80446248

Revision A
June 2011

Contact Cooled Rotary Screw Air Compressor PRINT LANGUAGE

R55-160 ENGLISH

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Product Maintenance Information

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Save These Instructions ROMANIAN

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Contents
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cleaning Air Cooled Sequential Cooling System . . . . . . . . . . . . . . . . . . 6

PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removing / Installing Air Cooled Cooler . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cleaning Water Cooled Cooler (for both Clean & Harsh
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Water Options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AIR COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Checking High Airend Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning Motor Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removing / Replacing Starter Box Power Drive Module (PDM) Filter
Element (For VSD only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning / Checking Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning / Installing Package Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Checking / Cleaning No Loss Drain Trap (where fitted) . . . . . . . . . . . . 8
Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Monitoring Fluid and Performing Shock Pulse Bearing Analysis . . . 8
Analyzing Food Grade Coolant Option . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING (VARIABLE SPEED DRIVE
Sampling Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSORS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Changing Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
R55-75 INTEGRATED DRYER MAINTENANCE . . . . . . . . . . . . . . . . 12
Checking Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Changing Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Inspecting Separator Tank / Pressure System . . . . . . . . . . . . . . . . . . . . 5 Cleaning Condensate Drains (Timed Drains Only) . . . . . . . . . . . . . . . 12

Cleaning / Checking Scavenge Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Testing Condensate Drains (No-Loss Drains Only) . . . . . . . . . . . . . . . 12

Replacing Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting Condensate Drains (Electronic

Drains Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Checking Minimum Pressure Check Valve (MPCV) . . . . . . . . . . . . . . . . 6
Disassembling the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . 12
Changing Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Regreasing Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Decommissioning the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . 12

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 All 80446339 80446164 80446347
R55-75 kW 80446271
Product Parts Information Manual R132-160 kW Single-Stage 80446057
R90-160 kW Two-Stage 80446065
* 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 Some maintenance procedures are technical in nature and require
of the compressor. It is extremely important that anyone involved with specialized tools, equipment, training and experience to accomplish
maintaining the compressor be familiar with the servicing procedures of correctly. In such situations, only allow Ingersoll Rand trained technicians
these compressors and be physically capable of conducting the procedures. to perform maintenance on this compressor. Service or inspections beyond
These personnel shall have skills that include: the procedures given in this manual shall not be attempted by operating
personnel.
1. Proper and safe use and application of mechanics common hand
tools as well as special Ingersoll Rand or recommended tools. For additional information contact the Ingersoll Rand factory or the nearest
service provider.
2. Safety procedures, precautions and work habits established by
accepted industry standards.

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

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AIR COMPRESSOR MAINTENANCE

 Maintenance Prompts  Maintenance Chart
The service warning and flashing LED will appear at intervals dependent Maintenance should be performed per the recommendations below in the
on the service level selected. Refer to the Product Information manual for following priority: (1) Perform maintenance when indicated by the controller;
information about service level settings. (2) Perform maintenance through either hourly intervals or scheduled
maintenance intervals, or (3) Annually.

