Cameron Handbook - TA3000 Product Manual Rev 4

Contents
Compression Systems
Engineering Data Release

AAEDR-H-081
The Turbo Air 3000

Centrifugal Compressor
Handbook
Attention:
Upon compressor receipt, it is recommended the
machine be registered at www.c-a-m.com for CCV S M
extended warranty, service information and
updates posted to the web site.
Revision History
Rev. #: 01 ECO# 1938315 January 2004
Rev. #: 02 ECO# 2042406 May 2005
Rev. #: 03 ECO# 2127389 September 2006
Rev. #: 04 ECO# 2318415 October 2008
The Turbo Air 3000 Centrifugal Compressor Handbook
ii
About ThisContents
Manual
About This Manual

This manual contains the basic information necessary for using and maintaining the Compression
Systems Turbo Air Oil Free Centrifugal Compressor, from the original startup and operation to inspec-
tion and servicing. However, since installations may vary, these instructions may not cover all details or
variations in the equipment supplied or every question which may possibly arise during use.
If a question or situation develops which is not answered directly in this manual, contact an authorized
Compression Systems sales or service representative for more information, or contact the factory
directly for specific answers and/or advice.
All operating personnel should become familiar with the contents of this manual before the compressor
is put into service. This is particularly important with regard to the safety precautions listed in the
Introduction and those included at relevant points of the procedures described in other sections of
this manual.
WARNING:
Read, be sure to clearly and completely understand, and then carefully follow all the
directions included in this manual. Failure to adhere to the guidelines and specific instruc-
tions provided could cause equipment damage and/or serious personal injury
or death.
Compression Systems reserves the right to make enhancements or improvements to the equipment at any
time, without notification. Such changes may have an impact on the accuracy of content in this document.
iii
iv
Contents
Table of Contents
About This Manual iii
Section One: Introduction

About Compression Systems 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
CC V 5-Year Warranty Program 112
Section Two: Specifications

General Compressor Specifications 2 3
Alarm and Trip Specifications 2 6
Compressor Lubricant Requirements 2 7
Section Three: Installation

General Considerations 3 3
The Installation Work Schedule 3 4
Site Considerations 3 6
Process Air Piping 3 8
Utility Piping 317
Electrical Interface 324
Receiving, Lifting, Moving, and Bolting 328
The Installation Inspection 330
Preparing for Startup 334
Initial Compressor Startup 336
Section Four: Routine Operation

Routine Startup 4 4
Routine Shutdown 4 5
The Operating Data Record 4 6
General Lubrication Considerations 4 7
The Compressor Lubrication System 4 8
Oil Pump Operation 4 9
Gearbox and Reservoir Venting 410
Optional Features 411
v
Section Five: Maintenance

Daily Inspection 5 4
Scheduled Maintenance 5 5
Professional Inspection 5 7
Filter Maintenance 5 8
Lubrication 511
Intercooler and Aftercooler Cleaning 516
Oil Cooler Cleaning 520
Control Valves 521
Section Six: Troubleshooting

How to Request Assistance 6 3
Alarm and Trip Functions 6 3
Drive Train Troubleshooting 6 4
Lubrication System Troubleshooting 6 5
Air System Troubleshooting 6 6
Control System Troubleshooting 6 7
Section Seven: Parts and Service

Aftermarket Support 7 3
Parts Ordering Procedure 7 4
Parts Availability 7 4
The Return Goods Policy 7 4
The Periodic Maintenance Parts Inventory 7 5
The Professional Inspection Parts Requirement 7 7
Control System Parts 710
Lubrication System Parts 712
Main Drive Coupling Parts 714
Heat Exchanger Parts 716
Air Piping Parts 719
Controls
Glossary
Contract Drawings
Supplemental Data
vi
Contents
vii
Introduction
Section One
Introduction
About Compression Systems
The Turbo Air Centrifugal

Compressor
Safety Precautions
Safety Labels
Warranty
Limitation on Liability
Unauthorized Repair
CC V 5-Year Warranty Program
11
12
Introduction
About Compression Systems

Compression Systemss reputation as a worldwide leader in the design and manufacture of high
technology centrifugal compressors is based upon an engineering tradition that spans over four
decades.
This tradition of technological innovation and leadership began in 1955, when the former Joy
Manufacturing Company developed the first integrally geared centrifugal compressor. In time, the
Joy Manufacturing Company grew and eventually evolved into Compression Systems. The original
machine developed in those early years became the prototype for the ingenious design that continues
to be the defining standard for oil-free centrifugal compressors.
The dependability, efficiency, and adaptability of its product line have established Compression Systems
as a global leader in the production of high technology centrifugal compressors. From the early MSG
Models, through the C-8 Models to the current range of plant air centrifugal compressors, the TURBO
AIR Series of compressors continue to be known for their ease of automation and high operating
reliability. Compression Systems centrifugal compressors operate in a diverse array of installations that
spans six continents. International concern for a cleaner environment has also motivated users to
choose these Compression Systems products, which allow them to harness the power of oil-free
compressed air as well as to minimize the ratio of energy consumption required.
The Buffalo, New York, USA, dedicated complex includes the manufacturing plant, a state-of-the-art
research and development facility and the training school. These resources, along with a worldwide
network of sales distributors and trained and authorized service representatives, enable Compression
Systems to provide the very best products and service to those industries which have come to rely on
Compression Systems centrifugal compressors.
Compression Systems is ISO 9001 and ISO 14001 Certified.
To learn more, look us up on the Internet:

Http//www.c-a-m.com
Figure 11 The Buffalo, New York, USA, Centralized Facilities
13
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 users needs in mind. The simple but rugged mechanical design provides many advantages. It
combines the best features of aerodynamic technology to achieve optimum energy efficiency, and it
delivers lower horsepower to cubic feet per minute (CFM) ratios than any other oil-free centrifugal
compressor available.
The Most Advanced

Compressor Components Available
The Turbo Air 3000 Compressor includes internal components which are unique to the industry. 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. Impellers
that 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 Maestro Control System

The Maestro control system is standard on the Turbo Air Compressor package. Maestro provides the
compressor owner with high performance solutions through faster response times, improved reliability
and reduced energy costs. This state-of-the-art system is compatible with all other centrifugal, recipro-
cating, and rotary screw compressors.
The various control modes available provide optimal efficiency in even the most demanding applica-
tions.
NOTE: The Turbo Air 3000 Compressor package is not a complete, stand-alone compressed air
system. To complete the system, additional components (such as the main drive motor starter, oil
pump starter, manifolds, inlet air filters, silencers, expansion joints, etc.) are also required. Com-
pression Systems offers a selection of optional equipment as part of the package or as add-ons after
installation.
14
Introduction
Other Design Features

Other outstanding design features of the Turbo Air 3000 compressor are shown in Figure 12
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. Shaft-driven main oil pump
8. Mounted water manifold (optional)
9. Mounted bypass valve (optional)
6
7
1 3
8
2
3
Figure 12 The Turbo Air 3000 Centrifugal Compressor
15
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.
Compression Systems expressly disclaims responsibility or liability for any injury or damage caused
by failure to observe specified or other common safety precautions or failure to exercise ordinary
caution, common sense, and due care required in operating the compressor even though not
specified herein.
The alert messages shown here appear throughout this manual to indicate those situations and times
when special care is necessary to prevent component harm or personal injury. There are three degrees
of urgency:
CAUTION:
This indicates that there may be the possibility of minor equipment damage.
WARNING:
This indicates that there could be the possibility of minor equipment damage
or personal injury.
DANGER:
This indicates that there will definitely be major equipment damage and/or personal injury
or death if all proper safety precautions are not carefully followed.
The safety guidelines included here are also included on the safety labels affixed to various parts of the
compressor. They alert the user to possible and probable hazards and serve to remind the user of
specific safety precautions. Before using the Turbo Air 3000 Centrifugal Compressor, be certain to
review the safety labels and the following safety guidelines.
WARNING:
Observe all safety precautions included in this manual and on the compressor safety labels.
Failure to do so may cause equipment damage and/or personal injury.
16
Introduction
Safety Labels
WARNING
HAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURY
OR DEATH
Disconnect all power supplies, lock-out and display
signs before servicing equipment.
DANGER
AIR UNDER PRESSURE. WILL CAUSE SEVERE INJURY
OR DEATH
DO NOT operate the compressor at pressure in excess of
the nameplate rating.
Close the discharge block valve and relieve system of
pressure before removing any caps or plugs, or servicing
compressor.
DO NOT play with compressed air.
Wear eye protection when using compressed air.
CAUTION
ELECTRICAL HAZARD. CAN SHOCK, BURN OR CAUSE
DEATH.
All electrical enclosures and components must be installed
and grounded in accordance with the National Electric Code
and other local codes.
17
Safety Labels
WARNING
HIGH SURFACE TEMPERATURES. CAN CAUSE INJURY.
Some surfaces of the compressor and motor have excessive
temperatures. To avoid burns, keep hands and other body
parts away while unit is operating.
DANGER
HOT OIL UNDER PRESSURE. WILL CAUSE SEVERE
INJURY OR DEATH.
Shut down compressor and pumps before removing any
caps or plugs, or servicing any parts.
DANGER
DO NOT USE DISCHARGE AIR FOR BREATHING OR
FOOD PROCESSING, AS IT WILL CAUSE SEVERE INJURY
OR DEATH.
Air from the compressor used for these processes in the U.S.A.
must meet OSHA 29 CFR 1910 or FDS 21 CFR 178.3570 filtra-
tion regulations.
CAUTION
ELECTRICAL OR CONTROL HAZARD. COULD CAUSE
INJURY OR MACHINERY DAMAGE.
DO NOT rewire or place jumpers in the control panel without
written consent from the Compression Systems Engineering or
Service Departments.
Periodically check all safety devices for proper operation.
18
Introduction
Safety Labels
WARNING
ROTATING SHAFTS COULD CAUSE SEVERE INJURY
OR DEATH.
DO NOT remove protective guards while the compressor is
in operation.
DO NOT attempt to service any part while the machine is
operating.
WARNING
UNIT CAN AUTOMATICALLY RESTART CAUSING
SEVERE INJURY OR DEATH.
Before removing the gearbox cover, lock the main power
OFF, close the system block valve, turn the lube pump OFF,
and remove the drive coupling.
CAUTION
Exercise cleanliness during maintenance and when
making repairs. Keep dirt away by covering parts and
exposed openings with a clean cloth.
Be sure no tools, rags, or loose parts are left on the com-
pressor or drive parts.
DO NOT use flammable solvents for cleaning parts.
WARNING
DO NOT operate the compressor in areas where there is a
possibility of ingesting flammable or toxic fumes.
19
Warranty
Compression Systems warrants that the compressor supplied conforms to applicable drawings and
specifications and that the compressor will be free from defects in material or workmanship for a
period of twelve (12) months from the date of initial operation or a period of fifteen (15) months from
the date of shipment, whichever period expires first.
If, within that period, Compression Systems receives written notice from the purchaser of any alleged
defect in or nonconformance of the compressor and if, in Compression Systemss judgment, the
compressor does not conform to the original specifications or is found to be defective in material or
workmanship, at its option Compression Systems will make restitution in one of these ways:
1. By furnishing a service representative to correct the defective workmanship.
2. By repairing or replacing the component upon the component having been returned FOB to the
Compression Systems factory in Buffalo, New York, USA.
3. By returning the full purchase price of the compressor (without interest) to the purchaser.
Compression Systemss sole responsibility and the purchasers exclusive remedy hereunder is
limited to such repair, replacement, or repayment of the full purchase price.
Equipment and accessories furnished by third parties that are not incorporated in the compressor
package manufactured by Compression Systems are warranted only to the extent of the original
manufacturers warranty to Compression Systems.
There are no other warrantiesexpress, statutory, or impliedincluding those of merchantability

and/or fitness for purpose. Moreover, there is no affirmation of fact or representation that extends
beyond the description of the face of this warranty.
This warranty shall be void and Compression Systems shall have no responsibility to repair, replace, or
repay the purchase price of defective or damaged compressors or component parts resulting directly or
indirectly from:
1. The purchasers use of repair or replacement parts or supplies not of Compression Systemss
manufacture or which have not been recommended by Compression Systems.
2. The purchasers failure to store, install, operate, and maintain the compressor according to Com-
pression Systemss written specifications, drawings, and good engineering practice.
See page 1-12 for information on CCV SM extended warranty program.
110
Introduction
Limitation on Liability
Compression Systemss total responsibility for any claims, damages, losses, or liabilities arising out of or
related to the performance of the products covered hereunder shall not exceed the original purchase
price.
In no event shall Compression Systems be liable for any special, indirect, incidental, or consequential
damages of any character, including but not limited to:
1. Loss of use of productive facilities or equipment.
2. Lost profits, property damage, and/or expenses incurred in reliance on Compression Systemss
performance hereunder.
3. Lost production, whether suffered by the purchaser or any other third party.
Compression Systems disclaims all liability for any and all costs, claims, demands, expenses, or
other damages, either direct or indirect, incident to all property damage arising out of any cause of
action based on strict liability.
Unauthorized Repair
In the event that the owner allows the compressor to be serviced or repaired by unauthorized
personnel, the coverage of the original warranty policy will be automatically terminated.
111
CC V 5-Year Warranty Program

SM
THE EDGE IS RELIABILITY
CONGRATULATIONS!
You have purchased the most reliable turbocompressor available, exclusively from Compression Systems.
Your new compressor is designed to meet your performance requirements with:
Oil-free compressed air
Energy efficiency
High reliability
Easy to install package units
Design flexibility to adapt machines to customer process conditions
Low life cycle costs
CC V is a no up-front-cost extended 5 year air end warranty, for your TurboAir 3000 compressor,
shipped after October 1, 2004. Simply perform the recommended maintenance outlined in the
Owners Manual using Compression Systems authorized service representatives. All maintenance will
be logged every quarter by your service rep. on our easy-to-use online CCV maintenance log tool.
Extended warranty on the compressor, air end only, can be obtained for up to 5 years from the date
of shipment. The parties mutually agree to compliance with the following mandatory requirements:
1. On-line registration at www.c-a-m.com
2. The compressor must incorporate TurboBlend or equivalent oil at initial startup.
3. Guidelines for compressor maintenance shall be followed in accordance with Compression Systems
operating manuals.
4. Only genuine Compression Systems parts may be used.
5. Maintenance performed by a Compression Systems authorized service representative in accordance

with maintenance program check-off lists is required.
6. Quarterly oil samples will be submitted to the designated location, or an oil analysis is to be
provided.
7. Compliance with 5-year warranty terms and conditions.
112
Specifications
Section Two
Specifications
General Compressor Specifications
Alarm and Trip Specifications
Compressor Lubricant Requirements
21
22
Specifications
Installation Weights
Complete Package with Motor
Turbo Air 3000 Compressor

Depending on the drive motor horsepower and options selected, the standard shipped compressor
with its drive motor may weigh up to 20,000 lbs (9200 kg).
The standard compressor (without its drive motor) weighs approximately 10,000 lbs (4600 kg).
Refer to data on the Installation Arrangement drawing supplied with the compressor for specific
weights.
Maintenance Weights
(Approximate Values, lbs/kg)
Item Weight Item Weight

Bullgear Cover 500 (227) 1st Stage Inlet 660 (300)
Bullgear Assembly 614 (277) 2nd Stage Inlet 300 (135)
Intercooler Bundles 300 (136) 3rd Stage Inlet 200 (90)
Connection Sizes
Connections are to American Standards (ANSI), expressed in inches.
Air Inlet 8 ANSI Pipe Condensate Drain 1/2 NPT **

Air Discharge 4 Victaulic* Air Ejector 1/2 NPT **
Air Coolers (Water) 1 1/2 NPT** Control Panel 1 Conduit
Oil Coolers (Water) 1 1/2 NPT** Pressure Transducers 1/4 Fitting
Manifold*** (Water) 3 Victaulic*
*ANSI pipe grooved to accept a Victaulic, or equivalent, pipe coupling.
**NPT = National Pipe Thread (tapered).
***Extra Cost Option.
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 +0.002
+0.003 +0.007
Recommendations for cold field alignment, taken at motor hub
0.0000 0.000
+0.001 Face +0.002 -0.002 RIM -0.005
+0.003 -0.007
Refer to the Installation Arrangement drawing for the shaft separation dimension.
23

Cooling Water Requirements
The following represents total cooling water requirements for the compressor package including the built-in
aftercooler and oil cooler. The values exhibited represent worst case conditions. Therefore, well maintained
heat exchangers will exhibit substantially better performance with less water
Compressor Rating (hp) 400 500 600 700 800

Water Flow (gpm/lps) 105/7.5 120/8.5 135/9.5 135/9.5 135/9.5
Water Pressure Drop (psi/bar) 6.0/0.42 9.0/0.62 12.0/0.83 12.0/0.83 12.0/0.83
Water Quality Requirements - Cooling service requires water that is low in suspended solids to prevent fouling, low in
dissolved solids to prevent deposits and erosion, free of organic growth, and free of chemicals that exhibit corrosive
properties to the copper tubes used as standard in the compressor heat exchangers. (Other tube materials with various
chemical resistances are available as options. Consult your authorized representative or Compression Systems Sales
Department directly.)
Drive Coupling Bolt Torque Values

Coupling Type English ft - lbs Metric Nm
Geared Dry (Lubed) 69 (52) 93 (70)
Disc Lubed 236 320
NOTE: For disc coupling torque use values found on coupling label
Lubrication System
English Metric
Reservoir Capacity 55 gallons (USA) 210 liters
Minimum Reservoir Temperature Prior to Startup 60F 15C
System Operating Temperature 110F - 120F 43 C - 49C
System Operating Pressure 110 psig - 120 psig 7.6 barg - 8.3 barg
Air Ejector Pressure Range 25 - 30 psig 1.7 - 2.0 barg
Discharge Connection Load Limits

English Metric
Maximum Allowable Force 350 lbs 1500 N
Maximum Allowable Moment 500 ft-lbs 675 Nm
Other Package Electrical Requirements***

Main Drive Motor* Furnished separately
Oil Pump Motor* 3 hp (2.25 kw) 3-phase 50/60Hz
Oil Heater (optional)** 1.5 kw 3-phase 50/60Hz
*Starter Required.
**Magnetic contactor required.
***Voltages must be specified at time of order entry.
24
Specifications
Alarm and Trip Specifications

The tables below show the Alarm and Trip values of the key parameters for the Turbo Air 3000 com-
pressor.
If an Alarm value is reached, the compressor will continue to run but the control system will show the
item that generated the alarm.
If a Trip value is reached, the control system will shut down the compressor.
ALARM and TRIP Setpoints (English Units)

ALARM TRIP
Condition Low High Low High
Standard:
Compressor Stage Vibration (mils) - 1.5 - 2.0
Oil Pressure (psi) 100 180 80 200
Oil Temperature (F) 70 135 60 145
Stage Inlet Air Temperature (F) - 130 - 140
Optional:
Inlet Air Filter Pressure Drop (inches of water) - 10 - -
Oil Filter Pressure Drop (psi) - 15 - 20
ALARM and TRIP Setpoints (Metric Units)

ALARM TRIP
Condition Low High Low High
Standard:
Compressor Stage Vibration (m) - 38 - 50
Oil Pressure (bar) 6.9 12.4 5.5 13.79
Oil Temperature (C) 21 57 16 63
Stage Inlet Air Temperature (C) - 55 - 60
Optional:
Inlet Air Filter Pressure Drop (mm of water) - 250 - -
Oil Filter Pressure Drop (bar) - 1.0 - 1.4
25
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 lubrication
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 Turbo Air 3000 Compressor
Operators Manual.
It is the users responsibility to provide all lubricants (including turbine oil, motor grease, and
coupling grease) at the initial startup and during subsequent operation. It is very important for all
compressor users to follow specific guidelines regarding lubricant selection and proper use in order
to assure optimal performance of the Turbo Air 3000 Compressor.
Compressor Oil Selection

The correct lubricating oil is critical to satisfactory overall compressor performance. When operating the
Turbo Air 3000 Compressor, use only high-quality, rust- and oxidation-inhibiting oil that resists foaming
and that does not break down under severe operating pressures and temperatures. Incorrect or poor
quality lubricating oil can adversely effect high-speed shaft dynamics and seriously damage critical
compressor components.
While there are many quality oil products on the market today, not all have been demonstrated to
function optimally in situations involving high-speed rotordynamics. For this reason, Compression
Systems 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 stock and performance
enhancing additives.
Hydrocracking is an advanced oil processing technology that is far superior to solvent refining. It
converts crude oils into base stocks of unparalleled purity. So pure, in fact, and so highly refined that
this new class of lubricant is free of the contaminants that cause lubricant breakdown ensuring longer-
lasting compressor performance. The only additives in TurboBlend Lubricating Oil are those selected
exclusively by Compression Systems scientists and engineers to increase performance. In test after test of
standard quality indicators, TurboBlend Lubricating Oil outperforms solvent refined, commercially
available oils.
TurboBlend Lubricating Oil is available through your authorized Compression Systems representative or
directly from the Compression Systems Parts Department. Refer to Section Seven of this manual for part
numbering and ordering information.
Standards
Excellent operating performance will be achieved when using TurboBlend Lubricating Oil. However, if
the compressor owner or user chooses to pursue a near equivalent substitute, the subject oil must
conform to the following characteristics:
26
Specifications
Refined from high-quality mineral oil stock.

