•

SSR-125/150/200 H.P.
SSR-250/300 H.P.
SSR-E300/350/400/450 H.P.
OPERATORS MANUAL
INSTALLATION
MAINTENANCE
Includes NEMA 4/12

INGERSOLL-RAND­
AIR COMPRESSORS

• APDD 202 D-89

5th Edition
April 1989

OPERATORS MANUAL
ALL SSR MODELS
ROTARY SCREW AIR COMPRESSOR
This unit was purchased from
Ingersoll-Rand Company reserves the
right to make changes or add improve­
ments without notice and without in­
curring any obligation to make such
changes or add such improvements to
products sold previously.
Model: ____________
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: ________ _ shipment. whichever occurs first.
Model number: _________
@ Ingersoll-Rand Company 1989
1
.•
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects m material and
workmanship !or a period of twelve months (see extended airend warranty) from the date of placing the Equipment in operation or
eighteen months (see extended airend warranty) from the date of shipment from Davidson, N�. whichever shall first occur. The
Purchaser shall be obligated to promptly report any failure to conform to. t his warranty, in wri�1ng to the Company in said pe.riod,
,
whereupon the Company shall, af its option, correct such nonconform1ty, 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 Equ1pmenl or any costs of labor performed by the Purchaser or others without the Company's
prior written approval.
The eflects 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 !or meeting such _performance warranties are limited to
specified tests, the Company's obligation shalt be to correct in the manner and tor 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 nonc�nformit1es whether patent or latenl, in the mannE:r and for the period of time provided above,
shall const1tule fulfillment of all liabilities of the Company lor such nonconformil1es whether based on contract, warranty
negligence, indemnity, strict liability or otherwise with respect to or arising out ol such Equipment
The Purchaser shatl 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.
Limitation of Liabilily
The remedies of the Purchaser set forth herein are exclusive, and the total liability of the Company with respect to this contract or
!he Equipment and services furnished hereunder, in connection with the performance or breach thereof, or from the manufacture,
sale, delivery, installation, repair or technical direction covered by or furnished under this contract. whether passed on contract.
warranty negligence, indemnity, strict liability or otherwise, shall not exceed the purchase price of the unit of Equipment upon
which such liability is based
The Company and its suppliers shall in no event be liable to the Purchaser, any successors in interest or any beneficiary or
assignee ol this contracl for any consequential, incidental. indirect, special or punitive damages arising out of this contract or any
breach thereol. or any delect m. or failure of, or malfunction of the Equipment hereunder, whether based upon loss of use, �est
profits or revenue, interest, lost goodwill, work stoppage, impairment cl other goods, loss by reason of shutdown or non-operation,
increased expenses of operation, cost of purchase of replacement power or claims of Purchaser or customers of Purchaser for
service interruption whether or not such !ass or damage is based on contract, warranty. negligence. indemnity. strict liability or
a�:;:;·t-rn000I·I·le·H·!·!·l�·ll:lt:>l·!·!·K·i:i
EXTENDED Al REND WARRANTY
The Ingersoll-Rand Company Rotary Screw Air Compressor that has been filled
prior to its original shipment from Ingersoll-Rand Company with ULTRA
COOLANT and which has been operated solely on ULTRA COOLANT there­
after shall have its AIREND warranted for twenty-four (24) months from the date
of placing the COMPRESSOR in operation or thirty ( 30) months from the date of
Except for the above warranty period. the standard warranty provisions shall
apply and the conditions outlined herein are understood to be a supplement to the
standard Ingersoll-Rand Company warranty.
This EXTENDED AIREND WARRANTY applies to all COMPRESSORS
operating on ULTRA COOLANT after February I. I987.
•
• SAFETY PRECAUTIONS
READ CAREFULLY BEFORE INSTALLING THE COMPRESSOR.
WARNING
COMPRESSED AIR AND ELECTRI­
CITY ARE DANGEROUS.
BEFORE DOING ANY WORK ON THIS
UNIT, BE SURE THE ELECTRICAL
SUPPLY HAS BEEN CUT OFF AND
THE ENTIRE COMPRESSOR SYSTEM
HAS BEEN VENTED OF ALL
PRESSURE.
SAFETY PRECAUTIONS
1. Do not remove the covers or
loosen or remove any fittings, connec­
tions or devices when this unit is in
operation. Hot liquid and air under
pressure that are contained within
this unit can cause severe injury.
•
2. The compressor has high and
dangerous voltage in the motor,
the starter, and control box. All in­
stallations must be in accordance
with recognized electrical codes.
Before working on the electrical
system, be sure to remove voltage
from the system by use of a manual­
disconnect switch. A circuit breaker
or fused safety switch must be pro­
vided 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 as stipulated in O.S.H.A.
1910.308 through 1910.329.
3. Do not operate the compressor at
higher discharge pressures than
those specified on the Compressor
Nameplate, or motor overload will oc­
cur. This condition will result in
motor and compressor shutdown.
4. Use only safety solvent for clean­
ing the compressor and auxiliary
equipment.
5. Install a manual shut off valve
(isolation type) in the discharge line
•
as close to the compressor as
possible.
FAILURE TO HEED THIS WARNING MAY RESULT IN AN
ACCIDENT CAUSING PERSONAL INJURY OR PROPERTY DAMAGE.
6. A safety valve is located on the
receiver-separator. Whenever
pressure is released through this
valve, it is due to excessive pressure
in the system. The cause for the ex­
cessive pressure should be in­
vestigated immediately.
7. Before doing any mechanical work
on the compressor:
a.) Shut the unit down.
b.) Electrically isolate the compressor
by use of the manual disconnect
switch in the power line to the unit.
Lock and tag the switch so that it
cannot be operated.
c.) Make sure the unit has blown
down, and close the unit isolation
valve to prevent possible backflow in­
to the unit from the air system.
8. There can be bad effects if com­
pressor lubricants are allowed to
enter plant air systems.
Air line separators, properly selected
and installed, can reduce any liquid
carryover close to zero.
The use of plastic bowls on line
filters without metal guards can be
hazardous. Their safety can be af­
fected by either synthetic lubricants,
or the additives used in mineral oils.
From a safety standpoint, metal
bowls should be useci on any
pressurized system. Review of your
plant air line system is recommended.
9. When a receiver is installed, it is
recommended that occupational safe­
ty and health standards as covered in
the Federal Register, volume 36
number 105 Part II paragraph
1910.169 be adhered to in the installa­
tion and maintenance of this receiver.
10. Before starting the compressor,
its maintenance instructions should
be throughly read and understood.
2
 •
FOREWORD
CJINGERSOLL-RAND®
The SSR data plate on the compressor Davidson, North Carolina
is affixed to the compressor housing
inside the cabinet. (See Figure 1.)
HP ·--- VOLTS ···················
It lists the rated operating pressure KW••···••·--- PHASE/HZ·-­
and the maximum discharge SER. FAC.····-··­ NEMA DES.·······-·­
pressure along with the compressor RPM---­
capacity, the electric motor charac­ FRAME---­
teristics and power. KVA CODE-··-­ MODEL--­
AMPS ····-····-··· TIME/HRS. ····-•·
Information has been prepared in
►

this manual to assist an operator to INS. CLASS········ MAX. AMBIENT-

understand, maintain and operate DRIVE END BEARING········--­
this compressor within the power OPPOSITE DRIVE END BEARING······-····-
limits shown on the name plate. CODE··-···-----------
Before installation or starting the
compressor for the first time, this
manual should be studied carefully
39519137
to obtain a clear knowledge of the
unit and of the duties to be
performed.
Take pride in your compressor-keep Figure 1
it clean and in good mechanical Compressor Data
condition.

•
3
•
SSR

•
Figure 2
Typical SSR Compressor

i
�;;;;;
El 1· \
\

Figure 2A
Typical SSR NEMA 4/12 Compressor

•
4

TABLE OF CONTENTS
General Information ..............6
Lubricant Circulation System .......8
Lubricant/ Air
Separation System ............12
Aircooled Compressors ..........13
Watercooled Compressors ........ 14
Installation Details............... 15
Electrical System ...............18
Instrumentation .................23
Dual Slowdown Valve
System .....................24
Capacity Control ................24
Regulation Adjustment
Instructions ..................27
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Operation .....................30
Lubrication ....................31
Safety Shutdown Checks .........32
Trouble Investigation.............32
Maintenance ...................33
Lubricant Time Change ..........34
Drive Motor Bearing
Maintenance Stored Units.......35
Long Term Storage ..............35
Compressor Change/
Lubricant Procedure ...........36
Prelube Procedure
304mm Airend (Only) ..........37

&WARNING&

•
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 also be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatability
between discharge piping, system accessories, and software must be assured.

"For the foregoing reasons, the use of plastic piping, soldered copper fittings, and rubber hose as discharge piping is not
recommended. In addition, flexible joints and/or flex lines can only be considernd 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&
STATEMENT CONCERNING THE USE OF THIS EQUIPMENT FOR BREATHING AIR AND/OR AQUA LUNG SERVICE
If the model number on this air compressor contains the letters "BAP", the compressor is suitable for use in breathing air
services. In the absence of such a designation, the compressor is NOT considered as capable of producing air of breathing
quality. For a compressor to be capable of use in breathing air services, it must be fitted with additional specialized equip­
ment to properly filter and/or purify the air to meet all applicable federal, state and local laws, rules, regulations and
codes, such as, but not limited to, OSHA 29 CFR 1910.134, Compressed Gas Association Commodity Specification
G-7, 1-1966, Grade D Breathing Air, and/or Canadian Standards Association. Should the Purchaser and/or User fail to add
such specialized equipment and proceeds to use the compressor for breathing air service, the Purhcaser/User assumes all
liability resulting therefrom without any responsibility or liability being assumed by Ingersoll-Rand Company.
The Purchaser is urged to include the above provision in any agreement for any resale of this compressor.

•
5
•
GENERAL
INFORMATION
The SSA compressor is an electric
motor driven, single stage, screw
compressor - complete with
accessories piped, wired and
baseplate mounted. It is a totally
self-contained air compressor
package.
A standard compressor is composed
of the following:
Inlet air filtration
Compressor and motor assembly
Pressurized lubricant system
with cooler
Separation system
Load control system
Motor starting control system
Instrumentation
Safety provisions
Air cooled aftercooler
(Moisture separator and drain trap)
Compression in the screw-type air
compressor is created by the
meshing of two helical rotors (male
and female) on parallel shafts,
enclosed in a heavy-duty cast iron
•
housing, with air inlet and outlet
ports located on opposite ends. The
grooves of the female rotor mesh
with, and are driven by, the male
rotor. Tapered roller bearings at the
discharge end prevent axial
movement of the rotors.
•
The air-lubrication mixture
discharges from the compressor into
the separation system. This system,
self-contained in the receiver tank,
removes all but a few PPM of the
lubricant from the discharge air. The
lubricant is returned to the system
and the air passes to the aftercooler.
The aftercooling system consists of
a heat exchanger, a condensate
separator, and a drain trap. By
cooling the discharge air, much of
the water vapor naturally contained
in the air is condensed and
eliminated from the downstream
plant-piping and equipment.
The compressor capacity is
governed by the load control
system. In the standard control
mode, the compressor will operate
"On-Off Line".
The compressor will operate to
maintain discharge line pressure at
or slightly above the rated pressure.
Optional accessories can provide for
such things as upper range modula­
tion and automatic starting and
stopping. This may be desirable in
a plant with widely varying air de­
mand. The field proven control
system is basically solid state for
long term, trouble-free operation.
The lubricant system consists of a
sump, a cooler, thermostatic lubri­
cant control valve and a filter. When
the unit is operating the lubricant is
pressurized and forced to the
compressor bearings.
Panel instrumentation is provided to
indicate the compressor operating
conditions, control power availability,
load control mode, a push-button
start-stoo station, condition of air
and lubricant filters, and. optionally,
a shutdown annunciation section.
Safety of operation is provided for
as the compressor will shut down
due to excessive discharge
temperature, excessive bearing
scavenge temperature, and elec­
trical overload.
Air filtration is handled by a large,
highly efficient, dry-type air cleaner.
Optional types of prefilters are
available, and pre-engineered to
handle virtually any type of
installation.
Effective lubricant filtration is pro­
vided by use of heavy duty
hydraulic type filters.
All of the above features are
described in greater detail and
discussed in the pertinent sections
of this manual.
All service connections are on the
back of the unit to provide ease of
connection and a clean looking
installation
6
 •
COMPRESSION
If one thinks of the female rotor
grooves and the compressor hous­
ing acting as a conventional
cylinder, and the sliding action of
the male rotor lobe as a piston, the
positive displacement nature of a
rotary screw compressor becomes
apparent.
As rotation of the compressor
begins, air is drawn into the
pockets opened between the male
rotor lobes and the female rotor
grooves at the intake end of the
compressor. This is illustrated in °
:·Figure 3-1. (A,·rnatihg··m�le�fo_bei '·1 1 - Intake Inlet air flow
and female-groove are marked with
dots to show the relative positions
of the rotors.)
With further rotation, the leading
strip of the male lobe reaches the
contour of the female groove, and
traps the air in the pocket Female rotor
previously formed. This air is mov­
ed down the female rotor groove
and is compressed.
Lubricant is injected during the

