Centrifugal Compressor Handbook

Contents

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 ECO-1910938

Rev. 01 May 2003

FWG

The Turbo Air 3000 Centrifugal Compressor Operator’s Manual

ii

About ThisContents Manual

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

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

iii


iv

Contents

Table of Contents About This Manual Section One:

iii

Introduction About Cooper Turbocompressor The Turbo Air Centrifugal Compressor Safety Precautions Safety Labels Warranty Limitation on Liability Unauthorized Repair

Section Two:

Specifications General Compressor Specifications Compressor Lubricant Requirements

Section Three:

3— 3— 3— 3—

3 4 8 9

4— 4— 4— 4— 4—

3 3 5 6 7

Routine Operation General Considerations The Operating Data Record Routine Startup Routine Shutdown Adjusting the System Pressure Setpoint

Section Five:

2— 3 2— 6

The Control System The Vantage Control Panel The Vantage User Interface Input or Operational Keys Pratice Exercise

Section Four:

1— 3 1— 4 1— 6 1— 7 1—10 1—11 1—11

Maintenance General Considerations Daily Inspection Scheduled Maintenance Professional Inspection Filter Maintenance Lubrication Additional Maintenance Procedures

5— 3 5— 4 5— 5 5— 6 5— 7 5—11 5—17

v


Section Six:

Troubleshooting General Considerations How to Use the Troubleshooting Guide How to Request Assistance Alarm and Trip Functions Drive Train Troubleshooting Control System Troubleshooting Air System Troubleshooting Lubrication System Troubleshooting

Section Seven:

Parts and Service Aftermarket Support Parts Ordering Procedure Parts Availability The Return Goods Policy The Periodic Maintenance Parts Inventory The Professional Inspection Parts Requirement Control System Parts Lubrication System Parts Main Drive Coupling Parts Heat Exchanger Parts Air Piping Parts

Appendix A:

A— 3 A— 4 A— 5 A— 6 A— 8 A—19 A—27 A—30 A—32 A—37 A—38 A—40 A—41

The Lubrication System General Considerations The Compressor Lubrication System Vantage Control of Compressor Lubrication Operational Guidelines Gearbox and Reservoir Venting Optional Features

vi

7— 3 7— 4 7— 4 7— 4 7— 5 7— 7 7— 9 7—12 7—14 7—15 7—18

Installation General Considerations The Installation Work Schedule Labor, Supplies, Equipment and Tools Site Considerations Process Air Piping Utility Piping Electrical Interface Receiving, Lifting, Moving, and Bolting Preparing for Startup Preventing Startup Problems The Inspection Prior to Initial Startup Schedule The Initial Startup Procedure Service Assistance

Appendix B:

6— 3 6— 4 6— 5 6— 6 6— 8 6—10 6—12 6—13

B— B— B— B— B— B—

3 4 5 6 7 8

Contents

Appendix C:

Vantage Control System Logic General Considerations Compressor Control Methods AUTO-OFFLINE Control AUTO-STANDBY Control AUTO-UNLOAD Control Compressor Safety Mechanisms

Appendix D:

Control System Setpoints Adjustments General Considerations The Operation Setpoint Adjustment Procedure Minimum Amp Setpoint Adjustment The Protection Setpoint Adjustment Procedure

Appendix E:

D— 3 D— 4 D— 7 D—11

Control System Initialization General Considerations Control System Initialization Analog Channel Initialization Factory Default Initialization

Appendix F:

C— 3 C— 4 C— 7 C—10 C—12 C—14

E— 3 E— 4 E—15 E—23

Glossary

Contract Drawings

Supplemental Data

vii


viii

Introduction

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

1—1


1—2

Introduction

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

Figure 1—1 The Buffalo, New York, USA, Home Office and Centralized Facilities

1—3


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

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

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

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

1—4

Introduction

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

Horizontally split gearbox casing Built-in aftercooler Built-in intercoolers Mounted control panel Self-contained lubrication system Inlet guide vanes (standard) Shaft-driven main oil pump Mounted water manifold (optional) Mounted bypass valve (optional)

4

6 7 9

5

1 3

2

8

3

Figure 1—2 The Turbo Air 3000 Centrifugal Compressor

1—5


Safety Precautions The Turbo Air 3000 Centrifugal Compressor is a powerful industrial machine that utilizes high-speed rotating elements and high voltages to produce high air pressures. Therefore, it is very important to use common sense and extra safety precautions whenever it is in operation as well as when performing maintenance or making repairs. Cooper Turbocompressor expressly disclaims responsibility or liability for any injury or damage caused by failure to observe specified or other common safety precautions or failure to exercise ordinary caution, common sense, and due care required in operating the compressor even though not specified herein. The alert messages shown here appears throughout this manual to indicate those situations and times when special care is necessary to prevent component harm or personal injury. There are three degrees of 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 damage or personal injury.

DANGER: This indicates that there will definitely be major equipment damage and/or personal injury or 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 the compressor. They alert the user to possible and probable hazards and serve to remind the user of specific safety precautions. Before using the Turbo Air 3000 Centrifugal Compressor, be certain to review 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.

1—6

Introduction

Safety Labels WARNING HAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURY OR DEATH Disconnect all power supplies, lock-out and display signs before servicing equipment.

DANGER AIR UNDER PRESSURE. WILL CAUSE SEVERE INJURY OR DEATH DO NOT operate the compressor at pressure in excess of the nameplate rating. Close the discharge block valve and relieve system of pressure before removing any caps or plugs, or servicing compressor. DO NOT play with compressed air. Wear eye protection when using compressed air.

CAUTION ELECTRICAL HAZARD. CAN SHOCK, BURN OR CAUSE DEATH. All electrical enclosures and components must be installed and grounded in accordance with the National Electric Code and other local codes.

1—7


Safety Labels WARNING HIGH SURFACE TEMPERATURES. CAN CAUSE INJURY. Some surfaces of the compressor and motor have excessive temperatures. To avoid burns, keep hands and other body parts away while unit is operating.

DANGER HOT OIL UNDER PRESSURE. WILL CAUSE SEVERE INJURY OR DEATH. Shut down compressor and pumps before removing any caps or plugs, or servicing any parts.

DANGER DO NOT USE DISCHARGE AIR FOR BREATHING OR FOOD PROCESSING, AS IT WILL CAUSE SEVERE INJURY OR 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 filtration regulations.

CAUTION ELECTRICAL OR CONTROL HAZARD. COULD CAUSE INJURY OR MACHINERY DAMAGE. DO NOT rewire or place jumpers in the control panel without written consent from the Cooper Engineering or Service Departments. Periodically check all safety devices for proper operation.

1—8

Introduction

Safety Labels

WARNING ROTATING SHAFTS COULD CAUSE SEVERE INJURY OR DEATH. DO NOT remove protective guards while the compressor is in operation. DO NOT attempt to service any part while the machine is operating.

WARNING UNIT CAN AUTOMATICALLY RESTART CAUSING SEVERE INJURY OR DEATH. Before removing the gearbox cover, lock the main power OFF, close the system block valve, turn the lube pump OFF, and remove the drive coupling.

CAUTION Exercise cleanliness during maintenance and when making repairs. Keep dirt away by covering parts and exposed openings with a clean cloth. Be sure no tools, rags, or loose parts are left on the compressor or drive parts. DO NOT use flammable solvents for cleaning parts.

WARNING DO NOT operate the compressor in areas where there is a possibility of ingesting flammable or toxic fumes.

1—9


Warranty Cooper Turbocompressor warrants that the compressor supplied conforms to applicable drawings and specifications and that the compressor will be free from defects in material or workmanship for a period of twelve (12) months from the date of initial operation or a period of fifteen (15) months from the date of shipment, whichever period expires first. If, within that period, Cooper Turbocompressor receives written notice from the purchaser of any alleged defect in or nonconformance of the compressor and if, in Cooper Turbocompressor’s judgment, the compressor does not conform to the original specifications or is found to be defective in material or workmanship, at its option Cooper Turbocompressor will make restitution in one of these ways: 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 the Cooper 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 is limited to such repair, replacement, or repayment of the full purchase price. Equipment and accessories furnished by third parties that are not incorporated in the compressor package manufactured by Cooper Turbocompressor are warranted only to the extent of the original manufacturer’s warranty to Cooper Turbocompressor. There are no other warranties—express, statutory, or implied—including those of merchantability and/or fitness for purpose. Moreover, there is no affirmation of fact or representation that extends beyond 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 directly or indirectly from: 1. The purchaser’s use of repair or replacement parts or supplies not of Cooper Turbocompressor’s manufacture or which have not been recommended by Cooper Turbocompressor. 2. The purchaser’s failure to store, install, operate, and maintain the compressor according to Cooper Turbocompressor’s written specifications, drawings, and good engineering practice.

1—10

Introduction

Limitation on Liability Cooper Turbocompressor’s total responsibility for any claims, damages, losses, or liabilities arising out of or related to the performance of the products covered hereunder shall not exceed the original purchase price. In no event shall Cooper Turbocompressor be liable for any special, indirect, incidental, or consequential 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’s performance 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, or other damages, either direct or indirect, incident to all property damage arising out of any cause of action based on strict liability.

Unauthorized Repair In the event that the owner allows the compressor to be serviced or repaired by unauthorized personnel, the coverage of the original warranty policy will be automatically terminated.

1—11


1—12

Specifications

Section Two Specifications In this section, the reader will learn about: ¨ General Compressor Specifications ¨ Compressor Lubricant Requirements

2—1


2—2

Specifications

General Compressor Specifications Installation Weights Complete Package with Motor

Compressor Rating (HP*) Weight in Pounds Weight in Kilograms

400 14000 6350

500 14000 6350

600 15500 7000

700 18000 8400

800 20000 9300

*HP = Horsepower

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

Air Inlet Air Discharge Air Coolers (Water) Oil Coolers (Water) Manifold*** (Water)

8” ANSI Pipe 4” Victaulic* 1 1/2” NPT** 3/4” NPT** 3” Victaulic*

Condensate Drain Air Ejector Control Panel Pressure Transducers

½” NPT ** ½” NPT ** 1” Conduit ¼” Fitting

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

Discharge Connection Load Limits English 350 lbs 500 ft-lbs

Maximum Allowable Force Maximum Allowable Moment

Metric 1500 N 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 (inch) 3/4 7/8 1

Torque Range (mm) 20 22 25

(ft-lbs) 143-157 192-212 285-315

(Nm) 195-210 260-285 385-425

Cold Alignment Specifications for Main Drive Motors Recommendations for cold field alignment, taken at compressor hub 0.0000 +0.002

Face

0.000 +0.001

+0.005

+.003

RIM +0.007

Recommendations For Cold Field Alignment, Take at Motor Hub 0.0000 +0.001

0.000 Face +0.003

+0.002

-0.002

RIM

-0.005

-0.007

2—3


General Compressor Specifications Cooling Water Requirements The following represents total cooling water requirements for the compressor package including the built-in aftercooler and oil cooler. The values exhibited represent “worst case” conditions. Therefore, well maintained heat exchangers will exhibit substantially better performance with less water

Compressor Rating (hp) Water Flow (gpm) Water Flow (lps) Water Pressure Drop (psi) Water Pressure Drop (bar)

400 105 7.5 6.0 0.42

500 120 8.5 9.0 0.62

600 135 9.5 12.0 0.83

700 135 9.5 12.0 0.83

800 135 9.5 12.0 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, low in dissolved solids to prevent depositions and erosion, free of organic growth, and free of chemicals that exhibit corrosive properties to the copper tubes used as standard in the compressor heat exchangers. (Other tube materials with various chemical resistances are available as options. Consult your authorized representative or Cooper Turbocompressor Sales Department directly.)

Coupling Bolt Torque Values English

Metric

100 ft-lbs

135 Nm

Lubrication System Reservoir Capacity Minimum Reservoir Temperature Prior to Startup System Operating Temperature System Operating Pressure Air Ejector Pressure Range

English

Metric

55 gallons (USA) 60°F 120°F 120 psig 25-30 psig

210 liters 15°C 50°C 8.3 barg 1.7-2.0 barg

Type

Amount

Turbine Oil* Grease* Grease* Grease*

55 gallons (USA) 1 lb (0.5 kg) 1 lb (0.5 kg) 1 lb (0.5 kg)

Lubricants Use Compressor Main Drive Motor Bearings** Main Drive Coupling Inlet Guide Vane Drive Screw *Refer to text for complete description and recommendations. **Anti-friction bearings only.

2—4

Specifications

General Compressor Specifications Control Housing Mechanical Specifications Attribute

English Units

Metric (ISO) Units

Height Width Depth Weight:

24 inches 20 inches 7 inches 55 pounds

610 mm 508 mm 178 mm 25 kg

Vantage Electrical Specifications Property Rated Voltage Input Voltage Range Rated Frequency Range Input Frequency Range Power Consumption Location Classification (per USA Standards): Standard Optional Optional

Value 100 – 240 VAC 90-264 VAC 50 – 60 Hz 47 – 63 Hz 1.0 KVA NEMA 4 (outdoor: watertight & dustproof) NEMA 4X (NEMA 4 with corrosion resistance) Class I, Groups C & D, Division 2 (limited hazardous)

Environmental Temperature: Operating Range* Storage Limits Humidity: Operating Range Storage Range

32° to 140°F -4° to 140°F

0° to 60°C -20° to 60°C

5 to 95% Relative Humidity (Non-Condensating) 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 Requirements Main Drive Motor* Oil Pump Motor* Oil Heater (optional)**

Furnished separately 5 hp (3.5 kw) 460V/3F/60Hz *** 1.5 kw 460V/3F/60Hz ***

*Starter Required. **Magnetic contactor required above 480 volts. ***Other voltages are available. Must be specified at time of order entry.

2—5


Compressor Lubricant Requirements The 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 procedures involving their use are included in Section Five, Maintenance, of the complete Turbo Air 3000 Compressor Operator’s Manual. It is the user’s responsibility to provide all lubricants (including turbine oil, motor grease, and coupling grease) at the initial startup and during subsequent operation. It is very important for all compressor users to follow specific guidelines regarding lubricant selection and proper use in order to assure optimal performance of the Turbo Air 3000 Compressor.

Compressor Oil Selection The correct lubricating oil is critical to satisfactory overall compressor performance. When operating the Turbo Air 3000 Compressor, use only high-quality, rust- and oxidation-inhibiting oil that resists foaming and that does not break down under severe operating pressures and temperatures. Incorrect or poor quality lubricating oil can adversely effect high-speed shaft dynamics and seriously damage critical compressor components. While there are many quality oil products on the market today, not all have been demonstrated to function optimally in situations involving high-speed rotordynamics. For this reason, Cooper Turbocompressor 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 stock and performance enhancing additives. Hydrocracking is an advanced oil processing technology that is far superior to solvent refining. It converts crude oils into base stocks of unparalleled purity. So pure, in fact, and so highly refined that this new class of lubricant is free of the contaminants that cause lubricant breakdown ensuring longerlasting compressor performance. The only additives in TurboBlend Lubricating Oil are those selected exclusively by Cooper Turbocompressor scientists and engineers to increase performance. In test after test of standard quality indicators, TurboBlend Lubricating Oil outperforms solvent refined, commercially available oils. TurboBlend Lubricating Oil is available through your authorized Cooper Turbocompressor representative or directly from the Cooper Turbocompressor Parts Department. Refer to Section Seven of this manual for part numbering and ordering information.

Standards Excellent operating performance will be achieved when using TurboBlend Lubricating Oil. However, if the compressor owner or user chooses to pursue a near equivalent substitute, the subject oil must conform to the following characteristics:

2—6

Specifications

· 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 of sufficient volume to cause very high, localized loadings that will lead to a premature breakdown of the load-carrying capacity of the oil. This will result in worn gears and scored bearings.

Specifications TurboBlend Lubricating Oil meets or exceeds the performance standards listed in Table 2—1. Any substitute or equivalent oil selected for use in the Turbo Air 3000 Compressor by the compressor owner must exhibit similar results.

