22607402
Revision D
May 2015
Two-Stage Reciprocating Air Compressors
Models 2340, 2475, 2545, 7100, 15T & 3000
Owner’s Manual
EN
Owner’s Manual
ES
Manual del usuario
FR
Manuel de l’utilisateur
Save These Instructions
Contents
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WARRANTY & PRODUCT REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EXPLANATION OF SAFETY SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RECEIPT & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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.
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
These compressors may be used for a variety of compressed air
application up to 250 PSIG (17.5 kg/cm²). Application of these
compressors as either a primary or supplementary source of air is
virtually unlimited in industrial plants, service stations and auto repair
shops. Supplementary service includes such uses as furnishing air at
pressure not carried in regular shop lines, air at isolated locations, and
standby service for air when larger compressors are shut down.
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TWO-STAGE OPERATION
SELECTING A LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COMPRESSOR LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ELECTRIC DRAIN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGRAMS & TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Typical Two-Stage, TwoCylinder Unit
Typical Two-Stage, ThreeCylinder Unit
ELECTRICAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WARRANTY & PRODUCT REGISTRATION
Ingersoll Rand warrants the equipment 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 occurs first.
Compressors operated solely on All Season Select synthetic
compressor lubricant will have their bare compressor pump (ONLY THE
PUMP) warranted for the earlier of twenty-four (24) months from the
date of initial operation or thirty (30) months from date of shipment.
To register your product, you must contact your local full service air
solutions provider. To locate your nearest provider:
1. Go to ingersollrandproducts.com in your Web browser.
2. Select Americas Region from main page.
3. Click “Customer Service”.
4. Click “Contact Us”.
5. Click “Compressed Air Solutions”.
6. If you are located in the United States, enter your 5-digit zip code
in the field to find your local full service air solutions provider
and then press “Search on Zip Code”. If you are located outside
of the United States, select your country from the “International
Locations” list and then press “Submit”.
GENERAL INFORMATION
INTRODUCTION
This manual provides safe and reliable instructions for the installation,
operation and maintenance of your Ingersoll Rand air compressor.
Carefully read this manual before attempting to operate or perform
any maintenance. If you are uncertain about any of the instructions
or procedures provided in this manual, contact Ingersoll Rand. We
recommend you retain this manual, and all publications provided with
your air compressor, in a location which is accessible to all personnel
who operate and service your compressed air equipment.
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 firststage compression is removed. On the suction stroke of the secondstage piston this cooled air enters the second-stage cylinder through
the inlet valve. The compression stroke of the second-stage piston
compresses the air to the final discharge pressure and forces it out
through the discharge valve into the receiver tank or system. If cooling
of the discharge air is required, an air-cooled aftercooler should be
installed between the compressor discharge and the receiver tank
or system. 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.
22607402 Rev.D
Lifting Equipment and Straps
EXPLANATION OF SAFETY SIGNAL WORDS
DANGER
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury or
property damage.
NOTICE
Indicates information or a company
policy that relates directly or indirectly
to the safety of personnel or protection
of property.
RECEIPT & INSPECTION
Ensure adequate lifting equipment is available for unloading and
moving the compressor to the installation site.
WARNING
• Lifting equipment must be properly rated for the weight of the
compressor. Weight information is printed on a label attached to
the shipping container.
• Lift the compressor by the shipping skid only.
• Do not use the motor lifting eye to lift the entire compressor. The
motor lifting eye is for removing the motor from the compressor
only.
• Do not work on or walk under the compressor while it is
suspended.
Use suitable lifting equipment (i.e. forklift) to lift and transport the
compressor to the installation site. Ensure the lifting equipment,
straps, etc. are capable of supporting the weight of the compressor.
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 compressor (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 compressor was damaged in transit reverts back to the claimant.
Read the compressor 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.
Do not use a triple voltage three-phase motor for 200-208 voltage
three phase application. Use a 200 volt motor only.
22607402 Rev.D EN-
GENERAL SAFETY RULES
DANGER
INHALATION HAZARD. Will cause serious injury or death.
• Can contain carbon monoxide or other contaminants.
Ingersoll Rand air compressors are not designed, intended,
or approved for breathing air applications. Ingersoll Rand
does not approve specialized equipment for breathing air
application and assumes no responsibility or liability for
compressors used for breathing air services.
