Troubleshooting Guide - Ingersoll Rand...

INGERSOLL-RAND�

AIR COMPRESSORS

CENTAC�

Troubleshooting Guide

CENTAC TROUBLESHOOTING GUIDE

CST-TP0007� 1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-Dec-94

Copyright Notice

Copyright 1996-1997 Ingersoll-Rand CompanyTHE CONTENTS OF THIS MANUAL ARE PROVIDED “AS IS” AND WITHOUT ANY IMPLIEDWARRANTIES WHATSOEVER.

Ingersoll-Rand air compressors are not designed, intended, or approved for breathing airapplications. Ingersoll-Rand does not approve specialized equipment for breathing airapplications and assumes no responsibility or liability for compressors used for breathing airservice.

CENTAC TROUBLESHOOTING GUIDE


Date of issue: January, 1999 Supersedes: 16-dec-94

Table of ContentsSurge______________________________________________________________________1Low Seal Air Pressure________________________________________________________2Low System Air Pressure _____________________________________________________3High Vibration ______________________________________________________________4Low Control Air Pressure _____________________________________________________5Low Instrument Air Pressure __________________________________________________5Failure to Start ______________________________________________________________6No Control Power ___________________________________________________________7Failure to Load ______________________________________________________________7Low Oil Pressure ____________________________________________________________8High Oil Temperature ________________________________________________________9High Air Temperature _______________________________________________________10Common Conversions and Information ________________________________________11

1. Temperature __________________________________________________________112. Pressure – gauge ______________________________________________________112. Pressure – gauge, continued ____________________________________________123. Length _______________________________________________________________124. Flow_________________________________________________________________135. Volume ______________________________________________________________136. Electrical _____________________________________________________________146. Electrical, continued ___________________________________________________157. Vibration _____________________________________________________________168. Water Quality Requirements_____________________________________________17

CENTAC TROUBLESHOOTING GUIDE 1



SurgeCause Solution

1. Dirty inlet air filter. Replace filter.

2. Too small inlet pipe (remote-mountedair filter).

Replace pipe.

3. High interstage air temperatures. Investigate. Check to see what isnecessary to lower air temperatures.Check water temperature, water flow,water pressure, etc.

4. Increase in water temperature. Investigate. Check to see if it is possibleto lower water temperature.

5. Increase in inlet air temperature. Lower setpoint.

6. Setpoint higher than design dischargepressure of compressor.

Lower setpoint.

7. Defective system pressure controller. Adjust or replace.

8. Too low CLL or LLR (throttle surge). Increase CLL or LLR setting.

9. Too low P1, PR3, or mechanical stopadjustment (unloaded surge).

Increase P1, PR3 or adjust mechanicalstop.

10. Improper calibration of valve I/P,positioner, or actuator.

Calibrate as necessary.

11. Defective bypass valve. Repair or replace.

12. Restriction in customer's system. Investigate. Take necessary steps tocorrect restriction. Check for closed blockvalve or excessive dryer pressure drop.

13. Restricted air flow through air coolers. Clean air coolers.

14. Dirt build-up on impeller vanes. Clean impeller.

15. Blockage of diffuser air passage. Clean diffuser.

16. Improper wheel clearance. Reset clearance.

17. Worn or damaged impeller. Replace.

18. Butterfly valve pin broken. Replace pin.

19. Discharge check valve hanging up. Repair or replace.

2 CENTAC TROUBLESHOOTING GUIDE

CST-TP0007� 1994 Ingersoll-Rand CompanyDate of issue: January, 1999 Supersedes: 16-Dec-94

Low Seal Air PressureCause Solution

1. Seal air regulator malfunctioning. Adjust, clean, or replace regulator.

2. Low instrument air pressure. Increase instrument air pressure.

3. Damaged seal air line. Replace.

4. Leaking fitting. Replace or tighten.

5. Leaking seals. Replace.

6. Seal air bleed valve open too far. Adjust.

7. Instrument air filter dirty. Clean or replace element.

8. Excessive clearance between pinionand seal.

Investigate. Replace seal and/or pinion.




