Ingersoll-Rand 2000P, 2000 User Manual

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Owner’s Manual

Installation, Operation and Maintenance

Instructions for Models 2000 & 2000P

Two-Stage Reciprocating Air Compressors

IMPORTANT INFORMATION! READ AND FOLLOW THESE INSTRUCTIONS. RETAIN FOR REFERENCE.

SAFETY

DEFINITIONS

DANGER WILL cause DEATH, SEVERE INJURY or

aWARNING CAN cause DEATH, SEVERE INJURY or

aCAUTION WILL or CAN cause MINOR INJURY or property

GENERAL SAFETY PRECAUTIONS

DANGER INTAKE AIR. Can contain carbon monoxide or

aWARNING HAZARDOUS VOLTAGE. Can cause serious injury

aCAUTION RISK OF BURSTING. Use only suitable air

substantial property damage.

damage.

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.

or death. Disconnect power and bleed pressure from the 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.

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.

HIGH PRESSURE AIR. Bypassing, modifying or removing safety/relief valves can cause serious injury or death. Do not bypass, modify or remove safety/relief valves. Do not direct air stream at body. Rusted tanks can cause explosion and severe injury or death. Drain tank daily or after each use. Drain valve located at bottom of tank.

handling parts acceptable for pressure of not less than the maximum allowable working pressure of the machine.

GENERAL INFORMATION

INTRODUCTION

This manual provides safe and reliable instructions for the installation, operation and maintenance of your Ingersoll-Rand air compressor. Carefully read this manual before attempting to operate or perform any maintenance. If you are uncertain about any of the instructions or procedures provided in this manual, contact Ingersoll-Rand. We recommend you retain this manual, and all publications provided with your air compressor, in a location which is accessible to all personnel who operate and service your compressed air equipment.

APPLICATION

Ingersoll-Rand’s standard two-stage lubricated air compressors are single-acting, air-cooled machines. Typical compressors are furnished as compact, self-contained, air receiver tank mounted units that are automatically regulated and driven by an electric motor. An air-cooled aftercooler, low oil level shutdown switch and automatic drain valve are among the optional accessories that can be furnished. Bare compressor pumps and baseplate-mounted units are also available.

These compressors may be used for a variety of compressed air application up to 250 PSIG (17.5 kg/cm²). Application of these compressors as either a primary or supplementary source of air is virtually unlimited in industrial plants, service stations and auto repair shops. Supplementary service includes such uses as furnishing air at pressure not carried in regular shop lines, air at isolated locations, and standby service for air when larger compressors are shut down.

TWO-STAGE OPERATION

The basic principle of operation is as follows: On the suction stroke of the first-stage piston(s), air at atmospheric pressure enters the cylinders through the inlet filter(s) and then the inlet valves located in the head. On the compression stroke of the first-stage piston(s), the air is compressed to an intermediate pressure and discharged through the discharge valves(s) into common manifold(s). From the manifold(s) the air passes through the intercooler tubes, where the heat of first-stage compression is removed. On the suction stroke of the second-stage piston this cooled air enters the second-stage cylinder through the inlet valve. The compression stroke of the second-stage piston compresses the air to the final discharge pressure and forces it out through the discharge valve into the receiver tank or system. If cooling of the discharge air is required, an air-cooled aftercooler should be installed between the compressor discharge and the receiver tank or system.

C.C.N.: 22284475 Rev. : A Date : February 2005

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For maintaining the receiver tank or system air pressure within predetermined limits, the compressor may be operated with automatic start & stop control or constant speed control regulation. The type of regulation used depends upon the application.

ADDITIONAL REFERENCES

Unless otherwise stated, dimensions, weights and measurements are provided in standard U.S. measure followed in parentheses by the metric conversion. Any torque values given are stated in inch or foot pounds followed by the Newton-meter equivalent in parentheses. Electrical characteristics are given in voltage-phase-hertz.

RECEIPT & INSPECTION

Ensure adequate lifting equipment is available for unloading and moving the unit to the installation site.

NOTE Lifting equipment must be properly rated for the

weight of the unit.

aCAUTION Lift the unit by the shipping skid only. Do not use

the motor lifting eye to lift the entire unit. The motor lifting eye is for removing the motor from the unit only.

aCAUTION! Do not work on or walk under the unit while it

is suspended.

Use suitable lifting equipment (i.e. forklift) to lift and transport the unit to the installation site. Ensure the lifting equipment, straps, etc. are capable of supporting the weight of the unit.

INSTALLATION

SELECTING A LOCATION

ELECTRIC MOTOR UNITS. For most electric motor units, select a

relatively clean and dry well-lighted indoor area with plenty of space for proper ventilation, cooling air flow and accessibility. Provide 1,000 cubic feet of fresh air per 5 horsepower. Locate the unit at least 15 inches (38 cm) from walls, and make sure the main power supply is clearly identified and accessible.

Unless the electrical components of the unit are specially protected for outdoor use, do not install an electric motor unit outdoors or in an area that will expose the electrical components to rain, snow or sources of appreciable moisture.

WARNING FOR UNITS EQUIPPED

WITH ELECTRIC DRAIN VALVE

aWARNING The electric drain valve incorporates arcing or

sparking parts, such as snap switches, receptacles and the like that tend to produce arcs or sparks and, therefore, when located in a garage, the compressor should be in a room or enclosure provided for the purpose, or the electric drain valve should be 18 inches (457 mm) or more above the floor.

