Centrifugal Compressor Handbook

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Transcript of Centrifugal Compressor Handbook


The Turbo Air 3000 Centrifugal Compressorwith the Vantage Control System

Compressor Handbook

Cooper Turbocompressor, Inc.3101 Broadway P.O. Box 209 Buffalo, New York 14225-0209 USA AAEDR-H-059 ECO-1910938 Rev. 01 May 2003


The Turbo Air 3000 Centrifugal Compressor Operators Manual


Contents About This Manual

About This ManualThis manual contains the basic information necessary for using and maintaining the Turbo Air 3000 Oil Free Centrifugal Compressor, from the original startup and operation to inspection and servicing. However, since installations may vary, these instructions may not cover all details or variations in the equipment supplied or every question which may possibly arise during use. If a question or situation develops which is not answered directly in this manual, contact an authorized Cooper Turbocompressor sales or service representative for more information, or contact the factory directly for specific answers and/or advice. All operating personnel should become familiar with the contents of this manual before the compressor is put into service. This is particularly important with regard to the safety precautions listed in the Introduction and those included at relevant points of the procedures described in other sections of this manual.

WARNING: Read, be sure to clearly and completely understand, and then carefully follow all the directions included in this manual. Failure to adhere to the guidelines and specific instructions provided could cause equipment damage and/or serious personal injury or death.


The Turbo Air 3000 Centrifugal Compressor Operators Manual



Table of ContentsAbout This Manual Section One: IntroductionAbout Cooper Turbocompressor The Turbo Air Centrifugal Compressor Safety Precautions Safety Labels Warranty Limitation on Liability Unauthorized Repair 1 3 1 4 1 6 1 7 110 111 111 iii

Section Two:

SpecificationsGeneral Compressor Specifications Compressor Lubricant Requirements 2 3 2 6

Section Three:

The Control SystemThe Vantage Control Panel The Vantage User Interface Input or Operational Keys Pratice Exercise 3 3 3 3 3 4 8 9

Section Four:

Routine OperationGeneral Considerations The Operating Data Record Routine Startup Routine Shutdown Adjusting the System Pressure Setpoint 4 4 4 4 4 3 3 5 6 7

Section Five:

MaintenanceGeneral Considerations Daily Inspection Scheduled Maintenance Professional Inspection Filter Maintenance Lubrication Additional Maintenance Procedures 5 3 5 4 5 5 5 6 5 7 511 517


The Turbo Air 3000 Centrifugal Compressor Operators Manual

Section Six:

TroubleshootingGeneral Considerations How to Use the Troubleshooting Guide How to Request Assistance Alarm and Trip Functions Drive Train Troubleshooting Control System Troubleshooting Air System Troubleshooting Lubrication System Troubleshooting 6 3 6 4 6 5 6 6 6 8 610 612 613

Section Seven:

Parts and ServiceAftermarket Support Parts Ordering Procedure Parts Availability The Return Goods Policy The Periodic Maintenance Parts Inventory The Professional Inspection Parts Requirement Control System Parts Lubrication System Parts Main Drive Coupling Parts Heat Exchanger Parts Air Piping Parts 7 3 7 4 7 4 7 4 7 5 7 7 7 9 712 714 715 718

Appendix A:

InstallationGeneral Considerations The Installation Work Schedule Labor, Supplies, Equipment and Tools Site Considerations Process Air Piping Utility Piping Electrical Interface Receiving, Lifting, Moving, and Bolting Preparing for Startup Preventing Startup Problems The Inspection Prior to Initial Startup Schedule The Initial Startup Procedure Service Assistance A 3 A 4 A 5 A 6 A 8 A19 A27 A30 A32 A37 A38 A40 A41

Appendix B:

The Lubrication SystemGeneral Considerations The Compressor Lubrication System Vantage Control of Compressor Lubrication Operational Guidelines Gearbox and Reservoir Venting Optional Features B B B B B B 3 4 5 6 7 8



Appendix C:

Vantage Control System LogicGeneral Considerations Compressor Control Methods AUTO-OFFLINE Control AUTO-STANDBY Control AUTO-UNLOAD Control Compressor Safety Mechanisms C 3 C 4 C 7 C10 C12 C14

Appendix D:

Control System Setpoints AdjustmentsGeneral Considerations The Operation Setpoint Adjustment Procedure Minimum Amp Setpoint Adjustment The Protection Setpoint Adjustment Procedure D 3 D 4 D 7 D11

