Compressor IRCentacManual

Centac Training
Manual
Overview
Principles of Operation
Planning & Installation
Commissioning
Airend Overhaul - 1CV
CMC Controls and Troubleshooting
Maintenance
Copyright Notice
 2001 Ingersoll-Rand Company
Proprietary Notices and Disclaimer
PROPRIETARY NOTICES
Copyright 2001 INGERSOLL-RAND COMPANY
CONFIDENTIAL AND TRADE SECRET INFORMATION. This manual contains confidential and
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“Proprietary Matter”). In consideration of the disclosure of the Proprietary Matter herein to the
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extent necessary to sue or service the equipment disclosed herein; and shall disclose such
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Matter is necessary. This manual shall be returned upon request by Ingersoll-Rand Company.
The unauthorised use of this manual may be punishable by law.
DISCLAIMERS
PROVIDED “AS IS”. THIS MANUAL AND THE CONTENTS THEREOF ARE PROVIDED “AS
IS” AND WITHOUT ANY IMPLIED WARRANTIES.
Introduction
Introduction & Index
Introduction Section 6—Airend Overhaul for Models

The Basic Centac Training Manual has been C250/C350
designed to provide you with fundamental This section is under development
knowledge about centrifugal air compressors. Its
purpose is to give you a grounding in the theory of Section 7—CMC Controls
pressure, temperature and volume, as well as the User Interface ................................................1-3
construction and operation of Centac Compressors. System Folder & Page Descriptions ..............4-5
Info Folder & Page Descriptions ....................6-8
The manual also prepares you for the hands-on Setting Folder & Page Descriptions.............9-12
practical training that you will receive on the Training Procedures ................................................13-20
Course. Short Test ....................................................... 21
Section 8—Trouble Shooting

Index CMC Controls ................................................1-2
Input/Output (I/O) System..............................3-8
Section 1—Overview Temperature Monitoring ..............................9-15
Machine Description ..................................... 1-4 Valve Control System ................................16-18
Centrifugal Compressor Product Line ........... 5-8 Pressure Monitoring System......................19-23
Digital Input System...................................24-25
Section 2—Principles of Operation Control Power System (CPS) ....................26-28
Basic Principles of Centrifugal Controller Problems (CMCS) .....................29-30
Compressors............................................ 1-5 Symptoms Possible
Changing Air Inlet Temperature Causes & Corrective Action..................31-34
& Pressure ............................................. 6-15 Short Test ..................................................35-38
Inlet & Bypass Valve Operation ................ 16-22
The Actuator.............................................. 23-24 Section 9—Maintenance
Butterfly Inlet & Bypass Valve ................... 25-26 Scheduled Preventative Maintenance ...........1-3
Regulation & Coalescing Filter.................. 27-29 Maintenance Procedures.............................4-10
Short Test.................................................. 30-31 Short Test ....................................................... 11
Section 3—Planning & Installation
Receiving Handling & Storage ...................... 1-5
Installation Planning ...................................... 6-9
Air Piping................................................... 10-17
Water System Piping................................. 18-21
Electrical Connection ................................ 22-23
Lubrication................................................. 24-27
Weights & Dimensions ............................. 28-29
Shaft Alignment......................................... 30-37
Section 4—Commissioning
Pre-Start Checklist ........................................ 1-3
Initial Start Preparation.................................. 4-6
Natural Surge Test ........................................ 7-8
Installation Check List .......................................9
Short Test........................................................10
Start up Registration Form ........................ 11-16
Warranty and Liability................................ 17-18
Section 5—1CV Airend Overhaul

Disassembly of Stage Components .............. 1-4
Disassembly of Bull Gear from the casing .... 5-6
Assembly of Bull Gear into the Casing.......... 7-9
Assembly of Stage Components............... 10-14
Impeller/Diffuser Clearance
Setting Procedure .................................... 15-19
Basic Centac Training Manual

Ingersoll-Rand (Asia Pacific) Service Team
Issue: 01/Australia, February, 2003
Basic Centac Manual
Overview
Section 1
Machine Description ...................................................1—4
Centrifugal Compressor Product Line ........................5—8

Overview Section 1
Machine Description
Machine Description
The Centac compressor is a dynamic centrifugal air
compressor driven by an electric motor. The
compressor and driver are direct coupled and the
entire unit is mounted on a common baseplate with
its own lube system, control system, and auxiliaries.
The compressor package contains:
• A main driver that directly drives a bullgear that is

common to all stages.
• Compression stages consisting of an impeller
mounted on its own shaft, enclosed within a
common cast iron casing
• Rotors consisting of an integral pinion gear driven
at its optimum speed by a common bullgear.
• An intercooler that is mounted within each stage.
• A moisture separator and a moisture removal
system are supplied after each cooler to remove
condensate.
• In some compressor configurations an aftercooler
is also mounted on the package.
Discharge 1st Stage

Main Oil Pump
Bullgear Shaft Seal Bullgear

Moisture
Separators
Plain
Bearing
Impeller Coolers
Inlet 1st Stage

Reverse
Thrust Bearing
Thrust Bearing
Pinion
Diffuser
Plain Vibration
Bearing Probe Cross section of an IR Centac Compressor
Carbon Ring
Seals

Issue: 01/Australia, March, 2003 Page 1
6 This sequence (1 to 5)
repeats in each succeeding
Section 1
stage until the compressor

5 achieves the desired
4 operating pressure.
3 Air then passes
The built-in intercooler through a stainless
The stationary
removes the heat of steel moisture
diffuser section
compression, which separator in a low
converts velocity
improves efficiency. velocity zone to
to pressure.
remove condensate.
1
Page 2
Air enters the
Machine Description
compressor
through the
machine mounted
inlet control valve.
How the Centac compressor works

Overview
Issue: 01/Australia, March, 2003

2 The air flows to the
first stage where
the impeller imparts
velocity to the air.
Overview Section 1
Machine Description
Rotor Assemblies Intercoolers

Each rotor assembly The Centac cartridge
consists of an efficient cooler is internal to the
and high quality compressor casing. The
stainless steel coolers are donut type, with
impeller and a the water over the tubes.
removable thrust The tubes are internally
collar mounted on a finned. Air passes through
the tubes while the water
helical geared pinion shaft. The makes a number of counter
impeller is secured to the shaft passes to the air flow. This
by a taper attachment and the arrangement results in highly efficient heat transfer
thrust collar is secured to the or exchanger. The internal fin design, along with the
shaft with a polygon straight through tube design, produces the best heat
attachment. All rotating parts transfer and lowest pressure drop.
are dynamically balanced as a
complete assembly. Cooler Design Features:
• Lead-free cooler
design and
Bearings construction
Thrust loads are absorbed at • Straight tube
each pinion by a design
hydrodynamic thrust bearing.
• Rolled tube to
The thrust bearings are
header bond
designed to maximize load
carrying capacities and to • Large diameter
minimize power loss. tubes equally spaced for accessibility during
Thrust Bearing cleaning.
The journal bearings are • TEMA constructed leak free brass headers
babbitt lined, fixed tilted pad design for maximum
stability and load capacity with minimum power loss.
Moisture Separators
Bullgear bearings for Centac compressor models The moisture separator
incorporate a hydrodynamic design. is a stainless steel mesh
screen type construction.
The thickness of the
Seals separator is designed to
A single cartridge seal is mounted separate the maximum
in the plain bearing housing amount of moisture at a
behind each impeller. Each minimal pressure drop.
cartridge consists of three, one The separators are
piece, fully floating non-contact located at points in the compressor where air
carbon rings. One ring is used as velocities are relatively low permitting effective
an air seal and the remaining two moisture separation.
as oil seals. Buffer air supplies air
to the oil seals assuring that lube
oil is not drawn past the seals, thus ensuring oil free Vibration Probes
air. A non-contacting
vibration probe is
mounted in each
Diffusers stage next to the
A diffuser is located between each plain bearing. The vibration probe measures the
impeller and cooler. The diffusers radial vibration of each rotor assembly. The probe is
are designed for maximum connected to a vibration transmitter. First stage
efficiency while limiting physical vibration protection is provided as standard on all
size, thereby keeping the compressors.
compressor as compact as
possible.

Overview Section 1
Machine Description
Casing 5. The remainder of the lubricant passes through

The gear case consists of a casing and casing the compressor and drains into the reservoir.
cover. The joint between the casing and cover is
vertical. This bolted assembly is only opened for All the necessary instruments and safety devices are
servicing the bullgear or its bearings. The cooler included in the lubrication system to protect the
assemblies, which are mounted onto the casing, can compressor. The compressor protection devices in
be easily removed for inspection or for dismantling the lubrication system include:
the rotor assemblies, diffusers, bearings, or seals. • A pressure transmitter senses oil pressure and
the compressor low oil pressure.
Compressor Driver • An RTD and temperature-transmitter senses
The Centac compressor is furnished with an electric abnormal oil temperature. An interlock is also
motor that is flange mounted and direct coupled to provided to prevent the unit from being started if
the compressor bullgear. Motor alignment is fixed by oil temperature is below the minimum.
the flange design and no adjustment is required. • A wet element type lube oil reservoir heater is
Safe and efficient operation of the main driver is of supplied to ensure adequate oil temperature for
prime importance to the overall performance of the compressor start-up.
compressor package. Because operation of the • The lube oil reservoir has provisions for a lube oil
main driver is critical, manufacturer's literature is drain with plug. The customer may install a valve
supplied as part of the compressor package. The on the connection to facilitate changing lubricant.
customer should refer to the driver instructions for a
• An oil temperature control device is supplied that
detailed description of the driver supplied.
automatically regulates proper oil temperature to
the bearings by mixing hot and cold lubricant.
Lubrication System
The lubrication system for the compressor is
completely self-contained and mounted on the
baseplate. This system is designed to provide clean
lubricant to the compressor bearings and gears for
operation. See the Process & Instrumentation
Diagram for the oil flow schematic.
The lubricant is drawn from the oil reservoir located

in the baseplate and passes through the oil pump.
The oil pump is an oversized positive displacement
type pump driven by an electric motor. The
discharge pressure of the pump is controlled by a
relief valve downstream from the oil cooler. The oil
pump is equipped with an inlet strainer for protection
against foreign particles. In the event of a main
driver or power failure, an overhead reservoir in the
casing will continue to supply lubricant to the
bearings and gears during coast down. The lubricant
follows this path:
1. The lubricant passes from the oil pump to the oil
cooler, where the oil is cooled to between 105°
and 115°F.
2. Lubricant from the cooler is mixed with hot
lubricant in the thermostatic control valve.
3. The lubricant then flows to the oil filter. The oil
filter supplied is a 10 micron treated paper
element type filter..
4. Next, the lubricant passes from the oil filter to the
bullgear and pinion bearings to the reservoir. The
relief valve, that is located after the cooler, allows
the input pressure to the compressor to be raised
or lowered by adjusting the valve setting.

Overview Section 1
Centrifugal Compressor Product Line
Centac I Original Centac baseplate mounted motor 1Pc. Cooler Cover
Code CMF HP Stages Comment

0C 1200-2000 300-450 2-3 stage Obsolete
1C 2100-3000 450-700 3-4 stage Obsolete
2C 3500-5500 800-1250 3, 4, 5 stage Obsolete
3C 6000-9000 1250-2500 3, 4, 5 stage 5th Stage is high pressure
4C 9000-15000 1250-2500 3, 4, 5 stage 5th Stage is high pressure

Overview Section 1
Centac II New version Centac baseplate mounted motor has cooler “Barrels”.

EPC 1300-2200 450-800 3 stage
1BCC 1400-2200 350-500 2 stage
1ACII 1500-3000 350-700 2 stage
2CC 2100-3500 350-800 2-3 stage Coupled CV2
2ASB 3000-4300 1100-1700 3 stage

2ACII 3200-5500 800-1250 2-3 stage
2ACII
Engine
Drive
2ACII
Process
Package
2CII 3200-4500 800-1500 2, 3 stage & DF 3rd stage is high pressure

3CII 6000-9000 1000-2000 2-3 stage
5CII 12500-30000 2000-5000 2-3 stage

Overview Section 1
CV Flange mounted motor, has cooler ”Barrels”

0CV 350-800 100-200 2 stage
1CV 800-1400 200-350 2 stage
1ACV 1500-3000 350-700 2 stage
1BCV 1400-2200 350-500 2 stage
EPF 1300-2200 450-800 3 stage
2CV 2100-3500 350-800 2-3 stage

Overview Section 1
CH Single stage machines. Flange mounted motor, similar to CV

3CH 400-800 75-125 Single stage
CVO
4CH 700-1400 100-150 Single stage
CV1
5CH 1500-3000 125-700 Low, Medium and High Pressure
Single stage machines, foot mounted motor.
5CCH 1500-3000 125-700 Low, Medium and High Pressure
6CCH 3200-5500 300-600 Low, Medium and High Pressure
X-Flo Single stage machines. Airend purchased from KHI, packaged in Mayfield.
Code CMF PSI Comment

L Series 2000-75,000 5-12
H Series 2000-75,000 12-27
R Series 5000-15,000 10-37
ST Series 1000-75,000 Steam Compressor

Basic Centac Manual
Principles of
Operation
Section 2
Basic Principles of Centrifugal Compressors .............1—5
Changing Air Inlet Temperature & Pressure...............6—15
Inlet & Bypass Valve Operation..................................16—22
The Actuator ...............................................................23—24
Butterfly Inlet & Bypass Valve ....................................25—26
Regulation & Coalescing Filter ...................................27—29
Short Test ...................................................................30—31

Principles of Operation Section 2
Basic Principles of Centrifugal Compressors
compressors as well as pumps. The term "head" is
In this section, you will learn one of these terms. In the centrifugal compressor, the
• Basic principles of Centrifugal compressors amount of work done in moving one pound of air
• Characteristic Pressure verses flow plot through the compressor is the "head”. The dimension
of head is foot-pounds per pound (ft-lbs/lb) and is a
• Actual head plot measure of work.
• Surge
• The effects of changing air inlet temperature The process that air undergoes in the centrifugal
and pressure compressor (velocity slows, pressure increases) can
be re-stated as: If flow decreases, pressure increases.
• Inlet Value control of throttle range
• Bypass valve control of system low flow This re-statement is true because it is a volume-of-air
demand that has velocity. The volume measurement used is
• Chock and Stonewall cubic foot or cubic meter of air. A volume that is
moving past a point on a per-unit time basis has a
rate. The term for rate is "flow" and its dimension is
Centac compressors are classified as dynamic cubic feet per minute (ft 3 /min).
compressors of the radial flow centrifugal type. A
Centac compressor is also classified as a constant psia
pressure-variable volume machine. Pressure PSIA
The compression process in a dynamic compressor ft/sec

is quite different from that of the reciprocating or
rotary screw type compressors. In a centrifugal
compressor work is done on the air by centrifugal
forces as the air passes through a rotating impeller.
The work input takes Temperature oF
place as an increase in
pressure and velocity
(speed) of the air flow
through the impeller. The
air flow subsequently
loses velocity in the
diffuser section.
Impeller Velocity (ft/sec)
The diffuser is a static
component that guides SUCTION IMPELLER RADIAL
DIFFUSER
DISCHARGE
DIFFUSER
the air flow as it leaves
the impeller. The Figure 1. Pressure, temperature and velocity
slowdown in the flow relationship in a centrifugal compressor
results in an additional
pressure increase. In a centrifugal compressor, at constant speed and
constant inlet cfm, the amount of work required to
Figure 1 shows the move one pound of air (head) remains constant
Diffuser velocity, pressure and regardless of inlet conditions as a study of Table 1
temperature changes reveals. The Items marked (*) on Table 1 are changes
that occur in a theoretical single stage centrifugal from the column labeled Design.
compressor. About two-thirds of the pressure
developed occurs in the impeller with one-third • Notice the horsepower changes when inlet air
produced in the diffuser. pressure changes.
• Observe what happens when inlet air temperature
The terms used in describing the process of
changes or as different density air enters the
compression in the centrifugal compressor come
machine.
from centrifugal pump theory.
• Take special note of how head remains constant
Air can be considered as a fluid, and the same as various conditions change.
thermodynamic principles and terms apply to

The head (work) remains constant, but the pressure characteristic pressure versus flow plot for the
developed will vary approximately as the density of theoretical compressor is a straight line that slopes
the inlet air. Air density varies with temperature, downward to the right.
humidity, pressure, and weight of different gases.
Table 1 examples use dry air (Humidity = 0%) for Notice, in Figure 2, how the pressure decreases as
clarity purposes. flow increases. The ideal characteristic plot is
affected by various energy losses in a real
The terms "head" and "pressure" are used compressor. A pressure versus flow curve for a real
interchangeably when discussing a compressor. or actual compressor is shown in Figure 3.
This is common terminology, but be aware that there
is a marked difference between the two. While 25 This plot is the ideal curve minus the energy losses.
psia is said to be the head the compressor is The dotted line shows energy losses.
producing, this is not the same head as the ft-lbs/lb.
Figure 3 illustrates that the actual curve is not usable
The volume of air that enters a centrifugal over the entire range of zero-to-maximum flow. On
compressor has several interchangeable words to the left of the actual curve, the pressure is shown to
define it. The terms for the moving volume are rise as flow increases. This rise cannot occur since;
capacity, flow or through-put. to remain stable, pressure must decrease as the
flow increases. The compressor is not usable in the
part of the curve where pressure is shown to
Item Design 1 2 3
increase as flow increases.
Inlet pressure (psia) 14.4 12.4* 14.4 14.4

Inlet temperature (°F) 60 60 100* 60
Molecular weight 29 29 29 20*
Relative Humidity (%) 0 0 0 0
Density (lb/ft 3 ) 0.0749 0.0645 0.0695 0.0516
PSIA
Total lbs/min. (W) 749 645 695 516

Discharge pressure (psia) 25.4 21.85 24.45 21.60
Discharge temperature °F) 180 180 220 142
Head (ft-lbs/lb) 17,490 17,490 17,490 17,490
BHP Horsepower 509 438 471 350
Characteristic Pressure versus Flow Plot

The compression process diagram for a theoretical Inlet (CFM)
single stage compressor with a backward-leaning
bladed impeller operating at constant speed is
Figure 3. Actual pressure plot
shown in
Figure 2. On the right end of the actual curve, the pressure
decreases in nearly a straight line downward as the
The ideal flow increases. For very small changes in flow in this
area there will be a large, change in pressure.
A centrifugal compressor cannot function over the

entire zero-to-maximum flow range because of the
PSIA
limits imposed by the losses.
The useful part of the actual pressure curve is

between the left and right limit areas. The pressure
in this middle area will decrease as flow increases in
a predictable and stable fashion. Figure 4 shows the
Inlet (CFM)
Figure 2. Ideal characteristic pressure vs flow plot

actual curve with the unusable areas eliminated. The When the discharge valve is closed, the compressor
unusable area on the left is where surge occurs and is ingesting more flow than the discharge valve can
the unusable area on the right is where choke pass. Pressure rises toward point P as the flow
occurs. decreases. At point P, surge occurs and the
operating point jumps to point J with reverse flow.
Figure 4 is a characteristic curve. It is the useful Reverse flow is on the left. The reversal of flow is
range curve, normally without the surge and choke accompanied by a noise that may sound like
labels, that is commonly seen when centrifugal "whomp”.
compressors are discussed.
The flow reversal causes pressure to decrease
along line J - K. Forward flow re-establishes as it
crosses the pressure axis. The flow at point Q is
larger than the flow that the discharge valve can
pass, so pressure starts to increase again along line
Q - P. When pressure reaches point P, the surge
process repeats. Figure 5 provides a way to
PSIA
visualize the surge phenomenon. This graph in

reality has large imperfections. The reality of surge
is that at the peak pressure, flow reverses, a noise is
SURGE heard, pressure drops, a rapid increase of positive
flow occurs, flow again decreases, pressure again
rises, surge is reached and the process repeats.
USEFUL OPERATING RANGE
CHOKE The terms "pumping" and "surge" are used

FLOW interchangeably. Pumping is a very descriptive word
Figure 4. Useful operating range for the appearance of surge. As soon as the surge
reversal occurs, the compressor can re-establish
Surge positive flow. The re-occurrence of surge happens
quickly and repeats until such time as actions to un-
Surge occurs at the peak pressure of the
load or otherwise stabilize the flow through the
characteristic curve and it exists because of the way
machine takes place. This repeating process of
losses affect ideal compression. When the
surge has the name pumping because of the in-out
compressor is in surge it is unstable and cannot
aspect of the flow.
perform a useful function. Surge is a momentary
reversal of flow in a compressor.
An operational machine can experience "incipient
surge" or "stall”. This is where a stage element,
Figure 5 shows a graphic model of the phenomenon
impeller, or diffuser, experiences a flow separation.
of surge. Assume a discharge valve alone controls
This separation is a stall that is not severe enough to
flow for a compressor and flow is at point Q.
constitute a full stage surge. The stage can remain
CYCLIC SURGE MODEL (LARGE VOLUME in the stall condition. It is very near the point of full or
complete surge when stall is occurring. A minor flow
disturbance in this condition can trigger a stage or
whole machine surge. Surge triggering can occur in
various areas in the impeller or diffuser.
The peak pressure point on the characteristic curve

is called the "natural surge point”. In multi-stage
machines, each stage has its own natural surge
point. A controlled test that causes a compressor to
reach its natural surge point checks the
compressor's suitability for use. Degradation of
internal components is indicated from the test if the
PSIA
machine surges at a pressure that is less than a

baseline reference. The compressor aerodynamics
are assumed to be good if the natural surge test
pressure remains the same as the reference. A
+ FLOW
"natural surge test" is usually done as part of an
- FLOW O
initial start-up to obtain on site baseline data.
Figure 5. Model of surge flow reversal

The physical geometry (shape) of the parts in a the stonewall point results in a situation where
specific compressor system determines its surge further flow increases stop as if a stone wall has
point. Damage or foreign matter build-up in the been placed in the flow path.
compressor elements can change the shape of
these parts. A reduced surge point on an operational The technical definition of stonewall is: That point on
compressor is quite often the result of a characteristic curve when the flow velocity reaches
environmentally caused material build-up on the the speed of sound. Flow near the speed of sound
diffuser and impeller. The build-up alters the shape results in a condition where the characteristic curve
of the impeller or diffuser. Changing the physical is vertical or nearly so and any increase in flow
shape changes the shape of the characteristic stops. There is a stone wall in the path of flow..
curve. The new curve describes a new lower surge
point. This new surge pressure may be near, at, or In cases of compressor deterioration, or if non-
below normal set pressure and if it is, surge occurs specification parts are installed, it is possible that a
when normal operation is attempted. lower stage in a multi-stage compressor may be in
choke, which in turn starves the downstream stages,
Surge happens when the bypass valve malfunctions causing surge or incipient surge.
in a way that limits flow. It happens when the system
demand decreases faster than the inlet valve can Choke is normally not associated with damage to
react to the decrease. When the inlet valve is the compressor as in the case of surge. Choke is an
improperly set up or adjusted, surge can occur. Any aerodynamic limit that causes no damage; however,
situation where the system pressure becomes if pressure becomes unstable in the choke situation,
greater than compressor discharge will likely result this could result in thrust bearing hammering as
in surge. An example is the high side pulsation pressure loads rapidly lessen and increase.
pressure from a reciprocating compressor feeding
the same header that a centrifugal is feeding. Effect of Air Density
The density of the inlet air affects the pressure
Surge is an abnormal operational event and, if developed by the compressor. Density of air is
allowed to continue, will eventually cause damage. influenced primarily by temperature, pressure, and
This damage is in the form of over-worked thrust humidity. The dimension of density is pounds-per-
bearings, since on reversal of flow, thrust reverses. cubic-foot at STP conditions. STP is the abbreviation
Pumping will "hammer" the thrust bearings over for standard temperature and pressure of air. The
time. Damage caused by overheating can happen values used for STP in the gas compression industry
with surge. When flow reverses, hot air (from the are 6°F, 14.7 psia, with a relative humidity of 0%.
heat of compression) flows to the inlet side of the The STP temperature used by general science and
impeller. The hot air receives more heat when it is industry is usually 6 °F
re-compressed. The temperature cycle is self
limiting, but very high temperatures are possible. As air temperature increases, the density decreases.
The occurrence of surge without pumping is not in The opposite is true for colder air. As air pressure
itself a damaging event. Performance of a natural increases the density increases. Decreasing
surge test or an occasional surge event will do no pressure results in decreasing density. The more
harm. It is the situation where rapid recurring surge water vapor that is in the air, the lighter a cubic foot
or pumping continues over a period of time where of air will be. On a very hot humid day, the air is light
damage may occur. and on a very cold dry day the air is heavy.
Choke and Stonewall The formula for the density of dry air is:
The area designated as choke is on the right side of
Figure 4. Choke is what limits the maximum flow Density = 1.325 X (Pb+T)
through the compressor. When in choke, the
compressor physically cannot pass any more air Where Pb = barometric pressure in inches of
volume due to the losses being encountered either mercury, and
in the compressor itself or in the discharge system. T = temperature in degrees Rankin
These losses can be considered, simply, as (°R = °F + 459.7).
resistance to flow. Choke is a fixed physical limit of
the compressor. Dry air at 60°F weighs approximately 0.074 lbs/ft3 . If
the temperature increases to 100°F, the air will
The point of demarcation between the useful range weigh 0.064 lbs/ft3.
and choke has the name "stonewall”. The name is
appropriate since an attempt to increase flow above

One pound of dry air at 60°F has a volume of about To summarize the effect of inlet density
13.5 ft3. At 100°F, one pound of air expands to fill changes:
15.6 ft3 .
The way density affects dynamic compression may • Higher density generally increases compression
be explained by way of an analogy. ratio, increasing the discharge pressure.
• A higher density generally increases the amount
Imagine attaching a string to a Ping-Pong ball and of work required to move a fixed volume of air.
then spinning it around in a circle. There will be • Lowering density generally has the reverse
some tension on the string as the ball goes around. effect.
This tension can be viewed as pressure. Now • In relating the density effects to the characteristic
imagine doing the same thing with a golf ball. The curve; the curve will move downward (less
tension on the string will be significantly higher. The pressure at same volume) with lower density air.
tension is higher because the golf ball weighs more
than the Ping-Pong ball. The heavier spinning object • The curve shifts upward with higher densities
exerts more tension or pressure. (higher pressure at same volume).
Similarly, denser (heavier) inlet air causes more

pressure to develop. Less dense (lighter) inlet air
develops less pressure. The density of air affects the
compression ratio of the compressor. The
compression ratio will increase with heavier air and
decrease with lighter air.
Density significantly affects how much work the

compressor is doing at any given time. It takes more
work to move heavier air..
As an example:
Assume a compressor will transfer 10000 ft3 per

minute at dry air inlet conditions.
• At 14.4 psia and 60°F, the compressor will

transfer {(10000 ft3 /min.) X (1 lb/13.5 ft3 )} = 749
lbs/min.
• At 14.4 psia and 100°F it will transfer 695 lbs/
min.
Less work is done on the 10000 ft3 in one minute at

100°F than at 60°F.
• At 60°F, the model's compression ratio is (25.4

psia +14.4 psia) =1.764.
• At the 100°F inlet condition, the compression
ratio is 1.698.

Changing Air Inlet Temperature & Pressure
The effects of Changing Air Inlet Barometric pressure change effect
Temperatures and Pressures
Discharge PSIA
In the graphs that follow, Figures 6, 7, and 8, no 14.4 PSIA
control valves are considered. The compressor is (Mayfield)
operating with a fully open inlet and with a fixed Low altitude
discharge resistance. Adding control valves alters
the effect that changing temperatures have on
compressor operation.
12.4
Discharge PSIA
PSIA
(Denver)
High
altitude
20oF
60oF Inlet (ICFM) 1000
Figure 7. Effect of decreased inlet pressure
100o Figure 7 describes the effect of changes in inlet

pressure. As inlet pressure decreases, density
decreases, discharge pressure decreases, and as
with all reductions in density, the work required to
move a fixed volume also decreases.
Altitude (geographic location) has a very significant

Inlet (ICFM) 1000 effect on the compressor. Weather-related barometric
pressure changes have an effect but it is usually not
Figure 6. Effect of change in inlet air temperature
significant. Figure 7 uses the city of Mayfield at low
altitude and the city of Denver at high altitude as
In Figure 6, effect of change in inlet air temperature, examples of how altitude affects the compressor.
the 60°F curve is the normal curve. When inlet Geographical location (altitude) is a vital consideration
temperature increases to 100°F, the curve shifts in compressor design.
down. Hotter air is less dense, pressure ratio is less,
and for the same ft3 /min flow, there is a reduced A multi-stage compressor has not been discussed yet,
pressure. At the same time, the amount of work but consider what would happen in a two-stage
required has decreased because there is less weight machine that has air cooling between the first and
to move. The volume remains the same, but second stage. Cooling water temperature has a very
because of its lower density, it weighs less and the significant effect on a compressor because of the
lbs/min flow has decreased. When flow is related to large temperature swings possible. The effect of high
the weight of air, it is given the name "mass flow," or low cooling water temperature, by itself or
for the air mass weight that is being compressed. combined with a high or low inlet air temperature on a
With hotter air, the surge point decreases. multi-stage compressor, can make the machine
practically useless from an air production capability
The opposite effect occurs when inlet temperature point of view. If the first stage has a low pressure due
decreases. The curve rises and the surge line to hot summer air, the second stage will have a low
moves to the left. The compressor's surge will be at pressure capability because its inlet pressure is lower.
a higher pressure with decreased inlet air Couple this low pressure with the effect of high
temperature. Pressure ratio will increase as the second-stage inlet temperature due to a
density of inlet air increases and more work will be malfunctioning cooler, and it should be easy to see
required to move the fixed heavier volume of air. that the overall compressor output is in big trouble.
Figure 8 is a graph of what may happen in the event
of these combined changes.

Discharge PSIA Changing Air Inlet Temperature & Pressure
0oF Air
plus
40oF Water
Normal
95oF Air
80oF Water
110oF Air
plus
110oF
Inlet (ICFM) 1000
Figure 8. Combined effect of high and low temperature air and

cooling water

The Centac Performance Curve The function of the Centac compressor is to provide
The Centac performance curve is an expansion of the oil-free compressed air at a specified pressure over
centrifugal compressor characteristic curve. A thorough a range of user-flow requirements. Controls allow
knowledge of the Centac performance curve will the CENTAC to perform its function. Figure 10 is a
provide a useful tool in the actual operation and stylized sketch of a single-stage centrifugal
maintenance of the Centac. compressor that has the valves necessary for
control. This stylized Centac compressor is the
model for discussions that follow.
Surge Radial
Diffuser
Design
Point
Impeller
100% Inlet Valve
PSIA
Drive
Shaft
Unloaded
Bypass Valve
Capacity (ICFM) 100%

SYSTEM
Figure 10. Stylized single-stage compressor with fixed position

inlet and bypass valves
Related
hp Figure 10 corresponds with Figure 9 and shows the
compressor running at design inlet conditions of
95°F inlet air temperature, a humidity of 0% and a
pressure of 14.4 psia at the fixed open inlet valve
BHP
entrance. In this condition, as long as inlet

conditions don't change, the compressor will supply
the design point flow at the design pressure. The
bypass valve in this example is fixed at fully closed
Capacity (ICFM) 100% and the full amount of air entering the compressor is
being discharged into the system.
Figure 9. Stylized CENTAC performance curve
If the system flow demand decreases, as it will when
A design point appears on the performance curve. A the user shuts a system air valve, the pressure will
Centac compressor is guaranteed to produce the rise as flow decreases. The pressure increase
design point flow and pressure. follows the performance curve as flow decreases. As
additional valves in the system close, the flow
For example: a machine may be built with a design decreases and the pressure rises higher and higher
point of 100 PSIG at 1800 ICFM. The impellers and until the pressure reaches the surge point. At the
diffusers will be configured for this specification and the surge pressure, the compressor will experience
head will be fixed by this configuration. The design pumping until such time as the system is able to
point and head determine what minimum horsepower accept more flow. Opening system valves causes
driver needs to be used. flow to increase and pressure to decrease along the
performance curve, re-establishing the design flow
The set of graphs that make up the performance curves and pressure.
include the brake horsepower versus capacity chart and
the discharge PSIG versus capacity chart. The
horsepower curve moves up and down with the effects
of changing density.

The addition of a discharge pressure sensor and a
device to open and close the inlet valve in proportion
to the discharge pressure provides the means for
constant pressure-variable volume-compressor
control. Figure 11 shows the stylized compressor
with a control system. The control system includes a
pressure sensor, a controller and an inlet valve
actuator.
Radial
Diffuser
Impeller
Inlet Valve
Drive Shaft
Inlet
Valve
Actuator
Bypass Valve
SYSTEM
Pressure
Sensor
Controller
Figure 11. Stylized single stage compressor with controlled inlet

valve

Inlet Valve Control of Throttle Range Inlet valve minimum closure

The control system shown in Figure 11 will provide Design
for control of the discharge as shown in Figure 12. In Surge Point
Figure 12, the compressor is operating at the 100%
minimum closure point, at 60% of capacity. As long
Discharge Pressure (PSIA)

as inlet conditions do not change, the system will be
supplied with 60% capacity at design pressure as
long as necessary.
If a valve in the system is opened, the flow will

increase and the pressure will decrease. The Unload
Throttle
pressure decrease will be sensed and an open range
signal will be sent to the inlet valve from the
controller. The valve will begin to open. Additional
60% 100%
flow can pass through the inlet valve with a larger
opening. The system will accept exactly as much Capacity (ICFM)
flow as needed and then pressure starts to rise. The
controller causes the valve to stop opening when the
Power at Coupling (BHP)

design pressure (or set pressure) is reached.
Rated hp
The system now is using increased flow at design Min. throttle

pressure with more horsepower being used. This
process repeats up to the pressure and flow point
where the inlet valve is full open. Any additional flow
demand by the system after the inlet valve is full
open will result in decreasing pressure and
eventually choke will occur if system demand 60% 100%
increases high enough. Capacity (ICFM)
If the system requires less flow, the pressure Figure 12. Inlet valve throttle range modulation curves
increases as flow decreases and the inlet valve is
sent a signal to close. The reduction in flow process If air entering the inlet valve is at a constant density,
can continue until the minimum valve closure point is the air after the inlet valve will be at some other
reached. The inlet valve is arranged so that it will not density. As the inlet valve closes from full open in
respond to any increases in system pressure when response to the decreased system demand, the flow
at the minimum closure point. through the valve is being limited. As the valve
closes, the air passing through it increases its
The process of opening and closing of the inlet valve velocity and the pressure after the valve will show a
in response to the system demand is termed corresponding decrease; the volume of entering air
modulation. The inlet valve is said to be modulating is being limited. With less dense inlet air, the
when it is opening and closing to meet system pressure developed by the compressor will
demand. The capacity (flow) that the inlet valve can decrease. The flow decreases because it is being
control between design point and near surge is limited by the inlet opening.
termed the compressor throttle range.
The function of the inlet valve is to control inlet flow
Figure 12 illustrates inlet valve modulation with the and inlet pressure in the throttle range of the
series of dotted lines above the inlet valve minimum performance curve.
closure point. Notice that the dotted lines have the
exact shape as the uppermost line. The movement Study Figure 12. When the inlet is at minimum
of the inlet valve causes the performance curve to closure (minimum throttle), the surge point is nearly
shift. The curve shifts because the density of the at the design pressure line. If the compressor has a
inlet air between the inlet valve and the impeller controlled inlet valve with no other controls, as
changes as inlet flow decreases or increases.. system flow demand reduces below the minimum
closure position, the machine will surge. A surge
caused by closing the inlet more than the minimum
closure point is called a throttle surge.