AMBIENT TEMPERATURE CONSIDERATIONS. Ideal operating

temperatures are between 32°F and 100°F (0°C and 37.8°C). If temperatures consistently drop below 32°F (0°C), install the compressor in a heated area. If this is not possible, you must protect safety/relief valves and drain valves from freezing. If temperatures are consistently below 40°F (4.4°C), consider installing an external crankcase heater kit, especially if the compressor has difficulty starting.

Before signing the delivery receipt, inspect for damage and missing parts. If damage or missing parts are apparent, make the appropriate notation on the delivery receipt, then sign the receipt. Immediately contact the carrier for an inspection.

All material must be held in the receiving location for the carrier’s inspection.

Delivery receipts that have been signed without a notation of damage or missing parts are considered to be delivered “clear.” Subsequent claims are then considered to be concealed damage claims. Settle damage claims directly with the transportation company.

If you discover damage after receiving the unit (concealed damage), the carrier must be notified within 15 days of receipt and an inspection must be requested by telephone with confirmation in writing. On concealed damage claims, the burden of establishing that the unit was damaged in transit reverts back to the claimant.

Read the unit nameplate to verify it is the model ordered, and read the motor nameplate to verify it is compatible with your electrical conditions. Make sure electrical enclosures and components are appropriate for the installation environment.

aCAUTION Never operate the compressor in temperatures

below -15°F (-26.1°C) or above 104°F (40°C).

HUMID AREAS. In frequently humid areas, moisture may form in the

pump and produce sludge in the lubricant, causing running parts to wear out prematurely. Excessive moisture is especially likely to occur if the unit is located in an unheated area that is subject to large temperature changes.

Two signs of excessive humidity are external condensation on the pump when it cools down and a “milky” appearance in petroleum lubricant.

You may be able to prevent moisture from forming in the pump by increasing ventilation, operating for longer intervals or installing an external crankcase heater kit.

NOISE CONSIDERATIONS. Consult local officials for information regarding acceptable noise levels in your area. To reduce excessive noise, use vibration isolator pads or intake silencers, relocate the unit or construct total enclosures or baffle walls.

MOUNTING

aWARNING Remove the unit from the skid before mounting.

The compressor must be bolted to a firm, level, solid foundation (such as a concrete floor) using the vibration isolation pads provided with the compressor. Installation on I-beams, open-grid flooring systems, or non-solid surfaces is not recommended.

Failure to install the unit using the pads provided with the unit and in accordance with the installation instructions as outlined in the operator's manual may result in mechanical failure to the compressor and cancellation of package warranty coverage. Ingersoll-Rand shall bear no responsibility for equipment installed on non-approved vibration isolation mounts or non-solid surfaces.

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To mount the unit, use the following procedure:

1. Mark the location of the mounting holes.

2. Drill 2-1/4" deep holes using a concrete drill bit sized per the

following table.

Tank Size Drill Bit (Gal.) Size

120 1/2"

240 5/8"

NOTE: It may be helpful to use a piece of tape on the

drill bit to mark the proper depth.

3. Drill a hole through the center of each isolation pad.

4. Drive the anchors into the mounting holes with the threaded portion

up.

5. Place the isolation pads over the anchors as shown in the illustration below.

6. Position the compressor over the drilled holes and slowly lower the unit to the isolation pads.

7. Bolt the compressor to the floor using the 4" long bolts provided. Torque each bolt in a criss-cross pattern to 10 ft lb.

After the unit has been anchored into position, check the unit for level by placing a level on the subbase and checking the readings from side-to-side and from front-to-back. Use metal shims under the "short" feet if necessary to obtain level.

Typical Remote Air Inlet Piping.

ELBOW

Direct to compressor air intake (if distance is less than 6 feet)

INTAKE HOSE

SUPPORT

PIPE

SUPPORT

TEE

HOSE FITTING

BUSHINGS

DRAIN VALVE

AIR INLET FILTER

OUTSIDE WALL

INSTALLING DISCHARGE PIPING

aWARNING Do not use plastic pipe, soldered copper

fittings, rubber hose, or lead-tin soldered joints anywhere in the compressed air system.

HOOD

A = Level concrete floor B = Foundation bolt / anchor C = Isolation pad D = Compressor mounting foot E = Washer F = Nut

INSTALLING REMOTE AIR INLET PIPING

aCAUTION Do not operate the unit without air inlet

If the air around the unit is relatively free of dirt, install the air inlet filter at the inlet connection at the pump. If the air is dirty, pipe the filter to a source of clean air. Use PVC plastic tubes for remote inlet piping. Do not use black pipe or galvanized pipe, as these promote sweating and rust. Consider installing an in-line type filter for ease of cleaning and replacement. Make the line as short and direct as possible and as large, or larger, than the diameter of the inlet connection on the pump. Do not install piping with a diameter lower than that of the pump intake.

Increase the pipe diameter one size for every 10 feet (3 m) of length or every 90° bend. Make sure the piping is adequately braced.

If you pipe the filter outdoors, cover it with a hood to prevent the entrance of rain or snow.

Heavy duty filter elements and filtration equipment are available for fine airborne dust, such as cement and rock dust.

filtration.

aCAUTION! If you will be using synthetic compressor

lubricant, all downstream piping material and system components must be compatible. Refer to the following material compatibility list. If there are incompatible materials present in your system, or if there are materials not included in the list, contact Ingersoll-Rand for recommendations.

