UP6-5-15c O & M Manual

SSR UP5–4, UP5–5.5, UP5–7.
5, UP5–11c
50Hz
SSR UP6–5, UP6–7.5, UP6–10, UP6–15c
60Hz
OPERATION AND MAINTENANCE MANUAL
This manual contains

important safety information
and must be made available
to personnel who operate and
maintain this machine.
C.C.N. : 22451884
REV. : B
DATE : JUNE 2005
AIR COMPRESSOR GROUP
BONDED WARRANTY & REGISTERED START UP
Warranty
The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in
material and workmanship for a period of twelve months from the date of placing the Equipment in operation or eighteen
months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be obligated to
promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the
Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement
part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment
in accordance with good industry practices and has complied with specific recommendations of the Company.
Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the
manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall
not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the
Purchaser or others without Company‘s prior written approval.
The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are
limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance
warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period
of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.
Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on
contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company
in writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.
Note that this is Ingersoll–Rand standard warranty. Any warranty in force at the time of purchase of the compressor
or negotiated as part of the purchase order may take precedence over this warranty.
Register on–line at air.irco.com
Ingersoll–Rand
Industrial Air Solutions
Swan Lane
Hindley Green
Wigan WN2 4EZ
Ingersoll Rand Asia Pacific

C/O Ingersoll–Rand South East Asia (Pte) Ltd.
42 Benoi Road
Singapore 629903
Ingersoll–Rand
Industrial Air Solutions
P.O. Box 1840
800–D Beaty Street
Davidson, NC 28036
CONTENTS & ABBREVIATIONS 1
CONTENTS ABBREVIATIONS & SYMBOLS
1 CONTENTS #### Contact Ingersoll–Rand for serial number
–>#### Up to Serial No.
2 FOREWORD ####–> From Serial No.
* Not illustrated
3 DECALS { Option
NR Not required
AR As required
8 SAFETY SM Sitemaster/Sitepack
HA High ambient machine
10 GENERAL INFORMATION WC Watercooled machine
AC Aircooled machine
ERS Energy recovery system
16 INSTALLATION / HANDLING T.E.F.C. Totally enclosed fan cooled motor (IP54)
O.D.P. Open drip proof (motor)
32 OPERATING INSTRUCTIONS ppm parts per million
cs Czech
35 MAINTENANCE da Danish
de German
el Greek
41 TROUBLE SHOOTING
en English
es Spanish
et Estonian
fi Finnish
fr French
hu Hungarian
it Italian
lt Lithuanian
lv Latvian, Lettish
mt Maltese
nl Dutch
no Norwegian
pl Polish
pt Portuguese
ru Russian
sk Slovak
sl Slovenian
sv Swedish
zh Chinese
http://air.irco.com en
2 FOREWORD
The contents of this manual are considered to be proprietary and The intended uses of this machine are outlined below and examples
confidential to Ingersoll–Rand and should not be reproduced without of unapproved usage are also given, however Ingersoll–Rand cannot
the prior written permission of Ingersoll–Rand. anticipate every application or work situation that may arise.
Nothing contained in this document is intended to extend any IF IN DOUBT CONSULT SUPERVISION.
promise, warranty or representation, expressed or implied, regarding
the Ingersoll–Rand products described herein. Any such warranties or
other terms and conditions of sale of products shall be in accordance This machine has been designed and supplied for use only in the
with the standard terms and conditions of sale for such products, which following specified conditions and applications:
are available upon request. . Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
This manual contains instructions and technical data to cover GENERAL INFORMATION section of this manual.
routine operation and scheduled maintenance tasks by operation and
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised Ingersoll–Rand service The use of the machine in any of the situation types listed in
department. table 1:–
a) Is not approved by Ingersoll–Rand,
b) May impair the safety of users and other persons, and
The design specification of this machine has been certified as c) May prejudice any claims made against Ingersoll–Rand.
complying with E.C. directives. Any modification to any part is
absolutely prohibited and would result in the CE certification and
marking being rendered invalid. TABLE 1
Use of the machine to produce compressed air for:
All components, accessories, pipes and connectors added to the a) direct human consumption
compressed air system should be: b) indirect human consumption, without suitable filtration and purity
. of good quality, procured from a reputable manufacturer and, checks.
wherever possible, be of a type approved by Ingersoll–Rand.
. clearly rated for a pressure at least equal to the machine maximum Use of the machine outside the ambient temperature range
allowable working pressure. specified in the GENERAL INFORMATION SECTION of this manual.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation, operation and Use of the machine where there is any actual or foreseeable risk of
maintenance. hazardous levels of flammable gases or vapours.
THIS MACHINE IS NOT INTENDED AND MUST NOT BE
Details of approved equipment are available from Ingersoll–Rand USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
Service departments. INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR
VAPOURS MAY BE PRESENT.
The use of non–genuine spare repair parts other than those Use of the machine fitted with non Ingersoll–Rand approved
included within the Ingersoll–Rand approved parts list may create components.
hazardous conditions over which Ingersoll–Rand has no control.
Therefore Ingersoll–Rand does not accept any liability for losses Use of the machine with safety or control components missing or
caused by equipment in which non–approved repair parts are installed. disabled.
Standard warranty conditions may be affected.
The company accepts no responsibility for errors in translation of

Ingersoll–Rand reserves the right to make changes and this manual from the original English version.
improvements to products without notice and without incurring any
obligation to make such changes or add such improvements to
products sold previously. © COPYRIGHT 2005
INGERSOLL–RAND COMPANY
en http://air.irco.com
DECALS 3
ISO SYMBOLS
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory Information / Instructions Warning
WARNING: Electrical shock risk. WARNING – Pressurised vessel. WARNING – Hot surface.
WARNING – Pressurised component or WARNING – Air/gas flow or Air discharge. Do not breathe the compressed air from this
system. machine.
Use fork lift truck from this side only. RESET Do not use fork lift truck from this side.
Emergency stop. On (power). Off (power).
Read the Operation and Maintenance manual Do not operate the machine without the guard Lifting point.
before operation or maintenance of this being fitted.
machine is undertaken.
ROTATION AIR DISCHARGE COOLANT FILTER
4 DECALS
AUTOMATIC RESTART MAINTENANCE MAINTENANCE PROHIBITED
COOLANT DRAIN CONDENSATE DRAIN FILTER
FRAGILE KEEP DRY THIS WAY UP
USE NO HOOKS NO SIDE CLAMPS HOURS
Use ULTRA–Plus Coolant only

POWER INSPECT
Failure to use the specified coolant may
result in damage to the machine
Every X months, if sooner than required by CHANGE / REPLACE CLEAN

operating hours
POWER INLET (AC) Pinch point hazard.

Keep hands clear.
DECALS 5
ANSI SYMBOLS
GRAPHIC FORM AND MEANING OF ANSI SYMBOLS
DANGER
INTAKE AIR. Can contain carbon monoxide or other contaminants. Will cause serious injury or death. Ingersoll–Rand
air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for
breathing air applications unless treated in accordance with all applicable codes and regulations.
WARNING
HAZARDOUS VOLTAGE. Can cause serious injury or death. Disconnect power and bleed pressure from tank before
servicing. Lockout/Tagout machine. Compressor must be connected to properly grounded circuit. See Grounding
Instructions in manual. Do not operate compressor in wet conditions. Store indoors.
RISK OF FIRE OR EXPLOSION. Electrical arcing from compressor components can ignite flammable liquids and
vapors which can result in serious injury. Never operate the compressor near flammable liquids or vapors. If used to
spray flammable materials, keep compressor at least 20ft away from the spray area.
HIGH PRESSURE AIR. Rusted tanks can cause explosion and severe injury or death. Receiver under pressure.
Operator should relieve tank pressure before performing maintenance. In addition to automatic drain, operate manual
drain valve weekly. Manual drain valve located at bottom of the tank.
MOVING PARTS. Can cause serious injury. Do not operate with guards removed. Machine may start automatically.
Disconnect power before servicing. Lockout/Tagout machine.
HOT SURFACES. Can cause serious injury. Do not touch. Allow to cool before servicing. Do not touch hot
compressor or tubing.
EXPOSED MOVING BELTS AND SHEAVES.

Can cause severe injury or death.
Do not operate without guard in place. Disconnect power before servicing.
Lockout/Tagout machine.
Air flow exhaust may contain flying debris.

Safety protection should be worn at all times.
Pinch point hazard.