Introduction See Figure 12, unloaded position, in the upper

A control system that has just an inlet valve, while graph: Once started, the compressor is operating at
providing service in the throttle range, doesn't allow the unloaded or start position that corresponds to
the air system to take advantage of the full 0%-to- the minimum opening position of the inlet valve. To
100% flow range. Flows between 60% and 100% load the compressor into the system, the inlet valve
can be utilized with inlet-only control and the effects initially opens to the minimum throttle point. The
of changing inlet temperature and pressure would be bypass valve begins to close once the inlet is at
partially controllable. An inlet-valve-only control minimum throttle. Depending on system pressure,
system is not very useful since low system flows and the bypass will modulate, and when it reaches fully
changing inlet conditions cannot be accommodated. closed, the inlet will modulate on system pressure.
In Figure 12, the slanted dotted line from the

Starting, Stopping and Un-loading Control unloaded capacity point to the surge point is called
Stopping presents no problem. Simply turning off the the load or surge line. The flow and pressure, in a
power supply (electricity, steam, or other) to the well tuned control system, increases very close to
driver will result in the compressor slowing down and this line as the inlet valve opens. The bypass valve
coming to a stop. When stopped, there is a very real is open at the time of loading and all flow vents out
possibility that the compressor will reverse rotate the bypass, keeping the machine from surge on
from a reverse flow caused by the pressurized loadup.
volume remaining in the system. An attached
discharge check valve (see Figure 13) will prevent With the inlet and bypass controls properly adjusted,
the pressurized air volume in the system from back- the compressor will provide 0%-to-100% of system
flowing through the machine. Reverse rotation demand at designed pressure, and allow for
cannot be tolerated because it will damage Centac compressor start, stop, load and unload.
compressor bearings. The check valve also serves
to prevent a large volume reverse flow in the event
of surge.
The Effect of Changes in Air Inlet
Conditions when the Electronic Control
Starting presents a problem. If the compressor is System is used
started with the inlet valve at the minimum throttle The electronic control system uses a motor
position, there will be a heavy starting load on the amperage signal (MinLoad) to establish the inlet
compressor driver. Flow would increase along with valve minimum closure (minimum throttle) point.
the increasing speed of the motor but the This signal reflects the driver horsepower where
acceleration under load forces are likely to cause (Amps X Volts X Phase factor X Power factor =
damage to compressor or driver components. The Watts) and (746 watts = 1 Horsepower). If volts,
high starting amperage in this type of start-up affects phase factor and power factor are constant, the
the electrical distribution system. amperage is proportional to horsepower. In reality,
power factor is variable with motor load and this
A control function that causes the inlet valve to open upsets the direct amperage to horsepower
to no more than about 5% to 20% on start is desired proportionally. Amps are nearly proportional to
to limit starting load. If flow is limited on start, the horsepower and for normal control purposes this
starting electrical and acceleration loads are limited. nearly proportional is adequate. Since horsepower is
directly proportional to flow at constant pressure, the
The compressor needs to have a small flow on start. throttle surge point can be related to motor
This flow keeps the compressor from becoming a amperage.
vacuum pump and prevents startup-throttle surging.
Running the compressor in a vacuum has two The inlet valve responds to a signal based on
detrimental effects: With no flow path, the impeller system pressure as does the electro-pneumatic
will impart energy to the stagnant air in the scheme, but an amperage level at which surge will
compressor, heat will be generated, and over time occur is entered as a set point. If load on the driver
this could cause damage. The bearings are nears this surge set point, the inlet valve will stop
designed for a minimum load, and running under closing and the bypass will start to open to vent
vacuum conditions puts stress on the bearings. To excess flow.
correct these problems on start, the control opens
the inlet valve a small amount and at this time the
bypass valve is fully open to vent off the starting
flow.

The major difference between the electro- Figure 14. Example IGV characteristic curve
pneumatic, LLR control, and the electronic control is
ine
that, in the electronic system the inlet valve will stop itL
Lim Design Point
closing at a specified amperage ≅. horsepower ≅ rge
flow) rather than a fixed percent open position. The Su
100%
effect of this is the same as re-adjustment of the
LLR for temperature-related growth of the
compressor. -10o
The electronic controller causes the minimum 0o

throttle position to be a continuously changing
+20o
position of the inlet valve. The effect of changing
inlet density is automatically compensated for in the +60o +40o
low flow region. This automatic compensation
results in less wasted horsepower when system
demand is in the low flow region of the throttle 40% 100%
Throttle Range
range. %
Capacity
In the high flow region of the throttle range, where
overload is possible with increased inlet air density, (straight in) and the impeller must do work to change
an amperage (flow) signal prevents the inlet valve the direction of the air from an axial to a radial flow.
from opening to the point where the motor is With spin imparted by the inlet guide vane (IGV),
overloaded. If the inlet valve was full open when the work is still required, but less is needed. The IGV
density change occurred, the inlet valve would close provides an increase in the efficiency of the overall
until the flow (horsepower) was reduced below the compressor.
overload point.
Each degree angle of the IGV vanes establishes a
The name given to the minimum throttle point control new curve of a different shape. This results from the
function in the Centac standard CMC electronic aerodynamic effects of the spin given to the inlet air.
control is "MinLoad”, (Minimum Load). The driver
overload protective function is called "MaxLoad”, The IGV's primary use is in the degree of accuracy
(Maximum Load). The unload position of the inlet and stability that can be obtained when the
valve control function is called "Inlet Valve Unload compressor is operated under conditions where
Position". Refer to the Centac Microcontroller CMC control of the pounds-per-hour (lbs/hour) mass flow
manual for detailed information of this system. is a requirement. IGVs offer a larger and more
precisely controllable throttle range than the
Function of the Inlet Guide Vane (IGV) standard inlet valve.
An inlet guide vane arrangement is used instead of
an inlet (butterfly) throttle valve in some applications. Basic Compressor Multi-Staging and
These applications are, normally, those processes Intercooling
that use air as a raw material for an end product or
Inherent mechanical and aerodynamic limitations
where precise control of the flow is required. An air- require the use of multiple-stage compressors to
to-nitrogen gas process or a pharmaceutical achieve design flows and pressures. A single-stage
fermentation process are examples..
high-flow, high-pressure dynamic compressor is not
practical due to impeller speed-related stress, and
Each angle of the inlet guide vane produces a other mechanical difficulties related to obtaining the
unique surge curve. The shape of the characteristic required head.
curve changes with vane angle in the IGV. This
makes the IGV very unlike the standard inlet valve. Centac uses 1, 2, 3, 4, and occasionally more
Figure 14 illustrates an example IGV characteristic stages, depending on customer need. The most
curve. common machines being built have 2 or 3 stages.
Each stage in an ideal multi-stage compressor will
The detailed theory of operation of the inlet guide do the same work. To do the same work, the stage
vane is complex. In the simplest of terms, the guide pressure ratios are the same since the lbs/hr flow
vane provides spin to the entering air as well as goes successively through each stage.
limiting flow. The spin given to the air results in less
work being required by the impeller. Without spin,
the air enters the impeller from an axial position

The calculations below demonstrate how to estimate Typical (Actual) Centac Performance Curve
the interstage pressures of a multi-stage compressor Figure 15 is a performance curve for a typical
operating at a specified discharge pressure. 2CV31M3 compressor. Arrowed labels have been
added to Figure 15 for instructional purposes. The
Pressure in psia is used in the calculations. If PSIG slope of an actual Centac curve is steeper than the
is used, a multiplier of 0 will enter the equation. model curve shapes used in earlier sections of this
Assume the inlet pressure is 14.4 psia and the discussion and is a typical general shape for actual
desired discharge pressure is 114.7 psia. compressors.
Overall compressor pressure ratio = The curves are based on a compressor that is
Pratio = Pout ÷ Pin and operating at design conditions. These conditions are
7.9653 = 114.7 psia ÷14.4 given on the form as ambient conditions. Pb =
Barometric pressure and is the pressure based on
Stage factor = Poverall ratio ( 1/# stages) height above sea level (altitude) where the
compressor would operate at. P1 = Inlet pressure,
2 stage calculation: called flange pressure, is the pressure that exits at
Compressor ratio = the compressor inlet flange downstream of the inlet
7.9653, Stage factor = √9653 . 7 = 2.8223 valve. The inlet valve is normally attached to the
1st stage in X stage factor = inlet flange.
1st stage out, 14.4 X
2.8223 = 40.64 psia
2nd stage in X stage factor =
2nd stage out, 40.64 X
2.8223 = 114.7 psia
3 stage calculation:
Compressor ratio =
7.9653, Stage factor =
3
√9653 . 7 = 1.9971
4 stage calculation:
Compressor ratio =
7.9653, Stage factor is
4
√9653 . 7 = 1.6799.
Figure 15. Typical actual performance curve.
The difference between Pb and P1 is the pressure

drop in the inlet pipe system between atmosphere
and the compressor flange. T1 = atmospheric (inlet)
air temperature. Rh = relative humidity and is a
measure of the water vapor in the air. Water vapor
contributes to inlet density.

The model 2CV31M3 is inter-cooled, and as a result, For users who normally operate at near design flow
condensate will be produced. As condensate drops an IGV has little practical use. Where continued
out of the air flow the air density will change in direct operation near the throttle surge point is anticipated
proportion. Stages 2 and 3 will respectively receive a an IGV provides power consumption advantages as
smaller percentage of water vapor in their inlet air well as its' precise flow control capabilities.
because of the condensate drop out in the coolers.
The 1st stage will do more work than down stream

stages per ft3 of air because of the percentage of
inlet water vapor. Tw = cooling water temperature
and is the temperature of the water entering the
coolers. Tw is the basis for determining what the inlet
temperatures in the 2nd and 3rd stages will be as
well as how much condensate will drop out.
The standard CENTAC design parameters are:
Pb = 14.4 psia
P1 = 14.1 psia
T1 = 95oF
Rh = 60% and
Tw = 80oF
Any one or all of these parameters may be different

in a specific design.
The difference in discharge psia between the surge

pressure and the design point pressure is called the
rise to surge pressure. A high rise to surge in an
actual machine normally indicates that the
compressor will have a corresponding larger throttle
range. A large throttle range is normally desirable.
The BHP (brake horse power) curve shows how the

horse power will be consumed from the natural
surge point to the choke point. It is important to
understand that the curves represent a compressor
with its' inlet open 100%. The curves show how the
pressure and BHP will react as flow is increased or
decreased by changes in flow demand by the
system the compressor is feeding.
The sloping line labeled butterfly throttle shows the

horse power decrease or increase as the inlet
throttle is opened 100% or closed to the minimum
throttle point. The dotted line shows the power
consumption when an IGV is utilized. An IGV
throttle, except at the design point, causes less
horsepower to be utilized for the same flow. There is
greater difference between the IGV and butterfly
BHP control in the low flow area; there is no
difference in BHP at the full open position of either
valve.

Bypass Valve Control of System Low Flow

Demands
To make available the full range of flow to the does not control inlet density or flow. It simply vents
system, keep the machine out of surge and excess flow in the 0%-to-60% range.
accommodate inlet air changes, a bypass valve is
added. Figure 13 illustrates the bypass valve control A disadvantage of operating in bypass is that vented
configuration. air represents wasted energy. The compressor will
always be compressing whatever volume the
The minimum throttle position of the inlet valve minimum closure of the inlet valve allows.
maintains the flow required to keep the compressor
out of surge. As system flow demand decreases So far in this discussion we have a compressor that
below the inlet minimum throttle position, pressure has a controlled inlet and bypass valve, it can
will start to rise. The control system responds to this provide a system with compressed air at design
rise in pressure by opening the bypass valve, pressure and flow from 0%-to-100%. It can also
venting off excess flow. accommodate some of the effect of changing inlet
conditions; however, additional controls are needed
The bypass valve uses system pressure like the inlet for starting, stopping, loading and unloading the
valve for control. A major difference between the compressor..
inlet and bypass valve function is that the bypass
Figure 13. Inlet and bypass control valve configuration
Diffuser
Impeller
Inlet Valve
Inlet Drive
Valve Shaft
Actuator
Bypass Valve Check Valve
SYSTEM
Bypass
Valve Pressure
Actuator
Controller

Inlet & Bypass Valve Operation
Inlet Valve Control of Throttle Range Inlet valve minimum closure

The control system shown in Figure 11 will provide Design
for control of the discharge as shown in Figure 12. In Surge Point
Figure 12, the compressor is operating at the 100%
minimum closure point, at 60% of capacity. As long
Discharge Pressure (PSIA)

as inlet conditions do not change, the system will be
supplied with 60% capacity at design pressure as
long as necessary.
If a valve in the system is opened, the flow will

increase and the pressure will decrease. The Unload
Throttle
pressure decrease will be sensed and an open range
signal will be sent to the inlet valve from the
controller. The valve will begin to open. Additional
60% 100%
flow can pass through the inlet valve with a larger
opening. The system will accept exactly as much Capacity (ICFM)
flow as needed and then pressure starts to rise. The
controller causes the valve to stop opening when the
Power at Coupling (BHP)

design pressure (or set pressure) is reached.
Rated hp
The system now is using increased flow at design

Min. throttle
pressure with more horsepower being used. This
process repeats up to the pressure and flow point
where the inlet valve is full open. Any additional flow
demand by the system after the inlet valve is full
open will result in decreasing pressure and
eventually choke will occur if system demand 60% 100%
increases high enough. Capacity (ICFM)
If the system requires less flow, the pressure Figure 12. Inlet valve throttle range modulation curves
increases as flow decreases and the inlet valve is
sent a signal to close. The reduction in flow process If air entering the inlet valve is at a constant density,
can continue until the minimum valve closure point is the air after the inlet valve will be at some other
reached. The inlet valve is arranged so that it will not density. As the inlet valve closes from full open in
respond to any increases in system pressure when response to the decreased system demand, the flow
at the minimum closure point. through the valve is being limited. As the valve closes,
the air passing through it increases its velocity and the
The process of opening and closing of the inlet valve pressure after the valve will show a corresponding
in response to the system demand is termed decrease; the volume of entering air is being limited.
modulation. The inlet valve is said to be modulating With less dense inlet air, the pressure developed by
when it is opening and closing to meet system the compressor will decrease. The flow decreases
demand. The capacity (flow) that the inlet valve can because it is being limited by the inlet opening.
control between design point and near surge is
termed the compressor throttle range. The function of the inlet valve is to control inlet flow
and inlet pressure in the throttle range of the
Figure 12 illustrates inlet valve modulation with the performance curve.
series of dotted lines above the inlet valve minimum
closure point. Notice that the dotted lines have the Study Figure 12. When the inlet is at minimum closure
exact shape as the uppermost line. The movement (minimum throttle), the surge point is nearly at the
of the inlet valve causes the performance curve to design pressure line. If the compressor has a
shift. The curve shifts because the density of the controlled inlet valve with no other controls, as system
inlet air between the inlet valve and the impeller flow demand reduces below the minimum closure
changes as inlet flow decreases or increases.. position, the machine will surge. A surge caused by
closing the inlet more than the minimum closure point
is called a throttle surge.

A control system that has just an inlet valve, while provided in different sizes for the various valve
providing service in the throttle range, doesn't allow the sizes. Figure 1 shows a typical arrangement with a
air system to take advantage of the full 0%-to-100% butterfly valve attached to the actuator.
flow range. Flows between 60% and 100% can be
utilized with inlet-only control and the effects of Each component will be described separately and
changing inlet temperature and pressure would be when combined in their application in the MP3
partially controllable. An inlet-valve-only control system electronic control systems.
is not very useful since low system flows and changing
inlet conditions cannot be accommodated.
Inlet and Bypass Valve Assembly

Introduction
The Ingersoll-Rand single acting diaphragm operated
inlet and bypass control valve assembly was introduced
in 1991 as the standard configuration for all Centac
products. The assembly provides superior quality with
enhanced reliability and performance over previously
used inlet and bypass valve operating devices.
The control valve assembly consists of three separate

major components. These are:
• the Positioner
• the Actuator, and
• the Valve.
Each valve assembly is also fitted with an instrument air

regulator and an air filter. The standard assembly is
Diaphragm operated
single acting
actuator
Instrument air
regulator
Air filter
Butterfly valve
Mechanical Stop
Positioner
Figure 1.Standard valve assembly

The Positioner The nozzle (9) senses the torque balance on the
Valve Positioner Operating Principle beam (3). When the input signal increases, the
The Ingersoll-Rand valve positioner consists of a balance beam (3) approaches the nozzle (9) and the
common housing that contains a 4 – 20 mA current nozzle pressure increases. This causes the
to pressure (I/P) transducer that controls the diaphragm piston (10), the beam (11), and the spool
attached pilot valve operated air to actuator (12) to move downward.
assembly. Valve motion feed back-linkages that are
necessary to provide the correct air pressure signal The pilot valve (13) moves to channel the 65 PSIG
to the actuator are an integral part of the positioner. (448 kPa) supply air to the upper side of the actuator
The positioner will output 0 to 65 psi (448 kPa) to the diaphragm. The actuator piston moves until the
actuator as set by span and zero controls. balance beam (11) is in equilibrium. At this point, the
actuator is in the exact position required by the input
The actuator is supplied an air signal from the signal.
positioner. The air signal provided by the positioner
is proportional to the microcontroller 4 – 20 mA The spring (14) causes a negative feed-back
output . The actuator provides the power to drive the between the first amplification stage nozzle (9) and
valve open or closed in proportion to the restriction (15) and the second stage pilot valve
microprocessor output control signal. assembly (13). The differential diaphragms
effectively offset the effect of any fluctuations in the
Refer to Figure 2 in following the description of the instrument air supply pressure.
principle of operation. Operation of the positioner is
based on the balanced torque principle. By changing the lower fastening point for the spring
(14) on the balance beam (3) the dynamics of the
Force coil (1) which is positioner can be adapted to suit the actuator size.
powered by the Larger actuators are required on the larger valves.
microcontroller 4 – 20 The zero adjustment (16) is mechanical and the
mA output signal is span (range) adjustment (17) is electrical.
located in the field of the
permanent magnet (2).
The signal provided to
the force coil creates a
torque through magnetic 15 10
repulsion.
11
A torque that is
proportional to the mA 12 16
signal is applied to the
balance beam (3) and
the balance beam 14
9
moves. 2
1
The feedback spring (4)
causes a counter-torque 13 3
on the balance beam (3). Vent Actuator
This counter torque is
proportional to the 4
actuator, and valve
position; this position is
6 5
transmitted to the
balance beam (3) via the 8
I/A 7
actuator shaft, the
coupling (5), the feed-
back shaft (6), the cam
(7) and the lever (8) as a
relative displacement to 17
the lower end of the
feed-back spring (4).
Figure 2. Positioner Schematic

cam between the dots are non-rising with respect to
Feed-back Cam the lever arm wheel.
The numbers stamped on the cam are input signal
ranges expressed in percentage. For example the 0 The purpose of this area is to provide a feed-back
to 100 corresponds to a 4 to 20 mA range. The other "dead band"
ranges are not used, for your information the 0 to 50 for the first
range refers to an input signal of 4 to 12 mA, and 50 few degrees
to 100% refers to 12 to of motion of
CW rotation to close bypass 20 mA. a ball valve
(see Figure
The 0 to 100 range is 3B).
20o
used on all standard
Centac Microprocessor
Dead applications. The arrow
band stamping refers to the Figure 3B Ball valve dead band
direction of turn of the
valve shaft. The dead band is not used on standard Centac
compressors. The center line of the roller should
Side A for Bypass valve align with the Zero dead band dot on the cam.
CCW rotation to open inlet
Figure 3 If the cam is removed for any reason, insure upon its
o re-installation that it is correctly seated against the
20
For Centac land on the operating shaft.
application, the A side
The shaft may slide towards the actuator when the
is for the bypass and Dead
the B side is for the band cam is removed. In this event there is no positive
inlet valve. means to know that the cam is properly seated.
To properly seat the cam, loosen the set screw on

Side B for Inlet valve the positioner to the actuator shaft. Hold the shaft
towards the positioner while tightening the cam and
Figure 3A locking wheel.
Open
4mA See Figure 5 for the correct configuration of the cam
on its shaft.
Positioner body
Locking wheel
Set screw
Cam
closed
20mA
Figure 4 closed
4mA Coupling
Indicator
Washer and “O” ring Gap
Figures 4 and 4A
show position of open Figure 5 Gap = Cam and body not touching. Malfunction
the lever arm roller 20mA will occur if cam
for correct cam and body touch.
positioning. No
dead band is
required.
The areas on the Figure 4A

Internal feed-back spring spring is anchored in the same position as on the old
The internal feed-back spring is identified on Figure positioner. The internal feed-back spring must be
1 as item (14). Figure 6 below is an expanded view positioned before doing the zero and span
of the attachment mechanism for this spring. adjustments to the positioner.
The internal feed-back spring anchoring point (a – e) Terminal Card Assembly

is preset for the particular size of the actuator being The terminal card assembly contains the span
used. The amplification of the positioner increases potentiometer, electrical filters and test points (See
as the spring anchor is moved from position a to e. Figure 7 item 35). The electrical condition of the
positioner can be measured without shutting down
the compressor. Remove the pin jumper (upper right
hand corner or terminal card). Using the exposed
Zero adjust terminals attach a voltmeter and ammeter as shown
in Diagram 1 to the pins to perform checks. See the
Internal feed back spring Table below for indications. Insure the jumper is
correctly reinstalled at completion of tests.
Balance
beam
Measurement
Feed back spring
Volts Amps Possible Faults
a b c d e
None (0) Meter goes Signal wire wrong
Anchoring positions
negative polarity
Figure 6. Feed back spring attachment
None (0) None (0) Signal wire defect.
The anchoring position of the internal feed-back Wire not connected
spring is set when the assembly is tested. This is Greater than When amps Coil connections or coil
done under ideal conditions with specific air supply 4 volts = 20 mA opened.
pressures, etc. Conditions in the field at customer 220 ohm shunt resistor
sites may be different than the set up test conditions. open
The spring may need to be re-adjusted.
None (0) Some amp Coil or shunt resistor
If it is found during operation that the valve reading shorted
overshoots or moves too slowly, the spring can be
moved in the a or e direction as required. If a new
(replacement) positioner is being installed on an
existing installation, insure the internal feed-back
Diagram 1. Terminal Card Schematic

Positioner Specifications:
• Input signal [direct current from microcontroller]
4 to 20 mA or 0 to 20 mA
• Split range capability [Not used]
4 to 12 mA and 12 to 20 mA
• Input resistance Max.
190 ohms
• Turning angle of feed-back shaft max.
90 degrees
• Relationship between turning angle and signal
Linear
• Supply air pressure
60 PSIG ( 414 kPa) minimum
65 PSIG ( 448 kPa) maximum
• Supply air quality [Instrument air quality]
Clean, dry and oil free
• Ambient temperature
-13 to 185° F (-25 to 85° C)
• Construction materials:
Case Anodized aluminum
Cover Poly carbonate
Internal parts Stainless steel
Springs Aluminum an
Stainless steel
Diaphragms and seals Nitrile rubber.
• Positioner air signal output
0 to 65 PSIG (414 kPa) maximu
Proportional to 4 – 20 mA input signal
between zero and span setting
! Note
The positioner itself is capable of accepting a
maximum of 115 PSIG (793 kPa) instrument air
pressure. The actuator can withstand a maximum of
65 PSIG (448 kPa). The actuator is the limiting
device in the air supply pressure specification for the
entire Standard Valve Assembly.
! Caution
DO NOT EXCEED 65 PSIG (448 kPa)
INSTRUMENT AIR SUPPLY TO THE POSITIONER
– ACTUATOR ASSEMBLY..INLET AND BYPASS
VALVE ASSEMBLY

Valve positioner 38 Screw Figure 7

39 O -- ring
Exploded view and parts identification list: 40 Internal feed-back spring
1 Housing assembly 41 Feed-back spring
2.1 Cover assembly 42 Spring
2.3 Name plate 43 O -- ring
2.4 Seal 44 Pilot valve assembly
2.5 Screw 45 Gasket
3 Protective cover 46 Change over piece
4 Screw 47 O -- ring
5 Beam assembly 48 Protective plate
6 Plate 49 Hex nut
7 Screw 50 Filter
8 Lower diaphragm plate 51 Plug
9 Middle diaphragm plate 52 Coupling
10 Upper diaphragm plate 55 Gasket
11 O -- ring 57 Grub screw
12 O -- ring 58 Upper support plate
13 Diaphragm 59 Gasket
14 Diaphragm 61 Zero adjustment nut
15 Screw
16 Hex nut
17 Diaphragm
housing
assembly
18 O -- ring
19 O -- ring
20 O -- ring
21 O -- ring
22 Diaphragm cover
23 Screw
24 Restriction
assembly
25 Screw
26 Shaft assy
27 Washer
28 O -- ring
29 Cam plate
30 Locking wheel
31 Screw
32 Pointer
33 Lever arm
34 Ring
35 Terminal card
assembly
36 Screw
37 Force coil nozzle

The Actuator
Actuator Operating Principle The vertical motion of the actuator rod is transformed
The Ingersoll-Rand actuator is designed for into an angular motion of the valve by the connector
proportional control of 90 ° rotary valves. It has a plate (5) and driver arm (6).
totally enclosed drive train that makes the actuator
safe to use and protects the drive train against The valve driver (7) is supported on either end by
damage or accidental changes in setting. The bushings in the actuator housing. The valve driver (7)
actuator mounts rigidly on the valve with the valve is rotated through 0 ° to 90 ° over the stroke of
driver lined up directly with the valve stem. the actuator rod (4). When the air signal is reduced
the excess air is vented through the port (1) back to
The actuator is a single acting (control air pressure the positioner and subsequently to the atmosphere.
on one side only) diaphragm operated spring return The reduced pressure on the diaphragm allows the
device. This feature makes the actuator fail safe. On spring to expand which in turn provides a reverse
loss of control air signal, the valve returns by way of motion to the actuator rod.
the spring pressure to its shut down condition. The
inlet valve closes and the bypass valve opens on Valve Open and Closed travel stops (8) for either end
loss of signal. of the stroke are provided. These are used to prevent
valve jambs on opening and closure by setting valve
travel limits.
Various sized actuators are used on the smaller to

larger Centac products. While one actuator may be
physically smaller or larger all are generally
constructed the same way. Larger sizes are
necessary to accommodate the increased loads on
the larger valves. The spring is not adjustable. The
maximum air pressure to the single acting diaphragm
controlled actuator is 65 PSIG ( 448 kPa). Diaphragm
rupture or premature failure will result from excess
signal pressures.
Normally closed or normally open valve rotation is

obtained by simple rotation of the valve drive from one
side to the other. The inlet valve opens with increasing
air signal while the bypass valve closes with
increasing air signal. The spring alone will shut the
inlet or open the bypass. The spring provides fail safe
operation of the valves. Except for setting of the travel
stops, there are no adjustments on the actuator.
Figure 8. Actuator cross section
Refer to Figure 8 in following the principle of

operation description. The positioner sends a power
air signal to the supply and vent port (1) of the
actuator. The PSIG of the power air is proportional
to the 4 to 20 mA microcontroller output signal being
fed to the positioner.
The air pressure on the diaphragm (2) forces the

spring (3) to be compressed to the point where the
spring pressure exactly equals the force being
applied by the air signal on the diaphragm. As the
spring (3) compresses, the actuator rod (4) moves
(downward).

The Actuator
Actuator Position for Inlet or Bypass Use Actuator Parts Identification List
To utilize the actuator for the bypass valve the driver Figure 10
position is as shown in Figure 9. For inlet valve use the
actuator is simply reversed as shown in Figure 9A. 1 Housing 26 N/A
2 Driver 27 Cap screw
3 Driver arm 28 Driver retainer
4 Actuator rod 29 Lock nut
5 Cover 30 Spring retainer
6 Pivot pin washer 31 Thrust washer
7 Connector plate 32 Spring housing
8 Pivot pin 33 N/A
9 Pivot pin retainer 34 Lock washer
10 Diaphragm plate 36 N/A
12 Position indicator 38 Cap screw
plate 39 N/A
13 N/A 52 Pivot pin 43 Compression spring
bearing 45 Plate
14 Diaphragm 50 Top driver bearing
15 Upper casing 51 Bottom driver bearing
19 Stop screw 52 Pivot pin bearing
20 N/A 53 Name plate
21 Cap screw 54 Tie rod
23 Jam Nut 55 Hex nut
24 Indicator pointer 60 Plate
25 Cap screw
Open Close Open Close

Reverse acting Direct acting
Air signal closes valve Air signal opens valve
Spring force opens valve Spring force closes valve
BYPASS VALVE INLET VALVE
Figure 9. Bypass valve Figure 9A. Inlet valve
Figure 10

Butterfly Inlet & Bypass Valve
Standard Butterfly Inlet Valve Segmented Ball Bypass Valve

The standard inlet butterfly valves are swing through Along with the introduction of the single acting
valves which have no internal stop. The diaphragm operated actuator, the segmented ball
valve has a bi-flow characteristic and is not flow valve was introduced as a standard on the smaller
direction sensitive. Figure 11 below shows a typical Centac frame sizes and was made optional for all
valve. other Centac products. The segmented ball valve
provides more stable control characteristics then the
butterfly valve and has been found to be an excellent
control valve in the lower flow demand applications.
Figure 12. Representation of the operating positionsof the ball

bypass valve.
Figure 11. Butterfly valve
The packing is normally Graphited Teflon Braid and

requires little to no maintenance over the life time of
the compressor. The valve shaft is stainless steel
and rides in a Graphited Bronze bearing.
The standard valve is designed for temperatures up

to 450° F (232° C). Special valves are available for
higher temperature applications.
Figure 12A Major components of the segmented ball valve.
When the valve is attached to the actuator, the
actuator travel stops are adjusted so that the valve The valve does not contain internal stops at the 90 °
corresponds to the open and closed position of the position. The actuator travel stops must be adjusted
actuator. so that a 90 ° rotation seats the segment.
Adjustment procedure for the valve with its attached The valve discharge has a larger diameter than the
actuator is contained in Adjustment of the assembly inlet and the valve is flow direction sensitive. Flow is
section. against the segment as shown in Figure 12.

Butterfly Inlet & Bypass Valve
Standard "Wafer" Type Butterfly Bypass

Valve
The standard butterfly bypass valve unlike the inlet
butterfly is a seated valve. The seated valve allows
for positive stoppage of flow when the valve is
closed. The bypass valve wafer (or disk) is offset
from the center lines of the valve body and the seat.
The eccentric location of the wafer pivot point
provides a means for the disk to lift away from and
clear the seat as it starts to open. See Figure 13
where the relationship of pivot to center lines is
shown. The TFE lip seal seat flexes to provide a
leak tight seal and the construction allows for self
compensation for wear. The seat is removable
should it ever need replacement.
Thrust washers on the shaft keep the disk centered.
The pin that holds the disk to the shaft is welded to
insure no chance of loosening.

Regulation & Coalescing Filter
range spring, which has been compressed by the
In this section, you will learn adjustment screw, causes the pintel to move
• The regulation and coalescing filter downward, opening the pintel valve and allowing air
flow.
• Adjustment and maintenance
• Troubleshooting indication The pressure builds up against the control
• Routine Maintenance diaphragm until the pintel valve closes to a point of
equilibrium between the spring and the air pressure
on the diaphragm.
Once the set pressure is reached it is maintained as

described below.
The Regulator and Coalescing Filter
Supply Air Regulator Downstream pressure drop: A drop in down stream
The supply air regulator is used to reduce the supply pressure reduces the air pressure on the diaphragm.
air pressure from a maximum inlet design pressure The equilibrium is upset and the pintel valve opens
of 120 PSIG (827 kPa) down to the maximum to the point where equilibrium is again established.
operating pressure of the actuator. Actuator
operating pressure is 60 PSIG (414 kPa) with a Downstream pressure increase: A sudden increase
maximum of 65 PSIG (448 kPa). The regulator has in downstream pressure acts on and lifts the
an integral 5 micron filter with drip well for the diaphragm off the pintel, causing the relief pintel
collection of moisture. A drip well drain is provided. seat in the diaphragm assembly to lift opening the
chamber below the diaphragm to the vent. The
The regulator is adjustable over the range of 0 to 60 excess pressure drops almost instantaneously to the
PSIG (0 - 414 kPa) and will normally be operated at equilibrium point at which time the relief pintel seat
60 PSIG (414 kPa). The principle of operation of the seals once again on the pintel.
regulator is balanced force where a calibrated spring
force is balanced by the discharge air pressure The 5 micron filter is nylon mesh with self cleaning
against a diaphragm. Refer to Figure 14. assisted by porting to the drip well area. The filter
and drip well should be removed and cleaned on a
Outlet air pressure is set with the adjusting screw. periodic basis.
Once set the regulator maintains the setting. The
Figure 14

Coalescing Filter Adjustments and Maintenance

Directly attached to the downstream side of the Tools and Materials Needed
valve assembly supply air regulator is a coalescing
The following tools are needed to efficiently adjust
filter. The purpose of the final filter stage (the
the standard single acting valve assembly
regulator provides the first stage of filtration) is to
remove any mist or particles that may have been
1. 4 – 20 mA source
passed by the first stage filter.
2. Flat blade screw driver (small)
3. Clean, dry air supply (instrument air provided
The coalescing filter will remove 99.9 % of all mist or
by customer)
particles down to .01 micron size. The filter media is
4. Allen wrench set
contained in replaceable tube form. The filter cannot
5. Reliable 0 – 100 PSIG (0 – 700 kPa) pressure
be cleaned by back flush or other means. When the
gauge
pressure drop reaches 10 PSIG (61 kPa) the filter
tube should be replaced.
Verifying Proper Operation of the Valve
Except for periodic filter tube changes the other Assembly
parts that may need replacement from time to time The procedure for verifying operation of the inlet or
are the seals. Lubrication on an "O" ring facilitates bypass valve assembly is the same. Valve action
its installation. The "O" ring seals are obtained in kit should be as noted below.
form from Centac Aftermarket. Figure 15 shows the
relative position of the "O" ring seals. Note that air Verify air supply:
flow is through the center of the filter tube. Remove regulator adjustment screw cap and back
off on the adjustment screw until pressure indicated
on the outlet pressure gauge is Zero. Increase
pressure to the operating pressure of 60 PSIG (414
kPa).
Verify positioner cam position:
INLET valve: Cam should be on side B
with the arrow of the 0 – 100% range
pointing to the left as the cam is viewed.
BYPASS valve: Cam should be on side A
with the arrow of the 0 – 100% range
pointing to the right as the cam is viewed.
Attach a 4 – 20 mA source ( + to + and - to - ) to the

positioner; (Use I-R test box). Adjust the source so
that 4 mA is being sent to the positioner and
observe valve action.
INLET and BYPASS valve action: Should
not have moved as a result of applying the
4 mA.
Adjust source to 20 mA. Note valve action

INLET valve action: Should open 90 ° .
The positioner indicator should show 90 °
rotation. BYPASS valve action: Should
close 90 ° . The positioner indicator
should show 90 ° rotation.
If valve action occurs as noted, the valves are

properly stroked and ready to receive control signals
from the MP3 microcontroller.

