CP 001

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ENGLISH R90 - 110N

BULGARIAN
R90 - 110I
CZECH
DANISH OPERATION AND MAINTENANCE MANUAL

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GREEK
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Ensure that the operator reads and understands the

decals and consults the manuals before maintenance
or operation.
Ensure that the Operation and Maintenance manual
is not removed permanently from the machine.
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance
Manuals.
C.C.N. : 80445802
DATE : FEBRUARY 2010
REV. : B
AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects
in material and workmanship for a period of twelve months 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 fulfillment 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.
1.0 CONTENTS
contents PAGE contents PAGE
1.0 CONTENTS 1 9.0 OPERATING INSTRUCTIONS 47

2.0 FOREWORD 2 9.1 OPERATING INSTRUCTIONS FOR VSD 47
3.0 ABBREVIATIONS & SYMBOLS 4 9.1.1 BASIC OPERATION 47
4.0 PURCHASE ORDER DETAILS 5 9.1.2 INTELLISYS CONTROLS (VSD) 49
5.0 SAFETY 6 9.1.3 DISPLAY SCREEN 50
5.1 SAFETY INSTRUCTIONS 6 9.1.4 CURRENT STATUS SCREEN 51
5.2 SAFETY PRECAUTIONS 6 9.1.5 MAIN MENU 52
5.3 TEXT DECALS 9 9.1.6 OPERATOR SETPOINTS 53
5.4 GRAPHIC FORM AND MEANING OF ISO 9.1.7 OPTIONS 55
SYMBOLS 12
9.1.8 SENSOR CALIBRATION 56
6.0 RECEIPT / HANDLING 14
9.1.9 TRIP HISTORY 57
6.1 RECEIPT 14
9.1.10 CLOCK FUNCTIONS 57
6.2 UNPACKING AND HANDLING 14
9.1.11 ENERGY STATUS MESSAGES 58
6.3 LONG TERM STORAGE 14
9.1.12 WARNINGS 59
7.0 INSTALLATION 15
9.1.13 SERVICE WARNINGS 59
7.1 LOCATION IN PLANT 15
9.1.14 INITIAL CHECK TRIPS: 59
7.2 DISCHARGE AND CONDENSATE PIPING 16
9.1.15 TRIPS 60
7.3 ELECTRICAL 17
9.2 OPERATING INSTRUCTIONS FOR FS 61
7.4 WATERCOOLED UNITS 19
10.0 MAINTENANCE 71
7.5 ENVIRONMENTAL LIMITS 21
10.1 MAINTENANCE PROMPTS 71
8.0 GENERAL INFORMATION 22
10.2 MAINTENANCE CHART 72
8.1 GENERAL ARRANGEMENT, AIR COOLED (R90-
10.3 MAINTENANCE PROCEDURES 73
110) 22
10.4 ROUTINE MAINTENANCE 75
8.1 GENERAL ARRANGEMENT, WATER COOLED
(R90-110) 28 10.5 STARTER BOX PANEL FILTER (VSD ONLY) 81
8.2 PROCESS AND INSTRUMENTATION DIAGRAM 11.0 FAULT FINDING (VSD) 82
(AC/WC) 90-160 KW (VSD) 33
11.1 GENERAL FAULTS 82
8.2 PROCESS AND INSTRUMENTATION DIAGRAM
11.2 INTELLISYS FAULTS (INDICATED ON THE
(A.C/W.C) 90-160 KW (FS) 35
INTELLISYS CONTROLLER) 85
8.2 PROCESS AND INSTRUMENTATION DIAGRAM
11.3 DRIVE FAULTS (INDICATED ON THE INTELLISYS
ENERGY RECOVERY SYSTEM 38
CONTROLLER) 87
8.3 SCHEMATIC, ELECTRICAL WIRING (VSD) 40
8.3 SCHEMATIC, ELECTRICAL WIRING (FIXED SPEED
- Y/D) (STANDARD) 42
8.3 SCHEMATIC, ELECTRICAL WIRING (FIXED SPEED
- SOFT STARTER) (OPTION) 44
8.4 GENERAL DESCRIPTION 46
R90 - 110N & R90 - 110I

http://www.ingersollrandproducts.com
2.0 FOREWORD
Machine models represented in this manual may be Details of approved equipment are available from Ingersoll
used in various locations worldwide. Machines sold and Rand Service departments.
shipped into European community countries requires
This machine has been designed and supplied for
that the machine display the EC Mark and conform to
use only in the following specified conditions and
various directives. In such cases, the design specification
applications:
of this machine has been certified ascomplying with EC
directives. Any modification to any part is absolutely • Compression of normal ambient air containing no
prohibited and would result in the CE certification and known or detectable additional gases, vapors or
marking being rendered invalid. particles
The contents of this manual are considered to be • Operation within the ambient temperature range
proprietary and confidential to Ingersoll Rand and specified in the GENERAL INFORMATION section of
should not be reproduced without the prior written this manual.
permission of Ingersoll Rand. IF IN DOUBT CONSULT SUPERVISION.
Nothing contained in this document is intended to The company accepts no responsibility for errors in
extend any promise, warranty or representation, translation of this manual from the original English
expressed or implied, regarding the Ingersoll Rand version.
products described herein. Any such warranties or other The design of this Compressor package and certain
terms and conditions of sale of products shall be in features within it are covered by patents held by
accordance with the standard terms and conditions of Ingersoll Rand and patents pending
sale for such products, which are available upon request.
SSR ULTRA COOLANT is a registered trademark of
This manual contains instructions and technical data to Ingersoll Rand Company USA.
cover all routine operation and scheduled maintenance
tasks by operation and maintenance staff. Major INTELLISYS is a registered trademark of Ingersoll Rand
overhauls are outside the scope of this manual and Company USA.
should be referred to an authorized HPM™, HYBRID PERMANENT MAGNET™ and HPM
Ingersoll Rand service department. Logo are trade marks registered by MOTEURS LE-ROY-
All components, accessories, pipes and connectors added SOMER
to the compressed air system should be:
• of good quality, procured from a reputable manufac- © COPYRIGHT 2010
turer and, wherever possible, be of a type approved Ingersoll Rand COMPANY
by Ingersoll Rand.
• clearly rated for a pressure at least equal to the ma-
chine maximum allowable working pressure.
• compatible with the compressor lubricant/coolant.
• accompanied with instructions for safe installation,
operation and maintenance.
Ingersoll Rand reserves the right to make changes and
improvements to products without notice and without
incurring any obligation to make such changes or add
such improvements to products sold previously.
R90 - 110N & R90 - 110I

2.0 fOREWORD
warning
The use of the machine in any of the situation types listed in table 1:-
a) Is not approved by Ingersoll Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll Rand.
TABLE 1
warning
Use of the machine to produce compressed air for the following is not permitted:
a) direct human consumption
b) indirect human consumption.
Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION
of this manual is not permitted.
Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or
vapors is not permitted.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR VAPORS MAY BE PRESENT.
Use of the machine fitted with non Ingersoll Rand approved components is not permitted.
Use of the machine with safety or control components missing or disabled is not permitted.
Connection to an electrical supply of incorrect voltage and/or frequency is not permitted.
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
• Decrease compressor performance.
• Increase maintenance.
• Invalidate all warranties.
(For VSD only)

The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such
as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with
cardiac pacemakers, defibrillators or other implanted electronic medical device.
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the
internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any
work on the drive unless trained. There are no user serviceable items behind the cover.
The compressor can operate in a pressurized shutdown mode. If the compressor stops automatically, the
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through
which any residual pressure will be vented. Downstream of the separator tank may still contain system
pressure which must also be vented.
notice
The manual is intended for worldwide use and contains both metric and imperial data where required.
R90 - 110N & R90 - 110I

3.0 ABBREVIATIONS & SYMBOLS
#### Contact Ingersoll Rand for serial number
->#### Up to Serial No.
####-> From Serial No.
* Not illustrated
† Option
NR Not required
AR As required
SM Sitemaster/Sitepack
VSD Variable Speed Drive
FS Fixed Speed
PDM Power Drive Module (Starter Box for VSD Units)
HA High ambient machine
WC Watercooled machine
AC Aircooled machine
ERS Energy recovery system
T.E.F.C. Totally enclosed fan cooled motor (IP54)
O.D.P. Open drip proof (motor)
ppm parts per million
bg Bulgarian lv Latvian, Lettish

cs Czech mt Maltese
da Danish nl Dutch
de German no Norwegian
el Greek pl Polish
en English pt Portuguese
es Spanish ro Romanian
et Estonian ru Russian
fi Finnish sk Slovak
fr French sl Slovenian
hu Hungarian sv Swedish
it Italian zh Chinese
lt Lithuanian
R90 - 110N & R90 - 110I

4.0 PURCHASE ORDER DETAILS
ROTARY SCREW AIR COMPRESSOR

This unit was purchased from
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
Ingersoll Rand Company reserves the right to make changes or add
improvements without notice and without incurring any obligation
to make such changes or add such improvements to products sold
previously.
No. of units on order:____________________________________________
Customer Order No:_____________________________________________
Ingersoll Rand Co. Order No______________________________________
For ready reference:
Record the serial number and model number of your unit here.
Serial Number:_ ________________________________________________
Model Number:_ _______________________________________________
R90 - 110N & R90 - 110I

5.0 SAFETY
5.1 SAFETY INSTRUCTIONS
Safety instructions in the operators manual are bold- Ensure that the Operation and Maintenance manual, and
faced for emphasis. The signal words DANGER, WARNING the manual holder, are not permanently removed from
and CAUTION are used to indicate hazard seriousness the machine.
levels as follows.
Ensure that maintenance personnel are adequately
Ensure that the operator reads and understands the trained, competent and have read the Maintenance
decals and consults the manuals before maintenance or Manuals.
operation.
danger
caution
Indicates the presence of a hazard which WILL
cause serious injury, death or property damage, if Indicates the presence of a hazard which WILL or
ignored. can cause injury or property damage, if ignored.
NOTICE
warning Indicates important set–up, operating or
Indicates the presence of a hazard which CAN maintenance information.
cause serious injury, death or property damage, if
ignored.
5.2 SAFETY PRECAUTIONS

General Information If more than one compressor is connected to one
common downstream plant, effective check valves and
Compressed air and electricity can be dangerous. Before
isolation valves must be fitted and controlled by work
undertaking any work on the compressor, ensure that the
procedures, so that one machine cannot accidentally be
electrical supply has been isolated, locked off, tagged and
pressurized / over pressurized by another.
the compressor has been relieved of all pressure.
If a safety valve is installed between the isolation valve
Make sure that all protective covers are in place and that
and the compressor, it must have sufficient capacity to
the canopy/doors are closed during operation.
relieve the full capacity of the compressor(s).
Installation of this compressor must be in accordance with
The discharged air contains a very small percentage of
recognized electrical codes and any local Health and Safety
compressor lubricating oil and care should be taken to
Codes.
ensure that downstream equipment is compatible.
Use only safety solvent for cleaning the compressor and
If the discharged air is to be ultimately released into a
auxiliary equipment.
confined space, adequate ventilation must be provided.
Compressed air
The use of plastic bowls on line filters without metal
Ensure that the machine is operating at the rated pressure guards can be hazardous. Their safety can be affected
and that the rated pressure is known to all relevant by either synthetic lubricants, or the additives used in
personnel. mineral oils. Metal bowls should be used on a pressurized
system.
All air pressure equipment installed in or connected to
the machine must have safe working pressure ratings of Compressed air must not be used for a direct feed to any
at least the machine rated pressure. form of breathing apparatus or mask.
When using compressed air always use appropriate
personal protective equipment.
R90 - 110N & R90 - 110I

5.0 SAFETY
All pressure containing parts, especially flexible hoses Transport
and their couplings, must be regularly inspected, be free
When loading or transporting machines ensure that the
from defects and be replaced according to the Manual
specified lifting and tie down points are used.
instructions.
It is recommended that the machine be moved using the
Compressed air can be dangerous if incorrectly handled.
fork lift slots in the machine base.
Before doing any work on the unit, ensure that all
pressure is vented from the system and that the machine Refer to section 8-General Information for reference
cannot be started accidentally. information.
Avoid bodily contact with compressed air. Electrical
The safety valve located in the separator tank must be The compressor has high and dangerous voltage in the
checked periodically for correct operation. motor starter and control box. All installations must be
in accordance with recognized electrical codes. Before
Whenever pressure is released through the pressure relief
working on the electrical system, be sure to remove
valve, it is due to excessive pressure in the system. The
voltage from the system by using a manual disconnect
cause for the excessive pressure should be investigated
switch. A circuit breaker or fuse safety switch must be
immediately.
provided in the electrical supply line leading to the
Materials compressor.
The following substances are used in the manufacture Those responsible for installation of this equipment
of this machine and may be hazardous to health if used must provide suitable grounds, maintenance clearance
incorrectly: and lightning arrestors for all electrical components in
accordance with National and Local code requirements.
• Preservative grease
• Rust preventative Keep all parts of the body and any hand-held tools or
other conductive objects, away from exposed live parts
• Compressor coolant
of the compressor electrical system. Maintain dry footing,
warning stand on insulating surfaces and do not contact any other
portion of the compressor when making adjustments or
AVOID INGESTION, SKIN CONTACT AND
repairs to exposed live parts of the compressor electrical
INHALATION OF FUMES
system. All personal protective equipment appropriate to
the voltage present should be worn while servicing live
Please see the coolant material safety data sheet for electrical systems.
further information. Material safety data sheets can be
Close and lock all access doors when the compressor is
obtained from your local Ingersoll Rand distributor.
left unattended.
Should compressor lubricant come into contact with the
Do not use extinguishers intended for Class A or Class B
eyes, then irrigate with water for at least 5 minutes.
fires on electrical fires. Use only extinguishers suitable for
Should compressor lubricant come into contact with the class BC or class ABC fires.
skin, then wash off immediately.
Attempt repairs only in clean, dry, well lighted and
Consult a physician if large amounts of compressor ventilated areas.
lubricant are ingested.
Connect the compressor only to electrical systems that
Consult a physician if compressor lubricant is inhaled. are compatible with its electrical characteristics and that
Never give fluids or induce vomiting if the patient is are within it’s rated capacity.
unconscious or having convulsions.
The above information contains data supplied in support
of United Kingdom Control of Substances Hazardous to
Health (C.O.S.H.H.) regulations.
R90 - 110N & R90 - 110I

5.0 SAFETY
Condensate disposal Coolant disposal
Condensate cannot be discharged into fresh/surface Steps to be taken in the case of spillage: Soak up with a
water drains. In some regions compressor condensate suitable absorbent material, then sweep into a plastic bag
containing ULTRA COOLANT can be fed directly into a for disposal.
drainage system that has downstream sewage treatment.
Burn in an approved incinerator, or according to local area
As waste water regulations vary by country and region it or country regulations.
is the responsibility of the user to establish the limitations
Please see the coolant material safety data sheet for
and regulations in their particular area. Ingersoll Rand
further information. Material safety data sheets can be
and its associated distributors are happy to advise and
obtained from your local Ingersoll Rand distributor.
assist in these matters.
warning
For VSD, this compressor contains a variable frequency drive. When it is switched off and the motor is stopped,
the internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt
any work on the drive unless trained. There are no user serviceable items behind the cover.
There is a high discharge air temperature shutdown function built into each compressor. It is factory preset
at 109 °C (228° F). This function should be checked at regular intervals for proper operation, twice a year is
recommended. Refer to maintenance section.
Failure to adhere to these recommendations can result in mechanical failure, property damage and serious
injury or death.
• All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port
connections must take into account vibration, pulsations, temperature, maximum pressure applied,
corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will
discharge some oil into the air stream; therefore, compatibility between discharge piping, system
accessories and software must be assured.
• For the foregoing reasons, the use of plastic piping and rubber hose as discharge piping is not
recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if
their specifications fit the operating parameters of the system.
• It is the responsibility of the installer and owner to provide the appropriate service pipework to and from
the machine.
“Ingersoll Rand air compressors are not designed, intended, or approved for breathing air applications.
Ingersoll Rand does not approve specialized equipment for breathing air application and assumes no
responsibility or liability for compressors used for breathing air services.”
For VSD, no portable communication devices emitting more than 7.5 volts per metre in the frequency range
from 250 MHz to 280 MHz should be operated within 5m (16.5ft) of the unit.
For VSD, the motor rotor contains a powerful magnetic field. This field can effect the operation of digital
devices such as watches, mobile phones etc.. Assembly or handling of the rotor should not be attempted by
personnel with cardiac pacemakers, defibrillators or other implanted electronic medical device.
The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas.
If such an application is required then all local regulations, codes of practice and site rules must be observed.
To ensure that the machine can operate in a safe and reliable manner, additional equipment such as gas
detection and intake (shut-off) valves may be required, dependant on local regulations or the degree of risk
involved.
For VSD, the compressor can operate in a pressurized shutdown mode. If the compressor stops automatically,
the airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the
which any residual pressure will be vented. Downstream of the separator tank may still contain system
pressure which must also be vented.
R90 - 110N & R90 - 110I

5.0 SAFETY
Depending on point of manufacture and point of use, the compressor and this manual will show symbols from the
following sections. Compressors for use within the European Community must be equipped with symbols from section
5.4. Read and understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your
supervisor.
5.3 TEXT DECALS
WARNING / AVERTISSEMENT / ADVERTENCIA / AVISO
Machine restarts automatically after power failure.

La machine redemarre automatiquement après une coupure de courant.
La maquina arranca automaticamente despues de una falla electrica.
Comença automaticamente apos interrupçao de eletricidade.
© ingersollrandproducts.com
Bezzle Decal (PORO)
93165959
Fan / Guard
WARNING / ADVERTENCIA /
ADVERTÊNCIA / AVERTISSEMENT
Rotating fan blade. Can cause severe injury.

Do not operate with guard removed. Disconnect power before
servicing. Lockout/Tagout machine.
Cuchilla giratoria del ventilador. Puede causar lesiones graves.
No debe operarse sin el protector. Desconecte la corriente antes de
dar servicio. Cierre con candado y etiqueta la máquina.
32343907-B
Pás de ventilador em rotação. Perigo de graves ferimentos.
Não opere com proteção removida. Desconecte a força antes de
Lock Out / Tag Out realizar manutenção. Travar/Rotular máquina.
Aube de ventilateur en rotation. Peut causer des blessures graves.

