cameron checklist1

Contents

The Turbo Air 3000Centrifugal Compressorwith the Vantage Control System

Compressor Handbook

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

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

The Turbo Air 3000 Centrifugal Compressor Operators Manual

ii

Contents

iii

About This Manual

About This ManualThis manual contains the basic information necessary for using and maintaining the Turbo Air 3000

Oil Free Centrifugal Compressor, from the original startup and operation to inspection and servicing.However, since installations may vary, these instructions may not cover all details or variations in theequipment supplied or every question which may possibly arise during use.

If a question or situation develops which is not answered directly in this manual, contact an authorizedCooper Turbocompressor sales or service representative for more information, or contact the factorydirectly for specific answers and/or advice.

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

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


iv

Contents

Table of Contents

About This Manual iii

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

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

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

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

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

v


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

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

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

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

vi

Contents

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

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

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

Appendix F: Glossary

Contract Drawings

Supplemental Data

vii


viii

Introduction

11

Section OneIntroduction

In this section, the reader will learn about:

Cooper Turbocompressor

The Turbo Air 3000 CentrifugalCompressor

Safety Precautions

Safety Labels

Warranty

Limitation on Liability

Unauthorized Repair


12

Introduction

13

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

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

The dependability, efficiency, and adaptability of its product line have established CooperTurbocompressor as a global leader in the production of high technology centrifugal compressors.From the early MSG model through the C-8 model to the recent Enhanced Turbo Air 2000 Compressorand the Turbo Air 3000 Compressor, these compressors are known for their ease of automation andhigh operating reliability. Cooper Turbocompressor centrifugal compressors operate in a diverse array ofinstallations that spans six continents. International concern for a cleaner environment has also moti-vated users to choose these Cooper Turbocompressor products, which allow them to harness thepower of oil-free compressed air as well as to minimize the ratio of energy consumption required.

The Buffalo, New York, USA, dedicated complex includes the home office, the manufacturing plant, astate-of-the-art research and development facility and the training school. These resources, along witha worldwide network of sales distributors and trained and authorized service representatives, enableCooper Turbocompressor, Inc. to provide the very best products and service to those industries whichhave come to rely on Cooper Turbocompressor centrifugal compressors.

Cooper Turbocompressor is ISO 9001 Certified.

To learn more, look us up on the Internet:Http//www.turbocompressor.com

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


14

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

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

The Vantage Control SystemThe Vantage control system is standard on the Turbo Air Compressor package. Vantage provides thecompressor owner with high performance solutions through faster response times, improved reliabilityand reduced energy costs over other OEM or PLC controllers. This state-of-the-art system is compatiblewith all other centrifugal, reciprocating, and rotary screw compressors. The Vantage system wasdeveloped as a result of a strategic alliance formed between Cooper Turbocompressor and Bay Con-trols.

The various control modes available provide optimal efficiency in even the most demanding applica-tions, or, when necessary, maintain air system pressure at a uniform level.

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

Introduction

15

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

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

Figure 12 The Turbo Air 3000 Centrifugal Compressor

12

3

4

5

6

7

8

9

3


16

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

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

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

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

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

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

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

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

Introduction

17

Safety Labels

WARNINGHAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURYOR DEATH

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

DANGERAIR UNDER PRESSURE. WILL CAUSE SEVERE INJURYOR DEATH

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

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

DO NOT play with compressed air.

Wear eye protection when using compressed air.

CAUTIONELECTRICAL HAZARD. CAN SHOCK, BURN OR CAUSEDEATH.

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


18

Safety Labels

WARNINGHIGH SURFACE TEMPERATURES. CAN CAUSE INJURY.

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

DANGERHOT OIL UNDER PRESSURE. WILL CAUSE SEVEREINJURY OR DEATH.

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

DANGER

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

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

CAUTIONELECTRICAL OR CONTROL HAZARD. COULD CAUSEINJURY OR MACHINERY DAMAGE.

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

Periodically check all safety devices for proper operation.

Introduction

19

Safety Labels

WARNINGROTATING SHAFTS COULD CAUSE SEVERE INJURYOR DEATH.

DO NOT remove protective guards while the compressor isin operation.

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

WARNINGUNIT CAN AUTOMATICALLY RESTART CAUSINGSEVERE INJURY OR DEATH.

