PSG Series

OIL/WATER SEPARATORS

INSTALLATION, OPERATION,
MAINTENANCE MANUAL AND
PARTS LIST

FAILURE TO READ AND UNDERSTAND THE FOLLOWING

INSTRUCTIONS MAY CAUSE YOU UNNECESSARY COMPLICATIONS
IN THE INSTALLATION OR OPERATION OF THIS EQUIPMENT.

More Than Air. Answers. C.C.N. : 38471157

Online answers: http://www.ingersollrandproducts.com
TELÉFONO: 1-800-AIR-COMP (1-800-247-2667)
REV. : A
DATE : SEPTEMBER 2009
 Limited One Year Warranty
The PSG Separators are warranted to be free from defects in material and workmanship, under
proper use, installation, application, and maintenance in accordance with the manufacturer’s
written recommendations and specification for a period of 18 months from the date of shipment
from the factory or 12 months from the date of installation, whichever comes first. The
manufacturer’s obligation under this warranty is limited to, and the sole remedy for any such
defect shall be, the repair or replacement (at manufacturer’s option) of unaltered products
returned to manufacturer within stated period.

In order to process a claim, Ingersoll Rand must get from the customer a proof of purchase (date
of purchase, invoice number). In no event, shall Ingersoll Rand be liable for business interruptions,
loss of profits, personal injury, costs of delay or any other special, indirect, incidental, or
consequential losses, cost, or damages.

NOTE - Routine maintenance and minor adjustments to the Ingersoll Rand oil/water separators
are not covered under this warranty. Prior to performing any possible warranty service or replacing
a possible warranted part, please contact your local Ingersoll Rand authorized representative.
All warranty claims must be performed by an Ingersoll Rand certified technician. Failure to
comply with this procedure will result in denial of warranty claim.

© INGERSOLL RAND COMPANY

 TABLE OF CONTENTS
1.0 GENERAL

2.0 HOW IT WORKS

3.0 INSTALLATION INS TRUCTIONS

3.1 Placement
3.2 Filter Preparation
3.3 Water Outlet Plumbing Preparation
3.4 Condensate Inlet Preparation
3.5 Collection Manifold Guidelines
3.6 Priming The System
3.7 Oil Outlet Tube Adjustment
3.8 Sample Testing
3.9 Commissioning

4.0 OPERATION INSTRUCTIONS

5.0 MAINTENANCE INSTRUCTIONS

5.1 Maintenance Schedule
5.2 Diffuser and Separation Filter Maintenance Procedure
5.3 Pre-Adsorber and Adsorption Module Replacement Procedure

6.0 SIZING

7.0 TROUBLESHOOTING

8.0 GENERAL DATA

9.0 PARTS LIST


1.0 GENERAL
(2) Processing: Both the Oil and Water enter the
The separator provides an environment where Vessel through exit holes in the Sediment Chamber.
the small percentage of an insoluble lubricant can Non emulsified oil will float to the surface and then be
rise to the surface to be skimmed off. Water that is removed via the Oil Outlet Tube to the Oil Container
displaced by fresh incoming condensate slowly sinks The Water slowly sinks to the bottom of the Vessel.
to the bottom, and then rises to pass through the It rises through a tube and enters the Pre-Adsorption
unique polar Adsorption Module. From there, the Chamber where it is pre-cleaned before it flows down
clean water can be safely discharged to your collection through the Adsorption Module for final polishing.
point. From there it exits the separator via the Water
Outlet Port located conveniently at the back of the
vessel.
2.0 HOW IT WORKS
(3) Monitoring: A translucent Oil Container is
(1) Depressurization: Condensate is depressurized provided to indicate just how much oil has collected
as it enters the separator through the three (3) ½” NPT for disposal.
Condensate Inlets in the Inlet Diffuser Assembly. Air Sample Jars are provided to collect water from the
is exhausted to atmosphere through the Filter located Sample Valve. A simple comparison test will confirm
in the top. Gravity draws the new condensate into the when it’s time to change the Adsorption Module.
Sediment Chamber and pushes the old condensate
through the Separation Filter. The Separation Filter
causes fine oil droplets to coalesce which speeds up
the separation process. It also prevents the dirt, rust
and scale from leaving the Sediment Chamber.

