The Turbo Air 3000 Centrifugal...

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The Turbo Air ® 3000 Centrifugal Compressor with the Vantage™ Control System Compressor Handbook Cooper Turbocompressor, Inc. 3101 Broadway P.O. Box 209 Buffalo, New York 14225-0209 USA AAEDR-H-059 Rev. 01 ECO-1910938 May 2003 FWG

Transcript of The Turbo Air 3000 Centrifugal...

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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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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

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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 1—10 Limitation on Liability 1—11 Unauthorized Repair 1—11

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 5—11Additional Maintenance Procedures 5—17

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The Turbo Air 3000 Centrifugal Compressor Operator’s 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 6—10Air System Troubleshooting 6—12Lubrication System Troubleshooting 6—13

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 7—12Main Drive Coupling Parts 7—14Heat Exchanger Parts 7—15Air Piping Parts 7—18

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 A—19Electrical Interface A—27Receiving, Lifting, Moving, and Bolting A—30Preparing for Startup A—32Preventing Startup Problems A—37The Inspection Prior to Initial Startup Schedule A—38The Initial Startup Procedure A—40Service Assistance A—41

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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Contents

Appendix C: Vantage Control System LogicGeneral Considerations C— 3Compressor Control Methods C— 4AUTO-OFFLINE Control C— 7AUTO-STANDBY Control C—10AUTO-UNLOAD Control C—12Compressor Safety Mechanisms C—14

Appendix D: Control System Setpoints AdjustmentsGeneral Considerations D— 3The Operation Setpoint Adjustment Procedure D— 4Minimum Amp Setpoint Adjustment D— 7The Protection Setpoint Adjustment Procedure D—11

Appendix E: Control System InitializationGeneral Considerations E— 3Control System Initialization E— 4Analog Channel Initialization E—15Factory Default Initialization E—23

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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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

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Introduction

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About Cooper TurbocompressorCooper Turbocompressor’s 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 1—1 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 user’s 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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Introduction

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Other Design FeaturesOther outstanding design features of the Turbo Air 3000 compressor are shown in Figure 1—2including:

1. Horizontally split gearbox casing2. Built-in aftercooler3. Built-in intercoolers4. Mounted control panel5. Self-contained lubrication system6. Inlet guide vanes (standard)7. Shaft-driven main oil pump8. Mounted water manifold (optional)9. Mounted bypass valve (optional)

Figure 1—2 The Turbo Air 3000 Centrifugal Compressor

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3

4

5

6

7

8

9

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Safety PrecautionsThe Turbo Air 3000 Centrifugal Compressor is a powerful industrial machine that utilizes high-speedrotating elements and high voltages to produce high air pressures. Therefore, it is very important touse common sense and extra safety precautions whenever it is in operation as well as when performingmaintenance or making repairs.

Cooper Turbocompressor expressly disclaims responsibility or liability for any injury or damagecaused by failure to observe specified or other common safety precautions or failure to exerciseordinary caution, common sense, and due care required in operating the compressor even thoughnot specified herein.

The alert messages shown here appears throughout this manual to indicate those situations and timeswhen special care is necessary to prevent component harm or personal injury. There are three degreesof urgency:

CAUTION:This indicates that there may be the possibility of minor equipment damage.

WARNING:This indicates that there could be the possibility of minor equipment damageor personal injury.

DANGER:This indicates that there will definitely be major equipment damage and/or personal injuryor death if all proper safety precautions are not carefully followed.

The safety guidelines included here are also included on the safety labels affixed to various parts of thecompressor. They alert the user to possible and probable hazards and serve to remind the user ofspecific safety precautions. Before using the Turbo Air 3000 Centrifugal Compressor, be certain toreview the safety labels and the following safety guidelines.

WARNING:Observe all safety precautions included in this manual and on the compressor safety labels.Failure to do so may cause equipment damage and/or personal injury.

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Introduction

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Safety Labels

WARNINGHAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURYOR DEATH

Disconnect all power supplies, lock-out and displaysigns before servicing equipment.

DANGERAIR UNDER PRESSURE. WILL CAUSE SEVERE INJURYOR DEATH

DO NOT operate the compressor at pressure in excess ofthe nameplate rating.

Close the discharge block valve and relieve system ofpressure before removing any caps or plugs, or servicingcompressor.

DO NOT play with compressed air.

Wear eye protection when using compressed air.

CAUTIONELECTRICAL HAZARD. CAN SHOCK, BURN OR CAUSEDEATH.

All electrical enclosures and components must be installedand grounded in accordance with the National Electric Codeand other local codes.

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Safety Labels

WARNINGHIGH SURFACE TEMPERATURES. CAN CAUSE INJURY.

Some surfaces of the compressor and motor have excessivetemperatures. To avoid burns, keep hands and other bodyparts away while unit is operating.

DANGERHOT OIL UNDER PRESSURE. WILL CAUSE SEVEREINJURY OR DEATH.

Shut down compressor and pumps before removing anycaps or plugs, or servicing any parts.

DANGER

DO NOT USE DISCHARGE AIR FOR BREATHING ORFOOD PROCESSING, AS IT WILL CAUSE SEVERE INJURYOR DEATH.

Air from the compressor used for these processes in the U.S.A.must meet OSHA 29 CFR 1910 or FDS 21 CFR 178.3570 filtra-tion regulations.

CAUTIONELECTRICAL OR CONTROL HAZARD. COULD CAUSEINJURY OR MACHINERY DAMAGE.

DO NOT rewire or place jumpers in the control panel withoutwritten consent from the Cooper Engineering or Service Depart-ments.

Periodically check all safety devices for proper operation.

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Introduction

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Safety Labels

WARNINGROTATING SHAFTS COULD CAUSE SEVERE INJURYOR DEATH.

DO NOT remove protective guards while the compressor isin operation.

DO NOT attempt to service any part while the machine isoperating.

WARNINGUNIT CAN AUTOMATICALLY RESTART CAUSINGSEVERE INJURY OR DEATH.

Before removing the gearbox cover, lock the main powerOFF, close the system block valve, turn the lube pump OFF,and remove the drive coupling.

CAUTIONExercise cleanliness during maintenance and whenmaking repairs. Keep dirt away by covering parts andexposed openings with a clean cloth.

Be sure no tools, rags, or loose parts are left on the com-pressor or drive parts.

DO NOT use flammable solvents for cleaning parts.

WARNINGDO NOT operate the compressor in areas where there is apossibility of ingesting flammable or toxic fumes.

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WarrantyCooper Turbocompressor warrants that the compressor supplied conforms to applicable drawings andspecifications and that the compressor will be free from defects in material or workmanship for aperiod of twelve (12) months from the date of initial operation or a period of fifteen (15) months fromthe date of shipment, whichever period expires first.

If, within that period, Cooper Turbocompressor receives written notice from the purchaser of anyalleged defect in or nonconformance of the compressor and if, in Cooper Turbocompressor’s judg-ment, the compressor does not conform to the original specifications or is found to be defective inmaterial or workmanship, at its option Cooper Turbocompressor will make restitution in one of theseways:

1. By furnishing a service representative to correct the defective workmanship.

2. By repairing or replacing the component upon the component having been returned FOB to theCooper Turbocompressor factory in Buffalo, New York, USA.

3. By returning the full purchase price of the compressor (without interest) to the purchaser.

Cooper Turbocompressor’s sole responsibility and the purchaser’s exclusive remedy hereunder islimited to such repair, replacement, or repayment of the full purchase price.

Equipment and accessories furnished by third parties that are not incorporated in the compressorpackage manufactured by Cooper Turbocompressor are warranted only to the extent of the originalmanufacturer’s warranty to Cooper Turbocompressor.

There are no other warranties—express, statutory, or implied—including those of merchantabilityand/or fitness for purpose. Moreover, there is no affirmation of fact or representation that extendsbeyond the description of the face of this warranty.

This warranty shall be void and Cooper Turbocompressor shall have no responsibility to repair, replace,or repay the purchase price of defective or damaged compressors or component parts resulting directlyor indirectly from:

1. The purchaser’s use of repair or replacement parts or supplies not of Cooper Turbocompressor’smanufacture or which have not been recommended by Cooper Turbocompressor.

2. The purchaser’s failure to store, install, operate, and maintain the compressor according to CooperTurbocompressor’s written specifications, drawings, and good engineering practice.

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Introduction

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Limitation on LiabilityCooper Turbocompressor’s total responsibility for any claims, damages, losses, or liabilities arising out ofor related to the performance of the products covered hereunder shall not exceed the original pur-chase price.

In no event shall Cooper Turbocompressor be liable for any special, indirect, incidental, or consequen-tial damages of any character, including but not limited to:

1. Loss of use of productive facilities or equipment.

2. Lost profits, property damage, and/or expenses incurred in reliance on Cooper Turbocompressor’sperformance hereunder.

3. Lost production, whether suffered by the purchaser or any other third party.

Cooper Turbocompressor disclaims all liability for any and all costs, claims, demands, expenses, orother damages, either direct or indirect, incident to all property damage arising out of any cause ofaction based on strict liability.

Unauthorized RepairIn the event that the owner allows the compressor to be serviced or repaired by unauthorizedpersonnel, the coverage of the original warranty policy will be automatically terminated.

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Specifications

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Section TwoSpecifications

In this section, the reader will learn about:

��General Compressor Specifications

��Compressor Lubricant Requirements

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

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Specifications

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General Compressor Specifications

Installation Weights Complete Package with Motor

Compressor Rating (HP*) 400 500 600 700 800Weight in Pounds 14000 14000 15500 18000 20000Weight in Kilograms 6350 6350 7000 8400 9300

*HP = Horsepower

Connection Sizes Connections are to American Standards (ANSI), expressed in inches.

Air Inlet 8” ANSI Pipe Condensate Drain ½” NPT **Air Discharge 4” Victaulic* Air Ejector ½” NPT **Air Coolers (Water) 1 1/2” NPT** Control Panel 1” ConduitOil Coolers (Water) 3/4” NPT** Pressure Transducers ¼” FittingManifold*** (Water) 3” Victaulic*

*ANSI pipe grooved to accept a Victaulic, or equivalent, pipe coupling. **NPT = National Pipe Thread (tapered).***Extra Cost Option.

Discharge Connection Load Limits

English MetricMaximum Allowable Force 350 lbs 1500 NMaximum Allowable Moment 500 ft-lbs 675 Nm

Bolt Torques Unless otherwise noted, all bolts must be torqued to the following. These values are based on clean, unlubricated threads.

Bolt Diameter Torque Range(inch) (mm) (ft-lbs) (Nm)

3/4 20 143-157 195-2107/8 22 192-212 260-2851 25 285-315 385-425

Cold Alignment Specifications for Main Drive Motors Recommendations for cold field alignment, taken at compressor hub

0.0000 0.000

+0.002 Face +0.001 +0.005 RIM

+.003 +0.007

Recommendations For Cold Field Alignment, Take at Motor Hub

0.0000 0.000

+0.001 Face +0.002 -0.002 RIM -0.005

+0.003 -0.007

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

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General Compressor Specifications

Cooling Water RequirementsThe following represents total cooling water requirements for the compressor package including the built-inaftercooler and oil cooler. The values exhibited represent “worst case” conditions. Therefore, well maintainedheat exchangers will exhibit substantially better performance with less water

Compressor Rating (hp) 400 500 600 700 800Water Flow (gpm) 105 120 135 135 135Water Flow (lps) 7.5 8.5 9.5 9.5 9.5Water Pressure Drop (psi) 6.0 9.0 12.0 12.0 12.0Water Pressure Drop (bar) 0.42 0.62 0.83 0.83 0.83

Abbreviations: hp = horsepower gpm = gallons per minute lps = liters per second psi = pounds per square inch bar = metric unit for fluid pressure

Water Quality Requirements - Cooling service requires that the water be low in suspended solids to prevent fouling, lowin dissolved solids to prevent depositions and erosion, free of organic growth, and free of chemicals that exhibit corrosiveproperties to the copper tubes used as standard in the compressor heat exchangers. (Other tube materials with variouschemical resistances are available as options. Consult your authorized representative or Cooper Turbocompressor SalesDepartment directly.)

Coupling Bolt Torque ValuesEnglish Metric

100 ft-lbs 135 Nm

Lubrication SystemEnglish Metric

Reservoir Capacity 55 gallons (USA) 210 litersMinimum Reservoir Temperature Prior to Startup 60�F 15�CSystem Operating Temperature 120�F 50�CSystem Operating Pressure 120 psig 8.3 bargAir Ejector Pressure Range 25-30 psig 1.7-2.0 barg

LubricantsUse Type Amount

Compressor Turbine Oil* 55 gallons (USA)Main Drive Motor Bearings** Grease* 1 lb (0.5 kg)Main Drive Coupling Grease* 1 lb (0.5 kg)Inlet Guide Vane Drive Screw Grease* 1 lb (0.5 kg)

*Refer to text for complete description and recommendations.**Anti-friction bearings only.

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Specifications

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General Compressor Specifications

Control Housing Mechanical SpecificationsAttribute English Units Metric (ISO) Units

Height 24 inches 610 mm Width 20 inches 508 mm Depth 7 inches 178 mmWeight: 55 pounds 25 kg

Vantage Electrical SpecificationsProperty ValueRated Voltage 100 – 240 VACInput Voltage Range 90-264 VACRated Frequency Range 50 – 60 HzInput Frequency Range 47 – 63 HzPower Consumption 1.0 KVALocation Classification (per USA Standards): Standard NEMA 4 (outdoor: watertight & dustproof) Optional NEMA 4X (NEMA 4 with corrosion resistance) Optional Class I, Groups C & D, Division 2 (limited hazardous)

EnvironmentalTemperature: Operating Range* 32� to 140�F 0� to 60�C Storage Limits -4� to 140�F -20� to 60�CHumidity: Operating Range 5 to 95% Relative Humidity (Non-Condensating) Storage Range 0 to 100% Relative Humidity (Non-Condensating)*Panel heaters and coolers are available options.

Safety Approvals (optional)UL (USA) CSA (Canada) CE (Europe)

Other Package Electrical RequirementsMain Drive Motor* Furnished separatelyOil Pump Motor* 5 hp (3.5 kw) 460V/3�/60Hz ***Oil Heater (optional)** 1.5 kw 460V/3�/60Hz *** *Starter Required. **Magnetic contactor required above 480 volts.***Other voltages are available. Must be specified at time of order entry.

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Compressor Lubricant RequirementsThe user must obtain the following required lubricants for use with the Turbo Air 3000 Compressor:

� Acceptable turbine oil� Acceptable motor bearing grease� Acceptable inlet guide vane assembly drive screw grease� Acceptable coupling grease

Complete information about these lubricants is included in this section. Specific instructions for proce-dures involving their use are included in Section Five, Maintenance, of the complete Turbo Air 3000Compressor Operator’s Manual.

It is the user’s responsibility to provide all lubricants (including turbine oil, motor grease, andcoupling grease) at the initial startup and during subsequent operation. It is very important for allcompressor users to follow specific guidelines regarding lubricant selection and proper use in orderto assure optimal performance of the Turbo Air 3000 Compressor.

Compressor Oil SelectionThe correct lubricating oil is critical to satisfactory overall compressor performance. When operatingthe Turbo Air 3000 Compressor, use only high-quality, rust- and oxidation-inhibiting oil that resistsfoaming and that does not break down under severe operating pressures and temperatures. Incorrector poor quality lubricating oil can adversely effect high-speed shaft dynamics and seriously damagecritical compressor components.

While there are many quality oil products on the market today, not all have been demonstrated tofunction optimally in situations involving high-speed rotordynamics. For this reason, CooperTurbocompressor has formulated a lubricant that is as advanced as today’s high-tech compressors.TurboBlendTM Lubricating Oil is an exceptional lubricant formulated using a hydrocracked base stockand performance enhancing additives.

Hydrocracking is an advanced oil processing technology that is far superior to solvent refining. Itconverts crude oils into base stocks of unparalleled purity. So pure, in fact, and so highly refined thatthis new class of lubricant is free of the contaminants that cause lubricant breakdown ensuring longer-lasting compressor performance. The only additives in TurboBlend Lubricating Oil are those selectedexclusively by Cooper Turbocompressor scientists and engineers to increase performance. In test aftertest of standard quality indicators, TurboBlend Lubricating Oil outperforms solvent refined, commer-cially available oils.

TurboBlend Lubricating Oil is available through your authorized Cooper Turbocompressor representa-tive or directly from the Cooper Turbocompressor Parts Department. Refer to Section Seven of thismanual for part numbering and ordering information.

StandardsExcellent operating performance will be achieved when using TurboBlend Lubricating Oil. However, ifthe compressor owner or user chooses to pursue a near equivalent substitute, the subject oil mustconform to the following characteristics:

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Specifications

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� Refined from high-quality mineral oil stock.� Free from any contaminants or impurities that may be abrasive or have a lapping action.� Contain additives to provide:

- a high level of oxidation stability,- a high degree of wear protection,- rapid separation from entrained gases,- foam-free operation,- rust-free and corrosion-free operation, and- resistance to the formation of sludge and harmful resin-like deposits.

� capable of maintaining high flow strength and not break down under extremes of pressure and temperature.

Animal, vegetable and mineral oils of poor quality must be avoided as these oils would tend to oxidize,develop acids, and form sludge or resin-like deposits on rotating elements. Such deposits may be ofsufficient volume to cause very high, localized loadings that will lead to a premature breakdown of theload-carrying capacity of the oil. This will result in worn gears and scored bearings.

SpecificationsTurboBlend Lubricating Oil meets or exceeds the performance standards listed in Table 2—1. Anysubstitute or equivalent oil selected for use in the Turbo Air 3000 Compressor by the compressor ownermust exhibit similar results.

Property Test Method PerformanceViscosity: at 40°C ASTM D445 46 Cst at 100°C ASTM D445 7 CstViscosity Index: ASTM D2270 �100Four Ball Wear Test: (40 Kg, 1200 RPM, 75°C, 1 Hour) ASTM D4172 � 0.4 mm

��Water Separability: (54°C and 82°C) ASTM D1401 �3 ml at 15 minutesFoaming Characteristic - Sequences I, II & III: Tendency/Stability ASTM D892 �10 ml / 0Gas Bubble Retention Time: at 50°C ASTM D3427 � 5 minutesRust Test: Distilled Water ASTM D665A Pass Synthetic Sea Water ASTM D665B PassRotating Bomb Oxidation Test: ASTM D2272 � 400 minutes

Base Oil is to be refined from high-grade mineral oil stock.

Table 2—1 Cooper Turbocompressor Oil Specification

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

2—8

Other Oil Selection ConsiderationsIncorrect or poor quality lubricating oil can seriously damage the compressor’s rotating and mechanicalelements. Do not merely rely on an oil dealer recommendation when selecting turbine oil, and do notcompromise quality in an attempt to economize. Many reputable brand name oil products exist, butnot all perform effectively in the demanding world of high-speed turbomachinery.

Do not mix different brands of oil. This is inadvisable because some oils are incompatible, and a wrongcombination of additives could cause serious machine damage and/or poor overall performance. Thelubrication requirements of the Turbo Air 3000 Compressor are not so severe as to require the qualitiesof high-cost synthetic oil. In addition, Cooper Turbocompressor products are not designed to usesynthetic oils. Therefore, use of such products is not recommended and is done at the owner’s risk.

CAUTION:To ensure optimum performance and to avoid possible compressor damage, always becertain to follow the guidelines listed below.

� Use only Cooper Turbocompressor TurboBlendTM Lubricating Oil or a high-quality turbine oil that meets the specifications in Table 2—1.� Do not mix different oils.� Avoid the use of synthetic oils.� Remember that use of unspecified oil is done at the owner’s risk.

Inspection and TestingOil samples from the compressor reservoir should be visually inspected and tested for viscosity andfreedom from contamination at regular intervals. This will insure that proper lubricant properties arealways being provided and early deterioration of the gearing and bearings is diminished.

� Color and AppearanceCompare an oil sample from the reservoir with new oil. Any color change suggests some type ofdeterioration. Darkness implies contamination from acid buildup while muddiness is an indicationof water.

� Viscosity, Acid and Particle CountTests for these properties required qualitative analyses by a reputable laboratory. Follow therecommendations of the laboratory with regard to oil replacement.

Cooper Turbocompressor offers an oil analysis service. Sampling kits and information about this serviceare available through an authorized Sales and Service Representative, or directly through the CooperTurbocompressor Aftermarket Department. (See Section 8 of this manual for sampling kit part numberinformation.)

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Specifications

2—9

Other Required LubricantsThe user must also provide an array of other lubricant products as specified.

Motor Bearing LubricantsThe user must provide lubricants for the main drive motor and the oil pump motor. To ensure long lifeof the bearings of both motors, it is necessary to maintain both proper alignment and proper lubrica-tion levels at all times. The large, squirrel cage inductor motor of the Turbo Air 3000 Compressoremploys (depending on the specific type of motor used) either anti-friction bearings or sleeve bearings.Each type of bearing has different lubrication requirements.

Refer to the motor manufacturer’s instructions provided separately for complete informationregarding correct oil bearing lubrication maintenance procedures for each type of motor.

Anti-Friction Bearings—GreaseFor best results with anti-friction bearings, use grease compounded from a non-soap base and a goodgrade of petroleum oil. Table 2—2 lists acceptable greases that meet those requirements.

Acceptable Motor Bearing GreasesChevron Oil SRI #2®

Exxon Unirex N2®

Shell Oil Dolium R®

Texaco Premium RB®

Cooper Turbocompressor does not recommend the products of any individual grease manufacturer.This listing constitutes neither endorsement of any product nor exclusion of comparable productsnot listed.

Table 2—2 Acceptable Motor Bearing Greases

Sleeve Bearings—OilIt is the user’s responsibility to fill the motor bearing oil reservoir and to maintain the correct oil level atall times. When lubricating sleeve bearings, use only a high quality, petroleum-based oil with a viscosityof 200-220 SSU at 100� F (40�C). Since motor bearings require the same type of oil as used in thecompressor itself, it is not necessary to maintain two separate supplies of oil if this type of bearing isused.

CAUTION:Before aligning or using this type of motor, always verify that the correct amount of oil isin the reservoir. Motors with sleeve bearings are sometimes shipped without oil in theirreservoirs.

Drive Coupling GreaseThe user must provide coupling grease at the time of installation and during compressor operation.This coupling grease must meet very specific requirements. Conventional factory greases do not providecomplete lubrication for high-speed flexible couplings. The lithium soaps used as thickeners separate,forcing the soaps into places that require lubrication. The soaps then act as abrasives that acceleratewear.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

2—10

Cooper Turbocompressor endorses only greases with a K 36 Test Rating of 0/24. These are the onlygreases found acceptable by the American Gear Manufacturer’s Association (AGMA) because of theirhigh resistance to centrifugal separation. (Cooper Turbocompressor Coupling Grease is specially formu-lated to meet this very specific requirement.)

CAUTION:Do not use a coupling grease with a K36 Test Rating above 0/24. Since other products maycause premature wear and/or other damage, always use Cooper Turbocompressor CouplingGrease only.

Inlet Guide Vane Assembly Drive Screw GreaseUse a high quality, synthetic grease when lubricating the actuator drive screw. Do not use anon-synthetic grease for lubrication of this assembly, since such greases tend to thicken during coldoperating conditions. Consequently, they tend to hinder or possibly even prevent proper operation ofthe inlet guide vane assembly

Bypass Valve LubricantCompressors equipped with AUTO-OFFLINE Control utilize a pop-action bypass valve to vent thedischarge side of the compressor. Two different size and type of valves are employed dependingupon volume flow requirements. The valve supplied with units rated up to 600 horsepower must belubricated periodically, while the larger valve for units rated 700 horsepower and larger requires nolubrication.

The only product Cooper Turbocompressor found acceptable for this service is Dow CorningMOLYCOAT 33®. Other products may gum up under certain operating conditions and cause thevalve to malfunction.

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The Control System

3—1

Section ThreeThe Control System

In this section, the reader will learn about:

��The Vantage Control Panel

��The Vantage User Interface

�� Input or Operational Keys

��Practice Exercise

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The Turbo Air 3000 Centrifugal Compressor Handbook

3—2

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The Control System

3—3

The Vantage Control PanelThe major components of the Vantage Controller are mounted in a weatherproof electrical enclosurewith a NEMA 4 rating. One or more Main Logic Modules (MLM) are included in the panel. Each MLMcontains a power supply, a microprocessor, and an I/O (input / output) segment. Depending upon theparticular application, up to two additional slave MLM units may accompany the master MLM toincrease I/O capacity.

Each master MLM also contains the hardware to support a User Interface Module (UIM). The UIM is afull-page, back-lit liquid crystal LCD display with an integrated 15 key, tactile keypad. The displayprovides 20 lines by 80 characters of detailed information on the operational condition and settings ofthe controller.

The acceptable operating environment of the control panel includes an operating temperature rangeof 32ºF to 140ºF (0ºC to 60ºC), and a maximum 95% relative humidity (non-condensing). The storagetemperature range is -4ºF to 140ºF (-20ºC to 60ºC).

The source power is 100 - 240 VAC, 50 or 60 Hz. A 10-amp fuse protects the MLM circuitry. All wiring,including grounding, must be in accordance with local codes and the National Electric Code (NEC) inthe USA.

CAUTION:The MLM is neither designed not intended to supply power to any other device.Do not wire any other devices from the MLM.

The display, or UIM, receives electrical power from the MLM through the DB9 cable with connectors.

