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47612267
Revision B
January 2019

Contact-Cooled Rotary Screw Air Compressor

RS45i, RS55i, RS75i

Product Maintenance Information

Save These Instructions

 EN

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

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EN

ABOUT THIS MANUAL

The purpose of this manual is to provide maintenance and troubleshooting guidelines for the compressor.
For supporting documentation refer to Table 1.
Table 1: Product Manuals
Part/Document Number by Region
Publication Product
Americas EMEA * Asia Pacific
Product Safety Information Manual All 80446313 80446156 80446321
Product Information Manual RS 45-75i 47612264 47612265 47612266
Product Maintenance Manual RS 45-75i 47612267 47612268 47612269
Product Parts Information Manual RS 45-75I 47612270
* Europe, Middle East and Africa
Product specification sheets and reference drawings are also available.
PERSONNEL
Proper use, inspections and maintenance increases the life and usefulness of the compressor. It is extremely important that
anyone involved with maintaining the compressor be familiar with the servicing procedures of these compressors and be
physically capable of conducting the procedures. These personnel shall have skills that include:
1. Proper and safe use and application of mechanics common hand tools as well as special Ingersoll Rand or
recommended tools.
2. Safety procedures, precautions and work habits established by accepted industry standards.
Some maintenance procedures are technical in nature and require specialized tools, equipment, training and experience
to accomplish correctly. In such situations, only allow Ingersoll Rand trained technicians to perform maintenance on this
compressor. Service or inspections beyond the procedures given in this manual shall not be attempted by operating personnel.
For additional information contact the Ingersoll Rand factory or the nearest service provider.

SAFETY
Before undertaking any work on the compressor, ensure that the electrical supply has been isolated, and remote start/stop
function is not enabled, locked off, tagged and the compressor has been relieved of all pressure. Ensure the compressor is
electrically isolated for at least 15 minutes before commencing any maintenance work. See the Product Safety Information
manual for additional information.
Ingersoll Rand cannot know of or provide all the procedures by which repairs may be conducted and the hazards and/or
results of each method. If maintenance procedures not specifically recommended by the manufacturer are conducted, ensure
that safety is not endangered by the actions taken.
If you are unsure of a maintenance procedure or step, place the compressor in a safe condition before consulting technical
assistance.
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and
increased maintenance and may invalidate all warranties.
For additional information contact the Ingersoll Rand factory or the nearest service provider.

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AIR COMPRESSOR MAINTENANCE

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

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EN

NOTICE

Inspect and replace coolant filter elements and separator elements more frequently in dirty operating environments.

„ ROUTINE MAINTENANCE „ DRAINING COOLANT

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

1. Stop the compressor.

2. Isolate the compressor from the external air system.
3. Press the emergency stop. Compressors can take
more than two minutes to fully de-pressurize once
stopped.
3 4
4. Slowly unscrew the coolant fill plug to verify all
pressure has been released.
3. Dispose of waste coolant in accordance with local and
5. Add coolant. governmental regulations.
6. Replace the coolant fill plug and restart the
NOTICE
compressor.
7. Recheck the coolant level. Shorter coolant change intervals may be necessary if
the compressor is operated in adverse conditions.
8. Repeat the above steps until the coolant level is
visible in the sight glass with the compressor both
running and stopped.