Free from any contaminants or impurities that may be abrasive or have a lapping action.
Contain additives to provide:
- a high level of oxidation stability,
- a high degree of wear protection,
- rapid separation from entrained gases,
- foam-free operation,
- rust-free and corrosion-free operation, and
- resistance to the formation of sludge and harmful resin-like deposits.
capable of maintaining high flow strength and not break down under extremes of pressure and
temperature.
Animal, vegetable and mineral oils of poor quality must be avoided as these oils would tend to oxidize,
develop acids, and form sludge or resin-like deposits on rotating elements. Such deposits may be of
sufficient volume to cause very high, localized loadings that will lead to a premature breakdown of the
load-carrying capacity of the oil. This will result in worn gears and scored bearings.
Specifications
TurboBlend Lubricating Oil meets or exceeds the performance standards listed in Table 21. Any
substitute or equivalent oil selected for use in the Turbo Air 3000 Compressor by the compressor owner
must exhibit similar results.
Property Test Method Performance

Viscosity:
at 40C ASTM D445 46 Cst
at 100C ASTM D445 7 Cst
Viscosity Index: ASTM D2270 >100
Four 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 minutes
Foaming Characteristic - Sequences I, II & III:
Tendency/Stability ASTM D892 <10 ml / 0
Gas Bubble Retention Time:
at 50C ASTM D3427 5 minutes
Rust Test:
Distilled Water ASTM D665A Pass
Synthetic Sea Water ASTM D665B Pass
Rotating Bomb Oxidation Test: ASTM D2272 > 400 minutes
Base Oil is to be refined from high-grade mineral oil stock.
Table 21 Compression Systems Oil Specification
27
Other Oil Selection Considerations

Incorrect or poor quality lubricating oil can seriously damage the compressors rotating and mechanical
elements. Do not merely rely on an oil dealer recommendation when selecting turbine oil, and do not
compromise quality in an attempt to economize. Many reputable brand name oil products exist, but
not all perform effectively in the demanding world of high-speed turbomachinery.
Do not mix different brands of oil. This is inadvisable because some oils are incompatible, and a wrong
combination of additives could cause serious machine damage and/or poor overall performance. The
lubrication requirements of the Turbo Air 3000 Compressor are not so severe as to require the qualities
of high-cost synthetic oil. In addition, Compression Systems products are not designed to use synthetic
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 be
certain to follow the guidelines listed below.
Use only Compression Systems 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 Testing

Oil samples from the compressor reservoir should be visually inspected and tested for viscosity and
freedom from contamination at regular intervals. This will insure that proper lubricant properties are
always being provided and early deterioration of the gearing and bearings is diminished.
Color and Appearance

Compare an oil sample from the reservoir with new oil. Any color change suggests some type of
deterioration. Darkness implies contamination from acid buildup while muddiness is an indication
of water.
Viscosity, Acid and Particle Count
Tests for these properties required qualitative analyses by a reputable laboratory. Follow the
recommendations of the laboratory with regard to oil replacement.
Compression Systems offers an oil analysis service. Sampling kits and information about this service are
available through an authorized Sales and Service Representative, or directly through the Compression
Systems Aftermarket Department. (See Table 7-1 of this manual for sampling kit part number informa-
tion.)
28
Specifications
Other Required Lubricants

The user must also provide an array of other lubricant products as specified.
Motor Bearing Lubricants

The user must provide lubricants for the main drive motor and the oil pump motor. To ensure long life
of the bearings of both motors, it is necessary to maintain both proper alignment and proper lubrica-
tion levels at all times. The large, squirrel cage inductor motor of the Turbo Air 3000 Compressor
employs (depending on the specific type of motor used) either anti-friction bearings or sleeve bearings.
Each type of bearing has different lubrication requirements.
Refer to the motor manufacturers instructions provided separately for complete information
regarding correct oil bearing lubrication maintenance procedures for each type of motor.
Anti-Friction BearingsGrease
For best results with anti-friction bearings, only use greases recommended by the motor manufacturer.
Sleeve BearingsOil
It is the users responsibility to fill the motor bearing oil reservoir and to maintain the correct oil level at
all times. When lubricating sleeve bearings, use only a high quality, petroleum-based oil with a viscosity
of 200-220 SSU at 100 F (40C). Since motor bearings require the same type of oil as used in the
compressor itself, it is not necessary to maintain two separate supplies of oil if this type of bearing is
used.
CAUTION:
Before aligning or using this type of motor, always verify that the correct amount of oil is
in the reservoir. Motors with sleeve bearings are sometimes shipped without oil in their
reservoirs.
Drive Coupling Grease

The user must provide coupling grease at the time of installation and during compressor operation.
This coupling grease must meet very specific requirements. Conventional factory greases do not provide
complete lubrication for high-speed flexible couplings. The lithium soaps used as thickeners separate,
forcing the soaps into places that require lubrication. The soaps then act as abrasives that accelerate
wear.
29
Compression Systems endorses only greases with a K 36 Test Rating of 0/24. These are the only greases
found acceptable by the American Gear Manufacturers Association (AGMA) because of their high
resistance to centrifugal separation. (Compression Systems Coupling Grease is specially formulated to
meet this very specific requirement.)
CAUTION:
Since other products may cause premature wear and/or other damage, always use Com-
pression Systems Coupling Grease only.
Inlet Guide Vane Assembly Drive Screw Grease

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

Compressors equipped with AUTO-UNLOAD Control utilize a pop-action bypass valve to vent the
discharge side of the compressor. Two different size and type of valves are employed depending
upon volume flow requirements. The valve supplied with units rated up to 600 horsepower must be
lubricated periodically, while the larger valve for units rated 700 horsepower and larger requires no
lubrication.
The only product Compression Systems found acceptable for this service is Dow Corning MOLYCOAT
33. Other products may gum up under certain operating conditions and cause the
valve to malfunction.
210
Installation
Section Three
Installation
General Considerations
The Installation Work Schedule
Site Considerations
Process Air Piping
Utility Piping
Electrical Interface
Receiving, Lifting, Moving .
The Installation Inspection
Preparing for Startup
Initial Compressor Startup
31
32
Installation
Advance planning and preparation help simplify and expedite the compressor installation process. This
Section gives an overview of the entire process, from preliminary site preparation to the final prepara-
tions before the initial startup of the compressor.
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 compressor startup, a factory-trained and authorized Compression Systems service
representative checks the completed installation work, including peripheral piping and electrical work.
The service representative also checks the lubrication system, verifies the control system configuration,
verifies motor alignment, starts the compressor and provides operating instructions.
33
Installation Work Schedule

Before beginning the actual compressor installation process, review the steps below for an overview of
the various considerations and procedures.
Before delivery, review all the technical documents provided, including this handbook and all the
relevant specifications and drawings supplied separately.
1. Select a well-suited location in accordance with the minimum recommended space and ambient
requirements for the compressor package.
2. Review the list of parts, supplies, tools, and labor required at installation, and arrange for them
all to be available.
3. Be sure that all required preparations and provisions have been made with regard to the founda-
tion, piping, and electrical connections.
4. Upon its arrival, inspect the compressor and check loose-shipped equipment against the packing
list; if any damage or shortage is noted, report it to the carrier immediately.
5. Set the compressor on the foundation and secure the compressor on the foundation bolts. If
temporary storage is necessary before installation can be completed, place the compressor in a
properly heated, indoor storage area. Store for a period of no more than three months.
6. At least two weeks before the projected initial startup date, contact your authorized Compres-
sion Systems service representative to schedule startup service.
7. Install the external air piping per the instructions in this section.*
8. Fabricate a manifold to connect to the coolant supply and return on the intercoolers and the oil
cooler. *
9. Install all piping between the compressor and the main coolant lines.
10. Fabricate the condensate drain pipes and control devices as indicated elsewhere in this section.*
11. Connect the clean, dry instrument air line to the reservoir vent ejector system.
12. Make all electrical connections, in compliance all applicable electrical codes.
13. Check the site a final time for conformance to all applicable codes and all installation require-
ments.
* Various factory-installed piping configuration options are available through Compression

Systems and can lead to considerable savings for the installer.
34
Installation
Labor, Supplies, Equipment, and Tools

It is the owners responsibility to prepare the site properly and to provide any necessary labor, supplies,
tools, or additional equipment needed to meet the compressor installation requirements.
The following list includes the typical items necessary for site preparation, installation, and future
maintenance.
Materials Required for Compressor Installation

Supplies
Foundation bolts
Shims (for leveling)
All external piping supplies
All external wiring and electrical conduits
TurboBlend oil (or suitable alternative - see Section 2, Lubrication)
Main drive coupling grease (if applicable)
Motor bearing lubricant
Equipment *
Main drive motor starter
Oil pump motor starter
Oil heater contactor (if necessary)
Specified inlet air filter
Specified Inlet startup screen
Expansion joints (for inlet and discharge piping)
Blow off valve silencer (if applicable)
Air system block valve
Cooling water control valves
Air dryer (if necessary)
Tools
Port-a-Power or hydraulic jack
Allen wrenches and Drive sockets with extensions
Digital multimeter
Pipe wrenches, Adjustable wrenches, and Vise grips
Torque wrench (to 200 ft-lbs. or 300 NM)
Screwdrivers
Open end and box wrenches
Drill motor
31/64, S, or 12.30 mm drills (for doweling of motor)
0.499, or 12.67 mm reamer (for doweling of motor)
*Some equipment may have been purchased with the compressor. Refer to engineering documents provided
separately for definition of Compression Systemss scope-of-supply.
Table 31. Materials Required for Compressor Installation
35
Site Considerations
Review the installation requirements specified both in this manual and in the model-specific drawings,
supplied separately. Select your installation site and make the required preparations prior to the
compressors delivery.
The standard Turbo Air Compressor is designed for indoor installation. For outdoor installation, both
the NEMA-4 electrical option and TEFC motor package are necessary.
Environment
A clean environment is important for optimal performance. Locate the compressor inlet air filter away
from chimneys, cooling towers, steam exhausts, or any other possible sources of air contamination
with foreign matter. In particular, be sure to locate the air filter at least 10 ft. (3.3 m) above ground
level and at least 6 ft. (2 m) from any window, wall, or roof to further isolate it from any airborne
contaminants.
When selecting an outdoor installation site, consider prevailing and local ground wind patterns as well
as the immediate atmospheric conditions surrounding the unit. Such factors may have long-term
effects on overall compressor operation.
CAUTION:
Select the compressor site carefully with regard to possible contamination by foreign
matter. Dust, corrosive vapors, or other airborne foreign matter will adversely affect
compressor performance and motor insulation life.
Acoustics
Compressor operation will affect sound levels in the surrounding area. If hard walls and low, hard
ceilings surround the installation site, they are likely to reflect and amplify noise to levels that exceed
the published levels of the compressor package. Proper sound abatement procedures should be
applied where needed.
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, apply insulation to components throughout the entire air path:
For more information about piping insulation and noise control consult Compression Systems.
Foundation
The Turbo Air 3000 Compressor can be installed directly on a floor that meets the following minimum
requirements:
Construction must be of a high quality continuous reinforced concrete.
The slab must have a minimum thickness of 4-6 in. (100-150 mm).
The floor must have minimal ambient vibration.
Compressor mounting
Secure the compressor on its mounting bolts and shim properly to achieve a level of flatness at 0.010
inches per foot (1 mm per meter). If necessary use the appropriate vibration isolation hardware to
ensure that the compressor is isolated from vibrations transmitted by nearby equipment.
36
Installation
Envelope
Provide an adequate envelope (space allowance) around the unit. Figure 31 illustrates the typical
dimensions of a standard compressor. Allow an additional 3 ft. (1 m) around the sides and back of the
compressor to provide adequate clearance for installation, inspection, and future maintenance. In the
front, allow at least 6 ft. (2 m) for intercooler and aftercooler bundle removal.
Ventilation
If installing the unit in a confined area, be certain to provide adequate ventilation to dissipate heat
generated by the package. The temperature immediately surrounding the compressor package
should not exceed 100F (38 C). The main drive motor is particularly susceptible to damage in areas of
high ambient temperatures or poor ventilation.
Water Supply and Drains

If the compressor is water-cooled, make every effort to provide clean cooling water with a low mineral
content.
Also, be sure to provide adequate open drains to carry away condensate from the intercoolers and
aftercooler. (Refer to the Utility Piping subsection for additional information and requirements for
water supply and condensate drain piping.)
78 inches
(200 cm)
134 inches
(340 cm) 72 inches
(180 cm)
Figure 31 Turbo Air 3000 Compressor Envelope
37
Process Air Piping

Figure 32 is a schematic illustration of the typical piping arrangement for a standard Turbo Air
compressor.
The process air system includes the inlet air piping, the discharge air piping, and the compressor
discharge valve piping arrangements. The Compression Systems Process and Instrumentation Diagram
(P&ID) drawing illustrates the required location for the various compressor system components. The
user must design and provide all external process air piping accordingly.
Improperly designed piping systems may cause later problems. Failure to follow the discharge piping
installation requirements, as shown on the model-specific drawings, is the most frequent cause of
compressor control problems.
To ensure a successful process air piping installation, be sure to:

Use clean pipes to be sure that no foreign material enters the compressor.
Keep the piping as short and direct as possible.
Clean the piping thoroughly after fabrication.
Install the isolating discharge block valve as indicated.
Support the piping properly so that the supports (rather than the compressor) carry the load.
Provide drains at low points to carry away any collected condensate.
DANGER:
Failure by the owner and installer to provide correct piping to and from the compressor,
following the requirements and recommendations listed, will result in mechanical failure,
property damage, serious injury or death.
38
Installation
E G
F
D
A. Inlet Filter
B. Inlet Screen
C. Expansion Joint
C
B D. Check Valve
E. Block Valve
F. Blowoff Valve
G. Silencer
Figure 32. Typical Process Air Piping for a Turbo Air 3000 Standard Compressor
39
Inlet Air Piping

Figure 33 shows a typical inlet piping arrangement with various standard and optional components.
A. Inlet Filter Silencer

B. Pipe Reducer (If applicable)
C. Inlet Startup Screen
A D. Inlet Expansion Joint
E. Inlet Guide Vane (IGV)
F. IGV Motor
C D STG. 1
E
B B
Figure 33 Inlet Air Piping
Inlet Pipe Connection

The standard inlet air connection 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 inlet air piping connections.
Figure 34 shows a detail of a typical inlet air piping arrangement.
Do not connect the final inlet air pipe to the compressor until the Compression Systems representative
inspects the piping during the startup service call.
Inlet Guide Assembly
Inlet Startup Screen
Inlet Expansion Joint
Figure 34 Detail of Inlet Air Connection with options
310
Installation
Inlet Piping Material

When selecting inlet piping material, it is advisable to either select corrosion-resistant piping or treat
the piping with additional corrosion protection. Also, be sure to provide suitable support to isolate the
piping forces from the compressor itself.
If you are considering fiberglass piping for the inlet air lines, be sure to:
Select pipe material that can tolerate bypass air temperatures of up to 350F (175C).
Use pipe and fittings that are filament wound with continuous glass filaments and epoxy resin.
Provide the fiberglass piping with additional reinforcement for even load distribution.
Insulate the pipe to minimize noise.
Fabrication
Use 10-inch (250 mm) or larger pipe size to connect the inlet air filter to the compressor. Smaller sizes
reduce inlet air pressure and impair compressor performance.
Provide a straight run of at least four pipe diameters before the inlet guide vanes (IGVs) to minimize
flow distortion. Also, avoid using many elbows and sharp bends in the compressor inlet piping.
Drains
Provide adequate drains at low points of the inlet piping to facilitate condensate removal. This deters
rusting which can eventually impede the aerodynamic characteristics of the components.
Inlet Filter/Silencer
The required inlet filter/silencer must be of the proper design and located according to the instructions
from Compression Systems. Failure to use a proper inlet filter voids any existing warranty.
Inlet Air Startup Screen

Inlet piping must prevent any solids from entering the compressor inlet. When long runs of inlet piping
are required, or when visual/physical inspection of the finished piping is difficult, the conical inlet air
startup screen must be installed before the initial compressor startup. In such instances, it is important
to locate the screen as close as possible to the compressor inlet. The correct inlet air startup screen is
available through your authorized Compression Systems representative.
CAUTION:
Be certain to remove the Inlet Air Startup Screen after approximately 40-50 hours of
compressor operation. If it is not removed, the pressure loss across the screen can signifi-
cantly reduce overall compressor performance.
Inlet Expansion Joint

Compression Systems recommends the use of the Inlet Expansion Joint option (which consists of a
rubber sleeve with stainless steel clamps) as a means of joining the inlet air pipe to the compressor. (See
Figure 34.) When making this connection, do not use pipe smaller than the recommended pipe size.
Larger pipe is preferable since the greater volume reduces both noise and pressure loss.
311
Discharge Air Piping

