Ingersoll Rand Air Compressor IRN100 200H 2S User Manual
IRN37−160K−CC  
IRN50−200H−CC  
IRN75−160K−2S  
IRN100−200H−2S  
IRN250−300H−2S  
OPERATION AND MAINTENANCE MANUAL  
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.  
TM  
C.C.N. : 54731245  
DATE : DECEMBER 2007  
REV. : J  
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1.0 CONTENTS  
CONTENTS  
PAGE  
CONTENTS  
PAGE  
1.0 CONTENTS  
1
2
4
5
6
6
6
9
9.6 OPERATOR SETPOINTS  
9.7 OPTIONS  
71  
73  
74  
75  
75  
76  
77  
77  
77  
78  
79  
79  
80  
81  
83  
91  
2.0 FOREWORD  
3.0 ABBREVIATIONS & SYMBOLS  
4.0 PURCHASE ORDER DETAILS  
5.0 SAFETY  
9.8 SENSOR CALIBRATION  
9.9 ALARM HISTORY  
9.10 CLOCK FUNCTIONS  
9.11 ENERGY STATUS MESSAGES  
9.12 WARNINGS  
5.1 SAFETY INSTRUCTIONS  
5.2 SAFETY PRECAUTIONS  
5.3 TEXT DECALS  
9.13 SERVICE WARNINGS  
9.14 INITIAL CHECK ALARMS:  
9.15 ALARMS  
5.4 GRAPHIC FORM AND MEANING OF ISO  
SYMBOLS  
13  
6.0 RECEIPT / HANDLING  
6.1 RECEIPT  
18  
18  
18  
19  
19  
10.0 MAINTENANCE  
10.1 MAINTENANCE PROMPTS  
10.2 MAINTENANCE CHART  
10.3 MAINTENANCE PROCEDURES  
10.4 ROUTINE MAINTENANCE  
11.0 FAULT FINDING  
6.2 UNPACKING AND HANDLING  
7.0 INSTALLATION  
7.1 LOCATION IN PLANT  
7.2 DISCHARGE AND CONDENSATE PIPING  
20  
7.3 ELECTRICAL  
21  
23  
7.4 WATERCOOLED UNITS  
7.5 SEA WATERCOOLED UNITS (SELECTED  
UNITS ONLY)  
25  
7.6 OUTDOOR SHELTERED INSTALLATION26  
8.0 GENERAL INFORMATION  
8.1 TECHNICAL INFORMATION  
8.2 INSTALLATION DRAWING  
27  
27  
33  
8.3 PROCESS AND INSTRUMENTATION  
DIAGRAM  
42  
50  
64  
65  
65  
67  
68  
69  
70  
8.4 ELECTRICAL SCHEMATIC  
8.5 GENERAL DESCRIPTION  
9.0 OPERATING INSTRUCTIONS  
9.1 BASIC OPERATION  
9.2 INTELLISYS CONTROLS  
9.3 DISPLAY SCREEN  
9.4 CURRENT STATUS SCREEN  
9.5 MAIN MENU  
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2.0 FOREWORD  
Machine models represented in this manual may be  
Details of approved equipment are available from Ingersoll  
Rand Service departments.  
used in various locations worldwide. Machines sold and  
shipped into European community countries requiresthat  
the machine display the EC Mark and conform tovarious  
directives. In such cases, the design specification of  
this machine has been certified ascomplying with EC  
directives. Any modification to any part is absolutely  
prohibited and would result in the CEcertification and  
marking being rendered invalid.  
This machine has been designed and supplied for  
use only in the following specified conditions and  
applications:  
•
Compression of normal ambient air containing no  
known or detectable additional gases, vapors or  
particles  
•
Operation within the ambient temperature range  
specified in the GENERAL INFORMATION section of  
this manual.  
The contents of this manual are considered to be  
proprietary and confidential to Ingersoll Rand and should  
not be reproduced without the prior written permission  
of Ingersoll Rand.  
IF IN DOUBT CONSULT SUPERVISION.  
Nothing contained in this document is  
The company accepts no responsibility for errors in  
translation of this manual from the original English  
version.  
intended to extend any promise, warranty or  
representation,expressed or implied, regarding the  
Ingersoll Rand products described herein. Any such  
warranties or other terms and conditions of sale of  
products shall be in accordance with the standard terms  
and conditions of sale for such products, which are  
available upon request.  
The design of this Compressor package and certain  
features within it are covered by patents held by  
Ingersoll Rand and patents pending  
SSR ULTRA COOLANT is a registered trademark of  
Ingersoll Rand Company USA.  
This manual contains instructions and technical  
data to cover all routine operation and scheduled  
maintenance tasks by operation and maintenance staff.  
Majoroverhauls are outside the scope of this manual  
and should be referred to an authorized  
INTELLISYS is a registered trademark of Ingersoll Rand  
Company USA.  
HPM™, HYBRID PERMANENT MAGNET™ and HPM  
Logo are trade marks registered by MOTEURS LE-ROY-  
SOMER  
Ingersoll Rand service department.  
All components, accessories, pipes and connectors added  
to the compressed air system should be:  
© COPYRIGHT 2007  
INGERSOLL RAND COMPANY  
•
of good quality, procured from a reputable manufac-  
turer and, wherever possible, be of a type approved  
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.  
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2.0 FOREWORD  
WARNING  
The use of the machine in any of the situation types listed in table 1:−  
a) Is not approved by Ingersoll Rand,  
b) May impair the safety of users and other persons, and  
c) May prejudice any claims made against Ingersoll Rand.  
TABLE 1  
WARNING − NOT PERMITTED  
Use of the machine to produce compressed air for:  
a) direct human consumption  
b) indirect human consumption.  
Use of the machine outside the ambient temperature range specified in the GENERAL INFORMATION SECTION  
of this manual.  
Use of the machine where there is any actual or foreseeable risk of hazardous levels of flammable gases or  
vapors.  
THIS MACHINE IS NOT INTENDED AND MUST NOT BE USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,  
INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR VAPOURS MAY BE PRESENT.  
Use of the machine fitted with non Ingersoll Rand approved components.  
Use of the machine with safety or control components missing or disabled.  
Connection to an electrical supply of incorrect voltage and/or frequency.  
WARNING  
The use of repair parts other than those included within the Ingersoll Rand approved parts list may create  
hazardous conditions over which Ingersoll Rand has no control. Therefore Ingersoll Rand cannot be held  
responsible for equipment in which non−approved repair parts are installed.  
WARNING  
The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such  
as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with  
cardiac pacemakers, defibrillators or other implanted electronic medical device.  
WARNING  
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the  
internal capacitors store a potentialy lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any  
work on the drive unless trained. There are no user serviceable items behind the cover.  
WARNING  
The compressor can operate in a pressurised shutdown mode. If the compressor stops automatically, the  
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the  
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through  
which any residual pressure will be vented. Downstream of the separator tank may still contain system  
pressure which must also be vented.  
NOTICE  
The manual is intended for worldwide use and contains both metric and imperial data where required.  
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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  
High ambient machine  
Watercooled machine  
Aircooled machine  
Energy recovery system  
Totally enclosed fan cooled motor (IP54)  
Open drip proof (motor)  
parts per million  
HA  
WC  
AC  
ERS  
T.E.F.C.  
O.D.P.  
ppm  
cs  
da  
de  
el  
Czech  
Danish  
German  
Greek  
en  
es  
et  
fi
English  
Spanish  
Estonian  
Finnish  
fr  
French  
hu  
it  
Hungarian  
Italian  
lt  
Lithuanian  
Latvian, Lettish  
Maltese  
Dutch  
lv  
mt  
nl  
no  
pl  
pt  
sk  
sl  
Norwegian  
Polish  
Portuguese  
Slovak  
Slovenian  
Swedish  
Chinese  
sv  
zh  
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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: _______________________________________________  
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5.0 SAFETY  
5.1 SAFETY INSTRUCTIONS  
Safety instructions in the operators manual are bold−faced for  
emphasis. The signal words DANGER, WARNING and CAUTION are  
used to indicate hazard seriousness levels as follows.  
Ensure that the Operation and Maintenance manual, and  
the manual holder, are not permanently removed from  
the machine.  
Ensure that the operator reads and understands the  
decals and consults the manuals before maintenance or  
operation.  
Ensure that maintenance personnel are adequately  
trained, competent and have read the Maintenance  
Manuals.  
DANGER  
Indicates the presence of a hazard which WILL  
cause serious injury, death or property damage, if  
ignored.  
CAUTION  
Indicates the presence of a hazard which WILL or  
can cause injury or property damage, if ignored.  
WARNING  
NOTICE  
Indicates the presence of a hazard which CAN  
cause serious injury, death or property damage, if  
ignored.  
Indicates important set–up, operating or  
maintenance information.  
5.2 SAFETY PRECAUTIONS  
General Information  
Compressed air and electricity can be dangerous. Before  
If more than one compressor is connected to one  
undertaking any work on the compressor, ensure that the common downstream plant, effective check valves and  
electrical supply has been isolated, locked off, tagged and isolation valves must be fitted and controlled by work  
the compressor has been relieved of all pressure.  
procedures, so that one machine cannot accidentally be  
pressurized / over pressurized by another.  
Make sure that all protective covers are in place and that  
the canopy/doors are closed during operation.  
If a safety valve is installed between the isolation valve  
and the compressor, it must have sufficient capacity to  
relieve the full capacity of the compressor(s).  
Installation of this compressor must be in accordance with  
recognized electrical codes and any local Health and Safety  
Codes.  
The discharged air contains a very small percentage of  
compressor lubricating oil and care should be taken to  
ensure that downstream equipment is compatible.  
Use only safety solvent for cleaning the compressor and  
auxiliary equipment.  
If the discharged air is to be ultimately released into a  
confined space, adequate ventilation must be provided.  
Compressed air  
Ensure that the machine is operating at the rated pressure  
and that the rated pressure is known to all relevant  
personnel.  
The use of plastic bowls on line filters without metal  
guards can be hazardous. Their safety can be affected  
by either synthetic lubricants, or the additives used in  
mineral oils. Metal bowls should be used on a pressurized  
system.  
All air pressure equipment installed in or connected to  
the machine must have safe working pressure ratings of  
at least the machine rated pressure.  
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5.0 SAFETY  
When using compressed air always use appropriate  
personal protective equipment.  
The above information contains data supplied in support  
of United Kingdom Control of Substances Hazardous to  
Health (C.O.S.H.H.) regulations  
All pressure containing parts, especially flexible hoses  
and their couplings, must be regularly inspected, be free  
from defects and be replaced according to the Manual  
instructions.  
Transport  
When loading or transporting machines ensure that the  
specified lifting and tie down points are used.  
Compressed air can be dangerous if incorrectlyhandled.  
Before doing any work on the unit, ensure that all  
pressure is vented from the system and that the machine  
cannot be started accidentally.  
It is recommended that the machine be moved using the  
fork lift slots in the machine base.  
Refer to section 8-General Information for reference  
information.  
Avoid bodily contact with compressed air.  
Electrical  
The safety valve located in the separator tank must be  
checked periodically for correct operation.  
The compressor has high and dangerous voltage in the  
motor starter and control box. All installations must be  
in accordance with recognized electrical codes. Before  
working on the electrical system, be sure to remove  
voltage from the system by using a manual disconnect  
switch. A circuit breaker or fuse safety switch must be  
provided in the electrical supply line leading to the  
compressor.  
Whenever pressure is released through the pressure relief  
valve, it is due to excessive pressure in the system. The  
cause for the excessive pressure should be investigated  
immediately.  
Materials  
The following substances are used in the manufacture  
of this machine and may be hazardous to health if used  
incorrectly:  
Those responsible for installation of this equipment  
must provide suitable grounds, maintenance clearance  
and lightning arrestors for all electrical components in  
accordance with National and Local code 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  
of the compressor electrical system. Maintain dry footing,  
stand on insulating surfaces and do not contact any other  
portion of the compressor when making adjustments or  
repairs to exposed live parts of the compressor electrical  
system.  
compressor coolant  
WARNING  
AVOID INGESTION, SKIN CONTACT AND  
INHALATION OF FUMES  
For further information, request and consult the coolant  
Material Data Sheet (UK ACGP 011/96 −ULTRA COOLANT  
ACGP 029/90−food grade coolant. For USA served areas,  
use MSDS sheet APDD 236) from your local IR office,  
Distributor or Air Center.  
Close and lock all access doors when the compressor is  
left unattended.  
Do not use extinguishers intended for Class A or Class B  
fires on electrical fires. Use only extinguishers suitable for  
class BC or class ABC fires.  
Should compressor lubricant come into contact with the  
eyes, then irrigate with water for at least 5 minutes.  
Attempt repairs only in clean, dry, well lighted and  
ventilated areas.  
Should compressor lubricant come into contact with the  
skin, then wash off immediately.  
Connect the compressor only to electrical systems that  
are compatible with its electrical characteristics and that  
are within it’s rated capacity.  
Consult a physician if large amounts of compressor  
lubricant are ingested.  
Consult a physician if compressor lubricant is inhaled.  
Never give fluids or induce vomiting if the patient is  
unconscious or having convulsions.  
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5.0 SAFETY  
Condensate disposal  
Coolant disposal  
Condensate cannot be discharged into fresh/surface  
water drains. In some regions compressor condensate  
containing ULTRA COOLANT can be fed directly into a  
drainage system that has downstream sewage treatment.  
Steps to be taken in the case of spillage: Soak up with a  
suitable absorbent material, then sweep into a plastic bag  
for disposal.  
Burn in an approved incinerator, or according to local area  
or country regulations.  
As waste water regulations vary by country and region it  
is the responsibility of the user to establish the limitations  
and regulations in their particular area. Ingersoll Rand  
and its associated distributors are happy to advise and  
assist in these matters.  
For further information, consult ULTRA COOLANT Material  
Data Sheets ACGP 011/96 or APDD 236. FOOD GRADE  
COOLANT Material Data Sheets IRACA145 or APDD190.  
WARNING  
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the  
internal capacitors store a potentially lethal high voltage. DO NOT REMOVE THE DRIVE COVER or attempt any  
work on the drive unless trained. There are no user serviceable items behind the cover.  
WARNING  
There is a high discharge air temperature shutdown function built into each compressor. lt is factory preset  
at 109 °C (228° F).This function should be checked at regular intervals for proper operation, once a month is  
recommended. Refer to maintenance section.  
Failure to adhere to these recommendations can result in mechanical failure, property damage and serious  
injury or death.  
•
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.  
WARNING  
“Ingersoll Rand air compressors are not designed, intended, or approved for breathing air applications.  
Ingersoll Rand does not approve specialized equipment for breathing air application and assumes no  
responsibility or liability for compressors used for breathing air services.”  
WARNING  
No portable communication devices emitting more than 7.5 volts per metre in the frequency range from 250  
MHz to 280 MHz should be operated within 5m (16.5ft) of the unit.  
WARNING  
The motor rotor contains a powerful magnetic field. This field can effect the operation of digital devices such  
as watches, mobile phones etc. Assembly or handling of the rotor should not be attempted by personnel with  
cardiac pacemakers, defibrillators or other implanted electronic medical device.  
WARNING  
The specification of this machine is such that the machine is not suitable for use in flammable gas risk areas.  
If such an application is required then all local regulations, codes of practice and site rules must be observed.  
To ensure that the machine can operate in a safe and reliable manner, additional equipment such as gas  
detection and intake (shut−off) valves may be required, dependant on local regulations or the degree of risk  
involved.  
WARNING  
The compressor can operate in a pressurized shutdown mode. If the compressor stops automatically, the  
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the  
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through  
which any residual pressure will be vented. Downstream of the separator tank may still contain system  
pressure which must also be vented  
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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  
NOTICE  
To obtain satisfactory compressor operation and  
maintenance, a minimum of 3 feet clearance on 3  
sides is required. 3 1/2 feet is required in front of  
the control panel (or minimum required by latest  
National Electrical code or applicable local codes.)  
Refer to the Instruction / Operators Manual before  
performing any maintenance.  
Hazardous voltage. Can cause severe injury or  
death.  
Disconnect power before servicing.  
Lockout/Tagout machine.  
DANGER  
WARNING  
Discharge air.  
Can contain carbon monoxide or other  
contaminants. Will cause severe injury or death.  
Do not breathe this air.  
Rotating fan blade. Can cause severe injury.  
Do not operate with covers removed.  
Disconnect power. Lock/out and tag out machine.  
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5.0 SAFETY  
WARNING  
CAUTION  
Incorrect lifting of machine can cause injury or  
property damage.  
Lift only from base channels  
Food contaminant.  
Can cause severe injury or death.  
WARNING  
Use only Ingersoll Rand SSR H-1F food grade coolan  
t.  
39568464 Rev. 03  
NOTICE  
High pressure air.  
Can cause severe injury or death.  
Compressor can operate in a pressurized  
shutdown mode.  
Lift here  
Relieve pressure before removing filter plugs/caps,  
fittings or covers.  
22061915 Rev. A  
NOTICE  
WARNING  
Air discharge  
CAUTION  
Use of incorrect coolant can cause system  
contamination.  
Hot surface.  
Can cause severe injury.  
Use only SSR ULTRA COOLANT  
Do not touch. Allow to cool before servicing.  
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5.0 SAFETY  
CAUTION  
Rotation  
R o t a t i o n  
Improper coolant filter replacement will cause  
compressor damage.  
Replace filter element after first 150 hours of  
operation and every 2000 hours thereafter or when  
coolant is changed.  
NOTICE  
WARNING HIGH VOLTAGE  
Do not attempt any work.  
Read manual.  
Rotation  
Trained service personnel only.  
Remove electrical supply.  
Wait 15 minutes.  
Check for zero voltage.  
Proceed with caution.  
WARNING  
Moving parts. Can cause severe injury.  
Do not operate with covers removed.  
Service only with machine blocked to prevent turn over.  
39540224 Rev. 04  
Air  
Discharge  
39540257 Rev. 04  
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5.0 SAFETY  
Condensate  
drain.  
Use 75˚C copper wire only.  
Nur 75˚C kupferdraht verwenden.  
Utilisez 75˚C uniquement fil de cuivre.  
Usar solamente cable de cobre para 75˚ C.  
usare 75˚C solamente cavi di rame.  
Use somente fio de cobre de 75˚.  
Electrical  
power inlet.  
39492384 Rev. 03  
Use 75°C copper wire only.  
IMPORTANT  
Before starting this air compressor unit  
the shipping brace(s) must be removed.  
Save the brace(s) for future use. Refer to  
Operators/Instruction Manual.  
WARNING  
39481130 Rev. 02  
IMPORTANT  
Before starting this air compressor unit the shipping  
brace(s) must be removed.  
Save the brace(s) for future use.  
Refer to Operators / Instruction Manual.  
Hazardous voltage. Can cause severe injury or  
death.  
Disconnect power before servicing.  
Lockout/Tagout machine.  
NOTICE  
To obtain satisfactory compressor operation and  
maintenance, a minimum of 3 feet clearance on 3  
sides is required. 3 1/2 feet is required in front of  
the control panel (or minimum required by latest  
National Electrical code or applicable local codes.)  
Refer to the Instruction / Operators Manual before  
performing any maintenance.  
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5.0 SAFETY  
5.4 GRAPHIC FORM AND MEANING OF ISO SYMBOLS  
Prohibition / Mandatory  
Information / Instructions  
Warning  
WARNING: Electrical shock risk.  
WARNING − Pressurized component or  
system.  
WARNING − Hot surface.  
WARNING − Pressure control.  
WARNING − Corrosion risk.  
WARNING − Air/gas flow or Air discharge.  
WARNING − Pressurized vessel.  
Do not remove the Operating and  
WARNING − Flammable liquid.  
Maintenance manual from this machine.  
WARNING − Rotor magnetic field  
can affect pacemakers.  
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5.0 SAFETY  
C
0°  
WARNING − Do not undertake any  
maintenance on this machine until the  
electrical supply is disconnected and the  
air pressure is totally relieved.  
WARNING − Consult the Operation  
and Maintenance manual before  
commencing any maintenance.  
WARNING − For operating temperature  
below 0°C, consult the Operation and  
Maintenance manual.  
Read the Operation and Maintenance  
manual before operation or maintenance  
of this machine is undertaken.  
Do not stack.  
Do not operate the machine without the  
guard being in place.  
Do not stand on any service valve or  
other parts of the pressure system.  
Do not operate with the doors or  
enclosure open.  
Do not use fork lift truck from this side.  
Do not breathe the compressed air from  
this machine.  
No naked lights.  
Do not open the service valve before the  
air hose is attached.  
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5.0 SAFETY  
Use fork lift truck from this side only.  
Emergency stop.  
Tie down point  
Lifting point.  
On (power).  
Off (power).  
SET  
SEQUENCER STATUS  
LOAD  
SEQUENCER (AUTOMATIC CONTROL)  
COMPRESSOR  
OFF LOAD (UNLOADED)  
RESET  
COMPRESSOR STATUS  
MODULATE  
MALFUNCTION  
POWER  
FOULED FILTER  
POWER INLET  
ELECTRIC MOTOR  
HOURS  
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5.0 SAFETY  
COOLANT SEPARATOR  
PRESSURIZED TANK  
AIR FILTER  
PRESSURE  
AIR DISCHARGE  
ON / OFF CYCLE  
COOLANT FILTER  
ON / OFF PUSH BUTTON  
COOLANT PRESSURE  
AIR PRESSURE  
STAR DELTA IEC 617−7  
AUTOMATIC RESTART  
HEAT EXCHANGER  
MAINTENANCE  
MAINTENANCE PROHIBITED  
COOLANT DRAIN  
CONDENSATE DRAIN  
PRESSURE CONTROL  
MANUAL (SELECT)  
TEMPERATURE  
HIGH TEMPERATURE  
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5.0 SAFETY  
BELT TENSION  
FILTER  
MOTOR LUBRICATION  
FRAGILE  
KEEP DRY  
THIS WAY UP  
USE NO HOOKS  
NO SIDE CLAMPS  
ROTATION  
POWER INLET (AC)  
WATER IN  
WATER OUT  
TRAINED SERVICE PERSONNEL  
WAIT TIME  
CHECK ZERO VOLTS  
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6.0 RECEIPT / HANDLING  
6.1 RECEIPT  
When you receive the compressor please inspect it closely. Any indication of careless handling by the carrier should be  
noted on the delivery receipt especially if the compressor will not be immediately unpacked. Obtaining the deIivery  
persons signed agreement to any noted damages will facilitate any future insurance claims.  
IMPORTANT  
READ THIS  
LOST OR DAMAGED GOODS  
THOROUGHLY INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL  
OUR RESPONSIBILITY FOR THIS SHIPMENT CEASED WHEN THE CARRIER SIGNED  
BILL OF LADING  
If goods are received short or in damaged condition, it is important that you notify the carrier and insist on a  
notation of the loss or damage across the face of the freight bill. Otherwise no claim can be enforced against the  
transportation company.  
If concealed loss or damage is discovered, notify your carrier at once and request an inspection. This is absolutely  
necessary. Unless you do this the carrier will not entertain any claim for loss or damage. The agent will make an  
inspection and grant a concealed damage notation. If you give the transportation company a clear receipt for  
goods that have been damaged or lost in transit, you do so at your own risk and expense.  
WE, AT lR, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE MANNER TO COLLECT CLAIMS FOR LOSS  
OR DAMAGE, BUT THE WILLINGNESS ON OUR PART DOES NOT MAKE US RESPONSIBLE FOR  
COLLECTION OF CLAIMS OR REPLACEMENT OF MATERIAL. THE ACTUAL FILING AND PROCESSING OF  
THE CLAIM IS YOUR RESPONSIBILITY.  
Ingersoll Rand Company  
6.2 UNPACKING AND HANDLING  
The compressor will normally be delivered with a polyethylene or other cover. If a knife has to be used to remove this  
cover, ensure that the exterior paintwork of the compressor is not damaged.  
Incorporated within the base of the compressor are slots to enable a fork lift truck to move the machine. Ensure truck  
forks are fully engaged on both sides. Alternatively a special lifting frame can be utilized to enable a crane or hoist to  
move the compressor. Use only marked lifting points.  
Once the packaging and pallet are discarded and the unit is in its final position, remove the transit brackets from the  
resilient mounts and store for future use or discard.  
On N75−160 units remove the screw in the base and slide the separator tank service bracket into the upper position on  
the slots and tighten screws.  
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7.0 INSTALLATION  
For technical information see section 8.0.  
7.1 LOCATION IN PLANT  
Ensure that the correct tie down points are used.  
It is recommended that provision be made for lifting  
heavy components during major overhaul. Use only  
lifting points provided.  
For major overhaul (i.e. motor removal) position the  
machine to obtain lifting access e.g. fork lift truck.  
Minimum space in front of control panel door as required  
by National or Local codes must be maintained.  
See diagram in reference section for minimum space  
requirements for normal operation and maintenance.  
The compressor can be installed on any level floor  
capable of supporting it. A dry, well ventilated area where  
the atmosphere is as clean as possible is recommended.  
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.  
Sufficient space all round and above the compressor must  
be allowed, to enable the effective removal of the cooling  
air which, in turn, will reduce the risk of recirculating the  
cooling air back through the compressor.  
Hard surfaces may reflect noise with an apparent  
increase in the decibel level. When sound transmission  
is important, a sheet of rubber or cork can be installed  
beneath the machine to reduce noise. Flexible piping  
may be required.  
CAUTION  
A minimum of 1 m (3.3ft) all round the compressor is recommended. If headroom is restricted, then the ex-  
haust 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.  
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7.0 INSTALLATION  
7.2 DISCHARGE AND CONDENSATE PIPING  
It is essential when installing a new compressor [1],  
to review the total air system. This is to ensure a safe  
and effective total system. One item which should be  
considered is liquid carryover. Installation of air dryers  
[3] is always good practice since properly selected and  
installed they can reduce any liquid carryover to zero.  
