The Turbo Air 6000 Centrifugal Compressor Handbook AAEDR-H-082 Rev 05 TA6000

Contents
Engineering Data Release

AAEDR-H-082
The Turbo Air® 6000

Centrifugal Compressor
Handbook
The Turbo Air 6000 Centrifugal Compressor Handbook
ii
About ThisContents
Manual
About This Manual

This manual contains the basic information necessary for using and maintaining the Ingersoll Rand
Turbo Air® Oil Free Centrifugal Compressor, from the original startup and operation to inspection and
servicing. However, since installations may vary, these instructions may not cover all details or variations
in the equipment supplied or every question which may possibly arise during use.
If a question or situation develops which is not answered directly in this manual, contact an authorized
Ingersoll Rand 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.
Ingersoll Rand 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 Ingersoll Rand 1— 3
The Turbo Air Centrifugal Compressor 1— 4
Safety Precautions 1— 6
Safety Labels 1— 7
Warranty 1—10
Limitation on Liability 1—11
Unauthorized Repair 1—11
Section Two: 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 3—17
Electrical Interface 3—24
Receiving, Lifting, Moving... 3—28
The Installation Inspection 3—30
Preparing for Startup 3—34
Initial Compressor Startup 3—36
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 4—10
Optional Features 4—11
v
Section Five: Maintenance

Daily Inspection 5— 4
Scheduled Maintenance 5— 5
Professional Inspection 5— 7
Filter Maintenance 5— 8
Lubrication 5—11
Intercooler and Aftercooler Cleaning 5—14
Oil Cooler Cleaning 5—18
Control Valves 5—19
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 7—10
Lubrication System Parts 7—12
Main Drive Coupling Parts 7—14
Heat Exchanger Parts 7—16
Air Piping Parts 7—19
Controls
Glossary
Contract Drawings
Supplemental Data
vi
Introduction
Section One
Introduction
♦ About Ingersoll Rand
♦ The Turbo Air Centrifugal

Compressor
♦ Safety Precautions
♦ Safety Labels
♦ Warranty
♦ Limitation on Liability
♦ Unauthorized Repair
1—1
1—2
Introduction
About Ingersoll Rand

For over 150 years, Ingersoll Rand has provided a wide range of technologically advanced, highly
reliable and low maintenance air compressors. We have a deep knowledge of the needs of the industry
and the demands placed on productivity, making us leaders in the field. We use that experience and
knowledge to provide you with the ideal air compressor solutions for your business. Our air compres-
sors are made with superior components and are backed by our worldwide parts and service organiza-
tion, providing the support you need to keep your business running. We stand behind our air compres-
sors and beside our customers during planning, installation, and maintenance. Ingersoll Rand offers a
full range of compressed air treatment products and services as well as air compressor parts and
accessories that you need to be successful in all of your compressor related business needs.
To learn more, visit centrifugal.ingersollrand.com
1—3
The Turbo Air 6000 Centrifugal Compressor

The Turbo Air 6000 Centrifugal Compressor is a state of the art source of oil-free air manufactured with
the user’s needs in mind. The simple but rugged mechanical design provides many advantages. It
combines the best features of aerodynamic technology to achieve optimum energy efficiency, and it
delivers lower horsepower to cubic feet per minute (CFM) ratios than any other oil-free centrifugal
compressor available.
The Most Advanced

Compressor Components Available
The Turbo Air 6000 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 6000 Compressor package is not a complete, stand-alone compressed air
system. To complete the system, additional components (such as main drive motor starter, oil pump
starter, manifolds, inlet air filters, silencers, expansion joints, etc.) are also required. Ingersoll Rand
offers a selection of optional equipment as part of the package or as add-ons after installation.
1—4
Introduction
Other Design Features

Other outstanding design features of the Turbo Air 6000 compressor are shown in Figure 1—2
including:
1. Horizontally split gearbox casing

2. Mounted aftercooler (optional)
3. Built-in intercoolers
4. Mounted control panel
5. Self-contained lubrication system
6. Inlet guide vanes
7. Shaft driven main oil pump
8. Mounted water manifold (optional)
9. Mounted bypass valve (optional)
1
3
6
3
Figure 1—2 The Turbo Air 6000 Centrifugal Compressor
1—5
Safety Precautions
The Turbo Air 6000 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.
Ingersoll Rand 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 6000 Centrifugal Compressor, be certain to
review the safety labels and the following safety guidelines.
WARNING:
Observe all safety precautions included in this manual and on the compressor safety labels.
Failure to do so may cause equipment damage and/or personal injury.
1—6
Introduction
Safety Labels
WARNING
HAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURY
OR DEATH
Disconnect all power supplies, lock-out and display
signs before servicing equipment.
DANGER
AIR UNDER PRESSURE. WILL CAUSE SEVERE INJURY
OR DEATH
DO NOT operate the compressor at pressure in excess of
the nameplate rating.
Close the discharge block valve and relieve system of
pressure before removing any caps or plugs, or servicing
compressor.
DO NOT play with compressed air.
Wear eye protection when using compressed air.
CAUTION
ELECTRICAL HAZARD. CAN SHOCK, BURN OR CAUSE
DEATH.
All electrical enclosures and components must be installed
and grounded in accordance with the National Electric Code
and other local codes.
1—7
Safety Labels
WARNING
HIGH SURFACE TEMPERATURES. CAN CAUSE INJURY.
Some surfaces of the compressor and motor have excessive
temperatures. To avoid burns, keep hands and other body
parts away while unit is operating.
DANGER
HOT OIL UNDER PRESSURE. WILL CAUSE SEVERE
INJURY OR DEATH.
Shut down compressor and pumps before removing any
caps or plugs, or servicing any parts.
DANGER
DO NOT USE DISCHARGE AIR FOR BREATHING OR
FOOD PROCESSING, AS IT WILL CAUSE SEVERE INJURY
OR DEATH.
Air from the compressor used for these processes in the U.S.A.
must meet OSHA 29 CFR 1910 or FDS 21 CFR 178.3570 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 Ingersoll Rand Engineering or Service
Departments.
Periodically check all safety devices for proper operation.
1—8
Introduction
Safety Labels
WARNING
ROTATING SHAFTS COULD CAUSE SEVERE INJURY
OR DEATH.
DO NOT remove protective guards while the compressor is
in operation.
DO NOT attempt to service any part while the machine is
operating.
WARNING
UNIT CAN AUTOMATICALLY RESTART CAUSING
SEVERE INJURY OR DEATH.
Before removing the gearbox cover, lock the main power
OFF, close the system block valve, turn the lube pump OFF,
and remove the drive coupling.
CAUTION
Exercise cleanliness during maintenance and when
making repairs. Keep dirt away by covering parts and
exposed openings with a clean cloth.
Be sure no tools, rags, or loose parts are left on the 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.
1—9
Warranty
Ingersoll Rand warrants that the compressor supplied conforms to applicable drawings and specifica-
tions 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 for North American Free Trade Agreement (NAFTA) countries or eighteen (18) months from
shipment for other countries, whichever period expires first.
If, within that period, Ingersoll Rand receives written notice from the purchaser of any alleged defect in
or nonconformance of the compressor and if, in Ingersoll Rand’s judgment, the compressor does not
conform to the original specifications or is found to be defective in material or workmanship, at its
option Ingersoll Rand 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
Ingersoll Rand factory in Buffalo, New York, USA.
3. By returning the full purchase price of the compressor (without interest) to the purchaser.
Ingersoll Rand’s sole responsibility and the purchaser’s exclusive remedy hereunder is limited to
such repair, replacement, or repayment of the full purchase price.
Equipment and accessories furnished by third parties that are not incorporated in the compressor
package manufactured by Ingersoll Rand are warranted only to the extent of the original
manufacturer’s warranty to Ingersoll Rand.
There are no other warranties—express, statutory, or implied—including those of merchantability

and/or fitness for purpose. Moreover, there is no affirmation of fact or representation that extends
beyond the description of the face of this warranty.
This warranty shall be void and Ingersoll Rand shall have no responsibility to repair, replace, or repay
the purchase price of defective or damaged compressors or component parts resulting directly or
indirectly from:
1. The purchaser’s use of repair or replacement parts or supplies not of Ingersoll Rand‘s manufacture
or which have not been recommended by Ingersoll Rand.
2. The purchaser’s failure to store, install, operate, and maintain the compressor according to
Ingersoll Rand’s written specifications, drawings, and good engineering practice.
3. Claims for shortages or damage in transit (obvious or concealed) are the purchaser’s responsibility
and should be made to the carrier. Ingersoll Rand will render reasonable assistance in securing
satisfactory adjustment of claims.
4. Deterioration and wear occasioned by chemical and abrasive action or excessive heat shall not
constitute defects.
1—10
Introduction
Limitation on Liability
Ingersoll Rand’s total responsibility for any claims, damages, losses, or liabilities arising out of or related
to the performance of the products covered hereunder shall not exceed the original purchase price.
In no event shall Ingersoll Rand 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 Ingersoll Rand’s perfor-
mance hereunder.
3. Lost production, whether suffered by the purchaser or any other third party.
4. Warranty work provided does not assure uninterrupted operation of the products. Ingersoll Rand
does not assume any liability for damages caused by any delays involving warranty work.
Ingersoll Rand disclaims all liability for any and all costs, claims, demands, expenses, or other
damages, either direct or indirect, incident to all property damage arising out of any cause of action
based on strict liability.
Unauthorized Repair
In the event that the owner allows the compressor to be serviced or repaired by unauthorized
personnel, the coverage of the original warranty policy will be automatically terminated.
1—11
1—12
Specifications
Section Two
Specifications
In this section, the reader will learn about:
♦ General Compressor Specifications
♦ Alarm and Trip Specifications
♦ Compressor Lubricant Requirements
2—1
2—2
Specifications
General Compressor Specifications

Installation Weights
Complete Package with Motor
Compressor Rating (hp) 800 900 1000 1250 1500

Weight (lbs) [A] 15000 16000 17000 18500 20000
Weight (kg) [A] 6750 7200 7600 8400 9000
Abbreviations: hp = horsepower, lbs - pounds, kg = kilograms
Notes: [A] The optional package - mounted aftercooler is not included
Maintenance Weights
(Approximate Values, lbs/kg)
Item Weight Item Weight

Bullgear Cover 500 (227) 1st Stage Inlet 500 (227)
Bullgear Assembly 450 (205) 2nd Stage Inlet 500 (227)
Intercooler Bundles 270 (123) 3rd Stage Inlet 300 (136)
Connection Sizes
Connections are to American Standards (ANSI)
Connection Size Connection Size

Air Inlet 10-inch (pipe) [A] Condensate Drain ½-inch NPT
Air Discharge 6-inch (pipe) [B] Air Ejector 3/8-inch NPT
Air Coolers (water) 3-inch (pipe) [B] Control Panel 1-inch (conduit)
Oil Cooler(s) (water) 1½-inch NPT Pressure Transducers ¼-inch (tubing)
Water Manifold (optional) 3-inch (pipe) typical [B]*
* 4-inch (pipe) with optional package-mounted aftercooler [B]
Abbreviations: ANSI = American National Standards Institute, NPT = National Pipe Thread
Notes: [A] Standard 10-inch pipe has an outside diameter of 10.75 inches (275 mm). An optional slip-on rubber
sleeve expansion joint is available as an extra cost option.
[B] This connection has been grooved to accept a Victaulic, or equivalent, pipe coupling.
Discharge Connection Load Limits

English Units Metric Units
Maximum Allowable Force 660 pounds 3000 Newtons
Maximum Allowable Moment 1000 foot-pounds 1350 Newton-meters
Bolt Torque Values

Unless otherwise noted, all bolts must be torqued to these values based on clean, unlubricated threads.
Bolt Size (Diameter) Torque Range

Inch mm Foot-Pounds Newton-meters
3/4 20 143 - 157 195 - 210
7/8 22 192 - 212 260 - 285
1 25 285 - 315 385 - 425
2—3

Cooling Water Requirements
The following represents total cooling water requirements for the standard compressor package including the two
intercoolers and the oil cooler. Cooling water requirement for the optional package-mounted aftercooler is listed
separately, but is additive to obtain the total compressor package. The values shown represent “worst case” conditions.
Properly maintained heat exchangers will exhibit substantially better performance with less water.
Compressor Rating (hp) 800 900 1000 1250 1500 1700