Ne pas faire marcher si la protection a été retirée. Déconnecter
l’alimentation avant d’effectuer l’entretien. Verrouiller/étiqueter la
machine.
32343550-A
Fan / Guard
WARNING/ADVERTENCIA/ADVERTÊNCIA/AVERTISSEMENT
Hot Sufaces. Can cause serious injury.
Do not touch any of the surfaces. Allow to cool before servicing.
Superficie Caliente. Puede causar lesiones graves.
No tocar ninguna superficie. Deje que se enfrie antes de dar servico.
Superfícies Aquecidas. Ponderão causar graves ferimentos.
Bezzle Decal (Standard) Não tocar em nenhuma das superfícies. Deixar esfriar antes de realizar serviços.
Surface Chaude. Peut causer des blessures graves.
Ne toucher aucune surface. Attendre le refroidissement avant de réparer.
32343584-A
Hot Surfaces
R90 - 110N & R90 - 110I

5.0 SAFETY
WARNING / ADVERTENCIA /
ADVERTÊNCIA / AVERTISSEMENT
High pressure air. Can cause severe injury or death.

Relieve pressure before removing filler plugs/caps,
fittings, valves or covers. 93166460
Aire a alta presión. Puede causar lesiones
personales severas o muerte. Coolant Drain
Alivie la presión antes de remover válaulas, tapones,
acoples o cubiertas.
23551559-A
Ar a alta pressão. Pode ser prejudicial à saúde ou
causar morte.
Aliviar a pressão antes de remover tampões, conexões,
vávulas ou tampas.
Air à haute pression. Peut causer des blessures graves
ou la mort.
Détendre la pression avant de retirer les bouchons/capuchons
de remplissage, les raccords, les soupapes ou les couvercles.
32343527-A
Pressure Vessel
Remove shipping brace
23540594-A
LY
X-T
ON
EN
D T
TM
COOLAN
Coolant Cap X-Tend
High Voltage
Coolant Cap Ultra 93166478
Condensate Drain
10 R90 - 110N & R90 - 110I

5.0 SAFETY
NOTICE / ADVISO / NOTA / AVIS
Air Discharge.
Descarga de aire.
Descarga de ar.
Refoulement de l’air.
32343543-A
Compressed Air
93166486
Customer Power
Don’t breath
Motor rotation
730Vdc
0Vdc
15 mins.
Variable frequency drive to be serviced by trained personnel only. After switching off the machine at its local
WARNING isolator, WAIT AT LEAST 15 MINUTES for the capacitors to fully discharge before removing the drive cover.
With caution, verify DC bus voltage is zero before servicing. Proceed with caution.
O módulo conversor de freqüência somente deve ser mantido por um técnico capacitado. Depois de
ADVERTÊNCIA desligar o equipamento no seu disjuntor local, ESPERE PELO MENOS 15 MINUTOS para que se
descarreguem completamente os capacitores antes da remossão das portas de proteção do módulo.
Antes da manutenção, verifique com cautela se a tensão DC bus está em zero. Prossiga com prudência.
El módulo conversor de frecuencia deberá somente ser mantenido por un técnico capacitado. Después de
ADVERTENCIA desconectar el equipo en su aislador local, ESPERE 15 MINUTOS COMO MÍNIMO para que se descarguen
por completo los condensadores antes de quitar la cubierta potectora del módulo. Antes de prover
matenimiento, verifique con precaución se el voltage DC Bus está en zero. Prosiga con prudencia.
La maintenance du variateur de vitesse doit être assurée par du personnel qualifié et habilité. Après mise
AVERTISSEMENT hors tension de la machine, attendre au moins 15 minutes que les condensateurs soient totalement
déchargés avant de retirer les protections du variateur. Bien s'assurer que la tension du Bus DC est nulle
avant d'intervenir. Procédez avec prudence.
23538754 Rev. A
15 min warning
R90 - 110N & R90 - 110I

11
5.0 SAFETY
5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS
WARNING / AVERTISSEMENT / ADVERTENCIA / AVISO
Machine restarts automatically after power failure.

La machine redemarre automatiquement après une coupure de courant.
La maquina arranca automaticamente despues de una falla electrica.
Comença automaticamente apos interrupçao de eletricidade.
92867522
© ingersollrandproducts.com
Bezzle Decal (Standard) Bezzle Decal (PORO)

Lock Out / Tag Out
93165959
Hot Surfaces Pressurised Vessel
Fan / Guard
23540594-A
LY
X-T
ON
EN
D T
TM
COOLAN
93166460
Coolant Cap Coolant Cap
Coolant Drain
23551559-A
93166478
Remove shipping brace High Voltage

Condensate Drain
12 R90 - 110N & R90 - 110I

5.0 SAFETY
92867498 93166486
Compressed Air Don't breath Customer Power
730Vdc
0Vdc
15 mins.
Variable frequency drive to be serviced by trained personnel only. After switching off the machine at its local
WARNING isolator, WAIT AT LEAST 15 MINUTES for the capacitors to fully discharge before removing the drive cover.
With caution, verify DC bus voltage is zero before servicing. Proceed with caution.
O módulo conversor de freqüência somente deve ser mantido por um técnico capacitado. Depois de
ADVERTÊNCIA desligar o equipamento no seu disjuntor local, ESPERE PELO MENOS 15 MINUTOS para que se
descarreguem completamente os capacitores antes da remossão das portas de proteção do módulo.
Antes da manutenção, verifique com cautela se a tensão DC bus está em zero. Prossiga com prudência.
El módulo conversor de frecuencia deberá somente ser mantenido por un técnico capacitado. Después de
ADVERTENCIA desconectar el equipo en su aislador local, ESPERE 15 MINUTOS COMO MÍNIMO para que se descarguen
por completo los condensadores antes de quitar la cubierta potectora del módulo. Antes de prover
matenimiento, verifique con precaución se el voltage DC Bus está en zero. Prosiga con prudencia.
La maintenance du variateur de vitesse doit être assurée par du personnel qualifié et habilité. Après mise
AVERTISSEMENT hors tension de la machine, attendre au moins 15 minutes que les condensateurs soient totalement
déchargés avant de retirer les protections du variateur. Bien s'assurer que la tension du Bus DC est nulle
avant d'intervenir. Procédez avec prudence.
23538754 Rev. A
Motor rotation IR Logo

15 min warning
R90 - 110N & R90 - 110I

13
6.0 RECEIPT / HANDLING
6.1 RECEIPT
When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier should be
noted on the delivery receipt especially if the compressor will not be immediately unpacked. Obtaining the delivery
persons signed agreement to any noted damages will facilitate any future insurance claims.
IMPORTANT
READ THIS
LOST OR DAMAGED GOODS
THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL
OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNED
BILL OF LADING
If goods are received short or in damaged condition, it is important that you notify the carrier and insist on a
notation of the loss or damage across the face of the freight bill. Otherwise no claim can be enforced against the
transportation company.
If concealed loss or damage is discovered, notify your carrier at once and request an inspection. This is absolutely
necessary. Unless you do this the carrier will not entertain any claim for loss or damage. The agent will make an
inspection and grant a concealed damage notation. If you give the transportation company a clear receipt for
goods that have been damaged or lost in transit, you do so at your own risk and expense.
WE, AT lR, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSS
OR DAMAGE, BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR
COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL. THE ACTUAL FILING AND PROCESSING OF
THE CLAIM IS YOUR RESPONSIBILITY.
Ingersoll Rand Company
6.2 UNPACKING AND HANDLING

The compressor will normally be delivered with a Once the packaging and pallet are discarded and the
polyethylene or other cover. If a knife has to be used to unit is in its final position, remove the yellow painted
remove this cover, ensure that the exterior paintwork of following transit brackets from the resilient mounts and
the compressor is not damaged. store for future use or discard:
Incorporated within the base of the compressor are slots For VSD
to enable a fork lift truck to move the machine. Ensure
• (3) brackets at the separator tank
truck forks are fully engaged on both sides. Alternatively
a special lifting frame can be utilized to enable a crane • (1) bracket from the air end discharge elbow.
or hoist to move the compressor. Use only marked lifting • (1) bracket from the air end support.
points. For FS
• (3) brackets at the separator tank
• (1) bracket from the air end support.
• (1) bracket from the motor mounting bracket.
6.3 LONG TERM STORAGE

If the compressor will not be commissioned within 6
months of receipt, the compressor should be prepared
for long term storage. Please contact your local Ingersoll
Rand distributor for details
14 R90 - 110N & R90 - 110I

7.0 INSTALLATION
7.1 LOCATION IN PLANT
7
4
6 3 4 2 5
8
Key Hard surfaces may reflect noise with an apparent

increase in the decibel level. When sound transmission
1. Compressor
is important, a sheet of rubber or cork can be installed
2. Air Receiver beneath the machine to reduce noise. Flexible piping may
be required.
3. Air Dryer
It is recommended that provision be made for lifting
4. Compressed Air Filters
heavy components during major overhaul. Use only
5. System Demand Points lifting points provided.
6. Vent/Drain Trap Minimum space in front of control panel door as required
7. Isolation Valve by National or Local codes must be maintained.
8. Wet Tank The compressor can be installed on any level floor

capable of supporting it. A dry, well ventilated area where
Ensure that the correct tie down points are used. the atmosphere is as clean as possible is recommended.
For major overhaul (i.e. motor removal) position the Sufficient space all round and above the compressor must
machine to obtain lifting access e.g. fork lift truck. be allowed, to enable the effective removal of the cooling
See diagram in reference section for minimum space air which, in turn, will reduce the risk of recirculating the
requirements for normal operation and maintenance. cooling air back through the compressor.
Ambient temperatures higher than 46° C (115° F) must be

avoided as well as areas of high humidity.
Consider also the environment surrounding or near the
compressor. The area selected for the location of the
compressor should be free of dust, chemicals, metal
filings, paint fumes and overspray.
caution
A minimum of 1 m (3.3ft) all round the compressor is recommended. If headroom is restricted, then the
exhaust should be ducted or deflected away from the machine.
Screw type compressors [1] should not be installed in air systems with reciprocating compressors without
means of isolation such as a common receiver tank. It is recommended that both types of compressor be
piped to a common receiver using individual air lines.
The machine is shipped with the shipping restraints in place. Ensure that these are removed to allow free
movement of the drive assembly during operation. Each restraint is painted yellow.
R90 - 110N & R90 - 110I

15
7.0 INSTALLATION
7.2 DISCHARGE AND CONDENSATE PIPING
7
4
6 3 4 2 5
8
It is essential when installing a new compressor [1], When two rotary units are operated in parallel, provide an
to review the total air system. This is to ensure a safe isolation vaIve (7) and drain trap (6) for each compressor
and effective total system. One item which should be before the common receiver. Ensure the discharge piping
considered is liquid carryover. Installation of air dryers is arranged to prevent water from being forced into the
[3] is always good practice since properly selected and non-operating machine.
installed they can reduce any liquid carryover to zero.
A wet tank (8) is recommended in cases where the air
A receiver [2] is recommended to ensure that the total dryer is regenerative desiccant type to prevent short
system volume is not less than 2.0 U.S. Gal. per rated cycling the compressor during purging cycle when plant
delivery C.F.M. air demand is slow.
Discharge piping should be at least as large as the The built-in aftercooler reduces the discharge air
discharge connection of the compressor. All piping temperature below the dew point (for most ambient
and fittings should be suitably rated for the discharge conditions), therefore, considerable water vapor
pressure. Discharge piping should not exert any is condensed. To remove this condensation, each
unresolved moments or force on unit. compressor with built-in aftercooler is furnished with a
combination condensate separator/trap.
It is good practice to install line filters [4].
A dripleg assembly and isolation valve should be
Include a means [6] to vent the discharge pipework
mounted near the compressor discharge. A drain line
downstream from the minimum pressure check valve
should be connected to the condensate drain in the base.
located on the separator tank. Upstream of the first
system isolation valve [7]. IMPORTANT: The drain line must slope downward from
the base to work properly. For ease of inspection of the
Unit has an internal discharge check valve, external check
automatic drain trap operation, the drain piping should
valve not required. Isolation valve [7] is required within
include an open funnel.
1m (36 inches) of the compressor discharge.
There should be no plastic or PVC piping attached to this NOTICE
unit or used for any lines down stream with exception of For low volume systems that may not include a
condensate removal lines. receiver [2], compressor response time may need
The discharged air contains a very small percentage of adjusting. Contact your local Ingersoll Rand service
compressor lubricating oil and care should be taken to agent.
ensure that downstream equipment is compatible.
caution
The use of plastic bowls on line filters and other plastic air line components without metal guards can be
hazardous. Their safety can be affected by either synthetic coolants or the additives used in mineral oils. From
a safety standpoint, metal bowls should be used on any pressurized system.
NOTICE
Do not use the compressor to support the discharge pipe.
R90 - 110N & R90 - 110I

16
7.0 INSTALLATION
7.3 ELECTRICAL
caution
This procedure should only be carried out by a qualified electrician, electrical contractor or your local
Ingersoll Rand Distributor or Customer Center.
The compressor should be properly grounded / On completion of electrical installation, check that blower
earthed in accordance with Local and National Code or fan motor rotation is correct.
requirements.
For VSD, this machine is designed for use, where the
Installation of this compressor must be in accordance electricity supply is separated from nearby residential
with recognized electrical codes and any local Health and and commercial areas. If the machine is to be used in the
Safety Codes. light industrial, residential or commercial environment
where the local supply network is shared, further radio
The compressor must have its own isolator situated
frequency (RF) screening measures may be required.
adjacent to it. The fuse protecting the circuit and the
Consult your local distributor/supplier for details of the
compressor must be selected in accordance with local
optional RF filter.
and national code requirements on the basis of the data
provided in the general information section For VSD, the compressor has a anti-condensation heater
and thermostat in the electrical box. This circuit can be
Feeder cables should be sized by the customer/electrical
connected to an independent electrical supply of either
contractor to ensure that the circuit is balanced and not
110V or 230V single phase, dependant on the country
overloaded by other electrical equipment. The length
of installation. The supply should be suitably fused
of wiring from a suitable electrical feed point is critical
and an independent isolator installed adjacent to the
as voltage drops may impair the performance of the
compressor. Verify that thermostat is adjusted to 85˚F
compressor.
(29˚C). This should be done in accordance with local
For VSD, cable sizes may vary considerably so the line and national codes. It is good practice and sometimes
reactor is equipped with copper bus connections. mandatory, to display suitable signs warning that the
These connections can accept bolts between 6mm and machine has two separate electrical supplies which both
12mm. must be isolated before any work is attempted.
Feeder cable connections to incoming terminals L1-L2-L3 For VSD, alternately the heater circuit can be supplied
should be tight and clean. from the 110V tapping of the control transformer and
connected as shown on schematic wiring diagram.
The applied voltage must be compatible with the
compressor data plate ratings.
caution
The control circuit transformer has different voltage
Never test the insulation resistance of any part of
tappings. Ensure that these are set for the specific applied the machines electrical circuits, including the motor
voltage prior to starting. without completely disconnecting the following.
A hole with removable blind plate is provided for • Primary side of control power transformer
incoming power connection. Remove blind plate to cut • Input power and motor cables from soft starter
hole as required. If it is necessary to make a hole in the (if equipped)
control box in a different location, care should be taken • Input power and motor cables from the main
to not allow metal shavings to enter the starter and other VSD (if equipped)
electrical components within the box. If another hole is
used, the original hole must be blocked off. • Input power and motor cables from the blower
VSD (if equipped)
The feeder cable must be suitably glanded in to the
starter box to maintain proper ingress protection. Fixed
speed starter boxes are rated for NEMA4/IP65, and VSD
NOTICE
starter boxes are rated for NEMA12/IP54. For VSD starter Main and fan motor insulation must be tested by
boxes, the feeder cable must be glanded to ensure that the competant electrician prior to initial Start-up
or following an extended shutdown period in cold
dirty air does not by-pass the filters. damp conditions.
R90 - 110N & R90 - 110I

17
7.0 INSTALLATION
caution
VERY IMPORTANT (For VSD only)
Supply voltage must be kept to a maximum imbalance of 3%. Voltage imbalances greater than these levels
can cause permanent damage to the drive.
Compressor must not be subjected to significant voltage spikes or surges. Exposure to spikes/surges in excess
of 780V peak for 380-460Vac applications (980V peak for 575Vac applications) can permanently damage the
drive. If the possibility of such exists it is recommended that adequate surge protection is fitted. See your
local Ingersoll Rand representative.
Failure of the drive due to voltage spikes, line notching, harmonics or other power quality related problems,
will not be covered by the standard compressor warranty.
The correct type and rating of line input fuse MUST BE fitted onto the customers isolator or breaker close to
the compressor. For Amp rating see technical information in Section 8.1.
Product Identification Fuse Type Fast Acting Class-J or Semiconductor type JFHR2,
Class - J or Current limiting, Interrupt Rating - 200,000 Amps
RMS SYM.
Alternate fuse may be used if the time current
Semiconductor TYPE JFH22 characteristics are faster than fuses recommended
in this section.
See your local Ingersoll Rand representative for a range of fuses and disconnect isolators matched to your particular
machine.
Example of voltage imbalance calculation (VSD)

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

VΔ max = 462 − 453 = 9v
... = (9 / 458) x 100 = 1.97%
R90 - 110N & R90 - 110I

18
7.0 INSTALLATION
7.4 WATERCOOLED UNITS
Cooling Water Piping Water temperature and pressure gauges should be
installed in the water piping for use in any fault finding
Water piping to and from the compressor package must
of the water system. Water pressure should ideally be
be at least as big as the package connection size, or
between 3 and 5 bar (43.5 and 72.5 psi) but must not be
larger. Do NOT undersize the water piping!
above 10 bar (145 psi)
Isolation valves with side drains should be installed
Water cleanliness is also extremely important. Cleaning of
on both the inlet and outlet lines. To maintain cooler
coolers as a result of fouling is a customer responsibility.
cleanliness and reliability, it is important to install a
Therefore, it is highly recommended that proper water
strainer of 2mm mesh size on the inlet line. Strainers are
quality must meet the requirements listed in WATER
available from Ingersoll Rand.
QUALITY RECOMMENDATIONS later in this section.
For sea water applications (sea water option only) a zinc
Venting the water system
anode is NOT recommended as it will deteriorate the
copper oxide film on the 70/30 Copper-Nickel alloy tubes Air should be vented from the water side of the system
in contact with sea water. To minimize galvanic corrosion to avoid poor performance and water hammer. Since
and provide the greatest corrosion protection to your the air compressor uses different type heat exchangers
coolers, it is strongly recommended that a section of iron depending on your selection of “fresh water cooled” or
pipe (>300mm length) be connected as close as possible “Harsh water cooled” system, the venting procedure is
to the air compressor package water inlet connection. The different. Be sure to use the correct procedure below.
iron pipe will act as the sacrificial anode for the Copper-
Fresh water coolers (brazed plate heat exchangers):
Nickel tubes and therefore must be considered a regular
maintenance & replacement item. For this reason the 1. Disconnect the water stop valve in the water outlet
section of iron pipe should be installed so that it can be line of the compressor.
easily replaced (i.e.: with a union joint).
2. Open the inlet water valve(s) to allow the water to
The air compressor has a normally closed solenoid valve flow to the package.
that is fitted to the water outlet side, within the package.
3. Allow all the air to escape from the system and water
The valve is wired into the air compressor control circuit
is observed at the water outlet port.
and closes when the compressor stops.
4. Connect the water stop valve.
Carefully inspect your water system before installing the
air compressor package. Ensure that the piping is free of 5. The system is now vented.
scale and deposits that may restrict water flow to the air Harsh water coolers (shell & tube heat
compressor package. If water cleanliness is poor, filtration exchangers):
installed on your water inlet pipe line is recommended.
1. Locate the water system vent cocks on top of the
Proper operation of your compressor requires that aftercooler and oil cooler.
the cooling water flow listed below be provided at a
maximum supply temperature of 46° C (115° F). Please 2. Open the water valve(s) allowing water to flow to the
see the compressor engineering data sheets for cooling package.
water flow rates. 3. Open the vent cocks and allow all air to escape from
the system. When water is observed at the vent cocks,
caution close them.
If you have a Harsh Water air compressor option
and you are using sea water or brackish water as 4. The system is now vented.
the cooling medium, DO NOT exceed the water Draining the water system
flow values listed on the compressor’s engineering
data sheets. Salts are very abrasive and their Should it become necessary to completely drain the
ability to erode the heat exchanger tubes increase water system, use the following procedures specific to the
significantly as the water velocity (flow) increases. water cooled option you have.
It is recommended that the pipe fitter or engineer
responsible for the supply piping include an Fresh water coolers (brazed plate heat exchangers):
appropriately sized flow control device such as an
orifice to limit the maximum potential flow to the 1. Disconnect the inlet water line from the connection
air compressor. Effects of erosion or corrosion are located at the rear of the unit.
specifically excluded from warranty considerations.
2. Disconnect the water stop valve in the water outlet
line of the compressor.
3. Allow the system to completely drain.
R90 - 110N & R90 - 110I

