Ingersoll rand 15t manual

Use only suitable air handling parts acceptable for pressure of not less than the maximum allowable working pressure of the machine. 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. Typical compressors are furnished as compact, self-contained, air receiver tank mounted units that are automatically regulated and driven by an electric motor or gasoline engine.

An air-cooled aftercooler, low oil level shutdown switch and automatic drain valve are among the optional accessories that can be furnished. Bare compressor pumps and baseplate-mounted units are also available. These compressors may be used for a variety of compressed air application up to PSIG This type of control applies to gasoline engine units.

When the receiver tank pressure reaches the factory pre-set maximum pressure usually PSI G , the unloader slows down the engine and the unit stops pumping. When the receiver tank pressure drops to the factory pre-set minimum usually PSIG , the unloader resets, the engine returns to full speed, and the unit resumes pumping. This type of control applies to electric motor units over 10 horsepower.

Select either automatic start and stop control or constant speed control by adjusting the knob on the auxiliary valve. For automatic start and stop control, turn the knob on the auxiliary valve fully clockwise to disable the auxiliary valve. The pressure switch will then start and stop the unit. NOTE For dual control models, automatic start and stop is preferred. Auxiliary Valve.

Turn the knob fully counterclockwise to run the unit continually. When the receiver tank pressure reaches PSIG, the unit runs but does not pump. Disconnect, lock and tag main power supply before making adjustments. NOTE Adjust the pressure switch only if adjustments are absolutely necessary.

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. 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. The pressure switches with the on-off lever do not have a differential adjustment control. Remove the pressure switch cover. 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. Replace cover, reconnect power supply and start the compressor.

Note the pressure gauge reading at which the compressor cuts out. Repeat adjustment procedure if necessary. Pressure Switch Range Adjustment. 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. 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. Replace the cover, reconnect the power supply and start the unit. Note the pressure gauge reading at which the unit cuts out. Repeat the adjustment procedure if necessary. 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. These factors must be considered when adjusting the switch and compensated for accordingly.

The acceptable operating range is 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.

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. Turning the rod clockwise increases the oil pressure setting, and turning the rod counterclockwise decreases the oil pressure.

When the oil pressure is set, tighten the retaining nut and replace the knurled cover. 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.

Position of weight and thrust pin when unit is operating. Position of weight and thrust pin when unit is stopped. 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.

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.

Remove the pilot valve tube and the tube fittings. Remove the pilot valve body and all existing shims. Screw the pilot valve body back into the frame end cover without any shims until contact with the thrust pin is felt. 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. While still inserted in the pilot valve, make a mark on the instrument even with the outside edge of the pilot valve body.

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.

Measure the gap between the pilot valve body and the frame end cover. Remove the pilot valve body and add enough shims to fill the gap measured in step five. Screw the pilot valve body back into the frame end cover until the body is tight on the shims. Reconnect the pilot valve tube and tube fittings. In the following example, a 5 horsepower compressor uses 2 ounces of oil every 20 hours of operation. NOTE New or rebuilt compressor pumps will discharge higher than normal amounts of oil until the piston rings are seated approximately operating hours.

These used parts may be, or may contain, substances that are regulated and must be disposed of in accordance with local, state, and federal laws and regulations. Take note of the positions and locations of parts during disassembly to make reassembly easier. The assembly sequences and parts illustrated may differ for your particular unit.

Any service operations not explained in this manual should be performed by an authorized service representative. Reference the engine owner's manual for engine care information. The following maintenance schedule has been developed for typical applications. Maintenance intervals should be shortened in harsher environments. Check lubricant level. Fill as needed. Drain receiver tank condensate if automatic draining device is not provided.

Open manual drain valve and collect and dispose of condensate accordingly. Check for unusual noise and vibration. Ensure beltguards and covers are securely in place. Ensure engine if supplied is filled with fuel and lubricant according to the manufacturer's recommendations. Ensure area around compressor is free from rags, tools, debris, and flammable or explosive materials. Check system oil pressure on pressure lubricated models while compressor is hot. Inspect air filter element s.

Clean if necessary. Inspect for air leaks. Squirt soapy water around joints during compressor operation and watch for bubbles. Check tightness of screws and bolts. Tighten as needed. Inspect drive belts. Adjust if necessary. Clean exterior. Change petroleum lubricant while crankcase is warm. Drain compressor oil and clean oil sight glass Replace oil filter and change lubricant if necessary on pressure lubricated models.

Install maintenance pak -or- Change synthetic lubricant while crankcase is warm. Replace filter element. Unscrew and remove the wing nut A securing the filter housing B to its base C. Remove the filter housing and withdraw the old filter element D. Clean the element with a jet of air or vacuum. Replace the filter element and housing, securing it in place with the wing nut previously removed. Remove the oil drain plug A and allow the lubricant to drain into a suitable container.

