PSG Series

OIL/WATER SEPARATORS

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.

C.C.N. : 38471157
More Than Air. Answers. REV. : B
Online answers: [Link] DATE : June 2011
PHONE: 1-800-AIR-COMP (1-800-247-2667)
 Limited One Year Warranty
The PSG Separators are 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 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 representative.
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.
 TABLE OF CONTENTS
1.0 GENERAL

2.0 HOW IT WORKS

3.0 INSTALLATION INSTRUCTIONS

3.1 Placement
3.2 Filter Preparation
3.3 Water Outlet Plumbing Preparation
3.4 Condensate Inlet Preparation
3.5 Collection Manifold Guidelines
3.6 Priming The System
3.7 Oil Outlet Tube Adjustment
3.8 Sample Testing
3.9 Commissioning

4.0 OPERATION INSTRUCTIONS

5.0 MAINTENANCE INSTRUCTIONS

5.1 Maintenance Schedule
5.2 Diffuser and Separation Filter Maintenance Procedure
5.3 Pre-Adsorber and Adsorption Module Replacement Procedure

6.0 SIZING

7.0 TROUBLESHOOTING

8.0 GENERAL DATA

9.0 PARTS LIST

1
 Performance Statement for Ingersoll Rand
Polysep PSG Series

The Polysep PSG Series is designed to separate a wide variety of compressor

lubricants from compressor condensate. PSG separators use gravity separation to float
and remove lubricants which separate easily and do not emulsify. Stable emulsions,
such as polyglycol based lubricants, are broken and removed by the absorption filter
modules incorporated in the PSG.

For lubricants which do not form stable emulsions, the PSG Series separators are
designed to remove oil from compressor condensate to a level of less than or equal to
10mg/liter (as per US EPA Method 1664 Oil & Grease).

For lubricants which form stable emulsions, the PSG Series separators are designed to
remove over 95% of lubricant present in the incoming compressor condensate.

This level of performance is obtainable only if the following conditions are met:

1. Installation, commissioning, and operation are done strictly following the

instructions in the installation and maintenance manual provided with the unit.
2. The sizing of the PSG separator is done using only the manufacturer’s software
or technical information and all of the required parameters are verified.
3. The actual operating conditions and lubricant of the compressed air plant are
verified to be identical to those provided for sizing.
4. There must be no mixing of oils or introduction of other materials in the
condensate sent to the PSG unit.
5. The filter modules are replaced according to the schedule in the maintenance
manual and are properly installed.
6. The compressor is optimized according to the manufacturer’s recommended
maintenance and inspection schedule (namely separator assembly).
 the separation process. It also prevents the dirt, rust
1.0 GENERAL and scale from leaving the Sediment Chamber.
The separator provides an environment where (2) Processing: Both the Oil and Water enter the
the small percentage of an insoluble lubricant can Vessel through exit holes in the Sediment Chamber.
rise to the surface to be skimmed off. Water that is Non emulsified oil will float to the surface and then be
displaced by fresh incoming condensate slowly sinks removed via the Oil Outlet Tube to the Oil Container
to the bottom, and then rises to pass through the The Water slowly sinks to the bottom of the Vessel.
unique polar Adsorption Module. From there, the It rises through a tube and enters the Pre-Adsorption
clean water can be safely discharged to your collection Chamber where it is pre-cleaned before it flows down
point. through the Adsorption Module for final polishing.
From there it exits the separator via the Water
2.0 HOW IT WORKS Outlet Port located conveniently at the back of the
(1) Depressurization: Condensate is depressurized vessel.
as it enters the separator through the three (3) ½” NPT (3) Monitoring: A translucent Oil Container is
Condensate Inlets in the Inlet Diffuser Assembly. Air provided to indicate just how much oil has collected
is exhausted to atmosphere through the Filter located for disposal.
in the top. Gravity draws the new condensate into the
Sediment Chamber and pushes the old condensate Sample Jars are provided to collect water from the
through the Separation Filter. The Separation Filter Sample Valve. A simple comparison test will confirm
causes fine oil droplets to coalesce which speeds up when it’s time to change the Adsorption Module.

