Ingersoll-Rand 2000 Manuel utilisateur

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Manuel utilisateur

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Owner’s Manual
Installation, Operation and Maintenance
Instructions for Models 2000 & 2000P
Two-Stage Reciprocating Air Compressors
IMPORTANT INFORMATION! READ AND FOLLOW THESE INSTRUCTIONS. RETAIN FOR REFERENCE.
© Ingersoll-Rand Company
Printed in U.S.A.
C.C.N.: 22284475
Rev. : A
Date : February 2005
SAFETY
DEFINITIONS
a
DANGER WILL cause DEATH, SEVERE INJURY or
substantial property damage.
aWARNING CAN cause DEATH, SEVERE INJURY or
substantial property damage.
aCAUTION WILL or CAN cause MINOR INJURY or property
damage.
GENERAL SAFETY PRECAUTIONS
a
DANGER 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.
aWARNING 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.
Lockout/Tagout 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.
aCAUTION 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 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. An air-cooled
aftercooler, low oil level shutdown switch and automatic drain valve
are among the optional accessories that can be furnished. Bare
compressor pumps and baseplate-mounted units are also available.
These compressors may be used for a variety of compressed air
application up to 250 PSIG (17.5 kg/cm²). Application of these
compressors as either a primary or supplementary source of air is
virtually unlimited in industrial plants, service stations and auto repair
shops. Supplementary service includes such uses as furnishing air at
pressure not carried in regular shop lines, air at isolated locations, and
standby service for air when larger compressors are shut down.
TWO-STAGE OPERATION
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, an air-cooled aftercooler should be installed
between the compressor discharge and the receiver tank or system.
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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.
aCAUTION 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.
aCAUTION! 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.
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
aWARNING 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.
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.
aCAUTION Never operate the compressor in temperatures
below -15°F (-26.1°C) or above 104°F (40°C).
HUMID AREAS. In frequently humid areas, moisture may form in the
pump and produce sludge in the lubricant, causing running parts to
wear out prematurely. Excessive moisture is especially likely to occur if
the unit is located in an unheated area that is subject to large
temperature changes.
Two signs of excessive humidity are external condensation on the
pump when it cools down and a “milky” appearance in petroleum
lubricant.
You may be able to prevent moisture from forming in the pump by
increasing ventilation, operating for longer intervals or installing an
external crankcase heater kit.
NOISE CONSIDERATIONS. Consult local officials for information
regarding acceptable noise levels in your area. To reduce excessive
noise, use vibration isolator pads or intake silencers, relocate the unit or
construct total enclosures or baffle walls.
MOUNTING
aWARNING Remove the unit from the skid before mounting.
The compressor must be bolted to a firm, level, solid foundation (such
as a concrete floor) using the vibration isolation pads provided with
the compressor. Installation on I-beams, open-grid flooring systems, or
non-solid surfaces is not recommended.
Failure to install the unit using the pads provided with the unit and in
accordance with the installation instructions as outlined in the
operator's manual may result in mechanical failure to the compressor
and cancellation of package warranty coverage. Ingersoll-Rand shall
bear no responsibility for equipment installed on non-approved
vibration isolation mounts or non-solid surfaces.
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To mount the unit, 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.
Tank Size Drill Bit
(Gal.) Size
120 1/2"
240 5/8"
NOTE: 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.
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
unit to the isolation pads.
7. Bolt the compressor to the floor using the 4" long bolts provided.
Torque each bolt in a criss-cross pattern to 10 ft lb.
After the unit has been anchored into position, check the unit for level
by placing a level on the subbase and checking the readings from
side-to-side and from front-to-back. Use metal shims under the "short"
feet if necessary to obtain level.
A = Level concrete floor
B = Foundation bolt / anchor
C = Isolation pad
D = Compressor mounting foot
E = Washer
F = Nut
INSTALLING REMOTE AIR INLET PIPING
aCAUTION 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.
INSTALLING DISCHARGE PIPING
aWARNING Do not use plastic pipe, soldered copper
fittings, rubber hose, or lead-tin soldered
joints anywhere in the compressed air
system.
aCAUTION! If you will be using synthetic compressor
lubricant, all downstream piping material and
system components must be compatible. Refer to
the following material compatibility list. If there
are incompatible materials present in your
system, or if there are materials not included in
the list, contact Ingersoll-Rand for
recommendations.