Condensate
Inlet Diffuser Inlets (3) Access Lid
Assembly Flow Adsorption
Indicator Module Pre-Adsorbtion
Chamber
Separation
Oil Outlet
Filter
Tube

Oil
Sediment Container
Chamber

Water Outlet
Port

Vessel

Sample
Valve


3.0 INSTRUCCIONES DE INSTALACIÓN 4. Reinstall the pre-wetted Pre-Adsorber and
Adsorption Module.
3.1 PLACEMENT Note: For ease of installation, roll the Adsorption
Module on the floor to elongate it. Pick-up the module
The separator must be installed on a flat and level in both hands and carry horizontally. Position the end
surface capable of supporting the entire functioning of the module at the top of the chamber and gently tip
weight of the installation. As gravity is responsible for up and slide into the chamber. Finally, press down on
the proper operation of the separator, it is highly the edges of the module to ensure it is fully installed
recommended that the unit be installed close to the and seated at the bottom of the chamber.
collection point for the treated condensate. Please
provide room around the unit for ease of maintenance 3.3 WATER OUTLET PLUMBING PREPARATION
and access to the filters.
1. Level the floor area where the separator will be placed to The size and location of the Water Outlet fitting will
ensure proper operation. control the water level in the separator.
2. Twist the external OIL OUTLET TUBE while raising it to its 1. Install a ¾” NPT elbow on the Water Outlet Port facing
maximum height. downward and route piping directly to the collection point
3. Position the translucent OIL CONTAINER below the OIL to limit any flow restriction.
OUTLET TUBE.
CAUTION: DO NOT RESTRICT OR REDUCE THE
DO NOT LOWER OIL OUTLET TUBE AT THIS TIME. SIZE OF THE WATER OUTLET PIPING.
RESTRICTING THE WATER OUTLET CAN RESULT
IMPORTANT: AMBIENT TEMPERATURE MUST IN DISCHARGING WATER INTO THE OIL
BE BETWEEN 35°F (2°C) AND 120oF (48°C). CONTAINER.
IMPORTANT: MAXIMUM DRAIN INLET
PRESSURE IS 250 PSIG (17 bar) NOTE: When using a common water outlet manifold,
install an elbow on the Water Outlet Port of each
NOTE: FLOW DIVIDER OPTION. When using multiple separator facing downward. All piping and manifold
separator units, centrally locate the Flow Divider must be lower than the height of the outlet and be
(CCN 2204432) to ensure uniform distribution. pitched toward the collection point.
The Flow Divider (CCN 2204432) must be installed securely 3.4 CONDENSATE INLET PREPARATION
above the separator units to ensure proper operation. Please
consult the Flow Divider (CCN 2204432) installation instruction The INLET DIFFUSER can be rotated by 90° or 180° to ease
section for further details. installation. To rotate the DIFFUSER follow
steps 1-3, otherwise proceed to step 4.
3.2 FILTER PREPARATION 1. Remove the four (4) socket head cap screws attaching the
INLET DIFFUSER to the separator.
The Pre-Adsorber and Adsorption Module are shipped 2. Rotate DIFFUSER to the desired position.
from the factory in plastic shipping bags to control dust 3. Reinstall the four (4) socket head cap screws and tighten.
and placed in their respective compartments. 4. Use flexible tubing to connect the condensate sources to
the Inlet Connections on the INLET DIFFUSER.
The following pre-wetting procedure removes dust 5. Refer to COLLECTION MANIFOLD GUIDELINES for
created during shipping and reduces the likelihood of installation of multiple drain lines.
air pockets.
1. Remove the Access Lid, Pre-Adsorber, and Adsorption NOTE: The use of a Flow Divider (CCN 2204432) is
Module from the separator unit.
recommended when demand style condensate drains
2. Remove the plastic shipping bags from the Pre- Adsorber
can collectively deliver more than 43 ounces.
and Adsorption Module.
3. Thoroughly hose-down the Pre-Adsorber and Adsorption
Module with fresh water while gently rolling until the rinse 3.5 COLLECTION MANIFOLD GUIDELINES
water runs clear.
Collection Manifolds permit several condensate drain sources
CAUTION: FAILURE TO THOROUGHLY PRE-WET to be combined into a single stream and one connection to
THE ADSORPTION MODULE MAY LEAVE AIR the separator or Flow Divider (CCN 2204432). The following
TRAPPED AND RESULT IN THE ADSORPTION suggestions are offered for the design and installation of a
MODULE FLOATING. Collection Manifold.

