Ingersoll-Rand M200-LV Operation And Maintenance Manual
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Ingersoll-Rand M200-LV Operation And Maintenance Manual

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This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.
SSR M200–LV
M250–LV
OPERATION AND MAINTENANCE MANUAL
M200
M250
C.C.N. : 22071393 en
REV.
DATE
SERIAL No :
2440110
SERIAL No :
2550255
: A
: MAY 2004
–>
–>

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  • Page 1 SSR M200–LV M250–LV OPERATION AND MAINTENANCE MANUAL M200 SERIAL No : 2440110 –> This manual contains important safety information SERIAL No : M250 2550255 –> and must be made available to personnel who operate and maintain this machine. C.C.N. : 22071393 en REV.
  • Page 2 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.
  • Page 3 CONTENTS & ABBREVIATIONS ABBREVIATIONS & SYMBOLS CONTENTS #### Contact Ingersoll–Rand for serial number CONTENTS –>#### Up to Serial No. ####–> From Serial No. FOREWORD Not illustrated Option ISO SYMBOLS Not required As required Sitemaster/Sitepack SAFETY High ambient machine Watercooled machine GENERAL INFORMATION Aircooled machine European serviced areas...
  • Page 4 FOREWORD TABLE 1 The contents of this manual are considered to be proprietary and confidential to Ingersoll–Rand and should not be reproduced without Use of the machine to produce compressed air for: the prior written permission of Ingersoll–Rand. a) direct human consumption b) indirect human consumption, without suitable filtration and purity checks.
  • Page 5 ISO SYMBOLS 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. WARNING –...
  • Page 6 ISO SYMBOLS WARNING – Do not undertake any WARNING – Consult the operation and maintenance on this machine until the Do not breathe the compressed air from this maintenance manual before commencing electrical supply is disconnected and the air machine. any maintenance.
  • Page 7 ISO SYMBOLS Lifting point. On (power). Off (power). Read the Operation and Maintenance manual When parking use prop stand, handrake and Contains asbestos. before operation or maintenance of this wheel chocks. machine is undertaken. SEQUENCER STATUS LOAD SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED) RESET...
  • Page 8 ISO SYMBOLS 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...
  • Page 9 ISO SYMBOLS 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 M200–LV M250–LV...
  • Page 10 SAFETY The discharged air contains a very small percentage of compressor WARNINGS lubricating oil and care should be taken to ensure that downstream Warnings call attention to instructions which must be followed equipment is compatible. precisely to avoid injury or death. CAUTIONS If the discharged air is to be ultimately released into a confined Cautions call attention to instructions which must be followed...
  • Page 11 SAFETY Electrical Coolant disposal Keep all parts of the body and any hand–held tools or other Steps to be taken in the case of spillage: Soak up with a suitable conductive objects, away from exposed live parts of the compressor absorbent material, then sweep into a plastic bag for disposal.