•
compression phase and takes up
heat of compression, lubricates the
rotors, and seals the rotor­
clearances against leakage. This
phase is illustrated in Figure 3-2.
When the male rotor lobe reaches
the end of the groove, the trapped
air is discharged along with the
lubricant. Figure 3-3. The mixture 2 - Compression
is piped through a check valve to
the receiver. In the receiver, the
lubricant will be separated from
the air and returned to the system.
The air will flow to the aftercooler
and then to the plant system. Discharge port

•
3 - Discharge

Figure 3
Rotor Compressor

7
•
LUBRICANT
CIRCULATION SYSTEM
Refer to Figures 4A and 4B for the
Aircooled Circulation System
Schematics.
Lubricant flows from the receiver­
separator to the inlet port of the
lubricant cooler and the bypass
port of the thermostatic control
valve.
The thermostatic oil control valve
controls the quantity of lubricant
necessary to provide a suitable
compressor injection temperature.
When the compressor starts cold,
part of the lubricant will by-pass the
cooler. As the system temperature
rises above the valve setting, the
lubricant will be directed to the
cooler. During periods of operation
in higher ambient temperatures, all
the lubricant flow will be directed
through the cooler.
The compressor injection minimum
temperature is controlled to preclude
the possibility of water vapor
condensing in the receiver. By
injecting lubricant at a sufficiently
high temperature, temperature of
the discharge air and lubricant
mixture will be kept above the dew
point.
The controlled-temperature lubricant
passes through a filter to the air end
under constant pressure.

DIFFERENTIAL
PRESSURE SWITCH (3DP)
OPERATES WARNING LIGHT (3Ll)
ON INSTRUMENT PANEL

COMBINATION MINIMUM PRESSURE

(60PSIG) CHECK VALVE MAINTAINS
PRESSURE IN TANK WHEN UNIT IS
LOADED AND PREVENTS CUSTOMER
AIR ENTERING SEPARATOR TANK.
ENSURE PROPER OIL FLOW.

• •

AIR/OIL
DISCHARGE DUMP TO
FROM A RE D OMPRESSOR INLET
�L SUMP �
AREA J

I
,,.,- -:
-)
' I I
, ..... _',..,:

- ENERGIZED
- - - -- DE-ENERGIZED

LOAD SOLENOID

•
VALVE (1SV)

Figure 4A
Lubricant Circulation System
Aircooled with Integral Coolers
8
 COOLER VENT SOLENOID (7SV)
VENTS ANY PRESSURE
IN COOLER AT SHUTDOWN #'.
•
DIFFERENTIAL
PRESSURE SWITCH
OPERATES LIGHT ON
INSTRUMENT PANEL

COOLANT
FILTER

INLET VALVE

•
POSITIONER

DUMP TO
OMPRESSOR INLET
�

i
' ' )
''-'< ... fI

l...�---- 1,,
..,..,____....,_.,.. ENERGIZED
- - - -- DE-ENERGIZED

•
LOAD SOLENOID
VALVE (1SV)

Figure 4B
Lubricant Circulation System
Aircooled with Remote Coolers

9
•
BLOWOOWN SOLENOID VALVE ilSV)
VENTS SEPARATOR TANK WHEN
UNIT UNLOADS OR IS SHUTDOWN.
IS OPERATED BY AIR PRESSU RE
SWITCH 1PS.
COMBINATION COLD START/BLOWDOWN
SOLENOID 8SV. WORKS IN PARALLEL
WITH 3SV WHEN INJECTED OIL
TEMPERATURE IS 120' F. OR HIGHER.
REMAINS CLOSED WHEN INJECTED OIL
TEMPERATURE IS LOWER THAN 120' F.
TO CREATE HIGHER UNLOADED SUMP
PRESSURE FOR COLD OIL FLOW.

L R TCH l1PS)
:!ilt�i ���
�g�mt� fo�i/ 1.
VACUUM SWITCH I1VAC) OPERATES
WARNING LIGHT i4LT) ON
INSTRUMENT PANEL WHEN AIR
FILTER BECOMES FOULED.

COMBINATION MINIMUM PRESSURE

(60 PSIG)/CHECK VALVE MAINTAINS · ·

1
PRESSURE IN TANK WHEN UNIT IS LOADED ·.
AND PREVENTS CUSTOMER AIR ENTE RING : ---���- SCAVENGE LINE
SEPA RATOR TANK. ORIFICE

6d'j
rt �·
FLANGE MOUNTED 1:; Ulf

I
SEPARATOR �l _

7
HIGH DISCHARGE AI R TEMPERATURE

•
:::::::E RELIE SWITCH (HAS) OPENS ON RISING
VALVE �I TEMPERATU RE TD SHUT UNIT DOWN.

�- Q
Oil FILL CHECK VALVE TO PREVENT BAC K
CONNECTION FLOW INTO AIREND AT SHUTDOWN

7 AIR/Oil MIXTURE DISCHARGE

OIL SUMP AREA FROM AIRENO

DISCHARGE AIR
TO PLANT SYSTEM
CONDENSATE
TO DRAIN
l�
j!'� ',7\) SINGLE NEEDLE AI R PR ESSURE GAUGE
LINE/SUMP PRESSURE SELECTOR VALVE. (MOUNTED ON INSTR UMENT PANEL)
USED TO DETERMINE DIFFERENTIAL
ACROSS SEPARATOR ELEMENT WHEN
UNIT IS FULLY LOAOEO
(MOUNTED ON INSTR UMENT PANEL)

Figure SA
Air Flow System
With Internal Aircooled Aftercooler

•
10
 •
SLOWDOWN SOLENOID VALVE IJSV)
VENTS SEPARATOR TANK WHEN COMBINATION COLD START/BLOWDOWN
UNIT UNLOADS OR IS SHUTDOWN. SOLENOID esv. WORKS IN PARALLEL
IS OPERATED BY AIR PRESSURE WITH JSV WHEN INJECTED OIL
SWITCH 1PS. TEMPERATURE IS 120' F. OR HIGHER.
REMAINS CLOSED WHEN INJECTED OIL
TEMPERATURE IS LOWER THAN 120' F.
TO CREATE HIGHER UNLOADED SUMP
PRESSURE FOR COLD OIL FLOW.
ADJUSTABLE AIR PRESSURE SWITCH 11PS)
CONTROLS LOAD/UNLOAD POINT.
VACUUM SWITCH 11YAC) OPERATES
CONDENSATE WARNING LIGHT 14LT) ON
SEPARATOR• INSTRUMENT PANEL WHEN AIR
TRAP FILTER BECOMES FOULED.
REMOTE

INLET AIR CONTROL VALVE

!BUTTERFLY TYPE)
>"
DISCHARGE AIR / /
TO PLANT SYSTEM
COMBINATION MINIMUM PRESSURE
CONDENSATE 160 PSIG)/CHECK VALVE MAINTAINS
DRAIN

1:: b,,.,,
PRESSURE IN TANK WHEN UNIT IS LOADED
ANO PREVENTS CUSTOMER AIR ENTERING
SEPARATOR TANK.
I I� A f1
<
FLANGE MOUNTED� • e::.

),{1.I�•, ·
SEPARATOR ,
ELEMENT �

•
PRESSURE RELIEF I
VALVE
I
,,.�',
:·�
OIL FILL
CONNECTION

7 AIR/OIL MIXTURE DISCHARGE

OIL SUMP AREA FROM AIREN0

SINGLE NEEDLE AIR PRESSURE GAUGE

LINE/SUMP PRESSURE SELECTOR VALVE (MOUNTED ON INSTRUMENT PANEL)
USED TO DETERMINE DIFFERENTIAL
ACROSS SEPARATOR ELEMENT WHEN
UNIT IS FULLY LOADED
(MOUNTED ON INSTRUMENT PANEL)

Figure Sb
Air Flow System
Aircooled with Remote Aftercooler

•
11
•
LUBRICANT/ AIR
SEPARATION
SYSTEM
The lubricant/air separation system
is composed of a receiver or
separator tank with specially
designed internals, a two-stage,
coalescing-type separator element,
and provision for return of the
separated fluid back to the com­
pressor.
OPERATION
The lubricant and air discharging
from the compressor flow into the
receiver where the mixture is
directed along the ir:,ner cir­
cumference, allowing the lubricant
stream to collect and drop to the
receiver sump.
The internal baffle maintains the
circumferential flow of remaining
lubricant droplets and air. In an
almost continuous change of direc­
tion of flow, more and more

•
droplets are removed from the air
by inertial action and then returned
to the sump.
The air stream, now a very fine
mist, is directed to the separator
element.
Figure 6
The separator element is con­ Separator Tank Internals
structed with two concentric­
cylindrical-sections of closely
packed fibers, each held in steel
mesh. It is flange mounted at the
receiver outlet cover.
The air stream enters the separator
element and the mist coalesces to
form droplets. The droplets col­
lected on the outer first stage fall
to the receiver sump. Those col­
lected on the inner second stage
collect on the bottom of the ele­
ment, and are drawn back to the
compressor inlet through a filter­
screen and orifice fitting installed
in the separator scavenge line.
The air stream, now essentially
free of lubricant, flows from the
separator to the aftercooler, then
to the condensate separator, and
on to the plant air system.

•
12
 •
AIRCOOLED COOLING FAN MOTOR
COMPRESSORS In a standard compressor, the
cooling fan motor is wired at the
DESIGN TEMPERATURES factory. It is a three phase motor.
It is protected by a suitable
The standard compressor is designed circuit breaker and/or fuses and
for operation in an ambient range of overload relay. The fan motor is
35 °F. to 100 ° F. (1.7 ° C. to 38 ° C.). If energized at the same time the
the compressors are to operate in compressor drive motor is energized.
ambient temperatures above 100 ° F. The fan motor overload is wired in
for periods of more than one hour or series with the compressor drive
two per day, it is assumed that they motor overload. If an overload
will have been ordered with optional occurs in the fan motor circuit,
higher temperature rated coolers, and both the fan motor and compressor
possibly drive motors. When drive motor will stop.
conditions other than the design
levels described are encountered, we
recommend you contact your nearest
Ingersoll-Rand representative for
additional information.
The standard maximum temperature
(100 ° F.) is applicable up to an
elevation of 7500 ft. (2300 meters)
above sea level. Above this altitude,
significant reductions in ambient
temperature are required if a
standard drive motor is to be used.

LUBRICANT COOLERS

•
For integral cooled systems, the
lubricant cooler is an integral part
of the compressor package. Cool­
ing air flows into the package
through the right end and exits out
the top. For remote cooled
systems, the cooler, fan, and fan
motor are mounted separate from
the compressor package.

AFTERCOOLER
The discharge air aftercooling
system consists of a heat ex­
changer, a condensate separator,
and a drain trap.
By cooling the discharge air, much
of the water vapor naturally con­
tained in the air is condensed and
eliminated from the downstream
plant-piping and equipment.

•
13
•
WATERCOOLED LUBRICANT
THERMOSTATIC
COMPRESSORS CONTROL
OUT VALVE
IN
DESIGN TEMPERATURES
The standard compressor is designed
for operation in a temperature range
of 35 ° F. to 100 ° F. (1.1 ° c. to 38 ° C.).
The standard shell and tube coolers
are designed to use clean fresh COOLER
cooling water at temperatures up to
90 ° F. (32°C.).

AFTERCOOLING .--� AIR

To reduce or eliminate downstream
condensation of water vapor, an
aftercooler is furnished as standard AFTERCOOLER
equipment. It is of shell and tube
construction, with the water flowing
through the tubes. COOLING
WATER
In a standard compressor, the 90 °F. (32 °C.)
cooling water flows to the MAXIMUM
aftercooler, and then to the l_ubricant
cooler. This "series" flow keeps the 1 - STANDARD COOLING
total required cooling water flow to a WATER SYSTEM
minimum. By bringing the cooling
water to the aftercooler first, lower

•
temperature air is discharaed to the
plant system. See Figure 7-1.
When the cooling water available is
LUBRICANT
at temperatures above the standard
requirement of 90 ° F. (32 ° C.), the
cooling water flow is in a "parallel"
arrangement. Thermostatic IN
temperature control is furnished THERMOSTATIC
similar to that of the air cooled units, CONTROL
VALVE
and a throttling valve is installed in
the aftercooler circuit to balance the
water flows. See Figure 7-2.
The standard cooling water system
COOLER
and the high water temperature­
systems are shown in Figure 7.

