Diagnostics - Rotary Compressors PDF

Fluid Analysis
Overview
4 Build a comprehensive database -

In this section, you will learn The results of each sample are saved in the
• Why Fluid Analysis is important Ingersoll Rand database, which is regularly
• Why the proper completion of the Sample evaluated and gives us the ability to trend all
Description Sheet is so Important parameters.
• When and where to sample
Benefits to the Customer
• The proper procedure for taking the sample
• Whilst taking the samples, qualified Ingersoll
• How to read the Test Reports. Rand Service Technicians also observe a
machine’s general condition and operating
environment and can highlight other problems.
• The independent laboratory analysis provides
recommendations for optimum lubricant and
What is the purpose of fluid analysis? filter element replacement based on condition,
Proper lubrication is critical to the performance of not hour-meter readings.
machinery.
• Machine condition monitoring and trending will
Lubricants break down and lose their lubricating determine when a major failure may occur,
abilities with usage. They also become which will reduce machine and/or plant
contaminated with metal particles that wear away downtime by avoiding catastrophic failures.
from the surface of machine parts and with other • Customers can better schedule major overhaul
substances, such as dirt and water. Thus, it is very and reduce inventory.
important to analyse used machinery lubricants as
part of an effective predictive maintenance program. Cost benefits of testing
Monitoring compressors with the fluid analysis
Through routine lubricant analysis, you can detect program results in significant maintenance cost
the early stages of fluid contamination and savings as it gives advanced warning of, and can
degradation, and machine wear. A regular program prevent, catastrophic failure. The program gives you
of lubricant analysis will reduce operation and repair time to rectify or prepare for the impending problem.
costs, increase equipment availability and The cost to benefit ratio in these situations can be
operational reliability, and improve the operational dramatic.
safety.
The fluid analysis program also saves money by:
The Fluid Analysis Program, which can analyse all • Reducing unnecessary fluid changes
coolants and lubricants, is available for rotary, • Reducing disposal costs
centrifugal and reciprocating air compressors and
• Better lubrication control and management
accessory units, manufactured by Ingersoll Rand
• Increasing equipment life
and our competitors
All of these benefits mean that customers will enjoy
Why is fluid analysis important? improved machine reliability, effectiveness, and life.
By taking and analysing fluid samples, we :
Benefits to Ingersoll Rand
1 Check Lubricant Condition -
Is the oil still able to do its job or is it at the end • Machine condition monitoring and trending can
of its useful ife and requires change out? determine when a major failure may occur
2 Check Lubricant Contamination - • This means better planning of inventory and
Are there chemicals or material in the oil that service personnel time.
can cause mechanical damage and • Independent technical evidence to provide
contaminate the fluid? What is the condition of operational solutions to machine and system
the system filters? problems.
3 Check Machine Condition - • An opportunity to improve existing customer
What is the machine wear condition and how relationships and create new ones.
long can it operate before a catastrophic failure
is likely? Quarterly sampling is extremely • Technical evidence for Warranty Claims.
important for trending the machine wear and
providing accurate predictions of imminent
machine and/or component failure.
Diagnostics Training Manual Page 1 Fluid Analysis

Ingersoll Rand Global Service Education Team
Issue: 06/Davidson, March, 2006. ©Ingersoll Rand Proprietary Information
Fluid Analysis
Overview
1. Wear Metal / Contaminants / Additives Element Sources
Analysis WEAR METALS
Relative motion between lubricated
parts is always accompanied by Iron Most common wear metal. Rotary screw, lobes,
friction between the contacting vanes, connecting rods, rocker arm, bearings,
cylinders, housing, shafts, roller bearings, oil pump,
surfaces. This friction causes a piston rings
gradual wearing away of these
Chrome Wear metal. Alloying element in roller bearings. Can
surfaces, despite the fact that the also be from cylinder liners and rings in some
parts themselves are usually Gear Wear is
reciprocating models.
caused by fatigue,
coated with a thin film of lubricant. scuffing or scoring
Copper Will be present if any brass elements are wearing or
corroding. Brass components include: thermostatic
Metal particles rubbed off in this control valve (some models), oil drain valve, stop
manner are small enough to remain suspended in a valve, also brass tubes in water cooled heat
circulating lubrication system and, since these wear exchangers (older models)
products are always composed of the same
materials from which they Lead Sleeve bearings (some models).
originated, the relative level of each Tin Found as alloying element in some journal bearings,
metal present in the used lubricant also as an overlay on some components.
relates directly to the wear
condition of the lubricated Aluminium Air cooled oil heat exchangers, tubes, cooler baffles,
plates
assemblies.
Nickel Bearings, cylinder guides, wear plates, thrust
Atomic Absorption Spectroscopy washers and some Air/Oil separator overlay.
Bearing Wear is
caused by rolling and Spark Emission Spectroscopy
contact failure. are used in determining wear metal CONTAMINANT METALS
(Magnification 1000x) levels in lubricants. In Atomic Silicon Contaminant/Additive. The most common
Absorption Spectroscopy, the contaminant. Usually indicates sand/dirt ingression.
principle employed entails the burning of a sample Can also be from silicon based contaminants.
of the lubricant in a flame which is in line with light
of the element being tested for. For example, Iron Sodium Contamination from environment, or from corrosion
inhibitor additive used in cooling water.
will give a characteristic
light picked by a Molybdenum Contamination/Wear Metal, such as friction modifier
photomultiplier detector . additive in gear oil or grease. Could be a wear metal
All metals are reported to as Molybdenum is sometimes used in ball and roller
bearings.
a very high accuracy of 1-
2 parts per million (ppm). Calcium Can indicate a mix with another lubricant, or possibly
Spark Emission grease contamination. Can also indicate water leak
Spectroscopy is used in heat exchanger.
predominantly for used
lubricant analysis to ADDITIVE METALS
determine the wear metal Zinc Wear Metal/Additive. Corrosion of zinc plated
and contaminant metal in Spheres are an early warning
of rolling element bearing components such as air/oil separator coverplate,
the lubricant. The failure. (Magnification 1000x) brass components. Usually present as part of anti-
principle used is similar to wear additive in mineral oils.
Atomic Absorption in that individual metals are
Magnesium Can indicate a mix with an engine oil.
detected at specific wavelengths, however, the
Spark Emission Spectroscope simultaneously Phosphorus Additive/Contamination. Usually present as part of
detects all the metals normally required. an anti-wear additive in mineral oils. May indicate
fluid mix if present in Ingersoll Rand synthetic fluids.
Typically, a Spectroscope simultaneously analyses
Barium Rust inhibitor in compressor fluids.
for the elements in the following table:
Boron Contaminant/Additive. Can be a common inhibitor in
some fluids. Usually indicates a contaminant from
either cooling water (corrosion inhibitor) or mixing of
fluids.
Diagnostics Training Manual Page 3 Fluid Analysis

Fluid Analysis
Testing
2. Physical Tests (b) Oxidation
(a) Water Content Lubricants oxidise when
Contamination of a lubricant by water can damage exposed to air. The
the metal to metal surfaces that the lubricant is oxidation level can be
designed to protect. The local frictional effects within determined using infra-red
the lubrication system can cause temperatures in signatures of the lubricant
excess of the boiling point of water. and any increase in
oxidation from the “new
Black oxides indicate
This boiling off can lead to lubricant” value, is a insufficient lubrication.
areas where the lubricant measure of how the (Magnification 1000x)
is forced out of the lubricant is standing up to
interface between the the harsh environment in which it must operate. The
moving surfaces, leading smaller the number quoted in the report, the lower
to wear. Water will the amount of oxidation. Conversely, a high
promote oxidation in the oxidation level will indicate the likelihood of
lubricant as well as thickening and eventual failure of the lubricated
possible corrosion in the component due to a lack of effective
compartment. It is lubrication.Oxidation preventing additives, called
Red Oxides indicate water in
therefore important to the oil or poor lubricant
oxidation inhibitors, are generally incorporated to
accurately ascertain the conditions. (Magnification 1000x) counteract the effect that oxygen and heat, the
water content in the major cause of the oxidation, have on the lubricant.
lubricant to assess the degree of contamination of This is applicable to mineral oils. Synthetic oils have
this type. a different molecular structure and show high
oxidation levels.
Excessive water in a system destroys a lubricant’s
ability to separate opposing moving parts, allowing (c) Nitration
severe wear to occur with resulting high frictional Nitrogen is a major component of air. In extreme
heat. cases, it can react with the lubricant and oxygen to
produce an effect called Nitration. In compartments
Moisture can come from atmospheric condensation. such as gear boxes, the nitration effect would be
minimal since the exposure to air and high heat
Possible reasons for high water in the lubricant (>300oC) is rarely encountered. As would be
expected, the value for new lubricant is low, as
• Discharge drain check valve not working
nitrogen based products are rarely used in the
• Inadequate weatherproofing or extremely high normal lubricant production.
humidity
• Moisture separator not working property (d) Viscosity
Viscosity: The resistance of a fluid to flow is the
• Compressor running too cold
most important physical property of lubricant.
• Heat exchanger leak (water cooled models) Lubricants must have suitable flow characteristics to
• Degraded/corroded seals ensure that an adequate supply reaches lubricated
parts at different operating temperatures. The
• Excessive idling
viscosities of lubricants vary depending on their
• No load for long periods classification or grade, as well as the degree of
• Light load after extended downtime oxidation and contamination in service.
• Failure to drain water off bottom of Air/oil
A rule of thumb is that if the viscosity of the lubricant
separator
differs by more than 10% from the nominal grade
• New lubricant not being stored properly when new, a replacement is recommended.
• Thermostatic valve not working property
Viscosity measurements of new and used lubricant
characterise the lubricant’s grade, which are listed
as SAE (grading at 100oC) or ISO (gradings for
lubricants are calculated as the Viscosity in mm2/s
(centistokes) at 40oC).
Diagnostics Training Manual Page 4 Fluid Analysis—Testing

