Ingersoll-Rand R4-11 kW Setup guide

80448517
Revision A
December 2014
Save These Instructions
Contact-Cooled Rotary Screw Air Compressor
Product Maintenance Information
R4-11 kW
RELEASED 16/Dec/2014 10:49:53 GMT
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EN
EN-2 80448517 Rev A
CONTENTS
ABOUT THIS MANUAL
PERSONNEL
SAFETY
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.
Before undertaking any work on the compressor, ensure that the electrical
supply has been isolated, locked o, tagged and the compressor has been
relieved of all pressure. For VSD units, ensure the compressor is electrically
isolated for at least 15 minutes before commencing any maintenance work.
Ensure the compressor’s remote start/stop feature has been switched o
prior to any maintenance. See the 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 specically 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.
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
Publication Product Part/Document Number by Region
Americas EMEA * Asia Pacic
Safety Information Manual R4-160kW 80446313 80446156 80446321
Maintenance Manual R4-11kW 80448517 80448525 80448533
Product Manual R4-11kW 80448483 80448491 80448509
Parts Information Manual R4-11kW 80448541
* Europe, Middle East and Africa
Product specication sheets and reference drawings are also available.
ABOUT THIS MANUAL ......................................2
PERSONNEL ................................................2
SAFETY ....................................................2
AIR COMPRESSOR MAINTENANCE...........................3
Maintenance Prompts .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..3
Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Checking Coolant Level ........................................ 4
Adding Coolant ............................................... 4
Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sampling Coolant ............................................. 5
Changing Coolant Filter Element ............................... 5
Checking Separator Element ................................... 5
Changing Separator Element................................... 5
Inspecting Airend/Pressure System/Receiver .................... 5
Cleaning / Checking Scavenge Orice........................... 5
Cleaning / Checking Blowdown Orice .......................... 6
Replacing Coolant Hoses....................................... 6
Checking Minimum Pressure Check Valve (MPCV) ............... 6
Changing Air Filter Element ................................... 6
Cleaning Air Cooled Combination Cooling System ............... 6
Removing / Installing Air Cooled Cooler......................... 6
Checking High Airend Temperature Sensor...................... 7
Cleaning Motor Cowl .......................................... 7
Removing / Replacing Starter Box Power Drive Element (PDM)
Filter Element (For VSD Only)................................... 7
Cleaning / Checking Condensate Drain.......................... 7
Cleaning / Installing Package Pre-Filter ......................... 7
Monitoring Fluid and Performing Shock Pulse Bearing Analysis .. 7
Aftermarket Kits .............................................. 7
Changing Pulleys / Belts ....................................... 7
TROUBLESHOOTING........................................9
R411 INTEGRATED DRYER MAINTENANCE................. 15
Maintenance Chart. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 15
Troubleshooting .............................................15
Disassembly of the Integrated Dryer...........................17
Decommissioning the Integrated Dryer ........................18
Filter Element Replacement ...................................18
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AIR COMPRESSOR MAINTENANCE
Maintenance Prompts
The service warning and ashing LED will appear at intervals dependent
on the service level selected. Refer to the Product Information manual for
information about service level settings.
Maintenance Chart
Maintenance should be performed per the recommendations below in the
following priority: (1) Perform maintenance when indicated by the controller;
(2) Perform maintenance through either hourly intervals or scheduled
maintenance intervals, or (3) Annually.
Table 2: Maintenance Chart
Period Action Maintenance Item
Daily
Check Connections and hoses for leaks
Check Coolant level
Check Condensate drain operation
Check Controller for service indicators
Check Package pre-lter for blockage
Monthly Inspect Air-cooled combination cooling system for blockage
Inspect Starter box power drive element (PDM) lter element (if applicable)
Every 1000 hours Inspect Air lter element
Analysis Food-grade Lubricant (Ultra FG)
Every 2000 hours or
3 months
Inspect Starter box power drive element (PDM) lter element (if applicable)
Inspect Drive belt
Inspect Airend/Pressure System/Receiver
Inspect Inspect and test pressure relief valve
Replace Air lter element
Replace Package pre-lter element
Replace Separator element
Replace Coolant lter element
Analysis Shock pulse bearing
Analysis Premium Coolant (Ultra/Ultra EL)
Every 4000 hours or
6 months
Inspect Scavenge tubes/orice and blowdown orice for blockage
Replace Starter box power drive element (PDM) lter element (if applicable)
Clean Air-cooled combination cooling system
Calibrate Pressure transducers (only applies to compressors equipped with Xe-70M controller)
Replace Dryer lter elements (if applicable)
Every 6000 hours Replace Food-grade Lubricant (Ultra FG)
Every 8000 hours or
annually
Replace Premium Coolant (Ultra) [8000 hours or every 2 years]”
Replace Minimum pressure check valve (MPCV)
16000 hours or 2 years
Replace Drive belts
Replace Extended Life Premium Coolant (Ultra EL) [16000 hours or every 3 years]”
Replace Rubber Coolant Hoses
24000 hours or 3 years Replace Contact tips
40000 hours or 5 years Replace Stainless Steel Coolant Hoses
NOTICE
Inspect and replace air ltration, coolant and separator elements more frequently in dirty operating environments
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EN
EN-4 80448517 Rev A
Routine Maintenance
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
A. Correct at operating temperature
B. Too much
C. Too little
Figure 1: Coolant Level in Sight Glass
See Figure 1.
