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Revision A
February 2011

Rotary Screw Air Compressor

R45 - 160N / R45 - 160I / R45 - 160NE / R45 - 160IE

Product Maintenance Information

Save These Instructions

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Contents
AIR COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 3 INTEGRATED DRYER MAINTENANCE . . . . . . . . . . . . . . . . . . . 12
MAINTENANCE PROMPTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INTEGRATED DRYER MAINTENANCE CHART. . . . . . . . . . . . . 12
AIR COMPRESSOR MAINTENANCE CHART. . . . . . . . . . . . . . . . 3
ROUTINE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DISASSEMBLING THE INTEGRATED DRYER . . . . . . . . . . . . . . 12
TROUBLESHOOTING (VSD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DECOMMISSIONING THE INTEGRATED DRYER. . . . . . . . . . . 12

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AIR COMPRESSOR MAINTENANCE

MAINTENANCE PROMPTS The service warning will return each subsequent 2000 hours.

The service warning and flashing LED will appear at intervals, dependent The machine will be master reset after service work conducted prior to the
on the service level selected. Refer to the Product Information manual for 2000 hour interval to prevent false indication.
information about service level settings.
AIR COMPRESSOR MAINTENANCE CHART
For service level 1, when a “Service Required” warning is issued, the warning
can be reset the same way as any other warning. Maintenance should be performed per the recommendations below in the
following priority: (1) Perform maintenance when indicated by the controller;
For service level 2, when a “Service Required” warning is issued, the customer (2) Perform maintenance through either hourly intervals or scheduled
can only reset the warning for 24 hours by pressing the “set” button. maintenance intervals, or (3) Annually.
Ingersoll Rand service engineers will master reset the warning after
completing the service work.
Table 1: Air Compressor Maintenance Chart
Period Action Maintenance Item
When indicated by Replace Air Filter
controller Replace Oil Filter
Replace Separator Element
Daily Check Check for leaks (connections and hoses)
Check Coolant Level
Check Drain Valve operation
Check Microcontroller for Service Indicators
Check Pre Package Filter for blockage
Monthly Inspect Air Cooled Coolers, check for blockages
Inspect Water Cooled Coolers, check screens
Inspect Starter Box (PDM) Filter
Analysis Water Cooled machines, Perform water analysis.
Every 500 Hrs Analysis Perform Food Grade Lubricant Analysis
Every 1000 hours Replace Food Grade Lubricant if not using Food Grade Filter system
Replace Filter, Food Grade Lubricant if not using Food Grade Filter System.
Every 2000 Hours or 3 Inspect Air Filter Element
Months Inspect Oil Filter Element
Inspect Starter Box Panel Filter (VSD Only)
Replace Food Grade Lubricant when using Food Grade Filter Module.
Replace Food Grade Filter Module
Analysis Shock Pulse Bearing Analysis
Analysis Perform Coolant Analysis
Every 4000 Hours or 6 Inspect Check Scavenge Screen for blockage.
Months Replace Air Filter Element
Replace Oil Filter Element
Replace PDM Air Filter Element
Replace Package Pre Filter
Clean Air Cooled Coolers
Inspect / Clean Water Cooled Coolers
Grease Grease Motors
Maintenance interval for typical rotary compressor installation. Motors in harsh environments / higher
ambients should be regreased more frequently.
Calibrate Calibration of the Pressure Transducers.
Analysis Perform Coolant Analysis
Analysis Perform Vibration Analysis
Every 8000 Hours or Replace Compressor coolant Lubricant - 8000 hours or every 2 years.
Annually Replace Separator Element
Replace No Loss Drain Valve Service Module
Service MPCV Service Kit
Service Inlet Valve Service Kit
16000 Hours Replace All Hoses
Replace Contact Tips
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** In dirty operating environments change coolant filters and separator element more frequently.
* Food Grade Filter and lubricant can last beyond 2000 hours between changes ONLY when analysis is done consistently every 500 hours and following manual
directions.

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ROUTINE MAINTENANCE
This section refers to the various components which require periodic
maintenance and replacement.
For all other maintenance, contact your local Ingersoll Rand service provider.
Refer to safety information and maintenance procedures prior to carrying out
any of the maintenance in the following sections.

Checking Coolant Level

The coolant level should be checked daily. A coolant level sight glass is
located on the side of the separator tank and while the machine is running on
load, coolant should always be visible in the sight glass. The normal position
is half way. The machine should be running for at least 40 seconds for this
check.
Stop the machine, ensure sump pressure is 0 psig and ensure coolant is still
visible in the sight glass.

