Rotary Screw Air Compressors

100-500 HP / 75-350 kW Single & 2-Stage

Delivering Compressed
MORE THAN
Air Solutions For More

125
Than 125 Years
For more than a century, Ingersoll-Rand air
compressors have helped build dams, bridges
and tunnels, produce cars, appliances and
electrical equipment, and package foods
and pharmaceuticals.

As more and more companies chose

Ingersoll-Rand air compressors, we answered
the call for new technologies and updated
designs, ensuring that our customers would get KNOWLEDGEABLE SALES STAFF
the maximum benefits from their compressed air.

Focused on Our Customers

Ingersoll-Rand strives to deliver value to
our customers in everything we do. We stay
focused on what you need, remaining true to
our goal: to help you achieve the best results
possible with your compressed air supply.

By maintaining solid relationships with our

customers, our dedicated sales staff and
distributor network relay changing requirements
to our engineering team. With this information,
our engineers make design improvements
that ensure that our customers get the quality
compressed air they’ve asked for.

If you want a single source supplier, you can

count on Ingersoll-Rand. Whether you need
compressed air systems, parts and service,
or technical support, we will be there to help
your system run at peak efficiency now and
in the future.

2
TECHNOLOGY LEADERSHIP

Ingersoll-Rand: Your
Compressed Air Resource
If you need compressed air, Ingersoll-Rand
is here to help. We’ll listen to what you need.
Then we’ll use our decades of leadership in
the air systems market to help you design
the best compressed air system for your
TECHNICAL ASSISTANCE application.

Today, we’re the only manufacturer that can

supply you with energy-efficient compressors
in all three available technologies: rotary
screw, reciprocating and centrifugal. And
since each technology has its benefits,
we can help you select the one that works
best for your application.

3
Digital Control
Our exclusive digitally controlled stepper
motor inlet valve system precisely matches
the airflow to the system demand. Just set
the preferred system pressure and the built-
in Intellisys ® microprocessor controller takes
care of the rest.

To further reliability the inlet control system

requires no maintenance. There are no
pressure switches to manually recalibrate
and no valves that can stick open - and, as
a matter of fact, there are no manual
adjustments required during the course
of normal operation.

100

Straight Modulation Energy Saving Control

Control
System
% FULL LOAD POWER

70 We equip each compressor with not

Geometry
Controller one, but three separate control modes:
On-line/Off-line, Upper Range Modulation,
50 and Auto Control Select. Simply set the
Intellisys® Control
Intellisys controller to the desired control
On Line/Off Line method, and the microprocessor does
the rest.
20
For the best overall efficiency, choose
IR’s patented Auto Control Select (ACS)
0 system. ACS constantly monitors the
20 40 60 80 100 compressor’s operation and automatically
% CAPACITY adjusts the control system to the mode
that best suits your system’s needs:
On-line/Off-line or Upper Range Modulation.

4
SSR: Unparalleled Reliability Advanced Airend Design
Our time-proven integral gear drive is the only At the core of the SSR is our rugged
maintenance-free drive system in the industry. and reliable airend. Used in thousands
The airend and motor are permanently of compressors worldwide, our airend
aligned, so during the course of normal is known for trouble-free operation and
operation no adjustments are ever required. minimal maintenance.

The drive train is totally enclosed so that no
dust or dirt can get in, and our triple-lip shaft
seal prevents leakage of coolant to the motor.
Energy Efficient Motor
Every SSR compressor incorporates a
durable high efficiency motor. SSR motors
operate at peak efficiency under full load
conditions, ensuring maximum energy savings.
I-R High Efficiency Motor Design Point
Our airends utilize only the highest quality
duplex tapered roller bearings. Roller bearings
provide line contact for thrust loads, and
dramatically improve the life of the airend.
The SSR airend also incorporates a bearing
coolant dam that traps coolant in the bearing
during shutdown. This ensures proper bearing
lubrication during the critical start-up phase,
and a longer bearing life.

100

95

90
Percent Efficiency

85
"Off the Shelf"
Competitive Motor
80 Design Point

75

70 Applied Point

100 105 110 115 120 125

Percent Load
5
Reduced Bearing Loads
A lower compression ratio in each stage
reduces bearing loads and increases airend
life. Our use of the highest quality bearings
available assures you of years of reliable,
efficient service.

Energy Efficient Airend

If you’re looking for the greatest efficiency
possible from a rotary screw then check out
our two-stage compressors. The heart of
the compressor is our time-proven two-stage
airend. By compressing the air in two steps
instead of one, energy savings of up to 15%
are realized.
Our rotors are precision machined in a
twenty-step process, ensuring unmatched
rotor profile accuracy, repeatability, and
efficiency.
Energy Cost/Year
Coolant Curtain
One of the keys to the efficiency of
the two-stage is the coolant curtain.
Significant cooling of the air is achieved
by injecting atomized oil into the
compressed air stream leaving the
first stage. Lowering the air
temperature prior to entering the
second stage significantly lowers
the energy required for compression.
The coolant curtain also eliminates
the need for an intercooler.

Single-Stage
15%
Energy Savings

Two-Stage

0 2000 4000 6000 8000

Operating Hours/Year
6
7
 SSR AIR-COOLED PACKAGE (FRONT VIEW)
The SSR Package
To fit the needs of your compressed air
system, we offer you the choice of an
air-cooled or water-cooled design.
Inherent Leak-Free Design
By using SAE O-ring fittings on all connections
1/4" and larger, we’ve significantly reduced
potential leakage problems associated with
conventional threaded connections.
8
End-to-End Cooling
The aftercooler is located at the inlet end of
the package. This allows cool compressed
air only 15°F/8°C above the ambient
temperature to pass downstream to the
air system.
115°F/46°C Ambient
SSR compressors operate in high ambient
conditions, making them suitable for locations
around the world. Even if the compressor is
not operated in sweltering climates, the high
temperature rating ensures fewer nuisance
shutdowns caused by fouled coolers.
Star-Delta Starter
This advanced starter gives the compressor
a controlled, cushioned start, eliminating
current surges and extending component
life for increased system reliability.
 SSR AIR-COOLED PACKAGE (BACK VIEW)
8000 Hour/2-Year Lubricant
UltraCoolant reduces maintenance costs
by going longer between changes. Also,
because of UltraCoolant’s superior separating
properties, less coolant is passed down-
stream to the air system, further minimizing
coolant costs.
Quiet Enclosure
A low sound enclosure is standard and keeps
sound levels to a minimum.
Easy Serviceability
The SSR package is remarkably uncluttered,
making servicing easy. All components are
readily accessible behind easily removable
panels.
Rugged Motor
The extra toughness built into the SSR motor
means it will run when other motors quit.
Maintenance and repair of the SSR motor
are just like any other motor you own.
Factory-Tested
Every SSR compressor undergoes state-of-
the-art computerized testing to ensure that
you get the best possible performance under
varying conditions.
Easy Connectivity
The SSR is fully piped and wired, resulting in
simple external connection of all utilities.
Convenient Top Exhaust
The cooling air flow discharges from the top
of the package facilitating easy ducting for
removal and/or recovery of exhaust heat.
9
Intellisys Gives You
Total Control of Your
Compressed Air Delivery
Whether you need eight hours of continuous
duty compressed air or an intermittent supply
over a 24 hour period, Intellisys® puts you in
complete control.
TOTAL CONTROL AT YOUR FINGERTIPS
With finger-touch control, the Intellisys
controller provides quick, comprehensive
access to your compressed air system.
EASY OPERATION
Intellisys is easy to learn and easy to operate.
ADJUSTABLE OPERATING PARAMETERS
To satisfy your system requirements, you can
change your operating parameters quickly
and easily.
SSR Options
The SSR compressor comes with several
options to ensure that you get the right
machine for your application. If there are any
special options or requirements you need,
we’ll work with you to find a solution. Just
contact your local Ingersoll-Rand distributor.
• Multiple unit sequencer
• Remote communications capability
• Automatic power outage restart option
• Remote starter/no starter
10
BUILT-IN SEQUENCER
You can sequence up to four similarly
equipped Intellisys compressors. The lead
machine automatically rotates among the
compressors based on accumulated hours,
so maintenance levels are kept equal.
TIMESAVING DIAGNOSTICS
Intellisys provides fast diagnosis of system
demand and displays a warning and/or stops
the compressor if it exceeds operating
parameters. This will keep troubleshooting
expenses and downtime to a minimum.
COMPREHENSIVE DATA DISPLAY
An easy-to-read, liquid crystal display
provides you with critical details of your
compressor’s operation, allowing you to
make fast adjustments when necessary.
GIVING YOU COMPLETE FLEXIBILITY
With Intellisys, you are always in control.
You can change your operating parameters
to maintain the best performance level.
• Variable frequency drive
• Air-cooled or water-cooled
• TEFC motors
• Premium efficiency motors (60Hz only)
• High-dust inlet filter
• No aftercooler
• Power phase monitor
• NEMA 4 electrical option
• Outdoor modification
• Low-ambient temperature option
60Hz SSR 125-450 HP Performance
Free Air Delivery - CFM

Nominal XF EP HP XP L W H Weight
HP 100 psig 125 psig 140 psig 165 psig (in) (in) (in) (lbs)
125 655 571 519 - 123 63 75 5770
150 739 670 610 558 123 63 75 5820
200 993 892 812 739 123 63 75 6020
250 1213 1066 979 864 148 76 86 10840
300 1359 1252 1150 - 148 76 86 11440
300E 1506 1363 1285 - 148 76 86 11440
350 1695 1537 1451 - 160 82 95 12815
400 1899 1719 1626 - 160 82 95 12815
450 2050 1866 1833 - 160 82 95 12815

60Hz SSR 2-Stage 100-500 HP Performance

Free Air Delivery - CFM

Nominal XFE EPE HPE HXPE L W H Weight

HP 100 psig 125 psig 140 psig 200 psig (in) (in) (in) (lbs)
100 560 504 470 - 123 63 75 6050
125 690 621 580 443 123 63 75 6770
150 825 743 693 548 123 63 75 6820
200 1100 990 924 735 123 63 75 7020
250 1380 1249 1167 960 148 76 85 13080
300 1685 1476 1428 1185 148 76 85 13080
350 1899 1740 1669 1366 160 82 96 14685
400 2200 1991 1924 1543 160 82 96 14685
450 2405 2245 2099 1739 160 82 96 14685
500 2600 2425 2266 1879 160 82 96 14685

50Hz SSR 90-300kW Performance

Free Air Delivery - M3/min

Nominal MLD MMD MHD L W H Weight

kW 7.5 barg 8.5 barg 10.0 barg (mm) (mm) (mm) (kg)
90 17.1 15.3 14.0 3124 1587 1905 2617
110 20.0 19.2 17.5 3124 1587 1905 2640
132 23.5 22.3 21.0 3124 1587 1905 2731
160 28.0 26.0 25.0 3124 1587 1905 2731
Nominal XF EP HP L W H Weight
HP 7.5 barg 8.5 barg 10.0 barg (mm) (mm) (mm) (kg)
250 33.8 29.6 27.1 3759 1930 2191 5189
300 38.2 35.0 32.1 4064 2083 2416 5813
350 46.9 43.8 41.3 4064 2083 2416 5813

50Hz SSR 2-Stage 90-350kW Performance

Free Air Delivery - M3/min

Nominal MLD MMD MHD MXUD L W H Weight

kW 7.5 barg 8.5 barg 10.0 barg 14.0 barg (mm) (mm) (mm) (kg)
75 15.7 14.2 13.1 - 3124 1587 1905 2744
90 18.0 17.5 15.4 12.5 3124 1587 1905 3071
110 22.1 20.4 18.9 15.4 3124 1587 1905 3094
132 26.2 24.2 23.1 18.4 3124 1587 1905 3184
160 31.1 29.6 27.2 22.2 3124 1587 1905 3184
Nominal XFE EPE HPE HXPE L W H Weight
HP 7.5 barg 8.5 barg 10.0 barg 14.0 barg (mm) (mm) (mm) (kg)
250 38.1 34.5 32.3 26.9 3759 1930 2146 5933
300 46.5 40.7 39.4 34.1 4064 2083 2416 6665
350 53.2 48.1 46.5 39.2 4064 2083 2416 6665
400 59.0 55.0 51.4 43.3 4064 2083 2416 6665
450 65.6 61.1 57.0 48.2 4064 2083 2416 6665
500 72.0 67.0 62.0 52.5 4064 2083 2416 6665

Notes: 1) FAD (Free Air Delivery) CFM and M3/min. are ratings of full package performance in accordance with CAGI-PNEUROP
acceptance test standard PN2CPTC2 or ISO1217: 1996 Appendix C.
Product improvement is a continuing goal at Ingersoll-Rand. Designs and specifications are subject to change without notice or obligation.

11
 More Than Air. Solutions.
Online solutions: www.air.ingersoll-rand.com

Ingersoll-Rand air compressors are not designed, intended or approved for breathing air. Compressed air should not be used
for breathing air applications unless treated in accordance with all applicable codes and regulations.

Nothing contained in this brochure is intended to extend any warranty or representation, expressed or implied, regarding
the products described herein. Any such warranties or other terms and conditions of sale shall be in accordance with
Ingersoll-Rand’s standard terms and conditions of sale for such products which are available upon request.

Product improvement is a continuing goal at Ingersoll-Rand. Designs and specifications are subject to change without notice
or obligation.

Ingersoll-Rand Company
Air Solutions
800-D Beaty Street
P.O. Box 1840
Davidson, NC 28036

© 2001 Ingersoll-Rand Company Form 3193-A Printed in USA

 SSR 2-Stage
Revision: January 2006
Cancels: February 2000

300 HP Davidson, NC 28036

XFE300-2S EPE300-2S HPE300-2S HXPE300-2S

GENERAL COMPRESSOR DATA

Capacity FAD (1) CFM 1685 1476 1428 1185
Compressor Power BHP 330 330 330 330
Full Load Package Discharge Pressure PSIG 100 125 140 200
Maximum Operating Pressure PSIG 110 135 150 210
Minimum Operating Pressure PSIG 65 65 65 65
Rotor Diameters - 1st/2nd MM 297/250 297/250 297/250 297/250
Male Rotor Speed - 1st Stage RPM 1860 1630 1576 1334
Male Rotor Speed - 2nd Stage RPM 1593 1406 1363 1165

COOLING DATA - GENERAL 115°F MAXIMUM AMBIENT

Operating Temperature °F 209 205 201 195
Airend Injection Temperature °F 160 160 160 160
Heat Removal - Oil Cooler 1000 BTU/Hr 714 714 714 714
Oil Cooler and After Cooler 1000 BTU/Hr 931 896 880 865
Oil Flow GPM 68 79 83 98

AIRCOOLED DATA
Aftercooler CTD (4) °F 15 15 15 15
Fan Air Flow CFM 24,000 24,000 24,000 24,000
Maximum Added Static Pressure In. Water .25 .25 .25 .25

WATERCOOLED DATA
Aftercooler CTD (4) °F 25 25 25 25
Cooling Water Required @ 50°F GPM 26 26 26 26
70°F GPM 35 35 35 35
90°F GPM 58 58 58 58
Water Temperature Rise @ 90°F °F 32 31 31 31
Water Pressure Drop @ 90°F
Oil Cooler PSID 6 6 6 6
Oil Cooler and After Cooler PSID 10 10 10 10
Fan Air Flow CFM 5000 5000 5000 5000
Maximum Added Static Pressure In. Water 0.25 0.25 0.25 0.25

LUBRICATION DATA
Sump Capacity Gal 16 16 16 16
Total Lubrication System Capacity Gal 33 33 33 33

SOUND LEVELS (5)

Standard Enclosure dBA 80 80 80 80
Low Sound Enclosure dBA N/A N/A N/A N/A
ELECTRICAL DATA (2) 460V 575V 2300V 4160V
Full Load BHP -Driver BHP 330 330 330 330
Full Load BHP -Fan BHP 16.5 16.5 16.5 16.5
Full Load BHP -Package BHP 346.5 346.5 346.5 346.5
Full Load Amps - Driver AMPS 381.7 308.0 83.6 41.8
Full Load Amps - Fan AMPS 22.6 17.6 22.6 (7) 22.6 (7)
Full Load Amps - Package AMPS 404.3 325.6 — —
Fan Horsepower (Watercooled) BHP 1.1 1.1 1.1 1.1
Drive Motor RPM RPM 1780 1780 1781 1781
Drive Motor Frame: ODP 447T 447T 449T 449T
TEFC 449T 449T 5010 5010
Driver (FV) Locked Rotor Amps (3) AMPS 2180 1744 425 249
Driver Efficiency/Power Factor - % of Load 100% 95.0 / 86.0 95.0 / 86.0 94.0 / 88.0 94.4 / 86.6
75% 95.0 / 85.0 95.0 / 85.0 95.0 / 86.0 94.5 / 84.5
50% 94.0 / 79.0 94.0 / 79.0 96.0 / 80.0 96.0 / 80.0
Starter Size: Star Delta D250 D180 N/A N/A
Full Voltage N/A N/A (8) (8)
NOTES:
(1) FAD (Free Air Delivery) is full package performance including all losses per CAGI / PNEUROP PN2CPTC2.
(2) Electrical data based on Reliance ODP motors, consult factory for others.
(3) Star Delta starting current inrush is 33% of full voltage KVA inrush.
(4) CTD (Cold Temperature Difference) based on 100 °F / 38 °C inlet air at 40% relative humidity.
(5) Sound levels are "Free field conditions" per CAGI / PNEUROP S5.1
(6) For weights, dimensions, and piping connections see general arrangement drawings.
(7) 460V Fan Motor.
(8) Remote Full Voltage IEC starter.
 SSR 2-Stage
100 - 500 HP
Ref: 7550.02
Date: 9 July 2003
QUIET ENCLOSED
Cancels: 15 May 1999 Davidson, NC 28036
Point of Manufacture—Davidson, NC, USA
GENERAL INFORMATION — 60 HZ
The SSR 2-Stage compressor is an electric motor driven, two stage, screw compressor complete with accessories piped,
wired and baseplate mounted. It is a totally self-contained air compressor package.

The compressor is available at the following horsepower sizes and full load pressure ratings.

Horsepower 100 PSIG (CFM) 125 PSIG (CFM) 140 PSIG (CFM) 200 PSIG (CFM)
100 HP 560 504 470 N/A
125 HP 690 621 580 443
150 HP 825 743 693 548
200 HP 1100 990 924 735
250 HP 1380 1249 1167 960
300 HP 1685 1476 1428 1185
350 HP 1899 1740 1669 1366
400 HP 2200 1991 1924 1543
450 HP 2405 2245 2099 1739
500 HP 2600 2425 2266 1879

Standard Equipment

• Two-stage, oil-lubricated airend with tapered roller bearing

• High Efficiency motor, Class F insulation, 115°F ambient rated
• Rugged, proven integral three gear drive with vibration isolation system
• Efficient coolant separation system (less than 2 ppm carryover)
• Factory fill of exclusive SSR Ultra Coolant
• Choice of integral aircooled coolers (Remote on 500) or watercooled design
• Aircooled or watercooled aftercooler
• Mounted (remote on 400, 450 and 500) Star Delta motor starter
• Intellisys Microprocessor control system with Stepper Motor
• Power-saving Intellisys ACS Control with on-line/off-line and upper range modulation control
• Intellisys LCD Display and Membrane Touch Panel
- 12 Normal Operation Information Displays
- 6 Fault Warning
- 16 Fault Shutdowns
• Protective Controls
- Air pressure relief
- Minimum pressure/check valve
- High temperature shutdown
• Quiet Enclosure

Optional Equipment

• Alternate Coolants

• Power Outage Restart Option

• Thermostatic Water Valve (watercooled)
• TEFC motor
• Premium Efficiency Motors (ODP and TEFC)
• High voltage motors
• High dust inlet filter
• Low ambient package
• Outdoor modification
• NEMA 4 electrics
• Phase monitor
 SSR 2-Stage
100 - 500 HP
Ref: 7551.01
QUIET ENCLOSED Date: 15 May 1999
Davidson, NC 28036 Cancels: 10 November 1995
Point of Manufacture—Davidson, NC, USA
DETAILED SPECIFICATIONS

INLET AIR FILTER:

Inlet air filtration is accomplished by a large 99.9% efficiency at 3 micron and above, dry type air cleaner. This is more
than suitable for the vast majority of applications; however, where high dust and dirt contamination is present, optional
filtration systems are available.

AIREND

Since the airend is the fundamental component in any rotary screw compressor package, reliability, performance and
efficiency are determined, for the most part, by the design, manufacturing tolerances and assembly of the airend itself.
All other elements in the compressor system are essentially support and monitoring devices, included to insure
dependable service and performance.

The pairs of rotors in SSR 2-stage compressors fit into a combined airend assembly. Compression is shared between
the 1st and 2nd stages, flowing in series, which increases overall compression efficiency up to 15% of the total full load
kilowatt consumption. To achieve peak efficiency, our two stage, rotary screw airend uses different Ingersoll-Rand profile
rotor sets, because the two compression stages have different objectives. Our first stage rotors utilize a profile for high
displacement, and discharge at relatively low pressure. The second stage profile achieves high efficiency compression
to final package pressure. The rotors are manufactured from AISI-C-1141 forged steel, rotor housings are made of close
grain high quality cast iron. After machining, all components are dimensionally checked to insure accuracy.

Air enters into the inlet of the 1st stage and is compressed as the male and female high displacement rotors rotate and
mesh with each other. To further enhance airend efficiency, coolant is injected into a channel at the 1st stage discharge
port. A precisely machined liquid orifice in the channel creates a curtain of coolant in the interstage passage. Air passes
through the curtain on its way to the 2nd stage, and through contact cooling, significantly lowers the 2nd stage inlet
temperature. This patented process eliminates expensive non-contact cooling devices such as air or water to coolant
heat exchangers.
© Ingersoll-Rand Company 1999

Cooled air from the interstage enters the inlet of the 2nd stage and is compressed by the high efficiency 2nd stage male
and female rotors. The compressed air passes through the 2nd stage discharge port, now at desired system pressure,
and exits the 2-stage airend through the discharge flange.
Printed in U.S.A.

DUPLEX TAPERED ROLLER BEARINGS

The bearing configuration used is the tapered roller bearing. The tapered roller bearing essentially consists of
constructing the roller elements, as well as the raceways, so that lines drawn coincide with the working surfaces of the
rollers and races will all meet at a common point on the axis of the bearing. This allows the bearing to handle all loads,
radial, thrust or both. With this bearing configuration, the discharge end of the male and female rotors are each equipped
with a pair of tapered roller bearings offset at opposing axis for maximum absorption of thrust and radial loads.

High quality cylindrical roller bearings are used to carry the radial loads on the inlet end of the rotors. All bearings, whether
thrust or radial, are premium cost, vacuum degassed, which provide truer, harder running surfaces for both inner and outer
bearing races.

Coolant dams are machined at the duplex taper roller bearing locations. The coolant dam provides an area for coolant
to collect or pond when the compressor is shut off. Upon startup the taper roller bearing which is resting in coolant ponded
by the coolant dam begins to rotate and is immediately lubricated. Airends without coolant dams have bearing systems
that operate dry for approximately six seconds on start up.
 SSR 2-Stage
100 - 500 HP
Ref: 7551.02
Date: 15 May 1999 QUIET ENCLOSED
Cancels: 10 November 1995 Davidson, NC 28036
Point of Manufacture—Davidson, NC, USA
DETAILED SPECIFICATIONS (Continued)

THREE GEAR INTEGRAL DRIVE

In order to utilize the inherent efficiency advantage of the SSR motor and airend, it was necessary to develop a means
of efficiently transmitting power from the driver to the compressor. The integral gear drive system was chosen because
it is an efficient, reliable and rugged design. The drive gear (center) is mounted directly on the motor shaft, and the driven
gears are mounted on the shafts of each male rotor, eliminating maintenance prone and mis-aligned coupling or power
robbing belts. The loads generated by the driven gears help to offset the load on the drive gear, further enhancing
reliability and life. The flanged motor is doweled for permanent alignment to the airend. The use of optimizing
(AGMA Class 11) gears allow the rotors to rotate at a specific speed, which allows maximum airend efficiency. The gear
housing is completely sealed against atmospheric contaminants to insure life-time trouble-free power transmission. A
self-centering Teflon impregnated motor shaft seal provides a positive system against leakage to the motor windings. The
entire assembly is vibration isolated from the package.

HIGH EFFICIENCY MOTOR

The main drive motor is exactly matched to the requirements of the SSR 2-Stage. Torque and load requirements of the
compressor were matched to specific design criteria that enabled the SSR motor to develop peak efficiency and power
factor at full load. This stated efficiency advantage is illustrated if one were to compare SSR motor efficiencies with typical
NEMA motor efficiencies; generally this advantage is 5%.

A. FRAME:

Motor frame and end brackets are of cast iron with integrally cast feet. This provides maximum strength and rigidity for
bearing support, uniform stator/rotor gap and flanged permanent alignment of all mating parts.

B. ELECTRICAL DESIGN:

Speed, torque and operating characteristics have been designed to match the load of the compressor. Motor efficiency
and power factor have been optimized to cover the entire capacity range of the SSR 2-Stage and are all rated at a 115°F
ambient.

C. BEARINGS:

Vacuum degassed ball bearings for the drive end and roller bearings for the discharge end provide dependable and
reliable service. Both bearings are grease lubricated with bearing housings having inlet and relief fittings to simplify the
lubrication procedures.

D. INSULATION:

The SSR high efficiency motor has class F insulation as standard. That means it is rated at continuous duty for up to a
115°C temperature rise. However, no SSR motor is ever applied for a temperature rise over 95°C, a difference of 20°C.
The extra conservatism built into every SSR motor means more reliability, increased life, and a much more forgiving motor
under adverse conditions.

And even with all these unique features, the SSR motor still utilizes NEMA design standards.

E. WIRING:

All windings and leads are copper with triple coats of insulating varnish to add extra margins of protection to the driver.
 SSR 2-Stage
100 - 500 HP
Ref: 7551.03
QUIET ENCLOSED Date: 15 May 1999
Davidson, NC 28036 Cancels: 10 November 1995
Point of Manufacture—Davidson, NC, USA
DETAILED SPECIFICATIONS (Continued)

LUBRICATION SYSTEM

A. COOLANT FILTRATION:

The full capacity coolant filters are 4 micron, spin-on, replaceable elements with pressure bypass.

B. COOLANT/LUBRICANT HEAT EXCHANGERS:

Integrally mounted (remote on 500 HP) aircooled heat exchangers are designed for ambient temperatures to 115°F. The
core, fan and fan motor are all mounted and prewired within the compressor package. Watercooled coolers are shell and
tube type designed to use fresh cooling water at inlet temperature up to 90°F. Other materials of construction and higher
temperature ratings are also available.

C. COOLANT/LUBRICANT TEMPERATURE CONTROL (AIRCOOLED AND WATERCOOLED UNITS):

The thermostatic control valve with three ports, (1) for the coolant from the cooler, (2) for the coolant from the pressurized
receiver/separator, and (3) for the coolant to the airend, is mounted in the piping system. The temperature sensitive
element controls the quantity of coolant from each source, cooled and uncooled, necessary to provide the proper injection
temperature and assure fast warm-up.

D. COOLANT INJECTION:

Coolant is injected internally to the 1st stage female rotor and the male and female rotors in the 2nd stage. This insures
the best possible presealing of the rotors. Coolant is also sprayed into an interstage coolant curtain to cool the interstage
air and improve efficiency.

E. COOLANT/AIR SEPARATION:
© Ingersoll-Rand Company 1999

After compression and discharge from the airend, the air heavily laden with coolant travels to the receiver/separator.
Entering through a tangential inlet, the air coolant mixture is directed in a circular motion around the inside of the tank.
The vortex or circular motion separates a major portion of the coolant from the air through centrifugal force. The air is
then directed through baffles, which further reduces the coolant content. The vortex action and baffling results in a pre-
Printed in U.S.A.

cleaning of the compressed air, prior to entering the separator element.

The separator element is a molded fiberglass two-stage reinforced separator. On all size SSR compressors, the carry-
over, after the separator element is 3-5 ppm. Compressed air then enters the optional aircooled or watercooled
aftercooler, where the carryover of 3-5 ppm will be further reduced by the aftercooler and condensate separator to a final
carryover figure of 2 ppm.

Hence, when calculating coolant makeup for SSR compressors, always use 3-5 ppm by weight.

MICROPROCESSOR CONTROL

The SSR 2-Stage compressor includes a microprocessor based control module which provides for starting, capacity
control, operating control, and safety control of the unit.

A. COMPRESSOR/CAPACITY CONTROLS:

The Intellisys microprocessor controls Ingersoll-Rand's innovative stepper motor inlet-control for precise inlet throttling
to match system requirements. This advanced control system will automatically throttle the compressor to match
pressure to load through our exclusive stepper motor.
 SSR 2-Stage
Ref: 7551.04
100 - 500 HP
Date: 9 July 2003 QUIET ENCLOSED
Cancels: 15 May 1999 Davidson, NC 28036
Point of Manufacture—Davidson, NC, USA
DETAILED SPECIFICATIONS (Continued)

Intellisys auto control selector (ACS), for the first time offers the user a microprocessor based, automated system to
deliver efficient, real time energy management. Intellisys ACS control operates the compressor in on-line, off-line during
low (0-60% capacity) demand periods, or in upper range modulation during medium to high (60-100% capacity) demand
periods. Realizing pressure is a function of volume, Intellisys control continuously monitors pressure and its rate of decay
or increase. Intellisys automatically selects the operating mode which will best fulfill the system's compressed air needs,
while operating the compressor in its most efficient control mode.

B. ADJUSTABLE OPERATING PARAMETERS: D. FAULT WARNINGS:

• Off-line pressure • Change inlet filter

• On-line pressure • Change coolant filter
• Control mode selection • Change separator element
- Intellisys Control, ACS • High airend discharge temperature
- Modulation only • High airend discharge pressure
- On-line/off-line • Sensor failure 4ATT
• Load/unload delay time
• Star Delta transition time
• Stop delay time E. FAULT SHUTDOWNS:
• Available as options
- Power Outage Rstart Option • High airend discharge temperature
• Low unloaded sump pressure
- Auto start and stop shutdown time • Low loaded sump pressure
- Sequencer control • Starter fault
- Power outage restart • Inlet control
- Power outage restart time • Main motor overload
• Fan motor overload
• Reverse rotation
C. DISPLAY STANDARDS: • Pressure transducer failure
• Temperature sensor failure
• Package discharge pressure • Microprocessor failure memory fault
• Package discharge temperature • Control power loss
• Airend discharge temperature
• Injection coolant temperature
• Sump pressure F. PROTECTIVE CONTROLS:
• Inlet filter condition
• Inlet vacuum • Air pressure relief
• Coolant filter condition • Minimum pressure/check valve
• Separator element pressure drop • High temperature shutdown
• Modulation % load
• Total hours/loaded hours

STAR DELTA STARTER

As a complete package, the SSR includes a Star Delta starter integrally mounted (Remote on 400, 450, and 500 HP) and
wired to the compressor package. Incoming line terminals are clearly marked and conveniently located for ease of
installation.

Starter overload protection is designed and sized specifically for SSR motor characteristics. A separate breaker and
overload relay is mounted and wired on the starter for the fan motor (not included on 400, 450, and 500 HP). The main
starter and fan motor protection circuit are electrically interlocked and wired for proper sequencing.

The Star Delta reduced voltage starter is thoroughly tested as a part of the compressor package prior to shipment.
 ROTARY
Ref: 7002.01
Date: 19 November 2003
Davidson, NC 28036 Cancels: 1 February 2001
Point of Manufacture—Davidson, N.C., U.S.A .
125-500 HP
MATERIALS OF CONSTRUCTION AND SPECIFICATIONS

AIREND:
Housing Cast Iron
Rotors AISI-C-1141 Forged Steel
Radial Bearings Vacuum Degassed Cylindrical Roller
Tapered Roller Bearings Cages are High Quality Carbon Steel

DRIVE TRAIN:
Speed Optimizing Gears Alloy Steel
Motor Shaft Seal FLUOROCARBON LIP
Gear Housing Cast iron

MOTOR:
Frame Cast Iron
Windings 100% Copper
Insulation F or H
Bearings Vacuum Degassed roller and/or ball

BASE: Fabricated Steel

RESERVOIR:
Receiver/separator tank Welded steel, ASME Section VIII, Division 1, unfired pressure vessel code
Separator element Two Stage, molded fiberglass, 99.9% efficient, .3 micron

TEMPERATURE CONTROL:
Aircooled Thermostatic control valve
Watercooled Thermostatic control valve (Water conservation valve optional)
© Ingersoll-Rand Company 2001

OIL COOLERS:
Aircooled Aluminum
Watercooled shell Steel
Tubes 1/4 or 3/8 Admiralty brass
Printed in U.S.A.

Tube sheets Steel

Tube bundles Fixed

OIL FILTER:
Oil filter Spin-on, single element paper 4 micron nominal
Pressure relief valve 25 psi differential

LUBRICATION: Pressure differential system

PIPING SPECIFICATIONS:
(Welded pipe assemblies 3" and larger)
Materials piping ASME SA 53-73 and SA53-73 E&F
Materials fittings ASTM A234 grade WPB
Welding ANSI B31.1

Screwed Pipe Assemblies (2" and smaller)

Materials piping ASME SA 106-73 Grade B; SA53-73 Type E&F
Materials fittings American Standard Black Mallable Iron

Pressure Limitations
Schedule 40 150 psi max working
Schedule 80 300 psi max working
 ROTARY
Ref: 7002.02
Date: 19 November 2003
Cancels: 1 February 2001 Davidson, NC 28036
Point of Manufacture—Davidson, N.C., U.S.A .
125-500 HP
MATERIALS OF CONSTRUCTION AND SPECIFICATIONS (CONTINUED)
TUBE ASSEMBLIES:
Size 1/4" and 3/8"
Material SAE J5225
Flares SAE J533 37 degree double flare
Fittings SAE J514; Sec I & II

Size 1/2" and larger

Material SAE J524, J525
Flares SAE J533 37 degree single flare
Fittings SAE J514; Sec I & II

ELECTRICAL COMPONENTS:
Listed by Underwriters Laboratories
Recognized of Canadian Standards Association
National Electrical Manufacturing Association
National Electric Code

AFTERCOOLERS:
Watercooled shell Steel
Tubes 3/8" Admiralty brass
Tube Sheet Steel
Tube Bundles Fixed

PAINT SPECIFICATIONS:
Primer TTP-664 Type resin
Top coat requirements Meet or exceed ASTM-D523-67, D870-54, D-117-73, D-22-7-68
Viscosity 69-65-KU
Weight/gallon 9.37 plus/minus .1 LB/gal
Solid/weight 45%
Solid/volume 30%
Reduction 5/1
 SSR 2-Stage
250-300HP
Aircooled Foundation Plan
 SSR 2-Stage
250-300HP
Aircooled Foundation Plan
 SSR
100-500HP 1-Stage & 2-Stage
Wiring Schematic
 SSR
100-500HP 1-Stage & 2-Stage
Wiring Schematic
 SSR
100-500HP 1-Stage & 2-Stage
Wiring Schematic
 SSR
100-500HP 1-Stage & 2-Stage
Wiring Schematic
 SSR 2-Stage
250-450HP
Air Cooled Process & Instrumentation Diagram
Desiccant Air Dryers
Heatless, Heated and Heated Blower
Desiccant Dryers...

Desiccant
Our reliable high strength, non-acidic desiccant
provides maximum performance and is easily
stored and handled. Environmentally friendly,
it eliminates worries associated with other
types of dryers, such as refrigerant leaks,
spills and disposal.

2 Desiccant Dryers
Designed for Reliability
When we designed the Ingersoll Rand heatless,
heated and heated blower desiccant dryers we
set our sights on creating the most reliable
desiccant dryers you can purchase and operate.
And our success was extraordinary. We set a
new standard, and, in fact, re-wrote the book.

One look tells you that these dryers are like

no others…extremely low silhouette…
manifolds and valves within an arm's reach of
the operator…readily accessible fill and drain
ports…just a few of the differences apparent
New Low Profile Design Traditional Design
on the outside. Both externally and internally,
each model combines innovative engineering
and technically advanced, highly durable
Low Profile Design
components, to provide easy installation,
Our easy access design places key maintenance
operation, maintenance, and, simply, the most
points at operator level for faster servicing and
reliable desiccant dryers available.
less downtime. The lower silhouette also allows
upright shipment and facilitates installation.

Easy to Maintain High Performance Valves

With manifolds angled toward the center at
operator level, the valves are easily accessed
for maintenance. A typical diaphragm valve in
a heatless dryer can be rebuilt in less than ten
minutes, without removing the valve from
the manifold.
State of the Art Controller
The advanced microprocessor-controller
maintains dryer performance at optimum levels.
It constantly monitors dryer functions and
provides alert when maintenance is required so
that downtime is held to a minimum.

Desiccant Dryers 3
Selecting An Ingersoll Rand
Desiccant Dryer
All three technologies – heatless, heated and
heated blower – use twin desiccant towers and
strategically positioned valves for the process
of drying compressed air. Each Ingersoll Rand
model incorporates high-strength desiccant
and durable, easily maintained valves for
unsurpassed reliability, performance and
customer value.
is thoroughly dried as it is directed through
the on-line desiccant-filled tower of the dryer.
As the desiccant in this tower adsorbs moisture
from the air, the desiccant in the dryer’s
off-line tower is purged of moisture and readied
for use. The basic difference in the three
technologies is the manner in which moisture
is desorbed from the desiccant, also known

Whether using a heatless, heated or heated as regeneration.

blower dryer, the compressed air produced

To air system

Heatless Dryers

Simplest of the three technologies, the heatless

dryer diverts a portion of the dried compressed
air to the off-line tower. This dry air then flows
through and regenerates the desiccant. The
purge air, now moisture laden, is harmlessly
exhausted through a muffler to the atmosphere.
Lowest in capital investment, this technology
may be more expensive to operate because it
requires a portion of the dried compressed
air to be diverted from the air system for
desiccant regeneration.

From air compressor

HL heatless desiccant dryer
Heatless dryers offer the lowest
capital investment.

4 Desiccant Dryers
 From air compressor

Heated

These dryers operate similarly to heatless dryers,

with a big exception. Dried air diverted from the
air system is first passed through a high efficiency
external heater before entering the off-line tank
to regenerate the desiccant. Since this heated air
can hold considerably more moisture than
unheated air, only about half the amount of
dried compressed air is needed for regeneration.
Although the addition of the heater and
associated components raises the initial capital
investment for a heated dryer, less diverted
compressed air means lower operating costs.
EH heated desiccant dryer
To air system
Heated dryers offer a compromise between
operating efficiency and capital investment.

