Ingersoll Rand Compressor Fault Codes (Intellisys)

How alarms show

Intellisys SG panel (for example SSR UP6 40 and 50PE): a warning flashes the alarm LED and the message alternates with the normal display every 4 seconds while the compressor keeps running; press SET once to reset it.

An alarm makes the controller execute an emergency stop, lights the alarm LED steady and shows the alarm message; use the arrow keys to see more messages, fix the cause and press SET twice within 3 seconds.

IRN 15-30 kW variable speed: the WARNING LED lights for a problem or approaching maintenance and the text appears above the bar graph; the ALARM LED lights when an alarm stops the machine; after the fix press Stop/Reset. All drive faults show one common message with the drive error code.

X8I System Automation: the fault LED slow flashes for an alarm (warning) and fast flashes for a trip (shutdown); every fault goes in the X8I error log and trips are reset by hand.

The code numbers listed with each message come from the Intellisys Remote Interface (IRI) lists: a building system reads the warning code and alarm code history over Modbus as numbers, while the Intellisys display shows the text. Xe-70M, Xe-90M and Xe-145M controllers are not covered here.

Safety first.

Ingersoll Rand: compressed air and electricity can be dangerous. Before any work on the compressor, isolate the electrical supply and relieve all pressure, and make sure the machine cannot start by accident.

If the machine stops automatically, the airend, separator tank and oil system can still hold high pressure air, and the system downstream of the separator tank may still be at system pressure. Electrical work and many repairs in the troubleshooting tables are marked for a competent electrician or an Ingersoll Rand authorized service technician.

IRN 15-30 kW machines carry a decal titled fifteen minutes before service. Sources: SSR UP6 40-50PE manual safety (PDF page 10), IRN 15-30 kW manual (PDF pages 8 and 31). Follow lockout/tagout and your site's safe-work procedures, and check the manual for your exact model before you act.

Quick lookup

Alarms stop the compressor and every line that runs on its air, so in OEE they are availability losses; warnings are early signs.

Type a message or a word (temperature, pressure, sensor, overload) to filter the list. Click a row for its causes and first checks. Each row's details name the controllers whose manual prints it.

Find a code or a word

66 codes

Message or code	What it means
STARTER FAULT	The controller saw the motor contactors switch in the wrong order while the compressor was starting or stopping, so it stopped the machine.
AIREND TEMPERATURE (warning)	The airend discharge temperature has reached 97% of the high airend temperature set point, about 223 F (106 C).
AIREND TEMPERATURE (alarm)	The airend discharge temperature went above the high temperature set point and the controller stopped the compressor.
MOTOR OVERLOAD	The main motor overload contacts are open, so the controller stopped the compressor.
REVERSE ROTATION	No sump pressure was detected in the first 2 seconds of running, which the controller treats as the motor turning the wrong way.
OVER PRESSURE	The line pressure is 15 psi (1 bar) above the rated discharge pressure, so the controller stopped the compressor.
TEMPERATURE SENSOR 1	The airend temperature sensor or its connecting cable has failed.
TEMPERATURE SENSOR 2	The separator tank temperature sensor or its connecting cable has failed.
PRESSURE SENSOR	The pressure transducer or its connecting cable has failed.
FAILED CALIBRATION	During the sensor calibration routine the controller found an error of more than 10% of scale.
CONTROL POWER LOSS	The 48 Vac control signal is not present at the controller.
REMOTE START FAILURE	The momentary remote start had not disengaged (was not released) before the star to delta transition.
REMOTE STOP FAILURE	The momentary remote stop switch had not disengaged (was not released) when the start signal was received.
EMERGENCY STOP	The emergency stop button is pressed in (on IRN machines: the emergency stop input is open), so the compressor stopped at once.
LOW SUMP PRESSURE	The sump pressure dropped below 15 psi (1 bar) during normal running.
HIGH DEW POINT	On machines with the integrated dryer, the dew point reading is above 65 F (18 C).
COOLANT FILTER	The pressure difference across the coolant filter is above 15 psi (1 bar), so the filter is getting blocked.
AIR FILTER	The air inlet filter is dirty or blocked and should be replaced.
SEPARATOR ELEMENT	The separator element is dirty or blocked and should be replaced.
High A/E Discharge Temperature	The air and coolant leaving the airend are hotter than the controller allows, so the compressor stops.
Sensor Failure 2ATT / 4ATT / 2CTT (temperature)	The named temperature sensor gives a reading the controller cannot use, so it treats the sensor as failed.
Sensor Failure 1AVPT / 3APT / 4APT / 6APT (pressure)	The named pressure transducer gives a reading the controller cannot use.
Check Motor Rotation	The controller suspects the motor turned the wrong way at start.
High Air Pressure	The discharge pressure went above the controller limit.
Fan Motor Overload	The cooling fan motor overload has tripped.
Door Open (Starter)	The starter cabinet door switch reports the door open.
Stepper Limit Switch	The limit switch on the stepper driven inlet control reports a fault.
Check Inlet Control / Check Inlet Control System	The controller reports a problem with the inlet control system.
Low Unload Sump Pressure	The sump pressure while running unloaded is lower than the controller expects.
Memory Fault	The controller found a fault in its own memory.
Service Required / 100 Hours/14 Days To Service / Alarm - Service Required	The service interval is close or reached.
High VSD Temperature	The variable speed drive on a Nirvana compressor is too hot.
VSD Communication Failure	The Intellisys controller lost communication with the variable speed drive.
VSD Initialization Fault	The variable speed drive did not complete its start up handshake with the controller.
Incorrect VSD Type	The drive fitted does not match the drive type the controller expects for this machine.
Stop Failure	The controller commanded a stop but the compressor did not stop as expected.
Check Set Points	The controller asks for the set points to be checked.
High Start Pressure	The pressure was too high for the controller to allow a start.
VSD Fault 0 to VSD Fault 44	The variable speed drive reported its own fault and the Intellisys shows it as VSD Fault with the drive fault number.
Auxiliary 1 / Auxiliary 2	A customer or option device wired to auxiliary input 1 or 2 has switched.
High Air Temperature Switch (HATS) Alarm	The high air temperature switch (HATS) input opened, so the controller stopped the machine on high air temperature.
P1 / P2 Sensor Calibration Failure	A sensor calibration was attempted on P1 or P2 and the zero (0 psi) reading was more than 10% off.
P1 / P2 Pressure Sensor Failure	The P1 or P2 pressure sensor current is below 3 mA or above 21 mA, outside the normal 4-20 mA range.
Incorrect Intellikey	The installed Intellikey does not match the drive size.
VFD Faults (drive fault codes)	Every drive fault shows the same common error message together with the error code from the drive itself.
Dryer Stopped High Pressure	The dryer is enabled and its status switch input is open.
Immediate Stop Pressure Exceeded	The pressure went above the immediate stop pressure.
High Dryer DP	The pressure before the dryer is more than 20 psi above the package discharge pressure.
Service Soon	20% or less of the service time is left, for example under 400 run hours or under 1752 annual maintenance hours.
Maintenance Due	The maintenance timer has reached zero.
ERR.01	The signal from the X8I control pressure sensor is out of range, below 3.5 mA or above 21.8 mA.
ERR.04	The 24 VDC supply inside the X8I controller is below 19.2 V. This is an internal controller fault.
ERR.05	The wire link between terminals +C and C1 of the controller is open.
ERR.06	The real time clock inside the controller has failed.
ERR.07	Data communication with the internal XPM-LED status display module was disrupted or lost.
ERR.12	Data communication with the external ir-PCB expansion module C:5-8 was disrupted or lost.
ERR.13	A short circuit was detected on the external ir-PCB expansion module C:5-8.
SYS.01	System pressure went above the set maximum pressure limit (PM).
SYS.02	System pressure fell below the set minimum pressure limit (Pm).
SYS.04	Not enough capacity: all available compressors are loaded and the pressure is still falling.
SYS.05 / SYS.06	The auxiliary input is set as an alarm input (AA always active, AR active when the unit runs) and is in a fault condition.
SYS.07 / SYS.08	The auxiliary input is set as a trip input (TA always active, TR active when the unit runs) and is in a fault condition.
E0836	The main processor clock was disrupted, by an internal failure or very high electrical interference, and the controller runs on a slow back up clock.
E0866	The low voltage logic supply inside the controller is below its minimum level.
E5000	The controller found disruption in its working memory (RAM) and must reset to clear it.
E5001	The controller found disruption in its permanent application memory (FLASH).