When two rotary units are operated in parallel, provide an  
isolation vaIve and drain trap for each compressor before  
the common receiver.  
The built−in aftercooler reduces the discharge air  
temperature below the dew point (for most ambient  
conditions), therefore, considerable water vapor  
is condensed. To remove this condensation, each  
compressor with built−in aftercooler is furnished with a  
combination condensate separator/trap.  
A receiver [2] may be necessary to ensure that the total  
system volume is not less than 2.0 U.S. Gal. per rated  
delivery C.F.M.  
Discharge piping should be at least as large as the  
discharge connection of the compressor. All piping  
and fittings should be suitably rated for the discharge  
pressure.  
A dripleg assembly and isolation valve should be  
mounted near the compressor discharge. A drain line  
should be connected to the condensate drain in the base.  
IMPORTANT: The drain line must slope downward from  
the base to work properly. For ease of inspection of the  
automatic drain trap operation, the drain piping should  
include an open funnel.  
It is good practice to locate an isolation valve close to the  
compressor and to install line filters [4].  
Include a means [6] to vent the discharge pipework  
downstream from the minimum pressure check valve  
located on the separator tank. Upstream of the first  
system isolation valve [7].  
NOTICE  
For low volume systems that may not include a  
receiver [2], compressor response time may need  
adjusting. Contact your local IR service agent.  
The discharged air contains a very small percentage of  
compressor lubricating oil and care should be taken to  
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.  
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7.0 INSTALLATION  
7.3 ELECTRICAL  
CAUTION  
This procedure should only be carried out by a qualified electrician, electrical contractor or your local Inger-  
soll Rand Distributor or Air Center.  
The feeder cable must be suitably glanded into the power  
drive module (P.D.M.) electrical box to ensure that dirty air  
does not by−pass the filter pads or degrade the cooling  
air flow.  
The compressor and drive should be properly grounded  
/ earthed in accordance with Local and National Code  
requirements.  
Installation of this compressor must be in accordance  
with recognized electrical codes and any local Health and  
Safety Codes.  
On completion of electrical installation, check that blower  
motor rotation is correct. N250H−300H utilizes a fan.  
The compressor must have its own isolator situated  
adjacent to it. The fuse protecting the circuit and the  
compressor must be selected in accordance with local  
and national code requirements on the basis of the data  
provided in the general information section  
This machine is designed for use in heavy industrial  
environments, where the electricity supply is separated  
from nearby residential and commercial areas. If the  
machine is to be used in the light industrial, residential or  
commercial environment where the local supply network  
is shared, further radio frequency (RF) screening measures  
may be required. Consult your local distributor/supplier  
for details of the optional RF filter. RF filter supplied as  
standard on N250−300H−2S  
Feeder cables should be sized by the customer/electrical  
contractor to ensure that the circuit is balanced and not  
overloaded by other electrical equipment. The length  
of wiring from a suitable electrical feed point is critical  
as voltage drops may impair the performance of the  
compressor.  
The compressor has a anti−condensation heater and  
thermostat in the electrical box. This circuit can be  
connected to an independent electrical supply of either  
110V or 230V single phase, dependant on the country  
of installation. The supply should be suitable fused  
and an independent isolator installed adjacent to the  
compressor.  
Cable sizes may vary considerably so the mains  
terminals will accept up to 50mm2 (1awg) (37/45k  
& 50/60H) and up to 90mm2 (3/0awg) (55/75k &  
75/100H) cable. The N75K−160K and N100H−200H  
machines mains terminals will accept 2 x 120mm2 (4/0  
AWG) cables. The N250H−300H−2S machines main  
terminals will accept 2 x 400 MCM cables.  
This should be done in accordance with local and national  
codes. It is good practice and sometimes mandatory, to  
display suitable signs warning that the machine has two  
separate electrical supplies which both must be isolated  
before any work is attempted.  
Feeder cable connections to incoming terminals  
L1−L2−L3 should be tight and clean.  
The applied voltage must be compatible with the motor  
and compressor data plate ratings.  
Alternately it can be supplied from the 110V tapping  
of the control transformer and connected as shown on  
schematic wiring diagram.  
The control circuit transformer has different voltage  
tappings. Ensure that these are set for the specific applied  
voltage prior to starting.  
A hole is provided for incoming power connection. If it is  
necessary to make a hole in the control box in a different  
location, care should be taken to not allow metal shavings  
to enter the starter and other electrical components  
within the box. If another hole is used, the original hole  
must be blocked off.  
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7.0 INSTALLATION  
CAUTION  
VERY IMPORTANT  
Supply voltage must be kept to a maximum imbalance of 2% on 50Hz and 3% on 60Hz applications. Voltage  
imbalances greater than these levels can cause permanent damage to the drive.  
Compressor must not be subjected to any voltage spikes or surges in excess of 575V. Exposure to spikes/surg-  
es in excess of 575V can permanently damage the drive. If the possibility of such exists it is recommended  
that adequate surge protection is fitted such as an Ingersoll Rand line reactor. See your local Ingersoll Rand  
representative.  
Failure of the drive due to voltage spikes, line notching, harmonics or other power quality related problems,  
will not be covered by the standard compressor warranty.  
The correct type and rating of line input fuse MUST BE fitted onto the customers isolator or breaker close to  
the compressor. For Amp rating see technical information in Section 8.1.  
Product Identification  
Class − J, Class − T, or  
Semiconductor  
Fuse Type  
Fast Acting Class−J, T or Semiconductor type,  
Current limiting, Interrupt Rating − 200,000 Amps  
RMS SYM.  
Alternate fuse may be used if the time current  
characteristics are faster than fuses recommended  
in this section.  
See your local Ingersoll Rand representative for a range of fuses and disconnect isolators matched to your particular  
machine.  
Example of voltage imbalance calculation  
U →V 462v  
V → W 459v  
W → U 453v  
V(m) = (462 + 459 + 453) / 3 = 458v  
VΔ max = 462 − 453 = 9v  
= (9 / 458) x 100 = 1.97%  
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7.0 INSTALLATION  
7.4 WATERCOOLED UNITS  
Cooling Water Piping  
Venting the water system  
Water piping to and from the compressor package must  
be 1”diameter or larger for N37/75K (N50/100H), 11/2”  
diameter or larger for N75/160K (N100H/200H) and 2.0”  
diameter or larger for N250/300H−2S. Isolation valves  
with side drains should be installed on both the inlet and  
outlet lines. Also a strainer of 2mm−mesh size should  
be installed on the inlet line. Strainers are available from  
Ingersoll Rand. Ingersoll Rand CPN 54689997 (N37/45K &  
N50/60H) or CPN 54690029 (N55/75K & N75/100H)  
At the initial installation or for start−up after draining the  
water system proceed to vent the system as follows.  
1. Locate the water system vent cocks on top of the  
aftercooler and lubricant cooler.  
2. Open the water valve(s) allowing water to flow to the  
package.  
3. Open the vent cocks and allow all air to escape from  
the system. When water is observed at the vent  
cocks, close them.  
A normally closed solenoid valve is fitted to the water  
outlet side of the compressor package. This is wired  
into the compressor control circuit and closes when the  
compressor stops.  
The system is now vented.  
Draining the water system  
Should it become necessary to completely drain the  
water system, proceed as follows.  
Carefully inspect your water system before installing  
the compressor package. Ensure that the piping is free  
of scale and deposits that may restrict water flow to the  
compressor package.  
1. Disconnect the inlet and discharge water lines from  
the connections located at the rear of the unit.  
Proper operation of your compressor requires that the  
water flow listed below be provided at a maximum supply  
temperature of 46° C (115° F).  
2. Locate the aftercooler and lubricant cooler. Remove  
the drain plugs located at the bottom of the coolers.  
Allow the system to completely drain.  
Model  
Range  
Minimum cooling water requirement vs  
water inlet temperatures, in litres per  
minute (US gallons per minute)  
N75−160k, N100−200H Watercooled  
See piping and instrumentation diagram (Section  
8.3). The coolers are piped in a ”parallel”water flow  
arrangement with a manual trim valve controlling the  
flow through the aftercooler. An additional automatic  
anti−condensation thermal valve controls the flow of  
water to the oilcooler. It has a sensor in the separator  
tank and capillary to signal the valve to open and close in  
order to avoid water condensing in the tank.  
10°F /  
50°F  
21°F /  
70°F  
32°C /  
90°F  
46°C /  
115°F  
N37  
N45  
N55  
N75  
23(6.0)  
27(7.0)  
23 (6.0)  
30(8.0)  
38 (10.0)  
49(13.0)  
38(10.0)  
46(12.0)  
57(15.0)  
76(20.0)  
38(10.0)  
53(14.0)  
76(20.0)  
72(19.0)  
87(23.0)  
106(28.0)  
51(13.5)  
95(25.0)  
46(12.0)  
68(18.0)  
Adjusting the Aftercooler Trim Valve  
N75-2S 175(46.0) 133(35.0) 106(28.0)  
The anti−condensation valve has no adjustment. The  
Aftercooler Trim Valve is factory set and should not need  
adjusting but if disturbed use following procedure.  
Close valve fully clockwise and then open 1/4 turn. With  
machine running loaded observe the package discharge  
temperature Intellisys display. It should be be approx 15°  
F (8° C) above the water inlet temperature. If it is higher,  
open the valve a little more. Put a ’Warning − Do Not  
Adjust’label on the valve or fit a lock.  
N90  
84(22.0)  
95(25.0)  
72(19.0)  
80(21.0)  
65(17.0)  
72(19.0)  
87(23.0)  
N110  
N132 110(29.0) 91(24.0)  
N160 125(33.0) 118(31.0) 106(28.0) 125(33.0)  
N250  
N300  
91(24.0) 110(29.0) 179(47.0)  
95(25.0) 133(35.0) 220(58.0)  
Water temperature and pressure gauges should be  
installed in the water piping for use in any fault finding  
of the water system. Water pressure should ideally be  
between 3 and 5 bar (43.5 and 72.5 psi) but must not be  
above 10 Bar (145 psi)  
Water cleanliness is also extremely important. Cleaning of  
coolers as a result of fouling is a customer responsibility.  
Therefore, it is highly recommended that proper water  
quality must meet the requirements listed in WATER  
QUALITY RECOMMENDATIONS later in this section.  
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7.0 INSTALLATION  
Water quality recommendations  
Cooling Water Analysis Chart  
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 operation  
of the system. Evaporation, corrosion, chemical and  
temperature changes, aeration, scale and biological  
formations effect the water makeup. Most problems in  
a cooling system show up first in a reduction in the heat  
transfer rate, then in a reduced flow rate and finally with  
damage to the system.  
Substances  
Test interval  
Acceptable  
concentration  
Corrosivity  
Monthly - if stable Langelier Index  
for 3 to 4 months, 0 to 1  
analyse quarterly.  
(Hardness,  
pH, Total  
Dissolved Solids,  
Temperature at  
inlet Alkalinity)  
Iron  
Monthly  
Monthly  
Monthly  
Monthly  
Monthly  
<2 ppm  
Sulphate  
Chloride  
Nitrate  
Silica  
<50 ppm  
<50 ppm  
<2 ppm  
< 100 ppm  
Scale: Scale formation inhibits effective heat transfer, yet  
it does help prevent corrosion. Therefore, a thin uniform  
coating of calcium carbonate is desired on the inner  
surface. Perhaps the largest contributor to scale formation  
is the precipitation of calcium carbonate out of the water.  
This is dependent on temperature and pH. The higher the  
pH value, the greater the chance of scale formation. Scale  
can be controlled with water treatment.  
Desolated  
Oxygen  
Daily - if stable,  
analyse weekly  
0 ppm (as low  
as possible)  
Oil & Grease  
Ammonia  
Monthly  
Monthly  
<5 ppm  
<1 ppm  
Corrosion: In contrast to scale formation is the problem  
of corrosion. Chlorides cause problems because of their  
size and conductivity. Low pH levels promote corrosion,  
as well as high levels of dissolved oxygen.  
Fouling: Biological and organic substances (slime)  
can also cause problems, but in elevated temperature  
environments such as cooling processes they are not a  
major concern. If they create problems with clogging,  
commercial shock treatment are available.  
To ensure good operation life and performance of  
the compressor cooling system, the recommended  
acceptable ranges for different water constituents are  
included below:  
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7.0 INSTALLATION  
7.5 SEA WATERCOOLED UNITS (SELECTED UNITS ONLY)  
Water cleanliness is extremely important. Strainers are  
available from Ingersoll Rand. Cleaning of coolers as a  
result of fouling is a customer responsibility.  
No oil cooler manufacturer can guarantee that its  
products will have an indefinite life and for this reason, we  
suggest that the cooling system is designed to minimize  
any damage caused by a leaking oil cooler. This can be  
achieved as follows ;  
Isolation valves with side drains should be installed on  
both the inlet and outlet lines.  
1. The oil pressure should be higher than the sea water  
pressure, so that in the event of a leak occurring, the  
oil will not be contaminated.  
A normally closed solenoid valve is fitted to the water  
outlet side of the compressor package.  
It is important to ensure that the recommended flow  
rate cannot be exceeded. This will normally mean that an  
orifice plate must be fitted in the pipework at least 1m  
(3.3ft) before the cooler, with the orifice size calculated to  
ensure that the maximum sea water flow rate cannot be  
exceeded. If these precautions are not taken, it is possible  
that the sea water flow rate through the cooler may be  
several times the recommended maximum, which will  
lead to rapid failure.  
2. If the sea water pressure is 100PSIG (7BARG) or above  
it is recommended that the water solenoid valve is  
changed to the water inlet side. This will protect the  
system from high pressure surges when not in use.  
3. The sea water outlet pipe from the cooler should  
have a free run to waste.  
Sea Water Pressure Bar  
(psi)  
Orifice diameter in mm  
(inch) to give a maximum  
sea water flow of 90l/min  
(23.76 US gall/min)  
3 (43.5)  
4 (58)  
12 (0.472)  
11 (0.433)  
10 (0.394)  
9.6 (0.378)  
9.2 (0.362)  
8.9 (0.35)  
8.7 (0.343)  
8.4 (0.33)  
5 (72.5)  
6 (87)  
7 (101.5)  
8 (116)  
9 (130.5)  
10 (145)  
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7.0 INSTALLATION  
7.6 OUTDOOR SHELTERED INSTALLATION  
Nirvana compressors are not suitable for outdoor  
installation.  
Installing a Nirvana compressor outside voids the  
warranty of the compressor.  
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8.0 GENERAL INFORMATION  
TECHNICAL INFORMATION-SINGLE STAGE  
N37K  
N45K  
N50H  
N60H  
General  
Sound pressure level dB(A) *  
Maximum ambient temperature ° C (° F)  
Minimum ambient temperature ° C (° F)  
Weight Kg (lbs)  
75  
75  
75  
75  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
1048 (2310)  
10 (145)  
4.5 (65)  
1048 (2310)  
10 (145)  
4.5 (65)  
1048 (2310)  
10 (145)  
4.5 (65)  
1048 (2310)  
10 (145)  
4.5 (65)  
Maximum pressure barg (psig)  
Minimum pressure barg (psig)  
Coolant capacity litres (US gal)  
HAT switch setting ° C (° F)  
Performance **  
18 (4.8)  
18 (4.8)  
18 (4.8)  
18 (4.8)  
120 (248)  
120 (248)  
120 (248)  
120 (248)  
Flow at 7.5 Barg (m³/min)  
Flow at 8.5 Barg (m³/min)  
Flow at 10 Barg (m³/min)  
Flow at 100 psig (cfm)  
6.43  
6.12  
5.83  
−
7.39  
7.02  
6.46  
−
−
−
−
−
−
−
235  
216  
209  
262  
248  
233  
Flow at 125 psig (cfm)  
−
−
Flow at 140 psig (cfm)  
−
−
Air Cooling System  
Cooling air flow m3/min (cfm)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Water Cooling System  
184 (6500)  
124 (0.5)  
8 (15)  
184 (6500)  
124 (0.5)  
8 (15)  
184 (6500)  
124 (0.5)  
8 (15)  
184 (6500)  
124 (0.5)  
8 (15)  
Cooling (clean) water flow l/min (US  
gallon/min) @ 10 ° C (50 ° F) / 32 ° C  
(90 ° F)  
23/38 (6/10)  
27/49 (7/13)  
23/38 (6 /10)  
27 /49 (7 /13)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Main Power Circuit A/C (W/C) ***  
Package full load current at 220V (A) **  
Package full load current at 400V (A) **  
Package full load current at 460V (A) **  
Package full load current at 575V (A) **  
Max fuse size @ 220V (A)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
140 (131)  
75 (70 )  
−
168 (159)  
90 (85)  
−
140 (131)  
−
168 (159)  
−
68 (63)  
56 (52)  
250  
81 (77)  
67 (63)  
250  
−
−
250  
250  
Max fuse size @ 400V (A)  
125  
125  
125  
125  
Max fuse size @ 460V (A)  
125  
125  
125  
125  
Max fuse size @ 575V (A)  
100  
100  
100  
100  
Fuse type  
Fast acting class J, T or semiconductor type, current limiting interrupt  
rating 200, 000 Amps RMS SYM.  
Heater Circuit  
110V Single Phase Rating (A)  
230V Single Phase Rating (A)  
Fuse type  
4
4
4
4
4
4
4
4
General purpose  
* In accordance with PNEUROP PN8NTC2.3  
** Tolerances in accordance with ISO 1217  
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable  
size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
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8.0 GENERAL INFORMATION  
N55K  
N75K  
N75H  
N100H  
General  
Sound pressure level dB(A) *  
Maximum ambient temperature ° C (° F)  
Minimum ambient temperature ° C (° F)  
Weight Kg (lbs)  
75  
75  
75  
75  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
1531 (3374)  
10 (145)  
4.5 (65)  
1531 (3374)  
10 (145)  
4.5 (65)  
1531 (3374)  
10 (145)  
4.5 (65)  
1531 (3374)  
10 (145)  
4.5 (65)  
Maximum pressure barg (psig)  
Minimum pressure barg (psig)  
Coolant capacity litres (US gal)  
HAT switch setting ° C (° F)  
Performance  
30 (8)  
30 (8)  
30 (8)  
30 (8)  
120 (248)  
120 (248)  
120 (248)  
120 (248)  
Flow at 7.5 Barg (m3/min)  
Flow at 8.5 Barg (m3/min)  
Flow at 10 Barg (m3/min)  
Flow at 100 psig (cfm)  
10.11  
9.29  
8.49  
−
12.94  
12.15  
11.50  
−
−
−
−
−
−
−
372  
328  
306  
479  
429  
413  
Flow at 125 psig (cfm)  
−
−
Flow at 140 psig (cfm)  
−
−
Air Cooling System  
Cooling air flow m3/min (cfm)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT° C (° F)  
Water Cooling System  
241 (8500)  
124 (0.5)  
8 (15)  
241 (8500)  
124 (0.5)  
8 (15)  
241 (8500)  
124 (0.5)  
8 (15)  
241 (8500)  
124 (0.5)  
8 (15)  
Cooling (clean) water flow l/min (US  
51/38  
95/46  
51/38  
95/46  
gallon/min) @ 10 ° C (50 ° F) / 32 ° C (90  
° F)  
(13.5 /10)  
(25 /12)  
(13.5/10)  
(25/12)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Main Power Circuit A/C (W/C) ***  
Package full load current at 220V (A) **  
Package full load current at 400V (A) **  
Package full load current at 460V (A) **  
Package full load current at 575V (A) **  
Max fuse size @ 220V (A)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
208 (196)  
110 (104)  
−
−
144 (138)  
−
208 (196)  
−
−
−
100 (94)  
82 (78)  
300  
131 (125)  
108 (103)  
400  
−
−
300  
400  
200  
200  
150  
Max fuse size @ 400V (A)  
150  
150  
200  
Max fuse size @ 460V (A)  
150  
150  
200  
Max fuse size @ 575V (A)  
125  
125  
150  
Fuse type  
Fast acting class J, T or semiconductor type, current limiting  
interrupt rating 200, 000 Amps RMS SYM.  
Heater Circuit  
110V Single Phase Rating (A)  
230V Single Phase Rating (A)  
4
4
4
4
4
4
4
4
Fuse type  
General purpose  
* In accordance with PNEUROP PN8NTC2.3  
** Tolerances in accordance with ISO 1217  
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable  
size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)  
2ꢁ  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
N90K  
N110K  
N125H  
N150H  
General  
Sound pressure level dB(A) *  
Maximum ambient temperature ° C (° F)  
Minimum ambient temperature ° C (° F)  
Weight Kg (lbs)  
75  
75  
75  
75  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
3175 (6985)  
10 (145)  
4.5 (65)  
3175 (6985)  
10 (145)  
4.5 (65)  
3175 (6985)  
10 (145)  
4.5 (65)  
3175 (6985)  
10 (145)  
4.5 (65)  
Maximum pressure barg (psig)  
Minimum pressure barg (psig)  
Coolant capacity litres (US gal)  
HAT switch setting ° C (° F)  
Performance **  
91 (24)  
91 (24)  
91 (24)  
91 (24)  
120 (248)  
120 (248)  
120 (248)  
120 (248)  
Flow at 7.5 Barg (m3/min)  
Flow at 8.5 Barg (m3/min)  
Flow at 10 Barg (m3/min)  
Flow at 100 psig (cfm)  
17.1  
15.3  
14.0  
−
20.0  
19.2  
17.5  
−
−
−
−
−
−
−
655  
571  
524  
739  
670  
610  
Flow at 125 psig (cfm)  
−
−
Flow at 140 psig (cfm)  
−
−
Air Cooling System  
Cooling air flow m3/min (cfm)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Water Cooling System  
382 (13500)  
124 (05)  
8 (15)  
382 (13500)  
124 (05)  
8 (15)  
382 (13500)  
124 (05)  
8 (15)  
382 (13500)  
124 (05)  
8 (15)  
Cooling (clean) water flow l/min (US  
84/65  
95/72  
84/65  
95/72  
gallon/min) @ 10° C (50° F) / 32° C (90° F)  
(22/17)  
(25/19)  
(22/17)  
(25/19)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Main Power Circuit A/C (W/C) ***  
Package full load current at 400V (A) **  
Package full load current at 460V (A) **  
Package full load current at 575V (A) **  
Max fuse size @ 380V − 415V (A)  
Max fuse size @ 440V − 480V (A)  
Max fuse size @ 550V − 575V (A)  
Fuse type  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
182 (170)  
218 (206)  
−
170 (160)  
140 (132)  
−
−
200 (190)  
165 (157)  
−
−
−
−
−
250  
−
350  
−
250  
250  
−
−
200  
200  
Fast acting class J, T or semiconductor type, current limiting  
interrupt rating 200, 000 Amps RMS SYM.  
Heater Circuit  
110V Single Phase Rating (A)  
230V Single Phase Rating (A)  
4
4
4
4
4
4
4
4
Fuse type  
General purpose  
* In accordance with PNEUROP PN8NTC2.3  
** Tolerances in accordance with ISO 1217  
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable  
size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
2ꢂ  
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8.0 GENERAL INFORMATION  
N132K  
N160K  
N200H  
General  
Sound pressure level dB(A) *  
Maximum ambient temperature ° C (° F)  
Minimum ambient temperature ° C (° F)  
Weight Kg (lbs)  
75  
75  
75  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
46 (115)  
1.7 (35)  
3175 (6985)  
10 (145)  
4.5 (65)  
3175 (6985)  
10 (145)  
4.5 (65)  
3175 (6985)  
10 (145)  
4.5 (65)  
Maximum pressure barg (psig)  
Minimum pressure barg (psig)  
Coolant capacity litres (US gal)  
HAT switch setting ° C (° F)  
Performance **  
91 (24)  
91 (24)  
91 (24)  
120 (248)  
120 (248)  
120 (248)  
Flow at 7.5 Barg (m3/min)  
Flow at 8.5 Barg (m3/min)  
Flow at 10 Barg (m3/min)  
Flow at 100 psig (cfm)  
23.5  
22.3  
21.0  
−
28.0  
26.0  
25.0  
−
−
−
−
993  
892  
819  
Flow at 125 psig (cfm)  
−
−
Flow at 140 psig (cfm)  
−
−
Air Cooling System  
Cooling air flow m3/min (cfm)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Water Cooling System  
382 (13500)  
124 (0.5)  
8 (15)  
382 (13500)  
124 (0.5)  
8 (15)  
382 (13500)  
124 (0.5)  
8 (15)  
Cooling (clean) water flow l/min (US gallon/  
min) @ 10° C (50° F) / 32° C (90° F)  
110/87  
(29/23)  
125/106  
(33/28)  
125/106  
(33/28)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Main Power Circuit A/C (W/C) ***  
Package full load current at 400V (A) **  
Package full load current at 460V (A) **  
Package full load current at 575V (A) **  
Max fuse size @ 380V − 415V (A)  
Max fuse size @ 440V − 480V (A)  
Max fuse size @ 550V − 575V (A)  
Fuse type  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
251 (239)  
301(289)  
−
255 (245)  
210 (202)  
−
−
−
−
−
350  
−
450  
−
350  
−
−
300  
Fast acting class J, T or semiconductor type, current limiting  
interrupt rating 200, 000 Amps RMS SYM.  