SYNTHETIC COMPRESSOR LUBRICANT

MATERIAL COMPATIBILITY LIST

SUITABLE

Viton®, Teflon®, Epoxy (Glass Filled), Oil Resistant Alkyd, Fluorosilicone, Fluorocarbon, Polysulfide, 2-Component Urethane, Nylon, Delrin®, Celcon®, High Nitrile Rubber (Buna N. NBR more than 36% Acrylonitrile), Polyurethane, Polyethylene, Epichlorohydrin, Polyacrylate, Melamine, Polypropylene, Baked Phenolics, Epoxy, Modified Alkyds (® indicates trademark of DuPont Corporation)

NOT RECOMMENDED

Neoprene, Natural Rubber, SBR Rubber, Acrylic Paint, Lacquer, Varnish, Polystyrene, PVC, ABS, Polycarbonate, Cellulose Acetate, Low Nitrile Rubber (Buna N. NBR less than 36% Acrylonitrile), EPDM, Ethylene Vinyl Acetate, Latex, EPR, Acrylics, Phenoxy, Polysulfones, Styrene Acrylonitrile (San), Butyl

NOTE All compressed air systems generate

condensate which accumulates in any drain point (e.g. tanks, filters, drip legs, aftercoolers, dryers). This condensate contains lubricating oil and/or substances which may be regulated and must be disposed of in accordance with local, state, and federal laws and regulations.

GENERAL REQUIREMENTS. The piping, fittings, air receiver tank, etc.

must be certified safe for at least the maximum working pressure of the unit. Use hard-welded or threaded steel or copper pipes and cast iron fittings that are certified safe for the unit’s discharge pressure and temperature. DO NOT USE PVC PLASTIC IN THE COMPRESSED AIR DISCHARGE LINE. Use pipe thread sealant on all threads, and make up joints tightly to prevent air leaks.

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CONDENSATE DISCHARGE PIPING. If installing a condensate discharge line, the piping must be at least one size larger than the connection, as short and direct as possible, secured tightly and routed to a suitable drain point or waste container. Condensate must be disposed of in accordance with local, state, and federal laws and regulations.

aWARNING If an aftercooler, check valve, block valve, or

any other restriction is added to the compressor discharge, install a properlysized ASME approved safety/relief valve between the compressor discharge and the restriction.

INSTALLING ELECTRICAL WIRING (ELECTRIC MOTOR UNITS)

aWARNING Electrical installation and service should be

performed by a qualified electrician who is familiar with all applicable local, state and federal laws and regulations.

GENERAL. The motor rating, as shown on the motor nameplate, and

the power supply must have compatible voltage, phase and hertz characteristics.

WIRE SIZE. The electrical wiring between the power supply and electric motor varies according to motor horsepower and other factors. Install adequately sized power leads to protect against excessive voltage drop during start-up. Refer to the National Electric Code (NEC) for information on selecting the proper wire size and securing electrical connections. If you connect additional electrical equipment to the same circuit, consider the total electrical load when selecting the proper wire size. DO NOT USE UNDERSIZE WIRE.

If wire size information is not available, the wire sizes shown in the following wire selection chart can be used as a safe guide, if the distance does not exceed 50 feet (15.3 m). For longer distances, consult and electrical contractor or the local electric company for recommendations.

MOTOR THREE

HP PHASE

200V 230V 460V 575V

20 3 4 8 10

25 1268

300168

COMPRESSOR LUBRICATION

aCAUTION Do not operate without lubricant or with

SYNTHETIC COMPRESSOR LUBRICANT. Ingersoll-Rand recommends

All-Season Select

ALTERNATE LUBRICANTS. You may use XL-300 or a comparable petroleum-based lubricant that is premium quality, does not contain detergents, contains only anti-rust, anti-oxidation, and anti-foam agents as additives, has a flashpoint of 440°F (227°C) or higher, and has an auto-ignition point of 650°F (343°C) or higher.

See the petroleum lubricant viscosity table below. The table is intended as a general guide only. Heavy duty operating conditions require heavier viscosities. Refer specific operating conditions to Ingersoll-Rand for recommendations.

Temperature Around Viscosity @ 100°F Viscosity Grade

Compressor (37.8°C)

°F °C SUS Centistokes ISO SAE

< 40 < 4.4 150 32 32 10

40-80 4.4-26.7 500 110 100 30

80-125 26.7-51.0 750 165 150 40

* = For Models 2000 and 2000P, use Ingersoll-Rand XL-740HT Compressor Oil in temperatures above 100°F (37.7°C).

If you use a petroleum-based compressor lubricant at start-up and decide to convert to All-Season Select decarbonized and flushed before conversion. Contact Ingersoll-Rand for more information.

FILLING PROCEDURES:

1. Unscrew and remove the oil fill plug.

2. Fill the crankcase with lubricant.

3. Replace the oil fill plug HAND TIGHT ONLY.

aCAUTION Do not remove the oil fill plug while the

Refer to the following table for crankcase capacity.

inadequate lubricant. Ingersoll-Rand is not responsible for compressor failure caused by inadequate lubrication.

synthetic lubricant from start-up.

later on, the pump must be

compressor is running.

MAGNETIC STARTER. If the motor installed on your unit has a motor

reset button, it does not require a magnetic starter. If the motor does not have this button and the unit does not have a factory-installed starter, install a magnetic starter with thermal overload protection. Follow the manufacturer’s instructions for installation. Ingersoll-Rand cannot accept responsibility for damages arising from failure to provide adequate motor protection.

FUSES. Refer to the NEC to determine the proper fuse or circuit breaker rating required. When selecting fuses, remember the momentary starting current of an electric motor is greater than its full load current. Time-delay or “slow-blow” fuses are recommended.

PRESSURE SWITCH. On units without a factory-installed pressure switch, wire a pressure switch in accordance with the appropriate wiring schematic in the DIAGRAMS section of this manual. Mount the pressure switch in accordance with the manufacturer’s recommendations. The connecting line to the receiver tank must be as short and direct as possible, and certified safe for at least the maximum working pressure of the unit.

