son cen OPERATORS eee seats MANUAL & available toll personnel wh operate andor maintain this product Carey read thie manal before attempting to PARTS LIST operate or perform maintenance on this compressor. CL eee MODELS 231/7T2/15T2 HIGH PRESSURE AIR COMPRESSORS (OF) Ingersoll Rand AIR SOLUTIONS REFER ALL COMMUNICATIONS TO THE NEAREST Form NSCD - 453-6 INGERSOLL-RAND SALES OFFICE OR YOUR DISTRIBUTOR OR 2000 July 2005 E-MAIL AT airsolutionsindia @irco.co Supersedes FORM : NSCD-453-AA\WARNING STATENENT CONCERNING THE USE OF THIS EGUIPHENT FOR BREATHING AIR ANDIOR AQUA LUNG SERVICE. tthe mad umber on a compressor contains the listers “BAP* the alrcampeasscr Is mutable fr brenthing sr services. Campressor that OO NGT bear this daaignaton are NOT expabla of producing ai of broatlung quay, For use in brosthing ait agploations an air compracsor must be fitadl wth acitional spicialized equiemart to propady liter andlor party tha av to meet ait applicable ‘ecaral, sista and local laws, rules regulates and codes, Should the Purevaser andr User fal to add suah spoeslzed equprnent, and procood to use te ai compressor for breathing sr cevien, thy PuichaearUor azeumee a Haallly recuting thar trom witrout any responsiblity olny being assumed by IngersolRand (inca) Li. The purchaser is urged to include he above provisions in any agreement for any resale ofthis compressor, Tneardous vapors. Can cause severe Rauses, alning ar daaih, ‘Compressed alr oF g2s ftom this compressor may contain polsonous vapors or gases. Certain sprayed material such as paints, insecticides, weed hile, sand, ete, may be harmful if inhaled or used in closed area Maver crectly aie the compressed alt of gas prociced by his corrpresvor ‘Always road contain: lables when spraying paints or pisons, Always use the compressor ina wallventited area Use a respirator or mask whenever thar Is a chance that you righ iniale any sprayed! atrial ask su al sruions pronded wit Ne mask to ensure it wit protect you irom the materials you ore spraying Warardous voltage. Can cause severe injury or death. Away dscoaneet the power euprly ear bolore parorming any msintonaace oF repel woe Always connect the pawer supply cord to @ giouded electicaleivult wi the speded vatage and fuse protscion, Nevar use the comrpreeear in ran, na wat arsa, or naar an explosive environment, Flammable vapors, Can cause a fre or explosion, and result In sovere Injury or death parka rom the motors olecical contacts ean grit famnable vapors from gabotne, natu! gao or elvents. Do not eperate the compressor in any areas where explosive oF fiammable vapors or quis may exist. Never smoke or use open fame in the vicinity ol tho compressor or any ges tte or sour. i opened aga hs ete Oorpresstang the bel, or cs, or sng a recevrwich snot mes tain Sn fortis Sere 2a ie ns ng cee Ss oan Snes ey cco Conan ws tert gre peterpan ene pee ann aoe Train ne boty rs rece i ene weaken a enone i pie ee, nd oan ser bay reac freee beyond enon Int aco th beter oer oor or ttde and reat i coer srercate ape ob A NS a pL TU non To Te tan rca gape hal vv get nial eer rsa DO NOT REMOVE TEST Seas Seer UTNE EON ne HELE VALE soto ste pons tae wom Srses hey. eval oe Coe stereo, be md Neve ied or are otk wear ry mae Oyo wenden toma a ese ror Presse ath nutter horton. etc ng tata ‘ie bg War atreupt na acne mee OrOWPaOE We PRESSURE SMe Cite Ch NOD ‘Si Prtetine oontwo. related GEN seri in yh te rca can ni BN si eel RH midatnel acai Camprestd ab Cm pope ean pel ania A a ay ew part an area ta mya orl ey pr dy oar oe Bats ter econ games oe ra Moving parts. Gan cause severe injury. Always disconnect the power supply before attempting to perform any maintenance or repair work. ‘Always ensure the presse is rleased trom tne compressor. betes, tanks, receiver and ar attachments batcre perform tng any mainisnance oF repab Work ‘Aways dlecanneet the power cupply on alctic motor modal it the compressa is tobe lft unattended Naor epertecereneaser wih olan etd yomevad, or be sick ie drag ey bok Hot parts. Compressors gel hot whit severe burns i touched! Never touch the encrprescor, materingine. oF lube duirg or shomy alt coryprestor operation,SECTION CONTENTS Holor Lebneation 8 Cave Air iclst Fiter’Silence! GENERAL DESCRIPTION 46 Airooles Intercne Application 8 Satsty Vales Internitent Duty Forma, 6 Starting Unloading Systerm Interosolor Pressure Ghac SECTION Aie-Ceoled Atercaalor Pilot Vave Adjuster? INSTALLATION AND START-UP Greuther Tobe HECOMMERLATION m0 Oil Gonsuripton Gireck Location and! Foundation 2 Inlet Papen, 7 SECTIONY Baseplale-Haunied Cornpressen 7 Low GL oval Saitoh 8 TROUBLE GUIDE Magnete Starter 8 Fleciscat waving 8 SECTIONYE Fuses a Dischage Piping 9 MAINTFAANC? 