Ingersoll-Rand RS15ie Setup guide

47629519
Revision C
May 2019
Save These Instructions
Contact-Cooled Rotary Screw Air Compressor
Product Maintenance Information
RS15ie, RS15ne, RS18ie, RS18ne, RS22ie, RS22ne,
RS11i, RS15i, RS15n, RS18i, RS18n, RS22i, RS22n
Product Maintenance Information
EN
Información de mantenimiento del producto
ES
Informations relatives à l’entretien du produit
FR
Informação sobre manutenção do produto
PT
RELEASED 23/May/2019 07:27:22 GMT
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ENGLISH
SPANISH
FRENCH
PORTUGUES

EN
EN-2 47629519 Rev. C
CONTENTS
ABOUTTHISMANUAL ................................3
PERSONNEL..........................................3
SAFETY ..............................................3
AIR COMPRESSOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . .4
MAINTENANCE PROMPTS . . . . . . . . . . . . . . . . . . . . . . . . .4
MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .5
CHECKINGCOOLANTLEVEL.................................5
ADDINGCOOLANT..........................................5
DRAININGCOOLANT........................................5
SAMPLING COOLANT FOR ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . 6
CHANGINGCOOLANTFILTER................................6
CHECKING SEPARATOR ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHANGING SEPARATOR ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTING SEPARATOR TANK/ PRESSURE SYSTEM . . . . . . . . . . 6
CLEANING/ CHECKING SCAVENGE SCREEN . . . . . . . . . . . . . . . . . . 7
REPLACINGCOOLANTHOSES ...............................7
CHECKING MINIMUM PRESSURE CHECK VALVE MPCV . . . . . . 7
CHANGINGAIRFILTER.......................................7
REGREASINGMOTOR........................................7
CLEANING AIRCOOLED COOLING SYSTEM . . . . . . . . . . . . . . . . . . 8
REMOVING/ INSTALLING AIRCOOLED COOLER . . . . . . . . . . . . . . 8
CHECKING HIGH AIREND TEMPERATURE SENSOR . . . . . . . . . . . . 9
CLEANINGMOTORCOWL....................................9
REMOVING/ REPLACING STARTER BOX POWER DRIVE
MODULE PDM FILTER ELEMENT FOR VSD ONLY . . . . . . . . . . . 9
CLEANING/ CHECKING CONDENSATE DRAIN. . . . . . . . . . . . . . . .10
CLEANING/ INSTALLING PACKAGE PREFILTER . . . . . . . . . . . . . .10
CHECKING/ CLEANING NO LOSS DRAIN TRAP
WHEREFITTED............................................10
MONITORING FLUID AND PERFORMING SHOCK PULSE
BEARINGANALYSIS.........................................10
BELT CHANGE / GAS STRUT CHANGE PROCEDURE . . . . . . . . . .10
TROUBLESHOOTING................................ 11
INTEGRATED DRYER MAINTENANCE FOR RS1122I,
RS1522N.......................................... 20
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DISASSEMBLY OF THE INTEGRATED DRYER . . . . . . . . . . 22
DECOMMISSIONING THE INTEGRATED DRYER . . . . . . . 22
INTEGRATED DRYER MAINTENANCE FOR RS1522IE,
RS1522NE ........................................ 23
CLEANING CONDENSATE DRAINS TIMED DRAINS ONLY . . .23
TESTING CONDENSATE DRAINS NOLOSS DRAINS ONLY. . .23
TROUBLESHOOTING CONDENSATE DRAINS ELECTRONIC
DRAINS ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DISASSEMBLING THE INTEGRATED DRYER . . . . . . . . . . 23
DECOMMISSIONING THE INTEGRATED DRYER . . . . . . . 23
RELEASED 23/May/2019 07:27:22 GMT