Do not attempt to supply power to the UIM from any other source other than the MLM.

The Vantage Controller operates similarly to a personal computer (PC). Operating system software isstored in flash memory located in the MLM. The operating system provides a real time, multi-taskingenvironment for control programs. Control programs are loaded and saved to flash memory prior toinstallation. Once loaded, these programs are maintained in memory by a small battery or saved to flashmemory. It is not necessary to load programs into the Vantage Controller except during certain specialinstallations, or if a new MLM is installed.

The MLM and UIM contain no user serviceable parts.

Cleaning - If the MLM becomes dirty, use only a dry cloth to clean the part. Never apply water or anysolvent. If the display, or UIM, should become dirty, a mild detergent can be used for cleaning. Use asoft, non-abrasive cloth to clean the display. Do not submerge any part.

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The Turbo Air 3000 Centrifugal Compressor Handbook

3—4

The Vantage Control Panel User Interface

Figure 3—1. User Interface Module

1. DisplayPresents critical diagnostic and operating information, including startup, shutdown, alarm warnings, trips,setpoint changes, and much more

2. Index or Menu KeysAccess screens that display information about compressor operation and control parameters, historical dataand networking.

3. Function KeysOperate the compressor, display and adjust accessible set points.

4. Input or Operational KeysAllows the operator to navigate through the various screens and to observe and change control parameters bychanging values, manipulate control valves, enter changes to control constraints.

5. EMERGENCY STOP Push Button (not shown)When pressed, immediately removes all power to the main drive motor. This device should only be used in caseof an emergency. (The Emergency Stop button must be pulled out before starting the compressor.)

���������������

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The Control System

3—5

Index or Menu KeysThese four keys provide the operator access to numerous screens that display compressor real-timeoperational data, along with control, historical and networking information from the Vantage ControlSystem.

The following descriptions and sample screens demonstrate data from both standard and optionalmonitoring instruments that may or may not be included on all models.

HomePress to display the "Home" screen as selected by the compressor user / owner.

ViewThis key displays a list of screens that show current compressor values. The compressorperformance settings cannot be changed using this key.

When this key is pressed, the screen below appears and allows the operator to selectany of the screens.

View Pages

Performance ControlMonitor PointsControl PointsMonitoring ChartProtection (Running)Protection (Startup)Startup StatusEfficiencyInformationAuxiliary ControlTurbo DryPak Control

HistoryPress this key to display records of compressor operation.The screens available include:• Protection History• Event History• Operation History• Motor Trip History• Set Point History• Surge Test Results

NetworkThis displays screens for managing the optional networking feature. When networkingis present on the system these screens include:• Compressor Network• Modbus Interface

�������

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The Turbo Air 3000 Centrifugal Compressor Handbook

3—6

Function KeysFour of these five keys are used to operate the compressor and to have it produce compressed air. Thefifth key allows the operator to adjust certain setpoints that regulate the compressor’s operation.

Some of the following screens demonstrate messages for accessory equipment or instrumentation thatmay not be installed on specific units. These screens will, however, alert the reader as to what some ofthese options are and how they are applied.

StartPress this key to initiate the compressor starting sequence. The screen below shows atypical start sequence. As the Vantage Controller proceeds through the sequence, thedisplay advances through each step in the sequence. The actual screen on your systemmay show other steps.

Compressor Start Sequence

Description Status1: Opening Water Valve Complete2: Oil Pressure > 100 psi Complete3: Oil Temperature > 70 Waiting4: Discharge Pressure < 5 psi5: Checking Water Flow6: Motor Enable7: Starting Compressor8: Waiting for Motor Speed9: Compressor Ready to Load

StopThis key initiates the compressor stop sequence. Screens below are typical of those yousee after pressing Stop. An initial screen tell you the compressor is unloading and thesecond goes through the remaining events of the sequence.

Compressor Stop Sequence

Description Status1: Motor Enable = OFF Completed2: Oil Pump = OFF Completed3: Turning Off Water = ON Waiting

1

3

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The Control System

3—7

AutoThis key launches the compressor automatic control mode enabling it to respondautomatically to changes in system demand per a pre-selected control method.(The control method for your system was determined at the time of order and isbased on the specific application. For information on control strategies and themethods available, refer to the Control Logic Appendix.)

UnloadThis key disables the Auto mode and unloads the compressor by opening the blow offvalve and closing the inlet guide vanes. The system continues to run but does notrespond to changes in air system demand until someone presses the Auto key.

Set PointsPressing this key displays the lists of set points you can open and change depending onyour level of access. The opening Set Points screen below shows the four access levels.

Set Points

OperatorMaintenanceServiceConfiguration

Access levels are password protected at the discretion of the owner. Some set pointsare factory set and cannot be changed.

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The Turbo Air 3000 Centrifugal Compressor Handbook

3—8

���

Input or Operational KeysThese keys allow the operator to communicate with the control system. Using these keys you canmaneuver among the control screens, change alpha-numeric values of set points, and changethe various control constraints or entered using these keys in the manner described below.You can simultaneously manipulate the throttling and blow-off valves by using the two sets ofpaired keys.

Increase and DecreaseUse this pair of keys to perform these operations:• Raise or lower the value of any numeric or alpha character highlighted on a

particular screen.• Toggle between two conditions (e.g.: ON/OFF; Alarm/Normal; Yes/No).• Manually step open or close the inlet valve or inlet guide vanes. (Full manual

control must be authorized to use this function. See: Set Points / ManualControl / Enter.)

EnterPress this key to navigate and perform the following operations:• Select and move into the highlighted field or screen. (e.g.: After navigating to

an item on a menu screen, press Enter to open or expose that subject's screen.)• Advance the cursor to the next entry data field or to the next digit within a

data field.• Confirm changed/displayed values (by moving away from the page).

BackPress this key to navigate and perform the following operations:• Return to the previous display screen.• Move the cursor back within a particular selection screen or data entry field.• Confirm changed/displayed values (by moving away from the page).

UpUse this pair of keys to:• Display additional information within a multi-paged screen. (Relocate "up" or

"down" to the next page.)• Navigate up or down within a list.• Manually step open or close a modulating blow-off valve. (Full manual control

must be authorized to use this function. See: Set Points / ManualControl / Enter.)

• Increase or Decrease the contrast of the LCD display when used incombination with the View key.

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The Control System

3—9

Practice ExerciseYou can use this practice exercise to gain familiarity with the various keys and to view representativescreens on the display before the actual startup and operation of the compressor under the VantageControl System.

When exploring the display screens with option lists, remember to use the Up and Down keys to movethrough the various selections. Press the Enter key to advance to the next screen.

DANGER:Be absolutely sure that the main motor starter connection has been disconnected andlocked out before attempting this practice exercise. Failure to do so may result in equip-ment damage, personal injury or death.

Temporary Power ConnectionIf your system's Vantage control panel is already wired to the main motor starter control power trans-former, disconnect the power supply directly at the Vantage Controller and reconnect the VantageController to a separate power source with a temporary power cable.

The source of power is 100-240 VAC, 50 or 60 Hz. Make the power connections at terminalblock J15, on the right side of the Main Logic Module (MLM).

Make the temporary power cable connection as follows:

1. Connect the main power lead to the terminal labeled L1.

2. Connect the neutral lead to L2.

3. Connect the earth ground to GND.

4. Avoid electrical interference problems by keeping the power leads away from the analogor communication wiring.

ProcedureSome of the sample screens shown here demonstrate data from both standard devices andoptional monitoring devices that may not be included on all models. It should also be noted thatthis exercise is intended to familiarize an individual with those features required to operate thecompressor in a safe and efficient manner. Details regarding control system setup,troubleshooting or maintenance are provided elsewhere.

Proceed with the practice exercise as follows:

1. Plug the temporary power cable into the power source.

2. Make sure that the Emergency Stop button is pulled out.

3. The LCD display should be visible. If the LCD display is difficult to read, try the following toimprove the clarity:

• Unplug the power cable from the electrical receptacle, and then plug the cable back in.

• If the panel is cold, it may take a few minutes for the display to improve.

• To adjust the backlighting further, press and hold the View key while simultaneouslypressing the Up or Down key to increase or decrease the contrast.

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The Turbo Air 3000 Centrifugal Compressor Handbook

3—10

4. Press the Home key to display the “Home” page selected by the compressor owner. Any ofthe View screens are practical choices to give the operator quick and easy access toimportant operation or protection data. Probably the most popular screen selected is the Perfor-mance Control Screen (seen below).

Performance Control

Performance Control Screen (Typical "Home" Screen)

5. Press the View key for a list of screens that provide compressor operational information;press Up or Down to move to Protection (Running),and press the Enter key to display theProtection (Running) screen (below).

Protection (Running)

Trip Alarm Alarm TripDescription Tag Low Low Data High High

1: System Air Pressure PT-100 70.0 98.2 110.0 110.02: 3rd Stage Discharge Press PT-106 101.1 130.0 135.03: Drive Motor Current IT-199 148 165 1734: Oil Pressure PT-159 70.0 80.0 110.0 140.05: Oil Temperature TE-147 60.0 70.0 110 140 1506: 1st Stage Vibration VT-192 0.23 1.50 2.007: 2nd Stage Vibration VT-194 0.14 1.50 2.008: 3rd Stage Vibration VT-196 0.17 1.50 2.009: Inlet Air Filter DPT-107 4.2 8.0 10.010: Motor Power JT-199 101411: Motor Stator A Temp TE-199A 112 150 165

The Protection (Running) screen shows the monitored points that protect the compressor theinstrumentation identification numbers (Tag). The Data column shows the current value of eachpoint, plus the Alarm and Trip set points of each attribute. Values shown are in units as defined.

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The Control System

3—11

6. Press Back (or View) to return to the View page.

7. Press Up or Down to move the highlight to Startup Status and press Enter to open the screen.

The Startup Status screen (sample screen below) is active only when the compressor is stopped. Theelements displayed, along with a status indication, are those necessary for a permissive start. Eachcondition must show a "Ready" status before a successful start.

Startup Status

Description Status2: 3rd Stage Discharge Pressure < 3.0 Not Ready3: Oil Temperature > 70 Ready4: Oil Pressure > 80.0 Not Ready

Other index keys access to additional history and networking information, not essential to the safeand efficient operation of the compressor. This practice exercise is only to help develop your confi-dence in the basic navigation and operation of the Vantage controller.

8. Press the Set Points key to display a list of set point selections.Press the Up or Down key as needed to highlight the Operator access level.Press the Enter key to open the screen. (In this example, the System Pressure is set at 98.0 psi.)

Operator

System Pressure Setpoint: 0 0 9 8.0System Pressure Offset: 3.0Maximum Motor Load (%): 100.0

For this exercise, raise the System Pressure Set Point from 98 psi to 103 psi in the followingmanner:• Press Enter to move the cursor to the hundreds column.• Press Increase to change the value in this column to 1.• Press Enter to acknowledge the new value, and to move to the next column.• Press Increase to change the value in the tens column to 0.• Press Enter to acknowledge, and to move to the units column.• Press Increase or Decrease repeatedly until a value of 3 appears.• Press Enter.• Press Enter again to confirm the new set point, and to return to the Set Points

selection screen.

9. Learn about other screens or panel functions by using the Input or Operational Keys as demon-strated in Step #8. Some set point values are critical to the protection of the compressor andcannot be changed by the operator.

10. When complete, unplug the temporary cable from the power source and restore the original panelpower connection. (A qualified electrician may be required to make this connection.)

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The Turbo Air 3000 Centrifugal Compressor Handbook

3—12

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Routine Operation

4—1

Section FourRoutine Operation

In this section, the reader will learn about:

� General Considerations

� The Operating Data Record

� Routine Startup — LOCAL Control

� Routine Shutdown — LOCAL Control

� Adjusting the Pressure Setpoint

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

4—2

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Routine Operation

4—3

General ConsiderationsAfter successful startup, the operator should keep detailed compressor operation and maintenancerecords. (Refer to Section Five, Maintenance, for schedules and instructions for routine and periodicpreventive maintenance procedures.)

Although it may be necessary to review and adjust setpoints to reflect changes in operating conditions,little other attention is required other than that described in Section Five. However, in addition tooperator inspection and attention at periodic intervals.

To assure long life and optimal output from the Turbo Air 3000 Centrifugal Compressor, always followthe prescribed maintenance procedures. If problems arise, contact a Cooper Turbocompressor factorytrained and authorized service representative for technical assistance.

WARNING:When in the process of starting or stopping compressor operation under routineconditions, do not attempt to restart the compressor until operation has stoppedcompletely. Restarting the compressor before full shutdown will cause equipmentdamage.

The Operating Data RecordCooper Turbocompressor recommends keeping an Operating Data Record to list inspections and tostore operating data for trend analysis. This record should contain the checklist items included in Table4—1, along with spaces for the operator’s initials and the time and/or date to ensure that each item orprocedure receives the recommended periodic attention. Keep in mind, however, that Table 4 actuallyincludes a wide range of options, and remember that not all options are included on all units. (Usersmay wish to mark those options that are included in any particular installation for easy reference.However, if other options are added at a later time, be sure to update the list.)

The Operating Data Record is included as part of the Daily Inspection Checklist contained in SectionFive, Maintenance.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

4—4

Operating Data RecordPressure� Discharge Air Pressure:

� System Air Pressure:

� Main Oil Pressure:

� * Inlet Air Filter Drop:

� * Oil Filter Pressure Drop:

Temperature� Oil Temperature:

� * Stage 2 Inlet Temperature:

� Stage 3 Inlet Temperature:

� * Discharge Air Temperature:

� * Motor Stator 1 Temperature:

� * Motor Stator 2 Temperature:

� * Motor Stator 3 Temperature:

� * Motor Bearing Temperature Drive End:

� * Motor Bearing Temperature Non-drive End:

Vibration� Stage 1 Vibration:

� * Stage 2 Vibration:

� * Stage 3 Vibration:

� * Motor Vibration at Drive End:

� * Motor Vibration at Non-drive End:

Power� Motor Current:

Time� Date:

� Time:

� Total Running Time:

� Current Running Time:* These are optional sensors which may not be included on all models.Table 4—1 The Operating Data Record

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Routine Operation

4—5

Routine Startup—Local ControlUse this procedure to start the compressor locally from the User Interface Module (UIM).

WARNINGOnly fully trained personnel should be allowed to start and operate this compressor.Failure to comply may result in serious injury or death.

1. Close the condensate drain bypass valves.

2. Turn on the cooling water supply. (May occur automatically as part of start sequence.)

3. Check the oil level in the oil reservoir.

4. Activate the oil reservoir vent system (air-powered ejector, or electric-powered vacuum pump),and adjust appropriately.

5. Rack in the main drive motor starter disconnect.

6. Inspect the compressor for any water or oil leaks.

7. Open the discharge air system block valve. (May occur automatically as part of start sequence.)

CAUTION:Do not open the air system block valve when the oil pump is not operating. Operationunder such conditions may cause compressor damage.

8. Press the START key on the Vantage Control Panel and observe the compressor start sequence.A screen appears similar to the screen shown below.

Starting

Description Status

1. Oil Pressure > 100.0 PSI Complete2. Oil Temperature > 70 Waiting 23. Discharge Pressure < 5 PSI4. Checking Water Flow = ON5. Motor Enable = ON6. Start Signal = 8.00

(This is sample screen that may contain extra messages.)

9. After startup, control defaults to the Auto mode. Press Home to observe selected processesand verify stability. To stop the Auto mode, press Unload.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

4—6

Routine Shutdown—Local ControlUse the following procedure to shutdown the compressor under normal conditions.

CAUTION:If the compressor is to be shutdown for an extended period in a cold environment, drainall water from the compressor's cooling system after the shutdown. Water in the heatexchangers may freeze and cause damage to the internal tubes. An alternative to drainingis to maintain some minimum flow through the coolers.

1. Press the STOP key.The automated stop sequence, including stopping the motor, begins.

Stopping

Description Status

1. Motor Enable = OFF Completed

2. Oil Pump = OFF Waiting 2

(Note: Messages and data displayed on stop sequence screen may differ among systems.)

2. When you press the STOP key, the Vantage control system software tells the bypass valve (orblow-off valve) to open and the inlet guide vanes (or other throttling device) to closecompletely. (This takes 10-15 seconds.) In addition to the closing of the inlet, theautomated stop sequence begins.

3. Close the air system block valve.*

4. Open the condensate drain bypass valves. (May occur automatically as part of sequence.)*

5. Allow the cooling water and oil to circulate for at least 30 minutes to remove heat.

6. Turn off the water supply, if not controlled automatically. (May occur automatically as part ofsequence.)

7. Stop the electric oil pump, if wired separately. (May occur automatically as part of sequence.)

8. Rack out the drive motor starter disconnect.

9. Turn off the reservoir venting system.

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Routine Operation

4—7

����Enter ���to move cursor

to the right

Adjusting the System Pressure Set PointDuring normal operation, it may become necessary to make small adjustments to the SystemPressure Set Point in order to alter the operating characteristic of the compressor. The example hereshows a System Pressure that has been set at 98.0 psi.

CAUTION:DO NOT operate the compressor at pressures greater than the nameplate rating.Doing so could result in equipment damage or personal injury.

Adjust the System Pressure Set Point as follows:

1. Press the Set Points key to display a list of set point selections.

2. Press the Up or Down key as needed to highlight Operator .

3. Press the Enter key to open the Operator screen. (Enter your Operator Access Code ifprompted)

Pressure Setpoint

System Pressure Setpoint: 0 0 9 8.0System Pressure Offset: 3.0

Maximum Motor Load (%): 100.0

4. Use the Up or Down key to move the cursor to the value you want to change.

5. Press Enter to move the cursor right to the digit you want to change.

6. Press the Increase or Decrease key to change the value of that digit.

7. Press Enter to move to continue moving through each digit, changing the value of digitsonly where necessary. (Back moves the cursor to the left.)

8. On completion press Enter to return to the Set Points selection screen.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

4—8

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Maintenance

5—1

Section FiveMaintenance

In this section, the reader will learn about:

� General Considerations� Daily Inspection� Scheduled Maintenance� Professional Inspection

� Filter MaintenanceInlet Air FilterBypass Valve FilterOil Reservoir Vent FilterStandard Oil FilterDuplex Oil Filter

� LubricationCompressor Lubricating OilOil Pump Motor BearingsMain Drive CouplingDrive Motor Ball BearingsInlet Guide Vane Drive ScrewBypass Valve

� Additional MaintenanceHeat ExchangersIntercooler CleaningOil Cooler CleaningAccumulator TestingDischarge Air Check Valve Inspection

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Maintenance

5—3

General ConsiderationsThe Turbo Air 3000 Centrifugal Compressor requires minimal maintenance. However, monitoringoperating conditions on a daily (or shift change) basis is good practice. It allows the operators tobecome familiar with a smooth running machine which will lead to early detection of potential prob-lems. The result is improved overall performance, a dependable supply of compressed air, longercompressor life, and lower overall compressed air costs.

Just as with any other type of machinery, compressors are subject to operational changes from environ-mental conditions, wear, or neglect. A plugged condensate drain, unusual noises, temperature orvibration increases, discolored oil, and/or fluid leaks are some examples of operational changes thatmay signal beginning of potential problems. Recognizing any changes in operation and appropriatelyresponding to those changes can prevent undesirable consequences such as unscheduled shutdownand/or the expense of unanticipated repairs.

WARNING:Do not attempt service procedures other than those described in this manual. Even aminor adjustment, incorrectly performed could cause serious damage. Since the Turbo Air3000 Centrifugal Compressor is a high technology product, for all other procedures alwaysconsult a Cooper Turbocompressor trained and authorized service representative.

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Daily InspectionA daily inspection takes only a short time, but it will allow the operator to develop a definite sense ofthe appearance, sounds, and other operating conditions of a smoothly performing compressor. Anychanges can be investigated and be given attention before major problems develop. Table 5 – 1 liststhe items that should be monitored daily (or with a shift change).

Daily Operator Inspection ChecklistWARNING: Exercise care when in the vicinity of hot surfaces, pressurized air, and high voltages.Procedures accompanied by the alert symbol (!) require special precautions as indicated.

Operating Data Log

� Operating Parameters recorded and within specifications

� Setpoints recorded

Gearcase (High surface temperatures)

� External surfaces wiped clean� No unusual noise or vibrations� No oil leaks� No water leaks� No frayed or worn electrical cables

Intercoolers and Aftercooler (Pressurized air, high surface temperatures)

� External surfaces wiped clean� Condensate drains functioning properly� No cooling water leaks� No air leaks

Lubrication System (High voltages at heater, pump motor)

� External surfaces wiped clean� Proper oil level in oil reservoir� Proper oil color� No mist from ejector system� No oil cooler water leaks� No oil leaks� No frayed or worn electrical cables

Compressor Drive Motor (Inspect visually only—high voltages, temperatures)

� External surfaces wiped clean� Properly ventilated� No erratic or noisy operation� No frayed or worn electrical cables� Inspected in accordance with manufacturer’s recommendations

Table 5—1 Daily Operator Inspection Checklist

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Maintenance

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Scheduled MaintenanceTable 5—2 lists suggested intervals for prescribed scheduled maintenance procedures such as thoseinvolving filters, lubrication, and other inspections and/or adjustments. Bear in mind, however, thatthese intervals may vary with operating conditions and/or actual hours of machine operation. Someitems may require attention more or less frequently as circumstances dictate.

Scheduled Maintenance ProceduresWhen servicing the Turbo Air 3000 Centrifugal Compressor, use only genuine Joy® and CooperTurbocompressor replacement parts and recommended supplies available through CooperTurbocompressor and/or authorized representatives.

Weekly:(or after about 150 hours of operation)

� Inlet air filter elements inspected, replaced if required� Oil reservoir venting system filter elements inspected, replaced if required� Bypass valve filter checked (if supplied)

Every Six Months:(or after about 4000 hours of operation)

� Oil reservoir venting system filter element changed� Oil system filter element changed� Lubrication system oil tested and changed if required� Coolant chemically tested� Bypass valve lubricated (if required – check instructions)� Inlet guide vane assembly drive screw lubricated� Main drive coupling inspected and lubricated.� Drive motor ball bearings lubricated with recommended grease. *� Oil pump motor lubricated with recommended grease

� Discharge air check valve inspected

*Refer to the motor instructions for specific interval guidelines.

Table 5—2 Scheduled Maintenance Procedures

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Professional InspectionA substantial part of any good preventative maintenance program also involves professional inspectionand replacement of common maintenance components after an established interval. Such in-depthinspection is particularly important when an unscheduled and/or long-term shutdown would seriouslyaffect production. Table 5—3 lists the items which require a professional service inspection wheneverenvironmental or operational conditions dictate. Contact a Cooper Turbocompressor trained andauthorized service representative for those procedures and for professional advice.

Service Inspection ChecklistTo be performed with a Cooper Turbocompressor authorized representative:

Gearcase*� Impellers, inlets, and diffusers cleaned� Impellers, inlets, and diffusers inspected� Gearing visually checked� Gearing backlash clearances measured� Axial pinion float checked� Clearances between impellers and inlets checked

Intercoolers* and Aftercooler*� Bundle tubes inspected, cleaned if required� Bundle fins inspected, cleaned if required� Cooler cavities cleaned and inspected

Lubrication System*� Piping connections checked for leaks� Oil visually inspected� Oil cooler inspected

Filters� All filter elements inspected

Control Panel� Inspected for proper operation

Control Valves� Inlet Guide Vane inspected� Bypass valve inspected� Discharge air check valve inspected

Drive Motor� Main drive coupling inspected and re-greased� Motor inspected in accordance with manufacturer’s instructions

*Replacement parts required. Use only genuine JOY® and Cooper Turbocompressor parts andsupplies available through the Cooper Turbocompressor and/or authorized representatives. (Refer toSection Seven, Parts and Service, for additional information regarding inspection kits.)

Table 5—3 Service Inspection Checklist

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Maintenance

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Filter MaintenanceSeveral filters located in different parts of the compressor system ensure that the air and oil passingthrough the system are always clean. For optimum performance the operator must regularly monitorthe condition of these filters, and clean or change filters as required.

Table 5—4 lists the various filters along with recommended inspection intervals and recommendedresponses for typical operating environments. Instructions for each procedure are included in thissection.

Filter Maintenance ScheduleFilter: Inspect: Clean or Change:

Inlet air filter elements* Weekly When dirty or after 12 monthsBypass valve filter* Weekly When dirty or after 12 monthsOil reservoir venting system* Weekly With misting or after 6 monthsOil system filter element* N/A At Alarm level or after 6 months

*When replacing filter elements, use only genuine JOY® and Cooper Turbocompressor products. Referto Section Seven, Parts and Service, for more information on parts availability through the CooperTurbocompressor Parts and Service Department and/or authorized representatives.

Table 5—4 Filter Maintenance Schedule

Inlet Air Filter Cleaning and ReplacementThe inlet air filter is a two-stage unit. While the primary filter may be cleaned, the secondary filterelement must be replaced when it becomes dirty and no longer functions properly.

Since compressor operation without the action of the primary filter will contaminate the second-ary filter very rapidly, Cooper Turbocompressor recommends that user’s stock a spare primaryfilter for use as required. It is also necessary to keep a supply of secondary filters for use asrequired, since the secondary filter cannot be cleaned and must always be replaced when itbecomes dirty and no longer functions properly.