Each code: causes and first checks

STARTER FAULT

Hits OEE: Availability

What it means: The controller saw the motor contactors switch in the wrong order while the compressor was starting or stopping, so it stopped the machine.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE); same message on Intellisys SE, SSR and Nirvana SGN. Same text on other Intellisys controllers. Intellisys Remote Interface (IRI) code numbers: SSR 17, SSR SG 17, SE 15-100 HP 04, Sierra 50-100 HP 04, Sierra 100-200 HP 17, Sierra 125-400 HP SG 17, Recip 34, Recip SG 17, Recip Booster 34, Pegasus SE 04, ESA SE 22-150 kW 04.

Controller response: Alarm: the controller executes an emergency stop, the alarm LED lights steady and the message shows; fix the cause, then press SET twice within 3 seconds; the compressor restarts only when all alarm conditions are cleared

Likely causes

Contactor sequence during start or stop is incorrect
Defective star/delta timer (listed under compressor fails to start)
Mains or control voltage not available

First checks, in this order

Check the incoming power supply and the control circuit fuse.
Check the transformer secondary windings for the control voltage.
Have an electrician check the star/delta contactors and timer; change the timer if it is defective.

AIREND TEMPERATURE (warning)

Warning: act before it becomes a stop

What it means: The airend discharge temperature has reached 97% of the high airend temperature set point, about 223 F (106 C). The compressor keeps running but is close to an over temperature stop.^[1]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE). If the temperature keeps rising it becomes the AIREND TEMPERATURE alarm.

Controller response: Warning: the alarm LED flashes and the message alternates with the normal display every 4 seconds while the compressor keeps running; press SET once to reset; it comes back if the fault is still there

Likely causes

Compressor operating above rated pressure
Package pre-filter blocked
Cooler blocked
Low coolant level
High ambient temperature or restricted cooling air flow
Enclosure panels missing or not fitted correctly

First checks, in this order

Check the coolant level and top up.
Clean the cooler and the package pre-filter.
Make sure all enclosure panels are fitted and the cooling air flow is not restricted.
Check that the pressure setting matches the machine rating.

AIREND TEMPERATURE (alarm)

Hits OEE: Availability

What it means: The airend discharge temperature went above the high temperature set point and the controller stopped the compressor.^[1]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE). On SSR, SSR SG and Nirvana controllers the same stop reads High A/E Discharge Temperature (separate row).

Likely causes

Compressor operating above rated pressure
Package pre-filter blocked
Cooler blocked
Low coolant level
High ambient temperature or restricted cooling air flow
Enclosure panels missing or not fitted correctly

First checks, in this order

Let the machine cool, then check the coolant level and look for leaks.
Clean the cooler and the package pre-filter.
Check the cooling air flow and the enclosure panels.
Set the pressure to the correct rating for the machine.

MOTOR OVERLOAD: Main motor overload

Hits OEE: Availability

What it means: The main motor overload contacts are open, so the controller stopped the compressor. The overload relay must be reset before the controller can be reset.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE); same stop on Intellisys SE and SSR. SSR and SSR SG list it as Motor Overload (Main). Intellisys Remote Interface (IRI) code numbers: SSR 18, SSR SG 18, SE 15-100 HP 05, Sierra 50-100 HP 05, Sierra 100-200 HP 18, Sierra 125-400 HP SG 18, Recip SG 18, Pegasus SE 05, ESA SE 22-150 kW 05.

Likely causes

Motor overload set to the wrong value
Line voltage variation, low or unbalanced voltage
Compressor operating above rated pressure
Separator cartridge contaminated (high current draw)
Damaged airend

First checks, in this order

Reset the motor overload, then reset the controller.
Have an electrician check that the overload is set to the correct value and switched to manual reset.
Check that the voltage does not drop more than 10% on start up and 6% running, and that phases are balanced.
Check the pressure setting and the separator cartridge.

REVERSE ROTATION

Hits OEE: Availability

What it means: No sump pressure was detected in the first 2 seconds of running, which the controller treats as the motor turning the wrong way.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE); same name on Intellisys SE, Pegasus SE and ESA SE. SSR, SSR SG and Nirvana controllers show Check Motor Rotation (separate row). Intellisys Remote Interface (IRI) code numbers: SE 15-100 HP 06, Pegasus SE 06, ESA SE 22-150 kW 06.

Likely causes

Mains supply phases connected in the wrong order

First checks, in this order

Isolate the machine.
Have an electrician reverse the mains supply connections before running again.