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

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

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

DO NOT use flammable solvents for cleaning parts.

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


110

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

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

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

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

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

Cooper Turbocompressors sole responsibility and the purchasers exclusive remedy hereunder islimited to such repair, replacement, or repayment of the full purchase price.

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

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

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

1. The purchasers use of repair or replacement parts or supplies not of Cooper Turbocompressorsmanufacture or which have not been recommended by Cooper Turbocompressor.

2. The purchasers failure to store, install, operate, and maintain the compressor according to CooperTurbocompressors written specifications, drawings, and good engineering practice.

Introduction

111

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

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

1. Loss of use of productive facilities or equipment.

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

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

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

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


112

Specifications

21

Section TwoSpecifications


General Compressor Specifications

Compressor Lubricant Requirements


22

Specifications

23


Installation Weights Complete Package with Motor

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

*HP = Horsepower

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

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

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

Discharge Connection Load Limits

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

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

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

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

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

0.0000 0.000

+0.002 Face +0.001 +0.005 RIM

+.003 +0.007

Recommendations For Cold Field Alignment, Take at Motor Hub

0.0000 0.000

+0.001 Face +0.002 -0.002 RIM -0.005

+0.003 -0.007


24


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

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

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

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

Coupling Bolt Torque ValuesEnglish Metric

100 ft-lbs 135 Nm

Lubrication SystemEnglish Metric

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

LubricantsUse Type Amount

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

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

Specifications

25


Control Housing Mechanical SpecificationsAttribute English Units Metric (ISO) Units

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

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

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

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

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


26

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

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

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

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

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

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

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

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

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

Specifications

27

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

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

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

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

SpecificationsTurboBlend Lubricating Oil meets or exceeds the performance standards listed in Table 21. Anysubstitute or equivalent oil selected for use in the Turbo Air 3000 Compressor by the compressor ownermust exhibit similar results.

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

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

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

Table 21 Cooper Turbocompressor Oil Specification


28

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

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

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

Use only Cooper Turbocompressor TurboBlendTM Lubricating Oil or a high-quality turbine oil that meets the specifications in Table 21. Do not mix different oils. Avoid the use of synthetic oils. Remember that use of unspecified oil is done at the owners risk.

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

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

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

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

Specifications

29

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

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

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

Anti-Friction BearingsGreaseFor best results with anti-friction bearings, use grease compounded from a non-soap base and a goodgrade of petroleum oil. Table 22 lists acceptable greases that meet those requirements.

Acceptable Motor Bearing GreasesChevron Oil SRI #2

Exxon Unirex N2

Shell Oil Dolium R

Texaco Premium RB

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

Table 22 Acceptable Motor Bearing Greases

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

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

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


210

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

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

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

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

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

The Control System

31

Section ThreeThe Control System


The Vantage Control Panel

The Vantage User Interface

Input or Operational Keys

Practice Exercise

The Turbo Air 3000 Centrifugal Compressor Handbook

32

The Control System

33

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

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

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

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

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

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

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

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

The MLM and UIM contain no user serviceable parts.

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


34

The Vantage Control Panel User Interface

Figure 31. User Interface Module

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

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

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

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

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

The Control System

35

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

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

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

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

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

View Pages

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

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

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


36

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

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

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

Compressor Start Sequence

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

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

Compressor Stop Sequence

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

1

3

The Control System

37

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

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

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

Set Points

OperatorMaintenanceServiceConfiguration

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


38

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

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

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

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

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

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

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

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

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

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

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

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

The Control System

39

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

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

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

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

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

Make the temporary power cable connection as follows:

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

2. Connect the neutral lead to L2.

3. Connect the earth ground to GND.

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

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

Proceed with the practice exercise as follows:

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

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

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

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

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

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


310

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

Performance Control

Performance Control Screen (Typical "Home" Screen)

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

Protection (Running)

Trip Alarm Alarm TripDescription Tag Low Low Data High High

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

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

The Control System

311

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

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

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

Startup Status

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

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

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

Operator

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

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

selection screen.

