop
speed seeking to match system demand. Motor Starts
Target Pressure
Nirvana Control Set Points Motor

Speed
Minimum Speed
Time
Immediate Stop
Nirvana Operation
Auto Stop
Motor
(Minimum 1 PSI Bandwidth)
Immediate Stop
Target Pressure
Minimum Plant Air Pressure
Auto Stop
Time
Motor Starts
Target Pressure
Motor
Speed
Minimum Speed
Time

Control Setpoints
Nirvana Control Setpoints Nirvana is manually started with zero pressure in the
Target Pressure air system. Nirvana ramps up in speed. In the
Nirvana will alter motor speed to maintain this event that the Nirvana unit is capable of handling
pressure system demand, the Nirvana unit will slow down to
match system demand at 102 PSIG.
Auto Stop
If motor is operating at minimum speed, Nirvana will If system demand exceeds Nirvana’s capacity, sys-
stop tem pressure will fall. Below 102 PSIG, the Nirvana
unit will ramp up to full speed. If system pressure
Immediate Stop continues to drop to 100 PSIG, the Fixed Speed Unit
Regardless of motor speed, Nirvana will stop to will be started and will come on-line. With both com-
prevent over pressurization of customer’s system pressors on-line at full capacity, system pressure will
likely rise. As system pressure rises to 102 PSIG,
the Nirvana unit will slow to match system demand.
System 2—One Nirvana Unit, One Fixed Speed In the event that pressure continues to rise to 108
Unit PSIG, and the Nirvana unit is at minimum speed, the
Nirvana unit will shut off. At this moment, the fixed
Setpoints: speed unit is fully loaded and operating alone.
Nirvana:
Target Pressure .....102 PSIG When system demand decreases below the capac-
Auto Stop ................108 PSIG ity of the Fixed Speed Machine, system pressure will
Immediate Stop.......120 PSIG rise. At 110 PSIG, the fixed speed unit will unload.
Fixed Speed Unit: With both Nirvana off and the Fixed Speed unit
On-Line ..................100 PSIG unloaded, system pressure will quickly drop. Once
Off-Line ...................110 PSIG pressure drops to 102 PSIG, the Nirvana unit will
Operating Mode ......On Line/Off Line automatically start. The Nirvana unit will vary its
Options....................Auto Start/Stop Enabled speed as required to maintain 102 PSIG. If the Nir-
vana’s capacity is able to meet system demand, the
Operation: Fixed Speed units will automatically shut off under
This control strategy integrates a Nirvana unit the parameters of automatic start/stop.
with a Fixed Speed Unit in a method that posi-
tions the Nirvana unit both as the base compres- System 3—One Nirvana Unit, Two Fixed Speed
sor while operating alone and as the trim ma- Units
chine when both compressors are required.
Setpoints:
Nirvana:
Target Pressure .....104 PSIG
One Nirvana, One Fixed Speed Unit Operation
Auto Stop ................108 PSIG
Immediate Stop.......124 PSIG
Nirvana Fixed Speed Unit 1:
On-Line ..................102 PSIG
Off-Line ...................112 PSIG
Operating Mode ......On Line/Off Line
Immediate Stop Options....................Automatic Restart Enabled
Fixed Speed Unit
Fixed Speed Unit 2:
Offline Pressure On-Line ..................100 PSIG
Auto Stop Off-Line ...................110 PSIG
Operating Mode ......On Line/Off Line
(10 PSI Minimum)
Options....................Automatic Restart Enabled
Target Pressure
Online Pressure
Time

Time
Control Setpoints
off. If system
One Nirvana, Two Fixed Speed Unit Operation pressure con-
tinues to rise to
110 PSIG,
Nirvana Fixed Speed #1 Fixed Speed #2 Fixed Speed
Unit 2 will
Immediate Stop
Offline Pressure
unload. With
Offline Pressure only one com-
pressor operat-
ing system
Auto Stop
pressure will
likely drop. As
Target Pressure system pres-
Online Pressure sure drops to
Online Pressure 104 PSIG, the
Nirvana unit
will start and
Time vary its speed
to match sys-
tem demand.
Operation: Unless the pressure drops to 100 PSIG, Fixed
This control strategy integrates a Nirvana unit Speed Unit 2 will automatically stop under the pa-
with two Fixed Speed Units in a method that po- rameters set in auto start/stop.
sitions the Nirvana unit both as the base com-
pressor while operating alone and as the trim Additionally, if system demand drops to the capacity
machine when multiple compressors are re- of the Nirvana unit, then Fixed Speed Unit 1 would
quired. unload and ultimately automatically stop.
Nirvana is manually started with zero pressure in the System 4—Two Nirvana Units, Setpoints:
air system. Nirvana ramps up in speed. In the event Nirvana 1:
that the Nirvana unit is capable of handling system Target Pressure .....105 PSIG
demand, the Nirvana unit will slow down to match Auto Stop ................110 PSIG
system demand at 104 PSIG. Immediate Stop.......125 PSIG
Nirvana 2:
In the event that system demand exceeds the Nir- Target Pressure .....100 PSIG
vana’s capacity, the system pressure will fall. Below Auto Stop ................104 PSIG
104 PSIG, the Nirvana unit will ramp up to full speed. Immediate Stop.......120 PSIG
If system pressure drops to 102 PSIG Fixed Speed
Unit 1 will automatically start. With both Nirvana and It is recommended that multiple Nirvana’s operate
Fixed Speed Unit 1 on-line at full capacity, system with Remote Pressure Sensor Option.
pressure will likely rise. As system pres-
sure reaches 104 PSIG, the Nirvana unit
will slow to match system demand. In Two Nirvanas
the event pressure rises to 108 PSIG
and Nirvana is at min speed, it will stop. Nirvana #1
Alternatively, if the Nirvana and Fixed
Immediate Immediate
Speed Unit 1 are unable to match sys-
tem demand pressure will fall. When Auto Stop
system pressure reaches 100 PSIG,
Fixed Speed Unit 2 will automatically
start.
Auto
With all three compressors on-line, sys- (Minimum 1 PSI
tem pressure will likely rise. As system Target
pressure reaches 104 PSIG, the Nirvana
unit will begin to slow. If system pres-
sure rises to 108 PSIG with Nirvana op-
erating at min speed, Nirvana will shut Time

Control Setpoints
Operation: One Nirvana, Two Fixed Speed Units on an ISC
This control strategy integrates two Nirvana units.
Under this control method the Nirvana 1 will act as Nirvana
the base load machine with Nirvana 2 trimming. In
the event that system demand only requires Nirvana Immediate Stop
ISC
1 it will trim as required.
Auto Stop
Nirvana 1 would start and adjust speed to match
system demand at 105 PSIG. In the event that sys-
tem demand exceeded Nirvana 1’s full speed output, Target ISC Bandwidth
pressure would drop. At 100 PSIG Nirvana 2 would
start. With Nirvana 1 at full speed, Nirvana 2 would
alter its speed to trim the system to maintain 100
PSIG. If system demand drops below the minimum ISC Target
capacity of Nirvana 2, then system pressure will rise. Pressure
Time
When system pressure reaches 104 PSIG, Nirvana
2 will stop.
If system demand falls below the full-speed output of Operation:

Nirvana 1 system pressure will rise. At 105 PSIG This control strategy integrates a two Nirvana
Nirvana 1 will alter its speed to match system de- units with two Fixed Speed Units in a method
mand. In the event that system demand is less than that adds or sheds compressors as required to
the minimum capacity of Nirvana 1, system pressure maintain system pressure
will rise. If the pressure reaches 110 PSIG with Nir-
vana 1 operating at minimum speed, Nirvana 1 will Nirvana 1 is started and alters its speed to match
stop. When pressure drops to 105 PSIG, Nirvana 1 system capacity. If Nirvana 1 is unable to meet sys-
will start and alter its speed to match system de- tem demand then system pressure will decrease.
mand. When system pressure reaches 104 PSIG, Nirvana
2 will start and alter its speed to match system de-
In the event that system demand exceeds the full- mand. In the event that both Nirvana 1 and Nirvana
speed capability of Nirvana 1, the pressure will fall. 2 are unable to meet system demand then pressure
When pressure reaches 100 PSIG Nirvana 2 will will decrease. When system pressure drops to 102
start and trim as discussed above. PSIG, Fixed Speed Unit 1 will automatically start-up
and load.
System 5—Two Nirvana Units, Two Fixed Speed
Units In the event that Nirvana 1, Nirvana 2 and Fixed
Speed Unit 1 are not able to match system capacity
Setpoints: system pressure will drop. At 100 PSIG, Fixed
Nirvana 1 Speed Unit 2 will automatically start-up and load.
Target Pressure ..... 110 PSIG With all four compressors on-line, system pressure
Auto Stop ................ 114 PSIG will likely rise. When system pressure reaches 104
Immediate Stop....... 130 PSIG PSIG, Nirvana 2 will alter its speed to match system
demand.
Nirvana 2:
Target Pressure ..... 104 PSIG If Nirvana 2 sees 108 PSIG at minimum speed it will
Auto Stop ................ 108 PSIG automatically stop. If pressure continues to rise to
Immediate Stop....... 124 PSIG 110 PSIG Nirvana 1 will begin to alter its speed. In
the event pressure continues to rise, Nirvana 1 will
Fixed Speed Unit 1: stop at 114 PSIG. At 116 PSIG, Fixed Speed Unit 2
On-Line ................... 102 PSIG will unload and energise the auto stop timer. Unless
Off-Line ................... 118 PSIG system pressure drops to 100 PSIG Fixed Speed
Operating Mode ...... On Line/Off Line Unit 2 will automatically shut off once the auto start/
Options ................... Auto-Restart Enabled stop parameter is met.
Fixed Speed Unit 2:
On-Line .................. 100 PSIG
Off-Line 116 PSIG Operating
ModeOn Line/Off Line
Options ................... Auto-Restart Enabled

Control Setpoints
With Fixed Speed Unit 1 acting as the base load
machine, it will remain loaded unless system pres-
sure reaches 118 PSIG. In the event that Fixed
Speed Unit 2 cannot maintain system pressure, Nir-
vana 1 will automatically start and begin trimming at
110 PSIG. Likewise, Nirvana 2 will automatically
start and begin trimming at 104 PSIG.
System 6—One Nirvana Unit, Two Fixed Speed

Units on ISC
Setpoints:
Nirvana:
Target Pressure ..... 100 PSIG
Auto Stop ................ 102 PSIG
Immediate Stop....... 103 PSIG
Fixed Speed Unit 1 and 2:
On-Line .................. Set Point Ignored by ISC
Off-Line ................... Set Point Ignored by ISC
Operating Mode ...... On Line/Off Line
Options.................... Automatic Restart Enabled
ISC
Target Pressure ............... 100 PSIG
Bandwidth ........................ 8 PSIG
Units Connected to ISC Fixed Speed Unit 1
and 2
Operation:
This control strategy utilises an ISC to control
the two fixed speed units. By adding an ISC the
dead band of the system is significantly re-
duced.
Nirvana is started and alters its speed to match sys-

tem capacity and maintain 100 PSIG. If Nirvana is
unable to meet system demand then system pres-
sure will decrease. When system pressure reaches
96 PSIG, Fixed Speed Unit 1 will automatically start
and load. In the event that system pressure contin-
ues to decrease Fixed Speed Unit 2 will also start.
As system pressure increases, Nirvana will stop at

102 PSIG if it is operating at minimum speed. If sys-
tem pressure reaches 104 PSIG, Fixed Speed Unit 2
will unload. Unless system pressure drops to 96
PSIG, Fixed Speed Unit 2 will automatically stop
under the parameters of auto start/stop. Addition-
ally, if the pressure reaches 104 PSIG with Fixed
Speed Unit 2 unloaded or off, Fixed Speed Unit 1
will unload. Fixed Speed Unit 1 will automatically
stop if the auto start/stop timer is satisfied.

Engineering Data

Diagnostics
Section 14
Fluid Analysis General
Overview ................................................................................... 1
Testing ...................................................................................... 2-5
Five Steps of fluid analysis........................................................ 6
Fluid Sampling Procedure......................................................... 7
Sample Description Sheet (SDS).............................................. 8-10
Test Report Results .................................................................. 11-15
Fluid Sampling Instructions ....................................................... 16
Short Test.................................................................................. 17
Fluid Analysis for Sierra Compressors

Ultracoolant Guide .................................................................... 18-21
Short Test.................................................................................. 22
Shock Pulse Monitoring (SPM)

IR30 Introduction....................................................................... 23-24
SPM Introduction....................................................................... 25-27
SPM Data Acquisition General Rules ....................................... 28
dBm/dBc Interpretation General Rules ..................................... 29-30
Vibration Severity Monitoring (VSM)......................................... 31
IR30 Trending ........................................................................... 32-33
Condmaster Pro Software......................................................... 34
IR30 Success Stories................................................................ 35
Short Test.................................................................................. 36
ISPM Measuring Points

Measuring Points ...................................................................... 37
CD8 Air End .............................................................................. 38-44
90kw/125hp—160kw/200hp units ............................................. 45
These sections have been extracted from the Diagnostics Training Manual

Fluid Analysis Section 14
Overview
4 Build a comprehensive database -
In this section, you will learn The results of each sample are saved in the IR
• Why Fluid Analysis is important database, which is regularly evaluated and gives
• Why is the completion of the Sample us the ability to trend all parameters.
Description Sheet so Important
• When and Where to sample Benefits to the Customer
• The proper procedure for taking the sample • Whilst taking the samples, qualified IR Service
Technicians also observe a machine’s general
• How to read the Test Reports? condition and can highlight other problems.
• The independent laboratory analysis provides
recommendations for optimum lubricant and
What is the purpose of fluid analysis? filter element replacement based on condition,
Proper lubrication is critical to the performance of not hour-meter readings.
machinery. • Machine condition monitoring and trending will
determine when a major failure may occur,
Lubricants break down and lose their lubricating which will reduce machine and/or plant
abilities with usage. They also become downtime by avoiding catastrophic failures.
contaminated with metal particles that wear away • Customers can achieve easier scheduling and
from the surface of machine parts and with other planning of maintenance and will receive
substances, such as dirt and water. Thus, it is very technical evidence to solve operational air
important to analyse used machinery lubricants as system problems.
part of an effective predictive maintenance program.
Cost benefits of testing
Through routine lubricant analysis, you can detect
Monitoring compressors with the fluid analysis
the early stages of contamination and degradation,
program results in significant maintenance cost
and machine wear. A regular program of lubricant
savings as it gives advanced warning of, and can
analysis will reduce operation and repair costs,
prevent, catastrophic failure. The program gives you
increase equipment availability and operational
time to rectify or prepare for the impending problem.
reliability, and improve the operational safety.
The cost to benefit ratio in these situations can be
dramatic.
The Fluid Analysis Program, which can analyse all
coolants and lubricants, is available for rotary,
The fluid analysis program also saves money by:
centrifugal and reciprocating air compressors and
• Reducing unnecessary fluid changes
accessory units, manufactured by Ingersoll-Rand
and our competitors • Reducing disposal costs
• Better lubrication control and management
• Increasing equipment life
Why is fluid analysis important?
By taking and analysing fluid samples, we :
All of these benefits mean that customers will enjoy
improved machine reliability, effectiveness, and life.
1 Check Lubricant Condition -
Is the oil still able to do its job or is it at the end
of its life, requiring change out? Benefits to IR
2 Check Lubricant Contamination - • Machine condition monitoring and trending can
Are there chemicals or material in the oil that determine when a major failure may occur
can cause mechanical damage? Is the current • This means better planning of inventory and
lubricant contaminated with other fluids? What service personnel time.
is the condition of the system filters? • Independent technical evidence to provide
3 Check Machine Condition - operational solutions to machine and system
What is the machine wear condition and how problems.
long can it operate before a catastrophic failure
• An opportunity to improve existing customer
is likely? Quarterly sampling is extremely
relationships and create new ones.
important for trending the machine wear and
providing accurate predictions of imminent • Technical evidence for Warranty Claims.
machine and/or component failure.
Diagnostics Reference Manual Section 2.1 Page 1

Issue: 04/Australia, Juney, 2004. Ingersoll-Rand Proprietary Information
Testing
Testing minimal since the exposure to air and high heat
IR’s laboratory carries out the following tests: (>300oC) is rarely encountered. As would be
expected, the value for new lubricant is low, as
1. Viscosity
nitrogen based products are rarely used in the
2. Oxidation normal lubricant production.
3. Nitration
4. Total Acid Number
4. Total Acid Number (TAN)
Total Acid Number (TAN) is a measure of the
5. Water Content lubricant’s acidity expressed as the equivalent
6. Wear Metal Analysis mass in milligrams (mg) potassium hydroxide
(KOH) per gram of the lubricant.
7. Particle Counting
The acid number is used as a guide to follow the
1. Viscosity
oxidative degradation of a lubricant in service.
Viscosity: The resistance of a fluid to flow is the
Lubricant changes are often indicated when the
most important physical property of lubricant.
TAN value reaches a predetermined level for a
Lubricants must have suitable flow characteristics to
given lubricant and application. An abrupt rise in
ensure that an adequate supply reaches lubricated
TAN would be indicative of abnormal operating
parts at different operating temperatures. The
conditions (e.g., overheating) that require
viscosities of lubricants vary depending on their
investigation.
classification or grade, as well as the degree of
oxidation and contamination in service.
Possible reasons for elevated Oxidation/TAN
If the viscosity of the lubricant differs by more than • Poor heat transfer in lubricant cooler due to
10% from the nominal grade, a replacement is dirt, varnish or dirt/debris plugging the fins
recommended. • Compressor starved of cooling air (i.e.,
blocked inlets, cramped locations) or cooling
Viscosity measurements of new and used lubricant water
characterise the lubricant’s grade, which are listed
• Intake air is contaminated with acid forming
as SAE (grading at 100oC) or ISO (gradings for
gases (e.g. Nitrous Oxides, Chlorides,
lubricants are calculated as the Viscosity in mm2/s
Ammonia, Sulfurous compounds, etc.)
(centistokes) at 40oC).
• Discharge pressure too high (high PSIG)
2. Oxidation • Running too fast (high RPM)
Lubricants oxidise when
• Lubricant level low
exposed to air. The oxidation
level can be determined using • Lubricant starvation/severe sliding wear
infra-red signatures of the • Incorrect lubricant specified/wrong viscosity
lubricant and any increase in
• Excessive water, wear debris, dirt in lubricant,
oxidation from the “new
etc.
lubricant” value, is a measure
of how the lubricant is • Air/lubricant separator clogged
Black oxides indicate standing up to the harsh • Intake filter or lubricant filter dirty
insufficient lubrication. environment in which it must
(Magnification 1000x) • Thermostatic valve not working properly
operate. The smaller the
number quoted in the report, the lower the amount
of oxidation. Conversely, a high oxidation level will
indicate the likelihood of thickening and eventual
failure of the lubricated component due to a lack of
effective lubrication.Oxidation preventing additives,
called oxidation inhibitors, are generally
incorporated to counteract the effect that oxygen
and heat, the major cause of the oxidation, have on
the lubricant.
3. Nitration
Nitrogen is a major component of air. In extreme
cases, it can react with the lubricant and oxygen to
produce an effect called Nitration. In compartments
such as gear boxes, the nitration effect would be
Testing
5. Water Content 6. Wear Metal Analysis
Contamination of a lubricant by water can damage Relative motion between
the metal to metal surfaces that the lubricant is lubricated parts is always
designed to protect. The local frictional effects within accompanied by friction between
the lubrication system can cause temperatures in the contacting surfaces. This
excess of the boiling point of water. friction causes a gradual wearing
away of these surfaces, despite
This boiling off can lead to areas where the lubricant the fact that the parts themselves
is forced out of the are usually coated with a thin film Gear Wear is
interface between the of lubricant. caused by fatigue,
moving surfaces, leading scuffing or scoring
to wear. Water will Metal particles rubbed off in this
promote oxidation in the manner are small enough to remain suspended in
lubricant as well as a circulating lubrication system and, since these
possible corrosion in the wear products are always composed of the same
compartment. It is materials from which they originated, the relative
therefore important to level of each metal present in the used lubricant
accurately ascertain the relates directly to the wear condition of the
water content in the Red Oxides indicate water in lubricated assemblies.
lubricant to assess the the oil or poor lubricant
degree of contamination conditions. (Magnification 1000x) Atomic Absorption Spectroscopy and Spark
of this type. Emission Spectroscopy are used in determining
wear metal levels in lubricants.
Water contamination should not exceed 0.25% for
most equipment. Excessive water in a system In Atomic Absorption Spectroscopy, the principle
destroys a lubricant’s ability to separate opposing employed entails the burning of a sample of the
moving parts, allowing severe wear to occur with lubricant in a flame which is in
resulting high frictional heat. line with light of the element
being tested for. For example,
Moisture can come from atmospheric condensation. Iron will give a characteristic
light and when trained on a
Possible reasons for high water in the lubricant photomultiplier detector can be
• Discharge drain check valve not working ‘zeroed’. With the exception of
Bearing Wear is Silicon and Tin, all metals are
• Inadequate weatherproofing or extremely high reported to an accuracy of 1
caused by rolling
humidity contact failure. part per million (ppm). Silicon
• Moisture separator not working property (Magnification 1000x)
and Tin are reported to an
• Compressor running too cool accuracy of 2ppm.
• Heat exchanger leak (water cooled models) Spark Emission Spectroscopy is used
• Degraded/corroded seals predominantly for used lubricant analysis to
• Excessive idling determine the wear metal and contaminant metal in
the lubricant. The principle used is similar to
• No load for long periods Atomic Absorption in that individual metals are
• Light load after extended downtime detected at specific wavelengths, however, the
• Failure to drain water off bottom of Air/oil Spark Emission
separator Spectroscope
simultaneously detects all
• New lubricant not being stored properly the metals normally
• Thermostatic valve not working property required.
Typically, a Spectroscope
simultaneously analyses
for the elements in the
following table:
Spheres are an early warning

of rolling element bearing
failure. (Magnification 1000x)

Testing
Element Sources
WEAR METALS
Iron Most common wear metal. Rotary screw, lobes, vanes, connecting rods, rocker
arm, bearings, cylinders, housing, shafts, roller bearings, oil pump, piston rings
Chrome Wear metal. Alloying element in roller bearings. Can also be from cylinder liners
and rings in some reciprocating models.
Copper Will be present if any brass elements are wearing or corroding. Brass components
include: thermostatic control valve (some models), oil drain valve, stop valve, also
brass tubes in water cooled heat exchangers (older models)
Lead Sleeve bearings (some models).
Tin Found as alloying element in some journal bearings, also as an overlay on some
components.
Aluminium Air cooled oil heat exchangers, tubes, cooler baffles, plates
Nickel Bearings, cylinder guides, wear plates, thrust washers and some Air/Oil separator
overlay.
CONTAMINANT METALS
Silicon Contaminant/Additive. The most common contaminant. Usually indicates sand/dirt
ingression. Can also be from silicon based contaminants.
Sodium Contamination from environment, or from corrosion inhibitor additive used in cooling
water.
Molybdenum Contamination/Wear Metal, such as friction modifier additive in gear oil or grease.
Could be a wear metal as Molybdenum is sometimes used in ball and roller
bearings.
Calcium Can indicate a mix with another lubricant, or possibly grease contamination. Can
also indicate water leak in heat exchanger.
ADDITIVE METALS
Zinc Wear Metal/Additive. Corrosion of zinc plated components such as air/oil separator
coverplate, brass components. Usually present as part of anti-wear additive in
mineral oils.
Magnesium Can indicate a mix with an engine oil.
Phosphorus Additive/Contamination. Usually present as part of an anti-wear additive in mineral

oils. May indicate fluid mix if present in IR synthetic fluids.
Barium Rust inhibitor in compressor fluids.
Boron Contaminant/Additive. Can be a common inhibitor in some fluids. Usually indicates

a contaminant from either cooling water (corrosion inhibitor) or mixing of fluids.