• Do not directly inhale compressed air.
• Follow precautions on container labels before spraying
materials such as paint, insecticide and weed killer.
• Wear a respirator when spraying.
WARNING
FLAMMABLE VAPORS. Can cause a fire or explosion and result in
serious injury or death.
• Do not operate electric motor driven compressors where
flammable or explosive liquids or vapors such as gasoline,
natural gas and solvents are present.
• Do not operate gasoline engine driven compressors near an
open flame.
HAZARDOUS VOLTAGE. Can cause serious injury or death.
• Disconnect power and relieve pressure from tank before
servicing.
• Compressor must be connected to properly grounded circuit
by a qualified electrician following applicable electrical
codes. Refer to the ELECTRICAL CONNECTIONS section of this
manual.
• Do not operate compressor in wet conditions. Store indoors.
MOVING PARTS. Can cause serious injury.
• Do not operate with guards or shields removed, damaged or
broken.
• Machine may start automatically. Disconnect power before
servicing.
• HOT SURFACES. Can cause serious injury. Burns may occur.
• Do not touch the compressor pump, motor or discharge
tubing during or shortly after operation. These parts become
hot. Allow to cool before touching.
HIGH PRESSURE AIR. Can cause serious injury.
• Do not remove, adjust, bypass, change, modify or make
substitutions for safety/relief valves or other pressure control
related devices.
• Rusted tanks can cause explosion and severe injury or death.
• Drain tank daily or after each use. Drain valve located at
bottom of tank.
• Do not over-pressurize the receiver tank or similar vessels
beyond design limits. Refer to compressor nameplate for this
information.
• Do not use a receiver tank or similar vessels that fail to meet
the design requirements of the compressor. Contact your
distributor for assistance.
• Do not drill into, weld or otherwise alter the receiver tank or
similar vessels.
• Do not use air tools or attachments without first determining
• Do not point air nozzles or sprayers toward anyone.
RISK OF BURSTING. Can cause serious injury.
• Use only suitable air handling parts acceptable for pressure
of not less than the maximum allowable working pressure
of the machine. Refer to compressor nameplate for this
information.
FLYING DEBRIS. Can cause serious injury to eyes.
• Wear eye protection at all times.
NOISE HAZARD. Can cause serious injury to ears.
• Wear ear protection at all times.
NOTICE
Do not remove, paint over or deface decals. Replace any missing
decals.
SELECTING A LOCATION
ELECTRIC MOTOR COMPRESSORS
For most electric motor compressors, 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 minute per 5 horsepower. Ventilation by gravity or mechanical
means is approved. Locate the compressor at least 12 inches (30 cm)
from walls, and make sure the main power supply is clearly identified
and accessible.
Unless the electrical components of the compressor are specially
protected for outdoor use, do not install an electric motor compressor
outdoors or in an area that will expose the electrical components to
rain, snow or sources of appreciable moisture.
WARNING
FOR COMPRESSORS EQUIPPED WITH ELECTRIC DRAIN VALVES
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 (45
cm) or more above the floor. To relocate the valve, contact your
local Ingersoll Rand dealer to obtain an electric drain valve
relocation kit.
GASOLINE ENGINE COMPRESSORS
For gasoline engine compressors, keep the engine at least 3 feet (1 m)
away from building walls and other equipment. Install the compressor
in a location with plenty of space for proper ventilation, cooling air
flow and accessibility. Do not install or operate a gasoline engine
compressor in a confined area.
AMBIENT TEMPERATURE CONSIDERATIONS
Ideal operating temperatures are between 32°F and 100°F (0°C and
37.8°C). If temperatures consistently drop below 32°F (0°C), install the
compressor in a heated area. If this is not possible, you must protect
safety/relief valves and drain valves from freezing. If temperatures
are consistently below 40°F (4.4°C), consider installing an external
crankcase heater kit, especially if the compressor has difficulty starting.
CAUTION
Never operate the compressor in temperatures below -15°F
(-26.1°C) or above 125°F (51.0°C).
the maximum pressure recommended for that equipment.
22607402 Rev.D
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
compressor 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.
NOTICE
It may be helpful to use a piece of tape on the drill bit to mark
the proper depth.
3)Drill a hole through the center of each isolation pad (if supplied
or mandated by local codes).
