2475N7.5-V
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.
/k CAUTION
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.
RISK OF BURSTING. Use only suitable air handling
parts acceptable for pressure of not less than the
maximum allowable working pressure of the
machine.
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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
Typical Two-Stage, Three
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,
© Ingersoll-Rand Company
Printed in U.S.A.
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.
z_ WARNING
WARNING FOR UNITS EQUIPPED
WITH ELECTRIC DRAIN VALVE
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.
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
below -15°F (-26.1°C) or above 125°F (51.0°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 (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.
Typical Permanent Mounting (Customer Supplied Hardware)
Flat Washer I
X ..f_..._3t8" Lag Screw
Isolator \ _...fq
11\ \
Shim beneath Floor line
isolator washer, if
necessary Lag screw anchor
for concrete
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.
ELBOW__
Direct to compressor SUPPORT-- [_
a_rIienta_a(ifdifsta._ce I I
/ P,PE--II
122 .mLL
F"T'NG/
BUSHINGS /
DRAIN VALVE
m
HOOD
AIR INLET
FILTER
-- OUTSIDE
WALL
INSTALLING
/k WARNING
A CAUTION!
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
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.
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
other restriction is added to the compressor
discharge, install a properly-sized ASME approved
safety/relief valve between the compressor
discharge and the restriction.
INSTALLING
UNITS)
A WARNING
ELECTRICAL WIRING (ELECTRIC MOTOR
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
excessivevoltagedropduringstart-up.RefertotheNational
ElectricCode(NEC)forinformationonselectingtheproperwire
sizeandsecuringelectricalconnections.Ifyouconnectadditional
electricalequipmenttothesamecircuit,considerthetotalelectrical
loadwhenselectingtheproperwiresize.DONOTUSE
UNDERSIZEWIRE.
Ifwiresizeinformationisnotavailable,thewiresizesshowninthe
followingwireselectionchartcanbeusedasasafeguide,ifthe
distancedoesnotexceed50feet(15.3m).Forlongerdistances,
consultandelectricalcontractororthelocalelectriccompanyfor
recommendations.
MOTOR SINGLE THREE
HP PHASE PHASE
115V 230V 200V 230V 460V 575V
12 14 14 14 14 14
10 14 14 14 14 14
8 14 14 14 14 14
8 12 14 14 14 14
1
1.5
2
3
5
7.5
10
15
20
25
30
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, the engine on the compressor unit must be
equipped with an alternator.
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.
Cable Maximum
Size (CA) Length
6 5' (1.5 m.)
4 7'-2.5" (2.1 m,)
2 12' (3.6 m.)
CONNECTION PROCEDURES:
1. Connect the battery positive (+) cable (A) to the starter solenoid
terminal (B).
B
/
"4 "A
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"
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
* = 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,
A
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
If the float is cocked in the low position, the unit
cannot start.
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 MODELS) __
1, Close the service valve.
2.
3.
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
NOTE
Unusual noise or vibration indicates a problem. Do
not continue to operate until you identify and
correct the source of the problem.
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.
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
NOTE
Turn the gasoline supply off when the compressor
is not being used.
Some gasoline engine driven compressors require
5-8 break-in hours of operation before reaching full
capacity and speed.
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.
KNOB"__
CLOCKWISE
COUNTERCLOCKWISE
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.
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
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.
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.
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,
Position of weight and thrust pin when unit is operating.
TUBE CONNECTION
TO ATMOSPHERE
t
!
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.
/
D
\
F
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
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).
A WARNING
NOTE
NOTE
NOTE
NOTE
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.
Daily or Before
Each
Operation
Weekly
Monthly
3/500 *
6/1000 *
12/2000 *
MAINTENANCE SCHEDULE
• Check for oil leaks.
• 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.
* 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.
/
A
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,
10
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,
(READ DOWN)
DEFLECTION
DISTANCE SCALE
(READ UP)
\
J
/
....... i /
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
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
can result in motor overload, excessive vibration,
and premature belt and/or bearing failure.
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
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.
11
_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
12
39
41
42, 43, 44, 46
42, 43, 44, 45, 46
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