SYNTHETIC COMPRESSOR LUBRICANT
MATERIAL COMPATIBILITY LIST
SUITABLE
Viton®, Teflon®, Epoxy (Glass Filled), Oil Resistant Alkyd, Fluorosilicone,
Fluorocarbon, Polysulfide, 2-Component Urethane, Nylon, Delrin®, Celcon®,
High Nitrile Rubber (Buna N. NBR more than 36% Acrylonitrile), Polyurethane,
Polyethylene, Epichlorohydrin, Polyacrylate, Melamine, Polypropylene, Baked
Phenolics, Epoxy, Modified Alkyds (® indicates trademark of DuPont
Corporation)
NOT RECOMMENDED
Neoprene, Natural Rubber, SBR Rubber, Acrylic Paint, Lacquer, Varnish,
Polystyrene, PVC, ABS, Polycarbonate, Cellulose Acetate, Low Nitrile Rubber
(Buna N. NBR less than 36% Acrylonitrile), EPDM, Ethylene Vinyl Acetate,
Latex, EPR, Acrylics, Phenoxy, Polysulfones, Styrene Acrylonitrile (San), Butyl
NOTE All compressed air systems generate
condensate which accumulates in any drain
point (e.g. tanks, filters, drip legs,
aftercoolers, dryers). This condensate
contains lubricating oil and/or substances
which may be regulated and must be
disposed of in accordance with local, state,
and federal laws and regulations.
GENERAL REQUIREMENTS. The piping, fittings, air receiver tank, etc.
must be certified safe for at least the maximum working pressure of
the unit. Use hard-welded or threaded steel or copper pipes and cast
iron fittings that are certified safe for the unit’s discharge pressure
and temperature. DO NOT USE PVC PLASTIC IN THE COMPRESSED AIR
DISCHARGE LINE. Use pipe thread sealant on all threads, and make up
joints tightly to prevent air leaks.
SUPPORT
SUPPORT
Direct to compressor
air intake (if distance
is less than 6 feet)
OUTSIDE
WALL
DRAIN VALVE
HOOD
ELBOW
BUSHINGS
HOSE
FITTING
TEE
PIPE
INTAKE HOSE
AIR INLET
FILTER
A
B
F
E
C
D
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A
B
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.
aWARNING If an aftercooler, check valve, block valve, or
any other restriction is added to the
compressor discharge, install a properly-
sized ASME approved safety/relief valve
between the compressor discharge and the
restriction.
INSTALLING ELECTRICAL WIRING (ELECTRIC MOTOR UNITS)
aWARNING 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 THREE
HP PHASE
200V 230V 460V 575V
20 3 4 8 10
25 1268
300168
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.
COMPRESSOR LUBRICATION
aCAUTION 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 Select
®
synthetic lubricant from start-up.
ALTERNATE LUBRICANTS. You may use XL-300 or a comparable
petroleum-based lubricant that is premium quality, does not contain
detergents, contains only anti-rust, anti-oxidation, and anti-foam
agents as additives, has a flashpoint of 440°F (227°C) or higher, and
has an auto-ignition point of 650°F (343°C) or higher.
See the petroleum lubricant viscosity table below. The table is intended
as a general guide only. Heavy duty operating conditions require
heavier viscosities. Refer specific operating conditions to
Ingersoll-Rand for recommendations.
Temperature Around Viscosity @ 100°F Viscosity Grade
Compressor (37.8°C)
°F °C SUS Centistokes 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
* = For Models 2000 and 2000P, use Ingersoll-Rand XL-740HT
Compressor Oil in temperatures above 100°F (37.7°C).
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.
aCAUTION Do not remove the oil fill plug while the
compressor is running.
Refer to the following table for crankcase capacity.
Model Crankcase Capacity
2000, 2000P 176 oz. (5205 ml.)
Use one of the following methods illustrated to determine when the
crankcase is full.
