Irn200h Cc

User Manual: irn200h-cc

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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.

C.C.N. : 54731245
DATE : DECEMBER 2007
REV. : J

Warranty

AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP

The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects
in material and workmanship for a period of twelve months from the date of placing the Equipment in operation
or eighteen months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall
be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period,
whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or,
furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and
operated such Equipment in accordance with good industry practices and has complied with specific recommendations
of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever
warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company
shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the
Purchaser or others without Company‘s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance
warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period of
time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR
IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such non conformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in
writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.
Note that this is Ingersoll Rand standard warranty. Any warranty in force at the time of purchase of the compressor or
negotiated as part of the purchase order may take precedence over this warranty.

1.0 contents
contents

PAGE

contents

PAGE

1.0 contents

9.6 OPERATOR SETPOINTS

2.0 FOREWORD

9.7 OPTIONS

3.0 ABBREVIATIONS & SYMBOLS

9.8 SENSOR CALIBRATION

4.0 PURCHASE ORDER DETAILS

9.9 ALARM HISTORY

5.0 SAFETY

9.10 CLOCK FUNCTIONS

5.1 SAFETY INSTRUCTIONS

9.11 ENERGY STATUS MESSAGES

5.2 SAFETY PRECAUTIONS

9.12 WARNINGS

5.3 TEXT DECALS

9.13 SERVICE WARNINGS

5.4 GRAPHIC FORM AND MEANING OF ISO
SYMBOLS
13

9.14 INITIAL CHECK ALARMS:

9.15 ALARMS

6.0 RECEIPT / HANDLING

10.0 MAINTENANCE

6.1 RECEIPT

10.1 MAINTENANCE PROMPTS

6.2 UNPACKING AND HANDLING

10.2 MAINTENANCE CHART

7.0 INSTALLATION

10.3 MAINTENANCE PROCEDURES

7.1 LOCATION IN PLANT

10.4 ROUTINE MAINTENANCE

11.0 FAULT FINDING

7.2 DISCHARGE AND CONDENSATE PIPING
20
7.3 ELECTRICAL

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

8.3 PROCESS AND INSTRUMENTATION
DIAGRAM

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
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.
The contents of this manual are considered to be
proprietary and confidential to Ingersoll Rand and should
not be reproduced without the prior written permission
of Ingersoll Rand.
Nothing contained in this document is
intended to extend any promise, warranty or
representation,expressed or implied, regarding the
Ingersoll Rand products described herein. Any such
warranties or other terms and conditions of sale of
products shall be in accordance with the standard terms
and conditions of sale for such products, which are
available upon request.
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
Ingersoll Rand service department.
All components, accessories, pipes and connectors added
to the compressed air system should be:
• of good quality, procured from a reputable manufacturer and, wherever possible, be of a type approved
by Ingersoll Rand.
• clearly rated for a pressure at least equal to the machine maximum allowable working pressure.
• compatible with the compressor lubricant/coolant.
• accompanied with instructions for safe
installation,operation and maintenance.
Ingersoll Rand reserves the right to make changes and
improvements to products without notice and without
incurring any obligation to make such changes or add
such improvements to products sold previously.

Details of approved equipment are available from Ingersoll
Rand Service departments.
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.
IF IN DOUBT CONSULT SUPERVISION.
The company accepts no responsibility for errors in
translation of this manual from the original English
version.
The design of this Compressor package and certain
features within it are covered by patents held by
Ingersoll Rand and patents pending
SSR ULTRA COOLANT is a registered trademark of
Ingersoll Rand Company USA.
INTELLISYS is a registered trademark of Ingersoll Rand
Company USA.
HPM™, HYBRID PERMANENT MAGNET™ and HPM
Logo are trade marks registered by MOTEURS LE-ROYSOMER
© COPYRIGHT 2007
INGERSOLL RAND COMPANY

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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

Not required

As required

Sitemaster/Sitepack

High ambient machine

Watercooled machine

Aircooled machine

ERS

Energy recovery system

T.E.F.C.

Totally enclosed fan cooled motor (IP54)

O.D.P.

Open drip proof (motor)

ppm

parts per million

Czech

Danish

German

Greek

English

Spanish

Estonian

Finnish

French

Hungarian

Italian

Lithuanian

Latvian, Lettish

Maltese

Dutch

Norwegian

Polish

Portuguese

Slovak

Slovenian

Swedish

Chinese

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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 operator reads and understands the
decals and consults the manuals before maintenance or
operation.

danger
Indicates the presence of a hazard which WILL
cause serious injury, death or property damage, if
ignored.

warning
Indicates the presence of a hazard which CAN
cause serious injury, death or property damage, if
ignored.

Ensure that the Operation and Maintenance manual, and
the manual holder, are not permanently removed from
the machine.
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance
Manuals.

caution
Indicates the presence of a hazard which WILL or
can cause injury or property damage, if ignored.

NOTICE
Indicates important set–up, operating or
maintenance information.

5.2 SAFETY PRECAUTIONS

General Information
Compressed air and electricity can be dangerous. Before
undertaking any work on the compressor, ensure that the
electrical supply has been isolated, locked off, tagged and
the compressor has been relieved of all pressure.
Make sure that all protective covers are in place and that
the canopy/doors are closed during operation.
Installation of this compressor must be in accordance with
recognized electrical codes and any local Health and Safety
Codes.
Use only safety solvent for cleaning the compressor and
auxiliary equipment.
Compressed air
Ensure that the machine is operating at the rated pressure
and that the rated pressure is known to all relevant
personnel.
All air pressure equipment installed in or connected to
the machine must have safe working pressure ratings of
at least the machine rated pressure.

If more than one compressor is connected to one
common downstream plant, effective check valves and
isolation valves must be fitted and controlled by work
procedures, so that one machine cannot accidentally be
pressurized / over pressurized by another.
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).
The discharged air contains a very small percentage of
compressor lubricating oil and care should be taken to
ensure that downstream equipment is compatible.
If the discharged air is to be ultimately released into a
confined space, adequate ventilation must be provided.
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.

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5.0 SAFETY
When using compressed air always use appropriate
personal protective equipment.
All pressure containing parts, especially flexible hoses
and their couplings, must be regularly inspected, be free
from defects and be replaced according to the Manual
instructions.
Compressed air can be dangerous if 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.
Avoid bodily contact with compressed air.
The safety valve located in the separator tank must be
checked periodically for correct operation.
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:
• preservative grease
• rust preventative
• 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.
Should compressor lubricant come into contact with the
eyes, then irrigate with water for at least 5 minutes.
Should compressor lubricant come into contact with the
skin, then wash off immediately.
Consult a physician if large amounts of compressor
lubricant are ingested.

The above information contains data supplied in support
of United Kingdom Control of Substances Hazardous to
Health (C.O.S.H.H.) regulations
Transport
When loading or transporting machines ensure that the
specified lifting and tie down points are used.
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.
Electrical
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.
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.
Keep all parts of the body and any hand−held tools or
other conductive objects, away from exposed live parts
of the compressor electrical system. Maintain dry footing,
stand on insulating surfaces and do not contact any other
portion of the compressor when making adjustments or
repairs to exposed live parts of the compressor electrical
system.
Close and lock all access doors when the compressor is
left unattended.
Do not use extinguishers intended for Class A or Class B
fires on electrical fires. Use only extinguishers suitable for
class BC or class ABC fires.
Attempt repairs only in clean, dry, well lighted and
ventilated areas.
Connect the compressor only to electrical systems that
are compatible with its electrical characteristics and that
are within it’s rated capacity.

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.

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.

Burn in an approved incinerator, or according to local area
or country regulations.
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 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

NOTICE

WARNING

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

Hazardous voltage. Can cause severe injury or
death.

DANGER

Disconnect power before servicing.
Lockout/Tagout machine.

WARNING
Discharge air.
Can contain carbon monoxide or other
contaminants. Will cause severe injury or death.
Do not breathe this air.

Rotating fan blade. Can cause severe injury.
Do not operate with covers removed.
Disconnect power. Lock/out and tag out machine.

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5.0 SAFETY

CAUTION

WARNING

Incorrect lifting of machine can cause injury or
property damage.
Lift only from base channels

WARNING

Food contaminant.
Can cause severe injury or death.
Use only Ingersoll Rand SSR H-1F food grade coolant.

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.
Use only SSR ULTRA COOLANT

Hot surface.
Can cause severe injury.
Do not touch. Allow to cool before servicing.

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5.0 SAFETY

CAUTION

Rotation

Improper coolant filter replacement will cause
compressor damage.

Rotation

Replace filter element after first 150 hours of
operation and every 2000 hours thereafter or when
coolant is changed.

NOTICE

WARNING
Rotation

HIGH VOLTAGE

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

WARNING

Moving parts. Can cause severe injury.
Do not operate with covers removed.
Service only with machine blocked to prevent turn over.

39540224 Rev. 04

Air
Discharge
39540257 Rev. 04

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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.

Electrical
power inlet.

WARNING

Use somente fio de cobre de 75˚.
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.

39481130 Rev. 02

Hazardous voltage. Can cause severe injury or
death.

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.

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
Maintenance manual from this machine.

WARNING − Flammable liquid.

WARNING − Rotor magnetic field
can affect pacemakers.

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5.0 SAFETY

0° C

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

PRESSURE

AIR DISCHARGE

PRESSURIZED TANK

ON / OFF CYCLE

COOLANT FILTER

AIR FILTER

ON / OFF PUSH BUTTON

COOLANT PRESSURE

AIR PRESSURE

STAR DELTA IEC 617−7

AUTOMATIC RESTART

HEAT EXCHANGER

MAINTENANCE

MAINTENANCE PROHIBITED

COOLANT DRAIN

CONDENSATE DRAIN

PRESSURE CONTROL

MANUAL (SELECT)

TEMPERATURE

HIGH TEMPERATURE

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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.
For major overhaul (i.e. motor removal) position the
machine to obtain lifting access e.g. fork lift truck.
See diagram in reference section for minimum space
requirements for normal operation and maintenance.
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.

It is recommended that provision be made for lifting
heavy components during major overhaul. Use only
lifting points provided.
Minimum space in front of control panel door as required
by National or Local codes must be maintained.
The compressor can be installed on any level floor
capable of supporting it. A dry, well ventilated area where
the atmosphere is as clean as possible is recommended.
Sufficient space all round and above the compressor must
be allowed, to enable the effective removal of the cooling
air which, in turn, will reduce the risk of 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 exhaust should be ducted or deflected away from the machine.
Screw type compressors [1] should not be installed in air systems with reciprocating compressors without
means of isolation such as a common receiver tank. It is recommended that both types of compressor be
piped to a common receiver using individual air lines.
The machine is shipped with the shipping restraints in place. Ensure that these are removed to allow free
movement of the drive assembly during operation. Each restraint is painted yellow.

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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.
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.
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].
The discharged air contains a very small percentage of
compressor lubricating oil and care should be taken to
ensure that downstream equipment is compatible.

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 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.

NOTICE
For low volume systems that may not include a
receiver [2], compressor response time may need
adjusting. Contact your local IR service agent.

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

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

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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 Ingersoll Rand Distributor or Air Center.
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.
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
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.
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.
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.
The control circuit transformer has different voltage
tappings. Ensure that these are set for the specific applied
voltage prior to starting.

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.
On completion of electrical installation, check that blower
motor rotation is correct. N250H−300H utilizes a fan.
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
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.
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.
Alternately it can be supplied from the 110V tapping
of the control transformer and connected as shown on
schematic wiring diagram.

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/surges in excess of 575V can permanently damage the drive. If the possibility of such exists it is recommended
that adequate surge protection is fitted such as an Ingersoll Rand line reactor. See your local Ingersoll Rand
representative.
Failure of the drive due to voltage spikes, line notching, harmonics or other power quality related problems,
will not be covered by the standard compressor warranty.
The correct type and rating of line input fuse MUST BE fitted onto the customers isolator or breaker close to
the compressor. For Amp rating see technical information in Section 8.1.
Product Identification
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.

