AP CentacTraining Manual V2 PDF

Centac Training
Manual
Overview
Principles of Operation
Planning & Installation
Commissioning
Airend Overhaul - Models 1CV , C250/C350
CMC Controls
Maintenance
Troubleshooting
Copyright Notice
 2001 Ingersoll-Rand Company
Proprietary Notices and Disclaimer
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Copyright 2001 INGERSOLL-RAND COMPANY
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DISCLAIMERS
PROVIDED “AS IS”. THIS MANUAL AND THE CONTENTS THEREOF ARE PROVIDED “AS
IS” AND WITHOUT ANY IMPLIED WARRANTIES.
Introduction
Introduction & Index
Introduction Section 5—Planning & Installation

The Basic Centac Training Manual has been Receiving Handling & Storage.................... 1—5
designed to provide you with fundamental Installation Planning.................................... 6—9
knowledge about centrifugal air compressors. Its Air Piping ................................................ 10—18
purpose is to give you a grounding in the theory of Water System Piping .............................. 19—22
pressure, temperature and volume, as well as the Electrical Connection .............................. 23—24
construction and operation of Centac Compressors. Weights & Dimensions.................................... 25
Recommended Tools...................................... 26
The manual also prepares you for the hands-on Shaft Alignment ...................................... 27—34
practical training that you will receive on the Training Short Test ............................................... 35—36
Course. Shaft Alignment Software ....................... 37—42
Section 6—Commissioning
Index Pre-Start Checklist...................................... 1—3
Initial Start Preparation ............................... 4—6
Section 1—Overview Natural Surge Testing................................. 7—8
Machine Description ................................... 1—6 Installation Checklist ......................................... 9
Centrifugal Compressor Product Line ....... 7—10 Short Test ....................................................... 10
Short Test .......................................................11 Start Up Registration Form ..................... 11—16
Warranty and Limitation of Liability......... 17—19
Section 2—Principles of Operation Short Test ....................................................... 20
Basic Principles of
Centrifugal Compressors .............. 1—3 Section 7—Airend Overhaul
Characteristic Pressure verses Flow Plot ... 4—5 Disassembly of Stage Components............ 1—4
Surge .......................................................... 6—7 Disassembly of Bull Gear from the casing.. 5—6
Choke and Stonewall ........................................8 Assembly of Bull Gear into the Casing ....... 7—9
The effect of air density.....................................9 Assembly of Stage Components ............ 10—14
Compressor Operating Methodology ...... 10—12 Impeller/Diffuser Clearance
Changing Air Inlet Setting Procedure ................. 15—18
Temperature & Pressure............ 13—14 Short Test ....................................................... 19
The Centac Performance Curve ............. 15—16
Inlet Valve Control of the Throttle Range........17 Section 8—Airend Ovehaul for Models
Stopping, Starting and Un-loading Control .....18 C250/C350
The effect of changes in Air Inlet Conditions ..19 Disassembly of Stage Components.......... 1—10
Inlet Guide Vane (IGV)....................................20 Disassemble the Bullgear ....................... 11—13
Basic Multi-Staging and Intercooling...............21 Re-assemble the Bullgear ...................... 14—17
Typical (Actual) Centac Performance Curve...22 Re-assemble the Stage Components..... 18—26
Bypass Valve Control......................................23 Setting Rotor Assembly Clearances ............... 27
Short Test .......................................................24 Impeller/Diffuser Clearance
Setting Procedure ................ 28—31
Section 3—Principles of Operation Installing the Coupling .................................... 32
Inlet & Bypass Valve Operation .................. 1—7
The Actuator................................................ 8—9 Section 9—CMC Technical Reference Manual
Butterfly Inlet & Bypass Valve ................. 10—11
Regulation & Coalescing Filter................ 12—14
Inlet and Bypass Valve Positioners......... 15—23 Section 10—Maintenance
Short Test........................................................24 Scheduled Preventative Maintenance ........ 1—4
Maintenance Procedures............................ 5—6
Section 3—Lubrication Setting Impeller Clearance ......................... 7—9
Overview ..................................................... 1—4 Maintenance Procedures........................ 10—11
Lubricant Conversion Procedures............... 5—7 Short Test ....................................................... 12
Material Safety Data Sheets ..................... 8—13
Short Test........................................................14 Section 11—Troubleshooting
Troubleshooting Guide ............................... 1—6
Common Conversions and Information .... 7—12
Basic Centac Training Manual

Ingersoll-Rand (Asia Pacific) Service Team
Issue: 01/Australia, July, 2003 Page 1
Basic Centac Manual
Overview
Section 1
Description of the Machine .........................................1—6
Centrifugal Compressor Product Line ........................7—10
Short Test ...................................................................11

Issue: 01/Australia, July, 2003
Overview Section 1
Description of the Machine

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

common to all stages.
• The compression stages consisting of an impeller,
mounted on its own shaft; and is enclosed within a
common cast iron casing.
• The rotors consisting of an integral pinion gear,
driven by a common bullgear, at its optimum
speed.
• An intercooler is mounted
within each stage casing.
External coolers are
optional and are often
used on Process
packages.
• A moisture separator and
a moisture removal 2ACII Process Package
with 3 external coolers
system, after each cooler,
to remove condensate.
• In some compressor configurations, an aftercooler
is also mounted on the compressor 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

Overview Section 1
Rotor Assemblies for Centac Models 1CV,

2CV and C250/C350
Each rotor assembly
consists of an efficient and
high quality stainless steel
impeller and a removable
thrust
collar
which is mounted on a helical
geared pinion shaft. The impeller is
secured to the shaft by a taper
attachment and the thrust collar is
secured to the shaft with a polygon
attachment. All rotating parts are
dynamically balanced as a
Reverse Thrust
complete assembly.
(inactive) Bearing.
Centac Model 1CV Rotor Assembly

Plain Bearing
Thrust Bearing
Centac Model C250/C350
Rotor Assembly
The plain and thrust bearings are hydrodynamic

fixed “tilted” pad bearings that ride on a thin film of
oil. This design prevents metal to metal contact and
low friction losses.
Centac Model 2CV Rotor Assembly

The tapered “key-per” design
secured the impeller is
Rotor Assembly secured to the pinion shaft.

Overview Section 1
Bearings Reverse Thrust Button.
Thrust loads are absorbed at Centac Models 2ACII, 3CII, 3ACII and 5CII
each pinion by a Use a Reverse Thrust Bearing at the pinion shaft
hydrodynamic thrust bearing.
The thrust bearings are
designed to maximize load
carrying capacities and to
minimize power loss.
Thrust Bearing
Journal bearings are “Babbitt”
lined, and are fixed tilted pad design, for maximum
stability and load capacity, with minimum power
loss.
The bullgear bearings, for the Centac compressor

model, incorporate a hydrodynamic design.
Centac Models 1CV & 1ACV

Use a Thrust button-type Bearing.
Seals
A single cartridge seal is mounted
in the plain bearing housing behind
each impeller. Each cartridge
consists of three, one piece, fully
floating non-contact carbon rings.
One ring is used as an air seal and
the other two rings are used as oil
seals. Clean instrument quality air
is supplied to the oil seals, as a buffer. This ensures
that the lube oil is not drawn past the seals, and that
air remains oil free.
Centac Models 1ACVII, 1ACV and 1BCV
Use an Oil Reverse Thrust Bearing without a
Diffusers
A diffuser is located between each
impeller and each cooler. The
diffusers are designed for
maximum efficiency, while limiting
physical size, thereby keeping the
compressor as compact as
possible.

Diffuser Deswirl Ring

Overview Section 1
Intercoolers The Casing
The Centac cartridge ‘donut- The gear case consists of a casing, and a casing
type’ cooler is housed inside the cover. The joint between the casing and the cover
compressor casing. Air passes is vertical. This bolted assembly is only opened for
through the tubes and water servicing the bullgear, or the gearcase bearings.
passes over the outside of the The cooler assemblies, which are mounted onto the
tubes. casing, can be easily removed for inspection, or for
dismantling the rotor assemblies, the diffusers, the
The heat exchange area is greatly increased by the bearings, or the seals.
internal fins and straight-through design of the tubes.
The Compressor Driver
The Cooler Design Features are: Centac Models 0CV, 1CV, 2CV, 5CH, 6CH, C250
• Lead-free cooler and C350 are furnished with a flange mounted
construction electric motor that is directly coupled to the
• Straight tube design compressor bullgear. The motor alignment is fixed
• Rolled tube to
by the flange design and no adjustment is required.
header bond
Centac Models 1CII, 2CII, 1ACII, 2ACII, 2CC, 3CII,
• Large diameter tubes
Internal Fins 5CII, OCI, 1C, 2C, 3C and 4C have foot mounted
are spaced equally motors that needs alignment.
to make them easy
to access when cleaning. Centac Models X-Flor and 2ACII are engine driven.
• TEMA constructed leak-free brass or stainless
steel headers Safe and efficient operation of the main driver is of
prime importance to the overall performance of the
compressor package. Operation of the main driver
Moisture Separators is critical and the manufacturer's literature is
The moisture separator
supplied, as part of the compressor package. The
is a stainless steel mesh
customer should refer to the driver instructions, for a
screen type of
detailed description of the driver supplied.
construction. The
thickness of the
separator is designed to
separate the maximum
amount of moisture at a
minimal pressure drop.
The separators are located at points in the
compressor where the air velocities are relatively
low, which permits effective moisture separation.
Vibration Probes
A non-contacting vibration probe is mounted in each
stage, next to the
plain bearing. The
vibration probe
measures the radial vibration of each rotor
assembly. The probe is connected to a vibration
transmitter. The first stage vibration protection is
standard on all the compressors.

Overview Section 1
Lubrication System Main Oil Pump

The lubrication system for the compressor is The Main Oil Pump is
completely self-contained. The lubrication system is an oversized positive
designed to provide clean lubricant to the displacement type
compressor bearings and the gears during pump driven by the
operation. main shaft.
Main
Oil is drawn from the sump portion of the gear A relief valve, located Oil
on the compressor Pump
casing by the oil pumps. Two oil pumps are
provide; Prelube and Main. casing cover and
directly connected to the oil galley, controls the
Prelube Oil Pump discharge pressure. The main oil pump is equipped
The Prelube Oil Pump serves to with an inlet strainer for protection against foreign
particles.
• prime the main oil pump
• lubricate the compressor bearings and gears In the event of a main drive or power failure, the
• fill the oil lines before the compressor starts main oil pump will continue to supply oil to the
bearing and gears during coast down.
The pump is driven by an electric three-phase motor
that starts when the The lubricant follows this path:
control panel is 1. The lubricant passes from the oil pump to the oil
Prelube Oil energized. The cooler, where the oil is cooled to between 105°
Pump pump runs until the and 115°F.
compressor is up 2. Lubricant from the cooler is mixed with hot
to speed and the lubricant in the thermostatic control valve.
main oil pump
3. The lubricant then flows to the oil filter. The oil
increases oil
pressure. filter supplied is a 10 micron treated paper
element type filter.
The prelube oil 4. Next, the lubricant passes from the oil filter to the
pump is not bullgear, the pinion bearings, and to the
intended to function as an auxiliary oil pump to reservoir. The relief valve, located after the
backup the main oil pump. cooler, allows the input pressure to the
compressor to be raised or lowered by adjusting
The Prelube Pump shuts down automatically when the valve setting.
the main oil pump starts supplying the required 5. The remainder of the lubricant passes through
system pressure. the compressor and drains into the reservoir.
When the unit trips on the shutdown cycle, the All the necessary instruments and safety devices are
prelube pump will start immediately and will included in the lubrication system to protect the
continue to run until the panel is de-energized. compressor. These include:
• A pressure transmitter that senses oil pressure
After the compressor shuts down, the prelube pump and the compressor low oil pressure.
should be allow to run 20 to 30 minutes to cool
• An RTD and temperature-transmitter that senses
down the compressor bearings.
abnormal oil temperature. An interlock is also
provided to prevent the unit from being started if
oil temperature is below the minimum.
• A wet element type lube oil reservoir heater that
ensures adequate oil temperature for compressor
start-up.
• The lube oil reservoir has provisions for a lube oil
drain with plug. The customer may install a valve
on the connection to facilitate changing lubricant.
• An oil temperature control device that
automatically regulates proper oil temperature to
the bearings by mixing hot and cold lubricant.

