60413.09.

45

80446164
Revision C
June 2013

Contact-Cooled Rotary Screw Air Compressor

R37-160 PRINT LANGUAGE NORWEGIAN HUNGARIAN

ENGLISH FINNISH LITHUANIAN

SPANISH PORTUGUESE LATVIAN

FRENCH GREEK POLISH

ITALIAN BULGARIAN MALTESE

GERMAN SLOVANIAN TURKISH

DUTCH SLOVAKIAN RUSSIAN

DANISH CZECH ROMANIAN

SWEDISH ESTONIAN

Product Information
EN Product Information SL Specifikacije izdelka
ES Especificaciones del producto SK Špecifikácie produktu
FR Spécifications du produit CS Specifikace výrobku
IT Specifiche prodotto ET Toote spetsifikatsioon
DE Technische Produktdaten HU A termék jellemzői
NL Productspecificaties LT Gaminio techniniai duomenys
DA Produktspecifikationer LV Ierices specifikacijas
SV Produktspecifikationer PL Dane techniczne narzędzia Rozmiar
NO Produktspesifikasjoner MT Prodott Informazzjoni
FI Tuote-erittely TU Ürün Bilgisi
PT Especificações do Produto RU Технические характеристики изделия
EL Προδιαγραφές προϊόντος RO Informaţii privind produsul
BG Информация за продукта

Save These Instructions

60413.09.45

EN

CONTENTS
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 OPERATING INSTRUCTIONS (XE SERIES CONTROLLER) . . . . . . .9
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

RECEIPT / HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 LED status icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Command keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Unpacking and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Navigation keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Display layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Folder navigation and icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Location in Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Page navigation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Discharge and Condensate Piping . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Accessing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Watercooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Dashboard icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Cooling Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Folder Options (Fixed Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Venting the water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Home folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Draining the water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operator settings folder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water quality recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Events folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Integrated Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Trip history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Environmental Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Maintenance folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

General settings folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Status folder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Integrated Dryer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Factory settings folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATING INSTRUCTIONS FOR VARIABLE SPEED DRIVE (VSD)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Folder Options (Variable Speed). . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Home folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Prior to starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operator settings folder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Initial check sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Events folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Start sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Trip history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Stop sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Warm up mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General settings folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Blower control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Status folder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Emergency stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Factory settings folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Restarting after emergency stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 NOTICES AND DISCLAIMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

80446164 Rev C EN-2

60413.09.45

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ABOUT THIS MANUAL

The purpose of this manual is to provide site planning, installation and operation guidelines for the compressor.
For supporting documentation refer to Table 1.
Table 1 : Product Manuals
Part/Document Number by Region
Publication Product
Americas EMEIA * Asia Pacific
Product Safety Information Manual All 80446313 80446156 80446321
Product Maintenance Manual All 80446354 80446248 80446362
R37-45 kW 80448095
R55-75 kW 80446271
Product Parts Information Manual
R132-160 kW Single-Stage 80446057
R90-160 kW Two-Stage 80446065
* Europe, Middle East and Africa
Product specification sheets and reference drawings are also available.

SAFETY
• Locate, read, understand and follow all Danger, Warning, Caution, and • It is your responsibility to make this information available to others.
Operating Instructions on the product and in all Manuals. Failure to
• If you have any questions about safety or procedures not included in
comply with safety precautions described in the manuals supplied with
this manual, ask your supervisor or contact any Ingersoll Rand office or
the product, this manual or any of the labels and tags attached to the
qualified Ingersoll Rand distributor.
product may result in death, serious injury or property damage.
• Check that all labels, tags and data (name) plates are in place and legible.

RECEIPT / HANDLING

 Receipt  Unpacking and Handling

Before signing the delivery receipt, inspect for damage and missing parts. If The compressor will normally be delivered with a polyethylene or other
damage or missing parts are apparent, make the appropriate notation on the cover. If a knife has to be used to remove this cover, ensure that the exterior
delivery receipt, then sign the receipt. Immediately contact the carrier for an paintwork of the compressor is not damaged.
inspection.
Incorporated within the base of the compressor are slots to enable a fork lift
All material shall be held in the receiving location for the carrier’s inspection. truck to move the compressor. Ensure truck forks are fully engaged on both
sides. Alternatively a special lifting frame can be used to enable a crane or
Delivery receipts that have been signed without a notation of damage or hoist to move the compressor. Use only marked lifting points.
missing parts are considered to be delivered “clear.” Subsequent claims are
then considered to be concealed damage claims. Settle damage claims Once the packaging and pallet are discarded and the compressor is in its
directly with the transportation company. final position, remove the yellow painted transit brackets from the resilient
mounts and store for future use or discard.
If you discover damage after receiving the compressor (concealed damage),
the carrier shall be notified within 15 days of receipt and an inspection shall For Variable Speed Drive (VSD)
be requested by telephone with confirmation in writing. On concealed • (3) brackets at the separator tank
damage claims, the burden of establishing that the compressor was
damaged in transit reverts back to the claimant. • (1) bracket from the air end discharge elbow.

Read the compressor nameplate to verify it is the model ordered, and read • (1) bracket from the air end support.
the motor nameplate to verify it is compatible with your electrical conditions. For Fixed Speed (FS)
Make sure electrical enclosures and components are appropriate for the • (3) brackets at the separator tank
installation environment.
• (1) bracket from the air end support.
• (1) bracket from the motor mounting bracket.

 Long Term Storage

If the product will not be commissioned within six months of receipt, it
should be prepared for long term storage. Please contact Ingersoll Rand for
details.

EN-3 80446164 Rev C

60413.09.45

EN

INSTALLATION
 Location in Plant
Figure 1 : Typical Air System

Key Discharge piping should be at least as large as the discharge connection

of the compressor. All piping and fittings should be suitably rated for the
1. Compressor discharge pressure. Discharge piping should not exert any unresolved
2. Air Receiver Dry Tank moments or force on the compressor.

3. Air Dryer It is good practice to install line filters (4).

4. Compressed Air Filters Include a vent or drain trap (6) to vent the discharge pipework downstream
from the minimum pressure check valve located on the separator tank and
5. System Demand Points upstream of the first system isolation valve (7).
6. Vent/Drain Trap This compressor has an internal discharge check valve. An external check
7. Isolation Valve valve is not required. An isolation valve (7) is required within 1 m (36 in) of the
compressor discharge.
8. Air Receiver (“Wet Tank”)
NOTICE
• The compressor can be installed on any level floor capable of supporting
it. A dry, well ventilated area where the atmosphere is as clean as possible There should be no plastic or PVC piping attached to this compressor
is recommended. or used for any lines down stream with exception of condensate
removal lines.
• The area selected for the location of the compressor should be free of
dust, chemicals, metal filings, paint fumes and overspray. NOTICE
• Hard surfaces may reflect noise with an apparent increase in the decibel level.
When sound transmission is important, a sheet of rubber or cork can be installed The discharged air contains a very small percentage of compressor
beneath the compressor to reduce noise. Flexible piping may be required. coolant and care should be taken to ensure that downstream
equipment is compatible.
• See the general arrangement drawing for minimum space requirements
for normal operation and maintenance.
When two rotary compressors are operated in parallel, provide an isolation
• Minimum space in front of the control panel door as required by national vaIve (7) and drain trap (6) for each compressor before the common receiver.
or local codes shall be maintained. Ensure the discharge piping is arranged to prevent water from being forced
• Ambient temperatures higher than 46 °C (115 °F) shall be avoided, as well into the non-operating compressor.
as areas of high humidity. A wet tank (8) is recommended in cases where the air dryer is a regenerative
desiccant type to prevent short cycling the compressor during the purging
cycle when plant air demand is slow.
NOTICE
The built-in aftercooler reduces the discharge air temperature below the dew
A minimum of 1 m (3.3 ft) all around the compressor is recommended. point (for most ambient conditions). Therefore, considerable water vapor is
If headroom is restricted, then the exhaust should be ducted or condensed. To remove this condensation, each compressor with a built-in
deflected away from the compressor. aftercooler is furnished with a combination condensate separator/trap.
Screw type compressors should not be installed in air systems with A dripleg assembly and isolation valve should be mounted near the
reciprocating compressors without means of isolation such as a common compressor discharge. A drain line should be connected to the condensate
receiver tank. It is recommended that both types of compressor be drain in the base.
piped to a common receiver tank using individual air lines.
NOTICE
The compressor is shipped with the shipping restraints in place.
Ensure that these are removed to allow free movement of the drive The drain line shall slope downward from the base to work properly.
assembly during operation. Each restraint is painted yellow. For ease of inspection of the automatic drain trap operation, the drain
piping should include an open funnel. The drain line must have a
minimum inside diameter of 8 mm (5/16 in)
 Discharge and Condensate Piping
See Figure 1. NOTICE
It is essential when installing a new compressor (1) to review the total air
system. This is to ensure a safe and effective total system. For low volume systems that may not include an air receiver tank (2),
compressor response time may need adjusting. Contact your local
One item which should be considered is liquid carryover. Installation of air Ingersoll Rand service provider.
dryers (3) is always good practice since, when properly selected and installed,
they can reduce any liquid carryover to zero.
NOTICE
An air receiver tank (2) is recommended to ensure that the total system
volume is sufficient. Do not use the compressor to support the discharge pipe.

80446164 Rev C EN-4

60413.09.45

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 Watercooled  Draining the water system

 Cooling Water Piping Should it become necessary to completely drain the water system, use the
following procedures specific to the water cooled option you have.
NOTICE Fresh water coolers (brazed plate heat exchangers):

Water piping to and from the compressor package shall be at least 1. Disconnect the inlet water line from the connection located at the rear
as large as the package connection size. Do not undersize the water of the compressor.
piping.
2. Disconnect the water stop valve in the water outlet line of the
Isolation valves with side drains should be installed on both the inlet and
compressor.
outlet lines. To maintain cooler cleanliness and reliability, it is important to
install a strainer of 2 mm mesh size on the inlet line. Strainers are available 3. Allow the system to completely drain.
from Ingersoll Rand.
Harsh water coolers (shell & tube heat exchangers):
For sea water applications (sea water option only) a zinc anode is not
recommended as it will deteriorate the copper oxide film on the 70/30 1. Disconnect the inlet and discharge water lines from the connections
copper-nickel alloy tubes in contact with sea water. To minimize galvanic located at the rear of the compressor.
corrosion and provide the greatest corrosion protection to the coolers, it
is strongly recommended that a section of iron pipe (>00 mm length) be 2. Locate the aftercooler and oil cooler. Remove the drain plugs located
connected as close as possible to the air compressor package water inlet at the bottom of the coolers.
connection. The iron pipe will act as the sacrificial anode for the copper-
nickel tubes and therefore shall be considered a regular maintenance and 3. Open the vent ports in the top of the aftercooler and oil cooler.
replacement item. For this reason, the section of iron pipe should be installed
so that it can be easily replaced (e.g. with a union joint.). 4. Allow the system to completely drain.