AIR

AFTERCOOLER

COOLING
.__......,..___ IN WATER
115 °F. (46 °C.)
MAXIMUM
'--------1► OUT

•
2 - HIGH TEMPERATURE
COOLING WATER.SYSTEM

Figure 7
Cooling Water Flow
14

INSTALLATION
DETAILS
GENERAL
The condition of the arriving com­
pressor should be carefully in­
spected. Any indication of
careless handling by the carrier
should be noted on the delivery
receipt especially if the com­
pressor will not be immediately un­
crated. Obtaining the delivery
man's signed agreement to any
noted damages will facilitate any
future insurance claims.
UNPACKING AND HANDLING
The compressor package has been
mounted on a skid type frame to
facilitate handling during ship­
ment. The shipping crate has been
marked to show the safe and cor­
rect sides that forklifts can be
used. Care in positioning the
forklifts is important because the
location of the center of gravity is
strongly affected by the inline
assembly of the compressor airend
and drive motor.
Slings can be used to lift the
crates but spreader bars must be
used to prevent the slings from ex­
erting a force against the sides of
the crates. After uncrating, the
above handling precautions should
still be observed. Forklift holes are
furnished in the steel base but lif­
ting should ONLY be on the com­
pressor airend and drive motor
side. If slings are used, spreader
bars must be used. Placing protec­
tive material between the slings
and the compressor enclosure
should not be attempted.
FOUNDATION REQUIREMENTS
Refer to the foundation plan for
the particular model compressor to
be installed. Foundation plans for
all models are furnished as part of
the service-literature-package sent
with each compressor, in addition
to other normal drawing-handling­
procedures.
Note that all piping and wiring con­
nections are made at the rear,
which is the side opposite to the
instrument panel of the com­
pressor.
The compressor can be installed
on any level floor that is capable of
supporting it. Compressor weights
are listed on the foundation plans.
15
When sound transmission is of
particular importance, it is often
helpful to install a sheet of rubber­
fabric-matting, or cork under the
compressor to reduce the possibili­
ty of resonant sounds being
transmitted or amplified through
the floor.
LOCATION IN PLANT
The compressor should be install­
ed in a dry, well-ventilated area
where the air is as clean as
possible.
Air cooled units, in particular, re­
quire a free flow of cooling air.
Cooling air enters at the end of the
enclosure (see Figure 8} and P.Xits at
the top side. The possibi lily of ex­
cessive recycling of cooling air
must be avoided.
Consideration must be given to the
need for clearances around the
compressor for ease of main­
tenance. The foundation plan
shows the minimum clearances re­
quired. The front of the unit, that
is, the instrument panel side,
should be left clear for a maximum
distance, because this side pro­
vides access to the compressor
and motor assembly.
CONDENSATE DRAIN PIPING
Condensate (condensed water
vapor). is removed from the com­
pressor system through an
automatic drain trap, and piped to
the plant drains. The location of
the condensate drain in the base
of the compressor is shown on the
foundation plans. -The drain piping
and lower half of condensate
separator must not be subject to
freezing.
COOLING
AIR OUT
Figure 8
Cooling Air Flow
•
For ease of inspection of the
automatic drain trap operation, the
drain piping should include an
open funnel.
It is essential in installing a new
compressor to review the total
plant air system. This is to insure
a safe and effective total system.
One item which must be con­
sidered is liquid carryover into the
plant air line. Installation of after­
coolers, air dryers and line
separators is always good practice
and these added safety features
are recommended.
Water condensation can affect the
operation of pneumatic devices.
Aftercoolers and the addition of air
dryers can eliminate this hazard.
Similarly, there can be bad effects
if compressor coolants or
lubricants are allowed to enter
plant air systems.
Air line separators, properly
selected and installed, can reduce
any liquid carryover close to zero.
•
CAUTION
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. From a safety
standpoint, metal bowls should be
used on any pressurized system.
Review of your plant air line
system is recommended.
CAUTION
Exhaust ductwork must be sized so
that no excessive back pressure is
exerted on the fan. (Maximum
allowable is .25 inches of water
column.)
COOLING
AIR IN
CAUTION
•
NEVER ELEVATE THE
COMPRESSOR UNIT
ABOVE THE FLOOR
LEVEL WHICH MAY
ALLOW AIR TO ENTER
THE CABINET UNDER
THE BASE.
PERFORMANCE WILL
BE AFFECTED.
•
liil D'il

I◄ B .. , A

Figure 9
Standard Enclosure
Overall Unit Dimensions

• (SEE FOUNDATION PLANS FOR SPECIFIC

DETAILS ON CONNECTIONS, ETC.)

DIMENSIONS IN INCHES

UNIT DESIGNATIONS A B C

SSR-125/150/200 HP 113.2 69.0 57.8

SSR-250/300 HP 124.0 84.0 63.8
SSR-E300/350 HP 124.0 84.0 63.8
SSR-400/450 HP 124.0 84.0 63.8

•
16
 •
[ii] Iii]
D

I� B A .I
Figure 10
Low Sound Enclosure

•
Overall Unit Dimensions

INTERNATIONAL AND DOMESTIC UNITS (50HZ and 60HZ)

(SEE FOUNDATION PLANS FOR SPECIFIC DETAILS ON CONNECTIONS, ETC.)

DIMENSIONS IN INCHES

UNIT DESIGNATIONS A B C

SSR-125/150/200 HP 113.2 69.0 75.3

SSR-250/300 HP 124.0 84.0 83.8

•
17
•
ELECTRICAL SYSTEM
GENERAL
The electrical system of each SSR
compressor is built with solid state
components and printed circuits as
its base. Plug-in modules and
relays allow variations and
additions to the standard control
circuit.
The standard electrical
components, enclosed in a readily
accessible, but lockable sheet
metal b·ox are (Refer to Figure 1l):
13
•
14
Components Located in Starter Box
1. Start-run contactor (1M) • •
2. Start contactor (1S)*•
•
3. Run-contactor (2M)*•
4. Star-Delta timer module (HR)
5. Overload relay (10L)* •
6. Control transformer (T)*•
7. Control relay (1 CR)
*Optional
**Machines with remote starters will have these components located in a separate box outside the compressor package.
1. The Compressor Motor Starter,
with auxiliary contacts and overload
relays.
2. The Cooling Fan Motor overload
relays and circuit breaker or fuses.
3. The main printed circuit board,
with Plug-in Power Control Module.
4. The Control Relay.
5. The Control Transformer and
Fuse.
Modifications to the capacity
control system are made by
plugging in solid state modules
which contain the necessary
special circuitry.
7 6 9
Figure 11
8. Power control module 15.Terminal strip (3TB)
9. Fuse (1 FU)*•
16.Auto stop-start module (3TR)*
10. Fan motor circuit breaker (1 CB)** 17.Auto stop-start relay (3TR)* (Not shown)
11.Overload relay (20L)*• 18. Shutdown annunciator module (1SA)
12.Main board assembly 19.A.C.S. System module (4TR)*
13.Terminal strip (1TB) 20.Vacuum Switch
14.Terminal strip (2TB) 21.Cold Start Relay (4CR)
18

AUTOMATIC UNLOADED START
CONTROL
To provide a manual and/or auto­
matic unloaded compressor start,
the following components have
been coordinated into the starting
system.
a. A Normal-Unload Selector
Switch.
An unloaded start is achieved by
preventing the inlet valve positioner
from opening the inlet valve before
the compressor has come up to full
speed.
The Normal-Unload Selector Switch
mounted on the compressor panel
performs this function. For manual
starting, placing the switch in the
Unload position de-energizes the
load solenoid valve circuit and
stops pressure from being
transmitted to the inlet valve
positioner thus preventing the
compressor from loading.
After approximately 2 minutes
operation, place selector switch
in the Normal position and allow
the compressor to load.
b. Star Delta Time Delay Unloading.
(Star Delta Starter only)
The use of the interlocking switch
(2Ma) in the Star Delta Starter pro­
vides for an automatic unloaded
start. The switch is connected to
insure that during the starting cycle
of the Star Delta Starter, the load
solenoid valve is shut down. When
the starter transfers to the run
position, the switch contacts close,
arming the load solenoid valve
circuit. The compressor will now
load. provided the Normal-Unload
Selector Switch is in the Normal
position on the compressor panel.
FULL VOLTAGE TYPE STARTER
(ACROSS LINE, MAGNETIC)
Refer to the electrical schematic
wiring drawing, Figure 15 or 17.
The starter coil is controlled by
the normally open contacts of the
control relay (1CR). Note that if
all protective temperature switches
and motor overload relays are
closed, the control relay (1CR)
will be energized when the start
button (2PB) is closed.
19
When the start button (2PB) is
closed, the following sequence
takes place:
Control voltage is placed across
the starter coil (1M). The com­
pressor motor will start and the
Normal Unload Selector Switch
should then be moved from the
Unload position to the Normal
position and the compressor will
load.
STAR-DELTA TYPE STARTERS
By use of the Star-Delta type
starter, the compressor motor can
be started and accelerated using a
greatly reduced "inrush" electric
current. The starter is completely
automatic and controlled by a
push button station mounted in the
compressor panel. The sequence
of operation of the starter is ex­
plained in the following section.
Refer to the electrical schematic
wiring drawing, Figure 16 or 18,
and note that the starter coils
and time delay relay are controlled
by the normally open contacts
of the control relay (1CR). Note,
too, that if all protective temper­
ature switches and motor overload
relays are closed, the control
relay (1CR) will be energized when
the start button (2PB) is closed.
When start button (2PB) is closed,
the following sequence takes place
automatically in the Star-Delta
Type Starter:
1. Control voltage is available
across the starter contactor coil
(1S) because the timer contact
(HR) and auxiliary contact (2Mb)
are both closed. The start contac­
tor coil (1S) will be energized and
auxiliary contacts (1Sa) will close
and (1Sb) will open.
•
2. The action of auxiliary contacts
(1Sa) and (1Sb) will put control
voltage across the start-run con­
tactor coil (1M), and wi11 prevent
the run contactor coil (2M) from be­
ing energized. Auxiliary contacts
(1 MA) will then close to provide an
interlock to hold the coil (1M) in an
energized state. The time delay
relay (HR) will be energized and
begin to time out. Contactors (1S)
and (1M) are now energized and
the compressor motor will start
and run in the "star connected"
mode.
3. When the time delay relay (HR)
runs out its time, which is ad­
justable and usually set to about
12-15 seconds, its contact (HR)
opens. This breaks the circuit to
the start contactor (1S), and
energizes the run contactor coil
(2M) through the auxiliary contact
(1Sb). Contactors (1M) and (2M)
are now energized and the com­
pressor is running in the "delta"
mode and the auxiliary contacts
(2Ma), (used as the unloaded start
automatic control) are closed per­
•
mitting the compressor to be
loaded.
4. A mechanical interlock exists
between contactors (1S) and (2M),
which prevents both these contac­
tors "pulling in" at the same time.
An additional interlock, electrical,
exists; auxiliary contact, (2Mb),
when contactor (2M) is energized.
This auxiliary contact opens,
preventing any possible energiza­
tion of the start contactors (1S).
5. The time delay relay (HR) is a
solid state module plugged into
the main printed circuit board. A
light, (?LT) mounted on the module
face, is lit when the time delay
relay is timing and can be used to
check the timer adjustment.
•
 * *
•
CAUTION
1Sb 2Mb
-II- 1Sa -II- 2Ma -II- 1Ma
Care should be exercised during
any such checks because of the
electrical hazards that will be pre­
sent when the electrical box is
* Normally
Closed
open.
1S 1M

SHUTDOWN ANNUNCIATOR -II- Normally

(OPTIONAL) Open
Start Run Start-Run
The SSR Compressor can be fur­
nished with a plug in module solid
state annunciator which indicates Figure 12
reasons for a compressor shut­
down. These are, Star Delta Contactors
1. High discharge air temperature
2. Compressor motor overcurrent
3. Cooling fan motor overcurrent
4. High bearing scavenge
temperature.
5. High motor windings
temperature (50 HZ only).
The indication of shutdown cause
is shown on the compressor con­
trol panel by lights and identifica­
tion. Only the reason for the shut­ LINE HZ LINE JUMPERS SEC SEC
down is indicated if a shutdown VOLTS VOLTS