Fluid Analysis
Testing
(e) Total Acid Number acid in the oil that can attack the components of the
Total Acid Number (TAN) is a measure of the machinery. However, if the acid material had been
lubricant’s acidity expressed as the equivalent mass neutralised by weak base contaminants such as
in milligrams (mg) potassium hydroxide (KOH) per ammonia it will not be corrosive to some metals, it
gram of the lubricant. will show the same value for TAN as if the ammonia
material was not present and will have a relatively
The acid number is used as a guide to follow the high pH.
oxidative degredation of a lubricant in service.
Lubricant changes are often indicated when the TAN On the other hand if the fluid contained a strong
value reaches a predetermined level for a given base contaminant such as Sodium Hydroxide the
lubricant and application. An abrupt rise in TAN acid material in the fluid would be partially or totally
would be indicative of abnormal operating conditions neutralised by the contaminant. In which case the
(e.g., overheating) that require investigation. value of the TAN measured would be low or non
existent and the pH high or very high. Alkali
Possible reasons for elevated Oxidation/TAN materials which give high pH values, like caustic
• Poor heat transfer in lubricant cooler due to dirt, soda would not be detected by measuring TAN
varnish or dirt/debris plugging the fins alone, but would be corrosive to metals such as
Aluminium.
• Compressor starved of cooling air (i.e., blocked
inlets, cramped locations) or cooling water By carrying out both tests, these problems would be
• Intake air is contaminated with acid forming detected, but TAN alone would not do so. We
gases (e.g. Nitrous Oxides, Chlorides, therefore believe both tests should be measured on
Ammonia, Sulfurous compounds, etc.) each occasion."
• Discharge pressure too high (high PSIG)
• Running too fast (high RPM)
• Lubricant level low
• Lubricant starvation/severe sliding wear
• Incorrect lubricant specified/wrong viscosity
• Excessive water, wear debris, dirt in lubricant,
etc.
• Air/lubricant separator clogged
• Intake filter or lubricant filter dirty
• Thermostatic valve not working properly
(f) Initial pH
We consider Initial pH to be essential when
monitoring fluids such as Ultracoolant.
"pH measures the concentration of Hydrogen ions in

the solution, which in turn indicates the corrosive
nature of the fluid, either from very low or very high
pH conditions.
TAN measures the amount of acidic material in the

fluid, which can combine with elements such as iron
and copper to cause corrosion of machinery metals.
Often a low pH indicates a high TAN and visa versa,

so in some ways the two tests are providing the
similar information, but in many other ways this is
not the case.
TAN is the amount of acidic material, which can

combine with Potassium Hydroxide to form a neutral
salt and as stated above indicates the quantity of

Fluid Analysis
Testing
3. Particle Counting (ISO Cleanliness) In 1999, the International Standard Organisation
This is an excellent way of monitoring the (ISO) introduced a series of new fluid cleanliness
cleanliness of a fluid in terms of both metallic and standards, summarised in the following table:
non-metallic debris.
Old New Description
The technique measures the total particles greater ISO 4402 ISO 11171 Automatic Particle counter
than 6 microns (1st number) and greater than 14 calibration procedures
microns (2nd number). The scale is partical counts (ACFTD to ISO MTD)
per million.
ISO ISO ISO Range code
4406:1987 4406:1999
Particle Count: a method used to count and classify
particulate in a fluid according to accepted size NAS 1638 SAE AS4059 Cleanliness levels by particle
ranges, usually to an ISO standard (ISO 4406 (99) 30 June Rev D April size.
or ISO 11171 (99)). High particle counts indicate 1992 2001
that there is a lot of solid contamination in the fluid,
including wear debris, sand and dirt, organic The change in calibration procedures (ISO 4402 to
material etc. Compressor fluid should be maintained ISO 11171) occurred for two reasons.
at low particle count levels. If the Fluid’s ISO
contamination code is 16/13, it indicates clean oil,
• First, the industry developed a new standard test
although some applications require more stringent
dust for calibration fluid. This new ISO Medium
limits.
Test Dust (ISO MTD) replaced the previously
Particle Count ISO Codes used AC Fine Test Dust (ACFTD), which is no
longer available.
Number of Particles per Number of particles Range
million per million Number • Secondly, there has been a change in how
Greater Than ...... Less Than .....
particle sizes are measured. By way of newer
technologies, particles are now measured in three
80000 160000 24 dimensions, whereas in the past they had been
40000 80000 23 measured in two dimensions.
20000 40000 22 How will these changes affect you?
10000 20000 21 In comparing the old standards to the new, the
5000 10000 20
following has not changed: The amount and the size
of solid contamination in your system is still the
2500 5000 19 same!
1300 2500 18
What has changed?
640 1300 17 The way particle size is specified has changed.
320 640 16 The new standards and reporting methods “move
160 320 15
the measuring stick” to correct for the inaccurate
calibration assumptions made over the past 40
80 160 14 years.
40 80 13 Under the old ISO 4406, three numbers represented
20 40 12 the number of particles greater than or equal to 2 µ,
5 µ and 15 µ. The new ISO 4406:1999 uses three
10 20 11
scale numbers, representing the number of particles
greater than or equal to 4 µ(c), 6 µ(c), and 14 µ(c) in
Possible reasons for high particle counts size.
• Lubricant filter clogged and/or bypassing
It is important to note that net effect of all these
• Air intake filter broken or bypassing changes keeps the ISO rating unchanged. In other
• Elevated wear debris generation words, a fluid that was determined to have an ISO
rating of 18/15/13 under ISO 4406:1987 will still
• Fluid Oxidation
have an ISO rating of 18/15/13 under ISO
• Heat exchanger leak (water cooled models) 4406:1999.
• Degraded and/or corroded seals and/or gaskets These changes ensure that the historical
• Excessive idling or ‘no load’ for long periods cleanliness requirements and fluid analysis data
• Light load after extended downtime also remain valid with the new calibration method.

Fluid Analysis
Sampling Procedure
Five steps of Fluid Analysis Use of a sample kit is easy. Simply follow the
1 Always follow the sampling procedure instructions contained within the kit to take the
2 Always complete a Sample Description Sheet coolant sample and fill out the Sample Description
and send it in the same container with the fluid Sheet indicating where the report should be sent.
sample to the laboratory .
The sample is then forwarded to the laboratory who
Keep a copy of the Sample Description will carry out the analysis.
Sheet for follow up.
The results will then be e-mailed to the e-mail
3 Interpreting the Analysis Report address indicated on the forms.
You will receive the Fluid Analysis Report by
e-mail To use the kit it is necessary to obtain a re-useable
sample pump CCN 91000000. It is recommended
4 You then take the appropriate action, depending
that each serviceman would carry one of these in his
on the diagnosis
standard tool kit.
5 Results are stored into Ingersoll Rand’s
database for evaluation
AP CPN’s
Kit - 91002550
Pump - 91000000 or 88176383
The kit and pump are available Ex APDC Singapore.
DSA CCN’s
Kit– 8 Pack 38035523
Pump 37990678
Tubing 37990751
ESA CPN’s
Kit
Pump
Tubing
Fluid Test Kit 91002550

This Fluid Test Kit can be used to check the
condition of Ultra Coolant, Techtrol Gold all coolants/
lubricants used in air compressors. Use of this kit
should become standard practise as part of your
diagnostic service procedures.
Fluid Test Kit
Diagnostics Training Manual Page 7 Fluid Analysis—Sampling Procedure

Fluid Analysis
Sampling Procedure
Step 1 Step 2
Sampling Procedure Completing the Sample Description
The sampling method is one of the most important Sheets
factors contributing to effective fluid analysis. Step
by step Sampling Instructions are in this manual For Coolant/Lubricant Analysis to be effective, it is
and also on the reverse of the Sample Description important for the laboratory to obtain as much detail
Sheet. as possible about the sample supplied.
When to take samples? The Sample Description Sheet provided with each
Samples should be taken at regular intervals. Use sampling kit, must be completed as per the
the following guide to determine sampling intervals guidelines on the next page.
based on time or running hours, whichever occurs
first. Any additional information that might be considered
When to Sample Hours or Period of Time unique to the operating compressor should be
included. The more information that is received by
1 New lubricant or 250 or 2 weeks the laboratory, the more meaningful the report will
change of lubricant be to you.
2 When the fluid report 500 or 1 month of
results indicate operation The Sample Description Sheet is divided into three
sections:
“caution”
• Machine Details
3 When the fluid report is 2,000 or 3 months • Customer Sample
satisfactory • Details
4 When the environment on the inspection report
suggests that more frequent sampling is required. Each section should be completed as shown on the
following pages.
5 Prior to every coolant/lubricant change
Where to sample?
Always draw the sample from the same point.
Draw samples from the ‘oil fill’ port of the system
reservoir, ensuring that the sample is taken from
the mid-level of the reservoir.
The main points to remember when sampling

are:
• Sample at regular intervals
• Keep sample procedure clean
• Always sample hot:
Allow the machine to run for 15 minutes in
loaded condition to come to full working
temperatures and pressures. This will ensure
that any contaminants are evenly distributed
in the system.
Make sure you isolate the unit and release
all pressure before taking samples.
• Always sample in the same manner
• Provide complete and accurate information on
the sample description sheet
Diagnostics Training Manual Page 8 Fluid Analysis—Sampling Procedure

Fluid Analysis
Fluid Sampling Instructions
Follow these instructions with care to gain the
maximum benefit from fluid analysis. 15) Insert the free end of the tube, up to the
‘mark’, into the reservoir
Preparation: 16) Draw back the
1) Ensure that the unit is at its normal operating handle of the suction
temperature pump – normally two
to three times is
2) Fluid must be well circulated when sampled enough to create a
(within 15 minutes of shutdown) vacuum in the bottle.
3) Avoid external contamination, clean all lubricant Fill the sample bottle
access areas prior to sampling; wash and dry ¾ full.
your hands 17) Remove the tube from the reservoir.
4) Use a new Fluid Test Kit for each sample you 18) Unscrew the sample
take bottle from the pump
5) Make sure that the Fluid Pump is clean and that and immediately close
there are no traces of fluid taken from previous it tightly.
tests. 19) Clean the end of the
tube in the pump
The Fluid Test Kit before removing it, to
6) Open the Fluid Test Kit carton and take out the avoid contaminating the pump.
black plastic container, which is the prepaid 20) Discard the tubing. Never reuse it
mailing container, so don’t throw it away.
21) Clean the pump thoroughly and store it in a
7) Open the black container and take out the sample clean, dry place.
bottle, the Sample Description sheet and the
absorbent paper Packing and Sending
8) NOTE: Don’t open the sample bottle until you are 22) Put the sample bottle into the plastic bag,
ready to take the sample seal it.
9) Complete the sample description sheet before 23) Put the Sample Description Sheet back into
taking the sample the black shipping container with the sample.
Taking the sample 24) Keep a copy or the top part of the SDS for
your reference.
10) Uncoil the plastic
tubing and insert one 25) Put the sample into the black container and
end through the head screw the lid on tightly
of the pump until it is
about 1cm past the O- Send the prepaid black mailing container to the
Ring, then tighten the Laboratory.
screw to hold the tube
in place.
By following the above recommendations you will
11) Put the pump and tubing into the carton to avoid
ensure that your samples are “representative” and
contamination while you perform Step 10. The
that the results will be consistently accurate.
tubing must never
touch the floor, soil or Dipstick
Mark distance on tube
any dirty surface prior

to sampling.
12) Now determine how Top of oil
much of the tubing to

Take sample
insert into the r from mid- level
reservoir. The sample Reservoir
should be taken from
the mid-level.
13) Mark that distance on the tube, from the free end.
14) Open the sample bottle and attach it tightly to the
pump.
Diagnostics Training Manual Page 19 Fluid Analysis—Fluid Sampling Instructions