The air compressor has a normally closed solenoid valve that is fitted to Adjusting the aftercooler trim valve
the water outlet side within the package. The valve is wired into the air See the piping and instrumentation diagram provided separately from
compressor control circuit and closes when the compressor stops. this manual. The coolers are piped in a “parallel” water flow arrangement
Carefully inspect the water system before installing the air compressor with a manual trim valve controlling the flow through the aftercooler. The
package. Ensure that the piping is free of scale and deposits that may aftercooler trim valve is factory set and should not need adjusting but if
restrict water flow to the air compressor package. If water cleanliness is poor, disturbed use following procedure.
filtration installed on the water inlet pipe line is recommended. 1. Close valve fully clockwise and then open two full turns.
Proper operation of the compressor requires that the cooling water flow
2. With the compressor running loaded observe the package discharge
be provided at a maximum supply temperature of 46 °C (115 °F). See the
compressor engineering data sheets for cooling water flow rates. temperature on the controller display. It should be approximately 8 °C
(15 °F) above the water inlet temperature.
Water temperature and pressure gauges should be installed in the water
piping for use in any fault finding of the water system. Water pressure should 3. If the temperature is too high, open the valve ¼ turn and wait one
ideally be between and 5 bar (43 .5 and 72.5 psi) but shall not be above minute. If the temperature is too low, close the valve ¼ turn and wait
10 bar (145 psi).
one minute. Repeat the incremental movements until the desired
Water cleanliness is also extremely important. Cleaning of coolers as a result temperature is reached.
of fouling is a customer responsibility. Therefore, it is highly recommended
that proper water quality shall meet the requirements listed in WATER 4. Put a “Warning − Do Not Adjust” label on the valve or fit a lock.
QUALITY RECOMMENDATIONS later in this section.
 Water quality recommendations
 Venting the water system
Water quality is often overlooked when the cooling system of a watercooled
Air should be vented from the water side of the system to avoid poor air compressor is examined. Water quality determines how effective the
performance and water hammer. Since the air compressor uses different heat transfer rate, as well as the flow rate, will remain during the life of the
type heat exchangers depending on your selection of “fresh water cooled” compressor. It should be noted that the quality of water used in any cooling
or “harsh water cooled” system, the venting procedure is different. Be sure to system does not remain constant during the operation of the system.
use the correct procedure below: Evaporation, corrosion, chemical and temperature changes, aeration, scale
and biological formations affect the water makeup. Most problems in a
Fresh water coolers (brazed plate heat exchangers):
cooling system first appear as a reduction in the heat transfer rate, then in a
1. Disconnect the water stop valve in the water outlet line of the reduced flow rate or increased pressure drop, and finally with damage to the
compressor. system.

2. Open the inlet water valve(s) to allow the water to flow to the Scale: Scale formation inhibits effective heat transfer, yet it does help
prevent corrosion. Therefore, a thin uniform coating of calcium carbonate
compressor. is acceptable on the inner surface. Perhaps the largest contributor to scale
3. Allow all the air to escape from the system and observe water at the formation is the precipitation of calcium carbonate out of the water. This is
dependent on temperature and pH level. The higher the pH value, the greater
water outlet port. the chance of scale formation. Scale can be controlled with water treatment.
4. Connect the water stop valve. Corrosion: In contrast to scale formation is the problem of corrosion.
Chlorides cause problems because of their size and conductivity. Low pH
Harsh water coolers (shell and tube heat exchangers):
levels promote corrosion, as well as high levels of dissolved oxygen.
1. Locate the water system vent cocks on top of the aftercooler and oil
Fouling: Biological and organic substances (slime) can also cause problems,
cooler. but in elevated temperature environments such as cooling processes they
are not a major concern. If they create problems with clogging, commercial
2. Open the water valve(s) allowing water to flow to the package.
shock treatments are available.
3. Open the vent cocks and allow all air to escape from the system. When
water is observed at the vent cocks, close them.

EN-5 80446164 Rev C

60413.09.45

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To ensure good operation life and performance of the compressor cooling

system, the recommended acceptable ranges for different water constituents
are included below:

Table 3 : Acceptable Limits for Cooling Water Constituents

ACCEPTABLE MAXIMUM LIMITS

Substance Test Interval Fresh Water Dirty Water / Sea Water
(Brazed Plate Heat Exchanger) (Shell & Tube Heat Exchanger)
Langelier Index (LI) Monthly 0 to 1 -0.5 to 2.5
Ammonia [NH3 ], ppm Monthly <1 <2
Ammonium [NH4-1], ppm Monthly <2 <5
Chlorides [Cl-], ppm Monthly <80 <1000
Copper [Cu], ppm Weekly <0.01 <0.5
Dissolved Oxygen (DO) [O2], ppm Monthly <0.1 <3
Iron + Manganese [Fe + Mn], ppm Monthly <0.3 <2
Nitrate [NO3 -], ppm Monthly <100 <125
Oil & Grease, ppm Monthly <5 <5
Silicon Dioxide (silica) [SiO2], ppm Monthly <30 <100
Sulfates [SO4-2], ppm Monthly <70 <250

 Integrated Dryer  Environmental Limits

Do not connect condensate drains common to other pressurized drain The standard compressor package is designed for the following conditions:
lines in a closed circuit. Make sure the outflow from the condensate drains • Indoors only
is unimpeded. Connect the condensate piping in such a way to ensure that
sound levels are kept to a minimum during drainage. • Area not considered to be a high dust area.

Ensure that all condensate is disposed of in a responsible manner, in • Ambient temperature range 2 to 46 °C (5-115 °F)
compliance with all applicable standards and regulations (local, state, Ingersoll Rand offers the following options for fixed speed compressors that
country, federal, etc.). extend the environmental limits:
The ambient air around the dryer and compressor shall not contain solid • Outdoor modification
or gaseous contaminants. All compressed and condensed gases can
• Low ambient option (-23 to 46 °C / -15 to 115 °F) at sea level
generate acids or chemical products which may damage the compressor or
components inside the dryer. Take particular care with sulphur, ammonia, • High ambient option (2 to 55 °C / 5 to 13 1 °F) at sea level
chlorine and installations in marine environments. • High dust air filter
• High dust package filter

80446164 Rev C EN-6

60413.09.45

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GENERAL INFORMATION
The compressor is an electric motor driven, contact cooled screw compressor,
complete with all necessary components piped, wired and baseplate NOTICE
mounted. It is a totally self contained air compressor package.
Standard air compressors are factory filled with compressor coolant.
The standard compressor is designed to operate in an ambient range of 2 °C It is recommended to perform a coolant analysis every 2000 hours or
to 46 °C (35 °F to 115 °F). The standard maximum temperature of 46 °C 3 months to monitor condition and determine when to change the
(115 °F) is applicable up to an elevation of 1000 m (3280 ft) above sea level. coolant. If an analysis is not performed, the recommended coolant
Above this altitude, significant reductions in ambient temperature are change interval is 8000 hours or two years, whichever comes first.
required if a standard motor is to be used.
For compressors supplied with optional food grade coolant, it is
The compressor is managed by the onboard electronic controller. The recommended to perform a coolant analysis every 500 hours or every
controller and drive system operate together to vary the speed of the month to monitor condition and determine when to change the
compressor to deliver compressed air at the target pressure. coolant. If an analysis is not performed, the recommended coolant
For fixed speed (FS) models, the capacity is automatically controlled via change intervals is 2000 hours or six months, when utilizing the food
‘ON-OFF LINE’. The compressor will operate to maintain a set discharge line grade filter supplied with the compressor. For compressors running
pressure and is provided with an auto restart system for use in plants where food grade coolant without the food grade filter, the change interval
air demand varies widely. should be 1000 hours or three months, whichever comes first.

Panel instrumentation is provided to indicate the compressor operating NOTICE

conditions and general status.
Fixed speed compressors should not be connected to variable speed
The air/coolant mixture discharges from the compressor into the separation
drives. Please contact your local Ingersoll Rand representative before
system. This system removes all but a few ppm of the coolant from the
inverter duty conversion.
discharge air. The coolant is returned to the cooling system and the air passes
to the aftercooler and out of the compressor through the moisture separator.
Air is pulled into the compressor by the cooling blower and through the CAUTION
coolant cooler and aftercooler.
For fixed speed models, the compressor may not reach its normal
By cooling the discharge air, much of the water vapor naturally contained in operating temperature during periods of low demand. Sustained
the air is condensed and is drained from the built-in moisture separator and operation at low demand can result in the buildup of condensate in
drain. the coolant. If this situation occurs, the lubricating characteristics
of the coolant can be impaired, which may lead to damage of the
The coolant system consists of a sump, cooler, thermostatic valve and a
compressor.
filter. When the compressor is operating, coolant is forced by air pressure
from the separator tank to the thermostatic element. The position of the The compressor should be allowed ample loading time.
element (a direct result of coolant temperature) will determine whether the
coolant circulates through the cooler, bypasses the cooler, or mixes the two
paths together to maintain an optimum compressor discharge temperature.  Integrated Dryer Operation
This temperature is controlled to preclude the possibility of water vapor
In the default mode, the dryer is non-cycling. The stop button must be
condensing. By injecting coolant at a sufficiently high temperature, the
pressed to shut off the dryer.
discharge air coolant mixture temperature will be kept above the dew point.
In the energy efficient mode, the dryer may run up to 6 minutes before
For variable speed drive models, the system is enhanced by a control logic
it shuts off automatically during the Start/Stop mode of the compressor
that varies the cooling blower speed dependent on the intake and discharge
package. Note the dryer could be off for an extended period if the
temperatures and hence controls the injection temperature even closer while
compressor needs to come back on right away.
saving blower motor energy.
The compressor is provided with a temperature sensor which will shut the NOTICE
compressor down in case of excessive temperature. This setting is typically
109 °C (228 °F). If ISO Class 4 dew point standards are critical to your application,
run the compressor in unload mode (fixed speed) or idle mode
Effective coolant filtration is provided by the use of a screw on, heavy duty (variable speed) for one minute at startup to allow the dryer to reach
coolant filter. the required dew point before the compressor begins providing
compressed air.