Replace the oil drain plug. Check belt tension should be occasionally, especially if looseness is suspected. New belts must also be properly tensioned upon installation. Belt tensioning can be achieved by loosening the motor or engine anchor screws, pushing the motor or engine away from the pump, and retightening the motor or engine anchor screws.

Some units are equipped with a belt tensioning bolt that, when turned, pulls the motor or engine away from the pump. Otherwise, the motor can be easily moved by placing a prying tool beneath it.

A commercially available spreader or other belt tensioning device can also be helpful. Follow the procedures outlined below to correctly set and measure belt tension on electric motor and gas engine models including ,, and with "A" belt type only.

Refer to the following illustration for a visual representation. Lay a straight edge across the top outer surface of the belt drive from pulley to sheave. At the center of the span, perpendicular to the belt, apply pressure to the outer surface of the belt with a tension gauge.

Compare the reading on the tension gauge to the table. Follow the procedures outlined below to correctly set and measure tension on 7. Measure the span length t of the drive. Force the belt to the predetermined deflection calculated in step 2. Ensure the pulley and sheave are properly aligned and the motor anchor screws are adequately retightened prior to restarting the compressor. 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.

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. Loose beltwheel or motor pulley, excessive end play in motor shaft or loose drive belts.

Inadequate ventilation around beltwheel. Lubricant viscosity too low. Air leaks in air discharge piping. Lubricant viscosity too high.

Lubricant level too high. Lubricant level too low. Detergent type lubricant being used. Extremely light duty cycles. Compressor located in damp or humid location. Pressure switch differential too narrow. Improper line voltage. Wiring or electric service panel too small. Poor contact on motor terminals or starter connections. Improper starter overload heaters. Poor power regulation unbalanced line. Drive belts too tight or misaligned.

Compressor valves leaky, broken, carbonized or loose. Automatic drain valve clogged, leaking or defective. Carbon build-up on top of piston s. Piston rings damaged or worn broken, rough or scratched. Excessive end gap or side clearance. Piston rings not seated, are stuck in grooves or end gaps not staggered. Cylinder s or piston s scratched, worn or scored.

Connecting rod, piston pin or crankpin bearings worn or scored. Loose bearing spacer on crankshaft. Defective ball bearings on crankshaft or motor shaft. Wrong beltwheel direction of rotation. Two-stage compressors consist of one or two first-stage cylinders with the same bore size and one second-stage cylinder with a smaller bore size.

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.

The type of regulation used depends upon the application. Unless otherwise stated, dimensions, weights and measurements are provided in standard U. 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. Ensure adequate lifting equipment is available for unloading and moving the unit to the installation site.

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. 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. 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, 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.

For gasoline engine units, keep the engine at least 3 feet 1 m away from building walls and other equipment. Install the unit in a location with plenty of space for proper ventilation, cooling air flow and accessibility. Do not install or operate a gasoline engine unit in a confined area. 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.

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. 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. Bolt the unit to a firm, level foundation such as a concrete floor.

Do not bolt uneven feet tightly to the foundation, as this will cause excessive stress on the receiver tank. Bolt the unit to a firm, level foundation. Gasoline engine units mounted on truck beds must be fastened securely without applying excessive stress on the receiver tank. We recommend installing a vibration isolator kit with gasoline engine models.

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. 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. 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.

The piping, fittings, air receiver tank, etc. Use pipe thread sealant on all threads, and make up joints tightly to prevent air leaks.

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.

The motor rating, as shown on the motor nameplate, and the power supply must have compatible voltage, phase and hertz characteristics. 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. 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 For longer distances, consult and electrical contractor or the local electric company for recommendations. 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. Ingersoll-Rand cannot accept responsibility for damages arising from failure to provide adequate motor protection. 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. 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.

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. A 12 volt battery with a minimum current rating of CCA cold cranking amps and minimum ampere-hour rating of 24 Ah should be sufficient for cranking most electric start engines. Refer to the following table for size and length recommendations.

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. Connect the battery negative - cable to the battery negative - terminal. Coat the terminals and cable ends with corrosion-preventive grease. Protect the pump from contamination by installing a fuel isolation valve and an inline filter between the pump fuel system.

Ingersoll-Rand is not responsible for compressor failure caused by inadequate lubrication. Ingersoll-Rand recommends All Season Select synthetic lubricant from start-up. 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. 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. Unscrew and remove the oil fill plug. Fill the crankcase with lubricant.

Use one of the following methods illustrated to determine when the crankcase is full. 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. 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.

If you are uncertain about any. We recommend you ret ain this manual, and all. T ypical compressors are. An air-cooled aftercooler , low oil level. Bare compressor pumps and. These compressors may be used for a variety of compressed air. Application of these.