Property Viscosity: at 40°C at 100°C Viscosity Index: Four Ball Wear Test: (40 Kg, 1200 RPM, 75°C, 1 Hour) Water Separability: (54°C and 82°C) Foaming Characteristic - Sequences I, II & III: Tendency/Stability Gas Bubble Retention Time: at 50°C Rust Test: Distilled Water Synthetic Sea Water Rotating Bomb Oxidation Test:

Test Method

Performance

ASTM D445 ASTM D445 ASTM D2270

46 Cst 7 Cst >100

ASTM D4172

£ 0.4 mm

ASTM D1401

<3 ml at 15 minutes

ASTM D892

<10 ml / 0

ASTM D3427

£ 5 minutes

ASTM D665A ASTM D665B ASTM D2272

Pass Pass > 400 minutes

Base Oil is to be refined from high-grade mineral oil stock. Table 2—1 Cooper Turbocompressor Oil Specification

2—7


Other Oil Selection Considerations Incorrect or poor quality lubricating oil can seriously damage the compressor’s rotating and mechanical elements. Do not merely rely on an oil dealer recommendation when selecting turbine oil, and do not compromise quality in an attempt to economize. Many reputable brand name oil products exist, but not 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 wrong combination of additives could cause serious machine damage and/or poor overall performance. The lubrication requirements of the Turbo Air 3000 Compressor are not so severe as to require the qualities of high-cost synthetic oil. In addition, Cooper Turbocompressor products are not designed to use synthetic 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 be certain 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 Testing Oil samples from the compressor reservoir should be visually inspected and tested for viscosity and freedom from contamination at regular intervals. This will insure that proper lubricant properties are always being provided and early deterioration of the gearing and bearings is diminished. ·

·

Color and Appearance Compare an oil sample from the reservoir with new oil. Any color change suggests some type of deterioration. Darkness implies contamination from acid buildup while muddiness is an indication of water. Viscosity, Acid and Particle Count Tests for these properties required qualitative analyses by a reputable laboratory. Follow the recommendations of the laboratory with regard to oil replacement.

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

2—8

Specifications

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

Motor Bearing Lubricants The user must provide lubricants for the main drive motor and the oil pump motor. To ensure long life of the bearings of both motors, it is necessary to maintain both proper alignment and proper lubrication levels at all times. The large, squirrel cage inductor motor of the Turbo Air 3000 Compressor employs (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 information regarding correct oil bearing lubrication maintenance procedures for each type of motor. Anti-Friction Bearings—Grease For best results with anti-friction bearings, use grease compounded from a non-soap base and a good grade of petroleum oil. Table 2—2 lists acceptable greases that meet those requirements.

Acceptable Motor Bearing Greases Chevron Oil Exxon Shell Oil Texaco

SRI #2® Unirex N2® Dolium R® 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 products not listed. Table 2—2 Acceptable Motor Bearing Greases Sleeve Bearings—Oil It is the user’s responsibility to fill the motor bearing oil reservoir and to maintain the correct oil level at all times. When lubricating sleeve bearings, use only a high quality, petroleum-based oil with a viscosity of 200-220 SSU at 100° F (40°C). Since motor bearings require the same type of oil as used in the compressor itself, it is not necessary to maintain two separate supplies of oil if this type of bearing is used. CAUTION: Before aligning or using this type of motor, always verify that the correct amount of oil is in the reservoir. Motors with sleeve bearings are sometimes shipped without oil in their reservoirs.

Drive Coupling Grease The 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 provide complete 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 accelerate wear.

2—9


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

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

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

Bypass Valve Lubricant Compressors equipped with AUTO-OFFLINE Control utilize a pop-action bypass valve to vent the discharge side of the compressor. Two different size and type of valves are employed depending upon volume flow requirements. The valve supplied with units rated up to 600 horsepower must be lubricated periodically, while the larger valve for units rated 700 horsepower and larger requires no lubrication. The only product Cooper Turbocompressor found acceptable for this service is Dow Corning MOLYCOAT 33®. Other products may gum up under certain operating conditions and cause the valve to malfunction.

2—10

The Control System

Section Three The Control System In this section, the reader will learn about: ¨ The Vantage Control Panel ¨ The Vantage User Interface ¨ Input or Operational Keys ¨ Practice Exercise

3—1

The Turbo Air 3000 Centrifugal Compressor Handbook

3—2

The Control System

The Vantage Control Panel The major components of the Vantage Controller are mounted in a weatherproof electrical enclosure with a NEMA 4 rating. One or more Main Logic Modules (MLM) are included in the panel. Each MLM contains a power supply, a microprocessor, and an I/O (input / output) segment. Depending upon the particular application, up to two additional slave MLM units may accompany the master MLM to increase I/O capacity. Each master MLM also contains the hardware to support a User Interface Module (UIM). The UIM is a full-page, back-lit liquid crystal LCD display with an integrated 15 key, tactile keypad. The display provides 20 lines by 80 characters of detailed information on the operational condition and settings of the controller. The acceptable operating environment of the control panel includes an operating temperature range of 32ºF to 140ºF (0ºC to 60ºC), and a maximum 95% relative humidity (non-condensing). The storage temperature 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) in the 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 is stored in flash memory located in the MLM. The operating system provides a real time, multi-tasking environment for control programs. Control programs are loaded and saved to flash memory prior to installation. Once loaded, these programs are maintained in memory by a small battery or saved to flash memory. It is not necessary to load programs into the Vantage Controller except during certain special installations, 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 any solvent. If the display, or UIM, should become dirty, a mild detergent can be used for cleaning. Use a soft, non-abrasive cloth to clean the display. Do not submerge any part.

3—3


Audubon Mens Club

The Vantage Control Panel User Interface

Figure 3—1. User Interface Module 1. Display Presents critical diagnostic and operating information, including startup, shutdown, alarm warnings, trips, setpoint changes, and much more

2. Index or Menu Keys Access screens that display information about compressor operation and control parameters, historical data and networking.

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

4. Input or Operational Keys Allows the operator to navigate through the various screens and to observe and change control parameters by changing 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 case of an emergency. (The Emergency Stop button must be pulled out before starting the compressor.)

3—4

The Control System

Index or Menu Keys These four keys provide the operator access to numerous screens that display compressor real-time operational data, along with control, historical and networking information from the Vantage Control System. The following descriptions and sample screens demonstrate data from both standard and optional monitoring instruments that may or may not be included on all models. Home Press to display the "Home" screen as selected by the compressor user / owner.

View This key displays a list of screens that show current compressor values. The compressor performance settings cannot be changed using this key. When this key is pressed, the screen below appears and allows the operator to select any of the screens. View Pages Performance Control Monitor Points Control Points Monitoring Chart Protection (Running) Protection (Startup) Startup Status Efficiency Information Auxiliary Control Turbo DryPak Control

History

History Press 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 Network This displays screens for managing the optional networking feature. When networking is present on the system these screens include: • Compressor Network • Modbus Interface 3—5


Function Keys Four of these five keys are used to operate the compressor and to have it produce compressed air. The fifth 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 that may not be installed on specific units. These screens will, however, alert the reader as to what some of these options are and how they are applied.

Start Press this key to initiate the compressor starting sequence. The screen below shows a typical start sequence. As the Vantage Controller proceeds through the sequence, the display advances through each step in the sequence. The actual screen on your system may show other steps. Compressor Start Sequence

1: 2: 3: 4: 5: 6: 7: 8: 9:

Description Opening Water Valve Oil Pressure > 100 psi Oil Temperature > 70 Discharge Pressure < 5 psi Checking Water Flow Motor Enable Starting Compressor Waiting for Motor Speed Compressor Ready to Load

Status Complete Complete Waiting 1

Stop This key initiates the compressor stop sequence. Screens below are typical of those you see after pressing Stop. An initial screen tell you the compressor is unloading and the second goes through the remaining events of the sequence. Compressor Stop Sequence Description 1: Motor Enable 2: Oil Pump 3: Turning Off Water

3—6

= OFF = OFF = ON

Status Completed Completed Waiting 3

The Control System

Auto This key launches the compressor automatic control mode enabling it to respond automatically 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 is based on the specific application. For information on control strategies and the methods available, refer to the Control Logic Appendix.)

Unload This key disables the Auto mode and unloads the compressor by opening the blow off valve and closing the inlet guide vanes. The system continues to run but does not respond to changes in air system demand until someone presses the Auto key.

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

Set Points Operator Maintenance Service Configuration

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

3—7


Input or Operational Keys These keys allow the operator to communicate with the control system. Using these keys you can maneuver among the control screens, change alpha-numeric values of set points, and change the 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 of paired keys. Increase and Decrease Use 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 / Manual Control / Enter.)

Enter

Enter Press 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).

Back Press 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).

Up Use 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 / Manual Control / Enter.) • Increase or Decrease the contrast of the LCD display when used in combination with the View key.

3—8

The Control System

Practice Exercise You can use this practice exercise to gain familiarity with the various keys and to view representative screens on the display before the actual startup and operation of the compressor under the Vantage Control System. When exploring the display screens with option lists, remember to use the Up and Down keys to move through 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 and locked out before attempting this practice exercise. Failure to do so may result in equipment damage, personal injury or death.

Temporary Power Connection If your system's Vantage control panel is already wired to the main motor starter control power transformer, disconnect the power supply directly at the Vantage Controller and reconnect the Vantage Controller 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 terminal block 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 analog or communication wiring.

Procedure Some of the sample screens shown here demonstrate data from both standard devices and optional monitoring devices that may not be included on all models. It should also be noted that this exercise is intended to familiarize an individual with those features required to operate the compressor 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 to improve 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 simultaneously pressing the Up or Down key to increase or decrease the contrast.

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4. Press the Home key to display the “Home” page selected by the compressor owner. Any of the View screens are practical choices to give the operator quick and easy access to important operation or protection data. Probably the most popular screen selected is the Performance 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 the Protection (Running) screen (below). Protection (Running) Description Tag 1: System Air Pressure PT-100 rd 2: 3 Stage Discharge Press PT-106 3: Drive Motor Current IT-199 4: Oil Pressure PT-159 5: Oil Temperature TE-147 st 6: 1 Stage Vibration VT-192 nd 7: 2 Stage Vibration VT-194 8: 3rd Stage Vibration VT-196 9: Inlet Air Filter DPT-107 10: Motor Power JT-199 11: Motor Stator A Temp TE-199A

Trip Low

70.0 60.0

Alarm Low 70.0

80.0 70.0

Data 98.2 101.1 148 110.0 110 0.23 0.14 0.17 4.2 1014 112

Alarm Trip High High 110.0 110.0 130.0 165 140.0 140 1.50 1.50 1.50 8.0

135.0 173 150 2.00 2.00 2.00 10.0

150

165

The Protection (Running) screen shows the monitored points that protect the compressor the instrumentation identification numbers (Tag). The Data column shows the current value of each point, plus the Alarm and Trip set points of each attribute. Values shown are in units as defined. 3—10

The Control System

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. The elements displayed, along with a status indication, are those necessary for a permissive start. Each condition must show a "Ready" status before a successful start. Startup Status Description

Status

rd

2: 3 Stage Discharge Pressure < 3.0 3: Oil Temperature > 70 4: Oil Pressure > 80.0

Not Ready Ready Not Ready

Other index keys access to additional history and networking information, not essential to the safe and efficient operation of the compressor. This practice exercise is only to help develop your confidence 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: System Pressure Offset: Maximum Motor Load (%):

0 0 9 8.0 3.0 100.0

For this exercise, raise the System Pressure Set Point from 98 psi to 103 psi in the following manner: • 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 demonstrated in Step #8. Some set point values are critical to the protection of the compressor and cannot be changed by the operator. 10. When complete, unplug the temporary cable from the power source and restore the original panel power connection. (A qualified electrician may be required to make this connection.) 3—11


3—12

Routine Operation

Section Four Routine 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

4—1


4—2

Routine Operation

General Considerations After successful startup, the operator should keep detailed compressor operation and maintenance records. (Refer to Section Five, Maintenance, for schedules and instructions for routine and periodic preventive 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 to operator inspection and attention at periodic intervals. To assure long life and optimal output from the Turbo Air 3000 Centrifugal Compressor, always follow the prescribed maintenance procedures. If problems arise, contact a Cooper Turbocompressor factory trained and authorized service representative for technical assistance.

WARNING: When in the process of starting or stopping compressor operation under routine conditions, do not attempt to restart the compressor until operation has stopped completely. Restarting the compressor before full shutdown will cause equipment damage.

The Operating Data Record Cooper Turbocompressor recommends keeping an Operating Data Record to list inspections and to store operating data for trend analysis. This record should contain the checklist items included in Table 4—1, along with spaces for the operator’s initials and the time and/or date to ensure that each item or procedure receives the recommended periodic attention. Keep in mind, however, that Table 4 actually includes a wide range of options, and remember that not all options are included on all units. (Users may 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 Section Five, Maintenance.

4—3


Operating Data Record Pressure Ö Discharge Air Pressure: Ö System Air Pressure: Ö Main Oil Pressure: Ö * Inlet Air Filter Drop: Ö * Oil Filter Pressure Drop: Temperature Ö Oil Temperature: Ö * Stage 2 Inlet Temperature: Ö Stage 3 Inlet Temperature: Ö * Discharge Air Temperature: Ö * Motor Stator 1 Temperature: Ö * Motor Stator 2 Temperature: Ö * Motor Stator 3 Temperature: Ö * Motor Bearing Temperature Drive End: Ö * Motor Bearing Temperature Non-drive End: Vibration Ö Stage 1 Vibration: Ö * Stage 2 Vibration: Ö * Stage 3 Vibration: Ö * Motor Vibration at Drive End: Ö * Motor Vibration at Non-drive End: Power Ö Motor Current: Time Ö Date: Ö Time: Ö Total Running Time: Ö Current Running Time: * These are optional sensors which may not be included on all models. Table 4—1 The Operating Data Record

4—4

Routine Operation

Routine Startup—Local Control Use this procedure to start the compressor locally from the User Interface Module (UIM). WARNING Only 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. Operation under 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 1. Oil Pressure 2. Oil Temperature 3. Discharge Pressure 4. Checking Water Flow 5. Motor Enable 6. Start Signal

Status > > < = = =

100.0 PSI 70 5 PSI ON ON 8.00

Complete Waiting 2

(This is sample screen that may contain extra messages.) 9. After startup, control defaults to the Auto mode. Press Home to observe selected processes and verify stability. To stop the Auto mode, press Unload.

4—5


Routine Shutdown—Local Control Use 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, drain all water from the compressor's cooling system after the shutdown. Water in the heat exchangers may freeze and cause damage to the internal tubes. An alternative to draining is 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 (or blow-off valve) to open and the inlet guide vanes (or other throttling device) to close completely. (This takes 10-15 seconds.) In addition to the closing of the inlet, the automated 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 of sequence.) 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.

4—6

Routine Operation

Adjusting the System Pressure Set Point During normal operation, it may become necessary to make small adjustments to the System Pressure Set Point in order to alter the operating characteristic of the compressor. The example here shows 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 if prompted)

Pressure Setpoint System Pressure Setpoint: System Pressure Offset: Maximum Motor Load (%):

0 0 9 8.0 3.0 100.0

Use Enter key to move cursor to the right

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 digits only where necessary. (Back moves the cursor to the left.) 8. On completion press Enter to return to the Set Points selection screen.

4—7


4—8

Maintenance

Section Five Maintenance In this section, the reader will learn about: ¨ ¨ ¨ ¨

General Considerations Daily Inspection Scheduled Maintenance Professional Inspection

¨ Filter Maintenance Inlet Air Filter Bypass Valve Filter Oil Reservoir Vent Filter Standard Oil Filter Duplex Oil Filter ¨ Lubrication Compressor Lubricating Oil Oil Pump Motor Bearings Main Drive Coupling Drive Motor Ball Bearings Inlet Guide Vane Drive Screw Bypass Valve ¨ Additional Maintenance Heat Exchangers Intercooler Cleaning Oil Cooler Cleaning Accumulator Testing Discharge Air Check Valve Inspection

5—1


5—2

Maintenance

General Considerations The Turbo Air 3000 Centrifugal Compressor requires minimal maintenance. However, monitoring operating conditions on a daily (or shift change) basis is good practice. It allows the operators to become familiar with a smooth running machine which will lead to early detection of potential problems. The result is improved overall performance, a dependable supply of compressed air, longer compressor life, and lower overall compressed air costs. Just as with any other type of machinery, compressors are subject to operational changes from environmental conditions, wear, or neglect. A plugged condensate drain, unusual noises, temperature or vibration increases, discolored oil, and/or fluid leaks are some examples of operational changes that may signal beginning of potential problems. Recognizing any changes in operation and appropriately responding to those changes can prevent undesirable consequences such as unscheduled shutdown and/or the expense of unanticipated repairs.

WARNING: Do not attempt service procedures other than those described in this manual. Even a minor adjustment, incorrectly performed could cause serious damage. Since the Turbo Air 3000 Centrifugal Compressor is a high technology product, for all other procedures always consult a Cooper Turbocompressor trained and authorized service representative.

