QUALITY MANUAL

WEST CHESTER, PA FACILITY

TABLE OF CONTENTS

Air Solutions Date: 1 September 2008

Davidson, NC 28036 Cancels:

The Ingersoll Rand Quality Manual for the West Chester, PA manufacturing facility is a proprietary document that
describes procedures for all Departments within the facility. Recognizing requests for Quality information and
respecting the proprietary nature of the contents of the master document, Ingersoll Rand provides the attached
summary of the sections for the Engineering, Manufacturing and Quality functions within the facility.
 Rev: 11/24/2008

TABLE OF CONTENTS

“ENGINEERING”

POLICY NUMBER POLICY TITLE

40.001.000 Engineering Change Requests / Log

40.002.000 Engineering Change Orders / Log
40.003.001 Engineering Capillary Tube Installation
40.004.000 Engineering Project Control Procedure
40.005.000 Engineering Request & Job Log (Pending)
40.006.000 Painting Specifications
40.007.000 50 Hertz Rundown Procedure
40.008.000 UL Panel Shop Procedure
40.009.000 PLC Programming Procedure
40.010.000 Qualification Testing – Shake Table
40.011.000 Physical Compliance Audit – BOM to Product
40.012.000 Test Cap Tube / Charge / CAGI Performance (Pending)
40.013.000 MTO Release (Pending)
40.014.000 Component Selection (Pending
40.015.000 New Product Release (Pending)
40.016.000 Refrigerant Leak Prevention Guide
40.017.000 R&D Testing – Expansion Device / Refrigerant Charge /
CAGI Performance
40.018.001 Pressure Vessels
40.019.000 Technical Manuals
40.020.000 (DPC) Digital Performance Controller Programming
40.021.000 Labor Standards Entry
40.022.003 UL508A
40.023.000 R&D Data Reporting and Data Storage
40.024.000 Ground Bonding
40.025.000 Item Master Guidelines
 Rev: 11/24/2008

TABLE OF CONTENTS

“MANUFACTURING”

POLICY NUMBER POLICY TITLE

50.000.000 Statement of Authority

50.001.000 Manual of Manufacturing Procedures
50.002.002 Control of MFG. Procedures - Controlled Copies Record
50.003.001 Organization Chart
50.004.000 ZEKS Manufacturing Procedures
50.005.000 Audits
50.006.000 Heat Reactivated Dryer Critical Set-up Functions
50.007.000 Records Retention
50.008.000 Remove Glycol/Water Contamination from 1000-1600
HSF Evaporator Assembly (Refrigerant Side)
50.009.003 Access Valve Torque Spec.
50.010.000 Access Valve Bubble Leak Test
50.011.002 Brass Cap Assembly (Gauge Connection)
50.012.002 Brass Cap Installation and Bubble Leak Test
50.013.004 Capillary Tube Installation & Routing
50.014.001 Double Flare Installation and Torque Requirements
50.015.000 Refrigerant Leak Prevention Guide
50.016.000 Glycol Re-circulating Pump Installation
50.017.001 Glycol / Water Controller and Mixture Check
50.018.000 Brown Kraft Paper (Packaging)
50.019.000 Operating Instructions and Process LV-8 Refrig.
Recovery
50.020.000 Maintenance Service Request Procedure
50.021.000 Automatic Charging
50.022.001 Refrigerated Dryer Freon Leak Testing
50.023.000 Calibrate High Temp Thermostat
50.024.000 Testing and Calibration of PC Boards
50.025.001 Leak Testing COR/ORF/PDC Vessels
 Rev: 11/24/2008

TABLE OF CONTENTS

“MANUFACTURING”

POLICY NUMBER POLICY TITLE

50.026.000 Compustat Probe Terminal to Board Connection

50.027.000 High Pot Check, Test and Trouble Shooting
50.028.000 Copper Scrap Handling
50.029.000 Recording 50/40 Run-down Time
50.030.000 Torque Spec for Assembly Screws
50.031.000 Insulation and Adhesive Applications
50.032.000 Refrigerated Dryer Q.C. Check Sheets & Rundown Data
Completion
50.033.000 Air System Pressure Testing
50.034.000 Blow Out Coils With OSHA Cert. Blow Gun
50.035.000 Manufacturing Employee Orientation & Training
50.036.000 Pre-cooler Crossover Leak Testing
50.037.000 Pneumatic Testing Procedure
50.038.006 Leak Testing Exchangers in Coil Shop Test Tank
50.039.000 Hydrostatic Testing Procedures
50.040.000 Coil Dept. Leak Test / Q.C. Check off Tag
50.041.000 Exchanger Degreasing Cleaner (Flush Out)
50.042.001 Desiccant / Heat Reactivated / Purifier Q.C. Check
Sheets
50.043.000 Transducer & Temperature Probe Labeling
50.044.000 Filter Leak Test Procedure
50.045.000 Available
50.046.000 Available
50.047.000 Procedure for Environmental Monitoring of ZEKS Paint
Inventory
50.048.000 Available
50.049.000 Computrol Discharge Temperature Probe Installation
 Rev: 11/24/2008