Condensate
Inlet Diffuser Inlets (3) Access Lid
Assembly Flow Adsorption
Indicator Module Pre-Adsorbtion
Chamber
Separation
Oil Outlet
Filter
Tube

Oil
Sediment Container
Chamber

Water Outlet
Port

Vessel

Sample
Valve

2
3.0 INSTALLATION 4. Reinstall the pre-wetted Pre-Adsorber and
Adsorption Module.
INSTRUCTIONS Note: For ease of installation, roll the Adsorption
Module on the floor to elongate it. Pick-up the module
3.1 PLACEMENT in both hands and carry horizontally. Position the end
The separator must be installed on a flat and level of the module at the top of the chamber and gently tip
surface capable of supporting the entire functioning up and slide into the chamber. Finally, press down on
weight of the installation. As gravity is responsible for the edges of the module to ensure it is fully installed
the proper operation of the separator, it is highly and seated at the bottom of the chamber.
recommended that the unit be installed close to the 3.3 WATER OUTLET PLUMBING PREPARATION
collection point for the treated condensate. Please
provide room around the unit for ease of maintenance The size and location of the Water Outlet fitting will
and access to the filters. control the water level in the separator.
1. Level the floor area where the separator will be 1. Install a ¾” NPT elbow on the Water Outlet Port
placed to ensure proper operation. facing downward and route piping directly to the
2. Twist the external OIL OUTLET TUBE while raising collection point to limit any flow restriction.
it to its maximum height.
3. Position the translucent OIL CONTAINER below the CAUTION: DO NOT RESTRICT OR REDUCE THE
OIL OUTLET TUBE. SIZE OF THE WATER OUTLET PIPING.
RESTRICTING THE WATER OUTLET CAN RESULT
DO NOT LOWER OIL OUTLET TUBE AT THIS TIME. IN DISCHARGING WATER INTO THE OIL
CONTAINER.
IMPORTANT: AMBIENT TEMPERATURE MUST
o o o o
BE BETWEEN 35 F (2 C) AND 120 F (48 C). NOTE: When using a common water outlet manifold,
install an elbow on the Water Outlet Port of each
IMPORTANT: MAXIMUM DRAIN INLET separator facing downward. All piping and manifold
PRESSURE IS 250 PSIG (17 bar) must be lower than the height of the outlet and be
pitched toward the collection point.
NOTE: FLOW DIVIDER OPTION. When using 3.4 CONDENSATE INLET PREPARATION
multiple separator units, centrally locate the Flow o o
Divider (CCN 2204432) to ensure uniform distribution. The INLET DIFFUSER can be rotated by 90 or 180
to ease installation. To rotate the DIFFUSER follow
The Flow Divider (CCN 2204432) must be installed steps 1-3, otherwise proceed to step 4.
securely above the separator units to ensure proper 1. Remove the four (4) socket head cap screws
operation. Please consult the Flow Divider (CCN attaching the INLET DIFFUSER to the separator.
2204432) installation instruction section for further 2. Rotate DIFFUSER to the desired position.
details. 3. Reinstall the four (4) socket head cap screws and
tighten.
3.2 FILTER PREPARATION 4. Use flexible tubing to connect the condensate
The Pre-Adsorber and Adsorption Module are shipped sources to the Inlet Connections on the INLET
from the factory in plastic shipping bags to control dust DIFFUSER.
and placed in their respective compartments. 5. Refer to COLLECTION MANIFOLD GUIDELINES
for installation of multiple drain lines.
The following pre-wetting procedure removes dust NOTE: The use of a Flow Divider (CCN 2204432) is
created during shipping and reduces the likelihood of recommended when demand style condensate drains
air pockets. can collectively deliver more than 43 ounces.
1. Remove the Access Lid, Pre-Adsorber, and
Adsorption Module from the separator unit. 3.5 COLLECTION MANIFOLD GUIDELINES
2. Remove the plastic shipping bags from the Pre- Collection Manifolds permit several condensate drain
Adsorber and Adsorption Module. sources to be combined into a single stream and one
3. Thoroughly hose-down the Pre-Adsorber and connection to the separator or Flow Divider (CCN
Adsorption Module with fresh water while gently 2204432). The following suggestions are offered for
rolling until the rinse water runs clear. the design and installation of a Collection Manifold.
CAUTION: FAILURE TO THOROUGHLY PRE-WET 1. Use 1” minimum pipe to limit flow restrictions.
THE ADSORPTION MODULE MAY LEAVE AIR 2. Use the bottom inlet connection of the INLET
TRAPPED AND RESULT IN THE ADSORPTION DIFFUSER or Flow Divider (CCN 2204432).
MODULE FLOATING.

