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Cooper Turbocompressor Turbo Air 3000 Handbook

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

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Summary of Contents for Cooper Turbocompressor Turbo Air 3000

  • Page 1 Contents ® The Turbo Air 3000 Centrifugal Compressor with the Vantage™ Control System Compressor Handbook Cooper Turbocompressor, Inc. 3101 Broadway P.O. Box 209 Buffalo, New York 14225-0209 USA AAEDR-H-059 Rev. 01 ECO-1910938 May 2003...
  • Page 2 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual...

  • Page 3: About This Manual

    Contents About This Manual About This Manual This manual contains the basic information necessary for using and maintaining the Turbo Air 3000 ® Oil Free Centrifugal Compressor, from the original startup and operation to inspection and servicing. However, since installations may vary, these instructions may not cover all details or variations in the equipment supplied or every question which may possibly arise during use.
  • Page 4 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual...

  • Page 5: Table Of Contents

    Contents Table of Contents About This Manual Section One: Introduction About Cooper Turbocompressor 1— 3 The Turbo Air Centrifugal Compressor 1— 4 Safety Precautions 1— 6 Safety Labels 1— 7 Warranty 1—10 Limitation on Liability 1—11 Unauthorized Repair 1—11 Section Two:...
  • Page 6 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Section Six: Troubleshooting General Considerations 6— 3 How to Use the Troubleshooting Guide 6— 4 How to Request Assistance 6— 5 Alarm and Trip Functions 6— 6 Drive Train Troubleshooting 6— 8 Control System Troubleshooting 6—10...
  • Page 7 Contents Appendix C: Vantage Control System Logic General Considerations C— 3 Compressor Control Methods C— 4 AUTO-OFFLINE Control C— 7 AUTO-STANDBY Control C—10 AUTO-UNLOAD Control C—12 Compressor Safety Mechanisms C—14 Appendix D: Control System Setpoints Adjustments General Considerations D— 3 The Operation Setpoint Adjustment Procedure D—...
  • Page 8 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual viii...
  • Page 9 Introduction Section One Introduction In this section, the reader will learn about: ¨ Cooper Turbocompressor ¨ The Turbo Air 3000 Centrifugal Compressor ¨ Safety Precautions ¨ Safety Labels ¨ Warranty ¨ Limitation on Liability ¨ Unauthorized Repair 1—1...
  • Page 10 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 1—2...

  • Page 11: About Cooper Turbocompressor

    From the early MSG model through the C-8 model to the recent Enhanced Turbo Air 2000 Compressor and the Turbo Air 3000 Compressor, these compressors are known for their ease of automation and high operating reliability. Cooper Turbocompressor centrifugal compressors operate in a diverse array of installations that spans six continents.
  • Page 12 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual The Turbo Air 3000 Centrifugal Compressor The Turbo Air 3000 Centrifugal Compressor is a state of the art source of oil-free air manufactured with the user’s needs in mind. The simple but rugged mechanical design provides many advantages. It...
  • Page 13 Introduction Other Design Features Other outstanding design features of the Turbo Air 3000 compressor are shown in Figure 1—2 including: 1. Horizontally split gearbox casing 2. Built-in aftercooler 3. Built-in intercoolers 4. Mounted control panel 5. Self-contained lubrication system 6. Inlet guide vanes (standard) 7.

  • Page 14: Safety Precautions

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Safety Precautions The Turbo Air 3000 Centrifugal Compressor is a powerful industrial machine that utilizes high-speed rotating elements and high voltages to produce high air pressures. Therefore, it is very important to use common sense and extra safety precautions whenever it is in operation as well as when performing maintenance or making repairs.

  • Page 15: Safety Labels

    Introduction Safety Labels WARNING HAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURY OR DEATH Disconnect all power supplies, lock-out and display signs before servicing equipment. DANGER AIR UNDER PRESSURE. WILL CAUSE SEVERE INJURY OR DEATH DO NOT operate the compressor at pressure in excess of the nameplate rating.
  • Page 16 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Safety Labels WARNING HIGH SURFACE TEMPERATURES. CAN CAUSE INJURY. Some surfaces of the compressor and motor have excessive temperatures. To avoid burns, keep hands and other body parts away while unit is operating.
  • Page 17 Introduction Safety Labels WARNING ROTATING SHAFTS COULD CAUSE SEVERE INJURY OR DEATH. DO NOT remove protective guards while the compressor is in operation. DO NOT attempt to service any part while the machine is operating. WARNING UNIT CAN AUTOMATICALLY RESTART CAUSING SEVERE INJURY OR DEATH.

  • Page 18: Warranty

    Cooper Turbocompressor’s judg- ment, the compressor does not conform to the original specifications or is found to be defective in material or workmanship, at its option Cooper Turbocompressor will make restitution in one of these ways: 1.

  • Page 19: Limitation On Liability

    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.
  • Page 20 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 1—12...

  • Page 21: General Compressor Specifications

    Specifications Section Two Specifications In this section, the reader will learn about: ¨ General Compressor Specifications ¨ Compressor Lubricant Requirements 2—1...
  • Page 22 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 2—2...
  • Page 23 Specifications General Compressor Specifications Installation Weights Complete Package with Motor Compressor Rating (HP*) Weight in Pounds 14000 14000 15500 18000 20000 Weight in Kilograms 6350 6350 7000 8400 9300 *HP = Horsepower Connection Sizes Connections are to American Standards (ANSI), expressed in inches.
  • Page 24 (Other tube materials with various chemical resistances are available as options. Consult your authorized representative or Cooper Turbocompressor Sales Department directly.)
  • Page 25 Specifications General Compressor Specifications Control Housing Mechanical Specifications Attribute English Units Metric (ISO) Units Height 24 inches 610 mm Width 20 inches 508 mm Depth 7 inches 178 mm Weight: 55 pounds 25 kg Vantage Electrical Specifications Property Value Rated Voltage 100 –...

  • Page 26: Compressor Lubricant Requirements

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Compressor Lubricant Requirements The user must obtain the following required lubricants for use with the Turbo Air 3000 Compressor: · Acceptable turbine oil · Acceptable motor bearing grease · Acceptable inlet guide vane assembly drive screw grease ·...

