SSR M90 M110

M132 M160
OPERATION AND MAINTENANCE MANUAL

M90 SERIAL No 2360446 –>

This manual contains
important safety information
M110 SERIAL No 2380444 –>
and must be made available to
personnel who operate and
maintain this machine. M132 SERIAL No 2400244 –>

M160 SERIAL No 2420400 –>

C.C.N. : 54624838 GB
DATE : JUNE 2002
 Machine models represented in this manual may be used in various locations world–wide. Machines sold and
shipped into European Union Territories require that the machine display the EC Mark and conform to various
directives. In such cases, the design specification of this machine has been certified as complying with EC directives.
Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being
rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

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

WE,

INGERSOLL–RAND COMPANY LIMITED

SWAN LANE
HINDLEY GREEN
WIGAN WN2 4EZ
UNITED KINGDOM

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

M90 M110 M132 M160

TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS
OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

EN29001, EN292, EN60204–1, EN1012, EN50081, EN50082

ISSUED AT HINDLEY GREEN ON 01/01/2002 BY H.SEDDON, QUALITY ASSURANCE

MANAGER.

H. SEDDON

EC Pressure Equipment Directive and Related Regulations

We declare that this product has been assessed according to the Pressure Equipment Directive
(97/23/EC) and, in accordance with the terms of this Directive, has been excluded from the scope
of this Directive.
It may carry ”CE” marking in compliance with other applicable EC Directives.
06/02
 CONTENTS & ABBREVIATIONS 1
ABBREVIATIONS & SYMBOLS
CONTENTS
#### Contact Ingersoll–Rand for serial number
1 CONTENTS
–>#### Up to Serial No.
####–> From Serial No.
2 FOREWORD
* Not illustrated
3 ISO SYMBOLS † Option
NR Not required
8 SAFETY
AR As required
10 GENERAL INFORMATION SM Sitemaster/Sitepack
HA High ambient machine
17 INSTALLATION / HANDLING
WC Watercooled machine

22 OPERATING INSTRUCTIONS AC Aircooled machine

ERS Energy recovery system
25 AIRCARE WARRANTY T.E.F.C. Totally enclosed fan cooled motor (IP54)
O.D.P. Open drip proof (motor)
26 MAINTENANCE
ppm parts per million
33 FAULT FINDING BR Brazil
CN China
DE Germany
DK Denmark
ES Spain
FI Finland
FR France
GB Great Britain (English)
IT Italy
NL Holland
NO Norway
PT Portugal
SE Sweden
US United States

M90 M110 M132 M160

2 FOREWORD
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.
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
checks.
Use of the machine outside the ambient temperature range
specified in the GENERAL INFORMATION SECTION of this manual.
Use of the machine where there is any actual or foreseeable risk of
hazardous levels of flammable gases or vapours.

Use of the machine fitted with non Ingersoll–Rand approved

This manual contains instructions and technical data to cover all
routine operation and scheduled maintenance tasks by operation and components.
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised Ingersoll–Rand service Use of the machine with safety or control components missing or
department. disabled.

The design specification of this machine has been certified as The company accepts no responsibility for errors in translation of
complying with E.C. directives. Any modification to any part is this manual from the original English version.
absolutely prohibited and would result in the CE certification and
marking being rendered invalid.
SSR ULTRACOOLANT is a registered trademark of
Ingersoll–Rand Company USA.
All components, accessories, pipes and connectors added to the
compressed air system should be:
. of good quality, procured from a reputable manufacturer and, INTELLISYS is a registered trademark of Ingersoll–Rand
wherever possible, be of a type approved by Ingersoll–Rand. Company USA.
. clearly rated for a pressure at least equal to the machine maximum
allowable working pressure.
. compatible with the compressor lubricant/coolant.  COPYRIGHT 2002
. accompanied with instructions for safe installation, operation and INGERSOLL–RAND COMPANY
maintenance.

Details of approved equipment are available from Ingersoll–Rand

Service departments.

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

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.

The intended uses of this machine are outlined below and examples
of unapproved usage are also given, however Ingersoll–Rand cannot
anticipate every application or work situation that may arise.

IF IN DOUBT CONSULT SUPERVISION.

This machine has been designed and supplied for use only in the
following specified conditions and applications:
. Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.

The use of the machine in any of the situation types listed in

table 1:–
a) Is not approved by Ingersoll–Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll–Rand.

M90 M110 M132 M160

 ISO SYMBOLS 3
GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING – Pressurised vessel. WARNING – Hot surface.

WARNING – Pressure control. WARNING – Corrosion risk. WARNING – Air/gas flow or Air discharge.

X,X BAR

WARNING – Maintain correct tyre pressure.

WARNING – Pressurised component or
WARNING – Hot and harmful exhaust gas. (Refer to the GENERAL INFORMATION
system.
section of this manual).

0
C

WARNING – Before connecting the tow bar WARNING – For operating temperature
WARNING – Flammable liquid. or commencing to tow consult the below 0
C, consult the operation and
operation and maintenance manual. maintenance manual.

M90 M110 M132 M160

4 ISO SYMBOLS

WARNING – Do not undertake any

WARNING – Consult the operation and
maintenance on this machine until the Do not breathe the compressed air from this
maintenance manual before commencing
electrical supply is disconnected and the air machine.
any maintenance.
pressure is totally relieved.

Do not remove the Operating and Maintenance Do not operate the machine without the guard
Do not stack.
manual and manual holder from this machine. being fitted.

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

XX
km/h
Do not open the service valve before the
Do not exceed the trailer speed limit. No naked lights.
airhose is attached.

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

M90 M110 M132 M160

 ISO SYMBOLS 5

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

a
Read the Operation and Maintenance manual
When parking use prop stand, handrake and
before operation or maintenance of this Contains asbestos.
wheel chocks.
machine is undertaken.

SET SEQUENCER STATUS LOAD

SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED)

RESET COMPRESSOR STATUS MODULATE

MALFUNCTION POWER SOILED FILTER

POWER INLET ELECTRIC MOTOR HOURS

M90 M110 M132 M160

6 ISO SYMBOLS

COOLANT SEPARATOR PRESSURE AIR DISCHARGE

PRESSURISED TANK ON / OFF CYCLE COOLANT FILTER

AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE

AIR PRESSURE STAR DELTA IEC 617–7 AUTOMATIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE

M90 M110 M132 M160

 ISO SYMBOLS 7

BELT TENSION FILTER MOTOR LUBRICATION

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS ROTATION

POWER INLET (AC) WATER IN WATER OUT

M90 M110 M132 M160

8 SAFETY
WARNINGS
Warnings call attention to instructions which must be followed
precisely to avoid injury or death.
CAUTIONS
Cautions call attention to instructions which must be followed
precisely to avoid damaging the product, process or its surroundings.
NOTES
Notes are used for supplementary information.
General Information
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation.
Ensure that the Operation and Maintenance manual, and the
manual holder, are not removed permanently from the machine.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
Compressed air and electricity can be dangerous. Before
undertaking any work on the compressor, ensure that the electrical
supply has been isolated and the compressor has been relieved of all
pressure.
Make sure that all protective covers are in place and that the
canopy/doors are closed during operation.
Installation of this compressor must be in accordance with
recognised electrical codes and any local Health and Safety Codes.
The use of plastic bowls on line filters without metal guards can be
hazardous. Their safety can be affected by either synthetic lubricants,
or the additives used in mineral oils. Metal bowls should be used on a
pressurised system.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
Compressed air
Ensure that the machine is operating at the rated pressure and that
the rated pressure is known to all relevant personnel.
All air pressure equipment installed in or connected to the machine
must have safe working pressure ratings of at least the machine rated
pressure.
If more than one compressor is connected to one common
downstream plant, effective check valves and isolation valves must be
fitted and controlled by work procedures, so that one machine cannot
accidently be pressurised / over pressurised by another.
Compressed air must not be used for a direct feed to any form of
breathing apparatus or mask.
The discharged air contains a very small percentage of compressor
lubricating oil and care should be taken to ensure that downstream
equipment is compatible.
If the discharged air is to be ultimately released into a confined
space, adequate ventilation must be provided.
When using compressed air always use appropriate personal
protective equipment.
M90 M110 M132 M160
All pressure containing parts, especially flexible hoses and their
couplings, must be regularly inspected, be free from defects and be
replaced according to the Manual instructions.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
Avoid bodily contact with compressed air.
The safety valve located in the separator tank must be checked
periodically for correct operation.
Materials
The following substances are used in the manufacture of this
machine and may be hazardous to health if used incorrectly:
. preservative grease
. rust preventative
. compressor coolant
AVOID INGESTION, SKIN CONTACT AND INHALATION OF
FUMES
For further information, consult Material Data Sheets ACGP 011/96
(Ultracoolant) and ACGP 029/90 (food grade coolant).
Should compressor lubricant come into contact with the eyes, then
irrigate with water for at least 5 minutes.
Should compressor lubricant come into contact with the skin, then
wash off immediately.
Consult a physician if large amounts of compressor lubricant are
ingested.
Consult a physician if compressor lubricant is inhaled.
Never give fluids or induce vomiting if the patient is unconscious or
having convulsions.
Transport
When loading or transporting machines ensure that the specified
lifting and tie down points are used.
Electrical
Keep all parts of the body and any hand–held tools or other
conductive objects, away from exposed live parts of the compressor
electrical system. Maintain dry footing, stand on insulating surfaces
and do not contact any other portion of the compressor when making
adjustments or repairs to exposed live parts of the compressor
electrical system.
Close and lock all access doors when the compressor is left
unattended.
Do not use extinguishers intended for Class A or Class B fires on
electrical fires. Use only extinguishers suitable for class BC or class
ABC fires.
Attempt repairs only in clean, dry, well lighted and ventilated areas.
Connect the compressor only to electrical systems that are
compatible with its electrical characteristics and that are within it’s rated
capacity.
 SAFETY 9
Condensate disposal
Condensate cannot be discharged into fresh/surface water drains.
In some regions compressor condensate containing Ultracoolant can
be fed directly into a drainage system that has downstream sewerage
treatment.

As waste water regulations vary by country and region it is the

responsibility of the user to establish the limitations and regulations in
their particular area. Ingersoll–Rand and its associated distributors are
happy to advise and assist in these matters.

Coolant disposal
Steps to be taken in the case of spillage: Soak up with a suitable
absorbent material, then sweep into a plastic bag for disposal.

Burn in an approved incinerator, or according to local area or

country regulations.

For further information, consult Material Data Sheets ACGP 011/96

(Ultracoolant) and ACGP 029/90 (food grade coolant).

M90 M110 M132 M160

10 GENERAL INFORMATION

LUBRICATION SYSTEM
KEY

A. LUBRICANT 5. ORIFICE & SCREEN

B. LUBRICANT / AIR
 ENERGISED
   DE–ENERGISED
1. CHECK VALVE
2. DISCHARGE PIPE
3. SEPARATOR TANK
4. DRAIN VALVE
6. COOLANT FILTER
7. COOLER
8. THERMOSTATIC VALVE
9. SOLENOID VALVE (1SV)
10.INLET VALVE POSITIONING CYLINDER
11.COOLANT STOP VALVE (5SV)

M90 M110 M132 M160

 GENERAL INFORMATION 11

AIRFLOW SYSTEM
KEY

A. LUBRICANT 6. MODULATION SOLENOID VALVE (2SV)(OPTIONAL)

B. LUBRICANT / AIR 7. SOLENOID VALVE (4SV)
C. AIR 8. PRESSURE TRANSDUCER (1PS)
 ENERGISED 9. CONDENSATE DRAIN
   DE–ENERGISED 10.MOISTURE SEPARATOR (OPTIONAL)
1. FILTER 11.AFTERCOOLER
2. COMPRESSOR 12.MODULATOR (OPTIONAL)
3. CHECK VALVE 13.MINIMUM PRESSURE VALVE
4. TEMPERATURE SENSOR 14.BLOWDOWN VALVE (3SV, 8SV)
5. SEPARATOR TANK

M90 M110 M132 M160

12 GENERAL INFORMATION

WATERCOOLING SYSTEM The standard compressor is designed to operate in an ambient

range of 1,7
C to 46
C. The standard maximum temperature of 46
C
KEY is applicable up to an elevation of 1000m (3280ft) above sea level.
Above this altitude significant reductions in ambient temperature are
required if a standard motor is to be used.
A WATER IN
B WATER OUT Compression in the screw type air compressor is created by the
meshing of two (male & female) helical rotors.
C. LUBRICANT OUT
D. LUBRICANT IN
The air/coolant mixture discharges from the compressor into the
E. LUBRICANT COOLER separation system. This system removes all but a few PPM of the
coolant from the discharge air. The coolant is returned to the cooling
F. AFTERCOOLER system and the air passes to the aftercooler and out of the compressor
through the moisture separator (optional).
G. AIR OUT
H. AIR IN
Air is pulled into the machine by the cooling fan and is pushed
J. WATER through the combined cooler / aftercooler.

By cooling the discharge air and passing it through the separator,

In water cooled compressors, the cooling water flows first to the
much of the water vapour which is naturally present in the air, can be
aftercooler and then to the lubricant cooler. This series flow is designed
removed.
to keep the total water requirement to a minimum (refer to T5328 – 1).
By taking the cooling water to the aftercooler first, lower temperature
air is discharged to the compressed air system. The coolant system consists of a sump, cooler, thermostatic valve
and a filter. When the unit is operating, the coolant is pressurised and
forced to the compressor bearings.

GENERAL OPERATION
The compressor is an electric motor driven, single stage screw
compressor, complete with accessories piped, wired and baseplate
mounted. It is a totally self contained air compressor package.
The compressor load control system is automatic ’On–Off line’. The
compressor will operate to maintain a set discharge line pressure and
is provided with an auto restart system for use in plants where the air
demand varies widely.

M90 M110 M132 M160

 GENERAL INFORMATION 13
Panel instrumentation is provided to indicate the compressor Safety of operation is provided for as the compressor will shut down
operating conditions and general status. if excessive temperatures, electrical overload conditions, or system
over pressure should occur.
(OPTIONAL)
Modulation hardware extends the control types to Modulation
(capacity control) and Automatic Control System when the compressor
switches between ’On–Off line’ and modulation as demand varies.

M90AC l D M110AC l D M90WC l D M110WC l D

PRESSURE 7,5 bar 8,5 bar 10,0 7,5 bar 8,5 bar 10,0 7,5 bar 8,5 bar 10,0 7,5 bar 8,5 bar 10,0
(L) (M) bar (L) (M) bar (L) (M) bar (L) (M) bar
(H) (H) (H) (H)
CAPACITY 16,7 15,3 14,00 20,0 19,2 17,5 16,7 15,3 14,00 20,0 19,2 17,5
m3/min m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min.