Adding Coolant
Figure 1: Coolant Drain
Run the compressor for a minimum of 40 seconds, the coolant level should
be visible in the sight glass. If not: 4. Start the compressor and check for leaks.

1. Stop the compressor. 5. Check the coolant level, refilling if necessary.

2. Isolate the compressor from the system. 6. Dispose of waste coolant in accordance with local and
governmental regulations.
3. Press the emergency stop to vent the separator tank and airend. FS
units can take more than two minutes to fully de-pressurize once It is recommended to perform a coolant analysis every 2000 hours or 3
stopped. months to monitor condition and determine when to change the coolant, if
analysis is not performed, the recommended coolant change interval is 8000
4. Slowly unscrew the coolant fill plug to verify all pressure has been hours or 2 years, whichever comes first.
released.
5. Add coolant. NOTICE

6. Replace the coolant fill plug and restart the compressor. Shorter coolant change intervals may be necessary if the compressor
is operated in adverse conditions.
7. Recheck the coolant level.
8. Repeat the above steps until the coolant level is visible in the sight
Food Grade Coolant Option
glass with the compressor both running and stopped.
It is recommended to have samples of the coolant analyzed every 500 hours
NOTICE or each month to determine when coolant should be changed.
If analysis is not performed, coolant should be changed after 2000 hours
Do not add coolant through the intake of the compressor, as this can
or every 6 months when utilizing the food grade filter supplied with the
result in overfilling, saturation of the separator filter element, and
machine.
coolant carry-over downstream.
For units running food grade coolant without the food grade filter, the
change interval should be 1000 hours or 6 months, whichever comes first.
Draining Coolant
It is better to drain the coolant immediately after the compressor has been Sampling Coolant
operating as the liquid will drain faster and any contaminant will still be in Bring unit up to operating temperature. Draw sample, using pump kit, from
suspension. separator tank port. DO NOT draw sample from drain port or oil filter. Use a
1. Install a drain hose (not supplied) in end of drain valve and place new hose on pump for each sample, failure to do this can give false readings.
end of hose in a suitable container.
2. Open drain valve to start drainage.
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3. After drainage, remove hose and close valve.

NOTICE

On air cooled units, you may also drain coolant from the oil cooler by
removing plug.
You may also drain additional coolant from airend by removing plug
in airend discharge elbow.

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4. Clean the sealing surface on both the tank and its cover. Check the
tank to be absolutely certain that no foreign objects such as rags
or tools have been allowed to fall into the tank. Install replacement
element down into the tank after checking the new element seal/
gasket for possible damage. Center the element up within the tank.
Rotate the tank cover back into position taking care not to damage
the seal/gasket , and locate the cover using 2 capscrews but do not
tighten down.
5. Completely remove the pivot bolt and tighten the cover bolts in a
cross-pattern to prevent over-tightening one side of the cover. An
improperly tightened cover will likely result in a leak.

NOTICE

Unscrew the jacking bolt sufficiently to ensure that the cover can be
fully tightened down without imparting any stress onto the jacking
points. Tighten down the cover bolts.

1. Tank cover bolt (M16 size) torque values 200 N-m (150 ft-lb) Inspect
tank scavenge screen and orifice. Clean if necessary following
instructions below.
2. Install scavenge tube down into the tank until the tube just touches
the separator element and then raise it 1/8inch (3 mm). Tighten
fittings.
3. Install the regulation lines in their original position.