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.
Carefully inspect your water system before installing
the compressor package. Ensure that the piping is free
of scale and deposits that may restrict water flow to the
compressor package.
Proper operation of your compressor requires that the
water flow listed below be provided at a maximum supply
temperature of 46° C (115° F).
Model
Range

Minimum cooling water requirement vs
water inlet temperatures, in litres per
minute (US gallons per minute)
10°F /
50°F

21°F /
70°F

32°C /
90°F

46°C /
115°F

N37

23(6.0)

23 (6.0)

38 (10.0)

57(15.0)

N45

27(7.0)

30(8.0)

49(13.0)

76(20.0)

N55

51(13.5)

46(12.0)

38(10.0)

N75

95(25.0)

68(18.0)

46(12.0)

53(14.0)

N75-2S 175(46.0)

133(35.0)

106(28.0)

76(20.0)

N90

84(22.0)

72(19.0)

65(17.0)

72(19.0)

N110

95(25.0)

80(21.0)

72(19.0)

87(23.0)

N132

110(29.0)

91(24.0)

87(23.0)

106(28.0)

N160

125(33.0)

118(31.0)

106(28.0)

125(33.0)

N250

91(24.0)

110(29.0)

179(47.0)

N300

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)

1. Locate the water system vent cocks on top of the
aftercooler and lubricant cooler.
2. Open the water valve(s) allowing water to flow to the
package.
3. Open the vent cocks and allow all air to escape from
the system. When water is observed at the vent
cocks, close them.
The system is now vented.
Draining the water system
Should it become necessary to completely drain the
water system, proceed as follows.
1. Disconnect the inlet and discharge water lines from
the connections located at the rear of the unit.
2. Locate the aftercooler and lubricant cooler. Remove
the drain plugs located at the bottom of the coolers.
Allow the system to completely drain.
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.
Adjusting the Aftercooler Trim Valve
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.

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
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.
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.

Cooling Water Analysis Chart
Substances

Test interval

Acceptable
concentration

Corrosivity
(Hardness,
pH, Total
Dissolved Solids,
Temperature at
inlet Alkalinity)

Monthly - if stable Langelier Index
for 3 to 4 months, 0 to 1
analyse quarterly.

Iron

Monthly

<2 ppm

Sulphate

Monthly

<50 ppm

Chloride

Monthly

<50 ppm

Nitrate

Monthly

<2 ppm

Silica

Monthly

< 100 ppm

Desolated
Oxygen

Daily - if stable,
analyse weekly

0 ppm (as low
as possible)

Oil & Grease

Monthly

<5 ppm

Ammonia

Monthly

<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.
Isolation valves with side drains should be installed on
both the inlet and outlet lines.
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.
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)

12 (0.472)

4 (58)

11 (0.433)

5 (72.5)

10 (0.394)

6 (87)

9.6 (0.378)

7 (101.5)

9.2 (0.362)

8 (116)

8.9 (0.35)

9 (130.5)

8.7 (0.343)

10 (145)

8.4 (0.33)

No oil cooler manufacturer can guarantee that its
products will have an indefinite life and for this reason, we
suggest that the cooling system is designed to minimize
any damage caused by a leaking oil cooler. This can be
achieved as follows ;
1. The oil pressure should be higher than the sea water
pressure, so that in the event of a leak occurring, the
oil will not be contaminated.
2. If the sea water pressure is 100PSIG (7BARG) or above
it is recommended that the water solenoid valve is
changed to the water inlet side. This will protect the
system from high pressure surges when not in use.
3. The sea water outlet pipe from the cooler should
have a free run to waste.

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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
General
Sound pressure level dB(A) *
Maximum ambient temperature ° C (° F)
Minimum ambient temperature ° C (° F)
Weight Kg (lbs)
Maximum pressure barg (psig)
Minimum pressure barg (psig)
Coolant capacity litres (US gal)
HAT switch setting ° C (° F)
Performance **
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)
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
Cooling (clean) water flow l/min (US
gallon/min) @ 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 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)
Max fuse size @ 400V (A)
Max fuse size @ 460V (A)
Max fuse size @ 575V (A)
Fuse type
Heater Circuit
110V Single Phase Rating (A)
230V Single Phase Rating (A)
Fuse type

N37K

N45K

N50H

N60H

75
46 (115)
1.7 (35)
1048 (2310)
10 (145)
4.5 (65)
18 (4.8)
120 (248)

6.43
6.12
5.83
−
−
−

7.39
7.02
6.46
−
−
−

−
−
−
235
216
209

−
−
−
262
248
233

184 (6500)
124 (0.5)
8 (15)

23/38 (6/10)

27/49 (7/13)

23/38 (6 /10)

27 /49 (7 /13)

62 (0.25)
14 (25)

140 (131)
168 (159)
140 (131)
168 (159)
75 (70 )
90 (85)
−
−
−
−
68 (63)
81 (77)
−
−
56 (52)
67 (63)
250
250
250
250
125
125
125
125
125
125
125
125
100
100
100
100
Fast acting class J, T or semiconductor type, current limiting interrupt
rating 200, 000 Amps RMS SYM.
4
4

4
4
4
4
General purpose

4
4

* 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)

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8.0 GENERAL INFORMATION
N55K

N75K

N75H

N100H

Maximum ambient temperature ° C (° F)

46 (115)

Minimum ambient temperature ° C (° F)

1.7 (35)

1531 (3374)

Maximum pressure barg (psig)

10 (145)

Minimum pressure barg (psig)

4.5 (65)

Coolant capacity litres (US gal)

30 (8)

120 (248)

Flow at 7.5 Barg (m3/min)

10.11

12.94

−

Flow at 8.5 Barg (m3/min)

9.29

12.15

−

Flow at 10 Barg (m3/min)

8.49

11.50

−

Flow at 100 psig (cfm)

−

372

479

Flow at 125 psig (cfm)

−

328

429

Flow at 140 psig (cfm)

−

306

413

241 (8500)

124 (0.5)

8 (15)

Cooling (clean) water flow l/min (US
gallon/min) @ 10 ° C (50 ° F) / 32 ° C (90
° F)

51/38
(13.5 /10)

95/46
(25 /12)

51/38
(13.5/10)

95/46
(25/12)

Maximum ΔP in air ducts Pa (inch WG)

62 (0.25)

14 (25)

Package full load current at 220V (A) **

208 (196)

−

208 (196)

−

Package full load current at 400V (A) **

110 (104)

144 (138)

−

Package full load current at 460V (A) **

−

100 (94)

131 (125)

Package full load current at 575V (A) **

−

82 (78)

108 (103)

Max fuse size @ 220V (A)

300

400

300

400

Max fuse size @ 400V (A)

150

200

150

200

Max fuse size @ 460V (A)

150

200

150

200

Max fuse size @ 575V (A)

125

150

125

150

Fuse type

Fast acting class J, T or semiconductor type, current limiting
interrupt rating 200, 000 Amps RMS SYM.

General
Sound pressure level dB(A) *

Weight Kg (lbs)

HAT switch setting ° C (° F)
Performance

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

Compressed air outlet ΔT ° C (° F)
Main Power Circuit A/C (W/C) ***

Heater Circuit
110V Single Phase Rating (A)

230V Single Phase Rating (A)

Fuse type
General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable
size should be calculated on basis of mean package full load current X1.25 (i.e. 25% margin)
28

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION

N90K

N110K

N125H

N150H

Maximum ambient temperature ° C (° F)

46 (115)

Minimum ambient temperature ° C (° F)

1.7 (35)

3175 (6985)

Maximum pressure barg (psig)

10 (145)

Minimum pressure barg (psig)

4.5 (65)

Coolant capacity litres (US gal)

91 (24)

120 (248)

Flow at 7.5 Barg (m3/min)

17.1

20.0

−

Flow at 8.5 Barg (m3/min)

15.3

19.2

−

Flow at 10 Barg (m3/min)

14.0

17.5

−

Flow at 100 psig (cfm)

−

655

739

Flow at 125 psig (cfm)

−

571

670

Flow at 140 psig (cfm)

−

524

610

382 (13500)

124 (05)

8 (15)

Cooling (clean) water flow l/min (US
gallon/min) @ 10° C (50° F) / 32° C (90° F)

84/65
(22/17)

95/72
(25/19)

84/65
(22/17)

95/72
(25/19)

Maximum ΔP in air ducts Pa (inch WG)

62 (0.25)

14 (25)

Package full load current at 400V (A) **

182 (170)

218 (206)

−

Package full load current at 460V (A) **

−

170 (160)

200 (190)

Package full load current at 575V (A) **

−

140 (132)

165 (157)

Max fuse size @ 380V − 415V (A)

250

350

−

Max fuse size @ 440V − 480V (A)

−

250

Max fuse size @ 550V − 575V (A)

−

200

General
Sound pressure level dB(A) *

Weight Kg (lbs)

HAT switch setting ° C (° F)
Performance **

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

Compressed air outlet ΔT ° C (° F)
Main Power Circuit A/C (W/C) ***

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)

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
N132K

N160K

N200H

Maximum ambient temperature ° C (° F)

46 (115)

Minimum ambient temperature ° C (° F)

1.7 (35)

General
Sound pressure level dB(A) *

Weight Kg (lbs)

3175 (6985)

Maximum pressure barg (psig)

10 (145)

Minimum pressure barg (psig)

4.5 (65)

Coolant capacity litres (US gal)

91 (24)

120 (248)

Flow at 7.5 Barg (m3/min)

23.5

28.0

−

Flow at 8.5 Barg (m3/min)

22.3

26.0

−

Flow at 10 Barg (m3/min)

HAT switch setting ° C (° F)
Performance **

21.0

25.0

−

Flow at 100 psig (cfm)

−

993

Flow at 125 psig (cfm)

−

892

Flow at 140 psig (cfm)

−

819

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)

Maximum ΔP in air ducts Pa (inch WG)

62 (0.25)

14 (25)

Package full load current at 400V (A) **

251 (239)

301(289)

−

Package full load current at 460V (A) **

−

255 (245)

Package full load current at 575V (A) **

−

210 (202)

Max fuse size @ 380V − 415V (A)

350

450

−

Max fuse size @ 440V − 480V (A)

−

350

−

300

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

Compressed air outlet ΔT ° C (° F)
Main Power Circuit A/C (W/C) ***

Max fuse size @ 550V − 575V (A)
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)

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
8.1 TECHNICAL INFORMATION − TWO STAGE
General
Sound pressure level dB(A) *
Maximum ambient temperature ° C (° F)
Minimum ambient temperature ° C (° F)
Weight Kg (lbs)
Maximum pressure barg (psig)
Minimum pressure barg (psig)
Coolant capacity litres (US gal)
HAT switch setting ° C (° F)
Performance **
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)
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
Cooling (clean) water flow l/min (US
gallon/min) @ 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

N75K

N90K

N110K

N100H

N125H

N150H

75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)

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

382
(13500)
124 (0.5)
8 (15)

175/106
(46/28)

84/65
(22/17)

95/72
(25/19)

175/106
(46/28)

84/65
(22/17)

95/72
(25/19)

62 (0.25)
14 (25)

153 (142)
−
−
250
−
−

182 (170) 218 (206)
−
−
−
−
−
139 (129) 170 (160) 200 (190)
−
−
114 (106) 140 (132) 165 (157)
250
350
−
−
−
−
−
200
250
250
−
−
200
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)
4
4
4
4
4
4
230V Single Phase Rating (A)
4
4
4
4
4
4
4Fuse type
General purpose
* In accordance with PNEUROP PN8NTC2.3
** Tolerances in accordance with ISO 1217
*** Always apply local electrical codes for sizing cables and fusing. In the absence of local codes the minimum cable
size should be calculated 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

8.0 GENERAL INFORMATION
General
Sound pressure level dB(A) *
Maximum ambient temperature ° C (° F)
Minimum ambient temperature ° C (° F)
Weight Kg (lbs)
Maximum pressure barg (psig)
Minimum pressure barg (psig)
Coolant capacity litres (US gal)
HAT switch setting ° C (° F)
Performance **
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)
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
Cooling (clean) water flow l/min (US gallon/
min) @
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
Heater Circuit
110V Single Phase Rating (A)
230V Single Phase Rating (A)
Fuse type

N132K

N160K

N200H

N250H

N300H

75
46 (115)
1.7 (35)
3650
(8030)
10 (145)
4.5 (65)
95 (25)
120 (248)

80
46 (115)
1.7 (35)
5933
(13,080)
10 (145)
4.5 (65)
152 (40)
120 (248)

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
−

382
(13500)
124 (0.5)
8 (15)

679
(24000)
62 (0.25)
8 (15)

110/87
(29/23)

125/106
(33/28)

352
(93)

62 (0.25)
14 (25)

251 (239)
301 (289)
−
−
−
−
−
255 (245)
335 (313)
406 (384)
−
−
210 (202)
267 (250)
324 (307)
350
450
−
−
−
−
−
350
−
600
−
−
300
−
500
Fast acting class J, T or semiconductor type, current limiting interrupt
rating 200, 000 Amps RMS SYM.
4
4

4
4

4
4
General purpose

4
4

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
B
Ø63mm (2.48”) Electrical inlet
C
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
D
Cooling airflow
E
Exhaust airflow
F
Cabinet cooling airflow

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.
H
INTELLISYS Controller
U
Right
V
Bottom
W
Front
X−X
Section through X−X
Y
Rear view
Z
Plan view

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

KEY
A
B
C
Note:

D
E
F
G

11/2” NPT Air discharge (Female) 60Hz units
11/2” BSP Air discharge (Female) 50Hz units
Ø63mm (2.48”) Electrical inlet
0.38“ NPT (Female)
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
Cooling airflow
Exhaust airflow
Cabinet cooling airflow
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.