Fluid Analysis
Short Test
Short Test
Answer each question as fully as you can, or tick the best option.
When you finish, check your answers by reading through the section again.
1 What are four major objectives of lubricant testing
2 Explain how you would convince a customer that fluid analysis carried out by
you would be more beneficial to them, than that done by another laboratory?
Give at least three reasons.
3 When should fluid samples be taken?
4 What would your recommendation be if fluid analysis report indicated a high

TAN ?
5 List three possible reasons for elevated TAN number
6 What are the main points to remember when taking samples?
7 What does the TN on the Fluid Sample Description Sheet indicate?
8 List four possible reasons for high water contamination in the fluid.
9 What do the three numbers in the Particle Count ISO Code mean?
10 What is the only additive in Ultracoolant?
Diagnostics Training Manual Page 20 Fluid Analysis—Short Test

Fluid Analysis for Rotary Compressors
Fluid Flushing Procedure
Rotary Compressors
In keeping with good maintenance procedures, it is
not recommended to mix coolants/lubricants. Some
lubricants
contain
additives or
basestocks that
are not
compatible with
one another.
Converting from Petroleum Oil or PAO (a synthetic Converting from Diesters or Diester/Polyglycol
Hydrocarbon) to Ultracoolant : Blends to Ultracoolant :
1) Operate the unit to bring the complete system 1) Operate the unit to bring the complete system
up to operating temperature. up to operating temperature.
2) Shut the unit down, and lockout/tag out power. 2) Shut the unit down, and lockout/tag out power.
Close the isolation valve and vent pressure. Close the isolation valve and vent pressure.
3) Drain the receiver-separator tank. Drain the oil 3) Drain the receiver-separator tank completely.
cooler. Drain the oil cooler and fluid lines.
4) Change the coolant filter element. 4) Change the coolant filter element.
5) Refill the unit with Ultra Coolant. 5) Do a ½ (one half) charge, or minimum safe fill
level machine flush. If the separator has a
6) Restart and run the unit for one week (or until high differential pressure (> 8 psig) change it
separator has differential pressure > 8 psig). also.
During this time, monitor oil filters and change
when necessary, as Ultra Coolant removes 6) (Note: If varnish or sludge is present, use
sludge and varnish left by the previous fluid. flush procedure as outlined above for PAO’s.)
7) At the end of one week (or high differential 7) Restart and run the unit for one hour.
pressure), change the fluid again (repeat steps 8) At the end of one hour, change fluid and fill to
2-5). If the separator has a high differential normal operating level.
pressure (> 8 psig) change it as well.
9) Start unit and check coolant level.
8) Start unit and check coolant level. Coolant
should be at normal fill level. 10) Place unit in normal service.
9) Place unit in normal service. 11) Fluid analysis or use of the field test kit is
suggested every 3 months to verify the
10) Fluid analysis or use of the field test kit is condition and remaining life of the fluid.
suggested every 3 months to verify the condition
and remaining life of the fluid.
When converting compressors

manufactured prior to 1978, consult
NOTE
Ingersoll Rand for guidance

concerning compatibility with old
style hoses and other components.
Diagnostics Training Manual Page 1 Fluid Analysis for Rotary Compressors

Ultracoolant Guide
Evaluation of Ultracoolant data from the Total Acid Number (TAN)

Asia Pacific region. CAUTION = 1 SERIOUS = 1.5
The evaluation that follows is based on
approximately 950 samples from the Asia Pacific This test gives an indication of the remaining
Region of Ultracoolant hours of operation. We have useful life of the fluid. The TAN starts out with a
plotted some trends to provide general guidance. value of about 0.1 in new Ultracoolant. When it
reaches a value of 1.0, we recommend that the
fluid be changed.
Report Interpretation Guide
CAUTION SERIOUS High TAN may be caused by several factors
including high operating temperature or intake of
Use Caution and Serious values in the following air containing acidic gases. It may also occur in an
guide for taking appropriate action, monitor/ initial charge as Ultracoolant dissolves varnish and
troubleshoot operation of the unit, and/or sludge, left by previous fluids.
Ultracoolant replacements.
Viscosity Ultracoolant TAN
CAUTION >56 <44 SERIOUS >58 0.60
Viscosity is the measurement of the resistance of a 0.50

fluid to flow. When it is new, Ultracoolant has a
0.40
viscosity of about 48 cSt @ 40oC and 9 cSt @
100oC. The fluid should be changed if the viscosity
TAN
0.30
changes by more than 20%. Normally, this change
will not occur within an 8000-hour period. 0.20
0.10
V is c o s ity o f u ltra c o o la n t
5 2 .0 0
0.00
<500 501-1000 1001-2000 2001-4000 4001-6000 6001-8000 >8001
5 1 .5 0 Hours
5 1 .0 0
Viscosity cSt
5 0 .5 0 This chart provides calculated trends for average,

5 0 .0 0 values of TAN over the time of operation of
4 9 .5 0
Ultracoolant. The expected average TAN number
after 8000 hours is 0.5
4 9 .0 0
<5 00 5 0 1 -1 0 0 0 1 0 0 1 -2 0 0 0 2 0 0 1 -4 0 0 0 4 0 0 1 -6 0 0 0 6 0 0 1 -8 0 0 0 >8001
U lt ra c o o la n t h o u rs
Possible reasons for elevated TAN numbers:
• Poor heat transfer in oil cooler due to dirt,
varnish or dirt/debris plugging the fins
This chart provides calculated trends for average • Intake air is contaminated with acid forming
values of viscosity versus hours of Ultracoolant gases ( e.g. Nitrous Oxides, Chlorides,
operation. The expected average viscosity after Ammonia, Sulfurous compounds)
8000 hours of normal operation is 52cSt • Discharge pressure too high
• Oil level low
Possible reasons for abnormal viscosity:
• Excessive water, wear debris, dirt in oil, etc
• Incorrect lubricant used
• Oil separator clogged
• Fluid oxidation
• Intake filter or oil filter dirty,
• Water contamination
• Thermostatic valve not working properly
• High amount of solid contamination (e.g wear
debris, sand/dirt)
• Condensation trap not working

Ultracoolant Guide
Water Content (%) Iron (Fe ppm)

0.5 < CAUTION < 0.65% SERIOUS >0.65% CAUTION > 10 ppm SERIOUS > 25 ppm
Water content affects operation of the unit and its Wear or corrosion of castings, bearings, rotors,
operating temperature. As a general rule of thumb the etc. Some iron will always be present. It may
water level is acceptable up to max of 0.3%. Coolant indicate a machine problem, but is also likely to
needs to be replaced if water reaches 0.6%. be corrosion from water in the system.
U ltr a c o o la n t W a te r c o n te n t U ltr a c o o la n t Ir o n c o n tn e n t v s h o u r s
0 .3 5 6 .0 0
0 .3 0 5 .0 0
0 .2 5 4 .0 0
Iron Content
Water contnet %
0 .2 0 3 .0 0
0 .1 5 2 .0 0
0 .1 0 1 .0 0
0 .0 5 0 .0 0
<500 5 0 1 -1 0 0 0 1 0 0 1 -2 0 0 0 2 0 0 1 -4 0 0 0 4 0 0 1 -6 0 0 0 6 0 0 1 -8 0 0 0 >8001
0 .0 0 H o u rs
<500 5 0 1 -1 0 0 0 1 0 0 1 -2 0 0 0 2 0 0 1 -4 0 0 0 4 0 0 1 -6 0 0 0 6 0 0 1 -8 0 0 0 >8 0 01
H o u rs o n o il
The expected average of Iron content after 8000

hours of normal operation is 6 PPM
From this chart, the expected average water content
after 8000 hours of normal operation is 0.28%
Other Metals
Possible reasons for high water content in the oil:
• Condensate traps do not operate properly Chromium (Cr) and Molybdenum (Mo)
• High humidity Worry about these if large amounts are present.
• Excessive idling / no load for long periods / light They are alloy metals for the steel used in
load after extended downtime bearings.
• New lubricant not being stored properly
• Thermostatic valve not working properly Aluminum (Al) and Copper (Cu)
Lubricant coolers are usually constructed from
one of these. Large amounts may indicate cooler
corrosion or ingestion of air containing particles of
these metals. For guidance, look at the TAN of
the lubricant. If it is less than 1.0, it is probably
just contaminated air, more than 1.0 may be
corrosion.
Lead (Pb), Tin (Sn), and Silver (Ag)

Babbit bearings usually contain Tin, Copper and
Antimony. Lead may also be present, and silver
is sometimes used as a lining of bearings. All this
is nice, but rotary compressors use non-friction
roller and/or ball bearings, so when these
elements show on a report they indicate either
contamination from the environment, or a
mistaken analysis.

Ultracoolant Guide
Contaminants Ultracoolant Guidelines

Silicon (Si) The following table provides caution and serious
If more than 12ppm is present in regular lubricants, it levels for parameters of Ultracoolant. When a
indicates dirt, sand, or other contaminants are being serious level is reached, the Ultracoolant should
ingested past the air filter. be replaced.
Sodium (Na), and Calcium (Ca)

Together may indicate a water leak across a cooling Ultracoolant
water exchanger.
Guidelines of Caution and Serious Levels
Magnesium (Mg) and Phosphorus (P)
Item Caution Serious
Not used in Ultracoolant, but is an additive in some
lubricants. If it shows up in a Ultracoolant analysis, it Viscosity >56 <44 or >58
is a contaminant.
Water >0.5% >0.65%
(5000 PPM) (6500 PPM)
Zinc (Zn)
In a rotary compressor, Zinc may come from TAN 1 1.5
corrosion of the galvanized parts of the air-oil
Sodium (Na) 100 ppm 120 ppm
separator. To see if this is a problem, check the
TAN. If the TAN is over 1.0, that is likely to be the Barium (Ba) <200 <100
source. If the TAN is normal, the Zinc may be
present as an additive in the lubricant. Ultracoolant Silicon (Si) 22 ppm 30 ppm
does not contain Zinc additives, because they are Iron (Fe) 10 ppm 25 ppm
not necessary in rotary compressors, and tend to
contribute to the formation of sludge and deposits. Copper (Cu) 12 ppm 30 ppm
Zinc (Zn) 200 ppm 300 ppm
Aluminum (Al) 5 ppm 30 ppm
Molybdenum (Mo) 3 ppm 5 ppm
Chromium (Cr) 1 ppm 3 ppm
ISO Cleanliness 22/19 24/21
Barium is the only additive in Ultracoolant. When Ultra-

coolant is new Barium will typically be 600-800PPM .