A = FULL level
B = ADD level
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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 MODLES)
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
4. Slowly open the service valve.
Typical Service Valve (A = Open, B = Closed)
aCAUTION Unusual noise or vibration indicates a
problem. Do not continue to operate until you
identify and correct the source of the
problem.
NOTE Ensure the direction of rotation is correct per
the arrow on the motor. If the rotation is
incorrect on three-phase units, interchange
any two of the three leads.
COMPRESSOR CONTROLS
ADJUSTMENT PROCEDURE. 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.
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.
NOTE The auxiliary valve is factory pre-set at 5 PSIG
lower than the factory pressure switch
setting.
NOTE Automatic Start & Stop Control is intended for
use when the motor will start no more than 6
times per hour.
aCAUTION 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.
A
uxiliary Valve.
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PRESSURE SWITCH ADJUSTMENT
aWARNING 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.
aCAUTION 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.
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
ADJUSTMENT CONTROL):
1. Remove the pressure switch cover.
2. Set the cut-in pressure with the range adjustment nut. Turn the nut
clockwise (in) to increase the pressure or counter-clockwise (out) to
decrease the pressure.
NOTE: One full turn changes the setting
approximately 2 PSIG.
3. Set the cut-out pressure with the differential adjustment. Turn the
differential adjustment nut clockwise (in) to increase the pressure
or counter-clockwise (out) to decrease the pressure.
NOTE: One full turn changes the setting
approximately 2 PSIG.
4. Replace the cover, reconnect the power supply and start the unit.
5. Note the pressure gauge reading at which the unit cuts out.
6. Repeat the adjustment procedure if necessary.
The minimum possible differential is approximately 20% of cutout
pressure. It is advisable to have as wide a differential as possible to
avoid frequent starting and stopping of the unit. Note the pressure
gauge reading at which the unit cuts-out and re-establish this point if
necessary.
Note the interaction between the range and differential adjustments,
i.e., if the cut-out is increased, the differential will also increase, or if the
differential is narrowed, the cut-out will be reduced, etc. These factors
must be considered when adjusting the switch and compensated for
accordingly.
ELECTRIC DRAIN 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 1/4" 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.
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.
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.
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STARTING UNLOADING SYSTEM (MODEL 2000)
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 (2000P)
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.
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.
A = Oil Pump
B = Oil Filter
C = Oil Pressure Gauge
D = Oil Pressure Switch
E = Hydraulic Unloader Valve
F = Head Unloaders
G = Shuttle Valve
H = Auxiliary Valve
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MAINTENANCE SCHEDULE
Check for oil leaks.
Daily or Before
Check lubricant level. Fill as needed.
Each
Drain receiver tank condensate (if automatic
Operation draining device is not provided). Open manual
drain valve and collect and dispose of
condensate accordingly.
Test drain valve for proper operation.
Clean filter screen if needed.
Check for unusual noise and vibration.
Ensure beltguards and covers are securely in
place.
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.
Weekly
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.
Monthly
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.
Clean drain valve filter screen.
3/500 *
Change petroleum lubricant while crankcase
is warm.
Drain compressor oil and clean oil sight glass
6/1000 *
Replace oil filter and change lubricant (if
necessary) on pressure lubricated modles.
12/2000 *
Change synthetic lubricant while crankcase
is warm.
Replace filter element
* indicates months/operating hours, whichever occurs first.
FILTER INSPECTION & CLEANING
1. Loosen the clamps securing the filter housing to its base.
2. Remove the filter housing and withdraw the old filter element.
Clean the element with a jet of air or vacuum.
3. Replace the filter element and housing.
OIL CHANGE
1. Remove the oil drain plug and allow the lubricant to drain into a
suitable container.
2. Replace the oil drain plug.
3. Follow the filling procedures in INSTALLATION section.
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
Ounces of Oil Used per Ounce
To apply this formula, consider the size of the machine. In the following
example, a 5 horsepower compressor uses 2 ounces of oil every
20 hours of operation.
5 Horsepower X 20 Hours of = 50 Horsepower
Operation Hours per Ounce
2 Ounces of Oil Used
The compressor in the example passes the oil consumption test.
NOTE New or rebuilt compressor pumps will
discharge higher than normal amounts of oil
until the piston rings are seated
(approximately 100 operating hours).