H
J
K
U
V
W
X−X
Y
Z

INTELLISYS Controller
1” NPT Water inlet (Female) 60Hz units
1” BSP Water inlet (Female) 50Hz units
1” NPT Water outlet (Female) 60Hz units
1” BSP Water outlet (Female) 50Hz units
Right
Bottom
Front
Section through X−X
Rear view
Plan view

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

KEY

2” NPT Air discharge (Female) 60Hz units
2” BSP Air discharge (Female) 50Hz units
B
Ø63mm (2.48”) Electrical inlet
C
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
D
Cooling airflow
E
Exhaust airflow
F
Cabinet cooling airflow

H
U
V
W
X−X
Y
Z

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.
INTELLISYS Controller
Right
Bottom
Front
Section through X−X
Rear view
Plan view

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

KEY
A
B
C
Note:

D
E
F
G

2” NPT Air discharge (Female) 60Hz units
2” BSP Air discharge (Female) 50Hz units
Ø63mm (2.48”) Electrical inlet
0.38“ NPT (Female)
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
Cooling airflow
Exhaust airflow
Cabinet cooling airflow
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.

H
J
K
U
V
W
X−X
Y
Z

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
(N100H−N150H)
2” BSP Air discharge (Female) 50Hz units
(N75K−N110K)
2 1/2” NPT Air discharge (Female) 60Hz units
(N200H)
2 1/2” BSP Air discharge (Female) 50Hz units
(N132K and N160K units)
B
Electrical inlet −
Ø75mm (3”)
Ø64mm 575V (Option)
C
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
D
Cooling airflow
E
Exhaust airflow

F
G

H
J
K
U
V
W
X−X
Y
Z

Cabinet cooling airflow
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.
INTELLISYS Controller
1.5” NPT Water inlet (Female) 60Hz units
1.5” BSP Water inlet (Female) 50Hz units
1.5” NPT Water outlet (Female) 60Hz units
1.5” BSP Water outlet (Female) 50Hz units
Right
Bottom
Front
Section through X−X
Rear view
Plan view

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)
2 1/2” NPT Air discharge (Female) 60Hz units
(N200H)
2 1/2” BSP Air discharge (Female) 50Hz units
(N132K and N160K units)
B
Electrical inlet − Ø75mm (3”)
Ø64mm 575V (Option)
C
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
D
Cooling airflow

E
F
G

H
U
V
W
X−X
Y
Z

Exhaust airflow
Cabinet cooling airflow
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.
INTELLISYS Controller
Right
Bottom
Front
Section through X−X
Rear view
Plan view

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

KEY

A
B

4” NPT Air discharge (Female)
Electrical inlet −
Ø75mm (3”)
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
D
Cooling airflow
E
Exhaust airflow
F
Cabinet cooling airflow

H
U
V
W
X
Y
Z

4 x Ø 14.2mm (0,6”)
Compressor should be bolted to the floor with
four M12 (0.5”) bolts using holes shown. Seal
base to floor with cork or rubber.
INTELLISYS Controller
Right
Bottom
Front
Left view
Rear view
Plan view

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
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8.0 GENERAL INFORMATION
22381206
Revision B

T21

1st

2nd

TWO STAGE ONLY

8.3 PROCESS AND INSTRUMENTATION DIAGRAM N37/45K-CC & N50/60H-CC

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
KEY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Air discharge
Compressor
Air filter
Vacuum switch 1VAC
Cooler, air
Cooler, coolant
Condensate discharge
Coolant filter
Pressure switch, coolant filter 1DPS
Drain valve, coolant
Temperature switch 1ATS
Air inlet check valve
Timed solenoid condensate drain.
(single stage)
Minimum pressure check valve
Moisture 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
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)

32
33
34
35
36
37
38
39
40
41
42
43
44
45
46

45
46
49

Receivers (customer equipment)
Dryer AUX warning
Line filter AUX warning
Receiver trap AUX warning
Remote pressure transducer 9APT (optional)
Water stop valve 4SV
Typical customer downstream air treatment
Anti − condensation valve 11SV
Cooling air exhaust box
Package discharge temperature transducer 4ATT
Injected coolant temperature sensor
Seal scavenge air supply
Seal scavenge line
Air intake temperature sensor. 1ATT
Electronic drain trap. Alternative to item 13.
(Standard equipment on 2 stage. Optional on
single stage).
Interstage pressure relief valve. (2 stage.)
Interstage pressure transducer. (2 stage)
Air/Coolant separator element

Air/coolant
Air
Coolant
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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23128994
Revision A

T21

P
16

1st

2nd

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com
EQUIPMENT
DOWNSTREAM
OF COMPRESSOR

SENSOR
CONNECTION

COMPRESSOR
ENCLOSURE

COOLING WATER
(W.C. ONLY)

CONDENSATE

COOLANT

AIR

AIR/COOLANT

PIPING LEGEND

TWO STAGE ONLY

8.0 GENERAL INFORMATION

8.3 PROCESS AND INSTRUMENTATION DIAGRAM N55/75K-CC & N75/100H-CC

8.0 GENERAL INFORMATION
KEY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

AIR DISCHARGE
COMPRESSOR
AIR FILTER
VACUUM SWITCH 1VAC
COOLER, AIR
COOLER, COOLANT
CONDENSATE DISCHARGE
COOLANT FILTER (S)
PRESSURE SWITCH, COOLANT FILTER 1DPS
DRAIN VALVE, COOLANT
HIGH AIR TEMPERATURE SWITCH 1ATS
AIR INLET/CHECK VALVE
TIMED SOLENOID CONDENSATE DRAIN SINGLE
STAGE UNITS ONLY)
MINIMUM PRESSURE CHECK VALVE
MOISTURE SEPARATOR
PRESSURE TRANSDUCER 4APT
PRESSURE RELIEF VALVE
SCAVENGE FILTER / ORIFICE / CHECK VALVE
SEPARATOR TANK (PRIMARY/SECONDARY)
OIL TEMPERATURE CONTROL VALVE
TEMPERATURE SENSOR 2ATT
BLOWDOWN SOLENOID VALVE 3SV
DRIVE MOTOR - VARIABLE SPEED
MOTOR, BLOWER - VARIABLE SPEED
COOLING AIR BLOWER
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 |
LINE FILTER AUX WARNING | AW1 (WIRE IN
SERIES)
RECEIVER TRAP AUX WARNING |

36
37
38
39
40
41
42
43
44
45
46

47
48
49
50

REMOTE AIR PRESSURE TRANSDUCER 9APT
(OPTIONAL)
WATER SHUTOFF VALVE 4SV (W.C.ONLY)
TYPICAL CUSTOMER DOWNSTREAM AIR
TREATMENT
ANTI-CONDENSATION VALVE 11SV
COOLING AIR EXHAUST BOX
PACKAGE DISCHARGE AIR TEMPERATURE SENSOR
4ATT
INJECTED COOLANT TEMPERATURE SENSOR
2CTT
ORIFICE, SEAL SCAVENGE AIR SUPPLY
SEAL SCAVENGE LINE DRAIN
PACKAGE INTAKE AIR TEMPERATURE SENSOR
1ATT
ELECTRONIC DRAIN TRAP-ALTERNATIVE TO ITEM
13 (STANDARD EQUIPMENT ON 2 STAGE
OPTIONAL ON SINGLE STAGE)
INTERSTAGE PRESSURE RELIEF VALVE (TWO
STAGE)
INTERSTAGE PRESSURE TRANSDUCER (TWO
STAGE)
AIR/COOLANT SEPARATOR ELEMENT
OIL COOLER OUT TEMPERATURE SENSOR 4CTT

Air/coolant
Air
Coolant
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
http://air.irco.com

22099006
Revision C

30
15

T21

T
T

1st

2nd

TWO STAGE ONLY

8.0 GENERAL INFORMATION
8.3 PROCESS AND INSTRUMENTATION DIAGRAM N90/160K &
N125/200H SINGLE STAGE AND N75/160K & N100/200H TWO STAGE

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
KEY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

Air discharge
Compressor
Air filter
Vacuum switch 1VAC
Cooler, air
Cooler, coolant
Condensate discharge
Coolant filter
Pressure switch, coolant filter 1DPS
Drain valve, coolant
Temperature switch 1ATS
Air inlet check valve
Timed solenoid condensate drain.
(single stage only)
Minimum pressure check valve
Moisture 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
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)

33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

Dryer AUX warning
Line filter AUX warning
Receiver trap AUX warning
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
Package discharge temperature transducer 4ATT
Injection temperature, transducer 2CTT
Seal scavenge air supply
Seal scavenge line
Temperature sensor 1ATT
Electronic drain trap. Alternative to item 13
(Optional on single stage)
Interstage pressure relief valve. 2 stage.
Interstage pressure transducer. 2 stage
Element, separator
Valve, aftercooler trim (W.C. only)
Valve, airend discharge temperature control
(W.C. only)

Air/coolant
Air
Coolant
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
http://air.irco.com

8.0 GENERAL INFORMATION

30
15

T21

P
13

V
4

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

T21

12
3

1st

2nd

22402135
Revision C

8.3 PROCESS AND INSTRUMENTATION DIAGRAM N250−300H TWO STAGE

8.0 GENERAL INFORMATION
KEY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

Air discharge
Compressor
Air filter
Vacuum switch 1VAC
Cooler, air
Cooler, coolant
Condensate discharge
Coolant filter
Pressure switch, coolant filter 1DPS
Drain valve, coolant
Temperature switch 1ATS
Air inlet/adaptor
Coolant stop solenoid valve 5SV
Minimum pressure check valve
Moisture 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
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)

33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52

Dryer AUX warning
Line filter AUX warning
Receiver trap AUX warning
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
Package discharge temperature transducer 4ATT
Injection temperature, transducer 2CTT
Orifice, seal scavenge air supply
Seal scavenge line
Temperature sensor 1ATT
Electronic drain trap
Interstage pressure relief valve. 2 stage.
Interstage pressure transducer. 2 stage
Element, separator
Valve, aftercooler trim (W.C. only)
Valve, airend discharge temperature control
(W.C. only)
Airend discharge check valve.

