Ingersoll-Rand M200-LV, M250-LV Operation And Maintenance Manual

SSR M200–LV

M250–LV

OPERATION AND MAINTENANCE MANUAL

This manual contains
important safety information
and must be made available to
personnel who operate and
maintain this machine.

M200 –>2440110

M250 –>

C.C.N. : 22071393 en
REV. : A
DATE : MAY 2004

SERIAL No :

SERIAL No :

2550255

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.

05/04

CONTENTS & ABBREVIATIONS

1

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

M200–LV M250–LV

2

FOREWORD

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.

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 i n 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.

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.

 COPYRIGHT 2004
INGERSOLL–RAND COMPANY

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.

M200–LV M250–LV

ISO SYMBOLS 3

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.

M200–LV M250–LV

ISO SYMBOLS4

WARNING – Do not undertake any

maintenance on this machine until the
electrical supply is disconnected and the air

pressure is totally relieved.

Do not remove the Operating and Maintenance

manual and manual holder from this machine.

Do not stand on any service valve or other

parts of the pressure system.

WARNING – Consult the operation and

maintenance manual before commencing

any maintenance.

Do not stack.

Do not operate with the doors or enclosure

open.

Do not breathe the compressed air from this

machine.

Do not operate the machine without the guard

being fitted.

Do not use fork lift truck from this side.

XX

km/h

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

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

M200–LV M250–LV

Do not open the service valve before the

airhose is attached.

ISO SYMBOLS 5

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

a

Read the Operation and Maintenance manual

before operation or maintenance of this

machine is undertaken.

SET SEQUENCER STATUS LOAD

SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED)

When parking use prop stand, handrake and

wheel chocks.

Contains asbestos.

RESET COMPRESSOR STATUS MODULATE

MALFUNCTION POWER SOILED FILTER

POWER INLET ELECTRIC MOTOR HOURS

M200–LV M250–LV

ISO SYMBOLS6

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 AUTOMA TIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE

M200–LV M250–LV

ISO SYMBOLS 7

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

8

SAFETY

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 af fected 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.

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.

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.

M200–LV M250–LV

SAFETY

9

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.

M200–LV M250–LV

10

GENERAL INFORMATION

AC

LUBRICA TION 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

M200–LV M250–LV