19
7.0 INSTALLATI ON
Harsh water coolers (shell & tube heat operation of the system. Evaporation, corrosion, chemical
exchangers): and temperature changes, aeration, scale and biological
formations affect the water makeup. Most problems in
1. Disconnect the inlet and discharge water lines from
a cooling system first appear as a reduction in the heat
the connections located at the rear of the unit.
transfer rate, then in a reduced flow rate or increased
2. Locate the aftercooler and oil cooler. Remove the pressure drop, and finally with damage to the system.
drain plugs located at the bottom of the coolers.
Scale: Scale formation inhibits effective heat transfer,
3. Open the vent ports in the top of the aftercooler and yet it does help prevent corrosion. Therefore, a thin
oil cooler uniform coating of calcium carbonate is desired on the
inner surface. Perhaps the largest contributor to scale
4. Allow the system to completely drain.
formation is the precipitation of calcium carbonate out of
Adjusting the Aftercooler Trim Valve the water. This is dependent on temperature and pH level.
See piping and instrumentation diagram (Section The higher the pH value, the greater the chance of scale
8.3). The coolers are piped in a “parallel” water flow formation. Scale can be controlled with water treatment.
arrangement with a manual trim valve controlling the Corrosion: In contrast to scale formation is the problem
flow through the aftercooler. The Aftercooler Trim Valve is of corrosion. Chlorides cause problems because of their
factory set and should not need adjusting but if disturbed size and conductivity. Low pH levels promote corrosion,
use following procedure. as well as high levels of dissolved oxygen.
1. Close valve fully clockwise and then open 2 full turns. Fouling: Biological and organic substances (slime)
2. With the machine running loaded observe the pack- can also cause problems, but in elevated temperature
age discharge temperature on the Intellisys display. It environments such as cooling processes they are not a
should be approximately 15° F (8° C) above the water major concern. If they create problems with clogging,
inlet temperature. commercial shock treatments are available.
3. If the temperature is too high, open the valve ¼ turn To ensure good operation life and performance of
and wait 1 minute. If the temperature is too low, close the compressor cooling system, the recommended
the valve ¼ turn and wait 1 minute. Repeat the incre- acceptable ranges for different water constituents are
mental movements until the desired temperature is included below:
reached.
4. Put a “Warning − Do Not Adjust” label on the valve or
fit a lock.
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 life of the
unit. It should be noted that the quality of water used in
any cooling system does not remain constant during the
ACCEPTABLE MAXIMUM LIMITS

Substance Test Interval Fresh Water (Brazed Plate Dirty Water / Sea Water (Shell &
Heat Exchanger 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 Monthly <0.01 <0.5
Dissolved Oxygen (DO) [O2], ppm Weekly <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
R90 - 110N & R90 - 110I

20
7.0 INSTALLATION
7.5 ENVIRONMENTAL LIMITS
The standard compressor package is designed for the following conditions:
• Indoors only
• Area not considered to be a high dust area.
• Ambient temperature range 2 to 46oC (35-115oF)
Ingersoll Rand offers the following options for fixed speed units that extend the environmental limits:
• Outdoor modification
• Low ambient option(-23 to 46oC / -15 to 115oF)
• High ambient option (2 to 55oC)
• High dust air filter
• High dust package filter.
R90 - 110N & R90 - 110I

21
8.0 GENERAL INFORMATION
8.1 GENERAL ARRANGEMENT, AIR COOLED (R90-110)
TOP
FRONT
LEFT END
23539836
REAR
Revision B RIGHT END
22 R90 - 110N & R90 - 110I

1430
[56.3]
105 827 374
4 [4.1] D
[0.2 ] [32.5] [14.7]
(TYPICAL FOR ALL
LATCHED DOORS)
610
E [24.0]
1466
[57.7]
1404
[55.3]
1190
57 2 [46.9]
[2.3] [0.1] DETAIL G
SCALE 1.000
SEE DETAIL G
DETAIL F
SCALE 1.000
TOP VIEW
2703
[106.4]
322 615 220 530 D
AIR FLOW
[12.7] [24.2] [8.7] [20.9]
R90 - 110N & R90 - 110I

499
[19.6]
AIR FLOW
C C
1260
[49.6]
158 2032
[6.2] [80.0]
B
1232
[48.5]
701
[27.6] 573
[22.6] 505
415 [19.9]
[16.3]
636,54
178 E
[7.0] SEE DETAIL F FRONT VIEW
1192
[46.9]
LEFT END VIEW 23539836
23
Revision B
18,579
18,579
24
SEE DETAIL H
2X 76
[3.0 ]
(BOTH SIDES)
RIGHT END 6 REAR VIEW 4X 203

[0.2] [8.0 ] 2X 24
VIEW (BOTH SIDES) [0.9 ]
(BOTH SIDES)
2X 890 2X 914
[35.0 ] [36.0 ]
(BOTH SIDES) (BOTH SIDES)
4X 23
R90 - 110N & R90 - 110I

60
[0.9 ] 1250 830
[2.3]
[49.2] [32.7]
1284
[50.6]
A
636,54
BOTTOM VIEW
23539836
DETAIL H
SCALE 0.500 Revision B
VSD UNITS)
FRONT
LEFT END 1860 1213 93

[73.2] [47.8] [3.7]
801
[31.6]
AIR FLOW
395
D [15.6]
R90 - 110N & R90 - 110I

AIR FLOW
2427 C
[95.6]
1232
[48.5]
580
[22.8]
322 615 2744

[12.7] [24.2] [108.0]
RIGHT END
VIEW
LEFT END
VIEW FRONT VIEW
8.1 GENERAL ARRANGEMENT WITH OPTIONAL OUTDOOR MODIFICATION (NOT AVAILABLE ON
23539836
25
Revision B
8.1 GENERAL ARRANGEMENT WITH OPTIONAL HIGH DUST PRE-FILTER (NOT AVAILABLE ON VSD
UNITS)
Revision B
23539836
FRONT VIEW
[116.0]
[117.6]
2946
2987
AIR FLOW
[9.6]
243
[4.5]
113
[70.8]
1800
AIR FLOW
[8.5]
215
FRONT
[62.1]
1577
LEFT END
VIEW
[31.2]
[23.5]
793
597
[13.1]
332
LEFT END
[9.9]
252
26 R90 - 110N & R90 - 110I

SEE DETAIL K
FRONT
LEFT END
FRONT VIEW
R90 - 110N & R90 - 110I

8.1 GENERAL ARRANGEMENT WITH OPTIONAL CONTAINMENT BASE
3
[0.1 ]
(THIS VALUE NEEDS TO
DETAIL K BE ADDED TO ALL
HEIGHT DIMENSIONS
SCALE 1.000
WHEN THIS OPTION
IS PURCHASED)
23539836
27
BOTTOM VIEW Revision B
8.1 GENERAL ARRANGEMENT, WATER COOLED (R90-110)
TOP
FRONT
LEFT END
23539844
REAR
Revision B RIGHT END
636,54
28 R90 - 110N & R90 - 110I

1460
[57.5]
105 827 374
4 [32.5] [14.7] D
[0.2 ] [4.1]
(TYPICAL FOR ALL
LATCHED DOORS)
E
750
1466 [29.5]
[57.7]
1404
[55.3]
2 1190
57 [46.9]
[2.3] [0.1] DETAIL L
SCALE 1.000
SEE DETAIL L
DETAIL K
SCALE 1.000
TOP VIEW
2703
[106.4]
322 615 220 530 D
AIR FLOW
[12.7] [24.2] [8.7] [20.9]
R90 - 110N & R90 - 110I

499
[19.6]
AIR FLOW
C C
1260
[49.6]
158 2032
[6.2] [80.0]
B
1232
[48.5]
701
[27.6] 573
[22.6] 490
415 [19.3]
[16.3]
636,54
178 E
[7.0] SEE DETAIL K FRONT VIEW
1192 23539844
[46.9]
29
LEFT END VIEW Revision B
30
SEE DETAIL H
F
2X 76
G [3.0 ]
(BOTH SIDES)
RIGHT END REAR VIEW 4X 203 93 527

VIEW [8.0 ] [3.7] [20.7] 70
SEE DETAIL M (BOTH SIDES) [2.8]
2X 890 2X 914
2X 24
[35.0 ] [36.0 ]
[0.9 ]
(BOTH SIDES) (BOTH SIDES)
(BOTH SIDES)
60 4X 23 1250 830
6 [0.9 ] [49.2] [32.7]

[2.3]
R90 - 110N & R90 - 110I

[0.2]
22 32 1284
[0.9 ] [1.2 ] [50.6]
(60 Hz - NPT) (50 Hz - BSPT)
636,54
BOTTOM VIEW
DETAIL M
23539844
DETAIL H SCALE 0.500
SCALE 0.375 Revision B
8.1 GENERAL ARRANGEMENT WITH OPTIONAL HIGH DUST PRE-FILTER (NOT AVAILABLE ON
VSD UNITS)
Revision B
23539844
FRONT VIEW
[116.0]
[117.6]
2946
2987
AIR FLOW
[9.6]
243
[4.5]
113
[70.8]
1800
AIR FLOW
[8.5]
215
[62.1]
FRONT
1577
LEFT END
VIEW
[31.2]
[23.5]
793
597
[13.1]
332
LEFT END
[9.9]
252
R90 - 110N & R90 - 110I 31

32
SEE DETAIL K
FRONT
LEFT END
FRONT VIEW
R90 - 110N & R90 - 110I

8.1 GENERAL ARRANGEMENT WITH OPTIONAL CONTAINMENT BASE
3
[0.1 ]
(THIS VALUE NEEDS TO
DETAIL K BE ADDED TO ALL
HEIGHT DIMENSIONS
SCALE 1.000
WHEN THIS OPTION
IS PURCHASED)
23539844
BOTTOM VIEW Revision B
40
23
25
M
39 2
M
12
WC 1st 2nd
25 24
22 M
41
AC
P
34 TWO STAGE ONLY
26
18
36 32
23 30
35
T 17 T
M 29
37 P
19 15
3 2 5 1
14
R90 - 110N & R90 - 110I

P CUST. AIR
10 28 TREATMENT
V 21 16
4 P
T
33
T 13
8.2 PROCESS AND INSTRUMENTATION DIAGRAM (AC/WC) 90-160 KW (VSD)
P
9B T
8 31 7
6
20 38
P 27
9A
T 23371677
11
33
Revision D
KEY
PIPING LEGEND
1 Air discharge
Air/coolant
2 Compressor
Air
3 Air filter
Coolant
4 Vacuum transducer (1AVPT)
Condensate
5 Cooler, air
Cooling water (W.C. only)
6 Cooler, coolant
Compressor enclosure
7 Condensate discharge
Sensor connection
8 Coolant filter (s)
Sub-system boundry
9A Pressure transducer, coolant filter out (5CPT)
Ingersoll Rand SCOPE
9B Pressure transducer, coolant filter out (6CPT)
Scope boundry
10 Drain valve, coolant
11 Oil cooler out temperature sensor 3CTT (Air CUST. SCOPE
cooled only)
12 Air inlet/check valve
13 Electronic no loss condensate drain
14 Minimum pressure check valve
15 Moisture separator
16 Pressure transducer package disch. Press. (4APT)
17 Pressure relief valve
18 Scavenge filter / orifice / check valve
19 Separator tank
20 Oil temperature control valve
21 Temperature airend discharge (2ATT)
22 Blowdown solenoid valve 3SV
23 Drive motor - variable speed
24 Motor, blower - variable speed
25 Cooling air blower
26 Cooling water inlet (W.C. ONLY)
27 Cooling water outlet (W.C. ONLY)
28 Pressure transducer wet sump pressure (3APT)
29 Pressure relief valve (OPTION CHINA)
30 Remote air pressure transducer 9APT (optional)
31 Water shutoff valve 4SV (W.C.ONLY)
32 Package discharge air temperature sensor 4ATT
33 Injected coolant temperature sensor 2CTT
34 Orifice, seal scavenge air supply
35 Seal scavenge line drain
36 Package intake air temperature sensor 1ATT
37 Air/coolant separator element
38 Valve, aftercooler trim (W.C. ONLY)
39 Motor, blower (W.C. ONLY)
40 Interstage pressure relief valve
41 Interstage pressure transducer
34 R90 - 110N & R90 - 110I

38
22
12
M
24 23 2
M
1st 2nd
39
11
P
TWO STAGE ONLY
25
18
36
T
22 33
32 17
M 30
31
19
35 15 1
P
3 2 5 1
14 16
21
R90 - 110N & R90 - 110I

V CUST. AIR
10 27 P TREATMENT
4
T
P
37
T
13
34
8.2 PROCESS AND INSTRUMENTATION DIAGRAM (A.C/W.C) 90-160 KW (FS)
P
9B
T 7
8 7
P 6
9A 20 29
26
28
23371669
35
STANDARD CONTROL SYSTEM Revision B
36
39
22
M
2
12 1st 2nd
24 23
M 40
P
TWO STAGE ONLY
11
25
38
18
30 33
22
33
17
31
M
19
35 15
P
3 2 5 1 1
14 16 36
R90 - 110N & R90 - 110I

21
V P T CUST. AIR
10 27 TREATMENT
4 T
P
37
T
13
34
8.2 PROCESS AND INSTRUMENTATION DIAGRAM (A.C/W.C) 90-1 60 KW (FS)
P
9B
T 7
8 7
6
P 20 29
9A
26
28
23371669
CONTROL SYSTEM WITH
MODULATION OPTION Revision B
KEY
1 Air discharge
PIPING LEGEND
2 Compressor
Air/coolant
3 Air filter
Air
4 Vacuum transducer (1AVPT)
Coolant
5 Cooler, air
Condensate
6 Cooler, coolant
7 Condensate discharge
8 Coolant filter
Sensor connection
9A Pressure transducer, coolant filter in (5CPT)
Sub-system boundry
9B Pressure transducer, coolant filter out (6CPT)
Ingersoll Rand SCOPE
10 Drain valve, coolant
Scope boundry
11 Load / blowdown valve (1SV)
12 Air inlet check valve CUST. SCOPE
13 Condensate drain valve (9SV)
14 Minimum pressure check valve
15 Moisture separator
16 Pressure transducer package disch. Pressure (4APT)
17 Pressure relief valve
18 Scavenge filter / orifice / check valve
19 Separator tank
20 Oil temperature control valve
21 Temperature thermistor airend discharge (2ATT)
22 Drive motor
23 Motor, fan
24 Cooling fan
25 Cooling water inlet (w.C. Only)
26 Cooling water outlet (w.C. Only)
27 Pressure transducer wet sump pressure (3APT)
28 Water shutoff valve (w.C. Only) (4SV)
29 Ball valve (w.C. Only) trim valve
30 Pressure relief valve (option china)
31 Check valve (motor seal scavenge)
32 Filter breather (motor seal scavenge)
33 Remote air pressure transducer (10APT) (optional)
34 Electronic drain trap-alternative to item 13
35 Air/coolant separator element
36 Package disch air temp sensor (4ATT)
37 Temperature thermistor oil injection (2CTT)
38 Modulation valve (5SV)
R90 - 110N & R90 - 110I 37

8.2 PROCESS AND INSTRUMENTATION DIAGRAM ENERGY RECOVERY SYSTEM
NOTES :
1. FOR CUSTOMER CONNECTION SIZES AND LOCATIONS SEE FOUNDATION PLAN OF UNIT.
4
1
T
5
9
6
23498108
Revision A
38 R90 - 110N & R90 - 110I

KEY
1 Compressor
2 Cooler, coolant (package)
3 Coolant filter
4 Separator tank (primary/secondary)
5 Oil temperature control valve (package)
6 Cooler, coolant (ERS)
7 Oil temperature control valve (ERS)
8 Cooling water inlet (ERS)
PIPING LEGEND
Air/coolant
Air
Coolant
Condensate
Sensor connection
R90 - 110N & R90 - 110I 39

8.3 SCHEMATIC, ELECTRICAL WIRING (VSD)
120V
0V X1
H6 DI1 1
110V SGNe
H5
380V X2 FMP
0V Gnd 2
H4
400V X3 RFI ES-1 206
100 MCB3 102 104 WATER
128 K2-1
200V X4
H3
415V 101 102 DI2 3 COOLED
0V
X5 115V 1 115V 207
460V
H2 230V X6 500VA 151 150 Gnd 4
480V
H1 0V 206
X7
151 DI3 5 FD 01 AIR
L1 L2 L3 150 110 207 COOLED
A2 KM1 A1 2 TX1
Gnd 6 FD 02
MCB1 MCB2 KM4-1 124 208
5L3 122 123 DI4 7
230V 111 209 ES-2
EMC 5L2 300VA BLU DVF 1.1 1.2 1.3 A2 K1 A1 3 TX2 Gnd 8
BLK (x2) KL1 210
1L3 1L2 125 C DI5 9
112 RSP
BRN
P3
150 KM4 4 TX3 211
LR CDV
A2 A1
T1 N Gnd 10
MCB4 GR 212
PE 118 120 DI6 11
K1-3 103 150 113
200V 213 RST
119 121 4SV 3SV 5 TX4 Gnd 12
P1
50VA
1L1 1L2 1L3
FM 214
DI7 13
FD 215 AW1
6 TX5
Gnd 14
MM
216
DR DI8 15
1L1 1L2 1L3 1L1 1L2 1L3
DVF EB 7 TX6 217 AW2
L1 L2 L3
Gnd 16
3SV 218
FU1, 2, 3 GND DI9 17
4SV PE 8 TX7
219 CDE
CDV 121 PORO Gnd 18
3L1 3L2 3L3 1
117
PX6
RFI 120 150

KM1 2 9 TX8
294
CAB 102 AO+ 9 FD 60
102
COM 1
P4
BP 4L1 4L2 4L3 295
PX1
127 150 AO1 10 FD 55

DOOR L1 L2 L3
N/O 2 K2 10 GND
RED
PSU GND AO1 1 282 + V+ 1
236 RED
1AVPT
PE
T1 AI1+ 2
WHT - P MCB5 Gnd 2
237 BLK
OV K1-2 105 238 WHI
283 AI1- 3 10APT 1 Sig1 3 P
12 WHT 244 12V 239 RED
SGN AI2 4 SG-NE P5-9 200 V+ 4 3APT
284 BLK 243 2 1 1 +12 240 BLK
18 0V 5 SG-NE P5-8
P10
Gnd 5
P1
281 201 Gnd
PX2
P2
285 +24V 6 3 2 2 241 WHI
27 Sig2 6 P
7 242 RED
206 DI1 K1-1 4 PSU V+ 7 4APT
FD 01 SG-NE P3-5 276 277 243 BLK
DI2 8 Gnd 8
207 279 ES-3 244 DR PX2-5 WHI
02 SG-NE P3-6 EN 9 Sig3 9 P
280 278 245 DR PX2-4 RED
294 0V 10 V+ 10 5CPT
60 SG-NE P4-9 KM1-1 RED 246
1 BLK
295 Gnd 11
P5
55 SG-NE P4-10 DR BLK 247
ES-4 2 WHI
296 ST BLK Sig4 12 P
1 7 248 RED
PX7
PE 297 WHT V+ 13 6CPT

2 8 249 BLK
Gnd 14
U V W 250 WHI
GND Sig5 15 P
251
V+ 16
BLK 252
2 RED 1 Gnd 17
SL 253
P8
FM 3 RED Sig5 18
PX3
6 BLK 2 254 RED

AIR V+ 19 2APT
COOLED 7 255 BLK
Gnd 20 (NOTE 3)
256 WHI P
YEL Sig6 21
1 1 A+
BLK 260
2 2 B- WHI
RED Sig1 1
3 3 SC+ 261 BLK T 2CTT
1L1 1L2 1L3 EXC Gnd 2
P7
GRE
4 4 SC- 262 WHI
PX4
BRO Sig2 3
5 5 SD+ 263 BLK T 2ATT
FMP 6 BLU Gnd 4
I> I> I> 6 SD- 264 WHI
7 VIO Sig3 5
265 BLK T 4ATT
303 Gnd 6
3L1 3L2 3L3 266 WHI
U V W 300 1 N/O
Sig4 7
MOTOR 267 BLK 3CTT (NOTE 2)
KM1
RUNNING KM4-1 CFO 301 Gnd 8 T
P2
2 C
P6
CONTACT 302 3 N/C
Sig5 9
U V W
304 Gnd 10
MM Sig6 11
FM Gnd 12
Sig7 13
Gnd 14
WATER COOLED 274 WHI
Sig8 15
275 BLK T 1ATT
Gnd 16
TH SHEET 1 OF 2
T1 100 300 MCB9 KM4-2 303 T

