47799053001

Revision B
Jul 2023

Contact-Cooled Rotary Screw Air Compressor

RM15-22ie,ne

Product Maintenance Information

EN Maintenance Information

Save These Instructions

 EN

CONTENTS
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COOLANT LEVEL CHECKING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COOLERS . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . 5
COOLANT FILTER CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
COOLANT CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR FILTER CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SEPARATOR ELEMENT ELEMENT CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AIREND BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MOTOR BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MOTOR BEARING LUBRICANT SPECIFICATION . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . 6
HIGH AMBIENT TEMPERATURE SENSOR CHECKING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 7
INTEGRATED DRYER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 8
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 8
Cleaning Condensate Drains (Timed Drains Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting Condensate Drains (Electronic Drains only) . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembling the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Decommissioning the Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

EN-2 47799053001 Rev A

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ABOUT THIS MANUAL

The purpose of this manual is to provide maintenance and troubleshooting guidelines for the
compressor.. For supporting documentation refer to Table 1..
Table 1: Product Manuals
Publication Product Asia Pacific
Product Safety Information Manual All 80446321
Product Information Manual RM15-22ie,ne 47799055001
Product Maintenance Information Manual RM15-22ie,ne 47799053001
Product Parts Information Manual RM15-22ie,ne 47799058001

Product specification sheets and reference drawings are also available..

PERSONNEL
Proper use, inspections and maintenance increases the life
and usefulness of the compressor.. It is extremely important
that anyone involved with maintaining the compressor be
familiar with the servicing procedures of these compressors
and be physically capable of conducting the procedures..
These personnel shall have skills that include:
1 . Proper and safe use and application of mechanics
common hand tools as well as special Ingersoll
Rand or recommended tools..
2. Safety procedures, precautions and work habits
established by accepted industry standards..
Some maintenance procedures are technical in nature
and require specialized tools, equipment, training and
experience to accomplish correctly.. In such situations,
only allow Ingersoll Rand trained technicians to perform
maintenance on this compressor.. Service or inspections
beyond the procedures given in this manual shall not be
attempted by operating personnel..
For additional information contact the Ingersoll Rand
factory or the nearest service provider..

SAFETY

Before undertaking any work on the compressor, ensure that If you are unsure of a maintenance procedure or step,
the electrical supply has been isolated and remote start/stop place the compressor in a safe condition before
function is not enabled, locked off, tagged and the compressor consulting technical assistance..
has been relieved of all pressure.. Ensure the compressor is The use of other than genuine Ingersoll Rand replacement
electrically isolated for at least 15 minutes before commencing
parts may result in safety hazards, decreased performance and
any maintenance work.. See the Product Safety Information
increased maintenance and may invalidate all warranties..
manual for additional information..
For additional information contact the Ingersoll Rand
Ingersoll Rand cannot know of or provide all the procedures
by which repairs may be conducted and the hazards and/
factory or the nearest service provider..
or results of each method.. If maintenance
procedures not specifically recommended by the
manufacturer are conducted, ensure that safety is
not endangered by the actions taken..