Heated Blower

This type of dryer does not divert dried

compressed air from the air system to remove From air compressor

moisture from the desiccant in the off-line tank.

Rather, it employs its own high performance
centrifugal blower to direct ambient air through
a heater and then through the off-line tank.
There the stream of heated air regenerates the
desiccant. Heated blower technology requires the
highest initial capital investment, but with no or
little diversion of compressed air from the
system for regeneration, it offers significantly
lower operating costs than the other two
desiccant dryer technologies.

So, how do you select the right desiccant dryer

technology? That depends on the variables, such as
system demand, compressed air capacity, air quality To air system
HB heated blower desiccant dryer
requirements, and applicable life cycle costs, that Heated blower dryers offer the lowest
operating cost.
are unique to your compressed air system.

Desiccant Dryers 5
Ingersoll Rand HL Heatless
Desiccant Dryer
entering the dryer, and an after-filter to make
sure that only clean dried air exits the dryer.
As an additional design precaution, the dryer’s
switching valves are normally open and purge
valves normally closed, to allow air flow
through the dryer in case of power loss.

A standard feature of every Ingersoll Rand

heatless desiccant dryer is its NEMA 4 package,
providing increased protection of electrical
components, as well as advanced digital dryer
controls and displays. It includes a NEMA 4
electrical enclosure to protect against water and
condensation, a UL/ULC panel, and an advanced
digital electronic controller. In addition, every
HL comes standard with a compressor interlock
feature. This substantially prolongs compressor
life and improves reliability.

While reliability has been a key focus of its

design, the Ingersoll Rand HL heatless desiccant
HL heatless desiccant dryer
dryer is also a leader in its class for energy
efficiency and the health and safety of
Available in flows ranging from 120 SCFM operating personnel and the environment.
3 3
(3.4 nm /min.) to 1800 SCFM (51.0 nm /min.),
Ingersoll Rand HL heatless desiccant dryers are
designed to ensure a constant –40°F (-40°C) or
optionally –100°F (-70°C) pressure dew point,
virtually eliminating costly interruption of
production due to moisture. Clean air is further
assured by use of strategically placed filters: a
pre-filter to remove oil andcontaminants in air

6 Desiccant Dryers
Ingersoll Rand EH Heated and
HB Heated Blower Desiccant Dryers
The EH and HB dryers use high performance
ball or butterfly valves for switching and
purge operations. These non-lubricated valves
are designed specifically for high temperature
applications and feature stainless steel
internals, filled PTFE seats, and include
double-acting pneumatic actuators.

EH heated desiccant dryer

Both EH heated and HB heated blower models
Ingersoll Rand EH heated desiccant dryers provide the reliability and safety features of
incorporate an external heater to heat dry heatless dryers, with
purge air. This allows EH dryers to divert increased energy
significantly less dry air from the air system efficiency. These features
for regenerating desiccant than is required by include heatless back-
heatless dryers. up mode in the event
Available in sizes ranging from 400 SCFM of heater or blower
3 3
(11.3 nm /min.) to 2100 SCFM (59.5 nm /min.), malfunction, and an
Ingersoll Rand EH dryers deliver –40°F (-40°C) innovative solid-state
pressure dew point air for critical applications. relay heater control
to extend valve and
heater life. NEMA 4
Ingersoll Rand HB heated blower desiccant
electrical enclosures
dryers are equipped with dedicated durable
are standard and
centrifugal blowers to provide purge air for
include an advanced
regeneration, eliminating the need to divert dry
multi-function
compressed air from the air system. Instead,
digital controller.
the blower directs ambient air through an
external heater and then through the off-line
tower to regenerate the desiccant. This means
more compressed air is available for critical
downstream applications. Available in sizes
from 1000 SCFM (28.3 nm3/min.) to 8000 SCFM
HB heated blower desiccant dryer
(226.5 nm3/min.), Ingersoll Rand HB dryers
deliver –40°F (-40°C) pressure dew point air.

Desiccant Dryers 7
Benefits Of Desiccant Dryers
All of our desiccant dryers are designed with energy
efficiency, reliability, productivity and safety in mind:
• Engineered for low pressure drop through
valve selection, tower size and filter design
• Optional Energy Management System (EMS)
reduces purge consumption while maintaining
a constant dew point, monitors the dew point
and extends the dryer cycle, greatly
High efficiency heater reducing energy costs
reduces air needed to
• Large sound attenuating purge mufflers
regenerate desiccant.
minimize noise and include built-in relief
valves to enhance safety
After-filters help improve
air quality, increasing
productivity.
Low profile design, with angled manifolds,
makes maintenance a snap!
8 Desiccant Dryers
• Low profile places valves at operator’s level
and provides ready access to fill and drain
ports, increasing operator safety, and ease
of maintenance
• Pre-filter and after-filter protect desiccant
and downstream air from oil contamination
and particulates to help improve air quality,
increasing productivity
• Easy to replace stainless steel desiccant
screen keeps downtime to a minimum
• Heater and/or blower controlled by outlet
regeneration temperature that shuts off to
save electrical power once desiccant has
been thoroughly regenerated (available with
EMS on heated dryers)
Stainless steel desiccant
screens prevent
contamination of
the downstream air
system and are easily
removed for cleaning.
Ingersoll Rand Desiccant
Dryer Controls

All Ingersoll Rand desiccant dryers, models HL,

EH and HB, are supplied with a digital
electronic multi-function controller as standard
equipment. This is the dryer’s command center.

The advanced digital controller is programmed

to execute all valve switching functions, as well
as to completely monitor dryer operations.
Further, it is MODBUS compatible, permitting
connection to MODBUS-capable networks, and
it makes possible some remarkable enhanced
dryer operating functions. The controller’s
full-featured panel includes:

• Backlit LCD Display for viewing critical

dryer parameters in all lighting conditions

• Integrated keypad, providing user with

access to all internal functions and
selectable displays

• Schematic depiction of dryer, offering visual

indication of current operating status

• Remote alarm contact

• Failure code storage

• Multiple displays, from “Dryer On/Off

Control” to “Regeneration Sequence Status”

Desiccant Dryers 9
Global Reach...

Unsurpassed Local Customer Support

Ingersoll Rand provides its products and market channel partnership, mean that friendly
services directly or through distributors to Ingersoll Rand support is close at hand. In
customers in close to 200 countries. We focus addition to parts availability, qualified on-site
on providing innovation to increase your service is available globally.
productivity and profitability. Expect more
with Ingersoll Rand. We are your total
Preventative Maintenance and Warranty
solutions provider.
Factory training and certified Ingersoll Rand
technicians can protect your investment
Ready to Use Desiccant
by providing high quality preventative
Each dryer is shipped with a desiccant testing kit.
maintenance. In addition we can offer a
This allows the user to easily confirm the
comprehensive 7 year parts and labor warranty.
condition of the desiccant providing maximum
desiccant life and dew point performance.

Replacement Parts Made Easy

Ensure that you have all the right parts on
hand with our simplified ordering. Ingersoll
Rand’s reputation for dryer parts availability
is second to none.

Long Term Value The best overall value is getting

There is more to value than simply price.
the most out of your investment.
The commitment of many thousands of
Ingersoll Rand customer support
dedicated compressed air specialists, either
directly employed or members of a select
teams will help you protect
your investment.

10 Desiccant Dryers
Desiccant Dryer Specifications
Model Capacity Heater Blower In/Out Dimensions in./(mm) Weight
3
SCFM nm /min. kW hp/(kW) Connection in. Width Depth Height lbs./(kg)

HL120 120 3.4 – – 1.0 NPT 40.5/(1029) 30/(762) 63/(1600) 563/(256)

HL160 160 4.5 – – 1.5 NPT 44.5/(1130) 32/(813) 66/(1676) 707/(321)
HL200 200 5.7 – – 1.5 NPT 44.5/(1130) 32/(813) 66/(1676) 731/(332)
HL250 250 7.1 – – 1.5 NPT 48.5/(1232) 32/(813) 67/(1702) 869/(395)
HL300 300 8.5 – – 2.0 NPT 48.5/(1232) 32/(813) 67/(1702) 924/(419)
HL400 400 11.3 – – 2.0 NPT 52.5/(1334) 32/(813) 68/(1727) 1115/(506)
HL500 500 14.2 – – 2.0 NPT 56.5/(1435) 34/(864) 82/(2083) 1564/(710)
HL600 600 17.0 – – 2.0 NPT 56.5/(1435) 34/(864) 82/(2083) 1664/(755)
HL800 800 22.7 – – 3.0 NPT 64/(1626) 42/(1067) 88/(2235) 2017/(916)
HL1000 1000 28.3 – – 3.0 NPT 64/(1626) 42/(1067) 88/(2235) 2237/(1016)
HL1200 1200 34.0 – – 3.0 NPT 64/(1626) 42/(1067) 88/(2235) 2424/(1100)
HL1500 1500 42.5 – – 4.0 FLG 78.5/(1994) 55/(1397) 81/(2057) 2974/(1350)
HL1800 1800 51.0 – – 4.0 FLG 84/(2134) 61/(1549) 94/(2388) 3905/(1773)

EH400 400 11.3 4.5 – 2.0 NPT 56.5/(1435) 34/(864) 82/(2083) 1539/(699)
EH500 500 14.2 4.5 – 2.0 NPT 56.5/(1435) 34/(864) 82/(2083) 1707/(775)
EH600 600 17.0 6 – 3.0 NPT 64/(1626) 47/(1194) 86/(2184) 2369/(1076)
EH800 800 22.7 7.5 – 3.0 NPT 64/(1626) 47/(1194) 86/(2184) 2681/(1217)
EH1000 1000 28.3 9 – 3.0 NPT 78.5/(1994) 48/(1219) 80/(2032) 3043/(1382)
EH1200 1200 34.0 12 – 3.0 NPT 78.5/(1994) 48/(1219) 80/(2032) 3285/(1491)
EH1500 1500 42.5 15 – 3.0 NPT 84/(2134) 55/(1397) 92/(2337) 4480/(2034)
EH1800 1800 51.0 18 – 4.0 FLG 84/(2134) 60/(1524) 92/(2337) 4956/(2250)
EH2100 2100 59.5 18 – 4.0 FLG 84/(2134) 60/(1524) 92/(2337) 5350/(2429)

HB1000 1000 28.3 24 7.5/(5.6) 3.0 NPT 78.5/(1994) 48/(1219) 80/(2032) 3767/(1710)
HB1200 1200 34.0 24 7.5/(5.6) 3.0 NPT 78.5/(1994) 48/(1219) 80/(2032) 4091/(1857)
HB1500 1500 42.5 30 15/(11.2) 3.0 NPT 84/(2134) 55/(1397) 92/(2337) 5515/(2504)
HB1800 1800 51.0 36 15/(11.2) 4.0 FLG 84/(2134) 60/(1524) 92/(2337) 6113/(2775)
HB2100 2100 59.5 45 15/(11.2) 4.0 FLG 84/(2134) 60/(1524) 92/(2337) 6911/(3138)
HB3000 3000 84.9 60 20/(14.9) 4.0 FLG 96/(2438) 66/(1676) 98/(2489) 9730/(4417)
HB4000 4000 113.3 80 25/(18.7) 6.0 FLG 102/(2591) 76/(1930) 90/(2286) 12167/(5524)
HB5000 5000 141.6 100 30/(22.4) 6.0 FLG 138/(3505) 87/(2210) 97/(2464) 13375/(6072)
HB6000 6000 169.9 125 30/(22.4) 6.0 FLG 150/(3810) 92/(2337) 103/(2616) 16000/(7264)
HB8000 8000 226.5 175 40/(29.8) 8.0 FLG 168/(4267) 98/(2489) 105/(2667) 19900/(9035)

Performance data per CAGI Standard 200 ADF 200

Maximum working pressure is 150 psig (10.3 barg)
Desiccant is factory installed on all models except HB3000 to HB8000
Dimensions and weights are approximate

Desiccant Dryers 11
Ingersoll Rand Industrial Technologies provides products, services and solutions to enhance the efficiency and
productivity of our commercial, industrial and process customers. Our innovative products include air compressors,
air systems components, tools, pumps, material and fluid handling systems and microturbines.

www.air.ingersollrand.com

Ingersoll Rand compressors are not designed, intended or approved for breathing air applications. Ingersoll Rand does not approve specialized equipment for breathing air applications
and assumes no responsibility or liability for compressors used for breathing air service.
Nothing contained on these pages is intended to extend any warranty or representation, expressed or implied, regarding the product described herein. Any such warranties or other
terms and conditions of sale of products shall be in accordance with Ingersoll Rand’s standard terms and conditions of sale for such products, which are available upon request.
Product improvement is a continuing goal at Ingersoll Rand. Designs and specifications are subject to change without notice or obligation.

Member of
R E S S U
P
R
E
K N O W

C MPRESSED AIR
CHALLENGE
®

www.cagi.org

Printed in USA ©2006 Ingersoll-Rand Company Limited XXXXXXXX Form 3508

 ELECTRICAL INFORMATION

HL, EH & HB
DESICCANT AIR DRYERS
Point of Manufacture – West Chester, PA, USA

Date: March 29, 2007

Revision 0

ELECTRICAL DETAILS

MCA MOP
MODEL
(amps) (amps)
HL @ 115/1/60 4 5

Heater MCA MOP Model Heater MCA MOP

MODEL (60 Hz)
KW (amps) (amps) (50Hz) Kw (amps) (amps)
EH300 3 5.1 6 EH300 3 6.1 7
EH400 4.5 7.5 8 EH400 4.5 8.9 10
EH500 4.5 7.5 8 EH500 4.5 8.9 10
EH600 6 9.8 10 EH600 6 11.8 12
EH800 9 14.5 15 EH800 9 17.5 20
EH1000 9 14.5 15 EH1000 9 17.5 20
EH1200 12 19.2 20 EH1200 12 23.1 25
EH1500 15 23.9 25 EH1500 15 28.9 30
EH1800 18 28.6 30 EH1800 18 34.6 35
EH2100 18 28.6 30 EH2100 18 34.6 35

Heater Blower MCA MOP

MODEL
KW HP (amps) (amps)
HB1000 24 7.5 49 50
HB1200 24 7.5 49 50
HB1500 30 15 71 80
HB1800 36 15 81 90
HB2100 45 15 93 100
HB3000 60 20 123 125
HB4000 80 25 165 175
HB5000 100 30 199 200
HB6000 125 30 239 250
HB8000 175 40 330 350
 EH HEATED
DESICCANT AIR DRYER
EH400 – EH2100
Air Solutions Date: 4 December 2006
Davidson, NC 28036 Cancels: New

ENGINEERING DATA – 60HZ

EH400 EH500 EH600 EH800 EH1000

Inlet Capacity (scfm) 400 500 600 800 1000

Purge (scfm) 30 38 45 60 75
Desiccant per tower (lbs) 302 374 504 635 700
Tower Diameter (inches) 16 16 20 20 24
Electrical 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60
Heater Rating (kw) 4.5 4.5 6 7.5 9
Average Heater kw 3.4 3.4 4.5 5.6 6.8
Air In/Out Connections (inches) 2" NPT 2" NPT 3" NPT 3" NPT 3" NPT
Width (inches) 56.5 56.5 64 64 78
Depth (inches) 38 40 52 52 57
Height (inches) 82 82 88 88 80
Shipping Weight (lbs) 1539 1707 2369 2681 3043

EH1200 EH1500 EH1800 EH2100

Inlet Capacity (scfm) 1200 1500 1800 2100

Purge (scfm) 90 113 135 158
Desiccant per tower (lbs) 800 1100 1300 1464
Tower Diameter (inches) 24 30 30 30
Electrical 460/3/60 460/3/60 460/3/60 460/3/60
Heater Rating (kw) 12 15 18 24
Average Heater kw 9 11.3 13.5 18
Air In/Out Connections (inches) 3" NPT 3" NPT 4" FLG 4" FLG
Width (inches) 78 84 84 84
Depth (inches) 57 68 67 64
Height (inches) 80 92 92 92
Shipping Weight (lbs) 3285 4480 4956 5350
• Capacity on all models is based on 100°F, 100 psig.
Maximum allowable inlet temperature is 120 F. Maximum inlet pressure is 150 psig. Safety valve set point is 165 psig
• NEMA cycle time for -40°F is8 hours. 3 hours of heating and 1 hour of cooling
 8 7 6 5 4 3 2 1
REVISIONS
54.00 CONTROLLER LCD DISPLAY POWER ON LIGHT ZONE REV ECN DESCRIPTION DATE DWN APPVD
1) DRYER ON/OFF CONTROL
3.00 (TYP) 2) DRYER ALARM LEFT TOWER REGEN LIGHT
FACE OF AIR INLET & OUTLET
(OPTIONAL 3-VALVE BYPASS) 3) HEATER OPERATION & TEMP CONTROL LEFT TOWER DRYING LIGHT
4) HIGH HEATER TEMP ALARM
5) HEATER FAILURE ALARM HEATER ON LIGHT
6) LEFT/RIGHT TOWER DRYING
7) LEFT/RIGHT TOWER REGEN
8) FAILURE TO SHIFT ALARM ALARM LIGHT
9) REGEN SEQUENCE STATUS
10) HIGH HUMIDITY ALARM (OPTIONAL) RIGHT TOWER REGEN LIGHT
D 11) ENERGY MANAGEMENT SYSTEM (EMS)
RIGHT TOWER DRYING LIGHT D
(OPTIONAL)
54.50
2.00 (TYP)
CONTROLLER PUSH BUTTONS
1) ON
77.00 2) OFF CONTROLLER & DISPLAY PANEL DETAIL
3) RESET
4) TEST
67.69 5) SET
47.00 6) SELECT DISPLAY
7) ENTER
43.00 8) +/-

22.50

2.69
OPTIONAL TOWER INSULATION
C (SHOWN IN THIS VIEW ONLY) C
PILOT AIR SHUT-OFF
VALVE CL OF AIR INLET
(4) .56'' O MOUNTING HOLES
3'' NPT AIR INLET
42.38 FACE OF INLET 12.00 CONNECTION
DESICCANT FILL PORT INLET FLOW VALVE
PREFILTER

L
CONTROLLER AND
DISPLAY PANEL CL OF AIR INLET
(SEE DETAIL)

TOWER PRESSURE GAUGE

TOWER TEMPERATURE GAUGE PURGE VALVE

CL OF AIR OUTLET
PURGE MUFFLER
B 91.88 B
RELIEF VALVE
ELECTRICAL
ENCLOSURE 68.81
NEMA 4 3'' NPT AIR OUTLET
CONNECTION
PURGE PRESSURE
GAUGE AFTERFILTER
48.00 ZTF TYPE ''G''
PURGE ADJUSTMENT
BLUE MOISTURE INDICATOR VALVE HEATER
PILOT AIR FILTER
OUTLET FLOW VALVES
DESICCANT DRAIN PORT

INLET PURGE
CHECK VALVES
22.50 24.50 FACE OF OUTLET
84.00 CL OF AIR OUTLET
42.38 18.00
54.00

A PROPRIETARY NOTICE NOUN CODE

A
UNLESS OTHERWISE SPECIFIED, REMOVE ALL BURRS
ALL DIMENSIONS ARE IN INCHES, THIS DRAWING CONTAINS CONFIDENTIAL AND TRADE SECRET
AND SHARP CORNERS
TOLERANCES ARE: INFORMATION, IS THE PROPERTY OF INGERSOLL-RAND CO., AND
IS GIVEN TO THE RECEIVER IN CONFIDENCE. THE RECEIVER BY
FRACTIONS DECIMALS ANGLE
± X/XX ± .50 ± X.X°
RECEPTION AND RETENTION OF THE DRAWING ACCEPTS THE CAD GENERATED DRAWING,
*NOTES: ± X.XXX
DRAWING IN CONFIDENCE AND AGREES THAT, EXCEPT AS AU-
THORIZED IN WRITING BY INGERSOLL-RAND CO. IT WILL (1) NOT
NO MANUAL REVISIONS ALLOWED DRAWN
THIRD ANGLE PROJECTION
DATE
TITLE
GENERAL ARRANGEMENT
1) MAXIMUM WORKING PRESSURE - 150 P.S.I.
2) SAFETY RELIEF VALVE SETTING - 165 P.S.I
USE THE DRAWING OR ANY COPY THEREOF OR THE CONFIDEN-
TIAL OR TRADE SECRET INFORMATION THEREIN; (2) NOT COPY SAJ 10/30/06 EH 1500
CHECKED
3) PILOT AIR LINES NOT SHOWN FOR CLARITY THE DRAWING; (3) NOT DISCLOSE TO OTHERS EITHER THE DRAW-
ING OR THE CONFIDENTIAL OF TRADE SECRET INFORMATION SIZE ESTIMATED WEIGHT DRAWING NO. REVISION
4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL
COPYRIGHT @ 2006
580012
THEREIN; AND (4) UPON COMPLETION OF THE NEED TO RETAIN
ELECTRICAL CODE'S LATEST EDITION. THE DRAWING, OR UPON DEMAND, RETURN THE DRAWING, ALL
COPIES THEREOF, AND ALL MATERIAL COPIED THEREFROM. INGERSOLL-RAND COMPANY
APPROVED
B -
SCALE: UNIT: SHEET
D O N OT SCAL E ALL RIGHTS RESERVED CFW 11/20/06 NONE 1 OF 1
8 7 6 5 4 3 2 1
 250-450 HP SINGLE STAGE UNITS
250-500 HP TWO STAGE UNITS
OPERATORS/
INSTRUCTION MANUAL
OPTIONS

Before installation or starting the compressor for the

first time, this manual should be studied carefully to
obtain a clear knowledge of the unit and of the duties
to be performed while operating and maintaining the
unit.

RETAIN THIS MANUAL WITH UNIT.

This Technical manual contains IMPORTANT SAFETY
DATA and should be kept with the air compressor at
all times.

More Than Air. Answers.

Online answers: http://www.air.irco.com
Phone: 1-800-526-3615

CCN: 80440431 REV: B FORM: APDD 746B

November 2002
 AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material
and workmanship for a period of twelve months (see extended airend warranty) from the date of placing the Equipment
in operation or eighteen months (see extended airend warranty) from the date of shipment from Davidson, NC, whichever
shall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to
the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair
to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed
maintained and operated such Equipment in accordance with good industry practices and has complied with specific
recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others,
shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the
Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs
of labor performed by the Purchaser or others without Company’s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are limited
to those specifically stated within the Company’s proposal. Unless responsibility for meeting such performance warranties
are limited to specified tests, the Company’s obligation shall be to correct in the manner and for the period of time
provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in
writing of its intention to do so. Any such Equipment will be at Purchaser’s sole risk and liability.

Note that this is Ingersoll-Rand’s standard warranty. Any warranty in force at the time of purchase of the compressor or
negotiated as part of the purchase order may take precendence over this warranty.

GENERAL INFORMATION
Weight ..............................See foundation plan, Section 8.0

Cooling Air Flow .............See foundation plan, Section 8.0

Ambient Temperature Limits ..........................35°F to 115°F

...........................................................................((2°C to 46°C)

Coolant.............................Factory Filled SSR Ultra Coolant

Coolant Change ............................8000 hours or two years

............................................................whichever comes first
Coolant Capacity
250-300 HP.......................................33.0 gallons (125 liters)
250-300 HP Two Stage....................40.0 gallons (152 liters)
300E HP............................................33.0 gallons (125 liters)
350-450 HP.......................................38.0 gallons (144 liters)
350-500 HP Two Stage....................42.0 gallons (160 liters)

Discharge Temperature Limit .........................228°F (109°C)

Power Inlet Wiring .........................Recommended conduit:

............................metallic flexible Greenfield, or equivalent

Tools ..............................................U.S. standard and metric

...................................are required to perform maintenance

©INGERSOLL-RAND COMPANY
ROTARY SCREW AIR COMPRESSOR

This unit was purchased from:

_______________________________________________

_______________________________________________

_______________________________________________

Ingersoll-Rand Company reserves the right to make

changes or add improvements without notice and without
incurring any obligation to make such changes or add such
improvements to products sold previously.

Number of units on order: __________________________

Customer Order Number: __________________________

Ingersoll-Rand Company Order Number: ______________

For ready reference, record the serial number and

model number of your unit here:

Serial Number: ___________________________________

Model Number:___________________________________

1
TABLE OF CONTENTS 6.0 TROUBLESHOOTING

0.0 SAFETY AND WARNINGS 7.0 OPTIONS

0.1 safety instructions 7.1 power outage with scheduled start/stop
0.2 safety precautions 7.2 sequencer
0.3 decals 7.3 low ambient
7.4 separator delta-p solenoid
1.0 RECEIPT OF EQUIPMENT 7.5 separator delta-p sensor
1.1 inspection 7.6 high dust filter
1.2 unpacking and handling 7.7 lead/lag cycle length
1.3 tools 7.8 schedule start/stop
7.9 remote load/unload
2.0 INSTALLATION 7.10 modbus
2.1 ventilation 7.11 integral sequencing
2.2 foundation requirements
2.3 piping 8.0 REFERENCE DRAWINGS
2.4 electrical installation 8.1 electrical schematic - built-in star-delta
2.5 outdoor sheltered 8.2 electrical schematic - remote star-delta
8.3 electrical schematic - remote high voltage
8.4 foundation plan - 250-300 hp, 300E; A/C
3.0 INTELLISYS®
8.5 foundation plan - 250-300 hp, A/C, two stage
3.1 intellisys controls
8.6 foundation plan - 250-300 hp, 300E; W/C
3.2 display screen
8.7 foundation plan - 250-300 hp, W/C, two stage
3.3 current status 8.8 foundation plan - 350-450 hp, A/C
3.4 main menu 8.9 foundation plan - 350-450 hp, A/C, two stage
3.5 operator setpoints 8.10 foundation plan - 350-450 hp, W/C
3.6 options 8.11 foundation plan - 350-500 hp, W/C, two stage
3.7 sensor calibration 8.12 foundation plan - 250-300 hp, A/C extended
3.8 alarm history 8.13 foundation plan - 250-300 hp, A/C extended,
3.9 warnings two stage
3.10 alarms 8.14 foundation plan - 250-300 hp, W/C extended
8.15 foundation plan - 250-300 hp, W/C extended,
4.0 SCHEDULED PREVENTATIVE MAINTENANCE two stage
4.1 maintenance schedule 8.16 flow schematic, A/C
4.2 maintenance records 8.17 flow schematic, A/C, two stage
4.3 maintenance procedures 8.18 flow schematic, W/C-90°F (32°C)
4.4 inlet air filter 8.19 flow schematic, W/C-90°F (32°C), two stage
4.5 coolant filter 8.20 flow schematic, W/C-115°F (46°C)
4.6 coolant 8.21 flow schematic, W/C-115°F (46°C), two stage
4.7 separator tank scavenge screen/orifice 8.22 typical system flow diagram
4.8 coolant separator element
9.0 WATER QUALITY RECOMMENDATIONS
4.9 cooler cores (cleaning)
4.10 motor lubrication
10.0 MAINTENANCE RECORD
4.11 long term storage
4.12 coolant/lubricant changeout
4.13 intellisys removal
4.14 coolant hoses
4.15 fluid and vibration monitoring
4.16 coolant sampling procedure

5.0 SYSTEMS
5.1 general system information
5.2 air cooled compressors
5.3 coolant system
5.4 compressed air system
5.5 coolant/air separation system
5.6 electrical system
5.7 stepper motor inlet control
5.8 capacity control system
5.9 automatic start/stop control
5.10 remote start/stop

2
0.0 SAFETY AND WARNINGS Safety instructions in the operators manual are bold-faced
0.1 SAFETY INSTRUCTIONS for emphasis. The signal words DANGER, WARNING and
Before you install this air compressor you should take the CAUTION are used to indicate hazard seriousness levels
time to carefully read all the instructions contained in this as follows:
manual.

Electricity and compressed air have the potential to cause
severe personal injury or property damage.
Before installing, wiring, starting, operating or making any
adjustments, identify the components of the air
compressor using this manual as a guide.
The operator should use common sense and good
working practices while operating and maintaining this
unit. Follow all codes, pipe adequately, understand the
starting and stopping sequence. Check the safety devices
by following the procedure contained in this manual.
Maintenance should be done by qualified personnel,
adequately equipped with proper tools. Follow the
maintenance schedules as outlined in the operators
manual to ensure problem free operation after start up.
0.2 SAFETY PRECAUTIONS
Danger is used to indicate the presence of
D! DANGER a hazard which will cause severe personal
injury, death, or substantial property
damage if the warning is ignored.
Warning is used to indicate the presence of
! WARNING a hazard which can cause severe personal
injury, death, or substantial property
damage if the warning is ignored.
Caution is used to indicate the presence of
! CAUTION a hazard which will or can cause minor
personal injury or property damage if the
warning is ignored.
Notice is used to notify people of
NOTICE installation, operation, or maintenance
information which is important but not
hazard-related.

BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
COMPRESSOR OR PERFORMING ANY MAINTENANCE
WARNING
COMPRESSED AIR AND ELECTRICITY
ARE DANGEROUS.
BEFORE DOING ANY WORK ON THIS
UNIT, BE SURE THE ELECTRICAL SUPPLY
HAS BEEN CUT OFF–LOCKED & TAGGED
AND THE ENTIRE COMPRESSOR SYSTEM
HAS BEEN VENTED OF ALL PRESSURE.
1. Do not remove the covers, loosen or
remove any fittings, connections or
devices when this unit is in operation. Hot
liquid and air under pressure that are
contained within this unit can cause
severe injury or death.
2. The compressor has high and
dangerous voltage in the motor starter and
control box. All installations must be in
accordance with recognized electrical
codes. Before working on the electrical
system, be sure to remove voltage from
the system by use of a manual-
disconnect-switch. A circuit breaker or
fuse safety switch must be provided in the
electrical supply line leading to the
compressor.
Those responsible for installation of this
equipment must provide suitable grounds,
maintenance clearance and lightning
arrestors for all electrical components as
stipulated in O.S.H.A. 1910.308 through
1910.329.
SAFETY PRECAUTIONS
3. Do not operate the compressor at higher
discharge pressure than those specified
on the Compressor Nameplate or motor
overload will occur. This condition will
result in compressor motor shutdown.
4. Use only safety solvent for cleaning the
compressor and auxiliary equipment.
5. Install a manual shut off valve (isolation
type) in the discharge line. When a safety
valve is installed between the isolation
valve and the compressor, it must have
sufficient capacity to relieve the full
capacity of the compressor(s).
6. Whenever pressure is released through
the pressure relief valve, it is due to
excessive pressure in the system. The
cause for the excessive pressure should
be investigated immediately.
7. Before doing any mechanical work on
the compressor:
a.) Shut the unit down.
b.) Electrically isolate the compressor by
use of the manual disconnect switch in the
power line to the unit. Lock and tag the
switch so that it cannot be operated.
c.) Vent pressure from the compressor and
isolate the unit from any other source of
air.
8. There can be adverse effects if
compressor lubricants are allowed to enter
plant air systems.
Air line separators, properly selected and
installed, will minimize any liquid carry-
over.
The use of plastic bowls on line filters
without metal guards can be hazardous.
From a safety standpoint, metal bowls
should be used on any pressurized
system. Review of your plant air line
system is recommended.
9. When a receiver is installed, it is
recommended that occupational safety
and health standards as covered in the
Federal Register, Volume 36, number 105,
part 11, paragraph 1910.169 be adhered to
in the installation and maintenance of this
receiver.
10. Before starting the compressor, its
maintenance instructions should be
thoroughly read and understood.
11. After maintenance functions are
completed, covers and guards must be
replaced.

3
 SAFETY SHUTDOWN
CHECK HIGH AIR TEMPERATURE
There is a high discharge air temperature shutdown function built into the Intellisys on each compressor. It is factory pre-set
at 228°F (109°C). This function should be checked at regular intervals for proper operation, once a month is recommended.
The procedure is:

1. Block off the cooling air discharge.

2. The compressor discharge temperature will rise at a rapid rate. Shutdown should occur when the discharge
temperature reaches the pre-set maximum discharge air temperature setting of the Intellisys. The display should
indicate “HIGH AIREND DISCH TEMP” and flash “ALARM”.

The actual temperature at which shutdown occurs should be recorded for comparison to the Intellisys set point and with
similar future test results.

WARNING
Failure to adhere to these recommendations can result in mechanical failure, property damage and serious injury or death.

All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must take
into account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In addition, it
should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility between
discharge piping, system accessories and software must be assured.

For the foregoing reasons, the use of plastic piping, soldered copper fittings and rubber hose as discharge piping is not
recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit
the operating parameters of the system.

It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine.

WARNING
“Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air. Ingersoll-Rand does not approve
specialized equipment for breathing air application and assumes no responsibility or liability for compressors used for
breathing air services.”

4
0.3 DECALS

This section contains representative examples of decals recommend that you obtain a replacement kit as listed in
which will be appearing throughout this manual and are the spare parts section of the Parts List Manual Form
applied to the compressor unit. If for some reason a APDD 735 for single stage and Form APDD 736 for two
decal is defaced, painted over, or parts are replaced, we stage units.

! WARNING ! WARNING ! WARNING

Hazardous voltage. Can cause

severe injury or death.
Disconnect power before servicing.
Lockout/Tagout machine.
39540174 Rev. 05
Hot surface. High pressure air.
Can cause severe injury. Can cause severe injury or death.
Do not touch. Allow to cool before Relieve pressure before removing filter
servicing. plugs / caps, fittings or covers.
39541362 Rev. 04 39540240 Rev. 04

CAUTION
39878657 Rev. 03 Improper maintenance of
coolant filter can cause
compressor damage.
*PORO OPTION
39584529 Change coolant filter after first
150 hours of operation and
every 2000 hours thereafter or
*REMOTE START- when coolant is changed.
STOP OPTION
39547708 39544143 Rev. 03

*FOOD GRADE
COOLANT OPTION
39568803
VIEWED
FROM
Lift Here FRONT ! WARNING
39540273 Rev. 04

2 REQUIRED - BASE Filler Cap.

Use only
! CAUTION
recommended coolant.
Read instruction book Use of incorrect coolant can cause
before servicing. system contamination.

Use only SSR ULTRA COOLANT.

39543921 Moving parts.
Can cause severe injury.

39543921 Rev. 03 39540265 Rev. 05

Do not operate with covers removed.
Service only with machine blocked to
* FOOD GRADE COOLANT * FOOD GRADE COOLANT prevent turn over.
OPTION ONLY OPTION 39568464
39540224 Rev. 04

*ITEMS MARKED WITH * ARE OPTIONS THAT

ARE AVAILABLE

5
 0.3 DECALS (continued)

! WARNING ! WARNING
Compressor Package Data
COMPRESSOR MODEL...............................
CAPACITY...................................................... CFM
RATED OPERATING PRESSURE................. PSIG
MAX. DISCHARGE PRESSURE................... PSIG
PSIG
Rotation. MAX. MODULATE PRESSURE.....................
NOMINAL DRIVE MOTOR............................
NOMINAL FAN MOTOR................................
TOTAL PACKAGE AMPS...............................
H.P.
H.P.

VOLTS............................................................
PHASE / HERTZ............................................
Moving parts. 39540182 Rev. 04 CONTROL VOLTAGE.....................................
SERIAL NUMBER..........................................
Can cause severe injury.
Exposed fan blade. Can cause severe CONTACTOR AMP. RATING.....................................
ASSEMBLY AMP. RATING........................................
injury. LOCKED ROTOR AMP. RATING OF ASSY. ............
Do not operate with covers removed. AIR SOLUTIONS GROUP
DAVIDSON, NORTH CAROLINA 28036
Service only with machine blocked to WWW.AIR.INGERSOLL-RAND.COM 39557095 Rev.05

prevent turn over. Do not operate with covers removed.

Disconnect power. Lock and tag. 39557095 Rev.05

39540224 Rev. 04 39540190 Rev. 04

Rotation.
Air
Discharge
! WARNING 39540257 Rev. 04
39544150 Rev. 03

Electrical
power inlet.
39541354 Rev. 03

Hot surface.
Can cause severe injury.

Do not touch. Allow to cool before

servicing. Condensate
drain.
39541362 Rev. 04
39541081 Rev. 04

*
Water out.
NOTICE
39541321 Rev. 04
To obtain satisfactory compressor
operation and maintenance a minimum
of 3 feet clearance on 3 sides is
VIEWED required 3-1/2 feet is required in front of
the control panel (or minimum required by
* FROM latest National Electrical code or
applicable local codes).
Water in. REAR Refer to the Instruction / Operators
Manual before any maintenance.
39541339 Rev. 03

Lift Here ! CAUTION

39540273 Rev. 04
Incorrect lifting of machine
can cause injury or property
! DANGER Do not operate without enclosure
panels and forklift covers in place.
damage.
Enclosure panels will affect performance.
Lift only from base channels.

39540232 Rev.03

Discharge air.
Can contain carbon monoxide or Motors must be greased periodically.
other contaminants. Will cause See Operators Manual for procedure.
severe injury or death.

Do not breathe this air. 39857552 Rev. 04

* WATERCOOLED UNITS ONLY 39540166 Rev. 06

6
0.3 DECALS (continued)

Compressor Package Data

COMPRESSOR MODEL...............................
CAPACITY...................................................... CFM
RATED OPERATING PRESSURE................. PSIG
MAX. DISCHARGE PRESSURE...................
MAX. MODULATE PRESSURE.....................
NOMINAL DRIVE MOTOR............................
NOMINAL FAN MOTOR................................
PSIG
PSIG
H.P.
H.P.
! WARNING
TOTAL PACKAGE AMPS...............................
VOLTS............................................................
PHASE / HERTZ............................................
CONTROL VOLTAGE.....................................
SERIAL NUMBER..........................................

CONTACTOR AMP. RATING.....................................

ASSEMBLY AMP. RATING........................................
LOCKED ROTOR AMP. RATING OF ASSY. ............
AIR SOLUTIONS GROUP
DAVIDSON, NORTH CAROLINA 28036
WWW.AIR.INGERSOLL-RAND.COM 39557095 Rev.05
Hazardous voltage. Can cause
39557095 Rev.05 - 2 REQUIRED severe injury or death.

Only use factory supplied inlet for

incoming power. See Operators/
Electrical Instruction manual.
Manual.
power inlet.
39541354 Rev 03 39543764 Rev. 04

! WARNING

! WARNING

Hazardous voltage. Can cause

severe injury or death.

Disconnect power before servicing.

Lockout/Tagout machine.
Hazardous voltage. Can cause
severe injury or death.
39540174 Rev. 05
Only use factory supplied inlet for
incoming power. See Operators/
Instruction manual.
Manual.