Overview Section 1
This model uses one Main Oil Pump driven by an
electric three-phase motor.
Main Oil Pump

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 A new version of the Centac baseplate mounted motor with barrel cooler.

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
with
external
coolers
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 with barrel coolers.

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

Overview Section 1
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 are the moving components in a Centac compressor?
2 What type of bearings are used in Centac Compressors?
3 How many different types of reverse thrust (inactive) bearings are used in
Centac compressors?
4 What type of moisture separator is used in Centac compressors?
5 What type of seal is used in the rotor assembly to protect against air and oil
leaks?
6 Which Centac model has external coolers?
7 Why do the tubes, in the intercooler, have internal fins?

Notes
Make your own notes about the training.
Centac Reference Manual

Issue: 01/Australia, August, 2002
Centac Training Manual
Principles of
Operation
Section 2
Basic Principles of Centrifugal Compressors .............1—3
Characteristic Pressure verses Flow Plot...................4—5
Surge ..........................................................................6—7
Choke and Stonewall..................................................8
The effect of air density ..............................................9
Compressor Operating Methodology..........................10—12
Changing Air Inlet Temperature & Pressure...............13—14
The Centac Performance Curve.................................15—16
Inlet Valve Control of the Throttle Range ...................17
Stopping, Starting and Un-loading Control .................18
The effect of changes in Air Inlet Conditions ..............19
Inlet Guide Vane (IGV) ...............................................20
Basic Multi-Staging and Intercooling ..........................21
Typical (Actual) Centac Performance Curve ..............22
Bypass Valve Control .................................................23
Short Test ...................................................................24

Principles of Operation Section 2
Basic Principles of Centrifugal Compressors
Centac machines are classified as dynamic, radial- The compression process, in a dynamic
flow centrifugal compressors. A Centac compressor, is quite different from that of the
compressor can also be classified as a constant reciprocating or rotary screw type compressors,
pressure-variable volume machine. because centrifugal forces work on the air it passes
through a rotating impeller.
4 The built-in intercooler

removes the heat of 5 Air then passes through a
compression from air. This stainless steel moisture
increases the efficiency of the separator, located in a low
compressor as the air velocity zone, to remove
is required for condensate. Bypass Valve
Intercooler Moisture
Separators
6
The steps 1-5
repeats in each
succeeding stage,
until the compressor
achieves the desired
operating pressure.
Air Filter
Inlet Valve
1 Atmospheric air is cleaned by an

Air Filter. The clean air then
enters the compressor through
the Inlet Valve that is mounted on
the compressor.
2 Air flows to the first stage where the

impeller increases pressure and velocity
(speed) of the air. The impeller develops
about two-thirds of the pressure.
Impeller
Rotor Assembly
3 The air flow loses velocity in the diffuser, which is
a static component that guides the air flow as it
leaves the impeller. Pressure increases as the
flow slows down
Diffuser

In this section, you will learn The terms used in describing the process of
• The basic operation of Centrifugal compressors compression in the centrifugal compressor come from
• The characteristic plot for “Pressure verses centrifugal pump theory.
Flow”
Air can be considered as a fluid, and the same
• The Actual Pressure plot thermodynamic principles and terms apply to
• Surge compressors as well as pumps. The term "head" is
• The effects of changing air inlet temperature one of these. In the centrifugal compressor, the
and pressure amount of work done to move one pound of air
through the compressor, is the "head”. The
• How the Inlet Valve controls throttle range
dimension of head is foot-pounds/per pound (ft-lbs/lb)
• How the Bypass Valve controls system low flow and is a measure of work.
demand
• Chock and Stonewall The process that air undergoes in the centrifugal
compressor (velocity slows, pressure increases) can
be re-stated as: If flow decreases, pressure increases.
The work input takes place as an increase in This is true because it is a volume-of-air that has
pressure and velocity (speed) of the air flow through velocity.
the impeller. The air flow subsequently loses
velocity in the diffuser section. The volume measurement used is cubic foot or cubic
meter of air. A volume that is moving past a point on a
Figure 1 shows the velocity, pressure and per-unit time basis has a rate. The term for rate is
temperature changes that occur in a theoretical "flow" and its dimension is cubic feet/per minute (ft 3 /
single stage centrifugal compressor. About two- min).
thirds of the pressure developed occurs in the
impeller with one-third produced in the diffuser. In a centrifugal compressor, (at constant speed and
constant inlet cfm) the amount of work required to
psia move one pound of air (head), remains constant
Pressure PSIA regardless of inlet conditions, as the following table
reveals. The Items marked (*) are changes from the
column labeled Design.
ft/sec
Item Design 1 2 3
Inlet pressure (psia) 14.4 12.4* 14.4 14.4

Temperature oF Inlet temperature (°F) 60 60 60
100*
Molecular weight 29 29 29 20*
Relative Humidity (%) 0 0 0 0
Density (lb/ft 3 ) 0.0749 0.0645 0.0695 0.0516
Total lbs/min. (W) 749 645 695 516
Discharge pressure (psia) 25.4 21.85 24.45 21.60
Velocity (ft/sec)
Discharge temperature °F) 180 180 220 142
SUCTION IMPELLER RADIAL DISCHARGE
DIFFUSER DIFFUSER Head (ft-lbs/lb) 17,490 17,490 17,490 17,490
Figure 1. BHP Horsepower 509 438 471 350
Pressure,
temperature and
velocity
relationship in a
centrifugal
compressor

• Notice how the horsepower changes when inlet
air pressure changes.
• Observe what happens when inlet air
temperature changes or
• See what happens when different density air
enters the machine.
• Take special note of how head remains constant
as various conditions change.
The head (work) remains constant, but the pressure
developed will vary in accordance with the density of
the inlet air. The air density varies with the
temperature, the humidity, the pressure, and the
weight of the different gases. The examples in the
table, use dry air (Humidity = 0%) for the purpose of
clarity.
The terms "head" and "pressure" are used

interchangeably when discussing a compressor.
This is common terminology, but be aware that there
is a marked difference between the two. While 25
psia is said to be the ‘head’ that the compressor is
producing, this is not the same ‘head’ as the ft-lbs/lb.
The terms used for the moving volume of air, that

enters a centrifugal compressor, are capacity, flow,
or through-put. These terms are interchangeable.

Pressure verses Flow Plot
Characteristic Pressure versus Flow Plot
The compression process diagram, for a theoretical
single stage compressor with a backward-leaning
bladed impeller, operating at constant speed, is
shown in Figure 2.
The ideal characteristic pressure

versus flow plot, for the theoretical
compressor, is a straight line that
100% slopes downward to the right.
Pre
ssu
re-F
low
Plo
t
PSIA
The pressure Actual Pressure Plot

decreases as flow In a real compressor, the ideal characteristic plot is
increases. affected by various energy losses. A pressure
versus flow curve for a real or actual compressor is
shown in Figure 3.
This plot is the ideal
0 Inlet (CFM) 100% curve minus the energy
losses. The red dotted
Figure 2. Ideal characteristic pressure vs flow plot 100% line shows energy losses.
Pre
s su r
e-F
l ow
PSIA
Plo
t
The Actual Pressure Plot is not usable

Actual Pressure Plot
over the entire range of zero-to-
maximum flow.
On the left of the Actual curve, the

pressure is shown to rise as flow
increases. This rise cannot occur
since; to remain stable, pressure must
decrease as the flow increases.
The compressor is not usable in the

part of the curve where pressure is
Losses
shown to increase as flow increases.
Inlet (CFM)
0 100%
Figure 3. Actual pressure plot

The useful part of the Actual
Pressure Plot is between the left
and right limit areas. The pressure On the right end of the Actual
in this middle area will decrease, Pressure Plot, the pressure decreases
as flow increases, in a predictable in nearly a straight line downward, as
and stable fashion. the flow increases. There will be large
changes in pressure, for very small
changes in flow, in this area .

Pressure verses Flow Plot
Figure 4 “Useful Operating Range, shows a
characteristic curve.
This area of the Actual This area of the Actual

Pressure Plot is Pressure Plot is
unusable because it is unusable because it is
where Surge occurs. where Choke occurs.
100%
The useful range curve

USEFUL (normally without the surge
OPERATING and choke labels) is
commonly seen when
RANGE
PSIA
centrifugal compressors are

discussed.
The term chock isused interchangeably with

SURGE CHOKE the term Stonewall.
Choke (stonewall) is defined as the point at

which the velocity of the flow reaches
MACH1. Choke is the physical limitation on
a centrifugal compressor. Operation near
this point is very inefficient.
0 FLOW 100%
Figure 4. Useful Operating Range

The point of demarcation
between the useful range
and choke is called the
"stonewall”.
Surge happens when the flow through a

centrifugal compressor reduces and pressure is
allowed to rise to the point where the
compressor becomes unstable. At surge, a
reversal of the flow commences.
Surge can easily occur if all the system users

closed off their compressed air supply at almost
the same time. Flow is stopped and before the
control valve can react, pressure rises to the
surge point. Surge is the maximum pressure
point on the centrifugal compressor’s
characteristic curve.

Surge
Surge
Surge is a momentary reversal of flow in a
compressor. Surge occurs at the peak pressure of
the characteristic curve and it exists because of the
way losses affect ideal compression. When the
compressor is in surge it is unstable and cannot
perform a useful function.
Figure 5 shows a graphic model of the surge

phenomenon. This graph, in reality, has a number of
imperfections.
9 When pressure
reaches point P, the
surge process repeats.
4 The operating point jumps to
point J with reverse flow on
the left. The reversal of flow is 3 Surge occurs at
point P, the
accompanied by a noise that may
natural surge point.
sound like "whomp”.
8 Pressure
starts to
CYCLIC SURGE MODEL (LARGE VOLUME
increase again
along line Q - P.
J P 2 Pressure rises
toward point P, as
5 The flow the flow decreases.
reversal
causes pressure
to decrease along K Q
line J - K.
1 Assume that only a
discharge valve
PSIA
controls flow for a

compressor, and that
flow is at point Q.
6 Forward flow is When the discharge

re-established as - FLOW O + FLOW
valve is closed, the
flow crosses the Figure 5. Model of surge flow reversal compressor discharge
pressure axis. pressure increases.
7 The flow at point Q is
larger than the flow that
the discharge valve can pass.

