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Related Manuals for Ingersoll-Rand CENTAC
Summary of Contents for Ingersoll-Rand CENTAC
- Page 1 CENTAC CENTAC CENTAC CENTAC Instruction Manual INGERSOLL-RAND ...
- Page 3 Proprietary Matter only to those of its employees whose use or knowledge of the Proprietary Matter is necessary. This manual shall be returned upon request by Ingersoll-Rand Company. The unauthorized use of this manual may be punishable by law. DISCLAIMERS PROVIDED “AS IS”.
- Page 5 8/14/00 DOM/INT’L Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 7 INSTRUCTION MANUAL NOTICE On receiving the Centac compressor, be sure to inspect the unit for evidence of damage during shipment. Immediately notify the carrier and the nearest Ingersoll-Rand representative if any damage is noted. The compressor should be stored on a level floor or supports, in a dry protected area.
- Page 8 CENTAC INSTRUCTION MANUAL Table of Contents Section 1 Planning & Installation Section 2 Description Section 3 Operation Section 4 Maintenance Section 5 Troubleshooting Section 6 Parts & Service Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 9 Safety This manual contains instructions for planning of the installation, operation and maintenance of your Ingersoll-Rand centrifugal air compressor that has been designed to provide safe and reliable service. However, it is both a pressure system and a rotating machine, therefore, the operator(s) must exercise good judgment and proper safety practices to prevent personal injury and avoid damage to the equipment and surroundings.
- Page 10 In addition to the many obvious safety rules, follow the safety procedures listed below when personnel are operating or maintaining Centac compressors: DO NOT USE THE DISCHARGE AIR FOR BREATHING. IT COULD CAUSE SEVERE INJURY OR DEATH.
- Page 11 Receiving/Handling/Storage Receiving Centac compressors are shipped in first class condition. They have been inspected prior to leaving the factory. Loading of the compressor has been supervised by Ingersoll-Rand personnel to ensure that the unit has not been damaged during loading and that all accessory equipment has been properly documented.
- Page 12 The unit must be started within the first 180 days following shipment from Ingersoll-Rand to assure the full 12-month operational warranty after start- up. Store all loose/spare parts in a controlled environment for adequate protection prior to usage.
- Page 13 Proper support of the machinery is required to give maximum reliability at minimum operating cost. In addition, a well-designed installation will result in lower installation and operating costs. See the General Arrangement drawing for compressor/customer connection details and lift points. Contact your local Ingersoll-Rand representative for further information. Centac Instruction Manual ...
- Page 14 Isolation pads are recommended in these instances. For the Centac compressor package, a simple continuous concrete pad or steel support structure is recommended for each compressor. Precautions should be taken to ensure a reasonably uniform base around the pad.
- Page 15 Leveling The Centac compressor should be leveled at the time of installation. To level the unit, place it over the anchor bolts with the feet resting on steel wedges or shims, if necessary (see Figure 1.3).
- Page 16 • Instrument air piping Centac products have no design provision for accepting the full weight of external piping connections. The discharge, inlet, bypass, water, and other piping connected to the machine must be self-supporting. Adequate piping supports are necessary to prevent excessive dead loads on the flanges of rotating machinery.
- Page 17 The inlet pipe and filter must be inspected before startup by an Ingersoll-Rand factory certified service representative. NOTE...
- Page 18 • A chemical type filter Check with your Ingersoll-Rand representative for specific filter information. The air filter should be located as close to the unit as possible to minimize pressure drop. If the filter is located outside the compressor building, the inlet housing should be at least 8 to 10 feet above the ground or roof and 6 feet away from the side of a wall.
- Page 19 1.5). The silencer should be kept as close to the compressor as possible and the total length of pipe kept short. In noise critical areas, the discharge piping from the silencer may be lagged to further reduce sound. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 20 All hot air discharge compressors (no internal aftercooler) • All steam turbine drivers – on the inlet and discharge. Expansion joint installers must consult the manufacturer’s instructions to ensure correct installation. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 21 NOTE While Ingersoll-Rand may recommend or even supply an expansion joint, proper installation is the customer’s responsibility. Discharge Air Piping For the best performance, a straight run of pipe which is at least 3 pipe diameters long should be interposed between the discharge check valve and a long radius elbow to allow for smooth operation of the check valve.