39543764 Rev. 03

NOTICE
IEC Starter Overload Setting

1. Full-Voltage Starter (Main or Fan Motor):

Multiply MOTOR nameplate amps by 1.11.

Star-Delta Starter (Main motors only):

Multiply MOTOR nameplate amps by 0.64. SCHEMATIC DECAL
2. Set corresponding overload relay at
this value.

3. Never exceed the following limits:

VOLTAGE DECAL OPTION
Full-Voltage Starter: 125% of MOTOR
nameplate amps. INSIDE STARTER BOX
Star-Delta Starter: 72% of MOTOR ON RIGHT SIDE
nameplate amps.

39921804 Rev. B

7
1.0 RECEIPT OF EQUIPMENT
1.1 INSPECTION
When you receive the compressor please inspect it
closely. Any indication of careless handling by the carrier
should be noted on the delivery receipt especially if the
compressor will not be immediately uncrated. Obtaining
the delivery man’s signed agreement to any noted
damages will facilitate any future insurance claims.

IMPORTANT
READ THIS
LOST OR DAMAGED GOODS

THOROUGHLY INSPECT THIS SHIPMENT

IMMEDIATELY UPON ARRIVAL

OUR RESPONSIBILITY FOR THIS SHIPMENT FORKLIFT PADDING

CEASED WHEN THE CARRIER SIGNED WILL REDUCE SCRATCHES
BILL OF LADING AND MARS

If goods are received short or in damaged condition, it is important that

you notify the carrier and insist on a notation of the loss or damage
across the face of the freight bill. Otherwise no claim can be enforced SPREADER
against the transportation company. BARS
If concealed loss or damage is discovered, notify your carrier at once
and request an inspection. This is absolutely necessary. Unless you do
this the carrier will not entertain any claim for loss or damage. The agent
will make an inspection and grant a concealed damage notation. If you
give the transportation company a clear receipt for goods that have been
damaged or lost in transit, you do so at your own risk and expense.

WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE

MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT THE
WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE
FOR COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL.
THE ACTUAL FILING AND PROCESSING OF THE CLAIM IS YOUR
RESPONSIBILITY.

Ingersoll-Rand Company
Davidson, North Carolina
APDDGFO-99-79

1.2 UNPACKING AND HANDLING

The compressor package has been mounted on a base
which provides for forklifting between the two side
channels to facilitate handling during shipment. Care in
positioning the forklifts is important because the location
of the center of gravity is strongly affected by the location
of the compression module and drive motor.

Slings can be used to lift the crates, but spreader bars IMPORTANT
must be used to prevent the slings from exerting a force
against the sides of the crates.
Before starting this air compressor unit, the
1.3 TOOLS shipping brace(s) must be removed.
Remove compressor unit from wooden skid. A crowbar Save the brace(s) for future use.
and hammer will be needed.
See tag in unit.
8
2.0 INSTALLATION
2.1 VENTILATION
Oil flooded rotary air compressors produce large
amounts of heat. Because of this large heat production,
the compressor must be placed in a room with adequate
ventilation.

If heated air from the compressor exhaust is allowed to

recirculate back to the compressor, the compressor will
overheat and shut down. This heat must be exhausted
from the room. You should take this into consideration
when you decide where to place the compressor within
your plant. Consider that the required maintenance
clearance is 3 ft (.9 m) all around the compressor.
However 42” (1.06m), or minimum required by latest NEC
or applicable local codes, must be maintained in front of
control panel.

Ambient temperatures higher than 115°F (46°C)

should be avoided as well as areas of high humidity.

42” (1.06m) OR
Consider also the environment surrounding or near CODE MINIMUM
36”
the compressor. The area selected for the location of (.9 m)
the compressor should be free of dust, chemicals,
metal filings, paint fumes and overspray.
36” (.9 m)

DUST CHEMICALS

METAL PAINT
FILINGS SPRAY

OVERSPRAY 2.3 PIPING

2.2 FOUNDATION REQUIREMENTS
Refer to the foundation plan for the particular model
compressor to be installed. See Section 8.0.
The compressor can be installed on any level floor that is
capable of supporting it. Compressor weights are listed
on the foundation plans.
When sound transmission is of particular importance it is
often helpful to install a sheet of rubber-fabric-matting, or
cork under the compressor to reduce the possibility of
resonant sounds being transmitted or amplified through
the floor.
NOTICE
Never elevate the compressor unit
above the floor level. This may allow air
to enter the cabinet under the base.
Performance will be affected.
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
oil. From a safety standpoint, metal bowls should be used
on any pressurized system. Review of your plant air line
system is recommended.
WARNING
Do not use plastic pipe, soldered copper
fittings or rubber hose for discharge piping.
The built-in aftercooler reduces the discharge air
temperature well below the dew point (for most ambient
conditions), therefore, considerable water vapor is
condensed. To remove this condensation, each
compressor with built-in aftercooler is furnished with a
combination condensate separator/trap.
9
2.3 PIPING (Continued)
A dripleg assembly and isolation valve should be
mounted near the compressor discharge. A drain line
should be connected to the condensate drain in the
base.

IMPORTANT: The drain line must slope downward from

the base to work properly.

NOTE: For ease of inspection of the automatic drain trap

operation, the drain piping should include an open funnel.

It is possible that additional condensation can occur if the

downstream piping cools the air even further and low DISCHARGE PIPING WITH AFTERCOOLER
points in the piping systems should be provided with
driplegs and traps.

IMPORTANT: Discharge piping should be at least as

large as the discharge connection at the compressor
enclosure. All piping and fittings must be suitable for the
maximum operating temperature of the unit and, at a
minimum, rated for the same pressure as the compressor
sump tank.

NOTICE
Do not use the compressor
to support the discharge pipe.

Careful review of piping size from the compressor

connection point is essential. Length of pipe, size of pipe,
number and type of fittings and valves must be
considered for optimum efficiency of your compressor.

It is essential when installing a new compressor to review ROTARY-RECIP IN PARALLEL

the total plant air system. This is to ensure a safe and
effective total system.
200
Liquid water occurs naturally in air lines as a result of
compression. Moisture vapor in ambient air is 160
concentrated when pressurized and condenses when
Gallons of Water/24
hours/1000 acfm

cooled in downstream air piping.

120
Moisture in compressed air is responsible for costly
problems in almost every application that relies on 80
compressed air. Some common problems caused by
moisture are rusting and scaling in pipelines, clogging of 40
instruments, sticking of control valves, and freezing of
outdoor compressed air lines. Any of these could result in
partial or total plant shutdown. 0

DEW POINT
Compressed air dryers reduce the water vapor con-
without 100°F/38°C 35°F /1.7°C -40°F/-40°C
centration and prevent liquid water formation in (with (Refrigerated
Aftercooling (Desiccant
compressed air lines. Dryers are a necessary companion Aftercooler) Dryer) Dryer)
to filters, aftercoolers, and automatic drains for improving
the productivity of compressed air systems.
MOISTURE CONTENT OF COMPRESSED AIR
10
Two types of dryers, refrigerated or desiccant, are used
to correct moisture related problems in a compressed air
system. Refrigerated dryers are normally specified where
compressed air pressure dew points of 33°F (1°C) to
39°F (4°C) are adequate. Desiccant dryers are required PRESSURE
RELIEF
where pressure dew points must be below 33°F (1°C). VALVE

PRESSURE
Contact your local Ingersoll-Rand distributor for GAUGE

assistance in selecting correct Ingersoll-Rand filtration or

drying products.

NOTE: Screw type compressors should not be installed

in air systems with reciprocating compressors without a
means of pulsation isolation, such as a common receiver
tank. We recommend both types of compressor units be
piped to a common receiver utilizing individual air lines.

When two rotary units are operated in parallel, provide an

isolation valve and drain trap for each compressor before
the common receiver.

2.4 ELECTRICAL INSTALLATION

Before proceeding further, we recommend that you ROTARY TWO COMPRESSOR SYSTEM
review the safety data in the front of this manual.

Locate the compressor data plate on the side of the

cooler box or end of the unit.

The data plate lists the rated operating pressure, the

maximum discharge pressure and the electric motor
characteristics and power.
Confirm that the line voltage and compressor nameplate
voltage are the same and that the standard starter box
meets the intent of NEMA 1 guidelines.
Open the starter box door. Confirm that all electrical
connections are made and tightened. Confirm that the
control transformer is wired correctly for supply voltage.
See Figure 2.4-1 on next page for typical control
Compressor Package Data
COMPRESSOR MODEL...............................
CAPACITY...................................................... CFM
RATED OPERATING PRESSURE................. PSIG
MAX. DISCHARGE PRESSURE................... PSIG
MAX. MODULATE PRESSURE..................... PSIG
H.P.
NOMINAL DRIVE MOTOR............................
NOMINAL FAN MOTOR................................ H.P.
TOTAL PACKAGE AMPS...............................
VOLTS............................................................
PHASE / HERTZ............................................
CONTROL VOLTAGE.....................................
SERIAL NUMBER..........................................
CONTACTOR AMP. RATING.....................................
ASSEMBLY AMP. RATING........................................
LOCKED ROTOR AMP. RATING OF ASSY. ............
AIR SOLUTIONS GROUP
DAVIDSON, NORTH CAROLINA 28036
WWW.AIR.INGERSOLL-RAND.COM 39557095 Rev.05

transformer wiring.
39557095 Rev.05

11
 110

110

110
110V

FIGURE 2.4-1 TYPICAL CONTROL TRANSFORMER WIRING

ELECTRICAL INSTALLATION (Continued)

Inspect the motor and control wiring for tightness.

Close and fasten the starter box door.

ROTATION CHECK
Locate the rotation decal on each motor.
DRIVE
DRIVE MOTOR END
The correct compressor drive motor rotation is
clockwise when viewed from the rear or non-drive
end of the motor. See Figure 2.4-2.

NON-DRIVE
END
CAUTION

If the compressor is operated in the

opposite direction of rotation, airend damage
can result and is not warrantable. FIGURE 2.4-2 DRIVE MOTOR ROTATION

12
ELECTRICAL INSTALLATION (Continued) Fan motor rotation is clockwise when viewed from
The Intellisys will automatically shut the unit down if the the fan motor side.
compressor rotation is incorrect, and the display will
indicate “CHECK MOTOR ROTATION” and will flash INTELLISYS OPERATING INSTRUCTIONS
“ALARM”. Read and understand the following Intellisys Operating
Instructions (See Figure 2.4-4) prior to operating the unit.
For the compressor motor rotation check, the motor
jogging time must be as short as possible. NOTE: These instructions are also contained on
the decal near the Intellisys panel of the unit.
After depressing the start button, IMMEDIATELY
depress the “EMERGENCY STOP” button. Should the
motor rotation be incorrect, put main disconnect in
the OFF position, lock and tag. See Figure 2.4-3.

HASP

LEVER

TAG

KEY
LOCK

FIGURE 2.4-3 MAIN DISCONNECT

LOCKED AND TAGGED

Open the starter box door.

Interchange any two line connections (L1, L2 or L3) at

the starter. Close and fasten the starter box door.
Recheck for correct rotation.

FAN MOTOR
Observe the compressor cooling fan. The rotation should
be in accordance with the fan rotation decal affixed to the
fan motor. Cooling air should exhaust through fan end of
compressor enclosure.
FIGURE 2.4-4 INTELLISYS
Should the motor rotation not be correct, put the main OPERATING INSTRUCTIONS
disconnect in the OFF position, lock and tag.

Interchange any two fan motor leads at the fan motor

manual starter (MMS). Close and fasten the starter box
door. Recheck for correct rotation.

13
2.5 OUTDOOR SHELTERED INSTALLATION
Many times a compressor must be installed outside due
to jobsite conditions or limited space within a
manufacturing facility. When this occurs there are certain
items that should be incorporated into the installation to
help ensure trouble free operation. These items have
been listed below plus Figure 2.5-1 has been included to
show a typical outdoor sheltered installation. The unit
must be purchased with the Outdoor Modification Option
to provide NEMA 4 electrics and a cabinet exhaust on
the end of the unit rather than the top to prevent recir-
culation of cooling air.
■ The compressor should be on a concrete pad
designed to drain water away. If the concrete pad is
sloped, then the compressor must be leveled. In order
to properly pull cooling air through the aftercooler, the
base/skid must be sealed to the concrete pad.
■ Condensate drains must never be allowed to dump on
the ground. Run to a suitable sump for future
collection and disposal or separation of lubricant and
water mixture.
■ Incoming power connections must use suitable
connectors for outdoor weather tight service.
■ A minimum of 3 ft (.9 m) clearance must be allowed
on all four sides of the unit for service access. If
possible, access by a forklift and/or an overhead beam
hoist should be kept in mind (for eventual service to
airend or motor).
■ If the area around the installation contains fine
airborne dust or lint and fibers etc., then the unit
should be purchased with the High Dust Filter Option
and TEFC motors.

■ The roof of the shelter should extend a minimum of ■ If larger debris, such as leaves or trash, are blowing in
4 ft (1.2 m) around all sides of the compressor to pre- the area, the Inlet Panel Filter Accessory should be
vent direct rain and snow from falling on the unit. purchased and added to the unit (ship loose item).

■ Air-cooled machines must be arranged under the ■ Some type of protection such as a fence or security
shelter in a way that prevents air recirculation (i.e. hot system, should be provided to prevent unauthorized
exhaust back to the package inlet). access.

■ If the installation includes more than one compressor,

the hot air exhaust should not be directed towards the
fresh air intake of the second unit or an Air Dryer.

■ If a standard machine is to be installed outside, the

ambient temperature must never drop below 35°F
(1.7°C).

■ If ambient temperature drops below 35°F (1.7°C) to as

low as –10°F (–23°C) the unit must be supplied with
the Low Ambient Option. Installations below –10°F
(–23°C) ambient are not recommended. The Low
Ambient Option requires a separate power source to
operate internal heaters.

■ Arrange the machine with the Intellisys con-

troller/starter enclosure facing away from the sun as
radiant heat can affect starter/lntellisys performance.
Also direct sunlight and UV rays will degrade the
membrane touch panel. This is not a warrantable
situation.

■ Power disconnect switch should be within line of sight

and in close proximity to the unit. N.E.C. and local
electrical codes must be followed when installing the
power disconnect switch.

14
 FIGURE 2.5-1 TYPICAL OUTDOOR SHELTERED INSTALLATION

15
16
INGERSOLLrAND
INTELLISYS
3.0 INTELLISYS

INTELLISYS CONTROLLER
3.0 INTELLISYS
3.1 INTELLISYS CONTROLS
EMERGENCY STOP
Pressing this switch stops the compressor immediately.
The compressor can not be restarted until the switch is
manually reset. Turn the switch knob clockwise to
reset.
EMEG
STOP
POWER ON LIGHT
This indicates the control voltage and the line voltage
are available for starting.
POWER
ON
The operator panel is divided into two areas. The
bottom row of four buttons provides direct control over
the starting, stopping, unloading and loading of the
compressor. These are defined by the symbols printed
on the buttons themselves, as shown here.
START
Pressing this button will start the compressor if the
display shows “Ready To Start”. The compressor will
start and load if there is sufficient demand for air.
STOP
Pressing this button will activate the unloaded stop
sequence. If the compressor is running loaded, it will
unload and continue to run unloaded for an adjustable
10 to 30 seconds and then stop. If the compressor is
running unloaded, it will stop immediately.
UNLOAD
Pressing this button will cause the compressor to
unload and remain unloaded. The display will indicate
the machine is “Running Unloaded”, and “Mode:
UNLOAD”.
LOAD
Pressing this button will cause the compressor to load
if the compressor is running and if the “Discharge
Pressure” is less than the “Online Pressure”. This also
returns the machine to the operating mode that is
specified by the “Mode of Operation” set point.
The other five buttons provide access to various
operator-selectable functions and machine operating
conditions. The purpose of each of these buttons is
defined by the display screen and the particular
function being performed at that time.
ARROWS
These up and down buttons have multiple functions
relating to the right half of the display screen. When
lists are presented, the buttons are used to move up or
down through the items on the list. The small arrow(s)
displayed in the upper right corner of the display
screen indicate when you can move up (designated by
arrow head pointing up) and/or down (designated by
arrow head pointing down) through the list.
When the value of a specific machine operating
parameter is highlighted on the display screen for the
purpose of changing that value, the buttons are used
to change the value itself.
DISPLAY BUTTONS
The functions of the three buttons below the display
screen change and are defined by the words
immediately above them in the bottom line of the
screen. Each function, such as MAIN MENU, STATUS,
SET, etc., is described in appropriate sections in this
manual.
17
3.2 DISPLAY SCREEN

- CURRENT STATUS-
Package Discharge Temp
100 PSI 103°F

Running Loaded Airend Discharge Temp

Mode: MOD/ACS 193°F
MAIN MENU

The display screen is divided into three functional
areas, as seen in the typical CURRENT STATUS
screen shown here.
The left side continuously shows the package
discharge pressure in large numbers, with the line
directly below the numbers showing the running
condition of the machine, and the line below that
showing the present mode of operation.
The right side shows various items or lists such as the
machine’s CURRENT STATUS readings, the MAIN
MENU, the OPERATOR SETPOINTS list, etc. Any of
the lists can be moved up or down by pressing the
arrow buttons to the right of the screen. The small
arrow(s) displayed in the upper right corner of the
screen indicate when you can move up (designated by
arrow head pointing up) and/or down (designated by
arrow head pointing down) through a list. The arrow
buttons are also used to change an individual item’s
value. At certain times, items and/or their values are
“highlighted”. This means they are displayed as light
characters on a dark background.
The bottom of the screen is divided into thirds with the
words in each small box showing the function of the
button directly beneath it. The words will change in
these boxes depending on what actions are permitted
at any particular time. The action resulting from
pressing each of these buttons is indicated in Figure
3.2.1, which can be used as a quick reference of how
to step the controller screen through any desired
function.

3.3 CURRENT STATUS

-CURRENT STATUS-
Package Discharge Temp
100 PSI 103°F

Running Loaded Airend Discharge Temp

Mode: MOD/ACS 193°F
MAIN MENU
The CURRENT STATUS screen is considered the The controller automatically returns the display to this
“normal” display that the controller shows. CURRENT STATUS screen from other screens if no
buttons are pressed within 30 seconds.
The following items and their present values can be
displayed on the right side of the screen by pressing The MAIN MENU screen can be accessed from the
the up and down arrow buttons. CURRENT STATUS screen by pressing the MAIN
MENU button, identified by the words “MAIN MENU” in
CURRENT STATUS Items the bottom line of the screen directly above the center
Discharge Temperature Inlet Vacuum button.
Airend Discharge Temperature Inlet Filter
Injected Temperature Total Hours
Sump Pressure Loaded Hours
Separator Pressure Drop % Load Modulation
Unloaded Inlet Vacuum
Coolant Pressure
Time & Date
Coolant Filter Software Title
and Version
18
 “Status” CURRENT STATUS

“Main Menu”

“Status”
MAIN MENU*
“Main Menu”

“Select”

“Main Menu” “Main Menu” “Main Menu” “Main Menu” “Main Menu” “Main Menu”
OPERATOR SENSOR ALARM CLOCK INTEGRAL
OPTIONS**
SETPOINTS** CALIBRATION** HISTORY** FUNCTIONS SEQUENCING
“Status” “Status” “Status” “Status” “Status” “Status”

“Select” “Select” “Select” “Select” “Select” “Select”

OPERATOR SENSOR “Main Menu” ALARM “Main Menu” “Main Menu” INTEGRAL
OPTIONS DATE AND

Figure 3.2.1
INTELLISYS
SETPOINTS CALIBRATION HISTORY SEQUENCING
ITEM*** TIME
ITEM*** ITEM**** “Status” ITEM***** “Status” ITEM***
“Status”

“Cancel” or “Set” “Cancel” or “Set” “Cancel” or “Calibrate” “Alarm

“Cancel” Hist.”
or “Set” “Cancel
“Cancel”otorSet”
“set” “Cancel
“Cancel” ot Set”
or “set”

Operator Panel Flow Diagram

NOTE - Use the UP and DOWN arrows to move between selections. Items will be highlighted in inverse display mode.

* - Selecting the highlighted item will display the corresponding menu.

** - Selecting the highlighted item will place the value in edit mode. This is indicated by only the value being displayed in inverse display mode.
*** - The UP and DOWN arrows will alter the value. Depressing “Cancel” will exit the edit mode and leave the value unchanged. Depressing
“Set” will save the new value and flash the value to indicate acceptance.
**** - Depressing “Cancel” will exit calibration mode. Depressing “Calibrate” will calibrate selected sensor.
***** - Use UP and DOWN arrows to scroll through list of status items.

19
3.4 MAIN MENU

-MAIN MENU-
Operator Setpoints
100 PSI Options
Sensor Calibration
Ready To Start Alarm History
Clock Functions

STATUS SELECT

The MAIN MENU screen is the point from which
various operator functions can be accessed. Refer to
the reference diagram in Figure 3.2.1.
Each of the functions can be chosen by using the up
and down arrows to highlight it on the screen.
The controller will go to the highlighted function if the
SELECT button is pressed or will return to the
CURRENT STATUS screen if the STATUS button is
pressed.

3.5 OPERATOR SETPOINTS

-OPERATOR SETPOINTS-

Offline Pressure
100 PSI 103 PSI
Ready To Start Online Pressure
93 PSI

STATUS MAIN MENU SELECT

Setpoints are user-adjustable variables in the

controller logic that can be set using the OPERATOR Setpoints associated with options are described in the
SETPOINTS screen. OPTIONS Section 3.6.

The name and value of each of the setpoints listed A setpoint’s value can be changed by first highlighting
below can be seen on the screen by moving the list up the item and its value and pressing the SELECT
and down using the arrow buttons. button to highlight just the value. When the value line is
highlighted by itself, the value can be adjusted using
OPERATOR SETPOINTS RANGE STEP UNIT
the up and down arrow buttons. The CANCEL and
Lead/Lag Lead or Lag --- ---
SET buttons appear at this time. Press the SET button
Offline Pressure 75 to RATED +3 1 PSIG
to enter the new value, or press the CANCEL button to
Online Pressure 65 to OFFLINE - 10 1 PSIG
return to the value of the setpoint prior to using the
Lag Offset 0 to 45 1 PSIG
arrows. The displayed value will flash twice to indicate
Mode of Operation MOD/ACS, ON/OFF LINE, --- ---
it has been entered into the setpoint, and the pair of
MODULATION ONLY
setpoint item and value display lines will again be
Max Modulation Pressure Online + 10 to Offline + 7 1 PSIG
highlighted together.
Stop Delay Time 10 to 60 1 SEC
Star-Delta Time* 5 to 20 1 SEC
Operator set points can be exited by pressing the
(Screen) Contrast 0 to 10 1 ---
STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to
* Does not apply to automatic across the line starters.
the CURRENT STATUS screen.

20
3.5.1 Lead/Lag- This setpoint is used for setting lead
or lag operation. If set to lead, the controller will load
and unload the compressor by the online and offline
setpoints. If set to lag, the controller will subtract the
lag offset (see 3.5.4) from the online and offline set
points and operate the compressor at the lower
pressure range.
3.5.6 Max Modulation Pressure- This setpoint is the
pressure the compressor will unload at if it is
modulating. As the package discharge pressure rises
toward this value, the inlet valve will start to close. The
compressor will unload once the package discharge
reaches this value. See section 5.8 for more
information on modulation.

3.5.2 Offline Pressure- This setpoint is the pressure 3.5.7 Stop Delay Time- This setpoint is the minimum
the compressor will unload at if it is operating in on/off amount of time the compressor will run unloaded
line mode. before stopping. This period does not apply to alarms
(shutdowns).
3.5.3 Online Pressure- This setpoint is the pressure
the compressor will load at. 3.5.8 Star-Delta Time- This setpoint is only used with
star-delta starters. It is not used if the starter is full
3.5.4 Lag Offset- This setpoint is used with the voltage or a remote starter. This is the time period
lead/lag operation. If the lead/lag set point is set to lag between starting and star-delta transition.
(see 3.5.1), the value of the lag offset will be
subtracted from the online and offline setpoints. 3.5.9 Contrast- This setpoint is used to improve the
display on the Intellisys.
3.5.5 Mode of Operation- This setpoint is used to
select the operating mode of the compressor. The
choices are MOD/ACS, ON/OFF LINE, and
MODULATION ONLY. See section 5.8 for more
information on these operating modes.

3.6 OPTIONS

-OPTIONS-

Auto Restart
100 PSI Off

Ready To Start Auto Restart Time

10 MINUTES
STATUS MAIN MENU SELECT

Options are turned on or off and their associated

values are set using the OPTION screen. OPTIONS ITEMS RANGE STEP UNIT
Auto Restart On/Off --- ---
Auto Restart Time 2 to 60 1 MIN
Some options require additional machine hardware Auto Restart Delay Time 0 to 60 1 SEC
and the proper “Option Module” to plug into the Sequencer On/Off --- ---
Intellisys controller. Descriptions of the options Remote Start/Stop On/Off --- ---
operations are in Section 7.0. The name and value of Power Out Restart On/Off --- ---
Power Out Restart Time 10 to 600 1 SEC
each of the options listed in the right hand column can Low Ambient On/Off --- ---
be seen by moving the list up and down using the Min. Cooler Out Temp 30 to 150 1 Deg. F
arrow buttons. Separator Delta-P Solenoid On/Off --- ---
Separator Delta-P Sensor On/Off --- ---
Lead/Lag Cycle Length 0-750 1 HRS
An Option item’s value can be changed the same way Scheduled Start 00:00 to 23:59 1 TIME
OPERATOR SETPOINTS values are changed. See Scheduled Stop 00:00 to 23:59 1 TIME
Section 3.5 for an explanation. High Dust Filter On/Off --- ---
Modbus Protocol On/Off/ICU --- ---
Modbus Address 1 to 247 1 ---

21
3.6 OPTIONS (CONTINUED)
3.6.1 Auto Restart- This setpoint is used to enable or
disable the auto restart option.
3.6.2 Auto Restart Time- This setpoint is the minimum
time period the compressor must run unloaded before
it can stop in the auto restart mode.
3.6.3 Auto Restart Delay Time- If the compressor is
stopped in auto restart, this setpoint is the number of
seconds the package discharge pressure must remain
below the online pressure setpoint before the
compressor will restart.
3.6.4 Sequencer- This setpoint is used to enable or
disable sequencer operation.
3.6.5 Remote Start/Stpop- This setpoint is used to
enable or disable the remote start/stop option.
3.6.6 Power Out Restart- This setpoint is used to
enable or disable the power out restart option, if it is
installed.
3.7.7 Power Out Restart Time- If the power out
restart option is installed and enabled, this setpoint is
time period between power returning to the
compressor and the compressor starting.
3.6.8 Low Ambient- This setpoint enables or disables
the low ambient option. If the low ambient option is
enabled, sensor 3CTT must be installed in the
compressor.
3.6.9 Minimum Cooler Out Temperature- When the
low ambient option is installed, this setpoint is the
minimum temperature to which the coolant must rise
before the compressor will load.
3.6.10 Separator Delta-P Solenoid- This setpoint
enables or disables the separator delta-p solenoid
option. Enabling this option will automatically disable
the Separator Delta-P Sensor option.
22
3.6.11 Separator Delta-P Sensor- This setpoint
enables or disables the separator delta-p sensor
option. Enabling this option will automatically disable
the Separator Delta-P Solenoid option.
3.6.12 Lead/Lag Cycle Length- This setpoint enables
the automatic cycling between lead and lag operation.
If it is set to a value greater than 0, the controller will
cycle between lead and lag operation. The value of this
set point is the cycle length in real time hours. A value
of 0 will disable the automatic cycling between lead
and lag.
3.6.13 Scheduled Start- If the scheduled start/stop
option is installed, this set point is the time of the day
(hour and minute) that the compressor will
automatically start. To disable this option, set it to the
same value as the scheduled stop (section 3.6.14).
3.6.14 Scheduled Stop- If the scheduled start/stop
option is installed, this setpoint is the time of the day
(hour and minute) that the compressor will
automatically stop. To disable this option, set it to the
same value as the scheduled start (section 3.6.13).
3.6.15 High Dust Filter- This option enables or
disables the high dust filter operation.
3.6.16 Modbus Protocol- This option is for Ingersoll-
Rand service use only.
3.6.17 Modbus Address- This feature is used with the
Modbus Protocol and is for Ingersoll-Rand service use
only.
3.7 SENSOR CALIBRATION

-SENSOR CALIBRATION-

Sensor 1AVPT
1 0 00 PSI CALIBRATE

Ready To Start Sensor 3APT

CALIBRATE
STATUS MAIN MENU SELECT

Pressure sensor calibration is done through the

SENSOR CALIBRATION screen. Sensor calibration
can only take place when the machine is stopped.
Calibration needs to be done only after a sensor has
been replaced or the Intellisys controller has been
replaced.
Each of the sensors listed below can be chosen by
using the up and down arrow buttons to highlight it on
the screen.
Select the highlighted sensor by pressing the SELECT
button. Press the CALIBRATE button to start the
automatic calibration procedure, or press the CANCEL
button to not calibrate it and return to the sensor list.
The calibration screen can be exited by pressing either
the STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to
the CURRENT STATUS screen.

SENSOR CALIBRATION Items

Sensor 1AVPT
Sensor 3APT
Sensor 4APT
Sensor 5CPT
Sensor 6APT

3.8 ALARM HISTORY

-ALARM HISTORY-

Alarm History 1
100 PSI MOTOR OVERLOAD

Ready To Start Alarm History 2

HIGH AIREND DISCH TEMP
STATUS MAIN MENU SELECT

Alarm History displays each of the Alarm messages
for the last 15 Alarms experienced by the machine. It
also gives access to displaying the machine operating
conditions that existed at the time of each Alarm. The
first one shown, “Alarm History 1”, was the most
recent Alarm to occur. Note that multiple, consecutive
EMERGENCY STOP Alarms are not recorded as
separate Alarms, only the first one will be shown.
Each of the last 15 Alarm messages can be seen by
moving the Alarm History list up and down using the
arrow buttons. Pressing the SELECT button when one
of the Alarms is highlighted will display the list of
machine values that existed at the time that particular
Alarm occurred.

23
 -ALARM HISTORY 1-

Package Disch Pressure

100 PSI 199 PSI

Ready To Start Package Discharge Temp

103°F
STATUS MAIN MENU ALARM HISTORY

The name and value of each of the items listed below

can be seen by moving the list up and down using the
arrow buttons. Pressing the ALARM HIST. button will Alarm histories can be exited by pressing either the
return the display to the ALARM HISTORY screen. STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to the
ALARM HISTORY Items CURRENT STATUS screen.
Discharge Pressure Coolant Filter
Discharge Temperature Inlet Vacuum
Airend Discharge Temperature Inlet Filter
Injected Temperature Total Hours
Sump Pressure Loaded Hours
Separator Press. Drop % Load Modulation
Unloaded Inlet Vacuum
Coolant Pressure
Time & Date

3.9 CLOCK FUNCTIONS

-CLOCK FUNCTIONS-

Time
100 PSI 01:15

Ready To Start Date

Jan 01, 00
STATUS MAIN MENU SELECT

The date and time for the real time clock is set through If DATE is selected, first the month will be highlighted.
the CLOCK FUNCTIONS screen. Use the up and Adjust the month by using the up and down arrows
down arrows to highlight either TIME or DATE. Select and then press SET to highlight the date. Once the
the highlighted setting by pressing SELECT. correct date is displayed, press SET to highlight the
year. Once the correct year is displayed, press SET to
If TIME is selected, first the hours will be highlighted. complete setting the date.
Adjust the hours (00-23 hour clock) by using the up
and down arrows. Once the correct time is in the
display, press SET to highlight the minutes. Adjust the
minutes (00-59) and then press SET to complete
setting the time.

24
3.10 INTEGRAL SEQUENCING

-INTEGRAL SEQUENCING-
Lead Compressor
100 PSI Off

Ready To Start Total Compressors

2

STATUS MAIN MENU SELECT

Integral Sequencing is set up using the INTEGRAL INTEGRAL SEQUENCING RANGE STEP UNIT
SEQUENCING screen. A description of integral is in Lead Compressor On/Off/Always/Never --- ---
section 7.0. The name and value of each of the Total Compressors 2 to 4 1 ---
integral sequencing setpoints as listed in the right Compressor Address 1 to Total Compressors 1 ---
hand column can be seen by moving the list up and Load Delay Time 10 to 60 1 SEC
down using the arrow buttons. Lead Change - Hours 0 to 750 1 HRS
Lead Change - Day Sun to Sat, Daily, Week 1 DAY
3.10.1 Lead Compressor- The choices for this Day, Week End
setpoint are On, Off, Always, and Never. On, means Lead Change - Time 00:00 to 23:59 1 TIME
the compressor is the lead unit. Off, means the
compressor is not the lead unit, but it could become
the lead unit. If Always is selected, the compressor is
the lead unit and it will not transfer the lead to another
3.10.5 Lead Change - Hours- This is the number of
compressor. Never, means the compressor is not the
hours the compressor will operate as the lead unit.
lead unit and will never become the lead unit. The
Once a compressor has operated as the lead for this
operator must set one unit (and only one) to On or
number of hours, it will transfer the lead to the next
Always to start integral sequencing.
compressor in the sequence. This setpoint does not
apply to a unit where the lead compressor is set to
3.10.2 Total Compressors- This is the total number of
always or never. If this setpoint is set to 0, the next 2
compressors in the integral sequence. This setpoint
setpoints will determine when the lead is transferred.
must be set to the same number on each compressor.
3.10.6 Lead Change - Day & Lead Change - Time-
3.10.3 Compressor Address- This is the address of
These two setpoints are used together. If the Lead
the compressor in the integral sequence. No two
Change - Hours setpoint is set to 0, these two
compressors can have the same address. Two
setpoints will be used to determine when the
compressors with the same address will cause
compressor will transfer the lead to the next
communication failures.
compressor in sequence. Lead Change - Day is the
day of the week that the compressor will transfer the
3.10.4 Load Delay Time- This is the number of
lead. Lead Change - Time is the time of the day that
seconds the lead compressor will wait for the package
the compressor will transfer the lead.
discharge pressure to start rising after issuing a load
command to another compressor. If the package
discharge pressure has not started rising at the end of
this time period, the lead compressor will load the next
compressor in the sequencer.

25
 3.11 WARNINGS
100 PSI
Running Unloaded
Mode: MOD/ACS
STATUS MAIN MENU
When a Warning occurs, a question mark will flash on
the display screen and appear in large letters as
shown above. The display message will indicate what
caused the warning.
If multiple Warnings exist, the small up/down arrows
100 PSI
Running Unloaded
Mode: MOD/ACS
WARNING MAIN MENU
Pressing the WARNING button will return the display
to the WARNING screen and the RESET button.
A Warning needs to be reset by the operator by
pressing the RESET button twice.
The possible Warning messages are as follows.
AIREND DISCHARGE TEMP- This will occur if the
Airend Discharge (2ATT) exceeds 97% of the alarm
limit, 228°F (109°C), and is not adjustable.
CHANGE COOLANT FILTER- This warning will occur
if the high side pressure is 20 psig (1.4 bar) greater
than the low side pressure of 1 DPS, and the Injected
Coolant temperature (2CTT) is greater than
120°F (49°C).
CHANGE INLET FILTER- This will occur if the Inlet
Vacuum (1AVPT) is greater than 0.7 psig (.05 bar) and
the machine is fully loaded (inlet valve is completely
open).
CHANGE SEPR ELEMENT- This warning will occur if
the pressure on the Separator (3APT) is 12 psig
(.8 bar) greater than the pressure at the Package
Discharge (4APT), and the machine is fully loaded.
26
?
Change Inlet Filter
Press RESET Twice
RESET
will appear in the upper right corner of the display
screen. The multiple Warnings can be seen by
pressing the up and down arrow buttons. Pressing the
STATUS button will display the CURRENT STATUS
screen with the WARNING button indicating a Warning
still exists.
-CURRENT STATUS-
Package Discharge Temp
103°F
Airend Discharge Temp
193°F
HIGH DISCHARGE PRESS- This can occur if the
machine’s loading function is being controlled by a host
device, such as a sequencer or an lSC. This warning
will occur when the package discharge pressure is
above the maximum offline pressure (rated pressure
plus 3 psig [.2 bar]) for more than 3 seconds. This
warning will cause the compressor to unload. The host
device will not be able to load the compressor until the
package discharge pressure falls to the rated pressure
of the machine.
SENSOR FAILURE 4ATT- This will occur if the
Package Discharge Temperature Sensor (4ATT) is
recognized as missing or broken.
AUXILIARY 1 (OR 2) - This warning will occur if either
of the auxiliary contacts closes.
HIGH SUMP/LINE DIF - This warning will occur if the
compressor is running loaded, the injected coolant
temperature is greater than or equal to 120 deg. F,
(49°C) the package discharge pressure is greater than
90 psig, (6.3 bar) the sump pressure is greater than the
compressor’s rated pressure, and the sump pressure is
25 psig (1.8 bar) or more above the package discharge
pressure.
 3.11 WARNINGS (CONTINUED)
COMMUNICATION FAIL 1 (or 2 - 4) - This warning
will occur if the compressor is the lead unit while using
integral sequencing and is unable to communicate with
another compressor.
SERVICED REQUIRED - The Intellisys has 2 levels of
service. The service level can be set at the factory or
by an Ingersoll-Rand service representative. Either
service level will issue a “SERVICE REQUIRED”
warning at 150 hours. This warning is a reminder for
initial service and can be cleared by the operator.
Level 1 - If service level 1 (default) is selected, a
“SERVICE REQUIRED” warning will be issued every
2000 operating hours. This warning is to serve as a
reminder to have the unit serviced and can be cleared
by the operator.
Level 2 - If service level 2 is selected, service
warnings will be issued every 2000 operating hours
(default) or in 3, 6, 9, or 12 month intervals, as
selected at the factory or by an I-R service
3.12 ALARMS
100 PSI
STOPPED BY ALARM
Mode: MOD/ACS
STATUS MAIN MENU
When an Alarm occurs, an exclamation mark will flash
on the display screen as shown above. The display
message will indicate what caused the Alarm.
100 PSI
STOPPED BY ALARM
Mode: MOD/ACS
ALARM MAIN MENU
The name and value of each of the items listed can be
seen by moving the list up and down using the arrow
buttons. Pressing the ALARM button will return the
display to the Alarm screen and the RESET button.
representative. Service warnings at level 2 are issued
in 3 stages. First a “100 HOURS TO SERVICE” or 14
DAYS TO SERVICE” (depending on the service
interval type) warning will be issued. This warning will
let the operator know that the time for service is
approaching and can be cleared by the operator.
Following that, 100 hours or 14 days later a “SERVICE
REQUIRED” warning will be issued. This warning can
be temporarily cleared by the operator, however it will
return 24 hours later if service has not been performed
by an I-R service representative. A new service period
will start when service is performed. If another 100
hours or 14 days elapses and service has not been
performed, an “ALARM-SERVICE REQUIRED”
warning will be issued. This warning can only be
cleared by an I-R service representative.
SENSOR FAILURE 6APT - This warning will occur if
the separator delta-p sensor option is installed and
sensor 6APT is recognized as missing or broken.
High Airend Disch Temp
229°F
Press RESET Twice
RESET
Pressing the STATUS button will display the ALARM
STATUS screen with the ALARM button indicating an
Alarm still exists. Alarm Status is the list of machine
operating conditions that existed at the time of the
Alarm.
-ALARM STATUS-
Package Disch Pressure
100 PSI
Package Discharge Temp
103°F
The Alarm needs to be reset by the operator by
pressing the RESET button twice. Any exceptions to
this are explained in the alarm descriptions.
27
The possible Alarm messages are as follows.
CHECK INLET CONTROL- This will occur if the
machine is unloaded and the inlet vacuum is less than
3 psig (.2 bar).
CHECK INLET CTRL SYS 1 (2) - This will occur if the
inlet butterfly valve fails to open or close properly. A 1
means the inlet valve failed to closer properly. A 2
means the inlet valve failed to open properly.
CHECK MOTOR ROTATION- This will occur if the
machine is started and the compressor has incorrect
rotation.
CONTROL POWER LOSS- This will occur if the
controller detects a loss of the 110 VAC or 120 VAC
control power.
EMERGENCY STOP- This will occur if the Emergency
Stop button is engaged. The button must be
disengaged before the alarm can be cleared.
FAN MOTOR OVERLOAD- This will occur if a fan
motor overload is sensed.
HIGH AIREND DISCH TEMP- This will occur if the
airend discharge temperature is greater than 228°F
(109°C).
LOW SUMP AIR PRESSURE- This will occur if the
machine is running fully loaded and the sump pressure
drops below 20 psig (1.4 bar).
LOW UNLOAD SUMP PRESS- This will occur if the
machine is running unloaded and the sump pressure
is less than 15 psig (1.0 bar) for 15 seconds.
MAIN MOTOR OVERLOAD- This will occur if a drive
motor overload is sensed.
CHECK SET POINTS- This will occur if the controller
has determined some of the data stored in memory
contains unacceptable values. When this occurs, the
sensors should be calibrated and all the set points
checked. It is normal for this alarm to occur after
changing controller software.
28
REMOTE START FAILURE- This will occur if the
Remote Start button is pressed after the machine is
running or if the Remote Start button remains closed.
REMOTE STOP FAILURE- This will occur if the
Remote Stop button remains open and either Start
button is pressed.
SENSOR FAILURE 1AVPT (or 3APT, 4APT,
5CPT,2CTT, 2ATT, 3CTT) - This will occur if a sensor
is recognized as missing or broken. This does not
apply to sensor 4ATT.
STARTER FAULT 1SL (2SL)- This will occur if the
starter contacts open while the machine is running. It
will also occur if the machine is given the stop
command and the starter contacts do not open. 1SL
refers to the auxiliary circuit on starter contact 1M. 2SL
refers to the auxiliary circuit on starter contacts 2M
and 1S.
STEPPER LIMIT SWITCH- This will occur if both limit
switches are activated at the same time.
INVALID CALIBRATION- This will occur during the
calibration process if the sensor reads greater than
20% of scale.
LOW COOLANT PRESSURE- This will occur if the
compressor is running and the following conditions are
met. The coolant must be less than 1 psi and either
the sump pressure is greater than 10 psi or the inlet
vacuum is less than 12 psi.
4.0 SCHEDULED PREVENTATIVE MAINTENANCE
4.1 MAINTENANCE SCHEDULE
THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE
COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT
NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST.