Surge
The reality of Surge is that, at the natural surge A reduced surge point, on an operational
point: compressor, is quite often the result of material
• flow reverses
build-up on the diffuser and impeller,which alters the
shape of the impeller or diffuser.
• a noise is heard
• pressure drops Changing the physical shape, changes the shape of
• a rapid increase of positive flow occurs the characteristic curve. The new curve describes a
new lower surge point. This new surge pressure
• flow again decreases
may be near, at, or below normal set pressure and if
• pressure again rises it is, surge occurs when normal operation is
• surge is reached and attempted.
• the process repeats Surge happens when
The terms "surge" and "pumping" are used • the bypass valve malfunctions in a way that limits
interchangeably. Pumping is a very descriptive flow.
word for the appearance of surge. As soon as the • system demand decreases faster than the inlet
surge reversal occurs, the compressor can re- valve can react to the decrease.
establish positive flow. The re-occurrence of surge
• The inlet valve is improperly set up or adjusted,
happens quickly and repeats until actions are taken
to either unload or to stabilize the flow through the
Surge is an abnormal operational event and, if
machine. This repeating process of surge is called
allowed to continue, will eventually cause damage in
“pumping” because of the in-out aspect of the flow.
the form of over-worked thrust bearings, since on
reversal of flow, thrust reverses. Pumping will
An operational machine can experience "incipient
"hammer" the thrust bearings over time.
surge" or "stall”. This is where a stage element,
impeller, or diffuser, experiences a flow separation.
Damage caused by overheating can happen with
This separation is a stall, and is not severe enough
surge. When flow reverses, hot air (from the heat of
to constitute a full stage surge.
compression) flows to the inlet side of the impeller.
The hot air receives more heat when it is re-
The stage can remain in the stall condition and is
compressed. The temperature cycle is self limiting,
very near the point of full or complete surge, when
but very high temperatures are possible.
the stall is occurring. A minor flow disturbance in
this condition can trigger a stage, or the whole
The occurrence of surge, without pumping, is not in
machine, to surge. Surge triggering can occur in
itself a damaging event. Carrying out a natural surge
various areas in the impeller or diffuser.
test or an occasional surge event will do no harm.
The peak pressure point on the characteristic curve
Damage may occur where rapid, recurring surge,
is called the "natural surge point”. In multi-stage
machines, each stage has its own natural surge or pumping, continues over a period of time.
point.
A controlled test, that causes a compressor to reach

its natural surge point, checks the compressor's
suitability for use. If the machine surges at a
pressure that is less than the baseline reference,
then the test is an indication of the degradation of
internal components. The compressor’s
aerodynamics are assumed to be good if the natural
surge test pressure remains the same as the
baseline reference. A "natural surge test" is usually
done, as part of an initial start-up, to obtain on-site
baseline data.
The physical geometry (shape) of the parts in a

specific compressor system determines its surge
point. Damage or foreign matter build-up in the
compressor elements can change the shape of
these parts.

Choke and Stonewall
Choke and Stonewall
Choke limits maximum flow through the compressor.
When in choke, the compressor physically cannot
pass any more air volume, due to the losses being
encountered either in the compressor itself or in the
discharge system. These losses can be considered,
simply, as resistance to flow. Choke is a fixed
physical limit of the compressor. (The area
designated as choke is on the right side of Figure 4.)
The point of demarcation between the useful range

and choke is called the "stonewall” because it acts
as a barrier and flow cannot be increased passed
that point.
The technical definition of stonewall is: That point,

on a characteristic curve, when the flow velocity
reaches the speed of sound. Flow that near the
speed of sound, results in a condition where the
characteristic curve is vertical or nearly so and any
increase in flow stops.
In cases of compressor deterioration, or if non-

specification parts are installed, it is possible that a
lower stage in a multi-stage compressor may be in
choke, which in turn starves the downstream stages,
causing surge or incipient surge.
Choke is normally not associated with damage

to the compressor as in the case of surge.
Choke is an aerodynamic limit that causes no

damage; however, if pressure becomes unstable
in the choke situation, this could result in thrust
bearing hammering, as pressure loads rapidly
lessen and increase.

The effect of Air Density
The Effect of Air Density The density of air affects the compression ratio of the
The density of the inlet air affects the pressure compressor. The compression ratio will increase with
developed by the compressor. heavier air and decrease with lighter air.
Density of air is influenced primarily by temperature, Density significantly affects how much work the
pressure, and humidity. The dimension of density is compressor is doing at any given time. It takes more
pounds-per-cubic-foot at Standard Temperature and work to move heavier air..
Pressure of air (STP) conditions.
As an example:
The values used for STP, in the gas compression
industry, are 60oF, 14.7 psia, with a relative humidity Assume a compressor will transfer 10000 ft3 per
of 0%. The STP temperature used by general minute at dry air inlet conditions.
science and industry is usually 60°F
• At 14.4 psia and 60°F, the compressor will
As air temperature increases, the density decreases. transfer {(10000 ft3 /min.) X (1 lb/13.5 ft3 )} = 749
The opposite is true for colder air; as air pressure lbs/min.
increases, the density increases. • At 14.4 psia and 100°F it will transfer 695 lbs/min.
Decreasing pressure results in decreasing density. Less work is done on the 10000 ft3 in one minute at
The more water vapor in the air, the lighter a cubic 100°F than at 60°F.
foot of air will be. On a very hot, humid day, the air is
light and on a very cold, dry day, the air is heavy. • At 60°F, the model's compression ratio is (25.4
psia +14.4 psia) =1.764.
The formula for the density of dry air is:
• At the 100°F inlet condition, the compression ratio
Density = 1.325 X (Pb+T) lbs/ft 3 is 1.698.
Where Pb = barometric pressure in inches of

mercury, and To summarise the effect of inlet density changes:
T = temperature in degrees Rankin
(°R = °F + 459.7). • Higher density generally increases compression
ratio and increasing the discharge pressure.
Dry air at 60°F weighs approximately 0.074 lbs/ft3. If • Higher density generally increases the amount of
the temperature increases to 100°F, the air will work required to move a fixed volume of air.
weigh 0.064 lbs/ft3. • Lower density generally has the reverse effect.
One pound of dry air at 60°F has a volume of about • In relating the density effects to the characteristic
13.5 ft3. At 100°F, one pound of air expands to fill curve; the curve will move downward (less
15.6 ft3 . pressure at same volume) with lower density air.
• The curve shifts upward with higher densities
The way density affects dynamic compression can (higher pressure at same volume).
be explained by way of an analogy.
Imagine attaching a string to a Ping-Pong ball and

then spinning it around in a circle. There will be
some tension on the string as the ball goes around.
This tension can be viewed as pressure.
Now, imagine doing the same thing with a golf ball.

The tension on the string will be significantly higher.
The tension is higher because the golf ball weighs
more than the Ping-Pong ball. The heavier spinning
object exerts more tension or pressure.
Similarly, denser (heavier) inlet air causes more

pressure to develop. Less dense (lighter) inlet air
develops less pressure.

Compressor Operating Methodology
Compressor Operating Methodology This period allows the compressor prelube pump to
In the following description of compressor operation, circulate oil throughout the casing and prevents
the term “state” is used to indicate what the restarting while the compressor is coasting down after
compressor is doing, or mode of operation, at any an electrical interruption.
given time. These operating states exist in a
hierarchy. For example, the two highest level states Not Ready
are “Stopped” and “Rotating”. All other states exist at When in this state, the compressor is “Not Ready To
a level below these two states. Start”. This state is entered when the Waiting Timer
has expired and whenever a compressor trip has
been identified or a stop command issued. A very
Compressor Operating States common, and quite often overlooked reason for the
Motor Driven Packages compressor being “Not Ready”, is when the
Emergency Stop push button has been engaged.
+ Compressor This state can exist indefinitely.
+ Stopped
Ready
Waiting This state could be redefined as “Ready to Start”. This
state is entered after all the compressor’s permissive
Not Ready functions have been satisfied. This state can exist
indefinitely.
Ready
+ Rotating Rotating
This mode does not necessarily mean that the
Starting compressor is actually rotating. It means that it is
Unloaded possibly rotating or rotation is pending and expected.
A-D Unloaded Starting

This state is entered any time after the compressor is
Surge Unload ready and a start command is given. The goal for this
period, is to get the compressor to rated speed and
Loading running unloaded.
MinLoad
“Starting” is allowed for only the Start Timer period
Loaded and is adjustable. This time period is limited to a
maximum of one minute, or 60 seconds. The reason
Full Load for the limit is to prevent the compressor from
operating in the critical speed for an extended period.
MaxLoad
Stage vibration alarm and trip setpoints are increased
Unloading
during this period, to get the compressor through the
Coasting critical speed region. After the compressor has
“Started”, the alarm and trip setpoints are adjusted
back to their original values. The same procedure
also occurs for stage air temperature.
Stopped This state exits only after the Starting Timer has
This state implies that the compressor is NOT expired. The compressor is always started
rotating. It is important to note that this may not be unloaded.
true. If the instrumentation is not working properly or
if the system is set up improperly, the compressor On exit of “Starting”, the compressor will return to the
could still be rotating. mode that it was in, the last time the compressor ran.
For example, typical operation implies that, prior to
Waiting stopping the compressor, the Unload key is pressed.
After the panel power is energized, the controller If this occurred, then the compressor will remain in
starts the Waiting Timer and does not allow further “Unload” after starting. If the compressor was running
User operation until after the timer expires. This and tripped, the compressor will automatically return
timer is set at the factory for two minutes (120 to the “Loaded” mode on exit of the Starting state.
seconds) and is not adjustable.

The User may also press the Load or Unload key a Stopped state. This state will remain as long as
prior to pressing the Start key to force the the adjustable Coast Timer is in effect. At the end of
compressor into either post-Starting state. the timer, the compressor will enter either the Ready
or Not Ready state.
Unloaded
The compressor is in this state after a start (and WARNING
Load Selected is not in effect) or when the User ! Warning
issues an unload command. Failure to set the Coast Timer for a period
greater than or equal to the actual coasting time can
A-D Unloaded and Surge Unload result in compressor damage.
These are also considered to be states. However,
these two states are really just reasons for being in
the Unloaded state.
AD Unloaded means “AutoDual Unloaded” which

occurs when AutoDual is enabled and the system
pressure has been high enough for a long enough
time to drive an unload command.
“Surge Unload” is similar in that a surge event drives

the unload command instead of AutoDual. These
states can exist indefinitely.
Loading
When a valid load command is issued, the
compressor will enter this state. This state exists
until the MinLoad state is satisfied. The duration of
this state depends upon PID settings for the inlet
valve at the MinLoad state and the demand for air.
MinLoad, Loaded, Full Load and MaxLoad

These states transition among themselves as
demand for air changes.
“MinLoad” means that the bypass valve is controlling

pressure and the inlet valve is maintaining the
MinLoad Control Setpoint.
“Loaded” means that the inlet valve is controlling

pressure and the bypass valve is closed.
“Full Load” occurs when the inlet valve has reached

the full open or 100% position.
“MaxLoad” means that the inlet valve is maintaining

the MaxLoad Setpoint to prevent motor damage. In
both the “Full Load” and “MaxLoad” states, system
pressure will be lower than setpoint pressure.
Unloading
This state occurs when a valid Unload command is
issued and will persist until the compressor reaches
the Unloaded state.
Coasting
When a trip or any stop command is issued, and the
compressor is running, the motor will be de-
energized and the compressor will begin to coast to

The following diagram graphically depicts the states

relative to valve position and is provided to assist in
the understanding of overall compressor operation.
Compressor Operating States

with Valve Position
Ready
Not Ready
Starting
Unloaded
Loading
Loaded
Loaded
Unloading
Unloaded
Coasting
Full Load
MaxLoad
MinLoad
Waiting
System Pressure Setpoint
Inlet System Pressure Bypass

Valve Valve
milli milli
% %
amps amps
100 20 4 100
75 16 8 75
Stop
Unload or Trip
50 12 12 50
Tight Closure
25 8 16 25
0 4 Load 20 0
Start Inlet Valve Unload Position
Power
On
Stopped Rotating

Changing Air Inlet Temperature & Pressure
The effects of Changing Air Inlet Barometric pressure change effect
Temperatures and Pressures
Discharge PSIA
In the following graphs (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.
When inlet temperature decreases to 12.4 PSIA

20oF. The curve rises and the surge (Denver)
line moves to the left. High altitude
The compressor's surge will be at a

higher pressure with decreased inlet
air temperature. Pressure ratio will
increase as the density of inlet air
increases and more work will be Inlet (ICFM) 1000
required to move the fixed heavier
volume of air. Figure 7. Effect of decreased inlet pressure
Figure 7 describes the effect of changes in inlet

Discharge PSIA
pressure. As inlet pressure decreases, density and

discharge pressure decrease, as well as the work
required to move a fixed volume.
Altitude (geographic location) has a very significant

effect on the compressor. Weather-related
barometric pressure changes have an effect, but it is
20oF usually not significant. Figure 7 uses the city of
Mayfield at low altitude and the city of Denver at
60oF high altitude, as examples of how altitude affects the
o compressor. Geographical location (altitude) is a
60 F is the
vital consideration in compressor design.
normal curve.
100o
A multi-stage compressor has not been discussed
yet, but consider what would happen, in a two-stage
machine, that has air cooling between the first and
second stage.
Inlet (ICFM) 1000
Figure 6. Effect of change in inlet air

Cooling water temperature has a very significant
effect on a compressor because of the large
temperature swings possible. The effect of high or
When inlet temperature increases to 100oF, the
low cooling water temperature, by itself or combined
curve shifts down. Hotter air is less dense,
with a high or low inlet air temperature on a multi-
pressure ratio is less, and for the same ft3 /min
stage compressor, can make the machine practically
flow, there is a reduced pressure. At the same
useless, from an air production capability point of
time, the amount of work required has
view.
decreased, because there is less weight to
move.
If the first stage has a low pressure, due to hot
summer air, the second stage will have a low
The volume remains the same, but because of
pressure capability, because its inlet pressure is
its lower density, it weighs less and the lbs/min
lower. Couple this low pressure with the effect of
flow has decreased. When flow is related to the
high second-stage inlet temperature, due to a
weight of air, it is given the name "mass flow,"
malfunctioning cooler, and it should be easy to see
for the air mass weight that is being
that the overall compressor output is in big trouble.
compressed. With hotter air, the surge point
decreases.