The coolant level should be checked daily. A coolant level sight glass is
located on the front of the sump. While the compressor is running loaded
at operating temperature (ten minutes running loaded), coolant should ll
the sight glass half-way (See Figure 1). Do not allow the coolant levels to go
beyond the centerline of the sight glass or increased carryover may occur. The
compressor includes a coolant level decal which shows the proper coolant
level range appropriate for operation. When the coolant level is visible in the
sight glass at the level indicated by the green area on the decal, then the
compressor has the proper quantity of coolant. If the coolant level is in the
red area above the green, then the compressor is over lled. If the coolant
level is in the red area below the green, the compressor is under lled.
When the unit is shut down, coolant will usually ll up the sight glass. Do not
adjust level based on level at shutdown. Proper level is always set for running
unit at operating temperature.
Adding Coolant
If it is determined that coolant must be added, follow the steps below:
1. Stop the compressor.
2. Isolate the compressor from the external air 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.
4. Ensure the main power disconnect is locked o and tagged.
5. Slowly unscrew the coolant ll plug to verify all pressure has been
released.
6. Add coolant.
7. Replace the coolant ll plug and restart the compressor.
8. Recheck the coolant level.
9. Repeat the above steps until the coolant level is visible within the
specied range, as explained above.
NOTICE
Do not add coolant through the intake of the compressor, as this can
result in overlling, saturation of the separator lter element, and
coolant carry-over downstream.
Draining Coolant
It is recommended to drain the coolant immediately after the compressor has
been operating as the coolant will drain faster and any contaminant will still
be in suspension.
12
34
Figure 2: Coolant Drain location
See Figure 2.
1. Slowly unscrew the coolant drain cap.
2. Screw drain hose (24096984) onto the drain valve. As you do so,
the drain valve will open, causing coolant to drain out through the
hose.
3. Allow the coolant to ow into a suitable container.
4. After drainage, remove the drain hose and replace drain valve cap.
5. Dispose of waste coolant in accordance with local and governmental
regulations.
NOTICE
Coolant should be drained from the cooler and coolant scavenge tube.
NOTICE
Shorter coolant change intervals may be necessary if the compressor
is operated in adverse conditions.
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80448517 Rev A EN-5
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Sampling Coolant
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 to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.
5. Draw a sample from the sump ll port. DO NOT draw a sample from
the drain port or coolant lter port.
Use a new hose on the pump for each sample. Failure to do this can give false
readings.
See Figure 3.
Figure 3: Coolant Sampling
Changing Coolant Filter Element
1. Stop the machine, electrically isolate and vent all trapped pressure.
2. Loosen lter element with the correct tool.
3. Remove the lter element from the housing.
4. Place the old lter element in a sealed bag and dispose of in a safe
way.
5. Clean the mating face of the housing, taking care to avoid any
particles entering the machine.
6. Remove the new Ingersoll Rand replacement lter element from its
protective package.
7. Apply a small amount of lubricant to the lter seal.
8. Screw the new lter element down until the seal makes contact with
the housing, then hand tighten a further full turn.
9. Start the compressor and check for leaks.
Checking Separator Element
Feature available only on machines equipped with Xe-70 controller.
With the compressor running on load, check the separator dierential
pressure via the controller. It will be necessary to change the element if the
dierential pressure equals zero or exceeds 1 bar (12 psig).
Changing Separator Element
1. Stop the machine, electrically isolate and vent all trapped pressure.
2. Loosen element with the correct tool.
3. Remove the element from the housing.
4. Place the old element in a sealed bag and dispose of in a safe way.
5. Clean the mating face of the housing, taking care to avoid any
particles entering the machine. 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.
6. Remove the new Ingersoll Rand replacement element from its
protective package.
7. Apply a small amount of lubricant to the element seal.
8. Screw the new element down until the seal makes contact with the
housing, then hand tighten a further 1/4 turn.
9. Start the compressor and check for leaks.
Inspecting Airend/Pressure System/Receiver
At 2000 hour intervals, inspect the external surfaces of the airend including
all ttings, for visible signs of impact damage, excessive corrosion and
abrasions.
The receiver (if applicable) should also be tested and inspected in accordance
with any national or local codes that may exist.
Cleaning / Checking Scavenge Orice
The orice is similar in appearance to a straight tubing connector and will
be located between the 6 mm (0.25 in) O.D. scavenge line tubing and the
integrated separator/MPCV manifold.
The main body is made from 17 mm hexagon shaped metal and the diameter
of the orice and a direction-of-ow arrow is stamped in at areas of the
hexagon. The orice should be examined and cleaned as recommended in
maintenance schedule.
Figure 4: Scavenge Orice
To remove the scavenge orice:
1. Stop the machine, electrically isolate and vent all trapped pressure.
2. Disconnect the scavenge line tubing from end and unscrew from
integrated separator/ MPCV manifold.
3. Inspect orice and tubing for clogging and clean prior to re-
installation. If there is any scaling or o-ring damage identied, the
scavenge orice will need to be replaced before the compressor is
put back into service.
4. When the assembly is installed, conrm the direction of ow to be
correct. Observe the small arrow stamped in the center section and
ensure the direction of ow to be from the separator tank to the
airend.
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EN-6 80448517 Rev A
Cleaning / Checking Blowdown Orice
The blowdown orice is integrated into the push-in connector at the inlet
valve (see gure 5). This blowdown orice should be examined and cleaned
as recommended in the maintenance schedule.