Table 2: Maintenance Chart

Period Action Maintenance Item
When indicated by Replace Air filter element
controller Replace Coolant filter element
Replace Separator element
Daily Check Connections and hoses for leaks
Check Coolant level
Check Condensate drain operation
Check Controller for service indicators
Check Package pre-filter for blockage
Monthly Inspect Air-cooled sequential cooling system for blockage
Inspect Water-cooled sequential cooling system screens
Inspect Starter box power drive module (PDM) filter element
Analysis Water from water-cooled sequential cooling system
Every 500 hours Analysis Food grade coolant
Every 1000 hours Replace Food grade coolant (if not using food grade filter module)
Replace Food grade coolant filter (if not using food grade filter module)
Every 2000 hours or Inspect Air filter element
3 months Inspect Coolant filter element
Inspect Starter box power drive module (PDM) filter element
Replace Food grade coolant (if using food grade filter module)
Replace Food grade filter module
Analysis Shock pulse bearing
Analysis Coolant
Every 4000 hours or 6 Inspect Scavenge screen for blockage
months Replace Air filter element
Replace Coolant filter element
Replace Starter box power drive module (PDM) filter element
Replace Package pre-filter element
Clean Air-cooled sequential cooling system
Inspect / Clean Water-cooled sequential cooling system
Grease All motors (as required)
Calibrate Pressure transducers
Analysis Coolant
Analysis Shock pulse bearing
Every 8000 hours or Replace Standard coolant (8000 hours or every two years)
annually Replace Separator element
Replace No-loss condensate drain service module
Service Minimum pressure check valve (MPCV) service kit
Service Inlet valve service kit
16000 hours Replace Coolant hoses
Replace Contact tips

NOTICE

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

NOTICE

Read the motor data plate(s) or call the motor manufacturer(s) to determine specific greasing requirements. For motors that require greasing,
grease them more frequently in harsh environments or higher ambient conditions.

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 Routine Maintenance Figure 1: Coolant Drain

This section refers to the various components which require periodic

maintenance and replacement.
Refer to safety information and maintenance procedures prior to carrying out
any of the maintenance in the following sections.

 Checking Coolant Level

The coolant level should be checked daily. A coolant level sight glass is
located on the side of the 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 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:
4. Dispose of waste coolant in accordance with local and
1. Stop the compressor. governmental regulations.
2. Isolate the compressor from the external air system. It is recommended to perform a coolant analysis every 2000 hours or three
3. Press the emergency stop to vent the separator tank and airend. months to monitor its condition and determine when to change the coolant.
Fixed speed compressors can take more than two minutes to fully If analysis is not performed, the recommended coolant change interval is
de-pressurize once stopped. 8000 hours or two years, whichever comes first.

4. Slowly unscrew the coolant fill plug to verify all pressure has been NOTICE
released.
5. Add coolant. Shorter coolant change intervals may be necessary if the compressor
is operated in adverse conditions.
6. Replace the coolant fill plug and restart the compressor.
7. Recheck the coolant level.  Analyzing Food Grade Coolant
8. Repeat the above steps until the coolant level is visible in the sight It is highly recommended to have samples of the coolant analyzed every
glass with the compressor both running and stopped. 500 hours or each month to determine when coolant should be changed.
If analysis is not performed, coolant should be changed after 2000 hours
NOTICE or every six months when utilizing the food grade filter supplied with the
compressor.
Do not add coolant through the intake of the compressor, as this can
result in overfilling, saturation of the separator filter element, and For compressors running food grade coolant without the food grade filter,
coolant carry-over downstream. the change interval should be 1000 hours or six months, whichever comes
first.
 Draining Coolant  Sampling Coolant
It is better to drain the coolant immediately after the compressor has been 1. Bring the compressor up to operating temperature.
operating as the coolant will drain faster and any contaminant will still be in
suspension. 2. Stop the compressor.

See Figure 1. 3. Isolate the compressor from the external air system.

1. Install a drain hose (not supplied) in the end of the drain valve and 4. Press the emergency stop to vent the separator tank and airend.
place the end of the hose in a suitable container. Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.
2. Open the drain valve to start drainage.
5. Draw a sample from the separator tank port using a pump kit. DO
3. After drainage, remove the hose and close the valve. 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
NOTICE false readings.
On air cooled compressors, you may also drain coolant from the See Figure 2.
coolant cooler by removing the plug.
You should also drain additional coolant from the airend by removing
the plug in the airend discharge elbow.

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Figure 2: Coolant Sampling tools have been allowed to fall into the tank. Install 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.