Calibrating the Inlet & Bypass Valve Decrease source to 4 mA and check zero
adjustment position of the valve.
Assembly
Zero Adjustment Repeat zero and span procedure until valves are
With 4 mA supplied to the positioner. fully open and closed at their respective mA values.
Rotate ZERO adjustment

nut wheel until: Troubleshooting Indications
Air continuously venting from the vent port on the
regulator indicates that the diaphragm has ruptured.
Air continuously venting from the positioner pilot

valve assembly indicates that the spool valve is not
seating and may have worn components.
4 mA Air venting from the area of the positioner diaphragm
housing indicates a ruptured lower diaphragm.
A high volume of air escaping from the positioner
nozzle is an indication of a ruptured upper
Blowdown Valve Inlet Valve is diaphragm.
is fully open fully closed
!
Note
A low volume of air is normal and required for
proper operation.
CLOSED
Air venting from any place on the actuator indicates
OPEN a ruptured diaphragm or loose actuator upper casing
Spin Adjustment
Increase to 20 mA and Routine Maintenance
Routine maintenance on the control valve assembly
is limited to the following:
Adjust the Spin adjustment on the
positioner terminal board until • The filters require periodic cleaning and
replacement. This period must be established at
each compressor site since it is the site air quality
that dictates when the cleaning and
replacements are required.
• A daily draining of the regulator and coalescing
filter will indicate severity of any air contamination
20 mA problem.
• Checking the calibration (stroking) of the control
valves is done, as a matter of routine, every six
months.
Blowdown Valve Inlet Valve is
is fully open fully closed
CLOSED
OPEN

Short Test
Short Test
Answer each question as fully as you can, or tick the best option.
When you finish, check your answers by reading through the section again.
1 What & how is 2/3rds of the pressure rise across a stage in a centrifugal air
compressor developed?
a) The diffuser by centrifugal force
b) The impeller by centrifugal force
c) The diffuser by dropping the velocity of the air
d) The impeller by dropping the velocity of the air
2 What is a centrifugal air compressor?
a) A dynamic compressor providing varying pressure at varying volumes.
b) Providing constant pressure a dynamic compressor at varying volumes.
c) A positive displacement compressor providing varying pressure at varying volumes.
d) A positive displacement compressor providing varying pressure at varying volumes.
3 What & how is 1/3 of the pressure rise across a stage in centrifugal air
Compressor developed?
a) The diffuser by centrifugal force.
b) The impeller by centrifugal force.
c) The diffuser by dropping the air’s velocity.
d) The impeller by dropping the air’s velocity.
4 What does the Actual Head Plot account for?
a) Energy losses in a real compressor.
b) Changes in the inlet air pressure.
c) Change in the inlet air temperature.
5 What is “ SURGE” condition?
a) A momentary reverse of flow.
b) Loose of power to the driver motor.
c) Air velocity reaches the speed of sound.
d) Air temperature reaches super heated levels
6 What is Choke?
7 What is Stonewall?

Short Test
8 What is the supply Air regulator used for?

a) To increase supply 65psi to 120psi operating pressure
b) To reduce the supply air pressure from a 120psi to 60psi operating pressure
9 Inlet Valve: The Cam should be on Side A, with the arrow of the 0-100% range
pointing to the left, as the Cam is viewed.
a) True
b) False
10 Bypass Valve: The Cam should be on Side B, with the arrow of the 0-100%
range pointing to the left, as the Cam is viewed.
a) True
b) False
11 Adjust source to 20mA, Inlet Valve action should be closed at 90 degrees. The
positioner should show 90 degrees rotation.
True
False
12 Adjust source to 20mA, Inlet Valve action should be open at 90 degrees. The
positioner should show 90 degrees rotation.
True
False
13 How do we know if the regulator diaphragm is ruptured?
14 Bellofram Positioner, Inlet Valve Open 7psig and Closed 15psig

True False
15 Bellofram Positioner, Bypass Valve Closed 10psig

True False
16 The Bray Positioner, adjust Bypass Valve span: 20mA, just open.
True False
17 The Bray Positioner, adjust Bypass Valve zero: 4mA, just closed.
True False

Basic Centac Manual
Planning &
Installation
Section 3
Receiving Handling & Storage....................................1—5
Installation Planning ...................................................6—9
Air Piping ....................................................................10—17
Water System Piping ..................................................18—21
Electrical Connection..................................................22—23
Lubrication ..................................................................24—27
Weights & Dimensions ...............................................28—29
Shaft Alignment ..........................................................30—37

Planning and Installation Section 3
Receiving, Handling and Storage
Receiving
In this section, you will learn Centac compressors are shipped in first class
• What to inspect when the compressor arrives condition. They have been inspected prior to leaving
• What to do if the machine is not started for the factory. Loading of the compressor has been
more than 120 days after arrival supervised by Ingersoll-Rand personnel to ensure
• How to lift the Centac compressor that the unit has not been damaged during loading
and that all accessory equipment has been properly
documented.
Inspect the compressor for shipping damage before

Introduction removing the compressor from carrier’s vehicle. If
This section serves as a reference guide for proper damage or indication of rough handling is evident,
Centac compressor installation. The information it file a claim with the carrier at once, and notify
contains is general in nature and is applicable to Ingersoll-Rand.
most Centac compressors.
The arrival inspection should include the following:
The Operation Manual, diagrams and prints
provided with each compressor need to be • Be particularly aware of the vibration probes,
consulted for specific data and information RTD’s, valve positioners, actuators and other
applicable to specific compressors. components that "stick out" and which could have
been damaged in shipment.
• All gauge glass or other components covered by
! Note glass or plastic (if any) should be intact.
Where found in this manual, the word must
means that the specification must be met • Insure that the coupling spool piece, coupling
to validate the Warranty. bolts and nuts, gaskets, spacers and o-rings are
received.
The word should means that it is a desirable • Paint should be intact with no rust or other
condition but not mandatory for the operation of the deterioration visible.
machine and failure to meet this specification does • Check for obvious major or minor damage.
necessarily affect the Warranty. Deviation from • Compare shipping documents with all the
specification may severely limit material received.
efficient operation or interfere with maintenance of
the machine.
Remove only the shipping notice. Do not remove
tags pertaining to lubrication, operation, and storage.
Prior to Centac compressor arrival Read all tags and instructions.
Many things must be known prior to the Centac
compressor arrival on site. Some of the most Document receipt of all items included with the
important of these things are: compressor, but packed separately. Make a list of
any items that were not received and notify your
• Will the machine be started within 120 days from Ingersoll-Rand representative. Store all items either
the date of shipment from the factory? with the compressor or in an appropriate secured
• Where will the machine be stored and what area.
ambient conditions will it be exposed to while it is
in storage? A plan for repairs or replacement of damaged
• What storage procedures will be implemented? components should be known before you depart the
customer's site. Contact Aftermarket and/or the
Customer Service Department as necessary to
obtain parts and materials.
Basic Centac Reference Manual

Handling/Lifting The CV series and 0CV model machines have lift

An experienced rigger should move and install the truck fork openings provided in the base for lifting
compressor. Adequate rigging and lifting equipment purposes. These are shown in Figure 1 at point A for
must be provided to safely handle the unit. Use the 1CV. The 0CV has similar openings. The lift
spreader bars to prevent damage to piping, tubing, truck openings are the preferred lifting points. The lift
gauges, and other accessory equipment. Provisions truck openings can be used with slings as well as
for lifting the unit are located at the corners of the fork truck lifting. An alternate lifting point for lifting
baseplate with rigging is shown at B in Figure 2. The rigging
(see Figure 1). must go through both casing ribs and under the
motor flange.
Figure 2
Centac compressor 1CV lifting fixtures
Figure 1
Lifting Diagram for Standard Unit
Storage
The compressor, as it is shipped from the factory
Installation of a Centac compressor can best be (flanges blanked and desiccant bags placed at inlet
done by the use of an overhead crane. Lifting points and discharge), can be stored on a level surface in a
have been provided in the baseplate for the purpose controlled environment for up to 180 days after the
of lifting the complete unit. To facilitate lifting and ship date tagged on the compressor unit without
avoid possible damage, spreader bars are requiring long-term storage preparation. The unit
recommended. Figure 1 illustrates the lift points for a must be started within the first 180 days following
standard unit. shipment from Ingersoll-Rand to assure the full 12-
month operational warranty after start-up. Store all
An overhead rail with a chain hoist will also simplify loose/spare parts in a controlled environment for
the removal of the largest component parts when adequate protection prior to usage.
maintenance is required. If the motor is supplied with sleeve bearings, fill the
motor bearing reservoir to the level recommended
by the manufacturer. Use a good grade of rust
! inhibiting oil. The shaft should be rotated a minimum
Warning of 10 revolutions every month to keep the bearings
Do not lift the unit by the lifting eyes on the lubricated. At the end of the storage time, the motor
compressor or driver. These eyes are for lifting the should be "meggered" to ground before connecting
individual component parts only. Damage to to the power line. Specific motor start-up instructions
equipment and injury to personnel could result from provided by the motor supplier must be followed.
misuse of the lifting eyes.
If the unit is to be stored for periods longer than 180
days, or in an uncontrolled environment, the unit will

require additional protection. Consult your local Under extreme conditions of dampness or dirt, any
Ingersoll-Rand representative for long term storage or all of the following may be necessary to protect
requirements and extended warranty coverage. the compressor. Exactly what should be done will
depend on the circumstances.
Consider a unit in storage when:
• Bleed (purge) dry nitrogen gas through the
• It has been delivered to the job site and is machine to absorb and displace moisture and
awaiting installation. eliminate free oxygen for corrosion reduction
• It has been installed but operation is delayed purposes.
pending completion of plant construction. • Provide for desiccant bag replacement or
• There are long periods (30 days or more) installation of desiccant bags in various areas.
between operating cycles. • Energize motor space heaters (if provided) while
• The plant (or department) is shut down. in storage.
• Manually spray the compressor bullgear and
Storage under adverse conditions pinions with compatible rust inhibitor oil.
The warranty does not cover damages resulting • Provide an energized 100 watt lamp in the
from adverse storage conditions. Precautions must control panel to drive off moisture.
be taken to assure that the machine is protected • Place machine in long-term storage.
from the elements. The specific precautions to take
will vary from site to site. Moisture and dirt must be
kept from contaminating the machine internals. Long-term storage
Preventing corrosion particle buildup (rust) in the If the unit will not be started within 120 days after
machine internal areas is the primary goal of the shipment, the long-term storage option should have
adverse storage condition procedures. been ordered from the factory. Under the factory
long-term storage option, the compressor is
A key to corrosion prevention is to maintain a shipped with the rotating assemblies removed and
constant temperature. If there are wide swings in packed in corrosion inhibiting material. Other
ambient temperature over a short period of time, special precautions are taken with the internals of
there is a tendency for condensate to form inside the the machine. An authorized Ingersoll-Rand
compressor. This natural condensate can accelerate technician is required to supervise or actually clean
corrosion build-up and cause potential damage to protected parts and reassemble the machine.
electrical components. To minimize the effects of
temperature changes, insure desiccant bags are Long term storage procedures are detailed and
renewed and all openings to the compressor specific. These procedures are available from the
internals are tightly covered. Place a lighted 100 Centrifugal Compressor Division. The terms of sale
watt incandescent lamp in the control panel to for the specific machine put into long-term storage
maintain a constant or elevated above ambient contains information relating to who will or has paid
temperature. for the cleaning and reassembly.
In construction areas, where there is an abnormal Pre-installation meeting

amount of dust and dirt in the air, it is advisable to The Area Manager will normally have had
keep the entire compressor covered. Be aware that numerous discussions with the customer or the
a tightly fitted waterproof cover over the compressor customer's contractor concerning the optimum site
may trap moisture inside and cause more harm than conditions for Centac compressor operation. Prior
good. Air circulation with no dirt accumulation is the to the planned start-up day, a service visit for an
desired result. on-site pre-installation review is recommended. The
Area Manager will normally conduct a pre-
installation meeting with customer personnel and
do a pre-installation inspection.
The primary goal of the pre-installation meeting is

to insure that all concerned have a clear
understanding of the importance of proper
installation to the lifetime of the compressor and to
clear up any areas of uncertainty regarding the
mechanics of installation.

The service visit can assist the Area Manager and

customer by bringing to their attention any
installation details that may have been overlooked.
Site information that will assist the service
organization in determining site readiness for the
start-up can be obtained at the same time. There are
few hard rules concerning exactly what constitutes
an unacceptable installation.
The Centac compressor engineering staff has

developed specifications and recommendations that
insure that all requirements for efficient, dependable
operation are met. Failure to meet some of these
requirements does not necessarily mean that the
installation is unacceptable from a machine-safety or
ability-to-operate position. Failure to fully incorporate
all the specifications and recommendations for
installation will degrade the efficiency, dependability
or other potential of the machine in some or all
respects.
When certain specifications for the Centac

compressor installation are not met, the warranty on
the machine will be in question. It is a Customer
Service Department responsibility to review the
specific situation and authorize a deviation from
these specifications so that the full warranty will
remain in effect, or to advise that the warranty is
void and that Ingersoll-Rand can have no
responsibility for the machine.
The deviation from specification authorization will

not be given in any case where there is any question
regarding the ability of the machine to operate
properly or safely. In the extreme case, a Waiver of
Liability, Ingersoll-Rand Form 83084 Revision 1, is
completed when the customer insists on starting a
machine where mandatory installation specifications
have not been met.
The service representative and Area Manager have

a responsibility to insist that the customer
incorporates all specifications and recommendations
for the Centac compressor installation. The overall
life of the machine in large measure depends on
proper installation.

Short Test
1 Why is it important to know the ambient conditions that the machine will be
exposed to during storage?
2 What are some of the components that could be damaged during shipment?
3 Mark the lifting points for a 1CV on this drawing.
4 What must be used to prevent damage to piping, etc?
5 What defines long term storage?
6 What must be done if the machine is to be stored long term?

Installation Planning
During installation, machinery can best be handled

In this section, you will learn with overhead crane facilities. Adequate space
• The importance of plant layout should be provided to permit easy handling of the
• Types of foundation unit during installation (see the General
• How to ensure that the machine is level Arrangement drawing for compressor maintenance
space).
• When grouting is needed and which types of
grounting to use. Provide floor space in the vicinity of machinery
where parts may be placed during periodic
inspection of the rotating elements and internal
parts. Make provisions for clearance requirements
General specified on the General Arrangement drawing.
Proper installation is a critical component of
satisfactory operation of all rotating machinery. Indoor/Outdoor Installation
The unit may be installed indoors or outdoors. For
Proper support of the machinery is required to give an outdoor installation, protective measures are
maximum reliability at minimum operating cost. In necessary for the motor, control panel, and other
addition, a well-designed installation will result in items. It is important when the compressor package
lower installation and operating costs. See the is purchased that Ingersoll-Rand is made aware of
General Arrangement drawing for compressor/ plans and makes any necessary recommendations
customer connection details and lift points. Contact for outdoor installation. If the unit is an indoor
your local Ingersoll-Rand representative for further installation, a heated building is preferred. Provide
information. adequate space for ease of handling during
installation.
Blow off valve
Discharge
Figure 1.2
Typical 2AC11
connection
Main motor
Ventilation
Compressor
Control
Panel
Ventilation around the unit is important. The unit
should not be installed in a damp or dusty
atmosphere or where corrosive vapors may enter
Inlet valve the compressor or driver. On motor driven units
the heat radiated to air in the room will be
approximately 6% of the total horsepower:
1HP=42.4 BTU/MIN – 1 KW=56.9 BTU/MIN
Noise
In areas where noise could be a problem, it is
Inlet important to treat hard reflective surfaces in the
connection area. Avoid installing the unit in an area with low
hard ceilings and walls.
Foundation
Water connections The compressor foundation does not need to be
Condensate traps massive but should be sufficient to provide support
for the unit. Since there are no out-of-balance
Plant Layout forces (such as reciprocating or shock loads) all
The location of a packaged centrifugal compressor loads on the foundation may be considered as static
within a plant facility is very important. The loads. If the unit is to be located in an area with
compressor should be located in an area that is other machinery, it is essential that vibrations are not
accessible to operators and maintenance personnel. transmitted to the compressor. Isolation pads are
recommended in these instances.
Machinery should be installed where it is easily
accessible for observation and maintenance. For the Centac compressor package, a simple
Operation and maintenance personnel will generally continuous concrete pad or steel support structure is
give better attention to a compressor located in a recommended for each compressor. Precautions
well planned, accessible area. Compressors should be taken to ensure a reasonably uniform
installed in elevated locations or in pits should have base around the pad. Uneven settling or thermal
stairways, catwalks, etc. for easy access to the expansion could cause machinery misalignment.
machinery.
Appropriate bolting must be used to keep the
compressor in place. Refer to the General The unit may be leveled using a machinist level or
Arrangement drawing for location and size of anchor transit level. When a machinist level is used, start at
bolt holes. one end of the unit and work side to side toward the
opposite end, placing the level on the machined
baseplate compressor pads. The compressor should
! Note
be level from 0 to 0.1 inch/foot (0 to 8 mm/M).
The design of the foundation is the responsibility After the unit is level with snug (not tightened)
of the customer. These comments are offered as an anchor bolts, the coupling should be aligned. Some
aid to assure a successful installation, but Ingersoll- baseplate distortion may be noted but this is
Rand Company cannot assume the responsibility unimportant so long as the machine pads remain
for the design. We recommend that the customer level. Precise driver alignment is not required until
consult a specialist skilled in the design of machin- the time of start-up, but should be within 1/16 inch
ery foundations. (1.5 mm). Follow the procedures found in the
Operation Manual once the compressor arrives on
site. The General Arrangement drawing lists the
values for the coupling alignment. Record the values
Leveling obtained, but do not dowel the driver or install the
Driver, compressor, and base levels are important coupling spacer.
for the following reasons:
After the coupling has been brought into rough
• If the machine is not level longitudinally, the alignment and the alignment values have
starting and stopping weight of the driver rotor been recorded, the Centac compressor is ready for
will bear on the thrust bearings (uphill or grouting.
downhill), resulting in possible premature wear.
• The same force will burden the compressor Grouting
bullgear thrust bearings and put stress on the Grouting forms are prepared and grout is poured
coupling. after level has been verified. When the grout has set
• If the level is off, the oil sump level, demister up, the wedges or shims are removed. The void
function and the coolers high point venting could space left in the wedge or shim area is then back-
be affected. filled with grout. If the wedges or shims are not
removed, corrosion will upset the level at a future
• Motor bearing lubrication and lubrication drain-off time. A nut used on the underside for leveling of the
could be affected resulting in possible premature base is not recommended because it too will corrode
failures. over time and upset the level.
• Proper drainage of condensate and general pipe
fit up could be affected by an out of-level Grouting serves two significant purposes. The first
condition. purpose is to provide full area support for the
machine's weight-bearing base structures. The
Before level readings can be taken, the compressor second purpose is to provide the means of support
must be resting on the foundation pad in its final when a machine needs to be levelled. There are
position with the anchor bolts (or nuts) snug. If it is other non-structural purposes for grouting which
known or suspected that the pad is not level, shims
or wedges can be installed at
the anchor bolt positions Anchor Bolt Figure 1.3.
when the unit is set in place. Wedge and shim
Level condition is determined Baseplate placement
by using a transit level,
machinist level, or other Leveling wedges Leveling shims
higher-technology means.
The Centac compressor

should be leveled at the time
of installation. To level the
unit, place it over the anchor
bolts with the feet resting on
steel wedges or shims, if
Foundation/Pad
necessary (see Figure 1.3).

have to do with housekeeping.
Epoxy grouts are recommended because they have
proven to be superior to the mortar based grouts,
although they are usually more expensive. Epoxy
grouts are not affected by spilled lubricants, are easy
to clean and present a neat appearance. Mortar
grout does not have these advantages.
For Centac compressors with flange-mounted

motors (1CV, 0CV, 3CH, 4CH, 2CV, etc.), no base
grouting is required as long as there is full base-plate
support contact with the pad and the machine is
within the specification for level. On these machines
there is little flexibility possible between the
compressor and the driver. The drive and driven
shafts are aligned by the flange that rigidly holds the
two together. Grouting this configuration serves no
structural purpose and is not necessary as long as
the base is supported and level. Grouting does
enhance the ease of housekeeping and overall
appearance of the installation. The exception to this
is when the foundation pad is not level. In this
instance grouting the base to a specified level plane
is required.
The supporting surfaces (underside) of all the

various Centac compressor baseplates are not
machined surfaces. The small imperfections in these
surfaces relative to a "machined surface" are
insignificant regarding the ability to support weight.
Similarly the small imperfections in a "smooth"
concrete surface are insignificant in terms of its
ability to support the compressor weight.
A simple but adequate method of determining if the

base-to-pad mating surface is satisfactory is to shine
a light from one side to the other. If undiffused light
can be seen, the surface is too rough and grouting is
needed. Regardless of which surface is rough, the
corrective action is to install grout.
For Centac compressors without flanged drivers (C

series, CII series, X-FLO and the larger CHs)
grouting of the baseplate support is required.
Grouting should be done on all Centac compressors

that have foot mounted coupled drivers. If it can be
shown that the base supports are in full contact with
the pad and the base is within the specification for
level, grouting is not required. This is very difficult to
determine in the large machines because support is
provided by structures that are hidden from view.
Grouting insures that all support areas, visible or not,
are providing the support intended.

Short Test
1 Why must the compress be easily assessable to operations and maintenance

personnel?
2 Why is ventilation important?
3 What are the recommended types of foundations for a Centac?
4 What can happen if the machine is not level longitudinally?
5 What is the procedure to follow when using a Machinist Level?
6 What purpose does grouting serve?
7 Why are epoxy grouts recommended?
8 What does grouting ensure?

Installation and Planning Section 3
Air Piping
To summarise, a satisfactory piping arrangement
In this section, you will learn about can normally be obtained by giving proper attention
• Inlet air piping and filters to:
• Bypass air piping
• Providing adequate support for all parts of the
• Expansion joints
piping system.
• Discharge air piping
• Allowing for expansion in a manner that will avoid
• Discharge air piping for multi-compressor piping strains on the compressor.
installation
• Installing a sufficient number of anchors in the
• Receivers piping system so that direction and magnitude of
• Control air piping / filtration expansion are controlled.
• Instrument air piping • Designing the inlet and discharge piping so as to
provide smooth flow with minimum pressure drop
and uniform velocity over the entire area of
Centac products have no design provision for piping.
accepting the full weight of external piping •
connections. The discharge, inlet, bypass, water,
and other piping connected to the machine must be
self-supporting. Adequate piping supports are !
Note
necessary to prevent excessive dead loads on the The design of the piping system is the
flanges of rotating machinery. responsibility of the customer. Data and comments
are offered as an aid to ensure a successful
Piping alignment to the compressor mating flanges
installation, but Ingersoll-Rand cannot assume
is essential. The piping must be installed and responsibility for its design or installation. We
supported to avoid strains on the casing. recommend that the customer consult a specialist
Misalignment, which is a frequent cause of vibration, skilled in the design of piping systems to supplement
can often be traced directly to piping strains. Three
and interpret the piping information and to ensure a
sources of piping strains are: successful installation. The inlet pipe and filter must
be inspected before startup by an Ingersoll-Rand
• Dead weight of the piping itself factory certified service representative.
• Expansion or contraction of the piping as it
undergoes temperature change
• Pressure within the piping !
Note
In the practical sense, if any pipe needs to be All air and water piping to and from the inlet and
levered or pried into position to match up the flange discharge port connections must take into account
face with the compressor, there will be excessive vibration, pulsations, temperature, maximum
pipe strain. A properly matched up pipe flange will pressure applied, corrosion, and chemical
have just enough space to slip in a gasket, will allow resistance. Where compatibility questions may exist,
all flange fasteners (bolts, studs, etc.) to pass contact your Ingersoll-Rand representative.
through the flange bolt bores without adjustment of
the mating flanges, and does not twist in any plane
when the fasteners are tightened.
Inlet Air Piping
All piping connected to the Centac compressor Inlet air is the lifeline of any compressor. It is
should have provisions for compressor imperative that the compressor receives clean
maintenance. This usually means that there are filtered air to function correctly with low
flanged sections or unions in the connecting pipe. A maintenance. A well thought out piping design will
sufficient number of removable sections of pipe save many hours and dollars in maintenance.
should be provided to allow ease of maintenance
and repair. Failure to make provisions for repair will Whether the inlet air piping is supplied with the
result in difficulty during disassembly. compressor or by others it must be inspected for
cleanliness by an Ingersoll-Rand factory certified
service technician prior to start-up.

Air Piping
Maintenance Access to the filter should be provided with ample
It is advisable that you install spool pieces that allow room around the filter for maintenance. A permanent
the casing sections to be removed and the piping to platform should always be built around elevated
be out of the way of personnel for maintenance. The filters to provide safety for personnel assigned to
inlet pipe will be removed for inspection at start-up. changing filter elements.
The importance of always operating the compressor For best performance the inlet air piping should
with clean air inlet piping must be stressed. No conform to the following recommendations:
compressor will accept the ingestion of foreign
material into the operating components without • The inlet piping, from the inlet filter to the
possible damage or loss of performance. compressor, must be clean and made from a
non-rusting material such as stainless steel,
Inlet Air Filter aluminum, or PVC, and suitably flanged so that it
An inlet air filter should be mounted by the customer may be inspected in sections.
at a suitable location. At minimum, it should be a
• Inlet piping should be short and direct, with the
high efficiency two-stage unit designed to remove
combined filter and piping pressure drop less
99.97% of all particles larger than 2 microns and
than 0.3 psi (2.1 kPa[a]).
90% of all particles larger than 0.4 microns. For
adverse environmental conditions, a more efficient • Always use long radius elbows.
inlet air filter is recommended. • Transitions in pipe diameters should be gradual.
• Any horizontal run of pipe should be installed so
The inlet filter is normally oversized to increase the that condensation in the piping will run away from
time between element changes and to reduce the the compressor.
velocity through the filter to give a lower noise level.
• Drain valves should be installed in the inlet piping
at low points to allow the removal of
Routine inspection of the filter is recommended and
condensation.
the addition of instrumentation to indicate pressure
drop across the filter elements is also suggested.
When this drop increases substantially, the elements Inlet Filter
should be cleaned or replaced..
Remote Inlet Air Filter (Panel Type)

When the filter is mounted at a remote location with Work platform
the inlet air piping supplied by others, the following 8 ft. (2.4 M) Min.
recommendations should be observed. Roof Line
The remote inlet air filter should be, at minimum, a

Entire pipe to be non- Max ∆p 0.3 psi (2.1 kPa
high efficiency unit designed to remove 99.97% of all
corroding material
particles at 2 microns or larger. For adverse
Pipe Hangers
environmental conditions it is recommended that you
use a special filter, such as:
∆p Removable
transition
• A 0.3 micron inlet air filter
piece
Inlet air temp
• An inertial spin filter
• A chemical type filter
Long radius elbow
Check with your Ingersoll-Rand representative for Inlet valve
specific filter information. Low point drain
Minimum
of 4 pipe
The air filter should be located as close to the unit as diameters
Figure 1.4
possible to minimize pressure drop. If the filter is Inlet Air Piping – Air Filter
located outside the compressor building, the inlet
housing should be at least 8 to 10 feet above the
ground or roof and 6 feet away from the side of a
wall. (See Figure 1.4)

Air Piping
Bypass Air Piping The bypass piping should be suitably flanged so that
Atmospheric bypass piping vents the compressed a minimum amount of pipe needs to be removed
air when the compressor is running unloaded or at during major maintenance. This will reduce
partial load. Bypass piping should be well supported maintenance time.
to minimize loading on the compressor flange. Care
should be taken in the piping design so that all The end of the pipe should be turned down or have
alignments can be made in the piping. a short run of pipe to prevent rain and snow from
entering the bypass piping. Expanded metal should
A bypass silencer should be installed in the be installed on the end of the pipe to prevent large
atmospheric bypass line to reduce noise. A suitable objects and animals from entering the pipe when the
silencer is offered as an option with the compressor compressor is stopped. To remove condensation
package and is customer mounted. The silencer has from the piping, install a drain in the lowest part.
acoustic absorption material at a controlled density.
The silencer is usually installed close to the Expansion Joints
compressor and the vent piped outside. Alternately, With proper piping layout and installation, expansion
the silencer may be installed outside the building. joints may not be required on all compressors.
Consult the certified drawings for complete details of However, expansion joints are required on:
the silencer.
• All hot air discharge compressors (no internal
For sound attenuation in piping, a straight horizontal aftercooler)
run of pipe from the compressor flange, at least 8
• All steam turbine driven
pipe diameters long, is suggested before entering a
long radius elbow (see Figure 1.5). The silencer • On the inlet and discharge
should be kept as close to the compressor as
possible and the total length of pipe kept short. In Expansion joint installers must consult the
noise critical areas, the discharge piping from the manufacturer’s instructions to ensure correct
silencer may be lagged to further reduce sound. installation.
Discharge deflector !
Warning
Roof Line Improperly applied and/or installed expansion joints
can result in severe injury, death, or property
Hanger (typ) damage due to over stressing and fatiguing of the
bellows material.
Silencer
! Note
Alt. Side wall
Long radius
While Ingersoll-Rand may recommend or even
discharge Drain
elbow Minimum supply an expansion joint, proper installation is the
8 pipe customer’s responsibility.
diameters
Figure 1.5
Bypass valve
Model Bypass Pipe
Discharge Air Piping
For the best performance, a straight run of pipe
Discharge piping from the silencer should be sized which is at least 3 pipe diameters long should be
so that the maximum backpressure on the silencer is interposed between the discharge check valve and a
5 psi or 35 kPa (a). Standard silencers are equipped long radius elbow to allow for smooth operation of
with ANSI 150# standard flanges. Bypass piping to the check valve. The piping should be the full size of
the silencer should be of the same diameter or the compressor discharge connection. Where pipe
larger than the bypass valve. Piping from the bypass diameter conversion is necessary, the transition
silencer should be of the same size or larger than should be gradual. The use of long radius elbows is
the silencer discharge. Refer to the certified drawing recommended and piping may be sized by normal
for complete details of silencer. methods.

Air Piping
On all compressors it is necessary to install a spool
piece that will allow parts of the compressor to be ! Warning
removed and piping to be out of the way of The use of plastic piping, soldered copper
maintenance personnel. The customer should install fittings, or rubber hose, as part of the discharge
a block valve in the discharge line to isolate the unit piping is not recommended. In addition, flexible
for maintenance. A safety relief valve should be joints and/or flex lines can only be considered for
installed between the block valve and the such purposes if their specifications fit the operating
compressor because the compressor will surge if the parameters of the system. Failure to adhere to these
block valve is not open before the compressor is recommendations can result in mechanical failure,
started. The safety relief valve allows the air to blow property damage, and serious injury or death.
and protects the compressor.(see Figure 1.6).
It is the responsibility of the installer and owner to
provide the appropriate service. piping to and from
! the machine.
Note
Drain valves should be installed in piping low points
to remove condensation, which might form during Adequate piping support is needed to prevent
periods of shutdown. Piping should be designed so excessive dead loads on the compressor flange.
that the condensation will not drain back to the Provisions should be made in the discharge piping
compressor. so that all alignments are made in the piping and not
the compressor.
Block valve
Figure 1.6
Model Discharge Pipe
Safety valve
Pipe hanger
CA tap in. To be located a

minimum of 10 pipe
Discharge temperature diameters from check valve
in non-turbulent flow area.
Discharge pressure Non-rusting control air line.

Connects to control panel at
connection marked ‘CA’.
Maintenance flange
Long radius elbow. Located a

minimum of 3 pipe diameters
from check valve. Compressor mounted
check valve.
Low point drain

Air Piping
Compressor Connections
1CV, 1CV, 1ACV 1ACV 1BCV ALL

1ACV, 1ACV, 1500 – 2300 CFM >2300 CFM
1BCV 1BCV
800 –1200 CFM >1200 CFM
Inlet Air Connection: 6 in. 150# 8 in. 150# 8 in. 150# 6 in. 125# 6 in. 125#
ANSI FF Flange
Discharge Air: 3 in. 150# 3 in. 150# 3 in. 125# 3 in. 125# 3 in. 125#
ANSI FF Flange
Discharge Air 3 in. 150# 3 in. 150# 4 in. 150# 4 in. 150# 4 in. 150#
Connection (HAD):
ANSI FF Flange
Bypass Air Recirc. Recirc. Recirc. 2 in. 125# 2 in. 125#
Connection: Pipe Pipe Pipe ANSI FF ANSI FF
Flange Flange
Bypass Air (HAD) 2 in. 150# 2 in. 150# 3 in. 150# 3 in. 150# 3 in. 150#
ANSI FF Flange:
Water Manifold Conn. 2 in. 150# 2 in. 150# 3 in. 150# 3 in. 150# 3 in. 150#
ANSI RF Flange

Air Piping
Discharge Air Piping for Multi-Compressor Centac compressor connections and sizes are
located on the certified customer prints. Refer to the
Installation General Arrangement Drawing and the Process and
Instrumentation Diagram for further detail.
Parallel Operation with Positive Displacement
Compressors Receivers
The steep performance curve of the Centac Receivers store compressed air for systems in which
compressor allows for operation in parallel with air demand fluctuates over a short period of time. A
piston or rotary screw compressors (see Figure 1.7). properly sized receiver will decrease the number of
However, piping layout design should isolate the times the compressor loads and unloads. This will
Centac compressor from the pulsations in the increase the compressor's efficiency and decrease
discharge produced by these compressors. Piping wear on valve components. Receivers can be
the Centac compressor into the discharge header installed as "Wet" (before the dryer) or "Dry" (after
downstream of the pulsation bottle or receiver the dryer) receivers or in both locations. Contact
effectively eliminates pulsation problems. your local Ingersoll-Rand representative for
assistance in properly sizing and locating this
Fast valve operation allows the lagging compressors equipment.
to supply huge quantities of air at system pressure.
Proper consideration to the entry of this added A receiver may also be used to isolate centrifugal
capacity into the system will eliminate control or compressors (or other equipment) from pulsations
surging problems commonly associated with this created by positive displacement air compressors. A
type of installation. pulsation bottle may be needed to eliminate
pulsations more effectively.
Discharge piping from the compressor should enter
the system header by way of long radius elbows or
at an angle in the direction of flow. By staggering
entry into the header the added capacity will have no
detrimental effect on the other units already on line.
Recips or Recips or
Centac Centac
Screws Screws
Receiver
Flow
Long radius elbow System Header
Angle with flow
Flow
Centac Centac
Centac
Centac
Figure 1.7
Centrifugal and Positive

Air Piping
Control Air Piping Instrument Air Piping

The control air pipe connection is made at a Instrument air must be provided for the operation of
minimum of 10 pipe diameters downstream of the the pneumatic control valves and for the seal buffer
discharge check valve in the discharge pipe (see air. The air used must be clean dry instrument
Figure 1.6). The control air line connects to the quality air. For best results, piping should be
control panel bulkhead fitting marked ‘CA’ (see connected to a refrigerated air dryer and filter prior
Figure 1.8), which is a 1/2 inch NPT connection. The to connection on the unit. The Centac compressor
control air line should be a minimum of 1/2 inch normally requires 10 SCFM (0.33 m 3 /m) of air at
diameter, made of a non-rusting material such as 60-120 PSIG (414-827 kPa).
stainless steel, aluminum, or copper. If the control
air line is to be installed in a horizontal run of The final filtering medium should be rated at a
discharge pipe, it should be located at the top of the theoretical efficiency of 99.9999%, particle size of
discharge pipe to minimize condensate or debris 0.01 micron, and a minimum or 25 SCFM (0.82 m 3 /
buildup in the line. m). This filter should be located close to the control
panel. An isolation valve may be located ahead of
The control air line should be routed to the control the filter.
panel in such a manner that the line will not have to
be disconnected in order to perform major Piping from the instrument air source should be
maintenance. A drip leg with a drain valve, which constructed of 1/2 inch minimum non-corroding
can be used to remove condensate, is material to limit the possibility of corrosion products
recommended as part of the customer’s control air entering the system. Instrument air piping connects
line. to the control panel at the 1/2 inch NPT bulkhead
fitting marked “IA”.
Seal Air
Power Air
Control Air PT3 PT4 Instrument Air

Figure 1.8
PT1
Control Panel Connections

Air Piping
Short Test
1 What are some sources of piping strain?
2 Why should the air filter be located close to the unit?
3 Why should bypass piping be flanged?
4 How do you ensure smooth operation of the check valve?
5 Why and where should a safety relief valve be installed?
6 How can you eliminated pulsation problems?
7 What is the rating for filtering medium?

Water System Piping
• Total hardness expressed as CaCO3 should be
In this section, you will learn less than 100 PPM.
• Cooling water piping – how it provides • Acidity should be within the 6.0 to 8.5 pH range.
cooling water to the air and oil coolers of the • Suspended solids should not exceed 50 PPM.
compressor
• The langelier saturation index should be between
• Cooling water specifications and +0.5 and +1.0.
recommendations for clean water
• Air cooler vent and drain connections to air The Langelier’s index is a technique of predicting
vents and cooler drains whether water will tend to dissolve or precipitate
• Condensate drain piping that provides a calcium carbonate. If water precipitates calcium
means of removing condensate from the carbonate, scale formation may result and this water
moisture removal sections will have a corrosive tendency. Other factors that
contribute to corrosion include:
• Temperature differences within a system.