47799053001 Rev A EN-3

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MAINTENANCE
MAINTENANCE CHART ROUTINE MAINTENANCE
PERIOD OPERATION MAINTENANCE This section refers to the various components which
When Replace Air Filter Element require periodic maintenance and replacement.
indicated Replace Coolant Filter Element The SERVICE/MAINTENANCE CHART indicates the
by various components’ descriptions and the intervals when
Controller Replace Separator Element
maintenance has to take place. Coolant capacities, etc.,
Check Connections and hoses for can be found in the Parts Manual Recommended Parts.
leaks
Compressed air can be dangerous if incorrectly
Check Coolant level handled. Before doing any work on the unit, ensure
Daily Check Controller for service that all pressure is vented from the system and that
indicators the machine cannot be started accidentally..
Check Package pre-filters for Ensure that maintenance personnel are adequately trained,
blockage competent and have read the Maintenance Manuals..
Inspect Air-cooled cooling system for
Monthly
blockage Prior to attempting any maintenance work, ensure that:
• All air pressure is fully discharged and isolated from
Replace Air filter element the system. If the automatic blowdown valve is used
Every Replace Coolant filter element for this purpose, then allow enough time for it to
2000 Inspect Shock pulse bearing complete the operation.
Hours Analysis Coolant ( Ultra SL) • The machine cannot be started accidentally or
Grease Inspect, replace if necessary otherwise, by posting warning signs and/or fitting
appropriate anti-start devices.
Inspect Scavenge screen for blockage
• All residual electrical power sources (mains and
Replace Air filter element
battery) are isolated.
Replace Coolant filter element Prior to opening or removing panels or covers to
Every 4000
Replace Separator Element work inside a machine, ensure that:
Hours
Inspect/ • Anyone entering the machine is aware of the reduced
Air-cooled cooling system
Clean level of protection and the additional hazards,
Calibrate Pressure Sensor including hot surfaces and intermittently moving parts..
Grease Replace if necessory • The machine cannot be started accidentally or
Replace Air filter element otherwise, by posting warning signs and/or fitting
Every Replace Coolant filter element appropriate anti-start devices.
8000 Replace Separator Element Prior to attempting any maintenance work on a
Hours Replace Coolant running machine, ensure that:
Service Intake Valve/MPCV/TCV • The work carried out is limited to only those tasks
16000 Rubber Hose, which require the machine to run.
Check
Hours Replace as required
• The work carried out with safety protection devices
Replace Flexible hose
disabled or removed is limited to only those tasks
40000 Replace Intake valve which require the machine to be running with safety
Hours Service Shaft sealing protection devices disabled or removed.
• All hazards present are known (e.g. pressurized
NOTES:  components, electrically live components, removed
panels, covers and guards, extreme temperatures,
The above period is based on the machine running in
the ideal environment and working conditions, and is not inflow and outflow of air, intermittently moving parts,
equal to the service life of spare parts. In the case of poor safety valve discharge etc.)
environment and working conditions, the maintenance
cycle needs to be shortened and the spare parts need to • Appropriate personal protective equipment is worn.
be replaced in advance • Loose clothing, jewellery, long hair etc. is made safe.
The coolant filter element need been changed, when the
• Warning signs indicating that Maintenance Work is in
Machine running for 150hours since the first start
 Progress are posted in a position that can be clearly seen.