302
304
151 301
HTR1 HTR2
110/120V
50/60Hz
305
305
NOTES:
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO
OUTPUT OF CONTROL TRANSFORMER T1. WIRE TO
TERMINAL NUMBERS 100 & 151.
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN
INDEPENDENT SOURCE; IN THAT CASE, FACTORY
SUPPLIED CONNECTION MUST BE DISCONNECTED.
3. ENSURE PARALLEL CONNECTION OF HEATERS.
TH
300 MCB9 KM4-2 303 T
302
304
301 HTR1 HTR2
220/230V
50/60Hz
305 305
23382245
Revision D
40 R90 - 110N & R90 - 110I

KEY
OV Zero voltage PTC Motor winding thermistor
1ATT Package inlet temperature RFI Radio frequency interface
1AVPT Inlet vacuum pressure RSP Remote stop
2APT Interstage air press (2S ONLY) RST Remote start
2ATT Airend discharge temperature SGNE Controller, intellisys
2CTT Injected coolent temperature SL Serial link
3APT Wet sump pressure ST Service tool connector
3CTT Coolant cooler out temp. T1 Control power transformer
3SV Blowdown valve TH Thermostat
4APT Package discharge pressure
4ATT Package discharge temperature Colors
4SV Water shut off valve (W/C ONLY) BLK Black
5CPT Coolant filter in pressure BLU Blue
6CPT Coolant filter out pressure BRO Brown
10APT Remote pressure GRE Green
AW1 Auxiliary warning 1 PIN Pink
AW2 Auxiliary warning 2 RED Red
BP Backpanel SCR Screen
CAB Cabinet VIO Violet
CDE Condensate drain error WHI White
CDV Condensate no loss drain valve YEL Yellow
CFO Common fault output Wires
DR Drive, main motor
Numbers Function Wire color
DVF Drive ventilation fan
EB Earthing bar 1-99 Power Black
EMC EMC Filter board 100-199 AC Control Red
ES Emergency stop button 100 - 199 Grounded AC White
EXC External communications 200-299 DC Control Blue
300-399 Auxiliary Orange
FD Drive, blower motor
GND Ground Green / Yellow
FM Fan motor
FMP Fan motor protector
FU- Fuses
GND Ground
HTR- Panel space heater
K1 Run relay
K2 Drive fault relay
LR Line reactor
KM1 Blower motor contactor
KM4 Drive fan motor contactor
KM5 Dryer motors contactor
MCB Circuit breakers
MM Main motor
PE Protected earth
PORO Power outage restart option
PSU Power suppply unit
R90 - 110N & R90 - 110I 41

42
L1 L2 L3
208
DI4 7
MCB3 ES-1 209 ES-2
MCB1 T1 101 101 Gnd 8
3L3 100 101 102
23771933
Revision A
1 115V DI5 9
115V 150 150
PE 3L1 REMOVE JUMPER
103 KM1-2 Gnd 10 K2-1 215
213 FR1 214 WHEN
150 4SV DI6 11 CORRESPONDING
K2 Gnd 12 OPTION HAS BEEN
FM MCB2 PURCHASED
216
MM L3 214 A1 FR1 A2 118 KM1-1 DI7 13
11 118 110 217 FMP
DCM L2 (AS NEEDED) 150 A2 KM1 A1 2 TX1 Gnd 14
215 1.1 1.2 1.3
14
DFM L1 KM3-1 DI8 15
EB KL1 119 KM3-2
SGN A2 KM2 A1 Gnd 16
220
1SV L3 CDV DI9 17
120 KM2-1 111 221 CDE
3SV L2 150 A2 KM3 A1 3 TX2 Gnd 18
222 RSP
4SV L1 DI10 19
223
P3
112
5SV L1 L2 L3 A2 KM4 A1 4 TX3 Gnd 20
224 RST
6SV 113 DI11 21
225
9SV KM4 150 1SV 5 TX4 Gnd 22
226
CAB DI12 23
2L1 2L2 2L3 227 RLL
L1 L2 L3 L1 L2 L3
P1
BP Gnd 24
228 RLE
DOOR 3SV DI13 25
KM2 229
PSU Gnd 26
KM1 KM3 230
TI 114 DI14 27
231 RLU
OV FMP 150 5SV 6 TX5 Gnd 28
232 AW1
CDV FR1 DI15 29
233
Gnd 30
U1 V1 W1 W2 U2 V2 115 234
DI16 31 AW2
150 9SV 7 TX6 235
I> I> I> Gnd 32
8 TX7 236 RED

V+ 1 1AVPT
MM U V W 237 BLK
Gnd 2
PORO 238 WHI
117 Sig1 3 P
150 9 TX8 239 RED
V+ 4 3APT
FM 240 BLK
Gnd 5
150 10 GND 241 WHI
Sig2 6 P
MCB5 242 RED
104 V+ 7 4APT
1 12V 243 BLK
Gnd 8
200 244 WHI
2 1 1 +12 Sig3 9 P
P5
245 RED
P1
P2
201
P10
V+ 10 5CPT
3 2 2 Gnd 246 BLK
Gnd 11
R90 - 110N & R90 - 110I

4 PSU 247 WHI
Sig4 12 P
248 RED
V+ 13 6CPT
249 BLK
Gnd 14
250 WHI
Sig5 15 P
251 RED
V+ 16 10APT
252 BLK
Gnd 17
P9
MCB4 253
402 WHI
1L1 LOW AMBIENT Sig6 18 P

3ATS
L2/N (40 C) OPTION 1 260 WHI
Sig1 1
8.3 SCHEMATIC, ELECTRICAL WIRING (FIXED SPEED - Y/D) (STANDARD)
2 261 BLK 2CTT

P8
Gnd 2 T
HEATER 3 262 WHI
Sig2 3
CIRCUIT, KM1-3 4 263 BLK T 2ATT
Gnd 4
CUSTOMER 264 WHI
SUPPLIED Sig3 5
120/1/60 404 404 403 403 403 403 265 BLK T 4ATT
Gnd 6
P7
OR 404 403 266 WHI

240/1/50 Sig4 7 (NOTE 2)
267 BLK T 3CTT
Gnd 8
P6
1 N/O
SSH DMH FMH 1SVT MSHT OSH OSH BLH Sig5 9
CFO
P2
2 C
Gnd 10
3 N/C
Sig6 11
Gnd 12
410 410 410 410 410 410 410 410
Sig7 13
Gnd 14
274 WHI
Sig8 15 (NOTE 2)
275 BLK 1ATT
Gnd 16 T
KEY
OV Zero voltage SG Controller, intellisys
1ATT Package inlet temperature SS Solid state relays
1AVPT Inlet vacuum pressure SSH Starter space heater
1SV Load valve T1 Control power transformer
1SVT 1SV heat trace TH Thermostat
2ATT Airend discharge temperature
2CTT Injected coolent temperature Colors
3APT Wet sump pressure BLK Black
3ATS Ambient temp thermostat BLU Blue
3CTT Coolant cooler out temp. BRO Brown
4APT Package discharge pressure GRE Green
4ATT Aftercooler discharge temp PIN Pink
4SV Water shut off valve (w/c only) RED Red
5CPT Coolant filter in pressure VIO Violet
5SV Modulation valve WHI White
6CPT Coolant filter out pressure YEL Yellow
9SV Condensate drain valve
10APT Remote pressure
WIRE NUMBER DESIGNATION LEGEND
AW1 Auxiliary warning 1
AW2 Auxiliary warning 2 Numbers Function Wire color
BLH Base level heater 1-99 Power Black
BP Backpanel 100-199 AC Control Red
CAB Cabinet 100-199 Grounded AC White
CDE Condensate drain error 200-299 DC Control Blue
CDV Condensate drain valve (no loss) 300-399 Auxiliary Orange
GND Ground Green / Yellow
CFO Common fault output
DMH Drive motor heater
EB Earthing bar
ES Emergency stop button
FM Fan motor
FMH Fan motor heater
FR1 Main motor overload
FU- Fuses
K2 Phase monitor relay
KM1 Main contactor
KM2 Delta contactor
KM3 Start contactor
KM4 Fan motor contactor
KM5 Dryer compressor contactor
MCB Circuit breakers
MM Main motor
MSHT Moisture separator heat trace
OSH Oil sump heater
PE Protected earth
PORO Power outage restart option
PSU Power suppply unit
PTC Motor Winding Thermistor
RLE Remote load enable
RLU Remote load / unload
RSP Remote stop
RST Remote start
R90 - 110N & R90 - 110I 43


44
L1 L2 L3 208
DI4 7 ES-2
23378540
209
Revision C
Gnd 8
MCB3 ES-1
MCB1 T1 101 102 DI5 9 REMOVE JUMPER WHEN
3L3 100 101
1 115V Gnd CORRESPONDING
10 K2-1 214 215 OPTION
115V 150 213 PTC
PE 3L1 HAS BEEN PURCHASED
103 KM1-2 DI6 11
102 215
150 4SV U1 Gnd 12
216
FM DI7 13 216 LOW
217 FMP FD 01
MM Gnd 14 217 AMBIENT
L3 FD 02 OPTION
DCM DI8 15
L2 118 KM1-1 Gnd 16
DFM 150 118 110
L1 A2 K1 A1 2 TX1 220
SGN EB DI9 17
U1 221 CDE
1SV L1 L2 L3 119 Gnd 18
98 97 222
A2 K2 A1
3SV L1 L2 L3 DI10 19
223
P3
KM1 1.1 1.2 1.3 RSP
4SV 111 Gnd 20
KL1 150 A2 KM1 A1 3 TX2 224
5SV KM4 DI11 21
225 RST
9SV CDV 112 Gnd 22
2L1 2L2 2L3 A2 KM4 A1 4 TX3 226
OV DI12 23
1L1 1L2 1L3 113 U1 120 227 RLL
CAB Gnd 24
14 13 228
A1 150 1SV 5 DI13 25
BP 1 3 5 229 RLE
P1
DOOR A2 150 TX4 Gnd 26
121 FMP 230
PSU IN1 102 DI14 27
K1-1 231 RLU
TI IN2 3SV Gnd 28
U1 232
97 118 DI15 29
114 233 AW1
98 119 Gnd 30
T1 T2 T3 T6 T4 T5 150 5SV 6 TX5 234
13 120 I> I> I> DI16 31
2 4 6 12 8 10 235 AW2
14 113 Gnd 32
U1 V1 W1 W2 U2 V2 115
U V W 150 9SV 7 TX6 236 RED
V+ 1 1AVPT
237 BLK
Gnd 2
MM 238 WHI
Sig1 3 P
8 TX7 239 RED
FM V+ 4 3APT
240 BLK
Gnd 5
PORO 117 241 WHI
150 9 TX8 Sig2 6 P
242 RED
V+ 7 4APT
243 BLK
Gnd 8
150 10 GND 244 WHI
Sig3 9 P
MCB5 245 RED
L1 L2 L3 104 V+ 10 5CPT
1 246 BLK
12V Gnd 11
P5
200 247 WHI

U1 2 1 1 +12 Sig4 12 P
FU1, 2, 3 248 RED
150
P1
P2
201
P10
I V+ 13 6CPT
3L1 3L2 3L3 LOW 3 2 2 Gnd 249 BLK
R90 - 110N & R90 - 110I

Gnd 14
AMBIENT 250 WHI
1 2 3 4 5 6 7 8 OPTION 4 PSU Sig5 15 P
KM4
251 RED
V+ 16 10APT
4L1 4L2 4L3
P9
252 BLK
Gnd 17
L1 L2 L3 253 WHI
Sig6 18 P
GND 254 RED
9 10 11 12 13 14 15 16 O PE 1 V+ 19 2APT
255 BLK
2 Gnd 20 (NOTE 3)
P8
256 WHI
SMC-3 DIP SWITCHES 3 Sig7 21 P

12
283
4
18 260 WHI
Sig1 1
284 261 BLK 2CTT
27 Gnd 2 T
262 WHI
P7
FD 216 Sig2 3
01 SG-NE P3-13 263 BLK 2ATT
217 Gnd 4 T
02 SG-NE P3-14 264 WHI
294 Sig3 5
294 265 BLK 4ATT
60 9 AO+ Gnd 6 T
P4
295 295 266 WHI

Sig4 7
55 10 AO1 267 3CTT (NOTE 2)
BLK T
Gnd
8.3 SCHEMATIC, ELECTRICAL WIRING (FIXED SPEED - SOFT STARTER) (OPTION)
8
P6
PE Sig5 9
Gnd 10
UVW 303 Sig6 11
MOTOR 300 1 N/O Gnd 12
KM4-1 CFO 301
P2
RUNNING 2 C Sig7 13
FM CONTACT 302 3 N/C Gnd 14
304 274 WHI
Sig8 15
275 BLK 1ATT (NOTE 2)
Gnd 16 T
SHEET 1 OF 2
MCB4
1L1
402
LOW AMBIENT
L2/N
3ATS
(40 C) OPTION
HEATER
CIRCUIT, KM1-3
CUSTOMER
SUPPLIED
120/1/60 404 403 403 403 403 403 403
OR 404 403
240/1/50
SSH DMH FMH 1SVT MSHT OSH OSH OSH BLH
410 410 410 410 410 410 410 410 410
KEY
OV Zero voltage KM5 Dryer compressor contactor
1ATT Package inlet temperature MCB Circuit breakers
1AVPT Inlet vacuum pressure MM Main motor
1SV Load valve MSHT Moisture separator heat trace
1SVT 1SV Heat trace OSH Oil sump heater
2APT Interstage air press (2S ONLY) PE Protected earth
2ATT Airend discharge temperature PORO Power outage restart option
2CTT Injected coolent temperature PSU Power suppply unit
3APT Wet sump pressure PTC Motor winding thermistor
3ATS Ambient temp thermostat RLE Remote load enable
3CTT Coolant cooler out temp. RLU Remote load / unload
4APT Package discharge pressure RSP Remote stop
4ATT Aftercooler discharge temp RST Remote start
4SV Water shut off valve (W/C ONLY) SG Controller, intellisys
5CPT Coolant filter in pressure SS Solid state relays
5SV Modulation valve SSH Starter space heater
6CPT Coolant filter out pressure T1 Control power transformer
9SV Condensate drain valve TH Thermostat
10APT Remote pressure U1 Soft starter
AW1 Auxiliary warning 1
AW2 Auxiliary warning 2 Colors
BLH Base level heater BLK Black
BP Backpanel BLU Blue
CAB Cabinet BRO Brown
CDE Condensate drain error GRE Green
CDV Condensate drain valve (NO LOSS) PIN Pink
CFO Common fault output RED Red
DMH Drive motor heater VIO Violet
EB Earthing bar WHI White
ES Emergency stop button YEL Yellow
FM Fan motor WIRE NUMBER DESIGNATION LEGEND
FM Fan motor
Numbers Function Wire color
FMH Fan motor heater
1-99 Power Black
100-199 AC Control Red
FR1 Main motor overload
100-199 Grounded AC White
FU- Fuses
200-299 DC Control Blue
K1 Start control relay
300-399 Auxiliary Orange
K2 Starter fault relay
400-499 AC Power Red
KM1 Isolation contactor GND Ground Green / Yellow
KM4 Fan motor contactor
R90 - 110N & R90 - 110I 45

8.4 GENERAL DESCRIPTION
The compressor is an electric motor driven, contact By cooling the discharge air, much of the water vapor
cooled screw compressor, complete with all necessary naturally contained in the air is condensed and is drained
components piped, wired and baseplate mounted. It is a from the built-in moisture separator and drain.
totally self contained air compressor package. The coolant system consists of a sump, cooler,
The standard compressor is designed to operate in an thermostatic valve and a filter. When the unit is operating,
ambient range of 1.7° C to 46° C (35° F to 115° F). The coolant is forced by air pressure from the separator tank
standard maximum temperature of 46° C (115° F) is to the thermostatic element. The position of the element
applicable up to an elevation of 1000m (3280ft) above (a direct result of coolant temperature) will determine
sea level. Above this altitude significant reductions in whether the coolant circulates through the cooler,
ambient temperature are required if a standard motor is bypasses the cooler, or mixes the two paths together to
to be used. maintain an optimum compressor injection temperature.
The compressor is managed by the onboard electronic This temperature is controlled to preclude the possibility
controller. The controller and drive system operate of water vapor condensing. By injecting coolant at a
together to vary the speed of the compressor to deliver sufficiently high temperature, the discharge air coolant
compressed air at the target pressure. mixture temperature will be kept above the dew point.
For FS the capacity is automatically controlled via ‘ON- For VSD the system is enhanced by a control logic that
OFF LINE’. The compressor will operate to maintain a set varies the cooling blower speed dependant on the intake
discharge line pressure and is provided with an auto and discharge temperatures and hence controls the
restart system for use in plants where air demand varies injection temperature even closer while saving blower
widely. motor energy.
Panel instrumentation is provided to indicate the The compressor is provided with a temperature sensor
compressor operating conditions and general status. which will shut the unit down in case of excessive
temperature, 109° C (228° F).
The air/coolant mixture discharges from the compressor
into the separation system. This system removes all Effective coolant filtration is provided by the use of a
but a few PPM of the coolant from the discharge air. screw on, heavy duty coolant filter.
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 machine by the cooling blower and
through the coolant cooler and aftercooler.
Notice
Standard air compressors are factory filled with SSR Ultra Coolant. It is recommended to perform a coolant
analysis every 2000 hours or 3 months to monitor condition and determine when to change the coolant. If
an analysis is not performed, the recommended coolant change interval is 8000 hours or 2 years, whichever
comes first.
For units supplied with optional Food Grade Coolant, is recommended to perform a coolant analysis every
500 hours or every month to monitor condition and determine when to change the coolant. If an analysis
is not performed, the recommended coolant change intervals is 2000 hours or 6 months, when utilizing the
X-Tend Food Grade filter supplied with the machine. For units running Food Grade Coolant WITHOUT the X-
Tend Food Grade Filter, the change interval should be 1000 hours or 6 months, whichever comes first.
The coolant must be changed at these intervals to avoid breakdown and equipment damage.
Notice
FS (Fixed Speed) compressor should not be connected to a VSD. Please contact your local Ingersoll Rand
representative before inverter duty conversion.
caution
LOW DEMAND APPLICATIONS
For FS during periods of low demand, the compressor may not reach its normal operating temperature.
Sustained operation at low demand can result in the build up of condensate in the coolant. If this situation
occurs, the lubricating characteristics of the coolant can be impaired which may lead to damage of the
compressor.
THE COMPRESSOR SHOULD BE ALLOWED AMPLE LOADED RUNNING TIME.
46 R90 - 110N & R90 - 110I

9.0 OPERATING INSTRUCTIONS
9.1 OPERATING INSTRUCTIONS FOR VSD
9.1.1 BASIC OPERATION
Prior to starting
warning
Refer to diagram T5716 above.
Ensure that all protective covers/guards are in place
before attempting to start the machine. Check that the coolant level is at least visible in the
center of the sight glass, add coolant if necessary. Refer to
warning maintenance procedures for setting correct level.
The compressor can operate in a pressurized Ensure that the discharge air isolation valve is open.
shutdown mode. If the compressor stops Switch on the main electrical isolation switch. The control
automatically, the airend, separator tank and oil panel will illuminate, indicating that the line and control
system can contain high pressure air. This can be voltages are available.
relieved by pressing the emergency stop button
and can be verified by unscrewing the coolant The contrast of the display may be adjusted by turning
fill plug which has a vent hole through which any the small screw which is on the right hand side of the
residual pressure will be vented. Downstream of the
separator tank may still contain system pressure controller when accessed through the starter cabinet
which must also be vented. door.
Initial check sequence
NOTICE The controller will perform an initial check sequence if the
compressor (1) receives initial power to the controller or
The language and units of measure displayed
on the Intellisys controller will be pre-set before (2) has experienced an trip reset. While the initial check
leaving the factory. If these are required to be sequence occurs, the controller will display a “Checking
changed, contact your local Ingersoll Rand Service Machine” message.
Department, Distributor or Air Center.
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 trip will
occur and the unit will not start.
After completion of the initial check sequence, the
controller will then display “READY TO START’. This process
should be completed within 10 seconds.
R90 - 110N & R90 - 110I 47