• Changing operating conditions.
• Presence of chemical treatment in the water.
Cooling Water Piping • Presence of dissolved oxygen in the water.
Unless otherwise stated, water flows are based on
the design conditions of the compressor for rated
discharge pressure with 80°F cooling water
Air Cooler Vent Lines
temperature. Air cooler vents with valves are provided at the
highest point on the air cooler casings. They are
Sizing of water pipe may be done by conventional supplied to ensure that the
methods based on the GPM flows given. The size of coolers are full of water
pipe may be determined so as to hold flow velocities when the compressor is
in the range of 6 to 7 ft/sec. The pipe design must operating and no air
allow for a minimum water pressure of 35 PSIG and pockets form in the
the maximum water pressure of 75 PSIG (see coolers. If part of the
General Arrangement Drawing for connection cooler is starved for water,
locations.). overheating may occur
resulting in damage.
A throttle valve is recommended on the discharge
line to aid in temperature control. Placing the throttle The vents should remain
valve on the discharge line helps ensure that the open at all times. The
coolers operate full of water. In addition, gate valves connections must be
should be fitted at the inlet of the water system to piped, by the customer, to
allow isolation of the compressor when necessary. a drain or suitably
connected to the
In dirty or silt laden water systems, a piping compressor water
arrangement that will allow for backflushing the discharge with a sight flow
coolers must be used. The backflush valve indicator for each air
Figure 1.9
arrangement is one where water flow may be cooler (see Figure 1.9). Visual indicator of water flow
reversed in the coolers and foreign matter flushed through vent lines.
out (see diagram of Cooling Water System Do not connect the vent
Backflush on next page). lines together. When a closed cooling water system
is utilized, casing vents should be piped to the lower
Regardless of the cooling system used, a strainer pressure discharge water line to ensure flow through
should be installed in the water supply line. the vent piping.
Cooling Water Specification Condensate Drain Piping

Water used for cooling should be clean and free of Air entering the first stage of the unit carries with it a
corrosive elements. It is best that the water used is certain amount of moisture. The amount of moisture
filtered and treated to fall within the following depends on the temperature and relative humidity.
specification: The maximum moisture content occurs on days of
high temperature and high relative humidity.

Water System Piping
= Water Line

Water System Piping
Moisture is removed from the air as it passes maintenance is minimal, a high-level condensate
through each stage of compression. As the air and shut down alarm should be used. If the traps
passes through the coolers, water vapor in the air is become clogged, water carry-over in the unit will
condensed and collected in the moisture separator. result.
This condensation is removed by condensate traps
to prevent water carryover into the next stage of ! Caution
compression. Excessive water carryover may create
problems. All air and water pipes, to and from the inlet
and discharge port connections, must take into
Condensate traps with bypass valves for each stage account: vibration, pulsations, temperature,
are factory installed (when ordered). Each maximum pressure applied, corrosion and chemical
condensate trap must be provided with a separate resistance. In addition, it should also be noted that
drain. In addition, each trap discharge should be lubricated compressors discharge some oil into the
piped to a drain that will allow a visual check of the air stream, therefore, compatibility between
individual trap function (see Figure 1.10). discharge piping, system accessories, and software
must be assured. Where compatibility questions
The location and size of the trap discharge exist, contact your nearest Ingersoll-Rand office.
connection is listed on the General Arrangement
Drawing. The piping arrangement is shown on the It is the responsibility of the installer and owner to
Process and Instrumentation Diagram. provide the appropriate service piping to and from
the machine.
If the unit is unattended or in a location where
Compressor stage (Typ)
Pressure Balance Line
Float Condensate Drain
Trap Bypass Valve
Valve
Drain Air Gap

Trough
To Floor Drain
Figure 1.10
Standard Condensate Trap and Drain Arrangement

Water System Piping
Short Test
1 What are the minimum and maximum water pressures that piping must allow
for?
2 What is the Langelier Index?
3 Why are air cooler vents needed?
4 When should these vents be closed?
5 Why is it important to have a visual check of the condensate traps?

Installation and Training Section 3
Electrical Connections
Control Panel Power

In this section you will learn about The standard Centac compressor control circuitry is
• Control panel power designed for a 120 VAC source. If the customers
• Starter interface source is greater than 120 VAC, a control
transformer must be used. Check the Electrical
• Main driver connections Schematic to determine whether the control
• Heater contactor transformer has been factory installed.
• Prelube pump starter
To properly make electrical connections to the
• Current transformer
control panel, refer to the Electrical Schematic to
• Optional switches identify the proper terminals for wire connection, and
refer to the panel outline drawing for conduit entry
size. Incoming power should be connected to the
WARNING appropriate terminal blocks in the control panel as
! shown by the Electrical Schematic.
Warning
Electrical-trade personnel must perform electric Starter Interface
installation on the Centac compressor. Electricity The standard starter connections are panel
can cause serious injury or even death if proper mounted. The remote starters are optional and they
handling and installation procedures are not require two interface points:
observed. Contact a qualified electrical installation
contractor for help installing and/or maintaining any
1. A feedback circuit, which indicates a running
electrical services to this compressor.
condition, is connected to the control circuits
inside of the compressor's control panel. This is
done by the customer.
! Caution 2. The starter’s on/off circuit is connected with the
panel’s start control relay. Local start pushbuttons
The unit must be properly grounded. There
on the starter should not be used. The starter’s
must be at least one grounding strap from the
120 VAC control circuit should be connected to
compressor skid or baseplate. The connection must
the control panel start circuit. Do not exceed 720
be made to an independent ground and not to a
VAC. The circuit must be wired in series with the
plant system ground. Inadequate grounding, or lack
starter. The starter must not be powered by any
of grounding, may result in operational problems.
other source other that Ingersoll-Rand’s control
Additional grounding may be required for the
panel.
compressor driver. Further information may be
obtained from the National Electric Code or other
electrical information sources. Motor Connections
Three-phase power must be connected to the starter
and the three-phase wiring must also be connected
from the starter to the main motor. The motor will be
! furnished with leads terminating in a junction box on
Note
Design and installation of disconnect, the side of the motor to which the three-phase wiring
overvoltage, short circuit, and overload protection is from the starter is to be terminated. Refer to the
the responsibility of the customer. main motor nameplate and manufacturer’s data
sheet to properly size the three-phase wiring that
connects the starter to the motor. The customer
should ensure that the incoming voltage matches
the voltage on the main motors nameplate. Before
wiring and applying power to the main motor, you
must test the insulation resistance using an
“Insulation and Continuity Tester” (Megger) to
ensure the integrity of the insulation.

Installation and Training Section 3
Electrical Connections
Heater Contactor Optional Switches

This device is required for operation of the oil Optional switches such as pressure, temperature,
reservoir heater. It must be sized according to the flow, etc. supplied by Ingersoll-Rand but mounted by
electrical information found on the oil reservoir the customer must be connected to the control
heater nameplate. Ingersoll-Rand supplied oil panel. Information on how to wire these devices to
reservoir heaters have thermostats mounted within the control panel is shown on the Electrical
the housing for “pilot” type operation of the Schematic.
contactor. Ingersoll-Rand supplied contactors are
mounted inside the control panel enclosure.
Prelube Pump Starter

This device is required for operation of the prelube
pump driver. It must be sized according to electrical
information found on the prelube pump motor
nameplate. Ingersoll-Rand supplied prelube pump
starters are mounted inside the control panel
enclosure.
!
Warning
Do not disconnect secondary wiring during
operation. Anytime secondary side of the current
transformer is disconnected from its load, a jumper
must be placed across secondary terminals to
prevent injury or death of personnel and/or damage
to equipment.
Current Transformer
This device may be required to provide a 0-5
ampere signal to one or more devices located in the
control panel. When supplied by Ingersoll-Rand, the
current transformer is often shipped loose for
installation by the customer. Refer to the unit's
electrical drawings, motor nameplate data, motor
manufacturers data sheet and starter manufacturers
data sheet to properly size the current transformer.
! Warning
An appropriate grounding strap should be
attached to the motor and a suitable ground.
DO NOT CONNECT TO A PLANT GROUND

CIRCUIT.

Lubrication
In this section, you will learn 6. Change position of the transfer valve at 15
• Procedures to flush piping and the casing minute intervals on systems having dual oil
filters and/or coolers.
• Standard oil and filter data
• Physical and Chemical requirements for 7. Shut off the prelube pump.
Techtrol Gold III Coolant
8. Drain the oil filter and inspect the element(s).
Continue with one of the following:
a) If foreign material is found in the filter
housing or element, replace the oil filter and
repeat step 4 through 8 until filter housing and
! Note element are clean upon inspection.
b) If no foreign material is found, go to step 9.
The initial fill of lubricant for the Centac
compressor should be installed under the
9. Replace the oil filter element(s) and inspect
supervision of an authorized Ingersoll-Rand
the housing for cleanliness.
Technical representative.
Cleanliness of the lubrication system is of vital

importance to the Centac air compressor. The Casing Flush.
system is flushed and fully tested at the factory. The
sump access cover should be wire sealed as 1. Reconnect lube piping to the gear casing.
shipped from the factory. If the wire seals have been
violated, then the following procedure must be 2. Apply instrument quality air to the seals
followed under the supervision of an authorized (6PSIG [41 kPa] minimum).
Ingersoll-Rand Technical representative.
3. Restart prelube pump and circulate lubricant
Piping Flush for one hour.
4. Tap any welded piping with a plastic or lead

1. Remove the sump access cover. Thoroughly
hammer during lubricant circulation to
clean the sump of any shipping oil and dry
dislodge any foreign material lodged at
with lint free rags.
welded joints.
2. Fill with recommended lubricant to the proper
5. Change position of the transfer valve at 15
level and replace sump access cover.
minute intervals on systems having dual oil
filters and/or coolers.
3. Disconnect the oil piping at the entrance to
the gear casing and use a flexible oil line to
6. Shut off the prelube pump.
route the lubricant to the sump in the
baseplate.
7. Drain oil filter and inspect the element(s).
Continue with one of the following:
4. Circulate the lubricant for a minimum of one
hour using the prelube pump. Optimum
If foreign material is found in the filter housing
flushing temperature is 100°F.
or element, replace the oil filter and repeat
step 3 through 7 until filter housing and
5. Tap any welded piping with a plastic or lead
element are clean upon inspection
hammer during lubricant circulation to
dislodge any foreign material lodged at the
If no foreign material is found, go to step 8.
welded joints.
! Warning
8. Replace the oil filter element(s) and inspect
the housing for cleanliness.
Hot oil can cause serious injury to personnel.
Precaution must be taken to prevent contact with 9. Fill sump to the proper level with
hot oil recommended lubricant.
10. Replace sump access cover and secure.

Lubrication
Recommended Lubricant Physical and Chemical Requirements for

Lubrication for the compressor system should be a Techtrol Gold III Coolant.
synthetic lubricant. The lubricant must have unusual
oxidation stability and contain defoaming inhibitors
and be free of inorganic acids or alkali. There must Property ASTM Limits
be no tendency toward permanent emulsification Test
and a minimum tendency to oxidize or form sludge Method
when agitated at operating temperatures when
mixed with air and water. Ingersoll-Rand highly Physical
recommends Techtrol Gold III a synthetic lubricant
as is specifically formulated for Centac compressors. ISO Viscosity Grade D2422 32
CAUTION
Viscosity Index D2270 139
! Caution Viscosity, cSt (SUS)
Some lubrication mixtures are incompatible with
each other and result in the formation of varnishes, @ 0oF/-17.8oC D445 895 (4195)
shellacs or lacquers which may be insoluble. Such
deposits may cause serious trouble, including @ 100oF/37.8oC D445 30 (142)
clogging of the oil filter. Avoid mixing lubricants of
the same type, but of different brands. A brand @ 104oF/40oC D445 28 (133)
change is best made at the time of a complete
lubrication change. @ 210oF/98.9oC D445 5.6 (45)
CAUTION
@ 212oF/100oC D445 5.5 (44)
! Caution Pour Point, oF (oC) D97-87 -40 (-40)

Lubricant obtained by the user for operation of Flash Point, COC F ( C) o o
D92 450 (232)
this equipment must comply with the following
specification and perform satisfactorily in the Flash Point, PMCC oF (oC) D93-85 390 (199)
compressor. The Ingersoll-Rand Company assumes
no responsibility for damages caused by non- Chemical
compliance to this specification within the period of
its standard equipment guarantee or thereafter. On Total acid number, mg D664 0.1
subsequent purchases of lubricant for use with this KOH/g, max.
equipment, the user is cautioned to be on the alert
pH D664 8
for any changes in the lubricant that may deviate
from this specification thereby causing equipment Density D941 0.988
damage. (Grams per cc @ 25oC
Specific Gravity D941 0.99
Copper Strip Corrosion, D130 1
3 hrs @ 212oF/100oC
Ferrous Metal Corrosion D665A Pass
(Rust Test)
Foam Tendency D892 0 (Nil)
(Sequence 1, 11, 111)
! Note
The initial lubricant supply required for the
compressor installation is not normally supplied
with the compressor.

Lubrication
!
Note
Failure to meet this specification may result in
damage to internal compressor components.
! Note
The Pour point specification must be met
unless there is a means available for heating the oil
when used in low temperature areas.
! Note
Lubrication specifications are constantly being
reviewed. Verify that correct lubricant is used by
consulting appropriate serial number manual.
Ingersoll-Rand does not endorse any other trade
name product or any individual oil company.
Reservoir Capacities
Sump Capacity
Model Number
(Gallons) (Liters)
2AC11 131 496
Actual capacities will vary with specific sumps. The
above listed values are for standard Centac
models. Review of the Specification section of the
compressor Operation Manual is recommended for
exact capacity of a specific unit. The above values
do not apply to API style sumps.
Standard Oil Cooler and Filter Data

Lube Oil Cooler
Water side design pressure 150 PSIG 1034 kPa
Shell side design pressure 150 PSIG 1034 kPa
Lube Oil Filter

Dual Element 10 Micron
Recommended Minimum Oil Temperatures

Starting 95°F
35°C
Operating Bearing Inlet 100°F to 115°F
37.5°C to 46°C.

Lubrication
Short Test
1 What must be done if the wire seals on the sump access cover are not intact?
2 What type of lubricant should be used in a Centac?
3 What can happen if the lubricant used does not comply with IR specifications?

Weights and Dimensions
Specific machine weights and dimensions will vary
according to motor selected and any additional
special options purchased. The weights and
dimensions provided are to be used for estimating
purposes only. Refer to the specific General
Arrangement drawing for actual dimensions.
Weight
Length Width Height without
motor
148
89 inches 74 inches 17,000 lb
inches
2261 mm 1880 mm 7,711 kg
3759 mm
Compressor Connections
Inlet Air Connection 10in. 125# ANSI FF Flange
Discharge Air Connection 6in. 125# ANSI FF Flange
Bypass Air Connection 4in. 125# ANSI FF Flange
Air Cooler Connections 2in. 125# ANSI FF Flange
Oil Cooler Water Connections 2in. NPT

Recommended Tools
The following list of standard mechanic’s tools is
provided as a guide for maintenance and installation
of a Centac compressor.
• Lifting Device (1/2 ton, or 500 kilos minimum)

• Allen wrenches
• Feeler gauges
• Drive sockets with extensions
• Open end and box wrenches
• Adjustable wrenches
• Pipe wrenches
• Torque wrench (to 200 ft-lb or 300 Nm)
• Vise grips
• Channel locks
• Rubber or Lead hammer
• Dial indicator with magnetic base
• Digital Multimeter
• Machinist scale
• Transit Level
• Micrometer

Shaft Alignment
An understanding of good shaft alignment
In this section you will learn about techniques must begin with a few basic definitions.
• Different methods of shaft alignment
Cold or ambient alignment is the procedure that
• How to use the shaft alignment map involves positioning the frames or casings of
• Hot alignment checks compressors and other rotating machines while at
standstill and ambient conditions. The “cold shaft
alignment” is normally accomplished using dial
Most compressors are factory tested with their indicators, feeler gauges, micrometers or a
contract drivers. The remainder are tested with shop combination of these instruments. This positioning
drivers. should allow for thermal growth and material
deflections that will occur between ambient
Even though all drivers are aligned for factory conditions and stabilised operating temperatures.
testing, they must be checked for alignment after The incremental movement used to establish the
completing installation of the compressor at the site. cold shaft alignment may be actual measurements
They must be re-aligned if necessary to bring within made during start up or shutdown, growths
the specified tolerance. The alignment tolerances estimated by the machinery manufacturer or
and recommended procedures are outlined in the estimates made by those installing the equipment.
following sections.
Testing has shown that the compressor drive motor
Dowel pins are not factory installed in the driver feet will rise slightly higher than the compressor upon
due to the possible need for realignment in the field. reaching their normal operating temperature. The
After final coupling alignment is complete, install vertical thermal growth of the motor shaft is greater
dowels in the driver fee as noted on the driver than the compressor shaft due to the heat from the
outline drawing. Pilot holes are provided in the driver oil reservoir which is located beneath the motor. It is
feet for dowels. recommended that the motor shaft be aligned to the
compressor shaft .000—.005 inches (.00—.13mm)
Compressors and their drivers are connected by low.
flexible couplings. These couplings are used
because changes in temperature and loadings Hot shaft alignment, also known as operating shaft
during normal operation, start up or shutdown can alignment or service alignment is a procedure for
cause one shaft to move relative to its companion monitoring the change in shaft alignment from cold
shaft end. or ambient conditions to normal operating
conditions. Knowing the cold shaft alignment and
All flexible couplings have limits within which they measuring the change, provides a method for
can operate without failure or undue wear. Even determining if the shaft alignment becomes collinear
when operating within the design limits, these at normal operating conditions. This method is
couplings generate some resistance to flexing. The indirect, but if properly done, provides the most
force usually increases as the misalignment realisable and acceptable methods available.
increases thereby increasing or decreasing bearing
load fluctuations as the shaft rotates. Furthermore, In Figure 14, the two machine shaft ends are
operating with collinear shafts at normal operating considered to be collinear aligned when the two
conditions minimise tooth sliding velocity or shaft ends rotate about the same straight line (no
diaphragm flexure while providing the maximum misalignment). All machinery shafts have some
reserve for movement in any direction should it be deflection; therefore, this reference is limited to the
required. center of rotation of one shaft and relative to the
opposite shaft end.
Experience indicates that excessive vibration of
compressors and their drivers is often caused by
improper shaft alignment. In extreme cases, poor
alignment can precipitate a coupling failure. For
smooth operation and long trouble-free runs, good
shaft alignment procedures are essential and cannot
be over emphasised.
Figure 14 Collinear Aligned Shafts

Shaft Alignment
Parallel offset indicates the amount of parallel Shaft Alignment Map
misalignment between the centerlines of two Preparation and use of a shaft alignment map
adjacent shaft ends. Figure 15 shows two shafts (Figure 18) is recommended. Use of a shaft
with only parallel offset. alignment map provides a convenient form on which
to record indicator readings and calculate equipment
moves. Maintaining this information for comparison
during maintenance inspections or for future
reference can provide valuable diagnostic
information should problems develop.
Offset
In addition to providing machine identification

information, data and shaft alignment method used,
Figure 15 Parallel Offset
the shaft alignment map provides a plan (top) and
vertical (side) elevation of the machine shafts,
Angular or face displacement indicates the
amount of angular misalignment at a shaft end. In complete with all the important reference points
Figure 16, shaft end “A” has zero angular identified. The horizontal or abscissa coordinate
should be scaled using some convenient scale such
displacement while shaft end “B” has an angular
displacement. Normally, angular displacement is as 1 or 2 inches per division (25 or 50 millimetres
measured in mils of offset per inch (mm of offset per per division)
cm) of coupling diameter or axial separation. Both
All support feet and coupling faces should be
definitions say the same thing as can be seen by an
analysis of similar right triangles in Figure 16. located. The vertical or ordinate coordinate should
be expanded scale such as 1 mil (0.03 millimetres)
per division in order to clearly identify misalignment.
Angular Displacement Mark North compass direction in plan view and
corresponding compass directions in indicator
reading circles so no confusion develops during
measurements.
“A” When making shaft alignment corrections, it is

“B”
usually advantageous to hold one machine in a fixed
Figure 16 Angular Displacement position and align the other machine to the fixed
machine. It is preferred to level the compressor and
When the coupling connecting two shaft ends is a move the driver into the desired cold alignment. The
gear type, an axial separation (Figure 17) of the plus compressor is factory doweled into position.
or minus .0625 inches (1.60mm) tolerance is usually
acceptable. Check coupling drawing and coupling The solid, dark, heavy lines on the shaft alignment
manufacturer’s drawing and/or instructions for map represent the designed hot shaft alignment; i.e.,
precise limits. collinear alignment. Plot historical or calculated
thermal expansion or contraction change for each
support location on shaft alignment map. Connect
Axial Separation
points plotted for each machine with a dashed line.
Use dashed line for desired “cold alignment setting.”

Read off differences between the two dashed lines
in vertical plane and record desired readings in
circles so marked. Plan or horizontal alignment
Figure 17 Axial Separation usually remains unchanged from ambient (cold) of
bottom reading.
The reverse indicator method is the recommended
alignment procedure when the distance between the
adjacent shaft ends is greater than one-half the
coupling diameter.

Shaft Alignment
Figure 18 Shaft Alignment Map

Shaft Alignment
! Note
For all Rim Measurements
Actual measurement is 1/2 TIR (Total Indicator
Reading), therefore value of measurement shown on
indicator reading circle should be twice the distance
indicated on plot.
Offset value is plus (+) if the projected centerline of

machine that the indicator is attached to, is above
coupling mark of the machine that the indicator is
riding on.
Sometimes the work descriptions such as used on

an alignment map can be confusing. Figures 19 and
20 are pictorial views of Note 3 and Note 4 on the
alignment map.
Figure 19 Pictorial of Note 3 on Shaft Alignment Map
Figure 20 Pictorial of Note 4 on Shaft Alignment Map

Shaft Alignment
Reverse Indicator Method of Shaft movement exceed 2 mils (0.05mm), piping strain
is considered excessive. The reason for the strain
Alignment must be investigated and the condition corrected
1) The reverse indicator method of shaft alignment before proceeding with alignment.
should be used when distance between the shaft 6) When spanning the coupling gap with an indicator
ends is greater than one-half the coupling rig or bracket, zero sag is impractical to achieve;
diameter. therefore, the actual amount of sag should be
determined and recorded on the alignment map.
! The bracket should be sturdily constructed to
Note minimise shifting and sag during use.
For alignment purposes, the effective distance
between shaft ends can be increased by spanning
the shaft end to obtain a dial indicator location !
inboard of actual shaft ends. The key factor is to Note
spread two indicators as far apart as practical with For purposes of this explanation, the fixed machine
negligible bracket sag. (As spread increases, so (compressor) is called Shaft “A”. The shaft of
does the possibility for bracket sag.) machine to be aligned to shat “A” will be called shaft
“B” (driver). Therefore, shaft “B” belongs to the
This method of shaft alignment eliminates the machine that will be moved.
need for taking face readings.
2) The reverse indicator method involves taking 7) Attach the indicator bracket to shaft “A”.
reading from one shaft to the rim surface on the
job of the adjoining shaft and vice versa as shown 8) Attach the dial indicator to the bracket so that
in Figure 21. the button will rest on the outer rim of coupling
hub “B”. The indicator button should contact in
about 0.25 inch (6mm) from the hub face.
First Set of Readings
Read here
9) Position dial indicator at top dead center, in line
with 0o marking on coupling “B” and zero the
indicator.
10) Rotate both shafts together and record dial
readings on alignment map at 90o, 180o and
Shaft “A” Shaft “B” 270o positions. On return to the top position, the
indicator should return to zero. Repeat this step
Second Set of Readings
several times to be certain no mistake has been
made or something has moved.
11) The accuracy of the readings may be verified
Read here by algebraically adding the side readings and
comparing this sum to bottom reading. The
readings should be equal to or within 1mil
(0.03mm).
Shaft “A” Shaft “B” 12) Remove the bracket from shaft “A” and install
Figure 21 Reverse Indicator Readings on shaft “B”. Using the same procedure obtain
indicator readings from shaft “B” to the rim of
3) Lubricate bearings before rotating shaft. coupling hub “A”.
4) Mark both the coupling hubs at four locations 90o 13) Using the two equations shown on the
apart so that their position can easily be seen at suggested shaft alignment map, calculate the
all times during the alignment work. vertical offset (Vo) and the horizontal or plan
view offset (Ho). Plot these results in the proper
5) All piping strain must be removed from the
equipment. For initial alignment work during view and in the axial location where indicator
installation, all piping should be left unconnected readings were taken. Note 3 or 4 on the
from machinery. After cold alignment has been alignment map can assist in determining the
shaft location above or below other shaft.
secured, arrange dial indicators between shaft
ends, to detect any movement of the equipment.
Connect one flange at a time and observe When making this determination, it is
indicator readings continuously. Should

Shaft Alignment
sometimes helpful to locate the centerline of Hot Alignment Check
shaft end “B” first that is shaft end of machine to A hot alignment check can be made after the
be moved and then the projected centerline of compressor has operated for several hours and
shaft end “B” at shaft end “A”. In this stable operating temperatures have been reached.
explanation shaft end “A” is fixed and therefore This check will indicate any final adjustments
shaft “B” must be located relative to shaft “A”. necessary to achieve collinear alignment of the
driver and compressor under operating conditions.
! The purpose of the hot alignment procedure is to
Note
Correct the bottom for sag in the bracket by measure the movement of one shaft and relative to
algebraically adding to the bottom indicator reading. the opposite shaft end. As the shaft rotates, it is not
No correction is needed on the side readings since it practical to measure the actual position of one shaft
is negative on both sides and will cancel out. and relative to its companion with dial indicators, or
similar instruments, as was the case during the cold
alignment procedures.
14) In each view draw a straight line through points Therefore, most hot alignment procedures make the
located in Step 13, extending the line to assumption that the machine casing and bearing
intersect both supports of machine “B”. Read off housing expand uniformly in a radial direction from
the distance between line just completed and the shaft center of rotation and maintain this
the desired cold shaft position (dashed line) at relationship to the shaft center regardless of the
each support for machine “B”. This casing temperature.
measurement represents the movement
necessary to obtain the correct cold alignment. This basic assumption appears to be valid as
compressors and turbines are nearly symmetrical
15) Make the adjustments indicated in Step 14.
about the shaft; therefore, distortions are minimised.
16) Repeat Steps 7 to 14 to verify the adjustments Using this principle, the following method may be
made in Step 15 were correct. used to make a hot alignment check.
17) Unless otherwise noted, a final hot alignment
should provide for an angular displacement The mechanical hot alignment method uses
between the machine coupling hub centerlines accurate measurements between fixed reference
and coupling spaces centerline of points on the baseplate and the machinery bearing
approximately 0.25 mil per inch (0.25 mm/m) at housings to indicate shaft movement between
the coupling gear teeth or flex elements. This ambient and normal operating conditions. This
angular displacement is not a limit but a method assumes that the fixed reference points do
suggested alignment goal. Refer to the coupling not move between cold alignment conditions and
literature for more information on maximum machinery operation.
allowable misalignment.
In general, this is a good assumption provided one
After cold alignment has been made, the baseplate side or area of the baseplate is not exposed to direct
must then be grouted. sun when the other is not. Unprotected hot steam
and process lines passing in close proximity to the
baseplate can also contribute to uncertainty in
incremental movements.

Shaft Alignment
Realign as necessary
Regardless of the method used for making hot
alignment check, it must be evaluated for accuracy
of information measured. Temperature variations
and air currents can cause significant changes in
support temperatures between cold alignment
conditions and operating conditions. Expansions,
contractions and heat flow are therefore seldom
linear. This can and does contribute to introducing
errors in care is not exercised in analaysing results.
!
Note
Before making alignment changes based on hot
alignment data, evaluate the setup to be sure data is
valid and logical.
When the hot alignment check confirms that the

driver has been properly aligned, the driver should
be doweled as indicated on the outline drawing.
Installation checks
The entire compressor installation must be checked
and pre-start adjustments must be made prior to the
initial start up. It is recommended that this be done
under the direction of an service representative.
Final pre-start adjustments of the compressor are to

be done in accordance with the instruction book
issued for each compressor.

Shaft Alignment
Short Test
1 What can improper shaft alignment cause?
2 What is meant by “collinear alignment”?
3 What does cold shaft alignment mean?
4 What do the solid dark lines on the Shaft Alignment Map mean?
5 When should the reverse indicator method of shaft alignment be used?

Basic Centac Manual
Commissioning
Section 4
Pre-Start Checklist......................................................1—3
Initial Start Preparation ...............................................4—6
Natural Surge Test .....................................................7—8
Installation Check List.................................................9
Short Test ...................................................................10
Start-up Registration Form .........................................11—16
Warranty & Liability.....................................................17—19

Commissioning Section 4
Pre-Start Checklist
Checklist Summary
All systems on the Centac compressor should be
checked prior to initial start-up. This check should
be completed under the direction of an Ingersoll-
Rand customer service representative.
The operational checklist should be completed in

accordance with the individual units Operation
Manual. The following checklist is provided to
prevent over-sights which could delay start-up of the
unit and additional expense in correcting these.
!
Caution
The importance of starting and operating the
compressor with clean inlet piping cannot be over-
emphasized. Loss of performance or physical
damage could result from the ingestion of foreign
material.
1 Inspect the following for corrosion and cleanliness just prior to start-up:
a. Oil Reservoir (on compressors that do not have sealed covers)

b. Inlet Air Filter
c. Inlet Air Piping
d. Discharge Piping
e. Bypass Piping
f. Water Piping
2 Check inlet air filter location and installation.
3 Check the following on the inlet air piping.
a. Material (stainless steel or non-ferrous)

b. Minimum size
c. Distance to first elbow (minimum of 4 pipe diameters)
d. Facilities for moisture removal on any horizontal run of pipe
e. Piping supports/strain
f. Manometer or differential pressure gages on inlet air filter
4 Check the following on the discharge piping:
a. Minimum size
b. Distance to first elbow (minimum of 3 pipe diameters)
c. Piping supports
d. Facilities for moisture removal on any horizontal run of pipe
e. Safety valve (located between block valve and compressor)
f. Block valve
5 Check the following on the bypass piping:
a. Minimum size
b. Distance to first elbow (minimum of 8 pipe diameters from bypass valve)
c. Piping supports
d. Location of silencer
e. Facilities for moisture removal on any horizontal run of pipe..

Pre-Start Checklist
6 Check the following on the controlled air piping
a. Material
b. Minimum size
c. Attached to control panel at bulkhead fitting "CA"
d. Attached to discharge air piping a minimum of 10 pipe diameters from check valve
7 Check the following on the instrument air piping:
a. Material
b. Minimum size
c. Attached to control panel at bulkhead fitting "IA"
d. Attached to dry, clean air source, 60-120 PSIG (414-827kPa) 10 SCFM (15 Nm 3 /hr) per stage
minimum
e. Absolute air filter 0.01 micron
f. Shut-off valve
8 Check the following on the water piping
a. Minimum size
b. Attached to the compressor
c. Attached to the oil cooler
d. Water pressure between 35 (minimum)-75 (maximum) PSIG (241-517 kPa)
e. Differential pressure between inlet and outlet flanges on air coolers is normally between 12 (minimum)-5
(maximum) PSIG (83-103 kPa)
f. Check for water leaks (leave condensate trap bypass valves open)
g. Throttle valves at outlets
h. Block valve on inlet
i. Casing vents open
9 Check piping on condensate traps (piped to open drain).
10 Check compressor lubricant, motor lubricant, and coupling grease for conformance to specifications.
11 Fill oil reservoir to “Normal” level.
12 Check anchor bolts and grouting.
13 Check unit level.
14 Check all control panel connections per applicable schematics.
15 Check proper grounding of electrical power supply.
16 Manually rotate compressor and driver shafts, checking for free, uncoupled rotation with oil pump running
and seal air “on”.
17 Check driver per manufacturer's instructions found in the driver instructions.
18 Check driver electrical connections.
19 Check to see that driver bearings are properly lubricated.
20 Check direction of rotation and magnetic center of main drive on motor driven units prior to coupling to
compressor.
21 Align driver to compressor
22 Install coupling spacer and Lubricate coupling per Manufacturer’s instructions.
23 Check rotation of prelube pump (three phase only).
24 Check clearances on thrust bearings. Disregard if the access covers are wire sealed
25 Check vibration monitor per control section (if applicable).
26 Check lubrication system for oil leaks.

Pre-Start Checklist
27 Check operation and calibration of the inlet and bypass valves, as per the Operation Manual.
28 Calibrate all temperature and pressure switches
29 Functionally test control system.
30 Check operation of main driver trip device
31 Start and run compressor
32 Correct any oil, water or air leaks

Initial Start Preparation
The first time a compressor is started requires a After lubrication, tighten lube plugs to a torque value
special procedure. Follow the procedures in this of 50 lb. ft. See Table below.
section for each of the following:
Grease Quantity Recommendations
• Coupling Lubrication
• Main Driver Preparation *Grease TighteningTorque
Capacity LB.-IN.
• Control System Adjustment
• Inlet Valve / Inlet Guide Vane and Bypass Valve Size Weight Shrouded Exposed
Adjustment Lb. – Oz Bolts Bolts
• Lube system Adjustment H-2 0-5 23 50
• Oil Pressure Setting
H-21/2 0-8 55 100
! Note
H-3 0 - 15 55 100
The preparation for and the initial start-up of *Lubricant capacities for each size and
the Centac compressor should be done under coupling style. This is the total
supervision of an Ingersoll-Rand service supervisor. lubricant required for both coupling
halves
Cenlube GL Grease
! Warning Ingersoll-Rand provides synthetic grease for
Coupling lubrication is critical. The use of lubricated couplings. This grease is a non-
proper and sufficient lubrication is part of a hazardous anti-friction bearing and coupling grease
successful installation. Do not use oil in gear designed for all speeds of machine between - 40°F
couplings. and 500°F.
Recommended Lubricants - Gear Coupling

Lubricating greases should equal or exceed these
Coupling Lubrication specifications:
Grade NLGI #1
! Warning
Do not run the Centac compressor without Base oil Viscosity Min. 3000 SSU at 100ºF
lubricating the coupling. 160 SSU at 210°F
Dropping Point, Min. 190°F
Coat the hub and sleeve gear with grease. Slide the
sleeve over the hub gear. Insert the gasket. Bolt the Four Ball Wear, ASTM D-2266: .500mm Maximum
sleeves and tighten uniformly.
Base oil content 87% Minimum
The coupling must be lubricated before operation.
Hand packing of grease in each half of the coupling K36 Factor, ASTM D-4425 KSG: K36 = 8/24 = .33
is recommended. Remove two fittings 180° apart.
Rotate the coupling to place the bottom hole 45° off Required Rust and Oxidation
horizontal. Pump or pour lubricant into the top hole Inhibitors
until excess appears at the bottom hole. Sufficient E. P. Additives
lubricant has now been added. The most reliable test of a suitable lubricant is often
the result of user experience and satisfaction. If a
lubricant has been known to sludge, separate into
! Caution heavy components or dry out, consider using other
Do not attempt to fill the coupling without lubricants that meet the minimum specifications..
venting the interior. An air lock can result in
incomplete filling or in damage to the 'o’ ring seal.
Centac Reference Manual

Main Driver Preparation Inlet Valve / Inlet Guide Vane and Bypass
The preparation of the main driver shall include but Valve – Current To Pressure (I/P)
not be limited to:
Transducer Adjustment
Check the bolted joints for signs of looseness.
Check to make sure the bearings have been
1 Turn off power to the panel and disconnect the
properly lubricated and the bearing reservoirs filled. current to pressure (I/P) transducer wires.
Rotate the shaft by hand to insure there is freedom 2 Connect to the I/P a DC power supply with a 4mA
of movement. to 20mA output capability. Observe for correct
Check the control device connections to make sure polarity.
they agree with the wiring diagrams.
Alternatively, the microcontroller may be used to
Refer to the manufacturer’s instructions for detailed supply the 4mA and 20mA signals to the I/P
initial starting and stopping instructions. transducers. To do this the unit must be prepared
for a simulated run. A simulated run is
accomplished with the block valve closed and the
motor controller locked open. Also, the lube oil
Control System Adjustment pressure shutdown setpoint must be adjusted to
Centac compressor control systems may be ordered zero.
with a wide variety of monitoring, control, and
protection features. Many options are available to The microcontroller will send a 4mA signal to the
meet specific needs of customer. transducers when the control panel is energized.
The microcontroller will send a 20mA signal to the
Pre-start adjustment may vary considerably transducers after the start pushbutton is depressed
depending on features ordered. Therefore, see the and the start cycle times out. (Note: mode selector
control panel instructions and electrical prints for switch should be in the "modulate" position.)
necessary adjustments.
3 Apply 80 PSIG (551 kPa) instrument air to the I/P
supply connections.
4 Apply a 4mA signal to the transducers:
• Adjust zero screw on inlet valve I/P to obtain 7
PSIG output.
• Adjust zero screw on bypass valve I/P to
obtain 3 PSIG output.
5 Apply a 20mA signal to the transducers:
• Adjust the span screw on inlet valve I/P to
• Adjust the span screw on bypass valve I/P to
6 Repeat steps 4 and 5 until correct outputs are
obtained at signal inputs of 4mA and 20mA. NOTE:
Readjust low oil pressure shutdown setpoint.