Figure 5: Blowdown Orice
To remove the blowdown orice:
1. Stop the machine, electrically isolate and vent all trapped pressure.
2. Disconnect the synex tubing from the blowdown orice.
3. Unscrew the blowdown orice from the body of the inlet valve.
4. Inspect blowdown orice and tubing for clogging and clean prior to
re-installation. If there is any scaling identied, the blowdown orice
will need to be replaced before the compressor is put back into
service.
5. Ensure synex tube is full inserted back into the blowdown orice
once re-installed on inlet valve.
Replacing Coolant Hoses
The exible hoses that carry coolant through the cooling system may
become brittle with age and will require replacement. Replace them as
recommended.
1. Depending on the location of the hose, it may contain compressor
coolant. It is recommended to drain the coolant into a clean
container. Cover the container to prevent contamination. If the
coolant is contaminated, replace with new coolant.
2. Remove the hose.
3. Install the new hose and rell the compressor with coolant.
4. Start the compressor, check for leaks and check coolant level. Rell as
necessary.
Checking Minimum Pressure Check Valve (MPCV)
The minimum pressure check valve (MPCV) shall be frequently tested and
regularly maintained. Verify that the valve opens at 60 psi and that the valve
fully seals in the reverse ow direction. 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
inuenced by such factors as the severity of the operating environment.
Changing Air Filter Element
1. Check the retaining cap for dirt and debris and wipe clean.
2. Unscrew the retaining cap and withdraw the old element.
3. Fit the new element and ret the retaining cap.
Cleaning Air Cooled Combination Cooling System
Air compressor operating temperatures will be higher than normal if the
external passages between the ns 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 eciency. When
performed frequently as determined by site conditions and airborne
contamination, more signicant cleaning or replacement may not be
necessary.
1. Stop the compressor.
2. Isolate the compressor from the system and vent all pressure. For TAS
compressors, isolate the compressor from the receiver by using the
ball valve located between the dryer discharge and the receiver inlet.
For non-TAS, receiver-mounted compressors, evacuate all air from
the receiver.
3. Press the emergency stop to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurized once stopped.
4. Ensure the main power disconnect switch is locked o and tagged.
NOTICE
For any required lifting of air compressor parts or required tools,
always use the proper certied lifting equipment, and employ sound
working principles.
5. Visually check the outside of the cooler core to determine the
appropriate cleaning method detailed as follows:
a. For loose dirt, dust and other light foreign material, gently blow
compressed air across the cooler surface from the top of the
machine. Remove the blower fan and cowl, then use a vacuum
hose with a soft brush to clean the exposed face of the cooler.
Repeat the process until the cooler is suciently clean. Replace
the blower fan and cowl before returning the compressor to
service.
b. For thick, packed dirt, coolant or grease, or other heavy material,
the cooler will need to be removed from the compressor for
pressure washing. Ingersoll Rand does not support the act
of 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 to vent the separator tank and airend.
Fixed speed compressors can take more than two minutes to fully
de-pressurize once stopped.
4. Ensure the main power disconnect switch is locked o and tagged.
NOTICE
For any required lifting of air compressor parts or required tools,
always use the proper certied lifting equipment, and employ sound
working principles.
5. Remove front and back access panels.
6. Disconnect aftercooler discharge tube or hose.
7. Remove top assembly by removing eight bolts while supporting
assembly properly.
8. Disconnect hoses from cooler.
9. Carefully remove cooler from cooler shroud.
To install:
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.
4. Ensure that the main power disconnect switch is locked o and
tagged.
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80448517 Rev A EN-7
EN
NOTICE
For any required lifting of air compressor parts or required tools,
always use the proper certied lifting equipment, and employ sound
working principles.
5. Carefully place cooler in its proper location.
6. Connect hoses to cooler and properly torque all connections.
7. While supporting the top assembly, fasten the eight bolts into the
opposing sides of the compressor to hold the top assembly in place.
8. Reconnect the aftercooler discharge tube or hose and properly
torque connections.
9. Rell the compressor with coolant to the proper level, following the
process outlined in the“Adding Coolant”procedure.
10. Run the machine and inspect for leaks.
11. Replace the access panels on the front and back of the machine.
Checking High Airend Temperature Sensor
It is recommended that the discharge temperature sensor (2ATT) is checked
regularly (2000 hours) by stopping the cooling fan by opening the fan/ fan
motor circuit breaker (QF4). The compressor should trip at 109C (228F). A trip
warning will appear on the controller display.
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.
Removing / Replacing Starter Box Power Drive Element
(PDM) Filter Element (For VSD Only)
See Figure 6.
1. Ensure compressor is electrically isolated for at least 15 minutes
before commencing any maintenance work.
2. Unclip the front grill of the starter box lter housing.
3. Remove the lter element from the housing and replace with a new
lter element.
4. Replace the front grill.
Figure 6: Open Power Drive Element (PDM)
to Replace Filter Element.
Cleaning / Checking Condensate Drain
1. Ensure the compressor is electrically isolated for at least 15 minutes,
before commencing any maintenance work.
2. Isolate the compressor from the system and fully discharge the
compressed air within the compressor.
3. Remove tubes from drain assembly.
4. Remove screen from drain assembly.
5. Carefully clean screen of debris.
6. Reinstall screen and reattach tubes to drain assembly.
Cleaning / Installing Package Pre-Filter
1. Ensure compressor is electrically isolated for at least 15 minutes
before commencing any maintenance work.