EN
47629519 Rev. C EN-3
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 and remote
start/stop function is not enabled, locked o, tagged and
the compressor has been relieved of all pressure. Ensure the
compressor is electrically isolated for at least 15 minutes
before commencing any maintenance work. See the Product
Safety Information manual for additional information.
Ingersoll Rand cannot know of or provide all the procedures
by which repairs may be conducted and the hazards and/
or results of each method. If maintenance procedures
not 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 EMEIA* Asia Pacic
Product Safety Information Manual All 80446313 80446156 80446321
Product Maintenance Manual RS15-22ie, ne
RS11-22i, RS15-22n 47629519 47629518 47629520
Product Information Manual - FS RS15-22ie, RS11-22i 47629513 47629512 47629514
Product Information Manual - VSD RS15-22ne, RS15-22n 47629516 47629515 47629517
Product Parts Information Manual RS15-22ie, ne 47629511
RS11-22i, RS15-22n 47636056
* Europe, Middle East, India and Africa
Product specication sheets and reference drawings are also available.
RELEASED 23/May/2019 07:27:22 GMT

EN
EN-4 47629519 Rev. C
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 (RS15-22ie/ne, RS11-22i, RS15-22n)
Period Action Maintenance Item
When indicated by
controller
Replace Air lter element
Replace Coolant lter 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-lter for blockage
Check Air lter indicator condition to ensure air lter operation
Weekly Check Control panel display for temperature
Monthly
Inspect/Clean Air-cooled cooling system for blockage
Inspect/Clean Starter box power drive module lter element
Clean Condenser (TAS only)
Check/Replace Inline Filter elements (TAS only)
Check Dryer operation (TAS only)
Every 2000 hours
Inspect Starter box power drive lter element
Replace Food-grade Filter Module
Analysis Shock pulse bearing
Analysis Premium Coolant (Ultra/Ultra EL/FG)
Every 4000 hours
Grease All motors (as required)
Replace Air lter element
Replace Coolant lter
Replace Separator element
Inspect Scavenge screen for blockage
Replace Starter box power drive lter element
Replace Package pre-lter element
Clean Air-cooled cooling system
Replace Inline Filter Elements (TAS only)
Calibrate Pressure transducers
Every 8000 hours
Check/Replace Condensate drain exible tube (TAS only)
Check All connecting pipes
Replace No-loss condensate drain service module
Replace Premium Coolant (Ultra/FG) [8000 hours]
Service Minimum pressure check valve (MPCV) service kit
Clean Drains with all their components (Timed Drains only)
Service Inlet valve service kit
Every 16000 hours
Replace Coolant hoses
Replace Belt
Replace Gas spring
Replace Extended-life Premium Coolant (Ultra EL)
NOTICE
Inspect and replace coolant lter elements and separator elements more frequently in dirty operating environments.
RELEASED 23/May/2019 07:27:22 GMT

47629519 Rev. C EN-5
EN
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.
NOTICE
Prior to opening or removing panels or covers to work
inside a machine, ensure that anyone entering the
machine is aware of the reduced level of protection
and the additional hazards, including hot surfaces and
intermittently moving parts.
Checking Coolant Level
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 top half of the sight glass. 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:
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. Slowly unscrew the coolant ll plug to verify all
pressure has been released.
5. Add coolant.
6. Replace the coolant ll plug and restart the
compressor.
7. Recheck the coolant level.
8. Repeat the above steps until the coolant level is
visible in the sight glass with the compressor both
running and stopped.
NOTICE
Do not add coolant through the intake of the
compressor, as this can result in overlling, saturation
of the separator lter element, and coolant carry-over
downstream.



Draining Coolant
It is better 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.
See Figure 1.
1. Stop the machine, electrically isolate and vent all
trapped pressure.
2. Place a suitable container close to the drain valve.
3. Slowly remove coolant ll/vent cap.
4. Remove plug from the drain valve.
5. Open the drain valve and drain coolant into container.
6. Close the drain valve.
7. Install plug in drain valve.
8. Rell the compressor with coolant to the proper level,
following the process outlined in the “Adding Coolant”
procedure. After initial ll, to purge any airlocks, the
machine should be run for a few minutes cycling
between load and no load, before checking that the
level is correct.
9. Replace and tighten coolant ll cap.
NOTICE
On air cooled compressors, you may also drain coolant
from the coolant cooler by removing the plug.
Figure 1: Coolant Drain
Drain Valve
Plug
NOTICE
Shorter coolant change intervals may be necessary if
the compressor is operated in adverse conditions.