The discharge air piping system, shown schematically in Figure 3 5, consists of the piping after the
discharge flange including the required expansion joint, discharge check valve, and isolating block valve
plus any accessory items for the specific installation (dryer, receiver, etc.).
A. Aftercooler 1. From final stage of compression

B. Flexible pipe coupling 2. To compressed air system
C. Victaulic flange (optional) 3. To compressor blow-off/bypass valve
D. Expansion joint (recommended) 4. To control panel - compressor discharge pressure
E. Check valve (required) 5. To control panel - system pressure (at plant header)
F. Block valve (required)
A 4
1
B C D E F
2
Figure 35 Typical Discharge Air Piping Arrangement
Discharge Connection
The compressor discharge air connection is machined to accept a Victaulic pipe coupling. When
attaching the discharge pipe, refer to the model-specific Installation Arrangement Drawings supplied
separately for specific size information.
Compression Systems offers the following optional types of connections:
Straight Coupling
Reducing Coupling
Vic-Flange Adapter
312
Installation
Piping Material
While corrosion on the discharge air side does not present the same problem as it does on the intake
air piping, it is still a concern. Rust can damage delicate instrumentation, pneumatic tools, or processes
that require non-contaminated air.
The principal consideration in the selection of piping materials should be safety. The United States,
Canada, and most other countries strictly prohibit the use of unprotected polyvinyl chloride (PVC)
piping to transport compressed air or other compressed gases. Compression Systems 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.
Compression Systems recommends that all pressure-holding pipe be in accordance with the standards
established by the American National Standards Institute (ANSI) as well as the American Society of
Mechanical Engineers (ASME) Standard B31.8-1986.
CAUTION:
Be certain to follow all specified requirements and guidelines. Failure to correctly follow
specified discharge air piping design guidelines can cause compressor malfunction and/or
damage.
Drains
It is necessary to provide drains at all low points to remove any condensate that collects in the
discharge system.
Fabrication
The combination of high pressures, accessories, and long piping runs require more detailed design
considerations in the discharge air line than with the intake air lines.
It is best that the pipe lengths from the compressor discharge connection to the discharge check valve
and from the discharge check valve to the blow-off or bypass valve are as small as practical. For proper
operation of the discharge check valve, straight piping runs of four pipe diameters each in length,
should immediately precede and follow the valve.
CAUTION:
To assure proper compressor unloading, do not allow the pipe volume to exceed 0.1% of
the design volume flow of the compressor. Excessive volumes may cause compressor
surging during unloading.
Refer to the specific requirements in the engineering drawings supplied separately for your system.
CAUTION:
Do not exceed the 400 lb. (1700 Nm) Maximum Allowable Force or the Maximum Allow-
able moment of 600 lbs. (800 Nm) on the compressor discharge connection. Excess
weight may cause pipe connection failure.
313
Discharge Expansion Joint

Compression Systems recommends installation of a discharge expansion joint in line (vertically) directly
at the discharge flange of the compressor. Braided type expansion joints require sufficient pre-tension
to counteract any collapsing force. For tied expansion joints, make sure the mounting hardware
permits full joint flexibility axially and laterally.
WARNING:
Be certain that the discharge expansion joint is installed correctly to avoid serious injury
that can result from the sudden release of high-pressure discharge air.
Discharge Check Valve

A discharge check valve is necessary to prevent the reverse flow of air through the compressor during
unloaded operation. (Refer to the Engineering drawings, supplied separately, for the exact location of
the discharge check valve.)
Compression Systems supplies a specifically sized, check valve for installation in a horizontal run of
piping where it can properly open and close. Be sure to install this check valve with a minimum of four
pipe diameters of straight pipe before and after the check valve. If the valve is not correctly sized
(particularly if it is oversized) the potential for shut-off failure is increased. Before installing the check
valve, refer to the Check Valve Installation drawing and locate the top marking on the valve itself to
determine the correct orientation.
WARNING:
Before operating the compressor, examine the top of the check valve to be sure that the
orientation of the valve is correct. Compression Systems cannot be held responsible for
damage or personal injury due to improper installation of the discharge check valve.
CAUTION:
Never use an oversized discharge check valve. Incorrect sizing can cause incorrect
operation and lead to failure of compressor components.
Discharge Block Valve

All compressor installations must include a discharge block valve, installed after the discharge check
valve, to isolate the compressor from the rest of the plant air system. This block valve provides
additional protection to the compressor in the event of a discharge check valve malfunction.
WARNING:
When servicing the compressor, close and lock the block valve. Failure to do so can cause
damage to compressor and personal injury.
Automatic Block Valve Option

Compression Systems strongly recommends installation of an automatically actuated isolation block
valve. This available option fits between two 150-lb. ANSI raised-face flanges in the discharge air piping
and quickly isolates a stopped or unloaded compressor from the plant air system, providing additional
protection in the event of a power disturbance or emergency shutdown.
Placement should be at least four pipe diameters after the discharge check valve. Be sure to allow room
for access if the automatic block valve is to serve as a lockout device during compressor service. (See
Compression Systems publication AAEDR-A-008 , Automatic Block Valve for additional information)
314
Installation
Compressor Discharge Valve Installation

If the owner/installer is installing the bypass valve or the modulating blow-off valve, the installation
must be in a branch of the discharge piping upstream from the discharge check valve. (Refer to the
model-specific P&ID drawings for details regarding the correct location in your system.)
The bypass or blow-off valve piping must be the same size as the valve itself. Figure 36 shows the
correct orientation of the discharge valve in relation to other components in the discharge line.
A. Compressor Discharge Flange

1. To compressed air system
B. Check Valve
2. Control signal from control panel
C. Block Valve
D. Modulating Blow-Off Valve (MBOV)
or Bypass Valve (BPV)
E. I/P Transducer*
F. Filter Regulator*
G. Source of Instrument Air
H. Vent Silencer*
*BOV only
Figure 36 Compressor Discharge Valve Piping Detail
315
Compressor Discharge Valve Piping

Depending on the control method, the Turbo Air compressor will either completely or partially unload
whenever the capacity of the compressor exceeds the compressed air systems demand. Upon a
reduced demand in the system, one control method uses a pop-action bypass valve (BPV) to fully unload
the compressor. Other control methods use a modulating blow-off valve (MBOV) to regulate the
amount of vented excess air pressure.
Bypass Valve (BPV)

The BPV operates in either a fully open or fully closed position. The compressor owner/installer is
responsible for the proper installation of this control valve (shipped separately) unless the compressor
includes the Mounted Bypass Valve option.
Modulating Blow-Off Valve (MBOV)

The MBOV operates in any position from fully closed to fully open. A pneumatic actuator, I/P
transducer, volume booster and a regulator are mounted and piped as an integral assembly on the
valve body. The owner/installer is responsible for the proper installation of the MBOV (shipped
separately).
CAUTION:
To assure proper compressor unloading and to prevent surging, keep a minimal pipe
volume between the compressor connection and the blow-off or bypass valve. Calculate
the maximum piping unit volume by multiplying the inlet volume flow per minute by
0.001 (one-tenth of 1%).
BOV Silencer
The high-pressure air expansion across the modulating blow-off valve creates considerable noise.
Compression Systems recommends the BOV silencer option to reduce noise produced during
compressor operation.
For maximum effectiveness, the silencer must be properly connected directly to the blow-off valve. Any
additional piping after the silencer should be no smaller in diameter than the silencer discharge flange.
The exhaust piping from the silencer should be sized to create a back pressure on the silencer less than
5 psig (0.3 bar).
To further reduce sound at the discharge, increase the outlet opening area by cutting the pipe end at a
sharp angle as shown in Figure 37. Avoid directing the exhaust pipe toward hard surfaces or noise-
sensitive areas.
Cut at sharp angle to

enlarge opening area Discharge
Figure 37 Angled Pipe End
316
Installation
Utility Piping
The utility piping is any external piping, tubing, or electrical conduit that supports subsystems required
to complete the installation of a compressor. Utility piping includes:
Cooling water (coolant) piping for heat exchangers
Condensate drain piping from the intercooler and aftercooler
Instrument air piping for the reservoir vent ejector system
Instrument tubing from the discharge and system pressure sensors
Electrical conduit for the main drive motor, control system, oil pump motor or optional lube oil
heater
Other tubing or conduit required for connecting any accessory sensors to the control panel
The user/installer is responsible for providing all external piping, tubing and conduit, as well as for the
basic design of the utility piping. Typical arrangements for some of the utility piping are included in
this section.
Installation Tips
Compression Systems recommends the following for successful utility piping installations:
1. Keep the piping, tubing or conduit as short and direct as possible.
2. Clean the piping and conduit thoroughly after fabrication or assembly.
3. Support the piping and conduit properly.
4. Provide drop legs or drains at all low points to carry away any collected condensate.
WARNING:
The owner and installer are responsible for providing proper utility piping to and from
the compressor. Failure to follow good industrial practices and the requirements and
recommendations listed may result in poor compressor performance, mechanical failure,
property damage, and/or personal injury.
317
Cooling Water (Coolant) Supply Piping

The typical Turbo Air 3000 Compressor package includes four water-cooled heat exchangers (two
intercoolers, an aftercooler, and the oil cooler). Figure 38 illustrates the location of the heat
exchangers. Refer to Section 2, Specifications for cooling water (coolant) requirements. The values in
Section 2 represent requirements for average usage. Actual requirements may differ depending on
variables such as temperature, humidity, and the condition of the heat exchangers.
4
2
1. Oil Cooler
2. 1st stage intercooler
3. 2nd stage intercooler
4. Aftercooler
Figure 38. Heat Exchanger Locations
318
Installation
Supply and Return Lines

Figure 39 illustrates a typical coolant supply and return piping arrangement.
The installer must consider the distance and routing of the coolant piping when determining the
appropriate sizing for the piping. Compression Systems also recommends installing, when necessary, a
pressure regulator to allow for pressure control of the cooling water.
CAUTION:
When fabricating the coolant supply piping (Figure 39), install the throttle valve on the
discharge side rather than the inlet side. This ensures that the coolers are always flooded
and that air locks do not form to restrict flow.
Flushing the Lines

After completing fabrication and installation of the coolant piping, and before connecting to the
compressor, clear the piping of any foreign matter that might clog the heat exchangers and reduce
system efficiency.
Install temporary filter screens in each of the supply branch lines, at the connection to each heat
exchanger. Flush the pipes thoroughly to remove all foreign matter from the pipes.
After flushing, remove the screens, reconnect the piping and verify there are no external leaks.
CAUTION:
The owner and installer are responsible for providing properly cleaned coolant piping.
Contaminated piping can result in fouling and blockages within the heat exchangers that
can cause inadequate cooling and subsequent damage to the compressor.
Figure 39. Typical Coolant Piping
319
Cooling Water Piping Options

Compression Systems offers several coolant piping and condensate drain options that can help simplify
the installation of the compressor and enhance its overall operation. Any of these features may be
easily retrofitted if not included at the time of the original machine order.
Cooling Water (Coolant) Manifold Option
When this option is selected, the intercoolers, aftercooler, and oil cooler are manifolded to single inlet
and outlet connections.
Figure 310. Cooling Water Manifold Option
Automatic Cooling Water Shutoff Valves

This option includes a pair of solenoid operated valves, installed at the inlet and outlet connection
points of the water manifold. The control system can shut off these valves whenever the compressor is
not running, to stop cooling water flow.
Automatic Coolant Water Flow Control Valves

This option includes a temperature sensor/controller installed in the compressed air stream and a
throttling valve installed in the cooling water stream; thus reducing water consumption during
compressor unloaded operation.
320
Installation
Condensate Drain Piping

During air compressor operation, condensate collects in the intercooler and aftercooler chambers as
the air cools. To remove the condensate and prevent its migrating into the next stage of compression,
each intercooler chamber must be individually drained into an open drain or trough. An open drain
allows visual verification of condensate removal while ensuring that it is not drawn back into the
compressor when the compressor is unloaded.
CAUTION:
Do not manifold the three drain assemblies. This is the single most common error made at
the time of compressor installation. Each must discharge individually into an open drain
or trough to prevent condensate from higher-pressure chambers being forced back into
lower pressure chambers.
Figure 311. Typical Condensate Removal Piping Arrangement
Several different types of control devices are appropriate for use in the condensate removal piping
system. Among the most common are the following:
Standard gate valves, operated by hand

Float traps that are self-actuating
Solenoid valves, operated by the control system
Three NPT condensate drain connections (one for each cooler cavity) are located at the front of the
compressor. It is necessary to include a manual bypass valve (A) and piping for each selected drain
control device (B). Figure 311 shows a typical condensate drain piping arrangement.
321
ReliaDrain Electronic Solenoid Condensate Drain Option

The ReliaDrainTM option is a zero loss condensate removal drain for compressed air systems. It features
an electronically controlled level sensor with integrated alarm function. Its purpose is to automatically
drain condensate from a compressed air system at natural collection points, without loss of compressed
air. See Compression Systems Engineering Data Release, AAEDR-D-006, for additional information.
7.08 inches
(180 mm)
Figure 312. ReliaDrainTM
Solenoid Condensate Drain Piping Option

The solenoid-operated drain valves are wired to the control system, which opens and closes the drain
valves at user set intervals. When the valve opens air pressure within the cooler chamber expels the
condensate to the open drain. See Figure 313 below.
Pneumatic Condensate Drain Option

The LiquidatorTM Pneumatic Condensate Draining System option is a demand-operated trap that
automatically drains condensate without any loss of compressed air. Energy savings can be realized
using this system over other, time-based, draining systems. See Compression Systems Engineering Data
Release, AAEDR-D-005, for additional information.
CAUTION:
The owner is responsible for properly maintaining the intercooler and aftercooler conden-
sate removal system. Failure to provide regular maintenance can damage intercooler
components and the compressors air handling parts.
A. Solenoid Drain Valve
B. Check Valve
C. Manual Bypass Valve
D. Manual Block Valve
C
10 inches
(250 mm)
A
B
Figure 313. Condensate Drain Piping Assembly Figure 314. LiquidatorTM Pneumatic
Condensate Drain Trap
322
Installation
Oil Reservoir Vent Ejector Piping

The compressor gearbox and oil reservoir require proper venting to prevent the migration of oil and/or
oil mist to the surrounding area or other parts of the compressor. Turbo Air compressors use a simple
ejector (venturi-tube) powered by clean, dry, filtered air to create a slight vacuum within the gearbox
oil reservoir.
The ejector and filter assembly is located at the top of the oil reservoir. Engineering drawings (supplied
separately) define the precise connection point and specific air requirements. It is recommended that a
pressure regulator with gauge be installed for control of pressure to the ejector.
The installer is responsible for correctly sizing the ejector air supply piping. (Section 4, The Lubrication
System, includes additional information about the operation of the ejector/filter system.)
CAUTION:
The supply air for the ejector must come from a clean and dry source. Water in the oil
reservoir will have adverse effects on the lubricating oil and can cause severe damage to
the compressor.
Instrument Tubing
The external instrument tubing required to complete the installation of your compressor is shown on
the contract-specific drawings.
Instrument tubing includes the connections from the required air pressure sensors and accessories to
the control panel. To ensure a successful instrument tubing installation, always:
Use steel tubing in order to avoid kinks or other common problems that are inherent with copper
tubing. (Stainless steel is preferred to be sure that no foreign matter such as rust or scale can
enter the pressure instruments.)
Keep the tubing runs as short and direct as possible.
Do not include any block or shut-off valves that can interrupt the pressure signal.
Provide drop legs at low points with drains to carry away any collected condensate.
Check for leaks at the connection points in order to avoid faulty sensor readings.
323
The user is responsible for the proper electrical connection of several components at the site
installation, including the control system, the oil pump motor, the main drive motor, and the oil heater
option (if applicable). Refer to the model-specific engineering drawings and other technical information
supplied with your system to determine the correct power supply requirements.
CAUTION:
Do not energize or start up the compressor until a Compression Systems authorized service
representative has given full approval. Failure to follow this requirement will compromise
any applicable warranties.
General Wiring Requirements

When planning and installing the electrical interface, it is necessary to meet the following minimum
requirements:
Be certain that the main power supply meets specifications, including voltage, frequency, and
(most importantly) the current-carrying capacity of the wires.
Provide an appropriate separate compressor earth ground that meets local and national code. (In
the United States, refer to Section 250-26 of the National Electrical Code for earth ground
definition.)
Include proper disconnects such as switches or circuit breakers (either fusible or non-fusible) to
provide complete isolation from the electrical supply.
If the main power switch that controls the compressor is remotely located or if it is difficult to
lock out the main switch, install a local switch that allows maintenance personnel to isolate the
unit safely.
WARNING
Install and use a lockout system, including the isolating block valve, whenever performing
maintenance procedures on this or any other such type of machinery.
WARNING:
Be certain that all electrical work is performed only by qualified personnel, in accordance
with product specifications, and in compliance with all applicable local or national codes.
Failure to follow this requirement may result in equipment damage, personal injury, or
death.
324
Installation
Electrical Conduit
The typical Turbo Air Compressor installation requires 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 Control
Panel. Other optional equipment, such as the oil heater, will also require electrical power. The
National Electrical Code in the United States, as well as most other national codes, requires that the
electrical wiring for this type of industrial service be encased in rigid conduit.
The user/installer is responsible for providing and designing the installation of all external electrical
conduit runs. To ensure successful electrical conduit installation always:
Use clean, non-corrosive conduit and fittings with no burrs or sharp edges.
Keep the conduit runs as short and direct as possible.
Support the conduit properly so as to not impart any unnecessary loads on the components to
which it is being connected.
Provide drop legs at low points with drains to remove any collected condensate.
WARNING:
The owner and installer are responsible for applying correct wiring practices. Failure to
follow local electrical codes and good industrial practices could cause property damage,
personal injury, or death.
325
Main Drive Motor Controls

The major functions of a motor-control system are:
Starting and stopping of the motor.
Governing motor acceleration, torque, output (power/amps), and other characteristics.
Protecting personnel and equipment.
Compression Systems Engineering Specification AAEDR-G-019, Requirements for Starter to Main Motor
Controls, completely details the minimum requirements for proper interface between the compressor
control system and the owner-supplied motor control equipment.
CAUTION:
The compressor inlet valve must be in the closed position throughout the period of motor
startup. The owner is responsible for maintaining control settings that accomplish this. If
the inlet valve opens before the compressor and drive motor have reached full speed,
equipment damage can occur.
There are three general categories of starters for single speed, induction drive motors:
Full-voltage starters
Reduced-voltage starters
Solid state starters.
When selecting the motor controls, consider the following information about these starter types.
Full Voltage Starters
The conventional full voltage starter applies full line-voltage directly to the motor terminals. These
starters are available in many types, including manual, magnetic, combination, and reversing. It is also
possible to add several other functions to improve protection or increase monitoring capability.
Reduced Voltage Starters and Solid-state Starters
The two commonly used types of reduced voltage starters are reduced voltage and solid state.
These starter systems limit the drive motor inrush current to provide more efficient power management
and better motor control than full voltage starters. Starting times for these systems may last up to 30
seconds. As above, the compressors inlet guide vanes must not be cycled open until the motor and
compressor have reached full speed.
Refer to the manufacturer documents supplied separately for more specific details on your compressors
motor controls.
NOTE:
Refer to Compression Systems Engineering Specification AAEDR-G-019, Requirements for Starter to
Main Motor Controls, for more information on minimal requirements for solid state starting equip-
ment.
326
Installation
Auxiliary Oil Pump Motor