  • Page 12: General Information

    GENERAL INFORMATION LUBRICATION SYSTEM: AIR COOLED MACHINES A. LUBRICANT 5. SAFETY VALVES B. LUBRICANT / AIR 6. COOLANT STOP VALVE (5SV) 1. COOLER 7. COOLANT FILTER 2. SEPARATOR TANK 8. THERMOSTATIC VALVE 3. FILLER PLUG 9. TO DRAIN VALVE 4. ORIFICE & SCREEN 10.THERMISTOR M200–LV M250–LV...
  • Page 13 GENERAL INFORMATION LUBRICATION SYSTEM: WATER COOLED MACHINES A. LUBRICANT 5. SAFETY VALVES B. LUBRICANT / AIR 6. COOLANT STOP VALVE (5SV) 1. COOLER 7. COOLANT FILTER 2. SEPARATOR TANK 8. THERMOSTATIC VALVE 3. FILLER PLUG 9. TO DRAIN VALVE 4. ORIFICE & SCREEN M200–LV M250–LV...
  • Page 14 GENERAL INFORMATION DISCHARGE AIR PIPING: AIR COOLED MACHINES A AIR 5. BLOWDOWN VALVE (3SV) B. LUBRICANT / AIR 6. PRESSURE TRANSDUCER 1. AFTERCOOLER 7. MOISTURE SEPARATOR (OPTION) 2. SEPARATOR TANK 8. MINIMUM PRESSURE VALVE 3. COMPRESSOR 9. SAFETY VALVE 4. CHECK VALVE 10.TO AIR DISCHARGE SOCKET M200–LV M250–LV...
  • Page 15 GENERAL INFORMATION AIR PIPING & WATER PIPING: WATER COOLED MACHINES A AIR 7. MOISTURE SEPARATOR (OPTION) B. LUBRICANT / AIR 8. COOLER 1. AFTERCOOLER 9. MINIMUM PRESSURE VALVE 2. SEPARATOR TANK 10.SAFETY VALVE 3. COMPRESSOR 11.TO WATER DISCHARGE SOCKET 4. CHECK VALVE 12.FROM WATER INLET SOCKET 5.
  • Page 16 GENERAL INFORMATION GENERAL OPERATION The coolant system consists of a sump, cooler, thermostatic valve and a filter. When the unit is operating, the coolant is pressurised and The compressor is an electric motor driven, single stage screw forced to the compressor bearings. compressor, complete with accessories piped, wired and baseplate mounted.
  • Page 17 GENERAL INFORMATION M250AC l D M250WC l D PRESSURE 7,5 bar 8,5 bar 10 bar 7,5 bar 8,5 bar 10 bar CAPACITY 43,9 m /min 42,5 m /min 38,8 m /min 43,9 m /min 42,5 m /min 38,8 m /min 1550 ft /min.
  • Page 18 GENERAL INFORMATION 22158653 Revision A M200–LV M250–LV...
  • Page 19 GENERAL INFORMATION Earth lead, Main terminal Fan motor Earth lead, motor Thermistor relay, motor windings Earth lead, sub–base MOL Main motor overload relay Earth lead, RFI filter RFI filter Earth lead, Fan motor PCB1 Printed circuit board, Power supply unit Earth lead, Control transformers HAT–1Switch, high air temperature (discharge air) Earth lead, Instrument panel...
  • Page 20 GENERAL INFORMATION 22065734 Revision A M200–LV M250–LV...
  • Page 21 GENERAL INFORMATION Earth lead, Main terminal Thermistor relay, motor windings Earth lead, motor MOL Main motor overload relay Earth lead, sub–base RFI filter Earth lead, RFI filter PCB1 Printed circuit board, Power supply unit Earth lead, Fan motor HAT–1Switch, high air temperature (discharge air) Earth lead, Control transformers Emergency stop Earth lead, Instrument panel...
  • Page 22 INSTALLATION / HANDLING LOCATION IN THE PLANT The compressor can be installed on any level floor capable of supporting it. A dry, well ventilated area where the atmosphere is as Electrical cable entry clean as possible is recommended. ” BSPP Condensate drain Sufficient space all round and above the compressor must be C 3”...
  • Page 23 INSTALLATION / HANDLING NOTE After the machine has been sited, remove the four transportation 1. Compressor bolts and spacers which are marked with fluorescent tags. Two are situated on the airend support and the other two on the motor support. 2.
  • Page 24 INSTALLATION / HANDLING Cooling Water Analyses Chart Minimum cooling water requirement at ambient temperatures, in litres per minute (UK gallons per minute) Model Range 50_F / 10_C 70_F / 21_C 90_F / 32_C Substances Test interval Acceptable M200 91(20) 110(24) 180(40) concentration M250...

