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  • Contents

    The Turbo Air 3000Centrifugal Compressorwith the Vantage Control System

    Compressor Handbook

    Cooper Turbocompressor, Inc.3101 Broadway P.O. Box 209Buffalo, New York 14225-0209 USA

    AAEDR-H-059 Rev. 01ECO-1910938 May 2003 FWG

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  • Contents

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    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 theequipment 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 authorizedCooper Turbocompressor sales or service representative for more information, or contact the factorydirectly for specific answers and/or advice.

    All operating personnel should become familiar with the contents of this manual before the compressoris put into service. This is particularly important with regard to the safety precautions listed in theIntroduction and those included at relevant points of the procedures described in other sections ofthis manual.

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

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  • Contents

    Table of Contents

    About This Manual iii

    Section One: Introduction About Cooper Turbocompressor 1 3 The Turbo Air Centrifugal Compressor 1 4 Safety Precautions 1 6 Safety Labels 1 7 Warranty 110 Limitation on Liability 111 Unauthorized Repair 111

    Section Two: SpecificationsGeneral Compressor Specifications 2 3Compressor Lubricant Requirements 2 6

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

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

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

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  • The Turbo Air 3000 Centrifugal Compressor Operators Manual

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

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

    Appendix A: InstallationGeneral Considerations A 3The Installation Work Schedule A 4Labor, Supplies, Equipment and Tools A 5Site Considerations A 6Process Air Piping A 8Utility Piping A19Electrical Interface A27Receiving, Lifting, Moving, and Bolting A30Preparing for Startup A32Preventing Startup Problems A37The Inspection Prior to Initial Startup Schedule A38The Initial Startup Procedure A40Service Assistance A41

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

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    Appendix C: Vantage Control System LogicGeneral Considerations C 3Compressor Control Methods C 4AUTO-OFFLINE Control C 7AUTO-STANDBY Control C10AUTO-UNLOAD Control C12Compressor Safety Mechanisms C14

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

    Appendix E: Control System InitializationGeneral Considerations E 3Control System Initialization E 4Analog Channel Initialization E15Factory Default Initialization E23

    Appendix F: Glossary

    Contract Drawings

    Supplemental Data

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  • Introduction

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    Section OneIntroduction

    In this section, the reader will learn about:

    Cooper Turbocompressor

    The Turbo Air 3000 CentrifugalCompressor

    Safety Precautions

    Safety Labels

    Warranty

    Limitation on Liability

    Unauthorized Repair

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  • Introduction

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    About Cooper TurbocompressorCooper Turbocompressors reputation as a worldwide leader in the design and manufacture of hightechnology centrifugal compressors is based upon an engineering tradition that spans over fourdecades.

    This tradition of technological innovation and leadership began in 1955, when the former JoyManufacturing Company developed the first integrally geared centrifugal compressor. In time, theJoy Manufacturing Company grew and eventually emerged as Cooper Turbocompressor. The originalmachine developed in those early years became the prototype for the ingenious design that continuesto be the defining standard for oil-free centrifugal compressors.

    The dependability, efficiency, and adaptability of its product line have established CooperTurbocompressor 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 Compressorand the Turbo Air 3000 Compressor, these compressors are known for their ease of automation andhigh operating reliability. Cooper Turbocompressor centrifugal compressors operate in a diverse array ofinstallations that spans six continents. International concern for a cleaner environment has also moti-vated users to choose these Cooper Turbocompressor products, which allow them to harness thepower 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, astate-of-the-art research and development facility and the training school. These resources, along witha worldwide network of sales distributors and trained and authorized service representatives, enableCooper Turbocompressor, Inc. to provide the very best products and service to those industries whichhave 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

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

    The Most AdvancedCompressor Components AvailableThe Turbo Air 3000 Compressor includes internal components which are unique to the industry. Supe-rior pinion bearings designed for unlimited life and operation at any load. Non-contacting, non-wearing labyrinth air and oil seals that require no buffering to ensure oil-free compressed air. Impellersthat are an advanced design which combines the best features of a sigma-radial impeller and a back-ward-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 thecompressor owner with high performance solutions through faster response times, improved reliabilityand reduced energy costs over other OEM or PLC controllers. This state-of-the-art system is compatiblewith all other centrifugal, reciprocating, and rotary screw compressors. The Vantage system wasdeveloped as a result of a strategic alliance formed between Cooper Turbocompressor and Bay Con-trols.

    The various control modes available provide optimal efficiency in even the most demanding applica-tions, 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 airsystem. To complete the system, additional components (such as main drive motor starter, oil pumpstarter, manifolds, inlet air filters, silencers, expansion joints, etc.) are also required. CooperTurbocompressor offers a selection of optional equipment as part of the package or as add-ons afterinstallation.

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    Other Design FeaturesOther outstanding design features of the Turbo Air 3000 compressor are shown in Figure 12including:

    1. Horiz