UP6 15, UP6 20, UP6 25, UP6 30 60Hz: Intellisys Option Dryer Option High Dust Option Outdoor Module Option PORO Option

UP6 15, UP6 20, UP6 25, UP6 30
60Hz
OPTIONS MANUAL
Intellisys Option
Dryer Option
High Dust Option
Outdoor Module Option
PORO Option
This manual contains

important safety information
and must be made available
to personnel who operate and
maintain this machine.
C.C.N. : 80445174
REV : B
DATE : JANUARY 2009
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
6 SAFETY SM Sitemaster/Sitepack
HA High ambient machine
8 INTELLISYS OPTION WC Watercooled machine
AC Aircooled machine
ERS Energy recovery system
31 DRYER OPTION T.E.F.C. Totally enclosed fan cooled motor (IP55)
O.D.P. Open drip proof (motor)
47 HIGH DUST FILTER OPTION
48 OUT DOOR MODULE OPTION
49 PORO OPTION – ELECTRO–PNEUMATIC
53 PORO OPTION – INTELLISYS
http:/air.ingersollrand.com UP6 15, UP6 20, UP6 25, UP6 30

2 FOREWORD
This manual is provided to cover instructions and technical data The intended uses of this machine are outlined below and examples
for additional options to the standard UP compressor range. It is of unapproved usage are also given, however Ingersoll Rand cannot
provided as a SUPPLEMENT to the standard operators and parts anticipate every application or work situation that may arise.
manuals and should NOT be used for the operation of the
complete machine.
IF IN DOUBT CONSULT SUPERVISION.
This machine has been designed and supplied for use only in the
following specified conditions and applications:
The contents of this manual are considered to be proprietary and . Compression of normal ambient air containing no known or
confidential to Ingersoll Rand and should not be reproduced without detectable additional gases, vapors, or particles
the prior written permission of Ingersoll Rand. . Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.
Nothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied, regarding The use of the machine in any of the situation types listed in
the Ingersoll Rand products described herein. Any such warranties or table 1:–
other terms and conditions of sale of products shall be in accordance a) Is not approved by Ingersoll Rand,
with the standard terms and conditions of sale for such products, which b) May impair the safety of users and other persons, and
are available upon request. c) May prejudice any claims made against Ingersoll Rand.
This manual contains instructions and technical data to cover TABLE 1

routine operation and scheduled maintenance tasks by operation and
maintenance staff. Major overhauls are outside the scope of this Use of the machine to produce compressed air for:
manual and should be referred to an authorized Ingersoll Rand service a) direct human consumption
department. b) indirect human consumption, without suitable filtration and purity
checks.
All components, accessories, pipes and connectors added to the Use of the machine outside the ambient temperature range
compressed air system should be: specified in the GENERAL INFORMATION SECTION of this manual.
. of good quality, procured from a reputable manufacturer and,
wherever possible, be of a type approved by Ingersoll Rand. Use of the machine where there is any actual or foreseeable risk of
. clearly rated for a pressure at least equal to the machine maximum
hazardous levels of flammable gases or vapors.
allowable working pressure.
. compatible with the compressor lubricant/coolant. THIS MACHINE IS NOT INTENDED AND MUST NOT BE
. accompanied with instructions for safe installation, operation and USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,
maintenance. INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR
VAPOURS MAY BE PRESENT.
Details of approved equipment are available from Ingersoll Rand Use of the machine fitted with non Ingersoll Rand approved
Service departments. components.
Use of the machine with safety or control components missing or

The use of non–genuine spare repair parts other than those
included within the Ingersoll Rand approved parts list may create disabled.
hazardous conditions over which Ingersoll Rand has no control.
Therefore Ingersoll Rand does not accept any liability for losses The company accepts no responsibility for errors in translation of
caused by equipment in which non–approved repair parts are installed. this manual from the original English version.
Standard warranty conditions may be affected.
INTELLISYS is a registered trademark of Ingersoll Rand

Ingersoll Rand reserves the right to make changes and Company USA.
improvements to products without notice and without incurring any
obligation to make such changes or add such improvements to
products sold previously. ¤ COPYRIGHT 2008
INGERSOLL RAND
UP6 15, UP6 20, UP6 25, UP6 30 http:/air.ingersollrand.com

DECALS 3
ISO SYMBOLS
GRAPHIC FORM AND MEANING OF ISO SYMBOLS
Prohibition / Mandatory Information / Instructions Warning
Use fork lift truck from this side only. RESET Do not use fork lift truck from this side.
Emergency stop. On (power). Off (power).
AUTOMATIC RESTART MAINTENANCE MAINTENANCE PROHIBITED
FRAGILE KEEP DRY THIS WAY UP
USE NO HOOKS NO SIDE CLAMPS HOURS

4 DECALS
Every X months, if sooner than required by

operating hours
POWER INSPECT
CHANGE / REPLACE CLEAN

MOISTURE

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.

6 SAFETY
DANGER! All air pressure equipment installed in or connected to the machine

Hazard that WILL cause DEATH, SEVERE INJURY or substantial must have safe working pressure ratings of at least the machine rated
property damage if ignored. Instructions must be followed precisely to pressure.
avoid injury or death.
If more than one compressor is connected to one common
WARNING! downstream plant, effective isolation valves must be fitted and
Hazard that CAN cause DEATH, SEVERE INJURY or substantial controlled by work procedures, so that one machine cannot accidently
property damage if ignored. Instructions which must be followed be pressurized / over pressurized by another.
precisely to avoid injury or death. Compressed air must not be used for a direct feed to any form of
CAUTIONS! breathing apparatus or mask.
Cautions call attention to instructions which must be followed The discharged air contains a very small percentage of compressor
precisely to avoid damaging the product, process or its surroundings. lubricant and care should be taken to ensure that downstream
equipment is compatible.
NOTES
Notes are used for supplementary information. If the discharged air is to be ultimately released into a confined
space, adequate ventilation must be provided.
BREATHING AIR PRECAUTION
Ingersoll Rand air compressors are not designed, intended or When using compressed air always use appropriate personal
approved for breathing air. Compressed air should not be used for protective equipment.
breathing air applications unless treated in accordance with all
applicable codes and regulations. All pressure containing parts, especially flexible hoses and their
couplings, must be regularly inspected, be free from defects and be
replaced according to the Manual instructions.
General Information
Compressed air can be dangerous if incorrectly handled. Before
Ensure that the operator reads and understands the decals and doing any work on the unit, ensure that all pressure is vented from the
consults the manuals before maintenance or operation. system and that the machine cannot be started accidentally.
Ensure that the Operation and Maintenance manual is not removed Avoid bodily contact with compressed air.
permanently from the machine.
All safety valves located in the separator tank must be checked
Ensure that maintenance personnel are adequately trained, periodically for correct operation.
competent and have read the Maintenance Manuals.
Do not over–pressurize the receiver tank or similar vessels beyond
Do not point air nozzles or sprayers toward anyone. design limits.
Compressed air and electricity can be dangerous. Before Do not use a receiver tank or similar vessels that fail to meet the
undertaking any work on the compressor, ensure that the electrical design requirements of the compressor. Contact your distributor for
supply has been isolated and the compressor has been relieved of all assistance.
pressure.
Do not drill into, weld or otherwise alter the receiver tank or similar
Wear eye protection when operating or servicing compressor. vessels.
All persons positioned near to operating machinery should be
equipped with hearing protection and given instructions on its use in
accordance with workplace safety legislation. Materials
The following substances are used in the manufacture of this
Make sure that all protective covers are in place and that the
machine and may be hazardous to health if used incorrectly:
canopy/doors are closed during operation.
. preservative grease
The specification of this machine is such that the machine is not . rust preventative
suitable for use in flammable gas risk areas. . compressor coolant
Installation of this compressor must be in accordance with AVOID INGESTION, SKIN CONTACT AND INHALATION OF
recognized electrical codes and any local Health and Safety Codes. FUMES
The use of plastic bowls on line filters can be hazardous. Their

safety can be affected by either synthetic lubricants, or the additives Transport
used in mineral oils. Ingersoll Rand recommends that only filters with
metal bowls should be used on a pressurized system. When loading or transporting machines ensure that the specified
lifting and tie down points are used.
Compressed air Lifting equipment must be properly rated for the weight of the
Compressed air can be dangerous if incorrectly handled. Before compressor.
doing any work on the unit, ensure that all pressure is vented from the
Do not work on or walk under the compressor while it is suspended.
system and that the machine cannot be started accidentally.
WARNING
Imposing a normal or emergency stop on the compressor will
only relieve presure upstream of the minimum pressure valve on
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
the compressor
Ensure that the machine is operating at the rated pressure and that
the rated pressure is known to all relevant personnel.

