Ingersoll-Rand M250-LV Operation and Maintenance Manual

Brand: Ingersoll-Rand

Model: M250-LV

Type: Operation and Maintenance Manual

This manual is also suitable for

M200-LV

2550255

SSR M200–LV

M250–LV

M250 –>

M200 –>2440110

OPERATION AND MAINTENANCE MANUAL

This manual contains

important safety information

and must be made available to

personnel who operate and

maintain this machine.

C.C.N. : 22071393 en

REV. : A

DATE : MAY 2004

SERIAL No :

05/04

Machine models represented in this manual may be used in various locations world–wide. Machines sold and

shipped into European Union Territories require that the machine display the EC Mark and conform to various

directives. In such cases, the design specification of this machine has been certified as complying with EC directives.

Any modification to any part is absolutely prohibited and would result in the CE Certification and marking being

rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

98/37/EC, 93/68/EEC, 89/336/EEC

WE,

INGERSOLL–RAND COMPANY LIMITED

SWAN LANE

HINDLEY GREEN

WIGAN WN2 4EZ

UNITED KINGDOM

DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY,

THE PRODUCT(S)

M200–LV M250–LV

TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS

OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

EN29001, EN292, EN60204–1, EN1012, EN50081, EN50082

ISSUED AT HINDLEY GREEN ON 01/01/2004 BY H.SEDDON, QUALITY ASSURANCE

MANAGER.

H. SEDDON

EC Pressure Equipment Directive and Related Regulations

We declare that this product has been assessed according to the Pressure Equipment Directive

(97/23/EC) and, in accordance with the terms of this Directive, has been excluded from the scope

of this Directive.

It may carry ”CE” marking in compliance with other applicable EC Directives.

CONTENTS & ABBREVIATIONS

M200–LV M250–LV

CONTENTS

1 CONTENTS

2 FOREWORD

3 ISO SYMBOLS

8 SAFETY

10 GENERAL INFORMATION

20 INSTALLATION / HANDLING

23 OPERATING INSTRUCTIONS

32 AIRCARE WARRANTY

33 MAINTENANCE

36 FAULT FINDING

ABBREVIATIONS & SYMBOLS

#### Contact Ingersoll–Rand for serial number

–>#### Up to Serial No.

####–> From Serial No.

* Not illustrated

{ Option

NR Not required

AR As required

SM Sitemaster/Sitepack

HA High ambient machine

WC Watercooled machine

AC Aircooled machine

ESA European serviced areas

ERS Energy recovery system

T.E.F.C. Totally enclosed fan cooled motor (IP54)

O.D.P. Open drip proof motor (IP23)

ppm parts per million

cs Czech

da Danish

de German

el Greek

en English

es Spanish

et Estonian

fi Finnish

fr French

hu Hungarian

it Italian

lt Lithuanian

lv Latvian, Lettish

mt Maltese

nl Dutch

no Norwegian

pl Polish

pt Portuguese

sk Slovak

sl Slovenian

sv Swedish

zh Chinese

FOREWORD

M200–LV M250–LV

The contents of this manual are considered to be proprietary and

confidential to Ingersoll–Rand and should not be reproduced without

the prior written permission of Ingersoll–Rand.

Nothing contained in this document is intended to extend any

promise, warranty or representation, expressed or implied, regarding

the Ingersoll–Rand products described herein. Any such warranties or

other terms and conditions of sale of products shall be in accordance

with the standard terms and conditions of sale for such products, which

are available upon request.

This manual contains instructions and technical data to cover all

routine operation and scheduled maintenance tasks by operation and

maintenance staff. Major overhauls are outside the scope of this

manual and should be referred to an authorised Ingersoll–Rand service

department.

The design specification of this machine has been certified as

complying with E.C. directives. Any modification to any part is

absolutely prohibited and would result in the CE certification and

marking being rendered invalid.

All components, accessories, pipes and connectors added to the

compressed air system should be:

. of good quality, procured from a reputable manufacturer and,

wherever possible, be of a type approved by Ingersoll–Rand.

. clearly rated for a pressure at least equal to the machine maximum

allowable working pressure.

. compatible with the compressor lubricant/coolant.

. accompanied with instructions for safe installation, operation and

maintenance.

Details of approved equipment are available from Ingersoll–Rand

Service departments.

The use of repair parts other than those included within the

Ingersoll–Rand approved parts list may create hazardous conditions

over which Ingersoll–Rand has no control. Therefore Ingersoll–Rand

cannot be held responsible for equipment in which non–approved

repair parts are installed.