Testing
7. Particle Counting (ISO Cleanliness) In 1999, the International Standard Organisation
This is an excellent way of monitoring the (ISO) introduced a series of new fluid cleanliness
cleanliness of a fluid in terms of both metallic and standards, summarised in the following table:
non-metallic debris.
Old New Description
The technique measured the total particles greater
than 6 microns (1st number) and greater than 14 ISO 4402 ISO 11171 Automatic Particle counter
calibration procedures
microns (2nd number). The scale is partical counts
(ACFTD to ISO MTD)
per million.
ISO ISO ISO Range code
Particle Count: a method used to count and classify 4406:1987 4406:1999
particulate in a fluid according to accepted size
ranges, usually to an ISO standard (ISO 4406 (99) NAS 1638 SAE AS4059 Cleanliness levels by particle
30 June Rev D April size.
or ISO 11171 (99)). High particle counts indicate
1992 2001
that there is a lot of solid contamination in the fluid,
including wear debris, sand and dirt, organic
material etc. Compressor fluid should be maintained The change in calibration procedures (ISO 4402 to
at low particle count levels. If the Fluid’s ISO ISO 11171) occurred for two reasons.
contamination code is 16/13, it indicates clean oil,
although some applications require more stringent • First, the industry developed a new standard test
limits. dust for calibration fluid. This new ISO Medium
Test Dust (ISO MTD) replaced the previously
Particle Count ISO Codes used AC Fine Test Dust (ACFTD), which is no
longer available.
Number of Particles per Number of particles Range
million per million Number • Secondly, there has been a change in how
particle sizes are measured. By way of newer
Greater Than ...... Less Than .....
technologies, particles are now measured in three
80000 160000 24 dimensions, whereas in the past they had been
40000 80000 23 measured in two dimensions.
20000 40000 22 How will these changes affect you?
10000 20000 21 In comparing the old standards to the new, the
following has not changed: The amount and the size
5000 10000 20
of solid contamination in your system is still the
2500 5000 19 same!
1300 2500 18
What has changed?
640 1300 17 The way particle size is specified has changed.
320 640 16 The new standards and reporting methods “move
the measuring stick” to correct for the inaccurate
160 320 15
calibration assumptions made over the past 40
80 160 14 years.
40 80 13 Under the old ISO 4406, three numbers represented
20 40 12 the number of particles greater than or equal to 2 µ,
5 µ and 15 µ. The new ISO 4406:1999 uses three
10 20 11
scale numbers, representing the number of particles
Possible reasons for high particle counts greater than or equal to 4 µ(c), 6 µ(c), and 14 µ(c) in
• Lubricant filter clogged and/or bypassing size.
• Air intake filter broken or bypassing It is important to note that net effect of all these
changes keeps the ISO rating unchanged. In other
• Elevated wear debris generation
words, a fluid that was determined to have an ISO
• Fluid Oxidation rating of 18/15/13 under ISO 4406:1987 will still
• Heat exchanger leak (water cooled models) have an ISO rating of 18/15/13 under ISO
4406:1999.
• Degraded and/or corroded seals and/or gaskets
• Excessive idling or ‘no load’ for long periods These changes ensure that the historical
cleanliness requirements and fluid analysis data
• Light load after extended downtime also remain valid with the new calibration method.

Sampling Procedure
Five steps of Fluid Analysis Use of a sample kit CCN 91002550 is easy. Simply
1 Strictly follow the sampling procedure when follow the instructions contained within the kit to take
taking samples the coolant sample and fill out the Sample Descrip-
2 Always complete a Sample Description Sheet tion Sheet indicating where the report should be
and send the sent. The sample is then forwarded to the labora-
* Sample, together with the tory who will carry out the analysis. The results will
* Sample Description Sheet then be mailed to the address indicated on the
to the laboratory forms. To use the kit it will be necessary that a re-
3 You will receive the Fluid Analysis Report by useable sample pump is obtained CCN 91000000.
mail It is recommended that each serviceman would
carry one in his standard tool kit.
4 You then take the appropriate action, depending
on the test results.
Kit - 91002550
5 Sample data and results are stored into IR’s
Pump - 91000000 or 88176383
database for evaluation
The kit and pump are available Ex APDC Singapore
Fluid Test Kit 91002550

This Fluid Test Kit can be used to check the condi-
tion of Ultra Coolant, Techtrol Gold all coolants/
lubricants used in air compressors.
Use of this kit should become standard practise as
part of your diagnostic service procedures.
Fluid Test Kit

Sampling Procedure
Sampling Procedure Completing the Sample Description
The sampling method is one of the most important Sheets
factors contributing to effective scheduled fluid
analysis. Step by step Sampling Instructions are in For Coolant/Lubricant Analysis to be effective, it is
this manual and also on the reverse of the Sample important for the laboratory to obtain as much detail
Description Sheet, use these to gain the maximum as possible about the sample supplied.
benefit from taking samples.
The Sample Description Sheet provided with each
When to take samples? sampling kit, outlines the important criteria required
Samples should be taken at regular intervals. Use so that tests can be carried out and interpreted in an
the following guide to determine sampling intervals appropriate manner.
based on time or running hours, whichever occurs
first. Any additional information that might be considered
unique to the operating compressor should be
When to Sample Hours or Period of Time included. The more information that is received by
the laboratory, the more meaningful the report will
1 New lubricant or 250 or 2 weeks
be to you.
change of lubricant
2 When the fluid report 500 or 1 month of The Sample Description Sheet is divided into three
results indicate operation sections:
“caution” • Machine Details
3 When the fluid report is 2,000 or 3 months • Customer Sample
satisfactory • Details
4 When the environment on the inspection report Each section should be completed as shown on the
suggests that more frequent sampling is required. following pages.
5 Prior to every coolant/lubricant change
Where to sample?
Always draw the sample from the same point.
Draw samples from the ‘oil fill’ port of the system
reservoir, ensuring that the sample is taken from
the mid-level of the reservoir.
The main points to remember when sampling are:

• Sample at regular intervals
• Keep sample procedure clean
• Always sample hot:
Allow the machine to run for 15 minutes in
loaded condition to come to full working
temperatures and pressures. This will ensure
that any contaminants are evenly distributed
in the system.
Make sure you isolate the unit and release
all pressure before taking samples.
• Always sample in the same manner
• Provide complete and accurate information on
the sample description sheet

Sample Description Sheet (SDS)
The Sample Description Sheet (SDS) is divided into Fluid test reports will be e-mailed. not
three sections, Machine Details, Fluid Details and posted.
Send Report To sections.
You must complete all relevant fields in Please make sure your e-mail address
the SDS. is included in the appropriate field on
the sample description Sheet.
TN is provided in this box. Top part of

SDS is for you to retain for reference and
the bottom part should be sent with the
bottle to the lab. This TN also indicates
that the fluid analysis and report have
been prepaid.
The Number and Model uniquely

identified the machine and are used to
accurately match up past histories and
analysis results.
Hours run on Fluid sample; it is vital

that the hours of fluid usage are known
to ensure the results given an accurate
indication of equipment wear and
service interval. If this information is
missing the sample cannot be used for
trend monitoring.
Hours run on machine is vital as wear

rates can vary dramatically from the
initial "running in" period to "normal
operating" conditions. Equipment usage
cannot be assumed, therefore if this
information is missing, the resulting
interpretation will not be accurate.
This information MUST be filled in;

without it, the fluid analysis will be
meaningless.
The Send Report To section is straight

forward and, when properly completed,
will speed up the Fluid Analysis Report
and ensure that the right person
received the report in a timely fashion.

The reverse of the Sample Description Sheet gives you information on sampling procedures
Further illustrates point 6
Dipstick
Mark dist anc e on tube
Top of oil
Take sample
r from mid- level
Reservoir

New Fluid Test kit, Part Number

91002550
All Asian IR operations and distributors
should send samples directly to the laboratory in
Singapore to the following address:
ALS Technichem
14 Little Road
#07-01 & #08-01 Tropical Industrial Building
Singapore 536987
Ph.: 6283 9268
Fax.: 6283 9689
Australian IR operations and distributors

should send fluid samples to:
ALS WearCheck
32 Shand Street
Stafford, Queensland, 4053,
Australia
Ph.: 07 3243 7200
Fax.: 07 3243 7221
ALS will only process the new Fluid

Test Kit, Part Number 91002550
• Reports will be e-mailed to the person

named on the sample description sheet.
• New laboratory has locations in
Singapore and Australia and will also
have a branch in China in the near future.
• The laboratory is part of global network of
independent laboratories
• Sample Description Sheet is dual
language: English and Chinese.

Test Report Results
Step 3 When a Caution value is reported, you will see
Interpreting the analysis reports an “orange (amber) light” indicating the need to
increase the frequency of checks, as it may
These reports are provided by a laboratory show abnormal conditions occurring. Fluid
possessing ISO 9001 accreditation. should be resampled after a further 500 hours of
operation, or 1 month, to assess the need for
Specialist Analytical Chemists can be likened to corrective action or return to “standard” 2000 hour
“Pathologists” providing valuable insight to the fluid test intervals.
Technical Service personnel (the “Doctors”) who
correct the causes of problems in machinery. If When the parameter reaches Serious level, a
regular fluid analysis shows that samples are within “red lightf” will appear on the report and
specification, then you can be confident that so is orrective action is required immediately. We
the vital equipment. If, on the other hand, a fault is recommend that the fluid be replaced and the
detected, you have early warning to check for the root source of the contamination/degradation be
problem and correct it before it can become “fatal” determined. After corrective action, the filter
to the machine. should be replaced and a new sample taken after
250 hours of operations.
The following two page report is part of the program
The unique Report Number is issued by the
and is completed by the laboratory and sent to you.
5 laboratory, any correspondence regarding a
report needs to refer to this number or Tracking
1 Customer Details come from the Sample
Description Sheet and are stored on the Number. This section of the report also details the
laboratory database. Accuracy is critical to ensure Sample Number, i.e. number of analysis carried
that the correct person received the report on time. out on the compressor, the Date the lubricant was
The Customer Number is issued by the laboratory taken (sampled) from the unit and the Date the
and is unique to each customer. sample was received by the laboratory.
2
Equipment Details come from the Sample
Description Sheet and are stored on the
6 Lubricant and equipment usage. The Hours on
both the Fluid and the Equipment, supplied by
laboratory database. Accuracy is critical for you. The accuracy of this information is critical for
ensuring that the sample is correctly related to past monitoring and trending.
and future analysis. The Equipment Serial Number
Current Sample Results
is supplied by you.
7 Shows the test results of the current sample.
It is important to understand that each machine
needs to be uniquely identified in order to (-) indicates that the test results was “Not
accurately match up past histories and apply the Determinable” due to factors such as insufficient
correct criteria for the analysis of the results. The sample supplied or extremely contaminated sample
laboratory generates a unique code based on the affecting some test results. For example, an
supplied serial number and compartment type. extremely high water content might cause the
determination of Viscosity at 100oC to be
Operation Details on the lubricant type, impossible.
3 lubricant top up and area or site of operation A rectangle in this column indicates an Abnormal
from the Sample Description Sheet.
8 Value for the respective test and will usually rate
Status. A quick reference to the overall an explanation for the current sample in the
4 conclusion of the report. comments section. Abnormal Values are depicted
for the current and previous sample.
Satisfactory; you will see a “green light” in
the top right hand corner of the report and fluid
should be resampled after a further 2000
hours, or 3 months of operation, whichever
comes first.

Test Report Results
1 2 5
11
4
7
9
6

Test Report Results
Page 2 of the Fluid Analysis Report
10

Test Report Results
Page 3 of the Fluid Analysis Report

Test Report Results
Results of the Last and Previous Analysis on the High Ferrous, Zinc/Copper/Other Metals
9 compressor.
1 Take airend vibration SPM readings. (Has unit
A graphical depiction of analysis results to become excessively noisy?)
10 enable an easy review of “trends” over time
occurring in the compressor. The six most 2 Change fluid filters and drain into container, check
recent sample results are depicted on the graph. for metal particles.
The horizontal axis indicates the Sample Numbers, 3 Check duty cycle. Does unit have light load
with time moving from right to left for the sake of allowing internal moisture build up leading to
consistency with the rest of the report. The example corrosion?
report indicates that only one sample was taken,
therefore no graphs/trends are shown. 4 Remove separator element. Is it corroded?
(possible Zinc source).
Step 4 5 Check thermostatic bypass valve element and
11 Diagnosis coolant stop valve internals. Are they corroded/
worn? (possible Copper source)
The comments about the results of the sample High Water / Silicon / Sodium /
analysis are a guide to what may be occurring in the
compressor. It outlines Recommended Action ISO Cleanliness Code
based on the analysis findings. These comments 1 Check inlet filtration, check for signs of dirt
are automatically generated by the analysis bypassing filters or damaged elements/seals
software. If you require clarification, please contact
IR Service. 2 Ensure sample taken from filler port and not
coolant drain
You can also follow the guidelines on the last 3 Check for wear particles as above
page of the report.
High Tan
1 Change fluid ensuring all old fluid is removed or
flushed
2 Replace fluid filters
Step 5
3 If fluid was used for less than 8000 hours – check Ingersoll-Rand’s Fluid Database
for accidental contamination with other fluids Details of every sample taken are automatically
during top up stored in the Laboratory’s database and that
information is sent to IR once a month, for further
4 Check for presence of Ammonia or Chlorine gas, evaluation.
metal-cleaning solvents, welding fumes, boiler or
vehicle exhaust. The sample population is reviewed, using statistical
The recommendation is to install an Air Analysis methods, and lubricant levels are evaluated at least
Kit CCN 68144765. twice a year.
5 Check operating temperature
This evaluation can only be successful if the
information in the database is correct and
meaningful. Therefore, it is imperative that the
information you write on the Sample Description
Sheet is correct and relevant.

Fluid Sampling Instructions
Follow these instructions with care to gain the
maximum benefit from fluid analysis. 13) Insert the free end of the tube, up to the
‘mark’, into the reservoir
Preparation: 14) Draw back the
1) Ensure that the unit is at its normal operating handle of the suction
temperature gun – normally two to
three times is
2) Fluid must be well circulated when sampled enough to create a
(within 15 minutes of shutdown) vacuum in the bottle.
3) Avoid external contamination, clean all lubricant Fill the sample bottle
access areas prior to sampling; wash and dry ¾ full.
your hands 15) Remove the tube from the reservoir.
4) Use a new Fluid Test Kit for each sample you 16) Unscrew the sample
take bottle from the pump
and immediately insert
The Fluid Test Kit the red stopper and the
5) Open the Fluid Test Kit carton and take out the cap.
black plastic container, which is the prepaid 17) Clean the end of the
mailing container, so don’t throw it away. tube in the pump
6) Open the black container and take out the before removing it, to avoid contaminating
sample bottle, the Sample Description sheet and the pump.
the absorbent paper 18) Discard the tubing. Never reuse it
NOTE: Don’t open the sample bottle until you
are ready to take the sample Packing and Sending
7) Complete the sample description sheet before 19) Place one of the barcode labels on top of the
taking the sample cap and keep the other label for your
reference.
Taking the sample 20) Put the sample bottle into the plastic bag,
8) Uncoil the plastic tubing and insert one end seal it and wrap the package in the
through the head of absorbent paper
the pump until it is 21) Put the Sample Description Sheet back into
about 1cm past the O the black mailing container
Ring, then tighten the
screw to hold the tube 22) Put the sample into the black container and
in place. screw the lid on tightly
9) Put the pump and Send the prepaid black mailing container to the
tubing into the carton Laboratory.
to avoid
contamination while you perform Step 10. The
tubing must never touch the floor, soil or any
By following the above recommendations you will
dirty surface prior to sampling.
ensure that your samples are “representative” and
10) Now determine how Dipstick that the results will be consistently accurate.
Mark distance on tube
much of the tubing

to insert into the
reservoir. The Top of oil
sample should be
taken from the mid- r
Take sample
from mid- level
level.
Reservoir
11) Mark that distance
on the tube, from the free end.
12) Open the sample bottle and attach it tightly to
the pump.

Short Test
Short Test
1 What are four major objectives of lubricant testing
2 Explain how you would convince a customer that fluid analysis carried out by
you would be more beneficial to them, than that done by another laboratory?
Give at least three reasons.
3 When should fluid samples be taken?
4 What would your recommendation be if fluid analysis report indicated a high

TAN ?
5 List three possible reasons for elevated TAN number
6 What are the main points to remember when taking samples?
7 What does a bar code on the Fluid Sample Description Sheet indicate?
8 List four possible reasons for high water contamination in the fluid.
9 What do the two numbers in the Particle Count ISO Code mean?
10 When a “sad face” appears on the Fluid report what you should do?

Fluid Analysis for Rotary Compressors Section 14
Ultracoolant Guide
Evaluation of Ultracoolant data from the Total Acid Number (TAN)
Asia Pacific region. CAUTION = 1 SERIOUS = 1.5
The evaluation that follows is based on
approximately 950 samples from the Asia Pacific This test gives an indication of the remaining
Region of Ultracoolant hours of operation. We have useful life of the fluid. The TAN starts out with a
plotted some trends to provide general guidance. value of about 0.1 in new Ultracoolant. When it
reaches a value of 1.0, we recommend that the
fluid be changed.
Report Interpretation Guide
CAUTION SERIOUS High TAN may be caused by several factors
including high operating temperature or intake of
Use Caution and Serious values in the following air containing acidic gases. It may also occur in an
guide for taking appropriate action, monitor/ initial charge as Ultracoolant dissolves varnish and
troubleshoot operation of the unit, and/or sludge, left by previous fluids.
Ultracoolant replacements.
Viscosity Ultracoolant TAN
55< CAUTION <42 SERIOUS >58 0.60
Viscosity is the measurement of the resistance of a 0.50

fluid to flow. When it is new, Ultracoolant has a
0.40
viscosity of about 48 cSt @ 40oC and 9 cSt @
100oC. The fluid should be changed if the viscosity
TAN
0.30
changes by more than 20%. Normally, this change
will not occur within an 8000-hour period. 0.20
0.10
V is c o s ity o f u ltra c o o la n t
5 2 .0 0
0.00
<500 501-1000 1001-2000 2001-4000 4001-6000 6001-8000 >8001
5 1 .5 0 Hours
5 1 .0 0
Viscosity cSt
5 0 .5 0 This chart provides calculated trends for average,

5 0 .0 0 values of TAN over the time of operation of
4 9 .5 0
Ultracoolant. The expected average TAN number
after 8000 hours is 0.5
4 9 .0 0
<5 00 5 0 1 -1 0 0 0 1 0 0 1 -2 0 0 0 2 0 0 1 -4 0 0 0 4 0 0 1 -6 0 0 0 6 0 0 1 -8 0 0 0 >8001
U lt ra c o o la n t h o u rs
Possible reasons for elevated TAN numbers:
• Poor heat transfer in oil cooler due to dirt,
varnish or dirt/debris plugging the fins
This chart provides calculated trends for average • Intake air is contaminated with acid forming
values of viscosity versus hours of Ultracoolant gases ( e.g. Nitrous Oxides, Chlorides,
operation. The expected average viscosity after Ammonia, Sulfurous compounds)
8000 hours of normal operation is 52cSt • Discharge pressure too high
• Oil level low
Possible reasons for abnormal viscosity:
• Excessive water, wear debris, dirt in oil, etc
• Incorrect lubricant used
• Oil separator clogged
• Fluid oxidation
• Intake filter or oil filter dirty,
• Water contamination
• Thermostatic valve not working properly
• High amount of solid contamination (e.g wear
debris, sand/dirt)
• Condensation trap not working

Ultracoolant Guide
Water Content (%) Iron (Fe ppm)
0.3 < CAUTION < 0.6% SERIOUS >0.6% CAUTION > 8 ppm SERIOUS > 26 ppm
Water content affects operation of the unit and its Wear or corrosion of castings, bearings, rotors,
operating temperature. As a general rule of thumb the etc. Some iron will always be present. It may
water level is acceptable up to max of 0.3%. Coolant indicate a machine problem, but is also likely to
needs to be replaced if water reaches 0.6%. be corrosion from water in the system.
U ltr a c o o la n t W a te r c o n te n t U ltr a c o o la n t Ir o n c o n tn e n t v s h o u r s
0 .3 5 6 .0 0
0 .3 0 5 .0 0
0 .2 5 4 .0 0
Iron Content
Water contnet %
0 .2 0 3 .0 0
0 .1 5 2 .0 0
0 .1 0 1 .0 0
0 .0 5 0 .0 0
<500 5 0 1 -1 0 0 0 1 0 0 1 -2 0 0 0 2 0 0 1 -4 0 0 0 4 0 0 1 -6 0 0 0 6 0 0 1 -8 0 0 0 >8001
0 .0 0 H o u rs
<500 5 0 1 -1 0 0 0 1 0 0 1 -2 0 0 0 2 0 0 1 -4 0 0 0 4 0 0 1 -6 0 0 0 6 0 0 1 -8 0 0 0 >8 0 01
H o u rs o n o il
The expected average of Iron content after 8000

hours of normal operation is 6 PPM
From this chart, the expected average water content
after 8000 hours of normal operation is 0.28%
Other Metals
Possible reasons for high water content in the oil:
• Condensate traps do not operate properly Chromium (Cr) and Molybdenum (Mo)
• High humidity Worry about these if large amounts are present.
• Excessive idling / no load for long periods / light They are alloy metals for the steel used in
load after extended downtime bearings.
• New lubricant not being stored properly
• Thermostatic valve not working properly Aluminum (Al) and Copper (Cu)
Lubricant coolers are usually constructed from
one of these. Large amounts may indicate cooler
corrosion or ingestion of air containing particles of
these metals. For guidance, look at the TAN of
the lubricant. If it is less than 1.0, it is probably
just contaminated air, more than 1.0 may be
corrosion.
Lead (Pb), Tin (Sn), and Silver (Ag)

Babbit bearings usually contain Tin, Copper and
Antimony. Lead may also be present, and silver
is sometimes used as a lining of bearings. All this
is nice, but rotary compressors use non-friction
roller and/or ball bearings, so when these
elements show on a report they indicate either
contamination from the environment, or a
mistaken analysis.

Ultracoolant Guide
Contaminants Ultracoolant Guidelines
Silicon (Si) The following table provides caution and serious
If more than 12ppm is present in regular lubricants, it levels for parameters of Ultracoolant. When a
indicates dirt, sand, or other contaminants are being serious level is reached, the Ultracoolant should
ingested past the air filter. be replaced.
Sodium (Na), and Calcium (Ca)

Together may indicate a water leak across a cooling Ultracoolant
water exchanger.
Guidelines of Caution and Serious Levels
Magnesium (Mg) and Phosphorus (P) Item Caution Serious
Not used in Ultracoolant, but is an additive in some
lubricants. If it shows up in a Ultracoolant analysis, it Viscosity <44 or >55 >58
is a contaminant. Water >0.3% >0.6%
TAN 1 1.5
Zinc (Zn)
In a rotary compressor, Zinc may come from Sodium (Na) 58 ppm 89 ppm
corrosion of the galvanized parts of the air-oil
Silicon (Si) 6 ppm 12 ppm
separator. To see if this is a problem, check the
TAN. If the TAN is over 1.0, that is likely to be the Iron (Fe) 8 ppm 26 ppm
source. If the TAN is normal, the Zinc may be Copper (Cu) 12 ppm 53 ppm
present as an additive in the lubricant. Ultracoolant
does not contain Zinc additives, because they are Zinc (Zn) 95 ppm 267 ppm
not necessary in rotary compressors, and tend to Aluminum (Al) 1 ppm 2 ppm
contribute to the formation of sludge and deposits.
Lead (Pb) 4 ppm 8 ppm
Molybdenum (Mo) 1 ppm 2 ppm
Chromium (Cr) 1 ppm 3 ppm
Retained Solids 200 250
ISO Cleanliness 22/19 24/21

Ultracoolant Guide
Reference Table
The following table provides average and maximum
values derived from the sample population in
different time brackets.
This table can be used as a reference for average

values and also gives you maximum values
measured throughout the Asia Pacific region.
Note: The maximum values measured in the region

for various operating hours on the Ultracoolant do
not represent the maximum allowable levels. If any
parameter of your Ultracoolant sample reaches the
maximum value, immediate action is required.
No Hours 1000-2000 2000-4000 4000-6000 6000-8000

Av. Max Av. Max Av. Max Av. Max
Water 0.24 0.83 0.25 0.71 0.29 0.83 0.28 0.93
Visc_40 50.42 57.17 50.91 62.61 51.25 60.49 51.48 59.26
Iron (Fe) 3.74 44.00 4.10 36.00 4.13 29.00 4.82 53.00
Chromium (Cr) 0.08 2.00 0.09 6.00 0.05 2.00 0.05 1.00
Copper(Cu) 1.45 63.00 1.31 21.00 1.94 40.00 2.66 64.00
Lead (Pb) 1.70 27.00 1.38 20.00 1.81 16.00 1.58 16.00
Aluminium (Al) 0.62 14.00 0.49 12.00 0.55 10.00 0.41 5.00
Tin (Sn) 8.63 57.00 8.95 45.00 8.67 55.00 10.72 42.00
Silicon(Si) 4.22 32.00 3.26 48.00 3.25 25.00 2.32 20.00
Sodium (Na) 35.59 156.00 40.81 133.00 47.37 367.00 51.73 360.00
Nickel (Ni) 0.28 2.00 0.14 1.00 0.08 2.00 0.10 1.00
Zinc (Zn) 13.74 117.00 17.61 134.00 21.53 177.00 19.44 135.00
Phosphorus (P) 15.72 79.00 18.29 173.00 22.08 156.00 19.04 215.00
Calcium (Ca) 6.51 27.00 7.55 70.00 11.86 78.00 11.63 127.00
Retained Solids 72.04 766.00 56.58 384.00 74.69 585.00 78.04 469.00
TAN 0.39 1.35 0.46 1.96 0.51 1.65 0.48 2.00
Oxidation 58.07 64.10 58.02 63.40 57.26 63.30 57.15 64.30
Nitration 10.54 13.60 10.53 12.90 10.46 12.80 10.47 14.50
Particles per 100ml
2to5 971,887 4,146,201 962,599 6,484,835 1,100,872 3,981,832 923,830 3,457,252
5to10 405,268 3,528,529 342,745 3,149,294 431,305 3,660,406 311,646 2,544,685
10to15 160,960 1,977,763 111,673 2,006,322 139,640 1,496,472 129,914 1,844,850
15to25 130,609 3,275,060 74,904 1,839,024 88,905 1,308,183 92,221 1,250,286
25to50 26,513 965,976 18,166 740,631 23,232 750,075 18,760 399,550
50to100 2,201 117,027 1,164 60,601 1,775 46,952 210 4,640
greater100 252 4,400 184 5,961 301 9,685 1,297 27,222
ISO_Greater
2 microns 21 23 20 24 20 23 20 23
5 microns 18 23 18 23 18 23 18 23
15 microns 15 22 15 22 15 21 15 21

Short Test
Short Test
1 What are four major objectives of lubricant testing?
2 When should fluid samples be taken?
3 What are the main points to remember when taking samples?
4 What does TN on the Fluid Sample Description Sheet indicate?

