slide air solutions -medium ssr 45-75 kw product overview

Slide # 1

Air Solutions - Medium

SSR 45-75 kW

Product Overview

Slide # 2


Standard configuration:

•Air cooled or Water cooled

•Intellisys SE controller

•230/380/460v/TEFC

•75dBA

•Modulation Control

•Star Delta

•NEMA I

Cougar 45-75 kW

Slide # 3


SSR Cougar Fixed-Speed, Contact Cooled Rotary Screw

Air Compressors 45-75kW / 60-100 hp

Nominal Motor

PowerRated Pressure Sound Range

kW / HP m3/min cfm Bar (g) / psi (g) dB (A)

45 kW

ML45 45 / 60 7.4 260 7.5 / 109 78 +/-3

MM45 45 / 60 7.1 250 8.5 / 123 78 +/-3

MH45 45 / 60 6.5 230 10 / 145 78 +/-3

55 kW

ML55 55 / 75 10.1 357 7.5 / 109 78 +/-3

MM55 55 / 75 9.1 325 8.5 / 123 78 +/-3

MH55 55 / 75 8.3 293 10 / 145 78 +/-3

MJ55 55 / 75 7.6 268 11.4 / 165

75 kW

ML75 75 / 100 13 459 7.5 / 109 78 +/-3

MM75 75 / 100 12.1 427 8.5 / 123 78 +/-3

MH75 75 / 100 11 389 10 / 145 78 +/-3

MJ75 75 / 100 10.2 360 11.4 / 165 78 +/-3

CapacityModel Designation

Slide # 4


Slide # 5


OBJECTIVES

• Component Review

• Control System

• Adjustments

• Installation

• Maintenance

• Parts

Slide # 6


AIR FILTER

• 3 micron system

– Improved separator element

life

– Change every 4000 hours

• Multi-Stage High Dust

Filter Optional

– Extended Life

• Pre-cleaner

• Primary element

• Secondary element

Slide # 7


INLET VALVE

• 4” Butterfly

– Oilite bearings with

lubrication points

• Pneumatic cylinder

controlled

Slide # 8


Slide # 9


AIRENDS

• 45 kW - 127.5mm

• 55 & 75 kW -

178.5mm

• Shock mounts

– 3- point system

• Cantilevered motor

support

Slide # 10


Slide # 11


• Types of Profiles

–Symmetric or Asymmetric

–Male: 4 lobes, Female: 6 lobes



1

3

2 1 2

3

4 4

5

6

AIRENDS

Slide # 12


Why does an airend have

bearings?

– Positions the rotor in the center of

airend housing

– Prevents movement of rotor due to

thrust

Bearings

Slide # 13


• Bearing Types

–Angular Contact Ball

Bearings

–Cylindrical roller bearing

–Tapered roller bearing

• Duplex or triplex

configuration

Bearings

Slide # 14


Angular Contact Ball

Bearings Tapered Roller Bearings

Bearings

Slide # 15


Duplex Tapered Roller

Bearings

Triplex Tapered Roller

Bearings

Bearings

Slide # 17


Size vs Speed

Thrust Load

Duplex tapered

Roller Bearings

14.4 psia

139.4 psia

100 mm 177 mm Rotor Area 38 in 2 120 in 2

Pressure 125 psig 125 psig

Axial Load 4,750 lbs 15,000 lbs

Bearings

Slide # 18


• Size vs Speed – Increasing the load by two, reduces the estimated bearing

life 10 times

• 2 X Load (-10) x Life

– Increasing the speed (RPM) by two, reduces the estimated

bearing life by one half.

• 2 x RPM 1/2 x Life

Applying Bearings

Slide # 19


Coolant Dams – Bearings require lubrication

at start up

– On average, competitive

units operate for 3 - 5

seconds dry at start up

– During one year of operation

this is equivalent to more

than 15 min without

lubrication (300 days, 1 start

per day)

Bearings

Slide # 20


DRIVE MOTOR

• Standard TEFC

• Integral gear drive

Slide # 21


Slide # 22


DISCHARGE CHECK VALVE

• Disc and Spring type

Slide # 23


DISCHARGE HOSE

• Connect airend to separator tank

• Isolates airend from separator tank

• Proper installation is critical

• Maintenance item

– Replace every 2 years

Slide # 24


Slide # 25


SEPARATOR TANK

• 12” & 14” Diameter

• Cone Baffle

• Deflector Plate

• Rigid Mount

• Supported by Cooler Support

Frame.