3
3. Use a chemical and corrosion resistant piping and 3. Clean the Sample Jar thoroughly after sampling,
fittings, such as PVC or copper. empty and dry.
4. Locate the manifold at an elevation above the 4. Store the Sample Jars in the Placement Wells
separator or Flow Divider (CCN 2204432). The molded into the top of the separator.
manifold should slope in the direction of flow. 5. Refer to the MAINTENANCE INSTRUCTIONS for
5. Secure the manifold to isolate the separator or Flow additional sampling details.
Divider (CCN 2204432) from pipe loads.
3.9 COMMISSIONING
6. Condensate drain lines should enter the Collection
Manifold from the top and at intervals no closer than The separator is now ready for operation.
one foot.
7. Provide a separate connection point for each drain
source.
3.6 PRIMING THE SYSTEM
The specific gravity differential between the water and
the lubricant is an important factor influencing
separation.
Filling the separator with fresh, clean tap water before
commissioning prepares the unit for proper operation.
[Link] fresh, clean tap water to fill the separator
through the opening surrounding the Oil Outlet Pipe.
CAUTION: TO PREVENT OVERFLOWING, REDUCE
THE FLOW WHEN WATER BEGINS TO SPILL INTO
THE ADSORPTION MODULE
2. The unit is primed when clear water begins to flow
from the Water Outlet.
3. Allow the unit to sit for five (5) minutes to balance
the water level before proceeding to Oil Outlet Tube
Adjustment.
3.7 OIL OUTLET TUBE ADJUSTMENT
The Oil Outlet Tube extends up into the separator
vessel to remove oil from the liquid surface. When
sufficient oil has accumulated, it will be skimmed off of
the surface and drained into the Oil Container via the
Oil Outlet Tube.
1. Locate the Oil Container under the Oil Outlet Tube.
2. Grasp the Oil Outlet Tube with one hand and begin
to lower the top of the tube by gently twisting the
tube back and forth.
3. Lower the Oil Outlet Tube to an elevation with the
top of the tube approximately ½” above the water
level.
NOTE: It may take several months or more to
collect enough oil in the separator for it to begin
draining into the Oil Container. This is normal!
3.8 SAMPLE TESTING
Two (2) Sample Jars are included to provide a
comparative method of testing to ensure the separator
is operating properly.
1. Fill one (1) of the Sample Jars with clean tap water.
This will be used as a reference.
2. The second Sample Jar will be used to collect a
sample from the separator Sample Outlet.