RELEASED 23/May/2019 07:27:22 GMT

EN
EN-6 47629519 Rev. C
Sampling Coolant for Analysis
1. Bring the compressor up to operating temperature.
2. Stop the compressor.
3. Isolate the compressor from the external air system.
4. Press the emergency stop 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 separator tank port using a
pump kit. DO NOT draw a sample from the drain port
or oil lter.
Use a new hose on the pump for each sample. Failure to do
this can give false readings.
See Figure 2.
Figure 2: Coolant Sampling
NOTE: The original separator tank is horizontal. These gures
are for reference only.
Changing Coolant Filter
1. Stop the machine, electrically isolate and vent all
trapped pressure.
2. Loosen the lter with the correct tool.
3. Remove the lter from the housing.
4. Place the old lter in a sealed bag and dispose of in a
safe way.
5. Remove the new Ingersoll Rand replacement lter
from its protective package.
6. Apply a small amount of lubricant to the lter seal.
7. Screw the new lter down until the seal makes
contact with the housing, then hand tighten a further
1/4 turn.
8. Start the compressor, check for leaks and check the
coolant level.


Checking Separator Element
XE-70M Controller:
With the compressor running on load, check the separator
dierential pressure using the controller. It will be necessary
to change the element if the dierential pressure equals to
zero or exceeds 1 bar (15psig).
XE-50M Controller:
It will be necessary to change the element if the controller
issue warning of“Service required”.
Changing Separator Element
1. Stop the machine, electrically isolate and vent all
trapped pressure.
2. Loosen the separator 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 faces of the housing.
6. Remove the new Ingersoll Rand replacement
element from 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
quarter turn.
9. Start the compressor and check for leaks.
Inspecting Separator Tank/ Pressure System
Inspect the external surfaces of the separator tank, including
all ttings, for visible signs of impact damage, excessive
corrosion and abrasions. When changing the separator
element, inspect the internal components and surfaces. Any
suspect parts shall be replaced before the compressor is put
back into service.
The separator tank should also be tested and inspected in
accordance with any national or local codes that may exist.



RELEASED 23/May/2019 07:27:22 GMT

47629519 Rev. C EN-7
EN
Cleaning/ Checking Scavenge Screen
The screen/orice assemblies will be located between airend
and 6 mm (0.25 in) O.D. scavenge line tubing.
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.
A removable screen and orice will require clearing as
outlined in the maintenance chart.
To remove the screen/orice:
1. Disconnect the scavenge line tubing from each end.
2. Hold the center section rmly and use a pair of pliers
to gently grasp the exit end of the assembly that seals
against the scavenge line tubing. The exit end is the
end toward which the arrow is pointing.
3. Pull the end out of the center section while using care
to prevent damage to the screen or sealing surfaces.
4. Clean and inspect all parts prior to reinstallation.
5. When the assembly is installed, conrm the
direction of ow to be correct. Observe the small
arrow stamped in the center section and ensure the
direction ow to be from the separator tank to the
airend.
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 needed or every four years.
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. Remove it
from the compressor for testing. If operating conditions are
particularly severe, the frequency of testing and maintenance
shall be increased accordingly. The user shall establish the
frequency of such tests as it is inuenced by such factors
as the severity of the operating environment. The MPCV is
installed as part of combination block.
The minimum pressure check valve (MPCV) should be
tested and re-calibrated in accordance with any national or
local codes that may exist. If no code exists, Ingersoll Rand
recommends that the valve is recalibrated at intervals of one
year by a licensed contractor or qualied service personnel.
Changing Air Filter
1. Check the retaining cap for dirt and debris and wipe
clean.
2. Unclip the retaining cap and withdraw the old
element.
3. Fit the new element and ret the retaining cap.
Regreasing Motor
The fan motor contains pre-greased, sealed bearings. They
cannot be re-greased and do not require re-greasing.
Motor Bearings - Clean the area around the inlet and outlet
plugs before removing the plugs. Add the specied quantity
of recommended grease using a hand lever gun. Replace the
inlet plug, run the machine for 10 minutes and then replace
the outlet plug.
NOTICE
Read the motor data plate(s). For motors that require
greasing, grease them more frequently in harsh
environments or higher ambient conditions.