Start sequence Blower control
The compressor will initially start by the operator The blower speed varies in some conditions to assist in
pressing the local start button or receiving a remote start controlling the aftercooler approach temperature and the
command. The compressor will start loaded and will ramp coolant injection temperature. The blower motor has its
up the motor speed to its minimum speed. Once the own variable speed drive and will ramp up and down as
minimum speed has been achieved, the compressor will the compressor starts and stops.
begin to control pressure by using its speed regulation.
Stopping the machine in an emergency
When the system pressure reaches the target pressure,
the compressor will start to slow. If the system pressure If the machine has to be stopped in an emergency
rises to the immediate stop pressure setpoint the DEPRESS THE EMERGENCY STOP BUTTON LOCATED
compressor will stop. If the system pressure rises to the UNDERNEATH THE INSTRUMENT PANEL.
auto stop setpoint and the compressor is at minimum
This will over-ride the normal unload/stop button and will
speed, if the blowdown mode is set to off, the compressor
immediately stop the machine.
will stop. However if the blowdown mode is set to on, the
compressor will open the blowdown valve for up to 10 Restarting after an emergency
seconds or until the pressure in the separator tank falls If the unit has been switched off because of a machine
to 2.4 Bar (35 psi) before stopping. The compressor will malfunction, identify and correct the fault before
restart once the system pressure falls below the target attempting to restart.
pressure.
If the unit has been switched off for reasons of safety,
Stop sequence ensure that the machine can be operated safely before
The compressor can be stopped by a local or remote restarting.
stop, a shutdown due to a trip or an emergency stop. Refer to the PRIOR TO STARTING and START SEQUENCE
All of the above conditions will cause the compressor instructions earlier in this section before restarting the
to stop immediately, except the local or remote stop. machine.
A local or remote stop will open the blowdown valve
and the compressor will run for up to 10 seconds or
until the pressure in the separator tank falls to 35 psi
before stopping. The compressor will stop if the system
pressure reaches the automatic stop or immediate stop
pressure setpoints. However, if the compressor stops for
this reason, it will automatically restart when the system
pressure falls below the target pressure.
Important: Depress the emergency stop button when
the compressor must be stopped immediately.
Warm Up Mode:
A warm up cycle occurs when the compressor’s airend
discharge temperature doesn’t reach the required
warm up temperature (82°C/180°F) for two consecutive
operational cycles. On a warm up cycle, instead of
stopping, the compressor will continue to run with the
blowdown valve open. The compressor will run in a fixed
speed mode, at minimum speed. The blower will operate
at minimum speed. The compressor will run like this for
approximately 5 minutes. During a warm up cycle, the
controller will display the message “Warm Up Mode”. If
the pressure falls during this time period, the compressor
will return to normal operation.
48 R90 - 110N & R90 - 110I

9.1.2 INTELLISYS CONTROLS (VSD)
7
F1 F2
2 4 5 3
1. Emergency stop 5. F2
Pressing this switch stops the compressor immediately. Not used.
The blowdown valve will open to vent pressure in
6. Arrows
the separator tank to atmosphere. Note the system
downstream of the separator tank may still contain These up and down buttons have multiple functions
pressure. The compressors can not be restarted until the relating to the right half of the display screen. When lists
switch is manually reset. Turn the switch knob clockwise are presented, the buttons are used to move up or down
and press the reset button twice to reset. through the items on the list. The small arrow(s) displayed
in the upper right hand corner of the display screen
On reset the controller will display a message, indicating
indicate when you can move up (designated by arrow
that the compressor is ready to start.
head pointing up) and/or down (designated by arrow
2. Start head pointing down) through the list.
Pressing this button will activate the start sequence. When the value of a specific machine operating
parameter is highlighted on the display screen for the
3. Stop
purpose of changing that value, the buttons are used to
Pressing this button will activate the stop sequence. change the value itself.
4. F1 7. Display buttons
Not used. The functions of the three buttons below the display
screen change and are defined by the words immediately
above them in the bottom line of the screen. Each
function, such as MAIN MENU, STATUS, etc., is described in
appropriate sections in this manual.
R90 - 110N & R90 - 110I 49

9.1.3 DISPLAY SCREEN
The display screen is divided into three functional areas, The right side shows various items or lists such as the
as seen in the typical CURRENT STATUS screen shown machine’s CURRENT STATUS readings, the MAIN MENU,
here. the OPERATOR SETPOINTS list, etc. Any of the lists can be
moved up or down by pressing the arrow buttons to the
The left side continuously shows the package discharge
right of the screen. The small arrow(s) displayed in the
pressure in large numbers with the line directly below
upper right corner of the screen indicate when you can
showing the running condition of the machine
move up and/or down through a list. The arrow buttons
are also used to change an individual item’s value. At
−CURRENT STATUS− certain times, items and/or their values are “highlighted”.
This means that they are displayed as light characters on
100 PSI PACKAGE DISCHARGE a dark background.
TEMP
The bottom of the screen is divided into thirds with the
102 F
words in each small box showing the function of the
READY TO START AIREND DISCHARGE button directly beneath it. The words will change in these
TEMP boxes depending on what actions are permitted at any
192 F particular time. The action resulting from pressing each
MAIN MENU of these buttons is indicated in the Operator Panel Flow
Diagram later in this section. This can be used as a quick
reference of how to step the controller screen through
any desired function.
50 R90 - 110N & R90 - 110I

9.1.4 CURRENT STATUS SCREEN
The CURRENT STATUS screen is considered to be the 13 Motor Speed

“normal” display that the controller shows.
14 Remote Pressure (optional)
The following items and their present values can be
displayed on the right side of the screen by pressing the 15 Time and Date
up and down arrow buttons 16 Program Name
The controller automatically returns the display to this 17 Version of Drive Software
CURRENT STATUS screen from other screens if no buttons
are pressed within 30 seconds. When the CURRENT STATUS screen is displayed, pressing
the ENERGY STATUS button will toggle the display to
Use the UP and DOWN arrows to move between the ENERGY STATUS screen. Likewise, when the ENERGY
selections. STATUS screen is displayed, pressing the STATUS button
CURRENT STATUS items will toggle the display to the CURRENT STATUS screen.
1 % Energy Saving The ENERGY STATUS screen displays the following items.
2 % Capacity ENERGY STATUS Items
3 Package kW 1 Average Package kW-hr
4 Package Discharge Temperature 2 Average % Capacity
5 Airend Discharge Temperature 3 Average Capacity
6 Injected Coolant Temperature 4 Energy Cost
7 Sump Pressure 5 Energy Savings
8 Separator Pressure Drop 6 Lifetime Energy Savings
9 Coolant Filter Pressure Drop

10 Inlet Vacuum
11 Inlet Filter
12 Total Hours
R90 - 110N & R90 - 110I 51

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

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

SETPOINTS CALIBRATION
ITEM ITEM
“Cancel or set” “Cancel or set” “Cancel or calibrate”
“Main Menu” “Main Menu” “Main Menu”

TRIP CLOCK ENERGY
HISTORY FUNCTIONS
“Status” “Status” “Status” STATUS
“Select” “Select”
“Main
Menu”
AVG. PACKAGE kW HRS
“Main Menu” “Main AVG. % CAPACITY
TRIP Menu” DATE
HISTORY ITEM AVG. CAPACITY
AND TIME
“Status” ENERGY COST
“Status”
ENERGY SAVINGS
“Status” LIFETIME ENERGY SAVINGS
“ Trip List” “Cancel or set”

“Cancel or set”
52 R90 - 110N & R90 - 110I

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

Target pressure 100 65 145 1 PSI
Automatic stop pressure 110 Target +1 Target +10 1 PSI
Immediate stop pressure 120 Auto Auto +10 1 PSI
Blowdown mode Off Off On - -
% savings compared to Modulation - - - -
Energy Rate 0 0 9999.999 - -
Reset Avg. -- - - Reset Date -
Service menu 1 1 25535 1 -
A setpoint’s value can be changed by first highlighting

the item and its value and pressing the SELECT button Unit Min Max (1S / 2S) Step
to highlight just the value. When the value line is PSI 65 145 1
highlighted by itself, the value can be adjusted using BAR 4.4 10 0.1
the up and down arrow buttons. The CANCEL and SET
kPa 440 1000 10
buttons appear at this time. Press the SET button to enter
the new value or press the CANCEL button to return KGCM2 4.5 10.2 0.1
the value of the setpoint prior to using the arrows. The
displayed value will flash twice to indicated that it has
been entered into the setpoint and the pair of setpoint
item and value display lines will again be highlighted
together.
Operator setpoints can be exited by pressing the STATUS
or MAIN MENU buttons. If no buttons are pressed within
30 seconds, the display will return to the CURRENT
STATUS screen.
Target pressure
The compressor will try to operate at this pressure setting.
The target pressure ranges and step sizes for each unit of
measure are listed in the table below.
R90 - 110N & R90 - 110I 53

Automatic stop pressure % savings compared to
The compressor will stop once the system pressure rises This setpoint is to determine what VSD’s percent of
to this pressure and the compressor is operating at the savings is compared to. The modes of operation for
minimum speed. The range for this setpoint will be the comparing VSD to are modulation, online/offline, and
target pressure+1 to target pressure+10 psi. geometry. The percent savings value is displayed by the
status message, % energy savings
Immediate stop pressure
Energy Rate
The compressor will stop if the system pressure rises
to this pressure. The range for this setpoint will be the The energy cost and the energy savings items on the
automatic stop pressure to automatic stop pressure+10 ENERGY STATUS screen will use this value for their
psi. calculations. It is intended to be a monetary value
representing the user’s power cost per kilowatt hour.
Blowdown Mode
Reset Averaging
2 stage compressors will always blowdown when
signaled to stop. When this setpoint is selected and the SET button is
pressed, the items on the ENERGY STATUS screen will be
If this mode is selected to ON the compressor will open
reset, and the date the reset occurred will be displayed
the blowdown valve anytime that it stops. This will vent
in this setpoint. This selects the beginning of the time
pressure from the airend and the separator tank. If this
period over which the ENERGY STATUS information will
mode is selected to OFF the blowdown valve will remain
be calculated. Note that the “Lifetime Energy Savings”
closed when the compressor stops due to an automatic
item will not be reset.
stop. Blowdown mode is set on at all times for 2 stage
models. Blowdown mode will be shown as ”Not Installed” Service Menu
at the controller display.
For use by Ingersoll Rand personnel only.
54 R90 - 110N & R90 - 110I

9.1.7 OPTIONS
Options are turned on or off and their associated values −OPTIONS−
are set using the OPTION screen shown opposite.
Some options are purchased, they require additional 100 PSI
REMOTE START/STOP ON
machine hardware and must first be enabled by service
personnel. The name and value of each of the following
options can be seen by moving the list up and down READY TO START REMOTE START/STOP ON
using the arrow buttons
An Option item’s value can be changed the same way that STATUS MAIN MENU SELECT
OPERATOR SETPOINTS values are changed.
OPTIONS Items SELECTION MIN. MAX. Step Unit Installed

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

If this setting is set to ON, the compressor will use If this setting is set to ON, the compressor will
a remote mounted pressure sensor for controlling automatically restart when power is returned to the
system pressure by comparing it to the Target Pressure compressor if it was operating when power was removed.
setting and the Auto Stop Pressure setting. The pressure
Note:
measured by this sensor is shown in the CURRENT STATUS
A kit including instruction manual is required to install
display as the Remote Pressure reading. The local sensor
this option.
at the package discharge is still used for Immediate Stop,
for certain Trip conditions and for display on the left side Power out restart time
of the screen.
If the power out restart setting is set to ON, this is the
Sequencer number of seconds from the time power is restored until
the compressor starts. The power out restart horn will
If this setting is set to ON, the compressor will be able to
sound during this time.
start and stop by commands from a host device. When
the Intellisys receives a load command from the host Scheduled start day
device, the compressor will start. When the Intellisys
This option is the selection for the day that a scheduled
receives an unload command the compressor will
start will take place. The selections are Sunday, Monday,
respond as though executing an immediate stop.
Tuesday, Wednesday, Thursday, Friday, Saturday, Daily (Su-
Remote start/stop Sa), Weekdays (M - F), or Weekends. This option setpoint
will work with the scheduled start setpoint.
If this setting is set to ON, the compressor can be started
and stopped from a remote device.
R90 - 110N & R90 - 110I 55

Scheduled start Scheduled stop
This option will cause the unit to start on the scheduled This option will cause the unit to stop on the scheduled
start day , at the time stored in this setpoint. To disable stop day, at the time stored in this setpoint. To disable this
this option, set the value of scheduled start equal to the option, set the value of scheduled stop equal to the value
value of scheduled stop. of scheduled start.
Scheduled stop day
This option is the selection for the day that a scheduled
stop will take place. The selections are Sunday, Monday,
Tuesday, Wednesday, Thursday, Friday, Saturday, Daily (Su
- Sa), Weekdays (M - F), or Weekends. This option setpoint
will work with the scheduled stop setpoint.
9.1.8 SENSOR CALIBRATION
Pressure sensor calibration is done through the SENSOR Each of the sensors listed below can be chosen by using
CALIBRATION screen. Sensor calibration can only take the up and down arrow buttons to highlight it on the
place when the machine is stopped. Calibration needs screen.
to be done only after a sensor has been replaced or the
SENSOR CALIBRATION Items
Intellisys controller has been replaced.
Sensor 1VAPT (Inlet Vacuum)
Sensor 4APT (Package Discharge)
Sensor 3APT (Wet Side Sump)
−SENSOR CALIBRATION−
Sensor 5CPT (Coolant Filter In)
100 PSI
SENSOR 4APT
Sensor 6CPT (Coolant Filter Out)
Sensor 2APT (Interstage) (On 2 stage compressors only)
CALIBRATE Sensor 7APT (Aftercooler-dryer units only)
READY TO START SENSOR 3APT Select the highlighted sensor by pressing the SELECT
button. Press the CALIBRATE button to start the automatic
CALIBRATE
calibration procedure, or press the CANCEL button to not
STATUS MAIN MENU SELECT calibrate it and return to the sensor list.
The calibration screen can be exited by pressing either
the STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to the
CURRENT STATUS screen.
56 R90 - 110N & R90 - 110I

9.1.9 TRIP HISTORY
Trip History displays each of the Trip messages for the Each of the last 15 Trip messages can be seen by moving
last 15 Trips experienced by the machine. It also gives the Trip History list up and down using the arrow buttons.
access to displaying the machine operating conditions Pressing the SELECT button when one of the Trips is
that existed at the time of each Trip. The first one shown, highlighted will display the list of machine values that
“Trip History 1”, was the most recent Trip to occur. Note existed at the time that particular Trip occurred.
that multiple, consecutive EMERGENCY STOP Trips are
The name and value of each of the items can be seen by
not recorded as separate Trips, only the first one will be
moving the list up and down using the arrow buttons.
shown.
Pressing the TRIP HIST. button will return the display to
the TRIP HISTORY screen.
−TRIP HISTORY− Trip histories can be exited by pressing either the STATUS
100 PSI
TRIP HISTORY 1
STATUS screen.
BLOWER MOTOR
OVERLOAD
READY TO START TRIP HISTORY 2
HIGH AIREND DISCH
TEMP
STATUS MAIN MENU SELECT
9.1.10 CLOCK FUNCTIONS

−CLOCK FUNCTIONS− The date and time for the real time clock is set through
the CLOCK FUNCTIONS screen. Use the up and down
Time
100 PSI 01:15
arrows to highlight either TIME or DATE. Select the
highlighted setting by pressing SELECT.
Date If TIME is selected, first the hours will be highlighted.

READY TO START Jan 01, 00 Adjust the hours (00-23 hour clock) by using the up and
down arrows. Once the correct time is in the display, press
STATUS MAIN MENU SELECT SET to highlight the minutes. Adjust the minutes (00-59)
and then press SET to complete setting the time.
If DATE is selected, first the month will be highlighted.
Adjust the month by using the up and down arrows and
then press SET to highlight the date. Once the correct
date is displayed, press SET to highlight the year. Once the
correct year is displayed, press SET to complete setting
the date.
R90 - 110N & R90 - 110I 57

9.1.11 ENERGY STATUS MESSAGES
−ENERGY STATUS− AVERAGE CAPACITY - Displays the compressor’s average
capacity in cfm or m3 for the time period that was started
AVERAGE PACKAGE kW
100 PSI HRS
by selecting the reset averaging setpoint.
ENERGY COST - Displays the energy cost of the
AVERAGE
G % CAPACITY−
C C compressor for the time period that was started by
READY TO START −AVERAGE CAPACITY selecting the reset averaging setpoint. This is calculated
by multiplying the kW hours of the motor and the blower
by the energy rate.
ENERGY SAVINGS - Displays the energy savings of the
The Energy Status display can be selected by pressing the compressor for the time period that was started by
ENERGY STATUS button. The following items and their selecting the reset averaging setpoint as compared to
present values will be displayed on the right side of the a conventional compressor. This value is determined by
screen by pressing the up and down arrows. calculating how much a conventional compressor motor
AVERAGE PACKAGE kW HOURS - This displays the would cost to operate at the same average capacity
average package kW per hour for the time period that and then subtracting the motor energy cost of the VSD
was started by selecting the reset averaging setpoint. This compressor from it. It is assumed that the blower cost is
value includes the blower power usage. the same in both packages.
AVERAGE % CAPACITY - Displays the compressor’s LIFETIME ENERGY SAVINGS - Displays the lifetime
average percent capacity for the time period that was energy savings of the compressor at the existing energy
started by selecting the reset averaging setpoint. The rate and at the average percent capacity as compared to a
value is determined by taking the average package kW conventional compressor.
per hour, removing the blower power usage and then
dividing that number by the motor kW per hour for that
size of compressor at 100% capacity.
58 R90 - 110N & R90 - 110I

9.1.12 WARNINGS
When a WARNING occurs, a large question mark will flash HIGH DISCHARGE PRESS - Will occur if the unit is under
on the display screen. the control of an external device, such as an ISC, and the
discharge pressure is greater than the immediate stop
If multiple WARNINGS exist, the small up/down arrows
pressure.
will appear in the upper right corner of the display screen.
The multiple WARNINGS can be seen by pressing the up AUXILIARY WARNING 1 or 2 - Will occur if the auxiliary
and down arrow buttons. Pressing the STATUS button will warning input closes.
display the CURRENT STATUS screen with the WARNING
REMOTE PRESSURE SENSOR FAILURE (option) - This will
button indicating that a WARNING still exists.
occur if the remote pressure sensor fails. If this happens,
A WARNING will not cause the unit to shut down. The the lntellisys will start using the package discharge
unit will continue to run in its normal operation and the pressure sensor to measure system pressure.
WARNING will remain displayed until reset.
CONDENSATE DRAIN ERROR - For units fitted with the
A Warning needs to be reset by the operator by pressing no loss drain trap, occur if the condensate drain error
the RESET button twice. contacts close while the unit is running.
The possible Warning messages are as follows; HIGH VSD AMBIENT TEMPERATURE - This warning will
occur if the VSD ambient temperature gets within 5% of
HIGH AIREND DISCHARGE TEMP - This will occur if
the shutdown value.
the Airend Discharge exceeds 221° F/105° C and is not
adjustable. HIGH SUMP PRESSURE - Occurs if the compressor is
running, the compressor is warm, the package discharge
CHANGE COOLANT FILTER - This warning will occur if
pressure is at least 65 psi, and the sump pressure is more
the high side pressure is 1.4 bar (20 psig) greater than the
than 15 psi above the target pressure. The occurrence of
low side pressure.
this warning will cause the controller to evaluate the need
CHANGE INLET FILTER - This will occur if the Inlet to lower the compressor’s speed.
Vacuum is greater than 0.05 bar (0.7 psig).
CHANGE SEPR ELEMENT - This will occur if the pressure
differential across the separator is 1.0 bar (12 psig).
SENSOR FAILURE - This will occur if a sensor is
recognized as missing or broken.
9.1.13 SERVICE WARNINGS