Heater Circuit  
110V Single Phase Rating (A)  
230V Single Phase Rating (A)  
4
4
4
4
4
4
Fuse type  
General purpose  
* In accordance with PNEUROP PN8NTC2.3  
** Tolerances in accordance with ISO 1217  
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable  
size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)  
30  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.1 TECHNICAL INFORMATION − TWO STAGE  
N75K  
N90K  
N110K  
N100H  
N125H  
N150H  
General  
Sound pressure level dB(A) *  
Maximum ambient temperature ° C (° F)  
Minimum ambient temperature ° C (° F)  
Weight Kg (lbs)  
75  
75  
75  
75  
75  
75  
46 (115)  
1.7 (35)  
3650  
46 (115)  
1.7 (35)  
3650  
46 (115)  
1.7 (35)  
3650  
46 (115)  
1.7 (35)  
3650  
46 (115)  
1.7 (35)  
3650  
46 (115)  
1.7 (35)  
3650  
(8030)  
(8030)  
(8030)  
(8030)  
(8030)  
(8030)  
Maximum pressure barg (psig)  
Minimum pressure barg (psig)  
Coolant capacity litres (US gal)  
HAT switch setting ° C (° F)  
Performance **  
10 (145)  
4.5 (65)  
95 (25)  
10 (145)  
4.5 (65)  
95 (25)  
10 (145)  
4.5 (65)  
95 (25)  
10 (145)  
4.5 (65)  
95 (25)  
10 (145)  
4.5 (65)  
95 (25)  
10 (145)  
4.5 (65)  
95 (25)  
120 (248)  
120 (248) 120 (248) 120 (248) 120 (248) 120 (248)  
Flow at 7.5 Barg (m3/min)  
Flow at 8.5 Barg (m3/min)  
Flow at 10 Barg (m3/min)  
Flow at 14 Barg (m3/min)  
Flow at 100 psig (cfm)  
15.7  
14.2  
13.1  
−
18.0  
17.5  
15.4  
12.5  
−
22.1  
20.4  
18.9  
15.4  
−
−
−
−
−
−
−
−
−
−
−
−
−
−
560  
504  
470  
−
690  
621  
580  
443  
825  
743  
693  
548  
Flow at 125 psig (cfm)  
−
−
−
Flow at 140 psig (cfm)  
−
−
−
Flow at 200 psig (cfm)  
−
−
−
Air Cooling System  
Cooling air flow m3/min (cfm)  
382  
382  
382  
382  
382  
382  
(13500)  
124 (0.5)  
8 (15)  
(13500)  
124 (0.5)  
8 (15)  
(13500)  
124 (0.5)  
8 (15)  
(13500)  
124 (0.5)  
8 (15)  
(13500)  
124 (0.5)  
8 (15)  
(13500)  
124 (0.5)  
8 (15)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Water Cooling System  
Cooling (clean) water flow l/min (US  
gallon/min) @ 10° C (50° F) / 32° C (90°  
F)  
175/106  
(46/28)  
84/65  
(22/17)  
95/72  
(25/19)  
175/106  
(46/28)  
84/65  
(22/17)  
95/72  
(25/19)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Main Power Circuit A/C (W/C)***  
Package full load current at 400V (A) **  
Package full load current at 460V (A) **  
Package full load current at 575V (A) **  
Max fuse size @ 380V − 415V (A)  
Max fuse size @ 440V − 480V (A)  
Max fuse size @ 550V − 575V (A)  
Fuse type  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
153 (142)  
182 (170) 218 (206)  
−
−
−
−
−
−
−
−
−
139 (129) 170 (160) 200 (190)  
114 (106) 140 (132) 165 (157)  
250  
−
250  
−
350  
−
−
−
−
200  
200  
250  
200  
250  
200  
−
−
−
Fast acting class J, T or semiconductor type, current  
limiting interrupt rating 200, 000 Amps RMS SYM.  
Heater Circuit  
110V Single Phase Rating (A)  
230V Single Phase Rating (A)  
4Fuse type  
4
4
4
4
4
4
4
4
4
4
4
4
General purpose  
* In accordance with PNEUROP PN8NTC2.3  
** Tolerances in accordance with ISO 1217  
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable  
size should be calculated onbasis of mean package full load current X1.25 (i.e. 25% margin)  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
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8.0 GENERAL INFORMATION  
N132K  
N160K  
N200H  
N250H  
N300H  
General  
Sound pressure level dB(A) *  
Maximum ambient temperature ° C (° F)  
Minimum ambient temperature ° C (° F)  
Weight Kg (lbs)  
75  
75  
75  
80  
80  
46 (115)  
1.7 (35)  
3650  
46 (115)  
1.7 (35)  
3650  
46 (115)  
1.7 (35)  
3650  
46 (115)  
1.7 (35)  
5933  
46 (115)  
1.7 (35)  
5933  
(8030)  
(8030)  
(8030)  
(13,080)  
10 (145)  
4.5 (65)  
152 (40)  
120 (248)  
(13,080)  
10 (145)  
4.5 (65)  
152 (40)  
120 (248)  
Maximum pressure barg (psig)  
Minimum pressure barg (psig)  
Coolant capacity litres (US gal)  
HAT switch setting ° C (° F)  
Performance **  
10 (145)  
4.5 (65)  
95 (25)  
120 (248)  
10 (145)  
4.5 (65)  
95 (25)  
120 (248)  
10 (145)  
4.5 (65)  
95 (25)  
120 (248)  
Flow at 7.5 Barg (m3/min)  
Flow at 8.5 Barg (m3/min)  
Flow at 10 Barg (m3/min)  
Flow at 14 Barg (m3/min)  
Flow at 100 psig (cfm)  
Flow at 125 psig (cfm)  
Flow at 140 psig (cfm)  
Flow at 200 psig (cfm)  
26.2  
24.2  
23.1  
18.4  
−
−
−
−
31.1  
29.6  
27.2  
22.2  
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
1100  
990  
924  
735  
1380  
1249  
1167  
−
1690  
1527  
1430  
−
Air Cooling System  
Cooling air flow m3/min (cfm)  
382  
382  
382  
679  
679  
(13500)  
124 (0.5)  
8 (15)  
(13500)  
124 (0.5)  
8 (15)  
(13500)  
124 (0.5)  
8 (15)  
(24000)  
62 (0.25)  
8 (15)  
(24000)  
62 (0.25)  
8 (15)  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Water Cooling System  
Cooling (clean) water flow l/min (US gallon/  
min) @  
110/87  
(29/23)  
125/106  
(33/28)  
125/106  
(33/28)  
352  
(93)  
352  
(93)  
10° C (50° F) / 32° C (90° F) ****  
Maximum ΔP in air ducts Pa (inch WG)  
Compressed air outlet ΔT ° C (° F)  
Main Power Circuit A/C (W/C) ***  
Package full load current at 400V (A) **  
Package full load current at 460V (A) **  
Package full load current at 575V (A) **  
Max fuse size @ 380V − 415V (A)  
Max fuse size @ 440V − 480V (A)  
Max fuse size @ 550V − 575V (A)  
Fuse type  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
62 (0.25)  
14 (25)  
251 (239)  
301 (289)  
−
255 (245)  
210 (202)  
−
−
−
406 (384)  
324 (307)  
−
−
−
350  
−
−
−
450  
−
335 (313)  
267 (250)  
−
−
−
350  
300  
600  
500  
−
−
Fast acting class J, T or semiconductor type, current limiting interrupt  
rating 200, 000 Amps RMS SYM.  
Heater Circuit  
110V Single Phase Rating (A)  
230V Single Phase Rating (A)  
Fuse type  
4
4
4
4
4
4
4
4
4
4
General purpose  
* In accordance with PNEUROP PN8NTC2.3  
** Tolerances in accordance with ISO 1217  
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable  
size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)  
**** Cooling water flow for N250H and N300H are @ 46 deg C (115 deg F)  
32  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.2 INSTALLATION DRAWING−N37/45K−CC & N50/60H−CC − AIR COOLED  
KEY  
A
11/2”NPT Air discharge (Female) 60Hz units  
11/2”BSP Air discharge (Female) 50Hz units  
G
4 x Ø 13.0mm (0,5”) Compressor should be  
bolted to the floor with fourM10 (0.38”) bolts using holes  
shown. Seal base tofloor with cork or rubber.  
B
C
Ø63mm (2.48”) Electrical inlet  
H
INTELLISYS Controller  
Right  
0.38“ NPT (Female)  
Note: Pipe condensate drain lines separately to an open  
drain due to differences in drain pressures.  
Use drain lines at least as large as the connection.  
Read operations manual and check local regulations  
U
V
Bottom  
W
X−X  
Y
Front  
Section through X−X  
Rear view  
D
E
F
Cooling airflow  
Exhaust airflow  
Z
Plan view  
Cabinet cooling airflow  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.2 INSTALLATION DRAWING− N37/45K−CC & N50/60H−CC − WATER COOLED  
H
J
INTELLISYS Controller  
KEY  
A
11/2”NPT Air discharge (Female) 60Hz units  
11/2”BSP Air discharge (Female) 50Hz units  
1”NPT Water inlet (Female) 60Hz units  
1”BSP Water inlet (Female) 50Hz units  
B
C
Ø63mm (2.48”) Electrical inlet  
0.38“ NPT (Female)  
K
1”NPT Water outlet (Female) 60Hz units  
1”BSP Water outlet (Female) 50Hz units  
Note: Pipe condensate drain lines separately to an  
open drain due to differences in drain pressures.  
Use drain lines at least as large as the connection.  
Read operations manual and check local  
regulations  
U
Right  
V
Bottom  
W
X−X  
Y
Front  
Section through X−X  
Rear view  
Plan view  
D
E
Cooling airflow  
Z
Exhaust airflow  
F
Cabinet cooling airflow  
G
4 x Ø 13.0mm (0,5”) Compressor should be  
bolted to the floor with four M10 (0.38”) bolts  
using holes shown. Seal base to floor  
with cork or rubber.  
3ꢀ  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.2 INSTALLATION DRAWING − N55/75K−CC & N75/100H−CC − AIR COOLED  
G
4 x Ø 13.0mm (0,5”)  
KEY  
Compressor should be bolted to the floor with  
four M10 (0.38”) bolts using holes shown. Seal  
base to floor with cork or rubber.  
A
2”NPT Air discharge (Female) 60Hz units  
2”BSP Air discharge (Female) 50Hz units  
B
C
Ø63mm (2.48”) Electrical inlet  
H
INTELLISYS Controller  
Right  
0.38“ NPT (Female)  
U
Note: Pipe condensate drain lines separately to an open  
drain due to differences in drain pressures. Use drain  
lines at least as large as the connection. Read operations  
manual and check local regulations  
V
Bottom  
W
X−X  
Y
Front  
Section through X−X  
Rear view  
D
E
F
Cooling airflow  
Exhaust airflow  
Z
Plan view  
Cabinet cooling airflow  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.2 INSTALLATION DRAWING−N55/75K−CC & N75/100H−CC−WATER COOLED  
H
J
INTELLISYS Controller  
KEY  
A
2”NPT Air discharge (Female) 60Hz units  
2”BSP Air discharge (Female) 50Hz units  
1”NPT Water inlet (Female) 60Hz units  
1”BSP Water inlet (Female) 50Hz units  
B
C
Ø63mm (2.48”) Electrical inlet  
0.38“ NPT (Female)  
K
1”NPT Water outlet (Female) 60Hz units  
1”BSP Water outlet (Female) 50Hz units  
Note: Pipe condensate drain lines separately to an  
open drain due to differences in drain pressures.  
Use drain lines at least as large as the connection.  
Read operations manual and check local  
regulations  
U
Right  
V
Bottom  
W
X−X  
Y
Front  
Section through X−X  
Rear view  
Plan view  
D
E
Cooling airflow  
Z
Exhaust airflow  
F
Cabinet cooling airflow  
G
4 x Ø 13.0mm (0,5”)  
Compressor should be bolted to the floor with  
four M10 (0.38”) bolts using holes shown. Seal  
base to floor with cork or rubber.  
36  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.2 INSTALLATION DRAWING − N90/160K − CC SINGLE STAGE & N90/160K −  
CC TWO STAGE − WATER COOLED  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
KEY  
A
2”NPT Air discharge (Female) 60Hz units  
F
Cabinet cooling airflow  
(N100H−N150H)  
2”BSP Air discharge (Female) 50Hz units  
(N75K−N110K)  
G
4 x Ø 13.0mm (0,5”)  
Compressor should be bolted to the floor with  
four M10 (0.38”) bolts using holes shown. Seal  
base to floor with cork or rubber.  
2 1/2”NPT Air discharge (Female) 60Hz units  
(N200H)  
2 1/2”BSP Air discharge (Female) 50Hz units  
(N132K and N160K units)  
H
J
INTELLISYS Controller  
1.5”NPT Water inlet (Female) 60Hz units  
1.5”BSP Water inlet (Female) 50Hz units  
B
C
Electrical inlet −  
Ø75mm (3”)  
Ø64mm 575V (Option)  
K
1.5”NPT Water outlet (Female) 60Hz units  
1.5”BSP Water outlet (Female) 50Hz units  
U
Right  
0.38“ NPT (Female)  
V
Bottom  
Note: Pipe condensate drain lines separately to an open  
drain due to differences in drain pressures. Use drain  
lines at least as large as the connection. Read operations  
manual and check local regulations  
W
X−X  
Y
Front  
Section through X−X  
Rear view  
Plan view  
D
E
Cooling airflow  
Exhaust airflow  
Z
3ꢁ  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.2 INSTALLATION DRAWING − N90/160K, N125/200H SINGLE STAGE &  
N75/160K, N100/200H TWO STAGE − AIR COOLED  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
KEY  
A
2”NPT Air discharge (Female) 60Hz units  
(N100H−N150H)  
2”BSP Air discharge (Female) 50Hz units  
(N75K−N110K)  
E
F
Exhaust airflow  
Cabinet cooling airflow  
G
4 x Ø 13.0mm (0,5”)  
Compressor should be bolted to the floor with  
four M10 (0.38”) bolts using holes shown. Seal  
base to floor with cork or rubber.  
2 1/2”NPT Air discharge (Female) 60Hz units  
(N200H)  
2 1/2”BSP Air discharge (Female) 50Hz units  
(N132K and N160K units)  
H
INTELLISYS Controller  
Right  
U
B
C
Electrical inlet − Ø75mm (3”)  
Ø64mm 575V (Option)  
V
Bottom  
W
X−X  
Y
Front  
0.38“ NPT (Female)  
Section through X−X  
Rear view  
Note: Pipe condensate drain lines separately to an  
open drain due to differences in drain pressures. Use drain  
lines at least as large as the connection. Read operations  
manual and check local regulations  
Z
Plan view  
D
Cooling airflow  
ꢀ0  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.2 INSTALLATION DRAWING − N250/300H TWO STAGE  
G
4 x Ø 14.2mm (0,6”)  
KEY  
A
Compressor should be bolted to the floor with  
four M12 (0.5”) bolts using holes shown. Seal  
base to floor with cork or rubber.  
4”NPT Air discharge (Female)  
B
Electrical inlet −  
Ø75mm (3”)  
H
U
V
W
X
Y
INTELLISYS Controller  
Right  
C
0.50“ NPT (Female)  
Note: Pipe condensate drain lines separately to an  
open drain due to differences in drain pressures. Use drain  
lines at least as large as the connection. Read operations  
manual and check local regulations  
Bottom  
Front  
Left view  
Rear view  
Plan view  
D
E
F
Cooling airflow  
Exhaust airflow  
Z
Cabinet cooling airflow  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.3 PROCESS AND INSTRUMENTATION DIAGRAM N37/45K-CC & N50/60H-CC  
ꢀ2  
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8.0 GENERAL INFORMATION  
KEY  
1
Air discharge  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
Receivers (customer equipment)  
2
Compressor  
Dryer AUX warning  
3
Air filter  
Line filter AUX warning  
4
Vacuum switch 1VAC  
Cooler, air  
Receiver trap AUX warning  
5
Remote pressure transducer 9APT (optional)  
Water stop valve 4SV  
6
Cooler, coolant  
7
Condensate discharge  
Coolant filter  
Typical customer downstream air treatment  
Anti − condensation valve 11SV  
Cooling air exhaust box  
8
9
Pressure switch, coolant filter 1DPS  
Drain valve, coolant  
Temperature switch 1ATS  
Air inlet check valve  
10  
11  
12  
13  
Package discharge temperature transducer 4ATT  
Injected coolant temperature sensor  
Seal scavenge air supply  
Timed solenoid condensate drain.  
(single stage)  
Seal scavenge line  
Air intake temperature sensor. 1ATT  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
Minimum pressure check valve  
Moisture separator  
Electronic drain trap. Alternative to item 13.  
(Standard equipment on 2 stage. Optional on  
single stage).  
Pressure transducer 4APT  
Pressure relief valve  
45  
46  
49  
Interstage pressure relief valve. (2 stage.)  
Interstage pressure transducer. (2 stage)  
Air/Coolant separator element  
Scavenge filter / orifice / check  
Separator tank (primary/secondary)  
Oil temperature control valve  
Temperature transducer 2ATT  
3SV blowdown solenoid valve  
Drive motor  
Air/coolant  
Air  
Coolant  
Condensate  
Blower motor  
Cooling water (W.C. only)  
Cooling air blower  
Compressor enclosure  
Sensor connection  
Cooling water inlet (W.C. only)  
Cooling water outlet (W.C. only)  
Pressure transducer 3APT  
Pressure transducer 6APT  
Dryer (customer supply equipment)  
Line filters (customer equipment)  
Equipment downstream of  
compressor  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.3 PROCESS AND INSTRUMENTATION DIAGRAM N55/75K-CC & N75/100H-CC  
ꢀꢀ  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
KEY  
1
AIR DISCHARGE  
36  
REMOTE AIR PRESSURE TRANSDUCER 9APT  
(OPTIONAL)  
2
COMPRESSOR  
37  
38  
WATER SHUTOFF VALVE 4SV (W.C.ONLY)  
3
AIR FILTER  
TYPICAL CUSTOMER DOWNSTREAM AIR  
TREATMENT  
4
VACUUM SWITCH 1VAC  
COOLER, AIR  
5
39  
40  
41  
ANTI-CONDENSATION VALVE 11SV  
COOLING AIR EXHAUST BOX  
6
COOLER, COOLANT  
7
CONDENSATE DISCHARGE  
COOLANT FILTER (S)  
PACKAGE DISCHARGE AIR TEMPERATURE SENSOR  
4ATT  
8
9
PRESSURE SWITCH, COOLANT FILTER 1DPS  
DRAIN VALVE, COOLANT  
HIGH AIR TEMPERATURE SWITCH 1ATS  
AIR INLET/CHECK VALVE  
42  
INJECTED COOLANT TEMPERATURE SENSOR  
2CTT  
10  
11  
12  
13  
43  
44  
45  
ORIFICE, SEAL SCAVENGE AIR SUPPLY  
SEAL SCAVENGE LINE DRAIN  
TIMED SOLENOID CONDENSATE DRAIN SINGLE  
STAGE UNITS ONLY)  
PACKAGE INTAKE AIR TEMPERATURE SENSOR  
1ATT  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
MINIMUM PRESSURE CHECK VALVE  
MOISTURE SEPARATOR  
46  
ELECTRONIC DRAIN TRAP-ALTERNATIVE TO ITEM  
13 (STANDARD EQUIPMENT ON 2 STAGE  
OPTIONAL ON SINGLE STAGE)  
PRESSURE TRANSDUCER 4APT  
47  
48  
INTERSTAGE PRESSURE RELIEF VALVE (TWO  
STAGE)  
PRESSURE RELIEF VALVE  
SCAVENGE FILTER / ORIFICE / CHECK VALVE  
SEPARATOR TANK (PRIMARY/SECONDARY)  
OIL TEMPERATURE CONTROL VALVE  
TEMPERATURE SENSOR 2ATT  
INTERSTAGE PRESSURE TRANSDUCER (TWO  
STAGE)  
49  
50  
AIR/COOLANT SEPARATOR ELEMENT  
OIL COOLER OUT TEMPERATURE SENSOR 4CTT  
BLOWDOWN SOLENOID VALVE 3SV  
DRIVE MOTOR - VARIABLE SPEED  
MOTOR, BLOWER - VARIABLE SPEED  
COOLING AIR BLOWER  
Air/coolant  
Air  
Coolant  
Condensate  
COOLING WATER INLET (W.C. ONLY)  
COOLING WATER OUTLET (W.C. ONLY)  
PRESSURE TRANSDUCER 3APT (WET)  
PRESSURE TRANSDUCER 6APT (DRY)  
DRYER (CUSTOMER EQUIPMENT)  
LINE FILTERS (CUSTOMER EQUIPMENT)  
RECEIVERS (CUSTOMER EQUIPMENT)  
DRYER AUX WARNING |  
Cooling water (W.C. only)  
Compressor enclosure  
Sensor connection  
Equipment downstream of  
compressor  
LINE FILTER AUX WARNING | AW1 (WIRE IN  
SERIES)  
35  
RECEIVER TRAP AUX WARNING |  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.3 PROCESS AND INSTRUMENTATION DIAGRAM N90/160K &  
N125/200H SINGLE STAGE AND N75/160K & N100/200H TWO STAGE  
ꢀ6  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
KEY  
1
Air discharge  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
Dryer AUX warning  
2
Compressor  
Line filter AUX warning  
3
Air filter  
Receiver trap AUX warning  
4
Vacuum switch 1VAC  
Cooler, air  
Remote pressure transducer 9APT (optional)  
Water stop valve 4SV (W.C. only)  
Typical customer downstream air treatment  
Anti − condensation valve 11SV  
Cooling air exhaust box  
5
6
Cooler, coolant  
7
Condensate discharge  
Coolant filter  
8
9
Pressure switch, coolant filter 1DPS  
Drain valve, coolant  
Temperature switch 1ATS  
Air inlet check valve  
Package discharge temperature transducer 4ATT  
Injection temperature, transducer 2CTT  
Seal scavenge air supply  
10  
11  
12  
13  
Seal scavenge line  
Timed solenoid condensate drain.  
(single stage only)  
Temperature sensor 1ATT  
Electronic drain trap. Alternative to item 13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
Minimum pressure check valve  
Moisture separator  
(Optional on single stage)  
47  
Interstage pressure relief valve. 2 stage.  
Pressure transducer 4APT  
Pressure relief valve  
48  
49  
Interstage pressure transducer. 2 stage  
Element, separator  
50  
51  
Valve, aftercooler trim (W.C. only)  
Scavenge filter / orifice / check  
Separator tank (primary/secondary)  
Oil temperature control valve  
Temperature transducer 2ATT  
3SV blowdown solenoid valve  
Drive motor  
Valve, airend discharge temperature control  
(W.C. only)  
Air/coolant  
Air  
Coolant  
Condensate  
Blower motor  
Cooling air blower  
Cooling water inlet (W.C. only)  
Cooling water outlet (W.C. only)  
Pressure transducer 3APT  
Pressure transducer 6APT  
Dryer (customer supply equipment)  
Line filters (customer equipment)  
Receivers (customer equipment)  
Cooling water (W.C. only)  
Compressor enclosure  
Sensor connection  
Equipment downstream of  
compressor  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.3 PROCESS AND INSTRUMENTATION DIAGRAM N250−300H TWO STAGE  
ꢀꢁ  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
KEY  
1
Air discharge  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
Dryer AUX warning  
2
Compressor  
Line filter AUX warning  
3
Air filter  
Receiver trap AUX warning  
4
Vacuum switch 1VAC  
Remote pressure transducer 9APT (optional)  
Water stop valve 4SV (W.C. only)  
Typical customer downstream air treatment  
Anti − condensation valve 11SV  
Cooling air exhaust box  
5
Cooler, air  
6
Cooler, coolant  
7
Condensate discharge  
Coolant filter  
8
9
Pressure switch, coolant filter 1DPS  
Drain valve, coolant  
Package discharge temperature transducer 4ATT  
Injection temperature, transducer 2CTT  
Orifice, seal scavenge air supply  
Seal scavenge line  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
Temperature switch 1ATS  
Air inlet/adaptor  
Coolant stop solenoid valve 5SV  
Minimum pressure check valve  
Moisture separator  
Temperature sensor 1ATT  
Electronic drain trap  
Interstage pressure relief valve. 2 stage.  
Interstage pressure transducer. 2 stage  
Element, separator  
Pressure transducer 4APT  
Pressure relief valve  
Scavenge filter / orifice / check  
Separator tank (primary/secondary)  
Oil temperature control valve  
Temperature transducer 2ATT  
3SV blowdown solenoid valve  
Drive motor  
Valve, aftercooler trim (W.C. only)  
Valve, airend discharge temperature control  
(W.C. only)  
52  
Airend discharge check valve.  
