Ingersoll-Rand RR125-F30 Setup guide

80165038
Edition 1
October 2005
Starter Relay Valve
RR125-F30 and RR152-F30
Installation and
Maintenance Information
Save These Instructions

280165038_ed1
WARNING
General Product Safety Information
• Important Safety Information enclosed.
• Read and understand this manual before operating this valve.
• It is your responsibility to make this safety information available to others that will operate this valve.
Safety Information - Explanation of Safety Signal Words
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury or property damage.
Indicates information or a company policy that relates directly or indirectly to the safety of
personnel or protection of property.
DANGER
WARNING
CAUTION
NOTICE
WARNING
Failure to observe the following warnings could result in injury
• Do not use this Starter Relay Valve with natural gas or other flammable gases.
• Always bleed off the air pressure before attempting to remove the Starter Relay Valve from the Receiver or before
attempting to perform any maintenance on the Starter Relay Valve.
• Never attempt to disassemble the Starter Relay Valve until after the air pressure has been bled off. Otherwise internal
parts of the Starter Relay Valve will be blown out with the great force.
• Always wear eye protection when installing, removing or performing maintenance on this Starter Relay Valve.
NOTICE
This Starter Relay Valve is specially designed and manufactured by Ingersoll-Rand for use on Starter installations.
Install it according to the following instructions:
Assembling Relay Valve on starter
1. Remove screws (7) and separate relay valve from outlet
flange (22).
2. Mount O-ring (23) on outlet flange (22). Install flange and
o-ring on starter with screws (21).
Apply grease to O-ring, and secure screws (21) with
Loctite® 242 or 243.
3. Mount the second O-ring (23) on outlet flange.
4. Assemble the relay valve on outlet flange with screws (7).
Secure screws (7) with Loctite® 242 or 243.
NOTICE
The use of other than genuine Ingersoll-Rand replacement parts may result in safety hazards, decreased starter relay
valve performance and increased maintenance, and will invalidate all warranties.
Ingersoll-Rand is not responsible for customer modification of valve for applications on which Ingersoll-Rand was not
consulted.
Repairs should be made only by authorized, trained personnel. Consult your nearest Ingersoll-Rand Authorized
Servicenter.

80165038_ed1 3
Specifications
(Dwg. 80176563)
1-1/2” ÆRR152-F30 - Order part number 38600714
1-1/4” ÆRR125-F30 - Order part number 38633764
Max. Inlet Pressure 30 Bar 435 psi
Max. Outlet Pressure 10 Bar 145 psi
Max. Flow 850 dm3/s 1800 scfm
Max. Temperature 80°C 176°F
Min. Temperature -25°C -13°F

480165038_ed1
Description
The RR152-F30 and RR125-F30 include valve and regulator
functions.
The RR152-F30 and RR125-F30 are made of three main
components:
1. The master regulator which sets the pilot pressure.
2. The solenoid valve which will open or close the system
when the operator actuates the switch key.
3. The slave regulator which is the main body.
(Dwg. 80176761)
The slave regulator (3) will receive the signal from the master
regulator (1) through the solenoid valve (Fig 2). For
pre-engage Starters (Fig 1) the signal pressure will come
from the master regulator through the solenoid valve to the
pilot “In” port of the air starter drive housing, giving the signal
to engage the drive pinion into the ring gear. After engaging
the drive pinion it will come out through the “Out” port of the
drive housing and will go to the top cover of the slave
regulator.
(Dwg. 80176910)
The Slave regulator using the pressure signal on top of the
diaphragm will force the piston off its seat. That allows air to
flow into control chamber below the diaphragm, through the
outlet port of the RR152 valve to the starter motor. Outlet
pressure increases in the downstream system and sensing
chamber (under the diaphragm) and applies an upward force
on the bottom of the diaphragm. The diaphragm and piston
move upward. Upward movement stops when the forces
below the diaphragm balance the force above the
diaphragm.
(Dwg. 80177017)
(Dwg. 80177082)
3
2
1
Figure 1 Figure 2