4
 4.0 OPERATION INSTRUCTIONS 5.2 DIFFUSER AND SEPARATION FILTER
MAINTENANCE PROCEDURE
Do not pour condensate, oil, or any other fluid directly
into the oil/water separator. The cleanliness of your piping will dictate how
frequently you will need to perform this procedure.
Weekly, collect a sample of the discharge water in a However, we recommend an annual cleaning to
clear glass vessel and, compare it to tap water, maintain the flow and to remove the dirt, rust and
checking for cloudiness. scale that has accumulated.
Replace the Adsorption Module when cloudiness 1. Shut off condensate flow to Inlet Diffuser
appears in the discharge water sample. Assembly.
2. Unscrew the four Socket Head Cap Screws that
For detailed analysis, contact your local authority or hold the Diffuser to the Vessel.
an approved testing laboratory. Ingersoll-Rand 3. Lift up the Diffuser and move it out of the way so
provides fluid testing services. To learn more about you can remove the Sediment Chamber.
the services, please contact your local Ingersoll-Rand 4. Grasp the edges of the Sediment Chamber and
service provider. slowly lift it from the vessel.
5. Tip the Sediment Chamber slightly to slowly pour
the contents through the Separation Filter and
5.0 MAINTENANCE back into the vessel until the liquid is emptied.
INSTRUCTIONS 6. Remove the Separation Filter from the recess
inside the Sediment Chamber and discard.
5.1 MAINTENANCE SCHEDULE 7. Clean the dirt, rust and scale from the Sediment
Chamber. Reinstall a new Separation Filter into
Daily the recess.
1. Check the Oil level in the translucent Oil 8. Seat the Sediment Chamber into the vessel by
Container. Empty it when the oil level reaches 3/4 slowly pouring tap water into it until the water
of capacity. exits the discharge holes in the Chamber walls.
Every Two Weeks 9. Remove and replace the Expansion Chamber
1. Take the empty Sample Jar and collect a sample element located on top of the Diffuser Assembly.
from the Sample Valve located above the Oil 10. Reinstall the Diffuser Assembly and secure with
Container. four socket head screws.
2. Hold both the Sample Jar and the Reference Jar 5.3 PRE-ADSORBER AND ADSORPTION
to a light for a visual turbidity comparison. MODULE REPLACEMENT PROCEDURE
3. Keep a spare Pre-Adsorber and Adsorption
Module in stock to avoid change out problems. Prepare the replacement Adsorption Module and Pre-
4. Change the Pre-Adsorber and Adsorption Module Adsorber for service as follows:
when the compared Condensate Sample
1. Remove them from their plastic bags.
appears cloudy.
2. Thoroughly hose down the Pre-Adsorber &
5. Pour the Condensate Sample back into the Pre-
Adsorption Module while rolling them until the
Adsorber Chamber.
water runs clear.
6. Wash and dry the Sample Jar before returning it
3. Shut off the condensate flow to the Inlet Diffuser
to the Placement Well.
Assembly and remove the Access Lid.
Note: The Sample Valve extracts the condensate 4. Use a polypropylene pad to adsorb and remove
sample 2/3rds of the way through the Adsorption any oil that is floating on the surface water in the
Module. This provides enough time and security for Adsorption Module Chamber.
replacing the Adsorption Module before PPM 5. Grab Adsorption Module Handles and slowly lift
violations should occur. out of chamber.
6. Suspend bag over chamber for a couple of
Annually
minutes to drain.
Keeping your separator in good working 7. Install new Pre-Adsorber & Adsorption Module.
condition prevents problems and pays you dividends 8. Reorder a spare Pre-Adsorber & Adsorption
all year long. Therefore, as part of a good Module.
preventative maintenance program, we recommend
cleaning out the Sediment Chamber and replacing ATTENTION: PLEASE BE SURE TO COMPLY
the Adsorption Module at least once a year. The WITH ALL APPLICABLE REGULATIONS WHEN
following sections will provide you with these DISPOSING OF LUBRICANT CONTAMINATED
servicing details. FILTERS.

