SSRRef: 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. thrust or both.350 Two Stage DETAILED SPECIFICATION This allows the bearing to handle all loads. . Coolant dams are machined at the duplex taper roller bearing locations. Both bearings are grease lubricated with bearing housings having inlet grease nipples to simplify the lubrication process. The use of optimising (AGMA Class 11) gears allow the rotors to rotate at a specific speed.SSR M RANGE Ref: Date: Cancels: E7752. All bearings.Hindley Green Manufacturing Facility. further enhancing reliability and life. it was necessary to develop a means of efficiently transmitting power from the drive to the compressor. C. The flanged motor is doweled for permanent alignment to the airend. High quality cylindrical roller bearings are used to carry the radial loads on the inlet end of the rotors. The integral gear drive system was chosen because it is an efficient. The loads generated by the driven gears help offset the load on the drive gear. With this bearing configuration. are premium cost which provide a truer. BEARINGS Ball bearings for the non drive end and roller bearings for the drive end provide dependable and reliable service. Airends without coolant dams operate dry for approximately six seconds on start up. The entire assembly is vibration isolated from the package. FRAME Motor frame and brackets are fabricated to provide maximum strength and rigidity for bearing support. eliminating maintenance prone couplings or belts. A self centering Teflon impregnated motor shaft seal provides a positive system against leakage to the motor windings. begins to rotate and is immediately lubricated. uniform stator/rotor gap and flanged permanent alignment of all mating parts. England SSR M75 . The coolant dam provides an area for coolant to collect or pond when the compressor is shut off. Motor efficiency and power factor have been optimised to cover the entire capacity range of the SSR-2-Stage and are all rated at 46º Cambient. harder running surface for both inner and outer bearing races. torque and operating characteristics have been designed to match the load of the compressor. The gear housing is completely sealed against atmospheric contaminants to insure lifetime trouble free power transmission. 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. The drive gear (centre) is mounted directly on the motor shaft. and the driven gears are mounted on the shafts of each male rotor.02 1st January 2001 1st March 1999 Point of Manufacture . ELECTRICAL DESIGN Speed. B. which allows maximum airend efficiency. THREE GEAR INTEGRAL DRIVE In order to utilise the inherent efficiency advantage of the SSR motor and airend. radial. Upon start-up. reliable and rugged design. whether thrust or radial. which is resting in the coolant dam. 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. DEDICATED MOTOR The main drive motor is exactly matched to the requirements of the SSR 2-Stage. the taper roller bearing. A. E. and a much more forgiving motor under adverse conditions. Correct coolant temperature is important due to the risk of causing condensate and emulsifying the coolant. is mounted in the piping system. (2) for the coolant from the pressurised receiver/separator. C. The vortex action and baffling results in a pre-cleaning of the compressed air. when calculating coolant makeup for the SSR compressors. The temperature sensitive element controls the quantity of coolant from each source. Coolant is also sprayed into an interstage coolant curtain to cool the interstage air and improve efficiency.. The core. The extra conservatism built into every SSR motor means more reliability. COOLANT/AIR SEPARATION After compression and discharge from the airend. However no SSR motor is ever applied for a temperature rise over 89ºC.SSR Ref: Date: Cancels: E7752.350 Two Stage DETAILED SPECIFICATION Point of Manufacture . always use 3-5 ppm by weight. fan and fan motor are all mounted and pre-wired within the compressor package. Entering through a tangential inlet. after the separator element is 5 ppm. On all SSR compressors. COOLANT FILTRATION Two full capacity coolant filters are 5 micron spin on replaceable elements with pressure bypass. Watercooled coolers are shell and tube type designed to use fresh cooling water at inlet temperature of upto 46ºC.03 1st January 2001 st 1 March 1999 M RANGE SSR M75 . COOLANT /LUBRICANT HEAT EXCHANGERS Integrally mounted aircooled heat exchanges are designed for ambient temperatures to 46ºC. the carryover. a difference of 26ºC. LUBRICATION SYSTEM A. which further reduces the coolant content. . B. England D. COOLANT INJECTION Coolant is injected internally to the 1st stage female rotor and the male and female rotors in the 2nd stage. The separator element is a moulded fibreglass two stage reinforced separator.Hindley Green Manufacturing Facility. This ensures the best possible pre-sealing of the rotors. Hence. COOLANT/LUBRICANT TEMPERATURE CONTROL The thermostatic control valve with three ports. and (3) for the coolant to the airend. the air coolant mixture is directed in a circular motion around the inside of the tank. increased life. the air heavily laden with coolant travels to the receiver /separator. INSULATION The SSR motor has class F insulation as standard. prior to entering the separator element. That means it is rated at continuous duty for up to a 115ºC temperature rise. 