MAINTENANCE
aWARNING 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 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.
NOTE 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.
NOTE Any service operations not explained in this
manual should be performed by an authorized
service representative.
NOTE The following maintenance schedule has been
developed for typical applications.
Maintenance intervals should be shortened in
harsher environments.
81295669
81295651
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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
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.
aCAUTION! 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.
aWARNING 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.
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 anchor screws, pushing the motor away from the pump, and
retightening the motor anchor screws. Some units are equipped with a
belt tensioning bolt that, when turned, pulls the motor 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
tension.
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.
aCAUTION Improper pulley/sheave alignment and belt
tension can result in motor overload,
excessive vibration, and premature belt and/or
bearing failure.
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TROUBLESHOOTING
COMPRESSOR (see causes and solutions on next page)
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, 11, 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 9, 10
or rusting in cylinders
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
Motor will not start 12
Oil Leaks 41
Low Oil Pressure 42, 43, 44, 46
Excessive oil pressure fluctuations (> 5 psi) 42, 43, 44, 45, 46
ELECTRIC DRAIN TROUBLESHOOTING
Trouble Cause Action
Valve will not close. 1. Debris in solenoid 1. Remove solenoid valve,
valve prevents disassemble, clean and
diaphragm from seating. reassemble.
2. Short in electrical 2. Check and replace power
component. 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.
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CHECK POSSIBLE CAUSE POSSIBLE SOLUTION
POINT
1 Clogged or dirty inlet and/or discharge line filter. Clean or replace.
2 Loose beltwheel or motor pulley, excessive end play in motor Check beltwheel, motor pulley, crankshaft, drive belt tension and
shaft or loose drive belts. alignment. Repair or replace as required.
3 Inadequate ventilation around beltwheel. Relocate compressor for better air flow.
4 Lubricant viscosity too low. Drain existing lubricant and refill with proper lubricant.
5 Air leaks in air discharge piping. Check tubing and connections. Tighten joints or replace as required.
6 Lubricant viscosity too high. Drain existing lubricant and refill with proper lubricant.
7 Lubricant level too high. Drain excess lubricant.
8 Lubricant level too low. Add lubricant to crankcase to proper level.
9 Detergent type lubricant being used. Drain existing lubricant and refill with proper lubricant.
10 Extremely light duty cycles. Run compressor for longer duty cycles.
Compressor located in damp or humid location. Relocate compressor or install crankcase heater kit.
11 Pressure switch differential too narrow. Adjust pressure switch to increase differential, if differential adjustment
provided. Install pressure switch with differential adjustment feature if
differential adjustment is desired.
12 Improper line voltage. Check line voltage and upgrade lines as required. Contact electrician.
Wiring or electric service panel too small. Install properly sized wire or service box. Contact electrician.
Poor contact on motor terminals or starter connections. Ensure good contact on motor terminals or starter connections.
Improper starter overload heaters. Install proper starter overload heaters. Contact electrician.
13 Poor power regulation (unbalanced line). Contact power company.
14 Drive belts too tight or misaligned. Adjust belts to proper tension and alignment.
15 Compressor valves leaky, broken, carbonized or loose. Inspect valves. Clean or replace as required. Install Valve/Gasket Step
Saver Kit.
16 Automatic drain valve clogged, leaking or defective. Inspect valve and clean, repair or replace as required.
17 Carbon build-up on top of piston(s). Clean piston(s). Repair or replace as required.
18 Piston rings damaged or worn (broken, rough or scratched). Install Ring/Gasket Step Saver Kit.
Excessive end gap or side clearance.
Piston rings not seated, are stuck in grooves or end gaps not Adjust piston rings.
staggered.
19 Cylinder(s) or piston(s) scratched, worn or scored. Repair or replace as required.
20 Connecting rod, piston pin or bearings worn or scored. Inspect all. Repair or replace as required. Install Bearing/Connecting Rod
Loose bearing spacer on crankshaft. Step Saver Kit.
21 Defective ball bearings on crankshaft or motor shaft. Inspect bearings and replace if required. Install Bearing/Connecting Rod
Step Saver Kit.