SAFETY 7
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
and do not contact any other portion of the compressor when making
adjustments or repairs to exposed live parts of the compressor
electrical system.
WARNING
Any electrical connections or adjustments should only be
made by a suitably qualified electrician
Close and lock all access doors when the compressor is left
unattended.
Do not use extinguishers intended for Class A or Class B fires on
electrical fires. Use only extinguishers suitable for class BC or class
ABC fires.
Attempt repairs only in clean, dry, well lighted and ventilated areas.
Connect the compressor only to electrical systems that are
compatible with its electrical characteristics and that are within it’s rated
capacity.
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
80440043 MSDS, Ultra Coolant English
80440068 MSDS, Ultra Coolant Spanish
80440050 MSDS, Ultra Coolant Portuguese
80442254 MSDS, Xtend Food Grade Coolant English

8 INTELLISYS OPTION
INTELLISYS CONTROL AND INSTRUMENTATION
PRIOR TO STARTING POWER OUT RESTART (Optional)

1. Check coolant level. Add if necessary. If this setting is set to ON, the compressor will automatically restart
when power is returned to the compressor if it was operating when
power was removed.
2. Make sure main discharge valve is open.
POWER OUT RESTART TIME
3. Turn on electrical isolator. The power L.E.D. will illuminate and the If the power out restart setting is set to ON, this is the number of
display will indicate ‘Ready to start’. seconds from the time power is restored until the compressor starts.
The power out restart horn will sound during this time.
WARNING NORMAL STOPPING

Make sure that all protective covers are in place.
1. Press ‘Unloaded Stop’[25]. The compressor will unload then stop.
STARTING
2. Turn off electrical isolator.
Press ‘Start’ [24]. The compressor will start and then load
automatically.

INTELLISYS OPTION 9
EMERGENCY STOP 15 L.E.D.–Set auto restart time.
1. Press ‘Emergency stop button’ [26] and the compressor will stop
immediately. 16 L.E.D.–Select options.
2. Turn off electrical isolator. 17 L.E.D.–Not used.
18 L.E.D.–Not used.
INSTRUMENT PANEL FUNCTION
1 PACKAGE DISCHARGE PRESSURE L.E.D.
This will illuminate when the display indicates the package 19 DISPLAY SELECT BUTTON
discharge pressure. Press to index through compressor operating conditions. The
corresponding L.E.D. will illuminate adjacent to display.
This is used to select alternative status displays (after
2 AIREND DISCHARGE TEMPERATURE L.E.D. approximately 5 minutes, the display defaults to the package discharge
This will illuminate when the display indicates the airend discharge pressure). Depressing this button in the set point routine will cause exit
temperature. to checking machine for 2 seconds, then ready to start.
3 SUMP PRESSURE L.E.D. 20 LOAD/UNLOAD BUTTON

This will illuminate when the display indicates the sump pressure. These are used to manually switch the compressor between a
loaded control mode (e.g. on/off line) and unloaded running.
See L.E.D.
4 SEPARATOR PRESSURE DROP L.E.D.
This will illuminate when the display indicates the separator
pressure drop. 21 SET BUTTON
Depressing this button when the compressor is stopped will enable
entry into the set point routine. When in the set point routine, depressing
5 TOTAL HOURS L.E.D. this button will cause the controller to move on to the next set point
This will illuminate when the display indicates the total compressor setting, saving the new value if one has been entered.
running hours. A warning reset is obtained by depressing this button (while the
machine is running). An alarm reset is obtained by depressing this
button twice within 3 seconds (the alarm condition will remain if the
6 LOADED HOURS L.E.D. indicated fault has not been rectified).
This will illuminate when the display indicates the total loaded
compressor hours.
22 LIQUID CRYSTAL DISPLAY
This indicates the status of the compressor, set up parameters and
7 LOAD/UNLOAD L.E.D.
warning/alarm messages. When the compressor is running, the
This will illuminate when the compressor is running onload.
display will normally show the package discharge pressure.
8 MODULATION L.E.D. 23 ARROW KEYS

This will illuminate when the compressor is running in modulation These are used to index through warning and alarm messages. In
mode. (Note: capacity modulation will occur only if the appropriate the set point routine, these buttons are used to increase/decrease set
regulation pneumatics are fitted to the compressor). point values and enable/disable some operation conditions.
9 UNLOAD L.E.D. The arrow keys are also used to select pressure bands 1 (Y) or 2
This will illuminate when the compressor is running in unload mode. (B) during normal operation of the compressor.
10 ALARM L.E.D. 24 START BUTTON

This will flash when a warning condition exists. The warning This button when depressed will cause the compressor to start and
detected will be displayed and the compressor will continue to run. The load automatically, provided that the controller detects a demand for air.
warning can be reset by depressing set [21]. When pressed in the display mode, it will cause exit to checking
It will illuminate when an alarm condition has occurred. The machine for 2 seconds, then ready to start.
compressor will shutdown immediately. The alarm can be reset by
depressing set [21] twice within 3 seconds.
25 UNLOADED STOP
This button when depressed while the compressor is running, will
OTHER L.E.D.s
unload the compressor (if not already unloaded) for 10 seconds and
These will illuminate during the set point routine to indicate which
then stop. This is the normal method for stopping the compressor. If the
function is being adjusted.
compressor is already stopped, it will execute an L.E.D. check (all the
L.E.D.s should illuminate) and display the controller software revision.
11 L.E.D.–Set off line pressure.
26 EMERGENCY STOP
12 L.E.D.–Set on line pressure. This button when depressed will stop the compressor immediately
and display an emergency stop alarm message.
13 L.E.D.–Select control mode.
14 L.E.D.–Set star delta time.

10 INTELLISYS OPTION
27 POWER L.E.D. AUTOMATIC START/STOP
This will illuminate when the 8V controller supply is available. For plants that have a widely varying plant air demand, larger air
storage capacity, and/or want automatically available stand–by air
capacity, Automatic Start–Stop Control Option is available.
28 AUTOMATIC RESTART L.E.D.
This will illuminate when the machine has shutdown due to low air During periods of low demand, if the line pressure rises to the off line
demand. The compressor will restart and load automatically as soon air pressure set point of the lntellisys® , a timer is energized and begins
as the demand for air resumes. to time out. The automatic restart time is adjustable in a 2–60 minute
range. The timer will continue to operate as long as the plant line
pressure remains above the on line set point of the Intellisys® . If the
DISPLAY MESSAGES timer continues to operate for as long as its adjusted time setting, a
When the compressor is running normally, the display will indicate contact in the lntellisys opens to de–energize the compressor starter
the package discharge pressure and illuminate the corresponding coils. At the same time, a yellow Automatic Restart light on the
L.E.D. [1]. An arrow will also appear in the far right of the display lntellisys® panel is lit and the message AUTO RESTART will be
indicating pressure band selection. Pressing display select [19] will displayed to indicate the compressor has shut down automatically and
change the display value and the corresponding L.E.D. will illuminate. will restart automatically.
The controller monitors all aspects of the compressor while running and The automatic restart will take place when the line pressure drops
will display warnings or in severe conditions execute an emergency to the online set point of the Intellisys® .
stop and display alarm conditions.
To operate in the automatic start/stop mode, proceed with the
following steps:
MACHINE CONTROL MODES
1. Press the SET button until the message AUTO S/S OFF is
CAPACITY CONTROL
displayed.
The compressor is designed to work with two types of capacity
control, to suit the individual plant requirements. These controls are:– 2. Push the up or down arrows to select the auto start/stop function (on
A. On line – Off line. (Fitted as standard) or off). AUTO S/S OFF in the display indicates auto start/stop is
B. On line – Off line, with Upper Range Modulation. (Optional extra) disabled (off). AUTO S/S ON in the display indicates auto start/stop is
Either is available by selection at the control panel. enabled (on). Press the SET button to store function. The display will
flash to acknowledge and then display AUTO S/S 10 MIN.
ON LINE – OFF LINE CONTROL 3. Press the up or down arrows to select the desired automatic restart
For applications that require a widely varying air demand, this time (2–60 min. range). The default value is 10 minutes. Press SET
mode of control will deliver air at full capacity or zero capacity with button to store the value.The display will flash to acknowledge. Press
low receiver pressure. the DISPLAY SELECT button or wait 30 seconds for the controller to
automatically exit the set routine.The display returns to READY TO
START.
This mode of operation is controlled by the pressure transducer
responding to changes in plant air pressure. This sensor energizes 4. Start the compressor and adjust the isolation valve to allow the unit
the load solenoid valve which in turn operates the venting valve to slowly reach the offline pressure and unload.The compressor should
(blowdown) and the closing of the atmospheric vent opening in the run for a minimum of 10 min. and unloaded for the pre–set time and then
air inlet valve. shut down.
5. The compressor should restart automatically when the system air
The compressor then delivers full capacity air to the plant pressure drops below the online air pressure setting.
system. If the air pressure in this system rises to the upper set point
of the pressure setting, the load solenoid valve is de–energized CONTROLLER WARNING MESSAGES
allowing the inlet valve to close. At the same time, the venting valve
opens allowing the receiver pressure to drop. In the event of a warning, the controller will display a message and
the alarm L.E.D. [10] will flash. The warning message will alternate with
the normal display every 4 seconds, the compressor will continue to run
The pressure setting has a range of 12 psi (0.83 bar) between but the fault should be rectified as soon as possible. The arrow keys
its upper and lower set points.The upper set point is set at 3 psi (0.2 [23] should be used to index the display for any additional warning
bar) above the compressor rated discharge pressure. messages. A warning message may be reset by depressing set [21]
once.
UPPER RANGE MODULATION CONTROL (Optional Extra)