SERVICE - Service warnings occur when the unit has This will be set prior to the compressor being shipped
operated a certain number of hours, based on the from the factory. When a service warning occurs, contact
total hours. Service warnings can have multiple levels, your local Ingersoll Rand service representative.
depending on the service level selection.
9.1.14 INITIAL CHECK TRIPS:
The following trips will only occur when the machine is CHECK SETPOINTS - Will occur if the controller has
not running. These trips are related to high temperature, determined that some of the data stored in memory
power loss, and sensor calibration. They will have the contains unacceptable values.
same display mode as other trips.
INVALID CALIBRATION - Will occur if the sensor zero
HIGH AIREND DISCH TEMP- Will occur if airend discharge value is -10% to +1% of its scale. See Sensor Calibration.
temperature is greater than 95% of 109° C
(228° F).
R90 - 110N & R90 - 110I 59

9.1.15 TRIPS
When a Trip occurs, a large exclamation mark in a triangle HIGH START PRESSURE - If the sump pressure is above
will flash on the display screen. The display message will 100 psi (6.9 bar) when the compressor starts, the Intellisys
indicate what caused the Trip. will open the blowdown valve during the first few
seconds of starting (3 to 7 seconds). If the sump pressure
The compressor will stop and cannot be re-started again
does not fall to 100 psi (6.9 bar) during that time period,
until the trip condition no longer exists and the trip
this shutdown will occur.
message reset.
CHECK MOTOR ROTATION - This will occur if the Intellisys
Pressing the STATUS button will display the STATUS
reads a negative speed from the VSD when starting.
screen. The presence of the TRIP button indicates that a
Trip condition still exists. Trip Status is the list of machine VSD COMMUNICATION FAILURE - This will occur if the
operating conditions that existed at the time of the Trip. Intellisys does not receive a response from the VSD when
requesting information. This trip will take about 8 seconds
The name and value of each of the items listed can be
to occur.
seen by moving the list up and down using the arrow
buttons. Pressing the TRIP button will return the display VSD INITIALIZATION FAULT - Will occur if the Intellisys is
to the Trip screen and the RESET button. unable to establish communications with the VSD after a
power up.
The Trip needs to be reset by the operator by pressing the
RESET button twice. Any exceptions to this are explained LOW SUMP PRESSURE - Will occur if the compressor is
in the trip descriptions. operating at or above the minimum speed and the sump
pressure drops below 15psi (1.03 bar) for 15 seconds.
−TRIP STATUS−
REPLACE COOLANT FILTER - This will occur if the coolant
filter is blocked and requires changing.
100 PSI PACKAGE DISCH
PRESSURE INCORRECT VSD TYPE - Will occur at power up if the VSD
100 psi type does not match the size of the compressor.
STOPPED BY PACKAGE DISCHARGE CONTROL POWER LOSS - This will occur if the
TRIP TEMP compressor should be running and the AC input voltage,
103 F as read from the VSD, falls below 100 VAC. There is a delay
of 2 seconds on this trip in case the power quickly returns.
TRIP MAIN MENU Phase monitor can also cause this trip.
The possible Trip messages are as follows; HIGH INTERSTAGE PRESSURE - If the interstage pressure
is over 100psi while the unit is running and the unit is a
EMERGENCY STOP- This will occur if the Emergency 2-stage.
Stop button is engaged. The button must be disengaged
before the trip can be cleared. HIGH COOLANT FILTER PRESSURE DROP - Occurs if
the unit has been running for at least 7 seconds, the
BLOWER FAULT- This will occur if a blower fault is sensed. compressor is warm, already has a change coolant filter
HIGH AIREND DISCH TEMP- This will occur if the airend warning, the motor is running, and the coolant filter
discharge temperature is greater than 109° C (228° F). pressure drop is greater than 35 psi.
REMOTE START FAILURE- This will occur if the Remote HIGH INLET VACUUM - Occurs if the compressor is
Start button is pressed after the machine is running or if running loaded, the motor is running, and the inlet
the Remote Start button remains closed. vacuum is greater than 1.8 psi (vacuum).
REMOTE STOP FAILURE- This will occur if the Remote Stop HIGH SUMP PRESSURE - Occurs if the compressor is
button remains open and either Start button is pressed. running, the compressor is warm, and any one of the 3
following conditions exist.
SENSOR FAILURE - This will occur if a sensor is
recognized as missing or broken. 1. The sump pressure is above the maximum offline
pressure by 25 psi.
VSD FAULT - The VSD fault is read from the drive. The
Intellisys will read the status menu of the variable 2. The separator pressure drop is measured to be more
speed drive. If a fault condition is returned in the status than 25 psi and the package discharge pressure is at
information, the Intellisys will issue a VSD FAULT trip and least 65 psi.
display the number of the fault condition. 3. The sump pressure is above 170 psi.
STOP FAILURE - This will occur if the compressor should
be stopped but the motor is still running above minimum
speed 4 seconds after the stop signal is given.
60 R90 - 110N & R90 - 110I

9.2 OPERATING INSTRUCTIONS FOR FS
2 4 5 3
INTELLISYS CONTROLS 5. LOAD

1. EMERGENCY STOP Pressing this button will cause the compressor to load
if the compressor is running and if the DISCHARGE
Pressing this switch stops the compressor immediately.
PRESSURE is less than the ONLINE PRESSURE. This also
The compressor can not be restarted until the switch is
returns the machine to the operating mode that is
manually reset. Turn the switch knob clockwise to reset.
specified by the MODE OF OPERATION set point.
The controller display will illuminate, indicating that the
The other five buttons provide access to various
line and control voltages are available.
operator–selectable functions and machine operating
2. START conditions. The purpose of each of these buttons is
defined by the display screen and the particular function
Pressing this button will start the compressor if the
being performed at that time.
display shows READY TO START. the compressor will start
and load if there is sufficient demand for air. 6. ARROWS
3. STOP These up and down buttons have multiple functions
relating to the right half of the display screen. When lists
Pressing this button will activate the unloaded stop
are presented, the buttons are used to move up or down
sequence. If the compressor is running loaded, it will
through the items on the list. The small arrow(s) displayed
unload and continue to run unloaded for an adjustable 10
in the upper right hand corner of the display screen
to 30 seconds and then stop. If the compressor is running
indicate when you can move up (designated by arrow
unloaded, it will stop immediately.
head pointing up) and/or down (designated by arrow
4. UNLOAD head pointing down) through the list.
Pressing this button will cause the compressor to unload When the value of a specific machine operating
and remain unloaded. The display will indicate that the parameter is highlighted on the display screen for the
machine is RUNNING UNLOADED and MODE:UNLOAD. purpose of changing that value, the buttons are used to
change the value itself.
7. DISPLAY BUTTONS
The functions of the three buttons below the display
screen change and are defined by the words immediately
above them in the bottom line of the screen. Each
function, such as MAIN MENU, STATUS, etc., is described in
appropriate sections in this manual.
R90 - 110N & R90 - 110I 61

7.5 barg –CURRENT STATUS–

PACKAGE DISCHARGE TEMP
39 C
RUNNING LOADED AIREND DISCHARGE TEMP
MODE: MOD/ACS 89 C
MAIN MENU
DISPLAY SCREEN The right side shows various items or lists such as the
machine’s CURRENT STATUS readings, the MAIN MENU,
The display screen is divided into three functional areas,
the OPERATOR SETPOINTS list, etc. Any of the lists can be
as seen in the typical CURRENT STATUS screen shown
moved up or down by pressing the arrow buttons to the
here.
right of the screen. The small arrow(s) displayed in the
The left side continuously shows the package discharge upper right corner of the screen indicate when you can
pressure in large numbers showing the running condition move up and/or down through a list. The arrow buttons
of the machine and the line below that showing the are also used to change an individual item’s value. At
present mode of operation. certain times, items and/or their values are “highlighted”.
This means that they are displayed as light characters on
a dark background.
7.5 barg –CURRENT STATUS–

39 C
RUNNING LOADED AIREND DISCHARGE TEMP
MODE: MOD/ACS 89 C
MAIN MENU
The bottom of the screen is divided into thirds with the CURRENT STATUS ITEMS
words in each small box showing the function of the
Package Discharge Temperature
button directly beneath it. The words will change in these
Airend Discharge Temperature
boxes depending on what actions are permitted at any
Injected Temperature
particular time. The action resulting from pressing each
Sump Pressure
of these buttons is indicated in the Operator Panel Flow
Separator Pressure Drop
Diagram later in this section. This can be used as a quick
Coolant Filter
reference of how to step the controller screen through
Coolant Filter IN PR
any desired function.
Coolant Filter OUT PR
CURRENT STATUS Inlet Vacuum
Inlet Filter
The CURRENT STATUS screen is considered to be the
Total Hours
“normal” display that the controller shows.
Loaded Hours
The following items and their present values can be Software Title and Version
displayed on the right side of the screen by pressing the
up and down arrow buttons.
62 R90 - 110N & R90 - 110I

CURRENT
STATUS
MAIN MENU
(1)
OPERATOR OPTIONS SENSOR TRIP HISTORY

SETPOINTS (2) CALIBRATION (2)
(2) (2)
OPERATOR OPTIONS ITEM SENSOR TRIP HISTORY

SETPOINTS ITEM (3) CALIBRATION ITEM ITEM
(3) (4) (3)
The controller automatically returns the display to this (2) Selecting the highlighted item will place the value in
CURRENT STATUS screen from other screens if no buttons edit mode. This is indicated by only the value being
are pressed within 30 seconds. displayed in inverse display mode.
The MAIN MENU screen can be accessed from the (3) The UP and DOWN arrows will alter the value.
CURRENT STATUS screen by pressing the MAIN MENU Depressing “Cancel” will exit the edit mode and leave
button, identified by the words “MAIN MENU” in the the value unchanged.
bottom line of the screen directly above the centre Depressing “Set” will save the new value and flash the
button. value to indicate acceptance.
(4) Depressing “Cancel” will exit the calibration mode.
NOTE: Use the UP and DOWN arrows to move
between selections. Items will be highlighted in Depressing “Calibrate” will calibrate the selected sen-
inverse display mode. sor.
Ensure that the unit is stopped and fully depressurised
(1) Selecting the highlighted item will display the cor- first.
responding menu. (5) Use the UP and DOWN arrows to scroll through the list
of status items.
–MAIN MENU–
7.5 barg
OPERATOR SETPOINTS
OPTIONS
READY TO START SENSOR CALIBRATION
TRIP HISTORY
STATUS SELECT
R90 - 110N & R90 - 110I 63

MAIN MENU
OPERATOR RANGE STEP UNIT
The MAIN MENU screen is the point from which various SETPOINTS
operator functions can be accessed. Refer to the Operator
Offline Pressure 75 to RATED +10 1 PSIG
Panel Flow Diagram.
Online Pressure 65 to OFFLINE – 10 1 PSIG
Each of the functions can be chosen by using the up and
down arrows to highlight it on the screen. Mode of MOD/ACS, ON/OFF LINE,
Operation MODULATION ONLY
The controller will go to the highlighted function if the Condensate 2 to 20 1 SEC
SELECT button is pressed or will return to the CURRENT Release
STATUS screen if the STATUS button is pressed. Condensate 90 to 270 1 SEC
OPERATOR SETPOINTS Inverter
Setpoints are user–adjustable variables in the controller Stop Delay Time 10 to 30 1 SEC
logic that can be set using the OPERATOR SETPOINTS Star–Delta Time* 5 to 30 1 SEC
screen. (Screen) Contrast 0 to 10 1 –
The name and value of each of the setpoints listed below
*Does not apply to automatic across the line starters.
can be seen on the screen by moving the list up and
down using the arrow buttons.
–OPERATOR SETPOINTS–
7.5 barg
OFFLINE PRESSURE
7,6 barg
READY TO START ONLINE PRESSURE
6,9 barg
Setpoints associated with options are described in the Operator set points can be exited by pressing the STATUS
OPTIONS sections. or MAIN MENU buttons. If no buttons are pressed within
A setpoint’s value can be changed by first highlighting
STATUS screen.
the item and its value and pressing the SELECT button
to highlight just the value. When the value line is
highlighted by itself, the value can be adjusted using
the up and down arrow buttons. The CANCEL and SET
buttons appear at this time. Press the SET button to enter
the new value or press the CANCEL button to return
the value of the setpoint prior to using the arrows. The
displayed value will flash twice to indicated that it has
been entered into the setpoint and the pair of setpoint
item and value display lines will again be highlighted
together.
–OPTIONS–
7.5 barg
AUTO RESTART
Off
READY TO START AUTO RESTART TIME
10 MINUTES
64 R90 - 110N & R90 - 110I

OPTIONS
OPTIONS RANGE STEP UNIT
Options are turned on or off and their associated values Items
are set using the OPTION screen.
Power Out ON/OFF – –
Some options require additional machine hardware and Restart
the correct “Option Module” to plug into the Intellisys Power Out 10 to 600 1 SEC
controller. Descriptions of the options operations can be Restart Time
found later in this section. The name and value of each of Low Ambient ON/OFF – –
the following options can be seen by moving the list up
and down using the arrow buttons. An Option item’s value can be changed the same way that
OPERATOR SETPOINTS values are changed.
–SENSOR CALIBRATION–
7.5 barg
SENSOR 1AVPT
CALIBRATE
READY TO START SENSOR 3APT
CALIBRATE
OPTIONAL FEATURES POWER OUT RESTART OPTION (PORO)

(Dependant on installed operations and/or installed
Modulation hardware extends the control types to
controls)
modulation (capacity control) and Automatic Control
System when the compressor switches between “On-Off For PORO to execute , the PORO option must be installed
line’ and modulation as demand varies. and the PORO set point must be set to ON. If power is lost
to the compressor while the unit is running or is stopped
Safety of the operation is provided for as the compressor
in auto start/stop, the controller will store the current
will shut down if excessive temperatures, electrical opening conditions in memory.
overload conditions, or system over pressure should
occur. When power is restored, the controller will energize the
horn and start a countdown on the display. The red LED
LOW AMBIENT OPTION (STANDARD & ENHANCED will flash indicating a warning condition and the horn will
COMPRESSORS) blow for the number of seconds set in the PORO time set
When the low ambient option is installed and selected point. At the end of the countdown, the horn will stop
and the A/E Discharge temperature is measured to be at blowing and the compressor will start.
or below 2oC (35oF), the compressor will be started when The PORO countdown may be stopped at any time by
commanded but will not load until the airend discharge pressing the Stop / Reset button on the user interface.
temperature is above 2oC (35oF). After the conditions are Pressing any button will cause the horn to stop blowing
met the controller will adjust the fan speed to maintain and the countdown to stop. The control will power up
proper operating temperatures. When the low ambient normally in a ready to start mode.
option is not installed, the machine will not start if the A/E
discharge temperature is below 2oC (35oF).
caution
If PORO or Scheduled Start/Stop are installed,
additional hardware is required to provide an
audible warning of pending re-start.
Contact Ingersoll Rand for details
R90 - 110N & R90 - 110I 65

SENSOR CALIBRATION SCHEDULED START / STOP
(Dependant on installed options and/or installed
Pressure sensor calibration is done through the SENSOR
controls)
CALIBRATION screen. Sensor calibration can only take
place when the machine is stopped. Calibration needs The scheduled start / stop option enables starting and
to be done only after a sensor has been replaced or the stopping the compressor at specified times. This mode
Intellisys controller has been replaced. of operation can be turned on and off by selecting the
desired mode in the scheduled start stop on / off set
Each of the sensors listed below can be chosen by using
point.
the up and down arrow buttons to highlight it on the
screen. When enabled, the horn will blow for 10 seconds to warn
anyone in the surrounding area that the compressor is
SENSOR CALIBRATION Items
about to start. The display screen will display the warning
Sensor 1AVPT
message “Scheduled Start in X seconds”, where “X” is
Sensor 3APT
a countdown from 10 to 0 seconds. After 10 seconds,
Sensor 4APT
the compressor will automatically start as long as the
Sensor 5CPT
compressor is not in a fault condition or manually
Sensor 6CPT
stopped by pressing the stop / reset button.
Select the highlighted sensor by pressing the SELECT
When a scheduled stop occurs, the compressor can be
button. Press the CALIBRATE button to start the automatic
manually re-started by pressing the control panel start
calibration procedure, or press the CANCEL button to not
button or closing the remote start signal.
calibrate it and return to the sensor list.
The calibration screen can be exited by pressing either
the STATUS or MAIN MENU buttons. If no buttons are
pressed within 30 seconds, the display will return to the
CURRENT STATUS screen.
66 R90 - 110N & R90 - 110I

– TRIP HISTORY –
7.5 barg
TRIP HISTORY 1
MAIN MOTOR OVERLOAD
READY TO START TRIP HISTORY 2
HIGH AIREND DISCH TEMP
TRIP HISTORY Each of the last 15 Trip messages can be seen by moving
the Trip History list up and down using the arrow buttons.
Trip History displays each of the Trip messages for the
Pressing the SELECT button when one of the Trips is
last 15 Trips experienced by the machine. It also gives
highlighted will display the list of machine values that
access to displaying the machine operating conditions
existed at the time that particular Trip occurred.
that existed at the time of each Trip. The first one shown,
“Trip History 1”, was the most recent Trip to occur. Note
that multiple, consecutive EMERGENCY STOP Trips are
not recorded as separate Trips, only the first one will be
shown.
– TRIP HISTORY 1 –
7.5 barg
PACKAGE DISCH PRESSURE
14,2 barg
READY TO START PACKAGE DISCHARGE TEMP
54 C
STATUS MAIN MENU TRIP HIST.
The name and value of each of the items listed below can Inlet Filter
be seen by moving the list up and down using the arrow Injected Temperature
buttons. Pressing the TRIP HIST. button will return the Total Hours
display to the TRIP HISTORY screen. Sump Pressure
Loaded Hours
TRIP HISTORY ITEMS
Separator Press. Drop
Package Discharge Pressure % Load Modulation
Coolant Filter
Trip histories can be exited by pressing either the STATUS
Package Discharge Temperature
Inlet Vacuum
Airend Discharge Temperature
STATUS screen.
WARNING
7.5 barg
CHANGE INLET FILTER
RUNNING UNLOADED PRESS RESET TWICE

MODE: MOD/ACS
STATUS MAIN MENU RESET
When a Warning occurs, the word WARNING will flash on If multiple Warnings exist, the small up/down arrows will
the display screen and appear in large letters as shown appear in the upper right corner of the display screen.
above. The display message will indicate what caused the The multiple Warnings can be seen by pressing the up
warning. and down arrow buttons. Pressing the STATUS button will
display the CURRENT STATUS screen with the WARNING
button indicating that a Warning still exists.
R90 - 110N & R90 - 110I 67

