Ingersoll-Rand PL-MANW Manual

PL-MANW
Rev.B, Nov’20
- 1 -
Contents: Page:
Safety Precautions
2
Preventative Maintenance Schedule
3
Unpacking and Inspection
4
Installation – Mechanical
5
Lubrication 6
Installation – Electrical 7-8
Start-up Procedures
9
Trouble-Shooting Guide
10-13
Ingersoll-Rand Limited Warranty
14-15
Please read this manual before
installing or using your Air
Compressor Unit. It contains
valuable information that will
help in the receiving,
installation, use, and
maintenance of the Unit.
Please keep this manual in a
safe place for future reference.
All of the information, policies, and
procedures in this reference manual apply
exclusively to Ingersoll Rand.
Pressure Lubricated
Air Compressor
Installation,
Maintenance,
And
Service Data
Ingersoll Rand
490 Welham Road,
Barrie, ON L4N 8Z4, Canada
Tele: 1-800-483-4981
Web: www.ingersollrand.com
Email: [email protected]

PL-MANW
Rev.B, Nov’20
- 2 -
Safety Precautions
To operate the Compressor Unit safely and correctly, we have opted to use the following symbols to make you
aware of important points. These points relate to user safety and preventing equipment problems. Please pay
close attention to these sections.
The following hazards may occur during the normal use
of the equipment. Please read the following chart.
Area: Hazard: Safeguards:
What to look for: What may occur if precautions are not observed. How to avoid the hazard.
Tampering with the Unit while under full or partial
pressure may cause an explosion.
Relieve all pressure from the Unit
before attempting any repair or
maintenance work.
As the Unit starts and stops automatically, serious
injury may result from working on the Unit with the
power still in the on position.
Shut off all power to the Unit before
attempting any repair or maintenance
work.
As the Unit starts and stops automatically, do not
come into contact with moving parts.
Shut off all power to the Unit before
attempting any repair or maintenance
work.
Air compressed by the Unit is not suitable for
inhaling. It may contain vapours harmful to your
health.
Compressor capable of pressures >50 psi.
Never directly inhale compressed air
produced by the Compressor.
Risk of injury, do not direct air stream
at body.
The Compressor Pump, Motor, and Tubing
become hot when running. Touching these areas
may cause severe burns.
Never touch the Pump, Motor, or
Tubing during or immediately after
operation.
As the electrical components on the Unit are
General Purpose, there is a potential for explosion
should vapours be present in the area.
The Compressor must be a minimum
of 20 feet (6.1 meters) from any source
of potentially explosive vapours.
Important safety Information.
A hazard that may cause
serious injury or loss of life.
Important information that
indicates how to prevent
damage to equipment, or how
to avoid a situation that may
cause minor injury.
Information that you should
pay special attention to.

PL-MANW
Rev.B, Nov’20
- 3 -
Preventative Maintenance Schedule
Noted below are general maintenance guidelines, which must be followed and documented, this in accordance
with the Ingersoll Rand Warranty. It is based on an approximate Compressor usage of 30 hours per week. If your
particular application varies from this, please adjust accordingly.
Notes
Daily
Weekly
Monthly
Every 3 Months
Every
12 Months
1st
Year Maint.
2nd
Year Maint.
3rd
Year Maint.
4th Year Maint. 5th
Year Maint.
6th
Year Maint.
7th Year Maint.
Normal Maintenance
Drain moisture from Air Receiver

‘Normal Maintenance’
items at left to be carried out
regularly throughout the years.
Check oil level and top up as required

Clean Air Filter

Check Belt Tension

Check Safety Valves

Check that Unit unloads when shutting down

Clean and/or blow dust/dirt off Unit

Replace Air Filter
1

Replace Oil (synthetic)
2

Check lubrication of Motor




Inspect Valve Assemblies in Cylinder Head(s)




Replace Check Valve




Inspect Pressure Gauge




Replace Belts
3



Replace Valve Discs and Springs 4



Replace CPR Unloader Kit 5

Replace Pressure Switch

Replace Safety Valves on Pump and Tank

Replace Pressure Gauge

Notes: 1. Air Filters are available separately or in a Maintenance Kit. Consult your Pump bulletin.
2. Synthetic Oil is available separately or in a Maintenance Kit. Consult your Pump bulletin.
3. Belts are available through your local Ingersoll Rand Distributor.
4. Valve Discs and Springs are available separately or in a Kit. Consult your Pump bulletin.
5. The CPR Unloader Assembly and Kit is noted in your Pump bulletin.
When servicing the Air Compressor, shut off all power to the Unit, and drain the Tank
of air pressure. Always re-install the Beltguard after adjusting the Belts or Pulleys.
Insist on Genuine
Ingersoll Rand parts and
kits when maintaining
your Compressor Unit
and Pump.