1. Use 1” minimum pipe to limit flow restrictions.

2. Use the bottom inlet connection of the INLET DIFFUSER or
Flow Divider (CCN 2204432).


3. Use a chemical and corrosion resistant piping and fittings,
such as PVC or copper. 1. Fill one (1) of the Sample Jars with clean tap water.
4. Locate the manifold at an elevation above the separator or This will be used as a reference.
Flow Divider (CCN 2204432). The manifold should slope in 2. The second Sample Jar will be used to collect a
the direction of flow. sample from the separator Sample Outlet.
5. Secure the manifold to isolate the separator or Flow Divider 3. Clean the Sample Jar thoroughly after sampling,
(CCN 2204432) from pipe loads. empty and dry.
6. Condensate drain lines should enter the Collection 4. Store the Sample Jars in the Placement Wells
Manifold from the top and at intervals no closer than one molded into the top of the separator.
foot. 5. Refer to the MAINTENANCE INSTRUCTIONS for
additional sampling details.
7. Provide a separate connection point for each drain source.
3.9 COMMISSIONING
3.6 PRIMING THE SYSTEM
The separator is now ready for operation.
The specific gravity differential between the water and
the lubricant is an important factor influencing separation.

Filling the separator with fresh, clean tap water before

commissioning prepares the unit for proper operation.

1. Use fresh, clean tap water to fill the separator

through the opening surrounding the Oil Outlet Pipe.

CAUTION: TO PREVENT OVERFLOWING, REDUCE

THE FLOW WHEN WATER BEGINS TO SPILL INTO
THE ADSORPTION MODULE

2. The unit is primed when clear water begins to flow

from the Water Outlet.
3. Allow the unit to sit for five (5) minutes to balance
the water level before proceeding to Oil Outlet Tube
Adjustment.

3.7 OIL OUTLET TUBE ADJUSTMENT

The Oil Outlet Tube extends up into the separator

vessel to remove oil from the liquid surface. When
sufficient oil has accumulated, it will be skimmed off of
the surface and drained into the Oil Container via the
Oil Outlet Tube.

1. Locate the Oil Container under the Oil Outlet Tube.

2. Grasp the Oil Outlet Tube with one hand and begin
to lower the top of the tube by gently twisting the
tube back and forth.
3. Lower the Oil Outlet Tube to an elevation with the
top of the tube approximately ½” above the water
level.

NOTE: It may take several months or more to

collect enough oil in the separator for it to begin
draining into the Oil Container. This is normal!

3.8 SAMPLE TESTING

Two (2) Sample Jars are included to provide a
comparative method of testing to ensure the separator
is operating properly.