5—3


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

Daily Operator Inspection Checklist WARNING: 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 3 Operating Parameters recorded and within specifications 3 Setpoints recorded Gearcase (High surface temperatures) 3 External surfaces wiped clean 3 No unusual noise or vibrations 3 No oil leaks 3 No water leaks 3 No frayed or worn electrical cables Intercoolers and Aftercooler (Pressurized air, high surface temperatures) 3 External surfaces wiped clean 3 Condensate drains functioning properly 3 No cooling water leaks 3 No air leaks Lubrication System (High voltages at heater, pump motor) 3 External surfaces wiped clean 3 Proper oil level in oil reservoir 3 Proper oil color 3 No mist from ejector system 3 No oil cooler water leaks 3 No oil leaks 3 No frayed or worn electrical cables Compressor Drive Motor (Inspect visually only—high voltages, temperatures) 3 External surfaces wiped clean 3 Properly ventilated 3 No erratic or noisy operation 3 No frayed or worn electrical cables 3 Inspected in accordance with manufacturer’s recommendations Table 5—1 Daily Operator Inspection Checklist

5—4

Maintenance

Scheduled Maintenance Table 5—2 lists suggested intervals for prescribed scheduled maintenance procedures such as those involving filters, lubrication, and other inspections and/or adjustments. Bear in mind, however, that these intervals may vary with operating conditions and/or actual hours of machine operation. Some items may require attention more or less frequently as circumstances dictate.

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

Weekly: (or after about 150 hours of operation)

3 3 3

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)

3 3 3 3 3 3 3 3 3 3

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

5—5


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

Service Inspection Checklist To be performed with a Cooper Turbocompressor authorized representative:

Gearcase* 3 Impellers, inlets, and diffusers cleaned 3 Impellers, inlets, and diffusers inspected 3 Gearing visually checked 3 Gearing backlash clearances measured 3 Axial pinion float checked 3 Clearances between impellers and inlets checked Intercoolers* and Aftercooler* 3 Bundle tubes inspected, cleaned if required 3 Bundle fins inspected, cleaned if required 3 Cooler cavities cleaned and inspected Lubrication System* 3 Piping connections checked for leaks 3 Oil visually inspected 3

Oil cooler inspected

Filters 3

All filter elements inspected

Control Panel 3 Inspected for proper operation Control Valves 3 Inlet Guide Vane inspected 3 Bypass valve inspected 3 Discharge air check valve inspected Drive Motor 3 Main drive coupling inspected and re-greased 3 Motor inspected in accordance with manufacturer’s instructions *Replacement parts required. Use only genuine JOY® and Cooper Turbocompressor parts and supplies available through the Cooper Turbocompressor and/or authorized representatives. (Refer to Section Seven, Parts and Service, for additional information regarding inspection kits.) Table 5—3 Service Inspection Checklist 5—6

Maintenance

Filter Maintenance Several filters located in different parts of the compressor system ensure that the air and oil passing through the system are always clean. For optimum performance the operator must regularly monitor the condition of these filters, and clean or change filters as required. Table 5—4 lists the various filters along with recommended inspection intervals and recommended responses for typical operating environments. Instructions for each procedure are included in this section.

Filter Maintenance Schedule Filter:

Inspect:

Clean or Change:

Inlet air filter elements* Bypass valve filter* Oil reservoir venting system* Oil system filter element*

Weekly Weekly Weekly N/A

When dirty or after 12 months When dirty or after 12 months With misting or after 6 months At Alarm level or after 6 months

*When replacing filter elements, use only genuine JOY® and Cooper Turbocompressor products. Refer to Section Seven, Parts and Service, for more information on parts availability through the Cooper Turbocompressor Parts and Service Department and/or authorized representatives. Table 5—4 Filter Maintenance Schedule

Inlet Air Filter Cleaning and Replacement The inlet air filter is a two-stage unit. While the primary filter may be cleaned, the secondary filter element 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 secondary filter very rapidly, Cooper Turbocompressor recommends that user’s stock a spare primary filter for use as required. It is also necessary to keep a supply of secondary filters for use as required, since the secondary filter cannot be cleaned and must always be replaced when it becomes dirty and no longer functions properly. Because contamination levels vary in different operating environments, the only reliable method to determine whether either cleaning or replacement is necessary is by measuring the pressure drop across 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 the new filter elements were installed. · If the current pressure drop is within 4” (or 100 mm) water column (WC) of the original reading, continue operation. ·

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

5—7


3. When necessary, it is possible to clean the primary filter (which has the screen across its face) in either 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 cleaning agent 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 is an indication that the secondary filters are still clean. However, if the air pressure drop remains high 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. Operation without proper filtration may cause compressor damage or malfunction.

Bypass Valve Filter Element Replacement On compressors so equipped, a filter is located in the pilot supply line to the bypass valve. It serves to prevent water and/or other contaminants from entering the bypass valve’s control mechanism. Use a Cooper 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 line and 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 canister.

5—8

Maintenance

Oil Reservoir Vent Filter Element Replacement The oil reservoir is vented through an ejector-filter system that does not require frequent maintenance if its supply air is clean and dry, or if the humidity in the surrounding environment is not excessively high. Moisture will collect in the filter element and eventually drain back into the reservoir contaminating 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 and will cause severe damage to the compressor. Be sure the ejector’s supply air is clean and dry 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 filter element. 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 to over-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 necessary, 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 the top of the trap line to reinstate the mist filter trap.

Standard Oil Filter Element Replacement The compressor must be shutdown before servicing the oil filter. When required, use the following procedure to replace the standard oil filter element. Use a Cooper Turbocompressor replacement filter 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 under pressure presents a safety hazard to personnel. 1. Shutdown and lock-out the compressor. 2. Shut off the oil pump.

5—9


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 an additional 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 Replacement The Duplex Oil Filter option allows for oil filter replacement without the necessity of shutting down the compressor in order to perform this routine maintenance task. Separate file chambers are incorporated with 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 attempt to remove the oil filter element until the oil pressure in that chamber is zero (O). Hot oil under pressure presents a safety hazard to personnel.

1. Using an Allen wrench, turn the bleed screw counterclockwise until the screw head touches the safety 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 reliable performance.

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

5—10

Maintenance

Lubrication Table 5—5 lists recommended intervals and the products necessary for proper lubrication of various Turbo Air 3000 Compressor components. Refer to Section Two, Compressor Specifications, for additional 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 Schedule Element

Interval

Lubricant [A]

Monitor daily. Change only as required.

Cooper Turbocompressor TurboBlendTM Lubricating Oil

Oil pump motor bearings

Six months

Table 2—2

Main drive coupling

Six months

Cooper Turbocompressor Coupling Grease

Drive motor ball bearings

[B]

Table 2—2

Drive motor sleeve bearings

[B]

Cooper Turbocompressor TurboBlendTM Lubricating Oil

Inlet guide vane actuator drive screw

Six months

High quality synthetic grease

Bypass valve (if applicable)

Six months

Molycoat® 33

Main oil reservoir

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 Oil Cooper Turbocompressor cannot specify a fixed interval between lubrication system oil changes because of the wide variety of operating conditions that exist. Therefore, the operator should inspect the oil visually daily to monitor changes and/or possible deterioration. Compare the appearance of oil from the reservoir 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 some contamination.

·

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

As the situation requires, have the oil tested for viscosity, acid, water and other contamination. A reputable commercial laboratory can easily detect the presence of any such contamination, Whenever the performance of the lubricating oil is suspect, Cooper Turbocompressor recommends additional testing for the presence of enhancing additives in accordance with The American Society for Testing and Material (ASTM) as defined in Table 2—1, Oil Specification.

5—11


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

Oil Pump Motor Bearing Lubrication Examine the compressor installation to determine the type of motor used. Although the standard Turbo Air compressor oil pump motor utilizes sealed bearings that do not require lubrication, some non-standard motors do require lubrication. The operator must identify the type of motor used in the installation 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 to periodically lubricate the oil pump motor. Use good quality, polyurea-based grease, adding 1/4 oz. (7 gm.) to each fitting. Table 2-2 offers acceptable motor bearing greases. It is not necessary to lubricate the oil pump coupling.

Main Drive Coupling Lubrication It is necessary to lubricate the main drive coupling every 6 months to meet the manufacturer’s specifications. (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 close the 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 Cooper Turbocompressor Coupling Grease into one of the holes in each sleeve until fresh grease flows from the opposite hole. WARNING: Use Cooper Turbocompressor Coupling Grease only. Other greases do not provide adequate protection.

5—12

Maintenance

4. Move the coupling center spool back and forth to verify free movement. (Total travel should be 0.160” 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 Lubrication The Turbo Air 3000 Compressor may be equipped with a squirrel-cage induction motor with ball bearings. The ball bearing grease must be changed in accordance with the motor manufacturer’s recommendations.

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

5—13


Inlet Guide Vane Assembly Drive Screw Lubrication The inlet guide vane assembly drive screw requires lubrication about every 6 months or as required. Be sure to use only recommended high quality, synthetic grease when performing this procedure. (Refer to Section 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 all surfaces thoroughly.

WARNING: Use only the recommended high quality, synthetic grease for this procedure. Under certain 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 the compressor. 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 bypass valve which requires periodic lubrication. The larger cylindrical, angled valve employed on higher rated machines (700 horsepower and larger) does not require lubrication. Both of these valves characteristically operate either in a fully opened or fully closed position. Every 6 months (or as required), it is necessary to lubricate the piston’s seals and guide rings of the smaller, box-shaped valve. Since other products do not provide the required level of protection and could gum up under service, use only the recommended lubricant. (Refer to Section 2, Specifications, and Section 7, Parts and Service, for full ordering information.)

5—14

Maintenance

Seal Kit

ebuildı it` Seal Kit

Lubricant

Figure 5—1 Bypass Valve

Figure 5—2 Bypass Valve

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

1. Completely shut down the compressor, lock out the motor starter and close the discharge block valve. 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 the bypass valve. 3. Remove the top plate to expose the spring and stem assembly and, using the stem assembly, push out the piston.

5—15


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

WARNING: If the bore appears damaged, do not attempt to rebuild the assembly. It will be necessary to 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 as required), lightly lubricate the piston bore and the seals on the piston assembly with the recommended grease.

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

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

5—16

Maintenance

Additional Maintenance Procedures In addition to periodic inspections and maintenance of the filter and lubrication systems, some maintenance will also be necessary on an “as required” basis. The necessity is determined by particular performance 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 Cooper Turbocompressor 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 Exchangers A decrease in heat exchanger performance is an indication that it may be necessary to clean the intercoolers, aftercooler and/or the oil cooler. The best indicator of the performance level of the intercoolers and aftercooler is the approach temperature. This is defined as the difference between the temperature of the air leaving the heat exchanger and that of the water entering the heat exchanger. Record that information for all heat exchangers when the compressor is first installed and running at full load. When an approach temperature increases by 15°F - 20°F (8°C - 11°C) above the original level, or when an Alarm condition occurs as a result 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 decrease in cooling capacity. The oil cooler should be cleaned whenever the intercoolers and aftercooler are 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 are utilized for different parts of the heat exchangers:

5—17


·

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

·

Fins The aluminum fins of the intercoolers and aftercooler must be cleaned using a high pressure air, steam, or water spray and then given an additional soaking with a commercial cleaning agent such as Coil BoilÒ.

Instructions for cleaning both the water and air sides of the intercoolers and aftercooler are included here, along with instructions for cleaning the oil cooler. Refer to Section Seven, Parts and Service, for complete information about ordering specified commercial products required for this procedure.

Intercoolers and Aftercooler Cleaning Water Side: Use a gun-cleaning or tube-cleaning kit for this procedure. Such commercially available kits come with a selection of brushes in varying sizes, making them ideally suited for this purpose. The recommended range of brush sizes is from 1/4” to 3/8” (6 to 10 mm), to allow the user to begin cleaning with a smaller 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 close the 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.

5—18

Maintenance

Front Tubesheet Gasket

Y-Gasket K-Seal

Upper Baffle Plate Intercooler Bundle

Header Gasket Figure 5—3 Intercooler Disassembly Water Cooler

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

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

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

5—19


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

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

WARNING: Be sure to follow the manufacturer’s instructions for safe handling and disposal of such products. 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 the descaling 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 the descaling agent to make contact with the intercooler fins. Failure to follow these instructions will cause component damage.

5. Allow the descaling agent to completely drain from the tubes, and then flush the tubes thoroughly with water. 6. Attach a 1/4” (6 mm) diameter soft bristle brush (nylon or brass) to a 20” (500 mm) long rod. Then connect 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 be constantly 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 Ubend. Forcing could cause damage to the tubes.

8. Repeat the previous step with the next larger brush size, progressing (using the same procedure with 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 the top 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 the descaling agent to make contact with the intercooler fins. Failure to follow these instructions will cause component damage.

5—20

Maintenance

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

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

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

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 cleaning agent such as Coil Boil.

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

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

5—21


Oil Cooler Cleaning Deterioration in oil cooler performance may be an indication that it is time to remove the mineral scale buildup 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 the cooler 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 a descaling agent such as Rydlyme.

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

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 to follow 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 thoroughly 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 entrapment in the cooler.

5—22

Maintenance

Discharge Air Check Valve Inspection At 6 month intervals, use the following procedure to inspect the discharge air check valve to determine whether 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 disc operates 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 the system 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 the centerline, 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 of proper orientation. Incorrect orientation will cause equipment damage.

5—23


5—24

Troubleshooting

Section Six: Troubleshooting In this section, the reader will learn about: ¨ General Considerations ¨ How to Use the Troubleshooting Guide ¨ How to Request Assistance ¨ Alarm and Trip Functions ¨ Drive Train Troubleshooting ¨ Control System Troubleshooting ¨ Air System Troubleshooting ¨ Lubrication System Troubleshooting

6—1


6—2

Troubleshooting

General Considerations This section includes suggestions that are designed to help answer questions or solve problems that may be encountered during operation of the Turbo Air 3000 Centrifugal Compressor. For troubleshooting purposes, the compressor installation is divided into four subsystems. These, along with relevant components or conditions, are shown in Table 6—1.

Compressor Installation Subsystems The 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 correct most problems. It may also be helpful to consult Section Two, Compressor Specifications, as well as any engineering drawings supplied separately.

6—3


How to Use the Troubleshooting Guide The Troubleshooting Guide that follows contains information compiled with the assistance of Cooper Turbocompressor Field Service supervisors. It is broken down into four subsections, one for each of the subsystems of the compressor installation. Each of the four subsections lists conditions that may be encountered during compressor operation. At the right of each Condition entry is a second list that mentions possible causes for that condition in order of likelihood. In the majority of cases, the operator should 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 to explore additional troubleshooting options. If this does not yield positive results, the operator should then return to the original Condition list and continue to troubleshoot until the correct solution is determined. If a problem still remains after considering all the Troubleshooting Chart suggestions, contact a Cooper Turbocompressor factory trained and authorized service representative for additional assistance and advice.

DANGER: When problems are encountered which are beyond the scope and experience of operating personnel, always request assistance from a Cooper Turbocompressor factory trained and authorized service representative. The Turbo Air 3000 Centrifugal Compressor is a high technology product, and improper servicing presents the risk of equipment damage and/or personal injury.

6—4

Troubleshooting

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

WARNING: For specialized service procedures, always use the services of a Cooper Turbocompressor trained and authorized service representative and only genuine Cooper Turbocompressor and JOY® replacement parts. Failure to heed this warning could seriously jeopardize the quality of the repair or replacement. For advice or service help, always contact your local authorized Cooper Turbocompressor sales and service representative. Refer to Section 7, Parts & Service, Aftermarket Support, for the name and address of your local representative.

6—5


Alarm and Trip Functions If compressor-operating parameters deviate from normal tolerances, the Vantage Control System will activate one of two levels of compressor protection. •

•

Alarm. An Alarm condition is a warning about a compressor operating condition that is outside of normal operating limits. The Alarm is intended to alert the operator to a condition that merits investigation, but does not present an immediate danger, or prevent the compressor from operating. Trip. A Trip condition is a protective measure initiated by the controller to safeguard the compressor. A compressor Trip condition requires immediate troubleshooting and correction before the compressor can be safely put back into operation.