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OPERATING INSTRUCTIONS FOR VARIABLE SPEED DRIVE (VSD)

 Basic Operation  Stop sequence
The compressor can be stopped by a local or remote stop, a shutdown due
NOTICE
to a trip, or an emergency stop. All of the above conditions will cause the
The language and compressors of measure displayed on the controller compressor to stop immediately, except the local or remote stop. A local or
will be preset before leaving the factory. If these are required to be remote stop will open the blowdown valve and the compressor will run for
changed, contact your local Ingersoll Rand service provider. up to 10 seconds or until the pressure in the separator tank falls to 2.4 bar
(35 psi) before stopping. The compressor will stop if the system pressure
reaches the automatic stop or immediate stop pressure setpoints. However,
 Prior to starting if the compressor stops for this reason, it will automatically restart when the
system pressure falls below the target pressure.
Check that the coolant level is at least visible in the center of the sight glass
and add coolant if necessary. Refer to the maintenance procedures for setting
the correct level.
NOTICE

Ensure that the discharge air isolation valve is open. Switch on the main If the compressor has to be stopped in an emergency depress the
electrical isolation switch. The control panel will illuminate, indicating that emergency stop button located underneath the instrument panel.
the line and control voltages are available.
The contrast of the SG controller display may be adjusted by turning the  Warm up mode
small screw which is on the right hand side of the controller when accessed A warm up cycle occurs when the compressor’s airend discharge temperature
through the starter cabinet door. doesn’t reach the required warm up temperature (82°C/180°F) for two
 Initial check sequence consecutive operational cycles. On a warm up cycle, instead of stopping,
the compressor will continue to run with the blowdown valve open.
The controller will perform an initial check sequence if the compressor The compressor will run in a fixed speed mode, at minimum speed. The
receives initial power to the controller or has experienced an trip reset. While blower will operate at minimum speed. The compressor will run like this
the initial check sequence occurs, the controller will display a “Checking for approximately five minutes. During a warm up cycle, the controller will
Machine” message. display the message “Warm Up Mode”. If the pressure falls during this time
period, the compressor will return to normal operation.
During the initial check sequence, the controller will check the control system
for proper operation. During this time, if any items are found inoperative, a  Blower control
trip will occur and the compressor will not start.
The blower speed varies in some conditions to assist in controlling the
After completion of the initial check sequence, the controller will then display aftercooler approach temperature and the coolant injection temperature. The
“READY TO START’. This process should be completed within 10 seconds. blower motor has its own variable speed drive and will ramp up and down as
the compressor starts and stops.
 Start sequence
The compressor will initially start by the operator pressing the local start
 Emergency stopping
button or receiving a remote start command. The compressor will start If the compressor has to be stopped in an emergency press the emergency
loaded and will ramp up the motor speed to its minimum speed. Once the stop button located underneath the instrument panel.
minimum speed has been achieved, the compressor will begin to control
pressure by using its speed regulation. When the system pressure reaches This will over-ride the normal unload/stop button and will immediately stop
the target pressure, the compressor will start to slow. If the system pressure the compressor.
rises to the immediate stop pressure setpoint the compressor will stop. If
 Restarting after emergency stopping
the system pressure rises to the auto stop setpoint and the compressor is at
minimum speed, the compressor will stop. If the compressor has been switched off because of a compressor
malfunction, identify and correct the fault before attempting to restart.

NOTICE If the compressor has been switched off for reasons of safety, ensure that the
compressor can be operated safely before restarting.
During the first startup of the compressor, check for the proper
Refer to the PRIOR TO STARTING and START SEQUENCE instructions earlier in
direction of rotation of the dryer condenser fan. If the fan is not
this section before restarting the compressor.
rotating in the direction indicated by the rotation arrow decal, reverse
two of the wires at the main power supply or at the contactor in the
package starter box. Perform the proper stop sequence and lockout/
tagout the main electrical supply before making changes to the
wiring.

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OPERATING INSTRUCTIONS (XE SERIES CONTROLLER)

 User Interface Icon Name Function
The standard user interface configuration of the controller consists of the Start Starts the compressor.
membrane and the LCD display. The membrane consists of five command
keys (START, STOP, LOAD, UNLOAD, and RESET), four navigation keys (UP,
RIGHT, LEFT and DOWN), and an Edit mode selection key (ENTER). These keys,
the color graphics display and the LED icons make up the user interface to Stop Stops the compressor. This button should be
the compressor.
pressed instead of the E-Stop for normal stopping
Figure 33 : Controller Interface operation.

Enter Toggles the display between the Navigation mode

and the Edit mode.

NOTICE

The LOAD and UNLOAD keys are not used on variable speed
compressors.

 Navigation keys
There are four navigation keys (UP, RIGHT, DOWN and LEFT). While the ENTER
key is not considered a navigation key, it is used in conjunction with the
navigation keys to make or confirm a selection.
 LED status icons
Figure 34 : Navigation Keys
Three LED icons are used to indicate the current status of the control system
from a distance and are located on the upper left side of the user interface.
Table 9 : LED Status Icons

Icon Name Function

OK Illuminates when no Warnings or Trips are sensed.
Can be in a Ready or Not Ready state.

Pressing one of the navigation keys will lead the user down a navigation path.
Alert Illuminates when an Warning (flashes) or Trip
Each time the key is pressed, another step in the path is taken. Once the end
(constant on) is sensed. Can be in a Ready of a navigation path is reached, pressing the key one more time will bring the
(Warning) or Not Ready (Trip) state. user back to the beginning of the path. Pressing the opposite key, will move
the user through the navigation path in the opposite direction. Once the
Auto Illuminates when the compressor stops in auto
beginning is reached, pressing the opposite key will take the user to the end
restart. of the path.

 Display layout
 Command keys Figure 35 : Display Layout
These keys command the controller to perform actions as specified in the
following table. When any of these keys are pressed the action below will be
initiated and logged in the event log.
Table 10 : Command Keys

Icon Name Function

--- None

Load Puts the compressor into the selected mode of

operation. Unit will load if the pressure conditions
are right.

Unload Puts the compressor into an unloaded state. Unit

Table 11 : Display Layout
will run unloaded.
Key Name Description
A Folder Bar Uses tabs to graphically identify each folder.
Reset Clears Warnings and Trips once the condition is
B Title Bar Identifies current folder and page (underlined).
corrected.
C Page Content Content of the current page.
D Dashboard Displays system status.

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 Folder navigation and icons Figure 36 : Numeric Entry Window

To move among the tabbed folders shown on the LCD display, press the
RIGHT and LEFT keys. The navigation rolls over from the last to the first folder
and vice-versa.
Table 12 : Folder Bar Icons

Folder Icon Description

Name
Home System performance and status main
information. The first page of this folder is the
default page when the controller first powers up. NOTICE
Operator System options and configuration settings. Not all pages have adjustable parameters. Some just have read-only
Settings information.
Events System events log.
 Dashboard icons

Trip History Details on the most recent trips. The dashboard is intended to be a quick at-a-glance view of system status.
The following table lists standard dashboard icons and their definition.
Note that the color of these icons changes based on the state set by the
Graphing On-board graphing of system data. (Optional for application while running.
some controllers)
Table 14 : Dashboard Icons
Maintenance Status and notification setup for compressor
maintenance items. Name Icon Description
General General settings such as Language, Time, and Network Network control is enabled.
Settings Units of Measure. Control

Integral Inter Module communication status and Service A service reminder is nearing or has expired
Sequencing configuration. Required (i.e.: an air or oil filter needs to be changed).

Status Measurements or status from/of all analog and Unloaded Compressor is in the unloaded state.
digital I/O. or

Factory Compressor tuning parameters. Also displays Loaded Compressor is in the loaded state.
Settings hardware and software versions.

 Page navigation  Folder Options (Fixed Speed)

Once the desired folder is selected, press the DOWN key to move to the page
selection area and then use the RIGHT and LEFT keys to select the desired  Home folder
page. Use the UP key to get back to the folder tabs.
Page 1: System Overview
Table 13 : Title Bar Page Icons
Figure 37 : Home Folder
Icon Description
Start of the page selection area.

Indicates that there are more pages available by navigating

right.

Indicates that there are more pages available by navigating

left.

 Accessing parameters
After the desired page is selected, the page’s parameters can be selected by
using the DOWN key. The cursor will move to the next parameter each time
the DOWN key is pressed. Use the UP key to go back to the previous one.
This is the factory default display after powering up the system.
The cursor rolls over, so once the last parameter is selected, pressing the
• Online Pressure Setpoint is indicated in the white box and by the white
DOWN key will navigate the cursor to the folder bar. If the first parameter is
arrow, which is always left of center on the gauge.
selected, pressing the UP key will move the cursor to the page selection area.
• Offline Pressure Setpoint is indicated in the white box and by the white
Once selected, access parameters by pressing the ENTER key. Make changes
arrow, which is always right of center on the gauge.
using the navigation keys and then enter the setting by pressing the ENTER
key again. After a parameter is accessed, pressing the ENTER key will enter • Package Discharge Pressure is indicated by the large numbers centered
the current setting into the control program and navigate the cursor back to below the gauge and by the red arrow.
the selected parameter on the page. • Pressure Unit of Measure is indicated below the Package Discharge
When the cursor is on a parameter that has an enabled/disabled box, Pressure. This is selectable from the General Settings folder.
pressing the ENTER key will cause the setting to toggle. • Airend Discharge Temperature is indicated by the numbers in the lower
This “X” icon appears on numeric entry windows as shown below. Placing the left of the display.
cursor on it and then pressing the ENTER key will cancel the entry and any • Temperature Unit of Measure is indicated to the right of the Airend
changes that were made. Discharge Temperature. This is selectable from the General Settings folder.

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• Run Hours indicate the number of hours the compressor has been • Coolant Filter Pressure Drop
running.
• Inlet Vacuum
• Aftercooler Discharge Pressure (integrated dryer compressors only)
NOTICE
• Remote Pressure (optional)
The online and offline set points can be selected and modified on this
page. All other information on this page is read only.
 Operator settings folder
Page 2 : Counters Pages 1-2: Operator Settings
Figure 38 : Counters Figure 40 : Operator Settings

• Hour Meters indicate the hours that: the controller has been powered
Table 15 : Operator Settings
up, the compressor has been running, and the compressor has running
loaded.
Operator Selection Min. Max. Default Step Unit
• Starts indicate the number of times a start is attempted on the Settings
compressor.
Offline --- 75 Rated+10 Rated+10 1 psi
• Date & Time is adjustable and configurable in the General Settings folder. Pressure

Pages 3-4: Analog Inputs Online --- 65 Offline-10 Offline-10 1 psi

Pressure
Figure 39 : Analog Inputs
Lead/Lag Lead/Lag --- --- Lead --- ---
Lag Offset --- 0 45 0 1 psi
Mode of Mode --- --- On/off line --- ---
Operation
Condensate --- 2 20 5 1 sec
Release
Condensate --- 90 270 180 1 sec
Interval
Stop Delay --- 10 30 10 1 sec
Time
Star-Delta --- 5 30 10 1 sec
Time / Start
Time
Pages 3-5: Operator Options
Icon Meaning Figure 41 : Operator Options
Pressure

Temperature

NOTICE

All information on these pages is read only.