• Provides Vibration Isolation

Slide # 26


Slide # 27


SEPARATOR ELEMENT

• Extended Surface Area

• Smaller Physical Size

• First stage mechanical separation of

coolant from air

• Reservoir for coolant

Slide # 28


UltraCoolant

1) Provides for rotor seal

2) Absorbs the heat of compression

3) Lubricates the rotor and bearing

Slide # 29


• IR Patent

• No falling off

• Low carry over

• Low sump

• Excellent heat transfer

• Wide temperature range up to

271 DegC

• 8000 hours or two years life

cycle

High Quality Ultracoolant

Slide # 30


• SAE “O”-Rings

– Leak-Free

– Reduces cleaning

costs

– Saves lubricant

– Reduces EPA

contamination

concerns

Package- Piping

Slide # 31


MINIMUM PRESSURE CHECK

VALVE (MPCV)

• Set at 60 PSIG

Slide # 32


AFTERCOOLER

• Combination oilcooler &

aftercooler

– Aftercooler 15° CTD 40%

RH

• pressure drop 1 PSI

– Oilcooler 100°F ETD

• pressure drop 5 PSI

• Hinged for easy access

for cleaning

Slide # 33


Slide # 34


• Operating temperature

• 115 °F/46 °C Design Temperature – Prevents nuisance shutdowns for high

temperature

– Allows an increased time between maintenance intervals of coolers in cooler climates

– The equipment operates cooler at lower temperatures and lubricant doesn’t break down as quickly

SSR Coolers

Slide # 35


Cooling System • 46DegC ambient means

– Decreased burden on the cooler

– Lower temp in the airend

– Lengthen the airend life

– Easy installation (Ventilation and environment)

Slide # 36


MOISTURE SEPARATOR

• Cyclone Type

• Aluminum Construction

Slide # 37


THERMAL VALVE

• Ingersoll Rand Body

• Caltherm Element set at

160°F

• Built in Pressure Relief to

Assist in Cold Start Oil

Flow. (approximately 50

psig)

Slide # 38


CONTROL

• Standard SE Intellisys

• SE Star Delta Control Scheme

• Solenoids, 1SV, 2SV, 3SV, 6SV, 10SV

• Modulation is an Option

– Uses Special Modulation Regulator with different orifices and

response than SE Modulation Regulator

Slide # 39


3-way with the

coil de-energized

DIRECT

OPERATED

1SV Control Solenoid and 6SV

Slide # 40


3-way with the

coil energized

DIRECT

OPERATED

1SV Control Solenoid and 6SV

Slide # 41


2-way normally

closed valve with the

coil de-energized

and valve closed

2SV Modulation Solenoid

DIRECT

OPERATED

Slide # 42


2-way normally


coil energized

and valve open

2SV Modulation Solenoid

DIRECT

OPERATED

Slide # 43


2-way normally

open valve with the

coil de-energized

and valve open

PILOT

OPERATED

3SV Blowdown Valve

Slide # 44


2-way normally

open valve with the

coil energized

and valve closed

3SV Blowdown Valve

PILOT

OPERATED

Slide # 45


2-way normally


coil de-energized

and valve closed

5SV Coolant Stop Valve

PILOT

OPERATED

Slide # 46


2-way normally


coil energized

and valve open

5SV Coolant Stop Valve

PILOT

OPERATED

Slide # 47


Slide # 48


INSTRUMENTATION

• Airend Discharge Temperature 2ATT

• Airend Discharge Temperature 1ATS

• Package Discharge Pressure 3APT

• Sump Pressure 3APT (10SV)

Slide # 49


1ATS

CLR

CF

AFTER CLR

STATUS: UNIT STOPPED

NO POWER

TCV C

B

A

MOISTURE

SEPARATOR

AND TRAP

A/E SE

2ATT

RELIEF

VALVE

SO

MPCV

5SV

DISC CHECK

VALVE

SEPARATOR

TANK

Inlet Valve

1SV

N.C. 6SV

N.O.

2SV

N.C.

3SV

N.O.

10SV

3APT

MV

1ATS

AF

CYL

Slide # 50


1ATS

CLR

CF

AFTER CLR

STATUS: UNIT UNLOADED

TCV C

B

A

MOISTURE

SEPARATOR

AND TRAP

A/E SE

2ATT

RELIEF

VALVE

SO

MPCV

5SV

DISC CHECK

VALVE

SEPARATOR

TANK

Inlet Valve

1SV

N.C. 6SV

N.O.

2SV

N.C.

3SV

N.O.

10SV

3APT

MV

1ATS

AF

CYL

Slide # 51


1ATS

CLR

CF

AFTER CLR

STATUS: UNIT LOADED

TCV C

B

A

MOISTURE

SEPARATOR

AND TRAP

A/E SE

2ATT

RELIEF

VALVE

SO

MPCV

5SV

DISC CHECK

VALVE

SEPARATOR

TANK

Inlet Valve

1SV

N.C. 6SV

N.O.