•
occurs - no other lights are lit. 220 50 H6-H7 NONE 95 X2-X3
230 60 H5-H7 NONE 120 X1-X3
STAR-DELTA STARTER AUXILIARY 380 50 H4-H7 NONE 95 X2-X3
CONTACTS 415 50 H3-H7 NONE 95 X2-X3
460 60 H2-H7 NONE 120 X1-X3
The auxiliary contacts which con­ 575 60 H1-H7 NONE 120 X1-X3
trol the starter sequencing are 380 60 H4-H7 NONE 120 X1-X3
located on the upper rear section 415 60 H3-H7 NONE 120 X1-X3
of the contactor which bears its
number. The auxiliary contacts on
a standard star-delta starter are
shown in Figure 12. Figure 13
CONTROL TRANSFORMER Control Transformer Connections
The control transformer, mounted
in the electrical control box, is a
universal type. It is suitable for
use with various primary voltages
and frequencies and is connected
according to the rated voltage of
the compressor: up to 575 volts.
The transformer primary-secondary H2 H3 H4 H5 H6 H7
connections should be confirmed
prior to initial start-up on the com­
pressor. The primary-secondary
connections for various primary
voltages are shown in Figure 13.
The electrical terminals at the trans­
former are as shown in Figure 14. H1 X3
rrn7
X2 X1

• Figure 14
Transformer Terminals

20
 •
2TI
2T2
"APPROVED FUSED DISCONNECT OR 21"3
CIRCUIT BREAKER PER NE.C. REOUIREMOffS
ri- MUST BE PROVIDED BY INSTAU.ER." IM ITI
LI •-i) 0-------- - -- ----- ---
.......
..
.. IT2
L2 u.1 I tr-- ------ --- --
,
_ , IT3
L3·-C ,-;..----------
0

IFU
ITB-1
9
ITB-5
PC XI· X2
.:TB-I ne-,
0

Z.TB-1 2TB·5
ZTB-10 5TS
4 PC
2J
PC
1TH
2TB-S
3TB- 2TB 7
p,; ·11 2TB-5

IC!I
PC
1TB
1CR
HB·I -12 24
IM 2T&-9

IJ PC
5SV
z 3TB-5 2TB·I I 7
2T8·5
C

3TB-t2 ' ,, ZTB·5

•
3TB·I 30P
3LT
,, '
PC Ill
2TB-l
91
lTB-6
2TB·6
4
' ,, zre-,
:nB-6 1LT 2T�
97
2TB-6
ITB·1
'!� 6J 2TB-Hl
ZTB-l
�c 96
2.TB·l2. ua-,
r , ,z 96 5J
ITB·IO 1CR

i
1ps
97
ITB-7 C

ITB-11
1CR
II
2.TB-13 zre-,

B-1 _4_ _2__0-4T...sO---IJ..._.___.LL.._--f.-4C

ITll-7 .,...________s_1___3_r,.... 1
2TB-5

Figure 15
Full Voltage Wiring Schematic
LEGEND
J Jumper Wire lPS Line Pressure Switch COOLER CIRCUIT
PC Printed Circuit tSV Load Solenoid Valve
1MTR Compressor Motor 2MTR Fan Motor
3SV Slowdown Solenoid Valve
1M 1MTR Slarl-Run ContacI0, 20L 2MTR Overcurrent Relay
5SV Oil Slop Solenoid Valve
10L 1MTR Overcurrent Relay 2FU Fuse
asv Cold Star! Blowdown Sol. Valve
1CR Control Relay lAS Normal-Unload Selector
T Control Transformer 1VAC Fouled Air Filter Switch
OPTIONAL EQUIPMENT
1FU Fuse 3DP Fouled Coolant Filler Swilch lSA Shutdown Annunciator Moaule - With Lignts
GAO Ground 4CR Cold SIar1 Control Relay BLT High Air Temperature - Red
1HM Hourmeter 9LT
1PB
High Bearing Scavenge Temperature
Stop Button INDICATING LIGHTS 10LT lMTR Overcurrent Relay - Red
2PB Start Button

•
1 lLT 2MTR Overcurrent Relay - Red
HAS High Air Temperature Swilch (Airend Disch.) 1LT Power On - While 3PB ReseI-TesI Bullon
5TS High Bearing Scavenge Temp. Switch 2L T' Power On - Red 2RS Control Mode Selector
4TS Cold Start Temperature Switch 3LT Fouled Coolant Filler - Amber 2SV Control Mode Solenoid Valve
4LT Fouled Air Filler - Amber
3TR AuIomaIic Starl-Slop Timer Module
13LT" Aulomalic Stan-Slop Timer - Red
14LT Slopped-Auto ResIar1 - Amber
4TR Aulo Control Selector (A.C.S.) Timer Module
15LT" A.C.S.-Modulale Mode - Red
'Localed in Starter Box 4SV Waler Shuloll Solenoid Valve
7SV Remote Cooler Solenoid Valve

21
•
ICB

"APPROVED FUSED DISCONNECT OR

CIRCUIT BREAKER PER NEC REQUIREMENTS
UST BE PROVIDED BY INSTALL£R:'
.-T•�
LI-� J t.�--- ------- --- - --- - -0------�1--+--+---<Y

L2 -4j
L3-�.l
..I-:..�--
_ ,
---------- - - -<>---+----<11---H F'-+--+---<>-'
t.'- ------------<;:-�:---=--+--..--t-+1 J!!!!---.---<>J
0. 0

ITB-5
XI X2 PC
ZTB-5
2TB-I ZTB-5
ZTB-10
4 'I-
ITB-14

PC
ZTB-5
PC 2TB-5
3TB-3
ICR ZTU 1
-II ZTB-5
2TB
II

PC
31"8·1

IJ

•
3TB�5

3TB-I ZTB-5
30P 91 3 TB:-12 91
PC ZTB-1
97
2TB-6

9
2TB-5
2TB-6
ZTB-5
ZTB-5
pc
ITB-7

II
2TB·5

Figure 16
Star Delta Wiring Schematic
LEGEND
J Jumper Wire 1PS Line Pressure Switch COOLER CIRCUIT
PC Printed Circuit ,sv Load Solenoid Valve
2MTR Fan Motor
1MTR Compressor Motor 3SV Slowdown Solenoid Valve
20L 2MTR Overcurrent Relay
1M 1MTR Start-Run Contactor 5SV Oil Stop Solenoid Valve
1CB Circuit Breaker
2M 1MTR Run Contactor 8SV Cold Start Blowdown Sol. Valve
1S 1MTR Start Contactor 1RS Normal-Unload Selector
OPTIONAL EQUIPMENT
1Ma Auxiliary Contacts 1TR Starter Time Delay Relay
2Ma,b Auxiliary Contacts 1VAC Fouled Air Filter Switch 1SA Shutdown Annunciator Module - With Lights

•
1Sa,b Auxiliary Contacts 3DP Fouled Coolant Filter Switch BLT High Air Temperature - Red
·10L 1MTR Overcurrent Relay 4CR Cold Start Control Relay 9LT High Bearing Scavenge Temperature
1CR Control Relay 10LT 1MTR Overcurrent Relay - Red
T Control Transformer INDICATING LIGHTS 11LT 2MTR Overcurrent Relay - Red
1FU Fuse 3PB Reset-Test Button
GAD Ground 1LT Power On - While �H::i Conl(cil MciclE!' sere_ctor
1HM Hourmeter 2Lr Power On - Red 2SV Con.trol Mode Solenoid Valve
1PB Stop Button 3LT Fouled Coolant Filler - Amber
2PB Start Button 4LT Fouled Air Filter - Amber 3TR Automatic Start-Stop Timer Module
HAS High Air Temperature Switch ?LT Starter Timer Energized - Red 13LT" Automatic Start-Stop Timer - Red
5TS High Bearing �cavenge Temp Sw;tch 14LT Stopped-Auto Restart - Amber
4TS Cold Start Temperature Switch 4TR Auto Control Selector (A.C.S.) Timer Module
15Lr A.C.S.-Modulale Mode - Red
• Located in Starter Box 4SV Water Shutoff Solenoid Valve

22

INSTRUMENTATION
CONTROL PANEL
Discharge Temperature Gauge - in­
dicates temperature of air leaving
the compressor. The temperature
sensing bulb is located in the
receiver tank in line with the
discharge air flow.
Dual Air Pressure Gauge - reads
receiver (sump) pressure and line
pressure simultaneously on the
same ga':lge using two separate
pointers. Line Pressure is in­
dicated by a Blue pointer while
Sump Pressure is indicated by a
White pointer. By reading the
pressure on either side of the
lubricant separator, the differential
shows the condition of the
separator element. Differential
pressure readings shou Id be taken
when the compressor is operating
at rated capacity and pressure.
The differential pressure should be
recorded when the unit is first
started or after a replacement ele­
ment is installed. This base
Hour Meter - reads the total time
of operation of the compressor. It
runs only when the motor starter
coils are energized. It should be
used to schedule maintenance
functions such as coolant, and
coolant-tilter changes.
Normal • Unload Selector - con­
trols the ability of the compressor
to "load up". When the selector is
in the Normal mode, the Load
Solenoid Valve can be energized,
and the Inlet Valve Positioner can
open the Inlet Valve. When the
selector is in the Unload mode,
the Load Solenoid Valve cannot be
energized. This selector position
is used when the compressor is
started manually.
On Line-Off Line/Modulate A.C.S.
Selector (Optional) - chooses the
type of compressor capacity con­
trol. Refer to the capacity control
section for an explanation of the
different modes of control. Each is
designed for varying plant needs.
Lubricant Filter Maintenance In­
dicator Light - Mounted on the
•
Air Filter Maintenance Indicator -
Mounted in the starter box, a
vacuum switch senses the
pressure drop across the air filter
element. As the filter element
traps dust, the pressure drop in­
creases causing the vacuum
switch to switch on the panel
mounted Air Filter Light indicating
that the filter element should be
replaced.
In addition to the pressure and
temperature indicators and other
instruments on the control panel,
each compressor is equipped with
a high pressure relief valve -
mounted on the receiver-separator.
It is set to open at the maximum
working pressure stamped on the
tank.

reading can then be used to deter­
mine the proper change period.
(See maintenance section.)
Power On Light - indicates that
control voltage is available to the
control circuit and that the line
voltage is available at the motor­
starter main-contacts.
Start-Stop Push Buttons - energize
or de-energize the control relay
(1 CR) to start or stop the com­
pressor.
•
lubricant filter. a differential
pressure switch senses the
pressure drop across the filter, and
switches on the panel mounted
Lubricant Filter light indicating
that the filter element should be
replaced. However, the indicator
coming on when the compressor
starts cold is a normal condition.
After operating for a short period
of time, the indicator must ex­
tinguish. Refer to the lubrication
section for specific details.

-
•
•
Figure 17 Figure 18
STD Instrument Panel NEMA 4/12 Instrument Panel

23
•
DUAL SLOWDOWN
VALVE SYSTEM
The SSA Compressor package
includes a dual blowdown valve
system, designed to maintain the
proper lubricant flow to the
compressor during all phases of
machine operation.
The system includes the main blow­
down valve, the cold start blowdown
valve, the cold start temperature
switch, and control relay.
The main blowdown valve (3SV), is an
electrically operated, normally open
solenoid valve, controlled by the
normal/unload switch (1RS), or the
pressure switch (1 PS).
The cold start blowdown valve (8SV)
is an electrically operated, normally
open solenoid valve, controlled by
the normal/unload switch (1RS), the
pressure switch (1 PS), or the cold
start temperature switch (4TS).
During initial cold, unloaded starting
These controls are:
A. On line-Off line (Standard,
Figure 19).
B. On line-Off line with Upper
Range Modulation (Optional, Fig­
ure 20) . . . and either is avail­
able by operation of the selector
switch on the compressor panel.
ON LINE-OFF LINE CONTROL
For those plants which have a widely
varying air demand, the On Line-
Off Line control will deliver air at
full capacity, (the compressor max­
imum efficiency condition) or will
operate at zero capacity with low
receiver pressure (the compressor
minimum power condition.)
COOLANT PRESSURE
The operating mode of the
compressor is controlled by the
pressure switch (1 PS) responding to
changes in plant air pressure. This
switch energizes the Load Solenoid
Valve (1 SV) and Slowdown Solenoid
Valves (3SV & 8SV) whenever the:
plant air pressure drops below the
lower set point of (1 PS) and keeps
these solenoid valves energized un­
til the upper set point is reached.
When these solenoid valves are
energized. pressurized coolant is fed
to the inlet valve positioner through
the Load Solenoid Valve (1SV) forcing
the inlet valve to open fully. The
Slowdown Solenoid Valve closes off
the atmostpheric vent.

