SSR M37 M45 OPERATION AND MAINTENANCE MANUAL

M37 SERIAL No : 2272000 –>

This manual contains
important safety information
M45 SERIAL No : 2280250 –>
and must be made available to
personnel who operate and
maintain this machine.

C.C.N. : 89270763 GB
DATE : APRIL 2002
 Machine models represented in this manual may be used in various locations worldwide. Machines sold and
shipped into European common market countries requires that the machine display the EC Mark and conform
to various directives. In such cases, the design specification of this machine has been certified as complying
with EC directives. Any modification to any part is absolutely prohibited and would result in the CE certification
and marking being rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

98/37/EC, 93/68/EEC, 89/336/EEC

WE,

INGERSOLL–RAND COMPANY LIMITED

SWAN LANE
HINDLEY GREEN
WIGAN WN2 4EZ
UNITED KINGDOM

DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY,
THE PRODUCT(S)

M37G M45G
TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS
OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

EN29001, EN292, EN60204–1, EN1012, EN50081, EN50082

ISSUED AT HINDLEY GREEN ON 01/01/2001 BY H.SEDDON, QUALITY ASSURANCE

MANAGER.

H. SEDDON
 CONTENTS & ABBREVIATIONS 1
ABBREVIATIONS & SYMBOLS
CONTENTS
#### Contact Ingersoll–Rand for serial number
1 CONTENTS
–>#### Up to Serial No.
####–> From Serial No.
2 FOREWORD * Not illustrated
{ Option
3 ISO SYMBOLS NR Not required
AR As required
SM Sitemaster/Sitepack
8 SAFETY
HA High ambient machine
WC Watercooled machine
10 GENERAL INFORMATION AC Aircooled machine
ERS Energy recovery system
14 INSTALLATION / HANDLING T.E.F.C. Totally enclosed fan cooled motor (IP54)
O.D.P. Open drip proof (motor)
ppm parts per million
18 OPERATING INSTRUCTIONS
D Germany
DK Denmark
21 AIRCARE WARRANTY E Spain
F France
22 MAINTENANCE GB Great Britain
I Italy
N Norway
26 FAULT FINDING
NL Netherlands
P Portugal
S Sweden
SF Finland

M37 M45
2 FOREWORD
The contents of this manual are considered to be proprietary and
confidential 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.
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
checks.
Use of the machine outside the ambient temperature range
specified in the GENERAL INFORMATION SECTION of this manual.
Use of the machine where there is any actual or foreseeable risk of
hazardous levels of flammable gases or vapours.

Use of the machine fitted with non Ingersoll–Rand approved

This manual contains instructions and technical data to cover all
routine operation and scheduled maintenance tasks by operation and components.
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised Ingersoll–Rand service Use of the machine with safety or control components missing or
department. disabled.

Connection to an electrical supply of incorrect voltage and/or

The design specification of this machine has been certified as frequency.
complying with E.C. directives. Any modification to any part is
absolutely prohibited and would result in the CE certification and
marking being rendered invalid. The company accepts no responsibility for errors in translation of
this manual from the original English version.
All components, accessories, pipes and connectors added to the
compressed air system should be:
. of good quality, procured from a reputable manufacturer and, SSR ULTRACOOLANT is a registered trademark of
wherever possible, be of a type approved by Ingersoll–Rand. Ingersoll–Rand Company USA.
. clearly rated for a pressure at least equal to the machine maximum
allowable working pressure. INTELLISYS is a registered trademark of Ingersoll–Rand
. compatible with the compressor lubricant/coolant. Company USA.
. accompanied with instructions for safe installation, operation and
maintenance.
 COPYRIGHT 2001
INGERSOLL–RAND COMPANY
Details of approved equipment are available from Ingersoll–Rand
Service departments.

The use of repair parts other than those included within the
Ingersoll–Rand approved parts list may create hazardous conditions
over which Ingersoll–Rand has no control. Therefore Ingersoll–Rand
cannot be held responsible for equipment in which non–approved
repair parts are installed.

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.

IF IN DOUBT CONSULT SUPERVISION.

This machine has been designed and supplied for use only in the
following specified conditions and applications:
. Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.

No portable communication devices emitting more than 7,5 volts

per metre in the frequency range from 250 MHz to 280 MHz should be
operated within 5 metres of the unit.

The use of the machine in any of the situation types listed in

table 1:–
a) Is not approved by Ingersoll–Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll–Rand.

M37 M45
 ISO SYMBOLS 3
GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING – Pressurised vessel. WARNING – Hot surface.

WARNING – Pressure control. WARNING – Corrosion risk. WARNING – Air/gas flow or Air discharge.

X,X BAR

WARNING – Maintain correct tyre pressure.

WARNING – Pressurised component or
WARNING – Hot and harmful exhaust gas. (Refer to the GENERAL INFORMATION
system.
section of this manual).

0_C

WARNING – Before connecting the tow bar WARNING – For operating temperature
WARNING – Flammable liquid. or commencing to tow consult the below 0_C, consult the operation and
operation and maintenance manual. maintenance manual.

M37 M45
4 ISO SYMBOLS

WARNING – Do not undertake any

WARNING – Consult the operation and
maintenance on this machine until the Do not breathe the compressed air from this
maintenance manual before commencing
electrical supply is disconnected and the air machine.
any maintenance.
pressure is totally relieved.

Do not remove the Operating and Maintenance Do not operate the machine without the guard
Do not stack.
manual and manual holder from this machine. being fitted.

Do not stand on any service valve or other Do not operate with the doors or enclosure
Do not use fork lift truck from this side.
parts of the pressure system. open.

XX
km/h
Do not open the service valve before the
Do not exceed the trailer speed limit. No naked lights.
airhose is attached.

Use fork lift truck from this side only. Emergency stop. Tie down point

M37 M45
 ISO SYMBOLS 5

Lifting point. On (power). Off (power).

a
Read the Operation and Maintenance manual
When parking use prop stand, handrake and
before operation or maintenance of this Contains asbestos.
wheel chocks.
machine is undertaken.

SET SEQUENCER STATUS LOAD

SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED)

RESET COMPRESSOR STATUS MODULATE

MALFUNCTION POWER SOILED FILTER

POWER INLET ELECTRIC MOTOR HOURS

M37 M45
6 ISO SYMBOLS

COOLANT SEPARATOR PRESSURE AIR DISCHARGE

PRESSURISED TANK ON / OFF CYCLE COOLANT FILTER

AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE

AIR PRESSURE STAR DELTA IEC 617–7 AUTOMATIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE

M37 M45
 ISO SYMBOLS 7

BELT TENSION FILTER MOTOR LUBRICATION

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS ROTATION

POWER INLET (AC) WATER IN WATER OUT

M37 M45
8 SAFETY
All pressure containing parts, especially flexible hoses and their
WARNINGS
couplings, must be regularly inspected, be free from defects and be
Warnings call attention to instructions which must be followed
replaced according to the Manual instructions.
precisely to avoid injury or death.