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

Operator Response to an Alarm or Trip Condition In 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 panel display. 2. Press the Home, View, History, or Network key to acknowledge the alarm and to turn off any external devices installed to alert the operator. The source of the alarm is maintained in the Protect 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 its relationship to the Alarm and Trip set points. 5. Analyze the information, and then take any appropriate action(s) as required to prevent further deterioration of the Alarm condition to a dangerous level. In the case of a Trip condition, it is necessary to correct the cause of the Trip before attempting to restart the compressor.

Example The next sample screen shows a representative Alarm message, in this instance signaling abnormal oil pressure.

Operator Response With 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.

6—6

Troubleshooting

3. Press the Enter key and compare the current operating oil pressure from the previous Protection History screen to the Alarm and Trip set points. Protection History # 001 002 003 004 005 006 007 008 009 010

Date 09-01-01 08-24-01 08-20-01 08-08-01 07-28-01 07-01-01 06-18-01 05-30-01 05-03-01 03-29-01

Time 20:43:25 16:58:15 05:10:40 10:10:05 17:21:44 20:52:10 09:25:40 17:37:50 00:21:10 12:00:45

Type Alarm Low Trip High Alarm High Alarm High Alarm High Trip High Alarm High Trip High Alarm High Alarm Low

Description Oil Pressure Oil Temperature Oil Temperature Oil Temperature Water Flow 1st Stage Vibration 1 Stage Vibration E-Stop 3rd Stage Inlet Temp Water Flow st

Tag

Data

PT-159A TE-147 TE-147 TE-147

79.8 151 143 144

VT-192 VT-192

2.0 1.55

TE-136

137

Protection History screen showing a low oil pressure alarm of 15.8 psig. Protection (Running) Description 1: System Air Pressure 2: 3rd Stage Discharge Pressure 3: Drive Motor Current 4: Oil Pressure 5: Oil Temperature 6: 1st Stage Vibration 7: 2nd Stage Vibration 8: 3rd Stage Vibration 9: Inlet Air Filter 10: Motor Power

Tag PT-100 PT-106 IT-199 PT-159 TE-147 VT-192 VT-194 VT-196 DPT-107 JT-199

Trip Low

Alarm Low 70.0

70.0 60.0

80.0 70.0

Data 98.2 101.1 148 115 120 0.23 0.14 0.17 4.2 1014

Alarm High

Trip High

110.0 130.0 165 180 140 1.50 1.50 1.50 8.0

110.0 135.0 173 200 150 2.00 2.00 2.00

Protection Running screen showing current data with alarm and trip set points. 4. Analyze the information and take appropriate action(s) to correct the cause of the malfunction. (It may be necessary to consult the Troubleshooting guidelines, which follow.)

6—7


Drive Train Troubleshooting Condition:

Possible Causes:

Motor Vibration/Unusual Sounds Starter malfunction Foundation bolts loose Other mechanical part(s) loose Excessive or unbalanced voltage Lubrication inadequate or excessive Dirt on fan Dirt in air gap Bearings worn Misalignment Drive coupling worn

Motor Overheating Ambient temperature too high Ventilation inadequate Voltage low, high, or unbalanced Motor Overload Control settings improper Lubrication inadequate or excessive Ground inadequate Connections improper Wiring improper Starter malfunction Dirt in air gap Windings shorted Single phasing Motor seized Compressor setpoints improper

Gearbox Oil Leak(s) Ejector trap not filled Ejector pressure incorrect Reservoir vent filter clogged Splitline seal faulty Oil seal malfunction Seal damaged

6—8

Troubleshooting

Drive Train Troubleshooting...continued Condition:

Possible Causes:

Compressor Vibration Sensor Reading Faulty Wiring in control panel incorrect High Oil Temperature Low Oil Temperature Low Oil Pressure Oil type incorrect Oil contaminated Surging Motor Vibration Misalignment Drive coupling damaged and/or worn Impellers dirty or damaged Rotor cartridge malfunction

6—9


Control System Troubleshooting Condition:

Possible Causes:

Compressor Start Failure Drive motor starter not racked in EMERGENCY STOP button depressed Start permissives not met Control panel inoperative Main power fuses blown or faulty Drive motor starter malfunction(s): Thermal overload relays Main contactor· Power fuses Control transformer Wiring Start / Stop circuit faulty Current transducer circuit faulty Compressor Trip condition (corrective action required) Motor windings shorted Motor seized. EMERGENCY STOP Message EMERGENCY STOP button depressed Start / Stop circuit faulty. Sensor Reading Faulty Wiring to control panel faulty Control panel power supply voltage(s) incorrect Vibration probe incorrectly gapped Pressure sensing line defective Sensor failed. Control Panel Inoperative Power to panel interrupted Main Logic Module fuse defective or blown Wiring connection error Main Logic Module or User Interface Module failure. Control Panel Display Inoperative Main Logic Module inoperative Loose Display cable Contrast set incorrectly Display backlight failed Keypad failure.

6—10

Troubleshooting

Control System Troubleshooting...continued Condition:

Possible Causes:

Motor Overload Maximum amp set point too high Inlet valve or guide vane assembly inoperative Inlet valve or guide vane assembly out of adjustment Thermal overload relay set improperly Current transducer faulty Starter problem Motor problem. Control Valve(s) Faulty Wiring from control panel faulty. Instrument air supply interrupted (pneumatic valves). Instrument air supply pressure too low (pneumatic valves only). Inlet valve or guide vane assembly adjusted improperly. Malfunction of mechanical linkage of control valves. Control solenoid valve malfunction (bypass valve). Inlet guide vane assembly motor or drive coupling Malfunction. Valve failure. Pneumatic actuator failure. Current to pneumatic transducer failure (pneumatic valves 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.

6—11


Air System Troubleshooting Condition:

Possible Causes:

High Air Pressure Low demand Air Pressure setpoint too high Sensor Reading Faulty Control Valve(s) Faulty Low Air Pressure Air Pressure setpoint incorrect Maximum Amp setpoint incorrect Air demand above compressor rating Sensor Reading Faulty Inlet air filter dirty or restricted Ambient air temperature excessive Impellers dirty Control Valve(s) Faulty

High Air Temperature Water flow to cooler(s) insufficient Coolant temperature too high Sensor Reading Faulty Intercooler(s)/aftercooler fouled Hot air bypassing intercoolers/aftercooler Coolant bypassing intercoolers/aftercooler Surging

Surging Air Pressure setpoint too high Sensor Reading Faulty Inlet air filter dirty or restricted Minimum Amp setpoint too low Control Valve(s) Faulty High Air Temperature Bypass silencer fouled

Check Valve Malfunction Valve oversized Seat or disc worn or dirty Disc movement impaired 6—12

Troubleshooting

Lubrication System Troubleshooting Condition:

Possible Causes:

Oil Leak(s) Connection loose Filter cartridge loose Gearbox Oil Leak(s) Pump shaft seal worn or damaged

Oil Mist Ejector vent filter clogged Filter trap not filled Ejector pressure incorrect

High Oil Temperature Water flow to cooler insufficient Coolant temperature too high Oil cooler fouled Sensor Reading Faulty Thermal mixing valve faulty Oil heater thermostat faulty

Low Oil Temperature Water flow through coolers excessive Sensor Reading Faulty Thermal mixing valve faulty or missing Oil heater thermostat faulty or missing

High Oil Filter Differential Pressure Oil filter element dirty or clogged Sensor Reading Faulty

High Oil Pressure Pressure regulator set improperly or malfunctioning Low Oil Temperature Sensor Reading Faulty

6—13


Lubrication System Troubleshooting...continued Condition:

Possible Causes:

Low Oil Pressure Oil level too low Pressure regulator set improperly or malfunctioning Fuses in pump motor starter blown or faulty Oil filter element dirty or clogged High Oil Temperature Leakage within gearbox Sensor Reading Faulty Pump motor starter overloads tripped Wiring or pump motor or starter incorrect Pump rotation incorrect Pump seized Pump coupling damaged Pump suction line restriction

Main Oil Pump Malfunction Sensor Reading Faulty Pump suction line restricted Pump coupling damaged Pump damaged Oil filter element dirty or clogged Pressure regulator set improperly or malfunctioning Oil level too low

6—14

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 Parts Inventory ¨ The Professional Inspection Parts Requirement ¨ Control System Parts ¨ Lubrication System Parts ¨ Main Drive Coupling Parts ¨ Heat Exchanger Parts ¨ Air Piping Parts

7—1


7—2

Parts and Service

Aftermarket Support As an important part of its commitment to its products and customers, Cooper Turbocompressor offers full aftermarket support. The array of aftermarket services includes inspection and repair, availability of genuine JOY® and Cooper Turbocompressor parts and recommended supplies, and compressor operator training 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 not attempt inspection, maintenance, or service procedures other than those described in this 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 service representative.

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

Parts Coordinator or

Field Service Department Cooper Turbocompressor 3101 Broadway PO Box 209 Buffalo, NY 14225-0209 USA Phone: (716) 896-6600 Fax: (716) 896-1233

7—3


Parts Ordering Procedure Since specific compressor models and installations may vary, always be sure to have the following information 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 Availability When ordering replacement and some spare parts, keep in mind that some parts are not available on an individual basis, and must always be purchased in sets. In addition, in certain instances Cooper Turbocompressor may change the part number and/or may substitute a part of equal or greater reliability without notice.

The Returned Goods Policy It is necessary to contact Cooper Turbocompressor for authorization before the return of any goods to the factory. All approved returns are immediately assigned a tracking number to prevent processing delays or loss of materials. This ARG (authorization to return goods) tracking number is then recorded at the factory. Senders must include the assigned ARG tracking number on the outside of the shipping container whenever goods are being returned. No goods may be returned to the factory without prior authorization and an assigned ARG tracking number.

7—4

Parts and Service

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

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

7—5


Recommended Periodic Maintenance Parts & SuppliesDescription QtyTurbocompressor

Description

Qty

Cooper Turbocompressor Part Number

Filters: · 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 P1401435-01233 Lubricants: [C] P1405340-00294 · TurboBlendTM Lubricating Oil (5-gallon / 20-liter pail) · 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 P1405340-00270 Parts: 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 P1405680-00002 Bypass Valve (Figure 7—15) · Rebuild Kit [E] 1 MB408539-00098 · Seal Kit [E] 1 MB408539-00202 Discharge 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 P0540024-00183 Main Drive Coupling (Figure 7—8) · O-Ring 2 P1406064-20018 · Gasket 2 P1406064-04117 Condensate 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 P1401581-00757 Instrumentation (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 Specific Notes: [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

7—6

Parts and Service

The Professional Inspection Parts Requirement Table 5—3, Service Inspection Checklist outlines the in-depth examination procedures to be performed with a Cooper Turbocompressor trained and authorized representative. These important preventative maintenance tasks involve removal of the gearbox cover to examine the gears, bearings and seals and exposing 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—2 lists the parts and supplies necessary for the Professional Inspection of the compressor. Some of these parts 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 Cooper Turbocompressor replacement parts and Cooper Turbocompressor approved supplies. Cooper Turbocompressor will accept no liability for damages caused by use of nonauthorized parts, supplies, or service.

7—7


Professional Service Inspection Parts & Supplies Description

Qty


Gearbox: · O-Ring, First Stage Inlet 1 · O-Ring, Second Stage Inlet 1 · O-Ring, Third Stage Inlet 1 · Seal, First Stage Diffuser 1 · Seal, Second Stage Diffuser 1 · Seal, Third Stage Diffuser 1 · O-Ring Lubricant 1 · Gearbox Splitline Sealant 1 Heat Exchangers: (Figures 7—9 & 7—10) · K-Seal 3 · Y-Gasket 6 · Head Gasket 3 · Front Tubesheet Gasket 3 · Rear Header Gasket (S-Tube Type Only) 3 Lubrication System: · Oil Cooler Gasket Kit [A] 1 · Oil Reservoir Vent Filter Element 1 · Oil System Filter Element (Single Filter Type) 1 · Oil System Filter Element (Dual Filter Type) 2 Filters: · Inlet Air Filter, Primary Element [B] · Inlet Air Filter, Secondary Element [B] Control Valves: Inlet Guide Vane (Figure 7—13) · Gasket, Inlet Guide Vane, 6” (150 mm) 1 · Gasket, Inlet Guide Vane, 8” (200 mm) 1 · Grease, Inlet Guide Vane Drive Screw 1 Bypass Valves (Figure 7—15) · Seal Kit [D] 1 · Grease, Valve [C] 1 · Seal and Rebuild Kit [D] 1 · Bypass Valve Air Line Filter Element [E] 1 Drive Motor: Main Drive Coupling (Figure 7—8) · O-Ring 2 · Gasket 2 · Grease, Coupling 1 Main Drive Motor · Grease, Ball Bearing 1 Notes: [A] For standard size cooler. Refer to Tables 7—6 and 7—7 for verification of oil cooler [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

7—8

P1406702-00395 P1406702-00386 P1406702-00383 P1794323-00005 P1794323-00002 P1794323-00002 R1409584-00000 R1405571-00012 P1408800-04941 P1408800-04926 P1793932-02100 P1793931-02100 P1793932-02101 P1405680-00002 P1404987-00014 P1404040-00207 P1401435-01233 [B] [B]

P1409511-00000 P1409511-00001 P1405340-00288 MB408539-00098 P1405340-00270 MB408539-00202 P0540018-00074

P1406064-20018 P1406064-04117 P1405340-00264 P1405340-00289 sizing and/or part number.

Parts and Service

07

Control System Parts 02/12 11

01

05 04/06/14/15

03 17

13

Figure 7—1. Control System Sensors

Item No.

Description

01 02 03 04 05 06 07 11 12 13 14 15 16 17 18 Notes:

[A] [B] [C] [D]

Qty

Standard Instrumentation: Vibration Probe, Stage 1 1 Vibration Probe Extension Cable (10 ft / 3 m) 1 RTD, Inlet Air Temperature, Stage 2 or 3 [A] 1 Transducer, System Gas Pressure 1 RTD, Oil Temperature 1 Transducer, Oil Pressure after the Filter 1 Tranducer, Drive Motor Current 1 Optional Instrumentation: Vibration Probe, Stages 2 and/or 3 1-2 Vibration Probe Extension Cable (10 ft / 3 m) 1-2 RTD, Inlet Air Temperature, Stage 2 [A] 1 Transducer, Compressor Discharge Pressure [B] 2 Transducer, Oil Pressure before the Filter [C] 1 RTD, Miscellaneous Temperatures (Not Shown) [D] 1-5 Switch, Oil Reservoir Level 1 Transducer, Air Filter Differential Pressure [D] 1 Air temperature into the last stage of compression is standard. Alternate locations are supplied as options. Required for all control methods. Reguired for filter differential pressure measurement. Shipped loose for field installation.

Cooper Turbocompressor Part Number P1407030-02002 P3403893-00006 P3403629-01585 P0540089-00182 P3403629-01585 P0540089-00182 Contract Specific P1407030-02002 P3403893-00006 P3403629-01585 P0540089-00182 P0540089-00182 P3403629-01585 P0540061-00199 P0540089-00059

Table 7—3. Control System Sensors

7—9


Control System Parts

01

03

02

04

(GEARBOX COVER)

(OIL/AIR SEAL)

(PINION) Figure 7—2. Vibration Probe Installation

Item No. 01 02 03 04 05 Notes:

Description Vibration Probe Retaining Plate Capscrew Tube Fitting Silicone Adhesive [A] [A] Apply adhesive to threads of capscrew and tube fitting.

Table 7—4. Vibration Probe Installation

7—10

Qty


1 1 1 1 1

P1407030-02002 P1407301-00003 P0902224-00412 P1791399-03539 R1405571-00005

Parts and Service

Control System Parts

02

01

03

04

08

07

06

05

Figure 7—3. Low-Voltage Compartment/Vantage Control Components Item No.