NOTICE

Do not add coolant through the intake of the

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

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EN
„ SAMPLING COOLANT FOR ANALYSIS
1. Bring the compressor up to operating temperature.
2. Stop the compressor.
3. Isolate the compressor from the external air system.
4. Press the emergency stop. Fixed speed compressors
can take more than two minutes to fully de-pressurize
once stopped.
5. Draw a sample from the separator tank port using a
pump kit. DO NOT draw a sample from the drain port
or oil filter.
Use a new hose on the pump for each sample. Failure to do
this can give false readings.
See Figure 2.
Figure 2: Coolant Sampling
„ CHANGING COOLANT FILTER
1. Loosen filter with the correct tool.
2. Remove the filter from the housing.
3. Place the old filter in a sealed bag and dispose of in a
safe way.
4. Clean the mating face of the housing taking care to
avoid any particles entering the machine.
5. Remove the new Ingersoll Rand replacement filter
from its protective package.
6. Apply a small amount of lubricant to the filter seal.
Screw the new filter down until the seal makes
contact with the housing, then hand tighten a further
half turn.
7. Start the compressor and check for leaks.
EN-6
„ CHECKING SEPARATOR ELEMENT
With the compressor running on load, check the separator
differential pressure via the controller. It will be necessary to
change the element if the differential pressure equals zero or
exceeds 1 bar (15 psig).
„ CHANGING SEPARATOR ELEMENT
1. Remove the fitting that holds the scavenge tube into
the tank and withdraw the tube assembly.
2. Disconnect the piping from the tank cover. Tag the
lines if required. Remove all the bolts securing the
over to the tank except the bolt opposite the pivot
bolt which should be left engaged by 2-3 threads
with at least 6.5 mm (0.25 in) clearance from the screw
head to the cover. Rotate the jacking bolt clockwise
until the cover lifts off the tank at least 2 mm (0.08 in)
all the way around the tank. Remove the remaining
bolt. The cover can now be rotated to allow access to
inside the tank.
3. Carefully lift the separator element up and out of the
tank. Discard the faulty element.
4. Clean the sealing surface on both the tank and its
cover. Check the tank to be absolutely certain that
no foreign objects such as rags or tools have been
allowed to fall into the tank. Lubricate a thin layer of
coolant on the separator seal top and bottom before
installing a replacement element down into the tank
after checking the new element seal for possible
damage. Center the element within the tank ensuring
that it is fully seated in the sealing groove. Rotate
the tank cover back into position taking care not to
damage the seal, and locate the cover using two bolts
but do not tighten down.
5. Loosen the jacking bolt to fully disengage the threads
and tighten the cover bolts in a cross-pattern to
prevent over-tightening one side of the cover. An
improperly tightened cover will likely result in a leak.
See Figure 3
6. Inspect the tank scavenge screen and orifice. Clean if
necessary following the instructions below.
7. Install the scavenge tube down into the tank until the
tube just touches the separator element and then
raise it 2 mm (0.10 in). Ensure tube is not raised less
than 2 mm (0.10 in) or more than 3 mm (0.125 in).
Tighten fittings.
NOTICE
Take extreme caution to not force the scavenge tube
into the tank. This could potentially damage the
separator element.
8. Install the piping in the original position.
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Figure 3: Recommended Bolt Tightening Cross Pattern
9. Start the compressor and check for leaks.
NOTICE
Do not use any form of sealant on either the separator
tank or the separator tank cover faces.
„ INSPECTING SEPARATOR TANK / PRESSURE SYSTEM
Inspect the external surfaces of the airend and separator
tank, including all fittings, for visible signs of impact damage,
excessive corrosion and abrasions. When changing the
separator element, inspect the internal components and
surfaces. Any suspect parts shall be replaced before the
compressor is put back into service.
The separator tank should also be tested and inspected in
accordance with any national or local codes that may exist.
„ CLEANING / CHECKING SCAVENGE SCREEN
The screen/orifice assemblies are similar in appearance to a
straight tubing connector and will be located between 0.25
inch hose and 6mm (0.25 in) O.D. scavenge line tubing.
The main body is made from 19 mm hexagon shaped metal
and the diameter of the orifice and a direction-of-flow arrow
is stamped in flat areas of the hexagon.
A removable screen and orifice will require clearing as
outlined in the maintenance chart.
To remove the screen/orifice:
1. Disconnect the scavenge line tubing from each end.
2. Hold the center section firmly and use a pair of pliers
to gently grasp the exit end of the assembly that seals
against the scavenge line tubing. The exit end is the
end toward which the arrow is pointing.
3. Pull the end out of the center section while using care
to prevent damage to the screen or sealing surfaces.
4. Clean and inspect all parts prior to reinstallation.
5. When the assembly is installed, confirm the
direction of flow to be correct. Observe the small
arrow stamped in the center section and ensure the
direction flow to be from the separator tank to the
airend.
47612267 Rev B
EN
„ CHECKING MINIMUM PRESSURE CHECK VALVE
(MPCV)
The minimum pressure check valve (MPCV) shall be
frequently tested and regularly maintained. Remove it
from the compressor for testing. If operating conditions are
particularly severe, the frequency of testing and maintenance
shall be increased accordingly. The user shall establish the
frequency of such tests as it is influenced by such factors as
the severity of the operating environment including, but not
limited to, cycles.
The minimum pressure check valve (MPCV) should be
tested and re-calibrated in accordance with any national or
local codes that may exist. If no code exists, Ingersoll Rand
recommends that the valve is recalibrated at intervals of one
year by a licensed contractor or qualified service personnel.
„ CHANGING AIR FILTER
1. Check the retaining cap for dirt and debris and wipe
clean.
2. Unclip the retaining cap and withdraw the old
element.
3. Fit the new element and refit the retaining cap.
„ REGREASING MOTOR
The blower motor contains pre-greased, sealed bearings.
They cannot be re-greased and do not require re-greasing.
Motor bearings - Clean the area around the inlet and outlet
plugs before removing the plugs. Add the specified quantity
of recommended grease using a hand lever gun. Replace the
inlet plug, run the machine for 10 minutes and then replace
the outlet plug
NOTICE
Read the motor data plate(s). For motors that require
greasing, grease them more frequently in harsh