For plants having a relatively high and constant air demand, NOTE:
Upper Range Modulation is the recommended mode of control. The warning will recur if the fault has not been rectified. The
following warning messages may be displayed:
Upper range modulation retains the features of On line – Off line

control but provides the throttling of the inlet air flow as the line SEPARATOR ELEMENT
pressure rises to the upper set point of the off–line pressure setting. The separator element is dirty or blocked and should be replaced.
By bleeding off a small amount from the regulator valve, which AIREND TEMPERATURE
energises the Modulate Solenoid Valve, a reduction in the air signal The airend temperature reaches 97% of the high airend
to the pneumatic cylinder on the inlet valve allows the cylinder to temperature set point (i.e. 223 F (106 C)).
‘trim’ the inlet valve position as dictated by changing line pressure.
Modulation begins when the compressor reaches about 94% of the
rated line pressure and is factory set to modulate down to
approximately 70% of rated capacity.
If the air demand decreases to a level below the 70% modulated

output, the line pressure will increase slightly to the upper limit of the
pressure setting, when the compressor then changes to the Off line
control position and operates with the receiver vented.

INTELLISYS OPTION 11
CONTROLLER ALARMS FIELD OPTION/S
In the event of an alarm, the controller will execute an emergency
stop, the alarm L.E.D. [10] will illuminate and an alarm message will be Before installation and operation of this option, these instructions
displayed. The arrow keys [23] should be used to index the display for should be studied carefully to obtain a clear knowledge of the option
any additional alarm messages. An alarm is reset by depressing set and its application to the compressor.
[21] twice within a 3 second period after the fault has been rectified. The
compressor will restart only when all alarm conditions have been
rectified. The following alarm messages may be displayed (For fault REMOTE START/STOP
correction see the Fault Finding section): The Remote Start/Stop Option allows the operator to control the
compressor from a remote mounted start/stop station.Terminal points
STARTER FAULT are provided in connector J1 in the top of the lntellisys controller; one
The contactor sequence during start or stop is incorrect. a connection for a normally closed stop switch (terminals 3 and 4), and
one for a normally open, momentary contact start switch (terminals 5
and 6). Refer to the compressor wiring schematic for specific
AIREND TEMPERATURE connection points.
The airend discharge temperature is above the high temperature
set point. For safety, a selection is available in the lntellisys set–points to
disable the remote start and stop function.This allows the compressor
to be fully controlled by the lntellisys and not from the remote
MOTOR OVERLOAD start/stop station.
The motor overload contacts are open. The motor overload must be
reset before the controller can be reset. If the remote start switch is momentarily closed, the lntellisys
starts the compressor.The remote stop switch is normally closed. If the
remote stop switch opens, the compressor will unload and stop.The
REVERSE ROTATION compressor cannot restart until the remote stop switch has been reset
No sump pressure is detected after the first 2 seconds of running. to a closed position. (EMERGENCY STOP will display on the
Isolate the machine and reverse the mains supply connections before lntellisys if the stop switch is not closed).
resuming.
To operate in the remote start/stop mode, proceed with the
following steps:
OVER PRESSURE
The line pressure is 15 psi (1 bar) greater than the rated discharge 1. Press the SET button until the message REMOTE S/S OFF is
pressure. displayed.
2. Push the up or down arrows to select the remote start/stop function
TEMPERATURE SENSOR 1 (on or off). REMOTE S/S OFF in the display indicates remote start/stop
The airend temperature sensor/ connecting cable has failed. is disabled (off). REMOTE S/S ON in the display indicates remote
start/stop in enabled (on). Press the SET button to store the function.
The display will flash to acknowledge. Press the DISPLAY SELECT
TEMPERATURE SENSOR 2 button or wait 30 seconds for the controller to automatically exit the set
The separator tank temperature sensor/connecting cable has routine.The display returns to READY TO START.
failed.
3. Start the compressor with the Start button on the Intellisys control
panel.The compressor must be started locally first before the Remote
PRESSURE SENSOR Start/Stop buttons are activated by the lntellisys.
Indicates pressure transducer failure / connecting cable fault.
FAILED CALIBRATION
During calibration routine, a 10% of scale error has been detected.
Ensure that the separator is completely blowndown and repeat
calibration.
CONTROL POWER LOSS

The 48Vac signal is not present at the controller.
REMOTE START FAILURE

Momentary remote start has not disengaged before star–delta
transition. This alarm is active only if the remote start/stop is enabled.
REMOTE STOP FAILURE

The momentary remote stop switch has not disengaged when the
start signal is received. This alarm is active only if the remote start/stop
is enabled.
EMERGENCY STOP
The emergency stop button is engaged.
LOW SUMP PRESSURE

The sump pressure drops below 15 psi (1 bar) during normal
operation.

ELECTRICAL SCHEMATIC – DOL WITH INTELLISYS CONTROL

INTELLISYS – DOL
Revision D
32343956

KEY
CON Controller, INTELLISYS NOTES

CPT Transformer, control 1. Approved fused disconnect or circuit breaker per code
EDV Valve, electric drain requirements must be provided by customer.
E–STOP Button, emergency stop 2. Dashed lines represent wiring by customer.
FU Fuse 3. Sizing of electrical components not supplied by Ingersoll Rand is
M Contactor (main) the responsibility of the customer and should be done in
accordance with the information on the compressor data plate
1M Coil, motor starter
and local electrical codes.
OL Overload, motor starter
4. Unit will not restart automaticlly after power outage, except with
1SV Valve, solenoid (load) N.C additional PORO option.
3SV Valve, solenoid (blowdown) N.O
5. Circuit shown in normal position de–energized.
10SV Valve, solenoid (line / sump) N.C
6. All wiring to be in accordance with local codes.
RST Remote start
(Optional)
RSP Remote stop
(Optional)
CFO Common fault output
PORO Power out restart (Optional)
2ATT Temperature sensor
3APT Pressure sensor

