Owner's Manual (jjj) Ingersollftand. 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.

SAFETY

DEFINITIONS _______________ _

&i.UUC1@ WILL cause DEATH, SEVERE INJURY or substantial property damage.

& WARNING CAN cause DEATH, SEVERE INJURY or substantial property damage.

& CAUTION WILL or CAN cause MINOR INJURY or property damage.

GENERAL SAFETY PRECAUTIONS _______ _

&i.UUC14;l 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. LockoutlTagout 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.

& 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.

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

© Ingersoll-Rand Company

Printed in U.SA

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 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 stand by 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.

Typica/ 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,

Form SCD-838A

August 2001

an air-cooled aftercooler should be installed between the compressor discharge and the receiver tank or system.

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.

& 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.

& 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.

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.

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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

& WARNING 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 (O°C and 37.8°C). If temperatures consistently drop below 32°F (O°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.

& 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

& 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)

Isolator Washer

Flat Washer

Shim beneath isolator washer, if necessary

3/8" Lag Screw

\---\

Floor line

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.

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

/ PIPE-

,~~ m~ 9 I~m '-----------' HOSE/ I ...

FITTING ~

BUSHINGS /

DRAIN VALVE

\ AIR INLET FILTER

OUTSIDE WALL

HOOD

3

INSTALLING DISCHARGE PIPING ________ _

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

& CAUTION! 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.

SUITABLE

SYNTHETIC COMPRESSOR LUBRICANT

MATERIAL COMPATIBILITY LIST

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.

& WARNING If an aftercooler, check valve, block valve, or any other restriction is added to the compressor discharge, install a properly-sized ASME approved safetylrelief valve between the compressor discharge and the restriction.

INSTALLING ELECTRICAL WIRING (ELECTRIC MOTOR UNITS) ________________ _

& WARNING 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 SINGLE THREE

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 Size (GA) 6 4 2

CONNECTION PROCEDURES:

Maximum Length 5' (1.5 m.) 7'-2.5" (2.1 m.) 12' (3.6 m.)

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

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B

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.

& 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 _________ _

& 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 (22rC) 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.S°C) of I °C SUS I Centistokes ISO I SAE

< 40 < 4.4 150 32 32

40-80 4.4-26.7 500 110 100

80-125' 26.7-51.0' 750 165 150

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

10

30

40

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

2340

2475

2545

7100

Crankcase Capacity

28 oz. (827 ml.)

41 oz. (1212 ml.)

73 oz. (2158 ml.)

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.

5

A

B g-D 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.

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 MODELS) __ _

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 Lever (If Equipped)

ON/AUTO OFF

4. Slowly open the service valve.

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

& 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.

START-UP (GASOLINE ENGINE UNITS) ______ _

& 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.

6

COMPRESSORCONTROLS __________ _

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 PSI G), 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 PSI G), 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. o CLOCKWISE

COUNTERCLOCKWISE 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 PSIG, 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.

& 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 _______ _

& 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.

& 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

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 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 ADJUSTMENTCONTRO~:

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.

7

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.

Position of weight and thrust pin when unit is operating.

Position of weight and thrust pin when unit is stopped.

STARTING UNLOADING SYSTEM (PRESSURE LUBRICATED MODELS) ___________ _

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 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.

8

A = Oil Pump

B = Oil Filter

C = Oil Pressure Gauge

D = Oil Pressure Switch

D

E = Hydraulic Unloader Valve

F = Head Unloaders

G = Shuttle Valve

H = Auxiliary Valve

F

H

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.

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 per Ounce

Ounces of Oil Used

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 Operation

50 Horsepower 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

& WARNING 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

NOTE

NOTE

NOTE

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.

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.

9

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.

OILCHANGE _______________ __

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.

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.

DEFLECTION FORCE SCALE (READ DOWN)

DEFLECTION DISTANCE SCALE (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

10

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.

Lt. CAUTION Improper pulley/sheave 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.

Lt. 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.

TROUBLESHOOTING

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

11

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 30 31 6, 14,37,38 12 39 41 42,43,44,46 42,43,44,45,46

CHECK POINT 1 2

3 4 5

6 7 8 9 10

11

12

13 14 15

16 17 18

19 20

21

22

23 24 25

26 27 28

29 30 31 32 33 34

35 36

37 38 39

40

41 42

43 44 45

46

12

POSSIBLE CAUSE

Clogged or dirty inlet and/or discharge line filter. Loose beltwheel or motor pulley, excessive end play in motor shaft or loose drive belts. Inadequate ventilation around beltwheel. Lubricant viscosity too low. Air leaks in air discharge piping.

Lubricant viscosity too high. Lubricant level too high. Lubricant level too low. Detergent type lubricant being used. Extremely light duty cycles. Compressor located in damp or humid location. Pressure switch differential too narrow.

Improper line voltage.

Wiring or electric service panel too small. Poor contact on motor terminals or starter connections. Improper starter overload heaters. Poor power regulation (unbalanced line). Drive belts too tight or misaligned. Compressor valves leaky, broken, carbonized or loose.

Automatic drain valve clogged, leaking or defective. Carbon build-up on top of piston(s). Piston rings damaged or worn (broken, rough or scratched). Excessive end gap or side clearance. Piston rings not seated, are stuck in grooves or end gaps not staggered. Cylinder(s) or piston(s) scratched, worn or scored. Connecting rod, piston pin or crankpin bearings worn or scored. Loose bearing spacer on crankshaft. Defective ball bearings on crankshaft or motor shaft.

Wrong beltwheel direction of rotation.

Leaking, broken or worn inlet unloader parts. Auxiliary valve dirty or seats worn. Crankshaft seal worn or crankshaft scored.

Leaking or maladjusted centrifugal pilot valve. Leaking check valve or check valve seat blown out. Extremely dusty atmosphere.

Defective safety/relief valve. High pressure inlet valve leaking. Low pressure discharge valve leaking. Automatic start and stop mode is not suitable for air demand. Pressure switch unloader leaks or does not work. Ambient temperature too low.