Keep hands clear.
6 DECALS
Item ccn Qty. Description Item ccn Qty. Description
1 93166502 1 Decal, replacement element 12 92867498 1 Decal, notice air discharge

Base mount only
2 92867530 1 Decal, warning hot surface
13 22547145 1 Decal, total air system
3 3 Decal, voltage Dryer packages only
4 93166460 1 Decal, coolant drain
14 22459200 1 Tag, rotation
5 92960593 2 Decal, warning hazardous voltage
15 SPEC 1 Specifications, compressor package
6 93166478 1 Decal, condensate drain
16 93166486 1 Decal, power inlet
7 22530331 1 Decal, dryer bypass instruction
17 22141311 1 Decal, place to cover hole
8 22417125 1 Decal, maintenance parts
18 22604276 1 Decal, multiple wiring circuit
9 92930585 1 Decal, pressurized vessel Dryer packages only
10 93165983 1 Decal, rotation direction 19 93493641 1 Decal, start up warning

11 92867407 2 Decal, do not inhale
DECALS 7
Item ccn Qty. Description Item ccn Qty. Description
20 93165959 1 Decal, use guards when running 25 22417109 1 Decal, facia

Rectangular hourmeter
21 1 Decal, wiring schematic diagram
22529291 1 Decal, facia
22 93171262 1 Decal, lift here both sides Round hourmeter
Base mount only
26 22050611 1 Decal, I–R logo
23 22425557 1 Decal, I–R logo
Base mount only 27 22454060 1 Decal, belt
22435713 1 Decal, I–R logo 28 Tank mount option
Receiver mount only
24 92930668 1 Decal, no maintenance before referring
to manual
8 SAFETY
DANGER! If more than one compressor is connected to one common

Hazard that WILL cause DEATH, SEVERE INJURY or substantial downstream plant, effective isolation valves must be fitted and
property damage if ignored. Instructions must be followed precisely to controlled by work procedures, so that one machine cannot
avoid injury or death. accidentally be pressurised / over pressurised by another.
WARNING! Compressed air must not be used for a direct feed to any form of
Hazard that CAN cause DEATH, SEVERE INJURY or substantial breathing apparatus or mask.
property damage if ignored. Instructions which must be followed
The discharged air contains a very small percentage of compressor
precisely to avoid injury or death. lubricant and care should be taken to ensure that downstream
CAUTIONS! equipment is compatible.
Cautions call attention to instructions which must be followed If the discharged air is to be ultimately released into a confined
precisely to avoid damaging the product, process or its surroundings. space, adequate ventilation must be provided.
NOTES When using compressed air always use appropriate personal
Notes are used for supplementary information. protective equipment.
BREATHING AIR PRECAUTION All pressure containing parts, especially flexible hoses and their
Ingersoll–Rand air compressors are not designed, intended or couplings, must be regularly inspected, be free from defects and be
approved for breathing air. Compressed air should not be used for replaced according to the Manual instructions.
breathing air applications unless treated in accordance with all
Compressed air can be dangerous if incorrectly handled. Before
applicable codes and regulations.
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
Avoid bodily contact with compressed air.
General Information
All safety valves located in the separator tank must be checked
Ensure that the operator reads and understands the decals and periodically for correct operation.
consults the manuals before maintenance or operation.
Do not over–pressurize the receiver tank or similar vessels beyond
Ensure that the Operation and Maintenance manual is not removed
design limits.
permanently from the machine.
Do not use a receiver tank or similar vessels that fail to meet the
Ensure that maintenance personnel are adequately trained,
design requirements of the compressor. Contact your distributor for
competent and have read the Maintenance Manuals.
assistance.
Do not point air nozzles or sprayers toward anyone.
Do not drill into, weld or otherwise alter the receiver tank or similar
Compressed air and electricity can be dangerous. Before vessels.
undertaking any work on the compressor, ensure that the electrical
supply has been isolated and the compressor has been relieved of all Before servicing the unit, vent pressure before removing the power
pressure. to ensure that the gauge reads zero pressure.
Wear eye protection when operating or servicing compressor.

Materials
All persons positioned near to operating machinery should be
equipped with hearing protection and given instructions on its use in The following substances are used in the manufacture of this
accordance with workplace safety legislation. machine and may be hazardous to health if used incorrectly:
. preservative grease
Make sure that all protective covers are in place and that the . rust preventative
canopy/doors are closed during operation. . compressor coolant
The specification of this machine is such that the machine is not AVOID INGESTION, SKIN CONTACT AND INHALATION OF
suitable for use in flammable gas risk areas. FUMES
Installation of this compressor must be in accordance with
recognised electrical codes and any local Health and Safety Codes.
Transport
The use of plastic bowls on line filters can be hazardous. Their When loading or transporting machines ensure that the specified
safety can be affected by either synthetic lubricants, or the additives lifting and tie down points are used.
used in mineral oils. Ingersoll –Rand recommends that only filters with
metal bowls should be used on a pressurised system. Lifting equipment must be properly rated for the weight of the
compressor.
Do not work on or walk under the compressor while it is suspended.

Compressed air
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the Electrical
Keep all parts of the body and any hand–held tools or other
conductive objects, away from exposed live parts of the compressor
electrical system. Maintain dry footing, stand on insulating surfaces
WARNING and do not contact any other portion of the compressor when making
Imposing a normal or emergency stop on the compressor will adjustments or repairs to exposed live parts of the compressor
only relieve pressure upstream of the minimum pressure valve on electrical system.
top of the separator tank.
If maintenance work is required downstream of this valve, ensure
that all pressure is relieved at the process vent point external to WARNING
the compressor Any electrical connections or adjustments should only be
made by a suitably qualified electrician
Ensure that the machine is operating at the rated pressure and that Close and lock all access doors when the compressor is left
the rated pressure is known to all relevant personnel. unattended.
All air pressure equipment installed in or connected to the machine Do not use extinguishers intended for Class A or Class B fires on
must have safe working pressure ratings of at least the machine rated electrical fires. Use only extinguishers suitable for class BC or class
pressure. ABC fires.
SAFETY 9
Attempt repairs only in clean, dry, well lighted and ventilated areas.
Connect the compressor only to electrical systems that are
compatible with its electrical characteristics and that are within it’s rated
capacity.
Condensate disposal
As waste water regulations vary by country and region it is the
responsibility of the user to establish the limitations and regulations in
their particular area. Ingersoll–Rand and its associated distributors are
happy to advise and assist in these matters.
For further information, consult Material Data Sheets CPN
88303979 for ULTRA–Plus Coolant.
The above information contains data supplied in support of United
Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.)
regulations.
10 GENERAL INFORMATION
PIPING AND INSTRUMENTATION
KEY
AR Air receiver (option) 22. Receiver air
ID Integral dryer (option) 23. Filter, general purpose air
SD Bara för S/D 24. Filter, high efficiency air
1. Filter, air 25. Valve, check

2. Valve, inlet 26. Recuperator
3. Airend assembly 27. Valve, isolation (option)
4. Motor
28. Moisture separator
5. Relay, overload Motor
29. Valve, check
6. Tank, separator – coarse
30. Evaporator
7. Tank, separator – fine
8. Valve, minimum pressure 31. Indicator, dew point
9. Aftercooler 32. Valve, condensate

10. Valve, blowdown 33. Tube, capillary
11. Switch, discharge pressure 34. Filter dryer, refrigerant
12. Switch, temperature
35. Condenser
13. Filter, coolant
36. Valve, hot gas bypass
14. Thermostat
37. Compressor, refrigerant
15. Cooler, oil
16. Reglerventil 38. Valve, auto drain
17. Valve, safety A. Air/Coolant
18. Valve, drain B. Air
19. Screen, scavenge C. Coolant

D. Condensate
20. Valve, solenoid
E. Refrigerant
21. Gauge, pressure
F. Component boundary
GENERAL INFORMATION 11
SCHEMATIC, ELECTRICAL UP6 5–15HP FV 3PH 60Hz DOL – U.S.A.
KEY
1FU, Fuse control circuit HATS Switch, high air temperature

2FU, 3FU
M Coil motor starter
4FU, 5FU Fuse
MIO Indicator, maintenance option
1Ma Contact, auxiliary starter
(instead of standard Hourmeter)
1Mb Contact, auxiliary starter
MOT Motor
CPT Transformer, control
OL Overload, motor starter
120/1/50–60
PS Switch, pressure
See transformer nameplate for wiring connection
requirements ST Push button start
CR Relay, control
TP Terminal points
CRa Contact, control relay
TS To supply
CS Customer supplied 115V / 1 / 60Hz
W Standby light
DO Dryer option
DM Motor, dryer
NOTES
EDV Valve, electric drain 120/1/50–60
1. (*) Furnished, mounted and wired outside of control panel, if
E–STOP Button, emergency stop required by order.
G Power on light 2. Circuit shown in normal position de–energized.
HM Hourmeter 3. All wiring to be marked in accordance with this schematic.
HM1 Indicator, maintenance 4. All wiring to be in accordance with NEC.
DECAL, SCHEMATIC 60Hz SD ELECTRO–MECHANICAL
KEY
1FU, 2FU Fuse, primary HATS Switch, high air temperature