CAUTIONS Compressed air can be dangerous if incorrectly handled. Before

Cautions call attention to instructions which must be followed doing any work on the unit, ensure that all pressure is vented from the
precisely to avoid damaging the product, process or its surroundings. system and that the machine cannot be started accidentally.

NOTES
Notes are used for supplementary information. Avoid bodily contact with compressed air.

The safety valve located in the separator tank must be checked

SAFETY PRECAUTIONS periodically for correct operation.
General Information
Ensure that the operator reads and understands the decals and Materials
consults the manuals before maintenance or operation. The following substances are used in the manufacture of this
machine and may be hazardous to health if used incorrectly:
Ensure that the Operation and Maintenance manual, and the . preservative grease
manual holder, are not removed permanently from the machine. . rust preventative
. compressor coolant

Ensure that maintenance personnel are adequately trained,

competent and have read the Maintenance Manuals. AVOID INGESTION, SKIN CONTACT AND INHALATION OF
FUMES

Compressed air and electricity can be dangerous. Before

undertaking any work on the compressor, ensure that the electrical
supply has been isolated and the compressor has been relieved of all
pressure.
Make sure that all protective covers are in place and that the
canopy/doors are closed during operation.
Installation of this compressor must be in accordance with
recognised electrical codes and any local Health and Safety Codes.
The use of plastic bowls on line filters without metal guards can be
hazardous. Their safety can be affected by either synthetic lubricants,
or the additives used in mineral oils. Metal bowls should be used on a
pressurised system.
For further information, consult Material Data Sheets ACGP 011/96
(Ultracoolant) and ACGP 029/90 (food grade coolant).
Should compressor lubricant come into contact with the eyes, then
irrigate with water for at least 5 minutes.
Should compressor lubricant come into contact with the skin, then
wash off immediately.
Consult a physician if large amounts of compressor lubricant are
ingested.
Consult a physician if compressor lubricant is inhaled.

Never give fluids or induce vomiting if the patient is unconscious or

Compressed air can be dangerous if incorrectly handled. Before having convulsions.
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
Transport
Compressed air When loading or transporting machines ensure that the specified
lifting and tie down points are used.
Ensure that the machine is operating at the rated pressure and that
the rated pressure is known to all relevant personnel.
It is recommended that the machine be moved using the fork lift slots
in the machine base.
All air pressure equipment installed in or connected to the machine
It is recommended that the machine be lifted from the backside due
must have safe working pressure ratings of at least the machine rated
to the position of the centre of gravity.
pressure.
The machine can be positioned from the front side.
Refer to section F6 Weight.
If more than one compressor is connected to one common
downstream plant, effective check valves and isolation valves must be
fitted and controlled by work procedures, so that one machine cannot
The above information contains data supplied in support of United
accidently be pressurised / over pressurised by another.
Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.)
regulations.
Compressed air must not be used for a direct feed to any form of
breathing apparatus or mask.

The discharged air contains a very small percentage of compressor

lubricating oil and care should be taken to ensure that downstream
equipment is compatible.

If the discharged air is to be ultimately released into a confined

space, adequate ventilation must be provided.

When using compressed air always use appropriate personal

protective equipment.

M37 M45

Electrical
Keep all parts of the body and any hand–held tools or other
conductive objects, away from exposed live parts of the compressor
electrical system. Maintain dry footing, stand on insulating surfaces
and do not contact any other portion of the compressor when making
adjustments or repairs to exposed live parts of the compressor
electrical system.
Close and lock all access doors when the compressor is left
unattended.
Do not use extinguishers intended for Class A or Class B fires on
electrical fires. Use only extinguishers suitable for class BC or class
ABC fires.
Attempt repairs only in clean, dry, well lighted and ventilated areas.
Connect the compressor only to electrical systems that are
compatible with its electrical characteristics and that are within it’s rated
capacity.
SAFETY 9
Condensate disposal
Condensate cannot be discharged into fresh/surface water drains.
In some regions compressor condensate containing Ultracoolant can
be fed directly into a drainage system that has downstream sewerage
treatment.
As waste water regulations vary by country and region it is the
responsibility of the user to establish the limitations and regulations in
their particular area. Ingersoll–Rand and its associated distributors are
happy to advise and assist in these matters.
Coolant disposal
Steps to be taken in the case of spillage: Soak up with a suitable
absorbent material, then sweep into a plastic bag for disposal.
Burn in an approved incinerator, or according to local area or
country regulations.
For further information, consult Material Data Sheets ACGP 011/96
(Ultracoolant) and ACGP 029/90 (food grade coolant).
M37 M45
10 GENERAL INFORMATION

FLOW DIAGRAM WITHOUT MODULATION

KEY

1. Air discharge 21.Pressure relief valve

2. Compressor 22.–
3 Filter, air 23.Separator scavenge filter
4. Air filter vacuum switch 24.Orifice
5 Aftercooler 25.Separator tank
6. Air piping 26.Temperature indicator
7. Coolant cooler 27.Temperature control valve
8. Condensate discharge 28.Normally open
9. Coolant filter 29.Normally closed
10.Coolant filter pressure switch 1SV. Load/unload solenoid valve
11.Coolant piping 3SV. Blowdown solenoid valve
12.Control piping
13.Drain valve GENERAL OPERATION
14.Temperature sensor The compressor is an electric motor driven, single stage screw
compressor, complete with accessories piped, wired and baseplate or
15.Check valve receiver mounted. It is a totally self contained air compressor package.
16.Inlet valve
(Normally closed) The standard compressor is designed to operate in an ambient
17.Line/sump solenoid valve range of 1,7_C to 46_C. The standard maximum temperature of 46_C
is applicable up to an elevation of 1000m (3280ft) above sea level.
18.Minimum pressure valve Above this altitude significant reductions in ambient temperature are
required if a standard motor is to be used.
19.Moisture separator
Compression in the screw type air compressor is created by the
20.Pressure indicator meshing of two (male & female) helical rotors.
20.Pressure transducer
M37 M45
 GENERAL INFORMATION 11

FLOW DIAGRAM WITH MODULATION

KEY

1. Air discharge 20 Pressure transducer

2. Compressor 21.Pressure relief valve
3 Filter, air 22.–
4. Air filter vacuum switch 23.Separator scavenge filter
5 Aftercooler 24.Orifice
6. Air piping 25.Separator tank
7. Coolant cooler 26.Temperature indicator
8. Condensate discharge 27.Temperature control valve
9. Coolant filter 28.Normally open
10.Coolant filter pressure switch 29.Normally closed
11.Coolant piping 30.–
12.Control piping 31.Modulation regulation (option)
13.Drain valve 32.Shuttle valve (option)
14.Temperature sensor 1SV. Load/unload solenoid valve
15.Check valve 2SV Solenoid valve (Modulate) (Optional)
16.Inlet valve 3SV. Blowdown solenoid valve
17.Line/sump solenoid valve 6SV Solenoid valve (Modulate) (Optional)
18.Minimum pressure valve
19.Moisture separator
M37 M45
12 GENERAL INFORMATION

WATER PIPING SYSTEM The coolant system consists of a sump, cooler, thermostatic valve
and a filter. When the unit is operating, the coolant is pressurised and
KEY forced to the compressor bearings.
A: AFTERCOOLER
B: LUBRICANT COOLER The compressor load control system is automatic ’On–Off line’. The
compressor will operate to maintain a set discharge line pressure and
C: VALVE is provided with an autorestart system for use in plants where the air
demand varies widely.
D: AIR OUT
E: AIR OUT Panel instrumentation is provided to indicate the compressor
F: LUBRICANT IN operating conditions and general status.