RELEASED 23/May/2019 07:27:22 GMT

EN
EN-8 47629519 Rev. C
Cleaning Air-Cooled 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.
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.
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 cores to
determine the appropriate cleaning method detailed
as follows:
a. For loose dirt, dust and other light foreign material,
open the access panel on the cooler plenum. Gently
blow compressed air across the cooler surface.
Repeat the process until the coolers are suciently
clean. Replace the access panels before returning the
compressor to service.
b. For thick, packed dirt, coolant or grease, or other
heavy material, the coolers will need to be removed
from the compressor for pressure washing. Ingersoll
Rand does NOT support pressure washing coolers
when they are installed in the compressor due to
the dangers of spraying water in or around potential
electrical power sources. Follow the steps below for
cooler removal.
Removing/ Installing Air-Cooled Cooler
To remove:
1. Stop the compressor.
2. Isolate the compressor from the system.
3. Press the emergency stop 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.
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. Drain the coolant from the coolant cooler by
removing the hex plug located at the lower side of
the coolant cooler. Place the straight end of the drain
hose in a suitable container. Install the other end of
the drain hose in the drain valve located at the lower
side of the coolant cooler. The coolant ows through
the drain hose automatically. After drainage, remove
the hose and close the valve.
6. Remove all hoses, pipes, and sensors from the coolers.
7. Remove the top panel (for RS15-22ie, ne) or
Remove front, rear door and top panel (for RS11-22i,
RS15-22n).
8. Properly secure the cooler and remove four screws at
the upper side of the cooler.
9. Re-install the coolant drain plug to 16 Nm (12 ft-lb).
To install:
1. Carefully place the cooler in its proper location and
install four screws (gun tight).
2. Re-attach all hoses and pipes, and properly torque
according to the Parts Information manual.
3. Install the top panel.
4. Rell the compressor with coolant to the proper level,
following the process outlined in the “Adding Coolant”
procedure.

RELEASED 23/May/2019 07:27:22 GMT

47629519 Rev. C EN-9
EN
Checking High Airend Temperature Sensor
It is recommended that the discharge temperature sensor
(2ATT) is checked regularly as follows:
a. For air cooled compressors, stop the cooling blower
by opening the blower / fan motor circuit breaker.
The compressor should trip at 109 °C (228 °F). 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 rear door 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 rear door.


Removing/ Replacing Starter Box Power Drive Module
(PDM) Filter Element (for VSD only)
See Figure 3.
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 3: Starter Box Power Drive Module (PDM) Filter Element Replacement
RELEASED 23/May/2019 07:27:22 GMT

EN
EN-10 47629519 Rev. C
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 the tube from the tting located on the
bottom of the moisture separator.
4. Remove the bowl of the moisture trap, clean and
replace.
Cleaning/ Installing Package Pre-Filter
1. Fix Speed (FS) Unit:
Unlatch the starter box panel and open the intake
panel.
Variable Speed (VSD) Unit:
Unlatch the rear door and open the intake panel.
2. Remove the four wing nuts and at washers.
3. Remove the lter grill.
4. Pull out the lter element.
5. Center the new element over the package intake
opening. Also note that the lter is washable with
mild detergent.
6. Push the lter over the grill studs so that the studs
poke through the lter media.
7. Install the lter grill.
8. Install the four wing nuts and at washers.
9. Close the intake panel and latch.
Checking/ Cleaning No Loss Drain Trap (where tted)
It is recommended to check the no loss drain trap daily
to ensure that condensate is draining from the moisture
separator system. To check for correct function:
1. Press the test button on the drain and listen for
condensate / air passing through the drain.
2. If the drain is clogged, replace the no loss drain valve
service module. The service module consists of the
lower portion of the drain trap and is not serviceable.
Additionally, it is recommended to replace the service module
every 8000 hours or once per year, whichever comes rst.
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.