Model Crankcase Capacity

2000, 2000P 176 oz. (5205 ml.)

Use one of the following methods illustrated to determine when the crankcase is full.

A = FULL level B = ADD level

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LOW OIL LEVEL SWITCH

A float activated low oil level switch may be installed to protect your unit against damage due to insufficient compressor oil level. Low oil level in the compressor crankcase causes the switch contacts to open, thus shutting the unit down until the proper oil level has been restored.

Proper protection against low oil level depends on proper adjustment of the low oil level switch. During the initial run, stop the unit and drain one quart of oil from the compressor crankcase into a suitable clean container. Listen for the switch to click or check the switch with a continuity tester.

The float sometimes gets cocked or stuck during shipping. If the float is cocked or stuck, open the disconnect switch, drain the remaining oil, remove the crankcase cover and then free the float. Reassemble and then reuse the same oil.

NOTE If the float is cocked in the low position, the unit

cannot start.

OPERATION

INTERMITTENT DUTY FORMULA

Units operating above 200 PSIG are to be operated according to the "Intermittent Duty Formula."

INTERMITTENT DUTY FORMULA

Pump-up time should not ordinarily exceed thirty (30) minutes or be less than ten (10) minutes. Shutdown periods between cycles of operation should be at least equal to the pump-up time. Note: When the compressor is regulated by constant speed control, the shutdown period is the time the compressor is operating unloaded.

A pump-up time limit with the following cool-down period is recommended to protect the valves and heads against stabilized high operating temperatures, which could rapidly build up carbon in these areas.

All inquiries for high-pressure compressor application where the "use" cycle differs from the "Intermittent Duty Formula" should be referred to Ingersoll-Rand.

START-UP (ELECTRIC MOTOR DRIVEN MODLES)

1. Close the service valve.

2. Release any remaining tank pressure by slowly opening the

manual drain valve.

3. Close the manual drain valve and apply power to the compressor. If the pressure switch is equipped with an “ON/AUTO-OFF” lever, flip the switch to the “ON/AUTO” position. If the unit is equipped with a control panel “ON/OFF” switch, move the switch to the “ON” position.

Typical Pressure Switch

Typical Service Valve (A = Open, B = Closed)

aCAUTION Unusual noise or vibration indicates a

problem. Do not continue to operate until you identify and correct the source of the problem.

NOTE En sure t he dir ec tion o f r otati on is correct per

the arrow on the motor. If the rotation is incorrect on three-phase units, interchange any two of the three leads.

COMPRESSOR CONTROLS

ADJUSTMENT PROCEDURE. Select either automatic start and stop

control or constant speed control by adjusting the knob on the auxiliary valve. For automatic start and stop control, turn the knob on the auxiliary valve fully clockwise to disable the auxiliary valve. The pressure switch will then start and stop the unit.

NOTE For dual control models, automatic start and

stop is preferred.

Auxiliary Valve.

uxiliary Valve.

Select constant speed control if the unit restarts in less than 10 minute intervals or runs more than 40 minutes per hour. Turn the knob fully counterclockwise to run the unit continually.

NOTE The auxiliary valve is factory pre-set at 5 PSIG

lower than the factory pressure switch setting.

NOTE Automatic Start & Stop Control is intended for

use when the motor will start no more than 6 times per hour.

aCAUTION Running unloaded for more than 20 minutes

per hour or more than 15 minutes continually with the use of constant speed control will cause oil pumping and should be avoided.

4. Slowly open the service valve.

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PRESSURE SWITCH ADJUSTMENT

aWARNING High voltage is present at the pressure switch

contacts when the power supply is connected. Disconnect, lock and tag main power supply before making adjustments.

aCAUTION Do not adjust the pressure switch to exceed

the maximum discharge pressure of the unit.

NOTE Adjust the pressure switch only if

adjustments are absolutely necessary.

CUT-IN & CUT-OUT. The cut-out (compressor shut-down) is the

pressure at which the switch contacts open, and the cut-in (compressor restart) is the pressure at which the switch contacts close.

ADJUSTMENT CONTROLS. All pressure switches have a range adjustment control (A). Some pressure switches also have a differential adjustment (B) control. On switches without a differential adjustment control, the span between cut-in and cut-out pressure levels switches is factory set for 40 ± 4 PSIG and cannot be adjusted.

NOTE Some pressure switches are equipped with

an on-off lever used to open and close the electrical contacts inside the switch. THIS LEVER IS NOT A DIFFERENTIAL ADJUSTMENT CONTROL. The pressure switches with the onoff lever do not have a differential adjustment control.

ADJUSTMENT PROCEDURES (SWITCHES WITHOUT DIFFERENTIAL ADJUSTMENT CONTROL):

1. Remove the pressure switch cover.

2. Adjust the range by turning the range adjustment screw clockwise

(in) to increase the cut-out point or counter-clockwise (out) to decrease the cut-out point.

NOTE: One full turn changes the setting

approximately 2 PSIG.

3. Replace cover, reconnect power supply and start the compressor.

4. Note the pressure gauge reading at which the compressor cuts out.

5. Repeat adjustment procedure if necessary.

Pressure Switch Range Adjustment

NOTE: One full turn changes the setting

approximately 2 PSIG.

4. Replace the cover, reconnect the power supply and start the unit.

5. Note the pressure gauge reading at which the unit cuts out.

6. Repeat the adjustment procedure if necessary.

The minimum possible differential is approximately 20% of cutout pressure. It is advisable to have as wide a differential as possible to avoid frequent starting and stopping of the unit. Note the pressure gauge reading at which the unit cuts-out and re-establish this point if necessary.