ELECTRICAL SCHEMATIC – STAR DELTA WITH INTELLISYS CONTROL

INTELLISYS – STAR DELTA
Revision E
32343931

KEY
CON Controller, INTELLISYS NOTES

CPT Transformer, control 1. Approved fused disconnect or circuit breaker per code
EDV Valve, electric drain requirements must be provided by customer.
E–STOP Button, emergency stop 2. Dashed lines represent wiring by customer.
FU Fuse 3. Sizing of electrical components not supplied by Ingersoll Rand is
1M Contactor (main) the responsibility of the customer and should be done in
accordance with the information on the compressor data plate
2M Contactor (delta)
and local electrical codes.
OL Overload, motor starter
4. Unit will not restart automaticlly after power outage, except with
1SV Valve, solenoid (load) N.C additional PORO option.
3SV Valve, solenoid (blowdown) N.O
5. Circuit shown in normal position de–energized.
10SV Valve, solenoid (line / sump) N.C
6. All wiring to be in accordance with local codes.
RST Remote start
(Optional) 7. Blue – 16 Volts AC
RSP Remote stop

(Optional)
CFO Common fault output
PORO Power out restart (Optional)
2ATT Temperature sensor
3APT Pressure sensor
1S Contactor (wye / star)

16
3SV
20
6SV
40
MODULATION (OPTION)
UP6 15, UP6 20, UP6 25, UP6 30

41
5SV
1SV
42
39
3
19
INTELLISYS OPTION
11
12
PIPING AND INSTRUMENTATION WITH INTELLISYS CONTROL
21 17
22
16 P
5
T 10
M
8
1 6 7 9
4
CONTINUED IN NEXT PAGE
2 34
18 32
33
PIPING LEGEND
INTELLISYS (OPTION)
A REPLACES 12
B
C 10SV
D
14 T
E 13
F INTELLISYS (OPTION)
REPLACES 10 AND 11
15 85584282
Revision D
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FROM PREVIOUS PAGE

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31
29
AIR RECEIVER (OPTION)
INTEGRAL DRYER (OPTION)
KEY
1. Filter, air 26.Filter, Refrigerant

2. Valve, inlet 27.Expansion Valve
3. Valve, solenoid (load) 28.Indicator, Dew Point
4. Airend assembly 29.Condensate Drain Valve
5. Motor 30.Receiver, Air
6. Tank, separator, Coarse 31.Auto Drain Valve
7. Separator, Fine 32.Valve, Solenoid 10sv (Line/Sump)
8. Valve, minimum pressure 33.Transducer, Pressure
9. Aftercooler 34.Sensor, Temperature
10.Gauge, pressure 35.Moisture Separator
11.Switch, discharge pressure 36.Filter, Air

37.3 Way Valve, Bypass
12.Switch, temperature
38.Valve, Isolation
13.Filter, coolant
39.Valve, Solenoid 5sv (Modulation)
14.Thermostat
40.Valve, Solenoid 6sv (Modulation)
15.Cooler
41.Valve, Shuttle
16.Relay, overload Motor
42.Valve, Modulation
17. Valve, safety
18. Valve, Drain A Air/Coolant
19. Screen, Scavenge B Air
20. Valve, Solenoid 3sv (Blowdown)
C Coolant
21. Orifice
D Condensate
22. Indicator, Air Filter Restriction
E Component boundary
23.Refrigerant Compressor
F Refrigerant
24.Evaporator
G Option
25.Condenser

INTELLISYS CONTROL AND INSTRUMENTATION DIAGRAM
KEY
1. Tank, separator 10.Valve, solenoid (Load)

2. Transducer, pressure 11.Indicator air filter
3. Valve, solenoid (Line / Sump) 12.Nipple
4. Connector 13.Adaptor
5. Combination block 14.Intake valve assembly
6. Elbow
7. Tee, male run NOTES:
8. Reducer bushing A. Tubing 3/8 inch
9. Valve, solenoid (Blowdown) B. Tubing 1/4 inch

INTELLISYS PARTS – INSTRUMENTATION AND ELECTRICAL SYSTEM
Item ccn Qty. Description Item ccn Qty. Description
1 39124813 AR Tube (Nylon) 22 96743992 4 Screw

2 39155460 1 Elbow 23 39495874 1 Gasket
3 39853809 1 Transducer 24 96742754 2 Screw
4 22107833 1 Bracket 25 22055909 1 Tee
5 92877018 5 Gland, cable 26 22177190 1 Cabinet door
6 39124821 AR Tube (Nylon) 27 39133467 3 Mount
7 54654652 1 Valve, solenoid (Blowdown) 28 22177315 1 Gasket, door
8 39155650 2 Elbow 29 22131155 1 Decal, controller
9 54774302 1 Valve, solenoid (Load) 30 22137848 1 Sensor, temperature
10 54755426 1 Bracket 31 39404157 1 ‘O’ Ring
11 95944625 2 Bushing 32 22113344 1 Button, emergency stop
12 39155577 4 Elbow 33 22289797 1 Valve, solenoid (line/sump)
13 93492072 2 Seal *34 39192000 4 Grommet
14 22177174 1 Cabinet 35 39156393 1 Connector
15 96737564 14 Nut 36 39156419 1 Connector
16 96743182 8 Screw 37 54774997 1 Bush
17 85584340 4 Latch 38 39404165 1 ‘O’ Ring
*18 92829308 1 Key 39 22131148 1 Decal
19 96703756 2 Nut 40 39155478 1 Elbow
20 22128763 1 Controller, INTELLISYS * Not illustrated
21 22091193 2 Hinge
INTELLISYS PARTS – C37 FULL VOLTAGE – DOL 60Hz – 575V 15/30hp
1 – 14 32342123 1 Lug, power grounding

2 39252937 4 Block, end stop 15 22113351 1 Panel
3 39164520 1 Block, terminal *16 39191648 1 Plug
11 position
4 39252903 27 Block, terminal
*17 39191655 1 Plug
5 39252911 1 Block, terminal ground 16 position
6 22114623 1 Bracket
*18 39186101 1 Plug
7 32342115 1 Bus, grounding 4 position
8 22132963 1 Contact, auxilliary *19 39191630 1 Plug

5 position
9 39251061 1 Contactor – C37
*20 39186093 1 Plug
10 22074033 3 Fuse 6 position
2.0A 125–250V
21 22056741 2 Rail
11 32342099 2 Fuse
1.5A 600V 22 23053754 1 Relay, overload
12 39479035 1 Fuse, holder 23 39491519 1 Transformer
13 39480504 1 Fuse, holder * Not illustrated

INTELLISYS PARTS – C43 FULL VOLTAGE – DOL 60Hz – 230/460V 15hp

11 position
*17 39191655 1 Plug
6 22114623 1 Bracket
*18 39186101 1 Plug

5 position
9 39250998 1 Contactor – C43
*20 39186093 1 Plug
2.0A 125–250V
21 22056741 2 Rail
11 32342099 2 Fuse

INTELLISYS PARTS – C85 FULL VOLTAGE – DOL 60Hz – 200V 15–25hp / 230/460 20–30hp

11 position
*17 39191655 1 Plug
6 22114623 1 Bracket
*18 39186101 1 Plug

5 position
9 39251020 1 Contactor – C85
*20 39186093 1 Plug
2.0A 125–250V
21 22056741 2 Rail
11 32342099 2 Fuse

INTELLISYS PARTS – D110 FULL VOLTAGE – DOL 60Hz – 200V 30hp
24 10 9 9 9 11 15 7
10
12
13
6
5
16
23
22
32343980 5
Revision D
*1 22113344 1 Assembly, emergency stop *14 39191648 1 Plug

11 position
push button
15 32342123 1 Lug, power grounding
2 39252937 2 Block, end stop
16 22050140 1 Panel
16 position
5 22630727 1 Kit, terminal
*18 39186101 1 Plug
6 22114623 1 Bracket
4 position
7 32342115 1 Bus, grounding
*19 39191630 1 Plug
8 22264873 1 Contactor – D110 5 position
9 22074033 3 Fuse *20 39186093 1 Plug
2.0A 125–250V 6 position
10 32342099 2 Fuse 22 22056741 1 Rail
1.5A 600V
23 39251095 1 Relay,overload
11 39479035 1 Fuse, holder
24 39491519 1 Transformer
12 39480504 1 Fuse, holder
* Not illustrated
13 1 Label