–CURRENT STATUS–
7.5 barg
39,4 C
RUNNING UNLOADED AIREND DISCHARGE TEMP
MODE: MOD/ACS 89,4 C
WARNING MAIN MENU
Pressing the WARNING button will return the display to CHANGE COOLANT FILTER – This warning will occur if
the WARNING screen and the RESET button. the high side pressure is 20 psig (1,4 bar) greater than
the low side pressure of 1 DPS and the Injected Coolant
A Warning needs to be reset by the operator by pressing
temperature (2CTT) is greater than 120°F (49°C).
the RESET button twice.
CHANGE INLET FILTER – This will occur if the Inlet
The possible Warning messages are as follows;
Vacuum (1AVPT) is greater than 0,7 psig (0,05 bar) and the
AIREND DISCHARGE TEMP – This will occur if the Airend machine is fully loaded (inlet valve is completely open).
Discharge (2ATT) exceeds 97% of the alarm limit, 228°F
CHANGE SEPR ELEMENT – This warning will occur if
(109°C) and is not adjustable.
the pressure on the Separator (3APT) is 15 psig (1,0 bar)
greater than the pressure at the Package Discharge
(4APT) and the machine is fully loaded.
TRIP
7.5 barg
HIGH AIREND DSCH TEMP
109,4 C
STOPPED BY TRIP
MODE: MOD/ACS PRESS RESET TWICE
STATUS MAIN MENU RESET
HIGH DISCHARGE PRESS – This can occur if the TRIPS

machine’s loading function is being controlled by a host
When an Trip occurs, the word TRIP will flash on the
device such as a sequencer or an ISC. This warning will
display screen and appear in large letters as shown above.
occur when the package discharge pressure is above the
The display message will indicate what caused the Trip.
maximum offline pressure (rated pressure plus 3 psig (0,2
bar)) for more than 3 seconds. This warning will cause the Pressing the STATUS button will display the STATUS
compressor to unload. The host device will not be able to screen. The presence of the TRIP button indicates that an
load the compressor until the package discharge pressure Trip condition still exists. Trip Status is the list of machine
falls to the rated pressure of the machine. operating conditions that existed at the time of the Trip.
SENSOR FAILURE 4ATT – This will occur if the Package
Discharge Temperature Sensor (4ATT) is missing or
broken.
– TRIP STATUS –
7.5 barg
PACKAGE DISCH PRESSURE
7,0 barg
STOPPED BY TRIP PACKAGE DISCHARGE TEMP
MODE: MOD/ACS 39,4 C
ALARM MAIN MENU
68 R90 - 110N & R90 - 110I

The name and value of each of the items listed can be machine is running fully loaded and the sump pressure
seen by moving the list up and down using the arrow drops below 20 psig (1,4 bar).
buttons. Pressing the TRIP button will return the display
LOW UNLOAD SUMP PRESS– This will occur if the
to the Trip screen and the RESET button.
machine is running unloaded and the sump pressure is
The Trip needs to be reset by the operator by pressing the less than 15 psig (1,0 bar) for 15 seconds.
RESET button twice. Any exceptions to this are explained
MAIN MOTOR OVERLOAD– This will occur if a drive
in the Trip descriptions.
motor overload is sensed.
The possible Trip messages are as follows;
MEMORY FAULT– This will occur if the controller has
CHECK MOTOR ROTATION – This will occur if the determined some of the data stored in memory contains
machine is started and the compressor has incorrect unacceptable values. When this occurs, the sensors
rotation. should be calibrated and all the set points checked. It
is normal for this trip to occur after changing controller
CONTROL POWER LOSS – This will occur if the controller
software.
detects a loss of the 110 VAC control power.
REMOTE START FAILURE– This will occur if the Remote
EMERGENCY STOP– This will occur if the Emergency
Start button is pressed after the machine is running or if
Stop button is engaged. The button must be disengaged
the Remote Start button remains closed.
before the trip can be cleared.
REMOTE STOP FAILURE– This will occur if the Remote
FAN MOTOR OVERLOAD– This will occur if a fan motor
Stop button remains open and either Start button is
overload is sensed.
pressed.
HIGH AIREND DISCH TEMP– This will occur if the airend
SENSOR FAILURE 1AVPT (or 3APT, 4APT,
discharge temperature is greater than 228°F (109°C).
2CPT,5CPT,6CPT 2ATT)– This will occur if a sensor is
HIGH SUMP PRESSURE– This will occur if the sump recognised as missing or broken. This does not apply to
pressure is above offline pressure by 25 psig and sump sensor 4ATT.
pressure drop is more than 25 psig. Can also occur if sump
HIGH INLET VACUUM – This will occurs if inlet vacuum is
pressure is above 165 psig.
greater than 1.8 psig for units with high dust factor, the
LOW SUMP AIR PRESSURE– This will occur if the threshold is 1.8 psig.
T5461
Revision 00
12/94
R90 - 110N & R90 - 110I 69

PRIOR TO STARTING 1. Check the coolant level in the sight tube/glass. Add
coolant if necessary.
Refer to the diagram T5461
2. Ensure that the discharge air isolation valve is open.
warning
3. Switch on the main electrical isolation switch. The
Ensure that all protective covers/guards are in place power on indicator will illuminate, indicating that the
before attempting to start the machine. line and control voltages are available.
2 4 5 3
STARTING THE MACHINE This will over–ride the normal unload/stop button and
will immediately stop the machine without the 10 second
Upon power up, the Intellisys will carry out a series of
delay.
checks, and the message CHECKING MACHINE will show
on the display. If all the check parameters are satisfactory,
caution
the display will then show READY TO START.
Never allow the machine to stand idle with pressure
Depress the start button (2) on the Intellisys unit. The in the system.
machine will start and automatically load.
STOPPING THE MACHINE RE–STARTING AFTER AN EMERGENCY
Depress the STOP button (3) which will automatically If the unit has been switched off because of a machine
unload the compressor for 10 seconds before stopping. malfunction, then identify and correct the fault before
attempting to re–start.
Switch off the main electrical isolation switch.
If the unit has been switched off for reasons of safety,
STOPPING THE MACHINE IN AN EMERGENCY then ensure that the machine can be operated safely
If the machine has to be stopped in an emergency before re–starting.
DEPRESS THE EMERGENCY STOP BUTTON (1) LOCATED Refer to the PRIOR TO STARTING and STARTING THE
ON THE INSTRUMENT PANEL. MACHINE instructions earlier in this section before
re–starting the machine.
70 R90 - 110N & R90 - 110I

10.0 MAINTENANCE
10.1 MAINTENANCE PROMPTS
The service warning and flashing LED will appear at Ingersoll Rand service engineers will master reset the
intervals, dependant on the service level selected. Refer warning after completing the service work.
to operating instructions.
The service warning will return each subsequent 2000
For service level 1, when a “Service Required” warning hours.
is issued, the warning can be reset the same way as any
The machine will be master reset after service work
other warning.
conducted prior to the 2000 hour interval to prevent false
For service level 2, when a “Service Required” warning is indication.
issued, the customer can only reset the warning for 24
hours by pressing the “set” button.
R90 - 110N & R90 - 110I 71

10.0 MAINTENANCE
10.2 MAINTENANCE CHART
Maintenance should be performed per the recommendations below in the following priority: (1) Perform Maintenance
When Indicated by the Controller; (2) Perform Maintenance through either Hourly Intervals or scheduled maintenance
intervals, or (3) Annually.
Period Action Maintenance Item
When indicated by Replace Air Filter
controller Replace Oil Filter
Replace Separator Element
Daily Check Check for leaks (connections and hoses)
Check Coolant Level
Check Drain Valve operation
Check Intellisys Controller for Service Indicators
Check Pre Package Filter for blockage
Monthly Inspect Air Cooled Coolers, check for blockages
Inspect Water Cooled Coolers, check screens
Inspect Starter Box (PDM) Filter
Analysis Water Cooled machines, Perform water analysis.
Every 500 Hrs Analysis Perform Food Grade Lubricant Analysis
Every 1000 hours Replace Food Grade Lubricant if not using X-Tend Food Grade Filter system
Replace Filter, Food Grade Lubricant if not using X-Tend Food Grade Filter System.
Every 2000 Hours Inspect Air Filter Element
or 3 Months Inspect Oil Filter Element
Inspect Starter Box Panel Filter (VSD Only)
Replace Food Grade Lubricant when using X-Tend Food Grade Filter Module.
Replace X-Tend Food Grade Filter Module
Analysis Shock Pulse Bearing Analysis
Analysis Perform Coolant Analysis
Every 4000 Hours Inspect Check Scavenge Screen for blockage.
or 6 Months Replace Air Filter Element
Replace Oil Filter Element
Replace PDM Air Filter Element
Replace Package Pre Filter
Clean Air Cooled Coolers
Inspect / Clean Water Cooled Coolers
Grease Grease Motors
Maintenance interval for typical rotary compressor installation. Motors in
harsh environments / higher ambients should be regreased more frequently.
Calibrate Calibration of the Pressure Transducers.
Analysis Perform Coolant Analysis
Analysis Perform Vibration Analysis
Every 8000 Hours Replace Ultra Coolant Lubricant - 8000 hours or every 2 years.
or Annually Replace Separator Element
Replace No Loss Drain Valve Service Module
Service MPCV Service Kit
Service Inlet Valve Service Kit
16000 Hours Replace All Hoses
Replace Contact Tips
** In dirty operating environments change coolant filters and separator element more frequently.
* X-Tend Food Grade Filter and lubricant can last beyond 2000 hours between changes ONLY when analysis is done
consistently every 500 hours and following manual directions.
72 R90 - 110N & R90 - 110I

10.0 MAINTENANCE
10.3 MAINTENANCE PROCEDURES
caution
Before beginning any work on the compressor, read and understand the safety instructions earlier on in this
manual. Open, lock and tag the main electrical disconnect and close the isolation valve on the compressor
discharge. Do not under any circumstances open any drain valve or remove components from the compres-
sor until this has been carried out. Ensure that all pressure has been vented from the compressor. Verify this
by slowly unscrewing the coolant fill cap one turn. Unscrewing the fill cap opens a vent hole, drilled in the
cap, allowing pressure to release to atmosphere. Do not remove the fill cap until all pressure has vented from
the unit. Note that pipework downstream of the separator tank may still contain pressure that must also be
vented to atmosphere before beginning any work.
caution
When using any form of liquid for cleaning, ensure that all electrical components are protected or
covered to prevent ingress of liquid.
warning
For VSD this compressor contains a variable frequency drive. When it is switched off and the motor is stopped,
the internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt
any work on the drive unless trained. There are no user serviceable items behind the cover.
danger
For VSD this compressor contains a variable frequency drive. When it is switched off and the motor is stopped,
the internal capacitors store a potentially lethal high voltage electric charge which gradually falls to zero over
time. After switching off the machine at its local isolator WAIT AT LEAST 15 MINUTES for the capacitors to fully
discharge before opening the power drive module doors.
warning
For VSD the compressor can operate in a pressurised shutdown mode. If the compressor stops automatically,
the airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the
which any residual pressure will be vented. Downstream of the separator tank may still contain system pres-
sure which must also be vented.
warning
Use suitable equipment for lifting heavy items and ensure loose components are adequately supported to
eliminate risk of dropping.
warning
For VSD the motor rotor contains a powerful magnetic field. This field can effect the operation of digital
devices such as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by
personnel with cardiac pacemakers, defibrillators or other implanted electronic medical device.
R90 - 110N & R90 - 110I 73

10.0 MAINTENANCE
Compressed air can be dangerous if incorrectly handled. Prior to attempting any maintenance work on a
Before doing any work on the unit, ensure that all running machine, ensure that:-
pressure is vented from the system and that the machine
• the work carried out is limited to only those tasks
cannot be started accidentally.
which require the machine to run.
Ensure that maintenance personnel are adequately • the work carried out with safety protection devices
trained, competent and have read the Maintenance disabled or removed is limited to only those tasks
Manuals. which require the machine to be running with safety
protection devices disabled or removed.
• all hazards present are known (e.g. pressurized
Prior to attempting any maintenance work, ensure
components, electrically live components, removed
that:-
panels, covers and guards, extreme temperatures,
• all air pressure is fully discharged and isolated from the inflow and outflow of air, intermittently moving parts,
system. If the automatic blowdown valve is used for safety valve discharge etc.).
this purpose, then allow enough time for it to complete • appropriate personal protective equipment is worn.
the operation.
• loose clothing, jewelry, long hair etc. is made safe.
• the machine cannot be started accidentally or
• warning signs indicating that Maintenance Work is in
otherwise, by posting warning signs and/or fitting
Progress are posted in a position that can be clearly
appropriate anti-start devices.
seen.
• all residual electrical power sources (mains and battery)
Upon completion of maintenance tasks and prior to
are isolated.
returning the machine into service, ensure that:-
Prior to opening or removing panels or covers to work
inside a machine, ensure that:- • the machine is suitably tested.
• all guards and safety protection devices are refitted.
• anyone entering the machine is aware of the reduced
level of protection and the additional hazards, • all panels are replaced, canopy and doors closed.
including hot surfaces and intermittently moving parts. • hazardous materials are effectively contained and
• the machine cannot be started accidentally or disposed of.
otherwise, by posting warning signs and/or fitting
appropriate anti-start devices.
74 R90 - 110N & R90 - 110I

10.0 MAINTENANCE
10.4 ROUTINE MAINTENANCE
This section refers to the various components which

require periodic maintenance and replacement. danger
For all other maintenance, contact your local Ingersoll Under no circumstance should the compressor be
Rand office, Distributor or Customer Center. operated with the coolant fill plug removed.
Refer to safety information and maintenance procedures Coolant change procedure

prior to carrying out any of the maintenance in the
following sections.
warning
The coolant filter and coolant may be hot!
Prior to starting
Coolant level checking procedure
Draining Coolant
The coolant level should be checked daily. A coolant level
sight glass is located on the side of the separator tank It is better to drain the coolant immediately after the
and while the machine is running on load, coolant should compressor has been operating as the liquid will drain
always be visible in the sight glass. The normal position faster and any contaminant will still be in suspension
is half way. The machine must running for at least 40 • Install a drain hose (not supplied) in end of drain
seconds for this check. valve and place end of hose in a suitable container.
Stop the machine, insure sump pressure is 0 psig and • Open drain valve to start drainage.
ensure coolant is still visible in the sight glass. • After drainage, remove hose and close valve.
Adding coolant • Can also drain coolant from( air cooled only) oil
Run the compressor for a minimum of 40 seconds, the cooler by removing plug.
coolant level should be visible in the sight glass. If not, • Can also drain additional coolant from airend by
stop the compressor, depressurize by isolating the removing plug in airend discharge elbow.
compressor from the system, pressing the emergency
stop to vent the separator tank & airend (FS units can take
more than 2 min to fully de-pressurize once stopped) ,
slowly unscrew the coolant fill plug to verify all pressure
has been released and add coolant. Replace the coolant
fill plug, restart the compressor and recheck the coolant
level. Repeat until the coolant level is visible in the sight
glass with the compressor both running and stopped.
Do not add coolant through the intake of the compressor,
as this can result in overfilling, saturation of the separator
filter element, and coolant carry-over downstream.
R90 - 110N & R90 - 110I 75

10.0 MAINTENANCE
Coolant Sampling Procedure
Bring unit up to operating temperature. Draw sample,
using pump kit, from separator tank port. DO NOT draw
sample from drain port or oil filter. Use a new hose on
pump for each sample, failure to do this can give false
readings.
COOLANT DRAIN
caution
Do not mix coolant types. Use only coolant specified
by Ingersoll Rand
• Start the compressor and check for leaks.
• Check the coolant level, refilling if necessary.
• Dispose of waste coolant in accordance with local
and governmental regulations.
• Standard air compressors are factory filled with
SSR Ultra coolant, it is recommended to perform
a coolant analysis every 2000 hours or 3 months
to monitor condition and determine when to
change the coolant, if analysis is not performed, the
recommended coolant change interval is 8000 hours
or 2 years, whichever comes first.
NOTICE
Shorter coolant change intervals may be necessary
if the compressor is operated in adverse conditions.
Food Grade Coolant option
• SSR Food Grade Coolant is a polyalphaolefin base
coolant. It is recommended to have samples of the
coolant analysed every 500 hours or each month to
determine when coolant should be changed.
• If analysis is not performed, coolant should be
changed after 2000 hours or every 6 months when
utilizing the X-Tend food grade filter supplied with
the machine.
• For units running food grade coolant without the X-
Tend food grade filter, the change interval should be
1000 hours or 6 months, whichever comes first.
76 R90 - 110N & R90 - 110I

10.0 MAINTENANCE
Coolant filter change procedure
warning
• Loosen filter element with the correct tool.
Unscrew the jacking bolt sufficiently to ensure that
• Remove the element from the housing. the cover can be fully tightened down without im-
• Place the old element in a sealed bag and dispose of parting any stress onto the jacking points. Tighten
in a safe way. down the cover bolts.
• Clean the mating face of the housing. • Tank cover bolt (M16 size) torque values 200 N-m
• Remove the new Ingersoll Rand replacement (150 ft-lb) Inspect tank scavenge screen and orifice.
element from its protective package. Clean if necessary following instructions below.
• Apply a small amount of coolant to the element seal. • Install scavenge tube down into the tank until the
• Screw the new element down until the seal makes tube just touches the separator element and then
contact with the housing, then hand tighten a raise it 1/8inch (3 mm). Tighten fittings.
further half turn. • Install the regulation lines in their original position.
• Start the compressor and check for leaks and check • Start unit, check for leaks, place in service.
the coolant level. RECOMMENDED BOLT TIGHTENING
Separator element checking procedure CROSS PATTERN
With the compressor running on load, check the

separator differential pressure via the Intellisys controller.
It will be necessary to change the element if the
differential pressure equals zero or exceeds 1 bar
(15 psig).
Separator element change procedure
• Remove the fitting that holds the scavenge tube
into the tank and withdraw the tube assembly
• Disconnect the piping from the tank cover. Tag the • Start the compressor and check for leaks and
lines if required. Remove all the capscrews securing coolant level.
the cover to the tank except the screw opposite
the pivot bolt which should be left engaged by 2-3 caution
threads with at least 6.5mm (0.25”) clearance from Do not use any form of sealant on either the separa-
the screw head to the lid. Rotate the jacking bolt tor tank or the separator tank cover faces.
clockwise until the cover lifts off the tank at least
2mm (0.08”) all the way around the tank. The cover Separator tank / Pressure system
can now be rotated to allow access to inside the At 2000 hour intervals, inspect the external surfaces of
tank. the airend and separator tank, including all fittings, for
• Carefully lift the separator element up and out of the visible signs of impact damage, excessive corrosion and
tank. Discard the faulty element. abrasions. When changing the separator element inspect
• Clean the sealing surface on both the tank and its the internal components and surfaces. Any suspect parts
cover. Check the tank to be absolutely certain that should be replaced before the compressor is put back
no foreign objects such as rags or tools have been into service.
allowed to fall into the tank. Install replacement The separator tank should also be tested and inspected
element down into the tank after checking the new in accordance with any national or local codes that may
element seal/gasket for possible damage. Center the exist.
element up within the tank. Rotate the tank cover
back into position taking care not to damage the
seal/gasket , and locate the cover using 2 capscrews
but do not tighten down.
• Completely remove the pivot bolt and tighten
the cover bolts in a cross-pattern to prevent over-
tightening one side of the cover. An improperly
tightened cover will likely result in a leak.
R90 - 110N & R90 - 110I 77