80165038_ed1 5
Operation
Clockwise rotation of screw (1) will open the seat in the
master regulator and will increase the pressure between the
master regulator and solenoid valve (4). Do not try to exceed
11 bar or 160 psig. The pressure you adjust at the slave
regulator will be slightly higher than the working pressure at
the starter. In order to easily adjust the working pressure
install a gauge on port (2).
(Dwg. 80177215)
The master pressure regulator is designed as a relieving
regulator. When the pressure below the diaphragm reaches
1.5 bars over the adjusted pressure, the regulator exhausts
the excess pressure.
While the relay valve is operating, a small amount of air will
bleed from a hole in a plug in the housing and from a hole in
the diaphragm cover.
Schematic
For inertia drive applications:
For pre-engaged drive applications:
(Dwg. 80177223)

680165038_ed1
Relay Valve Assembly Drawing
(Dwg. 80177256)
Relay Valve Parts List
23
22
9
31
32
5
13
14
17
19
18
16
15
7
26
25
30
24
33
4
3
28
1
2
27
21
6
11
23
10
8
12
29
20
Item Parts Description Part Number Item Parts Description Part Number
1 Cover Screw (12) 41322206 31 Flange Seal 38752358
2 Diaphragm Cover 38602546 32 Filter 38752325
3 Diaphragm 38602728 33 Plug 80162225
4 Diaphragm Support 38600524 Piston Kit RR152-K618 38747432
6 Housing 38602645 (For RR152-F30 and RR125-F30)
7 Assembly Screw (4) 38633616 Stem - Item no. 5
8 Plug 38667648 Plate - Item no. 12
9 Bleed 80162282 Piston Assembly - Item no. 13
10 Ring 38600607 O-ring - Item no. 14
18 Bottom Cover 38602405 Locknut - Item no. 15
19 Bottom Cover Screw (6) 4132-2606 Spring - Item no. 16
20 Plug 38648192
21 Screw for RR152-F30 (4) 38633624 Seal Kit RR152-TK2 38747440
21 Screw for RR125-F30 (4) 38634168 (For RR152-F30)
22 Outlet Flange 1” 1/2 38602652 O-ring - Item no. 11
Outlet Flange 1” 1/4 38634150 O-ring - Item no. 17
24 Mini regulator 10548774 O-ring - Item no. 23 (2)
25 Operator and Coil 49828460
26 Solenoid Valve 49828692 Seal Kit RR125-TK2 38747457
27 Probe Assembly 80162266 (For RR125-F30)
28 Adapter 38754933 O-ring - Item no. 11
29 Adapter 80162217 O-ring - Item no. 17
30 Adapter 80162233 O-ring - Item no. 23 (2)

80165038_ed1 7
Maintenance
Disassembly of Relay Valve
1. Remove screws (1). Remove cover (2) and
diaphragm (3).
2. WARNING: Bottom cover (18) is spring-loaded.
Clamp relay valve in arbor press before removing
bottom screws (19). Otherwise personal injury or
damage to parts may occur. Secure relay valve upside
down in arbor press, applying force to bottom cover.
3. Remove screws (19). Slowly raise arbor press to remove
cover (18).
4. To remove stem piston assembly: Hold diaphragm
support (4) with a spanner wrench. Turn locknut (15) with
a socket to unscrew the stem from the diaphragm
support.
5. If the locknut comes loose before the diaphragm support,
separate the piston (13), plate (12) and stem (5). Hold the
stem on the flats and unscrew the diaphragm support.
Assembly of Relay Valve
Apply Parker O-Lube grease to O-rings (11), (14), and (17),
and spring (16).
Clean with isopropyl alcohol and apply Loctite® 242 or 243 to
probe assembly (27), screws (1), screws (19), and
diaphragm support (4).
1. Insert stem (5) of stem/piston assembly through ring (10)
and O-ring (11) in housing (6).
2. Tighten diaphragm support (4) on stem piston assembly
to 4.5/3.4 Nm (40/30 inch-Lbs) by holding locknut (15).
3. WARNING: Bottom cover (18) is spring-loaded.
Clamp relay valve in arbor press before installing
bottom screws (19). Otherwise personal injury or
damage to parts may occur. Secure relay valve upside
down in arbor press. Align bottom cover and apply force
to bottom cover.
4. Install six screws (19). Tighten to 10.7/8.5 Nm
(95/75 inch-Lbs).
5. Install diaphragm (3) and cover (2).
6. Install twelve screws (1). Tighten to 7.0/5.7 Nm
(62/50 inch-Lbs).

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