3FU Fuse, secondary HM Hourmeter
4FU, 5FU Fuse, dryer
HM1 Indicator, maintenance
1LT Light, power on indicator (Green)
2LT Light, auto restart indicator (White) (instead of standard Hourmeter)
1M Contactor, main MTR Motor, compressor
1Ma, b, c Contact, auxiliary. main contactor OL Overload, main motor
2M Contactor, delta OLa Contact, main motor overload
2Ma, b Contacts, auxiliary. Delta contactor
PS Switch, pressure
1S Contactor, star
ST Push button, start
1Sa, b Contacts, auxiliary. Star contactor
TD Relay, delta starting (10sec.)
1SV Valve, solenoid (NC)
TDc Relay, delay off, contact
CR Relay, control
CRa Contact, control relay
NOTES
DM Motor, dryer required by order.
DO Dryer option 2. Circuit shown in normal position de–energized.
EDV Valve, electric drain (optional) 3. All wiring to be marked in accordance with this schematic.
E–STOP Switch, emergency stop 4. All wiring to be in accordance with NEC.
SCHEMATIC, ELECTRICAL UP6 5–15HP FV 1PH 60Hz – U.S.A.
KEY
1FU, Fuse control circuit M Coil motor starter

2FU, 3FU
4FU, 5FU Fuse, dryer (instead of standard Hourmeter)
1Ma Contact, auxiliary starter MTR Motor, compressor
1Mb Contact, auxiliary starter
OL Overload, motor starter
PS Switch, pressure
120/1/50–60
See transformer nameplate for wiring connection
requirements TP Terminal points
CR Relay, control TS To supply
CRa Contact, control relay W Standby light
DM Motor, dryer
DO Dryer option
NOTES
EDV Valve, electric drain
E–STOP Switch, emergency stop required by order.
G Power on light 2. Circuit shown in normal position de–energized.
HM Hourmeter 3. All wiring to be marked in accordance with this schematic.
HM1 Indicator, maintenance 4. All wiring to be in accordance with NEC.
SCHEMATIC, ELECTRICAL UP6 5–15HP FV 3PH 50Hz DOL
KEY
1FU Fuse, secondary MIO Indicator, maintenance option

2FU, 3FU Fuse, primary (instead of standard Hourmeter)
4FU, 5FU Fuse, dryer MM Motor, compressor
CR Relay, control MOL Overload, main motor
CS Customer supplied 230V / 1 / 50Hz MOL–1 Contact, main motor overload
DM Motor, dryer PS Switch, pressure

DO Dryer option ST Push button, start
EDV Valve, electric drain T1 Transformer, control
ES Switch, emergency stop TP Terminal points
HATS Switch, high air temperature TS To supply
HM Hourmeter
NOTES
HM1 Indicator, maintenance 1. (*) Furnished, mounted and wired outside of control panel, if
KM Contactor, main required by order.
KM–1,2 Contact, auxiliary. main contactor 2. Circuit shown in normal position de–energized.
LT1 Light, power on indicator (Green) 3. All wiring to be marked in accordance with this schematic.
LT2 Light, auto restart indicator (White) 4. All wiring to be in accordance with NEC.
DECAL, SCHEMATIC 50Hz SD ELECTRO–MECHANICAL
KEY
1SV Valve, solenoid (NC) KM2–1,2 Contacts, auxiliary. Delta contactor

CR Relay, control KM3 Contactor, star
CR–1 Contact, control relay KM3–1,2 Contacts, auxiliary. Star contactor
CS Customer supplied 230V / 1 / 50Hz LT1 Light, power on indicator (Green)
DM Motor, dryer LT2 Light, auto restart indicator (White)
DO Dryer option MIO Indicator, maintenance option
EDV Valve, electric drain (instead of standard Hourmeter)
HATS Switch, high air temperature MOL Overload, main motor

MOL–1 Contact, main motor overload
HM Hourmeter
HM1 Indicator, maintenance
T1 Transformer, control
MM Motor, compressor
TM1 Relay, delta starting (10sec.)
P Switch, pressure
TM1–1 Relay, delay off, contact
ES Switch, emergency stop
FU1, FU2 Fuse, primary NOTES
FU3 Fuse, secondary 1. (*) Furnished, mounted and wired outside of control panel, if
FU4, FU5 Fuse, dryer required by order.
KM1 Contactor, main 2. Circuit shown in normal position de–energized.

KM–1,2,3 Contact, auxiliary. main contactor 3. All wiring to be marked in accordance with this schematic.
KM2 Contactor, delta 4. All wiring to be in accordance with NEC.
16 INSTALLATION / HANDLING
VIEW TOP
ROTATION
VIEW FRONT VIEW RIGHT
VIEW LEFT
INSTALLATION / HANDLING 17
KEY
A Package pre–filter M Motor
B Hole, incoming power supply conduit N Integrated dryer (Optional)
C Gauge, pressure O Compressor and cooling air intake
D Yellow stand–by light P Filter, coolant
E Green power–on light Q Cartridge, coolant separator
F Green start push button R Valve, airend relief
G Emergency stop button S Plug, coolant filler
H Hourmeter T Sight–glass
I Starter box U Plug, coolant drain
J Lifting points V Valve, pilot

W Switch, pressure
K Mounting holes (4 x 14.0mm [0.550”] diameter)
X Cooling air exhaust
L Filter, air inlet
NOTES
1. Foundation or floor must be level and support all mounting bolt NOTE
locations equally. If necessary, shim or grout the fourth bolt location. All dimensions are in millimetres (inches) unless otherwise stated.
2. Foundation bolts should protect thru nuts a minimum of 13mm

(0.50”) to allow for levelling.
Ensure that the correct fork lift truck slots or marked lifting points are
3. Allow a minimum clearance of 1100mm (42”) on the front and used whenever the machine is lifted or transported.
920mm (36”) on the top, left right and rear of the package for proper air
circulation and serviceability.
4. Approximate package weight: 298kg (655lbs). UNPACKING
5. External piping shall not exert any unresolved moments or forces The compressor will normally be delivered with a polythene cover.
If a knife has to be used to remove this cover ensure that the exterior
on the unit. Use pipe size as large or larger at discharge connection. paintwork of the compressor is not damaged.
6. There should be no plastic or pvc piping attached to this unit or used
for any lines downstream. Ensure that all transport and packing materials are discarded in a
manner prescribed by local codes.
7. Do not pipe into a common header with a reciprocating compressor,
unless the reciprocating compressor utilizes a discharge pulsation
damper.
8. Sizing of electrical components not supplied by Ingersoll Rand is the
responsibility of the customer and should be done in accordance with
the information on the compressor data plate and national and local
electrical codes.
VIEW TOP
ROTATION
VIEW LEFT
KEY
A Package pre–filter P Filter, coolant
B Hole, incoming power supply conduit Q Cartridge, coolant separator
C Gauge, pressure R Valve, airend relief
D Yellow stand–by light S Plug, coolant filler
E Green power–on light T Sight–glass
F Green start push button U Plug, coolant drain
G Emergency stop button V Valve, pilot
H Hourmeter W Switch, pressure
I Starter box X Cooling air exhaust

