Compressor - Ingersoll-Rand Owner's Manual (15T)

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.
2
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 32F and 100F (OC and 37.8C). If
temperatures consistently drop below 32F (OC), 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 40F (4.4C), consider
installing an external crankcase heater kit, especially if the
compressor has difficulty starting.
& CAUTION Never operate the compressor in temperatures
below -15F (-26.1 C) or above 125F (51.0C).
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).
4
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 440F (22rC) or higher,
and has an auto-ignition point of 650F (343C) 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 @ 100F
Viscosity Grade
Compressor (37.SC)
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 100F
(37.7C).
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

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.
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.
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 excess lubricant.
Add lubricant to crankcase to proper level.
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
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
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

__ l) 'MOTOR
.--______ -----1
M
I 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
J
'PS *LOLS 'HA TS .
'-----D,
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

===::]J: 0
0 I
1L J

*ps *LOLS *HATS
*EDV
1

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

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
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
I-=- _ u-
11111- I
-I 11' 11,11
=F III L
16

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 =-
--
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

AIR
RECEIVER
,'" --,- "@,)
MANUAL CONDENSATE r;;j/
7
DRAIN
""1-1-'
---,_::[
-F::- F ::J::=-
1 "
.

-FF'II,,-' =
I-L'
- '"':;...:::'",<
, F
f

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 mainte-
nance and parts list information regarding the latest
design improvements on your Ingersoll-Rand air com-
pressor. 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. Depend-
ing on the air compressor purchased, the Low Oil Level
Switch is available as either standard or optional equip-
ment.
3. PRECEDENCE.
The maintenance procedures contained in Paragraph 6
supersede the corresponding data in the Instruction Man-
ual 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 com-
pressor 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, double-
throw 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 regu-
lar basis (Refer to the SCHEDULED MAINTENANCE
table in your Instruction Manual). Ingersoll-Rand Com-
pany cannot assume responsibility for any damage
which might occur as the result of operating the com-
pressor 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 re-
quires 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 re-
placed.
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 stand-
ard 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. (Re-
fer 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, sup-
ply 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
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
- 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 32F and lOOF (OC and 37.8C).
Crankcase heaters should be installed whenever the compressor is operated in ambients below 32F (OC).
- LUBRICATION
Please adhere to the following guidelines.
Consult factory for use of synthetic lubricants in ambients below 32F (OC).
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 32F (OC), 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

AIR COMPRESSORS
Supplement
Small Compressor Division Ingersoll-Rand Company Campbellsville, KY 42718
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
Reciprocating Compressor Division
Small Compressor Business Unit
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 build-
up 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 40F
(4.4C).
4). May be used reliably in operating temperatures that are
consistently below 30F (-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
30F (-1.1 QC). If your compressor has difficulty starting in
Printed in U.S.A.
temperatures below 30F (-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 auto-
ignition 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 premium-
quality, non-detergent lubricants containing only rust,
oxidation, and anti-foaming inhibitors. Substitute lubricants
must have a flashpoint of 440F (227C) or higher and an
auto-ignition point of 650F (343C) 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
30F (-1.1C), 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 Ingersoll-
Rand 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.
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 Ingersoll-
Rand 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.
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 265F
33 to 125F
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

__
CL

!j
w
n::.

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:
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.
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
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
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
30 2000E30-PS 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.
Questions? Parts? Service?
1-800 AIR SERV
Visit our website:
www.air.ingersoll-rand.com

Compressor - Ingersoll-Rand Owner's Manual (15T)

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Compressor - Ingersoll-Rand Owner's Manual (15T)

Uploaded by

Copyright:

Available Formats

Owner's Manual

You might also like

Compressor - Ingersoll-Rand Owner&#39;s Manual (15T)

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Compressor - Ingersoll-Rand Owner&#39;s Manual (15T)

Uploaded by

Copyright:

Available Formats

Owner's Manual

You might also like

Compressor - Ingersoll-Rand Owner's Manual (15T)

Compressor - Ingersoll-Rand Owner's Manual (15T)