Worn cylinder finish. Beltwheel out of balance, tubes not braced or secured, wrong pulley speed. Engine not grounded properly. Gasoline exceeds storage time or contains water. No fuel in tank. Fuel valve closed. Low oil pressure. Excessive condensate in receiver tank.

Loose fittings/elbows/connectors Maladjusted or defective oil pressure regulator valve

Maladjusted or defective hydraulic unloader valve Defective oil pressure gauge Oil foaming in crankcase

Debris or other obstruction blocking oil flow

POSSIBLE SOLUTION

Clean or replace. Check beltwheel, motor pulley, crankshaft, drive belt tension and alignment. Repair or replace as required. Relocate compressor for better air flow. Drain existing lubricant and refill with proper lubricant. Check tubing and connections. Tighten joints or replace as required. Drain existing lubricant and refill with proper lubricant. Drain excess lubricant. Add lubricant to crankcase to proper level. Drain existing lubricant and refill with proper lubricant. Run compressor for longer duty cycles. Relocate compressor or install crankcase heater kit. Adjust pressure switch to increase differential, if differential adjustment is provided. Install pressure switch with differential adjustment feature if differential adjustment is desired. Check line voltage and upgrade lines as required. Contact electrician. Intall properly sized wire or service box. Contact electrician. Ensure good contact on motor terminals or starter connections. Install proper starter overload heaters. Contact electrician. Contact power company. Adjust belts to proper tension and alignment. Inspect valves. Clean or replace as required. Install Valve/Gasket Step Saver Kit.. Inspect valve and clean, repair or replace as required. Clean piston(s). Repair or replace as required. Install Ring/Gasket Step Saver Kit.

Adjust piston rings.

Repair or replace as required. Inspect all. Repair or replace as required. Install Bearing/Connecting Rod Step Saver Kit. Inspect bearings and replace if required. Install Bearing/Connecting Rod Step Saver Kit. Check motor wiring for proper connections. Reverse two leads on three-phase motors. Inspect parts and replace as required. Inspect parts. Clean, adjust or replace as required. Replace seal. Install shaft sleeve if required. Install Bearing/Connecting Rod Step Saver Kit. Replace pilot valve o-ring. Adjust pilot valve. Replace check valve. Install remote air inlet piping and route to source of cleaner air. Install more effective filtration. Replace. Inspect, clean or repair as required. Inspect, clean or repair as required. Adjust auxiliary valve for constant speed operation. Realign stem or replace. Install crankcase heater kit. Convert to All Season T30 Select lubricant. Relocate compressor to warmer environment. Deglaze cylinder with 180 grit flex-hone. Check vibration level, change pulley or beltwheel if required, tighten tube clamps. Ground battery to engine as recommended. Replace gas, add fuel stabilizer. See manufacturer's instructions for refueling. Open fuel valve. See manufacturer's instructions. Drain receiver tank with manual drain valve or install automatic drain valve. Re-torque fittings per specified torque requirements Adjust valve to proper setting Replace regulator valve Replace hydraulic unloader valve assembly Replace gauge Drain existing lubricant, thoroughly clean crankcase, replace lubricant inspect/clean all oil passages

DIAGRAMS & TABLES

High Pressure Head Bolts Low Pressure Head Bolts Cylinder Flange Bolts Frame Cover Bolts Shaft Cover Bolts Crankpin Cap Screws Unloader Cover Screws High Pressure Inlet Valve Screws Low Pressure Inlet Valve Screws High Pressure Outlet Valve Screws Low Pressure Outlet Valve Screws Beltwheel Bolt High Pressure Head Center Bolts Low Pressure Head Center Bolts Unloader Guide Mounting Screw Low Oil Level Switch Baffle Screw Head Center Acorn Nuts Pilot Valve Unloader Body Assembly Bearing/Unloader Housing Bolts Valve Plate Studs

13

FASTENER TORQUE TABLE

2340 75 75 30 17 17 5.5

11-15 LB-IN 11-15 LB-IN 11-15 LB-IN 25-30 LB-IN 33

2475 75 75 50 17 17 11

11-15 LB-IN 25-30 LB-IN 11-15 LB-IN 25-30 LB-IN 60

2545 75 75 50 17 17 11 11 11-15 LB-IN 25-30 LB-IN 11-15 LB-IN 25-30 LB-IN 60 10 14-16

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

MODEL

2340 (14" Span)

2340 (19" Span)

2475 (14" Span)

2475 (19" Span)

2475F/X11GH

2475F/X9/11GK

2475N5 (14.5" Span, Cogged belt)

2545 (A Groove)

DEFLECTION (IN.)

0.25

0.29

0.25

0.29

0.34

0.25

0.23

0.29

BELT TENSION TABLE

TENSION (LB.) BELT HORSEPOWER

4.9 - 7.1 TYPE

4.9 - 7.1 B 7.5

4.9 - 7.1 10-15

4.9 - 7.1 C 20

5.5 - 8.0 25-30

11.25 - 13.0 5V 25-30

4.5 - 6.5

4.9 - 7.1

7100 75 75 50 20 20 12-15 11 5.5 5.5 26 26 113

2000 & 2000P 120 120 50 20 50

36 LB-IN 36 LB-IN 36 LB-IN 36 LB-IN 80

25 5 7 25 25 25 7

TENSION AT 1164" DEFLECTION PER INCH OF SPAN

7.0 - 10.0

8.0 -12.0

12.0 - 18.0

14.0 - 21.0

14

ELECTRICAL WIRING DIAGRAMS

Single Phase Wiring

TO SUPPL Y

/ L 1 L2'

M 9L -A T1 ~-I----'I ~

__ l) 'MOTOR

.--______ -----1MI T2 /-

lJ----------j11

1 2 F F •• SEE NOTE U U

A

C

EDV

T

L

FU

HATS

LOLS

M

OL

PS

SS

To supply

Wiring for optional electric drain valve

Electric drain valve

Supply Line Terminal

Load Terminal

Control Circuit Fuse

High Air Temperature Switch (#)

Low Oil Level Switch (#)

Motor Starter Coil

Motor Starter Overload

Pressure Switch

Selector Switch (#)

Alternate wiring for converting 3 phase starter to 1 phase application

(#) = if provided

~ON J ~ 'PS *LOLS 'HA TS . O~ '-----D, o--o~o--o~

SS 7 0 8 0---. 9 C; 6 5 4

Three Phase Wiring

M OL-A T1

"4 "3® M OL-C T3 f------------0

0-------111 @ -fl ~~ ~t ===::]J: 0

0 I 1L J ~

~ *ps *LOLS *HATS *EDV 1 SS~g '~' 6

M 5 • 4

NOTE On units requiring a starter, connect line power to the starter. do not connect line power to the pressure switch .