Because contamination levels vary in different operating environments, the only reliable method todetermine whether either cleaning or replacement is necessary is by measuring the pressure dropacross the filter elements. Use this procedure:

1. Install a differential pressure gauge in either the inlet filter housing or the inlet pipe.

2. Measure and record the current pressure drop. Compare that with the one initially taken when thenew filter elements were installed.

� If the current pressure drop is within 4” (or 100 mm) water column (WC) of the originalreading, continue operation.

� If the pressure drop exceeds the original reading by more than 4” (or 100 mm) WC, thatis an indication that the filters require maintenance.

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3. When necessary, it is possible to clean the primary filter (which has the screen across its face) ineither of these two ways:

� Blow 30 psi (2kg/cm2 or bar) of air from the clean side.— or —

� Soak and periodically agitate the filter in hot water containing a non-volatile cleaningagent and then air dry the filter completely before installation.

4. If after cleaning or replacing the primary air filter the air pressure drop returns to normal, that isan indication that the secondary filters are still clean. However, if the air pressure drop remainshigh with the clean or replacement primary filter, it is time to replace the secondary filters.

CAUTION:Do not operate the compressor for more than 2 minutes without the primary filter. Opera-tion without proper filtration may cause compressor damage or malfunction.

Bypass Valve Filter Element ReplacementOn compressors so equipped, a filter is located in the pilot supply line to the bypass valve. It serves toprevent water and/or other contaminants from entering the bypass valve’s control mechanism. Use aCooper Turbocompressor replacement filter only.

The replacement procedure is as follows:

1. Completely shut down the compressor and exhaust any pressure in the bypass valve air supply lineand filter.

2. Unscrew the canister that houses the filter from the base.

3. Remove the retaining nut that holds the filter element in place.

4. Inspect the canister o-ring seal; if damaged, replace it at this time.

5. Install the replacement filter element.

6. Replace the retaining nut (being careful not to over-tighten it) and then screw on the filter canis-ter.

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Maintenance

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Oil Reservoir Vent Filter Element ReplacementThe oil reservoir is vented through an ejector-filter system that does not require frequent maintenanceif its supply air is clean and dry, or if the humidity in the surrounding environment is not excessivelyhigh. Moisture will collect in the filter element and eventually drain back into the reservoir contaminat-ing the lubricating oil. Use a Cooper Turbocompressor replacement filter only.

WARNING:Introducing water into the oil reservoir will have adverse effects on the lubricating oil andwill cause severe damage to the compressor. Be sure the ejector’s supply air is clean anddry and the filter is properly maintained during periods of high humidity.

Check the exhaust port at least daily. If an oil mist is evident, that is an indication of a clogged filterelement. Using the following procedure, replace the element.

1. Remove the trap line between the bottom of the filter housing and the reservoir.

2. Unscrew the retaining nut at the bottom of the housing.

3. Catch any excess oil in a separate container.

4. Slide down the lower housing section to expose the filter element.

5. Remove the nut holding the filter element in place, remove the element, and (being careful not toover-tighten the retaining nut) install a new replacement element.

6. Inspect the o-ring seals at the top of the lower housing section and in the retaining nut. If neces-sary, replace the seals to prevent leaks.

7. Wipe the housing clean.

8. Reassemble the filter and then pour a small amount of oil into the fill connection provided at thetop of the trap line to reinstate the mist filter trap.

Standard Oil Filter Element ReplacementThe compressor must be shutdown before servicing the oil filter. When required, use the followingprocedure to replace the standard oil filter element. Use a Cooper Turbocompressor replacementfilter only. Filters that look the same may not necessarily perform the same.

WARNING:Do not attempt to remove the oil filter until oil pressure is at zero (O). Hot oil underpressure presents a safety hazard to personnel.

1. Shutdown and lock-out the compressor.

2. Shut off the oil pump.

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3. Remove the oil filter, which is of the spin-off variety.

4. Catch any excess oil in a separate container.

5. Inspect the new filter and then, using clean oil, lightly lubricate the gasket.

6. Install the new filter element by threading it on and continuing to turn it until hand tight, plus anadditional 1/4 turn.

7. Wipe the new filter clean and, after the oil pump has started, inspect for possible leaks.

8. Dispose of the used oil and old filter according to plant procedures.

Duplex Oil Filter Element ReplacementThe Duplex Oil Filter option allows for oil filter replacement without the necessity of shutting down thecompressor in order to perform this routine maintenance task. Separate file chambers are incorporatedwith a transfer valve. When required, replace the duplex oil filter elements as follows:

WARNING:Before servicing, be sure the chamber being serviced is not being utilized. Do not attemptto remove the oil filter element until the oil pressure in that chamber is zero (O). Hot oilunder pressure presents a safety hazard to personnel.

1. Using an Allen wrench, turn the bleed screw counterclockwise until the screw head touches thesafety plate on the side not in use (opposite the locking pin).

2. Catch any excess oil in a separate container.

3. Inspect the new filter and then, using clean oil, lightly lubricate the gasket.

CAUTION:Use a Cooper Turbocompressor replacement filter only. This will ensure safe and reliableperformance.

4. Unscrew the filter bowl, and remove the old filter element.

5. Install the new filter element and replace the filter bowl.

6. Depress the balance valve lever until oil begins to bleed through the bleed screw.

7. Turn the bleed screw clockwise until tight. Depress the balance valve lever once more to pressurizethe filter bowl.

8. Dispose of the used oil and old filter according to plant procedures.

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Maintenance

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LubricationTable 5—5 lists recommended intervals and the products necessary for proper lubrication of variousTurbo Air 3000 Compressor components. Refer to Section Two, Compressor Specifications, for addi-tional information regarding required lubricants. For ordering information, refer to Section Seven,Parts and Service.

Instructions for these periodic lubrication procedures are included in this section.

Compressor Lubrication ScheduleElement Interval Lubricant [A]

Main oil reservoir Monitor daily. Cooper TurbocompressorChange only as required. TurboBlendTM Lubricating Oil

Oil pump motor bearings Six months Table 2—2

Main drive coupling Six months Cooper TurbocompressorCoupling Grease

Drive motor ball bearings [B] Table 2—2

Drive motor sleeve bearings [B] Cooper TurbocompressorTurboBlendTM Lubricating Oil

Inlet guide vane actuator drive screw Six months High quality synthetic grease

Bypass valve (if applicable) Six months Molycoat® 33

Notes: [A] Use only oils and greases recommended by Cooper Turbocompressor [B] Refer to the motor manufacturer’s instructions for specific interval guidelines.

Table 5—5 Compressor Lubrication Schedule

Compressor Lubricating OilCooper Turbocompressor cannot specify a fixed interval between lubrication system oil changes becauseof the wide variety of operating conditions that exist. Therefore, the operator should inspect the oilvisually daily to monitor changes and/or possible deterioration. Compare the appearance of oil from thereservoir with new oil, and watch for changes in the appearance of the oil as follows:

� If the oil appears darker than normal, that is an indication that there is probably somecontamination.

� If the oil appears muddy or contains any white emulsion, that is an indication that there issome contamination with water.

As the situation requires, have the oil tested for viscosity, acid, water and other contamination. Areputable commercial laboratory can easily detect the presence of any such contamination,

Whenever the performance of the lubricating oil is suspect, Cooper Turbocompressor recommendsadditional testing for the presence of enhancing additives in accordance with The American Society forTesting and Material (ASTM) as defined in Table 2—1, Oil Specification.

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Follow the recommendations of the testing laboratory with regard to changing the oil in thereservoir. Be certain to use only Cooper Turbocompressor TurboBlendTM Lubricating Oil foroptimum performance.

Oil Pump Motor Bearing LubricationExamine the compressor installation to determine the type of motor used. Although the standardTurbo Air compressor oil pump motor utilizes sealed bearings that do not require lubrication, somenon-standard motors do require lubrication. The operator must identify the type of motor used in theinstallation in order to determine whether lubrication is necessary.

Inspect the oil pump motor visually. If grease fittings are included on the motor, it will be necessary toperiodically lubricate the oil pump motor. Use good quality, polyurea-based grease, adding 1/4 oz. (7gm.) to each fitting. Table 2-2 offers acceptable motor bearing greases.

It is not necessary to lubricate the oil pump coupling.

Main Drive Coupling LubricationIt is necessary to lubricate the main drive coupling every 6 months to meet the manufacturer’sspecifications. (For additional information on lubricant requirements, refer to Section Two,Compressor Specifications.)

WARNING:Before performing this procedure, be certain to lock out the main power supply and closethe air system block valve. Failure to follow this requirement may cause serious injury.

1. Stop the compressor. Lock out the main motor starter.

2. Remove the coupling guard.

3. Note that each coupling hub sleeve has two separate lubrication plugs; remove both plugs and,using a stiff wire brush, clean each one thoroughly.

Insert a grease fitting into each sleeve, and then pump approximately 2 oz. (60 cc) of CooperTurbocompressor Coupling Grease into one of the holes in each sleeve until fresh grease flowsfrom the opposite hole.

WARNING:Use Cooper Turbocompressor Coupling Grease only. Other greases do not provideadequate protection.

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4. Move the coupling center spool back and forth to verify free movement. (Total travel should be0.160” or 4 mm.)

5. Remove the grease fittings, and then replace all plugs.

6. If the center spool does not move freely, correct the interference as follows:

� Remove the center spool.

� Disassemble the sleeves.

� Clean any grease from the gearhubs and sleeves.

� Inspect gearhub teeth for wear; if required, replace the gearhubs and sleeves.

� Re-grease and reinstall the spool.

� Verify that the spool moves freely, and then reinstall the grease plugs.

7. Replace the coupling guard.

Drive Motor Ball Bearings LubricationThe Turbo Air 3000 Compressor may be equipped with a squirrel-cage induction motor with ballbearings. The ball bearing grease must be changed in accordance with the motor manufacturer’srecommendations.

CAUTION:Do not use excessive amounts of grease. Over-greasing may cause bearing and/ormotor failure.

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Inlet Guide Vane Assembly Drive Screw LubricationThe inlet guide vane assembly drive screw requires lubrication about every 6 months or as required. Besure to use only recommended high quality, synthetic grease when performing this procedure. (Refer toSection Two, Compressor Specifications, for complete information about lubricants.)

1. Unscrew the cover tube at the motor bracket.

2. Carefully pull away the cover tube, just enough to expose the drive screw.

3. Using a clean cloth, wipe off all the old grease from the drive screw surface.

4. Work fresh grease into the drive screw by hand, being sure to use sufficient grease to cover allsurfaces thoroughly.

WARNING:Use only the recommended high quality, synthetic grease for this procedure. Undercertain conditions, other products may contribute to mechanism malfunction.

5. After greasing is complete, replace the cover tube and screw it back to the original position.

Bypass Valve Lubrication (if applicable)Some TA 3000 compressors utilize two different types of bypass valves, depending on the rating of thecompressor. To correctly determine the type of valve used in a particular installation, refer to Figures 5—1 and 5—2, which illustrate the two types of valves.

Turbo Air 3000 Compressors rated up to and including 600 horsepower utilize a box-shaped bypassvalve which requires periodic lubrication. The larger cylindrical, angled valve employed on higher ratedmachines (700 horsepower and larger) does not require lubrication. Both of these valves characteristi-cally operate either in a fully opened or fully closed position. Every 6 months (or as required), it isnecessary to lubricate the piston’s seals and guide rings of the smaller, box-shaped valve. Since otherproducts do not provide the required level of protection and could gum up under service, use only therecommended lubricant. (Refer to Section 2, Specifications, and Section 7, Parts and Service, for fullordering information.)

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Figure 5—1 Bypass Valve Figure 5—2 Bypass Valve

WARNING:Before attempting this procedure, be certain to shut down the compressor, lock out themain power supply, and fully close the discharge block valve. Failure to follow theserequirements could cause severe injury from pressurized air.

1. Completely shut down the compressor, lock out the motor starter and close the discharge blockvalve. Exhaust all line pressures and disconnect the instrument line at the metering valve.

2. Remove the four bolts that hold the solenoid assembly and adapter to the bottom side of thebypass valve.

3. Remove the top plate to expose the spring and stem assembly and, using the stem assembly, pushout the piston.

Lubricant

SealKit

ebuildıit`

Seal Kit

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4. Clean all parts of the piston, and carefully inspect the piston bore and piston seals for wear and/ordamage.

WARNING:If the bore appears damaged, do not attempt to rebuild the assembly. It will be necessaryto replace the bypass valve at this time.

5. If any seals or o-rings appear damaged, replace them at this time.

6. If the piston bore appears to be in good condition (or after a replacement has been made asrequired), lightly lubricate the piston bore and the seals on the piston assembly with the recom-mended grease.

CAUTION:Use only the recommended lubricant for this procedure. Other products may contribute tomechanism malfunction under certain operating conditions.

7. When lubrication is complete, reassemble the valve and reconnect the air and electrical supply lines.

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Additional Maintenance ProceduresIn addition to periodic inspections and maintenance of the filter and lubrication systems, somemaintenance will also be necessary on an “as required” basis. The necessity is determined by particularperformance indicators or is performed on a periodic basis. Table 5—6 lists these procedures.Instructions for each follow.

Other Maintenance Procedures Procedure: When Required:

Intercoolers/aftercooler cleaning* With elevated interstage air temperatures

Oil cooler cleaning* With intercooler service — or —With elevated oil temperature

Discharge air check valve inspection At 6 month intervals

*Indicated procedures require the use of commercial products available through the CooperTurbocompressor Parts and Service Department. Refer to the specific procedures and Section Seven,Parts and Service, for more information about these products.Table 5—6 Other Maintenance Procedures

Heat ExchangersA decrease in heat exchanger performance is an indication that it may be necessary to clean the inter-coolers, aftercooler and/or the oil cooler.

The best indicator of the performance level of the intercoolers and aftercooler is the approach tempera-ture. This is defined as the difference between the temperature of the air leaving the heat exchangerand that of the water entering the heat exchanger. Record that information for all heat exchangerswhen the compressor is first installed and running at full load. When an approach temperature in-creases by 15°F - 20°F (8°C - 11°C) above the original level, or when an Alarm condition occurs as aresult of high interstage temperature, that is an indication that it is time for cleaning.

In the case of the oil cooler, however, the approach temperature cannot be used to determine a de-crease in cooling capacity. The oil cooler should be cleaned whenever the intercoolers and aftercoolerare cleaned, or when the compressor goes into an Alarm condition as a result of high oil temperature.

Other factors may also sometimes contribute to decreasing heat exchanger performance. Therefore,before cleaning the heat exchangers:

� Be sure that they are getting the required water flow.� Be sure that the oil and air resistive temperature detectors (RTD’s) are functioning properly.� Be sure that the condensate drains are functioning properly.

When it becomes apparent that cleaning is necessary, keep in mind that separate techniques areutilized for different parts of the heat exchangers:

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� Tubes The tubes must be cleaned using a series of brushes (in the case of the intercoolers andaftercooler) or a rod (in the case of the oil cooler) and then given a thorough soaking with acommercial descaling agent such as Rydlyme�.

� Fins The aluminum fins of the intercoolers and aftercooler must be cleaned using a high pressureair, steam, or water spray and then given an additional soaking with a commercial cleaning agentsuch as Coil Boil�.

Instructions for cleaning both the water and air sides of the intercoolers and aftercooler are includedhere, along with instructions for cleaning the oil cooler.

Refer to Section Seven, Parts and Service, for complete information about ordering specified commer-cial products required for this procedure.

Intercoolers and Aftercooler CleaningWater Side:Use a gun-cleaning or tube-cleaning kit for this procedure. Such commercially available kits come witha selection of brushes in varying sizes, making them ideally suited for this purpose. The recommendedrange of brush sizes is from 1/4” to 3/8” (6 to 10 mm), to allow the user to begin cleaning with asmaller size brush and then progress to the largest size.

1. Shut down the compressor and exhaust all air pressure. Lockout the main motor starter and closethe system block valve.

2. Shut off the cooling water and remove the supply piping.

3. Drain the coolant, and then remove the intercooler headers.

4. Remove the intercoolers from the cooler cavity. (Refer to Figure 5—3.)

5. Inspect the cooler casings for corrosion. If necessary, clean the casings.

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Figure 5—3 Intercooler Disassembly

1. Remove all loose scale from the interiors of the cooler cavity, the water headers, and the manifoldpipes.

CAUTION:Do not allow the loose debris to enter the condensate drain lines. This could causeplugging of the drains.

2. Using a 1/8” (3 mm) rod, probe the length of the intercooler tubes to check for any blockage.

Front Tubesheet Gasket

Upper Baffle Plate

K-Seal

Intercooler Bundle

Header Gasket

Water Cooler

Y-Gasket

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CAUTION:If the compressor is equipped with U-bend water tubes, do not force the rod into the U-bend. Doing so could cause damage to the tubes.

3. Stand the bundles with the tube openings up, and fill the tubes with commercial descaling agentsuch as Rydlyme.

WARNING:Be sure to follow the manufacturer’s instructions for safe handling and disposal of suchproducts. Failure to do so could cause personal injury and/or create a biohazard.

4. Allow the tubes to stand for 2 hours with the descaling agent inside; then completely drain thedescaling agent from the tubes and flush them thoroughly with water.

WARNING:Do not leave the descaling agent in the tubes for more than 2 hours, and do not allow thedescaling agent to make contact with the intercooler fins. Failure to follow these instruc-tions will cause component damage.

5. Allow the descaling agent to completely drain from the tubes, and then flush the tubes thoroughlywith water.

6. Attach a 1/4” (6 mm) diameter soft bristle brush (nylon or brass) to a 20” (500 mm) long rod. Thenconnect that assembly to a drill motor.

7. Use the drill motor to power the rod/brush assembly in and out of the tubes, which should beconstantly flushed with water. (The flushing is necessary to clear loose debris through the tubes.)

CAUTION:If the compressor is equipped with U-bend water tubes, do not force the rod into the U-bend. Forcing could cause damage to the tubes.

8. Repeat the previous step with the next larger brush size, progressing (using the same procedurewith each brush) until the largest size is reached.

9. When the brush cleaning is complete, drain all the water from the tubes and then fill them to thetop with a descaling agent. Allow the descaling agent to remain in the tubes for 1 hour.

CAUTION:Do not leave the descaling agent in the tubes for more than 1 hour, and do not allow thedescaling agent to make contact with the intercooler fins. Failure to follow these instruc-tions will cause component damage.

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10. Drain the descaling agent and thoroughly flush the tubes with clean water.

11. Again using the drill motor and the rod/brush assembly, brush in and out of the tubes using thelargest brush (3/8” or 10 mm) while simultaneously flushing out the tubes with clean water.

12. If necessary, clean the air side of the heat exchanger. (Refer to the following procedure for com-plete instructions.)

13. When the cleaning is complete, immediately reinstall the intercoolers. (If they are not reinstalledimmediately, it will be necessary to repeat Step 15 before they can be reinstalled.) Clean all gasketand seal surfaces, reassemble the unit using all new gaskets and seals, and then reposition it in thecooler cavity of the compressor.

Intercoolers and Aftercooler CleaningAir Side:It may also be necessary to clean airborne contaminants from the air side of the coolers. To clean theintercooler fins on the air side, use compressed air, pressurized water, or steam. Loosen any dirt ordebris as follows:

WARNING:Always wear eye protection and protective clothing and observe proper safety precautionswhen using compressed air or steam. Failure to heed this requirement may cause personalinjury.

1. Remove the upper and lower baffle plates to expose the complete finned surface.

2. Clean the fins by passing a 30 psi (2 kg/cm2 or bar) air stream across them.— or —

If air is not available, it is possible to use a low-pressure steam or water spray to clean the fins.

3. If necessary, clean any contaminant buildup from the aluminum fins by using a chemical cleaningagent such as Coil Boil.

WARNING:Be sure to follow the manufacturer’s instructions for safe handling and disposal of thechemical cleaning product. Failure to follow proper safety procedures may cause personalinjury and/or create a biohazard.

4. If any bent fins are visible after the cleaning procedure, carefully straighten them out by handbefore replacing the baffle plates.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

5—22

Oil Cooler CleaningDeterioration in oil cooler performance may be an indication that it is time to remove the mineral scalebuildup within the oil cooler tubes. When that occurs, clean the tubes as follows:

1. Shut down the compressor, lockout the main motor starter and close the system block valve.

2. Turn off the water and disconnect the two water pipes.

3. Remove the lower plug on the rear header and allow any remaining coolant to drain from thecooler before replacing the plug.

4. Remove the front and rear headers to expose the tubes. Retain the gaskets.

5. Using a 1/8” (3 mm) rod, probe the tubes to check for blockage. (Since this is a straight tube cooler,any blockages that are loosened can be safely and easily pushed through and out the end.)

6. When rod cleaning is complete, flush the tubes thoroughly with water.

7. Replace the water headers (using the original gaskets) and then fill all the cooler tubes with adescaling agent such as Rydlyme.

WARNING: Be certain to follow the manufacturer’s instructions for safe handling anddisposal of such products. Failure to do so could cause personal injury and/or create abiohazard.

8. Allow the descaling agent to remain in the tubes for 1 hour.

CAUTION:Do not allow the descaling agent to remain in the tubes for more than 1 hour. Failure tofollow these instructions will cause component damage.

9. Remove the front and rear headers to again expose the tubes.

10. Allow the descaling agent to completely drain from the tubes, and then flush out the tubes thor-oughly with water.

11. Reassemble the headers, this time using new replacement gaskets.

12. Recharge the cooler, being sure to loosen the vent plug on the rear header to prevent air entrap-ment in the cooler.

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Maintenance

5—23

Discharge Air Check Valve InspectionAt 6 month intervals, use the following procedure to inspect the discharge air check valve to determinewhether it is still in good working order or whether it must be replaced.

1. Shut down the compressor and lockout the main motor starter.

2. Close the system block valve and exhaust any pressure in the check valve line.

3. Remove the check valve from the piping.

4. Remove both plugs and the hinge pin, and then inspect the hinge pin, disc, and seat for wear.

5. If any parts are worn or damaged, replace the valve.— or —

If wear is not apparent, clean, reassemble, and reinstall the valve, being sure that the valve discoperates freely.

6. To verify correct orientation of the discharge air check valve, use the following criteria:

� The check valve should be located downstream of the blow-off valve and upstream of thesystem block valve.

� The arrow should be pointing in the direction of flow (away from the compressor).

� For horizontal installation (the recommended position) the hinge pin must be above thecenterline, which is assured when the metal label can be seen from the top of the valve.

WARNING:When installing a new discharge check valve or reinstalling a valve, always be certain ofproper orientation. Incorrect orientation will cause equipment damage.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

5—24

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Troubleshooting

6—1

Section Six:Troubleshooting

In this section, the reader will learn about:

� General Considerations

� How to Use theTroubleshooting Guide

� How to Request Assistance

� Alarm and Trip Functions

� Drive TrainTroubleshooting

� Control SystemTroubleshooting

� Air SystemTroubleshooting

� Lubrication SystemTroubleshooting

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

6—2

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Troubleshooting

6—3

General ConsiderationsThis section includes suggestions that are designed to help answer questions or solve problems thatmay be encountered during operation of the Turbo Air 3000 Centrifugal Compressor. For troubleshoot-ing purposes, the compressor installation is divided into four subsystems. These, along with relevantcomponents or conditions, are shown in Table 6—1.

Compressor Installation SubsystemsThe Drive Train

� Compressor gearbox� Main drive motor� Main drive motor starter

The Control System

� The Vantage Control Panel� Instrumentation� Control valves� Motor overload� Control performance

The Air System

� Piping� Filters� Other air path components

The Lubrication System

� Oil leaks� Oil mist� Temperature discrepancies� Pressure discrepancies

Table 6—1 Compressor Installation Subsystems

For each of the above subsystems, there is a corresponding subsection in the Troubleshooting Guide.The suggestions included in the subsections will enable the operator to properly identify and correctmost problems. It may also be helpful to consult Section Two, Compressor Specifications, as well as anyengineering drawings supplied separately.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

6—4

How to Use the Troubleshooting GuideThe Troubleshooting Guide that follows contains information compiled with the assistance of CooperTurbocompressor Field Service supervisors. It is broken down into four subsections, one for each of thesubsystems of the compressor installation. Each of the four subsections lists conditions that may beencountered during compressor operation. At the right of each Condition entry is a second list thatmentions possible causes for that condition in order of likelihood. In the majority of cases, the operatorshould be able to quickly identify and solve most problems.

Some of entries listed under the Possible Causes column may also appear in bold face (for example:Motor Overload). In such instances, the operator should refer to that entry under the Condition list toexplore additional troubleshooting options. If this does not yield positive results, the operator shouldthen return to the original Condition list and continue to troubleshoot until the correct solution isdetermined.

If a problem still remains after considering all the Troubleshooting Chart suggestions, contact aCooper Turbocompressor factory trained and authorized service representative for additionalassistance and advice.

DANGER:When problems are encountered which are beyond the scope and experience of operatingpersonnel, always request assistance from a Cooper Turbocompressor factory trained andauthorized service representative. The Turbo Air 3000 Centrifugal Compressor is a hightechnology product, and improper servicing presents the risk of equipment damage and/orpersonal injury.

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Troubleshooting

6—5

How to Request AssistanceCooper Turbocompressor has established a network of factory trained and authorized distributors andservice representatives throughout the United States and around the world. When additional guidanceor help is required, contact one of these representatives. (For additional information about parts andservice, refer to Section Seven, Parts and Service.)

WARNING:For specialized service procedures, always use the services of a Cooper Turbocompressortrained and authorized service representative and only genuine Cooper Turbocompressorand JOY® replacement parts. Failure to heed this warning could seriously jeopardize thequality of the repair or replacement.

