IRN37–160K–CC

IRN50–200H–CC
IRN75–160K–2S
IRN100–200H–2S
OPERATION AND MAINTENANCE MANUAL

N37K–CC SERIAL No : 2710306 –>

N45K–CC SERIAL No : 2730270 –>

N55K–CC SERIAL No : 2750156 –>

N75K–CC SERIAL No : 2770372 –>

N50H/N60H–CC SERIAL No : NV1558 –>

N75H/N100H–CC SERIAL No : NV5686 –>

N90K–CC SERIAL No : 2790010 –>

N110K–CC SERIAL No : 2800008 –>

N132K–CC SERIAL No : 2810002 –>

N160K–CC SERIAL No : 2820006 –>

TM N75K–2S SERIAL No : 2830000 –>

N90K–2S SERIAL No : 2840000 –>

N110K–2S SERIAL No : 2850000 –>

Ensure that the operator reads and understands the
decals and consults the manuals before maintenance or N132K–2S SERIAL No : 2860000 –>
operation.

Ensure that the Operation and Maintenance manual is N160K–2S SERIAL No : 2870000 –>
not removed permanently from the machine.
N125H–N200H–CC SERIAL No : NF50148 –>
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance
Manuals. N100H–N200H–2S SERIAL No : NFF0118 –>

C.C.N. : 54719091
DATE : MAY 2004
REV. :G
 Machine models represented in this manual may be used in various locations world–wide. Machines sold and
shipped into European Union Territories require that the machine display the EC Mark and conform to various
directives. In such cases, the design specification of this machine has been certified as complying with EC directives.
Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being
rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

98/37/EC, 97/23/EC, 93/68/EEC, 89/336/EEC

WE,

INGERSOLL–RAND COMPANY LIMITED

SWAN LANE
HINDLEY GREEN
WIGAN WN2 4EZ
UNITED KINGDOM

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

IRN37K–CC IRN45K–CC IRN55K–CC IRN75K–CC

IRN90K–CC IRN110K–CC IRN132K–CC IRN160K–CC
IRN75K–2S IRN90K–2S IRN132K–2S IRN160K–2S
TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS
OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

EN29001, EN292, EN60204–1, EN1012–1, EN61000–6

ISSUED AT HINDLEY GREEN ON 01/01/2004 BY H.SEDDON, QUALITY ASSURANCE

MANAGER.

H. SEDDON

THIS DECLARATION APPLIES TO UNITS WITH SERIAL NUMBERS OF THE FORMAT

27XXXXX & 28XXXXX.

UNITS WITH SERIAL NUMBERS OF THE FORMAT NV1XXX MAY NOT CONFORM TO CE
REGULATIONS AND ARE INTENDED FOR USE SOLELY OUTSIDE OF THE EUROPEAN
COMMUNITY.
01/04
 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 twenty four months from the date of placing the Equipment in operation
or thirty months from the date of shipment from the factory, whichever shall first occur (see extended airend
warranty). 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 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 compressor
or negotiated as part of the purchase order may take precedence over this warranty.
 CONTENTS

CONTENTS PAGE CONTENTS PAGE

1.0 CONTENTS 1 8.0 GENERAL INFORMATION 27

8.1 Technical information
2.0 FOREWORD 2
8.2 Installation drawing
3.0 ABBREVIATIONS & 4 8.3 Process and
SYMBOLS instrumentation diagram
8.4 Electrical schematic
4.0 PURCHASE ORDER 5
DETAILS 8.5 General description
9.0 OPERATING 54
5.0 SAFETY 6 INSTRUCTIONS
5.1 Safety instructions 9.1 Basic operation
5.2 Safety precautions 9.2 Intellisys controls
5.3 Text decals 9.3 Display screen
5.4 Graphic form and meaning 9.4 Current status screen
of ISO symbols 9.5 Main menu
9.6 Operator setpoints
6.0 RECEIPT AND 18
9.7 Options
HANDLING
9.8 Sensor calibration
6.1 Receipt
9.9 Alarm history
6.2 Unpacking and handling
9.10 Clock functions
7.0 INSTALLATION 19 9.11 Energy status messages
7.1 Location in plant 9.12 Warnings
7.2 Discharge and condensate 9.13 Service warnings
piping 9.14 Initial check alarms
7.3 Electrical 9.15 Alarms
7.4 Watercooled units
7.5 Sea watercooled units 10.0 MAINTENANCE 68
7.6 Outdoor sheltered 10.1 Maintenance prompts
installation 10.2 Maintenance chart
10.3 Maintenance procedures
10.4 Routine maintenance

11.0 FAULT FINDING 78

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 1

 2.0 FOREWORD

Machine models represented in this manual may be Details of approved equipment are available from
used in various locations worldwide. Machines sold and Ingersoll–Rand Service departments.
shipped into European community countries requires
that the machine display the EC Mark and conform to
This machine has been designed and supplied for use
various directives. In such cases, the design
only in the following specified conditions and
specification of this machine has been certified as
applications:
complying with EC directives. Any modification to any
. Compression of normal ambient air containing no
part is absolutely prohibited and would result in the CE known or detectable additional gases, vapors or
certification and marking being rendered invalid. particles
. Operation within the ambient temperature range
The contents of this manual are considered to be specified in the GENERAL INFORMATION section of
proprietary and confidential to Ingersoll–Rand and this manual.
should not be reproduced without the prior written
permission of Ingersoll–Rand. IF IN DOUBT CONSULT SUPERVISION .

Nothing contained in this document is intended to The company accepts no responsibility for errors in
extend any promise, warranty or representation, translation of this manual from the original English
expressed or implied, regarding the Ingersoll–Rand version.
products described herein. Any such warranties or
other terms and conditions of sale of products shall be
in accordance with the standard terms and conditions The design of this Compressor package and
of sale for such products, which are available upon certain features within it are covered by patents
request. held by Ingersoll–Rand and patents pending
SSR ULTRA COOLANT is a registered trademark of
This manual contains instructions and technical data to Ingersoll–Rand Company USA.
cover all routine operation and scheduled maintenance INTELLISYS is a registered trademark of
tasks by operation and maintenance staff. Major Ingersoll–Rand Company USA.
overhauls are outside the scope of this manual and
should be referred to an authorized Ingersoll–Rand HPMT, HYBRID PERMANENT MAGNETT and HPM
service department. Logo are trade marks registered by MOTEURS LE-
ROY–SOMER
All components, accessories, pipes and connectors  COPYRIGHT 2004
added to the compressed air system should be: INGERSOLL–RAND COMPANY
. of good quality, procured from a reputable
manufacturer and, wherever possible, be of a type
approved by Ingersoll–Rand.
. clearly rated for a pressure at least equal to the
machine maximum allowable working pressure.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation,
operation and maintenance.

Ingersoll–Rand reserves the right to make changes and

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

2 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 2.0 FOREWORD

WARNING
The use of the machine in any of the situation types listed in table 1:–
a) Is not approved by Ingersoll–Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll–Rand.

TABLE 1
WARNING – NOT PERMITTED
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption.
Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION
SECTION of this manual.
Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or
vapors.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY EXPLOSIVE
ATMOSPHERES, INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR VAPOURS MAY BE
PRESENT.
Use of the machine fitted with non Ingersoll–Rand approved components.
Use of the machine with safety or control components missing or disabled.
Connection to an electrical supply of incorrect voltage and/or frequency.

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

WARNING
The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such
as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with
cardiac pacemakers, defibrillators or other implanted electronic medical device.

WARNING
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the
internal capacitors store a potentialy lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt
any work on the drive unless trained. There are no user serviceable items behind the cover.

WARNING
The compressor can operate in a pressurised shutdown mode. If the compressor stops automatically, the
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through
which any residual pressure will be vented. Downstream of the separator tank may still contain system
pressure which must also be vented.

NOTICE
The manual is intended for worldwide use and contains both metric and imperial data where required.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 3

 3.0 ABBREVIATIONS & SYMBOLS

#### Contact Ingersoll–Rand for serial number

–>#### Up to Serial No.
####–> From Serial No.
* Not illustrated
† Option
NR Not required
AR As required
SM Sitemaster/Sitepack
HA High ambient machine
WC Watercooled machine
AC Aircooled machine
ERS Energy recovery system
T.E.F.C.Totally enclosed fan cooled motor (IP54)
O.D.P. Open drip proof (motor)
ppm parts per million

cs Czech
da Danish
de German
el Greek
en English
es Spanish
et Estonian
fi Finnish
fr French
hu Hungarian
it Italian
lt Lithuanian
lv Latvian, Lettish
mt Maltese
nl Dutch
no Norwegian
pl Polish
pt Portuguese
sk Slovak
sl Slovenian
sv Swedish
zh Chinese

4 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 4.0 PURCHASE ORDER DETAILS

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.
No. of units on order:
Customer Order No:
Ingersoll–Rand Co. Order No.:
For ready reference:
Record the serial number and model number of
your unit here.
Serial Number:
Model Number:

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 5

 5.0 SAFETY

5.1 SAFETY INSTRUCTIONS

Safety instructions in the operators manual are Ensure that the Operation and Maintenance manual,
bold–faced for emphasis. The signal words DANGER, and the manual holder, are not permanently removed
WARNING and CAUTION are used to indicate hazard from the machine.
seriousness levels as follows.
Ensure that maintenance personnel are adequately
Ensure that the operator reads and understands the trained, competent and have read the Maintenance
decals and consults the manuals before maintenance Manuals.
or operation.

DANGER CAUTION
Indicates the presence of a hazard which WILL cause Indicates the presence of a hazard which WILL or can
serious injury, death or property damage, if ignored. cause injury or property damage, if ignored.
WARNING NOTICE
Indicates the presence of a hazard which CAN cause Indicates important set–up, operating or maintenance
serious injury, death or property damage, if ignored. information.

5.2 SAFETY PRECAUTIONS

General Information If more than one compressor is connected to one

common downstream plant, effective check valves and
Compressed air and electricity can be dangerous. isolation valves must be fitted and controlled by work
Before undertaking any work on the compressor, procedures, so that one machine cannot accidentally
ensure that the electrical supply has been isolated, be pressurized / over pressurized by another.
locked off, tagged and the compressor has been
relieved of all pressure. If a safety valve is installed between the isolation valve
and the compressor, it must have sufficient capacity to
Make sure that all protective covers are in place and relieve the full capacity of the compressor(s).
that the canopy/doors are closed during operation.
The discharged air contains a very small percentage of
Installation of this compressor must be in accordance compressor lubricating oil and care should be taken to
with recognized electrical codes and any local Health ensure that downstream equipment is compatible.
and Safety Codes.
If the discharged air is to be ultimately released into a
Use only safety solvent for cleaning the compressor confined space, adequate ventilation must be provided.
and auxiliary equipment.
The use of plastic bowls on line filters without metal
Compressed air guards can be hazardous. Their safety can be affected
by either synthetic lubricants, or the additives used in
Ensure that the machine is operating at the rated mineral oils. Metal bowls should be used on a
pressure and that the rated pressure is known to all pressurized system.
relevant personnel.
When using compressed air always use appropriate
All air pressure equipment installed in or connected to personal protective equipment.
the machine must have safe working pressure ratings
of at least the machine rated pressure.

6 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 5.0 SAFETY
All pressure containing parts, especially flexible hoses Never give fluids or induce vomiting if the patient is
and their couplings, must be regularly inspected, be unconscious or having convulsions.
free from defects and be replaced according to the
The above information contains data supplied in
Manual instructions.
support of United Kingdom Control of Substances
Compressed air can be dangerous if incorrectly Hazardous to Health (C.O.S.H.H.) regulations
handled. Before doing any work on the unit, ensure that
all pressure is vented from the system and that the
machine cannot be started accidentally. Transport

Avoid bodily contact with compressed air. When loading or transporting machines ensure that the
specified lifting and tie down points are used.
The safety valve located in the separator tank must be
checked periodically for correct operation. It is recommended that the machine be moved using
the fork lift slots in the machine base.
Whenever pressure is released through the pressure
relief valve, it is due to excessive pressure in the Refer to section 8 for reference information.
system. The cause for the excessive pressure should
be investigated immediately.
Electrical
The compressor has high and dangerous voltage in the
motor starter and control box. All installations must be
Materials in accordance with recognized electrical codes. Before
working on the electrical system, be sure to remove
The following substances are used in the manufacture
of this machine and may be hazardous to health if used voltage from the system by using a manual disconnect
incorrectly: switch. A circuit breaker or fuse safety switch must be
. preservative grease provided in the electrical supply line leading to the
. rust preventative compressor.
. compressor coolant Those responsible for installation of this equipment
must provide suitable grounds, maintenance clearance
and lightning arrestors for all electrical components in
accordance with National and Local code
WARNING requirements.
AVOID INGESTION, SKIN CONTACT AND Keep all parts of the body and any hand–held tools or
INHALATION OF FUMES other conductive objects, away from exposed live parts
of the compressor electrical system. Maintain dry
footing, stand on insulating surfaces and do not contact
any other portion of the compressor when making
For further information, request and consult the coolant adjustments or repairs to exposed live parts of the
Material Data Sheet (UK ACGP 011/96 –ULTRA compressor electrical system.
COOLANT ACGP 029/90–food grade coolant. For
Close and lock all access doors when the compressor
USA served areas, use MSDS sheet APDD 236) from
is left unattended.
your local IR office, Distributor or Air Center.
Do not use extinguishers intended for Class A or Class
Should compressor lubricant come into contact with the B fires on electrical fires. Use only extinguishers
eyes, then irrigate with water for at least 5 minutes. suitable for class BC or class ABC fires.
Should compressor lubricant come into contact with the
Attempt repairs only in clean, dry, well lighted and
skin, then wash off immediately.
ventilated areas.
Consult a physician if large amounts of compressor
Connect the compressor only to electrical systems that
lubricant are ingested.
are compatible with its electrical characteristics and
Consult a physician if compressor lubricant is inhaled. that are within it’s rated capacity.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 7

 5.0 SAFETY
Condensate disposal Coolant disposal
Condensate cannot be discharged into fresh/surface Steps to be taken in the case of spillage: Soak up with
water drains. In some regions compressor condensate a suitable absorbent material, then sweep into a plastic
containing ULTRA COOLANT can be fed directly into a bag for disposal.
drainage system that has downstream sewage
treatment. Burn in an approved incinerator, or according to local
area or country regulations.
As waste water regulations vary by country and region
it is the responsibility of the user to establish the For further information, consult ULTRA COOLANT
limitations and regulations in their particular area. Material Data Sheets ACGP 011/96 or APDD 236.
Ingersoll–Rand and its associated distributors are FOOD GRADE COOLANT Material Data Sheets
happy to advise and assist in these matters. IRACA145 or APDD190.

WARNING
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the
internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt
any work on the drive unless trained. There are no user serviceable items behind the cover.

WARNING
There is a high discharge air temperature shutdown function built into each compressor. lt is factory preset
at 109_C (228_F).This function should be checked at regular intervals for proper operation, once a month is
recommended. Refer to maintenance section.
Failure to adhere to these recommendations can result in mechanical failure, property damage and serious
injury or death.
S 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.
S 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.
S 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 applications.
Ingersoll–Rand does not approve specialized equipment for breathing air application and assumes no
responsibility or liability for compressors used for breathing air services.”
WARNING
No portable communication devices emitting more than 7.5 volts per metre in the frequency range from 250
MHz to 280 MHz should be operated within 5m (16.5ft) of the unit.
WARNING
The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such
as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with
cardiac pacemakers, defibrillators or other implanted electronic medical device.
WARNING
The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas.
If such an application is required then all local regulations, codes of practice and site rules must be observed.
To ensure that the machine can operate in a safe and reliable manner, additional equipment such as gas
detection and intake (shut–off) valves may be required, dependant on local regulations or the degree of risk
involved.
WARNING
The compressor can operate in a pressurized shutdown mode. If the compressor stops automatically, the
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through
which any residual pressure will be vented. Downstream of the separator tank may still contain system
pressure which must also be vented.

8 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 5.0 SAFETY
Depending on point of manufacture and point of use, the compressor and this manual will show symbols
from the following sections. Compressors for use within the European Community must be equipped with
symbols from section 5.4. Read and understand thoroughly. Heed warnings and follow instructions. If you
do not understand, inform your supervisor.

5.3 TEXT DECALS

NOTICE WARNING
To obtain satisfactory compressor operation and
maintenance a minimum of 3 feet clearance on 3 sides
is required, 3–1/2 feet is required in front of the control
panel (or minimum required by latest National Electrical
code or applicable local codes).
Refer to the Instruction / Operators Manual before
performing any maintenance.

Hazardous voltage. Can cause severe injury or

death.
DANGER
Disconnect power before servicing.
Lockout/Tagout machine.

WARNING
Discharge air.
Can contain carbon monoxide or other
contaminants. Will cause severe injury or death.

Do not breathe this air.

Rotating fan blade. Can cause severe injury.

Do not operate with covers removed.

Disconnect power. Lock/out and tag out machine.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 9

 5.0 SAFETY

CAUTION WARNING
Incorrect lifting of machine can cause injury or
property damage.