Issue: 01/Australia, March, 2003 Page 13
Changing Air Inlet Temperature & Pressure
Figure 8 is a graph of what may happen in the event
of these combined changes.
Discharge PSIA
0oF Air
plus
40oF Water
Normal
95oF Air
80oF Water
0
110oF Air
plus
110oF Water
Inlet (ICFM) 1000
Figure 8. Combined effect of high and low temperature air and

cooling water

The Centac Performance Curve
The Centac Performance Curve The function of the Centac compressor is to provide
The Centac performance curve is an variation 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 necessary valves for
control. This stylized Centac compressor is the
Surge model for the discussions that follow.
100% Radial
A Design Point Diffuser
appears on the
performance
Impeller
curve. A Centac Inlet Valve
e
PSIA
lin
compressor is
ge
guaranteed to
ur
rS
produce the
do
design point flow

a
Lo
Drive
and pressure for Shaft
Unloaded specofoc inlet
conditions.
Capacity (ICFM) 100% Bypass Valve
Figure 9. Stylized Centac Performance curve.

Discharge PSIA versus Capacity Chart
SYSTEM
Figure 10. Stylized single-stage compressor with fixed position

inlet and bypass valves
Figure 10 corresponds with Figure 9 and shows the

Related compressor running at design inlet conditions of
hp 95°F inlet air temperature, a humidity of 0% and a
pressure of 14.4 psia at the fixed open inlet valve
entrance.
BHP
In this condition, as long as inlet conditions don't

change, the compressor will supply the design point
Capacity (ICFM) 100% flow at the design pressure. The bypass valve, in
this example, is fixed at fully closed and the full
Figure 9. Stylized Centac Performance curve. amount of air entering the compressor is being
Brake Horsepower versus Capacity Chart discharged into the system.
For example: a machine may be built with a design If the system flow demand decreases, as it will when
point of 100 PSIG at 1800 ICFM. The impellers and the user shuts a system air valve, the pressure will
diffusers will be configured for this specification and the rise as flow decreases. The pressure increase
head will be fixed by this configuration. The design follows the performance curve as flow decreases.
point and head determine what minimum horsepower
driver needs to be used. As additional valves in the system close, the flow
decreases and the pressure rises higher and higher
The set of graphs that make up the performance curves until the pressure reaches the surge point. At the
include the Brake Horsepower versus Capacity Chart surge pressure, the compressor will experience
and the Discharge PSIG versus Capacity Chart. The pumping until such time as the system is able to
horsepower curve moves up and down with the effects accept more flow.
of changing density.

The Centac Performance Curve
Opening system valves causes flow to increase and
pressure to decrease along the performance curve,
re-establishing the design flow and pressure.
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 the Throttle Range
Inlet Valve Control of the Throttle Range The dotted lines above the inlet
The control system shown in Figure 11 will provide valve minimum closure point
control of the discharge as shown in Figure 12. In have the exact same shape as
Figure 12, the compressor is operating at the the uppermost line.
minimum closure point, at 60% of capacity. As long
as inlet conditions do not change, the system will be Inlet valve
supplied with 60% capacity, at design pressure, for minimum closure Design
as long as necessary. Point
Surge
If a valve in the system is opened, the flow will 100%
increase and the pressure will decrease. The
Discharge Pressure (PSIA)

pressure decrease will be sensed and an open
e
lin
signal will be sent to the inlet valve, from the
ge
controller. The valve will begin to open.
ur
rS
o
ad
Additional flow can pass through the inlet valve with
Lo
a larger opening. The system will accept exactly as Unload Throttle
much flow as needed and then pressure starts to range
rise. The controller causes the valve to stop
opening when the design pressure (or set pressure) Capacity (ICFM) 60% 100%
is reached.
The movement of the inlet valve
The system now is using increased flow, at design causes the performance curve to
pressure, with more horsepower being used. This shift because the density of the inlet
process repeats up to the pressure and flow point air, between the inlet valve and the
where the inlet valve is full open. Any additional flow impeller, changes as inlet flow
demand by the system, after the inlet valve is full decreases or increases.
open, will result in decreasing pressure and
eventually choke will occur, if system demand
increases high enough.
Power at Coupling (BHP)
If the system requires less flow, the pressure

Rated hp Design Point
increases as flow decreases and the inlet valve is
sent a signal to close. The reduction in flow process
can continue until the minimum valve closure point is Min. throttle
Rated Pressure
reached. The inlet valve is arranged so that it will
not respond to any increases in system pressure
when it is at the minimum closure point.
The process of opening and closing the inlet valve, Capacity (ICFM) 60% 100%
in response to system demand, is called
“modulation”. The inlet valve is said to be Figure 12. Inlet valve throttle range modulation curves
modulating when it is opening and closing to meet
system demand. The capacity (flow) that the inlet With less dense inlet air, the pressure developed by
valve controls, between design point and near the compressor will decrease. The flow decreases
surge, is called the compressor “throttle range”. because it is limited by the inlet opening.
Figure 12 illustrates inlet valve modulation. If air The function of the inlet valve is to control inlet flow
enters the inlet valve at a constant density, the air and inlet pressure in the throttle range of the
after the inlet valve will be at some other density. As performance curve.
the inlet valve closes from full-open, in response to
decreased system demand, the flow through the Study Figure 12. When the inlet is at minimum
valve is limited. closure (minimum throttle), the surge point is nearly
at the design pressure line. If the compressor has a
As the valve closes, the air passing through it controlled inlet valve with no other controls, as
increases its velocity, and the pressure after the system flow demand reduces below the minimum
valve, will show a corresponding decrease; the closure position, the machine will surge. A surge
volume of air entering the valve is being limited. caused by closing the inlet more than the minimum
closure point is called a throttle surge.
Stopping, Starting and Un-loading Control
A control system that has just an inlet valve, while To correct these problems on start, the control
providing service in the throttle range, doesn't allow opens the inlet valve a small amount and fully opens
the air system to take advantage of the full 0%-to- the bypass valve to vent-off the starting flow.
100% flow range. Flows between 60% and 100%
can be utilized with inlet-only control and the effects Un-loading. See Figure 12, unloaded position, in
of changing inlet temperature and pressure would be the top graph. Once started, the compressor is
partially controllable. An inlet-valve-only control operating at the unloaded or start position that
system is not very useful since low system flows and corresponds to the minimum opening position of the
changing inlet conditions cannot be accommodated. inlet valve. To load the compressor into the system,
the inlet valve initially opens to the minimum throttle
Stopping, Starting and Un-loading Control point. The bypass valve begins to close once the
Stopping presents no problem. Simply turning off inlet is at minimum throttle. Depending on system
the power supply (electricity, steam, or other) to the pressure, the bypass will modulate, and when it
driver will result in the compressor slowing down and reaches fully closed, the inlet will modulate on
coming to a stop. When stopped, there is a very system pressure.
real possibility that the compressor will reverse
rotate, from a reverse flow, caused by the In Figure 12, the slanted line from the unloaded
pressurized volume remaining in the system. An capacity point to the surge point, is called the load or
attached discharge check valve (see Figure 13) will surge line. The flow and pressure, in a well tuned
prevent the pressurized air volume in the system control system, increases very close to this line as
from back-flowing through the machine. Reverse the inlet valve opens. The bypass valve is open at
rotation cannot be tolerated because it will damage the time of loading and all flow vents throught the
the Centac compressor bearings. The check valve bypass, keeping the machine from surging on
also serves to prevent a large volume reverse flow in loadup, i.e., keeping the flow to the right of the
the event of surge. Surge Line.
Starting presents a problem. If the compressor is With the inlet and bypass controls properly adjusted,
started with the inlet valve at the minimum throttle the compressor will provide 0%-to-100% of system
position, there will be a heavy starting load on the demand at designed pressure, and allow for
compressor driver. Flow would increase, along with compressor start, stop, load and unload.
the increasing speed of the motor, but the
acceleration under load forces are likely to cause The Effect of Changes in Air Inlet
damage to the compressor or the driver Conditions when the Electronic Control
components. The high starting amperage in this
type of start-up affects the electrical distribution System is used
system. The electronic control system uses a motor
amperage signal (MinLoad) to establish the inlet
A control function that causes the inlet valve to open valve minimum closure (minimum throttle) point.
to no more than about 5% to 20% on start, is
desired, to limit starting load. If flow is limited on This signal reflects the driver horsepower where
start, the starting electrical and acceleration loads (Amps X Volts X Phase factor X Power factor =
are limited. The bypass valve must be fully open on Watts) and (746 watts = 1 Horsepower). If volts,
start up. phase factor and power factor are constant, the
amperage is proportional to horsepower. In reality,
The compressor needs to have a small flow on start. the power factor is variable with motor load and this
This flow keeps the compressor from becoming a upsets the direct amperage to horsepower
vacuum pump and prevents startup-throttle surging. proportionally. Amps are nearly proportional to
Running the compressor in a vacuum has two horsepower and for normal control purposes this
detrimental effects: nearly proportional is adequate. Since horsepower
is directly proportional to flow at constant pressure,
• with no flow path, the impeller will impart energy
the throttle surge point can be related to motor
to the stagnant air in the compressor, heat will be
amperage.
generated and, over time, this could cause
damage.
The inlet valve responds to a signal based on
• the bearings are designed for a minimum load, system pressure, as does the electro-pneumatic
and running under vacuum conditions puts stress scheme. However, an amperage level, at which
on the bearings. surge will occur, is entered as a set point. If load on
the driver nears this surge set point, the inlet valve

The effect of changes in Air Inlet Conditions
will stop closing and the bypass will start to open to
vent excess flow.
The major difference between the electro-

pneumatic, Low Limit Relay (LLR) control, and the
electronic control is that, in the electronic system,
the inlet valve will stop closing at a specified
amperage/horsepower (flow), rather than a fixed
percent open position. The effect of this is the same
as re-adjustment of the LLR for summer and winter
operation.
The electronic controller causes the minimum

throttle position to change position of the inlet valve
according to inlet air temperature. The effect of
changing inlet density is automatically compensated
for in the low flow region. This automatic
compensation results in less wasted horsepower
when system demand is in the low flow region of the
throttle range.
In the high flow region of the throttle range, where

overload is possible with increased inlet air density,
an amperage (flow) signal prevents the inlet valve
from opening to the point where the motor is
overloaded. If the inlet valve was full open when the
density change occurred, the inlet valve would close
until the flow (horsepower) was reduced below the
overload point.
The name given to the minimum throttle point control

function in the Centac standard CMC electronic
control is "MinLoad”, (Minimum Load). The driver
overload protective function is called "MaxLoad”,
(Maximum Load). The unload position of the inlet
valve control function is called "Inlet Valve Unload
Position". Refer to the Centac Microcontroller CMC
manual for detailed information of this system.