Lube System Adjustment

Cleanliness of the lubricating system is of
paramount importance to the Centac compressor.
Although the system is flushed and fully tested at the
factory, the following steps should be taken prior to
initial startup.
Oil Pressure Setting

The Centac compressor lube system is designed to
operate between 20 and 30 PSIG (138-207 kPa).
When setting the system oil pressure, attention must
be given to both the lube pump internal relief valve
and the pressure sensing valve (PSV) mounted in
the lube system piping.
The following procedure should be followed to set

lube system pressure:
1 Start the lube pump with instrument air applied

to the seals, and the reservoir filled to proper
level with recommended oil.
2 Observe the oil pressure indication on the CMC
panel. Turn the system PSV adjusting screw
(CCW) to reduce pressure or the (CW) to
increase pressure. Set at 25 PSIG [179 kPa].
3 Start the compressor and allow oil to reach
operating temperature.
4 Readjust system PSV to obtain 25 PSIG [172
kPa] (nominal).
5 Lock down adjusting screw.
!
Warning
Operation of the unit without proper lubrication
can result in overheating of the bearings, bearing
failures, pump seizures and equipment failure
exposing operating personnel to personal injury.

Natural Surge Testing
Pressure VS Flow - Ideal or Real Ideal Head Plot gives a

Ideally there should be a one to one ratio between linear pressure output for a
the pressure developed by the compressor and the given flow condition. It
discharge capacity. does not account for losses
in a compressor.
Therefore the Ideal Head Plot would give a linear
pressure output for a given flow condition.
However this is ideal and does not account for the

losses that occur in real life.
Typical losses in a centrifugal air compressor are:
Friction
All rotating parts encounter friction of some type.
Restrictions
When you have a flowing fluid through passages
such as air through an air compressor it will
encounter small passages or turns in the piping or
components.
Actual Head Plot
Heat accounts for
When air is compressed heat is generated and this losses in a
energy is lost. compressor.
The Actual Head Plot, better known as Natural

Curve, does account for these losses and is no
longer linear in nature.
What Can We Really Use?
When dealing with a centrifugal air compressor only
a portion of the Actual Head Plot or Natural Curve
can be used effectively to
operate the compressor.
If the flow in a centrifugal air

compressor becomes too low,
a condition called surge will
result.
Also if the flow is too high the

compressor will go into a
choke condition.
Both of these conditions are

When the flow not ideal for operating a
is too high it
When the flow in a centrifugal air compressor thus
compressor is too will result in a
CHOKE limiting the useful operating
low, it will result in range for the compressor.
condition.
SURGE.
The actual operating range is limited.

Natural Surge Testing
Surge
Surge is defined as a reversal of flow through a
centrifugal compressor due to a reduction in flow.
Typically when surge occurs it is noted by a
“WHOMP” sound in the compressor.
While a single surge event is not necessarily

detrimental to centrifugal air compressor,
repeated surging (called Pumping) can be.
This should be avoided for the safe operation

of a centrifugal air compressor
Choke and Stonewall

In a Choke condition the compressor can not
physically pass any more air due to the losses.
When the flow demand continues to increase, the

centrifugal compressor can go to “Stonewall” which
is a condition that occurs when air velocity reaches
the speed of sound and the air flow stops, or acts as
if a “Stone Wall” was in the air path.
Again Choke or Stonewall is not necessarily

detrimental to the centrifugal air compressor, but the
force that keeps the compressor stable becomes
unbalanced and could result in vibration or other
operating issues.

Installation Check List
This listing is for general information only. Condensate drain
Arrival inspection 1 Provision for operator to view discharge

2 Termination above top of water level
Shipping damages (list any)
Cooling water
Foundation
1 Air cooler high point vent with flow indication
1 Anchor bolts (installed)
2 Flow switch properly installed
2 Access to drain (available)
3 Backflush properly installed (if provided)
Level of machine (satisfactory)
4 Stop valves
Grout (if required)
5 Throttle valve on discharge (if provided)
Piping general
6 Pressure and temperature gauges (if provided
1 Hangers and supports
7 Strainer (if provided)
2 Correctly sized
8 All general pipe requirements met
3 Proper material
Control Air
4 Expansion joints (when used)
(a) Properly anchored 1 Penetration into discharge pipe at a minimum of 10 pipe
(b) Shipping restraints diameters from discharge check valve
5 Flanged for maintenance and inspection. 2 Non-rusting material
6 Drip legs in horizontal run low 3 Minimum pipe size
Inlet pipe 4 Shut-off valve
1 Non-rusting material 5 Drain fitting
2 Long radius Instrument air
3 Pipe size reduction gradual transition 1 Clean, dry, oil free air supplied
4 Increases one size every thirty feet of total length 2 From downstream side of dryer
5 Filter 3 Provision for startup with no plant air available
(a) Not in air stream flow from plant exhausts,
4 Filter installed
water towers other inlet contaminants
(b) Delta P gauge Electrical
6 Provision made for pre start cleanliness inspection of 1 0CV reduced voltage starter installed (mandatory
pipe and filter
2 CT correctly installed
7 All general pipe requirements met
3 Starter pre-programmed (normally is customer
8 Temperature and pressure gauges (if provided) responsibility)
Bypass pipe 4 Control power provided
1 (a) Silencer properly installed (If provided) 5 Remote devices wired
(b) Drip leg added if installed in the horizontal position (a) RTD
(b) Inlet filter delta-P
2 Discharge protected from ingestion of rain, snow other
(c) Flow switch
contaminants
(d) Others (see P & ID Diagram
3 Directed so that foreign matter will not blow into inlet
6 CEM wired computer to compressor
filter
(a) Other electronic communications wired
4 Long radius elbows
7 Driver line voltage within 10% of rated voltage with 2%
5 All general pipe requirements met or less phase voltage imbalance.
Discharge pipe Other
1 All general pipe requirements met 1 Correct specification Lube oil available
2 Long radius elbow 2 Correct specification Coupling and motor bearing grease
available
3 Block valve
3 Coupling and motor bearings greased
4 Temperature and pressure gauges (if provided)
5 Control air connection

M.
Installation Check List
Short Test
1 Why is it important to start and operate the compress with clean inlet piping?
2 What is the normal differential pressure range between inlet and outlet flanges on
air coolers?
3 Oil can be used in gear couplings

a) True b) False
4 What can happen if the unit is operated without proper lubrication?
5 When will surge occur?

Start Up Registration Form
CENTAC START-UP REGISTRATION FORM

I. CUSTOMER INFORMATION
CUSTOMER:
ADDRESS:
CITY: ZIP CODE:
STATE: COUNTRY:
CUSTOMER CONTACT:
PHONE #: FAX #:
II. COMPRESSOR INFORMATION

SERIAL #: MODEL#:
START-UP DATE: DESIGN DISCHARGE PRESSURE:
III. MAIN DRIVER INFORMATION

TYPE MOTOR/TURBINE/ENGINE:
SERIAL #: FRAME #:
H.P.: VOLTS: AMPS:
STYLE: S.F.:
TYPE OF MAIN DRIVER OIL/GREASE:
MAIN DRIVER OIL/GREASE MEETS SPECIFICATIONS OF THE VENDOR INSTRUCTION MANUAL:
YES NO
(If no, explain why and obtain a Release of Liability from the Customer/Contractor)
MAIN DRIVER ROTATION CHECKED AND VERIFIED CORRECT TO THE ROTATION ARROW ON THE
COMPRESSOR GEAR CASE: YES NO
MOTOR STARTER TYPE:

MOTOR STARTER SERIAL #:
TURBINE DRIVER STEAM SUPPLY PIPE BLOWN CLEAN: YES NO

IV. GENERAL INFORMATION

UNIT LEVEL AND GROUTED: YES NO (Grout not required for CV Units)
FOUNDATION BOLTS TIGHT: YES NO
INLET AIR FILTER LOCATION: INSIDE OUTSIDE
INLET PIPE MATERIAL:
INLET PIPE INSPECTED AND CLEANED: YES NO
(If no a Release of Liability must be obtained from the Customer/Contractor)
OIL SUMP INSPECTED AND CLEANED: YES NO
(Not required for CV units with wired sump cover bolts)
TYPE OF COMPRESSOR OPERATING OIL:
OIL MEETS SPECIFICATIONS OF THE INSTRUCTION MANUAL: YES NO
COOLING WATER SUPPLY SOURCE:

COOLING WATER INLET PRESSURE: OUTLET PRESSURE:
AIR COOLERS HYDROTESTED: YES NO
AIR COOLER HYDROTEST PRESSURE/TIME:
CONTROL AIR (C.A.) SOURCE:
C.A. PIPE MATERIAL: C.A. DRIP LEG: YES NO
INSTRUMENT AIR (I.A.) SOURCE:
I.A. PIPE MATERIAL:
I.A. FILTER INSTALLED: YES NO
(If no, explain why)
ALL ELECTRICAL CONNECTIONS CHECKED: YES NO
COMPRESSOR OPENED FOR INSPECTION: YES NO
(If Yes, describe briefly condition as found)
V. COUPLING ALIGNMENT (not required for CV units)
SPACE BETWEEN SHAFTS:

NOTE: Compressors with sleeve bullgear bearings MUST be on mechanical center; Motors with sleeve bearings MUST
be on magnetic center; Turbines MUST be on mechanical center when spacing is checked and set.
VERTICAL OFFSET: HORIZONTAL OFFSET:

COUPLING FACE TO FACE OPEN AT BOTTOM:
ENGINE/GEAR BOX OR TURBINE/GEAR BOX
RADIAL VERTICAL OFFSET: RADIAL HORIZONTAL OFFSET:
ANGULAR VERTICAL OFFSET: ANGULAR HORIZONTAL OFFSET:
DRIVER VERTICAL OFFSET TO COMPRESSOR: HIGH LOW
DRIVER HOT ALIGNMENT CHECKED: YES NO
DRIVER DOWELED AFTER HOT ALIGNMENT CHECKED: YES NO
TYPE COUPLING GREASE:

COUPLING HAND-PACKED: YES NO
EXCESS GREASE REMOVED FROM COUPLING: YES NO
Vl. IMPELLER CLEARANCES

PRESSURE TIP CLEARANCES CHECKED: YES NO
(Not required if thrust bearing cover bolts are wired)
1ST STAGE PRESSURE TIP CLEARANCE:
2ND STAGE PRESSURE TIP CLEARANCE:
3RD STAGE PRESSURE TIP CLEARANCE:
4TH STAGE PRESSURE TIP CLEARANCE:
5TH STAGE PRESSURE TIP CLEARANCE:
ADDITIONAL STAGES :
Vll. PROTECTIVE FUNCTION VALUES ALERT SHUTDOWN
OIL PRESSURE:
LOW OIL TEMPERATURE:
HIGH OIL TEMPERATURE:
1ST STAGE VIBRATION:
2ND STAGE VIBRATION:
3RD STAGE VIBRATION:
4TH STAGE VIBRATION:
5TH STAGE VIBRATION:
S1 DISCHARGE AIR TEMP.:
FINAL DISCHARGE AIR TEMP.:
LOW SEAL AIR SWITCH (shutdown only):
VlIl. CONTROLS VALUES (CMC/MP3 Microcontroller)

SYSTEM PRESSURE SETPOINT:
THROTTLE LIMIT (TL)/CURRENT LIMIT LOW (CLL):
HIGH LOAD LIMIT (HLL)/CURRENT LIMIT HIGH (CLH):

ALERT
PROPORTIONAL BAND:
INTEGRAL TIME:
SETPOINT RAMP RATE:
INLET UNLOAD POSITION/P1:
AUTO DUAL SETPOINTS
RELOAD PERCENT:
UNLOAD POINT (BV % OPEN):
UNLOAD DELAY TIME:
Y/D TIME (MP3): PRELUBE TIME (MP3):
STARTING TIME (CMC):
CT RATIO:
SEAL AIR PRESSURE SETTING:
IX. CONTROLS VALUES (not Microcontroller)

PR1:
PR2:
PR3:
LLR:
X. OTHER VALUES/FUNCTIONS
OIL HEATER THERMOSTAT TEMP. SETTING:
OIL HEATER CONTACTOR CONTROLLED BY THERMOSTAT: YES NO
OPERATING OIL TEMPERATURE:
MAIN OIL PUMP PRESSURE AT OPERATING OIL TEMPERATURE:
PRELUBE PUMP PRESSURE AT OPERATION OIL TEMPERATURE:
LOW SEAL AIR PRESSURE SWITCH SHUTS OFF PRELUBE PUMP: YES NO
(If no, a detailed description is required)
NATURAL SURGE PRESSURE:

SURGE SENSOR OPERATION CHECKED AND VERIFIED BOTH AT YES NO
NATURAL SURGE AND T/CLL:
(If no, a detailed explanation is required)
INSTRUMENT AIR PRESSURE:

FULL LOAD AMPS: UNLOADED AMPS:

ENGINE DRIVEN UNITS

OVERSPEED TRIP SETPOINT:
UNDERSPEED TRIP SETPOINT:
ENGINE OPERATING SPEED:
BULLGEAR SPEED (not to exceed rated design speed):
OVERSPEED AND UNDERSPEED TRIPS VERIFIED: YES NO
IF NO, WHY?
ADDED PROTECTIVE FUNCTIONS (specify) ALERT SHUTDOWN
Xl. VALVE CALIBRATION

INLET VALVE OR INLET GUIDE VANE (ma or psi):
BYPASS VALVE (ma or psi):
Xll. ADDITIONAL INFORMATION

INSTRUCTION MANUALS: YES NO
CUSTOMER TRAINING REQUIRED: YES NO
SPARE PARTS REQUIRED: YES NO
RECOMMENDED SPARE PARTS LIST PROVIDED TO CUSTOMER: YES NO
UNRESOLVED PROBLEMS: YES NO
CUSTOMER INSTRUCTED TO FIRST CONTACT YOUR OFFICE FOR YES NO

SERVICE OR WITH ANY PROBLEMS OR QUESTIONS:

GENERAL COMMENTS:
(Please include compressor log sheet with

startup form)
STARTUP LOCATION (IRAC, DISTRIBUTOR or IR
BRANCH COMPLETE ADDRESS)
SERVICE TECHNICIAN SIGNATURE:
CERTIFICATION NUMBER: DATE:
Send:
ORIGINAL TO QUALITY ASSURANCE DEPARTMENT - MAYFIELD
COPY TO YOUR MACHINE FILE
COPY TO CUSTOMER
FORM# 1X15785 REV. C
Revised 19 August.2002.

Warranty and Limitation of Liability
Warranty *It is understood that when Techtrol Gold III is

The Seller warrants that the Equipment purchased, the warranty period for the compressor
manufactured by it and delivered hereunder will be airend bearings, seals, rotors, and bullgear only,
free of defects in material and workmanship for a less motor, cooler, and accessories, shall be
period of twelve months from the date of placing the considered revised to read “twenty-four months from
Equipment in operation or eighteen months from the the date of start up, or thirty months from the date of
date of shipment, whichever shall first occur*. The shipment, whichever first occurs”.
Buyer shall be obligated to promptly report any
failure to conform to this warranty, in writing to the *In addition, this warranty period (unoperational shelf
Seller within said period, whereupon the Seller shall, life or operational life) may also vary from the
at its option, correct such nonconformity, by suitable standard (12 months from startup or 18 months from
repair to such Equipment or, furnish a replacement shipment), if the Buyer has purchased the extended
part F.O.B. Jobsite, provided the Buyer has stored, warranty options outlined within Seller’s proposal.
installed, maintained and operated such Equipment
in accordance with good industry practices and has Limitation of Liability
complied with specific recommendations of the The remedies of the buyer set forth herein are
Seller. Accessories or equipment furnished by the exclusive, and the total liability of the seller with
Seller, but manufactured by others, shall carry respect to this contract, whether based on contract,
whatever warranty the manufacturers have warranty, negligence, indemnity, strict liability or
conveyed to the Seller and which can be passed on otherwise, shall not exceed the purchase price of the
to the Buyer. The Seller shall not be liable for any unit of equipment upon which such liability is based.
repairs, replacements, or adjustments to the
Equipment or any costs of labor performed by the The seller and its suppliers shall in no event be
Buyer or others without the Seller's prior written liable to the buyer, any successors in interest or any
approval. beneficiary or assignee of this contract for any
consequential, incidental, indirect, special or punitive
The effects of corrosion, erosion and normal wear damages arising out of this contract or any breach
and tear are specifically excluded. Performance thereof, or any defect in, or failure of, or malfunction
warranties are limited to those specifically stated of the equipment hereunder, whether based upon
within the Seller's proposal. Unless responsibility for loss of use, lost profits or revenue, interest, lost
meeting such performance warranties are limited to goodwill, work stoppage, impairment of other goods,
specified tests, the Seller's obligation shall be to loss by reason of shutdown or non-operation,
correct in the manner and for the period of time increased expenses of operation, cost of purchase
provided above. of replacement power or claims of buyer or
customers of buyer for service interruption whether
THE SELLER MAKES NO OTHER WARRANTY OR or not such loss or damage is based on contract,
REPRESENTATION OF ANY KIND warranty, negligence, indemnity, strict liability or
WHATSOEVER, EXPRESSED OR IMPLIED, otherwise.
EXCEPT THAT OF TITLE, AND ALL IMPLIED
WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE, ARE
HEREBY DISCLAIMED.
! Notice
Correction by the Seller of nonconformities whether On receiving the Centac compressor, be sure
patent or latent, in the manner and for the period of to inspect the unit for evidence of damage during
time provided above, shall constitute fulfillment of all shipment. Immediately notify the carrier and the
liabilities of the Seller for such nonconformities, nearest Ingersoll-Rand representative if any damage
whether based on contract, warranty, negligence, is noted. The compressor should be stored on a
indemnity, strict liability or otherwise with respect to level floor or supports, in a dry protected area.
or arising out of such Equipment. Based on these conditions, the Centac compressor
has been prepared for 180 days of storage. If the
The Buyer shall not operate equipment that is unit is to be stored for periods longer then 180 days,
considered to be defective, without first notifying the it will require additional protection.
Seller in writing of its intention to do so. Any such RNING
use of Equipment will be at the Buyer's sole risk and
liability.

!
Warning
Not to be used for breathing air application.
Ingersoll-Rand company air compressors are not
designed, intended or approved for breathing air
applications. Ingersoll-Rand does not approve
specialized equipment for breathing air applications
and assumes no responsibility or liability for
compressors used for breathing air service

Example Warranty Registration Form

Basic Centac Manual
1CV Airend
Overhaul
Section 5
Disassembly of Stage Components ...........................1—4
Disassembly of Bull Gear from the casing..................4—6
Assembly of Bull Gear into the Casing .......................7—8
Assembly of Stage Components ................................10—14
Impeller/Diffuser Clearance Setting Procedure ..........15—19

Airend Overhaul Section 5
Disassembly of Stage Components
In this section, you will learn

• To disassemble the stage components
• To remove the Bull Gear from the casing
• Installation of the Bull Gear into the casing
• Re-assembly of the stage components
• Impeller and diffuser clearance settings
Removal of Stage(s) Components:

Before you begin you must provide a bench or a
work area off the floor where the parts can be
inspected and cleaned. If more than one stage will
be removed, make sure there is enough room to
separate the stages to avoid mixing parts.
1 Tag out all service to the unit. 10 Tighten up on the inactive thrust bearing
adjusting screw.
2 Ensure that there is no power to the control
panel.
3 Remove the vibration probe and seal air injection

nipple in the plain bearing on the stage(s) that will
be disassembled.
4 Remove any service piping to/from the machine.
5 Disconnect the tubing and/or wiring to any

devices on the cooler housing. .
11 Check induction tip clearance, eye clearance.

6 If necessary, tag the tubing and/or wiring to
facilitate reconnection
7 Rig for lifting. Make sure that you use an

adequate weight handling technique.
8 Unbolt and remove the cooler housing and

cooler.
9 Install the lockbolt in the bull gear.

12 Measure the impeller volume tip clearance prior
to removing the diffuser. This measurement
provides an indication of wear and/or erosion.

13 Remove the diffuser using the following 19 Back off the inactive thrust bearing adjusting
procedure: screw one or two turns.
14 Match and mark the top of the diffuser and 20 Remove the thrust bearing cover and place the
casing with a felt pen or other suitable marker. cover and bolts on the work bench area.
15 Remove two or three of the six retaining bolts
and install guide studs in their place.
21 Clean out any dirt in the impeller Allen-head bolt

to allow full insertion of the wrench.
16 Remove the remaining retaining bolts.
17 Evenly jack the diffuser out of the bore using the

jackscrews in the holes provided.
22 Remove the left hand threaded impeller bolt with

an Allen wrench which must be in good condition
18 Place the diffuser on the workbench. Take care 23 Insert a rag to block oil drain back hole and to
as the diffuser may be heavy. prevent the shims or bolts from dropping into the
sump.
24 Lock the bull gear.
25 Loosen, but do not remove the thrust collar bolt

26 Remove the bull gear locking bolt 33 With someone holding the impeller to prevent
it from falling, jack the thrust bearing out
27 Remove the jackscrews in the thrust bearing, if evenly. The jacking will pull the impeller out of
installed. the pinion.
28 Remove the thrust bearing retaining bolts being

careful not to loosen the shims. (A magnet is
helpful.)
34 Place the impeller on the workbench.
! Caution
The impeller blade is very sharp. Use
caution when handling the impeller
35 Remove the thrust bearing, collar and pinion

as an assembly.
29 Slightly rotate the thrust bearing so as not to

jack on the adjustment area.
30 Install three long jackscrews (M10X1.25 or
3/8”-16, which ever is applicable).
31 Place flat washers or shim stock under the
jacking bolts.
32 Install jack bolts to jack thrust the bearing back
for impeller removal. Be sure to tighten the jack
bolts evenly in a clock wise direction.
36 Remove the thrust collar bolt and place the
assembly in an arbor press, resting on the
thrust bearing shell. .

37 Install a 5/16"-18 stud in the thrust end of the 43 Place the parts on the workbench.
pinion and push the pinion out of the collar.
44 Inspect the parts for wear and damage.
DON'T ALLOW THE PINION TO DROP!
45 Inspection of the bearings should be done both
before and after cleaning to detect any signs of
damage.
The bearings may be cleaned with safety

solvent to remove the oil.
If wiping (distortion) of the babbitt has occurred,

it will be necessary to replace the bearing.
If no distortion is apparent, the bearing can be

reused.
Any discoloration or varnish may be cleaned by

38 Place the parts on the workbench using gray or white Scotchbrite™ and safety
39 Verify the seal air injection nipple has been solvent.
removed. 46 The pinion, impeller, thrust collar, impeller bolt,
40 Remove the plain bearing retaining bolts. Use thrust collar bolt, and nose cone (if present)
the jackscrew holes provided; evenly jack the must be balanced as a unit.
plain bearing out of the bore
47 Cleaning of the diffuser can be accomplished
with solvents or by glass bead blasting.
48 Replacement of the seal cartridge is necessary
if any sign of damage is present, if the carbon
seal is cracked, or if the carbon rings ability to
move has been affected.
49 Remove cooler from the cooler casing. Keeping
the cooler wet will aid in the removal of the
cooler. The water acts as a lubricant and keeps
soft sludge in the slurry state.
50 Inspect and clean the cooler.
51 Test the air side fins for flexibility. If fins break
easily, the cooler should be replaced.
41 Remove the seal cartridge snap ring, at the
workbench. 52 Remove the moisture separator screens from
the cooler casing.
42 Use the jackscrew holes provided in the seal
cartridge and evenly jack the cartridge out of 53 Inspect and clean the screens. Steam cleaning
the plain bearing bore. is usually employed for cleaning.
54 Clean and preserve (paint) the casing air
passage and the cooler casing water and air
passages.

Disassembly of Bull Gear from the casing
Removal of the Bull gear From the Casing 7 Remove the shaft seal retainer and oil feed line.
This procedure is done after removal of the stage(s).
1 Remove the coupling (two heat sources are

recommended when removing the coupling hub),
oil manifold, oil RTD, demister, oil pump and oil
hoses.
2 Remove the retaining bolts or nuts from the
casing to the baseplate. Use a bottle jack or other
means, as necessary, to break the RTV seal
3 Loosen the casing from the baseplate.
4 Lift the casing off the baseplate. 8 Remove the wave spring.
! Note
The wave spring arrangement to ensure
proper reinstallation.
5 Lay the casing cooler side down on a skid or

wooden blocks.
9 Remove the alignment pins.
6 Remove the bolts from the bull gear shaft seal

cover.

Disassembly of Bull Gear from the casing
10 Remove the bull gear cover bolts and dowel pins. 15 Raise the bull gear slowly and straight to avoid
Use jackscrews to break the gearcase cover free damage or injury.
from the gearcase.
16 Lay on blocking in a clean area.
17 Inspect the bull gear and bearings.
! Note
It is suggested that the last couple of threads be
cut off the jackbolts to prevent the bolts from
binding up in the cover.
18 Remove and replace the bearings if necessary.

The anti-friction bearings on the bull gear will
11 Install alignment pins. require replacement on a periodic basis.
19 Clean mating surfaces thoroughly.

20 Stone to check for proud spots.
21 Wipe clean with lint free rag and safe solvent.
12 Tighten cap screws to break the seal between the

linebore and the gear cover.
13 Lift the cover off the casing and stand upright.
14 Place a 3/8"-16 eyebolt in the bull gear shaft,

coupling end.

Assembly of the Bull Gear into the casing
Installation of the Bull Gear into the Casing 6 Lubricate bearing and bore.
1 Thoroughly clean the RTV/sealant from the faces

of casing and cover.
2 Check the oil feed line on the thrust bearing side
and clean any blockage from the oil line and spray
nozzles.
3 Install new anti-friction bearings on the bull gear

using the following procedure:
• Install the radial type anti-friction bearing on

the coupling side.
7 Install the gearcase cover using locating studs.
• Install the thrust bearing on the oil pump Cover must be plumb.
side. Make sure the cage of the thrust
bearing (the brass and numbers) faces
towards you when viewed from the main oil
pump side.
4 Install the bull gear using the eye bolt that was
installed when the bull gear was removed. Use
caution to avoid damage to the bearings.
8 Start the dowel pins and tap in place to seat. Use

care to not peen over or mushroom the dowel
pins.
9 Install the bolts, with cleaned threads, on the
cover using a cross bolt pattern.
Use a level to check for plumb.
5 Apply a thin bead ((1/8”) of Loctite 515 sealant on

the gearcase cover. Route the sealant around the
oil galley, oil drain holes, and completely around
the cover inside the bolt circle.
Pop all air bubbles, there can be no voids.
! Caution 10 Install each of the following:

Do not use excessive sealant. Follow the • the wave spring,
sealant manufactures instructions.
• a new shaft seal and gasket, and
• the seal cover.
11 Tighten the seal cover and reconnect the oil feed

line.

12 Clean the baseplate and bottom of the casing. 11 Install the oil pump spacer in the casing with the
notch over the oil supply line tube. Ensure that it
fits flush against the casing.
12 Fit the key to the keyway.
13 Install new drain gaskets in the base.

14 Apply Loctite 515 sealant around the oil drain
back holes and around the base.
15 Mount the casing onto the baseplate and tighten

the hold down nuts.
13 Place the gerotor on the shaft with the key.
10 Inspect the oil pump gerotor, key, and spacer for

chips and burrs.
14 Insure free movement of the gerotor on the shaft.

Use a micrometer to measure the main oil
clearance of components.
Typical gerotor end clearance is 0.005” to 0.007”.
Verify shim clearance is in the range of 0.0-03” -
0.005”

15 Install the oil pump housing with a new o-ring
and bolt down. Use Parker O-ring lubricant on all
o-rings.
16 The bull gear or pump may need to be rotated to

aid in the installation of the oil pump
17 Reconnect the oil lines.
18 Install the Oil Demister and reconnect the oil

manifold and oil temperature RTD.
19 The compressor is now ready to accept

installation of the stage components.

Assembly of Stage Components
Assembly of the Stage(s): 5 Align the seal air injection hole in the bearing with
the casing hole and install the plain bearing, use a
gasket if applicable, in the casing.
!
Note
In the following procedure, DO NOT use any oil on
the parts unless instructed to do so. Lubrication will
be provided when the prelube system is started.
Lock the bull gear against rotation.
1 Place the seal in the plain bearing.
6 Use these pins to help hold the bearing for easier

installation.
2 Use Parker O-ring Lube to lightly lubricate the o-

rings. Be careful not to cut the o-rings.
7 Tighten the bearing retaining bolts until the

lockwashers, if used, just close up. Always pull
the bearing in slowly and evenly.
3 Install the retaining ring with the bevel up.

4 Wipe the seals with isopropyl alcohol using lint
free cloths. Lightly lubricate the bearing for
installation.
8 Install the seal air supply line.

9 Wipe the pinion with isopropyl alcohol using lint 14 Install a long 5/16"-18 bolt into the thrust end of
free cloths. Ensure the internal threads are also the pinion.
cleaned.
• Install the bearing in the bore until the
bearing is near the thrust collar shoulder of
the pinion.
• A LIGHT film of oil on the bearing shell and
in the bore will facilitate installing the
bearing.
• Pull the pinion into the bearing by hand,
using the long bolt to guide the pinion
through the bearing. Use care to not scrape
the babbitt.
10 Check Magnetism (gauss). This must be 2 guass • Push the thrust bearing into the bore until the
maximum. Gauss can be added to or subtracted flange is tight against the casing.
from the vibration reading on the panel. • Check the surface between the casing and
the bearing flange with a 0.0015" feeler to
ensure there are no proud spots. Re-stone
the casing as necessary until the 0.0015”
feeler will not pass between the bearing
flange and the casing.
15 Install the bull gear locking bolt. Heat the thrust
collar to approximately 200oF. A 100 watt light
bulb works fine for this. This takes approximately
20-30 minutes.
10 Align (center) the carbon seals by careful

insertion of the pinion from the impeller side. After 16 Lightly apply Tiolube 70 to the polygon, as
recommended in the Field Service
the seal is aligned, insert the pinion into the plain
Manual.
bearing from the motor side.
17 Align the match marks and slide the thrust collar
on the pinion. The thrust collar must be slid firmly
against the shoulder on the pinion. Use the 5/16”-
18 bolt to hold the pinion away from the thrust
bearing to avoid damaging the thrust face with a
hot thrust collar.
18 Clean the thrust collar bolt with isopropyl alcohol.
Install the thrust collar bolt and tighten until the
match marks align. Use a 1/2" box end wrench
with the bevel ground off for tightening.
19 Allow the collar to cool, remove the thrust collar
bolt and apply one drop of Loctite 271 to the
threads. Install and tighten the bolt to the match
mark.
11 Push the pinion forward until it just touches the 20 Install the vibration probe. Gently seat the
plain bearing shell. vibration probe against the pinion and then back
off.
12 Stone any suspected proud spots on the casing
or the thrust bearing on the bearing flange seating
areas.
13 Start the thrust bearing into the casing bore with
the oil drain holes pointed down.

21 Install the thrust bearing covers temporarily. Use 25 Clean the impeller bolt with isopropyl alcohol.
the following procedure to check for leaks: Apply one drop of Loctite 271 on the impeller
bolt.
1) Verify that the seal air piping has been
correctly re-installed. Pressurize the seal air 26 Preload the impeller and tighten the bolt until the
system to 7 PSIG. Test the circumference of match marks align.
the vane plates using a soap and water or
leak detecting liquid on all stages. Test all 27 Remove the clearance setting bracket installed
in step 12. Push the rotor assembly toward the
bolt and other plate penetrations for air
thrust end with the thrust bearing. This
leakage.
procedure is intended to get the impeller out of
2) Test the seal air inter-lock with the prelube the way of the diffuser.
pump starter to assure it is functioning
properly. Correct any discrepancy. 28 Install the diffuser, using M10 x 125 mm studs
to help facilitate installation. Tighten the bolts
3) Verify all lube oil piping has been correctly until the lockwashers just close.
installed. Untag and energize controller
control power to the prelube pump. Start the
prelube pump. Record oil temperature and
pressure.
4) Inspect the lubricating oil system for leaks.
Inspect the area of the pinion air seal for any
signs of oil migration. Inspect the gull gear
casing cover for any signs of oil leakage
through the split line.
5) Allow the system to operate for a minimum
of one hour. Thoroughly inspect for leaks
after the one-hour run time. Correct any
leaks.
6) Stop the prelube pump at the completion of
the satisfactory oil leak test. De-energize 29 Install diffuser cap screws.
and retag the control power system. Shut off
the seal air.
7) Remove the thrust bearing covers when you
are finished with leak checking and continue
with the assembly.
22 Install the clearance setting bracket to push and
hold the pinion toward the impeller end. Refer to
the Impeller/Diffuser Clearance Setting
Procedure.
23 Lightly apply Tiolube 70 to the impeller polygon, 30 Tighten cap screws to specified torque.
as recommended in the Field Service Manual.
24 Align the match marks and slide the impeller into
the pinion.

31 Push the rotor all the way forward. 35 Set up the indicator to read clearances. Set all
to zero. The 2 outer dial indicators are on the
thrust bearing shell and the centre indicator is on
the thrust collar.
32 Check the induction tip clearance
36 Ensure the inactive button bearing adjustment

screw is backed out.
37 Install the bearing cover.
33 Move the diffuser to achieve proper clearance.

The diffuser can be slightly tighter on the bottom
(0.001”).
38 Tighten up the bolts until the lock washers just

close up.
34 Install the dial indicator to check the total axial

travel.

39 Tighten the inactive adjustment screw, pushing 43 Supply seal air and set seal air pressure to 7 to
the rotor assembly toward the diffuser until the 9 PSIG.
screw stops turning.
44 Turn on the power to the control panel. This will
start the pre-lube pump so that the machine can
be safely rolled over by hand. The re-assembly
is complete.
45 Adjustment of the vibration probes and other
controls will be necessary.
46 Do not connect the motor to the compressor
until after correct motor rotation is observed.
! Caution
DO NOT FORCE THE SCREW.
Forcing the adjustment screw can damage
the inactive button bearing. Back the bolt
off 1/4 to 1/3 turn and tighten the lock nut.
This action provides for a 0.008” to 0.010”
total axial float clearance setting.
40 Install the cleaned moisture separator screens

in the cooler casing(s). The fine screen goes in
first. To eliminate airflow bypass, ensure both
screens fit snugly in the casing I.D.
41 Attach the cooler casing to the compressor

casing. Install the:
• o-rings
• cooler into the cooler casing
• cooler casing guide pins into the
compressor casing
• cooler casing to the compressor casing
42 Install the inlet and bypass valves, bypass pipe
and all instrumentation.
43 Install the vibration probe.

