SSR

Ref: Date: Cancels: E7752.01 1st January2001 1st March 1999

M RANGE

Point of Manufacture - Hindley Green Manufacturing Facility, England

SSR M75 - 350 Two Stage DETAILED SPECIFICATION

INLET AIR FILTER Inlet air filtration is accomplished by a large, 99.9% efficiency at 10 micron and above, dry type air cleaner. This is more than suitable for the vast majority of applications. Where high dust and dirt contamination is present, optional filtration systems are available. The INTELLISYS controller will tell the user when the filter is dirty. DRIVE TRAIN Ingersoll-Rand offers a two year unlimited hour warranty (subject to conditions) on drive train components. Our drive train includes a standard high efficiency motor, optimising gears, and our two stage airend. Each component complements the other, giving you the most reliable, rugged and simple form of power transmission ever built. AIREND The airend is a fundamental component in any rotary screw compressor package. Reliability, performance and efficiency are determined, for the most part, by the design, manufacturing tolerances and assembly of the airend itself. All other elements in the compressor system are essentially support and monitoring devices, included to ensure dependable service and performance. The pairs of rotors in the SSR 2-stage compressors fit into a combined airend assembly. Compression is shared between the 1st and 2nd stage, flowing in series, which increases overall compression efficiency up to 22% of the total full load kilowatt consumption. To achieve peak efficiency, our two stage, rotary screw airend uses different Ingersoll-Rand profile rotor sets, because the two compression stages have different objectives. Our first stage rotors utilise a profile for high displacement, and discharge at relatively low pressure. The second stage profile achieves high efficiency compression to final package pressure. The rotors are manufactured from AISI-C-1141 forged steel. The rotor housings are made of close grain, high quality cast iron. After machining, all components are checked dimensionally to ensure accuracy. Air enters the inlet of the 1st stage and is compressed as the male and female high displacement rotors rotate and mesh with each other. To further enhance airend efficiency, coolant is injected into a channel at the 1st stage discharge port. A precisely machined liquid orifice in the channel creates a curtain of coolant in the interstage passage. Air passes through the curtain on its way to the 2nd stage, and through contact cooling, significantly lowers the 2nd stage inlet temperature. This patented process eliminates expensive non-contact cooling devices such as air or water to coolant heat exchangers.

Cooled air from the interstage enters the inlet of the 2nd stage and is compressed by the high efficiency 2nd stage male and female rotors. The compressed air passes through the 2nd stage discharge port, now at desired system pressure, and exits the 2-stage airend through the discharge flange. For a 8.5 barg unit running fully loaded the pressure differential across the 1st stage rotors is 3.1 barg. The delta P across the 2nd stage is 5.5 barg . This significantly extends the bearing life compared to a similarly applied single stage airend. In a single stage air end the pressure differential is 8.5 barg on the area of the rotors. Lower inherent pressure differential across the rotors will reduce blow by losses which is a significant factor in better overall efficiency. DUPLEX TAPERED ROLLER BEARINGS Taper roller bearing configuration is used. The tapered roller bearing essentially consists of constructing the roller elements, as well as the raceways, so that lines coincide with the working surfaces of the rollers and races will all meet at a common point on the axis of the bearings.

SSR
M RANGE
Ref: Date: Cancels: E7752.02 1st January 2001 1st March 1999
Point of Manufacture - Hindley Green Manufacturing Facility, England