  • Page 27: Specifications

    This will result in worn gears and scored bearings. Specifications TurboBlend Lubricating Oil meets or exceeds the performance standards listed in Table 2—1. Any substitute or equivalent oil selected for use in the Turbo Air 3000 Compressor by the compressor owner must exhibit similar results. Property...
  • Page 28 The lubrication requirements of the Turbo Air 3000 Compressor are not so severe as to require the qualities of high-cost synthetic oil. In addition, Cooper Turbocompressor products are not designed to use synthetic oils.
  • Page 29 The large, squirrel cage inductor motor of the Turbo Air 3000 Compressor employs (depending on the specific type of motor used) either anti-friction bearings or sleeve bearings.
  • Page 30 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Cooper Turbocompressor endorses only greases with a K 36 Test Rating of 0/24. These are the only greases found acceptable by the American Gear Manufacturer’s Association (AGMA) because of their high resistance to centrifugal separation. (Cooper Turbocompressor Coupling Grease is specially formu- lated to meet this very specific requirement.)
  • Page 31 The Control System Section Three The Control System In this section, the reader will learn about: ¨ The Vantage Control Panel ¨ The Vantage User Interface ¨ Input or Operational Keys ¨ Practice Exercise 3—1...
  • Page 32 The Turbo Air 3000 Centrifugal Compressor Handbook 3—2...

  • Page 33: The Vantage Control Panel

    The Control System The Vantage Control Panel The major components of the Vantage Controller are mounted in a weatherproof electrical enclosure with a NEMA 4 rating. One or more Main Logic Modules (MLM) are included in the panel. Each MLM contains a power supply, a microprocessor, and an I/O (input / output) segment.
  • Page 34 The Turbo Air 3000 Centrifugal Compressor Handbook Audubon Mens Club The Vantage Control Panel User Interface Figure 3—1. User Interface Module 1. Display Presents critical diagnostic and operating information, including startup, shutdown, alarm warnings, trips, setpoint changes, and much more 2.
  • Page 35 The Control System Index or Menu Keys These four keys provide the operator access to numerous screens that display compressor real-time operational data, along with control, historical and networking information from the Vantage Control System. The following descriptions and sample screens demonstrate data from both standard and optional monitoring instruments that may or may not be included on all models.

  • Page 36: Function Keys

    The Turbo Air 3000 Centrifugal Compressor Handbook Function Keys Four of these five keys are used to operate the compressor and to have it produce compressed air. The fifth key allows the operator to adjust certain setpoints that regulate the compressor’s operation.
  • Page 37 The Control System Auto This key launches the compressor automatic control mode enabling it to respond automatically to changes in system demand per a pre-selected control method. (The control method for your system was determined at the time of order and is based on the specific application.

  • Page 38: Input Or Operational Keys

    The Turbo Air 3000 Centrifugal Compressor Handbook Input or Operational Keys These keys allow the operator to communicate with the control system. Using these keys you can maneuver among the control screens, change alpha-numeric values of set points, and change the various control constraints or entered using these keys in the manner described below.
  • Page 39 The Control System Practice Exercise You can use this practice exercise to gain familiarity with the various keys and to view representative screens on the display before the actual startup and operation of the compressor under the Vantage Control System. When exploring the display screens with option lists, remember to use the Up and Down keys to move through the various selections.
  • Page 40 The Turbo Air 3000 Centrifugal Compressor Handbook 4. Press the Home key to display the “Home” page selected by the compressor owner. Any of the View screens are practical choices to give the operator quick and easy access to important operation or protection data. Probably the most popular screen selected is the Perfor- mance Control Screen (seen below).
  • Page 41 The Control System 6. Press Back (or View) to return to the View page. 7. Press Up or Down to move the highlight to Startup Status and press Enter to open the screen. The Startup Status screen (sample screen below) is active only when the compressor is stopped. The elements displayed, along with a status indication, are those necessary for a permissive start.
  • Page 42 The Turbo Air 3000 Centrifugal Compressor Handbook 3—12...

  • Page 43: General Considerations

    Routine Operation Section Four Routine Operation In this section, the reader will learn about: ¨ General Considerations ¨ The Operating Data Record ¨ Routine Startup — LOCAL Control ¨ Routine Shutdown — LOCAL Control ¨ Adjusting the Pressure Setpoint 4—1...
  • Page 44 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 4—2...

  • Page 45: General Considerations

    Section Five. However, in addition to operator inspection and attention at periodic intervals. To assure long life and optimal output from the Turbo Air 3000 Centrifugal Compressor, always follow the prescribed maintenance procedures. If problems arise, contact a Cooper Turbocompressor factory trained and authorized service representative for technical assistance.
  • Page 46 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Operating Data Record Pressure Ö Discharge Air Pressure: Ö System Air Pressure: Ö Main Oil Pressure: Ö * Inlet Air Filter Drop: Ö * Oil Filter Pressure Drop: Temperature Ö Oil Temperature: Ö...

  • Page 47: Routine Startup

    Routine Operation Routine Startup—Local Control Use this procedure to start the compressor locally from the User Interface Module (UIM). WARNING Only fully trained personnel should be allowed to start and operate this compressor. Failure to comply may result in serious injury or death. 1.

  • Page 48: Routine Shutdown

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Routine Shutdown—Local Control Use the following procedure to shutdown the compressor under normal conditions. CAUTION: If the compressor is to be shutdown for an extended period in a cold environment, drain all water from the compressor's cooling system after the shutdown. Water in the heat exchangers may freeze and cause damage to the internal tubes.

  • Page 49: Adjusting The System Pressure Setpoint

    Routine Operation Adjusting the System Pressure Set Point During normal operation, it may become necessary to make small adjustments to the System Pressure Set Point in order to alter the operating characteristic of the compressor. The example here shows a System Pressure that has been set at 98.0 psi. CAUTION: DO NOT operate the compressor at pressures greater than the nameplate rating.
  • Page 50 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 4—8...
  • Page 51 Maintenance Section Five Maintenance In this section, the reader will learn about: ¨ General Considerations ¨ Daily Inspection ¨ Scheduled Maintenance ¨ Professional Inspection ¨ Filter Maintenance Inlet Air Filter Bypass Valve Filter Oil Reservoir Vent Filter Standard Oil Filter Duplex Oil Filter ¨...
  • Page 52 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 5—2...

  • Page 53: General Considerations

    Maintenance General Considerations The Turbo Air 3000 Centrifugal Compressor requires minimal maintenance. However, monitoring operating conditions on a daily (or shift change) basis is good practice. It allows the operators to become familiar with a smooth running machine which will lead to early detection of potential prob- lems.