4)Drive the anchors into the mounting holes with the threaded
portion up.
5)Place the isolation pads over the anchors as shown in the
illustration below.
6)Position the compressor over the drilled holes and slowly lower
the compressor feet over the holes.
7)Install the foundation bolts.
NOISE CONSIDERATIONS
Consult local officials for information regarding acceptable noise levels
in your area. To reduce excessive noise, use vibration isolator pads or
intake silencers, relocate the compressor or construct total enclosures
or baffle walls.
8)Install the nuts and torque each in a criss-cross pattern to 10 ft. lb.
Typical Mounting
MOUNTING
WARNING
Remove the compressor from the skid before mounting.
Refer to the RECEIPT & INSPECTION section of this manual for
information on lifting and handling the compressor.
NOTICE
• Local codes may mandate specific mounting requirements
including, but not limited to, the use of vibration isolation
mounts or pads. Mounting kits including vibration isolation
mounts or pads may be ordered through your Ingersoll Rand
dealer if not included with the compressor. Consult your local
Ingersoll Rand dealer for more information.
• Secure the compressor to a solid, flat and level mounting
surface.
• If vibration isolation mounts or pads are included with your
compressor, they must be properly installed. Failure to install
the compressor using the vibration isolation mounts or pads
provided with the compressor and in accordance with the
installation instructions may result in mechanical failure to
the compressor and cancellation of warranty coverage.
• Do not install the compressor on I-beams, open-grid flooring
systems, or non-solid surfaces.
• Ingersoll Rand shall bear no responsibility for equipment
installed on non-approved vibration isolation mounts or pads
or non-solid surfaces.
CONCRETE FLOORS (ELECTRIC MOTOR OR GASOLINE
ENGINE POWERED COMPRESSORS)
A = Mounting surface
B = Foundation bolt / anchor
C = Isolation pad (if supplied or required by local codes)
D = Compressor mounting foot
E = Washer
F = Nut
After all mounting nuts are installed, check for receiver stress by
loosening each nut individually to check for upward movement
of the foot. Upward movement indicates the requirement for an
appropriately sized metal shim to fill in the open elevation under the
foot. After all required shims have been inserted, re-tighten the nuts
to 10 ft. lb.
Do not secure uneven feet tightly, as this will cause excessive stress on
the receiver tank.
NOTICE
Mounting hardware kit 46822243 is available for mounting 3footed vertical tank compressors to concrete floors.
To mount the compressor to a concrete surface, use the following
procedure:
1) Mark the location of the mounting holes.
2) Drill 2-1/4” deep holes using a concrete drill bit sized per the
following table.
22607402 Rev.D Tank Size
(Gal.)
Drill Bit
Size (In.)
≤ 120
1/2
≥ 240
5/8
EN-
TRUCK BEDS (GASOLINE ENGINE POWERED
COMPRESSORS ONLY)
Typical Remote Air Inlet Piping.
NOTICE
Mounting hardware kit 46821641 is available for mounting
gasoline engine compressors to truck beds .
Gasoline engine compressors mounted on truck beds must be
fastened securely without applying excessive stress on the receiver
tank. Follow the general instructions for concrete floor installation in
this section using appropriate mounting hardware.
Truck Bed Mounting
AIR DISCHARGE CONNECTIONS
WARNING
Do not use plastic pipe, soldered copper fittings, rubber hose,
or lead-tin soldered joints anywhere in the compressed air
system. All hoses, piping, fittings, air receiver tanks, etc. must
be certified safe for at least the maximum working pressure and
temperature of the compressor.
DO NOT USE PVC PLASTIC IN THE COMPRESSED AIR DISCHARGE
LINE.
CAUTION
A = Nut
B = Washer (3 per foot)
C = Mounting surface (truck bed)
D = Isolation mount
E = Spacer
F = Washer
G = Compressor mounting foot
H = Washer
J = Bolt
AIR INLET CONNECTIONS
CAUTION
Do not operate the compressor without air inlet filtration.
If the air around the compressor is relatively free of dirt, install the
air inlet filter(s) at the inlet connection(s) at the compressor. If the
air is dirty, pipe the filter(s) to a source of clean air. If remote air inlet
filtration is required, 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.
If you will be using synthetic compressor lubricant, all
downstream piping material and system components must be
compatible. Refer to the following material compatibility list.