Description

01 02

User Interface Module (UIM) Main Logic Module (MLM)

03

Actuator Motor Capacitor*

04 05

Qty

P3798102-00010 P3798102-00000

1 1 1

Control Relays (optional)

P0540107-00012 P0540107-00019 Contact factory

1-4

Vibration Transmitters

P3403893-00416

3

06

Pressure Transmitters

P0540089-00140

2

07

Display Cable

P3798102-00020

1

P0540056-00221

1

08 Emergency Stop Button * If Required Table 7—5. Vantage Control Panel Components

110 VAC 220 VAC

7—11


Lubrication System Parts 09

12 11 10

Nut

Filter Housing

12 Nut Figure 7—4. Reservoir Vent Filter Assembly Item No. 01 02 03 04

05 06 07

08

09 10 11 12 13

Description Main (shaft-driven) Oil Pump Drive Coupling, Main Oil Pump Auxiliary (motor-driven) Oil Pump Motor, Auxiliary Oil Pump - 230-460 Volt / 60 Hz - 220-380 Volt / 50 Hz - 380 Volt / 60 Hz - 400, 415 & 440 Volt / 50 Hz - 400 Volt / 50 Hz (CE Mark) - 440 Volt / 60 Hz Drive Coupling, Auxiliary Oil Pump Pressure Regulator (Relief Valve) Cooler, Oil-to-Water (Heat Exchanger): - Complete Unit with 0.375” (10 mm) dia. copper tubes - Maintenance Gasket Kit Filter: - Complete Assembly - Replacement Element Reservoir Vent Assembly (Figure 7—4): - Ejector - Filter (complete assembly) - Replacement Filter Element - Filter Seal Kit Level Gauge

Table 7—6. Standard Lubrication System Components

7—12

Qty


1 1 1

P1401428-00614 P1402070-00254 P1401428-00604

1 1 1 1 1 1 1 1

P1402068-00728 P1402068-00728 P1402068-00732 P1402068-00728 P1402068-00734 P1402068-00735 P1402070-00249 P1401581-01707

1 1

P1401429-00981 P1405680-00001

1 1

P1401435-00289 P1404040-00207

1 1 1 1 1

P1403262-00107 P1401435-00228 P1404987-00014 P1401435-00229 P1401582-00014

Parts and Service

Lubrication System Parts

Figure 7—6. Reservoir Level Switch Option

Figure 7—5. Duplex Oil Filter Option Figure 7—7. Reservoir Heater Option Item No. 14

15

16 17 18

Notes:

Description

Qty


Cooler, Oil-to-Water (Heat Exchanger): [A] - Complete with 0.375 (10mm) dia. 90/10 alloy tubes [B] 1 - Maintenance Gasket Kit 1 Duplex Filter (Figure 7—5): [A] - Complete Assembly 1 - Replacement Element 2 Level Switch (Figure 7—6) [A] 1 Temperature Regulator [A] 1 Oil Heater (Figure 7—7): [A] - 230 Volt 1 - 380 Volt 1 - 400 Volt 1 - 415 Volt 1 - 440 Volt 1 - 480 Volt 1 - 575 Volt 1 [A] Not all lubrication systems are equipped with these optional features. Most retrofitted after the compressor has been shipped from the factory. [B] Direct replacement for P1401429-00981.

P1401429-01002 P1405680-00001 A3401435-00232 P1401435-01233 P0540061-00199 P1401581-01347 P0540063-00157 P0540063-00176 P0540063-00320 P0540063-00190 P0540063-00332 P0540063-00155 P0540063-00156 of these features can be

Table 7—7. Optional Lubrication System Components

7—13


Main Drive Coupling Parts

01 O-RING SLEEVE

BOLT GASKET 02

NUT

KEY

HUB

SPACER

BULLGEAR SHAFT

KEY

DRIVER SHAFT

BAFFLE PLATE

BAFFLE PLATE SLEEVE O-RING 01

HUB

GASKET 02

LUBE PLUG (2 PER SLEEVE) NUT

BOLT

Figure 7—8. Main Drive Coupling Assembly

Item No. 01 02 03

Description O-Ring Gasket Grease

Table 7—8. Main Drive Coupling Maintenance Parts

7—14

Qty 2 2 1

Cooper Turbocompressor Part Number P1406064-20018 P1406064-04117 P1405340-00264

Parts and Service

Heat Exchanger Parts

Front Tubesheet Gasket 04

Y-Gasket 02

01 K-Seal Upper Baffle Plate Intercooler Bundle

Header Gasket 03 Water Header Figure 7—9. Intercooler/Aftercooler Bundle Assembly Standard U-Tube Model

Item No. 01 02 03 04

Description K-Seal Y-Gasket Header Gasket Front Tubesheet Gasket

Qty 3 6 3 3

Cooper Turbocompressor Part Number P1408800-04941 P1408800-04926 P1793932-02100 P1793931-02100

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

7—15


Heat Exchanger Parts

Rear Water Header Gasket 05 K-Seal 01

Y-Gasket 02 Front Tubesheet Gasket 04

Upper Baffle Plate Intercooler Bundle

Header Gasket 03 Water Header Figure 7—10. Intercooler/Aftercooler Bundle Assembly Optional S-Tube Model

Item No. 01 02 03 04 05

Description K-Seal Y-Gasket Header Gasket Front Tubesheet Gasket Rear Header Gasket

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

7—16

Qty


3 6 3 3 3

P1408800-04941 P1408800-04926 P1793932-02100 P1793931-02100 P1793932-02101

Parts and Service

Heat Exchanger Parts 03

03 01 02

Figure 7—11. Solenoid-Operated Condensate Draining System (One set required for each heat exchanger) Item No. 01 01 02 03

Description

Qty

Solenoid Valve, 1/2” NPT, 110/120-Volt Solenoid Valve, 1/2” NPT, 220/240-Volt Check Valve, 1/2” NPT Gate Valve, 1/2” NPT


1 1 1 2

P1401581-01302 P1401581-01341 P1401581-01303 P1401581-00757

Table 7—11. Solenoid-Operated Condensate Draining System (One set required for each heat exchanger) 04

Vent Air Discharge Line 01

01

03 T Heat Exchanger

Drain Line

02

Figure 7—12. LiquidatorTM Pneumatic Condensate Drain System Figure 7—13. LiquidatorTM Pneumatic Condensate Drain Trap Item No. 01 02 03 04 05 --

Description Liquidator Drain Trap Gate Valve, 1/2” NPT Check Valve, 1/2” NPT Ball Valve, 1/4”-NPTF Tube Fitting, 1/4”-TUBE / 1/4”-NPTM Condensate Kit (containing all the above parts)

Qty


1 2 1 1 3 1

P1797145-00000 P1796081-00007 P1401581-01303 P1401581-01450 P0902962-00044 MB408187-00100

Table 7—12. LiquidatorTM Pneumatic Condensate Draining System Components (One set required for each heat exchanger) 7—17


Air Piping Parts

Inlet Guide Vane Assembly 01

01

02

Figure 7—14. Inlet Air Piping Components

Item No. 01 02

Description Startup Screen (for 8” pipe) Expansion Joint (for 8.625” O.D. pipe)

Table 7—13. Inlet Air Piping Components

7—18

Qty 1 1

Cooper Turbocompressor Part Number P1405344-00016 A3404999-00000

Parts and Service

Air Piping Parts 05

04 02, 03

01

06

07

Figure 7—15. Inlet Guide Vane and Actuator Assembly

Item No.

Description

Qty

Cooper Turbocompressor Part Number 6” (150mm)

01 02 03 04 05 06 07 Notes:

Inlet Pipe Reducer 1 Pipe Couping 1 Gasket, Pipe Coupling 1 Inlet Guide Vane Assembly 1 Gasket, Inlet Guide Vane 1 Actuator Assembly, 110/120-Volt 1 Actuator Assembly, 220/240-Volt 1 Actuator Motor, 110/120-Volt [A] 1[A] Actuator Motor, 220/240-Volt [A] 1[A] [A] The actuator motor is included in the actuator assembly.

P1409508-00000 P1404961-00200 P1404961-00602 A3409140-00200 P1409511-00001 A3408596-03000 A3408596-03050 P1408596-00100 P1408596-00500

8” (200mm) P1409508-03000 P1404961-00209 P1404961-00607 A3409140-00100 P1409511-00001 A3408596-03000 A3408596-03050 P1408596-00100 P1408596-00500

Table 7—14 Inlet Guide Vane and Actuator Components

7—19


Air Piping Parts

02

01 Figure 7—16. Inlet Air Filter Assembly

Item No. 01 02 03 04 Notes:

Description


AI-128-V Type [A] Primary Filter Element [C] P1400009-00770 Secondary Filter Element [C] P1400009-00771 AI-128 Type [B] Primary Filter Element [C] P0540009-00089 Secondary Filter Element [C] P0540009-00090 [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

7—20

Qty

Parts and Service

Air Piping Parts Figure 7—17 Bypass Valve Assemblies and Packaging Options 01, 02

04 04

01, 02 03 03 05, 06

05, 06

09

01, 08

07, 08

01 01

Item No.

01

02 03

04 05 06 07 08 09 Notes:

Description

Qty

Bypass Valve: - 120 V / 60 Hz 1 - 220 V / 50-60 Hz 1 Kit, Seal or Rebuild 1 Solenoid Valve: - 60 Hz 1 - 50 Hz 1 Metering Valve 1 Air Line Filter 1 Air Line Filter Element 1 Pipe Coupling Housing [C] 2 Pipe Coupling Gasket [C] 2 Flange Gasket [C] 1 [A] Compressor Power Rating. [B] Included with Item #01. [C] Parts for the packaging option. See figures above.

Cooper Turbocompressor Part Number <600 Hp [A]

>700 Hp [A]

P1401581-01256 P1401581-01259 MB408539-00098

P1401581-01501 P1401581-01501 MB408539-00202

[B] [B] P1409585-00000 P0540016-00091 P0540016-00074 P1404961-00628 P1404961-00259 (Not Required)

P1401581-01166 P1401581-01233 P1409585-00000 P0540016-00073 P0540016-00074 P1404961-00603 P1404961-00604 P0907411-00008

Table 7—16 Bypass Valve Assemblies and Packaging Options Components

7—21


Air Piping Parts

Volume Booster Diaphagm Actuator

Filter Regulator

Transducer

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

Control Valve

Item No. 01

Notes:

Description


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 [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

7—22

Qty

Parts and Service

Air Piping Parts Actuator Figure 7—19. Blow-Off Silencer Solenoid Filter Regulator

Lock-Out Valve Valve Body Figure 7—20. Discharge Air Check Valve

Figure 7—21. Automatic Block Valve Assembly

Connections Model Inlet [A] BMSV-8 BMSV-6 BMSV-8 LCV-10 Notes:

Discharge [A]

Overall Length

2” (NPT)[B] 8” (Flanged) 78” (2000 1 1/2” (Flanged) 6” (Flanged) 65” (1650 2” (Flanged) 8” (Flanged) 78” (2000 3” (Flanged) 10” (Flanged) 71” (1800 [A] Expressed per ANSI (USA) Standards for piping (in inches). [B] Taper-Threaded. National (USA) Pipe Thread (in inches).

mm) mm) mm) mm)


Table 7-18. Blow-Off Silencers Description 3” 3” 4” 4”

Valve Valve Valve Valve


Table 7-19. Discharge Air Check Valves Description 3” 3” 4” 4”

Valve, Valve, Valve, Valve,

110/120-Volt 220/240-Volt 110/120-Volt 220/240-Volt


Table 7—20. Automatic Block Valve Assemblies

7—23


7—24

Installation

Appendix A Installation 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 Initial Startup Schedule ¨ The Initial Startup Procedure ¨ Service Assistance

A—1


A—2

Installation

General Considerations Advance planning and preparation will help to simplify and expedite the compressor installation process. This Installation Appendix gives an overview of the entire process, from preliminary site preparation to the final preparations before the initial startup. The Installation Work Schedule lists the various considerations that the owner must address before and during the installation process, up to and including the initial startup procedure. During the Initial Startup Service Inspection, the Cooper Turbocompressor trained and authorized service representative will thoroughly inspect the installation work completed including all peripheral piping and electrical work. He will check the lubrication system, adjust the control system (if necessary), verify motor alignment, start the compressor and instruct operating personnel. For more information about specific procedures and/or illustrations of particular arrangements, refer to the appropriate subsection in this appendix or other relevant appendices.

A—3


The Installation Work Schedule Before beginning the actual compressor installation process, the installer should review this Installation Work Schedule for an overview of the various considerations and procedures involved. Each aspect of the installation listed in this schedule is fully described in subsequent text and/or Section Two, Compressor Specifications. Before delivery, review all technical documents provided, including the Installation Manual and all relevant specifications and drawings supplied separately. 1. Select a well-suited location in accordance with the minimum recommended space requirements for the compressor and future maintenance. 2. Review the list of parts, supplies, tools, and labor that the owner must supply at installation, and arrange 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 foundation, piping, and electrical connections, or (if necessary) arrange for suitable storage for the compressor until the time of installation. 4. At least two weeks before the projected initial startup date, contact a Cooper Turbocompressor representative to schedule startup assistance. 5. Upon its arrival, inspect the compressor and check loose-shipped equipment against the packing list; 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 may be 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 Cooper Turbocompressor. When included from the factory, considerable savings can be realized at installation. Details of these options are included later in this manual.

A—4

Installation

Labor, Supplies, Equipment, and Tools It is the owner’s responsibility to prepare the site and to provide any necessary labor, supplies, tools, or additional 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 tools necessary for installation and future maintenance. Since the Turbo Air 3000 Compressor is designed for easy installation, most of the tools or supplies required should be already on hand or easily available.

Materials Required for Compressor Installation Supplies Foundation 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

A—5


Site Considerations Select the installation site and make any required preparations before compressor delivery. This will allow for a quick startup shortly after the equipment arrives. When selecting and preparing the installation site, also keep in mind that equipment located in a well planned, easily accessible area generally gets better attention from operating and maintenance personnel. The standard Turbo Air 3000 Compressor is designed for indoor installation. For outdoor installation, it is necessary to purchase the optional TEFC motor and NEMA-4 electrical option as part of the package.

Environment A clean environment is important for optimal performance. Locate the compressor inlet air filter away from chimneys, cooling towers, steam exhausts, or any other possible sources of air contamination with foreign matter. In particular, be sure to locate the air filter at least 10 ft. (3.3 m) above ground level and at least 6 ft. (2 m) from any window, wall, or roof to further isolate it from any airborne contaminants. When selecting an outdoor installation site, consider prevailing and local ground wind patterns as well as the immediate atmospheric conditions surrounding the unit. Such factors may have long-term effects on overall compressor operation.

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

Envelope Provide an adequate envelope (space allowance) around the unit. Figure A—1 illustrates the recommended minimum envelope in keeping with the compressor’s overall dimensions. Allow an additional 3 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 and aftercooler bundle removal.

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

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

A—6

Installation

Water Supply and Drains If water is to be used as the coolant, whenever possible provide clean cooling water with low mineral content. This will optimize cooler performance and significantly reduce the possibility of cooler fouling during operation. Also, be sure to provide adequate open drains to carry away condensate from the intercoolers and aftercooler. Condensate from the Turbo Air 3000 Compressor is completely oil-free and environmentally safe. (Refer to the Utility Piping subsection for additional information and requirements for water supply and condensate drain piping.)

Foundation The Turbo Air 3000 Compressor can be installed directly onto the factory floor so long as the floor meets the following minimum requirements: · It must be constructed of good quality, reinforced concrete to provide a rigid and substantial base. · 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).

78 inches (2000mm)

134 inches (3400mm)

72 inches (1800mm)

Figure A—1. Compressor Envelope

A—7


Process Air Piping The process air system includes three subsystems: the inlet air piping, the discharge air piping, and the bypass piping arrangements. The Process and Instrumentation Diagram provided separately illustrates only the various compressor system components supplied by Cooper Turbocompressor. The user must provide 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 are the “lifelines” of any compressor installation. Improperly designed piping systems may cause later problems. The most common reason for compressor control problems is failure to follow the discharge piping installation guidelines and/or the requirements listed on the contract specificdrawings transmitted separately. If requirements and specifications are not met, the improperly designed 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 appropriate service piping to and from the compressor. Failure to follow the requirements and recommendations listed will cause mechanical failure, property damage, serious injury, and/or death.

A—8

Installation

G

E F D

A 1/2” Instrument Line

C

C

B

A. Inlet Filter B. Inlet Screen C. Expansion Joint D. Check Valve E. Block Valve F. Blowoff Valve G. Silencer

Figure A—2. Typical Process Air Piping

A—9


Inlet Air Piping Figure A— 4 shows a typical inlet air piping arrangement in detail, including various standard and optional components.

A. B. C. D. E. F.

A

F

12” Recommended Pipe Size C

B

Inlet Filter Silencer Pipe Reducer Inlet Startup Screen Inlet Expansion Joint Inlet Guide Vane (IGV) IGV Motor

D

STG. 1

B

E

Figure A—4. Inlet Air Piping When designing and installing the inlet air piping, it is important to carefully consider the following information and recommendations.