5
6.0 SIZING
Cold Climate: 60oF (15oC), 60% RH
Compressor Capacity (CFM)
IR Model
Screw Compressors Reciprocating Compressors
Turbine Oil Synthetic Oil Polyglycol PAO Ester Turbine Oil Diester
PS-7 60 60 60 60 60 60 60
PSG-15 850 640 175 850 640 425 361
PSG-30 1,700 1,275 390 1,700 1,275 850 723
PSG-60 3,400 2,550 750 3,400 2,550 1,700 1,445
PSG-90 5,100 3,825 950 5,100 3,825 2,550 2,168
PSGK-120 6,800 5,100 1,500 6,800 5,100 3,400 2,890
PSGK-180 10,200 7,650 1,900 10,200 7,650 5,100 4,335

Mild Climate: 80oF (27oC), 60% RH

Compressor Capacity (CFM)
Screw Compressors Reciprocating Compressors
IR Model
Turbine Oil Synthetic Oil Polyglycol PAO Ester Turbine Oil Diester
PS-7 60 60 60 60 60 60 60
PSG-15 450 340 175 450 340 225 191
PSG-30 900 685 390 900 685 450 383
PSG-60 1,800 1,370 750 1,800 1,370 900 765
PSG-90 2,700 2,050 950 2,700 2,050 1,350 1,148
PSGK-120 3,600 2,740 1,500 3,600 2,740 1,800 1,530
PSGK-180 5,400 4,100 1,900 5,400 4,100 2,700 2,295

Hot Climate: 90oF (32oC), 70% RH

Compressor Capacity (CFM)
Screw Compressors Reciprocating Compressors
IR Model
Turbine Oil Synthetic Oil Polyglycol PAO Ester Turbine Oil Diester
PS-7 60 60 60 60 60 60 60
PSG-15 290 215 175 290 215 145 123
PSG-30 575 430 390 575 430 288 244
PSG-60 1,150 860 750 1,150 860 575 489
PSG-90 1,725 1,300 950 1,725 1,300 863 733
PSGK-120 2,300 1,725 1,500 2,300 1,725 1,150 978
PSGK-180 3,450 2,600 1,900 3,450 2,600 1,725 1,466

NOTES: 1. Ratings are based on 4 PPM oil carryover

2. Filter life is one (1) year based on 4,000 operating hours per year.

6
7.0 TROUBLESHOOTING

Trouble Probable Cause/Remedy

Water in Oil Container Unit is not on a level surface.
• Level area as noted in “PLACEMENT” section.
Oil Outlet Tube is set too low allowing water to exit with the oil.
• Refer to “OIL OUTLET TUBE ADJUSTMENT” section for details.
A large condensate surge will elevate the water level above the Oil
Outlet Tube and allow water to escape before level adjusts.
• Install a Flow Divider (CCN 2204432) to prevent an overload by
controlling the surge.
• Install the proper demand drain to prevent surge, reduce
emulsification, and extend filter life. Contact IR for assistance.
Condensate spills out at base Large condensate surges can exceed the capacity of the Sediment
of Inlet Diffuser Assembly Chamber and cause it to overflow below the Inlet Diffuser
Assembly.
• Install a Flow Divider (CCN 2204432) to prevent an overload by
controlling the surge.
• Install the proper demand drain to prevent surge, reduce
emulsification, and extend filter life. Contact IR for assistance.
Condensate backs up inside Flow through Separation Filter is restricted by sludge or debris.
Diffuser Assembly • Replace Separation Filter. See “SEPARATION FILTER”
replacement instructions located in “MAINTENANCE
INSTRUCTIONS”
Oil layer is lumpy and foamy Bacterial contamination.
• Disassemble the separator. Pressure wash or steam clean vessel
and components. Rinse well and replace filters and modules.
No oil in Oil Container Oil accumulation will vary and may take months to establish a
layer.
• Check depth of oil layer in the vessel. Refer to the “OIL OUTLET
TUBE ADJUSTMENT” section for details.
• Oil Outlet Tube may be set too high.
Frequent Adsorption Module Lubricant has poor demulsibility characteristics and or unit is
Replacement undersized.
• Perform the “GLASS JAR TEST” as described in the
INTRODUCTION.
Contact IR for further assistance.
• Replace lubricant with another that has better demulsification
characteristics to extend the Adsorption Module life.
• Replace timer-style drains with demand drains to reduce
emulsification. Contact IR for assistance.
Turbulence due to large condensate surges allows emulsified oil
to enter Adsorption Module.
• Install a Flow Divider (CCN 2204432) to prevent turbulence by
controlling surges.
Atmospheric contaminants are creating irreversible emulsion.
• Determine source of contaminant and isolate from air intake.
• Disassemble and pressure wash or steam clean separator and
components. Rinse well and reassemble with new filters and
modules.
Different lubricants from multiple sources limits demulsification.
• Standardize on a lubricant on multiple compressor systems.
• Isolate different lubricant systems and install parallel systems.
Cross-contamination of lubricants.
• Use a dedicated transfer device for each lubricant and clean after
use.