Low System Air PressureCause Solution

1. Incorrect setpoint. Adjust.

2. Incorrect valve calibration. Restroke valves.

3. Bad controller. Repair or replace.

4. Dirty inlet filter. Replace filter elements.

5. Compressor operating unloaded. Switch selector switch to load.

6. System demand greater thancompressor capacity.

Check for excessive air usage like openvalves, leaking fittings, etc., and correct.Start additional compressor. Recommendthat customer purchase another Centac ifadditional capacity is required.

7. Compressor block valve closed. Open valve.

8. Incorrect controls calibration. Adjust controls.

9. Discharge check valve sticking. Repair or replace.

10. System air pressure sensing point inwrong location.

Relocate control air connection

11. Excessive pressure differential acrossair dryer.

Investigate and correct.

12. Too low CLH setting. Increase setting (Do not exceedFLA+SF).

13. Leaking bypass valve. Investigate and correct. Replace seat;free up sticking valve.

14. Bypass valve stays open; inlet valvefunctions normally.

Lower CLL to activate bypass valve onMP3 panel. Ensure 2TR is operatingproperly on Electro-Pneumatic panel.



High VibrationCause Solution

1. Low oil temperature. Increase oil temperature by adjusting oilheater thermostat. Close cooling watervalves to oil cooler. Circulate oil.

2. High oil pressure. Reduce pressure. Adjust main oil pumppressure relief valve with oil at operatingtemperature.

3. Oil not draining properly frombearings.

Investigate and correct. Check forrestriction, improper venting, too high oillevel.

4. Incorrect coupling alignment. Realign coupling.

5. Worn coupling. Replace.

6. Excessive grease in coupling. Remove excessive grease.

7. Bad bullgear or intermediate gearbearings.

Replace.

8. Unbalanced motor rotor. Have motor rotor balanced.

9. Bad motor bearings. Replace.

10. Worn rotor assembly parts. Replace rotor assembly or necessaryparts.

11. Excessive build-up on impellers. Clean and balance rotor assembly.12. Excessive pipe strain. Remove pipe strain.

13. Incorrect type of oil. Replace with correct oil.

14. Bad rotor assembly bearings or seals. Replace.

15. Excessive moisture carryover. Investigate and correct. Check forrestriction in condensate drainagesystem.

16. Inadequate oil supply to plainbearing.

Investigate and correct. Ensure oil supplygroove in plain bearing shell is alignedproperly with oil supply hole throughcasing.




Low Control Air PressureCause Solution

1. Too small control air line. Replace with larger diameter pipe.

2. Moisture in control air line. Remove moisture.Provide permanent method for moistureremoval.

3. Sensing control air pressure fromwrong location.

Change location of sensing pressure.

4. Leaking fittings or damaged pipe. Repair or replace.

5. Closed C.A. valve. Open valve.

Low Instrument Air PressureCause Solution

1. Instrument air line too small. Replace with a larger pipe.

2. Instrument air dryer malfunctioning. Repair or replace.

3. Instrument air valve closed. Open valve.

4. Instrument air supply pressure belowrecommended pressure.

Increase supply pressure. Obtain adifferent air source of adequate pressure.

5. Dirty I.A. filter. Clean or replace.

6. I.A. filter wrong size. Replace.

7. Leaking fittings or damaged pipe. Repair or replace.



Failure to StartCause Solution

1. No power to motor starter. Energize power.

2. Blown fuse. Replace blown fuse.

3. STOP button pushed in. Pull out STOP button.

4. Overloads tripped. Reset overloads.(If trip occurs do not reset find cause oftrip)

5. Control wiring incorrect. Investigate and correct.

6. Trips at transition. Mechanical linkage out of adjustment.Bad 2M contactor. Replace or repaircontactor.

7. Interlocks not satisfied. Investigate and correct. Adjustmechanical interlocks.

8. Bad motor starter. Repair or replace.

9. Loose or corroded wiring. Tighten and/or clean as necessary.

10. Control relay defective. Replace.

11. Low voltage. Investigate. Increase voltage supply.Increase wire size. Increase breaker size.

12. Control circuit not grounded properly. Ground neutral at transformer. Checkwiring.

13. Wiring to remote starter incorrect. Investigate and correct.




No Control PowerCause Solution

1. POWER ON selector switch OFF. Turn POWER ON switch to ON.

2. Blown fuse. Replace fuse.

3. Bad control power transformer. Replace.

4. Control power transformer wiredincorrectly.

Correct transformer wiring.