Note the interaction between the range and differential adjustments, i.e., if the cut-out is increased, the differential will also increase, or if the differential is narrowed, the cut-out will be reduced, etc. These factors must be considered when adjusting the switch and compensated for accordingly.

ELECTRIC DRAIN TIMER SETTINGS

The "time off" setting determines the interval between cycles from 30 seconds to 45 minutes. The "time on" setting determines the actual time the compressor drains condensate from the 1/4" or 1/2” condensate outlet port.

The timer’s cycle rate and drain opening time should be adjusted to open just long enough to discharge the condensate. The timer is properly set when it opens and discharges condensate and then vents air for approximately one second before closing. Adjustments may be made depending on many factors, including humidity and duty cycle.

OIL PRESSURE ADJUSTMENT (MODEL 2000P)

For pressure lubricated compressors, the oil pressure should be checked upon start-up by observing the oil pressure gauge. The acceptable operating range is 15-40 psig. It is normal for the oil pressure to vary slightly with oil temperature. Compressors equipped with an optional low oil pressure shutdown system will automatically shut down if the oil pressure drops below 10 psig.

The oil pump is equipped with an adjustable pressure regulator which may be reset if conditions warrant. Refer to the following illustration and instructions:

1. Use an adjustable wrench to remove the knurled cover for the valve on the right side of the oil pump housing (A).

2. Loosen the retaining nut (B) with a 7/16” wrench such that the threaded rod (C) is free to rotate.

3. Using a 1/8” hex key, adjust the threaded rod to the desired setting. Turning the rod clockwise increases the oil pressure setting, and turning the rod counterclockwise decreases the oil pressure.

4. When the oil pressure is set, tighten the retaining nut and replace the knurled cover.

ADJUSTMENT PROCEDURES (SWITCHES WITH DIFFERENTIAL ADJUSTMENT CONTROL):

1. Remove the pressure switch cover.

2. Set the cut-in pressure with the range adjustment nut. Turn the nut

NOTE: One full turn changes the setting

3. Set the cut-out pressure with the differential adjustment. Turn the

clockwise (in) to increase the pressure or counter-clockwise (out) to decrease the pressure.

approximately 2 PSIG.

differential adjustment nut clockwise (in) to increase the pressure or counter-clockwise (out) to decrease the pressure.

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STARTING UNLOADING SYSTEM (MODEL 2000)

The purpose of the system is to relieve cylinder pressure when the unit stops, permitting it to start against a light load. A light load increases the life of the driver and belts and also reduces the possibility of tripping the overload relay. The system operates in the following manner:

The centrifugal unloader is attached to the end of the crankshaft as shown in the following illustrations.

When the unit starts, centrifugal force acts upon the unloader weights and they swing outward. This permits the plunger and thrust pin to move inward and the pilot valve to close. The escape path to atmosphere for the cylinder pressure is now closed and the compressor pumps air in a normal manner.

When the unit stops, the weights retract, permitting the thrust pin spring to move the plunger and thrust pin outward. The thrust pin opens the pilot valve and the trapped air pressure escapes from the cylinder and intercooler through a passage in the frame end cover, through the unloader tube and to atmosphere through the inlet filter/silencer.

Position of weight and thrust pin when unit is operating.

open valve that closes on rising oil pressure. During compressor operation, the oil pressure holds the hydraulic unloader valve closed. Head unloader actuation is controlled by the auxiliary valve.

When oil pressure is lost, either due to compressor shutdown or to a lubrication problem during compressor operation, the hydraulic unloader opens, actuating the head unloaders (F). This action will either vent the shut down compressor in preparation for the next start-up or release compression load to minimize damage if oil pressure is lost while the compressor is running.

A = Oil Pump

B = Oil Filter

C = Oil Pressure Gauge

D = Oil Pressure Switch

E = Hydraulic Unloader Valve

F = Head Unloaders

G = Shuttle Valve

H = Auxiliary Valve

Position of weight and thrust pin when unit is stopped.

STARTING UNLOADING SYSTEM (2000P)

Pressure lubricated compressors use a hydraulic unloader system to provide loadless starting. This system has the added feature of providing emergency unloading should oil pressure be lost during compressor operation.

The hydraulic unloader circuit bypasses the auxiliary valve (H) to direct control air to the head unloaders when oil pressure is lost. This circuit is controlled by the hydraulic unloader valve (E), a normally

PILOT VALVE ADJUSTMENT

If the pilot valve tube line is excessively hot, it is a good indication that the pilot valve is leaking and adjustment is required. To adjust the pilot valve, proceed as follows:

1. Stop the unit and disconnect and tag the electrical supply main switch to prevent accidental start-up.

2. Remove the pilot valve tube and the tube fittings.

3. Remove the pilot valve body and all existing shims.

4. Screw the pilot valve body back into the frame end cover (without

any shims) until contact with the thrust pin is felt. Advance the pilot valve body 1/4 to 1/2 turn more.

If contact with the thrust pin cannot be felt, the following steps may be necessary to locate the contact point:

1. Insert a small instrument (punch, rod, nail, etc.) into the end of the pilot valve until it contacts the valve stem.

2. While still inserted in the pilot valve, make a mark on the instrument even with the outside edge of the pilot valve body.

3. Keeping the instrument pressed lightly against the valve stem, screw the pilot valve body into the frame end cover. When the mark on the instrument starts moving out away from the edge of the pilot valve body, contact has been made with the thrust pin.