IR30 and Condmaster Pro Section 14
IR30 - Introduction
The IR30 Sentinel
In this section, you will learn CCN 54636535
• The type of monitoring IR30 is capable of. This unit works in the same way as the
• Three models of IR30 and their differences. data logger instrument, with the
• SPM and how is it applied in industry exception that all data has to be
manually loaded prior to taking each
• Decibel Initial (dBi). reading and it has no PC loading/
• How you can take vibration readings using downloading capabilities. This unit has
the IR30. only SPM monitoring capabilities. The
• Which indicator is used for Bearing condition. IR30 Sentinel can be upgraded to IR
• Which indicator is used for lubrication 30 Logger at an extra cost
condition.
Vibration Accessory Kit
• Condmaster Pro software. CCN 38034872
The Vibration Accessory Kit consists of Vibration
Cable (VIC 19), Vibration Transducer (TRV 13),
What is the IR30? Vibration Transducer Probe (TRX 28) and can be
IR 30 is an Ingersoll-Rand hand held instrument used with the IR 30 Sentinel to take vibration
that can be used to: readings (mm/sec). The vibration severity
• analyse bearing condition measurement provides valuable information
• measure vibration about the general condition of the unit and can be
• log other parameters from the running used on any rotating machinery
compressor.
IR30 Accessories
The IR30 is primarily 20 x studs CPN 89218721
used for IR rotary 50 x studs CPN 89218739
compressors; however, Stud Mounting Kits
it is capable of analysing Drill and 90o Countersink
any roller element, or CPN 39262992
anti-friction bearings and
vibration severity on any
other rotating Benefits to the Customer
machinery. Customers benefit because they can:
• Minimise loss of production
There are 3 models of • Avoid costs resulting from secondary
the IR30 available. damage
• Utilise the entire lifetime of the compressor
The IR30 Data Logger Kit air ends
CCN 39263009
• Schedule major overhauls
includes:
• Avoid the costs of renting replacement
• IR30 Instrument
compressors
• CondMaster Pro Software
• Instruction manual
• PC cables and hardware key Benefits to IR
• SPM & Vibration probes • One of the key Airend business drivers
• Batteries • An objective method of verifying the
• Carrying case operating condition of rotary machinery
• Verifies the qualify of service and repair
work, such as bearing replacements
• Improves planning for the replacement of
In addition to SPM and vibration bearings and air ends
readings, rounds can be uploaded from a PC and
technicians can log other parameters such as
temperatures and pressures. This data can be
downloaded later to a PC for further evaluation
and trend monitoring.

IR30 - Introduction
The IR30 can also:
• Expand the number and size of service
contracts
• Allow IR to do bearing monitoring and vibration
analysis on other compressors, pumps, fans,
etc.
• Build IR’s database and increases our expertise
in vibration
• Enhance the professional image of IR service
IR30 - Description and Function Buttons

Menu Screen
Communication for COMMUNICATION

BATTERY TEST
IR30 Logger only VERSION
CURRENT SETUP
Clock
Date 00.07.29
Displays 4 lines with up to Time 14.31
16 characters per line
Condition Scale
Contrast
Light auto
Sensitivity 5
Brightness 5
Instrument
Light Sensor
Measuring Key
Set Key Enter Key

Time mm
o
Display C
English
Off 5 mins 0 Secs
Up Arrow Key Right Arrow Key
Left Arrow Key Down Arrow Key
Input Connector SPM Input Connector Vibration
Input Connector Software

SPM - Introduction
What is SPM (Shock Pulse Monitoring)?
The Shock Pulse Method was developed about 20 A shock pulse pattern consists of a rapid sequence
years ago as a method for measuring the true of strong and weak pulses. It is defined by two
operating conditions of rolling element bearings. measured values, Decibel Carpet (dBc) for the
large number of relatively weak shock pulses and
As a result of extensive research and development, Decibel Max (dBm) for the few strong pulses in the
it is now virtually the only method readily available pattern.
for that purpose. Not only can damage be detected
and quantified at an early stage, but the vital oil film Decibel Carpet (dBc)
thickness can be assessed. Imagine that you are waiting at a railway crossing
for a freight train to pass. You hear the normal
The basis of the technique is that it measures the ‘clickety-clack’ sound of the wheels crossing the
mechanical impacts generated by any rolling rail joints, but the sound is not always the same; it
element bearing, which is a function of the ball or is louder as the heavier wagons go past and less
roller velocity surface roughness. intense for the empty wagons. This sound is usual
for a freight train and, in SPM terms, it is called the
These Decibel Carpet.
mechanical
impacts What IR30 does Decibel Max (dBm)
generate However, if one of the wheels has a ‘flat spot’, it
pressure Transducer will make a repetitive banging sound as the flat
waves spot hits the rail. This banging sound can be heard
through the well above the Decibel Carpet and, in SPM terms,
bearing it is called
housing, Shock dBm the Decibel Max.
which can be waves dBc
detected by Decibel Initial (dBi)
piezo- This factor can be likened to calibrating your ear as
electric transducers (approximately 32kHz the train passes. This ‘calibration’ regulates the
frequency range). This frequency is convenient as it intensity with which the ear perceives Decibel Max
amplifies the shock signal and filters out machine and Decibel Carpet.
vibration..
Applying the technology
It is important to appreciate that the Shock Pulse Applying SPM technology to steel roller bearings
Method detects pressure waves, not physical requires only reasonable access to the outside
movement of material as in the case of vibration diameter of the monitored bearing, through an
measurement. Consequently the rules of SPM are uninterrupted metal path. Permanently attached
that the measuring point must be selected to provide metal studs are best for this purpose.
the shortest possible straight line to the bearing; no
additional interfaces other than the bearing housing A mechanical “clip-on” accelerometer is used to
and the outer race of the bearing must be present; anchor to and read the acoustical signature from
and it must be in the loaded zone of the bearing. the bearing, through the housing to the studs. A
hand held, contact probe can also be used with
Over the years, the Shock Pulse Method has been good results.
developed to an exceptionally high level of accuracy
and reliability, with sophisticated equipment being The IR30 reads the shock pulse dBm/dBc values
developed which is user-friendly, yet produces and displays them as two numerical values. Any type
results that enable the engineer to confidently plan of steel roller bearing can be monitored; however,
his production and maintenance schedules. With the the Shock Pulse Method has no application to sleeve
aid of CondMaster Pro software, it is now possible to bearings.
download directly to a PC and all the analysis and
results, with the action required, can be displayed or
printed.
There are 3 terms used in SPM. These are

• Decibel Carpet (dBc)
• Decibel Max (maximum) (dBm), and
• Decibel Initial (dBi)

SPM - Introduction
This is a short and simplified summary of some Carpet Value dBc
important facts needed to understand the Shock Shock pulses are generated in the rolling interface
Pulse Method (SPM) for bearing condition between the loaded rolling element and the raceway
monitoring: of the bearing. Bearing surfaces are rough. This
causes pressure variations in the oil film which
• Shock pulses are caused by impacts. An separates the moving surfaces, as well as collisions
impact is a single event caused by one body between peaks in the surfaces.
hitting another. In a
bearing, the impacts Results of an impact:
Both result in pressure
typically occur at random
waves - shock pulses -
(and extremely short)
which spread through
intervals.
the material of the
• The impact sends a shock
bearing, the bearing
wave through the material
housing, and adjacent
of both bodies. Vibration
machine parts.
follows impact as a
secondary event. In the 1. A shock wave spreads
shock pulse transducer, through the material
vibration is filtered out.
• The shock pulse
transducer reacts to the
amplitude of the wave
front at its own resonance
frequency. This magnifies
the low energy signal. The IR 30 samples the pattern and displays two
Only the wave front is 2. The body vibrates. measured values to quantify it, dBm and dBc
measured, causing one • Carpet value (dBc) is the measured value for
shock pulse from the transducer. the large number of weaker pulses in the
• The amplitude of the wave front is a function of pattern. It is directly related to the thickness of
impact velocity. This means, the higher the the lubricant film in the rolling interface.
rpm, the higher the shock level. Because the • The carpet value is low when the surfaces of
rotational speed of the bearing depends on its rolling elements and raceway are completely, or
size and the rpm, both are needed as input almost completely, separated by a lubricant film.
data. • The carpet value rises when lubricant film
• Shock pulses are transient signals. They lose thickness decreases and there is more metal to
their energy on the way through the material of metal contact between the bearings.
the machine. Also, they are reflected from
surfaces and severely dampened by interfaces
in the material. That is why we need defined Low Carpet Value High Carpet Value
measuring points.
• All impacts cause Shock pulse measurement
shock pulses. You
must make sure
that you are A A = f (v)
measuring a signal
from the bearing. 1. Shock waves converted to
electrical pulses
2. Pulse magnitude is measured,

vibration is filtered out.

SPM - Introduction
Maximum value dBm condition.
Maximum value (dBm) is the measured value of the • When you set the dBi to “- -” (below -9), the
strongest pulses detected during the measuring IR30 will take an unnormalised reading, in
interval. dBsv (absolute shock values). The condition
zones do not apply. This method is used for
While the bearing surfaces are undamaged, the comparative reading on different bearings and/
difference between dBm and dBc is small. or other shock pulse sources.
A high dBm and a

large difference
between dBm and
dBc is caused by
surface damage or
foreign particles
between rolling
element and
raceway.
The IR30 indicates “bad

operating
condition” (arrow
pointing at the red zone Different shock pulse patterns
of the condition scale). The signal from a bearing should be highest on the
bearing housing. If you get a higher signal outside of
the bearing housing (across an interface in the
material), you are most likely measuring shock
Initial value dBi pulses from another bearing or some other source.
Normalised and Unnormalised readings
The absolute shock pulse level of a bearing, a) For good bearings, the dBm is within the green
measured in dBsv (decibel shock value), is both a zone. dBm and dBc are not close together.
function of rolling velocity and of bearing condition. b) The shock pulse pattern from a damaged
To neutralise the effect of rolling velocity on the bearing contains strong pulses in the red zone, a
measured value, the IR30 has to be programmed random sequence, and a large difference
with shaft diameter (mm or in) and rotational speed between dBm and dBc. When you grease
(rpm). lubricate the bearing, the values should drop but
rise again.
The IR30 will then calculate the initial value dBi, the
c) A dry running bearing has a high carpet value
starting point of the condition scale for a particular
very close to the dBm. When you grease
bearing. You can also input the dBi directly. The
lubricate the bearing, the values should drop and
condition scale is graded in normalised shock
stay low. A similar pattern is caused by pump
values, dBn.
cavitation, in which case readings on the pump
housing are stronger than those taken on the
The IR30 takes a sample count of the shock pulses
bearing housing, and are not influenced by
occurring over a period of time and displays:
lubricating the bearing.
• the maximum value dBm for the small number d) A regular pattern, containing bursts of strong
of strong shock pulses. pulses in a rhythmic sequence, is likely caused
by scraping parts.
• The carpet value dBc for the large number of
weaker shock pulses. e) Individual pulses in a regular sequence are
• An arrow against a field on the condition scale: caused by clicking valves, knocking parts,
green, yellow and red. regular load shocks.
• The maximum value dBm defines the bearing’s f) A sudden drop in the shock pulse level is
position on the condition scale. The difference suspicious. Check your measuring equipment.
between dBm and dBc is used for a finer If the reading is correct, you may have a slipping
analysis of the causes for reduced or bad bearing ring.

SPM - Data Acquisition General Rules
Shock Pulse Bearing Monitoring using a hand held probe
Data acquisition is a simple process
You will find dBi (Decibel Initial) values for various IR
compressor models and the locations of bearing
probe points in the Specifications & Parts Lists
section of the Diagnostics Reference Manual, so you
can enter dBi into the IR30 without having to
determine the dBi value for the particular bearing(s).
dBi is calculated using the inside diameter of the

bearing (d) in mm and rotative speed (n) in rpm.
Where two different diameter bearings are used on a Hand held
shaft with near equal instrument should be
loads on both ends, an positioned radially to
average of both the bearing housing
diameters is used. The with +/- 5o angle
IR30 calculates Decibel
Initial (dBi once the
diameter of the bearing
and rotative speed are
keyed into the
instrument. Arrow indicates good SPM measuring points
We try to use bearing

housing flange edge
Bearing Data surfaces, since these
TLT on areas have ample depth,
3000 rpm
are free of air or oil
90 dmm dBI 26
passages, and provide a
direct (if somewhat curved)
solid metal path to the
outer race of the subject bearing. More accurate and consistent results are achieved by
installing permanent studs on the unit.
Refer to the following pictures for more information.
Studs are fitted by drilling
and tapping sites with M8
or 5/16” - 18P threads,
1/2” deep, with a 90
No direct Degree entering chamfer.
path It is important to check if
studs are installed
correctly and tightly to the
casing, as the IR30 could Good Bad
provide incorrect readings.
IR30 - SPM measurement using stud clip on probe.

Correct
Position
Air
Pocket

dBm/dBc Interpretation for Rotary Compressors
General Rules SPM in summary
dBm/dBc values are indicators of bearing condition

and lubrication deterioration.
Rule 1
dBm values, on new flooded/oil free compressors,
will run in the 20 to 40 range. dBc is about half the
dBm
Rule 2
dBm values which rise in the 45 range and above,
particularly when unit is loaded, are to be noted.
dBc will also rise, coming close to dBm.
Rule 3
Two consecutive dBm readings at or above 55 in • Shock pulses are pressure waves, generated
700 hours, signal a need to consider bearing in the contact zone between the loaded rolling
overhaul. elements and the raceway.
Rule 4 • Shock pulses are measured using specially
Sudden changes are to be especially noted and tuned transducer which amplifies the shock
monitoring frequency "doubled up". A cracked or signal and filters out machine vibration
loosened inner race will result in such drastic • A shock pulse pattern consists of a rapid
changes, and must receive immediate attention. sequence of strong and weak pulses
Rule 5 • dBc (Decibel Carpet) is the large number of
Oil Free Compressors will display consistent dBm relatively weak shock pulses
of 10, 15 points higher than dBc in normal running • dBm (Decibel Max) are the few strong pulses
condition, loaded or unloaded. in the pattern.
Rule 6 Ingersoll-Rand’s units have a number of

Flooded (Contact Cooled) single stage units seem bearings per casing, the shock pulse emissions
to display closer dBm/dBc points than oil free, and radiate and overlap as they are read from the
when running unloaded dBm/dBc will be equal to casing flanges; therefore, we use the following
or higher than loaded. When gas load is relieved, guide.
rotors seem to become more unstable and "rattle
around" in the bearing clearances. Bad Condition - dBm is above 55
Rule 7
Caution zone - dBm is between 45 - 55
Flooded two stage units display dBm/dBc loaded Good condition - dBm is between 20 - 45
points consistent with single stage and oil free
machines. However, unloaded dBm/dBc seem to • If dBm is above 55 another reading needs to be
run at, or considerably higher than, loaded figures. taken in 700 hours.
Therefore, on flooded units, loaded dBm/dBc • If the dBm stays above 55, the unit qualifies for
figures are to be considered dominant decision a bearing overhaul.
points. Drive motor bearings behave in a similar
manner. Do not give the verdict “bearing damage” before
making a further investigation.
Rule 8
Two stage units have four bearing points per As a first measure,
casing. The shock pulse emission from the four
• see if the peak indicator is
points radiates and overlaps as it is read from the
blinking.
casing flanges. However, trending, and observing
• use the probe transducer to
loaded dBm/dBc using these guidelines should
measure on and outside of the bearing housing
yield accurate indications of repair requirements.
to identify the shock pulse source.
• Make sure that TLT is above 15.

dBm/dBc Interpretation for Rotary Compressors
For specific maxiumum dBm values of newly started
units for different size airends, refer to dBMax values The effect of different lubricants, their quality,
in Section 4.4 viscosity, supply to the rolling interface, etc., on an
individual bearing can be immediately studied by
If you lack specifics for any particular model, comparing the resulting dBc numbers.
use:
• 25 dBi for contact cooled rotary units,and The high dBc number reveals poor lubrication films
• 35 dBi for oil free units. which are due to mechanical faults, such as
misaligned shafts, unround bearing housings or
This applies to competitive machines as well as IR installation faults.
units.
SPM Reading Indications
Early damage detection
The main purpose of bearing condition
High dBm Bearing Damage
measurements is the detection of individual
damaged bearings in time for a planned
replacement. This method is less expensive and
more reliable than periodic replacements, because a
bearing that has not failed before its scheduled High dBc Poor Oil Film Film
replacement is likely to be serviceable for a long
time.
Thus, bad bearing condition can be shown by a

single reading. Systematic measurements over a
Low dBc Adequate Oil Film
period of time will then provide a reliable basis for
selecting suitable replacement dates. Readings of
the following patterns can provide indications of
bearing damage, lubrication and bearing installation
problems.
Bearing Damage Lubrication Bearing Installation
The fact that the service life of bearings is mainly

dependent on lubrication is well known.
Very large sums can be saved if bearing life can be
extended by improving lubrication. There is a
relationship between the measured shock pulse
pattern and the lubrication condition of the bearing.
The IR30 displays a value called dBc (decibel

carpet) which decreases in proportion with the
thickness of the lubricant film between the rolling
elements and the raceway in the loaded part of the
bearing.

Vibration Severity Monitoring (VSM)
Vibration Severity Measurement

General machine vibration
increases when something is
loose, broken or out of balance.
Vibration severity readings
supply valuable information
about the general condition of
the unit.
VIB
ISO 10816
Class 3 2/76
mm/s
VIB V
• Vibration severity is defined as RMS value of

vibration velocity (mm/s, inch/s) in the
frequency range of 3 to 1000Hz.
• The evaluation consists of a comparison of the
measured value with vibration limits to
specification ISO 10816, which classifies
vibration severity into six grades, Class 1 to 6. VIB A
• IR has chosen Class 3 for its full range of H
machines. Class 3 applies to large machines VIB
on rigid foundations.
• Indications: up to 4.5mm/s acceptable; 4.5 -
11mm/s caution; above 11mm/s - warning.
• Vibration velocity is a measure for general
machine condition.
• By measuring in three directions you can get
indication of the causes for increased vibration:
VIB H: most representative for balance

condition
VIB V: most
representative for
structural weakness
VIB A: most
representative for faulty
alignment and bend
shafts.

IR30 - Trending
Decision making is based on the data acquired.

This consists of operating the machine in loaded
and unloaded condition, while measuring dBM/
dBC values with the IR30.
Each measuring point can be pre-determined and

the route stored in the IR30 Logger for later
acquisition, downloading to a PC and printing.
Electronic recording requires use of “Condmaster
Pro” software which comes with the IR30 Logger
Kit.
Data is taken:
From the Condmaster to the IR30 and data is acquired from

Pro software Logger the machine.
then downloaded from

the IR30 Logger
for 1). Trend Analysis
2). Database to the Condmaster Pro
3). Report writing software
Manual recording of data can also be done on

paper logs, designed by the user to suit the
purpose.
Normally, data is taken monthly for the first three

months of operation of a new machine, then
quarterly.

IR30 - Trending
Upload/Download
Acquisition process process
Decision Making Process

Condmaster Pro Software
Data Management with Condmaster Pro
Software
Condmaster Pro software provides an effective
means of reducing the administrative work
connected with large scale condition monitoring. It
supplies data entry forms, graphic displays of
measurements and alarm lists for bearings in bad
condition.
Work schedules for any desired time span can be

printed, including measuring point numbers,
instrument settings, last readings and space to
enter current results.
The user can store bearing data, measuring

schedules and readings.
Database
Decibel Trending
Alarm Indication

IR30 - Success Stories
IR30 success stories from China
Guangzhou Air Center recommended an airend
exchange program. The customer accepted the
Case Study 1 recommendation and the airend was changed
during a weekend.
Shanghai Air Center, ASG China
During overhaul it was found that bearings were
In September, Service Engineer Mr. He Minghua, worn and the rotor scratched. The air end would
visited Shanghai No. 5 Steel Mill, which has 5 have been damaged in a short period of time.
ML250 units .
Using the IR 30, he established that the vibration

on one air end was abnormally high. After
consultation with the customer the airend was
rebearing in the Air Center.
This air end would have

been damaged within 2
months, and would have
cost the customer over
US$15,000 in parts and over
US$50,000 per day of lost
production.
The IR30 helped the Air Center to bring in

revenue of US$4,000, built customer confidence
and satisfaction and secured further business.
Case Study 2
Guangzhou Air Center, ASG China
Over a 6 month period, Guangzhou Air Center,

used IR 30 for 35 customers and on over 130
units of rotary compressors.
IR 30 is playing a key role in closing deals for

overhaul, air end rebearing & rebuilding, valued
at over US$ 40,000.
For example, one customer

had 4 units of EP100, all of
them had run over 35,000
hours (since November,
1990) and they had no
intention of overhauling the
air ends.
SPM checks established that the dBM was at it’s

limit. If one unit stopped the customer would have
lost over US$25,000 per day.

IR30 - Introduction
Short Test
1 The basic principle of Shock Pulse Method is:
2 What does the abbreviated term dBi stand for?
3 What does the abbreviated term dBm stand for?
4 What does the abbreviated term dBc stand for?
5 If the dBi of a particular shaft is not known, describe briefly what two facts are
needed and then how dBi can be determined.
6 The IR30 instrument is capable of what two types of machinery condition

monitoring?
a)
b)
7 Decribe briefly the conditions required for a clean, solid shock pulse signal to
be transmitted from the outside diameter of the bearing to the stud location.
8 Why do sudden changes in dBC/dBM values need to be especially noted?
9 What is Condmaster Pro and how can it be applied with the IR30 Logger?
10 Why are dBm/dBc values are higher during compressor unloaded operation?