Inlet Guide Vane (IGV)
The function of the Inlet Guide Vane (IGV) The IGV's primary use is in the degree of accuracy
An inlet guide vane arrangement is used instead of and stability that can be obtained when the
an inlet (butterfly) throttle valve in some applications. compressor is operated under conditions where
These applications are, normally, those processes control of the pounds-per-hour (lbs/hour) mass flow
that use air as a raw material for an end product or is a requirement. IGVs offer a larger and more
where precise control of the flow is required. An air- precisely controllable throttle range than the
to-nitrogen gas process or a pharmaceutical standard inlet valve.
fermentation process are examples..
Each angle of the inlet guide vane produces a

unique surge curve. The shape of the characteristic
curve changes with vane angle in the IGV. This
makes the IGV very unlike the standard inlet valve.
Figure 14 illustrates an example IGV characteristic
curve.
Design
in e
Point
mit L
Li
rg e
Su
100%
-10o
0o
+20o
+60o +40o
40% Throttle Range 100%
Capacity
Figure 14. Example IGV characteristic curve The detailed

theory of operation of the inlet guide vane is
complex. In the simplest of terms, the guide vane
provides spin to the entering air as well as 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 (straight in)
and the impeller must do work to change the
direction of the air from an axial to a radial flow. With
spin imparted by the inlet guide vane (IGV), work is
still required, but less is needed. The IGV provides
an increase in the efficiency of the overall
compressor.
Each degree angle of the IGV vanes establishes a

new curve of a different shape. This results from the
aerodynamic effects of the spin given to the inlet air.

Basic Multi-Staging and Intercooling
Basic Compressor Multi-Staging and

Intercooling
Inherent mechanical and aerodynamic limitations
require the use of multiple-stage compressors to
achieve design flows and pressures. A single-stage
high-flow, high-pressure dynamic compressor is not
practical due to impeller speed-related stress, and
other mechanical difficulties related to obtaining the
required head.
Centac uses 1, 2, 3, 4, and occasionally more

stages, depending on customer’s need. The most
common machines being built have 2 or 3 stages.
Each stage, in an ideal multi-stage compressor, will
do the same work. To do the same work, the stage
pressure ratios are the same, since the lbs/hr flow
goes successively through each stage.
The calculations below demonstrate how to estimate

the interstage pressures of a multi-stage compressor
operating at a specified discharge pressure.
Pressure in psia is used in the calculations. If PSIG

is used, a multiplier of 0 will enter the equation.
Assume the inlet pressure is 14.4 psia and the
desired discharge pressure is 114.7 psia.
Overall compressor pressure ratio =

Pratio = Pout ÷ Pin and
7.9653 = 114.7 psia ÷14.4
Stage factor = Poverall ratio ( 1/# stages)
2 stage calculation:
Compressor ratio =
7.9653, Stage factor = √7.9653 = 2.8223
1st stage in X stage factor =
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
Compressor ratio =
7.9653, Stage factor = 3√7.9653 = 1.9971
Compressor ratio =
7.9653, Stage factor is 4√7.9653 = 1.6799.

Typical (Actual) Centac Performance Curve
Typical (Actual) Centac Performance Curve actual machine, normally indicates that the
Figure 15 is a performance curve for a typical compressor will have a corresponding larger throttle
2CV31M3 compressor. The slope of an actual range. A large throttle range is normally desirable.
Centac curve is steeper than the model curve
shapes used previously. This is a typical
general shape for actual compressors.
The curves are based on a compressor

that is operating at design conditions.
These conditions are given on the form as
ambient conditions.
Pb = Barometric pressure and is the

pressure based on height above sea level
(altitude), where the compressor will
operate. P1 = Inlet pressure, called flange
pressure, is the pressure that exits at the
compressor inlet flange downstream of the
inlet valve. The inlet valve is normally
attached to the inlet flange. 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.
Figure 15. Typical actual performance curve.
The model 2CV31M3 is inter-cooled, and
as a result, condensate will be produced.
As condensate drops out of the air flow, the air The BHP (brake horse power) curve shows how the
density will change in direct proportion. Stages 2 horse power will be consumed from the natural
and 3 will respectively receive a smaller percentage surge point to the choke point. It is important to
of water vapor in their inlet air because of the understand that the curves represent a compressor
condensate drop out in the coolers. with its' inlet open 100%. The curves show how the
pressure and BHP will react as flow is increased or
The 1st stage will do more work than down stream decreased by changes in flow demand by the
stages per ft3 of air because of the percentage of system the compressor is feeding.
inlet water vapor. Tw = cooling water temperature
and is the temperature of the water entering the The sloping line labeled butterfly throttle shows the
coolers. Tw is the basis for determining what the horse power decrease or increase as the inlet
inlet temperatures in the 2nd and 3rd stages will be, throttle is opened 100% or closed to the minimum
as well as how much condensate will drop out. throttle point. The dotted line shows the power
consumption when an IGV is utilized. An IGV
The standard CENTAC design parameters are: throttle, except at the design point, causes less
Pb = 14.4 psia horsepower to be utilized for the same flow. There
P1 = 14.1 psia is greater difference between the IGV and butterfly
T1 = 95oF BHP control in the low flow area; there is no
Rh = 60% and difference in BHP at the full open position of either
Tw = 80oF valve.
Any one or all of these parameters may be different An IGV has little practical use for users who
in a specific design. normally operate at near design flow . An IGV
provides power consumption advantages, as well as
The difference in discharge psia, between the surge precise flow control capabilities, where continued
pressure and the design point pressure, is called the operation near the throttle surge point is anticipated.
rise to surge pressure. A high rise to surge, in an

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

Short Test
Short Test
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?

Notes

Principles of
Operation
Section 3
Inlet & Bypass Valve Operation..................................1—7
The Actuator ...............................................................8—9
Butterfly Inlet & Bypass Valve ....................................10—11
Regulation & Coalescing Filter ...................................12—14
Inlet and Bypass Valve Positioners ............................15—23
Short Test ...................................................................24

Inlet & Bypass Valve Operation
A control system that has just an inlet valve, while Each valve assembly is also fitted with an instrument
providing service in the throttle range, doesn't allow air regulator and an air filter. The standard assembly
the air system to take advantage of the full 0%-to- is provided in different sizes for the various valve
100% flow range. Flows between 60% and 100% sizes. Figure 1 shows a typical arrangement with a
can be utilized with inlet-only control, and the effects butterfly valve attached to the actuator.
of changing inlet temperature and pressure would be
partially controllable. An inlet-valve-only control To achieve the best machine performance, the
system is not very useful, since low system flows following must be carried out:
and changing inlet conditions cannot be • The regulation and coalescing filter
accommodated.
• Adjustment and maintenance
• Troubleshooting indication
Inlet and Bypass Valve Assembly
• Routine maintenance
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 Diaphragm operated

separate major components. These are: single acting
actuator
• the Positioner
• the Actuator, and
• the Valve.
Instrument air
regulator
Air filter
Butterfly valve
The regulator and Air Filter

are used in all types of Inlet
Valves and BypassValves
Mechanical Stop
Positioner
Figure 1.Standard valve assembly

The Positioner output. The actuator provides the power to drive

the valve open or closed, in proportion to the
Valve Positioner Operating Principle
microprocessor output control signal.
The Ingersoll-Rand valve positioner consists of a
common housing that contains a 4 – 20 mA current
Refer to Figure 2 when following the description of
to pressure (I/P) transducer, that controls the
the principle of operation. Operation of the positioner
attached pilot valve operated air to actuator
is based on the balanced torque principle.
assembly. Valve motion feed back linkages, that
are necessary to provide the correct air pressure
Description of the principle of operation
signal to the actuator, are an integral part of the
positioner. The positioner will output 0 to 65 psi • The force coil, which is powered by the
(448 kPa) to the actuator as set by span and zero microcontroller 4 – 20 mA output signal, is
controls. located in the field of the permanent magnet.
The signal provided to the force coil creates a
The actuator is supplied an air signal from the torque through magnetic repulsion.
positioner. The air signal provided by the positioner
is proportional to the microcontroller 4 – 20 mA
Diaphragm
Piston
Restriction
Beam
Spool Zero Adjustment
Vent Spring Nozzle

Magnet
Force Coil
Pilot Valve Balance Beam

Actuator
Feedback
I/A Spring
Cam Coupling
Feedback
Lever
Shaft
Span (range)
Adjustment
Figure 2. Positioner Schematic

• A torque that is proportional to the mA signal is
applied to the balance beam and the balance
beam moves.
• The feedback spring causes a counter-torque on
the balance beam. This counter-torque is
proportional to the actuator, and valve position;
this position is transmitted to the balance beam
via the actuator shaft, the coupling, the feed-back
shaft, the cam and the lever as a relative
displacement to the lower end of the feed-back
spring.
• The nozzle senses the torque balance on the
beam. When the input signal increases, the
balance beam approaches the nozzle and the
nozzle pressure increases. This causes the
diaphragm piston, the beam, and the spool to
move downward.
• The pilot valve moves to channel the 65 PSIG
(448 kPa) supply air to the upper side of the
actuator diaphragm. The actuator piston moves
until the balance beam is in equilibrium. At this
point, the actuator is in the exact position
required by the input signal.
• The spring causes a negative feed-back between
the first amplification stage nozzle and restriction
and the second stage pilot valve assembly. The
differential diaphragms effectively offset the
effect of any fluctuations in the instrument air
supply pressure.
By changing the lower fastening point for the spring

on the balance beam the dynamics of the positioner
can be adapted to suit the actuator size. Larger
actuators are required on the larger valves. The zero
adjustment is mechanical and the span (range)
adjustment is electrical.

The areas on the cam between the dots are non-
Feed-back Cam rising with respect to 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 "dead band"
other ranges are not used, for your information the 0 for the first
to 50 range refers to an input signal of 4 to 12 mA, few degrees
and 50 to 100% refers of motion of
CW rotation to close bypass to 12 to 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, ensure upon
For Centac o its re-installation, that it is correctly seated against
20
application, the land on the operating shaft.
• the A side is for Dead The shaft may slide towards the actuator when the
the bypass and band cam is removed. In this event, there is no positive
• the B side is for means to know that the cam is properly seated.
the inlet valve.
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 the 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 the position open Figure 5 Gap = Cam and body not touching. Malfunction
will occur if cam
of the lever arm 20mA and body touch.
roller for correct
cam positioning.
No dead band is
required.
Figure 4A

Internal feed-back spring installation, insure the internal feed-back spring is

The internal feed-back spring is identified on Figure anchored in the same position as on the old
1 as item (14). Figure 6 below is an expanded view positioner. The internal feed-back spring must be
of the attachment mechanism for this spring. positioned before doing the zero and span
adjustments to the positioner.
The internal feed-back spring, anchoring point (a –
e), is preset for the particular size of the actuator Terminal Card Assembly
being used. The amplification of the positioner The terminal card assembly contains the span
increases as the spring anchor is moved from potentiometer, the electrical filters and the test
position a to e. points (See 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).
Zero adjust
Using the exposed terminals, attach a voltmeter and
ammeter, as shown in Diagram 1, to the pins to
Internal feed back spring perform checks. See the Table below for
indications. Insure the jumper is correctly reinstalled
Balance at completion of tests.
beam
Feed back spring Measurement

a b c d e Volts Amps Possible Faults
Anchoring positions
None (0) Meter goes Signal wire wrong
Figure 6. Feed back spring attachment negative polarity
The anchoring position of the internal feed-back None (0) None (0) Signal wire defect.
spring is set when the assembly is tested. This is Wire not connected
done under ideal conditions with specific air supply Greater than When amps Coil connections or coil
pressures, etc. Conditions in the field at customer 4 volts = 20 mA opened.
sites may be different than the set up test conditions. 220 ohm shunt resistor
The spring may need to be re-adjusted. open
If the valve overshoots or moves too slowly during None (0) Some amp Coil or shunt resistor
operation, the spring can be moved in the ‘a’ or ‘e’ reading shorted
direction as required. If a new (replacement)
positioner is being installed on an existing
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