Failure to LoadCause Solution

1. LOAD selector switch in the wrongposition.

Turn switch to LOAD.

2. Inlet valve stuck. Investigate and correct.

3. Controller setpoint too low. Adjust.

4. No control air signal. Investigate and correct. Check for closedvalve.

5. Surge sensor tripped. Adjust or replace.

6. Bypass valve will not close. Investigate and correct.

7. No power air to inlet or bypass valve. Investigate. Open power air shutoff valve.

8. Valve actuator or positionermalfunctioning.

Repair or replace.

9. REMOTE/LOCAL switch for CEM inwrong position.

Turn to REMOTE for CEM operation.

10. Incorrect CLL setting. Reset to correct value.



Low Oil PressureCause Solution

1. Incorrect relief valve adjustment. Adjust main oil relief valve to obtain 25-27psi at correct operating oil temperature.

2. Dirty oil filter. Replace.

3. Leaking check valve. Replace.

4. Defective main oil pump. Repair or replace.

5. Leaking bullgear cover seal. Remove cover and install new siliconesealant around oil supply groove.

6. Leaking or pinched suction line. Repair or replace.

7. Low oil level. Ensure 1-1/2" - 2" oil cover (minimum)above top of suction screens.

8. Excessive gerotor axial clearance. Tighten axial clearance.

9. Wrong prelube pump motor. Obtain correct prelube pump motor.

10. Wrong size pump. Install correct pump.

11. Too big prime line. Install smaller prime line or removeentirely.

12. Suction and discharge lines reversed. Correct.

13. Unloaded oil pressure low. Increase P1 value.




High Oil TemperatureCause Solution

1. Inadequate water flow. Provide adequate water flow to the oilcooler.

2. High water temperature. Lower water temperature; use a coolerwater source.

3. Bad AMOT valve. Replace.

4. Water control valve thermostat out ofcalibration.

Calibrate controller.

5. Dirty oil cooler on water side. Clean water side of oil cooler.

6. Incorrect oil. Check oil specification against I-R oilrequirements; install correct oil.

7. Water/glycol mixture greater than50/50.

Adjust mixture to ensure the glycol is notgreater than 50%.

8. Water temperature supply higher thanoil cooler design.

Install larger oil cooler or additionalcooler.

9. Heat exchanger radiating fins dirty. Clean fins.

10. Incorrect number of water passes. Investigate. Orient return bonnettcorrectly; replace bonnett gasket ifbypassing; install cooler with morepasses.



High Air TemperatureCause Solution

1. Inadequate water flow. Provide adequate water flow to the aircooler; adjust water flow to the air cooler.

2. High water temperature. Lower water temperature; use a coolerwater source.

3. Water control valve thermostat out ofcalibration.

Calibrate controller.

4. Plugged water passages or scale onthe tubes.

Clean water side of air cooler.

5. Water flow bypassing air cooler. Investigate and correct. Replace wafflegasket if it is missing or damaged. Reglueit if it is loose.If shroud is loose, reinstall with correctpop rivets. Never use aluminum poprivets.

6. Water/glycol mixture greater than50/50.

Adjust mixture to ensure the glycol is notgreater than 50%.

7. Heat exchanger radiating fins dirty. Clean fins.

8. Water flows backward. Cold waterinlet on cooler hot air inlet side isbackwards flow.

Investigate. Repipe if water piping isbackwards; switch backflush valve tocorrect position.

