Ingersoll-Rand UP5S 11 Installation and operating instructions

80448418
Revision C
June 2016
Save These Instructions
Contact-Cooled Rotary Screw Air Compressor
Installation, Operation and Maintenance
UP5S 11, UP5S 15, UP5S 18, UP5S 22
UP6S 15, UP6S 20, UP6S 25, UP6S 30
Installation, Operation and Maintenance
EN
RELEASED 20/Jul/2016 17:56:55 GMT

2 80448418 Rev.C
CONTENTS
FOREWORD..................................3
SAFETY......................................4
INSTALLATION / Handling . . . . . . . . . . . . . . . . . . . . . 5
LOCATIONINTHEPLANT ..............................5
DISCHARGEPIPING....................................5
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 7
GENERALOPERATION...........................7
OPERATING INSTRUCTIONS (XE-70M
CONTROLLER)................................8
USERINTERFACE ...............................8
LEDSTATUSICONS....................................8
COMMANDKEYS......................................8
NAVIGATIONKEYS.....................................8
DISPLAYLAYOUT......................................8
FOLDER NAVIGATION AND ICONS. . . . . . . . . . . . . . . . . . . . . .9
PAGENAVIGATION.....................................9
ACCESSINGPARAMETERS..............................9
DASHBOARDICONS...................................9
DASHBOARD STATUS MESSAGES. . . . . . . . . . . . . . . . . . . . . 10
FIXED SPEED COMPRESSOR . . . . . . . . . . . . . . . . . . . .10
HOMEFOLDER...................................... 10
OPERATOR SETTINGS FOLDER . . . . . . . . . . . . . . . . . . . . . . . 11
EVENTSFOLDER..................................... 14
TRIPHISTORY ....................................... 17
MAINTENANCEFOLDER ............................. 17
GENERALSETTINGSFOLDER......................... 17
INTEGRAL SEQUENCING FOLDER. . . . . . . . . . . . . . . . . . . . . 19
STATUSFOLDER..................................... 20
FACTORYSETTINGSFOLDER......................... 22
MAINTENANCE..............................24
TOP UP COOLANT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 25
COOLANT CHANGE PROCEDURE. . . . . . . . . . . . . . . . . . . . . 25
COOLANT FILTER CHANGE PROCEDURE . . . . . . . . . . . . . . 26
AIR FILTER ELEMENT CHANGE PROCEDURE. . . . . . . . . . . 26
SEPARATOR CARTRIDGE CHANGE PROCEDURE . . . . . . . 26
COOLER CLEANING PROCEDURE. . . . . . . . . . . . . . . . . . . . . 26
BELT CHANGE / GAS STRUT CHANGE PROCEDURE . . . . 27
ELECTRIC DRAIN VALVE - OPERATION AND
MAINTENANCE..............................28
PRODUCTDESCRIPTION............................. 28
OPERATION......................................... 28
TIMERSETTINGS .................................... 28
TROUBLESHOOTING................................. 28
MAINTENANCE...................................... 28
DRYER OPTION - OPERATION AND
MAINTENANCE..............................29
INSTALLATION....................................... 29
ELECTRICALCONNECTION........................... 29
CONDENSATEDRAINS............................... 29
START–UPANDOPERATION.......................... 29
STOPPINGTHEDRYER............................... 29
OPERATION......................................... 29
MAINTENANCE...................................... 30
MOISTURE SEPARATOR MAINTENANCE. . . . . . . . . . . . . . . 30
AIRFILTERMAINTENANCE........................... 30
DISASSEMBLINGTHEUNIT........................... 31
REFRIGERANT LEAKS IN THE REFRIGERATION CIRCUIT. 31
REFRIGERANTCHARGING............................ 31
CHARACTERISTICS OF REFRIGERANT R134A . . . . . . . . . . 31
TROUBLESHOOTING.........................32
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80448418 Rev.C 3
FOREWORD
The contents of this manual are considered to be
proprietary and condential to Ingersoll Rand and
should not be reproduced without the prior written
permission of Ingersoll Rand.
Nothing contained in this document is intended to
extend any promise, warranty or representation,
expressed or implied, regarding the Ingersoll Rand
products described herein. Any such warranties or other
terms and conditions of sale of products shall be in
accordance with the standard terms and conditions of
sale for such products, which are available upon request.
This manual contains instructions and technical data to
cover routine operation and scheduled maintenance tasks
by operation and maintenance sta. Major overhauls are
outside the scope of this manual and should be referred
to an authorized Ingersoll Rand service department.
All components, accessories, pipes and connectors added
to the compressed air system should be:
of good quality, procured from are putable manufac-
turer and, wherever possible, be of a type approved
by Ingersoll Rand.
clearly rated for a pressure atleast equal to the
machine maximum allowable working pressure.
compatible with the compressor lubricant/coolant.
accompanied with instructions for safe installation,
operation and maintenance.
Details of approved equipment are available from
Ingersoll Rand Service departments.
The use of non–genuine spare repair parts other than
those included within the Ingersoll Rand approved
partslist may create hazardous conditions over which
Ingersoll Rand has no control. Therefore
Ingersoll Rand does not accept any liabilitity for losses
caused by equipment in which non–approved repair
parts are installed. Standard warranty conditions may be
aected.
Ingersoll Rand reserves the right to make changes and
improvements to products without notice and without
incurring any obligation to make such changes or add
such improvements to products sold previously.
The intended uses of this machine are outlined below and
examples of unapproved usage are also given, however
Ingersoll Rand cannot anticipate every application or
work situation that may arise.
•
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IF IN DOUBT CONSULT SUPERVISION.
This machine has been designed and supplied for
use only in the following specied conditions and
applications:
Compression of normal ambient air containing no
known or detectable additional gases, vapors or
particles.
Operation within the ambient temperature range
specied in the Product specication sheet.
The use of the machine in any of the situation types
listed in
Is not approved by Ingersoll Rand,
May impair the safety of users and other persons,
and
May prejudice any claims made against
Ingersoll Rand.
TABLE 1
Use of the machine to produce compressed air for:
direct human consumption
indirect human consumption, without suitable
ltration and purity checks.
a)
b)
Use of the machine outside the ambient temperature
range specied in the Product specication sheet.
Use of the machine where there is any actual or
foreseeable risk of hazardous levels of ammable gases
or vapors.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE
USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR
VAPORS MAY BE PRESENT.
Use of the machine tted with non Ingersoll Rand
approved components.
Use of the machine with safety or control components
missing or disabled.
The company accepts no responsibility for errors in
translation of this manual from the original English
version.
•
•
a)
b)
c)
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4 80448418 Rev.C
SAFETY
Locate, read, understand and follow all Danger, Warning,
Caution, and Operating Instructions on the product and
in all Manuals. Failure to comply with safety precautions
described in the manuals supplied with the product,
this manual or any of the labels and tags attached to the
product may result in death, serious injury or property
damage.
Check that all labels, tags and data (name) plates are in
place and legible.
It is your responsibility to make this information available
to others.
If you have any questions about safety or procedures not
included in this manual, ask your supervisor or contact
any Ingersoll Rand oce or qualied Ingersoll Rand
distributor.
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80448418 Rev.C 5
INSTALLATION / HANDLING
1
KEY
1 Compressor
2 Air Receiver
3 Air Dryer
4 Compressed air lters
5 System demand points
NOTICE
Items [2] to [5] are optional or may be existing items
of plant. Refer to your Ingersoll Rand distributor /
representative for specic recommendations.
LOCATION IN THE PLANT
The compressor can be installed on any level oor
capable of supporting it. A dry, well ventilated area where
the atmosphere is clean is recommended. A minimum of
150 mm (6 inches) should be left at the rear and 1 m
(3 ft) at the sides of the machine for adequate service
access and ventilation.
Adequate clearance needs to be allowed around and
above the machine to permit safe access for specied
maintenance tasks.
Ensure that the machine is positioned securely and on
a stable foundation. Any risk of movement should be
removed by suitable means, especially to avoid strain on
any rigid discharge piping.
NOTICE
The Main Motor Overload Current set point is preset
into the compressor controller program before
leaving the factory and is not user adjustable. If this
is required to be changed, due to an input voltage
conversion, contact your local Ingersoll Rand service
provider.