environments or higher ambient conditions.
„ CLEANING AIR COOLED COOLING SYSTEM
Air compressor operating temperatures will be higher than
normal if the external passages between the fins of the
cooler cores become restricted with foreign material. Regular
cleaning of the cooler surfaces will support the reliable
operation of the air compressor system, improve the life of
the compressor coolant and improve overall compressor
efficiency. When performed frequently as determined by
site conditions and airborne contamination, more significant
cleaning or replacement may not be necessary.
1. Stop the compressor.
2. Isolate the compressor from the system.
3. Press the emergency stop. Fixed speed compressors
can take more than two minutes to fully de-pressurize
once stopped.
4. Ensure that the main power disconnect switch is
locked off and tagged.
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EN
NOTICE
For any required lifting of air compressor parts or
required tools, always use the proper certified lifting
equipment, and employ sound working principles.
5. Visually check the outside of the cooler cores to
determine the appropriate cleaning method detailed
as follows:
a. For loose dirt, dust and other light foreign material,
open the access panel on the cooler plenum. Gently
blow compressed air across the cooler surface.
Repeat the process until the coolers are sufficiently
clean. Replace the access panels before returning the
compressor to service.
b. For thick, packed dirt, coolant or grease, or other
heavy material, the coolers will need to be removed
from the compressor for pressure washing. Ingersoll
Rand does NOT support pressure washing coolers
when they are installed in the compressor due to
the dangers of spraying water in or around potential
electrical power sources. Follow the steps below for
cooler removal.
„ REMOVING / INSTALLING AIR COOLED COOLER
To remove:
1. Stop the compressor.
2. Isolate the compressor from the system.
3. Press the emergency stop. Fixed speed compressors
can take more than two minutes to fully de-pressurize
once stopped.
4. Ensure that the main power disconnect switch is
locked off and tagged.
5. Drain the coolant from the coolant cooler.
6. Remove all hoses, pipes, and sensors from the coolers.
7. Remove the external sheet metal panels.
8. Remove cooler mounting connection at both sides
of the cooler. (support cooler with appropriate lifting
provision prior to removing mounting connection).
9. Remove cooler out from mounting connection.
To install:
1. Stop the compressor.
2. Isolate the compressor from the system.
3. Press the emergency stop. Compressors can take
more than two minutes to fully de-pressurize once
stopped.
4. Ensure that the main power disconnect switch is
locked off and tagged.
5. Install cooler mounting connection at both sides of
cooling sheet metal plenum and keep it loosen.
EN-8
6. Carefully place the cooler on its proper location and
install mounting hardware. Fully tighten nut against
bolt shoulder.
7. Re-attach all hoses and pipes and properly torque
according part information manual
8. Refill the compressor coolant to proper level,
following the process outlined in the “Adding Coolant”
procedure.
„ CLEANING WATER COOLED COOLER (FOR BOTH
CLEAN & HARSH WATER OPTIONS)
A periodic inspection and maintenance program should
be implemented for water cooled heat exchangers. It is
recommended that you contact Ingersoll Rand for cleaning
services should you not have experience and equipment to
do this work.
If water inlet lines have strainers, inspect them and replace or
clean as required.
Mineral scale may be removed with a suitable de-scaling
agent containing amidosulphuric acid + citric acid and
Neutralit solutions for cleaning the coolers. As an alternative,
any weak acid mixed with water in the ratio of 1:4 may be
used.
Fouling should be removed with a suitable detergent in hot
water.
Back flush the cooler with a flow rate at least 1.5 times the
normal flow rate.
After using any cleaning solution, thoroughly flush out all
chemicals with clean water before returning the cooler to
service.
Mechanical cleaning methods are not recommended as
damage to the internal passages may occur.
After cleaning, examine the cooler for erosion or corrosion.
„ CLEANING MOTOR COWL
1. Ensure the compressor is electrically isolated
for at least 15 minutes before commencing any
maintenance work.
2. Remove the panels from the compressor.
3. Using a clean dry cloth, remove dust from the surface
of the motor cowl and ensure all ventilation slots are
free of obstructions.
4. Replace the panels.
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„ CLEANING/ CHECKING CONDENSATE DRAIN (WHERE „ CHECKING / CLEANING NO LOSS DRAIN TRAP (WHERE
FITTED) FITTED)
1. Ensure the compressor is electrically isolated It is recommended to check the no loss drain trap daily
for at least 15 minutes, before commencing any to ensure that condensate is draining from the moisture
maintenance work. separator system. To check for correct function:
2. Isolate the compressor from the system and fully 1. Press the test button on the drain and listen for
discharge the compressed air within the compressor. condensate / air passing through the drain.
3. Disconnect cable plug and tubing. Then remove 2. If the drain is clogged, replace the no loss drain valve
Condensate Drain Valve assembly from base. service module. The service module consists of the
lower portion of the drain trap and is not serviceable.
4. Slowly remove the plug from the strainer with a
suitable tool, ensuring pressure has been completely Additionally, it is recommended to replace the service module
released from valve. every 8000 hours or once per year, whichever comes first.
5. Remove the stainless steel filter screen and clean it. „ MONITORING FLUID AND PERFORMING SHOCK
Remove any debris that may be in the strainer body PULSE BEARING ANALYSIS
before replacing the filter screen.
Ingersoll Rand recommends incorporating predictive
6. Replace plug and tighten with suitable tool. maintenance, specifically the use of coolant and shock pulse
bearing analysis, into all preventative maintenance programs.
7. Reinstall Condensate Drain Valve assembly, and
Contact Ingersoll Rand for details.
reconnect cable plug and tubing.
8. Confirm Condensate Drain Valve is functioning
properly and check for leaks.
„ CLEANING / INSTALING PACKAGE PRE-FILTER
(COOLING SUCTION)
1. Unlatch the two 1/4 turn latches and open the intake
panel (panel is hinged)
2. Remove the nuts and flat washer.
3. Remove the filter grill.
4. Pull out the filter element.
5. Center the new element over the package intake
opening. Also note that the filter is washable with
mild detergent.
6. Push the filter over the grill studs so that the studs
poke through the filter media.
7. Install the filter grill.
8. Install the nuts and flat washers.
9. Close the intake panel and latch.