Ultracoolant Guide
Reference Table
The following table provides average and maximum
values derived from the sample population in
different time brackets.
This table can be used as a reference for average

values and also gives you maximum values
measured throughout the Asia Pacific region.
Note: The maximum values measured in the region

for various operating hours on the Ultracoolant do
not represent the maximum allowable levels. If any
parameter of your Ultracoolant sample reaches the
maximum value, immediate action is required.
No Hours 1000-2000 2000-4000 4000-6000 6000-8000

Av. Max Av. Max Av. Max Av. Max
Water 0.24 0.83 0.25 0.71 0.29 0.83 0.28 0.93

Visc_40 50.42 57.17 50.91 62.61 51.25 60.49 51.48 59.26
Iron (Fe) 3.74 44.00 4.10 36.00 4.13 29.00 4.82 53.00
Chromium (Cr) 0.08 2.00 0.09 6.00 0.05 2.00 0.05 1.00
Copper (Cu) 1.45 64.00 1.31 21.00 1.94 40.00 2.66 64.00
Lead (Pb) 1.70 27.00 1.38 20.00 1.81 16.00 1.58 16.00
Aluminium (Al) 0.62 14.00 0.49 12.00 0.55 10.00 0.41 5.00
Tin (Sn) 8.63 57.00 8.95 45.00 8.67 55.00 10.72 42.00
Silicon (Si) 4.22 32.00 3.26 48.00 3.25 25.00 2.32 20.00
Sodium (Na) 35.59 156.00 40.81 133.00 47.37 367.00 51.73 360.00
Nickel (Ni) 0.28 2.00 0.14 1.00 0.08 2.00 0.10 1.00
Zinc (Nz) 13.74 117.00 17.61 134.00 21.53 177.00 19.44 135.00
Phosphorus (P) 15.72 79.00 18.29 173.00 22.08 156.00 19.04 215.00
Calcium (Ca) 6.51 27.00 7.55 70.00 11.86 78.00 11.63 127.00
Retained Solids 72.04 766.00 56.68 384.00 74.69 585.00 78.04 469.00
TAN 0.39 1.35 0.46 1.96 0.51 1.65 0.48 2.00

Oxidation 58.07 64.10 58.02 63.40 57.26 63.30 57.15 64.30
Nitration 10.54 13.60 10.53 12.90 10.46 12.80 10.47 14.50
Particles per 100ml
2 to 5 971,887 4,146,201 962,599 6,484,835 1,100,872 3,981,832 923,830 3,457,252
5 to 10 405,268 3,528,529 342,745 3,149,294 431,305 3,660,406 311,646 2,544,685

10 to 15 160,960 1,977,763 111,673 2,006,322 139,640 1,496,472 129,914 1,844,850
15 to 25 130,609 3,275,060 74,904 1,839,024 88,905 1,308,183 92,221 1,250,286

25 to 50 26,513 965,976 18,166 740,631 23,232 750,075 18,760 399,550
50 to 100 2,201 117,027 1,164 60,601 1,775 46,952 210 4,640
greater than 100 252 4,400 184 5,961 301 9,685 1,297 27,222
ISO_Greater
4 microns 21 23 20 24 20 23 20 23
6 microns 18 23 18 23 18 23 18 23
14 microns 15 22 15 22 15 21 15 21

Ultra Plus Coolant Guide
Ultra Plus Guidelines
Mixing Ultracoolant and Ultraplus.
The following table provides caution and serious
levels for parameters of Ultra Plus. When a serious It is not recommended that Ultracoolant and Ultra Plus
level is reached, the Ultracoolant should be be mixed or converted from one to the other without
replaced. changing hoses.
From the hose Manufacturer:
The mixing of fluids and aging the hose in one fluid

Ultra Plus and changing the fluid to another resulted in a signifi-
cant drop in durometer s well as in tensile strength
Guidelines of Caution and Serious Levels and modules of elasticity. The polyol ester alone con-
Item Caution Serious tributes to volume swell whereas the SSR Ultra Cool-
ant reduces the volume swell. By either combining or
PH 5/10 4.5/11 substituting fluids, it appears that the polyol ester is
Viscosity < 30 or >41 <28 or >43
working against the Ultracoolant and vice versa. In
other words the Ultracoolant has one effect on the
Water >0.3% >0.4% physical characteristics of the inner tube compound
(3000 PPM) (4000 PPM) while the polyol ester has just the opposite effect.
TAN 1.5 2.0 While aging the hose alone in either fluid does not dra-
matically effect the physical properties, by aging the
Oxidation 1.8 2 hose in Ultracoolant and then changing the fluid to
polyol ester, the physical properties can be dramati-
Sodium (Na) >40 ppm >50 ppm
cally altered.
Barium (Ba) <100 <50
Therefore the following is recommended:
Silicon (Si) >40 ppm >50 ppm
1. If the fluid must be changed to another type, other
Iron (Fe) 10 ppm 20 ppm than the original fluid that was shipped with the
machine, the hoses must be changed with new.
Copper (Cu) 35 ppm 45 ppm 2. If the fluid type is the same as original, then the
hoses need not be changed except when when
Zinc (Zn) 100 ppm 200 ppm
performing routine maintenance.
Aluminum (Al) 3 ppm 5 ppm 3. If additional fluid is warranted, add the fluid of the
same type, then up to a 10% mixture is allowable
Molybdenum (Mo) 3 ppm 5 ppm without having to change the hoses. If more than
Chromium (Cr) 1 ppm 4 ppm
Pb (Lead) >40 ppm >50 ppm
Sn (tin) >40 ppm >50 ppm
Ca (Calcium) 50 ppm 100 ppm
Mg (Magnesium) >40 >50
P (Phosphor) 50 100
B (Boron) >40 >50
ISO Cleanliness 22/19 24/22
Ultra Plus contains No Additives.
Note: in June 2006 a slight reformulation was con-

ducted to minimize Chlorine and Copper reac-
tions. Exact formula changes not known as of

IR30 and Condmaster Pro
IR30 - Introduction
The IR30 Sentinel

In this section, you will learn CCN 54636535
• The type of monitoring IR30 is capable of. This unit works in the same way as the
• Two models of IR30 and their differences. data logger instrument, with the
• SPM and how is it applied in industry exception that all data has to be
manually loaded prior to taking each
• Decibel Initial (dBi). reading and it has no PC loading/
• How you can take vibration readings using downloading capabilities. This unit has
the IR30. only SPM monitoring capabilities. The
• Which indicator is used for Bearing condition. IR30 Sentinel can be upgraded to IR
• Which indicator is used for lubrication 30 Logger at an extra cost
condition.
The IR30 Compact
• Condmaster Pro software. The IR30 Compact uses the same
technology as logger and Sentinel to
take SPM readings. Can store ten
What is the IR30? readings. Has infrared temperature
IR30 is an Ingersoll Rand hand held instrument reading. Electronic stethoscope
that can be used to: capability with standard set of
• analyse bearing condition headphones
• measure vibration CCNS:
• log other parameters from the running IR30 Compact (A): 38444105 - without quick
compressor. connect cable
IR30 Compact (B): 38444113 - with quick
The IR30 is primarily connect cable
used for Ingersoll Rand
rotary compressors; Kit includes: IR30 Compact instrument,
however, it is capable of accessory bag, protective cover, AA batteries,
analyzing any roller quick start guide, evaluation guide, technical
element, or anti-friction documentation CD, and Ingersoll Rand packaging
bearings and vibration box.
severity on any other Vibration Accessory Kit
rotating machinery. CCN 38034872
The Vibration Accessory Kit consists of Vibration
There are 2 current Cable (VIC 19), Vibration Transducer (TRV 13),
models of the IR30 available. Vibration Transducer Probe (TRX 28) and can be
used with the IR 30 Sentinel to take vibration
The IR30 Data Logger Kit readings (mm/sec). The vibration severity
CCN 39263009 measurement provides valuable information
includes: about the general condition of the unit and can be
• IR30 Instrument used on any rotating machinery
• CondMaster Pro Software
• Instruction manual IR30 Accessories in AP
20 x studs CPN 89218721
• PC cables and hardware key
50 x studs CPN 89218739
• SPM & Vibration probes
Stud Mounting Kits
• Batteries Drill and 90o Countersink CPN 39262992
• Carrying case
IR30 Accessories in DSA
50 Adapters and Caps CCN
42464602
In addition to SPM and vibration Chamfer Drill CCN 39262993
readings, rounds can be uploaded from a PC and
technicians can log other parameters such as
temperatures and pressures. This data can be
downloaded later to a PC for further evaluation
and trend monitoring.
Diagnostics Training Manual Page 1 SPM and IR30

IR30 - Introduction
Benefits to the Customer • Verifies the qualify of service and repair work,
Customers benefit because they can: such as bearing replacements
• Minimize loss of production • Improves planning for the replacement of
• Avoid costs resulting from secondary damage bearings and air ends
• Utilize the entire lifetime of the compressor air The IR30 can also:
ends • Expand the number and size of service
• Schedule major overhauls contracts
• Avoid the costs of renting replacement • Allow Ingersoll Rand to do bearing monitoring
compressors and vibration analysis on other compressors,
Benefits to Ingersoll Rand pumps, fans, etc.
• One of the key Airend business drivers • Build Ingersoll Rand’s database and increases
• An objective method of verifying the operating our expertise in vibration
condition of rotary machinery • Enhance the professional image of Ingersoll
IR30 - Description and Function Buttons

Menu Screen
Communication for COM

MUN
IR30 Logger only ICAT
Clock
Date 00.07.29
Displays 4 lines with up to Time 14.31
Condition Scale
Contrast
Light auto
Sensitivity 5
Instrument
Light Sensor
Measuring Key
Set Key Enter Key

Time mm
o
Display C
English
Up Arrow Key Right Arrow Key
Left Arrow Key Down Arrow Key
Input Connector SPM Input Connector Vibration

Minimun value TL = 15
Input Connector Software

SPM - Introduction
What is SPM (Shock Pulse Monitoring)?