Figure 2: Coolant Sampling

Changing Coolant Filter
Figure 3: Recommended Bolt Tightening Cross Pattern
1. Loosen filter element with the correct tool. 4. Start the compressor and check for leaks
2. Remove the element from the housing.
NOTICE
3. Place the old element in a sealed bag and dispose of in a safe way.
4. Clean the mating face of the housing. Do not use any form of sealant on either the separator tank or the
separator tank cover faces.
5. Remove the new replacement element from its protective package.
5. Apply a small amount of coolant to the element seal. Inspecting Separator Tank / Pressure System
6. Screw the new element down until the seal makes contact with the At 2000 hour intervals, inspect the external surfaces of the airend and
housing, then hand tighten a further half turn. separator tank, including all fittings, for visible signs of impact damage,
Start the compressor and check for leaks and check the coolant level. excessive corrosion and abrasions. When changing the separator element,
inspect the internal components and surfaces. Any suspect parts should be
Checking Separator Element replaced before the compressor is put back into service.
With the compressor running on load, check the separator differential The separator tank should also be tested and inspected in accordance with
pressure via the microcontroller. It will be necessary to change the element if any national or local codes that may exist.
the differential pressure equals zero or exceeds 1 bar (15 psig).
Cleaning / Checking Scavenge Screen
Changing Separator Element
The screen/orifice assemblies are similar in appearance to a straight tubing
1. Remove the fitting that holds the scavenge tube into the tank and connector and will be located between two pieces of 1/4 inch O.D. scavenge
withdraw the tube assembly. line tubing.
2. Disconnect the piping from the tank cover. Tag the lines if required. The main body is made from 17mm hexagon shaped brass and the diameter
Remove all the capscrews securing the cover to the tank except the of the orifice and a direction-of-flow arrow is stamped in flat areas of the
screw opposite the pivot bolt which should be left engaged by 2-3 hexagon.
threads with at least 6.5 mm (0.25”) clearance from the screw head
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to the lid. Rotate the jacking bolt clockwise until the cover lifts off A removable screen and orifice will require clearing as outlined in the
the tank at least 2 mm (0.08”) all the way around the tank. The cover Maintenance Schedule.
can now be rotated to allow access to inside the tank.
3. Carefully lift the separator element up and out of the tank. Discard
the faulty element.

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To remove the screen/orifice 4. Visually check the outside of the cooler cores to determine the
appropriate cleaning method detailed as follows.
1. Disconnect the scavenge line tubing from each end.
a. For loose dirt, dust and other light foreign material, open the
2. Hold the center section firmly and use a pair of pliers to gently access panels on the sides of the cooler plenum and gently blow
grasp the exit end of the assembly that seals against the scavenge compressed air across the oil cooler surface. Use a vacuum hose
line tubing. with a soft brush to clean the exposed face of the air after cooler.
3. Pull the end out of the center section while using care to prevent Repeat the process until the coolers are sufficiently clean. Replace
damage to the screen or sealing surfaces. the access panels before returning the machine to service.

4. Clean and inspect all parts prior to reinstallation. b. For thick, packed dirt, oil or grease, or other heavy material, the
coolers will need to be removed from the machine for pressure
5. When the assembly is installed, confirm the direction of flow to washing. Ingersoll Rand does NOT support pressure washing
be correct. Observe the small arrow stamped in the center section coolers when they are installed in machinery due to the dangers
and ensure the direction flow to be from the separator tank to the of spraying water in or around potential electrical power sources.
airend. Follow the steps below for cooler removal.
Replacing Coolant Hoses Removing / Installing Air Cooled Cooler
The flexible hoses that carry coolant through the cooling system may To remove:
become brittle with age and will require replacement. Replace them as
needed or every 4 years. 1. Ensure that the compressor is isolated from the compressed air
system and is vented of all pressure.
1. Depending on the location of the hose, it may contain compressor
coolant. It is recommended to drain the coolant into a clean 2. Ensure that the main power disconnect switch is locked off and
container. Cover the container to prevent contamination. If the tagged.
coolant is contaminated, a new charge of coolant shall be used. 3. For any required lifting of air compressor parts or required tools,
2. Remove the hose. always use the proper certified lifting equipment, and employ
sound working principles.
3. Install the new hose and refill the unit with coolant.
4. Drain the oil from the oil cooler by removing the hex plug located
4. Start the compressor, check for leaks and check coolant level. Refill at the front of the air compressor, and lower side of the oil cooler.
as necessary.
5. Remove all hoses, pipes, and sensors from the coolers.
Checking Pressure Relief Valve
6. Remove the access panels on the sides of the cooler plenum
The pressure relief valve shall be frequently tested and regularly maintained.
7. Properly secure the air aftercooler and remove the (four) nuts from
Remove from the machine for testing. If operating conditions are particularly
the (two) bolts at the upper sides of the cooler.
severe, the frequency of testing and maintenance shall be increased
accordingly. A pressure relief valve check shall also be performed at the 8. Remove the (two) nuts from the bolts at the bottom of the cooler.
end of any non-service period. The user shall establish the frequency of
such tests as it is influenced by such factors as the severity of the operating 9. Carefully remove the air aftercooler.
environment. 10. Properly secure the oil cooler and remove the (four) nuts from the
The pressure relief valve should be tested and re-calibrated in accordance (two) bolts at the upper sides of the cooler.
with any national or local codes that may exist. If no code exists, Ingersoll 11. Remove the (two) nuts from the bolts at the bottom of the cooler.
Rand recommends that the pressure relief valve is recalibrated at intervals of
one year by a licensed contractor or qualified service personal. 12. Carefully remove the oil cooler.