Running Time Interval (whichever comes first)

Action Part or Item Hours 1 Week 1 Mo. 3 Mo. 6 Mo. Yearly 2 Years

Inspect Coolant level Weekly x

Inspect Discharge temperature (air) Weekly x
Inspect Separator element differential Weekly x
Inspect Air filter Delta P (at full load) Weekly x
Inspect Oil filter Delta P Weekly x
Replace Coolant filter* 150 x (initial change only)
Check Temperature sensor 1000 x
Replace Food grade coolant (when used) 1000 x
Inspect Hoses 1200 x
Replace Coolant filter* 2000 x (subsequent changes)
Analysis Coolant 2000 See Section 4.15 x
Analysis Vibration 2000 See Section 4.15 x
Clean Separator scavenge screen and orifice 4000 x
Clean Cooler cores** 4000 x
Replace Air filter* 4000 x
Replace Separator element* *See special note.
Replace Ultra Coolant* 8000 x
Inspect Starter contactors 8000 x
Service Drive motor lubrication See Section 4.10.

* In very clean operating environments and where inlet filter is changed at the above prescribed intervals.
In extremely dirty environments change coolant, filters, and separator elements more frequently.

** Clean cooler cores if discharge air temperature is excessive or if unit shutdown occurs on high air temperature.

4.2 MAINTENANCE RECORDS 4.3 MAINTENANCE PROCEDURES

It is very important that you, the owner, keep accurate
and detailed records of all maintenance work you, or the
Ingersoll-Rand Distributor or Air Center perform on your
compressor. This includes but is not limited to coolant
filter, separator, inlet air filter and so forth. This
information must be kept by you, the owner, should you
require warranty service work by your Ingersoll-Rand
Distributor or Air Center. Maintenance record sheets are
located at the back of this manual.
Before starting any maintenance, be certain the following
is heeded.
1. Read Safety Instructions.
2. Use correct tools.
3. Have recommended spares on hand.
SPECIAL NOTE:
Replace separator element when the separator
differential pressure ( ▲ P) reaches three times the
initial pressure drop or a maximum pressure
differential of 12 psi (.8 bar) at full load or if the
Intellisys warning CHANGE SEPARATOR ELEMENT is
displayed. See Section 3.9.

29
4.4 INLET AIR FILTER
To check condition of the inlet filter, run compressor in
the LOADED mode and observe “Inlet Filter” on the
CURRENT STATUS display screen. If the display says
“Inlet Filter OK”, then no maintenance is required. If “ ? ”
is flashing on the screen and the display says “CHANGE
INLET FILTER”, then the inlet filter should be changed.

To change inlet filter elements, loosen wing nut on top of

inlet filter housing. Lift cover up and away to expose
element/s.
INLET AIR FILTER
Carefully remove the old element/s to prevent dirt from
entering the inlet valve. Discard old element/s.

Thoroughly clean the element housing and wipe all

surfaces.

Install new element/s and inspect to ensure that they

have seated properly.

Install top of inlet filter housing. CAUTION

Inspect the rubber seal on the retainer wing nut and Improper maintenance of
replace seal if required. coolant filter can cause
Tighten wing nut.
compressor damage.

Start machine and run in the load mode to verify filter Change coolant filter after first
condition. 150 hours of operation and
every 2000 hours thereafter or
4.5 COOLANT FILTER when coolant is changed.
To check the condition of the coolant filter, the
compressor must be running. Observe “Injected
Temperature” on the CURRENT STATUS display screen.
If the temperature is less than 120°F (49°C), continue to
run the machine. When the temperature is greater than
120°F (49°C), observe “Coolant Filter” on the screen. If
the display says “Coolant Filter OK”, then the filter does
not need service. If “ ? ” is flashing on the screen and the
display says “CHANGE COOLANT FILTER”, then the
filter should be replaced.

Use a suitable device and loosen the old element. Use

drain pan to catch any leakage during removal. Discard VALVE
old element. FURNISHED
ONLY ON
Wipe the sealing surface of the filter with a clean, lint-free UNITS
EQUIPPED
rag to prevent the entry of dirt into the system. WITH
LUBRICANT
Remove the replacement element from its protective PUMP
package. Apply a small amount of clean lubricant on the
rubber seal and install the element.

Screw element/s on until the seal makes contact with the

head of the filter assembly. Tighten approximately
one-half turn additional. COOLANT FILTER
Start unit and check for leaks.

30
4.6 COOLANT Coolant fill quantity

■ SSR Ultra Coolant (Standard Factory Fill)

■ SSR H1-F Food Grade (Optional) 250-300 hp ....................................................33.0 gallons (125 liters)

SSR Ultra Coolant is a polyglycol base coolant. Change 250-300 hp - 2 stage......................................40.0 gallons (152 liters)
Ultra Coolant after every 8000 hours or every two years, 300E hp .........................................................33.0 gallons (125 liters)
whichever comes first.
350-450 hp .....................................................38.0 gallons (144 liters)
SSR Food Grade Coolant is a polyalphaolefin base 350-500 hp - 2 stage......................................42.0 gallons (160 liters)
coolant. Change after every 1000 hours or every 6
months whichever comes first. Do not operate unit
beyond this 1000 hour lubricant change interval, as
lubricant degradation will occur.

Items Required
In addition to the tools normally found in any reasonably
equipped serviceman’s toolbox, the following items
should be available at the work site:

1) Suitable drain pan and container to hold lubricant

drained from unit.
2) A quantity of proper lubricant sufficient to refill the
compressor.
3) A minimum of one replacement coolant filter element
of the proper type for the unit to be worked on.
COOLANT DRAIN
There is a coolant drain hose supplied with each
compressor. The drain hose is placed in the starter box
when shipped from the factory.
WARNING
The coolant should be drained soon after the compressor
has been shut down. When the coolant is hot, drainage
will be more complete and any particles in suspension in
the coolant will be carried out with the coolant.

Hot coolant can cause severe injury. Use care when

draining separator tank.
Hot coolant can cause severe injury.
Use care when near this area.
To drain the unit, remove plug from drain valve located on
the bottom of the separator tank. Install supplied drain
hose and fitting assembly in end of drain valve and place
end of hose in a suitable pan. Open drain valve to start
drainage. After draining is complete, close valve, remove
Filler Cap.
hose and fitting assembly from valve, and store in a
Use only
suitable location for future use. Replace plug in end of
drain valve. recommended coolant.
Read instruction book
Do not store drain hose in starter box after it has before servicing.
been used to drain the separator tank.

39543921

UNITS WITH FOOD GRADE

COOLANT OPTION ONLY

31
4.6 COOLANT (Continued)

After the unit is drained and a new coolant filter element

is installed, refill the system with fresh coolant. Bring the
receiver level of coolant up to the midpoint of the sight
glass. Replace the fill cap. Start the compressor and run
it for a short time. The correct coolant level is at the
midpoint of the sight glass with the unit running in the
‘UNLOADED” mode.

4.7 SEPARATOR TANK

SCAVENGE SCREEN/ORIFICE

TOOLS REQUIRED
■ Open end wrench
■ Pliers

PROCEDURE
The screen/orifice assemblies are similar in appearance
to a straight tubing connector and will be located
between two pieces of 1/4 inch O.D. scavenge line
tubing.

The main body is made from 1/2 inch hexagon shaped

steel and the diameter of the orifice and a direction-of-
flow arrow is stamped in flat areas of the hexagon.

A removable screen and orifice is located in the exit end

of the assembly (See Figure 4.7-1) and will require
cleaning as outlined in the Maintenance Schedule,
Section 4.1.
FIGURE 4.7-1 SEPARATOR TANK SCAVENGE
To remove the screen/orifice, disconnect the scavenge SCREEN/ORIFICE
line tubing from each end. Hold the center section firmly
and use a pair of pliers to gently grasp the exit end of the
assembly that seals against the scavenge line tubing.
Pull the end out of the center section while using care to
prevent damage to the screen or sealing surfaces.

Clean and inspect all parts prior to reinstallation.

When the assembly is installed, confirm the direction of

flow to be correct. Observe the small arrow stamped in
the center section and ensure the direction flow to be
from the separator tank to the airend.

32
4.8 COOLANT SEPARATOR ELEMENT
To check condition of separator element, run WARNING
compressor in full load mode and at rated pressure and
observe “Separator Pressure Drop” on the CURRENT
STATUS display screen. If the display says “xxPSI”, then
no maintenance is required. If “ ? ” is flashing on the
screen and the display says “CHANGE SEPR
ELEMENT”, then the separator element should be
replaced.
This machine contains high air pressure
Disconnect the scavenge tube at the airend. which can cause severe injury or death
from hot oil or flying parts.
Loosen the fitting that holds the scavenge tube into the Always relieve pressure before removing caps,
tank and withdraw the tube assembly. plugs, covers or other parts. Blow down
pressurized air system. Close isolation valve.
See Operator’s Instruction Manual.
Disconnect the piping from the tank cover. Tag the lines
if required.

Use a suitable wrench and remove the bolts that hold

the tank cover in position. Remove cover by lifting up
and away.

Carefully lift the separator element up and out of the RECOMMENDED BOLT TIGHTENING
tank. Discard the faulty element. CROSS PATTERN

Clean the gasket surface on both the tank and its cover.
Exercise care to prevent pieces of the old gasket from
falling down into the tank.

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 gaskets for
possible damage. Center the element up within the
tank.
250-500 HP
Place the tank cover in its correct position and install
bolts. Tighten the bolts in a cross-pattern to prevent
over-tightening one side of the cover. An improperly
tightened cover will likely result in a leak.

Tank cover bolt torque values

250-450 HP 3/4-10 UNC 210ft-lb. (285 n-M)

Inspect tank scavenge screen and orifice. Clean if

necessary following instructions in Section 4.7.

Install scavenge tube down into the tank until the tube
just touches the separator element and then raise it 1/8
inch (3.2 mm). Tighten fittings.

Install the regulation lines in their original position.

Start unit, check for leaks, place in service.

33
 4.9 COOLER CORES: CLEANING COOLANT COOLERS
Following are instructions for removal and internal
Ensure the compressor is isolated from the cleaning of coolant coolers.
compressed air system by closing the isolation valve
and venting pressure from the drip leg. Coolant Cooler
■ Remove panels and top cover.
Ensure the main power disconnect switch is locked ■ Drain the coolant. See Section 4.6.
open and tagged. (See Figure 4.9-1). ■ Remove side panels from coolant cooler box.
■ Disconnect piping from coolant cooler inlet and outlet
ports.
■ Plug cooler inlet and outlet ports to prevent possible
contamination.
■ Remove coolant cooler holding screws from sides of
coolant cooler and remove cooler through side of
cooler shroud.
HASP
Coolant Cooler Cleaning
■ It is recommended the cooler be taken to a
professional cooler service shop for flushing with an
LEVER
appropriate environmentally safe cleaning agent.
■ Reassemble in reverse order.
TAG ■ Make sure fan guards are replaced.
■ Refill the compressor with coolant. If contamination is
suspected, replace with new coolant.
KEY LOCK ■ Replace fill plug.
■ Run compressor for ten minutes. Check for possible
leaks. Check coolant level.
■ Replace enclosure panels.
FIGURE 4.9-1 MAIN DISCONNECT
LOCKED AND TAGGED

TOOLS REQUIRED
■ Screwdriver
■ Wrench set
■ Air hose equipped with approved O.S.H.A. nozzle.
On units sold outside the U.S.A. consult CAUTION
local codes.
Strong cleaners can harm
PROCEDURE
aluminum cooler parts. Follow cleaner
Visually check the outside of the cooler cores to be
manufacturer’s instructions for use.
certain that a complete outside cleaning of the cooler is
required. Frequently, dirt, dust or other foreign material, Wear appropriate safety equipment.
may only need to be removed with an air hose to remedy
the problem.

When the cooler is covered with a combination of

oil, grease or other heavy substances that may
affect the unit’s cooling, then it is recommended
that the cooler cores be thoroughly cleaned on the
outside.

If it is determined that the compressor operating

temperature is higher than normal due to the internal
passages of the cooler cores being restricted with
deposits or foreign material, then the cooler should be
removed for internal cleaning.

34
AFTERCOOLER
Following are instructions for the removal and internal
cleaning of aftercoolers.

Aftercooler
■ Disconnect hose from aftercooler inlet flange.
■ Disconnect tube from aftercooler outlet flange.
■ Remove aftercooler holding screws from aftercooler
support and remove cooler.

Aftercooler Cleaning
■ It is recommended the cooler be taken to a
professional cooler service shop for flushing with an
appropriate environmentally safe cleaning agent.
■ Reassemble in reverse order.
■ Replace enclosure panels.

35
4.10 MOTOR LUBRICATION
The induction-type squirrel cage motors have antifriction
ball or roller bearings front and rear. At periodic intervals
they require relubrication.

Relubrication Interval - 60 Hz
(or 9 months, whichever comes first)
1000 hours ......................................all TEFC drive motors
2000 hours .........all ODP drive motors and all fan motors

Relubrication amount
NOTICE
Lubricant Amount
Motor Frame Size in3 cc oz. grams

56-145*
182-215 .5 8 .4 11
254-286 1.0 16 .8 23
324-365 1.5 25 1.2 34
404-449 2.5 40 2.0 57
5000 Frame Series 1.0 16 .8 23

* No greasing required (permanently lubricated bearings)

CAUTION Motors must be greased periodically.

See Operator’s Manual for procedure.
Overgreasing can be a cause of bearing and
motor failure. Make sure dirt and contaminants
are not introduced when adding grease.

Procedure for relubrication

CAUTION

Grease should be added when the motor

is stopped and power disconnected.

When regreasing, stop motor. Disconnect power; lock out

and tag. Remove outlet plugs (or spring-loaded grease
relief plugs if present). The outlet plug may not be
accessible on the fan end of some TEFC motors.

36
4.10 MOTOR LUBRICATION (Continued)
Grease relief along shaft can occur, precluding necessity
of removing this plug if inaccessible. The inlet grease gun
fittings and outlet plugs (or spring-loaded reliefs) are
located at each end of the motor housing. The drive end
! WARNING
reliefs protrude out the circumference of the lower portion
of the end bell near a flange bolt. The drive end outlet
plugs are located just behind the flange in the air intake
area at about the 5 or 6 o’clock position.

1) Free drain hole of any hard grease (use piece of wire

if necessary).

2) Use a hand lever type grease gun. Determine in

advance the quantity of grease delivered with each
Hazardous voltage. Can cause
stroke of the lever. A graduated cylinder showing
severe injury or death.
cubic centimeters (cc) may be used, or a 35mm film
canister can give a close approximation for 2 cubic Disconnect power before servicing.
inches when filled. Lockout/Tagout machine.

3) Add the recommended volume of the recommended

lubricant. Do not expect grease to appear at the
outlet, but if it does, discontinue greasing at
once.

4) Run motor for about 30 minutes before replacing out-

MOTOR BEARING MAINTENANCE
let plugs or reliefs. BE SURE TO SHUT MOTOR
(STORED UNITS)
DOWN, DISCONNECT POWER, LOCK OUT AND
To ensure that complete contact is maintained between
TAG, AND REPLACE THESE DRAIN FITTINGS TO
the motor bearings and the bearing grease on units to be
PRECLUDE LOSS OF NEW GREASE AND
placed in storage for extended intervals, the following
ENTRANCE OF CONTAMINANTS!
motor maintenance procedure should be adhered to:

1) Prior to placing a unit in storage, rotate the motor

Recommended Motor Grease
several revolutions by hand in the proper direction of
rotation.
Most motors require:
2) Thereafter, rotate the motor as described in Step 1 at
Mobilith SHC 220 (39218193)
three month intervals until such time as the unit is
placed in service.
Use the grease as indicated on a special grease
information nameplate on the motor. Use of alternative
3) If the storage time is to exceed a total of nine (9)
greases can result in shortened motor life due to
months duration, the compressor must be ordered
incompatibility of greases. If there is not a grease
with long term storage option.
nameplate on the motor use:

Chevron Black Pearl #2 (39204292)

(Preferred)

Chevron SRI 2 (39161641)

37
4.11 LONG TERM STORAGE
GENERAL
The factory, upon special request, prepares compressor
units for long term storage. In such cases, a special
bulletin is supplied for storage and start-up procedures.
The bulletin provides special procedures for rotation and
lubrication of compressors during storage.
Before actual start-up of the compressor, the unit must
be drained of coolant containing vapor space inhibitors.
Procedure for long term storage start-up is covered in the
special bulletin APDD 339.
4.12 COOLANT/LUBRICANT CHANGEOUT
Ingersoll-Rand does not recommend changeout of
coolant/lubricants, however, if a coolant/lubricant
change cannot be avoided, procedure APDD 106E-87
should be obtained from your Ingersoll-Rand
representative.
4.13 INTELLISYS REMOVAL
Ensure the compressor is isolated from the
compressed air system by closing the isolation
valve and venting pressure from the drip leg.
Ensure the main power disconnect switch is locked
open and tagged (See Figure 4.13-1).
HASP
LEVER
TAG
KEY LOCK
FIGURE 4.13-1 MAIN DISCONNECT
LOCKED AND TAGGED
38
Follow these precautions to minimize damage from
static electricity. Static can cause severe damage to
microcircuits.
1) Make the least possible movement to avoid build-
ing up static electricity from your clothing or tools.
2) Discharge potential static electricity by touching
(grounding) yourself to the starter box.
3) Handle circuit boards only by their edges.
4) Do not place the controller or power supply
assembly on any metal surface.
5) Leave the replacement parts in their protective
bags until ready for installation.
Tools:
Screwdriver Size #1, flathead
3/8 inch hex driver
Before removing any components, open the starter box
door and check all wiring for tightness. A loose wire or
bad connection may be the cause of problems.
This section gives guidelines for removing/replacing the
Intellisys Controller assembly and the Intellisys Power
Supply assembly. The controller is mounted in the
starter box door, and the power supply is mounted on
the upper right corner of the starter backpanel on the
inside-rear of the starter box.
Controller Removal:
1) Open the starter box door.
2) Remove each plug-in connector, labeled P1-P10,
from the sides of the controller. If any of the
cables are not labeled, label them with the
appropriate plug designator, P1-P10. These
must be plugged into the correct sockets in
the replacement controller.
3) Remove and save the Option Module if one is
plugged into P9. This must be installed in the
replacement controller. Note that it is keyed to
plug into P9 only one way.
4) Remove the six holding screws from the con-
troller on the inside of the starter box door.
5) Remove the controller through the front of the
door, being careful to save the gasket that is
between the controller and the door.

Power Supply Removal:
1) Open the starter box door.
2) Remove each plug-in connector, labeled J1 -
J4, from the circuit board. If any of the cables
are not labeled, label them with the appro-
priate plug designator, J1-J4. These must
be plugged into the correct sockets in the
replacement power supply.
3) Remove the four screws holding the power
supply to the starter plate, save them for
mounting the replacement board, and remove
the power supply.
4.14 COOLANT HOSES
The flexible hoses that carry coolant to and from the oil
cooler may become brittle with age and will require
replacement. Have your local Ingersoll-Rand distributor
check them every 2 years.
Ensure the compressor is isolated from the
compressed air system by closing the isolation valve
and venting pressure from the drip leg.
Ensure the main power disconnect switch is locked
open and tagged.
REMOVAL
Remove enclosure panels.
Drain coolant into a clean container. Cover the container
to prevent contamination. If the coolant is contaminated,
a new charge of coolant must be used.
Hold fitting securely while removing hose.
INSTALLATION
Install the new hoses and reassemble the package by
reversing the disassembly procedure. Start the
compressor and check for leaks.
4.15 FLUID AND VIBRATION MONITORING
Ingersoll-Rand recommends incorporating predictive
maintenance, specifically the use of coolant and vibration
analysis, into all Preventative Maintenance programs.
Predictive Maintenance is designed to increase system
reliability and prevent costly downtime. Through the use
of sophisticated diagnostic tools, including fluid, vibration,
and optional air analysis, IRA Certified Service
Technicians can identify and correct potential problems
BEFORE they can cause expensive unscheduled
downtime.
How does predictive analysis work? By establishing an
initial baseline for normal operation, and then regularly
monitoring fluid and vibration conditions, any sudden
deviation or significant increase from this baseline can be
identified and investigated to pinpoint the cause. More
quickly diagnosing potential problems can directly save
money by preventing costly failures and reducing or
eliminating downtime. In addition, regular condition
monitoring also helps to maximize the time between
expensive preventative maintenance intervals, such as
component rebuilds and coolant changes.
4.16 COOLANT SAMPLING PROCEDURE
Bring unit up to operating temperature. Draw sample,
using pump kit, from separator tank port. DO NOT draw
sample from drain port or oil filter. Use new hose on
pump for each sample, failure to do this can give false
readings.
100%
50%
OI
LF
ILT
ER
39
5.0 SYSTEMS
5.1 GENERAL SYSTEM INFORMATION
The SSR compressor is an electric motor driven, single
stage, screw compressor—complete with accessories
piped, wired and baseplate mounted. It is a totally
self-contained air compressor package.
A standard compressor is composed of the following:
■ Inlet air filtration
■ Compressor and motor assembly
■ Pressurized coolant system with cooler
■ Separation system
■ Capacity control system with stepper motor inlet
■ Motor starting control system
■ Instrumentation
■ Safety provisions
■ Aftercooler
■ Moisture separator and drain trap.
Optional accessories can provide for such things as
automatic starting and stopping, remote starting or
stopping, and sequencer.
The motor, airend, separator tank, and piping are
mounted on independent supports. The supports are
isolated from the base by rubber isolation mounts.
Flexible hoses are utilized on the separator tank coolant
out and air discharge to isolate the motor/airend/tank.
5.2 AIR COOLED COMPRESSORS
DESIGN TEMPERATURES
The standard compressor is designed for operation in an
ambient range of 35°F to 115°F (1.7°C to 46°C). When
conditions other than the design levels described are
encountered, we recommend you contact your nearest
Ingersoll-Rand representative for additional information.
The standard maximum temperature 115°F (46°C) is
applicable up to an elevation of 3300 ft (1000 m) above
sea level. Above this altitude, significant reductions in
ambient temperature are required if a standard drive
motor is to be used.
COOLANT COOLER
The cooler is an integral assembly of core, fan and
fan-motor, all mounted in the end section of the
compressor enclosure. The cooling air flows in through
the left end of the enclosure, through the vertically
mounted cooler core, and discharges upward through the
right end of the enclosure.
40
COOLING FAN MOTOR
In a standard compressor, the cooling fan motor is wired
at the factory. It is a three-phase motor, protected by a
suitable circuit breaker and overload relay. The fan motor
is energized at the same time the compressor drive
motor is energized. The fan motor overload is wired in
series with the compressor drive motor overload. If an
overload occurs in the fan motor circuit, both the fan
motor and compressor drive motor will stop.
AFTERCOOLER
The discharge air aftercooling system consists of a heat
exchanger (located at the cooling air entrance of the
machine), a condensate separator, and an automatic
drain trap.
By cooling the discharge air, much of the water vapor
naturally contained in the air is condensed and
eliminated from the downstream plant-piping and
equipment.
5.3 COOLANT SYSTEM
Coolant is forced by pressure from the receiver/separator
sump to the inlet port of the coolant cooler and the
bypass port of the thermostatic control valve.
The thermostatic control valve controls the quantity of
coolant necessary to provide a suitable compressor
injection temperature. When the compressor starts cold,
part of the coolant will bypass the cooler. As the system
temperature rises above the valve setting, the coolant will
be directed to the cooler. During periods of operation in
higher ambient temperatures, all the coolant flow will be
directed through the cooler.
The compressor injection minimum temperature is
controlled to preclude the possibility of water vapor
condensing in the receiver. By injecting coolant at a
sufficiently high temperature, temperature of the
discharge air and lubricant mixture will be kept above the
dew point.
The controlled temperature coolant passes through a
filter to the airend under constant pressure.
5.4 COMPRESSED AIR SYSTEM
The air system is composed of:
1) Inlet air filter
2) Inlet valve/stepper motor
3) Rotors
4) Coolant/air separator
5) Minimum pressure/check valve
6) Aftercooler
7) Moisture separator/drain trap
Air enters the compressor, passing through the inlet air
filter and butterfly inlet valve.
Compression in the screw-type air compressor is created
by the meshing of two helical rotors (male and female) on
parallel shafts, enclosed in a heavy-duty cast iron
housing, with air inlet and outlet ports located on
opposite ends. The grooves of the female rotor mesh
with, and are driven by, the male rotor. Tapered roller
bearings at the discharge end prevent axial movement of
the rotors.
The air-coolant mixture discharges from the compressor
thru a discharge check valve into the separation system.
This system, self-contained in the separator tank,
removes all but a few PPM of the coolant from the
discharge air. The coolant is returned to the system and
the air passes to the aftercooler. The aftercooling system
consists of a heat exchanger, a condensate separator,
and a drain trap. By cooling the discharge air, much of
the water vapor naturally contained in the air is
condensed and eliminated from the downstream
plant-piping and equipment.
During unloaded operation, the butterfly inlet valve
closes, via stepper motor, and the blowdown solenoid
valve opens, expelling any compressed air back to the
compressor inlet.
5.5 COOLANT/AIR SEPARATION SYSTEM
The coolant/air separation system is composed of a
separator with specially designed internals, a two-stage
coalescing-type separator-element, and provision for
return of the separated fluid back to the compressor.
OPERATION
The coolant and air discharging from the compressor
flow into the separator through a tangential discharge
outlet. This outlet directs the mixture along the inner
circumference of the separator, allowing the coolant
stream to collect and drop to the separator sump.
Internal baffles maintain the circumferential flow of
remaining coolant droplets and air. In an almost
continuous change of direction of flow, more and more
droplets are removed from the air by inertial action and
then returned to the sump.
The air stream, now essentially a very fine mist, is
directed to the separator element.
The separator element is constructed with two
concentric, cylindrical sections of closely packed fibers,
each held in steel mesh. It is flange-mounted at the
separator-outlet-cover.
The air stream enters the separator element radially
and the mist coalesces to form droplets. The droplets
collected on the outer first stage fall to the separator
sump. Those collected on the inner second stage
collect near the outlet of the element, and are drawn
back to the compressor inlet through a filter-screen and
orifice fitting installed in the separator scavenge line.
The air stream, now essentially free of coolant, flows
from the separator to the aftercooler, then to the
condensate separator, and on to the plant air system.
5.6 ELECTRICAL SYSTEM
The electrical system of each SSR compressor is built
around the microprocessor-based Intellisys controller.
The standard electrical/electronic components,
enclosed in a readily accessible enclosure include:
1) IntelIisys controller
2) Compressor motor starter, with auxiliary contacts
and overload relays
3) Cooling fan motor overload relays and circuit
breaker or fuses
4) Intellisys Power Supply Board
5) Control transformer and fuses
Options, such as power outage restart can be enabled
by installing plug-in (option) modules in the Intellisys
controller.
41
5.6 ELECTRICAL SYSTEM (Continued)
STAR-DELTA TYPE STARTER
By use of the Star-Delta type starter, the compressor
motor can be started and accelerated using a greatly
reduced “inrush” electric current. The starter is completely
automatic and controlled by the Intellisys controller. Refer
to the Electrical Schematic 8.1 in Section 8.0.
5.7 STEPPER MOTOR INLET CONTROL
The inlet valve is opened and closed by a stepper motor
mounted on the inlet valve. The Intellisys controller
regulates the stepper motor to precisely position the inlet
valve based upon the demand of the plant air system
(See Section 5.8).
The stepper motor is maintenance free. Bearings are
lubricated at the factory and sealed for life.
No adjustment of the stepper motor/inlet valve system is
required.
5.8 CAPACITY CONTROL
The SSR compressor is supplied, as standard
equipment, with three operator selectable capacity
control systems, each designed for different plant air
requirements:
— MOD/ACS (Modulation/Automatic
Control Selector)
— On-Off Line
— Modulation Only
The desired control is selected at the Intellisys control
panel (See Section 3.0).
AUTOMATIC UNLOADED START
The compressor will always start in the unload mode.
When unloaded, the inlet valve is nearly closed, the
blowdown solenoid valve is open (tank vented), and the
compressor is operating at minimum power. The Intellisys
will open the inlet valve slightly to maintain the proper
sump pressure to ensure positive coolant flow and
smooth, quiet operation. When the injected coolant
temperature is less than 120°F (49°C), a separator
(sump) pressure of 45-50 psig (3.1 - 3.4 bar) will be
maintained. When the injected coolant temperature is
above 120°F (49°C), a receiver pressure of 24-33 psig
(1.7 - 2.3 bar) will be maintained. The minimum pressure
check valve will prevent any backflow of air from the plant
air system during unloaded operation.
42
ON-OFF LINE CONTROL
For those plants which have a widely varying air demand,
on-off line control will deliver air at full capacity
(compressor maximum efficiency condition) or will
operate at zero capacity (compressor minimum power
condition). The compressor is controlled by the Intellisys,
responding to changes in plant air pressure. The
Intellisys/stepper motor opens the inlet valve and closes
the blowdown valve (3SV) whenever plant air pressure
drops below the on-line pressure set point. The
compressor will then operate to deliver full capacity air to
the plant system. If the plant air system pressure rises to
the off-line set point of the Intellisys, the inlet valve closes
and the blowdown solenoid valve opens the separator
vent line, allowing separator pressure to drop. The
compressor will continue to run with minimum power
draw.
MODULATION/ACS CONTROL
For those plants which have relatively high, constant
air-demand relative to the compressor capacity, the
recommended control mode is modulation.
The modulation control system retains the features of
on-off line control, but provides for throttling of the inlet
flow up to the modulation off line air pressure set point.
The throttling position of the inlet valve is controlled by
the Intellisys, allowing the stepper motor to “trim” the inlet
valve position as dictated by the line pressure.
The modulating pressure range is 10 psig (.7 bar).
Modulation begins when the line pressure reaches the
maximum modulation pressure setting minus 10 psig (.7
bar) and continues as/if the line pressure rises.
Modulation becomes stable when the compressor output
equals the plant air demand. When the modulation is at
the maximum modulation pressure setting the maximum
capacity reduction will be down to approximately 60
percent of the compressor rated capacity. If the air
demand has decreased to a level below the 60 percent
modulated output, the line pressure will increase slightly
to actuate the Intellisys, unloading the compressor and
venting the separator.
5.8 CAPACITY CONTROL (Continued)
MODULATION/ACS CONTROL (Continued)
The automatic control selector (ACS) is designed to
continuously monitor the plant air demand and select
either the on-off line, or the modulate control mode -
whichever is most desirable at any time during an
operating day.
It allows the compressor to operate in its most efficient
mode without attendance, thereby reducing power costs
to a minimum.
When the compressor operates in the on-off line control
mode, the length of time the compressor remains in the
“off line” condition is an indication of the plant air
demand. Intellisys controller is sensing and awaiting a
sufficient line pressure decrease before signaling a shift
to the on line mode. If the “off line” time period is
relatively short, thereby indicating a high demand for air,
it is preferable to shift the control system to upper range
modulation.
The Intellisys does this, and does it automatically if the
compressor unloads 3 times within a 3 minute time
period.
If later, the plant demand decreases, and even under
modulate control the line pressure reaches the setting of
the Intellisys controller and the control shifts to the “off
line” mode, the time in this mode will still be monitored. A
long “off line” time period indicates a low plant air
demand, indicating the desirability of operating in the
on-off line mode.
The Intellisys then does this, and does it automatically if
the compressor operates unloaded for more than 3
minutes.
MODULATION ONLY
If MODULATION ONLY is turned on in the set point
routine, the unit will shift to Modulation control mode
immediately when the unit is running. The 3 cycles within
3 minutes time period required for ACS to change to
Modulation mode is bypassed. The unit will stay in
Modulation mode until the UNLOAD button is pressed or
the Mode of Operation set point is changed.
5.9 AUTOMATIC START/STOP CONTROL
Many plant air systems have widely varying air demands
or large air storage capacity which allows for automatic
standby air capacity control.
During periods of low air demand, if the line pressure
rises to the upper set point, the Intellisys begins to time
out. If the line pressure remains above the lower set point
for as long as the set time, the compressor will stop. At
the same time the display will indicate the compressor
has shut down automatically and will restart
automatically. An automatic restart will occur when the
line pressure drops to the lower set point.
The upper and lower set points and shutdown delay time
are set on the Intellisys control panel. There is a 10
second delay after shutdown during which the
compressor will not restart even if line air pressure drops
below the lower set point. This is to allow the motor to
come to a complete stop and the Intellisys controller to
collect current data of operating condition. If line air
pressure is below the lower set point at the end of 10
seconds, the unit will start unless the load delay timer is
set greater than 10 seconds.
Auto Restart Delay
This is the number of seconds the line pressure must
remain below the online set point before the compressor
will start if it was stopped due to an auto start/stop
situation. This timer will not delay an auto restart if the
time is set to 0.
Automatic Start/Stop Operation
When in operation, the compressor must meet two
specific timing intervals before the Intellisys controller will
stop the unit in an Automatic Start/Stop situation.
For this discussion, the timers will be called timer “A” and
timer “B”.
FIRST
Timer “A” prevents the compressor from automatically
starting more than 6 times an hour by requiring the unit
to run at least 10 minutes after each automatic start.
This 10 minute run period can be loaded, unloaded or a
combination of the two and allows dissipation of heat
generated within the motor windings at start.
43
SECOND
After the compressor has started and reached the off-line
setting and has unloaded, timer “B” requires the unit to
run unloaded for a period of time that the operator can
adjust between 2 and 60 minutes.
The setting of timer “B” is part of the options setpoint
routine and the timer cancels any accumulated time if the
compressor reloads before the timer cycle has finished.
An important point... This unloaded run time may, or may
not, be included in the mandatory 10 minute run time
used to cool the motor windings.
When the compressor has completed the settings of both
timer “A” and timer “B”, the Intellisys controller stops the
compressor and displays “STOPPED IN AUTO
RESTART.”
Pressure sensor 4APT continues to monitor the package
discharge pressure and sends information to the
controller which automatically restarts the compressor
when the pressure falls to the on-line setting.
An advantage to this method of automatic start/stop
control is allowing the compressor to stop much sooner
in certain situations and timer settings, thereby reducing
power costs.
44
Some Examples of Operation
EXAMPLE 1
The operator selects an unloaded run time of 2 minutes
in the OPTION routine and starts the compressor. The
unit runs loaded for 8 minutes, unloads and then runs
unloaded for two more minutes.
The total running time is 10 minutes which satisfies timer
“A” plus the unit ran two minutes unloaded which also
satisfies timer “B,” therefore, the unit stops automatically.
This example shows how timer “B” can sometimes be
included within the timer “A” interval. Think of the two
timers as running parallel.
EXAMPLE 2
The operator selects an unloaded run time of 3 minutes
in the OPTION routine and starts the compressor. The
unit runs loaded for 10 minutes and then unloads.
At this point, timer “A” has been satisfied but timer “B” still
wants the compressor to run unloaded 3 more minutes
before allowing an automatic stop.
The total run time for this example will be 13 minutes.
Remember.... If the unit reloads before timer “B” finishes
the 3 minute setting, the partial time is canceled and
timer “B” must restart the 3 minute cycle when the
compressor unloads again.
EXAMPLE 3
When starting the compressor from the remote location,
The operator selects an unloaded run time of 10 minutes
the Start button must be held depressed for
in the OPTION routine and starts the compressor. The
approximately 2 seconds to activate the remote start
unit runs loaded 12 minutes and then unloads.
function and then released within a maximum of 7
seconds or a Remote Start Failure alarm will occur.
After 12 minutes of running, the 10 minute mandatory
run-time for timer “A” has been met but the compressor
must continue to run unloaded an additional 10 minutes
to satisfy timer “B”.

