Ingersoll-Rand M200-LV Operation And Maintenance Manual Download Page 10

SAFETY

8

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.

Summary of Contents for M200-LV

Page 1: ...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 D...

Page 2: ...NGERSOLL 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 DEC...

Page 3: ...ion 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 enc...

Page 4: ...e 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...

Page 5: ...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 s...

Page 6: ...o 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...

Page 7: ...re 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 L...

Page 8: ...ISED 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...

Page 9: ...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...

Page 10: ...ected 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 downstreamplant effective check valves and is...

Page 11: ...re compatiblewith 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...

Page 12: ...C 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 THERMOSTAT...

Page 13: ...0 LV WC 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 TH...

Page 14: ...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 PRES...

Page 15: ...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 V...

Page 16: ...tic 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 opera...

Page 17: ...43 9 m3 min 1550 ft3 min 42 5 m3 min 1501 ft3 min 38 8 m3 min 1370 ft3 min FULL LOAD CURRENT MAXIMUM 380V 557 538 FULL LOAD CURRENT MAXIMUM 415V 536 519 STARTING CURRENT MAXIMUM 380V 1020 1020 STARTIN...

Page 18: ...GENERAL INFORMATION 16 M200 LV M250 LV Revision A 22158653 AC...

Page 19: ...in 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 bo...

Page 20: ...GENERAL INFORMATION 18 M200 LV M250 LV Revision A 22065734 WC...

Page 21: ...2 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 suppl...

Page 22: ...of the compressor are slots to enable a fork lift truck 5 ton minimum to move the machine Alternatively a special lifting frame can be supplied to enable a crane or hoist to move the compressor LOCATI...

Page 23: ...olts and spacers which are marked with fluorescent tags Two are situated on the airend support and the other two on the motor support ELECTRICAL DATA An independent electrical isolator should be insta...

Page 24: ...ally with damage to the system Scale Scale formation inhibits effective heat transfer yet it does help prevent corrosion Therefore a thin uniform coating of calcium carbonate is desired on the inner s...

Page 25: ...ESSURE is less than the ONLINE PRESSURE This also returns the machine to the operating mode that is specified by the MODE OF OPERATION set point The other five buttons provide access to various operat...

Page 26: ...ighted This means that they are displayed as light characters on a dark background barg CURRENT STATUS 7 5 barg PACKAGE DISCHARGE TEMP 39_C RUNNING LOADED AIREND DISCHARGE TEMP MODE MOD ACS 89_C MAIN...

Page 27: ...tions Items will be highlighted in inverse display mode 1 Selecting the highlighted item will display the corresponding menu 2 Selecting the highlighted item will place the value in edit mode This is...

Page 28: ...SEC Screen Contrast 0 to 10 1 Does not apply to automatic across the line starters OPERATOR SETPOINTS barg 7 5 barg OFFLINE PRESSURE 7 6 barg READY TO START ONLINE PRESSURE 6 9 barg STATUS MAIN MENU S...

Page 29: ...ENSOR 1AVPT CALIBRATE READY TO START SENSOR 3APT CALIBRATE STATUS MAIN MENU SELECT SENSOR CALIBRATION Pressure sensor calibration is done through the SENSOR CALIBRATION screen Sensor calibration can o...

Page 30: ...and value of each of the items listed below can be seen by moving the list up and down using the arrow buttons Pressing the ALARM HIST button will return the display to the ALARM HISTORY screen ALARM...

Page 31: ...a sequencer or an ISC This warning will occur when the package discharge pressure is above the maximum offline pressure rated pressure plus 3 psig 0 2 bar for more than 3 seconds This warning will ca...

Page 32: ...ontains unacceptable values When this occurs the sensors should be calibrated and all the set points checked It is normal for this alarm to occur after changing controller software REMOTE START FAILUR...

Page 33: ...itch STOPPING THE MACHINE IN AN EMERGENCY Refer to the diagram T5443 If the machine has to be stopped in an emergency DEPRESS THE EMERGENCY STOP BUTTON 1 LOCATED ON THE INSTRUMENT PANEL This will over...

Page 34: ...ough optimization and efficiency and reduced produc tion losses through fewer unexpected maintenance requirements and downtime An optional feature Intelliguard is used to reduce downtime by remote mon...

Page 35: ...r 1000 hours or as defined by local or national legislation Separator tank Fully inspect all external surfaces welds and fittings Report any excessive corrosion mechanical or impact damage leakage or...

Page 36: ...signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen Upon completion of maintenance tasks and prior to returning the machine into service ensure that...

Page 37: ...ny form of sealant on either the separator tank or the separator tank cover faces WARNING Do not remove the staple from the anti static gasket on the separator element since it serves to ground any po...

Page 38: ...shows OVERPRESSURE BLOWDOWN SYSTEM Check the operation of the load solenoid OVERPRESSURE INEFFECTIVE Check the operation of the unloader valve strip and clean if necessary Compressor will not DEMAND...

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