Rotary Compressors

1 Aftermarket Training April 2015

Contact-Cooled Rotary Compressors 2006
Our Portfolio…
• Fixed Speed Compressors
– Applications
Industrial Manufacturing
Most Environments
– Models
Single Stage and Two Stage from
5.5kW to 350kW
• Variable Speed Compressors
– Applications
Not to be installed outdoors
Must be in “clean” environments
Premium Efficiency
– Models
Single Stage and Two Stage from
5.5kW to 250kW
2 Aftermarket Training April 2015
 Major Rotary
Parts

3 Aftermarket Training April 2015

Major Parts of a Compressor
From compressing to cooling to controlling

Nirvana Drive Train

Airend
Induction Motor

Controller

Air/Oil Coolers
Starter Panel

4 Aftermarket Training April 2015

Airends
The heart of the machine
• Cast iron housing containing rotors, bearings,
seals and gaskets
• Made in several sizes to meet various power,
volume and pressure requirements
• Two Type of Contact Cooled Airends
– Single-Stage
– Two-Stage

5 Aftermarket Training April 2015

Airends
How air is compressed?
• Air enters the Airend at atmospheric pressure
and is compressed to a higher pressure with the
addition of coolant
• Compression takes place when air is trapped
between the rotor lobes and the housing

6 Aftermarket Training April 2015

Airend 2 Stage - Contact Cooled
Features of 2 Stages Airend
• Advantages
– Specific Power
– Extended Bearing Life
– Overall Efficiency
– Has two pairs of rotors within a common housing
• Coolant Curtain – Unique Ingersoll Rand
feature
– Injecting atomized oil into compressed air stream leaving
first stage of compression
– Lowers air temperature prior to entering second stage
– Significantly lowers energy required for compression
– Eliminates the need for an intercooler
7 Aftermarket Training April 2015
What can we offer…
Contact-Cooled Rotary Airend Rebuild Kit
• Airend bearings have a
limited life and should be
closely monitored after
25,000 hours
• SPM is a good diagnostic
tool to determine the
bearing condition
• Field re-bearing using Airend
Rebuild Kits provides an
affordable customer option

8 Aftermarket Training April 2015

What can we offer…
Contact-Cooled Rotary Airend Rebuild Kit
• Alternative to costly new machine or
remanufactured airends
– Cost of rebuild kit is a fraction of a new machine
– Warranty on Airend rebuild kit is 6 months with the
use of Ultra Coolant or Ultra EL
– Must be performed by accredited technicians
• When to sell?
– Re-bearing Preventive maintenance program
– Suitable for failures restricted to bearing damage
– For “No Budget” customers

9 Aftermarket Training April 2015

What can we offer…
Remanufactured Airends
• As airend gets older, wear and tear means deteriorating
efficiency and eventual possible airend failures
• Factory Remanufactured Airends provides an excellent
Overhaul option
• Cost efficient alternative for an airend replacement while
providing competitive service to our Distributors and
Customers
– Cost of Remanufactured Airend is about 20% to 25% of a new
machine
– Warranty on Remanufactured Airend is 1 year with Ultra Coolant
or Ultra EL
• When to sell?
– Major overhauls for old machines
– Preventive maintenance
– Replacement for failed airends

10 Aftermarket Training April 2015

What can we offer…
New Airends
• As airend gets older, wear and tear means deteriorating
efficiency and eventual possible airend failures
• New Airends provides the premium solution to a failed
airend
– Cost of New Airend is about 30-35% of a new machine
– Warranty on Remanufactured Airend is 1 year with Ultra Coolant
or Ultra EL
• When to sell?
– Major overhauls for old machines
– Preventive maintenance
– Replacement for failed airends

11 Aftermarket Training April 2015

Motors
Electrical driven device that turns the airend
• Main Drive Motor
– Connects to the male rotor of the airend using direct
coupling or integral gears
• Types of Motors
– ODP-Open Drip Proof
– TEFC-Totally Enclosed Fan Cooled
– Hybrid – Permanent Magnet (HPM)
Drive train use in VSD compressors
Rotor & stator can be purchased separately