  • Page 54: Daily Inspection

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Daily Inspection A daily inspection takes only a short time, but it will allow the operator to develop a definite sense of the appearance, sounds, and other operating conditions of a smoothly performing compressor. Any changes can be investigated and be given attention before major problems develop.

  • Page 55: Scheduled Maintenance

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

  • Page 56: Professional Inspection

    Main drive coupling inspected and re-greased Motor inspected in accordance with manufacturer’s instructions *Replacement parts required. Use only genuine JOY® and Cooper Turbocompressor parts and supplies available through the Cooper Turbocompressor and/or authorized representatives. (Refer to Section Seven, Parts and Service, for additional information regarding inspection kits.) Table 5—3 Service Inspection Checklist...

  • Page 57: Filter Maintenance

    Since compressor operation without the action of the primary filter will contaminate the second- ary filter very rapidly, Cooper Turbocompressor recommends that user’s stock a spare primary filter for use as required. It is also necessary to keep a supply of secondary filters for use as required, since the secondary filter cannot be cleaned and must always be replaced when it becomes dirty and no longer functions properly.
  • Page 58 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 3. When necessary, it is possible to clean the primary filter (which has the screen across its face) in either of these two ways: · Blow 30 psi (2kg/cm or bar) of air from the clean side.
  • Page 59 The compressor must be shutdown before servicing the oil filter. When required, use the following procedure to replace the standard oil filter element. Use a Cooper Turbocompressor replacement filter only. Filters that look the same may not necessarily perform the same.
  • Page 60 3. Inspect the new filter and then, using clean oil, lightly lubricate the gasket. CAUTION: Use a Cooper Turbocompressor replacement filter only. This will ensure safe and reliable performance. 4. Unscrew the filter bowl, and remove the old filter element.

  • Page 61: Lubrication

    Lubrication Table 5—5 lists recommended intervals and the products necessary for proper lubrication of various Turbo Air 3000 Compressor components. Refer to Section Two, Compressor Specifications, for addi- tional information regarding required lubricants. For ordering information, refer to Section Seven, Parts and Service.
  • Page 62 Insert a grease fitting into each sleeve, and then pump approximately 2 oz. (60 cc) of Cooper Turbocompressor Coupling Grease into one of the holes in each sleeve until fresh grease flows from the opposite hole. WARNING: Use Cooper Turbocompressor Coupling Grease only. Other greases do not provide adequate protection. 5—12...
  • Page 63 7. Replace the coupling guard. Drive Motor Ball Bearings Lubrication The Turbo Air 3000 Compressor may be equipped with a squirrel-cage induction motor with ball bearings. The ball bearing grease must be changed in accordance with the motor manufacturer’s recommendations.
  • Page 64 To correctly determine the type of valve used in a particular installation, refer to Figures 5— 1 and 5—2, which illustrate the two types of valves. Turbo Air 3000 Compressors rated up to and including 600 horsepower utilize a box-shaped bypass valve which requires periodic lubrication. The larger cylindrical, angled valve employed on higher rated machines (700 horsepower and larger) does not require lubrication.
  • Page 65 Maintenance Seal ebuildı Seal Kit Lubricant Figure 5—1 Bypass Valve Figure 5—2 Bypass Valve WARNING: Before attempting this procedure, be certain to shut down the compressor, lock out the main power supply, and fully close the discharge block valve. Failure to follow these requirements could cause severe injury from pressurized air.
  • Page 66 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 4. Clean all parts of the piston, and carefully inspect the piston bore and piston seals for wear and/or damage. WARNING: If the bore appears damaged, do not attempt to rebuild the assembly. It will be necessary to replace the bypass valve at this time.

  • Page 67: Additional Maintenance Procedures

    Maintenance Additional Maintenance Procedures In addition to periodic inspections and maintenance of the filter and lubrication systems, some maintenance will also be necessary on an “as required” basis. The necessity is determined by particular performance indicators or is performed on a periodic basis. Table 5—6 lists these procedures. Instructions for each follow.
  • Page 68 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual · Tubes The tubes must be cleaned using a series of brushes (in the case of the intercoolers and aftercooler) or a rod (in the case of the oil cooler) and then given a thorough soaking with a Ò...
  • Page 69 Maintenance Front Tubesheet Gasket Y-Gasket K-Seal Upper Baffle Plate Intercooler Bundle Header Gasket Figure 5—3 Intercooler Disassembly Water Cooler 1. Remove all loose scale from the interiors of the cooler cavity, the water headers, and the manifold pipes. CAUTION: Do not allow the loose debris to enter the condensate drain lines. This could cause plugging of the drains.
  • Page 70 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual CAUTION: If the compressor is equipped with U-bend water tubes, do not force the rod into the U- bend. Doing so could cause damage to the tubes. 3. Stand the bundles with the tube openings up, and fill the tubes with commercial descaling agent such as Rydlyme.
  • Page 71 Maintenance 10. Drain the descaling agent and thoroughly flush the tubes with clean water. 11. Again using the drill motor and the rod/brush assembly, brush in and out of the tubes using the largest brush (3/8” or 10 mm) while simultaneously flushing out the tubes with clean water. 12.
  • Page 72 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Oil Cooler Cleaning Deterioration in oil cooler performance may be an indication that it is time to remove the mineral scale buildup within the oil cooler tubes. When that occurs, clean the tubes as follows: 1.
  • Page 73 Maintenance Discharge Air Check Valve Inspection At 6 month intervals, use the following procedure to inspect the discharge air check valve to determine whether it is still in good working order or whether it must be replaced. 1. Shut down the compressor and lockout the main motor starter. 2.
  • Page 74 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 5—24...
  • Page 75 Troubleshooting Section Six: Troubleshooting In this section, the reader will learn about: ¨ General Considerations ¨ How to Use the Troubleshooting Guide ¨ How to Request Assistance ¨ Alarm and Trip Functions ¨ Drive Train Troubleshooting ¨ Control System Troubleshooting ¨...
  • Page 76 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 6—2...

  • Page 77: General Considerations

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

  • Page 78: How To Use The Troubleshooting Guide

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

  • Page 79: How To Request Assistance

    Failure to heed this warning could seriously jeopardize the quality of the repair or replacement. For advice or service help, always contact your local authorized Cooper Turbocompressor sales and service representative. Refer to Section 7, Parts & Service, Aftermarket Support, for the name and address of your local representative.