OVER PRESSURE

Hits OEE: Availability

What it means: The line pressure is 15 psi (1 bar) above the rated discharge pressure, so the controller stopped the compressor.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE). Intellisys SE family shows High Pressure; SSR and Nirvana show High Air Pressure (separate row). Intellisys Remote Interface (IRI) code numbers: SE 15-100 HP 12, Sierra 50-100 HP 12, Pegasus SE 12, ESA SE 22-150 kW 12.

Likely causes

Defective pressure switch or wrong pressure setting
Load solenoid valve defective
Blowdown valve defective
Inlet valve malfunction

First checks, in this order

Check the pressure setting against the machine rating.
Check the load solenoid valve, blowdown valve and inlet valve; fit the service kit if one is defective.

TEMPERATURE SENSOR 1: Temperature sensor 1 failure

Hits OEE: Availability

What it means: The airend temperature sensor or its connecting cable has failed.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE). Intellisys SE family: Temperature Sensor Failure 1. Intellisys Remote Interface (IRI) code numbers: SE 15-100 HP 02, Pegasus SE 02, ESA SE 22-150 kW 02.

Likely causes

Failed airend discharge temperature sensor (2ATT on this wiring diagram)
Damaged or loose sensor cable

First checks, in this order

Isolate power and check the sensor cable and connector.
Check the sensor and replace it if it has failed.

TEMPERATURE SENSOR 2: Temperature sensor 2 failure

Hits OEE: Availability

What it means: The separator tank temperature sensor or its connecting cable has failed.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE). ESA SE 22-150 kW lists Temperature Sensor Failure 2. Intellisys Remote Interface (IRI) code numbers: ESA SE 22-150 kW 03.

Likely causes

Failed separator tank temperature sensor
Damaged or loose sensor cable

First checks, in this order

Isolate power and check the sensor cable and connector.
Check the sensor and replace it if it has failed.

PRESSURE SENSOR: Pressure sensor failure

Hits OEE: Availability

What it means: The pressure transducer or its connecting cable has failed.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE). Intellisys SE family: Pressure Sensor Failure. Intellisys Remote Interface (IRI) code numbers: SE 15-100 HP 01, Sierra 50-100 HP 01, Pegasus SE 01, ESA SE 22-150 kW 01.

Likely causes

Failed pressure transducer (3APT line/sump on this wiring diagram)
Cable fault

First checks, in this order

Isolate power and check the transducer cable and connector.
Replace the transducer if it has failed.

FAILED CALIBRATION

Hits OEE: Availability

What it means: During the sensor calibration routine the controller found an error of more than 10% of scale.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE). Intellisys SE family: Calibration Error; Nirvana SGN: Invalid Calibration; SSR: 1AVPT Sensor Error (Calibration). Intellisys Remote Interface (IRI) code numbers: SSR 36, SSR SG 36, SE 15-100 HP 09, Sierra 50-100 HP 09, Sierra 125-400 HP SG 47, Recip SG 53, Nirvana SGN 36, Nirvana SGNe CC 36, Pegasus SE 09, ESA SE 22-150 kW 09, Nirvana SGNe oil-free 47.

Likely causes

Separator not fully blown down when calibration was started

First checks, in this order

Make sure the separator is completely blown down to zero pressure.
Repeat the calibration.

CONTROL POWER LOSS

Hits OEE: Availability

What it means: The 48 Vac control signal is not present at the controller.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE); same name on most Intellisys controllers. Intellisys Remote Interface (IRI) code numbers: SSR SG 20, SE 15-100 HP 16, Sierra 50-100 HP 16, Recip SG 20, Nirvana SGN 24, Nirvana SGNe CC 24, Pegasus SE 16, ESA SE 22-150 kW 16, Nirvana SGNe oil-free 46.

Likely causes

Control circuit fuse blown
Control transformer fault
Mains power interrupted

First checks, in this order

Check the incoming power supply and the control circuit fuse.
Check the transformer secondary windings for the control voltage.

REMOTE START FAILURE

Hits OEE: Availability

What it means: The momentary remote start had not disengaged (was not released) before the star to delta transition. Only active when remote start/stop is enabled.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE); same name on all Intellisys controllers in the IRI list. Intellisys Remote Interface (IRI) code numbers: SSR 26, SSR SG 26, SE 15-100 HP 08, Sierra 50-100 HP 08, Sierra 100-200 HP 26, Sierra 125-400 HP SG 26, Recip 45, Recip SG 26, Recip Booster 45, Nirvana SGN 26, Nirvana SGNe CC 26, Pegasus SE 08, ESA SE 22-150 kW 08, Nirvana SGNe oil-free 26.

Likely causes

Remote start button or relay held closed instead of momentary
Remote start wiring fault

First checks, in this order

Check that the remote start device gives a short pulse and releases.
Check the remote start wiring.

REMOTE STOP FAILURE

Hits OEE: Availability

What it means: The momentary remote stop switch had not disengaged (was not released) when the start signal was received. Only active when remote start/stop is enabled.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE); same name on all Intellisys controllers in the IRI list. Intellisys Remote Interface (IRI) code numbers: SSR 25, SSR SG 25, SE 15-100 HP 07, Sierra 50-100 HP 07, Sierra 100-200 HP 25, Sierra 125-400 HP SG 25, Recip 44, Recip SG 25, Recip Booster 44, Nirvana SGN 25, Nirvana SGNe CC 25, Pegasus SE 07, ESA SE 22-150 kW 07, Nirvana SGNe oil-free 25.

Likely causes

Remote stop button or relay not releasing
Remote stop wiring fault

First checks, in this order

Check that the remote stop device releases after use.
Check the remote stop wiring.

EMERGENCY STOP

Hits OEE: Availability

What it means: The emergency stop button is pressed in (on IRN machines: the emergency stop input is open), so the compressor stopped at once.^[1]^[2]^[3]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE); IRN 15-30 kW (20-40 HP) variable speed; all Intellisys controllers. IRN 15-30 kW: alarm whenever the emergency stop input is opened. Intellisys Remote Interface (IRI) code numbers: SSR 32, SSR SG 32, SE 15-100 HP 18, Sierra 50-100 HP 18, Sierra 100-200 HP 32, Sierra 125-400 HP SG 32, Recip 33, Recip SG 32, Recip Booster 33, Nirvana SGN 32, Nirvana SGNe CC 32, Pegasus SE 18, ESA SE 22-150 kW 18, Nirvana SGNe oil-free 32.