The Turbo Air Compressor electric motor driven oil pump is controlled by the control system. Once the
compressor is started and the shaft-driven main oil pump is supplying the necessary pressure, the
control system shuts down the electric auxiliary pump. Figure 315 illustrates typical oil pump motor
and control system contact wiring. (The user/installer is responsible for supplying the oil pump motor
starter unless it was included at the time of order entry.)
Figure 315. Auxiliary Oil Pump Motor Wiring
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 316. With voltage applications greater than
480 and below 600 VAC, refer to Figure 317 for a typical wiring diagram.
Figure 316. Oil Heater Option Wiring Figure 317. Oil Heater Option Wiring
(480 VAC or less) (above 480 VAC and below 600 VAC)
327
Receiving, Lifting, Moving, and Bolting

The time after the order for a new compressor has been placed and before the actual delivery of the
equipment can be spent planning for the installation. Much of the work described earlier can be
performed or planned for prior to the arrival of the compressor at the installation site.
The Turbo Air 3000 Centrifugal Compressor is shipped as a single assembly. The main drive motor,
lubrication system, and control system are packaged with the compressor on a single skid. However,
since there are many package and accessory options, it is important to refer to the model-specific
engineering drawings supplied separately for as complete listing of equipment included in Compression
Systemss Scope-of-Supply.
Receiving
Compression Systems personnel inspect each compressor thoroughly at the factory before shipment.
They then supervise the loading to be sure that no damage occurs and document all loose-shipped
equipment.
It is the responsibility of the purchaser to inspect the compressor for possible damage during transit.
Therefore, plan to inspect the compressor immediately upon delivery. If there appears to be any
damage, report it to the carrier and have the carrier inspect the compressor. After determining the
extent of the damage, have the carrier complete and submit a Concealed Damage Report.
Also, be sure to check all loose-shipped parts and equipment against the packing list. If anything is
missing, report the shortage to the carrier.
Shipments are FOB, Buffalo, NY, USA, and become the property of the purchaser at the risk of the
purchaser.
Lifting
The Turbo Air 3000 Compressor is a heavy and durable high technology product, but it can be dam-
aged as a result of improper treatment. It requires careful handling during all lifting and moving. The
unit includes clearly indicated lifting and moving points. Never use any other areas for lifting and
moving.
WARNING:
To avoid personal injury or compressor damage, always follow the proper procedures as
described in this manual. Personnel safety and compressor protection must always be
foremost concerns when lifting or moving the compressor.
The Turbo Air 3000 Compressor is designed to be moved with an overhead hoist and chain. Be sure that
both are properly rated for a maximum package weight of 18,500 lbs. (8400 kg), and be certain that
they are in good working order before attempting the move. Use the clearly designated lift points on
the compressor as shown in Figure 318. (In some instances it may be necessary to use spreader bars to
clear certain main drive motors.)
WARNING:
Be certain to use properly rated equipment and lift the compressor only as shown at the
lift points indicated. Improper lifting may cause compressor damage and/or personal
injury.
328
Installation
Figure 318. Compressor Lift Points
Moving
If an overhead hoist is not available, the compressor may be moved on rollers, dollies, or casters.
Alternatively, if a forklift is used to move the compressor, be certain to place the entire compressor on a
substantial pallet that supports the base between the liftpoints and lift only under the base between
the lift points indicated.
WARNING:
Before moving the compressor, verify that the moving device is the appropriate size and
sufficiently strong to bear the weight of the compressor. Improper moving may cause
compressor damage and/or personal injury.
Bolting
If the foundation has been properly prepared, the compressor may be put in place at this time. Com-
pression Systems recommends placing the compressor over foundation bolts, with the nuts tightened
to the recommended torque value. (Refer to Section Two, Compressor Specifications, for specific
information).
Take special care not to rack or twist the base of the compressor when placing it on the foundation. If
necessary, use shims to level the installation package.
329
The Installation Inspection

Before performing the installation inspection, review the Turbo Air 3000 Compressor installation
instructions again. Also, be sure to review any other applicable manufacturers instructions for
installation, operation, and maintenance of various other components and equipment including the
main drive motor, the main drive motor controller, the air dryer, etc..
After reviewing the previous items, thoroughly inspect the compressor installation using the
Installation Inspection Checklist in Table 32.
Inspection Prior to Initial Startup

As part of the initial startup service, your authorized Compression Systems service representative verifies
that the compressor is ready to be placed in full operation. The service representative should perform
the following inspections and tasks as part of the initial compressor startup service.
1. Check the compressor package for possible transit or handling damage.

2. Verify that the compressor installation is in accordance with the requirements of Compression
Systems.
3. Verify that the inlet and discharge air piping complies with the instructions in this manual and on
the contract-specific drawings.
4. Check the water and condensate drain piping for completeness.
5. Check that all electrical connections have been made correctly.
6. Verify that the compressor oil reservoir is filled with the correct amount TurboBlendTM
Lubricating Oil.
7. Rotate the compressor bullgear and main drive motor shaft (while uncoupled) by hand to verify
that both rotate freely.
8. Verify the correct rotation of the main drive motor and auxiliary oil pump motors.
9. Complete the final alignment of the motor shaft to the compressor shaft within the tolerances in
all planes.
10. Verify that the oil reservoir venting system is receiving the proper, clean, dry air supply.
11. Complete the 8-hour lubrication system flush procedure (Change oil filter element afterwards).
12. Verify the temperature setting of the oil heater option (if included).
13. Make any necessary control system adjustments to satisfy the users expected requirements.
14. Oversee the lubrication and reassembly of the main drive coupling.
15. Complete the Installation Inspection Checklist shown in Table 32 with customers installation
personnel before the initial compressor startup.
330
Installation
Installation Inspection Checklist

Foundation
Meets the material and thickness requirements
Compressor leveled within specification, foundation bolts properly torqued
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
Properly supported, with flexible connections at the compressor
Startup screen correctly in place (if required)
Clean and free of dirt and/or other foreign matter
Inlet Air Filter/Silencer

Located properly with proper surrounding clearance
Elements installed according to manufacturers instructions
Clean and free of dirt and other foreign matter
Discharge Air Piping

Correct pipe material and size
Properly supported, without excessive loads
Block valve installed
Check valve installed with recommended pipe volume
Bypass or Modulating Blow-Off Valve installed with recommended discharge pipe volume
Silencer installed (if required)
Clean and free of dirt and other foreign matter
Oil Reservoir Vent Ejector

Properly connected to the correct amount of clean, dry air
Table 32 The Installation Inspection Checklist
331
Installation Inspection Checklist continued

Earth ground installed at control panel
All applicable codes met
Motors wired according to manufacturers instructions
Motor controllers and starters wired according to manufacturers instructions
Control panel wired properly
Shaft Freedom
Motor shaft freely moved when turned by hand
Compressor shaft freely moved when turned by hand
Main Drive Motor

Motor manufacturers instruction manual reviewed
Motor bearings properly lubricated
Motor rotation direction checked
Motor rough alignment completed
Lubrication System
Reservoir filled with correct type and quantity of oil
Reservoir vent filter trap filled with oil
Optional oil reservoir heater thermostat set to 100 F (40 C)
Oil pump rotation checked
Control System
Air pressure sensors properly connected
Monitoring points checked for faults
Current transformer scale factor
Vibration probe wiring checked
Table 32. The installation Inspection Checklist
332
Installation
Main Drive Motor Installation Items

Before coupling the compressor and main drive motor, it is necessary to perform the following
verifications:
1. Carefully follow all of the motor manufacturers instructions (provided under separate cover)
regarding preparation and installation.
2. Verify that the rating voltage and frequency shown on the motor nameplate match the power
supply.
3. Bump (energize and quickly de-energize) the motor so that the shaft rotates only a few revolu-
tions, and verify the direction of rotation using the directional arrow on the compressor gearbox
cover. If required, change the phase wiring to reverse the direction of rotation.
4. Perform a rough motor alignment, using a straight edge.
5. Verify that motor fastening bolts are properly torqued as listed in Section Two, Compressor
Specifications.
6. Final motor alignment will be performed by authorized service representative. Tolerance specifica-
tions in Section Two must be achieved.
7. Dowel motor feet, per motor manufacturer requirements.
Oil Pump Motor Rotation Verification

It is necessary to verify the correct rotational deriction of the auxiliary oil pump motor as follows:
1. Note the arrow indicating the correct rotation direction on the mounting flange between the
pump and the motor.
2. Turn on the oil pump motor and observe the rotation direction of the motor fan. (The correct
rotation is clockwise, as indicated by the arrow.)
3. If the rotation of the motor fan is not clockwise, correct the pump rotation by interchanging two
of the three power phases connected to the motor.
333
Preparing for Startup

Each compressor undergoes comprehensive testing before it leaves the manufacturing facility.
However, after transit and installation, it is necessary to recheck certain items on site. Before the initial
startup procedure, several inspections and adjustments are required to verify that the compressor has
been installed correctly and to be sure that all subsystems are functioning correctly.
To ensure a proper and safe compressor startup and correct operation, a Compression Systems factory
trained and authorized service representative should be present to inspect the site, supervise the final
installation steps, and assist with the startup procedure.
The Installation Inspection Checklist lists the items that the user or installer should complete prior to the
arrival of the Compression Systems authorized startup representative. Should any concerns or questions
develop while executing this list, contact your representative.
WARNING:
Personnel safety and equipment protection must always be primary considerations during
compressor installation, startup, and operation. Failure to follow the safety precautions
throughout this document can result in equipment damage or personal injury
Avoiding Startup Problems

It is the owners responsibility to plan for the inspection and initial startup service. Contact your local
authorized Compression Systems service representative several weeks prior to the anticipated on-site
date to arrange for startup service.
Table 33 lists common problems or situations that can delay the installation and initial compressor
start-up. The owner installer should be aware of these items and correct them, if possible, prior to the
arrival of the authorized service representative.
Potential Installation Problems

Damage during shipment
Damage from improper lifting or from mishandling
Earth grounds not in place
Incorrect or incomplete electrical interface with motor controls
Incorrectly installed bypass or blow-off valve piping
Condensate drain piping manifolded together
Incorrect location of cooling water supply and return piping
Bypass valves not included on condensate drain piping
Reservoir vent ejector piping improperly installed
Excessive stresses on inlet, discharge, or water piping
Temporary inlet pipe screen not available on site (if applicable)
Correct quantity of TurboBlendTM Lubricating Oil not available on site
Correct type of motor and/or coupling grease not available on site
Necessary equipment, tools, supplies, and parts, not available on site
Necessary labor not available on site
Technical information (manuals and drawings) not available on site
Table 33 Potential Compressor Installation Problems
334
Installation
Initial Start-up Checklist

The authorized service representative uses the checklists below during initial compressor startup.
WARNING:
Do not attempt to start up the Turbo Air Centrifugal Compressor until a Compression
Systems authorized service representative has fully checked and approved the compressor
installation. Compression Systems recommends that a trained and authorized service
representative perform the initial startup procedure.
Before Applying Power

Verify that power to the drive motor is locked out.
Push in the control panel Emergency Stop button.
Verify that the isolating block valve is closed.
Verify the proper location of the discharge and system pressure sensors.
Check the control panel wiring for correctness, tight connections and secure harnessing.
Verify that earth grounding is present and secure.
Check motor starter interface wiring from control panel.
Check Main motor and auxiliary oil pump overload settings.
Powered Pre-Start Checks

Check the supplied panel power.
Verify that the control configuration matches the job site parameters.
Verify that vibration probe gaps are correct.
Verify the monitoring points for correct instrument locations and secure wiring.
Verify proper compressor inlet and discharge valve operation.
Verify that all control setpoints are in accordance with Compression Systems guidelines.
Turn-on the oil reservoir vent ejector.
Turn on the auxiliary oil pump motor starter.
Verify proper oil pump operation. Adjust oil pressure regulator, if required.
Rack in the main drive motor starter.
Pull out the Emergency Stop button on the control panel.
Turn on coolant.
Verify the start sequence status. Correct if necessary.
335
Initial Compressor Startup

Following completion of all installation procedures and pre-start checks, an authorized Compression
Systems Service representative uses the checklist below as a guide for conducting the initial compressor
startup.
Preparation
9 Rack in main power to compressor and control panel.
9 Verify status using the control panel screens
9 Verify that the isolating air system block valve is closed.
9 Verify proper operation of compressor inlet and discharge control valves.
9 Establish required vacuum in oil sump by adjusting regulated clean, dry air supply to
the air ejector.
9 Turn on coolant supply.
9 Close the condensate drain manual bypass valves.
9 Set the System Pressure setpoint, temporarily, to 0 psi. (This prevents the compressor from
trying to load, on initial start.)
Startup
9 Press Start on the control panel.
9 Measure and make a note of the acceleration time to full speed. When able, adjust the
starting sequence accordingly.
9 Press Unload on the control panel and run the compressor unloaded for approximately
30 minutes.
9 Perform walk-around inspection to check for any air, water, or oil leaks.
9 Periodically check that all operating parameters are at acceptable levels.
Manual Load
9 Open the isolating system block valve, if it is a non-automatic type.
9 Manually load the compressor to its design point and allow to warm up for one hour.
9 Verify proper operation of condensate removal system.
9 Check again for any leaks and for correct values of all parameters.
336
Installation
Offline Loop Tuning and Surge Testing
9 Perform the Natural Surge Test and record the results
9 Perform the surge tests per established service procedures and record the results
9 Tune the Inlet Maximum Load Control loop
9 Tune the Surge Control loop
9 Tune the Blow Off Discharge Pressure loop
Performance Control Parameter Entries

9 Unload the compressor
9 Enter all Performance Control parameters into the Maestro configuration, including
all surge test values
9 Review all control parameters and check for input errors
9 Set the proper Operator settings for Maestro
System Mode Tuning
9 Load the compressor in Automatic control and verify proper compressor operation in the
Automatic mode
9 Tune the Inlet System Pressure control loop per established procedures
9 Tune the Blow Off Pressure control loop
9 Prepare to shut down the compressor
9 Press Stop on the Maestro panel and verify the correct stopping sequences
Saving the Control Configuration
9 Make final adjustments to Control parameters, if required
9 Reset the Maestro Operation History
9 Save/document the final Maestro Configuration
337
338
Routine Operation
Section Four
Routine Operation
Routine Startup
Routine Shutdown
The Operating Data Record
General Lubrication Considerations
The Compressor Lubrication System
Oil Pump Operation
Gearbox and Reservoir Venting
Optional Features
41
42
Routine Operation
After successful startup, the operator should keep detailed compressor operation and maintenance
records. (Refer to Section Five, Maintenance, for schedules and instructions for routine and periodic
preventive maintenance procedures.)
To assure long life and optimal output from the Turbo Air Centrifugal Compressor, always follow the
prescribed maintenance procedures. If problems arise, contact a Compression Systems factory trained
and authorized service representative for technical assistance.
The Operating Data Record

Compression Systems recommends keeping an Operating Data Record to list inspections and store
operating data for trend analysis. Proper use of the record form ensures that each item or procedure
receives the recommended periodic maintenance.
43
Routine Startup
After the initial compressor commissioning and control loop tuning, use the following procedure for
routinely starting the compressor.
Optional features such as Automatic Start, Automatic Block Valve, or other remote features may
affect individual steps below or otherwise have an effect on the procedure in general. Refer to the
instructions supplied with the specific option to determine the appropriate variation(s) of this
routine startup procedure.
Startup procedure
1. Close the intercooler condensate drain bypass valves.
2. Open the main coolant supply valve.
3. Check the oil level in the compressor oil reservoir.
4. Turn on the air ejector supply pressure and adjust appropriately; if necessary.
5. Rack in the drive motor starter disconnect.
6. Start up the electric oil pump.
7. Inspect the compressor for any water or oil leaks.
8. Open the discharge air system block valve.
CAUTION:
Do not open the air system block valve when the oil pump is not operating. Operation
under such conditions may cause compressor damage.
9. Press the applicable key and verify that the starting sequence parameters are ready.
(See Controls Section for specifics.)
10. Pull out the red EMERGENCY STOP button.
11. Press the Start key. The compressor will go through its starting sequence.
Following this sequence, this compressor loads automatically if the system pressure is below its
setpoint.
44
Routine Operation
Routine Shutdown
Use the following procedure for shutting down the compressor under normal operating conditions.
Optional features such as Automatic Start option, Automatic Block Valve, or other remote features
may affect individual steps below or otherwise have an effect on the procedure in general. Refer to
the instructions supplied with the specific option to determine the appropriate variation(s) of this
routine startup procedure.
Shutdown Procedure
1. Unload the compressor by pressing the applicable key.
2. Allow the inlet guide vanes to close; then press STOP.
3. Close the air system block valve and wait for the sequence to complete.
4. Open the condensate drain bypass valves.
5. Allow the cooling water and the oil to circulate for at least 30 minutes to remove heat.
6. Turn off the water supply.
7. Stop the electric oil pump.
8. Rack out the drive motor starter disconnect.
9. Turn off the air ejector supply pressure.
CAUTION:
If the compressor is to be shut down for an extended period in a cold environment, drain
all water from the system after shutdown or, alternatively, continue to maintain some
flow through the coolers. Even small amounts of water remaining in the heat exchangers
can freeze and damage the tubes.
45
Operating Data Record

General Information
Compressor Number: Turbo Air Model:
Serial Number: Recorded By: Date:
Air System
3 System Air Pressure:
3 Discharge Air Pressure:
3 Inlet Air Filter Pressure Drop:
3 Stage 1 Inlet Temperature:
3 Discharge Air Temperature:
Vibration
3 Stage 1 Vibration:
Cooling
3 Coolant Temperature In:
3 Coolant Temperature Out:
3 Coolant Pressure In:
3 Coolant Pressure Out:
Lubrication System
3 Oil Temperature:
3 Oil Pressure:
3 Oil Filter Pressure Drop:
3 Oil Tank Vacuum:
Drive Motor
3 Motor Current:
3 Ambient Temperature:
3 Motor Bearing Temperatures:
3 Motor Stator Temperatures:
Miscellaneous
3 Total Running Time:
3 Control Mode:
Table 41 Operating Data Record (Typical)
46
Routine Operation
General Lubrication Considerations

Unlike some other types of rotating equipment, high-speed, geared compressors cannot operate
without the correct lubrication. The Turbo Air Compressor lubrication system provides the specified
supply of cooled, filtered lubricating oil to the compressor bearings and gear sprays continuously.
The main oil pump is driven by an extension of the bullgear shaft. The auxiliary oil pump is driven by a
separate electric motor. The system contains all of the necessary components required to regulate, cool,
filter and monitor the oil before it enters the compressor gearbox. Optional features such as dual
filters, automatic temperature regulation, and reservoir heaters are available as specific conditions
justify.
Helpful information about operating, maintaining and troubleshooting the lubrication system is
included throughout this manual. Also refer to Section Two, Specifications, and Section Seven, Parts &
Service, for replacement part details.
47
The Compressor Lubrication System