590 540 494 706 678 618 590 540 494 706 678 618
ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min.
FULL LOAD CURRENT 361 A 431 A 344 A 414 A
(MAXIMUM)
220V
FULL LOAD CURRENT 209 A 250 A 199 A 240 A
(MAXIMUM)
380V
FULL LOAD CURRENT 201 A 240 A 192 A 231 A
(MAXIMUM)
415V
STARTING CURRENT 847 A 977 A 728 A 858 A
(MAXIMUM)
220V
STARTING CURRENT 511 A 578 A 442 A 509 A
(MAXIMUM)
380V
STARTING CURRENT 547 A 624 A 484 A 561 A
(MAXIMUM)
415V
*NOISE LEVEL 74 ± 3 74 ± 3 74 ± 3 74 ± 3
CAGI PNEUROP 1m
* Equivalent continuous sound pressure level (workstation) (rated load)

WEIGHT 2430 kg 2580 kg 2430 kg 2580 kg

O.D.P.
WEIGHT 2700 kg 2850 kg 2700 kg 2850 kg
T.E.F.C.

M90 M110 M132 M160

14 GENERAL INFORMATION
M132AC l D M160AC l D M132WC l D M160WC l D

PRESSURE 7,5 bar 8,5 bar 10,0 7,5 bar 8,5 bar 10,0 7,5 bar 8,5 bar 10,0 7,5 bar 8,5 bar 10,0
(L) (M) bar (L) (M) bar (L) (M) bar (L) (M) bar
(H) (H) (H) (H)
CAPACITY 23,5 22,3 21,0 28,0 26,0 25,0 23,5 22,3 21,0 28,0 26,0 25,0
m3/min m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min. m3/min.

830 788 742 989 918 883 830 788 742 989 918 883
ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min. ft3/min.
FULL LOAD CURRENT 545 A 626 A 481 A 606 A
(MAXIMUM)
220V
FULL LOAD CURRENT 297 A 354 A 286 A 344 A
(MAXIMUM)
380V
FULL LOAD CURRENT 289 A 340 A 281 A 330 A
(MAXIMUM)
415V
STARTING CURRENT 1373 A 1457 A 1210 A 1325 A
(MAXIMUM)
220V
STARTING CURRENT 746 A 781 A 719 A 713 A
(MAXIMUM)
380V
STARTING CURRENT 806 A 835 A 785 A 767 A
(MAXIMUM)
415V
*NOISE LEVEL 75 ± 3 75 ± 3 75 ± 3 75 ± 3
CAGI PNEUROP 1m
* Equivalent continuous sound pressure level (workstation) (rated load)

WEIGHT 2840 kg 2970 kg 2590 kg 2600 kg

O.D.P.
WEIGHT 3075 kg 3075 kg 3190 kg 3000 kg
T.E.F.C.

M90 M110 M132 M160

 GENERAL INFORMATION 15

93167641
Revision C
09/94

M90 M110 M132 M160

16 GENERAL INFORMATION
KEY

CF1 – CF5 Control fuses The INTELLISYS controller enables the operator to customise the
following parameters via the front panel:
CFO Common fault output
CON Intellisys controller OFFLINE PRESSURE
3DP Pressure switch (Fouled coolant filter) (Pressure bands 1 and 2)

E Main earth The discharge pressure at which the compressor unloads.

ELK Earth link

ONLINE PRESSURE
ES Emergency stop (Pressure bands 1 and 2)
FF Fan fuses The pressure at which the compressor loads.
FM Fan motor
FOL Fan motor overload relay PRESSURE BANDS

1HAT Temperature switch (Discharge) Two pressure bands are selectable via the Intellisys controller. The
pressure band may be changed during normal operation of the
ISO Isolator (customer supplied) compressor by pressing the up arrow key () for pressure band 1 and
the down arrow key () for pressure band 2. Pressures within each
K1 – K4 Relay band cannot be changed whilst the compressor is in operation.
KM1 Main contactor
KM2 Delta contactor STAR–DELTA

KM3 Star contactor Star–delta adjustment enables the operator to adjust the time which
the motor remains in ’star’ during starting.
KM4 Fan contactor
L1 – L3 Mains terminals AUTO RESTART
MM Main motor If the compressor runs unloaded for a pre–determined time, it will
shut down automatically to conserve power. This delay time is
MOL Main motor overload relay
adjustable from 10–20 minutes.
PT Pressure transducer
RSP Remote stop DELAY LOAD TIMER

RST Remote start The compressor will load as soon as the discharge pressure falls
below online pressure. By varying the delay load time, it is possible to
1SV Solenoid valve (Load) smooth out pressure ripples in the system and avoid excessive on/off
line cycling.
2SV Solenoid valve (Modulate)(Optional)
3SV Solenoid valve (Blowdown)
OPTIONS
4SV Solenoid valve (Line/sump)
The controller can give remote start/stop control. It will also interface
5SV Solenoid valve (Coolant stop) with the optional INGERSOLL–RAND sequencer. A power out restart
option is also available, which will enable the compressor to
8SV Solenoid valve (Cold start) automatically restart following an interruption of the power supply.
T1 Transformer (20VA)
CONTROL MODE
T2 Transformer (130VA)
The compressor runs in ON Line–OFF Line as standard.
1TAS Temperature sensor (Discharge pipe)
Modulation and A.C.S. modes are an option.
TR Thermistor relay
4TS Temperature switch (Cold start) Modulation will reduce the delivery capacity to a minimum of 60%
of the capacity as stated on the data plate allowing a continuous
1VAC Vacuum switch (Fouled air filter) delivery of air when required. A.C.S. mode automatically switches
between modulation and on/off line to optimise performance and
The compressor is controlled and protected by an INTELLlSYS reduce running costs.
microprocessor controller. The transformer provides the INTELLISYS
unit with an 8–0–8 Vac power supply. By switching the 48Vac voltage,
the microprocessor controls and sequences the motor contactors and
the load solenoid. It continually monitors the status of the compressor,
which is shown on a single line backlit Liquid Crystal Display (L.C.D.).
Various machine functions can be displayed via the front panel buttons.
If a fault occurs, the controller takes immediate action and indicates the
cause of the fault.

The emergency stop will stop the compressor independently

of the INTELLISYS unit.

M90 M110 M132 M160

 INSTALLATION / HANDLING 17

M90/110AC
M90/160WC

KEY

A 2” BSPT Air discharge (WC) H Cooling air exhaust

B 1/ ” BSPT Condensate drain (WC) I Control panel
2
C 11/4” BSPT Water in/out (WC) J 100mm dia. Access panel to coolant drain
D 2” BSPT Air discharge (AC)
E 1/4” BSPT CONDENSATE DRAIN (AC)
F Cooling air intake NOTE
All dimensions are in millimetres unless otherwise stated.
G 100mm dia. Electrical cable entry

M90 M110 M132 M160

18 INSTALLATION / HANDLING

M132/160AC

KEY

A 2” BSPT Air discharge F Control panel

B 1/ ” BSPT Condensate drain G 100mm dia. Access panel to coolant drain
4
C Cooling air intake
D 100mm dia. Electrical cable entry
NOTE
E Cooling air exhaust All dimensions are in millimetres unless otherwise stated.

M90 M110 M132 M160

 INSTALLATION / HANDLING 19
UNPACKING / SHIPPING STRAP Minimum cooling water requirement at ambient
temperatures, in litres per minute (UK gallons per
Remove the yellow shipping strap (identified by two red minute)
Model Range
identification tags) as follows;
50
F / 10
C 70
F / 21
C 90
F / 32
C
1. remove the polythene cover and front access panel from the
M90 34(7.5) 45(10) 77(17)
machine,
M110 41(9) 59(13) 95(21)
2. remove the screw from the top of the starter cabinet,
M132 64(14) 82(18) 123(27)

3. remove the screw from the separator cover, M160 73(16) 95(21) 150(40)

4. discard the strap and tags, 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 ideally be between 3 and 5 bar.
5. replace the screw in the separator cover and tighten to a torque of
96 ft.lbs (4,04Nm), Water cleanliness is also extremely important. Cleaning of coolers as
a result of fouling is a customer responsibility. Therefore, it is highly
recommended that proper water quality must meet the requirements
6. replace the access panel. listed in WATER QUALITY RECOMMENDATIONS later in this section.