- Page 22 Adequate piping support is needed to prevent excessive dead loads on the compressor flange. Provisions should be made in the discharge piping so that all alignments are made in the piping and not the compressor. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 23 Discharge Air Piping for Multi-Compressor Installation Parallel Operation with Positive Displacement Compressors The steep performance curve of the Centac compressor allows for operation in parallel with piston or rotary screw compressors (see Figure 1.7). However, piping layout design should isolate the Centac compressor from the pulsations in the discharge produced by these compressors.
- Page 24 The air used must be clean dry instrument quality air. For best results, piping should be connected to a refrigerated air dryer and filter prior to connection on the unit. The Centac compressor normally requires 10 SCFM (0.33 m /m) of air at 60-120 PSIG (414-827 kPa).
- Page 25 The Langelier’s index is a technique of predicting whether water will tend to dissolve or precipitate calcium carbonate. If water precipitates calcium carbonate, scale formation may result and this water will have a corrosive tendency. Other factors that contribute to corrosion include: Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 26 The location and size of the trap discharge connection is listed on the General Arrangement Drawing. The piping arrangement is shown on the Process and Instrumentation Diagram. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 27 Compressor stage (Typ) Pressure Balance line Float Condensate drain Valve Trap bypass valve Air gap Drain trough To floor drain Figure 1.10 Standard Condensate Trap and Drain Arrangement Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 28 • Optional switches WARNING Electrical-trade personnel must do electric installation on the Centac compressor. Electricity can cause serious injury or even death if proper handling and installation procedures are not observed. Contact a qualified electrical installation contractor for help installing and/or maintaining any electrical services to this compressor.
- Page 29 Control Panel Power The standard Centac compressor control circuitry is designed for a 120 VAC source. If the customers source is greater than 120 VAC, a control transformer must be used. Check the Electrical Schematic to determine whether the control transformer has been factory installed.
- Page 30 Current Transformer This device may be required to provide a 0-5 ampere signal to one or more devices located in the control panel. When supplied by Ingersoll-Rand, the current transformer is often shipped loose for installation by the customer. Refer to the unit's electrical drawings, motor nameplate data, motor manufacturers data sheet and starter manufacturers data sheet to properly size the current transformer.
- Page 31 SECTION 1 PLANNING & INSTALLATION Lubrication NOTE The initial fill of lubricant for the Centac compressor should be installed under the supervision of an authorized Ingersoll-Rand Technical representative. Cleanliness of the lubrication system is of vital importance to the Centac air compressor.
- Page 32 Lubricant obtained by the user for operation of this equipment must comply with the following specification and perform satisfactorily in the compressor. The Ingersoll-Rand Company assumes no responsibility for damages caused by non- compliance to this specification within the period of its standard equipment guarantee or thereafter.
- Page 33 NOTE Oil specifications are constantly being reviewed. Verify that correct oil is used by consulting appropriate serial number manual. Ingersoll-Rand does not endorse any other trade name product or any individual oil company. Centac Instruction Manual ...
- Page 34 Actual capacities will vary with specific sumps. The above listed values are for standard 2CII Centac models. Review of the Specification section of the compressor Operation Manual is recommended for exact capacity of a specific unit. The above values do not apply to API style sumps.
- Page 35 Refer to the specific General Arrangement drawing for actual sizes. Recommended Tools The following list of standard mechanic’s tools is provided as a guide for maintenance and installation of a Centac compressor. • Lifting Device (1/2 ton, or 500 kilos minimum) •...
- Page 36 SECTION 1 – PLANNING & INSTALLATION Checklist Summary All systems on the Centac compressor should be checked prior to initial start-up. This check should be completed under the direction of an Ingersoll-Rand customer service representative. The following are inspected for corrosion and cleanliness prior to start-up: •...
- Page 37 PSIG (15 PSIG maximum) [83 kPa - 103 kPa maximum] • Check for water leaks (leave condensate trap bypass valves open) • Throttle valves at outlets • Block valve on inlet • Casing vents open Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 38 Assistance Ingersoll-Rand is committed to serving you. If you require information, service or parts, we are strategically located to serve your needs. When you need support for your Centac compressor, contact your local Ingersoll-Rand representative or call the factory direct.
- Page 39 Minimal installation time and cost How a compressor works The Centac compressor is a dynamic centrifugal type compressor. As shown in Figure 2.1, air enters the compressor through the machine mounted inlet control valve and flows to the first stage where the impeller (1) imparts velocity to the air. The air proceeds through the stationary diffuser section (2) that converts velocity to pressure.
