MORE THAN AIR. PRODUCTIVITY. RELIABILITY. EFFICIENCY.

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1 Variable-Speed Drive, Oil Free Rotary Screw Air Compressors MORE THAN AIR. PRODUCTIVITY. RELIABILITY. EFFICIENCY. ONLINE SOLUTIONS: Ingersoll-Rand compressors are not designed, intended or approved for breathing air applications. Ingersoll-Rand does not approve specialised equipment for breathing air applications and assumes no responsibility or liability for compressors used for breathing air service. Nothing contained on these pages is intended to extend any warranty or representation, expressed or implied, regarding the product described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with Ingersoll-Rand s standard terms and conditions of sale for such products, which are available upon request. OIL FREE Product improvement is a continuing goal at Ingersoll-Rand. Designs and specifications are subject to change without notice or obligation. Air Solutions Ingersoll-Rand European Sales Limited Swan Lane Hindley Green Wigan WN2 4EZ, UK Tel: +44 (0) Fax: +44 (0) CPN: Printed in the UK 2003 Ingersoll-Rand HPM, HYBRID PERMANENT MAGNET and HPM Logo are trademarks registered by MOTEURS LEROY-SOMER

2 EXCEPTIONAL RELIABILITY IR S TWO-STAGE OIL FREE AIREND IS TIME-PROVEN AND KNOWN AROUND THE WORLD FOR ITS MATCHLESS PRECISION AND RELIABILITY. INTRODUCING NIRVANA OIL FREE. A TRUE VARIABLE SPEED DRIVE OIL FREE AIR COMPRESSOR Only Ingersoll-Rand offers Nirvana Oil Free, the world s first true variable speed oil free compressor for critical oil free applications requiring the highest quality of air and the greatest reliability available on the market. By matching an innovative modular variable speed inverter with a HYBRID PERMANENT MAGNET motor, IR is again first-to-market, this time with a true variable-speed drive, oil free air compressor. The two-stage Nirvana Oil Free compressor has fewer rotating parts than any other rotary air compressor in its class. The Hybrid Permanent Magnet motor driving the Nirvana Oil Free raises the standard on compressor reliability to an unequalled level. There are no motor bearings in the HPM motor. Since the HPM motor directly drives the compressor, there are no pulleys, belts or couplings to wear out or need replacing. Furthermore, any possibility of mis-alignment is eliminated. Coupled with IR s time-proven, reliable two-stage oil free airend, Nirvana Oil Free is as reliable as an air compressor can get. TIME-PROVEN QUALITY AIREND Not everything in the Nirvana Oil Free compressor is brand new. At the core of every Nirvana Oil Free compressor is IR s rugged, reliable, two-stage oil free airend. Used in thousands of compressors worldwide, IR s advanced oil free airend is precision-machined in a twenty-step manufacturing process that ensures unmatched rotor profile accuracy and repeatability. Then the rotors are coated with UltraCoat, the most durable rotor coating available. NIRVANA OIL FREE'S INTEGRAL DESIGN, PATENTED FIELD-REPLACEABLE MOTOR STATOR PROVIDES DRAMATICALLY IMPROVED UPTIME Repairing the conventional air compressor motor usually means days or weeks of downtime and rental expense. Often the motor is sent to a motor repair centre, or back to the manufacturer, for costly rewinding, new bearings or other lengthy repair work. The Nirvana stator exchange program not only provides quick turnaround, it s less expensive than a motor rewind. THE REVOLUTIONARY HYBRID PERMANENT MAGNET MOTOR HAS NO BEARINGS AND VIRTUALLY NO PACKAGING AND HPM MOTOR ELIMINATE TROUBLE SPOTS, EFFICIENCY LOSS AND FAILURE. Nirvana Oil Free s high-efficiency HPM motor has virtually no wearing parts. Electromagnetic coils on the stator produce a powerful magnetic force between the stator and an array of permanent magnets on the rotor, which causes rotation at variable speeds. Should the motor be subjected to a catastrophic electrical surge or other electro-thermal event that damages one or more of the motor coils, the stator is quickly and easily replaced in the field by authorised technicians at a fraction of the cost to rewind a conventional motor. WEARING PARTS. 2 3