Venting the water system

UNPACKING
The compressor will normally be delivered with a polythene cover.
If a knife has to be used to remove this cover ensure that the exterior
paintwork of the compressor is not damaged.
Incorporated within the base of the compressor are slots to enable
a fork lift truck (2 ton minimum) to move the machine. Alternatively a
special lifting frame can be supplied to enable a crane or hoist to move
the compressor.
WATER COOLED UNITS
Cooling Water Piping
Water piping to and from the compressor package must be 1
1/4”diameter or larger. Isolation valves with side drains should be
installed on both the inlet and outlet lines. Also a strainer of 2mm–mesh
size should be installed on the inlet line. Strainers are available from
Ingersoll–Rand. Ingersoll–Rand CPN 54690052.
It is recommended that a normally closed solenoid valve be fitted to the
water outlet side of the compressor package. This is to be wired into the
compressor control circuit. This option detail is available from
Ingersoll–Rand.
Carefully inspect your water system before installing the compressor
package. Ensure that the piping is free of scale and deposits that may
restrict water flow to the compressor package.
Proper operation of your compressor requires that the water flow listed
below be provided at a maximum supply temperature of 32
C
At the initial installation or for start–up after draining the water system
proceed to vent the system as follows
1 Locate the water system vent cocks on top of the aftercooler and
lubricant cooler.
2 Open the water valve(s) allowing water to flow to the package.
3 Open the vent cocks and allow all air to escape from the system.
When water is observed at the vent cocks, close them
The system is now vented.
Draining the water system
Should it become necessary to completely drain the water system,
proceed as follows.
1 Disconnect the inlet and discharge water lines from the connections
located at the rear of the unit.
2 Locate the aftercooler and lubricant cooler. Remove the drain plugs
located at the bottom of the coolers.
Allow the system to completely drain.
Water quality recommendations
Water quality is often overlooked when the cooling system of a
water–cooled air compressor is examined. Water quality determines
how effective the heat transfer rate, as well as the flow rate will remain
during the operation life of the unit. It should be noted that the quality
of water used in any cooling system does not remain constant during
the operation of the system. Evaporation, corrosion, chemical and
temperature changes, aeration, scale and biological formations effect
the water makeup. Most problems in a cooling system show up first in
a reduction in the heat transfer rate, then in a reduced flow rate and
finally with damage to the system.

M90 M110 M132 M160

20 INSTALLATION / HANDLING
Scale: Scale formation inhibits effective heat transfer, yet it does help SEA WATER COOLED UNITS
prevent corrosion. Therefore, a thin uniform coating of calcium
carbonate is desired on the inner surface. Perhaps the largest It is important to ensure that the recommended flow rate cannot be
contributor to scale formation is the precipitation of calcium carbonate exceeded. This will normally mean that an orifice plate must be fitted
out of the water. This is dependent on temperature and pH. The higher in the pipework at least 1m before the cooler, with the orifice size
the pH value, the greater the chance of scale formation. Scale can be calculated to ensure that the maximum sea water flow rate cannot be
controlled with water treatment. exceeded. If these precautions are not taken, it is possible that the sea
water flow rate through the cooler may be several times the
Corrosion: In contrast to scale formation is the problem of corrosion. recommended maximum, which will lead to rapid failure.
Chlorides cause problems because of their size and conductivity. Low
pH levels promote corrosion, as well as high levels of dissolved
oxygen.
Sea Water Pressure in Bars Orifice diameter in mm to give a
Fouling: Biological and organic substances (slime) can also cause maximum sea water flow of
problems, but in elevated temperature environments such as cooling 120l/min
processes they are not a major concern. If they create problems with
clogging, commercial shock treatment are available. 3 bar 13
To ensure good operation life and performance of the compressor
4 bar 12
cooling system, the recommended acceptable ranges for different
water constituents are included below: 5 bar 12
Cooling Water Analyses Chart
6 bar 11

7 bar 11

8 bar 10
Substances Test interval Acceptable
concentration 9 bar 10
Corrosivity Monthly — if stable Langelier Index 0 to 10 bar 10
(Hardness, pH, Total for 3 to 4 months, 1
Dissolved Solids, analyse quarterly.
Temperature at inlet Water cleanliness is also extremely important. Strainers are available
Alkalinity) from Ingersoll–Rand. Cleaning of coolers as a result of fouling is a
customer responsibility.
Iron Monthly <2 ppm
Isolation valves with side drains should be installed on both the inlet and
Sulphate Monthly <50 ppm outlet lines.
Chloride Monthly <50 ppm It is recommended that a normally closed solenoid valve be fitted to the
water outlet side of the compressor package.
Nitrate Monthly <2 ppm

Silica Monthly < 100 ppm No oil cooler manufacturer can guarantee that its products will have
an indefinite life and for this reason, we suggest that the cooling system
Desolated Oxygen Daily — if 0 ppm (as low as
is designed to minimise any damage caused by a leaking oil cooler.
stable,analyse possible)
This can be achieved as follows ;
weekly

Oil & Grease Monthly <5 ppm 1. The oil pressure should be higher than the sea water pressure, so
that in the event of a leak occurring, the oil will not be contaminated.
Ammonia Monthly <1 ppm

The Ingersoll–Rand Hydro–check cooling water analysis kit
CPN89223481 provides a sample bottle and pre–addressed return
tube to our laboratory, where a full report on water quality will be issued.
2. When the hydraulic system is not being used, the coolers should be
isolated from sea water pressure.
3. The sea water outlet pipe from the cooler should have a free run to
waste.

M90 M110 M132 M160


T5326
Revision 02
06/03/01
LOCATION IN THE PLANT
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 is recommended.
Sufficient space all round and above the compressor must be
allowed, to enable the effective removal of the cooling air which, in turn,
will reduce the risk of re–circulating the cooling air back through the
compressor.
CAUTION: A minimum of 1 metre all round the compressor is
recommended. If headroom is restricted, then the exhaust should be
ducted or deflected away from the machine.
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 beneath the machine to reduce noise.
It is recommended that provision be made for lifting heavy
components during major overhaul.
CAUTION
Screw type compressors [1] should not be installed in air systems
with reciprocating compressors without means of isolation such as a
common receiver tank. It is recommended that both types of
compressor be piped to a common receiver using individual air lines.
CAUTION
The use of plastic bowls on line filters and other plastic air line
components without metal guards can be hazardous. Their safety can
be affected by either synthetic coolants or the additives used in mineral
oils. From a safety standpoint, metal bowls should be used on any
pressurised system.
DISCHARGE PIPING
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 discharge pressure.
INSTALLATION / HANDLING 21
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. One
item which should be considered is liquid carryover. Installation of air
dryers [3] is always good practice since properly selected and installed
they can reduce any liquid carryover to zero.
It is good practice to locate an isolation valve close to the
compressor and to install line filters [4].
ELECTRICAL DATA
An independent electrical isolator should be installed adjacent to the
compressor.
Feeder cables should be sized by the customer/electrical
contractor to ensure that the circuit is balanced and not overloaded by
other electrical equipment. The length of wiring from a suitable
electrical feed point is critical as voltage drops may impair the
performance of the compressor.
Feeder cable connections to studs L1–L2–L3 on isolator should be
tight and clean.
The applied voltage must be compatible with the motor and
compressor data plate ratings.
The control circuit transformer has different voltage tappings.
Ensure that these are set for the specific applied voltage prior to
starting.
CAUTION
Never test the insulation resistance of any part of the machines
electrical circuits, including the motor without completely disconnecting
the intellisys controller.
NOTE:
Main and fan motor insulation must be tested by a competent
electrician prior to initial start–up or following an extended shutdown
period in cold damp conditions.
NOTE
Fuses F1 and F2 are supplied loose in the starter cabinet. Do not
install until all electrical testing has been completed.
M90 M110 M132 M160
22 OPERATING INSTRUCTIONS