Figure 41 is a schematic illustration of the compressor lubrication system showing the normal circula-
tion of the oil through the compressor system. A description of the normal sequence of operation
follows.
Normal Operation
1. The main oil pump [B], driven off of an extension of the bullgear shaft, draws oil from the
reservoir [A], through check valve [N], and cycles it through the lubrication system and the
compressor gearbox. Check valve [C]prevents the oil from being pumped back into the reservoir
through the auxiliary oil pump [M].
2. Excess heat is removed from the oil as it passes through the oil cooler [D]. The throttle valve [E] in
the return water line regulates the flow of the cooling water through the oil cooler, thereby
keeping the temperature of the oil within the normal operating range.
3. The oil continues on to the oil filter [F] where impurities are removed.
4. In the gearbox [G], the oil flows through a manifold [H] where it is distributed to the bullgear
bearings [I], the pinion bearings [J], and the two gear-mesh spray nozzles [K].
5. The oil flows from the gearbox to the oil reservoir, passing around a baffle arrangement that
breaks down any foam before it enters the rest of the compressor lubrication system.
6. The pressure regulator valve [L] maintains the correct operating pressure throughout the
lubrication cycle and returns any excess oil to the reservoir.
NOTE: The auxiliary pump [M] does not run during normal operation. The main oil pump pro-
vides full compressor oil flow and pressure requirements.
Gearbox
G
Manifold
Pinion Bearings [J] H
Gear Spray Nozzles [K]
Bullgear Bearings [I]
Temperature
Regulator Sensor
Pressure T
L Sensor
P
Bleed
Lube Oil Valve
Reservoir
A Check
Valve Main Oil Oil Filter
N Pump B F
Check
Auxiliary
Oil Pump Valve
M C
Water In
Water Out
Oil Cooler E
D
Figure 41 Compressor Lubrication System Schematic
48
Routine Operation
Oil Pump Operation

Compression Systems 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 recommen-
dation to be followed, the oil pump must be electrically isolated from all other compressor systems.
In instances when the oil pump is not kept in continuous operation, it should be kept running for a
minimum of 30 minutes after compressor shutdown. This allows any excess heat to be removed from
the bearings and gearing.
CAUTION:
Always maintain the proper air supply pressure to the reservoir vent ejector/filter system
whenever the oil pump is in operation. Failure to do so may cause oil leaks, premature
wear, and component damage.
49
Gearbox and Reservoir Venting

During multi-geared, centrifugal compressor operation, the action of meshing gears and the rotation
of the bullgear cause air to become entrapped in the lubricating oil. As this air is released from the oil,
it forms an oil-laden mist in the gearbox and the oil reservoir. It is very important that both the gear-
box and oil reservoir are properly vented so that this oil mist is not allowed to escape.
Ejector/Filter
A simple venturi-type ejector/filter system creates a slight vacuum inside the gearbox and oil reservoir.
The required vacuum (8 to 10 in H20 / 200 to 250 mm H20 ) prevents oil or oil mist from migrating out
into the atmosphere and/or creating other oil leaks. The ejector/filter system is illustrated in Figure 4-2.
CAUTION:
Supply air to the ejector must be clean and dry and the filter must be properly main-
tained. Water in the oil reservoir has adverse effects on the lubricating oil that, in turn,
can cause severe damage to the compressor.
Clean, Dry
Compressed
Air
Mist FIlter
D
Air
Ejector
3/4 B A
Vent
Check
Trap Valve
Fill
Trap
E Lube Oil
Reservoir
C
Figure 42 The Ejector/Filter System
Ejector/Filter Operation
Under normal operating conditions, the Ejector/Filter Arrangement operates as follows:
1. Dry, filtered, compressed air enters the ejector inlet (A) and is transformed into a high velocity
stream in the ejector nozzle (B).
2. Air from the main oil reservoir (C) becomes entrained in this high velocity stream.
3. The resulting pumping action draws the oil-laden air from the reservoir and gearbox and delivers it
to the filter (D), where droplets of oil accumulate and are then returned to the main oil reservoir.
4. The oil return line includes a mist trap (E) before the oil reservoir. This mist trap serves as a vapor
lock to prevent the oil mist from bypassing the filter and escaping to the surrounding area.
410
Routine Operation
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.
Oil Reservoir Heater

The minimum startup oil temperature for the compressor lubrication system is 60F (15 C). Therefore,
compressors that are installed outdoors or in unheated buildings may require the use of the Oil
Reservoir Heater option. Such emersion heaters are rated at 1.5 kW and are available in any standard
three-phase voltage up to 600 volts. The heater is installed in the oil reservoir. Figure 43 shows the
Oil Heater option.
Figure 43 The Oil Heater Option
Thermostatic Mixing Valve

With the standard package, oil temperature is maintained by regulating the flow of cooling water
through the oil cooler. This method, though effective, may require seasonal adjustments. Including the
Thermostatic Mixing Valve option will automatically control oil temperature by regulating the oil flow
around the oil cooler, thus keeping the temperature of the oil entering the compressor constant. The
Thermostatic Mixing Valve option is shown in Figure 44.
From To
Oil Pump Oil Filter
Regulator
Water In
Water Out
Oil Cooler
Figure 44 The Thermostatic Mixing Valve Option
411
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, Compres-
sion Systems offers the Duplex Oil Filter option. The duplex oil filter eliminates the necessity for com-
pressor shutdown during filter maintenance. (Refer to Section Five, Maintenance, for full instructions
regarding this procedure.) The Duplex Oil Filter option is shown in Figure 45.
Figure 45 The Duplex Oil Filter
Oil Filter Differential Pressure Monitoring

With this optional feature, a second pressure transducer is installed before the oil filter. (The systems
standard pressure transducer is located between the filter and the gearbox.) In such instances, the
Maestro Control System is programmed to calculate the differential pressure across the oil filter and to
provide Alarm and Trip functions. The Oil Filter Differential Pressure Monitoring option is particularly
useful when included as part of a predictive maintenance program. Figure 46 shows the Oil Filter
Differential Pressure Monitoring option.
Oil from Cooler Oil to Gearbox
Oil Filter
Figure 46 Oil Filter Differential Pressure Monitoring Option
Low Oil Level Indicator

With the installation of the Low Oil Level Indicator option (a switch located in the main oil reservoir)
the Maestro Control System will report any oil level in the reservoir that is below a pre-defined level.
The control system then indicates an Alarm condition to alert the operator of the problem.
412
Maintenance
Section Five
Maintenance
Daily Inspection
Scheduled Maintenance
Professional Inspection
Filter Maintenance
Lubrication
Heat Exchanger Maintenance
Control Valves
51
52
Maintenance
The Compression Systems Turbo Air Centrifugal Compressor requires minimal maintenance. However,
monitoring operating conditions on a daily basis is good practice. It allows the operators to become
familiar with a smooth running machine, which enables early detection of potential problems.
As with other types of highly developed machinery, compressors are subject to operational changes
resulting from environmental conditions, wear, or neglect. A plugged condensate drain, unusual
noises, increases in temperature or vibration, and fluid leaks are some examples of operational changes
that signal potential problems. By recognizing and responding to changes in operation you can prevent
unscheduled shutdowns and the expense of unanticipated repairs.
CAUTION:
Do not attempt service procedures other than those described in this manual. Even a
minor adjustment, incorrectly performed could cause serious damage. Contact a Compres-
sion Systems trained and authorized service representative for help with all other proce-
dures.
53
Daily Inspection
A proper daily inspection allows the operator to develop a sense for the appearance, sounds, and
other operating conditions of a smoothly performing compressor.
Daily Operator Inspection Checklist

WARNING: Exercise care when in the vicinity of hot surfaces, pressurized air, and high voltages.
Procedures accompanied by the alert symbol S require special precautions as indicated.
Operating Data Log
3 Operating Parameters recorded and within specifications
3 Setpoints Checked
Gearcase
3 External surfaces wiped clean
3 No unusual noise or vibrations
3 No oil leaks
3 No air leaks
3 No frayed or worn electrical cables
Intercoolers and Aftercooler
3 Condensate drains functioning properly
3 No cooling water leaks
3 No air leaks
Lubrication System
3 Proper oil level in oil reservoir
3 Proper oil color
3 No mist from ejector system
3 No oil cooler water leaks
3 No oil leaks
Compressor Drive Motor (Inspect visually onlyhigh voltages, temperatures)
3 Properly ventilated
3 No erratic or noisy operation
3 Inspected in accordance with manufacturers recommendations
Table 51 Daily Operator Inspection Checklist
54
Maintenance
Table 52 lists the intervals for prescribed scheduled maintenance procedures. These intervals may
vary with operating conditions and/or actual hours of machine operation. Some items may require
attention more or less frequently as circumstances dictate.
NOTE: For maintenance of any compressor accessory not shown, refer to the specific maintenance
instructions for that item
Scheduled Maintenance Procedures

When servicing the Turbo Air 3000 Centrifugal Compressor, use only genuine Joy and Compres-
sion Systems replacement parts and recommended supplies available through Compression
Systems and/or authorized representatives.
Daily:
3 Operating data logged and reviewed
Monthly:
3 Inlet air filter elements inspected, replaced if required
3 Oil reservoir venting system filter elements inspected, replaced if required
3 Compressor bypass valve filter checked (if applicable)
3 Control system operation checked
3 Intercooler/Aftercooler condensate removal system checked
Quarterly:
3 Drive Motor ball lubricated per manufacturers instruction*
3 Condensate traps cleaned and inspected
3 Compressor operational data analyzed
3 Intercooler, aftercooler, and oil cooler performance verified
3 Lubrication system oil analyzed
3 Verfiy oil heater operation (if applicable)
3 Verify discharge check valve operation
*Refer to the motor instructions for specific interval guidelines.
Table 52 Scheduled Maintenance Procedures
Continued on next page.
55
Table 52 continued.
NOTE: For maintenance of any compressor accessory not shown, refer to the specific maintenance
instructions for that item
Scheduled Maintenance Procedures

When servicing the Turbo Air 3000 Centrifugal Compressor, use only genuine Joy and Compres-
sion Systems replacement parts and recommended supplies available through Compression
Systems and/or authorized representatives.
Every Six Months:
3 Main drive coupling inspected and regreased (if applicable)
3 Oil pump motor lubricated with recommended grease (if required)
3 Discharge air check valve inspected
3 Verify proper operation of inlet guide vanes and compressor discharge valve
3 Main drive motor maintenance checks completed*
3 Test E-stop circuit
3 Verify vibration gap voltage
3 Perform surge test and record results
3 Verify operation of main and aux pumps
3 Lubricate main drive motor (see motor manual)*
3 Verify proper motor alignment
3 Oil reservoir venting system filter element changed
3 Oil system filter element changed
3 Lubrication system oil tested and changed if required
3 Coolant and condensate chemically tested
3 Bypass valve air filter replaced, if applicable
3 Inlet guide vane assembly inspected and drive screw lubricated
3 Inspect inlet and blow-off valve
*Refer to the motor instructions for specific interval guidelines.

Table 52 Scheduled Maintenance Procedures - continued
56
Maintenance
Professional Inspection
An effective preventive maintenance program includes a professional inspection after an established
interval based on jobsite conditions. Table 5 3 lists items that are typically performed with a
professional service inspection. Contact a Compression Systems trained and authorized service repre-
sentative for those procedures as they are not intended for unauthorized personnel.
Service Inspection Checklist

To be performed with a Compression Systems authorized representative:
Operating Data Log

3 Recent data logs and maintenance history reviewed with customer
Gearcase*
3 Impellers, inlets, and diffusers cleaned and Inspected
3 Gearing visually checked
3 Gearing backlash clearances measured
3 Axial pinion floats measured
3 Clearances between impellers and inlets checked
Intercoolers* and Aftercooler*
3 Bundle tubes inspected, cleaned if required
3 Bundle fins inspected, cleaned if required
3 Cooler cavities cleaned and inspected
3 Condensate removal system cleaned and inspected
3 Cooling sensors checked
Lubrication System*
3 Piping connections checked for leaks
3 Oil visually inspected
3 Oil cooler inspected
3 Oil pumps inspected
3 Oil system sensors checked
Filters
3 All filter elements inspected and replaced as required
Control Panel
3 Inspected for proper configuration and operation (adjust as required)
Control Valves
3 Inlet Guide Vane inspected and adjusted
3 Discharge air check valve inspected
3 Compressor modulating blow off or bypass valve inspected and adjusted
3 Auto block valve inspected (where applicable)
Drive Motor
3 Main drive coupling inspected and re-greased (if applicable)
3 Motor inspected in accordance with manufacturers instructions
*Replacement parts required. Use only genuine JOY and Compression Systems parts and supplies
available through the Compression Systems and/or authorized representatives.
Table 53 Service Inspection Checklist
57
Filter Maintenance
Different types of filters are located in various parts of the compressor package. The operator must
regularly monitor the condition of these filters and clean or change them as required.
Table 54 lists the various filters along with recommended inspection intervals for typical operating
environments. Instructions for each procedure are included in this section.
Filter Maintenance Schedule

Filter: Inspect: Clean or Change:
Inlet air filter elements* Monthly When dirty or after 12 months
Bypass valve air supply filter* Monthly When dirty or after 6 months
Oil reservoir venting system* Monthly With misting or after 6 months
Oil system filter element* N/A At Alarm level or after 6 months
*When replacing filter elements, use only genuine Compression Systems products. Refer to Section
Seven, Parts and Service, for more information on parts that are available through your Compression
Systems representatives.
Table 54 Filter Maintenance Schedule
Inlet Air Filter

The standard inlet air filter is a two-stage unit. The primary filter may be removed, cleaned, and rein-
stalled but the secondary filter element is not serviceable and must be replaced when it becomes dirty.
Note: Special optional primary filters may not be cleanable
Since compressor operation without the action of the primary filter will contaminate the secondary
filter very rapidly, Compression Systems recommends that you keep a complete set of replacement
filters on hand.
Standard Primary Filter Cleaning

The only reliable method to determine whether cleaning or replacement is necessary is to monitor the
pressure drop across the filter elements. Use this procedure:
1. Install a differential pressure gauge in either the inlet filter housing or the inlet pipe.
2. Measure and record the current pressure drop. Compare that with the one intially taken when
the new filter elements were installed. A pressure drop that is 4" (100 mm) WC, or more, greater
than the original reading means the filters require maintenance.
3. Remove and inspect the primary filter element.
4. When If the primary filter is dirty, clean it using either of these methods:
Blow 30 psi (2kg/cm2 or bar) of air from the clean side, or...
Soak and periodically agitate the filter in hot water containing a non-volatile cleaning
agent. Be sure to air dry the filter completely before installation.
5. Measure and record the pressure drop with the new filter element installed.
6. If, after cleaning or replacing the primary air filter, the air pressure drop remains high with the
clean or replacement primary filter, replace the secondary filters.
CAUTION: Do not operate the compressor for more than 2 minutes without the primary
filter. Operation without proper filtration may cause compressor damage or malfunction.
58
Maintenance
Bypass Valve Air Supply Filter

(For solenoid unloading bypass valves only)
The solenoid bypass discharge control valve requires clean dry supply air for proper control. The line
filter in the pilot air supply prevents water and other contaminants from entering the valve and fouling
its control mechanism. Use only a Compression Systems replacement filter.
Filter Element Replacement
The replacement procedure is as follows:
1. Shut down the compressor and exhaust any pressure in the bypass valve air supply line.
2. Unscrew the filter canister from its base and separate the filter element by removing the filter
retaining nut.
3. Inspect the canister o-ring seal and replace if worn or damaged.
4. Install the new replacement filter element.
5. Replace the retaining nut (finger-tighten only) and screw the filter canister to its base.
Oil Reservoir Vent Filter

The oil reservoir is vented through an air ejector-filter system that requires a clean dry air supply to
function properly. Moisture that can accumulate in the filter element eventually drains back into the
reservoir, contaminating the lubricating oil. The filter element must be replaced at least every six
months. Use a Compression Systems replacement filter only.
CAUTION:
Water in the oil reservoir adversely affects the lubricating oil and can cause severe dam-
age to the compressor. Be sure the ejectors supply air is clean and dry and the filter is
properly maintained during periods of high humidity.

Check the exhaust port at least daily. If an oil mist is evident, that is an indication of a clogged filter
element. Using the following procedure, replace the element.
1. Remove the trap line between the bottom of the filter housing and the oil reservoir.
2. Unscrew the retaining nut at the bottom of the housing.
3. Catch any excess oil in a separate container.
4. Slide down the lower housing section to expose the filter element.
5. Remove the nut holding the filter element in place, remove the element, and (being careful not
to over-tighten the retaining nut) install a new replacement element.
6. Inspect the o-ring seals at the top of the lower housing section and in the retaining nut. Replace
the seals if worn.
7. Wipe the housing clean.
8. Begin filter reassembly by pouring a small amount of oil into the fill connection at the top of the
trap line to restore the mist filter trap. The ejector cannot function without this trap.
9. Complete the reassembly.
59
Standard Oil Filter Element Replacement

Compression Systems has specially designed bearing and gearing configurations, not found on other
compressors. Regular maintenance of the oil filtration system is critical to the lasting operation of these
sophisticated components. Use the following procedure to replace the standard oil filter element.
CAUTION:
Use only Compression Systems original equipment replacement filters. Use of improper
filters can damage internal compressor components and will void any existing warranties.
Filter Element Replacement Procedure

1. Shutdown and lock-out the compressor.
2. Close the manual isolating block valve.
3. After the compressor is completely stopped, verify that the discharge air pressure is zero, and
then shut off the oil pump.
WARNING:
Do not attempt to remove any oil filter until oil pressure is at zero (O). Hot oil under
pressure presents a safety hazard to personnel.
4. Remove the spin-off oil filter and catch any excess oil in a separate container.
5. Inspect the new filter and then, using clean oil, lightly lubricate the gasket.
6. Install the new filter element by threading it on and continuing to turn it until hand tight, plus
an additional 1/4 turn.
7. After verifying that the oil level is correct, start the pump and inspect for possible leaks.
Duplex Oil Filter Element Replacement

The Duplex Oil Filter option allows for oil filter replacement without shutting down the compressor.
When required, replace the duplex oil filter elements as follows:
WARNING:
Be sure the chamber to be serviced is not being used. Do not attempt to remove the oil
filter element until the oil pressure in the chamber is at zero (O). Hot oil under pressure
presents a safety hazard to personnel.