G: LUBRICANT OUT
As an option a modulation kit extends the control type to capacity
control when the compressor is switched between ’On–Off line’ and
modulation as demand varies.

GENERAL OPERATION
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 to the aftercooler and out of the compressor
through the moisture separator.
Refer to flow diagram.
Air is pulled into the machine by the cooling fan and is pushed
through the combined cooler / aftercooler.
By cooling the discharge air, much of the water vapour naturally
contained in the air is condensed and may be drained from the
downstream piping and equipment.

M37 M45
 GENERAL INFORMATION 13

93471944
Revision D
07/96

KEY

CF1–5 Control fuses L1–L3 Mains terminals

E1–8 Earth terminals LP1 Power on lamp
ELK Earth link LP2 Auto–restart lamp
FF Fan fuses MM Main motor
FM Fan motor MOL Main motor overload relay
FOL Fan motor overload relay 1PS Pressure switch
1HAT Temperature switch (Discharge) SP Stop button
2HAT Temperature switch (Airend Discharge) ST Start button
H Hourmeter 1SV Solenoid valve (Load)
ISO Isolator (customer supplied) 3SV Solenoid valve (Blowdown)
K1 Relay T1 Transformer
KM1 Main contactor TM1 Star Delta Timer
KM2 Delta contactor TM2 Run–on Time
KM3 Star contactor Refer to specific machine wiring diagram located in starter cabinet.
KM4 Fan contactor

M37 M45
14 INSTALLATION / HANDLING

KEY UNPACKING
The compressor will normally be delivered with a polythene cover.
A 11/2” BSP Air discharge If a knife has to be used to remove this cover ensure that the exterior
B 50mm Dia. Cable entry paintwork of the compressor is not damaged.

C 1/8” BSPT Condensate drain

Incorporated within the base of the compressor are slots to enable
D 3/8” BSPT Base drain a fork lift truck (2 ton minimum) to move the machine. Alternatively a
special lifting frame can be supplied to enable a crane or hoist to move
E Motor air inlet grill the compressor.
F Cooler air inlet grill
G Exhaust air outlet grill LOCATION IN PLANT

H. 3/4” BSP Water in. W/C only Ensure that the correct fork lift truck slots or marked lifting / tie down
points are used whenever the machine is lifted or transported.
I. 3/4” BSP Water out. W/C only
J. NOTE: The compressor can be installed on any level floor capable of
Diagram illustrates minimum space requirements for normal supporting it. A dry, well ventilated area where the atmosphere is as
operation and maintenance. clean as possible is recommended.
For major overhaul (i.e.motor removal) position the machine to
obtain lifting access (e.g. fork lift truck). Maximum lift weight of drive
assembly 450 Kg. Sufficient space all round and above the compressor must be
allowed, to enable the effective removal of the cooling air which, in turn,
K. Fixing brackets supplied as option kit. will reduce the risk of re–circulating the cooling air back through the
compressor.

NOTE
All dimensions are in millimetres unless otherwise stated. CAUTION:
A minimum of 1 metre all round the compressor is recommended. If
headroom is restricted, then the exhaust should be ducted or deflected
NOTE: away from the machine.
Diagram illustrates minimum space requirements for normal
operation and maintenance.
For major overhaul (i.e.motor removal) position the machine to
obtain lifting access (e.g. fork lift truck). Maximum lift weight of drive
assembly 500 Kg.

M37 M45

Revision 01
12/00
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 filters and other plastic air line
components without metal guards can be hazardous. Their safety can
be affected by either synthetic coolants or the additives used in mineral
oils. From a safety standpoint, metal bowls should be used on any
pressurised system.
Hard surfaces may reflect noise with an apparent increase in the
decibel level. When sound transmission is important, a sheet of rubber
or cork can be installed beneath the machine to reduce noise.
It is recommended that provision be made for lifting heavy
components during major overhaul.
CAUTION:
The machine is shipped with the shipping restraints in place. Ensure
that these are removed to allow free movement of the drive assembly
during operation. Each restraint is marked with a pink coloured tab.
Based on Decal 93156438
INSTALLATION / HANDLING 15
DISCHARGE PIPING
Discharge piping should be at least as large as the discharge
connection of the compressor. All piping and fittings should be suitably
rated for the discharge pressure.
It is essential when installing a new compressor [1], to review the
total air system. This is to ensure a safe and effective 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 carryover to zero.
It is good practice to locate an isolation valve close to the
compressor and to install line filters [4].
Retain and place the locking and jacking bolt as indicated for future
use during servicing.
ELECTRICAL DATA
An independent electrical isolator should be installed adjacent to the
compressor.
CAUTION: Do not remove the motor table transit bolt until the electrical
connection and correct rotation have been completed.
Feeder cables should be sized by the customer/electrical
contractor to ensure that the circuit is balanced and not overloaded by
other electrical equipment. The length of wiring from a suitable
electrical feed point is critical as voltage drops may impair the
performance of the compressor. Cable sizes may vary considerably
so the mains terminals will accept up to 16mm2 cable.
Feeder cable connections to studs L1–L2–L3 on isolator should be
tight and clean.
The applied voltage must be compatible with the motor and
compressor data plate ratings.
The control circuit transformer has different voltage tappings.
Ensure that these are set for the specific applied voltage prior to
starting.
M37 M45
16 INSTALLATION / HANDLING
WATER COOLED UNITS
Cooling Water Piping
Water piping to and from the compressor package must be
3/4”diameter or larger. Isolation valves with side drains should be
installed on both the inlet and outlet lines. Also a strainer of 3mm–mesh
size should be installed on the inlet line. Strainers are available from
Ingersoll–Rand. Ingersoll–Rand CPN 54689997.
It is recommended that a normally closed solenoid valve be fitted to the
water outlet side of the compressor package. This is to be wired into the
compressor control circuit. This option detail is available from
Ingersoll–Rand.
Carefully inspect your water system before installing the compressor
package. Ensure that the piping is free of scale and deposits that may
restrict water flow to the compressor package.
Scale: Scale formation inhibits effective heat transfer, yet it does help
prevent corrosion. Therefore, a thin uniform coating of calcium
carbonate is desired on the inner surface. Perhaps the largest
contributor to scale formation is the precipitation of calcium carbonate
out of the water. This is dependent on temperature and pH. The higher
the pH value, the greater the chance of scale formation. Scale can be
controlled with water treatment.
Corrosion: In contrast to scale formation is the problem of corrosion.
Chlorides cause problems because of their size and conductivity. Low
pH levels promote corrosion, as well as high levels of dissolved
oxygen.
Fouling: Biological and organic substances (slime) can also cause
problems, but in elevated temperature environments such as cooling
processes they are not a major concern. If they create problems with
clogging, commercial shock treatment are available.