1A Valve, ball
J Lifting points
0.75” N.P.T.
K Mounting holes
1B Air receiver
(4 x 17.5mm [0.68”) x 44.5mm [1.75”] slots)
( 620.0mm x 1168.4mm LG) ( 24.40” x 46.00” LG)
L Filter, air inlet
1C Location for manual receiver drain
M Motor
1D Valve, receiver relief
N Integrated dryer (Optional)
1E 0.25” discharge port for optional electric drain valve
O Compressor and cooling air intake
NOTES

damper.
electrical codes.
VIEW TOP
ROTATION
VIEW LEFT
KEY

1A Valve, ball
J Lifting points
0.75” N.P.T.
K Mounting holes
1B Air receiver
(4 x 17.5mm [0.68”) x 44.5mm [1.75”] slots)
( 618.0mm x 1701.0mm LG) ( 24.33” x 67.00” LG)
L Filter, air inlet
M Motor
NOTES

damper.
electrical codes.
VIEW TOP
ROTATION
VIEW LEFT
KEY

1A Valve, ball
J Lifting points
0.75” N.P.T.
K Mounting holes
1B Air receiver
(4 x 17.5mm [0.68”) x 44.5mm [1.75”] slots)
( 600.0mm x 1111.0mm LG) ( 23.62” x 43.74” LG)
L Filter, air inlet
M Motor
NOTES

damper.
electrical codes.
VIEW TOP
ROTATION
VIEW LEFT VIEW FRONT VIEW RIGHT
KEY

1A Valve, ball
J Lifting points
0.75” N.P.T.
K Mounting holes
1B Air receiver
(4 x 17.5mm [0.68”) x 44.5mm [1.75”] slots)
( 610.0mm x 1866.0mm LG) ( 24.02” x 73.46” LG)
L Filter, air inlet
M Motor
NOTES

damper.
electrical codes.
KEY CAUTION
The use of plastic bowls on line filters and other plastic air line
1. Compressor components can be hazardous. Their safety can be affected by
2. Air Dryer either synthetic coolants or the additives used in mineral oils.
Ingersoll –Rand recommends that only filters with metal bowls
3. Air Receiver should be used on any pressurised system.
4. Compressed air filters
5. System demand points
CAUTION
The standard compressor unit is not suitable for operation in
NOTE temperatures liable to cause freezing as Condensate water is
Items [2] to [5] are optional or may be existing items of plant. Refer liable to be produced in the after cooler and receiver where fitted.
to your Ingersoll–Rand distributor / representative for specific
recommendations. Refer to your Ingersoll–Rand distributor for further information.
LOCATION IN THE PLANT DISCHARGE PIPING

Discharge piping should be at least as large as the discharge
The compressor can be installed on any level floor capable of connection of the compressor. All piping and fittings should be suitably
supporting it. A dry, well ventilated area where the atmosphere is clean rated for the discharge pressure.
is recommended. A minimum of 150mm (6 inches) should be left at the
rear and 1m (3ft) at the sides of the machine for adequate service
access and ventilation. It is essential when installing a new compressor [1], to review the
total air system. This is to ensure a safe and effective total system. One
item which should be considered is liquid carryover. Installation of air
Adequate clearance needs to be allowed around and above the dryers [3] is always good practice since properly selected and installed
machine to permit safe access for specified maintenance tasks. they can reduce any liquid carryover to zero.
Ensure that the machine is positioned securely and on a stable It is good practice to locate an isolation valve close to the
foundation. Any risk of movement should be removed by suitable compressor and to install line filters [4].
means, especially to avoid strain on any rigid discharge piping.
It is a requirement for air dryers covered under AirCare that correctly

CAUTION sized Ingersoll–Rand pre and afterfilters are installed.
Screw type compressors [1] should not be installed in air
systems with reciprocating compressors without means of
isolation such as a common receiver tank. It is recommended that
both types of compressor be piped to a common receiver using
individual air lines.
60Hz UP6 5 UP6 7 UP6 10 UP6 15c
COMPRESSOR 125 150 210 125 150 210 125 150 210 125 150 210
Operating pressure 125 150 – 125 150 210 125 150 210 125 150 210
PSIG (bar) (8.6) (10.3) (8.6) (10.3) (14.5) (8.6) (10.3) (14.5) (8.6) (10.3) (14.5)
Factory set reload pressure 110 130 – 110 130 180 110 130 180 110 130 180
PSIG (bar) (7.58) (8.96) (7.58) (8.96) (12.41) (7.58) (8.96) (12.41) (7.58) (8.96) (12.41)
Flow rate 18.5 16.0 – 28.0 25.0 17.5 38.0 34.0 24.0 55.0 50.0 38.0
CFM (m3/MIN) (0.52) (0.45) (0.79) (0.71) (0.50) (1.08) (0.96) (0.68) (1.55) (1.42) (1.08)
Airend discharge temperature 228_F (109_C)

trip point
Ambient temperature 36_F(+2_C ) → 105_F(+40_C)
min. → max.
MOTOR
Motor enclosure ODP TEFC ODP TEFC ODP TEFC ODP TEFC
Nominal power 5HP 7.5HP 10HP 15HP
Speed 3500 RPM
Insulation class F
GENERAL DATA
Residual coolant content 3ppm (3 mg/m3)
Separator vessel capacity 0.8 gallons (3 Litres)
Coolant capacity 1.2 gallons (4.5 Litres )
Sound pressure level to 65 dB(A) 65 dB(A) 68 dB(A) 69 dB(A)
CAGI–PNEUROP
Weight – base mount unit 295kg (650lb)
Weight – 80 gallon Receiver 420kg (925lb)
mounted
Weight – 120 gallon Receiver 436kg (960lb)
mounted
CAUTION
230/460 Dual voltage machines are fitted with a decal to advise the correct voltage as connected from the factory.
There is a decal fitted to the starter door describing the procedure to change the connections for the alternative voltage
Rewiring should only be effected by a competent Electrician.
50Hz UP5 4 UP5 5 UP5 7 UP5 11c
COMPRESSOR 8 10 14.5 8 10 14.5 8 10 14.5 8 10 14.5
Operating pressure 115 145 210 115 145 210 115 145 210 115 145 210
PSIG (bar) (8) (10) (14.5) (8) (10) (14.5) (8) (10) (14.5) (8) (10) (14.5)
Factory set reload pressure 100 125 – 100 125 180 100 125 180 100 125 180
PSIG (bar) (7.58) (8.96) (7.93) (9.66) (13.10) (7.93) (9.66) (13.10) (7.93) (9.66) (13.10)
Flow rate 19.5 16.0 – 29.0 26.0 18.0 38.0 34.0 24.0 56.5 50.0 38.0
CFM (m3/MIN) (0.55) (0.45) (0.82) (0.74) (0.51) (1.08) (0.96) (0.68) (1.60) (1.92) (1.08)
Airend discharge temperature 228_F (109_C)

trip point
Ambient temperature 36_F(+2_C ) → 105_F(+40_C)
min. → max.
MOTOR
Motor enclosure TEFC
Nominal power 4KW 5.5KW 7.5KW 11KW
Speed 2900 RPM
Insulation class F
GENERAL DATA
Residual coolant content 3ppm (3 mg/m3)
Separator vessel capacity 0.8 gallons (3 Litres)
Coolant capacity 1.2 gallons (4.5 Litres )
Sound pressure level to 65 dB(A) 65 dB(A) 68 dB(A) 69 dB(A)
CAGI–PNEUROP
Weight – base mount unit 295kg (650lb)
Weight – 272 Litres Receiver 420kg (925lb)
mounted
Weight – 500 Litres Receiver 454kg (1000lb)
mounted
DRYER ENGINEERING DATA 60Hz 50Hz

Electrical supply 115V – 1ph – 60Hz 230V – 1ph – 50Hz
L.R.A. current (Amps) 30.0 12.6
F.L.A. current (Amps) 5.0 2.7
Total installed power (kW) 0.46 0.47
Electrical protection class (std) NEMA 1
(IP 20)
Factory refrigerant charge (lb/g) 0.78 lb
354 g
Refigeration type 134 A
CAUTION
230/460 Dual voltage machines are fitted with a decal to advise the correct voltage as connected from the factory.
There is a decal fitted to the starter door describing the procedure to change the connections for the alternative voltage
Rewiring should only be effected by a competent Electrician.
ELECTRICAL DATA — UP6 5
Standard voltage 230V/1PH 200V 230V/3PH 460V 575V
Full load current (maximum) 23.5A 15.5A 13.5A 6.8A 5.4A
Starting current DOL (Star Delta) – – – – –
Starting time DOL (Star Delta) 3–5 Sec (7–10 Sec)
Starts per hour (maximum) 6
Control voltage 120VAC
Recommended fuse rating See note 1 40A 25A 20A 10A 8A
Recommended wire size AWG See note 2 8 10 12 14 14
ELECTRICAL DATA — UP6 7.5

Full load current (maximum) 34.1A 26.5A 23.1A 11.5A 9.2A
Recommended fuse rating See note 1 50A 35A 35A 15A 12A
Recommended wire size AWG See note 2 6 8 10 14 14

Full load current (maximum) – 29.8A 26.0A 13.0A 10.3A
Recommended fuse rating See note 1 – 50A 45A 20A 15A
Recommended wire size AWG See note 2 – 8 8 12 14
ELECTRICAL DATA — UP6 15c