After 10 minutes of unloaded run time, the compressor is

stopped automatically and the total run time was 22
minutes. ! WARNING
5.10 REMOTE START/STOP
The remote start/stop option allows the operator to This machine is remote Disconnect power before
start and stop equipped. servicing.
control the compressor from a remote mounted start/stop
station. May start or stop at Lock and tag out.
anytime.
Two different switches can be wired to the controller for See Operators / Instruction
remote start/stop. (Refer to Electrical Schematic 8.1 for Can cause severe injury or Manual.
death.
wiring locations). The switches are customer supplied
and must be of momentary type. The stop switch
contacts are normally closed and the start switch
contacts are normally open.

45
 6.0 TROUBLESHOOTING CHART
TROUBLE CAUSE &/OR DISPLAY WHAT TO DO

Compressor fails to start. 110/120V control voltage not available, ■ Check fuses. Check transformer and wiring connections.
CONTROL POWER LOSS

STARTER FAULT ■ Inspect contactors.

EMERGENCY STOP ■ Rotate emergency stop button to disengage, and press reset button
twice.

MAIN (OR FAN) MOTOR OVERLOAD ■ Manually reset main or fan motor overload relay, and press reset
button twice.

SENSOR FAILURE XXXX ■ Check for defective sensor, bad sensor connection, or broken
sensor wires.

CHECK INLET CTRL SYS. ■ Call factory representative.

Intellisys 24 VAC control voltage not ■ Check fuses.

available

Display panel and power on light does ■ Check wiring. Verify 24 VAC is within voltage tolerance (± 15%).
not illuminate.

Compressor shuts down. HIGH AIREND DISCH TEMP. ■ Ensure that installation area has adequate ventilation.
■ Ensure that cooling fan is operating. If not, reset circuit breaker
inside starter box.
■ Check coolant level. Add if required.
■ Cooler cores dirty. Clean coolers.
NOTE: If a shutdown
occurs, press the Status LOW UNLOAD SUMP PRESS. ■ Check for air leak from tank or blowdown piping.
button once to activate ■ Check for slipping or broken stepper motor coupling.
the display table. Using
the adjacent up and CHECK INLET CTRL SYS. ■ Call factory representative.
down arrows, the values
displayed will be those SENSOR FAILURE XXXX ■ Check for defective sensor, bad sensor connection, or broken
immediately preceding sensor wires.
shutdown. Use these
values when CHECK MOTOR ROTATION ■ Interchange any two line connections (L1, L2, L3) at the starter.
troubleshooting a
problem. ■ Check for loose wires.
MAIN MOTOR OVERLOAD ■ Check supply voltage.
■ Check heater setting.

■ Check for loose wires.

FAN MOTOR OVERLOAD ■ Check supply voltage.
■ Check heater setting.
■ Check for dirty cooler cores.

■ Inspect starter connectors.

STARTER FAULT ■ Check for loose wires.

■ Reset to clear.
CHECK SET POINTS ■ Calibrate sensors.
■ Check all set points.

CONTROL POWER LOSS ■ Check fuses. Check transformer and wiring connections.

STEPPER LIMIT SWITCH ■ Call factory representative.

REMOTE STOP FAILURE ■ Check Remote Stop Switch and wiring.

REMOTE START FAILURE ■ Check Remote Start Switch and wiring.

EMERGENCY STOP ■ Disengage emergency stop button.

■ Press reset button twice.

LOW SUMP AIR PRESS ■ See LOW UNLOAD SUMP PRESS

CHECK INLET CONTROL ■ Check for air leaks at inlet valve.

■ Check for slipping or broken stepper motor coupling.

46
 6.0 TROUBLESHOOTING CHART (Continued)
TROUBLE CAUSE &/OR DISPLAY WHAT TO DO
Low system air pressure Compressor running in ■ Press LOAD button.
UNLOAD Mode.

Controller off-line set point too low. ■ Press STOP button.

Set off-line set point at a higher value.
Dirty air filter element. ■ Check filter condition. Replace as required.
Air leak. ■ Check air system piping.
Moisture separator trap drain ■ Inspect and repair.
stuck open.

Inlet valve not fully open. ■ Inspect and repair. Check control system operation.
System demand exceeds compressor ■ Install larger or an additional compressor.
delivery.

High coolant Excessive coolant level.
consumption/coolant in
air system Plugged separator element.
Separator element leak.
Plugged separator scavenge
screen/orifice.
■ Check level, lower if necessary by draining.
■ Check separator pressure drop.
■ Check separator pressure drop. If low, replace element.
■ Remove and inspect screen/orifice. Clean if required.

Compressor operating at low pressure ■ Operate at rated pressure. Reduce system load.
(75 psig [5.2 bar] or below).

Coolant system leak. ■ Inspect and repair leaks.

Water in air system Defective moisture ■ Inspect and clean if required.

separator/drain trap
Trap drain or drain piping plugged.
Aftercooler core dirty.
Enclosure panels not in place.
No aftercooler on unit.
Drain line/drip leg incorrectly installed.
No refrigerated or desiccant dryer
in air system.
Replace separator/trap if defective.
■ Inspect and clean.
■ Inspect and clean.
■ Install enclosure panels.
■ Install aftercooler.
■ Slope drain line away from trap. Install drip leg.
■ Contact local Ingersoll-Rand distributor.

Excessive noise level Compressor defective. (Bearing or gear ■ Contact authorized distributor immediately.
failure or rotor contact.) Do not operate unit.
Enclosure panels not in place. ■ Install enclosure panels.
Loose component mounting. ■ Inspect and tighten.

Excessive vibration Loose components. ■ Inspect and tighten.

Motor or compressor ■ Contact authorized distributor immediately.
bearing failure. Do not operate unit.
External sources. ■ Inspect area for other equipment.

Pressure relief valve Compressor operating over pressure. ■ Adjust Intellisys set points.
opens
Defective valve.
■ Replace valve.

47
7.0 OTIONS
7.1 POWER OUTAGE RESTART WITH SCHEDULED
START/STOP
For customers that have interruptions in their incoming
power supply to the compressor and must maintain an
uninterrupted supply of compressed air, the Power
Outage Restart Option allows an Intellisys compressor to
restart automatically 10-120 seconds (adjustable) after
incoming power is restored.
The Power Outage Restart Option is turned on by
plugging in the required option module and enabling it
thru the OPTION’S set point routine. The restart time
delay, which is adjustable from 10-120 seconds, can also
be adjusted while in the option’s set routine on the
Intellisys controller. Any time power is restored to the
compressor after a power interruption, a horn located on
the side of the starter box will sound during the restart
time delay (10-120 seconds), after which the compressor
will automatically start. After starting, the compressor will
return to the mode of operation that the compressor was
in prior to the power interruption.
This option may be factory installed or a field installation
kit is available.
7.2 SEQUENCER
The sequencer option is turned on by enabling it through
the OPTIONS set point routine. Enabling this
option will allow the compressor to be controlled by an
external device, such as an ISC or sequencer, using
the communications port (P7) on the Intellisys.
7.3 LOW AMBIENT
The low ambient option is turned on by enabling it through
the OPTIONS set point routine. Also temperature sensor,
3CTT, is added to the compressor and connected at P6-7
& 8 on the Intellisys. The options set point, minimum
cooler out temperature, is set to the minimum temperature
at which the unit can load. When this option is enabled,
the compressor, after being started, will not load until the
Intellisys reads a temperature from 3CTT at or higher
than the value of the minimum cooler out temperature set
point. If this option is enabled without installing 3CTT,
a SENSOR FAILURE 3CTT alarm will occur.
7.4 SEPARATOR DELTA-P SOLENOID
The separator delta-p solenoid option is turned on by
enabling it through the OPTIONS set point routine.
48
When this option is enabled, the Intellisys will measure
the pressure drop across the separator element by
first reading the wet side sump pressure. Next the
Intellisys will momentarily energize solenoid that will
switch the dry side sump pressure to the sump pressure
sensor (3APT). The Intellisys will then read the dry
side sump pressure and subtract it from the wet side
sump pressure to measure the pressure drop across the
separator element. Do not enable this option if the
separator delta-p solenoid is not installed. This will
result in an incorrect measurement of the pressure
drop across the separator element.
7.5 SEPARATOR DELTA-P SENSOR
The separator delta-p sensor option is turned on by
enabling it through the OPTIONS set point routine.
When this option is enabled, the Intellisys will measure
the pressure drop across the separator element by
subtracting the dry side sump pressure (6APT) from the
wet side sump pressure (3APT). Do not enable this
option if the separator delta-p sensor is not installed.
This will result in an incorrect measurement of the
pressure drop across the separator element and a
6APT sensor failure warning.
7.6 HIGH DUST FILTER
The high dust filter option is turned on by enabling it
through the OPTIONS set point routine. If this option
is enabled, the Intellisys; will change its measurement of
the inlet filter. Do not enable this option unless a high
dust filter is installed.
7.7 LEAD/LAG CYCLE LENGTH
The lead/lag cycle length option allows the Intellisys to
automatically switch the online and offline pressure
settings to the lead or lag values after a programmed
number of hours. This option is enabled by selecting a
number of hours greater than 0 in the OPTIONS set point
routine.
7.8 SCHEDULEDSTART/STOP
The scheduled start/stop option allows the customer to
automatically start and stop the compressor once each
day, based on the real time clock. This is an installed
option and is enabled by selecting a scheduled start and
scheduled stop time. Setting the scheduled start and
scheduled stop times to the same value will disable this
option.
7.9 REMOTE LOAD/UNLOAD
The remote load/unload option gives the operator the
ability to control the loading and unloading of the
compressor. This option is enabled when two switches
are wired to the Intellisys to perform this function.
The firstswitch is the master/local input (P3, 25 & 26)
and the second switch is the load/unload input (P3,
27 & 28). If the master/local switch is closed, the
Intellisys will read the load/unload switch for loading
and unloading the compressor. If the load/unload switch
is closed, the Intellisys will load the compressor.
If the load/unload switch is open, the Intellisys will
unload the compressor. If the master/local switch is
open, the Intellisys will ignore the load/unload switch
and operate the compressor normally.
7.10 MODBUS
The Modbus option uses the Modbus protocol and
modbus address set points in the OPTIONS menu. This
is used by the Ingersoll-Rand service organization.
7.11 INTEGRAL SEQUENCING
Integral sequencing allows one compressor, the lead, to
sequence up to 3 other compressors. The compressors
are daisy chained together using port P8 on the Intellisys.
Each compressor has a unique address and the lead
compressor will sequence the other units in numerical
order based on that address.
The lead compressor will be the first to load and the last
to unload. It is also the only compressor that can
modulate. If the lead compressor’s mode of operation is
Mod/ACS or Modulation Only, it will modulate when it is
loaded. Once loaded, if pressure falls to its online set
point, the lead compressor will transmit a load command
to the next compressor in sequence. The lead compressor
will then wait for a period of time for the line pressure to
rise. This time period is determined by the load delay time
set point. At the end of this time period, if line pressure is
not rising, the lead compressor will transmit a load
command to the next compressor in sequence. This will
be repeated until the line pressure starts to rise.
When line pressure rises to the lead compressor’s offline
set point, it will transmit an unload command to the last
loaded compressor in the sequence. The lead compressor
will do this every 10 seconds until the line pressure starts
to fall.
After a certain amount of time or at a certain time, the
lead compressor can change the sequence by transferring
the lead to the next compressor in the sequence. If the set
point, Lead Change - Hours, is set to a value greater than
0, the unit will operate as the lead compressor for that
number of hours before transferring the lead. If Lead
Change - Hours is set to 0, the set points Lead Change -
Day and Lead Change - Time will be used to determine
when the lead will be transferred. The Lead Change - Day
set point will contain the day of the week the lead will be
transferred. The time of the day will be contained in the
Lead Change - Time set point. The lead will be transferred
when the real time clock matches these 2 set points.
To connect the compressors for integral sequencing put
the 4 position connector into port P8. One connector, I-R
part number 39186101, will be needed for each
compressor. The total length of cable for an integral
sequencing system is not to exceed 1000 feet. For the
cable, use I-R part number 39204508 or equivalent. This
is a 4 wire, twisted pair cable. Use one pair for pins 1 and
2 and the other pair for pins 3 and 4. The connection on
port P8 is a one to one connection. The wire on pin 1 on
the first compressor will connect to pin 1 on the second
compressor and so on. This is true for all 4 wires.
49
8.0 REFERENCE DRAWINGS
8.1 ELECTRICAL SCHEMATIC 54418074
STAR DELTA REV B

50
51
8.2 ELECTRICAL SCHEMATIC
REMOTE STAR-DELTA
39886817
REV 04

52
 8.3 ELECTRICAL SCHEMATIC
REMOTE HIGH VOLTAGE
39886627
(FULL VOLTAGE)
REV 05

53
8.4 FOUNDATION PLAN
250-300 HP, 300E AIRCOOLED
(CONTINUED) 39930763
REV B
54
 8.4 FOUNDATION PLAN
250-300E HP AIRCOOLED,
39930763
REV B
55
8.5 FOUNDATION PLAN
250-300 HP AIRCOOLED - TWO STAGE
(CONTINUED) 39930821
REV B
56
 8.5 FOUNDATION PLAN
250-300 HP AIRCOOLED - TWO STAGE
39930821
REV B
57
8.6 FOUNDATION PLAN
250-300 HP, 300E WATERCOOLED
(CONTINUED)
39930771
REV C
58
 8.6 FOUNDATION PLAN
250-300E HP WATERCOOLED
39930771
REV C
59
8.7 FOUNDATION PLAN
250-300 HP WATERCOOLED - TWO STAGE 39930839
(CONTINUED) REV C
60
 8.7 FOUNDATION PLAN
39930839 250-300 HP WATERCOOLED - TWO STAGE
REV C
61
8.8 FOUNDATION PLAN
350-450 HP AIRCOOLED 54369681
(CONTINUED) REV B

62
 8.8 FOUNDATION PLAN
54369681 350-450 HP AIRCOOLED
REV B

63
8.9 FOUNDATION PLAN
350-450 HP AIRCOOLED - TWO STAGE 54369707
(CONTINUED) REV B
64
 8.9 FOUNDATION PLAN
54369707 350-450 HP AIRCOOLED - TWO STAGE
REV B
65
8.10 FOUNDATION PLAN
350-450 HP WATERCOOLED 54369699
(CONTINUED) REV C

66
 8.10 FOUNDATION PLAN
54369699 350-450 HP WATERCOOLED
REV C

67
8.11 FOUNDATION PLAN
350-500 HP WATERCOOLED - TWO STAGE 54369715
(CONTINUED) REV C

68
 8.10 FOUNDATION PLAN
54369715 350-500 HP WATERCOOLED TWO STAGE
REV C

69
8.12 FOUNDATION PLAN
250-300 HP AIRCOOLED EXTENDED 39930789
(CONTINUED) REV C

70
 8.12 FOUNDATION PLAN
39930789 250-300 HP AIRCOOLED EXTENDED
REV C

71
8.13 FOUNDATION PLAN
250-300 HP AIRCOOLED EXTENDED - TWO STAGE 39930847
(CONTINUED) REV B

72
 8.13 FOUNDATION PLAN
39930847 250-300 HP AIRCOOLED EXTENDED - TWO STAGE
REV B

73
8.14 FOUNDATION PLAN
250-300 HP WATERCOOLED EXTENDED 39930797
(CONTINUED) REV C

74
 8.14 FOUNDATION PLAN
39930797 250-300 HP WATERCOOLED EXTENDED
REV C

73
8.15 FOUNDATION PLAN
250-300 HP WATERCOOLED EXTENDED - TWO STAGE 39930854
(CONTINUED) REV C

76
 8.15 FOUNDATION PLAN
39930854 250-300 HP WATERCOOLED EXTENDED - TWO STAGE
REV C

77
 54579081
REV A

8.16 FLOW SCHEMATIC

AIRCOOLED

78
69
 54579792
REV C

8.17 FLOW SCHEMATIC

AIRCOOLED TWO STAGE

80
81
 54579503
REV A

8.18 FLOW SCHEMATIC

WATERCOOLED - 90°F (32°C)

82
83
 54580295
REV B

8.19 FLOW SCHEMATIC

WATERCOOLED - 90°F (32°C) TWO STAGE

84
85
 54579511
REV A

8.20 FLOW SCHEMATIC

WATERCOOLED 90°F (32°C)
TWO STAGE

86
87
 54580329
REV B

8.21 FLOW SCHEMATIC

WATERCOOLED 115°F (46°C)
TWO STAGE

88
89
 TYPICAL SYSTEM FLOW
DIAGRAM

8.22 TYPICAL SYSTEM FLOW DIAGRAMS

90
8.22 TYPICAL SYSTEM FLOW DIAGRAMS

91
8.22 TYPICAL SYSTEM FLOW DIAGRAMS

92
8.22 TYPICAL SYSTEM FLOW DIAGRAMS

93
8.22 TYPICAL SYSTEM FLOW DIAGRAMS

94
9.0 WATER QUALITY
RECOMMENDATIONS
Perhaps the largest contributor to scale formation is the
Water quality is often overlooked when the cooling
precipitation of calcium carbonate out of the water. This is
system of a water cooled air compressor is examined.
dependent on temperature and pH. The higher the pH
Water quality determines how effective the heat transfer
value the greater the chance of scale formation. Scale
rate, as well as the flow rate will remain during the
can be controlled with water treatment.
operation life of the unit. It should be noted that the
quality of water used in any cooling system does not
CORROSION
remain constant during the operation of the system. The
In contrast to scale formation is the problem of corrosion.
water makeup is affected by evaporation, corrosion,
Chlorides cause problems because of their size and
chemical and temperature changes, aeration, scale, and
conductivity. Low pH levels promote corrosion, as well as
biological formations. Most problems in a cooling system
high levels of dissolved oxygen.
show up first in a reduction in the heat transfer rate, then
in a reduced flow rate, and finally with damage to the
FOULING
system.
Biological and organic substances (slime) can also cause
problems, but in elevated temperature environments such
There are many constituents in the water system that
as cooling processes, they are not major concerns. If
must be balanced to have a good stable system. The
they create problems with clogging, commercial shock
following is a list of the major components that should be
treatments are available.
monitored:
To ensure good operation life and performance of the
SCALE
compressor cooling system, the recommended
Scale formation inhibits effective heat transfer, yet it does
acceptable ranges for different water constituents are
help prevent corrosion. Therefore, a thin uniform coating
included below:
of calcium carbonate is desired on the inner surfaces.

PARAMETER CONCENTRATION FREQUENCY OF ANALYSIS

Corrosivity (hardness, Langelier Index Monthly

pH, total dissolved solids, 0 to 1 (if stable for 3 to 4 months,
temperature at inlet, analyze quarterly)
alkalinity)

Iron < 2 ppm Monthly

Sulfate < 50 ppm Monthly

Chloride < 50 ppm Monthly

Nitrate < 2 ppm Monthly

Silica < 100 ppm Monthly

Dissolved oxygen 0 ppm Daily

(as low as possible) (if stable, analyze weekly)

Oil and grease < 5 ppm Monthly

Ammonia < 1 ppm Monthly

95
Recommended equipment for on-site analysis includes a
thermometer, pH meter, and dissolved oxygen meter.
Dissolved oxygen and temperature must be measured
on-site and it is recommended that pH be measured
on-site. All other analyses should be performed by a
professional water quality analyst. The Langelier Index
(Ll) is calculated using the following equation and the
tables found on the following pages.

Ll = pH - (9.30 + Total Dissolved Solids chart value +

Temperature chart value ) + Hardness chart valve +
Alkalinity chart value)

The Ll is zero when the water is in chemical balance. If

the Ll is greater than zero, there is a tendency to form
scale. If the Ll is less than zero, the water tends to be
corrosive.

Dissolved oxygen may be controlled in closed cooling

towers. Several types of treatments are commercially
available to remove dissolved oxygen. For open cooling
towers, dissolved oxygen is not an easily controlled
parameter. Also, a filtration system is recommended for
the water going into the air compressor when using an
open cooling tower.

It should be noted that Ingersoll-Rand’s guidelines and

recommendations should be used in evaluating the water
systems and the problems that may occur in the normal
operation of our air compressors. If water problems
persist or are not covered above, you should consult a
professional.

96
 LANGELIER INDEX CHART VALUES
Total dissolved solids (ppm) Temperature (°F)

UNITS

50 .07 0 2 4 6 8

75 .08 30 2.60 2.67 2.54 2.81

TOTAL SOLIDS (PPM)

100 .10 40 2.48 2.45 2.43 2.40 2.37

50 2.34 2.31 2.28 2.25 2.22

150 .11 60 2.20 2.17 2.14 2.11 2.09

70 2.06 2.04 2.03 2.00 1.97
200 .13 80 1.95 1.92 1.90 1.88 1.86
300 .14

TENS
90 1.84 1.82 1.80 1.78 1.76
100 1.74 1.72 1.71 1.09 1.67
400 .16 110 1.05 1.64 1.62 1.60 1.58

600 .18 120 1.67 1.63 1.53 1.51 1.50

800 .19 130 1.48 1.46 1.44 1.43 1.41
140 1.40 1.38 1.37 1.35 1.34

1000 .20 150 1.32 1.31 1.29 1.28 1.27

160 1.26 1.24 1.23 1.22 1.21
170 1.19 1.18 1.17 1.10

Hardness (ppm) Alkalinity (ppm)

UNITS UNITS

0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

0 0.08 0.20 0.30 0.38 0.43 0.51 0.56 0 0.00 0.30 0.48 0.60 0.70 0.78 0.85 0.90 0.93
10 0.60 0.64 0.68 0.72 0.73 0.78 0.81 0.83 0.86 0.88 10 1.00 1.04 1.08 1.11 1.15 1.18 1.20 1.23 1.26 1.29
20 0.90 0.92 0.94 0.96 0.98 1.00 1.02 1.03 1.05 1.06 20 1.30 1.32 1.34 1.36 1.38 1.40 1.42 1.43 1.45 1.46

30 1.08 1.09 1.11 1.12 1.13 1.15 1.16 1.17 1.18 1.19 30 1.48 1.49 1.51 1.52 1.53 1.54 1.56 1.67 1.58 1.59
40 1.20 1.21 1.23 1.24 1.25 1.26 1.26 1.27 1.28 1.29 40 1.60 1.61 1.62 1.63 1.64 1.65 1.66 1.67 1.68 1.69
50 1.30 1.31 1.32 1.33 1.34 1.34 1.35 1.36 1.37 1.37 50 1.70 1.71 1.72 1.72 1.73 1.74 1.75 1.76 1.76 1.77

60 1.38 1.39 1.39 1.40 1.41 1.42 1.42 1.43 1.43 1.44 60 1.78 1.79 1.79 1.80 1.81 1.81 1.82 1.83 1.83 1.84
70 1.45 1.45 1.46 1.47 1.47 1.48 1.48 1.49 1.49 1.50 70 1.85 1.85 1.86 1.86 1.87 1.88 1.88 1.89 1.89 1.90
80 1.51 1.51 1.52 1.52 1.53 1.53 1.54 1.54 1.55 1.55 80 1.90 1.91 1.91 1.92 1.92 1.93 1.93 1.94 1.94 1.95
TENS

TENS

90 1.56 1.56 1.57 1.57 1.58 1.58 1.58 1.59 1.59 1.60 90 1.95 1.96 1.96 1.97 1.97 1.98 1.98 1.99 1.99 2.00
100 1.60 1.61 1.61 1.61 1.62 1.62 1.63 1.63 1.64 1.64 100 2.00 2.00 2.01 2.01 2.02 2.02 2.03 2.03 2.03 2.04
110 1.64 1.65 1.65 1.66 1.66 1.66 1.67 1.67 1.67 1.68 110 2.04 2.05 2.05 2.05 2.06 2.06 2.06 2.07 2.07 2.08

120 1.68 1.68 1.69 1.69 1.70 1.70 1.70 1.71 1.71 1.71 120 2.08 2.08 2.09 2.09 2.09 2.10 2.10 2.10 2.11 2 11
130 1.72 1.72 1.72 1.73 1.73 1.73 1.74 1.74 1.74 1.75 130 2.11 2.12 2.12 2.12 2.13 2.13 2.13 2.14 2.14 2.14
140 1.75 1.75 1.75 1.76 1.76 1.76 1.77 1.77 1.77 1.78 140 2.15 2.15 2.15 2.16 2.16 2.16 2.16 2.17 2.17 2.17

150 1.78 1.78 1.78 1.79 1.79 1.79 1.80 1.80 1.80 1.80 150 2.18 2.18 2.18 2.18 2.19 2.19 2.19 2.20 2.20 2.20
160 1.81 1.81 1.81 1.81 1.82 1.82 1.82 1.82 1.83 1.83 160 2.20 2.21 2.21 2.21 2.21 2.22 2.22 2.23 2.23 2.23
170 1.83 1.84 1.84 1.84 1.84 1.85 1.85 1.85 1.85 1.85 170 2.23 2.23 2.23 2.24 2.24 2.24 2.24 2.25 2.25 2.25

180 1.86 1.86 1.86 1.86 1.87 1.87 1.87 1.87 1.88 1.88 180 2.26 2.26 2.26 2.26 2.26 2.27 2.27 2.27 2.27 2.28
190 1.88 1.88 1.89 1.89 1.89 1.89 1.89 1.90 1.90 1.90 190 2.28 2.28 2.28 2.29 2.29 2.29 2.29 2.29 2.30 2.30
200 1.90 1.91 1.91 1.91 1.91 1.91 1.92 1.92 1.92 1.92 200 2.30 2.30 2.30 2.31 2.31 2.31 2.31 2.32 2.32 2.32

TENS TENS

0 10 20 30 40 50 60 70 80 90 0 10 20 30 40 50 60 70 80 90

200 1.92 1.94 1.96 1.98 2.00 2.02 2.03 2.03 2.06 200 2.32 2.34 2.36 2.38 2.40 2.42 2.43 2.43 2.46
300 2.08 2.09 2.11 2.12 2.13 2.13 2.16 2.17 2.18 2.19 300 2.48 2.49 2.51 2.52 2.53 2.54 2.56 2.57 2.58 2.59
HUNDREDS

HUNDREDS

400 2.20 2.21 2.23 2.24 2.23 2.26 2.26 2.27 2.28 2.29 400 2.60 2.61 2.62 2.63 2.64 2.65 2.66 2.67 2.68 2.69

500 2.30 2.31 2.32 2.33 2.34 2.34 2.35 2.36 2.37 2.37 500 2.70 2.71 2.72 2.72 2.73 2.74 2.75 2.76 2.76 2.77
600 2.38 2.39 2.39 2.40 2.41 2.42 2.42 2.43 2.43 2.44 600 2.78 2.79 2.79 2.80 2.81 2.81 2.82 2.83 2.83 2.84
700 2.45 2.45 2.46 2.47 2.47 2.48 2.48 2.49 2.49 2.50 700 2.85 2.85 2.86 2.86 2.87 2.88 2.88 2.89 2.89 2.90

800 2.51 2.51 2.52 2.52 2.53 2.53 2.54 2.54 2.55 2.55 800 2.90 2.91 2.91 2.92 2.92 2.93 2.93 2.94 2.94 2.95
900 2.56 2.56 2.57 2.57 2.58 2.58 2.58 2.59 2.60 2.60 900 2.95 2.96 2.96 2.97 2.97 2.98 2.98 2.99 2.99 3.00

97
 10.0 MAINTENANCE RECORD

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

98
 MAINTENANCE RECORD

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

99
 MAINTENANCE RECORD

DATE RUN TIME WORK DONE QTY. UNIT WORK

(HOURS) MEASURE BY

100
 PolySep PS
OIL/WATER SEPARATOR

INSTALLATION, OPERATION,
MAINTENANCE MANUAL AND
PARTS LIST

FAILURE TO READ AND UNDERSTAND THE FOLLOWING

INSTRUCTIONS MAY CAUSE YOU UNNECESSARY COM-
PLICATIONS IN THE INSTALLATION OR OPERATION OF
THIS EQUIPMENT.

More Than Air. Answers.

Online answers: http://www.air.irco.com
PHONE: 1-800-526-3615

CCN: 80440589 REV.A

APDD 822A
July 2002
 Limited One Year Warranty
The POLYSEP PS is warranted to be free from defects in material and workmanship, under
proper use, installation, application, and maintenance in accordance with the manufacturer’s writ-
ten recommendations and specification for a period of 18 months from the date of shipment from
the factory or 12 months from the date of installation, whichever comes first. The manufacturer’s
obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the
repair or replacement (at manufacturer’s option) of unaltered products returned to manufacturer
within stated period.

In order to process a claim, Ingersoll-Rand must get from the customer a proof of purchase (date
of purchase, invoice number). In no event, shall Ingersoll-Rand be liable for business interrup-
tions, loss of profits, personal injury, costs of delay or any other special, indirect, incidental, or
consequential losses, cost, or damages.

NOTE - Routine maintenance and minor adjustments to the Ingersoll-Rand PolySep PS oil/water
separators are not covered under this warranty. Prior to performing any possible warranty service
or replacing a possible warranted part, please contact your local Ingersoll-Rand authorized rep-
resentative. All warranty claims must be performed by an Ingersoll-Rand certified technician.
Failure to comply with this procedure will result in denial of warranty claim.

© INGERSOLL-RAND COMPANY
 TABLE OF CONTENTS
1.0 GENERAL

2.0 HOW IT WORKS

3.0 INSTALLATION INSTRUCTIONS

3.1 Placement
3.2 Adsorption Module Backwash Procedure
3.3 Delivery System Installation
3.4 Service Preparation Procedure
3.5 System Commissioning

4.0 OPERATION INSTRUCTIONS

5.0 GENERAL DATA

6.0 PARTS LIST

6.1 Replacement Parts List
6.2 Installation Parts List

1
1.0 GENERAL
Traditional gravity type separators do very well in sepa-
rating oils that have good separation characteristics.
However, many compressor oils do not fully separate.
These types of oils,known as emulsions, tend to foul-up
the carbon filters as well as the pre-adsorption and coa-
lescing medias that are commonly installed in front of
the carbon filters. Those filters have to be replaced
before their capacity is fully used.
The PolySep PS was designed to effectively separate
emulsified compressor condensate to levels of 15 PPM*
or less without premature element failure and backup
spillages. To do this, the PolySep PS uses two very
unique features. First, the delivery system has a pneu-
matically operated pump that is used to feed the adsorp-
tion module. The use of pressure ensures the adsorption
module will not clog. Second, the Adsorption Module
contains a specially formulated zeolite adsorbent. The
substrate is coated with a hydrophobic compound. This
combination gives the media an ability to hold up to four
times the amount of oil that standard activated carbon
can hold.
Condensate Enters
1
Diffuser Chamber
2
Oil
Weir
3
Main
Reservoir
Pick-Up
Tube
4
*Based on modern piece of equipment W/<3ppm carryover properly sized and installed. Polysep PS is not recommended for use with silicon based or food grade oils.
Water discharge from the PolySep oil/water separator is not intended or approved for human consumption.
2
2.0 HOW IT WORKS:
The condensate enters the (1) Diffuser Chamber where
it is depressurized. The oily condensate then enters a (2)
Main Reservoir where sedimentation occurs. Any oil that
floats to the surface can be skimmed off through an
adjustable (3) Oil Weir. The condensate then moves to a
separate chamber through a (4) Pick-Up Tube. As the
condensate accumulates in the next chamber, a (5) Float
rises with the level of condensate. The float is connected
to a (6) Ball Valve by a lever arm. The increased level of
condensate causes the float to rise and open the ball
valve. As the valve opens, the air-operated (7) Pump is
allowed to push the condensate out to the (8) Adsorption
Module. If the level of condensate continues to rise, the
float also rises, further opening the ball valve. This
results in additional condensate being pushed to the
adsorption module. Thus, the system will self adjust to
the quantity of condensate entering the system. This
system ensures maximum contact time for the adsorp-
tion module. Clean water discharged (9) from the
adsorption module can then be disposed directly into the
facility’s sanitary sewer.
Pump Control Line Air Inlet
7 Filter Module
8
6 5
Ball Float
Valve
9
FIGURE 2-1 FLOW DIAGRAM
3.0 INSTALLATION
INSTRUCTIONS
3.1 PLACEMENT
Position the POLYSEP PS DELIVERY SYSTEM,
ADSORPTION MODULE and an Oil Collection
Container (not supplied) in an easily accessible location
near your Compressor Station. Unit must be
positioned on a level floor.
The following Adsorption Module Backwash Procedure
MUST be performed each time you install a new
Adsorption Module. It will purge the Adsorption Module
of air and clarify the water by removing the fine dust cre-
ated during transportation.
3.2 ADSORPTION MODULE BACKWASH
PROCEDURE
1. Remove the 2” npt plug from the Inlet Port on the
Adsorption Module. Replace with the 2” npt (m) x 3/4”
npt (f) reducing bushing and a 3/4” npt (m) x 3/4” hose
barb elbow.
2. Supply your required length of 3/4” discharge tubing
(clear is recommended) (not supplied) and secure it with
a hose clamp (not supplied) to the 3/4” hose barb con-
nection. Route this tubing to your Sanitary Sewer Floor
Drain.
3. Remove the 3/4” npt plug from the Outlet Port on Filter
Module AM250 and replace it with the 3/4” npt (m) x 3/4”
garden hose adapter.
Note: The Plug is 2” on Modules AM-560 & AM-1125.
Replace with a 2” npt (m) x 3/4” npt (f) reducing bushing.
Then install the garden hose adapter.
4. Connect one end of a garden hose to your tap water
valve. Next, connect the opposite end to the hose
adapter on the Adsorption Module. Open the Tap Water
Valve ONLY one-quarter (1/4) turn to purge the air and
fill the Adsorption Module with clean water. Continue to
backwash the Adsorption Module until the water exiting
the discharge hose runs clear.
5. When water runs clear, shut off the tap water valve,
disconnect the garden hose and, remove the garden
hose adapter fitting from the outlet port. (Keep the gar-
den hose adapter fitting for future use).
The Backwash Procedure is now complete. Prepare the
Adsorption Module for Air Compressor
Condensate Service as follows:
6. Remove the 3/4” npt (m) x 3/4” hose barb elbow and
discharge hose from the inlet port and, reinstall them
into the outlet port.
7. Install a 3/4” npt (m) x 3/8” npt (f) reducing bushing
into the inlet port, then install a 3/8” npt (m) x 3/8” tubing
adapter elbow. Next, fasten one end of the black 3/8”
condensate delivery tubing to the tubing adapter.
3.3 DELIVERY SYSTEM INSTALLATION
1. Level the Delivery System.
2. Thread the 1/4” npt (m) in-line, sintered bronze, partic-
ulate Control Air Filter into the Control Line Air Inlet port.
Connect a clean, dry, oil-free compressed air line to the
Filter.
NOTE: PROPER OPERATION OF THE DELIVERY
SYSTEM REQUIRES THAT CLEAN, DRY, OILFREE 30-
150 PSI COMPRESSED AIR BE. PIPED TO THE CON-
TROL AIR FILTER. FAILURE TO DO SO MAY DAM-
AGE THE PUMP AND VOID THE WARRANTY.
WE RECOMMEND INSTALLING A 1/4” NPT, .01
MICRON IRHE FILTER IF OIL IS PRESENT IN YOUR
CONTROL AIR.
3. Install the clear 3/4” x 18” hose into the Oil Outlet Port
with the 3/4” npt (m) x 3/4” hose barb elbow and, place
the end of the hose into your Oil Collection Container
(not supplied).
4. To connect the PolySep PS Delivery System to the
Adsorption Module, first, install a 3/8” npt (m) x 3/8” tub-
ing adapter into the 3/8” npt Condensate Discharge Port.
Then, fasten the black 3/8” Condensate Delivery Tube
(that you connected to the Filter Module in step #7) to
the tubing adapter. Be careful not to kink the tubing.
3.4 SERVICE PREPARATION PROCEDURE
1 . Remove the lid from the top of the Delivery System
by grasping the sides of the Diffuser Chamber with both
hands, and lifting the entire top straight-up. Carefully, set
the lid aside.
2. Check the Internal Pressure Gauge. It should read 20
PSI. DO NOT ADJUST ANY HIGHER.
3. Position the oil outlet elbow, located within the Main
Reservoir, so that it is pointing straight up.
4. Slowly, fill the Main Reservoir with tap water. (Water
will automatically exit though the pick-up tube and spill
into the Delivery System Reservoir.
3
5. The rising water level will open the discharge valve by
lifting the ball float. This will cause the pump to start
cycling and push the Water through the Adsorption
Module.

6. Watch the discharge hose on the Adsorption Module

to determine that water is being pumped through the
system. If it is not, add about a half-a-gallon to the reser-
voir and check again. The Pump will continue to run until
the receding water level lowers the ball float enough to
close the valve. This will stop the Pump.

3.5 SYSTEM COMMISSIONING

1. Replace the Lid on the Delivery System.

2. Connect your Condensate Drain Lines to the 1/2” npt

(F) inlet connections on the Diffuser Chamber.

Note: The Diffuser Chamber can be rotated at 90

degree intervals to ease your piping restraints. Simply
remove the four socket head capscrews, position as
needed and replace the screws.

3. SAVE ALL PLUGS AND FITTINGS!!!

4. The POLYSEP PS is ready for service.

4.0 OPERATION INSTRUCTIONS

The POLYSEP PS Delivery System will automatically
start and stop as required by the condensate load.

Do not pour condensate, oil, or any other fluid directly

into the oil/water separator.

Weekly, collect a sample of the discharge water in a

clear glass vessel and, compare it to tap water, checking
for cloudiness.