SSR M75 - 350 Two Stage DETAILED SPECIFICATION

This allows the bearing to handle all loads, radial, thrust or both. With this bearing configuration, the discharge end of the male and female rotors are each equipped with a pair of tapered roller bearings offset at opposing axis for maximum absorption of thrust and radial loads. High quality cylindrical roller bearings are used to carry the radial loads on the inlet end of the rotors. All bearings, whether thrust or radial, are premium cost which provide a truer, harder running surface for both inner and outer bearing races. Coolant dams are machined at the duplex taper roller bearing locations. The coolant dam provides an area for coolant to collect or pond when the compressor is shut off. Upon start-up, the taper roller bearing, which is resting in the coolant dam, begins to rotate and is immediately lubricated. Airends without coolant dams operate dry for approximately six seconds on start up. THREE GEAR INTEGRAL DRIVE In order to utilise the inherent efficiency advantage of the SSR motor and airend, it was necessary to develop a means of efficiently transmitting power from the drive to the compressor. The integral gear drive system was chosen because it is an efficient, reliable and rugged design. The drive gear (centre) is mounted directly on the motor shaft, and the driven gears are mounted on the shafts of each male rotor, eliminating maintenance prone couplings or belts. The loads generated by the driven gears help offset the load on the drive gear, further enhancing reliability and life. The flanged motor is doweled for permanent alignment to the airend. The use of optimising (AGMA Class 11) gears allow the rotors to rotate at a specific speed, which allows maximum airend efficiency. The gear housing is completely sealed against atmospheric contaminants to insure lifetime trouble free power transmission. A self centering Teflon impregnated motor shaft seal provides a positive system against leakage to the motor windings. The entire assembly is vibration isolated from the package. DEDICATED MOTOR The main drive motor is exactly matched to the requirements of the SSR 2-Stage. Torque and load requirements of the compressor were matched to specific design criteria that enabled the SSR motor to develop peak efficiency and power factor at full load. A. FRAME Motor frame and brackets are fabricated to provide maximum strength and rigidity for bearing support, uniform stator/rotor gap and flanged permanent alignment of all mating parts. B. ELECTRICAL DESIGN Speed, torque and operating characteristics have been designed to match the load of the compressor. Motor efficiency and power factor have been optimised to cover the entire capacity range of the SSR-2-Stage and are all rated at 46 Cambient. C. BEARINGS Ball bearings for the non drive end and roller bearings for the drive end provide dependable and reliable service. Both bearings are grease lubricated with bearing housings having inlet grease nipples to simplify the lubrication process.

SSR
Ref: Date: Cancels: E7752.03 1st January 2001 st 1 March 1999

M RANGE
SSR M75 - 350 Two Stage DETAILED SPECIFICATION

Point of Manufacture - Hindley Green Manufacturing Facility, England

D. INSULATION The SSR motor has class F insulation as standard. That means it is rated at continuous duty for up to a 115C temperature rise. However no SSR motor is ever applied for a temperature rise over 89C, a difference of 26C. The extra conservatism built into every SSR motor means more reliability, increased life, and a much more forgiving motor under adverse conditions. LUBRICATION SYSTEM A. COOLANT FILTRATION Two full capacity coolant filters are 5 micron spin on replaceable elements with pressure bypass. B. COOLANT /LUBRICANT HEAT EXCHANGERS Integrally mounted aircooled heat exchanges are designed for ambient temperatures to 46C. The core, fan and fan motor are all mounted and pre-wired within the compressor package. Watercooled coolers are shell and tube type designed to use fresh cooling water at inlet temperature of upto 46C. C. COOLANT/LUBRICANT TEMPERATURE CONTROL The thermostatic control valve with three ports, (1) for the coolant from the cooler, (2) for the coolant from the pressurised receiver/separator, and (3) for the coolant to the airend, is mounted in the piping system. The temperature sensitive element controls the quantity of coolant from each source, cooled and uncooled, necessary to provide the proper injection temperature and assure fast warm up. Correct coolant temperature is important due to the risk of causing condensate and emulsifying the coolant. D. COOLANT INJECTION Coolant is injected internally to the 1st stage female rotor and the male and female rotors in the 2nd stage. This ensures the best possible pre-sealing of the rotors. Coolant is also sprayed into an interstage coolant curtain to cool the interstage air and improve efficiency.

E. COOLANT/AIR SEPARATION After compression and discharge from the airend, the air heavily laden with coolant travels to the receiver /separator. Entering through a tangential inlet, the air coolant mixture is directed in a circular motion around the inside of the tank. The vortex of circular motion separates a major portion of the coolant from the air through centrifugal force. The air is then directed through baffles, which further reduces the coolant content. The vortex action and baffling results in a pre-cleaning of the compressed air, prior to entering the separator element. The separator element is a moulded fibreglass two stage reinforced separator. On all SSR compressors, the carryover, after the separator element is 5 ppm. Compressed air then enters the watercooled or aircooled aftercooler where the carryover of 5 ppm will be further reduced by the aftercooler and condensate separator to a final carryover figure of 3 ppm. Hence, when calculating coolant makeup for the SSR compressors, always use 3-5 ppm by weight..