9. Air cooler oriented incorrectly. Remove air cooler and rotate to align thewater ports correctly with the waterconnections of the casing.




Common Conversions and Information1. Temperature

Fahrenheit to Celsius °C = 5/9 (°F-32°)Celsius to Fahrenheit °F = 9/5°C + 32°

2. Pressure – gauge

PSI to Atmosphere PSI X 0.06805

PSI to inches of H2O at 68°F PSI X 27.73

PSI to inches of mercury (in Hg) at 0°C PSI X 2.036

PSI to kPa PSI X 6.8948

PSI to Kg/cm2 PSI X 0.07031

Kg/cm2 to Atmosphere Kg/cm

2 X 0.9678

Kg/cm2 to bars Kg/cm

2 X 0.98066

Kg/cm2 to inches of mercury (in Hg) at 0°C Kg/cm

2 X 28.96

Kg/cm2 to kPa Kg/cm

2 X 98.066

Kg/cm2 to PSI Kg/cm

2 X 14.223

kPa to PSI kPa X 0.145

bars to PSI bars X 14.504

inches of H2O at 68°F to inches of mercury (in Hg) at 0°C in H2O X 0.07342

inches of water at 68°F to psi in H2O X 0.03606

inches of water at 68°F to kPa in H2O X 0.2487

inches of water at 68°F to Kg/ cm2 in H2O X 0.002535

inches of water at 68°F to bar in H2O X 0.002487

inches of water at 68°F to standard atmosphere (atm) in H2O X 0.002454

inches of mercury at 0°C to inches of water at 68°F in Hg X 13.62inches of mercury at 0°C to psi in Hg X 0.03606inches of mercury at 0°C to kPa in Hg X 3.3864



2. Pressure – gauge, continued

inches of mercury at 0°C to Kg/cm2 in Hg X 0.034532

inches of mercury at 0°C to bar in Hg X 0.033864inches of mercury at 0°C to standard atmospheres (atm) in Hg X 0.03342

atmosphere (standard) to bar atm X 1.01325

atmosphere (standard) to psi atm X 14.696

atmosphere (standard) to Kg/cm2 atm X 1.0332

atmosphere (standard) to Kg/m2 atm X 10332

atmosphere (standard) to kPa atm X 101.325

3. Length

inches to meters (m) in. X 0.0254inches to centimeters (cm) in. X 2.54inches to millimeters (mm) in. X 25.4meters to inches (in.) m X 39.37centimeters to inches (in.) cm X 0.3937millimeters to inches (in.) mm X 0.03937mills (0.001") to millimeters 0.001" X 0.0254




4. Flow

cubic feet per minute (scfm) to cubic meters per second (nm3/s) scfm X 0.0004719

cubic feet per minute (scfm) to cubic meters per hour (nm3/h) scfm X 1.699

cubic feet per minute (scfm) to cubic centimeters per second(cm

3/s)

scfm X 471.9

cubic feet per minute (scfm) to cubic meters per minute (nm3/m) scfm X 0.02832

1000 scfm = 28.32 nm3/m

cubic meters per hour (nm3/h) to cubic meters per minute (scfm) nm

3/h X 0.016667

cubic meters per hour (nm3/h) to cubic meters per second (nm

3/s) nm

3/h X0.00027778

cubic meters per minute (nm3/m) to cubic feet per minute (scfm) nm

3/m X 35.315

gallons per minute (US) to cubic meters per minute (nm3/m) gpm X 0.0037854

gallons per minute (US) to cubic meters per hour (nm3/h) gpm X 0.2271

gallons per minute (US) to cubic feet per hour (scfh) gpm X 8.021gallons per minute (US) to liters per second (L/s) gpm X 0.06309