INTELLISYS PARTS – C60/C43 STAR/DELTA – 60Hz – 200V 25/30hp, 220/230V – 30hp

11 position
*19 39191655 1 Plug
6 22114623 1 Bracket
*20 39186101 1 Plug

5 position
9 39250998 1 Contactor – C43
*22 39186093 1 Plug
10 39251004 2 Contactor – C60 6 position
11 22074033 3 Fuse 23 22056741 2 Rail
2.0A 125–250V
24 23053770 1 Relay, overload
12 32342099 2 Fuse
1.5A 600V 25 39203443 1 Suppressor
15 39333257 1 Interlock

INTELLISYS PARTS – C23/16 STAR/DELTA – 60Hz – 440/460V – 20/25hp, 575V – 25/30hp

11 position
*18 39191655 1 Plug
6 22114623 1 Bracket
*19 39186101 1 Plug
8 22074413 1 Contactor – C16 *20 39191630 1 Plug

5 position
9 39252036 2 Contactor – C23
*21 39186093 1 Plug
2.0A 125–250V
22 22056741 2 Rail
11 32342099 2 Fuse
12 39479035 1 Fuse, holder 24 39203443 1 Suppressor
14 39333257 1 Interlock * Not illustrated

INTELLISYS PARTS – C23/23 STAR/DELTA – 60Hz – 380V 20hp
1 – 15 22113351 1 Panel
2 39252937 4 Block, end stop *16 39191648 1 Plug
11 position
*17 39191655 1 Plug
4 39252903 30 Block, terminal 16 position
5 39252911 1 Block, terminal ground
*18 39186101 1 Plug
6 22114623 1 Bracket 4 position
7 32342115 1 Bus, grounding *19 39191630 1 Plug

5 position
8 39252036 3 Contactor – C23
*20 39186093 1 Plug
2.0A 125–250V
21 22056741 2 Rail
10 32342099 2 Fuse
11 39479035 1 Fuse, holder 23 39203443 1 Suppressor
13 39333257 1 Interlock * Not illustrated
14 32342123 1 Lug, power grounding

INTELLISYS PARTS – C43/37 STAR/DELTA – 60Hz – 200V 20hp, 220/230V – 25hp

11 position
*19 39191655 1 Plug
6 22114623 1 Bracket
*20 39186101 1 Plug

5 position
9 39251061 1 Contactor – C37
*22 39186093 1 Plug
11 22074033 3 Fuse 23 22056741 2 Rail
2.0A 125–250V
12 32342099 2 Fuse
1.5A 600V 25 39203443 1 Suppressor
15 39333257 1 Interlock

INTELLISYS PARTS – C37/23 STAR/DELTA – 60Hz – 220/230V – 15–20hp, 440/460V – 30hp

11 position
*19 39191655 1 Plug
6 22114623 1 Bracket
*20 39186101 1 Plug

5 position
9 39252036 1 Contactor – C23
*22 39186093 1 Plug
11 22074033 3 Fuse 23 22056741 2 Rail
2.0A 125–250V
12 32342099 2 Fuse
1.5A 600V 25 39203443 1 Suppressor
220/230V & 440/460V
14 39480504 1 Fuse, holder
* Not illustrated
15 39333257 1 Interlock

INTELLISYS PARTS – C37/23 STAR/DELTA – 60Hz – 380V – 25/30hp

11 position
*19 39191655 1 Plug
6 22114623 1 Bracket
*20 39186101 1 Plug

5 position
9 39252036 1 Contactor – C23
*22 39186093 1 Plug
11 22074033 3 Fuse 23 22056741 2 Rail
2.0A 125–250V
12 32342099 2 Fuse
1.5A 600V 25 39203443 1 Suppressor
380V
14 39480504 1 Fuse, holder
* Not illustrated
15 39333257 1 Interlock

ASSEMBLY, STARTER C23/C16 60Hz SD (INTELLISYS) 575V
26 12 11 11 11 9 15 3
12
10
4
22
24
24
2
I-R PART
NUMBER AND
REV LEVEL
13
8
24
22
7
24
25
23
14
16
22650550
Revision B
1 - - - 15 32342123 1 Lug, Grounding

2 39252903 30 Block, Terminal 16 22113351 1 Panel
3 39164520 1 Block, Terminal 17 39191648 1 Plug, 11 Position
4 39252911 1 Block, Terminal GND. 18 39191655 1 Plug, 16 Position
5 22114623 1 Bracket, Fuse Block 19 39186101 1 Plug, 4 Position
6 32342115 1 Bus, Grounding 20 39191630 1 Plug, 5 Position
7 22074413 1 Contactor, C16 21 39186093 1 Plug, 6 Position
8 39252036 2 Contactor, C23 22 22056741 2 Rail, Din
9 39479035 1 Fuse, Holder 23 23053739 1 Relay, Overload
10 39480504 1 Fuse, Holder 24 39252937 4 Stop, Din Rail
11 22074033 3 Fuse, 125-250V 2.0A 25 39203443 1 Suppressor, Arc
12 32342099 2 Fuse, 600V 1.5A Primary 26 39491519 1 Transformer, Control Multi-
13 39333257 1 Interlock, Mechanical
14 1 Label, UL & CUL

DRYER OPTION 31
The UP series integrated dryer is not for use with the low ambient STOPPING THE DRYER
or outdoor module options.
a) Use the switch to stop the dryer (Fig.2b).
b) Stop the dryer at least 2 minutes after shutting down the air
INSTALLATION
compressor or interrupting the air flow to the dryer.
a) Do not obstruct the dryer air grilles. Compressed air must never enter the dryer when the dryer is switched
b) Allow sufficient gap around the unit to facilitate maintenance and off or when it is in an alarm situation which stops the refrigeration
ensure unimpeded air discharge from the condenser. compressor. The dryer can be bypassed in these conditions.
c) Avoid recirculation of hot condenser air back into the condenser air OPERATION
inlet. The dryer operates automatically. It is factory set for a dew point of
d) Do not connect condensate drains common to other pressurized 37 F (3 C) (ISO7183, Part 2) and therefore requires no further
drain lines in a closed circuit. Make sure the outflow from the condensate calibration.
drains is unimpeded. Connect the condensate piping in such a way to
For maximum performance from your dryer, follow the maintenance
ensure that sound levels are kept to a minimum during drainage.
Ensure that all condensate is disposed of in a responsible manner, in schedule.
accordance with local norms concerning environmental protection. The dewpoint thermometer gives an indication of performance of the
dryer. When the dryer is switched off at ambient conditions, it displays
e) The ambient air around the dryer and compressor must not contain
red. In normal conditions it should be operating in the green region. If the
solid or gaseous contaminants. All compressed and condensed gases
unit continues to operate in the red region, contact your local
can generate acids or chemical products which may damage the
compressor or components inside the dryer. Ingersoll Rand representative.
Take particular care with sulphur, ammonia, chlorine and installations in
Fig.1 shows the dryer’s refrigeration and air circuits.
marine environments. For further advice or assistance consult your local
Ingersoll Rand representative.
ELECTRICAL CONNECTION
The dryer is powered from single–phase that must be supplied
separately from the compressor three–phase supply. The dryer should
be connected to a single phase supply in accordance with local
requirements and codes.
CONDENSATE DRAINS
The dryer package is equipped with three automatic condensate float
drains in the moisture separator, the dryer’s compressor, and the
post–filter. Each float drain has a drainage port near the compressed air
outlet on the package.
THESE LINES MUST BE KEPT SEPARATE. Joining them will cause
improper operation.
START–UP AND OPERATION
Preliminary checks
Before starting the compressor, make sure that:
The power supply is correct for the dryer voltage.
Starting the dryer
a) Use the green switch to start the dryer (Fig.2b).

b) To protect dryer equipment, always start up the dryer before
activating the air compressor.
c) Wait about 5 minutes until the dryer is running at the correct operating
temperatures and pressures before starting the compressor. In order to bypass the dryer, stop the UP compressor and lock and tag
it out. Turn BOTH valves to a horizontal position, as shown. The
d) Always leave the dryer running while the air compressor is operating, compressor can be run and the dryer can be removed from the system
irrespective of load condition. for repair in bypass mode.
After stopping the dryer, wait at least 3 minutes before starting it again. Do not operate with valves in positions other than those shown here. This
may pressurize dryer with no air flow.