Lift only from base channels

Food contaminant.
Can cause severe injury or death.
Use only Ingersoll–Rand SSR H–1F food grade
coolant.
WARNING
39568464 Rev.03

High pressure air.

Can cause severe injury or death.
Compressor can operate in a pressurized
shutdown mode. NOTICE
Relieve pressure before removing filter plugs/caps,
fittings or covers. Lift here
22061915 Rev A

NOTICE
Air discharge
WARNING

CAUTION
Use of incorrect coolant can cause system Hot surface.
contamination. Can cause severe injury.

Use only SSR ULTRA COOLANT Do not touch. Allow to cool before servicing.

10 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 5.0 SAFETY

CAUTION Rotation
Improper coolant filter replacement will cause
compressor damage. Rotation
Replace filter element after first 150 hours of
operation and every 2000 hours thereafter or when
coolant is changed.

NOTICE

WARNING – HIGH VOLTAGE

Rotation Do not attempt any work.
Read manual.
Trained service personnel only.
Remove electrical supply.
Wait 15 minutes.
Check for zero voltage.
Proceed with caution.

WARNING

Moving parts. Can cause severe injury.

Do not operate with covers removed.

Service only with machine blocked to prevent turn over.

39540224 Rev. 04

Air
Discharge
39540257 Rev. 04

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 11

 5.0 SAFETY

Condensate
drain.
39541081 Rev. 04

Electrical
power inlet.
39541354 Rev. 03 Use 75°C copper wire only.

WARNING

Hazardous voltage. Can cause severe injury or IMPORTANT

death. Before starting this air compressor unit the shipping
brace(s) must be removed.
Save the brace(s) for future use.
Only use factory supplied inlet for incoming power. See Refer to Operators / Instruction Manual.
Operators / Instruction Manual.

39543764 Rev. 03

NOTICE
To obtain satisfactory compressor operation and
maintenance, a minimum of 3 feet clearance on 3
sides is required. 3 1/2 feet is required in front of
the control panel (or minimum required by latest
National Electrical code or applicable local codes.)

Refer to the Instruction / Operators Manual before

performing any maintenance.

39540158 Rev.05

12 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 5.0 SAFETY

5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING – Pressurized WARNING – Hot surface.

component or system.

WARNING – Air/gas flow or Air

WARNING – Pressure control. WARNING – Corrosion risk.
discharge.

Do not remove the Operating and

WARNING – Pressurized vessel. WARNING – Flammable liquid.
Maintenance manual from this
machine.

WARNING – Rotor magnetic field

can affect pacemakers.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 13

 5.0 SAFETY

0_C

WARNING – Do not undertake any

WARNING – Consult the WARNING – For operating
maintenance on this machine
Operation and Maintenance temperature below 0_C, consult
until the electrical supply is
manual before commencing any the Operation and Maintenance
disconnected and the air pressure
maintenance. manual.
is totally relieved.

Read the Operation and

Maintenance manual before Do not operate the machine without
Do not stack.
operation or maintenance of this the guard being in place.
machine is undertaken.

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

Do not breathe the compressed air Do not open the service valve before
No naked lights.
from this machine. the air hose is attached.

14 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 5.0 SAFETY

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

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

SET SEQUENCER STATUS LOAD

SEQUENCER (AUTOMATIC
COMPRESSOR OFF LOAD (UNLOADED)
CONTROL)

RESET COMPRESSOR STATUS MODULATE

MALFUNCTION POWER FOULED FILTER

POWER INLET ELECTRIC MOTOR HOURS

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 15

 5.0 SAFETY

COOLANT SEPARATOR PRESSURE AIR DISCHARGE

PRESSURIZED TANK ON / OFF CYCLE COOLANT FILTER

AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE

AIR PRESSURE STAR DELTA IEC 617–7 AUTOMATIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE

16 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 5.0 SAFETY

BELT TENSION FILTER MOTOR LUBRICATION

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS ROTATION

POWER INLET (AC) WATER IN WATER OUT

TRAINED SERVICE
WAIT TIME CHECK ZERO VOLTS
PERSONNEL

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 17

 6.0 RECEIPT / HANDLING

6.1 RECEIPT

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 unpacked. Obtaining the deIivery
persons 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 CEASED WHEN THE CARRIER SIGNED
BILL OF LADING

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 against the
transportation company.

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 lR, 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

6.2 UNPACKING AND HANDLING

The compressor will normally be delivered with a polyethylene or other cover. If a knife has to be used to remove this
cover, ensure that the exterior paintwork of the compressor is not damaged.
Incorporated within the base of the compressor are slots to enable a fork lift truck to move the machine. Ensure truck
forks are fully engaged on both sides. Alternatively a special lifting frame can be utilized to enable a crane or hoist to
move the compressor. Use only marked lifting points.
Once the packaging and pallet are discarded and the unit is in its final position, remove the transit brackets from the
resilient mounts and store for future use or discard.
On N75–160 units remove the screw in the base and slide the separator tank service bracket into the upper position
on the slots and tighten screws.

18 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 7.0 INSTALLATION

For technical information see section 8.0.

7.1 LOCATION IN PLANT

Ensure that the correct tie down points are used. It is recommended that provision be made for lifting
heavy components during major overhaul. Use only
For major overhaul (i.e. motor removal) position the
lifting points provided.
machine to obtain lifting access e.g. fork lift truck.
Minimum space in front of control panel door as
See diagram in reference section for minimum space
required by National or Local codes must be
requirements for normal operation and maintenance.
maintained.
Ambient temperatures higher than 46_C (115_F) must
be avoided as well as areas of high humidity. The compressor can be installed on any level floor
capable of supporting it. A dry, well ventilated area
Consider also the environment surrounding or near the where the atmosphere is as clean as possible is
compressor. The area selected for the location of the recommended.
compressor should be free of dust, chemicals, metal
filings, paint fumes and overspray. Sufficient space all round and above the compressor
must be allowed, to enable the effective removal of the
Hard surfaces may reflect noise with an apparent cooling air which, in turn, will reduce the risk of
increase in the decibel level. When sound transmission recirculating the cooling air back through the
is important, a sheet of rubber or cork can be installed compressor.
beneath the machine to reduce noise. Flexible piping
may be required.

CAUTION
A minimum of 1 m (3.3ft) all round the compressor is recommended. If headroom is restricted, then the
exhaust should be ducted or deflected away from the machine.
Screw type compressors [1] should not be installed in air systems with reciprocating compressors without
means of isolation such as a common receiver tank. It is recommended that both types of compressor be
piped to a common receiver using individual air lines.

The machine is shipped with the shipping restraints in place. Ensure that these are removed to allow free
movement of the drive assembly during operation. Each restraint is painted yellow.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 19

 7.0 INSTALLATION

7.2 DISCHARGE AND CONDENSATE PIPING

It is essential when installing a new compressor [1], to When two rotary units are operated in parallel, provide
review the total air system. This is to ensure a safe and an isolation vaIve and drain trap for each compressor
effective total system. One item which should be before the common receiver.
considered is liquid carryover. Installation of air dryers
The built–in aftercooler reduces the discharge air
[3] is always good practice since properly selected and
temperature below the dew point (for most ambient
installed they can reduce any liquid carryover to zero.
conditions), therefore, considerable water vapor is
A receiver [2] may be necessary to ensure that the condensed. To remove this condensation, each
total system volume is not less than 2.0 U.S. Gall per compressor with built–in aftercooler is furnished with a
rated delivery C.F.M. combination condensate separator/trap.
Discharge piping should be at least as large as the A dripleg assembly and isolation valve should be
discharge connection of the compressor. All piping and mounted near the compressor discharge. A drain line
fittings should be suitably rated for the discharge should be connected to the condensate drain in the
pressure. base.
It is good practice to locate an isolation valve close to IMPORTANT: The drain line must slope downward
the compressor and to install line filters [4]. from the base to work properly. For ease of inspection
Include a means [6] to vent the discharge pipework of the automatic drain trap operation, the drain piping
downstream from the minimum pressure check valve should include an open funnel.
located on the separator tank. Upstream of the first
system isolation valve [7]. NOTICE
The discharged air contains a very small percentage of For low volume systems that may not include a receiver
compressor lubricating oil and care should be taken to [2], compressor response time may need adjusting.
ensure that downstream equipment is compatible. Contact your local IR service agent.

CAUTION
The use of plastic bowls on line filters and other plastic air line components without metal guards can be
hazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils.
From a safety standpoint, metal bowls should be used on any pressurized system.

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

20 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 7.0 INSTALLATION

7.3 ELECTRICAL

CAUTION
This procedure should only be carried out by a qualified electrician, electrical contractor or your local
Ingersoll–Rand Distributor or Air Center.

The compressor and drive should be properly grounded The feeder cable must be suitably glanded into the
/ earthed in accordance with Local and National Code power drive module (P.D.M.) electrical box to ensure
requirements. that dirty air does not by–pass the filter pads or degrade
the cooling air flow.
Installation of this compressor must be in accordance
with recognized electrical codes and any local Health On completion of electrical installation, check that
and Safety Codes. blower motor rotation is correct.
The compressor must have its own isolator situated This machine is designed for use in heavy industrial
adjacent to it. The fuse protecting the circuit and the environments, where the electricity supply is separated
compressor must be selected in accordance with local from nearby residential and commercial areas. If the
and national code requirements on the basis of the data machine is to be used in the light industrial, residential
provided in the general information section or commercial environment where the local supply
network is shared, further radio frequency (RF)
Feeder cables should be sized by the
screening measures may be required. Consult your
customer/electrical contractor to ensure that the circuit
local distributor/supplier for details of the optional RF
is balanced and not overloaded by other electrical
filter.
equipment. The length of wiring from a suitable
electrical feed point is critical as voltage drops may The compressor has a anti–condensation heater and
impair the performance of the compressor. thermostat in the electrical box. This circuit can be
connected to an independent electrical supply of either
Cable sizes may vary considerably so the mains 110V or 230V single phase, dependant on the country
terminals will accept up to 50mm2 (1awg) (37/45k &
of installation. The supply should be suitable fused and
50/60H) and up to 90mm2 (3/0awg) (55/75k &
an independent isolator installed adjacent to the
75/100H) cable. The N75K–160K and N100H–200H
compressor.
machines mains terminals will accept 2 x 120mm2
(4/0 AWG) cables. This should be done in accordance with local and
national codes. It is good practice and sometimes
Feeder cable connections to incoming terminals mandatory, to display suitable signs warning that the
L1–L2–L3 should be tight and clean. machine has two separate electrical supplies which
The applied voltage must be compatible with the motor both must be isolated before any work is attempted.
and compressor data plate ratings.
Alternately it can be supplied from the 110V tapping of
The control circuit transformer has different voltage the control transformer and connected as shown on
tappings. Ensure that these are set for the specific schematic wiring diagram.
applied voltage prior to starting.
A hole is provided for incoming power connection. If it
is necessary to make a hole in the control box in a
different location, care should be taken to not allow
metal shavings to enter the starter and other electrical
components within the box. If another hole is used, the
original hole must be blocked off.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 21

 7.0 INSTALLATION

CAUTION
VERY IMPORTANT
Supply voltage must be kept to a maximum imbalance of 2% on 50Hz and 3% on 60Hz applications. Voltage
imbalances greater than these levels can cause permanent damage to the drive.
Compressor must not be subjected to any voltage spikes or surges in excess of 575V. Exposure to spikes/surges in
excess of 575V can permanently damage the drive. If the possibility of such exists it is recommended that adequate
surge protection is fitted such as an Ingersoll–Rand line reactor. See your local Ingersoll–Rand representative.
Failure of the drive due to voltage spikes, line notching, harmonics or other power quality related problems, will not
be covered by the standard compressor warranty.
The correct type and rating of line input fuse MUST BE fitted onto the customers isolator or breaker close to the
compressor. For Amp rating see technical information in Section 8.1.
Product Identification Fuse Type Fast Acting Class–J, T or Semiconductor type, Current
limiting, Interrupt Rating – 200,000 Amps RMS SYM.
Class – J, Class – T, or Alternate fuse may be used if the time current
Semiconductor characteristics are faster than fuses recommended in
this section.
See your local Ingersoll–Rand representative for a range of fuses and disconnect isolators matched to your particular
machine.

Example of voltage imbalance calculation

U→V 462v

V→W 459v

W→U 453v

V(m) = (462 + 459 + 453) / 3 = 458v

V∆ max = 462 – 453 = 9v

\ = (9 / 458) x 100 = 1.97%

22 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 7.0 INSTALLATION

7.4 WATERCOOLED UNITS

Cooling Water Piping Venting the water system

Water piping to and from the compressor package must At the initial installation or for start–up after draining the
be 1”diameter or larger for N37/75K (N50/100H) and water system proceed to vent the system as follows.
11/2” diameter or larger for N75/160K (N100H/200H).
1 Locate the water system vent cocks on top of the
Isolation valves with side drains should be installed on aftercooler and lubricant cooler.
both the inlet and outlet lines. Also a strainer of
2mm–mesh size should be installed on the inlet line. 2 Open the water valve(s) allowing water to flow to the
Strainers are available from Ingersoll–Rand. package.
Ingersoll–Rand CPN 54689997 (N37/45K & N50/60H) 3 Open the vent cocks and allow all air to escape from
or CPN 54690029 (N55/75K & N75/100H) the system. When water is observed at the vent cocks,
A normally closed solenoid valve is fitted to the water close them.
outlet side of the compressor package. This is wired The system is now vented.
into the compressor control circuit and closes when the
compressor stops. Draining the water system
Carefully inspect your water system before installing Should it become necessary to completely drain the
the compressor package. Ensure that the piping is free water system, proceed as follows.
of scale and deposits that may restrict water flow to the
1 Disconnect the inlet and discharge water lines from
compressor package.
the connections located at the rear of the unit.
Proper operation of your compressor requires that the 2 Locate the aftercooler and lubricant cooler. Remove
water flow listed below be provided at a maximum the drain plugs located at the bottom of the coolers.
supply temperature of 46_C (115_F). Allow the system to completely drain.
Minimum cooling water requirement at N75–160k, N100–200H Watercooled
ambient temperatures, in litres per See piping and instrumentation diagram (Section 8.3).
Model minute (US gallons per minute) The coolers are piped in a ”parallel” water flow
Range arrangement with a manual trim valve controlling the
50_F / 70_F / 90_F /
10_C 21_C 32_C flow through the aftercooler. An additional automatic
anti–condensation thermal valve controls the flow of
N37–45 15 (4) 23 (6.1) 38 (10) water to the oilcooler. It has a sensor in the separator
tank and capillary to signal the valve to open and close
N55 19 (5) 27 (7.1) 45 (11.9) in order to avoid water condensing in the tank.
N75 30 (7.7) 42 (11.1) 68 (18) Adjusting the Aftercooler Trim Valve
N90 34 (9.0) 45 (11.9) 77 (20.3) The anti–condensation valve has no adjustment. The
Aftercooler Trim Valve is factory set and should not
N110 41 (10.8) 59 (15.6) 95 (25.1) need adjusting but if disturbed use following procedure.
Close valve fully clockwise and then open 1/4 turn. With
N132 64 (16.9) 82 (21.7) 123 (32.5)
machine running loaded observe the package
N160 73 (19.3) 95 (25.1) 150 (39.6) discharge temperature Intellisys display. It should be
be approx 15_F (8_C) above the water inlet
Water temperature and pressure gauges should be temperature. If it is higher, open the valve a little more.
installed in the water piping for use in any fault finding Put a ’Warning – Do Not Adjust’ label on the valve or fit
of the water system. Water pressure should ideally be a lock.
between 3 and 5 bar (43.5 and 72.5 psi) but must not
be above 10 Bar (145 psi)
Water cleanliness is also extremely important. Cleaning
of coolers as a result of fouling is a customer
responsibility. Therefore, it is highly recommended that
proper water quality must meet the requirements listed
in WATER QUALITY RECOMMENDATIONS later in
this section.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 23

 7.0 INSTALLATION

Water quality recommendations To ensure good operation life and performance of the
compressor cooling system, the recommended
Water quality is often overlooked when the cooling acceptable ranges for different water constituents are
system of a water–cooled air compressor is examined.
included below:
Water quality determines how effective the heat
transfer rate, as well as the flow rate will remain during Cooling Water Analysis Chart
the life of the unit. It should be noted that the quality of
water used in any cooling system does not remain
constant during the operation of the system. Substances Test interval Acceptable
Evaporation, corrosion, chemical and temperature concentration
changes, aeration, scale and biological formations Corrosivity Monthly — if Langelier Index
effect the water makeup. Most problems in a cooling (Hardness, pH, stable for 3 to 4 0 to 1
system show up first in a reduction in the heat transfer Total Dissolved months, analyse
rate, then in a reduced flow rate and finally with damage Solids, quarterly.
to the system. Temperature at
Scale: Scale formation inhibits effective heat transfer, inlet Alkalinity)
yet it does help prevent corrosion. Therefore, a thin
uniform coating of calcium carbonate is desired on the Iron Monthly <2 ppm
inner surface. Perhaps the largest contributor to scale Sulphate Monthly <50 ppm
formation is the precipitation of calcium carbonate out
of the water. This is dependent on temperature and pH. Chloride Monthly <50 ppm
The higher the pH value, the greater the chance of scale
formation. Scale can be controlled with water Nitrate Monthly <2 ppm
treatment. Silica Monthly < 100 ppm
Corrosion: In contrast to scale formation is the
problem of corrosion. Chlorides cause problems Desolated Daily — if stable, 0 ppm (as low
because of their size and conductivity. Low pH levels Oxygen analyse weekly as possible)
promote corrosion, as well as high levels of dissolved Oil & Grease Monthly <5 ppm
oxygen.
Ammonia Monthly <1 ppm
Fouling: Biological and organic substances (slime)
can also cause problems, but in elevated temperature
environments such as cooling processes they are not
a major concern. If they create problems with clogging,
commercial shock treatment are available.