Proper operation of your compressor requires that the water flow listed To ensure good operation life and performance of the compressor
below be provided at a maximum supply temperature of 32_C. cooling system, the recommended acceptable ranges for different
water constituents are included below:

Minimum cooling water requirement at ambient temperatures, in litres Cooling Water Analyses Chart
per minute (UK gallons per minute)

50_F / 10_C 70_F / 21_C 90_F / 32_C Substances Test interval Acceptable
concentration
15(3.3) 23(5) 38(8.3)
Corrosivity Monthly — if stable Langelier Index 0 to 1
Water temperature and pressure gauges should be installed in the (Hardness, pH, Total for 3 to 4 months,
water piping for use in any fault finding of the water system. Water Dissolved Solids, analyse quarterly.
pressure should ideally be between 3 and 5 bar. Temperature at inlet
Alkalinity)
Water cleanliness is also extremely important. Cleaning of coolers as
a result of fouling is a customer responsibility. Therefore, it is highly Iron Monthly <2 ppm
recommended that proper water quality must meet the requirements
listed in WATER QUALITY RECOMMENDATIONS later in this section. Sulphate Monthly <50 ppm

Chloride Monthly <50 ppm

Venting the water system
Nitrate Monthly <2 ppm
At the initial installation or for start–up after draining the water system
proceed to vent the system as follows Silica Monthly < 100 ppm
1 Locate the water system vent cocks on top of the aftercooler and Desolated Oxygen Daily — if 0 ppm (as low
lubricant cooler. stable,analyse aspossible)
weekly
2 Open the water valve(s) allowing water to flow to the package.
3 Open the vent cocks and allow all air to escape from the system. Oil & Grease Monthly <5 ppm
When water is observed at the vent cocks, close them
Ammonia Monthly <1 ppm
The system is now vented.
Draining the water system The Ingersoll–Rand Hydro–check cooling water analysis kit
CPN88223481 provides a sample bottle and pre–addressed return
Should it become necessary to completely drain the water system,
tube to our laboratory, where a full report on water quality will be issued.
proceed as follows.
1 Disconnect the inlet and discharge water lines from the connections
located at the rear of the unit.
2 Locate the aftercooler and lubricant cooler. Remove the drain plugs
located at the bottom of the coolers. Allow the system to completely
drain.
Water quality recommendations
Water quality is often overlooked when the cooling system of a
water–cooled air compressor is examined. Water quality determines
how effective the heat transfer rate, as well as the flow rate will remain
during the operation life of the unit. It should be noted that the quality
of water used in any cooling system does not remain constant during
the operation of the system. Evaporation, corrosion, chemical and
temperature changes, aeration, scale and biological formations effect
the water makeup. Most problems in a cooling system show up first in
a reduction in the heat transfer rate, then in a reduced flow rate and
finally with damage to the system.

M37 M45
 INSTALLATION / HANDLING 17
SEA WATER COOLED UNITS M37
It is important to ensure that the recommended flow rate cannot be L M H U
exceeded. This will normally mean that an orifice plate must be fitted
PRESSURE
in the pipework at least 1m before the cooler, with the orifice size 7,5 bar 8,5 bar 10,0 bar 13,0 bar
(RATED)
calculated to ensure that the maximum sea water flow rate cannot be
exceeded. If these precautions are not taken, it is possible that the sea CAPACITY
water flow rate through the cooler may be several times the 6,30 6,02 5,50 4,78
m3/min.
recommended maximum, which will lead to rapid failure.
CAPACITY
222 212 194 169
ft3/min.

Sea Water Pressure in Bars Orifice diameter in mm to give a FULL LOAD CURRENT
maximum sea water flow of (MAXIMUM) 79A
90l/min 380V
FULL LOAD CURRENT
3 bar 12 (MAXIMUM) 77A
415V
4 bar 11
FULL LOAD CURRENT
5 bar 10 (MAXIMUM) 140A
220V
6 bar 9.6
STARTING CURRENT
7 bar 9.2 (MAXIMUM) 693A
380V
8 bar 8.9
STARTING CURRENT
9 bar 8.7 (MAXIMUM) 756A
415V
10 bar 8.4
STARTING CURRENT
(MAXIMUM) 1330A
Water cleanliness is also extremely important. Strainers are available 220V
from Ingersoll–Rand. Cleaning of coolers as a result of fouling is a
*NOISE LEVEL
customer responsibility. 72dBA
CAGI PNEUROP1m
Isolation valves with side drains should be installed on both the inlet and WEIGHT
outlet lines. 800
kg
It is recommended that a normally closed solenoid valve be fitted to the
water outlet side of the compressor package.
M45

No oil cooler manufacturer can guarantee that its products will have L M H U
an indefinite life and for this reason, we suggest that the cooling system PRESSURE
is designed to minimise any damage caused by a leaking oil cooler. 7,5 bar 8,5 bar 10,0 bar 13,0 bar
(RATED)
This can be achieved as follows ;
CAPACITY
7,45 7,12 6,79 5,92
m3/min.
1. The oil pressure should be higher than the sea water pressure, so
that in the event of a leak occurring, the CAPACITY
263 251 240 209
oil will not be contaminated. ft3/min.
FULL LOAD CURRENT
2. When the hydraulic system is not being used, the coolers should be (MAXIMUM) 95A
isolated from sea water pressure. 380V
FULL LOAD CURRENT
3. The sea water outlet pipe from the cooler should have a free run to (MAXIMUM) 93A
waste. 415V
FULL LOAD CURRENT
(1) At rated pressure. (MAXIMUM) 170A
220V
STARTING CURRENT
(MAXIMUM) 842A
380V
STARTING CURRENT
(MAXIMUM) 919A
415V
STARTING CURRENT
(MAXIMUM) 1615A
220V
*NOISE LEVEL
72dBA
CAGI PNEUROP1m
WEIGHT 800Kg
*Equivalent continuous sound pressure level (workstation) (rated
load)

M37 M45
18 OPERATING INSTRUCTIONS

PRIOR TO STARTING 1: PACKAGE DISCHARGE PRESSURE L.E.D.