PIPING LEGEND  
Air/coolant  
Blower motor  
Air  
Cooling air blower  
Coolant  
Cooling water inlet (W.C. only)  
Cooling water outlet (W.C. only)  
Pressure transducer 3APT  
Pressure transducer 6APT  
Dryer (customer supply equipment)  
Line filters (customer equipment)  
Receivers (customer equipment)  
Condensate  
Cooling water (W.C. only)  
Compressor enclosure  
Sensor connection  
Equipment downstream of  
compressor  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.4 WIRING SCHEMATIC N37K − N45K-CC / N50-60H−CC A/C BLOWER VFD  
P
210  
211  
212  
213  
214  
215  
216  
217  
KM5-1  
124  
MCB2  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
1
106  
107  
122  
BLU  
BLK  
MF  
1DPS  
AT  
SG-NE  
BRN  
ES-2  
DVF3  
GRN/YEL  
DVF  
OPT  
A+  
B-  
SC+  
SC-  
SD+  
SD-  
C
1VAC  
RSP  
EXC  
P7  
P3  
FM  
T1  
OV  
PSU  
RFI  
SGN  
CAB  
3SV  
DVF  
L1  
L2  
L3  
PE  
230V  
ES-1  
1ATS  
104  
105  
RST  
MM  
BP  
FD  
103  
1
2
3
4
200/230V-3ph-50/60Hz  
400/460V-3ph-50/60Hz  
K2-1  
P1  
AW1  
110  
KM1  
K1  
AW2  
EB  
L1  
11  
110V 100  
101  
102  
MCB3  
111  
CDE (OPT)  
121  
L3  
12  
120  
T1  
MCB1  
112  
KM5  
1
2
3
4
5
SS1  
SS2  
SS3  
TRR  
WR  
-
2
200V  
P4  
+
+
1
2
MMS  
KM1  
-
16 17 18  
105 (110V)  
PORO  
1
2
6
120  
113  
114  
-
3SV  
L1 L2 L3  
5
6
L1  
L2  
L3  
+
240  
116  
123  
125  
126  
12  
PE  
+24V  
K1-2  
241  
18 START  
11SV  
242  
214  
PE  
DR  
OPT  
STOP  
27  
120  
MCB4  
102  
115  
FD  
1
2
+252  
-253  
120  
4-20 mA  
OUTPUT  
9
K2  
01  
02  
60  
55  
FAULT  
215  
252  
253  
10  
116  
9
9SV  
+
GND  
BLK  
WHI  
YEL  
BLK  
RED  
GRE  
BRO  
BLU  
VIO  
-
PSU  
1
2
3
4
5
6
7
2
3
6
7
RED  
BLK  
DR  
108  
U
V
W
1
RED  
MCB5  
1
2
3
4
5
6
7
8
9
2
3
4
BLK  
WHI  
RED  
BLK  
WHI  
RED  
BLK  
WHI  
V
P1  
200  
201  
12V DC  
4APT  
1
2
1
2
P
P
P
RED  
P2  
P10  
U
W
V
V
V
3APT  
6APT  
BLK  
P5  
FM  
+ DC-BUS  
P5  
GND  
S
E
1
2
RED  
1
2
7
8
U
CK  
BLK  
BLK  
WHI  
10  
11  
12  
V
MM  
+ RECTIFIER  
OUT  
BLK  
3
WHI  
BLK  
RED  
W
ST  
WHI  
BLK  
1
2
3
4
5
6
7
8
SL  
1
2
2CTT  
2ATT  
4ATT  
1ATT  
P8  
P2  
T
T
T
T
1
AO1  
WHI  
WHI  
BLK  
WHI  
BLK  
WHI  
BLK  
A11+  
2
3
4
5
6
7
8
1
2
3
A11-  
A12  
OV  
P6  
CFO  
WHI  
BLK  
4-20mA  
+
-
RED  
WHI  
RED  
+24VDC  
9APT  
P
D11  
D12  
230  
231  
OPT  
K1-1  
ENABLE  
OV  
9
10  
GND  
GND  
TH  
T
23  
100  
20  
22  
KM5-1  
21  
110/120V  
50/60 HZ  
HTR2  
HTR1  
CDV  
OPT  
121  
25  
24  
MCB9  
T1  
PE  
TH  
T
23  
20  
22  
KM5-1  
21  
L
HTR1  
HTR2  
220/230 V  
50/60 HZ  
CDV  
OPT  
22775738  
Revision B  
25  
24  
N
MCB9  
PE  
50  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
KEY  
1ATS  
Switch, high airend discharge temperature  
PSU  
RFI  
RSP  
RST  
Power supply unit  
Filter, radio frequency interference  
Remote stop  
1DPS Switch, fouled oil filter  
1VAC Switch, fouled air filter  
1ATT  
2ATT  
2CTT Sensor, injected coolant temperature  
3APT Transducer, sump pressure, wet side  
Sensor, airend inlet.  
Sensor, airend discharge temperature  
Remote start  
SGNE Controller, Intellisys  
SL Serial link  
SS1−3 Relay, solid state  
3SV  
Valve, blowdown solenoid  
ST  
T1  
TH  
TRR  
WR  
Service tool  
Transformer, control  
Thermostat  
True running relay  
General warning  
Colors  
4APT Transducer, package air discharge pressure  
4ATT  
4SV  
6APT Transducer, sump air pressure, dry side  
9APT Transmitter, remote air pressure (optional)  
Sensor, package discharge temperature  
Valve, water stop solenoid (W/C only)  
9SV  
11SV  
AT  
AW1  
AW2  
BP  
Valve, condensate drain  
Valve, anti − condensation solenoid  
Autotransformer (if fitted)  
Auxiliary warning 1  
Auxiliary warning 2  
Backplate  
BLK  
BLU  
BRO  
GRE  
PIN  
RED  
SCR  
VIO  
Black  
Blue  
Brown  
Green  
Pink  
Red  
Screened  
Violet  
White  
C
Capacitor  
Cabinet  
CAB  
CDE  
CDV  
CFO  
CK  
Condensate drain error  
Condensate drain valve. (if fitted)  
Common fault output  
Choke  
External communications  
Drive  
WHI  
YEL  
Yellow  
Wires  
Numbers  
Function  
Wire color  
EXC  
DR  
1−99  
Power  
Black  
Red  
Blue  
100−199  
200−299  
300−399  
AC Control  
DC Control  
Auxiliary  
DVF  
EB  
ES  
Fan, drive box ventilation  
Earth bar  
Switch, emergency stop  
Drive, blower  
Orange  
FD  
FM  
Motor, blower  
GND  
HC  
Ground  
Heater circuit  
HTR1 Heater, spacer 25 Watts  
HTR2 Heater, spacer 25 Watts  
K1  
Relay, run  
K2  
Relay fault  
KM1  
KM5  
Contactor, main motor  
Contactor, Drive ventilation fan.  
MCB1 Breaker, miniature circuit, transformer  
MCB2 Breaker, miniature circuit, DVFMCB3  
Breaker, miniature circuit, control circuits  
MCB4 Breaker, miniature circuit, VFD supply  
MCB5 Breaker, miniature circuit, PSU  
MCB9 Breaker, miniature circuit, heater  
MF  
Mains filter (if fitted)  
MM  
Motor, main  
MMS Breaker, blower motor  
OPT  
OV  
PE  
Optional  
Zero voltage  
Protected earth  
PORO Power outage restart option (optional)  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
8.4 WIRING SCHEMATIC - N55-75K-CC / N75-100H-CC A/C  
BLOWER VFD  
P
210  
KM5-1  
124  
MCB2  
106  
1
2
107  
122  
BLU  
BLK  
BRN  
MF  
1DPS  
ES-2  
AT  
211  
212  
213  
214  
215  
216  
217  
SG-NE  
3
DVF3  
4
GRN/YEL  
DVF  
5
OPT  
A+  
B-  
C
6
7
1VAC  
RSP  
SC+  
SC-  
SD+  
SD-  
8
EXC  
P7  
P3  
FM  
T1  
L1  
L2  
L3  
9
PE  
10  
11  
12  
13  
14  
15  
16  
17  
18  
1
OV  
230V  
ES-1  
1ATS  
104  
105  
RST  
PSU  
RFI  
MM  
BP  
103  
1
2
3
4
200/230V-3ph-50/60Hz  
400/460V-3ph-50/60Hz  
K2-1  
P1  
AW1  
SGN  
CAB  
3SV  
DVF  
FD  
110  
111  
KM1  
K1  
AW2  
EB  
L1  
11  
110V 100  
121  
101  
102  
120  
MCB3  
CDE (OPT)  
L3  
12  
T1  
MCB1  
112  
KM5  
1
2
SS1  
SS2  
SS3  
TRR  
-
2
200V  
3
P4  
+
+
1
2
4
MMS  
KM1  
WR  
5
-
16 17 18  
L1 L2 L3  
105 (110V)  
PORO  
1
2
6
120  
113  
114  
-
3SV  
5
6
L1  
L2  
L3  
+
240  
116  
125  
126  
12  
PE  
+24V  
18 START  
STOP  
K1-2  
241  
123  
11SV  
242  
214  
PE  
OPT  
27  
120  
MCB4  
102  
115  
DR  
FD  
1
2
+252  
-253  
120  
4-20 mA  
OUTPUT  
9
K2  
01  
02  
60  
55  
FAULT  
215  
252  
10  
116  
9
9SV  
+
-
GND  
BLK  
253  
YEL  
BLK  
RED  
GRE  
BRO  
BLU  
VIO  
PSU  
1
2
3
4
5
6
7
WHI  
2
3
6
7
RED  
BLK  
DR  
108  
U
V
W
1
RED  
MCB5  
1
2
2
3
4
BLK  
WHI  
RED  
BLK  
WHI  
RED  
BLK  
WHI  
V
P1  
200  
201  
12V DC  
4APT  
3APT  
6APT  
1
1
2
P
P
P
3
RED  
P2  
P10  
U
W
V
4
2
V
V
5
BLK  
P5  
6
FM  
+ DC-BUS  
P5  
GND  
S
E
7
1
2
RED  
1
2
7
8
8
U
V
CK  
BLK  
BLK  
WHI  
9
10  
11  
12  
MM  
+ RECTIFIER  
OUT  
BLK  
WHI  
BLK  
RED  
3
W
ST  
WHI  
BLK  
1
2
SL  
1
2
2CTT  
2ATT  
4ATT  
1ATT  
4CTT  
P8  
P2  
T
T
T
T
T
1
2
3
4
5
6
7
8
AO1  
A11+  
A11-  
A12  
OV  
WHI  
WHI  
BLK  
3
1
2
3
4
P6  
WHI  
BLK  
WHI  
BLK  
WHI  
BLK  
CFO  
WHI  
BLK  
5
6
4-20mA  
+
RED  
WHI  
RED  
7
+24VDC  
D11  
9APT  
OPT  
-
P
8
230  
231  
D12  
9
K1-1  
ENABLE  
9
10  
10  
OV  
GND  
GND  
TH  
T
23  
100  
20  
22  
KM5-1  
21  
110/120V  
50/60 HZ  
HTR2  
HTR1  
CDV  
OPT  
121  
25  
24  
MCB9  
T1  
PE  
TH  
T
23  
20  
22  
21  
KM5-1  
L
HTR1  
HTR2  
220/230 V  
50/60 HZ  
CDV  
OPT  
25  
24  
N
23131337  
Revision A  
MCB9  
PE  
LABEL DESCRIPTION  
LABEL DESCRIPTION  
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE  
3SV VALVE, BLOWDOWN SOLENOID  
1ATS  
SWITCH, HIGH AIR END DISCHARGE  
TEMPERATURE  
1DPS SWITCH, FOULED OIL FILTER  
1VAC SWITCH, FOULED AIR FILTER  
4APT TRANSDUCER, PACKAGE AIR DISCHARGE  
PRESSURE  
1ATT  
2ATT  
SENSOR, AIREND INLET  
SENSOR, AIREND DISCHARGE TEMPERATURE  
4ATT  
SENSOR, PACKAGE AIR DISCHARGE  
TEMPERATURE  
4CTT SENSOR, OIL COOLER OUT TEMPERATURE  
2CTT SENSOR, INJECTED COOLENT TEMPERATURE  
52  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
KEY  
4SV  
VALVE, WATER STOP SOLENOID (W/C ONLY)  
T1  
TRANSFORMER, CONTROL  
6APT TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE  
9APT TRANSMITTER, REMOTE AIR PRESSURE  
(OPTIONAL)  
TH  
TRR  
WR  
THERMOSTAT  
TRUE RUNNING  
GENERAL WARNING  
9SV  
11SV  
AT  
AW1  
AW2  
BP  
VALVE, CONDENSATE DRAIN  
VALVE, ANTI-CONDENSATION SOLENOID  
AUTOTRANSFORMER (IF FITTED)  
AUXILIARY WARNING 1  
AUXILIARY WARNING 2  
BACKPLATE  
COLORS  
BLK  
BLU  
BLACK  
BLUE  
BRO  
GRE  
PIN  
BROWN  
GREEN  
PINK  
C
CAPACITOR  
CAB  
CDE  
CDV  
CFO  
CK  
CABINET  
RED  
SCR  
VIO  
WHI  
YEL  
RED  
CONDENSATE DRAIN ERROR  
CONDENSATE DRAIN VALVE (IF FITTED)  
COMMON FAULT OUTPUT  
CHOKE  
SCREEN  
VIOLET  
WHITE  
YELLOW  
EXC  
DR  
DVF  
EB  
ES  
FD  
EXTERNAL COMMUNICATIONS  
DRIVE  
FAN, DRIVE BOX VENTILATION  
EARTH BAR  
SWITCH, EMERGENCY STOP  
DRIVE, BLOWER  
MOTOR, BLOWER  
Wires  
Numbers  
Function  
Wire color  
1−99  
Power  
Black  
Red  
Blue  
100−199  
200−299  
300−399  
NOTES:  
AC Control  
DC Control  
Auxiliary  
Orange  
FM  
GND  
GROUND  
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO  
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER  
100 & 121.  
HTR1 HEATER, SPACER 25 WATTS  
HTR2 HEATER, SPACER 25 WATTS  
K1  
RELAY, RUN  
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN  
K2  
RELAY, FAULT  
INDEPENDENT SOURCE: IN THAT CASE, FACTORY  
SUPPLIED CONNECTION MUST BE DISCONNECTED.  
KM1  
KM5  
CONTACTOR, MAIN MOTOR  
CONTACTOR, DRIVE VENTILATION FAN  
3. ENSURE PARALLEL CONNECTION OF HEATERS.  
MCB1 BREAKER, MINIATURE CIRCUIT, TRANSFORMER  
MCB2 BREAKER, MINIATURE CIRCUIT, DVF  
MCB3 BREAKER, MINIATURE CIRCUIT, CONTROL  
CIRCUITS  
MCB4 BREAKER, MINIATURE CIRCUIT, VFD SUPPLY  
MCB5 BREAKER, MINATURE CIRCUIT, PSU  
MCB9 BREAKER, MINIATURE CIRCUIT, HEATERS  
NOTES:  
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE  
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE  
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT  
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN  
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE  
DISCONNECTED.  
MF  
MAINS FILTER (IF FITTED)  
MM  
MOTOR, MAIN  
2. ENSURE SERIES CONNECTION OF HEATERS.  
MMS BREAKER, FAN MOTOR  
OPT  
OV  
PE  
OPTIONAL  
ZERO VOLTAGE  
PROTECTED EARTH  
PORO POWER OUTAGE RESTART OPTION (OPTIONAL)  
PSU  
RFI  
RSP  
RST  
POWER SUPPLY UNIT  
FILTER, RADIO FREQUENCY INTERFERENCE  
REMOTE STOP  
REMOTE START  
SGNE CONTROLLER, INTELLISYS  
SL SERIAL LINK  
SS1-3 RELAY, SOLID STATE  
ST SERVICE TOOL  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
53  
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8.0 GENERAL INFORMATION  
8.4 WIRING SCHEMATIC - N37/45K-CC/N50/60H-CC W/C  
KM5-1  
124  
106  
107  
122  
BLU  
BLK  
MCB5  
BRN  
GRN/YEL  
DVF3  
MF  
DVF  
AT  
C
P
210  
211  
212  
213  
214  
215  
216  
217  
1
2
OPT  
1DPS  
ES-2  
SGNE  
3
4
FM  
T1  
L1  
L2  
L3  
5
MMS-1  
PE  
A+  
B-  
6
OV  
7
230V  
1VAC  
RSP  
SC+  
SC-  
SD+  
SD-  
PSU  
RFI  
MM  
BP  
8
EXC  
P7  
P3  
200/230V-3ph-50/60Hz  
400/460V-3ph-50/60Hz  
9
SGN  
CAB  
3SV  
4SV  
10  
11  
12  
13  
14  
15  
16  
17  
18  
ES-1  
1ATS  
104  
105  
RST  
EB  
11  
L1  
L3  
110V 100  
121  
101  
102  
120  
103  
1
2
MCB3  
K2-1  
P1  
AW1  
9SV  
DVF  
12  
110  
KM1  
T1  
MCB1  
AW2  
200V  
CDE (OPT)  
MMS  
4SV  
K1  
KM1  
1
2
3
4
5
6
111  
16 17 18  
1
3
4
SS1  
SS2  
SS3  
TRR  
-
2
L3  
L2  
L1  
P4  
+
+
1
2
112  
KM4  
125  
126  
WR  
116  
KM4  
KM5  
123  
-
105 (110V)  
PORO  
1
2
PE  
DR  
MCB4  
-
102  
115  
1
2
+
U
W
120  
V
K2  
120  
113  
114  
3SV  
5
6
OPT  
120  
FM  
YEL  
GND  
11SV  
RED  
BLK  
4-20 mA  
OUTPUT  
9
2
3
1
2
3
4
5
6
BLK  
DR  
10  
116  
RED  
GRE  
9
6
7
9SV  
BLK  
PSU  
BRO  
BLU  
WHI  
108  
1
RED  
MCB5  
1
2
VIO  
2
3
4
BLK  
WHI  
RED  
BLK  
WHI  
RED  
BLK  
WHI  
V
7
P1  
200  
201  
12V DC  
4APT  
3APT  
6APT  
1
1
2
P
P
P
+ DC-BUS  
3
GND  
S
E
RED  
P2  
P10  
1
2
4
2
U
V
V
CK  
5
BLK  
P5  
6
P5  
V
+ RECTIFIER  
OUT  
MM  
7
RED  
3
1
2
7
8
8
W
BLK  
BLK  
WHI  
9
10  
11  
12  
AO1  
A11+  
A11-  
A12  
OV  
1
2
3
4
BLK  
WHI  
BLK  
RED  
WHI  
ST  
WHI  
BLK  
WHI  
BLK  
1
2
3
4
5
6
7
8
SL  
1
2
2CTT  
2ATT  
4ATT  
P8  
P2  
T
T
T
5
6
WHI  
BLK  
4-20mA  
+
RED  
WHI  
RED  
+24VDC  
D11  
9APT  
OPT  
1
2
3
-
P
7
P6  
WHI  
BLK  
CFO  
230  
231  
D12  
8
K1-1  
ENABLE  
9
10  
OV  
GND  
GND  
TH  
T
23  
100  
20  
22  
KM5-1  
21  
110/120V  
50/60 HZ  
HTR2  
HTR1  
CDV  
OPT  
121  
25  
24  
MCB9  
T1  
PE  
TH  
T
23  
20  
22  
KM5-1  
21  
L
HTR1  
HTR2  
220/230 V  
50/60 HZ  
CDV  
OPT  
22776520  
Revision B  
25  
24  
N
MCB9  
PE  
5ꢀ  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
KEY  
1ATS  
SWITCH, HIGH AIR END DISCHARGE  
TEMPERATURE  
MMS BREAKER, FAN MOTOR  
OPT  
OV  
PE  
OPTIONAL  
ZERO VOLTAGE  
PROTECTED EARTH  
1DPS SWITCH, FOULED OIL FILTER  
1VAC SWITCH, FOULED AIR FILTER  
1ATT  
2ATT  
SENSOR, AIREND INLET  
SENSOR, AIREND DISCHARGE TEMPERATURE  
PORO POWER OUTAGE RESTART OPTION (OPTIONAL)  
PSU  
RFI  
RSP  
RST  
POWER SUPPLY UNIT  
FILTER, RADIO FREQUENCY INTERFERENCE  
REMOTE STOP  
2CTT SENSOR, INJECTED COOLENT TEMPERATURE  
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE  
3SV  
VALVE, BLOWDOWN SOLENOID  
REMOTE START  
4APT TRANSDUCER, PACKAGE AIR DISCHARGE  
PRESSURE  
SGNE CONTROLLER, INTELLISYS  
SL SERIAL LINK  
SS1-3 RELAY, SOLID STATE  
4ATT  
SENSOR, PACKAGE AIR DISCHARGE  
TEMPERATURE  
ST  
SERVICE TOOL  
4SV  
VALVE, WATER STOP SOLENOID (W/C ONLY)  
T1  
TH  
TRANSFORMER, CONTROL  
THERMOSTAT  
6APT TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE  
9APT TRANSMITTER, REMOTE AIR PRESSURE  
(OPTIONAL)  
TRR  
WR  
TRUE RUNNING  
GENERAL WARNING  
9SV  
11SV  
AT  
AW1  
AW2  
BP  
VALVE, CONDENSATE DRAIN  
VALVE, ANTI-CONDENSATION SOLENOID  
AUTOTRANSFORMER (IF FITTED)  
AUXILIARY WARNING 1  
AUXILIARY WARNING 2  
BACKPLATE  
COLOR  
BLK  
BLU  
BRO  
GRE  
PIN  
BLACK  
BLUE  
BROWN  
GREEN  
PINK  
C
CAPACITOR  
RED  
SCR  
VIO  
WHI  
YEL  
Wires  
RED  
CAB  
CDE  
CDV  
CFO  
CK  
CABINET  
SCREEN  
VIOLET  
WHITE  
YELLOW  
CONDENSATE DRAIN ERROR  
CONDENSATE DRAIN VALVE (IF FITTED)  
COMMON FAULT OUTPUT  
CHOKE  
EXC  
DR  
EXTERNAL COMMUNICATIONS  
DRIVE  
Numbers  
Function  
Wire color  
DVF  
EB  
ES  
FD  
FM  
FAN, DRIVE BOX VENTILATION  
EARTH BAR  
SWITCH, EMERGENCY STOP  
DRIVE, BLOWER (A/C ONLY)  
MOTOR, BLOWER  
1−99  
Power  
Black  
Red  
Blue  
100−199  
200−299  
300−399  
NOTES:  
AC Control  
DC Control  
Auxiliary  
Orange  
GND  
GROUND  
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO  
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER  
100 & 121.  
HTR1 HEATER, SPACER 25 WATTS  
HTR2 HEATER, SPACER 25 WATTS  
K1  
RELAY, RUN  
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN  
K2  
RELAY, FAULT  
INDEPENDENT SOURCE: IN THAT CASE, FACTORY  
SUPPLIED CONNECTION MUST BE DISCONNECTED.  
KM1  
KM4  
KM5  
CONTACTOR, MAIN MOTOR  
CONTACTOR, FAN MOTOR (W/C ONLY)  
CONTACTOR, DRIVE VENTILATION FAN  
3. ENSURE PARALLEL CONNECTION OF HEATERS.  
MCB1 BREAKER, MINIATURE CIRCUIT, TRANSFORMER  
MCB2 BREAKER, MINIATURE CIRCUIT, DVF  
MCB3 BREAKER, MINIATURE CIRCUIT, VFD SUPPLY  
MCB4 BREAKER, MINIATURE CIRCUIT, VFD SUPPLY  
MCB5 BREAKER, MINIATURE CIRCUIT, PSU  
NOTES:  
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE  
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE  
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT  
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN  
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE  
DISCONNECTED.  