PRIOR TO STARTING KEY

1. Check coolant level. Add if necessary.
1: PACKAGE DISCHARGE PRESSURE L.E.D.
2. Make sure main discharge valve is open.
This will illuminate when the display indicates the package
discharge pressure.
3. Turn on electrical isolator. The power L.E.D. will illuminate and the
display will indicate ‘Ready to start’.
2: AIREND DISCHARGE TEMPERATURE L.E.D.
This will illuminate when the display indicates the airend discharge
temperature.
WARNING
Make sure that all protective covers are in place.
3: SUMP PRESSURE L.E.D.
This will illuminate when the display indicates the sump pressure.

STARTING
4: SEPARATOR PRESSURE DROP L.E.D.
1. Press ‘Start’ [24]. The compressor will start and then load
automatically. This will illuminate when the display indicates the separator
pressure drop.

NORMAL STOPPING
5: TOTAL HOURS L.E.D.
1. Press ‘Unloaded Stop’[25]. The compressor will unload then stop.
This will illuminate when the display indicates the total compressor
running hours.
2. Turn off electrical isolator.

6: LOADED HOURS L.E.D.

EMERGENCY STOP
This will illuminate when the display indicates the total loaded
1. Push ‘Emergency Stop Button’ [26]. The compressor will stop compressor hours.
immediately.

7: LOAD/UNLOAD L.E.D.
2. Turn off electrical isolator.
This will illuminate when the compressor is running onload.

8: MODULATION L.E.D.
CAUTION
After shutdown never allow unit to stand idle with pressure in This will illuminate when the compressor is running in modulation
receiver/separator system. mode. (Optional)

M90 M110 M132 M160


9: UNLOAD L.E.D.
This will illuminate when the compressor is running in unload mode.
10:ALARM L.E.D.
This will flash when a warning condition exists. The warning
detected will be displayed and the compressor will continue to run. The
warning can be reset by depressing set [22].
It will illuminate when an alarm condition has occurred. The
compressor will shutdown immediately. The alarm can be reset by
depressing set [22] twice within 3 seconds.
OTHER L.E.D.s
These will illuminate during the set point routine to indicate which
function is being adjusted.
11:L.E.D.–Set off line pressure.
12:L.E.D.–Set on line pressure.
13:L.E.D.–Select control mode.
14:L.E.D.–Set star delta time.
15:L.E.D.–Set auto restart time.
16:L.E.D.–Select options.
17:L.E.D.–Not used.
18:L.E.D.–Not used.
INSTRUMENT PANEL FUNCTION
19:LIQUID CRYSTAL DISPLAY
This indicates the status of the compressor, set up parameters and
warning/alarm messages. When the compressor is running, the
display will normally show the package discharge pressure.
20:DISPLAY SELECT BUTTON
Press to index through compressor operating conditions. The
corresponding L.E.D. will illuminate adjacent to display.
This is used to select alternative status displays (after
approximately 5 minutes, the display defaults to the package discharge
pressure). Depressing this button in the set point routine will cause exit
to checking machine for 2 seconds, then ready to start.
21:ARROW KEYS
These are used to index through warning and alarm messages. In
the set point routine, these buttons are used to increment/decrement
set point values and enable/disable some operation conditions.
The arrow keys are also used to select pressure bands 1 () or 2
() during normal operation of the compressor.
22:SET BUTTON
Depressing this button when the compressor is stopped will enable
entry into the set point routine. When in the set point routine, depressing
this button will cause the controller to move on to the next set point
setting, saving the new value if one has been entered.
A warning reset is obtained by depressing this button (whilst the
machine is running). An alarm reset is obtained by depressing this
button twice within 3 seconds (the alarm condition will remain if the
indicated fault has not been rectified).
OPERATING INSTRUCTIONS 23
23:LOAD/UNLOAD BUTTON
These are used to manually switch the compressor between a
loaded control mode (e.g. on/off line) and unloaded running.
See L.E.D. [7].
24:START BUTTON
This button when depressed will cause the compressor to start and
load automatically, provided that the controller detects a demand for air.
When pressed in the display mode, it will cause exit to checking
machine for 2 seconds, then ready to start.
25:UNLOADED STOP
This button when depressed while the compressor is running, will
unload the compressor (if not already unloaded) for 10 seconds and
then stop. This is the normal method for stopping the compressor. If the
compressor is already stopped, it will execute an L.E.D. check (all the
L.E.D.s should illuminate) and display the controller software revision.
26:EMERGENCY STOP
This button when depressed will stop the compressor immediately
and display an emergency stop alarm message.
27:POWER L.E.D.
This will illuminate when the 8V controller supply is available.
28:AUTOMATIC RESTART L.E.D.
This will illuminate when the machine has shutdown due to low air
demand. The compressor will restart and load automatically as soon
as the demand for air resumes.
DISPLAY MESSAGES
When the compressor is running normally, the display will indicate
the package discharge pressure and illuminate the corresponding
L.E.D. [1]. An arrow will also appear in the far right of the display
indicating pressure band selection. Pressing display select [20] will
change the display value and the corresponding L.E.D. will illuminate.
The controller monitors all aspects of the compressor whilst running
and will display warnings or in severe conditions execute an
emergency stop and display alarm conditions.
MACHINE CONTROL MODES
CAPACITY CONTROL
The compressor is fitted with ON LINE–OFF LINE control as
standard. Modulation can be fitted as an option. If modulation is fitted
it is activated by selection at the control panel.
ON LINE – OFF LINE CONTROL
For applications that require a widely varying air demand, this mode
of control will deliver air at full capacity or zero capacity with low
receiver pressure.
This mode of operation is controlled by the pressure transducer
(1PS) responding to changes in plant air pressure. This sensor
energises the load solenoid valve (1SV) which in turn operates the
venting valve (blowdown) and the closing of the atmospheric vent
opening in the air inlet valve.
The compressor then delivers full capacity air to the plant system.
If the air pressure in this system rises to the upper set point of the
pressure setting, the load solenoid valve is de–energised allowing the
inlet valve to close. At the same time, the venting valve opens allowing
the receiver pressure to drop.
The pressure setting has a range of 0,83 bar between its upper and
lower set points.The upper set point is set at 0,2 bar above the
compessor rated discharge pressure.
M90 M110 M132 M160
24 OPERATING INSTRUCTIONS
UPPER RANGE MODULATION CONTROL (OPTIONAL)
For plants having a relatively high and constant air demand, Upper
Range Modulation is the recommended mode of control.
Upper range modulation retains the features of On line – Off line
control but provides the throttling of the inlet air flow as the line pressure
rises to the upper set point of the off–line pressure setting.
By bleeding off a small amount from the regulator valve, which
energises the Modulate Solenoid Valve, a reduction in the air signal to
the pneunatic cylinder on the inlet valve allows the cylinder to ‘trim’ the
inlet valve position as dictated by changing line pressure. Modulation
begins when the compressor reaches about 94% of the rated line
pressure and is factory set to modulate down to aproximately 70% of
rated capacity.
If the air demand decreases to a level below the 70% modulated
output, the line pressure will increase slightly to the upper limit of the
pressure setting, when the compressor then changes to the Off line
control position and operates with the receiver vented.
CONTROLLER WARNING MESSAGES
In the event of a warning, the controller will display a message and
the alarm L.E.D. [10] will flash. The warning message will alternate with
the normal display every 4 seconds, the compressor will continue to run
but the fault should be rectified as soon as possible. The arrow keys
[21] should be used to index the display for any additional warning
messages. A warning message may be reset by depressing set [22]
once.
NOTE:
The warning will recur if the fault has not been rectified. The
following warning messages may be displayed:
COOLANT FILTER
The pressure differential across the coolant filter exceeds 1 bar.
AIR FILTER
The air filter is dirty or blocked and should be replaced.
SEPARATOR ELEMENT
The separator element is dirty or blocked and should be replaced.
AIREND TEMPERATURE
The airend temperature reaches 97% of the high airend
temperature set point (i.e. 106°C).
CONTROLLER ALARMS
In the event of an alarm, the controller will execute an emergency
stop, the alarm L.E.D. [10] will illuminate and an alarm message will be
displayed. The arrow keys [21] should be used to index the display for
any additional alarm messages. An alarm is reset by depressing set
[22] twice within a 3 second period after the fault has been rectified. The
compressor will restart only when all alarm conditions have been
rectified. The following alarm messages may be displayed (For fault
correction see the Fault Finding section):
STARTER FAULT
The contactor sequence during start or stop is incorrect.
AIREND TEMPERATURE
The airend discharge temperature is above the high temperature
set point.
M90 M110 M132 M160
MOTOR OVERLOAD
The motor overload contacts are open. The motor overload must be
reset before the controller can be reset.
REVERSE ROTATION
No sump pressure is detected after the first 2 seconds of running.
Isolate the machine and reverse the mains supply connections before
resuming.
OVER PRESSURE
The line pressure is 1 bar (15 psi) greater than the rated discharge
pressure.
TEMPERATURE SENSOR 1
The airend temperature sensor/ connecting cable has failed.
Refer to diagram T5106
PRESSURE SENSOR
Indicates pressure transducer failure / connecting cable fault.
FAILED CALIBRATION
During calibration routine, a 10% of scale error has been detected.
Ensure that the separator is completely blowndown and repeat
calibration.
[CONTROL POWER OR]
The 48Vac supply is not present at the controller, or:–
REMOTE START FAILURE
Momentary remote start has not disengaged before star–delta
transition. This alarm is active only if the remote start/stop is enabled.
REMOTE STOP FAILURE
The momentary remote stop switch has not disengaged when the
start signal is received. This alarm is active only if the remote start/stop
is enabled.
EMERGENCY STOP
The emergency stop button is engaged.
LOW SUMP PRESSURE
The sump pressure drops below 1bar during normal operation.
MAINTENANCE PROMPTS
The service warning and flashing LED will appear after the first 150
hours and every 2000 hours thereafter, cycling every 2 seconds with
the current display message.
The customer can only reset the warning for 24 hours by pressing
the “set” button.
Ingersoll–Rand service engineers will master reset the warning
after completing the service work.
The service warning will return each subsequent 2000 hours.
The machine will be master reset after service work conducted prior
to the 2000 hour interval to prevent false indication.
 AIRCARE WARRANTY 25