1. Check coolant level. Add if necessary. This will illuminate when the display indicates the package
discharge pressure.
2.. Make sure main discharge valve is open.
2: AIREND DISCHARGE TEMPERATURE L.E.D.
3. Turn on power at electrical isolator, Green LED will illuminate.
This will illuminate when the display indicates the airend discharge
WARNING temperature.
Make sure that all protective covers are in place. 3: SUMP PRESSURE L.E.D.
This will illuminate when the display indicates the sump pressure.
4:. SEPARATOR PRESSURE DROP L.E.D.
STARTING
This will illuminate when the display indicates the separator
1. Press ‘Start’ [24]. The compressor will start and then load
pressure drop.
automatically.
5: TOTAL HOURS L.E.D.
This will illuminate when the display indicates the total compressor
NORMAL STOPPING
running hours.
1. Press ‘Unloaded Stop’[25]. The compressor will unload then stop.
6: LOADED HOURS L.E.D.
2. Turn off electrical isolator.
This will illuminate when the display indicates the total loaded
compressor hours.
EMERGENCY STOP. 7: LOAD/UNLOAD L.E.D.
1. Push ‘Emergency Stop Button’ [26]. The compressor will stop This will illuminate when the compressor is running onload.
immediately.
8: MODULATION L.E.D.
2. Turn off electrical isolator. This will illuminate when the compressor is running in modulation
mode. (Optional)
CAUTION 9: UNLOAD L.E.D.
After shutdown never allow unit to stand idle with pressure in
receiver/separator system. This will illuminate when the compressor is running in unload mode.
M37 M45

10:ALARM L.E.D.
This will flash when a warning condition exists. The warning detected
will be displayed and the compressor will continue to run. The warning
can be reset by depressing set [22].
It will illuminate when an alarm condition has occurred. The
compressor will shutdown immediately. The alarm can be reset by
depressing set [22] twice within 3 seconds.
OTHER L.E.D.s
These will illuminate during the set point routine to indicate which
function is being adjusted.
11:L.E.D.–Set off line pressure.
12:L.E.D.–Set on line pressure.
13:L.E.D.–Select control mode.
14:L.E.D.–Set star delta time.
15:L.E.D.–Set auto restart time.
16:L.E.D.–Select options.
17:L.E.D.–Not used.
18:L.E.D.–Not used.
INSTRUMENT PANEL FUNCTION
19:LIQUID CRYSTAL DISPLAY
This indicates the status of the compressor, set up parameters and
warning/alarm messages. When the compressor is running, the
display will normally show the package discharge pressure.
20:DISPLAY SELECT BUTTON
Press to index through compressor operating conditions. The
corresponding L.E.D. will illuminate adjacent to display.
This is used to select alternative status displays (after
approximately 5 minutes, the display defaults to the package discharge
pressure). Depressing this button in the set point routine will cause exit
to checking machine for 2 seconds, then ready to start.
21:ARROW KEYS
These are used to index through warning and alarm messages. In
the set point routine, these buttons are used to increment/decrement
set point values and enable/disable some operation conditions.
The arrow keys are also used to select pressure bands 1 (Y) or 2
(B) during normal operation of the compressor.
22:SET BUTTON
Depressing this button when the compressor is stopped will enable
entry into the set point routine. When in the set point routine, depressing
this button will cause the controller to move on to the next set point
setting, saving the new value if one has been entered.
A warning reset is obtained by depressing this button (whilst the
machine is running). An alarm reset is obtained by depressing this
button twice within 3 seconds (the alarm condition will remain if the
indicated fault has not been rectified).
23:LOAD/UNLOAD BUTTON
These are used to manually switch the compressor between a
loaded control mode (e.g. on/off line) and unloaded running.
See L.E.D. [7].
24:START BUTTON
This button when depressed will cause the compressor to start and
load automatically, provided that the controller detects a demand for air.
When pressed in the display mode, it will cause exit to checking
machine for 2 seconds, then ready to start.
25:UNLOADED STOP
This button when depressed while the compressor is running, will
unload the compressor (if not already unloaded) for 10 seconds and
then stop. This is the normal method for stopping the compressor. If the
compressor is already stopped, it will execute an L.E.D. check (all the
L.E.D.s should illuminate) and display the controller software revision.
OPERATING INSTRUCTIONS 19
26:EMERGENCY STOP
This button when depressed will stop the compressor immediately
and display an emergency stop alarm message.
27:POWER L.E.D.
This will illuminate when the 8V controller supply is available.
28:AUTOMATIC RESTART L.E.D.
This will illuminate when the machine has shutdown due to low air
demand. The compressor will restart and load automatically as soon
as the demand for air resumes.
DISPLAY MESSAGES
When the compressor is running normally, the display will indicate
the package discharge pressure and illuminate the corresponding
L.E.D. [1]. An arrow will also appear in the far right of the display
indicating pressure band selection. Pressing display select [20] will
change the display value and the corresponding L.E.D. will illuminate.
The controller monitors all aspects of the compressor whilst running
and will display warnings or in severe conditions execute an
emergency stop and display alarm conditions.
MACHINE CONTROL MODES
CAPACITY CONTROL
The compressor is fitted with ON LINE–OFF LINE control as
standard. Modulation can be fitted as an option. If modulation is fitted
it is activated by selection at the control panel.
ON LINE – OFF LINE CONTROL
For applications that require a widely varying air demand, this mode
of control will deliver air at full capacity or zero capacity with low
receiver pressure.
This mode of operation is controlled by the pressure transducer
(1PS) responding to changes in plant air pressure. This sensor
energises the load solenoid valve (1SV) which in turn operates the
venting valve (blowdown) and the closing of the atmospheric vent
opening in the air inlet valve.
The compressor then delivers full capacity air to the plant system.
If the air pressure in this system rises to the upper set point of the
pressure setting, the load solenoid valve is de–energised allowing the
inlet valve to close. At the same time, the venting valve opens allowing
the receiver pressure to drop.
The pressure setting has a range of 0,83 bar between its upper and
lower set points.The upper set point is set at 0,2 bar above the
compessor maximum discharge pressure.
OPTIONAL UPPER RANGE MODULATION CONTROL
For plants having a relatively high and constant air demand, Upper
Range Modulation is a recommended mode of control.
Upper range modulation retains the features of On line – Off line
control but provides the throttling of the inlet air flow as the line pressure
rises to the upper set point of the off–line pressure setting.
By bleeding off a small amount from the regulator valve, which
energises the Modulate Solenoid Valve, a reduction in the air signal to
the pneunatic cylinder on the inlet valve allows the cylinder to ‘trim’ the
inlet valve position as dictated by changing line pressure. Modulation
begins when the compressor reaches about 94% of the rated line
pressure and is factory set to modulate down to aproximately 70% of
rated capacity.
If the air demand decreases to a level below the 70% modulated
output, the line pressure will increase slightly to the upper limit of the
pressure setting, when the compressor then changes to the Off line
control position and operates with the receiver vented.
CONTROLLER WARNING MESSAGES
In the event of a warning, the controller will display a message and
the alarm L.E.D. [10] will flash. The warning message will alternate with
the normal display every 4 seconds, the compressor will continue to run
but the fault should be rectified as soon as possible. The arrow keys
[21] should be used to index the display for any additional warning
messages. A warning message may be reset by depressing set [22]
once.
M37 M45
20 OPERATING INSTRUCTIONS
NOTE: MOTOR OVERLOAD
The warning will recur if the fault has not been rectified. The The motor overload contacts are open. The motor overload must be
following warning messages may be displayed: reset before the controller can be reset.