If there are incompatible materials present in your system, or
if there are materials not included in the list, contact Ingersoll
Rand for recommendations.
SYNTHETIC COMPRESSOR LUBRICANT MATERIAL
COMPATIBILITY LIST
SUITABLE
FKM (Fluoroelastomer), PTFE, Epoxy (Glass Filled), Oil Resistant
Alkyd, Fluorosilicone, Fluorocarbon, Polysulfide, 2-Component
Urethane, Nylon, POM (Polyoxymethylene/Polyacetel), High
Nitrile Rubber (Buna N. NBR more than 36% Acrylonitrile),
Polyurethane, Polyethylene, Epichlorohydrin, Polyacrylate,
Melamine, Polypropylene, Baked Phenolics, Epoxy, Modified
Alkyds.
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
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.
22607402 Rev.D
NOTICE
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
• Use flexible piping at the compressor’s discharge connection.
• Use hard-welded or threaded steel or copper pipes and cast
iron fittings along the remaining air discharge line.
• Slope the piping downward in the direction of airflow to
permit condensate to drain properly.
• Use pipe thread sealant on all threads, and secure 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 safety/relief valve between the
compressor discharge and the restriction
ELECTRICAL CONNECTIONS
GROUNDING. In the event of an electrical short circuit, grounding
reduces the risk of electric shock by providing an escape wire for the
electric current. Ground terminals are identified with a ground symbol
and/or the letters “G”, “GR” or “PE” (Potential Earth).
Ground Symbol
Compressors equipped with motor starters include a ground terminal
inside the starter enclosure. For compressors with single-phase
motors having thermal overload protection and no motor starter, the
ground terminal is located inside the pressure switch. Ground must
be established with a grounding wire sized according to the voltage
and minimum branch circuit requirements printed on the compressor
specifications decal. Ensure good bare metal contact at all grounding
connection points, and ensure all connections are clean and tight.
WARNING
Improper grounding can result in electrical shock and can cause
severe injury or death. This product must be connected to a
grounded, metallic, permanent wiring system or an equipmentgrounding terminal or lead. All grounding must be performed by
a qualified electrician and comply with applicable electric codes.
NOTICE
Verify grounding connections after initial installation and
periodically thereafter to ensure good contact and continuity
has been maintained. Consult with a qualified electrician
or service technician if the grounding instructions are not
completely understood, or if in doubt as to whether the product
is properly grounded.
Starter wiring
PERMANENTLY CONNECTED ELECTRIC COMPRESSORS
WARNING
Electrical installation and service must be performed by a
qualified electrician who is familiar with all applicable electrical
codes.
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 applicable electric
codes in your area 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.
MAGNETIC STARTER. If the motor installed on your compressor has
a motor reset button, it does not require a magnetic starter. If the
motor does not have this button and the compressor 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.
A – To/from motor (factory connection)
B – To/from pressure switch (factory connection)
C – To/from power supply (customer connection)
Ground wires not shown for clarity. Equipment must be properly
grounded.
FUSES. Refer to applicable local codes 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.
22607402 Rev.D EN-
Pressure Switch Wiring (For Compressors Not Requiring a Starter)
4. Refer to the torque values listed on side of the contactor when
tightening the wire terminal screws.
5. The overload current setting formula is as follows:
Motor Nameplate Amps X Motor Service Factor = Overload
Setting
Example: 10.0 (Motor Amps) x 1.15 (Service Factor) = 11.50 Overload
Setting
GASOLINE ENGINE COMPRESSORS
NOTICE
If you will be making connections to a remote battery, the
engine on the compressor must be equipped with an alternator.
A – To/from motor (factory connection)
B – To/from power supply (customer connection)
Ground wires not shown for clarity. Equipment must be properly
grounded.
IEC POWER CONNECTION AND OVERLOAD
ADJUSTMENT
IEC Connection
BATTERY. A 12 volt battery with a minimum current rating of 275
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)
Maximum Length
6
5’ (1.5 m.)
4
7’-2.5” (2.1 m.)
2
12’ (3.6 m.)
CONNECTION PROCEDURES:
1) Connect the battery positive (+) cable (A) to the starter solenoid
terminal (B).