5. Volume

gallons (US) to cubic inches (in3) gal. X 231

gallons (US) to cubic meters (m3) gal. X 0.0037854

gallons (US) to liters (L) gal. X 3.7854

liters (L) to cubic inches (in3) L X 61.024

liters (L) to cubic meters (m3) L X 0.001

liters (L) to gallons (US) L X 0.26418

cubic inches (in3) to cubic meters (m

3) in

3 X (16.387 X 10

-

6)

cubic meters (m3) to cubic inches (in

3) m

3 X 61024

cubic meters (m3) to cubic ft. (ft

3) m

3 X 35.315

cubic feet (ft3) to cubic meters (m

3) ft

3 X 0.02832



6. ElectricalAmps (I) = currentOhm (R) = resistanceWatts (W) = electric powerKilowatts (KW) = electric powerKilovolt - amps (kVA) = apparent electric powerKilowatt hour (KW/hr) = unit of electric energy or work performedJoule (J) = metric unit of energy in watt per sec.Volt (E) = unit of electric pressure or electromotive forceeff = efficiency (expressed as a decimal)pf = power factor (expressed as a decimal)hp = horsepower outputAC = alternating currentOhms Law Relationship (direct current - DC)

E I R� �

E WI

�

E WR� W I R�2

W ER

�

2

W E I� �

I ER

� I WE

� I WR

�R E

I� R W

I� 2 R E

W�

2

kva IE�

1000 single phase AC( ) kva IE

�

1 731000. (3- phase AC)

KW IE�

1000 (DC) KW IE pf

�

( ) (1000

single phase AC)

KW IE pf�

1 731000

. ( ) (3- phase AC)

Power Factor (pf) =kvakw




6. Electrical, continued

hp IE eff�

( )746

(DC) hp IE eff pf�

( )( )746

(single phase AC)

hp IE eff pf�

1 73746

. ( )( ) (3- phase AC)

J IE�

sec (DC) J IE eff pf

�

( )( )sec

(single phase AC)

J IE eff pf�

1 73. ( )( )sec

(3- phase AC)

Amps(hp known) (DC)�

746( )( )

hpE eff

Amps (hp known) (single phase AC)�

746( )( )( )

hpE eff pf

Amps(hp known) (3- phase AC)�

7461 73

( ). ( )( )

hpE eff pf

Amps(KW known) (DC)�

1000KWE

Amps(KW known) (single phase AC)�

1000KWE pf( )

Amps(KW known) (3- phase AC)�

10001 73

KWE pf. ( )

Amps(kva known) (single phase AC)�

1000kvaE

Amps(kva known) (3- phase AC)�

10001 73

kvaE.



7. VibrationA = Acceleration in g's (in/sec

2) = Peak

V = Velocity in in/sec = PeakD = Displacement in mils = Peak - Peakf = Frequency in Hz

V Af

� �61 34.V f D� � �0 0031416.

D Vf

� �318 3. D Af

� �19 570 2,

A D f� � �0 0000511 2. A V f� � �0 0162.

RMS (root mean square) = 0.707 XPeak

RMS = 1.111 X average RMS = 0.354 X Pk - Pk

average = 0.637 X Peak average = 0.900 X RMS2 average = 0.318 X Pk - Pk

Pk - Pk (Peak to Peak) = 2 X Peak Pk - Pk = 2.828 X RMS Pk - Pk = 3.142 X average

Pk (Peak) = 1.414 X RMS Pk = 1.571 X average




in mm/ sec. / sec. .� � 0 03937

mm in/ sec. / sec. .� � 25 40

total vibration(in mils) = 1 25 12000. �

RPM

8. Water Quality Requirements

Total hardness (expressed as CaCo3) less than 100 PPM

Suspended solids less than 50 PPMMaximum water temperature (cooler discharge) 140°F/60°CpH range 6.0 - 8.5Langlier saturation index (LI) +0.5 - +1.0

A low pH level promotes corrosion and high levels of dissolved oxygen.A high pH level increases the chance of scale formation.A low LI indicates the water tends to be corrosive.A high LI indicates a tendency to form scale.It is recommended to contact a reputable water treatment professional if there are questionsregarding water quality.Rev. C24 Mar. 1995

AVERAGE RMS

PEAK TO PEAK

PEAK0+

-

0.7070.637

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