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EN
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by
thorough inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart
below provides a brief guide to common symptoms, probable causes and remedies.
SYMPTOM
Compressor will not start.
Compressor stops and will not
restart.
Compressor is stopped and
will not restart.
Compressor will not meet
pressure required by system.
Compressor will not meet
pressure required by system.
Pressure produced by
compressor is too high due
to speed not reducing as
demand reduces.
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TROUBLESHOOTING
Table 3: General Faults
CAUSE REMEDY
No power supply to compressor. Check supply is switched on. If so, contact a
qualified electrician.
Controller failure. Check supply to controller. Replace controller.
Starter failure. Isolate supply, lock off and tag. Replace failed
component or contact your local Ingersoll
Rand representative.
Controller has tripped the compressor. See Table 4
Maximum number of starts per hour See Table 4
exceeded.
Controller has tripped the compressor and See Table 4
has not been reset.
Emergency stop has been pressed and not Identify reason why, repair fault, disengage
released. button and reset controller.
Emergency stop has been pressed and Repair fault and reset controller.
released but controller has not been reset.
Compressor not sized to meet system Contact your local Ingersoll Rand
requirements or requirements have been representative.
changed.
Air loss due to pipe, hose, joint or seal Repair or replace.
failure.
Air loss due to blowdown valve stuck Repair or replace.
open.
Air loss through pressure relief valve not Repair or replace.
seating or set incorrectly.
Air loss due to moisture separator drain Repair or replace.
trap stuck open.
Controller fault. Repair or replace.
Pressure transducer faulty, incorrectly Recalibrate or replace.
calibrated or EMF interference.
Incorrect controller settings. Check and modify settings.
Inlet grill or ducting is blocked. Check and clean.
Air filter dirty or collapsed. Replace.
Inlet valve not opening fully. Repair or replace.
Separator element dirty or collapsed. Replace.
Pipe / Hoses blocked or collapsed. Clean or replace.
Cooler core blocked. Clean or replace.
Minimum pressure check valve not Repair or replace.
functioning correctly.
Equipment between compressor and Review system requirements.
customer measuring point causing
pressure drop / pressure loss.
Controller set incorrectly. Check and modify settings.
Pressure transducer may be faulty, Recalibrate or replace.
incorrectly calibrated or not receiving
pressure signal.
Drive settings fault. Contact your local Ingersoll Rand
representative.
47612267 Rev B