2. Open starter box door.
3. Remove elastic band from bolts.
4. Remove pre-lter from bolts.
5. Line the new pre-lter over the mounting bolts.
6. Push pre-lter down over bolts.
7. Reinstall elastic band over bolts to secure pre-lter.
8. Replace nuts on bolts.
9. Close the panel and latch.
Monitoring Fluid and Performing Shock Pulse Bearing
Analysis
Ingersoll Rand recommends incorporating predictive maintenance,
specically the use of coolant and shock pulse bearing analysis, into all
preventative maintenance programs. Contact Ingersoll Rand for details.
Aftermarket Kits
Ingersoll Rand may oer aftermarket kits to the customer which will
augment characteristics of the compressor. No aftermarket kit is available
which converts a non-tank-mounted compressor into a tank-mounted
compressor.
Changing Pulleys / Belts
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.
4. Ensure the main power disconnect switch is locked o and tagged.
NOTICE
For any required lifting of air compressor parts or required tools,
always use the proper certied lifting equipment, and employ sound
working principles.
NOTICE
Always remain aware of nip points, pinch points and other associated
hazards caused by weighted and/or moving parts. Do not remove
guard at back (non-drive end) of motor. Do not insert anything
between the motor support plate and the airend support. See Figure 5
5. Remove the outer belt guard from the airend support by removing
the nut and washer from the threaded stud, two bolts and washers
from the airend support, and remove the clips between the guards.
6. Loosen the four motor support plate bolts to allow the plate to pivot.
7. Loosen the nut on the belt tensioning (carriage) bolt.
8. Locate the jack bolt which is found on the motor support plate
towards the non-drive end of the motor.
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EN-8 80448517 Rev A
9. Screw the jack bolt down into the motor plate to raise the assembly.
10.Replace the old belt with a new belt as called out in the Parts Manual.
11.After belt is in place, use the jack bolt to slowly lower the motor
support plate.
12.Locate the tensioning bolt, which is the carriage bolt coming from
underneath the motor support plate below the airend.
13.Use the nut/washer from the tensioning bolt along with loosening
the jack bolt to correctly tension the belt. Proper belt tension
frequencies are found in table 3 below.
14.Once belt is aligned and tensioned, replace the front belt guard.
Table 3: Belt tension chart
Power Pressure Belt Tension
Frequency (hz) N/mm lbf/in Power Pressure Belt Tension Frequency (hz) N/mm lbf/in
5 hp
110 PSIG 60 75/21.2 16.9/0.83
7.5 hp
1-Phase
110 PSIG 71 75/17.2 16.9/0.68
125 PSIG 62 75/20.6 16.9/0.81 125 PSIG 67 75/18.4 16.9/0.73
145 PSIG 61 75/20.7 16.9/0.81 145 PSIG 69 75/18.0 16.9/0.71
200 PSIG 72 75/16.9 16.9/0.66
7.5 hp
110 PSIG 71 75/17.2 16.9/0.68
5.5 kW
7.5 Barg 74 75/16.4 16.9/0.65
125 PSIG 67 75/18.5 16.9/0.73 8.5 Barg 74 75/16.3 16.9/0.64
145 PSIG 68 75/18.0 16.9/0.71 10 Barg 76 75/15.9 16.9/0.63
200 PSIG 71 75/16.9 16.9/0.66 14 Barg 74 75/16.3 16.9/0.64
10 hp
110 PSIG 72 75/16.8 16.9/0.66
7.5 kW
7.5 Barg 74 75/16.3 16.9/0.64
125 PSIG 73 75/16.5 16.9/0.65 8.5 Barg 74 75/16.3 16.9/0.64
145 PSIG 74 75/16.3 16.9/0.64 10 Barg 75 75/16.1 16.9/0.63
200 PSIG 76 75/15.8 16.9/0.62 14 Barg 79 75/15.1 16.9/0.59
15 hp
110 PSIG 74 108/16.4 24.3/0.64
11 kW
7.5 Barg 74 105/16.2 23.6/0.64
125 PSIG 74 105/16.3 23.6/0.64 8.5 Barg 75 105/16.1 23.6/0.63
145 PSIG 75 105/16.1 23.6/0.63 10 Barg 73 105/16.5 23.6/0.65
200 PSIG 73 105/16.5 23.6/0.65 14 Barg 74 105/16.4 23.6/0.65
Figure 7: Do not insert anything between motor support plate and airend support.
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80448517 Rev A EN-9
EN
TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specic causes to problems is best identied 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 4: General Faults
SYMPTOM CAUSE REMEDY
Compressor will not start.
No power supply to compressor. Check supply is switched on. If so, contact a qualied
electrician.
Controller failure. Check supply to controller. Replace controller.
Starter failure. Isolate supply, lock o and tag. Replace failed component
or contact your local Ingersoll Rand representative.
Compressor stops and will not
restart.
Drive controller has tripped. See Tables 5 and 6.
Controller has tripped the compressor. See Tables 5 and 6.
Exceeded the maximum number of starts per hour
(6 starts).
Must wait 1 hour before attempting to restart. Contact
your local Ingersoll Rand representative if the problem
continues.
Compressor is stopped and will not
restart.
Controller has tripped the compressor and has not
been reset. See Tables 5 and 6.
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
controller has not been reset. Repair fault and reset controller.
