Case Studies of Universal Autodual Applications

Compressor type: 25HP I-R Type 30 Compressor

SPP Equipment Installed:

Standard AD-115 Compressor Controller w/ basic features

AD Options:

 L.O.L.    (Low Oil Level) shutdown

 Automatic timed tank drain.

Customer Profile:

Customer added a new 50HP screw compressor to meet increased air demand during the day, but required the use of his existing 25HP compressor for 2 hours a day to meet high air volume sand blasting operations, and required use of 25HP compressor on 2nd and 3rd shift as the main Lead compressor.

Benefit of installation:

Installation of the Universal AutoDual on 25HP I-R compressor placed 25HP compressor in continuous “standby mode”. Compressor automatically came on during high air demand on first shift, and during 2nd and 3rd shift, when 50HP screw compressor was shut off, continued to supply adequate air demand. AD Standard Automatic compressor shutoff was performed as needed, with idle timeout to cool motor down before shutoff. Efficient compressor startup was assured by the AD’s Automatic initial unload delay of 5 seconds, limiting high current loaded startup.

Compressor type: 40HP Leroi Screw Compressor

SPP Equipment Installed:

Standard AD-115 Compressor Controller w/ basic features

Customer Profile:

Customer air demand dropped considerably, due to production process change. This process change increased the idle time of compressor, adding unnecessary energy

Benefit of installation:

Installation of the Universal AutoDual on Leroi compressor reduced pumping and operating time from 8 hrs to 2 hours a day, saving customer thousands of dollars in energy costs and compressor wear. AD Standard Automatic compressor shutoff was performed as needed, with idle timeout to cool motor down before shutoff.

Compressor type: Two 25HP Quincy 5120 compressors

SPP Equipment Installed:

ADLL-115 Lead/Lag compressor controllers

Customer Profile:

Customer air demand dropped considerably, due to production process change. This process change increased the idle time of compressor, adding unnecessary energy

Benefit of installation:

Installation of the Universal AutoDual on Leroi compressor reduced pumping and operating time from 8 hrs to 2 hours a day, saving customer thousands of dollars in energy costs and compressor wear. AD Standard Automatic compressor shutoff was performed as needed, with idle timeout to cool motor down before shutoff.

Compressor type: I-R Oilless Duplex 25 HP

SPP Equipment Installed:

ADF-115 Automatic Lead/Lag controller

Customer Profile:

Duplex I-R was undersized for plant load. Compressor 1 never shut down, and did not allow the existing alternator to shift to the other compressor during peak plant loads. This caused heavy loading on one compressor, and under utilized the second compressor.

Benefit of installation:

Installation of the Universal AutoDual on the I-R Duplex AutoDual forced lead lag switching between both compressors. Based on the timed switching of the AutoDual lead/lag control (set onsite t 2 hours switching) the duplex system functioned as intended, and switched compressors every 2 hours whether under full load or off. This functionality balance load, wear, and cycling equally between compressors.

Additionally, the 5 second initial unload delay reduced start up load on the motors, and the idle-to-stop function (set to 10 min) allowed the motors to idle and cool off before stopping.,

Compressor type: 2 Sullair Duplex 10HP Compressor

SPP Equipment Installed:

ADSE-115 Single enclosure lead/lag Controller

Customer Profile:

Customer purchased 2 Sullair Duplex compressors, (1 horizontal tank mount) operating under constant speed control.

Benefit of installation:

Installation of the Universal AutoDual SE on both compressors reduced wasted energy from idling both compressors during production.on the I-R Duplex AutoDual forced lead lag switching between both compressors. Based on the timed switching of the AutoDual lead/lag control (set onsite t 2 hours switching) the duplex system functioned as intended, and switched compressors every 2 hours whether under full load or off. This functionality balance load, wear, and cycling equally between compressors.

Additionally, the 5 second initial unload delay reduced start up load on the motors, and the idle-to-stop function (set to 10 min) allowed the motors to idle and cool off before stopping.

Compressor type: 3 - IR XLE 300 HP compressors

SPP Equipment Installed: 

3- AD-230 Compressor Controls

3-Way Manual Lead/Lag Control:

Customer Profile

Customer complaint that 2 of the 3 XLE compressors were pumping air approximately 3 hours per day, and idling the rest of the time. Compressors needed to be available due to sporadic fluctuation in air usage. All 3 compressors were running under constant speed control.

Benefit of installation:

Installation of 1 Autodual controller on each of the 3 compressors immediately stopped long term idling of 2 XLE compressors. The addition of the 3-way manual lead/lag control allowed plant engineers to select the lead compressor on a scheduled basis, allowing equal wear on all 3 compressors.

Additionally, the 5 second initial unload delay reduced start up load on the motors, and the idle-to-stop function (set to 10 min) allowed the motors to idle and cool off before stopping.

Reported savings in energy in the first month of installation $9437.00 !!!