Piping legend
Air/coolant
Air
Coolant
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
http://air.irco.com

8.0 GENERAL INFORMATION

8.4 WIRING SCHEMATIC N37K − N45K-CC / N50-60h−cc a/c

blower vfd
P

124

KM5-1

106

MCB2

BLU
BLK
BRN
GRN/YEL

107
122

DVF3
OPT

DVF

CAB

SC-

7
P7

SD+

230V

200/230V-3ph-50/60Hz

400/460V-3ph-50/60Hz

ES-1

104

103

1ATS

110V 100

101

121

215
216

RSP
RST
AW1

14
15

111

AW2

112

KM5

CDE (OPT)

18
1

2
P4

KM1

SS1 -

SS2 +

5
16 17 18

120

L1 L2 L3

241
214
215
252
253

01
02
60
55

116
PX6
PE
DR

FAULT

+
-

BLK

RED

3
4

BRO
V

115

RED

108

MCB5

BLK

2
3

S
1

CK
+ RECTIFIER
OUT

7
8

PX2

AO1
A11+
A11A12
OV
+24VDC
D11
D12
ENABLE
OV

1
P2

2
3
4
5

200
201

12V DC

1
RED
BLK
P5

P10

5
P5

BLK
RED

CFO

1
2

2
3
P6

2
3

RED 4-20mA
+
WHI
P

7 230
8
K1-1
9 231
10

BLK

V
P

WHI

9APT

4
5
6
7
8

OPT

BLK

V
P

WHI
BLK
WHI

V
P

BLK

T 2CTT

WHI
BLK

T 2ATT

WHI
BLK
WHI
BLK

T 4ATT
T 1ATT

110/120V
50/60 HZ

KM5-1 22

HTR1

CDV

HTR2

OPT

121

24
MCB9

T1
PE

TH
L

22775738
Revision B

KM5-1 22

220/230 V
50/60 HZ

HTR1

CDV

HTR2

OPT

24
MCB9

6APT

WHI

TH
20

3APT

RED

GND
GND

100

4APT

RED

BLK
WHI

BLK
RED

RED

1
WHI

7
9

BLK
WHI

6
8

BLK

WHI

+252
-253
BLK

RED

SL
1

4-20 mA 9
OUTPUT

WHI

PORO

+ DC-BUS

105 (110V)

1
2

PSU

GND

116

9SV

120

102

SS3 -

TRR

2
1

120

VIO

114

11SV

BLU

GRE
U

126

6
5

MCB4

GND

YEL

U V W

125

123
1

113

3SV

PX1

242

PX3

K1-2

+24V
18 START
27 STOP
12

PX4

240

1VAC

217

200V
MMS

214

120

MCB1

ES-2

213

102

MCB3

R
FI

DVF

1DPS

212

1
110

210
211

SD105

K2-1
KM1

3SV

BSC+

EXC

SGN

A+

OV
RFI

2
3

PSU

SG-NE

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

OPT

8.0 GENERAL INFORMATION
KEY
1ATS
Switch, high airend discharge temperature
1DPS Switch, fouled oil filter
1VAC Switch, fouled air filter
1ATT
Sensor, airend inlet.
2ATT
Sensor, airend discharge temperature
2CTT Sensor, injected coolant temperature
3APT Transducer, sump pressure, wet side
3SV
Valve, blowdown solenoid
4APT Transducer, package air discharge pressure
4ATT
Sensor, package discharge temperature
4SV
Valve, water stop solenoid (W/C only)
6APT Transducer, sump air pressure, dry side
9APT Transmitter, remote air pressure (optional)
9SV
Valve, condensate drain
11SV
Valve, anti − condensation solenoid
AT
Autotransformer (if fitted)
AW1
Auxiliary warning 1
AW2
Auxiliary warning 2
BP
Backplate
C
Capacitor
CAB
Cabinet
CDE
Condensate drain error
CDV
Condensate drain valve. (if fitted)
CFO
Common fault output
CK
Choke
EXC
External communications
DR
Drive
DVF
Fan, drive box ventilation
EB
Earth bar
ES
Switch, emergency stop
FD
Drive, blower
FM
Motor, blower
GND
Ground
HC
Heater circuit
HTR1 Heater, spacer 25 Watts
HTR2 Heater, spacer 25 Watts
K1
Relay, run
K2
Relay fault
KM1
Contactor, main motor
KM5
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
Optional
OV
Zero voltage
PE
Protected earth
PORO Power outage restart option (optional)

PSU
RFI
RSP
RST
SGNE
SL
SS1−3
ST
T1
TH
TRR
WR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires

Power supply unit
Filter, radio frequency interference
Remote stop
Remote start
Controller, Intellisys
Serial link
Relay, solid state
Service tool
Transformer, control
Thermostat
True running relay
General warning
Colors
Black
Blue
Brown
Green
Pink
Red
Screened
Violet
White
Yellow

Numbers

Function

Wire color

1−99
100−199
200−299
300−399

Power
AC Control
DC Control
Auxiliary

Black
Red
Blue
Orange

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
8.4 Wiring schematic - n55-75k-cc / n75-100h-cc a/c

blower vfd
P

124

KM5-1

106

BLU
BLK
BRN
GRN/YEL

107
122

MCB2

DVF3
OPT

SG-NE

2
3
4

DVF

A+

BSC+

EXC

SC-

230V

PSU

ES-1

104

103

RFI

200/230V-3ph-50/60Hz

SGN

400/460V-3ph-50/60Hz

CAB

1ATS

110V 100

DVF

101

SD-

RF
I

216

RSP
RST
AW1

14
15

111

120

AW2

CDE (OPT)

18
1

112

KM5

2
P4

KM1

SS1

120

L1 L2 L3

SS2

241
214
215
252
253

27
01

116

1
2

+
U V

RED

116

9SV

1
2

108
MCB5

BLK

WHI

1
2

1
P1

1
P2
2

200

12V DC

201

5
P5

RED

1
2
3
4
5
6

1
2

2
3

1
P6

CFO

WHI

BLK
RED 4-20mA
+
WHI
P

RED

V
P

WHI

4APT

RED
BLK

V
P

WHI

3APT

RED
BLK
WHI

V
P

6APT

BLK
RED

WHI

7 230
8
K1-1
9 231
10

BLK

BLK
WHI

RED

WHI

7
9

BLK

6
8

BLK

PX2

P10

+ RECTIFIER
OUT

AO1
A11+
A11A12
OV
+24VDC
D11
D12
ENABLE
OV

1
RED
BLK
P5

+ DC-BUS

-253
BLK

U
V

OPT

+252
10

PSU

RED

GND

4-20 mA 9
OUTPUT

120

VIO

105 (110V)

120

BLU

1
2

PORO

114

11SV

BRO
W

126

115

GRE
U

BLK

MCB4

102

GND

YEL

SS3

TRR

2
1

125

123

PE
DR

FAULT

02
60

PX6

PX1

242

+24V
START
STOP

PX3

K1-2

PX4

240

+
-

113

3SV

4
5

1VAC

217

200V
MMS

215

MCB3

MCB1

214

12
P1

102

121

ES-2

213

1
110

1DPS

212

105

K2-1
KM1

3SV

7
P7

SD+

210
211

5
6

9APT

7
8

OPT

9
10

WHI
BLK

T 2CTT

WHI
BLK

T 2ATT

WHI
BLK

T 4ATT

WHI
BLK

T 1ATT

WHI
BLK

T 4CTT

GND
GND

TH
100

KM5-1

110/120V
50/60 HZ

HTR1

CDV

HTR2

OPT

121

24
MCB9

T1
PE

TH
20

KM5-1

220/230 V
50/60 HZ

HTR1

CDV

HTR2

OPT

23131337
Revision A

24
MCB9

LABEL DESCRIPTION
1ATS
SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
1DPS SWITCH, FOULED OIL FILTER
1VAC SWITCH, FOULED AIR FILTER
1ATT
SENSOR, AIREND INLET
2ATT
SENSOR, AIREND DISCHARGE TEMPERATURE
2CTT SENSOR, INJECTED COOLENT TEMPERATURE
52

LABEL
3APT
3SV
4APT
4ATT
4CTT

DESCRIPTION
TRANSDUCER, SUMP PRESSURE, WET SIDE
VALVE, BLOWDOWN SOLENOID
TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
SENSOR, OIL COOLER OUT TEMPERATURE

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
KEY
4SV
6APT
9APT
9SV
11SV
AT
AW1
AW2
BP
C
CAB
CDE
CDV
CFO
CK
EXC
DR
DVF
EB
ES
FD
FM
GND
HTR1
HTR2
K1
K2
KM1
KM5
MCB1
MCB2
MCB3
MCB4
MCB5
MCB9
MF
MM
MMS
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNE
SL
SS1-3
ST

VALVE, WATER STOP SOLENOID (W/C ONLY)
TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
TRANSMITTER, REMOTE AIR PRESSURE
(OPTIONAL)
VALVE, CONDENSATE DRAIN
VALVE, ANTI-CONDENSATION SOLENOID
AUTOTRANSFORMER (IF FITTED)
AUXILIARY WARNING 1
AUXILIARY WARNING 2
BACKPLATE
CAPACITOR
CABINET
CONDENSATE DRAIN ERROR
CONDENSATE DRAIN VALVE (IF FITTED)
COMMON FAULT OUTPUT
CHOKE
EXTERNAL COMMUNICATIONS
DRIVE
FAN, DRIVE BOX VENTILATION
EARTH BAR
SWITCH, EMERGENCY STOP
DRIVE, BLOWER
MOTOR, BLOWER
GROUND
HEATER, SPACER 25 WATTS
HEATER, SPACER 25 WATTS
RELAY, RUN
RELAY, FAULT
CONTACTOR, MAIN MOTOR
CONTACTOR, DRIVE VENTILATION FAN
BREAKER, MINIATURE CIRCUIT, TRANSFORMER
BREAKER, MINIATURE CIRCUIT, DVF
BREAKER, MINIATURE CIRCUIT, CONTROL
CIRCUITS
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINATURE CIRCUIT, PSU
BREAKER, MINIATURE CIRCUIT, HEATERS
MAINS FILTER (IF FITTED)
MOTOR, MAIN
BREAKER, FAN MOTOR
OPTIONAL
ZERO VOLTAGE
PROTECTED EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL

T1
TH
TRR
WR

TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
GENERAL WARNING

COLORS
BLK
BLACK
BLU
BLUE
BRO
BROWN
GRE
GREEN
PIN
PINK
RED
RED
SCR
SCREEN
VIO
VIOLET
WHI
WHITE
YEL
YELLOW
Wires
Numbers

Function

Wire color

1−99
Power
Black
100−199
AC Control
Red
200−299
DC Control
Blue
300−399
Auxiliary
Orange
NOTES:
1. FACTORY SUPPLIED AS SHOWN BY CONNECTION TO
OUTPUT OF CONTROL TRANSFORMER T1. WIRE NUMBER
100 & 121.
2. ALTERNATIVELY THE SUPPLY MAY BE TAKEN FROM AN
INDEPENDENT SOURCE: IN THAT CASE, FACTORY
SUPPLIED CONNECTION MUST BE DISCONNECTED.
3. ENSURE PARALLEL CONNECTION OF HEATERS.
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.

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
8.4 Wiring schematic - n37/45k-cc/n50/60h-cc w/c
124

KM5-1

106

BLU
BLK
BRN
GRN/YEL

107
122

MCB5

DVF3

DVF

OPT

SGNE

2
3
4

OV
MM

RFI

SC-

200/230V-3ph-50/60Hz
ES-1

110V 100

4SV

101

102

DVF

I
RF

110

KM1

MMS
17

PX6
1

PX1

YEL

125

102
115

RED

GRE

3
4

120

116

1
P2
2

200

PORO

4-20 mA 9
OUTPUT

RED

201

1
WHI
2
3
WHI
4
BLK
5
RED

RED 4-20mA
+
WHI
P

1
2

CFO

OPT

BLK
WHI

2
3
P6

T 2CTT

WHI
BLK

T 2ATT

BLK

TH
KM5-1

HTR1

CDV

HTR2

OPT

24
MCB9

T1
PE

TH
20

KM5-1

220/230 V
50/60 HZ

HTR1

CDV

HTR2

OPT

24
MCB9

6APT

BLK

121

WHI

5
6

110/120V
50/60 HZ

WHI

K1-1

3APT

RED

BLK
RED

4APT

BLK
WHI

9APT

100

WHI

BLK

RED

BLK

WHI

RED

BLK

P10

RED

GND
GND

22776520
Revision B

105 (110V)

120

BLK
P5

7
230
8
9
231
10

2
1

12V DC

TRR

2
1

WHI

AO1
A11+
A11A12
OV
+24VDC
D11
D12
ENABLE
OV

SS3

CK
+ RECTIFIER
OUT

BLK

2
3

MCB5

U
V

SS2

PSU
108

GND

114

9SV

BLK

113

3SV
11SV

+ DC-BUS

3
6

SS1

KM5
120

VIO

2
P4

BLU

112

KM4

RED

DR
PX3

AW2
CDE (OPT)

1
3

126
MCB4

GND

BLK

BRO

PX2

PX4

111

PE
DR

AW1

4SV

116
123

RST

KM4

RSP

KM1

1VAC

217

18
L2

216

200V

MMS-1

215

MCB1

214

120

ES-2

213

105

K2-1

121

1DPS

212

SD-

1ATS

104

103

MCB3

9SV

7
P7

SD+

400/460V-3ph-50/60Hz

CAB
3SV

SC+

EXC

SGN

B-

230V

PSU

A+

210
211

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

T 4ATT

OPT

8.0 GENERAL INFORMATION
KEY
1ATS
1DPS
1VAC
1ATT
2ATT
2CTT
3APT
3SV
4APT
4ATT
4SV
6APT
9APT
9SV
11SV
AT
AW1
AW2
BP
C
CAB
CDE
CDV
CFO
CK
EXC
DR
DVF
EB
ES
FD
FM
GND
HTR1
HTR2
K1
K2
KM1
KM4
KM5
MCB1
MCB2
MCB3
MCB4
MCB5
MCB9
MF
MM

SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
SWITCH, FOULED OIL FILTER
SWITCH, FOULED AIR FILTER
SENSOR, AIREND INLET
SENSOR, AIREND DISCHARGE TEMPERATURE
SENSOR, INJECTED COOLENT TEMPERATURE
TRANSDUCER, SUMP PRESSURE, WET SIDE
VALVE, BLOWDOWN SOLENOID
TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
VALVE, WATER STOP SOLENOID (W/C ONLY)
TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
TRANSMITTER, REMOTE AIR PRESSURE
(OPTIONAL)
VALVE, CONDENSATE DRAIN
VALVE, ANTI-CONDENSATION SOLENOID
AUTOTRANSFORMER (IF FITTED)
AUXILIARY WARNING 1
AUXILIARY WARNING 2
BACKPLATE
CAPACITOR
CABINET
CONDENSATE DRAIN ERROR
CONDENSATE DRAIN VALVE (IF FITTED)
COMMON FAULT OUTPUT
CHOKE
EXTERNAL COMMUNICATIONS
DRIVE
FAN, DRIVE BOX VENTILATION
EARTH BAR
SWITCH, EMERGENCY STOP
DRIVE, BLOWER (A/C ONLY)
MOTOR, BLOWER
GROUND
HEATER, SPACER 25 WATTS
HEATER, SPACER 25 WATTS
RELAY, RUN
RELAY, FAULT
CONTACTOR, MAIN MOTOR
CONTACTOR, FAN MOTOR (W/C ONLY)
CONTACTOR, DRIVE VENTILATION FAN
BREAKER, MINIATURE CIRCUIT, TRANSFORMER
BREAKER, MINIATURE CIRCUIT, DVF
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINIATURE CIRCUIT, PSU
BREAKER, MINIATURE CIRCUIT, HEATERS
MAINS FILTER (IF FITTED)
MOTOR, MAIN

MMS
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNE
SL
SS1-3
ST
T1
TH
TRR
WR
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires

BREAKER, FAN MOTOR
OPTIONAL
ZERO VOLTAGE
PROTECTED EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
GENERAL WARNING
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW

Numbers

Function

Wire color

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
8.4 Wiring schematic - n55-75k-cc / n75-100h-cc W/c

124

KM5-1

106

BLU
BLK
BRN
GRN/YEL

107
122

MCB5

DVF3

DVF

OPT

SGNE

2
3
4

OV
MM

RFI

SC-

200/230V-3ph-50/60Hz
ES-1

110V 100

4SV

101

102

DVF

104

103

RF
I

121

110

MMS
17

PX6
PE
DR

PX1

YEL

125

102
115

RED

GRE

3
4

120

4-20 mA 9
OUTPUT

2
3

WHI

P2
2

200

12V DC
RED

201

P10

5
P5

RED

1
WHI
2
3
WHI
4
BLK
5

RED 4-20mA
+
WHI
P

RED

BLK

1
2

2
3

1
CFO

OPT

2
3

K1-1

4
5
6

BLK

8
9
10

110/120V
50/60 HZ

BLK
WHI

T 2ATT

WHI
BLK

HTR1

BLK

HTR2

23131345
Revision A

220/230 V
50/60 HZ

HTR1

CDV

HTR2

OPT

24
MCB9

T 4ATT

WHI

TH
22

6APT

T 2CTT

KM5-1

WHI
BLK

BLK

MCB9

3APT

WHI

OPT

4APT

RED

CDV

121

WHI

TH
KM5-1

GND
GND

RED

BLK
RED

9APT

100

WHI

BLK
WHI

RED

WHI

7
9

BLK

6
8

BLK

7
230
8
9
231
10

BLK
P5

105 (110V)

AO1
A11+
A11A12
OV
+24VDC
D11
D12
ENABLE
OV

116

+ RECTIFIER
OUT

2
1

BLK

+
-

SS3

TRR

2
1

PORO

MCB5
+ DC-BUS

SS2

120

PSU

U
V

SS1

114

9SV

BLK

108

GND

113

3SV
11SV

VIO

KM5
120

BLU

2
P4

112

3
6

AW2
CDE (OPT)

1
3

RED

DR
PX3

AW1

18
111

KM4

RST

126
MCB4

GND

BLK

BRO

PX2

PX4

RSP

116
123

1VAC

217

4SV
K1

216

KM1

MMS-1

215

KM4

214

200V

ES-2

213

P1
KM1

1DPS

212

SD105
1

120

MCB1

1ATS

K2-1

MCB3

9SV

7
P7

SD+

400/460V-3ph-50/60Hz

CAB
3SV

SC+

EXC

SGN

B-

230V

PSU

A+

210
211

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

T 4CTT

OPT

8.0 GENERAL INFORMATION
KEY
1ATS
1DPS
1VAC
1ATT
2ATT
2CTT
3APT
3SV
4APT
4ATT
4CTT
4SV
6APT
9APT
9SV
11SV
AT
AW1
AW2
BP
C
CAB
CDE
CDV
CFO
CK
EXC
DR
DVF
EB
ES
FD
FM
GND
HTR1
HTR2
K1
K2
KM1
KM4
KM5
MCB1
MCB2
MCB3
MCB4
MCB5
MCB9
MF

SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
SWITCH, FOULED OIL FILTER
SWITCH, FOULED AIR FILTER
SENSOR, AIREND INLET
SENSOR, AIREND DISCHARGE TEMPERATURE
SENSOR, INJECTED COOLENT TEMPERATURE
TRANSDUCER, SUMP PRESSURE, WET SIDE
VALVE, BLOWDOWN SOLENOID
TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
SENSOR, OIL COOLER OUT TEMPERATURE
VALVE, WATER STOP SOLENOID (W/C ONLY)
TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
TRANSMITTER, REMOTE AIR PRESSURE
(OPTIONAL)
VALVE, CONDENSATE DRAIN
VALVE, ANTI-CONDENSATION SOLENOID
AUTOTRANSFORMER (IF FITTED)
AUXILIARY WARNING 1
AUXILIARY WARNING 2
BACKPLATE
CAPACITOR
CABINET
CONDENSATE DRAIN ERROR
CONDENSATE DRAIN VALVE (IF FITTED)
COMMON FAULT OUTPUT
CHOKE
EXTERNAL COMMUNICATIONS
DRIVE
FAN, DRIVE BOX VENTILATION
EARTH BAR
SWITCH, EMERGENCY STOP
DRIVE, BLOWER (A/C ONLY)
MOTOR, BLOWER
GROUND
HEATER, SPACER 25 WATTS
HEATER, SPACER 25 WATTS
RELAY, RUN
RELAY, FAULT
CONTACTOR, MAIN MOTOR
CONTACTOR, FAN MOTOR (W/C ONLY)
CONTACTOR, DRIVE VENTILATION FAN
BREAKER, MINIATURE CIRCUIT, TRANSFORMER
BREAKER, MINIATURE CIRCUIT, DVF
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINIATURE CIRCUIT, VFD SUPPLY
BREAKER, MINIATURE CIRCUIT, PSU
BREAKER, MINIATURE CIRCUIT, HEATERS
MAINS FILTER (IF FITTED)

MM
MMS
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNE
SL
SS1-3
ST
T1
TH
TRR
WR
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires

MOTOR, MAIN
BREAKER, FAN MOTOR
OPTIONAL
ZERO VOLTAGE
PROTECTED EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
GENERAL WARNING
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW

Numbers

Function

Wire color

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
8.4 Wiring schematic - n75-160k-cc / n125-200h-cc A/c
L1

MCB1

HTR

CDV

3SV

9SV

CAB

KM1

ES-1

104

103

SHT 2

1ATS

101
121

B-

SC+

120

SC-

SD+

SD-

6
7
P3

105

110

120

113

3SV

242
214
215
252
253

9SV

102

123

2 P1

RECTIFIER

1
2
7

YEL

RED

201

P10

BLU

1
2

DI2

DI1

+24Vdc

0V
AI2

V
W

BLK

BLK
RED

1
2

230

K1-1 1-STG ONLY

230

K1-1 2-STG ONLY

8
9

CFO

9APT

BLK
WHI

P
V

WHI

3APT

P
V
P

6APT
2APT
2 STG
ONLY

WHI
BLK

T 2CTT

WHI
BLK

T 2ATT

WHI

BLK

T 4ATT

WHI
BLK

T 1ATT

WHI

BLK

T 4CTT

WHI

MAIN INPUT
TERMINALS
OPTIONS

TH
KM5-2

MAINS FILTER
L1

CDV

BLK
RED
BLK

MCB9

110/120 V
50/60 HZ
FROM SHT 1

OPT

RED

AI1-

WHI 4-20mA
RED
+
P

4APT

RED

11
12

WHI

231

HEATER CIRCUITS:100

BLK

BLK
WHI

WHI

RED

BLK

WHI

AI1+
AO1

BLK

ENABLE

GND
1

RED

BLK

RED

3
4

VIO

SIGNAL

GND

PX2

BRO

PX3

BLK

RED

252

GRE

WR
105 (110V)

253

12V DC

PX4

200

BLK

GND
U

1
2

WHI

1
3

+ DC-BUS

+12V

PSU
MCB4

116

9
10

4-20 mA
OUTPUT

120

FAULT

U V

TRR

120

108

11
20

SS3

2
1

PORO

9
12

2
7

SS2

151

PX1

K1-2
241

4
6

SS1

3
5

114

11SV

MCB3

L1 L2 L3
240

CDE (OPT)

152
PX6

AW1
AW2

MMS1
16

RST

153

RSP

2
151

200v 150

1VAC

217

2
W

OPT

HTR1

STANDARD HEATER
CONNECTIONS AS
DELIVERED

HTR2

L2
LINE

AUTO - TRANSFORMER
L3

LOAD
L2

L1
L1

L3
L3

121
SUPPLIED BY CUSTOMER
TH
MCB10
OR

KM5-2

F10
110/120 V
50/60 HZ
EXTERNAL SUPPLY

100
MCB9

110/120 V
50/60 HZ
FROM SHT 1

HTR1

HTR2

ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
110 / 120 V SUPPLY

HTR2

ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
220 / 230 V SUPPLY

CDV

OPT

SUPPLIED BY CUSTOMER
TH

121

MCB10
OR

121

KM5-2

F10

22093058
Revision M
58

214B
MMS2-1

216

112

KM5

214A
MMS1-1

215

KM5
V

214

ES-2

213

111

1DPS

212

11
P1

KM1

102
RF
I

MCB2
13

210
211

K2-1

110v

A+

EXC

MMS2

SG-Ne
11SV

SGNe

RFI

PSU

380-480V
50/60 Hz 3ph + PE

220/230 V
50/60 HZ
EXTERNAL SUPPLY

HTR1

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

OPT

8.0 GENERAL INFORMATION
KEY
1ATS

SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
1ATT
SENSOR, INLET TEMPERATURE
1DPS SWITCH, FOULED OIL FILTER
1VAC SWITCH, FOULED AIR FILTER
2APT SENSOR, INTERSTAGE PRESSURE (2STG ONLY)
2ATT
SENSOR, AIREND DISCHARGE TEMPERATURE
2CTT SENSOR, INJECTED COOLENT TEMPERATURE
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE
3SV
VALVE, BLOWDOWN SOLENOID
4APT TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
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)
9SV
VALVE, CONDENSATE DRAIN
11SV
VALVE, ANTI-CONDENSATION SOLENOID 1
AT
AUTOTRANSFORMER (IF FITTED)
AW1
AUXILIARY WARNING 1
AW2
AUXILIARY WARNING 2
BP
BACKPLATE
C
CAPACITOR
CAB
CABINET
CDE
CONDENSATE DRAIN ERROR (OPTIONAL)
CDV
CONDENSATE DRAIN VALVE (IF FITTED)
CFO
COMMON FAULT OUTPUT
CK
CHOKE
DR
DRIVE
EB
EARTH BAR
ES
SWITCH, EMERGENCY STOP
EXC
EXTERNAL COMMUNICATIONS
F10
FUSE, EXTERNAL HEATER SUPPLY
FD
FAN DRIVE
FM
MOTOR, BLOWER
GND
GROUND
HB
HEATSINK BLOWER
HTR1 HEATER, 125 WATTS
K1
RELAY, RUN
K2
RELAY, FAULT
KM1
CONTACTOR, MAIN MOTOR
KM5
CONTACTOR, HEATSINK BLOWER
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)
MF
MAINS FILTER (IF FITTED)

MM
MMS1
MMS2
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNe
SL
SS1-3
ST
T1
TH
TRR
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires

MOTOR, MAIN
BREAKER, FAN MOTOR
BREAKER, HEATSINK BLOWER
OPTIONAL
ZERO VOLTAGE
PROTECTIVE EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW

Numbers

Function

Wire color

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
8.4 Wiring schematic - n75-160k-cc / n125-200h-cc W/c

MCB1

CDV

HTR

3SV

9SV

SGNe

RFI

PSU

CAB

380-480V
50/60 Hz 3ph + PE

11SV

1
KM1
EXC

SHT 2

ES-1

KM5

101

110v

1ATS

104

103

102

RF
I

121

2
3

A+

B-

SC+

SC-

SD+

SD-

110

KM1

ES-2

213
214
215

214A
MMS1-1

MMS2-1

216
1VAC

217

RSP
RST

12
P1

1DPS

212

11
1

120

210
211

10
105

K2-1

MCB2
15

SG-Ne

AW1

AW2

16
2

MMS2
U

MMS1

151

200v 150

153

4SV
MCB3

FM
L1

112

KM5
PX6
PX1

1
2

120

102
123

114

11SV

120

113

3SV

SS2

108

MCB4

2 P1

116

200

12V DC

BLK

4-20 mA
OUTPUT

WHI

VIO

ENABLE

DI2

DI1

+24Vdc

GND
1

BLK

0V
AI2

V
W

AI1-

AI1+

AO1

K1-1 1-STG ONLY

230

K1-1 2-STG ONLY

WHI 4-20mA
RED
+
P

OPT
CFO

3
BLK
WHI

T 2CTT

WHI
BLK

T 2ATT

BLK

T 4ATT
T 1ATT

WHI
BLK

T 4CTT

MAIN INPUT
TERMINALS
OPTIONS

TH
23

MAINS FILTER
L1

L2
LINE

AUTO - TRANSFORMER
L3

CDV

OPT

HTR1

STANDARD HEATER
CONNECTIONS AS
DELIVERED

HTR2

LOAD
L2

L1
L1

L3
L3

121
SUPPLIED BY CUSTOMER
TH
MCB10
OR

KM5-2

F10
110/120 V
50/60 HZ
EXTERNAL SUPPLY

100
MCB9

110/120 V
50/60 HZ
FROM SHT 1

HTR1

HTR2

ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
110 / 120 V SUPPLY

HTR2

ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
220 / 230 V SUPPLY

CDV

OPT

SUPPLIED BY CUSTOMER
TH

121

MCB10
OR

121

KM5-2

F10

22258891
Revision E

220/230 V
50/60 HZ
EXTERNAL SUPPLY

2APT
2 STG
ONLY

WHI

MCB9

110/120 V
50/60 HZ
FROM SHT 1

BLK

6APT

WHI

P
V

WHI

KM5-2

BLK

9APT

3APT

RED

WHI

RED

HEATER CIRCUITS:100

BLK

4APT

RED

BLK
RED

WHI

230

BLK

RED

BLK
WHI

WHI

231

BLK

P10

WHI

RED

1
RED

201

GND

BLU

PORO

BLK

PX2

BRO

102 (110V)

1
2

120
6

BLK

PX4

GRE

PX3

RED

3
6

RED

2
1

BLK

BLK
GND

YEL

TRR

2
1

10
9SV

RECTIFIER

SS3

PSU
+ DC-BUS

4
6

151

SS1

3
5

152

CDE (OPT)

111

HTR1

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

OPT

8.0 GENERAL INFORMATION
KEY
1ATS

SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
1ATT
SENSOR, INLET TEMPERATURE
1DPS SWITCH, FOULED OIL FILTER
1VAC SWITCH, FOULED AIR FILTER
2APT SENSOR, INTERSTAGE PRESSURE (2STG ONLY)
2ATT
SENSOR, AIREND DISCHARGE TEMPERATURE
2CTT SENSOR, INJECTED COOLENT TEMPERATURE
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE
3SV
VALVE, BLOWDOWN SOLENOID
4APT TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
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)
9SV
VALVE, CONDENSATE DRAIN
11SV
VALVE, ANTI-CONDENSATION SOLENOID 1
AT
AUTOTRANSFORMER (IF FITTED)
AW1
AUXILIARY WARNING 1
AW2
AUXILIARY WARNING 2
BP
BACKPLATE
C
CAPACITOR
CAB
CABINET
CDE
CONDENSATE DRAIN ERROR (OPTIONAL)
CDV
CONDENSATE DRAIN VALVE (IF FITTED)
CFO
COMMON FAULT OUTPUT
CK
CHOKE
DR
DRIVE
EB
EARTH BAR
ES
SWITCH, EMERGENCY STOP
EXC
EXTERNAL COMMUNICATIONS
F10
FUSE, EXTERNAL HEATER SUPPLY
FM
MOTOR, BLOWER
GND
GROUND
HB
HEATSINK BLOWER
HTR1 HEATER, 125 WATTS
K1
RELAY, RUN
K2
RELAY, FAULT
KM1
CONTACTOR, MAIN MOTOR
KM5
CONTACTOR, HEATSINK BLOWER
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)
MF
MAINS FILTER (IF FITTED)

MM
MMS1
MMS2
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNe
SL
SS1-3
ST
T1
TH
TRR
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires

MOTOR, MAIN
BREAKER, FAN MOTOR
BREAKER, HEATSINK BLOWER
OPTIONAL
ZERO VOLTAGE
PROTECTED EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW

Numbers

Function

Wire color

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

8.0 GENERAL INFORMATION
8.4 Wiring schematic - n250-300H
L1

P
EB

MCB1

CDV

HTR

3SV

9SV

CAB

EXC
KM1

230v
124 MCB5

115

107

106

5SV

K1-3

KM5-1

DVF

ES-1

122

1ATS

104

103

SHT 2

101
I
RF

120

A+

B-

SC+

SC-

SD+

SD-

6
7

105

112

151

120

113

3SV

214
215
252
253

20
21

PX6
1

PX1

9SV

102
123

2 P1

RECTIFIER

PX3

BLK

RED

201

P10

VIO

GND
1

ENABLE

DI2

DI1

+24Vdc

0V
AI2

PX2

AI1AI1+

AO1

HEATER CIRCUITS:21

100

BLK

230

K1-1 1-STG ONLY

230

K1-1 2-STG ONLY

WHI 4-20mA
RED
+
P

9APT

OPT

T 2CTT
T 2ATT

BLK

MAINS FILTER
L2
LINE

BLK

AUTO - TRANSFORMER
L3

OPT

HTR1

STANDARD HEATER
CONNECTIONS AS
DELIVERED

HTR2

LOAD
L2

L1
L1

L3
L3

121
SUPPLIED BY CUSTOMER
TH
MCB10
OR

KM5-2

F10
110/120 V
50/60 HZ
EXTERNAL SUPPLY

100
MCB9

110/120 V
50/60 HZ
FROM SHT 1

HTR1

HTR2

ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
110 / 120 V SUPPLY

HTR2

ALTERNATIVE HEATER
CONNECTION FOR EXTERNAL
220 / 230 V SUPPLY

CDV

OPT

SUPPLIED BY CUSTOMER
TH

121

MCB10
OR

121

KM5-2

F10

22407100
Revision C

220/230 V
50/60 HZ
EXTERNAL SUPPLY

HTR1

T 4ATT

WHI

MAIN INPUT
TERMINALS
OPTIONS
23

2APT
2 STG
ONLY

WHI
BLK

WHI

6APT

BLK

CDV

P
V

WHI

MCB9

110/120 V
50/60 HZ
FROM SHT 1

7
BLK
WHI

3APT

WHI

RED

WHI

CFO

WHI

TH
KM5-2

BLK
RED
BLK

1
1

4APT

RED

11
12

WHI

231

BLK

BLK
RED

RED

8
BLK
WHI

WHI

BLK

GND

BLU

RED

BLK

RED

BLK

RED

SIGNAL

PX4

BRO

252

YEL

GRE

WR
105 (110V)

253

BLK

GND

12V DC

WHI

200

+12V

PSU

3
+ DC-BUS

116

9
10

4-20 mA
OUTPUT

120

MCB4

TRR

120

FAULT

U V

SS3

2
1

PORO

108

151

9
11

SS2

4
5

114

11SV

MCB3

SS1

CDE (OPT)

152

2
7

AW1
AW2

L1 L2 L3

242

RST

MMS1

K1-2

RSP

241

1VAC

217

214B
MMS2-1

216

153

240

214A
MMS1-1

215

200v 150

214

ES-2

213

111

KM5

1DPS

212

210
211

110

MCB2
121

KM1

102

K2-1

110v

SG-Ne
11SV

SGNe

RFI

PSU

380-480V
50/60 Hz 3ph + PE

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
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T 1ATT

OPT

8.0 GENERAL INFORMATION
KEY
1ATS

SWITCH, HIGH AIR END DISCHARGE
TEMPERATURE
1ATT
SENSOR, INLET TEMPERATURE
1DPS SWITCH, FOULED OIL FILTER
1VAC SWITCH, FOULED AIR FILTER
2APT SENSOR, INTERSTAGE PRESSURE (2STG ONLY)
2ATT
SENSOR, AIREND DISCHARGE TEMPERATURE
2CTT SENSOR, INJECTED COOLENT TEMPERATURE
3APT TRANSDUCER, SUMP PRESSURE, WET SIDE
3SV
VALVE, BLOWDOWN SOLENOID
4APT TRANSDUCER, PACKAGE AIR DISCHARGE
PRESSURE
4ATT
SENSOR, PACKAGE AIR DISCHARGE
TEMPERATURE
6APT TRANSDUCER, SUMP AIR PRESSURE, DRY SIDE
9APT TRANSDUCER, REMOTE AIR PRESSURE
(OPTIONAL)
9SV
VALVE, CONDENSATE DRAIN
11SV
VALVE, ANTI-CONDENSATION SOLENOID 1
AT
AUTOTRANSFORMER (IF FITTED)
AW1
AUXILIARY WARNING 1
AW2
AUXILIARY WARNING 2
BP
BACKPLATE
C
CAPACITOR
CAB
CABINET
CDE
CONDENSATE DRAIN ERROR (OPTIONAL)
CDV
CONDENSATE DRAIN VALVE (IF FITTED)
CFO
COMMON FAULT OUTPUT
CK
CHOKE
DR
DRIVE
EB
EARTH BAR
ES
SWITCH, EMERGENCY STOP
EXC
EXTERNAL COMMUNICATIONS
F10
FUSE, EXTERNAL HEATER SUPPLY
FD
FAN DRIVE
FM
MOTOR, BLOWER
GND
GROUND
HTR1 HEATER, 125 WATTS
K1
RELAY, RUN
K2
RELAY, FAULT
KM1
CONTACTOR, MAIN MOTOR
KM5
CONTACTOR, HEATSINK BLOWER
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)
MF
MAINS FILTER
MM
MOTOR, MAIN

MMS1
OPT
OV
PE
PORO
PSU
RFI
RSP
RST
SGNe
SL
SS1-3
ST
T1
TH
TRR
DVF
5SV
COLOR
BLK
BLU
BRO
GRE
PIN
RED
SCR
VIO
WHI
YEL
Wires

BREAKER, FAN MOTOR
OPTIONAL
ZERO VOLTAGE
PROTECTIVE EARTH
POWER OUTAGE RESTART OPTION (OPTIONAL)
POWER SUPPLY UNIT
FILTER, RADIO FREQUENCY INTERFERENCE
REMOTE STOP
REMOTE START
CONTROLLER, INTELLISYS
SERIAL LINK
RELAY, SOLID STATE
SERVICE TOOL
TRANSFORMER, CONTROL
THERMOSTAT
TRUE RUNNING
FAN, DRIVE VENTILATION
VALVE, COOLANT STOP
BLACK
BLUE
BROWN
GREEN
PINK
RED
SCREEN
VIOLET
WHITE
YELLOW

Numbers

Function

Wire color

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
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8.0 GENERAL INFORMATION
8.5 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 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.
Air is pulled into the machine by the cooling blower
(N250−300H use a propeller fan for cooling) and through
the combined cooler / aftercooler.
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.

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 compressor is provided with a temperature sensor
which will shut the unit down in case of excessive
temperature, 109° C (228° F).
Effective coolant filtration is provided by the use of a
screw on, heavy duty coolant filter.

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.

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
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9.0 OPERATING INSTRUCTIONS
9.1 BASIC OPERATION

Prior to starting

warning
Ensure that all protective covers/guards are in place before
attempting to start the machine.

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.

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.

Refer to diagram T5716 above.
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.
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 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.
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.
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.

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
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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”.