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M RANGE
SSR M75 - 350 Two Stage DETAILED SPECIFICATION
COMPRESSOR/CAPACITY CONTROLS On / Off line control: When this operating mode is selected, on line/off line control allows the compressor to operate at 100% full flow at max. operating pressure and the second is 0 % flow (off load). Upon reaching Pmax the compressor will simply unload and go into idle operation. If there is no further air demand, the compressor will shut down at the end of the run-on time, assuming the pre-set minimum motor-running time has expired. The compressor is now in automatic stand-by and will automatically start again to load the system when Pmin is reached. Pmax. and Pmin are adjustable via the INTELLISYS control panel and monitored via the pressure transducer at the discharge flange of the compressor. Auto Control Selection: This Automatic Control Selection (ACS) control mode is one of the most advanced control systems used on air compressors today. From experience one knows that most compressor applications have a varying air flow demand during the day, with wide swings of peak loads at a very unpredictable load pattern. This unique ACS mode has specifically been designed to match exactly the actual air demand in operation. ACS looks at the air demand by monitoring the system pressure via the discharge pressure transducer. During low air demand periods (0 - 60 % compressor capacity) ACS operates the compressor in straight ON/OFF line mode. For higher demands - from 60 - 100 % capacity the machine is then operating in modulation control, where the inlet valve is constantly throttling the flow to match the air demand. This is done by means of an advanced inlet stepper motor arrangement, positioning the inlet valve in direct proportion to the air pressure. Since volume is a function of pressure INTELLISYS monitors the pressures rate of decay or increase. Thus forcing the stepper motor to open up the inlet valve and allow for more inlet air. If the pressure increases indicating less air demand - the stepper motor closes the inlet valve to reduce flow. Overall, the exact inlet valve position is achieved by the stepper motor in 1 increments to maintain almost a constant system pressure. The mode of operation can be selected from the INTELLISYS control panel by the user. If ACS is selected the INTELLISYS controller will automatically select the operating mode which will best fulfil the requirements while maintaining the most efficient operating point. In summary, ACS control provides a constant pressure when the demand is constant. Stepper motor inlet valve.

Ref: Date: Cancels:

E7752.04 1st January 2001 1st March 1999

Point of Manufacture - Hindley Green Manufacturing Facility, England

STARTER BOX The SSR includes a star/delta starter integrally mounted and wired to the compressor package in an IP54 starter box, with a hinged door panel. Incoming line terminals are clearly marked and conveniently located for ease of installation. Overload protection is designed and sized specifically for SSR motor characteristics. A separate breaker and overload relay is mounted and wired in the starter for the fan motor. The main starter and fan motor protection are electrically interlocaked and wired for proper sequencing. As a safety feature all components are shielded by a perspex cover. Contacts for remote common trip alarm and remote start & stop are also included within the starter. The control circuit operates on 110V AC and is protected by circuit breakers.. All electrical equipment is designed as standard to conform to the EN electrical codes: - Electrical installation EN 60204 - Electrical components EN 60947 - Starter box assembly EN 60529 The customer should provide suitable power isolation to the compressor package.

SSR
M RANGE
SSR M75 - 350 Two Stage INTELLISYS DESCRIPTION
Ref: Date: Cancels: E7752.05 1st January 2001 1st March 1999
Point of Manufacture - Hindley Green Manufacturing Facility, England

INGERSOLL-RAND INTELLISYS
6.95 bar
Running Loaded Mode: ON/OFF LINE - CURRENT STATUS Package Discharge Temp. 32 C Airend Discharge Temp. 90 C

MAIN MENU

MICROPROCESSOR INTELLISYS CONTROL The SSR compressor includes a microprocessor based control module which provides for starting, capacity control, operating control, safety control and investment protection of the unit. POWER CONSERVATION SYSTEM The INTELLISYS controller will monitor the compressor's operating cycle and reduce the off load running time to a minimum. Providing the motor has run for more than 8 minutes from start up the run on time can be as low as 2 minutes. This is compared to 10 minutes for a compressor which does not have this feature. The controller will not allow the number of motor starts per hour to be exceeded, 6 starts per hour.

A. ADJUSTABLE OPERATING PARAMETERS Off-line pressure On-line pressure Lead / lag off-set Control mode selection - INTELLISYS control ACS - Modulation only - On-line/off-line Auto start and stop time Stop delay time Load/unload delay time Star Delta transition time Available as options - Remote start and stop - Sequence control - Power outage restart (if PORO kit is fitted) - Power outage restart time

C. OPERATIONAL WARNINGS Change inlet filter Change coolant filter Change separator element High airend discharge temperature High airend discharge pressure Sensor failure 4ATT (Package discharge temperature sensor) SERVICE D. FAULT SHUTDOWNS High airend discharge temperature Low unloaded sump pressure Low loaded sump pressure Starter failure Main motor overload Fan motor overload Control power loss Reverse rotation Inlet control Sensor failure INTELLISYS memory fault Remote start failure (if connected) Remote stop failure (if connected)