8 Comprelste Warranty Registration 10 Routine Inspection And Serace seerion in REGULATION Automatic Start and stop Contra. Pressure Sunich Adjustment Constant Speed Corgral Dual Goria Intermittent Duty Fares OPERATION Orerating Checks Cornpressor -ubsica‘ion Framo © General Bir Valve Ceaning Bel fasialiaion end Aclustment Torque values Fision Ring Replacement SECTION VII OPTIONAL EQUIPMENTS AND ADCESSONIES, Ghack Yeive SEcTIONIY ‘Water Cooled Afercooiar High Pressivo Air Reveiver 1216 2 SECTION VII 2 hange 12 TYPICAL WERING DIAGHAMS 12 Lubricating Oil Recommendation A WARNING UNDERTAKING AS TO SAFETY We have ensured thal our oquipmont ie safe ane without riak to the health Of the workers when properly used In accordance with the information and advice relating to its use contained in the instruction Book/Operator’s Manual. it will be, therefore, af utmost importance that you use our ‘equipment only after going through the Book/Manual thoroughly, which frag, inter alis, cetalled inetructions, information and advice for the safety Of operators and workers in your feclory, The equipment is suid and supplied to you on the basis of your express undertaking that you will take the steps spocificd in tho Book/Manual in ordor to oncure that tho equipment sold and supplied by us will be sale and without risk to the health of your workers when properly used. 2 1% B 18 1 16 16 16 18 2° 8 19 ‘0 20 20 21 2a 2s 23 2 >aSECTION [ : GENERAL DESCRIPTION _/— DISCHARGE SAFETY VALYE FIRGT STAGE AIR HEAD, SECOND STAGE AIR HEAD INLET FILTER/SILENCER ——— COMPAESSOR DISCHARGE —3t imiwovep@erueane Ceig TWGTALL OPTIONAL ly y-— eaLrieet an DIDeHARGE CHECK VALVE) ie i pram tes ——e a Manuuae onan VALVE ——25 2 0°25 inmencooies sarery valve AFTERCOOLER _/ INTERCOOLER, Figure 1.1 Model 231 Two-stage. two cylinder high-pressure air compressor. FIRgT STAGE PRESBURE GAUGE AFTERCOOLER INTERCOOLER SAFETY VALVE AFTERCOOLER ‘SAFETY VALVE SECOND s1AGE ‘AIR MEAD FARST STAGE AIR HEAD COMPRESGOR DISCHARGE {REMOVE PIPE PLUG AND. INSTALL OPTIONAL DISCHARGE GHEGK VALE) DRAIN LEG INLET FILTERSILENCER, (MANUAL DRAIN VALVE. PLOT VALVE \ Sichtenenice (1 DRAIN PLUG. Figuro 1.2 Modal 7T2 Two-stago, two cylinder high-pressure air compressor.GENERAL DESCRIPTION FIROT STAGE PPESSURE GAUGE AFTERCOOLEN ‘SECOND STAGE PRESSURE GAUGE SECOND STAGE AM MEAD AFTERGOOLER SAFETY VALVE “o SECOND STAGE SAFETY VALVE FIRST STAGE SAFETY VALVE RIRHERD TY tO RGR ee” gc, ee — ART STAGE AIR MEAD . SO : (OPTIONAL) INLET 386 SOLENOID YALE ‘COMPRESSOR DISCHARGE CHECK VALVE DRAIN LEG HS 5 INLET FILTER/SILENCER (OPTIONAL SOLENOIO VALVE. FOR TIMED AUTOMATIC ‘CONDENSATE DRAIN PILOT VALVE AUTOMATIC DRAIN VALVE, SK ol FILLER GALIGE (OPTIONAL) LOW OIL LEVEL wre” SN OlL DRAIN PLUG Figure 1.9 Model 1572 Two-stage, threo cylinder high-pressure air compressor.APPLICATION Inge:so.iftand’s Models 28% and 712 conareesors snc intendad to sunny ai for annieatirs requiting air areseure Irom 300 PSIG (24.2 gle” to 500 PIO 95:2 sgien Model 1572 is intended to supply ae pressiire from 300 PSIG 1211 kgleer’) to 1900 PSI (70.3 kg'ent The actual ax delivery cavers a range from 4.6 GFA 135 oFinn) we 31.9 GFN (B86 MmINy The Models 231 and 772 aim compact 2-siage re eiprocating compressors designed with properly propor tioned compression ratios and sflicieat iraeicoolets 10 provide a dependable source of high pressure ar The basic orinciple of operation ¢ 5 follows: on the suclian stvoko of tho iirat stage piston. arr at atmo. spheric pressure enters tae fist stage oylinger whrough the infet fier and inlet valve. The compression stroke: cempeesses this air to an iniermeciale prassure and. Ascharges it through the discha'ge valve we the inter= cooler tubing where ihe heat af tzst-stege comprension is removed by the action of tne beliwheel fan passing ‘on01 alr over the intereoalers finned tubes The suction stoke of the second-stage: piston now cleawe the caolod air thraugh the seconel-siage inlet valve and into the second-stage oylinver whard it is come pressed to a sill higher pressure. On the compression stioke of the second stage. the air is compressed to 5, final pressure and loreed oUt through the air cooled atiercooier and condensate sepaator inte thr extemal system, The Model 1872 is a compact 3-stale raciprocating compresser dasignoc with propasty proportioned con pression ratios and efficiant intercoolers 10 provide a dependable source at ngi pressure alr The basic princiole of operation is as follows em the suction stroke of the first-stage piston aie at almonpherio, pressure enters the First stage eylnde: trough the 2h Jet filter ancé niet valve. The compressicn stioke com- presses this air to an intermediate pressure and dis- charges it through the discharge value inio the inter eooior tubing where the hoat of fet-stage compression ‘s removed Ly tne action ef the belts:heel fan passing 00! air avor the intecccolers linn tues, ‘The suction stroke af the second-stage piston now draws tho cecled airthraugh the zecond sage: inlet welv> and into the second-stage cylinder whore 4 is cf pressed to a sill higher pressure, On the compression sticke the air is forced into the third-stage steeple cy inder through the secord.stage intercoalar eandancata ap and thitd-stage inlet valve, On the compression slioke of the third-stage steeple piston. the ait 1s com= pressed lo its final pressure and forced aut through th sircooled aftercocter and condensate separator rio tha external air system The finned tube intercodlers and atiersoo.er serve io sissipaie hea fren