TABLE OF CONTENTS

“MANUFACTURING”

POLICY NUMBER POLICY TITLE

50.050.000 Sheet Metal First Piece Inspection

50.051.001 Z-trol Controller Processing & Setup Procedures
50.052.000 Threaded Pipe Cleaning/Degreasing
50.053.004 Replenishment of Bulk Refrigerant Cylinders & Daily
Shutdown of Refrigerant Pumping Stations
50.054.000 Application of Thermal Mastic and Temperature Probes
in Temperature Well Tubes
50.055.000 Chip Removal Process for Machining of CFX Vessels
50.056.000 New Employee Orientation and Training Program
50.057.001 Soldering & Brazing Certification and Recertification
50.058.000 Coil Shop & Final Assembly Basic Skills Training
50.059.000 Quality Audit Procedure
50.060.000 Water Removal Procedure for Water Cooled Refrigerated
Dryers
50.061.000 Intrepid Filter Assembly
50.062.000 Use and Storage of DOT 55 Gallon Drums
50.063.000 Available
50.064.000 Hydro-test Preventative Maintenance
50.065.000 Sandblasting Preparation Procedure
50.066.000 Refrigerated Dryer Paint Specifications
50.067.002 Desiccant Dryer Paint Specifications
50.068.000 Welding Specification
50.069.000 Installation of Desiccant
50.070.001 Desiccant Dryer Leak Testing
50.071.000 Standard Hot Gas Valve Setup
50.072.000 Temperature Probe Insertion Depth Verification into Well Tube

TABLE OF CONTENTS
 Rev: 11/24/2008

“MANUFACTURING”

POLICY NUMBER POLICY TITLE

50.073.000 Leak Testing CFX Exchangers in Coil Shop Test Tank

50.074.000 Element Retaining, Filter
50.075.000 Moisturizers, Breathing Air
50.076.000 Refrigerated Dryer Pre-charging Rate of Rise Test
50.077.002 75-150 HSG Glycol Pump Priming
50.078.001 Desiccant Dryer Moisture Load Control Setup
50.079.001 Maneurop Compressor Rotolock Installation & Torque
Specification
50.080.000 Leak Testing Glycol System on CFX Exchangers
50.081.000 Printed Circuit Board (PCB) Anti-static Handling &
Installation
50.082.000 Audit & Performance Plan
50.083.000 DC Cartridge Regeneration
50.084.000 DC Filter Cartridge Packaging
50.085.000 Test Procedure for Delta P Switch Gauge (630270)
50.086.001 CFX Leak Test Procedure
50.087.000 Grounding for 120vac MPS and HPS Desiccant Dryers
50.088.000 Copper Tubing Drilled Hole Diameter for Access Valve
Insertion
50.089.000 Refrigerant Handling Procedure
50.090.002 Calibration of Refrigeration Gauge Sets
50.091.000 Available
50.092.000 Available
50.093.000 Available
50.094.000 Humidistat Calibration
50.095.001 Solder 059” Capillary Tube to Refrigerant Pressure Gage
 Revised: 11/24/08

TABLE OF CONTENTS

“QUALITY”

POLICY NUMBER POLICY TITLE

80.001.000 Nitrogen Tank Gauge Calibration

80.002.000 ZEKS Corporate Quality Statement
80.003.000 Outside Supplier Corrective Action Request
80.004.000 Internal Corrective Action Procedure
80.005.000 Auto Charge Station – Testing & Calibration
80.006.000 Quality Audit Procedure
80.007.000 Receiving Inspection Procedure
80.008.000 Calibration of Manufacturing and Test Equipment
80.009.000 Refrigerant Leak Prevention Guide
80.010.000 Audit and Performance
80.011.000 Control of Non-Conforming Product Discrepant Parts &
Material