32 DRYER OPTION
MAINTENANCE MOISTURE SEPARATOR MAINTENANCE

Before accessing live electrical parts, disconnect the power supply to the The moisture separator will operate indefinitely under normal working
dryer using disconnect switch or disconnect the cable connections. conditions, however at some time it may be necessary to replace the
seals should the housing leak.
Preventive maintenance
1. Isolate the housing from the air supply.
For optimum performance from your dryer, follow the periodic
maintenance schedule described below. 2. Fully depressurize in drain bowl as appropriate.
3. Unscrew bowl and remove. If pressure has not been completely
CONDENSATE DRAINS released from the housing, air will escape from the warning hole giving
WEEKLY
Verify that the condensate drains an audible alarm. Screw back bowl and repeat instruction 2 before
attempting again. Should resistance to unscrewing be experienced,
are operating correctly.
provision is made for a ’C’ spanner to fit onto the ribs of the bowl.
MONTHLY COMPRESSOR
Make sure the refrigerant 4. Check condition of bowl seal and replace if necessary. Clean screw
compressor temperature is below threads.
140 F (60 C) when running. 5. The autodrain assembly is not serviceable and must be replaced if
EVERY 4 MONTHS CONDENSER faulty.
Remove any dust from the
6. Refit bowl with ’O’ ring seal.
condenser fins.
COMPRESSOR 7. Repressurize and check for leaks. If leaks occur they will most
Make sure compressor power probably be from the bowl ’O’ ring. Depressurize housing and remove ’O’
consumption complies with data ring as stated above and inspect and clean. Ensure that mating surfaces
plate specifications. are clean and then refit ’O’ ring and repressurize.
YEARLY CONDENSATE DRAINS

Completely disassemble the
drains and clean all their
components.
AIR FILTER
Replace air filter element.
Auto – drain assembly
AIR FILTER MAINTENANCE

In order to ensure optimum compressed air quality the filter element
should be replaced as follows. (Used filter elements must be disposed
of in accordance with local regulations.)
Use only genuine Ingersoll Rand replacement elements.
2
1
> 30s
4 5
0 bar 0 bar
0 psi 0 psi

DRYER OPTION 33
5 6
RECYCLING DISASSEMBLY
1 Frame and panels Steel / epoxy resin polyester
Heat exchanger (cooler) Copper
Pipes Copper
Drainage system Polyamide
7 8 Heat exchanger insulation EPS (polystyrene sintered)
Pipe insulation Gum synthetic
Compressor Steel / copper / aluminium / oil
Condenser Steel / copper / aluminium
Refrigerant R134a
0 bar
0 psi
Valve Brass
9 10
Electrical cable Copper / PVC
REFRIGERANT LEAKS IN THE REFRIGERATION CIRCUIT

2
1
The unit is dispatched in perfect working order, already charged.
0 bar
Refrigerant leaks may be identified by tripping of the compressor
0 bar
0 psi 0 psi
overload protector (SK).
12
IF A LEAK IS DETECTED IN THE REFRIGERANT CIRCUIT, SEEK
1
TECHNICAL ASSISTANCE.
2
REFRIGERANT CHARGING
THIS OPERATION MUST ONLY BE PERFORMED BY A
REFRIGERANT SPECIALIST.
WHEN REPAIRING THE REFRIGERANT CIRCUIT, COLLECT ALL
THE REFRIGERANT IN A CONTAINER AND DISPOSE OF IT IN THE
APPROPRIATE MANNER.
CHARACTERISTICS OF REFRIGERANT R134A
In normal temperature and pressure conditions the above refrigerant is
DISASSEMBLING THE UNIT a colorless, class A1/A1 gas with TVL value of 1000ppm (ASHRAE
classification).
The unit has been designed and constructed to guarantee continuous
If a refrigerant leak occurs, thoroughly air the room before commencing
operation.
work.
The long service life of some components such as the fan and
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
be recovered in compliance with current norms in the country where the
machine is installed.

34 DRYER OPTION
REFRIGERANT CIRCUIT
Cod. 713.0007.13.00 – Rev. 00

Model UP6 15-20 HP
UP5 11-15 KW
Cod. 713.0057.07.00 – Rev. 00

Model UP6 25-30 HP
UP5 18-22 KW
Condensate drain Refrigerant line
Air inlet Compressed air line
Air outlet Condensate drain line
Equalization line

DRYER OPTION 35
LEGEND
Pos. DESCRIPTION K1 Contactor switch

1A1 Electronic Controller K2 Fan contactor switch
1B1 Drain solenoid valve coil PCP Thermal protection
1M1 Refrigerant compressor PR Air-air heat exchanger
1M2 Fan Motor PSC Air-air heat exchanger (D__IT)
1P1 High pressure Switch RBF Tap with strainer
1P2 Fan pressure Switch RR Rotalock cock
1Q1 Compressor circuit breaker RT1 - RT4 Temperature probes
1Q2 Fan circuit breaker SC Heat exchanger base
1S1 Main power switch SCO Condensate separator
1S2 Plug SLI Liquid separator
1T1 Transformer SSC Condensate drain
1V1 Solenoid drain Valve TEMP Time setter
CB Compressor box TH Time setter
CBL Cables TLT Remote cont. Thermostat
CND Condenser VB By-pass hot gas valve
CNV Fan capacitor VE Expansion valve
CPL Capillary tube VNR One way valves with strainer
EB Electrical box VT Fan blade
ED 10 micron filter element X1-X2, X3-XM Terminal blocks
EH 0.01 micron filter element

EP 1 micron filter element
EQ 5 micron filter element
EVA Evaporator
F1-F2 Fuses
FD Air filter 10 micron
FF Filter dryer
FH Air filter 0.01 micron
FP Air filter 1 micron
FQ Air filter 5 micron
FR Drain screen
FV Fan motor fuse
G Grid
IM Moisture indicator

36 DRYER OPTION
WIRING DIAGRAM
Cod. 714.0172.01.00 – Rev. 00

Models UP6 15 – 30 HP (115V/1Ph/60Hz)

DRYER OPTION 37
DATA SHEET
MODEL UP6 15-20 HP UP6 25-30 HP
AR CFM 83 125
AIR FLOW RATE* m3/h 140 212
POW SUPPY VOLT/PH/HZ 115/1/60
1M1 HP 2/3 3/4
COMPRESSOR kW 0.71 0.83
Max kW 1.14 1.37
RLA 8.16 9.69
FLA 11.6 14
LRA 46 54
1M2 QTY 1 1
FAN MOTOR HP 1/46 1/20
RLA 1.00 1.60
LRA 1.36 2.10
TOTAL A A 9.2 11.3
CONNECTION NPT 3/4” 3/4”
AIR T °F 104
°C 40
AIR T MAX °F 162
°C 72
AMB T °F 77
°C 25
AMB T MIN-MAX °F 36 – 122
°C 2 – 50
AIR W PRESS psi 123
bar 8.5
AIR PRESS MAX psi 203
bar 14
DEW POINT* °F < 50 (ISO CLASS 6)
°C < 10 (ISO CLASS 6)
REF. TYPE R134a
REFRIGERANT LB 0.99 1.65
OZ 15.9 26.46
KG 0.45 0.75
W LB 138 147
WEIGHT KG 63 67
EVAP. TEMP.* °F 37 – 41
°C 3–5
SUCTION TEMP.* °F 39 – 64
°C 4 – 18
DISCH. PRESS.* psig 170 - 230
Bar 12 – 16
HP SWITCH SETTING psig 435
Bar 30
FAN SWITCH SETTING psig 123 – 160
Bar 8,5 – 11
THERMOSTAT SWITCH °F 212 239
SETTING °C 100 115
*Rating conditions of: 40°C (104°F) and 123 psig Ai r Inlet, 25°C (77°F) Ambient temperature
*Conditions de fonctionnement de: 40°C (104°F) et 1 23 psig air en entrée, 25°C (77°F) température ambi ant
Performance and specifications - Performances et caractéristiques techniques + / -5%