Ingersoll–Rand reserves the right to make changes and

improvements to products without notice and without incurring any

obligation to make such changes or add such improvements to

products sold previously.

The intended uses of this machine are outlined below and examples

of unapproved usage are also given, however Ingersoll–Rand cannot

anticipate every application or work situation that may arise.

IF IN DOUBT CONSULT SUPERVISION.

This machine has been designed and supplied for use only in the

following specified conditions and applications:

. Compression of normal ambient air containing no known or

detectable additional gases, vapours. or particles

. Operation within the ambient temperature range specified in the

GENERAL INFORMATION section of this manual.

No portable communication devices emitting more than 7,5 volts

per metre in the frequency range from 250 MHz to 280 MHz should be

operated within 5 metres of the unit.

The use of the machine in any of the situation types listed in

table 1:–

a) Is not approved by Ingersoll–Rand,

b) May impair the safety of users and other persons, and

c) May prejudice any claims made against Ingersoll–Rand.

TABLE 1

Use of the machine to produce compressed air for:

a) direct human consumption

b) indirect human consumption, without suitable filtration and purity

checks.

Use of the machine outside the ambient temperature range

specified in the GENERAL INFORMATION SECTION of this manual.

Use of the machine where there is any actual or foreseeable risk of

hazardous levels of flammable gases or vapours.

THIS MACHINE IS NOT INTENDED AND MUST NOT BE

USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES,

INCLUDING SITUATIONS WHERE FLAMMABLE GASES OR

VAPOURS MAY BE PRESENT.

Use of the machine fitted with non Ingersoll–Rand approved

components.

Use of the machine with safety or control components missing or

disabled.

The company accepts no responsibility for errors in translation of

this manual from the original English version.

SSR ULTRA COOLANT is a registered trademark of

Ingersoll–Rand Company USA.

INTELLISYS is a registered trademark of Ingersoll–Rand

Company USA.

INGERSOLL–RAND COMPANY

ISO SYMBOLS 3

M200–LV M250–LV

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING – Pressurised vessel. WARNING – Hot surface.

WARNING – Pressure control. WARNING – Corrosion risk. WARNING – Air/gas flow or Air discharge.

X,XBAR

WARNING – Pressurised component or

system.

WARNING – Hot and harmful exhaust gas.

WARNING – Maintain correct tyre pressure.

(Refer to the GENERAL INFORMATION

section of this manual).

0_C

WARNING – Flammable liquid.

WARNING – Before connecting the tow bar

or commencing to tow consult the

operation and maintenance manual.

WARNING – For operating temperature

below 0_C, consult the operation and

maintenance manual.

ISO SYMBOLS4

M200–LV M250–LV

WARNING – Do not undertake any

maintenance on this machine until the

electrical supply is disconnected and the air

pressure is totally relieved.

WARNING – Consult the operation and

maintenance manual before commencing

any maintenance.

Do not breathe the compressed air from this

machine.

Do not remove the Operating and Maintenance

manual and manual holder from this machine.

Do not stack.

Do not operate the machine without the guard

being fitted.

Do not stand on any service valve or other

parts of the pressure system.

Do not operate with the doors or enclosure

open.

Do not use fork lift truck from this side.

km/h

Do not exceed the trailer speed limit. No naked lights.

Do not open the service valve before the

airhose is attached.

Use fork lift truck from this side only. Emergency stop. Tie down point

ISO SYMBOLS 5

M200–LV M250–LV

Lifting point. On (power). Off (power).

Read the Operation and Maintenance manual

before operation or maintenance of this

machine is undertaken.

When parking use prop stand, handrake and

wheel chocks.

Contains asbestos.

SET SEQUENCER STATUS LOAD

SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED)

RESET COMPRESSOR STATUS MODULATE

MALFUNCTION POWER SOILED FILTER

POWER INLET ELECTRIC MOTOR HOURS

ISO SYMBOLS6

M200–LV M250–LV

COOLANT SEPARATOR PRESSURE AIR DISCHARGE

PRESSURISED TANK ON / OFF CYCLE COOLANT FILTER

AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE

AIR PRESSURE STAR DELTA IEC 617–7 AUTOMATIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE

ISO SYMBOLS 7

M200–LV M250–LV

BELT TENSION FILTER MOTOR LUBRICATION

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS ROTATION

POWER INLET (AC) WATER IN WATER OUT

SAFETY

M200–LV M250–LV

WARNINGS

Warnings call attention to instructions which must be followed

precisely to avoid injury or death.

CAUTIONS

Cautions call attention to instructions which must be followed

precisely to avoid damaging the product, process or its surroundings.