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

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


312

Routine Operation

41

Section FourRoutine Operation


General Considerations

The Operating Data Record

Routine Startup LOCAL Control

Routine Shutdown LOCAL Control

Adjusting the Pressure Setpoint


42

Routine Operation

43

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

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

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

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

The Operating Data RecordCooper Turbocompressor recommends keeping an Operating Data Record to list inspections and tostore operating data for trend analysis. This record should contain the checklist items included in Table41, along with spaces for the operators initials and the time and/or date to ensure that each item orprocedure receives the recommended periodic attention. Keep in mind, however, that Table 4 actuallyincludes a wide range of options, and remember that not all options are included on all units. (Usersmay wish to mark those options that are included in any particular installation for easy reference.However, if other options are added at a later time, be sure to update the list.)

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


44

Operating Data RecordPressure Discharge Air Pressure: System Air Pressure: Main Oil Pressure: * Inlet Air Filter Drop: * Oil Filter Pressure Drop:Temperature Oil Temperature: * Stage 2 Inlet Temperature: Stage 3 Inlet Temperature: * Discharge Air Temperature: * Motor Stator 1 Temperature: * Motor Stator 2 Temperature: * Motor Stator 3 Temperature: * Motor Bearing Temperature Drive End: * Motor Bearing Temperature Non-drive End:Vibration Stage 1 Vibration: * Stage 2 Vibration: * Stage 3 Vibration: * Motor Vibration at Drive End: * Motor Vibration at Non-drive End:Power Motor Current:Time Date: Time: Total Running Time: Current Running Time:* These are optional sensors which may not be included on all models.Table 41 The Operating Data Record

Routine Operation

45

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

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

1. Close the condensate drain bypass valves.

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

3. Check the oil level in the oil reservoir.

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

5. Rack in the main drive motor starter disconnect.

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

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

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

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

Starting

Description Status

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

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

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


46

Routine ShutdownLocal ControlUse the following procedure to shutdown the compressor under normal conditions.

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

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

Stopping

Description Status

1. Motor Enable = OFF Completed

2. Oil Pump = OFF Waiting 2

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

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

3. Close the air system block valve.*

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

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

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

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

8. Rack out the drive motor starter disconnect.

9. Turn off the reservoir venting system.

Routine Operation

47

Enter to move cursor

to the right

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

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

Adjust the System Pressure Set Point as follows:

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

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

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

Pressure Setpoint

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

Maximum Motor Load (%): 100.0

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

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

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

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

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


48

Maintenance

51

Section FiveMaintenance


General Considerations Daily Inspection Scheduled Maintenance Professional Inspection

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

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

Additional MaintenanceHeat ExchangersIntercooler CleaningOil Cooler CleaningAccumulator TestingDischarge Air Check Valve Inspection


52

Maintenance

53

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

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

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


54

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

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

Operating Data Log

Operating Parameters recorded and within specifications

Setpoints recorded

Gearcase (High surface temperatures) External surfaces wiped clean No unusual noise or vibrations No oil leaks No water leaks No frayed or worn electrical cables

Intercoolers and Aftercooler (Pressurized air, high surface temperatures) External surfaces wiped clean Condensate drains functioning properly No cooling water leaks No air leaks

Lubrication System (High voltages at heater, pump motor) External surfaces wiped clean Proper oil level in oil reservoir Proper oil color No mist from ejector system No oil cooler water leaks No oil leaks No frayed or worn electrical cables

Compressor Drive Motor (Inspect visually onlyhigh voltages, temperatures) External surfaces wiped clean Properly ventilated No erratic or noisy operation No frayed or worn electrical cables Inspected in accordance with manufacturers recommendations

Table 51 Daily Operator Inspection Checklist

Maintenance

55

Scheduled MaintenanceTable 52 lists suggested intervals for prescribed scheduled maintenance procedures such as thoseinvolving filters, lubrication, and other inspections and/or adjustments. Bear in mind, however, thatthese intervals may vary with operating conditions and/or actual hours of machine operation. Someitems may require attention more or less frequently as circumstances dictate.

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

Weekly:(or after about 150 hours of operation)

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

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

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

Discharge air check valve inspected

*Refer to the motor instructions for specific interval guidelines.

Table 52 Scheduled Maintenance Procedures


56

Professional InspectionA substantial part of any good preventative maintenance program also involves professional inspectionand replacement of common maintenance components after an established interval. Such in-depthinspection is particularly important when an unscheduled and/or long-term shutdown would seriouslyaffect production. Table 53 lists the items which require a professional service inspection wheneverenvironmental or operational conditions dictate. Contact a Cooper Turbocompressor trained andauthorized service representative for those procedures and for professional advice.