SYMPTOM
Compressor discharge air too
hot.
SYMPTOM
Compressor package
produces excessive noise.
Discharge air is contaminated
with coolant.
Discharge air is contaminated
with condensate.
Compressor package draws
too much current.
Excessive coolant
consumption.
Solenoid condensate valve
will not close
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EN
CAUSE REMEDY
High ambient temperature. Review installation and system parameters.
Insufficient cooling air. Check ducting and cooling air path, check
direction of blower rotation.
Dirty, blocked aftercooler (cooling air side). Clean or replace.
Table 3: General Faults (cont.)
CAUSE REMEDY
Panels or doors are not closed properly. Rectify fault.
Air leaks from internal pipework / Repair or replace.
components.
Blower or blower motor bearings worn. Repair or replace.
Loose debris impacting on blower during Remove and rectify any damage.
rotation.
Blowdown valve stuck open. Repair or replace.
Pressure relief valve not seating correctly. Repair or replace.
Vibration due to motor, airend or blower Repair or replace.
imbalance.
Airend requires repair. Contact your local Ingersoll Rand
representative.
Scavenge pipe is blocked, broken or o-ring Clean or replace.
is not sealing.
Separator element is punctured, or Replace.
incorrect, or requires changing, or not
sealing correctly.
Incorrect coolant has been added. Drain system, check for damage. Clean, refill
with correct coolant.
System has been overfilled with coolant. Check for damage, drain excess.
Aftercooler not functioning correctly. Clean or replace.
Moisture separator drain trap faulty. Repair or replace.
Continuous low speed / low ambient Review system requirements and contact your
operation causing condensate build up. local Ingersoll Rand representative.
Compressor operating above rated Check and modify settings. Review system
pressure. requirements and contact your local Ingersoll
Rand representative.
Separator filter element dirty or blocked. Replace.
Voltage supply is low or unbalanced. Contact your local Ingersoll Rand
representative or a qualified electrician.
Airend is damaged. Contact your local Ingersoll Rand
representative.
Coolant system leak. Repair or replace.
See also ‘discharge air is contaminated See above.
with coolant’.
Debris in solenoid valve prevents Remove solenoid valve, disassemble, clean
diaphragm from seating. and reassemble.
Short in electrical component. Check and replace power cord or timer as
needed.
EN-11