1. Using an Allen wrench, turn the bleed screw counterclockwise until the screw head touches the
safety plate on the side not in use (opposite the locking pin).
2. Inspect the new filter and then, using clean oil, lightly lubricate the gasket.
3. Unscrew the filter bowl, and remove the old filter element. Catch any spillage in a separate
container.
4. Install the new filter element and replace the filter bowl. Use only a Compression Systems
replacement filter.
5. Depress the balance valve lever until oil begins to bleed through the bleed screw.
6. Turn the bleed screw clockwise until tight. Depress the balance valve lever once more to
pressurize the filter bowl.
510
Maintenance
Lubrication
Table 55 lists recommended intervals and the products necessary for proper lubrication of various
Turbo Air Compressor components.
Instructions for these periodic lubrication procedures are included in this section.
Compressor Lubrication Schedule

Element Interval Lubricant
Main oil reservoir Monitor daily. Compression Systems
Change only as required. TurboBlendTM Lubricating Oil
Auxilliary Oil pump motor bearings Six months Refer to Section 2
(If applicable)
Main drive coupling Six months Compression Systems
(If applicable) Coupling Grease
Drive motor ball bearings [A] [A]
Drive motor sleeve bearings [A] [A]
Inlet guide vane actuator drive screw Six months High quality synthetic grease
Bypass valve (if applicable) Six months Molycoat 33 (if applicable)
[A] Refer to the motor manufacturers instructions for specific interval guidelines.
Table 55 Compressor Lubrication Schedule
Compressor Lubricating Oil

Compression Systems cannot specify a fixed interval between lubrication system oil changes because of
the wide variety of operating conditions that exist. Therefore, daily the operator should check the oil
visually to monitor changes and/or possible deterioration.
If the oil appears darker than normal, there is probably some contamination.
If the oil appears muddy or contains any white emulsion, there is some contamination with water.
Quarterly or as the situation requires, have the oil tested for viscosity, acid, water and other contamina-
tion. A reputable commercial laboratory can easily detect the presence of any such contamination.
Whenever the performance of the lubricating oil is suspect, Compression Systems recommends addi-
tional testing for the presence of enhancing additives in accordance with The American Society for
Testing and Material (ASTM) as defined in Table 21, Oil Specification.
CAUTION:
Be certain to use only Compression Systems TurboBlendTM Lubricating Oil for optimum
performance. Use of any incorrect oil can cause extensive damage to internal components
and will void any existing warranties.
511
Auxiliary Oil Pump Motor Bearing Lubrication

Examine the electric oil pump motor to determine the type of bearings it has. The standard Turbo Air
compressor oil pump motor uses sealed bearings that do not require lubrication. However, the bearings
in some non-standard motors do require lubrication.
Periodic lubrication is necessary if the oil pump motor bearings have grease fittings. Use a good quality,
polyurea-based grease, adding 1/4 oz. (7 gm.) to each fitting. It is not necessary to lubricate the oil
pump coupling.
Main Drive Coupling Inspection and Lubrication

It is necessary to lubricate the geared main drive coupling every six months to meet the coupling
manufacturers specifications.
WARNING:
Shut down the compressor before performing this procedure. Then lock out the main
power supply and close the air system block valve. Failure to follow this safety precaution
may result in serious injury or death.
1. Stop the compressor, close the isolating air system block valve, and lock out the main motor
starter.
2. Remove the coupling guard and the center spool.
3. Carefully slide back the flexible coupling hub sleeves on the motor and compressor shafts to
expose the gear teeth on the fixed hubs.
4. Remove all grease; then inspect the teeth and anti-rotation keys on each hub.
5. Replace any defective parts with Compression Systems parts only.
6. Apply grease to the gear teeth by hand to ensure full coverage.
CAUTION:
Use Compression Systems coupling grease only. Application of other grease may cause
coupling failure and void any existing warranty.
7. Reinstall the sleeves over the fixed hubs, while carefully avoiding damage to the seals on the shaft
key seat.
8. Reinstall the center spool and tighten all bolts uniformly to the specified torque.
WARNING
Failure to apply proper torque will result in premature wear, serious damage or personal
injury
9. Move the coupling center spool back and forth to verify free movement. If it does not move
freely, repeat the disassembly and inspection procedure completely.
10. Note that each coupling hub sleeve has two lubrication plugs. For each sleeve, remove both plugs
and clean thoroughly with a stiff brush. Install grease fittings and then pump in 2 oz. (60 cc) of
Compression Systems Coupling Grease into each.
11. Remove the grease fittings and replace all plugs.
12. Again, float the center spool back and forth several times to verify free movement of the cou-
pling assembly.
13. Replace the coupling guard.
512
Maintenance
Drive Motor Ball Bearing Lubrication

Most Turbo Air Compressors are driven by a squirrel-cage induction motor with ball bearings. The ball
bearing grease must be changed in accordance with the motor manufacturers recommendations. Be
aware that many motor manufacturers require lubrication every three months.
CAUTION:
Do not use excessive amounts of grease. Over-greasing may cause premature bearing wear
and motor failure.
Drive Motor Sleeve Bearing Lubrication

Some Compression Systems Turbo Air Compressors have drive motors equipped with sleeve bearings.
Most of these have oil reservoirs in the motor bearing housings. Fill the reserviors and maintain per the
motor vendors recommendations. Other sleeve bearing motors are lubricated directly from the
compressors lubrication system; periodically check the oil pressure to the motor and adjust to read 20
to 30 psi.
Inlet Guide Vane Assembly Drive Screw

Most Turbo Air 3000 compressors have an electrically driven inlet guide vane assembly with a drive
screw mechanism.
NOTE:
Inlet guide vanes driven by a pneumatic actuator do not have drive screws.
Drive Screw Lubrication

The inlet guide vane assembly drive screw requires lubrication every six months using the following
procedure:
1. Unscrew the cover tube at the motor bracket.
2. Carefully pull away the cover tube, just enough to expose the drive screw.
3. Using a clean cloth, wipe off all the old grease from the drive screw surface.
4. Work fresh grease into the drive screw by hand, being sure to use sufficient grease to cover all
surfaces thoroughly.
WARNING:
Use only the recommended high quality, synthetic grease for this procedure. Under certain
conditions, other products may contribute to mechanism malfunction.
5. After greasing is complete, replace the cover tube and screw it back to the original position.or
manufacturers instructions for specific lubricant requirements and minimum lubrication inter-
vals.
513
Bypass Valve Lubrication (Non-modulating Valves Only)

Compressors that do not have a modulating blow off valve use either of two different types of bypass
valve, depending on the airflow rating of the compressor. Refer to Figures 51 and 52 to determine
which valve is used in your installation. Each is a two-position valve that operates only fully-opened or
fully-closed.
Turbo Air Compressors rated up to 600 horsepower typically use a box-shaped bypass valve (Fig 52),
which requires periodic lubrication. Every 6 months (or as required), it is necessary to lubricate the
piston seals and guide rings of the smaller, box-shaped valve. Since other products do not provide the
required level of protection and could gum up under service, use only the recommended lubricant.
The larger cylindrical, angled valve (Fig 51), typically installed on machines rated at 700 horsepower
and larger, does not require lubrication. Attempts to lubricate these larger valves will result in prema-
ture wear and malfunction.
Rebuild
Kit
Seal Kit
Figure 51 Bypass Valve 700Hp and up (Do not lubricate)
514
Maintenance
Seal
Kit
Lubricant
Figure 52 Bypass Valve Up to 600 Hp Lubricate per procedure below
WARNING:
Failure to follow these insctructions could cause severe injury from pressurized air.
Lubrication Procedure
1. Shut down the compressor, lock out the motor starter and close the discharge block valve.
Exhaust all line pressures and disconnect the instrument line at the metering valve.
2. Remove the four bolts that hold the solenoid assembly and adapter to the bottom side of the
bypass valve.
3. Remove the top plate to expose the spring and stem assembly and, using the stem assembly, push
out the piston.
4. Clean all parts of the piston, and carefully inspect the piston bore and piston seals for wear and/
or damage.
5. Replace the seal kit if any seals or o-rings are damaged.
6. If the piston bore appears to be in good condition (or after a replacement has been made as
required), lightly lubricate the piston bore and the seals on the piston assembly with the
recommended grease.
7. When lubrication is complete, reassemble the valve and reconnect the air and
electrical supply lines.
515
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.
Instructions for each follow.
Other Maintenance Procedures

Procedure: When Required:
Intercooler/aftercooler cleaning* With elevated interstage air temperatures
Condensate drain cleaning Quarterly, or sooner if required.
Oil cooler cleaning* With elevated oil temperature
Inlet guide vane and blow off valve inspection At 6-month intervals
Discharge air check valve inspection At 6-month intervals
Additional main drive motor items Per manufacturers instructions
*Indicated procedures require the use of parts available through your authorized Compression Systems
representative.
Table 56 Other Maintenance Procedures
Intercooler and Aftercooler Cleaning

In most cases, the intercoolers should be cleaned when the interstage air temperatures increase
significantly. Before doing so, check for other possible causes of an increase in air temperatures:
1. Verify that ambient conditions are not above compressor design parameters.
2. Be sure the temperature sensors are functioning properly.
3. Verify proper coolant temperature and flow.
4. Be sure that all condensate drains are functioning properly.
The best indicator of the performance level of the intercoolers and aftercooler is the approach tem-
perature. This is the difference between the temperature of the air leaving the cooler and that of the
coolant entering it. Record that information for each cooler when the compressor is first installed and
running at full load. If an approach temperature exceeds the original value by 15F (8C), the coolers
should be inspected, and cleaned if required.
The Compression Systems compressors have tube-and-fin style intercoolers and aftercoolers, with
coolant flowing through the tubes. A U-tube design is standard. Straight tubes are available as an
option.
The following pages provide the recommended procedures for proper disassembly and thorough
cleaning of the tube-and-fin cooling units.
516
Maintenance
Intercooler Disassembly
Follow this procedure to separate the tube bundle from its casing:
1. Shut down the compressor and exhaust all air pressure. Lockout the main motor starter and
close the system block valve.
2. Shut off the cooling water supply and remove the supply piping at the compressor.
3. Drain the coolant, and then remove the intercooler front headers.
4. Remove the intercoolers from the cooler cavity. Referring to Figure 53, determine the type of
bundle (U-tube or straight tube). If it is a straight tube type, remove the rear header.
5. Inspect the cooler casings for corrosion.
6. Remove all loose scale from the interiors of the cooler cavity, water headers, and manifold pipes.
CAUTION:
Do not allow the loose debris to enter the condensate drain lines. This could cause plug-
ging of the drains.
Always Apply
NEW Gaskets
and Seals on
Reassembly
Standard U-Tubed Intercooler Optional Straight-Tube Intercooler
Figure 53 Intercooler Disassembly
517
Water Side Cleaning

After disassembly, proceed with the cleaning as directed below:
1. Using a 1/8" (3 mm) rod, probe the length of the intercooler tubes to check and clear any block-
age.
NOTE: If the cooler has U-tubes do not force the rod into the U-bend.
2. For straight-tube bundles, attempt to rod them out per steps 5 through 7 below. If successful
proceed to step 11, below; otherwise continue with the next step.
3. Stand the bundles with the tube openings up, and fill the tubes with commercial descaling agent
such as Rydlyme.
4. Allow the tubes to stand for 2 hours with the descaling agent inside; then completely drain the
descaling agent from the tubes and flush them thoroughly with water.
WARNING:
Be sure to follow the manufacturers instructions for safe handling and disposal of such
products. Failure to do so could cause personal injury and/or create a biohazard.
5. Attach a 1/4" (6 mm) diameter soft bristle brush (nylon or brass) to a 20" (500 mm) long rod and
connect the assembly to a drill motor.
6. Power the rod/brush assembly in and out of the tubes, while continuously flushing with water
throughout the procedure to clear loose debris from the tubes.)
NOTE: If the cooler has U-tubes do not force the rod into the U-bend.
7. Repeat the previous step with the next larger brush size, progressing (using the same procedure
with each brush) until the largest size is reached.
8. When the brush cleaning is complete, drain all the water from the tubes and then fill them to the
top with a descaling agent. Allow the descaling agent to remain in the tubes for 1 hour.
CAUTION:
Do not leave the descaling agent in the tubes for more than 1 hour, and do not allow the
descaling agent to make contact with the intercooler fins
9. Drain the descaling agent and thoroughly flush the tubes with clean water.
10. 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.
11. If necessary, clean the air side of the heat exchanger. (Refer to the procedure that follows for
complete instructions.)
12. Clean all gasket and seal surfaces, reassemble the unit using all new gaskets and seals, and then
reposition it in the cooler cavity of the compressor.
518
Maintenance
Air Side Cleaning

It may also be necessary to clean airborne contaminants from the air side of the coolers. To clean the
intercooler fins on the air side, use compressed air, pressurized water, or steam. Loosen any dirt or
debris as follows:
1. Remove the upper and lower baffle plates to expose the complete finned surface.
2. Clean the fins by passing a 30 psi (2 kg/cm2 or bar) air stream across them. If air is not available,
use a low-pressure steam or water spray to clean the fins.
3. If necessary, clean any contaminant buildup from the aluminum fins by using a chemical cleaning
agent such as Coil Boil. Make sure the cleaner is safe to use on aluminium.
WARNING:
Be sure to follow the manufacturers instructions for safe handling and disposal of the
chemical cleaning product. Failure to follow proper safety procedures may cause personal
injury and/or create a biohazard.
4. If any bent fins are visible after the cleaning procedure, carefully straighten them out by hand
before replacing the baffle plates.
5. Clean all gasket and seal surfaces, reassemble the unit using all new gaskets and seals, and then
reposition it in the cooler cavity of the compressor.
Condensate Drain Cleaning

All the components within all condensate removal lines on the compressor should be inspected regu-
larly and cleaned as needed. Proper operation of the condensate removal system is among the most
commonly overlooked preventive maintenance items in compressed air systems, and as a result, conden-
sate build-up within intercooler chambers is likely to damage aluminum fins of the bundle.
Furthermore, condensate carry-over from one stage can harm inlets, diffuser plates, and impellers of
stages downstream.
CAUTION:
Always clean and inspect the condensate removal system following any intercooler clean-
ing procedures.
519
Oil Cooler Cleaning

Deterioration in oil cooler performance may be an indication that it is time to remove the mineral scale
buildup within the oil cooler tubes. When that occurs, clean the tubes as follows:
1. Shut down the compressor, lockout the main motor starter and close the system block valve.
2. Turn off the water and disconnect the two water pipes.
3. Remove the lower plug on the rear header and allow any remaining coolant to drain from the
cooler before replacing the plug.
4. Remove the front and rear headers to expose the tubes. Retain the gaskets.
5. Using a 1/8 (3 mm) rod, probe the tubes to check for blockage. (Since this is a straight tube
cooler, any blockages that are loosened can be safely and easily pushed through and out the
end.)
6. When rod cleaning is complete, flush the tubes thoroughly with water.
7. Replace the water headers (using the original gaskets) and then fill all the cooler tubes with a
descaling agent such as Rydlyme.
WARNING:
Be certain to follow the manufacturers instructions for safe handling and disposal of such
products. Failure to do so could cause personal injury and/or create a biohazard.
8. Allow the descaling agent to remain in the tubes for 1 hour.
CAUTION:
Do not allow the descaling agent to remain in the tubes for more than 1 hour. Failure to
follow these instructions will cause component damage.
9. Remove the front and rear headers to again expose the tubes.
10. Allow the descaling agent to completely drain from the tubes, and then flush out the tubes
thoroughly with water.
11. Reassemble the headers, this time using new replacement gaskets.
12. Recharge the cooler, being sure to loosen the vent plug on the rear header to prevent air entrap-
ment in the cooler.
520
Maintenance
Control Valve Inspections

At six-month intervals, Inspect the inlet guide vanes (IGV) and compressor blow-off valve (BOV) to verify
proper operation and position.
1. Shut down the compressor and lockout the main motor starter.
2. Close the system block valve and exhaust any pressure remaining in the check valve line.
3. Clean the external surface of both the guide vane assembly and the blow-off valve.
4. Verify the fully-open and fully-closed positions of the BOV by stroking it in each direction from
the control panel,
5. Remove the inlet expansion boot to view the inlet guide vanes.
6. Stroke the IGV, using the control panel, to check the proper closed and fully-open positions of
the vanes. Verify each position visually.
Discharge Air Check Valve Inspection

At six-month intervals, use the following procedure to inspect the discharge air check valve to deter-
mine whether it is still in good working order or whether it must be replaced.
1. Shut down the compressor and lockout the main motor starter.
2. Close the system block valve and exhaust any pressure in the check valve line.
3. Remove the check valve from the piping.
4. Remove both plugs and the hinge pin, and then inspect the hinge pin, disc, and seat for wear.
5. If any parts are worn or damaged, replace the valve.
or
If wear is not apparent, clean, reassemble, and reinstall the valve, being sure that the valve disc oper-
ates freely.
6. To verify correct orientation of the discharge air check valve, use the following criteria:
The check valve should be located downstream of the blow-off valve and upstream of the
system block valve.
The arrow should be pointing in the direction of flow (away from the compressor).
For horizontal installation (the recommended position) the hinge pin must be above the
centerline, which is assured when the metal label can be seen from the top of the valve.
WARNING:
When installing a new discharge check valve or reinstalling a valve, always be certain of
proper orientation. Incorrect orientation will cause equipment damage.
Additional Main Drive Motor Maintenance

Preventive maintenance must be performed on the main drive motor, in addition to those motor
bearing lubrication items described in the Lubrication portion of this Section.
Refer to the motor manufacturers supplied instruction for specific requirements and procedures.
CAUTION:
Failure to comply with the motor manufacturers-specified preventive maintenance re-
quirement can result in extensive equipment damage. Improper or inadequate motor
maintenance procedures can void all existing warranties.
521
522
Troubleshooting
Section Six:
Troubleshooting
How to Request Assistance
Alarm and Trip Functions
Drive Train
Troubleshooting
Lubrication System
Troubleshooting
Air System
Troubleshooting
Control System
Troubleshooting
61
62
Troubleshooting
This section provides a guide for troubleshooting compressor system malfunctions. Because of the
variety of compressed air system applications, it is not possible to isolate the cause of every single
problem using this guide alone.
The troubleshooting charts that follow are arranged by compressor system and indicate the likely and
most-frequent causes of common problems.
Whenever an Alarm or Trip condition occurs, use logical thinking in conjunction with the listings in the
following troubleshooting tables to determine the cause and prevent reoccurrence of the condition.
Section Two, Specifications, may also be helpful along with any separately supplied engineering draw-
ings.
CAUTION:
The Compression Systems Turbo Air compressor is a unique, highly-engineered design.
Whenever a problem occurs that is beyond the experience of operating personnel, always
request assistance from a factory-trained, authorized service representative.
How to Request Assistance

Compression Systems has established a network of factory trained and authorized distributors and
service representatives throughout the United States and around the world. When additional guidance
or help is required, contact one of these representatives. (For additional information about parts and
service, refer to Section Seven, Parts and Service.)
WARNING:
For specialized service procedures, always use the services of a Compression Systems
trained and authorized service representative and only genuine Compression Systems
replacement parts. Improper servicing may cause equipment damage or personal injury.
Compression Systems will not accept responsible for problems resulting from improper
service procedures.
Alarm and Trip Functions