Standard Package Water Flow (gpm) 142 142 160 160 180 180
Standard Package Water Flow (lps) 9.0 9.0 10.0 10.0 11.3 11.3
Package-Mounted Aftercooler Water Flow (gpm) 75 80 90 100 90* 90*
Package-Mounted Aftercooler Water Flow (lps) 4.7 5.0 5.7 6.3 5.7* 5.7*
Water Supply Pressure (max psi) 150 150 150 150 150 150
Water Supply Pressure (max bar) 10.3 10.3 10.3 10.3 10.3 10.3
Water Pressure Drop (psi) 14 14 18 18 23 23
Water Pressure Drop (bar) 1.0 1.0 1.3 1.3 1.6 1.6
*Requires 6-foot long aftercooler; whereas, the 4-foot long aftercooler is typical.
Abbreviations: hp = horsepower gpm = U.S. gallons per minute lps = liters per second
psi = pounds per square inch bar = the accepted ISO unit for measuring fluid pressure
Water Quality Requirements - Cooling service requires that the water be low in suspended solids to prevent fouling, low
in dissolved solids to prevent depositions and erosion, free of organic growth, and free of chemicals that exhibit
corrosive properties to the copper tubes used as standard in the compressor heat exchangers. (Other tube materials
with various chemical resistances are available as options. Consult an authorized representative or Ingersoll Rand
Aftermarket Sales Departments directly.)
Drive Coupling Bolt Torque Values
Coupling Type English ft - lbs Metric Nm

Disc Lubed 236 320
Cold Alignment Specifications for Main Drive Motors

Recommendations For Cold Field Alignment, Take at Motor Hub
0.0000 0.000
+0.002 Face +0.002 -0.010 RIM -0.010
+0.004 -0.020
Shaft separation specification is 12.00” (304.8 mm) ±0.012” (0.3 mm) unless otherwise noted on the
installation arrangement drawing.
2—4
Specifications

Cooling Water Requirements
Lubrication System
Element English Units Metric Units
Reservoir Capacity 85 gallons (U.S.) 320 liters
Minimum Reservoir Temperature Before Start 60°F 15°C
System Operating Temperature 120°F 50°C
System Operating Pressure 120 psig 8.3 barg
Air Ejector Pressure Range * 20-50 psig 1.7-3.5 barg
* NOTE: Adjust air ejector pressure so gearbox vacuum is between 8-12” of water column.
Other Package Electrical Requirements

Main Drive Motor* Furnished separately
Oil Pump Motor* 5 hp (3.5 kw) 3Ph/50-60Hz ***
Oil Heater (optional)** 1.5 kw 3Ph/50-60Hz ***
*Starter Required.
**Magnetic contactor required above 480 volts.
***Voltages must be specified at time of order entry.
2—5
Alarm and Trip Specifications

The tables below show the Alarm and Trip values of the key parameters for the Turbo Air 6000 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 (ºF) 70 135 60 145
Stage Inlet Air Temperature (ºF) - 130 - 140
Optional:
Inlet Air Filter Pressure Drop (inches of water) - 10 - -
Oil Filter Pressure Drop (psi) Single - 15 - 20
Oil Filter Pressure Drop (psi) Duplex - 30 - 50
ALARM and TRIP Setpoints (Metric Units)

ALARM TRIP
Condition Low High Low High
Standard:
Compressor Stage Vibration (µm) - 38 - 50
Oil Pressure (bar) 6.9 12.4 5.5 13.79
Oil Temperature (ºC) 21 57 16 63
Stage Inlet Air Temperature (ºC) - 55 - 60
Optional:
Inlet Air Filter Pressure Drop (mm of water) - 250 - -
Oil Filter Pressure Drop (bar) Single - 1.0 - 1.4
Oil Filter Pressure Drop (bar) Duplex - 2.0 - 3.4
2—6
Specifications
Compressor Lubricant Requirements

The user must obtain the following required lubricants for use with the Turbo Air 6000 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 6000 Compressor
Operator’s Manual.
It is the user’s responsibility to provide all lubricants (including turbine oil, motor grease, and
coupling grease) at the initial startup and during subsequent operation. It is very important for all
compressor users to follow specific guidelines regarding lubricant selection and proper use in order
to assure optimal performance of the Turbo Air 6000 Compressor.
Compressor Oil Selection

The correct lubricating oil is critical to satisfactory overall compressor performance. When operating
the Turbo Air 6000 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, Ingersoll Rand has
formulated a lubricant that is as advanced as today’s high-tech compressors. TurboBlendTM Lubricating
Oil is an exceptional lubricant formulated using a hydrocracked base stock and performance enhancing
additives.
Hydrocracking is an advanced oil processing technology that is far superior to solvent refining. It
converts crude oils into base stocks of unparalleled purity. So pure, in fact, and so highly refined that
this new class of lubricant is free of the contaminants that cause lubricant breakdown ensuring longer-
lasting compressor performance. The only additives in TurboBlend Lubricating Oil are those selected
exclusively by Ingersoll Rand 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 Ingersoll Rand representative or
directly from the Ingersoll Rand Parts Department. Refer to Section Seven of this manual for part
numbering and ordering information.
Standards
Excellent operating performance will be achieved when using TurboBlend Lubricating Oil. However, if
the compressor owner or user chooses to pursue a near equivalent substitute, the subject oil must
conform to the following characteristics:
2—7
• Refined from high-quality mineral oil stock.

• Free from any contaminants or impurities that may be abrasive or have a lapping action.
• Contain additives to provide:
- a high level of oxidation stability,
- a high degree of wear protection,
- rapid separation from entrained gases,
- foam-free operation,
- rust-free and corrosion-free operation, and
- resistance to the formation of sludge and harmful resin-like deposits.
• capable of maintaining high flow strength and not break down under extremes of pressure and
temperature.
Animal, vegetable and mineral oils of poor quality must be avoided as these oils would tend to oxidize,
develop acids, and form sludge or resin-like deposits on rotating elements. Such deposits may be of
sufficient volume to cause very high, localized loadings that will lead to a premature breakdown of the
load-carrying capacity of the oil. This will result in worn gears and scored bearings.
Specifications
TurboBlend Lubricating Oil meets or exceeds the performance standards listed in Table 2—1. Any
substitute or equivalent oil selected for use in the Turbo Air 6000 Compressor by the compressor owner
must exhibit similar results.
Property Test Method Performance

Viscosity:
at 40°C ASTM D445 46 Cst
at 100°C ASTM D445 7 Cst
Viscosity Index: ASTM D2270 >100
Four Ball Wear Test:
(40 Kg, 1200 RPM, 75°C, 1 Hour) ASTM D4172 ≤ 0.4 mm
Water Separability:
(54°C and 82°C) 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 50°C 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 2—1 Ingersoll Rand Oil Specification
2—8
Specifications
Other Oil Selection Considerations

Incorrect or poor quality lubricating oil can seriously damage the compressor’s rotating and mechanical
elements. Do not merely rely on an oil dealer recommendation when selecting turbine oil, and do not
compromise quality in an attempt to economize. Many reputable brand name oil products exist, but
not all perform effectively in the demanding world of high-speed turbomachinery.
Do not mix different brands of oil. This is inadvisable because some oils are incompatible, and a wrong
combination of additives could cause serious machine damage and/or poor overall performance. The
lubrication requirements of the Turbo Air 6000 Compressor are not so severe as to require the qualities
of high-cost synthetic oil. In addition, Ingersoll Rand products are not designed to use synthetic oils.
Therefore, use of such products is not recommended and is done at the owner’s risk.
CAUTION:
To ensure optimum performance and to avoid possible compressor damage, always be
certain to follow the guidelines listed below.
• Use only Ingersoll Rand TurboBlendTM Lubricating Oil or a high-quality turbine

oil that meets the specifications in Table 2—1.
• Do not mix different oils.
• Do not use synthetic oils.
• Remember that use of unspecified oil is done at the owner’s risk.
Inspection and Testing

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

Compare an oil sample from the reservoir with new oil. Any color change suggests some type of
deterioration. Darkness implies contamination from acid buildup while muddiness is an indication
of water.
• Viscosity, Acid and Particle Count
Tests for these properties required qualitative analyses by a reputable laboratory. Follow the
recommendations of the laboratory with regard to oil replacement.
Ingersoll Rand offers an oil analysis service. Sampling kits and information about this service are avail-
able through an authorized Sales and Service Representative, or directly through the Ingersoll Rand
Aftermarket Department. (See Table 7-1 of this manual for sampling kit part number information.)
2—9
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 6000 Compressor
employs (depending on the specific type of motor used) either anti-friction bearings or sleeve bearings.
Each type of bearing has different lubrication requirements.
Refer to the motor manufacturer’s instructions provided separately for complete information
regarding correct oil bearing lubrication maintenance procedures for each type of motor.
Anti-Friction Bearings—Grease
For best results with anti-friction bearings, only use greases recommended by the motor manafacturer.
ptable Motor Bearing Greases
Sleeve Bearings—Oil
It is the user’s responsibility to fill the motor bearing oil reservoir and to maintain the correct oil level at
all times. When lubricating sleeve bearings, use only a high quality, petroleum-based oil with a viscosity
of 200-220 SSU at 100° F (40°C). Since motor bearings require the same type of oil as used in the
compressor itself, it is not necessary to maintain two separate supplies of oil if this type of bearing is
used.
CAUTION:
Before aligning or using this type of motor, always verify that the correct amount of oil is
in the reservoir. Motors with sleeve bearings are sometimes shipped without oil in their
reservoirs.
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
2—10
Installation
Section Three
Installation
♦ General Considerations
♦ The Installation Work Schedule
♦ Site Considerations
♦ Process Air Piping
♦ Utility Piping
♦ Electrical Interface
♦ Receiving, Lifting, Moving & Bolting
♦ The Installation Inspection
♦ Preparing for Startup
♦ Initial Compressor Startup
3—1
3—2
Installation
General Considerations
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 Ingersoll Rand service represen-
tative 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.
3—3
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 Ingersoll
Rand 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 and control valve
actuators (if applicable).
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 Ingersoll Rand and
can lead to considerable savings for the installer.
3—4
Installation
Labor, Supplies, Equipment, and Tools

It is the owner’s 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, Lubricant Requirements)
Motor bearing lubricant
Equipment *
Main drive motor starter
Oil pump motor starter
EVC Starter (if necessary)
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 800 ft-lbs. or 1100 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 Ingersoll Rand’s scope-of-supply.
Table 3—1. Materials Required for Compressor Installation
3—5
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
compressor’s 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 Ingersoll Rand.
Foundation
The Turbo Air 6000 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 6-8 in. (150-200 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.
3—6
Installation
Envelope
Provide an adequate envelope (space allowance) around the unit. Figure 3—1 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 100°F (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.)
Figure 3—1 Turbo Air 6000 Compressor Envelope

With Optional Aftercooler
3—7
Process Air Piping

Figure 3—2 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 Ingersoll Rand 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.
3—8
Installation
A. Inlet Filter B
B. Inlet Screen
C. Expansion Joint
D. Check Valve
E. Block Valve
F. Blowoff Valve
G. Silencer
Figure 3—2. Typical Process Air Piping for a Turbo Air 6000 Standard Compressor
3—9
TheTurbo
The u
TrboAir
Air 3000
6000 Centrifugal
Compressor Handbook Handbook
Inlet
Inlet AirAir Piping
Piping
Figure
Figure 3 shows
3—3 3 shows a typical
a typical inlet
inlet piping piping arrangement
arrangement with and
with various standard various standard
optional and optional comp
components.
A.Inlet
A. Filter
Inlet Filter SilencerSilencer
B. Pipe Reducer (If applicable)
B. Pipe Reducer (If applicable)
C. Inlet Startup ScreenScreen
C.Inlet Startup
A D.Inlet Expansion
A D. Inlet Expansion Joint Joint
E. Inlet Guide VaneV(IGV)
E.Inlet Guide ane (IGV)
F. IGV Motor
F. IGV Motor
FF
C
C D
D STG.1 1
STG.
B EE
B
B B
Figure3—3
Figure 3 3Inlet
Inlet Air Piping
Air Piping
Inlet
Inlet Pipe
Pipe Connection
Connection
Thestandard
The standard
inletinlet air connection
air connection is a cast ironis a cast
,the
reducer, the
ironoutside
reducer
outside of matches
of which which matches standard steel
standard steel
pipe. (American National Standards Institute: ANSI B36.10). This inlet reducer
pipe. (American National Standards Institute: ANSI B36.10). This inlet reducer may be removed and may be remov
machined to accept a number of different style inlet air
machined to accept a number of different style inlet air piping connections. piping connections.
Figure
Figure 3 shows
3—4 4 shows a detail
a detail of inlet
of a typical a typical
air pipinginlet air piping arrangement.
arrangement.
Do not
Do notconnect
connect the inlet
the final final inlet
air pipe aircompressor
to the pipe to until
the the
compressor until
Ingersoll Rand the Compression
representative inspects Systems re
inspects the piping during the
the piping during the startup service call. startup service call.
Inlet
Inlet Guide
Guide Assembly
Assembly
Inlet
Inlet Startup
Startup ScreenScreen
Inlet
Inlet Expansion
Expansion Joint Joint
Figure3—4
Figure 3 4Detail
Detail of Air
of Inlet Inlet Air Connection
Connection with optionswith options
3 10
3—10
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 350°F (175°C).
• Use pipe and fittings that are filament wound with continuous glass filaments and epoxy resin.
• Provide the fiberglass piping with additional reinforcement 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 (IGV’s) 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 Ingersoll Rand 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