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. cooled and uncooled. The air is then directed through baffles. necessary to provide the proper injection temperature and assure fast warm up. D. The vortex of circular motion separates a major portion of the coolant from the air through centrifugal force. (1) for the coolant from the cooler. . the compressor will shut down at the end of the run-on time.Electrical installation EN 60204 . England STARTER BOX The SSR includes a star/delta starter integrally mounted and wired to the compressor package in an IP54 starter box. From experience one knows that most compressor applications have a varying air flow demand during the day. operating pressure and the second is 0 % flow (off load). Overall. The mode of operation can be selected from the INTELLISYS control panel by the user.from 60 .04 1st January 2001 1st March 1999 Point of Manufacture . Overload protection is designed and sized specifically for SSR motor characteristics. The compressor is now in automatic stand-by and will automatically start again to load the system when Pmin is reached. Since volume is a function of pressure INTELLISYS monitors the pressures rate of decay or increase.Electrical components EN 60947 . where the inlet valve is constantly throttling the flow to match the air demand. with wide swings of peak loads at a very unpredictable load pattern.SSR M RANGE SSR M75 . All electrical equipment is designed as standard to conform to the EN electrical codes: . Upon reaching Pmax the compressor will simply unload and go into idle operation. In summary. with a hinged door panel. If the pressure increases indicating less air demand . . If there is no further air demand. This unique ACS mode has specifically been designed to match exactly the actual air demand in operation.Starter box assembly EN 60529 The customer should provide suitable power isolation to the compressor package. ACS looks at the air demand by monitoring the system pressure via the discharge pressure transducer. Thus forcing the stepper motor to open up the inlet valve and allow for more inlet air. 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. Ref: Date: Cancels: E7752.60 % compressor capacity) ACS operates the compressor in straight ON/OFF line mode. and Pmin are adjustable via the INTELLISYS control panel and monitored via the pressure transducer at the discharge flange of the compressor. positioning the inlet valve in direct proportion to the air pressure. on line/off line control allows the compressor to operate at 100% full flow at max. For higher demands . The main starter and fan motor protection are electrically interlocaked and wired for proper sequencing. Auto Control Selection: This Automatic Control Selection (ACS) control mode is one of the most advanced control systems used on air compressors today. As a safety feature all components are shielded by a perspex cover. Incoming line terminals are clearly marked and conveniently located for ease of installation. During low air demand periods (0 .the stepper motor closes the inlet valve to reduce flow. Contacts for remote common trip alarm and remote start & stop are also included within the starter. the exact inlet valve position is achieved by the stepper motor in 1 º increments to maintain almost a constant system pressure. Pmax. This is done by means of an advanced inlet stepper motor arrangement.100 % capacity the machine is then operating in modulation control.350 Two Stage DETAILED SPECIFICATION COMPRESSOR/CAPACITY CONTROLS On / Off line control: When this operating mode is selected. The control circuit operates on 110V AC and is protected by circuit breakers. assuming the pre-set minimum motor-running time has expired. Stepper motor inlet valve. ACS control provides a constant pressure when the demand is constant.Hindley Green Manufacturing Facility. A separate breaker and overload relay is mounted and wired in the starter for the fan motor. 