For advice or service help, always contact your local authorized Cooper Turbocompressor sales andservice representative. Refer to Section 7, Parts & Service, Aftermarket Support, for the name andaddress of your local representative.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

6—6

Alarm and Trip FunctionsIf compressor-operating parameters deviate from normal tolerances, the Vantage Control System willactivate one of two levels of compressor protection.

• Alarm. An Alarm condition is a warning about a compressor operating condition that isoutside of normal operating limits. The Alarm is intended to alert the operator to a condition thatmerits investigation, but does not present an immediate danger, or prevent the compressor fromoperating.

• Trip. A Trip condition is a protective measure initiated by the controller to safeguard thecompressor. A compressor Trip condition requires immediate troubleshooting and correctionbefore the compressor can be safely put back into operation.

In either instance, when an abnormal condition occurs, the Vantage Control Panel will automaticallyrevert to the Protection History Screen where the most recent event will be positioned at the top ofthe screen indicating date, time, type, description, instrument tag number, and data involved in theevent.

Operator Response to an Alarm or Trip ConditionIn the case of a compressor Alarm or Trip condition, the operator should respond as follows:

1. Identify and assess the nature of the Alarm or Trip message that appears on the control paneldisplay.

2. Press the Home, View, History, or Network key to acknowledge the alarm and to turn off anyexternal devices installed to alert the operator. The source of the alarm is maintained in theProtect History file for future review.

3. Press the View key and use the Up or Down keys to select the Protection (Running) screen.

4. Press the Enter to open the screen. Review the current monitoring point information and itsrelationship to the Alarm and Trip set points.

5. Analyze the information, and then take any appropriate action(s) as required to prevent furtherdeterioration of the Alarm condition to a dangerous level. In the case of a Trip condition, it isnecessary to correct the cause of the Trip before attempting to restart the compressor.

ExampleThe next sample screen shows a representative Alarm message, in this instance signaling abnormal oilpressure.

Operator ResponseWith the Protection History screen being displayed on the control panel, the operator should:

1. Take note of the actual oil pressure as displayed under the Data column.

2. Press the View key and use the Up or Down keys to select the Protection (Running) screen.

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Troubleshooting

6—7

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

6—8

Drive Train TroubleshootingCondition: Possible Causes:

Motor Vibration/Unusual Sounds

Starter malfunctionFoundation bolts looseOther mechanical part(s) looseExcessive or unbalanced voltageLubrication inadequate or excessiveDirt on fanDirt in air gapBearings wornMisalignmentDrive coupling worn

Motor Overheating

Ambient temperature too highVentilation inadequateVoltage low, high, or unbalancedMotor OverloadControl settings improperLubrication inadequate or excessiveGround inadequateConnections improperWiring improperStarter malfunctionDirt in air gapWindings shortedSingle phasingMotor seizedCompressor setpoints improper

Gearbox Oil Leak(s)

Ejector trap not filledEjector pressure incorrectReservoir vent filter cloggedSplitline seal faultyOil seal malfunctionSeal damaged

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Troubleshooting

6—9

Drive Train Troubleshooting...continued

Condition: Possible Causes:

Compressor Vibration

Sensor Reading FaultyWiring in control panel incorrectHigh Oil TemperatureLow Oil TemperatureLow Oil PressureOil type incorrectOil contaminatedSurgingMotor VibrationMisalignmentDrive coupling damaged and/or wornImpellers dirty or damagedRotor cartridge malfunction

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

6—10

Control System TroubleshootingCondition: Possible Causes:

Compressor Start Failure

Drive motor starter not racked inEMERGENCY STOP button depressedStart permissives not metControl panel inoperativeMain power fuses blown or faultyDrive motor starter malfunction(s):Thermal overload relaysMain contactor·Power fusesControl transformerWiringStart / Stop circuit faultyCurrent transducer circuit faultyCompressor Trip condition (corrective action required)Motor windings shortedMotor seized.

EMERGENCY STOP Message

EMERGENCY STOP button depressedStart / Stop circuit faulty.

Sensor Reading Faulty

Wiring to control panel faultyControl panel power supply voltage(s) incorrectVibration probe incorrectly gappedPressure sensing line defectiveSensor failed.

Control Panel Inoperative

Power to panel interruptedMain Logic Module fuse defective or blownWiring connection errorMain Logic Module or User Interface Module failure.

Control Panel Display Inoperative

Main Logic Module inoperativeLoose Display cableContrast set incorrectlyDisplay backlight failedKeypad failure.

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Troubleshooting

6—11

Control System Troubleshooting...continued

Condition: Possible Causes:

Motor Overload

Maximum amp set point too highInlet valve or guide vane assembly inoperativeInlet valve or guide vane assembly out of adjustmentThermal overload relay set improperlyCurrent transducer faultyStarter problemMotor problem.

Control Valve(s) Faulty

Wiring from control panel faulty.Instrument air supply interrupted (pneumatic valves).Instrument air supply pressure too low (pneumaticvalves only).Inlet valve or guide vane assembly adjustedimproperly.Malfunction of mechanical linkage of control valves.Control solenoid valve malfunction (bypass valve).Inlet guide vane assembly motor or drive couplingMalfunction.Valve failure.Pneumatic actuator failure.Current to pneumatic transducer failure (pneumaticvalves only).Solid state relay failure on Main Logic Module(electric actuated only).Analog output failure on Main Logic Module(pneumatic actuated only).

Compressor Control Performance Abnormal

Set points incorrect.Sensor reading faulty.Control valve(s) faulty.Control system tuning faulty.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

6—12

Air System TroubleshootingCondition: Possible Causes:

High Air Pressure

Low demandAir Pressure setpoint too highSensor Reading FaultyControl Valve(s) Faulty

Low Air Pressure

Air Pressure setpoint incorrectMaximum Amp setpoint incorrectAir demand above compressor ratingSensor Reading FaultyInlet air filter dirty or restrictedAmbient air temperature excessiveImpellers dirtyControl Valve(s) Faulty

High Air Temperature

Water flow to cooler(s) insufficientCoolant temperature too highSensor Reading FaultyIntercooler(s)/aftercooler fouledHot air bypassing intercoolers/aftercoolerCoolant bypassing intercoolers/aftercoolerSurging

Surging

Air Pressure setpoint too highSensor Reading FaultyInlet air filter dirty or restrictedMinimum Amp setpoint too lowControl Valve(s) FaultyHigh Air TemperatureBypass silencer fouled

Check Valve Malfunction

Valve oversizedSeat or disc worn or dirtyDisc movement impaired

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Troubleshooting

6—13

Lubrication System TroubleshootingCondition: Possible Causes:

Oil Leak(s)

Connection looseFilter cartridge looseGearbox Oil Leak(s)Pump shaft seal worn or damaged

Oil Mist

Ejector vent filter cloggedFilter trap not filledEjector pressure incorrect

High Oil Temperature

Water flow to cooler insufficientCoolant temperature too highOil cooler fouledSensor Reading FaultyThermal mixing valve faultyOil heater thermostat faulty

Low Oil Temperature

Water flow through coolers excessiveSensor Reading FaultyThermal mixing valve faulty or missingOil heater thermostat faulty or missing

High Oil Filter Differential Pressure

Oil filter element dirty or cloggedSensor Reading Faulty

High Oil Pressure

Pressure regulator set improperly or malfunctioningLow Oil TemperatureSensor Reading Faulty

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

6—14

Lubrication System Troubleshooting...continued

Condition: Possible Causes:

Low Oil Pressure

Oil level too lowPressure regulator set improperly or

malfunctioningFuses in pump motor starter blown or

faultyOil filter element dirty or cloggedHigh Oil TemperatureLeakage within gearboxSensor Reading FaultyPump motor starter overloads trippedWiring or pump motor or starter incorrectPump rotation incorrectPump seizedPump coupling damagedPump suction line restriction

Main Oil Pump Malfunction

Sensor Reading FaultyPump suction line restrictedPump coupling damagedPump damagedOil filter element dirty or cloggedPressure regulator set improperly or malfunctioningOil level too low

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7—1

Parts and Service

Section Seven:Parts and Service

In this section, the reader will learn about:

� Aftermarket Support

� The Parts Ordering Procedure

� Parts Availability

� The Returned Goods Policy

� The Periodic Maintenance PartsInventory

� The Professional Inspection PartsRequirement

� Control System Parts

� Lubrication System Parts

� Main Drive Coupling Parts

� Heat Exchanger Parts

� Air Piping Parts

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7—2

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

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7—3

Parts and Service

Aftermarket SupportAs an important part of its commitment to its products and customers, Cooper Turbocompressor offersfull aftermarket support. The array of aftermarket services includes inspection and repair, availability ofgenuine JOY� and Cooper Turbocompressor parts and recommended supplies, and compressor operatortraining seminars at the factory training facilities in the USA or at the user’s site.

WARNING:Since the Turbo Air 3000 Centrifugal Compressor is a high technology product, do notattempt inspection, maintenance, or service procedures other than those described inthis manual. For any service of a more specialized nature and service of internal parts,it is necessary to contact a Cooper Turbocompressor trained and authorized servicerepresentative.

For parts and/or service, always contact an authorized Cooper Turbocompressor sales and servicerepresentative or else contact the factory directly.

Parts Coordinatoror

Field Service Department

Cooper Turbocompressor3101 BroadwayPO Box 209Buffalo, NY 14225-0209 USAPhone: (716) 896-6600Fax: (716) 896-1233

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7—4

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Parts Ordering ProcedureSince specific compressor models and installations may vary, always be sure to have the followinginformation available when placing an order:

1. The compressor serial number (included on the compressor nameplate located on the gearbox).

2. The compressor model: Turbo Air 3000

3. The part description (name).

4. The part reference number.

Parts AvailabilityWhen ordering replacement and some spare parts, keep in mind that some parts are not available onan individual basis, and must always be purchased in sets. In addition, in certain instances CooperTurbocompressor may change the part number and/or may substitute a part of equal or greater reliabil-ity without notice.

The Returned Goods PolicyIt is necessary to contact Cooper Turbocompressor for authorization before the return of any goods tothe factory. All approved returns are immediately assigned a tracking number to prevent processingdelays or loss of materials. This ARG (authorization to return goods) tracking number is then recordedat the factory. Senders must include the assigned ARG tracking number on the outside of the shippingcontainer whenever goods are being returned.

No goods may be returned to the factory without prior authorization and an assigned ARGtracking number.

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7—5

Parts and Service

The Periodic Maintenance Parts InventoryCooper Turbocompressor recommends keeping a basic inventory of replacement and spare parts and stock-ing of all the recommended supplies mentioned in this operator’s manual. This will eliminate or help reduceunanticipated shutdown time during those occasions when it may be necessary to maintain or replace one ormore compressor parts. Table 7—1 is a recommended list of materials and parts that should be in activeinventory for routine maintenance activities.

CAUTION:When replacing parts or ordering supplies, always use genuine JOY® and/or CooperTurbocompressor replacement parts and Cooper Turbocompressor approved supplies.Cooper Turbocompressor will accept no liability for damages caused by use of non-authorized parts, supplies, or service.

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7—6

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Recommended Periodic Maintenance Parts & SuppliesDescription

QtyTurbocompressor Description Qty Cooper Turbocompressor

Part NumberFilters:��� Inlet Air Filter, Primary and Secondary Elements [A] [A]���Bypass Valve Air Line Filter Element [B] P0540016-00074���Oil Reservoir Vent Filter Element 1 P1404987-00014�� �Oil System Filter Element (Single Filter Type) 1 P1404040-00207�� �Oil System Filter Element (Dual Filter Type) 2 P1401435-01233Lubricants:�� �TurboBlendTM Lubricating Oil (5-gallon / 20-liter pail) [C] P1405340-00294���TurboBlendTM Lubricating Oil (55-gallon / 210-liter drum) [C] P1405340-00295���Oil Sample Kit 1 P1797385-00000���Oil Pump Motor & Main Drive Motor Ball Bearing Grease 1 P1405340-00289�� �Main Drive Coupling Grease 1 P1405340-00264�� � Inlet Guide Vane Drive Screw Grease 1 P1405340-00288�� �Bypass Valve Lubricant [D] 1 P1405340-00270Parts:Heat Exchangers (Figures 7—9 & 7—10)�� �K-Seal 3 P1408800-04941�� � Y-Gasket 6 P1408800-04926�� � Header Gasket 3 P1793932-02100�� �Front Tubesheet Gasket 3 P1793931-02100�� �Rear Header Gasket (S-Tube Type Only) 3 P1793932-02101���Oil Cooler Gasket Kit 1 P1405680-00002Bypass Valve (Figure 7—15)���Rebuild Kit [E] 1 MB408539-00098���Seal Kit [E] 1 MB408539-00202Discharge Air Check Valve (Figure 7—18)���Check Valve, 3” 1 P0540024-00118���Check Valve, 3” 1 P0540024-00185���Check Valve, 4” 1 P0540024-00072���Check Valve, 4” 1 P0540024-00183Main Drive Coupling (Figure 7—8)���O-Ring 2 P1406064-20018�� �Gasket 2 P1406064-04117Condensate Drains (Figure 7—11)���Solenoid Valve, 110/120-Volt 3 P1401581-01302���Solenoid Valve, 220/240-Volt 3 P1401581-01341�� �Check Valve 3 P1401581-01303�� �Gate Valve 3 P1401581-00757Instrumentation (Figure 7—1)�� �Vibration Probe [F] P1407030-02002�� �Vibration Probe Extension Cable [F] P3403893-00006�� � RTD (Temperature Transducer) [F] P3403629-01585�� � Pressure Transducer [F] P0540089-00182���Drive Motor Current Transducer 1 Contract SpecificNotes: [A] Refer to Figure 7—14, Inlet Air Filter Assembly

[B] Refer to Figure 7—15, Bypass Valve Assemblies[C] Refer to Section 2, Specifications, for reservoir capacity information.[D] Only one specific bypass valve requires lubrication. Refer to Section 5, Maintenance.[E] Only one kit is required depending which valve has been supplied.[F] As required.

Table 7—1 Periodic Maintenance Parts and Supplies

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7—7

Parts and Service

The Professional Inspection Parts RequirementTable 5—3, Service Inspection Checklist outlines the in-depth examination procedures to be performedwith a Cooper Turbocompressor trained and authorized representative. These important preventativemaintenance tasks involve removal of the gearbox cover to examine the gears, bearings and seals andexposing of the heat exchanger bundles and the aerodynamic components for cleaning and inspection.Certain gaskets, o-rings and seals must be ordered well in advance of the scheduled visit. Table 7—2lists the parts and supplies necessary for the Professional Inspection of the compressor. Some of theseparts may already be on-hand as part of the Periodic Maintenance Parts Inventory.

CAUTION:When replacing parts or ordering supplies, always use genuine JOY® and/or CooperTurbocompressor replacement parts and Cooper Turbocompressor approved supplies.Cooper Turbocompressor will accept no liability for damages caused by use of non-authorized parts, supplies, or service.

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7—8

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Professional Service Inspection Parts & Supplies

Description Qty Cooper TurbocompressorPart Number

Gearbox:� O-Ring, First Stage Inlet 1 P1406702-00395� O-Ring, Second Stage Inlet 1 P1406702-00386� O-Ring, Third Stage Inlet 1 P1406702-00383� Seal, First Stage Diffuser 1 P1794323-00005� Seal, Second Stage Diffuser 1 P1794323-00002� Seal, Third Stage Diffuser 1 P1794323-00002� O-Ring Lubricant 1 R1409584-00000� Gearbox Splitline Sealant 1 R1405571-00012Heat Exchangers: (Figures 7—9 & 7—10)� K-Seal 3 P1408800-04941� Y-Gasket 6 P1408800-04926� Head Gasket 3 P1793932-02100� Front Tubesheet Gasket 3 P1793931-02100� Rear Header Gasket (S-Tube Type Only) 3 P1793932-02101Lubrication System:� Oil Cooler Gasket Kit [A] 1 P1405680-00002� Oil Reservoir Vent Filter Element 1 P1404987-00014� Oil System Filter Element (Single Filter Type) 1 P1404040-00207� Oil System Filter Element (Dual Filter Type) 2 P1401435-01233Filters:� Inlet Air Filter, Primary Element [B] [B]� Inlet Air Filter, Secondary Element [B] [B]Control Valves:Inlet Guide Vane (Figure 7—13)� Gasket, Inlet Guide Vane, 6” (150 mm) 1 P1409511-00000� Gasket, Inlet Guide Vane, 8” (200 mm) 1 P1409511-00001� Grease, Inlet Guide Vane Drive Screw 1 P1405340-00288Bypass Valves (Figure 7—15)� Seal Kit [D] 1 MB408539-00098� Grease, Valve [C] 1 P1405340-00270� Seal and Rebuild Kit [D] 1 MB408539-00202� Bypass Valve Air Line Filter Element [E] 1 P0540018-00074Drive Motor:Main Drive Coupling (Figure 7—8)� O-Ring 2 P1406064-20018� Gasket 2 P1406064-04117� Grease, Coupling 1 P1405340-00264Main Drive Motor� Grease, Ball Bearing 1 P1405340-00289Notes: [A] For standard size cooler. Refer to Tables 7—6 and 7—7 for verification of oil cooler sizing and/or part number.

[B] Refer to Figure 7—14, Inlet Air Filter Assembly[C] Only one specific bypass valve requires lubrication.

Refer to Section 5, Maintenance.[D] Refer to Figure 7—15, Bypass Valve Assemblies[E] Both bypass valves require this same filter element.

Table 7—2 Professional Service Inspection Parts and Supplies

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7—9

Parts and Service

Item Cooper TurbocompressorNo. Description Qty Part Number

Standard Instrumentation:01 Vibration Probe, Stage 1 1 P1407030-0200202 Vibration Probe Extension Cable (10 ft / 3 m) 1 P3403893-0000603 RTD, Inlet Air Temperature, Stage 2 or 3 [A] 1 P3403629-0158504 Transducer, System Gas Pressure 1 P0540089-0018205 RTD, Oil Temperature 1 P3403629-0158506 Transducer, Oil Pressure after the Filter 1 P0540089-0018207 Tranducer, Drive Motor Current 1 Contract Specific

Optional Instrumentation:11 Vibration Probe, Stages 2 and/or 3 1-2 P1407030-0200212 Vibration Probe Extension Cable (10 ft / 3 m) 1-2 P3403893-0000613 RTD, Inlet Air Temperature, Stage 2 [A] 1 P3403629-0158514 Transducer, Compressor Discharge Pressure [B] 2 P0540089-0018215 Transducer, Oil Pressure before the Filter [C] 1 P0540089-0018216 RTD, Miscellaneous Temperatures (Not Shown) [D] 1-5 P3403629-0158517 Switch, Oil Reservoir Level 1 P0540061-0019918 Transducer, Air Filter Differential Pressure [D] 1 P0540089-00059

Notes: [A] Air temperature into the last stage of compression is standard. Alternate locations are supplied as options.[B] Required for all control methods.[C] Reguired for filter differential pressure measurement.[D] Shipped loose for field installation.

Table 7—3. Control System Sensors

Figure 7—1. Control System Sensors

17

03

13

1101

02/12

04/06/14/15

07

05

Control System Parts

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Item Cooper TurbocompressorNo. Description Qty Part Number01 Vibration Probe 1 P1407030-0200202 Retaining Plate 1 P1407301-0000303 Capscrew 1 P0902224-0041204 Tube Fitting 1 P1791399-0353905 Silicone Adhesive [A] 1 R1405571-00005

Notes: [A] Apply adhesive to threads of capscrew and tube fitting.

Table 7—4. Vibration Probe Installation

Figure 7—2. Vibration Probe Installation

(PINION)

(GEARBOX COVER)(OIL/AIR SEAL)

04

0103

02

Control System Parts

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7—11

Parts and Service

Item Cooper Turbocompressor No. Description Part Number Qty

01 User Interface Module (UIM) P3798102-00010 102 Main Logic Module (MLM) P3798102-00000 1

03 Actuator Motor Capacitor* 110 VAC P0540107-00012 1220 VAC P0540107-00019

04 Control Relays (optional) Contact factory 1-4

05 Vibration Transmitters P3403893-00416 3

06 Pressure Transmitters P0540089-00140 2

07 Display Cable P3798102-00020 1

08 Emergency Stop Button P0540056-00221 1* If RequiredTable 7—5. Vantage Control Panel Components

Figure 7—3. Low-Voltage Compartment/Vantage Control Components

01 02 03

04

05060708

Control System Parts

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7—12

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Item Cooper Turbocompressor No. Description Qty Part Number

01 Main (shaft-driven) Oil Pump 1 P1401428-0061402 Drive Coupling, Main Oil Pump 1 P1402070-0025403 Auxiliary (motor-driven) Oil Pump 1 P1401428-0060404 Motor, Auxiliary Oil Pump

- 230-460 Volt / 60 Hz 1 P1402068-00728 - 220-380 Volt / 50 Hz 1 P1402068-00728 - 380 Volt / 60 Hz 1 P1402068-00732 - 400, 415 & 440 Volt / 50 Hz 1 P1402068-00728 - 400 Volt / 50 Hz (CE Mark) 1 P1402068-00734 - 440 Volt / 60 Hz 1 P1402068-00735

05 Drive Coupling, Auxiliary Oil Pump 1 P1402070-0024906 Pressure Regulator (Relief Valve) 1 P1401581-0170707 Cooler, Oil-to-Water (Heat Exchanger):

- Complete Unit with 0.375” (10 mm) dia. copper tubes 1 P1401429-00981 - Maintenance Gasket Kit 1 P1405680-00001

08 Filter: - Complete Assembly 1 P1401435-00289 - Replacement Element 1 P1404040-00207Reservoir Vent Assembly (Figure 7—4):

09 - Ejector 1 P1403262-0010710 - Filter (complete assembly) 1 P1401435-0022811 - Replacement Filter Element 1 P1404987-0001412 - Filter Seal Kit 1 P1401435-0022913 Level Gauge 1 P1401582-00014

Table 7—6. Standard Lubrication System Components

Figure 7—4. Reservoir Vent Filter Assembly

09

12

11

Nut

Filter Housing

12Nut

10

Lubrication System Parts

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7—13

Parts and Service

Item Cooper Turbocompressor No. Description Qty Part Number

14 Cooler, Oil-to-Water (Heat Exchanger): [A] - Complete with 0.375 (10mm) dia. 90/10 alloy tubes [B] 1 P1401429-01002 - Maintenance Gasket Kit 1 P1405680-00001

15 Duplex Filter (Figure 7—5): [A] - Complete Assembly 1 A3401435-00232 - Replacement Element 2 P1401435-01233

16 Level Switch (Figure 7—6) [A] 1 P0540061-0019917 Temperature Regulator [A] 1 P1401581-0134718 Oil Heater (Figure 7—7): [A]

- 230 Volt 1 P0540063-00157 - 380 Volt 1 P0540063-00176 - 400 Volt 1 P0540063-00320 - 415 Volt 1 P0540063-00190 - 440 Volt 1 P0540063-00332 - 480 Volt 1 P0540063-00155 - 575 Volt 1 P0540063-00156

Notes: [A] Not all lubrication systems are equipped with these optional features. Most of these features can be retrofitted after the compressor has been shipped from the factory.[B] Direct replacement for P1401429-00981.