CAUTION
Screw type compressors [1] should not be installed
in air systems with reciprocating compressors
without means of isolation such as a common
receiver tank. It is recommended that both types of
compressor be piped to a common receiver using
individual air lines.
CAUTION
The use of plastic bowls on line lters and other
plastic air line components can be hazardous. Their
safety can be aected by either synthetic coolants
or the additives used in mineral oils. Ingersoll Rand
recommends that only lters with metal bowls
should be used on any pressurised system.
CAUTION
Before starting machine remove shipping bolt and
discard.
CAUTION
The standard compressor unit is not suitable for
operation in temperatures liable to cause freezing
as condensate water is liable to be produced in the
after cooler and receiver where tted.
Refer to your Ingersoll Rand distributor for further
information.
DISCHARGE PIPING
Discharge piping should be at least as large as the
discharge connection of the compressor. All piping
and ttings should be suitably rated for the discharge
pressure.

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6 80448418 Rev.C
INSTALLATION / HANDLING
It is essential when installing a new compressor [1],
to review the total air system. This is to ensure a safe
and eective total system. One item which should be
considered is liquid carryover. Installation of air
dryers [3] is always good practice since properly selected
and installed they can reduce any liquid carry over to
zero.
It is good practice to locate an isolation valve close to the
compressor and to install line lters [4].
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80448418 Rev.C 7
OPERATING INSTRUCTIONS
GENERAL OPERATION
The compressor is an electric motor driven, single stage
screw compressor, complete with accessories piped,
wired and baseplate mounted. It is a totally self contained
air compressor package.
The standard compressor is designed to operate in an
ambient range of 35.6 °F – 104 °F (2 °C to 40 °C) with a
special option package available to operate in ambient
temperatures ranges from 35.6 °F up to124 °F (2 °C up to
50 °C). The maximum temperature is applicable to either
version up to a maximum elevation of 3280 ft (1000 m)
above sea level. Above this altitude signicant reduction
in maximum allowable ambient temperature is required.
Compression in the screw type air compressor is created
by the meshing of two (male & female) helical rotors.
The air/coolant mixture discharges from the compressor
into the separation system. This system removes all but
a few PPM of the coolant from the discharge air. The
coolant is returned to the cooling system and the air
passes through the aftercooler and out of the compressor.
Cooling air is moved through the coolers by the cooling
fan and discharged from the machine.
CAUTION
Cooling air is drawn in at the end of the machine
package passing through the lter and cooler
before being discharged from the top of the
machine. Care should be taken to avoid blocking the
airow, or causing any restriction in excess of the
maximum backpressure allowed for ducting.
Do not direct the airow at face or eyes.
The power transmission from the drive motor to the
airend male rotor is by pulley and belts. The constant
auto tensioning system, using airend mass torque and
gas arm, ensures that the belts are always under the
correct tension, eliminating the need for adjustment and
maximizing the life of the belts.
By cooling the discharge air, much of the water vapor
naturally contained in the air is condensed and may be
drained from the downstream piping and equipment.
The coolant system consists of a sump, cooler,
thermostatic valve and a lter. When the unit is operating,
the coolant is pressurized and forced to the compressor
bearings.The compressor load control system is
automatic on–o line.
The compressor will operate to maintain a set discharge
line pressure and is provided with an auto restart
system for use in plants where the air demand varies
suciently to allow a compressor to shut down and save
power. Signicant system volume will assist this and is
recommended.
NOTICE
Not all Xe-70 Controller options available on this
compressor model (UP Series).
WARNING
When the unit stops running as the result of low air
demand, normally indicated by auto restart light, it
may restart and return to load at any time.
Safety of operation is provided as the compressor will
shut down if excessive temperatures or electrical overload
conditions should occur.
CAUTION
This unit is not designed or intended to operate
when contaminated with silicone. Lubricants,
greases or other items containing silicone should
not be used on this unit.
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8 80448418 Rev.C
OPERATING INSTRUCTIONS XE70M CONTROLLER
USER INTERFACE
The standard user interface conguration of the
controller consists of the membrane and the LCD display.
The membrane consists of ve command keys (Start,
Stop, Load, Unload, and Reset), four navigation keys
(Up, Right, Left and Down), and an Edit mode selection
key (Enter). These keys, in conjunction with the graphics
display and the LED icons, make up the user interface to
the compressor.
Figure 1: Xe-70M
LED STATUS ICONS
Three LED icons are used to indicate the current status of
the control system from a distance and are located on the
upper left side of the user interface.
Table 1: Xe-70M LED Status Icons
Icon Name Function
OK Illuminates when no Warnings or
Trips are sensed. Can be in a Ready
or Not Ready state. This icon will
ash when the machine is Running
Unloaded.
Alert Illuminates when a Warning
(ashes) or Trip (constant ON)
is sensed. Can be in a Ready
(Warning) or Tripped state.
Auto Illuminates when the compressor
stops in auto restart.
COMMAND KEYS
These keys command the controller to perform actions as
specied in the following table. When any of these keys
are pressed the action below will be initiated and logged
in the event log.
Table 2: Xe-70M Command Keys
Icon Name Function
Load Puts the compressor into the
selected mode of operation.
Unit will load if the pressure
conditions are right.
Unload Puts the compressor into an
unloaded state. Unit will run
unloaded indenitely.