The Shock Pulse Method was developed about 20 A shock pulse pattern consists of a rapid sequence
years ago as a method for measuring the true of strong and weak pulses. It is defined by two
operating conditions of rolling element bearings. measured values, Decibel Carpet (dBc) for the
large number of relatively weak shock pulses and
As a result of extensive research and development, Decibel Max (dBm) for the few strong pulses in the
it is now virtually the only method readily available pattern.
for that purpose. Not only can damage be detected
and quantified at an early stage, but the vital oil film Decibel Carpet (dBc)
thickness can be assessed. Imagine that you are waiting at a railway crossing
for a freight train to pass. You hear the normal
The basis of the technique is that it measures the ‘clickety-clack’ sound of the wheels crossing the
mechanical impacts generated by any rolling rail joints, but the sound is not always the same; it
element bearing, which is a function of the ball or is louder as the heavier cars go past and less
roller velocity surface roughness. intense for the empty cars. This sound is usual for
a freight train and, in SPM terms, it is called the
These Decibel Carpet.
mechanical
impacts What IR30 does Decibel Max (dBm)
generate However, if one of the wheels has a ‘flat spot’, it
pressure Transducer will make a repetitive banging sound as the flat
waves spot hits the rail. This banging sound can be heard
through the well above the Decibel Carpet and, in SPM terms,
bearing it is called the Decibel Max.
housing, Shock dBm
which can be waves dBc
Decibel Initial (dBi)
detected by This factor can be likened to calibrating your ear as
piezo- the train passes. This ‘calibration’ regulates the
electric transducers (approximately 32kHz intensity with which the ear perceives Decibel Max
frequency range). This frequency is convenient as it and Decibel Carpet.
amplifies the shock signal and filters out machine
vibration. Applying the technology
Applying SPM technology to steel roller bearings
It is important to appreciate that the Shock Pulse requires only reasonable access to the outside
Method detects pressure waves, not physical diameter of the monitored bearing, through an
movement of material as in the case of vibration uninterrupted metal path. Permanently attached
measurement. Consequently the rules of SPM are metal studs are best for this purpose.
that the measuring point must be selected to provide
the shortest possible straight line to the bearing; no A mechanical “clip-on” accelerometer is used to
additional interfaces other than the bearing housing anchor to and read the acoustical signature from
and the outer race of the bearing must be present; the bearing, through the housing to the studs. A
and it must be in the loaded zone of the bearing. hand held, contact probe can also be used with
good results.
Over the years, the Shock Pulse Method has been
developed to an exceptionally high level of accuracy The IR30 reads the shock pulse dBm/dBc values
and reliability, with sophisticated equipment being and displays them as two numerical values. Any type
developed which is user-friendly, yet produces of steel roller bearing can be monitored; however,
results that enable the engineer to confidently plan the Shock Pulse Method has no application to sleeve
his production and maintenance schedules. With the bearings.
aid of CondMaster Pro software, it is now possible to
download directly to a PC and all the analysis and
results, with the action required, can be displayed or
printed.
There are 3 terms used in SPM. These are

• Decibel Carpet (dBc)
• Decibel Max (maximum) (dBm), and
• Decibel Initial (dBi)

SPM - Introduction
This is a short and simplified summary of some Carpet Value dBc
important facts needed to understand the Shock Shock pulses are generated in the rolling interface
Pulse Method (SPM) for bearing condition between the loaded rolling element and the raceway
monitoring: of the bearing. Bearing surfaces are rough. This
causes pressure variations in the oil film which
• Shock pulses are caused by impacts. An separates the moving surfaces, as well as collisions
impact is a single event caused by one body between peaks in the surfaces.
hitting another. In a
bearing, the impacts Results of an impact:
Both result in pressure
typically occur at random
waves - shock pulses -
(and extremely short)
which spread through
intervals.
the material of the
• The impact sends a shock
bearing, the bearing
wave through the material
housing, and adjacent
of both bodies. Vibration
machine parts.
follows impact as a
secondary event. In the 1. A shock wave spreads
shock pulse transducer, through the material
vibration is filtered out.
• The shock pulse
transducer reacts to the
amplitude of the wave
front at its own resonance
frequency. This magnifies
the low energy signal. The IR 30 samples the pattern and displays two
Only the wave front is 2. The body vibrates. measured values to quantify it, dBm and dBc
measured, causing one • Carpet value (dBc) is the measured value for
shock pulse from the transducer. the large number of weaker pulses in the
• The amplitude of the wave front is a function of pattern. It is directly related to the thickness of
impact velocity. This means, the higher the the lubricant film in the rolling interface.
rpm, the higher the shock level. Because the • The carpet value is low when the surfaces of
rotational speed of the bearing depends on its rolling elements and raceway are completely, or
size and the rpm, both are needed as input almost completely, separated by a lubricant film.
data. • The carpet value rises when lubricant film
• Shock pulses are transient signals. They lose thickness decreases and there is more metal to
their energy on the way through the material of metal contact between the bearings.
the machine. Also, they are reflected from
surfaces and severely dampened by interfaces
in the material. That is why we need defined Low Carpet Value High Carpet Value
measuring points.
• All impacts cause Shock pulse measurement
shock pulses. You
must make sure
that you are A A = f (v)
measuring a signal
from the bearing. 1. Shock waves converted to
electrical pulses
2. Pulse magnitude is measured,

vibration is filtered out.

SPM - Introduction
Maximum value dBm • When you set the dBi to “- -” (below -9), the
Maximum value (dBm) is the measured value of the IR30 will take an unnormalized reading, in
strongest pulses detected during the measuring dBsv (absolute shock values). The condition
interval. zones do not apply. This method is used for
comparative reading on different bearings and/
While the bearing surfaces are undamaged, the or other shock pulse sources.
difference between dBm and dBc is small.
A high dBm and a

large difference
between dBm and
dBc is caused by
surface damage or
foreign particles
between rolling
element and
raceway.
The IR30 indicates “bad

operating
condition” (arrow
pointing at the red zone Different shock pulse patterns
of the condition scale). The signal from a bearing should be highest on the
bearing housing. If you get a higher signal outside of
the bearing housing (across an interface in the
material), you are most likely measuring shock
Initial value dBi pulses from another bearing or some other source.
Normalized and Unnormalized readings
The absolute shock pulse level of a bearing, a) For good bearings, the dBm is within the green
measured in dBsv (decibel shock value), is both a zone. dBm and dBc are not close together.
function of rolling velocity and of bearing condition. b) The shock pulse pattern from a damaged
To neutralise the effect of rolling velocity on the bearing contains strong pulses in the red zone, a
measured value, the IR30 has to be programmed random sequence, and a large difference
with shaft diameter (mm or in) and rotational speed between dBm and dBc. When you grease
(rpm). lubricate the bearing, the values should drop but
rise again.
The IR30 will then calculate the initial value dBi, the
c) A dry running bearing has a high carpet value
starting point of the condition scale for a particular
very close to the dBm. When you grease
bearing. You can also input the dBi directly. The
lubricate the bearing, the values should drop and
condition scale is graded in normalised shock
stay low. A similar pattern is caused by pump
values, dBn.
cavitation, in which case readings on the pump
housing are stronger than those taken on the
The IR30 takes a sample count of the shock pulses
bearing housing, and are not influenced by
occurring over a period of time and displays:
lubricating the bearing.
• the maximum value dBm for the small number d) A regular pattern, containing bursts of strong
of strong shock pulses. pulses in a rhythmic sequence, is likely caused
by scraping parts.
• The carpet value dBc for the large number of
weaker shock pulses. e) Individual pulses in a regular sequence are
• An arrow against a field on the condition scale: caused by clicking valves, knocking parts,
green, yellow and red. regular load shocks.
• The maximum value dBm defines the bearing’s f) A sudden drop in the shock pulse level is
position on the condition scale. The difference suspicious. Check your measuring equipment.
between dBm and dBc is used for a finer If the reading is correct, you may have a slipping
analysis of the causes for reduced or bad bearing ring.
condition.
SPM– Data Acquisition Rules
Shock Pulse Bearing Monitoring using a hand held probe
Data acquisition is a simple process
You will find dBi (Decibel Initial) values for various
Ingersoll Rand compressor models and the locations
of bearing probe points in the Specifications & Parts
Lists section of the Diagnostics Reference Manual,
so you can enter dBi into the IR30 without having to
determine the dBi value for the particular bearing(s).
dBi is calculated using the inside diameter of the

bearing (d) in mm and rotative speed (n) in rpm.
Where two different diameter bearings are used on a Hand held
shaft with near equal instrument should be
loads on both ends, an positioned radially to
average of both the bearing housing
diameters is used. The with +/- 5o angle
IR30 calculates Decibel
Initial (dBi once the
diameter of the bearing
and rotative speed are
keyed into the
instrument. Arrow indicates good SPM measuring points
We try to use bearing

housing flange edge
Bearing Data surfaces, since these
TLT on areas have ample depth,
3000 rpm
are free of air or oil
90 dmm dBI 26
passages, and provide a
direct (if somewhat curved)
solid metal path to the
outer race of the subject bearing. More accurate and consistent results are achieved by
installing permanent studs on the unit.
Refer to the following pictures for more information.
Studs are fitted by drilling
and tapping sites with M8
or 5/16” - 18P threads,
1/2” deep, with a 90
No direct Degree entering chamfer.
path It is important to check if
studs are installed
correctly and tightly to the
casing, as the IR30 could Good Bad
provide incorrect readings.
IR30 - SPM measurement using stud clip on probe.

Correct
Position
Air
Pocket

dBm/dBc Interpretation for Rotary
General Rules SPM in summary
dBm/dBc values are indicators of bearing condition

and lubrication deterioration.
Rule 1
dBm values, on new flooded/oil free compressors,
will run in the 20 to 40 range. dBc is about half the
dBm.
Rule 2
dBm values which rise in the 45 range and above,
particularly when unit is loaded, are to be noted.
dBc will also rise, coming close to dBm.
Rule 3
Two consecutive dBm readings at or above 55 in • Shock pulses are pressure waves, generated
700 hours, signal a need to consider bearing in the contact zone between the loaded rolling
overhaul. elements and the raceway.
• Shock pulses are measured using specially
Rule 4 tuned transducer which amplifies the shock
Sudden changes are to be especially noted and signal and filters out machine vibration.
monitoring frequency "doubled up". A cracked or • A shock pulse pattern consists of a rapid
loosened inner race will result in such drastic sequence of strong and weak pulses.
changes, and must receive immediate attention.
• dBc (Decibel Carpet) is the large number of
Rule 5 relatively weak shock pulses.
Oil Free Compressors will display consistent dBm • dBm (Decibel Max) are the few strong pulses
of 10, 15 points higher than dBc in normal running in the pattern.
condition, loaded or unloaded.
Rule 6 Ingersoll Rand units have a number of bearings

Flooded (Contact Cooled) single stage units seem per casing, the shock pulse emissions radiate
to display closer dBm/dBc points than oil free, and and overlap as they are read from the casing
when running unloaded dBm/dBc will be equal to flanges; therefore, we use the following guide.
or higher than loaded. When gas load is relieved,
rotors seem to become more unstable and "rattle Bad Condition - dBm is above 55
around" in the bearing clearances.
Caution zone - dBm is between 45 - 55
Rule 7 Good condition - dBm is between 20 - 45
Flooded two stage units display dBm/dBc loaded
points consistent with single stage and oil free • If dBm is above 55 another reading needs to be
machines. However, unloaded dBm/dBc seem to taken in 700 hours.
run at, or considerably higher than, loaded figures. • If the dBm stays above 55, the unit qualifies for
Therefore, on flooded units, loaded dBm/dBc a bearing overhaul.
figures are to be considered dominant decision
points. Drive motor bearings behave in a similar Do not give the verdict “bearing damage” before
manner. making a further investigation.
Rule 8 As a first measure,
Two stage units have four bearing points per
• see if the peak indicator is
casing. The shock pulse emission from the four
blinking.
points radiates and overlaps as it is read from the
• use the probe transducer to
casing flanges. However, trending, and observing
measure on and outside of the bearing housing
loaded dBm/dBc using these guidelines should
to identify the shock pulse source.
yield accurate indications of repair requirements.
• Make sure that TLT is above 15.