Ingersoll Rand 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
3—4.) 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.
3—11
Discharge Air Piping

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

B. Victaulic flange (optional) 2. To compressed air system
C. Expansion joint (recommended) 3. To compressor blow-off/bypass valve (shipped loose)
D. Check valve (required) 4. To compressor by-pass (packaged)
E. Block valve (required) 5. To control panel - compressor discharge pressure
6. System pressure (at plant header)
A
6
5 3
C D E
1 B
2
Compressor Package Limit
Figure 3—5 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.
Ingersoll Rand offers the following optional types of connections:
• Straight Coupling
• Vic-Flange Adapter
3—12
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. Ingersoll Rand 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.
Ingersoll Rand 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 660 lb. (3000 Nm) Maximum Allowable Force or the Maximum Allow-
able moment of 1000 lbs. (1350 Nm) on the compressor discharge connection. Excess
weight may cause pipe connection failure.
3—13
Discharge Expansion Joint

Ingersoll Rand 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.)
Ingersoll Rand 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. Ingersoll Rand 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

Ingersoll Rand 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
Ingersoll Rand publication AAEDR-A-008 , Automatic Block Valve for additional information)
3—14
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 3—6 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* 2
H Vent Silencer*
M. Stepper Motor
*BOV only
E
M
D H
A B C
1
Figure 3—6 Compressor Discharge Valve Piping Detail
3—15
The uTrbo Air
The Turbo Air 3000
6000 Centrifugal
Compressor HandbookHandbook
Compressor Discharge
Compressor Discharge alve
V Piping
Valve Piping
Depending onthe
Depending on the control
control method,method, urbo
the
the Turbo Air
Air Tcompressor
compressor willcompletely
will either either completely or partially unlo
or partially unload
whenever
whenever the capacity of the compressor exceeds the compressed air system’s demand. Upon a s demand. Upon a
the capacity of the compressor exceeds the compressed air system
reduced demandinin
reduced demand the the system,
system, one method
one control control method
uses uses bypass
a pop-action a pop-action
valve (BPV)bypass valve (BPV) to fu
to fully unload
the
the compressor. Other control methods use a modulating blow-off valve (MBOV) to regulate the to regulate the
compressor
. Other control methods use a modulating blow-off valve (MBOV)
amount ofvented
amount of vented excess
excess air pressure.
air pressure.
Bypass a
Vlve (BPV)
Bypass Valve (BPV)
The BPVoperates
The BPV operates in either
in either fully
a fully aopen
open or closed
or fully fullyposition.
closed The
position.
compressorThe compressor
owner/installer is owner/installer
responsible for the proper installation of this control valve (shipped separately)
responsible for the proper installation of this control valve (shipped separately) unless the compressor unless t
includes the Mounted Bypass
alve Voption.
includes the Mounted Bypass Valve option.
Modulating Blow-Off
Modulating Blow-Off alve
V (MBOV)
Valve (MBOV)
The MBOV operates
The MBOV operates in position
in any any position
from fullyfrom
closedfully
to fullyclosed
open. A to fully
48 volt open. ,
DC stepper A I/P
pneumatic
motor actuator actuator
transducer , volume
with positioner booster
is mounted and
to the a body.
valve regulator are mounted
The owner/installer and piped
is responsible for as
the an integral assembly on t
proper
valve body
. The owner/installer is
installation of the MBOV (shipped separately). responsible for the proper installation of the MBOV (ship
separately).
CAUTION:
CAUTION:
To assure proper compressor unloading and to prevent surging, keep a minimal pipe
Tvolume
o assure proper
between thecompressor unloadingand
compressor connection and
theto prevent
blow-off surging,
or bypass keep
valve. a minimal pipe
Calculate
volume between the compressor connection and the blow-off or bypass
the maximum piping unit volume by multiplying the inlet volume flow per minute by valve. Calculate
the maximum piping unit
0.001 (one-tenth of 1%). volume by multiplying the inlet volume flow per minute by
0.001 (one-tenth of 1%).
BOV
BOV Silencer
Silencer
The high-pressure
The high-pressure air expansion
air expansion across theacross theblow-off
modulating modulating blow-off
valve creates valve noise.
considerable creates considerable n
Compression Systems recommends the BOV silencer option to reduce noise produced during
Ingersoll Rand recommends the BOV silencer option to reduce noise produced during compressor
compressor
operation. operation.
For maximum effectiveness,

For maximum effectiveness, the must
the silencer silencer mustconnected
be properly be properly
directlyconnected directly
to the blow-off to the blow-off
valve. Any
additional
additional piping after the silencer should be no smaller in diameter than the silencer discharge flange. silencer dis
piping after the silencer should be no smaller in diameter than the
The exhaust
The exhaust piping
piping from from the silencer
the silencer should
should be sized be sized
to create to create
a back pressure a silencer
on the back pressure
less than on the silen
55 psig
psig(0.3
(0.3 bar).
bar).
TTo
o further
further reduce
reduce soundsound
at the at the discharge,
discharge, increase
increase the outlet thearea
opening outlet opening
by cutting area
the pipe end by
at acutting the
sharp
sharp angle as shown in Figure 3—7. Avoid directing the exhaust pipe toward hard surfaces or noise-hard surfaces o
angle as shown in Figure 3 7. Avoid directing the exhaust pipe toward
sensitive areas.
sensitive areas.
Cut atsharp
Cut at sharp angle
angle to to
enlarge opening
enlarge opening area area Discharge
Discharge
Figure 3 7 Angled
Figure 3—7 Angled Pipe
Pipe End End
33—16
16
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
Ingersoll Rand 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.
3—17
Cooling Water (Coolant) Supply Piping

The typical Turbo Air 6000 Compressor package includes four water-cooled heat exchangers (two
intercoolers, an aftercooler, and the oil cooler). Figure 3—8 illustrates the location of the heat
exchangers. Refer to Section Two, Specifications for cooling water (coolant) requirements. The values in
Section Two represent requirements for average usage. Actual requirements may differ depending on
variables such as temperature, humidity, and the condition of the heat exchangers.
4
1
1. Oil Cooler 3
2. 1st stage intercooler
3. 2nd stage intercooler
4. Aftercooler (optional) 2
Figure 3—8. Heat Exchanger Locations
3—18
Installation
Supply and Return Lines

Figure 3—9 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. Ingersoll Rand 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 3—9), 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 3—9. Typical Coolant Piping
3—19
Cooling Water Piping Options

Ingersoll Rand 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 3—10. Cooling Water Manifold Option
Automatic Cooling Water Shutoff Valves

This option includes a solenoid operated (air actuated) valve, installed at the outlet connection point of
the water manifold. The control system can shut off the valve 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.
3—20
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 3—11. 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 ½” 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 3—11 shows a typical condensate drain piping arrangement.
3—21
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 Ingersoll Rand Engineering Data Release, AAEDR-D-006, for additional information.
The u
Trbo Air 3000 Centrifugal Compressor Handbook
Solenoid Condensate Drain Piping Option

Figure 3—12. ReliaDrain
TM
The solenoid-operated drain valves are wired to the control system, which opens and closes th
valves at user
Solenoid set intervals.
Condensate When the
Drain Piping valve opens air pressure within the cooler chamber exp
Option
condensate to the open drain. See Figure 3 12 below
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
Pneumatic
condensate toCondensate
the open drain.Drain Option
See Figure 3—13 below
The LiquidatorTM
Pneumatic Condensate Draining System option is a demand-operated trap that
Pneumatic Condensate Drain Option
automatically TMdrains condensate without any loss of. compressed Energy savingsair can be realized
The Liquidator Pneumatic Condensate Draining System option is a demand-operated trap that
using this system over , time-based,
other draining systems. See Compression Systems Engineering Data
automatically drains condensate without any loss of compressed air. Energy savings can be realized
Release, AAEDR-D-005, for additional information.
using this system over other, time-based, draining systems. See Ingersoll Rand Engineering Data Release,
AAEDR-D-005, for additional information.
CAUTION:
The owner is responsible for properly maintaining the intercooler and aftercooler conden
CAUTION:
sate removal system. Failure to provide regular maintenance can damage intercooler
The owner is responsible for properly maintaining the intercooler and aftercooler conden-
components and the compressors air handling parts.
sate removal system. Failure to provide regular maintenance can damage intercooler
components and the compressors air handling parts.
A. Solenoid Drain alveV

A. Solenoid Drain Valve
B. Check aVlve
B. Check Valve
C. Manual Bypassalve V
C. Manual Bypass Valve
D. Manual Block alveV
D. Manual Block Valve
C
C
1010 inches
inches
(250mm)
(250 mm)
DD
A
B
B
Figure 3—13. Condensate Drain Piping Assembly Figure 3—14. Liquidator TM Pneumatic
Condensate Drain Trap
Figure
3—22 3 12. Condensate Drain Piping Assembly Figure
TM
Pneumatic
3 13. Liquidator
Condensate Drain
rap T
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 Four, 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.
3—23
Electrical Interface
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 Ingersoll Rand 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.
3—24
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.
3—25
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.
Ingersoll Rand Engineering Specification AAEDR-K-108, Requirement 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 compressor’s 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 compressor’s
motor controls.
NOTE:
Refer to Ingersoll Rand Engineering Specification AAEDR-K-108, Requirement for Starter to Main
Motor Controls, for more information on minimal requirements for solid state starting equipment.
3—26
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 3—16 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
FORSECTION3,PAGE27

Figure 3—16. Auxiliary Oil Pump Motor Wiring
EVCPumpMotorStarter
EVC Pump Motor Starter

TheTurboAirCompressorEVCmotorisnotcontrolledbythecontrolsystem.Afterthecompressor
controlsystemisenergized,andbeforethecompressorisstarted,theEVCshouldbestarted.Figure3—
The Turbo Air Compressor EVC motor is not controlled by the control system. After the compressor
XXillustratesatypicalmotorcontactorwiring.(Theuser/installerisresponsibleforsupplyingthemotor
control system is energized, and before the compressor is started, the EVC should be started. Figure
starterunlessitwasincludedatthetimeoforderentry.)
3—17 illustrates a typical motor contactor wiring. (The user/installer is responsible for supplying the

motor starter unless it was included at the time of order entry.)