- Page 40 SECTION 2 – DESCRIPTION Machine Description The Centac compressor is a centrifugal air compressor driven by an electric motor. The compressor and driver are direct coupled and the entire unit is mounted on a common baseplate with its own lube system, control system, and auxiliaries.
- Page 41 The journal bearings are babbitt lined, fixed tilted pad design for maximum stability and load capacity with minimum power loss. Bullgear bearings for Centac compressor models incorporate a hydrodynamic design. Thrust Bearing Seals A single cartridge seal is mounted in the plain bearing housing behind each impeller.
- Page 42 Intercoolers The Centac cartridge cooler is internal to the compressor casing. The coolers are donut type, with the water over the tubes. The tubes are internally finned. Air passes through the tubes while the water makes a number of counter passes to the air flow.
- Page 43 Compressor Driver The Centac compressor is furnished with an electric motor that is flange mounted and direct coupled to the compressor bullgear. Motor alignment is fixed by the flange design and no adjustment is required.
- Page 44 • An oil temperature control device is supplied that automatically regulates proper oil temperature to the bearings by mixing hot and cold lubricant. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 45 Ingersoll-Rand Company expressly disclaims responsibility or liability for any injury or damage caused by failure to observe those specified, or other common precautions or by failure to exercise that ordinary caution, common sense, and due care required in operating or handling the compressor even though not expressly specified above.
- Page 46 Distance to first elbow (minimum of 8 pipe diameters from bypass valve) Piping supports Location of silencer Facilities for moisture removal on any horizontal run of pipe. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 47 Manually rotate compressor and driver shafts, checking for free, uncoupled rotation with prelube pump running (ensure seal air is on the compressor). Check driver per manufacturer's instructions found in the driver instructions. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 48 Calibrate all temperature and pressure switches. Functionally test control system. Check operation of main driver trip device. Start and run compressor. Correct any oil, water or air leaks. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 49 • Oil Pressure Setting • NOTE The preparation for and the initial start-up of the Centac compressor should be done under supervision of an Ingersoll-Rand service supervisor. WARNING Coupling lubrication is critical. The use of proper and sufficient lubrication is part of a successful installation.
- Page 50 The Centac compressor is furnished with a limited end float, spacer coupling between the driver and the compressor. The total axial float on motor driven units is limited to approximately three sixteenths (3/16) of an inch (4.8-mm).
- Page 51 Coupling Lubrication (Gear Type Only) WARNING Do not run the Centac compressor without lubricating the coupling. Coat the hub and sleeve gear with grease. Slide the sleeve over the hub gear. Insert the gasket. Bolt the sleeves to coupling spacer and tighten uniformly.
- Page 52 * Lubricant capacities for each size and coupling style. This is the total lubricant required for both coupling halves Cenlube GL Grease Ingersoll-Rand provides synthetic grease for lubricated couplings. This grease is a non-hazardous anti-friction bearing and coupling grease designed for all speeds of machine between - 40°F and 500°F.
- Page 53 Refer to the manufacturer’s instructions for detailed initial starting and stopping instructions. Control System Adjustment Centac compressor control systems may be ordered with a wide variety of monitoring, control, and protection features. Many options are available to meet specific needs of customer.
- Page 54 SECTION 3 – OPERATION Lube System Adjustment Cleanliness of the lubricating system is of paramount importance to the Centac compressor. Although the system is flushed and fully tested at the factory, the following steps should be taken prior to initial startup.
- Page 55 3.11 Oil Pressure Setting The Centac compressor lube system is designed to operate between 20 and 30 PSIG (138-207 kPa). When setting the system oil pressure, attention must be given to both the prelube pump internal relief valve and the pressure sensing valve (PSV) mounted in the lube system piping.
- Page 56 Check the discharge pressure set point. Adjust if necessary. Press the start button on the control panel. Oil pressure should increase to 26 - 30 PSIG at 110 - 115°F. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 57 At this setting, the air temperature leaving the cooler, with a full load, should no more than 20°F of the inlet water temperature. The Centac compressor is automatic in operation and contains the following minimum protective devices: •...
- Page 58 Cooling water – as above. If cooling water (rather than a water/glycol mix) is used and it is possible for the Centac compressor to shut down without draining, the following items may be insulated and/or heat traced to prevent possible freezing of the undrained water.