Connection The inlet air connection to the Turbo Air 3000 Compressor is a cast iron reducer, the outside of which matches standard steel pipe. (American National Standards Institute: ANSI B36.10). This inlet reducer may be removed and machined to accept a number of different style couplings, thus allowing the installer 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 Inlet Expansion Joint options are also included in this arrangement. Refer to relevant headings for more information about these components.) Do not make the final inlet air pipe connections to the compressor. The Cooper Turbocompressor representative must inspect the piping for cleanliness during the startup service call before the final connection is made.

A—10

Installation

Inlet Guide Assembly Inlet Startup Screen

Inlet Expansion Joint

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

Piping Material When selecting the pipe to be used, it is advisable to either select corrosion-resistant piping or, alternatively, 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 compressor itself. In those instances when fiberglass piping will be used for the inlet air lines, be sure to follow these recommendations: · 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.

Drains Provide adequate drains at low points to accommodate the condensate that collects on the inlet line during compressor shutdown periods. This will deter rusting and eventual erosion of aerodynamic components, either of which would otherwise reduce overall compressor performance and component life span.

Fabrication Use 8” or larger (or comparable size) pipe to connect the inlet air filter to the compressor. Do not use pipe smaller than 8” (or comparable size), since the smaller size will cause reduced inlet air pressures and impaired compressor performance. Provide a straight run of approximately four pipe diameters before the inlet guide vanes (IGV’s) to minimize flow distortion. Also, avoid using many elbows and sharp bends in the compressor inlet piping.

A—11


Inlet Expansion Joint Cooper Turbocompressor recommends the use of the Inlet Expansion Joint option (which consists of a rubber 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 pipe size; larger pipe is in fact preferable, since the increased volume will reduce both noise and pressure loss.

Inlet Air Startup Screen The inlet piping must be designed to prevent any solids from entering the compressor inlet. When long runs 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 air supply before they can reach the compressor and damage internal components. In such instances, it is important to locate the screen as close as possible to the compressor inlet. The Inlet Air Startup Screen is shown in Figure A—6.

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

Outer Screen (10 x 10 Mesh / .32 wire) Inner Screen (8 x 8 Mesh / .063 wire) 8” (200mm) Material: 302 or 304 Stainless Steel

12” (300mm) Figure A—6. Inlet Air Startup Screen

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

A—12

Installation

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

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. Aftercooler B. Flexible Pipe Coupling C. Victaulic Flange (option) D. Check Valve E. Block Valve

3 4 A

5 Recommended Pipe Size B

1

C 4”

4” 2 D

E

Figure A—7. Typical Discharge Air Piping Arrangement When designing and installing the discharge air system, the following information and recommendations should be taken into consideration.

Connection The compressor discharge air connection is machined to accept a Victaulic pipe coupling. When attaching the discharge pipe, refer to the contract-specific Installation Arrangement Drawings supplied separately for specific size information. Cooper Turbocompressor offers the following coupling options: · Straight Coupling · Reducing Coupling · Vic-Flange Adapter

A—13


Piping Material While corrosion on the discharge air side does not present the same problem as it does on the intake air piping, it is still a concern. Rust can damage delicate instrumentation, pneumatic tools, or processes that 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 also advises against using soldered copper fittings and rubber hoses in discharge air piping. If fabricating the air piping with flexible joints and flexlines, be sure that they meet the operating parameters of the system. Cooper Turbocompressor recommends that all pressure-holding pipe be in accordance with the standards established by the American National Standards Institute (ANSI) as well as the American Society of Mechanical Engineers’ (ASME) Standard B31.8-1986.

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

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

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

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

Depending on the control method utilized, the pressure-sensing lines should be located either before and/or after the check valve. Refer to the Flow Schematic and Installation Arrangement drawings supplied separately for specific placement. With all control methods, it is necessary to keep the pipe volume between the compressor discharge connection, the discharge check valve, and the blow-off or bypass valve minimal. For proper operation of the discharge check valve, 18” (450mm) of straight piping should precede and follow the valve.

A—14

Installation

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

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

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

Discharge Check Valve A discharge check valve must be included in the discharge piping arrangement to prevent the reverse flow of air through the compressor during unloaded operation. (Refer to the Engineering drawings supplied separately for the precise location of the discharge piping.) Cooper Turbocompressor supplies a contoured, disc-type check valve that must be mounted properly so as to pivot open and close. It is necessary to install this valve in a horizontal run of piping, with a recommended minimum of four pipe diameters of straight pipe before and after the valve. In order to hold the valve disc in a fully opened position, a flowing differential pressure of 0.5 psi (0.3kPa) is required. If the valve is not correctly sized (particularly if it is oversized), the potential for shut-off failure is increased. Before installing the check valve, refer to the Check Valve Installation drawing and examine 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 that the orientation of the valve is correct. Cooper Turbocompressor will not accept responsibility for damage or personal injury incurred as a result of improper installation of the check valve.

A—15


Block Valve All compressor installations must include a block valve to insulate the compressor from the remainder of the pressure system in case of a check valve failure. The user must supply the block valve, which must be 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 being serviced or otherwise not functional.

Automatic Block Valve Option The Automatic Block Valve option fits between two 150-lb. ANSI raised-face flanges in the discharge air piping. The recommended installation is after the aftercooler (if so equipped) and at least four pipe lengths 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 during compressor service. The valve actuator requires a 60-psig air supply for a three-stage compressor or a 30-psig air supply for a two-stage compressor. If available, use the instrument air supply; alternatively, tap the pipe located immediately upstream of the valve itself. The supply air should be connected to the lockout valve on the 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 Piping Depending on the control method being applied, the Turbo Air 3000 will either completely or partially unload whenever the capacity of the compressor exceeds the compressed air system’s demand. Under AUTO-OFFLINE control, the compressor is unloaded by completely bypassing the compressed air system and venting discharge air back to the inlet of the compressor or out to atmosphere. In other cases, a portion of the discharge air is partially vented or blown-off in order to maintain Constant Pressure or constant mass flow into the compressed air system.

Bypass Valve The AUTO-OFFLINE Control method utilizes a pop-action bypass valve (BPV). The BPV operates in either a fully open or fully closed position. The compressor owner/installer is responsible for the proper installation of this control valve (which is shipped separately) unless the Mounted Bypass Valve option is purchased. (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 position from fully closed to fully open. A pneumatic actuator, and I/P transducer, a volume booster and a filter regulator 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.

A—16

Installation

Valve Installation In 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 check valve. (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 pipeline and the venting valve) is 10 ft. (3 m). The size of the bypass or blow-off valve piping should match the size of the valve itself. Figure A—8 shows the correct installation of the control valve when it is owner installed.

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

A. B. C. D. E. F. G.

Compressor Flange Check Valve Block Valve Bypass or Modulating Blow-Off Valve I/P Transducer Filter Regulator Source of Instrument Air

1. To compressed air system 2. Control signal from control panel 2 IP E

G

FR F

Vent D

H

Recommended Pipe Size

4” A

3”

3” B

1 C

Figure A—8. Blow-Off Piping Detail

Mounted Bypass Valve Option The Mounted Bypass Valve option is available with the AUTO-OFFLINE Control method only. In such instances, the valve is installed between the compressor inlet and the discharge piping and is electrically connected to the Vantage Control Panel. Including this option with AUTO-OFFLINE applications eliminates the necessity for owner installation of the control valve. When this option is factory installed, the bypass air is re-circulated to the compressor inlet. This also eliminates the necessity for separate atmospheric vent piping as well as for the Vent Silencer option described under Sound Suppression. A—17


Sound Suppression Inlet and discharge air piping are major sound emitters in any compressor installation. For greater sound suppression, insulate local surfaces with sound absorbing materials. For maximum sound suppression, 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 inlet flange. · 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 Cooper Turbocompressor Engineering Data Release EDR-A-005, Insulation for Noise Control, available upon request.

Vent Silencer Since the high-pressure air expansion across the blow-off valve creates considerable noise, Cooper Turbocompressor recommends using the Vent Silencer option to reduce noise produced during compressor operation. (This option is not required in instances when the Mounted Bypass Valve option is included in the package.) For maximum effectiveness, this silencer must be properly installed directly on the blow-off valve or the bypass valve. Any additional piping should be the same size as the silencer discharge flange, and may be extended beyond the silencer. The exhaust piping from the silencer should be sized for a maximum back 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 airborne noise is directional, aim the discharge in a non-critical direction. Do not direct the exhaust pipe onto a hard surface which could cause resonance.

Cut at sharp angle to increase exit area

Figure A—9. Angled Pipe End

A—18

Discharge

Installation

Utility Piping The utility piping is defined as any piping, tubing or electrical conduit external to the compressor package, which support subsystems required to complete the compressor installation. Included in this category 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 the basic design of the utility piping. Typical arrangements for some of the utility piping are included in this 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 utility piping to and from the compressor. Failure to follow good industrial practices and the requirements and recommendations listed could cause poor compressor performance, mechanical failure, property damage, and/or personal injury.

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

A—19


1-1/2” NPT

3/4” NPT

Throttle Valve

3” (76mm) Recommended Pipe Size

Figure A—10. Typical Water Manifold

Figure A—11 illustrates a cooling water piping arrangement with typical feed and return piping, shutoff valves, throttle valve, various gauges, and drain connections. Cooling water (coolant) requirements are 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 condition of 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 appropriate sizing for the piping. Cooper Turbocompressor also recommends installing, when necessary, a pressure regulator to allow for pressure control of the water.

A—20

Installation

CAUTION: When fabricating the coolant supply piping (Figure A—11), always install the throttle valve on the discharge side of the manifold rather than the inlet side. This will ensure that the 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 the pipes thoroughly, and when it is determined that the supply piping is completely free of any foreign matter, remove the screens. Reconnect the compressor manifold, and verify that there are no external leaks. To verify that there are no internal leaks, open the condensate drains of the intercoolers and aftercooler.

C

C A. B. C. D. E.

3” Victaulic Connection

D E

A B

Temperature Gauge Pressure Gauge Shut-Off Valve Throttle Valve Drain Connection

A B

Figure A—11. Typical Water Supply and Return Piping

A—21


Condensate Drain Piping During 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 the condensate from being carried over and entering the next stage of compression, the condensate in each of the intercooler chambers must be drained into an open drain or trough. The open drain allows not only visual verification of condensate removal, but it also assures that the condensate will not be drawn back into the compressor when the compressor is unloaded.

CAUTION: Do not manifold the condensate drains. Since the cooler cavities operate at different pressures, manifolding will cause malfunctions due to excessive amounts of condensate from higher pressure chambers being forced into lower pressure chambers and consequently 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. The condensate piping and control devices attach to these connections. Figure A—12 illustrate a typical condensate drain piping arrangement. It is also necessary to include a manual bypass valve and piping with whichever type of drain control device is utilized. The isolation valves ahead of the control device are optional. It is also advisable to keep the condensate draining system open during shutdown to prevent condensate accumulation in the compressor. This will also provide compressor protection in case of an intercooler tube failure.

A

A. Hand Valve B. Trap or Solenoid Valve B

Figure A—12. Typical Condensate Removal Piping Arrangement A—22

Installation

Optional Features Cooper Turbocompressor offers an array of cooling water piping and condensate drain options that may ease the installation of the compressor or enhance the overall operation of the compressor. Any of 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 Option When this option is selected, the intercoolers, aftercooler, and oil cooler are manifolded to single inlet and outlet connections. The Cooper Turbocompressor design is compact and precise and will reduce installation time.

Figure A—13. Cooling Water Manifold Option

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

Automatic Coolant Water Flow Control Valves This option includes a temperature sensor/controller installed in the air stream and a throttling valve installed in the water stream; thus reducing water consumption during compressor unloaded operation.

A—23


Condensate Drain Piping Option When this option is purchased at the time of order entry, a piping assembly including a solenoidoperated drain valve and manually operated bypass gate valve is fabricated and attached to the drain connection of the intercoolers and aftercoolers. The solenoid-operated drain valves are in turn wired to the Vantage Control Panel. The Vantage Control System will open and close the drain valves at set intervals to drain accumulated condensate from the heat exchanger chambers. The Cooper Turbocompressor design is again compact and very effective. It will save installation cost and 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 together. They must individually discharge into an open drain or trough to prevent condensate from higher-pressure chambers being forced back into lower pressure chambers. This is the single most common error made at the time of compressor installation.

A. B. C. D.

Solenoid Drain Valve Check Valve Manual Bypass Valve Manual Block Valve C 10 inches (250 mm) D A B

Figure A—14. Condensate Drain Piping Assembly

Figure A—15. LiquidatorTM Pneumatic Condensate Drain Trap

Pneumatic Condensate Drain Option Figure 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 drains condensate without any loss of compressed air. Significant energy savings could result when using this system instead of other time-based draining systems. The Liquidator Draining System may be purchased initially with the compressor or retrofitted later. Request additional information from an authorized Cooper Turbocompressor representative. Engineering Data Release, EDR-D-005, explains this system and provides complete installation, operation and maintenance information.

A—24

Installation

Oil Reservoir Vent Ejector Piping The gearbox and oil reservoir must be vented in a way that will prevent migration of oil and/or oil mist to the surrounding area or other parts of the compressor. The Turbo Air 3000 Compressor utilizes a simple ejector (or venturi-tube) powered by clean, dry, filtered air. This ejector creates a slight vacuum inside 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 and will cause severe damage to the compressor. Be sure the ejector’s supply air comes from a clean and dry source.

The ejector and filter assembly is located at the top of the oil reservoir. The relevant engineering drawings (supplied separately) define the precise connection point and define the specific air requirements. If the air supply pressure varies, it is recommended that a pressure regulator with gauge be installed for control of pressure to the ejector. The regulator should be installed in the air supply line just before the ejector itself. Since it is the routing and distance of the piping at any particular installation are the principal determining factors, it is the installer’s responsibility to correctly size the air supply piping. (Appendix B, The Lubrication System, includes additional important information about the operation of the ejector/filter system.)

Instrument Tubing Figures A—2 and A—3 illustrate the external instrument tubing required to complete the compressor installation. Pressure sensing points in the user’s discharge piping must be connected to pressure transducers located on the compressor package. These pressure sensors are located in an enclosure just underneath the Vantage Control Panel. Various applicable engineering drawings (supplied separately) 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 a successful instrument tubing installation, always: · Use steel tubing in order to avoid kinks or other common problems, which are inherent with copper 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.

A—25


Electrical Conduit The typical Turbo Air 3000 Compressor installation will require that medium voltage, and possibly high voltage, electrical power is delivered to complete the compressor installation. The standard packagemounted components requiring electrical power are the main drive motor, the oil pump motor and the Vantage Control Panel. Other optional equipment, such as the oil heater, will also require electrical power. The National Electrical Code in the United States, as well as most other national codes, require that 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 electrical conduit 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 wiring practices. Failure to follow local electrical codes and good industrial practices could cause property damage and/or personal injury or death.

A—26

Installation

Electrical Interface The user is responsible for the proper electrical connection of several components at the site installation, including the Vantage Control Panel, the oil pump motor, the main drive motor, and the oil heater option (if included). Refer to other technical data and/or engineering drawings supplied separately to determine the correct power supply requirements.

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

General Wiring In addition to the basic wiring design, the user must also provide the wire, conduit, protection equipment, etc. When designing and installing the electrical interface, it is necessary to meet the following minimum 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. (In the United States, refer to Section 250-26 of the National Electrical Code for earth ground definition.) · Include proper disconnects such as switches or circuit breakers (either fusible or non-fusible) to provide complete isolation from the electrical supply. · If the main power switch that controls the compressor is remotely located or if it is difficult to lock out the main switch, install a local switch to enable maintenance personnel to isolate the unit. · Install and use a lockout system whenever performing maintenance procedures on this or any other such type of machinery. If the user requires accessories such as the Solenoid Valve Condensate Removal option, it will be necessary to supply additional interconnections. Refer to the specifications provided separately, or contact a Cooper Turbocompressor representative for specific requirements.

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

A—27


Main Drive Motor Controls The 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, Cooper Turbocompressor specifies the proper hardware and design for easy compatibility with the compressor’s Vantage Microprocessor Control System. Cooper Turbocompressor Engineering Specification EDR-G-009, Requirements for Owner-Supplied Motor Controls, completely details the minimum requirements for proper interface between the compressor control system and the owner-supplied motor control equipment. However, because there are different types of motor starting equipment and an even wider variety of optional features available, 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, full voltage starters and reduced voltage starters. When selecting the motor controls, consider the following information about these two types.