05 1st January 2001 1st March 1999 Point of Manufacture .INTELLISYS control ACS . POWER CONSERVATION SYSTEM The INTELLISYS controller will monitor the compressor's operating cycle and reduce the off load running time to a minimum.95 bar Running Loaded Mode: ON/OFF LINE . Providing the motor has run for more than 8 minutes from start up the run on time can be as low as 2 minutes.Modulation only .CURRENT STATUS Package Discharge Temp.Hindley Green Manufacturing Facility. A.SSR M RANGE SSR M75 . safety control and investment protection of the unit. operating control. This is compared to 10 minutes for a compressor which does not have this feature. ADJUSTABLE OPERATING PARAMETERS • • • Off-line pressure On-line pressure Lead / lag off-set Control mode selection . 90 ºC MAIN MENU MICROPROCESSOR INTELLISYS CONTROL The SSR compressor includes a microprocessor based control module which provides for starting. England INGERSOLL-RAND INTELLISYS 6. The controller will not allow the number of motor starts per hour to be exceeded.350 Two Stage INTELLISYS DESCRIPTION Ref: Date: Cancels: E7752. 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 . 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. 6 starts per hour.Power outage restart time • • • • • C. 32 ºC Airend Discharge Temp.On-line/off-line Auto start and stop time Stop delay time Load/unload delay time Star Delta transition time Available as options . 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.Remote start and stop .Power outage restart (if PORO kit is fitted) . capacity control.Sequence control . 8. Stop button. unloaded etc. 6. Pressing the stop button will activate the unloaded stop sequence. Actual status window: This continuously shows the compressor package discharge pressure (4APT). The display will indicate the machine is “RUNNING UNLOADED” and “MODE: UNLOAD”.350 Two Stage INTELLISYS DESCRIPTION INGERSOLL-RAND INTELLISYS 6. In addition. 32 ºC Airend Discharge Temp. Pressing this button will start the compressor if the display shows “READY TO START”. 4. Unload button.will require a selection to move through the program or select menu values. The bottom screen is divided into three areas. Three function buttons. This will cause the compressor to load if the unit is running and if the discharge pressure is less than the on-line pressure.06 1st January 2001 1st March 1999 Point of Manufacture . customer setpoints. .CURRENT STATUS Running Loaded Mode: ON/OFF LINE 1 Package Discharge Temp. In the line below the actual running condition of the compressor (e. A small arrow in the upper right hand corner indicates when the operator can move through a list of options. related to the display screen area.g on/off line or MOD/ACS) 2. Each box. 9. 5. England SSR M75 . 90 ºC 2 4 MAIN MENU 3 5 6 INTELLISYS CONTROLLER FACIAL The INTELLISYS facial as shown in the above picture has the following window and display areas. located immediately above each button. 1. 7 8 9 7.depending on the machine status (status / main menu / select). Arrows up/down to select program parameters.Hindley Green Manufacturing Facility. If the compressor is running loaded. (e.g. Display screen with three functional areas. Also it returns the machine to the operating mode that is specified by the mode of operation set point. Menu location: This area on the right hand side shows various aspects of the machine such as current status. the following buttons are located on the facial panel.95 bar . adjust specific values or highlight options. it will unload and continue to run unloaded for an adjustable 10 to 30 seconds and then stop. This will cause the machine to unload and remain unloaded. alarm. These arrows are used in conjunction with the small arrow in the top right hand corner of the display screen. Start button. etc. The compressor will now start and after the star/delta timer load provided there is sufficient demand for air. In case the compressor is already unloaded it will immediately stop. Load button.SSR M RANGE Ref: Date: Cancels: E7752. calibration.) is shown and below the present mode of operation is shown. loaded. 3. 32 ºC Airend Discharge Temp. option.7 bar Modulation/ACS.1bar 1 sec 1 sec 1 sec --------1 min ----- . 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. (4). 3APT Separator pressure drop. Software title and version. measured prior to coolant injection.95 bar Running Loaded Mode: ON/OFF LINE .07 Date: 1st January 2001 Cancels: 1st March 19999 Point of Manufacture . measured at discharge port of the airend Injection temperature 2CTT.95 bar Running Loaded Mode: ON/OFF LINE . ON/OFF Modulation only 0 to 60 STEP SIZE 0. 