the compossed air. this con. dening Goriained maisictr. This conelenaaca 1s then separated and collected in suilabyy designed tags. ‘esiorsars ecuppad witha complcic stent- ing urtoacing system. This automabicely relievas mies: eylincers ontercaclers and the sttereno.e¢ emprogacr stop INTERMITTENT DUTY FORMULA, Models opciatng avove 209 psig (14 kgieny am) ave to be opmiarse! accorkng to the "hifermitters Duty For mula’ INTERMITTENT DUTY FORMULA Pump-up time should net orclinarily exeeccd 'y (30) minutes or be less than ten (10) minutes, Shut-lown periods betwecn cycles of operation strould be ai least equal to ihe pump- up time. Note: When tho compressor is rogu- laied by constant speed contial, the shutdown Period is she time the campressor Is operating unleaded, 4. Tho tovnular is net I fast rule. rogerded an a haed and 2. A mavimum operating time limit with # following Cool ciamn nerad Is nacesxary to ovatest tho valvaw and aw heade against atabilzed high ap: eming temperalues, which could alow raps valve cavuerization 3. Aminimum operating time limit is raquitee ta pre. vent formuiation af condeneate which will cause rusting of cyinders valves and frame parts. As ‘cumulaton of coridensate in the frame could sive a false roading of oil leval. Water ans oll do net mix ae their presence together eausa vant brunkcown of the ail. The minimum time ef op eration shaule be fang enough 4 avew ine com presso: Io warm up sulliciently te evaporate condensated meisture 4, Wien machine opecation in tow shomt for tempece ture fo reach te noma) level, 2 temperature contro. crankease heater may be required. This is particularly te for areas of nigh humidity, sich as slang seacoaste, All opeiaiig i:swuclions should be tag tho oughly id followed carelully by anyone oper ing these machines to give most efficient opera. tien and longest possible machine lite All inguites for highroressure compressa’ apptica ‘uch where the “use cyele aiffers fram the Intermittant Duty Fo:mula” shocld ba relared to the nearest Inger solland braruh offiea(SECTION Il : INSTALLATION AND START-UP RECOMMENDATIONS) step 1. Unload the cempressor rom delivering vahicle - the urchasoe must arranga for adequata liftng oquipmant at the job site WPORTANT NOTE : The purchase assumes tifa to the compresser equipment at the manufacturers nipping dock immediately upon recoup of the equipmers i] snould ve inspected for any ueniage that ay have occu ed during shipment if damage is present, damand an inspectan immechataly by an inspector fram the cersor, Ask him how to fila a clas tor damages. step 2, Check compressor namepialé to De suufe [NS unit is the mocal and size ordored. Do thie before uncrating Check receiver nameplaic to be sure the tank is adequate for pressure at which you intend te operate. Step 3. Gheck motor nameplate 10 be Sure molD: Is Sullabie fer your elec write bravectzos | est bauer FILeR/SIGEMEE hen poe catioor a) wer FILenss uence TBeanaeed orrengenest) Figure 2-1. NOTE I contionss (Vools-Prase-Heit2) Typical Alternate Inlet Piping Arrangerrent Stop 4 . - Step 5 LOCATION & FOUNDATION. mer Pena Ideal ambient temperature 1s 70°F (21°C) Ifthe aan te vicinity of the compressor Is unduly In cald climates it ig desirable to instal the compressor witin a heated puilging. Cheose a clean “eletively cool Incation and provide ample space around the unit for cooling anc general accessibilty. Place the Deltwheal sido toward the wal Ioaviag ai least 15" 380 myn} lor air groulatan to the Letieel fan. The lovation 10ul also be near a Source of water alu drain Tine to simplify piping connections it a watercooled aitercosler is ty bo used, NOTE : if a delached recener ve to be used, consider placing the racaiver outdoors to provide more effactive heat dissipation, keepang in mind that condansed water én the receiver ray treeze. A woll ventisted locator! shuld be selectad lor this raghing when operating in very damp climatos oF under conditions 0! hgh humidity. Theses almasoheris cordiuns are conducive {9 the formation of water in the crankcase and f adequate aparation and vartilation 2F@ ROL provided, rusting, ail shidging and rapid wear of turning pars will zeault, This 9 partioulely tur whan aperating on very inteamijten duty application Provide adequate tresh air and exhaust ventilation from area in which the compressor is located. Provide 3,000 cu. ft. fresh air per minute per 5 horsepowsr Ventilation by gravity or mechanical means is approved, clsty ar contains corrosive fumes we recommend piping the air fltoriodoncer to a source of clean air or use an optional toay duty Siter# itis found necessery to stall lat piping, make tne line as shertand direct as possible ‘and as large 0° larger thon the diameter of the inlet connection at *ha compressor The inlet piping must Incteage in diamsoter ior neary 69 foal. (16.26m) of langth ifthe total length botween SU feet (15-25m) and 109 toot {20.5my, Increase te pips diameter at the mic fooint in the length ac. ifthe iotal lengthis 80 fee! (24 4m} mmevease the pipe diamater at the 46 fact (12.4m) point Attached the az fitevsilencer to the end of