NOTICE

Unscrew the jacking bolt sufficiently to ensure that the cover can be
fully tightened down without imparting any stress onto the jacking
points. Tighten down the cover bolt to 81 N m (60 ft lb) for 75 kW
and smaller compressors or 200 N m (150 ft lb) for 90 kW and larger
compressors. Refer to Figure 3 for the tightening sequence of the
bolts.

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 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.

Figure 3: Recommended Bolt Tightening Cross Pattern
3 3
11 8 8

 Changing Coolant Filter 5

5 10
10
1. Loosen the filter element with the correct tool.
2 1
2. Remove the element from the housing. 1
2
3. Place the old element in a sealed bag and dispose of in a safe way.
9 6 9
4. Clean the mating face of the housing. 6
7 12 7
5. Remove the new replacement element from its protective package. 4 4

6. Apply a small amount of coolant to the element seal. 90-160 kW 55-75 kW

7. Screw the new element down until the seal makes contact with the 9. Start the compressor and check for leaks.
housing, then hand tighten a further half turn.
Start the compressor, check for leaks and check the coolant level. NOTICE
 Checking Separator Element Do not use any form of sealant on either the separator tank or the
separator tank cover faces.
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).  Inspecting Separator Tank / Pressure System
 Changing Separator Element At 2000 hour intervals, inspect the external surfaces of the airend and
separator tank, including all fittings, for visible signs of impact damage,
1. Remove the fitting that holds the scavenge tube into the tank and excessive corrosion and abrasions. When changing the separator element,
withdraw the tube assembly. inspect the internal components and surfaces. Any suspect parts shall be
2. Disconnect the piping from the tank cover. Tag the lines if required. replaced before the compressor is put back into service.
Remove all the bolts securing the cover to the tank except the The separator tank should also be tested and inspected in accordance with
bolt opposite the pivot bolt which should be left engaged by 2-3 any national or local codes that may exist.
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  Cleaning / Checking Scavenge Screen
lifts off the tank at least 2 mm (0.08 in) all the way around the tank.
The screen/orifice assemblies are similar in appearance to a straight tubing
Remove the remaining bolt. The cover can now be rotated to allow
connector and will be located between two pieces of 6 mm (0.25 in) O.D.
access to inside the tank.
scavenge line tubing.
3. Carefully lift the separator element up and out of the tank. Discard
The main body is made from 17 mm hexagon shaped metal and the diameter
the faulty element.
of the orifice and a direction-of-flow arrow is stamped in flat areas of the
4. Clean the sealing surface on both the tank and its cover. Check the hexagon.
tank to be absolutely certain that no foreign objects such as rags or

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A removable screen and orifice will require clearing as outlined in the 4. Ensure that the main power disconnect switch is locked off and
maintenance chart. tagged.
To remove the screen/orifice:
NOTICE
1. Disconnect the scavenge line tubing from each end.
For any required lifting of air compressor parts or required tools,
2. Hold the center section firmly and use a pair of pliers to gently
always use the proper certified lifting equipment, and employ sound
grasp the exit end of the assembly that seals against the scavenge
working principles.
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 5. Visually check the outside of the cooler cores to determine the
damage to the screen or sealing surfaces. appropriate cleaning method detailed as follows:

4. Clean and inspect all parts prior to reinstallation. a. For loose dirt, dust and other light foreign material, open the
access panels on the sides of the cooler plenum and gently
5. When the assembly is installed, confirm the direction of flow to blow compressed air across the coolant cooler surface. Use a
be correct. Observe the small arrow stamped in the center section vacuum hose with a soft brush to clean the exposed face of the
and ensure the direction flow to be from the separator tank to the air aftercooler. Repeat the process until the coolers are sufficiently
airend. clean. Replace the access panels before returning the compressor to
service.
 Replacing Coolant Hoses
b. For thick, packed dirt, coolant or grease, or other heavy material,
The flexible hoses that carry coolant through the cooling system may the coolers will need to be removed from the compressor for
become brittle with age and will require replacement. Replace them as pressure washing. Ingersoll Rand does NOT support pressure
needed or every four years. washing coolers when they are installed in the compressor due
1. Depending on the location of the hose, it may contain compressor to the dangers of spraying water in or around potential electrical
coolant. It is recommended to drain the coolant into a clean power sources. Follow the steps below for cooler removal.
container. Cover the container to prevent contamination. If the
 Removing / Installing Air Cooled Cooler
coolant is contaminated, replace with new coolant.
To remove:
2. Remove the hose.
1. Stop the compressor.
3. Install the new hose and refill the compressor with coolant.
2. Isolate the compressor from the system.
4. Start the compressor, check for leaks and check coolant level. Refill
as necessary. 3. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
 Checking Minimum Pressure Check Valve (MPCV) de-pressurize once stopped.
The minimum pressure check valve (MPCV) shall be frequently tested and 4. Ensure that the main power disconnect switch is locked off and
regularly maintained. Remove it from the compressor for testing. If operating tagged.
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 NOTICE
environment.
For any required lifting of air compressor parts or required tools,
The minimum pressure check valve (MPCV) should be tested and re- always use the proper certified lifting equipment, and employ sound
calibrated in accordance with any national or local codes that may exist. If working principles.
no code exists, Ingersoll Rand recommends that the valve is recalibrated at
intervals of one year by a licensed contractor or qualified service personnel.
5. Drain the coolant from the coolant cooler by removing the hex plug
 Changing Air Filter located at the front of the air cooler, and lower side of the coolant
cooler.
1. Check the retaining cap for dirt and debris and wipe clean.
6. Remove all hoses, pipes, and sensors from the coolers.
2. Unclip the retaining cap and withdraw the old element.
7. Remove the external sheet metal panels.
3. Fit the new element and refit the retaining cap.
8. Remove the access panels on the sides of the cooler plenum.
 Regreasing Motor
9. Properly secure the air aftercooler and remove the four nuts from
The blower motor contains pre-greased, sealed bearings. They cannot be the two bolts at the upper sides of the cooler.
re-greased and do not require re-greasing. For the main motor, consult the
motor manufacturer to confirm that the motor may be greased and to obtain 10. Remove the two nuts from the bolts at the bottom of the cooler.
instructions for regreasing.
11. Carefully remove the air aftercooler.
 Cleaning Air Cooled Sequential Cooling System 12. Properly secure the coolant cooler and remove the four nuts from
Air compressor operating temperatures will be higher than normal if the the two bolts at the upper sides of the cooler.
external passages between the fins of the cooler cores become restricted 13. Remove the two nuts from the bolts at the bottom of the cooler.
with foreign material. Regular cleaning of the cooler surfaces will support
the reliable operation of the air compressor system, improve the life of 14. Carefully remove the coolant cooler.
the compressor coolant and improve overall compressor efficiency. When
15. Re-install the coolant drain plug to 23 N m (17 ft lb) for compressors
performed frequently as determined by site conditions and airborne
75 kW and smaller or 65 N m (48 ft lb) for compressors 90 kW and
contamination, more significant cleaning or replacement may not be
larger.
necessary.
1. Stop the compressor.
2. Isolate the compressor from the system.
3. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.

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To install: If water inlet lines have strainers, inspect them and replace or clean as
required.
1. Stop the compressor.
Mineral scale may be removed with a suitable de-scaling agent containing
2. Isolate the compressor from the system. amidosulphuric acid + citric acid and Neutralit solutions for cleaning the
3. Press the emergency stop to vent the separator tank and airend. coolers. As an alternative, any weak acid mixed with water in the ratio of 1:4
Fixed speed compressors can take more than two minutes to fully may be used.
de-pressurize once stopped. Fouling should be removed with a suitable detergent in hot water.
4. Ensure that the main power disconnect switch is locked off and Back flush the cooler with a flow rate at least 1.5 times the normal flow rate.
tagged.
After using any cleaning solution, thoroughly flush out all chemicals with
clean water before returning the cooler to service.
NOTICE
Mechanical cleaning methods are not recommended as damage to the
For any required lifting of air compressor parts or required tools, internal passages may occur.
always use the proper certified lifting equipment, and employ sound
working principles. After cleaning, examine the cooler for erosion or corrosion.