  • Page 80: Alarm And Trip Functions

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Alarm and Trip Functions If compressor-operating parameters deviate from normal tolerances, the Vantage Control System will activate one of two levels of compressor protection. • Alarm. An Alarm condition is a warning about a compressor operating condition that is outside of normal operating limits.
  • Page 81 Troubleshooting 3. Press the key and compare the current operating oil pressure from the previous Protection History screen to the Alarm and Trip set points. 4. Analyze the information and take appropriate action(s) to correct the cause of the malfunction. (It may be necessary to consult the Troubleshooting guidelines, which follow.) 6—7...

  • Page 82: Drive Train Troubleshooting

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Drive Train Troubleshooting Condition: Possible Causes: Motor Vibration/Unusual Sounds Starter malfunction Foundation bolts loose Other mechanical part(s) loose Excessive or unbalanced voltage Lubrication inadequate or excessive Dirt on fan Dirt in air gap...
  • Page 83 Troubleshooting Drive Train Troubleshooting ...continued Condition: Possible Causes: Compressor Vibration Sensor Reading Faulty Wiring in control panel incorrect High Oil Temperature Low Oil Temperature Low Oil Pressure Oil type incorrect Oil contaminated Surging Motor Vibration Misalignment Drive coupling damaged and/or worn Impellers dirty or damaged Rotor cartridge malfunction 6—9...

  • Page 84: Control System Troubleshooting

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Control System Troubleshooting Condition: Possible Causes: Compressor Start Failure Drive motor starter not racked in EMERGENCY STOP button depressed Start permissives not met Control panel inoperative Main power fuses blown or faulty...
  • Page 85 Troubleshooting Control System Troubleshooting ...continued Condition: Possible Causes: Motor Overload Maximum amp set point too high Inlet valve or guide vane assembly inoperative Inlet valve or guide vane assembly out of adjustment Thermal overload relay set improperly Current transducer faulty Starter problem Motor problem.

  • Page 86: Air System Troubleshooting

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Air System Troubleshooting Condition: Possible Causes: High Air Pressure Low demand Air Pressure setpoint too high Sensor Reading Faulty Control Valve(s) Faulty Low Air Pressure Air Pressure setpoint incorrect Maximum Amp setpoint incorrect...

  • Page 87: Lubrication System Troubleshooting

    Troubleshooting Lubrication System Troubleshooting Condition: Possible Causes: Oil Leak(s) Connection loose Filter cartridge loose Gearbox Oil Leak(s) Pump shaft seal worn or damaged Oil Mist Ejector vent filter clogged Filter trap not filled Ejector pressure incorrect High Oil Temperature Water flow to cooler insufficient Coolant temperature too high Oil cooler fouled Sensor Reading Faulty...
  • Page 88 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Lubrication System Troubleshooting ...continued Condition: Possible Causes: Low Oil Pressure Oil level too low Pressure regulator set improperly or malfunctioning Fuses in pump motor starter blown or faulty Oil filter element dirty or clogged...
  • Page 89 Parts and Service Section Seven: Parts and Service In this section, the reader will learn about: ¨ Aftermarket Support ¨ The Parts Ordering Procedure ¨ Parts Availability ¨ The Returned Goods Policy ¨ The Periodic Maintenance Parts Inventory ¨ The Professional Inspection Parts Requirement ¨...
  • Page 90 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 7—2...

  • Page 91: Aftermarket Support

    Parts and Service Aftermarket Support As an important part of its commitment to its products and customers, Cooper Turbocompressor offers full aftermarket support. The array of aftermarket services includes inspection and repair, availability of ® genuine JOY and Cooper Turbocompressor parts and recommended supplies, and compressor operator training seminars at the factory training facilities in the USA or at the user’s site.

  • Page 92: Parts Ordering Procedure

    The Returned Goods Policy It is necessary to contact Cooper Turbocompressor for authorization before the return of any goods to the factory. All approved returns are immediately assigned a tracking number to prevent processing delays or loss of materials. This ARG (authorization to return goods) tracking number is then recorded at the factory.

  • Page 93: The Periodic Maintenance Parts Inventory

    Parts and Service The Periodic Maintenance Parts Inventory Cooper Turbocompressor recommends keeping a basic inventory of replacement and spare parts and stock- ing of all the recommended supplies mentioned in this operator’s manual. This will eliminate or help reduce unanticipated shutdown time during those occasions when it may be necessary to maintain or replace one or more compressor parts.
  • Page 94 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Recommended Periodic Maintenance Parts & Supplies Description QtyTurbocompressor Description Cooper Turbocompressor Part Number Filters: · Inlet Air Filter, Primary and Secondary Elements · Bypass Valve Air Line Filter Element P0540016-00074 · Oil Reservoir Vent Filter Element P1404987-00014 ·...

  • Page 95: The Professional Inspection Parts Requirement

    When replacing parts or ordering supplies, always use genuine JOY ® and/or Cooper Turbocompressor replacement parts and Cooper Turbocompressor approved supplies. Cooper Turbocompressor will accept no liability for damages caused by use of non- authorized parts, supplies, or service. 7—7...
  • Page 96 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Professional Service Inspection Parts & Supplies Description Cooper Turbocompressor Part Number Gearbox: · O-Ring, First Stage Inlet P1406702-00395 · O-Ring, Second Stage Inlet P1406702-00386 · O-Ring, Third Stage Inlet P1406702-00383 · Seal, First Stage Diffuser P1794323-00005 ·...

