For Ingersoll-Rand Co., portable air compressors have always been a significant part of its business. Even its first electrical generators, introduced in the '80s, were packaged with an air compressor.

But things are changing at I-R as the company looks to continue diversifying its product line and become a force in the power generation business, leveraging its brand and industry focus in an effort to turn its new PowerSource generator line into one of its flagship products.

Air compressors have always been associated with I-R and at one time dominated the division's business, said David Puck, director global marketing at the Davidson, N.C.-based Utility Equipment Division. "A majority of our revenue globally came from portable air compressors. We were really very product oriented--essentially a one-man band."

But the band has grown to an orchestra as I-R has diversified its product portfolio over the last two years as part of a strategy to focus on products specifically targeting the midsized contractor. "It was the beginning of the transformation and expansion of our business, as we realized that portable compressors would not provide sustainable growth opportunities to get us where we wanted to be" said Puck. "As a business, we focused on the areas of product, channel and brand and looked at how to leverage what we do well.

"Generators were a good first step, a natural progression to business expansion, because of the competencies we've developed over the past 100 years building air compressors. It would not have made much sense to go right from offering compressors to wheel loaders. Taking the next step needs to be done gradually, and leveraged off of what you do very well while stepping out of your comfort zone."

While gen-sets were I-R's initial extension, the company has continued to expand its portfolio, adding a full line of concrete products, wheel loaders, excavators and backhoes, all of which are aimed at midsized contractors. I-R's core product line still includes air compressors and light towers but has gradually grown to include mobile generators which I-R, through its Utility Equipment Division, will launch a total of 11 new models.

The new gen-sets are being marketed under the PowerSource name, aligning them with I-R's AirSource air compressors and LightSource light towers. The first six models (10 to 100 kW) will be available for order during the fourth quarter of 2005 and will be launched at Power Gen International 2005 in Las Vegas. The additional 155 to 500 kW models (G190, G240, G330, G440 and G625) will be introduced in 2006 with the onset of Tier 3 engine emissions standards.

Included in the initial launch is the G10, G25, G40, G60, G80 and G125 with output ratings of 10, 21, 30, 46, 66 and 100 kW, respectively. These six 60 Hz units are the next evolution of IR's environmental generators introduced last year. "For I-R, this is the future of power generation" said Todd Howe, product marketing manager, mobile generators at I-R. "This is the platform that we will build upon and grow. It has the features and requirements that the market demands."

Within the lineup, the three smaller models, the G10, G25 and G40, are equipped with 1.3, 2.5 and 3.3 L, three- and four-cylinder Mitsubishi diesel engines rated 16, 32 and 45 hp at 1800 rpm. John Deere's three-, four-and five-cylinder PowerTech 4045, 5030 and 6068 diesels drive the rest of the range. These 3.1, 4.5 and 6.8 L engines are rated 72, 102 and 150 hp at 1800 rpm.

Both Tier 2 engines are prepackaged with a cooling assembly that includes a Toyo radiator on the Mitsubishi engine. The cooling system also incorporates an engine-driven fan and a redesigned airflow pattern that also provides sound attenuation, the company said. An air inlet grating on each side of the unit directs cool air across the alternator and engine block, which the engine fan pushes through the radiator and out the roof-mounted exhaust grating. The engine package also includes a Denso alternator and Nelson air cleaner.

A Leroy-Somer alternator is directly driven off the engine through a flexible coupling. The alternator is integrated with switchable voltage and designed with an AREP (auxiliary regulation excitation principle) brushless excitation system which Howe said provides more starting kVa during motor start. "Motor starting is typically the most difficult application for a generator due to the tremendous amount of surge energy required to accelerate the motor from rest up to rated speed," he said. "With AREP it translates into 25% more motor starting capability, which means you're starting bigger motors with smaller generators."

New to the PowerSource generators is an analog control panel that is common among the entire lineup. Based on recommendations from its customers, I-R has designed a simpler, easier-to-use platform which has been relocated to the rear of the machine. One of the more significant changes to the panel is in the engineering of the patent-pending three-position voltage selector switch, which is now located on the control panel behind a panel door that when opened, shuts down the engine. "When you open that door it immediately shuts off the engine and trips the circuit breaker so the operator cannot physically change the voltage selection," said Howe. "It is going to save service calls and unnecessary costly replacement of the switch."