The following inputs are displayed in this section:

• Package Discharge Pressure
• Sump Pressure
• Airend Discharge Temperature
• Injected Coolant Temperature
• Aftercooler Discharge Temperature
• Separator Pressure Drop

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Table 16 : Operator Options

Operator Options Selection Min. Max. Def. Step Unit Installed option
required?
Enable Auto Restart ON/OFF --- --- Off --- --- No
Auto Restart Time --- 2 60 10 1 min No
Auto Restart Delay --- 0 60 0 1 sec No
Comm Control ON/OFF --- --- Off --- --- No
Remote Start/Stop ON/OFF --- --- Off --- --- No
Power Out Restart ON/OFF --- --- Off --- --- Yes
Power Out Restart Time --- 10 600 10 1 sec Yes
Low Ambient Temp* --- 30 60 35 1 degF No
Lead/Lag Cycle Time** --- 0 750 0 1 hours No
Scheduled Start - Day --- Day Day Sun 1 day Yes
Scheduled Start --- 00:00 23:59 00:00 1 time Yes
Scheduled Stop - Day --- Day Day Sun 1 day Yes
Scheduled Stop --- 00:00 23:59 00:00 1 time Yes
High Dust Filter ON/OFF --- --- Off --- --- Yes
Remote Sensor ON/OFF --- --- Off --- --- Yes
* The low ambient temperature is only adjustable if the low ambient factory set point is on.
** A value of 0 will disable the lead/lag cycle time feature.
Pages 6-7: Sensor Calibration
Figure 42 : Sensor Calibration  Events folder
Pages 1-42 (max.)
Figure 43 : Events Folder

Sensor calibration can only take place when the compressor is stopped.
There should be no pressure on a sensor when it is calibrated. Calibration
only needs to take place after a sensor is replaced, the controller is replaced,
or the operator suspects the sensor reading is in error. Calibrate a sensor by The pages in the Events folder document up to the last 250 events that the
selecting the checkbox beside the sensor name. controller has experienced, and time stamps each. The events are recorded
in sequence, with number one being the newest and 250 being the oldest.
Each of the sensors listed below can be calibrated: When a new event occurs, it becomes number one and all others are shifted
• Inlet Vacuum (1AVPT) up in number.
• Sump Pressure (3APT) The page numbers in the Title Bar are used to scroll through the events, with
• Package Discharge Pressure (4APT) each page displaying up to seven. Page one displays events one through six,
page two displays seven through twelve, and so on.
• Coolant Filter Inlet Pressure (5CPT)
The following items will generate an event:
• Coolant Filter Outlet Pressure (6CPT)
• Power On
• Remote Pressure (10APT) – Only on compressors with the remote sensor
option • Power Off

• Interstage Pressure (2APT) – Only on 2-stage compressors • Press the Start Key

• Aftercooler Discharge Pressure (7APT) – Only on compressors with • Press the Stop Key
integrated dryer • Press the Load Key
Please note that if a sensor is currently reading a value that is +/- 10% of • Press the Unload Key
its range from zero, the sensor will not be able to be calibrated. Please • Warning
make sure the sensor is being exposed to atmosphere before attempting
calibration. • Trip
• Start Inhibit

Active Warnings will be highlighted in amber while cleared Warnings will

have amber text.

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Active Trips will be highlighted in red while cleared Trips will have red text. equal to the service time period set point. However, 100 hours before this
a “100 HOURS TO SERVICE” warning will occur. This warning can be reset
Active Start Inhibits will be listed in the Event log, but not highlighted. The
the same as any other warning. One hundred hours later the “SERVICE
display will indicate the compressor is not ready to start if a start inhibit is
REQUIRED” warning will occur. This warning can be reset the same as any
active.
other warning, however this warning will return in 24 hours if the service
See the following lists for details about messages in each type of event. complete factory set point has not be set. If the service complete has not
been set, 100 hours later, the “ALARM – SERVICE REQUIRED” warning will be
Warning Events List issued. This warning can only be cleared by the service complete factory
Change Inlet Filter set point. Once the service complete factory set point is set, indicating the
service is completed, the time for the next “SERVICE REQUIRED” warning will
Will occur if 1AVPT is greater than 0.7 psi vacuum (or 1.3 psi vacuum if the be calculated by adding the service time period to the total hours value, with
high dust filter option is enabled) and the compressor has been loaded for at the “100 HOURS TO SERVICE” warning occurring 100 hours before and the
least 8 seconds. This condition must exist for 3 seconds before the warning “ALARM – SERVICE REQUIRED” warning occurring 100 hours after that time.
is issued.
Communication Failure
Change Coolant Filter
This will occur if the compressor is the lead compressor in integral
This will occur if the compressor has been running loaded for at least 8 sequencing and is unable to communicate with another compressor.
seconds, is warmed up, and the coolant filter pressure drop (5CPT - 6CPT)
is greater than 25 psi. This condition must exist for 3 seconds before the Sensor Failure 10APT – Remote Sensor
warning is issued. This will occur if the remote sensor option is on and the remote sensor
Sensor Failure is recognized as missing or broken. If this occurs, the compressor will
automatically start using 4APT for loading and unloading the compressor.
This will occur whenever sensors 4ATT, 5DTT, 6DTT, and 7APT are recognized Units equipped with an integrated dryer cannot have a remote pressure
as missing or broken. The sensor failure message shall follow the following sensor. This condition must exist for 3 seconds before the warning is issued.
format: SENSOR FAILURE 4ATT. The 5DTT, 6DTT, and 7APT sensor failures will
be shown only when the integrated dryer is installed (accessed in the factory High Discharge Pressure
settings menu). This condition must exist for 3 seconds before the warning Will occur if the compressor is using a remote sensor or is under the control
is issued. of an external device, such as an 8XI, is loaded, and the discharge pressure
Change Separator Element (4APT) is greater than the maximum offline pressure. This condition must
exist for 3 seconds before the warning is issued. If this condition occurs, the
Will occur if the compressor is loaded, the compressor is warmed up (the compressor will automatically unload. The compressor will be available to
injected coolant temperature is at least 120 °F), the package discharge reload once the discharge pressure falls to the rated pressure value.
pressure is at least 90 psi, and the separator pressure drop is greater than
12 psi. This condition must exist for 3 seconds before the warning is issued. Condensate Drain Error

High Airend Discharge Temperature This will occur if the compressor is running, the package discharge pressure is
over 50 psi, and the condensate drain error contact closes for at least
Will occur if the compressor is running and 2ATT is greater than 221 °F (97% 240 seconds. This warning will be ignored for 4.5 minutes after starting.
of 228) and the compressor is running. This condition must exist for
3 seconds before the warning is issued. Freeze Warning

High Sump Pressure This will occur if the evaporator sensor has a value of 687 (about 0.5 C)
or below (low temp) while the dryer is running, on compressors with the
If the compressor is running loaded, has been loaded for at least 8 seconds integrated dryer. This is a dryer fault. If this happens, the compressor will
and the sump pressure is more than 25 psi above the rated pressure for the continue to run, but the dryer will stop. The condition must exist for at least
compressor. If this warning occurs, the online and offline pressures will be 180 seconds before the warning will occur. NOTE: If this warning is reset
reduced. For example, a rated pressure of 100 psi would have a maximum while the conditions for running the dryer exist, the dryer can restart. Also the
offline pressure of 110 psi. This warning would occur if the sump pressure dryer can restart if the evaporator value rises to 709 (about 5 C). However the
goes above 125 psi in this example. This condition must exist for 3 seconds warning will still be displayed.
before the warning is issued.
Dryer High Pressure
Auxiliary 1
On compressors with the integrated dryer, this will occur if the dryer high
This will occur if auxiliary input 1 closes. The contact must be closed for at pressure switch opens while the dryer is running. This is a dryer fault. If this
least 3 seconds before the warning will occur. happens, the compressor will continue to run, but the dryer will stop. The
contact must be open for at least 3 seconds before the warning will occur.
Auxiliary 2
If this warning is reset while the conditions for running the dryer exist, the
This will occur if auxiliary input 2 closes. The contact must be closed for at dryer can restart. However, this switch is a locking switch. The switch must be
least 3 seconds before the warning will occur. reset before the dryer can run. Resetting the warning on the display does not
reset the switch.
Service
Condenser Temperature High
Service warnings occur when the compressor has operated a certain number
of hours, based on the total hours. Service warnings can have multiple This will occur if the condenser sensor has a value above high temperature
levels, depending on the service level selection. A service level selection of 0 threshold while the dryer is running, on compressors with the integrated
disables service warnings. dryer. This is not a dryer fault. If this happens, the compressor and dryer will
continue to run. The condition must exist for at least 180 seconds before the
Service Level 1 warning will occur.
If service level 1 has been selected for the compressor, a “SERVICE REQUIRED” Condenser Temperature Low
warning will be issued on hour intervals equal to the service time period set
point. This warning can be reset the same as any other warning. This will occur if the condenser sensor has a value below the low temperature
threshold while the dryer is running, on compressors with the integrated
Service Level 2 dryer. This is not a dryer fault. If this happens, the compressor and dryer will
If service level 2 has been selected for the compressor, the service complete continue to run. The condition must exist for at least 180 seconds before the
factory set point will be used to clear a level 2 service warning and reset warning will occur.
the service time or date. The service complete can be reset before a service Change HE Filter
warning occurs.
The HE filter is located between the aftercooler discharge and the inlet to the
The initial “SERVICE REQUIRED” warning will occur at total hour intervals dryer and is only on compressors with an integrated dryer. The drop across