SPM Measuring Points for Sierra Compressors Section 14
General Guide
Sierra Measuring Points

On Sierra Compressors, we take readings on male
and female rotor bearings on drive and non-drive ends
and bullgear bearings, when the unit is loaded and
unloaded.
We also recommend taking SPM readings on the

motor drive and non-drive end.
r
ea
HPF2 llg
Bu
HPM2
HPM1
HPF1 LPM2
LPF2
LPM1
LPF1
LP
M1
Monitoring
LP Studs
F1

CD8 Air End
LPM1
LPF1

CD8 Air End
LPM2
LPF2

CD8 Air End
HPF1
HPM1

CD14 Air End
BG1
LPM
2
LPF2

CD14 Air End
LPM1
LPF1

CD14 Air End
HPM1
HPF1

CD14 Air End
HPM2
HPF2

Shock Pulse Data Acquisition Section 14
Nirvana—Oil Free Compressor
90KW/125HP - 160KW/200HP Units
Shock Pulse data acquisition procedure is the same
for either model of Nirvana.
Five points will be measured:
DBI Data
LPM1 LPM2 HPM1 HPM2 BG

IRN90KW / 125HP-OF 33 33 36 36 20
IRN110KW/150HP-OF 34 34 37 37 26
IRN132KWHP-OF(ESA) Only 34 34 37 37 26
IRN160KW/200HP-OF 36 36 39 39 26
Procedure:
Compressor should be running at or near maximum
speed and pressure.
Set DBI in the instrument, and acquire data in the
normal manual manner outlined in APDD 741 or
APDD 766.
IR30 – Data Acquisition Page 45

©2003 Ingersoll-Rand Company
Date of Issue: November 2003
Operation and
Maintenance Manual

IRN90–160K–OF
IRN125–200H–OF
UNCONTROLLED COPY – for reference only
OPERATION AND MAINTENANCE MANUAL
TM
N125–200H–OF SERIAL No : TNXXXXU03180 –>

Ensure that the operator reads and understands the
decals and consults the manuals before maintenance or N90K–OF SERIAL No : 2653001 –>
operation.
Ensure that the Operation and Maintenance manual is N110K–OF SERIAL No : 2663001 –>
not removed permanently from the machine.
N132K–OF SERIAL No : 2673001 –>
trained, competent and have read the Maintenance
Manuals. N160K–OF SERIAL No : 2683001 –>
C.C.N. : 22310387
DATE : JANUARY 2004
REV. :B
Machine models represented in this manual may be used in various locations world–wide. Machines sold and
shipped into European Union Territories require that the machine display the EC Mark and conform to various
directives. In such cases, the design specification of this machine has been certified as complying with EC directives.
Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being
rendered invalid. A declaration of that conformity follows:
EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES
98/37/EC, 93/68/EEC, 89/336/EEC
WE,
INGERSOLL–RAND COMPANY LIMITED

SWAN LANE
HINDLEY GREEN
WIGAN WN2 4EZ
UNITED KINGDOM
DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY,
THE PRODUCT(S)
IRN90K–OF IRN110K–OF IRN132K–OF IRN160K–OF
TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS

OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.
EN29001, EN292, EN60204–1, EN1012–1, EN61000–6
ISSUED AT HINDLEY GREEN ON 01/01/2004 BY H.SEDDON, QUALITY ASSURANCE

MANAGER.
H. SEDDON
EC Pressure Equipment Directive and Related Regulations

We declare that this product has been assessed according to the Pressure Equipment Directive
(97/23/EC) and, in accordance with the terms of this Directive, has been excluded from the scope
of this Directive.
It may carry ”CE” marking in compliance with other applicable EC Directives.
01/04
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 twenty four months from the date of placing the Equipment in operation
or thirty months from the date of shipment from the factory, whichever shall first occur (see extended airend
warranty). The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to
the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable
repair to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has
stored, installed, maintained and operated such Equipment in accordance with good industry practices and has
complied with specific recommendations of the Company. Accessories or equipment furnished by the Company,
but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to the Company and
which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or
adjustments to the Equipment or any costs of labor performed by the Purchaser or others without Company‘s prior
written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance
warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period
of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company
in writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.
Note that this is Ingersoll–Rand standard warranty. Any warranty in force at the time of purchase of the compressor
or negotiated as part of the purchase order may take precedence over this warranty.
CONTENTS
CONTENTS PAGE CONTENTS PAGE
1.0 CONTENTS 1 8.0 GENERAL INFORMATION 26

8.1 Technical information
2.0 FOREWORD 2
8.2 Installation drawing
3.0 ABBREVIATIONS & 4 8.3 Process and
SYMBOLS instrumentation diagram
8.4 Electrical schematic
4.0 PURCHASE ORDER 5
DETAILS 8.5 General description
9.0 OPERATING 62
5.0 SAFETY 6 INSTRUCTIONS
5.1 Safety instructions 9.1 Basic operation
5.2 Safety precautions 9.2 Intellisys controls
5.3 Text decals 9.3 Display screen
5.4 Graphic form and meaning 9.4 Current status screen
of ISO symbols 9.5 Main menu
9.6 Operator setpoints
6.0 RECEIPT AND HANDLING 18
9.7 Options
6.1 Receipt
9.8 Sensor calibration
6.2 Unpacking and handling
9.9 Alarm history
9.10 Clock functions
7.0 INSTALLATION 19
9.11 Energy status messages
7.1 Location in plant
9.12 Warnings
7.2 Discharge and condensate
piping 9.13 Service warnings
7.3 Electrical 9.14 Initial check alarms
7.4 Watercooled units 9.15 Alarms
7.5 Sea watercooled units
10.0 MAINTENANCE 77
7.6 Outdoor sheltered
installation 10.1 Maintenance prompts
10.2 Maintenance chart
10.3 Maintenance procedures
10.4 Routine maintenance
11.0 FAULT FINDING 85
IRN90–160K–OF & IRN125–200H–OF 1

2.0 FOREWORD
Machine models represented in this manual may be Details of approved equipment are available from
used in various locations worldwide. Machines sold and Ingersoll–Rand Service departments.
shipped into European community countries requires
that the machine display the EC Mark and conform to
This machine has been designed and supplied for use
various directives. In such cases, the design
only in the following specified conditions and
specification of this machine has been certified as
applications:
complying with EC directives. Any modification to any
. Compression of normal ambient air containing no
part is absolutely prohibited and would result in the CE known or detectable additional gases, vapors or
certification and marking being rendered invalid. particles
. Operation within the ambient temperature range
The contents of this manual are considered to be specified in the GENERAL INFORMATION section of
proprietary and confidential to Ingersoll–Rand and this manual.
should not be reproduced without the prior written
permission of Ingersoll–Rand. IF IN DOUBT CONSULT SUPERVISION .
Nothing contained in this document is intended to The company accepts no responsibility for errors in
extend any promise, warranty or representation, translation of this manual from the original English
expressed or implied, regarding the Ingersoll–Rand version.
products described herein. Any such warranties or
other terms and conditions of sale of products shall be
in accordance with the standard terms and conditions The design of this Compressor package and
of sale for such products, which are available upon certain features within it are covered by patents
request. held by Ingersoll–Rand and patents pending
SSR ULTRA COOLANT is a registered trademark of
This manual contains instructions and technical data to Ingersoll–Rand Company USA.
cover all routine operation and scheduled maintenance INTELLISYS is a registered trademark of
tasks by operation and maintenance staff. Major Ingersoll–Rand Company USA.
overhauls are outside the scope of this manual and
should be referred to an authorized Ingersoll–Rand HPMT, HYBRID PERMANENT MAGNETT and HPM
service department. Logo are trade marks registered by MOTEURS LE-
ROY–SOMER
All components, accessories, pipes and connectors  COPYRIGHT 2004
added to the compressed air system should be: INGERSOLL–RAND COMPANY
. of good quality, procured from a reputable
manufacturer and, wherever possible, be of a type
approved by Ingersoll–Rand.
. clearly rated for a pressure at least equal to the
machine maximum allowable working pressure.
. compatible with the compressor oil.
. accompanied with instructions for safe installation,
operation and maintenance.
Ingersoll–Rand reserves the right to make changes and

improvements to products without notice and without
incurring any obligation to make such changes or add
such improvements to products sold previously.
2 IRN90–160K–OF & IRN125–200H–OF

2.0 FOREWORD
WARNING
The use of the machine in any of the situation types listed in table 1:–
a) Is not approved by Ingersoll–Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll–Rand.
TABLE 1
WARNING – NOT PERMITTED
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption.
Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION
SECTION of this manual.
Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or
vapors.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY EXPLOSIVE
ATMOSPHERES, INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR VAPOURS MAY BE
PRESENT.
Use of the machine fitted with non Ingersoll–Rand approved components.
Use of the machine with safety or control components missing or disabled.
Connection to an electrical supply of incorrect voltage and/or frequency.
WARNING
The use of repair parts other than those included within the Ingersoll–Rand approved parts list may create
hazardous conditions over which Ingersoll–Rand has no control. Therefore Ingersoll–Rand cannot be held
responsible for equipment in which non–approved repair parts are installed.
WARNING
The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such
as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with
cardiac pacemakers, defibrillators or other implanted electronic medical device.
WARNING
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the
internal capacitors store a potentialy lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt
any work on the drive unless trained. There are no user serviceable items behind the cover.
NOTICE
The manual is intended for worldwide use and contains both metric and imperial data where required.
IRN90–160K–OF & IRN125–200H–OF 3

3.0 ABBREVIATIONS & SYMBOLS
#### Contact Ingersoll–Rand for serial number

–>#### Up to Serial No.
####–> From Serial No.
* Not illustrated
† Option
NR Not required
AR As required
SM Sitemaster/Sitepack
HA High ambient machine
WC Watercooled machine
AC Aircooled machine
ERS Energy recovery system
T.E.F.C. Totally enclosed fan cooled motor (IP54)
O.D.P. Open drip proof (motor)
ppm parts per million
pt Brazil
zh China
de Germany
da Denmark
es Spain
fi Finland
fr France
en Great Britain (English)
it Italy
nl Holland
no Norway
pt Portugal
sv Sweden
en United States
4 IRN90–160K–OF & IRN125–200H–OF

4.0 PURCHASE ORDER DETAILS
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:
IRN90–160K–OF & IRN125–200H–OF 5

5.0 SAFETY
5.1 SAFETY INSTRUCTIONS
Safety instructions in the operators manual are Ensure that the Operation and Maintenance manual,
bold–faced for emphasis. The signal words DANGER, and the manual holder, are not permanently removed
WARNING and CAUTION are used to indicate hazard from the machine.
seriousness levels as follows.
Ensure that the operator reads and understands the trained, competent and have read the Maintenance
decals and consults the manuals before maintenance Manuals.
or operation.
DANGER CAUTION
Indicates the presence of a hazard which WILL cause Indicates the presence of a hazard which WILL or can
serious injury, death or property damage, if ignored. cause injury or property damage, if ignored.
WARNING NOTICE
Indicates the presence of a hazard which CAN cause Indicates important set–up, operating or maintenance
serious injury, death or property damage, if ignored. information.
5.2 SAFETY PRECAUTIONS
General Information All air pressure equipment installed in or connected to

the machine must have safe working pressure ratings
Compressed air and electricity can be dangerous. of at least the machine rated pressure.
Before undertaking any work on the compressor,
ensure that the electrical supply has been isolated, If more than one compressor is connected to one
locked off, tagged and the compressor has been common downstream plant, effective check valves and
relieved of all pressure. isolation valves must be fitted and controlled by work
procedures, so that one machine cannot accidentally
Make sure that all protective covers are in place and be pressurized / over pressurized by another.
that the canopy/doors are closed during operation.
If a safety valve is installed between the isolation valve
Installation of this compressor must be in accordance and the compressor, it must have sufficient capacity to
with recognized electrical codes and any local Health
relieve the full capacity of the compressor(s).
and Safety Codes.
If the discharged air is to be ultimately released into a
Use only safety solvent for cleaning the compressor confined space, adequate ventilation must be provided.
and auxiliary equipment.
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
Compressed air mineral oils. Metal bowls should be used on a
Ensure that the machine is operating at the rated pressurized system.
pressure and that the rated pressure is known to all When using compressed air always use appropriate
relevant personnel. personal protective equipment.
6 IRN90–160K–OF & IRN125–200H–OF

5.0 SAFETY
All pressure containing parts, especially flexible hoses Never give fluids or induce vomiting if the patient is
and their couplings, must be regularly inspected, be unconscious or having convulsions.
free from defects and be replaced according to the
The above information contains data supplied in
Manual instructions.
support of United Kingdom Control of Substances
Compressed air can be dangerous if incorrectly Hazardous to Health (C.O.S.H.H.) regulations
handled. Before doing any work on the unit, ensure that
all pressure is vented from the system and that the
machine cannot be started accidentally. Transport
Avoid bodily contact with compressed air. When loading or transporting machines ensure that the
specified lifting and tie down points are used.
The safety valve located in the interstage and
aftercooler must be checked periodically for correct It is recommended that the machine be moved using
operation. the fork lift slots in the machine base.
Refer to section 8 for reference information.

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 Electrical
be investigated immediately. 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
Materials working on the electrical system, be sure to remove
The following substances are used in the voltage from the system by using a manual disconnect
manufacture of this machine and may be hazardous switch. A circuit breaker or fuse safety switch must be
to health if used incorrectly: provided in the electrical supply line leading to the
. preservative grease compressor.
. rust preventative Those responsible for installation of this equipment
. compressor oil must provide suitable grounds, maintenance clearance
and lightning arrestors for all electrical components in
accordance with National and Local code
requirements.
WARNING Keep all parts of the body and any hand–held tools or
AVOID INGESTION, SKIN CONTACT AND other conductive objects, away from exposed live parts
INHALATION OF FUMES of the compressor electrical system. Maintain dry
footing, stand on insulating surfaces and do not contact
any other portion of the compressor when making
For further information, request and consult the coolant adjustments or repairs to exposed live parts of the
Material Data Sheet (UK ACGP 011/96 –ULTRA compressor electrical system.
COOLANT ACGP 029/90–food grade coolant. For
Close and lock all access doors when the compressor
USA served areas, use MSDS sheet APDD 236) from
is left unattended.
your local IR office, Distributor or Air Center.
Do not use extinguishers intended for Class A or Class
Should compressor oil come into contact with the B fires on electrical fires. Use only extinguishers
eyes, then irrigate with water for at least 5 minutes. suitable for class BC or class ABC fires.
Should compressor oil come into contact with the
Attempt repairs only in clean, dry, well lighted and
skin, then wash off immediately. ventilated areas.
Consult a physician if large amounts of compressor
Connect the compressor only to electrical systems that
oil are ingested.
are compatible with its electrical characteristics and
Consult a physician if compressor oil is inhaled. that are within it’s rated capacity.
IRN90–160K–OF & IRN125–200H–OF 7

5.0 SAFETY
Condensate disposal Burn in an approved incinerator, or according to local
area or country regulations.
As waste water regulations vary by country and region
it is the responsibility of the user to establish the For further information, consult ULTRA COOLANT
limitations and regulations in their particular area. Material Data Sheets ACGP 011/96 or APDD 236.
Ingersoll–Rand and its associated distributors are
happy to advise and assist in these matters.
Oil disposal
Steps to be taken in the case of spillage: Soak up with
a suitable absorbent material, then sweep into a plastic
bag for disposal.
WARNING
internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt
WARNING
There is a high discharge air temperature shutdown function built into each compressor. It is factory
preset. Refer to the operation section for shutdown temperatures. This function should be checked at
regular intervals for proper operation, once a month is recommended. Refer to maintenance section.
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.
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.”
WARNING
No portable communication devices emitting more than 7.5 volts per metre in the frequency range from 250
MHz to 280 MHz should be operated within 5m (16.5ft) of the unit.
WARNING
WARNING
The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas.
If such an application is required then all local regulations, codes of practice and site rules must be observed.
To ensure that the machine can operate in a safe and reliable manner, additional equipment such as gas
detection and intake (shut–off) valves may be required, dependant on local regulations or the degree of risk
involved.
8 IRN90–160K–OF & IRN125–200H–OF

5.0 SAFETY
Depending on point of manufacture and point of use, the compressor and this manual will show symbols
from the following sections. Compressors for use within the European Community must be equipped with
symbols from section 5.4. Read and understand thoroughly. Heed warnings and follow instructions. If you
do not understand, inform your supervisor.
5.3 TEXT DECALS
NOTICE WARNING
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.
Hazardous voltage. Can cause severe injury or

death.
DANGER
Disconnect power before servicing.
Lockout/Tagout machine.
WARNING
Discharge air.
Can contain carbon monoxide or other
contaminants. Will cause severe injury or death.
Do not breathe this air.
Rotating fan blade.

Can cause severe injury.
Do not operate without guard in place

Disconnect power before servicing
Lockout/Tagout machine
IRN90–160K–OF & IRN125–200H–OF 9

5.0 SAFETY
CAUTION CAUTION
Incorrect lifting of machine can cause injury or Use of incorrect coolant can cause system
property damage. contamination.
Lift only from base channels Use only SSR ULTRA COOLANT
NOTICE
WARNING
Lift here
High pressure air.

Can cause severe injury or death. WARNING
Relieve pressure before removing filter plugs/caps,
fittings or covers.
39540240 Rev.04
NOTICE Hot surface.

Can cause severe injury.
Air discharge
Do not touch. Allow to cool before servicing.
NOTICE
Rotation
10 IRN90–160K–OF & IRN125–200H–OF

5.0 SAFETY
Air
Rotation Discharge
Rotation 39540257 Rev. 04
Condensate
drain.
39541081 Rev. 04
Electrical
power inlet.
39541354 Rev. 03
WARNING
WARNING – HIGH VOLTAGE

Do not attempt any work.
Read manual.
Trained service personnel only.
Remove electrical supply.
Wait 15 minutes.
Check for zero voltage. Hazardous voltage. Can cause severe injury or
Proceed with caution. death.
Only use factory supplied inlet for incoming power. See

Operators / Instruction Manual.
39543764 Rev. 03
WARNING
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
Moving parts. Can cause severe injury. National Electrical code or applicable local codes.)
Do not operate with covers removed. Refer to the Instruction / Operators Manual before
Service only with machine blocked to prevent turn over. performing any maintenance.
39540224 Rev. 04 39540158 Rev.05
IRN90–160K–OF & IRN125–200H–OF 11

5.0 SAFETY
IMPORTANT
Use 75°C copper wire only. Before starting this air compressor unit the shipping
brace(s) must be removed.
Save the brace(s) for future use.
Refer to Operators / Instruction Manual.
12 IRN90–160K–OF & IRN125–200H–OF

5.0 SAFETY
5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory Information / Instructions Warning
WARNING: Electrical shock risk. WARNING – Pressurized WARNING – Hot surface.

component or system.
WARNING – Air/gas flow or Air

WARNING – Pressure control. WARNING – Corrosion risk.
discharge.
Do not remove the Operating and

WARNING – Pressurized vessel. WARNING – Flammable liquid.
Maintenance manual from this
machine.
WARNING – Rotor magnetic field

can affect pacemakers.
IRN90–160K–OF & IRN125–200H–OF 13

5.0 SAFETY
0C
WARNING – Do not undertake any

WARNING – Consult the WARNING – For operating
maintenance on this machine
Operation and Maintenance temperature below 0C, consult
until the electrical supply is
manual before commencing any the Operation and Maintenance
disconnected and the air pressure
maintenance. manual.
is totally relieved.
Read the Operation and

Maintenance manual before Do not operate the machine without
Do not stack.
operation or maintenance of this the guard being in place.
machine is undertaken.
Do not stand on any service valve or Do not operate with the doors or Do not use fork lift truck from this
other parts of the pressure system. enclosure open. side.
Do not breathe the compressed air Do not open the service valve before
No naked lights.
from this machine. the air hose is attached.
14 IRN90–160K–OF & IRN125–200H–OF

5.0 SAFETY
Use fork lift truck from this side only. Emergency stop. Tie down point
Lifting point. On (power). Off (power).
SET SEQUENCER STATUS LOAD
SEQUENCER (AUTOMATIC
COMPRESSOR OFF LOAD (UNLOADED)
CONTROL)
RESET COMPRESSOR STATUS MODULATE
MALFUNCTION POWER FOULED FILTER
POWER INLET ELECTRIC MOTOR HOURS
IRN90–160K–OF & IRN125–200H–OF 15

5.0 SAFETY
OIL SEPARATOR PRESSURE AIR DISCHARGE
PRESSURIZED TANK ON / OFF CYCLE OIL FILTER
AIR FILTER ON / OFF PUSH BUTTON OIL PRESSURE
AIR PRESSURE STAR DELTA IEC 617–7 AUTOMATIC RESTART
HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED
OIL DRAIN CONDENSATE DRAIN PRESSURE CONTROL
MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE
16 IRN90–160K–OF & IRN125–200H–OF

5.0 SAFETY
BELT TENSION FILTER MOTOR LUBRICATION
FRAGILE KEEP DRY THIS WAY UP
USE NO HOOKS NO SIDE CLAMPS ROTATION
POWER INLET (AC) WATER IN WATER OUT
TRAINED SERVICE
WAIT TIME CHECK ZERO VOLTS
PERSONNEL
IRN90–160K–OF & IRN125–200H–OF 17

6.0 RECEIPT / HANDLING
6.1 RECEIPT
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 unpacked. Obtaining the deIivery
persons 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 lR, 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
6.2 UNPACKING AND HANDLING
The compressor will normally be delivered with a polyethylene or other cover. If a knife has to be used to remove this
cover, ensure that the exterior paintwork of the compressor is not damaged.
Incorporated within the base of the compressor are slots to enable a fork lift truck to move the machine. Ensure truck
forks are fully engaged on both sides. Alternatively a special lifting frame can be utilized to enable a crane or hoist to
move the compressor. Use only marked lifting points.
Once the packaging and pallet are discarded and the unit is in its final position, remove the transit brackets from
the resilient mounts and store for future use or discard.
18 IRN90–160K–OF & IRN125–200H–OF

7.0 INSTALLATION
For technical information see section 8.0.
7.1 LOCATION IN PLANT
Ensure that the correct tie down points are used. It is recommended that provision be made for lifting
heavy components during major overhaul. Use only
For major overhaul (i.e. motor removal) position the
lifting points provided.
machine to obtain lifting access e.g. fork lift truck.
Minimum space in front of control panel door as
See diagram in reference section for minimum space
required by National or Local codes must be
requirements for normal operation and maintenance.
maintained.
Ambient temperatures higher than 46C (115F) must
be avoided as well as areas of high humidity. The compressor can be installed on any level floor
capable of supporting it. A dry, well ventilated area
Consider also the environment surrounding or near the where the atmosphere is as clean as possible is
compressor. The area selected for the location of the recommended.
compressor should be free of dust, chemicals, metal
filings, paint fumes and overspray. Sufficient space all round and above the compressor
must be allowed, to enable the effective removal of the
Hard surfaces may reflect noise with an apparent cooling air which, in turn, will reduce the risk of
increase in the decibel level. When sound transmission recirculating the cooling air back through the
is important, a sheet of rubber or cork can be installed compressor.
beneath the machine to reduce noise. Flexible piping
may be required.
CAUTION
A minimum of 1 m (3.3ft) all round the compressor is recommended. If headroom is restricted, then the
exhaust should be ducted or deflected away from the machine.
Screw type compressors [1] should not be installed in air systems with reciprocating compressors without
means of isolation such as a common receiver tank. It is recommended that both types of compressor be
piped to a common receiver using individual air lines.
The machine is shipped with the shipping restraints in place. Ensure that these are removed to allow free
movement of the drive assembly during operation. Each restraint is painted yellow.
NOTICE
If ducting is fitted to the machine, the sump breather needs to be piped outside the enclosure to avoid
back pressure into the compression module.
IRN90–160K–OF & IRN125–200H–OF 19

7.0 INSTALLATION
7.2 DISCHARGE AND CONDENSATE PIPING
It is essential when installing a new compressor [1], to The built–in intercooler and aftercooler reduce the
review the total air system. This is to ensure a safe and discharge air temperature below the dew point (for most
effective total system. One item which should be ambient conditions), therefore, considerable water
considered is liquid carryover. Installation of air dryers vapor is condensed. To remove this condensation,
[3] is always good practice since properly selected and each compressor with built–in aftercooler is furnished
installed they can reduce any liquid carryover to zero. with two moisture separator/solenoid valve
combinations. Since these solenoid valves discharge
A receiver (2) may be necessary to ensure that the total at different pressures, it is extremely important that they
system volume is not less than 2.0 U.S.Gallons per are piped separately into an open drain.
rated delivery C.F.M
A dripleg assembly and isolation valve should be
Discharge piping should be at least as large as the mounted near the compressor discharge. A drain line
discharge connection of the compressor. All piping and should be connected to the condensate drain in the
fittings should be suitably rated for the discharge base.
pressure.
IMPORTANT: The drain line must slope downward
It is important to install an isolation valve [7] within 3 feet from the base to work properly. For ease of inspection
(1 meter) of the compressor.
of the automatic drain trap operation, the drain piping
It is good practice to install line filters [4]. should include an open funnel.
Include a means [6] to vent the discharge pipework
downstream from the machine’s check valve and
upstream of the first system isolation valve [7]. NOTICE
When two rotary units are operated in parallel, provide For low volume systems, compressor response time
an isolation vaIve and drain trap for each compressor may need adjusting. Contact your local IR service
before the common receiver. agent.
CAUTION
The use of plastic bowls on line filters and other plastic air line components without metal guards can be
hazardous. Their safety can be affected by either synthetic oils or the additives used in mineral oils. From
a safety standpoint, metal bowls should be used on any pressurized system.
NOTICE
Do not use the compressor to support the discharge pipe.
20 IRN90–160K–OF & IRN125–200H–OF

7.0 INSTALLATION
7.3 ELECTRICAL
CAUTION
This procedure should only be carried out by a qualified electrician, electrical contractor or your local
Ingersoll–Rand Distributor or Air Center.
The compressor and drive should be properly grounded The feeder cable must be suitably glanded into the
/ earthed in accordance with Local and National Code power drive module (P.D.M.) electrical box to ensure
requirements. that dirty air does not by–pass the filter pads or degrade
the cooling air flow.
Installation of this compressor must be in accordance
with recognized electrical codes and any local Health On completion of electrical installation, check that
and Safety Codes. both the main blower motor and heat sink blower
motor rotations are correct.
The compressor must have its own isolator situated
adjacent to it. The fuse protecting the circuit and the This machine is designed for use in heavy industrial
compressor must be selected in accordance with local environments, where the electricity supply is separated
and national code requirements on the basis of the data from nearby residential and commercial areas. If the
provided in the general information section machine is to be used in the light industrial, residential
or commercial environment where the local supply
Feeder cables should be sized by the
network is shared, further radio frequency (RF)
customer/electrical contractor to ensure that the circuit
screening measures may be required. Consult your
is balanced and not overloaded by other electrical
local distributor/supplier for details of the optional RF
equipment. The length of wiring from a suitable
filter.
electrical feed point is critical as voltage drops may
impair the performance of the compressor. The compressor has a anti–condensation heater and
thermostat in the electrical box. This circuit can be
Cable sizes may vary considerably so the mains
connected to an independent electrical supply of either
terminals will accept up to 50mm2 (1 AWG)
110V or 230V single phase, dependant on the country
(37/45k & 50/60H) and up to 90mm2 (3/0 AWG)
of installation. The supply should be suitable fused and
(55/75k & 75/100H) cable. The N75K–160K and
N100H–200H machines mains terminals will an independent isolator installed adjacent to the
accept 2 x 120mm2 (4/0 AWG) cables. compressor.
This should be done in accordance with local and
Feeder cable connections to incoming terminals
national codes. It is good practice and sometimes
L1–L2–L3 should be tight and clean.
mandatory, to display suitable signs warning that the
The applied voltage must be compatible with the motor machine has two separate electrical supplies which
and compressor data plate ratings. both must be isolated before any work is attempted.
The control circuit transformer has different voltage Alternately it can be supplied from the 110V tapping of
tappings. Ensure that these are set for the specific the control transformer and connected as shown on
applied voltage prior to starting. schematic wiring diagram.
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. If another hole is used, the
original hole must be blocked off.
IRN90–160K–OF & IRN125–200H–OF 21