the inlet air ling, and if the Inlet 1 psped outdoors, it shoud be: hooded to prevant the entrance ot rain or snow See Figure 2-1. Fina armorne dust. such as cement and rock dust r@quire Speers! filtration equioment not farished a3 standard equipment on thia cempressor ‘Suen fitranior equipment is avallaole tree your local Ingersoll-Rand DistibutonOitice Step 6. BASEPLATE-MOUNTED COMPRESSOR The baseplate may be doltad to any substantial relatively level Hloor ee bane. If such a surface is rot availaule. an edequate base must be constructed Should a concrete base be necessary, made certaintne foundation ualts are positioned comes to aucept Ine baseplate feat and that these halts proyect at lane: =" (25.4 mm} aaqve the auriace of the Fouadatior. ‘The baseplata musi be levelled anc belied in a mamner which avoids pre-strassing the baseplate in paler 1 pravert vibration and insure proper apacatian, The following tachniqua is racommendad for anssoring the compresso: ta Its base A. Tighten eveniy, andtaa madirate torque the ruts of any three of the four baseplate faet an check {the baseplate is not level, inset metal stig undter ane oF wo of the feet 19 onlin level ang retighten the nuts. 2 Netethedistancethe unanchored ual ie elevated shove the base and inst a moval slic of equal thickness under this fact {© provide firm suppor Shims rust be al minimum the same dimension 8 bottom of foot G. After a2 snims are nserted ane ine Daseplate is level tighten the nuts on all vasaplate feel io a moderate inot mcessivedy fight) torque D. Check for baseplate sites ny loasiag nuts sone ata tee) and note any upware movement of the mounting foct. Any noticeable movenent indicates step 8 myst an repeated fo level Severe vibravions will resull when Is are pulled down tightly and feet are not level. This ean lea to welds cracking of fatigue failure of basentate, This is a very important part of installation THE COMPRESSOR SHOULD NEVER, OPERATED WHILE MOUNTED TO THE SHIPPING CRATE SKID, Step 7. LOW OIL LEVEL SWITCH {Optional Equipment) A float activated switch can be netalled to protest your compressor against damage due to insufficient oll level. The switch operates on a fail-safe pranople ard is mechanically actuated for sealed friction-less ‘partion. Low oil lavel in the framas causes ihe switch, contacts te opan, thus shutting the urit down until the ‘roper cll level has pen restored f fe seo _ Hazardous voltage. Connecting pressure switch 7 low oil Tovel sivitch directly to motor can cause severe injury or death, Y Always insure the pressure switch o- low oil level swilch is eannceted through the central circuit of @ magnetis starier. Proper protection agaist lo proper a cil levels depenes on iyusiment of the las a: Ievel aston, Dung the snitar ru, stup unit and drait one lice ot foil hom crankcase into clean contaner anc: listen ior switch te eck or check uta centinalty teste’ This is a Hest” tye swan which sometimes gets cocked ir shipping. F’ cocked or stuck, ayer uisconnect Switch, urain revsaivng oil, remove crankcase caver and then fe the feat, Beassersble and then reusn the seme oil HOTE ; 11 Moat is cocked in the low position. compressor will no! start Step MAGNEYIC STARTER (See olectrizal viagrame on Page 24) ‘This compressor must he equipped wth 2 opticna, magnetic starter. Note-thal the Pressure Smcch, the Oil Lave: Sitch and the Or-CHF Switch are were to she operating c2il of the magretic starter and sevos te imenrupt curent flow ta tie metor All stariers must inciude theringl overload protection to prevent possiale motar clamage fram averacling These starters ere lurnished with the menuigcturers instiuetions for installation, lage's-Rand cannick accept Eesponsibiity for damages arising from fale to prowse adeduate motor protect.on. Step 9. ELECTRICAL WIRING. (Gee electrical diagrams on Page 24) To aver invalidating your fire insurance. *t is advisable to have the eiestrical werk done by a licansed electrician who is falar eth the rogulshons of the Nationa! Llecrcal Code and the requvements of the lecal code cr ‘OGFAS.CABLE SIZE IN SQ. MM. WHEN LAID IN AR RECOMMENDED BACK UP FUSE RATING IN AMPERES RECOMMFNDED CABLE SIZE wr ALLUiamiuM | COPPER RECOMMENDED HRC FUSE RATING 1 15 15 HP boL STAR/DELTA 2, 15 1S 1 6 7 3 a 18 2 16 s 19 5 3 ry € Te tes 5 28 a —"o 35 =o 75 25 76 : 125 o Bs 10 2 2 5 t 18 35 2 70 z ia Ea 3 = 76 7 20 30 2 a 16 ann 25 cy 32 3 Eg s 30 e 30 a % Ls 5 oS (3g — @ 00 ee TYPE: PYG LOW CORE TENSION ARMCURED 80 100 EJ (PYG THOPEDORE ARMOURED) 1 CORE CABLE “OGFAS | DIREGTOR GENERAL, FACTORY ADVISE The sutable f ¥e siz3 1ecammended in Ine above table are lhe compressor unit. Hi other electrical 2quigmant 1s connected to the same circuit, the total electrical oad! rust ba oencidorad in satecting the proper wie sues. A burned gut moter due to low veliage may -esull, unless it is properly protecitc. Batfore wring the compressor to the power supply, Ihe electrical rating of the motor, ar shown on the metnr nameplate, myst be checked against the electrical supply. they are nat she game} clo not connect the motor. It is important that the wire used be