When the operating parameters of a compressor deviate beyond the defined range of normal toler-
ances, the control system activates one of two levels of compressor protection.
Alarm. An Alarm condition is a warning about a compressor operating condition that is outside
of normal operating limits. The purpose of the alarm is to alert the operator of a condition that
merits investigation, but does not prevent the compressor from operating.
Trip. A Trip condition is a protective measure initiated by the controller that shuts down the
compressor. A Trip condition requires correction before the compressor can be placed back into
operation.
When either type of event occurs the control system automatically displays the Protection History
screen, See Controls Section for specific details on how your controls systrem displays Alarms and Trips.
63
Drive Train Troubleshooting

Conditions Possible Causes
Motor Starter Problems
Refer to manufacturers instructional materials
Motor Overheating
Incorrect motor control setpoint
Ambient temperature too high
Ventilation inadequate
Motor Overload / Improperly sized relay
Incorrect motor bearing lubrication
Incorrect motor supply voltage
Inadequate grounding
Improper wiring terminations
Improper wiring
Starter malfunction
Dirt in air gap
Windings shorted
Single phasing
Motor seized
Motor Vibration/Unusual Sounds
Motor mounting bolts loose
Incorrect motor bearing lubrication
Other mechanical part(s) loose
Excessive or unbalanced voltage
Misalignment
Dirt on fan
Dirt in air gap
Motor bearings worn
Drive coupling worn
Main Drive Coupling Problem
Improper lubrication
Incorrect alignment
Incorrect assembly
Incorrect Start/Stop procedures
Compressor Vibration/Unusual Sounds
Faulty vibration sensor component
Control panel not grounded (earth ground)
Incorrect control setpoints
Incorrect or contaminated oil
Operating in unstable aerodynamic conditions
Operating with high oil temperature
Incorrect motor alignment
Main drive coupling damaged
Internal components worn or damaged
64
Troubleshooting
Lubrication System Troubleshooting

Condition: Possible Causes:
Oil Leak(s)
Loose piping connection
Oil filter cartridge loose
Insufficient vacuum (see below)
Pump shaft seal worn or damaged
Gearbox cover loose or improperly sealed
Oil Mist
Incorrect air ejector air supply
Air ejector vent filter dirty or water-laden
Air ejector vent filter trap not filled
Insufficient vacuum for other reasons
Low Oil Pressure
Oil level too low
Oil filter element dirty or clogged
Sensor reading faulty
Pressure regulator set improperly or malfunctioning
Oil leaking (see above)
Incorrect wiring to oil pump motor or starter
Oil pump motor starter overloads tripped
Fuses in pump motor starter blown
Oil pump coupling damaged
Oil pump seized
High Oil Pressure
Improper pressure regulator setting
Oil pump problem
High Oil Temperature
Insufficient coolant flow
Coolant temperature too high
Thermal mixing valve faulty (if applicable)
Oil cooler headers oriented improperly
Oil cooler tubes fouled or damaged
Oil heater thermostat faulty
Low Oil Temperature
Compressor area ambient too low
Oil heater thermostat faulty or missing
65
Air System Troubleshooting

High Compressor Output
Low air demand
Control setpoints too high
Pressure sensor faulty
Faulty current, power, or flow sensor
Faulty control valve(s)
Ambient conditions beyond design limits
Impeller clearances too tight
Low Compressor Output
Air demand excessive
Control setpoints incorrect
Pressure sensor faulty
Ambient air temperature excessive
Interstage air temperature too high (see below)
Inlet air filter dirty or restricted
Impellers dirty
Condensate removal problem
Impeller clearances too large
Worn or damaged inlet diffuser or impeller
High Interstage Air Temperature
Ambient air temperature excessive
Water flow to cooler(s) insufficient
High coolant temperature
Inter cooler(s)/aftercooler fouled or damaged
Hot air bypassing intercoolers/aftercooler
Compressor surging (see below)
Compressor Surging
Incorrect control valve tuning parameters
Inlet air filter dirty or restricted
Air temperatures excessive
Compressor discharge valve or check valve
improperly located or improperly sized
Ambient conditions beyond design limits
Condensate removal problem
Incorrect impeller clearances
Worn or damaged compressor components
66
Troubleshooting
Control System Troubleshooting

The most effective troubleshooting tool is clear, logical thinking. Most control panel problems are the
result of wiring errors, incorrect control settings, or a fault in a device connected to the panel.

Control Panel Inoperative
Power to panel interrupted or incorrect
Improper grounding
Wiring error or connection problem
Display Inoperative
Power to display interrupted or incorrect
Contrast set incorrectly
Display backlight failure
Faulty display
Improper Control of Compressor Operation
Incorrect control configuration
Incorrect monitoring point scale factor(s)
Incorrect control tuning parameters
Improper electrical grounding
Wiring problem
Faulty power supply to sensors
Control board failure
Other Compressor Operation Problems
Incorrect location or sizing of inlet or
discharge valve
Incorrect adjustment of inlet valve or discharge
valve stroke
Incorrect location or sizing of discharge check valve
Worn check valve or bypass valve (if applicable)
Damaged control valve
67
68
Parts and Service
Section Seven:
Parts and Service
Aftermarket Support
The Parts Ordering Procedure
Parts Availability
The Returned Goods Policy
The Periodic Maintenance Parts

Inventory
The Professional Inspection Parts

Requirement
Control System Sensors
Lubrication System Parts
Main Drive Coupling Parts
Heat Exchanger Parts
Condensate Drain Parts
Air Piping Parts
71
72
Parts and Service
Aftermarket Support
As an important part of its commitment to its products and customers, Compression Systems offers full
aftermarket support. The array of aftermarket services includes on site service, inspection and repair,
availability of genuine JOY and Compression Systems parts and recommended supplies, and customer
training seminars.
WARNING:
Since the Turbo Air 3000 Centrifugal Compressor is a high technology product, do not
attempt inspection, maintenance, or service procedures other than those described in
this manual. For any service of a more specialized nature and service of internal parts,
it is necessary to contact a Compression Systems trained and authorized service
representative.
For parts and/or service, always contact your local authorized Compression Systems sales and service
representative, or contact the factory directly.
Parts Coordinator
or
Field Service Department
Compression Systems
3101 Broadway PO Box 209
Buffalo, NY 14225-0209 USA
Phone: (716) 896-6600
Fax: (716) 896-1233
73
Parts Ordering Procedure

Since specific compressor models and installations may vary, always be sure to have the following
information available when placing an order:
1. The compressor serial number (included on the compressor nameplate located on the gearbox).
2. The compressor model: Turbo Air 3000

3. The part description (name).
4. The part reference number.
Parts Availability
When ordering replacement and some spare parts, keep in mind that some parts are not available on
an individual basis, and must always be purchased in sets. Also, in certain instances Compression
Systems may change the part number and/or may substitute a part of equal or greater reliability
without notice.
The Returned Goods Policy

It is necessary to contact Compression Systems for authorization before the return of any goods to the
factory. All approved returns are immediately assigned a tracking number to prevent processing delays
or loss of materials. This ARG (authorization to return goods) tracking number is then recorded at the
factory. Senders must include the assigned ARG tracking number on the outside of the shipping
container whenever goods are being returned.
No goods may be returned to the factory without prior authorization and an assigned ARG tracking
number.
74
Parts and Service
The Periodic Maintenance Parts Inventory

Compression Systems recommends keeping a basic inventory of replacement and spare parts and
stocking of all the recommended supplies mentioned in this operators manual. This will eliminate or
help reduce unanticipated shutdown time during those occasions when it may be necessary to maintain
or replace one or more compressor parts. Table 71 is a recommended list of materials and parts that
should be in active inventory for routine maintenance activities.
CAUTION:
When replacing parts or ordering supplies, always use genuine JOY and/or Compression
Systems replacement parts and Compression Systems approved supplies. Compression
Systems will accept no liability for damages caused by use of non-authorized parts, sup-
plies, or service.
75
Recommended Periodic Maintenance Parts & SuppliesDescription

QtyTurbocompressor
Description Qty Compression Systems
Part Number
Filters:
Inlet Air Filter, Primary and Secondary Elements [A] [A]
Bypass Valve Air Line Filter Element [B] AAP0540016-00074
Oil Reservoir Vent Filter Element 1 AAP1404987-00014
Oil System Filter Element (Single Filter Type) 1 AAP1404040-00207
Oil System Filter Element (Dual Filter Type) 2 AAP1401435-01233
Lubricants:
TurboBlendTM Lubricating Oil (5-gallon / 20-liter pail) [C] AAP1405340-00294
TurboBlendTM Lubricating Oil (55-gallon / 210-liter drum) [C] AAP1405340-00295
Oil Sample Kit 1 AAP1797385-00000
Oil Pump Motor & Main Drive Motor Ball Bearing Grease 1 AAP1405340-00289
Main Drive Coupling Grease 1 AAP1405340-00264
Inlet Guide Vane Drive Screw Grease 1 AAP1405340-00288
Bypass Valve Lubricant [D] 1 AAP1405340-00270
Parts:
Heat Exchangers (Figures 79 & 710)
K-Seal 3 AAP1408800-04941
Y-Gasket 6 AAP1408800-04926
Header Gasket 3 AAP1793932-02100
Front Tubesheet Gasket 3 AAP1793931-02100
Rear Header Gasket (S-Tube Type Only) 3 AAP1793932-02101
Oil Cooler Gasket Kit (Not Shown) 1 AAP1405680-00002
Bypass Valve (Figure 717)
Rebuild Kit [E] 1 AAMB408539-00098
Seal Kit [E] 1 AAMB408539-00202
Discharge Air Check Valve (Figure 720)
Check Valve, 3 1 AAP0540024-00185
Check Valve, 4 1 AAP0540024-00183
Check Valve, 5 1 AAP0540024-00186
Main Drive Coupling (Figure 78)
O-Ring 2 AAP1406064-20018
Gasket 2 AAP1406064-04117
Condensate Drains (Figure 711)
Solenoid Valve, 110/120-Volt 3 AAP1401581-01302
Solenoid Valve, 220/240-Volt 3 AAP1401581-01341
Check Valve 3 AAP1401581-01303
Gate Valve 3 AAP1401581-00757
Instrumentation (Figure 71)
Vibration Probe [F] AAP1407030-02006
RTD (Temperature Transducer) [F] AAP3403629-01585
Pressure Transmitter Discharge [F] AAP0540089-00210
Pressure Transmitter System (Not Shown) [F] AAP0540089-00216
Drive Motor Current Transducer 1 Contract Specific
Notes: [A] Refer to Figure 714, Inlet Air Filter Assembly
[B] Refer to Figure 715, Bypass Valve Assemblies
[C] Refer to Section 2, Specifications, for reservoir capacity information.
[D] Only one specific bypass valve requires lubrication. Refer to Section Five, Maintenance.
[E] Only one kit is required depending which valve has been supplied.
[F] As required.
Table 71 Periodic Maintenance Parts and Supplies
76
Parts and Service
The Professional Inspection Parts Requirement

Table 53, Service Inspection Checklist outlines the in-depth examination procedures to be performed
with a Compression Systems trained and authorized representative. These important preventative
maintenance tasks involve removal of the gearbox cover to examine the gears, bearings and seals and
exposing of the heat exchanger bundles and the aerodynamic components for cleaning and inspection.
Certain gaskets, o-rings and seals must be ordered well in advance of the scheduled visit. Table 72
lists the parts and supplies necessary for the Professional Inspection of the compressor. Some of these
parts may already be on-hand as part of the Periodic Maintenance Parts Inventory.
CAUTION:
When replacing parts or ordering supplies, always use genuine JOY and/or Compression
Systems replacement parts and Compression Systems approved supplies. Compression
Systems will accept no liability for damages caused by use of non-authorized parts, sup-
plies, or service.
77
Professional Service Inspection Parts & Supplies

Description Qty Compression Systems
Part Number
Gearbox:
O-Ring, First Stage Inlet 1 AAP1406702-00395
O-Ring, Second Stage Inlet 1 AAP1406702-00386
O-Ring, Third Stage Inlet 1 AAP1406702-00383
Seal, First Stage Diffuser 1 AAP1794323-00005
Seal, Second Stage Diffuser 1 AAP1794323-00002
Seal, Third Stage Diffuser 1 AAP1794323-00002
O-Ring Lubricant 1 AAR1409584-00000
Gearbox Splitline Sealant 1 AAR1405571-00012
Heat Exchangers: (Figures 79 & 710)
K-Seal 3 AAP1408800-04941
Y-Gasket 6 AAP1408800-04926
Head Gasket 3 AAP1793932-02100
Front Tubesheet Gasket 3 AAP1793931-02100
Rear Header Gasket (S-Tube Type Only) 3 AAP1793932-02101
Lubrication System:
Oil Cooler Gasket Kit [A] 1 AAP1405680-00002
Oil Reservoir Vent Filter Element 1 AAP1404987-00014
Oil System Filter Element (Single Filter Type) 1 AAP1404040-00207
Oil System Filter Element (Dual Filter Type) 2 AAP1401435-01233
Filters:
Inlet Air Filter, Primary Element [B] [B]
Inlet Air Filter, Secondary Element [B] [B]
Control Valves:
Inlet Guide Vane (Figure 713)
Gasket, Inlet Guide Vane, 6 (150 mm) 1 AAP1409511-00000
Gasket, Inlet Guide Vane, 8 (200 mm) 1 AAP1409511-00001
Grease, Inlet Guide Vane Drive Screw 1 AAP1405340-00288
Bypass Valves (Figure 715)
Seal Kit [D] 1 AAMB408539-00098
Grease, Valve [C] 1 AAP1405340-00270
Seal and Rebuild Kit [D] 1 AAMB408539-00202
Bypass Valve Air Line Filter Element [E] 1 AAP0540018-00074
Drive Motor:
Main Drive Coupling (Figure 78)
O-Ring 2 AAP1406064-20018
Gasket 2 AAP1406064-04117
Grease, Coupling 1 AAP1405340-00264
Main Drive Motor
Grease, Ball Bearing 1 AAP1405340-00289
Notes: [A] For standard size cooler. Refer to Tables 76 and 77 for verification of oil cooler sizing and/or part number.
[B] Refer to Figure 714, Inlet Air Filter Assembly
[C] Only one specific bypass valve requires lubrication.
Refer to Section Five, Maintenance.
[D] Refer to Figure 715, Bypass Valve Assemblies
[E] Both bypass valves require this same filter element.
Table 72 Professional Service Inspection Parts and Supplies
78
Parts and Service
This page intentionally

left blank.
79

08,06,15
(inside Panel)
01 11
05
06
03
17
13
Figure 71. Control System Sensors
Item Compression Systems

No. Description Qty Part Number
Standard Instrumentation:
01 Vibration Probe, Stage 1 1 AAP1407030-02006
03 RTD, Inlet Air Temperature, Stage 2 or 3 [A] 1 AAP3403629-01585
04 Transmitter, System Pressure [D] 1 AAP0540089-00216
05 RTD, Oil Temperature 1 AAP3403629-01585
06 Transducer, Oil Pressure after the Filter 1 AAP0540089-00210
07 Tranducer, Drive Motor Current 1 Contract Specific
08 Transmitter, Compressor Discharge Pressure [B] 2 AAP0540089-00210
Optional Instrumentation:
11 Vibration Probe, Stages 2 and/or 3 1-2 AAP1407030-02004
13 RTD, Inlet Air Temperature, Stage 2 [A] 1 AAP3403629-01585
14 Transducer, Oil Pressure before the Filter [C] 1 AAP0540089-00210
15 RTD, Miscellaneous Temperatures (Not Shown) [D] 1-5 AAP3403629-01585
16 Switch, Oil Reservoir Level 1 AAP0540061-00199
17 Transducer, Air Filter Differential Pressure [D] 1 AAP0540089-00127
Notes: [A] Air temperature into the last stage of compression is standard. Alternate
locations are supplied as options.
[B] Required for all control methods.
[C] Reguired for filter differential pressure measurement.
[D] Shipped loose for field installation.
Table 73. Control System Sensors
710
Parts and Service
01
03
02 04
(GEARBOX COVER)
(OIL/AIR SEAL)
(PINION)
Figure 72. Vibration Probe Installation

01 Vibration Probe 1 AAP1407030-02006
02 Retaining Plate 1 AAP1407301-00003
03 Capscrew 1 AAP0902224-00512
04 Tube Fitting 1 AAP1791399-03539
05 Adhesive [A] 1 AAR1405571-00005
Notes: [A] Apply adhesive to threads of capscrew and tube fitting.
Table 74. Vibration Probe Installation
711

09
12
11
10
Nut
Filter Housing
12
Nut
Figure 74. Reservoir Vent Filter Assembly

01 Main (shaft-driven) Oil Pump 1 AAP1401428-00614
02 Drive Coupling, Main Oil Pump 1 AAP1402070-00254
03 Auxiliary (motor-driven) Oil Pump 1 AAP1401428-00604
04 Motor, Auxiliary Oil Pump Consult Factory
05 Drive Coupling, Auxiliary Oil Pump 1 AAP1402070-00249
06 Pressure Regulator (Relief Valve) 1 AAP1401581-01707
07 Cooler, Oil-to-Water (Heat Exchanger):
- Complete Unit with 0.375" (10 mm) dia. copper tubes 1 AAP1401429-00981
- Maintenance Gasket Kit 1 AAP1405680-00001
08 Oil Filter(single):
- Complete Assembly 1 AAP1401435-00289
- Replacement Element 1 AAP1404040-00207
Reservoir Vent Assembly (Figure 74):
09 - Ejector 1 AAP1403262-00107
10 - Filter (complete assembly) 1 AAP1401435-00228
11 - Replacement Filter Element 1 AAP1404987-00014
12 - Filter Seal Kit 1 AAP1401435-00229
13 Oil Level Sight Gauge 1 AAP1401582-00014
Table 76. Standard Lubrication System Components
712
Parts and Service
Figure 76. Reservoir Level Switch Option
Figure 75. Duplex Oil Filter Option
Figure 77. Reservoir Heater Option

14 Cooler, Oil-to-Water (Heat Exchanger): [A] 1 AAP1401429-00981
- Maintenance Gasket Kit 1 AAP1405680-00001
15 Duplex Filter (Figure 75): [A]
- Complete Assembly 1 AAA3401435-00232
- Replacement Element 2 AAP1401435-01233
16 Oil Level Switch (Figure 76) [A] 1 AAP0540061-00199
17 Oil Temperature Regulator [A] 1 AAP1401581-01347
18 Oil Heater (Figure 77): [A]
- 230 Volt 1 AAP0540063-00379
- 380 Volt 1 AAP0540063-00365
- 400 Volt 1 AAP0540063-00384
- 415 Volt 1 AAP0540063-00371
- 440 Volt 1 AAP0540063-00385
- 460/480 Volt 1 AAP0540063-00363
- 575 Volt 1 AAP0540063-00364
Notes: [A] Not all lubrication systems are equipped with these features. Most features can be retrofitted after the
compressor has been shipped from the factory.
Table 77. Optional Lubrication System Components
713
BOLT TORQUE
VALUES:
Refer to Section 2
Figure 78A. Main Drive Coupling Assembly (optional)