7.0 INSTALLATION
CAUTION
VERY IMPORTANT
Supply voltage must be kept to a maximum imbalance of 2% on 50Hz and 3% on 60Hz applications. Voltage
imbalances greater than these levels can cause permanent damage to the drive.
Compressor must not be subjected to any voltage spikes or surges in excess of 575V. Exposure to spikes/surges in
excess of 575V can permanently damage the drive. If the possibility of such exists it is recommended that adequate
surge protection is fitted such as an Ingersoll–Rand line reactor. See your local Ingersoll–Rand representative.
Failure of the drive due to voltage spikes, line notching, harmonics or other power quality related problems, will not
be covered by the standard compressor warranty.
The correct type and rating of line input fuse MUST BE fitted onto the customers isolator or breaker close to the
compressor. For Amp rating see technical information in Section 8.1.
Product Identification Fuse Type Fast Acting Class–J, T or Semiconductor type, Current
limiting, Interrupt Rating – 200,000 Amps RMS SYM.
Class – J, Class – T, or Alternate fuse may be used if the time current
Semiconductor characteristics are faster than fuses recommended in
this section.
See your local Ingersoll–Rand representative for a range of fuses and disconnect isolators matched to your particular
machine.
Example of voltage imbalance calculation
U→V 462v
V→W 459v
W→U 453v
V(m) = (462 + 459 + 453) / 3 = 458v
V∆ max = 462 – 453 = 9v
\ = (9 / 458) x 100 = 1.97%
22 IRN90–160K–OF & IRN125–200H–OF

7.0 INSTALLATION
7.4 WATERCOOLED UNITS
Cooling Water Piping Water temperature and pressure gauges should be

installed in the water piping for use in any fault finding
Water piping to and from the compressor package
of the water system. Water pressure should ideally be
must be at least the size of the water connections on
between 3 and 5 bar (43.5 and 72.5 psi) but must not
the machine. Refer to the installation drawing section
be above 10 Bar (145 psi)
for this size. Isolation valves with side drains should
be installed on both the inlet and outlet lines. Also a Water cleanliness is also extremely important. Cleaning
strainer of 2mm–mesh size should be installed on the of coolers as a result of fouling is a customer
inlet line. Strainers are available from Ingersoll–Rand. responsibility. Therefore, it is highly recommended that
Ingersoll–Rand CCN 39116397(additional 95453759 proper water quality must meet the requirements listed
nipple required for KW rated units) in WATER QUALITY RECOMMENDATIONS later in
this section.
Carefully inspect your water system before installing
the compressor package. Ensure that the piping is free Venting the water system
of scale and deposits that may restrict water flow to the
compressor package. At the initial installation or for start–up after draining the
water system proceed to vent the system as follows.
Proper operation of your compressor requires that the
water flow listed below be provided at a maximum 1 Locate the water system vent cocks on top of the
intercooler , aftercooler, and oil cooler.
supply temperature of 46C (115F).
2 Open the water valve(s) allowing water to flow to the
package.
Minimum cooling water
requirement at ambient 3 Open the vent cocks and allow all air to escape from
temperatures, in litres per the system. When water is observed at the vent cocks,
Model Range minute (US gallons per close them.
minute) The system is now vented.
80F / 27C Draining the water system
N125H, N90K 125 (33) Should it become necessary to completely drain the
water system, proceed as follows.
N150H, N110K 144 (38)
1 Disconnect the inlet and discharge water lines from
N132K 160 (42) the connections located at the rear of the unit.
N200H, N150K 182 (48) 2 Locate the intercooler, aftercooler, and oil coolers.
Disconnect the water inlet connections to drain each
cooler. Also, drain any piping between the coolers
and the water shut off solenoid valve (it is normally
closed).
IRN90–160K–OF & IRN125–200H–OF 23

7.0 INSTALLATION
Water quality recommendations To ensure good operation life and performance of the
compressor cooling system, the recommended
Water quality is often overlooked when the cooling acceptable ranges for different water constituents are
system of a water–cooled air compressor is examined.
included below:
Water quality determines how effective the heat
transfer rate, as well as the flow rate will remain during Cooling Water Analysis Chart
the life of the unit. It should be noted that the quality of
water used in any cooling system does not remain
constant during the operation of the system. Substances Test interval Acceptable
Evaporation, corrosion, chemical and temperature concentration
changes, aeration, scale and biological formations Corrosivity Monthly — if Langelier Index
effect the water makeup. Most problems in a cooling (Hardness, pH, stable for 3 to 4 0 to 1
system show up first in a reduction in the heat transfer Total Dissolved months, analyse
rate, then in a reduced flow rate and finally with damage Solids, quarterly.
to the system. Temperature at
Scale: Scale formation inhibits effective heat transfer, inlet Alkalinity)
yet it does help prevent corrosion. Therefore, a thin
uniform coating of calcium carbonate is desired on the Iron Monthly <2 ppm
inner surface. Perhaps the largest contributor to scale Sulphate Monthly <50 ppm
formation is the precipitation of calcium carbonate out
of the water. This is dependent on temperature and pH. Chloride Monthly <50 ppm
The higher the pH value, the greater the chance of scale
formation. Scale can be controlled with water Nitrate Monthly <2 ppm
treatment. Silica Monthly < 100 ppm
Corrosion: In contrast to scale formation is the
problem of corrosion. Chlorides cause problems Desolated Daily — if 0 ppm (as low
because of their size and conductivity. Low pH levels Oxygen stable,analyse as possible)
promote corrosion, as well as high levels of dissolved weekly
oxygen. Oil & Grease Monthly <5 ppm
Fouling: Biological and organic substances (slime)
Ammonia Monthly <1 ppm
can also cause problems, but in elevated temperature
environments such as cooling processes they are not
a major concern. If they create problems with clogging,
commercial shock treatment are available.
24 IRN90–160K–OF & IRN125–200H–OF

7.0 INSTALLATION
7.6 OUTDOOR SHELTERED INSTALLATION
Nirvana compressors are not suitable for outdoor installation.

Installing a Nirvana compressor outside voids the warranty of the compressor.
IRN90–160K–OF & IRN125–200H–OF 25

8.0 GENERAL INFORMATION
8.1 TECHNICAL INFORMATION
Nirvana Model :
IRN90K – OF
GENERAL COMPRESSOR DATA. (1)
Capacity FAD (at stated pressure) Compressor shaft power (at stated
pressure)
psig barg CFM m3/min HP kW
150 10.3 426 12.1 132.8 99.0
145 10.0 438 12.4 132.8 99.0
140 9.7 450 12.7 132.8 99.0
135 9.3 462 13.1 132.8 99.0
130 9.0 474 13.4 132.8 99.0
125 8.6 486 13.7 132.8 99.0
120 8.2 497 14.1 132.8 99.0
115 7.9 509 14.4 132.8 99.0
110 7.6 521 14.8 132.8 99.0
105 7.2 533 15.1 132.8 99.0
100 6.9 545 15.4 132.8 99.0
65 4.5 628 17.8 132.8 99.0
Efficiency and speed data.
Specific shaft power (at stated pressure) Min/Max motor speed

psig barg HP/100CFM kW/m3/min Max Min % Turn down
150 10.3 31.2 8.2 1530 1500 2
145 10.0 30.3 8.0 1566 1500 4
140 9.7 29.5 7.8 1602 1500 6
135 9.3 28.8 7.6 1638 1500 8
130 9.0 28.0 7.4 1674 1500 10
125 8.6 27.3 7.2 1710 1500 12
120 8.3 26.7 7.0 1746 1500 14
115 7.9 26.1 6.9 1782 1500 16
110 7.6 25.5 6.7 1818 1500 17
105 7.2 24.9 6.6 1854 1500 19
100 6.9 24.4 6.4 1890 1500 21
65 4.5 21.1 5.6 2142 1500 30
Operating Characteristics PSIG BAR

Full load target pressure (Maximum) 150 10.3
Full load target pressure (Minimum) 65 4.5
Maximum operating pressure 155 10.7
Minimum operating pressure 65 4.5
26 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN90K – OF
Module data
Primary rotor maximum speed –1st Stage (RPM) 9233
Primary rotor minimum speed – 1st Stage (RPM) 6466
Primary rotor diameter – 1st Stage 5.72 (145.2)
Inches (mm)
Primary rotor maximum speed – 2nd Stage (RPM) 14092
Primary rotor minimum speed – 2nd Stage (RPM) 9868
Primary rotor diameter – 2nd Stage 3.42 (86.7)
Inches (mm)
Cooling Data (115_F/46_C Maximum ambient temperature, 40% RH)
Heat removal @ 100_F/38_C (2) 100 psig 1,000 Btu/hr 1,000 kJ/hr
Intercooler 154 163
Aftercooler 149 157
Oil cooler 19 20
Total 321 339
Aftercooler CTD (3) F (C) 20 (11)

Cooling air flow CFM (m3/min) 14500 (411)
Maximum added static pressure in H2O (Pa) 0.5 (124.5)
Cooling air nT (approximate) F (C) 40 (22)
Lubrication data
Lubrication type Ultra–coolant
Oil–pressure Normal operation psig (barg) 35 (2.4)
Oil–temperature Normal operation F(C) 135 (57)
Oil–pump type positive displacement, gear type
Sump capacity Gallons (Liters) 15 (57)
Total lubrication capacity Gallons (Liters) 17 (64)
Sound Level (4) dB(A)

Standard enclosure 79
Electrical data
Main drive motor (5), (6)

Motor type Hybrid Permanent Magnet (HPM)
Nominal shaft power HP(kW) 120.7 (90)
Motor frame size ODP (IP23) HPM473
Motor service factor 1.25
Full load current at 380V (A) 178.6
Max speed (RPM) 2142
Min speed (RPM) 1500
Efficiency at full speed/power (%) 95.9
Efficiency at min speed/power @150psig (%) 95.3
IRN90–160K–OF & IRN125–200H–OF 27

Nirvana Model :
IRN90K – OF
Fan motor
Motor type Inverter Duty Induction
Installed motor power (=max.shaft power) HP(kW) 10 (7.5)
Cooling fan input power (no ducting) HP(kW) 8.5 (6.3)
Number of poles 6
Fan motor speed at (RPM) 1170
Fan motor frame size IP55(TEFV) 256T
Efficiency at full load IP55(TEFV) 89.6
Fan motor amps at full load 380V (A) 16.9
Fan motor inverter efficiency (%) 96.0
Total package (5)

Total installed package power (main & fan motor) HP(kW) 143.3(106.8)
Full load package absorbed current 380V (A) 195.6
Inverter
Power factor 0.95
Efficiency (%) 97
Construction – General data (7)

Package Dimensions LxWxH Inches(mm) 100.4 x 71.9 x 96
(2550 x 1826 x 2438)
Shipping weight, total package (standard scope) lbs(kg) 7088 (3215)
Discharge air connection BSPT(inches) 2
Condensate drain connection (intercooler) BSPT(inches) 0.38
Condensate drain connection (aftercooler) BSPT(inches) 0.38
Electrical power cable hole diameter inches (mm) 3 (76)
Notes:
1. FAD (Free Delivery) is actual flow rate at the compressor inlet measured at the discharge terminal point of the
package in accordance with ISO 1217 Annex C.
2. Heat removal including latent heat.
3. CTD (Cold Temperature Difference) based on 100F/38C inlet air at 40% relative humidity.
4. Sound levels are “free field conditions” per Pnuerop PN8NTC2.3, +/–3 dB(A).
5. Electrical data based on Ingersoll–Rand IP23 main motor plus TEFV fan motor.
6. Motor rating is maintained up to an altitude of 1,000 metres/3.280 feet above sea level.
7. For details on dimensions and piping connections see the General Arrangement Drawing.
Product improvement is an ongoing process at IR. Data is subject to change without notice.
28 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN110K – OF
pressure)
150 10.3 543 15.4 162.3 121.0
145 10.0 555 15.7 162.3 121.0
140 9.7 567 16.1 162.3 121.0
135 9.3 579 16.4 162.3 121.0
130 9.0 592 16.7 162.3 121.0
125 8.6 604 17.1 162.3 121.0
120 8.3 616 17.4 162.3 121.0
115 7.9 628 17.8 162.3 121.0
110 7.6 640 18.1 162.3 121.0
105 7.2 652 18.5 162.3 121.0
100 6.9 664 18.8 162.3 121.0
65 4.5 681 19.3 145.2 108.3

150 10.3 29.9 7.9 1880 1500 20
145 10.0 29.2 7.7 1918 1500 22
140 9.7 28.6 7.5 1956 1500 23
135 9.3 28.0 7.4 1994 1500 25
130 9.0 27.4 7.2 2032 1500 26
125 8.6 26.9 7.1 2070 1500 28
120 8.3 26.4 6.9 2108 1500 29
115 7.9 25.9 6.8 2146 1500 30
110 7.6 25.4 6.7 2184 1500 31
105 7.2 24.9 6.6 2222 1500 33
100 6.9 24.4 6.6 2260 1500 34
65 4.5 21.3 5.6 2300 1500 35

IRN90–160K–OF & IRN125–200H–OF 29

Nirvana Model :
IRN110K – OF
Module data
Inches (mm)
Inches (mm)
Intercooler 186 196
Aftercooler 184 194
Oil cooler 19 20
Total 388 410

Lubrication data

Electrical data

30 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN110K – OF
Fan motor
Number of poles 6
Total package (5)

Total installed package power (main & fan motor) HP(kW) 172.8 (128.8)
Inverter
Power factor 0.95
Efficiency (%) 97

(2549 x 1825 x 2437)
Notes:
IRN90–160K–OF & IRN125–200H–OF 31

Nirvana Model :
IRN132K – OF
pressure)
150 10.3 658 18.6 194.7 145.2
145 10.0 671 19.0 194.7 145.2
140 9.7 684 19.4 194.7 145.2
135 9.3 696 19.7 194.7 145.2
130 9.0 709 20.1 194.7 145.2
125 8.6 722 20.4 194.7 145.2
120 8.3 735 20.8 194.7 145.2
115 7.9 748 21.2 194.7 145.2
110 7.6 761 21.5 194.7 145.2
105 7.2 774 21.9 194.7 145.2
100 6.9 787 22.3 194.7 145.2
65 4.5 878 24.9 194.7 145.2

150 10.3 29.6 7.8 2240 1500 33
145 10.0 29.0 7.6 2280 1500 34
140 9.7 28.5 7.5 2320 1500 35
135 9.3 28.0 7.4 2360 1500 36
130 9.0 27.5 7.2 2400 1500 38
125 8.6 27.0 7.1 2440 1500 39
120 8.3 26.5 7.0 2480 1500 40
115 7.9 26.0 6.9 2520 1500 40
110 7.6 25.6 6.7 2560 1500 41
105 7.2 25.2 6.6 2600 1500 42
100 6.9 24.7 6.5 2640 1500 43
65 4.5 22.2 5.8 2920 1500 49

32 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN132K – OF
Module data
Inches (mm)
Inches (mm)
Intercooler 225 237
Aftercooler 222 234
Oil cooler 21 22
Total 468 493

Lubrication data

Electrical data

IRN90–160K–OF & IRN125–200H–OF 33

Nirvana Model :
IRN132K – OF
Fan motor
Number of poles 6
Total package (5)

Total installed package power (main & fan motor) HP(kW) 205.2 (153)
Inverter
Power factor 0.95
Efficiency (%) 97

(2549 x 1825 x 2437)
Notes:
34 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN160K – OF
pressure)
150 10.3 805 22.8 236.0 176.0
145 10.0 816 23.1 236.0 176.0
140 9.7 828 23.4 236.0 176.0
135 9.3 839 23.8 236.0 176.0
130 9.0 851 24.1 236.0 176.0
125 8.6 862 24.4 236.0 176.0
120 8.3 880 24.9 236.0 176.0
115 7.9 898 25.4 236.0 176.0
110 7.6 903 25.6 233.1 173.8
105 7.2 903 25.6 229.6 171.2
100 6.9 903 25.6 226.1 168.6
65 4.5 903 25.6 201.1 149.9

150 10.3 29.3 7.7 2710 1500 45
145 10.0 28.9 7.6 2750 1500 45
140 9.7 28.5 7.5 2790 1500 46
135 9.3 28.1 7.4 2830 1500 47
130 9.0 27.7 7.3 2870 1500 48
125 8.6 27.4 7.2 2910 1500 48
120 8.3 26.8 7.1 2950 1500 49
115 7.9 26.3 6.9 2990 1500 50
110 7.6 25.8 6.8 3000 1500 50
105 7.2 25.4 6.7 3000 1500 50
100 6.9 25.0 6.6 3000 1500 50
65 4.5 22.3 5.9 3000 1500 50

IRN90–160K–OF & IRN125–200H–OF 35

Nirvana Model :
IRN160K – OF
Module data
Inches (mm)
Inches (mm)
Intercooler 261 275
Aftercooler 257 271
Oil cooler 25 26
Total 542 572

Lubrication data

Electrical data

36 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN160K – OF
Fan motor
Number of poles 6
Total package (5)

Inverter
Power factor 0.95
Efficiency (%) 97

(2549 x 1825 x 2437)
Notes:
IRN90–160K–OF & IRN125–200H–OF 37

Nirvana Model :
IRN125H – OF
pressure)
150 10.3 444 12.6 137.5 102.5
145 10.0 456 12.9 137.5 102.5
140 9.7 468 13.2 137.5 102.5
135 9.3 480 13.6 137.5 102.5
130 9.0 492 13.9 137.5 102.5
125 8.6 504 14.3 137.5 102.5
120 8.3 515 14.6 137.5 102.5
115 7.9 527 14.9 137.5 102.5
110 7.6 539 15.3 137.5 102.5
105 7.2 551 15.6 137.5 102.5
100 6.9 563 15.9 137.5 102.5
65 4.5 646 18.3 137.5 102.5

150 10.3 31.0 8.2 1590 1500 6
145 10.0 30.2 7.9 1626 1500 8
140 9.7 29.4 7.7 1662 1500 10
135 9.3 28.7 7.5 1698 1500 12
130 9.0 28.0 7.4 1734 1500 13
125 8.6 27.3 7.2 1770 1500 15
120 8.3 26.7 7.0 1806 1500 17
115 7.9 26.1 6.9 1842 1500 19
110 7.6 25.5 6.7 1878 1500 20
105 7.2 25.0 6.6 1914 1500 22
100 6.9 24.4 6.4 1950 1500 23
65 4.5 21.3 5.6 2202 1500 32

38 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN125H – OF
Module data
Inches (mm)
Inches (mm)
Intercooler 158 167
Aftercooler 151 159
Oil cooler 22 23
Total 331 349

Lubrication data

Electrical data

IRN90–160K–OF & IRN125–200H–OF 39

Nirvana Model :
IRN125H – OF
Fan motor
Number of poles 6
Total package (5)

Inverter
Power factor 0.95
Efficiency (%) 97

(2549 x 1825 x 2437)
Discharge air connection NPT(inches) 2
Condensate drain connection (intercooler) NPT(inches) 0.38
Condensate drain connection (aftercooler) NPT(inches) 0.38
Notes:
40 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN150H – OF
pressure)
150 10.3 555 15.7 165.0 123.0
145 10.0 567 16.1 165.0 123.0
140 9.7 579 16.4 165.0 123.0
135 9.3 591 16.7 165.0 123.0
130 9.0 603 17.1 165.0 123.0
125 8.6 616 17.4 165.0 123.0
120 8.3 628 17.8 165.0 123.0
115 7.9 640 18.1 165.0 123.0
110 7.6 652 18.5 165.0 123.0
105 7.2 664 18.8 165.0 123.0
100 6.9 676 19.1 165.0 123.0
65 4.5 681 19.3 145.2 108.3

150 10.3 29.7 7.8 1920 1500 22
145 10.0 29.1 7.7 1958 1500 23
140 9.7 28.5 7.5 1996 1500 25
135 9.3 27.9 7.3 2034 1500 26
130 9.0 27.3 7.2 2072 1500 28
125 8.6 26.8 7.1 2110 1500 29
120 8.3 26.3 6.9 2148 1500 30
115 7.9 25.8 6.8 2186 1500 31
110 7.6 25.3 6.7 2224 1500 33
105 7.2 24.9 6.5 2262 1500 34
100 6.9 24.4 6.4 2300 1500 35
65 4.5 21.3 5.6 2300 1500 35

IRN90–160K–OF & IRN125–200H–OF 41

Nirvana Model :
IRN150H – OF
Module data
Inches (mm)
Inches (mm)
Intercooler 189 200
Aftercooler 188 198
Oil cooler 21 23
Total 398 420

Lubrication data

Electrical data

42 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN150H – OF
Fan motor
Number of poles 6
Total package (5)

Inverter
Power factor 0.95
Efficiency (%) 97

(2549 x 1825 x 2437)
Notes:
IRN90–160K–OF & IRN125–200H–OF 43

Nirvana Model :
IRN200H – OF
pressure)
150 10.3 751 21.3 220.0 164.1
145 10.0 764 21.6 220.0 164.1
140 9.7 777 21.0 220.0 164.1
135 9.3 790 22.4 220.0 164.1
130 9.0 803 22.7 220.0 164.1
125 8.6 816 23.1 220.0 164.1
120 8.3 829 23.5 220.0 164.1
115 7.9 842 23.8 220.0 164.1
110 7.6 855 24.2 220.0 164.1
105 7.2 868 24.6 220.0 164.1
100 6.9 881 24.9 220.0 164.1
65 4.5 904 25.6 201.0 149.9

150 10.3 29.3 7.7 2530 1500 41
145 10.0 28.8 7.6 2570 1500 42
140 9.7 28.3 7.5 2610 1500 43
135 9.3 27.8 7.3 2650 1500 43
130 9.0 27.4 7.2 2690 1500 44
125 8.6 27.0 7.1 2730 1500 45
120 8.3 26.5 7.0 2770 1500 46
115 7.9 26.1 6.9 2810 1500 47
110 7.6 25.7 6.8 2850 1500 47
105 7.2 25.3 6.7 2890 1500 48
100 6.9 25.0 6.6 2930 1500 49
65 4.5 22.2 5.9 3000 1500 50

44 IRN90–160K–OF & IRN125–200H–OF

Nirvana Model :
IRN200H – OF
Module data
Inches (mm)
Inches (mm)
Intercooler 254 268
Aftercooler 251 265
Oil cooler 24 25
Total 529 558

Lubrication data

Electrical data

IRN90–160K–OF & IRN125–200H–OF 45

Nirvana Model :
IRN200H – OF
Fan motor
Number of poles 6
Total package (5)

Inverter
Power factor 0.95
Efficiency (%) 97

(2549 x 1825 x 2437)
Notes:
46 IRN90–160K–OF & IRN125–200H–OF

8.2 INSTALLATION DRAWING – N90/160K, N125/200H OIL FREE AIR COOLED
IRN90–160K–OF & IRN125–200H–OF 47

KEY
A Air discharge Notes:

2” N.P.T. – 60Hz
2” B.S.P.T. – 50Hz 1 Weight approximate: 3215 kg (7088 lbs)
B Power inlet location for conduit 2 Cooling air flow: 411 m3/min – 14500 CFM.
∅ 75mm (3”) 3 Pipe condensate drain lines separately to an open drain due to
difference in drain pressures. Check local regulations.
C Intercooler solenoid condensate drain
0.38” N.P.T. 4 Lube oil fill quantity: 64 litres (17 US gallons) approximately.
D Intercooler manual condensate drain 5 All dimensions in millimeters (inches).
0.25” N.P.T.
6 Tolerance on all dimensions: ±6 mm (± .25 inch).
E Aftercooler solenoid condensate drain
0.38” N.P.T. 7 Recommended clearance on three sides 915mm (36 inches). Side
with electrical box 1067mm (42 inches) or minimum as required by
F Aftercooler manual condensate drain latest national electrical code or applicable local codes.
0.25” N.P.T.
8 External piping shall not exert any unresolved moments or forces
G Breather piping connection on unit. Use pipe size as large or larger at discharge location.
1” N.P.T. – 60Hz
1” B.S.P.T. – 50Hz 9 There should be no plastic or PVC piping attached to this unit or
used for any lines downstream.
H Seal vent opening – do not plug
10 Remove the isolation mount restraints before the initial start. The
I Air intake two restraints can be discarded.
J Cooling air exhaust 11 Field installed ducting to and from compressor cannot add more
K 4 x ∅13.00mm (0.51”) than 12mm (0.5 inches) of water total air resistance. Gear box breather
must be piped external.
L Controller, INTELLISYS
12 Unit has internal discharge check valve. External check valve not
T Left hand required. Isolation valve is required within 915mm (36inches) of the
compressor discharge.
U Right hand
13 Compressor should be bolted to the floor with four M12 (1/2 inch)
V Bottom
bolts located as shown. Seal base to floor with cork or rubber.
W Front
14 Do not pipe into a common header with a reciprocating
X Detail compressor, unless reciprocating compressor utilizes a discharge
pulsation dampener.
Y Rear
Z Plan view 15 Denotes center of gravity.
A3 Bushing 2” BSPT 50Hz only (Ship loose) 16 Sizing of electrical components not supplied by Ingersoll–Rand is
the responsibility of the customer and should be done in accordance
A4 Bushing 1” BSPT 50Hz only (Ship loose) with the information on the compressor data plate, National and local
electrical codes.
17 A 75mm (3 inches) diameter electrical power inlet connection hole
is provided in side of electrical box as indicated. Size and positioning
can be changed by customer in accordance with note 16.
18 When installed indoors or under a shelter, the cooling air inlet or
exhaust must be ducted away from the unit to prevent recirculation of
hot exhaust air.
48 IRN90–160K–OF & IRN125–200H–OF