 Checking High Airend Temperature Sensor

5. Carefully place the coolant cooler in its proper location and install
It is recommended that the discharge temperature sensor (2ATT) is checked
the two sets of lower nuts and bolts, tightly.
regularly as follows:
6. Install the two sets of upper side nuts and bolts, finger tight + ¼
a. For air cooled compressors, stop the cooling blower by opening the
turn. Next, add the second nut to each tightly. This second nut is
blower / fan motor circuit breaker.
used to lock the first in place. It is important the first nut is not too
tight so it can allow the cooler to expand and contract without b. For water cooled compressors, shut off the cooling water.
stressing the cooler’s brazed joints.
The compressor should trip at 109° C (228° F). A trip warning will appear on
7. Ensure the rubber seal on the air aftercooler is in place on the the controller display.
cooler and in good condition.
 Cleaning Motor Cowl
8. Carefully place the air aftercooler cooler in its proper location and
install the two sets of lower nuts and bolts tightly. 1. Ensure the compressor is electrically isolated for at least 15 minutes
before commencing any maintenance work.
9. Install the two sets of upper side nuts and bolts finger tight + ¼
turn. Next add the second nut to each tightly. This second nut is 2. Remove the panels from the compressor.
used to lock the first in place. It is important the first nut is not too 3. Using a clean dry cloth, remove dust from the surface of the motor
tight so it can allow the cooler to expand and contract without cowl and ensure all ventilation slots are free of obstructions.
stressing the cooler’s brazed joints.
4. Replace the panels.
10. Re-attach all hoses, pipes and sensors, and properly torque
according to the Parts Information manual.  Removing / Replacing Starter Box Power Drive Module (PDM)
11. Replace the access panels on the sides of the cooler plenum. Filter Element (For VSD only)

12. Refill the compressor with coolant to the proper level, following the See Figure 4.
process outlined in the “Adding Coolant” procedure. 1. Ensure compressor is electrically isolated for at least 15 minutes
before commencing any maintenance work.
 Cleaning Water Cooled Cooler (for both Clean & Harsh Water
Options) 2. Unclip the front grill of the starter box filter housing.
A periodic inspection and maintenance program should be implemented for 3. Remove the filter element from the housing and replace with a new
water cooled heat exchangers. It is recommended that you contact Ingersoll filter element.
Rand for cleaning services should you not have experience and equipment
4. Replace the front grill.
to do this work.

Figure 4: Starter Box Power Drive Module (PDM) Filter Element Replacement

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 Cleaning / Checking Condensate Drain  Checking / Cleaning No Loss Drain Trap (where fitted)
1. Ensure the compressor is electrically isolated for at least 15 minutes, It is recommended to check the no loss drain trap daily to ensure that
before commencing any maintenance work. condensate is draining from the moisture separator system. To check for
correct function:
2. Isolate the compressor from the system and fully discharge the
compressed air within the compressor. 1. Press the test button on the drain and listen for condensate / air
passing through the drain.
3. Remove the tube from the fitting located on the bottom of the
moisture separator. 2. If the drain is clogged, replace the no loss drain valve service
module. The service module consists of the lower portion of the
4. Remove the bowl of the moisture trap, clean and replace. drain trap and is not serviceable.
 Cleaning / Installing Package Pre-Filter Additionally, it is recommended to replace the service module every 8000
1. Unlatch the two 1/4 turn latches and open the intake panel (panel hours or once per year, whichever comes first.
is hinged)  Monitoring Fluid and Performing Shock Pulse Bearing
2. Remove the six wing nuts and flat washers. Analysis
3. Remove the filter grill. Ingersoll Rand recommends incorporating predictive maintenance,
specifically the use of coolant and shock pulse bearing analysis, into all
4. Pull out the filter element. preventative maintenance programs. Contact Ingersoll Rand for details.
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 six wing nuts and flat washers.
9. Close the intake panel and latch.