Likely causes

Emergency stop button pressed
Open circuit in the emergency stop wiring

First checks, in this order

Find out why the button was pressed and make the machine safe.
Turn the button clockwise to release it, then reset the controller.
If the message stays with the button released, check the emergency stop wiring.

LOW SUMP PRESSURE

Hits OEE: Availability

What it means: The sump pressure dropped below 15 psi (1 bar) during normal running.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE); Intellisys SE family. SSR and Nirvana controllers: Low Sump Air Pressure. Intellisys Remote Interface (IRI) code numbers: SSR 30, SSR SG 30, SE 15-100 HP 19, Nirvana SGN 30, Nirvana SGNe CC 30, Pegasus SE 19, ESA SE 22-150 kW 19.

Likely causes

Inlet valve malfunction
Load solenoid valve defective
Blowdown valve defective

First checks, in this order

Check the inlet valve, load solenoid valve and blowdown valve (the valves the troubleshooting table lists for low system air pressure).
Check the sump pressure reading against a gauge.

HIGH DEW POINT: High dew point (dryer option)

Hits OEE: Availability

What it means: On machines with the integrated dryer, the dew point reading is above 65 F (18 C).^[1]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE) with dryer option.

Likely causes

Dryer compressor or fan failed
Low refrigerant charge
Dryer high pressure switch tripped (dirty condenser coil or fan problem)
Ambient conditions above the maximum

First checks, in this order

Check that the dryer is running properly and that maximum ambient conditions are not exceeded.
Check the dryer electrical supply.
Check the condenser coil for debris and the fan operation, then reset the manual high pressure switch.
Have the refrigerant circuit checked for leaks.

COOLANT FILTER: Coolant filter (optional)

Warning: act before it becomes a stop

What it means: The pressure difference across the coolant filter is above 15 psi (1 bar), so the filter is getting blocked.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE). SSR and Nirvana: Change Coolant Filter; Nirvana SGN also has Replace Coolant Filter (Idle Mode). Intellisys Remote Interface (IRI) code numbers: SSR 35, SSR SG 35, Sierra 100-200 HP 35, Sierra 125-400 HP SG 35, Nirvana SGN 28/35, Nirvana SGNe CC 28/35, ESA SE 22-150 kW 14.

Likely causes

Coolant filter element dirty or clogged

First checks, in this order

Change the coolant filter element.

AIR FILTER

Warning: act before it becomes a stop

What it means: The air inlet filter is dirty or blocked and should be replaced.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE). SSR and Nirvana: Change Inlet Filter. Intellisys Remote Interface (IRI) code numbers: SSR 33, SSR SG 33, Sierra 100-200 HP 33, Nirvana SGN 33, Nirvana SGNe CC 33, ESA SE 22-150 kW 13.

Likely causes

Dirty or blocked air filter element

First checks, in this order

Replace the air filter element.

SEPARATOR ELEMENT

Warning: act before it becomes a stop

What it means: The separator element is dirty or blocked and should be replaced.^[1]^[2]

Also on: Controllers: Intellisys SG (SSR UP6 40, UP6 50PE, UP6 50PEI, HF50-PE, EP50-PE, HP50-PE, HXP50-PE); Intellisys SE family. SSR and Nirvana: Change Separator Element. Intellisys Remote Interface (IRI) code numbers: SSR 34, SSR SG 34, SE 15-100 HP 15, Nirvana SGN 34, Nirvana SGNe CC 34, Pegasus SE 15, ESA SE 22-150 kW 15.

Likely causes

Separator element contaminated or blocked

First checks, in this order

Replace the separator element.

High A/E Discharge Temperature: High airend discharge temperature

Hits OEE: Availability

What it means: The air and coolant leaving the airend are hotter than the controller allows, so the compressor stops.^[2]^[1]

Also on: Controllers: Intellisys SSR, SSR SG and Nirvana SGN (names from the IRI code lists); Intellisys SE family as High Airend Discharge Temperature. Intellisys Remote Interface (IRI) code numbers: SSR 31, SSR SG 31, SE 15-100 HP 10, Nirvana SGN 31, Nirvana SGNe CC 31, Pegasus SE 10, ESA SE 22-150 kW 10. Causes and checks are from the over temperature rows of the SSR UP6 40-50PE manual.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Compressor operating above rated pressure
Cooler or package pre-filter blocked
Low coolant level
High ambient temperature or restricted cooling air flow

First checks, in this order

Check the coolant level and top up.
Clean the cooler and pre-filter.
Check the cooling air flow and ventilation.
Check the pressure setting against the machine rating.

Sensor Failure 2ATT / 4ATT / 2CTT (temperature): Temperature sensor failure (by tag)

Hits OEE: Availability

What it means: The named temperature sensor gives a reading the controller cannot use, so it treats the sensor as failed. ATT tags are air temperature sensors and CTT tags coolant temperature sensors; 2ATT is the airend discharge temperature sensor on the SSR UP6 40-50PE wiring diagrams.^[2]^[1]

Also on: Controllers: Intellisys SSR, SSR SG and Nirvana SGN (names from the IRI code lists); Nirvana SGNe. Intellisys Remote Interface (IRI) code numbers: SSR 09/10/11, SSR SG 09/10/11, Sierra 100-200 HP 09/11, Sierra 125-400 HP SG 09/11, Recip SG 13/15, Nirvana SGN 09/10/11, Nirvana SGNe CC 09/10/11, Nirvana SGNe oil-free 09/11. The tag-to-location meaning differs by model; check the wiring diagram of your machine.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Failed temperature sensor
Damaged or loose sensor cable or connector

First checks, in this order

Isolate power and check the cable and connector of the named sensor.
Replace the sensor if it has failed.

Sensor Failure 1AVPT / 3APT / 4APT / 6APT (pressure): Pressure sensor failure (by tag)

Hits OEE: Availability

What it means: The named pressure transducer gives a reading the controller cannot use. APT tags are air pressure transducers and 1AVPT is the inlet vacuum transducer; 3APT is the line/sump pressure sensor on the SSR UP6 40-50PE wiring diagrams.^[2]^[1]

Also on: Controllers: Intellisys SSR, SSR SG and Nirvana SGN (names from the IRI code lists); Nirvana SGNe. Intellisys Remote Interface (IRI) code numbers: SSR 01/02/03, SSR SG 01/02/03/05, Sierra 100-200 HP 01/03/04, Sierra 125-400 HP SG 01/03/04, Recip SG 03, Nirvana SGN 01/02/03, Nirvana SGNe CC 01/02/03, Nirvana SGNe oil-free 01/03/04. The tag-to-location meaning differs by model; check the wiring diagram of your machine.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Failed pressure transducer
Damaged or loose transducer cable or tubing

First checks, in this order

Isolate power and check the cable and connector of the named transducer.
Replace the transducer if it has failed.