• Connect ground wire to ground lug

• L3 used for 3-phase motors & starters only

Typical Baseplate Unit

ENCLOSED BEL TGUARO

AIR 0 ~

AIR INLET FILTER

OIL FILL

_____ J, I I I I I I I I I I I I I I I I I I

11 I I

:i--------LJ " I-__ '=~

15

fL--------~:

AIR COOLED AFTERCOOLER (OPTIONAL)

Typical Horizontal Simplex Unit

AIR FIC5W

AIRCOOLED AFTERCOOLER (OPTIONAL)

MANUAL DRAIN VALVE (LOCATION WHEN SUPPLIED WITH AUTO DRAIN VALVE)

I

AIR COOLED~ AFTER COOLER

CONNECTION

MOUNTED MOTOR STARTER (OPTIONAL)

OIL FILL

LOW OIL LEVEL SWITCH

OIL DRAIN

DISCHARGE SAFETY/RELIEF VALVE

AUTO CONDENSATE DRAIN VALVE-1/8"

NPT DRAIN PORT

(OPTIONAL)

INTERCOOLER SAFETY/RELIEF VALVE

AIR OUTLET

(

AIR INLET FILTER

__ A__ (OUTDOOR OPTION)

LOW OIL LEVEL SWITCH (OPTIONAL)

OIL DRAIN

MOUNTED MOTOR 5T ARTER (OPTIONAL)

MOUNTING HOLES

CONSTANT SPEED UNLOADERS

AIR RECEIVER TANK J J MOUNTING HOLES

MANUAL DRAIN VALVE (LOCATION WHEN NOT SUPPLIED WITH AUTO DRAIN VALVE)

PRESSURE SWITCH, GAUGE, RECEIVER SAFETY /RELI EF VALVE AND AUXILIARY VALVE

ENCLOSED BELTGUARD

INSPECTION OPENINGS (BOTH SIDES)

AIR OUTLET SERVICE VALVE

Typical Vertical Simplex Unit

'IL Lr"III-

F F E~,-I-=- _ u-

11111- I

-I 11' 11,11 =F III L

16

T~I----

C ::,- 'TI',-II

EIIII :'

Typical Gasoline Engine Unit ENGINE FUEL TANK

GASOLINE ENGINE \

ENGINE AIR CLEANER \

ENGINE EXHAUST MUFFLER (REAR)

ENGINE OIL DIPSTICK

ENGINE OIL DRAIN ---___ --,..,~~

AIR OUTLET SERVICE VALVE

Typical Duplex Unit iFT::IHE ITC[I _ [I' -- ~ TT I - =_ [I

"'IL I L_

1 f 1

I':, :'11 IF =-

-- -'-II~--

FF IF

'-1- [

-=TI [I -- FF

-I I" ri' ==- T ) F'-

RECEIVER PRESSURE GAUGE, DISCHARGE & RECEIVER SAFETY/RELIEF VALVE, DISCHARGE UNLOADER

F' 111::-­FIL-EF":

INTERSTAGE SAFETY/RELIEF VALVE

OIL FILL PLUG

OIL DRAIN PLUG

INSPECTION OPENING

(BOTH ENDS)

ISOLATION MOUNT (4 REQUIRED)

ENCLOSED BEL TGUARD

AIR INLET

FILTER~

AIR RECEIVER (~~ ,'" --,-"@,)

MANUAL CONDENSATE r;;j/ 7

DRAIN VALVE~

""1-1-' ---,_::[ -F::- F ::J::=-

1 "

rl{~~~li .

~',t~,p~[lli:

I-'~ -FF'II,,-' =

I-L'

- '"':;...:::'",<

, F f ~I

~.~ t~;

I -'"I '=f

-I 1

I,' 111'1-11 I)F'-JF- C'F'-I FJ'T

AIR

FLOW ----

C ® INGERSOLL -RAND® TEOINlCAL MANUAL

SUPPLEMENT

Small Compressor Division

INGERSOlL -RAND COMPANY Campbellsville, KY 47218

LOW OIL LEVEL SWITCH PART NUMBER 32276313

1. PURPOSE.

Can Cause Severe Injury or Death.

Always release air pressure from the compressor, air receiver and associated tubing and components before servicing this compressor.

The purpose of this publication is to provide mainte­nance and parts list information regarding the latest design improvements on your Ingersoll-Rand air com­pressor. The information contained herein has not yet been incorporated in the Instruction and Parts List Manuals provided with your compressor.

2. SCOPE.

This supplement is applicable to all Type 30 (T30) air compressors manufactured after April 1 , 1994. Depend­ing on the air compressor purchased, the Low Oil Level Switch is available as either standard or optional equip­ment.

3. PRECEDENCE.

The maintenance procedures contained in Paragraph 6 supersede the corresponding data in the Instruction Man­ual supplied with your air compressor. When ordering spare or replacement parts, the part numbers listed in Paragraph 8 should be used in place of those shown in the Parts List. This publication, along with the Instruction Manual and Parts List should be kept in a location which is accessible to operation and maintenance personnel.

4. DESCRIPTION.

A properly functioning Low Oil Level Switch is critical to the operation of your compressor. Operating the com­pressor with a defective switch can cause extensive damage should the frame oil level drop to an unsafe point undetected. The switch is a single-pole, double­throw device, and is NEMA 4 rated. Switch data is listed in Table 1.

@ 1994 Ingersoll-Rand Company Printed in the U.S.A.

Can Cause Severe Injury or Death.

Always disconnect power supply before performing any maintenance or repair work on this compressor.