dBm/dBc Interpretation for Rotary
For specific maximum dBm values of newly started The effect of different lubricants, their quality,
units for different size Airends, refer to dBMax values viscosity, supply to the rolling interface, etc., on an
for Rotary compressors. individual bearing can be immediately studied by
comparing the resulting dBc numbers.
If you lack specifics for any particular model,
use: The high dBc number reveals poor lubrication films
• 25 dBi for contact cooled rotary units,and which are due to mechanical faults, such as
• 35 dBi for oil free units. misaligned shafts, unround bearing housings or
This applies to competitive machines as well as installation faults.
Ingersoll Rand units.
Early damage detection SPM Reading Indications

The main purpose of bearing condition monitoring is
the early detection of bearing damage. This method
High dBm Bearing Damage
is less expensive and more reliable than periodic
replacements, because a bearing that has not failed
before its scheduled replacement is likely to be
serviceable for a long time.
High dBc Poor Oil Film Film
Thus, bad bearing condition can be shown by a
single reading. Systematic measurements over a
period of time will then provide a reliable trend and
basis for selecting suitable replacement dates.
Readings of the following patterns can provide
Low dBc Adequate Oil Film
indications of bearing damage, lubrication and
bearing installation problems.
The fact that the service life of bearings is mainly

dependent on lubrication is well known.
Bearing Damage Lubrication Bearing Installation
Very large sums can be saved if bearing life can be

extended by improving lubrication. There is a
relationship between the measured shock pulse
pattern and the lubrication condition of the bearing.
The IR30 displays a value called dBc (decibel

carpet) which decreases in proportion with the
thickness of the lubricant film between the rolling
elements and the raceway in the loaded part of the
bearing.
Note when using the Manual Probe on the IR 30 make

sure that TL value is >15. Lower number indicates there
is a comunication proble or the probe is defective.
.
Vibration Severity Monitoring (VSM)
Vibration Severity Measurement

General machine vibration
increases when something is
loose, broken or out of balance.
Vibration severity readings
supply valuable information
about the general condition of
the unit.
VIB
ISO 10816
Class 3 2/76
mm/s
VIB V
• Vibration severity is defined as RMS (Root

Mean Square) value of vibration velocity (mm/
s, inch/s) in the frequency range of 3 to
1000Hz.
• The evaluation consists of a comparison of the
measured value with vibration limits to
specification ISO 10816, which classifies VIB A
vibration severity into six grades, Class 1 to 6. H
• Ingersoll Rand has chosen Class 3 for its full VIB
range of machines. Class 3 applies to large
machines on rigid foundations.
• Indications: up to 4.5mm/s acceptable; 4.5 -
11mm/s caution; above 11mm/s - warning.
• Vibration velocity is a measure for general
machine condition.
• By measuring in three directions you can get
indication of the causes for increased vibration:
VIB H: most
representative for
balance condition
VIB V:
most representative for
structural weakness
VIB A:
most representative for
faulty alignment and
bend shafts.

IR30 - Trending
Decision making is based on the data acquired. This

consists of operating the machine in loaded and
unloaded condition, while measuring dBM/dBC
values with the IR30.
Each measuring point can be pre-determined and

the route stored in the IR30 Logger for later
acquisition, downloading to a PC and printing.
Electronic recording requires use of “Condmaster
Pro” software which comes with the IR30 Logger Kit.
Data is taken:
1 From the Condmaster 2 to the IR30 3 and data is acquired from

Pro software Logger the machine.
then downloaded from

the IR30 Logger
for 1). Trend Analysis 5
2). Database to the Condmaster Pro 4
3). Report writing software
Manual recording of data can also be done on

paper logs, designed by the user to suit the
purpose.
Normally, data is taken monthly for the first three

months of operation of a new machine, then
quarterly.

IR30 - Trending
Upload/Download
Acquisition process process
Decision Making Process

Condmaster Pro Software
Data Management with Condmaster Pro

Software
Condmaster Pro software provides an effective
means of reducing the administrative work
connected with large scale condition monitoring. It
supplies data entry forms, graphic displays of
measurements and alarm lists for bearings in bad
condition.
Work schedules for any desired time span can be

printed, including measuring point numbers,
instrument settings, last readings and space to
enter current results.
The user can store bearing data, measuring

schedules and readings.
Database
Decibel Trending
Alarm Indication

IR30 - Success Stories
IR30 success stories from China Guangzhou Air Center recommended an airend
exchange program. The customer accepted the
recommendation and the airend was changed
Case Study 1 during a weekend.
Shanghai Air Center, ASG China During overhaul it was found that bearings were
worn and the rotor scratched. The air end would
In September 2003, an Ingersoll Rand Service have been damaged in a short period of time.
Engineer visited a Steel Mill in Shanghai, which
had 5 ML250 units .
Using the IR 30, he established that the vibration

on one air end was abnormally high. After
consultation with the customer the airend was
overhauled and new bearings were installed.
This air end would have

been damaged within 2
months, and would have
cost the customer over
US$15,000 in parts and over
US$50,000 per day of lost
production.
The IR30 helped the Air Center to bring in

revenue of US$4,000, built customer confidence
and satisfaction and secured further business.
Case Study 2
Guangzhou Air Center, ASG China
Over a 6 month period, Guangzhou Air Center,

used IR 30 for 35 customers and on over 130
units of rotary compressors.
IR 30 is playing a key role in closing deals for

overhaul, air end rebearing & rebuilding.
For example, one customer

had 4 units of EP100, all of
them had run over 35,000
hours (since November,
1990) and they had no
intention of overhauling the
air ends.
SPM checks established that the dBM was at it’s

limit. If one unit stopped the customer would have
lost over US$25,000 per day.

Short Test
Short Test
Answer each question as fully as you can, or tick the best option.
When you finish, check your answers by reading through the section again.
1 The basic principle of Shock Pulse Method is:
2 What does the abbreviated term dBi stand for?
3 What does the abbreviated term dBm stand for?
4 What does the abbreviated term dBc stand for?
5 If the dBi of a particular shaft is not known, describe briefly what two facts are
needed and then how dBi can be determined.
6 What two types of machinery condition monitoring can be performed by IR30?

a)
b)
7 Decribe briefly the conditions required for a clean, solid shock pulse signal to
be transmitted from the outside diameter of the bearing to the stud location.
8 Why do sudden changes in dBC/dBM values need to be especially noted?
9 What kinds of machinery faults can be identified by using the vibration severity
capability function of the IR 30 Logger and sentinel.
10 Why are dBm/dBc values are higher during compressor unloaded operation?

SPM Measuring Points for Rotary Compressors
General
Oil Flooded Rotary Measuring Points

On oil flooded (contact cooled) compressors, we take the
following readings when the unit is fully loaded.
Single Stage Compressor
MR2 Male Rotor Inlet Bearing (roller bearing)

MR1 Male rotor Discharge Bearing (tapered bearing)
MBRG Motor Bearing
Two Stage Compressor
LPMR2 Low Pressure Male Rotor Inlet Bearing

LPMR1 Low Pressure Male Rotor Discharge Bearing
HPMR2 High Pressure Male Rotor Inlet Bearing
HPMR1 High Pressure Male Rotor Discharge Bearing
MBRG Motor Bearing
We also recommend taking SPM readings on motor non-drive

end bearings.
Monitoring
Stud MR2
Single Stage
Two Stage
MBRG
MR2 MR1
LPMR2
LPMR1
HPMR1 HPMR2
Diagnostics Training Manual Page 1 SPM Measuring Points for Rotary Compressors
Single Stage Flooded - General Guide
VIB V
MR1
VIB A
H
VIB
VIB V
MR2
MTB
VIB A
H
VIB
CF90 Air End
MR2 DE
Male Rotor
MR1 NDE (thrust)

Male Rotor
178.5mm Air End
MR2 DE
Male Rotor
MR1 NDE (thrust)

Male Rotor
226mm (World Wide) Air End
MR2 DE
Male Rotor
MR1 NDE (thrust)

Male Rotor
226mm Extended Air End
MR2 DE
Male Rotor
Two Stage - General Guide
VIB V
VIB V
LPMR2
VIB A
H MTB
VIB LPM1
VIB A
H
VIB
HPM1
HPM2
297mm/250mm Air End
1 MR2 DE Male
Rotor 1st Stage
1 MR1 NDE (thrust)

Male Rotor 1st Stage
297mm/250mm Air End
2 MR2 DE
2nd Stage
2 MR1 NDE
2nd Stage
dBi Values for Rotary Compressors
50Hz Single Stage Units
Legend:
GD = Gear Driven
SSR M11-50kw GD & BD HG Built BD = Belt Driven
HG = Hindley Green
Male Female Motor D = Davidson
Unit Airend dBi dBi DE dBi NDE dBi
SSR ML11 100 20 16 17 21
SSR MM11 100 19 15 17 21
SSR MH11 100 18 14 17 21
SSR ML15 100 22 18 23 21
SSR MM15 100 21 18 23 21
SSR MH15 100 21 17 23 21
SSR ML18.5 100 23 20 23 21
SSR MM18.5 100 23 19 23 21

SSR MH18.5 100 22 18 23 21
SSR ML22 100 25 24 23 21
SSR MM22 100 25 21 23 21
SSR MH22 100 24 20 23 21
SSR ML30 100 26 23 24 22
SSR MM30 100 26 23 24 22
SSR MH30 100 26 22 24 22
SSR ML37 100 29 25 23 24
SSR MM37 100 28 25 23 24
SSR MH37 100 28 24 23 24
SSR ML45 127.5 28 23 23 23
SSR MM45 127.5 27 23 23 23
SSR MH45 127.5 26 22 23 23
SSR ML50 127.5 28 24 25 24
SSR MM50 127.5 27 23 25 24
SSR MH50 127.5 27 23 25 24
M37 LATE 23 24
M45 LATE 23 23
SSR M15-18.5kw BD HG Built

Male Female Motor
SSR ML15 100 22 18 23 21
SSR MM15 100 21 17 23 21
SSR MH15 100 20 17 23 21
SSR MU15 100 18 15 23 21
SSR ML18.5 100 23 20 23 22
SSR MM18.5 100 23 19 23 22
SSR MH18.5 100 22 19 23 22
SSR MU18.5 100 20 16 23 22
SSR M22-30 BD HG Built

Male Female Motor
SSR ML22 100 24 21 24 22
SSR MM22 100 24 21 23 21
SSR MH22 100 23 20 23 21
SSR MU22 100 22 18 23 21
SSR ML30 100 26 23 23 21
SSR MM30 100 26 22 23 21
SSR MH30 100 25 22 23 21
SSR MU30 100 23 20 23 21
Diagnostics Training Manual Page 10 dBi Values for Rotary Compressors

Legend:
GD = Gear Driven
SSR M37BD (CF75) HG Built BD = Belt Driven
HG = Hindley Green
SSR ML37 CF75 24 20 23 25
SSR MM37 CF75 23 19 23 25
SSR MH37 CF75 23 19 23 25
SSR MU37 CF75 25 21 23 25
SSR M37BD (100MM) HG Built

Male Female Motor
SSR ML37 100 22 19 23 25
SSR MM37 100 22 18 23 25
SSR MH37 100 21 18 23 25
SSR MU37 100 24 20 23 25
SSR M37/45GD (CF90) HG Built