12 Aftermarket Training April 2015

Coolers
Removes heat from air and coolant
• Two styles of coolers
Air Cooled
• Panel, radiator type
• For Air-cooled machines
• Air and Oil Combo
• Cooler only
Replace as a whole
13 Aftermarket Training April 2015
Water Cooled
• Tube Bundle type
• For Water-cooled machines
• Cooler + gaskets/o-rings +
tube bundle
Replace bonnets, gaskets, o-
rings and the tube bundles
Coolers - Types
Types of coolers in the machine
• Intercooler
– Cools the air from the output of the first
stage before entering the second stage
• Aftercooler
– Cools the air from the discharge of the final
stage prior to exiting the compressor
• Oil Cooler
– Cools the compressor lubricant prior to
injecting into the Airend

14 Aftermarket Training April 2015

Starters
Starting the compressors…
• An electrically operated switch that uses magnetic
induction to provide the startup current for a motor
– Protects the motor from overheating
• Three Types of starters available :
1. Full Voltage - across the line starter
2. Star Delta (WYE delta) Starter
3. Solid State or Soft Start

15 Aftermarket Training April 2015

Starters
Full Voltage
• Starting current will be
500 to 800% of the full
load current
• Snap start and a huge
power spike
• Apply full line voltage
through only one set of
contacts to the motor for
starting purposes

16 Aftermarket Training April 2015

Starters
Star-Delta
• Uses three contactors
to even out the
current load through
transition
• Once at speed, full
voltage is applied
• Replaceable parts
include; contactors,
relays, aux contacts
and kits
17 Aftermarket Training April 2015
Onboard Controllers
What is Intellisys?
• The Intellisys control system is an exclusive
Ingersoll-Rand design developed for
reliable compressor control and
monitoring of operation
• The microprocessor based system utilizes
a finger touch membrane panel for all
compressor control functions to include
operating parameter settings and display
information

18 Aftermarket Training April 2015

Onboard Controllers
What type of Intellisys?
• Evolution of Intellisys over the years :
– 1st Generation or “Redeye”
Retrofit kit available to convert to SG. Refer to Services Program
Book
– SE Controller
– SG Controller
– “SGN” or “SGNe” Exclusively for Nirvana machines only
– SGV and SGNeV for R-Series 90kW to 160kW from launch
till March 2012
Retrofit kit CCN 24061293 available to convert to Xe Series
– Xe Series – R-Series
55-75kW - since inception, Oct 2011
90-160kW – began March 2012
More details will be covered in subsequent topics
19 Aftermarket Training April 2015
 Contact Cooled
Spare Parts

20 Aftermarket Training April 2015

Spare Parts on Rotary Compressor
Consumables and Wearables
• Consumables
Items that are changed on defined regular basis
Lubricant, filter elements, separator elements
• Wearables
Items that are changed on a less defined regular basis
– LONG TERM (3-5 Years after machine has been
purchased)
Valves, rings, bearings, seals, hoses, belts

21 Aftermarket Training April 2015

Consumables
Air Filter Element
• Standard 3 micron element @ 99%
efficiency
– Clean air prior to entering the Airend
– Extend the Airend life
– Extend the Separator Element life
• High Dust Filtration Option
– Used in sites that have high dust and
dirt contamination
– Same rating as standard filters;
however, they can carry much more
dust, having a higher dust holding
capacity

22 Aftermarket Training April 2015

 Consumables
High Dust Filtration Field Install Kit
• Single CCN covering each kit of parts, making
product identification and ordering much easier
– Each kit includes all necessary components to carry out a field
installation, including installation documentation
Hose
High-Dust Elements - Elements -
Filters (Only)
Family Description Filter Kit Primary Secondary
CCN Kit
CCN CCN CCN
CCN
50 HP – 100 HP 42452722 39844113 39207964 39207972 N/A
Serial Numbers: 50-100 HP
CA & CK only
125-200 HP 1 Stg Air 42426569 39814926 39322201 35123520 N/A
Cooled
100-200 HP 2 Stg Air 42426577 39814926 39322201 35123520 N/A
Cooled
125-200 HP 1 Stg Water 42426585 39814926 39322201 35123520 N/A
125-200 HP SSR Cooled
100-200 HP 2 Stg Water 42426593 39814926 39322201 35123520 N/A
Cooled
IRN 125-200H 42542753 22100895 22100903 22100911 N/A
IRN 125-200HP-OF A/C 42565952 22100895 22100903 22100911 N/A

You can find more models in Services Program Book!

23 Aftermarket Training April 2015

Consumables
New R-Series Air Filtration System

• More than 20% larger surface

area over our premium
Nirvana air filter today.
• R – Series Air Filters have
GREEN LINE - CURRENT higher dust holding capacity.
Nirvana Premium Air Filter
BLUE LINE - NEW R-Series
• Pleat stability incorporated
Air Filters into filter for longer life.
• Metal free eco-friendly
design.