•
of the machine, the cold start blow­
down valve (8SV) remains closed as
long as the lubricant injection
temperature is less than 120 ° F.
(49 ° C.) and the main blowdown valve
(3SV) is open. This results in an
INLET
elevated receiver (sump) pressure, VALVE
approximately 50 psig (3.4 BAR), to
provide adequate lubricant flow until Figure 19
the compressor has reached the On Line-Off Line Control
120 ° F. minimum warm-up
temperature.
As the injected lubricant temperature COOLANT PRESSURE INLET AIR
rises to 120 ° F. (49 ° C.), the normally VENT FLOW
closed, cold start temperature switch
(4TS) opens, de-energizing and
opening the cold start blowdown
valve (8SV), allowing the receiver
pressure to decrease to the normal
unloaded level, approximately 25 psig
(1.7 BAR).
The main and cold start blowdown
valves operate simultaneously once

"'
the injection temperature reaches the
120 ° F. (49 ° C.) minimum warm-up
temperature. INLET
VALVE

CAPACITY CONTROL
MODULATOR

•
The SSA compressor is equipped
with two types of capacity control -
each designed to suit the individual LINE PRESSURE
plant requirements. ( t"\OOU L A 1 El
Figure 20
On Line-Off Line with Upper Range Modulation
Control
(Optional)

24

Line pressure increases
110 when compressor output
is greater than plant
105 air demand. -
-n-
•
The compressor will then operate to
deliver full capacity air to the plant
system. If the plant air system
pressure rises to that of the pressure
Pr essure switch ( 1 PS)
switch upper set point, all

--
'- solenoids will be de-energized.
� ,1 upper set point
100 -i:. H � ..... rll The Load Solenoid Valve will shut off
� ,:. the flow of pressured coolant to the
I inlet valve positioner, allowing the
95
-
I
I inlet valve to close.
Compressor rated
>, tI L--._
discharge pressure

1
� The Slowdown Solenoid Valves
·c:; 90 (3SV & 8SV) will open the receiver
ro Compressor I,,
vent line, and allow the receiver
a. 85 .... capacity increases �

t
pressure to drop.
when line pressure
The compressor will continue to run,
"O
80 .... drops to reset ,_

-
but since most pressure has been
ro point of 1 PS I
Compressor
I., ,..� relieved, ii will do so with a minimum

r
75 I � capacity drops power draw.
t._.....v to zero when
0
:::,g
0
I line pressure The Pressure Switch (1 PS) has a 12
70 I
I l reaches upper psi (0.83 BAR) range between its

65 V
Reset pressure.
I I set point of 1 PS upper and lower set-point pressures.
The upper set-point pressure is
tI t factory set at slightly above the
compressor rated discharge
60 I
pressure. The correct upper-set-point
I Line pressure decreases ; pressures are listed in Regulation
I\ as air consumption Adjustment Section of this manual

•
'".Jl li"u_ lliJ
o and, also, on decals affixed to the

i I�
compressor.
A graph indicating the relationships
0 90 95 100 105 between the compressor output, the
% of rated line pressure line pressure, and the pressure
switch 11PS) setting is shown in
Figure 21 Figure 21.
Operating Sequence
Using On Line-Off Line Control

•
25
•
ON LINE-OFF LINE WITH UPPER
RANGE MODULATION CONTROL
(OPTIONAL)
For those plants which have
relatively high and constant air
demand, relative to the compressor
capacity, the recommended control
mode is Upper Range Modulation
(URM).
The URM control system retains the
features of the On line-Off line
control, but provides for throttling of
the inlet air flow as the line pressure
rises to the upper set point of the
pressure switch (1 PS).
By applying line pressure to a spring
loaded diaphragm valve, that is, the
Modulator, the throttling position of
the inlet valve is controlled. The inlet
valve positioner is part of the linkage,
but does not act to do other than
move the inlet valve to the open
position, allowing the modulator to
"trim·· the inlet valve position as
dictated by the line pressure.
The modulating pressure range is
about 7 psi (0.5 BAR) and the
AUTOMATIC START-STOP CONTROL
(OPTION)
For those plants which have a widely
varying plant air demand, large air
storage capacity and/or want
automatically available standby air
capacity, Automatic Start-Stop
Control by solid state module
addition is available.
During periods of low demand, if the
line pressure rises to the upper set
point of pressure switch (1 PS), a time
delay relay (3TR) is energized and
begins to time out. The timer,
mounted on the main board in the
starter box, is adjustable in a 0-15
minute range. The timer will
continue to operate as long as the
plant line-pressure remains above the
lower set-point of the pressure
switch.
Factory
setting
f od u lator
If the timer continues to operate for
as long as its adjusted time setting,
a relay contact in the timer module
opens to de-energize the compressor
motor and fan motor coils. At the
same time. an amber light (14LT) on
the instrument panel is lit to indicate
that the compressor has shut down
automatically and will restart
autornatically.
The automatic restart will take place
when the line pressure drops to the
lower set point of pressure switch
(1 PS).
An indicating light. red (13LT), is lit
when the timer is running. This light
can be used to confirm the timer
setting and can be of assistance if
electrical checks are being
considered. It is mounted on the
face of the Automatic Start-Stop
module.
Optional Pressure
field settings switch ( 1 PS)

�,
of modulator upper set

•
om
moculator is factory set to straddle
the compressor rated pressure. 105 '\ ,-..... � point
Moculation begins when the line \ � \
�
..... ,_ 1--C >- � ...
pressure reaches about 96 percent of
�
100 -!►

\ \
the compressor rated pressure and
I �
-
con:inues as/if the line pressure
rises. Modulation becomes stable 95 ... Modulate to
I
\
\ )-

-
whe1 the compressor output equals 94% capacity
I \ �
the ::,lant air demand. When the
:::,:. 90
moculation is at the factory setting
the maximum capacity reduction will ·uro I \
\
\
I� Modulate to
a. 85
I \
be c::wm to approximately 60 percent I � 1--
85% capacity
�
of tr:e compressor rated capacity. ro
I
-... ''
(.)
80 I\
If the air demand has decreased to a
levei below the 60 percent modulated
'O
Q) I 1
out::,ut. the line pressure will increase ro
75 I \
sli�htly to actuate the pressure
switch (1 PS). The compressor will II \ �
>- - 1-- Modulate to
72'½, capacity
then shift to the off line control ?ft. 70 I \
position. and operate at unload with
the receiver vented. 65
I l
I I\
It is sometimes desirable to begin
moculation at a higher pressure than 60 I \
.,__ 60%
Modulate to
the standard factory setting thereby I capacity

.-
increasing the modulated capacity at
the time the pressure switch (1 PS) is
,r 1�, I I
actuated. Reference to Figure 22 will
indicate the typical modulated
I
capacities available v1hen this is
done.
90 95 100 105

•
% of rated line pressure

Figure 22
Modulation Capacity

26

AUTOMATIC CONTROL SELECTOR
(ACS) (OPTIONAL)
The automatic control selector
(ACS) is designed to continuously
monitor the plant air demand and
select either the on line-off line, or
the modulate control mode -
whichever is most desirable at any
time during an operating day.
It allows the compressor to
operate in its most efficient mode
without attendance, thereby reduc­
ing power costs to a minimum.
When the compressor operates in
the on line-off line control mode,
the length of time the compressor
remains in the "off line" condition
is an indication of the plant air de­
mand. The compressor switch
(1 PS) is sensing and awaiting a
sufficient line pressure decrease
before signaling a shift to the on­
line mode. If the "off-line" time
period is relatively short, thereby
indicating a high demand for air, it
is preferable to shift the control
system to upper range modulation.
•
REGULATION
ADJUSTMENT
INSTRUCTIONS
IF PROPER ADJUSTMENT IS LOST,
PROCEED AS FOLLOWS TO RE­
ESTABLISH CORRECT SETTING:
ON LINE-OFF LINE CONTROL
A. Setting the inlet control valve
1. Remove bolt (A). Loosen clamp
screw (B). Slide the travel stop (d)
in the direction of the arrow in
Figure 23 until it stops.
2. Rotate the inlet air control valve
shaft counterclockwise until the
valve plate (E) is in the closed
position. While assuring the valve
plate (E) is closed, position the
lever arm (F) against the travel
stop (D) as shown in Figure 23
Tighten the clamp screw (B).
B. Setting the inlet valve positioner
linkage
1. Adjust the length of the inlet
valve positioner linkage (G) until

•
the lever end bolt (A) threads
The ACS control does this. and easily into lever (F) while the lever
does it automatically. is held against the travel stop (D).
Tighten bolt (A).
If later. the plant demand de­
creases, and even under modu- C. Setting the pressure switch
late control the line pressure
reaches the setting of the pressure
switch (1 PS). and the control shifts TABLE I
to the "Off-line" mode. the time in
this mode will still be monitored.
A long "off-line" time-period in­ MAXIMUM
dicates a low plant air demand. in­ MODEL DISCHARGE PRESSURE
dicating the desirability of opera­
ting in the on line-off line mode. XF 103 PSIG
EP 128 PSIG
The ACS control then does this, HP 150 PSIG
and does it automatically.
The ACS control is a solid state
module addition to the standard
compressor control system. It can
operate independently of any other
optional equipment. It can add
additional usefullness to an auto­
matic start-stop control system.

D B
Figure 23
E

Inlet Control Valve

INLET
VALVE

•
27
•
4. Slowly close the isolation
CAUTION valve, allowing the line
When adjusting differential, adjust pressure to rise to the max-
switch so that maximum discharge imum discharge pressure or
pressure does not exceed value "trip" setting of the pressure
listed in Table 1. switch as shown in Table 1,
P. 27.

5. Remove cover from pressure

Setting Pressure Switch switch. Adjust as required by
turning range adjustment
screw clockwise to increase
and counterclockwise to
decrease trip setting. When
1 PS trips the compressor
should unload and vent the
receiver/separator tank. When
the Iine pressure fal Is to the
reset point of 1 PS (about 12
psig), the unit should reload.
The pressure switch differen­
tial is adjustable and factory
set at about 12 psig to meet
the requirements of the
average application.

Limited receiver and line

storage may require a wider
differential. Sufficient receiver
DIFFERENTIAL
and line storage can accept a

•
ADJUSTMENT
narrower differential. If adjust­
SCREW ment is required turn differen­
tial adjustment screw
clockwise to decrease the dif­
ferential and counter-clockwise
to increase the differential.
See Figure 25.

6. Vent air from customer system

Figure 25
to confirm switch operation is
Pressure Switch (1PS) satisfactory.

1. Open isolation valve. allowing 7. Replace switch cover and

control system to sense "line·· place unit in service.
pressure.

2. Place the Normal/Unload

rocker switch in the "Unload··
position an the optional con­
trol selector in the ··On/Off
Line·· Position.

3. Start the compressor. Place

the normal/unload rocker
switch in the "Normal"· posi­
tion. The compressor should
load if the line pressure is
lower than the switch reset
(lower pressure) setting. It
may be necessary to vent air
from customer system to load