90 ºC MAIN MENU The current Status screen (2) can display the following items with the appropriate values: • • • Discharge temperature 4ATT.SSR M RANGE Ref: E7752.Hindley Green Manufacturing Facility. difference between 4APT and 3APT. • • • • 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.2 to rated pressure +0. measured at the package discharge flange.350 Two Stage INTELLISYS DESCRIPTION 6. • • • • • • • • Sump pressure. England SSR M75 .2 barg 4.MAIN MENU Operator Setpoints Options Sensor Calibration Alarm History STATUS SELECT From the main menu screen the operator can access the following features. Coolant filter delta P Inlet filter condition Total hours Loaded hours % load modulation. Airend discharge temperature 2ATT.1bar 0.CURRENT STATUS Package Discharge Temp.5 bar to offline pressure -0. 6. bar. When the inlet vacuum (1AVPT) is greater than 0. Not included on early controllers) . The possible WARNING messages are as follows: Airend discharge temperature. High discharge pressure. England SSR M75 . bar kW Star-Delta. If the operator presses reset twice the warning will go away. the small arrow will appear in the upper right hand corner of the display screen. The warning will occur if the coolant delta P across the filter element (1DPS) is greater than 1. These values cannot be changed by the operator. When unloaded display will show a higher inlet vacuum.F°.2bar) for more than 3 seconds. The warning needs to be reset by the operator by pressing the RESET button twice.83 bar greater than the pressure at the package discharge (4APT) when the machine is fully loaded. 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.08 Date: 1st January 2001 Cancels: 1st March 1999 Point of Manufacture . This warning will occur if the pressure on the separator (3APT) is 0. This warning message can occur if the compressor loading function is being controlled by a host device (Sequencer). Change inlet filter .. the compressor comes with the following parameters already adjusted and preset by the factory.Hindley Green Manufacturing Facility. SETPOINT • Language • Units of measure • Rated pressure • Power rating • Starter type • Total hours • Loaded hours ADJUSTED TO any of the EC languages C°. This will occur if the package discharge temperature sensor (4ATT) is faulty for any reason such as a loose wire. (To be introduced. Sensor failure 4ATT. Change coolant filter. etc. The Ingersoll-Rand authorised service technician will be able to reset the warning once the routine service has been completed. DOL. But if the machine is not serviced the warning will re-appear 24hrs later. This warning will occur every 2000 hours or a set number of months.g. SERVICE. The warning will cause the compressor to unload. The warning message will allow the operator to take necessary precautions before the compressor actually shuts down. This will occur if the airend discharge temperature (2ATT) exceeds 97% of the alarm limit (109°) e. If multiple warnings exist.38 bar and when the coolant injection temperature (2CTT) is greater than 49°C. 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 host device will not be able to load the compressor until the package discharge pressure falls to the rated pressure of the machine. psi.5 bar and the machine is fully loaded. alarm message flashes at 106°C. Change separator element.SSR M RANGE Ref: E7752. The warning will occur when the package discharge pressure is above the maximum off-line pressure (rated pressure +0.350 Two Stage INTELLISYS DESCRIPTION In addition to the operator setpoints. 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. • • • . Each of the 15 alarm messages can be seen by moving the alarm history list up and down by using the arrow buttons.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. the INTELLISYS offers as standard the display of the last 15 alarms experienced by the compressor. 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. England SSR M75 . • • Discharge pressure relief valve High air temperature switch. 3APT.SSR M RANGE Ref: E7752.2 bar) Check inlet control system (when the inlet butterfly valve is in the incorrect position) Check motor rotation (at start. It also gives access to displaying the machines operating conditions that existed at the time of each alarm.Hindley Green Manufacturing Facility. The alarm message needs to be reset by the operator by pressing RESET twice. • • • • • High airend discharge temperature (109°C) Check inlet control (inlet vacuum <0. 4APT. 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.09 Date: 1st January 2001 Cancels: 1st March 1999 Point of Manufacture . 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. In addition to the INTELLISYS safety devices the compressor has the following mechanical safety devices. 3APT or 4APT sensors exceed 10% of range) As a service feature.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.