COOLANT FILTER
The pressure differential across the coolant filter exceeds 1 bar.
REVERSE ROTATION
No sump pressure is detected after the first 2 seconds of running.
Isolate the machine and reverse the mains supply connections before
resuming.

OVER PRESSURE
AIR FILTER
The line pressure is 1 bar (15 psi) greater than the rated discharge
The air filter is dirty or blocked and should be replaced. pressure.

SEPARATOR ELEMENT
TEMPERATURE SENSOR 1
The separator element is dirty or blocked and should be replaced.
The airend temperature sensor/ connecting cable has failed.

AIREND TEMPERATURE
PRESSURE SENSOR
The airend temperature reaches 97% of the high airend
Indicates pressure transducer failure / connecting cable fault.
temperature set point (i.e. 106°C).

FAILED CALIBRATION
SERVICE
During calibration routine, a 10% of scale error has been detected.
The service warning will occur at 150 hours then every 2000 hours Ensure that the separator is completely blowndown and repeat
thereafter. A service due will warn at 100 hours prior to service. calibration.
A service fault will occur if not serviced within 100 hours of due time.
However the machine will not stop, but a service technitian will be
required for this operation. [CONTROL POWER OR]
The 48Vac supply is not present at the controller, or:–
CONTROLLER ALARMS
In the event of an alarm, the controller will execute an emergency REMOTE START FAILURE
stop, the alarm L.E.D. [10] will illuminate and an alarm message will be
displayed. The arrow keys [21] should be used to index the display for Momentary remote start has not disengaged before star–delta
any additional alarm messages. An alarm is reset by depressing set transition. This alarm is active only if the remote start/stop is enabled.
[22] twice within a 3 second period after the fault has been rectified. The
compressor will restart only when all alarm conditions have been
rectified. The following alarm messages may be displayed (For fault REMOTE STOP FAILURE
correction see the Fault Finding section):
The momentary remote stop switch has not disengaged when the
start signal is received. This alarm is active only if the remote start/stop
is enabled.
STARTER FAULT
The contactor sequence during start or stop is incorrect.
EMERGENCY STOP
The emergency stop button is engaged.
AIREND TEMPERATURE
The airend discharge temperature is above the high temperature
set point (i.e. 109_C). LOW SUMP PRESSURE
The sump pressure drops below 1bar during normal operation.

M37 M45
 AIRCARE WARRANTY 21

Superior Service Solutions for Air Systems

AirCare is a responsive and flexible contract maintenance program custom designed for the owner who requires planned maintenance for increased
system reliability.
The AirCare program provides you with reduced maintenance costs, reduced energy usage through optimization and efficiency, and reduced produc-
tion losses through fewer unexpected maintenance requirements and downtime. An optional feature, Intelliguard is used to reduce downtime by remote
monitoring.

Air Care Options

Unit Status Coverage Service Level
Inspection and diagnostic service only or
Sign up for AirCare within the warranty period Five Year Drivetrain or Package coverage Preventative maintenance and diagnostic
service

To enroll in AirCare or Intelliguard, contact your local Ingersoll–Rand representative today.

M37 M45
22 MAINTENANCE

MAINTENANCE PROMPTS NOTE

The service warning and flashing LED will appear after the first 150
hours and every 2000 hours thereafter, cycling every 2 seconds with
the current display message.
The customer can only reset the warning for 24 hours by pressing
the “set” button.
IR service engineers will master reset the warning after completing
the service work.
The service warning will return each subsequent 2000 hours.
The machine will be master reset after service work conducted prior
to the 2000 hour interval to prevent false indication.
PERIOD MAINTENANCE
Daily Check the coolant level and replenish if
necessary.
All new units covered by 5 year air care warranty. (Refer to
Ingersoll–Rand to register.)
Note:
On some sea water cooled models the oil cooler and after cooler are
fitted with sacrificial zinc anodes (pencils) that are located in the end
bonnets of the coolers. These sacrificial zinc anodes should be
checked after the first 50 hours of operation to determine if corrosive
conditions exist. If satisfactory this interval may be extended to 500
hours.
NOTE:
1 If sacrificial zinc anode is 50% corroded it should be replaced.
2 Coastal/harbour waters can contain corrosive chemicals from
pollution and may reduce anode/cooler life.
3 Effects of corrosion or erosion are specifically excluded from
warranty considerations.

First 150 hours Change the coolant filter.

Each week Check the safety valve
1 month Check the operation of the high
temperature protection switch (109_C).
Check the cooler(s) for build up of foreign
matter. Clean if necessary by blowing out
with air or by pressure washing.
1 monthly intervals. On water cooled and sea water cooled
models check the water input line strainer for
build up of foreign matter, clean if required
Each 3 months Check all hoses for signs of deterioration,
cracks, hardening etc.
2000 hours / 6 Check the pressure differential
months Change the separator element if the
pressure drop is zero or exceeds 1 bar (15
p.s.i.g.)
Change the coolant filter.
Replace the element sooner if the visual
indicator warning is shown.
1 year Change the air filter element.
Replace the element sooner if the visual
indicator warning is shown.
1 year / 8000 hours Check the scavenge screen for blockage,
clean if required
2000 hours Lubricate the main motor drive end bearing.
Quantity of grease required:
B: 12g ([)
L: 20g ([)
([) ([) To determine the correct letter
designation (B,L) consult the CPN field on
the main motor data plate.
B: 4000 hours ([) Lubricate the main motor non–drive end
L: 2000 hours ([) bearing.
Quantity of grease required:
B: 6g ([)
L: 20g ([)
([) ([) To determine the correct letter
designation (B,L) consult the CPN field on
the main motor data plate.
2 years/8000 hours Replace the Ultracoolant at whichever
or as defined by interval occurs first
local or national Also replace the separator element and
legislation. coolant filter.
4 years Replace all hoses
ROUTINE MAINTENANCE
This section refers to the various components which require
periodic maintenance and replacement.
The SERVICE/MAINTENANCE CHART indicates the various
components’ descriptions and the intervals when maintenance has to
take place. Coolant capacities, etc., can be found in the GENERAL
INFORMATION section of this manual.
CAUTION: Before beginning any work on the compressor, open,
lock and tag the main electrical disconnect and close the isolation
valve on the compressor discharge. Vent pressure from the unit
by slowly unscrewing the coolant fill cap one turn. Unscrewing
the fill cap opens a vent hole, drilled in the cap, allowing pressure
to release to atmosphere. Do not remove the fill cap until all
pressure has vented from the unit. Also vent piping by slightly
opening the drain valve. When opening the drain valve or the
coolant fill cap, stand clear of the valve discharge and wear
appropriate eye protection.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
Prior to attempting any maintenance work, ensure that:–
. all air pressure is fully discharged and isolated from the system. If
the automatic blowdown valve is used for this purpose, then allow
enough time for it to complete the operation.
. the machine cannot be started accidently or otherwise, by posting
warning signs and/or fitting appropriate anti–start devices.
. all residual electrical power sources (mains and battery) are
isolated.
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.
. the machine cannot be started accidently or otherwise, by posting
warning signs and/or fitting appropriate anti–start devices.
WARNING
Use suitable equipment for lifting heavy items and ensure
loose components are adequately supported to eliminate risk of
dropping.