B. DISPLAY STANDARDS Package discharge pressure Package discharge air temperature Airend discharge temperature Injection coolant temperature Sump pressure Inlet filter condition Inlet vacuum Coolant filter condition Separator element condition

SSR
M RANGE
Ref: Date: Cancels: E7752.06 1st January 2001 1st March 1999
Point of Manufacture - Hindley Green Manufacturing Facility, England

SSR M75 - 350 Two Stage INTELLISYS DESCRIPTION

INGERSOLL-RAND INTELLISYS
6.95 bar
- CURRENT STATUS Running Loaded Mode: ON/OFF LINE

Package Discharge Temp. 32 C Airend Discharge Temp. 90 C

MAIN MENU

3 5

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INTELLISYS CONTROLLER FACIAL The INTELLISYS facial as shown in the above picture has the following window and display areas; Display screen with three functional areas. 1. Actual status window: This continuously shows the compressor package discharge pressure (4APT). In the line below the actual running condition of the compressor (e.g. loaded, unloaded etc.) is shown and below the present mode of operation is shown. (e.g on/off line or MOD/ACS) 2. Menu location: This area on the right hand side shows various aspects of the machine such as current status, customer setpoints, calibration, alarm, etc. A small arrow in the upper right hand corner indicates when the operator can move through a list of options.

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7. Unload button. This will cause the machine to unload and remain unloaded. The display will indicate the machine is RUNNING UNLOADED and MODE: UNLOAD. 8. Load button. This will cause the compressor to load if the unit is running and if the discharge pressure is less than the on-line pressure. Also it returns the machine to the operating mode that is specified by the mode of operation set point. 9. Stop button. Pressing the stop button will activate the unloaded stop sequence. If the compressor is running loaded, it will unload and continue to run unloaded for an adjustable 10 to 30 seconds and then stop. In case the compressor is already unloaded it will immediately stop.

3. The bottom screen is divided into three areas. Each box- depending on the machine status (status / main menu / select)- will require a selection to move through the program or select menu values. In addition, the following buttons are located on the facial panel. 4. Arrows up/down to select program parameters, adjust specific values or highlight options. These arrows are used in conjunction with the small arrow in the top right hand corner of the display screen. 5. Three function buttons, related to the display screen area, located immediately above each button. 6. Start button. Pressing this button will start the compressor if the display shows READY TO START. The compressor will now start and after the star/delta timer load provided there is sufficient demand for air.

SSR
M RANGE
Ref: E7752.07 Date: 1st January 2001 Cancels: 1st March 19999
Point of Manufacture - Hindley Green Manufacturing Facility, England

SSR M75 - 350 Two Stage INTELLISYS DESCRIPTION

6.95 bar
Running Loaded Mode: ON/OFF LINE

- CURRENT STATUS Package Discharge Temp. 32 C Airend Discharge Temp. 90 C

MAIN MENU
The current Status screen (2) can display the following items with the appropriate values: Discharge temperature 4ATT, measured at the package discharge flange. Airend discharge temperature 2ATT, measured at discharge port of the airend Injection temperature 2CTT, measured prior to coolant injection. Sump pressure, 3APT Separator pressure drop, difference between 4APT and 3APT. Coolant filter delta P Inlet filter condition Total hours Loaded hours % load modulation, option. Software title and version.

6.95 bar
Running Loaded Mode: ON/OFF LINE

- MAIN MENU Operator Setpoints Options Sensor Calibration Alarm History

STATUS

SELECT

From the main menu screen the operator can access the following features. Operator setpoints Options Sensor calibration Alarm history

SETPOINT Off line Online

Setpoints for the following operating parameters are user adjustable (within the compressor limits) by using the the SELECT button to highlight the value and be using the up/down arrow buttons. (4).