NOTES

Notes are used for supplementary information.

General Information

Ensure that the operator reads and understands the decals and

consults the manuals before maintenance or operation.

Ensure that the Operation and Maintenance manual, and the

manual holder, are not removed permanently from the machine.

Ensure that maintenance personnel are adequately trained,

competent and have read the Maintenance Manuals.

Compressed air and electricity can be dangerous. Before

undertaking any work on the compressor, ensure that the electrical

supply has been isolated and the compressor has been relieved of all

pressure.

WARNING

Imposing a normal or emergency stop on the compressor will

only relieve presure upstream of the minimum pressure valve on

top of the separator tank.

If maintenance work is required downstream of this valve, ensure

that all pressure is relieved at the process vent point external to

the compressor

This state is advised by selecting PACKAGE DISCHARGE

PRESSURE on the control panel.

Make sure that all protective covers are in place and that the

canopy/doors are closed during operation.

Installation of this compressor must be in accordance with

recognised electrical codes and any local Health and Safety Codes.

The use of plastic bowls on line filters without metal guards can be

hazardous. Their safety can be affected by either synthetic lubricants,

or the additives used in mineral oils. Metal bowls should be used on a

pressurised system.

Compressed air can be dangerous if incorrectly handled. Before

doing any work on the unit, ensure that all pressure is vented from the

system and that the machine cannot be started accidentally.

Compressed air

Ensure that the machine is operating at the rated pressure and that

the rated pressure is known to all relevant personnel.

All air pressure equipment installed in or connected to the machine

must have safe working pressure ratings of at least the machine rated

pressure.

If more than one compressor is connected to one common

downstream plant, effective check valves and isolation valves must be

fitted and controlled by work procedures, so that one machine cannot

accidentally be pressurised / over pressurised by another.

Compressed air must not be used for a direct feed to any form of

breathing apparatus or mask.

The discharged air contains a very small percentage of compressor

lubricating oil and care should be taken to ensure that downstream

equipment is compatible.

If the discharged air is to be ultimately released into a confined

space, adequate ventilation must be provided.

When using compressed air always use appropriate personal

protective equipment.

All pressure containing parts, especially flexible hoses and their

couplings, must be regularly inspected, be free from defects and be

replaced according to the Manual instructions.

Compressed air can be dangerous if incorrectly handled. Before

doing any work on the unit, ensure that all pressure is vented from the

system and that the machine cannot be started accidentally.

Avoid bodily contact with compressed air.

The safety valve located in the separator tank must be checked

periodically for correct operation.

Materials

The following substances are used in the manufacture of this

machine and may be hazardous to health if used incorrectly:

. preservative grease

. rust preventative

. compressor coolant

AVOID INGESTION, SKIN CONTACT AND INHALATION OF

FUMES

For further information, consult Material Data Sheets ACGP 011/96

(ULTRA COOLANT) and IRACA145 (food grade coolant).

Should compressor lubricant come into contact with the eyes, then

irrigate with water for at least 5 minutes.

Should compressor lubricant come into contact with the skin, then

wash off immediately.

Consult a physician if large amounts of compressor lubricant are

ingested.

Consult a physician if compressor lubricant is inhaled.

Never give fluids or induce vomiting if the patient is unconscious or

having convulsions.

Transport

When loading or transporting machines ensure that the specified

lifting and tie down points are used.

When refitting any enclosure panels or doors, it is essential to

ensure that no persons or equipment remain inside the compressor.

SAFETY

M200–LV M250–LV

Electrical

Keep all parts of the body and any hand–held tools or other

conductive objects, away from exposed live parts of the compressor

electrical system. Maintain dry footing, stand on insulating surfaces

and do not contact any other portion of the compressor when making

adjustments or repairs to exposed live parts of the compressor

electrical system.

Close and lock all access doors when the compressor is left

unattended.

Do not use extinguishers intended for Class A or Class B fires on

electrical fires. Use only extinguishers suitable for class BC or class

ABC fires.

Attempt repairs only in clean, dry, well lighted and ventilated areas.

When refitting any enclosure panels or doors, it is essential to

ensure that no persons or equipment remain inside the compressor.

Connect the compressor only to electrical systems that are

compatible with its electrical characteristics and that are within it’s rated

capacity.

Condensate disposal

Condensate cannot be discharged into fresh/surface water drains.

In some regions compressor condensate containing ULTRA

COOLANT can be fed directly into a drainage system that has

downstream sewerage treatment.