01 O-Ring 2 AAP1406064-20018
02 Gasket 2 AAP1406064-04117
03 Grease 1 AAP1405340-00264
Table 78A. Main Drive Coupling Maintenance Parts
714
Parts and Service
3 HEX-HEAD BOLTS
WITH THICK WASHER KEY
THICK WASHER (3X BEFORE BOLTS)

(CROWNED SIDE TOWARDS DISC PACK)
DISK
THIN WASHER PACK
(3X BETWEEN DISC PACK AND SHAFT
SPACER)
3 D-HEAD BOLTS
HEX NUTS WITH THIN WASHER
THIN WASHER (3X BETWEEN HUB

AND DISC PACK)
(CROWNED SIDE TOWARDS DISC
PACK)
THICK WASHER
(3X BEFORE NUTS)
SPACER
TYPICAL EACH END BOLT TORQUE

VALUES:
Refer to Section 2
Figure 78B. Main Drive Coupling Assembly (Dry Type - Bibby)

01 Disk Pack & Fasteners 2 AAP1406064-06901
* Coupling hardware is metric
Table 78B. Main Drive Coupling Maintenance Parts
715
Front Tubesheet Gasket

04
Upper Baffle Plate
Y-Gasket
02
01
K-Seal
Header Gasket
03
Intercooler Bundle
Water Header
Figure 79. Intercooler/Aftercooler Bundle Assembly

Standard U-Tube Model

01 K-Seal 3 AAP1408800-04941
02 Y-Gasket 6 AAP1408800-04926
03 Header Gasket 3 AAP1793932-02100
04 Front Tubesheet Gasket 3 AAP1793931-02100
Table 79. Intercooler/Aftercooler Maintenance Parts

Standard U-Tube Model
716
Parts and Service
Front Tubesheet Gasket

04
Upper Baffle Plate

K-Seal
01
Rear Water
Header
Header Gasket Gasket
03 05
Y-Gasket
02
Intercooler Bundle
Water Header
Figure 710. Intercooler/Aftercooler Bundle Assembly

Optional S-Tube Model

01 K-Seal 3 AAP1408800-04941
02 Y-Gasket 6 AAP1408800-04926
03 Header Gasket 3 AAP1793932-02100
04 Front Tubesheet Gasket 3 AAP1793931-02100
05 Rear Header Gasket 3 AAP1793932-02101
Table 710. Intercooler/Aftercooler Maintenance Parts
Standard S-Tube Model
717
Figure 711. ReliaDrainTM Zero Loss Condensate Removal Drain

(One set required for each heat exchanger)

-- ReliaDrain Model 3000/110, 110 VAC 1 AAP0540025-00132
-- ReliaDrain Model 3000/220, 220 VAC 1 AAP0540025-00140
-- ReliaDrain 3000 Rebuild 1 AAMB540025-00140
-- 110v Heater 1 AAP0540025-00146
-- 220v Heater 1 AAP0540025-00147
-- Insulation Shell 1 AAP0540025-00149
Table 711. ReliaDrainTM Zero Loss Condensate Removal Drain
718
Parts and Service
03
03
01
02
Figure 712. Solenoid-Operated Condensate Draining System


01 Solenoid Valve, 1/2 NPT, 110/120-Volt 1 AAP1401581-01302
01 Solenoid Valve, 1/2 NPT, 220/240-Volt 1 AAP1401581-01341
02 Check Valve, 1/2 NPT 1 AAP1401581-01303
03 Gate Valve, 1/2 NPT 2 AAP1401581-00757
Table 712. Solenoid-Operated Condensate Draining System
04
Vent Air
Discharge Line
01 01
03
T Drain Line
Heat Exchanger
02
Figure 713a. LiquidatorTM Pneumatic

Condensate Drain System
Figure 713b. LiquidatorTM Pneumatic
Condensate Drain Trap

01 Liquidator Drain Trap 1 AAP1797145-00000
02 Gate Valve, 1/2 NPT 2 AAP1796081-00007
03 Check Valve, 1/2 NPT 1 AAP1401581-01303
04 Ball Valve, 1/4-NPTF 1 AAP1401581-01450
05 Tube Fitting, 1/4-TUBE / 1/4-NPTM 3 AAP0902962-00044
-- Condensate Kit (containing all the above parts) 1 AAMB408187-00100
Table 713. LiquidatorTM Pneumatic Condensate Draining System Components
719
Air Piping Parts
Inlet Guide Vane Assembly

01
01
02
Figure 714. Inlet Air Piping Components

01 Startup Screen (for 8 pipe) 1 AAP1405344-00016
02 Expansion Joint (for 8.625 O.D. pipe) 1 AAA3404999-00000
Table 714. Inlet Air Piping Components
720
Parts and Service
Air Piping Parts

02, 03
05
04
01
06
07
Figure 715. Inlet Guide Vane and Actuator Assembly

6 (150mm) 8 (200mm)
01 Inlet Pipe Reducer 1 Contact Factory Contact Factory
02 Pipe Couping 1 AAP1404961-00200 AAP1404961-00209
03 Gasket, Pipe Coupling 1 AAP1404961-00602 AAP1404961-00607
04 Inlet Guide Vane Assembly 1 AAA3409140-00200 AAA3409140-00100
05 Gasket, Inlet Guide Vane 1 AAP1409511-00001 AAP1409511-00001
06 Actuator Assembly, 110/120-Volt 1 AAA3408596-03000 AAA3408596-03000
Actuator Assembly, 220/240-Volt 1 AAA3408596-03050 AAA3408596-03050
07 Actuator Motor, 110/120-Volt [A] 1[A] AAP1408596-00100 AAP1408596-00100
Actuator Motor, 220/240-Volt [A] 1[A] AAP1408596-00500 AAP1408596-00500
Notes: [A] The actuator motor is included in the actuator assembly.
Table 715 Inlet Guide Vane and Actuator Components
721
Air Piping Parts
02
01
Figure 716. Inlet Air Filter Assembly

AI-128-V Type [A]
01 Primary Filter Element [C] AAP1400009-00770
02 Secondary Filter Element [C] AAP1400009-00771
AI-128 Type [B]
03 Primary Filter Element [C] AAP0540009-00089
04 Secondary Filter Element [C] AAP0540009-00090
Notes: [A] Characterized by 18 x 18 (450 mm x 450 mm) elements
[B] Characterized by 24 x 24 (835 mm x 835 mm) elements
[C] Quantity could be 2, 3 or 4, dependent upon the number of inlet ports on the filter housing.
Table 716. Inlet Air Filter Replacement Elements
722
Parts and Service
Air Piping Parts

Figure 717. Bypass Valve Assemblies and Packaging Options
01, 02
04
01, 02 04
03
03 05, 06
05, 06
09 07, 08
07, 08
01
10
01
( 600HP) ( 700HP)

<600 Hp [A] >700 Hp [A]

01 Bypass Valve:
- 120 V / 60 Hz 1 AAP1401581-01256 AAP1401581-01501
- 220 V / 50-60 Hz 1 AAP1401581-01259 AAP1401581-01501
02 Kit, Seal or Rebuild 1 AAMB408539-00098 AAMB408539-00202
03 Solenoid Valve:
- 60 Hz 1 [B] AAP1401581-01166
- 50 Hz 1 [B] AAP1401581-01233
04 Metering Valve 1 AAP1409585-00000 AAP1409585-00000
05 Air Line Filter 1 AAP0540016-00091 AAP0540016-00073
06 Air Line Filter Element 1 AA P0540016-00074 AAP0540016-00074
07 Pipe Coupling Housing 2 AAP1404961-00628 AAP1404961-00603
08 Pipe Coupling Gasket 2 AAP1404961-00259 AAP1404961-00604
09 Flange Gasket [Valve Inlet] 1 (Not Required) AAP0907411-00008
10 Flange Gasket [Valve Discharge] 1 (Not Required) AAP0901597-00006
Notes: [A] Compressor Power Rating.
[B] Included with Item #01.
Table 717. Bypass Valve Assemblies and Packaging Options Components
723
Air Piping Parts
Positioner Positioner
Instrument Ar Connection Instrument Air Connection
Filter Regulator Filter Regulator
Actuator Actuator
Butterfly Valve
Ball Valve
Figure 718. Modulating Blow-Off Valve (MBOV) Assembly

01 Modulating Blow-Off Valve Assembly [A]
- 2.0 (50 mm) Ball valve 1 AAP1401581-01871
- 3.0 (75 mm) Butterfly valve 1 AAP0540008-00794
Notes: [A] Valve assemblies are complete with these components mounted and integrally piped:
diaphragm actuator, filter regulator, volume booster, and I/P transducer.
Table 718. Modulating Blow-Off Valve Assemblies
724
Parts and Service
Air Piping Parts

Actuator
Figure 719. Blow-Off
Silencer
Solenoid
Filter Regulator
Lock-Out
Valve
Valve
Body
Figure 721. Automatic Block Valve
Figure 720. Discharge Air
Assembly
Check Valve
Connections
Model Overall Compression Systems
Inlet [A] Discharge [A] Length Part Number
BMSV-8 2" (NPT)[B] 8" (Flanged) 78" (2000 mm) AAP0540010-07091
BMSV-8 2" (Flanged) 8" (Flanged) 78" (2000 mm) AAP0540010-02082
LCV-10 3" (Flanged) 10" (Flanged) 71" (1800 mm) AAP0540010-07092
Notes: [A] Expressed per ANSI (USA) Standards for piping (in inches).
[B] Taper-Threaded. National (USA) Pipe Thread (in inches).
Table 7-19. Blow-Off Silencers
Compression Systems
Description Part Number
3 Valve AAP0540024-00185
4 Valve AAP0540024-00183
5 Valve AAP0540024-00186
Table 7-20. Discharge Air Check Valves
Compression Systems
Description Part Number
2stage units
6" Valve, 110/120-Volt AAP0540008-00927
6" Valve, 220/240-Volt AAP0540008-00928
3-stage units
4" Valve, 110/120-Volt AAP0540008-00800
4" Valve, 220/240-Volt AAP0540008-00823
Table 721. Automatic Block Valve Assemblies
725
726
Glossary
Glossary
Glossary
Air End the part of the compressor package that includes the gearbox and the air moving
components.
Airflow the movement of air or process gas through the compressor or the compressed air system.
Aftercooler a heat exchanger that cools the process air after the final stage of compression.
Alarm a warning about a compressor operating condition that is outside of normal operating limits.
Blow-Off Valve an airflow control device that vents compressor discharge air to the atmosphere.
(Also see Modulating Blow-Off Valve.)
BOV the abbreviation for Blow-Off Valve.
BPV the abbreviation for Bypass Valve.
Bypass Valve an airflow control device that vents compressor discharge air back into the inlet pipe
of the compressor.
Bullgear the main input gear that drives the higher speed pinions.
Bundle refers to the intercooler or aftercooler heat exchanger core. Consists of the tubesheet, tubes
and baffles.
Check Valve a device that permits the flow of air, water or oil in one direction only.
Controller, Motor (See Motor Controller.)
Control Method the specific technique used by the control system to deliver compressed air to meet
specific process demands.
Control Setpoints those setpoints that supervise routine compressor operation.
Cooler device used to remove heat. (See Aftercooler, Intercooler, Oil Cooler, or Panel Cooler.)
Coupling, Main Drive the device that connects the motor shaft to the bullgear shaft.
Data Log (See Operators Data Log.)
DCS the abbreviation for Distribution Control System.
Design Standard the operating condition of the compressor to which the aerodynamic performance
is rated, generally a worst case or hot summer day condition.
Distribution Control System a functionally related group of electronic devices used for industrial
machine sequencing and operation.
Diffuser the component of a compressor stage that helps convert the high velocity airflow into a
pressure rise.
Discharge Pressure the air pressure measured between the compressor exit and the compressor
discharge check valve.
Display the screen that presents operating information on the Maestro Control Panel.
Drive End the end of a rotating machine that contains the drive shaft extension.
Drive Train the part of the compressor package that contains the main drive motor, the main drive
coupling, and the gearbox.
Ejector the component that creates a slight vacuum inside the gearbox and oil reservoir to properly
handle oil mist.
EMERGENCY STOP Button the device on the Maestro Control Panel that serves to immediately
interrupt power to the main motor causing the compressor to stop operating. (For emergency use only.)
FLA the abbreviation for Full Load Amperage.
Full Load Amperage the amperage rating of a motor (less Service Factor), the value of which is listed
on motor nameplate.
Gearbox the parts of the compressor package that contains the gears, bearings, and seals.
Heat Exchanger a device that is used to cool air or oil during compressor operating.
(See Aftercooler, Intercooler, or Oil Cooler.)
IGV the abbreviation for Inlet Guide Vane.
Impeller the aerodynamic component that rotates at a very high speed, thereby increasing the
airflow velocity and imparting energy into the airstream.
Inlet 1. the component of a compressor stage that covers the impeller and diffuser, thus creating a
very tightly toleranced air passage.
2. the point of the compressor stage at which the air enters.
Inlet Air Filter a device that removes dirt, dust, and other airborne contaminants from the intake
air before it is allowed to enter the compressor.
Inlet Air Startup Screen a conical-shaped screen that is placed in the inlet air piping at the initial
startup of the compressor, when required, to stop larger airborne particles from entering the
compressor.
Inlet Guide Vane a device that throttles inlet airflow to the compressor, while also imparting a
pre-whirl to the airstream.
Intercooler the heat exchangers that cool the process air between stages of compression.
LED the abbreviation for Light Emitting Diode.
Light Emitting Diode a status indicating light on the Maestro Control Panel.
Load or Loaded any number of compressor operating points where airflow, discharge pressure,
and power consumption are at or near rated values.
MANUAL Control Method an operating condition during which the position and movement of the
inlet guide vane and blow-off valve are controlled solely by the compressor operator.
MBOV the abbreviation for Modulating Blow-Off Valve.
Mist Filter a device that collects the oil vapor that is vented from the oil reservoir.
Modulating Blow-Off Valve an airflow control device that vents compressor discharge air to the
atmosphere.
Motor Controller a device that is used to start, stop and protect electric motors.
(Also referred to as a Motor Starter.)
Glossary
Off Design Operation a compressor operating condition when the ambient environment is other
than the design standard.
Oil Cooler the heat exchanger that cools the lubricating oil.
Operators Data Log a periodic record of compressor operation.
Opposite Drive End the end of a rotating machine that is opposite of the drive shaft extension.
Optical Coupler an electronic device similar to an electrical relay (also referred to as OPTO).
OPTO the abbreviation for Optical Coupler.
Panel Cooler an optional heat exchanger that is used to cool the interior of the Maestro Control
Panel.
Pinion the gear element to which the impeller(s) are mounted.
PLC the abbreviation for Programmable Logic Controller.
Programmable Logic Controller a computer-based device typically used to administer plant-wide
production information.
Potentiometer an electronic device that varies resistance in an electrical circuit.
Receiver a storage device (such as a tank, extended length of system piping, etc.) in the compressed
air system used to hold compressed air.
Reservoir, Oil the tank on the compressor package that is used to hold lubricating oil.
Reservoir Vent the filtration system comprised of the ejector and mist filter.
Resistive Temperature Detector a device that is used for temperature measurement.
RTD the abbreviation for Resistive Temperature Detector.
Scroll the component of a compressor stage that collects the high velocity air exiting the impeller.
Sensor a device that is used to measure parameters such as, temperature and vibration.
Service Factor as applied to motors, a factor whereby a motor can be loaded beyond its horsepower
rating without overheating or suffering insulation damage.
Setpoint a control measurement that protects the compressor or the compressed air system.
(It may or not be capable of being changed by the operator.)
Shaft Alignment the relative position of the drive train components to each other.
Shutdown the process of unloading and stopping the compressor.
Silencer the device that is used to reduce sound levels.
Stage a set of aerodynamic components including the scroll, inlet, impeller and diffuser.
Starter, Motor (See Motor Controller.)
Startup the process of starting and loading the compressor.
Startup Screen a device that is temporarily installed in the inlet air piping to prevent foreign material
from entering the compressor.
Surge a compressor operating condition characterized by a momentary reversal of airflow back

through the compressor.
System Pressure the pressure of the compressed air measured after the compressor check valve.
Transducer a sensor that converts a measured parameter (such as pressure or temperature) to a
voltage output in an established way.
Transmitter a specific type of transducer that converts a measured parameter (such as pressure)
to a current output (typically 4-20 mA).
Trip a shutdown initiated by the Maestro Control System to protect the compressor.
Trip Recall Function a Control Panel Diagnostics function that allows the operator to review
compressor operating data at the time of a compressor Trip condition.
Turndown Range the extent to which the airflow through the compressor may be throttled without
encountering surge while maintaining setpoint pressure.
Unloaded an operating condition where airflow through the compressor, and thus power
consumption, are at a minimum.
User Interface the part of the Maestro Control Panel that allows the user the view data, monitor
compressor operating, and adjust operating parameters (such as setpoints).
Worst Case Operating Condition the ambient circumstances (also referred to as a hot
summer day) when the air is less dense and filled with water vapor resulting in adverse compressor
performance.

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Contents

Engineering Data Release

The Turbo Air 3000

About This Manual

About This Manual iii

Section One: Introduction

Section Two: Specifications

Section Three: Installation

Section Four: Routine Operation

Section Five: Maintenance

Section Six: Troubleshooting

Section Seven: Parts and Service

About Compression Systems

The Turbo Air Centrifugal

CC V 5-Year Warranty Program

About Compression Systems

Compression Systems is ISO 9001 and ISO 14001 Certified.

To learn more, look us up on the Internet:

Figure 11 The Buffalo, New York, USA, Centralized Facilities

The Turbo Air 3000 Centrifugal Compressor

The Most Advanced

The Maestro Control System

Other Design Features

1. Horizontally split gearbox casing

Figure 12 The Turbo Air 3000 Centrifugal Compressor

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

There are no other warrantiesexpress, statutory, or impliedincluding those of merchantability

See page 1-12 for information on CCV SM extended warranty program.

1. Loss of use of productive facilities or equipment.

CC V 5-Year Warranty Program

THE EDGE IS RELIABILITY

1. On-line registration at www.c-a-m.com

2. The compressor must incorporate TurboBlend or equivalent oil at initial startup.

4. Only genuine Compression Systems parts may be used.

5. Maintenance performed by a Compression Systems authorized service representative in accordance

7. Compliance with 5-year warranty terms and conditions.

General Compressor Specifications

Alarm and Trip Specifications

Compressor Lubricant Requirements

General Compressor Specifications

Turbo Air 3000 Compressor

Item Weight Item Weight

Air Inlet 8 ANSI Pipe Condensate Drain 1/2 NPT **

Cold Alignment Specifications for Main Drive Motors

General Compressor Specifications

Compressor Rating (hp) 400 500 600 700 800

Drive Coupling Bolt Torque Values

Discharge Connection Load Limits

Other Package Electrical Requirements***

Alarm and Trip Specifications

ALARM and TRIP Setpoints (English Units)

ALARM and TRIP Setpoints (Metric Units)

Compressor Lubricant Requirements

Acceptable turbine oil

Compressor Oil Selection

Refined from high-quality mineral oil stock.

Property Test Method Performance

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

Table 21 Compression Systems Oil Specification