Ingersoll Rand 2475N7.5-V Owner’s Manual

Ingers011Rand Owner's Manual

Installation, Operation and Maintenance Instructions

for Standard Two-Stage Lubricated Air Compressors

(Electric Motor and Gasoline Engine Models Up to 30 Horsepower)

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

_.'f.'!=1_/b'd

DEFINITIONS

A__ WILL cause DEATH, SEVERE INJURY or substantial

property damage.

/k WARNING CAN cause DEATH, SEVERE INJURY or substantial

property damage.

/_ CAUTION WILL or CAN cause MINOR INJURY or property

damage.

GENERAL SAFETY PRECAUTIONS

A__'_ INTAKE AIR. Can contain carbon monoxide or other

contaminants. Will cause serious injury or death. Ingersoll-Rand air compressors are not designed,

intended or approved for breathing air. Compressed air should not be used for breathing air applications

unless treated in accordance with all applicable codes and regulations.

/_ WARNING HAZARDOUS VOLTAGE. Can cause serious injury

or death. Disconnect power and bleed pressure from 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.

LockoutJTagout 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.

/k CAUTION

RISK OF BURSTING. Use only suitable air handling parts acceptable for pressure of not less than the

maximum allowable working pressure of the machine.

[€-]:1_1:1dL,ImlII_I_o -v];_.111Ko]_I

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

IngersolI-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 or gasoline engine. 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

Two-stage compressors consist of one or two first-stage cylinders with the same bore size and one second-stage cylinder with a

smaller bore size.

Typical Two-Stage, Two

Cylinder Unit

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,

Typical Two-Stage, Three Cylinder Unit

Form SCD-838A

August 2001

anair-cooledaftercoolershouldbeinstalledbetweenthe compressordischargeandthereceivertankorsystem.

Formaintainingthereceivertankorsystemairpressurewithin predeterminedlimits, 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.

I;3_[o]_lh_lull_:_1_ll_E."]_l_[o]ulKo_l

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.

,_,CAUTION 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.

z_ CAUTION! 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.

iiii

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,

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

z_ WARNING

GASOLINE ENGINE UNITS. For gasoline engine units, keep the engine at least 3 feet (1 m) away from building walls and other

equipment. Install the unit in a location with plenty of space for proper ventilation, cooling air flow and accessibility. Do not install or

operate a gasoline engine unit in a confined area.

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.

z_ CAUTION Never operate the compressor in temperatures

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 (except on Models 2000 and

2000P) or intake silencers, relocate the unit or construct total enclosures or baffle walls.

MOUNTING

A WARNING Remove the unit from the skid before mounting.

ELECTRIC MOTOR UNITS. Bolt the unit to a firm, level foundation

(such as a concrete floor). Do not bolt uneven feet tightly to the foundation, as this will cause excessive stress on the receiver tank.

Use metal shims under the "short" feet if necessary. DO NOT USE

VIBRATION ISOLATOR PADS ON MODELS 2000 AND 2000P.

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.

below -15°F (-26.1°C) or above 125°F (51.0°C).

Typical Permanent Mounting (Customer Supplied Hardware)

Flat Washer I

X ..f_..._3t8" Lag Screw

Isolator \ _...fq

Shim beneath Floor line isolator washer, if

necessary Lag screw anchor

GASOLINE ENGINE UNITS. Bolt the unit to a firm, level foundation. Do not bolt uneven feet tightly to the foundation, as this

will cause excessive stress on the receiver tank. Use metal shims under the "short" feet if necessary. Gasoline engine units mounted

on truck beds must be fastened securely without applying excessive stress on the receiver tank. We recommend installing a vibration

isolator kit with gasoline engine models.

INSTALLING REMOTE AIR INLET PIPING

/_ CAUTION Do not operate the unit without air inlet filtration.

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.

Typical Remote Air Inlet Piping.

Direct to compressor SUPPORT-- [_

a_rIienta_a(ifdifsta._ce I I

11\ \

for concrete

ELBOW__

AIR INLET FILTER

HOOD

/ P,PE--II

-- OUTSIDE WALL

122 .mLL

F"T'NG/

BUSHINGS /

DRAIN VALVE

INSTALLING

/k WARNING

A CAUTION!

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

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.

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.

A WARNING If an aftercooler, check valve, block valve, or any

INSTALLING

DISCHARGE PIPING

Do not use plastic pipe, soldered copper fittings, rubber hose, or lead-tin soldered joints anywhere in the compressed air system.

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

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.

other restriction is added to the compressor discharge, install a properly-sized ASME approved

safety/relief valve between the compressor discharge and the restriction.