8.2 INSTALLATION DRAWING – N90/160K, N125/200H OIL FREE WATER COOLED
IRN90–160K–OF & IRN125–200H–OF 49

KEY
A Air discharge Notes:

2” N.P.T. – 60Hz
2” B.S.P.T. – 50Hz 1 Weight approximate: 3215 kg (7088 lbs)
B Power inlet location for conduit 2 Cooling air flow: 113 m3/min – (4,000cfm).
∅ 75mm (3”) 3 Pipe condensate drain lines separately to an open drain due to
difference in drain pressures. Check local regulations.
C Intercooler solenoid condensate drain
0.38” N.P.T. 4 Lube oil fill quantity: 64 litres (17 US gallons) approximately.
D Intercooler manual condensate drain 5 All dimensions in millimeters (inches).
0.25” N.P.T.
6 Tolerance on all dimensions: ±6 mm (± .25 inch).
E Aftercooler solenoid condensate drain
0.38” N.P.T. 7 Recommended clearance on three sides 915mm (36 inches). Side
with electrical box 1067mm (42 inches) or minimum as required by
F Aftercooler manual condensate drain latest national electrical code or applicable local codes.
0.25” N.P.T.
8 External piping shall not exert any unresolved moments or forces
G Breather piping connection on unit. Use pipe size as large or larger at discharge location.
1” N.P.T. – 60Hz
1” B.S.P.T. – 50Hz 9 There should be no plastic or PVC piping attached to this unit or
used for any lines downstream.
H Seal vent opening – do not plug
10 Remove the isolation mount restraints before the initial start. The
I Air intake two restraints can be discarded.
J Cooling air exhaust 11 Field installed ducting to and from compressor cannot add more
K 4 x ∅13.00mm (0.51”) than 6mm (0.25 inches) of water total air resistance. Gear box breather
must be piped external.
L Controller, INTELLISYS
12 Unit has internal discharge check valve. External check valve not
T Left hand required. Isolation valve is required within 915mm (36inches) of the
compressor discharge.
U Right hand
13 Compressor should be bolted to the floor with four M12 (1/2 inch)
V Bottom
bolts located as shown. Seal base to floor with cork or rubber.
W Front
14 Do not pipe into a common header with a reciprocating
X Detail compressor, unless reciprocating compressor utilizes a discharge
pulsation dampener.
XX Detail
Y Rear 15 Denotes center of gravity.
Z Plan view 16 Sizing of electrical components not supplied by Ingersoll–Rand is
the responsibility of the customer and should be done in accordance
A1 Water in: with the information on the compressor data plate, National and local
2” NPT – 60Hz electrical codes.
2” BSPT – 50Hz
17 A 75mm (3 inches) diameter electrical power inlet connection hole
A2 Water out: is provided in side of electrical box as indicated. Size and positioning
2” NPT – 60Hz can be changed by customer in accordance with note 16.
2” BSPT – 50Hz
18 When installed indoors or under a shelter, the cooling air inlet or
A3 Bushing 2” BSPT 50Hz only (Ship loose) exhaust must be ducted away from the unit to prevent recirculation of
A4 Bushing 1” BSPT 50Hz only (Ship loose) hot exhaust air.
50 IRN90–160K–OF & IRN125–200H–OF

8.3 PROCESS AND INSTRUMENTATION DIAGRAM N90/160K & N125/200H AIR COOLED
IRN90–160K–OF & IRN125–200H–OF 51

KEY
1 Air filter 35 Oil bypass check valve – 25 PSIG

2 LP Airend 36 Gear case breather
3 LP Discharge silencer 37 1ATT–LP Inlet temperature thermistor
4 Intercooler 38 1AVPT–LP Inlet vacuum transducer
5 Interstage moisture separater 39 2ATT–LP Discharge temperature RTD
6 HP Airend 40 2APT–HP Inlet pressure transducer
7 HP Discharge silencer 41 3ATT–HP Inlet temperature thermistor
8 Aftercooler 42 3APT–HP Discharge pressure transducer
9 Moisture separator 43 4ATT–HP Discharge temperature RTD
10 Check valve 44 4APT Compressor discharge pressure transducer
11 Air discharge (customer connection) 45 7ATT Compressor discharge temperature
thermistor
12 Interstage blowdown solenoid valve 5SV
46 50TT Oil manifold temperature thermistor
13 Blowdown silencer
47 50PT Oil filter inlet pressure transducer
14 Blowdown solenoid valve 3SV
48 60PT Oil filter out pressure transducer
49 9APT Remote air pressure transducer
16 Interstage pressure relief valve – 50 PSIG
50 Drive motor – variable speed
17 Pressure relief valve – 165 PSIG
51 Blower motor – variable speed
18 Interstage ball valve (bypass condensate solenoid)
52 Blower cooling air
19 Interstage condensate check valve 60 Dryer (customer equipment)
20 Interstage condensate strainer 61 Line filters (customer equipment)
21 Interstage timed condensate solenoid 6SV 62 Receivers (customer equipment)
22 Interstage condensate discharge 63 Dryer condensate discharge (customer equipment)
(customer connection)
23 Interstage condensate ball valve (shipped loose) 64 Dryer AUX warning
24 Package discharge ball valve 65 Line filter AUX warning
(bypass condensate solenoid)
66 Receiver trap AUX warning
25 Package discharge condensate strainer
67 Typical customer downstream air treatment
26 Package discharge timed condensate solenoid
9SV
27 Package discharge condensate discharge
Piping legend
28 Package discharge condensate ball valve
(shipped loose) A Compressed Air
29 Oil sump B Module
30 Oil pump C Coolant
31 Oil bypass valve – 35 PSIG D Condensate
32 Oil cooler E Compressor enclosure
33 Oil temperature control valve F Sensor connection
34 Oil filter G Equipment downstream of compressor
52 IRN90–160K–OF & IRN125–200H–OF

8.3 PROCESS AND INSTRUMENTATION DIAGRAM N90/160K & N125/200H WATER COOLED
IRN90–160K–OF & IRN125–200H–OF 53

KEY
1 Air filter 36 1ATT–LP Inlet temperature thermistor

1 LP Airend 37 1AVPT–LP Inlet vacuum transducer
2 LP Discharge silencer 38 2ATT–LP Discharge temperature RTD
3 Intercooler 39 2APT–HP Inlet pressure transducer
4 Interstage moisture separater 40 3ATT–HP Inlet temperature thermistor
5 HP Airend 41 3APT–HP Discharge pressure transducer
6 HP Discharge silencer 42 4ATT–HP Discharge temperature RTD
7 Aftercooler 43 4APT Compressor discharge pressure transducer
8 Moisture separator 44 7ATT Compressor discharge temperature
thermistor
9 Check valve
45 50TT Oil manifold temperature thermistor
10 Air discharge (customer connection)
46 50PT Oil filter inlet pressure transducer
11 Interstage blowdown solenoid valve 5SV
47 60PT Oil filter out pressure transducer
48 9APT Remote air pressure transducer
13 Blowdown solenoid valve 3SV
49 Drive motor – variable speed
50 Water inlet (customer connection)
15 Interstage pressure relief valve – 50 PSIG
51 Water shut off valve 4SV
16 Pressure relief valve – 165 PSIG
52 Water outlet (customer connection)
17 Interstage ball valve (bypass condensate solenoid)
53 Blower motor – variable speed
18 Interstage condensate check valve 54 Blower cooling air
19 Interstage condensate strainer 60 Dryer (customer equipment)
20 Interstage timed condensate solenoid 6SV 61 Line filters (customer equipment)
21 Interstage condensate discharge 62 Receivers (customer equipment)
63 Dryer condensate discharge (customer equipment)
22 Interstage condensate ball valve (shipped loose)
23 Package discharge ball valve 64 Dryer AUX warning
(bypass condensate solenoid)
65 Line filter AUX warning
24 Package discharge condensate strainer
66 Receiver trap AUX warning
25 Package discharge timed condensate solenoid
67 Typical customer downstream air treatment
9SV
26 Package discharge condensate discharge
27 Package discharge condensate ball valve
(shipped loose) Piping legend
28 Oil sump A Compressed Air
29 Oil pump B Module
30 Oil bypass valve – 35 PSIG C Coolant
31 Oil cooler D Condensate
32 Oil temperature control valve E Compressor enclosure
33 Oil filter F Sensor connection
34 Oil bypass check valve – 25 PSIG G Equipment downstream of compressor
35 Gear case breather H Cooling water
54 IRN90–160K–OF & IRN125–200H–OF

8.4 ELECTRICAL SCHEMATIC N90–160K, N125–200H AIR COOLED
IRN90–160K–OF & IRN125–200H–OF 55

KEY
1ATT Sensor, LP inlet temperature. BP Backplate

1AVPT Transducer, LP inlet vacuum. CAB Cabinet
2APT Transducer, interstage pressure. CFO Common fault output
CK Choke
2ATT Sensor, LP discharge temperature.
DR Drive
3APT Transducer, HP discharge pressure.
EB Earth bar
3ATT Sensor, HP inlet temperature.
ES Switch, emergency stop
3SV Valve, package discharge blowdown solenoid. EXC External communications
4APT Transducer, package discharge pressure. F10 Fuse, external heater supply
4ATT Sensor, HP discharge temperature. GND Ground
5OPT Transducer, oil filter in pressure. H1 110/120V, 50/60Hz From SHT 1
5OTT Sensor, bearing oil temperature. H2 110/120V, 50/60Hz From SHT 1
5SV Valve, interstage blowdown solenoid. H3 110/120V, 50/60Hz External supply
H4 220/230V, 50/60Hz External supply
6OPT Transducer, oil filter out pressure.
H5 Alternative heater connection for external
6SV Valve, interstage condensate drain/solenoid 110/120V supply.
7ATT Sensor, package discharge temperature. H6 Alternative heater connection for external
220/230V supply.
9SV Valve, package discharge condensate
drain/solenoid. HB Heatsink blower
AW2 Auxiliary warning 2 K1 Relay, run
BD Drive Blower K2 Relay fault
BM Motor, Blower KM1 Contactor, main motor
56 IRN90–160K–OF & IRN125–200H–OF

KM5 Contactor, heatsink blower TH Thermostat
MCB1 Breaker, miniature circuit, transformer TRR True running relay
MCB2 Breaker, miniature circuit, control circuits WR General warning
MCB3 Breaker miniature circuits, drive
MCB4 Breaker, miniature circuit, PSU Notes:
MCB9 Breaker, miniature circuit, heater independent source: in that case, factory supplied
MCB10 Breaker, miniature circuit, heater (external) connection must be disconnected.
Colors
MI Main input terminals options
BLK Black
MM Motor, main
BLU Blue
BRO Brown
MMS2 Breaker, heatsink blower motor
GRE Green
OPT Optional
PIN Pink
OV Zero voltage
RED Red
PE Protected earth
SCR Screened
PORO Power outage restart option (optional)
VIO Violet
WHI White
YEL Yellow
RSP Remote stop
RST Remote start Wires
SBC Supplied by customer
Numbers Function Wire color
1–99 Power Black
SH Standard heater connections as delivered
SL Serial link 100–199 AC Control Red
SS1–3 Relay, solid state 200–299 DC Control Blue
ST Service tool 300–399 Auxiliary Orange
T1 Transformer, control
IRN90–160K–OF & IRN125–200H–OF 57

8.4 ELECTRICAL SCHEMATIC N90–160K, N125–200H WATER COOLED
58 IRN90–160K–OF & IRN125–200H–OF

KEY
1ATT Sensor, LP inlet temperature. AW2 Auxiliary warning 2

1AVPT Transducer, LP inlet vacuum. BP Backplate
2APT Transducer, interstage pressure. CAB Cabinet
CFO Common fault output
2ATT Sensor, LP discharge temperature.
CK Choke
3APT Transducer, HP discharge pressure.
DR Drive
3ATT Sensor, HP inlet temperature.
EB Earth bar
3SV Valve, package discharge blowdown solenoid. ES Switch, emergency stop
4APT Transducer, package discharge pressure. EXC External communications
4ATT Sensor, HP discharge temperature. FM Motor, fan.
4SV Valve, water solenoid. F10 Fuse, external heater supply
5OPT Transducer, oil filter in pressure. GND Ground
5OTT Sensor, bearing oil temperature. H1 110/120V, 50/60Hz From SHT 1
5SV Valve, interstage blowdown solenoid. H2 110/120V, 50/60Hz From SHT 1
6OPT Transducer, oil filter out pressure.
6SV Valve, interstage condensate drain/solenoid
H5 Alternative heater connection for external
7ATT Sensor, package discharge temperature. 110/120V supply.
9ATP Transmitter, remote air pressure (optional) H6 Alternative heater connection for external
220/230V supply.
9SV Valve, package discharge condensate
drain/solenoid. HB Heatsink blower
IRN90–160K–OF & IRN125–200H–OF 59

K1 Relay, run ST Service tool
K2 Relay fault T1 Transformer, control
KM1 Contactor, main motor TH Thermostat
KM5 Contactor, heatsink blower TRR True running relay
MCB1 Breaker, miniature circuit, transformer WR General warning
MCB2 Breaker, miniature circuit, control circuit
MCB3 Breaker miniature circuit, drive Notes:
MCB4 Breaker, miniature circuit, PSU independent source: in that case, factory supplied
MCB9 Breaker, miniature circuit, heater connection must be disconnected.
MCB10 Breaker, miniature circuit, heater (external)
Colors
BLK Black
MI Main input terminals options
BLU Blue
MM Motor, main
BRO Brown
GRE Green
MMS2 Breaker, heatsink blower motor
PIN Pink
OPT Optional
RED Red
OV Zero voltage
SCR Screened
PE Protected earth
VIO Violet
PORO Power outage restart option (optional)
WHI White
YEL Yellow
RSP Remote stop Wires
RST Remote start
Numbers Function Wire color
SBC Supplied by customer
1–99 Power Black
SH Standard heater connections as delivered 100–199 AC Control Red
SL Serial link 200–299 DC Control Blue
SS1–3 Relay, solid state 300–399 Auxiliary Orange
60 IRN90–160K–OF & IRN125–200H–OF

8.5 GENERAL DESCRIPTION
The compressor is an electric motor driven, oil free, two Air is pulled into the machine by the cooling blower and
stage screw compressor, complete with all necessary through the heat exchangers (for air cooled).
components piped, wired and baseplate mounted. It is
By cooling the discharge air, much of the water vapor
a totally self contained air compressor package.
naturally contained in the air is condensed and is
The standard compressor is designed to operate in an drained from the built–in moisture separators and
ambient range of 1.7C to 46C (35F to 115F). The drains.
standard maximum temperature of 46C (115F) is
The oil sump and pump are integral within the gearcase.
applicable up to an elevation of 1000m (3280ft) above The oil pump is a positive displacement gear–type
sea level. Above this altitude significant reductions in pump, and is driven by the motor/bullgear shaft. The
ambient temperature are required if a standard motor gearcase is vented to a mounted breather. The breather
is to be used. exhaust is piped to the top of the package.
The compressor is managed by the onboard electronic The compressor is provided with a temperature sensor
controller. The controller and drive system operate which will shut the unit down in case of excessive oil or
together to vary the speed of the compressor to deliver air temperatures.
compressed air at the target pressure.
Effective oil filtration is provided by the use of a screw
Panel instrumentation is provided to indicate the on, heavy duty oil filter.
compressor operating conditions and general status.
NOTICE
Nirvana 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 oil must be changed at these intervals to avoid breakdown and equipment damage.
IRN90–160K–OF & IRN125–200H–OF 61

9.0 OPERATING INSTRUCTIONS
10
9.1 BASIC OPERATION
WARNING Switch on the main electrical isolation switch. The

control panel will illuminate, indicating that the line and
Ensure that all protective covers/guards are in
control voltages are available.
place before attempting to start the machine.
The contrast of the display may be adjusted by turning
the small screw which is on the right hand side of the
NOTICE controller when accessed through the starter cabinet
door.
The language and units of measure displayed on
the Intellisys controller will be pre–set before Initial check sequence
leaving the factory. If these are required to be
changed, contact your local Ingersoll–Rand The controller will perform an initial check sequence if
the compressor (1) receives initial power to the
Service Department, Distributor or Air Center.
controller or (2) has experienced an alarm reset. While
the initial check sequence occurs, the controller will
display a “Checking Machine” message.
Prior to starting
During the initial check sequence, the controller will
Refer to diagram T5716 above
check the control system for proper operation. During
Check that the oil level is at least visible in the center of this time, if any items are found inoperative an alarm will
the sight glass, add oil if necessary. Refer to occur and the unit will not start.
maintenance procedures for setting correct level.
After completion of the initial check sequence, the
controller will then display “READY TO START’. This
Ensure that the discharge air isolation valve is open. process should be completed within 10 seconds.
62 IRN90–160K–OF & IRN125–200H–OF

Start sequence Blower control
The compressor will initially start by pressing the local The blower speed varies to minimize energy
start button or receiving a remote start command. The consumption while optimizing cooler performance. The
Intellisys will energize the start output to start the blower motor has its own variable speed drive and will
compressor. Both blowdown valves will de–energize to ramp up and down as the compressor starts and stops.
start the unit unloaded. The compressor will ramp up
to its minimum speed. Once the minimum speed has Stopping the machine in an emergency
been achieved, the Intellisys will energize the
blowdown valves and the compressor will start to If the machine has to be stopped in an emergency
control pressure by using its speed regulation. When DEPRESS THE EMERGENCY STOP BUTTON
the system pressure approaches the target pressure, LOCATED UNDERNEATH THE INSTRUMENT
the motor will start to slow. If the system pressure rises PANEL.
to the immediate stop pressure set point, the Intellisys
will perform its stop sequence immediately. If the This will over–ride the normal unload/stop button and
Intellisys reaches its auto–stop pressure it will wait until will immediately stop the machine.
the drive is running at minimum speed and if pressure Restarting after an emergency
is maintained above the auto–stop pressure, the
Intellisys will perform its stop sequence. Immediate If the unit has been switched off because of a machine
stop and auto–stop conditions will leave the malfunction, identify and correct the fault before
compressor in an auto–start state where it will attempting to restart.
automatically start if the system pressure falls below If the unit has been switched off for reasons of safety,
the target pressure. This process will continue until the ensure that the machine can be operated safely before
Intellisys receives a stop command or has an alarm restarting.
Refer to the PRIOR TO STARTING and START
Stop sequence
SEQUENCE instructions earlier in this section before
The compressor has two stop sequences. If the restarting the machine.
emergency stop button is pressed or if a shutdown
occurs as a result of an alarm, the start output will
de–energize and the compressor will stop immediately.
The emergency stop must be reset and the alarm must
be cleared before the compressor can be restarted.
If the pressure reaches the automatic stop or

immediate stop pressure or if the stop button (local or
remote) is pressed, the compressor will de–energize
the package discharge blowdown valve and
de–energize the condensate solenoid valves. The
compressor will then run for 10 seconds with the
package discharge valve open. The compressor will
stop after 10 seconds if the system pressure is greater
than the target pressure and if the second stage
discharge pressure is less than 50 psig. Immediate
stop and autostop conditions leave the compressor in
an auto–start state where it will automatically start if the
system pressure falls below the target pressure. The
compressor will not automatically restart if the local or
remote stop button is pressed.
IRN90–160K–OF & IRN125–200H–OF 63

9.2 INTELLISYS CONTROLS
1. Emergency stop 5. F2
Pressing this switch stops the compressor immediately. Not used.
This switch should only be pressed in emergency
situations. The discharge blowdown valve will open to
vent pressure downstream of the check valve to 6. Arrows
atmosphere. Note: the system downstream of the These up and down buttons have multiple functions
check valve may still contain pressure. The relating to the right half of the display screen. When lists
compressors can not be restarted until the switch is are presented, the buttons are used to move up or down
manually reset. Turn the switch knob clockwise and through the items on the list. The small arrow(s)
press the reset button twice to reset. displayed in the upper right hand corner of the display
screen indicate when you can move up (designated by
On reset the controller will display a message, arrow head pointing up) and/or down (designated by
indicating that the compressor is ready to start. arrow head pointing down) through the list.
When the value of a specific machine operating
2. Start parameter is highlighted on the display screen for the
purpose of changing that value, the buttons are used to
Pressing this button will activate the start sequence. change the value itself.
3. Stop 7. Display buttons

Pressing this button will activate the stop sequence. The functions of the three buttons below the display
screen change and are defined by the words
immediately above them in the bottom line of the
4. F1
screen. Each function, such as MAIN MENU, STATUS,
Not used. etc., is described in appropriate sections in this manual.
64 IRN90–160K–OF & IRN125–200H–OF

9.3 DISPLAY SCREEN
The display screen is divided into three functional The right side shows various items or lists such as the
areas, as seen in the typical CURRENT STATUS machine’s CURRENT STATUS readings, the MAIN
screen shown here. MENU, the OPERATOR SETPOINTS list, etc. Any of
the lists can be moved up or down by pressing the arrow
The left side continuously shows the package buttons to the right of the screen. The small arrow(s)
discharge pressure in large numbers with the line displayed in the upper right corner of the screen indicate
directly below showing the running condition of the when you can move up and/or down through a list. The
machine arrow buttons are also used to change an individual
item’s value. At certain times, items and/or their values
are “highlighted”. This means that they are displayed as
–CURRENT STATUS– light characters on a dark background.
100 PSI PACKAGE DISCHARGE The bottom of the screen is divided into thirds with the
TEMP words in each small box showing the function of the
button directly beneath it. The words will change in
102F these boxes depending on what actions are permitted
READY TO START PACKAGE DISCHARGE at any particular time. The action resulting from
PRESSURE pressing each of these buttons is indicated in the
Operator Panel Flow Diagram later in this section. This
100 PSI
can be used as a quick reference of how to step the
MAIN MENU controller screen through any desired function.
IRN90–160K–OF & IRN125–200H–OF 65

9.4 CURRENT STATUS SCREEN
The CURRENT STATUS screen is considered to be the 14 SECOND STAGE AIREND DISCHARGE TEMP
“normal” display that the controller shows.
15 BEARING OIL PRESS
The following items and their present values can be
displayed on the right side of the screen by pressing the 16 BEARING OIL TEMP
up and down arrow buttons. 17 MOTOR SPEED
The controller automatically returns the display to this 18 MOTOR CURRENT
CURRENT STATUS screen from other screens if no
buttons are pressed within 30 seconds. 19 INPUT VOLTAGE
Use the UP and DOWN arrows to move between 20 DC BUS VOLTAGE

selections. 21 TIME & DATE
22 PROGRAM NAME
CURRENT STATUS items 23 VSD
1 % ENERGY SAVINGS
When the CURRENT STATUS screen is displayed,
2 % CAPACITY pressing the ENERGY STATUS button will toggle the
display to the ENERGY STATUS screen. Likewise,
3 PACKAGE KW
when the ENERGY STATUS screen is displayed,
4 PACKAGE DISCHARGE TEMP pressing the STATUS button will toggle the display to
the CURRENT STATUS screen.
5 PACKAGE DISCHARGE PRESSURE
The ENERGY STATUS screen displays the following
6 INLET VACUUM
items.
7 INLET FILTER
ENERGY STATUS Items
8 OIL FILTER PRESSURE DROP
1 Average Package kW–hr
9 FIRST STAGE INLET TEMP
2 Average % Capacity
10 FIRST STAGE AIREND DISCHARGE TEMP
3 Average Capacity
11 SECOND STAGE AIREND INLET PRESS
4 Energy Cost
12 SECOND STAGE AIREND INLET TEMP
5 Energy Savings
13 SECOND STAGE AIREND DISCHARGE PRESS
6 Lifetime Energy Savings
66 IRN90–160K–OF & IRN125–200H–OF