Male Female Motor
ML37 CF90 26 23 23 25
MM37 CF90 26 23 23 25
MH37 CF90 25 22 23 25
MU37 CF90 24 21 23 25
ML45 CF90 28 25 23 23
MM45 CF90 27 24 23 23
MH45 CF90 27 24 23 23
MU45 CF90 26 23 23 23
SSR M55-75 HG Built (non Intellisys)

Male Female Motor
SSR ML55 178.5 22 19 19 18
SSR MM55 178.5 21 18 19 18
SSR MH55 178.5 21 18 19 18
SSR MU55 178.5 19 16 19 18
SSR ML75 178.5 25 22 20 20
SSR MM75 178.5 24 21 20 20
SSR MH75 178.5 24 21 20 20
SSR MU75 178.5 22 18 20 20
BCP TECV (ALL) 20 20
LEROY M55 19 19
LEROY M75 20 19
SSR M55-75 with Intellisys

Male Female Motor
SSR ML55 178.5 22 19 19 19
SSR MM55 178.5 21 18 19 19
SSR MH55 178.5 21 18 19 19
SSR MU55 178.5 19 16 19 19
SSR ML75 178.5 25 22 19 19
SSR MM75 178.5 24 21 19 19
SSR MH75 178.5 24 21 19 19
SSR MU75 178.5 22 18 19 19

Legend:
GD = Gear Driven
SSR M90-150SS BD = Belt Driven
HG = Hindley Green
SSR ML90 226 20 15 20 19
SSR MM90 226 19 14 20 19
SSR MH90 226 18 14 20 19
SSR MU90 226 16 11 20 19
SSR ML110 226 21 17 20 19
SSR MM110 226 21 16 20 19
SSR MH110 226 20 16 20 19
SSR MU110 226 19 14 20 19
SSR ML132 226 23 18 21 20
SSR MM132 226 22 18 21 20
SSR MH132 226 21 17 21 20
SSR MU132 226 19 15 21 20
SSR ML150 226 24 19 21 20
SSR ML150 226 23 19 21 20
SSR ML150 226 22 18 21 20
SSR MU150 226 21 17 21 20
BCP TECV M90 20 20
BCP TECV M110 20 20
BCP TECV M132 20 20
BCP TECV M150 20 20
SSR M90-150SS-ER
Male Female Motor
SSR ML90 226ER 20 16 20 19
SSR MM90 226ER 19 15 20 19
SSR MH90 226ER 18 14 20 19
SSR MU90 226ER 16 12 20 19
SSR ML110 226ER 21 18 20 19
SSR MM110 226ER 21 17 20 19
SSR MH110 226ER 20 17 20 19
SSR MU110 226ER 19 15 20 19
SSR ML132 226ER 23 19 21 20
SSR MM132 226ER 22 18 21 20
SSR MH132 226ER 21 18 21 20
SSR MU132 226ER 19 15 21 20
SSR ML150 226ER 24 20 21 20
SSR ML150 226ER 23 19 21 20
SSR ML150 226ER 23 19 21 20
SSR MU150 226ER 21 17 21 20
BCP TECV M90 20 20
BCP TECV M110 20 20
BCP TECV M132 20 20
BCP TECV M150 20 20

Legend:
GD = Gear Driven
BD = Belt Driven
SSR M90-150SS-ER2 HG = Hindley Green
D = Davidson
Male Female Motor
SSR ML90 226ER2 20 16 20 19
SSR MM90 226ER2 19 15 20 19
SSR MH90 226ER2 19 14 20 19
SSR MU90 226ER2 16 12 20 19
SSR ML110 226ER2 22 18 20 19
SSR MM110 226ER2 21 17 20 19
SSR MH110 226ER2 21 17 20 19
SSR MU110 226ER2 19 15 20 19
SSR ML132 226ER2 23 19 21 20
SSR MM132 226ER2 23 18 21 20
SSR MH132 226ER2 22 18 21 20
SSR MU132 226ER2 20 15 21 20
SSR ML150 226ER2 24 20 21 20
SSR ML150 226ER2 24 19 21 20
SSR ML150 226ER2 23 19 21 20
SSR MU150 226ER2 22 17 21 20
BCP TECV M90 20 20
BCP TECV M110 20 20
BCP TECV M132 20 20
BCP TECV M150 20 20
SSR M200-250SS-ER
Male Female Motor
SSR ML200 226ER 26 22 26 26
SSR MM200 226ER 26 22 26 26
SSR MH200 226ER 25 21 26 26
SSR ML250 226ER 28 24 26 26
SSR MM250 226ER 27 24 26 26
SSR MH250 226ER 26 23 26 26
BCP TEFV M200 26 26
BCP TEFV M250 26 26
SSR M200-250SS-ER2
Male Female Motor
SSR ML200 226ER2 27 22 21 21
SSR MM200 226ER2 26 22 21 21
SSR MH200 226ER2 26 21 21 21
SSR ML250 226ER2 28 24 21 21
SSR MM250 226ER2 28 24 21 21
SSR MH250 226ER2 27 23 21 21
LS TEFV M200 21 21
LS TEFV M250 21 20
BCP ODP M200 20 20
BCP ODP M250 20 20
BCP TEFV M200 22 20
BCP TEFV M250 22 20

Legend:
GD = Gear Driven
BD = Belt Driven
SSR M300-350FATBOY HG = Hindley Green
D = Davidson
Male Female Motor
SSR ML300 304FB 28 25 20 20
SSR ML300 304FB 28 25 20 20
SSR MH300 304FB 27 24 20 20
SSR ML350 304FB 30 27 20 20
SSR MM350 304FB 30 26 20 20
SSR MH350 304FB 29 26 20 20
BCP TEFV M300 22 20
BCP TEFV M350 22 20
LS ODP M300 21 21
LS ODP M350 21 21
LS TEFV M300 21 21
LS TEFV M350 21 21
SSR M300-350CI
Male Female Motor
SSR ML300 304CI 0 0 20 20
SSR M300 304CI 0 0 20 20
SSR MH300 304CI 0 0 20 20
SSR ML350 304CI 0 0 20 20
SSR MM350 304CI 0 0 20 20
SSR MH350 304CI 0 0 20 20
BCP TEFV M300 22 20
BCP TEFV M350 22 20
LS ODP M300 21 21
LS ODP M350 21 21
LS TEFV M300 21 21
LS TEFV M350 21 21

50Hz Two Stage Units
SSR M75-150-2S
1st Stage 2nd Stage
Male Female Male Female Motor
Unit Airend dBi dBi dBi dBi DE dBi NDE dBi
SSR ML75 226/182 18 14 17 15 20 19
SSR MM75 226/182 17 14 17 15 20 19
SSR MH75 226/182 17 13 16 14 20 19
SSR MXU75 226/182 15 11 15 13 20 19
SSR ML90 226/182 20 16 19 17 20 19
SSR MM90 226/182 19 15 18 16 20 19
SSR MH90 226/182 18 15 18 16 20 19
SSR MXU90 226/182 17 13 16 14 20 19
SSR ML110 226/182 21 17 20 18 20 19
SSR MM110 226/182 21 17 20 18 20 19
SSR MH110 226/182 20 16 19 17 20 19
SSR MXU110 226/182 19 15 18 16 20 19
SSR ML132 226/182 22 19 22 20 21 20
SSR MM132 226/182 22 18 21 19 21 20
SSR MH132 226/182 21 18 21 19 21 20
SSR MXU132 226/182 20 16 19 17 21 20
SSR ML150 226/182 24 20 23 21 21 20
SSR MM150 226/182 23 20 23 20 21 20
SSR MH150 226/182 22 19 22 20 21 20
SSR MXU150 226/182 21 18 21 19 21 20
LS TEFV M75 19 19
LS TEFV M90 19 19
LS TEFV M110 20 20
LS TEFV M132 21 20
LS TEFV M150 21 20
SSR M200-350-2S
1st Stage 2nd Stage
Male Female Male Female Motor
Unit Airend dBi dBi dBi dBi DE dBi NDE dBi
SSR ML200 297/250 21 16 18 15 21 21
SSR MM200 297/250 21 16 18 15 21 21
SSR MH200 297/250 20 15 17 14 21 21
SSR MXU200 297/250 18 13 15 13 21 21
SSR ML250 297/250 23 18 20 17 21 21
SSR MM250 297/250 22 17 19 16 21 21
SSR MH250 297/250 21 17 19 16 21 21
SSR MXU250 297/250 20 15 17 14 21 21
SSR ML300 297/250 24 19 21 18 21 21
SSR MM300 297/250 24 19 21 18 21 21
SSR MH300 297/250 23 18 20 17 21 21
SSR MXU300 297/250 21 17 19 16 21 21
SSR ML350 297/250 25 20 22 19 21 21
SSR MM350 297/250 25 20 22 19 21 21
SSR MH350 297/250 24 19 21 18 21 21
SSR MXU350 297/250 23 18 20 17 21 21
LS TEFV M200 21 21
LS TEFV M250 21 21
LS TEFV M300 21 21
LS TEFV M350 21 21

Single Stage, SSR Compressors dBi Data

MR1 MR2 MBGR Max dBm
60 Hz Models A/E Size dBi dBi dBi
HP, EP, XF, 50 hp 26 26 24 50
127.5 mm
HP, EP, XF, 60 hp 27 27 25 50
HP, EP, XF, 75 hp 22 22 20 50
178.5 mm
HP, EP, XF, 100 hp 24 24 20 50
HP, EP, XF, 125 hp 20 20 21 50-54
HP, EP, XF, 150 hp 21 21 21 50-54
HP, EP, XF, 200 hp 226 mm 23 23 23 50-54
HP, EP, XF, 250 hp 24 24 23 50-54
HP, EP, XF, 300 hp 26 26 23 50-54
HP, EP, XF, 250 hp 304 mm 21 21 23 50-54
HP, EP, XF, 250 hp 25 25 23 50-54
255 mm
HP, EP, XF, 300 hp 26 26 23 50-54
HPE, EPE, XFE, 300 hp 23 20 23 50-54
HP, EP, XF, 350 hp 304 mm 24 24 23 50-54
HP, EP, XF, 400 hp 25 25 23 50-54
HP, EP, XF, 450 hp 26 26 23 50-54
All other single stage oil flooded 25 25 25
Models