Compressor will not meet pressure
required by system.
Compressor not sized to meet system requirements
or requirements have been changed. Contact your local Ingersoll Rand representative.
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
set incorrectly. Repair or replace.
Air loss due to moisture separator drain trap stuck
open. Repair or replace.
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 6.
Controller fault. Repair or replace.
Drive motor fault. See Table 6.
Pressure transducer faulty, incorrectly calibrated or
EMF interference. Recalibrate or replace.
Incorrect controller settings. Check and modify settings.
Inlet grill or ducting is blocked. Check and clean.
Air lter 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 functioning
correctly. Repair or replace.
Equipment between compressor and customer
measuring point causing pressure drop / pressure
loss.
Review system requirements.
Pressure produced by compressor is
too high due to speed not reducing
as demand reduces.
Controller set incorrectly. Check and modify settings.
Pressure transducer may be faulty, incorrectly
calibrated or not receiving pressure signal. Recalibrate or replace.
Drive settings fault. Contact your local Ingersoll Rand representative.
Compressor discharge air too hot.
High ambient temperature. Review installation and system parameters.
Insucient cooling air. Check ducting and cooling air path, check direction of
blower rotation.
Dirty, blocked aftercooler (cooling air side). Clean or replace.
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EN
EN-10 80448517 Rev A
Table 4: General Faults (cont.)
SYMPTOM CAUSE REMEDY
Compressor package produces
excessive noise.
Panels or doors are not closed properly. Rectify fault.
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
coolant.
Scavenge pipe is blocked, broken or o-ring is not
sealing. Clean or replace.
Separator element is punctured, or incorrect, or
requires changing, or not sealing correctly. Replace.
Incorrect coolant has been added. Drain system, check for damage. Clean, rell with correct
coolant.
System has been overlled with coolant. Check for damage, drain excess.
Discharge air is contaminated with
condensate.
Aftercooler not functioning correctly or may be dirty. Clean or replace.
Moisture separator drain trap faulty. Repair or replace.
Continuous low speed / low ambient operation
causing condensate build up.
Review system requirements and contact your local
Ingersoll Rand representative.
Screen blocked Clean or replace.
Compressor package draws too much
current.
Compressor operating above rated pressure. Check and modify settings. Review system requirements
and contact your local Ingersoll Rand representative.
Separator lter element dirty or blocked. Replace.
Voltage supply is low or unbalanced. Contact your local Ingersoll Rand representative or a
qualied 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 lter element.
Ice formation in dryer. Low evaporator pressure. Check hot gas valve setting.
Solenoid condensate valve will not
close
Debris in solenoid valve prevents diaphragm from
seating.
Remove solenoid valve, disassemble, clean and
reassemble.
Short in electrical component. Check and replace power cord or timer as needed.
Machine stops with no controller
message (Xe-50 only) Controller power supply lost. Check controller power supply fuses and breakers.
Machine stop with the following
controller messages: (Xe-70 only)
Blower fault
4APT failure
Controller power supply lost. Check controller power supply fuses and breakers.
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80448517 Rev A EN-11
EN
Table 5: Controller Faults (indicated on the controller)
Xe-50 DISPLAY MEANING CAUSE REMEDY
Warnings
A:2040 “Freeze Warning
(Dryer Package Only)” Dryer low temperature warning. This serves as a log that the compressor is running in low- ambient conditions.
A:2050 “Dryer High Pressure
(Dryer Pressure Only)” Dryer high pressure warning.
This is a locking switch and the dryer high pressure switch
must be reset (contact closed) before this warning can be
reset.
A:2118 High Airend Discharge
Pressure
Discharge pressure is greater than
oine pressure by 1.45 psi for a
period of 3 seconds or longer
Discharge pressure must fall to the rated pressure value
before the unit is available for reload.
A:2128
High Airend Discharge
Temperature (above
105°C)
Compressor operating above rated
pressure.
Check and modify settings. Review system requirements
and contact your local Ingersoll Rand representative.
Low coolant level. Check for leaks. See also if discharge air is contaminated
with coolant. Top o coolant.
High ambient temperature. Review installation and system parameters.
Insucient cooling air. Check ducting and cooling air path.
Dirty, blocked coolant cooler
(cooling air side). Clean or replace.
Fan motor direction of rotation
incorrect. Wire correctly.
A:2816 Power Failure Detected If power supply to controller is
inconsistant. Check power supply.
A:4804 Service Due Service interval hours counter has
reduced to zero Service compressor.
Trips
E:0010 Emergency Stop
24Vac input not being detected
on terminal R1C (emergency stop
button pressed)
Identify reason why, repair fault, disengage button (if
pressed) and reset conroller.
E:0020 Main or Blower Motor
Overload
Will occur if the fan or main motor
overload relays open for three
seconds. Fan is blocked, damaged
or blower fan is faulty.
Remove blockage, repair or replace damaged
components.
E:0115 Pressure Sensor Fault 4-20mA signal out-of-range
(<3.8mA or >20.8mA) Install, repair or replace faulty sensor.
E:0119 High Airend Discharge
Pressure
Discharge pressure is greater than
oine pressure by 4.35 psi
Check and modify settings. Review system requirements
and contact your local Ingersoll Rand representative.
E:0125 Temperature Sensor
Fault
Signal out of range (<-50°C or
>250°C) Install, repair or replace faulty sensor.
E:0129 Excess Temperature Shutdown limit exceeded Can be reset only when airend discharge temperature is
lower than 107°C.