•
unit

28

D. Setting Receiver Pressure
1. Turn the Normal/Unload switch
to "Unload." Start the com­
pressor. Allow the unit to
reach operating temperature
with both blowdown valves ex­
ahusting.
2. Close the isolation valve.
3. Rotate the lever arm (F) until
25-30 PSIG or (1.7-2.0 BARS for
50 Hz Units) Sump pressure is
read on the air pressure gauge.
(See Figure 23).
4. Loosen travel stop bolts (C).
Slide the travel stop (D) until ii
touches the lever arm (F).
Tighten the travel stop bolts (C).
5. Adjustment is now complete.
ON LINE-OFF LINE WITH UPPER
RANGE MODULATION CONTROL
A. Setting the Inlet Control Valve
1. Remove bolt (A). Loosen clamp
screw (B). Loosen travel stop
bolts (C). Slide the travel stop
(D) in the direction of the arrow
in Figure 26 until it stops.
2. Rotate the inlet air control valve
shaft counterclockwise until
valve plate (E) is in the closed
position. While assuring the
valve plate (E) is closed, position
the lever arm (F) against the travel
stop (D) as shown in Figure 26.
Tighten clamp screw (8).
Figure 26. Inlet Control Valve With Modulator
29
B. Setting the inlet valve positioner
linkage
1. While being sure that the lever
arm (G) of the modulator (H) is
against its full open stop (I),
adjust the length of the inlet valve
positioner linkage (J) until the
lever end bolt (A) threads easily
into lever (F) while the lever is held
against the travel stop (D).
Tighten bolt (A).
C. Setting the modulator
1. Remove the acorn nut (K) from the
modulator (H), loosen locknut (L),
and run adjusting screw (M) in a
few turns.
2. Start the compressor with the
Normal/Unload selector switch in
the ··unload" position and the
On/Off Line/Modulate selector in
the "On/Off Line" position. Allow
the unit to reach operating
temperature.
3. Turn the Normal/Unload selector
switch to the "Normal" position.
This allows the positioner (N) to
be actuated, opening the inlet con­
trol valve (E) loading the com­
pressor.
4. Insure that the pressure switch
(1PS) is operating properly by
closing the isolation valve located
on the discharqe line of the.com­
pressor. Watch the pressure
gauge to insure that the pressure
switch (1 PS) opens at the correct
maximum discharge pressure for
the model being adjusted. These
maximum discharge pressures or
upper trip settings of the line
pressure switch (1PS) are as
follows:
J
N C
H D L M K B
•
60 HZ
UNITS
Model "XF" compressors 103 PSIG
Model "EP" compressors 128 PSIG
Model "HP" compressors 150 PSIG
5. After confirming the upper trip
setting of the pressure switch
(1PS), open the isolation valve and
set the discharge pressure 4 psi
(0.3 BAR) below the rated opera-
ting pressure listed on the com-
pressor data plate.
6. After adjusting the discharge
pressure with the isolation valve,
confirm that the inlet air valve is
fully open.
7 Turn the compressor control
selector to the "Modulate"
position.
8. Airflow should be sensed coming
from the orifice located in the
bottom of the modulator body (H).
9 Turn the modulator adjusting
screw (M) until lever (G) begins to
move off stop (I).
•
NOTE: Confirm !ine pressure has
held steady and the inlet valve is
still fully open.
10. While holding adjusting screw
(M) firm, tighten locknut (L).
Replace acorn nut (K).
11. Raise the line pressure by the
use of the isolation valve to just
below the upper trip setting of
the Iine pressure switch (1 PS).
Set adjustment lock bolt (0) so
that it just contacts lever (G).
Tighten locknut on bolt.
•
•
D. Setting receiver pressure
1. Turn the Normal/Unload switch to
"Unload," and compressor control
selector to "On/Off Line." Allow
unit to blowdown fully with both
blowdown valves exhausting.
2. Close the isolation valve.
3. Rotate the lever arm (F) until 25-30
psig or (1.7-2.0 BARS for 50 Hz
Units) is read on the air pressure
gauge.
4. Loosen travel stop bolts (C). Slide
travel stop (D) until it touches the
lever arm (F). Tighten the travel
stop bolts (C).
5. Adjustment is now complete.
OPERATION
INITIAL PREPARATIONS AND
START-UP
1. Inspect and confirm that all pip­
ing and electrical work is tight
and that the main disconnect
switch is in the OFF position.
•
2. Confirm ihat line voltage and
compressor nameplate voltage
are the same. Confirm that the
control transformer is connected
correctly. Refer to the electrical
section of this manual for trans­
former hook-up.
3. The unit will normally be prefilled
with Ingersoll-Rand lubricant
and it is only necessary to check
the level gauge before and imme­
diately after start-up. Add two
quarts of lubricant through the
compressor inlet.
4. Remove the panel section in the
enclosed unit to expose the com­
pressor motor. Inspect the
motor and control wiring for
tightness and safety.
5. Place the main disconnect
switch in the ON position. Note
whether the white "power on"
light on the panel is lit, indica­
ting control voltage is available
to the control circuit.
6. Place the Normal/Unload selec­
tor switch in the Unload position,
the control selector in the "On/
Off Line" position.
•
7. Look through the compressor­
motor cooling-air-access and,
with a flashlight, observe a blade
of the compressor motor cooling
fan. Have an assistant jog the
compressor motor and note the
direction of rotation of the
motor. The rotation must be in
accordance with the directional­
arrow-decal affixed to the motor.
Note: The correct motor rotation
is clockwise when the motor is
viewed from the end opposite the
drive end.
CAUTION
For the motor rotation check, the
motor jogging must be for as short
a time as possible. After depressing
the start switch, immediately
depress the stop switch.
WARNING
If main motor rotation is not
correct, disconnect the main
power, and interchange any two line
connections (L 1, L2, or L3) at the
starter.
8. For air cooled units, or cabinet
vented units, when the compres­
sor rotation is correct, the cool­
ing or venting fan motors will
also be correct. In each case,
cooling air should be exiting
from the enclosure. If, for some
reason, this is not so, the fan
motor rotation should be re­
versed. Put the main disconnect
in the "OFF" position, and inter­
change any two fan motor leads
(2T1, 2T2, or 2T3) at the fan
motor overload relay (2OL).
9. Check to determine that the
lubricant level is at the mid-point
of the sight glass provided.
10. If the compressor is watercooled,
turn on the cooling water. Close
the discharge isolation valve.
Start the compressor.
11. Check for tightness of all fit­
tings, particularly in the
lubricant system. After a few
minutes operation, shut the
unit down and check the lubri­
cant level in the receiver.
12. Because some lubricant will
remain in the piping and acces­
sories, it may be necessary to
add lubricant to bring the level
back to the mid-point of the sight
glass. Tighten the fill plug
securely.
13. Start the compressor and let it
warm up for approximately 2
minutes while operating in the
"Unload" and "On/Off Line"
control modes.
14. When operating the compressor
in the "Unload" mode, observe
the Sump Pressure Reading on
the Air Pressure Gauge. The
sump pressure should not fall
below 25 psig (1.7 BAR). If so,
please refer to section D of
Regulation Adjustment instruc­
tion elsewhere in this manual.
15. After approximately 2 minutes,
switch the load control to
"Normal".
16. SLOWLY open the discharge
isolation valve to put the
compressor on the line.
17. If the compressor is discharging
into a non-pressurized system, it
is good practice to use the
isolation valve to develop a back
pressure of about 5 psig (0.4
BAR) below the compressor
rated pressure. When the
system is pressurized, open the
isolation valve completely, and
allow the unit to operate
normally.
18 For air cooled units, the
discharge temperature should
rise to near 190 ° F. (88 ° C.) and
may rise to as high as 210 ° F.
(99 ° C.) at full load if the ambient
cooling air is as high as 100 ° F.
(38 ° C.).
30

LUBRICATION
LUBRICANT
SSR ULTRA Coolant
Rotary screw compressor fluids have
a triple function to perform. They
lubricate the bearings and contacting
surfaces of the rotors; they seal
internal clearances within the rotor
chamber; and they provide for the
cooling of the compression process.
The bulk of the fluid is actually used
for cooling with only small amounts
used for lubrication and sealing.
The lubricant used in the SSR com­
pressor has been specially blended
and formulated to perform the
above three functions exceptional­
ly well. Its lubricating qualities ex­
ceed those of standard petroleum
oils as well as those of previously
available synthetic lubricants. Its
•1iscos1ty characteristics are such as
to pro·;ide excellent sealing of
intern2.I clearances over broad
ranges of operating temperatures. In
fact. 1�e viscosity change with
tempe·ature is small enough to
permit the lubricant to be used
over the entire range of ambients
from 20 ° F. (-7 ° C.) to 115 ° F. (46 ° C.)
without significant loss of its
qualities. When conditions other
than the design levels described
are encountered. we recommend
you contact your nearest Ingersoll­
Rand representative for additional
information.
Most important is the performance of
the fluid as a coolant. In this function
the SSR ULTRA Coolant demon­
strates its outstanding abilities. It has
exceptional oxidation stability at
system operating temperatures so as
to provide long life. Advanced rust
inhibitors assure clean piping, clean
cooler tubes, and clean separator
tanks.
31
Due to the large volume of lubricant
circulated and its direct contact with
the air being compressed, foaming at
blowdown or other pressure change
conditions is often a problem with
rotary compressors. The SSR ULTRA
Coolant has quick air release
characteristics and minimal air­
entrainment, such that foaming has
been largely eliminated as an
operating concern.
In addition, the SSR ULTRA Coolant
has little affinity for water as well as
quick, effective water release at
shutdown. These characteristics
provide for maximum bearing
lubrication integrity, as even small
amounts of water in the lubricant can
be highly detrimental. These factors
also provide for easy draining of
condensation from the vertical
separator receiver tank.
Each SSR compressor will normally
be filled, tested, and shipped with a
complete charge of Ingersoll-Rand
SSR ULTRA Coolant. This fluid is
changed each 8000 hours of oper­
ation or once a year, whichever
comes first. While operation far
beyond this time frame is possible
under favorable conditions, change­
out at the recommended times will
assure maximum unit protection and
operating life for all installations.
Filter change-periods should be
strictly adhered to for proper fluid
maintenance. See the Filtration
Section for specific filter change
recommendations.
Readily available but normally
ordered and shipped with the unit is
a service kit which includes air and
lubricant filter elements and make­
up lubricant for approximately one
year's operation.
If a situation arises where. for some
reason. this fluid cannot be used.
consult Ingersoll-Rand for specifica­
tions and recommendations on
possible substitutes.
•
LUBRICANT FILTRATION
Each compressor has a hydraulic­
type full flow filter with a single
replaceable element.
The filter is mounted downstream of
the cooler and the thermostatic
control valve.
It is rated at 10 microns.
It has a differential-pressure-bypass­
valve set to open in the event that
the pressure drop across the filter
element rises to as high as 15 psi,
which indicates an excessively
fouled element. as well as poor
maintenance practice.
To eliminate this latter possibility, a
maintenance indicator consisting of
a filter mounted differential pressure
switch and a panel mounted indi­
cating light, is provided. This
indicator will signal that a differential
pressure of 15 psi has been reached
and the filter element should be
replaced.
During some start-ups. if the coolant
is cold. the indicator may light up.
This is normal. If the filter element
•
is serviceable. the indicator will
extinguish as the compressor
temperature rises.
LUBRICANT FILTER INDICATOR
However. regardless of the main­
tenance indicator reading. the filter
element should be changed after the
first 150 hours of operation and
again after each 2000 hours of
operation. If the compessor operates
less than 2000 hours per year. the
element should be replaced when the
annual lubricant chanqe is made.
The procedure for renewing the filter
element is outlined in the
maintenance section of this manual.
Spare elements and gaskets should
be kept in stock at the installation to
facilitate regular replacement.
The procedure for change out of the
lubricant is outlined in the
maintenance section. Make-up
lubricant for use between annual
changes should also be kept in
plant stock.
•
•
SAFETY SHUTDOWN
CHECKS
HIGH AIR TEMPERATURE
A high air temperature shutdown
switch is located at the discharge
port of the compressor.
This switch should be checked at
regular intervals; about once a month
is recommended.
This switch can be checked for
proper operation by either:
1. Shutting down the cooling fan on
an aircooled unit by opening the
disconnect switch on the fan motor
circuit breaker, or,
2. Shutting off the cooling water on
a watercooled unit.
In either case, the discharge
temperature will rise at a fairly rapid
rate. Shutdown should occur at
about 230 ° F. (110 ° C.).
The temperature at which the shut­
down occurs should be recorded for
comparison with similar future test
(2TB-5) for an open temperature
switch, an open overload relay, an
open "stop" push button or a
defective control relay (1CR).
If the trouble is in the motor starter
control circuit, check across ter­
minals (2TB-11) and (HB-13) to
confirm that the time delay relay
contacts (HR) are closed. If they
are open. the time delay relay solid
state module should be replaced.
COMPRESSOR WILL NOT BUILD
UP RATED PRESSURE
The air demand may be too high.
Check for plant air leaks or open
service valves.
The pressure switch (1 PS) may be
set too low. Check the pressure
setting when the unit is operating
in "Normal". and the line-off line
control mode. If the pressure set­
ting is increased. it must not be
set higher than the upper set point
pressure listed on the Compressor
Data Plate.
COMPRESSOR FAILS TO DELIVER
manifold block. The proper injec­
tion temperature, for test purposes,
is in the 130 ° F. to 150 ° F. range
(55 °C. to 65 ° C.).
3. Fouled coolers. Check external
cooler surface of aircooled units
and internal cooler tubes of water
cooled units.
4. Operating air cooled units in ex­
cessively high ambients.
5. Insufficient ventilation.
6. Defective thermostatic valve.
7. Operating above rated
discharge pressure. This also
shortens motor insulation life
because of the overload the motor
must carry.
EXCESSIVE LUBRICANT
CONSUMPTION
A ruptured or fouled separator ele­
ment or a blocked scavenge
orifice-screen-assembly will in­
crease coolant-lubricant consump­
tion. The orifice-screen-assembly
should be checked regularly.
An increase in pressure differential
across the separator is the indica­
tion of a fouled separator.