Figure 3—17. EVC Pump Motor Starter Wiring

Oil Heater Option

Figure3—XX.EVCMotorWiring
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 3—18. With voltage applications greater than
480 and below 600 VAC, refer to Figure 3—19 for a typical wiring diagram.
Figure 3—18. Oil Heater Option Wiring Figure 3—19. Oil Heater Option Wiring
(480 VAC or less) (above 480 VAC and below 600 VAC)
3—27
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 6000 Centrifugal Compressor is shipped as a single assembly. The airend, lubrication
system, and control system are packaged with the compressor on a single skid. The main drive motor,
when supplied, may be installed or shipped loose depending on the size and weight of the driver.
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
Ingersoll Rand’s Scope-of-Supply.
Receiving
Ingersoll Rand 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 equip-
ment.
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.
Lifting
The Turbo Air 6000 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 6000 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 20,000 lbs. (9072 kg) plus the weight of the
driver, 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 3—20. (In some instances it may be neces-
sary 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.
3—28
Installation
Figure 3—20. Compressor Lift Points
Moving
If an overhead hoist is not available, the compressor may be moved on 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. Rollers are not recommended.
WARNING:
Before moving the compressor, verify that the moving device is the appropriate size and
sufficiently strong to bear the weight of the compressor. Use of improper moving devices
and/or improper moving may cause compressor damage, personal injury and/or other
property damage.
Bolting
If the foundation has been properly prepared, the compressor may be put in place at this time.
Ingersoll Rand recommends placing the compressor over foundation bolts, with the nuts tightened to
the recommended torque value. (Refer to Section Two, 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.
3—29
Closed Top Containers

The compressor may be secured to a wooden pallet and loaded into a closed top container using a
pallet lift truck with extended forks. Removal from the container should include similar properly rated
equipment rated as shown below. Be sure to lift only under the pallet straddling the center runner of
the pallet.
Refer to the contract specific Engineering drawings supplied for the compressor weight. The
compressor is to remain secured to the pallet until removed clear of the shipping container.
The compressor may also be moved on rollers, dollies, or casters.
WARNING: Before moving the compressor, verify 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.
Figure 3—21. Closed Top Container
3—30
Installation
The Installation Inspection

Before performing the installation inspection, review the Turbo Air 6000 Compressor installation
instructions again. Also, be sure to review any other applicable manufacturer’s instructions for
installation, operation, and maintenance of various other components and equipment including the
main drive motor, the main drive motor controller, the air dryer, etc.
After reviewing the previous items, thoroughly inspect the compressor installation using the
Installation Inspection Checklist in Table 3—2.
Inspection Prior to Initial Startup

As part of the initial startup service, your authorized Ingersoll Rand 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 Ingersoll Rand.
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 of 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 user’s expected requirements.
14. Oversee the reassembly of the main drive coupling.
15. Complete the Installation Inspection Checklist shown in Table 3—2 with customer’s installation
personnel before the initial compressor startup.
3—31
Installation Inspection Checklist

Foundation
3 Meets the material and thickness requirements
3 Compressor leveled within specification, foundation bolts properly torqued
Cooling Water (Coolant) Piping

3 Correctly routed and strain-free
3 Shut-off valves installed
3 Inlet and outlet correctly connected
3 Cleaned and flushed free of dirt and/or other foreign matter
Condensate Drain Piping

3 Automatic or manual traps or valves installed
3 Piped individually into open drains
Inlet Air Piping

3 Sized correctly, with minimal use of elbows
3 Properly supported, with flexible connections at the compressor
3 Startup screen correctly in place (if required)
3 Clean and free of dirt and/or other foreign matter
Inlet Air Filter/Silencer

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

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

3 Properly connected to the correct amount of clean, dry air
Table 3—2 The Installation Inspection Checklist
3—32
Installation
Installation Inspection Checklist continued…

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

3 Motor manufacturer’s instruction manual reviewed
3 Motor bearings properly lubricated
3 Motor rotation direction checked
3 Motor ‘rough’ alignment completed
Lubrication System
3 Reservoir filled with correct type and quantity of oil
3 Reservoir vent filter trap filled with oil
3 Optional oil reservoir heater thermostat set to 100° F (40° C)
3 Oil pump rotation checked
Control System
3 Air pressure sensors properly connected
3 Monitoring points checked for faults
3 Current transformer scale factor
3 Vibration probe wiring checked
Table 3—2. The Installation Inspection Checklist
3—33
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 manufacturer’s 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, 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 direction 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.
EVC Motor Rotation Verification

It is necessary to verify the correct rotational direction of the EVC motor as follows:
1. After powering the panel, observe the air flow from the discharge downspout of the EVC unit.
2. If the air does not discharge, correct the rotation by interchanging two of the three power
phases connected to the motor.
3—34
Installation
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 Ingersoll Rand 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 Ingersoll Rand 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 owner’s responsibility to plan for the inspection and initial startup service. Contact your local
authorized Ingersoll Rand service representative several weeks prior to the anticipated on-site date to
arrange for startup service.
Table 3—3 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 3—3 Potential Compressor Installation Problems
3—35
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 Ingersoll Rand
authorized service representative has fully checked and approved the compressor installa-
tion. Ingersoll Rand recommends that a trained and authorized service representative
perform the initial startup procedure.
Before Applying Power

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

ü Check the supplied panel power.
ü Verify that the control configuration matches the job site parameters.
ü Verify that vibration probe gaps are correct.
ü Verify the monitoring points for correct instrument locations and secure wiring.
ü Verify proper compressor inlet and discharge valve operation.
ü Verify that all control setpoints are in accordance with Ingersoll Rand guidelines.
ü Turn-on the oil reservoir vent ejector.
ü Turn on the auxiliary oil pump motor starter.
ü Verify proper oil pump operation. Adjust oil pressure regulator, if required.
ü Rack in the main drive motor starter.
ü Pull out the Emergency Stop button on the control panel.
ü Turn on coolant.
ü Verify the start sequence status. Correct if necessary.
3—36
Installation
Initial Compressor Startup

Following completion of all installation procedures and pre-start checks, an authorized Ingersoll Rand
Service representative uses the checklist below as a guide for conducting the initial compressor startup.
Preparation
ü Rack in main power to compressor and control panel.
ü Verify status using the control panel screens
ü Verify that the isolating air system block valve is closed.
ü Verify proper operation of compressor inlet and discharge control valves.
ü Establish required vacuum in oil sump by adjusting regulated clean, dry air supply to
the air ejector, (or turning on EVC).
ü Turn on coolant supply.
ü Close the condensate drain manual bypass valves.
ü Press Unload on the control panel to prevent automatic loading.
Startup
ü Press Start on the control panel.
ü Measure and make a note of the acceleration time to full speed. When able, adjust the
starting sequence accordingly.
ü Run the compressor unloaded for at least 30 minutes.
ü Perform walk-around inspection to check for any air, water, or oil leaks.
ü Periodically check that all operating parameters are at acceptable levels.
Manual Load
ü Open the isolating system block valve, if it is a non-automatic type.
ü Manually load the compressor to its design point and allow to warm up for one hour.
Do not run into the system yet.
ü Verify proper operation of condensate removal system.
ü Check again for any leaks and for correct values of all parameters.
3—37
Offline Loop Tuning and Surge Testing
ü Run compressor loaded for approximately 1 hour to achieve thermal equilibrium. Perform
the Natural Surge Test and record the results.
ü Perform the surge line tests per established service procedures and record the results.
ü Tune the ‘non-system’ control loops to optimum responses.
Performance Control Parameter Entries
ü Unload the compressor.
ü Enter all Performance Control parameters into the Maestro configuration, including
all surge test values.
ü Review all control parameters and check for input errors.
ü Set the proper Operator settings for Maestro.
System Mode Tuning
ü Load the compressor in Automatic control and verify proper response to control set points.
ü Tune the System Pressure control loops to achieve optimum response.
ü Prepare to shut down the compressor.
ü Press Stop on the Maestro panel and verify the correct stopping sequences.
Saving the Control Configuration
ü Make final adjustments to Control parameters, if required.
ü Reset the Maestro Operation History.
ü Save/document the final Maestro Configuration.
3—38
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
4—1
4—2
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 factory trained and authorized service
representative for technical assistance.
The Operating Data Record

It is recommended to keep 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 recom-
mended periodic maintenance.
4—3
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 and verify correct pressure and temperature.
7. Check for any water or oil leaks.
8. Verify correct control mode and setpoints.
9. Press the applicable key to view and verify that the starting sequence parameters are ready.
(See Controls Section for specifics.)
10. Pull out the red EMERGENCY STOP button.
11. Open the discharge air system block valve.
CAUTION:
Do not open the air system isolating block valve before this step. Operation under such
conditions may cause compressor damage.
12. Press the Start key. The compressor will go through its starting sequence.
4—4
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 shutdown procedure.
Shutdown Procedure
1. Unload compressor by pressing the applicable control key.
2. Allow the compressor to fully unload, then press STOP.
WARNING:
Never attempt to restart the compressor unless it has completely stopped. Refer to the
drive motor instruction manual regarding the permissible time interval between motor
starts.
3. Close the air system isolating block valve.

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 cooling water supply, if desired.
7. Stop the electric oil pump, if desired.
8. Rack out the drive motor starter disconnect, if desired.
9. Turn off the air ejector supply pressure, if desired.
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.
4—5
Operating Data Record

General Information
Compressor Number: Turbo Air Model:
Serial Number: Recorded By: Date:
Air System
P System Air Pressure:
P Discharge Air Pressure:
P Inlet Air Filter Pressure Drop:
P Stage 1 Inlet Temperature:
P Discharge Air Temperature:
Vibration
P Stage 1 Vibration:
Cooling
P Coolant Temperature In:
P Coolant Temperature Out:
P Coolant Pressure In:
P Coolant Pressure Out:
Lubrication System
P Oil Temperature:
P Oil Pressure:
P Oil Filter Pressure Drop:
P Oil Tank Vacuum:
Drive Motor
P Motor Current:
P Ambient Temperature:
P Motor Bearing Temperatures:
P Motor Stator Temperatures:
Miscellaneous
P Total Running Time:
P Control Mode:
Table 4—1 Operating Data Record (Typical)
4—6
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.
4—7
The Compressor Lubrication System

Figure B—1 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 bottom of the gearbox to the oil reservoir, passing around a baffle ar-
rangement that breaks down any foam.
6. The pressure regulator valve [L] maintains the correct operating pressure throughout the
lubrication cycle and returns any excess oil to the reservoir.
7. The air ejector [Q] provides the correct vacuum in the gearbox to prevent oil leakage from the
pinion oil seals.
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]
Air Pressure Temperature
Ejector Regulator Sensor
Q L Pressure T
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 4—1 Compressor Lubrication System Schematic
4—8
Routine Operation
Oil Pump Operation

Many customers elect to keep the auxiliary oil pump in continuous operation (even during compressor
shutdown) to ensure proper lubrication at all times. However, in order for this to be done, 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 will cause oil leaks.
4—9
The Turbo
The u Air 6000
Trbo Centrifugal
Air 3000 Compressor
Centrifugal Handbook Handbook
Compressor
Gearbox
Gearboxand Reservoir
and Venting
Reservoir enting
V
During centrifugal compressor operation, the action of meshing gears and the rotation of the bullgear
During centrifugal compressor operation, the action of meshing gears and the rotation of
cause air to become entrapped in the lubricating oil. As this air is released from the oil, it forms an oil-
cause air to become entrapped in the lubricating oil. As this air is released from the oi
laden mist in the gearbox and the oil reservoir. It is very important that both the gearbox and oil
laden mist in the gearbox and the oil . Itreservoir
is very important that both the gearbox and oil
reservoir are properly vented so that this oil mist is not allowed to escape.
reservoir are properly vented so that this oil mist is not allowed to escape.
Ejector/Filter
Ejector/Filter
A simple venturi-type ejector/filter system creates a slight vacuum inside the gearbox and oil reservoir.
A simple venturi-type ejector/filter system creates a slight vacuum inside the . gearbox an
The required vacuum (8 to 10 in H20 / 200 to 250 mm H20) prevents oil or oil mist from migrating out
The required vacuum (8 to 210 0 /in200
H to 250 mm 0 H
) prevents oil or oil mist from migrating out
into the atmosphere and/or creating other oil leaks. The ejector/filter
2
system is illustrated in Figure 4-2.
into the atmosphere and/or creating other oil leaks. The ejector/filter system is illustr
CAUTION:
CAUTION:
Supply air to the ejector must be clean and dry and the filter must be properly main-
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,
tained. Water in the oil reservoir has adverse effects on the lubricating oil that,
can cause severe damage to the compressor.
can cause severe damage to the compressor .
Clean, Dry
Clean, Dry
Compressed
Compressed
Air
Air
Mist Filter
Mist FIlter
DD Air
Air
Ejector
Ejector
3/4
3/4” BB AA
Vent
Vent
Check
Check
Trap
Trap Valve
Valve
Fill
Fill
Trap
Trap
EE Lube Oil
Lube Oil
Reservoir
Reservoir
C
C
Figure 4—24 The