E:0866 Power Supply 24V DC
Low
24V DC power supply to controller
is low.
Check controller power supply and call your local
Ingersoll Rand representative.
E:0821 Power Supply Analog
Inputs Low
Analog input power supply to
controller is low.
Check controller power supply and call your local
Ingersoll Rand representative.
Start
Inhibit
A:3129
High Airend Discharge
Temperature (above
103°C)
Airend discharge temperature
above 103°C. Abnormal operating condition which is self-clearning.
A:3123 Run Inhibited Temperature is below set low
temperture run inhibit limit.
Will self-reset when temperature increases above the
temperature limit; cannot be manually reset.
A:3423 Load Inhibited Temperature is below set low
temperature load inhibit limit.
Will self-reset when temperature increases above the
temperature limit; cannot be manually reset.
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EN
EN-12 80448517 Rev A
Xe-70 DISPLAY MEANING CAUSE REMEDY
Warning
High A/E Disch T High Airend Discharge
Temperature
Compressor operating above rated
pressure.
Check and modify settings. Review system
requirements and contact your local Ingersoll Rand
representative.
Low coolant level. Check for leaks. See also if discharge air is
contaminated with coolant. Top o coolant.
High ambient temperature. Review installation and system parameters.
Insucient cooling air. Check ducting and cooling air path.
Dirty, blocked coolant cooler (cooling
air side). Clean or replace.
Fan motor direction of rotation
incorrect. Wire correctly.
SVC Required Service Level 1: Service
required Service timer has alarmed. Service machine and reset warning.
“100 hours to
SVC
SVC Required
Service Alarm”
“Service Level 2: 100
hours till service
required
Service required
100 hours after service
requirement”
“Preliminary service timer has alarmed.
Service timer has alarmed.
Late service timer has alarmed.”
“Plan machine service and reset warning.
Service machine and reset warning.
Service machine and set the service complete factory
set point.”
High Disch Pres High Discharge Pressure
Will occur if the unit is using a remote
sensor or is under the control of an
external device, such as an X81, is
loaded, and the discharge pressure
(4APT) is greater than the maximum
oine pressure. If occurs for longer
than 3 seconds, the compressor will
automatically unload.
Discharge pressure must fall to the rated pressure
value before the unit is available for reload.
High VSD Amb T High VSD Ambient
Temperature
VSD ambient temperature reaches
52.4°C for three seconds.
Check and modify settings. Review system
requirements and contact your local Ingersoll Rand
representative.
Dryer Temp Dryer Temp Warning
Dewpoint temperature exceeds 14.5°C
for 6 minutes or longer. Or if the
temperature probe in the dryer fails.
Install, repair or replace faulty sensor. Contact your
local Ingersoll Rand representative.
Dryer High Pres Dryer High Pressure
Will occur if the dryer high pressure
switch opens for at least 3 seconds while
the dryer is running. This is a locking
switch and the dryer high pressure
switch must be reset (contact closed)
before this warning can be reset.
This is a locking switch and the dryer high pressure
switch must be reset (contact closed) before this
warning can be reset.
Invalid Cal Invalid Calibration Calibration done with pressure in
compressor.
Depressurize and recalibrate with pressure pipe
to sensor disconnected. If fault still exists, replace
pressure transducer.
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80448517 Rev A EN-13
EN
Xe-70 DISPLAY MEANING CAUSE REMEDY
Trips
High A/E Disch T
High Airend Discharge
Temperature (above
109°C)
Compressor operating above rated
pressure.
Check and modify settings. Review system
requirements and contact your local Ingersoll Rand
representative.
Low coolant level. Check for leaks. See also if discharge air is
contaminated with coolant. Top o coolant.
High ambient temperature. Review installation and system parameters.
Insucient cooling air. Check ducting and cooling air path.
Dirty, blocked coolant cooler (cooling
air side). Clean or replace.
Fan motor direction of rotation
incorrect. Wire correctly.
Ck Motor Rot Check Motor Rotation Drive system fault. Contact your local Ingersoll Rand representative.
Overload Fan Motor Overload
Will occur if the fan or main motor
overload relays open for three seconds.
Fan is blocked, damaged or blower fan
is faulty.
Remove blockage, repair or replace damaged
components.
Main Motor OL Main Motor Overload
Will occur the current transformers
indicate that the motor amp draw
is excessive. Trip only applicable for
compressors with current transformers
installed.
R4-11kW units typically do not have current
transformers installed.
Rem Start Fail Remote Start Failure
Remote start button is pressed after
compressor is running or remote start
button remains closed.
Check operation of buttons or operating procedures.
Rem Stop Fail Remote Stop Failure Remote stop button remains open and
either start button is pressed. Check operation of buttons or operating procedures.
4APT Failure
2ATT Failure Sensor Failure Sensor is missing or faulty Install, repair or replace faulty sensor.
VSD Fault “X” VSD Fault The compressor’s variable speed drive is
reporting a fault. Refer to Table 6.
VSD Comm Fail VSE Communication
Failure
Controller does not receive a response
from the VSD when requesting
information.
Contact your local Ingersoll Rand representative.
Drive Init Error VSD Initialization Fault Controller is unable to properly setup
the drive after boot or after a reset. Contact your local Ingersoll Rand representative.
VSD Comm
Except VSD Initialization Fault Controller receives invalid communications from VSD. Refer to Table 6.