24 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 7.0 INSTALLATION

7.5 SEA WATERCOOLED UNITS (SELECTED UNITS ONLY)

Water cleanliness is extremely important. Strainers are Sea Water Pressure Orifice diameter in mm
available from Ingersoll–Rand. Cleaning of coolers as Bar (psi) (inch) to give a maximum
a result of fouling is a customer responsibility. sea water flow of 90l/min
Isolation valves with side drains should be installed on (23.76 US gall/min)
both the inlet and outlet lines. 3 (43.5) 12 (0.472)
A normally closed solenoid valve is fitted to the water
4 (58) 11 (0.433)
outlet side of the compressor package.
It is important to ensure that the recommended flow rate 5 (72.5) 10 (0.394)
cannot be exceeded. This will normally mean that an
6 (87) 9.6 (0.378)
orifice plate must be fitted in the pipework at least 1m
(3.3ft) before the cooler, with the orifice size calculated 7 (101.5) 9.2 (0.362)
to ensure that the maximum sea water flow rate cannot
be exceeded. If these precautions are not taken, it is 8 (116) 8.9 (0.35)
possible that the sea water flow rate through the cooler
may be several times the recommended maximum, 9 (130.5) 8.7 (0.343)
which will lead to rapid failure. 10 (145) 8.4 (0.33)

No oil cooler manufacturer can guarantee that its

products will have an indefinite life and for this reason,
we suggest that the cooling system is designed to
minimize any damage caused by a leaking oil cooler.
This can be achieved as follows ;
1. The oil pressure should be higher than the sea water
pressure, so that in the event of a leak occurring, the
oil will not be contaminated.
2. If the sea water pressure is 100PSIG (7BARG) or
above it is recommended that the water solenoid
valve is changed to the water inlet side. This will
protect the system from high pressure surges when
not in use.
3. The sea water outlet pipe from the cooler should
have a free run to waste.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 25

 7.0 INSTALLATION

7.6 OUTDOOR SHELTERED INSTALLATION

Nirvana compressors are not suitable for outdoor installation.

Installing a Nirvana compressor outside voids the warranty of the compressor.

26 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.1 TECHNICAL INFORMATION – SINGLE STAGE

N37K N45K N50H N60H
General
Sound pressure level dB(A) * 75 75 75 75
Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115) 46 (115)
Minimum ambient temperature _C (_F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35)
Weight Kg (lbs) 1048 (2310) 1048 (2310) 1048 (2310) 1048 (2310)
Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) 10 (145)
Minimum pressure barg (psig) 4.5 (65.25) 4.5 (65.25) 4.5 (65.25) 4.5 (65.25)
Coolant capacity litres (US gal) 18 (4.75) 18 (4.75) 18 (4.75) 18 (4.75)
HAT switch setting _C (_F) 120 (248) 120 (248) 120 (248) 120 (248)
Performance **
Flow at 7.5 Barg (m3/min) 6.43 7.39 – –
Flow at 8.5 Barg (m3/min) 6.12 7.02 – –
Flow at 10 Barg (m3/min) 5.83 6.46 – –
Flow at 100 psig (cfm) – – 235 262
Flow at 125 psig (cfm) – – 216 248
Flow at 140 psig (cfm) – – 209 233
Air Cooling System
Cooling air flow m3/min (cfm) 184 (6500) 184 (6500) 184 (6500) 184 (6500)
Maximum ∆P in air ducts Pa (inch WG) 124 (0.5) 124 (0.5) 124 (0.5) 124 (0.5)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15) 8 (15)
Water Cooling System
Cooling (clean) water flow l/min (US 15/38 15/38 15/38 15/38
gallon/min) @ 10_C (50_F) / 32_C (90_F) (4/10) (4/10) (4/10) (4/10)
Maximum ∆P in air ducts Pa (inch WG) 62 (0.25) 62 (0.25) 62 (0.25) 62 (0.25)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15) 8 (15)
Main Power Circuit A/C (W/C) ***
Package full load current at 220V (A) ** 140 (129) 168 (157) 140 (129) 168 (157)
Package full load current at 400V (A) ** 77 (71) 92 (86) – –
Package full load current at 460V (A) ** – – 67 (62) 80 (75)
Package full load current at 575V (A) ** – – 54 (50) 64 (60)
Max fuse size @ 220V (A) 250 250 250 250
Max fuse size @ 400V (A) 125 125 125 125
Max fuse size @ 460V (A) 125 125 125 125
Max fuse size @ 575V (A) 100 100 100 100
Fuse type Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.
Heater Circuit
110V Single Phase Rating (A) 4 4 4 4
230V Single Phase Rating (A) 4 4 4 4
Fuse type General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on
basis of mean package full load current X1.25 (i.e. 25% margin)

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 27

 8.0 GENERAL INFORMATION
N55K N75K N75H N100H
General
Sound pressure level dB(A) * 75 75 75 75
Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115) 46 (115)
Minimum ambient temperature _C (_F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35)
Weight Kg (lbs) 1531 (3374) 1531 (3374) 1531 (3374) 1531 (3374)
Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) 10 (145)
Minimum pressure barg (psig) 4.5 (65.25) 4.5 (65.25) 4.5 (65.25) 4.5 (65.25)
Coolant capacity litres (US gal) 30 (8) 30 (8) 30 (8) 30 (8)
HAT switch setting _C (_F) 120 (248) 120 (248) 120 (248) 120 (248)
Performance
Flow at 7.5 Barg (m3/min) 10.11 12.94 – –
Flow at 8.5 Barg (m3/min) 9.29 12.15 – –
Flow at 10 Barg (m3/min) 8.49 11.50 – –
Flow at 100 psig (cfm) – – 372 479
Flow at 125 psig (cfm) – – 328 429
Flow at 140 psig (cfm) – – 306 413
Air Cooling System
Cooling air flow m3/min (cfm) 241 (8500) 241 (8500) 241 (8500) 241 (8500)
Maximum ∆P in air ducts Pa (inch WG) 124 (0.5) 124 (0.5) 124 (0.5) 124 (0.5)
Compressed air outlet ∆T _C (_F) 8 (46.4) 8 (46.4) 8 (46.4) 8 (46.4)
Water Cooling System
Cooling (clean) water flow l/min (US 30/68 30/68 30/68 30/68
gallon/min) @ 10_C (50_F) / 32_C (90_F) (8/18) (8/18) (8/18) (8/18)
Maximum ∆P in air ducts Pa (inch WG) 62 (0.25) 62 (0.25) 62 (0.25) 62 (0.25)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15) 8 (15)
Main Power Circuit A/C (W/C) ***
Package full load current at 220V (A) ** 205 (193) – 205 (193) –
Package full load current at 400V (A) ** 113 (106) 147 (140) – –
Package full load current at 460V (A) ** – – 98 (92) 128 (122)
Package full load current at 575V (A) ** – – 79 (74) 102 (97)
Max fuse size @ 220V (A) 300 400 300 400
Max fuse size @ 400V (A) 150 200 150 200
Max fuse size @ 460V (A) 150 200 150 200
Max fuse size @ 575V (A) 125 150 125 150
Fuse type Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.
Heater Circuit
110V Single Phase Rating (A) 4 4 4 4
230V Single Phase Rating (A) 4 4 4 4
Fuse type General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on
basis of mean package full load current X1.25 (i.e. 25% margin)

28 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION
N90K N110K N125H N150H
General
Sound pressure level dB(A) * 75 75 75 75
Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115) 46 (115)
Minimum ambient temperature _C (_F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35)
Weight Kg (lbs) 3175 (6985) 3175 (6985) 3175 (6985) 3175 (6985)
Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) 10 (145)
Minimum pressure barg (psig) 4.5 (65) 4.5 (65) 4.5 (65) 4.5 (65)
Coolant capacity litres (US gal) 90 (24) 90 (24) 90 (24) 90 (24)
HAT switch setting _C (_F) 120 (248) 120 (248) 120 (248) 120 (248)
Performance **
Flow at 7.5 Barg (m3/min) 17.1 20.0 – –
Flow at 8.5 Barg (m3/min) 15.3 19.2 – –
Flow at 10 Barg (m3/min) 14.0 17.5 – –
Flow at 100 psig (cfm) – – 655 739
Flow at 125 psig (cfm) – – 571 670
Flow at 140 psig (cfm) – – 524 610
Air Cooling System
Cooling air flow m3/min (cfm) 382 (13500) 382 (13500) 382 (13500) 382 (13500)
Maximum ∆P in air ducts Pa (inch WG) 124 (05) 124 (05) 124 (05) 124 (05)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15) 8 (15)
Water Cooling System
Cooling (clean) water flow l/min (US 42/95 53/121 42/95 53/121
gallon/min) @ 10_C (50_F) / 32_C (90_F) (11/25) (14/32) (11/25) (14/32)
Maximum ∆P in air ducts Pa (inch WG) 62 (0.25) 62 (0.25) 62 (0.25) 62 (0.25)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15) 8 (15)
Main Power Circuit A/C (W/C) ***
Package full load current at 400V (A) ** 177 (167) 214 (203) – –
Package full load current at 460V (A) ** – – 159 (150) 189 (180)
Package full load current at 575V (A) ** – – 127 (120) 151 (144)
Max fuse size @ 380V – 415V (A) 250 350 – –
Max fuse size @ 440V – 480V (A) – – 250 250
Max fuse size @ 550V – 575V (A) – – 200 200
Fuse type Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.
Heater Circuit
110V Single Phase Rating (A) 4 4 4 4
230V Single Phase Rating (A) 4 4 4 4
Fuse type General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on
basis of mean package full load current X1.25 (i.e. 25% margin)

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 29

 8.0 GENERAL INFORMATION
N132K N160K N200H
General
Sound pressure level dB(A) * 75 75 75
Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115)
Minimum ambient temperature _C (_F) 1.7 (35) 1.7 (35) 1.7 (35)
Weight Kg (lbs) 3175 (6985) 3175 (6985) 3175 (6985)
Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145)
Minimum pressure barg (psig) 4.5 (65) 4.5 (65) 4.5 (65)
Coolant capacity litres (US gal) 90 (24) 90 (24) 90 (24)
HAT switch setting _C (_F) 120 (248) 120 (248) 120 (248)
Performance **
Flow at 7.5 Barg (m3/min) 23.5 28.0 –
Flow at 8.5 Barg (m3/min) 22.3 26.0 –
Flow at 10 Barg (m3/min) 21.0 25.0 –
Flow at 100 psig (cfm) – – 993
Flow at 125 psig (cfm) – – 892
Flow at 140 psig (cfm) – – 819
Air Cooling System
Cooling air flow m3/min (cfm) 382 (13500) 382 (13500) 382 (13500)
Maximum ∆P in air ducts Pa (inch WG) 124 (0.5) 124 (0.5) 124 (0.5)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15)
Water Cooling System
Cooling (clean) water flow l/min (US 76/170 76/170 76/170
gallon/min) @ 10_C (50_F) / 32_C (90_F) (20/45) (20/45) (20/45)
Maximum ∆P in air ducts Pa (inch WG) 62 (0.25) 62 (0.25) 62 (0.25)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15)
Main Power Circuit A/C (W/C) ***
Package full load current at 400V (A) ** 251 (241) 302 (253) –
Package full load current at 460V (A) ** – – 245 (236)
Package full load current at 575V (A) ** – – 196 (189)
Max fuse size @ 380V – 415V (A) 350 450 –
Max fuse size @ 440V – 480V (A) – – 350
Max fuse size @ 550V – 575V (A) – – 300
Fuse type Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.
Heater Circuit
110V Single Phase Rating (A) 4 4 4
230V Single Phase Rating (A) 4 4 4
Fuse type General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on
basis of mean package full load current X1.25 (i.e. 25% margin)

30 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.1 TECHNICAL INFORMATION – TWO STAGE

N75K N90K N110K N100H N125H N150H

General
Sound pressure level dB(A) * 75 75 75 75 75 75
Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115) 46 (115) 46 (115) 46 (115)
Minimum ambient temperature _C (_F) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35) 1.7 (35)
Weight Kg (lbs) 3650 3650 3650 3650 3650 3650
(8030) (8030) (8030) (8030) (8030) (8030)
Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145) 10 (145) 10 (145) 10 (145)
Minimum pressure barg (psig) 4.5 (65) 4.5 (65) 4.5 (65) 4.5 (65) 4.5 (65) 4.5 (65)
Coolant capacity litres (US gal) 90 (24) 90 (24) 90 (24) 90 (24) 90 (24) 90 (24)
HAT switch setting _C (_F) 120 120 120 120 120 120
(248) (248) (248) (248) (248) (248)
Performance **
Flow at 7.5 Barg (m3/min) 15.7 18.0 22.1 – – –
Flow at 8.5 Barg (m3/min) 14.2 17.5 20.4 – – –
Flow at 10 Barg (m3/min) 13.1 15.4 18.9 – – –
Flow at 14 Barg (m3/min) – 12.5 15.4 – – –
Flow at 100 psig (cfm) – – – 560 690 825
Flow at 125 psig (cfm) – – – 504 621 743
Flow at 140 psig (cfm) – – – 470 580 693
Flow at 200 psig (cfm) – – – – 443 548
Air Cooling System
Cooling air flow m3/min (cfm) 382 382 382 382 382 382
(13500) (13500) (13500) (13500) (13500) (13500)
Maximum ∆P in air ducts Pa (inch WG) 124 (0.5) 124 (0.5) 124 (0.5) 124 (0.5) 124 (0.5) 124 (0.5)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15) 8 (15) 8 (15) 8 (15)
Water Cooling System
Cooling (clean) water flow l/min (US 34/80 42/95 53/121 34/80 42/95 53/121
gallon/min) @ 10_C (50_F) / 32_C (90_F) (9/21) (11/25) (14/32) (9/21) (11/25) (14/32)
Maximum ∆P in air ducts Pa (inch WG) 62 (0.25) 62 (0.25) 62 (0.25) 62 (0.25) 62 (0.25) 62 (0.25)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15) 8 (15) 8 (15) 8 (15)
Main Power Circuit A/C (W/C) ***
Package full load current at 400V (A) ** 149 (139) 177 (167) 214 (203) – – –
Package full load current at 460V (A) ** – – – 129 (120) 159 (150) 189 (180)
Package full load current at 575V (A) ** – – – 103 (96) 127 (120) 151 (144)
Max fuse size @ 380V – 415V (A) 250 250 350 – – –
Max fuse size @ 440V – 480V (A) – – – 200 250 250
Max fuse size @ 550V – 575V (A) – – – 200 200 200
Fuse type Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.
Heater Circuit
110V Single Phase Rating (A) 4 4 4 4 4 4
230V Single Phase Rating (A) 4 4 4 4 4 4
4Fuse type General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on
basis of mean package full load current X1.25 (i.e. 25% margin)

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 31

 8.0 GENERAL INFORMATION
N132K N160K N200H
General
Sound pressure level dB(A) * 75 75 75
Maximum ambient temperature _C (_F) 46 (115) 46 (115) 46 (115)
Minimum ambient temperature _C (_F) 1.7 (35) 1.7 (35) 1.7 (35)
Weight Kg (lbs) 3650 (8030) 3650 (8030) 3650 (8030)
Maximum pressure barg (psig) 10 (145) 10 (145) 10 (145)
Minimum pressure barg (psig) 4.5 (65) 4.5 (65) 4.5 (65)
Coolant capacity litres (US gal) 90 (24) 90 (24) 90 (24)
HAT switch setting _C (_F) 120 (248) 120 (248) 120 (248)
Performance **
Flow at 7.5 Barg (m3/min) 26.2 31.1 –
Flow at 8.5 Barg (m3/min) 24.2 29.6 –
Flow at 10 Barg (m3/min) 23.1 27.2 –
Flow at 14 Barg (m3/min) 18.4 22.2 –
Flow at 100 psig (cfm) – – 1100
Flow at 125 psig (cfm) – – 990
Flow at 140 psig (cfm) – – 924
Flow at 200 psig (cfm) – – 735
Air Cooling System
Cooling air flow m3/min (cfm) 382 (13500) 382 (13500) 382 (13500)
Maximum ∆P in air ducts Pa (inch WG) 124 (0.5) 124 (0.5) 124 (0.5)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15)
Water Cooling System
Cooling (clean) water flow l/min (US 76/170 76/170 76/170
gallon/min) @ 10_C (50_F) / 32_C (90_F) (20/45) (20/45) (20/45)
Maximum ∆P in air ducts Pa (inch WG) 62 (0.25) 62 (0.25) 62 (0.25)
Compressed air outlet ∆T _C (_F) 8 (15) 8 (15) 8 (15)
Main Power Circuit A/C (W/C) ***
Package full load current at 400V (A) ** 251 (241) 302 (253) –
Package full load current at 460V (A) ** – – 245 (236)
Package full load current at 575V (A) ** – – 196 (189)
Max fuse size @ 380V – 415V (A) 350 450 –
Max fuse size @ 440V – 480V (A) – – 350
Max fuse size @ 550V – 575V (A) – – 300
Fuse type Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.
Heater Circuit
110V Single Phase Rating (A) 4 4 4
230V Single Phase Rating (A) 4 4 4
Fuse type General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable size should be calculated on
basis of mean package full load current X1.25 (i.e. 25% margin)

32 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.2 INSTALLATION DRAWING – N37/45K–CC & N50/60H–CC

A 11/2” NPT Air discharge (Female) 60Hz units G 4 x Ø 13.0mm (0,5”)

11/2” BSP Air discharge (Female) 50Hz units Compressor should be bolted to the floor with four
B Ø63mm (2.48”) Electrical inlet M10 (0.38”) bolts using holes shown. Seal base to
floor with cork or rubber.
C 0.38“ NPT (Female)
Note: Pipe condensate drain lines separately to an H INTELLISYS Controller
open drain due to differences in drain pressures. Use U Right
drain lines at least as large as the connection. Read
operations manual and check local regulations V Bottom
W Front
D Cooling airflow X–X Section through X–X
E Exhaust airflow Z Plan view
F Cabinet cooling airflow

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 33

 8.0 GENERAL INFORMATION

8.2 INSTALLATION DRAWING – N37/45K–CC & N50/60H–CC – Water Cooled

A 11/2” NPT Air discharge (Female) 60Hz units H INTELLISYS Controller

11/2” BSP Air discharge (Female) 50Hz units J 1” NPT Water inlet (Female) 60Hz units
B Ø63mm (2.48”) Electrical inlet 1” BSP Water inlet (Female) 50Hz units
C 0.38“ NPT (Female) K 1” NPT Water outlet (Female) 60Hz units
Note: Pipe condensate drain lines separately to an 1” BSP Water outlet (Female) 50Hz units
open drain due to differences in drain pressures. Use U Right
drain lines at least as large as the connection. Read
V Bottom
operations manual and check local regulations
D Cooling airflow W Front
E Exhaust airflow X–X Section through X–X
F Cabinet cooling airflow Z Plan view
G 4 x Ø 13.0mm (0,5”)
Compressor should be bolted to the floor with four
M10 (0.38”) bolts using holes shown. Seal base to
floor with cork or rubber.