Stop sequence
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.
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 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.
Stopping the machine in an emergency
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.
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.

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
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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.

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.
3. Stop
Pressing this button will activate the stop sequence.
4. F1
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.
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.
7. Display buttons
The functions of the three buttons below the display screen
change and are defined by the words immediately above them in
the bottom line of the screen. Each function, such as MAIN MENU,
STATUS, etc., is described in appropriate sections in this manual.

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
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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 left side continuously shows the package discharge pressure
in large numbers with the line directly below showing the running
condition of the machine

100

− CURRENT STATUS −
PACKAGE DISCHARGE
TEMP
102° F
AIREND DISCHARGE
TEMP
192° F

PSI

READY TO START
MAIN MENU

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 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.

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
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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.
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

14 Motor Speed
15 Motor Current
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

Use the UP and DOWN arrows to move between selections.

20 Time and Date

CURRENT STATUS items

21 Program Name

% Energy Saving

22 Version of Drive Software

% Capacity

Package kW

Package Discharge Temperature

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.

Airend Discharge Temperature

Injected Coolant Temperature

Inlet Temperature

Sump Pressure

Separator Pressure Drop

10 Interstage Pressure
11 Coolant Filter
12 Inlet Filter

19 Remote Pressure (optional)

The ENERGY STATUS screen displays the following items.
ENERGY STATUS Items
1

Average Package kW−hr

Average % Capacity

Average Capacity

Energy Cost

Energy Savings

Lifetime Energy Savings

13 Total Hours

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
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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

The MAIN MENU screen is the point from which various operator
functions can be accessed. Refer to the Operator Panel Flow
Diagram.

PSI
−MAIN MENU−

READY TO START

Each of the functions can be chosen by using the up and down
arrows to highlight it on the screen.
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”

OPERATOR SETPOINTS
OPTIONS
SENSOR CALIBRATION
ALARM HISTORY

STATUS

CURRENT
STATUS/ENERGY
STATUS

SELECT

Energy
Status

“Main Menu”
“Status”

MAIN MENU

“Main Menu”
“Select”
“Main Menu”

“Main
Menu”

OPERATOR
SETPOINTS

“Status”

“Main Menu”

OPTIONS

“Status”

“Status”
“Select”

“Select”

OPERATOR
SETPOINTS
ITEM

“Main Menu”
“Status”

SENSOR
CALIBRATION
ITEM

“Cancel or set”

ALARM
HISTORY

“Main Menu”
“Status”

ALARM
HISTORY ITEM

“Status”

“Alarm hist”

“Cancel or calibrate”

CLOCK
FUNCTIONS
“Select”

“Select”
“Main Menu”

“Select”

OPTIONS ITEM

“Cancel or set”

“Main
Menu”
“Status”

SENSOR
CALIBRATION

DATE
AND TIME

“Main Menu”
“Status”

ENERGY
STATUS

“Main
Menu”

AVG. PACKAGE kW HRS
AVG. % CAPACITY
AVG. CAPACITY
ENERGY COST
ENERGY SAVINGS
“Status” LIFETIME ENERGY SAVINGS

“Cancel or set”
“Cancel or set”

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
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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
DEFAULT

MIN.

MAX.

STEP

UNIT

Target pressure

OPERATOR SETPOINTS

100

145 / 203

PSI

Automatic stop pressure

110

Target +1

Target +10

PSI

Immediate stop pressure

120

Auto

Auto +10

PSI

Blowdown mode

Off

−

Condensate release

SEC.

Condensate interval

180

270

SEC.

Modulation

−

% savings compared to
Energy Rate

9999.999

−

Reset Avg.

−

Reset Date

−

Service menu

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.
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.

Unit

Min

Max (1S / 2S)

Step

PSI

145 / 203

BAR

4.4

10 / 14

0.1

kPa

440

1000 / 1400

KGCM2

4.5

10.2 / 14.2

0.1

Note: the max target pressure for N250/300H−2S is 145 PSI, 10 BAR ,
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.

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
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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.

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.
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.

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
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.
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

−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
An Option item’s value can be changed the same way that
OPERATOR SETPOINTS values are changed.
OPTIONS Items

SELECTION

PSI

READY TO START

REMOTE START/STOP ON

STATUS

MIN.

REMOTE START/STOP ON

MAX.

MAIN MENU
Step

Unit

SELECT
Installed
Option
Required

Remote Pressure Sensor

ON/OFF

Sequencer

ON/OFF

Remote Start/Stop

ON/OFF

Yes

Power Out Restart

ON/OFF

Power Out Restart Time
Scheduled Start Day
Scheduled Start
Scheduled Stop Day
Scheduled Stop
Modbus Protocol
Modbus Address

Yes
10

600

SEC

Yes

day

Yes

00:00

23:59

time

Yes

day

Yes

00:00

23:59

time

Yes

ON/OFF/ICU

No
1

247

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.

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.
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.

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.
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.

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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
the time stored in this setpoint. To disable this option, set the value
of scheduled start equal to the value of scheduled stop.

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 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.
100

PSI
−SENSOR CALIBRATION−

READY TO START

STATUS

SENSOR 4APT
CALIBRATE
SENSOR 3APT
CALIBRATE
MAIN MENU

SELECT

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)
Sensor 9APT (Remote Sensor)
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.

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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.
100

PSI
−ALARM HISTORY−

READY TO START

STATUS

ALARM HISTORY 1
BLOWER MOTOR
OVERLOAD
ALARM HISTORY 2
HIGH AIREND DISCH
TEMP
MAIN MENU

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.
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.

SELECT

9.10 CLOCK FUNCTIONS
100

PSI
−CLOCK FUNCTIONS−

READY TO START

Time
01:15
Date
Jan 01, 00

STATUS

MAIN MENU

SELECT

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.
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.
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
100

PSI
−ENERGY STATUS−

READY TO START

AVERAGE PACKAGE kW
HRS
AVERAGE % CAPACITY−
−AVERAGE CAPACITY

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.

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.
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.
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.
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).

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.
A Warning needs to be reset by the operator by pressing the RESET
button twice.
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.

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.
AUXILIARY WARNING 1 or 2 − Will occur if the auxiliary warning
input closes.
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.
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.
HIGH AIREND DISCH TEMP− Will occur if airend discharge
temperature is greater than 95% of 109° C (228° F).

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
−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.
The compressor will stop and cannot be re−started again until the
alarm condition no longer exists and the alarm message reset.
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.
The name and value of each of the items listed can be seen by
moving the list up and down using the arrow buttons. Pressing the
ALARM button will return the display to the Alarm screen and the
RESET button.
The Alarm needs to be reset by the operator by pressing the RESET
button twice. Any exceptions to this are explained in the alarm
descriptions.
100

PSI
−ALARM STATUS−

STOPPED BY
ALARM

PACKAGE DISCH
PRESSURE
100 psi
PACKAGE DISCHARGE
TEMP
103° F

ALARM

MAIN MENU

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.
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).
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.
REMOTE STOP FAILURE− This will occur if the Remote Stop button
remains open and either Start button is pressed.

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.
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.
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.
CHECK MOTOR ROTATION − This will occur if the Intellisys reads a
negative speed from the VSD when starting .
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.
VSD INITIALIZATION FAULT − Will occur if the Intellisys is unable to
establish communications with the VSD after a power up.
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.
REPLACE COOLANT FILTER − This will occur if the coolant filter is
blocked and requires changing.
INCORRECT VSD TYPE − Will occur at power up if the VSD type
does not match the size of the compressor
125HP (90kW) machines and above also have the following alarm
messages;
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.
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.
HIGH INTERSTAGE PRESSURE − If the interstage pressure is over
100psi while the unit is running and the unit is a 2−stage.

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 customer can only reset the warning for 24 hours by
pressing the “set” button.

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.

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:

150
(1st time
only)

™

500
1000

2000
6000

4000
12000

1500
2500
3000

10000
14000
18000

20000

Change

Air filter **

Check
pressure

Change

Separator element ***

Check
pressure

Change

Sample

Change

Check /
clean

Check

Daily
Coolant filter

Change

ULTRA COOLANT*

Check

Power Drive Module filter *

Check

Scavenge screen **
Hoses ***
High Air Temperature sensor

Check

Pressure relief valve

8000
16000

Cooler Core(s)

Check /
clean

Moisture separator

Check /
clean

Motor cowl

Check /
clean

Vibration Analysis

Analysis

Coolant Analysis

Analysis

Regrease

Food Grade Coolant *

Analysis at every 500
Change at every 1000

Blower Motor / Fan Motor
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 compressor until this has been carried out. Ensure that all pressure has been vented from the compressor. Verify this
by slowly unscrewing the coolant fill cap one turn. Unscrewing the fill cap opens a vent hole, drilled in the
cap, allowing pressure to release to atmosphere. Do not remove the fill cap until all pressure has vented from
the unit. Note that pipework downstream of the separator tank may still contain pressure that must also be
vented to atmosphere before beginning any work.

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

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

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10.0 MAINTENANCE
Compressed air can be dangerous if incorrectly handled.
Before doing any work on the unit, ensure that all
pressure is vented from the system and that the machine
cannot be started accidentally.
Ensure that maintenance personnel are adequately
trained, competent and have read the Maintenance
Manuals.
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.
• the machine cannot be started accidentally or
otherwise, by posting warning signs and/or fitting
appropriate anti−start devices.
• all residual electrical power sources (mains and battery)
are isolated.
Prior to opening or removing panels or covers to work
inside a machine, ensure that:−
• anyone entering the machine is aware of the reduced
level of protection and the additional hazards,
including hot surfaces and intermittently moving parts.
• the machine cannot be started accidentally or
otherwise, by posting warning signs and/or fitting
appropriate anti−start devices.

Prior to attempting any maintenance work on a
running machine, ensure that:−
• the work carried out is limited to only those tasks
which require the machine to run.
• 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.).
• appropriate personal protective equipment is worn.
• loose clothing, jewelry, long hair etc. is made safe.
• warning signs indicating that Maintenance Work is in
Progress are posted in a position that can be clearly
seen.
Upon completion of maintenance tasks and prior to
returning the machine into service, ensure that:−
•
•
•
•

the machine is suitably tested.
all guards and safety protection devices are refitted.
all panels are replaced, canopy and doors closed.
hazardous materials are effectively contained and
disposed of.

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10.0 MAINTENANCE
10.4 ROUTINE MAINTENANCE

This section refers to the various components which
require periodic maintenance and replacement.
For all other maintenance, contact your local Ingersoll
Rand office, Distributor or Air Center.
Refer to safety information and maintenance procedures
prior to carrying out any of the maintenance in the
following sections.
Prior to starting

danger
Under no circumstance should the compressor be
operated with the coolant fill plug removed.
Coolant change procedure

warning
The coolant filter and coolant may be hot!

Coolant level checking procedure
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.
Stop the machine and ensure coolant is still visible in the
sight glass.
Adding coolant
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.
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.

The compressor features a ’no drip’ coolant drain feature
which requires no special tools and minimizes the risk of
coolant spillage.
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
• Remove the cap from the drain valve located at the
front of the separator vessel.
• Place a suitable container close to the drain valve.
• 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.
• Refill with correct quantity of coolant.
See 8.0 General Information.

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10.0 MAINTENANCE
Drain sequence for N250/300H−2S
• Remove plug from drain valve located on the bottom
of the separator tank.
• Install supplied drain hose and fitting assembly in
end of drain valve and place end of hose in a suitable
pan.
• Open drain valve to start drainage.
• After draining is complete, close valve, remove hose
an fitting assembly from valve, and store in a suitable
location for future use.
• 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.
Coolant fill quantity
250−300 hp − 2 stage
40.0 gallons (152 liters)

Coolant filter change procedure
• Loosen filter element with the correct tool.
• Remove the element from the housing.
• Place the old element in a sealed bag and dispose of
in a safe way.
• Clean the mating face of the housing.
• Remove the new Ingersoll Rand replacement
element from its protective package.
• 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.
• Start the compressor and check for leaks and check
the coolant level.
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

COOLANT DRAIN

caution
Do not mix coolant types. Use only coolant specified
by IR
• Start the compressor and check for leaks.
• Check the coolant level, refilling if necessary.
• Dispose of waste coolant in accordance with local
and governmental regulations.

NOTICE
Shorter coolant drain intervals may be necessary if
the compressor is operated in adverse conditions.
Food Grade Coolant option
• SSR Food Grade Coolant is a polyalphaolefin base
coolant. 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.