Table 7—7. Optional Lubrication System Components

Figure 7—7. Reservoir Heater Option

Figure 7—5. Duplex Oil Filter Option

Figure 7—6. Reservoir Level Switch Option

Lubrication System Parts

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7—14

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Item Cooper Turbocompressor No. Description Qty Part Number

01 O-Ring 2 P1406064-2001802 Gasket 2 P1406064-0411703 Grease 1 P1405340-00264

Table 7—8. Main Drive Coupling Maintenance Parts

Figure 7—8. Main Drive Coupling Assem-bly

NUT

KEY

DRIVERSHAFT SLEEVE

GASKET02

HUB

SPACER

BAFFLEPLATE

BOLT

BOLT

BAFFLEPLATE

HUBSLEEVE

GASKET02 NUT

KEY

BULLGEARSHAFT

LUBE PLUG(2 PER SLEEVE)

01O-RING

O-RING01

Main Drive Coupling Parts

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7—15

Parts and Service

Item Cooper Turbocompressor No. Description Qty Part Number

01 K-Seal 3 P1408800-0494102 Y-Gasket 6 P1408800-0492603 Header Gasket 3 P1793932-0210004 Front Tubesheet Gasket 3 P1793931-02100

Table 7—9. Intercooler/Aftercooler Maintenance Parts Standard U-Tube Model

Figure 7—9. Intercooler/Aftercooler Bundle Assembly Standard U-Tube Model

Front Tubesheet Gasket04

Header Gasket03

Intercooler Bundle

01K-Seal

Upper Baffle Plate

Water Header

Y-Gasket02

Heat Exchanger Parts

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7—16

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Item Cooper Turbocompressor No. Description Qty Part Number

01 K-Seal 3 P1408800-0494102 Y-Gasket 6 P1408800-0492603 Header Gasket 3 P1793932-0210004 Front Tubesheet Gasket 3 P1793931-0210005 Rear Header Gasket 3 P1793932-02101

Table 7—10. Intercooler/Aftercooler Maintenance Parts Standard S-Tube Model

Figure 7—10. Intercooler/Aftercooler Bundle Assembly Optional S-Tube Model

Y-Gasket02

Upper Baffle Plate

Rear WaterHeader

Front Tubesheet Gasket04

Intercooler Bundle

Header Gasket03

Water Header

K-Seal01

Gasket05

Heat Exchanger Parts

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7—17

Parts and Service

Figure 7—11. Solenoid-Operated Condensate Draining System (One set required for each heat exchanger)

Item Cooper Turbocompressor No. Description Qty Part Number 01 Solenoid Valve, 1/2” NPT, 110/120-Volt 1 P1401581-01302 01 Solenoid Valve, 1/2” NPT, 220/240-Volt 1 P1401581-01341 02 Check Valve, 1/2” NPT 1 P1401581-01303 03 Gate Valve, 1/2” NPT 2 P1401581-00757

Table 7—11. Solenoid-Operated Condensate Draining System (One set required for each heat exchanger)

Figure 7—12. LiquidatorTM Pneumatic Condensate Drain System

Figure 7—13. LiquidatorTM Pneumatic Condensate Drain Trap

Vent AirDischarge Line

Drain Line

Heat Exchanger

01

04

02

03

T

03

02

03

01

Item Cooper Turbocompressor No. Description Qty Part Number 01 Liquidator Drain Trap 1 P1797145-00000 02 Gate Valve, 1/2” NPT 2 P1796081-00007 03 Check Valve, 1/2” NPT 1 P1401581-01303 04 Ball Valve, 1/4”-NPTF 1 P1401581-01450 05 Tube Fitting, 1/4”-TUBE / 1/4”-NPTM 3 P0902962-00044 -- Condensate Kit (containing all the above parts) 1 MB408187-00100

Table 7—12. LiquidatorTM Pneumatic Condensate Draining System Components (One set required for each heat exchanger)

01

Heat Exchanger Parts

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7—18

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Item Cooper Turbocompressor No. Description Qty Part Number

01 Startup Screen (for 8” pipe) 1 P1405344-0001602 Expansion Joint (for 8.625” O.D. pipe) 1 A3404999-00000

Table 7—13. Inlet Air Piping Components

Figure 7—14. Inlet Air Piping Components

01

02

Inlet Guide Vane Assembly

01

Air Piping Parts

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7—19

Parts and Service

Figure 7—15. Inlet Guide Vane and Actuator Assembly

Item Cooper Turbocompressor No. Description Qty Part Number

6” (150mm) 8” (200mm)01 Inlet Pipe Reducer 1 P1409508-00000 P1409508-0300002 Pipe Couping 1 P1404961-00200 P1404961-0020903 Gasket, Pipe Coupling 1 P1404961-00602 P1404961-0060704 Inlet Guide Vane Assembly 1 A3409140-00200 A3409140-0010005 Gasket, Inlet Guide Vane 1 P1409511-00001 P1409511-0000106 Actuator Assembly, 110/120-Volt 1 A3408596-03000 A3408596-03000

Actuator Assembly, 220/240-Volt 1 A3408596-03050 A3408596-0305007 Actuator Motor, 110/120-Volt [A] 1[A] P1408596-00100 P1408596-00100

Actuator Motor, 220/240-Volt [A] 1[A] P1408596-00500 P1408596-00500 Notes: [A] The actuator motor is included in the actuator assembly.

Table 7—14 Inlet Guide Vane and Actuator Components

06

07

01

0504

02, 03

Air Piping Parts

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7—20

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Item Cooper Turbocompressor No. Description Qty Part Number

AI-128-V Type [A]01 Primary Filter Element [C] P1400009-0077002 Secondary Filter Element [C] P1400009-00771

AI-128 Type [B]03 Primary Filter Element [C] P0540009-0008904 Secondary Filter Element [C] P0540009-00090

Notes: [A] Characterized by 18” x 18” (450 mm x 450 mm) elements[B] Characterized by 24” x 24” (835 mm x 835 mm) elements[C] Quantity could be 2, 3 or 4, dependent upon the number of inlet ports on the filter housing.

Table 7—15. Inlet Air Filter Replacement Elements

Figure 7—16. Inlet Air Filter Assembly

02

01

Air Piping Parts

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7—21

Parts and Service

Item Cooper Turbocompressor No. Description Qty Part Number

<600 Hp [A] >700 Hp [A]01 Bypass Valve:

- 120 V / 60 Hz 1 P1401581-01256 P1401581-01501 - 220 V / 50-60 Hz 1 P1401581-01259 P1401581-01501

02 Kit, Seal or Rebuild 1 MB408539-00098 MB408539-0020203 Solenoid Valve:

- 60 Hz 1 [B] P1401581-01166 - 50 Hz 1 [B] P1401581-01233

04 Metering Valve 1 P1409585-00000 P1409585-0000005 Air Line Filter 1 P0540016-00091 P0540016-0007306 Air Line Filter Element 1 P0540016-00074 P0540016-0007407 Pipe Coupling Housing [C] 2 P1404961-00628 P1404961-0060308 Pipe Coupling Gasket [C] 2 P1404961-00259 P1404961-0060409 Flange Gasket [C] 1 (Not Required) P0907411-00008

Notes: [A] Compressor Power Rating.[B] Included with Item #01.[C] Parts for the packaging option. See figures above.

Table 7—16 Bypass Valve Assemblies and Packaging Options Components

Figure 7—17 Bypass Valve Assemblies and Packaging Options

01, 08

01

04

05, 06

01, 02

01, 02

03

04

05, 06

07, 0809

01

03

Air Piping Parts

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7—22

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Item Cooper Turbocompressor No. Description Qty Part Number

01 Modulating Blow-Off Valve Assembly [A] - 1.5” (40 mm) 1 P0540008-00780 - 2.0” (50 mm) 1 P0540008-00781 - 2.5” (65 mm) 1 P0540008-00782 - 3.0” (75 mm) 1 P0540008-00783

Notes: [A] Valve assemblies are complete with these components mounted and integrally piped: diaphragm actuator, filter regulator, volume booster, and I/P transducer.

Table 7—17. Modulating Blow-Off Valve Assemblies

Figure 7—18.Modulating Blow-Off Valve (MBOV) Assembly

Control Valve

Filter Regulator Transducer

Volume Booster

DiaphagmActuator

Air Piping Parts

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7—23

Parts and Service

Figure 7—20. Discharge Air Check Valve

Connections Model Overall Cooper Turbocompressor

Inlet [A] Discharge [A] Length Part Number BMSV-8 2” (NPT)[B] 8” (Flanged) 78” (2000 mm) P0540010-07091 BMSV-6 1 1/2” (Flanged) 6” (Flanged) 65” (1650 mm) P0540010-00104 BMSV-8 2” (Flanged) 8” (Flanged) 78” (2000 mm) P0540010-02082 LCV-10 3” (Flanged) 10” (Flanged) 71” (1800 mm) P0540010-07092

Notes: [A] Expressed per ANSI (USA) Standards for piping (in inches).[B] Taper-Threaded. National (USA) Pipe Thread (in inches).

Table 7-18. Blow-Off Silencers

Figure 7—21. Automatic Block Valve Assembly

Figure 7—19. Blow-Off Silencer

Cooper TurbocompressorDescription Part Number

3” Valve P0540024-001183” Valve P0540024-001854” Valve P0540024-000724” Valve P0540024-00183

Table 7-19. Discharge Air Check Valves

Cooper TurbocompressorDescription Part Number

3” Valve, 110/120-Volt P0540008-008093” Valve, 220/240-Volt P0540008-008224” Valve, 110/120-Volt P0540008-008004” Valve, 220/240-Volt P0540008-00823

Table 7—20. Automatic Block Valve Assemblies

Actuator

Solenoid

Filter Regulator

Lock-OutValve

ValveBody

Air Piping Parts

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7—24

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

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Installation

A—1

Appendix AInstallation

In this appendix, the reader will learn about:

� General Considerations

� The Installation Work Schedule

� Labor, Supplies, Equipment ….

� Site Considerations

� Process Air Piping

� Utility Piping

� Electrical Interface

� Receiving, Lifting, Moving ….

� Preparing for Startup

� Preventing Startup Problems

� The Inspection Prior to InitialStartup Schedule

� The Initial Startup Procedure

� Service Assistance

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

A—2

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Installation

A—3

General ConsiderationsAdvance planning and preparation will help to simplify and expedite the compressor installationprocess. This Installation Appendix gives an overview of the entire process, from preliminary site prepa-ration to the final preparations before the initial startup.

The Installation Work Schedule lists the various considerations that the owner must address before andduring the installation process, up to and including the initial startup procedure. During the InitialStartup Service Inspection, the Cooper Turbocompressor trained and authorized service representativewill thoroughly inspect the installation work completed including all peripheral piping and electricalwork. He will check the lubrication system, adjust the control system (if necessary), verify motor align-ment, start the compressor and instruct operating personnel.

For more information about specific procedures and/or illustrations of particular arrangements, refer tothe appropriate subsection in this appendix or other relevant appendices.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

A—4

The Installation Work ScheduleBefore beginning the actual compressor installation process, the installer should review this InstallationWork Schedule for an overview of the various considerations and procedures involved. Each aspect ofthe installation listed in this schedule is fully described in subsequent text and/or Section Two, Compres-sor Specifications.

Before delivery, review all technical documents provided, including the Installation Manual and allrelevant specifications and drawings supplied separately.

1. Select a well-suited location in accordance with the minimum recommended space requirementsfor the compressor and future maintenance.

2. Review the list of parts, supplies, tools, and labor that the owner must supply at installation, andarrange for them all to be readily available on site.

3. Be sure that all required preparations and provisions have been made with regard to the founda-tion, piping, and electrical connections, or (if necessary) arrange for suitable storage for the com-pressor until the time of installation.

4. At least two weeks before the projected initial startup date, contact a Cooper Turbocompressorrepresentative to schedule startup assistance.

5. Upon its arrival, inspect the compressor and check loose-shipped equipment against the packinglist; if any damage or shortage is noted, immediately report it to the carrier.

6. Set the compressor on the foundation or (if required) put it into storage until the installation maybe completed.

7. After it is in place, secure the compressor on the foundation bolts.

8. Install the external air piping. *

9. Fabricate a manifold to connect the intercoolers and the oil cooler. *

10. Install all piping between the compressor and the main coolant lines.

11. Fabricate the condensate drain pipes and control devices. *

12. Connect the instrument air line to the reservoir vent ejector system.

13. Make all electrical connections.

14. Check the site a final time for conformance to all applicable codes, all relevant recommendations,and for overall cleanliness and tidiness.

* Certain packaging options involving various piping configurations are available through CooperTurbocompressor. When included from the factory, considerable savings can be realized atinstallation. Details of these options are included later in this manual.

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Installation

A—5

Labor, Supplies, Equipment, and ToolsIt is the owner’s responsibility to prepare the site and to provide any necessary labor, supplies, tools, oradditional equipment required for installation beyond what is included in the purchase package.

The following lists include the supplies necessary for site preparation and installation and the toolsnecessary for installation and future maintenance. Since the Turbo Air 3000 Compressor is designed foreasy installation, most of the tools or supplies required should be already on hand or easily available.

Materials Required for Compressor InstallationSuppliesFoundation bolts

Shims (for leveling)

All external piping supplies

All external wiring and electrical conduits

Turbine oil (See Specifications)

Coupling grease (See Specifications)

Motor bearing grease (See Specifications)

Equipment *Main drive motor controller (starter)

Oil pump motor starter and Oil heater contactor (if necessary)

Inlet air filter

Inlet startup screen

Expansion joints (for inlet and discharge piping)

Vent silencer

Condensate traps, or valves

Air system block valve

Cooling water control valves

Air dryer (if necessary)

Tools **“Port-a-Power” or hydraulic jack

Allen wrenches and Drive sockets with extensions

Digital multimeter

Pipe wrenches, Adjustable wrenches, and Vise grips

Torque wrench (to 200 ft-lbs. or 300 NM)

Screwdrivers

Open end and box wrenches

Drill motor

31/64”, “S”, or 12.30 mm drills (for doweling of motor)

0.499”, or 12.67 mm reamer (for doweling of motor)

*Some equipment may have been purchased with the compressor. Check engineering documents provided

separately for definition of Cooper Turbocompressor’s scope-of-supply.

**All fasteners are in U.S.A. units (inches).

Table A—1. Materials Required for Compressor Installation

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

A—6

Site ConsiderationsSelect the installation site and make any required preparations before compressor delivery. This willallow for a quick startup shortly after the equipment arrives. When selecting and preparing the instal-lation site, also keep in mind that equipment located in a well planned, easily accessible area generallygets better attention from operating and maintenance personnel.

The standard Turbo Air 3000 Compressor is designed for indoor installation. For outdoor installation, itis necessary to purchase the optional TEFC motor and NEMA-4 electrical option as part of the package.

EnvironmentA clean environment is important for optimal performance. Locate the compressor inlet air filter awayfrom chimneys, cooling towers, steam exhausts, or any other possible sources of air contaminationwith foreign matter. In particular, be sure to locate the air filter at least 10 ft. (3.3 m) above groundlevel and at least 6 ft. (2 m) from any window, wall, or roof to further isolate it from any airbornecontaminants.

When selecting an outdoor installation site, consider prevailing and local ground wind patterns as wellas the immediate atmospheric conditions surrounding the unit. Such factors may have long-termeffects on overall compressor operation.

CAUTION:Select the compressor site carefully with regard to possible contamination with foreignmatter. Dust, corrosive vapors, or other airborne foreign matter will adversely affectcompressor performance and motor insulation life.

EnvelopeProvide an adequate envelope (space allowance) around the unit. Figure A—1 illustrates the recom-mended minimum envelope in keeping with the compressor’s overall dimensions. Allow an additional3 ft. (1 m) around the sides and back of the compressor to provide adequate clearance for installation,inspection, and future maintenance. In the front, allow at least 6 ft. (2 m) for intercooler andaftercooler bundle removal.

VentilationIf installing the unit in a confined area, be certain to provide adequate ventilation to dissipate heatgenerated by the package. The temperature immediately surrounding the compressor packageshould not exceed 100°F (40° C).

AcousticsThe mechanical processes of compressor operation will affect sound levels in the area immediatelyaround the compressor. If the installation site is an area where hard walls and low, hard ceilings willreflect and amplify noise, it is advisable to cover the reflective surfaces with acoustical insulation.

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Water Supply and DrainsIf water is to be used as the coolant, whenever possible provide clean cooling water with low mineralcontent. This will optimize cooler performance and significantly reduce the possibility of cooler foulingduring operation.

Also, be sure to provide adequate open drains to carry away condensate from the intercoolers andaftercooler. Condensate from the Turbo Air 3000 Compressor is completely oil-free and environ-mentally safe.

(Refer to the Utility Piping subsection for additional information and requirements for water supplyand condensate drain piping.)

FoundationThe Turbo Air 3000 Compressor can be installed directly onto the factory floor so long as the floormeets the following minimum requirements:

� It must be constructed of good quality, reinforced concrete to provide a rigid and substantialbase.

� It must be one continuous integral slab with a minimum thickness of 4-6 in. (100-150 mm).� It must be isolated from vibrations from surrounding equipment.� Flatness must be 0.010 in. per foot (1 mm per meter).

Figure A—1. Compressor Envelope

78 inches(2000mm)

72 inches(1800mm)

134 inches(3400mm)

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Process Air PipingThe process air system includes three subsystems: the inlet air piping, the discharge air piping, and thebypass piping arrangements. The Process and Instrumentation Diagram provided separately illustratesonly the various compressor system components supplied by Cooper Turbocompressor. The user mustprovide all external process air piping and supports as well as the piping design itself.

When designing and fabricating the compressor air piping, keep in mind that these piping systems arethe “lifelines” of any compressor installation. Improperly designed piping systems may cause laterproblems. The most common reason for compressor control problems is failure to follow thedischarge piping installation guidelines and/or the requirements listed on the contract specific-drawings transmitted separately. If requirements and specifications are not met, the improperlydesigned piping system will cause delays and may require costly and time-consuming modifications.

To ensure a successful process air piping installation, always:

� Use clean pipes to be sure that no foreign material enters the compressor.� Keep the piping as short and direct as possible.� Clean the piping thoroughly after fabrication.� Use a discharge block valve as indicated.� Support the piping properly so that the supports (rather than the compressor) carry the load.� Provide drains at low points to carry away any collected condensate.

DANGER:Remember that it is the owner’s and installer’s responsibility to provide appropriateservice piping to and from the compressor. Failure to follow the requirements and recom-mendations listed will cause mechanical failure, property damage, serious injury, and/ordeath.

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Figure A—2. Typical Process Air Piping

1/2” Instrument Line

A. Inlet FilterB. Inlet ScreenC. Expansion JointD. Check ValveE. Block ValveF. Blowoff ValveG. Silencer

E

DF

G

A

CB

C

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Inlet Air PipingFigure A— 4 shows a typical inlet air piping arrangement in detail, including various standard andoptional components.

Figure A—4. Inlet Air Piping

When designing and installing the inlet air piping, it is important to carefully consider the followinginformation and recommendations.

ConnectionThe inlet air connection to the Turbo Air 3000 Compressor is a cast iron reducer, the outside of whichmatches standard steel pipe. (American National Standards Institute: ANSI B36.10). This inlet reducermay be removed and machined to accept a number of different style couplings, thus allowing theinstaller to select among several options when making the inlet air pipe attachment to the compressor.

Figure A—5 shows a detail of the inlet air piping arrangement. (The Inlet Air Startup Screen and InletExpansion Joint options are also included in this arrangement. Refer to relevant headings for moreinformation about these components.)

Do not make the final inlet air pipe connections to the compressor. The Cooper Turbocompressorrepresentative must inspect the piping for cleanliness during the startup service call before the finalconnection is made.

A. Inlet Filter SilencerB. Pipe ReducerC. Inlet Startup ScreenD. Inlet Expansion JointE. Inlet Guide Vane (IGV)F. IGV Motor

A

B BE

F

DC

12” Recommended Pipe Size

STG. 1

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Figure A—5. Detail of Inlet Air Connection with Options

Piping MaterialWhen selecting the pipe to be used, it is advisable to either select corrosion-resistant piping or, alterna-tively, to treat the pipe to provide additional corrosion protection. When fabricating the inlet air piping,also take care to provide suitable support so as to sufficiently isolate the piping forces from the com-pressor itself.

In those instances when fiberglass piping will be used for the inlet air lines, be sure to follow theserecommendations:

� Select pipe material that can tolerate bypass air temperatures of up to 350°F (175°C).� Use pipe and fittings that are filament wound with continuous glass filaments and epoxy resin.� Provide the fiberglass piping with additional reinforcement to evenly distribute the load along

the pipe.� Insulate the pipe to minimize noise.

DrainsProvide adequate drains at low points to accommodate the condensate that collects on the inlet lineduring compressor shutdown periods. This will deter rusting and eventual erosion of aerodynamiccomponents, either of which would otherwise reduce overall compressor performance and componentlife span.

FabricationUse 8” or larger (or comparable size) pipe to connect the inlet air filter to the compressor. Do not usepipe smaller than 8” (or comparable size), since the smaller size will cause reduced inlet air pressuresand impaired compressor performance.

Provide a straight run of approximately four pipe diameters before the inlet guide vanes (IGV’s) tominimize flow distortion. Also, avoid using many elbows and sharp bends in the compressor inletpiping.

Inlet Startup Screen

Inlet Guide Assembly

Inlet Expansion Joint

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Inlet Expansion JointCooper Turbocompressor recommends the use of the Inlet Expansion Joint option (which consists of arubber sleeve with stainless steel clamps) as a means of joining the inlet air pipe to the compressor.(See Figure A—5.) When making this connection, do not use pipe smaller than the recommended pipesize; larger pipe is in fact preferable, since the increased volume will reduce both noise and pressureloss.

Inlet Air Startup ScreenThe inlet piping must be designed to prevent any solids from entering the compressor inlet. When longruns of inlet piping are required, or when visual/physical inspection of the finished piping is difficult,the temporary conical Inlet Air Startup Screen option serves to filter substances from the intake airsupply before they can reach the compressor and damage internal components. In such instances, it isimportant to locate the screen as close as possible to the compressor inlet. The Inlet Air Startup Screenis shown in Figure A—6.

CAUTION:Be certain to remove the Inlet Air Startup Screen after approximately 40-50 hours ofcompressor operation. If it is not removed, the pressure loss across the screen can signifi-cantly reduce overall compressor performance.

Figure A—6. Inlet Air Startup Screen

Inlet Filter/SilencerThe Inlet Filter/Silencer option will remove airborne particles that would otherwise erode aerodynamiccomponents, foul heat exchangers and tend to accumulate within the air flow passages. The silencerfeature of this component will reduce compressor noise that travels through the inlet air piping. Theinlet filter/silencer is a permanently installed component.

8” (200mm)

12” (300mm)

Material:302 or 304Stainless Steel

Outer Screen(10 x 10 Mesh / .32 wire)

Inner Screen(8 x 8 Mesh / .063 wire)

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Discharge Air PipingThe discharge air piping system is shown schematically in Figure A—7. It consists of the piping andother accessories required for a specific installation, including a receiver, a block valve, a check valve,and expansion joints.

Figure A—7. Typical Discharge Air Piping Arrangement

When designing and installing the discharge air system, the following information and recommenda-tions should be taken into consideration.

ConnectionThe compressor discharge air connection is machined to accept a Victaulic pipe coupling. When attach-ing the discharge pipe, refer to the contract-specific Installation Arrangement Drawings suppliedseparately for specific size information.

Cooper Turbocompressor offers the following coupling options:

� Straight Coupling� Reducing Coupling� Vic-Flange Adapter

A. AftercoolerB. Flexible Pipe CouplingC. Victaulic Flange (option)D. Check ValveE. Block Valve

1. From last stage of compression.2. To compressed air system.3. To bypass valve for venting.4. To control panel - system pressure.5. To control panel - compressor discharge pressure

A

3

4

5

BC

4”4”

RecommendedPipe Size

E2

D

1

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Piping MaterialWhile corrosion on the discharge air side does not present the same problem as it does on the intakeair piping, it is still a concern. Rust can damage delicate instrumentation, pneumatic tools, or processesthat require non-contaminated air.

The principal consideration in the selection of piping materials should be safety. The United States,Canada, and most other countries strictly prohibit the use of unprotected polyvinyl chloride(PVC) piping to transport compressed air or other compressed gases. Cooper Turbocompressor alsoadvises against using soldered copper fittings and rubber hoses in discharge air piping. If fabricatingthe air piping with flexible joints and flexlines, be sure that they meet the operating parameters of thesystem.

Cooper Turbocompressor recommends that all pressure-holding pipe be in accordance with the stan-dards established by the American National Standards Institute (ANSI) as well as the American Societyof Mechanical Engineers’ (ASME) Standard B31.8-1986.

WARNING:Be certain to follow all specified requirements and guidelines. Failure to correctly followthe above or other specified discharge air piping design guidelines will cause compressormalfunction and/or damage.

DrainsThe high pressure air leaving the compressor contains some moisture. Therefore, it is necessary toprovide drains at all low points to remove any condensate that may collect along the discharge system.

FabricationThe high pressures, long piping runs, and heavy accessories in the discharge air line makes designconsiderations necessarily more detailed than with the intake air lines. When fabricating the dis-charge piping system, do not exceed specified pipe volumes (0.1% of design flow in cubic feetper minute) between the compressor discharge flange, the blow-off valve, and the dischargecheck valve. (Additional information about blow-off valve and check valve installation is included laterin this appendix.)

WARNING:Do not exceed the 400 lb. (1700 Nm) Maximum Allowable Force or the Maximum Allow-able moment of 600 lbs. (800 Nm) on the compressor discharge connection. Excess weightmay cause pipe connection failure.

Depending on the control method utilized, the pressure-sensing lines should be located either beforeand/or after the check valve. Refer to the Flow Schematic and Installation Arrangement drawingssupplied separately for specific placement.

With all control methods, it is necessary to keep the pipe volume between the compressor dischargeconnection, the discharge check valve, and the blow-off or bypass valve minimal. For proper operationof the discharge check valve, 18” (450mm) of straight piping should precede and follow the valve.

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CAUTION:To assure proper compressor unloading, do not allow the pipe volume to exceed 0.1% ofthe volume flow in cubic feet per minute (CFM). Excessive volumes may cause compressorsurging during unloading.

Discharge Expansion JointCooper Turbocompressor recommends the use of the Discharge Expansion Joint option to ensure a safedischarge piping system design. The discharge expansion joint must be mounted vertically, directly atthe discharge flange of the compressor. Because braided type expansion joints cannot withstand acollapsing force, it is necessary to install such joints with sufficient pre-tension to counteract suchforces. If a “tied” expansion joint is utilized, it is necessary to take special care to be certain that theaxial and lateral flexibilities of the joint are not unduly restricted.

WARNING:Be certain that the discharge expansion joint is installed correctly. With improper installa-tion, the release of higher-pressure energy in the discharge air poses the threat of seriousinjury to operating personnel.

Discharge Check ValveA discharge check valve must be included in the discharge piping arrangement to prevent the reverseflow of air through the compressor during unloaded operation. (Refer to the Engineering drawingssupplied separately for the precise location of the discharge piping.)

Cooper Turbocompressor supplies a contoured, disc-type check valve that must be mounted properly soas to pivot open and close. It is necessary to install this valve in a horizontal run of piping, with arecommended minimum of four pipe diameters of straight pipe before and after the valve. In order tohold the valve disc in a fully opened position, a flowing differential pressure of 0.5 psi (0.3kPa) isrequired. If the valve is not correctly sized (particularly if it is oversized), the potential for shut-offfailure is increased. Before installing the check valve, refer to the Check Valve Installation drawing andexamine the valve itself for the top marking to determine the correct orientation.