34 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.2 INSTALLATION DRAWING – N55/75K–CC & N75/100H–CC

A 2” NPT Air discharge (Female) 60Hz units F Cabinet cooling airflow

2” BSP Air discharge (Female) 50Hz units
G 4 x Ø 13.0mm (0,5”)
B Ø63mm (2.48”) Electrical inlet Compressor should be bolted to the floor with four
C 0.38“ NPT (Female) M10 (0.38”) bolts using holes shown. Seal base to
Note: Pipe condensate drain lines separately to an floor with cork or rubber.
open drain due to differences in drain pressures. Use H INTELLISYS Controller
drain lines at least as large as the connection. Read
operations manual and check local regulations U Right
V Bottom
D Cooling airflow W Front
E Exhaust airflow

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 35

 8.0 GENERAL INFORMATION

8.2 INSTALLATION DRAWING – N55/75K–CC & N75/100H–CC – Water Cooled

A 2” NPT Air discharge (Female) 60Hz units G 4 x Ø 13.0mm (0,5”)

2” BSP Air discharge (Female) 50Hz units Compressor should be bolted to the floor with four
B Ø63mm (2.48”) Electrical inlet M10 (0.38”) bolts using holes shown. Seal base to
floor with cork or rubber.
C 0.38“ NPT (Female)
Note: Pipe condensate drain lines separately to an H INTELLISYS Controller
open drain due to differences in drain pressures. Use J 1” NPT Water inlet (Female) 60Hz units
drain lines at least as large as the connection. Read 1” BSP Water inlet (Female) 50Hz units
operations manual and check local regulations
K 1” NPT Water outlet (Female) 60Hz units
1” BSP Water outlet (Female) 50Hz units
D Cooling airflow
U Right
E Exhaust airflow
V Bottom
F Cabinet cooling airflow
W Front

36 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.2 INSTALLATION DRAWING – N75/160K–CC – Water Cooled

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 37

 8.0 GENERAL INFORMATION
A 2” NPT Air discharge (Female) 60Hz units D Cooling airflow
(N100H–N150H)
E Exhaust airflow
2” BSP Air discharge (Female) 50Hz units
(N75K–N110K) F Cabinet cooling airflow
2 1/2” NPT Air discharge (Female) 60Hz units G 4 x Ø 13.0mm (0,5”)
(N200H) Compressor should be bolted to the floor with four
2 1/2” BSP Air discharge (Female) 50Hz units M10 (0.38”) bolts using holes shown. Seal base to
(N132K and N160K units) floor with cork or rubber.
H INTELLISYS Controller
B Electrical inlet –
J 1.5” NPT Water inlet (Female) 60Hz units
Ø75mm (3”)
1.5” BSP Water inlet (Female) 50Hz units
Ø64mm 575V (Option)
K 1.5” NPT Water outlet (Female) 60Hz units
C 0.38“ NPT (Female)
1.5” BSP Water outlet (Female) 50Hz units
Note: Pipe condensate drain lines separately to an
open drain due to differences in drain pressures. Use U Right
drain lines at least as large as the connection. Read
operations manual and check local regulations V Bottom
W Front

38 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.2 INSTALLATION DRAWING – N90/160K, N125/200H SINGLE STAGE &

N75/160K, N100/200H TWO STAGE

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 39

 8.0 GENERAL INFORMATION
A 2” NPT Air discharge (Female) 60Hz units D Cooling airflow
(N100H–N150H)
E Exhaust airflow
2” BSP Air discharge (Female) 50Hz units
(N75K–N110K) F Cabinet cooling airflow
2 1/2” NPT Air discharge (Female) 60Hz units G 4 x Ø 13.0mm (0,5”)
(N200H) Compressor should be bolted to the floor with four
2 1/2” BSP Air discharge (Female) 50Hz units M10 (0.38”) bolts using holes shown. Seal base to
(N132K and N160K units) floor with cork or rubber.
H INTELLISYS Controller
B Electrical inlet –
U Right
Ø75mm (3”)
Ø64mm 575V (Option) V Bottom
C 0.38“ NPT (Female) W Front
Note: Pipe condensate drain lines separately to an
open drain due to differences in drain pressures. Use X–X Section through X–X
drain lines at least as large as the connection. Read Z Plan view
operations manual and check local regulations

40 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.3 PROCESS AND INSTRUMENTATION DIAGRAM N37/75K–CC & N50/100–CC

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 41

 8.0 GENERAL INFORMATION
KEY

1 Air discharge 26 Cooling water inlet (W.C. only)

2 Compressor 27 Cooling water outlet (W.C. only)
3 Air filter 28 Pressure transducer 3APT
4 Vacuum switch 1VAC 29 Pressure transducer 6APT
5 Cooler, air 30 Dryer (customer supply equipment)
6 Cooler, coolant 31 Line filters (customer equipment)
7 Condensate discharge 32 Receivers (customer equipment)
8 Coolant filter 33 Dryer AUX warning
9 Pressure switch, coolant filter 1DPS 34 Line filter AUX warning
10 Drain valve, coolant 35 Receiver trap AUX warning
11 Temperature switch 1ATS 36 Remote pressure transducer 9APT (optional)
12 Air inlet check valve 37 Water stop valve 4SV
13 Timed solenoid condensate drain. 38 Typical customer downstream air treatment
(single stage)
39 Anti – condensation valve 11SV
14 Minimum pressure check valve
40 Cooling air exhaust box
15 Moisture separator
41 Package discharge temperature transducer 4ATT
16 Pressure transducer 4APT
42 Injected coolant temperature sensor
17 Pressure relief valve
43 Seal scavenge air supply
18 Scavenge filter / orifice / check
44 Seal scavenge line
19 Separator tank (primary/secondary)
45 Air intake temperature sensor. 1ATT
20 Oil temperature control valve
46 Electronic drain trap. Alternative to item 13.
21 Temperature transducer 2ATT (Standard equipment on 2 stage. Optional on
single stage).
22 3SV blowdown solenoid valve
45 Interstage pressure relief valve. (2 stage.)
23 Drive motor
46 Interstage pressure transducer. (2 stage)
24 Blower motor
49 Air/Coolant separator element
25 Cooling air blower

Piping legend

Air/coolant Compressor enclosure

Air Sensor connection
Coolant Equipment downstream of
compressor
Condensate
Cooling water (W.C. only)

42 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.3 PROCESS AND INSTRUMENTATION DIAGRAM N90/160K &

N125/200H SINGLE STAGE AND N75/160K & N100/200H TWO STAGE

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 43

 8.0 GENERAL INFORMATION
KEY

1 Air discharge 27 Cooling water outlet (W.C. only)

2 Compressor 28 Pressure transducer 3APT
3 Air filter 29 Pressure transducer 6APT
4 Vacuum switch 1VAC 30 Dryer (customer supply equipment)
5 Cooler, air 31 Line filters (customer equipment)
6 Cooler, coolant 32 Receivers (customer equipment)
7 Condensate discharge 33 Dryer AUX warning
8 Coolant filter 34 Line filter AUX warning
9 Pressure switch, coolant filter 1DPS 35 Receiver trap AUX warning
10 Drain valve, coolant 36 Remote pressure transducer 9APT (optional)
11 Temperature switch 1ATS 37 Water stop valve 4SV (W.C. only)
12 Air inlet check valve 38 Typical customer downstream air treatment
13 Timed solenoid condensate drain. 39 Anti – condensation valve 11SV
(single stage only)
40 Cooling air exhaust box
14 Minimum pressure check valve
41 Package discharge temperature transducer 4ATT
15 Moisture separator
42 Injection temperature, transducer 2CTT
16 Pressure transducer 4APT
43 Seal scavenge air supply
17 Pressure relief valve
44 Seal scavenge line
18 Scavenge filter / orifice / check
45 Temperature sensor 1ATT
19 Separator tank (primary/secondary)
46 Electronic drain trap. Alternative to item 13
20 Oil temperature control valve (Optional on single stage)
21 Temperature transducer 2ATT 47 Interstage pressure relief valve. 2 stage.
22 3SV blowdown solenoid valve 48 Interstage pressure transducer. 2 stage
23 Drive motor 49Element, separator
24 Blower motor 50 Valve, aftercooler trim (W.C. only)
25 Cooling air blower 51 Valve, airend discharge temperature control
26 Cooling water inlet (W.C. only) (W.C. only)

Piping legend

Air/coolant Compressor enclosure

Air Sensor connection
Coolant Equipment downstream of
compressor
Condensate
Cooling water (W.C. only)

44 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.4 DECAL, WIRING SCHEMATIC A/C T1 MOD DRIVE N37K – N75K / N50H – N100H BLOWER VFD

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 45

 8.0 GENERAL INFORMATION
KEY

1ATS Switch, high airend discharge temperature MCB3 Breaker, miniature circuit, control circuits
1DPS Switch, fouled oil filter MCB4 Breaker, miniature circuit, VFD supply
1VAC Switch, fouled air filter MCB5 Breaker, miniature circuit, PSU
1ATT Sensor, airend inlet. MCB9 Breaker, miniature circuit, heater
2ATT Sensor, airend discharge temperature MF Mains filter (if fitted)
2CTT Sensor, injected coolant temperature MM Motor, main
3APT Transducer, sump pressure, wet side MMS Breaker, blower motor
3SV Valve, blowdown solenoid OPT Optional
4APT Transducer, package air discharge pressure OV Zero voltage
4ATT Sensor, package discharge temperature PE Protected earth
4SV Valve, water stop solenoid (W/C only) PORO Power outage restart option (optional)
6APT Transducer, sump air pressure, dry side PSU Power supply unit
9APT Transmitter, remote air pressure (optional) RFI Filter, radio frequency interference
9SV Valve, condensate drain RSP Remote stop
11SV Valve, anti – condensation solenoid RST Remote start
AT Autotransformer (if fitted) SGNE Controller, Intellisys
AW1 Auxiliary warning 1 SL Serial link
AW2 Auxiliary warning 2 SS1–3 Relay, solid state
BP Backplate ST Service tool
C Capacitor T1 Transformer, control
CAB Cabinet TH Thermostat
CDE Condensate drain error TRR True running relay
WR General warning
CDV Condensate drain valve. (if fitted)
CFO Common fault output Colors
CK Choke BLK Black
EXC External communications BLU Blue
DR Drive BRO Brown
DVF Fan, drive box ventilation GRE Green
EB Earth bar PIN Pink
ES Switch, emergency stop RED Red
FD Drive Blower SCR Screened
FM Motor, Blower VIO Violet
GND Ground WHI White
HC Heater circuit YEL Yellow
HTR1 Heater, spacer 25 Watts
HTR2 Heater, spacer 25 Watts Wires
K1 Relay, run
K2 Relay fault Numbers Function Wire color
KM1 Contactor, main motor 1–99 Power Black
KM5 Contactor, Drive ventilation fan. 100–199 AC Control Red
MCB1 Breaker, miniature circuit, transformer 200–299 DC Control Blue
MCB2 Breaker, miniature circuit, DVF 300–399 Auxiliary Orange

46 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.4 DECAL, WIRING SCHEMATIC W/C T1 MOD DRIVE N37K – N75K / N50H – N100H BLOWER VFD

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 47

 8.0 GENERAL INFORMATION
KEY

1ATS Switch, high airend discharge temperature MCB3 Breaker, miniature circuit, control circuits
1DPS Switch, fouled oil filter MCB4 Breaker, miniature circuit, VFD supply
1VAC Switch, fouled air filter MCB5 Breaker, miniature circuit, PSU
1ATT Sensor, airend inlet. MCB9 Breaker, miniature circuit, heater
2ATT Sensor, airend discharge temperature MF Mains filter (if fitted)
2CTT Sensor, injected coolant temperature MM Motor, main
3APT Transducer, sump pressure, wet side MMS Breaker, blower motor
3SV Valve, blowdown solenoid OPT Optional
4APT Transducer, package air discharge pressure OV Zero voltage
4ATT Sensor, package discharge temperature PE Protected earth
4SV Valve, water stop solenoid (W/C only) PORO Power outage restart option (optional)
6APT Transducer, sump air pressure, dry side PSU Power supply unit
9APT Transmitter, remote air pressure (optional) RFI Filter, radio frequency interference
9SV Valve, condensate drain RSP Remote stop
11SV Valve, anti – condensation solenoid RST Remote start
AT Autotransformer (if fitted) SGN Controller, Intellisys
AW1 Auxiliary warning 1 SL Serial link
AW2 Auxiliary warning 2 SS1–3 Relay, solid state
BP Backplate ST Service tool
C Capacitor T1 Transformer, control
CAB Cabinet TDO Timer, delay off
CDE Condensate drain error TH Thermostat
TRR True running relay
CDV Condensate drain valve. (if fitted)
WR General warning
CFO Common fault output
CK Choke Colors
EXC External communications BLK Black
DR Drive BLU Blue
DVF Fan, drive box ventilation BRO Brown
EB Earth bar GRE Green
ES Switch, emergency stop PIN Pink
FD Drive Blower RED Red
FM Motor, Blower SCR Screened
GND Ground VIO Violet
HC Heater circuit WHI White
HTR1 Heater, spacer 25 Watts YEL Yellow
HTR2 Heater, spacer 25 Watts
K1 Relay, run Wires
K2 Relay fault
Numbers Function Wire color
KM1 Contactor, main motor
1–99 Power Black
KM5 Contactor, Drive ventilation fan.
KM4 Contactor, fan motor 100–199 AC Control Red
MCB1 Breaker, miniature circuit, transformer 200–299 DC Control Blue
MCB2 Breaker, miniature circuit, VFD 300–399 Auxiliary Orange

48 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.4 ELECTRICAL SCHEMATIC N75K/N160K, N100H/N200H AC