the proper size az all connections scuured mechanivally end electrically. The size of the wire shown in the ta'2 abou 1s a safe guide. H the distanae is more than 30 foal (18.9m), larger wsi'e will probably be necessary and your electrical contractor o¢ onal alaetric company shoul be consumed for recommencations. The .e of too smali wire results in sluggish operation, Unnacessary tipping of the covelload relays ar blown fuses. Siep 10. FUSES Fuse fail.ee usualy results from the use of lus sngufficient capacity. If fuses are tha correct siz and Stil fail, chock for condians Brat cause lecal "eating. such 46 bem, weak or corroded tuse clips. Rafer to the table below tor recommendations on the proper fuse size to be sed Also cater to the regulations of the National Eiestiical Coda and raquiromonis of the lacal cows, SERVICE AND LABOUR INSTITUTE BOUBAY. Step 11. __ DISCHARGE PIPING ‘The fokowing genera. wnstructions cover only te installation of cischarge piping and placement ol satety valves, prossure switrh. pressure guage, cain valves, shutoll valves, ete. 1 systems using 2 detached receives, See Figuec 2-2. Discharge piping chould bo Iho same size 2s the compressor discharge connection oF the raciver slischarge cennecton, All pipe ang fitings must be certfied safe far the aressure involved. Pipe thread saalanti«s te be used on all threads, and all PRESSERE Presse ain vccerver OE SHEE DiscaarCe Ty VANE ; siete Wave swrcore N i scant N. FF ain aecewven Some tare Figure 2-2. Typical piping arranged for compressar and detached receiver.40 joints are 1098 mate up tightly, ihe discharae system are the largest single cause of high operating costs. ¥ your compressor rans mare then yeu boliove i chould. the mast likely eougs 19 a feaky vipe fine. Leaks ase easly locaied by squining soz and water soluticn around the joints and watening for bubbles. Figure 2-2 is a typical «nstallation for a bare compressor connected ta an-air recelver. Rele: te Figure 2-2 and observe the folowing precautions whan instaling the discharge line and the high pressure air 1eceiver A The compreseor discharge line may be high pressure tubing or pipe. The mnimum see to ise foe maximum capacity for your patticulsr model is, as indicated below. Models 22° use a rrininwam UE (6.8mm) |,D. Mode! 772 use a minimum 9/8 (8.5mm) LD... aud Model 1512 use a minimum ¥W2 |12.2me) LD The cischarge line fitting, high pressure air recewas, ots. must be sertified safe for tha pressure involved, 8. The line is 19 be short, direct and adequately braced. tg a good prsetise to stati a shut off valve between the compressor clischerge and the high piessure air secelver and also beween the high pressure air receiver and the point 2t whic the air is usad. Always instal a high pressure cedediapprovad safaty valve betwaon the shut off valve & the air beitle ©. Insta!l the pressure switch and guage at a Dulsation free point in the system that eegistars aetual air rocower prosecute. Select a high point here condensate ‘ill nal accumukiie, The Pressure switch may be mounted in any positon but Lote it and ee quage must he securely mounted against solid surface. The eannectag ling is to be short and clireat and nertliec sate tor the pressure involves Wire the pressure suite according ‘a the schermatic diagram on page 24. D. the compressor uramn verve disenarge may pe piped curdoors oF 10 a suitable open drain, Tre rnin pipe oF tubing must be as large or larger than the drair fiting ond must be firmiy sac. 9d This machine contains high pressure air, Can cause injury or death from flying paris. Han aftercooler, chesle vahe, bloc vyelvs. or avy olher restriction is added to the compressor discharge, an approved salety valve must be installed betuoen the comprasser discharge and the vestretion Step 12. —_. COMPLETE WARRANTY REGISTRATION Comp.etion af the registration form incicares satistectory installation arid gerlormance of start-up operations. Itany detects arc apparent in the equipment contact the nanrost |-f Distrauter or Ingorsall-Aand Distr office The FR seivies Iterature included with the uret nas instructions for minor adjustirents Minor Aqlustments art nct consicleeed warrantySECTION Ill : REGULATION AUTOMATIC START AND STOP CONTROL This tyae ei regulation is used when the cremated for air ig smal or leimittent, but whers pressule must be continuously maintained Automatic Sait and Slop Control is ostaince by mneans of a aressure switch which makes or breaks an sicetrios, cucu. stasing and stopping Ihe drving motor theresy mamntaining the sir “eceivor preceurs wrtlin cefinte fimts, The pressure sisitch ts pised 1 the reenter ard is actualed by changes i air receiver presi Autematic Start and Stop should only be Lead bers Moiot Starts MAK More shan GB lenes pt HUM PRESSURE SWITCH ADJUSTMENT ‘The pressure switch automatically regulates the compressor, starting and stopping the driving mator at specific receme: pressures. To change the GUT IN or CUT OUT points, rater to instructions accompanying Ihe switch, Its advisable to have os uada clifecertial As possible 10 aveld frequent starting ang slogsing oF the compresses. ‘Typleal Automatic Stop and Stat Awangement, This machine contains high pressure i ait, Can cause injury or deamn from | flying par's. Do not neroaso tne cut-out setting of the pressure switch Leyord the pont t angiratly established at the factory for your particular mocel CONSTANT SPEED UNLOADING Gonstant seed unloacing s accomplished by intake suction! unioader tarated at compressor wniake. This unloader unloads compressor by shutting of mtake sir bbefore it wnters low pressure eylinder. Thus camoressor constantly min in unioaded condilon, Whew receiver pressure drops, aunillary valve closed ard unioeder eames ‘0 il rormal agsiticr allowing ai: % enter 9 1c ow preacura eyinido DUAL CONTROL .