Superior Service Solutions for Air Systems

AirCare is a responsive and flexible contract maintenance program custom designed for the owner who requires planned maintenance for increased
system reliability.
The AirCare program provides you with reduced maintenance costs, reduced energy usage through optimization and efficiency, and reduced produc-
tion losses through fewer unexpected maintenance requirements and downtime. An optional feature, Intelliguard is used to reduce downtime by remote
monitoring.

Air Care Options

Unit Status Coverage Service Level
Inspection and diagnostic service only or
Sign up for AirCare within the warranty period Five Year Drivetrain or Package coverage Preventative maintenance and diagnostic
service

To enroll in AirCare or Intelliguard, contact your local Ingersoll–Rand representative today.

M90 M110 M132 M160

26 MAINTENANCE

PERIOD MAINTENANCE PERIOD MAINTENANCE

Daily Check the coolant level and replenish if 2000 hours Lubricate the main motor drive end bearing.
necessary. M90/110/132/150 Quantity of grease required:
TEFC 30g
When the separator Check the pressure differential.
element indicator 4000 hours Lubricate the main motor non–drive end
light flashes * Change the separator element if the bearing.
pressure drop is zero or exceeds 1 bar (15 Quantity of grease required:
p.s.i.g.) 20g
First 150 hours Change the coolant filter. Replace the Ultracoolant at whichever
8000 hours / 2 years
Check that the safety valve easing gear interval occurs first.
Each week
moves freely. Also replace the separator element and
1 month Check the operation of the high temperature coolant filter.
protection switch(es) 4 years Replace all hoses.
(109
C standard or 100
C for TUV
applications)
NOTE
1 month Check the cooler(s) for build up of foreign
matter. Clean if necessary by blowing out () To determine the correct letter designation (B,L) consult the CPN
with air or by pressure washing. field on the main motor data plate.

1 monthly intervals. On water cooled and sea water cooled mod-
els check the water input line strainer for
build up of foreign matter, clean if required
Each 3 months Check all hoses for signs of deterioration,
cracks, hardening etc.
Each 2000 hours Change the coolant filter.
Note:
On some sea water cooled models the oil cooler and after cooler are
fitted with sacrificial zinc anodes (pencils) that are located in the end
bonnets of the coolers. These sacrificial zinc anodes should be
checked after the first 50 hours of operation to determine if corrosive
conditions exist. If satisfactory this interval may be extended to 500
hours.

6 months Check the calibration of the pressure

NOTE:
transducer.
1 If sacrificial zinc anode is 50% corroded it should be replaced.
1 year Change the air filter element.
Replace the element sooner if the indicator 2 Coastal/harbour waters can contain corrosive chemicals from
light flashes. pollution and may reduce anode/cooler life.
8000 hours / 1 year Check the scavenge screen for blockage, 3 Effects of corrosion or erosion are specifically excluded from
clean if required. warranty considerations.
1 year Remove the safety valve from the
compressor, inspect and re–calibrate. WARNING
Do not under any circumstances open any drain valve or remove
4000 hours Lubricate the main motor drive end bearing. components from the compressor without first ensuring that the
M90 ODP Quantity of grease required: compressor is FULLY SHUT– DOWN, power isolated and all air
B: 20g () pressure relieved from the system.
L: 40g ()
Lubricate the main motor non–drive end
bearing. * Caution: The separator tank lid and element are heavy and should
Quantity of grease required: only be removed using suitable lifting equipment. Never try to remove
B: 16g () by hand.
L: 40g () Wear protective gloves due to potential sharp edges/burrs.
4000 hours Lubricate the main motor drive end bearing.
M110 ODP Quantity of grease required: COOLANT LEVEL CHECKING PROCEDURE
B: 40g () The coolant level should be checked daily. A coolant level sight
L: 40g () glass is located on the side of the separator tank and while the machine
Lubricate the main motor non–drive end is running on load, coolant should always be visible in the sight glass.
bearing. The normal position is half way.
Quantity of grease required: ADDING COOLANT
B: 20g ()
L: 40g () Run the compressor for a minimum of 40 seconds before stopping,
then add coolant until the level is up to the mid–point of the sight glass.
B: 4000 hours () Lubricate the main motor drive end bearing.
L: 2000 hours () Quantity of grease required:
M132/160 B: 40g () COOLANT FILTER CHANGE PROCEDURE
ODP L: 50g ()
. Loosen filter element with the correct tool.
Lubricate the main motor non–drive end
bearing. . Remove the element from the housing.
Quantity of grease required: . Place the old element in a sealed bag and dispose of in a safe way.
B: 20g ()
L: 50g () . Clean the mating face of the housing.
. Remove the new Ingersoll–Rand replacement element from its
protective package.
. Apply a small amount of lubricant to the element seal.
. Screw the new element down until the seal makes contact with the
housing, then hand tighten a further half turn.
. Start the compressor and check for leaks.