WARNING:Before operating the compressor, examine the top of the check valve to be sure thatthe orientation of the valve is correct. Cooper Turbocompressor will not acceptresponsibility for damage or personal injury incurred as a result of improper installationof the check valve.

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Block ValveAll compressor installations must include a block valve to insulate the compressor from the remainder ofthe pressure system in case of a check valve failure. The user must supply the block valve, which mustbe installed after the check valve.

WARNING:Whenever the compressor is being serviced, be certain to close and lock the block valve.These measures are necessary to protect the compressor whenever the check valve is beingserviced or otherwise not functional.

Automatic Block Valve OptionThe Automatic Block Valve option fits between two 150-lb. ANSI raised-face flanges in the discharge airpiping. The recommended installation is after the aftercooler (if so equipped) and at least four pipelengths beyond the discharge check valve. While the valve orientation is at the installer’s discretion,accessibility should be considered if the Automatic Block Valve is to be used as a lockout device duringcompressor service.

The valve actuator requires a 60-psig air supply for a three-stage compressor or a 30-psig air supply fora two-stage compressor. If available, use the instrument air supply; alternatively, tap the pipe locatedimmediately upstream of the valve itself. The supply air should be connected to the lockout valve onthe block valve assembly. Verify correct operation of the Automatic Block Valve at the initial startup,since valve malfunction may cause compressor surging. Refer to Cooper Turbocompressor EDR-A-008,Automatic Block Valve, for additional information on the Automatic Block Valve option.

Control Valve PipingDepending on the control method being applied, the Turbo Air 3000 will either completely or partiallyunload whenever the capacity of the compressor exceeds the compressed air system’s demand. UnderAUTO-OFFLINE control, the compressor is unloaded by completely bypassing the compressed air systemand venting discharge air back to the inlet of the compressor or out to atmosphere. In other cases, aportion of the discharge air is partially vented or blown-off in order to maintain Constant Pressure orconstant mass flow into the compressed air system.

Bypass ValveThe AUTO-OFFLINE Control method utilizes a pop-action bypass valve (BPV). The BPV operates in either afully open or fully closed position. The compressor owner/installer is responsible for the proper installa-tion of this control valve (which is shipped separately) unless the Mounted Bypass Valve option ispurchased. (Refer to the relevant heading for additional information about that option.)

Modulating Blow-Off Valve (MBOV)All control methods may utilize a modulating blow-off valve (MBOV) which operates in any positionfrom fully closed to fully open. A pneumatic actuator, and I/P transducer, a volume booster and a filterregulator all come mounted and integrally piped to the valve body as a complete assembly. The owner/installer is responsible for the proper installation of the MBOV, which is shipped separately.

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Valve InstallationIn instances when the bypass valve or the modulating blow-off valve is installed by the owner/installer,the installation must be in a branch of the discharge piping located upstream from the discharge checkvalve. (Refer to the Flow Schematic supplied separately for a placement illustration.)

The recommended maximum length for this line (which is located between the main process pipelineand the venting valve) is 10 ft. (3 m). The size of the bypass or blow-off valve piping should match thesize of the valve itself. Figure A—8 shows the correct installation of the control valve when it is ownerinstalled.

CAUTION:In order to ensure proper compressor unloading and to prevent surging, be certain to keepthe pipe volume between the compressor connection and the blow-off or bypass valveminimal. To determine the specific maximum volume, multiply the compressor design flow(CFM) by .001.

Figure A—8. Blow-Off Piping Detail

Mounted Bypass Valve OptionThe Mounted Bypass Valve option is available with the AUTO-OFFLINE Control method only. In suchinstances, the valve is installed between the compressor inlet and the discharge piping and is electricallyconnected to the Vantage Control Panel.

Including this option with AUTO-OFFLINE applications eliminates the necessity for owner installation ofthe control valve. When this option is factory installed, the bypass air is re-circulated to the compressorinlet. This also eliminates the necessity for separate atmospheric vent piping as well as for the VentSilencer option described under Sound Suppression.

A. Compressor FlangeB. Check ValveC. Block ValveD. Bypass or Modulating Blow-Off ValveE. I/P TransducerF. Filter RegulatorG. Source of Instrument Air

1. To compressed air system2. Control signal from control panel

2

GE F

D HVent

4” 3” 3”

BA C

RecommendedPipe Size

IP FR

1

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Sound SuppressionInlet and discharge air piping are major sound emitters in any compressor installation. For greatersound suppression, insulate local surfaces with sound absorbing materials. For maximum sound sup-pression, it is necessary to insulate the entire air path as follows:

� All inlet air piping from the opening in the compressor room (if housed indoors) to the inletflange.

� All discharge air components, including piping and fittings.� All blow-off valve piping, including the blow-off valve and silencer.

Additional information about the insulation of piping for noise control is contained in CooperTurbocompressor Engineering Data Release EDR-A-005, Insulation for Noise Control, available uponrequest.

Vent SilencerSince the high-pressure air expansion across the blow-off valve creates considerable noise, CooperTurbocompressor recommends using the Vent Silencer option to reduce noise produced during com-pressor operation. (This option is not required in instances when the Mounted Bypass Valve option isincluded in the package.)

For maximum effectiveness, this silencer must be properly installed directly on the blow-off valve or thebypass valve. Any additional piping should be the same size as the silencer discharge flange, and maybe extended beyond the silencer. The exhaust piping from the silencer should be sized for a maximumback pressure of 5 psig (.3 bar) on the silencer.

To increase the exit area, cut the pipe end at a sharp angle as shown in Figure A—9. Since airbornenoise is directional, aim the discharge in a non-critical direction. Do not direct the exhaust pipe onto ahard surface which could cause resonance.

Figure A—9. Angled Pipe End

Cut at sharp angle toincrease exit area Discharge

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Utility PipingThe utility piping is defined as any piping, tubing or electrical conduit external to the compressorpackage, which support subsystems required to complete the compressor installation. Included in thiscategory are:

� The cooling water (coolant) piping for the four water-cooler heat exchangers.� The condensate drain piping.� The instrument air piping for the reservoir vent ejector system.� The instrument tubing which connects various pressure-sensing points to transducers located on

the compressor package.� Any medium- and/or high-voltage electrical conduit for the main drive motor, Vantage Control

Panel, oil pump motor and optional lubricating oil heater.

The user/installer is responsible for providing all external piping, tubing and conduit, as well as for thebasic design of the utility piping. Typical arrangements for some of the utility piping are included inthis section.

To ensure successful utility piping installations, always:� Use clean piping to be sure no foreign material enters the compressor’s subsystems’ components.� Keep the piping, tubing or conduit as short and direct as possible.� Clean the piping and conduit thoroughly after fabrication.� Support the piping and conduit properly, where necessary, so that the support (rather than the

compressor) carry the load.� Provide drop legs or drains at low points to carry away any collected condensate.

WARNING:Remember that it is the owner’s and installer’s responsibility to provide appropriate utilitypiping to and from the compressor. Failure to follow good industrial practices and therequirements and recommendations listed could cause poor compressor performance,mechanical failure, property damage, and/or personal injury.

Cooling Water (Coolant) Supply PipingThe typical Turbo Air 3000 Compressor package includes four water-cooled heat exchangers (twointercoolers, an aftercooler, and an oil cooler). Figure A—10 illustrates the manifolding of these heatexchangers to provide a single feed connection and single return connection for cooling water at thecompressor. Figure A—10 also shows the placement of a valve to throttle water flow to the oil coolerto control oil temperature. (This throttle valve is required only when the Automatic Oil TemperatureControl option is not included at the time of order or has been retrofitted into the lubrication system.)

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Figure A—10. Typical Water Manifold

Figure A—11 illustrates a cooling water piping arrangement with typical feed and return piping, shut-off valves, throttle valve, various gauges, and drain connections. Cooling water (coolant) requirementsare included in the Section 2, Specifications. The values given are representative of average usage.Actual requirements may differ according to such variables as temperature, humidity, and the conditionof the heat exchangers. When the heat exchangers are regularly cleaned as described in Section 5,Maintenance, significantly better performance will be possible.

The installer must consider the distance and routing of the water piping when determining the appro-priate sizing for the piping. Cooper Turbocompressor also recommends installing, when necessary, apressure regulator to allow for pressure control of the water.

1-1/2” NPT

3” (76mm)Recommended Pipe Size

Throttle Valve

3/4” NPT

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CAUTION:When fabricating the coolant supply piping (Figure A—11), always install the throttlevalve on the discharge side of the manifold rather than the inlet side. This will ensure thatthe coolers are always flooded and that no air locks will form to restrict flow.

After fabrication of the cooling water piping is complete and before the initial compressor startup,install temporary filter screens in the supply lines just before entry to the heat exchangers. Flush thepipes thoroughly, and when it is determined that the supply piping is completely free of any foreignmatter, remove the screens. Reconnect the compressor manifold, and verify that there are no externalleaks. To verify that there are no internal leaks, open the condensate drains of the intercoolers andaftercooler.

Figure A—11. Typical Water Supply and Return Piping

A. Temperature GaugeB. Pressure GaugeC. Shut-Off ValveD. Throttle ValveE. Drain Connection

3” Victaulic ConnectionA

AB

BE

D

C C

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Condensate Drain PipingDuring air compressor operation, condensate collects in each intercooler chamber as the air is cooled.(This is not the case when the compressor is used in dry nitrogen service.) In order to prevent thecondensate from being carried over and entering the next stage of compression, the condensate ineach of the intercooler chambers must be drained into an open drain or trough. The open drainallows not only visual verification of condensate removal, but it also assures that the condensate willnot be drawn back into the compressor when the compressor is unloaded.

CAUTION:Do not manifold the condensate drains. Since the cooler cavities operate at differentpressures, manifolding will cause malfunctions due to excessive amounts of condensatefrom higher pressure chambers being forced into lower pressure chambers and conse-quently through the compressor.

A variety of control devices can be used in the condensate removal piping system, including:� Standard gate valves, operated by hand.� Float traps which are self-actuating.� Solenoid valves, operated by the Vantage Control System.

Three ½” NPT connections (one for each cooler cavity) are located at the front of the compressor. Thecondensate piping and control devices attach to these connections. Figure A—12 illustrate a typicalcondensate drain piping arrangement. It is also necessary to include a manual bypass valve and pipingwith whichever type of drain control device is utilized. The isolation valves ahead of the control deviceare optional.

It is also advisable to keep the condensate draining system open during shutdown to prevent conden-sate accumulation in the compressor. This will also provide compressor protection in case of an inter-cooler tube failure.

Figure A—12. Typical Condensate Removal Piping Arrangement

A. Hand ValveB. Trap or Solenoid Valve

A

B

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Optional FeaturesCooper Turbocompressor offers an array of cooling water piping and condensate drain options thatmay ease the installation of the compressor or enhance the overall operation of the compressor. Anyof these features may be easily retrofitted if not included at the time of the original machine order.These are briefly described below.

Cooling Water (Coolant) Manifold OptionWhen this option is selected, the intercoolers, aftercooler, and oil cooler are manifolded to single inletand outlet connections. The Cooper Turbocompressor design is compact and precise and will reduceinstallation time.

Figure A—13. Cooling Water Manifold Option

Automatic Cooling Water Shutoff ValvesThis option includes a pair of solenoid operated valves to be installed at the inlet and outlet connectionpoints of the water manifold. These valves will be controlled by the Vantage Control System to shutoffwater flow to the four water-cooled heat exchangers whenever the compressor is not running. Thisfeature is intended to save cooling water and the operator’s time to perform a normal compressorshutdown.

Automatic Coolant Water Flow Control ValvesThis option includes a temperature sensor/controller installed in the air stream and a throttling valveinstalled in the water stream; thus reducing water consumption during compressor unloaded opera-tion.

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Condensate Drain Piping OptionWhen this option is purchased at the time of order entry, a piping assembly including a solenoid-operated drain valve and manually operated bypass gate valve is fabricated and attached to the drainconnection of the intercoolers and aftercoolers. The solenoid-operated drain valves are in turn wired tothe Vantage Control Panel. The Vantage Control System will open and close the drain valves at setintervals to drain accumulated condensate from the heat exchanger chambers.

The Cooper Turbocompressor design is again compact and very effective. It will save installation costand efficiently allow condensate to drain from the cooler chambers without wasting compressed air.

WARNING:Remember that the outlets of these three drain assemblies must not be manifolded to-gether. They must individually discharge into an open drain or trough to prevent conden-sate from higher-pressure chambers being forced back into lower pressure chambers. Thisis the single most common error made at the time of compressor installation.

Figure A—14. Condensate Drain Piping Assembly Figure A—15. LiquidatorTM Pneumatic Condensate Drain Trap

Pneumatic Condensate Drain OptionFigure A—15 illustrates an alternate to the solenoid-operated drain valve system. The LiquidatorTM

Pneumatic Condensate Draining System option is a demand-operated trap that automatically drainscondensate without any loss of compressed air. Significant energy savings could result when using thissystem instead of other time-based draining systems. The Liquidator Draining System may be purchasedinitially with the compressor or retrofitted later. Request additional information from an authorizedCooper Turbocompressor representative. Engineering Data Release, EDR-D-005, explains this system andprovides complete installation, operation and maintenance information.

A. Solenoid Drain ValveB. Check ValveC. Manual Bypass ValveD. Manual Block Valve

A

C

B

D

10 inches(250 mm)

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Oil Reservoir Vent Ejector PipingThe gearbox and oil reservoir must be vented in a way that will prevent migration of oil and/or oil mistto the surrounding area or other parts of the compressor. The Turbo Air 3000 Compressor utilizes asimple ejector (or venturi-tube) powered by clean, dry, filtered air. This ejector creates a slight vacuuminside the gearbox and oil reservoir to prevent the unwanted migration of oil and oil mist.

WARNING:Introducing water into the oil reservoir will have adverse effects on the lubricating oil andwill cause severe damage to the compressor. Be sure the ejector’s supply air comes from aclean and dry source.

The ejector and filter assembly is located at the top of the oil reservoir. The relevant engineeringdrawings (supplied separately) define the precise connection point and define the specific air require-ments. If the air supply pressure varies, it is recommended that a pressure regulator with gauge beinstalled for control of pressure to the ejector. The regulator should be installed in the air supply linejust before the ejector itself.

Since it is the routing and distance of the piping at any particular installation are the principal deter-mining factors, it is the installer’s responsibility to correctly size the air supply piping. (Appendix B, TheLubrication System, includes additional important information about the operation of the ejector/filtersystem.)

Instrument TubingFigures A—2 and A—3 illustrate the external instrument tubing required to complete the compressorinstallation. Pressure sensing points in the user’s discharge piping must be connected to pressuretransducers located on the compressor package. These pressure sensors are located in an enclosurejust underneath the Vantage Control Panel. Various applicable engineering drawings (supplied sepa-rately) precisely locate the connection point(s) on the Turbo Air 3000 Compressor package, as well as,schematically illustrate from where the tubing run(s) should originate.

The control method determines the number of instrument tubing runs that are required. To ensure asuccessful instrument tubing installation, always:

� Use steel tubing in order to avoid kinks or other common problems, which are inherent withcopper tubing. (Stainless steel is preferred to be sure that no foreign matter, like rust or scale,can enter the pressure instruments.)

� Keep the tubing runs as short and direct as possible.� Do not include block or shut-off valves that can interrupt the pressure signal.� Provide drop legs at low points with drains to carry away any collected condensate.� Check for leaks at the connection points in order to avoid faulty pressure readings.

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Electrical ConduitThe typical Turbo Air 3000 Compressor installation will require that medium voltage, and possibly highvoltage, electrical power is delivered to complete the compressor installation. The standard package-mounted components requiring electrical power are the main drive motor, the oil pump motor and theVantage Control Panel. Other optional equipment, such as the oil heater, will also require electricalpower. The National Electrical Code in the United States, as well as most other national codes, requirethat the electrical wiring for this type industrial service must be encased in rigid conduit.

The user/installer is responsible for providing and designing the installation of all external electricalconduit runs. To ensure successful electrical conduit installation always:

� Use clean, non-corrosive conduit and fittings with no burrs or sharp edges.� Keep the conduit runs as short and direct as possible.� Support the conduit properly so as to not impart any unnecessary loads on the components to

which it is being connected.� Provide drop legs at low points with drains to remove any collected condensate.

WARNING:Remember that it is the owner’s and installer’s responsibility to apply correct wiringpractices. Failure to follow local electrical codes and good industrial practices could causeproperty damage and/or personal injury or death.

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Electrical InterfaceThe user is responsible for the proper electrical connection of several components at the site installa-tion, including the Vantage Control Panel, the oil pump motor, the main drive motor, and the oil heateroption (if included). Refer to other technical data and/or engineering drawings supplied separately todetermine the correct power supply requirements.

WARNING:Do not energize or start up the compressor until a Cooper Turbocompressor service repre-sentative has given full approval. Failure to follow this requirement will compromise anyapplicable warranties.

General WiringIn addition to the basic wiring design, the user must also provide the wire, conduit, protection equip-ment, etc. When designing and installing the electrical interface, it is necessary to meet the followingminimum requirements:

� Be certain that the main power supply meets specifications, including voltage, frequency, and(most importantly) the current-carrying capacity of the wires.

� Provide an appropriate separate compressor earth ground that meets local and national code. (Inthe United States, refer to Section 250-26 of the National Electrical Code for earth grounddefinition.)

� Include proper disconnects such as switches or circuit breakers (either fusible or non-fusible) toprovide complete isolation from the electrical supply.

� If the main power switch that controls the compressor is remotely located or if it is difficult tolock out the main switch, install a local switch to enable maintenance personnel to isolate theunit.

� Install and use a lockout system whenever performing maintenance procedures on this orany other such type of machinery.

If the user requires accessories such as the Solenoid Valve Condensate Removal option, it will be neces-sary to supply additional interconnections. Refer to the specifications provided separately, or contact aCooper Turbocompressor representative for specific requirements.

DANGER:Be certain that all electrical work is performed by qualified personnel according to productspecifications and all applicable local or national codes. Failure to heed this requirementmay cause equipment damage, and/or personal injury or death.

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Main Drive Motor ControlsThe major functions of a motor-control system are:

� Starting and stopping of the motor.� Governing motor speed, torque, output (horsepower/kilowatts), and other characteristics.� Protecting personnel and equipment.

When the main drive motor controller is purchased along with the compressor, CooperTurbocompressor specifies the proper hardware and design for easy compatibility with the compressor’sVantage Microprocessor Control System.

Cooper Turbocompressor Engineering Specification EDR-G-009, Requirements for Owner-SuppliedMotor Controls, completely details the minimum requirements for proper interface between thecompressor control system and the owner-supplied motor control equipment. However, because thereare different types of motor starting equipment and an even wider variety of optional features avail-able, many factors have to be considered when making an appropriate choice.

There are two general categories of starters for single speed, squirrel cage induction motors, fullvoltage starters and reduced voltage starters. When selecting the motor controls, consider the follow-ing information about these two types.

Full Voltage StartersThese apply full-line voltage directly to the motor terminals and are available in many types, includingmanual, magnetic, combination, and reversing. It is also possible to add several other functions toimprove protection or increase monitoring capability.

Reduced Voltage StartersThese systems, which limit the drive motor current inrush, work well when normal considerations foruse of reduced voltage starting are observed. Starting times for reduced voltage systems are generallyless than 30 seconds. However, with reduced voltage starters the compressor’s inlet guide vanes mustnot be cycled open until the motor and compressor have reached full speed. (The Vantage ControlSystem has the capability to delay loading with a variable timer.)

Although two general types of reduced voltage starters are commonly used, stepped starters and solidstate starters, stepped starters have been shown to give more consistent and reliable performance. Thewide variety of solid state starting equipment, along with contributing effects of various options and/orfeatures, makes performance of solid state starters inconsistent and difficult to predict.

CAUTION:It is advisable to use stepped starters for reduced voltage motor controls.In certain applications, solid state starter performance may be unreliable or inconsistent.

Refer to Cooper Turbocompressor Engineering Specification EDR-G-008, Solid State Starter Specifica-tions, for more information on minimal requirements for solid state starting equipment.

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Oil Heater OptionThe supply voltage determines the wiring method for the Oil Heater option. For typical wiring forvoltage applications of 480 VAC or less, refer to Figure A—19. With voltage applications greater than480 and below 600 VAC, refer to Figure A—20 for a typical wiring diagram.

Figure A—19. Oil Heater Option Wiring (480 VAC or less)

Figure A—20. Oil Heater Option Wiring (above 480 VAC and below 600 VAC)

CAUTION:DO NOT CHANGE

JUMPER ARRANGEMENT

Thermostat

Three-Phase PowerFrom Three-Pole

Disconnect Switch

Heater Terminal Box (Front)

Heater Element Connections

Three-PhasePower

L 3-1L 2-1L 1-1

L 3-2L 2-2L 1-2

L 3-1L 2-1L 1-1

Thermostat

Three-Phase PowerFrom Three-Pole

Disconnect Switch

Heater Terminal Box (Front)

Three-PhasePower

L 3-1L 2-1L 1-1

L 3-2L 2-2L 1-2

L 3-1L 2-1L 1-1

Heater Element Connections

Additional WiringRefer to contract-specific drawings to determine additional wiring requirements for other installationoptions such as blow-off valves, water valves, transmitters, etc.

WARNING:Remember that the control of hazardous energy sources is the responsibility of the com-pressor installer and user, and that adherence to the guidelines above and any othernational or local codes is of critical importance. Failure to follow proper procedures mayresult in equipment damage, and/or personal injury or death.

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Receiving, Lifting, Moving, and BoltingThe time after the order for a new compressor has been placed and before the actual delivery of theequipment can be spent planning for the installation. Much of the work described earlier can beperformed or planned for prior to the arrival of the compressor at the installation site.

The Turbo Air 3000 Centrifugal Compressor is shipped as a single assembly. The main drive motor,lubrication system, and control system are packaged with the compressor on a single skid. However,since there are many package and accessory options, it is important to refer to the contract-specificengineering drawings supplied separately for as complete listing of equipment included in CooperTurbocompressor’s Scope-of-Supply.

ReceivingCooper Turbocompressor personnel inspect each compressor thoroughly at the factory before ship-ment. They then supervise the loading to be sure that no damage occurs and document all loose-shipped equipment.

It is the responsibility of the purchaser to inspect the compressor for possible damage during transit.Therefore, plan to inspect the compressor immediately upon delivery. If there appears to be anydamage, report it to the carrier and have the carrier inspect the compressor. After determining theextent of the damage, have the carrier complete and submit a Concealed Damage Report.

Also, be sure to check all loose-shipped parts and equipment against the packing list. If anything ismissing, report the shortage to the carrier.

Shipments are FOB, Buffalo, NY, USA, and become the property of the purchaser at the risk of thepurchaser.

LiftingThe Turbo Air 3000 Compressor is a heavy and durable high technology product, but it can be dam-aged as a result of improper treatment. It requires careful handling during all lifting and moving. Theunit includes clearly indicated lifting and moving points. Never use any other areas for lifting andmoving.

WARNING:To avoid personal injury or compressor damage, always follow the proper procedures asdescribed in this manual. Personnel safety and compressor protection must always beforemost concerns when lifting or moving the compressor.

The Turbo Air 3000 Compressor is designed to be moved with an overhead hoist and chain. Be sure thatboth are properly rated for a maximum package weight of 18,500 lbs. (8400 kg), and be certain thatthey are in good working order before attempting the move. Use the clearly designated lift points onthe compressor as shown in Figure A—21. (In some instances it may be necessary to use spreader barsto clear certain main drive motors.)

WARNING:Be certain to use properly rated equipment and lift the compressor only as shown at thelift points indicated. Improper lifting may cause compressor damage and/or personalinjury.

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Figure A—21. Compressor Lift Points

MovingIf an overhead hoist is not available, the compressor may be moved on rollers, dollies, or casters.Alternatively, if a forklift is used to move the compressor, be certain to place the entire compressor on asubstantial pallet that supports the base between the liftpoints and lift only under the base betweenthe lift points indicated.

WARNING:Before moving the compressor, verify that the moving device is the appropriate size andsufficiently strong to bear the weight of the compressor. Improper moving may causecompressor damage and/or personal injury.

BoltingIf the foundation has been properly prepared, the compressor may be put in place at this time. CooperTurbocompressor recommends placing the compressor over foundation bolts, with the nuts tightenedto the recommended torque value. (Refer to Section Two, Compressor Specifications, for specificinformation).

Take special care not to rack or twist the base of the compressor when placing it on the foundation. Ifnecessary, use shims to level the installation package.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

A—32

Preparing for StartupAlthough each compressor undergoes rigorous and comprehensive testing before it leaves the manu-facturing facility, after transit and installation it is necessary to test and recheck certain components onsite. Therefore, after all the preparations described previously are completed and before the initialstartup procedure, several inspections and adjustments are required to verify that the compressor hasbeen installed correctly and to be sure that all subsystems are functioning correctly.

To ensure a proper and safe compressor startup and correct operation, a Cooper Turbocompressorfactory trained and authorized service representative should be present to inspect the site, supervisethe final installation steps, and assist with the startup procedure.

A Pre-Startup Inspection Checklist follows which arranges the tasks or responsibilities that the user orinstaller should be able to complete prior to the arrival of the Cooper Turbocompressor startup repre-sentative. Should any concerns or questions develop while executing this list, it should be brought tothe attention of the startup representative.