Replace the Adsorption Module when cloudiness

appears in the discharge water sample.

PolySep PS can not be used with 100% food grade lubri-

cants and/or silicon base lubricants.

For detailed analysis, contact your local authority or an

aproved testing laboratory. Ingersoll-Rand provides fluid
testing services. To learn more about the services,
please contact your local Ingersoll-Rand service
provider.

4
5.0 GENERAL DATA

DIMENSIONAL DATA

SIZE A B C D LBS.

PS250 20 15 7.5 .75 90

PS560 28.5 18.6 9.3 2 200
PS1125 32.5 23 11.5 2 400

NOTES:

NOTE 1: ALL DIMENSIONS ARE IN INCHES.

NOTE 2: TOLERANCES - ALL DIMENSIONS ARE .50 UNLESS OTHERWISE SHOWN
NOTE 3: DIFFUSER IS ROTATABLE IN 90 DEGREE INCREMENTS

FIGURE 5.1 OUTLINE DIMENSION DRAWING

5
6.0 PARTS LIST

FIGURE 6.1 REPLACEMENT PARTS LIST

6
 INSTALLATION PARTS LIST

Ref
No. CCN Quantity Description

1 38331237 1 Diffuser Pad

2 38331245 1 Diffuser Assembly
3 38331252 1 Shroud
4 38331310 1 Tank Assembly
5 38331260 1 Pump / Float Assembly
5a 38331278 1 Pump
5b 38331286 1 Valve Assembly
5c 38331294 1 Float Assembly
6 38331302 1 Regulator Assembly
7a 42528513 1 15 Gallon Adsorption Module (not shown)
7b 42528521 1 30 Gallon Adsorption Module (not shown)
7c 42528539 1 55 Gallon Adsorption Module
8 38331328 1 Module Piping Kit
8a 38332342 1 Air Filter for Control Air
8b 38332359 2 2" X 3/4" NPT Tank Fitting
8c 95298352 1 3/4" X 3/8" Reducing Bushing
8d 38332367 1 Brass, 3/4" Garden Hose Connector (not shown)
8e 38332875 1 3/4" NPT X 3/4" Female Tube Elbow
8f 38332338 1 3/8" NPT X 3/8" Tube Elbow Fitting
8g 38332409 18" 3/4" Clear Flexible PVC Tube (not shown)
8h 39124821 72" 3/8" Nylon Tubing
8i 38332763 1 3/4" NPT X 3/4" Barb Straight Fitting

7
 EH SERIES DESICCANT DRYER
MODELS 400-2100
OPERATORS MANUAL

Ensure that the operator reads and understands the

decals and consults the manuals before maintenance
or operation.

a Ensure that the Operation and Maintenance manual is

not removed permanently from the machine.

Ensure that maintenance personnel are adequately

trained, competent and have read the Maintenance
Manuals.

C.C.N. : 80442841
DATE : JANUARY 2007
REV. :A
 CONTENTS

CONTENTS PAGE CONTENTS PAGE

1.0 CONTENTS 1 8.6 ENERGY MANAGEMENT
2.0 INTRODUCTION 2 SYSTEM (EMS) (OPTIONAL)
3.0 WARRANTY 2 8.7 HIGH OUTLET TEMPERATURE
4.0 HEAT REACTIVATED DRYER (OPTIONAL)
NOMENCLATURE 2 8.8 ALARM LIST
5.0 RECEIVING AND INSPECTION 3 9.0 TECHNICIAN MODE 10
5.1 INSPECTIONS 9.1 ENTERING TECHNICIAN MODE
5.2 UNPACKING AND HANDLING 9.2 OPERATING MODE (BI-MODE)
6.0 SAFETY AND OPERATION 9.3 HEATER TEMPERATURE SETPOINT
PRECAUTIONS 3 (HEATED PURGE MODE ONLY)
7.0 PRINCIPLES OF OPERATION 4 9.4 ENERGY MANAGEMENT SYSTEM /
7.1 INTRODUCTION DEW POINT DISPLAY (OPTIONAL)
7.2 DRYING CYCLE 9.4.1 ENABLING / DISABLING ENERGY
7.3 REGENERATION CYCLE MANAGEMENT SYSTEM
7.3.1 SETTING THE REGENERATION 9.4.2 SETPOINT ADJUSTMENT
AIR FLOW 9.5 PURGE TEMPERATURE (OPTIONAL,
7.3.2 HEATED PURGE REGENERATION HEATED PURGE MODE)
7.3.3 HEATLESS PRESSURE SWING 9.6 RESTART MODE
REGENERATION 9.7 EXTENDED HEATING (OPTIONAL)
7.4 TOWER REPRESSURIZATION 9.8 HIGH DEW POINT ALARM (OPTIONAL)
7.4.1 HEATED PURGE REPRESSURIZATION 9.8.1 DESCRIPTION AND ACTIVATION
7.4.2 HEATLESS PRESSURE SWING 9.8.2 SETPOINT ADJUSTMENT
REPRESSURIZATION 9.9 PROGRAM JOG
7.5 VALVES 9.10 SHUTDOWN SEQUENCE
7.6 CONTROLS 10.0 INSTALLATION AND START-UP 15
7.6.1 MICROPROCESSOR CONTROL 10.1 EQUIPMENT APPLICATION
USER INTERFACE GUIDELINES
7.6.2 STATUS PANEL USER INTERFACE 10.2 LOCATING AND MOUNTING
7.6.3 MICROPROCESSOR CONTROL 10.3 PIPING
DISPLAY PARAMETERS 10.4 FILTRATION
7.7 TIMING SEQUENCE 10.5 ELECTRICAL CONNECTION
7.7.1 HEATED PURGE TIMER CYCLE 10.6 START-UP
7.7.2 HEATLESS PRESSURE SWING 10.7 SHUT DOWN PROCEDURES
TIMER CYCLE 11.0 MAINTENANCE AND
7.8 RESTART MODES SYSTEM CHECK 17
7.8.1 MANUAL MODE (ZERO) 11.1 SCHEDULED MAINTENANCE
7.8.2 AUTO RESTART MODE (LAST) 11.2 PRE-FILTERS AND POST-FILTERS
7.9 OPERATING TIMES 11.2.1 THREADED FILTERS
8.0 ALARMS AND INDICATORS 8 11.2.2 FLANGED FILTERS
8.1 MOISTURE INDICATOR 11.3 MUFFLER CHANGE-OUT
(STANDARD) PROCEDURE
8.2 HEATER HIGH TEMPERATURE 11.4 NO-LOSS DRAIN VALVES
ALARM WITH INTERLOCK 11.5 PILOT OPERATED ACTUATOR
(STANDARD) 11.6 DESICCANT CHANGEOUT
8.3 HEATER FAILURE ALARM PROCEDURE
(STANDARD) 12.0 TROUBLESHOOTING 20
8.4 FAILURE TO SHIFT ALARM 13.0 GENERAL ARRANGEMENT 21
(STANDARD) 14.0 WIRING DIAGRAM 28
8.4.1 FAILURE TO REPRESSURIZE 15.0 FLOW DIAGRAM 35
8.4.2 FAILURE TO DEPRESSURIZE 16.0 REPLACEMENT PARTS 37
8.5 HIGH DEW POINT ALARM 17.0 ENGINEERING SPECIFICATIONS 40
(INCLUDED WITH EMS)

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 2.0 INTRODUCTION

Ingersoll Rand Heat Reactivated Desiccant Dryers are designed to
adsorb moisture from compressed air. The dryers are constructed with
two towers, each containing desiccant beads, that alternate between on-
line (drying) and offline (regenerating) modes, yielding a continuous
stream of dry air at the dryer's outlet.
During normal operation, wet air passes through the on line tower and
water vapor from the air is adsorbed (collected) on the desiccant beads.
While air is being adsorbed in the on-line tower, the moisture on the
desiccant in the offline tower is removed by a process called desorption
(regeneration). In standard heat reactivated operation, after an initial
rapid depressurization, a portion of dried air from the on-line tower
passes through a heater and over the desiccant bed and carries the
moisture off the bed and out the dryer's exhaust. With the dryer's Bi-
Mode feature, the dryers may also be operated in a Heatless mode,
which uses more purge air but does not require use of the heater.
The continuous, alternating process of adsorption and desorption is
controlled using a customized Programmable Logic Controller that
switches the towers in a specific timed sequence. Very dry compressed
air dew points are achieved through the continuous switching and
operation of this dryer. Ingersoll Rand offers heat reactivated dryers to
provide either -40°F or -100°F pressure dew point outlet air.

3.0 WARRANTY

The Company warrants that the equipment manufactured by it and
delivered hereunder will be free of defects in material and workmanship
for a period of twelve months from the date of placing the Equipment in
operation or eighteen months from the date of shipment from the factory,
whichever shall first occur. The Purchaser shall be obligated to promptly
report any failure to conform to this warranty, in writing to the Company
in said period, whereupon the Company shall, at its option, correct such
nonconformity, by suitable repair to such equipment or, furnish a
replacement part F.O.B. point of shipment, provided the Purchaser has
stored, installed, maintained and operated such Equipment in
accordance with good industry practices and has complied with specific
recommendations of the Company. Accessories or equipment furnished
by the Company, but manufactured by others, shall carry whatever
warranty the manufactures have conveyed to the Company and which
can be passed on to the Purchaser. The Company shall not be liable for
any repairs, replacements, or adjustments to the Equipment or any costs
of labor performed by the Purchaser or others without Company's prior
written approval.
The effects of corrosion, erosion and normal wear and tear are
specifically excluded. Performance warranties are limited to those
specifically stated within the Company's proposal. Unless responsibility
for meeting such performance warranties are limited to specified tests,
the Company's obligation shall be to correct in the manner and for the
period of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR
REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR
IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE HERBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent,
in the manner and for the period of time provided above, shall constitute
fulfillment of all liabilities of the Company for such nonconformities
whether based on contract, warranty negligence, indemnity, strict liability
or otherwise with respect to or arising out of such Equipment.
The Purchaser shall not operate Equipment which is considered to be
defective, without first notifying the Company in writing of its intention to
do so. Any such use of Equipment will be at Purchaser's sole risk and
liability.
Note that this is Ingersoll Rand standard warranty. Any warranty in force
at the time of purchase of the equipment or negotiated as part of the
purchase order may take precedence over this warranty.

4.0 HEAT REACTIVATED DRYER NOMENCLATURE

NOMINAL*
FLOW POWER / NEMA/ ELECTRICAL ELECTRICAL MECHANICAL
PREFIX (SCFM) DEW POINT MAWP OPTION OPTION OPTION FILTERS
EH 400-2100 4 = 460-3-60 / -40 H = NEMA 4 / 0 = Standard 0 = Standard 0 = Standard A = Filters Attached
D= 460-3-60/ -100 150 psig MAWP F = EMS for L = Filters Loose
6 = 575/3/60 / -40 Heated Dryers
F=575-3-60/ -100

* Nominal Flows indicated are for 100°F inlet temperature, 100°F ambient temperature and 100 psig compressed air pressure.

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 5.0 RECEIVING AND INSPECTION

5.1 INSPECTION a WARNING

Upon receiving your Ingersoll Rand air dryer, please inspect the unit
closely. Visually check the dryer to make certain that all air lines and Under no circumstances should any person attempt to lift heavy
electrical connections are securely fastened and were not damaged in objects without proper lifting equipment (i.e., crane, hoist, slings or fork
transit. If rough handling has been detected, please note it on your truck). Lifting any unit without proper lifting equipment, can cause
delivery receipt, especially if the dryer will not be immediately uncrated. serious injury.
Obtaining the delivery person's signed agreement to any noted damage
will facilitate any insurance claim.

5.2 UNPACKING AND HANDLING

Refer to the General Arrangement drawing for the appropriate means for
lifting or moving the dryer. When lifting the dryer, ensure that no stress
is applied to the piping or valving. Refer to Section 10.2 for locating and
mounting of dryer.

6.0 SAFETY AND OPERATION PRECAUTIONS

Because an air dryer is pressurized and contains rotating parts, the
same precautions should be observed as with any piece of machinery
of this type where carelessness in operation or maintenance could be
hazardous to personnel. In addition to obvious safety rules that should
be followed with this type of machinery, safety precautions as listed
below must be observed:
1. Only qualified personnel shall be permitted to adjust, perform
maintenance or repair this air dryer.
2. Read all instructions completely before operating unit.
3. Pull main electrical disconnect switch and disconnect any separate
control lines, if used, before attempting to work or perform maintenance
on the unit.
4. Do not attempt to service any part while machine is in an operational
mode.
5. Do not attempt to remove any parts without first relieving the entire air
system of pressure.
6. Do not operate the dryer at pressures in excess of its rating.
7. Do not operate the dryer without guards, shields and screen in place.
8. Inspect unit daily to observe and correct any unsafe operating conditions.
OSHA
Heading Descriptions
a WARNING
“Warning” is used to indicate a hazardous situation which has some
probability of death or severe injury. Warning should not be considered
for property damage accidents unless personal injury risk is present.
a CAUTION
“Caution” is used to indicate a hazardous situation which may result in
minor or moderate injury.
a NOTICE
“Notice” is used to indicate a statement of company policy as the
message relates directly or indirectly to the safety of personnel or
protection of property. Notice should not be associated directly with a
hazard or hazardous situation and must not be used in place of
“Danger,” “Warning,” or “Caution.”
a NOTICE
The user of any air dryer manufactured by Ingersoll Rand, is hereby
warned that failure to follow the above Safety and Operation
Precautions may result in personal injury or equipment damage.
However, Ingersoll Rand does not state as fact, nor does it mean to
imply, that the preceding list of Safety and Operating Precautions is all
inclusive, and further, that the observance of this list will prevent all
personal injury or equipment damage.

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 7.0 PRINCIPLES OF OPERATION
7.1 INTRODUCTION
As described in Section 1, water vapor is removed from compressed air
by diverting air flow alternately between two towers filled with activated
alumina desiccant. While one tower processes the compressed air
stream adsorbing water vapor, the opposite tower regenerates by
desorbing the water vapor and venting it to atmosphere.
The Microprocessor Controller provides the ability to select between
heated or heatless regeneration. Both heated and heatless regeneration
methods are described in the following sections.
a NOTICE
The Microprocessor Controller must be in the OFF position prior to
changing the mode (heated purge / heatless) of the dryer. After the
change is made and the Microprocessor Control is subsequently
turned ON, the dryer will be in the new mode of operation.
7.2 DRYING CYCLE
Saturated compressed air enters the dryer and is diverted to the
appropriate tower by the Inlet Flow Valves. (Refer to the Process and
Instrumentation Diagram.) The Right Tower Flow Valve is actuated to a
closed position to prevent air flow from entering the regenerating tower.
Simultaneously, the Left Tower Flow Valve is actuated to an open
position allowing air flow to the drying tower. During this time, the Left
Tower Purge Valve is actuated to a closed position, preventing the
compressed air from venting to atmosphere. As the compressed air
flows through the desiccant material in the left tower at pressure,
removal of water vapor from the air stream begins to occur through
adsorption. In the adsorption process, the desiccant material draws
water vapor out of the compressed air and "holds" it until the left tower
drying cycle is complete. Compressed air flows out of the tower for
delivery to the process use. The Outlet Flow Check Valves provide air
flow diversion to the outlet air connection of the dryer.
7.3 REGENERATION CYCLE
Previously adsorbed moisture removed from the process stream gets
stripped or desorbed from the desiccant material in the regeneration
process. The first stage of regeneration is tower depressurization. After
the Inlet Flow Valves are switched to divert air flow away from the
regenerating tower, the appropriate Purge Valve will be opened and the
tower will be depressurized. Through depressurization, a significant
portion of the previously adsorbed water vapor is stripped off the
desiccant material and exhausted to atmosphere.
a CAUTION
Any time the dryer is switched between two operating modes, care
must be taken to ensure the purge adjustment valve is adjusted
correctly. Refer to the specification sheet in this manual for proper
gauge setting.
7.3.1 SETTING THE REGENERATION AIR FLOW
Proper setting of the purge flow is necessary to achieve
proper dryer performance in the heatless and externally
heated modes. Setting the purge flow too high will waste
compressed air and if set too low, the dryer will not achieve
dew point performance. The purge adjustment manifold
consists of the purge adjustment valve, purge pressure
gauge, and the purge orifice. The purge pressure gauge is
located between the purge adjustment valve and purge
orifice. Manually adjust the purge adjustment valve until the
reading on purge pressure gauge matches the purge
pressure setting listed on the tag attached to the gauge. Note
that there are two purge gauge values, corresponding to each
mode of operation.
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7.3.2 HEATED PURGE REGENERATION
In the heat reactivated mode, the dryer uses 7.5% of dry
compressed air expanded to atmospheric pressure.
However, after air expansion through the Purge Orifice, the
purge air is passed through the purge heater. This expanded,
heated purge air is then passed through the regenerating
tower and exhausted out to atmosphere. After a three minute
delay, the heating process occurs for 2 hours and 57 minutes.
During the heating process the electric heater is cycled on
and off by Ingersoll Rand' temperature controller Solid State
relay. This advanced controller precisely monitors purge air
temperature and adjusts the heater temperature accordingly.
This results in a regeneration air temperature that remains
within 1.5 °F from the heater setpoint for the entire
regeneration cycle, eliminating temperature swings
associated with contactor-based heating system. Upon
completion of the three-hour heating period, the electric
heater turns off. The dry regeneration air continues to flow for
57 minutes in order to cool down the desiccant bed.
7.3.3 HEATLESS PRESSURE SWING REGENERATION
In the heatless mode, following depressurization,
regeneration uses approximately 15% of the dry compressed
air expanded to atmospheric pressure to complete the
desorption process. As shown on the P & ID, the compressed
air exits the drying tower and a portion of the air flows through
the purge adjustment valve and the Purge Orifice. Once the
air has passed through the Purge Orifice, it expands to
atmospheric pressure and continues the regeneration
process. Desorption occurs as the desiccant releases water
vapor into the regeneration air and is exhausted through the
Outlet Purge Valves.
7.4 TOWER REPRESSURIZATION
Upon completion of tower regeneration, and prior to changing the Inlet
Flow Valve position to switch towers, the regenerated tower must be
repressurized. Repressurization is accomplished by closing the
appropriate purge valve. Closing the Purge Valve allows the
regeneration air to pressurize the tower.
a NOTICE
Failure to repressurize prior to tower switchover will result in shocking
the desiccant material and cause premature desiccant dusting.
7.4.1 HEATED PURGE REPRESSURIZATION
Three minutes prior to tower switch-over, repressurization is
accomplished by closing the appropriate Purge Valve. When
the Purge Valve closes, the regeneration air begins to
pressurize the tower. If the dryer is supplied with the optional
repressurization piping, the Repressurization Valve opens,
allowing some additional air from the outlet of the dryer to
assist the purge air and to ensure adequate pressurization.
During normal tower regeneration, the Repressurization Valve
is held closed so that the only source of air for regeneration
passes through the purge adjustment assembly.
7.4.2 HEATLESS PRESSURE SWING REPRESSURIZATION
45 seconds prior to tower switch-over, repressurization is
accomplished by closing the appropriate Purge Valve. When
the Purge Valve closes, the regeneration air begins to
pressurize the tower. If the dryer is supplied with the optional
repressurization piping, the Repressurization Valve opens,
allowing some additional air from the outlet of the dryer to
assist the purge air and to ensure adequate pressurization.
During normal tower regeneration, the Repressurization Valve
is held closed so that the only source of air for regeneration
passes through the purge adjustment assembly.
 7.0 PRINCIPLES OF OPERATION
7.5 VALVES
Flow and Purge Valves are two-way valves that are switched using air-
operated double-acting actuators. Each valve is actuated by a four-way
solenoid valve as shown on the P & ID.
Outlet Check Valves, as well as Purge Check Valves are single-direction
check valves that will allow flow in the direction shown on the P & ID, but
not allow flow in the opposite direction.
7.6 CONTROLS

a NOTICE 7.6.1 MICROPROCESSOR CONTROL USER INTERFACE

The Microprocessor Control display provides the user with the
Actuated valves require 75 psi min. pressure for proper operation.
operating parameters and their corresponding values. When
power is supplied to the dryer, the Microprocessor Control will
The Inlet Flow Valves are connected as normally open valves. When
illuminate and default to the "Standby" mode, displaying the
the dryer is de-energized, the solenoid valves for the Inlet Flow Valves
"Press ON" prompt.
supply control air to the "open" port on the appropriate valve actuator.
The following illustration summarizes the keypad functions.
Purge Valves are connected as normally closed valves. When the dryer
is de-energized, the solenoid valves for the Purge Valves supply control
air to the "closed" port on the appropriate valve actuator.

PRESS ON

Figure 1 - Microprocessor Controller

BUTTONS

• ON • RESET
Initiates PLC program. Begins system monitoring and valve Pressing once clears the local alarm indication and de-energizes
switching functions. the remote alarm contact for many alarm conditions. Should the
alarm condition persist, the alarm will return after the alarm inhibit
• OFF
time has expired.
Stops PLC program. Stops valve switching functions. Initiates
Shutdown Sequence. Opens Inlet Flow Valves. Closes Purge • SET
Valves. Permits the adjustment of parameters in TECHNICIAN MODE.
• SELECT DISPLAY • ENTER
Allows the user to scroll through the available displays. The last Used to accept changed parameters and set point values.
display selected will remain displayed as the default display. • TEST
• +/- Not used in Desiccant Dryer applications
Allows user to increase set point values. Set point values cycle • i
through a fixed range. Also allows entering negative numbers in Restricted Level access for factory use only.
Technician.
• Õ
Allows user to step backwards to the previous level of the menu.

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 7.0 PRINCIPLES OF OPERATION
7.6.2 STATUS PANEL USER INTERFACE
The status panel provides clear indication of dryer status via
bright LED indicators. The following illustration summarizes
the panel’s features:
Dryer ON (Green)
Left Tower Regeneration
(Yellow)
Left Tower Drying
(Yellow)
Figure 2 - Status Panel
NOTE: Ingersoll Rand solid state temperature controller modulates the
heater repeatedly during the heating cycle. Pulsating of the heater LED
will occur as a result and should be considered normal dryer operation.
7.6.3 MICROPROCESSOR CONTROL DISPLAY PARAMETERS
The Microprocessor Controller is capable of displaying a
number of system parameters in the default CUSTOMER
MODE. The following summarizes the parameters that can be
accessed by depressing the SELECT DISPLAY button from
the Microprocessor Controller. (Note that some displays are
optional and may not appear on all models):
• Tower Status {LT DRY / RT REGEN or LT REGEN / RT
DRY}: Provides visual confirmation of tower drying and
regenerating status.
• Step Timer {ie STEP 4 TIME 120}: Information screen
displaying the current step in the program and the time
remaining for the displayed step.
• Dew Point Temperature (OPTIONAL) - {DEW POINT TEMP:
XX}: When equipped with the optional EMS feature,
provides accurate display of dryer outlet pressure dew point.
• Purge Status (OPTIONAL) - {PURGE / NO PURGE}:
Indicates whether unit is currently consuming purging air.
Requires EMS.
• Heater Status (HEATED PURGE MODE ONLY) - {On /
OFF}: Indicates that the heater is being given a signal to
heat the purge air.
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Dryer OFF / Alarm
(Red)
Right Tower Regeneration
(Yellow)
Heater Operation
(Green)
Right Tower Drying
(Yellow)
• Heater Temperature (HEATED PURGE MODE ONLY) -
{HEATER TEMP: XX}: Indicates the heater temperature set
point..
• Alarms {ALARM LIST - PRESS ENTER}: Depressing
<ENT> at this prompt permits viewing of current alarm status
and alarm history, which includes the time and date of the
alarm occurrence.
• Operating & Purge Times - {OPERATING TIMES - PRESS
ENTER}: Depressing <ENT> at this prompt provides access
to the operating and purge hours of operation.
• Operating Mode {OPERATING MODE: HEATLESS /
HEATED PURGE}: EH dryers are capable of operating in
Heated Purge and Heatless Pressure Swing modes. This
display indicates mode of operation for dryer.
Once the last screen is displayed, depressing the SELECT DISPLAY
button will return the display to the top of the list.
7.7 TIMING SEQUENCE
All timing functions are performed by Ingersoll Rand' Microprocessor
Controller, an advanced micro PLC designed exclusively for Ingersoll
Rand dryers. The Microprocessor Controller is completely programmed
at the factory and does not require any further adjustment. The standard
timing cycle switches the Inlet Flow Valve, which alternates the drying
tower. At the same time as the Inlet Flow Valve opens, the appropriate
tower Purge Valve opens to begin the purge flow generation. Once the
purge regeneration flow portion of the dryer cycle is complete, tower
repressurization begins as previously described.
 7.0 PRINCIPLES OF OPERATION

7.7.1 HEATED PURGE TIMER CYCLE 7.9 OPERATING TIMES

In the externally heated operating mode, the Microprocessor In the CUSTOMER MODE, the Microprocessor Controller provides
Control controls an eight-hour cycle. The tower switch-over access to the operating hours of the dryer. The following describe the
occurs every four hours. Ten seconds after switch-over method to access and review the operating and purge hours for the
occurs, the regenerating tower depressurizes for 50 seconds. dryer:
After depressurization, heated regeneration begins and
extends for 2 hours and 58 minutes. The heating supply is
turned off and the purge air flow continues for the next 58
minutes. The purge air supply during this time is used to cool OPERATING TIMES
SELECT
down the hot desiccant. After the cool down stage, a
DISPLAY
repressurization stage repressurizes the offline tower for 3 PRESS ENTER
minutes.
Depress the SELECT DISPLAY button until the OPERATING
7.7.2 HEATLESS PRESSURE SWING TIMER CYCLE
TIMES display appears.
In the heatless operating mode, the Microprocessor Control
controls a ten-minute cycle. The tower switch-over occurs
every five minutes. Ten seconds after tower switch-over
occurs, the regenerating tower depressurizes and tower
regeneration occurs for four minutes and 15 seconds. At that BEGIN TIMES
ENTER
time, tower repressurization begins.

7.8 RESTART MODES

Depressing the ENTER button enters the OPERATING TIMES
The Microprocessor Controller includes a Shutdown Sequence that is menu.
activated when the dryer OFF button is depressed. This feature
positions the valves to their failsafe position and resets the program and
is the recommended method of shutting down the dryer. When the dryer
is subsequently energized, the dryer is ready to run at the start of the
program. Should, however, power be cut to the dryer before the SELECT OPERATING HOURS
DISPLAY
Shutdown Sequence has been initiated, as would be the case from a 000000065
power failure, the dryer can be configured to restart in one of two restart
modes. Note that when the dryer is shut down using the OFF button, Depressing the SELECT DISPLAY button displays the
the dryer will require user intervention to restart the dryer. cumulative operating hours of the dryer.

7.8.1 MANUAL MODE (ZERO)

Ingersoll Rand dryers are shipped from the factory in the
Manual Mode. After power is re-supplied to the dryer, the user SELECT PURGE HOURS
will be presented with the "PRESS ON" display. The valve DISPLAY
switching and timing operations will only start once the ON
000000009
button is depressed. In this configuration, to restart the dryer,
the user must manually depress the ON button on the Depressing the SELECT DISPLAY button displays the
Microprocessor Control panel. cumulative hours the dryer has used purge air.

7.8.2 AUTO RESTART MODE (LAST)

In this mode, the dryer will re-start automatically once power BEGIN TIMES
is applied to the dryer. The Microprocessor Control will pick up SELECT
DISPLAY
where it left off in the program once power is applied.

Depressing the ENTER button returns the display to the top of

the OPERATING TIMES menu.

OPERATING TIMES
Õ PRESS ENTER
Depressing the Õ button returns the controller to the
CUSTOMER MODE

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 8.0 ALARMS AND INDICATORS
8.1 MOISTURE INDICATOR (STANDARD)
The moisture indicator senses a sample of the control air which is taken
from the dryer outlet. The indicator provides a gross indication of dew
point deterioration at the outlet of the dryer. Under normal operating
conditions, the indicator is blue. In the event of a dryer malfunction or
prolonged dryer shut down, it will turn gray in the presence of moisture.
8.2 HEATER HIGH TEMPERATURE ALARM
WITH INTERLOCK (STANDARD)
The Heater High Temperature Alarm monitors the internal temperature
of the heater housing. Should a component failure occur or system
conditions result in the heater temperature rising above the alarm set
point, the dryer will alarm. During the alarm condition, the heater is
prevented from operating, the Microprocessor Control halts the program
at the point where the alarm occurred and displays the condition in the
Microprocessor Control LCD display. The dryer will be unable to be reset
until the temperature of the heater has fallen below the alarm point. To
reinstate the dryer, depress the RESET button on the Microprocessor
Controller AND manually reset the Heater High Temperature Safety in
the electrical enclosure. Note that the alarm condition will return should
proper corrective action not be taken.
8.3 HEATER FAILURE ALARM (STANDARD)
This feature produces an alarm should the heater fail to generate heat
at the beginning of the heating cycle. During the initial ten minutes of
the heating cycle, the Microprocessor Controller monitors the heater
temperature. Should the heater temperature fail to rise to 150 °F within
the ten minute period, the Heater Failure Alarm will be triggered. During
this alarm condition, power to the heater is removed and the program is
halted. Depressing the RESET button on the Microprocessor Controller
will reinstate the program and provided the heater problem has been
remedied, continue with normal operation.
8.4 FAILURE TO SHIFT ALARM (STANDARD)
Ingersoll Rand Failure To Shift Alarm monitors the dryer sequencing
functions to insure proper dryer operation by sensing the pressure in each
tower via tower pressure switches. Should one of the following conditions
occur, the Microprocessor Controller will communicate the alarm
condition. There are several types of switching failure modes that can be
detected by the Failure To Shift Alarm feature. They are as follows:
8.4.1 FAILURE TO REPRESSURIZE
At the end of the repressurization stage of the dryer operation,
both towers should be at line pressure. Should the pressure
switches indicate that both towers are not at line pressure, the
Failure to Shift Alarm will activate and the Microprocessor
Control will stop the program at it's current position in the
program. The user must depress the RESET button followed
by the ON button, at which time the Microprocessor Control
will start at the beginning of the program.
8.4.2 FAILURE TO DEPRESSURIZE
At the end of the depressurization stage of the dryer
operation, the regenerating tower should be at atmospheric
pressure. Should the pressure switches indicate that this is
not the case, the Failure to Shift Alarm will activate and the
Microprocessor Control will stop the program at it's current
position in the program. The user must depress the RESET
button followed by the ON button, at which time the
Microprocessor Control will start at the beginning of the
program.
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8.5 HIGH DEW POINT ALARM (INCLUDED WITH EMS)
The purpose of the High Dew Point Alarm is to provide the operator an
alarm indication should the equipment fail to supply air at its designed
pressure dew point. The EMS dew point sensor communicates the
pressure dew point reading to the Microprocessor Controller. Should
the pressure dew point rise above the alarm set point, the
Microprocessor Controller will display the alarm condition on the
controller screen.
8.6 ENERGY MANAGEMENT SYSTEM (EMS) (OPTIONAL)
EMS is an energy savings feature that matches moisture loading and
regeneration energy usage. Drying equipment is typically operated below
full flow rating and/or below maximum water loading capacity of the
desiccant bed. The EMS option includes a dew point transmitter that
transmits the outlet pressure dew point to the Microprocessor Controller.
The Microprocessor Controller displays the outlet pressure dew point in
real-time. The EMS feature utilizes the data communicated from the dew
point sensor and extends the normal timed switching sequence in
proportion to the moisture loading on the dryer. When the EMS feature is
turned off, all switching sequences occur as described in Section 7.3.
When the EMS feature is activated, the drying sequence is governed by
the outlet pressure dew point as measured by the dew point sensor. When
the sampled outlet dew point registers below the customer set point (-43°F
default for -40°F dryers; -102°F on -100°F dryers), an immediate change
in dryer operation will not be noticeable. The dryer will continue its normal
regeneration process through tower re-pressurization. Once the tower is
re-pressurized, both towers will be at line pressure but air will only flow
through the tower indicated by the status panel. Tower switch over
sequence is delayed until the dew point elevates above the EMS set point,
at which point tower switch over will occur.
In addition to monitoring the outlet pressure dew point of the drying tower,
the EMS feature monitors the temperature of the purge exhaust air on the
regenerating tower. After a tower switch-over, and at the beginning of
tower regeneration, the purge exhaust temperature will be relatively low
(normally 90 to 110°F). The purge exhaust temperature will increase as
desiccant regeneration progresses. As nearly all of the previously
adsorbed moisture is driven off of the desiccant, the exhaust temperature
will begin to rise. The timing for the temperature change will vary
depending on moisture loading on the towers. When the purge exhaust
temperature reaches 195°F, which indicates that the desiccant heating is
complete, the Microprocessor Controller will remove power to the heater.
Once the heater is turned off, the tower cool down process begins and
continues for 57 minutes. Purge air will continue to exhaust and the
exhaust air temperature will continue to rise (250°F is not uncommon) as
it removes the heat from the regenerated desiccant material. As the cool
down progresses, the exhaust temperature will begin to decrease. After
cooling, the Purge Valves close and the optional Repressurization Valve
(if equipped) opens. The off-line tower remains pressurized until the tower
switchover sequence is initiated.
8.7 HIGH OUTLET TEMPERATURE (OPTIONAL)
This option provides continuous monitoring of the the dryer discharge air
temperature via a thermostat that senses the outlet air temperature
during dryer operation. Should a high outlet temperature condition exist,
the alarm is displayed on the Microprocessor Controller to alert
maintenance personnel of a malfunction. This alarm does not interrupt
the dryer program. Depressing the RESET button will clear the alarm
provided the alarm condition as been addressed. Note that the alarm
will clear automatically once the high temperature condition is corrected.
 8.0 ALARMS AND INDICATORS

8.8 ALARM LIST

SELECT FAIL TO SHIFT
The Microprocessor Controller stores the 20 most recent alarm DISPLAY
conditions. These alarms are stored with the type of alarm as well as TM 1635 DATE 1104
the date and time the alarm occurred. This list can greatly facilitate
troubleshooting the dryer and provide an indication of dryer operation Depressing the SELECT DISPLAY list displays the most
during unattended service. The following describe the method to access recent of the alarms stored by the Microprocessor Control.
and review the alarms stored in the Microprocessor Controller: Refer to the diagram at the end of this section for an
explanation of the ALARM LIST Display.

SELECT ALARM LIST Depressing the SELECT DISPLAY button will reveal the previous alarm
DISPLAY condition(s), as well as the remaining available alarm placeholders for
PRESS ENTER alarms. To EXIT the ALARM LIST, perform the following:

Depress the SELECT DISPLAY button until the ALARM LIST

display appears.
BEGIN ALARMS
Õ
BEGIN ALARMS
ENTER
Depressing the Õ button returns the controller to the top of
the ALARM LIST.
Depressing the ENTER button enters the ALARM LIST menu.

ALARM LIST
Õ
PRESS ENTER
SELECT ALARM OFF
DISPLAY Depressing the Õ button again returns the controller to the
CUSTOMER MODE.
Depressing the SELECT DISPLAY button advances the menu
to the current alarm status.

Alarm Condition

FAIL TO SHIFT
TM 1635 DATE 1104

Time of Alarm Date of Alarm

(Military Time) (Date-Month)
Example shows April 11

Figure 3 - Alarm Screen Details

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 9.0 TECHNICIAN MODE

The Microprocessor Control provides a protected TECHNICIAN MODE 9.2 OPERATING MODE (BI-MODE)
to manipulate several parameters not accessible by the casual operator. As described in Section 7, Heat Reactivated Dryers can operate in a
Below is a list of parameters that can be accessed and manipulated by heated purge mode as well as a heatless pressure swing mode. To
the technician in the TECHNICIAN MODE: change the operation mode of the dryer, perform the following
keystrokes:
Parameter Display Set Point
OPERATION
OPERATION MODE HTLS, HEATED
MODE
DEW POINT ADJUSTER SETTING
PDP ADJUSTER -40, -4, +38 SELECT
SET OP MODE
(HEATLESS MODE ONLY)
ENERGY MANAGEMENT
DISPLAY HEATED PURGE
EMS OFF , ON
SYSTEM (OPTIONAL)
ENERGY MANAGEMENT SYSTEM Depress the SELECT DISPLAY button until the SET
EMS SET POINT -76 - +68 OPERATION MODE screen is displayed.
SETPOINT (OPTIONAL)
PURGE TEMPERATURE PURGE TEMP OFF , ON
RESTART MODE RESTART LAST, ZERO
+
SET OP MODE
EXTENDED HEATING EXTENDED HTG OFF , ON
- HEATLESS
PURGE FLOW ADJUSTER
SETTING (HEATLESS MODE PURGE ADJUST 30% - 100%
ONLY) Depress the +/- button until the desired operating mode is
displayed. Pressing SELECT DISPLAY saves the current
HIGH DEW POINT ALARM
HI DEW POINT OFF , ON selection.
ACTIVATION (OPTIONAL)

* NOTE: Setpoints indicated are adjustable ONLY when dryer is

equipped with the Energy Management System option. Setpoints are a NOTICE
non-adjustable on dryers
The Microprocessor Controller must be in the OFF position prior to
9.1 ENTERING TECHNICIAN MODE changing the mode (heated purge / heatless) of the dryer. After the
change is made and the Microprocessor Control is subsequently
a WARNING turned ON, the dryer will be in the new mode of operation.

TECHNICIAN MODE should only be entered by qualified service a CAUTION

personnel. Altering the set points in TECHNICIAN MODE will have a
significant effect on the operation of the dryer. Incorrect set points may
damage dryer and cause potential serious injury.
To enter the TECHNICIAN MODE, perform the following keystrokes:
BEGIN
Any time the dryer is switched between two operating modes, care
must be taken to ensure the purge adjustment valve is adjusted
correctly. Refer to the specification sheet in this manual for proper
gauge setting.
9.3 HEATER TEMPERATURE SETPOINT (HEATED PURGE MODE
ONLY)
The Microprocessor Controller permits the user to adjust the
temperature of the heater, thereby altering the regeneration temperature
in the heated purge mode.

2 3 TECHNICIAN MODE a WARNING

The user is advised to only alter the regeneration temperature after
Pressing the “2” and “3” buttons simultaneously enters the being instructed to do so by Ingersoll Rand factory personnel.
TECHNICIAN MODE. Improper or inappropriate manipulation of the heater temperature can
result in degraded dryer performance, equipment damage and serious
injury. Notify Ingersoll Rand Compressed Air Solutions prior to altering
the heater temperature.
SELECT
SET OPMODE
DISPLAY HEATLESS The following illustrates the method of adjusting the setpoint for the
heater temperature:
Depressing SELECT DISPLAY scrolls through the available
parameters.
SELECT HEATER TEMP
DISPLAY
375
Depress the SELECT DISPLAY button until the HEATER
TEMPERATURE SET POINT screen is displayed.