MCB9 BREAKER, MINIATURE CIRCUIT, HEATERS  
MF  
MAINS FILTER (IF FITTED)  
MM  
MOTOR, MAIN  
2. ENSURE SERIES CONNECTION OF HEATERS.  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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55  
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8.0 GENERAL INFORMATION  
8.4 WIRING SCHEMATIC - N55-75K-CC / N75-100H-CC W/C  
KM5-1  
124  
MCB5  
106  
107  
122  
BLU  
BLK  
BRN  
GRN/YEL  
DVF3  
MF  
DVF  
AT  
C
P
210  
211  
212  
213  
214  
215  
216  
217  
1
2
OPT  
1DPS  
ES-2  
SGNE  
3
4
FM  
T1  
L1  
L2  
L3  
5
MMS-1  
PE  
A+  
B-  
6
OV  
7
230V  
1VAC  
RSP  
SC+  
SC-  
SD+  
SD-  
PSU  
RFI  
MM  
BP  
8
EXC  
P7  
P3  
200/230V-3ph-50/60Hz  
400/460V-3ph-50/60Hz  
9
SGN  
CAB  
3SV  
4SV  
10  
11  
12  
13  
14  
15  
16  
17  
18  
ES-1  
1ATS  
104  
105  
RST  
EB  
11  
L1  
L3  
110V 100  
121  
101  
102  
120  
103  
1
2
MCB3  
K2-1  
P1  
AW1  
9SV  
DVF  
12  
110  
KM1  
T1  
MCB1  
AW2  
200V  
CDE (OPT)  
MMS  
4SV  
K1  
KM1  
1
2
3
4
5
6
111  
16 17 18  
1
3
4
SS1  
SS2  
SS3  
TRR  
-
2
L3  
L2  
L1  
P4  
+
+
1
2
112  
KM4  
125  
126  
WR  
116  
KM4  
KM5  
123  
-
105 (110V)  
PORO  
1
2
PE  
DR  
MCB4  
-
102  
115  
1
2
+
U
W
120  
V
K2  
120  
113  
114  
3SV  
5
6
OPT  
120  
FM  
YEL  
GND  
11SV  
RED  
BLK  
4-20 mA  
OUTPUT  
9
2
3
1
2
3
4
5
6
BLK  
DR  
10  
116  
RED  
GRE  
9
6
7
9SV  
BLK  
PSU  
BRO  
BLU  
WHI  
108  
1
RED  
MCB5  
1
2
VIO  
2
3
4
BLK  
WHI  
RED  
BLK  
WHI  
RED  
BLK  
WHI  
V
7
P1  
200  
201  
12V DC  
4APT  
3APT  
6APT  
1
1
2
P
P
P
+ DC-BUS  
3
GND  
S
E
RED  
P2  
P10  
1
2
4
2
U
V
V
CK  
5
BLK  
P5  
6
P5  
V
+ RECTIFIER  
OUT  
MM  
7
RED  
3
1
2
7
8
8
W
BLK  
BLK  
WHI  
9
10  
11  
12  
AO1  
A11+  
A11-  
A12  
OV  
1
2
3
4
BLK  
WHI  
BLK  
RED  
WHI  
ST  
WHI  
BLK  
WHI  
BLK  
1
2
SL  
1
2
2CTT  
2ATT  
4ATT  
P8  
P2  
T
T
T
5
6
WHI  
BLK  
4-20mA  
+
RED  
WHI  
RED  
3
+24VDC  
D11  
9APT  
1
2
3
-
P
4
7
P6  
WHI  
BLK  
CFO  
OPT  
230  
231  
5
D12  
8
K1-1  
6
ENABLE  
9
7
10  
OV  
8
GND  
GND  
WHI  
BLK  
9
4CTT  
T
10  
TH  
T
23  
100  
20  
22  
KM5-1  
21  
110/120V  
50/60 HZ  
HTR2  
HTR1  
CDV  
OPT  
121  
25  
24  
MCB9  
T1  
PE  
TH  
T
23  
20  
22  
KM5-1  
21  
L
23131345  
Revision A  
HTR1  
HTR2  
220/230 V  
50/60 HZ  
CDV  
OPT  
25  
24  
N
MCB9  
PE  
56  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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8.0 GENERAL INFORMATION  
KEY  
1ATS  
SWITCH, HIGH AIR END DISCHARGE  
TEMPERATURE  
MM  
MOTOR, MAIN  
MMS BREAKER, FAN MOTOR  
1DPS SWITCH, FOULED OIL FILTER  
1VAC SWITCH, FOULED AIR FILTER  
OPT  
OV  
PE  
OPTIONAL  
ZERO VOLTAGE  
PROTECTED EARTH  
1ATT  
2ATT  
SENSOR, AIREND INLET  
SENSOR, AIREND DISCHARGE TEMPERATURE  
PORO POWER OUTAGE RESTART OPTION (OPTIONAL)  
2CTT SENSOR, INJECTED COOLENT TEMPERATURE  
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE  
PSU  
RFI  
RSP  
RST  
POWER SUPPLY UNIT  
FILTER, RADIO FREQUENCY INTERFERENCE  
REMOTE STOP  
3SV  
VALVE, BLOWDOWN SOLENOID  
4APT TRANSDUCER, PACKAGE AIR DISCHARGE  
PRESSURE  
REMOTE START  
SGNE CONTROLLER, INTELLISYS  
SL SERIAL LINK  
SS1-3 RELAY, SOLID STATE  
ST  
T1  
TH  
TRR  
WR  
COLOR  
BLK  
BLU  
BRO  
GRE  
PIN  
RED  
SCR  
VIO  
WHI  
YEL  
Wires  
4ATT  
SENSOR, PACKAGE AIR DISCHARGE  
TEMPERATURE  
4CTT SENSOR, OIL COOLER OUT TEMPERATURE  
4SV VALVE, WATER STOP SOLENOID (W/C ONLY)  
6APT TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE  
9APT TRANSMITTER, REMOTE AIR PRESSURE  
(OPTIONAL)  
SERVICE TOOL  
TRANSFORMER, CONTROL  
THERMOSTAT  
TRUE RUNNING  
GENERAL WARNING  
9SV  
11SV  
AT  
AW1  
AW2  
BP  
VALVE, CONDENSATE DRAIN  
VALVE, ANTI-CONDENSATION SOLENOID  
AUTOTRANSFORMER (IF FITTED)  
AUXILIARY WARNING 1  
AUXILIARY WARNING 2  
BACKPLATE  
BLACK  
BLUE  
BROWN  
GREEN  
PINK  
C
CAPACITOR  
RED  
CAB  
CDE  
CDV  
CFO  
CK  
CABINET  
SCREEN  
VIOLET  
WHITE  
YELLOW  
CONDENSATE DRAIN ERROR  
CONDENSATE DRAIN VALVE (IF FITTED)  
COMMON FAULT OUTPUT  
CHOKE  
EXC  
DR  
EXTERNAL COMMUNICATIONS  
DRIVE  
Numbers  
Function  
Wire color  
DVF  
EB  
ES  
FD  
FM  
FAN, DRIVE BOX VENTILATION  
EARTH BAR  
SWITCH, EMERGENCY STOP  
DRIVE, BLOWER (A/C ONLY)  
MOTOR, BLOWER  
1−99  
Power  
Black  
Red  
Blue  
100−199  
200−299  
300−399  
NOTES:  
AC Control  
DC Control  
Auxiliary  
Orange  
GND  
GROUND  
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO  
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER  
100 & 121.  
HTR1 HEATER, SPACER 25 WATTS  
HTR2 HEATER, SPACER 25 WATTS  
K1  
RELAY, RUN  
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN  
K2  
RELAY, FAULT  
INDEPENDENT SOURCE: IN THAT CASE, FACTORY  
SUPPLIED CONNECTION MUST BE DISCONNECTED.  
KM1  
KM4  
KM5  
CONTACTOR, MAIN MOTOR  
CONTACTOR, FAN MOTOR (W/C ONLY)  
CONTACTOR, DRIVE VENTILATION FAN  
3. ENSURE PARALLEL CONNECTION OF HEATERS.  
NOTES:  
MCB1 BREAKER, MINIATURE CIRCUIT, TRANSFORMER  
MCB2 BREAKER, MINIATURE CIRCUIT, DVF  
MCB3 BREAKER, MINIATURE CIRCUIT, VFD SUPPLY  
MCB4 BREAKER, MINIATURE CIRCUIT, VFD SUPPLY  
MCB5 BREAKER, MINIATURE CIRCUIT, PSU  
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE  
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE  
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT  
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN  
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE  
DISCONNECTED.  
MCB9 BREAKER, MINIATURE CIRCUIT, HEATERS  
MF  
MAINS FILTER (IF FITTED)  
2. ENSURE SERIES CONNECTION OF HEATERS.  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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57  
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8.0 GENERAL INFORMATION  
8.4 WIRING SCHEMATIC - N75-160K-CC / N125-200H-CC A/C  
L1  
L2  
L3  
PE  
P
210  
211  
212  
213  
214  
215  
216  
217  
EB  
380-480V  
50/60 Hz 3ph + PE  
1
2
L1  
L3  
1
2
1DPS  
ES-2  
SG-Ne  
3
1
2
3
4
5
6
A+  
B-  
4
214A  
214B  
MCB1  
5
SC+  
SC-  
SD+  
SD-  
MMS1-1  
1VAC  
RSP  
MMS2-1  
EXC  
P7  
6
KM1  
7
8
P3  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
ES-1  
1ATS  
104  
105  
103  
RST  
1
2
3
4
5
6
SHT 2  
K2-1  
P1  
AW1  
110  
111  
KM1  
K1  
101  
102  
110v  
MMS2  
AW2  
MCB2  
13 14 15  
121  
120  
CDE (OPT)  
1
2
112  
113  
114  
KM5  
1
2
3
4
5
6
KM5  
3SV  
11SV  
1
2
SS1  
SS2  
SS3  
TRR  
-
U
V
W
151  
200v 150  
153  
120  
P4  
+
1
2
WR  
+
HB  
105 (110V)  
-
T1  
1
2
MCB3  
-
+
L1  
L2  
L3  
PORO  
120  
MMS1  
152  
151  
OPT  
16 17 18  
+12V  
253  
252  
L1 L2 L3  
9
10  
4-20 mA  
OUTPUT  
240  
2
7
8
9
9SV  
9
SIGNAL  
K1-2  
116  
102  
123  
DR  
BLK  
1
2
242  
120  
FD  
WHI  
K2  
PSU  
241  
200  
201  
12V DC  
RED  
108  
214  
215  
252  
253  
1
1
1
2
1
2
11  
12  
20  
21  
MCB4  
BLK  
WHI  
RED  
BLK  
WHI  
RED  
BLK  
WHI  
V
V
V
V
FAULT  
RED  
BLK  
2
3
P1  
P2  
P10  
4APT  
P
2
3
-
+
4
+
-
+ DC-BUS  
RECTIFIER  
5
3APT  
P
CK  
U
V
W
6
RED  
BLK  
BLK  
WHI  
1
2
7
8
P5  
7
8
6APT  
P
GND  
U
W
9
V
BLK  
WHI  
BLK  
RED  
RED  
BLK  
RED  
BLK  
10  
11  
12  
2
3
6
7
2APT  
2 STG  
ONLY  
YEL  
BLK  
RED  
GRE  
BRO  
BLU  
VIO  
ST  
1
2
3
4
5
6
7
SL  
1
2
WHI  
P
FM  
P8  
WHI  
BLK  
1
2
1
2CTT  
2ATT  
4ATT  
1ATT  
4CTT  
T
T
T
T
T
GND  
WHI  
BLK  
1
2
3
231  
3
1
2
0V  
CFO  
4-20mA  
-
WHI  
RED  
4
9APT  
OPT  
ENABLE  
DI2  
P6  
WHI  
BLK  
WHI  
BLK  
WHI  
BLK  
K1-1 1-STG ONLY  
K1-1 2-STG ONLY  
230  
230  
RED  
5
+
P
3
P2  
6
4
GND  
U
DI1  
7
5
1
2
3
+24Vdc  
0V  
BLK  
WHI  
8
6
9
7
AI2  
V
MM  
10  
8
AI1-  
WHI  
9
AI1+  
AO1  
W
10  
HEATER CIRCUITS:-  
MAIN INPUT  
TERMINALS  
OPTIONS  
TH  
T
KM5-2  
21  
22  
23  
100  
MCB9  
MAINS FILTER  
AUTO - TRANSFORMER  
L1  
L2  
L3  
LINE  
STANDARD HEATER  
CONNECTIONS AS  
DELIVERED  
110/120 V  
50/60 HZ  
FROM SHT 1  
MF  
OR  
CDV  
OPT  
HTR1  
HTR2  
LOAD  
L2  
L1  
L3  
AT  
L1  
L2  
L3  
L1  
L2  
L3  
121  
SUPPLIED BY CUSTOMER  
TH  
T
KM5-2  
22  
23  
MCB10  
OR  
F10  
ALTERNATIVE HEATER  
CONNECTION FOR EXTERNAL  
110 / 120 V SUPPLY  
110/120 V  
50/60 HZ  
EXTERNAL SUPPLY  
HTR1  
HTR2  
100  
MCB9  
21  
110/120 V  
50/60 HZ  
CDV  
OPT  
SUPPLIED BY CUSTOMER  
FROM SHT 1  
TH  
T
121  
KM5-2  
22  
23  
MCB10  
OR  
121  
F10  
ALTERNATIVE HEATER  
CONNECTION FOR EXTERNAL  
220 / 230 V SUPPLY  
220/230 V  
50/60 HZ  
EXTERNAL SUPPLY  
22093058  
Revision M  
HTR1  
HTR2  
5ꢁ  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
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8.0 GENERAL INFORMATION  
KEY  
1ATS  
SWITCH, HIGH AIR END DISCHARGE  
MM  
MOTOR, MAIN  
TEMPERATURE  
SENSOR, INLET TEMPERATURE  
MMS1 BREAKER, FAN MOTOR  
MMS2 BREAKER, HEATSINK BLOWER  
1ATT  
1DPS SWITCH, FOULED OIL FILTER  
1VAC SWITCH, FOULED AIR FILTER  
2APT SENSOR, INTERSTAGE PRESSURE (2STG ONLY)  
OPT  
OV  
PE  
OPTIONAL  
ZERO VOLTAGE  
PROTECTIVE EARTH  
2ATT  
SENSOR, AIREND DISCHARGE TEMPERATURE  
PORO POWER OUTAGE RESTART OPTION (OPTIONAL)  
2CTT SENSOR, INJECTED COOLENT TEMPERATURE  
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE  
PSU  
RFI  
RSP  
RST  
POWER SUPPLY UNIT  
FILTER, RADIO FREQUENCY INTERFERENCE  
REMOTE STOP  
3SV  
VALVE, BLOWDOWN SOLENOID  
4APT TRANSDUCER, PACKAGE AIR DISCHARGE  
PRESSURE  
REMOTE START  
SGNe CONTROLLER, INTELLISYS  
SL SERIAL LINK  
SS1-3 RELAY, SOLID STATE  
4ATT  
SENSOR, PACKAGE AIR DISCHARGE  
TEMPERATURE  
4CTT SENSOR, OIL COOLER OUT TEMPERATURE  
6APT TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE  
9APT TRANSDUCER, REMOTE AIR PRESSURE  
(OPTIONAL)  
ST  
T1  
TH  
SERVICE TOOL  
TRANSFORMER, CONTROL  
THERMOSTAT  
TRR  
COLOR  
BLK  
BLU  
BRO  
GRE  
PIN  
RED  
SCR  
VIO  
TRUE RUNNING  
9SV  
11SV  
AT  
AW1  
AW2  
BP  
VALVE, CONDENSATE DRAIN  
VALVE, ANTI-CONDENSATION SOLENOID 1  
AUTOTRANSFORMER (IF FITTED)  
AUXILIARY WARNING 1  
AUXILIARY WARNING 2  
BACKPLATE  
BLACK  
BLUE  
BROWN  
GREEN  
PINK  
C
CAPACITOR  
RED  
CAB  
CDE  
CDV  
CFO  
CK  
CABINET  
SCREEN  
VIOLET  
WHITE  
YELLOW  
CONDENSATE DRAIN ERROR (OPTIONAL)  
CONDENSATE DRAIN VALVE (IF FITTED)  
COMMON FAULT OUTPUT  
CHOKE  
WHI  
YEL  
Wires  
DR  
DRIVE  
EB  
EARTH BAR  
Numbers  
Function  
Wire color  
ES  
SWITCH, EMERGENCY STOP  
EXTERNAL COMMUNICATIONS  
FUSE, EXTERNAL HEATER SUPPLY  
FAN DRIVE  
1−99  
Power  
Black  
Red  
Blue  
EXC  
F10  
FD  
100−199  
200−299  
300−399  
NOTES:  
AC Control  
DC Control  
Auxiliary  
Orange  
FM  
MOTOR, BLOWER  
GND  
HB  
GROUND  
HEATSINK BLOWER  
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO  
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER  
100 & 121.  
HTR1 HEATER, 125 WATTS  
K1  
RELAY, RUN  
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN  
K2  
KM1  
KM5  
RELAY, FAULT  
CONTACTOR, MAIN MOTOR  
CONTACTOR, HEATSINK BLOWER  
INDEPENDENT SOURCE: IN THAT CASE, FACTORY  
SUPPLIED CONNECTION MUST BE DISCONNECTED.  
3. ENSURE PARALLEL CONNECTION OF HEATERS.  
MCB1 BREAKER, MINIATURE CIRCUIT, TRANSFORMER  
MCB2 BREAKER, MINIATURE CIRCUIT, CONTROL  
CIRCUITS  
MCB3 BREAKER, MINIATURE CIRCUIT, DR  
MCB4 BREAKER, MINIATURE CIRCUIT, PSU  
MCB9 BREAKER, MINIATURE CIRCUIT, HEATER  
MCB10 BREAKER, MINIATURE CIRCUIT, HEATER  
(EXTERNAL)  
NOTES:  
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE  
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE  
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT  
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN  
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE  
DISCONNECTED.  
2. ENSURE SERIES CONNECTION OF HEATERS.  
MF  
MAINS FILTER (IF FITTED)  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
5ꢂ  
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8.0 GENERAL INFORMATION  
8.4 WIRING SCHEMATIC - N75-160K-CC / N125-200H-CC W/C  
L1  
L2  
L3  
PE  
EB  
380-480V  
50/60 Hz 3ph + PE  
L1  
L3  
1
2
P
210  
211  
212  
213  
214  
1
2
MCB1  
1DPS  
ES-2  
SG-Ne  
1
2
3
4
5
6
A+  
B-  
3
KM1  
4
214A  
SC+  
SC-  
SD+  
SD-  
5
EXC  
P7  
215 MMS1-1  
MMS2-1  
6
216  
217  
7
1VAC  
RSP  
SHT 2  
8
P3  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
ES-1  
1ATS  
KM5  
104  
105  
101  
102  
120  
103  
RST  
110v  
1
2
MCB2  
K2-1  
P1  
15  
121  
AW1  
AW2  
110  
111  
14  
KM1  
K1  
13  
1
2
3
CDE (OPT)  
MMS2  
MMS1  
151  
200v 150  
153  
U
V
W
U
V
W
1
2
3
4
5
6
1
4SV  
KM5  
3SV  
11SV  
9SV  
SS1  
SS2  
SS3  
T1  
TRR  
-
2
MCB3  
P4  
+
+
1
2
HB  
FM  
112  
113  
114  
WR  
L1  
L2  
L3  
4
5
6
9
102 (110V)  
-
152  
151  
1
2
-
120  
+
PORO  
120  
OPT  
102  
123  
DR  
1
2
120  
9
K2  
10  
BLK  
4-20 mA  
OUTPUT  
116  
WHI  
PSU  
RED  
BLK  
WHI  
RED  
BLK  
WHI  
RED  
BLK  
WHI  
RED  
BLK  
WHI  
200  
201  
12V DC  
1
2
108  
+
-
+ DC-BUS  
RECTIFIER  
1
1
1
2
V
MCB4  
4APT  
P
CK  
RED  
BLK  
2
3
P1  
P2  
P10  
3
2
4
V
V
V
5
3APT  
P
6
GND  
P5  
RED  
BLK  
BLK  
WHI  
1
2
7
8
7
2
3
6
7
8
6APT  
P
RED  
BLK  
YEL  
9
1
BLK  
WHI  
BLK  
RED  
BLK  
RED  
GRE  
BRO  
BLU  
VIO  
10  
11  
12  
2APT  
2 STG  
ONLY  
2
3
4
5
6
7
ST  
P
SL  
1
2
1
P8  
GND  
WHI  
BLK  
231  
1
2
1
2
0V  
2CTT  
2ATT  
4ATT  
1ATT  
4CTT  
T
T
T
T
T
4-20mA  
-
WHI  
RED  
9APT  
OPT  
ENABLE  
DI2  
WHI  
BLK  
K1-1 1-STG ONLY  
K1-1 2-STG ONLY  
230  
230  
RED  
1
2
3
3
+
P
3
CFO  
4
4
GND  
U
DI1  
P6  
WHI  
BLK  
WHI  
BLK  
WHI  
BLK  
5
5
1
2
3
+24Vdc  
0V  
BLK  
WHI  
P2  
6
6
7
7
AI2  
V
8
MM  
8
AI1-  
WHI  
9
9
AI1+  
AO1  
W
10  
10  
MAIN INPUT  
TERMINALS  
OPTIONS  
HEATER CIRCUITS:-  
TH  
T
KM5-2  
21  
22  
23  
MAINS FILTER  
AUTO - TRANSFORMER  
100  
MCB9  
L1  
L2  
L3  
LINE  
MF  
OR  
LOAD  
L2  
STANDARD HEATER  
CONNECTIONS AS  
DELIVERED  
L1  
L3  
AT  
110/120 V  
50/60 HZ  
FROM SHT 1  
CDV  
OPT  
HTR1  
HTR2  
L1  
L2  
L3  
L1  
L2  
L3  
121  
SUPPLIED BY CUSTOMER  
TH  
T
KM5-2  
22  
23  
MCB10  
OR  
F10  
ALTERNATIVE HEATER  
CONNECTION FOR EXTERNAL  
110 / 120 V SUPPLY  
110/120 V  
50/60 HZ  
EXTERNAL SUPPLY  
HTR1  
HTR2  
100  
MCB9  
21  
110/120 V  
50/60 HZ  
CDV  
OPT  
SUPPLIED BY CUSTOMER  
FROM SHT 1  
TH  
T
121  
KM5-2  
22  
23  
MCB10  
OR  
121  
F10  
ALTERNATIVE HEATER  
CONNECTION FOR EXTERNAL  
220 / 230 V SUPPLY  
220/230 V  
50/60 HZ  
EXTERNAL SUPPLY  
22258891  
Revision E  
HTR1  
HTR2  
60  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
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8.0 GENERAL INFORMATION  
KEY  
1ATS  
SWITCH, HIGH AIR END DISCHARGE  
TEMPERATURE  
MM  
MOTOR, MAIN  
MMS1 BREAKER, FAN MOTOR  
1ATT  
SENSOR, INLET TEMPERATURE  
MMS2 BREAKER, HEATSINK BLOWER  
1DPS SWITCH, FOULED OIL FILTER  
1VAC SWITCH, FOULED AIR FILTER  
2APT SENSOR, INTERSTAGE PRESSURE (2STG ONLY)  
OPT  
OV  
PE  
OPTIONAL  
ZERO VOLTAGE  
PROTECTED EARTH  
2ATT  
SENSOR, AIREND DISCHARGE TEMPERATURE  
PORO POWER OUTAGE RESTART OPTION (OPTIONAL)  
2CTT SENSOR, INJECTED COOLENT TEMPERATURE  
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE  
PSU  
RFI  
RSP  
RST  
POWER SUPPLY UNIT  
FILTER, RADIO FREQUENCY INTERFERENCE  
REMOTE STOP  
3SV  
VALVE, BLOWDOWN SOLENOID  
4APT TRANSDUCER, PACKAGE AIR DISCHARGE  
PRESSURE  
REMOTE START  
SGNe CONTROLLER, INTELLISYS  
SL SERIAL LINK  
SS1-3 RELAY, SOLID STATE  
ST  
T1  
4ATT  
SENSOR, PACKAGE AIR DISCHARGE  
TEMPERATURE  
4CTT SENSOR, OIL COOLER OUT TEMPERATURE  
4SV VALVE, WATER STOP  
6APT TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE  
9APT TRANSMITTER, REMOTE AIR PRESSURE  
(OPTIONAL)  
SERVICE TOOL  
TRANSFORMER, CONTROL  
THERMOSTAT  
TH  
TRR  
COLOR  
BLK  
BLU  
BRO  
GRE  
PIN  
RED  
SCR  
VIO  
TRUE RUNNING  
9SV  
11SV  
AT  
AW1  
AW2  
BP  
VALVE, CONDENSATE DRAIN  
VALVE, ANTI-CONDENSATION SOLENOID 1  
AUTOTRANSFORMER (IF FITTED)  
AUXILIARY WARNING 1  
AUXILIARY WARNING 2  
BACKPLATE  
BLACK  
BLUE  
BROWN  
GREEN  
PINK  
RED  
C
CAPACITOR  
SCREEN  
VIOLET  
WHITE  
YELLOW  
CAB  
CDE  
CDV  
CFO  
CK  
CABINET  
CONDENSATE DRAIN ERROR (OPTIONAL)  
CONDENSATE DRAIN VALVE (IF FITTED)  
COMMON FAULT OUTPUT  
CHOKE  
WHI  
YEL  
Wires  
DR  
DRIVE  
Numbers  
Function  
Wire color  
EB  
ES  
EXC  
F10  
FM  
EARTH BAR  
1−99  
Power  
Black  
Red  
Blue  
SWITCH, EMERGENCY STOP  
EXTERNAL COMMUNICATIONS  
FUSE, EXTERNAL HEATER SUPPLY  
MOTOR, BLOWER  
100−199  
200−299  
300−399  
NOTES:  
AC Control  
DC Control  
Auxiliary  
Orange  
GND  
HB  
GROUND  
HEATSINK BLOWER  
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO  
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER  
100 & 121.  
HTR1 HEATER, 125 WATTS  
K1  
RELAY, RUN  
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN  
K2  
KM1  
KM5  
RELAY, FAULT  
CONTACTOR, MAIN MOTOR  
CONTACTOR, HEATSINK BLOWER  
INDEPENDENT SOURCE: IN THAT CASE, FACTORY  
SUPPLIED CONNECTION MUST BE DISCONNECTED.  
3. ENSURE PARALLEL CONNECTION OF HEATERS.  
MCB1 BREAKER, MINIATURE CIRCUIT, TRANSFORMER  
MCB2 BREAKER, MINIATURE CIRCUIT, CONTROL  
CIRCUITS  
MCB3 BREAKER, MINIATURE CIRCUIT, DR  
MCB4 BREAKER, MINIATURE CIRCUIT, PSU  
MCB9 BREAKER, MINIATURE CIRCUIT, HEATER  
MCB10 BREAKER, MINIATURE CIRCUIT, HEATER  
(EXTERNAL)  
NOTES:  
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE  
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE  
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT  
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN  
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE  
DISCONNECTED.  