ELECTRICAL WIRING (ELECTRIC MOTOR

UNITS)

A WARNING

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

Electrical installation and service should be performed by a qualified electrician who is familiar

with all applicable local, state and federal laws and regulations.

excessivevoltagedropduringstart-up.RefertotheNational ElectricCode(NEC)forinformationonselectingtheproperwire sizeandsecuringelectricalconnections.Ifyouconnectadditional

electricalequipmenttothesamecircuit,considerthetotalelectrical loadwhenselectingtheproperwiresize.DONOTUSE

UNDERSIZEWIRE.

Ifwiresizeinformationisnotavailable,thewiresizesshowninthe followingwireselectionchartcanbeusedasasafeguide,ifthe distancedoesnotexceed50feet(15.3m).Forlongerdistances, consultandelectricalcontractororthelocalelectriccompanyfor

recommendations.

"4 "A

MOTOR SINGLE THREE

HP PHASE PHASE

115V 230V 200V 230V 460V 575V

1.5 2

7.5

10 15

20 25

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.

CONNECTING A BATTERY (GASOLINE ENGINE UNITS) __

NOTE If you will be making connections to a remote

BATTERY. A 12 volt battery with a minimum current rating of 250

CCA (cold cranking amps) and minimum ampere-hour rating of 24 Ah should be sufficient for cranking most electric start engines.

BATTERY CABLES. Refer to the following table for size and length recommendations.

CONNECTION PROCEDURES:

1. Connect the battery positive (+) cable (A) to the starter solenoid terminal (B).

12 14 14 14 14 14 10 14 14 14 14 14

8 14 14 14 14 14 8 12 14 14 14 14

battery, the engine on the compressor unit must be equipped with an alternator.

Cable Maximum Size (CA) Length

6 5' (1.5 m.) 4 7'-2.5" (2.1 m,)

2 12' (3.6 m.)

2. Connect the battery negative (-) cable (C) to the bolt shown in the following illustration. Secure the wire in place by screwing a

suitably-sized nut onto the bolt and down onto the terminal.

Kohler Honda

Kawasaki Ingersoll-Rand

3. Connect the battery positive (+) cable (A) to the battery positive (+) terminal.

4. Connect the battery negative (-) cable to the battery negative (-) terminal.

5. Coat the terminals and cable ends with corrosion-preventive grease.

A WARNING Remove the cable from the negative (-) side of the

battery before servicing.

Refer to the engine manufacturer's instructions for more

information.

FUEL PUMP INSTALLATION (GASOLINE ENGINE UNITS) _

Some engines use an optional fuel pump to supply gasoline to the engine directly from a vehicle's onboard fuel system. Install the fuel

pump within 12 inches (30 cm) of the bottom surface of the vehicle's fuel tank. Protect the pump from contamination by installing a fuel

isolation valve and an inline filter between the pump fuel system.

COMPRESSOR LUBRICATION

/k CAUTION Do not operate without lubricant or with inadequate

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

SYNTHETIC COMPRESSOR LUBRICANT. Ingersoll-Rand

recommends All Season T30 Select synthetic lubricant from start-up. See the WARRANTY section for extended warranty information.

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,

Seethepetroleumlubricantviscositytablebelow.Thetableis intendedasageneralguideonly.Heavydutyoperatingconditions requireheavierviscosities.Referspecificoperatingconditionsto

Ingersoll-Randforrecommendations.

TemperatureAround

Compressor

oF oC

<40 < 4.4

40-80 4.4-26.7

80-125" 26.7-51.0"

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

(37.7°0).

If you use a petroleum-based compressor lubricant at start-up and decide to convert to All Season T30 Select later on, the pump must be 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.

/_ CAUTION Do not remove the oil fill plug while the compressor

is running,

Refer to the following table for crankcase capacity.

Model Crankcase Capacity

2340 28 oz.(827 ml.) 2475 41 oz.(1212 ml.)

2545 73 oz.(2158 ml.) 7100 80 oz.(2365 ml.)

15T, 2000,2000P 144 oz.(4258 ml.)

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

Viscosity @ 100°F

(37.8°C)

SUS I Centistokes

150 32

500 110 750 165

Viscosity Grade

ISO I SAE

32 10

100 30 150 40

E F

A = FULL level at bottom thread of oil fill opening on units without

sight glass or dipstick. B = ADD level below bottom thread of oil fill opening on units

without sight glass or dipstick. C = FULL level on units with sight glass.

D = ADD level on units with sight glass. E = ADD level on units with dipstick. F = FULL level on units with dipstick.