Additional tasks required, but not explained in earlier text include:� Main drive motor rotation verification.� Oil pump motor rotation verification.� Lubrication system flush.

Instructions for each of these procedures are included after the Pre-Startup Inspection Checklist(Table A—2).

WARNING:Personnel safety and equipment protection must always be primary considerations duringcompressor installation, startup, and operation. The high voltages associated with thismachinery, the shaft rotation speeds, and the highly pressurized process air produced bythe compressor are major safety hazards when proper safety precautions are not strictlyfollowed at all times.

The Prestart InspectionBefore performing the prestart inspection, review the Turbo Air 3000 Compressor installation instruc-tions again. Also, be sure to review any other applicable manufacturer’s instructions for installation,operation, and maintenance of various other components and equipment including the main drivemotor, the main drive motor controller, the air dryer, etc..

After reviewing the previous items, thoroughly inspect the compressor installation using the Pre-StartupInspection Checklist in Table A—2.

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Pre-Startup Inspection ChecklistFoundation Bolts

� Properly tightened

Cooling Water (Coolant) Piping

� Correctly routed and strain-free

� Shut-off valves installed

� Inlet and outlet correctly connected

� Cleaned and flushed free of dirt and/or other foreign matter

Condensate Drain Piping

� Automatic or manual traps or valves installed

� Piped individually into open drains

Inlet Air Piping

� Sized correctly, with minimal use of elbows

� Properly supported, with flexible connections at the compressor

� Startup screen correctly in place (if required)

� Clean and free of dirt and/or other foreign matter

Inlet Air Filter/Silencer

� Located properly

� Elements installed according to manufacturer’s instructions

� Clean and free of dirt and other foreign matter

Discharge Air Piping

� Correct pipe material and size

� Properly supported, without excessive loads

� Block valve installed

� Check valve installed with recommended pipe volume

� Bypass or Modulating Blow-Off Valve installed with recommended discharge pipe volume

� Silencer installed (if required)

� Clean and free of dirt and other foreign matter

Oil Reservoir Vent Ejector

� Properly connected to a supply of clean, dry air

Table A—2 The Prestart Inspection Checklist

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Pre-Startup Inspection Checklist continued…

Electrical Interface

� Earth ground installed

� All applicable codes met

� Motors wired according to manufacturer’s instructions

� Motor controllers and starters wired according to manufacturer’s instructions

� Control panel wired properly

Shaft Freedom

� Motor shaft freely moved when turned by hand

� Compressor shaft freely moved when turned by hand

Main Drive Motor

� Motor bearings properly lubricated

� Motor rotation direction checked

� Main drive coupling properly installed and lubricated

Lubrication System

� Reservoir filled with correct type and quantity of oil

� Reservoir vent filter trap filled with oil

� Optional oil reservoir heater thermostat set to 100� F (40� C)

� Pump motor bearings properly greased

� Oil pump rotation checked

� Pump operated for at least 2 hours to completely flush system

� New oil filter element installed after system is flushed

� No leaks detected when pump motor is operating

Control System

� Air pressure transducers properly connected

� Initialization checked

� Setpoints checked

� Inlet guide vane assembly operation checked

� Bypass or Modulating Blow-off Valve operation checked

� Current sensor checked

� Probe gaps checked

Table A—2. The Prestart Inspection Checklist

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Installation

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Main Drive Motor Rotation VerificationBefore coupling the compressor and main drive motor, it is necessary to verify that the phase sequencewiring will provide the correct rotation direction.

To verify correct rotation, follow this sequence:

1. Verify that motor fastening bolts are properly torqued as listed in Section Two, Compressor Specifi-cations.

2. Verify that the rating voltage and frequency shown on the motor nameplate match the powersupply.

3. Carefully follow all of the motor manufacturer’s instructions (provided under separate cover)regarding preparation and installation.

4. “Bump” (energize and quickly de-energize) the motor so that the shaft rotates only a few revolu-tions, and verify the direction of rotation using the directional arrow on the compressor gearboxcover.

5. If required, change the phase wiring to reverse the direction of rotation.

Oil Pump Motor Rotation VerificationThis inspection is required to ensure that the oil pump will generate the required pressure duringstartup and subsequent operation.

Confirm the correct rotation of the oil pump motor as follows:

1. Note the arrow indicating the correct rotation direction on the mounting flange between the pumpand the motor.

2. Turn on the oil pump motor and observe the rotation direction of the motor fan. (The correctrotation is clockwise, as indicated by the arrow.)

3. If the rotation of the motor fan is not clockwise, correct the pump rotation by interchanging two ofthe three power phases connected to the motor.

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Lubrication System FlushAlthough factory testing includes full operation of the compressor lubrication system, it is necessary tothoroughly flush the system before the initial startup to clear the system of any contaminants that mayhave been introduced during shipment and installation.

1. Fill the reservoir with the Cooper Turbocompressor TurboBlendTM Lubricating Oil.

2. Verify that the compressor oil temperature is at least 60� F (15� C).

3. If necessary to warm the oil, energize the oil heater (an optional feature not necessarily includedwith all units).

4. Circulate the oil for at least 2 hours.

5. Shut off the oil pump after the circulation period.

6. Remove and inspect the oil filter for any signs of contamination.

The Cooper Turbocompressor service representative must observe this last inspection point and(if required because of contamination) the changing of the oil filter element before the initialcompressor startup.

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Preventing Startup ProblemsIt is the owner’s responsibility to plan for the inspection and initial startup service by the CooperTurbocompressor representative and to provide all tools, equipment, supplies, and labor required asdescribed earlier in this section. Contact the Cooper Turbocompressor service representative at leasttwo weeks before the required on-site date to arrange for startup service.

To ensure proper and safe compressor startup and operation, a Cooper Turbocompressor trainedand authorized service representative should be present to inspect the site and to assist in thefinal installation steps and the initial startup procedure.

The list given in Table A—3 includes common problems and/or situations that may delay or unnecessar-ily complicate the installation and initial start-up procedure. Avoid such situations, or correct thembefore the Initial Startup Service Inspection. (Refer to the relevant heading in this Appendix for specificinformation about each area.)

Potential Compressor Startup Problems� Compressor damage during shipment.� Compressor damage from improper lifting or from having been stepped on.� Earth grounds not in place.� Incorrect or incomplete electrical interface with motor controls.� Incorrectly installed bypass or blow-off valve piping.� Bypass valves not included on condensate drain piping.� Condensate drain piping manifolded together.� Reservoir vent ejector piping improperly installed.� Excessive stresses on inlet, discharge, or water piping.� Correct quantity of TurboBlendTM Lubricating Oil not available on site.� Correct type of motor and/or coupling grease not available on site.� Necessary equipment, tools, supplies, and parts, not available on site.� Necessary labor not available on site.� Contract-specific information (manuals and drawings) not available on site.

Table A—3 Potential Compressor Startup Problems

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The Inspection Prior to Initial Startup ScheduleAs part of the site evaluation, a factory trained and authorized Cooper Turbocompressor servicerepresentative will verify that the compressor is ready to be put into full operation. The service repre-sentative will perform the following inspections and tasks as part of the initial compressor startupservice.

1. Check the compressor package for possible transit or handling damage.

2. Inspect the compressor installation site, including other supporting air system equipment.

3. Verify that the discharge air piping complies with Cooper Turbocompressor design requirements asstated in this manual as well as on the contract-specific drawings supplied separately. (This includeschecking the locations of control valves, the inclusion of a system block valve, compressor flangeload limits, etc.).

4. Verify that the inlet air piping complies with Cooper Turbocompressor design requirements asstated in this manual and on contract-specific drawings supplied separately. (This includes checkingthe location of the inlet air filter/silencer, the position of the inlet air startup screen, compressorflange load limits, etc.)

5. Inspect the water and condensate drain piping for completeness.

6. Verify that all electrical connections have been made correctly.

7. Verify that the compressor oil reservoir is filled with TurboBlendTM Lubricating Oil.

8. Rotate the compressor bullgear and main drive motor shaft (while uncoupled) by hand to verifythat both rotate freely.

9. Check the rotation of the main drive and oil pump motors.

10. Make the final alignment of the motor shaft to the compressor shaft, doweling the motor in placewhen complete.

11. Verify that the oil reservoir venting system is receiving the proper dry air supply.

12. Begin the lubrication system flush procedure.

13. Verify the temperature setting of the oil heater option (if included).

14. Make any necessary Vantage Control System adjustments to satisfy the user’s expected require-ments.

15. Inspect the oil filter element and change it, if necessary.

16. Oversee the installation of the main drive coupling, the lubrication of the coupling, and installationof the coupling guard.

17. Complete the Pre-Startup Inspection Checklist shown in Table A—2 with installation personnelbefore the initial compressor startup procedure.

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Initial Start-up Checklist

The instructions given here provide a sequence of steps to follow during initial compressor operation.

WARNING:Do not attempt to start up the Turbo Air Centrifugal Compressor until after a CTC-authorized service representative has fully inspected and approved the compressorinstallation. Cooper Turbocompressor recommends that a trained and authorized servicerepresentative perform the initial startup procedure.

Before Applying Power

Check the following before turning power on:

� Verify the manual block valve is closed.

� Check the location of the system pressure transducer.

� Check wiring for correctness, loose wires.

� Verify earth grounding.

� Check motor starter interface wiring from Vantage.

� Remove oil pump opto and motor circuit optos.

� Check Main motor and auxiliary oil pump overload settings.

� Check the supplied panel power.

Powered Pre-Start Checks

Apply power and perform the following checks before starting the compressor:

� Turn off access codes.

� Verify the configuration in the Vantage matches the configuration checked beforetraveling to the job site and make any changes required.

� Check vibration probe gap.

� Verify the instrumentation (wiring & monitoring points).

� Verify valve operation.

� Verify the Vantage Maximum Motor Current setting equals the motor FLA.

� Turn-on oil reservoir vent ejector.

� Verify oil pump operation.

� Verify start-up status.

� Bump main motor verify rotation & re-couple.

� Turn on coolant.

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Initial Start up ProcedureStart the compressor and:

1. Measure and record the acceleration time (___ seconds).

2. Unload the compressor.

3. Verify normal compressor operation while unloaded.

� Check inlet valve unloaded position.

� Check for oil and water leaks.

� Check and record operating levels.

� Check main motor for oil leaks and over heating.

4. Open inlet valve to maximum full-load amps.

5. Verify proper operation of the condensate removal system.

6. Tune Blow Off Discharge Pressure Loop.

7. Set BOV System Pressure loop tuning equal to BOV Discharge Pressure loop.

8. Tune Inlet Valve Maximum Load loop.

9. Set Inlet valve system pressure loop setting and Inlet minimum flow setting equalto the Inlet valve maximum load loop setting above.

10. Tune inlet minimum flow control loop.

11. Setup the manual valve display.

12. Surge test the compressor.

� Surge point 1: Head__________, Power__________.

� Surge point 2: Head__________, Power__________.

� Surge point 3: Head__________, Power__________.

13. Setup Maintenance Performance control.

14. Setup Operator setpoints.

15. Unload compressor and open the block valve.

16. Place the compressor in Automatic and load.

17. Tune the Blow Off System Pressure loop.

18. Tune the Inlet System Pressure loop.

19. Place compressor in Automatic and observe proper control.

20. Shutdown compressor.

21. Correct the start sequence based on the actual acceleration time.

22. Reset the operation history.

23. Put in access codes.

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Service AssistanceThe Turbo Air 2000 Centrifugal Compressor is a high technology product. When problems developwhich are beyond the scope of operating personnel, request assistance from a CooperTurbocompressor trained and authorized service representative or the Cooper Turbocompressor FieldService Department.

For any questions regarding installation, operation, or maintenance, or to schedule a service visit,contact a trained and authorized Cooper Turbocompressor representative:

or:

Cooper TurbocompressorField Service Department3101 Broadway P.O. Box 209Buffalo, NY 14425-0209 USAPhone: (716) 896-6600Fax: (716) 896-1233

Authorized Cooper Turbocompressor Service

Name:

Address:

Phone:

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The Lubrication System

B—1

Appendix BThe Lubrication System

In this appendix, the reader will learn about:

� General Considerations

� The Compressor Lubrication System

� Vantage Control of CompressorLubrication

� Operational Guidelines

� Gearbox and Reservoir Venting

� Optional Features

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

B—2

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The Lubrication System

B—3

General ConsiderationsUnlike some other types of rotating equipment, high-speed, geared compressors cannot operate, evenfor very brief periods, without adequate lubrication. The Turbo Air 3000 Compressor lubrication systemis a self-contained part of the compressor package and is designed to provide a constant supply ofcooled, filtered lubricating oil to the compressor bearings and gear sprays at all times, even duringemergency situations such as power outages.

The main oil pump is mounted directly onto the compressor gearbox and is driven by an extension ofthe bullgear shaft. The auxiliary oil pump is driven by a separate electric motor. The system contains allof the necessary components required to regulate, cool, filter and monitor the oil before it enters thecompressor gearbox. Several optional features, such as dual filters, automatic temperature regulation,reservoir heaters and more, are available as specific conditions justify.

Helpful information about operating, maintaining and troubleshooting the lubrication system isincluded throughout this manual. Also refer to Section 2, Specifications, for information aboutTurboBlendTM Lubricating Oil, and Section 7, Parts & Service, for replacement part numbering details.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

B—4

The Compressor Lubrication SystemFigure B—1 is a schematic illustration of the compressor lubrication system, indicating how the oilcirculates through the system and through standard compressor components. The following describesthe principles of normal operation.

Normal Operation

1. The main oil pump [B], mounted on the compressor gearbox and driven off of an extension of thebullgear shaft, draws oil from the reservoir [A], through check valve [N], and cycles it through thelubrication system and the compressor gearbox. Check valve [C]prevents the oil from beingpumped back into the reservoir through the auxiliary oil pump [M].

2. Excess heat is removed from the oil as it passes through the oil cooler [D]. The throttle valve [E] inthe return water line regulates the flow of the cooling water through the oil cooler, therebykeeping the temperature of the oil within the normal operating range.

3. The oil continues on to the oil filter [F] where impurities are removed.

Figure B—1 Compressor Lubrication System Schematic

4. In the gearbox [G] the oil flows through a manifold [H] where it is distributed to the bullgearbearings [I], the pinion bearings [J], and the two gear-mesh spray nozzles [K].

5. The oil flows from the gearbox to the oil reservoir, where it passes around a baffle arrangementthat breaks down any foam before it is allowed to continue to recycle through the compressorlubrication system.

6. The pressure regulator valve [L] maintains the correct operating pressure throughout the

lubrication cycle and returns any excess oil to the reservoir.

NOTE: The auxiliary pump does not run during normal operation. The main oil pumpprovides full compressor oil flow and pressure requirements.

Oil FilterF

Pinion Bearings [J]

Bullgear Bearings [J]

GearboxG

RegulatorL Pressure

SensorP

Water InWater Out

Oil CoolerD

AuxiliaryOil Pump

M

Lube OilReservoir

A

TemperatureSensor

T

Gear Spray Nozzles [K]

CheckValve

C

Main OilPump B

CheckValve

N

BleedValve

E

ManifoldH

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The Lubrication System

B—5

Vantage Control of Compressor LubricationThroughout the lubrication cycle, the Vantage control system continuously monitors the compressorlubrication system to guarantee safe and efficient operation. The oil pressure sensor [P] and oiltemperature sensor [T], shown in Figure B—1, ensure that all critical mechanical components arebeing properly lubricated and cooled by the oil.

These sensors allow the operator to see present lubrication system conditions on the Vantage displaypanel. When operating conditions warrant, the control system will initiate either a compressor Alarmcondition or a compressor Trip condition (depending on the severity of the problem).

Full discussions of Alarm and Trip messages and compressor setpoints are included in Section Six,Troubleshooting.

In addition to monitoring the operation of the lubrication system, the Vantage control system controlsthe action of the auxiliary oil pump for the following two circumstances.

Startup Operation

1. Prior to the starting of the compressor, the motor driven auxiliary oil pump is energized. Thispump [M] draws oil from the reservoir and cycles it through the lubrication system and thecompressor gearbox. Check valve [N] prevents oil from being pumped back into the reservoirthrough the main oil pump.

2. The oil flows through the lubrication system and compressor gearbox as described earlier.

3. The compressor may now be started following routine procedures.

4. After the compressor reaches full speed, additional oil pressure is present because both the shaft-driven main oil pump and the auxiliary oil pump are feeding the system. The Vantage controlsystem shuts down the auxiliary pump if the oil pressure transducer [P] senses oil pressure greaterthan the Lube Oil System High Pressure Set Point.

5. After the auxiliary oil pump shuts down, the lubrication system functions as described underNormal Operation.

Shutdown Operation

1. Upon initiation of normal shutdown, the Vantage control system starts the auxiliary pump.

2. The auxiliary pump remains on for a set period to maintain lube oil pressure as the compressorcoasts to a full stop.

Emergency OperationWhen a malfunction occurs during operation that results in a loss of oil pressure, the Vantage controlsystem operates the lubrication system in the following manner:

1. The oil pressure transducer [P] senses a pressure value below the Lube Oil System Low Pressure SetPoint. This causes the Vantage control system to activate an alarm condition that starts theauxiliary pump.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

B—6

2. The auxiliary pump, operating in tandem with the main oil pump, restores normal system oilpressure and the compressor continues to operate.

3. A continued decrease in oil pressure initiates a trip condition and the Vantage control system shutsdown the main drive motor.

4. Similarly, if the oil temperature exceeds predetermined set points, the Vantage control systemactivates an alarm condition or shuts down the compressor, depending on conditions.

Operational GuidelinesTo obtain the best and safest operation of the Turbo Air Compressor, apply the following guidelinesand recommendations.

Oil Pump OperationCooper Turbocompressor recommends keeping the auxiliary oil pump in continuous operation (evenduring compressor shutdown) to ensure proper lubrication at all times. However, in order for thisrecommendation to be followed, the oil pump must be electrically isolated from all other compressorsystems.

In instances when for some reason the oil pump is not kept in continuous operation, it should be keptrunning for a minimum of 30 minutes after compressor shutdown. This will assure that any excess heatwill be removed from the bearings and gearing.

CAUTION:Always maintain the proper air supply pressure to the reservoir vent ejector/filter systemwhenever the oil pump is in operation. Failure to do so may cause oil leaks, premature wear,and component damage.

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The Lubrication System

B—7

Gearbox and Reservoir VentingDuring multi-geared, centrifugal compressor operation, the action of meshing gears and the rotationof the bullgear cause air to become entrapped in the lubricating oil. As this air is released from the oil,it forms an oil-laden mist in the gearbox and the oil reservoir. It is very important that both the gear-box and oil reservoir are properly vented so that this oil mist is not allowed to escape.

Ejector/FilterThe Turbo Air 3000 Compressor utilizes a simple venturi-type ejector/filter system to create a slightvacuum inside the gearbox and oil reservoir. This vacuum prevents oil or oil mist from migrating outinto the atmosphere and/or creating other oil leaks. The ejector/filter system is illustrated in Figure B—2.

WARNING:Introducing water into the oil reservoir will have adverse effects on the lubricating oil andwill cause severe damage to the compressor. Be sure the ejector’s supply air is clean anddry and the filter is properly maintained.

Figure B—2 The Ejector/Filter System

Under normal operating conditions, the Ejector/Filter Arrangement operates as follows:

1. Dry, filtered, compressed air enters the ejector inlet (A) and is transformed into a high velocitystream in the ejector nozzle (B).

2. Air from the main oil reservoir (C) becomes entrained in this high velocity stream.

3. The resulting pumping action draws the oil-laden air from the reservoir and gearbox and delivers itto the filter (D), where droplets of oil accumulate and are then returned to the main oil reservoir.

4. The oil return line includes a mist trap (E) before the oil reservoir. This mist trap serves as a vaporlock to prevent the oil mist from bypassing the filter and escaping to the surrounding area.

Lube OilReservoir

C

TrapE

TrapFill

3/4”Vent

Mist FIlterD

Clean, DryCompressed

Air

AirEjector

AB

CheckValve

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

B—8

Optional FeaturesAlthough the following components are not required for safe operation of the Turbo Air 3000 Com-pressor, they will bring added convenience to the overall operation of the lubrication system. If notincluded with the initial compressor package, they may be added at any time.

Oil Reservoir HeaterThe minimum startup oil temperature for the compressor lubrication system is 60°F (15° C). Therefore,compressors that are installed outdoors or in unheated buildings may require the use of the Oil Reser-voir Heater option. Such emersion heaters are rated at 1.5 kW and are available in any standard three-phase voltage up to 600 volts. The heater is installed in the oil reservoir. Figure B—3 shows the OilHeater option.

Figure B—3 The Oil Heater Option

Thermostatic Mixing ValveWith the standard package, oil temperature is maintained by regulating the flow of cooling waterthrough the oil cooler. This method, though effective, may require seasonal adjustments. Including theThermostatic Mixing Valve option will automatically control oil temperature by regulating the oil flowaround the oil cooler, thus keeping the temperature of the oil entering the compressor constant. TheThermostatic Mixing Valve option is shown in Figure B—4.

Figure B—4 The Thermostatic Mixing Valve Option

Oil Cooler

FromOil Pump

Regulator

ToOil Filter

Water In

Water Out

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The Lubrication System

B—9

Duplex Oil FilterIn many instances, compressed air systems operate on a continuous basis. Since it is frequently inconve-nient to completely shut down compressor operation to perform a simple maintenance task, CooperTurbocompressor offers the Duplex Oil Filter option. The duplex oil filter eliminates the necessity forcompressor shutdown during filter maintenance. (Refer to Section Five, Maintenance, for full instruc-tions regarding this procedure.) The Duplex Oil Filter option is shown in Figure B—5.

Figure B—5 The Duplex Oil Filter

Oil Filter Differential Pressure MonitoringWith this optional feature, a second pressure transducer is installed before the oil filter. (The system’sstandard pressure transducer is located between the filter and the gearbox.) In such instances, theVantage Control System is programmed to calculate the differential pressure across the oil filter and toprovide Alarm and Trip functions. The Oil Filter Differential Pressure Monitoring option is particularlyuseful when included as part of a predictive maintenance program. Figure B—6 shows the Oil FilterDifferential Pressure Monitoring option.

Figure B—6 Oil Filter Differential Pressure Monitoring Option

Low Oil Level IndicatorWith the installation of the Low Oil Level Indicator option (a switch located in the main oil reservoir)the Vantage Control System will report any oil level in the reservoir that is below a pre-defined level.The control system then indicates an Alarm condition to alert the operator of the problem.

Oil to GearboxOil from Cooler

Oil Filter

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

B—10

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Vantage Control System Logic

C—1

Appendix CVantage Control System Logic

In this appendix, the reader will learn about:

��General Considerations

��Compressor Control Methods

��AUTO-OFFLINE Control

��AUTO-STANDBY Control

��AUTO-UNLOAD Control

��Compressor Safety Mechanisms

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The Turbo Air 3000 Centrifugal Compressor Handbook

C—2

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Vantage Control System Logic

C—3

General ConsiderationsThis appendix provides detailed descriptions of each of the three compressor control methods. Itincludes the theoretical basis, performance maps for each of the five control loops and theirassociated setpoints for each operating method. This information is of a highly specialized nature andnot necessary required reading for all operating personnel. It is written only as a reference for skilledtechnicians when it becomes necessary to fine-tune compressor controls or to troubleshoot variousoperating conditions.

The reader should bear in mind that the information contained in this appendix covers variousoptional features or options that may not be part of any specific compressor package or installation.Before referring to this appendix, determine which specific optional features are included and whichoperating method applies.

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The Turbo Air 3000 Centrifugal Compressor Handbook

C—4

Control MethodsVantage offers three distinct load control methods to provide flexibility in meeting widely varyingjobsite compressed air needs.

� Auto – Offline*� Auto – Standby*� Auto – Unload

Each Vantage control method uses all five valve control loops shown Table C—1. Detailed descriptionsof these methods appear latter in this Appendix.

*Note: Both the Auto-Offline and Auto-Standby mode require a modulating blow offdischarge valve.

Load Control Loops

The Vantage control system performs load control through five independent control loops. Each loopmodulates either the inlet valve or the discharge valve, also called the Modulating Blow Off Valve orMBOV

Inlet Valve Control Discharge Valve ControlControl loop Setpoint Control loop Setpoint

Maximum Power Maximum Motor Load Blow-Off System System PressurePressure Offset

System Pressure System Pressure Blow-Off Discharge Max. DischargePressure Pressure

Minimum Flow Surge Control Offset

Table C—1 Vantage Control Loops and their Setpoints

A description of the setpoints follows.

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Vantage Control System Logic

C—5

Inlet Valve Control SetpointsThe Vantage control system modulates the compressor inlet valve in response to the control setpointsassociated with the three control loops described on the preceding page.

Each of the control loops constantly reviews the operational status of the compressor relative to itssetpoint. Vantage sends opening and closing signals to the inlet valve to maintain the desired systempressure (System Pressure setpoint) and prevent the motor from overloading (Max Motor Loadsetpoint), while protecting the compressor from surge (Surge Control Offset ).

All inlet valve moves are governed by user-set tuning parameters for each control loop. Control of theinlet valve can be transferred among loops but the output of only one loop at a time can be incontrol.

NOTE: The active control loop appears on the Performance Control tab ofthe VIEW screen.