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TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specific causes to problems are best identified by thorough inspections performed
by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common symptoms, probable
causes and remedies.
Table 3: General Faults
SYMPTOM CAUSE REMEDY
Compressor will not start. No power supply to compressor. Check supply is switched on. If so, contact a qualified
electrician.
Controller failure. Check supply to controller. Replace controller.
Starter failure. Isolate supply, lock off and tag. Replace failed component
or contact your local Ingersoll Rand representative.
Compressor stops and will not Drive controller has tripped. See Tables 3 and 4.
restart. Controller has tripped the compressor. See Tables 3 and 4.
Maximum number of starts per hour exceeded.

Compressor is stopped and will not Controller has tripped the compressor and has not See Tables 3 and 4.
restart. been reset.
Emergency stop has been pressed and not released. Identify reason why, repair fault, disengage button and
reset controller.
Emergency stop has been pressed and released but Repair fault and reset controller.
controller has not been reset.
Compressor will not meet pressure Compressor not sized to meet system requirements Contact your local Ingersoll Rand representative.
required by system. or requirements have been changed.
Air loss due to pipe, hose, joint or seal failure. Repair or replace.
Air loss due to blowdown valve stuck open. Repair or replace.
Air loss through pressure relief valve not seating or Repair or replace.
set incorrectly.
Air loss due to moisture separator drain trap stuck Repair or replace.
open.
Motor speed too low caused by drive incorrectly set. Contact your local Ingersoll Rand representative.
Motor speed too low caused by fault in drive settings. See Table 4.
Controller fault. Repair or replace.
Drive motor fault. See Table 4.
Pressure transducer faulty, incorrectly calibrated or Recalibrate or replace.
EMF interference.
Incorrect controller settings. Check and modify settings.
Inlet grill or ducting is blocked. Check and clean.
Air filter dirty or collapsed. Replace.
Compressor will not meet pressure Inlet valve not opening fully. Repair or replace.
required by system. Separator element dirty or collapsed. Replace.
Pipe / Hoses blocked or collapsed. Clean or replace.
Cooler core blocked. Clean or replace.
Minimum pressure check valve not functioning Repair or replace.
correctly.
Equipment between compressor and customer Review system requirements.
measuring point causing pressure drop / pressure
loss.
Pressure produced by compressor is Controller set incorrectly. Check and modify settings.
too high due to speed not reducing
Pressure transducer may be faulty, incorrectly Recalibrate or replace.
as demand reduces.
calibrated or not receiving pressure signal.
Drive settings fault. Contact your local Ingersoll Rand representative.
Compressor discharge air too hot. 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.

EN- 80446248 Rev A

 EN

Table 3: General Faults (cont.)