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

To utilize the actuator for the bypass valve the driver
position is as shown in Figure 9. For inlet valve use the
actuator is simply reversed as shown in Figure 9A.
Actuator Parts Identification List

Figure 10
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
Open Close Open Close bearing 45 Plate
Reverse acting Direct acting
Air signal closes valve Air signal opens valve 14 Diaphragm 50 Top driver bearing
Spring force opens valve Spring force closes valve 15 Upper casing 51 Bottom driver bearing
BYPASS VALVE INLET VALVE 19 Stop screw 52 Pivot pin bearing
20 N/A 53 Name plate
Figure 9. Bypass valve Figure 9A. Inlet valve
21 Cap screw 54 Tie rod
23 Jam Nut 55 Hex nut
24 Indicator pointer 60 Plate
25 Cap screw
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 or 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
pintel to move downward, opening the pintel
In this section, you will learn valve and allowing air flow.
• The regulation and coalescing filter • The pressure builds up against the control
• Adjustment and maintenance diaphragm until the pintel valve closes to a point
• Troubleshooting indication of equilibrium between the spring and the air
pressure on the diaphragm.
• Routine Maintenance
• Once the set pressure is reached it is maintained
as described below.
The Regulator and Coalescing Filter • Downstream pressure drop: A drop in down
stream pressure reduces the air pressure on the
Supply Air Regulator diaphragm. The equilibrium is upset and the
The supply air regulator is used to reduce the supply pintel valve opens to the point where equilibrium
air pressure, from a maximum inlet design pressure is again established.
of 120 PSIG (827 kPa), down to the maximum
operating pressure of the actuator. Actuator • Downstream pressure increase: A sudden
operating pressure is 60 PSIG (414 kPa) with a increase in downstream pressure acts on and
maximum of 65 PSIG (448 kPa). The regulator has lifts the diaphragm off the pintel, causing the
an integral 5 micron filter with drip well, for the relief pintel seat, in the diaphragm assembly, to
collection of moisture. A drip well drain is provided. lift and open the chamber below the diaphragm
to the vent. The excess pressure drops almost
The regulator is adjustable over the range of 0 to 60 instantaneously to the equilibrium point, at which
PSIG (0 - 414 kPa) and will normally be operated at time the relief pintel seat seals once again on the
60 PSIG (414 kPa). The principle of operation of the pintel.
regulator is balanced force, where a calibrated
spring force is balanced, by the discharge air The 5 micron filter is nylon mesh with self cleaning,
pressure, 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
periodic basis.
• Outlet air pressure is set with the adjusting
screw. Once set, the regulator maintains the
setting. The range spring, which has been
compressed by the adjustment screw, causes the
Figure 14
Adjusting Screw
Lock Nut
Bonnet
Spring Guide
Range Spring
Relief Seat
Vent
Diaphragm Assembly
Body
Inlet
Outlet
Pinlet Valve
Dripwell Housing
Pinlet Spring
Pinlet Spring Screw 5 Micron Filter
Dripwell Hold Down Screw
Pelcock

Coalescing Filter Adjustments and Maintenance -

A coalescing filter is directly attached to the Tools and Materials Needed
downstream side of the valve assembly supply air
The following tools are needed to efficiently adjust
regulator. 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. The filter
gauge
tube should be replaced when the pressure drop
reaches 10 PSIG (61 kPa).
Verifying Proper Operation of the Valve
Except for periodic filter tube changes, the seals Assembly
may need replacement from time to time. The procedure for verifying operation of the inlet or
Lubrication on an "O" ring facilitates its installation. bypass valve assembly is the same. Valve action
The "O" ring seals are obtained in kit form from should be as noted below.
Centac Aftermarket. Figure 15 shows the relative
position of the "O" ring seals. Note that air flow is Verify air supply:
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).
Inlet Outlet Verify positioner cam position:

• INLET valve:
Bow Cam should be on Side B, with the arrow of the
“O” Ring Seal 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.
Filter Tube Drain Attach a 4 – 20 mA source ( + to + and - to - ) to the

positioner; (Use IR 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
Figure 15. Coalescing Filter Internals 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
1) Air that is continuously venting from
• the vent port on the regulator, indicates that
the diaphragm has ruptured.
• the positioner pilot valve assembly, indicates
that the spool valve is not seating and may
have worn components.
4 mA • the area of the positioner diaphragm housing,
indicates a ruptured lower diaphragm.
2) 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
OPEN 3. Air venting from any place on the actuator
indicates a ruptured diaphragm or loose actuator
upper casing
Spin Adjustment
Increase to 20 mA and
Routine Maintenance
Adjust the Spin adjustment on the Routine maintenance on the control valve assembly
positioner terminal board until is limited to the following:
• 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.
20 mA • A daily draining of the regulator and coalescing
filter will indicate the severity of any air
contamination problem.
• Checking the calibration (stroking) of the control
Blowdown Valve Inlet Valve is valves is done, as a matter of routine, every six
is fully open fully closed months.
CLOSED
OPEN

Inlet and Bypass Valve Positioners
Introduction The purpose of the valve positioner is to receive a
Prior to the introduction of the Ingersoll-Rand control signal, amplify it, and send a power air-
standard Inlet and Bypass valve assembly, the operating signal to a valve actuator.
BELLOFRAM Type 80 Universal Valve positioner
and the BRAY series 64 SR/CCK type positioner The actuator is the device that physically drives the
were used extensively in the Centac inlet and bypass control valve open or closed. The control signal,
valve control system. provided to the positioner, is a small air signal. This
control signal is, normally, a variable 3 to 15 PSIG.
The purpose of this section is to provide a technical This control signal is varied by a milliamp (mA) to air
information reference source, for service personnel pressure transducer (I/P).
who may encounter the BELLOFRAM or BRAY
Positioners when servicing Centacs. The transducer receives its mA signal from the MP3
or other process system controller.
This information has been taken from the
BELLOFRAM Installation instruction dated 12/84 and Figure 1 illustrates the relationship between the I/P,
provided by Rexnord Company under form R215-19. the BELLOFRAM positioner, the actuator, and the
Information concerning the BRAY positioner is taken valve being controlled. The actuator illustrated in
from the BRAY International Inc., BRAY control Figure 1 is a BRAY device. Centac has used BRAY
accessory modules, Series 64 for rotary actuator's actuators in combination with BELLOFRAM and
publication. BRAY positioners. Other type actuators are also
used.
Information and data, relative to how these devices
are used in the Centac control system, is also Normal supply air pressure to the BELLOFRAM
provided. positioner is 80 to 100 PSIG. The supply air, by
specification, is instrument grade air. At pressures
less than 80 PSIG there may be insufficient power
The BELLOFRAM Positioner available to move the valves being controlled.
I/P, positioner, actuator and valve relationship
Air in Transducer
(I/P)
Air in
BELLOFRAM
positioner
Butterfly
valve
Actuator
Figure 1. Valve control with

BELLOFRAM positioner

BELLOFRAM TYPE 80 • Air from output chamber 1 is fed to the servo
Principles of Operation chamber through a restriction, with the pilot
The Type 80 double acting positioner controls the nozzle serving to control the servo chamber
position of the valve actuator and thereby the valve exhaust rate. Any change in clearance between
by providing air pressure in the correct direction to the nozzle and signal piston produces a
move the valve. Use Figure 2 to follow the corresponding change in servo chamber
description of operation. pressure.
• The servo diaphragms 1 and 2 are designed to
• A chain and stem connector arm are linked to a produce 1:1 inverse operation of output valves 1
feedback (Range) spring. and 2. An increase in servo pressure opens
valve 1 and closes valve 2 and exhausts output
• The feedback spring system causes the valve
chamber 2. A decrease in servo pressure closes
motion to stop at a specific control signal dictated
valve 1, exhausts output chamber 1, and opens
position.
valve 2.
• A force balance condition is initially established
• The combined and simultaneous action of
at set-up between the feedback spring and the
increasing pressure from valve 1 and decreasing
force developed by the signal piston assembly
pressure from vale 2, entering the actuator from
for the range of instrument signal pressures. In
opposite ends causes a "push-pull" effect and
the case of Centac, signal pressures between 3
moves the actuator shaft, stem connector arm
and 15 PSIG are nominally used. Any change in
and feedback spring to the new position that
this force balance condition, either because of a
satisfies the previously described force balance
change in control signal pressure or a change in
condition.
valve stem position caused by external forces,
immediately produces a change in the clearance • The working or balance pressure in the actuator
between the signal piston and the pilot nozzle. can be adjusted by means of the balance
Figure 2. Functional cutaway diagram of

BELLOFRAM Type 80 positioner
Stem connector arm
Range adjustment spring seat

Zero adjustment
Signal pressure Locking seat

Balance pressure Range spring
adjusting screw
Signal piston chamber
Pilot nozzle
Signal pressure
Servo diaphram No. 2
Servo diaphram No. 1
Servo chamber No. 2
Servo chamber No. 1
Output chamber No. 2 Output chamber No. 1
Output pressure Output pressure 1
OUTPUT No. 2 OUTPUT No. 1
Output valve No. 2 Output valve No. 1
Instrument air supply Restriction

pressure adjustment screw. Turning the screw from chamber 1 increases, the valve stem will move
clockwise increases the spring force acting to in the direction that stretches the feedback spring.
open valve 2.
• This produces an increase in output pressure of Zero and Span Adjustment
valve 2 that is immediately balanced by an Adjustment of the positioner to the stroke zero or
increase in output pressure of valve 1 in valve stem starting
satisfying the original force balance condition. A position, for the Spring attachment
decrease in balance pressure is accommodated corresponding
by turning the adjustment screw desired minimum
counterclockwise. input signal, is
Valve stem collar
made by means of
Feedback Spring the zero adjustment
The feedback (Range) spring screw.
adjustment disks are named Zero adjust
spring seats. The zero stroke screw
position of the inlet
These seats have a threaded valve is just fully
closed when a 3 Positioner
center hole. The zero adjustment
PSIG signal is fed to clevis
is screwed into the center hole
after the seats are positioned on Figure 3. Spring seat the positioner from
the spring. the I/P. The zero
stroke position of
To assemble the range spring to the positioner, first the bypass valve is
assemble the two just fully open with a
Figure 4. Feedback spring seats to the 3 PSIG signal. In
spring and spring, by inserting either case a 4 mA
attachments the spring wire (end signal is being fed to
opposite the hook) the
Figure 5. Attachment of spring
through the hole in I/P at the zero stroke
the top of the disk position.
and then screw the
seat onto the Adjustment of the positioner for signal span or full
spring. valve stem travel for the corresponding desired
maximum input signal is made by changing the
Figure 3 shows the spring rate of the feedback spring. This rate change
top (closed) side of is accomplished by changing the number of spring
the seat. This top coils between the spring seat and the positioner.
side is where the The full travel position of the inlet valve is just fully
spring wire is open when a 15 PSIG signal is sent to the positioner
inserted. The from the I/P. The full travel position of the bypass
closed side of the spring seat should face the hook valve is just full closed when a 15 PSIG signal is fed
end of the spring. to the positioner.
There are two spring seats. The first spring seat Regardless of which compressor control valve is
should be screwed on approximately 3 turns, the being stroked, the first step in the stroke adjustment
second is screwed on 2 turns. See Figure 4. procedure is to properly stroke the I/P.
After the spring seats are installed, attach the Valve Stroke Specifications
feedback spring hook to the positioner clevis. The
next step is to screw the zero adjustment screw MP3 output 4 mA 20 mA
through both seats. The chain is attached to the I/P input signal
valve stem collar as illustrated in Figure 5. I/P output signal 3 PSIG 15 PSIG
Positioner input
To achieve proper operation, the positioner output
from the feedback spring side of the positioner Inlet valve position Just full CLOSED Just full OPEN
(Output chamber 1) must be attached to the Bypass valve position Just full OPEN Just full CLOSED
actuator in such a way that, when output pressure