A = Incoming power leads
B = Existing control circuit wires
C = Contactor
D = Thermal overload
E = Stop/test button
F = Incoming grounding lug (see note 2)
G = Motor leads
H = Reset button & selector switch (set for manual reset)
J = Motor current setting (see note 5)
B
K = Switch position indicator
L = Coil voltage (see note 1)
M = Incoming power connection (see notes 3 & 4)
1. Confirm that the supply voltage matches the voltage rating of the
starter/contactor.
2. Connect the power supply to a properly grounded electrical
circuit with specified voltage and fuse protection.
3. When connecting the incoming power wires to the contactor,
ensure that the existing control circuit wires remain under the
terminal pressure plates and are secure after tightening the screw
terminals.
D
Kohler Engine Battery (+) Positive cable connection point
22607402 Rev.D
D
COMPRESSOR LUBRICATION
CAUTION
Do not operate without lubricant or with inadequate lubricant.
Ingersoll Rand is not responsible for compressor failure caused
by inadequate lubrication.
RECOMMENDED LUBRICANT
Ingersoll Rand recommends All Season Select® synthetic lubricant
from startup.
B
ALTERNATE LUBRICANTS.
You may use XL-300 or a comparable petroleum-based lubricant that
is premium quality, does not contain detergents, contains only antirust, anti-oxidation, and anti-foam agents as additives, has a flashpoint
of 440°F (227°C) or higher, and has an auto-ignition point of 650°F
(343°C) or higher
See the petroleum lubricant viscosity table below. The table is
intended as a general guide only. Heavy duty operating conditions
require heavier viscosities. Refer specific operating conditions to
Ingersoll Rand for recommendations.
Honda Engine Battery (+) Positive cable connection point.
NOTE: Circuit Fuse location at (D). Electric Start will not work if Fuse
is blown. Unit can be rope started, however will not charge battery
if Fuse is blown
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.
Temperature
Around
Compressor
Viscosity @
100°F (37.8°C)
Viscosity
Grade
°F
°C
SUS
Centi
stokes
ISO
SAE
< 40
< 4.4
150
32
32
10
40-80
4.4-26.7
500
110
100
30
80-125
26.7-51.0
750
165
150
40
If you use a petroleum-based compressor lubricant at start-up and
decide to convert to All Season 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.
Use one of the following methods illustrated to determine when the
crankcase is full.
3)Connect the battery positive (+) cable (A) to the battery positive
(+) terminal.
4)Connect the battery negative (-) cable (C) 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.
A = Oil fill opening, B = Sight glass, C = Dipstick
Refer to the following table for crankcase capacity.
22607402 Rev.D EN-
Model
Crankcase Capacity
2340
28 oz. (827 ml.)
2475
41 oz. (1212 ml.)
2545
73 oz. (2158 ml.)
7100
80 oz. (2365 ml.)
15T, 3000
144 oz. (4258 ml.)
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.
NOTICE
If the float is cocked in the low position, the unit cannot start
CAUTION
Unusual noise or vibration indicates a problem. Do not continue
to operate until you identify and correct the source of the
problem.
NOTICE
Ensure the direction of rotation is correct per the arrow on the
motor or on the beltguard above the motor. If the rotation is
incorrect on three phase compressors, disconnect the main
power and contact a qualified electrician to interchange any
two of the three leads per the ELECTRICAL CONNECTIONS
section of this manual.
COMPRESSOR CONTROLS (ELECTRIC MOTOR
COMPRESSORS)
AUTOMATIC START & STOP CONTROL.
NOTICE
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 preset maximum
pressure, the pressure switch stops the compressor. When the receiver
tank pressure drops below the factory preset minimum, the pressure
switch resets and restarts the compressor.
DUAL CONTROL. 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 compressor.
Auxillary Valve
Auxiliary
Valve
OPERATION
DAILY PRE-OPERATION CHECKS
MAINTENANCE / MANTENIMIENTO / ENTRETIEN
• Drain air tank daily.
• Drenar el tanque de aire una vez al dia.
• Purgez le réservoir d’air tous les jours.
• Check oil level weekly.
• Verificar el nivel de aceite una vez por semana.
• Contrôlez le niveau d'huile chaque semaine.
= ADD - AGREGAR - AJOUTER
= FULL - LLENO - PLEIN
• Clean air filter monthly.
• Verificar el estado del filtro de aire una ves por mes.