SYMPTOM CAUSE REMEDY
Compressor package produces Panels or doors are not closed properly. Rectify fault.
excessive noise.
Air leaks from internal pipework / components. Repair or replace.
Blower or blower motor bearings worn. Repair or replace.
Loose debris impacting on blower during rotation. Remove and rectify any damage.
Blowdown valve stuck open. Repair or replace.
Pressure relief valve not seating correctly. Repair or replace.
Vibration due to motor, airend or blower imbalance. Repair or replace.
Airend requires repair. Contact your local Ingersoll Rand representative.
Discharge air is contaminated with Scavenge pipe is blocked, broken or o-ring is not Clean or replace.
coolant. sealing.
Separator element is punctured, or incorrect, or Replace.
requires changing, or not sealing correctly.
Incorrect coolant has been added. Drain system, check for damage. Clean, refill with correct
coolant.
System has been overfilled with coolant. Check for damage, drain excess.
Discharge air is contaminated with Aftercooler not functioning correctly. Clean or replace.
condensate. Moisture separator drain trap faulty. Repair or replace.
Continuous low speed / low ambient operation Review system requirements and contact your local
causing condensate build up. Ingersoll Rand representative.
Compressor package draws too much Compressor operating above rated pressure. Check and modify settings. Review system requirements
current. and contact your local Ingersoll Rand representative.
Separator filter element dirty or blocked. Replace.
Voltage supply is low or unbalanced. Contact your local Ingersoll Rand representative or a
qualified electrician.
Airend is damaged. Contact your local Ingersoll Rand representative.
Excessive coolant consumption. Coolant system leak. Repair or replace.
See also ‘discharge air is contaminated with coolant’. See above.
High dewpoint. Refrigeration compressor not supplied power. Check incoming power supply.
Check the dryer protection fuse.
Check auxiliary contact on main motor contactor.
Condensate system malfunction. Check operation of drain valve.
Check operation of condensate check valves.
Condenser dirty. Clean condenser and replace panel filter element.
Ice formation in dryer. Low evaporator pressure. Check hot gas valve setting.

80446248 Rev A EN-10

 EN

Table 4: Controller Faults (indicated on the controller)

FAULT CAUSE REMEDY
Emergency stop. Emergency stop button has been Identify reason why, repair fault, disengage button and reset controller.
pressed.
Blower motor overload. Blower is blocked, damaged or blower Remove blockage, repair or replace damaged components.
motor is faulty.
High airend discharge temperature. Compressor operating above rated Check and modify settings. Review system requirements and contact
pressure. your local Ingersoll Rand representative.
Low coolant level. Check for leaks. See also ‘discharge air is contaminated with coolant’.
Top up coolant.
High ambient temperature. Review installation and system parameters.
Insufficient cooling air. Check ducting and cooling air path.
Dirty, blocked coolant cooler (cooling Clean or replace.
air side).
Blower motor direction of rotation Wire correctly.
incorrect.
Check setpoints. Controller software has been changed. Recalibrate all sensors and check setpoints.
Remote start failure. Remote start button is pressed after Check operation of buttons or operating procedures.
compressor is running or remote start
button remains closed.
Remote stop failure. Remote stop button remains open and Check operation of buttons or operating procedures.
either start button is pressed.
Sensor failure. Sensor is missing or faulty. Install, repair or replace faulty sensor.
Compressor trips indicating a high Insufficient cooling taking place. If compressor is watercooled or sea watercooled, check that the cooling
compressor temperature. water is flowing. Check that there is no air in the water cooling system.
Check that the strainer is not blocked.
Controller has tripped the A fault has occurred. Repair fault / reset controller.
compressor.
Invalid calibration. Calibration done with pressure in Depressurize and re calibrate with pressure pipe to sensor
compressor. disconnected. If fault still exists, replace pressure transducer.
Low sump pressure. System leak. Located and repair.
Minimum pressure check valve faulty. Repair with service kit.
Blowdown valve faulty. Repair with service kit.
Loss of control power. Check 110V circuit breaker.
Check wiring.
Check contactor KM1.
Check motor rotation. Drive system fault. Contact your local Ingersoll Rand representative.
VSD communication failure. Communication wiring faulty. Check and replace if required.
Drive faulty. Contact your local Ingersoll Rand representative.
Controller faulty. Contact your local Ingersoll Rand representative.
VSD initialization fault. Communication wiring faulty. Check and replace if required.
Drive faulty. Contact your local Ingersoll Rand representative.
Controller faulty. Contact your local Ingersoll Rand representative.

Table 5: Drive Faults (indicated on the controller)

The drive controller is directly linked to the controller. Faults in the drive controller will be displayed on the 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 Ingersoll Rand customer support
representative.