Figure 2 Ejector/Filter System
The Ejector/Filter System
Ejector/Filter Operation
Ejector/Filter Operation
Under
Undernormal
normal operating conditions,
operating the Ejector/Filter
conditions, the Arrangement
Ejector/Filter operates as follows: operates as follows:
Arrangement
1. 1.Dry,
Dry, filtered, compressed air enters the ejector inlet into
filtered, compressed air enters the ejector inlet (A) and is transformed (A) aand
highisvelocity
transformed into a
stream in the ejector nozzle
stream in the ejector nozzle (B).(B).
2. 2.AirAir
fromfrom the main
theoil reservoir
main oil (C) becomes entrained
reservoir (C) becomesin this high velocity stream.
entrained in this high velocity stream.
3. 3.TheThe resulting pumping action draws the oil-laden airand
resulting pumping action draws the oil-laden air from the reservoir gearbox
from the and delivers it and gearbox an
reservoir
to to
the the
filter filter
(D), where(D),
droplets of oil accumulate and are then returned
where droplets of oil accumulate and are then returnedto the main oil reservoir. . to the main
4. 4.The oil return
The line includes
oil return linea mist trap (E)abefore
includes mistthe oil reservoir.
trap This
(E) before mist
. Thisthetrap serves
mist
oil as aserves
reservoir
trap vapor as a vapor
lock to prevent
lock the oil mist
to prevent thefrom oilbypassing
mist from the filter and escaping
bypassing to the surrounding
the filter area. to the surroundi
and escaping
4—10
4 10
Routine Operation
Routine Operation
Optional eatures
F
Optional Features
Although
Although thethe following
following components
components are notfor
are not required required for of
safe operation safe operation
urbo Air
the Turbo Air 3000
6000ofCom-
the
Com-
T
pressor, they will bring added convenience to the overall operation of the lubrication
pressor, they will bring added convenience to the overall operation of the lubrication system. If not syste
included with the initial compressor package, they may be
included with the initial compressor package, they may be added at any time. added at any time.
Oil Reservoir
Oil Reservoir Heater
Heater
The minimum startup
The minimum startup oil temperature
oil temperature for the lubrication
for the compressor compressor lubrication
system system
is 60°F (15° C). is 60 F (15 C).
Therefore,
compressors that are installed outdoors or in unheated buildings may
compressors that are installed outdoors or in unheated buildings may require the use of the Oil require the use of th
Reservoir Heater option. Such emersion heaters are rated at 1.5 kW and
Reservoir Heater option. Such emersion heaters are rated at 1.5 kW and are available in any standardare available in any
three-phase voltage up to 600 volts. The heater is installed . Figure
in the 4 oil
3 shows
reservoir
three-phase voltage up to 600 volts. The heater is installed in the oil reservoir. Figure 4—3 shows the the
Oil Heater
Oil Heater option.
option.
Figure 4 3 The
Figure 4—3 The
Oil Oil Heater
Heater OptionOption
Thermostatic Mixing
Thermostatic Mixing alve
V
Valve
With the standard package, oil temperature is maintained by regulating the flow of cooling
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. Includi
through the oil cooler. This method, though effective, may require seasonal adjustments. Including the
Thermostatic Mixing alveV option will automatically control oil temperature by regulating the o
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
around the oil cooler, thus keeping the temperature of the oil entering the compressor constant. The
Thermostatic Mixing alveV option is shown in Figure 4 4.
Thermostatic Mixing Valve option is shown in Figure 4—4.
From
From To
To
Oil Pump
Oil Pump Oil Filter
Oil Filter
Regulator
Regulator
Water
Water InIn
Water Out
Water Out
Oil Cooler
Oil Cooler
Figure 4 4 The
Figure 4—4 The Thermostatic
Thermostatic Mixing
Mixing alveOption
Valve V
Option
4—11
4 11
The
The uTu
Trbo
rbo Air
Air 3000
3000 Centrifugal
Compressor Handbook
Handbook
Duplex
DuplexOil
Duplex Oil
OilFilter
Filter
Filter
In
Inmany
In manyinstances,
many compressed
instances,
instances, air systems
compressed
compressed airoperate
air systems
systemson aoperate
continuous
operate on
onbasis. Since it is frequently
aa continuous
continuous basis.inconve-
Since it is freque
nient
nient
nient toto
completely
to shut down
completely
completely shutcompressor
shut down operation to
down compressor
compressor perform a simple
operation
operation to maintenance
to perform
perform task, Ingersoll
a simple maintenance task, Co
Rand
sion offers
sion the Duplex
Systems
Systems offers
offers Oil the
FilterDuplex
the option. The
Duplex Oilduplex
Oil Filter
Filteroil filter eliminates
option.
option. The the
The necessity
duplex
duplex oilforfilter
compressor
eliminates the nece
shutdown
pressor during
pressor shutdown filterduring
shutdown maintenance.
during filter
filter(Refer to Section Five,(Refer
maintenance.
maintenance. Maintenance,
(Refer to for full instructions
to Section
Section regard-
Five, Maintenance, for full i
ing this procedure.)
regarding
regarding this The Duplex Oil Filter
this procedure.)
procedure.) The option
The Duplex
Duplex is shown
Oil in Figureoption
Oil Filter
Filter 4—5. is shown in Figure 4 5.
option
Figure4—5
Figure
Figure 44 55The
The Duplex
Duplex
The Oil Filter
Oil Filter
Duplex Oil Filter
OilFilter
Oil
Oil Filter
Filter Differential
Differential Pressure Monitoring
Differential Pressure Monitoring
Withthis
With
With this
this optional
optional
optional feature,feature,
feature, aa second
second
a second pressure pressure
pressure
transducer transducer
transducer
is installed is oil
before the installed
filter.. (The
(The before
system
system’s thes oil filter
standard
standard
standard pressure
pressure
pressure transducer
transducer
transducer is
is locatedis located
located
between between
between
the filter the
the
and the filterInand
filter
gearbox.) suchthe gearbox.)
instances, the In such insta
MaestroControl
Maestro
Maestro Control
Control SystemSystem
System is programmed
is programmed
is programmed to the
to
to calculate calculate
calculate the
differentialthe differential
differential
pressure across the oilpressure across the oil
filter and to
provide
provide
provide Alarm
Alarm
Alarm and
andand ripfunctions.
rip
Trip TTfunctions.
functions. The
The OilThe Oil
Oil
Filter Filter Pressure
Filter
Differential Differential
Differential Pressure
Monitoring Monitoring option is par
option is particularly
useful
useful
useful when
when
when included
included
included as
as partas part
of part of aa maintenance
of
a predictive predictiveprogram.
predictive maintenance
maintenance program.
Figure 4—6 shows the Figure 4 6 shows the Oil
Oil Filter
Differential
Differential
Pressure
Pressure Monitoring
Monitoring
Monitoring option. option.
option.
Oil
Oilfrom Cooler
from Cooler Oil
Oiltoto
Oil Gearbox
Gearbox
Oil from Cooler
Oil
OilFilter
Oil Filter
Filter
Figure 44 66 Oil
Figure Oil Filter
Filter Differential
Pressure Monitoring
Monitoring Option
Option
Figure 4—6 Oil Filter Differential Pressure Monitoring Option

Low Oil
Low Oil Level
Level Indicator
Indicator
With the
With the installation
installation of of the
the Low
Low Oil
Oil Level
Level Indicator
Indicator option
option (a (a switch
switch located
located in in the
the main
main o
o
Low
the
the Oil Level
Maestro
Maestro Control
ControlIndicator
System will report any oil level in the reservoir that
System will report any oil level in the reservoir that is below a pre-d is below a pre-d
The control
The
With control
the system
system
installation then
then
of the indicates
Low indicates an Alarm
an Alarm
Oil Level Indicator condition
optioncondition to alert
to
(a switch located alert the oil
the
in the main operator
operator of the
reservoir) of the problem.
problem.
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.
44 12
12
4—12
FORSECTION3,PAGE3Ͳ23 Routine Operation
ElectricVacuumCoalesing(EVC)MistEliminatorOption
Inplaceofanairdrivenmisteliminatorforgearboxandoilreservoirventing,anElectricVacuum
Coalesingfilterassemblymaybesupplied.Thisoptionaldeviseincludesanelectricmotordrivenvacuum
Electric Vacuum Coalesing (EVC) Mist Eliminator
pumptoinduceavacuuminthecompressorgearboxandoilreservoir.ThisdevicefeaturesaCoalesing
In place of an air driven mist eliminator for gearbox and oil reservoir venting, an Electric Vacuum
filterelementtoseparatethefineoilmist/vaporfromtheairbeingpulledfromthecompressor.Theoil
Coalesing filter assembly may be supplied. This optional device includes an electric motor driven
vacuum drainsfromthefiltercanisterbackintotheoilreservoir;theairisdischargedtoatmosphere.Tocontrol
pump to induce a vacuum in the compressor gearbox and oil reservoir. This device features a
coalesing filter element to separate the fine oil mist/vapor from the air being pulled from the compres-
thevacuumbeingpulledaballvalvewithfilterisusedtodrawoutsideairthroughthefiltercanister.
sor. The oil drains from the filter canister back into the oil reservoir; the air is discharged to atmo-
sphere. To
control the vacuum being pulled a ball valve with filter is used to draw outside air through
the filter canister.

G

A

E

A. Inlet Filter
B
B. Ball Valve
F
C. Oil Drain
Line
D. Vapor Suction Line
E. Coalesing
Filter Housing
F. Air Discharge Vent
C D
G. Motorized
Vacuum Pump
Figure 4—7. EVC
FORSECTION3,PAGE3Ͳ33
EVCMotorRotationverification
ItisnecessarytoverifythecorrectrotationaldirectionoftheEVCmotorasfollows:
1.Afterpoweringthepanel,observetheairflowfromthedischargedownspoutoftheEVCunit.
2.Iftheairdoesnotdischarge,correcttherotationbyinterchangingtwoofthethreepowerphases
connectedtothemotor.
4—13
4—14
Maintenance
Section Five
Maintenance
♦ Daily Inspection
♦ Scheduled Maintenance
♦ Professional Inspection
♦ Filter Maintenance
♦ Lubrication
♦ Heat Exchanger Maintenance
♦ Control Valves
5—1
5—2
Maintenance
The Ingersoll Rand Turbo Air Centrifugal Compressor requires minimal maintenance. However, monitor-
ing 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 an
Ingersoll Rand trained and authorized service representative for help with all other proce-
dures.
5—3
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 p require special precautions as indicated.
Operating Data Log
P Operating Parameters recorded and within specifications
P Setpoints Checked
Gearcase
P External surfaces wiped clean
P No unusual noise or vibrations
P No oil leaks
P No air leaks
P No frayed or worn electrical cables
Intercoolers and Aftercooler
P Condensate drains functioning properly
P No cooling water leaks
P No air leaks
Lubrication System
P Proper oil level in oil reservoir
P Proper oil color
P No mist from ejector system
P No oil cooler water leaks
P No oil leaks
Compressor Drive Motor (Inspect visually only—high voltages, temperatures)
P Properly ventilated
P No erratic or noisy operation
P Inspected in accordance with manufacturer’s recommendations
Table 5—1 Daily Operator Inspection Checklist
5—4
Maintenance
Scheduled Maintenance
Table 5—2 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 6000 Centrifugal Compressor, use only genuine Ingersoll Rand
replacement parts and recommended supplies available through Ingersoll Rand and/or authorized
representatives.
Daily:
P Operating data logged and reviewed
Monthly:
P Inlet air filter elements inspected, replaced if required
P Oil reservoir venting system filter elements inspected, replaced if required
P Compressor bypass valve filter checked (if applicable)
P Control system operation checked
P Intercooler/Aftercooler condensate removal system checked
Quarterly:
P Drive Motor ball lubricated per manufacturer’s instruction*
P Condensate traps cleaned and inspected
P Compressor operational data analyzed
P Intercooler, aftercooler, and oil cooler performance verified
P Lubrication system oil analyzed
P Verfiy oil heater operation (if applicable)
P Verify correct operation of compressor inlet and discharge valves
P Verify discharge check valve operation
P Control setpoints checked
*Refer to the motor instructions for specific interval guidelines.
Table 5—2 Scheduled Maintenance Procedures
Continued on next page.
5—5
Scheduled Maintenance
Table 5—2 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 6000 Centrifugal Compressor, use only genuine Ingersoll Rand
replacement parts and recommended supplies available through Ingersoll Rand and/or authorized
representatives.
Every Six Months:
P Lubricate main drive motor (see motor manual)*
P Main drive motor maintenance checks completed*
P Main drive coupling checked
P Verify proper motor alignment
P Lubrication system oil tested and changed if required
P Oil pump motor lubricated with recommended grease (if required)
P Verify operation of main and aux pumps
P Oil system filter element changed
P Oil reservoir venting system filter element changed
P Coolant and condensate chemically tested
P Intercooler / Aftercooler condensate removal system cleaned and inspected
P Inlet guide vane assembly inspected and drive screw lubricated
P Bypass valve air filter replaced, if applicable
P Inspect compressor discharge valve
P Discharge air check valve inspected
P Verify vibration gap voltage
P Test E-stop circuit
P Verify proper control panel set up
P Perform surge test and record results
*Refer to the motor instructions for specific interval guidelines.