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 49

 8.0 GENERAL INFORMATION
KEY

1 110/120V, 50/60Hz From SHT 1 MCB1 Breaker, miniature circuit, transformer

1ATS Switch, high airend discharge temperature MCB2 Breaker, miniature circuit, control circuits
1ATT Sensor, inlet temperature MCB3 Breaker miniature circuits. DR
1DPS Switch, fouled oil filter MCB4 Breaker, miniature circuit, PSU
1VAC Switch, fouled air filter MCB9 Breaker, miniature circuit, heater
2 110/120V, 50/60Hz From SHT 1 MCB10 Breaker, miniature circuit, heater (external)
2APT Sensor, Interstage pressure (2STG only) MF Mains filter (if fitted)
2ATT Sensor, airend discharge temperature MI Main input terminals options
2CTT Sensor, injected coolant temperature MM Motor, main
3 110/120V, 50/60Hz External supply MMS1 Breaker, blower motor
3APT Transducer, sump pressure, wet side MMS2 Breaker, heatsink blower
3SV Valve, blowdown solenoid OPT Optional
4 220/230V, 50/60Hz External supply OV Zero voltage
4APT Transducer, package air discharge pressure PE Protected earth
4ATT Sensor, package discharge temperature PORO Power outage restart option (optional)
5 Alternative heater connection for external PSU Power supply unit
110/120V supply. RFI Filter, radio frequency interference
6 Alternative heater connection for external RSP Remote stop
220/230V supply.
RST Remote start
6APT Transducer, sump air pressure, dry side
SBC Supplied by customer
9APT Transmitter, remote air pressure (optional)
SGN Controller, Intellisys
9SV Valve, condensate drain
SH Standard heater connections as delivered
11SV Valve, anti – condensation solenoid 1
SL Serial link
AT Autotransformer (if fitted)
SS1–3 Relay, solid state
AW1 Auxiliary warning 1
ST Service tool
AW2 Auxiliary warning 2
T1 Transformer, control
BP Backplate
TH Thermostat
C Capacitor
TRR True running relay
CK Choke
CAB Cabinet Colors
CDE Condensate drain error (optional) BLK Black
CDV Condensate drain valve. (if fitted) BLU Blue
CFO Common fault output BRO Brown
DR Drive GRE Green
EB Earth bar PIN Pink
ES Switch, emergency stop RED Red
EXC External communications SCR Screened
F10 Fuse, external heater supply VIO Violet
FD Fan drive WHI White
FM Motor, Blower YEL Yellow
GND Ground
HB Heatsink blower Wires
HC Heater circuits
Numbers Function Wire color
HTRI Heater 125 watts
1–99 Power Black
K1 Relay, run
K2 Relay fault 100–199 AC Control Red
KM1 Contactor, main motor 200–299 DC Control Blue
KM5 Contactor, heatsink blower 300–399 Auxiliary Orange

50 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.4 ELECTRICAL SCHEMATIC N75K/N160K WC, N100H/N200H WC

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 51

 8.0 GENERAL INFORMATION
KEY

1 110/120V, 50/60Hz From SHT 1 MCB1 Breaker, miniature circuit, transformer

1ATS Switch, high airend discharge temperature MCB2 Breaker, miniature circuit, control circuits
1ATT Sensor, inlet temperature MCB3 Breaker miniature circuits. DR
1DPS Switch, fouled oil filter MCB4 Breaker, miniature circuit, PSU
1VAC Switch, fouled air filter MCB9 Breaker, miniature circuit, heater
2 110/120V, 50/60Hz From SHT 1 MCB10 Breaker, miniature circuit, heater (external)
2APT Sensor, Interstage pressure (2STG only) MF Mains filter (if fitted)
2ATT Sensor, airend discharge temperature MI Main input terminals options
2CTT Sensor, injected coolant temperature MM Motor, main
3 110/120V, 50/60Hz External supply MMS1 Breaker, blower motor
3APT Transducer, sump pressure, wet side MMS2 Breaker, heatsink blower
3SV Valve, blowdown solenoid OPT Optional
4 220/230V, 50/60Hz External supply OV Zero voltage
4APT Transducer, package air discharge pressure PE Protected earth
4ATT Sensor, package discharge temperature PORO Power outage restart option (optional)
4SV Valve, water stop PSU Power supply unit
5 Alternative heater connection for external RFI Filter, radio frequency interference
110/120V supply. RSP Remote stop
6 Alternative heater connection for external RST Remote start
220/230V supply.
SBC Supplied by customer
6APT Transducer, sump air pressure, dry side
SGNe Controller, Intellisys
9APT Transmitter, remote air pressure (optional)
SH Standard heater connections as delivered
9SV Valve, condensate drain
SL Serial link
11SV Valve, anti – condensation solenoid 1
SS1–3 Relay, solid state
AT Autotransformer (if fitted)
ST Service tool
AW1 Auxiliary warning 1
T1 Transformer, control
AW2 Auxiliary warning 2
TH Thermostat
BP Backplate
TRR True running relay
C Capacitor
CK Choke Colors
CAB Cabinet BLK Black
CDE Condensate drain error (optional) BLU Blue
CDV Condensate drain valve. (if fitted) BRO Brown
CFO Common fault output GRE Green
DR Drive PIN Pink
EB Earth bar RED Red
ES Switch, emergency stop SCR Screened
EXC External communications VIO Violet
F10 Fuse, external heater supply WHI White
FM Motor, Blower YEL Yellow
GND Ground
HB Heatsink blower Wires
HC Heater circuits
Numbers Function Wire color
HTRI Heater 125 watts
1–99 Power Black
K1 Relay, run
K2 Relay fault 100–199 AC Control Red
KM1 Contactor, main motor 200–299 DC Control Blue
KM5 Contactor, heatsink blower 300–399 Auxiliary Orange

52 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 8.0 GENERAL INFORMATION

8.5 GENERAL DESCRIPTION

The compressor is an electric motor driven, contact The coolant system consists of a sump, cooler,
cooled screw compressor, complete with all thermostatic valve, anti–condensation valve and a
necessary components piped, wired and baseplate filter. When the unit is operating, coolant is forced by
mounted. It is a totally self contained air compressor air pressure from the separator tank to the
package. thermostatic element. The position of the element (a
The standard compressor is designed to operate in direct result of coolant temperature) will determine
an ambient range of 1.7_C to 46_C (35_F to 115_F). whether the coolant circulates through the cooler,
The standard maximum temperature of 46_C (115_F) bypasses the cooler, or mixes the two paths together
is applicable up to an elevation of 1000m (3280ft) to maintain an optimum compressor injection
above sea level. Above this altitude significant temperature. The two position anti–condensation
reductions in ambient temperature are required if a valve can reduce the coolant flow and hence the
standard motor is to be used. temperature rise of coolant through the compressor.
This temperature is controlled to preclude the
The compressor is managed by the onboard possibility of water vapor condensing. By injecting
electronic controller. The controller and drive system coolant at a sufficiently high temperature, the
operate together to vary the speed of the compressor discharge air coolant mixture temperature will be kept
to deliver compressed air at the target pressure. above the dew point. On the N90/160K,
Panel instrumentation is provided to indicate the N125/200H–SS, N75/160K–2S and N100/200H–2S,
compressor operating conditions and general status. the system is enhanced by a control logic that varies
the cooling blower speed dependant on the intake
The air/coolant mixture discharges from the and discharge temperatures and hence controls the
compressor into the separation system. This system injection temperature even closer while saving blower
removes all but a few PPM of the coolant from the motor energy.
discharge air. The coolant is returned to the cooling
system and the air passes to the aftercooler and out The compressor is provided with a temperature
of the compressor through the moisture separator. sensor which will shut the unit down in case of
excessive temperature, 109_C (228_F).
Air is pulled into the machine by the cooling blower
and through the combined cooler / aftercooler. Effective coolant filtration is provided by the use of a
screw on, heavy duty coolant filter.
By cooling the discharge air, much of the water vapor
naturally contained in the air is condensed and is
drained from the built–in moisture separator and
drain.

NOTICE
Nirvana air compressors are factory filled with SSR ULTRA COOLANT which is designed to operate for 8,000
hours or two years, whichever comes first.
Units supplied with optional Food Grade Coolant are designed to operate 1000 hours or 6 months, whichever
comes first.
The coolant must be changed at these intervals to avoid breakdown and equipment damage.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 53

 9.0 OPERATING INSTRUCTIONS
9

9.1 BASIC OPERATION

WARNING Check that the coolant level is at least visible in the

center of the sight glass, add coolant if necessary. Refer
Ensure that all protective covers/guards are in
to maintenance procedures for setting correct level.
place before attempting to start the machine.
Ensure that the discharge air isolation valve is open.
WARNING Switch on the main electrical isolation switch. The
The compressor can operate in a pressurized control panel will illuminate, indicating that the line and
shutdown mode. If the compressor stops control voltages are available.
automatically, the airend, separator tank and oil The contrast of the display may be adjusted by turning
system can contain high pressure air. This can be the small screw which is on the right hand side of the
relieved by pressing the emergency stop button controller when accessed through the starter cabinet
and can be verified by unscrewing the coolant fill door.
plug which has a vent hole through which any
residual pressure will be vented. Downstream of Initial check sequence
the separator tank may still contain system The controller will perform an initial check sequence if
pressure which must also be vented. the compressor (1) receives initial power to the
controller or (2) has experienced an alarm reset. While
NOTICE the initial check sequence occurs, the controller will
The language and units of measure displayed on display a “Checking Machine” message.
the Intellisys controller will be pre–set before During the initial check sequence, the controller will
leaving the factory. If these are required to be check the control system for proper operation. During
changed, contact your local Ingersoll–Rand this time, if any items are found inoperative an alarm will
Service Department, Distributor or Air Center. occur and the unit will not start.
After completion of the initial check sequence, the
Prior to starting
controller will then display “READY TO START’. This
Refer to diagram T5716 above process should be completed within 10 seconds.

54 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 9.0 OPERATING INSTRUCTIONS
Start sequence Blowdown mode
The compressor will initially start by the operator If the blowdown mode is set to on, the compressor will
pressing the local start button or receiving a remote open the blowdown valve anytime that it stops. This will
start command. The compressor will start loaded and release pressure from the airend and separator tank.
will ramp up the motor speed to its minimum speed. If the blowdown mode is set to off, the blowdown valve
Once the minimum speed has been achieved, the will remain closed when the compressor stops due to an
compressor will begin to control pressure by using its automatic stop
speed regulation. When the system pressure reaches
Blower control N37/160K–1S, N50/200H–1S &
the target pressure, the compressor will start to slow. If
N75/160–2S, N100/200H–2S
the system pressure rises to the immediate stop
pressure setpoint the compressor will stop. If the The blower speed varies in some conditions to assist in
system pressure rises to the auto stop setpoint and the controlling the coolant injection temperature. The
compressor is at minimum speed, if the blowdown blower motor has its own variable speed drive and will
mode is set to off, the compressor will stop. However ramp up and down as the compressor starts and stops.
if the blowdown mode is set to on, the compressor will
Stopping the machine in an emergency
open the blowdown valve for up to 10 seconds or until
the pressure in the separator tank falls to 2.4 Bar (35 If the machine has to be stopped in an emergency
psi) before stopping. The compressor will restart once DEPRESS THE EMERGENCY STOP BUTTON
the system pressure falls below the target pressure. LOCATED UNDERNEATH THE INSTRUMENT
PANEL.
Stop sequence
The compressor can be stopped by a local or remote This will over–ride the normal unload/stop button and
stop, a shutdown due to an alarm or an emergency will immediately stop the machine.
stop. All of the above conditions will cause the Restarting after an emergency
compressor to stop immediately, except the local or
remote stop. A local or remote stop will open the If the unit has been switched off because of a machine
malfunction, identify and correct the fault before
blowdown valve and the compressor will run for up to
attempting to restart.
10 seconds or until the pressure in the separator tank
falls to 35 psi before stopping. The compressor will stop If the unit has been switched off for reasons of safety,
if the system pressure reaches the automatic stop or ensure that the machine can be operated safely before
immediate stop pressure setpoints. However, if the restarting.
compressor stops for this reason, it will automatically
restart when the system pressure falls below the target Refer to the PRIOR TO STARTING and START
SEQUENCE instructions earlier in this section before
pressure.
restarting the machine.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 55

 9.0 OPERATING INSTRUCTIONS

9.2 INTELLISYS CONTROLS

1. Emergency stop 5. F2
Pressing this switch stops the compressor immediately. Not used.
The blowdown valve will open to vent pressure in the
separator tank to atmosphere. Note: the system
6. Arrows
downstream of the separator tank may still contain
pressure. The compressors can not be restarted until These up and down buttons have multiple functions
the switch is manually reset. Turn the switch knob relating to the right half of the display screen. When lists
clockwise and press the reset button twice to reset. are presented, the buttons are used to move up or down
through the items on the list. The small arrow(s)
On reset the controller will display a message,
displayed in the upper right hand corner of the display
indicating that the compressor is ready to start.
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.
2. Start
When the value of a specific machine operating
Pressing this button will activate the start sequence. parameter is highlighted on the display screen for the
purpose of changing that value, the buttons are used to
change the value itself.
3. Stop
7. Display buttons
Pressing this button will activate the stop sequence.
The functions of the three buttons below the display
screen change and are defined by the words
4. F1 immediately above them in the bottom line of the
screen. Each function, such as MAIN MENU, STATUS,
Not used. etc., is described in appropriate sections in this manual.

56 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 9.0 OPERATING INSTRUCTIONS

9.3 DISPLAY SCREEN

The display screen is divided into three functional The right side shows various items or lists such as the
areas, as seen in the typical CURRENT STATUS machine’s CURRENT STATUS readings, the MAIN
screen shown here. MENU, the OPERATOR SETPOINTS list, etc. Any of
the lists can be moved up or down by pressing the arrow
The left side continuously shows the package buttons to the right of the screen. The small arrow(s)
discharge pressure in large numbers with the line displayed in the upper right corner of the screen indicate
directly below showing the running condition of the when you can move up and/or down through a list. The
machine arrow buttons are also used to change an individual
item’s value. At certain times, items and/or their values
are “highlighted”. This means that they are displayed as
–CURRENT STATUS– light characters on a dark background.
100 PSI PACKAGE DISCHARGE The bottom of the screen is divided into thirds with the
TEMP words in each small box showing the function of the
button directly beneath it. The words will change in
102_F these boxes depending on what actions are permitted
READY TO START AIREND DISCHARGE at any particular time. The action resulting from
TEMP pressing each of these buttons is indicated in the
Operator Panel Flow Diagram later in this section. This
192_F
can be used as a quick reference of how to step the
MAIN MENU controller screen through any desired function.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 57

 9.0 OPERATING INSTRUCTIONS

9.4 CURRENT STATUS SCREEN

The CURRENT STATUS screen is considered to be the 14 Motor Speed

“normal” display that the controller shows.
15 Motor Current
The following items and their present values can be
displayed on the right side of the screen by pressing the 16 Motor Voltage
up and down arrow buttons. 17 Input Voltage
The controller automatically returns the display to this 18 DC Bus Voltage
CURRENT STATUS screen from other screens if no
buttons are pressed within 30 seconds. 19 Remote Pressure (optional)

Use the UP and DOWN arrows to move between 20 Time and Date
selections. 21 Program Name
22 Version of Drive Software
CURRENT STATUS items
When the CURRENT STATUS screen is displayed,
1 % Energy Saving pressing the ENERGY STATUS button will toggle the
2 % Capacity display to the ENERGY STATUS screen. Likewise,
when the ENERGY STATUS screen is displayed,
3 Package kW pressing the STATUS button will toggle the display to
4 Package Discharge Temperature the CURRENT STATUS screen.
5 Airend Discharge Temperature The ENERGY STATUS screen displays the following
items.
6 Injected Coolant Temperature
7 Inlet Temperature ENERGY STATUS Items
8 Sump Pressure 1 Average Package kW–hr
9 Separator Pressure Drop 2 Average % Capacity
10 Interstage Pressure 3 Average Capacity
11 Coolant Filter 4 Energy Cost
12 Inlet Filter 5 Energy Savings
13 Total Hours 6 Lifetime Energy Savings

58 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 9.0 OPERATING INSTRUCTIONS

9.5 MAIN MENU

The MAIN MENU screen can be accessed from the The language and units of measure are pre–set prior to
CURRENT STATUS screen by pressing the MAIN the compressor leaving the factory.
MENU button, identified by the words “MAIN MENU” in
the bottom line of the screen directly above the center
–MAIN MENU–
button.
The MAIN MENU screen is the point from which various
operator functions can be accessed. Refer to the
100 PSI
OPERATOR SETPOINTS
Operator Panel Flow Diagram. OPTIONS
Each of the functions can be chosen by using the up READY TO START SENSOR CALIBRATION
and down arrows to highlight it on the screen.
ALARM HISTORY
The controller will go to the highlighted function if the
SELECT button is pressed or will return to the STATUS SELECT
CURRENT STATUS screen if the STATUS button is
pressed.