—__.. Dyal caatal is the combination of bote automatic start and step and corsiaut speed conirel operation. INTERMITTENT DUTY FORMULA —___ (Also sce Paye 5.) Compressors operating above 200 psrgi 14 egisa, emi are to os operated according to the "Intermittent Duty Formula’ INTERMITTENT DUTY FORMULA Pump-up time should net ordinary 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 : Wien the compressor Is regulated by constant specd controi, the shut down period is the time the compressor is oparating unlosded. A pitp-up tine iamt wih the follewing cool-down petiodis :nannmsnden to prowet the valves and naacis against sabiled hugh operating temperatures, which ‘oul rapid aulld up eardon sn thase arexs, Allinquiries ‘or high-pressure campresser anpliaation here the, wae" syste ditfors froin the "intermittont Duty Formula’ shuld be relered to Ine nearest Ingersol- Rand branch ct.ce. a“12 SECTION IV : OPERATION OPERATING CHECKS. Satisfactory operation of aay pieze of mechanical equipment depends to a kuge degree. upon adherence 10 a prevantive marmenance schedule Te abran optimum perfarmance at minimum eest caseive the ‘Maentenance’ guide an page 77. COMPRESSOR LUBRICATION Check the oil Ieval in the bave compraséor before aach use by removing the oil filer plug and wiping clean. Fer Model 23% the cil should 62 level wih the tor: 3 threatt of the oil filler hole, Fo: Models 72 ang 1572, place the cell guage with the writing up into tne filler hale until the threads ‘ouch (DO NOT ENGAGE THE “er : THREADS} Remove the guaze a] and eed the of level. Ia leve:| MODEL 1572 MODEL 772 crops below ine sale point, aad fo bring ieval back to tha FUL mark. Do nat aver fill, Replace or plug HAND TIGHTEN ONLY. FROMOWLCHANGE Oil changes should be mede every 508 hours of operation ar every 99 days. whichever occurs First Important: For maximum removal of impurities, drain only when frame cil is hot. Afier tae operator has observed the condijion of the oil fom a number of charges, the length of tima patween changes may be extended il so warranted. Fraime cil capaattios ere fallovis: Mode! 281 - 7/8 Gl {0.83 Liters), Mode 772 ~ 2 W2Gks, (2.37 Liters) Model 1572- § Cis. (4.73 Liters) AWARNING Flushing compressor frame with gasoline, kerosene or Hermmable uid can cause severe injury or death, Use a regular flushing oil to flusiv out compressor frame, LUBRICATING OIL RECOMMENDATIONS IngersotrRand doos not secommend any particuar brand cf oll, but a potoloum Iubfeating ol io peaterrod in this particular ype of air compressor. The potolaum lubricating oil shoulébe a nan-detergent, containing ony rust, oxirlation. arel ab-loaming inbibiters with ether a haphihane or paratino base. The viscosity st:ould ne se eetad for ‘he temperature iminedistely sucrotding he iit shan itis ie enerstion OIL VISCOSITY TABLE Tap, Mange B78. | sus | censckes worsesoencceeien | cs | 20 Fta bs b Below 144-6 & 26. 2°Cs | 300) 0 aorwias i nebwrmrcestcc| roo | es The ‘escositias givon :n the table are intended as 2 general guide only Haavy-duty operaling vonditioay require heavier viscosities and where porcierlene temperature conditions are encountered, the v'scosty index of the cil should be considered. Alays -nfer your sorafic operating conditions lo your »neustral ludrieant euppiio’ tor recernmandatiors MOTOR LUBRICATIONS & CARE __ Depending unar the hype of electric mator deving your unit, the fusewing lusneabry schedule should be abserved. BALL BEARING MOTORS WITH GREASE FITTINGS - Ball beating motersthat hava gence ftir gs and plugs nent the bearings are to be repseches! with grease ance a veal. Use 2 vary goou grade af pall near grease. RALL BEARING MOTORS PRELUBRICATED FOR LIFE - Bal bearing moters that have no greace fittings 1 plugs rear the bearing anc do rot requile Luaneaticr. Severs majo" paints cartibuting ts proper enctcr operation ardsee ava givan in the following paragraphs, Formos detaited insteustions refer to he menviaesure's specilic recommengasons It is also 4 geod practice fo manthiy blow off the moter windings with 9 jet of air to prevent on accumulation of clit. Ar. aucasional revaraishacg oF the windings will greatly prolong tne Ie et the meter. lithe moter is located in an almosphove whera it ie exposed 10 adpreciable gamities of water. «dit oF fumes, It rust be specially constructed.43 ALR INLET FILTERISILENCER itis very important thai the air inlet sitar’siencer be kept