24 Aftermarket Training April 2015

Consumables
New R-Series Coolant Filtration System
• New highest efficiency media
technology
• 99.5% efficient at 10 micron and 95%
efficient filtration at 5 micron
• Cleaner lubricant increases reliability
of all system components
• 4000 hour interval change-out (twice
the life of previous oil filter element
• Eco- friendly non- metallic disposal
element
• Ingersoll Rand exclusive element with
globally patented design

25 Aftermarket Training April 2015

Consumables
Captures 20x more particles at 10 micron

Standard
SPIN ON
Filter

R-Series 20x
Cleaner

For every 100,000 particles, R-Series prevents fewer downstream!

26 Aftermarket Training April 2015

Consumables
Coolant Separator Element
• Moulded fibreglass two stage
reinforced element
– Outer layer is of a fine medium (0.5
micron) designed to remove debris and
contamination from the compressed air
as it passes through the element
– Inner layer is of a coarse medium (25
micron) and is designed to cause any
coolant vapour which passes through the
element to coalesce and drain to the
bottom of the element
Separator element life varies depending on the
coolant condition and site conditions, typical life will
vary between 4,000 - 8,000 hours

27 Aftermarket Training April 2015

Consumables
New R-Series Separator Element..Easiest to
replace!
• Swing out separator lid on all fixed
speed machines.
– No more heavy lifting!
• New formed ring separator element
put the seal on the element and not
the tank.
– No more scraping gaskets!
• Element size significantly larger than
current.
• 8000 hour separator element rating
from better overall system filtration –
not just the element.

28 Aftermarket Training April 2015

 Wearables Parts
Repair Kits for Wearable Parts
• We have Repair Kits for some of the wearable parts on
the machine
Determine CCN of
the Part and its
corresponding Repair
Kit
Check machine model

Blow- Blow- Min

50 to 100 HP (“CA” Oil Stop Oil Stop
down down Pressure
or “CK” serial Repair Kit Repair Kit Valve Repair Kit Valve Repair Kit
Valve Valve Check
number) (NEMA 1) (NEMA 4)
(NEMA 1) (NEMA 4) Valve
XFE/EPE/HPE 50 39136932 22124085 39479563 22124085 42552836 39170204 42552836 54750369 37956075

XF/EP/HP 60 39136932 22124085 39479563 22124085 42552687 39165949 42550293 54750379 37956075

XF/EP/HP/XP 75 42535922 39123070 22870190 39123070 42552687 39165949 42550293 54750379 37956075

XF/EP/HP/XP 100 42535922 39123070 22870190 39123070 42552687 39165949 42550293 54750379 37954971

Check Services Program Book for other kits!

29 Aftermarket Training April 2015
Oil Free Rotary

30 Aftermarket Training April 2015

Current Production Machines
Our Portfolio…
• Current Production Models
– Fixed Speed
Sierra (37-150kW)
– CD8 & CD14
Sierra (200-300kW)
– CD26
Applications
– Pharmaceuticals, Food and Beverage applications, power
generation, Textiles, oil and gas
– Variable Speed
Nirvana Oil Free (37kW-160kW)
Applications
– Not for outdoors
– Requires Clean environment
– No high pressure units

31 Aftermarket Training April 2015

 Major Sierra
Components

32 Aftermarket Training April 2015

Major Components of Sierra
The workhorse of a Sierra machine…
• Compression Module
– CD8 (37-75kW), CD14 (90-150kW), CD26 (200-
300kW)
• Low Pressure & High Pressure Airends
• Main Drive Motor
• Air cooled and Water cooled Coolers
– Inter cooler, After cooler, Oil Cooler
• Starters

All Sierra are Fixed Speed machines but can be made variable by adding
Aftermarket Bolt-On VFD. However, not all models are approved. Please check
with Engineering on applicability first!