38 DRYER OPTION
LEGEND
POS. DESCRIPTION POS. DESCRIPTION

AR Air flow rate AIR PRESS MAX Max. air pressure
POW SUPPY Power supply DEWP Pressure dew point
HP Nominal power REF. Refrigerant
kW Nominal consumption MAX FUSE Max fuse size
Max kW Full load consumption MINCIRCUIT Minimum circuit
RLA Nominal Current AMPACITY ampacity
FLA Full load current W Weight
LRA Locked rotor current EVAP. TEMP. Evaporation
TOTAL A Total current Temperature
CONNECTION Air connections SUCTION TEMP. Suction Temperature
AIR T Air inlet temperature DISCH. PRESS. Discharge Pressure
AIR T MAX Max. air inlet temperature HP SWITCH SETTING High pressure switch
AMB T Ambient temperature setting
AMB T MIN-MAX Min-Max. ambient THERMOSTAT SWITCH Thermostat switch
temperature SETTING setting
AIR W PRESS Air working pressure
DRYER DIMENSIONS
826 (32.52”)
23 (0.91”)
600 (23.62”)
103 (4.07”)
125 (4.92”)
AIR IN
413 (16.28”)
AIR OUT
100 (3.94”)
576 (22.67”) 250 (9.85”)

145 (5.71”)
210 (8.27”)

DRYER OPTION 39
CALIBRATION
Notes:
The dryer is supplied factory set and therefore requires no further 1. Electrical data refers to dryer only.
calibration. 2. The dryer requires a separate power supply from the compressor
drive.
ENGINEERING DATA 3. Rated at:
Working Pressure (psig) 100

Compressor UP6 15 - 30
Inlet Air Temperature ( F) 100
Maximum operating 125 150 200
pressure psig (bar) (8.62) (10.34) (13.79) Ambient Temperature ( F) 100
Factory set reload 110 135 185 100
Relative Humidity (%)
pressure psig (bar) (7.58) (9.31) (12.76)
Notes on the use of the Schrader non–return valve.
Model ATTENTION
UP6 15 UP6 20 UP6 25 UP6 30
1. This unit is equipped with refrigerant as for quantity and kind clearly
Pressure Dew Point ( F) 38 shown in operating manual and with identification label.
(see note 3. below)
2. Any ordinary test and / or refrigerant recharge by means of
Base–Mounted Dryer 1367 1411 1451 1537 connections can take place only after refrigerant evacuation. The
Package Weight (lb) evacuation must be proportional to dimensions and length of the
120 Gallon Tank Dryer 1691 1735 1775 1861 connections used. The use of the valve can be justified only when the
Package Weight (lb) dryer is not in working order.
240 Gallon Tank Dryer 1960 2004 2044 2130 3. During the unit guarantee period, the Schrader valve can be used by
Package Weight (lb) authorized staff only, otherwise any damage caused by a wrong
Electrical Supply 115V / 1ph / 60Hz refrigerant recharge will invalidate warranty.
(+/– 10%) (AC)
(see note 2. below)
L.R.A. Current (Amps) 45.0 45.0 48.8 48.8
F.L.A. Current (Amps) 9.6 9.6 12.3 12.3
Total Installed Power (kW) 0.96 0.96 1.19 1.19
Electrical Protection Class NEMA 1 (IP20)

(Std.)
Refrigerant Type 134a

40 DRYER OPTION
BASE MOUNTED UNITS
317.3 (12.5)
596.3 (23.5) 165
49
600
413.5
KEY
A Pre filter H Button, emergency stop
B Compressor and cooling air intake I Primary compressor service door

J 0.25 inch BSPT moisture separator drain
C Starter box
K 0.25 inch BSPT dryer drain
D Cooling air exhaust
L 0.25 inch BSPT air filter drain
E 1.00” BSPT air discharge
M 1.00 inch NPT plug
E 1.00” NPT air discharge N Dryer air inlet
F Customer power inlet O Dryer air exhaust
G Fork lift openings P Filter restriction indicator
Fork lift hole covers must be installed after unit is in place to Q Dryer On/Off switch
reduce noise and ensure proper cooling of package)
R Dew point indicator

DRYER OPTION 41
TANK MOUNTED (120 GALLON)
60 Hz UNITS
KEY
A Pre filter L Primary compressor service door
B Compressor and cooling air intake M Inspection port

N Dryer air inlet
C Starter box
O Dryer air exhaust
P 0.25 inch BSPT moisture separator drain
Q 0.25 inch BSPT dryer drain
F Customer power inlet R 0.25 inch BSPT air filter drain
G Fork lift openings S 1.00 inch NPT plug
H Air receiver (120 gallons) T Filter restriction indicator
I Automatic drain valve W Dryer On/Off switch
J Valve, drain X Dew point indicator
K Button, emergency stop

42 DRYER OPTION
TANK MOUNTED (240 GALLON)
60 Hz UNITS
KEY
A Pre filter L Primary compressor service door
B Compressor and cooling air intake M Inspection port

N Dryer air inlet
C Starter box
O Dryer air exhaust
P 0.25 inch BSPT moisture separator drain
Q 0.25 inch BSPT dryer drain
F Customer power inlet R 0.25 inch BSPT air filter drain
G Fork lift openings S 1.00 inch NPT plug
H Air receiver (240 gallons) T Filter restriction indicator
I Automatic drain valve W Dryer On/Off switch
J Valve, drain X Dew point indicator
K Button, emergency stop

DRYER OPTION 43
ELECTRO – PNEUMATIC CONTROL AND INSTRUMENTATION DIAGRAM
KEY
1 Valve, isolation 12 Evaporator

2 Valve, three way bypass 13 Refrigerant compressor
3. Filter, air
4 Moisture separator
5. Valve, autodrain A Air/Coolant
6 Receiver, air B Air
7. Valve, drain C Coolant
8. Indicator, dew point colour D Condensate
9 Valve, expansion E Component boundary
10 Filter, refrigerant F Refrigerant
11.Condenser G Option

44 DRYER OPTION
27
43
27
42
41
1 23320955 1 Dryer 7B 96705058 2 Setscrew

60Hz – 15- 20HP
8 22100556 1 Bracket
23335631 1 Dryer
60Hz – 25-30 HP 9 22097968 1 Panel
10 95937538 4 Connector
2 22067292 1 Panel
11 85565182 1 Filter, air
3 22100648 1 Bracket
60Hz 12 92368687 14 Setscrew
4 23321920 1 Panel 13 85560985 1 Hose assembly
5 95937520 1 Connector 14 22099295 1 Panel
60HZ
15 95954269 1 Tee
6 22100549 1 Tube assembly
16 22098750 1 Valve, ball
7 22070304 1 Bracket
17 95953576 2 Nipple
7A 96737564 2 Nut
18 95996153 2 Connector

DRYER OPTION 45
27
43
27
42
41
19 22097869 1 Cover 30 85561215 1 Hose assembly

20 85560275 1 Hose assembly 31 95937645 1 Elbow
21 95937637 1 Elbow 32 22101414 AR Tube (Nylon)
22 22097588 1 Valve, ball 33 39155577 1 Elbow
23 96742689 6 Setscrew 34 85583367 1 Grommet
24 96742689 AR Screw 35 39124813 AR Tube (Nylon)
24A 96742689 AR Plug 36 54514583 3 Fitting
25 95937652 1 Elbow 37 22132971 2 Adaptor
26 22070825 1 Tube assembly 38 95928040 2 Nipple
27 95937520 3 Connector 39 39155478 1 Elbow
28 22101083 1 Separator, water 40 37143542 3 Elbow
29 22098859 1 Connector

46 DRYER OPTION
ADDITIONAL SPARE PARTS FOR DRYER OPTION
CCN DESCRIPTION
38457636 SCREEN, DRAIN
38457461 COMPRESSOR, REFRIGERANT 115V - 15/20HP (11/15KW)

* 38461364 COMPRESSOR, REFRIGERANT 115V - 25/30HP (18/22KW)
* 38461471 FAN MOTOR - 16W, 115V
38461497 FAN MOTOR - 16W, 230V
38461463 FAN MOTOR - 34W, 115V
38461505 FAN MOTOR - 34W, 230V
38461372 FAN BLADE
38459665 DRAIN SOLENOID VALVE - 115V
38457537 DRAIN SOLENOID VALVE - 230V
38459723 RELAY
38461380 THERMOMETER
38461398 FAN PRESSURE SWITCH
*
* 38461406 HIGH PRESSURE SWITCH
38461414 TIMER
38457826 ON/OFF SWITCH
* 38457602 DEHYDRATING FILTER
* 38461422 FILLING GAS VALVE
* 38461430 HEAT EXCHANGER - 15/20HP (11/15KW)
* 38461448 HEAT EXCHANGER - 25/30HP (18/22KW)
* 38459186 CONDENSER - 15/20HP (11/15KW)