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

INTERMITTENT DUTY FORMULA

Units operating above 200 PSIG are to be operated according to the

"Intermittent Duty Formula."

If the float is cocked in the low position, the unit cannot start.

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 MODELS) __

1, Close the service valve.

Release any remaining tank pressure by slowly opening the manual drain valve.

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 Lever (if Equipped)

ON/AUTO OFF

4. Slowly open the service valve.

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

A_.

Z_CAUTION

Unusual noise or vibration indicates a problem. Do not continue to operate until you identify and correct the source of the problem.

NOTE

Ensure the direction of rotation 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

AUTOMATIC START & STOP CONTROL. This type of control applies to electric motor driven models under 10 horsepower.

NOTE Automatic Start & Stop Control is intended for use

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

When the receiver tank pressure reaches the factory pre-set maximum pressure (usually 175 PSIG), the pressure switch stops

the unit. When the receiver tank pressure drops below the factory pre-set minimum (usually 135 PSIG), the pressure switch resets

and restarts the unit. CONSTANT SPEED CONTROL. This type of control applies to

gasoline engine units. When the receiver tank pressure reaches the factory pre-set

maximum pressure (usually 175 PSIG), the unloader slows down the engine and the unit stops pumping. When the receiver tank

pressure drops to the factory pre-set minimum (usually 145 PSIG), the unloader resets, the engine returns to full speed, and the unit

resumes pumping.

DUAL CONTROL. This type of control applies to electric motor

units over 10 horsepower. 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.

CLOCKWISE

COUNTERCLOCKWISE

START-UP (GASOLINE ENGINE UNITS)

z_ WARNING Do not operate gasoline engine units in an enclosed

area.

1. Release any remaining tank pressure by slowly opening the manual

drain valve.

2. Turn on the engine gasoline supply.

3. Put the choke in the "on" position.

4. Close the service valve and put the unloader lever in the "unload" (A) position for Kawasaki and Honda engine driven models, or the

"load" (B) position for Kohler engine driven models.

5. Start the engine, release the choke, and allow the engine to warm up for two to three minutes.

6. Return the unloader lever to the "load" (B) position on Kawasaki and Honda engine driven models.

Typical Unloader (A = Unload, B = Load)

NOTE

Turn the gasoline supply off when the compressor is not being used.

NOTE

Some gasoline engine driven compressors require 5-8 break-in hours of operation before reaching full

capacity and speed.

KNOB"__

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. When the receiver tank pressure reaches 170 PSlG, the unit runs but does not pump.

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

than the factory pressure switch setting,

A CAUTION 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,

PRESSURE SWITCH ADJUSTMENT

z_ WARNING 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.

A CAUTION 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. See COMPRESSOR CONTROLS. 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

adjustmentcontrol,thespanbetweencut-inandcut-outpressure levelsswitchesisfactorysetfor40_+4PSIGandcannotbe

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 on-off 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.

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

decrease the pressure.

NOTE: One full turn changes the setting approximately 2

PSIG.

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

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

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.

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.

STARTING UNLOADING SYSTEM

The starting unloading feature exists on certain models. 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,

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.

Position of weight and thrust pin when unit is operating.

TUBE CONNECTION

TO ATMOSPHERE

Position of weight and thrust pin when unit is stopped.

TUBE CONNECTION

TO ATMOSPHERE

STARTING UNLOADING SYSTEM (PRESSURE LUBRICATED MODELS)

Pressure lubricated compressors use a hydraulic unloader system to provide Ioadless 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 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

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.

BREATHER/UNLOADER BY-PASS

The breather/unloader by-pass tube lines eliminates air pressure build-up 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.

OILCONSUMPTIONCHECK

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

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).

A WARNING

NOTE

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.

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.

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.

Any service operations not explained in this manual should be performed by an authorized service

representative. Reference the engine owner's manual for engine

care information. The following maintenance schedule has been

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

environments.

Operation Hours per Ounce

MAINTENANCE SCHEDULE

• Check for oil leaks.

Daily or Before Each

Operation

Weekly

Monthly

3/500 *

6/1000 *

12/2000 *

* indicates months/operating hours, whichever occurs first.

FILTER INSPECTION & CLEANING

1. Unscrew and remove the wing nut (A) securing the filter housing (B)

to its base (C).

2. Remove the filter housing and withdraw the old filter element (D). Clean the element with a jet of air or vacuum.

3. Replace the filter element and housing, securing it in place with the

wing nut previously removed.

• Check lubricant level. Fill as needed.