  • Page 97: Control System Parts

    Parts and Service Control System Parts 02/12 04/06/14/15 Figure 7 1. Control System Sensors — Item Cooper Turbocompressor Description Part Number Standard Instrumentation: Vibration Probe, Stage 1 P1407030-02002 Vibration Probe Extension Cable (10 ft / 3 m) P3403893-00006 RTD, Inlet Air Temperature, Stage 2 or 3 [A]...
  • Page 98 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Control System Parts (GEARBOX COVER) (OIL/AIR SEAL) (PINION) Figure 7 2. Vibration Probe Installation — Item Cooper Turbocompressor Description Part Number Vibration Probe P1407030-02002 Retaining Plate P1407301-00003 Capscrew P0902224-00412 Tube Fitting P1791399-03539...
  • Page 99 Parts and Service Control System Parts Figure 7 3. Low-Voltage Compartment/Vantage Control Components — Item Cooper Turbocompressor Description Part Number User Interface Module (UIM) P3798102-00010 Main Logic Module (MLM) P3798102-00000 Actuator Motor Capacitor* 110 VAC P0540107-00012 220 VAC P0540107-00019 Control Relays (optional)

  • Page 100: Lubrication System Parts

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Lubrication System Parts Filter Housing Figure 7 4. Reservoir Vent Filter Assembly — Item Cooper Turbocompressor Description Part Number Main (shaft-driven) Oil Pump P1401428-00614 Drive Coupling, Main Oil Pump P1402070-00254 Auxiliary (motor-driven) Oil Pump...
  • Page 101 Figure 7 5. Duplex Oil Filter Option — Figure 7 7. Reservoir Heater Option — Item Cooper Turbocompressor Description Part Number Cooler, Oil-to-Water (Heat Exchanger): [A] - Complete with 0.375 (10mm) dia. 90/10 alloy tubes [B] P1401429-01002 - Maintenance Gasket Kit P1405680-00001 Duplex Filter (Figure 7—5): [A]...

  • Page 102: Main Drive Coupling Parts

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Main Drive Coupling Parts O-RING BOLT SLEEVE GASKET SPACER BULLGEAR SHAFT LUBE PLUG BAFFLE (2 PER SLEEVE) GASKET PLATE BAFFLE PLATE DRIVER SLEEVE BOLT SHAFT O-RING Figure 7 8. Main Drive Coupling Assem- —...

  • Page 103: Heat Exchanger Parts

    Y-Gasket K-Seal Upper Baffle Plate Intercooler Bundle Header Gasket Water Header Figure 7 9. Intercooler/Aftercooler Bundle Assembly — Standard U-Tube Model Item Cooper Turbocompressor Description Part Number K-Seal P1408800-04941 Y-Gasket P1408800-04926 Header Gasket P1793932-02100 Front Tubesheet Gasket P1793931-02100 Table 7 9.
  • Page 104 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Heat Exchanger Parts Rear Water Header Gasket K-Seal Y-Gasket Front Tubesheet Gasket Upper Baffle Plate Intercooler Bundle Header Gasket Water Header Figure 7 10. Intercooler/Aftercooler Bundle Assembly — Optional S-Tube Model Item...
  • Page 105 Parts and Service Heat Exchanger Parts Figure 7—11. Solenoid-Operated Condensate Draining System (One set required for each heat exchanger) Item Cooper Turbocompressor Description Part Number Solenoid Valve, 1/2” NPT, 110/120-Volt P1401581-01302 Solenoid Valve, 1/2” NPT, 220/240-Volt P1401581-01341 Check Valve, 1/2” NPT P1401581-01303 Gate Valve, 1/2”...

  • Page 106: Air Piping Parts

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Air Piping Parts Inlet Guide Vane Assembly Figure 7 14. Inlet Air Piping Components — Item Cooper Turbocompressor Description Part Number Startup Screen (for 8” pipe) P1405344-00016 Expansion Joint (for 8.625” O.D. pipe)
  • Page 107 Parts and Service Air Piping Parts 02, 03 Figure 7 15. Inlet Guide Vane and Actuator Assembly — Item Cooper Turbocompressor Description Part Number 6” (150mm) 8” (200mm) Inlet Pipe Reducer P1409508-00000 P1409508-03000 Pipe Couping P1404961-00200 P1404961-00209 Gasket, Pipe Coupling...
  • Page 108 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Air Piping Parts Figure 7 16. Inlet Air Filter Assembly — Item Cooper Turbocompressor Description Part Number AI-128-V Type [A] Primary Filter Element P1400009-00770 Secondary Filter Element P1400009-00771 AI-128 Type [B] Primary Filter Element...
  • Page 109 17 Bypass Valve Assemblies and Packaging Options — 01, 02 01, 02 05, 06 05, 06 07, 08 01, 08 Item Cooper Turbocompressor Description Part Number <600 Hp [A] >700 Hp [A] Bypass Valve: - 120 V / 60 Hz P1401581-01256 P1401581-01501...
  • Page 110 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Air Piping Parts Volume Booster Diaphagm Actuator Filter Regulator Transducer Figure 7 18. Modulating Blow-Off Valve (MBOV) Assembly — Control Valve Item Cooper Turbocompressor Description Part Number Modulating Blow-Off Valve Assembly [A] - 1.5”...
  • Page 111 Figure 7 21. Automatic Block Valve — Figure 7 20. Discharge Air — Assembly Check Valve Connections Model Overall Cooper Turbocompressor Inlet [A] Discharge [A] Length Part Number BMSV-8 2” (NPT)[B] 8” (Flanged) 78” (2000 mm) P0540010-07091 BMSV-6 1 1/2” (Flanged) 6”...
  • Page 112 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual 7—24...
  • Page 113 Installation Appendix A Installation In this appendix, the reader will learn about: ¨ General Considerations ¨ The Installation Work Schedule ¨ Labor, Supplies, Equipment …. ¨ Site Considerations ¨ Process Air Piping ¨ Utility Piping ¨ Electrical Interface ¨ Receiving, Lifting, Moving …. ¨...
  • Page 114 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual A—2...

  • Page 115: General Considerations

    The Installation Work Schedule lists the various considerations that the owner must address before and during the installation process, up to and including the initial startup procedure. During the Initial Startup Service Inspection, the Cooper Turbocompressor trained and authorized service representative will thoroughly inspect the installation work completed including all peripheral piping and electrical work.

  • Page 116: The Installation Work Schedule

    (if necessary) arrange for suitable storage for the com- pressor until the time of installation. 4. At least two weeks before the projected initial startup date, contact a Cooper Turbocompressor representative to schedule startup assistance.

  • Page 117: Labor, Supplies, Equipment And Tools

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

  • Page 118: Site Considerations

    The standard Turbo Air 3000 Compressor is designed for indoor installation. For outdoor installation, it is necessary to purchase the optional TEFC motor and NEMA-4 electrical option as part of the package.
  • Page 119 Foundation The Turbo Air 3000 Compressor can be installed directly onto the factory floor so long as the floor meets the following minimum requirements: · It must be constructed of good quality, reinforced concrete to provide a rigid and substantial base.