44 Reconnect any wiring and/or tubing to the
devices on the casing.

Impeller/Diffuser Clearance Setting Procedure
! Note
The bull gear locking bolt should be removed
prior to performing this procedure.
1 Carefully push the rotor assembly toward the

diffuser until it touches the diffuser.
2 Holding the rotor assembly against the diffuser,

you should be able to pull the thrust bearing shell
away from the casing before the thrust bearing
contacts the thrust collar.
3 Check and record the total axial float of the rotor

assembly using a dial indicator installed on the
thrust collar. This is the distance the rotor can
travel between the impeller contacting the diffuser
in one direction and the casing in the other
direction.
4 Start the three retaining bolts and jacking screws

in the thrust bearing.
5 Install the Clearance Setting Bracket.

6 Install each dial indicator as illustrated.
Place two of the indicators on the bearing shell
approximately 180° degrees apart. The third
indicator is positioned on the thrust collar or in line
with the thrust collar bolt, on the clearance setting
bracket.
Front View
4th Dial Jack Bolt

if used
Lock Bolt
Lock Bolt
Jack Bolt Jack Bolt
Stud in bearing
cover bolt hole Lock Bolt
Thrust setting bracket
Dial mounting fixtures

(Example)
All thread
Jack Bolt
Dial
Side View
indicators
Thrust setting
bracket All thread in cover
bolt hole

7 Adjust all of the indicators to zero. 17 Push the assembly all the way in against the
thrust bearing.
8 Jack out the bearing evenly until it just picks up
the thrust collar as shown by the indicator on the 18 Set an indicator on the thrust collar bolt and set it
thrust collar or clearance setting bracket. to zero.
9 Record the movement of the bearing shell at this 19 Pull the thrust collar back. This distance is the,
point. remaining axial float. The remaining axial float
plus the established pressure tip clearance should
10 Jack out the rotor assembly with the thrust equal the total axial float measured in step 3.
bearing until the indicator on the clearance setting (Total float = clearance + axial float).
bracket is at the required pressure tip clearance.
20 Push the rotor assembly toward the diffuser and
11 Move the assembly 0.001" at a time on each remove the indicator.
jackscrew keeping all dial indicators as even as
possible.
! Note
If the remaining axial float plus the established
pressure tip clearance does not equal the total
axial float determined above, then check the
stage components to determine the problem.
21 Adjust the reverse (inactive) thrust clearance in

accordance with the procedure given starting at
step 39 in the Assembly of Stage Components
Procedure.
12 Tap the bearing lightly and often to keep it square Pressure tip or “Y” clearance
in the bore.
Shim
Thickness
13 At 0.005" from the desired clearance, move the
assembly 0.0005" at a time until the desired
pressure tip clearance is attained.
14 Read the value of the bearing shell indicators and

grind the thrust bearing shims to this thickness.
15 Use taper feeler gauges to measure and check

the impeller or inducer clearance, this is the
volume tip clearance.
It is the distance between the impeller and the

diffuser at the inlet. The clearance should be
within 0.002" of center on all sides.
Jacking Screw
The volume tip clearance is set by component
design and must not be adjusted in the field. If a
volume tip clearance problem is suspected or
discovered, contact Customer Service.
16 Remove the dial indicators and clearance
adjusting bracket. Remove the jacking bolts.
Install the shims and tighten the thrust bearing
bolts.

The impeller clearance setting tool can be used at
the thrust bearing end of all Centac compressors. All
Centac service personnel should have a clearance
setting bracket when working on a Centac
compressor. See Figure 3.
Never attempt to set the clearances without a

clearance setting bracket.
Figure 3. Clearance Setting Tool
!
Note
• The purpose of the spring bracket impeller
clearance setting tool is to apply a positive
pressure (inward) on the R/A while the thrust
bearing is being jacked (outward) for setting the
pressure tip clearance. See Figure 4.
• The tool can be used in an end to end, or
reversed, manner as may be required by the
Centac model.
• Adjust bolt length to achieve flat position of tool.
• Material for tool is a common bar stock.
• Bracket anchoring bolt (all thread) sized to
Centac bearing cover capscrew threads.
1.1/4 x 3/8-16 Allen Head Screw 2 x 3/8-16 Allen Head Screw
Anchoring Stud and Nut

Lock Nut
Lock Nut
Casing
Thrust Collar
Figure 4. Placement of the clearance setting tool

Short Test
1 What are the three (3) clearances to be set when assembling the Rotor
assembly on the machine?
a)
b)
c)
2 How many diameter indicators must be used when setting Pressure Tip “Y”
clearance?
3 How do you set the Inactive or Reverse thrust clearance?
4 When do you service the discharge check valve?
5 What must you look for when servicing the discharge check valve?
6 When must the Inlet and Bypass valves be calibrated?

Basic Centac Manual
Airend Ovehaul for
Models C250/C350
Section 6

Airend Overhaul for Models C250/C350 Section 6
Disassembly and Assembly
This section of the manual is under development.

Basic Centac Manual
CMC Controls
Section 7
User Interface .............................................................1—3
System Folder & Page Descriptions...........................4—5
Info Folder & Page Descriptions.................................6—8
Setting Folder & Page Descriptions............................9—12
Procedures .................................................................13—20
Short Test ...................................................................21

CMC Controls Section 7
User Interface
Folders
OUI (Operator User Interface)
The User interface is the means by which people
interact with the compressor control system. Page
Page Number
SYSTEM INFO SETTINGS
The standard configuration of the CMC has two
components of the user interface. They are the OUI System Inlet
and the device plate. Pressure 105.1 Valve 100
Pressure Bypass
The CMC OUI consists of: Setpoint 105.0 Valve 0
• Six command buttons that “command” the
compressor to perform actions. When any of Motor
these keys are pressed the action will be logged Current 323.4
in the event log.
Running Hours: 11445 31-Aug-1999 12:00:00
• Four navigation keys
Load Selected
• Edit mode selection key Loaded
• Contrast key. Remote 1/4
Status Bar
These keys, in conjunction with the 240x128-pixel
graphics display, make up the user interface to the Compressor Compressor Compressor
compressor. The bezel that surrounds the OUI Operating Control Status
State Location
ensures that the NEMA 4 rating is maintained for the
OUI.
Graphic Display
The 240x128-pixel graphic display allows us to
provide a flexible interface between the user and the
compressor. The display has three distinct regions
as shown in the diagram above.
Acknowledge Command Key
Silences the optional horn or
Contrast Key
acknowledges an alarm.
This key changes the contrast of the backlight for the graphic
LCD display. Pressing this key steps among each of the sixteen
contrast levels. When stepped to the sixteenth level, pressing
the key again returns to the first contrast level.
Reset Command
Key
Clears all trip
latches. Required
to be pressed
Navigation Keys
after a trip
The arrow keys for Up,
condition to
Right, Left and Down
restart the
perform differently
compressor.
depending upon the current
display-operating mode.
Start Command Enter Key - Display

Key Operating Mode
Starts the The Enter key toggles the
compressor. display between the
Navigation and the edit mode.
Stop Command Key

Load Command Key
Stops the compressor.
Engages Modulate or Unload Command Key
This button should be pressed instead
Autodual control mode. Unloads the compressor
of the E-Stop for normal operation.

Issue: 01/Australia, February, 2003 Page 1
User Interface
Graphic Display Compressor Status

The Compressor Status Field messages are:
Folders • Trip
• E-Stop (emergency stop button pressed)
Page • RMT-Stop (a remote stop has been pressed)
Page Number
• Start Disabled (an optional permissive start
condition has not been satisfied)
System Inlet
Pressure 105.1 Valve 100 • Alarm, Unload Selected (the compressor will
stay in “Unload” after “Starting” has been
Pressure Bypass completed), and
Setpoint 105.0 Valve 0 • Load Selected (the compressor will go to
“Minload” after “Starting” has been completed).
Motor
Current 323.4 Compressor Control Location
The Compressor Control Location Field messages
Running Hours: 11445 31-Aug-1999 12:00:00
are:
Load Selected
Loaded Remote 1/4
• Local, Remote (remote hardwired commands
i.e. start, stop, load, unload etc.)
• Network (MODBUS, DF1 or CEM
Status Bar
communication with a UCM), and
Compressor Compressor Compressor • Remote/Net (both Remote and Network). This
Operating Control Status indicates to the operator that a remote location is
State Location
in control of the compressor and the compressor
may start, stop, load, unload, etc. without the
local operator initiating any commands.
Folder and Page
It is important to provide much of the information These three fields combine to provide the operator
required for operating and troubleshooting the with the necessary information to create a cursory
compressor. The tabbed folder with multiple pages determination of the status of the compressor. When
has been used to reduce the complexity of dealing a more thorough determination is required, the
with at least ten pages of information. For the operator can get additional detail by looking through
standard design, the maximum number of keys the other pages in the system.
required to get to any of the ten pages is four.
Page Number
• SYSTEM Folder provides information about The Page Number indicates the current page for the
the compressor system. current folder with the number of pages in the folder.
• INFO Folder gives various types of The number of pages is given so that the user
information about the unit always knows where he is in the system.
• SETTINGS Folder used to perform compressor
setup.
Status Bar
The Status Bar provides four distinct types of
information and is always visible from any folder and
page combination.
Compressor Operating State

This Field is displayed in large text so that the
operator can determine the compressor’s current
operating state at a glance. See Section titled
“Compressor Operating Methodology” for a list of the
messages provided.

User Interface
Edit (Setpoint Changes) Mode

Pressing the Enter key to
toggle from Navigation to
Edit mode can change
Setpoints for a page.
Once in this mode, the highlight will move from
around the folder name to item to be changed.
Use the Right and Left arrow keys to move
among the changeable items and the Up and
Down arrow keys to change the value of the item.
When changes are complete,
press the Enter key again to return to Navigation
mode.
Navigation Mode
Navigation mode is active

when a folder name
0 (SYSTEM, INFO or
SETTINGS) is highlighted.
0 When inactive, press the
ENTER key to activate.
Folder Navigation
To move among the tabbed folders, press the
RIGHT or LEFT key.
The folder list is circular; that is, when the SYSTEM

folder is displayed and the LEFT key is pressed, the
SETTINGS folder becomes active. The same is true
when the SETTINGS folder is displayed and the
RIGHT key is pressed, the SYSTEM folder becomes
active.
Page Navigation
To move among the pages, press the UP and
DOWN keys.
The page list is also circular. So, when page 1/4

(page 1 of 4) is active and the UP key is pressed,
page 4/4 becomes active. Also, when page 4/4 is
active and the DOWN key is pressed, page 1/4
becomes active.
The current page for a folder is persistent. For

example, if you begin on the SYSTEM folder page
2, change to the INFO folder and return to the
SYSTEM folder, page 2 will be the page displayed.

System Folder and Page Descriptions
SYSTEM Folder Analog Input Page
The SYSTEM folder provides information about the
compressor system. The number of pages in this
folder is at least four; but could be more for two SYSTEM INFO SETTINGS
stage machines with special analog options Press Temp Vib
purchased, or for compressors with three stages or
more. Stage 1 30.1 95.8 0.25
Stage 2 106.6 93.5 0.22
Oil 20.3 105.5

System Inlet
Pressure 105.1 Valve 100 Load Selected
Pressure Bypass Loaded
105.0 0
Remote 2/4
Setpoint Valve
Motor
Current 323.4 This page provides the actual value for each stage
pressure, temperature and vibration, oil pressure
Running Hours: 11445 31-Aug-1999 12:00:00 and temperature. If additional analog inputs have
been purchased or more stages exist as standard, it
Load Selected
Loaded Remote 1/4
is likely that an additional page or pages will be
added. The units are as defined by the Settings
page. There are no changeable setpoints on this
page.
This page shows the main compressor operating

Digital Input Page
parameters, running hours, date and time. The
System Pressure and Pressure Setpoint are in
units as defined by the Settings page, Motor SYSTEM INFO SETTINGS
Current is in Amps and valve positions are in
percent open. Pressure Setpoint is always editable Digital Inputs
while the Inlet and Bypass Valve positions are edit a Starter Feedback
enabled when in the Manual mode only.
E-Stop Pressed
Low Seal Air
Info Folder Page 1 Edit Parameters Table Load Selected

Loaded Remote 3/4
Minimum Maximum Stop

Variable Units This page shows the current state of the digital
Value Value Size
(discrete) inputs for the system. The number of
Pressure Set point pressure 00 999.9 0.1 inputs will vary depending upon the number of
optional inputs purchased.
Inlet Valve Position
percent 0 1.00 1
(manual mode only) A tick in the box to the left of the test indicates a true
Bypass Valve Position condition, whereas no tick indicates a false
percent 0 1.00 1
(manual mode only) condition. For example, a tick in the “E-Stop
Pressed” boxed means that the Emergency Stop
push button has been pressed.
It is possible to have multiple Digital Input pages.

System Folder and Page Descriptions
Digital Output Page

Digital Outputs
Prelube Pump Running
a CR1
Remote Trouble
Load Selected
Loaded Remote 4/4
This page is similar to the Digital Input page except

that it shows the current state of the digital (discrete)
outputs for the system. The number of outputs will
vary depending upon the number of optional items
purchased.
A tick in the box to the left of the text indicates a true

condition, whereas, no tick indicates a false
condition.
It is possible to have multiple Digital Output pages.
The SYSTEM folder’s four pages give the current

operating status for the compressor. The User is
always within two keystrokes of all operating
parameters.

Info Folder and Page Descriptions
Info Folder Pressing the Enter key to initiate Scroll Mode allows
The INFO folder contains the OUI key map, the access to events 17 through 224. Scroll Mode is
compressor event log and the hour meters. There indicated by the reverse video of the event numbers.
are no changeable set points in this folder. The OUI
key map will be the default page on power up. The Each Down Arrow press displays the next seven
keys are labelled in English and the local language, events. An Up Arrow press will display the previous
depending upon the current language selected. seven events. Any time a Trip occurs, the system
will send the display to the first seven events.
Key Map Page
A list of all possible events is shown on the following
pages.
CONTRAST
Hours Page
HORN SILENCE UP SYSTEM SETTINGS

0 INFO
LEFT RIGHT Power On Hours 12338
0
RESET DOWN Running Hours 11445
START LOAD UNLOAD ENTER Loaded Hours 11223
STOP Number of Starts 35
Load Selected
Loaded Remote 1/3
BCM Ver: 2.51
Load Selected
Loaded Remote 3/3
Event Log Page

This last INFO Folder page shows the hour meters
Event Name Time Date and number of starts. Power On Hours is the time
1 Low oil Pressure Trip 09:18:44 0720 that the panel power has been on. The Running
2 Low oil Pressure Alarm 09:18:43 0720
Hours is the amount of time that the compressor has
been operating between each start and stop
3 Reset key pressed 09:18:34 0720 sequence. The Loaded Hours is the amount of time
4 Low oil Pressure Trip 09:08:43 0720 that the compressor has been running and not
5 Low oil Pressure Alarm 08:58:23 0720
running unloaded. It can also be defined as the
number of hours that the inlet valve is not in the Inlet
6 Load key pressed 08:24:01 0720 Unload Position. The Number of (Compressor)
7 Start key pressed 08:23:12 0720 Starts is self-explanatory.
Trip
Not Ready Remote 2/3 !
Note:
Most electric motors are only rated for two cold
starts or one hot start per hour. It is the operator’s
The Event Log details the last two-hundred and
responsibility not to exceed the electric motor’s
twenty-four (224) “events” that have occurred. Each
limitation. The control system allows the compressor
”event” has a date and time stamp. This log for all
to be started when the compressor is ready, not the
Alarms and Trips satisfies first-out indication. Any
motor.
time an Alarm or Trip is indicated on the Status Bar,
the detail for that fault is included here.
The last item on this page is the Base Control
The event labelled as “1” is the newest event and”7” Module Version number. This will be used by field
is the oldest event. For events that have identical personnel for quick reference to determine if newer
Time and Date values, the order is still correct software is available.
(newest to oldest, top to bottom). Once the list is full,
each new event knocks off the last event.

Possible Events List
Event Name Description
* * End of List * * Displayed for the event name whenever the event list is not full.
A/I Alarm. The actual value for Analog Input “AI” is greater than the Alarm value
A/I Trip. The actual value for Analog Input “AI” is greater than the Trip value
Acknowledge (Location) An Acknowledge command has been issued from Location.
Auto Start An automatic start occurred (typically from Auto Hot or Cold Start).
Auto Stop An automatic stop occurred (typically from Running Unloaded Shutdown Timer).
BCM 2 Failure Alarm Communications have been lost to Base Control Module #2.
BCM 3 Failure Alarm Communications have been lost to Base Control Module #3.
Compressor Started. The compressor has started
DI Alarm. The Discrete Input “DI” is in an alarm condition
Discrete Surge A discrete surge switch has detected a surge.
DI Trip. The Discrete Input “DI” is in a trip condition
Edit-x AI Alarm SP The Analog Input “AI” Alarm setpoint value has been edited from location x.
Edit-x AI Trip SP. The Analog Input “AI” Trip setpoint value has been edited from location x
Edit-x A/D Reload Pct. The AutoDual Reload Percent value has been edited from location x
Edit-x A/D Unload Dly. The value has been edited from location x
Edit-x A/D Unload Pt. The AutoDual Unload Point value has been edited from location x
Edit-x AHS Pressure . The Auto Hot Start Pressure value has been edited from location x
Edit-x Auto Stop Time The Auto Stop Timer value has been edited from location x.
Edit-x BV Position The Bypass Valve Position value has been edited while in Manual from location x.
Edit-x BV-PID D The Bypass Valve Pressure PID Derivative value has been edited from location x.
Edit-x BV-PID It The Bypass Valve Pressure PID Integral Time value has been edited from location x.
Edit-x BV-PID Pb. The Bypass Valve Pressure PID Proportional Band value has been edited from location x
Edit-x Coasting Timer. The Coasting Timer value has been edited from location x
Edit-x CT Ratio. The CT Ratio value has been edited from location x
Edit-x Day The Day value for the Date field has been edited from location x.
Edit-x IV Position. The Inlet Valve Position value when in Manual has been edited from location x
Edit-x IV Unload Pos The Inlet Valve Unload Position value has been edited from location x.
Edit-x IV-PID D. The Inlet Valve Pressure PID Derivative value has been edited from location x
Edit-x IV-PID It. The Inlet Valve Pressure PID Integral Time value has been edited from location x
Edit-x IV-PID Pb The Inlet Valve Pressure PID Proportional Band value has been edited from location x.
Edit-x MaxLoad SP The MaxLoad Setpoint value has been edited from location x.
Edit-x MaxLoad-PID D. The Inlet Valve MaxLoad PID Derivative value has been edited from location x
Edit-x MaxLoad-PID It The Inlet Valve MaxLoad PID Integral Time value has been edited from location x.
Edit-x MaxLoad-PID Pb The Inlet Valve MaxLoad PID Proportional Band value has been edited from location x.
Edit-x MinLoad Index The MinLoad Surge Index Increment value has been edited from location x.
Edit-x MinLoad SP. The MinLoad Setpoint value has been edited from location x
Edit-x MinLoad-PID D The Bypass Valve Pressure PID Derivative value has been edited from location x.
Edit-x MinLoad-PID It The Bypass Valve Pressure PID Integral Time value has been edited from location x.
Edit-x MinLoad-PID Pb The Bypass Valve Pressure PID Proportional Band value has been edited from location x.
Edit-x Month. The Month value for the Date field has been edited from location x
Edit-x PSP Ramp Rate. The Pressure Setpoint Ramp Rate value has been edited from location x
Edit-x Sensitivity. The Surge Sensitivity value has been edited from location x
Edit-x Starting Timer. The Starting Timer value has been edited from location x
Edit-x Sys Press SP The System Pressure Setpoint value has been edited from location x.
Edit-x Time. The Time value has been edited from location x
Edit-x Year The Year value for the Date field has been edited from location x.

E-Stop pressed Emergency Stop push button has been pressed.
Load (Location) A Load command has been issued from network communications.
Loss of Motor Current Motor current feedback was lost while running.
MinLoad Clamped The MinLoad Control or User Setpoint value has been limited to the MaxLoad Setpoint
value.
MinLoad Incremented The MinLoad Control Setpoint value has been incremented as a result of surge.
MinLoad Reset The MinLoad Control Setpoint value has been reset to the MinLoad User Setpoint value.
Starting Fail Driver feedback was not received after a Start command was issued.
Starter Failure Feedback was not received from the starter after a Start command was issued.
Power Down The Base Control Module (BCM) was de-energized.
Power Up The Base Control Module (BCM) was energized.
Reset (Location) A Reset command has been issued from Location.
Start (Location) A Start command has been issued from Location.
Starter Failure Starter feedback was not received after a Start command was issued.
Stop (Location) A Stop command has been issued from Location.
Surge The controller has detected a Surge.
Surge Unload Alarm The alarm condition when the compressor has unloaded as a result of multiple surges.
Unload (Location) An Unload command has been issued from Location.
NOTE 1:
• “Location” is replaced by “Comm” for
communications network
• “Local” for local compressor display and
• “Remote” for hardwired remote communications.
NOTE 2:
• “x” is replaced by “C” for edits from a
communication network and
• “L” for edits from the local display.
NOTE 3:
• All Analog Inputs get edit local, edit
communications, alarm and trip event messages.
NOTE 4:
• All Discrete Inputs for Alarm or Trip get alarm
and trip event messages.

Settings Folder and Page Descriptions
Settings Folder The Date is set with three separate values (1) Year,
The SETTINGS folder is used for compressor setup. including century (2) Month and (3) Day. The Time is
also set with three values (1) Hour, (2) Minutes and
In this folder, the User will enter performance and
control operating parameters, analog health (3) Seconds.
monitoring settings for Alarm and Trip conditions,
control mode selection, setpoint changes, password, Edit Parameters for:
and user interface language. This folder is the Password, Language, Time & Date Page
primary location for editing setpoints.
Variable Units Minimum Maximum Step
Value Value Size
Password, Language, Time and Date Page
Password Digit Dimension- 0 9 1
less
Date (Year) years 1990 2069 1
Password * * * *
Date (Month) months 1 12 1
Setpoint Changes Enabled
Date (Day) days 1 31 1
Language and Units
Time (Hours) hours 0 23 1
English degF mils amps psi
Time (Minutes) minutes 0 59 1
English degC mils amps Kg/cm2
Time (Seconds) seconds 0 59 1
Date, yyyy/mm/dd 1999/08/31
Time, hh:mm:ss 12:30:00
Load Selected
Loaded Remote 1/6
The Password is used for determining whether

Setpoint Changes can be made. The Password
takes four numbers. If the Password is entered
properly, changes will be enabled (a tick will be in
the box); otherwise, they are disabled. This enabling
and disabling applies to all changeable setpoints
except, Pressure Setpoint, Throttle Limit, language
selection and the Password, these items are always
modifiable.
Each control system is shipped with two languages

and units of measure combinations. The first set is
for the English language, pressures in units of PSIG,
temperatures in units of degrees F and vibrations in
units of mils. The other set will be localized for the
customer. The default alternate language is English
with Metric units.
Language support will be provided as standard for

English, all European languages required for the CE
Mark, and Chinese. Others will be available as
required and translations can be obtained.
This system has the ability for any language

because of the graphics display. Asian character
support will require additional screens because
these characters require four times the number of
pixels. There are no limitations on the units of
measure. Each analog input has its own scaling
factor and offset.

Anti-surge Settings and Driver Over-Load • MinLoad Surge Index Increment is the value that
Protection Page the Control Setpoint is indexed after a surge has
been detected. If the value for Surge Index
Increment is equal to zero, Surge Indexing is
disabled.
MaxLoad (HLL), amps 400.0
MinLoad
!
User Setpoint (TL), amps 100.0 Caution
Control Setpoint, amps 100.0 When Surge Indexing is enabled and the
Surge Index Increment, amps 1.0
compressor surges several times, the compressor
will begin bypassing air sooner than when Surge
Indexing is disabled. You should periodically reset
Surge Absorber Enabled
the MinLoad Control Setpoint to prevent excessive
Surge Sensitivity 9.0 air bypass
Load Selected
Loaded Remote 2/6 To reset the MinLoad Control Setpoint to the
MinLoad User Setpoint, hold the reset key for at
least five seconds. The indication that it has been
This page has all of the settings for controlling and reset will be in the event log. The event message
detecting surge conditions and protecting the main “MinLoad Reset” will be displayed.
driver from over load conditions.
• The MaxLoad (HLL) setpoint prevents the
Another indication is when the MinLoad User
compressor driver from overloading. Setpoint value equals the MinLoad Control Setpoint
value. The Surge Absorber Enabled checkbox
allows the user to turn off or on the Surge Absorber
! feature. When disabled, the compressor will Unload
Caution on any surge condition.
The MaxLoad (HLL) value should not exceed
the value determined in the section titled Setting The Surge Sensitivity setting has a range from one
MaxLoad. Failure to set this properly could result (1) to ten (10) where one is not sensitive (a “soft”
in damage to the motor surge condition could exist without being identified)
and ten is very sensitive (a “soft” surge condition
• MinLoad User Setpoint (TL) is the value used to would be identified).
determine what the initial value (before indexing)
when the bypass valve begins constant pressure The machine is shipped with a default value of nine
control in lieu of the inlet valve. (9). This setting will pick up most surge conditions.
• MinLoad Control Setpoint is the actual value

used to determine when the bypass valve begins ! Caution
constant pressure control in lieu of the inlet
valve. This value equals the MinLoad User Repeated surging can cause damage to the
Setpoint plus the number of surges times the compressor; therefore, use caution when
index increment value. desensitizing the Surge Sensitivity setting.
Edit Parameters for:

! Note: Anti-Surge and Driver Overload Protection Page
MinLoad Control Setpoint is the motor amperage Variable Units Minimum Maximum Step
value used to determine when the bypass valve Value Value Size
opens. MinLoad Control Setpoint will always be
equal to or greater than the Throttle Limit Value Max Load (HLL) amps 0.0 9999.9 0.1
Min Load User amps 0.0 100.0 0.1

Set point (TL)
Min Load Surge amps 0.0 9999.9 0.1

Index Increment
Surge Sensitivity Dimension- 0.0 10.9 0.1
less

Control Parameters (PID) Page Control Mode Selection Page
SYSTEM INFO SETTINGS SYSTEM INFO SETTINGS

PB IT D Control Mode
Rep/sec Sec
Manual
Inlet Valve
Modulate
Pressure 10.0 0.5 0.0
Autodual
MinLoad (TL) 25.0 0.5 0.0
Relaod Pressure, % of Setpoint 98
MaxLoad (HLL) 100.0 0.5 0.0
Unload Point, BV % Open 1
Bypass Valve
Unload Delay Timer, seconds 1
Pressure 10.0 0.5 0.0
Load Selected
Loaded Remote 3/6 Loaded
Load Selected
Remote 4/6
This page is used for matching the control system to This page allows the User to select between the two
the local application. standard control modes, Modulate and Autodual.
This selection process is performed with the radio
The Proportional Band (PB), Integral Time (IT) and button selector. To change the selection, press the
Derivative (D) settings are provided for both the inlet Up or Down arrow key.
valve and bypass valves.
Reload Percent, Unload Point and Unload Delay
This gives the controller precise control for Time are all setpoints for Auto dual control.
modelling the air system over the entire operating
range of the compressor. Ticking the Manual checkbox enables manual valve
control. In this mode, the inlet valve may be stroked
With this release, the Derivative constant has been when the compressor is not running, and the bypass
added to give even more capability to match the valve can be stroked at any time. If a surge condition
control system to the air system. However we occurs while manually controlling these valves, the
recommend that this value remain at zero unless CMC will automatically take over the valves.
you fully understanding how this parameter works.
!
! Caution
Caution Manual should only be used for compressor
Setting the Derivative parameter to a value setup.
other than zero for any of the PID settings may
cause the valve output to change rapidly. Please
change this value with caution.
Edit Parameters for:
Control Mode Selection
Edit Parameters for: Variable Units Minimum Maximum Step
Control Parameters (PID) Page Value Value Size
Variable Units Minimum Maximum Step Auto Dual Reload % of Set 0 99 1

Value Value Size Pressure Point
Each PB dimensionle 0.0 99.99 0.1 Auto Dual Unload BV % Open 1 99 1

(Proportional ss Point
Band)
Auto Dual Unload seconds 0.0 999 1
Each IT (Integral Repeats/ 0.0 99.99 0.1 Delay Time
Band) seconds
Each D seconds 0.0 99.99 0.1
(Derivative Band)

Miscellaneous Page
Edit Parameters for Miscellaneous Page
Variable Units Minimum Maximum Step
Starting Timer, seconds 20 Value Value Size
Coasting Timer, seconds 240
Starting Timer seconds 5 60 1
CT Ratio
Coasting Timer seconds 60 9999 1
Motor Failure Trip Enable
Inlet Valve Unload Position, % 15
CT Ratio Dimension- 60 9999 1
Setpoint Ramp Rate, pressure / scan 5.0 less
Inlet Valve percent 0 100 1
Unload Position
Load Selected
Loaded Remote 5/6 Set point Ramp
Rate
Pressure/
scan
0 999.9 0.1
Starting Timer is the length of time prior to enabling

the loading of the compressor. Typically, this time
includes the starter transition time (Y-D time). When
this timer expires, the prelube pump will turn off and Alarm and Trip Page
the compressor is enabled for loading.
Coasting Timer is the length of time that it takes for Alarm Trip
the driver to stop rotating. Stage 1 Temperature 120 125
Stage 1 Vibration 0.80 1.00
! Caution
Stage 2 Temperature 120 125
Failure to set the Coast Timer for a period Stage 2 Vibration 0.75 0.95
greater than or equal to the actual coasting time Oil Pressure 18 16
can result in compressor damage. High Oil Temperature 120 125
Low oil Temperature 100 95
Load Selected
CT Ratio is the ratio of the current transformer
primary to the secondary; i.e., if the CT primary Loaded Remote 6/6
winding is 300 and the secondary winding is 5, then
the CT Ratio is 60.
Loaded Remote Load Selected The Alarm and Trip
When ticked, Motor Failure Trip Enable tests that the Settings Page provides the means for changing the
zero amp motor current has been reached after a analog health monitoring values.
start command has been initiated and that motor
current is not lost while the compressor is running. The number of inputs varies depending upon the
Do not tick this box for dry run conditions. number of compression stages and optional inputs.
Additional pages will be added as needed after this
The Inlet Unload Position is the position of the inlet page. All line items are changeable for the Alarm and
valve when in the unload state. Setpoint Ramp Rate Trip setpoints.
is used to prevent system pressure overshoot during
compressor loading.
Additional settings will be added to this page for

“special” features.

Procedures
To Start and Load a Compressor
1. Press Reset
2. Look for “Ready”
3. Press Start
4. Press Load
To Unload and Stop a Compressor
1. Press Unload
2. Wait 20 seconds
3. Press Stop

Procedures
Compressor Operating States for motor driven packages.
Unload
Motor Motor Full Load Amps Plus Service Factor
Current
Amps, %
MaxLoad Setpoint Amps
100 Motor Full Load Amps
MinLoad Setpoint Amps

Load
Any
Stops or
Trips
No
Stops or
Trips Start Unload Amps
Zero Amp Offset
Stopped Rotating
Power
On
Indicator, Switch and Light Layout
In addition to the CMC OUI there may be a variety of
indicators, switches, and lights mounted on the
control panel door. In conjunction with the CMC OUI
these devices make up the User Interface for the
CMC. A typical device layout consists of the
following lights, push buttons and selector switches.
Lights
• The green CONTROL POWER ON light, which
is integral to the CONTROL POWER OFF/ON
switch,
• the amber PRELUBE PUMP RUNNING light
and
• the red TROUBLE INDICATION light.
Push Buttons
The red EMERGENCY STOP push button stops
the compressor any time that it is pressed. This
push button is used to initiate a stop in the case of
an emergency.
Switches
The CONTROL POWER OFF/ON selector switch
turns the panel power on or off
Procedures
CMC Tuning Procedures

When commissioning a new compressor,
troubleshooting an existing compressor, or tuning a
system, the following procedures may be required.
The procedures are performed, and any changes
required are made through the CMC OUI. For
instructions on how to use the OUI refer to the
section titled User Interface. The following Figure 18
- Plant ASir System, will be referenced in the
procedures.
PT
1 PT Bypass
2 Valve
Pneumatic Tubing
Base 4-20 mA Block Valve

Check
Control Valve
Module
CT Starter
Motor Compressor
Plant Air System
Inlet Valve
4-20 mA
Inlet Filter
Setting MaxLoad
The MaxLoad Setpoint keeps the motor within the
allowable current range. To determine the value for
MaxLoad, an Adjusted Service Factor (ASF) is
multiplied by the motor full load amps (FLA). The
(ASF) is found by obtaining the motor service
factor from the motor nameplate and selecting the
adjustment factor from the table below. The motor
full load amps is found on the motor nameplate.
Motor Service Factor Adjusted Service Factor
1.15 1.05
1.25 1.10
Example: MaxLoad = FLA X ASF

FLA: 134 Amps
Motor service factor: 1.15
MaxLoad: 140

Procedures
Setting MinLoad b. Allow the system to stabilize at MinLoad. It

the system does not stay at MinLoad,
MinLoad establishes the minimum flow through the
slightly decrement the valve position to force
machine when loaded, it is the maximum point of
the machine to throttle to MinLoad.
inlet valve throttling. If system demand is below this
c. Decrement (MinLoad) 2%.
throttle point, the compressor must bypass air or
d. Verify the last stage pressure equals the
unload. If flow were allowed to go below MinLoad,
pressure setpoint and adjust the bypass
the machine would eventually hit the surge line and
valve position if necessary.
surge. By stopping inlet valve throttling at MinLoad
e. Repeat 5.2-4 until the compressor surges.
the machine is kept out of surge. To find the
MinLoad setting, the machine is run into the surge
line, and the value of load (amps, kilowatts, SCFM) 6. Increase MinLoad by five percent.
at surge is recorded. The recorded value is then
incremented by five percent and set as the value for 7. Exit MinLoad editing by pressing the Enter
MinLoad. Key.
8. Unload the machine.

1. Before continuing this procedure, verify the
following:
a. The inlet and bypass control valves have been 9. Disable manual valve control by unchecking
calibrated. the manual check box.
b. The machine is running unloaded.
c. The block valve at the inlet to the plant air
system (Figure 18) is closed. Setting MinLoad Surge Index Increment
d. The pressure setpoint is set to the pressure at When Surge Indexing is enabled (MinLoad Surge
which the machine is going to operate. Index Increment is greater than zero), the Index
Increment value is the amount added to the
2. Set initial MinLoad estimates. MinLoad Control Setpoint upon a surge.
a. In the Settings Folder, select the Edit Data cell
for MinLoad. The MinLoad Control Setpoint will stop being
b. Increment or decrement the value to achieve a incremented when and if the value reaches
value of approximately 95% of full MaxLoad.
3. Preset the manual bypass valve position to

100. Setting Surge Sensitivity
a. On the OUI select the Settings Folder and The Surge Sensitivity setting should be set
enable manual valve control by highlighting the sensitive enough to detect a surge, yet not trigger
manual check box. on spurious noise in the system. To set the surge
sensor the machine is forced to surge by running
! Note: the machine at MinLoad and the MinLoad setpoint
When Manual is enabled, both control valves is dropped until the machine audibly surges. The
can be positioned while stopped, while only the process is repeated until the correct setting is
Bypass Valve can be positioned when Loaded. found.
b. Switch to the System Folder Page 1 and press 1. Before continuing this procedure, verify the
the Enter Key to enable edit mode. following:
c. Use the horizontal navigation keys to select a. The plant can tolerate a pressure disturbance
the bypass valve. when the machine surges.
d. Increment the value to position the valve to b. Surge Indexing (by placing MinLoad Surge
100 percent. Index Increment to zero) is disabled.
c. Surge Absorber is disabled.
4. Load the compressor by pressing the Load d. The pressure setpoint is set to the pressure at
Key. which the machine is going to operate.
e. The machine is running unloaded.
5. Find the throttled surge point.
a. Slowly decrement the bypass valve position 2. Set the initial Surge Sensitivity setting to 9.
until the last stage discharge pressure equals a. In the Settings Folder, select the Edit Data cell
the pressure setpoint. for Surge Sensitivity.
b. Increment or decrement the value to achieve a
setting of 9.