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

Reduced Voltage Starters These systems, which limit the drive motor current inrush, work well when normal considerations for use of reduced voltage starting are observed. Starting times for reduced voltage systems are generally less than 30 seconds. However, with reduced voltage starters the compressor’s inlet guide vanes must not be cycled open until the motor and compressor have reached full speed. (The Vantage Control System has the capability to delay loading with a variable timer.) Although two general types of reduced voltage starters are commonly used, stepped starters and solid state starters, stepped starters have been shown to give more consistent and reliable performance. The wide variety of solid state starting equipment, along with contributing effects of various options and/or features, 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 Specifications, for more information on minimal requirements for solid state starting equipment.

A—28

Installation

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

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

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

Heater Terminal Box (Front) Heater Element Connections CAUTION: DO NOT CHANGE JUMPER ARRANGEMENT Thermostat L 3-2 L 2-2 L 1-2

Three-Phase Power From Three-Pole Disconnect Switch

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

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

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

Heater Terminal Box (Front) Heater Element Connections

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

Three-Phase Power From Three-Pole Disconnect Switch

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

Additional Wiring Refer to contract-specific drawings to determine additional wiring requirements for other installation options such as blow-off valves, water valves, transmitters, etc.

WARNING: Remember that the control of hazardous energy sources is the responsibility of the compressor installer and user, and that adherence to the guidelines above and any other national or local codes is of critical importance. Failure to follow proper procedures may result in equipment damage, and/or personal injury or death.

A—29


Receiving, Lifting, Moving, and Bolting The time after the order for a new compressor has been placed and before the actual delivery of the equipment can be spent planning for the installation. Much of the work described earlier can be performed 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-specific engineering drawings supplied separately for as complete listing of equipment included in Cooper Turbocompressor’s Scope-of-Supply.

Receiving Cooper Turbocompressor personnel inspect each compressor thoroughly at the factory before shipment. They then supervise the loading to be sure that no damage occurs and document all looseshipped 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 any damage, report it to the carrier and have the carrier inspect the compressor. After determining the extent 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 is missing, report the shortage to the carrier. Shipments are FOB, Buffalo, NY, USA, and become the property of the purchaser at the risk of the purchaser.

Lifting The Turbo Air 3000 Compressor is a heavy and durable high technology product, but it can be damaged as a result of improper treatment. It requires careful handling during all lifting and moving. The unit includes clearly indicated lifting and moving points. Never use any other areas for lifting and moving. WARNING: To avoid personal injury or compressor damage, always follow the proper procedures as described in this manual. Personnel safety and compressor protection must always be foremost 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 that both are properly rated for a maximum package weight of 18,500 lbs. (8400 kg), and be certain that they are in good working order before attempting the move. Use the clearly designated lift points on the compressor as shown in Figure A—21. (In some instances it may be necessary to use spreader bars to clear certain main drive motors.) WARNING: Be certain to use properly rated equipment and lift the compressor only as shown at the lift points indicated. Improper lifting may cause compressor damage and/or personal injury. A—30

Installation

Figure A—21. Compressor Lift Points

Moving If 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 a substantial pallet that supports the base between the liftpoints and lift only under the base between the lift points indicated.

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

Bolting If the foundation has been properly prepared, the compressor may be put in place at this time. Cooper Turbocompressor recommends placing the compressor over foundation bolts, with the nuts tightened to the recommended torque value. (Refer to Section Two, Compressor Specifications, for specific information). Take special care not to rack or twist the base of the compressor when placing it on the foundation. If necessary, use shims to level the installation package.

A—31


Preparing for Startup Although each compressor undergoes rigorous and comprehensive testing before it leaves the manufacturing facility, after transit and installation it is necessary to test and recheck certain components on site. Therefore, after all the preparations described previously are completed and before the initial startup procedure, several inspections and adjustments are required to verify that the compressor has been 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 Turbocompressor factory trained and authorized service representative should be present to inspect the site, supervise the final installation steps, and assist with the startup procedure. A Pre-Startup Inspection Checklist follows which arranges the tasks or responsibilities that the user or installer should be able to complete prior to the arrival of the Cooper Turbocompressor startup representative. Should any concerns or questions develop while executing this list, it should be brought to the 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 during compressor installation, startup, and operation. The high voltages associated with this machinery, the shaft rotation speeds, and the highly pressurized process air produced by the compressor are major safety hazards when proper safety precautions are not strictly followed at all times.

The Prestart Inspection Before performing the prestart inspection, review the Turbo Air 3000 Compressor installation instructions 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 drive motor, the main drive motor controller, the air dryer, etc.. After reviewing the previous items, thoroughly inspect the compressor installation using the Pre-Startup Inspection Checklist in Table A—2.

A—32

Installation

Pre-Startup Inspection Checklist Foundation Bolts

3

Properly tightened

Cooling Water (Coolant) Piping

3 3 3 3

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

3 3

Automatic or manual traps or valves installed Piped individually into open drains

Inlet Air Piping

3 3 3 3

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

3 3 3

Located properly Elements installed according to manufacturer’s instructions Clean and free of dirt and other foreign matter

Discharge Air Piping

3 3 3 3 3 3 3

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

3

Properly connected to a supply of clean, dry air

Table A—2 The Prestart Inspection Checklist

A—33


Pre-Startup Inspection Checklist

continued…

Electrical Interface

3 3 3 3 3

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

3 3

Motor shaft freely moved when turned by hand Compressor shaft freely moved when turned by hand

Main Drive Motor

3 3 3

Motor bearings properly lubricated Motor rotation direction checked Main drive coupling properly installed and lubricated

Lubrication System

3 3 3 3 3 3 3 3

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

3 3 3 3 3 3 3

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

A—34

Installation

Main Drive Motor Rotation Verification Before coupling the compressor and main drive motor, it is necessary to verify that the phase sequence wiring 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 Specifications. 2. Verify that the rating voltage and frequency shown on the motor nameplate match the power supply. 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 revolutions, and verify the direction of rotation using the directional arrow on the compressor gearbox cover. 5. If required, change the phase wiring to reverse the direction of rotation.

Oil Pump Motor Rotation Verification This inspection is required to ensure that the oil pump will generate the required pressure during startup 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 pump and the motor. 2. Turn on the oil pump motor and observe the rotation direction of the motor fan. (The correct rotation 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 of the three power phases connected to the motor.

A—35


Lubrication System Flush Although factory testing includes full operation of the compressor lubrication system, it is necessary to thoroughly flush the system before the initial startup to clear the system of any contaminants that may have 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 included with 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 initial compressor startup.

A—36

Installation

Preventing Startup Problems It is the owner’s responsibility to plan for the inspection and initial startup service by the Cooper Turbocompressor representative and to provide all tools, equipment, supplies, and labor required as described earlier in this section. Contact the Cooper Turbocompressor service representative at least two weeks before the required on-site date to arrange for startup service. To ensure proper and safe compressor startup and operation, a Cooper Turbocompressor trained and authorized service representative should be present to inspect the site and to assist in the final installation steps and the initial startup procedure. The list given in Table A—3 includes common problems and/or situations that may delay or unnecessarily complicate the installation and initial start-up procedure. Avoid such situations, or correct them before the Initial Startup Service Inspection. (Refer to the relevant heading in this Appendix for specific information 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

A—37


The Inspection Prior to Initial Startup Schedule As part of the site evaluation, a factory trained and authorized Cooper Turbocompressor service representative will verify that the compressor is ready to be put into full operation. The service representative will perform the following inspections and tasks as part of the initial compressor startup service. 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 as stated in this manual as well as on the contract-specific drawings supplied separately. (This includes checking the locations of control valves, the inclusion of a system block valve, compressor flange load limits, etc.). 4. Verify that the inlet air piping complies with Cooper Turbocompressor design requirements as stated in this manual and on contract-specific drawings supplied separately. (This includes checking the location of the inlet air filter/silencer, the position of the inlet air startup screen, compressor flange 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 verify that 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 place when 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 requirements. 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 installation of the coupling guard. 17. Complete the Pre-Startup Inspection Checklist shown in Table A—2 with installation personnel before the initial compressor startup procedure.

A—38

Installation

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 CTCauthorized service representative has fully inspected and approved the compressor installation. Cooper Turbocompressor recommends that a trained and authorized service representative perform the initial startup procedure.

Before Applying Power Check the following before turning power on: c

Verify the manual block valve is closed.

c

Check the location of the system pressure transducer.

c

Check wiring for correctness, loose wires.

c

Verify earth grounding.

c

Check motor starter interface wiring from Vantage.

c

Remove oil pump opto and motor circuit optos.

c

Check Main motor and auxiliary oil pump overload settings.

c

Check the supplied panel power.

Powered Pre-Start Checks Apply power and perform the following checks before starting the compressor: c

Turn off access codes.

c

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

c

Check vibration probe gap.

c

Verify the instrumentation (wiring & monitoring points).

c

Verify valve operation.

c

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

c

Turn-on oil reservoir vent ejector.

c

Verify oil pump operation.

c

Verify start-up status.

c

Bump main motor verify rotation & re-couple.

c

Turn on coolant.

A—39


Initial Start up Procedure Start the compressor and: 1. Measure and record the acceleration time

(___ seconds).

2. Unload the compressor. 3. Verify normal compressor operation while unloaded. c

Check inlet valve unloaded position.

c

Check for oil and water leaks.

c

Check and record operating levels.

c

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 equal to 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. c

Surge point 1: Head__________, Power__________.

c


c


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.

A—40

Installation

Service Assistance The Turbo Air 2000 Centrifugal Compressor is a high technology product. When problems develop which are beyond the scope of operating personnel, request assistance from a Cooper Turbocompressor trained and authorized service representative or the Cooper Turbocompressor Field Service Department. For any questions regarding installation, operation, or maintenance, or to schedule a service visit, contact a trained and authorized Cooper Turbocompressor representative:

Authorized Cooper Turbocompressor Service Name: Address: Phone:

or:

Cooper Turbocompressor Field Service Department 3101 Broadway P.O. Box 209 Buffalo, NY 14425-0209 USA Phone: (716) 896-6600 Fax: (716) 896-1233

A—41


A—42

The Lubrication System

Appendix B The Lubrication System In this appendix, the reader will learn about: ¨ General Considerations ¨ The Compressor Lubrication System ¨ Vantage Control of Compressor Lubrication ¨ Operational Guidelines ¨ Gearbox and Reservoir Venting ¨ Optional Features

B—1


B—2


General Considerations Unlike some other types of rotating equipment, high-speed, geared compressors cannot operate, even for very brief periods, without adequate lubrication. The Turbo Air 3000 Compressor lubrication system is a self-contained part of the compressor package and is designed to provide a constant supply of cooled, filtered lubricating oil to the compressor bearings and gear sprays at all times, even during emergency situations such as power outages. The main oil pump is mounted directly onto the compressor gearbox and is driven by an extension of the bullgear shaft. The auxiliary oil pump is driven by a separate electric motor. The system contains all of the necessary components required to regulate, cool, filter and monitor the oil before it enters the compressor 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 is included throughout this manual. Also refer to Section 2, Specifications, for information about TurboBlendTM Lubricating Oil, and Section 7, Parts & Service, for replacement part numbering details.

B—3


The Compressor Lubrication System Figure B—1 is a schematic illustration of the compressor lubrication system, indicating how the oil circulates through the system and through standard compressor components. The following describes the principles of normal operation.

Normal Operation 1.

The main oil pump [B], mounted on the compressor gearbox and driven off of an extension of the bullgear shaft, draws oil from the reservoir [A], through check valve [N], and cycles it through the lubrication system and the compressor gearbox. Check valve [C]prevents the oil from being pumped 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] in the return water line regulates the flow of the cooling water through the oil cooler, thereby keeping the temperature of the oil within the normal operating range.

3.

The oil continues on to the oil filter [F] where impurities are removed. Gearbox G Manifold H

Pinion Bearings [J] Gear Spray Nozzles [K] Bullgear Bearings [J]

Temperature Sensor T Pressure Sensor P

Regulator L

Lube Oil Reservoir Check A Valve N Auxiliary Oil Pump M

Bleed Valve Main Oil Pump B

Oil Filter F

Check Valve C

Oil Cooler D

E

Water In Water Out

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 bullgear bearings [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 arrangement that breaks down any foam before it is allowed to continue to recycle through the compressor lubrication 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 pump provides full compressor oil flow and pressure requirements.

B—4


Vantage Control of Compressor Lubrication Throughout the lubrication cycle, the Vantage control system continuously monitors the compressor lubrication system to guarantee safe and efficient operation. The oil pressure sensor [P] and oil temperature sensor [T], shown in Figure B—1, ensure that all critical mechanical components are being properly lubricated and cooled by the oil. These sensors allow the operator to see present lubrication system conditions on the Vantage display panel. When operating conditions warrant, the control system will initiate either a compressor Alarm condition 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 controls the 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. This pump [M] draws oil from the reservoir and cycles it through the lubrication system and the compressor gearbox. Check valve [N] prevents oil from being pumped back into the reservoir through 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 shaftdriven main oil pump and the auxiliary oil pump are feeding the system. The Vantage control system shuts down the auxiliary pump if the oil pressure transducer [P] senses oil pressure greater than the Lube Oil System High Pressure Set Point. 5. After the auxiliary oil pump shuts down, the lubrication system functions as described under Normal 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 compressor coasts to a full stop.

Emergency Operation When a malfunction occurs during operation that results in a loss of oil pressure, the Vantage control system 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 Set Point. This causes the Vantage control system to activate an alarm condition that starts the auxiliary pump. B—5


2. The auxiliary pump, operating in tandem with the main oil pump, restores normal system oil pressure and the compressor continues to operate. 3. A continued decrease in oil pressure initiates a trip condition and the Vantage control system shuts down the main drive motor. 4. Similarly, if the oil temperature exceeds predetermined set points, the Vantage control system activates an alarm condition or shuts down the compressor, depending on conditions.

Operational Guidelines To obtain the best and safest operation of the Turbo Air Compressor, apply the following guidelines and recommendations.

Oil Pump Operation Cooper Turbocompressor recommends keeping the auxiliary oil pump in continuous operation (even during compressor shutdown) to ensure proper lubrication at all times. However, in order for this recommendation to be followed, the oil pump must be electrically isolated from all other compressor systems. In instances when for some reason the oil pump is not kept in continuous operation, it should be kept running for a minimum of 30 minutes after compressor shutdown. This will assure that any excess heat will be removed from the bearings and gearing. CAUTION: Always maintain the proper air supply pressure to the reservoir vent ejector/filter system whenever the oil pump is in operation. Failure to do so may cause oil leaks, premature wear, and component damage.

B—6


Gearbox and Reservoir Venting During multi-geared, centrifugal compressor operation, the action of meshing gears and the rotation of 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 gearbox and oil reservoir are properly vented so that this oil mist is not allowed to escape.

Ejector/Filter The Turbo Air 3000 Compressor utilizes a simple venturi-type ejector/filter system to create a slight vacuum inside the gearbox and oil reservoir. This vacuum prevents oil or oil mist from migrating out into 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 and will cause severe damage to the compressor. Be sure the ejector’s supply air is clean and dry and the filter is properly maintained. Clean, Dry Compressed Air Mist FIlter D 3/4” Vent

Air Ejector B

A

Check Valve

Trap Fill

Trap E

Lube Oil Reservoir C

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 velocity stream 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 it to 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 vapor lock to prevent the oil mist from bypassing the filter and escaping to the surrounding area. B—7


Optional Features Although the following components are not required for safe operation of the Turbo Air 3000 Compressor, they will bring added convenience to the overall operation of the lubrication system. If not included with the initial compressor package, they may be added at any time.

Oil Reservoir Heater The 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 Reservoir Heater option. Such emersion heaters are rated at 1.5 kW and are available in any standard threephase voltage up to 600 volts. The heater is installed in the oil reservoir. Figure B—3 shows the Oil Heater option.