3 UNEQUALLED PERFORMANCE ULTRACOAT. SOLVING THE NEED FOR BETTER OIL FREE PERFORMANCE AND ENERGY SAVINGS The challenge: to give our customers an oil free rotary compressor that operates at peak performance throughout its lifetime. With the introduction of our fixed speed oil free compressor, SIERRA, we introduced UltraCoat. After 10 years of superior performance and peak performance in real world applications, UltraCoat has proven to be unmatched in its performance. We use UltraCoat to protect every SIERRA airend and now every NIRVANA Oil Free airend. ULTRACOAT PROTECTION AND PERFORMANCE The first step to full UltraCoat protection is the superior surface preparation of the rotors and housings. As the images on the left show, our component surface treatments allow for the tightest possible grip for the coating. In the next step, UltraCoat is applied using robotics for the thinnest, most even coat available. Then the rotors and housings are heat-cured to solidify the bond between the coating and the rotor or housing surface. Ingersoll-Rand s exclusive UltraCoat rotor and housing coating process uses a mechanical and chemical bond to ensure the thinnest coating with the tightest possible grip. First, the rotor and housing surfaces are mechanically prepared to accept the coating. Then UltraCoat is precision-applied to ensure the most even coat possible. Finally, all surfaces are heat-cured to solidify the mechanical/chemical bond. Compared to other coatings, UltraCoat delivers longer life and 10% energy savings. THE ULTRACOAT ADVANTAGE To help our customers get the best performance, we did not limit our design efforts to the coating. We selected stainless steel and aluminium for the piping linking the intercooler with the stainless steel second-stage rotors. Condensation created in the cooling process cannot corrode these materials, eliminating the possibility of rust formation and carry through, further lengthening the life of the coating and rotors. Design innovations such as this and Ultracoat are what separate Nirvana Oil Free from any other compressor in its class. SURFACE PREPARATION CREATES MINUTE CREVICES IN OUR ROTORS AND HOUSING THAT TIGHTLY GRIP THE ULTRACOAT COATING. THE RESULT IS THE MOST DURABLE PERFORMANCE ON THE MARKET, LOWERING OUR CUSTOMERS ENERGY COSTS AND INCREASING THE LIFE OF THE AIREND IN THE NIRVANA OIL FREE COMPRESSOR. WHEN COMPARED WITH OTHER COATINGS, ULTRACOAT IS A CLEAR WINNER. OUR CUSTOMERS GET MAXIMUM CAPACITY AND LOWER ENERGY COSTS OVER A LONGER AIREND LIFE 4 5

4 ENERGY EFFICIENCY Oil Free Rotary 10 Year Life Cycle Cost TRADITIONAL PURCHASE DECISION FACTORS REPRESENT ONLY 20% OF THE COST TO OWN AND OPERATE A ROTARY SCREW COMPRESSOR WHILE ENERGY REPRESENTS 60% OF THE LIFE CYCLE COST. ONLY NIRVANA WILL SAVE AT LEAST 30% OF THE ENERGY COST OVER ITS LIFE. LOW SOUND Given an average operating ambient temperature of 29 C for oil free compressors, versus a design-rated operating temperature of 46ºC, the variable speed cooling fan on the Nirvana Oil Free compressor will run less often and only as long as needed to maintain an ideal package temperature. At an average load of 70%, this delivers up to a 5 db(a) reduction in sound since the cooling fan doesn t work as hard. NIRVANA WILL REDUCE THE TOTAL LIFE CYCLE COST TO OWN AND OPERATE AN AIR COMPRESSOR IR s exclusive VSD makes possible a range of operating characteristics that produce this unequalled energy efficiency. In a conventional air compressor, starting up the motor creates an enormous energy draw, as much as 800% of the full-load normal running current. Nirvana s HPM drive system limits the in-rush current to less than 100%. This significant decrease in starting amp requirements minimises peak charges, leading to a lower energy bill. UNEQUALLED EFFICIENCY AND RELIABILITY. NIRVANA SAVES ENERGY Unlike conventional on-line/off-line air compressors, Nirvana does not unload. Instead, Nirvana compressors simply reduce speed, and volume, to meet demand. Rather than run unloaded, a Nirvana compressor simply shuts off. Since Nirvana compressors allow unlimited starts per hour with no decrease in motor life, energy savings are tremendous. Couple this with IR's two exclusives: the HPM motor and UltraCoat, Nirvana Oil Free is the most reliable oil free compressor available and delivers a 30% energy savings compared to standard, fixed-speed oil free compressors. 6 7