Mode of Operation Load delay Time Stop delay time 10 to 30 Star delta time 10 to 20 Sceen contrast 0 to 10 Auto restart On/Off Auto restart 2 to 60 time Remote Start/ On/Off stop

RANGE 5.2 to rated pressure +0.2 barg 4.5 bar to offline pressure -0.7 bar Modulation/ACS, ON/OFF Modulation only 0 to 60

STEP SIZE 0.1bar 0.1bar

1 sec 1 sec 1 sec --------1 min

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SSR
M RANGE
Ref: E7752.08 Date: 1st January 2001 Cancels: 1st March 1999
Point of Manufacture - Hindley Green Manufacturing Facility, England

SSR M75 - 350 Two Stage INTELLISYS DESCRIPTION

In addition to the operator setpoints, the compressor comes with the following parameters already adjusted and preset by the factory. These values cannot be changed by the operator. SETPOINT Language Units of measure Rated pressure Power rating Starter type Total hours Loaded hours ADJUSTED TO any of the EC languages C,F, bar, psi, etc. bar kW Star-Delta, DOL, no starter hours hours The available options can be turned on of off and their associated values are set by using the OPTION screen. Some options require additional machine hardware and the appropriate software module to plug in to the INTELLISYS controller. OPTION Sequencer Power Out Restart RANGE On/off On/off 10 to 120 STEP SIZE ---1 sec

In the event that any operating parameter is approaching the safety limit the INTELLISYS controller will flash on the display the word WARNING with the message which caused the warning. The warning message will allow the operator to take necessary precautions before the compressor actually shuts down. If multiple warnings exist, the small arrow will appear in the upper right hand corner of the display screen. The warning needs to be reset by the operator by pressing the RESET button twice. The possible WARNING messages are as follows: Airend discharge temperature. This will occur if the airend discharge temperature (2ATT) exceeds 97% of the alarm limit (109) e.g. alarm message flashes at 106C. Change coolant filter. The warning will occur if the coolant delta P across the filter element (1DPS) is greater than 1.38 bar and when the coolant injection temperature (2CTT) is greater than 49C. Change inlet filter . When the inlet vacuum (1AVPT) is greater than 0.5 bar and the machine is fully loaded. When unloaded display will show a higher inlet vacuum.

Change separator element. This warning will occur if the pressure on the separator (3APT) is 0.83 bar greater than the pressure at the package discharge (4APT) when the machine is fully loaded. High discharge pressure. This warning message can occur if the compressor loading function is being controlled by a host device (Sequencer). The warning will occur when the package discharge pressure is above the maximum off-line pressure (rated pressure +0.2bar) for more than 3 seconds. The warning will cause the compressor to unload. The host device will not be able to load the compressor until the package discharge pressure falls to the rated pressure of the machine. Sensor failure 4ATT. This will occur if the package discharge temperature sensor (4ATT) is faulty for any reason such as a loose wire. SERVICE.. This warning will occur every 2000 hours or a set number of months. If the operator presses reset twice the warning will go away. But if the machine is not serviced the warning will re-appear 24hrs later. The Ingersoll-Rand authorised service technician will be able to reset the warning once the routine service has been completed. (To be introduced. Not included on early controllers)

SSR
M RANGE
Ref: E7752.09 Date: 1st January 2001 Cancels: 1st March 1999
Point of Manufacture - Hindley Green Manufacturing Facility, England

SSR M75 - 350 Two Stage INTELLISYS DESCRIPTION

In the event than any operating parameter of the compressor package has exceeded its preset limit the INTELLISYS controller will flash an alarm message in the display screen and will stop the compressor. The alarm message needs to be reset by the operator by pressing RESET twice. High airend discharge temperature (109C) Check inlet control (inlet vacuum <0.2 bar) Check inlet control system (when the inlet butterfly valve is in the incorrect position) Check motor rotation (at start, when the motor is incorrectly rotating) Control power loss (if the 110VAC control power is lost) If the power drops below -15% of nominal voltage this alarm could shut the machine down. Emergency stop (if the emergency stop button is engaged) Fan motor overload Main motor overload

Low sump air pressure (if the sump pressure is <1.4 barg when fully loaded for at least 8 seconds) Low unload sump pressure (when the machine is running unloaded and the sump pressure is less than 1.03 barg for more than 15 secs) Memory fault (controller determined memory contains unacceptable values) Remote start failure Remote stop failure Sensor failure (if 1AVPT, 3APT, 4APT, 2CTT or 2ATT is missing of broken) Start fault (if contactors fail to transition correctly) Stepper limit switch (if both switches are activated at the same time) Invalid calibration (1AVPT, 3APT or 4APT sensors exceed 10% of range)

As a service feature, the INTELLISYS offers as standard the display of the last 15 alarms experienced by the compressor. It also gives access to displaying the machines operating conditions that existed at the time of each alarm. Each of the 15 alarm messages can be seen by moving the alarm history list up and down by using the arrow buttons. In addition to the INTELLISYS safety devices the compressor has the following mechanical safety devices. Discharge pressure relief valve High air temperature switch.