Appendix E:

Control System InitializationGeneral Considerations Control System Initialization Analog Channel Initialization Factory Default Initialization E 3 E 4 E15 E23

Appendix F:


Contract Drawings

Supplemental Data


The Turbo Air 3000 Centrifugal Compressor Operators Manual



Section One IntroductionIn this section, the reader will learn about: Cooper Turbocompressor The Turbo Air 3000 Centrifugal Compressor Safety Precautions Safety Labels Warranty Limitation on Liability Unauthorized Repair


The Turbo Air 3000 Centrifugal Compressor Operators Manual



About Cooper TurbocompressorCooper Turbocompressors reputation as a worldwide leader in the design and manufacture of high technology centrifugal compressors is based upon an engineering tradition that spans over four decades. This tradition of technological innovation and leadership began in 1955, when the former Joy Manufacturing Company developed the first integrally geared centrifugal compressor. In time, the Joy Manufacturing Company grew and eventually emerged as Cooper Turbocompressor. The original machine developed in those early years became the prototype for the ingenious design that continues to be the defining standard for oil-free centrifugal compressors. The dependability, efficiency, and adaptability of its product line have established Cooper Turbocompressor as a global leader in the production of high technology centrifugal compressors. From the early MSG model through the C-8 model to the recent Enhanced Turbo Air 2000 Compressor and the Turbo Air 3000 Compressor, these compressors are known for their ease of automation and high operating reliability. Cooper Turbocompressor centrifugal compressors operate in a diverse array of installations that spans six continents. International concern for a cleaner environment has also motivated users to choose these Cooper Turbocompressor products, which allow them to harness the power of oil-free compressed air as well as to minimize the ratio of energy consumption required. The Buffalo, New York, USA, dedicated complex includes the home office, the manufacturing plant, a state-of-the-art research and development facility and the training school. These resources, along with a worldwide network of sales distributors and trained and authorized service representatives, enable Cooper Turbocompressor, Inc. to provide the very best products and service to those industries which have come to rely on Cooper Turbocompressor centrifugal compressors. Cooper Turbocompressor is ISO 9001 Certified. To learn more, look us up on the Internet: Http//www.turbocompressor.com

Figure 11 The Buffalo, New York, USA, Home Office and Centralized Facilities


The Turbo Air 3000 Centrifugal Compressor Operators Manual

The Turbo Air 3000 Centrifugal CompressorThe Turbo Air 3000 Centrifugal Compressor is a state of the art source of oil-free air manufactured with the users needs in mind. The simple but rugged mechanical design provides many advantages. It combines the best features of aerodynamic technology to achieve optimum energy efficiency, and it delivers lower horsepower to cubic feet per minute (CFM) ratios than any other oil-free centrifugal compressor available.

The Most Advanced Compressor Components AvailableThe Turbo Air 3000 Compressor includes internal components which are unique to the industry. Superior pinion bearings designed for unlimited life and operation at any load. Non-contacting, nonwearing labyrinth air and oil seals that require no buffering to ensure oil-free compressed air. Impellers that are an advanced design which combines the best features of a sigma-radial impeller and a backward-leaning impeller. Vaned diffusers that are matched to the impellers for incomparable efficiency. Finally, inlet guide vanes that are mounted close to the impeller to achieve maximum benefit.

The Vantage Control SystemThe Vantage control system is standard on the Turbo Air Compressor package. Vantage provides the compressor owner with high performance solutions through faster response times, improved reliability and reduced energy costs over other OEM or PLC controllers. This state-of-the-art system is compatible with all other centrifugal, reciprocating, and rotary screw compressors. The Vantage system was developed as a result of a strategic alliance formed between Cooper Turbocompressor and Bay Controls. The various control modes available provide optimal efficiency in even the most demanding applications, or, when necessary, maintain air system pressure at a uniform level.

NOTE: The Turbo Air 3000 Compressor package is not a complete, stand-alone compressed air system. To complete the system, additional components (such as main drive motor starter, oil pump starter, manifolds, inlet air filters, silencers, expansion joints, etc.) are also required. Cooper Turbocompressor offers a selection of optional equipment as part of the package or as add-ons after installation.



Other Design FeaturesOther outstanding design features of the Turbo Air 3000 compressor are shown in Figure 12 including: 1. 2. 3. 4. 5. 6. 7. 8. 9. Horizontally s