60Hz Two Stage Units
2 Stage, SSR Compressors dBi Data

LP M1 LP M2 HP M1 HP M2 MBRG
60 Hz Models dBi dBi dBi dBi dBi
XFE100-2S 18 18 18 18 21
EPE100-2S 18 18 17 17 21
HPE100-2S 18 18 16 16 21
XFE125-2S 21 21 19 19 21
EPE125-2S 20 20 19 19 21
HX/HPE125-2S 19 19 18 18 21
XFE150-2S 22 22 21 21 21
EPE150-2S 21 21 20 20 21
HX/HPE150-2S 21 21 20 20 21
XFE200-2S 25 25 23 23 23
EPE200-2S 24 24 22 22 23
HX/HPE200-2S 24 24 22 22 23
XFE250-2S 19 19 18 18 23
EPE250-2S 19 19 17 17 23
HPE250-2S 18 18 17 17 23
HXPE250-2S 16 16 15 15 23
XFE300-2S 21 21 20 20 23
EPE300-2S 20 20 18 18 23
HPE300-2S 20 20 18 18 23
HXPE300-2S 18 18 17 17 23
XFE350-2S 22 22 21 21 23
EPE350-2S 21 21 20 20 23
HPE350-2S 21 21 19 19 23
HXPE350-2S 21 21 20 20 23
XFE400-2S 23 23 21 21 23
EPE400-2S 23 23 21 21 23
HPE400-2S 22 22 20 20 23
HXPE400-2S 20 20 18 18 23
XFE450-2S 24 24 22 22 23
EPE450-2S 24 24 22 22 23
HPE450-2S 23 23 21 21 23
HXPE450-2S 21 21 20 20 23
XFE500-2S 25 25 23 23 23
EPE500-2S 24 24 22 22 23
HPE500-2S 24 24 22 22 23
HXPE500-2S 22 22 21 21 23

60Hz Single Stage Belt Driven Units
Single Stage Belt Driven, SSR Compressors dBi Data

MR1 MR2 MR Max dBm
HP 60 Hz Models A/E Size dBi dBi RPM Drive
ESP 20 20 3055 38 Belt
7.5-10 CE55R2
ESP/SE/"Lynx" Belt 25 25 40 Belt
CE55R3
ESP 20 20 38 Belt
15 CE55R2
ESP/SE/"Lynx" Belt 25 25 40 Belt
CE55R3
3 ESP 14 14 1850 35 Belt
5 ESP 19 19 3400 38 Belt
SE EP 7.5 66 mm 19 19 3376 40 Belt
7.5
SE HP 7.5 18 18 2981 40 Belt
SE XP 7.5 17 17 2565 38 Belt
SE EP 10 21 21 4157 44 Belt
10
SE XP 10 19 19 3520 44 Belt
SE EP 30 25 25 4365 45 Belt
30-40
SE HP 30 24 24 4075 45 Belt
SE HXP 30 CF75D5 22 22 3225 45 Belt
SE EP 40 27 27 5655 50 Belt
SE HP 40 26 26 5310 50 Belt
SE HXP 40 25 25 4316 45 Belt
EP15U 26 26 45 Belt
15-25
HP15U 25 25 4718 45 Belt
XP15U U85 mm 24 24 4314 45 Belt
EP25U 30 30 48
HP 25U 29 29 7168 50 Belt
XP25U 28 28 6616 50 Belt
20-30 XF thru HXP "Jaguar" 85 mm 26 26 45 Belt
15-25 SE Model 27 27 45 Belt
90 mm
20-25 ESP 27 27 45 Belt
EPE 25 25 45 Belt
25-40
HPE U100 28 28 45
XPE 35 35 45 Belt
30-50 30 ESP 23 23 45 Belt
25 100 mm 21 21 40 Belt
30 SE Models 23 23 45 Belt
40 25 25 45 Belt
50 28 28 50 Belt

Acceptable Values-Different Airend Sizes
The following lists are for recent and current NOTE:

Production Air Ends used in Oil Flooded Screw Maximum dBm Values are subject to change
Compressors and give Decibel Initial Values, and
projected maximum dBm values indicating repair
requirement.
Maximum
Airend CCN HP Used in Model(s) Drive M.R. RPM dBi Value
(Ave.) dBm
CE55R2 42437491 7.5-10 ESP Belt 3055 20 38
42437483 15 ESP
CE55R3 39248117 7.5-10 ESP/SE/”Lynx” Belt 25 40
15
66MM 39230131 3 ESP Belt 1850 14 35
5 ESP Belt 3400 19 38
7.5 SE EP 7.5 Belt 3376 19 40
7.5 SE HP 7.5 Belt 2981 18 40
7.5 SE XP 7.5 Belt 2565 17 38
10 SE EP 10 Belt 4157 21 44
10 SE XP 10 Belt 3520 19 44
CF75D5 39225297 30-40 SE EP 30 Belt 4365 25 45
30-40 SE HP 30 Belt 4075 24 45
30-40 SE HXP 30 Belt 3225 22 45
30-40 SE EP 40 Belt 5655 27 50
30-40 SE HP 40 Belt 5310 26 50
30-40 SE HXP 40 Belt 4316 25 45
U85MM 39694708 15-25 EP15U Belt 26 45
15-25 HP15U Belt 4718 25 45
15-25 XP15U Belt 4314 24 45
15-25 EP25U Belt 30 48
15-25 HP 25U Belt 7168 29 50
15-25 XP25U Belt 6616 28 50
85 MM 39895230 20-30 XF thru Belt 26 45
HXPJaguar”
90 MM 39845052 15-25 SE Model Belt 27 45
20-25 ESP Belt 27 45

Acceptable Values-Different Airend Sizes
Maximum
Airend CCN HP Used in Model(s) Drive M.R. RPM dBi Value
(Ave.) dBm
CF 90 42455501 60 HP60ESP Gear 25 50
42448654 60 XF60ESP Gear 25 50
42448662 75 XF75ESP Gear 25 50
42427716 60 EP60ESP Gear 25 50
42427724 76 EP75ESP Gear 25 50
U100 39694716 25-40 EPE25,30,40U Belt 25 45
HPE25,30,40U Belt 28 45
XPE25,30,40U Belt 35 45
100 MM 42377028 30-50 30 ESP Belt 23 45
25 SE Models Belt 21 40
100 MM 39036967 15-40 Gear 25 45
39675814 50 ESP & SSR Gear 28 48
127.5MM 39014469 50-60 XFE, EPE, HPE Gear 27 50
178.5MM 39632146 75-100 XF, EP, HP Gear 27 50
39605449 “Cougar” 25 50-54
226MM 39014600 150-300 XF, EP, HP Gear 25 50-54
255MM 39656194 250-300 XF, EP, HP Gear 25 50-54
304MM 39632237 300-450 XF, EP, HP Gear 26 50-54
(“Fat Man”)
304MM 42379362 300-450 XF, EP, HP Gear 26 50-54
350MM 39014634 Gear 25 50-54
255/204MM 39072343 900 60 HZ Gear See Book 52-55
39072350 1200 60 HZ Gear See Book 52-55
42362715 1350 60 HZ Gear See Book 52-55
226/182MM 39871082 100,200SSR 2 Stage Gear See Book 52-55
297/250MM 42389429 250-450SSR 2 Stage Gear See Book 52-55
45 KW “Nirvana” Shock Pulse Data Is Acquired At “Fixed Speed” 29 50
75 KW “Nirvana” Shock Pulse Data Is Acquired At “Fixed Speed” 26 50
Notes: Decibel Maximum values are acquired with the compressor at full load and pressure. Unloaded values,
while useful, are not the dominant values used to make decisions regarding bearing replacement.
Two stage oil flooded units will always have unloaded dBm values significantly higher than loaded values.
Therefore, unloaded dBm / dBc values must be noted, but discarded.

SPM Logs for Rotary Compressors
Single Stage Units

Two Stage Units

Two Stage Units


Diagnostics - Rotary Compressors PDF

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Fluid Analysis

4 Build a comprehensive database -

Diagnostics Training Manual Page 1 Fluid Analysis

Diagnostics Training Manual Page 3 Fluid Analysis

Diagnostics Training Manual Page 4 Fluid Analysis—Testing

"pH measures the concentration of Hydrogen ions in

TAN measures the amount of acidic material in the

Often a low pH indicates a high TAN and visa versa,

TAN is the amount of acidic material, which can

Diagnostics Training Manual Page 5 Fluid Analysis—Testing

Diagnostics Training Manual Page 6 Fluid Analysis—Testing

Fluid Test Kit 91002550

Fluid Test Kit

Diagnostics Training Manual Page 7 Fluid Analysis—Sampling Procedure

The main points to remember when sampling

Diagnostics Training Manual Page 8 Fluid Analysis—Sampling Procedure

any dirty surface prior

much of the tubing to

Diagnostics Training Manual Page 19 Fluid Analysis—Fluid Sampling Instructions

1 What are four major objectives of lubricant testing

3 When should fluid samples be taken?

4 What would your recommendation be if fluid analysis report indicated a high

5 List three possible reasons for elevated TAN number

6 What are the main points to remember when taking samples?

7 What does the TN on the Fluid Sample Description Sheet indicate?

10 What is the only additive in Ultracoolant?

Diagnostics Training Manual Page 20 Fluid Analysis—Short Test

When converting compressors

Ingersoll Rand for guidance

Diagnostics Training Manual Page 1 Fluid Analysis for Rotary Compressors

Evaluation of Ultracoolant data from the Total Acid Number (TAN)

Viscosity Ultracoolant TAN

CAUTION >56 <44 SERIOUS >58 0.60

Viscosity is the measurement of the resistance of a 0.50

5 0 .5 0 This chart provides calculated trends for average,

Diagnostics Training Manual Page 2 Fluid Analysis for Rotary Compressors

Water Content (%) Iron (Fe ppm)

The expected average of Iron content after 8000

Lead (Pb), Tin (Sn), and Silver (Ag)

Diagnostics Training Manual Page 3 Fluid Analysis for Rotary Compressors

Contaminants Ultracoolant Guidelines

Sodium (Na), and Calcium (Ca)

Zinc (Zn) 200 ppm 300 ppm

Aluminum (Al) 5 ppm 30 ppm

Molybdenum (Mo) 3 ppm 5 ppm

Chromium (Cr) 1 ppm 3 ppm

ISO Cleanliness 22/19 24/21

Barium is the only additive in Ultracoolant. When Ultra-

Diagnostics Training Manual Page 4 Fluid Analysis for Rotary Compressors

This table can be used as a reference for average

Note: The maximum values measured in the region

No Hours 1000-2000 2000-4000 4000-6000 6000-8000

Water 0.24 0.83 0.25 0.71 0.29 0.83 0.28 0.93

TAN 0.39 1.35 0.46 1.96 0.51 1.65 0.48 2.00

Nitration 10.54 13.60 10.53 12.90 10.46 12.80 10.47 14.50

Particles per 100ml

2 to 5 971,887 4,146,201 962,599 6,484,835 1,100,872 3,981,832 923,830 3,457,252

5 to 10 405,268 3,528,529 342,745 3,149,294 431,305 3,660,406 311,646 2,544,685

15 to 25 130,609 3,275,060 74,904 1,839,024 88,905 1,308,183 92,221 1,250,286

50 to 100 2,201 117,027 1,164 60,601 1,775 46,952 210 4,640

Diagnostics Training Manual Page 5 Fluid Analysis for Rotary Compressors

From the hose Manufacturer:

The mixing of fluids and aging the hose in one fluid