• Nettoyez le filtre à air chaque mois.
• Consult instruction manual for more detail.
• Ver el manual de instrucciones para mas detalles.
• Pour de plus amples informations, consulter le manuel
d’instruction.
56258809-01
• Drain condensate from air tank
• Check oil level(s) of compressor and engine (if applicable)
• Check cleanliness of air filter(s)
START-UP (ELECTRIC MOTOR DRIVEN COMPRESSORS)
1) Close the service valve.
2) 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 compressor is equipped with a
control panel “ON/OFF” switch, move the switch to the “ON”
position.
NOTICE
For dual control compressors, automatic start and stop is
preferred.
Select constant speed control if the compressor restarts in less than 10
minute intervals or runs more than 40 minutes per hour. Turn the knob
fully counterclockwise to run the compressor continually.
NOTICE
The auxiliary valve is factory preset 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.
3) Slowly open the service valve.
10
22607402 Rev.D
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.
NOTICE
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.
STANDARD PRESSURE SWITCH. The Standard NEMA-1 Pressure
Switch is Pre-set at the required pressures and the range and
differential settings ARE NOT adjustable. These Pressure Switches
should not be tampered with in any way and no attempt should be
made to adjust the pressure settings as this could damage the Switch
to the point of failure and/or void any warranty for the Pressure
Switches.
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.
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.
ADJUSTMENT PROCEDURES (ADJUSTABLE SWITCHES):
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.
NOTICE
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.
NOTICE
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.
22607402 Rev.D EN-11
Position of weight and thrust pin when unit is stopped.
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
Ounces of Oil Used
=
Horsepower Hours per
Ounce
To apply this formula, consider the size of the machine. In the
following example, a 5 horsepower compressor uses 2 ounces of oil
every 20 hours of operation.
5 Horsepower X 20 Hours of Operation
50 Horsepower
=
Hours per Ounce
2 Ounces of Oil Used
The compressor in the example passes the oil consumption test.
NOTICE
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.
New or rebuilt compressor pumps will discharge higher
than normal amounts of oil until the piston rings are seated
(approximately 100 operating hours).
START-UP (GASOLINE ENGINE COMPRESSORS)
WARNING
Do not operate gasoline engine compressors in an enclosed
area.
1) Release any residual 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.
Unloader
Unloader
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.
12
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.
NOTICE
Some gasoline engine driven compressors require 5-8 break-in
hours of operation before reaching full capacity and speed.
22607402 Rev.D
WHEN TRANSPORTING THE COMPRESSOR
- FOR GASOLINE ENGINE UNITS
Maintenance
CAUTION
•
When transporting the compressor, shut off the Engine and
turn the fuel shut off valve to the off position. See Figure below.
•
If the compressor is permanently mounted on a vehicle, shut
off the Engine and turn the fuel shut off valve to the off position
when the unit is not in use. See Figure below.
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.
Gasoline Shut Off Valve (Shown in off position)
Daily or Before
Each Operation
• 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.
COMPRESSOR CONTROLS (GASOLINE ENGINE
COMPRESSORS)
• Observe operation of safety/relief valves
CONSTANT SPEED CONTROL. This type of control applies to gasoline
engine compressors.
When the receiver tank pressure reaches the factory preset maximum
pressure, the unloader slows down the engine and the compressor
stops pumping. When the receiver tank pressure drops to the factory
preset minimum, the unloader resets, the engine returns to full speed,
and the compressor resumes pumping.
Weekly
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.
Monthly
• Check tightness of screws and bolts.
Tighten as needed.
• Inspect drive belts. Adjust if necessary.
• Clean exterior.
• Change petroleum lubricant while
3/500 *
crankcase is warm.
• Drain compressor oil and clean oil sight
glass
• Install maintenance pak
— or —
12/2000 *
• Change synthetic lubricant while
crankcase is
• warm.
• Replace filter element.
* indicates months/operating hours, whichever occurs first.
22607402 Rev.D EN-13
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.
1. Lay a straight edge across the top outer surface of the belt drive
from pulley to sheave.
OIL CHANGE
1. Remove the oil drain plug (A) and allow the lubricant to drain into a
suitable container.
2. Replace the oil drain plug.
3. Follow the filling procedures in OPERATION section.
BELT ADJUSTMENT
CHECKING BELT TENSION.