•
results.
HIGH BEARING SCAVENGE
TEMPERATURE
A high bearing scavenge lubricant
temperature switch is located in
the compressor rear bearing
scavenge manifold piping
This switch will open and shut the
unit down at a bearing scavenge
temperature of about 230 ° F.
(110 °C).
TROUBLE
INVESTIGATION
COMPRESSOR FAILS TO START
1. If the main disconnect switch is
closed and the "power on·· light
bulb is good but does not light up.
the control voltage is probably not
available. Check the transformer
secondary for control voltage and
check the fuse (1 FU) for continuity.
If the fuse is blown. check for the
fault.
2. If "power on" light (1 LT) is lit
and starter button is depressed.
RATED .CAPACITY
A decrease of pressure differential
A fouled inlet air-filter will reduce from the previous reading would in­
the actual weight flow of air which dicate a ruptured separator.
will show up as reduced capacity
Differential pressure should be
of the compressor. The filter ele­
noted and recorded. It should be
ment should be changed when the
taken when the compressor is
panel-mounted indicator light
operating at rated capacity and
comes on.
pressure.
A faulty adjustment of the capacity
regulation system could cause
modulation of capacity at incorrect CAUTION
pressures. Check the inlet valve Hoses should be checked every
positioner and the modulator.
A defective modulator needle and
three months for signs of
deterioration. Hairline cracks and
seat could cause modulation at hardening are two signs to look
lower than intended line pressures. for; replace hoses as required. A
Inspection of the inlet valve posi­ service life of two to four years is
tion during modulation will in­ normal.
dicate this condition. The inlet­
valve should be in a throttle posi­
tion consistent with the curves
shown in the "Upper Range
Modulation Control" section of this
manual.
COMPRESSOR
OVERTEMPERATURE SHUTDOWN
Compressor overtemperature shut­

•
check the voltage across the hour
meter terminals (2TB-11) and
(2TB-5). If full control voltage ex­
ists across the hour meter, the
trouble is in the motor starter. If
full voltage does not exist across
the hour meter, check the protec­
tive control circuit from (1TB-1) to
down may be caused by:
1. Insufficient lubricant being cir­
culated. Check the lubricant level
in receiver sump.
2. Insufficient cooling of lubricant.
Check injection temperature by in­
serting a dial type thermometer in
the specially provided port in the

32

EXCESSIVE LINE CURRENT
If shutdown occurs because of
electrical overload, a trip indicator
projects from an opening in the lower
portion of the relay.
Overload relays can trip if line
voltage is excessively low. This
condition causes the motor to draw
higher current. Unbalanced electrical
phase can contribute to this problem.
Operating at pressures above the
rated pressure will cause higher
motor currents.
All starter contacts must be in good
condition. The contacts can be
inspected by removing the arc box
from the front of the starter.
WATER CARRYOVER TO
DISCHARGE LINES
A fouled or defective condensate trap
that does not drain condensate will
allow the condensate to be carried to
the plant system. The trap operation
must be checked regularly.
Condensate should flow whenever
the aftercooler lowers the discharge
air temperature below the dew point.
Under atmospheric conditions of very
low humidity, it is possible that no
water vapor is condensed and
therefore there will be no flow from
the condensate trap.
The use of an open funnel in the
drain line has been recommended to
make a visual inspection easier.
LAMP TEST PROCEDURE
Periodic maintenance of the com­
pressor should include checks of the
safety shutdown devices, and
problem warning lights. Each of the
four lamps on the instrument panel
may be tested by using a short test
jumper wire with a clip on one end
and a test probe on the other.
CAUTION
Care should be exercised during
these lamp checks because of the
electrical hazards that will be
present when the electrical box
is open.
By applying main power to the
compressor the control transformer
will be energized to supply proper
voltage for testing the lamps.
Provided the 1FU is not open, the
Power On (1LT) lamp will light as
soon as power is applied to the
transformer.
33
By connecting the test wire clip to
(1TB-1) carefully touch the probe to
(3TB-12). This applies power to the
Coolant Filter Lamp (3LT). If the
lamp is good it will light up.
Leaving the clip connnected to
(HB-1), move the probe to (3TB-13).
This applies power to the Air Filter
Warning Lamp (4LT). If the lamp is
good it will light up.
Still leaving the clip connected to
(HB-1), move the probe to (3TB-8).
This applies power to the Automatic
Restart Lamp (14L T). If the lamp is
good it will light up.
LUBRICANT LEVEL CHECK
With the unit not running, lubricant
should appear in the sight glass.
With the unit runnina unloaded and
the lubricant at operating
temperature, the lubricant level
should be at mid-range in the sight
glass.
MAINTENANCE
GENERAL
The SSA Compressor requires a
minimum of maintenance. The major
concerns are the air cleanliness, the
quality of the lubricant and the
lubrication of the electric motors.
Over relatively long periods of time,
other system accessories will require
replacement; items such as the air
separator element.
The procedures to follow when
servicing the compressor or
replacing major accessories are
described in the following
paragraphs.
LUBRICANT FILTER ELEMENT
Time of Change - after first 150
hours and every 2000 hours
thereafter. or when the filter indicator
shows the need for element change,
or when the lubricant is being
changed.
WARNING
Confirm all pressure is relieved
from the compressor system and
that the main electric disconnect
switch is open and tagged to
remain open.
•
Procedure -
Place a suitable container under the
filter housing drain valve which is
located near the bottom of the
housing.
Remove the bolt at the bottom of the
housing. This will free the housing
and element from the filter head.
Remove the "O" ring gasket.
Inspect the element and housing for
foreign particles which have been
trapped in the element and also for
general overall condition - then
discard the element and clean the
housing.
Reassemble the filter using a new
element and "O" ring. Each
replacement element is furnished
with replacement gaskets -including
one which fits under the bolt head.
Torque the bolt to 20 Lb.-Ft.
AIR FILTER ELEMENT
Time of change - when the panel
mounted indicator lights up. or
annually, when the coolant is
•
changed. Indicator should be
observed at full load.
Procedure -
Shut down the compressor.
Loosen wing nut on top of inlet filter
housing. Lift cover up and away to
expose element.
Carefully remove the old element to
prevent dirt from entering the inlet
valve. Discard old element.
Thoroughly clean the element
housing and wipe all surfaces.
Install new element and inspect to
insure that it has seated properly.
Install top of inlet filter housing.
Inspect the rubber seal on the
retainer wing nut and replace seal if
required.
Tighten wing nut.
Place unit in service.
•
•
LUBRICANT CHANGE TIME
AFTER EVERY 8000 HOURS OR
ANNUALLY (SSA ULTRA)
Procedure and Comments -
There are two points of lubricant
drainage on each compressor; 1) a
valved drain in the base, and 2) a
draincock or valve in the oil filter
housing. Both of these drainage
points should be used to obtain
the maximum drainage of used
_!_yg_r icant.
WARNING
No drainage points should be
opened until the compressor has
been isolated electrically and all air
pressure has been removed from
the system.
The lubricant should be drained soon
after the compressor has been shut
down_ When the lubricant is hot, the
drainage will be more complete and
•
any particles in suspension in the
lubricant will be carried out with the
lubricant.
WARNING
Extreme care should be exercised
when draining the hot lubricant so
that no possibility of injury to
personnel elCists.
After the unit is drained and a new
filter element is installed, refill the
system with fresh lubricant.
RECOMMENDED
MODEL LUBRICANT
CAPACITY
SSR-125 thru 200 HP 22 Gal.
SSR-250 thru 300 HP 35 Gal.
SSR-E300 thru 350 HP 32 Gal.
SSR-400 thru 450 HP 28 Gal.
Bring the receiver level of lubric,ant
up to the mid-point of the gauge
:;ilass. Replace the fill cap.
•
Start the compressor and run it for a
short '.',hile. Shut it do•:;n and check
the lubricant le•iel 1n the receiver.
Add enough lu:::ir1cant so that it
appears in the sight glass
LUBRICANT SEPARATOR
ELEMENT
Time of Change - when the
differential pressure across the
element reaches three times the
initial pressure drop or a maximum
of 15 psi at full load.
NOTE: A drop to zero differential
also indicates a failing or by passing
element that must be replaced.
Procedure -
CAUTION
Shut down the compressor, close
the service air line isolation valve
and open the main electrical dis­
connect switch. Confirm all air
pressure is relieved from receiver.
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
receiver 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.
Dirty Environment Clean Environment
Enclosure Frame or Non-Continuous and Continuous
Type Size
Open OP 404T to 449T
Enclosed-Fe 405T to 449T
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.
Install scavenge tube down into the
tank until the tube just touches the
separator element. Tighten fittings_
Install the regulation lines in their
original position.
Start unit, check for leaks, place in
service.
DRIVE MOTOR LUBRICATION
The induction-type squirrel cage
motor have anti-friction ball or roller
bearings front and rear.
The periods between re-greasings of
the motor bearings can vary, primarily
with the severity of the service
conditions under which the motor
operates. As a general rule the
following would apply:
Frequency of Lubrication
Service Condition
Lubrication
Operation Operation Amount
1 to 3 Months 6 Months 2.5 cu. in.
1 to 3 Months 6 Months 2.5 cu. in.
34