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

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

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

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

Filters All filter elements inspected

Control Panel Inspected for proper operation

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

Drive Motor Main drive coupling inspected and re-greased Motor inspected in accordance with manufacturers instructions

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

Table 53 Service Inspection Checklist

Maintenance

57

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

Table 54 lists the various filters along with recommended inspection intervals and recommendedresponses for typical operating environments. Instructions for each procedure are included in thissection.

Filter Maintenance ScheduleFilter: Inspect: Clean or Change:

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

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

Table 54 Filter Maintenance Schedule

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

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

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

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

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

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

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


58

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

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

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

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

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

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

The replacement procedure is as follows:

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

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

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

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

5. Install the replacement filter element.

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

Maintenance

59

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

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

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

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

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

3. Catch any excess oil in a separate container.

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

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

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

7. Wipe the housing clean.

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

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

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

1. Shutdown and lock-out the compressor.

2. Shut off the oil pump.


510

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


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

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

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

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

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

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

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


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

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

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

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

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

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

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

Maintenance

511

LubricationTable 55 lists recommended intervals and the products necessary for proper lubrication of variousTurbo Air 3000 Compressor components. Refer to Section Two, Compressor Specifications, for addi-tional information regarding required lubricants. For ordering information, refer to Section Seven,Parts and Service.

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

Compressor Lubrication ScheduleElement Interval Lubricant [A]

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

Oil pump motor bearings Six months Table 22

Main drive coupling Six months Cooper TurbocompressorCoupling Grease

Drive motor ball bearings [B] Table 22

Drive motor sleeve bearings [B] Cooper TurbocompressorTurboBlendTM Lubricating Oil

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

Bypass valve (if applicable) Six months Molycoat 33

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

Table 55 Compressor Lubrication Schedule

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

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

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

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

Whenever the performance of the lubricating oil is suspect, Cooper Turbocompressor recommendsadditional testing for the presence of enhancing additives in accordance with The American Society forTesting and Material (ASTM) as defined in Table 21, Oil Specification.


512

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

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

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

It is not necessary to lubricate the oil pump coupling.

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

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

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

2. Remove the coupling guard.

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

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

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

Maintenance

513

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

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

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

Remove the center spool.

Disassemble the sleeves.

Clean any grease from the gearhubs and sleeves.

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

Re-grease and reinstall the spool.

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

7. Replace the coupling guard.

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

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


514

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

1. Unscrew the cover tube at the motor bracket.

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

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

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

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

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

Bypass Valve Lubrication (if applicable)Some TA 3000 compressors utilize two different types of bypass valves, depending on the rating of thecompressor. To correctly determine the type of valve used in a particular installation, refer to Figures 51 and 52, which illustrate the two types of valves.

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

Maintenance

515

Figure 51 Bypass Valve Figure 52 Bypass Valve

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

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

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

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

Lubricant

SealKit

ebuildit`

Seal Kit


516

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

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

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

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

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

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

Maintenance

517

Additional Maintenance ProceduresIn addition to periodic inspections and maintenance of the filter and lubrication systems, somemaintenance will also be necessary on an as required basis. The necessity is determined by particularperformance indicators or is performed on a periodic basis. Table 56 lists these procedures.Instructions for each follow.

Other Maintenance Procedures Procedure: When Required:

Intercoolers/aftercooler cleaning* With elevated interstage air temperatures

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

Discharge air check valve inspection At 6 month intervals

*Indicated procedures require the use of commercial products available through the CooperTurbocompressor Parts and Service Department. Refer to the specific procedures and Section Seven,Parts and Service, for more information about these products.Table 56 Other Maintenance Procedures

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

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

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

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

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

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


518

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

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

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

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

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

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

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

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

4. Remove the intercoolers from the cooler cavity. (Refer to Figure 53.)

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

Maintenance

519

Figure 53 Intercooler Disassembly

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

CAUTION:Do not allow the loose

cameron checklist1

Documents

control system parts

air system

air piping parts

lubrication system parts

parts availability

vthe turbo air

fwgthe turbo air

contentsthe turbo air