As waste water regulations vary by country and region it is the

responsibility of the user to establish the limitations and regulations in

their particular area. Ingersoll–Rand and its associated distributors are

happy to advise and assist in these matters.

Coolant disposal

Steps to be taken in the case of spillage: Soak up with a suitable

absorbent material, then sweep into a plastic bag for disposal.

Burn in an approved incinerator, or according to local area or

country regulations.

For further information, consult Material Data Sheets ACGP 011/96

(ULTRA COOLANT) and IRACA145 (food grade coolant).

The above information contains data supplied in support of United

Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.)

regulations.

GENERAL INFORMATION

M200–LV M250–LV

LUBRICATION SYSTEM: AIR COOLED MACHINES

KEY

A. LUBRICANT

B. LUBRICANT / AIR

1. COOLER

2. SEPARATOR TANK

3. FILLER PLUG

4. ORIFICE & SCREEN

5. SAFETY VALVES

6. COOLANT STOP VALVE (5SV)

7. COOLANT FILTER

8. THERMOSTATIC VALVE

9. TO DRAIN VALVE

10.THERMISTOR

GENERAL INFORMATION

M200–LV M250–LV

LUBRICATION SYSTEM: WATER COOLED MACHINES

KEY

A. LUBRICANT

B. LUBRICANT / AIR

1. COOLER

2. SEPARATOR TANK

3. FILLER PLUG

4. ORIFICE & SCREEN

5. SAFETY VALVES

6. COOLANT STOP VALVE (5SV)

7. COOLANT FILTER

8. THERMOSTATIC VALVE

9. TO DRAIN VALVE

GENERAL INFORMATION

M200–LV M250–LV

DISCHARGE AIR PIPING: AIR COOLED MACHINES

KEY

A AIR

B. LUBRICANT / AIR

1. AFTERCOOLER

2. SEPARATOR TANK

3. COMPRESSOR

4. CHECK VALVE

5. BLOWDOWN VALVE (3SV)

6. PRESSURE TRANSDUCER

7. MOISTURE SEPARATOR (OPTION)

8. MINIMUM PRESSURE VALVE

9. SAFETY VALVE

10.TO AIR DISCHARGE SOCKET

GENERAL INFORMATION

M200–LV M250–LV

AIR PIPING & WATER PIPING: WATER COOLED MACHINES

KEY

A AIR

B. LUBRICANT / AIR

1. AFTERCOOLER

2. SEPARATOR TANK

3. COMPRESSOR

4. CHECK VALVE

5. BLOWDOWN VALVE (3SV)

6. PRESSURE TRANSDUCER

7. MOISTURE SEPARATOR (OPTION)

8. COOLER

9. MINIMUM PRESSURE VALVE

10.SAFETY VALVE

11.TO WATER DISCHARGE SOCKET

12.FROM WATER INLET SOCKET

13.TO AIR DISCHARGE SOCKET

GENERAL INFORMATION

M200–LV M250–LV

GENERAL OPERATION

The compressor is an electric motor driven, single stage screw

compressor, complete with accessories piped, wired and baseplate

mounted. It is a totally self contained air compressor package.

The standard compressor is designed to operate in an ambient

range of 1,7_C to 46_C. The standard maximum temperature of 46_C

is applicable up to an elevation of 1000m (3280ft) above sea level.

Above this altitude significant reductions in ambient temperature are

required if a standard motor is to be used.

Compression in the screw type air compressor is created by the

meshing of two (male & female) helical rotors.

The air/coolant mixture discharges from the compressor into the

separation system. This system removes all but a few PPM of the

coolant from the discharge air. The coolant is returned to the cooling

system and the air passes to the aftercooler and out of the compressor

through the moisture separator (optional).

Air is pulled into the compressor by the cooling fan and is pushed

through the coolers.

By cooling the discharge air and passing it through the separator,

much of the water vapour which is naturally present in the air, can be

removed.

The coolant system consists of a sump, cooler, thermostatic valve

and a filter. When the unit is operating, the coolant is pressurised and

forced to the compressor bearings.

The compressor load control system is automatic ’On–Off line’. The

compressor will operate to maintain a set discharge line pressure and

is provided with an auto restart system for use in plants where the air

demand varies widely.

Panel instrumentation is provided to indicate the compressor

operating conditions and general status.

The modulation system extends the control types to Modulation

(capacity control) and Automatic Control System when the compressor

switches between ’On–Off line’ and modulation as demand varies.

The electrical components are housed in a readily accessible sheet

metal cabinet.

Safety of operation is provided for as the compressor will shut down

if excessive temperatures, electrical overload conditions, or system

over pressure should occur.