9.5 MAIN MENU
The MAIN MENU screen can be accessed from the The language and units of measure are pre–set prior to
CURRENT STATUS screen by pressing the MAIN the compressor leaving the factory.
MENU button, identified by the words “MAIN MENU” in
the bottom line of the screen directly above the center
–MAIN MENU–
button.
The MAIN MENU screen is the point from which various
operator functions can be accessed. Refer to the
100 PSI
OPERATOR SETPOINTS
Operator Panel Flow Diagram. OPTIONS
Each of the functions can be chosen by using the up READY TO START SENSOR CALIBRATION
and down arrows to highlight it on the screen.
ALARM HISTORY
The controller will go to the highlighted function if the
SELECT button is pressed or will return to the STATUS SELECT
CURRENT STATUS screen if the STATUS button is
pressed.
CURRENT Energy
“Status” STATUS/ENERGY
STATUS Status
“Main Menu”
“Status”
MAIN MENU
“Main Menu”
“Select”
“Main Menu” “Main “Main Menu”

OPERATOR Menu” SENSOR
SETPOINTS OPTIONS
CALIBRATION
“Status” “Status” “Status”
“Select” “Select” “Select”
OPERATOR OPTIONS ITEM SENSOR

SETPOINTS CALIBRATION
ITEM ITEM
“Cancel or set” “Cancel or set” “Cancel or calibrate”
“Main Menu” “Main Menu” “Main Menu”

ALARM CLOCK ENERGY
HISTORY FUNCTIONS
“Status” “Status” “Status” STATUS
“Select” “Select”
“Main
Menu”
AVG. PACKAGE kW HRS
“Main Menu” “Main AVG. % CAPACITY
ALARM Menu” DATE
HISTORY ITEM AVG. CAPACITY
AND TIME
“Status” ENERGY COST
“Status”
ENERGY SAVINGS
“Status” LIFETIME ENERGY SAVINGS
“Alarm hist” “Cancel or set”

“Cancel or set”
IRN90–160K–OF & IRN125–200H–OF 67

9.6 OPERATOR SETPOINTS
Setpoints are user–adjustable variables in the –OPERATOR SETPOINTS–

controller logic that can be set using the OPERATOR
SETPOINTS screen shown opposite. 100 PSI
TARGET PRESSURE
The name and value of each of the setpoints listed can
be seen on the screen by moving the list up and down 105 psi
using the arrow buttons. READY TO START
Setpoints associated with options are described in the
OPTIONS sections.
STATUS MAIN MENU SELECT
FACTORY DEFAULTS
OPERATOR SETPOINTS DEFAULT MIN. MAX. STEP UNIT
Target pressure 100 65 150 1 PSI
Automatic stop pressure 105 Target +1 Target +10 1 PSI
Immediate stop pressure 115 Auto Auto +10 1 PSI
Condensate release 10 2 10 1 SEC.
Condensate interval 60 60 360 1 SEC.
Energy Rate 0 0 9999.999 – –
Reset Avg. – – – Date
Service menu 1 1 25535 1 –
A setpoint’s value can be changed by first highlighting Target pressure

the item and its value and pressing the SELECT button
to highlight just the value. When the value line is The compressor will try to operate at this pressure
highlighted by itself, the value can be adjusted using the setting. The target pressure ranges and step sizes for
up and down arrow buttons. The CANCEL and SET each unit of measure are listed in the table below.
buttons appear at this time. Press the SET button to
enter the new value or press the CANCEL button to Unit Min Max (1S / Step
return the value of the setpoint prior to using the arrows. 2S)
The displayed value will flash twice to indicated that it
has been entered into the setpoint and the pair of PSI 65 150 1
setpoint item and value display lines will again be BAR 4.4 10.3 0.1
highlighted together.
kPa 440 1034 10
Operator setpoints can be exited by pressing the
STATUS or MAIN MENU buttons. If no buttons are KGCM2 4.5 10.5 0.1
pressed within 30 seconds, the display will return to the
CURRENT STATUS screen.
68 IRN90–160K–OF & IRN125–200H–OF

Automatic stop pressure Condensate Release
The compressor will unload once the system pressure This is the number of seconds that the condensate
rises to the automatic stop pressure and the solenoid will be open (de–energized) when blowing out
compressor is operating at the minimum speed. The the condensation.
range for this set point will be target pressure + 1 psi to
target pressure + 10 psi or 155 psi whichever is less
Condensate Interval
Immediate stop pressure This is the time interval between condensation
blowdowns
The compressor will unload if the system pressure rises
to this pressure. The range for this set point will be the Energy Rate
automatic stop pressure to automatic stop pressure +
5 psi or 160 psi – whichever is less. If the remote sensor The energy cost and the energy savings items on the
is ’on’, the maximum immediate stop pressure will ENERGY STATUS screen will use this value for their
always be automatic stop pressure + 5 psi. calculations. It is intended to be a monetary value
representing the user’s power cost per kilowatt hour.
Reset Averaging
When this setpoint is selected and the SET button is
pressed, the items on the ENERGY STATUS screen
will be reset, and the date the reset occurred will be
displayed in this setpoint. This selects the beginning
of the time period over which the ENERGY STATUS
information will be calculated. Note that the “Lifetime
Energy Savings” item will not be reset.
Service Menu
For use by IR personnel only.
IRN90–160K–OF & IRN125–200H–OF 69

9.7 OPTIONS
Options are turned on or off and their associated values –OPTIONS–

are set using the OPTION screen shown opposite.
Some options are purchased, they require additional 100 PSI
REMOTE START/STOP ON
machine hardware and must first be enabled by service
personnel. The name and value of each of the following
options can be seen by moving the list up and down READY TO START REMOTE START/STOP
using the arrow buttons OFF
An Option item’s value can be changed the same way
that OPERATOR SETPOINTS values are changed. STATUS MAIN MENU SELECT
OPTIONS Items SELECTION MIN. MAX. Step Unit Installed

Option
Required
Remote Pressure Sensor ON/OFF No
Sequencer ON/OFF No
Remote Start/Stop ON/OFF Yes
Power Out Restart ON/OFF Yes
Power Out Restart Time 10 600 1 SEC Yes
Scheduled Start Day day day 1 day Yes
Scheduled Start 00:00 23:59 1 time Yes
Scheduled Stop Day day day 1 day Yes
Scheduled Stop 00:00 23:59 1 time Yes
Modbus Protocol ON/OFF/ICU No
Modbus Address 1 247 1 No
Condensate Level Installed Yes/No No
Remote pressure sensor Power out restart

If this setting is set to ON, the compressor will use a If this setting is set to ON, the compressor will
remote mounted pressure sensor for controlling system automatically restart when power is returned to the
pressure by comparing it to the Target Pressure setting compressor if it was operating when power was
and the Auto Stop Pressure setting. The pressure removed.
measured by this sensor is shown in the CURRENT
Note:
STATUS display as the Remote Pressure reading. The
A kit including instruction manual is required to install
local sensor at the package discharge is still used for
this option.
Immediate Stop, for certain Alarm conditions and for
display on the left side of the screen. Power out restart time
Sequencer If the power out restart setting is set to ON, this is the
If this setting is set to ON, the compressor will be able number of seconds from the time power is restored until
to start and stop by commands from a host device. the compressor starts. The power out restart horn will
When the Intellisys receives a load command from the sound during this time.
host device, the compressor will start. When the Scheduled start day
Intellisys receives an unload command the compressor
will respond as though executing an immediate stop. This option is the selection for the day that a scheduled
start will take place. The selections are Sunday,
Monday, Tuesday, Wednesday, Thursday, Friday,
Remote start/stop Saturday, Daily (Su Sa), Weekdays (M F), or
— —
If the remote start/stop option is installed and this Weekends. This option setpoint will work with the
setting is set to ON, the compressor can be started and scheduled start setpoint.
stopped from a remote device.
70 IRN90–160K–OF & IRN125–200H–OF

Scheduled start Scheduled stop
This option will cause the unit to start on the scheduled This option will cause the unit to stop on the scheduled
start day , at the time stored in this setpoint. To disable stop day, at the time stored in this setpoint. To disable
this option, set the value of scheduled start equal to the this option, set the value of scheduled stop equal to the
value of scheduled stop. value of scheduled start.
Scheduled stop day Modbus protocol and address
This option is the selection for the day that a scheduled See the Modbus manual.
stop will take place. The selections are Sunday,
Monday, Tuesday, Wednesday, Thursday, Friday,
Saturday, Daily (Su — Sa), Weekdays (M — F), or
Weekends. This option setpoint will work with the
scheduled stop setpoint.
9.8 SENSOR CALIBRATION
Pressure sensor calibration is done through the Each of the sensors listed below can be chosen by
SENSOR CALIBRATION screen. Sensor calibration using the up and down arrow buttons to highlight it on
can only take place when the machine is stopped. the screen.
Calibration needs to be done only after a sensor has
been replaced or the Intellisys controller has been SENSOR CALIBRATION Items
replaced. Sensor 1AVPT (LP Inlet Vacuum)
Sensor 2APT (Interstage Pressure)
Sensor 3APT (HP Discharge Pressure)
–SENSOR CALIBRATION– Sensor 4APT (Package Discharge Pressure)
Sensor 5OPT (Oil Filter In Pressure)
100 PSI
SENSOR 4APT
Sensor 6OPT (Oil Filter Out Pressure)
Sensor 9APT (Remote Sensor)
CALIBRATE
READY TO START SENSOR 3APT Select the highlighted sensor by pressing the SELECT
button. Press the CALIBRATE button to start the
CALIBRATE automatic calibration procedure, or press the CANCEL
STATUS MAIN MENU SELECT button to not calibrate it and return to the sensor list.
The calibration screen can be exited by pressing either
the STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to the
CURRENT STATUS screen.
IRN90–160K–OF & IRN125–200H–OF 71

9.9 ALARM HISTORY
Alarm History displays each of the Alarm messages for Each of the last 15 Alarm messages can be seen by
the last 15 Alarms experienced by the machine. It also moving the Alarm History list up and down using the
gives access to displaying the machine operating arrow buttons. Pressing the SELECT button when one
conditions that existed at the time of each Alarm. The of the Alarms is highlighted will display the list of
first one shown, “Alarm History 1”, was the most recent machine values that existed at the time that particular
Alarm to occur. Note that multiple, consecutive Alarm occurred.
EMERGENCY STOP Alarms are not recorded as
separate Alarms, only the first one will be shown. The name and value of each of the items can be seen
by moving the list up and down using the arrow buttons.
–ALARM HISTORY– Pressing the ALARM HIST. button will return the display
to the ALARM HISTORY screen.
100 PSI
ALARM HISTORY 1
Alarm histories can be exited by pressing either the
STATUS or MAIN MENU buttons. If no buttons are
BLOWER MOTOR pressed within 30 seconds, the display will return to the
OVERLOAD CURRENT STATUS screen.
READY TO START ALARM HISTORY 2
HIGH AIREND DISCH
TEMP
9.10 CLOCK FUNCTIONS
–CLOCK FUNCTIONS– The date and time for the real time clock is set through
the CLOCK FUNCTIONS screen. Use the up and down
Time
100 PSI 01:15 arrows to highlight either TIME or DATE. Select the
highlighted setting by pressing SELECT.
Date If TIME is selected, first the hours will be highlighted.

READY TO START Jan 01, 00 Adjust the hours (00–23 hour clock) by using the up and
down arrows. Once the correct time is in the display,
press SET to highlight the minutes. Adjust the minutes
STATUS MAIN MENU SELECT (00–59) and then press SET to complete setting the
time.
If DATE is selected, first the month will be highlighted.
Adjust the month by using the up and down arrows and
then press SET to highlight the date. Once the correct
date is displayed, press SET to highlight the year. Once
the correct year is displayed, press SET to complete
setting the date.
72 IRN90–160K–OF & IRN125–200H–OF

9.11 ENERGY STATUS MESSAGES
–ENERGY STATUS– AVERAGE CAPACITY – Displays the compressor’s

average capacity in cfm or m3 for the time period that
AVERAGE PACKAGE kW
was started by selecting the reset averaging setpoint.
100 PSI HRS
ENERGY COST – Displays the energy cost of the
AVERAGE % CAPACITY– compressor for the time period that was started by
READY TO START –AVERAGE CAPACITY selecting the reset averaging setpoint. This is
calculated by multiplying the kW hours of the motor and
the blower by the energy rate.
ENERGY SAVINGS – Displays the energy savings of
The Energy Status display can be selected by pressing the compressor for the time period that was started by
the ENERGY STATUS button. The following items and selecting the reset averaging setpoint as compared to
their present values will be displayed on the right side a conventional compressor. This value is determined by
calculating how much a conventional compressor
of the screen by pressing the up and down arrows.
motor would cost to operate at the same average
AVERAGE PACKAGE kW HOURS – This displays the capacity and then subtracting the motor energy cost of
average package kW per hour for the time period that the Nirvana compressor from it. It is assumed that the
was started by selecting the reset averaging setpoint. blower cost is the same in both packages.
This value includes the blower power usage.
LIFETIME ENERGY SAVINGS – Displays the lifetime
AVERAGE % CAPACITY – Displays the compressor’s energy savings of the compressor at the existing
average percent capacity for the time period that was energy rate and at the average percent capacity as
started by selecting the reset averaging setpoint. The compared to a conventional compressor.
value is determined by taking the average package kW
per hour, removing the blower power usage and then
dividing that number by the motor kW per hour for that
size of compressor at 100% capacity.
IRN90–160K–OF & IRN125–200H–OF 73

9.12 WARNINGS
When a WARNING occurs, a large question mark will SENSOR FAILURE – This will occur if a sensor is
flash on the display screen. recognized as missing or broken.
If multiple WARNINGS exist, the small up/down arrows HIGH DISCHARGE PRESS – Will occur if the unit is
will appear in the upper right corner of the display under the control of an external device, such as an ISC,
screen. The multiple WARNINGS can be seen by and the discharge pressure is greater than the
pressing the up and down arrow buttons. Pressing the immediate stop pressure.
STATUS button will display the CURRENT STATUS
screen with the WARNING button indicating that a AUXILIARY WARNING 1 or 2 – Will occur if the
WARNING still exists. auxiliary warning input closes.
A WARNING will not cause the unit to shut down. The REMOTE PRESSURE SENSOR FAILURE (option) –
unit will continue to run in its normal operation and the This will occur if the remote pressure sensor fails. If this
WARNING will remain displayed until reset. happens, the lntellisys will start using the package
discharge pressure sensor to measure system
A Warning needs to be reset by the operator by pressure.
pressing the RESET button twice.
FAILED CHECK VALVE – Will occur if the 2nd stage
The possible Warning messages are as follows; discharge pressure exceeds 50 psig when the
compressor is running unloaded. If this happens, DO
NOT hit the Emergency Stop button. The Intellisys
disables the STOP button and operates unloaded until
CHANGE OIL FILTER – Will occur if 5OPT–6OPT is
the warning is cleared. The warning can be cleared
greater than 0.9 bar (13 psi) and 5OTT is greater than
after the isolation valve is closed. The stop button will
120F / 49C.
be enabled once the warning is cleared. Press the stop
button to stop the compressor. DO NOT re–start the
CHANGE INLET FILTER – This will occur if the Inlet compressor without servicing the check valve.
Vacuum is greater than 0.05 bar (0.7 psig).
9.13 SERVICE WARNINGS
SERVICE – Service warnings occur when the unit has This will be set prior to the compressor being shipped
operated a certain number of hours, based on the total from the factory. When a service warning occurs,
hours, or has operated for a certain number of months, contact your local IR service representative.
based on the real time clock. Service warnings can
have multiple levels, depending on the service level
selection.
9.14 INITIAL CHECK ALARMS:
The following alarms will only occur when the machine HIGH BEARING OIL TEMPERATURE – Will occur if
is not running. These alarms are related to high 5OTT is greater than 95% of the high bearing oil
temperature, power loss, and sensor calibration. They temperature set point.
will have the same display mode as other alarms.
CHECK SETPOINTS – Will occur if the controller has CONTROL POWER LOSS – Will occur if the controller
determined that some of the data stored in memory detects a loss of the 120 VAC control power.
contains unacceptable values.
INVALID CALIBRATION – Will occur if the sensor zero
value is –10% to +1% of its scale. See Sensor
Calibration.
74 IRN90–160K–OF & IRN125–200H–OF

9.15 ALARMS
When an Alarm occurs, a large exclamation mark in a –ALARM STATUS–

triangle will flash on the display screen. The display
message will indicate what caused the Alarm.
The compressor will stop and cannot be re–started
100 PSI PACKAGE DISCH
PRESSURE
again until the alarm condition no longer exists and the
alarm message reset. 100 psi
Pressing the STATUS button will display the STATUS STOPPED BY PACKAGE DISCHARGE
screen. The presence of the ALARM button indicates ALARM TEMP
that an Alarm condition still exists. Alarm Status is the 103F
list of machine operating conditions that existed at the
time of the Alarm. ALARM MAIN MENU
The name and value of each of the items listed can be

seen by moving the list up and down using the arrow
buttons. Pressing the ALARM button will return the
display to the Alarm screen and the RESET button.
The Alarm needs to be reset by the operator by
pressing the RESET button twice. Any exceptions to
this are explained in the alarm descriptions.
The possible Alarm messages are as follows;
BLOWER MOTOR OVERLOAD – Will occur if a VSD INITIALIZATION FAULT – Will occur if the
blower motor overload relay contact opens. Intellisys is unable to establish communications with
the VSD after a power up.
REMOTE STOP FAILURE – Will occur if the REMOTE
START/STOP option is enabled, the remote stop HIGH I/C CONDENSATE – This will occur if COND
button remains open and either start button is pressed. LEVEL INSTALLED is YES and the High Condensate
Level switch remains on for 1 minute.
REMOTE START FAILURE – Will occur if the unit is
started by the remote start button and the button stays HIGH INTERCOOLER PRESSURE – Will occur if
closed for 7 seconds after the unit starts. 2APT is greater than 43 psi / 3 bar and the unit is running
or 5 psi / 0.3 bar while the unit is stopped.
SENSOR FAILURE – Will occur when a sensor is
recognized as missing or broken. The sensors affected HIGH 2ND STAGE PRESSURE – Will occur if 3APT is
by this alarm are 1AVPT, 2APT, 3APT, 4APT, 6OPT, greater than the rated discharge pressure plus 15 psi /
1ATT, 2ATT, 3ATT, 4ATT, 5OTT. The sensor should be 1 bar.
displayed along with the sensor failure message. The
sensor failure message shall follow the following
HIGH LINE AIR PRESSURE – This will occur if the
format: SENSOR FAILURE 4APT.
discharge pressure (from 4APT) is greater than the
rated discharge pressure plus 15 psi / 1 bar.
EMERGENCY STOP – Will occur when the
EMERGENCY STOP button is engaged.
LOW BEARING OIL PRESSURE – This will occur if
6OPT is less than 17 psi / 1.2 bar and the unit is running.
VSD FAULT – The VSD fault is read from the drive. The
Intellisys will read the status menu of the variable speed
drive. If a fault condition is returned in the status HIGH 1ST STAGE TEMPERATURE – This will occur
if 2ATT is greater than 482F / 250C.
information, the Intellisys will issue a VSD FAULT alarm
and display the number of the fault condition.
HIGH 2ND STAGE TEMPERATURE – Will occur when
4ATT is greater than 520F / 271C.
CHECK MOTOR ROTATION – This will occur if the
Intellisys reads a negative speed from the VSD when
starting. HIGH I/C AIR TEMPERATURE – This will occur if
temperature sensor 3ATT is greater than 140F / 60C.
VSD COMMUNICATION FAILURE – This will occur if
the Intellisys does not receive a response from the VSD
when requesting information. This alarm will take about
8 seconds to occur.
IRN90–160K–OF & IRN125–200H–OF 75

HIGH BEARING OIL TEMPERATURE – This will INLET RESTRICTION – This will occur if the unit is
occur if temperature sensor 5OTT is greater than running and 1AVPT is greater than 1.45 psi / 0.1 bar.
170F / 77C.
HIGH BEARING OIL PRESSURE – This will occur if
2ND STAGE OVER RATIO – This alarm will occur if 6OPT is greater than 35 psig / 2.4 bar and the 5OTT is
(3APT+14.5psi )/(2APT + 14.5psi) is greater than 5. greater than 135F / 57C.
76 IRN90–160K–OF & IRN125–200H–OF

10.0 MAINTENANCE
10.1 MAINTENANCE PROMPTS
The service warning and flashing LED will appear at The service warning will return each subsequent 2000
intervals, dependant on the service level selected. hours.
Refer to operating instructions. The machine will be master reset after service work
The customer can only reset the warning for 24 hours conducted prior to the 2000 hour interval to prevent
by pressing the “set” button. false indication.
IR service engineers will master reset the warning after
completing the service work.
IRN90–160K–OF & IRN125–200H–OF 77

10.0 MAINTENANCE
10.2 MAINTENANCE CHART
The MAINTENANCE CHART indicates the various components and the intervals when maintenance has to take place.
Where a service interval is stated in both hours and months, it is the sooner of the two intervals that must be adhered
to. Coolant capacities etc can be found in the GENERAL INFORMATION section of this manual. Note that any Local
or National codes that require specific maintenance that exceeds the requirements of this section must be adhered
to.
Maintenance Schedule
TM
Hours: 150 500 2000 4000 8000

(1st time 1000 6000 12000 16000
only)
1500 10000 20000
2500 14000
3000 18000
Daily
Oil filter Change Change
Air filter ** Check Change Change
pressure
ULTRA COOLANT* Check Sample Sample Change
Power Drive Module filter * Check Change Change Change
Hoses *** Check / Check / Check /
clean clean clean
Pressure relief valve Check Check Check
Cooler Core(s) Check / Check / Check / Check /
clean clean clean clean
Moisture separator Check / Check / Check / Check /
Motor cowl Check / Check / Check / Check /
Vibration Analysis Analysis Analysis Analysis
Coolant Analysis Analysis Analysis Analysis
Blower Motor Regrease Regrease
Expansion joint bolt torque Check Check
Condensate stainers Clean Clean Clean Clean
Check valve Inspect Replace
Blowdown valves Inspect Inspect
Airend intake batts ** Check
Breather Check Check Check
If the compressor is run less than 4,000 hours per year,

* Maintain every 6 months
** Maintain every year
*** Maintain every 2 years
78 IRN90–160K–OF & IRN125–200H–OF

10.0 MAINTENANCE
10.3 MAINTENANCE PROCEDURES
CAUTION
Before beginning any work on the compressor, read and understand the safety instructions in this manual.
Open, lock and tag the main electrical disconnect and close the isolation valve on the compressor discharge.
Do not under any circumstances open any drain valve or remove components from the compressor until this
has been carried out. Note that pipework downstream of the check valve may still contain pressure that must
also be vented to atmosphere before beginning any work.
CAUTION
When using any form of liquid for cleaning, ensure that all electrical components are protected or covered
to prevent ingress of liquid.
WARNING
internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt
DANGER
internal capacitors store a potentially lethal high voltage electric charge which gradually falls to zero over
time. After switching off the machine at its local isolator WAIT AT LEAST 15 MINUTES for the capacitors to
fully discharge before opening the power drive module doors.
WARNING
Use suitable equipment for lifting heavy items and ensure loose components are adequately supported to
eliminate risk of dropping.
WARNING
Compressed air can be dangerous if incorrectly Prior to opening or removing panels or covers to
handled. Before doing any work on the unit, ensure that work inside a machine, ensure that:–
all pressure is vented from the system and that the
anyone entering the machine is aware of the reduced
machine cannot be started accidentally.
level of protection and the additional hazards,
Ensure that maintenance personnel are adequately including hot surfaces and intermittently moving
trained, competent and have read the Maintenance parts.
Manuals.
the machine cannot be started accidentally or
Prior to attempting any maintenance work, ensure appropriate anti–start devices.
that:–
all air pressure is fully discharged and isolated from
the system. If the automatic blowdown valve is used Prior to attempting any maintenance work on a
for this purpose, then allow enough time for it to running machine, ensure that:–
complete the operation.
the work carried out is limited to only those tasks
the machine cannot be started accidentally or which require the machine to run.
the work carried out with safety protection devices
disabled or removed is limited to only those tasks
all residual electrical power sources (mains and which require the machine to be running with safety
battery) are isolated. protection devices disabled or removed.
IRN90–160K–OF & IRN125–200H–OF 79