Table 5—2 Scheduled Maintenance Procedures - continued
5—6
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 an Ingersoll Rand trained and authorized service representa-
tive for those procedures as they are not intended for unauthorized personnel.
Service Inspection Checklist

To be performed with an Ingersoll Rand authorized representative:
Operating Data Log

P Recent data logs and maintenance history reviewed with customer
Gearcase*
P Impellers, inlets, and diffusers cleaned and Inspected
P Gearing visually checked
P Gearing backlash clearances measured
P Axial pinion floats measured
P Clearances between impellers and inlets checked
Intercoolers* and Aftercooler*
P Bundle tubes inspected, cleaned if required
P Bundle fins inspected, cleaned if required
P Cooler cavities cleaned and inspected
P Condensate removal system cleaned and inspected
P Cooling sensors checked
Lubrication System*
P Piping connections checked for leaks
P Oil visually inspected
P Oil cooler inspected
P Oil pumps inspected
P Oil system sensors checked
Filters
P All filter elements inspected and replaced as required
Control Panel
P Inspected for proper configuration and operation (adjust as required)
Control Valves
P Inlet Guide Vane inspected and adjusted
P Discharge air check valve inspected
P Compressor modulating blow off or bypass valve inspected and adjusted
P Auto block valve inspected (where applicable)
Drive Motor
P Main drive coupling inspected
P Motor inspected in accordance with manufacturer’s instructions
*Replacement parts required. Use only genuine Ingersoll Rand parts and supplies available through
the Ingersoll Rand and/or authorized representatives.
Table 5—3 Service Inspection Checklist
5—7
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 5—4 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 Ingersoll Rand products. Refer to Section Seven,
Parts and Service, for more information on parts that are available through your Ingersoll Rand repre-
sentatives.
Table 5—4 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, Ingersoll Rand 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.
5—8
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 an Ingersoll Rand 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 an Ingersoll Rand 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 ejector’s supply air is clean and dry and the filter is
properly maintained during periods of high humidity.

Check the exhaust port at least daily. If an oil mist is evident, that is an indication of a clogged filter
element. Using the following procedure, replace the element.
1. Remove the trap line between the bottom of the filter housing and the 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.
5—9
Standard Oil Filter Element Replacement

Ingersoll Rand has specially designed bearing and gearing configurations, not found on other compres-
sors. Regular maintenance of the oil filtration system is critical to the lasting operation of these sophisti-
cated components. Use the following procedure to replace the standard oil filter element.
CAUTION:
Use only Ingersoll Rand 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 an Ingersoll Rand replace-
ment 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.
5—10
Maintenance
Lubrication
Table 5—5 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. Ingersoll Rand
Change only as required. TurboBlendTM Lubricating Oil
Auxilliary Oil pump motor bearings Six months Refer to Section Two
(If applicable)
Drive motor ball bearings [A] [A]
Drive motor sleeve bearings [A] [A]
Inlet guide vane actuator drive screw Six months High quality synthetic grease
[A] Refer to the motor manufacturer’s instructions for specific interval guidelines.
Table 5—5 Compressor Lubrication Schedule
Compressor Lubricating Oil

Ingersoll Rand 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, Ingersoll Rand recommends additional
testing for the presence of enhancing additives in accordance with The American Society for Testing
and Material (ASTM) as defined in Table 2—1, Oil Specification.
CAUTION:
Be certain to use only Ingersoll Rand TurboBlendTM Lubricating Oil for optimum perfor-
mance. Use of any incorrect oil can cause extensive damage to internal components and
will void any existing warranties.
5—11
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.
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 manufacturer’s 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 Ingersoll Rand Turbo Air Compressors have drive motors equipped with sleeve bearings. Most of
these have oil reservoirs in the motor bearing housings. Fill the reservoirs and maintain per the motor
vendor’s recommendations. Other sleeve bearing motors are lubricated directly from the compressor’s
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 6000 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.
5—12
Maintenance
Additional Maintenance Procedures

In addition to periodic inspections and maintenance of the filter and lubrication systems, some
maintenance will also be necessary on an “as required” basis.
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
Main Drive Coupling Annual
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 manufacturer’s instructions
* Indicated procedures require the use of parts available through your authorized Ingersoll Rand
representative.
Table 5—6 Other Maintenance Procedures
Intercooler and Optional Aftercooler Cleaning

In most cases, the coolers 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 15°F (8°C), the coolers
should be inspected, and cleaned if required.
The Ingersoll Rand compressors have tube-and-fin style intercoolers and aftercoolers, with coolant
flowing through the tubes. A U-tube design is standard for intercoolers. Straight tubes are available as
an option on intercoolers, standard on aftercoolers.
The following pages provide the recommended procedures for proper disassembly and thorough
cleaning of the tube-and-fin cooling units.
5—13
Intercooler and Aftercooler 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 5—1, 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
Figure 5—1 Intercooler Disassembly

(Aftercooler not shown, similar to S-tube intercooler)
5—14
Maintenance
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 for any
blockage.
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 manufacturer’s 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.
5—15
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 manufacturer’s instructions for safe handling and disposal of the
chemical cleaning product. Failure to follow proper safety procedures may cause personal
injury and/or create a biohazard.
4. If any bent fins are visible after the cleaning procedure, carefully straighten them out by hand
before replacing the baffle plates.
5. 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.
5—16
Maintenance
Oil Cooler Cleaning

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

Main motor couplings do not require any specific periodic maintenance, but it is recommended that
the following checks are carried out on an annual basis:
1. Verify that axial and parallel alignments are still within the acceptable limits of the coupling and
that no major machinery movement has occurred (refer to Section Two of this handbook for
limits).
2. Verfiy that all bolts are still correctly tightened (refer to Section Two of this handbook for torque
specs).
3. Visually inspect the disc packs for signs of fatique cracking local to the washer anchor points or
general signs of fretting corrosion. Although slight bowing or ‘S’ like distortion of the lamination
is not detrimental to the operation of the unit, make sure it is not excessive.
4. Visually inspect the condition of the fixed hubs on the compressor and motor shafts, making sure
that there is no degradation in their keyway fits. If any is found, the hubs must be replaced.
5—17
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 manufacturer’s supplied instruction for specific requirements and procedures.
CAUTION:
Failure to comply with the motor manufacturer’s-specified preventive maintenance re-
quirement can result in extensive equipment damage. Improper or inadequate motor
maintenance procedures can void all existing warranties.
5—18
Troubleshooting
Section Six:
Troubleshooting
♦ How to Request Assistance
♦ Alarm and Trip Functions
♦ Drive Train
Troubleshooting
♦ Lubrication System
Troubleshooting
♦ Air System
Troubleshooting
♦ Control System
Troubleshooting
6—1
6—2
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 Turbo Air 6000 compressor is a unique, highly-engineered design. If 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

There is an established established network of factory trained and authorized service representatives
throughout the United States and around the world. When additional guidance or help is required,
contact your regional authorized representative.
WARNING:
For specialized service procedures, always use the services of an Ingersoll Rand trained and
authorized service representative and only genuine Ingersoll Rand replacement parts.
Improper servicing may cause equipment damage or personal injury. Ingersoll Rand will
not accept responsibility 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 system displays Alarms and Trips.
6—3
Drive Train Troubleshooting

Conditions Possible Causes
Motor Starter Problems
Refer to manufacturer’s 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 (if applicable)
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
6—4
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
6—5
Air System Troubleshooting

High Compressor Output
Low air demand
Control setpoints incorrect
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
6—6
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
6—7
6—8
Parts and Service
Section Seven:
Parts and Service
In this section, the reader will learn about:
♦ Aftermarket Support
♦ The Parts Ordering Procedure
♦ Parts Availability
♦ The Returned Goods Policy
♦ The Periodic Maintenance Parts

Inventory
♦ The Professional Inspection Parts

Requirement
♦ Control System Sensors
♦ Lubrication System Parts
♦ Main Drive Coupling Parts
♦ Heat Exchanger Parts
♦ Air Piping Parts
7—1
7—2
Parts and Service
Aftermarket Support
As an important part of its commitment to its products and customers, Ingersoll Rand offers full after-
market support. The array of aftermarket services includes on site service, inspection and repair, avail-
ability of genuine Ingersoll Rand parts and recommended supplies, and customer training seminars.
WARNING:
Since the Turbo Air 6000 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 an Ingersoll Rand trained and authorized service representative.
For parts and/or service, always contact your local authorized Ingersoll Rand sales and service represen-
tative, or contact the factory directly.
Parts Coordinator
or
Field Service Department
Ingersoll Rand
3101 Broadway PO Box 209
Buffalo, NY 14225-0209 USA
Phone: (716) 896-6600
Fax: (716) 896-1233
7—3
Parts Ordering Procedure

Since specific compressor models and installations may vary, always be sure to have the following
information available when placing an order:
1. The compressor serial number (included on the compressor nameplate located on the gearbox).
2. The compressor model: Turbo Air 6000

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 Ingersoll Rand 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 Ingersoll Rand for authorization before the return of any goods to the factory.
All approved returns are immediately assigned a tracking number to prevent processing delays or loss of
materials. This ARG (authorization to return goods) tracking number is then recorded at the factory.
Senders must include the assigned ARG tracking number on the outside of the shipping container
whenever goods are being returned.
No goods may be returned to the factory without prior authorization and an assigned ARG
tracking number.
7—4
Parts and Service
The Periodic Maintenance Parts Inventory

Ingersoll Rand recommends keeping a basic inventory of replacement and spare parts and stocking of
all the recommended supplies mentioned in this operator’s manual. This will eliminate or help reduce
unanticipated shutdown time during those occasions when it may be necessary to maintain or replace
one or more compressor parts. Table 7—1 is a recommended list of materials and parts that should be
in active inventory for routine maintenance activities.
CAUTION:
When replacing parts or ordering supplies, always use genuine Ingersoll Rand replacement
parts and Ingersoll Rand approved supplies. Ingersoll Rand will accept no liability for
damages caused by use of non-authorized parts, supplies, or service.
7—5
VanRecommended Periodic Maintenance Parts & SuppliesDescription

QtyTurbocompressor
Description Qty Ingersoll Rand
Part Number
Filters:
• Inlet Air Filter, Primary and Secondary Elements [A] [A]
• Bypass Valve Air Line Filter Element 1 [B]
• Oil Reservoir Vent Filter Element 1 AAP1404987-00014
• Oil System Filter Elements:
- Single Filter Only 1 AAP1404040-00217
- Duplex Filter [D] 2 AAP1401435-01233
- Dual Filter / Dual Cooler Configuration 2 AAP1404040-00207
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
• Inlet Guide Vane Drive Screw Grease 1 AAP1405340-00288
Parts:
Heat Exchangers (Figures 7—9 & 7—10)
• K-Seal 2 AAP1408800-04952
• Y-Gasket 3 AAP1408800-04953
• Header Gasket 2 AAP1408531-03811
• Front Tubesheet Gasket 2 AAP1408530-03800
• Rear Header Gasket (S-Tube Type Only) 2 AAP1408531-03801
• Oil Cooler Gasket Kit 1 AAP1405680-00001
Bypass Valve (Figure 7—17) [B]
• Seal Kit (>1000 HP) 1 AAMB408539-00301
• Seal Kit (<1000 HP) 1 AAMB408539-00207
Discharge Air Check Valve (Figure 7—20)
• Check Valve, 5” (>900 HP) 1 AAP0540024-00186
• Check Valve, 6” 1 AAP0540024-00187
Condensate Drains (Figure 7—11) [E]
• Solenoid Valve, 110/120-Volt 1 AAP1401581-01302
• Solenoid Valve, 220/240-Volt 1 AAP1401581-01341
• Check Valve 1 AAP1401581-01303
• Gate Valve 2 AAP1401581-00757
Instrumentation (Figure 7—1)
• Vibration Probe 1 AAP1407030-02006
• RTD (Temperature Transducer) 1 AAP3403629-01585
• Pressure Transmitter 1 AAP0540089-00210
• Drive Motor Current Transducer 1 Consult Factory
Notes: [A] Refer to Figure 7—16, Inlet Air Filter Assembly

[B] Refer to Figure 7—17, Bypass Valve Assemblies
[C] Reservoir capacity is 85 gallons.
[D] Refer to Figure 7—5, Duplex Oil Filter Option.
[E] The below quantities are required for each heat exchanger, including the mounted aftercooler option.
Table 7—1 Periodic Maintenance Parts and Supplies
7—6
Parts and Service
The Professional Inspection Parts Requirement

Table 5—3, Service Inspection Checklist outlines the in-depth examination procedures to be performed
with a Ingersoll Rand trained and authorized representative. These important preventative mainte-
nance tasks involve removal of the gearbox cover to examine the gears, bearings and seals and expos-
ing of the heat exchanger bundles and the aerodynamic components for cleaning and inspection.
Certain gaskets, o-rings and seals must be ordered well in advance of the scheduled visit. Table 7—2
lists the parts and supplies necessary for the Professional Inspection of the compressor. Some of these
parts may already be on-hand as part of the Periodic Maintenance Parts Inventory.
CAUTION:
When replacing parts or ordering supplies, always use genuine Ingersoll Rand replacement
parts and Ingersoll Rand approved supplies. Ingersoll Rand will accept no liability for
damages caused by use of non-authorized parts, supplies, or service.
7—7
Professional Service Inspection Parts & Supplies