Full load current (maximum) – 43.2A 37.6A 18.8A 15.1A
Recommended fuse rating See note 1 – 75A 65A 30A 25A
Recommended wire size AWG See note 2 – 4 6 10 10
1. If a circuit breaker is selected it should only be a magnetic trip type, i) PVC insulated cable, armoured, copper conductors.
set above the anticipated starting current of the machine, but below the ii) Cable clipped to a wall, in free air.
maximum prospective fault current for the circuit. The circuit breaker iii) Ambient temperature of 40_C (104_F) and relative humidity of 40%.
or fuseable disconnect must be capable of breaking the prospective iv) 20m (65ft) cable run.
fault current at its terminals. v) Volt drop limited to –10% during starting, –4% during normal
running.
2. PVC/PVC Type Calculated using the following conditions: vi) Protected by the circuit breaker listed above.
Standard voltage 380V 400V
Full load current (maximum) 8.9A 8.5A
Starting current DOL (Star Delta) 66 63
Recommended fuse rating See note 1 16A 16A
Recommended wire size See note 2 4 mm@Cu 4 mm@Cu

Starting current DOL (Star Delta) 100 95

Starting current DOL (Star Delta) 121 (94) 114 (52)
ELECTRICAL DATA — UP5 11c

Starting current DOL (Star Delta) (79) (75)
1. If a circuit breaker is selected it should only be a magnetic trip type, i) PVC insulated cable, armoured, copper conductors.
set above the anticipated starting current of the machine, but below the ii) Cable clipped to a wall, in free air.
maximum prospective fault current for the circuit. The circuit breaker iii) Ambient temperature of 40_C (104_F) and relative humidity of 40%.
or fuseable disconnect must be capable of breaking the prospective iv) 20m (65ft) cable run.
fault current at its terminals. v) Volt drop limited to –10% during starting, –4% during normal
running.
2. PVC/PVC Type Calculated using the following conditions: vi) Protected by the circuit breaker listed above.
If there are any deviations from the above, or special regulations Feeder cables / wires connections to isolator or disconnect should
apply, the installation must be planned by a competent, qualified be tight and clean.
engineer.
The applied voltage must be compatible with the motor and
compressor data plate ratings.
NOTE
All data applies to standard product only. The control circuit transformer has different voltage tappings.
Ensure that these are set for the specific applied voltage prior to
starting.
ELECTRICAL DATA
An independent electrical isolator or disconnect should be installed
adjacent to the compressor. CAUTION
Never test the insulation resistance of any part of the machines
electrical circuits, including the motor without completely
Feeder cables/wires should be sized by the customer/electrical disconnecting the electronic controller (where fitted).
contractor to ensure that the circuit is balanced and not overloaded by
other electrical equipment. The length of wiring from a suitable
electrical feed point is critical as voltage drops may impair the CAUTION
performance of the compressor. Ensure that the motor rotates in the correct direction as
indicated by direction arrows.
32 OPERATING INSTRUCTIONS
GENERAL OPERATION By cooling the discharge air, much of the water vapour naturally
contained in the air is condensed and may be drained from the
The compressor is an electric motor driven, single stage screw downstream piping and equipment.
compressor, complete with accessories piped, wired and baseplate
mounted. It is a totally self contained air compressor package.
The coolant system consists of a sump, cooler, thermostatic valve
and a filter. When the unit is operating, the coolant is pressurized and
The standard compressor is designed to operate in an ambient forced to the compressor bearings.
range of 35.6_F – 104_F (2_C to 40_C). The maximum temperature is
applicable to either version up to a maximum elevation of 3280ft
(1000m) above sea level. Above this altitude significant reduction in The compressor load control system is automatic on–off line. The
maximum allowable ambient temperature is required. compressor will operate to maintain a set discharge line pressure and
is provided with an auto restart system for use in plants where the air
demand varies sufficiently to allow a compressor to shut down and
Compression in the screw type air compressor is created by the save power. Significant system volume will assist this and is
meshing of two (male & female) helical rotors. recommended.
The air/coolant mixture discharges from the compressor into the When the compressor is equipped with the optional dryer, the dryer
separation system. This system removes all but a few PPM of the will cycle on and off with the compressor.
coolant from the discharge air. The coolant is returned to the cooling
system and the air passes through the aftercooler and out of the
compressor.
WARNING
When the unit stops running as the result of low air demand,
Cooling air is moved through the coolers by the cooling fan and
normally indicated by auto restart light, it may restart and return
discharged from the machine.
to load at any time.
Safety of operation is provided as the compressor will shut down if

excessive temperatures or electrical overload conditions should occur.
CAUTION
Cooling air is drawn in at the end of the machine package
passing through the filter and cooler before being discharged
from the top of the machine. Care should be taken to avoid CAUTION
blocking the airflow, or causing any restriction in excess of the This unit is not designed or intended to operate when
maximum backpressure allowed for ducting. contaminated with silicone. Lubricants, greases or other items
Do not direct the airflow at face or eyes. containing silicone should not be used on this unit.
OPERATING INSTRUCTIONS 33
COMPRESSOR CONTROLS AUTOMATIC START & STOP CONTROL
Direct online starting:
The compressor is equipped for Automatic Start & Stop Control. NOTE
When the receiver tank pressure reaches the factory pre–set Automatic Start & Stop Control is intended for use when the motor
maximum pressure, the pressure switch stops the unit. When the will start no more than 6 times per hour.
receiver tank pressure drops below the factory pre–set minimum. The
pressure switch resets and restarts the unit.
When the receiver tank pressure reaches the factory pre–set
The pressure switch cover can be removed by unscrewing the two maximum pressure, the pressure switch stops the unit. When the
screws holding the cover. receiver tank pressure drops below the factory pre–set minimum, the
Pressure switch adjustment: pressure switch resets and restarts the unit.
The compressor package will cut–in and cut–out at factory preset

pressure settings. Adjust the pressure switch only if absolutely DUAL CONTROL
necessary.
Select either automatic start and stop control or constant speed
Adjustments are to be carried out only when the switch is mounted, control by adjusting the knob on the auxiliary valve. For automatic start
under pressure and voltage–free. and stop control, turn the knob on the auxiliary valve fully clockwise to
disable the auxiliary valve. The pressure switch will then start and stop
the unit.
WARNING
High voltage is present at the pressure switch contacts when the
power supply is connected. Disconnect, lock and tag main power
supply before making adjustments.
WARNING
Do not adjust the pressure switch to exceed the maximum
discharge pressure of the unit
NOTE
When replacing the pressure switch cover, ensure the selector
knob on the cover and the lever on the switch are both in the ”OFF” posi-
tion.
NOTE
When the compressor is equipped with the optional dryer and filters,
the pressure switch differential should be increased 10psi to account
for the added pressure drop of the filters and dryer.
Auxiliary Valve.
A. Knob
B. Clockwise
C. Counterclockwise
Select constant speed control if the unit restarts in less than 10 minute
intervals or runs more than 40 minutes per hour. Turn the knob fully
counterclockwise to run the unit continually.
NOTE
The auxilIary valve is factory pre–set at 5 psig (0,3 bar) lower than
the factory pressure switch setting.
A. Upper Pressure Setting CAUTION

Running unloaded with no air demand, will cause the unit to be shut
B. Pressure Differential off by the pressure switch.
34 OPERATING INSTRUCTIONS
1. PRESSURE GAUGE PRIOR TO STARTING

Indicates the system pressure.
1. Make visual check of the machine, ensure that all guards secure
and that nothing is obstructing the proper ventilation of, or free access
to the machine.
WARNING 2. Check coolant level. Add if necessary.

DO NOT operate the compressor at discharge pressures
exceeding the maximum operating pressure.
3. Make sure air discharge valve is open.
4. Turn on electrical isolator or disconnect. The Power on (5) indicator

will light, indicating that line and control voltages are available.
2. HOURMETER
Records the total running time of the compressor.
5. Check direction of rotation at initial start or following interruption in
power supply.
3. STOP BUTTON / EMERGENCY STOP
When depressed will stop the compressor immediately. The
’Power on’ indicator will remain illuminated. The STOP button must WARNING
be released before the compressor can be restarted. Make sure that all protective covers are in place.
Cooling air flow exhaust may contain flying debris. Safety
4. ON PUSH BUTTON SWITCH protection should be worn at all times to avoid injury.
When depressed will cause the unit to start and run in a loaded
condition if there is a demand for air. If there is no demand, the machine
will stop automatically. STARTING
1. Press the START button. The compressor will start and then load
5. POWER ON INDICATOR LIGHT (Green) automatically.
Indicates the presence of control voltage.
NORMAL/EMERGENCY STOPPING
6. STOPPED/AUTO RESTART INDICATOR LIGHT (Amber) 1. Press STOP button (3) and the compressor will stop immediately.
Will illuminate when the machine has shut-down due to low air
demand. The machine will restart and load automatically as soon as
the demand for air returns. 2. Turn off electrical isolator or disconnect.
7. DEW POINT INDICATOR (Dryer Option)