- Page 59 SECTION 4 – MAINTENANCE Section 4 -- Maintenance The Centac compressor does not require constant attendance. However, a few items should be checked periodically. Scheduled preventive maintenance and inspection is essential for continued optimum performance and long service life of the compressor. The following are general requirements and schedules for inspection and preventive maintenance.
- Page 60 Disconnect and tie back all unused wires from terminal strips. • Check the vibration transmitter wires to make sure they run directly to the microcontroller terminal strips. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 61 When using Techtrol Gold III, the lubricant must be changed every three years of after every 24,000 hours of use. CAUTION Servicing of the internal parts is not recommended without the presence of an Ingersoll-Rand service supervisor. For technical assistance, please call your local Ingersoll-Rand representative. Centac Instruction Manual 2000 Ingersoll-Rand Company...
- Page 62 Section 3, Operation, under the heading Initial Start Preparation. Main Driver Depending upon the customer's requirements, different drivers are used with the Centac compressor. Consult the driver manufacturer's literature provided in this manual to insure proper lubrication and maintenance procedures.
- Page 63 7. Slide the panel filter into housing and latch all latches to the panel filter sides. All latches must be fastened to properly seal the final stage panel filter to the housing. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 64 • If no foreign material is found, go to step 9. 9. Replace the oil filter element(s) and inspect the housing for cleanliness. Continue with Casing Flush. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 65 (2) mils on three thousand to thirty-six hundred (3000-3600) RPM drivers and two and one half (2-1/2) mils on fifteen to eighteen hundred (1500-1800) RPM drivers. If Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 66 NOTE Never attempt to set the clearances without an impeller clearance setting tool. See the Centac Clearance Setting Tool diagram on the next page. Install the clearance setting tool against the thrust bolt using one of the bearing cover bolt holes to support the other end.
- Page 67 SECTION 4 – MAINTENANCE CENTAC UNIVERSAL CLEARANCE SETTING TOOL TAP 3/8-16 NC DRILL 9/16 " TAP 3/8-16 NC 1 " 1/2 " 1/2 " 3/8 " RADIUS 1/4 " 1 3/4 " 2 1/4 " 3 1/2 " 1 7/16 "...
- Page 68 Rinse screen in solvent to clean. Oil Filter A single line type oil filter is furnished as standard equipment on the Centac compressor. Some Centac compressors are furnished, as optional equipment, with a dual line type filter with a transfer valve.
- Page 69 For more stubborn deposits, wire brushes or rods can be used. Mist Arrestor A reservoir mist arrestor is furnished as standard equipment on the Centac compressor. Centac Instruction Manual 2000 Ingersoll-Rand Company...
- Page 70 3. Inspect orifice seats for any corrosion or undesirable condition. 4. Inspect the leverage system for freedom of movement. Similar maintenance care should be given to other optional styles of condensate removal systems. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 71 Leaking or pinched oil line. Repair or replace oil line. Dirty oil filter. Replace with clean filter. Defective main oil pump. Repair or replace main oil pump. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 72 Rotor assembly unbalance due to Contact Ingersoll-Rand service damaged aero parts. representative. Repair or replacement and balance check required. Induced vibration from driver. Balance motor rotor. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: 12 September, 2000...
- Page 73 Reduction in motor efficiency. Consult motor manufacturer. Excessive load. Reduce load. High Drive Motor Low primary voltage. Restore voltage to specification. Amperage High load. Reduce load. Centac Instruction Manual 2000 Ingersoll-Rand Company Date of Issue: December, 2003...
- Page 75 Ingersoll-Rand is ready. When you need results, Ingersoll-Rand produces. Ingersoll-Rand is committed to serving you. If you require information, service or parts, we are strategically located to serve your needs. When you need support for you Centac compressor, contact your local Ingersoll-Rand representative or call the factory direct.
- Page 76 This number will preclude material loss or processing delay at the factory. After Hours Emergency Parts INGERSOLL-RAND CENTAC DIVISION supports a 24-hour emergency parts program. For emergency parts service call the factory direct at (800) 247-8640. 6.1 PARTS IDENTIFICATION When ordering renewal parts, the information listed below should be given.
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Questions and answers
How does the Centac Driers assist in improving the compressor performance?
Ingersoll-Rand Centac compressors use built-in intercoolers and aftercoolers to improve performance. These components remove the heat of compression between stages, which increases efficiency. Additionally, stainless steel moisture separators lower the amount of moisture in the air, helping to maintain optimal compressor operation.
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