PL-MANW
Rev.B, Nov’20
- 4 -
Unpacking and Inspection
It is the responsibility of the receiver of the goods, either the Distributor or Customer, to ensure that the product
has been shipped in full and has arrived in suitable condition. Damage to the product may not be visible at time of
off-loading but may only become apparent upon unpacking or start-up.
Some areas to initially check are as follows:
a) Check for damage to the crating and/or packaging.
b) Check for damage to the Beltguard.
c) If the BeltGuard appears damaged, remove the Guard and turn the Flywheel by hand to ensure the
Crankshaft has not been bent, and the Belt drive is properly aligned and free of distortion.
d) Check the Air Tank thoroughly for possible damage.
Should there be damage to the product or shortages in shipment:
1) Stop any further unpacking or operation of the product.
2) Make note of the problem on the Freight Bill, should it concern a shortage or visible
damage to the product.
3) Should the damage be noticed only after the product has been received, contact the
transport company immediately to file a claim.
Depending on the problem, it may be wise to photograph the damage. Also, it may
be wise to discuss with the carrier representative the time allotted to give notice of loss
or damage to the product; there may be guidelines which limit timeframes of same.
4) Do not attempt further unpacking or operation of the product. Also, do not discard
any packing material used.
5) A Loss or Damage Claim must be submitted to the carrier and supported by the
following documents:
- Copy of Freight Bill of Lading
- Copy of the Invoice and Estimate to repair, in case of damage
- Damage Report
- Copy of photos, if applicable.
Each Ingersoll-Rand Air Compressor is carefully tested and
inspected before shipment. Though every attempt is made to
ensure the safe and complete shipment of our product, freight
damage or misplacement of goods may occur.
Shipments of Ingersoll-Rand products are the property of the
Consignee when the products leave our facility. Ingersoll-Rand
Inc. is not responsible for any damages or shortages caused to
the product after it has left our shipping dock.

PL-MANW
Rev.B, Nov’20
-5 -
Never clamp or bolt Air Receiver Feet to the floor
or support structure. Doing so can greatly
increase stress on the Tank, causing it to weaken
and/or fracture. Use Vibration Pads.
To reduce the risk of electric shock or injury, use
indoors only.
The Compressor must not be operated in a
confined area where the heat from the Unit
cannot readily escape.
Installation – Mechanical
Location of the Unit.
Ingersoll-Rand
Installation Kit
Compressor
Horsepower
IK515 5 to 15 HP
IK2530 25 and 30 HP
If installed in a compressor room, ensure that the
room is adequately ventilated (One Horsepower
produces approximately 2500 BTU/HR.).
Eg: 15 HP Unit x 2500 BTU/HP = 37,500 BTU/hour.
The ambient temperature should be between
50°F and 104°F (10°C to 40°C).
Items to consider when installing the Unit are as
follows:
The Unit must be located indoors in a dry, clean,
cool, dust free, and well-ventilated area. If
possible, the Compressor should be located in a
separate room or area, away from the general
operations of the shop.
Allow a minimum of 18” around and 24” above
the Unit, this being for both the proper ventilation
of the Unit and ease of servicing.
If installing the Unit on a mezzanine, ensure
that the structure can safely support the weight
of the Unit. The Vibration Pads will help to
lessen the sound level of the Unit caused by
harmonics created by the structure.
All Compressor Units must be anchored and
installed as shown below. Failure to do this will
affect the Tank Warranty.

Ensure that the floor under the Unit is smooth,
level and capable of bearing the weight of the
Compressor. The Compressor must sit squarely
on the floor.
This unit must be anchored to the floor as
indicated at above-right.Ingersoll-Rand has
available Installation Kits which include (4)
Vibration Isolator Pads, (1) Stainless Steel Flex
Hose, and Steel and Rubber Washers.
Building
Wall, etc
18” (0.5 m)
minimum
Beltguard
Compressor
Floor
½” Rubber
Washer
(SS-1536)
(& Opposite)
Anchor c/w
Hex Nut
(By
Installer)
Isolator
Pad
(UDH-9700)
½” Steel
Washer
(SS-
1535)
Compressor
Foot