The low oil level switch does not alleviate the need to check the frame oil level in your compressor on a regu­lar basis (Refer to the SCHEDULED MAINTENANCE table in your Instruction Manual). Ingersoll-Rand Com­pany cannot assume responsibility for any damage which might occur as the result of operating the com­pressor without adequate lubrication.

AMPS VOLTAGE

0.4 575 VAC PILOT DUTY

1/4 250 VDC - NON-INDUCTIVE

1/2 125 VDC - NON-INDUCTIVE

3-112 24 VDC - NON-INDUCTIVE

10 125,250,480 VAC

TABLE 1. SWITCH DATA.

5. OPERATION.

If the oil level in the compressor frame reaches an unsafe level, the float will cause the switch contacts to open and shut down the unit. When the proper lubricant level has been restored, the float will reset to its original position, closing the switch contacts. The compressor can then be restarted.

6. MAINTENANCE.

Under normal operation, the low oil level switch re­quires no operator intervention or routine maintenance. If the switch fails, as evidenced by frequently shutting off the motor, or failing to shut off the motor if the oil level drops to an unsafe point, it should be removed and

FORM SCD-599 March 1994

NORMAL OPERATING POSITION

r- - -- -- ------ -- ---, • ~ --r--------

) ________________ J

INSTALLA liON POSITION

FIGURE 1. SWITCH ALIGNMENT.

checked immediately. A defective switch must be re­placed.

A. REMOVAL. (NOTE: Frame end cover removal is not required to remove the low oil level switch).

1). Disconnect the main power supply and drain the oil from the frame (refer to your Instruction Manual for oil change procedures).

2). Disconnect the switch wires from the control circuit.

3). Loosen the three set screws and remove the switch cover.

4). Remove the switch body from the compressor frame. (NOTE: If the switch is to be removed from the compressor for an extended period of time, install a 3/4" NPT plug into the frame opening to keep dust and dirt out of the frame).

B. CLEANING. Thoroughly clean the float with a dry rag. If necessary, a non-flammable solvent can be used provided the float is wiped clean before the switch is reinstalled.

C. TESTING. The switch can be tested with a stand­ard 12-volt automotive test light.

1). Align the cover on the switch body as shown in Figure 1.

2). Hold the float up so that the contact rod and cover do not make contact. The test light should be on.

3). Release the float. When the rod and cover make contact, the test light should go off.

D. INSTALLATION.

1). With the switch cover removed, apply pipe thread sealant to the switch threads.

2). With the float extended straight out, insert the switch body into the frame and tighten. When properly installed, the switch should be aligned as illustrated in Figures 1 and 2.

3). Hold the contact rod straight up at a 90° angle. Install the switch cover with the arrow pointing straight up at a 90° angle.

4). Carefully and evenly tighten the three set screws to secure the cover to the switch body, using caution not to over-tighten and damage the switch. The set screws should be torqued to 24-32 In. Oz.

5). Connect the switch wires to the control circuit. (Refer to your Instruction Manual).

6). Fill the compressor frame with lubricant. (Re­fer to your Instruction Manual).

FLOAT

I /

LOW OIL LEVEL SWITCH

FIGURE 2. SWITCH INSTALLATION.

7. PARTS LIST DATA.

Should it ever be necessary to replace the switch, sup­ply the information in Table 2. when ordering.

PART NBR. DESCRIPTION

32276313 SWITCH, LOW OIL LEVEL

TABLE 2. PARTS LIST DATA.

SCD-599

INGERSOLL-RAND® AIR COMPRESSORS

Supplement

Small Compressor Division Ingersoll-Rand Company Campbellsville, KY 42718

This form provides supplemental information for: Automatic Drain Valves

Part Numbers 32296238 & 32310690 32296238 Used On the Following Models: 2340 Simplex 2475 Simplex OL Simplex & Duplex 32310690 Used On the Following Models: 2545 Simplex & Duplex 7100 Simplex & Duplex 3000 Simplex & Duplex 15T Simplex & Duplex 2340 Duplex 2475 Duplex

PURPOSE ________________________ _____

This supplement applies only to units equipped with an optional automatic drain valve (part numbers 32296238 and 32310690). It contains information which is not included in the product literature provided with your unit. Keep this supplement with your product literature for future reference.

DESCRIPTION ______________________ _

The automatic drain valve removes condensed water and oil from compressed air systems. This device will not restrict air flow, create a pressure drop or open the system to the atmosphere. Its unique design maintains systems pressure and volume during operation, and increases productivity.

OPERA TlON _____________________ _

The automatic drain valve functions on the principle of piston movement which is achieved by intermittent pressure provided at the pilot port. The forward motion of the piston due to pressure at the pilot port allows condensate from the receiver to flow into the valve reservoir. When the pressure at the pilot port drops the piston comes back to its original position and the condensate is expelled from the condensate outlet. The constant speed control or automatic

© 1996 Ingersoll-Rand Company Printed in U.S.A.

start-stop mode of compressor delivers this intermittent pressure.

INSTALLATION ______________________ _

On compressors that have been in service without an automatic drain valve, all debris at the bottom of the tank should be cleaned and blown out. If the debris is not removed, or if the compressor is more than two years old, we recommend installing a y-type strainer ahead of the drain valve.

MAINTENANCE ______________________ _

RESERVOIR PART NUMBER 32498317 (STAN)ARDJ PART NUM8ER 32498309 (LARGE SIZE FOR MODEL 3000 DUPLEX)

ELSOW,TlIIE - 114" 3 PART NUMBER 32311080

114 NPT PLOT PORT

118 NPT

114 NPT MANUAL DRAIN PORT

CONDENSATE OUTLET

Figure 1. Typical Automatic Drain Valve Cutaway View. (32296238 Automatic Drain Valve Illustrated).

Form SCD-671C November 1996

Replaces SCD-671 B

2

Constant leak of air present at

Troubleshooting Guide

long enough in automatic start and stop mode or in constant speed mode does not run unloaded long enough to remove

on when compressor shuts off and does not allow piston to return allowing discharge. (Crack open compression fitting on intermittent air end of valve and see if valve

discharge port after compressor is worn.