! Note 8) Lock the spring seats in position by holding the

The Centac standard electro-pneumatic control spring seat nearest to the positioner and turning
system uses a common pressure control signal the other spring seat clockwise until both seats
from a single pneumatic controller for both inlet and are locked together.
bypass valves. The procedure for stroking the
positioner is the same except that there are BELLOFRAM Positioner Output Pressure
different values for the zero and full travel (span)
pressures. Balance Setting Procedure
1) Ensure no external forces are being exerted on
The nominal signal stroking values are: the valve or valve stem.
2) With full supply pressure (instrument air) to the
Inlet Valve: positioner input (80 to 100 PSIG), set the input
• OPEN = 15 PSIG signal pressure at the mid point of the span (9
• CLOSED = 7 PSIG PSIG, 12 mA to I/P).
Bypass Valve: 3) Adjust the balance adjusting screw so that the
• CLOSED = *10 PSIG output pressures are approximately equal and the
• OPEN = *3 PSIG output pressure is 50% to 60% of the supply
pressure. As an example, the balance pressure
* These values will vary with ambient conditions. with 80 PSIG supply should be between 40 and
48 PSIG. Balance pressure at 100 PSIG should
be between 50 and 60 PSIG. For proper
operation, a minimum of 10 psi differential should
be allowed between supply pressure and the
BELLOFRAM Positioner Stroking balance pressure setting.
Procedure
1) Check the inlet valve and ensure it is fully in the Maintenance of the BELLOFRAM Positioner
mechanically closed position. The bypass valve Maintenance other than calibration is required if the
is checked in the fully open position. Check the positioner is supplied contaminated instrument air.
spring seats and ensure they are separated Routine maintenance consists of cleaning the two
(unlocked) by approximately 1 spring wire turn. installed 40 micron filters.
Use of the I/P output is recommended for setting
the signal pressure to ensure compatibility Access to these filters is gained through the chrome
between the mA control signal and resultant plated hex bolts on the back side of the mounting
valve motion. plate. Remove filters and clean or replace as
required by on site conditions.
2) With full supply pressure (instrument air) to the
positioner input (80 to 100 PSIG), set the input Contaminated supply air can damage diaphragms
signal pressure at the low end of the span (3 and clog internal passages. Corrective maintenance
PSIG). (overhaul or replacement) is required in the event of
3) Adjust the zero adjusting screw until the desired damage or contamination.
valve stem position is obtained -
Inlet = Closed, Bypass = Open. Ruptured diaphragms are indicated by an excess
4) Set the input signal pressure to the maximum amount of air exiting from the exhaust ports.
span pressure; 15 PSIG.
5) Hold the feedback spring with one hand and with
the other hand grasp and turn both spring seats
together until the desired valve stem position is
reached - Inlet = Open, Bypass = Closed.
6) Recheck and adjust the low end span as per
steps 1 and 2.
Repeat steps 3 to 5 until the desired stroke versus
signal is obtained. Span is correct when a very light
touch on the feedback spring in either the zero or
full stroke signal condition causes the valve to start
to respond. Response is detected by valve motion
and air exhaust sound from the positioner.

The BRAY Positioner BRAY SERIES 64, SR/CCK

I/P, Positioner, Actuator and Valve Relationship Principle of Operation
Figure 6 illustrates the relationship between the I/P, Use Figure 7 to follow the description of the principle
BRAY positioner, and actuator for the inlet valve. of operation of the BRAY positioner.
The configuration for the bypass valve is the same,
except for the cam and the power hose connection. The SR/CCK positioner consists of a
The initial valve position control signal originates • diaphragm, that is activated by the air signal
from the MP3 Microcontroller or another process pressure from the I/P,
controller. This signal is in the control span of 4 to
20 mA. The mA signal activates the I/P where the • feedback spring, that acts in opposition to the
mA signal is converted to an air signal pressure. signal pressure,
The air signal pressure provides the control feed to • double action spool valve,
the valve positioner. The process of valve control, • stem that connects the spool valve to the
when using the BRAY positioner, is the same as diaphragm and
when the BELLOFRAM positioner is used. • cam that moves with the controlled valve to
provide valve position feedback.
Air in
Range Supply pressure
I/P adjustment (Instrument air) Exhaust
ring nut Exhaust
Zero adjustment Spool valve Spring

ring nut Stem
Lever
Cam roller
Cam
4-20 mA
from MP3
BRAY positioner
Feedback spring
Pointer Diaphragm
Actuator Signal from I/P
Output to actuator (F) Spool valve
Output to actuator (E)

Spring cap
Figure 7. Representative functional cutaway diagram of the

BRAY SR/CCK positioner
An increase in air signal pressure on the diaphragm

Butterfly valve
causes a movement of the spool valve , the spool
valve motion allows supply air to pressurize output
(F) and exhaust output (E). The output and exhaust
functions power the controlled valve motion. Valve
shaft rotation is transmitted to the feedback spring
through the cam, the cam roller, and the lever . The
Figure 6. Inlet Valve control configuration (BRAY) force of the feedback spring balances the signal
pressure on the diaphragm.
Normal supply air pressure to the BRAY positioner
is 80 to 100 PSIG (max. 150 PSIG). Supply air, by When the feedback spring and the signal forces
specification, is instrument grade. At pressures acting on the diaphragm are in the balanced state
less than 80 PSIG, there may be insufficient power the spool valve is in the neutral position. The
available to move the valve actuator under some controlled valve will remain in a stationary position
conditions. as long as the feedback spring's force is equal to
signal air force on the diaphragm.
A decrease in signal air pressure upsets the balance Proper connection of the power air hoses to the
and the feedback spring causes the spool valve to actuator is required for correct valve rotation. In the
move in the opposite direction. Output (F) will case of the inlet valve (direct acting), view the
exhaust and output (E) will pressurize. positioner from the side, the cam is facing up with
the plastic cover to the left. The power outlet fitting
The controlled valve will move, the cam will move in in the positioner body is the right hand fitting and the
response to the valve motion and the feedback left fitting is for the gauge. The power hose goes
spring will balance the signal air pressure. Under from the power outlet to the left inlet connection on
balanced conditions, the spool valve returns to the the actuator. Figure 6 illustrates the inlet valve
neutral position. connections.
The cam has three lobes. Each lobe is designed to In the case of the bypass valve, the power
serve a specific signal pressure and linear range. connection from the positioner is made to the right
One side of the cam is used for a direct action valve inlet connection on the actuator.
and the other for a reverse action valve. The inlet
valve is direct acting, since it opens as the signal Zero and Span Adjustment
rises. The bypass is a reverse acting valve, since it The zero and span adjustments are made in a
closes as the signal rises. The cam is marked D for manner similar to the BELLOFRAM. The coils of the
direct use and R for reverse use. The lobes are feedback spring are tensioned to achieve zero and
also lettered with their linearity and signal pressures. the number of active coils is adjusted to achieve the
The lobe that is used for both inlet and bypass is the range. An Allen wrench is provided to make the
one marked 0 - 90°, 3 - 15 psi. The inlet valve uses zero and span adjustments. It is stored on clips
the side of the cam marked D and the bypass uses within the covered area.
the side marked R. Figure 8 illustrates how the cam
is configured for inlet or bypass valve use. The zero adjustment nut is enclosed by the spring.
The Allen wrench is positioned between the spring
Inlet valve configuration Figure 8. Positioning coils and inserted into a hole provided in the nut to
of cam for Inlet or
Bypass valve turn the zero adjustment ring.
Valve rotation configuration
Open The range adjustment nut clamps to the spring with
an Allen screw located in the handle of the range
adjustment nut. The tab is made of plastic and can
easily be broken off if excessive tightening force is
applied to the screw. Do not attempt to take an
extra tightening turn on this screw because the tab
will crack or break away. Figure 9 illustrates the
major components used in setting the zero and
span of the BRAY positioner.
3-15 psi, 0-90°
Allen wrench
Cam shown in inlet valve closed position Allen set screw
Pointer Pointer hold down screw
Bypass valve cam configuration Range
adjusting
Valve rotation ring
Close
3-15 psi, 0-90°
Zero adjust ring nut Active coils

Wrench attachment holes
Cam shown in Bypass valve open position
Figure 9. Zero and span adjustments

Inlet Valve Calibration ! Note

1. The inlet valve must be in the fully closed The positioner exhausts into the area covered
position and the cam positioned with the D side by the see-through cover. Holes are provided
up, on the 3 - 15 PSIG, 0 - 90° lobe with the cam in the bottom of the cam housing to vent off this
roller at the lowest point on the lobe (bottom of exhaust to the atmosphere. If these vent holes
the stroke). See the inlet valve configuration in are blocked by a bracket or other structure, a
Figure 7. If it is necessary to move the cam, provision must be made to vent the exhausting air
loosen the recessed screws around the cam and to the atmosphere; i.e., notch the cover, drill small
the pointer, hold down screw from the center of hole, etc. A tight cover with vents blocked will
the cam. Rotate the cam and align the "0" cause a back pressure in the positioner and it will
indication with the contact point of the roller. not function properly. The positioner must be
Then align the pointer along the direction of the able to exhaust.
zero indication mark that is on the see-through
cover.
2. Instrument air must be turned on. Use a 4 - 20 Bypass Valve Calibration

mA source and apply a 4 mA signal to the I/P.
Hold the spring and range adjust nut to prevent 1. The R (Reverse) side of the cam is used in the
them from turning, and rotate the zero adjust bypass valve configuration. See Figure 7 for
ring-nut until the inlet valve is just at the fully cam configuration. The bypass valve is just full
closed point. Rotation of the zero adjust ring-nut open at 4 mA and just fully closed at 20 mA.
towards the roller support (clockwise rotation) Zero and span are set accordingly using the
decreases the zero start point. Rotation in the same general procedure as for the inlet valve.
counterclockwise direction – zero adjust away Refer to the inlet valve procedure if details are
from the roller support increases the start point. necessary.
2. Adjust zero: 4 mA, just open.
3. Apply a 20 mA signal to the I/P. Loosen the 3. Adjust span: 20 mA, just closed.
Allen screw in the range adjust nut and hold the
spring to prevent it from turning while the range 4. Repeat steps 2 and 3 until bypass valve position
adjustment is being made. Rotate the range matches requirement.
adjustment nut without turning the spring until the 5. Pointer at “0” when full open, “90” when closed.
inlet valve is just fully open. Gently retighten the
Allen hold down screw. Moving the range nut Maintenance of the BRAY Positioner
towards the roller support decreases the range Routine Maintenance, other than calibration, consists
span. Movement away from the roller support of cleaning the spool valve. This is required if the
increases the span. positioner is supplied with contaminated instrument
air.
4. Apply a 4 mA signal. If the valve goes to the
“just at the closed point”, the valve is zeroed. If To clean the spool valve,
the valve is not at the “just closed point”, repeat • remove the hex head bolt (spool valve cap) on
steps 2 and 3 until both the zero and span the back side body of the positioner.
conditions are met.
• remove the valve and clean with solvent.
5. Replace the Allen wrench in its holder and • the spool valve is inserted long end first.
reinstall the see-through cover. The pointer
should be aligned to the “0” mark when the inlet Use care not to drop the spring when the cap is
valve is closed and to the “90” mark on the removed.
cover, when the inlet valve is open.
! Caution
A constant rush of air, in excess of normal
exhaust venting, from under the see-through
cover indicates a diaphragm rupture. Overhaul or
replacement is required in the event of diaphragm
damage

Actuators
Bray Actuator
Figure 10 is a functional diagram of the BRAY rotary
actuator. Power air from the positioner is supplied to
move the pistons in the CCW or CW direction. No
routine maintenance is required.
Travel limit is set with the travel adjusting screws.