M37 M45

Prior to attempting any maintenance work on a running
machine, ensure that:–
. the work carried out is limited to only those tasks which require the
machine to run.
. the work carried out with safety protection devices disabled or
removed is limited to only those tasks which require the machine to be
running with safety protection devices disabled or removed.
. all hazards present are known (e.g. pressurised components,
electrically live components, removed panels, covers and guards,
extreme temperatures, inflow and outflow of air, intermittently moving
parts, safety valve discharge etc.).
. appropriate personal protective equipment is worn.
. loose clothing, jewellery, long hair etc. is made safe.
. warning signs indicating that Maintenance Work is in Progress are
posted in a position that can be clearly seen.
Upon completion of maintenance tasks and prior to returning
the machine into service, ensure that:–
. the machine is suitably tested.
. all guards and safety protection devices are refitted.
. all panels are replaced, canopy and doors closed.
. hazardous materials are effectively contained and disposed of.
WARNING
Do not under any circumstances open any drain valve or remove
components from the compressor without first ensuring that the
compressor is FULLY SHUT– DOWN, power isolated and all air
pressure relieved from the system.
COOLANT LEVEL CHECKING PROCEDURE
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.
ADDING COOLANT
Run the compressor for a minimum of 40 seconds unloaded before
stopping, then add coolant until the level is up to the mid–point of the
sight glass.
COOLANT FILTER CHANGE PROCEDURE
. Loosen filter element with the correct tool.
. Remove the element from the housing.
. Place the old element in a sealed bag and dispose of in a safe way.
. Clean the mating face of the housing.
. Remove the new Ingersoll–Rand replacement element from its
protective package.
. Apply a small amount of Ultracoolant to the element seal.
. Fill new element with Ultracoolant.
. Screw the new element down until the seal makes contact with the
housing, then hand tighten a further half turn.
. Start the compressor and check for leaks.
SSR ULTRACOOLANT – CHANGE PROCEDURE (Capacity 19
litres)
It is better to drain the coolant immediately after the compressor has
been operating as the liquid will drain more easily and any contaminant
will still be in suspension.
. Place a suitable container close to the drain valve.
. Remove the plug, open the valve and completely drain the coolant.
. Close the valve.
. Replace the coolant filter.
. Replace the separator element.
. Replace the plug and refill the compressor.
MAINTENANCE 23
. CAUTION – DO NOT MIX OILS WITH SSR ULTRACOOLANT.
. Start the compressor and check for leaks.
. Check the coolant level, refilling if necessary.
. Dispose of waste coolant in accordance with local and
governmental regulations.
NOTE
Shorter coolant drain intervals may be necessary if the compressor
is operated in adverse conditions.
AIR FILTER CHANGE PROCEDURE
. Unscrew the retaining cap and withdraw the old element.
. Fit the new element ensuring that the retaining nut is secured.
SEPARATOR ELEMENT CHECKING PROCEDURE
With the compressor running on load, depress the line/sump
selector. It will be necessary to change the element if the differential
pressure equals zero or exceeds 15 psig (1 bar).
SEPARATOR ELEMENT CHANGE PROCEDURE
. Disconnect the scavenge tube from the airend and loosen the fitting
that secures the scavenge tube to the separator tank cover and then
remove the scavenge tube.
. Disconnect all piping from the separator tank cover.
. Remove the setscrews securing the cover to the tank and remove
the complete cover assembly.
. Withdraw the used element, place it in a sealed bag and dispose of
it safely.
. Clean the gasket surface on both the tank and the cover.
. Install the replacement element.
CAUTION
Do not use any form of sealant on either the separator tank or the
separator tank cover faces.
. Re–assemble the components in reverse order.
. Start the compressor and check for leaks.
WARNING
Do not remove the staple from the anti–static gasket on the
separator element since it serves to ground any possible static
build–up.
AIREND BEARINGS
Airend bearings are lubricated by the compressor coolant and
require no maintenance.
MOTOR BEARINGS
Clean the area around the inlet and outlet plugs before removing the
plugs. Add the specified 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.
MOTOR BEARING LUBRICANT SPECIFICATION
Use ESSO UNIREX N3 grease or equivalent.
CAUTION:
Do not over pack the motor bearings with grease as this may lead
to motor failure.
CAUTION:
Ensure dirt and/or other contaminants are not introduced into the
bearing during the greasing process.
M37 M45
24 MAINTENANCE
CAUTION: Before beginning any work on the compressor, open, CAUTION: Ensure that the compressor is isolated from the
lock and tag the main electrical disconnect and close the isolation compressor air system by closing the isolation valve and
valve on the compressor discharge. Vent pressure from the unit bleeding pressure from the drain valve.
by slowly unscrewing the coolant fill cap one turn. Unscrewing
the fill cap opens a vent hole, drilled in the cap, allowing pressure
to release to atmosphere. Do not remove the fill cap until all
pressure has vented from the unit. Also vent piping by slightly
opening the drain valve. When opening the drain valve or the Use only genuine Ingersoll–Rand replacement parts to ensure the
coolant fill cap, stand clear of the valve discharge and wear correct belt size and length. Incorrectly sized belts can lead to
appropriate eye protection. overloading of bearings and eventual airend or motor failure.

The INTELLISYS controller enables the user to adjust the operating

parameters of the compressor to suit the application. To enter set point
adjustment depress set [22] when the display shows ready to start. The
arrow keys [21] are used to increment or decrement values or ONLINE PRESSURE
parameters. Depressing set [22] stores the new value and moves on (Pressure band 1)
to the next value.