Air continuously leaks from Seals on are worn. port while compressor is running.

NOTICE

water cap """',,, .. ,,'" Number 32310971).

(Part Number 32314924 or 32310.989, depending on automatic drain valve used. See table of

NOTICE Considering normal operation ofthe duplex in which both compressors are operating and cycling with each other, the automatic drain valve has been piped to one compressor only (the one closer to the service valve). Therefore, the automatic drain valve will function as long as this compressor is operating. If this compressor is shut off for long periods of time, then manual draining of the receiver must be performed.

In Model 3000 duplex compressors, a larger reservoir (Part Number 32496309) is used. This must be noted when ordering replacements.

NOTICE

The automatic drain valve requires very little operator intervention. However, it will be necessary to periodically clean the screen inside the valve to keep it functioning at maximum capacity. Blowing out the receiver will clean out the strainer screen in the valve. Note there may be a small amount of water between the bottom ofthe receiver and the drain valve. (In harsh conditions, removal of the manual drain prior to exhaust may be required for complete cleaning). Reinstall manual drain valve. Follow the daily

The automatic drain valve functions only if the unit is running in a start-stop mode or constant speed control mode. Ifthe unit is running in continuous duty mode, then draining the receiver with the manual drain valve is recommended.

maintenance procedures outlined in your product literature.

Most ofthe individual components ofthe valve are not sold separately. The only parts sold separately are those in the service kits available from Ingersoll-Rand. If replacement parts are necessary, order from the list of available kits.

INGERSOLL-RAND® AIR COMPRESSORS Small Compressor Division Ingersoll-Rand Company

Supplement

Campbellsville, KY 42718

This form provides supplemental information for:

- PURPOSE

Cold Weather Operation of Type 30 Products

This supplement applies to all two-stage air compressor products. It contains information regarding the operation of your unit in cold weather conditions. The information contained herein supplements the information contained in the product literature provided with your unit when shipped.

-INSTALLATION

• T30 compressors should be installed where ambient temperatures are between 32°F and lOO°F (O°C and 37.8°C). • Crankcase heaters should be installed whenever the compressor is operated in ambients below 32°F (O°C).

- LUBRICATION

Please adhere to the following guidelines.

• Consult factory for use of synthetic lubricants in ambients below 32°F (O°C). • Non-detergent petroleum lubricating oil containing only rust, oxidation and anti-foaming inhibitors can be used in all

Type-30 air compressors (exception: HPI000 and 20H40NG compressors).

The petroleum-based lubricant viscosities given in the following table are intended as a general guide only. Heavy duty operating conditions require heavier viscosities. Where borderline temperature conditions are encountered, the viscosity index of the oil should be considered. Always refer your specific operating conditions to your lubricant supplier for recommendations.

150 32 32 10

500 110 100 30

750 165 150 40

Table 1. Viscosity for Petroleum-based Lubricants.

- GENERAL

• When operating compressors in ambients below 32°F (O°C), the compressor control valves, pressure relief valves, regulators and drain valves must be protected against freezing.

• Starting torque is critical for cold weather starts. Remember that a 10% drop in supply voltage will reduce starting torque by 19%.

© 1996 Ingersoll-Rand Company Printed in USA

Form SCD-680 January 1996

INGERSOLL-RAND~ AIR COMPRESSORS

Supplement

Small Compressor Division Ingersoll-Rand Company Campbellsville, KY 42718

This form provides supplemental information for:

Pressure Switches NOTICE

This supplement does not apply to optional pressure switches with a differential adjustment. These optional pressure switches can be provided at an additional cost.

PURPOSE ________________________ __

The purpose of this supplement is to provide updated information for the standard pressure switches provided on Ingersoll-Rand compressor packages.

The information contained in this supplement is not included in the literature provided with your compressor. Please keep this supplement for future reference.

PRESSURE SWITCH, __________________ __

Standard pressure switches provided on Ingersoll-Rand compressor packages are no longer equipped with a differential adjustment control to establish the span between cut-in and cut-out pressure levels. The span is factory set for 40 ± 4 PSIG and cannot be adjusted.

NOTICE 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.

The range adjustment control is still provided to set the cut-in and cut-out pressure levels.

For additional information, refer to the instructions provided for the pressure switch.

(c) 1996 Ingersoll-Rand Company Printed in the U.S.A.

RANGE ADJUSTMENT

The pressure switch is equipped with a range adjustment control only. No differential adjustment controls are provided.

Form SCD-697 June 1996

INGERSOLL-RAND,. AIR COMPRESSORS

Ingersoll-Rand Company Reciprocating Compressor Division

Small Compressor Business Unit Campbellsville, KY 42718

Supplement For

Compressor Lubrication (All Season T30 Select ® Synthetic Lubricant)

NOTICE Synthetic lubricants such as All Season T30 Select have a detergent action and may dissolve or break loose existing deposits in used compressors and compressed air systems.

You must be certain that the downstream components of your compressed air system will not be damaged by the action of this lubricant, as this lubricant is not compatible with certain materials.

Please refer to the material compatibility table.

If there are any materials present downstream in your compressed air system that are not included in the material compatibility table, we urge you to contact your local Ingersoll-Rand distributor for information.

DESCRIPTION _____________ _

All Season T30 Select is an all-temperature diester synthetic lubricant. The benefits of All Season T30 Select are as follows:

1). Reduces wear and eliminates much of the carbon build­up found when some petroleum-based lubricants are used. This elimination increases compressor efficiency and significantly decreases maintenance and downtime.

2). All-temperature blend provides more consistent viscosity and protection in high and low operating temperatures.

3). Faster splash lubrication to moving parts and less cranking resistance at operating temperatures below 40°F (4.4°C).

4). May be used reliably in operating temperatures that are consistently below 30°F (-1.1 QC).

APPLICATION _____________ _

All Season T30 Select is recommended for Type 30 standard and high pressure reciprocating air compressors. It is not recommended for aluminum units, vacuum pumps, CNG units or non-Iube units.