  • Page 25: Operating Instructions

    OPERATING INSTRUCTIONS INTELLISYS CONTROLS 5. LOAD 1. EMERGENCY STOP Pressing this button will cause the compressor to load if the compressor is running and if the DISCHARGE PRESSURE is less Pressing this switch stops the compressor immediately. The than the ONLINE PRESSURE. This also returns the machine to the compressor can not be restarted until the switch is manually reset.
  • Page 26 OPERATING INSTRUCTIONS barg barg –CURRENT STATUS– PACKAGE DISCHARGE TEMP 39_C RUNNING LOADED AIREND DISCHARGE TEMP MODE: MOD/ACS 89_C MAIN MENU DISPLAY SCREEN The display screen is divided into three functional areas, as seen in the typical CURRENT STATUS screen shown here. The left side continuously shows the package discharge pressure in large numbers showing the running condition of the machine and the line below that showing the present mode of operation.
  • Page 27 OPERATING INSTRUCTIONS CURRENT STATUS MAIN MENU OPERATOR OPTIONS SENSOR ALARM HISTORY SETPOINTS CALIBRATION OPERATOR OPTIONS ITEM SENSOR ALARM HISTORY SETPOINTS ITEM CALIBRATION ITEM ITEM The controller automatically returns the display to this CURRENT (3) The UP and DOWN arrows will alter the value. STATUS screen from other screens if no buttons are pressed within 30 Depressing “Cancel”...
  • Page 28 OPERATING INSTRUCTIONS MAIN MENU OPERATOR RANGE STEP UNIT SETPOINTS The MAIN MENU screen is the point from which various operator functions can be accessed. Refer to the Operator Panel Flow Diagram. Offline Pressure 75 to RATED +3 PSIG Online Pressure 65 to OFFLINE PSIG –...
  • Page 29 OPERATING INSTRUCTIONS OPTIONS OPTIONS Range Step Unit Items Options are turned on or off and their associated values are set using the OPTION screen. Power Out ON/OFF – – Restart Power Out 10 to 120 Some options require additional machine hardware and the correct Restart Time “Option Module”...
  • Page 30 OPERATING INSTRUCTIONS –ALARM HISTORY– barg barg ALARM HISTORY 1 MAIN MOTOR OVERLOAD READY TO START ALARM HISTORY 2 HIGH AIREND DISCH TEMP STATUS MAIN MENU SELECT ALARM HISTORY Each of the last 15 Alarm messages can be seen by moving the Alarm History list up and down using the arrow buttons.
  • Page 31 OPERATING INSTRUCTIONS –CURRENT STATUS– barg barg PACKAGE DISCHARGE TEMP 39,4_C RUNNING UNLOADED AIREND DISCHARGE TEMP MODE: MOD/ACS 89,4_C WARNING MAIN MENU Pressing the WARNING button will return the display to the CHANGE COOLANT FILTER – This warning will occur if the high side WARNING screen and the RESET button.
  • Page 32 OPERATING INSTRUCTIONS CHECK INLET CTRL SYS – This will occur if the inlet butterfly valve MAIN MOTOR OVERLOAD– This will occur if a drive motor overload is in an incorrect position. is sensed. CHECK MOTOR ROTATION – This will occur if the machine is started MEMORY FAULT–...
  • Page 33 OPERATING INSTRUCTIONS STARTING THE MACHINE RE–STARTING AFTER AN EMERGENCY Refer to the diagram T5443 If the unit has been switched off because of a machine malfunction, then identify and correct the fault before attempting to re–start. Upon power up, the Intellisys will carry out a series of checks, and If the unit has been switched off for reasons of safety, then ensure the message CHECKING MACHINE will show on the display.
  • Page 34 AIRCARE WARRANTY Superior Service Solutions for Air Systems AirCare is a responsive and flexible contract maintenance program custom designed for the owner who requires planned maintenance for increased system reliability. The AirCare program provides you with reduced maintenance costs, reduced energy usage through optimization and efficiency, and reduced produc- tion losses through fewer unexpected maintenance requirements and downtime.
  • Page 35 MAINTENANCE PERIOD MAINTENANCE PERIOD MAINTENANCE After 24 hours Visual check of machine for any leaks, dust 2000 hours / 6 Take coolant sample for fluid analysis. build up or unusual noise/vibration. months Contact IR authorised distributor if in doubt. 2000 hours / 6 Check scavenge screen for blockage, clean Daily Check the coolant level and replenish if...
  • Page 36 MAINTENANCE ROUTINE MAINTENANCE all panels are replaced, canopy and doors closed. This section refers to the various components which require periodic maintenance and replacement. hazardous materials are effectively contained and disposed of. The SERVICE/MAINTENANCE CHART indicates the various WARNING components’ descriptions and the intervals when maintenance has to Do not under any circumstances open any drain valve or remove take place.
  • Page 37 MAINTENANCE Start the compressor and check for leaks. MOTOR BEARINGS Clean the area around the grease nipple and remove the protective cover. Add the correct amount of grease (refer to the Check the coolant level, refilling if necessary. SERVICE/MAINTENANCE CHART earlier in this section). Replace the protective cover and clean the area of surplus grease.

  • Page 38: Fault Finding

    FAULT FINDING FAULT CAUSE REMEDY ’Power on’. L.E.D. does CONTROL VOLTAGE NOT Check the control fuses. not illuminate. AVAILABLE Check the transformer secondary windings for the control voltage. Controller indicates trip CONTROL CIRCUIT Check machine for indicated fault. Attempt to ’reset’ the controller. If the fault condition.

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M250-lv

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