Changing Air Filter 13. Re-install the oil drain plug to 65 N-m (48 Ft-Lbs).

1. Unclip the retaining cap and withdraw the old element. To install:

2. Fit the new element and refit the retaining cap. 1. Ensure that the compressor is isolated from the compressed air
system and is vented of all pressure.
Regreasing Blower Motor
2. Ensure that the main power disconnect switch is locked off and
The blower motor contains pre-greased, sealed bearings. They cannot be re- tagged.
greased and do not require re-greasing.
3. For any required lifting of air compressor parts or required tools,
Cleaning Air Cooled Cooler always use the proper certified lifting equipment, and employ
sound working principles.
Air compressor operating temperatures will be higher than normal if the
external passages between the fins of the cooler cores become restricted 4. Carefully place the oil cooler in its proper location and install the
with foreign material. Regular cleaning of the cooler surfaces will support (two) sets of lower fasteners, tightly.
the reliable operation of your air compressor system and improve the life of 5. Install the (two) sets of upper side fasteners, finger tight + ¼ turn.
your compressor oil. When performed frequently as determined by your site Next add the second nut to each tightly. This second nut is used to
conditions and airborne contamination, more significant cleaning or heat lock the first in place. It is important the first nut is not too tight so
exchanger replacement may not be necessary. it can allow the cooler to expand and contract without stressing the
1. Ensure that the compressor is isolated from the compressed air cooler’s brazed joints.
system and is vented of all pressure. 6. Ensure the rubber seal on the air aftercooler is in place on the
2. Ensure that the main power disconnect switch is locked off and cooler and in good condition.
tagged. 7. Carefully place the air aftercooler cooler in its proper location and
3. For any required lifting 160x50
of air compressor install the (two) sets of lower fasteners, tightly.
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always use the proper certified lifting equipment, and employ 8. Install the (two) sets of upper side fasteners, finger tight + ¼ turn.
sound working principles. Next add the second nut to each tightly. This second nut is used to
lock the first in place. It is important the first nut is not too tight so
it can allow the cooler to expand and contract without stressing the
cooler’s brazed joints.

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9. Re-attach all hoses, pipes and sensors, and properly torque Cleaning / Checking Moisture Separator
according to the table shown…
1. Ensure compressor is electrically isolated for at least 15 minutes,
10. Replace the access panels on the sides of the cooler plenum. before commencing any maintenance work.
11. Refill the machine with oil to the proper level. 2. Isolate the compressor from the system and fully discharge the
compressed air within the unit.
Cleaning Water Cooled Cooler (for both Clean & Harsh Water Options)
3. Remove tube from the fitting located on the bottom of the
A periodic inspection and maintenance program should be implemented for moisture separator.
water cooled heat exchangers. It is recommended that you contact Ingersoll
Rand for cleaning services should you not have experience and equipment 4. Remove the bowl of the moisture trap, clean and replace.
to do this work.
Cleaning / Installing Package Pre-Filter
If water inlet lines have strainers, inspect them and replace or clean as
required. 1. Unlatch the two 1/4 turn latches and open intake panel (panel is
hinged)
Mineral scale may be removed with a suitable de-scaling agent containing
amidosulphuric acid + citric acid and Neutralit solutions for cleaning the 2. Remove the (six) wing nuts
coolers. As an alternative, any weak acid mixed with water in the ratio of 1:4 3. Remove filter grill
may be used.
4. Pull out filter element
Fouling should be removed with a suitable detergent in hot water.
5. Center new element over package intake opening. Also note that
Back flush the cooler with a flow rate at least 1.5 times the normal flow rate. filter is washable with mild detergent.
After using any cleaning solution, thoroughly flush out all chemicals with 6. Push filter over grill studs so that studs poke through the filter
clean water before returning the cooler to service. media
Mechanical cleaning methods are not recommended as damage to the 7. Install filter grill
internal passages may occur.
8. Install (six) wing nuts
After cleaning, examine the cooler for erosion or corrosion.
9. Close intake panel and latch
Checking High Airend Temperature Sensor
Checking / Cleaning No Loss Drain Trap (where fitted)
It is recommended that the discharge temperature sensor (2ATT) is checked
It is recommended to check the no loss drain trap daily to insure that
regularly as follows:
condensate is draining from the moisture separator system. To check for
For air cooled machines, stop the cooling blower by opening the blower / fan correct function.
motor circuit breaker.
1. Press the test button on the unit and listen for condensate / air
For water cooled machines, shut off the cooling water. passing through the drain.