5 TRANSCENDENT TECHNOLOGY IR S INNOVATIVE TRIPLE-INLET COOLER COOLS MORE EFFICIENTLY AND SAVES COST Oil free rotary screw air compressors run much hotter than any comparable contact-cooled unit with coolant flooding the rotors. Nirvana Oil Free combats heat with a unique triple inlet cooling system that moreefficiently cools the compressed air and eliminates the costly, failure-prone precooler found on competitive units. The exclusive Nirvana Oil Free triple inlet cooler splits the compressed air stream into three separate pipes that are cooled by the ambient inlet air as it s drawn into the compressor. MODULAR DRIVE Ingersoll-Rand uses an all-new, compressor-specific modular drive, designed for Nirvana with the latest technology, but using all standard components for easy repair and diagnosis. Forced air ventilation over the modular drive heat sinks allows the drive to run cooler and the heat sinks to last longer. On-board drive diagnostics are displayed on the Intellisys controller. Field-replaceable standard modular components eliminate costly VFD replacement. NIRVANA OIL FREE COOLING AIR CONDITIONER COMPENSATES FOR AMBIENT TEMPERATURES, REDUCES NOISE AND ELIMINATES THERMAL CYCLING Ingersoll-Rand has spent years designing and perfecting air compressor technology. Through the years one fundamental design criteria has remained: the cooler a compressor runs, the longer the life expectancy. This fundamental design criteria has been enhanced in the Nirvana Oil Free compressor. It uses a variable speed motor on the package cooling fan. This allows Nirvana to air condition the compressor package and hold the package temperature constant, regardless of the ambient. The patented modular drive can be diagnosed and serviced on site by qualified IR service personnel, minimising valuable downtime. 60% smaller than standard frequency inverters. THE APPROACH TEMPERATURE OF THE SECOND STAGE AIR HEADED TOWARD THE AFTERCOOLER IS LOWERED THROUGH THE EFFICIENT ACT OF PASSING THE AIR THROUGH THE PRECOOLER MANIFOLD OF PIPES THAT CROSS IN FRONT OF THE TRIPLE-INLET COOLER, DIRECTLY IN THE AIRFLOW THAT MAINTAINS THE OVERALL COOLER TEMPERATURE. 8 9

6 NIRVANA OIL FREE TWO-YEAR PACKAGE WARRANTY Nirvana features a two-year bumper-to-bumper package warranty covering everything except periodic maintenance. TIME PROVEN AIREND DESIGN By using the SIERRA airend design updated for variable speed operation, the Nirvana Oil Free yields the best performance at both full and part load. Maintaining a constant specific power efficiency at any point in the operating curve will maximise energy savings for the end user. TRIPLE-INLET COOLER DESIGN Eliminating the need for an expensive pre-cooler, Nirvana s patented triple-inlet cooler design maintains the optimum cooler operating temperature. Traditional oil free cooler designs require a pre-cooler that is prone to failure. The triple-inlet cooler design maximises the reliability of the Nirvana design. 46 C AMBIENT RATED IR Nirvana compressors are designed to operate in high ambient conditions, making them ideal for locations anywhere in the world. Even if the compressor is not operated in sweltering climates, Nirvana s high temperature rating ensures fewer nuisance shutdowns caused by fouled coolers. FREQUENCY INVERTER DRIVE This advanced, modular drive system gives the Nirvana compressor a controlled, soft start, eliminating current surges and extending component life for increased system reliability. NOBLE MATERIALS Critical to reliable, consistent air quality are the materials used that come in contact with compressed air. Inside the Nirvana compressor module, all components that come in contact with compressed air are coated with UltraCoat. In addition, from the second stage onwards, all materials are stainless steel or aluminium to prevent harmful particulate from going downstream. MAXIMUM PERFORMANCE - FOR THE LIFE OF NIRVANA Unlike competitive oil free compressors, Nirvana s patented UltraCoat rotor coating does not allow the performance of the compressor to degrade over time. That means that the performance attained in year one will be the same performance seen in year five. QUIET AND AMBIENT COMPENSATED Thanks to the patented Cooling Air Conditioner, the Nirvana Oil Free compressor compensates for ambient conditions and manages the cooling air flow to achieve a constant discharge temperature. Under average operating conditions, the Nirvana compressor will operate 9 db(a) quieter than the standard compressor. INTELLISYS MICROPROCESSOR C ONTROLLER PROVIDES TOTAL CONTROL OF YOUR NIRVANA COMPRESSOR Whether your application requires eight hours of continuous-duty compressed air or an intermittent supply over a 24-hour period, the Intellisys microprocessor puts you in complete control. AT YOUR FINGERTIPS With finger-touch control, the Intellisys controller provides quick, comprehensive access to your compressed air system. Nothing could be more intuitive and user-friendly than the Intellisys controller. With Intellisys, you are always in command. You can quickly and easily adjust the operating parameters of the Nirvana compressor to meet your plant air system s requirements and minimise operating costs. TIMESAVING DIAGNOSTICS Intellisys provides fast diagnosis of system demand, displays a warning and/or stops the compressor if it exceeds operating parameters, and provides a history of events leading up to the condition. This will keep troubleshooting expenses and downtime to a minimum. An easy-to-read, liquid crystal display provides you with the critical details of your Nirvana compressor s operation, allowing you to make fast adjustments when necessary