4. Advance the pilot valve body 1/4 to 1/2 turn more and proceed with step five.

5. Measure the gap between the pilot valve body and the frame end cover.

6. Remove the pilot valve body and add enough shims to fill the gap measured in step five.

7. Screw the pilot valve body back into the frame end cover until the body is tight on the shims.

8. Reconnect the pilot valve tube and tube fittings.

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BREATHER/UNLOADER BY-PASS

The breather/unloader by-pass tube lines eliminates air pressure buildup in the compressor frame by providing a passage for the air to escape through the inlet unloader (if opened) or (if closed) through the check valve, therefore, by-passing the inlet unloader and escaping to atmosphere through the inlet filter/silencer.

OIL CONSUMPTION CHECK

A rule of thumb in determining a “passing grade” for oil consumption is to consider consumption at or above 50 horsepower-hours per ounce to be acceptable. The formula is as follows:

Horsepower X Hours of Operation = Horsepower Hours

Ounces of Oil Used per Ounce

To apply this formula, consider the size of the machine. In the following example, a 5 horsepower compressor uses 2 ounces of oil every 20 hours of operation.

5 Horsepower X 20 Hours of = 50 Horsepower

Operation Hours per Ounce

2 Ounces of Oil Used

The compressor in the example passes the oil consumption test.

NOTE New or rebuilt compressor pumps will

discharge higher than normal amounts of oil until the piston rings are seated (approximately 100 operating hours).

MAINTENANCE

aWARNING Before performing maintenance, release air

pressure from the system and disconnect, lock and tag the main power supply or disconnect the wire from the engine spark plug.

NOTE All compressed air systems contain

maintenance parts (e.g. lubricating oil, filters, separators) which are periodically replaced. These used parts may be, or may contain, substances that are regulated and must be disposed of in accordance with local, state, and federal laws and regulations.

NOTE Take note of the positions and locations of

parts during disassembly to make reassembly easier. The assembly sequences and parts illustrated may differ for your particular unit.

NOTE Any service operations not explained in this

manual should be performed by an authorized service representative.

NOTE The following maintenance schedule has been

developed for typical applications. Maintenance intervals should be shortened in harsher environments.

MAINTENANCE SCHEDULE

Check for oil leaks.

•

Daily or Before Each Operation draining device is not provided). Open manual

Weekly

Monthly

3/500 *

6/1000 *

12/2000 *

* indicates months/operating hours, whichever occurs first.

FILTER INSPECTION & CLEANING

1. Loosen the clamps securing the filter housing to its base.

2. Remove the filter housing and withdraw the old filter element.

Clean the element with a jet of air or vacuum.

3. Replace the filter element and housing.

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OIL CHANGE

1. Remove the oil drain plug and allow the lubricant to drain into a

suitable container.

2. Replace the oil drain plug.

3. Follow the filling procedures in INSTALLATION section.

Check lubricant level. Fill as needed.

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Drain receiver tank condensate (if automatic

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drain valve and collect and dispose of condensate accordingly. Test drain valve for proper operation.

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Clean filter screen if needed. Check for unusual noise and vibration.

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Ensure beltguards and covers are securely in

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place. Ensure area around compressor is free from

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rags, tools, debris, and flammable or explosive materials. Check system oil pressure on pressure

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lubricated models while compressor is hot. Observe operation of safety/relief valves while

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the compressor is running. Replace safety/ relief valves that do not operate freely. Inspect air filter element(s). Clean if necessary.

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Inspect for air leaks. Squirt soapy water

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around joints during compressor operation and watch for bubbles. Check tightness of screws and bolts. Tighten

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as needed. Inspect drive belts. Adjust if necessary.

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Clean exterior.

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Clean drain valve filter screen.

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Change petroleum lubricant while crankcase

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is warm. Drain compressor oil and clean oil sight glass

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Replace oil filter and change lubricant (if

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necessary) on pressure lubricated modles. Change synthetic lubricant while crankcase

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is warm. Replace filter element

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81295651

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BELT ADJUSTMENT

CHECKING BELT TENSION. Check belt tension should be occasionally,

especially if looseness is suspected. New belts must also be properly tensioned upon installation.

TENSIONING BELTS. Belt tensioning can be achieved by loosening the motor anchor screws, pushing the motor away from the pump, and retightening the motor anchor screws. Some units are equipped with a belt tensioning bolt that, when turned, pulls the motor away from the pump. Otherwise, the motor can be easily moved by placing a prying tool beneath it. A commercially available spreader or other belt tensioning device can also be helpful.

To prevent these problems from occurring, ensure the pulley and sheave are aligned and belt tension is satisfactory after installing new belts or tensioning existing belts.

ELECTRIC DRAIN MAINTENANCE

NOTE: The following maintenance schedule has been

developed for typical applications. Maintenance intervals should be shortened in harsher environments.

DRAIN VALVE MAINTENANCE SCHEDULE

DAILY Test the valve for proper

operation. Clean the filter screen if needed.

MONTHLY (EVERY 30 DAYS) Clean the filter screen.

To clean the filter screen, perform the following steps:

1. Close the strainer ball valve completely to isolate it from the air receiver tank.

2. Press the TEST button on the timer to vent the pressure remaining in the valve. Repeat until all pressure is removed.

aCAUTION! High pressure air can cause injury from flying

debris. Ensure the strainer ball valve is completely closed and pressure is released from the valve prior to cleaning.

3. Remove the plug from the strainer with a suitable wrench. If you

hear air escaping from the cleaning port, STOP IMMEDIATELY and repeat steps 1 and 2.

4. Remove the stainless steel filter screen and clean it. Remove any debris that may be in the strainer body before replacing the filter screen.