M200AC   M200WC  

PRESSURE 7.5 bar

(L)

8.5 bar

(M)

10.0 bar

(H)

7.5 bar

(L)

8.5 bar

(M)

10.0 bar

(H)

CAPACITY 34.3 m

/min

1211 ft

/min.

32.9 m

/min

1162 ft

/min.

30.2 m

/min

1066 ft

/min.

34.3 m

/min

1211 ft

/min.

32.9 m

/min

1162 ft

/min.

30.2 m

/min

1066 ft

/min.

FULL LOAD CURRENT

(MAXIMUM)

380V

465 433

FULL LOAD CURRENT

(MAXIMUM)

415V

431 407

STARTING CURRENT

(MAXIMUM)

380V

862 862

STARTING CURRENT

(MAXIMUM)

415V

942 942

*NOISE LEVEL

CAGI PNEUROP 1m

84 +/– 3dB(A) 84 +/– 3dB(A)

* Equivalent continuous sound pressure level (workstation) (rated load)

WEIGHT

O.D.P.

3930 kg 4030 kg

WEIGHT

T.E.F.C.

4560 kg 4660 kg

GENERAL INFORMATION

M200–LV M250–LV

M250AC   M250WC  

PRESSURE 7,5 bar

(L)

8,5 bar

(M)

10 bar

(H)

7,5 bar

(L)

8,5 bar

(M)

10 bar

(H)

CAPACITY 43,9 m

/min

1550 ft

/min.

42,5 m

/min

1501 ft

/min.

38,8 m

/min

1370 ft

/min.

43,9 m

/min

1550 ft

/min.

42,5 m

/min

1501 ft

/min.

38,8 m

/min

1370 ft

/min.

FULL LOAD CURRENT

(MAXIMUM)

380V

557 538

FULL LOAD CURRENT

(MAXIMUM)

415V

536 519

STARTING CURRENT

(MAXIMUM)

380V

1020 1020

STARTING CURRENT

(MAXIMUM)

415V

1115 1115

*NOISE LEVEL

CAGI PNEUROP 1m

84 +/– 3dB(A) 84 +/– 3dB(A)

* Equivalent continuous sound pressure level (workstation) (rated load)

WEIGHT

O.D.P.

4680 kg 4780 kg

WEIGHT

T.E.F.C.

5284 kg 5384 kg

GENERAL INFORMATION

M200–LV M250–LV

Revision A

22158653

GENERAL INFORMATION

M200–LV M250–LV

KEY

PE Earth lead, Main terminal

MM Earth lead, motor

SB Earth lead, sub–base

E1 Earth lead, RFI filter

E2 Earth lead, Fan motor

E3 Earth lead, Control transformers

E4 Earth lead, Instrument panel

E5 Earth lead, 5SV

E6 Earth lead, 3SV

E7 Earth lead, PCB1

E8 Earth lead, 0V

FOL Fan motor, Relay, overload

L1 – L3 Mains terminals

MCB1 Miniature circuit breaker, transformer T1 supply

MCB2 Miniature circuit breaker, 110V control circuits

MCB3 Miniature circuit breaker, 24V control circuits

MCB4 Miniature circuit breaker, fan motor

KM1 Main contactor

KM2 Delta contactor

KM3 Star contactor

KM4 Fan contactor

MM Main motor

FM Fan motor

TR Thermistor relay, motor windings

MOL Main motor overload relay

RFI RFI filter

PCB1 Printed circuit board, Power supply unit

HAT–1Switch, high air temperature (discharge air)

ES Emergency stop

SMC Stepper motor controller

SM Stepper motor

5SV Coolant stop valve

3SV Blowdown valve

CON Intellisys controller

3DP Pressure switch (Fouled coolant filter)

3APT Pressure transducer, separator pressure

1AVPTPressure transducer, inlet vacuum

4APT Pressure transducer, package discharge pressure

2ATT Temperature sensor, airend discharge

4ATT Temperature sensor, package discharge

2CTT Temperature sensor, injected coolant

CFO Common fault output

RSP Remote stop

RST Remote start

GENERAL INFORMATION

M200–LV M250–LV

Revision A

22065734

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Ingersoll-Rand M250-LV Operation and Maintenance Manual

Brand: Ingersoll-Rand

Model: M250-LV

Type: Operation and Maintenance Manual

This manual is also suitable for

M200-LV

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Ingersoll-Rand M250-LV Operation and Maintenance Manual

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Ingersoll-Rand M250-LV Operation and Maintenance Manual

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