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 9.0 TECHNICIAN MODE

HEATER TEMP a NOTICE

SET
New desiccant has a moisture holding capacity higher than the dryer’s
___ design regeneration capacity. The desiccant ages in a three- to six-
month time period at which point it stabilizes to an "aged" state. During
Pressing the SET button permits the value of the HEATER this aging process at initial start-up or after desiccant replacement, the
TEMPERATURE SETPOINT to be changed Energy Management System feature should be deactivated.

3
HEATER TEMP
9.4.1 ENABLING / DISABLING ENERGY MANAGEMENT
3__ SYSTEM
The following illustrates the method of accessing and
Use the numbers on the keypad to enter the desired value adjusting the Energy Management System feature:
for the HEATER TEMPERATURE setpoint.

8
HEATER TEMP SELECT
EMS: OFF
38_ DISPLAY

Use the numbers on the keypad to enter the desired value Depress the SELECT DISPLAY button until the ENERGY
for the HEATER TEMPERATURE setpoint. MANAGEMENT SYSTEM screen is displayed.

0
HEATER TEMP +
- EMS: ON
380
Use the numbers on the keypad to enter the desired value Depress the +/- button until the desired set point is displayed.
for the HEATER TEMPERATURE setpoint. Pressing SELECT DISPLAY saves the current selection.

HEATER TEMP 9.4.2 SETPOINT ADJUSTMENT

ENTER
380 On dryers equipped with the optional Energy Management
System the setpoint can be adjusted to match the dryers
Depressing ENTER saves the selected set point. operation to the desired pressure dew point.

The following illustrates the method of adjusting the setpoint

for the Energy Management System feature:
9.4 ENERGY MANAGEMENT SYSTEM (OPTIONAL)
The Energy Management System option includes a dew point sensor
that transmits the outlet pressure dew point to the Microprocessor SELECT EMS SET POINT
Controller. The Microprocessor Controller displays the outlet pressure DISPLAY
-43
dew point in real-time. This option package also includes Energy
Management System, an energy savings feature that matches moisture
Depress the SELECT DISPLAY button until the EMS SET
loading and regeneration energy usage. Drying equipment is typically
POINT screen is displayed.
operated below full flow rating and/or below maximum water loading
capacity of the desiccant bed. The Energy Management System feature
utilizes the data communicated from the dew point sensor and extends
the normal timed switching sequence in proportion to the moisture SET
EMS SET POINT
loading on the dryer. ___
When the Energy Management System feature is turned off, all Pressing the SET button permits the value of the EMS
switching sequences occur as described in Section 7.3. When the SETPOINT to be changed
Energy Management System feature is activated, the drying sequence
is governed by the outlet pressure dew point as measured by the dew
point sensor. When the sampled outlet dew point registers below the
customer set point (-43°F default for -40°F dryers; -102°F on -100°F
+ EMS SET POINT
-
dryers), an immediate change in dryer operation will not be noticeable. -___
The dryer will continue its normal regeneration process through tower
re-pressurization. Once the tower is re-pressurized, both towers will be To enter a negative number, depress the +/- button.
at line pressure but air will only flow through the tower indicated by the Otherwise, proceed to the next step.
status panel. Tower switch over sequence is delayed until the dew point
elevates above the Energy Management System setpoint, at which point
tower switch over will occur.
4 EMS SET POINT
-4__
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the EMS setpoint.

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 9.0 TECHNICIAN MODE
1 EMS SET POINT
-41_
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the EMS setpoint.
ENTER
EMS SET POINT
-41
Depressing ENTER saves the selected set point.
9.5 PURGE TEMPERATURE (OPTIONAL, HEATED PURGE MODE)
On dryers equipped with EMS, the temperature of the purge exhaust is
monitored and displayed on the Microprocessor Controller. After a tower
switch-over, and at the beginning of tower regeneration, the purge
exhaust temperature will be relatively low (normally 90 to 110°F). The
purge exhaust temperature will increase as desiccant regeneration
progresses. As nearly all of the previously adsorbed moisture is driven
off of the desiccant, the exhaust temperature will begin to rise. The
timing for the temperature change will vary depending on moisture
loading on the towers . When the purge exhaust temperature reaches
195°F, which indicates that the desiccant heating is complete, the
Microprocessor Controller will remove power to the heater. Once the
heater is turned off, the tower cool down process begins and continues
for 57 minutes. Purge air will continue to exhaust and the exhaust air
temperature will continue to rise (250°F is not uncommon) as it removes
the heat from the regenerated desiccant material. As the cool down
progresses, the exhaust temperature will begin to decrease. After
cooling, the Purge Valves close and the optional Repressurization Valve
(if equipped) opens. The off-line tower remains pressurized until the
tower switchover sequence is initiated. Activation of the Purge
Temperature feature is via the Microprocessor Controller.
The following illustrates the method of accessing and activating the
Purge Temperature feature:
SELECT
PURGE TEMP: OFF
DISPLAY
Depress the SELECT DISPLAY button until the POWER
SAVER screen is displayed.
+ PURGE TEMP: ON
-
Depress the +/- button until the desired set point is displayed.
Pressing SELECT DISPLAY saves the current selection.
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9.6 RESTART MODE
Ingersoll Rand dryers can be configured to restart in one of two
operating modes. As described in Section 7.8, the dryer may be
configured for Manual operation (factory default) or Auto Restart, which
permits the dryer to operate automatically once power is re-applied to
the dryer after a power failure. The following illustrates the method of
accessing and adjusting the different start modes for the dryer:
SELECT
RESTART
DISPLAY ZERO
Depress the SELECT DISPLAY button until the START
MODE screen is displayed.
+ RESTART
-
LAST
To change the start mode from its current selection to the
alternate setting, depress the +/- button until the desired set
point is displayed. Pressing SELECT DISPLAY saves the
current selection.
a NOTICE
The restart modes will only affect restarting should power be
unexpectedly removed from the dryer. After proper shut down, the
dryer will require the user to depress the ON button to initiate the
operation of the dryer program.
9.7 EXTENDED HEATING (OPTIONAL)
On dryers equipped with both the Energy Management System option,
the dryer may be operated in an extended heating mode. In this mode,
the heating cycle is extended while the Energy Management System
function prolongs the drying cycle. This feature is particularly useful
when operating the dryer with new desiccant. As described earlier in this
manual, new desiccant has the ability to adsorb more moisture than the
dryer can desorb in a fixed regeneration cycle. With the Extended
Heating operation, the Energy Management System feature can be
used immediately without the need to age the desiccant. To enable the
Extended Heating mode, perform the following keystrokes:
SELECT
EXTENDED HEATING
DISPLAY OFF
Depress the SELECT DISPLAY button until the EXTENDED
HEATING screen is displayed.
EXTENDED HEATING
+
-
ON
Depress the +/- button until the desired set point is displayed.
Pressing SELECT DISPLAY saves the current selection.
 9.0 TECHNICIAN MODE
9.8 HIGH DEW POINT ALARM (OPTIONAL)
9.8.1 DESCRIPTION AND ACTIVATION
When the dryer is equipped with the optional Energy
Management System feature, the dew point sensor transmits
the dew point to the Microprocessor Control Should the outlet
pressure dew point exceed the customer specified set point,
High Dew Point Alarm will activate.
The following illustrates the method of activating the High
Dew Point Alarm feature:
SELECT HIGH DEW PT
DISPLAY
OFF
Depress the SELECT DISPLAY button until the HIGH DEW
POINT screen is displayed.
+ HIGH DEW PT
-
ON
Depress the +/- button until the desired set point is displayed.
Pressing SELECT DISPLAY saves the current selection.
9.8.2 SETPOINT ADJUSTMENT
On dryers equipped with the optional Energy Management
System, the High Dew Point Alarm setpoint can be adjusted
as follows. Factory settings on -40°F dryers is -28°F.
The following illustrates the method of adjusting the setpoint
for the High Dew Point Alarm feature:
HI PDP SETPOINT
SELECT
DISPLAY -10
Depress the SELECT DISPLAY button until the HIGH DEW
POINT SET POINT screen is displayed.
HI PDP SETPOINT
SET
___
Pressing the SET button permits the value of the HIGH
DEW POINT ALARM SETPOINT to be changed
+ HI PDP SETPOINT
-
-___
To enter a negative number, depress the +/- button.
Otherwise, proceed to the next step.
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2 HI PDP SETPOINT
-2__
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the EMS setpoint.
1 HI PDP SETPOINT
-21_
Use the numbers on the keypad to enter the desired
pressure dew point temperature for the HIGH DEW POINT
ALARM setpoint.
HI PDP SETPOINT
ENTER
-41
Depressing ENTER saves the selected set point.
a NOTICE
The High Dew Point Alarm set point should not be greater than the
Energy Management System set point. Failure to do so will result in an
alarm indication. Ingersoll Rand recommends setting the High Dew
Point Alarm at least 10°F wetter than the Energy Management System
setpoints.
9.9 PROGRAM JOG
All heated purge dryers come equipped with a Program Jog feature that
is accessible via the Microprocessor Controller. This feature allows the
dryer cycle to be accelerated for troubleshooting and routine inspection
purposes. By accessing the Program Jog routine in the Microprocessor
Control, the customer can advance the program to the next program
step. Note that the program advance feature will not advance through all
steps of the program.
a WARNING
When the Program Jog is initiated in the middle of the heating cycle,
advancing the program without allowing normal tower cool down will
result in an outlet air temperature that may exceed 300°F. As such,
proper precautions must be taken to protect downstream equipment
from high temperature exposure.
a NOTICE
During the Program Jog routine, the display may show intermediate
steps in the program that are not active in the current program set up.
This should be considered normal operation.
The Microprocessor Controller will only permit the jog function during
specific stages of the program. Should the program be at a stage where
the program can not advance, the following will be displayed:
SELECT JOG MODE
DISPLAY
WAIT
Depress the SELECT DISPLAY button until the JOG MODE
display appears. The WAIT prompt will appear should the
program not be able to advance at this stage.
13
 9.0 TECHNICIAN MODE

Should the program be at a stage whereby the Microprocessor Control

permits the jog feature, the following will be displayed:
JOG: ENT TO JOG
STEP 6 TME10699
Depress the SELECT DISPLAY button until the JOG MODE
display appears. The PRESS ENTER prompt will appear,
along with the current step and remaining time, should the
program be able to advance at this stage.
JOG MODE
ENTER
STEP 8 TME00550
Depressing the ENTER button advances the program to the
next step. The display will indicate the next step has been
initiated.
a NOTICE
The Program Jog advances steps #6, #8, #20 & #22, which are the
longest program steps. The balance of the steps are not advanced in
Program Jog Mode.
a NOTICE
To exit the TECHNICIAN MODE, press the “+ / -” key to the initial “SET
OPMODE” screen and depress the Õ button to return to the
CUSTOMER MODE.
9.10 SHUTDOWN SEQUENCE
When the OFF button is pressed, SHUTDOWN SEQUENCE will be
displayed for 30 seconds. During this time the offline tower will
represurrize. Both main flow valves will open and purged air will cool the
heater element.

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 10.0 INSTALLATION AND START-UP
10.1 EQUIPMENT APPLICATION GUIDELINES
Ingersoll Rand Regenerative air dryers are shipped complete with
desiccant up to and including model EH2100. On larger units, the
desiccant is packaged separately for ease in handling. Refer to Section
9.6 for desiccant fill procedures.
To achieve the best dryer performance, carefully check that the design
and installation requirements outlined below are satisfied.
Ingersoll Rand dryers are available with an operating range from 75 -
150 PSIG. Air available for your usage will vary with operating pressure.
The maximum design pressure of the standard Desiccant Dryers is 150
PSIG. For units that require higher operating pressures, consult your
Ingersoll Rand representative.
Dryers are sized according to flow and pressure drop, not pipe size. The
difference between the inlet and the outlet flow is the amount of purge
air required. This air is exhausted to atmosphere and is not available for
use downstream. Make certain air supply to dryer meets air demand
plus purge air requirements.
a NOTICE
The standard dryer is not rated for any gas other than air.
a NOTICE
Ingersoll Rand recommends that the mufflers be cleaned after initial start-
up to remove any desiccant dust generated during shipment. After running
dryer for initial 30 minute period, de-energize / depressurize dryer and
remove mufflers. Disassemble and clean the removable insert inside the
muffler core. Reinstall mufflers prior to operating dryer.
10.2 LOCATING AND MOUNTING
The dryer must never be installed where air and/or ambient temperature
exceeds 120°F or drops below +35°F. Locate dryer to avoid extremes
of heat and cold from ambient or other conditions. Where applicable,
dryer towers may be insulated to reduce heat loses. Avoid locating
dryer outside or where it is exposed to the elements.
The dryer, or any air system component, must be located to avoid
exposure to pulsation in the compressed air as well as possible surges
due to fluctuating demand. In addition, care must be used to minimize
exposure to vibration transmitted through mounting pads or piping.
Provide adequate space around the dryer for normal maintenance
requirements and service.
If the dryer is shipped with the desiccant packaged separately, install the
desiccant after locating and mounting. Desiccant has been provided
separately to minimize handling difficulty and placing unnecessary
stress on the dryer assembly.
Bolt the dryer to the foundation using the bolt holes provided in the base
frame. Anchor bolts should project a minimum of 3.5 inches above the
foundation and allow proper nut and washer assembly.
10.3 PIPING
Pipe the compressed air lines to the inlet and outlet connections. Locate
the pre-filters as close as possible to the dryer. Ensure the positioning
allows for ease of servicing.
Note that the wet air inlet is located at the dryer's upper manifold and the
dry outlet air is located at dryer's lower manifold. In situations where air
supply is required 24- hours a day (it is undesirable to interrupt the airflow),
a three-valve bypass system is recommended to bypass the dryer. To
keep pressure drop at a minimum, use the fewest elbows necessary
To eliminate noise created by frequent tower release of purge exhaust, the
dryer's exhaust may be piped to an outside or more remote location. This
will also eliminate any possible problems caused by indoor accumulation
of condensed moisture from the purge exhaust. If extending the exhaust
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pipe, install it horizontal or downward to avoid accumulation of condensate
at low points. If the purge exhaust is required to run upward, install a valve
at the low point. Keep this valve partially (50-75%) open to continually drain
any liquid water. If extending the exhaust pipe farther than 15 feet, consult
the factory for recommendations.
Once all piping has been connected all joints, including those on the
dryer, should be soap bubble tested at line pressure to ensure no joints
have been damaged in transit and site placement.
10.4 FILTRATION
It is important that a pre-filter and an post-filter be provided in your dryer
installation. These are included with the dryer. They are mounted on
models EH1500 and below.
a NOTICE
All dryers must have proper filtration. Liquid water and oil must be
removed before the air enters the dryer. Ensure separators, pre-filters
and drains are in good working order. Failure to do so will void
warranty.
It is recommended that a mechanical separator be installed immediately
preceding the pre-filter to remove the bulk liquid and entrained water.
Coalescing pre-filters, located before the dryer, protect desiccant beds from
contamination by oil, entrained water, pipe scale, etc., thereby, extending
dryer desiccant life. Locate pre-filters as close to dryer as possible.
FAILURE TO PROVIDE AND MAINTAIN A HIGH EFFICIENCY
COALESCING PRE-FILTER WILL VOID DRYER WARRANTY.
Post-filters, located after the dryer, help eliminate the possibility of
desiccant dusting carrying over into the air system.
a WARNING
High temperature filters must be used to prevent rupture possibility in the
event dryer failure should occur. Consult your Ingersoll Rand
representative for appropriate filter selection.
10.5 ELECTRICAL CONNECTION
Refer to wiring diagram for all electrical connections. Electrical
connection must be hard piped with an external fused disconnect switch
with proper overload protection.
Size field connection knock-out for the conduit fitting required by the NEC.
Service wires must be sized according to the minimum circuit ampacity
shown on the dryer serial nameplate and the requirements of the NEC.
The power connections are marked L1, L2 and L3.
a NOTICE
Dryer must be grounded with the full sized ground wire connected to
an earth ground.
10.6 START-UP
a NOTICE
Initial dryer start-up must be in the Heated Purge Mode
• With dryer de-energized, slowly pressurize the dryer. When the dryer
reaches full operating pressure, check the system for air leaks. Soap test
all joints and fitting. To maintain desired dew point, any leaks detected
must be repaired, especially those on the outlet side of the dryer.
• Turn on dryer disconnect switch to apply power to the dryer.
15
 10.0 INSTALLATION AND START-UP
PRESS ON
Once power is applied to the dryer and after a brief initialization
sequence, the PRESS ON prompt will be displayed.
• Verify all actuated valves are in their failsafe position.
• Using a voltmeter, check the power connections for the correct voltage
shown on the dryer serial nameplate
• Close and secure all electrical panel covers.
• Ensure that the purge adjustment valve is in the open position.
LT DRY RT REGEN
ON
Depress the ON button to initiate the dryer program. The
Microprocessor Controller will display the first CUSTOMER
MODE screen
• The sequence will initiate proper Inlet and Purge Valve positioning and
tower depressurization.
• If the dryer has been in storage or off for an extended period of time,
the Blue Moisture Indicator may be gray, the High Dew Point Alarm (if
equipped) may be activated and the Dew Point Display (if equipped)
may indicate a high dew point. Depending upon the duration of idle
time, it may take anywhere from one to twelve hours for the alarm to
deactivate, the BMI to return to its normal blue state and dew point to
drop.
• For dryers equipped with EMS, refer to Section 9.4 regarding the use
of this option.
a NOTICE
-100° F dryers require flow through the dryer to lower the pressure dew
point to design levels. Failure to permit air flow through the dryer
(dead-heading) will result in elevated outlet dew points. Once air is
permitted to flow through the dryer, the pressure dew point will
gradually reduce to design levels.
10.7 SHUT DOWN PROCEDURES
The following procedures must be followed to properly shut down the
Heat Reactivated Dryer to avoid damage to the unit and preserve dryer
performance. The dryer requires compressed air to actuate the valves.
Removing the compressed air supply prior to shutting down the dryer
will result in improper valve positioning. In addition, the dryer must
complete a specific Shutdown Sequence prior to being turned off.
Should power be removed from the dryer or air pressure removed from
the dryer prior to the completion of the Shutdown Sequence, damage to
the dryer may occur. Lastly, the inlet valves are configured to open on
a loss of power and the purge valves configured to close (fail safe).
Should a valve open to a depressurized tower, as would be the case if
the dryer were stopped in mid-cycle, a rapid pressurization will occur.
a NOTICE
The force of repeated rapid pressurizations will damage the dryer.
16 EH Series Desiccant Dryer Models 400-2100
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a NOTICE
On dryers equipped with EMS, merely leaving the unit in EMS without
a compressed air supply is not advised, as it is likely that the system
pressure will decay over time. Should this occur, the unit will go into a
FTS alarm as well as risk misalignment of valves should switchover
occur prior to reinstating the air compressor.
a CAUTION
Dryer should not be shut down during the heating cycle. Doing so may
cause the Heater High Temperature alarm to activate, which will
require the user to manually reset the Heater High Temperature safety
in the control enclosure. If the dryer must be shut down during the
heating cycle, advance the program via the Program Jog function (see
Section 9.9) to the end of the heating cycle prior to initiating the
Shutdown Sequence.
For all Heat Reactivated Dryers Ingersoll Rand recommends that an
isolation valve be installed at the dryer outlet. Upon restarting the dryer,
it is likely that the pressure downstream of the dryer will have decayed.
When starting the dryer without the valve (or with the valve in the fully
open position), the high velocities of the air through the towers could
damage the desiccant, as well as provide unprocessed air down stream.
a NOTICE
Prior to removing power or compressed air from the dryer, depress the
OFF button on the Microprocessor Control This initiates the Shutdown
Sequence, which closes the purge valves, repressurizes the off-line
tower and opens the flow valves. DO NOT REMOVE POWER OR
COMPRESSED AIR FROM THE DRYER DURING THE SHUTDOWN
SEQUENCE.
Shut Down Procedure:
• Maintain a compressed air source to the dryer and a
supply of power to the Microprocessor Controller.
SHUTDOWN
OFF
SEQUENCE
Depress the OFF button to initiate the SHUTDOWN SEQUENCE.
• Permit the dryer to complete the full SHUTDOWN
SEQUENCE (30 seconds)
PRESS ON
Once the PRESS ON Prompt is displayed, the dryer has
completed the SHUTDOWN SEQUENCE. Power and air may be
safely removed from the dryer.
• De-energize the dryer
• Shut down air compressor or bypass dryer
• Close Isolation Valves (if equipped)
Note: On the subsequent Start-up, the outlet isolation valve should be
in the closed position. Slowly open the valve to build pressure
downstream.
 11.0 MAINTENANCE AND SYSTEM CHECK

11.1 SCHEDULED MAINTENANCE a NOTICE

Daily Maintenance Functions:
• Check and record inlet pressure, temperature and flow. Verify that it is
within specifications.
• Check tower pressure gauge readings within operating tolerance.
• Check tower pressure gauges for proper dryer cycling.
• Check that pre-filter condensate drains are functioning properly.
Replace cartridges sooner if necessary as required by differential
pressure indicator.
• Verify that pressure in purging tower is 5 PSIG or less.
• Verify that pre-filter and post-filter differential pressure is within
operating limits. Replace cartridges sooner if necessary as required by
differential pressure indicator.
Should the drying system be overloaded and/or malfunctioning causing
high pressure drop, HB post-filters will prematurely plug. This problem
can be avoided by frequent inspection and cleaning of elements.
a WARNING
Depressurize the system before disassembling filters. Failure to do so
may result in injury or death.
Filter elements should be changed as indicated on the pressure
differential gauge. Change carbon elements when hydrocarbons are first
detected downstream or every six months, whichever comes first.

Monthly Maintenance Functions: Certain filters contain multiple elements. When replacing filter elements,
• Check your operating conditions: inlet flow, inlet pressure, and inlet all elements should be replaced simultaneously. Mixing new and old
temperature. elements can result in reduced air quality.
• Check pre-filter(s) and post-filter(s) differential pressure and drains.
Replace cartridges sooner if necessary as required by differential
11.2.1 THREADED FILTERS:
pressure indicator.
• Check dryer cycle and sequence of operations (i.e. drying,
depressurizing, regenerating).

Quarterly Maintenance Functions:

• Replace pre-filter(s) and post-filter(s) cartridges. Replace cartridges
sooner if necessary as required by differential pressure indicator.
• Check pilot air filter element and replace as needed.

Semi-Annual Maintenance Functions:

• Check outlet dew point.
• Check amp draw on heater.
• Replace pre-filter and post-filter elements and / or cartridges. Replace
cartridges sooner if necessary as required by differential pressure
indicator.

Annual Maintenance Functions:

• Check desiccant and replace if necessary.
• Inspect and clean no-loss drain valves and check valves. Replace
worn or damaged seats and parts as required.
• Test lights and switches, replace as necessary.
• Test electrical components, replace as necessary.
• Check and repair any air leaks, loose bolts, flanges and fittings.

Every Two Years:

• Change check valves STEP 1 - Rotate filter bowl counter-clockwise to loosen bowl from filter
• Change control no-loss drain valves head. If necessary, a spanner and/or strap wrench may be used.
• Check and change temperature probes Remove bowl.

Every Three to Five Years: STEP 2 - Elements are removed by grasping element and pulling
• Replace desiccant. downward. Note that filter bowl need only be dropped approximately 2"
to permit element to drop from head.

a NOTICE STEP 3 - Inspect element prior to installation. If necessary, lubricate o-

Refer to Section 9.7 for the proper way to shut down the Heat
Reactivated Dryer.
11.2 PRE-FILTERS AND POST-FILTERS
Pre-filter elements must be changed as often as required to prevent
contamination of the regenerative dryer’s desiccant bed.
rings on upper end cap to facilitate installation.
Inspect filter head o-ring. Lubricate, reseat or replace as required. If
equipped with internal float drain, inspect drain operation. Repair or
replace as required.
STEP 4 - Insert element into filter head and push into place.

Pre-filter drains must be checked daily. Failure to drain condensed liquid
from the sump of the filter housing will result in carry over and damage
to the desiccant material. HB post-filters are used to prevent desiccant
dust particulate contamination from migrating downstream into plant
processes. Elements should be changed as pressure drop increases to
an undesirable level.
Reinstall filter bowl. Alternately, the element may be placed within the
center of the filter bowl with the o-rings facing upward. The element will
seat itself in the filter head as the bowl is threaded into place.
STEP 5 - With replacement element installed, tighten filter bowl such
that the flat of the filter bowl is in contact with the filter head.

STEP 6 - With filter bowl tightened, slowly pressurize filter. Avoid rapid
introduction of compressed air to the filter.

EH Series Desiccant Dryer Models 400-2100 17

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 11.0 MAINTENANCE AND SYSTEM CHECK

11.2.2 FLANGED FILTERS:

STEP 1 - Using STEP 2 -

a 2" socket with Remove old
an extension, element from
carefully loosen filter housing.
element.

STEP 3 - Install STEP 4 - Hand

new element by tighten element
carefully in place until
inserting element o-ring
element in top contacts top
plate. plate.

STEP 5 - Using STEP 6 -

a 2" socket with Repeat
an extension, procedure as
tighten element required to
one half turn. replace all
DO NOT OVER- elements.
TIGHTEN.

11.3 MUFFLER CHANGE-OUT PROCEDURE a CAUTION

• Turn control power off per shutdown procedures described in Section 9.7.
a WARNING
To avoid injury, depressurize dryer before performing any service
• Once the dryer has been depressurized, replace the muffler.
• Follow normal start-up procedures as described in Section 9.
11.4 NO-LOSS DRAIN VALVES
Periodically clean all no-loss drain valves. Cleaning can be
accomplished by removing the no-loss drain, removing the mufflers and
removing the valve bodies from the manifold. Check and replace o-rings
as necessary. If the no-loss drain valves fail to operate, check the
following:
• Control Circuit - Verify that the no-loss drain is receiving electric
current.
• Burned out no-loss drain coil.
• High/low voltage - Voltage should be +/- 10% of nameplate readings.
• No-loss drain valve leaking - Disassemble, clean and repack or
replace.
11.5 PILOT OPERATED ACTUATOR
Should the actuator fail to rotate, disconnect the pilot lines to check if the
actuator is receiving pilot pressure.
If the actuator is receiving pressure:
• Verify that control pressure is 75 psig min.
• Ensure the inlet valve is not plugged.
Be sure to wear respiratory protection during the draining and filling
process to minimize inhalation of desiccant, as desiccant will produce
dust during this procedure.
• Desiccant dryers are furnished with fill and drain ports on each
desiccant tower. Remove the caps on both ports.
• To assist in getting the desiccant to flow from the tower, insert a small
rod in to the drain port as necessary. This may be required as the
desiccant is packed into the towers which may interfere with the
desiccant flow from the towers.
• Retainer screens, located at the inlet and outlet piping connections of
the tower, are removable on all models. It is suggested that these
screens be removed and cleaned at the time of desiccant changeout.
These screens can be accessed by disconnecting the upper and lower
manifolds from the dryer towers.
• After cleaning the retainer screens, replace screens and reattach the
outlet port plug.
• With the fill port plug removed, fill the dryer tower with the appropriate
grade and size desiccant. The level and grade of the desiccant should
be consistent with the Desiccant Fill Chart.
a CAUTION
Desiccant quantity, positioning and grades must match the
corresponding values in the Desiccant Fill Chart. Failure to do so may
result in poor dryer performance.

11.6 DESICCANT CHANGEOUT PROCEDURE • Once the towers have been filled, replace the fill port plug on each
tower.
a WARNING • Any connections disturbed in the desiccant changeout process should
To avoid injury, depressurize dryer before performing any service. be leak tested prior to re-commissioning the dryer.

18 EH Series Desiccant Dryer Models 400-2100

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 11.0 MAINTENANCE AND SYSTEM CHECK

EH -40 °F Dryers EH -100 °F Dryers

ACTIVATED ALUMINA (4-8 mm) ACTIVATED ALUMINA (4-8 mm)

ACTIVATED ALUMINA (2-5 mm) ACTIVATED ALUMINA (2-5 mm)

MOLECULAR SIEVE

Model No A B C
EH400 23” 64.38” 50.37”
EH500 10” 62.75” 45.50”
EH600 20.25” 75.50” 59.75”
EH800 4.00” 75.50” 55.75”
EH1000 14.50” 69.50” 52.50”
EH1200 6.00” 69.50” 50.25”
EH1500 25.75” 78.50” 63.00”
EH1800 14.75” 78.50” 60.00”
EH2100 5.50” 78.50” 60.00”
Tolerance = +/- .50”

DESICCANT FILL CHART

EH LB. AA LB. AA LB. MS DESCRIPTION CCN

MODEL -40°F -100°F -100°F ACTIVATED ALUMINA 2-5 MM QTY. (1) 2000 LB.
DRYERS DRYERS DRYERS 38341939
SACK
300 111 359 117 ACTIVATED ALUMINA 2-5 MM QTY. (42) 50 LB. BAGS 38004826
400 160 444 151
ACTIVATED ALUMINA 4-8 MM QTY. (1) 2000 LB.
500 178 570 187 38340659
SACK
600 86 922 252
ACTIVATED ALUMINA 4-8 MM QTY. (42) 50 LB. BAGS 38004834
800 86 1184 316
1000 142 1258 350 MOLECULAR SIEVE QTY. (1) 275 LB. DRUM 38449971
1200 142 1464 402
1500 266 1934 550
1800 266 2334 650
2100 266 2662 732

AA = ACTIVATED ALUMINA NOTE: Qty. is per dryer

MS = MOLECULAR SIEVE

EH Series Desiccant Dryer Models 400-2100 19

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 12.0 TROUBLESHOOTING

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Elevated dew point Insufficient purge rate / I Check purge flow settings.

Check purge piping for obstruction.

Clean purge piping and muffler.

Inlet air/gas pressure below design condition. Check pressure source.

Flow rate higher than design condition. Check flow rate and cause for increased demand.

Inlet temperature above design condition. Check aftercooler, clean and service as necessary.

Entrained water entering desiccant bed. Check air/moisture separator and pre-filter. Replace
dryer desiccant if necessary.

Desiccant contaminated by oil. Install suitable pre-filter. Replace dryer desiccant.

Excessive pressure drop in Excessive flow rate. Check flow rate and cause for increased air demand.
dryer
Inlet pressure below design condition. Check pressure source.

Excessive back pressure in Air is leaking across valve. Check inlet valve. Verify inlet valve is closed to purging
regenerating tower (Above tower (0 PSIG tower).
5 PSIG).

Excessively high pressure at Improper calibration Check gauge against tower gauges when in switching
the purge gage (Blower and sequence. Replace gauge as required.
Heatless Modes)

Failure to Shift No input power Check power input.

(Switching Failure)
Defective no-loss drain valve Check no-loss drain valve.

No pilot air / Low pilot air pressure Check pilot air line. Check that control air line filter is
clean. Check regulator setpoint.

Defective pressure switch Check switch. Open pressure: > 65 psig; close pressure:
< 40 psig

Failure to Shift Faulty purge valve Check purge valve and its no-loss drain valve.
(Dryer fails to pressurize.)
Check that repressurization circuit is sending control
signal.

Failure to Shift (Dryer fails to Purge valve does not open. Purge valve stuck Check no-loss drain valve. Repair and replace if
depressurize.) in closed position. necessary.

Heater High Temp. Alarm Contactor stuck closed. Replace contactor.

(Heater runs continuously)
Defective thermocouple Replace thermocouple.

Defective temperature control Replace temperature control.

Heat High Temp. Alarm Valve switching failure Contact Ingersoll Rand Distributor / Factory
(Loss of flow across heater)

a NOTICE a NOTICE
The Heater High Temperature Alarm halts the Microprocessor Control To reset the Heater High Temperature Alarm, reset the Microprocessor
program. Prior to reinstating dryer, note the position of all valves. This Controller using the RESET button and manually reset the Heater High
is critical in determining the possible cause of the alarm condition. Temperature safety in the control enclosure.

20 EH Series Desiccant Dryer Models 400-2100

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 CONTROLLER LCD DISPLAY POWER ON LIGHT
38.50 1) DRYER ON/OFF CONTROL
2) DRYER ALARM LEFT TOWER REGEN LIGHT
2.00 (TYP) 3) HEATER OPERATION & TEMP CONTROL LEFT TOWER DRYING LIGHT
FACE OF AIR INLET & OUTLET 4) HIGH HEATER TEMP ALARM
(OPTIONAL 3-VALVE BYPASS) 5) HEATER FAILURE ALARM HEATER ON LIGHT
6) LEFT/RIGHT TOWER DRYING
7) LEFT/RIGHT TOWER REGEN
8) FAILURE TO SHIFT ALARM ALARM LIGHT
9) REGEN SEQUENCE STATUS
10) HIGH HUMIDITY ALARM (OPTIONAL) RIGHT TOWER REGEN LIGHT
11) ENERGY MANAGEMENT SYSTEM (EMS)
(OPTIONAL) RIGHT TOWER DRYING LIGHT
2.00 (TYP)
34.81
CONTROLLER PUSH BUTTONS
46.00 1) ON
2) OFF CONTROLLER & DISPLAY PANEL DETAIL
3) RESET
4) TEST
5) SET
28.00 32.00 6) SELECT DISPLAY
7) ENTER
8) +/-

11.19

OPTIONAL TOWER INSULATION

(SHOWN THIS VIEW ONLY)

(4) .56'' DIA. MTG. HOLES

HEATER INSULATION
INLET FLOW OF AIR INLET
22.50 FACE OF AIR INLET VALVE
DESICCANT FILL PORT 9.50 PREFILTER

1 1/2'' FPT AIR INLET INLET FLOW

CONNECTION VALVE
OF AIR INLET
TOWER PRESSURE
GAUGE
L PURGE
VALVE
RELIEF VALVE
PURGE MUFFLER

http://air.irco.com
TOWER TEMPERATURE
GAUGE
REACTIVATION
HEATER
1 1/2'' FPT AIR OUTLET
CONTROLLER AND CONNECTION
DISPLAY PANEL OF AIR OUTLET
(SEE DETAIL) L
AFTERFILTER
ELECTRICAL
ENCLOSURE
68.00 NEMA 4 PILOT AIR
SHUTOFF

EH Series Desiccant Dryer Models 400-2100

60.25 VALVE

OUTLET FLOW
13.0 GENERAL ARRANGEMENT

BLUE MOISTURE CHECK VALVES

INDICATOR
PURGE ADJUSTMENT VALVE
34.00
PILOT AIR FILTER
DESICCANT DRAIN PORT PURGE PRESSURE GAUGE

FACE OF AIR OUTLET

INLET PURGE
11.19 20.81 OF OUTLET CHECK VALVES
12.50
52.50 22.44
33.62

GENERAL ARRANGEMENT
*NOTES:
1) MAXIMUM WORKING PRESSURE - 150 P.S.I. EH 300
2) SAFETY RELIEF VALVE SETTING - 165 P.S.I
3) PILOT AIR LINES NOT SHOWN FOR CLARITY
4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL
ELECTRICAL CODE'S LATEST EDITION. 580008

21
 22
40.50 POWER ON LIGHT
FACE OF AIR INLET & OUTLET CONTROLLER LCD DISPLAY
(OPTIONAL 3-VALVE BYPASS) 1) DRYER ON/OFF CONTROL
2.00 (TYP) LEFT TOWER REGEN LIGHT
2) DRYER ALARM
3) HEATER OPERATION & TEMP CONTROL LEFT TOWER DRYING LIGHT
4) HIGH HEATER TEMP ALARM
5) HEATER FAILURE ALARM HEATER ON LIGHT
6) LEFT/RIGHT TOWER DRYING
(4) .56''O MTG. HOLES 7) LEFT/RIGHT TOWER REGEN
8) FAILURE TO SHIFT ALARM ALARM LIGHT
41.00 @ EH 400 2.00 (TYP) 9) REGEN SEQUENCE STATUS
42.50 @ EH 500 10) HIGH HUMIDITY ALARM (OPTIONAL) RIGHT TOWER REGEN LIGHT
11) ENERGY MANAGEMENT SYSTEM (EMS)
(OPTIONAL) RIGHT TOWER DRYING LIGHT

CONTROLLER PUSH BUTTONS

1) ON
53.18 @ EH 400 2) OFF CONTROLLER & DISPLAY PANEL DETAIL
54.68 @ EH 500 3) RESET
4) TEST
5) SET
29.00 33.00 6) SELECT DISPLAY
7) ENTER
8) +/-

12.19

12.00 OF INLET
27.50 @ 500 ZHA FACE OF AIR INLET INLET FLOW VALVE
OPTIONAL TOWER INSULATION HEATER INSULATION 26.00 @ 400ZHA PREFILTER
(SHOWN THIS VIEW ONLY)
2'' FPT AIR INLET
DESICCANT FILL PORT CONNECTION
OF AIR INLET

CONTROLLER AND
DISPLAY PANEL
(SEE DETAIL) PURGE VALVE

TOWER PRESSURE GAUGE

HEATER
TOWER TEMPERATURE GAUGE PURGE MUFFLER

http://air.irco.com
RELIEF VALVE
2'' FPT AIR OUTLET
CONNECTION
82.50 AFTERFILTER
ELECTRICAL
ENCLOSURE 73.38
NEMA 4 PILOT AIR SHUT-OFF VALVE
OF AIR OUTLET

EH Series Desiccant Dryer Models 400-2100

BLUE MOISTURE INDICATOR PURGE ADJUSTMENT VALVE
PURGE PRESSURE GAUGE
PILOT AIR FILTER
13.0 GENERAL ARRANGEMENT

40.00 OUTLET FLOW VALVES

DESICCANT DRAIN PORT

FACE OF AIR OUTLET
OF AIR OUTLET INLET PURGE CHECK VALVES

12.19 20.81 11.25

40.50
26.00
56.50

*NOTES:
GENERAL ARRANGEMENT
1) MAXIMUM WORKING PRESSURE - 150 P.S.I. EH 400 - 500
2) SAFETY RELIEF VALVE SETTING - 165 P.S.I
3) PILOT AIR LINES NOT SHOWN FOR CLARITY
4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL
ELECTRICAL CODE'S LATEST EDITION.
580009
 44.00 CONTROLLER LCD DISPLAY POWER ON LIGHT
1) DRYER ON/OFF CONTROL
FACE OF AIR INLET & OUTLET 2) DRYER ALARM LEFT TOWER REGEN LIGHT
(OPTIONAL 3-VALVE BYPASS) 3.00 (TYP)
3) HEATER OPERATION & TEMP CONTROL LEFT TOWER DRYING LIGHT
4) HIGH HEATER TEMP ALARM
5) HEATER FAILURE ALARM HEATER ON LIGHT
6) LEFT/RIGHT TOWER DRYING
7) LEFT/RIGHT TOWER REGEN
8) FAILURE TO SHIFT ALARM ALARM LIGHT
9) REGEN SEQUENCE STATUS
10) HIGH HUMIDITY ALARM (OPTIONAL) RIGHT TOWER REGEN LIGHT
11) ENERGY MANAGEMENT SYSTEM (EMS)
(OPTIONAL) RIGHT TOWER DRYING LIGHT
46.25

2.00 (TYP)
CONTROLLER PUSH BUTTONS
64.25 1) ON
2) OFF CONTROLLER & DISPLAY PANEL DETAIL
OPTIONAL TOWER INSULATION 3) RESET
(SHOWN THIS VIEW ONLY) 52.00 4) TEST
5) SET
6) SELECT DISPLAY
32.00 36.00 7) ENTER
8) +/-

18.00

PILOT AIR SHUT-OFF OF AIR INLET

(4) .56 O MOUNTING HOLES HEATER VALVE
INLET FLOW VALVE
34.00 12.25 3'' FPT AIR INLET
DESICCANT FILL PORT FACE OF AIR INLET CONNECTION
PREFILTER

OF AIR INLET

ELECTRICAL PURGE VALVE

ENCLOSURE
NEMA 4

3'' FPT AIR OUTLET

OF AIR OUTLET CONNECTION

http://air.irco.com
TOWER PRESSURE GAUGE
RELIEF VALVE
TOWER TEMPERATURE GAUGE
PURGE MUFFLER
87.62
CONTROLLER AND
DISPLAY PANEL
(SEE DETAIL) AFTERFILTER
69.25
OUTLET FLOW VALVES

PURGE PRESSURE GAUGE

EH Series Desiccant Dryer Models 400-2100

BLUE MOISTURE INDICATOR 45.00
PURGE ADJUSTMENT VALVE
PILOT AIR FILTER
13.0 GENERAL ARRANGEMENT

DESICCANT DRAIN PORT

INLET PURGE CHECK VALVES

64.00 18.00 18.00 OF AIR OUTLET 16.00

FACE OF AIR OUTLET 44.00
34.00

GENERAL ARRANGEMENT
*NOTES: EH 600 - 800
1) MAXIMUM WORKING PRESSURE - 150 P.S.I.
2) SAFETY RELIEF VALVE SETTING - 165 P.S.I
3) PILOT AIR LINES NOT SHOWN FOR CLARITY
4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL
ELECTRICAL CODE'S LATEST EDITION. 580010

23
 24
CONTROLLER LCD DISPLAY POWER ON LIGHT
1) DRYER ON/OFF CONTROL
2) DRYER ALARM LEFT TOWER REGEN LIGHT
3) HEATER OPERATION & TEMP CONTROL LEFT TOWER DRYING LIGHT
FACE OF AIR INLET & OUTLET 4) HIGH HEATER TEMP ALARM
(OPTIONAL 3-VALVE BYPASS) 5) HEATER FAILURE ALARM HEATER ON LIGHT
6) LEFT/RIGHT TOWER DRYING
7) LEFT/RIGHT TOWER REGEN
8) FAILURE TO SHIFT ALARM ALARM LIGHT
9) REGEN SEQUENCE STATUS
10) HIGH HUMIDITY ALARM (OPTIONAL) RIGHT TOWER REGEN LIGHT
11) ENERGY MANAGEMENT SYSTEM (EMS)
(OPTIONAL) RIGHT TOWER DRYING LIGHT

49.38
CONTROLLER PUSH BUTTONS
1) ON
2) OFF CONTROLLER & DISPLAY PANEL DETAIL
3) RESET
68.88 4) TEST
5) SET
6) SELECT DISPLAY
56.68 7) ENTER
8) +/-

37.00 41.00

19.50

2.00 OF AIR INLET

OPTIONAL TOWER INSULATION
(SHOWN THIS VIEW ONLY) PILOT AIR SHUT-OFF
HEATER VALVE FACE OF INLET
(4) .56 O MOUNTING HOLES 37.18 12.38 3'' FPT AIR INLET
CONNECTION
DESICCANT FILL PORT
PREFILTER

CONTROLLER AND
DISPLAY PANEL
(SEE DETAIL) ELECTRICAL
TOWER PRESSURE GAUGE ENCLOSURE OF AIR INLET
NEMA 4
INLET FLOW VALVE
TOWER TEMPERATURE GAUGE
L PURGE VALVE
OF AIR OUTLET
RELIEF VALVE

http://air.irco.com
PURGE MUFFLER

80.06 3'' FPT AIR OUTLET

CONNECTION

59.62 AFTERFILTER
BLUE MOISTURE INDICATOR

EH Series Desiccant Dryer Models 400-2100

PILOT AIR FILTER PURGE PRESSURE GAUGE 48.00
PURGE ADJUSTMENT VALVE
13.0 GENERAL ARRANGEMENT

DESICCANT DRAIN PORT OUTLET FLOW VALVES

OF AIR OUTLET
INLET PURGE CHECK VALVES
18.50
19.50 21.50 FACE OF OUTLET
54.00
37.19

*NOTES: GENERAL ARRANGEMENT

1) MAXIMUM WORKING PRESSURE - 150 P.S.I.
2) SAFETY RELIEF VALVE SETTING - 165 P.S.I EH 1000 - 1200
3) PILOT AIR LINES NOT SHOWN FOR CLARITY
4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL
ELECTRICAL CODE'S LATEST EDITION.