Figure B—3 The Oil Heater Option

Thermostatic Mixing Valve With the standard package, oil temperature is maintained by regulating the flow of cooling water through the oil cooler. This method, though effective, may require seasonal adjustments. Including the Thermostatic Mixing Valve option will automatically control oil temperature by regulating the oil flow around the oil cooler, thus keeping the temperature of the oil entering the compressor constant. The Thermostatic Mixing Valve option is shown in Figure B—4. From Oil Pump

To Oil Filter

Regulator

Water In Water Out Oil Cooler

Figure B—4 The Thermostatic Mixing Valve Option B—8


Duplex Oil Filter In many instances, compressed air systems operate on a continuous basis. Since it is frequently inconvenient to completely shut down compressor operation to perform a simple maintenance task, Cooper Turbocompressor offers the Duplex Oil Filter option. The duplex oil filter eliminates the necessity for compressor shutdown during filter maintenance. (Refer to Section Five, Maintenance, for full instructions 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 Monitoring With this optional feature, a second pressure transducer is installed before the oil filter. (The system’s standard pressure transducer is located between the filter and the gearbox.) In such instances, the Vantage Control System is programmed to calculate the differential pressure across the oil filter and to provide Alarm and Trip functions. The Oil Filter Differential Pressure Monitoring option is particularly useful when included as part of a predictive maintenance program. Figure B—6 shows the Oil Filter Differential Pressure Monitoring option.

Oil to Gearbox

Oil from Cooler Oil Filter

Figure B—6 Oil Filter Differential Pressure Monitoring Option

Low Oil Level Indicator With 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. B—9


B—10

Vantage Control System Logic

Appendix C Vantage 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

C—1


C—2


General Considerations This appendix provides detailed descriptions of each of the three compressor control methods. It includes the theoretical basis, performance maps for each of the five control loops and their associated setpoints for each operating method. This information is of a highly specialized nature and not necessary required reading for all operating personnel. It is written only as a reference for skilled technicians when it becomes necessary to fine-tune compressor controls or to troubleshoot various operating conditions. The reader should bear in mind that the information contained in this appendix covers various optional 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 which operating method applies.

C—3


Control Methods Vantage offers three distinct load control methods to provide flexibility in meeting widely varying jobsite compressed air needs. · Auto – Offline* · Auto – Standby* · Auto – Unload Each Vantage control method uses all five valve control loops shown Table C—1. Detailed descriptions of these methods appear latter in this Appendix. *Note: Both the Auto-Offline and Auto-Standby mode require a modulating blow off discharge valve.

Load Control Loops The Vantage control system performs load control through five independent control loops. Each loop modulates either the inlet valve or the discharge valve, also called the Modulating Blow Off Valve or MBOV

Inlet Valve Control

Discharge Valve Control

Control loop

Setpoint

Control loop

Setpoint

Maximum Power

Maximum Motor Load

Blow-Off System Pressure

System Pressure Offset

System Pressure

System Pressure

Blow-Off Discharge Pressure

Max. Discharge Pressure

Minimum Flow

Surge Control Offset Table C—1 Vantage Control Loops and their Setpoints

A description of the setpoints follows.

C—4


Inlet Valve Control Setpoints The Vantage control system modulates the compressor inlet valve in response to the control setpoints associated 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 its setpoint. Vantage sends opening and closing signals to the inlet valve to maintain the desired system pressure (System Pressure setpoint) and prevent the motor from overloading (Max Motor Load setpoint), 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 the inlet valve can be transferred among loops but the output of only one loop at a time can be in control. NOTE: The active control loop appears on the Performance Control tab of the VIEW screen.

Maximum Motor Load Setpoint Drive motor amperage is one indicator of the compressors’ output. Motor amps are directly proportional to the position of the compressor inlet valve; as the inlet valve opens, the motor will draw more amperage. However, the Maximum Motor Load setpoint establishes a limit on the opening of the inlet valve to prevent running the motor in an overload condition. When displayed, this setpoint 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 System Pressure Setpoint. If this setpoint is exceeded, the inlet valve will be throttled accordingly. Under the Performance Control tab, the System Pressure setpoint is identified as SP, where the actual system pressure 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 will decrease and plant pressure levels will remain stable. However, if the flow drops too low the compressor could surge. To prevent a ‘low-flow’ surge, Vantage maintains a minimum flow, using the Surge Control Offset value as a setpoint. At all points along the Surge Control Offset line, Vantage controls the actual system pressure to the System Pressure Offset setpoint. When the system reaches this setpoint, control transfers to the compressor discharge valve control loops. NOTE: There is an ‘Output’ indication on the Vantage Performance Control screen that shows 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 the direction of travel (+ for open; - for close) and how fast the inlet is opening or closing.

C—5


Discharge Valve Control Setpoints This control mode functions exactly the same as Auto-Offline, up to the point where the check valve closes. Then, instead of unloading, Auto–Standby opens the blow off valve further, to operate the compressor at a discharge pressure (Standby Mode Offset) less than the System Pressure setpoint. This method allows the unit to fully load much quicker, when the system pressure drops below the System Pressure setpoint.

System Pressure Offset Setpoint Under the inlet valve’s Minimum Flow control loop, Vantage allows the actual system pressure to increase 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 the Inlet Valve Control section. Note that the Vantage modulates the inlet valve to maintain system pressure, and it modulates 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, the compressor will surge. Vantage uses the Maximum Discharge Pressure Setpoint to prevent surging. If the Max Discharge Pressure setpoint is reached, that control loop will quickly modulate the blow off valve to keep the discharge pressure under control. The proper setting is for this setpoint is at a value above Max System Pressure, and below the compressor’s high-pressure surge point. Note: The position of the blow off valve can be seen on the Performance Control screen in the same manner as that of the inlet valve.

C—6


Auto-Offline Control With Auto-Offline Control, the inlet valve modulates to satisfy the System Pressure setpoint (within the Maximum Motor Load setpoint limits). In cases of low demand, the control throttles back to the Minimum Flow control line setpoint. The Minimum Flow control loop controls system pressure to the System Pressure Offset setpoint and flow to the Surge Control Offset line. The compressor inlet valve responds to the Surge Control line. If system pressure reaches its Offset value, Vantage modulates the compressor’s discharge blow off valve. As the blow off valve reaches point of closing the discharge check valve, Vantage unloads the compressor. When the system pressure drops below the System Pressure 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 Pressure 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-Offline unloads the compressor 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 C—7


Auto-Offline Control Inlet Valve Control When the actual system pressure is lower than the System Pressure Setpoint, the Vantage controller begins to load the compressor. During the initial load cycle, the inlet valve opens to a Minimum Flow value when the compressor discharge valve begins closing. During this initial load cycle, the Inlet Maximum Load control loop controls the inlet valve and quickly loads 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 full load amps (FLA). As the system air pressure approaches the System Pressure setpoint, the Inlet System Pressure control loop 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 setpoint by reducing the compressor output through inlet valve throttling moves. This throttling continues until the compressor reaches its minimum stable operating point, and the Inlet Minimum Flow control loop resumes automatic control of the inlet valve. In the Minimum Flow control loop, the inlet valve is controlled along the minimum flow Surge Control Offset 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 allowed to increase above the System Pressure setpoint, to the System Pressure Offset setpoint. When the measured pressure reaches the System Pressure Offset value, Auto-Offline then smoothly transfers control to the compressor discharge valve control loops.

C—8


Discharge Valve Control Discussion As explained, the Vantage discharge valve control loops do not come into play until system pressure is allowed to increase to the System Pressure Offset setpoint. Until then the compressor discharge valve remains fully closed. Note: The System Pressure Offset setpoint for the blow-off control loop is displayed on the 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 to modulate the compressor discharge valve under its Blow Off System Pressure control loop. If there is no blow-off valve, the compressor unloads. The blow off valve continues to open until the compressor’s discharge check valve closes. When the check valve closes, Auto-Offline unloads the compressor by fully opening the blow off valve and closes the inlet valve to its unloaded position. The compressor continues to run unloaded until the actual system pressure drops to a level below the System 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 certain transitional periods. The Blow Off Discharge Pressure control loop, and its corresponding Maximum Discharge Pressure setpoint come into play under certain compressor operating conditions. The Blow Off Discharge Pressure control loop provides a fast response when the discharge pressure climb 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 highpressure surge point of the compressor. Although the Vantage control loops are tuned at Cooper Turbocompressor prior to shipment, it is important to verify the tuning under the actual jobsite conditions. Proper tuning is the key to quick and efficient interaction among the five control loops.

C—9


Auto-Standby Control This control mode operates the same as Auto-Offline until the check valve closes. Then, instead of unloading, Auto–Standby opens the blow off valve further to operate the compressor at a discharge pressure (Standby Mode Offset) less than the System Pressure setpoint. This method allows the unit to fully 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 System Pressure 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-Standby continues to open the blow off valve until the compressor discharge pressure drops to the Standby 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 Pressure setpoint.

Figure C—2: Auto-Standby Control Operation C—10


Auto-Standby Control The Auto-Standby control method is for air systems that experience dramatic variations in demand yet do not have a lot of receiver capacity. In these cases, an unloaded compressor may not be able to respond fast enough to sudden increases in demand. Auto-Standby handles this situation by partially unloading the compressor to a user-set level below the required system pressure. To take advantage of this feature, the compressor must have a modulating blow off valve.

Operational Characteristics Auto-Standby control is identical to Auto-Offline control (detailed previously), until the situation where the discharge check valve closes during blow off, under Blow Off System Pressure control. At this point, Auto-Offline unloads the compressor. However, in the Auto-Standby mode, the compressor is not allowed to unload. Instead, the controller will 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 System Pressure setpoint. The control setpoint for Auto-Standby is called the Standby Mode Offset, and it is a DP value. For example: Where the system pressure setpoint is 115 psig, and the desired standby pressure is 105 psig, input a Standby Mode Offset of 10 psig. The compressor continues to operate at the reduced standby pressure until the actual system pressure drops to a level below the System Pressure setpoint. When this happens, the unit will fully load through the inlet valve control loops.

C—11


Auto-Unload Control In this Vantage control mode, inlet control is the same as Auto-Offline, but now only to the point where the Maximum System Pressure setpoint is reached. Then, instead of blowing off, Auto-Unload unloads 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 method unloads the compressor by first fully opening the compressor discharge bypass valve, and then closing 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

C—12


Auto-Unload Control The Auto-Unload control method is used for compressors that have a discrete (open/close) discharge bypass valve (and not a modulating blow-off valve). Vantage handles this through the Auto-Unload control method by unloading the compressor instead of blowing off. This control method may also be useful when working with several compressors in the same air header. It may be desirable to immediately unload and possibly turn off a small compressor before allowing larger units to blow off.

Operational Characteristics Auto-Unload control is identical to Auto-Offline control up to the point where the System Pressure Offset 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 inlet valve to its minimum position. The controller automatically reloads the compressor when the actual system air pressure falls below the System Pressure setpoint.

C—13


Compressor Safety Mechanisms The Vantage Control System provides compressor protection by continuously monitoring vital functions to ensure correct and safe operation of all compressor systems. Whenever operating conditions diverge from predetermined safety parameters (the setpoints), the control system automatically triggers an appropriate system response.

General Operating Principle A variety of sensor devices are strategically located throughout the compressor’s various subsystems to provide measurement of vital operating parameters. These measurements are monitored by the Vantage 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 divergent or dangerous level, the control system triggers a control panel display message and the appropriate safety response.

Sensors A variety of sensor devices monitor the compressor process air, lubrication, electrical, and mechanical components to ensure their correct operation. · · · ·

A current sensor located in the main drive motor terminal box measures the main motor current. Electronic proximity devices, or vibration probes measure displacement (or vibration) of the pinions at various standard and optional locations. Temperature sensors, or resistive temperature detectors (RTD’s) measure the oil temperature in the compressor lubrication system, the third stage inlet air temperature, and other optional locations. Pressure transducers measure the oil pressure in the compressor lubrication system as well as the 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 described above. Whenever a sensor device detects an operating condition that varies from predetermined parameters, a compressor safety mechanism is activated.

C—14


Standard and Optional Measurements Standard: Main Drive Motor Current System Air Pressure Compressor Discharge Air Pressure First Stage Vibration Oil Pressure Oil Temperature Final Stage Inlet Air Temperature

Optional: Second Stage Vibration Third Stage Vibration (three stage units only) Second Stage Inlet Air Temperature (three stage units only) Inlet Air Filter Pressure Drop Oil Filter Pressure Drop Oil Reservoir Level Compressor Discharge Air Temperature Mass Flow Measurement Multi-channel Temperature Monitor (motor bearing & stator windings) Table C—1 Standard and Optional Measurements

Alarm and Trip Conditions When operating conditions deviate from any of the preset setpoints, when a compressor or auxiliary device fails, or when compressor performance becomes degraded, the control system will activate one of two types of compressor safety mechanisms. The mechanism activated depends on the degree of deviation, 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 that requires some attention. Trip. When a Trip condition occurs, the Vantage Control System will initiate a complete compressor shutdown in order to protect vital components. This will occur whenever one or more operating conditions exceed the predetermined levels governing operating safety.

The Vantage Control System records all operating conditions current during both Trip and Alarm conditions and shows them on the control panel display. As part of the control panel Diagnostics function, the operator may also call up similar information for the four most recent Trip conditions or compressor shutdowns. Trip messages (from most to least recent) are available for review.

C—15


Table C—2 shows Alarm and Trip levels for the Turbo Air 3000 Compressor. During an Alarm or Trip condition, the control system will signal the control panel with that information. This will cause the associated indicator light on the control panel to come on. Additionally, any associated auxiliary warning device attached to the control system will also come on and/or sound.

ALARM and TRIP Setpoints (English Units) ALARM Condition

TRIP

Low

High

Low

High

80 70

1.5 140 135

70 60

2.0 150 145

-

130

-

140

Inlet Air Filter Pressure Drop (inches of water) Oil Filter Pressure Drop (psi) Compressor Bullgear Vibration (mils)

-

10 15 2.5

-

20 3.0

Drive Motor Vibration (mils) Drive Motor Stator Temperature (ºF)

-

2.5 330

-

3.0 340

Standard: Compressor Stage Vibration (mils) Oil Pressure (psi) Oil Temperature (ºF) Stage Inlet Air Temperature (ºF)

Optional:

Table C—2 ALARM and TRIP Setpoints (English Units)

ALARM and TRIP Setpoints (Metric Units) ALARM Condition

TRIP

Low

High

Low

High

Compressor Stage Vibration (µm) Oil Pressure (bar) Oil Temperature (ºC)

5.5 20

38 9.7 57

4.8 15

50 10.3 63

Stage Inlet Air Temperature (ºC)

-

55

-

60

Inlet Air Filter Pressure Drop (mm of water) Oil Filter Pressure Drop (bar) Compressor Bullgear Vibration (µm)

-

250 1.0 65

-

1.4 75

Drive Motor Vibration (µm) Drive Motor Stator Temperature (ºC)

-

65 165

-

75 170

Standard:

Optional:

Table C—2 ALARM and TRIP Setpoints (Metric Units)

C—16

Glossary

Glossary


Glossary

Air End — the part of the compressor package that includes the gearbox and the air moving components. 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 pipe of 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 meet specific 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 performance is rated, generally a “worst case” or “hot summer day” condition. Distribution Control System — a functionally related group of electronic devices used for industrial machine sequencing and operation. Diffuser — the component of a compressor stage that helps convert the high velocity airflow into a pressure rise. Discharge Pressure — the air pressure measured between the compressor exit and the compressor discharge 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 drive coupling, and the gearbox. Ejector — the component that creates a slight vacuum inside the gearbox and oil reservoir to properly handle oil mist.


EMERGENCY STOP Button — the device on the Vantage Control Panel that serves to immediately interrupt 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 of which 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 the airflow velocity and imparting energy into the airstream. Inlet — 1. the component of a compressor stage that covers the impeller and diffuser, thus creating a very 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 intake air 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 initial startup of the compressor, when required, to stop larger airborne particles from entering the compressor. Inlet Guide Vane — a device that throttles inlet airflow to the compressor, while also imparting a pre-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 the inlet 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 motor amperage 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 the atmosphere. Motor Controller — a device that is used to start, stop and protect electric motors. (Also referred to as a Motor Starter.)

Glossary

“Off Design” Operation — a compressor operating condition when the ambient environment is other than 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 Control Panel. 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-wide production 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 compressed air 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 horsepower rating 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 material from entering the compressor.


Surge — a compressor operating condition characterized by a momentary reversal of airflow back through 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 a voltage 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 review compressor operating data at the time of a compressor Trip condition. Turndown Range — the extent to which the airflow through the compressor may be throttled without encountering surge while maintaining setpoint pressure. Unloaded — an operating condition where airflow through the compressor, and thus power consumption, are at a minimum. User Interface — the part of the Vantage Control Panel that allows the user the view data, monitor compressor operating, and adjust operating parameters (such as setpoints). “Worst Case” Operating Condition — the ambient circumstances (also referred to as a “hot summer day”) when the air is less dense and filled with water vapor resulting in adverse compressor performance.

Centrifugal Compressor Handbook

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