2SV

N.C.

3SV

N.O.

10SV

3APT

MV

1ATS

AF

CYL

Slide # 52


1ATS

CLR

CF

AFTER CLR

STATUS: UNIT LOADED

and MODULATING

TCV C

B

A

MOISTURE

SEPARATOR

AND TRAP

A/E SE

2ATT

RELIEF

VALVE

SO

MPCV

5SV

DISC CHECK

VALVE

SEPARATOR

TANK

Inlet Valve

1SV

N.C. 6SV

N.O.

2SV

N.C.

3SV

N.O.

10SV

3APT

MV

1ATS

AF

CYL

Slide # 53


1ATS

CLR

CF

AFTER CLR

STATUS: UNIT LOADED,

MODULATING & 10SV SHIFTED

TCV C

B

A

MOISTURE

SEPARATOR

AND TRAP

A/E SE

2ATT

RELIEF

VALVE

SO

MPCV

5SV

DISC CHECK

VALVE

SEPARATOR

TANK

Inlet Valve

1SV

N.C. 6SV

N.O.

2SV

N.C.

3SV

N.O.

10SV

3APT

MV

1ATS

AF

CYL

Slide # 54


INTELLISYS Controller－SE

Adjustable Operating Parameters

• Off-line pressure

• On-line pressure

• Display time

• Mode of operation

• Delay load time

• Auto start and stop shutdown time

• Auto start and stop on/off

• Sequencer control on/off

• Remote start and stop on/off

• Lead/lag settings

Display Standards

• Package discharge pressure

• Total hours/loaded hours

• Airend discharge temperature

• Sump pressure

• Separator element pressure drop

Slide # 55


Fault Shutdowns

• High airend discharge tempera-ture

• Low unloaded sump pressure

• Calibration failure

• Emergency stop

• Starter failure

• Main/fan motor overload

• Reverse rotation

• Sensor failure

• Control power loss

• High sump pressure

Fault Warnings

• High airend discharge tempera-ture

• Change separator element

Protective Controls

• Air pressure relief

• Minimum pressure/check valve

• High temperature shutdown

• Main/fan overloads

INTELLISYS Controller－SE

Slide # 56


Ingersoll-Rand Intellisys

INTELLISYS Controller

Pressure

Transducer

Discharge

Pressure

Slide # 57


INTELLISYS Controller

• On/Off Line

–Recommended for

operation at loads less than 60% of

compressor capacity

–Energy Saving

• Modulation

–Effective from 60 to 100% of compressor

capacity

–Constant Pressure

–Less Airend wear

• ACS

–Integrated On-Line/ Off-Line with Upper

Range Modulation

–Decides the best mode of operation

depending on the load conditions

Slide # 58


ADJUSTMENTS

• Sump pressure

– adjusted by moving end of hydraulic cylinder

• Online/Offline, ETC...

– adjusted on SE controller

• Modulation

– adjusted using regulator valve.

Slide # 59


INSTALLATION

CONSIDERATIONS

• Standard ambient 35°F - 115°F

• Adequate Ventilation

• Away from chemicals and dust

• Protect from weather

• Service access around unit (minimum 42”)

• Do not reduce size of piping

Slide # 60


CUSTOMER CONNECTIONS

• Air Discharge

– Location - Back Left Corner

• Condensate

– Location - Back Left Corner

• Power

– Location - Left Side at Top of Starter Enclosure

Slide # 61


ROUTINE MAINTENANCE

• Air Filter

– change every 4000 hours

• Coolant Filter

– Initial change after 150 hours

– subsequent changes every 2000 or when coolant is changed

• Coolant

– every 8000 hours or 2 years, whichever comes 1st

Slide # 62


• Separator Element

– every 8000 hours or when differential pressure is => 12 PSID

• Clean Coolers

• Grease Motor

– 1000 hours for TEFC

– 2000 hours for ODP

• Clean scavenge orifice

– At every oil filter change

ROUTINE MAINTENANCE

Drive Seal

–every 2 years

Replace Hoses

–Every 2 years

Slide # 63


PARTS TO STOCK

• Air Filter

• Coolant Filter

• Coolant

• MPCV Kit

• Blowdown Valve Kit

• Thermal Valve Element

• Separator Element

• 3APT Pressure Sensor

• Thermistor

• HATS

• Inlet Cylinder

• Modulation Regulator

• Shaft Seal and Sleeve

• Fuses

• Auxiliary contacts

slide air solutions -medium ssr 45-75 kw product overview

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