CRANKCASEHEATERS _________________ __

While providing exceptional lubrication at normal and high operating temperatures, All Season T30 Select is formulated to be used in low operating temperatures as well. Depending on model and prevailing voltage conditions, some compressors may require the occasional use of crankcase heaters in operating temperatures below 30°F (-1.1 QC). If your compressor has difficulty starting in

© Ingersoll-Rand Company

Printed in U.S.A.

temperatures below 30°F (-1.1 °C), a crankcase heater may be required. Contact your nearest Ingersoll-Rand Full Service Distributor for more details.

WARRANTY ______________ _

A two-year warranty is available for Type 30 two stage cast iron bare compressor pumps that run solely on All Season T30 Select from start-up through an entire two-year period. Models 2340,2475,2545,7100, 15T and 3000 that are operated solely on All Season T30 Select brand synthetic lubricant will have their bare compressor pump warranted for a period of twenty-four (24) months from the date of initial operation or thirty (30) months from the date of shipment, whichever shall occur first.

The extended warranty applies only to Type 30 two stage cast iron bare compressor pumps. Motors, receivers and any other package components do not qualify for extended warranty.

The extended warranty does not apply to Type 30 single stage models, high pressure models or 6R models.

NOTE: Proof of All Season T30 Select purchase may be required with warranty claim.

Fire or explosion hazard!

Do not use alternate lubricants that fail to meet minimum f1ashpoint and auto­ignition temperature requirements.

Use of improper lubricants result in coking (carbon deposits) which can block heat exchangers, discharge lines, compressor valves, safety/relief valves and control lines and result in a fire or explosion which can cause severe injury or death.

Certain petroleum-based lubricants may be used in most Type-30 model compressors provided they are premium­quality, non-detergent lubricants containing only rust, oxidation, and anti-foaming inhibitors. Substitute lubricants must have a flashpoint of 440°F (227°C) or higher and an auto-ignition point of 650°F (343°C) or higher. BREAK-IN PROCEDURES ________________ _

NOTE: These break-in instructions apply only to Type 30 single and two stage cast iron air compressor models. High pressure and 6R models require a 1 OO-hour break-in with petroleum-based lubricant only. ..

Form SCD-698B

August 1998

Replaces SCD-698A

1). Fill the crankcase with All Season T30 Select. Refer to your instruction manual for crankcase capacity.

2). On used compressors that have been converted to All Season T30 Select, operate the compressor for approximately 200 hours, then inspect. If necessary, clean the compressor inlet and discharge valves.

NOTICE Used compressors must be decarbonized before converting to All Season T30 Select.

For revised valve maintenance and lubricant change intervals, refer to the routine maintenance table.

Table 1. All Season T30 Select Material Compatibility.

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 r.nlrnn,,,,,tinn\

COLD WEATHER STARTING ________ _

When using All Season T30 Select in temperatures below 30°F (-1.1°C), always follow these starting procedures.

1). Release all pressure from receiver and all associated tubing and components. Pull the rings on all relief valves.

2). Start the compressor.

3). If compressor has difficulty starting, crankcase heaters may be required.

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

Table 2. Routine Maintenance Schedule with use of All Season T30 Select.

NL (non-Iube) els

Vacuum pump models

High pressure models *

models *

* - 100-hour break-in with petroleum-based lubricant required.

as

not approved (Use petroleum-based lubricant such as

year oil change and valve inspection

change and 1500 hours I 1 year valve

INGERSOLL-RAND. AIR COMPRESSORS

Inge .. oll-Rand Company Reciprocating CompreHor Division

Small Compreuor Buslne .. Unit Campballavllle, KY 42718

- Supplement -Fuse Requirements For Electric Units

Depending on your particular unit, control circuit fuses mayor may not be provided. Units without control circuit fusing are identified by a decal on the starter box that states "BRANCH CIRCUIT PROTECTION MAX. 45 AMPS".

If the Ingersoll-Rand unit does not have control circuit fusing, as evidenced by the presence of the decal, then the branch circuit protection device provided by the installer/end user must not exceed 45 amps, in accordance with National Electric Code (NEC).

NOTE: The 45 amp branch circuit limitation requires the use of time delay fuses or inverse time circuit breakers. If time delay protection devices are not used, control circuit fusing must be installed, in accordance with NEC. A control circuit fusing kit (1-R Part Number 56274780) is available for these installations.

NOTE: The presence of control circuit fusing on an Ingersoll­Rand unit does not eliminate the need for the installer to provide proper branch circuit protection. A branch circuit protection device must be installed in accordance with National Electric Code (NEC) on all units.

Please see the owner's manual and wiring diagrams and refer to the NEC for additional information.

© Ingersoll-Rand Company

Printed in U.S.A.

Form SCD-832

November 1998

INGERSOLL-RAND. AIR COMPRESSORS

Inge .. oll-Rand Company Reciprocating Comp"'lSor Division

Small CompntlSOr Busln ... Unit Campballavtlle, to' 42718

- Supplement -Fuse Requirements For Electric Units

Depending on your particular unit, control circuit fuses mayor may not be provided. Units without control circuit fusing are identified by a decal on the starter box that states "BRANCH CIRCUIT PROTECTION MAX. 45 AMPS".

If the Ingersoll-Rand unit does not have control circuit fusing, as evidenced by the presence of the decal, then the branch circuit protection device provided by the installer/end user must not exceed 45 amps, in accordance with National Electric Code (NEC).

NOTE: The 45 amp branch circuit limitation requires the use of time delay fuses or inverse time circuit breakers. If time delay protection devices are not used, control circuit fusing must be installed, in accordance with NEC. A control circuit fusing kit (1-R Part Number 56274780) is available for these installations.

NOTE: The presence of control circuit fusing on an Ingersoll­Rand unit does not eliminate the need for the installer to provide proper branch circuit protection. A branch circuit protection device must be installed in accordance with National Electric Code (NEC) on all units.

Please see the owner's manual and wiring diagrams and refer to the NEC for additional information.

© Ingersoll-Rand Company

Printed in U.S.A.