Check Motor Rotation

Hits OEE: Availability

What it means: The controller suspects the motor turned the wrong way at start. On the Intellisys SG panel the same check is named REVERSE ROTATION: no sump pressure within 2 seconds of running.^[2]^[1]

Also on: Controllers: Intellisys SSR, SSR SG and Nirvana SGN (names from the IRI code lists); Nirvana SGNe oil-free. Intellisys Remote Interface (IRI) code numbers: SSR 22, SSR SG 22, Nirvana SGN 22, Nirvana SGNe CC 22, Nirvana SGNe oil-free 53.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Mains supply phases connected in the wrong order

First checks, in this order

Isolate the machine and have an electrician swap the mains supply connections.

High Air Pressure

Hits OEE: Availability

What it means: The discharge pressure went above the controller limit. On the Intellisys SG panel the matching stop is OVER PRESSURE: 15 psi (1 bar) above rated pressure.^[2]^[1]

Also on: Controllers: Intellisys SSR, SSR SG and Nirvana SGN (names from the IRI code lists); Nirvana SGNe. Intellisys Remote Interface (IRI) code numbers: SSR 29, SSR SG 29, Nirvana SGN 29, Nirvana SGNe CC 29, Nirvana SGNe oil-free 29.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Wrong pressure setting
Load solenoid, blowdown or inlet valve malfunction

First checks, in this order

Check the pressure settings against the machine rating.
Check the load solenoid valve, blowdown valve and inlet valve.

Fan Motor Overload

Hits OEE: Availability

What it means: The cooling fan motor overload has tripped.^[2]

Also on: Controllers: Intellisys SSR, SSR SG and Nirvana SGN (names from the IRI code lists); Intellisys SE 15-100 HP. Intellisys Remote Interface (IRI) code numbers: SSR 19, SSR SG 19, SE 15-100 HP 17, Sierra 100-200 HP 19, Sierra 125-400 HP SG 19, Nirvana SGN 19, Nirvana SGNe oil-free 19. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Fan motor overload tripped

First checks, in this order

Reset the fan motor overload and check the fan turns freely.
Have an electrician check the fan motor current and the overload setting.

Door Open (Starter): Starter door open

Hits OEE: Availability

What it means: The starter cabinet door switch reports the door open.^[2]

Also on: Controllers: Intellisys SSR. Intellisys Remote Interface (IRI) code numbers: SSR 20. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Starter door open or door switch out of position

First checks, in this order

Close the starter door and check the door switch.

Stepper Limit Switch

Hits OEE: Availability

What it means: The limit switch on the stepper driven inlet control reports a fault.^[2]

Also on: Controllers: Intellisys SSR, SSR SG. Intellisys Remote Interface (IRI) code numbers: SSR 21, SSR SG 21. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Inlet control stepper at a limit or limit switch fault

First checks, in this order

Check the inlet control stepper mechanism and its limit switch wiring.

Check Inlet Control / Check Inlet Control System: Check inlet control

Hits OEE: Availability

What it means: The controller reports a problem with the inlet control system.^[2]^[1]

Also on: Controllers: Intellisys SSR, SSR SG. Intellisys Remote Interface (IRI) code numbers: SSR 23/27, SSR SG 23/27. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Inlet valve or inlet control malfunction

First checks, in this order

Check the inlet valve and its control; fit the inlet valve service kit if it is defective.

Low Unload Sump Pressure: Low unloaded sump pressure

Warning: act before it becomes a stop

What it means: The sump pressure while running unloaded is lower than the controller expects.^[2]

Also on: Controllers: Intellisys SSR, SSR SG; Intellisys SE as Low Unloaded Sump Pressure. Intellisys Remote Interface (IRI) code numbers: SSR 28, SSR SG 28, SE 15-100 HP 21. The IRI list gives the name only; the type is not stated.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Minimum pressure valve or blowdown valve problem

First checks, in this order

Check the minimum pressure valve and the blowdown valve.

Memory Fault

Hits OEE: Availability

What it means: The controller found a fault in its own memory.^[2]

Also on: Controllers: Intellisys SSR, SSR SG, SE family, Sierra. Intellisys Remote Interface (IRI) code numbers: SSR 37, SSR SG 37, SE 15-100 HP 20, Sierra 50-100 HP 20, Sierra 100-200 HP 37, Sierra 125-400 HP SG 37, Recip SG 52. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Controller memory failure

First checks, in this order

Contact an Ingersoll Rand distributor; the controller may need service.

Service Required / 100 Hours/14 Days To Service / Alarm - Service Required: Service required

Warning: act before it becomes a stop

What it means: The service interval is close or reached. 100 Hours/14 Days To Service is the early reminder, Service Required means service is due, and Alarm - Service Required is the alarm level of the same reminder.^[2]

Also on: Controllers: Intellisys SSR SG, Nirvana SGN, Nirvana SGNe, Pegasus SE, ESA SE. Intellisys Remote Interface (IRI) code numbers: SSR SG 38/39/40, Sierra 125-400 HP SG 42, Nirvana SGN 38/39/40, Nirvana SGNe CC 38/39, Pegasus SE 21, ESA SE 22-150 kW 21, Nirvana SGNe oil-free 38/39.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Service interval reached

First checks, in this order

Carry out the scheduled service and reset the service timer.

High VSD Temperature

Hits OEE: Availability

What it means: The variable speed drive on a Nirvana compressor is too hot.^[2]

Also on: Controllers: Intellisys Nirvana SGN, Nirvana SGNe. Intellisys Remote Interface (IRI) code numbers: Nirvana SGN 18, Nirvana SGNe CC 18, Nirvana SGNe oil-free 18. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Drive cooling problem or high ambient temperature

First checks, in this order

Check the drive cooling air path and the ambient temperature.

VSD Communication Failure

Hits OEE: Availability

What it means: The Intellisys controller lost communication with the variable speed drive.^[2]

Also on: Controllers: Intellisys Nirvana SGN, Nirvana SGNe. Intellisys Remote Interface (IRI) code numbers: Nirvana SGN 20, Nirvana SGNe CC 20, Nirvana SGNe oil-free 50. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Communication cable or connection fault between controller and drive

First checks, in this order

Check the communication cable and connections between the controller and the drive.