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the HE filter is measured by subtracting the package discharge pressure this fault occurs, the operator can reset it and start the compressor. This fault
from the aftercooler discharge pressure. If the compressor is running, will be logged in the trip history to indicate that the compressor is being
the measured drop across the HE filter is at or above 10 psi (0.7 bar), the started in low ambient conditions.
compressor is hot (injected coolant temp above 120 °F), and the package
discharge pressure (4APT) is above 90 psi, this warning can occur. The High Interstage Pressure
condition must exist for at least 3 seconds before the warning will occur. This This will occur if the compressor is running and the interstage pressure
is not a dryer fault. If this happens, the warning will be displayed, but the (2APT) is greater than 75 psi. This trip will only occur in 2 stage compressors.
dryer will continue to run.
Invalid Calibration
Trip Events List
Will occur if the sensor zero value is +/- 10% of its scale. This will only occur
Low Sump Pressure when a sensor is calibrated.
Will occur if the compressor is running unloaded or loaded and 3APT is less Start Inhibit List
than 13 psi for 15 seconds.
High Airend Discharge Temperature
High Airend Discharge Temperature
This will occur if 2ATT is greater than 95% of 228 °F.
This will occur if 2ATT is greater than 228 °F and the compressor is running.
High Sump Pressure
Check Motor Rotation
This will occur if the sump pressure (3APT) is 25 psi or higher than the rated
This will occur if 3APT is less than 1 psi on a compressor, 3 seconds after pressure of the compressor.
starting (6 seconds if the compressor is equipped with a soft starter or airend
discharge temperature is less than 50 °F). This condition can be caused by
the motor running in reverse. Once correct motor rotation is established, this  Trip history
trip will not be checked again unless power is removed from the controller.
Pages 1-4 (max.)
Main Motor Overload
Figure 44 : Trip History
This will occur if the motor overload relay contact opens. The contact must
be open for at least 3 seconds before the trip will occur.
Fan Motor Overload
Will occur if a fan motor overload relay contact opens. The contact must be
open for at least 3 seconds before the trip will occur.
Remote Stop Failure
Will occur if the remote start/stop option is enabled, the remote stop button
remains open and either start button is pressed.
Remote Start Failure
Will occur if the remote start/stop option is enabled, the compressor is
started by the remote start button, and the button stays closed for 7 seconds
after the compressor starts.
Sensor Failure The pages in the Trip History folder document up to the last 15 trips that the
This will occur when a sensor is recognized as missing or broken. The sensors controller has experienced, and time stamps each. The trips are recorded in
affected by this trip are 1AVPT, 3APT, 4APT, 5CPT, 6CPT, 2APT (if 2 stage sequence, with number one being the newest and 15 being the oldest. When
compressor), 2CTT, and 2ATT. The sensor should be displayed along with the a new trip occurs, it becomes number one and all others are shifted up in
sensor failure message. The sensor failure message shall follow the following number.
format: SENSOR FAILURE 1AVPT. The page numbers in the Title Bar are used to scroll through the events, with
Emergency Stop each page displaying up to seven. Page one displays events one through five,
page two displays six through ten, and so on.
This will occur when the emergency stop button is engaged.
The following items will generate an event.
High Sump Pressure
• Power On
This will occur if the compressor is running loaded for at least 8 seconds, and • Power Off
any one of the 3 following conditions exist. (1) The sump pressure is above
the rated pressure by 35 psi. (2) The separator pressure drop is measured to • Press the Start Key
be more than 25 psi and the package discharge pressure at least equal to the • Press the Stop Key
minimum online set point value. (3) The sump pressure is above 165 psi if the
rated pressure is less than 190 psi or the sump pressure is above 220 if the • Press the Load Key
rated pressure is 190 psi. • Press the Unload Key
High Coolant Filter Pressure Drop • Warning
This will occur if the compressor has been running loaded for at least 8 • Trip
seconds, is warmed up, already has a change coolant filter warning, and the
• Start Inhibit
coolant filter pressure drop (5CPT - 6CPT) is greater than 35 psi.
High Inlet Vacuum Active Trips will be highlighted in red while cleared Trips will have red text.

This will occur if the compressor is running loaded and the inlet vacuum is The trip history also records compressor data at the time of the trip to assist
greater than 1.8 psi. If the compressor has a high dust filter, the trip threshold in diagnostics and troubleshooting. Navigating to the trip entry and hitting
for inlet vacuum is 2.4 psi. the enter button will bring up the trip history dialog box.

Unit Too Cold To Start

This will occur if the compressor does not have the low ambient option,
the airend discharge temperature (2ATT) is less than 35 °F, and the operator
attempts to start the compressor. This fault can only occur once a day. Once

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Figure 45 : Trip History Dialog

This page allows the user to set the service interval and to reset the counter
While the dialog box is active, press the left and right keys in order to scroll after the service has been performed.
through the displayed data. The name of the trip will always be shown in
the title bar of the dialog box. Press enter when finished viewing the data to
return to the trip history screen.  General settings folder

 Maintenance folder NOTICE

Page 1: Filter Status
All parameters in this folder are adjustable.
Figure 46 : Filter Status
Page 1: Language Selection
Figure 49 : Language Selection

This page displays the following:

• Coolant Filter Status
• Separator Element Status
Language is selectable from the following 30 choices:
• Inlet Filter Status
• English (default) • Korean
Page 2: Maintenance Status
• Bulgarian • Latvian
Figure 47 : Maintenance Status
• Chinese, simplified • Lithuanian
• Croatian • Maltese
• Czech • Norwegian
• Danish • Polish
• Dutch • Portuguese
• Estonian • Romanian
• Finish • Russian
• French • Slovak
• German • Slovenian
• Greek • Spanish
• Hungarian • Swedish
• Italian • Thai
This page displays the time until the compressor should be serviced.
• Indonesian • Turkish
Page 3: Maintenance Configuration
Figure 48 : Maintenance Configuration

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The controller will display all screens in the selected language and only one Figure 52 : Time & Date Settings
language can be selected at a time.
Each language appears in its native translation.
Page 1: Units of Measure Settings
Figure 50 : Units of Measure Settings

All items are adjustable.

The following settings are displayed in this section:
Table 19 : Time & Date Settings
The following compressors of measure settings are displayed in this section.
Display Text Description
Table 17 : Units of Measure Settings
Hours Allows the current hour to be set. The hours format is
Display Text Description fixed on 24-hour.
Temperature Selectable between °F and °C. Minutes Allows current minutes to be set.
Pressure Selectable among psi, kpa, bar, kg/cm2. Seconds Allows current seconds to be set.
Power Selectable between kW and HP. Year Allows current year to be set.
Page 3: Home Page Selection Month Allows current month to be set.

Figure 51 : Home Page Selection Day Allows current day to be set.

Date Format Selectable between dd/mm/yyyy (default) and mm/dd/
yyyy.
Confirm New Used to verify that changes to selections are desired. An
Time and Date “x” must appear in the checkbox before any changes will
take affect.
The controller will continue to display any changes, even when the selections
have not been confirmed and the user exits the page, then returns. Cycling of
the power returns all selections to their current settings.

NOTICE

The controller does not support Daylight Savings Time.

Page 6: Backlight Settings

Table 18 : Home Page Selection Figure 53 : Backlight Settings

Display Text Description

Auto Return to Enables the controller to return the display back to the
Home selected Home Page if there is no user activity for the
Delay Time shown. This is only enabled when an “x”
appears in the checkbox.
Delay Time Determines how many seconds of inactivity it will take
before the controller will return to the Home Page.
Select Home Used to select the Home folder.
Folder
Select Home Used to select the Home Page within the selected Home
Page folder.

Pages 4-5: Time & Date Settings

The following settings are displayed in this section:

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Table 20 : Backlight Settings

 Status folder
Display Text Description
Backlight Adjusts the brightness of the display. NOTICE
Brightness
All information on these pages is read only.
Enable Backlight Enables the controller to shut-off the backlight if
Auto-Off there is no user activity for the delay time shown.
Pages 1-3: Analog Inputs
Backlight Auto-Off Determines how many seconds of inactivity it will
Delay Time take before the controller will shut-off the backlight. Figure 55 : Analog Inputs

NOTICE

The backlight will be switched on whenever any of the controller’s

keys are pressed.
The START, STOP, LOAD, UNLOAD, RESET, and ACKNOWLEDGE keys on
the controller remain functional while the backlight is switched off. It
is recommended to press the ENTER key or one of the navigation keys
in order to switch the backlight on.

Pages 7-8: Ethernet Settings

Figure 54 : Ethernet Settings

The following inputs are displayed in this section:

• Package Discharge Pressure
• Sump Pressure
• Airend Discharge Temperature
• Injected Coolant Temperature
• Aftercooler Discharge Temperature
• Separator Pressure Drop
• Coolant Filter Pressure Drop
• Inlet Vacuum
• Aftercooler Discharge Pressure (integrated dryer compressors only)
• Remote Pressure (optional)
Table 21 : Ethernet Settings • Coolant Filter Inlet Pressure
Display Text Description • Coolant Filter Outlet Pressure
Enable Ethernet Allow connection by users to utilize the • Interstage Pressure (2-stage compressors only)
network enabled functionality of the controller • Evaporator
Enable DHCP Allow the controller to automatically receive an • Condenser
IP address from the Local Area Network (LAN)
Page 4: Compressor Data
IP Address Setting When DHCP is not enabled, this setpoint sets
the IP address of the controller. Figure 56 : Compressor Data
IP Address Actual This will match the IP address setting when
DHCP is not enabled. If DHCP is enabled
this will display the address assigned to the
controller by the DHCP server.
MAC Address This is the unique hardware MAC address for
the controller. This can not be changed.
Subnet Mask Setting Setpoint for the subnet mask
Subnet Mask Actual Current reading/setting for the subnet mask
Default Gateway Setting Setpoint for the default gateway.
Default Gateway Actual Current reading/setting for the default gateway.
Accept After editing the desired setpoint navigate
to the accept setting and press enter in order
for the values in the setting variables to be
confirmed by the controller.
Cancel Discard any changes made to the Ethernet The following data are displayed in this section:
settings. • Power On Hours
• Running Hours
• Loaded Hours
• Real Time Clock

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Pages 5-6: Digital Inputs Page 9: Analog Outputs

Figure 57 : Digital Inputs Figure 59 : Analog Outputs

The value for the analog outputs will be in mA.

A marked checkbox beside a digital input indicates that the input is in its
TRUE state. For example, Starter Feedback is TRUE when its input is in the • VSD Blower Output
high state, where as, E-Stop is TRUE when its input is at 0Vdc. • Analog Output 2
• Emergency Stop
• Main Motor Overload NOTICE
• Fan Motor Overload (RO) indicates read-only values.
• Condensate Drain Error
• Remote Stop
• Remote Start  Factory settings folder
• Remote Lead/Lag This folder is for factory and service personnel. A password must be entered
on page one in order to adjust values in this folder. This folder is used for
• Remote Load Enable
setting parameters that are specific to that compressor and displaying
• Remote Load/Unload software information for the controller.
• Auxiliary Input 1 Page 1: Password
• Auxiliary Input 2 Figure 60 : Password
• Dryer High Pressure

Pages 7-8: Digital Outputs

Figure 58 : Digital Outputs

Table 22 : Password

Display Text Description

Password Provides access to enter a valid password to gain access
A marked checkbox beside a digital output indicates that it is energized. to password protected parameters. The password is
entered by scrolling down to the password value and
• Starter Contact 1 • PORO Horn pressing the RETURN key.
• Starter Contact 2 • Trip Relay Password This checkbox will indicate a valid password has been
• Fan Starter Contact • Warning Relay entered entered. If this checkbox is blank, a valid password has
not been entered or it has timed out. This is read only.
• Blowdown Solenoid • Low Voltage Output 1
Password Checking this box will enable the password time feature.
• Modulation Solenoid • Low Voltage Output 2
timeout
• Condensate Drain • Low Voltage Output 3 enable
• Dryer Run / Fan Run • Low Voltage Output 4 Password This timeout along with the password timeout enable
timeout allows the user to set an adjustable amount of time
to require a valid password to be re-entered. Once
NOTICE
this timeout is reached re-entry of a valid password is
(RO) indicates read-only values. required.