CURRENT Energy
“Status” STATUS/ENERGY
STATUS Status

“Main Menu”

“Status”
MAIN MENU

“Main Menu”

“Select”

“Main Menu” “Main “Main Menu”

OPERATOR Menu” SENSOR
SETPOINTS OPTIONS
CALIBRATION
“Status” “Status” “Status”

“Select” “Select” “Select”

OPERATOR OPTIONS ITEM SENSOR

SETPOINTS CALIBRATION
ITEM ITEM

“Cancel or set” “Cancel or set” “Cancel or calibrate”

“Main Menu” “Main Menu” “Main Menu”

ALARM CLOCK ENERGY
HISTORY FUNCTIONS
“Status” “Status” “Status” STATUS

“Select” “Select”
“Main
Menu”
AVG. PACKAGE kW HRS
“Main Menu” “Main AVG. % CAPACITY
ALARM Menu” DATE
HISTORY ITEM AVG. CAPACITY
AND TIME
“Status” ENERGY COST
“Status”
ENERGY SAVINGS
“Status” LIFETIME ENERGY SAVINGS

“Alarm hist” “Cancel or set”

“Cancel or set”

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 59

 9.0 OPERATING INSTRUCTIONS

9.6 OPERATOR SETPOINTS

Setpoints are user–adjustable variables in the –OPERATOR SETPOINTS–

controller logic that can be set using the OPERATOR
SETPOINTS screen shown opposite. 100 PSI
TARGET PRESSURE
The name and value of each of the setpoints listed can
be seen on the screen by moving the list up and down 105 psi
using the arrow buttons. READY TO START
Setpoints associated with options are described in the
OPTIONS sections.
STATUS MAIN MENU SELECT

FACTORY DEFAULTS
OPERATOR SETPOINTS DEFAULT MIN. MAX. STEP UNIT
Target pressure 100 65 145 / 203 1 PSI
Automatic stop pressure 110 Target +1 Target +10 1 PSI
Immediate stop pressure 120 Auto Auto +10 1 PSI
Blowdown mode Off Off On – –
Condensate release 5 2 20 1 SEC.
Condensate interval 180 90 270 1 SEC.
% savings compared to Modulation – – – –
Energy Rate 0 0 9999.999 – –
Reset Avg. – – Reset Date –
Service menu 1 1 25535 1 –

A setpoint’s value can be changed by first highlighting Target pressure

the item and its value and pressing the SELECT button
to highlight just the value. When the value line is The compressor will try to operate at this pressure
highlighted by itself, the value can be adjusted using the setting. The target pressure ranges and step sizes for
up and down arrow buttons. The CANCEL and SET each unit of measure are listed in the table below.
buttons appear at this time. Press the SET button to
enter the new value or press the CANCEL button to Unit Min Max (1S / Step
return the value of the setpoint prior to using the arrows. 2S)
The displayed value will flash twice to indicated that it
has been entered into the setpoint and the pair of PSI 65 145 / 203 1
setpoint item and value display lines will again be BAR 4.4 10 / 14 0.1
highlighted together.
kPa 440 1000 / 1400 10
Operator setpoints can be exited by pressing the
STATUS or MAIN MENU buttons. If no buttons are KGCM2 4.5 10.2 / 14.2 0.1
pressed within 30 seconds, the display will return to the
CURRENT STATUS screen.

60 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 9.0 OPERATING INSTRUCTIONS
Automatic stop pressure Condensate Release
The compressor will stop once the system pressure This is the number of seconds that the condensate
rises to this pressure and the compressor is operating solenoid will be open (energized) when blowing out the
at the minimum speed. The range for this setpoint will condensation.
be the target pressure+1 to target pressure+10 psi if the
target pressure is 145 psi or less, to target pressure+7 Condensate Interval
psi if the target pressure is greater than 145, but less This is the time interval between condensation
than or equal to 175 psi, or target pressure +5 psi if the
blowdowns
target pressure is greater than 175 psi. If the remote
sensor is ’on’, the maximum automatic stop pressure % savings compared to
will always be target pressure +5 psi.
This setpoint is to determine what Nirvana’s percent of
Immediate stop pressure savings is compared to. The modes of operation for
comparing Nirvana to are modulation, online/offline,
The compressor will stop if the system pressure rises
and geometry. The percent savings value is displayed
to this pressure. The range for this setpoint will be the
automatic stop pressure to automatic stop pressure+10 by the status message, % energy savings
psi if the target pressure is 145 psi or less, to automatic Energy Rate
stop pressure+7 psi if the target pressure is greater
than 145, but less than or equal to 175 psi, or automatic The energy cost and the energy savings items on the
stop pressure +5 psi if the target pressure is greater ENERGY STATUS screen will use this value for their
than 175 psi. If the remote sensor is ’on’, the maximum calculations. It is intended to be a monetary value
immediate stop pressure will always be automatic stop representing the user’s power cost per kilowatt hour.
pressure +5 psi. Reset Averaging
Blowdown Mode When this setpoint is selected and the SET button is
If this mode is selected to ON the compressor will open pressed, the items on the ENERGY STATUS screen
the blowdown valve anytime that it stops. This will vent will be reset, and the date the reset occurred will be
pressure from the airend and the separator tank. If this displayed in this setpoint. This selects the beginning of
mode is selected to OFF the blowdown valve will the time period over which the ENERGY STATUS
remain closed when the compressor stops due to an information will be calculated. Note that the “Lifetime
automatic stop. Energy Savings” item will not be reset.
Service Menu
For use by IR personnel only.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 61

 9.0 OPERATING INSTRUCTIONS

9.7 OPTIONS

Options are turned on or off and their associated values –OPTIONS–

are set using the OPTION screen shown opposite.
Some options are purchased, they require additional 100 PSI
REMOTE START/STOP ON
machine hardware and must first be enabled by service
personnel. The name and value of each of the following
options can be seen by moving the list up and down READY TO START REMOTE START/STOP ON
using the arrow buttons
An Option item’s value can be changed the same way STATUS MAIN MENU SELECT
that OPERATOR SETPOINTS values are changed.

OPTIONS Items SELECTION MIN. MAX. Step Unit Installed

Option
Required
Remote Pressure Sensor ON/OFF No
Sequencer ON/OFF No
Remote Start/Stop ON/OFF Yes
Power Out Restart ON/OFF Yes
Power Out Restart Time 10 600 1 SEC Yes
Scheduled Start Day day day 1 day Yes
Scheduled Start 00:00 23:59 1 time Yes
Scheduled Stop Day day day 1 day Yes
Scheduled Stop 00:00 23:59 1 time Yes
Modbus Protocol ON/OFF/ICU No
Modbus Address 1 247 1 No

Remote pressure sensor Power out restart

If this setting is set to ON, the compressor will use a If this setting is set to ON, the compressor will
remote mounted pressure sensor for controlling system automatically restart when power is returned to the
pressure by comparing it to the Target Pressure setting compressor if it was operating when power was
and the Auto Stop Pressure setting. The pressure removed.
measured by this sensor is shown in the CURRENT
Note:
STATUS display as the Remote Pressure reading. The
A kit including instruction manual is required to install
local sensor at the package discharge is still used for
this option.
Immediate Stop, for certain Alarm conditions and for
display on the left side of the screen. Power out restart time
Sequencer If the power out restart setting is set to ON, this is the
If this setting is set to ON, the compressor will be able number of seconds from the time power is restored until
to start and stop by commands from a host device. the compressor starts. The power out restart horn will
When the Intellisys receives a load command from the sound during this time.
host device, the compressor will start. When the Scheduled start day
Intellisys receives an unload command the compressor
will respond as though executing an immediate stop.. This option is the selection for the day that a scheduled
start will take place. The selections are Sunday,
Monday, Tuesday, Wednesday, Thursday, Friday,
Remote start/stop Saturday, Daily (Su Sa), Weekdays (M F), or
— —

If the remote start/stop option is installed and this Weekends. This option setpoint will work with the
setting is set to ON, the compressor can be started and scheduled start setpoint.
stopped from a remote device.

62 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 9.0 OPERATING INSTRUCTIONS
Scheduled start Scheduled stop
This option will cause the unit to start on the scheduled This option will cause the unit to stop on the scheduled
start day , at the time stored in this setpoint. To disable stop day, at the time stored in this setpoint. To disable
this option, set the value of scheduled start equal to the this option, set the value of scheduled stop equal to the
value of scheduled stop. value of scheduled start.
Scheduled stop day Modbus protocol and address
This option is the selection for the day that a scheduled See the Modbus manual.
stop will take place. The selections are Sunday,
Monday, Tuesday, Wednesday, Thursday, Friday,
Saturday, Daily (Su — Sa), Weekdays (M — F), or
Weekends. This option setpoint will work with the
scheduled stop setpoint.

9.8 SENSOR CALIBRATION

Pressure sensor calibration is done through the Each of the sensors listed below can be chosen by
SENSOR CALIBRATION screen. Sensor calibration using the up and down arrow buttons to highlight it on
can only take place when the machine is stopped. the screen.
Calibration needs to be done only after a sensor has
been replaced or the Intellisys controller has been SENSOR CALIBRATION Items
replaced. Sensor 4APT (Package Discharge)
Sensor 3APT (Wet Side Sump)
Sensor 6APT (Dry Side Sump)
–SENSOR CALIBRATION– Sensor 2APT (Interstage)
Sensor 9APT (Remote Sensor)
100 PSI
SENSOR 4APT
Select the highlighted sensor by pressing the SELECT
CALIBRATE button. Press the CALIBRATE button to start the
READY TO START SENSOR 3APT automatic calibration procedure, or press the CANCEL
button to not calibrate it and return to the sensor list.
CALIBRATE
The calibration screen can be exited by pressing either
STATUS MAIN MENU SELECT the STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to the
CURRENT STATUS screen.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 63

 9.0 OPERATING INSTRUCTIONS

9.9 ALARM HISTORY

Alarm History displays each of the Alarm messages for Each of the last 15 Alarm messages can be seen by
the last 15 Alarms experienced by the machine. It also moving the Alarm History list up and down using the
gives access to displaying the machine operating arrow buttons. Pressing the SELECT button when one
conditions that existed at the time of each Alarm. The of the Alarms is highlighted will display the list of
first one shown, “Alarm History 1”, was the most recent machine values that existed at the time that particular
Alarm to occur. Note that multiple, consecutive Alarm occurred.
EMERGENCY STOP Alarms are not recorded as
separate Alarms, only the first one will be shown. The name and value of each of the items can be seen
by moving the list up and down using the arrow buttons.
–ALARM HISTORY– Pressing the ALARM HIST. button will return the display
to the ALARM HISTORY screen.
100 PSI
ALARM HISTORY 1
Alarm histories can be exited by pressing either the
STATUS or MAIN MENU buttons. If no buttons are
BLOWER MOTOR pressed within 30 seconds, the display will return to the
OVERLOAD CURRENT STATUS screen.
READY TO START ALARM HISTORY 2
HIGH AIREND DISCH
TEMP
STATUS MAIN MENU SELECT

9.10 CLOCK FUNCTIONS

–CLOCK FUNCTIONS– The date and time for the real time clock is set through
the CLOCK FUNCTIONS screen. Use the up and down
Time
100 PSI 01:15 arrows to highlight either TIME or DATE. Select the
highlighted setting by pressing SELECT.

Date If TIME is selected, first the hours will be highlighted.

READY TO START Jan 01, 00 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
STATUS MAIN MENU SELECT (00–59) and then press SET to complete setting the
time.
If DATE is selected, first the month will be highlighted.
Adjust the month by using the up and down arrows and
then press SET to highlight the date. Once the correct
date is displayed, press SET to highlight the year. Once
the correct year is displayed, press SET to complete
setting the date.

64 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 9.0 OPERATING INSTRUCTIONS

9.11 ENERGY STATUS MESSAGES

–ENERGY STATUS– AVERAGE CAPACITY – Displays the compressor’s

average capacity in cfm or m3 for the time period that
AVERAGE PACKAGE kW
was started by selecting the reset averaging setpoint.
100 PSI HRS
ENERGY COST – Displays the energy cost of the
AVERAGE % CAPACITY– compressor for the time period that was started by
READY TO START –AVERAGE CAPACITY selecting the reset averaging setpoint. This is
calculated by multiplying the kW hours of the motor and
the blower by the energy rate.
STATUS MAIN MENU SELECT
ENERGY SAVINGS – Displays the energy savings of
The Energy Status display can be selected by pressing the compressor for the time period that was started by
the ENERGY STATUS button. The following items and selecting the reset averaging setpoint as compared to
their present values will be displayed on the right side a conventional compressor. This value is determined by
calculating how much a conventional compressor
of the screen by pressing the up and down arrows.
motor would cost to operate at the same average
AVERAGE PACKAGE kW HOURS – This displays the capacity and then subtracting the motor energy cost of
average package kW per hour for the time period that the Nirvana compressor from it. It is assumed that the
was started by selecting the reset averaging setpoint. blower cost is the same in both packages.
This value includes the blower power usage.
LIFETIME ENERGY SAVINGS – Displays the lifetime
AVERAGE % CAPACITY – Displays the compressor’s energy savings of the compressor at the existing
average percent capacity for the time period that was energy rate and at the average percent capacity as
started by selecting the reset averaging setpoint. The compared to a conventional compressor.
value is determined by taking the average package kW
per hour, removing the blower power usage and then
dividing that number by the motor kW per hour for that
size of compressor at 100% capacity.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 65

 9.0 OPERATING INSTRUCTIONS

9.12 WARNINGS

When a WARNING occurs, a large question mark will CHANGE INLET FILTER – This will occur if the Inlet
flash on the display screen. Vacuum is greater than 0.05 bar (0.7 psig).
If multiple WARNINGS exist, the small up/down arrows CHANGE SEPR ELEMENT – This will occur if the
will appear in the upper right corner of the display pressure differential across the separator is 1.0 bar (12
screen. The multiple WARNINGS can be seen by psig).
pressing the up and down arrow buttons. Pressing the
STATUS button will display the CURRENT STATUS SENSOR FAILURE – This will occur if a sensor is
screen with the WARNING button indicating that a recognized as missing or broken.
WARNING still exists. HIGH DISCHARGE PRESS – Will occur if the unit is
A WARNING will not cause the unit to shut down. The under the control of an external device, such as an ISC,
unit will continue to run in its normal operation and the and the discharge pressure is greater than the
WARNING will remain displayed until reset. immediate stop pressure.

A Warning needs to be reset by the operator by AUXILIARY WARNING 1 or 2 – Will occur if the
pressing the RESET button twice. auxiliary warning input closes.

The possible Warning messages are as follows; REMOTE PRESSURE SENSOR FAILURE (option) –
This will occur if the remote pressure sensor fails. If this
HIGH AIREND DISCHARGE TEMP – This will occur if the happens, the lntellisys will start using the package
Airend Discharge exceeds 97% of the alarm limit, discharge pressure sensor to measure system
109_C (228_F) and is not adjustable. pressure.

CHANGE COOLANT FILTER – This warning will occur CONDENSATE DRAIN ERROR – On 2 stage units,
this will occur if the condensate drain error contacts
if the high side pressure is 1.4 bar (20 psig) greater than
close while the unit is running.
the low side pressure.

9.13 SERVICE WARNINGS

SERVICE – Service warnings occur when the unit has This will be set prior to the compressor being shipped
operated a certain number of hours, based on the total from the factory. When a service warning occurs,
hours, or has operated for a certain number of months, contact your local IR service representative.
based on the real time clock. Service warnings can
have multiple levels, depending on the service level
selection.

9.14 INITIAL CHECK ALARMS:

The following alarms will only occur when the machine CHECK SETPOINTS – Will occur if the controller has
is not running. These alarms are related to high determined that some of the data stored in memory
temperature, power loss, and sensor calibration. They contains unacceptable values.
will have the same display mode as other alarms.
INVALID CALIBRATION – Will occur if the sensor zero
HIGH AIREND DISCH TEMP– Will occur if airend value is –10% to +1% of its scale. See Sensor
discharge temperature is greater than 95% of 109_C Calibration.
(228_F).

66 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 9.0 OPERATING INSTRUCTIONS

9.15 ALARMS

When an Alarm occurs, a large exclamation mark in a –ALARM STATUS–

triangle will flash on the display screen. The display
message will indicate what caused the Alarm.
The compressor will stop and cannot be re–started
100 PSI PACKAGE DISCH
PRESSURE
again until the alarm condition no longer exists and the
alarm message reset. 100 psi

Pressing the STATUS button will display the STATUS STOPPED BY PACKAGE DISCHARGE
screen. The presence of the ALARM button indicates ALARM TEMP
that an Alarm condition still exists. Alarm Status is the 103_F
list of machine operating conditions that existed at the
time of the Alarm. 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.
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.

The possible Alarm messages are as follows;

EMERGENCY STOP– This will occur if the Emergency CHECK MOTOR ROTATION – This will occur if the
Stop button is engaged. The button must be Intellisys reads a negative speed from the VSD when
disengaged before the alarm can be cleared. starting .
BLOWER FAULT– This will occur if a blower fault is VSD COMMUNICATION FAILURE – This will occur if
sensed. the Intellisys does not receive a response from the VSD
when requesting information. This alarm will take about
HIGH AIREND DISCH TEMP– This will occur if the
airend discharge temperature is greater than 109_C 8 seconds to occur.
(228_F). VSD INITIALIZATION FAULT – Will occur if the
REMOTE START FAILURE– This will occur if the Intellisys is unable to establish communications with
Remote Start button is pressed after the machine is the VSD after a power up.
running or if the Remote Start button remains closed. LOW SUMP PRESSURE – Will occur if the
REMOTE STOP FAILURE– This will occur if the compressor is operating at or above the minimum
Remote Stop button remains open and either Start speed and the sump pressure drops below 15psi (1.03
button is pressed. bar) for 15 seconds.

SENSOR FAILURE – This will occur if a sensor is REPLACE COOLANT FILTER – This will occur if the
recognized as missing or broken. coolant filter is blocked and requires changing.