33 Aftermarket Training April 2015

Major Components of Sierra
Compression Module
• Cast iron housing containing Rotors, Bearings to
support the Rotors, Seals and Gaskets
• Two Stages
• Positive Displacement Compression
• Oil Free
• Shaft driven Oil Pump
• Airends are made in several sizes to meet various
power, volume and pressure requirements
– Two Types
Low Pressure 1st stage takes ambient air and compress it
to 20-40psi
High Pressure 2nd stage compress air to the final delivery
pressure
34 Aftermarket Training April 2015
Major Components of Sierra
Compression Module Replacement

• Remanufactured and new airends

• Individual stages or complete module
• Field rebuild kits not available

35 Aftermarket Training April 2015

Major Components of Sierra
Motors – Main Drive and Fan
• Types of Motors:
– ODP - Open Drip Proof
– TEFC - Totally Enclosed Fan Cooled
• Two Categories:
– Drive Motor connects to the male rotor of the Airend
using a direct coupling
– Fan Motor small motor (TEFC) usually in the 1-20HP
range, having a fan blade connected to the shaft and
used to force air flow over the exterior of the oil cooler
and after cooler cores

36 Aftermarket Training April 2015

 Major Components of Sierra
After-Cooler – Air Cooled
• Cools the air for delivery
• Rated for 115° F Ambient
• Made of Aluminum
Stainless Steel (Option)
Heresite (Option)
• CTD – “Cooling Temp.
Differential” They Cool the Machine!
37-75kW 25° F
90-150kW 20° F
200-300kW 25° F

37 Aftermarket Training April 2015

Major Components of Sierra
After-Cooler – Water Cooled
• Rated for 115° F ambient
• Heads are cast
iron/aluminum
• CTD
– 37-300kW 15° F
• Tubes
– Copper tubes w/ removable
bundles
– CuNi tubes w/ removable bundles
– Stainless steel tubes w/ removable
bundles (Optional)

38 Aftermarket Training April 2015

Major Components of Sierra
Inter-Cooler – Air Cooled
• Cools the air between 1st and 2nd Stage
• Rated for 115° F Ambient
• Made of Aluminum
• CTD
– 37-75kW 25° F
– 90-150kW 20° F
– 200-300kW 25° F

No Stainless Steel Available

Except 200kW above - After Cooler Standard

39 Aftermarket Training April 2015

Major Components of Sierra
Inter-Cooler – Water Cooled
• Rated for 115° F Ambient
• Heads are cast iron/aluminum
• CTD
– 37-300kW 15° F
• Tubes
– Copper tubes w/ removable bundles
– CuNi tubes w/ removable bundles
– Stainless steel tubes w/ removable bundles (Optional)

40 Aftermarket Training April 2015

How to quote Cooler conversion
Choosing the right Cooler conversion kits
STAINLESS STEEL AFTERCOOLER KITS
AIR COOLED AFTERCOOLER CCN
50-100 HP (CD-8) 42459081
125-200 HP Conversion kits CCN
Pre-BOBCAT Original Aluminum After coolers
42467456
(S/N TSXXXXU97180 and Lower)
(Stainless Steel Replacement)
39865662 39862081
39841028 39823042
125-200 HP 42469346
Pre-BOBCAT Original Aluminum After cooler (Kit converts machine back to
39912704 cold-side check valve.)
125-200 HP
Post-BOBCAT Original Aluminum After cooler 42467449
(S/N: TSXXXXU97180 and Higher) (Stainless Steel Replacement)
39903851
WATER COOLED AFTERCOOLER
CCN
Converting to a removable SS bundle kits
50-100 HP (CD-8) 42448712
125-200 HP (CD-14) 42448720
NEW STYLE REMOVEABLE BUNDLE WATER COOLED
CCN
INTERCOOLER AND AFTERCOOLER
50-100 HP (CD-8)
Copper 42452219
Stainless Steel What model of 42452227 NEW 150 PSIG STAINLESS
125-200 HP (CD-14) the compressor STEEL AIR COOLED COOLERS
Copper 42452193
Stainless Steel or what is the 42452201 39919758 replaces 39896865
50-100 HP (CD-8)
ASME Coded Cooler
CCN of the 39907613 39919741 replaces 39829536
ASME Coded Tube Bundle existing cooler? 42459032
125-200 HP (CD-14)
ASME Coded Cooler 39908850
ASME Coded Tube Bundle 42459040
41 Aftermarket Training April 2015
Major Components of Sierra
Inlet Valve
• Butterfly Type Valve
– Full Flow
Load/No Load
– Orifice for Makeup air
– Load/Unload control cylinder
– Hydraulic actuation *
– Solid mechanical linkage with blow-off valve *

* Items may be purchased separately

42 Aftermarket Training April 2015

 How to quote a Valve repair kit
Choosing the right Inlet Valve & Blow Down
Valve Kits