  • Page 120: Process Air Piping

    The process air system includes three subsystems: the inlet air piping, the discharge air piping, and the bypass piping arrangements. The Process and Instrumentation Diagram provided separately illustrates only the various compressor system components supplied by Cooper Turbocompressor. The user must provide all external process air piping and supports as well as the piping design itself.
  • Page 121 Installation 1/2” Instrument Line A. Inlet Filter B. Inlet Screen C. Expansion Joint D. Check Valve E. Block Valve F. Blowoff Valve G. Silencer Figure A—2. Typical Process Air Piping A—9...
  • Page 122 Connection The inlet air connection to the Turbo Air 3000 Compressor is a cast iron reducer, the outside of which matches standard steel pipe. (American National Standards Institute: ANSI B36.10). This inlet reducer may be removed and machined to accept a number of different style couplings, thus allowing the installer to select among several options when making the inlet air pipe attachment to the compressor.
  • Page 123 Installation Inlet Guide Assembly Inlet Startup Screen Inlet Expansion Joint Figure A—5. Detail of Inlet Air Connection with Options Piping Material When selecting the pipe to be used, it is advisable to either select corrosion-resistant piping or, alterna- tively, to treat the pipe to provide additional corrosion protection. When fabricating the inlet air piping, also take care to provide suitable support so as to sufficiently isolate the piping forces from the com- pressor itself.
  • Page 124 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Inlet Expansion Joint Cooper Turbocompressor recommends the use of the Inlet Expansion Joint option (which consists of a rubber sleeve with stainless steel clamps) as a means of joining the inlet air pipe to the compressor.
  • Page 125 The compressor discharge air connection is machined to accept a Victaulic pipe coupling. When attach- ing the discharge pipe, refer to the contract-specific Installation Arrangement Drawings supplied separately for specific size information. Cooper Turbocompressor offers the following coupling options: · Straight Coupling · Reducing Coupling ·...
  • Page 126 Canada, and most other countries strictly prohibit the use of unprotected polyvinyl chloride (PVC) piping to transport compressed air or other compressed gases. Cooper Turbocompressor also advises against using soldered copper fittings and rubber hoses in discharge air piping. If fabricating the air piping with flexible joints and flexlines, be sure that they meet the operating parameters of the system.
  • Page 127 Discharge Expansion Joint Cooper Turbocompressor recommends the use of the Discharge Expansion Joint option to ensure a safe discharge piping system design. The discharge expansion joint must be mounted vertically, directly at the discharge flange of the compressor. Because braided type expansion joints cannot withstand a collapsing force, it is necessary to install such joints with sufficient pre-tension to counteract such forces.
  • Page 128 Automatic Block Valve, for additional information on the Automatic Block Valve option. Control Valve Piping Depending on the control method being applied, the Turbo Air 3000 will either completely or partially unload whenever the capacity of the compressor exceeds the compressed air system’s demand. Under AUTO-OFFLINE control, the compressor is unloaded by completely bypassing the compressed air system and venting discharge air back to the inlet of the compressor or out to atmosphere.
  • Page 129 Installation Valve Installation In instances when the bypass valve or the modulating blow-off valve is installed by the owner/installer, the installation must be in a branch of the discharge piping located upstream from the discharge check valve. (Refer to the Flow Schematic supplied separately for a placement illustration.) The recommended maximum length for this line (which is located between the main process pipeline and the venting valve) is 10 ft.
  • Page 130 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Sound Suppression Inlet and discharge air piping are major sound emitters in any compressor installation. For greater sound suppression, insulate local surfaces with sound absorbing materials. For maximum sound sup- pression, it is necessary to insulate the entire air path as follows: ·...

  • Page 131: Utility Piping

    Cooling Water (Coolant) Supply Piping The typical Turbo Air 3000 Compressor package includes four water-cooled heat exchangers (two intercoolers, an aftercooler, and an oil cooler). Figure A—10 illustrates the manifolding of these heat exchangers to provide a single feed connection and single return connection for cooling water at the compressor.
  • Page 132 Maintenance, significantly better performance will be possible. The installer must consider the distance and routing of the water piping when determining the appro- priate sizing for the piping. Cooper Turbocompressor also recommends installing, when necessary, a pressure regulator to allow for pressure control of the water.
  • Page 133 Installation CAUTION: When fabricating the coolant supply piping (Figure A—11), always install the throttle valve on the discharge side of the manifold rather than the inlet side. This will ensure that the coolers are always flooded and that no air locks will form to restrict flow. After fabrication of the cooling water piping is complete and before the initial compressor startup, install temporary filter screens in the supply lines just before entry to the heat exchangers.
  • Page 134 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Condensate Drain Piping During air compressor operation, condensate collects in each intercooler chamber as the air is cooled. (This is not the case when the compressor is used in dry nitrogen service.) In order to prevent the condensate from being carried over and entering the next stage of compression, the condensate in each of the intercooler chambers must be drained into an open drain or trough.

  • Page 135: Optional Features

    Installation Optional Features Cooper Turbocompressor offers an array of cooling water piping and condensate drain options that may ease the installation of the compressor or enhance the overall operation of the compressor. Any of these features may be easily retrofitted if not included at the time of the original machine order.
  • Page 136 Vantage Control Panel. The Vantage Control System will open and close the drain valves at set intervals to drain accumulated condensate from the heat exchanger chambers. The Cooper Turbocompressor design is again compact and very effective. It will save installation cost and efficiently allow condensate to drain from the cooler chambers without wasting compressed air.
  • Page 137 The gearbox and oil reservoir must be vented in a way that will prevent migration of oil and/or oil mist to the surrounding area or other parts of the compressor. The Turbo Air 3000 Compressor utilizes a simple ejector (or venturi-tube) powered by clean, dry, filtered air. This ejector creates a slight vacuum inside the gearbox and oil reservoir to prevent the unwanted migration of oil and oil mist.
  • Page 138 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Electrical Conduit The typical Turbo Air 3000 Compressor installation will require that medium voltage, and possibly high voltage, electrical power is delivered to complete the compressor installation. The standard package- mounted components requiring electrical power are the main drive motor, the oil pump motor and the Vantage Control Panel.