Icon Name Function
Reset Clears Warnings and Trips once
the fault condition is corrected.
Start Starts the compressor.
Stop Stops the compressor. This
button should be pressed
instead of the Emergency Stop
for normal stopping operation.
Enter Toggles the display between the
Navigation mode and the Edit
mode.
NOTICE
The Load and Unload keys are not used on the
variable speed compressors.
NAVIGATION KEYS
There are four navigation keys (UP, RIGHT, DOWN and
LEFT). While the ENTER key is not considered a navigation
key, it is used in conjunction with the navigation keys to
make or conrm a selection.
Figure 2 : Navigation Keys
The navigation keys roll over. Pressing one of the
navigation keys will lead the user down a navigation path.
Each time the key is pressed, another step in the path
is taken. Once the end of a navigation path is reached,
pressing the key one more time will bring the user back
to the beginning of the path. Pressing the opposite
key will move the user through the navigation path in
the opposite direction. Once the beginning is reached,
pressing the opposite key will take the user to the end of
the path.
DISPLAY LAYOUT
Figure 3 : Display Layout
A
B
C
D
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
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80448418 Rev.C 9
Table 3 : Display Layout
Key Name Description
A Folder Bar Uses tabs to graphically identify
each folder.
B Title Bar Identies current folder and page
(underlined).
C Page
Content Content of the current page.
D Dashboard Displays system status.
FOLDER NAVIGATION AND ICONS
To move among the tabbed folders shown on the LCD
display, press the RIGHT and LEFT keys. The navigation
rolls over from the last to the rst folder and vice-versa.
Table 4 : Folder Bar Icons
Folder
Name Icon Description
Home System performance and status
main information. The rst page
of this folder is the default page
when the controller rst powers
up.
Operator
Settings System options and conguration settings.
Events System events log.
Trip History Details on the most recent trips.
Maintenance Status and notication setup for
compressor maintenance items.
General
Settings General settings such as Language, Time, and Units of
Measure.
Integral
Sequencing Integral Sequencing communication status and
conguration.
Status Measurements or status from/of
all analog and digital I/O.
Factory
Settings Compressor tuning parameters. Also displays hardware and
software versions.
PAGE NAVIGATION
Once the desired folder is selected, press the DOWN key
to move to the page selection area and then use the
RIGHT and LEFT keys to select the desired page. Use the
UP key to get back to the folder tabs.
Table 5 : Title Bar Page Icons
Icon Description
Start of the page selection area.
Indicates that there are more pages available
by navigating right.
Indicates that there are more pages available
by navigating left.