Maximum Motor Load Setpoint

Drive motor amperage is one indicator of the compressors’ output. Motor amps are directlyproportional to the position of the compressor inlet valve; as the inlet valve opens, the motor willdraw more amperage. However, the Maximum Motor Load setpoint establishes a limit on the openingof the inlet valve to prevent running the motor in an overload condition. When displayed, thissetpoint value appears as a % of the motor’s nameplate full load amps (FLA).

System Pressure Setpoint

Within its motor amperage range, the inlet valve control loop will attempt to achieve the SystemPressure Setpoint. If this setpoint is exceeded, the inlet valve will be throttled accordingly. Under thePerformance Control tab, the System Pressure setpoint is identified as SP, where the actual systempressure is shown as the process variable (PV).

Surge Control Offset

In the case of low plant demand, as the inlet valve closes, the flow through the compressor willdecrease and plant pressure levels will remain stable. However, if the flow drops too low thecompressor could surge. To prevent a ‘low-flow’ surge, Vantage maintains a minimum flow, using theSurge Control Offset value as a setpoint. At all points along the Surge Control Offset line, Vantagecontrols the actual system pressure to the System Pressure Offset setpoint.

When the system reaches this setpoint, control transfers to the compressor discharge valve controlloops.

NOTE: There is an ‘Output’ indication on the Vantage Performance Control screen thatshows the position of the inlet valve as a % of available flow.In the case of an electrically actuated inlet valve, the Output indication will show thedirection of travel (+ for open; - for close) and how fast the inlet is opening or closing.

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The Turbo Air 3000 Centrifugal Compressor Handbook

C—6

Discharge Valve Control Setpoints

This control mode functions exactly the same as Auto-Offline, up to the point where the check valvecloses. Then, instead of unloading, Auto–Standby opens the blow off valve further, to operate thecompressor at a discharge pressure (Standby Mode Offset) less than the System Pressure setpoint. Thismethod allows the unit to fully load much quicker, when the system pressure drops below the SystemPressure setpoint.

System Pressure Offset Setpoint

Under the inlet valve’s Minimum Flow control loop, Vantage allows the actual system pressure toincrease to the value of the System Pressure Offset setpoint.

A typical value for this setpoint is about 2 to 3 psi. above the System Pressure setpoint.

If this maximum system pressure is reached, Vantage will then modulate the compressor blow-off valve(if it exists) to keep the plant’s pressure at the System Pressure Offset value.

The actual system pressure (displayed as PV under the Performance Control tab) is the same as in theInlet Valve Control section.

Note that the Vantage modulates the inlet valve to maintain system pressure, and itmodulates the blow off valve to maintain maximum system pressure.

Maximum Discharge Pressure Setpoint

Discharge pressure is the direct output pressure of the compressor, before the discharge check valve,and air conditioning items (aftercoolers, dryers, etc). If the discharge pressure becomes too high, thecompressor will surge. Vantage uses the Maximum Discharge Pressure Setpoint to prevent surging. Ifthe Max Discharge Pressure setpoint is reached, that control loop will quickly modulate the blow offvalve to keep the discharge pressure under control.

The proper setting is for this setpoint is at a value above Max System Pressure, and below thecompressor’s high-pressure surge point.

Note: The position of the blow off valve can be seen on the Performance Control screen in the samemanner as that of the inlet valve.

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Vantage Control System Logic

C—7

Auto-Offline ControlWith Auto-Offline Control, the inlet valve modulates to satisfy the System Pressure setpoint (within theMaximum Motor Load setpoint limits). In cases of low demand, the control throttles back to theMinimum Flow control line setpoint. The Minimum Flow control loop controls system pressure to theSystem Pressure Offset setpoint and flow to the Surge Control Offset line. The compressor inlet valveresponds to the Surge Control line. If system pressure reaches its Offset value, Vantage modulates thecompressor’s discharge blow off valve. As the blow off valve reaches point of closing the dischargecheck valve, Vantage unloads the compressor. When the system pressure drops below the SystemPressure setpoint, Vantage reloads the compressor through the inlet valve control loops.

Auto-Offline Control Setpoints

� Maximum Motor Load Setpoint: Prevents motor overload condition.

� System Pressure Setpoint: Establishes the initial pressure control point.

� Surge Control Offset Line: Prevents compressor surging at minimum flow conditions.

� System Pressure Offset: Sets an upper level for allowable system pressure.

� Maximum Discharge Pressure: Prevents compressor surging at over-pressure conditions.

Auto-Offline Control Steps (see Figure C— 1)

1. Compressor loads to achieve the System Pressure setpoint (position 1).

2. If demand is low, the inlet valve throttles to the Minimum Flow line (position 2).

3. The inlet Minimum Flow control loop operates the compressor along the Surge Control Offset line(B), between position 2 and the System Pressure Offset setpoint (position 3).

4. At the System Pressure Offset setpoint (pos.3), control switches to the Blow Off System Pressurecontrol loop, which begins to modulate the compressor blow off valve.

5. If blow off increases to the point that the discharge check valve closes, Auto-Offline unloads thecompressor by first fully opening the blow off valve, and then closing the inlet (pos.4).

6. The compressor reloads when the system pressure drops below the System Pressure setpoint.

Figure C—1: Auto-Offline Control Operation

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The Turbo Air 3000 Centrifugal Compressor Handbook

C—8

Auto-Offline Control

Inlet Valve Control

When the actual system pressure is lower than the System Pressure Setpoint, the Vantage controllerbegins to load the compressor. During the initial load cycle, the inlet valve opens to a Minimum Flowvalue when the compressor discharge valve begins closing.

During this initial load cycle, the Inlet Maximum Load control loop controls the inlet valve and quicklyloads the compressor within the Maximum Motor Load setpoint constraints.

Note: The proper Motor Load setting for 1.15 service factor motors is 112% of motor fullload amps (FLA).

As the system air pressure approaches the System Pressure setpoint, the Inlet System Pressure controlloop obtains control of the inlet valve (if the motor amps are below maximum).

In cases of low air demand, Inlet System Pressure control loop maintains the System Pressure setpointby reducing the compressor output through inlet valve throttling moves. This throttling continuesuntil the compressor reaches its minimum stable operating point, and the Inlet Minimum Flow controlloop resumes automatic control of the inlet valve.

In the Minimum Flow control loop, the inlet valve is controlled along the minimum flow Surge ControlOffset line, a user-set specific offset along the entire actual surge curve.

An important aspect of the Minimum Flow control loop, is that the actual system pressure is allowedto increase above the System Pressure setpoint, to the System Pressure Offset setpoint. When themeasured pressure reaches the System Pressure Offset value, Auto-Offline then smoothly transferscontrol to the compressor discharge valve control loops.

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Vantage Control System Logic

C—9

Discharge Valve Control DiscussionAs explained, the Vantage discharge valve control loops do not come into play until system pressure isallowed to increase to the System Pressure Offset setpoint. Until then the compressor discharge valveremains fully closed.

Note: The System Pressure Offset setpoint for the blow-off control loop is displayed onthe right side the bar graph area of the Vantage Performance Control screen.

When system pressure rises above this offset value, the Auto-Offline control mode attempts tomodulate the compressor discharge valve under its Blow Off System Pressure control loop. If there isno blow-off valve, the compressor unloads.

The blow off valve continues to open until the compressor’s discharge check valve closes. When thecheck valve closes, Auto-Offline unloads the compressor by fully opening the blow off valve and closesthe inlet valve to its unloaded position.

The compressor continues to run unloaded until the actual system pressure drops to a level below theSystem Pressure setpoint. Then it reload under inlet valve control, as before.

Vantage also has one more blow-off valve control loop to enhance control response time in certaintransitional periods.

The Blow Off Discharge Pressure control loop, and its corresponding Maximum Discharge Pressuresetpoint come into play under certain compressor operating conditions.

The Blow Off Discharge Pressure control loop provides a fast response when the discharge pressureclimb suddenly. This can occur because of a sticking check valve, closed block valve, or plugged dryer.The proper setting of the Maximum Discharge Pressure setpoint is a value below the natural high-pressure surge point of the compressor.

Although the Vantage control loops are tuned at Cooper Turbocompressor prior to shipment, it isimportant to verify the tuning under the actual jobsite conditions.

Proper tuning is the key to quick and efficient interaction among the five control loops.

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The Turbo Air 3000 Centrifugal Compressor Handbook

C—10

Auto-Standby ControlThis control mode operates the same as Auto-Offline until the check valve closes. Then, instead ofunloading, Auto–Standby opens the blow off valve further to operate the compressor at a dischargepressure (Standby Mode Offset) less than the System Pressure setpoint. This method allows the unit tofully load more quickly when the system pressure drops below the System Pressure setpoint.

Auto-Standby Control Setpoints

� Maximum Motor Load Setpoint: Prevents motor overload condition.

� System Pressure Setpoint: Establishes the initial pressure control point.

� Surge Control Offset Line: Prevents compressor surging at minimum flow conditions.

� System Pressure Offset: Sets an upper level for allowable system pressure.

� Maximum Discharge Pressure: Prevents compressor surging at over-pressure conditions.

Auto-Standby Control Steps (see Figure C—2)

1. Compressor loads to achieve the System Pressure setpoint (position 1).

2. If demand is low, the inlet valve is throttled to the Minimum Flow line (position 2).

3. The inlet Minimum Flow control loop operates the compressor along the Min Flow control line(B), between position 2 and the System Pressure Offset setpoint (position 3).

4. At the System Pressure Offset setpoint (pos.3), control switches to the Blow Off SystemPressure discharge control loop, which begins to modulate the compressor blow off valve.

5. If blow off increases to the point that the discharge check valve closes, Auto-Standbycontinues to open the blow off valve until the compressor discharge pressure drops to theStandby Mode Offset pressure , which must be below the System Pressure setpoint (pos.4).

6. The compressor reloads fully when the system pressure drops below the System Pressuresetpoint.

Figure C—2: Auto-Standby Control Operation

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Vantage Control System Logic

C—11

Auto-Standby ControlThe Auto-Standby control method is for air systems that experience dramatic variations in demand yetdo not have a lot of receiver capacity. In these cases, an unloaded compressor may not be able torespond fast enough to sudden increases in demand.

Auto-Standby handles this situation by partially unloading the compressor to a user-set level below therequired system pressure. To take advantage of this feature, the compressor must have a modulatingblow off valve.

Operational CharacteristicsAuto-Standby control is identical to Auto-Offline control (detailed previously), until the situationwhere the discharge check valve closes during blow off, under Blow Off System Pressure control. Atthis point, Auto-Offline unloads the compressor.

However, in the Auto-Standby mode, the compressor is not allowed to unload. Instead, the controllerwill continue to open the compressor blow off valve after the check valve has closed.

Blow off continues until the compressor discharge pressure drops to a user-set level below the SystemPressure setpoint.

The control setpoint for Auto-Standby is called the Standby Mode Offset, and it is a �P value.

For example: Where the system pressure setpoint is 115 psig, and the desired standby pressure is 105psig, input a Standby Mode Offset of 10 psig.

The compressor continues to operate at the reduced standby pressure until the actual system pressuredrops to a level below the System Pressure setpoint. When this happens, the unit will fully loadthrough the inlet valve control loops.

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The Turbo Air 3000 Centrifugal Compressor Handbook

C—12

Auto-Unload Control

In this Vantage control mode, inlet control is the same as Auto-Offline, but now only to the pointwhere the Maximum System Pressure setpoint is reached. Then, instead of blowing off, Auto-Unloadunloads the compressor. The compressor reloads as described above.

Auto-Unload Control Setpoints

Maximum Motor Load Setpoint: Prevents motor overload condition.

System Pressure Setpoint: Establishes initial pressure control point.

Surge Control Offset Line: Prevents compressor surging at minimum flow conditions.

System Pressure Offset: Sets an upper level for allowable system pressure.

Maximum Discharge Pressure: Prevents compressor surging at over-pressure conditions.

Auto-Unload Control Steps (see Figure C—3)

1. Compressor loads to achieve System Pressure setpoint (position 1).

2. When demand is low, the inlet valve throttles to the Minimum Flow line (position 2).

3. The inlet Minimum Flow control loop operates the compressor along the Min Flow control line(B), between position 2 and the System Pressure Offset setpoint (position 3).

4. When the System Pressure Offset reaches setpoint (pos.3), the Auto-Unload control methodunloads the compressor by first fully opening the compressor discharge bypass valve, and thenclosing the inlet valve to its minimum position (pos.4).

5. The compressor reloads when system pressure drops below the System Pressure setpoint.

Figure C—3: Auto-Unload Control Operation

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Vantage Control System Logic

C—13

Auto-Unload Control

The Auto-Unload control method is used for compressors that have a discrete (open/close) dischargebypass valve (and not a modulating blow-off valve). Vantage handles this through the Auto-Unloadcontrol method by unloading the compressor instead of blowing off.

This control method may also be useful when working with several compressors in the same airheader. It may be desirable to immediately unload and possibly turn off a small compressor beforeallowing larger units to blow off.

Operational Characteristics

Auto-Unload control is identical to Auto-Offline control up to the point where the System PressureOffset value is reached. Then, instead of blowing off, the compressor immediately unloads.

In the unload process, the control system fully opens the compressor bypass valve then closes the inletvalve to its minimum position. The controller automatically reloads the compressor when the actualsystem air pressure falls below the System Pressure setpoint.

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The Turbo Air 3000 Centrifugal Compressor Handbook

C—14

Compressor Safety Mechanisms

The Vantage Control System provides compressor protection by continuously monitoring vital functionsto ensure correct and safe operation of all compressor systems. Whenever operating conditions divergefrom predetermined safety parameters (the setpoints), the control system automatically triggers anappropriate system response.

General Operating PrincipleA variety of sensor devices are strategically located throughout the compressor’s various subsystems toprovide measurement of vital operating parameters. These measurements are monitored by the Van-tage Control System, and the control panel provides a dynamic readout for data logging and trending,adjustment, and diagnostic purposes. Whenever operating conditions reach a conspicuously divergentor dangerous level, the control system triggers a control panel display message and the appropriatesafety response.

SensorsA variety of sensor devices monitor the compressor process air, lubrication, electrical, and mechanicalcomponents to ensure their correct operation.

� A current sensor located in the main drive motor terminal box measures the main motorcurrent.

� Electronic proximity devices, or vibration probes measure displacement (or vibration) of thepinions at various standard and optional locations.

� Temperature sensors, or resistive temperature detectors (RTD’s) measure the oil temperaturein the compressor lubrication system, the third stage inlet air temperature, and other optionallocations.

� Pressure transducers measure the oil pressure in the compressor lubrication system as well asthe air system pressure and (when necessary) the compressor discharge air pressure.

Table C—1 lists the various standard and optional measurements taken by these sensor devices de-scribed above.

Whenever a sensor device detects an operating condition that varies from predetermined parameters, acompressor safety mechanism is activated.

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Vantage Control System Logic

C—15

Standard and Optional MeasurementsStandard:Main Drive Motor Current

System Air PressureCompressor Discharge Air PressureFirst Stage VibrationOil PressureOil TemperatureFinal Stage Inlet Air Temperature

Optional:Second Stage VibrationThird Stage Vibration (three stage units only)Second Stage Inlet Air Temperature (three stage units only)

Inlet Air Filter Pressure DropOil Filter Pressure DropOil Reservoir LevelCompressor Discharge Air TemperatureMass Flow Measurement

Multi-channel Temperature Monitor (motor bearing & stator windings)

Table C—1 Standard and Optional Measurements

Alarm and Trip ConditionsWhen operating conditions deviate from any of the preset setpoints, when a compressor or auxiliarydevice fails, or when compressor performance becomes degraded, the control system will activate oneof two types of compressor safety mechanisms. The mechanism activated depends on the degree ofdeviation, one being a warning signal and the other involving protective action.

The two compressor safety mechanisms are:

� Alarm. When an Alarm condition occurs, all compressor systems will continue operation. However,the control panel display will record the Alarm to alert the operator of an operating condition thatrequires some attention.

� Trip. When a Trip condition occurs, the Vantage Control System will initiate a complete compressorshutdown in order to protect vital components. This will occur whenever one or more operatingconditions exceed the predetermined levels governing operating safety.

The Vantage Control System records all operating conditions current during both Trip and Alarmconditions and shows them on the control panel display. As part of the control panel Diagnosticsfunction, the operator may also call up similar information for the four most recent Trip conditions orcompressor shutdowns. Trip messages (from most to least recent) are available for review.

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The Turbo Air 3000 Centrifugal Compressor Handbook

C—16

Table C—2 shows Alarm and Trip levels for the Turbo Air 3000 Compressor. During an Alarm or Tripcondition, the control system will signal the control panel with that information. This will cause theassociated indicator light on the control panel to come on. Additionally, any associated auxiliarywarning device attached to the control system will also come on and/or sound.

ALARM and TRIP Setpoints (English Units) ALARM TRIP Condition Low High Low HighStandard:Compressor Stage Vibration (mils) - 1.5 - 2.0Oil Pressure (psi) 80 140 70 150Oil Temperature (ºF) 70 135 60 145

Stage Inlet Air Temperature (ºF) - 130 - 140

Optional:Inlet Air Filter Pressure Drop (inches of water) - 10 - -Oil Filter Pressure Drop (psi) - 15 - 20Compressor Bullgear Vibration (mils) - 2.5 - 3.0

Drive Motor Vibration (mils) - 2.5 - 3.0Drive Motor Stator Temperature (ºF) - 330 - 340

Table C—2 ALARM and TRIP Setpoints (English Units)

ALARM and TRIP Setpoints (Metric Units) ALARM TRIP

Condition Low High Low HighStandard:Compressor Stage Vibration (µm) - 38 - 50Oil Pressure (bar) 5.5 9.7 4.8 10.3Oil Temperature (ºC) 20 57 15 63

Stage Inlet Air Temperature (ºC) - 55 - 60

Optional:Inlet Air Filter Pressure Drop (mm of water) - 250 - -Oil Filter Pressure Drop (bar) - 1.0 - 1.4Compressor Bullgear Vibration (µm) - 65 - 75

Drive Motor Vibration (µm) - 65 - 75Drive Motor Stator Temperature (ºC) - 165 - 170

Table C—2 ALARM and TRIP Setpoints (Metric Units)

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Glossary

Glossary

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

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Glossary

Air End — the part of the compressor package that includes the gearbox and the air movingcomponents.

Airflow — the movement of air or process gas through the compressor or the compressed air system.

Aftercooler — a heat exchanger that cools the process air after the final stage of compression.

Alarm — a warning about a compressor operating condition that is outside of normal operating limits.

Blow-Off Valve — an airflow control device that vents compressor discharge air to the atmosphere.(Also see Modulating Blow-Off Valve.)

BOV — the abbreviation for Blow-Off Valve.

BPV — the abbreviation for Bypass Valve.

Bypass Valve — an airflow control device that vents compressor discharge air back into the inlet pipeof the compressor.

Bullgear — the main input gear that drives the higher speed pinions.

Check Valve — a device that permits the flow of air, water or oil in one direction only.

Controller, Motor — (See Motor Controller.)

Control Method — the specific technique used by the control system to deliver compressed air to meetspecific process demands.

Control Setpoints — those setpoints that supervise routine compressor operation.

Cooler — device used to remove heat. (See Aftercooler, Intercooler, Oil Cooler, or Panel Cooler.)

Coupling, Main Drive — the device that connects the motor shaft to the bullgear shaft.

Data Log — (See Operator’s Data Log.)

DCS — the abbreviation for Distribution Control System.

Design Standard — the operating condition of the compressor to which the aerodynamic performanceis rated, generally a “worst case” or “hot summer day” condition.

Distribution Control System — a functionally related group of electronic devices used for industrialmachine sequencing and operation.

Diffuser — the component of a compressor stage that helps convert the high velocity airflow into apressure rise.

Discharge Pressure — the air pressure measured between the compressor exit and the compressordischarge check valve.

Display — the screen that presents operating information on the Vantage Control Panel.

Drive End — the end of a rotating machine that contains the drive shaft extension.

Drive Train — the part of the compressor package that contains the main drive motor, the main drivecoupling, and the gearbox.

Ejector — the component that creates a slight vacuum inside the gearbox and oil reservoir to properlyhandle oil mist.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

EMERGENCY STOP Button — the device on the Vantage Control Panel that serves to immediatelyinterrupt power to the main motor causing the compressor to stop operating. (For emergency use only.)

FLA — the abbreviation for Full Load Amperage.

Full Load Amperage — the maximum amperage rating of a motor (less Service Factor), the value ofwhich is listed on motor nameplate.

Gearbox — the parts of the compressor package that contains the gears, bearings, and seals.

Heat Exchanger — a device that is used to cool air or oil during compressor operating.(See Aftercooler, Intercooler, or Oil Cooler.)

IGV — the abbreviation for Inlet Guide Vane.

Impeller — the aerodynamic component that rotates at a very high speed, thereby increasing theairflow velocity and imparting energy into the airstream.

Inlet — 1. the component of a compressor stage that covers the impeller and diffuser, thus creating avery tightly toleranced air passage.

2. the point of the compressor stage at which the air enters.

Inlet Air Filter — a device that removes dirt, dust, and other airborne contaminants from the intakeair before it is allowed to enter the compressor.

Inlet Air Startup Screen — a conical-shaped screen that is placed in the inlet air piping at the initialstartup of the compressor, when required, to stop larger airborne particles from entering thecompressor.

Inlet Guide Vane — a device that throttles inlet airflow to the compressor, while also imparting apre-whirl to the airstream.

Intercooler — the heat exchangers that cool the process air between stages of compression.

LED — the abbreviation for Light Emitting Diode.

Light Emitting Diode — a status indicating light on the Vantage Control Panel.

Load or Loaded — any number of compressor operating points where airflow, discharge pressure,and power consumption are at or near rated values.

MANUAL Control Method — an operating condition during which the position and movement of theinlet guide vane and blow-off valve are controlled solely by the compressor operator.

MBOV — the abbreviation for Modulating Blow-Off Valve.

Minimum Amp Setting — a setpoint of the control system associated to the main drive motoramperage draw that relates to the low-flow surge operating point of the compressor.

Mist Filter — a device that collects the oil vapor that is vented from the oil reservoir.

Modulating Blow-Off Valve — an airflow control device that vents compressor discharge air to theatmosphere.

Motor Controller — a device that is used to start, stop and protect electric motors.(Also referred to as a Motor Starter.)

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Glossary

“Off Design” Operation — a compressor operating condition when the ambient environment is otherthan the design standard.

Oil Cooler — the heat exchanger that cools the lubricating oil.

Operator’s Data Log — a periodic record of compressor operation.

Opposite Drive End — the end of a rotating machine that is opposite of the drive shaft extension.

Optical Coupler — an electronic device similar to an electrical relay (also referred to as OPTO).

OPTO — the abbreviation for Optical Coupler.

Panel Cooler — an optional heat exchanger that is used to cool the interior of the Vantage ControlPanel.

Pinion — the gear element to which the impeller(s) are mounted.

PLC — the abbreviation for Programmable Logic Controller.

Programmable Logic Controller — a computer-based device typically used to administer plant-wideproduction information.

Potentiometer — an electronic device that varies resistance in an electrical circuit.

Receiver — a storage device (such as a tank, extended length of system piping, etc.) in the compressedair system used to hold compressed air.

Reservoir, Oil — the tank on the compressor package that is used to hold lubricating oil.

Reservoir Vent — the filtration system comprised of the ejector and mist filter.

Resistive Temperature Detector — a device that is used for temperature measurement.

RTD — the abbreviation for Resistive Temperature Detector.

Scroll — the component of a compressor stage that “collects” the high velocity air exiting the impeller.

Sensor — a device that is used to measure parameters such as, temperature and vibration.

Service Factor — as applied to motors, a factor whereby a motor can be loaded beyond its horsepowerrating without overheating or suffering insulation damage.

Setpoint — a control measurement that protects the compressor or the compressed air system.(It may or not be capable of being changed by the operator.)

Shaft Alignment — the relative position of the drive train components to each other.

Shutdown — the process of unloading and stopping the compressor.

Silencer — the device that is used to reduce sound levels.

Stage — a set of aerodynamic components including the scroll, inlet, impeller and diffuser.

Starter, Motor — (See Motor Controller.)

Startup — the process of starting and loading the compressor.

Startup Screen — a device that is temporarily installed in the inlet air piping to prevent foreign materialfrom entering the compressor.

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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

Surge — a compressor operating condition characterized by a momentary reversal of airflow backthrough the compressor.

System Pressure — the pressure of the compressed air measured after the compressor check valve.

Transducer — a sensor that converts a measured parameter (such as pressure or temperature) to avoltage output in an established way.

Transmitter — a specific type of transducer that converts a measured parameter (such as pressure)to a current output (typically 4-20 mA).

Trip — a shutdown initiated by the Vantage Control System to protect the compressor.

Trip Recall Function — a Control Panel Diagnostics function that allows the operator to reviewcompressor operating data at the time of a compressor Trip condition.

Turndown Range — the extent to which the airflow through the compressor may be throttled withoutencountering surge while maintaining setpoint pressure.

Unloaded — an operating condition where airflow through the compressor, and thus powerconsumption, are at a minimum.

User Interface — the part of the Vantage Control Panel that allows the user the view data, monitorcompressor operating, and adjust operating parameters (such as setpoints).

“Worst Case” Operating Condition — the ambient circumstances (also referred to as a “hotsummer day”) when the air is less dense and filled with water vapor resulting in adverse compressorperformance.