* 38461455 CONDENSER - 25/30HP (18/22KW)
* 38461356 BY-PASS VALVE
* Must have EPA certified technician to order.
AUTOMATIC DRAIN MANUAL DRAIN
Model Filter
Element
BSPT NPT
85564664 85565182 85565703

85566404 85566412
85566446

HIGH DUST FILTER OPTION 47
5
4
4
10
10
1 36897999 1 Filter 6 96712153 2 Screw

2 35393685 1 Element, air filter 7 22155345 1 Hose
3 22245534 1 Bracket 8 22153647 2 Pipe
4 95340683 4 Clamp 9 92368687 2 Screw
5 89295935 2 Hose 10 23411135 2 Clamp, Bridge

48 OUT DOOR MODULE OPTION
1 22134597 1 Cover 4 22127328 1 Box

2 22127500 1 Louvre 5 22053730 1 Louvre
3 92368687 AR Screw

PORO OPTION – ELECTRO–PNEUMATIC 49
POWER OUTAGE RESTART OPTION
For customers that have interruptions in their incoming power supply
to the compressor and must maintain an uninterrupted supply of
compressed air, the Power Outage Restart Option allows a
compressor to restart automatically 10 seconds (adjustable) after
incoming power is restored.
FUNCTION TEST
To test the operation of the Power Outage Restart Option:
1. Slowly open the main isolation valve.
2. Start the compressor.
3 The compressor will load automatically if there is sufficient demand
for air. Allow the compressor to load.
4. Open the main disconnect to remove power from the compressor.
5. Close the main disconnect to reapply power to the compressor. The
horn will sound for ten seconds; then the compressor will start
automatically.


PORO OPTION – ELECTRO–PNEUMATIC 51
PARTS LIST FOR POWER OUTAGE RESTART OPTION
(P/N 22396600)
ITEM PART NUMBER QUANTITY DESCRIPTION
1 22113344 1 Button, emergency stop
2 35266788 8 Tie, cable
3 22265946 1 Contact, auxilliary
4 22396592 1 Controller, LOGIC PORO
5 22140545 1 Decal: PORO
6 39194097 1 Decal: Power Out Restart Option
7 22388037 1 Decal: Schematic
8 39331954 1 DIN rail
9 35275494 1 Hub
10 39108949 2 Locknut
11 22396618 1 Instructions
12 39100136 1 Horn, Weather Resistant
13 39133467 8 Mount
14 95785192 1 Nipple
15 39146733 1 Plug
16 39203443 1 Suppressor

ITEM PART NUMBER QUANTITY DESCRIPTION
17 39252937 2 Block, end stop
18 39309554 1 Tape, adhesive
19 35246131 1 Terminal
20 39204763 1.2m (4ft) Wire, Blue 16 Ga
21 39129085 1.2m (4ft) Wire, Red 16 Ga
22 39146790 1.2m (4ft) Wire, Green 16 Ga

PORO OPTION – INTELLISYS 53
OPERATION Function test
POWER OUTAGE RESTART OPTION To test the operation of the Power Outage Restart Option:
For customers that have interruptions in their incoming power supply 1. Slowly open the main isolation valve.
to the compressor and must maintain an uninterrupted supply of
compressed air, the Power Outage Restart Option allows an Intellisys 2. Push the green START button on the Intellisys display to start the
compressor to restart automatically 10–120 seconds (adjustable) after compressor.
incoming power is restored. 3. The compressor will load automatically if there is a sufficient
The Power Outage Restart Option is turned on by using the customer demand for air. Allow the compressor to load.
set routine on the Intellisys controller. The restart time delay, which
4. Open the main disconnect to remove power from the compressor.
is adjustable from 10–120 seconds, can also be adjusted while in the
set routine on the Intellisys controller. Any time power is restored to
the compressor after a power interruption and if the compressor was 5. Close the main disconnect to reapply power to the compressor.The
running when power was lost, a horn located on the side of the starter horn will sound and the Intellisys display will read START IN
box will sound during the restart time delay (10–120 seconds), after ___SEC.The display will count down the time until the compressor
which the compressor will automatically start. After starting, the starts automatically and the horn stops. After starting, the compressor
compressor will return to the mode of operation that the compressor will automatically return to the same mode of operation as prior to the
was in prior to the power interruption. power interruption.
To operate in the power outage restart mode, proceed with Fault Analysis
following steps:
1. If the Intellisys display indicates the count down message and the
1. Power up the unit and wait for the Intellisys display to read READY horn does not sound, check the wiring of the horn.
TO START.
2. If the Intellisys display does not indicate the count down message,
2. Press the SET button once to enter the customer set point the horn does not sound and the unit does not restart automatically,
routine. The Set Offline Air Pressure indicator will light and the verify that the Option has been turned on.
display will show the set point pressure.
3. Press and release the SET button multiple times until the message
PWR OUT RSTR OFF is displayed.
4. Push the up or down arrows to change to the desired condition. ON
in the display indicates Power Outage Restart is turned on and OFF in
the display indicates Power Outage Restart is turned off.
5. Once the selection has been made, press SET button to put the
selection into Intellisys memory. The display will flash twice and the
message will change to STR DELAY 10 Sec if the option was turned
on. This message will only display if the Power Outage Restart Option
is turned on.
6. Use the up or down arrows to select the desired delay time (10–120
sec.).
7. Press SET and the display will flash twice indicating the change has
been made.
8. Push the DISPLAY SELECT BUTTON or wait 30 seconds for the
controller to automatically exit the set routine. The display returns to
READY TO START.

54 PORO OPTION – INTELLISYS
1 39194097 1 Option, Module 4 39108949 2 Locknut

2 35275494 1 Connector, bulkhead 5 39146733 1 Plug
3 95934279 1 Nipple 6 39100136 1 Horn

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This manual contains

48 OUT DOOR MODULE OPTION

49 PORO OPTION – ELECTRO–PNEUMATIC

53 PORO OPTION – INTELLISYS

http:/air.ingersollrand.com UP6 15, UP6 20, UP6 25, UP6 30

This manual contains instructions and technical data to cover TABLE 1

Use of the machine with safety or control components missing or

INTELLISYS is a registered trademark of Ingersoll Rand

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Prohibition / Mandatory Information / Instructions Warning

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

AUTOMATIC RESTART MAINTENANCE MAINTENANCE PROHIBITED

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS HOURS

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Every X months, if sooner than required by

CHANGE / REPLACE CLEAN

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EXPOSED MOVING BELTS AND SHEAVES.

Air flow exhaust may contain flying debris.

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DANGER! All air pressure equipment installed in or connected to the machine

The use of plastic bowls on line filters can be hazardous. Their

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INTELLISYS CONTROL AND INSTRUMENTATION

PRIOR TO STARTING POWER OUT RESTART (Optional)

WARNING NORMAL STOPPING

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2. Turn off electrical isolator. 17 L.E.D.–Not used.

3 SUMP PRESSURE L.E.D. 20 LOAD/UNLOAD BUTTON

8 MODULATION L.E.D. 23 ARROW KEYS

10 ALARM L.E.D. 24 START BUTTON

13 L.E.D.–Select control mode.

14 L.E.D.–Set star delta time.

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UPPER RANGE MODULATION CONTROL (Optional Extra)

Upper range modulation retains the features of On line – Off line

If the air demand decreases to a level below the 70% modulated

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CONTROL POWER LOSS

REMOTE START FAILURE

REMOTE STOP FAILURE

LOW SUMP PRESSURE

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ELECTRICAL SCHEMATIC – DOL WITH INTELLISYS CONTROL

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CON Controller, INTELLISYS NOTES

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ELECTRICAL SCHEMATIC – STAR DELTA WITH INTELLISYS CONTROL

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CON Controller, INTELLISYS NOTES

RSP Remote stop

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UP6 15, UP6 20, UP6 25, UP6 30

CONTINUED IN NEXT PAGE

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AIR RECEIVER (OPTION)

1 22113344 1 Assembly, emergency stop 14 39191648 1 Plug