• 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.
• Carefully withdraw the used element, place it in a
sealed bag and dispose of it safely.
• Remove the O−rings from the top of the tank, the
separator element sealing face and the scavenge
tube sealing face.
• 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
• Re−fit the separator element spacer with the notch
over the scavenge tube.
• 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.

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
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10.0 MAINTENANCE
Separator element change procedure for N250/
300H−2S
• Disconnect the scavenge tube at the airend.
• Loosen the fitting that holds the scavenge tube into
the tank and withdraw the tube assembly
• Disconnect the piping from the tank cover. Tag the
lines if required.
• 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.
• 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.
• 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.
• Tank cover bolt torque values
250−300 HP
3/4−10 UNC
210ft−lb. (285 n−M)
• Inspect tank scavenge screen and orifice. Clean if
necessary following instructions in Section 4.7.
• 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.
• Install the regulation lines in their original position.
• Start unit, check for leaks, place in service.
RECOMMENDED BOLT TIGHTENING
CROSS PATTERN

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.
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.
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.
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.
SCREW HOUSING

O−RING
SCREEN
ORIFICE

SEPARATOR TANK SCAVENGE SCREEN/ORIFICE

warning
Unscrew the jacking bolt sufficiently to ensure that
the cover can be fully tightened down without imparting any stress onto the jacking points. Tighten
down the cover setscrews.
• Start the compressor and check for leaks and
coolant level.

caution
Do not use any form of sealant on either the separator tank or the separator tank cover faces.
Separator tank / Pressure system

250 − 300 HP

Scavenge screen clean/check procedure
The screen/orifice assemblies are similar in appearance to
a straight tubing connector and will be located between
two pieces of 1/4 inch O.D. scavenge line tubing.

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.
The separator tank should also be tested and inspected
in accordance with any national or local codes that may
exist.

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10.0 MAINTENANCE
Blower motor Re−Grease
(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
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
• 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.
• 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.
• Remove the hose.
• Install the new hose and refill the unit with coolant.
Start the compressor, check for leaks and check
coolant level. Refill as necessary
Pressure relief valve check
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.

caution
High pressure air will discharge through the discharge ports of the valve during pressure relief
valve check. Wear ample clothing, gloves, safety
glasses and ear protection during valve testing.

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.
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.
Air filter change procedure
• Unclip the retaining cap and withdraw the old
element.
• Fit the new element and refit the retaining cap.
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.
• Thoroughly clean the element housing and wipe all
surfaces
• Install new element and inspect to ensure that they
have seated properly.
• Install top of inlet filter housing.
• Inspect the rubber seal on the retainer wing nut and
replace seal if required.
• Tighten wing nuts.
Aircooled Cooler Cleaning
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.
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
the enclosure and cleaning of the cooler.
• Remove 6 screws from lower rear fixed panel and
remove panel.
• Remove 10 screws from the rear intake panel and
remove panel.
• Loosen clamp and disconnect the air inlet hose from
the intake plenum.
• 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 hose from elbow in aftercooler inlet. Plug
elbow in inlet hole of aftercooler.
• Unscrew the fitting connecting the aftercooler to the
discharge tube.
• 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.
• 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.
• 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.

warning
Strong cleaners can harm aluminium cooler parts.
Follow cleaner manufacturers instructions for use.
Wear appropriate safety equipment.
• After cleaning is complete, reassemble in reverse
order.
N125/200H (N90/160K) SINGLE STAGE and N100/200H
(N75K−160K) TWO STAGE
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.

Instructions for cleaning the coolers while installed in
the compressor.
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 4 screws from enclosure panel below
moisture separator and remove panel.
• 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.
• Cover inlet of blower wheel with plastic sheeting to
prevent entrance of cleaning fluid.
• 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.
• 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.
• 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.
If the cooler cores are unable to be cleaned while installed 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.
• Remove 8 screws from the intake panel and remove
panel.
• 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.

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
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10.0 MAINTENANCE
• Remove 6 screws from top panel above cooler and
remove panel.
• Using lifting device from above, attach lifting straps
to lifting supports on each side of cooler.
• With the weight of the cooler supported by the
lifting device, remove the 10 screws securing the
cooler and remove the cooler.
• Clean coolers with a mild cleaning solution.

warning
Strong cleaners can harm aluminium cooler parts.
Follow cleaner manufacturers instructions for use.
Wear appropriate safety equipment.
• After cleaning is complete, reassemble in reverse
order.
N250/300H−TWO STAGE
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.
• 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.
• It is recommended the cooler be taken to a
professional cooler service shop for flushing with an
appropriate environmentally safe cleaning agent.
• Reassemble in reverse order.
• Make sure fan guards are replaced.
• Refill the compressor with coolant. If con tamination
is suspected, replace with new coolant.
• Replace fill plug.
• Run compressor for ten minutes. Check for possible
leaks. Check coolant level.
• Replace enclosure panels.

warning
Strong cleaners can harm aluminum cooler parts.
Follow cleaner manufacturer‘s instructions for use.
Wear appropriate safety equipment.
AFTERCOOLER
• Following are instructions for the removal and
internal cleaning of aftercoolers.

• Disconnect hose from aftercooler inlet flange.
• Disconnect tube from aftercooler outlet flange.
• Remove aftercooler holding screws from aftercooler
support and remove cooler.
• It is recommended the cooler be taken to a
professional cooler service shop for flushing with an
appropriate environmentally safe cleaning agent.
• Reassemble in reverse order.
• Replace enclosure panels.
Watercooled Cooler Cleaning
A periodic inspection and maintenance program should
be implemented for watercooled heat exchangers. The
following steps should be taken:
• Inspect filters in system and replace or clean as
required.
• 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.
• 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.
• 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.
• When reinstalling bonnets to cooler shell, tighten
bolts uniformly in a cross−pattern. Overtightening
can result in cracking of the bonnet.
• Cleaning solutions must be compatible with the
metallurgy of the cooler
• Care must be taken to avoid damaging tubes if
mechanical cleaning procedures are used.
Airend bearings
Airend bearings are lubricated by the compressor coolant
and require no maintenance.
High Airend Temperature Sensor checking procedure
It is recommended that the discharge temperature sensor
(2ATT) is checked regularly as follows:
Aircooled machines
Stop the cooling blower by opening the blower / fan motor circuit breaker.

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
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10.0 MAINTENANCE
Watercooled machines
Shut off the cooling water.
The machine should trip at 109° C (228° F).

caution
Under no circumstances should these discharge
temperatures be exceeded. If the machine fails to
trip A FAULT EXISTS. Investigate immediately.
Separator tank scavenge check valve/orifice
• Disconnect tubing at each end of check valve/
screen/ orifice assembly.
• 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.
• 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.
Blower / fan Motor Bearing Maintenance
(Stored units)
• Prior to placing a unit in storage for extended
intervals, rotate the blower motor several revolutions
by hand in the direction of rotation.
• On N75 − 160, N250 − 300H aircooled units, whilst
rotating the motor, pump grease into the bearing
until grease is seen at the relief port.
• Thereafter rotate the motor as described above
every three months until such time as the unit is
placed in service.
• If the storage time is to exceed a total of nine (9)
months duration, the compressor must be ordered
for long term storage.
Motor cowl cleaning N75−160 units only

• Remove the filter pad from the housing and replace
with a new filter pad from Ingersoll Rand.
• Replace front grill to the drive box filter.
Moisture Separator Check / Cleaning
• Ensure compressor is electrically isolated for at least
15 minutes, before commencing any maintenance
work.
• Isolate the compressor from the system and fully
discharge the compressed air within the unit.
• Remove plastic tube from the fitting located on the
bottom of the moisture separator.
• Remove the bowl of the moisture trap, clean and
replace.
Condensate (Moisture) Drain Valve / Trap
• Ensure compressor is electrically isolated for 15
minutes and all pressure is relieved from system.
• 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:−
Timed Solenoid Drain Valves (where fitted) Check /
Cleaning
• 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.
• Similarly check and clean the ball valve and needle
valve.
• Replace any defective parts as identified in parts
manual.
• 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).

• 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.

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
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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).
• 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

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.

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.

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
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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 personnel and that the safety and maintenance sections of this manual have been read and are fully understood and
followed. Major overhauls should only be carried out by a qualified Ingersoll Rand representative. Failures
caused by fitting parts not recommended by Ingersoll Rand or non−authorized Ingersoll Rand personnel may
not be covered by the terms of any warranty agreement
SYMPTOM

FAULT

REMEDY

Compressor will not
start

No power supply to package

Check supply is switched on. If so, contact a
qualified electrician.

Compressor stops and
will not restart

Intellisys controller failure

Check supply to unit. Replace unit.

Starter failure

Isolate supply, lock off and tag. Replace
failed
component or contact your local
Ingersoll Rand representative

Drive controller has tripped

See section 11.2 & 11.3

Intellisys controller has tripped the
compressor

See section 11.2 & 11.3

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
not released

Identify reason why, repair fault, disengage
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

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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
not seating or set incorrectly

Overhaul or replace

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

Overhaul or replace

Drive motor fault

See section on drive faults

Pressure transducer faulty,
incorrectly calibrated or EMF
interference

Recalibrate or replace

Incorrect Intellisys controller settings Check and modify settings
Inlet grill or ducting is blocked

Check and clean

Air filter dirty or collapsed

Replace

Inlet valve not opening fully

Overhaul or replace

Separator element dirty or collapsed Replace
Pipe / Hoses blocked or collapsed

Clean or replace

Cooler core blocked

Clean or replace

Minimum pressure check valve not
functioning correctly

Overhaul or replace

Equipment between compressor
Review system requirements
and customer measuring point
causing pressure drop / pressure loss

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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

Pressure transducer may be
faulty, incorrectly calibrated or
not receiving pressure signal

Recalibrate or replace

Drive settings fault

Contact your local IR representative

Compressor discharge air too
hot

High ambient temperature

Review installation and system parameters

Insufficient cooling air

Check ducting and cooling air path, check
direction of blower rotation

Blocked aftercooler matrix

Clean or replace

Panels or doors are not closed
properly

Rectify fault

Compressor package produces
excessive noise

Air leaks from internal pipework / Overhaul or replace
components

Discharge air is contaminated
with coolantcoolant

Blower or blower motor bearings
worn

Overhaul or replace

Loose debris impacting on
blower during rotation

Remove and rectify any damage

Blowdown valve stuck open

Overhaul or replace

Pressure relief valve not seating
correctly

Overhaul or replace

Vibration due to motor, airend or
blower imbalance

Overhaul or replace

Airend requires overhaul

Contact your local IR representative

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.

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11.0 FAULT FINDING
SYMPTOM

FAULT

REMEDY

Discharge air is contaminated
with condensate

Aftercooler not functioning correctly

Clean or replace

Moisture separator drain trap faulty

Overhaul or replace

Continuous low speed / low ambient
operation causing condensate build
up

Review system requirements and
contact your local IR representative

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

Contact your local IR representative

Coolant system leak

Overhaul or replace

Compressor package draws too
much current

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

Review installation and system parameters

Insufficient cooling air

Check ducting and cooling air path.

Blocked coolant cooler matrix

Clean or replace

Blower motor direction of
rotation incorrect

Wire correctly

Controller software has been
changed

Recalibrate all sensors and check setpoints

Check setpoints

IRN37 - 160K - CC & IRN50 - 200H -CC & IRN75 - 160K - 2S & IRN100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

11.0 FAULT FINDING
FAULT

CAUSE

REMEDY

Remote start failure

Remote start button is pressed
after machine is running or
remote start button remains
closed.

Check operation of buttons or operating
procedures

Remote stop failure

Remote stop button remains
open and either start button is
pressed

Check operation of buttons or operating
procedures

Sensor failure

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
in compressor.

Depressurise and re calibrate with pressure pipe
to sensor disconnected. If fault still exists, replace
pressure transducer.

Low sump pressure

System leak

Located and repair

Minimum pressure check valve
faulty

Repair with service kit

Blowdown valve faulty

Repair with service kit

Loss of control power

Check 110V circuit breaker
Check wiring
Check contactor KM1

Check motor rotation

Drive system fault

Contact your local IR representative

VSD communication failure

Communication wiring faulty

Check and replace if required

Drive faulty

Contact your local IR representative

Intellisys faulty

Contact your local IR representative

Communication wiring faulty

Check and replace if required

Drive faulty

Contact your local IR representative

Intellisys faulty

Contact your local IR representative

VSD initialisation fault

IRN37 - 160K - CC & IRN50 - 200H & IRN75 - 160K - 2S & IRN - 100 - 200H - 2S & IRN 250 - 300H - 2S
http://air.irco.com

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

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