  • Page 139: Electrical Interface

    (if included). Refer to other technical data and/or engineering drawings supplied separately to determine the correct power supply requirements. WARNING: Do not energize or start up the compressor until a Cooper Turbocompressor service repre- sentative has given full approval. Failure to follow this requirement will compromise any applicable warranties.
  • Page 140 It is advisable to use stepped starters for reduced voltage motor controls. In certain applications, solid state starter performance may be unreliable or inconsistent. Refer to Cooper Turbocompressor Engineering Specification EDR-G-008, Solid State Starter Specifica- tions, for more information on minimal requirements for solid state starting equipment.
  • Page 141 Installation Oil Heater Option The supply voltage determines the wiring method for the Oil Heater option. For typical wiring for voltage applications of 480 VAC or less, refer to Figure A—19. With voltage applications greater than 480 and below 600 VAC, refer to Figure A—20 for a typical wiring diagram. Three- L 3-1 L 3-1...

  • Page 142: Receiving, Lifting, Moving, And Bolting

    The Turbo Air 3000 Compressor is designed to be moved with an overhead hoist and chain. Be sure that both are properly rated for a maximum package weight of 18,500 lbs. (8400 kg), and be certain that they are in good working order before attempting the move.
  • Page 143 Installation Figure A—21. Compressor Lift Points Moving If an overhead hoist is not available, the compressor may be moved on rollers, dollies, or casters. Alternatively, if a forklift is used to move the compressor, be certain to place the entire compressor on a substantial pallet that supports the base between the liftpoints and lift only under the base between the lift points indicated.

  • Page 144: Preparing For Startup

    A Pre-Startup Inspection Checklist follows which arranges the tasks or responsibilities that the user or installer should be able to complete prior to the arrival of the Cooper Turbocompressor startup repre- sentative. Should any concerns or questions develop while executing this list, it should be brought to the attention of the startup representative.
  • Page 145 Installation Pre-Startup Inspection Checklist Foundation Bolts Properly tightened Cooling Water (Coolant) Piping Correctly routed and strain-free Shut-off valves installed Inlet and outlet correctly connected Cleaned and flushed free of dirt and/or other foreign matter Condensate Drain Piping Automatic or manual traps or valves installed Piped individually into open drains Inlet Air Piping Sized correctly, with minimal use of elbows...
  • Page 146 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Pre-Startup Inspection Checklist continued… Electrical Interface Earth ground installed All applicable codes met Motors wired according to manufacturer’s instructions Motor controllers and starters wired according to manufacturer’s instructions Control panel wired properly...
  • Page 147 Installation Main Drive Motor Rotation Verification Before coupling the compressor and main drive motor, it is necessary to verify that the phase sequence wiring will provide the correct rotation direction. To verify correct rotation, follow this sequence: 1. Verify that motor fastening bolts are properly torqued as listed in Section Two, Compressor Specifi- cations.
  • Page 148 5. Shut off the oil pump after the circulation period. 6. Remove and inspect the oil filter for any signs of contamination. The Cooper Turbocompressor service representative must observe this last inspection point and (if required because of contamination) the changing of the oil filter element before the initial compressor startup.

  • Page 149: Preventing Startup Problems

    It is the owner’s responsibility to plan for the inspection and initial startup service by the Cooper Turbocompressor representative and to provide all tools, equipment, supplies, and labor required as described earlier in this section. Contact the Cooper Turbocompressor service representative at least two weeks before the required on-site date to arrange for startup service.

  • Page 150: The Inspection Prior To Initial Startup Schedule

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual The Inspection Prior to Initial Startup Schedule As part of the site evaluation, a factory trained and authorized Cooper Turbocompressor service representative will verify that the compressor is ready to be put into full operation. The service repre- sentative will perform the following inspections and tasks as part of the initial compressor startup service.

  • Page 151: The Initial Startup Procedure

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

  • Page 152: Initial Start Up Procedure

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Initial Start up Procedure Start the compressor and: 1. Measure and record the acceleration time (___ seconds). 2. Unload the compressor. 3. Verify normal compressor operation while unloaded. Check inlet valve unloaded position.

  • Page 153: Service Assistance

    The Turbo Air 2000 Centrifugal Compressor is a high technology product. When problems develop which are beyond the scope of operating personnel, request assistance from a Cooper Turbocompressor trained and authorized service representative or the Cooper Turbocompressor Field Service Department.
  • Page 154 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual A—42...
  • Page 155 The Lubrication System Appendix B The Lubrication System In this appendix, the reader will learn about: ¨ General Considerations ¨ The Compressor Lubrication System ¨ Vantage Control of Compressor Lubrication ¨ Operational Guidelines ¨ Gearbox and Reservoir Venting ¨ Optional Features B—1...
  • Page 156 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual B—2...

  • Page 157: General Considerations

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

  • Page 158: The Compressor Lubrication System

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual The Compressor Lubrication System Figure B—1 is a schematic illustration of the compressor lubrication system, indicating how the oil circulates through the system and through standard compressor components. The following describes the principles of normal operation.

  • Page 159: Vantage Control Of Compressor Lubrication

    The Lubrication System Vantage Control of Compressor Lubrication Throughout the lubrication cycle, the Vantage control system continuously monitors the compressor lubrication system to guarantee safe and efficient operation. The oil pressure sensor [P] and oil temperature sensor [T], shown in Figure B—1, ensure that all critical mechanical components are being properly lubricated and cooled by the oil.

  • Page 160: Operational Guidelines

    Oil Pump Operation Cooper Turbocompressor recommends keeping the auxiliary oil pump in continuous operation (even during compressor shutdown) to ensure proper lubrication at all times. However, in order for this recommendation to be followed, the oil pump must be electrically isolated from all other compressor systems.

  • Page 161: Gearbox And Reservoir Venting

    Ejector/Filter The Turbo Air 3000 Compressor utilizes a simple venturi-type ejector/filter system to create a slight vacuum inside the gearbox and oil reservoir. This vacuum prevents oil or oil mist from migrating out into the atmosphere and/or creating other oil leaks.

  • Page 162: Optional Features

    The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Optional Features Although the following components are not required for safe operation of the Turbo Air 3000 Com- pressor, they will bring added convenience to the overall operation of the lubrication system. If not included with the initial compressor package, they may be added at any time.
  • Page 163 The Lubrication System Duplex Oil Filter In many instances, compressed air systems operate on a continuous basis. Since it is frequently inconve- nient to completely shut down compressor operation to perform a simple maintenance task, Cooper Turbocompressor offers the Duplex Oil Filter option. The duplex oil filter eliminates the necessity for compressor shutdown during filter maintenance.
  • Page 164 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual B—10...