Form SCD-832

November 1998

<f!j) Ingersollland® Instruction Sheet Installation, Operation & Maintenance Instructions

For Model EDV-2000 Electric Condensate Drains

PRODUCT DESCRIPTION

The EDV-2000 removes condensed water and oil from the air receiver tank. Additional drains may be installed throughout your compressed air system, including aftercoolers, filters, drip legs and dryers.

The EDV-2000 operates on a timer which can be set to automatically drain the air receiver tank at operator-determined intervals.

Key features include:

• 100% continuous duty

• NEMA 4 enclosure

• Adjustable time on (.5 - 10 seconds)

• Adjustable time off (.5 - 45 minutes)

• Stainless steel operator

• LED to indicate electrical power is on

• LED to indicate valve is open

• Manual override

• 6' power cord (AC plug on 110/220 volt drains only)

• Agency approval

RECEIPT & INSPECTION Remove the EDV-2000 from packaging and inspect for transportation damage. Ensure the voltage rating on the solenoid valve matches your power supply.

INSTALLATION On compressors that have been in service without an automatic drain, all debris at the bottom of the tank should be cleaned and blown out before installing the electric drain.

WARNING: DO NOT install the EDV-2000 on a pressurized tank. Depressurize the tank and disconnect the power supply before installing.

NOTE: For ease of installation, it may be necessary to elevate the tank. Ensure adequate lifting equipment is available.

1. Install EDV-2000 using proper sealant (Le., Loctite 567) on the threads. Ensure sealant does not enter the valve body.

2. Supply EDV-2000 with the proper electrical supply voltage.

OPERATION

CAUTION: Do not operate the EDV-2000 outside the following pressure and temperature ranges:

Maximum Operating Pressure: Compressed Air Temperature: Ambient Temperature:

1. Open the strainer ball valve.

250 psig 33 to 265°F 33 to 125°F

Strainer Ball Valve.

OPEN

2. Set the "time off" and "time on" knobs. See TIMER SETTINGS (below) for an explanation of the settings.

3. During compressor operation, check for air leaks.

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 114" 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 .

TROUBLESHOOTING

Trouble Cause Action

Valve will not close. 1. Debris in solenoid 1. Remove solenoid valve prevents valve, disassemble, diaphragm from clean and seating. reassemble.

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

as needed.

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

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.

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.

CAUTION! 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 tOU hear air escaping from the cleaning port, STOP IMMEDIATE Yand 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.

6. When putting the EDV-2000 back into service, press the TEST button to confirm proper function.

Form SeD-87gB

August 2002

PARTS LIST

EDV-2000 Drain Valve With Strainer/Ball Valve Assembly

PART NO. DESCRIPTION MAX DISCHARGE RATE (GALLONS PER 5 NPT SIZE ORIFICE 110/120V 230/240 V PRESS. SECONDS "ON TIME") •• SIZE

(PSI) 38018222 38018230 EDV-2000 250 UPTOO.1 1/4" 3/32" 38018289 38018206 EDV-2000 250 UPTO 1.0 1/4" 7/16" 38018198 38018214 EDV-2000 250 UPTO 1.6 1/2" 7/16"

EDV-2000 Field Retrofit Assembly (Includes Drain Valve, Strainer/Ball Valve Assembly, Connector and Manual Drain Valve)

PART NO. DESCRIPTION 110/120 V 230/240 V

54579248 97339402 EDV-2000 FIELD RETROFIT ASSEMBLY

MISCELLANEOUS REPLACEMENT PARTS

PART NO. 38000154 95480273

NOTES:

DESCRIPTION STAINLESS STEEL FILTER SCREEN O-RING

ON DIAl... (S[C.)

TWI$l KNOB fOR MANUAL DRAIN

VALV" 0 .... , "'WAl /1 ! /3" NPl OUllH PORT

.230 volt models are supplied without AC plugs.

• Discharge rate based upon 90 PSIG air system and 5 seconds valve "on time." Flow rates may vary with installation.

MAX PRESS. (PSI) 250

• For Commercial Garages, Repair And Storage installations, refer to the National Electric Code (NEC 1999) Article 511 for the proper installation instructions.

• Disposal of any liquid should be done in accordance with the local, state or federal guidelines that apply to your area.

DISCHARGE RATE (GALLONS PER 5 SECONDS "ON TIME") ••

UPTOO.1

NPT SIZE ORIFICE SIZE

1/4" 3/32"

~ CL

1St ~

or-r----'~~------_1 __ JF~~~ CL

~~§§~~----------(::)6.r.~~ !j w n::.

Inuersollfland~ Supplement Sheet Pressure Switches

Models 2340, 2475, 2545, 7100, 15T, 3000, 2000

This supplement sheet contains installation, maintenance and replacement parts information that has not yet been incorporated into the owner's manual and parts list for your air compressor. Please retain this information for reference.

ADJUSTING THE PRESSURE SWITCH SETTINGS

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.

CAUTION! Do not adjust the pressure switch to exceed the maximum discharge pressure of the unit. Cut-off failure can occur by over adjusting the range nut.

NOTE Adjust the pressure switch only if adjustments are absolutely necessary.

To properly adjust the range, follow the instructions below:

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 (360°) changes the setting approximately 6 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 INSTALLATION PRECAUTIONS

Diaphragm leaks can occur if a new pressure switch is installed improperly. During installation of a new pressure switch, do not tighten the pressure switch by turning the switch body by hand. Putting sideways pressure on the switch body puts stress on the body-to-diaphragm connection and may cause later failure due to vibration, temperature expansion, or pressure.

In addition, do not use the pressure switch assembly as a handle when moving the compressor. This places stress on the body-to-diaphragm connection and can distort internal components.

Failure can occur by putting undue stress on the unloader body while tightening the unloader tubing with a wrench. Do not adjust the orientation of the pressure switch by turning the entire assembly with a wrench placed on the unloader connection.

© Ingersoll-Rand Company

Printed in U.SA

TYPICAL PRESSURE SWITCH SETTINGS

Minimum On 100

Maximum Off 175

Differential (Non-Adjustable)

30-40

Form SCO-914

July 2000

PART NUMBERS AND DESCRIPTIONS FOR PRESSURE SWITCHES

The pressure switch part numbers shown below are for 175 psi air compressors that are equipped with standard NEMA 1 electrical enclosures.