580011
 54.00 CONTROLLER LCD DISPLAY POWER ON LIGHT
1) DRYER ON/OFF CONTROL
3.00 (TYP) 2) DRYER ALARM LEFT TOWER REGEN LIGHT
FACE OF AIR INLET & OUTLET
(OPTIONAL 3-VALVE BYPASS) 3) HEATER OPERATION & TEMP CONTROL LEFT TOWER DRYING LIGHT
4) HIGH HEATER TEMP ALARM
5) HEATER FAILURE ALARM HEATER ON LIGHT
6) LEFT/RIGHT TOWER DRYING
7) LEFT/RIGHT TOWER REGEN
8) FAILURE TO SHIFT ALARM ALARM LIGHT
9) REGEN SEQUENCE STATUS
10) HIGH HUMIDITY ALARM (OPTIONAL) RIGHT TOWER REGEN LIGHT
11) ENERGY MANAGEMENT SYSTEM (EMS)
(OPTIONAL) RIGHT TOWER DRYING LIGHT
54.50
2.00 (TYP)
CONTROLLER PUSH BUTTONS
1) ON
77.00 2) OFF CONTROLLER & DISPLAY PANEL DETAIL
3) RESET
4) TEST
67.69 5) SET
47.00 6) SELECT DISPLAY
7) ENTER
43.00 8) +/-

22.50

2.69
OPTIONAL TOWER INSULATION
(SHOWN IN THIS VIEW ONLY)
PILOT AIR SHUT-OFF
VALVE OF AIR INLET
(4) .56''O MOUNTING HOLES
3'' NPT AIR INLET
42.38 FACE OF INLET 12.00 CONNECTION
DESICCANT FILL PORT INLET FLOW VALVE
PREFILTER

L
CONTROLLER AND
DISPLAY PANEL OF AIR INLET
(SEE DETAIL)

http://air.irco.com
TOWER PRESSURE GAUGE

TOWER TEMPERATURE GAUGE PURGE VALVE

OF AIR OUTLET
PURGE MUFFLER
91.88

RELIEF VALVE
ELECTRICAL

EH Series Desiccant Dryer Models 400-2100

ENCLOSURE 68.81
NEMA 4 3'' NPT AIR OUTLET
CONNECTION
PURGE PRESSURE
GAUGE AFTERFILTER
48.00 ZTF TYPE ''G''
PURGE ADJUSTMENT
BLUE MOISTURE INDICATOR VALVE
13.0 GENERAL ARRANGEMENT

HEATER
PILOT AIR FILTER
OUTLET FLOW VALVES
DESICCANT DRAIN PORT

INLET PURGE
CHECK VALVES
22.50 24.50 FACE OF OUTLET
84.00 OF AIR OUTLET
42.38 18.00
54.00

GENERAL ARRANGEMENT
*NOTES: EH 1500
1) MAXIMUM WORKING PRESSURE - 150 P.S.I.
2) SAFETY RELIEF VALVE SETTING - 165 P.S.I
3) PILOT AIR LINES NOT SHOWN FOR CLARITY
4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL
ELECTRICAL CODE'S LATEST EDITION. 580012

25
 26
CONTROLLER LCD DISPLAY POWER ON LIGHT
1) DRYER ON/OFF CONTROL
2) DRYER ALARM LEFT TOWER REGEN LIGHT
3) HEATER OPERATION & TEMP CONTROL LEFT TOWER DRYING LIGHT
54.00 4) HIGH HEATER TEMP ALARM
5) HEATER FAILURE ALARM HEATER ON LIGHT
3.00 (TYP) 6) LEFT/RIGHT TOWER DRYING
7) LEFT/RIGHT TOWER REGEN
8) FAILURE TO SHIFT ALARM ALARM LIGHT
9) REGEN SEQUENCE STATUS
10) HIGH HUMIDITY ALARM (OPTIONAL) RIGHT TOWER REGEN LIGHT
11) ENERGY MANAGEMENT SYSTEM (EMS)
(OPTIONAL) RIGHT TOWER DRYING LIGHT

2.00 (TYP)
CONTROLLER PUSH BUTTONS
1) ON
2) OFF CONTROLLER & DISPLAY PANEL DETAIL
3) RESET
4) TEST
64.25 5) SET
47.00 6) SELECT DISPLAY
7) ENTER
43.00 8) +/-

2.69
OPTIONAL TOWER INSULATION
(SHOWN IN THIS VIEW ONLY)
PILOT AIR SHUT-OFF
VALVE CL OF AIR INLET
(4) .56''O MOUNTING HOLES
39.00 FACE OF INLET 21.00
DESICCANT FILL PORT 4'' FLANGE AIR INLET
CONNECTION INLET FLOW VALVE

L
CONTROLLER AND
DISPLAY PANEL CL OF AIR INLET
(SEE DETAIL)

TOWER PRESSURE GAUGE

TOWER TEMPERATURE GAUGE
PURGE VALVE

PURGE MUFFLER
91.88 C OF

http://air.irco.com
L AIR OUTLET
RELIEF VALVE
ELECTRICAL HEATER
ENCLOSURE PURGE PRESSURE 67.31
NEMA 4 GAUGE 4'' FLANGE AIR OUTLET
CONNECTION
PURGE ADJUSTMENT
VALVE
BLUE MOISTURE INDICATOR OUTLET FLOW VALVES

EH Series Desiccant Dryer Models 400-2100

PILOT AIR FILTER
26.13
DESICCANT DRAIN PORT

INLET PURGE
CHECK VALVES
13.0 GENERAL ARRANGEMENT

22.50 24.50 24.00

84.00 39.00 FACE OF OUTLET CL OF AIR OUTLET
54.00

GENERAL ARRANGEMENT
*NOTES:
1) MAXIMUM WORKING PRESSURE - 150 P.S.I. EH 2100
2) SAFETY RELIEF VALVE SETTING - 165 P.S.I
3) PILOT AIR LINES NOT SHOWN FOR CLARITY
4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL
ELECTRICAL CODE'S LATEST EDITION. 580013
 CONTROLLER LCD DISPLAY POWER ON LIGHT
1) DRYER ON/OFF CONTROL
2) DRYER ALARM LEFT TOWER REGEN LIGHT
3) HEATER OPERATION & TEMP CONTROL LEFT TOWER DRYING LIGHT
54.00 4) HIGH HEATER TEMP ALARM
5) HEATER FAILURE ALARM HEATER ON LIGHT
3.00 (TYP) 6) LEFT/RIGHT TOWER DRYING
7) LEFT/RIGHT TOWER REGEN
8) FAILURE TO SHIFT ALARM ALARM LIGHT
9) REGEN SEQUENCE STATUS
10) HIGH HUMIDITY ALARM (OPTIONAL) RIGHT TOWER REGEN LIGHT
11) ENERGY MANAGEMENT SYSTEM (EMS)
(OPTIONAL) RIGHT TOWER DRYING LIGHT

2.00 (TYP)
CONTROLLER PUSH BUTTONS
1) ON
2) OFF CONTROLLER & DISPLAY PANEL DETAIL
3) RESET
4) TEST
64.25 5) SET
47.00 6) SELECT DISPLAY
7) ENTER
43.00 8) +/-

2.75
OPTIONAL TOWER INSULATION
(SHOWN IN THIS VIEW ONLY)
PILOT AIR SHUT-OFF
VALVE OF AIR INLET
(4) .56''O MOUNTING HOLES
39.00 FACE OF INLET 21.00
DESICCANT FILL PORT 4'' FLANGE AIR INLET
CONNECTION INLET FLOW VALVE

L
CONTROLLER AND
DISPLAY PANEL OF AIR INLET
(SEE DETAIL)

TOWER PRESSURE GAUGE

http://air.irco.com
TOWER TEMPERATURE GAUGE PURGE VALVE
OF AIR OUTLET
PURGE PRESSURE
GAUGE PURGE MUFFLER
91.88 PURGE ADJUSTMENT
VALVE
RELIEF VALVE
ELECTRICAL HEATER
ENCLOSURE 67.31

EH Series Desiccant Dryer Models 400-2100

NEMA 4 4'' FLANGE AIR OUTLET
CONNECTION

BLUE MOISTURE INDICATOR

37.50
13.0 GENERAL ARRANGEMENT

PILOT AIR FILTER OUTLET FLOW VALVE

DESICCANT DRAIN PORT

INLET PURGE
CHECK VALVE
22.50 24.50 FACE OF OUTLET 24.00
84.00 OF AIR OUTLET
37.62
54.00

GENERAL ARRANGEMENT
*NOTES: EH 1800
1) MAXIMUM WORKING PRESSURE - 150 P.S.I.
2) SAFETY RELIEF VALVE SETTING - 165 P.S.I
3) PILOT AIR LINES NOT SHOWN FOR CLARITY
4) ALL WIRING IS IN ACCORDANCE WITH THE NATIONAL
ELECTRICAL CODE'S LATEST EDITION. 580044

27
 14.0 WIRING DIAGRAM

WIRING DIAGRAM FOR

EH3004H000

28 EH Series Desiccant Dryer Models 400-2100

http://air.irco.com
14.0 WIRING DIAGRAM

EH4004H000 - EH5004H000
WIRING DIAGRAM FOR

EH Series Desiccant Dryer Models 400-2100 29

http://air.irco.com
 14.0 WIRING DIAGRAM

WIRING DIAGRAM FOR

EH6004HH000

30 EH Series Desiccant Dryer Models 400-2100

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14.0 WIRING DIAGRAM

EH8004H000 - EH10004H000
WIRING DIAGRAM FOR

EH Series Desiccant Dryer Models 400-2100 31

http://air.irco.com
 14.0 WIRING DIAGRAM

WIRING DIAGRAM FOR

EH12004H000

32 EH Series Desiccant Dryer Models 400-2100

http://air.irco.com
14.0 WIRING DIAGRAM

WIRING DIAGRAM FOR

EH15004H000

EH Series Desiccant Dryer Models 400-2100 33

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 14.0 WIRING DIAGRAM

EH18004H000 - EH21004H000
WIRING DIAGRAM FOR

34 EH Series Desiccant Dryer Models 400-2100

http://air.irco.com
 15.0 FLOW DIAGRAM

STANDARD W/OPTIONS
FLOW DIAGRAM
EH 300 - 400

EH Series Desiccant Dryer Models 400-2100 35

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 15.0 FLOW DIAGRAM

STANDARD W/OPTIONS
FLOW DIAGRAM
EH 500 - 2100

36 EH Series Desiccant Dryer Models 400-2100

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 16.0 REPLACEMENT PARTS
DESCRIPTION EH3004H000A EH4004H000A EH5004H000A EH6004H000A EH8004H000A QTY/UNIT SPARES
1 2 3
BLUE MOISTURE INDICATOR 38054284 38054284 38054284 38054284 38054284 1
DESICCANT, 2-5mm GRADE D NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1
DESICCANT, 4-8mm GRADE D NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1
DESICCANT, MOLECULAR SIEVE NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1
DISPLAY BOARD, PANEL 38053682 38053682 38053682 38053682 38053682 1
ELEMENT, CONTROL FILTER 38446522 38446522 38446522 38446522 38446522 1 1 1 2
ELEMENT, POST-FILTER 38333209 38336365 38336365 38336373 38336373 1 1 1 2
ELEMENT, PRE-FILTER 38446308 - - - - 1 1 1 2
ELEMENT, PRE-FILTER - 38446316 38446316 - - 1 1 1 2
ELEMENT, PRE-FILTER - - - 38446324 38446324 1 1 1 2
FUSE, CONTROL PRIMARY, 0.5A 600V 38054268 38054268 38054268 38054268 38054268 2 2 2 4
GAUGE, PURGE, 1 1/2" 0-160 PSI 38053674 38053674 38053674 38053674 38053674 1
GAUGE, FILTER, DELTA-P DUAL FACE 38053278 38053278 38053278 38053278 38053278 1
GAUGE, TOWER PRESSURE 2 1/2" 0-300PSI 38053310 38053310 38053310 38053310 38053310 2
GAUGE, TOWER TEMPERATURE 38053302 38053302 38053302 38053302 38053302 2
HEATER 38053476 - - - - 1
HEATER, 4.5KW - 38054391 38054391 - - 1
HEATER, 6 KW - - - 38054425 - 1
HEATER, 9.0KW - - - - 38054466 1
MUFFLER, PURGE, 1 1/2" MPT - 38054540 - - - 2 2 2 2
MUFFLER, PURGE, 1" MPT 38054524 - - - - 2 2 1 1
MUFFLER, CONTROL AIR, 1/4" 38053286 38053286 38053286 38053286 38053286 1 1 1 1
MUFFLER, PURGE, 2" MPT - - 38054045 38054045 38054045 2 2 2 2
OVERLAY, CONTROLLER 38053864 38053864 38053864 38053864 38053864 1
POWER SUPPLY, 5V/24VDC 38053724 38053724 38053724 38053724 38053724 1 1 1 1
PROBE, TEMPERATURE 38053641 38053641 38053641 38053641 38053641 1 1 1 1
PROGRAMMABLE LOGIC cONTROLLER 38054185 38054185 38054185 38054185 38054185 1 1 1 1
REGULATOR, CONTROL AIR 38053633 38053633 38053633 38053633 38053633 1
RELAY, SSR, 20A@48-600VAC 38053690 38053690 38053690 38053690 38053690 3
RESISTOR, THERMISTOR, 10K OHM 38054144 38054144 38054144 38054144 38054144 1
RESISTOR, 5V LOAD, 200 OHM 38054151 38054151 38054151 38054151 38054151 1
RETAINER, DESICCANT SCREEN ASSEMBLY 38054557 - - - - 4
RETAINER, DESICCANT SCREEN
- 38054573 38054573 - - 4
ASSEMBLY 3 X 2
RETAINER, DESICCANT SCREEN ASSEMBLY 3" - - 38054318 38054565 38054565 4
SWITCH, LOW PRESSURE, FAIL TO SHIFT 38053260 38053260 38053260 38053260 38053260 2
THERMOSTAT, HEATER HITEMP SFTY 38053609 38053609 38053609 38053609 38053609 1
TRANSFORMER, CONTROL, 0.15KVA 38053260 38053260 38053260 38053260 38053260 1
VALVE, PURGE ADJUST 38053351 38053351 38053351 38053351 38053351 1
VALVE, BALL 1 1/2" - - - 38054052 38054052 1
VALVE, BALL 1 1/2" - PNEUMATICALLY
38053427 38053427 38053427 38053427 38053427 2
OPERATED
VALVE, BALL 1" 38054417 - - - - 1
VALVE, BALL 1" - 38054037 38054037 - - 2
VALVE, BALL, CONTROL AIR, 1/4" 38054086 38054086 38054086 38054086 38054086 1
VALVE, BALL, PNEUMATIC OPERATED, 2" - 38053435 - - - 2
VALVE, BALL 3/4" 38054516 - - - - 1
VALVE, BUTTERFLY, PNEUMATIC
- - 38053393 38053393 38053393 2
OPERATED, 3"
VALVE, CHECK, FLOW, 1 1/2" MPT 38054441 - - - - 2
VALVE, CHECK, PURGE, 1 1/2" UNION INSERT - - - 38054474 38054474 2
VALVE, CHECK, PURGE, 1" UNION INSERT - 38054490 38054490 - - 2
VALVE, CHECK, FLOW, 2" MPT - 38054458 38054458 38054458 - 2
VALVE, CHECK, FLOW, 3" MPT - - - - 38053484 2
VALVE, CHECK, PURGE, 3/4" UNION INSERT 38054508 - - - - 2
VALVE, SAFETY/RELIEF 1/2" - - - 38054060 38054060 2
VALVE, SAFETY/RELIEF 1/4" 38053294 38053294 38053294 - - 2
VALVE, CONTROL AIR SOLENOID 4 WAY 38053625 38053625 38053625 38053625 38053625 1
NOTE 1: Refer to the Desiccant Fill Chart in the Maintenance section.

Spare. Quantities under this heading reflect the number of each item which we recommend be kept on hand for maintenance or repair.
The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.
Class Quantity Suggested for
1 Minimum Domestic service where interruptions in service are acceptable.
2 Average Domestic service where some interruptions in service are acceptable.
3 Maximum Export service or for domestic service where interruptions in service are unacceptable.

EH Series Desiccant Dryer Models 400-2100 37

http://air.irco.com
 16.0 REPLACEMENT PARTS
DESCRIPTION EH10004H000A EH12004H000A EH15004H000A EH18004H000L EH21004H000L QTY/UNIT SPARES
1 2 3
BLUE MOISTURE INDICATOR 38054284 38054284 38054284 38054284 38054284 1
DESICCANT, 2-5mm GRADE D NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1
DESICCANT, 4-8mm GRADE D NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1
DESICCANT, MOLECULAR SIEVE NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1
DISPLAY BOARD, PANEL 38053682 38053682 38053682 38053682 38053682 1
ELEMENT, CONTROL FILTER 38446522 38446522 38446522 38446522 38446522 1 1 1 1
1/1/1/ 1/1/1/ 1/1/1/
ELEMENT, POST-FILTER 38336373 38336381 38336381 38336399 38336399 1/1/1/3/4
3/4 3/4 3/4
1/1/1/ 1/1/1/ 1/1/1/
ELEMENT, PRE-FILTER 38446324 38446332 38446340 38446357 38446357 1/1/1/3/4
3/4 3/4 3/4
FUSE, CONTROL PRIMARY, 0.5 A 600V 38054268 38054268 38054268 38054268 38054268 2 2 2 4
FUSE, CONTROL SECONDARY, 2A 250V 38054227 38054227 38054227 38054227 38054227 1 1 1 2
GAUGE, PURGE, 1 1/2" 0-160 PSI 38053674 38053674 38053674 38053674 38053674 1
GAUGE, FILTER DELTA-P DUAL FACE 38053278 38053278 38053278 - - 2
GAUGE, TOWER PRESSURE 2 1/2" 0-
38053310 38053310 38053310 38053310 38053310 2
300PSI
GAUGE, TOWER TEMPERATURE 38053302 38053302 38053302 38053302 38053302 2
HEATER, 12KW - 38054409 38054409 - - 1
HEATER, 18KW - - - 38054433 38054433 1
HEATER, 9.0KW 38054466 - - - - 1
MUFFLER, CONTROL AIR, 1/4" 38053286 38053286 38053286 38053286 38053286 1 1 1 1
MUFFLER, PURGE, 2" MPT 38054045 38054045 38054045 38054045 38054045 2 2 2 2
POWER SUPPLY, 5V/24VDC 38053724 38053724 38053724 38053724 38053724 1 1 1 1
PROBE, TEMPERATURE 38053641 38053641 38053641 38053641 38053641 1 1 1 1
PROGRAMMABLE LOGIC CONTROLLER 38054185 38054185 38054185 38054185 38054185 1 1 1 1
REGULATOR, CONTROL AIR 38053633 38053633 38053633 38053633 38053633 1
RELAY, SSR, 20A@48-600VAC 38053690 38053690 - - - 3
RELAY, SSR, 30A@48-600VAC - - 38053708 - - 3
RELAY, SSR, 45A@48-600VAC - - 38053716 38053716 3
RESISTOR, THERMISTOR, 10K OHM 38054144 38054144 38054144 38054144 38054144 1
RESISTOR, 5V LOAD, 200 OHM 38054151 38054151 38054151 38054151 38054151 1
RETAINER, DESICCANT SCREEN
38054292 38054292 38054326 38054326 38054326 4
ASSEMBLY
SWITCH, LOW PRESSURE, FAIL TO
38053260 38053260 38053260 38053260 38053260 2
SHIFT
THERMOSTAT, HEATER HITEMP SAFETY 38053609 38053609 38053609 38053609 38053609 1
TRANSFORMER, CONTROL, 0.15KVA 38053260 38053260 38053260 38053260 38053260 1
VALVE, PURGE ADJUST 38053351 38053351 38053351 38053351 38053351 1
VALVE, BALL 1 1/2" 38054052 38054052 38054052 - - 1
VALVE, BALL 1 1/2" - PNEUMATICALLY
38053427 38053427 38053427 - - 2
OPERATED
VALVE, BALL, CONTROL AIR, 1/4" 38054086 38054086 38054086 38054086 38054086 1
VALVE, BALL 2" - - - 38053435 38053435 2
VALVE, BALL 2" - - - 38054532 38054532 2
VALVE, BUTTERFLY, PNEUMATIC
38053393 38053393 38053393 - - 2
OPERATED, 3"
VALVE, BUTTERFLY, PNEUMATIC
- - - 38053401 38053401 2
OPERATED, 4"
VALVE, CHECK, PURGE, 1 1/2" UNION
38054474 38054474 - - - 2
INSERT
VALVE, CHECK, PURGE, 2" UNION
- - - 38054482 - 2
INSERT
VALVE, CHECK, FLOW, 3" MPT 38053484 38053484 38053484 38053484 38053484 2
VALVE, CHECK, FLOW, 4" - - - - 38053567 2
VALVE, SAFETY/RELIEF 1/2" 38054060 38054060 - - - 2
VALVE, SAFETY/RELIEF 3/4" - - 38054375 38054375 38054375 2
VALVE, CONTROL AIR SOLENOID 4 WAY 38053625 38053625 38053625 38053625 38053625 1

Spare. Quantities under this heading reflect the number of each item which we recommend be kept on hand for maintenance or repair.
The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.
Class Quantity Suggested for
1 Minimum Domestic service where interruptions in service are acceptable.
2 Average Domestic service where some interruptions in service are acceptable.
3 Maximum Export service or for domestic service where interruptions in service are unacceptable.
38 EH Series Desiccant Dryer Models 400-2100
http://air.irco.com
 16.0 REPLACEMENT PARTS

DIAPHRAGM VALVE REBUILD KITS

VALVE CCN * SEAL KIT CCN HARDWARE KIT CCN

38052924 38053021 38053039
38052932 38052668 38052825
38052940 38052114 38052635
38052957 38052668 38052783
38052981 38053005 38053013
38053070 38052866 38052882
38053088 38052866 38052965
38446571 38052114 38052619
38446894 38052114 38052635

* Refer to the list of individual parts at the beginning of the REPLACEMENT PARTS
section to determine which Valve listed in the above table is applicable to your dryer.
CCN's for the relevant Seal Kits and Hardware Kits will be found in the adjacent
columns.

EMS PARTS

DESCRIPTION CCN

TRANSMITTER, DEWPOINT -40°F 38053047

TRANSMITTER, DEWPOINT -100°F 38053062

CABLE, TRANSMITTER 38053112

BLOCK, SAMPLE -40°F 38053120

BLOCK, SAMPLE -100°F 38053138

EH Series Desiccant Dryer Models 400-2100 39

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 17.0 ENGINEERING SPECIFICATIONS

Flow -40 Shipping

Heater MCA MOP Purge Depth in w/o Depth in.w/ Height in Air In & Out
MODEL Dewpoint Width in. (cm) Weight
KW (amps) (amps) SCFM Bypass. (cm) Bypass (cm) (cm) Connection
SCFM lbs (kg)
EH300 300 3 5.1 6 21 52.5(133.3) 33.6(85.3) 46(116.8) 68(172.7) 1 1/2 1191(540)

EH400 400 4.5 7.5 8 28 56.5(143.5) 38.2(97) 53.2(135) 82.5(208.3) 2 1539(698)

EH500 500 4.5 7.5 8 35 56.5(143.5) 39.7(100.8) 54.7(139) 82.5(208.3) 2 1707(774)

EH600 600 6 9.8 10 42 64(162.5) 52(132) 64.2(163.2) 88(223.5) 3 2369(1075)

EH800 800 9 11.6 12 56 64(162.5) 52(132) 64.2(163.2) 88(223.5) 3 2681(1216)

EH1000 1000 9 11.6 12 70 78.5(199.4) 56.7(144) 69(175.2) 80(203) 3 3043(1380)

EH1200 1200 12 15.4 17.5 84 78.5(199.4) 56.7(144) 69(175.2) 80(203) 3 3285(1490)

EH1500 1500 15 23.9 25 105 84(213.4) 67.7(172) 77(195.6) 92(234) 3 4480(2032)

EH1800 1800 18 28.6 30 126 84(213.4) 67.2(170.8) N/A 92(234) 4 4956(2248)

EH2100 2100 18 28.6 30 147 84(213.4) 64.2(160.6) N/A 92(234) 4 5350(2427)

Note: All above dryers rated at 150 psig, 120 ° F max. inlet temperature. Capacity basis 100 psig, 100 ° F inlet.

a NOTICE
Specification information above accurate at time of publication. Refer to equipment serial label
for actual specifications for units.

40 EH Series Desiccant Dryer Models 400-2100

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Air Solutions Group
Davidson, NC 28036
AC Filter Series
This high efficiency carbon
filter is capable of removing
oil vapor and odor from
compressed air. The
maximum remaining oil
carryover is < 0. 003mg/ m3
W at 21°C (< 0.003 ppm W
at 70°F). It is suitable for
the food and drug
processing industry as well
as laboratories. The initial
rated pressure drop at the
inlet air pressure and rated
flows will not exceed1 psig.
FILTERS 2000
General Description
The AC filter should be
installed after the HE filter,
which in turn should be
preceded by a DP grade.
The AC filter is also used in
food and drug processing
and medical and laboratory
installations.
The filter element is long
lasting and easy to install.
The element is constructed
of a multi-layered activated
carbon filter media, glass
filled nylon end caps, and a
perforated stainless steel
inner and outer support
core.
Ref: 21001.03
Date: 1 October 2000
FIRST EDITION
The housing is constructed
of either die-cast aluminum
alloy or pressure vessel
quality steel. The filter
includes a manual drainage
system.
The lift and twist mechanism
makes for easy element
exchange. The durable
stainless steel element inner
and outer cores will
withstand sudden pressure
surges of up to 100 psig.
The element top end cap
has an over molded seal
and patented taper location
that ensures a perfect seal.
Engineering Data

Tank Specifications
All standard tanks are shipped with a primer unless an external paint option is selected. The
specifications on the primer is as follows:

● Tanks less than 48" in diameter will be supplied with a baked on powder coat gray primer.
● Larger diameter tanks will be primed with a red water based primer.
All standard tanks pressures are listed at max allowable working pressure (MAWP). See
Technical Spefications below for details.

ASME CODE

IR Remote Receiver Tanks are constructed under the strict rules of the ASME Code Section VIII,
Division 1 and CSA B.51 latest edition.

MAX ALLOWABLE WORKING PRESSURE

The pressure indicated on the product chart is defined as Max Allowed Working Pressure (MAWP).
IR Tanks are designed to operate at pressures equal or below MAWP. To ensure user safety and to
meet the ASME Code requirements, IR Remote Receiver Tanks are tested after completion to ensure
that they can sustain pressures 1.3 times their MAWP.

CRN (Canadian Registration Number)

All Standard IR Remote Receiver Tanks are already approved and have a CRN number assigned for
use in Canada. For "Special" Remote Receiver Tanks please indicate on your order if a CRN is
necessary.

All high pressure tanks do not have CRNs automatically. This can be added as a special feature.

OTHER CODES

IR Remote Receivers have a National Board Number (NBN) located on the nameplate. Available
under special request are U1A Forms, Overload and Coast Guard Specifications, American Board of
Shipping (ABS), and California pressure specification. Please indicate document requirements in the
text of your order.
Engineering Data

Guidelines for Sizing a Safety Relief Valve

The pressure setting of the safety relief valve must be less than or equal to the maximum allowable
working pressure of the tank.

The inlet size of the safety valve must be less than or equal to the size of the tank port into which the
valve will be installed.

The flow rating (in SCFM, standard cubic feet per minute) of the safety valve must be greater than or
equal to the SCFM produced by the system. To determine the minimum required flow rating, divide
the compressor’s SCFM by 0.87 (temperature correction factor).

Valve flow rating = compressor SCFM ¸ 0.87

See ASME Section VIII for further information.

Paint Options
EXTERNAL - Now our customers have the option to choose between our standard Primer or IR-Beige
in either Epoxy or Enamel.

The new IR-Beige specifications (standard tanks) are:

● Epoxy – 2 Coats of ICI Devoe Epoxy Lining, 3-5 Mils DFT per Coat
● Enamel – 1 Coat of ICI Devoe Primer 2-4 Mils DFT, 1 Coat of ICI Devoe Enamel 2-4 Mils DFT

All IR’s standard pressure receiver exterior paint preparations have Seal Welded/SSPC-SP 6 sand
blasted clean.

All IR's high pressure receivers exterior paint are hand cleaned and prime painted.

If we did not fulfill your needs with the options above you can use IR’s remote receiver Special
Request Form to personalize your color.

Galvanized Remote Receiver Tanks are also available. A special request form is needed.

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Engineering Data

INTERNAL - IR customers now have two choices for the interior coating, our new Internal Standard
Epoxy or IR’s FDA Epoxy.

Interior Coating Specifications - Standard Pressure Tanks

● Internal Standard Epoxy:

- 2 Coats of ICI Devoe, Epoxy Lining, 3-5 Mils DFT per Coat.

● Interior FDA Approved Epoxy:

- 2 Coats of ICI Devoe Epoxy Lining, 3-5 Mils DFT per Coat

All interior coatings have Seal Welded/SSPC 10 Sand Blasted Clean.

Small diameter tanks (30"-36"Dia.) have added a manway only for the purpose of interior painting for
standard pressures. High pressure tanks do not have a manway.

Standard Remote Receiver Tanks with internal coating have a 6-10 week lead time.

High pressure remote receivers that are 24"and 30" in diameter have an 8 week leadtime. Tanks that
are 36" in diameter have a 12 week leadtime.

Interior Coating Specification for 550 psig and 725 psig tanks:

● SSPC-SP6 blast cleanded before assembly and 4 Mils baked on powder coat high
temperature black epoxy

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Tank Drawing

660-8000 Gallon - Standard Skirt

Tank Drawing

Pricing
CCN PSI GAL DIA X L
38002804 137 660 42 X 120
38002812 150 660 42 X 120
38002838 150 1060 48 X 144
38002846 175 1060 48 X 144
38002861 137 1550 54 X 166
38016168 150 2000 60 X 174
38002903 150 2560 60 X 220
38016184 125 3800 72 X 228
38016176 137 3000 66 X 214
38016192 150 3800 72 X 228
38016374 125 4500 78 X 235
38016382 150 4500 78 X 235
38016390 1258 5200 84 X 238
38016408 150 5200 84 X 238
38016416 125 6000 90 X 241
38016424 150 6000 90 X 241
38016432 125 7000 96 X 244
38016440 150 7000 96 X 244
38016457 125 8000 102 X 247
38016465 150 8000 102 X 247

Note: Pricing for standard primer only. For paint options, contact Davidson. Price does not include frieght.
Flange Openings (NPT) Dimensions

CCN PSI GAL DIA X L C D E F G I J K L M BC

38002804 137 660 42 X 120 - 4 1 3 1 1/4 8 20 25 25 11/16 38

38002812 150 660 42 X 120 - 6 1 3 1 1/4 8 20 25 25 11/16 38

38002838 150 1060 48 X 144 - 6 1 3 1 1/4 8 24 32 32 11/16 38

38002846 175 1060 48 X 144 - 6 1 3 1 1/4 8 24 32 32 11/16 38

38002861 137 1550 54 X 166 - 6 1-1/4 3 1 1/4 8 26 38 38 11/16 44

38016168 150 2000 60 X 174 - 6 1-1/4 3 1 1/4 8 26 38 38 11/16 44

38002903 150 2560 60 X 220 - 6 1-1/4 3 1 1/4 8 26 56 56 11/16 44

38016184 125 3800 72 X 228 - 6 1-1/4 3 1 1/4 8 28 46 46 11/16 50

38016176 137 3000 66 X 214 - 6 1-1/4 3 1 1/4 8 28 46 46 11/16 50

38016192 150 3800 72 X 228 - 6 1-1/4 3 1 1/4 8 30 56 56 11/16 58

38016374 125 4500 78 X 235 - 6 1-1/4 3 1 1/4 8 34 50 67 7/8 58

38016382 150 4500 78 X 235 - 6 1-1/4 3 1 1/4 8 34 50 67 7/8 58

Tank Drawing

38016390 125 5200 84 X 238 - 6 1-1/4 3 1 1/4 8 34 50 70 7/8 78

38016408 150 5200 84 X 238 - 6 1-1/4 3 1 1/4 8 34 50 70 7/8 78

38016416 125 6000 90 X 241 - 6 1-1/4 3 1 1/4 8 36 50 72 7/8 78

38016424 150 6000 90 X 241 - 6 1-1/4 3 1 1/4 8 36 50 72 7/8 78

38016432 125 7000 96 X 244 - 6 1-1/4 3 1 1/4 8 38 50 68 7/8 90

38016440 150 7000 96 X 244 - 6 1-1/4 3 1 1/4 8 38 50 68 7/8 90

38016457 125 8000 102 X 247 - 6 1-1/4 3 1 1/4 8 40 50 70 7/8 90

38016465 150 8000 102 X 247 - 6 1-1/4 3 1 1/4 8 40 50 70 7/8 90