EN
FAULT
Emergency stop.
Blower motor overload.
High airend discharge
temperature.
Check setpoints.
Remote start failure.
Remote stop failure.
Sensor failure.
Compressor trips indicating
a high compressor
temperature.
Controller has tripped the
compressor.
Invalid calibration.
Low sump pressure.
Check motor rotation.
Change separator element
and/or high sump pressure.
Machine stops but no alarm
message
Motor current fault
EN-12
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Table 4: Controller Faults (indicated on the controller)
CAUSE
Emergency stop button has
been pressed.
Blower is blocked, damaged or
blower motor is faulty.
Compressor operating above
rated pressure.
Low coolant level.
High ambient temperature.
Insufficient cooling air.
Dirty, blocked coolant cooler
(cooling air side).
Blower motor direction of
rotation incorrect.
Controller software has been
changed.
Remote start button is pressed
after compressor is running or
remote start button remains
closed.
Remote stop button remains
open and either start button is
pressed.
Sensor is missing or faulty.
Insufficient cooling taking place.
A fault has occurred.
Calibration done with pressure
in compressor.
System leak.
Minimum pressure check valve
faulty.
Blowdown valve faulty.
Loss of control power.
Drive system fault.
Faulty pressure transducer
measurement.
Moisture separator condensate
drain trap faulty.
Separator element dirty or
blocked.
Loss of outputs of control power. Check controller outputs (110V AC) power supply (fuses/
mini circuit breaker).
Loss of control power.
Sump pressure too high.
Faulty motor or Airend.
REMEDY
Identify reason why, repair fault, disengage button and
reset controller.
Remove blockage, repair or replace damaged
components.
Check and modify settings. Review system requirements
and contact your local Ingersoll Rand representative.
Check for leaks. See also ‘discharge air is contaminated
with coolant’. Top up coolant.
Review installation and system parameters.
Check ducting and cooling air path.
Clean or replace.
Wire correctly.
Recalibrate all sensors and check setpoints.
Check operation of buttons or operating procedures.
Check operation of buttons or operating procedures.
Install, repair or replace faulty sensor.
If compressor is watercooled or sea watercooled, check
that the cooling water is flowing. Check that there is no
air in the water cooling system. Check that the strainer is
not blocked.
Repair fault / reset controller.
Depressurize and re calibrate with pressure pipe to
sensor disconnected. If fault still exists, replace pressure
transducer.
Located and repair.
Repair with service kit.
Repair with service kit.
Check 110V circuit breaker.
Check wiring.
Check contactor KM1.
Contact your local Ingersoll Rand representative.
Calibrate and validate the wet sump and package
discharge transducers.
Ensure condensate drain system is functioning
properly, and condensate is being drained. See Table 4:
Troubleshooting Chart.
Change separator element.
Check control power circuit and breaker.
Check separator element pressure drop.
Contact your local Ingersoll Rand representative.
47612267 Rev B
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EN

INTEGRATED DRYER MAINTENANCE

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

In normal temperature and pressure conditions, the

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

47612267 Rev B EN-13

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EN

„ DECOMMISSIONING THE INTEGRATED DRYER

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

EN-14 47612267 Rev B

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 RELEASED 11/Feb/2019 01:43:20 GMT

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