The machine should trip at 109° C (228° F). 2. If the drain is clogged, replace the no loss drain valve service
module. The service module consists of the lower portion of the
Cleaning Motor Cowl drain trap and is not serviceable.
1. Ensure compressor is electrically isolated for at least 15 minutes Additionally, it is recommended to replace the service module every 8000
before commencing any maintenance work. hours or once per year, whichever comes first.
2. Remove panels from the compressor. Monitoring Fluid and Vibration
3. Using a clean dry cloth, remove dust from the surface of the motor Ingersoll Rand recommends incorporating predictive maintenance,
cowl and ensure all ventilation slots are free of obstructions. specifically the use of coolant and vibration analysis, into all Preventative
4. Replace panels. Maintenance programs. Contact Ingersoll Rand for details.

Removing / Replacing Drive Box Filter (For VSD only)

1. Ensure compressor is electrically isolated for at least 15 minutes
before commencing any maintenance work.
2. Unclip the front grill of the drive box filter.
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3. Remove the filter pad from the housing and replace with a new
filter pad.
4. Replace front grill.

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STARTER BOX PANEL FILTER (VSD ONLY)

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Figure 4: Starter Box Panel Filter Replacement (VSD)

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TROUBLESHOOTING (VSD)
Table 2: General Faults
SYMPTOM FAULT REMEDY
Compressor will not start No power supply to package Check supply is switched on. If so, contact a qualified
electrician.
Microcontroller failure Check supply to unit. Replace unit.
Starter failure Isolate supply, lock off and tag. Replace failed component
or contact your local
Ingersoll Rand representative
Compressor stops and will not restart Drive controller has tripped See Tables 3 and 4.
Microcontroller has tripped the compressor See Tables 3 and 4.
Maximum number of starts per hour exceeded
Compressor is stopped and will not Microcontroller has tripped the compressor and has See Tables 3 and 4.
restart not been reset
Emergency stop has been pressed and not released Identify reason why, repair fault, disengage button and
reset microcontroller
Emergency stop has been pressed and released but Repair fault and reset microcontroller
microcontroller has not been reset
Compressor will not meet pressure Compressor not sized to meet system requirements Contact your local Ingersoll Rand representative
required by system or requirements have been changed.
Air loss due to pipe, hose, joint or seal failure Overhaul or replace
Air loss due to blowdown valve stuck open Overhaul or replace
Air loss through pressure relief valve not seating or Overhaul or replace
set incorrectly
Air loss due to moisture separator drain trap stuck Overhaul or replace
open
Motor speed too low caused by drive incorrectly set Contact your local Ingersoll Rand representative
Motor speed too low caused by fault in drive settings See Table 4.
Microcontroller fault Overhaul or replace
Drive motor fault See Table 4.
Pressure transducer faulty, incorrectly calibrated or Recalibrate or replace
EMF interference
Incorrect microcontroller settings Check and modify settings
Inlet grill or ducting is blocked Check and clean
Air filter dirty or collapsed Replace
Compressor will not meet pressure Inlet valve not opening fully Overhaul or replace
required by system Separator element dirty or collapsed Replace
Pipe / Hoses blocked or collapsed Clean or replace
Cooler core blocked Clean or replace
Minimum pressure check valve not functioning Overhaul or replace
correctly
Equipment between compressor and customer Review system requirements
measuring point causing pressure drop / pressure
loss
Pressure produced by compressor is Microcontroller set incorrectly Check and modify settings
too high compressor is too high due
Pressure transducer may be faulty, incorrectly Recalibrate or replace
to speed not reducing as demand
calibrated or not receiving pressure signal
reduces
Drive settings fault Contact your local Ingersoll Rand representative
Compressor discharge air too hot High ambient temperature Review installation and system parameters
Insufficient cooling air Check ducting and cooling air path, check direction of
blower rotation
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Dirty, blocked aftercooler (cooling air side) Clean or replace

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Table 2: General Faults (cont.)