Belt Change / Gas Strut Change Procedure
Figure 4: Belt / Gas Strut Change
A. Gas Strut
B. Support bracket (part of pivoted assembly)
C. Tension cam
1. Stop the machine, electrically isolate and vent all
trapped pressure.
2. Fit a 1/2” square drive wrench in the tension cam
located above the airend (access from front door) Turn
clockwise 1/4 turn to Position II to release gas strut
tension on the belts.
3. Using a small screwdriver under the spring clip, ease
the ball ends o the spherical studs at the ends of the
gas strut.
4. Replace the gas strut and the studs at the same time
by removing and replacing the studs then pushing
the new gas strut rmly onto the studs until it clicks
into place.
5. Turn the tension cam clockwise 1/4 turn to Position III
to raise and support the airend.
6. Replace the belts from the left side of the machine.
7. Turn the tension cam counter–clockwise 1/2 turn to
Position I to tension the gas strut.
8. Spin the drive to check alignment of the belt ribs on
the pulleys (sheaves).

RELEASED 23/May/2019 07:27:22 GMT

47629519 Rev. C EN-11
EN
TROUBLESHOOTING
This section provides basic troubleshooting information. Determination of specic causes to problems are 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 3: 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 4 and 6.
Controller has tripped the compressor. See Tables 4 and 6.
Maximum number of starts per hour
exceeded. See Tables 4 and 6.
Compressor is stopped and
will not restart.
Controller has tripped the compressor and
has not been reset. See Tables 4 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.
Compressor will not meet
pressure required by system.
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.
Belt slippage. Replace belt and gas spring.
Gas spring failed. Replace gas spring.
Equipment between compressor and
customer measuring point causing
pressure drop / pressure loss. Review system requirements.
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EN
EN-12 47629519 Rev. C
SYMPTOM CAUSE REMEDY
Pressure produced by
compressor is too high due
to speed not reducing as
demand reduces (VSD only).
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.
Compressor package
produces excessive noise.
Panels or doors are not closed properly. Rectify fault.
Air leaks from internal pipework /
components. Repair or replace.
Fan motor bearings worn. Repair or replace.
Loose debris impacting on fan during
rotation. Remove and rectify any damage.
Blowdown valve stuck open. Repair or replace.
Pressure relief valve not seating correctly. Repair or replace.
Belt slippage. Replace belt and gas spring.
Vibration due to motor, airend or fan
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. 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.
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.
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47629519 Rev. C EN-13
EN
SYMPTOM CAUSE REMEDY
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.
Black residue on belt guard or
airend.
Drive belt slippage. Replace belt and gas spring.
Pulley misaligned. Re-align pulley.
Worm pulleys. Replace pulley and belt.
Gas spring failed. Replace gas spring.
Inlet valve will not actuate and
load package.
Blowdown valve not functioning. Examine and clean/replace if necessary.
Contamination/liquid in controls tubing. Examine and clean/replace if necessary.
Either orice is contaminated. Examine and clean/replace if necessary.
Table 4: XE-70 Controller Faults (indicated on the controller)
FAULT CAUSE REMEDY
Emergency stop. Emergency stop button has been
pressed. Identify reason why, repair fault, disengage button and reset controller.
Fan motor overload. Fan is blocked, damaged or fan
motor is faulty. Remove blockage, repair or replace damaged components.
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‘discharge air is contaminated
with coolant’. Top up 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.
Check setpoints. Controller software has been
changed. Recalibrate all sensors and check setpoints.
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.
Remote stop failure. Remote stop button remains open and either start button is
pressed. Check operation of buttons or operating procedures.
Sensor failure. Sensor is missing or faulty. Install, repair or replace faulty sensor.
Controller has tripped the
compressor. A fault has occurred. Repair fault/reset controller.
Invalid calibration. Calibration done with pressure in
compressor.
Depressurize and re calibrate with pressure pipe to
sensor disconnected. If fault still exists, replace pressure
transducer.
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EN
EN-14 47629519 Rev. C
FAULT CAUSE REMEDY
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.
Change separator element
and/or high sump pressure.
Faulty pressure transducer
measurement. Calibrate and validate the wet sump and package discharge transducers (for RS15-22n, RS15-22ie/ne).
Moisture separator condensate
drain trap faulty. Ensure condensate drain system is functioning properly, and condensate is being drained.
Separator element dirty or
blocked. Change separator element.
Machine stops but no alarm
message. Loss of outputs of control power. Check controller outputs (110V AC) power supply (fuses/ mini circuit breaker).
Motor current fault.
Loss of control power.
Sump pressure too high.
Faulty motor or Airend.
Check control power circuit and breaker.
Check separator element pressure drop.
Contact your local Ingersoll Rand representative.
CT failure Fault CT, wiring or loss of control
power. Check wiring and control power circuit.
RELEASED 23/May/2019 07:27:22 GMT