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Pages 2-3: Factory Settings  Folder Options (Variable Speed)

Figure 61 : Factory Settings
 Home folder
Page 1: System Overview
Figure 63 : Systems Overview

These pages are used for setting parameters that are specific to the
compressor. All of the factory settings that are adjustable are listed below.
All settings on these pages are password protected.
• Rated Pressure (psi – 100, 115, 135, 190)
• Enable Two Stage (On/Off ) This is the factory default display after powering up the system.
• Target Pressure Setpoint is indicated in the white box and by the white
• Starter Type (Star-delta, Remote Starter, Soft Starter)
arrow, which is always centered on the gauge. This is the pressure that
• Service Level (0, 1, or 2) the compressor is trying to maintain.
• Service Time Period (1000 – 8000, in increments of 1000 hours) • Automatic Stop Setpoint is indicated in the white box and by the
• Enable Modulation (On/Off ) white arrow, which is always right of center on the gauge. When the
compressor reaches this setpoint the compressor will unload and stop.
• Enable PAC (On/Off )
• Package Discharge Pressure is indicated by the large numbers centered
• Enable Dryer (On/Off ) below the gauge and by the red arrow. This is the output pressure of the
• Running Hours (adjustable) compressor.

• Loaded Hours (adjustable) • Pressure Unit of Measure is indicated below the Package Discharge
Pressure. This is selectable from the GENERAL SETTINGS folder.
• VSD Blower (On/Off )
• Percent Capacity is indicated on the lower left side of the screen in
• Enable Low Ambient (On/Off ) numeric and bar graph form. This is how much air the compressor is
producing as a percentage of its maximum capacity.
Pages 4-5: Factory Settings
• Airend Discharge Temperature is indicated by the numbers in the lower
Figure 62 : Factory Settings right of the display.
• Temperature Unit of Measure is indicated to the right of the Airend
Discharge Temperature. This is selectable from the GENERAL SETTINGS
folder.
• Run Hours indicate the number of hours the compressor has been
running.

NOTICE

The target pressure and automatic stop set points can be selected and
modified on this page. All other information on this page is read only.

Page 2: Counters
Figure 64 : Counters

These pages are used for displaying software information for the controller.
All items are read only.

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• Hour Meters indicate the hours that: the controller has been powered up,
and the compressor has been running.  Operator settings folder
• Starts indicate the number of times a start is attempted on the
Pages 1-2: Operator Settings
compressor.
• Date & Time is adjustable and configurable in the GENERAL SETTINGS Figure 66 : Operator Settings
folder.

NOTICE

All information on this page is read only.

Pages 3-5: Analog Inputs & Compressor Information

Figure 65 : Analog Inputs & Compressor Information

The parameters below are adjustable at any time:

Table 23 : Operator Settings

Operator Default Min. Max. Step Unit

Settings
Target Pressure 100 65 145 1 psi
Automatic Stop 110 Target+1 Target+10 1 psi
Pressure
Icon Meaning Immediate Stop 120 Auto Auto+10 1 psi
Pressure Pressure
% Savings Modulation --- --- --- ---
Temperature
Compared To
Energy Rate 0.000 0.000 9999.999 --- ---
NOTICE Reset Averaging --/--/-- - - - date
All information on these pages is read only. Pages 3-5: Operator Options
Figure 67 : Operator Options
The following analog inputs are displayed in this section:
• Package Discharge Pressure
• Sump Pressure
• Airend Discharge Temperature
• Injected Coolant Temperature
• Aftercooler Discharge Temperature
• Separator Pressure Drop
• Coolant Filter Pressure Drop
• Inlet Vacuum
• Remote Pressure (optional)
• Aftercooler Discharge Pressure (integrated dryer compressors only)

Additionally, the following compressor status readings are included in this The parameters immediately below are only adjustable when the compressor
section: is stopped.
• Motor Speed
The options set points are similar to the operator set points except these set
• Package kW points cannot be changed while the compressor is running.
• Average Package kW/hour Table 24 : Operator Options
• Average % Capacity
Option Selection Min. Max. Step Unit Installed
• Average Capacity
Items option
• Energy Cost required?
• Energy Savings Remote ON/OFF --- --- --- --- No
Sensor
• Lifetime Energy Savings
Comm ON/OFF --- --- --- --- No
Control

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Remote Start- ON/OFF --- --- --- --- No

Stop  Events folder
Enable PORO ON/OFF --- --- --- --- Yes Pages 1-42 (max.)
PORO Time --- 10 600 1 sec Yes Figure 69 : Events Folder
Scheduled --- Day Day 1 day Yes
Start Day
Scheduled --- 00:00 23:59 1 time Yes
Start Hour
Scheduled --- Day Day 1 day Yes
Stop Day
Scheduled --- 00:00 23:59 1 time Yes
Stop Hour
Modbus ON/OFF/ --- --- --- --- No
Protocol ICU
Modbus --- 1 247 1 --- No
Address

If an option has not been purchased and installed in the compressor, the
message “Not Installed” will be shown on the selection display screen. The pages in the Events folder document up to the last 250 events that the
Installation of options will be done using the Ingersoll Rand service tool. controller has experienced, and time stamps each. The events are recorded
in sequence, with number one being the newest and 250 being the oldest.
* The low ambient temperature is only adjustable if the low ambient factory When a new event occurs, it becomes number one and all others are shifted
set point is on. up in number.
** A value of 0 will disable the lead/lag cycle time feature. The page numbers in the Title Bar are used to scroll through the events, with
Pages 6-7: Sensor Calibration each page displaying up to seven. Page one displays events one through six,
page two displays seven through twelve, and so on.
Figure 68 : Sensor Calibration
The following actions will generate an event:
• Power On
• Power Off
• Press the Start Key
• Press the Stop Key
• Press the Load Key
• Press the Unload Key
• Warning
• Trip
• Start Inhibit

Active Warnings will be highlighted in amber while cleared Warnings will

have amber text.
Sensor calibration can only take place when the compressor is stopped.
Active Trips will be highlighted in red while cleared Trips will have red text.
There should be no pressure on a sensor when it is calibrated. Calibration
only needs to take place after a sensor is replaced, the controller is replaced, Active Start Inhibits will be listed in the Event log, but not highlighted. The
or the operator suspects the sensor reading is in error. Calibrate a sensor by display will indicate the compressor is not ready to start if a start inhibit is
selecting the checkbox beside the sensor name. active.
Each of the sensors listed below can be calibrated. See the following lists for details about messages in each type of event.
• Inlet Vacuum (1AVPT)
Warning Events List
• Sump Pressure (3APT)
Change Inlet Filter
• Package Discharge Pressure (4APT)
This will occur if the compressor has been running for at least 7 seconds, the
• Coolant Filter Inlet Pressure (5CPT) motor speed is equal to or greater than the minimum speed, and the inlet
• Coolant Filter Outlet Pressure (6CPT) vacuum is greater than 0.7 psi.

• Remote Pressure (10APT) – Only on compressors with the remote sensor Change Coolant Filter
option
This will occur if the compressor has been running for at least 7 seconds, the
• Interstage Pressure (2APT) – Only on 2-stage compressors injected coolant temperature is at least 140 °F, the motor speed is at least
equal to the minimum speed, and the coolant filter pressure drop (5CPT
• Aftercooler Discharge Pressure (7APT) – Only on compressors with
- 6CPT) is greater than 25 psi.
integrated dryer
Sensor Failure (Units without Integrated Dryer)
Please note that if a sensor is currently reading a value that is +/- 10% of
its range from zero, the sensor will not be able to be calibrated. Please Will occur whenever a sensor is recognized as missing or broken. The sensors
make sure the sensor is being exposed to atmosphere before attempting affected by this warning are 1ATT, 2ATT, 4ATT, and 3CTT. The sensor failure
calibration. message shall follow the following format: SENSOR FAILURE 4ATT.

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Sensor Failure (Units with Integrated Dryer) Freeze Warning

Will occur whenever a sensor is recognized as missing or broken and the This will occur if the evaporator sensor has a value of 687 (about 0.5 °C)
compressor has an integrated dryer (3.3.1.6). The sensors affected by this or below (low temp) while the dryer is running, on compressors with the
warning are 7APT, 5DTT, and 6DTT. The sensor failure message shall follow integrated dryer. This is a dryer fault. If this happens, the compressor will
the following format: SENSOR FAILURE 7APT. continue to run, but the dryer will stop. The condition must exist for at
least 180 seconds before the warning will occur. NOTE: If this warning is
Change Separator Element reset while the conditions for running the dryer exist, the dryer can restart.
This will occur if the compressor has been running for at least 7 seconds, Also the dryer can restart if the evaporator value rises to 709 (about 5 °C).
the injected coolant temperature is at least 120 °F, the package discharge However the warning will still be displayed.
pressure is at least 65 psi, and the separator pressure drop is at least 12 psi. Dryer High Pressure
If the target pressure is less than 90 psi, the warning value will increase 1 psi
per 5 psi in reduced target pressure. For example, if the target pressure is On compressors with an integrated dryer, this will occur if the dryer high
between 89 and 85 psi, the warning value will be 13 psi. pressure switch opens while the dryer is running. This is a dryer fault. If this
happens, the compressor will continue to run, but the dryer will stop. The
High Airend Disch Temp contact must be open for at least three seconds before the warning will
Will occur if the compressor is running and 2ATT is greater than 221 °F (97% occur. If this warning is reset while the conditions for running the dryer exist,
of 228) or the compressor is in idle mode (3.3.7.1) and 2ATT is greater than the dryer can restart. However, this switch is a locking switch. The switch
184 °F. This warning will normally have a 5 second delay, however, if the hot must be reset before the dryer can run. Resetting the warning on the display
side thermal valve (3.3.1.5) is set to ON, this warning will have a 90 second does not reset the switch.
delay. Sensor Failure Remote
High Discharge Press This will occur whenever the remote sensor is recognized as missing or
Will occur if the compressor is under the control of an external device, such broken. The sensor failure message shall follow the following format:
as an X-series, and the discharge pressure is greater than the immediate stop SENSOR FAILURE REMOTE. If this warning occurs, the compressor will
pressure. automatically switch to the package discharge pressure sensor for control.