PL-MANW
Rev.B, Nov’20
-6 -
Lubrication
Compressor Lubricant
All Season Select is a synthetic fluid specifically formulated to protect and preserve you Ingersoll Rand small
reciprocating air compressor through a broad range of temperature as well as better start-up in colder climate
conditions. With its outstanding formulation, All Season Select enables you to run 2000 hours of service between
changeouts under normal operating conditions.
PART NO.
DESCRIPTION
32318875
Lubricant, All Season Select - QUART
32318883
Lubricant, All Season Select - CASE OF 12 QUARTS
Oil Filler Plug
Initial Start-up.
Each Compressor Unit built is extensively tested at the
factory before shipment.
Check the oil level and for any oil leaks on a daily
basis. This must be done when the Unit is off. Top up
the Oil level on a monthly basis.
Use only Ingersoll-Rand All Season Select Oil. Also, do
not mix the Ingersoll-Rand oil with any other lubricant.
Oil Changes.
Drain the existing oil from the Unit. Running the Unit
prior to draining the oil will ensure that the oil will drain
relatively quickly.
Fill the Oil Reservoir to the bottom thread at the Oil
Filler Plug. Do not under or overfill. See drawing below.
Do not attempt to operate the Unit without first
checking whether there is oil in the Pump
Crankcase. Add oil as required. Serious
damage may result from use, however limited,
without oil.
Use of improper oil may negatively affect
Compressor performance or shorten Unit life.
Resulting problems are not covered by the
Ingersoll-Rand Warranty.
Condensation (water) may form in the Pump if
the Compressor has limited use or is installed
in a very humid environment. As the water will
tend to settle on the bottom of the Reservoir,
drain the water from the Reservoir until you
notice oil draining. Top up with new oil. Also,
change the oil more often than indicated on the
Maintenance Schedule.
O Ring
Proper Oil Level
(to bottom thread of Oil Fill Port)
Section Through Crankcase
At Oil Fill Port

PL-MANW
Rev.B, Nov’20
-7 -
Installation - Electrical
General Information.
It is your responsibility to ensure that the Compressor
Unit is electrically connected in a safe and correct
manner. Any electrical work must be carried out by
a competent Electrician and be done in such a way
that it meets all applicable Codes and Regulations.
Ensure that a suitable Fused Disconnect or Breaker (by
others than Ingersoll-Rand) is installed in the electrical
supply before the Compressor Unit.
AMagnetic Starter must be an integral part of the
Compressor Unit circuit as it provides overload
protection to the electric Motor. A Magnetic Starter can
be purchased separate from the Unit, or factory-
mounted at the time of Unit manufacture.
Failure to correctly connect the
Compressor to your building's electrical
services may result in serious personal
injury or damage to the equipment.
Before servicing the Unit, ensure the power
source has been shut down and locked off.
Read and understand the information
contained in this manual before installing
or operating the Unit.
This product must be connected to a
grounded, metallic, permanent wiring
system, or an equipment-grounding
terminal or lead on the product.
Failure to observe any of the above
precautions could result in severe personal
injury or death, and/or damage to the Unit.
Typical Electrical Installation
Of a Compressor Unit
L1 L2 L3
Pressure
Switch
Coil
Motor
Typical Magnetic Starter Wiring
(Subject to Local Codes and Authorities)
Main Fuse
Box
Fused Disconnect
or Circuit Breaker
Magnetic
Starter
Correct Pump
Rotation
Protective
Earth
For 3 Phase Units:
Connect ground wire to Protective
Earth terminal.
Bring power to L1, L2, L3.
See page 10 for start-up
procedures.
For 1-Phase Units:
Connect ground wire to Protective
Earth terminal.
Bring power to L1 and L2.
See page 10 for start-up
procedures.

PL-MANW
Rev.B, Nov’20
-8 -
Installation – Electrical (cont’d)
Motors.
Pump Rotation.
The Compressor is to be wired in a manner that
the rotation of the Pumps Flywheel causes the air
to be blown from the Beltguard forward over the
Pump. This, coupled with the unobstructed area
behind the Beltguard of 18” (0.5 m) minimum,
allows the Pump to cool properly.
Ensure that the voltage on your site is reflected on the
Motor nameplate, +/- 10%. In the case of 208 volts 3
phase electrics, the Unit must be 200 volts.
For single phase Motors, the voltage variance is 230
volts +/- 10%. A 208 volt power supply requires a
transformer to increase the voltage to 230 volts.
Use of an incorrect Motor for your particular
building service will result in premature Motor
failure, something not covered by the Ingersoll-
Rand or Motor manufacturers Warranty.
The Warranty that exists on the Electric Motor is that of
the original Motor manufacturer. In the event of a Motor
failure, contact your Ingersoll-Rand Distributor or
Service Centre for the location of the nearest
authorized Motor Service Centre.
Why Hire a Licensed Electrician?
To ensure that your new Ingersoll-Rand Unit works as
designed and required, you must ensure that it is
correctly wired to your building service. It is the
responsibility of your Licensed Electrician to ensure
that:
The Unit you purchased is suitable for your
particular buildings electrical service.
Protective devices such as Magnetic Starters,
Fused Disconnects, etc have been sized and
installed correctly.
Any electrical accessories purchased with your
Compressor have been installed and wired
correctly.
The wiring of the Unit meets with all applicable
codes and regulations.
When completed, the Unit works in both a safe
and correct manner.
Failure of the Compressor Unit due to an incorrect
electrical installation is not covered by the
manufacturer’s warranty.
When facing the Compressor
(as shown at right), the
Flywheel must rotate in a
clockwise direction.