  • Page 165: Vantage Control System Logic

    Vantage Control System Logic Appendix C Vantage Control System Logic In this appendix, the reader will learn about: ¨ General Considerations ¨ Compressor Control Methods ¨ AUTO-OFFLINE Control ¨ AUTO-STANDBY Control ¨ AUTO-UNLOAD Control ¨ Compressor Safety Mechanisms C—1...
  • Page 166 The Turbo Air 3000 Centrifugal Compressor Handbook C—2...

  • Page 167: General Considerations

    Vantage Control System Logic General Considerations This appendix provides detailed descriptions of each of the three compressor control methods. It includes the theoretical basis, performance maps for each of the five control loops and their associated setpoints for each operating method. This information is of a highly specialized nature and not necessary required reading for all operating personnel.
  • Page 168 The Turbo Air 3000 Centrifugal Compressor Handbook Control Methods Vantage offers three distinct load control methods to provide flexibility in meeting widely varying jobsite compressed air needs. · Auto – Offline* · Auto – Standby* · Auto – Unload Each Vantage control method uses all five valve control loops shown Table C—1. Detailed descriptions of these methods appear latter in this Appendix.
  • Page 169 Vantage Control System Logic Inlet Valve Control Setpoints The Vantage control system modulates the compressor inlet valve in response to the control setpoints associated with the three control loops described on the preceding page. Each of the control loops constantly reviews the operational status of the compressor relative to its setpoint.
  • Page 170 The Turbo Air 3000 Centrifugal Compressor Handbook Discharge Valve Control Setpoints This control mode functions exactly the same as Auto-Offline, up to the point where the check valve closes. Then, instead of unloading, Auto–Standby opens the blow off valve further, to operate the compressor at a discharge pressure (Standby Mode Offset) less than the System Pressure setpoint.
  • Page 171 Vantage Control System Logic Auto-Offline Control With Auto-Offline Control, the inlet valve modulates to satisfy the System Pressure setpoint (within the Maximum Motor Load setpoint limits). In cases of low demand, the control throttles back to the Minimum Flow control line setpoint. The Minimum Flow control loop controls system pressure to the System Pressure Offset setpoint and flow to the Surge Control Offset line.
  • Page 172 The Turbo Air 3000 Centrifugal Compressor Handbook Auto-Offline Control Inlet Valve Control When the actual system pressure is lower than the System Pressure Setpoint, the Vantage controller begins to load the compressor. During the initial load cycle, the inlet valve opens to a Minimum Flow value when the compressor discharge valve begins closing.
  • Page 173 The proper setting of the Maximum Discharge Pressure setpoint is a value below the natural high- pressure surge point of the compressor. Although the Vantage control loops are tuned at Cooper Turbocompressor prior to shipment, it is important to verify the tuning under the actual jobsite conditions.

  • Page 174: Auto-Standby Control

    The Turbo Air 3000 Centrifugal Compressor Handbook Auto-Standby Control This control mode operates the same as Auto-Offline until the check valve closes. Then, instead of unloading, Auto–Standby opens the blow off valve further to operate the compressor at a discharge pressure (Standby Mode Offset) less than the System Pressure setpoint.
  • Page 175 Vantage Control System Logic Auto-Standby Control The Auto-Standby control method is for air systems that experience dramatic variations in demand yet do not have a lot of receiver capacity. In these cases, an unloaded compressor may not be able to respond fast enough to sudden increases in demand.

  • Page 176: Auto-Unload Control

    The Turbo Air 3000 Centrifugal Compressor Handbook Auto-Unload Control In this Vantage control mode, inlet control is the same as Auto-Offline, but now only to the point where the Maximum System Pressure setpoint is reached. Then, instead of blowing off, Auto-Unload unloads the compressor.
  • Page 177 Vantage Control System Logic Auto-Unload Control The Auto-Unload control method is used for compressors that have a discrete (open/close) discharge bypass valve (and not a modulating blow-off valve). Vantage handles this through the Auto-Unload control method by unloading the compressor instead of blowing off. This control method may also be useful when working with several compressors in the same air header.

  • Page 178: Compressor Safety Mechanisms

    The Turbo Air 3000 Centrifugal Compressor Handbook Compressor Safety Mechanisms The Vantage Control System provides compressor protection by continuously monitoring vital functions to ensure correct and safe operation of all compressor systems. Whenever operating conditions diverge from predetermined safety parameters (the setpoints), the control system automatically triggers an appropriate system response.
  • Page 179 Vantage Control System Logic Standard and Optional Measurements Standard: Main Drive Motor Current System Air Pressure Compressor Discharge Air Pressure First Stage Vibration Oil Pressure Oil Temperature Final Stage Inlet Air Temperature Optional: Second Stage Vibration Third Stage Vibration (three stage units only) Second Stage Inlet Air Temperature (three stage units only) Inlet Air Filter Pressure Drop Oil Filter Pressure Drop...
  • Page 180 The Turbo Air 3000 Centrifugal Compressor Handbook Table C—2 shows Alarm and Trip levels for the Turbo Air 3000 Compressor. During an Alarm or Trip condition, the control system will signal the control panel with that information. This will cause the associated indicator light on the control panel to come on.
  • Page 181 Glossary Glossary...
  • Page 182 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual...
  • Page 183 Glossary Air End — the part of the compressor package that includes the gearbox and the air moving components. Airflow — the movement of air or process gas through the compressor or the compressed air system. Aftercooler — a heat exchanger that cools the process air after the final stage of compression. Alarm —...
  • Page 184 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual EMERGENCY STOP Button — the device on the Vantage Control Panel that serves to immediately interrupt power to the main motor causing the compressor to stop operating. (For emergency use only.) FLA — the abbreviation for Full Load Amperage.
  • Page 185 Glossary “Off Design” Operation — a compressor operating condition when the ambient environment is other than the design standard. Oil Cooler — the heat exchanger that cools the lubricating oil. Operator’s Data Log — a periodic record of compressor operation. Opposite Drive End —...
  • Page 186 The Turbo Air 3000 Centrifugal Compressor Operator’s Manual Surge — a compressor operating condition characterized by a momentary reversal of airflow back through the compressor. System Pressure — the pressure of the compressed air measured after the compressor check valve.

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