2. ENSURE SERIES CONNECTION OF HEATERS.  
MF  
MAINS FILTER (IF FITTED)  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
61  
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8.0 GENERAL INFORMATION  
8.4 WIRING SCHEMATIC - N250-300H  
L1  
L2  
L3  
PE  
P
210  
211  
212  
213  
214  
215  
216  
217  
EB  
380-480V  
50/60 Hz 3ph + PE  
1
2
L1  
L3  
1
2
1DPS  
ES-2  
SG-Ne  
3
1
2
3
4
5
6
A+  
B-  
4
214A  
214B  
MCB1  
5
SC+  
SC-  
SD+  
SD-  
MMS1-1  
1VAC  
RSP  
MMS2-1  
EXC  
P7  
6
115  
107  
106  
KM1  
7
230v  
5SV  
8
K1-3  
103  
124 MCB5  
KM5-1  
P3  
9
DVF  
10  
11  
12  
13  
14  
15  
16  
17  
18  
ES-1  
1ATS  
122  
104  
105  
RST  
1
2
3
4
5
6
SHT 2  
K2-1  
P1  
AW1  
110  
111  
KM1  
K1  
101  
102  
120  
110v  
AW2  
MCB2  
121  
CDE (OPT)  
1
2
112  
113  
114  
1
2
3
4
5
6
KM5  
3SV  
11SV  
1
2
SS1  
SS2  
SS3  
TRR  
-
151  
200v 150  
153  
120  
P4  
+
1
2
WR  
+
105 (110V)  
-
T1  
1
2
MCB3  
-
+
L1  
L2  
L3  
PORO  
120  
MMS1  
152  
151  
OPT  
16 17 18  
L1 L2 L3  
+12V  
253  
252  
9
10  
4-20 mA  
OUTPUT  
240  
2
7
9SV  
9
SIGNAL  
K1-2  
116  
102  
123  
DR  
BLK  
1
2
242  
120  
FD  
WHI  
8
K2  
PSU  
241  
9
200  
201  
12V DC  
RED  
108  
214  
215  
252  
253  
1
1
1
2
1
2
11  
12  
20  
21  
MCB4  
BLK  
WHI  
RED  
BLK  
WHI  
RED  
BLK  
WHI  
V
V
V
V
FAULT  
RED  
BLK  
2
3
P1  
P2  
P10  
4APT  
P
2
3
-
+
4
+
-
+ DC-BUS  
RECTIFIER  
5
3APT  
P
CK  
U
V
W
6
RED  
BLK  
BLK  
WHI  
1
2
7
8
P5  
7
8
6APT  
P
GND  
U
W
9
V
BLK  
WHI  
BLK  
RED  
RED  
BLK  
RED  
BLK  
10  
11  
12  
2
3
6
7
2APT  
2 STG  
ONLY  
YEL  
BLK  
RED  
GRE  
BRO  
BLU  
VIO  
1
2
3
4
5
6
7
ST  
SL  
1
2
WHI  
P
FM  
P8  
WHI  
BLK  
1
2
3
4
5
6
7
8
1
2CTT  
2ATT  
4ATT  
1ATT  
T
T
T
T
GND  
WHI  
BLK  
1
2
3
231  
1
2
0V  
CFO  
4-20mA  
WHI  
RED  
9APT  
OPT  
-
ENABLE  
DI2  
P6  
WHI  
BLK  
WHI  
BLK  
K1-1 1-STG ONLY  
K1-1 2-STG ONLY  
230  
230  
RED  
+
P
3
P2  
4
GND  
U
DI1  
5
1
2
3
+24Vdc  
0V  
BLK  
6
WHI  
7
AI2  
V
MM  
8
AI1-  
WHI  
9
AI1+  
AO1  
W
10  
MAIN INPUT  
TERMINALS  
OPTIONS  
HEATER CIRCUITS:-  
TH  
T
KM5-2  
21  
22  
23  
MAINS FILTER  
AUTO - TRANSFORMER  
100  
MCB9  
L1  
L2  
L3  
LINE  
MF  
OR  
LOAD  
L2  
STANDARD HEATER  
CONNECTIONS AS  
DELIVERED  
L1  
L3  
AT  
110/120 V  
50/60 HZ  
FROM SHT 1  
CDV  
OPT  
HTR1  
HTR2  
L1  
L2  
L3  
L1  
L2  
L3  
121  
SUPPLIED BY CUSTOMER  
TH  
T
KM5-2  
22  
23  
MCB10  
OR  
F10  
ALTERNATIVE HEATER  
CONNECTION FOR EXTERNAL  
110 / 120 V SUPPLY  
110/120 V  
50/60 HZ  
EXTERNAL SUPPLY  
HTR1  
HTR2  
100  
MCB9  
21  
110/120 V  
50/60 HZ  
CDV  
OPT  
SUPPLIED BY CUSTOMER  
FROM SHT 1  
TH  
T
121  
KM5-2  
22  
23  
MCB10  
OR  
121  
F10  
ALTERNATIVE HEATER  
CONNECTION FOR EXTERNAL  
220 / 230 V SUPPLY  
22407100  
Revision C  
220/230 V  
50/60 HZ  
EXTERNAL SUPPLY  
HTR1  
HTR2  
62  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  
8.0 GENERAL INFORMATION  
KEY  
1ATS  
SWITCH, HIGH AIR END DISCHARGE  
MMS1 BREAKER, FAN MOTOR  
TEMPERATURE  
SENSOR, INLET TEMPERATURE  
1DPS SWITCH, FOULED OIL FILTER  
OPT  
OV  
PE  
OPTIONAL  
ZERO VOLTAGE  
PROTECTIVE EARTH  
1ATT  
1VAC SWITCH, FOULED AIR FILTER  
PORO POWER OUTAGE RESTART OPTION (OPTIONAL)  
2APT SENSOR, INTERSTAGE PRESSURE (2STG ONLY)  
PSU  
RFI  
RSP  
RST  
POWER SUPPLY UNIT  
FILTER, RADIO FREQUENCY INTERFERENCE  
REMOTE STOP  
2ATT  
SENSOR, AIREND DISCHARGE TEMPERATURE  
2CTT SENSOR, INJECTED COOLENT TEMPERATURE  
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE  
REMOTE START  
3SV  
VALVE, BLOWDOWN SOLENOID  
SGNe CONTROLLER, INTELLISYS  
SL SERIAL LINK  
SS1-3 RELAY, SOLID STATE  
4APT TRANSDUCER, PACKAGE AIR DISCHARGE  
PRESSURE  
4ATT  
SENSOR, PACKAGE AIR DISCHARGE  
TEMPERATURE  
ST  
SERVICE TOOL  
T1  
TH  
TRANSFORMER, CONTROL  
THERMOSTAT  
6APT TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE  
9APT TRANSDUCER, REMOTE AIR PRESSURE  
(OPTIONAL)  
9SV  
11SV  
AT  
AW1  
AW2  
BP  
TRR  
DVF  
5SV  
COLOR  
BLK  
BLU  
BRO  
GRE  
PIN  
TRUE RUNNING  
FAN, DRIVE VENTILATION  
VALVE, COOLANT STOP  
VALVE, CONDENSATE DRAIN  
VALVE, ANTI-CONDENSATION SOLENOID 1  
AUTOTRANSFORMER (IF FITTED)  
AUXILIARY WARNING 1  
AUXILIARY WARNING 2  
BACKPLATE  
CAPACITOR  
CABINET  
CONDENSATE DRAIN ERROR (OPTIONAL)  
CONDENSATE DRAIN VALVE (IF FITTED)  
COMMON FAULT OUTPUT  
CHOKE  
BLACK  
BLUE  
BROWN  
GREEN  
PINK  
C
CAB  
CDE  
CDV  
CFO  
CK  
RED  
SCR  
VIO  
WHI  
YEL  
Wires  
RED  
SCREEN  
VIOLET  
WHITE  
YELLOW  
DR  
EB  
DRIVE  
EARTH BAR  
ES  
SWITCH, EMERGENCY STOP  
EXTERNAL COMMUNICATIONS  
FUSE, EXTERNAL HEATER SUPPLY  
FAN DRIVE  
MOTOR, BLOWER  
GROUND  
Numbers  
Function  
Wire color  
EXC  
F10  
FD  
FM  
GND  
1−99  
Power  
Black  
Red  
Blue  
100−199  
200−299  
300−399  
NOTES:  
AC Control  
DC Control  
Auxiliary  
Orange  
HTR1 HEATER, 125 WATTS  
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO  
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER  
100 & 121.  
K1  
RELAY, RUN  
K2  
RELAY, FAULT  
KM1  
KM5  
CONTACTOR, MAIN MOTOR  
CONTACTOR, HEATSINK BLOWER  
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN  
INDEPENDENT SOURCE: IN THAT CASE, FACTORY  
SUPPLIED CONNECTION MUST BE DISCONNECTED.  
MCB1 BREAKER, MINIATURE CIRCUIT, TRANSFORMER  
MCB2 BREAKER, MINIATURE CIRCUIT, CONTROL  
CIRCUITS  
MCB3 BREAKER, MINIATURE CIRCUIT, DR  
MCB4 BREAKER, MINIATURE CIRCUIT, PSU  
MCB9 BREAKER, MINIATURE CIRCUIT, HEATER  
MCB10 BREAKER, MINIATURE CIRCUIT, HEATER  
(EXTERNAL)  
3. ENSURE PARALLEL CONNECTION OF HEATERS.  
NOTES:  
1. CONNECTIONS FOR USE ON 200/230V SYSTEMS. THE  
SUPPLY IS INDEPENDENT OF THE MAIN COMPRESSOR. THE  
CUSTOMER MUST PROVIDE AN ISOLATOR / DISCONNECT  
SWITCH ADJACENT TO THE MACHINE FOR THIS SUPPLY. IN  
THAT CASE, FACTORY SUPPLIED CONNECTION MUST BE  
DISCONNECTED.  
MF  
MM  
MAINS FILTER  
MOTOR, MAIN  
2. ENSURE SERIES CONNECTION OF HEATERS.  
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8.0 GENERAL INFORMATION  
8.5 GENERAL DESCRIPTION  
The compressor is an electric motor driven, contact  
cooled screw compressor, complete with all necessary  
components piped, wired and baseplate mounted. It is a  
totally self contained air compressor package.  
The coolant system consists of a sump, cooler,  
thermostatic valve, anti−condensation valve and a  
filter. When the unit is operating, coolant is forced by  
air pressure from the separator tank to the thermostatic  
element. The position of the element (a direct result  
of coolant temperature) will determine whether the  
coolant circulates through the cooler, bypasses the  
cooler, or mixes the two paths together to maintain  
an optimum compressor injection temperature. The  
two position anti−condensation valve can reduce the  
coolant flow and hence the temperature rise of coolant  
through the compressor. This temperature is controlled  
to preclude the possibility of water vapor condensing. By  
injecting coolant at a sufficiently high temperature, the  
discharge air coolant mixture temperature will be kept  
above the dew point. On the N90/160K, N125/200H−SS,  
N75/160K−2S, N100/200H−2S and N250/300H−2S, the  
system is enhanced by a control logic that varies the  
cooling blower speed dependant on the intake and  
discharge temperatures and hence controls the injection  
temperature even closer while saving blower motor  
energy.  
The standard compressor is designed to operate in an  
ambient range of 1.7° C to 46° C (35° F to 115° F). The  
standard maximum temperature of 46° C (115° F) is  
applicable up to an elevation of 1000m (3280ft) above  
sea level. Above this altitude significant reductions in  
ambient temperature are required if a standard motor is  
to be used.  
The compressor is managed by the onboard electronic  
controller. The controller and drive system operate  
together to vary the speed of the compressor to deliver  
compressed air at the target pressure.  
Panel instrumentation is provided to indicate the  
compressor operating conditions and general status.  
The air/coolant mixture discharges from the compressor  
into the separation system. This system removes all  
but a few PPM of the coolant from the discharge air.  
The coolant is returned to the cooling system and the  
air passes to the aftercooler and out of the compressor  
through the moisture separator.  
The compressor is provided with a temperature sensor  
which will shut the unit down in case of excessive  
temperature, 109° C (228° F).  
Air is pulled into the machine by the cooling blower  
(N250−300H use a propeller fan for cooling) and through  
the combined cooler / aftercooler.  
Effective coolant filtration is provided by the use of a  
screw on, heavy duty coolant filter.  
By cooling the discharge air, much of the water vapor  
naturally contained in the air is condensed and is drained  
from the built−in moisture separator and drain.  
NOTICE  
Nirvana air comrpessors are factory filled with SSR ULTRA COOLANT which is designed to operate for 8,000  
hours or two years, whichever comes first.  
Units supplied with optional Food Grade Coolant are designed to operate 1000 hours or 6 months, whichever  
comes first.  
The coolant must be changed at these intervals to avoid breakdown and equipment damage.  
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9.0 OPERATING INSTRUCTIONS  
9.1 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 maintenance  
procedures for setting correct level.  
WARNING  
Ensure that the discharge air isolation valve is open. Switch on the  
main electrical isolation switch. The control panel will illuminate,  
indicating that the line and control voltages are available.  
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  
The contrast of the display may be adjusted by turning the small  
screw which is on the right hand side of the controller when  
accessed through the starter cabinet door.  
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.  
Initial check sequence  
The controller will perform an initial check sequence if the  
compressor (1) receives initial power to the controller or (2) has  
experienced an alarm reset. While the initial check sequence occurs,  
the controller will display a “Checking Machine”message.  
NOTICE  
The language and units of measure displayed on the Intellisys  
controller will be pre−set before leaving the factory. If these  
are required to be changed, contact your local Ingersoll Rand  
Service 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 an alarm 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.  
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9.0 OPERATING INSTRUCTIONS  
Start sequence  
Blowdown mode  
The compressor will initially start by the operator pressing the  
local start button or receiving a remote start command. The  
compressor will start loaded and will ramp up the motor speed to  
its minimum speed. Once the minimum speed has been achieved,  
the compressor will begin to control pressure by using its speed  
regulation. When the system pressure reaches the target pressure,  
the compressor will start to slow. If the system pressure rises to  
the immediate stop pressure setpoint the compressor will stop.  
If the system pressure rises to the auto stop setpoint and the  
compressor is at minimum speed, if the blowdown mode is set to  
off, the compressor will stop. However if the blowdown mode is set  
to on, the compressor will open the blowdown valve for up to 10  
seconds or until the pressure in the separator tank falls to 2.4 Bar (35  
psi) before stopping. The compressor will restart once the system  
pressure falls below the target pressure.  
All 2 stage compressors will blowdown when compressor is signaled  
to stop. Intellisys indicates that Blowdown Mode is ”not installed”.  
If the blowdown mode is set to on, the compressor will open the  
blowdown valve anytime that it stops. This will release pressure  
from the airend and separator tank. If the blowdown mode is set to  
off, the blowdown valve will remain closed when the compressor  
stops due to an automatic stop  
Blower control N37/160K−1S, N50/200H−1S &  
N75/160−2S, N100/200H−2S  
Fan control N250/300H−2S  
The blower speed varies in some conditions to assist in controlling  
the coolant injection temperature. The blower motor has its own  
variable speed drive and will ramp up and down as the compressor  
starts and stops.  
Stop sequence  
Stopping the machine in an emergency  
The compressor can be stopped by a local or remote stop, a  
shutdown due to an alarm or an emergency stop. All of the above  
conditions will cause the compressor to stop immediately, except  
the local or remote stop. 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.  
If the machine has to be stopped in an emergency DEPRESS  
THE EMERGENCY STOP BUTTON LOCATED UNDERNEATH THE  
INSTRUMENT PANEL.  
This will over−ride the normal unload/stop button and will  
immediately stop the machine.  
Restarting after an emergency  
If the unit has been switched off because of a machine malfunction,  
identify and correct the fault before attempting to restart.  
The N250/300H − 2S compressor will operate for 30 seconds with  
the blowdown valve open and at reduced speed before stopping.  
This sequence occurs for local or remote stops and when the  
system pressure reaches the automatic or immediate stop pressure  
setpoints. The compressor will automatically restart when the  
system pressure falls below the target pressure.  
If the unit has been switched off for reasons of safety, ensure that  
the machine can be operated safely before restarting.  
Refer to the PRIOR TO STARTING and START SEQUENCE instructions  
earlier in this section before restarting the machine.  
Important: Depress the emergency stop button when the  
compressor must be stopped immediately.  
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9.0 OPERATING INSTRUCTIONS  
9.2 INTELLISYS CONTROLS  
1. Emergency stop  
5. F2  
Pressing this switch stops the compressor immediately. The  
blowdown valve will open to vent pressure in the separator tank to  
atmosphere. Note: the system downstream of the separator tank  
may still contain pressure. The compressors can not be restarted  
until the switch is manually reset. Turn the switch knob clockwise  
and press the reset button twice to reset.  
Not used.  
6. Arrows  
These up and down buttons have multiple functions relating to  
the right half of the display screen. When lists are presented, the  
buttons are used to move up or down through the items on the  
list. The small arrow(s) displayed in the upper right hand corner of  
the display screen indicate when you can move up (designated by  
arrow head pointing up) and/or down (designated by arrow head  
pointing down) through the list.  
On reset the controller will display a message, indicating that the  
compressor is ready to start.  
2. Start  
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 purpose of changing that  
value, the buttons are used to change the value itself.  
3. Stop  
Pressing this button will activate the stop sequence.  
7. Display buttons  
4. F1  
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.  
Not used.  
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9.0 OPERATING INSTRUCTIONS  
9.3 DISPLAY SCREEN  
The display screen is divided into three functional areas, as seen in  
the typical CURRENT STATUS screen shown here.  
The right side shows various items or lists such as the machine’s  
CURRENT STATUS readings, the MAIN MENU, the OPERATOR  
SETPOINTS list, etc. Any of the lists can be moved up or down by  
pressing the arrow buttons to the right of the screen. The small  
arrow(s) displayed in the upper right corner of the screen indicate  
when you can move up and/or down through a list. The arrow  
buttons are also used to change an individual item’s value. At  
certain times, items and/or their values are “highlighted”. This means  
that they are displayed as light characters on a dark background.  
The left side continuously shows the package discharge pressure  
in large numbers with the line directly below showing the running  
condition of the machine  
− CURRENT STATUS −  
PACKAGE DISCHARGE  
100  
PSI  
The bottom of the screen is divided into thirds with the words in  
each small box showing the function of the button directly beneath  
it. The words will change in these boxes depending on what  
actions are permitted at any particular time. The action resulting  
from pressing each 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.  
TEMP  
102° F  
AIREND DISCHARGE  
TEMP  
READY TO START  
192° F  
MAIN MENU  
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9.0 OPERATING INSTRUCTIONS  
9.4 CURRENT STATUS SCREEN  
The CURRENT STATUS screen is considered to be the “normal”  
display that the controller shows.  
14 Motor Speed  
15 Motor Current  
The following items and their present values can be displayed on  
the right side of the screen by pressing the up and down arrow  
buttons  
16 Motor Voltage  
17 Input Voltage  
The controller automatically returns the display to this CURRENT  
STATUS screen from other screens if no buttons are pressed within  
30 seconds.  
18 DC Bus Voltage  
19 Remote Pressure (optional)  
20 Time and Date  
Use the UP and DOWN arrows to move between selections.  
21 Program Name  
22 Version of Drive Software  
CURRENT STATUS items  
1
2
3
4
5
6
7
8
9
% Energy Saving  
When the CURRENT STATUS screen is displayed, pressing the  
ENERGY STATUS button will toggle the display to the ENERGY  
STATUS screen. Likewise, when the ENERGY STATUS screen is  
displayed, pressing the STATUS button will toggle the display to the  
CURRENT STATUS screen.  
% Capacity  
Package kW  
Package Discharge Temperature  
Airend Discharge Temperature  
Injected Coolant Temperature  
Inlet Temperature  
The ENERGY STATUS screen displays the following items.  
ENERGY STATUS Items  
1
2
3
4
5
6
Average Package kW−hr  
Average % Capacity  
Average Capacity  
Energy Cost  
Sump Pressure  
Separator Pressure Drop  
10 Interstage Pressure  
11 Coolant Filter  
12 Inlet Filter  
Energy Savings  
Lifetime Energy Savings  
13 Total Hours  
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9.0 OPERATING INSTRUCTIONS  
9.5 MAIN MENU  
The MAIN MENU screen can be accessed from the CURRENT STATUS  
screen by pressing the MAIN MENU button, identified by the words  
“MAIN MENU”in the bottom line of the screen directly above the  
center button.  
The language and units of measure are pre−set prior to the  
compressor leaving the factory.  
100  
PSI  
The MAIN MENU screen is the point from which various operator  
functions can be accessed. Refer to the Operator Panel Flow  
Diagram.  
−MAIN MENU−  
READY TO START  
OPERATOR SETPOINTS  
OPTIONS  
Each of the functions can be chosen by using the up and down  
arrows to highlight it on the screen.  
SENSOR CALIBRATION  
ALARM HISTORY  
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.  
STATUS  
SELECT  
CURRENT  
Energy  
Status  
“Status”  
STATUS/ENERGY  
STATUS  
“Main Menu”  
MAIN MENU  
“Status”  
“Main Menu”  
“Select”  
“Main  
“Main Menu”  
“Status”  
“Main Menu”  
“Status”  
OPERATOR  
SETPOINTS  
SENSOR  
Menu”  
OPTIONS  
CALIBRATION  
“Status”  
“Select”  
“Select”  
“Select”  
SENSOR  
CALIBRATION  
ITEM  
OPERATOR  
SETPOINTS  
ITEM  
OPTIONS ITEM  
“Cancel or set”  
“Cancel or set”  
“Cancel or calibrate”  
“Main Menu”  
“Status”  
“Main Menu”  
“Status”  
“Main Menu”  
“Status”  
CLOCK  
FUNCTIONS  
ALARM  
ENERGY  
STATUS  
HISTORY  
“Select”  
“Select”  
“Main  
Menu”  
AVG. PACKAGE kW HRS  
AVG. % CAPACITY  
“Main  
“Main Menu”  
“Status”  
ALARM  
DATE  
AND TIME  
Menu”  
AVG. CAPACITY  
HISTORY ITEM  
ENERGY COST  
ENERGY SAVINGS  
LIFETIME ENERGY SAVINGS  
“Status”  
“Status”  
“Alarm hist”  
“Cancel or set”  
“Cancel or set”  
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9.0 OPERATING INSTRUCTIONS  
9.6 OPERATOR SETPOINTS  
Setpoints are user−adjustable variables in the controller logic that  
can be set using the OPERATOR SETPOINTS screen shown opposite.  
100  
PSI  
OPERATOR SETPOINTS−  
The name and value of each of the setpoints listed can be seen on  
the screen by moving the list up and down using the arrow buttons.  
READY TO START  
TARGET PRESSURE  
105 psi  
Setpoints associated with options are described in the OPTIONS  
sections.  
STATUS  
MAIN MENU  
SELECT  
FACTORY DEFAULTS  
OPERATOR SETPOINTS  
Target pressure  
DEFAULT  
MIN.  
MAX.  
145 / 203  
Target +10  
Auto +10  
On  
STEP  
UNIT  
PSI  
PSI  
PSI  
−
100  
65  
1
Automatic stop pressure  
Immediate stop pressure  
Blowdown mode  
Condensate release  
Condensate interval  
% savings compared to  
Energy Rate  
110  
Target +1  
1
120  
Auto  
Off  
2
1
Off  
−
5
20  
1
SEC.  
SEC.  
−
180  
90  
−
270  
1
Modulation  
−
−
0
--  
1
0
9999.999  
−
−
Reset Date  
1
−
Reset Avg.  
−
−
Service menu  
1
25535  
−
A setpoint’s value can be changed by first highlighting 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.  
Unit  
PSI  
Min  
65  
Max (1S / 2S)  
145 / 203  
Step  
1
BAR  
kPa  
4.4  
440  
4.5  
10 / 14  
0.1  
10  
1000 / 1400  
10.2 / 14.2  
KGCM2  
0.1  
Note: the max target pressure for N250/300H−2S is 145 PSI, 10 BAR ,  
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.  
1000 kPa, 10.2 KGCM2.  
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.  
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9.0 OPERATING INSTRUCTIONS  
Automatic stop pressure  
Condensate Release  
The compressor will stop once the system pressure rises to this  
pressure and the compressor is operating at the minimum speed.  
The range for this setpoint will be the target pressure+1 to target  
pressure+10 psi if the target pressure is 145 psi or less, to target  
pressure+7 psi if the target pressure is greater than 145, but less  
than or equal to 175 psi, or target pressure +5 psi if the target  
pressure is greater than 175 psi. If the remote sensor is ’on’, the  
maximum automatic stop pressure will always be target pressure  
+5 psi.  
This is the number of seconds that the condensate solenoid will be  
open (energized) when blowing out the condensation.  
Condensate Interval  
This is the time interval between condensation blowdowns  
% savings compared to  
This setpoint is to determine what Nirvana’s percent of savings is  
compared to. The modes of operation for comparing Nirvana to are  
modulation, online/offline, and geometry. The percent savings value  
is displayed by the status message, % energy savings  
Immediate stop pressure  
The compressor will stop if the system pressure rises to this  
pressure. The range for this setpoint will be the automatic stop  
pressure to automatic stop pressure+10 psi if the target pressure  
is 145 psi or less, to automatic stop pressure+7 psi if the target  
pressure is greater than 145, but less than or equal to 175 psi, or  
automatic stop pressure +5 psi if the target pressure is greater than  
175 psi. If the remote sensor is ’on’, the maximum immediate stop  
pressure will always be automatic stop pressure +5 psi.  
Energy Rate  
The energy cost and the energy savings items on the ENERGY  
STATUS screen will use this value for their calculations. It is intended  
to be a monetary value representing the user’s power cost per  
kilowatt hour.  
Reset Averaging  
When this setpoint is selected and the SET button is pressed, the  
items on the ENERGY STATUS screen will be reset, and the date  
the reset occurred will be displayed in this setpoint. This selects  
the beginning of the time period over which the ENERGY STATUS  
information will be calculated. Note that the “Lifetime Energy  
Savings”item will not be reset.  
Blowdown Mode  
2 stage compressors will always blowdown when signaled to stop.  
If this mode is selected to ON the compressor will open the  
blowdown valve anytime that it stops. This will vent pressure from  
the airend and the separator tank. If this mode is selected to OFF  
the blowdown valve will remain closed when the compressor stops  
due to an automatic stop. Blowdown mode is set on at all times for  
2 stage models. Blowdown mode will be shown as ”Not Installed”at  
the controller display.  
Service Menu  
For use by IR personnel only.  
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9.0 OPERATING INSTRUCTIONS  
9.7 OPTIONS  
Options are turned on or off and their associated values are set  
using the OPTION screen shown opposite.  
100  
PSI  
−OPTIONS−  
Some options are purchased, they require additional 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 using the arrow buttons  
READY TO START  
REMOTE START/STOP ON  
REMOTE START/STOP ON  
An Option item’s value can be changed the same way that  
OPERATOR SETPOINTS values are changed.  
STATUS  
MAIN MENU  
SELECT  
OPTIONS Items  
SELECTION  
MIN.  
MAX.  