10.0 MAINTENANCE
Scavenge screen clean/check procedure The pressure relief valve should be tested and re-
calibrated in accordance with any national or local
The screen/orifice assemblies are similar in appearance to
codes that may exist. If no code exists, Ingersoll Rand
a straight tubing connector and will be located between
recommend that the pressure relief valve is recalibrated at
two pieces of 1/4 inch O.D. scavenge line tubing.
intervals of one year by a licensed contractor or qualified
The main body is made from 17mm hexagon shaped service personal.
brass and the diameter of the orifice and a direction-of-
Air filter change procedure
flow arrow is stamped in flat areas of the hexagon.
• Unclip the retaining cap and withdraw the old
A removable screen and orifice (see figure) will require
element.
clearing as outlined in the Maintenance Schedule
Section 10.2. • Fit the new element and refit the retaining cap.
Blower Motor Re-Grease
To remove the screen/orifice, disconnect the scavenge
line tubing from each end. Hold the center section firmly The blower motor contains pre-greased, sealed bearings.
and use a pair of pliers to gently grasp the exit end of They cannot be re-greased and do not need it over its
the assembly that seals against the scavenge line tubing. normal life time.
Pull the end out of the center section while using care to
Air-cooled Cooler Cleaning
prevent damage to the screen or sealing surfaces.
Air compressor operating temperatures will be higher
Clean and inspect all parts prior to reinstallation.
than normal if the external passages between the fins of
When the assembly is installed, confirm the direction of the cooler cores become restricted with foreign material.
flow to be correct. Observe the small arrow stamped in Regular cleaning of the cooler surfaces will support the
the center section and ensure the direction flow to be reliable operation of your air compressor system and
from the separator tank to the airend. improve the life of your compressor oil. When performed
frequently as determined by your site conditions and
Coolant hoses
airborne contamination, more significant cleaning or heat
• The flexible hoses that carry coolant through the exchanger replacement may not be necessary.
cooling system may become brittle with age and
1. Ensure that the compressor is isolated from the
will require replacement. Replace them as needed or
compressed air system and is vented of all pressure.
every 4 years.
• Depending on the location of the hose, it may 2. Ensure that the main power disconnect switch is
contain compressor coolant. It is recommended to locked off and tagged.
drain the coolant into a clean container. Cover the 3. For any required lifting of air compressor parts or
container to prevent contamination. If the coolant required tools, always use the proper certified lifting
is contaminated, a new charge of coolant must be equipment, and employ sound working principles.
used.
4. Visually check the outside of the cooler cores to
• Remove the hose.
determine the appropriate cleaning method detailed
• Install the new hose and refill the unit with coolant. as follows.
Start the compressor, check for leaks and check
coolant level. Refill as necessary 4.1. Light cleaning – For loose dirt, dust and other
Pressure relief valve check light foreign material, open the access panels on
the sides of the cooler plenum and gently blow
The pressure relief valve must be frequently tested and
compressed air across the oil cooler surface. Use a
regularly maintained. Remove from the machine for
vacuum hose with a soft brush to clean the exposed
testing. If operating conditions are particularly severe, the
face of the air after cooler. Repeat the process until
frequency of testing and maintenance must be increased
the coolers are sufficiently clean. Replace the access
accordingly. A pressure relief valve check must also be
panels before returning the machine to service.
performed at the end of any non-service period. The
user must establish the frequency of such tests as it is
4.2. Heavy cleaning – For thick, packed dirt, oil or
influenced by such factors as the severity of the operating
grease, or other heavy material, the coolers will
environment.
need to be removed from the machine for pressure
washing. Ingersoll Rand does NOT support
pressure washing coolers when they are installed in
machinery due to the dangers of spraying water in or
around potential electrical power sources. Follow the
steps below for cooler removal.
78 R90 - 110N & R90 - 110I

10.0 MAINTENANCE
Air-cooled Cooler Removal important the first nut is not too tight so it can allow
the cooler to expand and contract without stressing
1. Ensure that the compressor is isolated from the
the cooler’s brazed joints.
compressed air system and is vented of all pressure.
6. Ensure the rubber seal on the air aftercooler is in
2. Ensure that the main power disconnect switch is
place on the cooler and in good condition.
locked off and tagged.
7. Carefully place the air aftercooler cooler in its proper
3. For any required lifting of air compressor parts or
location and install the (2) sets of lower fasteners,
required tools, always use the proper certified lifting
tightly.
equipment, and employ sound working principles.
8. Install the (2) sets of upper side fasteners, finger tight
4. Drain the oil from the oil cooler by removing the M22
+ ¼ turn. Next add the second nut to each tightly.
hex plug located at the front of the air compressor,
This second nut is used to lock the first in place. It is
and lower side of the oil cooler.
important the first nut is not too tight so it can allow
5. Remove all hoses, pipes, and sensors from the the cooler to expand and contract without stressing
coolers. the cooler’s brazed joints.
6. Remove the access panels on the sides of the cooler 9. Re-attach all hoses, pipes and sensors, and properly
plenum torque according to the table shown…
7. Properly secure the air aftercooler and remove the 10.Replace the access panels on the sides of the cooler
(4) nuts from the (2) bolts at the upper sides of the plenum.
cooler.
11. Refill the machine with oil to the proper level.
8. Remove the (2) nuts from the bolts at the bottom of
Water-cooled Cooler Cleaning (for both Clean & Harsh
the cooler.
Water Options)
9. Carefully remove the air aftercooler.
A periodic inspection and maintenance program should
10. Properly secure the oil cooler and remove the (4) be implemented for water cooled heat exchangers. It
nuts from the (2) bolts at the upper sides of the is recommended that you contact Ingersoll Rand for
cooler. cleaning services should you not have experience and
equipment to do this work.
11. Remove the (2) nuts from the bolts at the bottom of
Pre-Inspection:
the cooler.
• If water inlet lines have strainers, inspect them and
12. Carefully remove the oil cooler.
replace or clean as required.
13. Re-install the M22 oil drain plug to 65 N-m (48 Ft- Cleaning:
Lbs).
• Mineral scale may be removed with a suitable de-
warning scaling agent containing amidosulphuric acid + citric
acid and Neutralit solutions for cleaning the coolers.
Strong cleaners can harm aluminum coolers and
As an alternative, any weak acid mixed with water in
associated parts. Use the appropriate cleaners for
the ratio of 1:4 may be used.
aluminum, and follow the manufacturer’s instructions
closely. Always wear the appropriate safety equipment. • Fouling should be removed with a suitable detergent
in hot water.
Air-cooled Cooler Installation
• Back flush the cooler with a flow rate at least 1.5
1. Ensure that the compressor is isolated from the times the normal flow rate.
compressed air system and is vented of all pressure. • After using any cleaning solution, thoroughly flush
2. Ensure that the main power disconnect switch is out all chemicals with clean water before returning
locked off and tagged. the cooler to service.
• Mechanical cleaning methods are not recommended
3. For any required lifting of air compressor parts or
as damage to the internal passages may occur.
required tools, always use the proper certified lifting
equipment, and employ sound working principles. Post-Cleaning Inspection:
4. Carefully place the oil cooler in its proper location • Examine the cooler for erosion or corrosion.
and install the (2) sets of lower fasteners, tightly. Airend bearings
5. Install the (2) sets of upper side fasteners, finger tight Airend bearings are lubricated by the compressor coolant
+ ¼ turn. Next add the second nut to each tightly. and require no maintenance.
This second nut is used to lock the first in place. It is
R90 - 110N & R90 - 110I 79

10.0 MAINTENANCE
High Airend Temperature Sensor checking procedure To Install Pre-Filter element:-
It is recommended that the discharge temperature sensor • Center element over package intake opening
(2ATT) is checked regularly as follows: • Push filter over grill studs so that studs poke through
Aircooled machines the filter media
Stop the cooling blower by opening the blower / fan mo- • Install filter grill
tor circuit breaker. • Install Six (6) wing nuts
Watercooled machines • Close intake panel and latch
Shut off the cooling water. No Loss Drain Trap (where fitted) Check / Cleaning
The machine should trip at 109° C (228° F). • It is recommended to check the no loss drain trap
daily to insure that condensate is draining from
caution the moisture seperator system. To check for correct
Under no circumstances should these discharge function, press the test button on the unit and listen
temperatures be exceeded. If the machine fails to for condensate / air passing through the drain. If
trip A FAULT EXISTS. Investigate immediately. the drain is clogged, replace the no loss drain valve
Motor cowl cleaning service module. The service module consists of the
lower portion of the drain trap and is not servicable.
• Ensure compressor is electrically isolated for at least
• Additionally, it is recommended to replace the
15 minutes before commencing any maintenance
service module every 8000 hours or once per year,
work.
whichever comes first.
• Remove panels from the compressor.
Fluid and Vibration Monitoring
• Using a clean dry cloth, remove dust from the
surface of the motor cowl and ensure all ventilation Ingersoll Rand recommends incorporating predictive
slots are free of obstructions. maintenance, specifically the use of coolant and vibration
analysis, into all Preventative Maintenance programs.
• Replace panels to the compressor.
Predictive Maintenance is designed to increase system
Drive Box Filter Removal / Replacement (For VSD only) reliability and prevent costly downtime. Through the
• Ensure compressor is electrically isolated for at least use of sophisticated diagnostic tools, including fluid,
15 minutes before commencing any maintenance vibration, and optional air analysis, Ingersoll Rand
work. Certified Service Technicians can identify and correct
potential problems BEFORE they can cause expensive
• Unclip the front grill of the drive box filter.
unscheduled downtime.
• Remove the filter pad from the housing and replace
with a new filter pad from Ingersoll Rand. How does predictive analysis work? By establishing an
initial baseline for normal operation, and then regularly
• Replace front grill to the drive box filter.
monitoring fluid and vibration conditions, any sudden
Moisture Separator Check / Cleaning deviation or significant increase from this baseline can
• Ensure compressor is electrically isolated for at least be identified and investigated to pinpoint the cause.
15 minutes, before commencing any maintenance More quickly diagnosing potential problems can directly
work. save money by preventing costly failures and reducing
• Isolate the compressor from the system and fully or eliminating downtime. In addition, regular condition
discharge the compressed air within the unit. monitoring also helps to maximize the time between
expensive preventative maintenance intervals, such as
• Remove tube from the fitting located on the bottom component rebuilds and coolant changes.
of the moisture separator.
• Remove the bowl of the moisture trap, clean and
replace.
Package Pre-Filter (is washable with mild detergent)
To remove Pre-Filter element:-
• Unlatch the two 1/4 turn latches and open intake
panel (panel is hinged)
• Remove the Six (6) wing nuts
• Remove filter grill
• Pull out filter element
80 R90 - 110N & R90 - 110I

10.0 MAINTENANCE
10.5 STARTER BOX PANEL FILTER (VSD ONLY)
1
PULL
R90 - 110N & R90 - 110I 81

11.0 FAULT FINDING (VSD)
11.1 GENERAL FAULTS
warning
When attempting to identify and remedy any fault or failure, ensure it is only attempted by qualified person-
nel and that the safety and maintenance sections of this manual have been read and are fully understood and
followed. Major overhauls should only be carried out by a qualified Ingersoll Rand representative. Failures
caused by fitting parts not recommended by Ingersoll Rand or non-authorized Ingersoll Rand personnel may
not be covered by the terms of any warranty agreement
SYMPTOM FAULT REMEDY

Compressor will not start No power supply to package Check supply is switched on. If so, contact a
qualified electrician.
Intellisys controller failure Check supply to unit. Replace unit.
Starter failure Isolate supply, lock off and tag. Replace
failed component or contact your local
Ingersoll Rand representative
Compressor stops and Drive controller has tripped See section 11.2 & 11.3
will not restart Intellisys controller has tripped the See section 11.2 & 11.3
compressor
Maximum number of starts per hour
exceeded
Compressor is stopped Intellisys controller has tripped the See section 11.2 & 11.3
and will not restart compressor and has not been reset
Emergency stop has been pressed and Identify reason why, repair fault, disengage
not released button and reset Intellisys controller
Emergency stop has been pressed and Repair fault and reset Intellisys controller
released but Intellisys controller has not
been reset
82 R90 - 110N & R90 - 110I

Http://www.ingersollrandproducts.com
11.0 FAULT FINDING
Compressor will not meet Compressor not sized to Contact your local Ingersoll Rand
pressure required by system meet system requirements or representative
requirements have been changed.
Air loss due to pipe, hose, joint or Overhaul or replace
seal failure
Air loss due to blowdown valve stuck Overhaul or replace
open
Air loss through pressure relief valve Overhaul or replace
not seating or set incorrectly
Air loss due to moisture separator Overhaul or replace
drain trap stuck open
Motor speed too low caused by drive Contact your local Ingersoll Rand
incorrectly set representative
Motor speed too low caused by fault See section on drive faults
in drive settings
Intellysis controller fault Overhaul or replace
Drive motor fault See section on drive faults
Pressure transducer faulty, Recalibrate or replace
incorrectly calibrated or EMF
interference
Incorrect Intellisys controller settings Check and modify settings
Inlet grill or ducting is blocked Check and clean
Air filter dirty or collapsed Replace
Inlet valve not opening fully Overhaul or replace
Separator element dirty or collapsed Replace
Pipe / Hoses blocked or collapsed Clean or replace
Cooler core blocked Clean or replace
Minimum pressure check valve not Overhaul or replace
functioning correctly
Equipment between compressor Review system requirements
and customer measuring point
causing pressure drop / pressure loss
R90 - 110N & R90 - 110I 83

11.0 FAULT FINDING
Pressure produced by Intellisys set incorrectly Check and modify settings
compressor is too high Pressure transducer may be Recalibrate or replace
compressor is too high due to faulty, incorrectly calibrated or
speed not reducing as demand not receiving pressure signal
reduces
Drive settings fault Contact your local Ingersoll Rand
representative
Compressor discharge air too High ambient temperature Review installation and system parameters
hot Insufficient cooling air Check ducting and cooling air path, check
direction of blower rotation
Dirty, blocked aftercooler Clean or replace
(cooling air side)
Compressor package produces Panels or doors are not closed Rectify fault
excessive noise properly
Air leaks from internal pipework / Overhaul or replace
components
Blower or blower motor bearings Overhaul or replace
worn
Loose debris impacting on Remove and rectify any damage
blower during rotation
Blowdown valve stuck open Overhaul or replace
Pressure relief valve not seating Overhaul or replace
correctly
Vibration due to motor, airend or Overhaul or replace
blower imbalance
Airend requires overhaul Contact your local Ingersoll Rand
representative
Discharge air is contaminated Scavenge pipe is blocked, broken Clean or replace
with coolant or o-ring is not sealing
Separator element is punctured, Replace
or incorrect, or requires changing,
or not sealing correctly
Incorrect coolant has been added Drain system, check for damage. Clean, refill
with correct coolant.
System has been overfilled with Check for damage, drain excess.
coolant
84 R90 - 110N & R90 - 110I

11.0 FAULT FINDING

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

Emergency Stop Emergency stop button has Identify reason why, repair fault, disengage button
been pressed. and reset Intellisys controller
Blower motor overload Blower is blocked, damaged or Remove blockage, repair or replace damaged
blower motor is faulty. components
High airend discharge Compressor operating above Check and modify settings. Review system
temperature rated pressure requirements and contact your local Ingersoll Rand
representative
Low coolant level Check for leaks. See also ‘discharge air is
contaminated with coolant’. Top up coolant.
High ambient temperature Review installation and system parameters
Insufficient cooling air Check ducting and cooling air path.
Dirty, blocked coolant cooler Clean or replace
(cooling air side)
Blower motor direction of Wire correctly
rotation incorrect
Check setpoints Controller software has been Recalibrate all sensors and check setpoints
changed
R90 - 110N & R90 - 110I 85

11.0 FAULT FINDING
FAULT CAUSE REMEDY

Remote start failure Remote start button is pressed Check operation of buttons or operating
after machine is running or procedures
remote start button remains
closed.
Remote stop failure Remote stop button remains Check operation of buttons or operating
open and either start button is procedures
pressed
Sensor failure Sensor is missing or faulty Install, repair or replace faulty sensor
Compressor trips indicating a Insufficient cooling taking place If machine is watercooled or sea watercooled,
high compressor temperature. check that the cooling water is flowing. Check
that there is no air in the water cooling system.
Check that the strainer is not blocked.
Intellisys controller has A fault has occurred Repair fault / reset Intellisys controller
tripped the compressor
Invalid Calibration Calibration done with pressure Depressurise and re calibrate with pressure pipe
in compressor. to sensor disconnected. If fault still exists, replace
pressure transducer.
Low sump pressure System leak Located and repair
Minimum pressure check valve Repair with service kit
faulty
Blowdown valve faulty Repair with service kit
Loss of control power Check 110V circuit breaker
Check wiring
Check contactor KM1
Check motor rotation Drive system fault Contact your local Ingersoll Rand representative
VSD communication failure Communication wiring faulty Check and replace if required
Drive faulty Contact your local Ingersoll Rand representative
Intellisys faulty Contact your local Ingersoll Rand representative
VSD initialisation fault Communication wiring faulty Check and replace if required
Drive faulty Contact your local Ingersoll Rand representative
Intellisys faulty Contact your local Ingersoll Rand representative
86 R90 - 110N & R90 - 110I

11.0 FAULT FINDING
11.3 DRIVE FAULTS (INDICATED ON THE INTELLISYS CONTROLLER)
The drive controller is directly linked to the Intellisys controller. Faults in the drive controller will be displayed on the
Intellisys controller as ‘VSD fault 0, VSD fault 1’ etc.
The following VSD faults may be investigated and remedied at source. For all other VSD faults, contact your local
Ingersoll Rand customer support representative.
FAULT CAUSE ACTION

VSD Fault 1 Over-current Check separator element.
Check cooler, pipework and moisture separator for
blockages.
Check operation of minimum pressure check valve.
VSD Fault 3 Drive temperature too high Check drive filter, replace if necessary
Check drive cooling fan circuit breaker
Check wiring
R90 - 110N & R90 - 110I 87


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PRINT LANGUAGE

ENGLISH R90 - 110N

DANISH OPERATION AND MAINTENANCE MANUAL

Ensure that the operator reads and understands the

1.0 CONTENTS 1 9.0 OPERATING INSTRUCTIONS 47

R90 - 110N & R90 - 110I 

R90 - 110N & R90 - 110I

(For VSD only)

R90 - 110N & R90 - 110I

bg Bulgarian lv Latvian, Lettish

R90 - 110N & R90 - 110I

ROTARY SCREW AIR COMPRESSOR

R90 - 110N & R90 - 110I

5.2 SAFETY PRECAUTIONS

 R90 - 110N & R90 - 110I

R90 - 110N & R90 - 110I

 R90 - 110N & R90 - 110I

5.3 TEXT DECALS

WARNING / AVERTISSEMENT / ADVERTENCIA / AVISO

Machine restarts automatically after power failure.

Bezzle Decal (PORO)

Rotating fan blade. Can cause severe injury.

Aube de ventilateur en rotation. Peut causer des blessures graves.

R90 - 110N & R90 - 110I

High pressure air. Can cause severe injury or death.

Coolant Cap Ultra 93166478

10 R90 - 110N & R90 - 110I

R90 - 110N & R90 - 110I

WARNING / AVERTISSEMENT / ADVERTENCIA / AVISO

Machine restarts automatically after power failure.

Bezzle Decal (Standard) Bezzle Decal (PORO)

Remove shipping brace High Voltage

12 R90 - 110N & R90 - 110I

Compressed Air Don't breath Customer Power

Motor rotation IR Logo

R90 - 110N & R90 - 110I

THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL

Ingersoll Rand Company

6.2 UNPACKING AND HANDLING

6.3 LONG TERM STORAGE

14 R90 - 110N & R90 - 110I

Key Hard surfaces may reflect noise with an apparent

8. Wet Tank The compressor can be installed on any level floor

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

R90 - 110N & R90 - 110I

R90 - 110N & R90 - 110I

R90 - 110N & R90 - 110I

Example of voltage imbalance calculation (VSD)

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

R90 - 110N & R90 - 110I

R90 - 110N & R90 - 110I

ACCEPTABLE MAXIMUM LIMITS

R90 - 110N & R90 - 110I

R90 - 110N & R90 - 110I

22 R90 - 110N & R90 - 110I

322 615 220 530 D

R90 - 110N & R90 - 110I

RIGHT END 6 REAR VIEW 4X 203

R90 - 110N & R90 - 110I

LEFT END 1860 1213 93

R90 - 110N & R90 - 110I

322 615 2744

26 R90 - 110N & R90 - 110I

R90 - 110N & R90 - 110I

R90 - 110N & R90 - 110I

R90 - 110N & R90 - 110I