4.0 OPERATION INSTRUCTIONS 1. Shut off condensate flow to Inlet Diffuser Assembly.
2. Unscrew the four Socket Head Cap Screws that
Do not pour condensate, oil, or any other fluid directly hold the Diffuser to the Vessel.
into the oil/water separator.
3. Lift up the Diffuser and move it out of the way so
Weekly, collect a sample of the discharge water in a clear glass you can remove the Sediment Chamber.
vessel and, compare it to tap water, checking for cloudiness.
4. Lift up the Diffuser and move it out of the way so
Replace the Adsorption Module when cloudiness you can remove the Sediment Chamber.
appears in the discharge water sample. 5. Tip the Sediment Chamber slightly to slowly pour
For detailed analysis, contact your local authority or the contents through the Separation Filter and
an approved testing laboratory. Ingersoll Rand back into the vessel until the liquid is emptied.
provides fluid testing services. To learn more about 6. Remove the Separation Filter from the recess
the services, please contact your local Ingersoll Rand inside the Sediment Chamber and discard.
service provider.
7. Clean the dirt, rust and scale from the Sediment
Chamber. Reinstall a new Separation Filter into
5.0 MAINTENANCE INSTRUCTIONS the recess.
8. Seat the Sediment Chamber into the vessel by
5.1MAINTENANCE SCHEDULE
Daily slowly pouring tap water into it until the water
1. Check the Oil level in the translucent Oil exits the discharge holes in the Chamber walls.
Container. Empty it when the oil level reaches 3/4 9. Remove and replace the Expansion Chamber
of capacity. element located on top of the Diffuser Assembly.
10. Reinstall the Diffuser Assembly and secure with
Every Two Weeks four socket head screws.
1. Take the empty Sample Jar and collect a sample
from the Sample Valve located above the Oil
5.3 PRE-ADSORBER AND ADSORPTION MODULE
Container.
REPLACEMENT PROCEDURE
2. Hold both the Sample Jar and the Reference Jar
to a light for a visual turbidity comparison. Prepare the replacement Adsorption Module and Pre-
3. Keep a spare Pre-Adsorber and Adsorption Adsorber for service as follows:
Module in stock to avoid change out problems. 1. Remove them from their plastic bags.
4. Change the Pre-Adsorber and Adsorption Module 2. Thoroughly hose down the Pre-Adsorber &
when the compared Condensate Sample Adsorption Module while rolling them until the
appears cloudy. water runs clear.
5. Pour the Condensate Sample back into the Pre- 3. Shut off the condensate flow to the Inlet Diffuser
Adsorber Chamber. Assembly and remove the Access Lid.
6. Wash and dry the Sample Jar before returning it 4. Use a polypropylene pad to adsorb and remove
to the Placement Well. any oil that is floating on the surface water in the
Note: The Sample Valve extracts the condensate Adsorption Module Chamber.
sample 2/3rds of the way through the Adsorption
Module. This provides enough time and security for 5. Grab Adsorption Module Handles and slowly lift
replacing the Adsorption Module before PPM out of chamber.
violations should occur. 6. Suspend bag over chamber for a couple of minutes to
Annually drain.
7. Install new Pre-Adsorber & Adsorption Module.
Keeping your separator in good working condition prevents
8. Reorder a spare Pre-Adsorber & Adsorption Module.
problems and pays you dividends all year long. Therefore,
as part of a good preventative maintenance program, we
ATTENTION: PLEASE BE SURE TO COMPLY WITH ALL
recommend cleaning out the Sediment Chamber and
APPLICABLE REGULATIONS WHEN DISPOSING OF
replacing the Adsorption Module at least once a year. The
LUBRICANT CONTAMINATED FILTERS.
following sections will provide you with these servicing details.

5.2 DIFFUSER AND SEPARATION FILTER MAINTENANCE

PROCEDURE
The cleanliness of your piping will dictate how
frequently you will need to perform this procedure.
However, we recommend an annual cleaning to
maintain the flow and to remove the dirt, rust and
scale that has accumulated.