Step  
Unit  
Installed  
Option  
Required  
Remote Pressure Sensor  
Sequencer  
ON/OFF  
ON/OFF  
ON/OFF  
ON/OFF  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
No  
No  
Remote Start/Stop  
Power Out Restart  
Power Out Restart Time  
Scheduled Start Day  
Scheduled Start  
10  
600  
day  
1
1
1
1
1
SEC  
day  
day  
00:00  
day  
23:59  
day  
time  
day  
Scheduled Stop Day  
Scheduled Stop  
00:00  
23:59  
time  
Modbus Protocol  
Modbus Address  
ON/OFF/ICU  
1
247  
1
Remote pressure sensor  
Power out restart  
If this setting is set to ON, the compressor will use a remote  
mounted pressure sensor for controlling system pressure by  
comparing it to the Target Pressure setting and the Auto Stop  
Pressure setting. The pressure measured by this sensor is shown in  
the CURRENT STATUS display as the Remote Pressure reading. The  
local sensor at the package discharge is still used for Immediate  
Stop, for certain Alarm conditions and for display on the left side of  
the screen.  
If this setting is set to ON, the compressor will automatically restart  
when power is returned to the compressor if it was operating when  
power was removed.  
Note:  
A kit including instruction manual is required to install this option.  
Power out restart time  
If the power out restart setting is set to ON, this is the number of  
seconds from the time power is restored until the compressor starts.  
The power out restart horn will sound during this time.  
Sequencer  
If this setting is set to ON, the compressor will be able to start and  
stop by commands from a host device. When the Intellisys receives  
a load command from the host device, the compressor will start.  
When the Intellisys receives an unload command the compressor  
will respond as though executing an immediate stop.  
Scheduled start day  
This option is the selection for the day that a scheduled start 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 start  
setpoint.  
Remote start/stop  
If the remote start/stop option is installed and this setting is set  
to ON, the compressor can be started and stopped from a remote  
device.  
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9.0 OPERATING INSTRUCTIONS  
Scheduled start  
Scheduled stop  
This option will cause the unit to start on the scheduled start day , at This option will cause the unit to stop on the scheduled stop day, at  
the time stored in this setpoint. To disable this option, set the value  
of scheduled start equal to the value of scheduled stop.  
the time stored in this setpoint. To disable this option, set the value  
of scheduled stop equal to the value of scheduled start.  
Scheduled stop day  
Modbus protocol and address  
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.  
See the Modbus manual.  
9.8 SENSOR CALIBRATION  
Pressure sensor calibration is done through the SENSOR  
CALIBRATION screen. Sensor calibration can only take place when  
the machine is stopped. Calibration needs to be done only after  
a sensor has been replaced or the Intellisys controller has been  
replaced.  
Each of the sensors listed below can be chosen by using the up and  
down arrow buttons to highlight it on the screen.  
SENSOR CALIBRATION Items  
Sensor 4APT (Package Discharge)  
Sensor 3APT (Wet Side Sump)  
Sensor 6APT (Dry Side Sump)  
Sensor 2APT (Interstage)  
100  
PSI  
−SENSOR CALIBRATION−  
Sensor 9APT (Remote Sensor)  
READY TO START  
SENSOR 4APT  
CALIBRATE  
SENSOR 3APT  
CALIBRATE  
Select the highlighted sensor by pressing the SELECT button. Press  
the CALIBRATE button to start the automatic calibration procedure,  
or press the CANCEL button to not 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.  
STATUS  
MAIN MENU  
SELECT  
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9.0 OPERATING INSTRUCTIONS  
9.9 ALARM HISTORY  
Alarm History displays each of the Alarm messages for the last  
15 Alarms experienced by the machine. It also gives access to  
displaying the machine operating conditions that existed at the  
time of each Alarm. The first one shown, “Alarm History 1”, was  
the most recent Alarm to occur. Note that multiple, consecutive  
EMERGENCY STOP Alarms are not recorded as separate Alarms, only  
the first one will be shown.  
Each of the last 15 Alarm messages can be seen by moving the  
Alarm History list up and down using the arrow buttons. Pressing  
the SELECT button when one of the Alarms is highlighted will  
display the list of machine values that existed at the time that  
particular Alarm occurred.  
The name and value of each of the items can be seen by moving the  
list up and down using the arrow buttons. Pressing the ALARM HIST.  
button will return the display to the ALARM HISTORY screen.  
100  
PSI  
Alarm histories 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.  
−ALARM HISTORY−  
READY TO START  
ALARM HISTORY 1  
BLOWER MOTOR  
OVERLOAD  
ALARM HISTORY 2  
HIGH AIREND DISCH  
TEMP  
STATUS  
MAIN MENU  
SELECT  
9.10 CLOCK FUNCTIONS  
The date and time for the real time clock is set through the CLOCK  
FUNCTIONS screen. Use the up and down arrows to highlight either  
TIME or DATE. Select the highlighted setting by pressing SELECT.  
100  
PSI  
−CLOCK FUNCTIONS−  
If TIME is selected, first the hours will be highlighted. Adjust the  
hours (00−23 hour clock) by using the up and down arrows. Once  
the correct time is in the display, press SET to highlight the minutes.  
Adjust the minutes (00−59) and then press SET to complete setting  
the time.  
READY TO START  
Time  
01:15  
Date  
Jan 01, 00  
STATUS  
MAIN MENU  
SELECT  
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.  
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9.0 OPERATING INSTRUCTIONS  
9.11 ENERGY STATUS MESSAGES  
AVERAGE CAPACITY − Displays the compressor’s average capacity  
in cfm or m3 for the time period that was started by selecting the  
reset averaging setpoint.  
100  
PSI  
−ENERGY STATUS−  
ENERGY COST − Displays the energy cost of the compressor for  
the time period that was started by selecting the reset averaging  
setpoint. This is calculated by multiplying the kW hours of the motor  
and the blower by the energy rate.  
READY TO START  
AVERAGE PACKAGE kW  
HRS  
AVERAGE % CAPACITY−  
−AVERAGE CAPACITY  
ENERGY SAVINGS − Displays the energy savings of the compressor  
for the time period that was started by selecting the reset averaging  
setpoint as compared to a conventional compressor. This value is  
determined by calculating how much a conventional compressor  
motor would cost to operate at the same average capacity and then  
subtracting the motor energy cost of the Nirvana compressor from  
it. It is assumed that the blower cost is the same in both packages.  
STATUS  
MAIN MENU  
SELECT  
The Energy Status display can be selected by pressing the ENERGY  
STATUS button. The following items and their present values will  
be displayed on the right side of the screen by pressing the up and  
down arrows.  
AVERAGE PACKAGE kW HOURS − This displays the average  
package kW per hour for the time period that was started by  
selecting the reset averaging setpoint. This value includes the  
blower power usage.  
LIFETIME ENERGY SAVINGS − Displays the lifetime energy savings  
of the compressor at the existing energy rate and at the average  
percent capacity as compared to a conventional compressor.  
AVERAGE % CAPACITY − Displays the compressor’s average  
percent capacity for the time period that was started by selecting  
the reset averaging setpoint. The value is determined by taking the  
average package kW per hour, removing the blower power usage  
and then dividing that number by the motor kW per hour for that  
size of compressor at 100% capacity.  
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9.0 OPERATING INSTRUCTIONS  
9.12 WARNINGS  
When a WARNING occurs, a large question mark will flash on the  
display screen.  
CHANGE INLET FILTER − This will occur if the Inlet Vacuum is  
greater than 0.05 bar (0.7 psig).  
If multiple WARNINGS exist, the small up/down arrows will appear  
in the upper right corner of the display screen. The multiple  
WARNINGS can be seen by pressing the up and down arrow  
buttons. Pressing the STATUS button will display the CURRENT  
STATUS screen with the WARNING button indicating that a  
WARNING still exists.  
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.  
HIGH DISCHARGE PRESS − Will occur if the unit is under the  
control of an external device, such as an ISC, and the discharge  
pressure is greater than the immediate stop pressure.  
A WARNING will not cause the unit to shut down. The unit will  
continue to run in its normal operation and the WARNING will  
remain displayed until reset.  
AUXILIARY WARNING 1 or 2 − Will occur if the auxiliary warning  
input closes.  
A Warning needs to be reset by the operator by pressing the RESET  
button twice.  
REMOTE PRESSURE SENSOR FAILURE (option) − This will occur  
if the remote pressure sensor fails. If this happens, the lntellisys  
will start using the package discharge pressure sensor to measure  
system pressure.  
The possible Warning messages are as follows;  
HIGH AIREND DISCHARGE TEMP − This will occur if the Airend  
Discharge exceeds 97% of the alarm limit, 109° C (228° F) and is not  
adjustable.  
CONDENSATE DRAIN ERROR − On 2 stage units, this will occur if  
the condensate drain error contacts close while the unit is running.  
CHANGE COOLANT FILTER − This warning will occur if the high  
side pressure is 1.4 bar (20 psig) greater than the low side pressure.  
9.13 SERVICE WARNINGS  
SERVICE − Service warnings occur when the unit has operated a  
certain number of hours, based on the total hours, or has operated  
for a certain number of months, based on the real time clock.  
Service warnings can have multiple levels, depending on the service  
level selection.  
This will be set prior to the compressor being shipped from the  
factory. When a service warning occurs, contact your local IR service  
representative.  
9.14 INITIAL CHECK ALARMS:  
The following alarms will only occur when the machine is not  
running. These alarms are related to high temperature, power loss,  
and sensor calibration. They will have the same display mode as  
other alarms.  
CHECK SETPOINTS − Will occur if the controller has determined  
that some of the data stored in memory contains unacceptable  
values.  
INVALID CALIBRATION − Will occur if the sensor zero value is  
HIGH AIREND DISCH TEMP− Will occur if airend discharge  
temperature is greater than 95% of 109° C (228° F).  
−10% to +1% of its scale. See Sensor Calibration.  
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9.0 OPERATING INSTRUCTIONS  
9.15 ALARMS  
When an Alarm occurs, a large exclamation mark in a triangle will  
flash on the display screen. The display message will indicate what  
caused the Alarm.  
CONTROL POWER LOSS − This will occur if the control circuit is  
broken by a bad connection or safety switch (e.g. HAT Switch/ Phase  
Monitor). Any fall of voltage below 100VAC for more than 2 seconds  
will cause this alarm trip.  
The compressor will stop and cannot be re−started again until the  
alarm condition no longer exists and the alarm message reset.  
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.  
Pressing the STATUS button will display the STATUS screen. The  
presence of the ALARM button indicates that an Alarm condition  
still exists. Alarm Status is the list of machine operating conditions  
that existed at the time of the Alarm.  
HIGH START PRESSURE − If the sump pressure is above 100 psi  
(6.9 bar) when the compressor starts, the Intellisys will open the  
blowdown valve during the first few seconds of starting (3 to 7  
seconds). If the sump pressure does not fall to 100 psi (6.9 bar)  
during that time period, this shutdown will occur.  
The name and value of each of the items listed can be seen by  
moving the list up and down using the arrow buttons. Pressing the  
ALARM button will return the display to the Alarm screen and the  
RESET button.  
CHECK MOTOR ROTATION − This will occur if the Intellisys reads a  
negative speed from the VSD when starting .  
The Alarm needs to be reset by the operator by pressing the RESET  
button twice. Any exceptions to this are explained in the alarm  
descriptions.  
VSD COMMUNICATION FAILURE − This will occur if the Intellisys  
does not receive a response from the VSD when requesting  
information. This alarm will take about 8 seconds to occur.  
100  
PSI  
VSD INITIALIZATION FAULT − Will occur if the Intellisys is unable to  
−ALARM STATUS−  
establish communications with the VSD after a power up.  
STOPPED BY  
ALARM  
PACKAGE DISCH  
PRESSURE  
LOW SUMP PRESSURE − Will occur if the compressor is operating  
at or above the minimum speed and the sump pressure drops  
below 15psi (1.03 bar) for 15 seconds.  
100 psi  
PACKAGE DISCHARGE  
TEMP  
REPLACE COOLANT FILTER − This will occur if the coolant filter is  
blocked and requires changing.  
103° F  
INCORRECT VSD TYPE − Will occur at power up if the VSD type  
does not match the size of the compressor  
ALARM  
MAIN MENU  
125HP (90kW) machines and above also have the following alarm  
messages;  
The possible Alarm messages are as follows;  
EMERGENCY STOP− This will occur if the Emergency Stop button is  
engaged. The button must be disengaged before the alarm can be  
cleared.  
CONTROL POWER LOSS − This will occur if the compressor should  
be running and the AC input voltage, as read from the VSD, falls  
below 100 VAC. There is a delay of 2 seconds on this alarm in case  
the power quickly returns. An open HAT switch or phase monitor are  
two things that can cause this alarm.  
BLOWER FAULT− This will occur if a blower fault is sensed.  
HIGH AIREND DISCH TEMP− This will occur if the airend discharge  
temperature is greater than 109° C (228° F).  
STOP FAILURE − This will occur if the compressor should be  
stopped, but the motor speed has not dropped below the minimum  
motor speed setpoint. The Intellisys will wait 4 seconds for the  
compressor to stop before issuing this alarm.  
REMOTE START FAILURE− This will occur if the Remote Start  
button is pressed after the machine is running or if the Remote Start  
button remains closed.  
HIGH INTERSTAGE PRESSURE − If the interstage pressure is over  
100psi while the unit is running and the unit is a 2−stage.  
REMOTE STOP FAILURE− This will occur if the Remote Stop button  
remains open and either Start button is pressed.  
SENSOR FAILURE − This will occur if a sensor is recognized as  
missing or broken.  
VSD FAULT − The VSD fault is read from the drive. The Intellisys will  
read the status menu of the variable speed drive. If a fault condition  
is returned in the status information, the Intellisys will issue a VSD  
FAULT alarm and display the number of the fault condition.  
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10.0 MAINTENANCE  
10.1 MAINTENANCE PROMPTS  
The service warning and flashing LED will appear at  
intervals, dependant on the service level selected. Refer  
to operating instructions.  
The service warning will return each subsequent 2000  
hours.  
The machine will be master reset after service work  
conducted prior to the 2000 hour interval to prevent false  
indication.  
The customer can only reset the warning for 24 hours by  
pressing the “set”button.  
IR service engineers will master reset the warning after  
completing the service work.  
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10.0 MAINTENANCE  
10.2 MAINTENANCE CHART  
The MAINTENANCE CHART indicates the various components and the intervals when maintenance has to take place.  
Where a service interval is stated in both hours and months, it is the sooner of the two intervals that must be adhered  
to. Coolant capacities etc can be found in the GENERAL INFORMATION section of this manual. Note that any Local or  
National codes that require specific maintenance that exceeds the requirements of this section must be adhered to.  
Maintenance Schedule  
™
Hours:  
Daily  
150  
(1st time  
only)  
500  
2000  
6000  
4000  
8000  
1000  
12000  
16000  
1500  
2500  
3000  
10000  
14000  
18000  
20000  
Coolant filter  
Air filter **  
Change  
Change  
Change  
Change  
Change  
Change  
Check  
pressure  
Separator element ***  
Check  
pressure  
Change  
Change  
ULTRA COOLANT*  
Check  
Sample  
Change  
Sample  
Change  
Change  
Change  
Power Drive Module filter *  
Scavenge screen **  
Check  
Check  
Check /  
clean  
Check /  
clean  
Check /  
clean  
Hoses ***  
Check /  
clean  
Check /  
clean  
High Air Temperature sensor  
Pressure relief valve  
Cooler Core(s)  
Check  
Check  
Check  
Check  
Check  
Check  
Check /  
clean  
Check /  
clean  
Check /  
clean  
Check /  
clean  
Moisture separator  
Motor cowl  
Check /  
clean  
Check /  
clean  
Check /  
clean  
Check /  
clean  
Check /  
clean  
Check /  
clean  
Check /  
clean  
Check /  
clean  
Vibration Analysis  
Coolant Analysis  
Analysis  
Analysis  
Analysis  
Analysis  
Analysis  
Analysis  
Food Grade Coolant *  
Analysis at every 500  
Change at every 1000  
Blower Motor / Fan Motor  
Regrease  
Regrease  
If the compressor is run less than 4,000 hours per year,  
HPM 250L motor Regrease at 2000hrs and 4000hrs N250/300H-2S only  
* Maintain every 6 months  
** Maintain every year  
*** Maintain every 2 years  
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10.0 MAINTENANCE  
Note:  
On some sea watercooled models the oil cooler and aftercooler are fitted with sacrificial zinc anodes (pencils) that are  
located in the end bonnets of the coolers. These sacrificial zinc anodes should be checked after the first 50 hours of  
operation to determine if corrosive conditions exist. If satisfactory this interval may be extended to 500 hours.  
NOTE:  
1. If sacrificial zinc anode is 50% corroded it should be replaced.  
2. Coastal/harbor waters can contain corrosive chemicals from pollution and may reduce anode/cooler life.  
3. Effects of corrosion or erosion are specifically excluded from warranty considerations.  
10.3 MAINTENANCE PROCEDURES  
CAUTION  
Before beginning any work on the compressor, read and understand the safety instructions earlier on in this  
manual. Open, lock and tag the main electrical disconnect and close the isolation valve on the compressor  
discharge. Do not under any circumstances open any drain valve or remove components from the 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  
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  
This compressor contains a variable frequency drive. When it is switched off and the motor is stopped, the  
internal capacitors store a potentially lethal high voltage electric charge which gradually falls to zero over  
time. After switching off the machine at its local isolator WAIT AT LEAST 15 MINUTES for the capacitors to fully  
discharge before opening the power drive module doors.  
WARNING  
The compressor can operate in a pressurised shutdown mode. If the compressor stops automatically, the  
airend, separator tank and oil system can contain high pressure air. This can be relieved by pressing the  
emergency stop button and can be verified by unscrewing the coolant fill plug which has a vent hole through  
which any residual pressure will be vented. Downstream of the separator tank may still contain system 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  
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.  
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10.0 MAINTENANCE  
Compressed air can be dangerous if incorrectly handled.  
Prior to attempting any maintenance work on a  
running machine, ensure that:−  
Before doing any work on the unit, ensure that all  
pressure is vented from the system and that the machine  
cannot be started accidentally.  
•
the work carried out is limited to only those tasks  
which require the machine to run.  
Ensure that maintenance personnel are adequately  
trained, competent and have read the Maintenance  
Manuals.  
•
the work carried out with safety protection devices  
disabled or removed is limited to only those tasks  
which require the machine to be running with safety  
protection devices disabled or removed.  
•
all hazards present are known (e.g. pressurized  
components, electrically live components, removed  
panels, covers and guards, extreme temperatures,  
inflow and outflow of air, intermittently moving parts,  
safety valve discharge etc.).  
Prior to attempting any maintenance work, ensure  
that:−  
•
all air pressure is fully discharged and isolated from the  
system. If the automatic blowdown valve is used for  
this purpose, then allow enough time for it to complete  
the operation.  
•
•
•
appropriate personal protective equipment is worn.  
loose clothing, jewelry, long hair etc. is made safe.  
•
•
the machine cannot be started accidentally or  
otherwise, by posting warning signs and/or fitting  
appropriate anti−start devices.  
warning signs indicating that Maintenance Work is in  
Progress are posted in a position that can be clearly  
seen.  
all residual electrical power sources (mains and battery)  
Upon completion of maintenance tasks and prior to  
returning the machine into service, ensure that:−  
are isolated.  
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.  
all panels are replaced, canopy and doors closed.  
•
anyone entering the machine is aware of the reduced  
level of protection and the additional hazards,  
including hot surfaces and intermittently moving parts.  
hazardous materials are effectively contained and  
disposed of.  
•
the machine cannot be started accidentally or  
otherwise, by posting warning signs and/or fitting  
appropriate anti−start devices.  
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10.0 MAINTENANCE  
10.4 ROUTINE MAINTENANCE  
This section refers to the various components which  
require periodic maintenance and replacement.  
DANGER  
Under no circumstance should the compressor be  
operated with the coolant fill plug removed.  
For all other maintenance, contact your local Ingersoll  
Rand office, Distributor or Air Center.  
Coolant change procedure  
Refer to safety information and maintenance procedures  
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  
The compressor features a ’no drip’coolant drain feature  
which requires no special tools and minimizes the risk of  
coolant spillage.  
The coolant level should be checked daily. A coolant level  
sight glass is located on the side of the separator tank  
and while the machine is running on load, coolant should  
always be visible in the sight glass. The normal position is  
half way.  
It is better to drain the coolant immediately after the  
compressor has been operating as the liquid will drain  
faster and any contaminant will still be in suspension  
Stop the machine and ensure coolant is still visible in the  
sight glass.  
•
Remove the cap from the drain valve located at the  
front of the separator vessel.  
Adding coolant  
•
•
Place a suitable container close to the drain valve.  
Run the compressor for a minimum of 40 seconds, the  
coolant level should be visible in the sight glass. If not,  
stop the compressor, depressurize by isolating the  
compressor from the system, pressing the emergency  
stop to vent the separator tank & airend & then slowly  
unscrew the coolant fill plug to verify all pressure has  
been released and add coolant. Replace the coolant fill  
plug, restart the compressor and recheck the coolant  
level. Repeat until the coolant level is visible in the sight  
glass with the compressor both running and stopped.  
Screw the coolant drain hose onto the drain valve.  
As the threads engage, the valve will automatically  
open and the coolant will drain.  
•
Remove the drain hose. The valve will automatically  
close and seal.  
•
•
Replace the cap on the drain valve.  
For a complete drain, remove the plug near the  
vessel inlet flange and replace when complete.  
•
•
Replace the coolant filter element.  
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.  
Refill with correct quantity of coolant.  
See 8.0 General Information.  
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10.0 MAINTENANCE  
Coolant filter change procedure  
Drain sequence for N250/300H−2S  
•
Remove plug from drain valve located on the bottom  
of the separator tank.  
•
•
•
Loosen filter element with the correct tool.  
Remove the element from the housing.  
•
Install supplied drain hose and fitting assembly in  
end of drain valve and place end of hose in a suitable  
pan.  
Place the old element in a sealed bag and dispose of  
in a safe way.  
•
•
Clean the mating face of the housing.  
•
•
Open drain valve to start drainage.  
Remove the new Ingersoll Rand replacement  
element from its protective package.  
After draining is complete, close valve, remove hose  
an fitting assembly from valve, and store in a suitable  
location for future use.  
•
•
Apply a small amount of coolant to the element seal.  
Screw the new element down until the seal makes  
contact with the housing, then hand tighten a  
further half turn.  
•
•
Replace plug in end of drain valve.  
Do not store drain hose in starter box after it has  
been used to drain the separator tank.  
•
Start the compressor and check for leaks and check  
the coolant level.  
Coolant fill quantity  
250−300 hp − 2 stage  
40.0 gallons (152 liters)  
Separator element checking procedure  
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  
(12 psig).  
Separator element change procedure  
•
Remove all the capscrews securing the cover to the  
tank except the screw opposite the pivot bolt which  
should be left engaged by 2−3 threads with at least  
6.5mm (0.25”) clearance from the screw head to the  
lid. Rotate the jacking bolt clockwise until the cover  
lifts off the tank at least 2mm (0.08”) all the way  
around the tank. The cover can now be rotated to  
allow access to inside the tank.  
•
Carefully lift out the element spacer and retain for  
reassembly. Do not damage the flat surfaces of the  
spacer as this may cause higher oil carryover or leaks.  
A hoist is available for 175HP (90kW) machines and  
above if required.  
COOLANT DRAIN  
CAUTION  
Do not mix coolant types. Use only coolant specified  
by IR  
•
•
Carefully withdraw the used element, place it in a  
sealed bag and dispose of it safely.  
•
•
•
Start the compressor and check for leaks.  
Check the coolant level, refilling if necessary.  
Remove the O−rings from the top of the tank, the  
separator element sealing face and the scavenge  
tube sealing face.  
Dispose of waste coolant in accordance with local  
and governmental regulations.  
•
•
•
Clean the surfaces on both the tank and the cover.  
Install new O−rings  
Install replacement element remembering to fit the  
small O−ring on the scavenge tube and positioning  
the tube into the matching hole in the Separator  
Tank  
NOTICE  
Shorter coolant drain intervals may be necessary if  
the compressor is operated in adverse conditions.  
•
•
Re−fit the separator element spacer with the notch  
over the scavenge tube.  
Food Grade Coolant option  
•
SSR Food Grade Coolant is a polyalphaolefin base  
coolant. Change after 1000 hours or every 6 months  
whichever comes first. Do not operate unit past this  
1000 hour change interval, as coolant degradation  
will occur.  
Rotate the tank cover back into position taking care  
not to damage the O−ring, and locate the cover  
using 2 capscrews but do not tighten down.  
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10.0 MAINTENANCE  
Separator element change procedure for N250/  
300H−2S  
The main body is made from 1/2 inch hexagon  
shaped steel and the diameter of the orifice and a  
direction−of−flow arrow is stamped in flat areas of the  
hexagon.  
•
•
Disconnect the scavenge tube at the airend.  
Loosen the fitting that holds the scavenge tube into  
the tank and withdraw the tube assembly  
A removeable screen and orifice is located in the exit end  
of the assembly. (see figure) and will require clearing as  
outlined in the Maintenance Schedule Section 10.2.  
•
•
Disconnect the piping from the tank cover. Tag the  
lines if required.  
To remove the screen/orifice, disconnect the scavenge  
line tubing from each end. Hold the center section firmly  
and use a pair of pliers to gently grasp the exit end of  
the assembly that seals against the scavenge line tubing.  
Pull the end out of the center section while using care to  
prevent damage to the screen or sealing surfaces.  
Use a suitable wrench and remove the bolts that  
hold the tank cover in position. Remove cover by  
lifting up and away.  
•
•
Carefully lift the separator element up and out of the  
tank. Discard the faulty element.  