ACCESSING PARAMETERS
After the desired page is selected, the page’s parameters
can be selected by using the DOWN key. The cursor will
move to the next parameter each time the DOWN key is
pressed. Use the UP key to go back to the previous one.
The cursor rolls over, so once the last parameter is
selected, pressing the DOWN key will navigate the
cursor to the Folder Bar. If the rst parameter is selected,
pressing the UP key will move the cursor to the page
selection area.
Once selected, access parameters by pressing the ENTER
key. Make changes using the NAVIGATION keys and then
enter the setting by pressing the ENTER key again. After a
parameter is accessed, pressing the ENTER key will enter
the current setting into the control program and navigate
the cursor back to the selected parameter on the page.
When the cursor is on a parameter that has an enabled/
disabled box, pressing the ENTER key will cause the
setting to toggle.
This icon appears on numeric entry windows (see
Figure 69). Placing the cursor on it and then pressing the
ENTER key will cancel the entry and any changes that
were made.
Figure 4 : Numeric Entry Window
NOTICE
Not all pages have adjustable parameters. Some just
have read-only information.
DASHBOARD ICONS
The dashboard is intended to be a quick at-a-glance
view of system status. The following table lists standard
dashboard icons and their denition. Note that the color
of these icons changes based on the state set by the
application while running.


OPERATING INSTRUCTIONS XE70M CONTROLLER
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10 80448418 Rev.C
Table 6 : Dashboard Icons
Name Icon Description
Remote
Control Remote control is enabled. This can be Remote Start/Stop, COM
Control, Integral Sequencing or
Web Control.
Service
Required A service reminder is nearing or has expired
(i.e.: an air or oil lter needs to be
changed).
Unloaded
or
Loaded
Compressor is in the unloaded
state.
Compressor is in the loaded state.
DASHBOARD STATUS MESSAGES
The dashboard also displays the current operating
state of the compressor. The following states can be
encountered during machine operation:
Ready to Start – The compressor currently has no trip
or start inhibit conditions present. The machine can be
started by pressing the start button at any time.
Starting – A start command has been given to
the compressor and the start sequence is being
performed. The time period for this state can vary
depending on the starter type of the machine.
Load Delay – The compressor is waiting for a small
period of time after starting before allowing the
machine to load. This ensures the machine is at
operating conditions before loading.
Running Loaded – The compressor is operating and
producing air. The inlet valve is open and the blow-o
valve is closed.
Running Unloaded – The compressor is operating,
but not producing air. The inlet valve is closed and the
blow-o valve is open.
Reload Delay – This is a brief period of time after the
compressor has unloaded before it is allowed to load
again. This gives the inlet and bypass valves time to
reach their proper positions.
Auto-Restart – The compressor has stopped due to
pressure rising above the oine or auto-stop setpoints
and auto-restart being enabled. The compressor will
automatically restart when pressure falls to the online
or target pressure setpoint.
Stopping – The compressor has received a stop
command and the stop sequence is being performed.
Blowdown – The compressor must wait for a brief
period of time after stopping its motor before it is
allowed to start again. The compressor will restart at
the end of the blowdown period if a start command is
recieved during blowdown.
Not Ready – The compressor has detected a condition
that will not allow the compressor to start. The
condition must be cleared before a start is allowed, but
does not need to be acknowledged.
Tripped – The compressor has detected an abnormal
operational condition that has stopped the machine. A
trip must be acknowledged by hitting the reset button
before the compressor can start.
Processor Init – The controller is being initialized.

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FIXED SPEED COMPRESSOR
HOME FOLDER
Page 1: System Overview
Figure 5 : Home Folder
This is the factory default display after powering up the
system.
Online Pressure Setpoint - indicated in the black box
and arrow, which is always left of center on the gauge.
The compressor will load when package discharge
pressure falls below this value.
Oine Pressure Setpoint - indicated in the black
box and arrow, which is always right of center on the
gauge. The compressor will unload when package
discharge pressure rises above this value.
Package Discharge Pressure - indicated by the large
numbers centered below the gauge and by the black
arrow below the gauge. This is the air pressure that the
compressor is supplying to the plant.
Pressure Unit of Measure - indicated below the
Package Discharge Pressure. This is selectable from the
GENERAL SETTINGS folder.
Airend Discharge Temperature - indicated by the
numbers in the lower right of the display. This is the
temperature of the air/oil mixture at the discharge of
the compression module.
Temperature Unit of Measure - indicated to the right
of the Airend Discharge Temperature. This is selectable
from the GENERAL SETTINGS folder.
Run Hours – indicated by the numbers in the
lower left of the display. The number of hours the
compressor motor has been running.
NOTICE
The online and oine set points can be selected and
modied on this page. All other information on this
page is read only.


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OPERATING INSTRUCTIONS XE70M CONTROLLER
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