Green indicates good dew point. Red indicates dew point above CAUTION
50_F (10_C) Blue indicates freezing. After shutdown never allow unit to stand idle with pressure in
receiver/separator system.
MAINTENANCE 35
SSR UP Series Maintenance Schedule ROUTINE MAINTENANCE
This section refers to the various components which require
periodic maintenance and replacement.
PERIOD MAINTENANCE
Each 24 hours Check the coolant level and replenish if . It should be noted that the intervals between service requirement
operation necessary. may be significantly reduced as a consequence of poor operating
environment. This would include effects of atmospheric contamination
Visual check of Report immediately, contact
and extremes of temperature.
machine for any Ingersoll–Rand authorized distributor for
leaks, dust build up assistance if in doubt
or unusual noise or The SERVICE/MAINTENANCE CHART indicates the various
vibration components’ descriptions and the intervals when maintenance has to
When compressor Drain air receiver of condensate, or check take place. Oil capacities, etc., can be found in the GENERAL
is receiver mounted that automatic drain is operating INFORMATION section of this manual.
Visual check Blow clean if needed

condition of Compressed air can be dangerous if incorrectly handled. Before
package pre–filter doing any work on the unit, ensure that all pressure is vented from the
First 150 hours Change the coolant filter.
Each month or 100 Remove and clean package pre–filter,
hours replace if needed
CAUTION: Before beginning any work on the compressor, open,
Check the cooler(s) for build up of foreign lock and tag the main electrical disconnect and close the isolation
matter. Clean if necessary by blowing out valve on the compressor discharge. Vent pressure from the unit
with air or by pressure washing. by slowly unscrewing the coolant fill cap one turn. Unscrewing
the fill cap opens a vent hole, drilled in the cap, allowing pressure
Each 3 months Operate the safety valve manually to verify
to release to atmosphere. Do not remove the fill cap until all
that the valve mechanism is functioning
pressure has vented from the unit. Also vent piping by slightly
correctly and that a small amount of air is
opening the drain valve. When opening the drain valve or the
released.
coolant fill cap, stand clear of the valve discharge and wear
Each year or Check the operation of the high appropriate eye protection.
3000 hours temperature protection switch (109_C).
Replace elements in IRGP and IRHE
WARNING: This machine may have a separate single phase
filters.
circuit for dryer and/or electric drain valve. It is vital that power is
Change the coolant filter. disconnected from all circuits and the disconnect tagged before
any work is attempted on the machine.
Check scavenge screen for blockage,
clean if required.
Change the separator element. Ensure that maintenance personnel are properly trained,
competent and have read the Maintenance Manuals.
Change the Air Filter element.
Take coolant sample for fluid analysis. Prior to attempting any maintenance work, ensure that:–
Change the package pre–filter. . all air pressure is fully discharged and isolated from the system. If
Check Drive Belts. the automatic blowdown valve is used for this purpose, then allow
enough time for it to complete the operation.
1 year external and Separator vessel and air receiver when
6 years internal fitted.
pressure vessel Fully inspect all external surfaces, and . the machine cannot be started accidentally or otherwise.
inspection. fittings. Report any excessive corrosion,
Frequency may be mechanical or impact damage, leakage or
. all residual electrical power sources (mains and battery) are
otherwise defined other deterioration.
isolated.
by local or national
legislation.
Every two years or Prior to opening or removing panels or covers to work inside
Change drive belts. a machine, ensure that:–
9000 hours
Replace the Ultra Plus Coolant at
whichever interval occurs first.
. anyone entering the machine is aware of the reduced level of
Check and replace all items included within protection and the additional hazards, including hot surfaces and
3000 hour service intermittently moving parts.
Fit the following reconditioning parts as

appropriate: . the machine cannot be started accidentally or otherwise.
Solenoid valves
Prior to attempting any maintenance work on a running
Inlet valve kit
machine, ensure that:–
Minimum Pressure valve kit
Thermostatic Valve Kit
Every 4 years or Replace all hoses.
18000 hours DANGER
Strip, clean and re–Grease motor bearings
of ODP motors. Only properly trained and competent persons should
undertake any maintenance tasks with the compressor running or
Fit replacement electrical contactor tips. with electrical power connected.
36 MAINTENANCE
. the work carried out is limited to only those tasks which require the
machine to run.
. the work carried out with safety protection devices disabled or

removed is limited to only those tasks which require the machine to be
running with safety protection devices disabled or removed.
. all hazards present are known (e.g. pressurised components,

electrically live components, removed panels, covers and guards, A. Correct at operating temperature
extreme temperatures, inflow and outflow of air, intermittently moving
parts, safety valve discharge etc.). B. Too much
C. OK
. appropriate personal protective equipment is worn.
D. Too little
. loose clothing, jewellery, long hair etc. is made safe.

Repeat this procedure to get coolant to proper level when up to
operating temperature.
. warning signs indicating that Maintenance Work is in Progress are
posted in a position that can be clearly seen.
When the unit is shut down, coolant will usually fill up sight glass.
Do not adjust level based on level at shutdown. Proper level is always
Upon completion of maintenance tasks and prior to returning set for a running unit at operating temperature.
the machine into service, ensure that:–
. the machine is suitably tested.
CAUTION
. all guards and safety protection devices are refitted and correctly
Ensure that SSR ULTRA–PLUS coolant is used. Failure to do
working.
so will void manufacturers warranty.
. all panels are replaced, canopy and doors closed.
. hazardous materials are effectively contained and disposed of in a COOLANT CHANGE PROCEDURE
manner compliant with local or National environmental protection
codes. It is better to drain the coolant immediately after the compressor has
been operating as the liquid will drain more easily and any contaminant
will still be in suspension.
1. Stop the machine, electrically isolate and vent all trapped pressure.
WARNING
Do not under any circumstances open any drain valve or
remove components from the compressor without first ensuring 2. Place a suitable container close to the drain valve.
that the compressor is FULLY SHUT– DOWN, power isolated and
all air pressure relieved from the system. 3. Slowly remove fill cap.
4. Remove plug from drain valve.
5. Open the drain valve and drain coolant into container.

TOP UP COOLANT PROCEDURE
1 Slowly remove fill cap. 6. Close the drain valve.
2 Pour coolant into spout until spout almost overflows.

7. Replace plug in drain valve.
3. Replace and tighten oil fill cap.

8. Refill the machine following the ”top up coolant” procedure above.
After initial fill, to purge any airlocks, the machine should be run for a
4. Start unit for about 10 seconds (until coolant drains out the bottom few minutes cycling between load and no load, before checking that the
of the sight glass). level is correct.
5. Slowly remove fill cap. 9. Replace and tighten fill cap.
6. Re–fill into spout until spout almost overflows.

COOLANT FILTER CHANGE PROCEDURE
7. Replace and tighten oil fill cap. 1. Stop the machine, electrically isolate and vent all trapped pressure.
8. Run unit. 2. Loosen filter with the correct tool.
3. Remove the filter from the housing.
4. Place the old filter in a sealed bag and dispose of in a safe way.
Note:
Coolant level is correct when a unit is showing coolant in bottom half
of sight glass when up to operating temperature (ten minutes running 5. Clean the mating face of the housing taking care to avoid any
loaded). particles entering the machine.
MAINTENANCE 37
6. Remove the new Ingersoll–Rand replacement filter from its 7. Screw the new element down until the seal makes contact with
protective package. the housing, then hand tighten a further half turn.
7. Apply a small amount of lubricant to the filter seal. 8. Start the compressor and check for leaks.
8. Screw the new filter down until the seal makes contact with the
housing, then hand tighten a further half turn. CAUTION
This unit is not designed or intended to operate when
contaminated with silicone. Lubricants, greases or other items
9. Start the compressor and check for leaks. containing silicone should not be used on this unit.
COOLER CLEANING PROCEDURE
AIR FILTER ELEMENT CHANGE PROCEDURE 1. Stop the machine, electrically isolate and vent all trapped pressure.
1. Stop the machine, electrically isolate and vent all trapped pressure.
2. Remove the top cover to obtain access to the cooler.
2. Unscrew the retaining cap and withdraw the old element.