Clean the gasket surface on both the tank and its  
cover. Exercise care to prevent pieces of the old  
gasket from falling down into the tank.  
Clean and inspect all parts prior to reinstallation.  
When the assembly is installed, confirm the direction of  
flow to be correct. Observe the small arrow stamped in  
the center section and ensure the direction flow to be  
from the separator tank to the airend.  
•
Check the tank to be absolutely certain that no  
foreign objects such as rags or tools have been  
allowed to fall into the tank. Install replacement  
element down into the tank after checking the new  
element gaskets for possible damage. Center the  
element up within the tank.  
O−RING  
SCREW HOUSING  
SCREEN  
•
•
Place the tank cover in its correct position and  
install bolts. Tighten the bolts in a cross−pattern to  
prevent over−tightening one side of the cover. An  
improperly tightened cover will likely result in a leak.  
ORIFICE  
Tank cover bolt torque values  
250−300 HP  
3/4−10 UNC  
210ft−lb. (285 n−M)  
SEPARATOR TANK SCAVENGE SCREEN/ORIFICE  
•
•
Inspect tank scavenge screen and orifice. Clean if  
necessary following instructions in Section 4.7.  
WARNING  
Install scavenge tube down into the tank until the  
tube just touches the separator element and then  
raise it 1/8inch (3.2 mm). Tighten fittings.  
Unscrew the jacking bolt sufficiently to ensure that  
the cover can be fully tightened down without im-  
parting any stress onto the jacking points. Tighten  
down the cover setscrews.  
•
•
Install the regulation lines in their original position.  
Start unit, check for leaks, place in service.  
•
Start the compressor and check for leaks and  
coolant level.  
RECOMMENDED BOLT TIGHTENING  
CROSS PATTERN  
CAUTION  
Do not use any form of sealant on either the separa-  
tor tank or the separator tank cover faces.  
Separator tank / Pressure system  
At 2000 hour intervals, inspect the external surfaces of  
the airend and separator tank, including all fittings, for  
visible signs of impact damage, excessive corrosion and  
abrasions. When changing the separator element inspect  
the internal components and surfaces. Any suspect parts  
should be replaced before the compressor is put back  
into service.  
250 − 300 HP  
Scavenge screen clean/check procedure  
The separator tank should also be tested and inspected  
The screen/orifice assemblies are similar in appearance to in accordance with any national or local codes that may  
a straight tubing connector and will be located between  
two pieces of 1/4 inch O.D. scavenge line tubing.  
exist.  
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10.0 MAINTENANCE  
Blower motor Re−Grease  
Run the compressor for about 10 minutes by venting  
air from the system to let the unit warm up. With the  
unit running, test at or near the maximum operating  
pressure by opening the valve for the minimum period  
required to flush the valve seat free of debris. This can  
be accomplished by holding the test lever fully open or  
unscrewing the spring pressure retaining cap, depending  
on the type of valve installed. If there is no evidence of  
discharge or the valve does not fully close, discontinue  
use of equipment and contact a licensed contractor or  
qualified service personnel.  
(N75−160 Aircooled units)  
6 Months or 4000 Hrs  
Apply high melting point grease into the blower motor  
drive end bearing using a grease gun at the nipple  
provided.  
Stop when excess grease is seen at the relief port.  
Main motor Re−Grease instructions  
HPM 250L motor Re-Grease (N250/300N-2S units only)  
Every 2000 hours  
The pressure relief valve should also be tested and  
re−calibrated in accordance with any national or local  
codes that may exist. If no code exists, IR recommend that  
the pressure relief valve is recalibrated at intervals of one  
year.  
Apply Exxon Polyrex - EM or Mobilith - CHC 220 grease  
into main motor drive end and non-drive end bearings  
using a grease gun at the nipple provided.  
Drive end and non-drive end grease quantity 75 grams.  
Stop when excess grease is seen at the relief port.  
Coolant hoses  
Air filter change procedure  
•
Unclip the retaining cap and withdraw the old  
element.  
•
Fit the new element and refit the retaining cap.  
•
The flexible hoses that carry coolant through the  
cooling system may become brittle with age and  
will require replacement. Have your local Ingersoll  
Rand Distributor or Air Center inspect them every 3  
months and replace them as needed or every 2 years.  
Air filter change procedure N250/300H−2S  
•
•
•
•
Loosen wing nut on top of inlet filter housing. Lift  
cover up and away to expose elements.  
Carefully remove the old element to prevent dirt  
from entering the the compressor inlet.  
•
Depending on the location of the hose, it may  
contain compressor coolant. It is recommended to  
drain the coolant into a clean container. Cover the  
container to prevent contamination. If the coolant  
is contaminated, a new charge of coolant must be  
used.  
Thoroughly clean the element housing and wipe all  
surfaces  
Install new element and inspect to ensure that they  
have seated properly.  
•
•
Remove the hose.  
•
•
Install top of inlet filter housing.  
Install the new hose and refill the unit with coolant.  
Start the compressor, check for leaks and check  
coolant level. Refill as necessary  
Inspect the rubber seal on the retainer wing nut and  
replace seal if required.  
•
Tighten wing nuts.  
Pressure relief valve check  
Aircooled Cooler Cleaning  
The pressure relief valve must be frequently tested  
and regularly maintained. Remove from the machine  
and check for the correct operating pressure. Adjust as  
necessary. If operating conditions are particularly severe,  
the frequency of testing and maintenance must be  
increased accordingly. A pressure relief valve check must  
also be performed at the end of any non−service period.  
The user must establish the frequency of such tests as it is  
influenced by such factors as the severity of the operating  
environment.  
Ensure that the compressor is isolated from the  
compressed air system and is vented of all pressure. When  
undertaking any work on the compressor always use  
certified lifting equipment and employ sound working  
principles.  
Ensure that the main power disconnect switch is locked  
off and tagged.  
Visually check the outside of the cooler cores to be  
certain that a complete cleaning of the cooler is required.  
Frequently, dirt, dust or other foreign material may  
only need to be removed with a vacuum to remedy the  
problem.  
CAUTION  
High pressure air will discharge through the dis-  
charge ports of the valve during pressure relief  
valve check. Wear ample clothing, gloves, safety  
glasses and ear protection during valve testing.  
When the cooler is covered with a combination of oil,  
grease or other heavy substances that may affect the  
unit’s cooling, then it is recommended that the cooler  
cores be thoroughly cleaned on the outside.  
If it is determined that the compressor operating  
temperature is higher than normal due to the external  
passages between the fins of the cooler cores being  
restricted with deposits of foreign material, then the  
cooler should be removed for cleaning.  
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10.0 MAINTENANCE  
N50/100H (N37/75K)  
Following are instructions for tilting the cooler away from Instructions for cleaning the coolers while installed in  
the enclosure and cleaning of the cooler.  
the compressor.  
•
•
•
•
Remove 6 screws from lower rear fixed panel and  
remove panel.  
While cleaning coolers, great care must be taken to  
protect the rest of the machine from moisture and  
contamination by covering sensitive parts with plastic  
sheeting.  
Remove 10 screws from the rear intake panel and  
remove panel.  
Loosen clamp and disconnect the air inlet hose from  
the intake plenum.  
•
•
•
•
Remove 4 screws from enclosure panel below  
moisture separator and remove panel.  
Remove intake plenum. Note, plenum is  
unsupported, before removing the 8 screws from  
the intake plenum, block underside of plenum  
prior to removing screws to prevent plenum from  
falling.  
Remove 4 screws from enclosure panel above  
moisture separator and remove panel.  
Remove the 16 screws securing the access panels on  
the cooling plenum and remove covers.  
Cover main drive motor, PDM Heat sink blower  
motor, drain valve, and cooling motor variable speed  
drive with plastic sheeting to prevent damage from  
entrance of cleaning solution.  
•
•
•
Remove hose from elbow in aftercooler inlet. Plug  
elbow in inlet hole of aftercooler.  
Unscrew the fitting connecting the aftercooler to the  
discharge tube.  
•
•
Cover inlet of blower wheel with plastic sheeting to  
prevent entrance of cleaning fluid.  
Loosen mounting bolts on moisture separator to  
allow moisture separator to slide down in mounting  
bracket. Once lowered, remove the discharge tube  
connecting the moisture separator to the aftercooler  
outlet.  
Cover the inlet grill of the intake panel with plastic  
sheeting to prevent cleaning solution from exiting  
the compressor.  
•
•
Attach drain hose to the coupling on the bottom of  
the plenum to allow the cleaning solution to drain  
outside the compressor. Alternately, place large  
bucket underneath plenum to collect cleaning fluid.  
•
•
Plug aftercooler discharge hole.  
To tilt cooler forward, remove 6 screws holding the  
cooler in place. While removing the last screw,  
hold the top of the cooler in place to prevent the  
cooler from tilting. Once the screw is removed,  
allow the cooler to tilt forward until the pivot  
brackets touch the pivot stops. The cooler will stop  
tilting at 45 degrees.  
Use an extended length nozzle and a mild cleaning  
solution to clean the coolers.  
WARNING  
Strong cleaners can harm aluminium cooler parts.  
Follow cleaner manufacturers instructions for use.  
Wear appropriate safety equipment.  
•
•
Cover the main drive motor with plastic sheeting to  
prevent cleaning solution from entering the motor.  
Before cleaning coolers, check to ensure aftercooler  
intake and discharge holes are plugged to prevent  
contamination of compressor system. Clean coolers  
with a mild cleaning solution.  
•
Cleaning fluid will collect on both sides of the cooler  
core. If required, periodically drain fluid from intake  
plenum and bucket to prevent them from over  
flowing.  
•
After cleaning is complete, dry off plenum, intake,  
and cooler core. Reassemble parts in reverse order.  
WARNING  
Strong cleaners can harm aluminium cooler parts.  
Follow cleaner manufacturers instructions for use.  
Wear appropriate safety equipment.  
If the cooler cores are unable to be cleaned while in-  
stalled in the compressor, remove cooler as follows:  
•
Remove 5 screws from panel below the intake panel  
and remove panel. Be careful not to damage the  
electrical leads entering the panel.  
•
After cleaning is complete, reassemble in reverse  
order.  
N125/200H (N90/160K) SINGLE STAGE and N100/200H  
(N75K−160K) TWO STAGE  
•
•
•
•
Remove 8 screws from the intake panel and remove  
panel.  
The coolers in these machines can either be cleaned by  
removing the complete cooler for off site cleaning or  
’back flushing’in place using a high pressure hose and  
gaining access through the holes in the intermediate  
plenum.  
Remove 8 screws from the intake plenum supports  
and remove the supports.  
Remove the 10 screws securing the intake plenum  
and remove the plenum  
Disconnect both oil lines and both air lines from the  
cooler. Plug all 4 inlets to prevent cleaning fluid from  
entering the cooler cores.  
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10.0 MAINTENANCE  
•
•
•
Remove 6 screws from top panel above cooler and  
remove panel.  
•
•
•
Disconnect hose from aftercooler inlet flange.  
Disconnect tube from aftercooler outlet flange.  
Using lifting device from above, attach lifting straps  
to lifting supports on each side of cooler.  
Remove aftercooler holding screws from aftercooler  
support and remove cooler.  
With the weight of the cooler supported by the  
lifting device, remove the 10 screws securing the  
cooler and remove the cooler.  
•
It is recommended the cooler be taken to a  
professional cooler service shop for flushing with an  
appropriate environmentally safe cleaning agent.  
•
Clean coolers with a mild cleaning solution.  
•
•
Reassemble in reverse order.  
Replace enclosure panels.  
WARNING  
Watercooled Cooler Cleaning  
Strong cleaners can harm aluminium cooler parts.  
Follow cleaner manufacturers instructions for use.  
Wear appropriate safety equipment.  
A periodic inspection and maintenance program should  
be implemented for watercooled heat exchangers. The  
following steps should be taken:  
•
After cleaning is complete, reassemble in reverse  
order.  
•
Inspect filters in system and replace or clean as  
required.  
N250/300H−TWO STAGE  
•
Carefully examine cooler tubes for scale and clean if  
necessary. If a cleaning solution is used, be sure to  
wash out all chemicals thoroughly with clean water  
before returning the compressor to service. After  
cleaning, examine the cooler for erosion or corrosion.  
COOLANT COOLERS  
•
Following are instructions for removal and internal  
cleaning of coolant coolers.  
•
•
•
•
Remove panels and top cover.  
Drain the coolant. See Section 4.6.  
Remove side panels from coolant cooler box.  
•
The internal cooler tubes can be cleaned by several  
methods. Flushing a high velocity stream of water  
through the tubes will remove many forms of  
deposits. More severe deposits may require running  
wire brushes or rods through the tubes. Also, rubber  
plugs can be forced through the tubes if a special air  
or water gun is available for this procedure.  
Disconnect piping from coolant cooler inlet and  
outlet ports.  
•
•
Plug cooler inlet and outlet ports to prevent possible  
contamination.  
Remove coolant cooler holding screws from sides of  
coolant cooler and remove cooler through side of  
cooler shroud.  
•
•
A qualified cleaning service should be used for the  
cleaning process. These organizations can evaluate  
the type of deposit to be removed and supply the  
appropriate solution and method for a complete  
cleaning job.  
•
It is recommended the cooler be taken to a  
professional cooler service shop for flushing with an  
appropriate environmentally safe cleaning agent.  
When reinstalling bonnets to cooler shell, tighten  
bolts uniformly in a cross−pattern. Overtightening  
can result in cracking of the bonnet.  
•
•
•
Reassemble in reverse order.  
Make sure fan guards are replaced.  
Refill the compressor with coolant. If con tamination  
is suspected, replace with new coolant.  
•
•
Cleaning solutions must be compatible with the  
metallurgy of the cooler  
•
•
Replace fill plug.  
Care must be taken to avoid damaging tubes if  
mechanical cleaning procedures are used.  
Run compressor for ten minutes. Check for possible  
leaks. Check coolant level.  
Airend bearings  
•
Replace enclosure panels.  
Airend bearings are lubricated by the compressor coolant  
and require no maintenance.  
WARNING  
High Airend Temperature Sensor checking procedure  
Strong cleaners can harm aluminum cooler parts.  
Follow cleaner manufacturer‘s instructions for use.  
Wear appropriate safety equipment.  
It is recommended that the discharge temperature sensor  
(2ATT) is checked regularly as follows:  
AFTERCOOLER  
Aircooled machines  
Stop the cooling blower by opening the blower / fan mo-  
tor circuit breaker.  
•
Following are instructions for the removal and  
internal cleaning of aftercoolers.  
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10.0 MAINTENANCE  
Watercooled machines  
•
Remove the filter pad from the housing and replace  
Shut off the cooling water.  
with a new filter pad from Ingersoll Rand.  
•
Replace front grill to the drive box filter.  
The machine should trip at 109° C (228° F).  
Moisture Separator Check / Cleaning  
CAUTION  
•
Ensure compressor is electrically isolated for at least  
15 minutes, before commencing any maintenance  
work.  
Under no circumstances should these discharge  
temperatures be exceeded. If the machine fails to  
trip A FAULT EXISTS. Investigate immediately.  
•
•
•
Isolate the compressor from the system and fully  
discharge the compressed air within the unit.  
Separator tank scavenge check valve/orifice  
Remove plastic tube from the fitting located on the  
bottom of the moisture separator.  
•
Disconnect tubing at each end of check valve/  
screen/ orifice assembly.  
Remove the bowl of the moisture trap, clean and  
replace.  
•
Check orifice and clean if required. Use suitable tool  
and remove orifice from its housing. Be careful not to  
damage flared end of fitting or O−ring.Wash housing  
in safety solvent and blow dry.  
Condensate (Moisture) Drain Valve / Trap  
•
Ensure compressor is electrically isolated for 15  
minutes and all pressure is relieved from system.  
•
•
Press the check valve/orifice into fitting block.  
Assemble the check valve/orifice assembly to the  
tubing lines.The fitting must be re−installed with the  
check valve on the upstream side of the orifice as  
indicated by the flow arrow.  
•
Remove all pipes going to and from the valve (or  
trap).  
•
•
Disconnect any electrical cables to the valve (or trap).  
Determine the type of condensate drain device and  
continue in the appropriate section below:−  
Blower / fan Motor Bearing Maintenance  
(Stored units)  
Timed Solenoid Drain Valves (where fitted) Check /  
Cleaning  
•
•
•
•
Prior to placing a unit in storage for extended  
intervals, rotate the blower motor several revolutions  
by hand in the direction of rotation.  
•
•
Remove the central nut and then the electrical coil.  
Remove screws holding bonnet of valve and carefully  
split the valve. Clean and inspect all internal parts.  
On N75 − 160, N250 − 300H aircooled units, whilst  
rotating the motor, pump grease into the bearing  
until grease is seen at the relief port.  
•
•
•
Similarly check and clean the ball valve and needle  
valve.  
Thereafter rotate the motor as described above  
every three months until such time as the unit is  
placed in service.  
Replace any defective parts as identified in parts  
manual.  
If the storage time is to exceed a total of nine (9)  
months duration, the compressor must be ordered  
for long term storage.  
Re−assemble and later, with machine running, check  
that condensate and air is expelled at frequency  
and duration set into the INTELLISYS controller (see  
section 9.6).  
Motor cowl cleaning N75−160 units only  
•
Ensure compressor is electrically isolated for at least  
15 minutes before commencing any maintenance  
work.  
•
•
Remove panels from the compressor.  
Using a clean dry cloth, remove dust from the  
surface of the motor cowl and ensure all ventilation  
slots are free of obstructions.  
•
Replace panels to the compressor.  
Drive Box Filter Removal / Replacement  
•
Ensure compressor is electrically isolated for at least  
15 minutes before commencing any maintenance  
work.  
•
Unclip the front grill of the drive box filter.  
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10.0 MAINTENANCE  
No Loss Drain Trap (where fitted) Check / Cleaning  
Coolant Sampling Procedure  
•
Remove the four socket head screws then carefully  
split the trap. Clean and inspect all internal parts  
with particular attention to the water level sensor(s).  
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.  
•
•
•
If the stainless steel strainer mesh is blocked, remove  
it and clean in a weak detergent solution.  
Replace any defective parts (see parts manual for  
repair kit).  
Re−assemble and later, with machine running, check  
that condensate is expelled at regular period and no  
alarms are signaled on trap or on INTELLISYS display.  
Fluid and Vibration Monitoring  
Ingersoll Rand recommends incorporating predictive  
maintenance, specifically the use of coolant and vibration  
analysis, into all Preventative Maintenance programs.  
Predictive Maintenance is designed to increase system  
reliability and prevent costly downtime. Through the  
use of sophisticated diagnostic tools, including fluid,  
vibration, and optional air analysis, IR Certified Service  
Technicians can identify and correct potential problems  
BEFORE they can cause expensive unscheduled  
downtime.  
How does predictive analysis work? By establishing an  
initial baseline for normal operation, and then regularly  
monitoring fluid and vibration conditions, any sudden  
deviation or significant increase from this baseline can  
be identified and investigated to pinpoint the cause.  
More quickly diagnosing potential problems can directly  
save money by preventing costly failures and reducing  
or eliminating downtime. In addition, regular condition  
monitoring also helps to maximize the time between  
expensive preventative maintenance intervals, such as  
component rebuilds and coolant changes.  
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11.0 FAULT FINDING  
11.1 GENERAL FAULTS  
WARNING  
When attempting to identify and remedy any fault or failure, ensure it is only attempted by qualified 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  
Starter failure  
Check supply to unit. Replace unit.  
Isolate supply, lock off and tag. Replace  
failed  
component or contact your local  
Ingersoll Rand representative  
Compressor stops and  
will not restart  
Drive controller has tripped  
See section 11.2 & 11.3  
See section 11.2 & 11.3  
Intellisys controller has tripped the  
compressor  
Maximum number of starts per hour  
exceeded  
Compressor is stopped  
and will not restart  
Intellisys controller has tripped the  
compressor and has not been reset  
See section 11.2 & 11.3  
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  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
ꢂ1  
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11.0 FAULT FINDING  
SYMPTOM  
FAULT  
REMEDY  
Compressor will not meet  
pressure required by system  
Compressor not sized to  
meet system requirements or  
requirements have been changed.  
Contact your local IR representative  
Air loss due to pipe, hose, joint or  
seal failure  
Overhaul or replace  
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  
drain trap stuck open  
Overhaul or replace  
Motor speed too low caused by drive Contact your local IR representative  
incorrectly set  
Motor speed too low caused by fault See section on drive faults  
in drive settings  
Intellysis controller fault  
Drive motor fault  
Overhaul or replace  
See section on drive faults  
Recalibrate or replace  
Pressure transducer faulty,  
incorrectly calibrated or EMF  
interference  
Incorrect Intellisys controller settings Check and modify settings  
Inlet grill or ducting is blocked  
Air filter dirty or collapsed  
Inlet valve not opening fully  
Check and clean  
Replace  
Overhaul or replace  
Separator element dirty or collapsed Replace  
Pipe / Hoses blocked or collapsed  
Cooler core blocked  
Clean or replace  
Clean or replace  
Minimum pressure check valve not  
functioning correctly  
Overhaul or replace  
Equipment between compressor  
and customer measuring point  
causing pressure drop / pressure loss  
Review system requirements  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
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11.0 FAULT FINDING  
SYMPTOM  
FAULT  
REMEDY  
Pressure produced  
by compressor is too  
highcompressor is too high  
due to speed not reducing as  
demand reducesreduces  
Intellisys set incorrectly  
Check and modify settings  
Recalibrate or replace  
Pressure transducer may be  
faulty, incorrectly calibrated or  
not receiving pressure signal  
Drive settings fault  
Contact your local IR representative  
Compressor discharge air too  
hot  
High ambient temperature  
Insufficient cooling air  
Review installation and system parameters  
Check ducting and cooling air path, check  
direction of blower rotation  
Blocked aftercooler matrix  
Clean or replace  
Rectify fault  
Compressor package produces  
excessive noise  
Panels or doors are not closed  
properly  
Air leaks from internal pipework / Overhaul or replace  
components  
Blower or blower motor bearings Overhaul or replace  
worn  
Loose debris impacting on  
blower during rotation  
Remove and rectify any damage  
Blowdown valve stuck open  
Overhaul or replace  
Overhaul or replace  
Pressure relief valve not seating  
correctly  
Vibration due to motor, airend or Overhaul or replace  
blower imbalance  
Airend requires overhaul  
Contact your local IR representative  
Discharge air is contaminated  
with coolantcoolant  
Scavenge pipe is blocked, broken Clean or replace  
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  
coolant  
Check for damage, drain excess.  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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11.0 FAULT FINDING  
SYMPTOM  
FAULT  
Aftercooler not functioning correctly Clean or replace  
Moisture separator drain trap faulty Overhaul or replace  
REMEDY  
Discharge air is contaminated  
with condensate  
Continuous low speed / low ambient Review system requirements and  
operation causing condensate build  
up  
contact your local IR representative  
Compressor package draws too  
much current  
Compressor operating above rated  
pressure  
Check and modify settings. Review  
system requirements and contact your  
local IR representative  
Separator filter element dirty or  
blocked  
Replace  
Voltage supply is low or unbalanced  
Contact your local IR representative or a  
qualified electrician  
Airend is damaged  
Coolant system leak  
Contact your local IR representative  
Overhaul or replace  
Excessive coolant consumption  
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  
been pressed.  
Identify reason why, repair fault, disengage button  
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  
temperature  
Compressor operating above  
rated pressure  
Check and modify settings. Review system  
requirements and contact your local IR  
representative  
Low coolant level  
Check for leaks. See also ‘discharge air is  
contaminated with coolant’. Top up coolant.  
High ambient temperature  
Insufficient cooling air  
Review installation and system parameters  
Check ducting and cooling air path.  
Blocked coolant cooler matrix Clean or replace  
Blower motor direction of  
rotation incorrect  
Wire correctly  
Check setpoints  
Controller software has been  
changed  
Recalibrate all sensors and check setpoints  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
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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  
remote start button remains  
closed.  
procedures  
Remote stop failure  
Sensor failure  
Remote stop button remains  
Check operation of buttons or operating  
open and either start button is procedures  
pressed  
Sensor is missing or faulty  
Install, repair or replace faulty sensor  
Compressor trips indicating a  
high compressor temperature.  
Insufficient cooling taking place If machine is watercooled or sea watercooled,  
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  
tripped the compressor  
A fault has occurred  
Repair fault / reset Intellisys controller  
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  
Loss of control power  
Repair with service kit  
Check 110V circuit breaker  
Check wiring  
Check contactor KM1  
Check motor rotation  
Drive system fault  
Communication wiring faulty  
Drive faulty  
Contact your local IR representative  
Check and replace if required  
VSD communication failure  
Contact your local IR representative  
Contact your local IR representative  
Check and replace if required  
Intellisys faulty  
VSD initialisation fault  
Communication wiring faulty  
Drive faulty  
Contact your local IR representative  
Contact your local IR representative  
Intellisys faulty  
IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S  
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11.0 FAULT FINDING  
11.3 DRIVE FAULTS  
(INDICATED ON THE INTELHYS CONTROLLER)  
The drive controller is directly linked to the Intellisys controller. Faults in the drive controller will be displayed on the  
Intellisys controller as ‘VSD fault 0, VSD fault 1’etc.  
The following VSD faults may be investigated and remedied at source. For all other VSD faults, contact your local IR  
customer support representative.  
FAULT  
CAUSE  
ACTION  
VSD Fault 1  
Over−current  
Check separator element.  
Check cooler, pipework and moisture separator for  
blockages.  
Check operation of minimum pressure check valve.  
VSD Fault 3  
Drive temperature too high  
Check drive filter, replace if necessary  
Check drive cooling fan circuit breaker  
Check wiring  
IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S  
http://air.irco.com  
ꢂ6  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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