claen at all imes. A dirty inet filler reduces the onpueity of the corproasar. Sen Figure 4- it L ‘The fitaring element should ba saken aut at least orice a month and deared by vaccuming or washing 9 sleldatergent and water. Atow to dry ad then remscall = | Cleaning air Inlet fier with gesoline, kerosene of flammable fluid can cause an explosion or fire which ean essult in severe injury or death Use ssarm soapy water far clexning fir Inlet itor, Figure 4-1, Typieal Ae inot FiterSilencer The standard inet air fiteris suitable orty for normal industrial applicatians. Should the compressor be located in an ara where the atmosphere contains a npevy eoncentiavon of dust anc dit an air iller ilicing a specially designed, heavy duty @ moron) element shoult be used All epplications of this nature should be reiarred to the nearest Ingersoll-Rand sales officer or distributor AIRCOOLEDINTERCOOLER An airculed iatercoaler is located between each stage of compenssion to remove the heat ol the previous stage of compression belore the ait enters the next higher compression stage. Newer petit the air flow to these tubes te become obstructed, and clean tne surlaces of the tubes Fhonever deposits of oil, ditt or qmeese are observe. Use a non-flammable safety solvant for cleaning purposea. During regular overhau periods the tubes: should Be iemoved from Meir headers and nspeatod internally, IH the snterior of the tubes requires cleaning cap one endl and ill t with 2 rionlammabie safety solvent te he'p lassen Internal daposits of ail. crt and aaron, Always flush the tubes with waim water and grit them to day thoroughly before replacing Two-slaye compressors have ore intercacler localed between the vissharge of ine fiest.stage aid the intake to the second-stage. AWARNING This machine conteins high pressure air. Can cause injury oF death from fying parts Da nol open an intercooker dracn valve: while the compressor is sunning Three stage compressors have lwo intercoolers, cily located setueen ihe discharge ¢! the fisi-staye and the intake io the second stage cylinder anc the Second interecolarlocared between the discharge o! the second stage and tne niaiee to the third-stage cylinder. When necessary the intercooler will be titcd with condensate drain log and valve. When these valves are provired, the eardansate should he dinined off at periodic intenvacs, “The intercoolers guage pressuces are atrue indication as to the cxrrect operation of the comoressor. The fooler pressure will vary ewh individual machines, with ‘operating temperatures, and with elovation, above sea. level. Note the pressure winen the machine is new, and any marked deviation thereatter requires investigations fol the cause: thus, possible trouties may be discovered afore serious damage rasults Il the intercosler pressure is aonormally high. one of mere of the following conditons may be present in the nex! stage of conpressizn. 1. fnlet 01 dacharga valve beckon. stuck or leating boacly, Inlet or cischarge valve soring vrokenor weakened enesagh to allow ar ‘sli Caiboruzed valves 0° passages which restact sir flow A. Air leaking past valve seat Ifthe intercooler pressure (s abnormally ow, one oF more of the odowing conditions may be present in ether proaeding ctage of compression 1. Piston fings broken or stuck in grooves 2 Heng gasket blowe or head wot boiled tighty to oylindes 3. Inlet valve leaking or stuck, spring aroken ar weakorod 4, Disclaige valve broken, stuck oF toaking 5. Leaks im ntercaoles arpucid the tube ftungs 0: @ erecded ane. leaking tube, SAFETY VALVES —__ A safety valve is provided in each intercooler it ar intereooier safety valve blows and continues to blow for mora than @ minute the camprossor should be Stepped at once. It rdicates a leaky. broken 9r carbonizes discharge valve in the next higher pressure cylinder.i A discharge safety valve is tumished) es standard 2avipment on all models. See saiety vaive chart below SAFETY VALVE SETTING PSIG (Bar) TaoneL [OISCHARGE] FIRST-STAGE | SECOND-STAGE] INTERCCOLER | INTERGOOLER. zor | morse | 10 PSIG ve | soopsis | reo PsIG tst2 {1200 psig] AO PSIG 260 PSIG ame | oensoous| Figure 4-2. Typicel Intercooler Tubes and Safely Valves. A WARNING ‘This machine contains high press- | sure air. Can cause injury or death from flying parts” Do not remove, change. oF make Sub- stitutions fer the safety vaves. Shey should be replaced only by apruine TR repiacoment paris STARTING UNLOADING SYSTEM OPERATION OF STARTING UNLOADING SYSTEM ‘The purpose of the system és 10 relieve eyvades pressure when the campressar stoos permitthag it to Slart against a ight load. increasing, the lite af fre driver and bel's and also reducing the possibility of tipping the nverload relay. Tha ayotem operates inthe following As Shown n Figure 4-9 & 4-4 the centilugal unloadsr 1s attached fo the end of tha crantstatt, thus whan the ‘comprectar 1s in operation, centifugal farce acts upon, bie unloader veights and Bey swing eutward (See Figure: 4.9 anG Figure 4.6), When the compressor stops these weights retract (Figure 4-3 and Figure 4.2) permitting tho thrust pin spring te mova