VSD FAULT – The VSD fault is read from the drive. The INCORRECT VSD TYPE – Will occur at power up if the
Intellisys will read the status menu of the variable speed VSD type does not match the size of the compressor
drive. If a fault condition is returned in the status 125HP (90kW) machines and above also have the
information, the Intellisys will issue a VSD FAULT alarm
following alarm messages;
and display the number of the fault condition.
CONTROL POWER LOSS – This will occur if the CONTROL POWER LOSS – This will occur if the
control circuit is broken by a bad connection or safety compressor should be running and the AC input
switch (e.g. HAT Switch/ Phase Monitor). voltage, as read from the VSD, falls below 100 VAC.
Any fall of voltage below 100VAC for more than There is a delay of 2 seconds on this alarm in case the
2 seconds will cause this alarm trip. power quickly returns. An open HAT switch or phase
monitor are two things that can cause this alarm.
STOP FAILURE – This will occur if the compressor
should be stopped but the motor is still running above STOP FAILURE – This will occur if the compressor
minimum speed 4 seconds after the stop signal is given. should be stopped, but the motor speed has not
dropped below the minimum motor speed setpoint. The
Intellisys will wait 4 seconds for the compressor to stop
HIGH START PRESSURE – If the sump pressure is before issuing this alarm.
above 100 psi (6.9 bar) when the compressor starts, the
Intellisys will open the blowdown valve during the first HIGH INTERSTAGE PRESSURE – If the interstage
few seconds of starting (3 to 7 seconds). If the sump pressure is over 100psi while the unit is running and the
pressure does not fall to 100 psi (6.9 bar) during that unit is a 2–stage.
time period, this shutdown will occur.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 67

 10.0 MAINTENANCE

10.1 MAINTENANCE PROMPTS

The service warning and flashing LED will appear at The service warning will return each subsequent
intervals, dependant on the service level selected. 2000 hours.
Refer to operating instructions. The machine will be master reset after service work
The customer can only reset the warning for 24 hours conducted prior to the 2000 hour interval to prevent
by pressing the “set” button. false indication.
IR service engineers will master reset the warning
after completing the service work.

68 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 10.0 MAINTENANCE

10.2 MAINTENANCE CHART

The MAINTENANCE CHART indicates the various components and the intervals when maintenance has to take
place. Where a service interval is stated in both hours and months, it is the sooner of the two intervals that must
be adhered to. Coolant capacities etc can be found in the GENERAL INFORMATION section of this manual. Note
that any Local or National codes that require specific maintenance that exceeds the requirements of this section
must be adhered to.

Maintenance Schedule
TM

Hours: 150 500 2000 4000 8000

(1st time 1000 6000 12000 16000
only)
1500 10000 20000
2500 14000
3000 18000
Daily
Coolant filter Change Change Change Change
Air filter ** Check Change Change
pressure
Separator element *** Check Change Change
pressure
ULTRA COOLANT* Check Sample Sample Change
Power Drive Module filter * Check Change Change Change
Scavenge screen ** Check / Check / Check /
clean clean clean
Hoses *** Check / Check / Check /
clean clean clean
High Air Temperature switch Check Check Check Check
Pressure relief valve Check Check Check
Cooler Core(s) Check / Check / Check / Check /
clean clean clean clean
Moisture separator Check / Check / Check / Check /
clean clean clean clean
Motor cowl Check / Check / Check / Check /
clean clean clean clean
Vibration Analysis Analysis Analysis Analysis
Coolant Analysis Analysis Analysis Analysis
Food Grade Coolant * Analysis at every 500
Change at every 1000
Blower Motor Regrease Regrease

If the compressor is run less than 4,000 hours per year,

* Maintain every 6 months
** Maintain every year
*** Maintain every 2 years

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 69

 10.0 MAINTENANCE
Note:
On some sea watercooled models the oil cooler and aftercooler are fitted with sacrificial zinc anodes (pencils) that
are located in the end bonnets of the coolers. These sacrificial zinc anodes should be checked after the first 50
hours of operation to determine if corrosive conditions exist. If satisfactory this interval may be extended to 500
hours.

NOTE:
1 If sacrificial zinc anode is 50% corroded it should be replaced.
2 Coastal/harbor waters can contain corrosive chemicals from pollution and may reduce anode/cooler life.
3 Effects of corrosion or erosion are specifically excluded from warranty considerations.

10.3 MAINTENANCE PROCEDURES

CAUTION
Before beginning any work on the compressor, read and understand the safety instructions earlier on in
this manual. Open, lock and tag the main electrical disconnect and close the isolation valve on the
compressor discharge. Do not under any circumstances open any drain valve or remove components
from the compressor until this has been carried out. Ensure that all pressure has been vented from the
compressor. Verify this by slowly unscrewing the coolant fill cap one turn. Unscrewing the fill cap opens
a vent hole, drilled in the cap, allowing pressure to release to atmosphere. Do not remove the fill cap until
all pressure has vented from the unit. Note that pipework downstream of the separator tank may still
contain pressure that must also be vented to atmosphere before beginning any work.

CAUTION
When using any form of liquid for cleaning, ensure that all electrical components are protected or
covered to prevent ingress of liquid.

WARNING
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the
internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt
any work on the drive unless trained. There are no user serviceable items behind the cover.

This compressor contains a variable frequency drive. When it is switched off and the motor is stopped,
the internal capacitors store a potentially lethal high voltage electric charge which gradually falls to zero
over time. After switching off the machine at its local isolator WAIT AT LEAST 15 MINUTES for the
capacitors to fully discharge before opening the power drive module doors.

WARNING
The compressor can operate in a pressurised shutdown mode. If the compressor stops automatically, the
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole
through which any residual pressure will be vented. Downstream of the separator tank may still contain
system pressure which must also be vented.

WARNING
Use suitable equipment for lifting heavy items and ensure loose components are adequately supported to
eliminate risk of dropping.

WARNING
The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices
such as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by
personnel with cardiac pacemakers, defibrillators or other implanted electronic medical device.

70 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 10.0 MAINTENANCE
Compressed air can be dangerous if incorrectly Prior to attempting any maintenance work on a
handled. Before doing any work on the unit, ensure running machine, ensure that:–
that all pressure is vented from the system and that
S the work carried out is limited to only those tasks
the machine cannot be started accidentally.
which require the machine to run.
Ensure that maintenance personnel are adequately
S the work carried out with safety protection devices
trained, competent and have read the Maintenance
disabled or removed is limited to only those tasks
Manuals.
which require the machine to be running with
safety protection devices disabled or removed.
Prior to attempting any maintenance work, S all hazards present are known (e.g. pressurized
ensure that:– components, electrically live components, removed
panels, covers and guards, extreme temperatures,
S all air pressure is fully discharged and isolated inflow and outflow of air, intermittently moving
from the system. If the automatic blowdown valve parts, safety valve discharge etc.).
is used for this purpose, then allow enough time
for it to complete the operation. S appropriate personal protective equipment is worn.
S the machine cannot be started accidentally or S loose clothing, jewelry, long hair etc. is made safe.
otherwise, by posting warning signs and/or fitting
S warning signs indicating that Maintenance Work is
appropriate anti–start devices.
in Progress are posted in a position that can be
S all residual electrical power sources (mains and clearly seen.
battery) are isolated.
Upon completion of maintenance tasks and prior
Prior to opening or removing panels or covers to to returning the machine into service, ensure
work inside a machine, ensure that:– that:–
S anyone entering the machine is aware of the S the machine is suitably tested.
reduced level of protection and the additional
S all guards and safety protection devices are
hazards, including hot surfaces and intermittently
refitted.
moving parts.
S all panels are replaced, canopy and doors closed.
S the machine cannot be started accidentally or
otherwise, by posting warning signs and/or fitting S hazardous materials are effectively contained and
appropriate anti–start devices. disposed of.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 71

 10.0 MAINTENANCE

10.4 ROUTINE MAINTENANCE

This section refers to the various components which S Remove the cap from the drain valve located at
require periodic maintenance and replacement. the front of the separator vessel.
For all other maintenance, contact your local S Place a suitable container close to the drain valve.
Ingersoll–Rand office, Distributor or Air Center.
S Screw the coolant drain hose onto the drain valve.
Refer to safety information and maintenance As the threads engage, the valve will automatically
procedures prior to carrying out any of the open and the coolant will drain.
maintenance in the following sections.
S Remove the drain hose. The valve will
automatically close and seal.
Prior to starting S Replace the cap on the drain valve.
S For a complete drain, remove the plug near the
vessel inlet flange and replace when complete.
Coolant level checking procedure
S Replace the coolant filter element.
The coolant level should be checked daily. A coolant
S Refill with correct quantity of coolant. See 8.0
level sight glass is located on the side of the
General Information.
separator tank and while the machine is running on
load, coolant should always be visible in the sight
glass. The normal position is half way.
CAUTION
Stop the machine and ensure coolant is still visible in Do not mix coolant types. Use only coolant
the sight glass. specified by IR
Adding coolant
Run the compressor for a minimum of 40 seconds, S Start the compressor and check for leaks.
the coolant level should be visible in the sight glass.
S Check the coolant level, refilling if necessary.
If not, stop the compressor, depressurize by isolating
the compressor from the system, pressing the S Dispose of waste coolant in accordance with local
emergency stop to vent the separator tank & airend & and governmental regulations.
then slowly unscrew the coolant fill plug to verify all
pressure has been released and add coolant.
Replace the coolant fill plug, restart the compressor NOTICE
and recheck the coolant level. Repeat until the Shorter coolant drain intervals may be necessary if
coolant level is visible in the sight glass with the the compressor is operated in adverse conditions.
compressor both running and stopped.
Do not add coolant through the intake of the Food Grade Coolant option
compressor, as this can result in overfilling, saturation
of the separator filter element, and coolant carry–over S SSR Food Grade Coolant is a polyalphaolefin base
downstream. coolant. Change after 1000 hours or every 6 months
whichever comes first. Do not operate unit past this
1000 hour change interval, as coolant degradation
will occur.
DANGER
Under no circumstance should the compressor
be operated with the coolant fill plug removed. Coolant filter change procedure
S Loosen filter element with the correct tool.

Coolant change procedure S Remove the element from the housing.

S Place the old element in a sealed bag and dispose
of in a safe way.
WARNING S Clean the mating face of the housing.
The coolant filter and coolant may be hot! S Remove the new Ingersoll–Rand replacement
element from its protective package.
S Apply a small amount of coolant to the element
The compressor features a ’no drip’ coolant drain
feature which requires no special tools and minimizes seal.
the risk of coolant spillage. S Screw the new element down until the seal makes
contact with the housing, then hand tighten a
It is better to drain the coolant immediately after the
further half turn.
compressor has been operating as the liquid will
drain faster and any contaminant will still be in S Start the compressor and check for leaks and
suspension. check the coolant level.
72 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S
 10.0 MAINTENANCE
Separator element checking procedure To remove the screen/orifice, disconnect the scavenge
line tubing from each end. Hold the center section firmly
With the compressor running on load, check the and use a pair of pliers to gently grasp the exit end of
separator differential pressure via the Intellisys the assembly that seals against the scavenge line
controller. It will be necessary to change the element tubing. Pull the end out of the center section while using
if the differential pressure equals zero or exceeds 1 care to prevent damage to the screen or sealing
bar (12 psig). surfaces.
Clean and inspect all parts prior to reinstallation.
Separator element change procedure
When the assembly is installed, confirm the direction of
S Remove all the capscrews securing the cover to flow to be correct. Observe the small arrow stamped in
the tank except the screw opposite the pivot bolt the center section and ensure the direction flow to be
which should be left engaged by 2–3 threads with from the separator tank to the airend.
at least 6.5mm (0.25”) clearance from the screw
head to the lid. Rotate the jacking bolt clockwise
until the cover lifts off the tank at least 2mm (0.08”) O–RING
all the way around the tank. The cover can now be SCREW HOUSING
SCREEN
rotated to allow access to inside the tank.
ORIFICE
S Carefully lift out the element spacer and retain for
reassembly. Do not damage the flat surfaces of
the spacer as this may cause higher oil carryover
or leaks. A hoist is available for 175HP (90kW)
machines and above if required.
S Carefully withdraw the used element, place it in a
sealed bag and dispose of it safely.
S Remove the O–rings from the top of the tank, the SEPARATOR TANK SCAVENGE SCREEN/ORIFICE
separator element sealing face and the scavenge
tube sealing face. WARNING
S Clean the surfaces on both the tank and the cover. Unscrew the jacking bolt sufficiently to ensure
that the cover can be fully tightened down
S Install new O–rings without imparting any stress onto the jacking
S Install replacement element remembering to fit the points. Tighten down the cover setscrews.
small O–ring on the scavenge tube and positioning
the tube into the matching hole in the Separator
S Start the compressor and check for leaks and
Tank coolant level.

S Re–fit the separator element spacer with the notch

over the scavenge tube. CAUTION
Do not use any form of sealant on either the
separator tank or the separator tank cover faces.
S Rotate the tank cover back into position taking
care not to damage the O–ring, and locate the
cover using 2 capscrews but do not tighten down. Separator tank / Pressure system
At 2000 hour intervals, inspect the external surfaces
Scavenge screen clean/check procedure of the airend and separator tank, including all fittings,
for visible signs of impact damage, excessive
The screen/orifice assemblies are similar in corrosion and abrasions. When changing the
appearance to a straight tubing connector and will be separator element inspect the internal components
located between two pieces of 1/4 inch O.D. scavenge and surfaces. Any suspect parts should be replaced
line tubing. before the compressor is put back into service.
The main body is made from 1/2 inch hexagon shaped The separator tank should also be tested and
steel and the diameter of the orifice and a inspected in accordance with any national or local
direction–of–flow arrow is stamped in flat areas of the
codes that may exist.
hexagon.
A removeable screen and orifice is located in the exit
Blower motor Re–Grease
end of the assembly. (see figure) and will require
clearing as outlined in the Maintenance Schedule (N75–160 Aircooled units)
Section 10.2. 6 Months or 4000 Hrs.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 73

 10.0 MAINTENANCE
Apply high melting point grease into the blower motor Run the compressor for about 10 minutes by venting
drive end bearing using a grease gun at the nipple air from the system to let the unit warm up. With the
provided. unit running, test at or near the maximum operating
pressure by opening the valve for the minimum
Stop when excess grease is seen at the relief port.
period required to flush the valve seat free of debris.
This can be accomplished by holding the test lever
Coolant hoses fully open or unscrewing the spring pressure retaining
cap, depending on the type of valve installed. If there
S The flexible hoses that carry coolant through the
is no evidence of discharge or the valve does not fully
cooling system may become brittle with age and
close, discontinue use of equipment and contact a
will require replacement. Have your local
licensed contractor or qualified service personnel.
Ingersoll–Rand Distributor or Air Center inspect
them every 3 months and replace them as needed The pressure relief valve should also be tested and
or every 2 years. re–calibrated in accordance with any national or local
codes that may exist. If no code exists, IR
S Depending on the location of the hose, it may recommend that the pressure relief valve is
contain compressor coolant. It is recommended to recalibrated at intervals of one year.
drain the coolant into a clean container. Cover the
container to prevent contamination. If the coolant Air filter change procedure
is contaminated, a new charge of coolant must be
used. S Unclip the retaining cap and withdraw the old
element.
S Remove the hose.
S Fit the new element and refit the retaining cap.
S Install the new hose and refill the unit with coolant.
Start the compressor, check for leaks and check Aircooled Cooler Cleaning
coolant level. Refill as necessary
Ensure that the compressor is isolated from the
compressed air system and is vented of all pressure.
Pressure relief valve check When undertaking any work on the compressor
The pressure relief valve must be frequently tested always use certified lifting equipment and employ
and regularly maintained. Remove from the machine sound working principles.
and check for the correct operating pressure. Adjust Ensure that the main power disconnect switch is
as necessary. If operating conditions are particularly locked off and tagged.
severe, the frequency of testing and maintenance
must be increased accordingly. A pressure relief Visually check the outside of the cooler cores to be
valve check must also be performed at the end of certain that a complete cleaning of the cooler is
any non–service period. The user must establish the required. Frequently, dirt, dust or other foreign
frequency of such tests as it is influenced by such material may only need to be removed with a vacuum
factors as the severity of the operating environment. to remedy the problem.
When the cooler is covered with a combination of oil,
grease or other heavy substances that may affect the
CAUTION unit’s cooling, then it is recommended that the cooler
High pressure air will discharge through the cores be thoroughly cleaned on the outside.
discharge ports of the valve during pressure
relief valve check. Wear ample clothing, gloves, If it is determined that the compressor operating
safety glasses and ear protection during valve temperature is higher than normal due to the external
testing. passages between the fins of the cooler cores being
restricted with deposits of foreign material, then the
cooler should be removed for cleaning.
N50/100H (N37/75K)

Following are instructions for tilting the cooler away

from the enclosure and cleaning of the cooler.

S Remove 6 screws from lower rear fixed panel and

remove panel.
S Remove 10 screws from the rear intake panel and
remove panel.
S Loosen clamp and disconnect the air inlet hose
from the intake plenum.