Procedures
3. Press the Load Key. Tuning Stability
The CMC controls stability with four Proportion
4. Run the compressor at MinLoad at pressure. Integral Derivative (PID) control loops.
The machine can be forced to MinLoad and
pressure by either: • When the machine is running above the MinLoad
a. Running the plant at a higher pressure than point and below the MaxLoad point, pressure is
pressure setpoint. regulated with the Inlet Valve Pressure control
b. Decreasing load in the plant. loop.
c. Verify the compressor is at pressure by
observing the last stage pressure on Page 2 • When the machine is running at the MinLoad
of the Settings Folder. point, pressure is regulated with the Bypass
Valve Pressure control loop
5. Find the throttled surge point. • Motor current is regulated with the Inlet Valve
a. Select the MinLoad cell in the Settings Folder MinLoad control loop.
and slowly decrement the value until the • When the machine is running at MaxLoad motor
machine surges. Typically the machine will current is regulated with the Inlet Valve MaxLoad
make a puffing or popping noise upon surge, control loop.
this is your indication surge has occurred.
For each PID loop, Proportional, Integral and
6. Press the Unload Key. Derivative parameters are used to stabilize the
system. For a definition of the parameters and their
7. Determine if Surge was recorded. effect on stability, refer to the section titled “How
a. Inspect the Status Bar. If the message Surge does Constant Pressure Modulation Work.” The
Unload is displayed surge was recorded, if the proportional and integral terms are labelled by their
message is not displayed surge was not respective loops, Inlet Valve, Bypass Valve,
recorded. MinLoad, and MaxLoad
8. Check the Surge Sensitivity setting.

a. If the surge was recorded, the setting may be Calibrating the Control Valves
correct or the Surge Sensor may be too The purpose of this procedure is to position the inlet
sensitive, skip to the too sensitive step, which and bypass valves by opening and closing each
follows. valve from the CMC analog outputs. The valves
b. If the surge was not recorded, the setting is not should be adjusted to physically correspond with the
sensitive enough, skip to the not sensitive valve positions displayed on the OUI.
enough step which follows.
1. Stop the compressor.
9. Surge Sensor too sensitive.
a. Select the Surge Sensitivity Setting in the
Settings Folder.
! Note:
b. Decrease the value for Surge Sensitivity by Performing this procedure while the
0.1. compressor is operating may cause serious
c. Press the Reset Key. damage.
d. Skip to step 11.
2. On the OUI enable Setpoint changes by entering
10. Surge Sensor not sensitive enough. the password on the Settings Folder.
a. Select the Surge Sensitivity Setting in the 3. Verify the OUI status bar displays “Ready” or
Settings Folder. “Not Ready”.
b. Increase the value for Surge Sensitivity by 0.1.
c. Press the Reset Key. 4. On the OUI select the Settings Folder and enable
manual valve control by highlighting the manual
11. Repeat the procedure until the Surge check box.
Sensitivity setting is found which just
catches a surge but does not miss a surge. Note:
a. Return to step 3. !
When Manual is enabled, both control valves
can be positioned while stopped, while only the
12. Restore all values but Surge Sensitivity. Bypass Valve can be positioned when Loaded.

Procedures
5. Switch to the System Folder Page 1 and press Unload Delay Time (seconds)
the Enter Key to enable edit mode. The Unload Delay Timer should be set to prevent
6. Use the horizontal navigation keys to select the unloading during short excursions through the
valve requiring positioning. Unload Point. Typically, when the check valve
closes, system demand requires the check valve to
7. Use the vertical arrows to increment and
open again soon thereafter due to the demand being
decrement the valve position sent to the valve.
on the verge of requiring the compressor. If the
8. Disassemble Manual Valve control by blanking compressor had unloaded when the check valve first
the manual check box. closed, a reload would be immediately required and
the machine would go through the automatic unload/
load cycle until demand was consistently low
! Note: enough to keep the check valve closed. For this
For the Inlet and Bypass Valves, the displayed reason, the timer is used to inhibit Unload until
position corresponds to percent open. demand has consistently remained low.
1. Run the compressor at MinLoad by either:

Autodual Control Settings a. Running the plant at a higher pressure than
For a detailed definition of the Autodual control pressure setpoint.
mode refer to the section titled “Control b. Shedding load in the plant.
Methodology”. The procedure for tuning Autodual
requires the setting of the following variables: 2. Determine delay time.
a. Observe time when bypass valve first hits
Unload Point (Bypass Valve % Open)
unload point.
The Bypass Valve Unload Point is selected to
correspond to the check valve closing as shown in b. Observe time when bypass valve remains
Figure 18, since at this point the machine is not below unload point, typically less than 300
supplying the system. This position is found by seconds.
running the machine at MinLoad and monitoring the c. Enter the time difference as the Delay Time.
System and Discharge pressures. When the System
pressure is 5% of setpoint greater than the last Reload Percent
stage pressure as shown in the System Folder, the The Reload Percent determines the System
check valve is assumed to be closed. Pressure at which the machine will automatically
load into the system. This value should be set
Example: Given the following conditions the Unload according to the customer’s minimum acceptable
Point would be set at 35. system pressure.
Variable Case 1 Case 2
Pressure Set point 100 100 Setting the Start Time

PT1 (system pressure) 100 100 The Start Time is set to the transition time of a built-
in reduced voltage starter or the acceleration time of
PT2 (last stage pressure) 100 94 a customer supplied starter. This procedure requires
Bypass Valve Position 13 35 the Inlet Unload Position to have been set.
Assumed check valve position Open Closed
1. Initially set the Start Time to 25 Seconds.
Caution: Damage to the starter contacts could
result if starter transition occurs before the
1. Run the machine at MinLoad by elevating the compressor is up to full speed.
system pressure no more than 3% or decrease
the pressure setpoint no more than 3%. 2. Stop the compressor.
2. Monitor the difference between the Discharge 3. On the OUI record the time and press the start
and System Pressures by using the System button.
Folder Pages 1 and 2. 4. Wait for the compressor to stop accelerating and
3. When the Discharge Pressure is approximately again record the time.
5% of setpoint less than the System Pressure, 5. Calculate the difference between the two values
record the Bypass Valve Position. and enter as the Start Time.
4. Enter the recorded Bypass Valve Position as the
Unload Point.
Procedures
Setting the CT Ratio Setting Set Point Ramp Rate

Locate the CT and find the rating, which is typically Setpoint ramp rate determines the rate at which the
printed, on the side of the CT. Divide the primary machine transitions from unloaded to loaded. The
by the secondary and enter the value as the CT setting should be set as high as possible without
Ratio. creating excessive overshoot when the machine
enters the system.
Example: CT is printed with 600:5, the value
entered is 120. 1. Verify the machine is unloaded by the “Unloaded”
message in the OUI Status Bar.
Inlet Unload Position 2. Determine overshoot.

The purpose of this variable is to set the inlet valve a) Load the machine
position when the machine is running unloaded. b) Monitor the pressure overshoot.
For a description of the Unloaded state refer to the
section titled “Unload”. 3. If overshoot is excessive.
a) Decrease the Setpoint Ramp Rate.
b) Repeat step 2.
1. If the inlet valve is a butterfly type, enter an
initial value for Inlet Unload Position of 15. If the 4. If overshoot is satisfactory and time to load is
inlet valve is a inlet guide vane type, enter an excessive.
initial value for Inlet Unload Position of 5. a) Increase the Setpoint Ramp Rate.
2. Start the machine. If during startup the motor b) Repeat step 2.
trips on overload, is drawing what is considered
excessive amperage or sounds labored, stop 5. If overshoot is satisfactory and time to load is
the machine and decrease the Unload Position satisfactory the Setpoint Ramp Rate is correct.
by 2.
3. Run the machine in the Unloaded state and
monitor the first stage pressure. Alarm and Trip Settings
4. Adjust the Unload Position to achieve 1 PSIG The values for vibration, temperature, pressure etc.
on the first stage discharge, or until a positive alarm and trip setpoints are located on the electrical
pressure is felt at the first stage trap bypass. schematic. These values determine when the
5. If the inlet air temperature is relatively cold, controller will indicate an alarm or trip condition.
increase the setting 2%, this will accommodate
hot day operation.

Procedures
Tuning the Controller Setup Lower the amps step by step using 7 amps until
compressor surge. Observe until the compressor surge
and record the amps during surge 245 amps.
Minload
The Bypass Valve is controlling pressure and the Set MinLoad (TL) to 5% above Surge amps.
Inlet Valve is maintaining the Minload control
setpoint. Example: 245 x 5% = 12.25 + 245 = 257.25 amp Set
Minload.
Loaded
The Inlet Valve is controlling pressure and the
Bypass Valve is closed.
Full Load
The Inlet Valve has reached the full open or 100%
open position.
MaxLoad
The Inlet Valve is maintaining the MaxLoad setpoint
to prevent motor damage.
Setting MaxLoad
The MaxLoad Setpoint keeps the motor within the
allowable current range.
To determine the value for MaxLoad, an Adjusted

Service Factor (ASF) is multiplied by the motor full
load amps (FLA).
The ASF is found by obtaining the motor service

factor from the motor nameplate and selecting the
adjustment factor from :
Motor Service Factor Adjusted Service Factor

1.15 1.05
1.25 1.10
The motor full load amps is found on the motor nameplate.
Example: MaxLoad = FLA x ASF
FLA of 134 Amps x

Motor Service Factory of 1.15 equals a
MaxLoad of 140.
Setting MinLoad ATL

Throttled Surge initial setting is 95% of FLA.
Example: Motor FLA 380 x .95% = 361 Amps.
If the motor actual amps are lower than the initial amps
setting, the compressor will never load.
After loaded, the compressor lowers the amps setting by

2% of the amps setting.
Example: User Setpoint (TL)

Amps setting 340 x .02 = 6.8 amps
7 amps (on higher side)

Procedures
Short Test
1 Which button do you press to re-start the machine?
2 Which button do you press to unload the machine?
3 How do you reset the MinLoad Control Setpoint?
4 Where do you find information on the ‘running hours’?
5 What do you do if there has been a surge and surge equals zero?

Basic Centac Manual
Trouble Shooting
Section 8
CMC Controls .............................................................1—2
Input/Output (I/O) System...........................................3—8
Temperature Monitoring .............................................9—15
Valve Control System .................................................16—18
Pressure Monitoring System ......................................19—23
Digital Input System....................................................24—25
Control Power System (CPS) .....................................26—28
Controller Problems (CMCS)......................................29—30
Symptoms, Possible Causes & Corrective Action ......31—34
Short Test ...................................................................35—38

Troubleshooting Section 8
CMC Controls
The following procedures provide direction on
troubleshooting the CMC System, control panel, and
associated instrumentation.
Faults are either Event Logged, which means the

fault is displayed in the INFO Folder on the OUI, or
Non-Event Logged.
The distinction helps to expedite the troubleshooting

process.
When a control system fault is suspected, the

following table is used to categorize the fault and
breaks each category down into specific items,
which can cause a particular fault.
A Control System Fault is suspected

The fault is logged in the Event Log
Compressor Related Event correctly involves a problem. Refer to the Compressor Operating
Manual
I/O Fault Readings incorrect for Input/Output (I/O) System
• Temperature
• Pressure
• Load
• Valve
• etc.
The fault is not logged in the Event Log

I/O Fault Readings incorrect for Input/Output (I/O) System
• Temperature
• Pressure
• Load
• valve, etc.
Control Problems Compressor CMC Tuning Procedures

• fails to load
• fails to trip
• fails to start
• Surging
• etc.
Stability Problems Unstable CMC Tuning Procedures

• Inlet valve
• bypass valve
• control variables (mass flow,
system pressure, Kw, amps)
Controller Problems • OUI failed Controller Problems Section
• BCM failed
• UCM failed
• Communications failed

CMC Controls
Troubleshooting Example Trouble Procedure Execution:

The following example will serve as a guide to follow Step 1 of PMS #1 requires disconnecting of the
when troubleshooting specific problems. pressure transducer (PT) wires at the transmitter.
When this step is performed, one of the connections
Problem Indication: is found to be intermittent. When the poor
Plant air pressure is low and the CMC OUI is found connection is corrected, the erratic reading on the
as shown. OUI becomes solid
Probable Cause Determination:

The machine Tripped on Low Oil Pressure, which
means the oil pressure, was below the Oil Pressure
Trip Value.
The previous table leads to the assumption that the

problem is either compressor or I/O related, because
the fault is Event Logged.
There are two most likely causes for this event.
A Actual oil pressure is low.

The prelube pump is found to be running and
installation of a calibrated pressure sensor
shows the actual oil pressure to be above the Oil
Pressure Trip Value. Therefore, the mechanical
system is operating correctly.
B The value read by the CMC is incorrect.

• The oil pressure value displayed on Page 2 of
the System Folder shows the oil pressure to be
below the test sensor reading and erratic.
Additionally, all other analog input readings are
normal and not erratic. Therefore, the problem
can be isolated to the oil pressure, analog input
circuit.
• The Pressure Monitoring System (PMS)
troubleshooting table, found in the following
section “The Pressure Monitoring System”
identifies the probable cause for an erratic
reading as a loose wire/terminal/connector and
specifies Troubleshooting Procedure PMS #1
and 2 as the appropriate procedures.

CMC Controls Input/Output (I/O) System
Vibration Monitoring System (VMS)

Description:
The vibration transmitter is used to convert the
proximity probe signal into a 4 -20 mA signal, which
is monitored by the CMC. The system is based on a
15-foot (4.575 m) total electrical length.
Component specifications:
Transmitter:
• 100 mv/mil = 0.1 volt per 0.001 in (0.0254 mm)
• 4 mil (0.1016 mm) scale
• 4-20 mA output
Probe:
• Gap setting 0.030 to 0.060 in (0.762 to 1.524
mm), 0.050 in (1.27 mm) is nominal gap
• Probe gap corresponds to 3 to 6 volts VDC, 5
VDC nominal
• Probe ohm value 7-12 ohms
Troubleshooting:
The following table identifies typical problems,
probable causes, and appropriate procedures for
verifying the probable cause:
Typical Problem Probable Cause VSM Troubleshooting Procedure

1 2 3 4 5
Zero OUI readout (when Open circuit/cable disconnected 9 9 9
compressor is running)
Loss of power to transmitter 9
Malfunctioning transmitter 9
Transmitter not calibrated 9
Erratic OUI readout Loose wire/terminal/connector 9 9 9
Incorrect OUI readout Any 9 9 9 9 9

Checking Vibration Transmitter Power

VMS #1
1) Connect a DC voltmeter to the + and - terminals
of the transmitter.
2) With control power on, there should be
approximately 24 VDC present at the terminals.
3) If approximately 24 VDC is not present; see the
section titled “Control Power System”.
!
Note
Under no circumstances should the vibration
transmitter zero or span be adjusted. Calibration of
the vibration transmitter requires special tooling and
calibration fixtures. Contact the factory if calibration
is required.
To BCM J1 Connector
(See electrical schematic for point).
Vibration Transmitter

Checking Vibration Circuit

VMS #2
1) With control power on, check the dc voltage at
the COM and TEST terminals on the transmitter.
A reading of 3 to 6 VDC should be present [this
corresponds to a 0.030 to 0.060 inches (0.762 to
1.524 mm)] probe gap.
2) If less than 3 volts is present the probe gap may
be incorrect, or a short circuit may exist. Check
the cable connections and cable.
3) If more than 6 volts is present the probe gap may
be incorrect, or an open circuit may exist. Check
the cable connections and cable.
4) If no voltage exists, the transmitter may be faulty.
Remove control power and swap connections
with another transmitter and test.
Compressor Casing
Vibration Transmitter
Vibration Probe
Probe Extension cable

Check the Vibration Probe, and Cable

VMS #3
1) Turn control power off and disconnect the probe
extension cable from the transmitter.
2) Check resistance of the extension cable and
probe together, the reading should be 7 to 20
ohms.
Probe Connector
Probe Cable
Computer Casing
Connect test lead

to outer shell.
Connect test lead

to inner pin.
Probe Extension
Cable Vibration Probe

Checking the Vibration Probe

VMS #4
1. Turn control power off and disconnect the probe
extension cable from the transmitter.
2. Check resistance of the probe alone, the reading
should be 7 to 12 ohms.
Connect test lead

to outer shell.
Probe Connector
Probe Cable
Vibration Probe
Connect test lead

to inner pin.

Check the BCM

VMS #5
1) With control power off connect a 4-20 mA
simulator at the input points of the suspected
faulty device at connector J1, (see electrical
schematic for connection points).
2) Turn control power on and vary the signal. If the
value tracks according to the table below, the
wiring is faulty.
3) Verify the connector at J1 is fully seated. If the
value does not track correctly, the BCM may be
faulty.
BCM
J2-Floating Analog Inputs, (4-20mA) Channels 1-2
J1-Grounded Analog Inputs, (4-20mA) Channels 3-23
Pin 25
Pin 1
BCM Conversion chart

mA percent Mils mA
(from simulator) (on OUI) (from simulator)
100% 4.0 20
50% 2.0 12
0% 0.0 4.50

CMC Controls Temperature Monitoring
Temperature Monitoring System (TMS)

Description:
An RTD (Resistance Temperature Detector-2 Wire)
with external transmitter is used by the CMC for
temperature monitoring. An RTD resistance (ohmic
value) varies with temperature. A transmitter for
monitoring by the CMC analog input channel
converts the resistance to a 4- 20 mA signal.
Component specification:
Probe:
• 100 ohm Platinum resistance at 32 °F (0°C). Two
types are used: Transmitter:
• The transmitter may be mounted in the RTD
connection head fitting or in the control panel
enclosure.
The transmitter is supplied 24 VDC and outputs
4-20mA over a fixed range of either 0 to 200°F (-
17.7 to +93.3°C), or 0-500°F (-17.7 to +260°C).
Troubleshooting:

Typical Problem Probable Cause TMS Troubleshooting Procedure

1 2 3 4
High OUI readout High resistance connection 9

RTD failure 9
Transmitter failure 9
Low OUI readout Transmitter failure 9
RTD failure 9
Erratic OUI readout Loose terminal connection 9
RTD internal wire fault 9
Transmitter failure 9
Incorrect OUI readout Transmitter not calibrated 9
RTD or transmitter failure 9 9
Any 9 9 9 9

Checking for Power to the Temperature

Transmitter
TMS #1
1) Disconnect the wires at terminals #1 and #2 on

the transmitter and connect a voltmeter to these
wires.
3) If approximately 24 VDC is not present, see the
1234
BCM
Pin 25
Pin 1
Temperature transmitter RTD

Checking for a Faulty RTD

TMS #2
1) Turn control power off.
2) Check ohms versus temperature. Use an
Ohmmeter and the following tables to determine
if the RTD is faulty. Vary the temperature to the
RTD and check the ohms around the normal
operating range.
Thermometer
RTD
32 F
Ice Water

Degrees Fahrenheit versus Ohms value

chart for 100 OHM Platinum RTD
°F 0 1 2 3 4 5 6 7 8 9
0 93.01 93.22 93.44 93.66 93.88 94.10 94.32 94.54 94.76 94.98
10 95.20 95.42 95.63 95.85 96.07 96.29 96.51 96.73 96.95 97.17
20 97.38 97.60 97.82 98.04 98.26 98.47 98.69 98.91 99.13 99.35
30 99.56 99.78 100.00 100.20 100.40 100.70 100.90 101.10 101.30 101.50
40 101.70 102.00 102.20 102.40 102.60 102.80 103.00 103.30 103.50 103.70
50 103.90 104.10 104.30 104.60 104.80 105.00 105.20 105.40 105.60 105.80
60 106.10 106.30 106.50 106.70 106.90 107.10 107.40 107.60 107.80 108.00
70 108.20 108.40 108.70 108.90 109.10 109.30 109.50 109.70 109.90 110.20
80 110.40 110.60 110.80 111.00 111.20 111.50 111.70 111.90 112.10 112.30
90 112.50 112.70 113.00 113.20 113.40 113.60 113.80 114.00 114.30 114.50
100 114.70 114.90 115.10 115.30 115.50 115.80 116.00 116.20 116.40 116.60
110 116.80 117.00 117.30 117.50 117.70 117.90 118.10 118.30 118.50 118.80
120 119.00 119.20 119.40 119.60 119.80 120.00 120.20 120.50 120.70 120.90
130 121.10 121.30 121.50 121.70 122.00 122.20 122.40 122.60 122.80 123.00
140 123.20 123.40 123.60 123.90 124.10 124.30 124.50 124.70 124.90 125.20
150 125.40 125.60 125.80 126.00 126.20 126.40 126.60 126.90 127.10 127.30
160 127.50 127.70 127.90 128.10 128.30 128.60 128.80 129.00 129.20 129.40
170 129.60 129.80 130.00 130.30 130.50 130.70 130.90 131.10 131.30 131.50
180 131.70 132.00 132.20 132.40 132.60 132.80 133.00 133.20 133.40 133.60
190 133.90 134.10 134.30 134.50 134.70 134.90 135.10 135.30 135.50 135.80
200 136.00 136.20 136.40 136.60 136.80 137.00 137.20 137.40 137.70 137.90
210 138.10 138.30 138.50 138.70 138.90 139.10 139.30 139.60 139.80 140.00
220 140.20 140.40 140.60 140.80 141.00 141.20 141.40 141.70 141.90 142.10
230 142.30 142.50 142.70 142.90 143.10 143.30 143.50 143.80 144.00 144.20
240 144.40 144.60 144.80 145.00 145.20 145.40 145.60 145.90 146.10 146.30
250 146.50 146.70 146.90 147.10 147.30 147.50 147.70 147.90 148.20 148.40
260 148.60 148.80 149.00 149.20 149.40 149.60 149.80 150.00 150.20 150.50
270 150.70 150.90 151.10 151.30 151.50 151.70 151.90 152.10 152.30 152.50
280 152.70 153.00 153.20 153.40 153.60 153.80 154.00 154.20 154.40 154.60
290 154.80 155.00 155.20 155.40 155.70 155.90 156.10 156.30 156.50 156.70
300 156.90 157.10 157.30 157.50 157.70 157.90 158.10 158.40 158.60 158.80
310 159.00 159.20 159.40 159.60 159.80 160.00 160.20 160.40 160.60 160.80
320 161.00 161.30 161.50 161.70 161.90 162.10 162.30 162.50 162.70 162.90
330 163.10 163.30 163.50 163.70 163.90 164.10 164.30 164.60 164.80 165.00
340 165.20 165.40 165.60 165.80 166.00 166.20 166.40 166.60 166.80 167.00
350 167.20 167.40 167.60 167.80 168.10 168.30 168.50 168.70 168.90 169.10
360 169.30 169.50 169.70 169.90 170.10 170.30 170.50 170.70 170.90 171.10
370 171.30 171.50 171.80 172.00 172.20 172.40 172.60 172.80 173.00 173.20
380 173.40 173.60 173.80 174.00 174.20 174.40 174.60 174.80 175.00 175.20
390 175.40 175.60 175.80 176.00 176.30 176.50 176.70 176.90 177.10 177.30
400 177.50 177.70 177.90 178.10 178.30 178.50 178.70 178.90 179.10 179.30
410 179.50 179.70 179.90 180.10 180.30 180.50 180.70 180.90 181.10 181.30
420 181.50 181.80 182.00 182.20 182.40 182.60 182.80 183.00 183.20 183.40
430 183.60 183.80 184.00 184.20 184.40 184.60 184.80 185.00 185.20 185.40
440 185.60 185.80 186.00 186.20 186.40 186.60 186.80 187.00 187.20 187.40
450 187.60 187.80 188.00 188.20 188.40 188.60 188.80 189.00 189.20 189.40
460 189.70 189.90 190.10 190.30 190.50 190.70 190.90 191.10 191.30 191.50
470 191.70 191.90 192.10 192.30 192.50 192.70 192.90 193.10 193.30 193.50
480 193.70 193.90 194.10 194.30 194.50 194.70 194.90 195.10 195.30 195.50
490 195.70 195.90 196.10 196.30 196.50 196.70 196.90 197.10 197.30 197.50
500 197.70 197.90 198.10 198.30 198.50 198.70 198.90 199.10 199.30 199.50

Degrees Celsius versus Ohms value chart

for 100 OHM Platinum RTD This chart was converted from the Fahrenheit chart
using formula °C= ((°F-32)/1.8).
°C 0.00 0.62 1.23 1.85 2.47 3.09 3.70 4.32 4.94 5.56
-17.78 93.01 93.22 93.44 93.66 93.88 94.10 94.32 94.54 94.76 94.98
-12.22 95.20 95.42 95.63 95.85 96.07 96.29 96.51 96.73 96.95 97.17
-6.67 97.38 97.60 97.82 98.04 98.26 98.47 98.69 98.91 99.13 99.35
-1.11 99.56 99.78 100.00 100.22 100.43 100.65 100.87 101.08 101.30 101.52
4.44 101.74 101.95 102.17 102.39 102.60 102.82 103.04 103.25 103.47 103.69
10.00 103.90 104.12 104.34 104.55 104.77 104.98 105.20 105.42 105.63 105.85
15.56 106.07 106.28 106.50 106.71 106.93 107.14 107.36 107.58 107.79 108.01
21.11 108.22 108.44 108.66 108.87 109.09 109.30 109.52 109.73 109.95 110.16
26.67 110.38 110.60 110.81 111.03 111.24 111.46 111.67 111.89 112.10 112.32
32.22 112.53 112.75 112.96 113.18 113.39 113.61 113.82 114.04 114.25 114.47
37.78 114.68 114.89 115.11 115.32 115.54 115.75 115.97 116.18 116.40 116.61
43.33 116.83 117.04 117.25 117.47 117.68 117.90 118.11 118.32 118.54 118.75
48.89 118.97 119.18 119.39 119.61 119.82 120.04 120.25 120.46 120.68 120.89
54.44 121.11 121.32 121.53 121.75 121.96 122.17 122.39 122.60 122.81 123.03
60.00 123.22 123.43 123.65 123.87 124.08 124.30 124.51 124.73 124.94 125.16
65.56 125.37 125.58 125.79 126.01 126.22 126.43 126.65 126.86 127.07 127.28
71.11 127.50 127.71 127.92 128.13 128.35 128.56 128.77 128.98 129.20 129.41
76.67 129.62 129.83 130.04 130.26 130.47 130.68 130.89 131.10 131.32 131.53
82.22 131.74 131.95 132.16 132.38 132.59 132.80 133.01 133.22 133.43 133.65
87.78 133.86 134.07 134.28 134.49 134.70 134.91 135.12 135.34 135.55 135.76
93.33 135.97 136.18 136.39 136.60 136.81 137.02 137.24 137.45 137.66 137.87
98.89 138.08 138.29 138.50 138.71 138.92 139.13 139.34 139.55 139.76 139.97
104.44 140.18 140.39 140.60 140.81 141.02 141.24 141.45 141.66 141.87 142.08
110.00 142.29 142.50 142.71 142.92 143.13 143.34 143.55 143.76 143.97 144.18
115.56 144.39 144.59 144.80 145.01 145.22 145.43 145.64 145.85 146.06 146.27
121.11 146.48 146.69 146.90 147.11 147.32 147.53 147.73 147.94 148.15 148.36
126.67 148.57 148.78 148.99 149.20 149.41 149.61 149.82 150.03 150.24 150.45
132.22 150.66 150.87 151.08 151.28 151.49 151.70 151.91 152.12 152.33 152.54
137.78 152.74 152.95 153.16 153.37 153.58 153.78 153.99 154.20 154.41 154.62
143.33 154.82 155.03 155.24 155.45 155.66 155.86 156.07 156.28 156.49 156.69
148.89 156.90 157.11 157.32 157.52 157.73 157.94 158.15 158.35 158.56 158.77
154.44 158.98 159.18 159.39 159.60 159.80 160.01 160.22 160.42 160.63 160.84
160.00 161.05 161.25 161.46 161.67 161.87 162.08 162.29 162.49 162.70 162.91
165.56 163.11 163.32 163.52 163.73 163.94 164.14 164.35 164.56 164.76 164.97
171.11 165.17 165.38 165.59 165.79 166.00 166.20 166.41 166.62 166.82 167.03
176.67 167.23 167.44 167.64 167.85 168.06 168.26 168.47 168.67 168.88 169.08
182.22 169.29 169.49 169.70 169.90 170.11 170.32 170.52 170.73 170.93 171.14
187.78 171.34 171.55 171.75 171.96 172.16 172.37 172.57 172.78 172.98 173.19
193.33 173.39 173.59 173.80 174.00 174.21 174.41 174.62 174.82 175.03 175.23
198.89 175.44 175.64 175.84 176.05 176.25 176.46 176.66 176.86 177.07 177.27
204.44 177.48 177.68 177.88 178.09 178.29 178.49 178.70 178.90 179.11 179.31
210.00 179.51 179.72 179.92 180.12 180.33 180.53 180.73 180.94 181.14 181.35
215.56 181.55 181.75 181.95 182.16 182.36 182.56 182.77 182.97 183.17 183.38
221.11 183.58 183.78 183.98 184.19 184.39 184.59 184.80 185.00 185.20 185.40
226.67 185.60 185.81 186.01 186.21 186.41 186.62 186.82 187.02 187.22 187.43
232.22 187.63 187.83 188.03 188.24 188.44 188.64 188.84 189.04 189.25 189.45
237.78 189.65 189.85 190.05 190.25 190.46 190.66 190.86 191.06 191.26 191.46
243.33 191.67 191.87 192.07 192.27 192.47 192.67 192.87 193.08 193.28 193.48
248.89 193.68 193.88 194.08 194.28 194.48 194.68 194.88 195.09 195.29 195.49
254.44 195.69 195.89 196.09 196.29 196.49 196.69 196.89 197.09 197.29 197.49
260.00 197.69 197.89 198.09 198.29 198.49 198.70 198.90 199.10 199.30 199.50

Checking the RTD Transmitter

TMS #3
1) With control power off, connect a 100-ohm
resistor to terminals #3 and #4 of the transmitter.
2) Turn control power on, the OUI reading should
be 32°F (0°C) ±10%.
3) If the reading is not within specification, the
transmitter may be faulty.
BCM
J1-Grounded Analog Inputs, (4-20mA) Channels
Pin 25
Pin 1
100
OHM
Temperature transmitter

Checking proper operation of the BCM and

wiring
TMS #4
1) Ensure control power is off. At the affected RTD
transmitter, disconnect the wires at transmitter
terminal #1 and #2. Connect a 4-20mA source to
these terminals (Observe correct polarity). Power
up the control panel and then vary the simulator
output.
2) At 12 mA (50%) the OUI should read 1/2 the
RTD transmitter range; 100 or 250°F (37.7 or
121.1°C). The readout should change as the
simulator output is varied.
3) If the reading on the OUI is incorrect or does not
change, turn control power off and reconnect the
4 to 20 mA simulator at the respective terminals
at connector J1, (see electrical schematic for
connection points).
4) Turn control power on and observe the OUI
readout while varying the 4-20mA. If the reading
is correct there is an open or short in the wire or
terminals connecting the CMC to the RTD
transmitter. If reading is not correct the BCM may
be faulty.
BCM
J1-Grounded Analog Inputs, (4-20mA) Channels
Pin 25
Pin 1

CMC Controls Valve Control System
Valve Control System (VCS)

Description:
The BCM generates a 4-20 mA signal for valve

control. The signal is wired to the I/P (current to
pressure) transducer for conversion to a pneumatic
signal for positioning the inlet or bypass control
valve.
Specification:
• 4-20mA input = 3 to 15 psi output
• 60 to 120 PSIG instrument air input to I/P
Troubleshooting:
Typical Problem Probable Cause VCS Troubleshooting

Procedure
1 2
IV or BV not operating Failure of BCM 9

Positioner or actuator 9
malfunction
Failure of I/P 9


wiring
VCS #1
1) With control power off, lift the wires at J3 for the
suspected circuit and install a test meter capable
of reading milliamps as shown below, (the pin
numbers are found on the electrical schematic).
2) Restore control power.
3) If the meter reads 4 mA , the BCM is satisfactory.
4) If 4 mA is not present, refer to the section titled
“Control Power System”.
5) Restore connections.
6) Remove control power.
7) Lift wires at suspected I/P, and install meter as in
previous step.
8) Restore control power.
9) If the meter reads 4 mA, the BCM and wiring is
satisfactory.
BCM
J3-Analog Outputs, (4-20mA) Channels 1-4
Pin 25
Pin 1
Pin 1

Checking proper operation of the I/P and
positioner VCS #2
1) Connect a 4-20 mA simulator to the I/P.
2) Ensure instrument air is present at the supply
connection on the I/P.
3) Vary the simulator between 4-20 mA. The output
of the I/P and the positioner should follow. If the
valve tracks the 4-20 mA signal correctly the I/P
and the positioner are satisfactory.

Troubleshoting Section 8
CMC Controls Pressure Monitoring System
Pressure Monitoring System (PMS)

Description:
A Pressure Transducer (PT) is used to convert

pressure (psi) to a 4-20 mA signal for
monitoring by the CMC.
Component specification:
• 0-50 PSIG (344.75 kPa) range
• 0-200 PSIG (1379 kPa) range
• Power = 24 VDC
Troubleshooting:

Typical Problem Probable Cause PMS Troubleshooting Procedure
1 2 3 4
Zero OUI readout Open circuit/cable disconnected 9 9

Loss of power to transmitter 9
Malfunctioning transmitter 9 9
Erratic OUI readout Loose wire/terminal/connector 9 9
Incorrect OUI readout Any 9 9 9 9

Checking for Power to the Pressure

Transmitter
PMS #1
1) Ensure control power is off. Disconnect the wires
at the suspect PT and connect a voltmeter to
these wires.
3) If approximately 24 VDC is not present, see the
BCM
Pin 25
Pin 1

wiring
PMS #2
1) Ensure control power is off. Disconnect the wires
at the suspect PT and connect a 4-20 mA source
to the lifted wires (Observe correct polarity).
2) Restore control power and then vary the
simulator output.
3) At 12 mA (50%) the OUI should read 1/2 the PT
range. The readout should change as the
4) simulator output is varied.
5) If the reading on the OUI is incorrect or does not
change, turn control power off and reconnect the
4 -20 mA simulator at the respective terminals at
connector J1, (see electrical schematic for
connection points).
6) Turn control power on and observe the OUI
readout while varying the 4-20 mA. If the reading
is correct there is an open or short in the wire or
terminals connecting the CMC to the PT. If the
reading is not correct the BCM may be faulty.
BCM
Pin 25
Pin 1

Quick check of the PT

PMS #3
1) Connect an ohmmeter to the disconnected wires
coming from the PT.
2) If there is no continuity either the wiring or the PT
is faulty.

Functional PT test
PMS #4
1) Remove control power.
2) Remove the PT and connect a regulated air
supply to the pressure connection. Power up the
CMC and vary the regulated air supply. The OUI
should read the pressure being applied.