A major cause of bearing failure is
over-greasing.Follow the procedure
below to prevent over-greasing:
• Run the compressor for 1 5 to 30
minutes, then shut the com­
pressor down and open, lock and
tag the main electrical
disconnect.
• Remove the lower grease outlet
plugs.
• Clean the grease fittings.
• With a hand-operated grease gun
add 2.5 cubic inches of grease.
Determine in advance the number
of strokes required to deliver 2.5
cubic inches of grease.If grease
appears at the outlet while you
are adding grease, stop pumping.
• Start the unit and let it run un­
loaded for about 10 minutes.
• Shut the compressor down, open,
lock and tag the main electrical
disconnect.
• Replace the lower grease outlet
plugs.
Recommended Motor Greases
(or equals)
Chevron SRl-2 .......Standard Oil
of California
Premium RB ............. Texaco
Unirex #2 ................. Exxon
Dolium .................... Shell
Polyrex .................. Exxon
WARNING
Grease should only be added
when the motor is stopped and
power disconnected.
DRIVE MOTOR
BEARING
MAINTENANCE­
STORED UNITS
GENERAL
To ensure that complete contact is
maintained between the motor
bearings and the bearing grease on
units to be placed in storage for
extended intervals, the following
motor maintenance procedures
should be adhered to:
404T THROUGH 449T
FRAME DRIVE MOTORS
35
1. Prior to placing a unit in storage,
rotate the drive motor several revo­
lutions by hand in the proper direc­
tion of rotation. This can be accom­
plished by carefully turning the rotor
with the fan blades located at each
end of the rotor.
2. Thereafter, rotate the motor as
described in Step 1 at three month
intervals until such time as the unit
is placed in service.
3. If the storage time should exceed
a total of six (6) months duration, re­
grease the motor using the amount
of type of grease described in the
maintenance section of this manual
covering the specific unit.
After re-greasing, continue to rotate
the motor at three (3) month
intervals as previously described.
MOTOR FRAMES LARGER
THAN 449T
1. Prior to placing a unit in storage,
grease the motor bearings using the
amount and type of grease de­
scribed in the Maintenance Section
of the Operator's Manual.
2. Rotate the motor by hand several
times in the proper direction of
rotation. This can be accomplished
by carefully turning the motor with
the fan blades located at either end
of the rotor.
3. Thereafter, rotate the motor as
described in Step 2 at three (3)
month intervals until such time as
the unit is placed in service.
4. When the unit has been removed
from storage, re-grease the motor at
start-up using the complete proce­
dure as outlined in the Maintenance
section of this manual.
LONG TERM
STORAGE
GENERAL
The factory upon special request
prepares compressor units for long
term storage. In such cases. the
following guidelines and recommen­
dations apply.
CAUTION
VAPOR SPACE INHIBITORS
Before actual start up of the
compressor. the unit must be
drained of lubricant containing
vapor space inhibitors.
•
REFER TO THE OPERATION
SECTION of this Manual for initial
preparation and start up instruc­
tions. However, before putting the
unit into operation, the Vapor
Space Inhibitors must be drained
and replaced with new lubricant as
follows:
Procedure and Comments -
1. There are two points of lubri­
cant drainage on each compressor.
1) A valved drain in the base, 2)
drain cock in the lubricant filter
housing.
Both of these drainage points should
be used to obtain maximum drain­
age of the used lubricant.
WARNING
No drainage points should be
opened until the compressor has
been isolated electricaly and all
air pressure has been relieved
from the system.
2. A hand operated transfer pump.
•
connected to the base drain cou­
pling will be a convenient way to
remove the used lubricant.
3. The lubricant should be drained
soon after the compressor has
been shut down. When the lubri­
cant is hot, the drainage will be
more complete and any particles in
suspension in the lubricant will be
carried out with the lubricant.
WARNING
Extreme care should be excercised
when draining the hot coolant so
that no possibility of injury to per•
sonnet exists.
4. After the unit is drained. close all
drain valves and refill the system
with fresh lubricant. Add two
gallons of lubricant to the com­
pressor through the air inlet piping
while holding the inlet valve open.
Bring the receiver level of lubricant
up to the midpoint of the gauge
glass.
5. Start the compressor and run it
•
for a short while. Shut it down and
check the lubricant level in the
receiver. Add enough lubricant to
bring the level back to the gauge
midpoint.
•
COMPRESSOR
CHANGE/LUBRICANT
PROCEDURE
GENERAL
To drain coolant/lubricant from
compressor as completely as
possible when changing types of
coolant/lubricant to avoid
contamination or dilution of
new fluid.
CAUTION
ULTRA coolant is not compatible
with certain "Compressor Condi­
tioner" fluids often utilized to
remove varnish deposits from
machines running on pertroleum
oil products. Addition of these
products to ULTRA Coolant can
lead to plugged filters and
bearing lines, potentially leading
to severe mechanical problems.
Therefore, do not flush the com­
pressor system with a "Com­
pressor Conditioner" prior to
•
filling with ULTRA Coolant.
NOTE: If changing to food grade
coolant/lubricant SSA H-1 F, the
following procedure is mandatory.
The initial fill of SSA H-1 F should be
run a few hours (2-10 hours) at NO
LOAD and then drained. A fresh
change of SSA H-1 F is then added
and the unit is placed in normal
service.
CAUTION
(SYSTEM CONTAMINATION)
The factory does not recommend
field changes from SSR Coolant
to SSR H-1F based on tests and
experience as of January 1986.
We believe that in a majority of
applications it may be impractical
and undesirable to follow this
course of action.
The residual dye from SSR
Coolant will tint the replacement
coolant after the double flush pro­
cedure has been completed. The
factory recommends that the
•
customer take this fact into con­
sideration before decision is
made to make a chargeout uti­
lizing SSR H-1F Food Grade
coolant.
ITEMS REQUIRED
In addition to the tools normally
found in any reasonably equipped
serviceman's toolbox, the following
items should be available at the
work site:
A suitable drain pan and container
to hold coolant drained from unit.
A quantity of proper coolant
sufficient to refill the compressor.
A minimum of one replacement
coolant filter element.
PROCEDURE
WARNING
No drainage points should be
opened until the compressor has
been isolated electrically and all
air pressure has been removed
from the system.
Operate the unit to bring the
complete system up to operating
temperature. Shut compressor
down.
Initiate remainder of change
procedure while system is still warm.
WARNING
Extreme care should be exercised
when draining the hot lubricant
so that no possibility of injury to
personnel exists.
Drain the module, lubricant cooler.
and any low points in the lubricant
piping system.
Change the coolant filter element.
Refill the unit with proper type
coolant. Exercise care to prevent
entry of any contamination.
Start unit and check coolant level.
With unit running unloaded the
coolant will be visible between the
bottom of the sight glass to midpoint
of the sight glass. DO NOT
OVER Fl LL. Add additional coolant if
required. Check for any leaks.
Thoroughly clean a suitable area of
the module near the coolant fill
connection. Install the correct decal,
as shown below, for the fluid now
installed in compressor.
NOTE: 1. Module area must be dry
and completely free of dirt prior to
applying a decal.
NOTE: 2. Decals in sufficient
quantities must be ordered from
Piscataway Parts Center, contact
your Ingersoll-Rand distributor.
NOTE: 3. Units running on Food
Grade Coolant SSA H-1 F must have
the coolant changed at least every
3000 hours or more frequently under
dirty environmental conditions.
CAUTION
THIS COMPRESSOR UNIT CONTAINS
INGERSOLL-RAND SSR-ULTAA
COOLANT. SSR-UL TRA IS FREE OF
HYDROCARBONS AND IS SUITABLE FOR
USE IN INSTRUMENT AIR SYSTEMS.
AVOID THE USE OF ANY OTHER
FLUID IN THIS UNIT. REFER TO
SPECIAL INSTRUCTION SHEET
APDD HM! FOR DETAILS.
FAILURE TO HEED THIS WARNING
'
MAY RESULT IN SYSTEM CONTAMI-
■ NATION. •1N2c
CAUTION
THIS COMPRESSOR UNIT CONTAINS
INGERSOLL-RAND SSA H·1F FOOD
GRADE COMPRESSOR COOLANT.
INGERSOLL-RANO RECOMMENDS THIS
COOLANT BE CHANGED EVERY J.000
HOURS.
AVOID THE USE OF ANY OTHER
FLUID IN THIS UNIT. REFER TO
SPECIAL INSTRUCTION SHEET
APDO 106 FOR DETAILS.
FAILURE TO HEED THIS WARNING
'
MAY RESULT IN SYSTEM CONTAMI-
■ NATION. ll51U06
36

PRELUBE
PROCEDURE:
304MM AIREND
{ONLY)
REQUIRED BEFORE STARTING:
Under the following circumstances:
1. It is preferred that this start-up
prelube procedure be done on all
new units being started even if
they are within 6 months from the
date of shipment from our
factory.
2. It is absolutely required when unit
has been in long term storage. (6
months or more)
3. Unit is to be re-started after any
major component of the coolant
system has been changed or
drained for any reason.
4. When changing the coolant filter
element, install replacement
element in housing and slowly
pour coolant into housing to fill.
Install, cover, and tighten.
CAUTION
This procedure should only be
carried out by a qualified
Ingersoll-Rand Service
Representative. Contact your
nearest Ingersoll-Rand
Distributor or Air Center.
FAILURE TO FOLLOW THIS
PROCEDURE MAY RESULT IN
EQUIPMENT DAMAGE.
Objectives of the prelube procedure:
Utilizing an auxiliary source of clean
pressurized air and a small pump,
fresh coolant-lubricant under
pressure will be injected into the oil
piping, coolers and airend. The
resulting air pressure will push the
coolant-lubricant through the piping
and coolers to purge the system of
air pockets.
In addition, the small pump will be
used to inject 1/2 gallon (2 liters) of
fresh coolant directly into each of
the two thrust bearing assemblies.
37
CAUTION
The coolant-lubricant used
during the Prelube procedure,
must be the same type that is
contained in the unit. (i.e. SSR
ULTRA Coolant, SSR Blue, SSR
Food Grade).
Items required, in addition to tools,
normally found in any reasonably
equipped serviceman's toolbox are
as follows:
A. Small pump of type found at most
local hardware or tool supply
stores capable of being driven by
a drill motor.
B. 1/4" or 3/8" drill motor and
extension cord.
C. Clean container to hold the
coolant which will be pumped
into the thrust bearings.
D. Various hoses or tubing to
connect pump suction to the
clean coolant container and to
also connect pump discharge to
the 3/8" NPT female connections
at airend thrust bearing housing.
E. A source of 110 AC volts to
energize coolant stop solenoid
valve (5SV), and to operate your
drill motor. Extension cord of
suitable lengths.
F. A source of clean and dry
auxiliary air capable of 15-25 psig
to pressurize the receiver­
separator tank and a hose with
fittings to connect with 1/4" NPT
female port on side of receiver­
separator tank.
G. One each 1" NPT pipe plug, one
each 1/4" NPT pipe plug, one
each 1/4" NPT pipe tee and a
short 1/4" NPT nipple.
PROCEDURE
1. If the airend is a replacement,
connect all components and
piping on installed replacement
airend. Refill receiver-separator
sump with clean IA lubricant of
proper type (SSA ULTRA, Blue or
Food Grade).
•
2. Install new oil filter element and
slowly fill canister with clean
lubricant. Pour oil slowly to allow
any air to rise to top of canister as
lubricant is poured over the
element. Replace filter cover
using new "O" ring provided with
element. Tighten cover.
Steps One and Two do not apply to
new long term storage units. 1 & 2
do apply to airend replacements,
etc.
3. Locate blowdown valves 3SV and
8SV and remove from tank cover
by loosening the tubing manifold
at end connected to 1" tube x 1"
NPT 90 elbow screwed into
separator-tank cover. Remove 90
elbow from the cover and plug
hole by installing 1" NPT plug
described in the "items required"
list.
4. Loosen and remove 1/4" O.D.
tube from separator scavenge
orifice-screen. Remove orifice­
screen and adapter-tube
assemblies from separator
cover.
•
Install 1/4" NPT plug described
in "items required" list into tank
cover.
Do not damage any
components as they are to be
reinstalled after completing
prelube.
5. Locate 1/4" NPT x 1/4" O.D.
tube 90 fitting on side of the
receiver-separator tank that
provides a signal for "SUMP"
gauge. (See Figure C).
ORIGINAL ¼P x '/,T
TANK 90 ° FITTING
1) REMOVE TUBE FROM FITTING
2) REMOVE FITTING FROM TANK
•
Figure C.
•
Remove tubing and fitting from
tank and install short 1/4" NPT
nipple and tee as shown in
sketch "D". Install previously
removed 90 fitting into the tee
and connect "SUMP" signal
line. (See Figure D).
TUBE TO PANEL
GAUGE "SUMP'
TANK
CLEAN.DRY
AUXILIARY AIR
AT 15-25 PSIG
Figure D.
Connect auxiliary air pressure
source in remaining hole (1/4"
•
NPT tee). Do not apply air
pressure.
6. Locate coolant stop solenoid
valve 5SV near oil filter. Remove
cover from coil and disconnect
the two red wires attached to
coil terminals.
Connect extension cord to coil
terminals on 5SV and place coil
back in proper position on
coolant stop valve assembly.
Install cover and tighten nut.
7. After 5SV coil is back in its
correct location with cover in
place, connect extension cord
to 11 O VAC power source to
energize coil. This in turn.
opens the valve and will allow
coolant to flow through when
air pressure is applied to sump.
CAUTION
Do not apply power to coil unless
coil is on valve or damage to coil
will result!
•
CAUTION
Use care to prevent any electrical
shock hazard .
8. Loosen vent valve on coolant
filter cover and disconnect oil
hose that feeds oil to female
side of the rear bearing housing.
(See Figure "A" or "8'').
THRUST BEARING
FEED LINE
FROM OIL
FILTER
Figure A. NEW PIPING
THRUST BEARING
FEED LINE FROM
OIL FILTER "NPT PLUGS
12 PLACES1
Figure B. OLD PIPING
9. Slowly apply 15-25 psig of air
pressure to the sump and
monitor pressure on "SUMP"
indicator of panel mounted
pressure gauge.
10. Observe the loosened vent valve
on coolant filter cover until
coolant begins to flow from
vent. Close valve when coolant
appears.
11. Maintain 15-25 psig of pressure
in the tank until coolant-lubri­
cant flows from oil feedhose
previously disconnected from
rear bearing housing.
NOTE: This may take a few
moments as the volume of air in
the coolant cooler and its
associated piping must be
purged.
When coolant flows from hose,
immediately reconnect hose to
its proper fitting.
Allow the receiver-separator to
remain pressurized at 15-20 psig
for approximately two additional
minutes to allow coolant to
enter airend feed lines.
After two minutes, vent all air
pressure from receiver­
separator tank and remove
auxiliary air line, pipe tee and
nipple. Re-install original 90
fitting and "SUMP" signal line in
side of tank. (See Figure C).
12. Remove 1" plug and 1/4" plug
in tank cover and re-install
scavenge lines and blowdown
valves as originally found.
Remove extension cord from
5SV and reconnect the red wires
as originally found. Replace
cover, and tighten.
Locate and remove the two 3/8"
NPT plugs in top of rear bearing
housing. (See Figure A).
Connect auxiliary pump suction
to clean container of coolant
and place pump discharge line
in waste container. Pump ap­
proximately 1/2 liter (1 quart) of
oil into waste container to flush
any dirt from pump or the
connecting lines.
Connect pump discharge line to
either of the two 3/8" NPT
fittings at top of rear bearing
housing and pump approxi­
mately 2 liters (1/2 gallon) of
new clean coolant-lubricant into
housing. Install the other of the
two 3/8" plugs to prevent
spillage during pumping
process.
38
14. After pumping coolant into the
first side, change fittings and
repeat pumping with 2 liters (1/2
gallon) into other side.
Remove pumping connections
and install 3/8" NPT plugs back
•
in rear bearing housing and
tighten.
15. Observe drive motor coolant
fans and slowly rotate drive
motor BY HAND in direction of
proper rotation to remove any
excess coolant accumulated in
the rotor housing during
prelube procedure.
NOTE: If airend has excessive
oil in the rotor housing, it will
seem to "lock-up". However,
this is due to coolant trapped
between the rotors and is easily
removed from the airend by
maintaining a gentle but firm
pull on the motor. Turn motor
slowly in the normal direction of
rotation. When excess coolant
has been cleared, the rotors will

•
turn smooth and free.
16. Refill receiver-separator sump
to correct level and check all
piping and electrical connec-
tions for proper location and
tightness.
17. Follow normal start up proce-
dure. Shut unit down after two
minutes: Check for system
leaks.

•
39
•

•
•

•
•

•
•