Stop Failure Stop Failure
Occurs when compressor should be
stopped, but motor speed has not
dropped below minimum motor speed
set point for 4 seconds.
Usually indication that run delay (K1) did not open
when de-energized; due to this, the isolation contact
should open when this fault occurs. The isoaltion
contact can close when fault is cleared.
Emergency Stop Emergency Stop Emergency stop button has been
pressed.
Identify reason why, repair fault, disengage button
and reset conroller.
Unit Too Cold Unit Too Cold to Start
Airend discharge temparature (2ATT)
is less than 35°F, and the operator
attempts to start compressor.
Reset and start compressor if desired. Will be logged
that compressor is being used in low ambient
conditions.
Start
Inhibit
High A/E Disch T High Airend Discharge
Temperature Will occur if 2ATT is greater than 103°C Abnormal operating condition which is self-clearning.
VSD Initializing VSD Initialization
This will occur if the compressor
VSD has not responded to the initial
communications from the controller.
Abnormal operating condition which is self-clearning.
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.
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EN
EN-14 80448517 Rev A
Table 6: Drive Faults (indicated on the controller)
FAULT CAUSE ACTION
High VSD Ambient Temperature VSD ambient temperature gets within 5%
of the shutdown value (55°C)
Check machine ambient temperature.
Check PDM lters, replace if necessary.
Check drive cooling fan(s).
Chk Motor Rot Main motor reverse rotation Check main motor rotation
Contact your local Ingersoll Rand representative.
VSD Comm Fail
Communication wiring faulty. Check and replace if required.
Drive faulty. Contact your local Ingersoll Rand representative.
Controller faulty. Contact your local Ingersoll Rand representative.
Wrong VSD Type Wrong VSD type Contact your local Ingersoll Rand representative.
Stop Failure Run relay or wiring fault Check run relay
Contact your local Ingersoll Rand representative.
Drive Init Error
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 Fault
Internal Fault
24V Supply Low
1.8V Supply Low
Speed Limit
Dangerous Fail
Drive faulty. Contact your local Ingersoll Rand representative.
No Motor
Phase U Missing
Phase V Missing
Phase W Missing
Motor connection lost Check drive/motor connection
Line Phase Loss
DC Voltage High
DC Voltage Low
DC Overvoltage
DC Undervoltage
Voltage Limit
Mains Failure
Problem with incoming power network Check incoming power leads, voltage
Short Circuit There is short-circuiting in the motor or
motor wiring. Check the motor, repair or change.
Internal Fan Fault
External Fan Fault
Fans Error
Drive fans not working properly Check for proper fan operation.
Contact your local Ingersoll Rand representative.
Motor Ther Over Motor overheated Check ambient conditions, get the motor cooled down
Over Current
Compressor operating above rated
pressure.
Check and modify settings. Review system requirements and contact
your local Ingersoll Rand representative.
Separator lter element dirty or blocked. blocked.
Replace.
Voltage supply is low or unbalanced. Contact your local Ingersoll Rand representative or a qualied
electrician.
Airend is damaged. Contact your local Ingersoll Rand representative.
Ground Fault Earth (ground) fault on start-up. Check for proper earthing (grounding) and loose connections.
Heatsink Temp VSD heatsink temp too high
Check ambient temp
PDM lters dirty or heatsink dirty
Check VSD heatsink fan operation
Inrush Fault Too many power ups Let the unit cool down
Torque Limit
Current Limit
Compressor operating above rated
pressure.
Check and modify settings. Review system requirements and contact
your local Ingersoll Rand representative.
Airend is damaged. Contact your local Ingersoll Rand representative.
Heatsink Temp Lo The frequency converter is too cold to
operate. Check the ambient temp
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80448517 Rev A EN-15
EN
R4-11 INTEGRATED DRYER MAINTENANCE
Maintenance Chart
For optimum performance from your dryer, follow the periodic maintenance
schedule described below. Review the Information Manual for details on
dryer operation.
Table 7: Maintenance Chart
WEEKLY * Verify the temperature on the control panel
display is acceptable.
* Visually check if condensate is drained regularly.
MONTHLY * Clean condenser with compressed air, do not
damage ns.
* Check condition of any lters and replace if
necessary.
* Check if dryer is working properly after above
procedures.
YEARLY * Check condition of exible tube used for
condensate drainage and replace if necessary.
* Check if all connecting pipes are properly
tightened and xed.
* Check if dryer is working properly after above
procedures.
Troubleshooting
NOTICE
The following behaviors are normal characteristics of operation and
not troubles:
•Variable speed of the fan (Mod D12IN-A ÷D600IN-A)
•Display of message ESA and ES2 in case of operation without load
or low load.
•A 2 minute delay for dryer to start after pressing the on/o switch.
* Check condition of exible tube used for
condensate drainage and replace if necessary.
* Check if all connecting pipes are properly
tightened and xed.
* Check if dryer is working properly after above
procedures.
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EN
EN-16 80448517 Rev A
Table 8: General Faults (Dryer)
TROUBLE DISPLAY POSSIBLE CAUSE REMEDY
WATER IN THE SYSTEM
Control panel display
is blank
No power in the line. Restore the power in the line.
Problems with cabling. Check cabling; if the trouble persists, replace it.
Problems with the electronic control board. Check the electronic control board; if the trouble persists, replace it.
The dryer is o. Check the remote ON/OFF contact.