FAULT CAUSE ACTION

VSD Fault 1 Over-current. Check separator element.
Check cooler, pipework and moisture separator for blockages.
Check operation of minimum pressure check valve (MPCV).
VSD Fault 3 Drive temperature too high. Check drive filter, replace if necessary.
Check drive cooling fan circuit breaker.
Check wiring.

EN-11 80446248 Rev A

 EN

R55-75 INTEGRATED DRYER MAINTENANCE

Table 7: Condensate Drain Troubleshooting Chart
! WARNING
TROUBLE CAUSE ACTION
Before accessing live electrical parts, disconnect the power supply Solenoid Debris in solenoid valve Remove solenoid valve,
to the dryer using the disconnect switch or disconnecting the cable condensate valve prevents diaphragm disassemble, clean and
connections.
will not close. from seating. reassemble.
Short in electrical Check and replace power
 Maintenance Chart component. cord or timer as needed.
For optimum performance from your dryer, follow the periodic maintenance
schedule described below.  Disassembling the Integrated Dryer
Table 6: Maintenance Chart
NOTICE
WEEKLY CONDENSATE DRAINS (TIMED AND NO-LOSS
DRAINS) The dryer shall be disassembled, charged or repaired by a refrigerant
specialist.
Verify that the condensate drains are operating
correctly by pressing the TEST button. Refrigerant liquid and lubricating oil inside the refrigeration circuit
shall be recovered in compliance with current norms in the country
EVERY 4 MONTHS CONDENSER where the dryer is installed.
Remove any dust from the condenser fins.
EVERY 6 MONTHS AIR FILTER NOTICE

Replace air filter element. Refrigerant leaks may be identified by tripping of the refrigeration
overload protector.
YEARLY (TIMED DRAINS ONLY)
If a leak is detected in the refrigerant circuit, seek technical assistance.
Completely disassemble the drains and clean all
their components. If a refrigerant leak occurs, thoroughly air the room before
commencing work.
 Cleaning Condensate Drains (Timed Drains Only)
Periodically clean the screen inside the valve to keep the drain functioning at NOTICE
maximum capacity. To do this, perform the following steps:
In normal temperature and pressure conditions, the R-404A
1. Close the strainer ball valve completely to isolate it from the air refrigerant is a colorless, class A1/A1 gas with TVL value of 1000 ppm
receiver tank. (ASHRAE classification).
2. Press the TEST button on the timer to vent the pressure remaining
in the valve. Repeat until all pressure is removed.
 Decommissioning the Integrated Dryer
! WARNING Decommission the dryer and the relevant packaging in compliance with the
rules locally in force.
High pressure air can cause injury from flying debris. Ensure the
strainer ball valve is completely closed and pressure is released from Pay particular attention to the refrigerant, as it contains part of the
the valve prior to cleaning. refrigerating compressor lubricating oil.
Contact a waste disposal and recycling utility.
3. Remove the plug from the strainer with a suitable wrench. If you
Table 8. Integrated Dryer Materials of Construction.
hear air escaping from the cleaning port, STOP IMMEDIATELY and
repeat steps 1 and 2. RECYCLING DISASSEMBLY
4. Remove the stainless steel filter screen and clean it. Remove any Frame and panels Steel / epoxy resin polyester
debris that may be in the strainer body before replacing the filter
screen. Heat exchanger (cooler) Stainless steel / aluminum
Pipes Copper
5. Replace plug and tighten with wrench.
Insulation Gum synthetic
6. When putting the valve back into service, press the TEST button to
confirm proper function. Compressor Steel / copper / aluminum / oil
Condenser Aluminum
 Testing Condensate Drains (No-Loss Drains Only)
Refrigerant R-404A
Press the TEST button to confirm proper function.
Valve Steel
 Troubleshooting Condensate Drains (Electronic
Drains Only)
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.

80446248 Rev A EN-12

Notes
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