M90 M110 M132 M160

 MAINTENANCE 27
SSR ULTRACOOLANT – CHANGE PROCEDURE CAUTION
(Capacity [75] litres) Do not use any form of sealant on either the separator tank or the
separator tank cover faces.
It is better to drain the coolant immediately after the compressor has
been operating as the liquid will drain more easily and any contaminant
will still be in suspension.
. Re–assemble the components in reverse order.
. Position a suitable container under the drain plug.
. Start the compressor and check for leaks.
. Remove the plug and completely drain the coolant.

. Replace the coolant filter. WARNING

Do not remove the staple from the anti–static gasket on the
separator element since it serves to ground any possible static
. Replace the separator element. build–up.

. Replace the plug and refill the compressor.

AIREND BEARINGS
Airend bearings are lubricated by the compressor coolant and
. CAUTION – DO NOT MIX OILS WITH SSR ULTRACOOLANT. require no maintenance.

. Start the compressor and check for leaks.
. Check the coolant level, refilling if necessary.
MOTOR BEARINGS
Clean the area around the inlet and outlet plugs before removing the
plugs. Add the specified quantity of recommended grease using a hand
lever gun. Replace the inlet plug, run the machine for 10 minutes and
then replace the outlet plug.

. Dispose of waste coolant in accordance with local and MOTOR BEARING LUBRICANT SPECIFICATION
governmental regulations.
Use ESSO UNIREX N3 grease or equivalent.

NOTE
Shorter coolant drain intervals may be necessary if the compressor CAUTION:
is operated in adverse conditions. Do not over pack the motor bearings with grease as this may lead
to motor failure.

AIR FILTER CHANGE PROCEDURE

CAUTION:
. Unscrew the retaining nut and withdraw the old elements. Ensure dirt and/or other contaminants are not introduced into the
bearing during the greasing process.
. Fit the new element ensuring that the retaining nut is secured.

SEPARATOR ELEMENT CHECKING PROCEDURE H.A.T. SWITCH CHECKING PROCEDURE

With the compressor running on load, depress the line/sump
selector. It will be necessary to change the element if the differential
pressure equals zero or exceeds 15 psig (1 bar).
SEPARATOR ELEMENT CHANGE PROCEDURE
It is recommended that the temperature switches (1TAS and 2TAS)
are checked regularly as follows:
AIr cooled machines
Stop the cooling fan by opening the fan motor circuit breaker.

.Disconnect the scavenge tube from the airend and loosen the fitting
that secures the scavenge tube to the separator tank cover and then Water cooled machines
remove the scavenge tube. Shut off the cooling water.

. Disconnect all piping from the separator tank cover. The machine should trip at 109
C standard, 100
C TUV
application.

. Remove the setscrews securing the cover to the tank and remove
the complete cover assembly.
CAUTION:
Under no circumstances should these discharge temperatures be
* Heavy cover– use lifting equipment
exceeded. If the machine fails to trip A FAULT EXISTS. Investigate
immediately.
. Withdraw the used element, place it in a sealed bag and dispose of
it safely.

The temperature at which the machine stops should be recorded for

* Wear safety gloves against sharp edges comparison with future results.

. Clean the gasket surface on both the tank and the cover. HIGH BEARING TEMPERATURE SWITCH (5TAS)
Should the airend bearing temperature reach 109
C standard or
. Install the replacement element. 100
C TUV application, the machine will stop.

M90 M110 M132 M160

28 MAINTENANCE
COLD START / RAPID WARM–UP SWITCH (4TS)
The purpose of this switch is to reduce the unloaded sump pressure
to save energy (refer section on dual blowdown system) and to
automatically load the compressor when there is a demand for air –
providing the service switch is set to the load position. The switch is set
to open at 49
C.

T5359
Revision 01
09/94

KEY NOTE – It is important that the correct size spanner is used and on no
account must a stillson type wrench be used on any part of this
componemt. Tighten the cap to a torque of 150Nm (110 lb.ft.)
1. Housing
2. Cap
The scratches should be over the area covered by and extending
3. Disc beyond the outer seat face.
4. Filter & screen
5. Retaining cap TO SERVICE
Unscrew the cap using a spanner. If the disc and body are only
OPERATION slightly worn, they can be refurbished by lapping individually on a flat
surface plate. If the wear is too great to be rectified, the whole assembly
On the underside of the disc [3] is a machined circular groove, whilst must be replaced.
the opposite side is plain with a single scratch toward the outer edge.

The filter can be removed and cleaned. To re–assemble, replace the

The unit is best suited to clean operating conditions. If the operating filter and retaining cap .A fine smear of molybdenum disulphide grease
conditions are dirty, unscrew the cap and turn over the disc so that the should be applied to the threads.
plain side with a bleed scratch is toward the seating faces. In extremely
dirty conditions, it may be necessary to deepen the bleed scratch or to
make additional scratches up to a maximum of 3.

Replace the cap using a suitable high temperature anti–seize

grease on the thread.

M90 M110 M132 M160

 MAINTENANCE 29

KEY Slide the travel stop bracket D as far as possible in the direction of
the arrow.

1: UL88 modulator (Optional) Rotate the air inlet valve shaft counter clockwise until the butterfly
2: Cylinder valve E is in the closed position.

3: Coolant pressure
Ensuring that the butterfly valve E is closed, position the linkage arm
4: Vent F against the travel stop bracket D.
5: Inlet air flow
Tighten the screw B to secure the linkage arm F to the shaft.
6: Line pressure (modulate) (Optional)
7: Vent (Optional)
INLET VALVE POSITIONER LINKAGE ADJUSTMENT
8: Inlet valve
Refer to diagram T5360
9: Open
10:Closed Ensure that the modulator lever G is against the stop H. (If fitted)

Ensure that the linkage arm F is against the travel stop bracket D.
NOTE:–
Parts of this section refer to the modulation system, which may not Adjust the length of the inlet valve positioner linkage P until the
be fitted if you have a standard machine. screw A threads easily into the linkage arm F.

Tighten screw A.

INLET CONTROL VALVE ADJUSTMENT

UNLOADED RUNNING RECEIVER PRESSURE ADJUSTMENT
Refer to diagram T5360
Refer to diagram T5360

Remove screw A securing the cylinder to the linkage arm F.

Loosen screw B securing the linkage arm F to the shaft.
Loosen screws C securing the travel stop bracket D to the mounting
bracket.
An indicator line should be scribed horizontally on the butterfly valve
spindle to record the position of the valve.
Using the stop bracket D and screws C push the linkage arm F
clockwise until the scribed line is at approximately 10
and then tighten
the screws C.