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

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Table 3: Microcontroller Faults (indicated on the microcontroller)

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

Table 4: Drive Faults (indicated on the microcontroller)

The drive controller is directly linked to the microcontroller. Faults in the drive controller will be displayed on the microcontroller as ‘VSD fault 0, VSD fault 1’ etc.
The following VSD faults may be investigated and remedied at source. For all other VSD faults, contact your local Ingersoll Rand customer support
representative.

FAULT CAUSE ACTION

VSD Fault 1 Over-current Check separator element.
Check cooler, pipework and moisture separator for blockages.
Check operation of minimum pressure check valve.
VSD Fault 3 Drive temperature
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Check drive cooling fan circuit breaker
Check wiring

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INTEGRATED DRYER MAINTENANCE

DISASSEMBLING THE INTEGRATED DRYER
WARNING

Before accessing live electrical parts, disconnect the power supply NOTICE
to the dryer using disconnect switch or disconnect the cable
The unit must be disassembled, charged or repaired by a refrigerant
connections.
specialist.
Refrigerant liquid and lubricating oil inside the refrigeration circuit
INTEGRATED DRYER MAINTENANCE CHART must be recovered in compliance with current norms in the country
For optimum performance from your dryer, follow the periodic maintenance where the machine is installed.
schedule described below.
Table 5: Integrated Dryer Maintenance Chart NOTICE

WEEKLY CONDENSATE DRAINS (TIMED AND NO-LOSS Refrigerant leaks may be identified by tripping of the refrigeration
DRAINS) overload protector.
Verify that the condensate drains are operating If a leak is detected in the refrigerant circuit, seek technical assistance.
correctly by pressing the TEST button.
If a refrigerant leak occurs, thoroughly air the room before
EVERY 4 MONTHS CONDENSER commencing work.
Remove any dust from the condenser fins.
EVERY 6 MONTHS AIR FILTER
NOTICE

Replace air filter element. In normal temperature and pressure conditions, the R404 refrigerant
is a colorless, class A1/A1 gas with TVL value of 1000 ppm (ASHRAE
YEARLY (TIMED DRAINS ONLY) classification).
Completely disassemble the drains and clean all
their components. DECOMMISSIONING THE INTEGRATED DRYER
Troubleshooting Condensate Drains (Electronic Drains Only) Decommission the machine and the relevant packaging in compliance with
Table 6: Condensate Drain Troubleshooting Chart the rules locally in force.
Pay particular attention to the refrigerant, as it contains part of the
TROUBLE CAUSE ACTION refrigerating compressor lubricating oil.
Solenoid Debris in solenoid valve Remove solenoid valve,
Contact a waste disposal and recycling utility.
condensate valve prevents diaphragm disassemble, clean and
will not close. from seating. reassemble. Table 7. Integrated Dryer Materials of Construction.
Short in electrical Check and replace power RECYCLING DISASSEMBLY
component. cord or timer as needed.
Frame and panels Steel / epoxy resin polyester
• Cleaning Condensate Drains (Timed Drains Only) Heat exchanger (cooler) Stainless steel / aluminum
Periodically clean the screen inside the valve to keep the drain functioning at Pipes Copper
maximum capacity. To do this, perform the following steps:
Insulation Gum synthetic
1. Close the strainer ball valve completely to isolate it from the air Compressor Steel / copper / aluminum / oil
receiver tank.
Condenser Aluminum
2. Press the TEST button on the timer to vent the pressure remaining
in the valve. Repeat until all pressure is removed. Refrigerant R-404A
Valve Steel
WARNING

High pressure air can cause injury from flying debris. Ensure the
strainer ball valve is completely closed and pressure is released from 1075.jpg (JPEG Image, 160x50 pixels)
the valve prior to cleaning.

3. Remove the plug from the strainer with a suitable wrench. If you
hear air escaping from the cleaning port, STOP IMMEDIATELY and
repeat steps 1 and 2.
4. Remove the stainless steel filter screen and clean it. Remove any
debris that may be in the strainer body before replacing the filter
screen.
5. Replace plug and tighten with wrench.
6. When putting the Electric Drain Valve back into service, press the
TEST button to confirm proper function.
Testing Condensate Drains (No-Loss Drains Only)
Press the TEST button to confirm proper function.

EN-12
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Notes

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