Check belt tension should be occasionally, especially if looseness
is suspected. New belts must also be properly tensioned upon
installation.
TENSIONING BELTS.
Belt tensioning can be achieved by loosening the motor or engine
anchor screws, pushing the motor or engine away from the pump,
and retightening the motor or engine anchor screws. Some units are
equipped with a belt tensioning bolt that, when turned, pulls the
motor or engine away from the pump. Otherwise, the motor can be
easily moved by placing a prying tool beneath it. A commercially
available spreader or other belt tensioning device can also be helpful.
2. At the center of the span, perpendicular to the belt, apply pressure
to the outer surface of the belt with a tension gauge. Force the belt to
the deflection indicated in the BELT TENSION TABLE in the DIAGRAMS
& TABLES section. Compare the reading on the tension gauge to the
table.
Follow the procedures outlined below to correctly set and measure
tension on 7.5 through 30 horsepower models 2545, 7100, 15T and
3000 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.
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.
ELECTRIC DRAIN MAINTENANCE
NOTICE
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.
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.
14
22607402 Rev.D
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 you
hear air escaping from the cleaning port, STOP IMMEDIATELY and
repeat steps 1 and 2.
4. Remove the stainless steel filter screen and clean it. Remove any
debris that may be in the strainer body before replacing the filter
screen.
5. Replace plug and tighten with wrench.
Strainer Ball Valve
6. When putting the EDV-2000 back into service, press the TEST button
to confirm proper function.
TANK INSPECTION
The life of an air receiver tank is dependent upon several factors
including, but not limited to, operating conditions, ambient
environments, and the level of maintenance. The exact effect of these
factors on tank life is difficult to predict; therefore, Ingersoll Rand
recommends that you schedule a certified tank inspection within the
first five years of compressor service. To arrange a tank inspection,
contact Ingersoll Rand.
If the tank has not been inspected within the first 10 years of
compressor service, the receiver must be taken out of service until it
has passed inspection. Tanks that fail to meet requirements must be
replaced.
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.
22607402 Rev.D EN-15
TROUBLESHOOTING
PROBLEM
CHECK POINT
Abnormal piston, ring or cylinder wear
4, 8, 9, 19, 28, 35
Air delivery drops off
1, 6, 15, 16, 18, 19, 29
Automatic drain valve leaks or does not drain automatically
16
Auxiliary valve chatters or leaks around stem
23, 24
Broken intercooler or aftercooler tubes
36
Compressor does not come up to speed
2, 6, 12, 15, 21
Compressor is slow to come up to speed
26, 27, 33, 34
Compressor runs excessively hot
3, 14, 15, 22
Compressor will not unload cycle
23, 24, 26
Compressor will not unload when stopped
26, 33
Excessive noise during operation
2, 6, 15, 16, 21, 27, 32
Excessive starting and stopping
5, 16, 32, 40
Knocks or rattles
2, 15, 17, 19, 20, 21
Lights flicker or dim when running
12, 13
Moisture in crankcase or “milky” appearance in petroleum lubricant or rusting in cylinders 9, 10
Motor overload trips or draws excessive current
5, 6, 12, 13, 14, 15, 16, 19, 20, 21, 34
Oil in discharge air (oil pumping)
4, 7, 9, 18, 19, 25, 35
Oil leaking from shaft seal
25
Safety/relief valve “pops”
1, 5, 29, 30
High interstage pressure
30
Low interstage pressure
31
Engine cranks slowly or will not start
6, 14, 37, 38
Motor will not start
12
Engine will not start
39
Oil Leaks
41
ELECTRIC DRAIN TROUBLESHOOTING
Trouble
Cause
Action
Valve will not close.
1. Debris in solenoid valve prevents
diaphragm from seating.
1. Remove solenoid valve, disassemble, clean and
reassemble.
2. Short in electrical component.
2. Check and replace power cord or timer as
needed.
1. No electrical supply.
1. Apply power.
2. Timer malfunction
2. Replace timer.
3. Clogged port.
3. Clean valve.
4. Solenoid valve malfunction.
4. Replace solenoid valve.
5. Clogged strainer.
5. Clean strainer.
Timer will not activate.
16
22607402 Rev.D
CHECK POSSIBLE CAUSE
POINT
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
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.
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.