M90 M110 M132 M160

30 MAINTENANCE
Start the compressor and allow it to reach its normal working
temperature. (Refer to STARTING THE MACHINE in the OPERATING
INSTRUCTIONS section).
Using the service load/unload button located on the control panel,
unload the compressor.
Close the isolation valve.
Using the stop bracket D and screws C with the display reading
sump pressure, adjust the inlet valve stop until the sump pressure
reads 1,7 to 2,0 bar on the display. (Clockwise increases the pressure).
The compressor is now operating correctly unloaded and can be
returned to load mode after opening the isolation valve.
MODULATOR ADJUSTMENT (OPTIONAL)
Refer to diagram T5360
Remove the nut J from the modulator K.
Loosen the locknut L and adjust screw M a few turns
Start the compressor and run it with modulation mode off.
M90 M110 M132 M160
Allow the machine to reach its normal operating temperature, then
load the machine. This allows the load cylinder to be actuated, opening
the inlet control valve E and loading the compressor.
Open the isolation valve and set the discharge pressure to 0,3 bar
below the rated operating pressure which is stated on the compressor
data plate.
Confirm that the air inlet valve is fully open and then stop the
compressor normally. Press the SET button [4] and select SELECT
CONTROL MODE. Press the arrow keys [3] until the MODULATION
option is displayed. Restart the compressor. Air flow should then be
detected coming from the orifice (vent 7) located in the bottom of the
modulator body K.
Turn the modulator adjusting screw M until the lever G begins to
move off the stop H.
NOTE: Confirm at this stage that the line pressure has remained
steady and that the air inlet valve is still fully open.
Whilst holding adjusting screw M firm, tighten the locknut L.
Replace nut J.
Raise the line pressure by means of the isolation valve to just below
the off–line pressure setting. Set the adjustment lockbolt N so that it just
makes contacts with lever G. Tighten the locknut on the bolt.
 MAINTENANCE 31

Refer to diagram T5307

The INTELLISYS controller enables the user to adjust the operating
102 PSI ↑
parameters of the compressor to suit the application. To enter set point
adjustment depress set [22] when the display shows ready to start. The
arrow keys [21] are used to increment or decrement values or
§ P2 = P1 – 0,3bar (5psi) max.
4,4bar (65psi) min.
parameters. Depressing set [22] stores the new value and moves on
to the next value. INCREMENT VALUE 0,1bar (1psi)

READY TO START

OFFLINE PRESSURE
(Pressure band 1)

OFFLINE PRESSURE
(Pressure band 2)

112 PSI ↑
ML 7,7bar (112psi) max. (maks.)
MM 8,7bar (126psi) max. (maks.)
MH 10,0bar (145psi) max. (maks.)
MU 13,0bar (189psi) max. (maks.)
ALL 5,1 bar (75psi) min.
INCREMENT VALUE 0,1 bar (1psi)
112 PSI ↑
ML 7,7bar (112psi) max. (maks.)
MM 8,7bar (126psi) max. (maks.)
MH 10,0bar (145psi) max. (maks.)
MU 13,0bar (189psi) max. (maks.)
ALL 5,1 bar (75psi) min.
INCREMENT VALUE 0,1 bar (1psi)

ONLINE PRESSURE
(Pressure band 1)
M90 M110 M132 M160
32 MAINTENANCE
SEQUENCER ENABLE/DISABLE
(Only functions if an Ingersoll–Rand sequencer is connected)

ONLINE PRESSURE SEQUENCER OFF

(Pressure band 2)
ON/OFF
102 PSI ↑
§ P2 = P1 – 0,3bar (5psi) max.
4,4bar (65psi) min.
INCREMENT VALUE 0,1bar (1psi)

REMOTE START/STOP
ENABLE/DISABLE
(Compressor will only start/stop via remote signalling)

REM START OFF

CONTROL MODE REMOTE START ON/OFF

ON/OFF LINE

ON/OFF LINE/
(MODULATION/
AUTOMATIC CONTROL SYSTEM (OPTIONAL))

DELAY LOAD TIME

Delay between the online signal and compressor load.

DELAY LOAD TIMER

STAR–DELTA TIME 0 – 60 SECONDS

5 SEC

4 – 15 SECONDS

OFF–LINE PRESSURE

112 PSI ↑
AUTO RESTART TIME

10 MIN

OFF/10–20 MINUTES CHECKING MACHINE

READY TO START

§ KEY
P1 = OFFLINE PRESSURE
P2 = ONLINE PRESSURE

M90 M110 M132 M160

 FAULT FINDING 33
FAULT CAUSE REMEDY
’Power on’. L.E.D. does CONTROL VOLTAGE NOT Check the control fuses.
not illuminate. AVAILABLE
Check the transformer secondary windings for the control voltage.
Controller indicates trip CONTROL CIRCUIT Check machine for indicated fault. Attempt to ’reset’ the controller. If the fault
condition. INTERRUPTED BY A SAFETY persists investigate further.
DEVICE
Compressor trips INSUFFICIENT COOLANT Check the coolant level.
indicating a high CIRCULATION
compressor Check the temperature sensor
temperature. Change coolant filters
Check the operation of thermostatic valve and oil stop valve
POOR ELECTRICAL H.A.T. thermistors fail-safe. The unit will trip due to open or short circuit.
CONNECTION
INSUFFICIENT COOLING TAKING Check that the cooling air flow is not obstructed at:
PLACE . The inlet to the package
. The cooler matrix
. The exhaust vents
EXCESSIVELY HIGH AMBIENT Improve the ventilation to the compressor room.
TEMPERATURE
(i.e. greater than 46oC (115oF).
INSUFFICIENT COOLING TAKING If machine is water cooled or seawater cooled, check that the cooling water is
PLACE flowing. Check that there is no air in the water cooling system. Check that the
strainer is not blocked.
Compressor trips and EXCESSIVE CURRENT HAS Check the actual operating pressure and lower the setting if it is too high. Isolate
indicates CAUSED THE THERMAL the electrical supply and check that the airend and motor rotate freely. Check the
motor overload. OVERLOAD (MOL) TO TRIP separator element for excessive pressure drop.
Check supply voltage
Compressor shutdown. ISOLATION VALVE CLOSED. Open the valve and restart.
Display shows
OVERPRESSURE. BLOWDOWN SYSTEM Check the operation of the load solenoid.
INEFFECTIVE.
Check the operation of the unloader valve – strip and clean if necessary.
Compressor will not DEMAND TOO HIGH Check for leaks, open service valves or exceptionally high demand.
build up rated pressure.
OFFLINE PRESSURE SET TOO Check the offline pressure setting.
LOW
Compressor will not INLET VALVE NOT OPENING Check that the valve is free to open.
load.
Check the operation of the load solenoid valve 1SV.
Compressor fails to – Check the operation of the inlet valve.
deliver rated
capacity. Check the operation of the load solenoid valve 1SV.
Check the offline/online pressure setting.
Check the inlet filter for contamination. The L.E.D. should indicate if it is blocked.
Excessive coolant BLOCKED SCAVENGE LINE Clear the blockage.
consumption.
RUPTURED OR FOULED Change the element.
SEPARATOR ELEMENT
Rapid cycling or RAPID LOAD/UNLOAD CYCLING Duty cycle too rapid – Increase system capacity.
receiver will not
blow–down to unloaded MINIMUM PRESSURE VALVE Strip the MPV, examine and repair if necessary.
running pressure. (MPV) STUCK OPEN

Safety valve blows MPV STUCK CLOSED Strip MPV, examine and repair if necessary.
when compressor goes
on load. SAFETY VALVE FAULTY Check the setting of the safety valve and the rated pressure.
BLOCKED SEPARATOR ELEMENT Check pressure differential and replace

M90 M110 M132 M160

Printed in the United Kingdom