 6.0 SIZING

Cold Climate: 15º C (60º F), 60% HR

Compressor Capacity (CFM)
IR Model
Compresores de tornillo Reciprocating Compressors

Turbine Oil Synthetic Oil Polyglycol PAO Ester Turbine Oil Diester

PS-7 60 60 60 60 60 60 60
PSG-15 850 640 175 850 640 425 361
PSG-30 1,700 1,275 390 1,700 1,275 850 723
PSG-60 3,400 2,550 750 3,400 2,550 1,700 1,445
PSG-90 5,100 3,825 950 5,100 3,825 2,550 2,168
PSKG-120 6,800 4,100 1,500 6,800 5,100 3,400 2,890
PSKG-180 10,200 7,650 1,900 10,200 7,650 5,100 4,335

Mild Climate: 27º C (80º F), 60% HR

Compressor Capacity (CFM)
IR Model
Compresores de tornillo Reciprocating Compressors

Turbine Oil Synthetic Oil Polyglycol PAO Ester Turbine Oil Diester

PS-7 60 60 60 60 60 60 60
PSG-15 450 340 175 450 340 225 191
PSG-30 900 685 390 900 685 450 383
PSG-60 1,800 1,370 750 1,800 1,370 900 765
PSG-90 2,700 2,050 950 2,700 2,050 1,350 1,148
PSKG-120 3,600 2,740 1,500 3,600 2,740 1,800 1,530
PSKG-180 5,400 4,100 1,900 5,400 4,100 2,700 2,295

Hot Climate:: 32º C (90º F), 70% HR

Compressor Capacity (CFM)
IR Model
Compresores de tornillo Reciprocating Compressors

Turbine Oil Synthetic Oil Polyglycol PAO Ester Turbine Oil Diester

PS-7 60 60 60 60 60 60 60
PSG-15 290 215 175 290 215 145 123
PSG-30 575 430 390 575 430 288 244
PSG-60 1,150 860 750 1,150 860 575 489
PSG-90 1,725 1,300 950 1,725 1,300 863 733
PSKG-120 2,300 1,725 1,500 2,300 1,725 1,150 978
PSKG-180 3,450 2,600 1,900 3,450 2,600 1,725 1,466

NOTES: 1. Ratings are based on 4 PPM oil carryover

2. Filter life is one (1) year based on 4,000 operating hours per year.


7.0 TROUBLESHOOTING
Trouble Probable Cause/Remedy
Water in Oil Container Unit is not on a level surface.
· Level area as noted in “PLACEMENT” section.
Oil Outlet Tube is set too low allowing water to exit with the oil.
· Refer to “OIL OUTLET TUBE ADJUSTMENT” section for details.
A large condensate surge will elevate the water level above the Oil
Outlet Tube and allow water to escape before level adjusts.
· Install a Flow Divider (CCN 2204432) to prevent an overload by
controlling the surge.
· Install the proper demand drain to prevent surge, reduce emulsification,
and extend filter life. Contact IR for assistance.
Condensate spills out at base Large condensate surges can exceed the capacity of the Sediment
of Inlet Diffuser Assembly Chamber and cause it to overflow below the Inlet Diffuser
Assembly.
· Install a Flow Divider (CCN 2204432) to prevent an overload by
controlling the surge.
· Install the proper demand drain to prevent surge, reduce emulsification,
and extend filter life. Contact IR for assistance.
Condensate backs up inside Flow through Separation Filter is restricted by sludge or debris.
Diffuser Assembly · Replace Separation Filter. See “SEPARATION FILTER” replacement
instructions located in “MAINTENANCE INSTRUCTIONS”
Oil layer is lumpy and foamy Bacterial contamination.
· Disassemble the separator. Pressure wash or steam clean vessel and
components. Rinse well and replace filters and modules.
No oil in Oil Container Oil accumulation will vary and may take months to establish a layer.
· Check depth of oil layer in the vessel. Refer to the “OIL OUTLET TUBE
ADJUSTMENT” section for details.
· Oil Outlet Tube may be set too high.