PL-MANW
Rev.B, Nov’20
-9 -
Do not attempt to operate the Unit without first checking
whether there is oil in the Pump. Add oil as required. Serious
damage may result from use, however limited, without oil.
Initial Start-up
1) Remove the Oil Filler Plug and ensure that there
is sufficient Oil in the Crankcase. Refer to the
‘Lubrication’ section (Page 6) in this manual for
proper type and level of Oil.
2) Replace the Oil Filler Plug and use a
crescent wrench to tighten snug plus 1/4 turn.
3) Do a visual inspection of the Unit and ensure that
all Bolt heads are sufficiently tightened. This must
be done, as some fasteners may become loose
in transit.
4) Turn the Compressor 'On' momentarily by
positioning the Fused Disconnect or Breaker in
the 'On' position. Ensure that the Flywheel is
turning in the correct direction. See the ‘Pump
Rotation’ (Page 8).
Start-up Procedures
6
Do not place any materials near the
Compressor. Placing materials against or
close to the Unit will limit the cooling
required and could lead to premature failure.
6) After having run the Unit unloaded for 5 minutes,
close the Ball Valve, and allow the Unit to reach
maximum operating pressure.
7) Ensure that the Compressor shuts off at the
factory preset maximum pressure, and the head
pressure is released through the Unloader at
either the front of the Pump (the ‘CPR’) or at the
Pressure Switch.
8) Measure the amp draw as the Unit reaches
maximum pressure. It should not exceed the
motor amp.
9)Once off, check the Compressor and piping
systems for any air leaks. Correct as required.
Shut off all power to the Compressor Unit
before attempting any repair or maintenance.
During the first few days of operation, check the Unit
periodically to ensure it is running smoothly. Should you have
any concerns, contact your Ingersoll-Rand Distributor.
On Compressors with 3 phase power, switch
‘L1’ and ‘L3’ at the input into the Magnetic
Starter if the rotation is incorrect.
5) Open the Compressor’s Ball Valve and start the
Unit. Ensure that air is escaping to atmosphere.
Allow the Unit to operate in this fashion for 5
minutes. This lubricates the Pistons, Bearings,
and all internal surfaces.

PL-MANW
Rev.B, Nov’20
-10 -
Trouble Shooting Guide
The ‘Conditions’, ‘Causes’, and ‘Suggested Corrections’ as indicated below and on the following page(s) are only
a guideline for failures that we have found to be most common.
Though this information is provided in this booklet, it is assumed and expected that any personnel involved in the
servicing of an Air Compressor Unit is knowledgeable with this type of equipment. Do not attempt to service a
Compressor Unit unless you are familiar with it, as there are many issues that may come into play, the most
important being personal safety and the welfare of the Unit.
Should you have any questions, or require servicing to your Unit, please contact your local Ingersoll-Rand
Distributor.
Condition:
Cause:
Suggested Correction:
A. Unit won’t start. No power to the Unit.
Pressure may not be low enough in the
Tank to allow the Unit to start.
Loose and/or missing wires in the electrical
circuit.
Starter Overload is tripped.
If an Oil Monitor is mounted on the Unit, the
oil level in the Pump could be too low.
Check that power at the disconnect or breaker
is on. Also, check any fuses.
Drop pressure below the Pressure Switch ‘cut-
in’ pressure.
Check that all wiring connections are tight.
With a wiring schematic, check that all wiring is
present and correct.
Reset the overload in the Magnetic Starter.
Check the oil level and add oil as required.
B. No or Insufficient Air
Flow.
Air Filter is dirty.
Restricted air intake piping if a remote air
intake is used.
Loose Belts.
Pump Valves, Aftercooler, or Tank Check
Valve leaking, sticking, or plugged.
Air leaks at Compressor in piping system.
Unit is too small for the compressed air
requirements.
Replace the Air Filter.
Clean the intake Filter and piping.
Tighten as required. Do not over-tighten.
Clean, repair, or replace.
Fix leaks. Soap/water mixture will assist in
finding small leaks.
Contact your Ingersoll-Rand Distributor for
assistance.
When servicing the Air Compressor, shut off all
power to the Unit, and drain it of air pressure.