22 Wrong beltwheel direction of rotation. Check motor wiring for proper connections. Reverse two leads on
three-phase motors.
23 Leaking, broken or worn inlet unloader parts. Inspect parts and replace as required.
24 Auxiliary valve dirty or seats worn. Inspect parts. Clean, adjust or replace as required.
25 Crankshaft seal worn or crankshaft scored. Replace seal. Install shaft sleeve if required. Install Bearing/Connecting
Rod Step Saver Kit.
26 Leaking or maladjusted centrifugal pilot valve. Replace pilot valve o-ring. Adjust pilot valve.
27 Leaking check valve or check valve seat blown out. Replace check valve.
28 Extremely dusty atmosphere. Install remote air inlet piping and route to source of cleaner air.
Install more effective filtration.
29 Defective safety/relief valve. Replace.
30 High pressure inlet valve leaking. Inspect, clean or repair as required.
31 Low pressure discharge valve leaking. Inspect, clean or repair as required.
32 Automatic start and stop mode is not suitable for air demand. Adjust auxiliary valve for constant speed operation
33 Pressure switch unloader leaks or does not work. Realign stem or replace.
34 Ambient temperature too low. Install crankcase heater kit. Convert to All-Season Select
®
lubricant.
Relocate compressor to warmer environment.
35 Worn cylinder finish. Deglaze cylinder with 180 grit flex-hone.
36 Beltwheel out of balance, tubes not braced or secured, Check vibration level, change pulley or beltwheel if required, tighten
wrong pulley speed. tube clamps.
37 Excessive condensate in receiver tank. Drain receiver tank with manual drain valve or install automatic
drain valve.
38 Loose fittings/elbows/connectors Re-torque fittings per specified torque requirements
39 Maladjusted or defective oil pressure regulator valve Adjust valve to proper setting
Replace regulator valve
40 Maladjusted or defective hydraulic unloader valve Replace hydraulic unloader valve assembly
41 Defective oil pressure gauge Replace gauge
42 Oil foaming in crankcase Drain existing lubricant, thoroughly clean crankcase, replace lubricant
43 Debris or other obstruction blocking oil flow Inspect/clean all oil passages
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DIAGRAMS & TABLES
FASTENER TORQUE TABLE
High Pressure Head Bolts 120
Low Pressure Head Bolts 120
Cylinder Flange Bolts 50
Frame Cover Bolts 20
Shaft Cover Bolts 50
Crankpin Cap Screws
Unloader Cover Screws
High Pressure Inlet Valve Screws 36 LB-IN
Low Pressure Inlet Valve Screws 36 LB-IN
High Pressure Outlet Valve Screws 36 LB-IN
Low Pressure Outlet Valve Screws 36 LB-IN
Beltwheel Bolt 80
High Pressure Head Center Bolts
Low Pressure Head Center Bolts
Unloader Guide Mounting Screw 25
Low Oil Level Switch Baffle Screw 5
Head Center Acorn Nuts 7
Pilot Valve 25
Unloader Body Assembly 25
Bearing/Unloader Housing Bolts 25
Valve Plate Studs 7
NOTE Tighten all fasteners evenly using a cross pattern in two stages.
NOTE All values given are in LB-FT unless otherwise specified.
BELT TENSION TABLE
BELT HORSEPOWER TENSION AT 1/64” DEFLECTION
TYPE PER INCH OF SPAN
5V 25-30 14.0 - 21.0
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ELECTRICAL WIRING DIAGRAMS
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
NOTE Connect line power to the starter. Do not connect line power to the
pressure switch.
Connect ground wire to ground lug
Starter
To Power Supply
SS
SS
S
SS
SS
S
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Model 2000 Bare Unit
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15
Model 2000P Bare Unit
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16
Model 2000 Baseplate Unit
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Model 2000P Baseplate Unit
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Model 2000 120 Gal. Simplex Unit
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19
Model 2000P 120 Gal. Simplex Unit
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20
Model 2000 240 Gal. Simplex Unit
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Ingersoll-Rand 2000 Manuel utilisateur

Catégorie
Compresseurs d'air
Taper
Manuel utilisateur
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