5. Replace plug and tighten with wrench.

Strainer Ball Valve

Follow the procedures outlined below to correctly set and measure tension.

1. Measure the span length (t) of the drive.

2. Determine the amount of deflection (in inches) required to measure

3. Lay a straight edge across the top outer surface of the belt drive

4. At the center of the span, perpendicular to the belt, apply pressure

Ensure the pulley and sheave are properly aligned and the motor anchor screws are adequately retightened prior to restarting the compressor.

aCAUTION Improper pulley/sheave alignment and belt

deflection force (in pounds) by multiplying the span length (t) by 1/

64. For example, a 32” span length multiplied by 1/64 equals 1/2” of deflection required to measure deflection force.

from pulley to sheave.

to the outer surface of the belt with a tension gauge. Force the belt to the predetermined deflection calculated in step 2. Compare the reading on the tension gauge to the BELT TENSION TABLE in the DIAGRAMS & TABLES section.

tension can result in motor overload, excessive vibration, and premature belt and/or bearing failure.

6. When putting the EDV-2000 back into service, press the TEST

button to confirm proper function.

TANK INSPECTION

The life of an air receiver tank is dependent upon several factors including, but not limited to, operating conditions, ambient environments, and the level of maintenance. The exact effect of these factors on tank life is difficult to predict; therefore, Ingersoll-Rand recommends that you schedule a certified tank inspection within the first five years of compressor service. To arrange a tank inspection, contact Ingersoll-Rand.

If the tank has not been inspected within the first 10 years of compressor service, the receiver must be taken out of service until it has passed inspection. Tanks that fail to meet requirements must be replaced.

aWARNING Failure to replace a rusted air receiver tank

could result in air receiver tank rupture or explosion, which could cause substantial property damage, severe personal injury, or death. Never modify or repair tank. Obtain replacement from service center.

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TROUBLESHOOTING

COMPRESSOR (see causes and solutions on next page)

PROBLEM CHECK POINT Abnormal piston, ring or cylinder wear 4, 8, 9, 19, 28, 35 Air delivery drops off 1, 6, 15, 16, 18, 19, 29 Automatic drain valve leaks or does not drain automatically 16 Auxiliary valve chatters or leaks around stem 23, 24 Broken intercooler or aftercooler tubes 36 Compressor does not come up to speed 2, 6, 12, 15, 21 Compressor is slow to come up to speed 26, 27, 33, 34 Compressor runs excessively hot 3, 14, 15, 22 Compressor will not unload cycle 23, 24, 26 Compressor will not unload when stopped 26, 33 Excessive noise during operation 2, 6, 15, 16, 21, 27, 32 Excessive starting and stopping 5, 11, 16, 32, 40 Knocks or rattles 2, 15, 17, 19, 20, 21 Lights flicker or dim when running 12, 13 Moisture in crankcase or “milky” appearance in petroleum lubricant 9, 10 or rusting in cylinders Motor overload trips or draws excessive current 5, 6, 12, 13, 14, 15, 16, 19, 20, 21, 34 Oil in discharge air (oil pumping) 4, 7, 9, 18, 19, 25, 35 Oil leaking from shaft seal 25 Safety/relief valve “pops” 1, 5, 29, 30 High interstage pressure 30 Low interstage pressure 31 Motor will not start 12 Oil Leaks 41 Low Oil Pressure 42, 43, 44, 46 Excessive oil pressure fluctuations (> 5 psi) 42, 43, 44, 45, 46

ELECTRIC DRAIN TROUBLESHOOTING

Trouble Cause Action

Valve will not close. 1. Debris in solenoid 1. Remove solenoid valve,

Timer will not activate. 1. No electrical supply. 1. Apply power.

valve prevents disassemble, clean and diaphragm from seating. reassemble.

2. Short in electrical 2. Check and replace power component. cord or timer as needed.

2. Timer malfunction 2. Replace timer.

3. Clogged port. 3. Clean valve.

4. Solenoid valve 4. Replace solenoid

malfunction. valve.

5. Clogged strainer. 5. Clean strainer.

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CHECK POSSIBLE CAUSE POSSIBLE SOLUTION POINT 1 Clogged or dirty inlet and/or discharge line filter. Clean or replace. 2 Loose beltwheel or motor pulley, excessive end play in motor Check beltwheel, motor pulley, crankshaft, drive belt tension and

3 Inadequate ventilation around beltwheel. Relocate compressor for better air flow. 4 Lubricant viscosity too low. Drain existing lubricant and refill with proper lubricant. 5 Air leaks in air discharge piping. Check tubing and connections. Tighten joints or replace as required. 6 Lubricant viscosity too high. Drain existing lubricant and refill with proper lubricant. 7 Lubricant level too high. Drain excess lubricant. 8 Lubricant level too low. Add lubricant to crankcase to proper level. 9 Detergent type lubricant being used. Drain existing lubricant and refill with proper lubricant. 10 Extremely light duty cycles. Run compressor for longer duty cycles.

11 Pressure switch differential too narrow. Adjust pressure switch to increase differential, if differential adjustment

12 Improper line voltage. Check line voltage and upgrade lines as required. Contact electrician.

13 Poor power regulation (unbalanced line). Contact power company. 14 Drive belts too tight or misaligned. Adjust belts to proper tension and alignment. 15 Compressor valves leaky, broken, carbonized or loose. Inspect valves. Clean or replace as required. Install Valve/Gasket Step

16 Automatic drain valve clogged, leaking or defective. Inspect valve and clean, repair or replace as required. 17 Carbon build-up on top of piston(s). Clean piston(s). Repair or replace as required. 18 Piston rings damaged or worn (broken, rough or scratched). Install Ring/Gasket Step Saver Kit.