7 NIRVANA OIL FREE ADDS UNEQUALLED RELIABILITY, EFFICIENCY AND PRODUCTIVITY TO YOUR CURRENT OIL FREE SYSTEM Ingersoll-Rand s Solutionizing Process will save 25%-50% of the operating cost associated with the compressed air system. RELIABILITY Few applications are as critical as those requiring oil free air. No compressor is more reliable than Nirvana. Coupling a superior compressor designed for reliability with the exclusive IR Solutionizing process often will turn off a compressor in the average compressed air system. Turning off compressors leads to a significant increase in system reliability and integrity. PRODUCTIVITY Adding a Nirvana oil free compressor to your system not only reduces costs, it makes your entire system more efficient and more productive. One of the primary goals of the Solutionizing process is to provide stable, reliable pressure. Stable pressure that is available when the production process needs it will improve operating efficiency. EFFICIENCY POINT-OF-USE Applications The compressed air system uses 10% of the energy consumed by the average plant or production facility. Even small improvements in efficiency can be valuable. The variable-speed Nirvana is the most efficient compressor ever built, resulting in major energy savings for you. Solutionizing also seeks out the energy wasting processes on both the demand and supply side of the system. Managing your compressed air system as a whole will lower operating costs

8 INGERSOLL-RAND. MORE THAN AIR. SOLUTIONS. AIRCARE. FLEXIBLE MAINTENANCE. CONSTANT QUALITY. Ingersoll-Rand became the world leader in compressed air technology not by building more air compressors, but by providing more problem-solving system solutions for its customers. No one offers more solutions than IR: rotary screw or centrifugal, versatile controls, air system audits, turnkey installation, air over the fence, financing, rentals and full service. Ingersoll-Rand customers know that IR is with them for the life of their compressed air installation. INGERSOLL-RAND S YEARS OF APPLICATION EXPERIENCE WILL HELP YOU ARRIVE AT YOUR COMPRESSED AIR SOLUTION. Ingersoll-Rand has tackled virtually every conceivable compressed air system application in the world, and yet every day there is a new customer need to be addressed. You can be certain, whatever the size or nature of your application, IR will have the experience, the right product and the right system solution for you. THE INGERSOLL-RAND TEAM. WITH YOU FOR THE LONG HAUL. Ingersoll-Rand s team of professionals, from product design and development to sales consulting, application engineering, installation, startup and aftersale service, know how to keep your compressed air system operating costs down while maintaining peak performance for the life of your system. IR s 24/7 parts and service network is ready to serve you 365 days a year with whatever it takes to keep your system up and running. AirCare, an Ingersoll-Rand exclusive, is a responsive and flexible contract maintenance program custom-designed to provide customers with factory-authorised scheduled maintenance for increased system reliability. AirCare helps eliminate unscheduled downtime and relieves customers of the costly investment in monitoring equipment, ongoing training and a thorough knowledge of compressor technology. WARRANTY EXTENDED TO FIVE YEARS IR s AirCare program allows you the opportunity to extend the drivetrain or full package warranty out through five years, providing you with total peace of mind. COMPREHENSIVE COVERAGE FOR ANY COMPRESSOR AirCare is available for new machines or with overhauls and exchanges. In addition, AirCare can be coupled with service contracts for total coverage of parts and preventive maintenance service. LOWER COST. INCREASED PRODUCTIVITY. A compressor installation covered by the AirCare program can expect: Reductions in emergency maintenance costs thanks to periodic inspections Reductions in energy costs thanks to increased operating efficiency Increased productivity thanks to dramatically shortened downtime THE AIRCARE PROGRAM No long-term maintenance program is more comprehensive than AirCare. The chief highlights of the program include: Certified, professional technicians will perform routine inspections and diagnostic service Performance will be enhanced through exclusive use of genuine IR parts and lubricants All-inclusive fluid analysis program will comprehensively monitor the lubricant in the compressor to detect problems at the earliest possible opportunity Vibration analysis diagnostics pinpoint the need for component replacement through monitoring and trend analysis that predicts the service life of critical components REMOTE MONITORING An added option to AirCare is IR s Intelliguard remote monitoring feature. This 24-hour-aday, seven-days-a-week, surveillance of the air compressor installation helps identify potential problems at an early stage and prevent unexpected repairs