VSD Initialization Fault

Hits OEE: Availability

What it means: The variable speed drive did not complete its start up handshake with the controller.^[2]

Also on: Controllers: Intellisys Nirvana SGN, Nirvana SGNe. Intellisys Remote Interface (IRI) code numbers: Nirvana SGN 21, Nirvana SGNe CC 21, Nirvana SGNe oil-free 51. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Drive or controller setup problem

First checks, in this order

Check the drive power and the communication link to the controller.
If it repeats, contact an Ingersoll Rand distributor with the message.

Incorrect VSD Type

Hits OEE: Availability

What it means: The drive fitted does not match the drive type the controller expects for this machine.^[2]

Also on: Controllers: Intellisys Nirvana SGN, Nirvana SGNe. Intellisys Remote Interface (IRI) code numbers: Nirvana SGN 27, Nirvana SGNe CC 27, Nirvana SGNe oil-free 27. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Wrong drive fitted or controller set up for another model

First checks, in this order

Check the drive rating and the controller setup against the machine data plate.

Stop Failure

Hits OEE: Availability

What it means: The controller commanded a stop but the compressor did not stop as expected.^[2]

Also on: Controllers: Intellisys Nirvana SGN, Nirvana SGNe. Intellisys Remote Interface (IRI) code numbers: Nirvana SGN 23, Nirvana SGNe CC 23, Nirvana SGNe oil-free 52. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Drive or starter not responding to the stop command

First checks, in this order

Isolate the machine and have the drive and control wiring checked.

Check Set Points

Warning: act before it becomes a stop

What it means: The controller asks for the set points to be checked.^[2]

Also on: Controllers: Intellisys Nirvana SGN, Nirvana SGNe, Pegasus SE, ESA SE. Intellisys Remote Interface (IRI) code numbers: Nirvana SGN 37, Nirvana SGNe CC 37, Pegasus SE 20, ESA SE 22-150 kW 20, Nirvana SGNe oil-free 37. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Set points lost or out of range

First checks, in this order

Review the set points against the machine settings and correct them.

High Start Pressure

Hits OEE: Availability

What it means: The pressure was too high for the controller to allow a start.^[2]

Also on: Controllers: Intellisys Nirvana SGN, Nirvana SGNe CC. Intellisys Remote Interface (IRI) code numbers: Nirvana SGN 43, Nirvana SGNe CC 43. The IRI list gives the name only.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

System or sump pressure above the start limit

First checks, in this order

Let the pressure fall, then check the blowdown and the pressure settings.

VSD Fault 0 to VSD Fault 44: VSD fault (drive fault number)

Hits OEE: Availability

What it means: The variable speed drive reported its own fault and the Intellisys shows it as VSD Fault with the drive fault number. Over the IRI the number is sent as 100 plus the drive fault number (VSD Fault 14 reads as code 114).^[2]

Also on: Controllers: Intellisys Nirvana SGN, Nirvana SGNe CC, Nirvana SGNe oil-free. IRI codes 100 to 144 (VSD Fault 0 to VSD Fault 44; code 132 is not listed for Nirvana SGN). The drive fault names are not in the IRI manual.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Fault inside or around the variable speed drive; the drive fault number tells which one

First checks, in this order

Note the VSD fault number.
Look the number up in the drive documentation for your machine or give it to an Ingersoll Rand distributor.

Auxiliary 1 / Auxiliary 2: Auxiliary input

Warning: act before it becomes a stop

What it means: A customer or option device wired to auxiliary input 1 or 2 has switched.^[2]

Also on: Controllers: Intellisys SSR SG, Nirvana SGN, Nirvana SGNe. Intellisys Remote Interface (IRI) code numbers: SSR SG 41/42, Sierra 125-400 HP SG 40/41, Nirvana SGN 41/42, Nirvana SGNe CC 41/42, Nirvana SGNe oil-free 41/42. The IRI list gives the name only; alarm or warning depends on setup.

Controller response: Shown on the Intellisys display; the code number is what a Modbus host reads through the IRI (warning code and alarm code history registers)

Likely causes

Optional or customer device on the auxiliary input activated

First checks, in this order

Check the device wired to that auxiliary input.

High Air Temperature Switch (HATS) Alarm: High air temperature switch

Hits OEE: Availability

What it means: The high air temperature switch (HATS) input opened, so the controller stopped the machine on high air temperature. The maintenance schedule checks this switch (109 C) each year or 2000 hours.^[3]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed.

Controller response: Alarm: the ALARM LED lights and the machine stops automatically; when the cause is corrected, press Stop/Reset to restart

Likely causes

High airend temperature from low coolant
Line voltage variation out of range

First checks, in this order

Top up the coolant.
Check that the line voltage is within the operating limits and free of spikes.
Check the high temperature protection switch at the yearly service.

P1 / P2 Sensor Calibration Failure: Pressure sensor calibration failure

Hits OEE: Availability

What it means: A sensor calibration was attempted on P1 or P2 and the zero (0 psi) reading was more than 10% off.^[3]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed.

Controller response: Alarm: the ALARM LED lights and the machine stops automatically; when the cause is corrected, press Stop/Reset to restart

Likely causes

Pressure still present on the sensor during calibration
Faulty sensor

First checks, in this order

Vent all pressure from the sensor and repeat the calibration.
Replace the sensor if it still fails.

P1 / P2 Pressure Sensor Failure: Pressure sensor failure

Hits OEE: Availability

What it means: The P1 or P2 pressure sensor current is below 3 mA or above 21 mA, outside the normal 4-20 mA range.^[3]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed.

Controller response: Alarm: the ALARM LED lights and the machine stops automatically; when the cause is corrected, press Stop/Reset to restart

Likely causes

Broken or shorted sensor wiring
Failed pressure sensor

First checks, in this order

Check the sensor wiring and connector.
Replace the sensor if the signal stays out of range.

Incorrect Intellikey

Hits OEE: Availability

What it means: The installed Intellikey does not match the drive size.^[3]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed.

Controller response: Alarm: the ALARM LED lights and the machine stops automatically; when the cause is corrected, press Stop/Reset to restart

Likely causes

Wrong Intellikey fitted for this drive size

First checks, in this order

Check that the Intellikey matches the drive size on the data plate; fit the correct one.