CMC Controls Digital Input System
Digital Input System (DIS)

Description:
The digital input devices associated with the CMC

are on/off devices that turn on or off the associated
CMC digital input.
1) Typical digital device name and type:

2) Low seal air pressure (Pressure)
3) Low cooling water flow (Flapper)
4) Low oil level (Float)
5) High condensate level (Float)
6) Dirty inlet filter (Differential pressure)
7) Dirty oil filter (Differential pressure)
8) High motor temperature (Thermistor)
Troubleshooting:

Typical Problem Probable Cause DIS Troubleshooting Procedure
False alarm or trip Faulty device DIS #1 9

Faulty wiring DIS #1 9

CMC Controls Digital Input System
Checking proper operation of the digital

devices
DIS #1
1) Verify approximately 24 VDC is present as
described in the section titled “Troubleshooting
the Power System”.
2) If approximately 24 VDC is present, install a
multimeter with VDC selected between J4 or J5
pin1 and the input pin (the input pin can be
determined from the electrical schematic, or wire
number).
3) Ensure the digital device is not in the trip
condition, the meter should read 0 VDC.
4) Actuate the switch, the meter should read
approximately 24 VDC.
J6-RS232 Serial Data Link (Display)

Female DB9 BCM
J5-Digital (Discrete)
Inputs (24 VDC)
Channels 9-16
Pin 1
J4-Digital (Discrete)
Inputs (24 VDC)
Channels 1-8
Pin 1
Air Seal Switch
J3-Analog Outputs (4-20mA)

Channels 1-4

CMC Controls Control Power System (CPS)
Control Power System (CPS)

Description:
The control power system provides 24 VDC to the

CMC system for processing logic, displaying data,
and monitoring instrumentation. The 24 VDC power
supply feeds the Base Control Module (BCM) at
connector J10. Overcurrent protection and power
distribution are performed as shown below:
J2 J1
Power Supply AC2 pin 3
+24 VDC pins 11 thru 14
F1 BCM shown
AC2 pin 1 cover removed
Return pins 7 thru 10
Fuse 5A/250VAC, normal blo.
J12-Digital Output Power 120 or 220 VAC (Pin 1)
To OUI J2 pin 2
To OUI J2 pin 1 OUI Power
To Ground Bar
J10-Power Input (24 VDC)

F103
F101
F100
F102
J9-Current Transformer
(0-5 amp)
CPU Power
All BCM Fuses are 5x20mm, GMA 1.5 amp, Fast Blow BCM
Digital Input Power

Analog Input/Output Power
J4 & J5-Digital Input Power 24 VDC (pin 1)
J3-Analog Output Power 24 VDC (pins 2 & 8) J1-Analog Input Power 24 VDC (pin 26)
LEGEND: Trace
Wire

Power Supply:
• Input power: 85-132 VAC, or 180-264 VAC (auto-

selecting input), 2.5A RMS max, 47-63 Hz.
• Output power: 24 VDC, 4.3 A maximum at 50 °C.
Troubleshooting:
verifying the probable cause.
Power Supply: Probable Cause CPS Troubleshooting Procedure
1 2 3 4 5 6 7 8
All analog inputs are zero or negative on No AC power 9
System Page
No analog input power 9
No DC power 9
OUI displays: No CPU power 9
“INGERSOLL-RAND Centrifugal
Compressor Division”
BCM problems Refer to CMCS #3
OUI is black No AC power 9
No DC power 9
No OUI power 9
Event Log indicates all digital alarms and No AC power 9
trips active
No DC power 9
No digital input power 9
All digital outputs not working No AC power 9
No DC power 9
No digital output power 9
All analog outputs not working No AC power 9
No DC power 9
No analog output power 9

No AC power verified from the electrical schematic.
CPS #1 No analog input power

1) Ensure control power is off. CPS #5
2) Install a multimeter set for VAC between pins 1 1) Ensure control power is off.
and 3 at connector J1 on the power supply. 2) Install a multimeter set for VDC between pin 26
3) Restore control power, the meter should read at connector J1 on the BCM and the
120 VAC or 220 VAC depending upon the rated 3) ground bar.
supply power. The rated supply power can be 4) Restore control power, the meter should read
verified from the electrical schematic. approximately 24 VDC. If approximately 24 VDC
is not present, check F102 on the BCM, if F102 is
good, check for DC power.
No DC power
CPS #2
1) Ensure control power is off.
No analog output power
2) Install a multimeter set for VDC between pins 11- CPS #6
14 and 7-10 at connector J2 on the 1) Ensure control power is off.
3) power supply. 2) Install a multimeter set for VDC between pin 2 at
4) Restore control power, the meter should read connector J3 on the BCM and the ground bar.
approximately 24 VDC. If approximately 24 VDC 3) Restore control power, the meter should read
is not present, check F1 on the power supply, if approximately 24 VDC. If approximately 24 VDC
fuse is good, the power supply may be faulty. is not present, check F102 on the BCM, if F102 is
5) Ensure control power is off. good, check for DC power.
6) Install a multimeter set for VDC between pins 1
and 2 at connector J10 on the BCM.
No OUI power
7) Restore control power, the meter should read
approximately 24 VDC. If approximately 24 VDC CPS #7
is not present, check the wiring between the 1) Ensure control power is off.
power supply and the BCM.
2) Install a multimeter set for VDC between pins 1
and 2 at connector J1 on the OUI.
3) Restore control power, the meter should read
No digital input power approximately 24 VDC. If approximately
CPS #3 4) 24 VDC is not present, check F101 on the BCM,
1) Ensure control power is off. if F101 is good, check for DC power.
2) Install a multimeter set for VDC between pin 1 at
connector J4 on the BCM and the ground bar. No CPU power
3) Restore control power, the meter should read CPS #8
approximately 24 VDC. If approximately 24 VDC
1) Ensure control power is off.
is not present, check F103 on the BCM, if F103 is
good, check for DC power. 2) Verify approximately 24 VDC is present at J10.
3) Check F100, if F100 is blown the BCM must be
replaced, not the fuse.
No digital output power 4) If F100 is not blown, and the BCM is not
CPS #4 functioning, the BCM must be replaced.
1] Ensure control power is off.
2] Install a multimeter set for VAC between pin 1 at
connector J12 on the BCM and the ground bar.
3] Restore control power, the meter should read
120 VAC or 220 VAC depending upon the rated
supply power. The rated supply power can be

CMC Controls Controller Problems (CMCS)
Controller Problems
Description:
The CMC System is generally comprised of a Base

Control Module (BCM), Operator User Interface
(OUI), and Power Supply (PS). There are few user
serviceable components within the system, however,
a brief understanding of the system will help in
overall troubleshooting. All components require 24
VDC and rely on hardware and software to perform
correctly, if the problem cannot be isolated to a
power problem it is most likely a hardware or
software problem, which will require Ingersoll-Rand
support to correct.
Component Specification:
• VDC power required

• Software required
Troubleshooting:

Procedures are detailed on the following page.
Typical Problem: Probable Cause CMCS Troubleshooting

Procedure
1 2 3 4 5
BCM fault suspected No power 9
OUI is dim Wrong contrast selected 9
Backlight failing 9
OUI displays: Cable disconnected 9
“INGERSOLL-RAND Centrifugal
Compressor Division”
OUI is black No power 9
OUI displays “Status XXH” Many Refer to Status Codes under
Where XX is a specific number System Information Section.
MODBUS communications problem No power 9
Many Refer to the UCM Section.

Issue: 01/Australia, February 2003 Page 29
CMC Controls Controller Problems (CMCS)
CMC Troubleshooting Procedures
CMCS #1 (OUI is dim)

1. Depress the contrast key to step to the desired
brightness.
2. Replace the OUI backlight as described in the
section titled “Backlight Replacement Proce-
dure”. If the backlight does not fix the problem
the OUI may be faulty.
CMCS #2 (OUI is black)

1. Check for OUI power as described in the section
titled “The Control Power System”. If approxi-
mately 24 VDC is present the OUI may be faulty.
CMCS #3 (OUI displays “INGERSOLL-RAND

Centrifugal Compressor Division”)
1. Check the cabling between OUI J1 and BCM J6.
2. The BCM may require programming.
3. Check the BCM CPU power.
4. The BCM may be faulty.
CMCS #4 (BCM is not controlling)

1. Check the CPU power as described in the sec-
tion titled “The Control Power System”.
CMCS #5 (All UCM LED’s are not lit)
1. Check for approximately 24 VDC at pins 1 and 2

at J3 on the UCM.
2. If power is present at J3 the UCM may be faulty.

Issue: 01/Australia, February 2003 Page 30
Symptoms, Possible Causes & Corrective Action
Troubleshooting compressed from leaking out of the compressor

Continued efficient running of the Centac depends before it exits into the process system.
on the smooth operation of a number of integrated
systems. The control system provides all the necessary
components to control the discharge pressure or the
Accurate troubleshooting of compressor faults flow of air through the compressor. Included in the
requires a carefully thought out process of control system are alarm and warning functions.
sequential elimination of properly functioning These functions provide audible or visual indications
systems. This process of elimination efficiently and automatic compressor unloading or shutdown
identifies the system that is not operating correctly. when the designated values of the operational
parameters are exceeded. The control system also
Once the faulty system is identified, a new process provides readout information pertaining to various
of elimination is directed at that system. other compressor operating parameters.
Components within the faulty system that are
functioning properly are sequentially tested until the There are many sub-systems within the control
faulty one or more components are identified. The system. The vibration information and alarm system
faulty components are then replaced or repaired. is one such sub-system. The pressure control
The intent of the repairs is to restore the compressor system includes the inlet and bypass valves that are
to normal operation. in yet another control sub-system. Parameter
monitoring is other sub-system. The system and
Being familiar with the interrelated system concept sub-system list is lengthy.
of machine operation will prove to be of great value
when the time comes to perform troubleshooting on Maintainers should become familiar with the
the compressor. integrated systems of the Centac. When faults occur,
use of the system and component elimination
For the skilled technician, the system and process rather than the hunt and peck method of
component process of elimination utilized in fault finding a problem will get the machine back on line
finding is a skill that is effortlessly applied. The quicker and at less cost.
failure to apply or the absence of this skill in fault
finding is loosely referred to as the “hunt and peck
method” of troubleshooting.
Hunt and peck troubleshooting is being employed

when component after component is replaced until
finally the faulty component is replaced. The
problem is solved by luck rather than process. Much
time, effort, and maintenance funds are wasted
when the hunt and peck method of troubleshooting
is employed.
Taking the time to formulate a plan, a process, for

determining the source of a fault, pays dividends,
such as reduced down time, parts usage, and
efficient utilization of the workforce.
One of the systems that is integral in the Centac is

the lubricating oil system. This system provides the
means whereby the various pinions and other shafts
can rotate in their journals without overheating and
seizing.
The oil sealing system provides the means whereby

the air compressed in the machine is maintained oil
free. The various oil sealing components prevent
bearing and gear lubricant from leaking out of the
machine. The air sealing system components
prevent the air that is in process of being

Possible Cause Corrective Action
Fail to start
Failure to clear shutdown or interlock devices. Correct shutdown or interlock condition that is
indicated by panel light.
No primary power to starter. Check voltage to starter. Check fuses.
No control panel power to compressor control Check voltage to panel/starter.
panel or starter. Check control transformer.
Loose or corroded connection or defective power Check connections. Clean, tighten and replace as
cables. necessary.
Defective motor starter or starting circuit. Troubleshoot starter per manufacturer's
recommendation.
Ineffective lube Pump

Improper adjustment of lube pump relief valve. Adjust relief valve for correct pressure.
Pump not running. Troubleshoot pump starter. Check for proper voltage.
Defective motor. Repair or replace motor.
Defective pump. Repair or replace pump.
No seal air. (Seal air interlock is optional feature.) Establish seal air.
High Oil Temperature

Low or no flow to oil cooler. Establish correct water flow.
Higher water temperature than realized.water Take necessary steps to lower the water supply
temperature.
Improper temperature device setting. Calibrate instrument.
Dirty or plugged oil cooler on water side. Clean cooler tubes. Provide water strainers as
necessary.
Low Oil Pressure

Improper adjustment of system pressure relief Adjust system pressure relief valve for correct oil
valve. pressure.
Leaking or pinched oil line. Repair or replace oil line.
Dirty oil filter. Replace with clean filter.
Defective main oil pump. Repair or replace main oil pump.
High Air Temperature

Low or no water flow to air cooler. Establish correct water flow.
Higher water temperature than realized. Take necessary steps to lower the water supply
temperature.
Improper temperature device setting. Calibrate device.
Dirty or plugged air cooler on water side. Clean water passages in cooler. Provide water
strainers as necessary. Contact Ingersoll-Rand
service representative.

Low Seal Air Pressure

Low instrument air pressure. See “Low Instrument Air Pressure” below.
Improper adjustment of seal air pressure Adjust regulator to obtain correct seal air pressure.
regulator.
Excessive bleed off valve adjustment. (If Reduce seal air bleed off.
supplied).
Worn seals. Replace seals. Consult Ingersoll-Rand service
representative.
Low Instrument or Valve Operating Air Pressure

No supply pressure, pinched or leaking air lines. Establish instrument air supply pressure. Repair or
replace air lines.
Improper adjustment of air regulator. Adjust regulator to obtain correct instrument air
pressure.
High Vibration
Low oil temperature. Allow warm-up period for oil.
Driver to compressor misalignment. Check and correct alignment (dowel motor feet after
alignment).
Worn coupling or spacer. Lubricate. Replace coupling and/or spacer.
Rotor assembly unbalance due to foreign matter Contact Ingersoll-Rand service representative.
build up. Cleaning and balance check required.
Rotor assembly unbalance due to damaged aero Contact Ingersoll-Rand service representative. Repair
parts. or replacement and balance check required.
Induced vibration from driver. Balance motor rotor..
Fail to Load
Mode selector switch in UNLOAD position. Turn selector switch to Modulate or Auto-Dual
operating mode.
Low set point on pressure controller. Adjust controller to desired operating pressure.
Bypass valve not closed or inlet valve not open. Correct improper operation of the inlet or bypass
valve.
Low System Air

Compressor not loaded. See “Fail to Load” above.
Dirty inlet filter. Change filter elements.
Low surge. See "Continual Surging" below.

Greater demand than realized. Repair ALL air leaks. Turn off unnecessary demands.

Continual Surge (Pumping)

Discharge block valve closed. Open block valve.
Improper calibration of surge sensor. Calibrate instrument. Insure surge sensor switch is
not stuck.
Dirty inlet filter. Change filter elements.
Improper adjustment of throttle limit (LLR, CLL, Adjust throttle limit.

TL).
High inter stage air temperature. Establish correct water flow to air coolers.
Higher water temperature than realized. Reduce the cooling water temperature.
Worn or fouled aerodynamics parts. Contact Ingersoll-Rand service representative.
Excessive Power Consumption

Lower ambient temperature than realized. Reduce compressor load. Consult Ingersoll-Rand
service representative.
Low primary voltage. Consult power company. Check power source.
Reduction in motor efficiency. Consult motor manufacturer.
Excessive load. Reduce load.
High Drive Motor Amperage

Low primary voltage. Restore voltage to specification.
High load. Reduce load.

Short test

• CMC tuning procedure
• OUI (Operator User Interface)
• Setting Maxload
• Setting Minload
• Setting Surge sensitivity
Pre-work test Centac Certification course.
1 In CMC electronic control, what is the driver motor overload protection called?
a)
2. In CMC electronic control, what is the minimum throttle point control function
called?
a)
3. What should the nominal vibration probe gap setting be?

a)
4. The probe gap corresponds to (a) VCD and normal gap should be set (b)
VCD
a) VCD
b) VCD
5. How do we check the transmitter loss of power?

a)
6. How do we check the vibration transmitter malfunction?

a)

Short test
7. How do we check, (a) the probe resistance and (b) what should the reading
be?
a)
b)
8. If the platinum show 98°F, what should the Ohm be?

a)
9. How do we check if the BMC fail?

a)
10. How do we check if the RTD transmitter is faulty?
11. How do we check if the RTD is faulty?

a)
12. BMC bus fuse F100 protects what component?

a) The OUI
b) The CPU card
c) The Digital inputs
d) The Analog Inputs

a) The OUI
b) The CPU card
c) The Digital Inputs
d) The Analog Inputs

Short test

a) The OUI
b) The CPU
d) The Analogue Inputs
15. BMC bus fuse protects what component?

a) The OUI
b) The CPU
d) The Analogue Inputs
16. A negative value shown for all the Analogue inputs on the OUI display is an
indication of what?
a) Fuse F102 has blown
b) The line filter has failed
c) The control power transformer has failed
d) A loss of the 110V AC to the power supply
17. If the E-Stop pressed indication is checked on the OUI display and does not
clear even with the E-Stop pulled out, this could be an indication of what?
b) Fuse F103 has blown
c) The line filter has failed
d) A lossof the 110 VAC to the power supply
18. If the OUI display goes completely dark and blank this could be an indication
of what?
b) Fuse F101 has blown
c) F102 has blown

Short test
19. Which Fuse is used for the BMC

a) 0.5 amps
b) 1.0amps
c) 1.5 amps
d) 2.0 amps
20. What supplied the power to the OUI?

a) Fuse F100
b) Fuse F103
c) Control PowerTransformer
d) 102 VAC to 24 VDC power supply

Basic Centac Manual
Maintenance
Section 9
Scheduled Preventative Maintenance ........................1—3
Maintenance Procedures............................................4—10
Short Test ...................................................................11

Maintenance Section 9
Scheduled Preventive Maintenance

Daily and Each Start-Up
• Procedure for setting Volume tip or “Z”
clearance. 1 Check and record instrument air pressure.
• Procedure for setting Pressure tip or “Y” 2 Check the compressor reservoir oil level.
clearance
3 Check and record the oil temperature to the
• Procedure for setting Inactive or Reverse compressor.
thrust clearance.
• Maintenance Schedules 4 Check and record the compressor oil supply
pressure.
5 Check the vibration level on each stage of the
compressor
The Centac compressor does not require constant 6 Check and record all interstage pressures (if
attendance. However, a few items should be available).
checked periodically.
7 Check and record all interstage temperatures.
Scheduled preventive maintenance and inspection is 8 Check and record the inlet air temperature (if
essential for continued optimum performance and available).
long service life of the compressor. The following are
general requirements and schedules for inspection 9 Inspect for tubing/fitting leakage.
and preventive maintenance. Since unusual service 10 Check and record the air cooler water temperature,
conditions and environment affect equipment both to and from the coolers (if available).
reliability, these items and schedules should be
adjusted in time and content as necessary to suit 11 Check and blow down the condensate traps.
your specific requirements.
12 Check and record the inlet air filter differential
pressure.
Example Yearly Planner for
Scheduled Preventive Maintenance 13 Check to make sure the air coolers are
continuously venting. Vent valves are located on top
January February March April
S M T W T F S S M T W T F S S M T W T F S S M T W T F S of the casing.
Daily Maintenance
Daily Daily Daily 14 Drain the condensate from the inlet air line drip leg.
Maintenance Maintenance Quarterly Maintenance
Maintenance Do not open the valve with the compressor
operating.
May June July August
S M T W T F S S M T W T F S S M T W T F S S M T W T F S
Daily Maintenance
15 Drain the condensate from the discharge header
Daily Daily Daily drip leg.
Maintenance Semi-Annual Maintenance Maintenance
Maintenance 16 Drain the condensate from the bypass air line drip
September October November December leg.
S M T W T F S S M T W T F S S M T W T F S S M T W T F S
Daily Maintenance Daily Maintenance
Daily Daily 17 Drain the drip legs on any other horizontal run of air
Quarterly Maintenance Maintenance Annual piping.
Maintenance Maintenance
18 Check for oil leaks. Correct as necessary.
19 Inspect for gasket / o-ring leakage.
20 Check for water leaks. Correct as necessary.
21 Open the control air line drip leg valve to remove

any moisture that may have collected.
22 Check the instrument air line filter. Drain any

moisture, which may have collected.
23 Check and record the oil filter differential pressure,

if available. Replace the filter element as necessary.

Quarterly Maintenance Semiannual Maintenance

1 Inspect instrument air filter. 1 Follow the quarterly schedule.
• Drain and clean the filter. 2 Lubricate the main driver coupling. Dry-type coupling
• Replace the element. components must be inspected.
2 Drain control air drip leg. 3 Change oil filter.
3 Inspect condensate traps. 4 Leak test the air coolers.
• Remove and clean 5 Change the driver bearing grease.

• Replace parts as necessary.
6 Obtain an oil sample and have it analyzed (see
• Replace trap if necessary. Technical Flyer in Appendix).
4 Grease motor bearings. 7 Check the control system per the procedure found in
the Control section of the Operation Manual.
• Use correct type and amount of grease.
8 Check the inlet and bypass valve calibration.
• Use hand-pump grease gun only.
• Bearings should be greased with the motor
5 Visually inspect the inlet air filter.
• Clean element. Annual Maintenance

• Replace element as necessary.
• Inspect seams of the filter for cracks for 1 Inspect the main driver per the manufacturer's
potential bypassing. Seal seams as needed. instructions found in the Operation Manual.
2 Visually inspect the coupling. Lubricate as required.
6 Change oil mist arrestor element.
• Add oil to U-tube. 3 Manually rotate bullgear to feel for roughness on

models with bullgear anti-friction bearings.
• Clean element housing.
• Inspect old element for over-crushing. Add 4 Inspect and clean the oil reservoir suction screens.
restricting nuts to prevent over-crushing.
• Eliminate lock washer under wing nut, if 5 Visually inspect the oil cooler tubes. Clean the water
installed. side of the oil cooler if necessary.
• Replace seal washer under wing nut. 6 Visually inspect the zinc anodes (pencils) in the oil
• Check to insure the element cover is making cooler. Replace if necessary.
good contact with the element. The cover
7 Visually inspect the inlet throttle valve.
should fit squarely on the housing.
7 Inspect the Mist Eliminator element and replace as 8 Visually inspect the bypass valve
needed. Mist Eliminator elements are a long life
item and should not require routine replacement. 9 Visually inspect the discharge check valve.
8 Inspect control panel. 10 Change the oil once a year or after 8,000 hours of
use, unless Techtrol Gold III is used. When using
• Watch for: loose wiring, wrong line filter, Techtrol Gold III, the lubricant must be changed every
damaged line filter, and adequate arc three years / or after every 24,000 hours of use.
suppressors.
• Clean panel fan filters and panel.
• Disconnect and tie back all unused wires from !
terminal strips.
Caution
• Check the vibration transmitter wires to make Servicing of the internal parts is not recommended
sure they run directly to the microcontroller
terminal strips.
without the presence of an Ingersoll-Rand service
supervisor. For technical assistance, please call
your local Ingersoll-Rand representative. WARNING

The following procedures are added to supplement
! the information presented in the Operation Section
Warning under the heading Initial Start Preparation.
Develop and use a “Red Tag” procedure or similar
system whereby maintenance personnel can lock off Main Driver
the power switch during maintenance. Depending upon the customer's requirements,
different drivers are used with the Centac
compressor. Consult the driver manufacturer's
Replacement coolers, rotor assemblies, bearings, literature provided in this manual to insure proper
and seals are available in a variety of options: lubrication and maintenance procedures.
• Exchange for factory trade-ins. Control Panel

• Return the part for refurbishing. The control panel checkout procedure is designed to
• Return damaged parts for scrap and obtain credit verify that a control panel is functioning properly. The
toward new parts. checkout can be used for initial testing or in
• Factory warranty program on all exchange parts. conjunction with routine maintenance schedules.
Refer to the control drawings and checkout
• Rapid cooler cleaning and hydrotesting.
procedure included with the Control Panel
Instructions in this manual to insure proper
adjustments and calibrations.
Intake Filter
All filtration systems have a maximum recommended
pressure drop at which the filter element should be
cleaned or replaced. Because of the many types of
atmospheric conditions that exist it is difficult to
accurately determine the life of a given filter element.
It is therefore advisable and highly recommended
that a weekly pressure drop measurement be
recorded for both the primary and final stage filter
elements to determine the useful element life.
Filter maintenance is a necessary and important part

of the entire air system. A properly maintained inlet
air filter will result in optimum air compressor
operation. An increase in filter differential pressure is
an indication that the inlet air filter is performing as
intended.
"Panel" Type Inlet Filters

The following maximum pressure differential levels
should be followed:
• Primary Stage Element(s). Clean or replace at 4"
W.C. differential pressure.
• Final Stage Element(s). Replace at 4" W.C.
differential pressure.
• Total differential pressure across filter of 8" W.C.:
Clean or replace primary stage element(s) and
replace final stage element(s).
When indicated by the above differential pressure

data, the filter elements should be removed for either
cleaning or replacement. It is recommended that the
filter be serviced when the compressor is not in
operation.

Maintenance Procedures
Primary Stage Element(s) Cleaning Guidelines: Inlet Valve
Periodically stroke the inlet valve to aid in optimum
1 Unlatch the weatherhood and swing it up. performance of the compressor. See the
2 Grasp the removal strap located on the face of Manufacturer’s Installation Bulletin located in the
the panel filter and pull straight forward. Vendor Literature Section of this manual for
guidelines on stroking the inlet valve. Observe for
3 Install cleaned or new prefilter, making sure the freedom of movement of the inlet valve during the
removal strap is facing you and is in a horizontal stroking procedure.
position.
4 Swing the weatherhood down and secure the Bypass Valve
latches into the slots on the side of the filter Periodically stroke the bypass valve to aid in
housing. optimum performance of the compressor. See the
Manufacturer’s Installation Bulletin located in the
5 Clean first by using compressed air. Blow off Vendor Literature Section of this manual for
dust by directing the compressed air from back guidelines on stroking the bypass valve. In addition
to front. Next, water wash by agitating the panel to stroking, the bypass valve should be removed
filter in hot water (approx. 150°F) and mild from the air piping system annually to inspect the
cleaning agent solution. seals for damage. Replace damaged seals as
6 Rinse with clean water and air dry for at least required and reinstall valve.
12 hours. The panel filter should be completely
dry before reinstallation to prevent premature Checking Vibration
dirt loading. Periodically monitor shaft vibration on both sides of
the coupling with a vibration analyzer. In normal
operation do not run the unit when vibration levels,
as measured on the shaft, exceed two (2) mils on
! Note three thousand to thirty-six hundred (3000-3600)
RPM drivers. If vibration is measured using a non-
Inspect both front and rear gaskets, making
contacting probe, add one half (1/2) mil to the above
sure they are not damaged. Do not touch the panel
levels. If vibration levels exceed the above values
filter media portion of the panel element. Handle
shut the unit down and determine the cause of
only by grasping the metal frame.
vibration.
The panel filter corner angles indicate the bottom,
and pull rings indicate the front. Impeller to diffuser clearance
Impeller to diffuser clearances are factory set on
7 Slide the panel filter into housing and latch all new compressors, but the clearance should be
latches to the panel filter sides. All latches must checked prior to initial start-up after an overhaul or
be fastened to properly seal the final stage any start-up after a rotor assembly or bearing has
panel filter to the housing. been removed from the unit. This procedure should
be done under the supervision of an Ingersoll-Rand
service supervisor.
Final Stage Panel:
1 Remove the primary panel filter as noted

above.
2 Unlatch the latches on the side of the filter
housing.
3 Grasp the pull devices located on the front
sides of the panel filter and pull straight
forward.
4 Install a new final stage panel filter.
Final stage panels are not cleanable and must be

replaced when dirty. Replace at a 4" W.C.
differential pressure.

Procedure for setting impeller clearance for
units which require shims.
1 Remove the bearing cover and bearing locking

bolts.
2 Tighten the jacking screws until the bearing is
free to move, then loosen the jacking screws.
3 Push the bearing in until it seats against the gear
case.
4 Push the rotor assembly in by the thrust collar
until resistance is felt.
!
Note
Never attempt to set the clearances without an
impeller clearance setting tool. See the Centac
Clearance Setting Tool diagram on the next
page.
5 Install the clearance setting tool against the
thrust bolt using one of the bearing cover bolt
holes to support the other end.
6 Install (3) dial indicators on a post installed in
one of the other thrust cover bolt holes.
7 Set (1) dial indicator to contact the top of the
clearance-setting tool above the thrust bolt. The
purpose of this is to show the movement of the
rotor.
8 Set (1) dial indicator to contact the thrust bearing
flange. The purpose of this indicator is to indicate
the movement of the bearing.
9 Zero both indicators.
10. Begin tightening the jacking bolts in

sequence. Each turn of the jacking bolt should
cause no more than .001 inch (0.03mm) of
bearing movement. Gently tap bearing flange
near jacking bolt using soft hammer.
10 Note that the bearing moves before the rotor
assembly begins to move.
11 Continue to tighten the jacking bolts until the
specified pressure tip clearance is indicated on
the rotor assembly dial indicator.
12 The reading on the bearing flange dial indicator is
the thickness required for the thrust bearing
shims.
13 Use specified shims and grind to the correct size
-- should be less than .100 inch (.393mm).
14 Install the shims under the 3 locking bolts, back
off the jacking bolt (1) full turn and tighten locking
bolts.
15 Install the bearing cover.
Back of Impeller in Contact with Casing
To back
maximum
distance
away from
the
diffuser.
Total Axial Float of Pinion
Total Axial Float of Pinion
PUSH
Push
forward
to
Diffuser
Volume tip or “Z” clearance

Measure each blade tip

Inactive or reverse
thrust clearance
Shim
Inactive thrust adjusting

screw and locking nut
Pressure tip or “Y” clearance
Shim
Thickness
Jacking Screw

Centac universal clearance setting tool
Material: Common 1/4” bar stock
Universal clearance setting tool -

Method of use
Use any combination of threaded and unthreaded
holes in the clearance setting bracket to apply
bracket spring pressure on the thrust collar. This
action keeps the thrust collar in positive contact with
the thrust bearing as the thrust adjustment screws
are moved in to establish and set the impeller to
diffuser running clearance.
Thrust bearing.

Discharge Check Valve Single Filter

The discharge check valve must be removed from
the piping system for inspection. When inspecting 1 Provide suitable means of collecting and
the check valve, look for: disposing of used oil
1 Rust 2 Loosen center post to disassemble the filter.

2 Broken Springs 3 Discard the element. Clean remaining parts.
3 Damaged Seals 4 Reassemble the housing center post, conical
spring and one metal backup washer.
4 Freedom of Movement
Repair or replace as necessary and reinstall !

discharge check valve. Note
Conical spring is to be installed with large end
When check valve is mounted in a horizontal run of against the housing.
pipe, the valve should be oriented so that the stem is
vertical. 5 Lubricate the two rubber seals received with
new element.
Oil Suction Screen 6 Install one seal over the center post and
The oil suction screen is an open type screen against the backup washer.
located within the reservoir on the inlet of the oil
pump. Each time oil reservoir is drained the suction 7 Place new element over the center post and
screen should be removed and cleaned. Rinse engage the rubber seal into the recess in the
screen in solvent to clean. element end cap.
8 Install second seal into the recess at the top
Oil Filter end of the element.
A single line type oil filter is furnished as standard
equipment on the Centac compressor. Some Centac 9 Lubricate seal located on filter head.
compressors are furnished, as optional equipment, 10 Position housing assembly into place on filter
with a dual line type filter with a transfer valve. Both head and tighten center post.
single and dual filters have throwaway replaceable
cartridge elements. The following will serve as
guidelines when changing filter elements.
! Caution
Filter elements should be replaced when the Keep housing from rotating while tightening
pressure drop exceeds 8 PSIG from when the filter center post to 20 ft. Lbs. Torque.
was new.
! Warning
Lube system pressure may reach 50 PSIG
and temperatures of 160°F or more. Do not
penetrate lube system while machinery is operating.
! Warning
Hot oil can cause serious injury to personnel.
Precaution must be taken to prevent contact with hot
oil.

Oil Cooler Condensate Trap

Inspection: The condensate trap is a float type liquid drainer and
requires periodic inspection and cleaning.
1 Remove bonnets from oil cooler and inspect
zinc anode for erosion or oxide deposits.
Scrape to brighten surface and replace if more
than half is corroded away. !
Warning
2 Carefully examine tubes for scale and clean Shut off compressor before performing any
if necessary. After cleaning, examine for maintenance on the condensate system.
erosion or corrosion.
3 After maintenance inspection or cleaning, During normal operation the trap should have
both shell and tube side should be carefully
• an intermittent discharge,
vented and full of liquid.
• a dribble or semi-continuous discharge, or
• a constant discharge flow of liquid.
Cleaning:
The shell side of the oil cooler generally will not
Any of these conditions are indications of proper trap
need to be cleaned. Flushing a high velocity stream
operation.
of water through them may clean the tube side of the
cooler. For more stubborn deposits, wire brushes or
No discharge indicates possible trouble.
rods can be used.
• Open condensate bypass valve.
Mist Arrestor
A reservoir mist arrestor is furnished as standard • A small amount of condensate discharged
equipment on the Centac compressor. The element indicates a light condensate load to the trap.
on the Mist Arrestor must be replaced; it is non-able • A large amount of condensate discharge
to be cleaned. indicates trap has failed and should be repaired
To replace element:
! Warning
1 Remove wing nut on top of breather.
Condensate bypass valves should be opened
2 Lift off top, exposing element. slowly as condensate may be discharged at pres-
sures exceeding 125 PSIG. Hearing protection
3 Remove element. Dispose of properly. must be worn when bypass valves are open.
4 Replace with new element.
5 Replace top of breather and wing nut. Continuous air discharge from the trap indicates it
has failed and should be repaired.
1 Remove the bolts holding the body together.

2 Carefully remove and clean the internal
parts.
3 Inspect orifice seats for any corrosion or
undesirable condition.
4 Inspect the leverage system for freedom of
movement.
To clean the trap:

Similar maintenance care should be given to other
optional styles of condensate removal
systems.

Short Test
1 When should the oil filter differential pressure be checked?
2 What are the steps to follow when changing the oil mist arrestor element?
3 What must you look for when inspecting the control panel?
4 Why should you record the pressure drop measurement on a weekly basis?
5 When should the oil suction screen be cleaned?
6 When should oil filter elements be replaced?


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Centac Training

Planning & Installation

Airend Overhaul - 1CV

CMC Controls and Troubleshooting

Proprietary Notices and Disclaimer

Introduction Section 6—Airend Overhaul for Models

Section 8—Trouble Shooting

Section 5—1CV Airend Overhaul

Basic Centac Training Manual

Basic Centac Training Manual

• A main driver that directly drives a bullgear that is

Discharge 1st Stage

Bullgear Shaft Seal Bullgear

Inlet 1st Stage

Basic Centac Training Manual

stage until the compressor

Ingersoll-Rand (Asia Pacific) Service Team

Issue: 01/Australia, March, 2003

Rotor Assemblies Intercoolers

Basic Centac Training Manual

Casing 5. The remainder of the lubricant passes through

The lubricant is drawn from the oil reservoir located

Basic Centac Training Manual

Centac I Original Centac baseplate mounted motor 1Pc. Cooler Cover

Code CMF HP Stages Comment

4C 9000-15000 1250-2500 3, 4, 5 stage 5th Stage is high pressure

Basic Centac Training Manual

Code CMF HP Stages Comment

2ASB 3000-4300 1100-1700 3 stage

2CII 3200-4500 800-1500 2, 3 stage & DF 3rd stage is high pressure

5CII 12500-30000 2000-5000 2-3 stage

Basic Centac Training Manual

CV Flange mounted motor, has cooler ”Barrels”

Code CMF HP Stages Comment

1CV 800-1400 200-350 2 stage

1ACV 1500-3000 350-700 2 stage

1BCV 1400-2200 350-500 2 stage

EPF 1300-2200 450-800 3 stage

2CV 2100-3500 350-800 2-3 stage

Basic Centac Training Manual

CH Single stage machines. Flange mounted motor, similar to CV

Code CMF HP Stages Comment

Single stage machines, foot mounted motor.

5CCH 1500-3000 125-700 Low, Medium and High Pressure

6CCH 3200-5500 300-600 Low, Medium and High Pressure

Code CMF PSI Comment

H Series 2000-75,000 12-27

R Series 5000-15,000 10-37

ST Series 1000-75,000 Steam Compressor

Basic Centac Training Manual

Basic Centac Training Manual

pressure-variable volume machine. Pressure PSIA

The compression process in a dynamic compressor ft/sec

The work input takes Temperature oF

Basic Centac Training Manual

Inlet pressure (psia) 14.4 12.4* 14.4 14.4

Total lbs/min. (W) 749 645 695 516

Characteristic Pressure versus Flow Plot

A centrifugal compressor cannot function over the

limits imposed by the losses.

The useful part of the actual pressure curve is

Figure 2. Ideal characteristic pressure vs flow plot

Basic Centac Training Manual

visualize the surge phenomenon. This graph in