Description Qty Ingersoll Rand
Part Number
Gearbox:
• O-Ring, First Stage Inlet 1 AAP1406702-00388
• O-Ring, Second Stage Inlet 1 AAP1406702-00389
• O-Ring, Third Stage Inlet 1 AAP1406702-00385
• Seal, First Stage Diffuser 1 AAP1794323-00006
• Seal, Second Stage Diffuser 1 AAP1794323-00005
• Seal, Third Stage Diffuser 1 AAP1794323-00005
• O-Ring Lubricant 1 AAR1409584-00000
• Gearbox Splitline Sealant 1 AAR1405571-00012
Heat Exchangers: (Figures 7—9 & 7—10)
• K-Seal 2 AAP1408800-04952
• Y-Gasket 3 AAP1408800-04953
• Head Gasket 2 [F]
• Front Tubesheet Gasket 2 AAP1408530-03800
• Rear Header Gasket (S-Tube Type Only) 2 AAP1408531-03801
Lubrication System:
• Oil Cooler Gasket Kit 1 AAP1405680-00001
• Oil Reservoir Vent Filter Element 1 AAP1404987-00014
• Oil System Filter Element (Single Filter Type) 1 AAP1404040-00217
• 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 7—15)
• Gasket, Inlet Guide Vane, 6” (150 mm) 1 AAP1409511-00005
• Gasket, Inlet Guide Vane, 8” (200 mm) 1 AAP1409511-00001
• Grease, Inlet Guide Vane Drive Screw 1 AAP1405340-00288
Bypass Valves (Figure 7—17)
• Seal Kit 1 [D]
• Bypass Valve Air Line Filter Element 1 [D]
Notes:
[B] Refer to Figure 7—16, Inlet Air Filter Assembly
[D] Refer to Figure 7—17, Bypass Valve Assemblies
[F] Refer to Figure 7—9, 7-10.
Table 7—2 Professional Service Inspection Parts and Supplies
7—8
Parts and Service
This page intentionally

left blank.
7—9
Control System Sensors

3
7
11
6,8,14
5
13
Figure 7—1. Control System Sensors
Item Ingersoll Rand

No. Description Qty Part Number
Standard Instrumentation:
01 Vibration Probe, Stage 1 1 AAP1407030-02006
03 RTD, Inlet Air Temperature, Stage 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 [B] 1 AAP0540089-00210
07 Tranducer, Drive Motor Current (In Motor Term Box) 1 Consult Factory
08 Transmitter, Compressor Discharge Pressure [B] 1 AAP0540089-00210
Optional Instrumentation:
11 Vibration Probe, Stages 2 and/or 3 1-2 AAP1407030-02006
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 (Figure 7-6) 1 AAP0540061-00199
17 Transducer, Air Filter Differential Pressure [D] 1 AAP1794463-00127
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] Required for filter differential pressure measurement.
[D] Shipped loose for field installation.
Table 7—3. Control System Sensors
7—10
Parts and Service
Control System Sensors
01
03
02 04
(GEARBOX COVER)
(OIL/AIR SEAL)
(PINION)
Figure 7—2. Vibration Probe Installation
Item Ingersoll Rand

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 7—4. Vibration Probe Installation
7—11
Lubrication System Parts 01

02
10
09
12
11
Housing
12
Nut
07 08
17
13 18 03 06 05 04
Figure 7—4. Reservoir Vent Filter Assembly
16
15
Figure 7—5. Duplex Oil Filter Option Figure 7—6. Reservoir Level Switch Option
Replaces Standard Sight Gauge
7—12
Parts and Service
Lubrication System Parts
Item Ingersoll Rand

01 Main (shaft-driven) Oil Pump 1 AAP1401428-00624 or (-622) 50 Hz
02 Drive Coupling, Main Oil Pump 1 AAP1402070-00256
03 Auxiliary (motor-driven) Oil Pump 1 AAP1401428-00623 or (-621) 50 Hz
04 Motor, Auxiliary Oil Pump
- 230-460 Volt / 60 Hz 1 AAP1402068-00751
- 220-380 Volt / 50 Hz 1 AAP1402068-00728
- 380 Volt / 60 Hz 1 AAP1402068-00716
- 400, 415 & 440 Volt / 50 Hz 1 AAP1402068-00728
- 440 Volt / 60 Hz 1 AAP1402068-00769
05 Drive Coupling, Auxiliary Oil Pump 1 AAP1402070-00187
06 Pressure Regulator (Relief Valve) 1 AAP1401581-01329
07 Cooler, Oil-to-Water (Heat Exchanger):
- Standard unit with 0.375” (10 mm) dia. copper tubes 1 AAP1401429-01004
- Maintenance Gasket Kit 1 AAP1405680-00001
08 Single Filter:
- Complete Assembly 1 AAP1401435-00291
- Replacement Element 1 AAP1404040-00217
Reservoir Vent Assembly:
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 Sight Level Gauge 1 AAP1401582-00014
Table 7—6. Standard Lubrication System Components (See Figure 7-4)
Item Ingersoll Rand

Duplex Filter (Figure 7—5): [A]
- Complete Assembly 1 AAA3401435-00232
15 - Replacement Element 2 AAP1401435-01233
16 Level Switch (Figure 7—6) [A] 1 AAP0540061-00199
17 Temperature Regulator [A] (Figure 7-4) 1 AAP1401581-01347
18 Oil Heater: [A] (Figure 7-4)
- 230 Volt 1 AAP0540063-00379
- 380 Volt 1 AAP0540063-00365
- 400 Volt 1 AAP0540063-00384
- 415 Volt 1 AAP0540063-00380
- 440 Volt 1 AAP0540063-00385
- 460/480 Volt 1 AAP0540063-00363
- 575 Volt 1 AAP0540063-00156
Notes: [A] Not all lubrication systems are equipped with these optional features. Most of these features can be
retrofitted after the compressor has been shipped from the factory.
Table 7—7. Optional Lubrication System Components (See Figures 7-4, 7-5 and 7-6)
7—13
The Turbo Air 6000 Centrifugal Compressor Handbook Parts and Service
Main Drive
Main Drive Coupling
Coupling Parts
Parts
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
TYPICALEACH
EACHEND
END BOLTTORQUE
BOLT TORQUE
TYPICAL
VALUES:
VALUES:
Referto
Refer toSection
Section22
Figure77—
Figure 8B.Main
—8B. MainDrive
DriveCoupling
CouplingAssembly
Assembly(Dry
(DryType
Type--“Bibby”)
“Bibby”)
Item
Item Ingersoll
Compression Rand
Systems
No.
No. Description
Description Qty
Qty PartNumber
Part Number
01
01 Standard
Disk Pack &Disk Pack & Fasteners (Model DC163)
Fasteners 22 AAP1406064-03601
AAP1406064-06901
** Coupling
Over size hardware is use
drivers may metric
model DC193, consult factory if driver shaft size larger than 4.125 (105mm).
Table77—
Table 8B. Main
—8B. MainDrive
DriveCoupling
CouplingMaintenance
MaintenanceParts
Parts
7—14 7—15
Parts and Service
Heat Exchanger Parts
Tubesheet Gasket
04
Y-Seal
02
01
K-Seal
Baffle Header Gasket

03
Intercooler Bundle
* Diffuser Water Header

Y-Seal
Plate
02
Figure 7—9. Intercooler/Aftercooler Bundle Assembly

Standard U-Tube Model
Item Ingersoll Rand

01 K-Seal 2 AAP1408800-04952
02 Y-Seal 4 AAP1408800-04953
03 Header Gasket 2 AAP1408531-03811
04 Tubesheet Gasket 2 AAP1408530-03800
* Diffuser Plate supplied on 1st Stage Intercooler Only
Table 7—9. Intercooler Maintenance Parts - Standard U-Tube Model
7—15
Heat Exchanger Parts
Tubesheet Gasket
04
Rear Water
Header
K-Seal
01
Gasket
05
Baffle
Intercooler Bundle
* Diffuser Plate
Y-Seal
02
Header Gasket
03
Figure 7—10. Intercooler/Aftercooler Bundle Assembly
Optional S-Tube Model
Item Ingersoll Rand
01 K-Seal 2 AAP1408800-04952
02 Y-Gasket 4 AAP1408800-04953
03 Header Gasket 2 AAP1408531-03801
04 Tubesheet Gasket 2 AAP1408530-03800
05 Rear Header Gasket 2 AAP1408529-03800
*Diffuser Plate Supplied on 1st Stage Intercooler Only
Table 7—10. Intercooler Maintenance Parts - Standard S-Tube Model
Item Ingersoll Rand

4 Ft. Mounted Aftercooler
01 - K-Seal 1 AAP1408800-04930
02 - Y-Seal 2 AAP1408800-04928
04 - Front Tubesheet Gasket 1 AAP1797269-04830
03 - Header Gasket 1 AAP1797269-02700
6 Ft. Mounted Aftercooler
01 - K-Seal 1 AAP1408800-04930
02 - Y-Seal 2 AAP1408800-04929
04 - Front Tubesheet Gasket 1 AAP1797269-04830
03 - Header Gasket 1 AAP1797269-02700
Table 7-11. Aftercooler Maintenance Parts – (No illustration)

7—16
Parts and Service
Condensate Drain Parts
Figure 7—11. ReliaDrainTM Zero Loss Condensate Removal Drain

(One set required for each heat exchanger)
Item Ingersoll Rand

-- ReliaDrain Model 6000/110, 110 VAC 1 AAP0540025-00134
-- ReliaDrain Model 6000/220, 220 VAC 1 AAP0540025-00145
-- ReliaDrain 6000 Rebuild 1 AAMB540025-00145
-- 110v Heater 1 AAP0540025-00146
-- 220v Heater 1 AAP0540025-00147
Table 7—11. ReliaDrainTM Zero Loss Condensate Removal Drain
7—17
The
The Turbo
The Trbo Air
u Air6000 Centrifugal
3000 Compressor
Centrifugal HandbookHandbook
Compressor
Compressor Handbook
Condensate Drain
Condensate DrainParts
arts
P
03
03
03
03
03
01
01
02
02
Figure
Figure7—12.
Figure 12.Solenoid-Operated
77 12. Condensate
Solenoid-Operated
Solenoid-Operated DrainingDraining
Condensate
Condensate System System
Draining System
(One set required
(One for
(One seteach heat exchanger)
required
required for
for each
each heat
heat exchanger)
exchanger)
ItemItem Compression Systems