READY TO START
102PSI ↑
P2 = P1 – 0,3bar (5psi) max.
OFFLINE PRESSURE
(Pressure band 1)
§ 4,4bar (65psi) min.
INCREMENT VALUE 0,1bar (1psi)

Y
112PSI ↑
B
ML 7,7bar (112psi) max.
MM 8,7bar (126psi) max.
MH 10,0bar (145psi) max. OFFLINE PRESSURE
MU 13,0bar (189psi) max. (Pressure band 2)
ALL 5,1bar (75psi) min.
INCREMENT VALUE 0,1bar (1psi

Y
↓
B 112PSI

M37 M45
 MAINTENANCE 25
ML 7,7bar (112psi) max.
MM 8,7bar (126psi) max.
MH 10,0bar (145psi) max.
MU 13,0bar (189psi) max. SEQUENCER ENABLE/DISABLE
ALL 5,1bar (75psi) min. (Only functions if an Ingersoll–Rand sequencer is connected)
INCREMENT VALUE 0,1bar (1psi)

Y
SEQUENCER OFF

B ON/OFF

Y
ONLINE PRESSURE
(Pressure band 2)
B
102PSI ↓
REMOTE START/STOP
P2 = P1 – 0,3bar (5psi) max.
ENABLE/DISABLE
§ 4,4bar (65psi) min.
(Compressor will only start/stop via remote signalling)
INCREMENT VALUE 0,1bar (1psi)

Y
REM START OFF

B REMOTE START ON/OFF

Y
CONTROL MODE B
ON/OFF LINE

DELAY LOAD TIME

ON/OFF LINE/
Delay between the online signal and compressor load.
(MODULATION/
AUTOMATIC CONTROL SYSTEM (OPTIONAL))
DELAY LOAD TIMER

Y
B 0 – 60 SECONDS

Y
STAR–DELTA TIME
B
5 SEC
OFF–LINE PRESSURE
4 – 15 SECONDS
112PSI

Y
B
CHECKING MACHINE

AUTO RESTART TIME

READY TO START
10 MIN
KEY
P1 = OFFLINE PRESSURE
OFF/ 2–60 MINUTES § P2 = ONLINE PRESSURE

Y
B

M37 M45
26 FAULT FINDING
FAULT CAUSE
Compressor unit fails to NO POWER SUPPLY
start.
NO CONTROL VOLTAGE
’Power on’. L.E.D. does CONTROL VOLTAGE NOT
not illuminate. AVAILABLE
Compressor will not DEMAND TOO HIGH.
build up rated pressure.
OFFLINE PRESSURE SET TOO
LOW
Controller indicates trip CONTROL CIRCUIT
condition. INTERRUPTED BY A SAFETY
DEVICE
Compressor trips LOW COOLANT LEVEL
indicating a high
discharge temperature. HIGH AMBIENT TEMPERATURE
DIRTY / OBSTRUCTED COOLERS
FAULTY THERMOSTATIC BYPASS
VALVE
FAULTY TEMPERATURE SENSOR
LOOSE WIRE IN PROTECTION
CIRCUIT
INCORRECT DUCT SIZE
LOW COOLING WATER FLOW
BLOCKED COOLANT FILTER
COOLING FAN NOT RUNNING
Compressor trips indi- INSUFFICIENT COOLING TAKING
cating a high com- PLACE
pressor temperature.
Compressor trips and EXCESSIVE CURRENT HAS
indicates CAUSED THE THERMAL
motor overload. OVERLOAD (MOL) TO TRIP
Compressor shutdown. ISOLATION VALVE CLOSED.
Display shows
OVERPRESSURE. BLOWDOWN SYSTEM
INEFFECTIVE.
Compressor will not INLET VALVE NOT OPENING
load.
M37 M45
REMEDY
Apply power. Switch on the circuit breaker.
See “Power on LED” does not illuminate.
Check the control circuit breaker CB3.
Check the transformer secondary windings for the control voltage.
Check for leaks, open service valves or exceptionally high demand.
Check the offline pressure setting.
Check machine for indicated fault. Attempt to ’reset’ the controller. If the fault
persists investigate further.
Check and add if required.
Ensure temperature is below 46_C. Improve the ventilation to the compressor
room.
Check that the cooling air flow is not obstructed and clean coolers.
Replace thermostatic bypass valve.
Check / Replace temperature sensor.
Check / Repair any loose wires.
Contact Ingersoll–Rand for advice.
Check and rectify cooling water flow.
Renew coolant filter cartridge.
Check and rectify cooling fan operation.
If machine is water cooled or seawater cooled, check that the cooling water is
flowing. Check that there is no air in the water cooling system. Check that the
strainer is not blocked.
Check the actual operating pressure and lower the setting if it is too high.
Isolate the electrical supply and check that the airend and motor rotates freely.
Check the separator element for excessive pressure drop.
Open the valve and restart.
Check the operation of the load solenoid.
Check the operation of the unloader valve.
Check that the valve is free to open.
Check the operation of the load solenoid valve Y1.
 FAULT FINDING 27
FAULT CAUSE REMEDY
Compressor fails to INLET VALVE NOT OPENING Check the operation of the inlet valve.
deliver rated
capacity. Check the operation of the load solenoid valve Y1.
Check the offline/online pressure setting.
Check the inlet filter for contamination. The L.E.D. should indicate if it is blocked.
Excessive coolant BLOCKED SCAVENGE LINE Clear the blockage.
consumption.
RUPTURED OR FOULED Change the element.
SEPARATOR ELEMENT
Rapid cycling or RAPID LOAD/UNLOAD CYCLING Duty cycle too rapid – Increase system capacity.
receiver will not
blow–down to unloaded MINIMUM PRESSURE VALVE Strip the MPV, examine and repair if necessary.
running pressure. (MPV) STUCK OPEN

Safety valve blows MPV STUCK CLOSED Strip MPV, examine and repair if necessary.
when compressor goes
on load.
OFFLINE PRESSURE SET TOO Check the offline pressure setting.
HIGH.
COOLANT SEPARATOR BLOCKED Change coolant, coolant filter, separator element.

SAFETY VALVE FAULTY Check the setting of the safety valve and the rated pressure.
Coolant in air piping. DRAINAGE LINE CLOGGED Check, clean.
FAULTY COOLANT SEPARATOR Exchange.
CARTRIDGE
COOLANT LEVEL IN SEPARATOR Bring to normal level.
TANK TOO HIGH
MIN. PRESSURE TOO LOW Check min. pressure.
Coolant escaping INTAKE CONTROLLER FAILS TO Check, exchange if necessary.
through intake nozzle CLOSE
after shutdown of
compressor.
Sluggish starting of MAINS VOLTAGE TOO LOW (ON Provide sufficient power supply.
compressor unit. LOAD)
TRANSFER TIME STAR – DELTA Readjust: transfer to delta immediately after nominal speed is reached.
TOO LONG
CONTROL VALVE DEFECTIVE Exchange.
2PHASE RUNNING Check the incoming wires.
MIN. PRESSURE VALVE Check.
DEFECTIVE
Compressor unit FAULT SIGNAL See under ”Fault signals on operator panel”.
tripped before
discharge pressure is
reached.

NOTE
Whenever there is any operational malfunction on the control
system, you should always contact our aftersales service.

M37 M45
Printed in the United Kingdom