Dryer in stand-by. Wait 2 minutes after the dryer is switched on.
Compressed air inlet/outlet inverted. Check if the compressed air inlet/outlet is connected properly.
The ow rate and/or temperature of the
air entering the dryer are higher than the
nominal values.
Restore the nominal conditions.
The condenser is dirty. Restore the nominal conditions.
Condensate drain is not functioning.
See Figure 8.
Clean the condenser.
Replace the coil of the drainage solenoid valve if burned.
Clean or replace the drainage solenoid valve if clogged/jammed.
Check the C8 and C9 parameters of the electronic control board; if the
trouble persists, replace it.
The temperature control probe is
positioned improperly or faulty. Check the probe; if the trouble persists, replace it.
Problems with cabling or with the
electronic control board.
Check the cabling and the electronic control board, if the trouble
persists, replace them.
Activation of compressor’s internal thermal
protection.
Wait one hour and check again. If the fault persists: stop dryer and call
your local Ingersoll Rand distributor.
Problems with the electrical components
of the compressor. Check the electrical components of the compressor.
Defective compressor. Replace the compressor.
The ow rate and/or temperature of the
air entering the dryer are higher than the
nominal values.
Restore the nominal conditions.
The ambient temperature is higher than
the nominal values. Restore the nominal conditions.
The condenser is dirty. Clean the condenser.
The temperature control probe is
positioned improperly or faulty. Check the probe; if the trouble persists, replace it.
Fan pressure switch defective or burned
out (if present). Turn o the dryer and call your local Ingersoll Rand distributor.
High pressure switch defective or burned
out (if present). Turn o the dryer and call your local Ingersoll Rand distributor.
Gas leakage in the refrigerating circuit Turn o the dryer and call your local Ingersoll Rand distributor.
Defective fan. Replace the fan.
Protection fuse burned out (if present). Replace the fuse.
The temperature control probe is
positioned improperly or faulty. Check the probe; if the trouble persists, replace it.
Gas leakage in the refrigerating circuit
without load. Turn o the dryer and call your local Ingersoll Rand distributor.
The temperature control probe is
positioned improperly or faulty. Check the probe; if the trouble persists, replace it.
Series of alarms very close to each other. Call your local Ingersoll Rand distributor.
RELEASED 16/Dec/2014 10:49:53 GMT

80448517 Rev A EN-17
EN
TROUBLE DISPLAY POSSIBLE CAUSE REMEDY
LOW PRESSURE IN THE LINE
Ice formation in the evaporator.
Check the probe; if the trouble persists, replace it.
Check the electronic control board; if the trouble persists, replace it.
Contact our Service Centre to check the gas charge.
Clog.
Check if the compressed air inlet/outlet is connected properly.
Check if the connecting tubing is clogged; in case proceed accordingly.
Check if any valves are closed.
Check the condition of any lter.
Air ows continuously through the
condensate drainage.
Drainage solenoid valve jammed, clean or replace it.
Verify the condensate drainage times set on the electronic control
board (C8 and C9).
Check the signal from the control board: if it is continuous, replace the
control board.
Disassembly of the Integrated Dryer
NOTICE
The dryer shall be disassembled, charged or repaired by a refrigerant
specialist.
Refrigerant liquid and lubricating oil inside the refrigeration circuit
shall be recovered in compliance with current norm in the country
where the dryer is installed.
NOTICE
Refrigerant leaks may be identied by tripping of the refrigeration
overload protector.
If a leak is detected in the refrigerant circuit, seek technical assistance.
If a refrigerant leak occurs, thoroughly air the room before
commencing work.
NOTICE
In normal temperature and pressure conditions, the R134a refrigerant
is a colorless, class A1/A1 gas with TVL value of 1000 ppm (ASHRAE
classication).
NOTICE
The temperature control probe is extremely delicate. Do not remove
the probe from its position. In case of any kind of problem, please
contact your local Ingersoll Rand distributor. Figure 8: Cleaning of Drain Solenoid Valve
RELEASED 16/Dec/2014 10:49:53 GMT

EN
EN-18 80448517 Rev A
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. Always contact a waste disposal and
recycling utility.
Table 9: Recycling Disassembly
RECYCLING DISASSEMBLY
Frame and panels Steel / epoxy resin polyester
Heat exchanger
(cooler)
Stainless steel / aluminum
Pipes Copper
Insulation Gum synthetic/polystyrene
Compressor Steel / copper / aluminum / oil
Condenser Copper/aluminum/steel
Refrigerant R-134a
Valve Brass
Filter Element Replacement
1. Close all air inlets and depressurize the lter housing. Filter housing is
under pressure and must be depressurized.
2. Turn carefully the bowl in counter-clockwise direction.
3. Unscrew the bowl completely from the lter head and pull it o.
4. To remove the exhausted element unscrew from the lter head.
5. Clean the O-ring seat of the head where you insert the element, the
threads of the head, the bowl and the inside of the bowl.
6. Insert the new element on the lter head taking care not to damage
the O-ring.
7. Screw the bowl on to the lter head again and let the arrows match
vertically.
8. Gently reopen the valves and let the air ow through the system.
9. Exhausted lter elements must be sent to the institutions qualied for
its disposal, in accordance to local regulations.
10. It is advisable to have the O-rings changed as well as any element
replacement.
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RELEASED 16/Dec/2014 10:49:53 GMT

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RELEASED 16/Dec/2014 10:49:53 GMT