3. Clean the cooler.
3. Fit the new element.

4. Rebuild in reverse order.
4. Replace the retaining cap.
BELT CHECKING AND ADJUSTMENT PROCEDURE

Check belt tension occasionally, especially if looseness is
suspected. A quick check to determine if adjustment is proper may be
SEPARATOR ELEMENT CHANGE PROCEDURE made by observing the slack side of the belt for a slight bow when the
unit is in operation. If a slight bow is evident, the belt is usually adjusted
1. Stop the machine, electrically isolate and vent all trapped pressure. satisfactorily.
A belt tension measurement device can be used to determine the
2. Loosen separator element with the correct tool.
tension of the belt.
Belt tensioning can be achieved by loosening the airend anchor
3. Remove the element from the housing; place it in a sealed bag
and dispose of it safely. screws, a belt tensioning bolt is provided to aid in moving the airend.
Follow the procedures outlined below to correctly set and measure belt
4. Clean the mating face of the housing. tension.
1. Lay a straight edge across the top outer surface of the belt drive
5. Remove the new Ingersoll–Rand replacement element from its from pulley to sheave.
protective package.
2. At the center of the span, perpendicular to the belt, apply pressure
to the outer surface of the belt with a tension gauge. Force the belt to
6. Apply a small amount of lubricant to the element seal. the deflection indicated in the table below, and compare the reading on
the tension gauge to the figures shown.
BELT TENSION
5hp/4kw * 7.5hp/5.5kw * 10hp/7.5kw * 15hp/11kw **

New Used New Used New Used New Used
60hz
125 psig 75 Lb 62 Lb 110 Lb 90 Lb 110 Lb 90 Lb 140 Lb 120 Lb
(34 Kg) (28 Kg) (50 Kg) (41 Kg) (50 Kg) (41 Kg) (64 Kg) (54 Kg)
50hz
8 bar 85 Lb 70 Lb 85 Lb 70 Lb 110 Lb 90 Lb 140 Lb 120 Lb
10 bar 90 Lb 75 Lb 85 Lb 70 Lb 120 Lb 100 Lb 140 Lb 120 Lb
14.5 bar 90 Lb 75 Lb 100 Lb 80 Lb 120 Lb 100 Lb 150 Lb 125 Lb
* ”Krikit I” gauge or equal

** ”Krikit II” gauge or equal
38 MAINTENANCE
Ensure the pulley and sheave are properly aligned and the motor TROUBLESHOOTING
anchor screws are adequately retightened prior to restarting the
compressor.
TROUBLE CAUSE ACTION
CAUTION Valve will not 1. Debris in solenoid 1. Remove solenoid
Improper pulley/sheave alignment and belt tension can result in close. valve prevents valve, disassemble,
motor overload, excessive vibration, and premature belt and/or bearing diaphragm from clean and reassemble.
failure. seating.
To prevent these problems from occurring, ensure the pulley and
sheave are aligned and belt tension is satisfactory after installing new 2. Short in electrical 2. Check and replace
belts or tensioning existing belts. component. power cord or timer as
needed.
ELECTRIC DRAIN VALVE (OPTIONAL) Timer will not 1. No electrical 1. Apply power.
activate supply.
PRODUCT DESCRIPTION 2. Timer malfunction 2. Replace timer.
The Electric Drain Valve removes condensed water and coolant from 3. Clogged port. 3. Clean valve.
the air receiver tank. Additional drains may be installed throughout your
compressed air system, including aftercoolers, filters, drip legs and 4 Solenoid valve 4. Replace solenoid
dryers. malfunction. valve.
5. Clogged strainer. 5. Clean strainer.
The Electric Drain Valve operates on a timer which can be set to
automatically drain the air receiver tank at operator–determined
intervals. MAINTENANCE
Key features include: Periodically clean the screen inside the valve to keep the drain
functioning at maximum capacity. To do this, perform the following
• 100% continuous duty steps:
• NEMA 4 enclosure 1. Close the strainer ball valve completely to isolate it from the air
receiver tank.
• Adjustable time on (0.5 – 10 seconds)
2. Press the TEST button on the timer to vent the pressure remaining
• Adjustable time off (0.5 – 45 minutes) in the valve. Repeat until all pressure is removed.
• Stainless steel operator
CAUTION! High pressure air can cause injury from flying debris.
• LED to indicate electrical power is on Ensure the strainer ball valve is completely closed and pressure
is released from the valve prior to cleaning.
• LED to indicate valve is open
3. Remove the plug from the strainer with a suitable wrench. If you hear
• Manual override air escaping from the cleaning port, STOP IMMEDIATELY and repeat
steps I and 2.
OPERATION
4. Remove the stainless steel filter screen and clean it. Remove any
1. Open the strainer ball valve. debris that may be in the strainer body before replacing the filter screen.
5. Replace plug and tighten with wrench.
Strainer Ball Valve.
6. When putting the Electric Drain Valve back into service, press the
OPEN CLOSED
TEST button to confirm proper function.
2. Set the “time off” and “time on” knobs. See TIMER SETTINGS
(below) for an explanation of the settings.
3. During compressor operation, check for air leaks.
TIMER SETTINGS
The “time off” setting determines the interval between cycles from 30
seconds to 45 minutes. The “time on” setting determines the actual time
the compressor drains condensate.
The timer’s cycle rate and drain opening time should be adjusted to
open just long enough to discharge the condensate. The timer is
properly set when it opens and discharges condensate and then vents
air for approximately one second before closing. Adjustments may be
made depending on many factors, including humidity and duty cycle.
MAINTENANCE 39
MAINTENANCE 1. Stop compressor, lock and tag out machine.
Before accessing live electrical parts, disconnect the power supply to
the dryer using disconnect switch or disconnect the cable connections.
Preventive maintenance
For optimum performance from your dryer, follow the periodic
maintenance schedule described below.
WEEKLY CONDENSATE DRAINS

Verify that the condensate drains
are operating correctly.
EVERY 4 MONTHS CONDENSER
Remove any dust from the
condenser fins.
COMPRESSOR
Make sure compressor power
consumption complies with data
plate specifications.
YEARLY CONDENSATE DRAINS
Completely disassemble the
drains and clean all their
components.
AIR FILTER
Replace air filter element.
MOISTURE SEPARATOR MAINTENANCE

The moisture separator will operate indefinitely under normal working
conditions, however at some time it may be necessary to replace the
seals should the housing leak.
1. Isolate the housing from the air supply.
2. Fully depressurize in drain bowl as appropriate.

3. Unscrew bowl and remove. If pressure has not been completely
released from the housing, air will escape from the warning hole giving
an audible alarm. Screw back bowl and repeat instruction 2 before
attempting again. Should resistance to unscrewing be experienced,
provision is made for a ’C’ spanner to fit onto the ribs of the bowl.
4. Check condition of bowl seal and replace if necessary. Clean screw
threads.
5. Refit bowl with ’O’ ring seal. DISASSEMBLING THE UNIT

6. Repressurize and check for leaks. If leaks occur they will most The unit has been designed and constructed to guarantee continuous
probably be from the bowl ’O’ ring. Depressurize housing and remove operation.
’O’ ring as stated above and inspect and clean. Ensure that mating
The long service life of some components such as the fan and
surfaces are clean and then refit ’O’ ring and repressurize.
compressor depends on good maintenance.
The unit must only be disassembled by a refrigerant specialist.

Refrigerant liquid and lubricating oil inside the refrigeration circuit must
AIR FILTER MAINTENANCE
be recovered in compliance with current norms in the country where the
In order to ensure optimum compressed air quality the filter element machine is installed.
should be replaced as follows. (Used filter elements must be disposed
of in accordance with local regulations.)
Use only genuine Ingersoll–Rand replacement elements.
RECYCLING DISASSEMBLY
Frame and panels Steel / epoxy resin polyester
Heat exchanger (cooler) Stainless steel
Pipes Copper
Insulation Gum synthetic
Compressor Steel / copper / aluminium / oil
Condenser Aluminium
Refrigerant R134a
Valve Steel
40 MAINTENANCE
REFRIGERANT LEAKS IN THE REFRIGERATION CIRCUIT MAINTENANCE
The unit is despatched in perfect working order, already charged. Periodically clean the screen inside the valve to keep the drain
functioning at maximum capacity. To do this, perform the following
Refrigerant leaks may be identified by tripping of the refrigeration steps:
overload protector .
1. Close the strainer ball valve completely to isolate it from the air
IF A LEAK IS DETECTED IN THE REFRIGERANT CIRCUIT, SEEK receiver tank.
TECHNICAL ASSISTANCE.
2. Press the TEST button on the timer to vent the pressure remaining
REFRIGERANT CHARGING in the valve. Repeat until all pressure is removed.
THIS OPERATION MUST ONLY BE PERFORMED BY A CAUTION! High pressure air can cause injury from flying debris.
REFRIGERANT SPECIALIST. Ensure the strainer ball valve is completely closed and pressure
is released from the valve prior to cleaning.
WHEN REPAIRING THE REFRIGERANT CIRCUIT, COLLECT ALL
THE REFRIGERANT IN A CONTAINER AND DISPOSE OF IT IN 3. Remove the plug from the strainer with a suitable wrench. If you hear
THE APPROPRIATE MANNER. air escaping from the cleaning port, STOP IMMEDIATELY and repeat
steps I and 2.
CHARACTERISTICS OF REFRIGERANT R134A
4. Remove the stainless steel filter screen and clean it. Remove any
In normal temperature and pressure conditions the above refrigerant debris that may be in the strainer body before replacing the filter screen.
is a colorless, class A1/A1 gas with TVL value of 1000ppm (ASHRAE
5. Replace plug and tighten with wrench.
classification).
6. When putting the Electric Drain Valve back into service, press the
If a refrigerant leak occurs, thoroughly air the room before commencing
TEST button to confirm proper function.
work.
TROUBLESHOOTING
TROUBLE CAUSE ACTION
Solenoid 1. Debris in solenoid 1. Remove solenoid