10.0 MAINTENANCE
all hazards present are known (e.g. pressurized Upon completion of maintenance tasks and prior
components, electrically live components, removed to returning the machine into service, ensure that:–
panels, covers and guards, extreme temperatures,
inflow and outflow of air, intermittently moving parts,
the machine is suitably tested.
safety valve discharge etc.).
all guards and safety protection devices are refitted.
appropriate personal protective equipment is worn.
loose clothing, jewelry, long hair etc. is made safe.
all panels are replaced, canopy and doors closed.
warning signs indicating that Maintenance Work is in
hazardous materials are effectively contained and
Progress are posted in a position that can be clearly
seen. disposed of.
10.4 ROUTINE MAINTENANCE
This section refers to the various components which OIL AND OIL FILTER
require periodic maintenance and replacement.
Change oil filter after every 8,000 hours or less as
For all other maintenance, contact your local required (see checking procedure below).To check the
Ingersoll–Rand office, Distributor or Air Center. condition of the oil filter, the compressor must be
running and the oil temperature must be greater than
Refer to safety information and maintenance
49C (120F). With these conditions met select ”OIL
procedures prior to carrying out any of the maintenance FILTER PRESS DROP” from current status screen. If
in the following sections. ”OIL FILTER PRESS DROP is less than 0,9 bar (13 psi)
then the oil and filter do not need service. If the warning
Prior to starting light is on and ”CHANGE OIL FILTER” warning is
displayed, then the oil should be drained and the filter
replaced.
Oil level checking procedure.
The oil level should be checked daily. level sight glass To change the oil and filter, the oil should be warm for
is located on the oil sump while the machine is running more effective drainage. Remove the two enclosure
on load, oil should always be visible in the sight glass. panels at the rear of the machine. remove the pipe plug
The normal position is 3/4 to full from the oil drain connection in the rear of the
Adding oil baseplate. Place a suitable drain pan under the drain
connection and open the valve.
Run the compressor for a minimum of 40 seconds, the
oil level should be 3/4 to full as seen in the sight glass.If
not, stop the compressor and slowly unscrew the oil fill Dispose of waste oil according to local regulations.
plug. Add Ultra–Coolant and recheck the oil level. When the gearcase is empty, close the valve and
Repeat until the oil level is visible in the sight glass with replace the pipe plug. Position the empty drain pan
the compressor running under the oil filter. Remove the filter and allow the oil to
drain from the oil cooler as well. Wipe the sealing
surface of the filter adaptor with a clean, lint–free cloth.
WARNING Remove the replacement filter from its protective
Under no circumstance should the compressor be package. Apply a small amount of clean oil on the
operated with the oil fill plug removed rubber seal and install the element. Screw the element
on until the seal makes contact with the seat on the
adaptor head. Tighten the filter a further 1/2 to 3/4 of a
turn.
Unscrew the oil fill plug and add oil until the level
reaches the top of the gearcase sight glass.
Replace the oil fill plug and tighten
80 IRN90–160K–OF & IRN125–200H–OF

10.0 MAINTENANCE
Start the compressor and check the oil filter and oil Apply high melting point grease into the blower motor
drain valve for leaks. Select ”BEARING OIL PRESS” bearings using a grease gun at the nipple provided.
from the current status screen to insure that adequate
Stop when excess grease is seen at the relief port.
oil pressure has been attained. Inspect the gearcase
sight glass, the correct oil level for the sump during
operation is 3/4 to 4/4 full. Some amount of foaming in
the sight glass is normal. The oil level is interpreted as Oil hoses
the level in the sight glass below the top foam, where a The flexible hoses that carry oil through the cooling
line of separation can be seen. If additional oil is system may become brittle with age and will require
required, stop the compressor and add oil as needed. replacement. Have your local Ingersoll–Rand
Distributor or Air Center inspect them every 3 months
Tools required and replace them as needed or every 2 years.
Wide–blade screwdriver or M10 wrench or M10 socket
with ratchet Depending on the location of the hose, it may contain
400mm adjustable wrench compressor oil. It is recommended to drain the oil into
600mm adjustable wrench a clean container. Cover the container to prevent
Oil filter wrench contamination. If the oil is contaminated, a new charge
of oil must be used
Parts required
Oil filter element Remove the hose.
Approximately 64 litre (17 U.S. gal) of Ultra Coolant
hydraulic oil. Install the new hose and refill the unit with oil. Start
the compressor, check for leaks and check coolant
level. Refill as necessary.
Replace the oil fill plug and tighten
Pressure system
At 2000 hour intervals, inspect the external surfaces of Pressure relief valve check
the airends and piping, including all fittings, for visible The pressure relief valve must be frequently tested and
signs of impact damage, excessive corrosion and regularly maintained. Remove from the machine and
abrasions. Any suspect parts should be replaced check for the correct operating pressure. Correct,
before the compressor is put back into service. replace as necessary. If operating conditions are
particularly severe, the frequency of testing and
maintenance must be increased accordingly. A
Gearcase breather pressure relief valve check must also be performed at
the end of any non–service period. The user must
To service the gearcase breather, remove the establish the frequency of such tests as it is influenced
appropriate panel. Remove the breather cover by by such factors as the severity of the operating
unscrewing the four retaining screws. Remove all of the environment.
breather media and clean with a suitable solvent. Allow
the media to dry. Re–install the media, the cover, and
the enclosure panel.
CAUTION
Condensate drain functionality High pressure air will discharge through the
To verify the functionality of the condensate drains, discharge ports of the valve during pressure relief
simply observe the timed operation of each. Each drain
valve check. Wear ample clothing, gloves, safety
should open at least every 3 minutes while the
glasses and ear protection during valve testing.
compressor is loaded. (The intercooler drain exhausts
at a much lower pressure than the aftercooler).
Oil free condensate can be disposed of via a sewer Run the compressor for about 10 minutes by venting air
drain. from the system to let the unit warm up. With the unit
Condensate strainers running, test at or near the maximum operating
pressure by opening the valve for the minimum period
In order to service the condensate strainers (both required to flush the valve seat free of debris. This can
interstage and discharge), the strainer service valves be accomplished by holding the test lever fully open or
preceding the strainers should be closed. Remove the unscrewing the spring pressure retaining cap,
screens from the strainers, while noting the direction. depending on the type of valve installed. If there is no
Clean any debris from the screens and reinstall. Open evidence of discharge or the valve does not fully close,
the strainer service valves. discontinue use of equipment and contact a licensed
contractor or qualified service personnel.
The pressure relief valve should also be tested and
re–calibrated in accordance with any national or local
Blower motor Re–Grease
codes that may exist. If no code exists, IR recommend
(N75–160 Aircooled units) that the pressure relief valve is recalibrated at intervals
6 Months or 4000 Hrs. of one year.
IRN90–160K–OF & IRN125–200H–OF 81

10.0 MAINTENANCE
Air filter change procedure Cover the inlet grill of the intake panel with plastic
sheeting to prevent cleaning solution from exiting
Unclip the retaining cap and withdraw the old
the compressor.
element.
Remove enclosure intake batts
Fit the new element and refit the retaining cap.
Use an extended length nozzle and a mild cleaning
solution to clean the coolers.
Aircooled Cooler Cleaning
Ensure that the compressor is isolated from the WARNING
compressed air system and is vented of all pressure. Strong cleaners can harm aluminium cooler parts.
When undertaking any work on the compressor always Follow cleaner manufacturers instructions for use.
use certified lifting equipment and employ sound Wear appropriate safety equipment.
working principles.
Ensure that the main power disconnect switch is locked Cleaning fluid will collect on both sides of the cooler
off and tagged. core. If required, periodically drain fluid from intake
plenum and bucket to prevent them from over
Visually check the outside of the cooler cores to be flowing.
certain that a complete cleaning of the cooler is
required. Frequently, dirt, dust or other foreign material After cleaning is complete, dry off plenum, intake,
may only need to be removed with a vacuum to remedy and cooler core. Reassemble parts in reverse order.
the problem.
When the cooler is covered with a combination of oil,
grease or other heavy substances that may affect the Watercooled Cooler Cleaning
unit’s cooling, then it is recommended that the cooler A periodic inspection and maintenance program should
cores be thoroughly cleaned on the outside. be implemented for watercooled heat exchangers. The
If it is determined that the compressor operating following steps should be taken:
temperature is higher than normal due to the external Inspect filters in system and replace or clean as
passages between the fins of the cooler cores being required.
restricted with deposits of foreign material, then the
cooler should be removed for cleaning. Carefully examine cooler shells for scale and clean
if necessary. If a cleaning solution is used, be sure
to wash out all chemicals thoroughly with clean
water before returning the compressor to service.
WARNING After cleaning, examine the cooler for erosion or
Strong cleaners can harm aluminium cooler parts. corrosion.
Follow cleaner manufacturers instructions for use. A qualified cleaning service should be used for the
Wear appropriate safety equipment. cleaning process. These organizations can
evaluate the type of deposit to be removed and
supply the appropriate solution and method for a
The coolers in these machines can either be cleaned by complete cleaning job.
removing the complete cooler for off site cleaning or When reinstalling bonnets to cooler shell, tighten
’back flushing’ in place using a high pressure hose and bolts uniformly in a cross–pattern. Overtightening
gaining access through the holes in the intermediate can result in cracking of the bonnet.
plenum.
Cleaning solutions must be compatible with the
metallurgy of the cooler
Instructions for cleaning the coolers while Care must be taken to avoid damaging tubes if
installed in the compressor. mechanical cleaning procedures are used.
While cleaning coolers, great care must be taken to
protect the rest of the machine from moisture and Airend bearings
contamination by covering sensitive parts with plastic Airend bearings are lubricated by the compressor oil
sheeting. and require no maintenance.
Remove plenum sheet metal to gain access to the
coolers from the blower side. CAUTION
Remove the 16 screws securing the access panels Under no circumstances should these discharge
on the cooling plenum and remove covers. temperatures be exceeded. If the machine fails to
trip A FAULT EXISTS. Investigate immediately.
Cover main drive motor, PDM Heat sink blower
motor, drain valve, air filter, and cooling motor
variable speed drive with plastic sheeting to prevent Blower Motor Bearing Maintenance (Stored units)
damage from entrance of cleaning solution.
Prior to placing a unit in storage for extended
Cover inlet of blower wheel with plastic sheeting to intervals, rotate the blower motor several
prevent entrance of cleaning fluid. revolutions by hand in the direction of rotation.
82 IRN90–160K–OF & IRN125–200H–OF

10.0 MAINTENANCE
On N75 – 160 aircooled units, whilst rotating the Condensate (Moisture) Drain Valve / Trap
motor, pump grease into the bearing until grease is
Ensure compressor is electrically isolated for 15
seen at the relief port.
minutes and all pressure is relieved from system.
Thereafter rotate the motor as described above Remove all pipes going to and from the valve (or
every three months until such time as the unit is trap).
placed in service.
Disconnect any electrical cables to the valve (or
If the storage time is to exceed a total of nine (9) trap).
months duration, the compressor must be ordered
for long term storage. Determine the type of condensate drain device and
continue in the appropriate section below:–
Motor cowl cleaning
Ensure compressor is electrically isolated for at Timed Solenoid Drain Valves Check / Cleaning
least 15 minutes before commencing any Remove the central nut and then the electrical coil.
maintenance work.
Remove screws holding bonnet of valve and
Remove panels from the compressor. carefully split the valve. Clean and inspect all
Using a clean dry cloth, remove dust from the internal parts.
surface of the motor cowl and ensure all ventilation Similarly check and clean the ball valve and needle
slots are free of obstructions. valve.
Replace panels to the compressor. Replace any defective parts as identified in parts
manual.
Drive Box Filter Removal/Replacement
Re–assemble and later, with machine running,
Ensure compressor is electrically isolated for at check that condensate and air is expelled at
least 15 minutes before commencing any frequency and duration set into the INTELLISYS
maintenance work. controller (see section 9.6).
Unclip the front grill of the drive box filter.
Remove the filter pad from the housing and replace
with a new filter pad from Ingersoll–Rand.
Replace front grill to the drive box filter.
Moisture Separator Check/Cleaning

Ensure compressor is electrically isolated for at
least 15 minutes, before commencing any
maintenance work.
Isolate the compressor from the system and fully
discharge the compressed air within the unit.
Remove plastic tube from the fitting located on the
bottom of the moisture separator.
Remove the bowl of the moisture trap, clean and
replace.
IRN90–160K–OF & IRN125–200H–OF 83

10.0 MAINTENANCE
Fluid and Vibration Monitoring Oil Sampling Procedure
Ingersoll–Rand recommends incorporating predictive With unit at sump oil temperature of 130 – 140 F, stop
maintenance, specifically the use of oil and vibration the compressor. Wait 5 minutes, or sufficient time until
analysis, into all Preventative Maintenance programs. oil in sight glass becomes clear, and any entrained air
Predictive Maintenance is designed to increase system bubbles in the oil dissipate.
reliability and prevent costly downtime. Through the
use of sophisticated diagnostic tools, including fluid, Remove oil fill cap from oil fill tube. Using oil sample
vibration, and optional air analysis, IR Certified Service pump kit, install a new hose on the pump. Insert the
Technicians can identify and correct potential problems hose into the fill tube, and push the sample tube all the
BEFORE they can cause expensive unscheduled way to the bottom of the oil sump. You will feel the hose
downtime. hit the the bottom of the sump. Once the bottom is felt,
pull the hose up about one inch. This prevents a sample
from gathering any sediment that may be on the bottom
How does predictive analysis work? By establishing an of the sump. Extract the sample.
initial baseline for normal operation, and then regularly
monitoring fluid and vibration conditions, any sudden Remove the hose, remove the sample cup cap the cup,
deviation or significant increase from this baseline can and reinstall the oil cap. Label and process the sample..
be identified and investigated to pinpoint the cause.
More quickly diagnosing potential problems can directly
save money by preventing costly failures and reducing
or eliminating downtime. In addition, regular condition
monitoring also helps to maximize the time between
expensive preventative maintenance intervals, such as
component rebuilds and oil changes.
84 IRN90–160K–OF & IRN125–200H–OF

11.0 FAULT FINDING
11.1 GENERAL FAULTS
WARNING
When attempting to identify and remedy any fault or failure, ensure it is only attempted by qualified personnel and that
the safety and maintenance sections of this manual have been read and are fully understood and followed. Major
overhauls should only be carried out by a qualified Ingersoll–Rand representative. Failures caused by fitting parts not
recommended by Ingersoll–Rand or non–authorized Ingersoll–Rand personnel may not be covered by the terms of
any warranty agreement
SYMPTOM FAULT REMEDY

Compressor will not No power supply to package Check supply is switched on. If so, contact a
start qualified electrician.
Intellisys controller failure Check supply to unit. Replace unit.
Starter failure Isolate supply, lock off and tag. Replace failed
component or contact your local Ingersoll–Rand
representative
Compressor stops and Drive controller has tripped See section 11.2 & 11.3
will not restart
Intellisys controller has tripped See section 11.2 & 11.3
the compressor
Compressor is stopped Intellisys controller has tripped See section 11.2 & 11.3
and will not restart the compressor and has not
been reset
Emergency stop has been Identify reason why, repair fault, disengage button
pressed and not released and reset Intellisys controller
Emergency stop has been Repair fault and reset Intellisys controller
pressed and released but
Intellisys controller has not been
reset
IRN90–160K–OF & IRN125–200H–OF 85

11.0 FAULT FINDING

Compressor will not Compressor not sized to meet Contact your local IR representative
meet pressure required system requirements or
by system requirements have been
changed.
Air loss due to pipe, hose, joint Overhaul or replace
or seal failure
Air loss due to blowdown valve Overhaul or replace
stuck open
Air loss through pressure relief Overhaul or replace
valve not seating or set
incorrectly
Air loss due to moisture Overhaul or replace
separator drain trap stuck open
Motor speed too low caused by Contact your local IR representative
drive incorrectly set
Motor speed too low caused by See section on drive faults
fault in drive settings
Intellysis controller fault Overhaul or replace
Drive motor fault See section on drive faults
Pressure transducer faulty, Recalibrate or replace
incorrectly calibrated or EMF
interference
Incorrect Intellisys controller Check and modify settings
settings
Inlet grill or ducting is blocked Check and clean
Air filter dirty or collapsed Replace
Pipe / Hoses blocked or Clean or replace
collapsed
Cooler core blocked Clean or replace
Check valve not functioning Overhaul or replace
correctly
Equipment between compressor Review system requirements
and customer measuring point
causing pressure drop /
pressure loss
86 IRN90–160K–OF & IRN125–200H–OF

11.0 FAULT FINDING

Pressure produced by Intellisys set incorrectly Check and modify settings
compressor is too high
Pressure transducer may be Recalibrate or replace
due to speed not
faulty, incorrectly calibrated or
reducing as demand
not receiving pressure signal
reduces
Drive settings fault Contact your local IR representative
Compressor discharge High ambient temperature Review installation and system parameters
air too hot
Insufficient cooling air Check ducting and cooling air path, check direction of
blower rotation
Blocked aftercooler matrix Clean or replace
Compressor package Panels or doors are not closed Rectify fault
produces excessive properly
noise
Air leaks from internal pipework / Overhaul or replace
components
Blower or blower motor bearings Overhaul or replace
worn
Loose debris impacting on Remove and rectify any damage
blower during rotation
Blowdown valve stuck open Overhaul or replace
Pressure relief valve not seating Overhaul or replace
correctly
Vibration due to motor, airend or Overhaul or replace
blower imbalance
Airend requires overhaul Contact your local IR representative
IRN90–160K–OF & IRN125–200H–OF 87

11.0 FAULT FINDING

Discharge air is Aftercooler not functioning Clean or replace
contaminated with correctly
condensate
Timed solenoids not set properly Adjust the timed solenoid Interval and/or duration
for environment. through the Operator Setpoints menu
Moisture separator drain lines Clean or replace
blocked.
Compressor package Compressor operating above Check and modify settings. Review system
draws too much current rated pressure requirements and contact your local IR representative
Voltage supply is low or Contact your local IR representative or a qualified
unbalanced electrician
Airend is damaged Contact your local IR representative
11.2 INTELLISYS FAULTS

(INDICATED ON THE INTELLISYS CONTROLLER)
FAULT CAUSE REMEDY

Emergency Stop Emergency stop button has Identify reason why, repair fault, disengage button
been pressed. and reset Intellisys controller
Blower motor overload Blower is blocked, damaged or Remove blockage, repair or replace damaged
blower motor is faulty. components
High airend discharge Compressor operating above Check and modify settings. Review system
temperature rated pressure requirements and contact your local IR representative
High ambient temperature Review installation and system parameters
Insufficient cooling air Check ducting and cooling air path.
Blocked cooler matrix Clean or replace
Blower motor direction of rotation Wire correctly
incorrect
Check setpoints Controller software has been Recalibrate all sensors and check setpoints
changed
88 IRN90–160K–OF & IRN125–200H–OF

11.0 FAULT FINDING
FAULT CAUSE REMEDY

Remote start failure Remote start button is pressed Check operation of buttons or operating procedures
after machine is running or
remote start button remains
closed.
Remote stop failure Remote stop button remains Check operation of buttons or operating procedures
open and either start button is
pressed
Sensor failure Sensor is missing or faulty Install, repair or replace faulty sensor
Compressor trips Insufficient cooling taking place If machine is watercooled, check that the cooling
indicating a high water is flowing. Check that there is no air in the
compressor water cooling system. Check that the strainer is not
temperature. blocked.
Intellisys controller has A fault has occurred Repair fault / reset Intellisys controller
tripped the compressor
Invalid Calibration Calibration done with pressure in Depressurise and recalibrate with pressure pipe to
compressor. sensor disconnected. If fault still exists, replace
pressure transducer.
Check motor rotation This will occur if the Intellisys Contact your local IR representative
reads a negative speed from the
VSD when starting.
VSD communication Communication wiring faulty Check and replace if required
failure
Drive faulty Contact your local IR representative
Intellisys faulty Contact your local IR representative
VSD initialisation fault Communication wiring faulty Check and replace if required
Drive faulty Contact your local IR representative
Intellisys faulty Contact your local IR representative
High I/C condensate This will occur if COND LEVEL Check operation of condensate removal system
INSTALLED is YES and the
High Condensate Level switch
remains on for 1 minute
High intercooler Air blockage, Airend damage Check piping, contact IR representative
pressure
High 2nd stage 3APT is greater than the rated Too high of pressure drop between 2nd stage
pressure discharge pressure plus 15 psi / discharge and package or remote pressure sensing,
1 bar check piping
High line air pressure This will occur if the discharge Too high of pressure drop, check piping, system
pressure (from 4APT) is greater check valve failure, other compressor in system
than the rated discharge creating high pressure
pressure plus 15 psi / 1 bar.
IRN90–160K–OF & IRN125–200H–OF 89

11.0 FAULT FINDING
FAULT CAUSE REMEDY

Low bearing oil This will occur if 6OPT is less Check oil level (between 3/4 and full in sightglass), oil
pressure than 17 psi / 1.2 bar and the unit leaks, oil filter dirty or plugged, oil relief valve leaking,
is running.
High 1st stage This will occur if 2ATT is greater Assure machine has adequate ventilation, ambient
temperature than 482F / 250C. temperature is not above 115F / 46C, assure
cooling blower is operating, coolers are clean, airend
damage
High 2nd stage Will occur when 4ATT is greater Assure machine has adequate ventilation, ambient
temperature than 520F / 271C.. temperature is not above 115F / 46C, assure
cooling blower is operating, coolers are clean, airend
damage
High I/C air This will occur if temperature Assure machine has adequate ventilation, ambient
temperature sensor 3ATT is greater than temperature is not above 115F / 46C, assure
140F / 60C. cooling blower is operating, coolers are clean
High bearing oil This will occur if temperature Assure machine has adequate ventilation, ambient
temperature sensor 5OTT is greater than temperature is not above 115F / 46C, assure
170F / 77C. cooling blower is operating, coolers are clean,
thermal valve failure
2nd stage over ratio This alarm will occur if Failed discharge check valve.
(3APT+14.5psi )/(2APT +
14.5psi) is greater than 5
Inlet restriction This will occur if the unit is Dirty inlet air filter, intake duct blocked
running and 1AVPT is greater
than 1.45 psi / 0.1 bar.
FAILED CHECK This warning will occur if the DO NOT hit the Emergency Stop Button. Close the
VALVE second stage discharge isolation valve immediately to isolate the compressor
pressure exceeds 50 psig when from the system. Clear the warning and stop the
the compressor is operating compressor using the stop button on the Intellisys.
unloaded. Inspect the check valve and replace if necessary.
Inspect the package discharge blowdown valve and
replace if necessary.
90 IRN90–160K–OF & IRN125–200H–OF

11.0 FAULT FINDING
11.3 DRIVE FAULTS

(INDICATED ON THE INTELLISYS CONTROLLER)
The drive controller is directly linked to the Intellisys controller. Faults in the drive controller will be displayed on the
Intellisys controller as ‘VSD fault 0, VSD fault 1’ etc.
The following VSD faults may be investigated and remedied at source. For all other VSD faults, contact your local IR
customer support representative.
FAULT CAUSE ACTION

VSD Fault 1 Over–current Check cooler, pipework and moisture separator for
blockages.
Check operation of check valve.
VSD Fault 3 Drive temperature too high Check drive filter, replace if necessary
Check drive cooling fan circuit breaker
Check wiring
IRN90–160K–OF & IRN125–200H–OF 91

FSM (Davidson)

Drawings and Electrical
Schematics


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Nirvana

Service and Maintenance

Proprietary Notices and Disclaimer

Introduction SGNe Intelllisys

Nirvana Oil Free Training Manual Page 5

Fluid Analysis for Rotary Compressors

Operation and Maintenance Manual

Drawings & Electrical Schematics

Nirvana Oil Free Training Manual Page 6

Nirvana Oil Free Training Manual

In this section, you will learn about:

How to identify the Nirvana Oil Free

The following identification explanation applies to

European built units have different identification

Nirvana Oil Free compressors are designed for the

Compressor Model Number

IR Nominal Power Oil Free

Therefore 132KW unit will have the following Model

Nirvana Oil Free Training Manual Page 1

60 Hz NIRVANA OIL FREE 125-200 HP Specifications

125 646 444 100.4 72 96 7088

150 681 555 100.4 72 96 7088

200 904 751 100.4 72 96 7088

50 Hz NIRVANA OIL FREE 90-160 kW Specifications

Lowest pressure Highest Pressure L W H Weight

90 17.8 12.1 2550 1826 2438 3215

110 19.3 15.4 2550 1826 2438 3215

132 24.9 18.6 2550 1826 2438 3215

160 25.6 22.8 2550 1826 2438 3215

Nirvana Oil Free Training Manual Page 2

are helically twisted in an axial direction, comparable

Nirvana Oil Free Training Manual Page 3

The motor and airend are integrally mounted and

Pressure balancing pockets with discharge to the

This assembly is isolated from the base by rubber

Nirvana Oil Free Training Manual Page 4

Operating Pressures Compressed Air System

An expansion joint is utilised between the moisture

2nd Stage Venturi

Nirvana Oil Free Training Manual Page 5

Strainers are provided upstream of the condensate

• Before any maintenance is

The opening duration is preset at three (3) seconds

The manual bypass valves are located on the

Nirvana Oil Free Training Manual Page 6

Nirvana Oil Free compressors are factory filled

From the pump, the oil travels past a pressure relief

At the discharge side of the oil cooler is a thermo-

The oil then passes through a filter to a distribution

The gearcase is vented to the atmosphere through a

Nirvana Oil Free Training Manual Page 7

Oil Cooler This diagram shows

Nirvana Oil Free Training Manual Page 8

The Nirvana Oil Free utilizes a Triple Inlet After-

From 2nd Stage,

This diagram shows a typical 2nd stage discharge pipeworks

Cooling System (Water Cooled)

Cooling water flows through each of the three com-

Nirvana Oil Free Training Manual Page 9

3 Explain the following Model Number: IRH 160 K OF

4 What is the horsepower and maximum/minimum operating pressure of an

Nirvana Oil Free Training Manual Page 10

Nirvana Oil Free Training Manual

In this section, you will learn