7
 J

K
P
L Model A B C D E F G J K L M N P Q R
PSG
15 29.7 27.0 20.7 14.5 11.3 5.3 16.0 26.5 26.0 9.0 14.0 19.5 4.5 2.7 10.7

30 39.0 36.3 20.7 14.5 11.3 5.3 16.0 26.5 26.0 9.0 14.0 19.5 4.5 2.7 10.7

60 39.0 36.3 30.0 20.2 17.1 4.7 23.0 35.0 32.0 21.8 26.8 31.5 6.0 6.9 18.0

M N 90 45.0 41.3 36.0 26.0 23.1 4.7 29.0 35.0 32.0 21.8 26.8 31.5 6.0 16.9 18.0
8.0 GENERAL DATA

NOTES: 1. ALL DIMENSIONS IN INCHES, UNLESS OTHERWISE SHOWN.

R 2. ALL DIMENSIONS ARE +/- .5, UNLESS OTHERWISE SHOWN.
Access Cover 3. DIFFUSER IS ROTATABLE IN 90 INCREMENTS.
Condensate Inlets 4. PSG-60 USED TO ILLUSTRATE DIMENSIONS.
(3) 1/2 NPT

Diffuser Sample Jar

(See Note 3)
1.75
Reference Jar
1.75
Water Out Connection
F 3/4 NPT - PSG 15-30
1 NPT - PSG 60-90

Water Sample Valve

Oil Outlet Tube

A

C G
D
E
9.0 PARTS 1 7
7

1
2a

8 8
2a

3 2c 3

2c

2b
2b
9

9
5 5

2d
6
2d
6

10
10
4
11 4 11

PSG-15/30 PSG-60/90
PSG PARTS TABLE
Part Description PSG-15 Qty PSG-30 Qty PSG-60 Qty PSG-90 Qty
1 Diffuser Cover Ring 38339875 1 38465662 1 38465662 1 38465662 1
2a Diffuser Pad 1 1 1 1
2b Separation Filter 1 1 1 1
38339057 38465712 38465761 38469052
2c Adsorption Module 1 2 4 4
2d Pre-Adsorption Pad 1 1 1 1
3 Diffuser Assembly 38339891 1 38465670 1 38465670 1 38465670 1

4 Vessel 38339966 1 38465720 1 38465753 1 38465688 1

5 Sediment Chamber 38339917 1 38465696 1 38465696 1 38465696 1
6 Sample Jar 38339925 2 38339925 2 38339925 2 38339925 2

7 Flow Indicator 38339933 1 38469532 1 38469532 1 38469532 1

8 Cover 38339941 1 38465704 1 38465746 1 38465746 1
9 Oil Outlet Tube 38339958 1 38469540 1 38469540 1 38469540 1
10 Sample Valve 38339974 1 38339974 1 38339974 1 38339974 1

11 Oil Container 38339982 1 38339982 1 38339982 1 38339982 1