• Drain receiver tank condensate (if automatic draining device is not provided). Open manual drain valve and collect and dispose of

condensate accordingly.

• Check for unusual noise and vibration.

• Ensure beltguards and covers are securely in place.

• Ensure engine (if supplied) is filled with fuel and lubricant according to the manufacturer's

recommendations.

• Ensure area around compressor is free from rags, tools, debris, and flammable or explosive materials.

• Check system oil pressure on pressure lubricated models while compressor is hot.

• Observe operation of safety/relief valves while the compressor is running. Replace

safety/relief valves that do not operate freely.

• Inspect air filter element(s). Clean if necessary.

• Inspect for air leaks. Squirt soapy water around joints during compressor operation and watch for bubbles.

• Check tightness of screws and bolts. Tighten as needed.

• Inspect drive belts. Adjust if necessary.

• Clean exterior.

• Change petroleum lubricant while crankcase is warm.

• Drain compressor oil and clean oil sight glass

• Replace oil filter and change lubricant (if necessary) on pressure lubricated models.

• Install maintenance pak

--or-

• Change synthetic lubricant while crankcase is

warm.

• Replace filter element.

OIL CHANGE

1. Remove the oil drain plug (A) and allow the lubricant to drain into a suitable container.

2. Replace the oil drain plug.

3. Follow the filling procedures in OPERATION section,

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 or engine anchor screws, pushing the motor or engine away from the pump, and retightening the motor or engine

anchor screws. Some units are equipped with a belt tensioning bolt that, when turned, pulls the motor or engine 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.

BELT TENSION f_J_

i3oL..r _ /i'l!

Follow the procedures outlined below to correctly set and measure belt tension on electric motor and gas engine models including

2340, 2475, and 2545 (with "A" belt type only). Refer to the following illustration for a visual representation.

.............................It) _LT 8PAN ..............................

I)EFLECTIO!I _ .._/__"

O-RINGS . i ) DIRECTION OF 1

'. I/ FORCE APPLIED \

P# gT'gX,

DEFLECTION DISTANCE SCALE

(READ DOWN)

(READ UP)

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

from pulley to sheave.

2. At the center of the span, perpendicular to the belt, apply pressure to the outer surface of the belt with a tension gauge. Force the belt

....... i /

to the deflection indicated in the BELT TENSION TABLE in the

DIAGRAMS & TABLES section. Compare the reading on the tension

gauge to the table.

Follow the procedures outlined below to correctly set and measure

tension on 7.5 through 30 horsepower models 2545, 7100, 15T and 2000 with "B" and "C" belt types.

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

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

3. Lay a straight edge across the top outer surface of the belt drive from pulley to sheave.

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

Ensure the pulley and sheave are properly aligned and the motor

anchor screws are adequately retightened prior to restarting the compressor.

A CAUTION Improper pulleylsheave alignment and belt tension

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.

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.

A WARNING Failure to replace a rusted air receiver tank could

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

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.

_o_] _[oIo_€_

PROBLEM Abnormal piston, ring or cylinder wear

Air delivery drops off Automatic drain valve leaks or does not drain automatically Auxiliary valve chatters or leaks around stem

Broken intercooler or aftercooler tubes Compressor does not come up to speed

Compressor is slow to come up to speed Compressor runs excessively hot

Compressor will not unload cycle Compressor will not unload when stopped Excessive noise during operation

Excessive starting and stopping Knocks or rattles

Lights flicker or dim when running Moisture in crankcase or "milky" appearance in petroleum lubricant or rusting in cylinders

Motor overload trips or draws excessive current Oil in discharge air (oil pumping)

Oil leaking from shaft seal Safety/relief valve "pops" High interstage pressure

Low interstage pressure Engine cranks slowly or will not start

Motor will not start Engine will not start

Oil Leaks Low Oil Pressure Excessive oil pressure fluctuations (> 5 psi)

CHECK POINT 4, 8, 9, 19, 28, 35

1,6, 15, 16, 18, 19, 29 16

23, 24 36

2,6,12,15,21 26, 27, 33, 34

3, 14, 15, 22 23, 24, 26

26, 33 2, 6, 15, 16, 21, 27, 32 5, 11, 16, 32, 40

2, 15, 17, 19, 20, 21

12, 13

9,10

5, 6, 12, 13, 14, 15, 16, 19, 20, 21, 34 4, 7, 9, 18, 19, 25, 35 25

1,5, 29, 30

3O 31 6, 14, 37, 38

39 41 42, 43, 44, 46 42, 43, 44, 45, 46

+ 23 hidden pages