74 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 10.0 MAINTENANCE
S Remove intake plenum. Note, plenum is S Remove the 16 screws securing the access panels
unsupported, before removing the 8 screws on the cooling plenum and remove covers.
from the intake plenum, block underside of
S Cover main drive motor, PDM Heat sink blower
plenum prior to removing screws to prevent
motor, drain valve, and cooling motor variable speed
plenum from falling.
drive with plastic sheeting to prevent damage from
S Remove hose from elbow in aftercooler inlet. Plug entrance of cleaning solution.
elbow in inlet hole of aftercooler.
S Cover inlet of blower wheel with plastic sheeting to
S Unscrew the fitting connecting the aftercooler to prevent entrance of cleaning fluid.
the discharge tube.
S Cover the inlet grill of the intake panel with plastic
S Loosen mounting bolts on moisture separator to sheeting to prevent cleaning solution from exiting
allow moisture separator to slide down in the compressor.
mounting bracket. Once lowered, remove the
discharge tube connecting the moisture separator S Attach drain hose to the coupling on the bottom of
the plenum to allow the cleaning solution to drain
to the aftercooler outlet.
outside the compressor. Alternately, place large
S Plug aftercooler discharge hole. bucket underneath plenum to collect cleaning fluid.
S To tilt cooler forward, remove 6 screws holding the
cooler in place. While removing the last screw, S Use an extended length nozzle and a mild cleaning
hold the top of the cooler in place to prevent solution to clean the coolers.
the cooler from tilting. Once the screw is
removed, allow the cooler to tilt forward until the
pivot brackets touch the pivot stops. The cooler
will stop tilting at 45 degrees.
WARNING
Strong cleaners can harm aluminium cooler
S Cover the main drive motor with plastic sheeting parts. Follow cleaner manufacturers instructions
to prevent cleaning solution from entering the for use. Wear appropriate safety equipment.
motor.
S Before cleaning coolers, check to ensure
aftercooler intake and discharge holes are S Cleaning fluid will collect on both sides of the cooler
plugged to prevent contamination of compressor core. If required, periodically drain fluid from intake
system. Clean coolers with a mild cleaning plenum and bucket to prevent them from over
solution. flowing.
S After cleaning is complete, dry off plenum, intake,
and cooler core. Reassemble parts in reverse order.
WARNING
Strong cleaners can harm aluminium cooler
parts. Follow cleaner manufacturers instructions
for use. Wear appropriate safety equipment. If the cooler cores are unable to be clean
while installed in the compressor, remove
cooler as follows:
S After cleaning is complete, reassemble in reverse S Remove 5 screws from panel below the intake panel
order. and remove panel. Be careful not to damage the
N125/200H (N90/160K) SINGLE STAGE and electrical leads entering the panel.
N100/200H (N75K–160K) TWO STAGE S Remove 8 screws from the intake panel and remove
The coolers in these machines can either be cleaned by panel.
removing the complete cooler for off site cleaning or S Remove 8 screws from the intake plenum supports
’back flushing’ in place using a high pressure hose and and remove the supports.
gaining access through the holes in the intermediate
plenum. S Remove the 10 screws securing the intake plenum
and remove the plenum
S Disconnect both oil lines and both air lines from the
cooler. Plug all 4 inlets to prevent cleaning fluid from
Instructions for cleaning the coolers while
entering the cooler cores.
installed in the compressor.
S Remove 6 screws from top panel above cooler and
While cleaning coolers, great care must be taken to
remove panel.
protect the rest of the machine from moisture and
contamination by covering sensitive parts with plastic S Using lifting device from above, attach lifting straps
sheeting. to lifting supports on each side of cooler.
S Remove 4 screws from enclosure panel below S With the weight of the cooler supported by the lifting
moisture separator and remove panel. device, remove the 10 screws securing the cooler
and remove the cooler.
S Remove 4 screws from enclosure panel above
moisture separator and remove panel. S Clean coolers with a mild cleaning solution.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 75

 10.0 MAINTENANCE

WARNING CAUTION
Strong cleaners can harm aluminium cooler Under no circumstances should these discharge
parts. Follow cleaner manufacturers instructions temperatures be exceeded. If the machine fails to
for use. Wear appropriate safety equipment. trip A FAULT EXISTS. Investigate immediately.

Separator tank scavenge check valve/orifice

S After cleaning is complete, reassemble in reverse S Disconnect tubing at each end of check
order. valve/screen/ orifice assembly.
S Check orifice and clean if required. Use suitable
tool and remove orifice from its housing. Be careful
Watercooled Cooler Cleaning not to damage flared end of fitting or O–ring.Wash
A periodic inspection and maintenance program housing in safety solvent and blow dry.
should be implemented for watercooled heat S Press the check valve/orifice into fitting block.
exchangers. The following steps should be taken:
S Assemble the check valve/orifice assembly to the
S Inspect filters in system and replace or clean as tubing lines.The fitting must be re–installed with the
required. check valve on the upstream side of the orifice as
S Carefully examine cooler tubes for scale and indicated by the flow arrow.
clean if necessary. If a cleaning solution is used,
be sure to wash out all chemicals thoroughly with Blower Motor Bearing Maintenance (Stored units)
clean water before returning the compressor to
S Prior to placing a unit in storage for extended
service. After cleaning, examine the cooler for
intervals, rotate the blower motor several
erosion or corrosion.
revolutions by hand in the direction of rotation.
S The internal cooler tubes can be cleaned by
S On N75 – 160 aircooled units, whilst rotating the
several methods. Flushing a high velocity stream
motor, pump grease into the bearing until grease
of water through the tubes will remove many
is seen at the relief port.
forms of deposits. More severe deposits may
require running wire brushes or rods through the S Thereafter rotate the motor as described above
tubes. Also, rubber plugs can be forced through every three months until such time as the unit is
the tubes if a special air or water gun is available placed in service.
for this procedure.
S If the storage time is to exceed a total of nine (9)
S A qualified cleaning service should be used for the months duration, the compressor must be ordered
cleaning process. These organizations can for long term storage.
evaluate the type of deposit to be removed and
supply the appropriate solution and method for a Motor cowl cleaning
complete cleaning job.
S Ensure compressor is electrically isolated for at
S When reinstalling bonnets to cooler shell, tighten least 15 minutes before commencing any
bolts uniformly in a cross–pattern. Overtightening maintenance work.
can result in cracking of the bonnet.
S Remove panels from the compressor.
S Cleaning solutions must be compatible with the
metallurgy of the cooler S Using a clean dry cloth, remove dust from the
surface of the motor cowl and ensure all
S Care must be taken to avoid damaging tubes if ventilation slots are free of obstructions.
mechanical cleaning procedures are used.
S Replace panels to the compressor.

Airend bearings Drive Box Filter Removal/Replacement

Airend bearings are lubricated by the compressor S Ensure compressor is electrically isolated for at
coolant and require no maintenance. least 15 minutes before commencing any
maintenance work.
S Unclip the front grill of the drive box filter.
High Airend Temperature Sensor checking S Remove the filter pad from the housing and
procedure replace with a new filter pad from Ingersoll–Rand.
It is recommended that the discharge temperature S Replace front grill to the drive box filter.
sensor (2ATT) is checked regularly as follows:
Aircooled machines Moisture Separator Check/Cleaning
Stop the cooling blower by opening the blower
S Ensure compressor is electrically isolated for at
motor circuit breaker.
least 15 minutes, before commencing any
Watercooled machines maintenance work.
Shut off the cooling water.
S Isolate the compressor from the system and fully
The machine should trip at 109_C (228_F). discharge the compressed air within the unit.
76 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S
 10.0 MAINTENANCE
S Remove plastic tube from the fitting located on the Fluid and Vibration Monitoring
bottom of the moisture separator.
Ingersoll–Rand recommends incorporating predictive
S Remove the bowl of the moisture trap, clean and maintenance, specifically the use of coolant and
replace. vibration analysis, into all Preventative Maintenance
programs. Predictive Maintenance is designed to
Condensate (Moisture) Drain Valve / Trap increase system reliability and prevent costly
downtime. Through the use of sophisticated
S Ensure compressor is electrically isolated for 15 diagnostic tools, including fluid, vibration, and
minutes and all pressure is relieved from system. optional air analysis, IR Certified Service Technicians
S Remove all pipes going to and from the valve (or can identify and correct potential problems BEFORE
trap). they can cause expensive unscheduled downtime.

S Disconnect any electrical cables to the valve (or How does predictive analysis work? By establishing
trap). an initial baseline for normal operation, and then
regularly monitoring fluid and vibration conditions,
S Determine the type of condensate drain device any sudden deviation or significant increase from this
and continue in the appropriate section below:– baseline can be identified and investigated to pinpoint
the cause. More quickly diagnosing potential
Timed Solenoid Drain Valves (where fitted) Check problems can directly save money by preventing
/ Cleaning costly failures and reducing or eliminating downtime.
In addition, regular condition monitoring also helps to
S Remove the central nut and then the electrical maximize the time between expensive preventative
coil. maintenance intervals, such as component rebuilds
S Remove screws holding bonnet of valve and and coolant changes.
carefully split the valve. Clean and inspect all
internal parts. Coolant Sampling Procedure
S Similarly check and clean the ball valve and Bring unit up to operating temperature. Draw sample,
needle valve. using pump kit, from separator tank port. DO NOT
draw sample from drain port or oil filter. Use a new
S Replace any defective parts as identified in parts hose on pump for each sample, failure to do this can
manual. give false readings.
S Re–assemble and later, with machine running,
check that condensate and air is expelled at
frequency and duration set into the INTELLISYS
controller (see section 9.6).

No Loss Drain Trap (where fitted) Check /

Cleaning
S Remove the four socket head screws then
carefully split the trap. Clean and inspect all
internal parts with particular attention to the water
level sensor(s).
S If the stainless steel strainer mesh is blocked,
remove it and clean in a weak detergent solution.
S Replace any defective parts (see parts manual for
repair kit).
S Re–assemble and later, with machine running,
check that condensate is expelled at regular
period and no alarms are signaled on trap or on
INTELLISYS display.

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 77

 11.0 FAULT FINDING

11.1 GENERAL FAULTS

WARNING
When attempting to identify and remedy any fault or failure, ensure it is only attempted by qualified personnel and that
the safety and maintenance sections of this manual have been read and are fully understood and followed. Major
overhauls should only be carried out by a qualified Ingersoll–Rand representative. Failures caused by fitting parts not
recommended by Ingersoll–Rand or non–authorized Ingersoll–Rand personnel may not be covered by the terms of
any warranty agreement

SYMPTOM FAULT REMEDY

Compressor will not No power supply to package Check supply is switched on. If so, contact a
start qualified electrician.
Intellisys controller failure Check supply to unit. Replace unit.
Starter failure Isolate supply, lock off and tag. Replace failed
component or contact your local Ingersoll–Rand
representative
Compressor stops and Drive controller has tripped See section 11.2 & 11.3
will not restart
Intellisys controller has tripped See section 11.2 & 11.3
the compressor
Maximum number of starts per
hour exceeded
Compressor is stopped Intellisys controller has tripped See section 11.2 & 11.3
and will not restart the compressor and has not
been reset
Emergency stop has been Identify reason why, repair fault, disengage button
pressed and not released and reset Intellisys controller
Emergency stop has been Repair fault and reset Intellisys controller
pressed and released but
Intellisys controller has not been
reset

78 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 11.0 FAULT FINDING

SYMPTOM FAULT REMEDY

Compressor will not Compressor not sized to meet Contact your local IR representative
meet pressure required system requirements or
by system requirements have been
changed.
Air loss due to pipe, hose, joint Overhaul or replace
or seal failure
Air loss due to blowdown valve Overhaul or replace
stuck open
Air loss through pressure relief Overhaul or replace
valve not seating or set
incorrectly
Air loss due to moisture Overhaul or replace
separator drain trap stuck open
Motor speed too low caused by Contact your local IR representative
drive incorrectly set
Motor speed too low caused by See section on drive faults
fault in drive settings
Intellysis controller fault Overhaul or replace
Drive motor fault See section on drive faults
Pressure transducer faulty, Recalibrate or replace
incorrectly calibrated or EMF
interference
Incorrect Intellisys controller Check and modify settings
settings
Inlet grill or ducting is blocked Check and clean
Air filter dirty or collapsed Replace
Inlet valve not opening fully Overhaul or replace
Separator element dirty or Replace
collapsed
Pipe / Hoses blocked or Clean or replace
collapsed
Cooler core blocked Clean or replace
Minimum pressure check valve Overhaul or replace
not functioning correctly
Equipment between compressor Review system requirements
and customer measuring point
causing pressure drop /
pressure loss

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 79

 11.0 FAULT FINDING

SYMPTOM FAULT REMEDY

Pressure produced by Intellisys set incorrectly Check and modify settings
compressor is too high
Pressure transducer may be Recalibrate or replace
due to speed not
faulty, incorrectly calibrated or
reducing as demand
not receiving pressure signal
reduces
Drive settings fault Contact your local IR representative
Compressor discharge High ambient temperature Review installation and system parameters
air too hot
Insufficient cooling air Check ducting and cooling air path, check direction of
blower rotation
Blocked aftercooler matrix Clean or replace
Compressor package Panels or doors are not closed Rectify fault
produces excessive properly
noise
Air leaks from internal pipework / Overhaul or replace
components
Blower or blower motor bearings Overhaul or replace
worn
Loose debris impacting on Remove and rectify any damage
blower during rotation
Blowdown valve stuck open Overhaul or replace
Pressure relief valve not seating Overhaul or replace
correctly
Vibration due to motor, airend or Overhaul or replace
blower imbalance
Airend requires overhaul Contact your local IR representative
Discharge air is Scavenge pipe is blocked, Clean or replace
contaminated with broken or o–ring is not sealing
coolant
Separator element is punctured, Replace
or incorrect, or requires
changing, or not sealing
correctly
Incorrect coolant has been Drain system, check for damage. Clean, refill with
added correct coolant.
System has been overfilled with Check for damage, drain excess.
coolant

80 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 11.0 FAULT FINDING

SYMPTOM FAULT REMEDY

Discharge air is Aftercooler not functioning Clean or replace
contaminated with correctly
condensate
Moisture separator drain trap Overhaul or replace
faulty
Continuous low speed / low Review system requirements and contact your local
ambient operation causing IR representative
condensate build up
Compressor package Compressor operating above Check and modify settings. Review system
draws too much current rated pressure requirements and contact your local IR representative
Separator filter element dirty or Replace
blocked
Voltage supply is low or Contact your local IR representative or a qualified
unbalanced electrician
Airend is damaged Contact your local IR representative
Excessive coolant Coolant system leak Overhaul or replace
consumption
See also ‘discharge air is See above
contaminated with coolant’

11.2 INTELLISYS FAULTS

(INDICATED ON THE INTELLISYS CONTROLLER)

FAULT CAUSE REMEDY

Emergency Stop Emergency stop button has Identify reason why, repair fault, disengage button
been pressed. and reset Intellisys controller
Blower motor overload Blower is blocked, damaged or Remove blockage, repair or replace damaged
blower motor is faulty. components
High airend discharge Compressor operating above Check and modify settings. Review system
temperature rated pressure requirements and contact your local IR representative
Low coolant level Check for leaks. See also ‘discharge air is
contaminated with coolant’. Top up coolant.
High ambient temperature Review installation and system parameters
Insufficient cooling air Check ducting and cooling air path.
Blocked coolant cooler matrix Clean or replace
Blower motor direction of rotation Wire correctly
incorrect
Check setpoints Controller software has been Recalibrate all sensors and check setpoints
changed

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 81

 11.0 FAULT FINDING

FAULT CAUSE REMEDY

Remote start failure Remote start button is pressed Check operation of buttons or operating procedures
after machine is running or
remote start button remains
closed.
Remote stop failure Remote stop button remains Check operation of buttons or operating procedures
open and either start button is
pressed
Sensor failure Sensor is missing or faulty Install, repair or replace faulty sensor
Compressor trips Insufficient cooling taking place If machine is watercooled or sea watercooled, check
indicating a high that the cooling water is flowing. Check that there is
compressor no air in the water cooling system. Check that the
temperature. strainer is not blocked.
Intellisys controller has A fault has occurred Repair fault / reset Intellisys controller
tripped the compressor
Invalid Calibration Calibration done with pressure in Depressurise and re calibrate with pressure pipe to
compressor. sensor disconnected. If fault still exists, replace
pressure transducer.
Low sump pressure System leak Located and repair
Minimum pressure check valve Repair with service kit
faulty
Blowdown valve faulty Repair with service kit
Loss of control power Check 110V circuit breaker
Check wiring
Check contactor KM1
Check motor rotation Drive system fault Contact your local IR representative
VSD communication Communication wiring faulty Check and replace if required
failure
Drive faulty Contact your local IR representative
Intellisys faulty Contact your local IR representative
VSD initialisation fault Communication wiring faulty Check and replace if required
Drive faulty Contact your local IR representative
Intellisys faulty Contact your local IR representative

82 IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S

 11.0 FAULT FINDING

11.3 DRIVE FAULTS

(INDICATED ON THE INTELLISYS CONTROLLER)

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

FAULT CAUSE ACTION

VSD Fault 1 Over–current Check separator element.
Check cooler, pipework and moisture separator for
blockages.
Check operation of minimum pressure check valve.
VSD Fault 3 Drive temperature too high Check drive filter, replace if necessary
Check drive cooling fan circuit breaker
Check wiring

IRN37–160K–CC & IRN50–200H–CC & IRN75–160K–2S & IRN100–200H–2S 83