47629519 Rev. C EN-15
EN
Table 5: XE-50 Controller Faults (indicated on the controller)
Xe-50 DISPLAY MEANING CAUSE REMEDY
Warnings
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 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.
RELEASED 23/May/2019 07:27:22 GMT

EN
EN-16 47629519 Rev. C
Xe-50M DISPLAY MEANING CAUSE REMEDY
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.
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.
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.
RELEASED 23/May/2019 07:27:22 GMT

47629519 Rev. C EN-17
EN
Xe-50M 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 Fan is blocked, damaged
or fan motor is faulty. Remove blockage, repair or replace damaged components.
Main Motor OL Main Motor Overload
Will occur if the main
motor overload relays
open for a time period of
3 seconds.
Remove blockage, repair or
replace damaged components.
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
2 ATT Failure Sensor Failure Sensor is missing or faulty Install, repair or replace faulty
sensor.
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.
RELEASED 23/May/2019 07:27:22 GMT

EN
EN-18 47629519 Rev. C
Table 6: 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.
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 NO. 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 38
Drive faulty Contact your local Ingersoll Rand representative.
24V Supply Low 47
1.8V Supply Low 48
Speed Limit 49
Dangerous Fail 72
DC link voltage high 5
DC link voltage low 6
DC over-voltage 7
Phase U Missing 30
Motor connection lost. Check drive/motor connection.Phase V Missing 31
Phase W Missing 32
Mains phase loss 4
Problem with incoming power
network. Check incoming power leads, voltage.
Mains failure 36
Phase imbalance 37
DC under voltage 8
Short Circuit 16 There is short-circuiting in the
motor or motor wiring. Check the motor, repair or change.
Internal Fan Fault 23 Drive fans not working properly. Check for proper fan operation.
External Fan Fault 24
Motor Thermal Overload 10, 11 Motor overheated. Check ambient conditions, get the motor cooled
down.
Over Current 13
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.
RELEASED 23/May/2019 07:27:22 GMT

47629519 Rev. C EN-19
EN
FAULT NO. CAUSE ACTION
Ground Fault 14 Earth (ground) fault on start-up. Check for proper earthing (grounding) and loose
connections.
Inrush Fault 33 Too many power ups. Let the unit cool down.
Heatsink Temp 29 VSD heatsink temp too high.
Check ambient temp.
PDM lters dirty or heatsink dirty Check VSD
heatsink fan operation.
Torque Limit Current Limit 12
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 Low 66 The frequency converter is too
cold to operate. Check the ambient temp.
RELEASED 23/May/2019 07:27:22 GMT

EN
EN-20 47629519 Rev. C
INTEGRATED DRYER MAINTENANCE (For RS11-22i, RS15-22n)
Troubleshooting
NOTICE
The following behaviors are normal characteristics of
operation and not troubles:
Variable speed of the fan.
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.
Table 7: 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.
Dryer in stand-by. Wait 2 minutes after the dryer is
switched on.
The condenser is dirty. Restore the nominal conditions.
Condensate drain is not
functioning. See Figure 5.
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.
RELEASED 23/May/2019 07:27:22 GMT