condensate valve prevents valve, disassemble,
valve will not diaphragm from clean and reassemble.
close. seating.
2. Short in electrical 2. Check and replace
component. power cord or timer as
needed.
Drain timer will 1. No electrical 1. Apply power.
not operate. supply.
2. Timer malfunction 2. Replace timer.
3. Clogged port. 3. Clean valve.
4 Solenoid valve 4. Replace solenoid
malfunction. valve.
5. Clogged strainer. 5. Clean strainer.
TROUBLE SHOOTING 41
PROBLEM CAUSE REMEDY
Compressor fails to Mains power or Control voltage not available. § Check incoming power supply.
start § Check the control circuit fuse.
§ Check the transformer secondary windings for the
control voltage.
Defective Star / Delta timer. § Change Star / Delta timer.
Machine shuts down High airend temperature. Top up coolant.
periodically
Motor overload. § Set overload to correct value and switch to manual
reset.
Line voltage variation. § Ensure voltage does not drop below 10% on start up
and 6% running.
High current draw Compressor operating above rated pressure. Set pressure to correct rating for machine.
Separator element contaminated Change air filter, and separator element.
Low voltage. § Ensure voltage does not drop below 10% on start up
and 6% running.
Unbalanced voltage. Correct incoming supply voltage.
Damaged airend. † Change Airend.
Low current draw Air filter contaminated. Change air filter.
Compressor operating unloaded. Set pressure to correct rating for machine.
High voltage. Reduce site voltage to correct operating voltage.
Defective inlet valve. † Fit inlet valve service kit.
High discharge Defective or incorrect pressure switch setting. Replace or set pressure to correct rating for machine.
pressure
Blowdown valve defective. † Fit blowdown solenoid service kit.
Inlet valve malfunction. † Fit inlet valve service kit.
Low system air Separator element contaminated. Fit new Separator element.
pressure
Incorrect pressure switch setting. Set pressure to correct rating for machine.
Minimum pressure valve malfunction. † Fit Minimum pressure valve service kit.
Drive belt slipping. Fit new belt.
Air system leaks. † Fix leaks.
System demand exceeds compressor delivery. Reduce demand or install additional compressor.
Compressed air filters contaminated.. Replace air filter elements.
High dewpoint Refrigeration compressor not supplied power. Check incoming power supply.
Check the dryer protection fuse.
Check auxiliary contact on main motor contactor.
Condensate system malfunction. Check operation of drain valve.
Check operation of condensate check valves.
Condenser dirty. Clean condenser and replace panel filter element.
Ice formation in dryer Low evaporator pressure. Check hot gas valve setting.
NOTES:
§ Must be carried out by a competent electrician.
† This work is recommended to be carried out only by an Ingersoll–Rand authorized service technician.
42 TROUBLE SHOOTING
PROBLEM CAUSE REMEDY
Compressor trips due to Compressor operating above rated pressure. Set pressure to correct rating for machine.
over temperature
Package pre–filter blocked. Clean / replace package pre–filter.
Cooler blocked. Clean cooler.
Missing or incorrectly fitted enclosure panels Ensure that all enclosure panels are correctly fitted
Low coolant level. Top up coolant and check for leaks.
High ambient temperature. Re–site compressor.
Restricted cooling air flow. Ensure correct air flow to compressor.
Excessive coolant Separator element leak. Fit new Separator element.
consumption
Blocked separator element drain. † Remove fittings and clean.
Compressor operating below rated pressure. Set pressure to correct rating for machine.
Coolant system leak. † Fix leaks.
Excessive noise level Air system leaks. † Fix leaks.
Airend defective. † Change Airend.
Belts Slipping. Replace belt and tensioner.
Motor defective. † Replace motor.
Loose components. † Retighten loose items.
Shaft seal leaking Defective shaft seal. † Fit Airend shaft seal kit.
Pressure relief valve Defective switch or incorrect pressure switch setting. Replace or set pressure to correct rating for machine.
opens
Minimum pressure valve malfunction. † Fit Minimum pressure valve service kit.
Pressure relief valve defective. Check the setting of the pressure relief valve and the
rated pressure.
Black residue on belt Drive belt slipping. Replace belt and tensioner.
guard/cooler box
Pulleys misaligned. Re–align pulleys.
Worn pulleys. † Replace pulleys and belt.
Safety valve blows Minimum pressure valve stuck closed. Strip minimum pressure valve, examine and repair if
when compressor goes necessary.
on load.
load
Safety valve faulty Check the setting of the safety valve and the rated
pressure.
NOTES:
§ Must be carried out by a competent electrician.
† This work is recommended to be carried out only by an Ingersoll–Rand authorized service technician.

UP6-5-15c O & M Manual

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SSR UP5–4, UP5–5.5, UP5–7.

This manual contains

Register on–line at air.irco.com

Ingersoll Rand Asia Pacific

The company accepts no responsibility for errors in translation of

Prohibition / Mandatory Information / Instructions Warning

Emergency stop. On (power). Off (power).

ROTATION AIR DISCHARGE COOLANT FILTER

AUTOMATIC RESTART MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN FILTER

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS HOURS

Use ULTRA–Plus Coolant only

Every X months, if sooner than required by CHANGE / REPLACE CLEAN

POWER INLET (AC) Pinch point hazard.

EXPOSED MOVING BELTS AND SHEAVES.

Air flow exhaust may contain flying debris.

Pinch point hazard.

Item ccn Qty. Description Item ccn Qty. Description

1 93166502 1 Decal, replacement element 12 92867498 1 Decal, notice air discharge

10 93165983 1 Decal, rotation direction 19 93493641 1 Decal, start up warning

Item ccn Qty. Description Item ccn Qty. Description

20 93165959 1 Decal, use guards when running 25 22417109 1 Decal, facia

DANGER! If more than one compressor is connected to one common

Wear eye protection when operating or servicing compressor.

Do not work on or walk under the compressor while it is suspended.

PIPING AND INSTRUMENTATION

AR Air receiver (option) 22. Receiver air

ID Integral dryer (option) 23. Filter, general purpose air

SD Bara för S/D 24. Filter, high efficiency air

1. Filter, air 25. Valve, check

9. Aftercooler 32. Valve, condensate

17. Valve, safety A. Air/Coolant

18. Valve, drain B. Air

19. Screen, scavenge C. Coolant

1FU, Fuse control circuit HATS Switch, high air temperature

1FU, 2FU Fuse, primary HATS Switch, high air temperature

1FU, Fuse control circuit M Coil motor starter

1FU Fuse, secondary MIO Indicator, maintenance option

4FU, 5FU Fuse, dryer MM Motor, compressor

CR Relay, control MOL Overload, main motor

CS Customer supplied 230V / 1 / 50Hz MOL–1 Contact, main motor overload

DM Motor, dryer PS Switch, pressure

1SV Valve, solenoid (NC) KM2–1,2 Contacts, auxiliary. Delta contactor

HATS Switch, high air temperature MOL Overload, main motor

KM1 Contactor, main 2. Circuit shown in normal position de–energized.

VIEW FRONT VIEW RIGHT

A Package pre–filter M Motor

B Hole, incoming power supply conduit N Integrated dryer (Optional)

C Gauge, pressure O Compressor and cooling air intake

D Yellow stand–by light P Filter, coolant

E Green power–on light Q Cartridge, coolant separator

F Green start push button R Valve, airend relief

G Emergency stop button S Plug, coolant filler

I Starter box U Plug, coolant drain

J Lifting points V Valve, pilot

2. Foundation bolts should protect thru nuts a minimum of 13mm

4. Approximate package weight: 298kg (655lbs). UNPACKING

VIEW FRONT VIEW RIGHT

A Package pre–filter P Filter, coolant