19 Cylinder(s) or piston(s) scratched, worn or scored. Repair or replace as required. 20 Connecting rod, piston pin or bearings worn or scored. Inspect all. Repair or replace as required. Install Bearing/Connecting Rod

21 Defective ball bearings on crankshaft or motor shaft. Inspect bearings and replace if required. Install Bearing/Connecting Rod

22 Wrong beltwheel direction of rotation. Check motor wiring for proper connections. Reverse two leads on

23 Leaking, broken or worn inlet unloader parts. Inspect parts and replace as required. 24 Auxiliary valve dirty or seats worn. Inspect parts. Clean, adjust or replace as required. 25 Crankshaft seal worn or crankshaft scored. Replace seal. Install shaft sleeve if required. Install Bearing/Connecting

26 Leaking or maladjusted centrifugal pilot valve. Replace pilot valve o-ring. Adjust pilot valve. 27 Leaking check valve or check valve seat blown out. Replace check valve. 28 Extremely dusty atmosphere. Install remote air inlet piping and route to source of cleaner air.

29 Defective safety/relief valve. Replace. 30 High pressure inlet valve leaking. Inspect, clean or repair as required. 31 Low pressure discharge valve leaking. Inspect, clean or repair as required. 32 Automatic start and stop mode is not suitable for air demand. Adjust auxiliary valve for constant speed operation 33 Pressure switch unloader leaks or does not work. Realign stem or replace. 34 Ambient temperature too low. Install crankcase heater kit. Convert to All-Season Select

35 Worn cylinder finish. Deglaze cylinder with 180 grit flex-hone. 36 Beltwheel out of balance, tubes not braced or secured, Check vibration level, change pulley or beltwheel if required, tighten

37 Excessive condensate in receiver tank. Drain receiver tank with manual drain valve or install automatic

38 Loose fittings/elbows/connectors Re-torque fittings per specified torque requirements 39 Maladjusted or defective oil pressure regulator valve Adjust valve to proper setting

40 Maladjusted or defective hydraulic unloader valve Replace hydraulic unloader valve assembly 41 Defective oil pressure gauge Replace gauge 42 Oil foaming in crankcase Drain existing lubricant, thoroughly clean crankcase, replace lubricant 43 Debris or other obstruction blocking oil flow Inspect/clean all oil passages

shaft or loose drive belts. alignment. Repair or replace as required.

Compressor located in damp or humid location. Relocate compressor or install crankcase heater kit.

provided. Install pressure switch with differential adjustment feature if differential adjustment is desired.

Wiring or electric service panel too small. Install properly sized wire or service box. Contact electrician. Poor contact on motor terminals or starter connections. Ensure good contact on motor terminals or starter connections. Improper starter overload heaters. Install proper starter overload heaters. Contact electrician.

Saver Kit.

Excessive end gap or side clearance. Piston rings not seated, are stuck in grooves or end gaps not Adjust piston rings. staggered.

Loose bearing spacer on crankshaft. Step Saver Kit.

Step Saver Kit.

three-phase motors.

Rod Step Saver Kit.

Install more effective filtration.

lubricant.

Relocate compressor to warmer environment.

wrong pulley speed. tube clamps.

drain valve.

Replace regulator valve

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DIAGRAMS & TABLES

FASTENER TORQUE TABLE

High Pressure Head Bolts 120

Low Pressure Head Bolts 120

Cylinder Flange Bolts 50

Frame Cover Bolts 20

Shaft Cover Bolts 50

Crankpin Cap Screws —

Unloader Cover Screws —

High Pressure Inlet Valve Screws 36 LB-IN

Low Pressure Inlet Valve Screws 36 LB-IN

High Pressure Outlet Valve Screws 36 LB-IN

Low Pressure Outlet Valve Screws 36 LB-IN

Beltwheel Bolt 80

High Pressure Head Center Bolts —

Low Pressure Head Center Bolts —

Unloader Guide Mounting Screw 25

Low Oil Level Switch Baffle Screw 5

Head Center Acorn Nuts 7

Pilot Valve 25

Unloader Body Assembly 25

Bearing/Unloader Housing Bolts 25

Valve Plate Studs 7

NOTE Tighten all fasteners evenly using a cross pattern in two stages.

NOTE All values given are in LB-FT unless otherwise specified.

BELT TENSION TABLE

BELT HORSEPOWER TENSION AT 1/64” DEFLECTION TYPE PER INCH OF SPAN

5V 25-30 14.0 - 21.0

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ELECTRICAL WIRING DIAGRAMS

A To supply

C Wiring for optional electric drain valve

EDV Electric drain valve

T Supply Line Terminal

L Load Terminal

FU Control Circuit Fuse

HATS High Air Temperature Switch (#)

LOLS Low Oil Level Switch (#)

M Motor Starter Coil

OL Motor Starter Overload

PS Pressure Switch

SS Selector Switch (#)

* Alternate wiring for converting 3 phase starter to

1 phase application

(#) = if provided

Three Phase Wiring

To Power Supply

Starter

NOTE Connect line power to the starter. Do not connect line power to the

Connect ground wire to ground lug

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pressure switch.

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Model 2000 Bare Unit

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Model 2000P Bare Unit

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Model 2000 Baseplate Unit

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Model 2000P Baseplate Unit

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Model 2000 120 Gal. Simplex Unit

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Model 2000P 120 Gal. Simplex Unit

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Model 2000 240 Gal. Simplex Unit

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Model 2000P 240 Gal. Simplex Unit

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Model 2000 Duplex Unit

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