EN-4 47799053001 Rev A


MAINTENANCE
Upon completion of maintenance tasks and prior
to returning the machine into service, ensure that:
• The machine is suitably tested. compressor unit has been just shut down. At this time, it's
• All guards and safety protection devices are refitted. easier to drain the coolant, and the contaminant are still
• All panels are replaced, canopy and doors closed. suspended in the coolant.
• Hazardous materials are effectively contained and
disposed.
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, and the oil
sight glass is on the side of the oil separator tank. The
coolant level should be between the midpoint and the top of
the oil sight glass, when the unit is loaded running and the
coolant is under the normal work temperature.
COOLERS
Once a month, the coolers should be checked for coolant and
dirt accumulation on the exterior surfaces. Clean the core of the
coolers by using compressed air, with a non-flammable safety
solvent if possible.
COOLANT FILTER CHANGE PROCEDURE
• Loosen filter element with the correct tool.
• Remove the oil filter.
• 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 lubricant to the element seal.
• Screw the new element down until the seal makes contact
with the housing, then hand tighten a further half turning.
• Check the coolant level, re-filling if necessary.
• Start the compressor and check for leaks.
47799053001 Rev A
EN
COOLANT CHANGE PROCEDURE
It is better to drain the coolant immediately after the
WARNING
EXTREME CARE should be taken when
draining the HOT COOLANT.
• To ensure the coolant to be drained, a drain valve is
located under the separator tank.
• Open the sluice valve and completely drain the
coolant into a suitable container.
• Close the sluice valve and re-fill the new coolant into
the compressor unit.
CAUTION
- Do not mix coolant with ULTRA SL COOLANT.
• Start the compressor and check for leaking
• Check the coolant level, re-filling if necessary..
• Dispose of waste coolant in accordance with local
and governmental regulations.
NOTICE
Shorten the coolant replace intervals may be
necessary if the unit is operated in worse conditions.
AIR FILTER CHANGE PROCEDURE
WARNING
Do not remove the filter(s) without first making sure
that the machine is stopped and the system has been
completely relieved of all air pressure. (Refer to
STOPPING THE MACHINE in the OPERATING
INSTRUCTIONS section of this manual)
Remove the clamping securing the filter cover.
Fit the new element(s) and re-assemble the
components in reverse order.
EN-5
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MAINTENANCE
SEPARATOR ELEMENT CHANGE PROCEDURE
• Loosen the separator element with the correct tool.
• Remove the separator element.
• 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 lubricant to the element seal.
• Screw the new separator element down until the seal
makes contact with the housing, then hand tighten a
further half turning.
• Check the coolant level, re-filling if necessary.
• Start the compressor and check for leaks.
Do not use any type of sealant on either the
separator tank or the separator tank cover faces.
AIR-END BEARINGS
Air­end bearings are lubricated by the compressor
coolant and require no maintenance.
EN-6
FS MOTOR BEARINGS
Clean the area around the grease nipple and remove
the protective cover. Add the correct amount of grease
refer to the SERVICE/MAINTENANCE CHART earlier
in this section). Replace the protective cover and clean
the area of surplus grease.
FS MOTOR BEARING LUBRICANT
SPECIFICATION
Use POLYREX EM grease or equivalent or grease
brand grade on the motor nameplate.
HIGH AMBIENT TEMPERATURE SENSOR
CHECKINGPROCEDURE
It is recommended that the discharge temperature
sensor is checked regularly as follows:
Air cooled machines:
Stop the cooling fan by opening the fan motor circuit breaker
The machine should trip at 109°C of the air-end
discharge temperature.
CAUTION
Under no circumstances should these discharge
temperatures be exceeded. If the machine fails to
trip, A FAULT EXISTS. Investigate immediately.
The temperature at which the machine stops should
be recorded for comparison with the future results
47799053001 Rev A
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TROUBLESHOOTING
FAULT CAUSE ACTION
Check the control fuses.
“Power on” LED does Control voltage not
not illuminate. available Check the transformer secondary windings for the
control voltage.
Controller tripping Control circuit interrupted Check machine for indicated fault. Attempt to ’reset’
operation by a safety device the controller. If the fault persists investigate further.
Check the coolant level.
Check if the coolers are clean.
Insufficient coolant
Check the coolant system for blockages.
Check the operation of thermostatic valve.
H.A.T. thermistors failure protection. The unit will trip
Poor electrical connection
Indicating a high due to open or short circuit
compressor Check that the cooling air flow is not obstructed at:
temperature. • The inlet grille
Insufficient cooling taking • The cooler fin
place •The exhaust vents
Check that the ducting (if fitted) is the correct size
or/and exhaust resistance.
High ambient temperature Improve the ventilation condition to the compressor
(i.e. greater than 40°C ) room.
Check the actual operating pressure and lower the
setting if it is too high.
Isolate the electrical supply and check that the Air-
Compressor trips and Excessive current has end and motor rotate freely.
indicates caused the thermal Check the separator element for excessive pressure
"motor overload" overload(MOL) to trip drop.
Check that the mains voltage is not below the
specified value.
Isolation valve closed Open the shut valve and restart.
Compressor shutdown
Check the operation of the load solenoid valve
Display shows Blowdown system
“OVERPRESSURE” ineffective Check the unloading solenoid valve and clean as
required
Compressor will not Check for leaks, open discharge valves or
Demand too high
build up rated exceptionally high demand
pressure Off-line pressure set too low Check the offline pressure setting
Ensuring that all power to the machine is switched off,
Compressor will not check that the valve is free to open
Inlet valve not opening
load
Check the operation of the cylinder
Invet valve not open completely Check the operation of intake valve
Compressor fails to MPCV working unnormally Check the offline/online pressure setting
deliver rated capacity Check the inlet filter/Inlet Pad for contamination. The
Air filter dirty or blocked
LED Should indicate if the inlet filter is blocked
Blocked scavenge line Clear the blockage.
High coolant
consumption Ruptured or fouled
Change the separator element.
separator element
Rapid cycling or Duty cycle too rapid-Increase system capacity.
receiver will not blow– Rapid load/unload cycling
Change the controller to show modulation operation
down to unloaded
running pressure. MPCV stuck open Strip the MPV, inspect and repair if necessary
Safety valve blows MPCV stuck closed Strip MPV, examine and repair if necessary..
when compressor Check the setting of the safety valve and the rated
goes on load Safety valve fault
pressure
Compressor trips • Check the air cooler is clean or dirty
indicating high Insufficient cooling taking
• Check the cooling fan is working or not
compressor place
temperature. • Check the TCV is working normally or not