VFD Faults (drive fault codes): Drive fault

Hits OEE: Availability

What it means: Every drive fault shows the same common error message together with the error code from the drive itself.^[3]^[5]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed; IRN 7.5-15 HP. IRN 7.5-15 HP: the indicator watches the Drive Fault input; the motor icon and LED stay on until the drive fault is corrected, then reset automatically. To reset by cycling the E-stop, the on/off selector must be OFF.

Controller response: Shown as a common drive fault message with the error code

Likely causes

Fault detected by the variable frequency drive; the code tells which one
Line voltage variation out of range

First checks, in this order

Note the drive error code shown with the message.
Check that the line voltage is within limits.
Give the code to an Ingersoll Rand authorized service technician.

Dryer Stopped High Pressure

Warning: act before it becomes a stop

What it means: The dryer is enabled and its status switch input is open. The compressor keeps running.^[3]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed with integrated dryer.

Controller response: Warning: the WARNING LED lights and the text shows in the warning area of the status screen; the compressor keeps running

Likely causes

Refrigeration compressor not supplied with power
Dirty condenser

First checks, in this order

Check the dryer power supply and the dryer protection fuse.
Clean the condenser and replace the panel filter element.

Immediate Stop Pressure Exceeded

Warning: act before it becomes a stop

What it means: The pressure went above the immediate stop pressure. The compressor stops and resets itself when the pressure falls below the target pressure.^[3]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed.

Controller response: Warning that stops the compressor and resets automatically when the pressure falls below target

Likely causes

Monitored pressure above the immediate stop pressure

First checks, in this order

Check the target pressure and the immediate stop pressure settings.
If it happens often, check the inlet valve, which the troubleshooting table lists for high discharge pressure.

High Dryer DP: High dryer differential pressure

Warning: act before it becomes a stop

What it means: The pressure before the dryer is more than 20 psi above the package discharge pressure. The machine keeps running.^[3]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed with integrated dryer. The manual calls the condition Dryer Delta Pressure.

Controller response: Warning: the WARNING LED lights and the text shows in the warning area of the status screen; the machine keeps running

Likely causes

Pressure drop across the integrated dryer above 20 psi

First checks, in this order

Check the dryer and its air path for a restriction.
Compare the pressure before the dryer with the package discharge pressure.

Service Soon

Warning: act before it becomes a stop

What it means: 20% or less of the service time is left, for example under 400 run hours or under 1752 annual maintenance hours.^[3]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed.

Controller response: Warning text above the bar graph; the warning LED flashes from 400 to 200 run hours left and is steady below 200

Likely causes

Service interval nearly reached

First checks, in this order

Plan the service.

Maintenance Due

Warning: act before it becomes a stop

What it means: The maintenance timer has reached zero.^[3]

Also on: Controllers: IRN 15-30 kW (20-40 HP) variable speed.

Controller response: Warning: the WARNING LED lights and the text shows in the warning area of the status screen

Likely causes

Service interval reached

First checks, in this order

Carry out the scheduled maintenance and reset the timer.

ERR.01: Pressure Sensor Fault

Hits OEE: Availability

What it means: The signal from the X8I control pressure sensor is out of range, below 3.5 mA or above 21.8 mA.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Controller response: Trip (shutdown): the X8I fault LED fast flashes, X8I control stops and each compressor falls back to its own pressure settings; logged in the X8I error log and must be reset by hand

Likely causes

Broken or shorted sensor wiring
Failed pressure sensor

First checks, in this order

Check the pressure sensor wiring and connections.
Replace the sensor if the signal stays out of range.

ERR.04: Internal 24V Fault

Hits OEE: Availability

What it means: The 24 VDC supply inside the X8I controller is below 19.2 V. This is an internal controller fault.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Likely causes

Internal controller power supply fault

First checks, in this order

Check the supply to the unit; if the fault stays, renew the controller.

ERR.05: Emergency Stop

Hits OEE: Availability

What it means: The wire link between terminals +C and C1 of the controller is open. The link is fixed on the X8I terminal PCB, so this should never happen in normal use.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Likely causes

Link between +C and C1 broken or disturbed

First checks, in this order

Check the +C to C1 link on the X8I terminal PCB.

ERR.06: Real Time Clock Error

Hits OEE: Availability

What it means: The real time clock inside the controller has failed.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Likely causes

Internal clock device failure

First checks, in this order

Contact your product supplier; the controller may need renewing.

ERR.07: XPM-LED Module Error

Hits OEE: Availability

What it means: Data communication with the internal XPM-LED status display module was disrupted or lost.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Likely causes

Loose or faulty connection to the XPM-LED module

First checks, in this order

Check the connection to the XPM-LED module.

ERR.12: Ir-PCB Expansion Module C5-8 (communication)

Hits OEE: Availability

What it means: Data communication with the external ir-PCB expansion module C:5-8 was disrupted or lost.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Likely causes

Expansion module wiring or power fault

First checks, in this order

Check the wiring and power to the C:5-8 expansion module.

ERR.13: Ir-PCB Expansion Module C5-8 (short circuit)

Hits OEE: Availability

What it means: A short circuit was detected on the external ir-PCB expansion module C:5-8.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Likely causes

Short circuit on the expansion module or its wiring

First checks, in this order

Isolate power and check the C:5-8 module wiring for a short.

SYS.01: Excess Pressure (PM)

Warning: act before it becomes a stop

What it means: System pressure went above the set maximum pressure limit (PM).^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer). The menu calls it the Maximum Pressure Alarm.

Controller response: Alarm (warning): the X8I fault LED slow flashes and the X8I keeps running; logged in the X8I error log

Likely causes

System pressure above the PM limit set in the X8I

First checks, in this order

Check the PM (maximum pressure) setting.
Check that the connected compressors unload when the X8I commands it.

SYS.02: Min Pressure (Pm)

Warning: act before it becomes a stop

What it means: System pressure fell below the set minimum pressure limit (Pm).^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer). The menu calls it the Minimum Pressure Alarm.

Controller response: Alarm (warning): the X8I fault LED slow flashes and the X8I keeps running; logged in the X8I error log

Likely causes

System pressure below the Pm limit set in the X8I

First checks, in this order

Check the Pm (minimum pressure) setting.
Check that all compressors are available and loading.

SYS.04: Capacity Alarm (Warning)

Warning: act before it becomes a stop

What it means: Not enough capacity: all available compressors are loaded and the pressure is still falling.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Controller response: Alarm (warning): the X8I fault LED slow flashes and the X8I keeps running; logged in the X8I error log

Likely causes

Air demand above the capacity of the compressors available to the X8I

First checks, in this order

Check which compressors are available to the X8I.
Reduce demand or add capacity.