21
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.
22
Wrong beltwheel direction of rotation.
23
24
25
Leaking, broken or worn inlet unloader parts.
Auxiliary valve dirty or seats worn.
Crankshaft seal worn or crankshaft scored.
26
27
28
Leaking or maladjusted centrifugal pilot valve.
Leaking check valve or check valve seat blown out.
Extremely dusty atmosphere.
29
30
31
32
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.
19
20
33
34
35
36
37
38
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.
22607402 Rev.D 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.
Check line voltage and upgrade lines as required. Contact electrician.
Install 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 threephase 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 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.
EN-17
CHECK POSSIBLE CAUSE
POINT
39
POSSIBLE SOLUTION
40
No fuel in tank.
Fuel valve closed.
Low oil pressure.
Excessive condensate in receiver tank.
41
Loose fittings/elbows/connectors
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
DIAGRAMS & TABLES
FASTENER TORQUE TABLE
2340
2475
2545
7100
15T
3000
High Pressure Head Bolts
75
75
75
75
75
75
Low Pressure Head Bolts
75
75
75
75
75
75
Cylinder Flange Bolts
30
50
50
50
50
50
Frame Cover Bolts
17
17
17
20
20
20
Shaft Cover Bolts
17
17
17
20
20
20
Crankpin Cap Screws
5.5
11
11
12-15
12--15
12-15
Unloader Cover Screws
-
-
11
11
20
11
High Pressure Inlet Valve Screws
11-15 LB-IN
11-15 LB-IN
11-15 LB-IN
5.5
-
5.5
Low Pressure Inlet Valve Screws
11-15 LB-IN
25-30 LB-IN
25-30 LB-IN
5.5
-
5.5
High Pressure Outlet Valve Screws
11-15 LB-IN
11-15 LB-IN
11-15 LB-IN
26
50
26
Low Pressure Outlet Valve Screws
25-30 LB-IN
25-30 LB-IN
25-30 LB-IN
26
90
26
Beltwheel Bolt
33
60
60
113
213
213
High Pressure Head Center Bolts
-
-
10
-
-
-
Low Pressure Head Center Bolts
-
-
14-16
-
-
-
NOTICE
Tighten all fasteners evenly using a cross pattern in two stages.
BELT TENSION TABLE
OTHER MODELS
MODEL
DEFLECTION (IN.)
TENSION (LB.)
2340 (14” Span)
0.25
4.9 -7.1
2340 (19” Span)
0.29
4.9 -7.1
2475 (14” Span)
0.25
4.9 -7.1
2475 (19” Span)
0.29
4.9 -7.1
2475F/X13GH
0.36
5.5 -8.0
2475F/X14G
0.36
5.5-8.0
2475N5 (14.5” Span, Cogged
belt)
0.23
4.5 -6.5
2545 (A Groove)
0.29
4.9 -7.1
18
BELT
TYPE
B
C
HORSEPOWER
TENSION AT 1/64”
DEFLECTION PER INCH
OF SPAN
7.5
7.0 -10.0
10-15
8.0 -12.0
20
12.0 -18.0
25-30
14.0 -21.0
22607402 Rev.D
ELECTRICAL WIRING DIAGRAMS
Single Phase Wiring
A
To supply
C
Wiring for optional electric drain valve
EDV
Electric drain valve
T
Supply Line Terminal
L
Load Terminal
FU
Control Circuit Fuse
HATS
High Air Temperature Switch (#)
LOLS
Low Oil Level Switch (#)
M
Motor Starter Coil
OL
Motor Starter Overload
PS
Pressure Switch
SS
Selector Switch (#)
*
Alternate wiring for converting 3 phase starter to 1 phase
application
(#) = if provided
Three Phase Wiring
NOTICE
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
22607402 Rev.D EN-19
Typical Baseplate Unit
Typical Horizontal Simplex Unit
20
22607402 Rev.D
Typical Vertical Simplex Unit
Typical Gasoline Engine Unit
Typical Duplex Unit
22607402 Rev.D EN-21
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 Select synthetic 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 MERCHANTABILITY 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 E UIPMENT 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 E UIPMENT 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 CONSE UENTIAL, 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 E UIPMENT, 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.
22
22607402 Rev.D
ingersollrandproducts.com
© 2015 Ingersoll-Rand
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