47799053001 Rev A EN-7

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INTEGRATED DRYER MAINTENANCE

WARNING

Before accessing live electrical parts, disconnect the

power supply to the dryer using the disconnect switch
or disconnecting the cable connections

.
TROUBLE CAUSE ACTION
WEEKLY CONDENSATE DRAINS (TIMED AND NO- Solenoid Debris in solenoid Remove solenoid
LOSS DRAINS) condensate valve prevents valve, disassemble,
valve will not diaphragm from clean and
Verify that the condensate drains are close. seating. reassemble.
operating correctly by pressing the TEST
Short in electrical Check and replace
button. component. power cord or timer
EVERY 4 CONDENSER as needed.
MONTHS
Remove any dust from the condenser „ DISASSEMBLING THE INTEGRATED DRYER
fins.
EVERY 6 AIR FILTER NOTICE
MONTHS The dryer shall be disassembled, charged or repaired by
Replace air filter element.
a refrigerant specialist
YEARLY (TIMED DRAINS ONLY)

.
Refrigerant liquid and lubricating oil inside the
Completely disassemble the drains and refrigeration circuit shall be recovered in compliance
clean all their components. with current norms in the country where the dryer is
„ CLEANING CONDENSATE DRAINS (TIMED DRAINS installed
.
ONLY)
NOTICE
Periodically clean the screen inside the valve to keep the drain
Refrigerant leaks may be identified by tripping of the
functioning at maximum capacity. To do this, perform the
refrigeration overload protector
following steps:
.
If a leak is detected in the refrigerant circuit, seek
1. Close the strainer ball valve completely to isolate it
technical assistance
from the air receiver tank.
.
If a refrigerant leak occurs, thoroughly air the room
2. Press the TEST button on the timer to vent the
before commencing work
pressure remaining in the valve. Repeat until all
.
pressure is removed. NOTICE
WARNING In normal temperature and pressure conditions, the
R404a refrigerant is a colorless, class A1/A1 gas with
High pressure air can cause injury from flying debris
TVL value of 1000 ppm (ASHRAE classification) .
.
Ensure the strainer ball valve is completely closed and
pressure is released from 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 valve back into service, press the
TEST button to confirm proper function.

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RECYCLING DISASSEMBLY
Frame and panels Steel / epoxy resin polyester
Heat exchanger (cooler) Stainless steel / aluminum
Pipes Copper
Insulation Gum synthetic
Compressor Steel / copper / aluminum / oil
Condenser Aluminum
Refrigerant R404a
Valve Steel

47799053001 Rev A EN-9

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