KITS & Valves CCN

INLET BLOWDOWN REPAIR KITS
Cylinder, hydraulic 50-100 HP (swivel eye) 54386511
Cylinder, hydraulic 125-400 HP (swivel eye) 54386529
Kit, Hydraulic Cylinder - retrofit to swivel eye (50-400 HP) 54386537
Kit, Hydraulic Cylinder - rebuild (50-100 HP) 54386545
Kit, Hydraulic Cylinder - rebuild (125-400 HP) 54386552
Kit, Blowdown Valve Rebuild (50-100 HP new design) 54386560
Kit, Blowdown Valve Retrofit to new design (50-100 HP) 54386578
Kit, Blowdown Valve Rebuild (125-400 HP new design) 54386586
Kit, Blowdown Valve Retrofit to new design (125-200 HP) 54386594
Complete Blowdown Valve (125-400 HP new design) 22699821
Kit, Linkage/Lever Arm - complete with screws 22097059
You can find more information
Kit, Linkage/Lever Arm - Rebuild 22097034 in Services Program Book!
NEW GHH RAND CONTROLLED INLET VALVE
Valve, Inlet / Blowdown assembly (50-100 HP new design) 22475347
Valve, Inlet / Blowdown assembly (125-200 HP new design) 22475354
Valve, Inlet / Blowdown assembly (250-400 HP) 22475362

43 Aftermarket Training April 2015

Major Components of Sierra
Onboard Controllers

Intellisys SE Controller Xe-145M Controller

50-200 Hp 250-400 Hp

Onboard Controller MANAGES it all!

Matches the pressure required by application,
monitors compressor health, tells you what
maintenance is required

44 Aftermarket Training April 2015

Major Components of Nirvana-OF
The workhorse of a Nirvana Oil Free machine
• Compression Module
CD4, CD8, CD14
No CD26 Airend used on these model
• LP & HP Individual Airends
CD4 only offered as individual airend
• Drive Train
Airend / Rotor / Stator assembly
• Combination Air Cooled Oil and After Coolers

All Nirvana’s are variable speed machines

45 Aftermarket Training April 2015

Major Components of Nirvana-OF
Compression Module
• Cast iron housing containing Rotors, Bearings to
support the Rotors, Seals and Gaskets
• Two Stages
• Positive Displacement Compression
• Oil Free
• Shaft driven Oil Pump
• Airends are made in several sizes to meet various
power, volume and pressure requirements
– Two Types
Low Pressure 1st stage takes ambient air and compress it
to 20-40psi
High Pressure 2nd stage compress air to the final delivery
pressure
46 Aftermarket Training April 2015
Major Components of Nirvana-OF
Aftercooler – Air Cooled
• Cools Air
• Rated for 115° F Ambient
• Made of Aluminum
• After Cooler CTD
– 37-160kW 20° F
• Triple Inlet Cooler
– Separates the air stream into three points to even
out the thermal stresses on the cooler
– Completely eliminates a pre-cooler

47 Aftermarket Training April 2015

Major Components of Nirvana-OF
Aftercooler – Water Cooled
• Copper Tubes w/ removable bundles
• Heads are Cast Iron/aluminum
• Rated for 115° F Ambient
• After Cooler CTD
– 15° F

48 Aftermarket Training April 2015

Major Components of Nirvana-OF
Nirvana Modular Drive
• Nirvana comes standard with the
following control system features:
– Matched inverter made for purpose
integrating the motor drive and air system
controls
– Nirvana controller monitors system energy
usage and maximizes efficiency
– On-board diagnostics displayed
on Nirvana controller
• 60% smaller than standard frequency
inverters
• 115º F Ambient Rating

49 Aftermarket Training April 2015

Consumables / Wearables / Hard Parts

• Consumables
– Items that are changed on defined regular basis
Lubricant, Filter elements
• Wearables
– Items that are changed on a less defined regular basis
– LONG TERM (3-5 Years after machine has been
purchased)
Valves, rings, bearings, seals, hoses, moisture separator
element
• Hard Parts
– Unplanned replacement Parts
Airends, coolers, motors, controllers
50 Aftermarket Training April 2015
Services Opportunities

• Sierra Service kits and Coolers Updates

– Check valve kits
– Inlet blowdown repair kit
– Stainless steal after-cooler kit
– High dust filter kits
– Chemical filters

• Nirvana field option kits

– PORO field kit
– Remote Start and stop field kit

51 Aftermarket Training April 2015

52 Aftermarket Training April 2015