tha plunger and ‘hrust pin outward. The thrust pir epens the pilot valve ond te: trapped oir prascure escapes tom the cylinder and ingercooier theaugi a pustaye in the frame eno cover (See Figure 4-5). through the unloades tube and 40 atmosphere through the iret fitensilencer ane tiga? RUST PW (le. Figure 4.3. Position of weight and thrust pin when compressor is stopped. (Mocels 261) ~ a Tuc conection TEMCERGE™ are : Puunsen t coven | wane seat | gear a Figure 4-4, Position o! weight and thrust pin ‘when compressor Is stopped. (Nodeis 712, 15T2) When the compressar starts, centtitugal ferce acts upon the unleacer weights and they swing outward. Tors Fermits the olsger antl ivust pin to mave inwarel and The pilot vaxve to classe. Tho ascaze eth to atmosphere for the cylinder g1essure 1s Maw clascd ane the ceompressor punips air ina normal manners If te pilot valve tube ine is exeassivaly Het. I iso gead indication that the pilot valve is leaking and adjusione-t in required,45 — - we ar vanes : us . 6 | twee ' 1 GRAN i a , snonbore | aston set | Figure 4-5. Pee! when compressa of weight and thiuet pin Figure 4.6. Position of weight ard thrust pin when. operating. (Models 231). ‘compressor is operating. (Motela 772, 3612).ae PILOT VALVE ADJUSTMENT To acjust the pilot valve, rater to Figures 4-9 ane 4 5 for Models 2211 and proceed as follows! 1. 5tap the compressor (Disconnect the electrical supply main suite te prevent accidental startup 2. Remove the pilst valve lube. fitings. and leasen lodk nut 5. Screw pilot vale assembly nip trae end cove until thrust pin is left, Advanoe valve assembly fo 1/4 fo 12 tenn Hold valve assembly at this position and tighten loot nut 5. Reconnect pilot valve tubing and start the con pressor. Place hand over front sce of Lock, Hut 5. there is ne flow of air pitot valve is adjusted properly. ti air flow ws evident readjust valve storting with atop ¢4) To aujust ine pot valve, refer w Figures a-4 anu + 5 ter Motels 712 and 1512 and proceed as falas 1, Stop the compressas. (Disconnest -he electrical supply ain swith fo prevent accivental start up. Remove the plot valve tube anc one tube tings, Remove the pilot valve bedy and all existing 4 Serew the pilal valve body buck inta the fame end cover jnithout any shims) wal contact with ‘he Uys! pints fell, Advance the pital valve boa 14 © 172 tum inoxe, If contact sith the thrust pir cant be ‘elt the lotiowing stops may bo nazensary to locate the nentact son 1, Inset a stra instrument !Punet, we, nil, ete. inte the ene! of the pot valve unil & sontacts tha v0 tom 2. While stl inserted in the pull valve, make a mark or the instruments even sith tre outside edge cf the pest waive noc 3. Keesirg the instument prossed lightly against tha vate stom. rerew the pilot valve bery into Ihe trare end cover, Wher the mark on ce inst-ament starts mowing out away ‘rom the eage of the pint valve hedy. cantact has necr mace sath tha tanust pin 4. Rovance Ine silat valve beady 1M to 12 war more and pingee eh Siep lve, Measure the gap between she pilot valve body d the frame end cover. (Sane Figure 4-43 8. Remove the pilct value body ard séd enough shins to fil the gy measured in steps 7. Screw he pilot valve Deey pack into the Fare end cover untd the kody 1S ‘ight on ‘he shins 8. Abconnest the pilot valve tube and tubs ‘tings. HW leakage still exists repeat the above srops. IF leaking cuinet be siogped! by achusiment. rep acenent bf the pla; valve may be required, use tne above procedure ‘her inslalling the new plot valve, BREATHER TUBE ‘The breather tubs connects the interior of the frame la tha inboard side of the inlet fitcxisilencer, This con nestinn. penrits aulsatans created by the reseproniting acuch oF the esstons fo be vented to atmosphere. thus preventing any pressure bulld up wllnin eve Trane, pressure vead on your unit itt this ease. It is rovers: machine is new, and this reading shold be u | NTERCOOLER PRESSURE CHART Dus to variable operating eenditions. the prescure stad in tha chart mny not be ioentival to the i coeler ‘ed that the inlersonler pressit2 be recordae when she sed as the normal ntetvacler pressure, Tacdet Discharge Pressure ‘ist Stage Intercooler Bnd Stage Intercooler 281 500 PSIG (94.48 BAR) 80 TO8s PSIG (6.5270 5.85 BAR) we 500 PSIG (64.48 BAR} 8 TO 7 PSIG (as9TOSascAR —j S00 PSIG (24.48 BAR) 38 TO37 PSIG 185 TO 180 PSIG (241 T0285 BARD (01.38 TO 12.01 BAR) 1812 750 PSIG (51.71 BAAD 37 TO 38 PSIG 180 TO 200 PSI (2.5570 2.69 BAR) 62.41 7013. 79BAR) 1000 PSIG (88.95 BAN) 38 TO a! PSIG 218 TO2Z40 PSIG (2.0210 283 BAR £14.82 70 18.65 BAR} ‘AIR-COOLED AFTERCOOLER Compressor models, 231, 772 and 1572 are equipped wilh an air-cooied aftercooler hich resemble the intercooler's finned tubes. The altacccoler lunctions te remove the neat of compressiar from the final discharge ar belo its stored in the recever. De nol povewt tne ar flow to the fan-belt wheel became obstucied and keep the aftsrcocles tubes ang fins (ee ‘row: dust anu dit. Tne attercocler condensate dean trap shoul! be drained as frequerity 5s necessary to prevent condersale water ‘rom entenng he comprescur,