Frequent Adsorption Module Lubricant has poor demulsibility characteristics and or unit is
Replacement undersized.
· Perform the “GLASS JAR TEST” as described in the INTRODUCION..
Contact IR for further assistance.
· Replace lubricant with another that has better demulsification
characteristics to extend the Adsorption Module life.
· Replace timer-style drains with demand drains to reduce emulsification.
Contact IR for assistance.
Turbulence due to large condensate surges allows emulsified oil
to enter Adsorption Module.
· Install a Flow Divider (CCN 2204432) to prevent turbulence by
· controlling surges.
Atmospheric contaminants are creating irreversible emulsion.
· Determine source of contaminant and isolate from air intake.
· Disassemble and pressure wash or steam clean separator and
components. Rinse well and reassemble with new filters and modules.
Different lubricants from multiple sources limits demulsification.
· Standardize on a lubricant on multiple compressor systems.
· Isolate different lubricant systems and install parallel systems.
Cross-contamination of lubricants.
· Use a dedicated transfer device for each lubricant and clean after use.



J

K
P
L Model A B C D E F G J K L M N P Q R
PSG
15 29.7 27.0 20.7 14.5 11.3 5.3 16.0 26.5 26.0 9.0 14.0 19.5 4.5 2.7 10.7

30 39.0 36.3 20.7 14.5 11.3 5.3 16.0 26.5 26.0 9.0 14.0 19.5 4.5 2.7 10.7
8.0 GENERAL DATA

60 39.0 36.3 30.0 20.2 17.1 4.7 23.0 35.0 32.0 21.8 26.8 31.5 6.0 6.9 18.0

M N 90 45.0 41.3 36.0 26.0 23.1 4.7 29.0 35.0 32.0 21.8 26.8 31.5 6.0 16.9 18.0

NOTES: 1. ALL DIMENSIONS IN INCHES, UNLESS OTHERWISE SHOWN.

R 2. ALL DIMENSIONS ARE +/- .5, UNLESS OTHERWISE SHOWN.
Access Cover 3. DIFFUSER IS ROTATABLE IN 90 INCREMENTS.
Condensate Inlets 4. PSG-60 USED TO ILLUSTRATE DIMENSIONS.
(3) 1/2 NPT

Diffuser Sample Jar

(See Note 3)
1.75
Reference Jar
1.75
Water Out Connection
F 3/4 NPT - PSG 15-30
1 NPT - PSG 60-90

Water Sample Valve

Oil Outlet Tube

A

C G
D
E
9.0 PARTS

1 7
7

1
2a

8 8
2a

3 2c 3

2c

2b
2b
9

9
5 5

2d
6
2d
6

10
10
4
11 4 11

36* 36*

PSG PARTS TABLE

Part Description PSG-15 Qty PSG-30 CANT PSG-60 CANT PSG-90 CANT
1 Diffuser Cover Ring 38339875 1 38465662 1 38465662 1 38465662 1
2a Diffuser Pad 1 1 1 1
2b Separation Filter 1 1 1 1
38339057 38465712 38465761 38469052
2c Adsorption Module 1 2 4 4
2d Pre-Adsorption Pad 1 1 1 1
3 Diffuser Assembly 38339891 1 384656570 1 38465670 1 38465670 1
4 Vessel 38339966 1 38465720 1 38465753 1 38465688 1
5 Sediment Chamber 38339917 1 38465696 1 38465696 1 38465696 1
6 Sample Jar 38339925 2 38339925 2 38339925 2 38339925 2
7 Flow Indicator 38339933 1 38469532 1 38469532 1 38469532 1
8 Cover 38339941 1 38465704 1 38465746 1 38465746 1
9 Oil Outlet Tube 38339958 1 38469540 1 38469540 1 38469540 1
10 Sample Valve 38339974 1 38339974 1 38339974 1 38339974 1
11 Oil Container 38339982 1 38339982 1 38339982 1 38339982 1