Auxiliary Warning 1 (2) High Sump Pressure

This will occur if the auxiliary warning input closes. This will occur if the compressor is running, the package discharge pressure
is at least 65 psi, and the sump pressure is more than 15 psi above the target
Service pressure. The occurrence of this warning will cause the controller to evaluate
Service warnings could change significantly once the predictive maintenance the need to lower the maximum speed (see 4.11).
warnings have been determined. Condenser Temperature High
Service warnings occur when the compressor has operated a certain number This will occur if the condenser sensor has a value of 1019 (about 65 °C)
of hours, based on the total hours. Service warnings can have multiple levels, or above (high temp) while the dryer is running, on compressors with the
depending on the service level selection. Selecting service level 0 disables integrated dryer. This is not a dryer fault. If this happens, the compressor and
service warnings. dryer will continue to run. The condition must exist for at least 180 seconds
Service Level 1 before the warning will occur.

If service level 1 (3.3.1.9) has been selected for the compressor, a “SERVICE Condenser Temperature Low
REQUIRED” warning will be issued the amount of operating hours in the This will occur if the condenser sensor has a value of 887 (about 40 °C)
Service Time Period set point (3.3.1.10). This warning can be reset the same as or below (low temp) while the dryer is running, on compressors with the
any other warning. integrated dryer. This is not a dryer fault. If this happens, the compressor and
Service Level 2 dryer will continue to run. The condition must exist for at least 180 seconds
before the warning will occur.
If service level 2 has been selected for the compressor, the service complete
factory set point (3.3.1.11) will be used to clear a level 2 service warning and Change HE Filter
reset the service time or date. The service complete can be reset before a The HE filter is located between the aftercooler discharge and the inlet to the
service warning occurs. dryer and is only on compressors with an integrated dryer. The drop across
The first “SERVICE REQUIRED” warning will occur at the total hours value of the HE filter is measured by subtracting the package discharge pressure
the service time period set point (3.3.1.10). However, 100 hours before this a from the aftercooler discharge pressure. If the compressor is running at a
“100 HOURS TO SERVICE” warning will occur. This warning can be reset the minimum of 75% capacity, the measured drop across the HE filter is at or
same as any other warning. One hundred hours later, at the total hours value above 10 psi (0.7 bar), the compressor is hot (injected coolant temp above
of the service time period, the “SERVICE REQUIRED” warning will occur. This 120 °F), and the package discharge pressure (4APT) is above 90 psi, this
warning can be reset the same as any other warning, however this warning warning can occur. The condition must exist for at least 3 seconds before the
will return in 24 hours if the service complete factory set point has not be set. warning will occur. This is not a dryer fault. If this happens, the warning will
If the service complete has not been set, 100 hours later (service time period be displayed, but the dryer will continue to run.
+ 100) the “ALARM – SERVICE REQUIRED” warning will be issued. This warning Trip Events List
can only be cleared by the service complete factory set point. Once the
service complete factory set point is set, indicating the service is completed, High Airend Disch Temp
the time for the next “SERVICE REQUIRED” warning will be calculated by This will occur if 2ATT is greater than 228 °F during normal operation. This
adding the service time period to the total hours value, with the “100 HOURS trip will occur at 200 °F if the compressor is in idle mode.
TO SERVICE” warning occurring 100 hours before and the “ALARM – SERVICE
REQUIRED” warning occurring 100 hours after that time. Blower Fault
Condensate Drain Error Will occur if the fault contact opens for 3 seconds on the blower VSD.
This will occur if the compressor is running, the package discharge pressure is Remote Stop Failure
over 50 psi, and the condensate drain error contact closes for at least
240 seconds. This warning will be ignored for 4.5 minutes after starting. Will occur if the REMOTE START/STOP option is enabled, the remote stop
button remains open and either start button is pressed.
High VSD Ambient Temperature
Remote Start Failure
This warning will occur if the VSD ambient temperature gets within 5% of the
shutdown value (133 °F). Will occur if the compressor is started by the remote start button and the
button stays closed for 7 seconds after the compressor starts.

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Sensor Failure This will occur if the compressor should be running and the AC input voltage,
as read from the VSD, falls below 100 VAC. There is a delay of 2 seconds on
This will occur when a sensor is recognized as missing or broken. The sensors this trip in case the power quickly returns. A phase monitor is something that
affected by this trip are 4APT, 3APT, 2APT, 1AVPT, 5CPT, 6CPT, and 2ATT. The can cause this trip.
sensor should be displayed along with the sensor failure message. The
sensor failure message shall follow the following format: SENSOR FAILURE Stop Failure
4APT. Sensor 4APT has the following additional logic. A sensor failure 4APT
will be issued if the sump pressure is over 100 psi and the package discharge This will occur if the compressor should be stopped, but the motor speed has
pressure (4APT) is 50 psi less than the sump pressure. not dropped below the minimum motor speed set point. The controller will
wait 4 seconds for the compressor to stop before issuing this trip.
Emergency Stop
High Interstage Pressure
This will occur when the EMERGENCY STOP button is engaged.
This will occur if the compressor is running, is a two stage compressor, and
VSD Fault the interstage pressure is above 75 psi.
The VSD fault is read from the drive. The controller will read the status High Coolant Filter Pressure Drop
menu of the variable speed drive. If a fault condition is returned in the
status information, the controller will issue a VSD FAULT trip and display the This will occur if the compressor has been running for at least seven seconds,
number of the fault condition. VSD faults 39 – 42 and 44 cannot be cleared the injected coolant temperature is at least 140 °F, already has a change
by pressing the reset button. All other VSD faults can be cleared by pressing coolant filter warning, the motor speed is at least equal to the minimum
the reset button. The only way to clear a VSD fault 39 – 42 or 44 is by cycling speed, and the coolant filter pressure drop (5CPT - 6CPT) is greater than
the power on the compressor. Cycling the power causes the VSD to execute 35 psi.
a power module test. The power module test must be passed before the High Inlet Vacuum
compressor can be restarted after a VSD fault 39 – 42 or 44. VSD faults 39,
40, and 41 (IGBT failures) have additional logic associated with them. Due This will occur if the compressor is running loaded, the motor speed is at least
to false trips the logic was modified to allow an automatic restart. If the minimum speed, and the inlet vacuum is greater than 1.8 psi (vacuum).
VSD fault 39, 40, or 41 occurs, the controller will trip and display the fault High Sump Pressure
message. After two minutes, the controller will issue a command to the VSD
to run the power module test. While the VSD is running the power module This will occur if the compressor is running and any one of the three
test, the controller will force itself into a reset. Upon completing the reset, following conditions exist: (1) The sump pressure is above the target pressure
the controller will monitor the VSD for completion of the power module test. by 25 psi. (2) The separator pressure drop is measured to be more than 25 psi
If the power module test is completed and all conditions have passed, the and the package discharge pressure is at least 65 psi. (3) The sump pressure
controller will automatically restart the compressor. If the power module is above 168 psi.
test is failed, the controller will show the power module test failure message
Start Inhibit List
and the failure code. The controller will not allow more than five automatic
restarts of VSD Fault 39 – 41 within a 24 hour period. The controller will also High Airend Discharge Temperature
not allow two automatic restarts of VSD Fault 39 – 41 within a 10 minute
period. If a VSD Fault 39 – 41 occurs and violates the time periods, the This will occur if 2ATT is greater than 95% of 228 °F.
controller will not issue a power module test and restart. It will display the High Sump Pressure
fault and not allow a reset from the controller. The operator must cycle
power. Another exception on all drives are VSD faults 10, 12 – 14, and 16. If This will occur if the sump pressure (3APT) is 25 psi or higher than the rated
the compressor trips due to one of these faults, instead of shutting down pressure of the compressor.
on the VSD fault, the controller will reset and then restart the compressor.
Waiting for VSD Comms
If the compressor is equipped with a power outage restart option (PORO),
the controller will execute a PORO restart. If the compressor does not This will occur if the compressor VSD has not responded to the initial
have PORO, the controller will restart the compressor 10 seconds after the communications from the controller.
controller has reset. A compressor will be allowed to do this up to five times
in a one hour period. If the compressor exceeds five occurrences within a one
hour period, the sixth occurrence will be treated like a regular VSD fault.  Trip history
Low Sump Pressure Pages 1-4 (max.)

This will occur if the compressor is operating and the sump pressure drops Figure 70 : Trip History
below 13 psi for 15 seconds.
Check Motor Rotation
This will occur if the controller reads a negative speed from the VSD when
starting.
VSD Communication Failure
This will occur if the controller does not receive a response from the VSD
when requesting information. This trip will take about 8 seconds to occur.
VSD Initialization Fault
This will occur if the controller is unable to establish communications with
the VSD after a power up.
Replace Coolant Filter
This will occur if the idle mode is set to on. This trip is used as a reminder
to Ingersoll Rand service to only use idle mode if a new coolant filter is The pages in the Trip History folder document up to the last 15 trips that the
installed. controller has experienced, and time stamps each. The trips are recorded in
sequence, with number one being the newest and 15 being the oldest. When
Incorrect VSD Type
a new trip occurs, it becomes number one and all others are shifted up in
This will occur at power up if the VSD type does not match the size of number.
compressor. The controller will determine this by comparing the compressor
The page numbers in the Title Bar are used to scroll through the events, with
type with the drive ID board.
each page displaying up to seven. Page one displays events one through five,
Control Power Loss page two displays six through ten, and so on.

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The following actions will generate an event: Page 2: Maintenance Status

• Power On Figure 73 : Maintenance Status
• Power Off
• Press the Start Key
• Press the Stop Key
• Press the Load Key
• Press the Unload Key
• Warning
• Trip
• Start Inhibit

Active Trips will be highlighted in red while cleared Trips will have red text.
The trip history also records compressor data at the time of the trip to assist
in diagnostics and troubleshooting. Navigating to the trip entry and pressing
the enter button will activate the trip history dialog box.
This page displays the time until the compressor should be serviced.
Figure 71 : Trip History Dialog
Page 3: Maintenance Configuration
Figure 74 : Maintenance Configuration

While the dialog box is active, press the left and right keys to scroll through
the displayed data. The name of the trip will always be shown in the title bar
of the dialog box. Press enter when finished viewing the data to return to the This page allows the user to set the service interval and to reset the counter
trip history screen. after the service has been performed.

 Maintenance folder
 General settings folder
Page 1: Filter Status
Figure 72 : Filter Status NOTICE

All parameters in this folder are adjustable.