Systems
Ingersoll Rand
Compression
No.
No. No. Description
Description Qty
Qty
Qty Part Number
Number
Part Number
Part
01 01
01 Solenoid Valve,
Solenoid
Solenoidalve,
alve, 1/2”
VV NPT,,,NPT
1/2
1/2 110/120-Volt
NPT Volt
110/120-
Volt
110/120- 1 AA P1401581-01302
AAP1401581-01302
AAP1401581-01302 11
01 01
01 Solenoid Valve,
Solenoid
alve, V1/2” NPT,,,NPT
1/2
1/2 220/240-Volt
220/240-
NPT Volt
220/240-
Volt 1 AAP1401581-01341
AAP1401581-01341
AAP1401581-01341 11
02 02
02 Check Valve,
Check
Check 1/2” NPT
Valve,
Valve, 1/2 NPT
1/2 NPT 11 AAP1401581-01303
AAP1401581-01303
AAP1401581-01303
03 03
03 Gate Valve,
Gate
Gate 1/2” NPT
Valve,
Valve, 1/2 NPT
1/2 NPT 2 AAP1401581-00757
AAP1401581-00757
AAP1401581-00757
Table
Table7—12.
Table 12.Solenoid-Operated
77 12. Solenoid-Operated
Solenoid-Operated Condensate DrainingDraining
Condensate
Condensate System System
Draining System
(One set required for each heat exchanger)
04
04
04
Vent
VentAir
Vent Air
Air
Discharge LineLine
Discharge
Discharge Line
01
01 01
01
03
03
03
TT Drain
DrainLine
Drain Line
Line
Heat Exchanger
Heat
Heat Exchanger
Exchanger
02
02
Figure
Figure7—13a.
Figure Liquidator
77 13a.
13a. Liquidator
TM
Liquidator
TM
TM Pneumatic
Pneumatic
Pneumatic
Condensate Drain
Condensate
Condensate DrainSystem
Drain System
System
Figure
Figure7—13b.
Figure 13b.Liquidator
77 13b. Liquidator
TM
Liquidator
TM
TM
Pneumatic
Pneumatic
Pneumatic
Condensate Drain
Condensate
Condensate DrainTrap
rap
Drain
rapTT
ItemItem
Item Ingersoll RandSystems
Compression
Compression Systems
No. No. Description
Description
Description Qty
Qty
Qty Part
PartNumber
Part Number
Number
01 01
01 Liquidator Drain Trap
Liquidator
Liquidator rap
Drain TT
rap
Drain 1 AAP1797145-00000
AAP1797145-00000
AAP1797145-00000 11
02 02
02 Gate Valve,
Gate
Gate 1/2” NPT
Valve,
Valve, 1/2 NPT
1/2 NPT 2 AAP1401581-00757
AAP1796081-00007
AAP1796081-00007
03 03
03 Check Valve,
Check
Check 1/2” NPT
Valve,
Valve, 1/2 NPT
1/2 NPT 1 AAP1401581-01303
AAP1401581-01303
AAP1401581-01303
04 04
04 BallBall
Valve,Valve,
Ball 1/4”-NPTF
Valve, 1/4 -NPTF
1/4 -NPTF 1 AAP1401581-01450
AAP1401581-01450
AAP1401581-01450
05 05
05 Tube
ube
ubeTT Fitting,
Fitting,
Fitting,1/4”-TUBE
TUBE
1/4 -
TUBE
1/4 /-//
1/4”-NPTM
1/4 -NPTM
1/4 -NPTM 3 AAP0902962-00044
AAP0902962-00044
AAP0902962-00044 33
-- --
-- Condensate
Condensate
Condensate Kit (containing
Kit all the aboveall
Kit (containing
(containing parts)
all the above
the above parts)
parts) 11 AAMB408187-00100
AAMB408187-00100
AAMB408187-00100
Table
able7—13.
Table
T 13.Liquidator
77 13. Liquidator
Liquidator
TM
TM
TM
Pneumatic
PneumaticCondensate
CondensateDraining
Condensate System
Draining
Draining Components
System
System Components
Components
(One
(Onesetset
(One required
set for eachfor
required
required heateach
for exchanger)
each heat exchanger)
heat exchanger)
7—18
18
7 18
7
Parts and Service
Air Piping Parts
Inlet Guide Vane Assembly

01
01
02
Figure 7—14. Inlet Air Piping Components
Item Ingersoll Rand

01 Startup Screen (for 10” pipe) 1 AAP1405344-00017
02 Expansion Joint (for 10.75” O.D. pipe) 1 AAA3404999-00001
Table 7—14. Inlet Air Piping Components
7—19
Air Piping Parts
05
04
02, 03
01
06
07
Figure 7—15. Inlet Guide Vane and Actuator Assembly
Item Ingersoll Rand

10” (250 mm) 8” (200 mm)
01 Inlet Pipe Reducer 1 Consult Factory Consult Factory
02 Pipe Coupling 1 AAP1404961-00217 AAP1404961-00209
03 Gasket, Pipe Coupling 1 AAP1404961-00108 AAP1404961-00607
04 Inlet Guide Vane Assembly 1 AAA3409140-06010 AAA3409140-06008
05 Gasket, Inlet Guide Vane 1 AAP1409511-00005 AAP1409511-00001
06 Actuator Assembly, 110/120-Volt 1 AAP3408596-00001 AAA3408596-00001
Actuator Assembly, 220/240-Volt 1 AAP3408596-05001 AAA3408596-06001
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 7—15 Inlet Guide Vane and Actuator Components
7—20
Parts and Service
Air Piping Parts
02
01
Figure 7—16. Inlet Air Filter Assembly
Item Ingersoll Rand

CTF Type [A]
01 Primary Filter Element [C] AAP1400009-00770
02 Secondary Filter Element [C] AAP1400009-00871
AI-128 Type [B]
01 Primary Filter Element [C] AAP0540009-00089
02 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, 4, or 6 dependent upon the number of inlet ports on the filter housing.
Table 7—16. Inlet Air Filter Replacement Elements
7—21
The Turbo Air 6000 Centrifugal Compressor Handbook Parts and Service
Air Piping
Air Parts
Pipingarts
P
Figure 7—717
Figure 17 Bypass Valve
Bypass V Assemblies
alve andand
Assemblies Packaging
ackaging
P Options
Options
(Bypass Valves
alves are employed
(Bypass
are in Auto-unload
employed
V ControlControl
in Auto-unload only applications.)
only applications.)
04
04
01,
01, 02 02
03
03 08
08
05, 06
05, 06
07
07
08
08
07
07
≤ 1000
≤ 1000HPHP > 1000
> 1000HPHP
Item
Item Ingersoll Rand
Compression Systems
No.No. Description
Description Qty
Qty Part
PartNumber
Number
≤1000
≤1000 Hp
Hp >
> 1000
1000Hp
Hp
01
01 Bypass
BypassValve:
Valve:
- 120 V / 60
- 120 V /Hz60 Hz 1
1 AAP1401581-01501
P1401581-01501
AA AAP1401581-01503
AAP1401581-01503
- 220 V / 50-60
- 220 Hz
V / 50-60 Hz 1
1 AAP1401581-01501
AAP1401581-01501 AAP1401581-01503
AAP1401581-01503
02
02 Kit,
Kit,Seal
Seal 1
1 AAMB408539-00207
AAMB408539-00207 AAMB408539-00301
AAMB408539-00301
03
03 Solenoid
SolenoidValve:Valve:
- 60 Hz Hz
- 60 11 AAP1401581-01166
AAP1401581-01166 AAP1401581-01166
AAP1401581-01166
- 50 Hz Hz
- 50 11 AAP1401581-01233
AAP1401581-01233 AAP1401581-01233
AAP1401581-01233
04
04 Metering
MeteringValve Valve 11 AAP1409585-00000
AAP1409585-00000 AAP1409585-00000
AAP1409585-00000
05
05 Air
AirLine FilterFilter
Line 11 AAP0540016-00073
AAP0540016-00073 AAP0540016-00073
AAP0540016-00073
06
06 Air
AirLine FilterFilter
Line ElementElement 11 AAP0540016-00074
AAP0540016-00074 AAP0540016-00074
AAP0540016-00074
07
07 Flange
FlangeGasket,
Gasket,Bypass Valve Inlet
Bypass Valve Inlet 22 AAP0907411-00008
AAP0907411-00008 AAP0907411-00010
AAP0907411-00010
08
08 Flange
FlangeGasket,
Gasket,Bypass Valve Discharge
Bypass Valve Discharge22 AAP0901597-00006
AAP0901597-00006 AAP0901597-00008
AAP0901597-00008
Table
Table7— 17 Bypass
7 17 BypassValve
V Assemblies
alve andand
Assemblies Packaging
ackaging
P Options
OptionsComponents
Components
7—22 7 23
Parts and Service
Air Piping Parts
02 02
01
03
Figure 7—18. Modulating Blow-Off Valve (MBOV) Assembly
Item Ingersoll Rand

Modulating Blow-Off Valve Assembly [A]
01 - 2.0” (50 mm) Ball Valve 1 AAP1401581-02037
02 48 VDC Actuator with Positioner 1 AAP3408596-02203
03 - 3.0” (75 mm) Butterfly Valve 1 AAP0540008-01119
Notes: [A] Valve assemblies are complete with components mounted and integrally piped.
Table 7—18. Modulating Blow-Off Valve Assemblies
7—23
Air Piping Parts

Actuator
Figure 7—19. Blow-Off
Silencer
Solenoid
Filter Regulator
Lock-Out
Valve
Valve
Body
Figure 7—21. Automatic Block Valve
Figure 7—20. Discharge Air
Assembly
Check Valve
Connections
Model Overall Ingersoll Rand
Inlet [A] Discharge [A] Length Part Number
BMSV-6 2” (Flanged) 8” (Flanged) 78” (2000 mm) AAP0540010-01302
BMSV-8 3” (Flanged) 10” (Flanged) 71” (1800 mm) AAP0540010-01303
LCV-10 4” (Flanged) 10” (Flanged) 71” (1800 mm) AAP0540010-01304
6” (Flanged) 14” (Flanged) 96” (2438 mm) AAP0540010-07335
Notes: [A] Expressed per ANSI (USA) Standards for piping (in inches).
Table 7-19. Blow-Off Silencers
Ingersoll Rand
Description Part Number
5” Valve (for > 900 HP) AAP0540024-00186
6” Valve (2 Stage) AAP0540024-00187
Table 7-20. Discharge Air Check Valves
Ingersoll Rand
Description Part Number
6” Valve, 110/120-Volt AAP0540008-00927
6” Valve, 220/240-Volt AAP0540008-00928
4” Valve, 110/120-Volt AAP0540008-00800
4” Valve, 220/240-Volt AAP0540008-00823
Table 7—21. Automatic Block Valve Assemblies
7—24
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 Operator’s Data Log.)
DCS — the abbreviation for Distribution Control System.
Design Standard — the operating condition of the compressor to which the aerodynamic performance
is rated, generally a “worst case” or “hot summer day” condition.
Distribution Control System — a functionally related group of electronic devices used for industrial
machine sequencing and operation.
Diffuser — the component of a compressor stage that helps convert the high velocity airflow into a
pressure rise.
Discharge Pressure — the air pressure measured between the compressor exit and the compressor
discharge check valve.
Display — the screen that presents operating information on the 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.)
EVC — the abbreviation for Electric Vapor Coalescer.
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.
Operator’s Data Log — a periodic record of compressor operation.
Opposite Drive End — the end of a rotating machine that is opposite of the drive shaft extension.
Optical Coupler — an electronic device similar to an electrical relay (also referred to as OPTO).
OPTO — the abbreviation for Optical Coupler.
Panel Cooler — an optional heat exchanger that is used to cool the interior of the 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.
Revision History:
ECO
Rev ID Number Date Author Change Description
01 1938315 January 2005 Initial Release
02 2127389 September 2006
03 2318415 October 2008
04 2561476 June 2011
05 4775599 January 2016 Jason M. Smythe
Department Approval Date

Prepared By: Digitally signed
by: jason.
J. Smythe Project Management smythe@irco.
jason. com
DN: CN = jason.
smythe@ smythe@irco.
irco.com com
Date: 2016.02.02
14:07:46 -04'00'
Tom
Reviewed By: Digitally signed by Tom
T. Bass Engineering Bass
DN: cn=Tom Bass,
o=Ingersoll Rand, ou=CTS,
Bass
email=thomas.bass@irco.co
m, c=US
Date: 2016.02.04 09:33:51
-05'00'
Approved By: charles. Digitally signed by: charles.
impastato@irco.com
C. Impastato Engineering impastato DN: CN = charles.impastato@irco.
@irco. com
Date: 2016.02.04 10:08:52 -05'00'
com
Approved By:
Spec to be electronically distributed to Centrif - CTC-MSG IL & EDR Distribution Listing in

Global Contacts. Ref. DEP-1108

The Turbo Air 6000 Centrifugal Compressor Handbook AAEDR-H-082 Rev 05 TA6000

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Contents

Engineering Data Release

The Turbo Air® 6000

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 Ingersoll Rand

♦ The Turbo Air Centrifugal

About Ingersoll Rand

To learn more, visit centrifugal.ingersollrand.com

The Turbo Air 6000 Centrifugal Compressor

The Most Advanced

The Maestro Control System

Other Design Features

1. Horizontally split gearbox casing

Figure 1—2 The Turbo Air 6000 Centrifugal Compressor

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

There are no other warranties—express, statutory, or implied—including those of merchantability

1. Loss of use of productive facilities or equipment.

In this section, the reader will learn about:

♦ General Compressor Specifications

♦ Alarm and Trip Specifications

♦ Compressor Lubricant Requirements

General Compressor Specifications

Compressor Rating (hp) 800 900 1000 1250 1500

Item Weight Item Weight

Connection Size Connection Size

Discharge Connection Load Limits

Bolt Torque Values

Bolt Size (Diameter) Torque Range

General Compressor Specifications

Compressor Rating (hp) 800 900 1000 1250 1500 1700

Drive Coupling Bolt Torque Values

Coupling Type English ft - lbs Metric Nm

Cold Alignment Specifications for Main Drive Motors

General Compressor Specifications

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 2—1 Ingersoll Rand Oil Specification

Other Oil Selection Considerations

• Use only Ingersoll Rand TurboBlendTM Lubricating Oil or a high-quality turbine

Inspection and Testing

• Color and Appearance

Other Required Lubricants

Motor Bearing Lubricants

Inlet Guide Vane Assembly Drive Screw Grease