HP MODEL PART NO. DESCRIPTION

5 2340L5 SINGLE PHASE 56288806 SWITCH, PRESSURE 2340L5 THREE PHASE 56288764 SWITCH, PRESSURE - WITH UNLOADER VALVE 2-2340E5 56288764 SWITCH, PRESSURE - WITH UNLOADER VALVE

AND 56288798 SWITCH, PRESSURE 2545N5-PS 56288798 SWITCH, PRESSURE 2475N5 STANDARD 56288772 SWITCH, PRESSURE - WITH UNLOADER VALVE AND LEVER 2475N5 TOTALLY PACKAGED 56288764 SWITCH, PRESSURE - WITH UNLOADER VALVE

7-1/2 2475N7.5 56288772 SWITCH, PRESSURE - WITH UNLOADER VALVE AND LEVER 2-2475E7.5 56288764 SWITCH, PRESSURE - WITH UNLOADER VALVE

AND 56288798 SWITCH, PRESSURE 2545N7.5-PS 56288780 SWITCH, PRESSURE - WITH LEVER

10 2545E10V 56288772 SWITCH, PRESSURE - WITH UNLOADER VALVE AND LEVER 2-2545A10V 56288764 SWITCH, PRESSURE - WITH UNLOADER VALVE

AND 56288798 SWITCH, PRESSURE 2545E10 56288780 SWITCH, PRESSURE - WITH LEVER 2545K10 56288780 SWITCH, PRESSURE - WITH LEVER 7100E10-PS 56288798 SWITCH, PRESSURE

15 7100E15 56288798 SWITCH, PRESSURE 15TE15 56288798 SWITCH, PRESSURE 15TE15-PS 56288798 SWITCH, PRESSURE 7100E15V 56288772 SWITCH, PRESSURE - WITH UNLOADER VALVE AND LEVER

20 15TE20 56288798 SWITCH, PRESSURE 2000E20-PS 56288798 SWITCH, PRESSURE 3000E20 56288798 SWITCH, PRESSURE

25 2000E25-PS 56288798 SWITCH, PRESSURE 2000A25-PS 56288798 SWITCH, PRESSURE 3000E25 56288798 SWITCH, PRESSURE

30 2000E30-PS 56288798 SWITCH, PRESSURE 3000E30 56288798 SWITCH, PRESSURE

HP = MOTOR HORSEPOWER

17

WARRANTY

Ingersoll-Rand Company warrants that the Equipment manufactured by it and delivered hereunder shall be free of defects in material and workmanship for a period of twelve (12) months from the date of placing the Equipment in operation or eighteen (18) months from the date of shipment, whichever shall occur first. The foregoing warranty period shall apply to all Equipment, except for the following: (A) Compressors that are operated solely on All Season T30 Select sunthetic compressor lubricant will have their bare compressor warranted for the earlier of twenty-four (24) months from the date of initial operation or thirty (30) months from the date of shipment. (B) Replacement parts will be warranted for six (6) months from the date of shipment. Should any failure to conform to this Warranty be reported in writing to the Company within said period, the Company shall, at its option, correct such nonconformity by suitable repair to such Equipment, or furnish a replacement part F.O.B. point of shipment, provided the purchaser has installed, maintained and operated such equipment in accordance with good industry practices and has complied with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturer conveyed to Ingersoll-Rand Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser without the Company's prior written approval.

The Company makes no performance warranty unless specifically stated within its proposal and the effects of corrosion, erosion and normal wear and tear are specifically excluded from the Company's Warranty. In the event performance warranties are expressly included, the Company's obligation shall be to correct in the manner and for the period of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY OF REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILlTY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.

Correction by the Company of nonconformities, whether patent or latent, in the manner and for the period of time provided above, shall constitute fulfillment of all liabilities of the Company and its Distributors for such nonconformities with respect to or arising out of such Equipment.

LIMITATION OF LIABILITY

THE REMEDIES OF THE PURCHASER SET FORTH HEREIN ARE EXCLUSIVE, AND THE TOTAL LIABILITY OF THE COMPANY, ITS DISTRIBUTORS AND SUPPLIERS WITH RESPECT TO CONTRACT OR THE EQUIPMENT AND SERVICES FURNISHED, IN CONNECTION WITH THE PERFORMANCE OR BREACH THEREOF, OR FROM THE MANUFACTURE, SALE, DELIVERY, INSTALLATION, REPAIR OR TECHNICAL DIRECTION COVERED BY OR FURNISHED UNDER CONTRACT, WHETHER BASED ON CONTRACT, WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE SHALL NOT EXCEED THE PURCHASE PRICE OF THE UNIT OF EQUIPMENT UPON WHICH SUCH LIABILITY IS BASED.

THE COMPANY, ITS DISTRIBUTORS AND ITS SUPPLIERS SHALL IN NO EVENT BE LIABLE TO THE PURCHASER, ANY SUCCESSORS IN INTEREST OR ANY BENEFICIARY OR ASSIGNEE OF THE CONTRACT FOR ANY CONSEQUENTIAL, INCIDENTAL, INDIRECT, SPECIAL OR PUNITIVE DAMAGES ARISING OUT OF THIS CONTRACT OR ANY BREACH THEREOF, OR ANY DEFECT IN, OR FAILURE OF, OR MALFUNCTION OF THE EQUIPMENT, WHETHER OR NOT BASED UPON LOSS OF USE, LOSS PROFITS OR REVENUE, INTEREST, LOST GOODWILL, WORK STOPPAGE, IMPAIRMENT OF OTHER GOODS, LOSS BY REASON OF SHUTDOWN OR NON-OPERATION, INCREASED EXPENSES OF OPERATION, COST OF PURCHASE OF REPLACEMENT POWER, OR CLAIMS OF PURCHASER OR CUSTOMERS OF PURCHASER FOR SERVICE INTERRUPTION WHETHER OR NOT SUCH LOSS OR DAMAGE IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE.

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1-800 AIR SERV

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