Page 1: Language Selection

Figure 75 : Language Selection

This page displays the following:

• Coolant Filter Status
• Separator Element Status
• Inlet Filter Status
•

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Language is selectable from the following 30 choices: The following settings are displayed in this section:
Table 26 : Home Page Selection
• English (default) • Korean
• Bulgarian • Latvian Display Text Description
• Chinese, simplified • Lithuanian Auto Return to Home Enables the controller to return the display back to
• Croatian • Maltese the selected Home Page if there is no user activity
for the Delay Time shown. This is only enabled
• Czech • Norwegian when an “x” appears in the checkbox.
• Danish • Polish Delay Time Determines how many seconds of inactivity it will
• Dutch • Portuguese take before the controller will return to the Home
Page.
• Estonian • Romanian
Select Home Folder Used to select the Home folder.
• Finish • Russian
Select Home Page Used to select the Home Page within the selected
• French • Slovak
Home folder.
• German • Slovenian
Page 4-5: Time & Date Settings
• Greek • Spanish
Figure 78 : Time & Date Settings
• Hungarian • Swedish
• Italian • Thai
• Indonesian • Turkish
The controller will display all screens in the selected language and only one
language can be selected at a time.
Each language appears in its native translation.
Page 1: Units of Measure Settings
Figure 76 : Units of Measure Settings

All items are adjustable.

The following settings are displayed in this section:
Table 27 : Time & Date Settings

Display Text Description

Hours Allows the current hour to be set. The hours format is
fixed on 24-hour.
Minutes Allows current minutes to be set.

The following compressors of measure settings are displayed in this section: Seconds Allows current seconds to be set.
Year Allows current year to be set.
Table 25 : Units of Measure Settings
Month Allows current month to be set.
Display Text Description Day Allows current day to be set.
Temperature Selectable between ºF and ºC. Date Format Selectable between dd/mm/yyyy (default) and mm/
Pressure Selectable among psi, kpa, bar, kg/cm2. dd/yyyy.

Power Selectable between kW and HP. Confirm New Used to verify that changes to selections are desired.
Time and Date An “x” must appear in the checkbox before any changes
Page 3: Home Page Selection will take effect.
Figure 77 : Home Page Selection The controller will continue to display any changes, even when the selections
have not been confirmed and the user exits the page, then returns. Cycling of
the power returns all selections to their current settings.

NOTICE

The controller does not support Daylight Savings Time.

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Page 6 : Backlight Settings

Display Text Description
Figure 79 : Backlight Settings IP Address Actual This will match the IP address setting when DHCP
is not enabled. If DHCP is enabled this will display
the address assigned to the controller by the
DHCP server.
MAC Address This is the unique hardware MAC address for the
controller. This can not be changed.
Subnet Mask Setting Setpoint for the subnet mask.
Subnet Mask Actual Current reading/setting for the subnet mask.
Default Gateway Setpoint for the default gateway.
Setting
Default Gateway Current reading/setting for the default gateway.
Actual
Accept After editing the desired setpoint navigate to the
accept setting and press enter in order for the
The following settings are displayed in this section: values in the setting variables to be confirmed by
the controller.
Table 28 : Backlight Settings
Cancel Discard any changes made to the Ethernet
settings.
Display Text Description
Backlight Adjusts the brightness of the display.
 Status folder
Brightness
Enable Backlight Enables the controller to shut-off the backlight if
Auto-Off there is no user activity for the delay time shown. NOTICE
Backlight Auto-Off Determines how many seconds of inactivity it will All information on these pages is read only.
Delay Time take before the controller will shut-off the backlight.
Pages 1 -2: Analog Inputs
NOTICE Figure 81 : Analog Inputs

The backlight will be switched on whenever any of the controller’s

keys are pressed.
The START, STOP, LOAD, UNLOAD, RESET, and ACKNOWLEDGE keys on
the controller remain functional while the backlight is switched off. It
is recommended to press the ENTER key or one of the navigation keys
in order to switch the backlight on.

Pages 7-8: Ethernet Settings

Figure 80 : Ethernet Settings

The following inputs are displayed in this section:

• Package Discharge Pressure
• Sump Pressure
• Airend Discharge Temperature
• Injected Coolant Temperature
• Aftercooler Discharge Temperature
• Separator Pressure Drop
• Coolant Filter Pressure Drop
The following settings are displayed in this section: • Inlet Vacuum
Table 29 : Ethernet Settings • Aftercooler Discharge Pressure (integrated dryer compressors only)
Display Text Description • Remote Pressure (optional)
Enable Ethernet Allow connection by users to utilize the network • Coolant Filter Inlet Pressure
enabled functionality of the controller.
• Coolant Filter Outlet Pressure
Enable DHCP Allow the controller to automatically receive an IP
• Interstage Pressure (2-stage compressors only)
address from the Local Area Network (LAN).
• Evaporator
IP Address Setting When DHCP is not enabled, this setpoint sets the
IP address of the controller. • Condenser

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Page 4: Compressor Data The following are displayed in this section:

Figure 82 : Compressor Data • Emergency Stop
• Main Motor Overload
• Fan Motor Overload
• Condensate Drain Error
• Remote Stop
• Remote Start
• Remote Lead/Lag
• Remote Load Enable
• Remote Load/Unload
• Auxiliary Input 1
• Auxiliary Input 2
• Dryer High Pressure

The following are displayed in this section: Pages 9-10: Digital Outputs
• % Energy Savings Figure 84 : Digital Outputs
• % Capacity
• Package Power
• Power On Hours
• Running Hours
• Motor Speed
• Time
• Motor Current
• Motor Voltage
• AC Input Voltage
• DC Bus Voltage
• IGBT U Temperature
• IGBT V Temperature A marked checkbox beside a digital output indicates that it is energized.
• IGBT W Temperature • Starter Contact 1
• Input Rectifier Temperature • Starter Contact 2
• VSD Ambient Temperature • Fan Starter Contact
• Remote Maximum Speed • Blowdown Solenoid
• Remote Maximum Pressure • Modulation Solenoid
• Target Pressure • Condensate Drain
Pages 7-8: Digital Inputs • Dryer Run / Fan Run

Figure 83 : Digital Inputs • PORO Horn

• Trip Relay
• Warning Relay
• Low Voltage Output 1
• Low Voltage Output 2
• Low Voltage Output 3
• Low Voltage Output 4

NOTICE

(RO) indicates read-only values.

A marked checkbox beside a digital input indicates that the input is in its
TRUE state. For example, Starter Feedback is TRUE when its input is in the
high state, where as, E-Stop is TRUE when its input is at 0Vdc.

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Page 11: Analog Outputs Pages 2-3: Factory Settings

Figure 85 : Analog Outputs Figure 87 : Factory Settings

The value for the analog outputs will be in mA.

These pages are used for setting parameters that are specific to the
• VSD Blower Output compressor. All of the factory settings that are adjustable are listed below.
• Analog Output 2 All settings on these pages are password protected.
Compressor Type will be selected here. The choices are listed below:
 Factory settings folder • 37 kW/50 HP 1-S (46, 47) (38, 39)
• 45 kW/60 HP 1-S (47) (39)
This folder is for Ingersoll Rand factory and service personnel. A password
must be entered on page one in order to adjust values in this folder. This • 55 kW/75 HP 1-S (48, 49) (40, 41)
folder is used for setting parameters that are specific to that compressor and
• 75kW/100HP 1-S (49) (41)
displaying software information for the controller.
• 90 kW 1-S (50, 51) (42, 43)
Page 1: Password
• 125 HP 1-S (50, 51) (42, 43)
Figure 86 : Password
• 110 kW 1-S (51) (43)
• 150 HP 1-S (51) (43)
• 132 kW 1-S (52, 53) (44, 45)
• 200 HP 1-S (53) (45)
• 160kW 1-S (53) (45)
• 90 kW 2-S (50, 51) (42, 43)
• 125 HP 2-S (50, 51) (42, 43)
• 110 kW 2-S (51) (43)
• 150 HP 2-S (51) (43)
• 132 kW 2-S (52, 53) (44, 45)
• 200 HP 2-S (53) (45)
• 160 kW 2-S (53) (45)
Table 30 : Password
Water Cooled (On/Off )
Password: Provides access to enter a valid password to gain access to
password protected parameters. The password is entered Hot Side Thermal Valve (On/Off )
by scrolling down to the password value and pressing the Enable PAC (On/Off )
return key.
Enable Dryer (On/Off )
Password This checkbox will indicate a valid password has been
Entered: entered. If this checkbox is blank, a valid password has not Constant Running Dryer (On/Off )
been entered or it has timed out. This is read only.
Running Hours (adjustable)
Password Checking this box will enable the password time feature.
Loaded Hours (adjustable)
Timeout
Enable:
Timeout This timeout along with the password timeout enable allows
Delay: the user to set an adjustable amount of time to require
a valid password to be re-entered. Once this timeout is
reached re-entry of a valid password is required.

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Pages 4-5: Software Information Pages 13 -16: VSD Service Menus

Figure 88 : Software Information Figure 91 : VSD Service Menus

These pages are used for displaying software information for the controller. The VSD service menus contain parameters used to set up the compressor for
All items are read only. optimal operation.
Pages 6-10: Maximum Values
NOTICE
Figure 89 : Maximum Values
These screens must only be used by authorized service technicians.
The password must be entered in order to modify these parameters.

The maximum values pages are used to record the highest value the
controller has seen since the last time the maximum values have been reset.
Each maximum value entry displays the highest value recorded as well as the
time and date stamp of when these maximum values have occurred.
The final maximum value page has a reset setting at the bottom of the page,
highlighting this button and hitting enter will cause the controller to clear all
history of maximum values and begin recording them again. The password
must be entered in order to use this reset functionality.
Pages 11-12: VSD Diagnostics
Figure 90 : VSD Diagnostics

The VSD Diagnostics screens are used to troubleshoot any drive problems.

NOTICE

These screens must only be used by authorized service technicians.

The password must be entered in order to activate these diagnostic
tests.

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NOTICES AND DISCLAIMERS

Machine models represented in this manual may be used in various locations worldwide. Machines sold and shipped into European community countries
shall display the EC Mark and conform to various directives. In such cases, the design specification of this compressor 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.
The contents of this manual are considered to be proprietary and confidential to Ingersoll Rand and should not be reproduced without the prior written
permission of Ingersoll Rand.
Nothing contained in this document is intended to extend any promise, warranty or representation, expressed or implied, regarding the Ingersoll Rand
products described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with the standard terms and
conditions of sale for such products, which are available upon request.
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.
Details of approved equipment are available from Ingersoll Rand Service departments.
The company accepts no responsibility for errors in translation of this manual from the original English version.
The design of this Compressor package and certain features within it are covered by patents held by Ingersoll Rand and patents pending.

WARRANTY
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of
twelve months from the date of placing the Equipment in operation or eighteen months from the date of shipment from the factory, whichever shall first
occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon
the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. point of shipment,
provided the Purchaser has stored, installed, maintained and operated such Equipment in accordance with good industry practices and has complied
with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever
warranty the 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
fulfilment of all liabilities of the Company for such non conformities 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.

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