SYS.05 / SYS.06: Remote Alarm (Warning)

Warning: act before it becomes a stop

What it means: The auxiliary input is set as an alarm input (AA always active, AR active when the unit runs) and is in a fault condition.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Controller response: Alarm (warning): the X8I fault LED slow flashes and the X8I keeps running; logged in the X8I error log

Likely causes

External device wired to the auxiliary input reports a fault

First checks, in this order

Check the external device wired to the auxiliary input.

SYS.07 / SYS.08: Remote Trip (Shutdown)

Hits OEE: Availability

What it means: The auxiliary input is set as a trip input (TA always active, TR active when the unit runs) and is in a fault condition.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Likely causes

External device wired to the auxiliary input reports a fault

First checks, in this order

Check the external device wired to the auxiliary input, then reset the trip.

E0836: PLL Unlock

Hits OEE: Availability

What it means: The main processor clock was disrupted, by an internal failure or very high electrical interference, and the controller runs on a slow back up clock.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Controller response: Trip (shutdown): compressors continue on local pressure regulation; reset by removing and re-applying main power

Likely causes

Internal failure
Excessive electrical interference

First checks, in this order

Remove and re-apply the controller main power to reset.
Look for sources of electrical interference; consult your supplier if it repeats.

E0866: Controller internal power supply fault

Hits OEE: Availability

What it means: The low voltage logic supply inside the controller is below its minimum level.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Controller response: Trip (shutdown): must be reset by hand from the keypad

Likely causes

Internal controller power supply fault

First checks, in this order

Reset the trip from the keypad; renew the controller if it persists.

E5000: Internal memory map error

Hits OEE: Availability

What it means: The controller found disruption in its working memory (RAM) and must reset to clear it.^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Controller response: Trip (shutdown): reset by removing and re-applying main power

Likely causes

Internal memory disruption

First checks, in this order

Remove and re-apply the controller main power; renew the controller if it persists.

E5001: Internal memory failure

Hits OEE: Availability

What it means: The controller found disruption in its permanent application memory (FLASH).^[4]

Also on: Controllers: X8I System Automation (multi-compressor sequencer).

Controller response: Trip (shutdown): reset by removing and re-applying main power

Likely causes

Application memory corrupted

First checks, in this order

Remove and re-apply main power.
Re-load the main application software first; renew the controller if it persists.

Log it, or the same alarm comes back

A compressor alarm stops the compressor, and when compressed air drops, every machine that needs it stops too, so in OEE terms it is a breakdown for each line it feeds. Log the message, the compressor and the minutes lost on the lines; warnings are early signs worth logging.

Reason code: the message plus the compressor, for example Ingersoll Rand SSR high airend discharge temperature, compressor 1, so a cooler that clogs every summer shows up as a pattern.
Loss bucket: a stop that needs a reset, a part or a technician is an availability loss (breakdown). Stops shorter than your micro-stop threshold go to performance (minor stops). The six big losses page shows where each one belongs.
What to count: how often each code fires per week and the minutes it costs. Two numbers a week turn "that alarm comes up sometimes" into a ranked list. The MTBF and MTTR calculator and the downtime cost calculator do the math.

The free OEE tracker logs each stop with its reason and turns the week into a downtime Pareto, so the code that costs the most rises to the top.

fabrico.io has an air compressor troubleshooting guide. An alarm tells you what the controller measured, not what the lines downstream lost while the air was gone. Fabrico's camera-based OEE software syncs line camera video with machine data, so you can replay the moment a line stopped next to the cause.

Frequently asked questions

Where can I find a list of Ingersoll Rand compressor fault codes?

Each controller family has its own list. For Intellisys controllers, the Intellisys Remote Interface manual (C.C.N. 80440985) lists the alarm and warning names and numbers for SSR, SSR SG, SE, Sierra, Nirvana and other families, and the operation and maintenance manual of each machine explains the messages. This page puts those together. The Xe-70M, Xe-90M and Xe-145M controllers are not covered here.

Is there an Ingersoll Rand compressor fault codes PDF?

Yes, for older Intellisys machines. Ingersoll Rand still hosts the Intellisys Remote Interface manual with numbered code tables on its manual archive, and machine manuals such as the SSR UP6 40-50PE and IRN 15-30 kW operation and maintenance manuals on irtechpubs.com. The source list at the bottom of this page links each one.

What is the difference between a warning and an alarm on an Ingersoll Rand Intellisys?

A warning flashes the alarm LED and the compressor keeps running; press SET once to clear it, and it comes back if the cause is still there. An alarm makes the controller execute an emergency stop and the alarm LED stays on. Fix the cause, then press SET twice within 3 seconds. The compressor restarts only when all alarm conditions are cleared.

What does Sensor Failure 4ATT or 2CTT mean on an Ingersoll Rand compressor?

It means the controller cannot use the reading from the named sensor, usually because the sensor or its cable has failed. ATT tags are air temperature sensors, CTT tags are coolant temperature sensors and APT tags are pressure transducers. The exact location behind each tag depends on the model, so check the wiring diagram in your machine manual, then check the cable and connector before replacing the sensor.

What does Check Motor Rotation or Reverse Rotation mean?

The controller saw no sump pressure in the first 2 seconds of running and assumes the motor is turning backwards. Ingersoll Rand says to isolate the machine and reverse the mains supply connections before running again. Have an electrician do this.

How do I reset an alarm on an Ingersoll Rand compressor?

On the Intellisys SG panel, fix the cause and press SET twice within 3 seconds; a motor overload must be reset at the overload relay first. On IRN 15-30 kW machines, fix the cause and press Stop/Reset. An emergency stop button is released by turning it clockwise. On the X8I sequencer, trips are reset by hand and some internal E codes need the main power removed and re-applied.

Sources

Codes and meanings follow the manufacturer documentation below. Wording is ours, simplified for the shop floor; the manual for your exact model and software version wins if it differs.

See the moment the line stopped

Fabrico, a light MES with computer vision, syncs camera footage with machine and timeline data, so you can replay the exact moment the line stopped and review the cause next to the compressor alarm. Cameras also catch short stops and a line that is switched on but not producing, the losses nobody writes down. Machines connect through a PLC, a Fabrico IoT device or an AI camera.

Book a Fabrico demo

The lookup stays free.

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