Both travel screws are adjusted to limit travel of the
pistons. The pinion is connected to the valve stem
with a collar. O rings provide for air tight sealing of
caps and pinion.
Pinion (1) Stop nut (2)

Piston (2) Travel adjusting stop screw (2)
Cap (2)
Cap hold down

screw (8)
* Air in to move CCW * Air exhaust
* Reverse flows cause CW rotation
Upper bearing with O ring
Lower bearing with O ring
Figure 10. BRAY rotary actuator functional diagram

Vane Type Rotary Actuator

Figure 11 is a functional diagram of the vane type of
actuator. No routine maintenance is required. A
thin coat of silicone grease on the vane seal may
release an actuator that is sticking due to
contaminated air supply. Keep instrument air clean
and free of moisture.
Air exhaust*
Actuator body
Shaft
TOP VIEW
Vane seal
Vane
Air in to move CW *
* Reverse flows cause CCW rotation
Positioner coupling end

Self lubricating bushing
Travel stop pads Shaft
SIDE VIEW
Vane
Vane seal
Valve drive coupling end
Figure 11. Typical vane operated rotary actuator

Short Test
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

Notes

Basic Centac Manual
Lubrication
Section 4
Overview.....................................................................1—4
Lubricant Conversion Procedures ..............................5—7
Material Safety Data Sheets.......................................8—13
Short Test ...................................................................14

Lubrication Section 4
Overview
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.
Basic Centac Reference Manual

Overview
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 Property ASTM Limits
oxidation stability and Test
contain defoaming Method
inhibitors and be free
of inorganic acids or Physical
alkali. There must be
no tendency toward ISO Viscosity Grade D2422 32
permanent
Viscosity Index D2270 139
emulsification and a
minimum tendency to
Viscosity, cSt (SUS)
oxidize or form sludge when agitated at operating
temperatures when mixed with air and water. @ 0oF/-17.8oC D445 895 (4195)
Ingersoll-Rand only recommends Techtrol Gold III a
synthetic lubricant as is specifically formulated for @ 100oF/37.8oC D445 30 (142)
Centac compressors. CAUTION
@ 104oF/40oC D445 28 (133)
! Caution @ 210oF/98.9oC D445 5.6 (45)
Some lubrication mixtures are incompatible with
each other and result in the formation of varnishes, @ 212oF/100oC D445 5.5 (44)
shellacs or lacquers which may be insoluble. Such
deposits may cause serious trouble, including Pour Point, oF (oC) D97-87 -40 (-40)
clogging of the oil filter. Avoid mixing lubricants of o
Flash Point, COC F ( C) o
D92 450 (232)
the same type, but of different brands. A brand
change is best made at the time of a complete Flash Point, PMCC oF (oC) D93-85 390 (199)
lubrication change.
CAUTION Chemical
Total acid number, mg D664 0.1
! Caution KOH/g, max.
Lubricant obtained by the user for operation of this
pH D664 8
equipment must comply with the following
specification and perform satisfactorily in the Density D941 0.988
compressor. The Ingersoll-Rand Company assumes (Grams per cc @ 25oC
no responsibility for damages caused by non-
compliance to this specification within the period of Specific Gravity D941 0.99
its standard equipment guarantee or thereafter. On Copper Strip Corrosion, D130 1
subsequent purchases of lubricant for use with this 3 hrs @ 212oF/100oC
equipment, the user is cautioned to be on the alert
for any changes in the lubricant that may deviate Ferrous Metal Corrosion D665A Pass
from this specification thereby causing equipment (Rust Test)
damage. 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.

Overview
! Standard Oil Cooler and Filter Data

Note Lube Oil Cooler
Failure to meet this specification may result in Water side design pressure 150 PSIG 1034 kPa
damage to internal compressor components. Shell side design pressure 150 PSIG 1034 kPa
Lube Oil Filter

Dual Element 10 Micron
! Note Recommended Minimum Oil Temperatures
The Pour point specification must be met unless Starting 95°F
there is a means available for heating the oil when 35°C
used in low temperature areas. Operating Bearing Inlet 100°F to 115°F
37.5°C to 46°C.
! 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.
Centac Sump Capacities

Model/Frame Gal.
Size
CV0 15
CV1 32
CV1A 32
CH3 12
CH4 32
CH5 55
CH6 55

Overview
Lubricants and Coolants

Since lubricants and coolants are a vital portion of
IR parts sales, we have included a brief chapter on
them for your quick reference. This section gives a
brief overview of Ingersoll-Rand’s lubricants and
coolants as well as part numbers and sizes for
reference.
Where Products Are Used
Coolant/ Basestock Viscosity Hours ISO SAE Where Used

Lubricant Index Viscosity Grade
Grade
Techtrol Gold PAG-Ester 139 16000 32 10W20 Centac compressors.
or 2 years
CV0 Fluid Diester 100 8000 32 - Centac model 0CV only
Coolants And Lubricant Literature

The following literature can be obtained from
Washington, USA, Advertising:
Fluid Form Number Title Description
Centac 8487 Techtrol Gold Includes features & benefits.

Techtrol Synthetic Fluid
Gold TF0005 Material Safety Data Includes ingredients, fire data, health hazards,
Sheet disposal, & first aid information.
TF0003 Technical Data Presents typical properties of Techtrol Gold.
TF0006 Fluid/Lubricant Contains terms and definitions concerning Techtrol

Glossary Gold lubricant.
TF0009 Material Compatibility Lists materials that are compatible as well as those
that are not compatible.
TF0001 Fluid Comparison Compares properties of Techtrol Gold and Techtrol
Silver to standard mineral lubricants.
TF002 Change out Procedure Contains procedures that should be followed when
changing from any other lubricant to Techtrol Gold
CVO AMS 123-G-90B Material Safety Data Includes ingredients, fire data, health hazards,
Sheet disposal, & first aid information.
* Material Safety & Data Sheets (MSDS) are also available on the IR website – www.air.ingersoll-rand.com
IR also has two (2) Ultra Coolant Test Kits available:

37971736 − 15 bottles and 39160783 − 30 bottles

Overview
Lubricant Conversion Procedure separator has a high differential pressure (> 8

In keeping with good maintenance procedures, it is psi) change it as well.
not recommended that you mix coolants and 10) Start the unit and check coolant level.
lubricants. Some lubricants contain additives or 11) Place the unit in normal service.
basestocks that are not compatible with one another.
12) Fluid analysis or use of the field test kit is
Varnished Unit that has been used for an suggested every 3 months to verify the
extended period with Petroleum Oils condition and remaining life of the fluid.
1) Operate the unit to bring the complete system up ! Note

to operating temperature.
When converting compressors manufactured
2) Shut the unit down, and lockout/tag out power. prior to 1978, consult an authorized Ingersoll-Rand
3) Close the isolation valve and vent pressure from distributor for guidance concerning compatibility with
the unit. old-style hoses and other components.
4) Drain the receiver-separator tank.
5) If possible, drain the oil cooler. Varnished Unit which has been run with Pao
6) Change the coolant filter element. (Synthetic Hydrocarbon)
7) Refill the unit with Ultra Coolant.
1) Operate the unit to bring the complete system
8) Restart and run the unit for one week. During
up to operating temperature.
this time, monitor oil filters and change filters
when necessary, as Ultra Coolant removes 2) Shut the unit down, and lockout/tag out power.
sludge and varnish left by the previous fluid. 3) Close the isolation valve and vent pressure from
9) At the end of one week, change the fluid again the unit.
(repeat step 2-5), except this time fill the unit 4) Drain the receiver-separator tank.
completely with Ultra Coolant (normal fill level).
5) If possible, drain the oil cooler.
If the separator has a high differential pressure
(> 8 psi) change it as well. 6) Change the coolant filter element.
10) Start the unit and check the coolant level. 7) Refill the unit with Ultra Coolant.
11) Place the unit in normal service. 8) Restart and run the unit for one week. During
this time, monitor oil filters and change when
12) Fluid analysis or use of the field test kit is
necessary, as Ultra Coolant removes sludge
suggested every 3 months to verify the condition
and varnish left by the previous fluid.
and remaining life of the fluid.
9) At the end of one week, change the fluid again
(repeat step 2-5), except this time fill the unit
Unit that has been used only briefly with completely with Ultra Coolant (normal fill level).
Petroleum Oils (No Varnish Deposits) If the separator has a high differential pressure
(> 8 psi) change it as well.
1) Operate the unit to bring the complete system 10) Start the unit and check coolant level.
up to operating temperature. 11) Place the unit in normal service.
2) Shut the unit down, and lockout/tag out power.
Fluid analysis or use of the field test kit is suggested
3) Close the isolation valve and vent pressure from
every 3 months to verify the condition and remaining
the unit.
life of the fluid.
6) Change the coolant filter element.
7) Do a ½ (one half) machine flush.
8) Restart and run the unit for one hour.
9) At the end of one hour, change the fluid (repeat
step 2-5), except this time fill the unit completely
with Ultra Coolant (normal fill level). If the

Overview
Unit that has been run with Pao (Synthetic Unit that has been run with Diester Coolant and
Hydrocarbon), but is free of Varnish Deposits is free of Deposits
1) Operate the unit to bring the complete system 1) Operate the unit to bring the complete system
up to operating temperature. up to operating temperature.
2) Shut the unit down, and lockout/tag out power. 2) Shut the unit down, and lockout/tag out power.
Close the isolation valve and vent pressure
3) Close the isolation valve and vent pressure from
from the unit.
the unit.
5) If possible, drain the oil cooler and fluid lines.
6) Do a ½ (one half) machine flush.
7) Do a ½ (one half) machine flush. If the
7) Restart and run the unit for one hour. separator has a high differential pressure (> 8
8) At the end of one hour, change the fluid (repeat psi) change it also.
step 2-5), except this time fill the unit 8) Restart and run the unit for one hour.
9) Start the unit and check coolant level.
If the separator has a high differential pressure
(> 8 psi) change it as well. 10) Place the unit in normal service.
10) Place the unit in normal service. every 3 months to verify the condition and remaining
life of the fluid.
life of the fluid. ! Note
This IR procedure omits flushing. Diester is
Unit that has been run with Diester Coolant and more compatible with Ultra Coolant than most other
has Sludge Deposits fluid types. It would be permissible to omit flushing if
a machine was effectively drained. If you wish to
1) Operate the unit to bring the complete system have a more uniform and conservative flushing
up to operating temperature. procedure, substitute the one for PAO – no varnish
2) Shut the unit down, and lockout/tag out power. here).
Close the isolation valve and vent pressure
from the unit.
Unit that has been run on Diester/Polyglycol
3) Drain the receiver-separator tank. Blends
5) Change the coolant filter element. 1) Operate the unit to bring the complete system
6) Refill the unit with Ultra Coolant. up to operating temperature.
7) Restart and run the unit for one week. During 2) Shut the unit down, and lockout/tag out power.
this time, monitor oil filters and change when Close the isolation valve and vent pressure from
necessary, as Ultra Coolant removes sludge the unit.
and varnish left by the previous fluid. 3) Drain the receiver-separator tank.
8) At the end of one week, change the fluid again 4) If possible, drain the oil cooler and fluid lines.
(repeat step 2-5), except this time fill the unit 5) Change the coolant filter element.
If the separator has a high differential pressure 6) Do a ½ (one half) machine flush. If the
(> 8 psi) change it as well. separator has a high differential pressure (> 8
psi) change it also.
7) Restart and run the unit for one hour.
10) Place the unit in normal service.
Fluid analysis or use of the field test kit is suggested 9) Place the unit in normal service.
life of the fluid.

Overview

life of the fluid.
! Note
This IR procedure omits flushing. Diester is
more compatible with Ultra Coolant than most other
fluid types. It would be permissible to omit flushing
if a machine was effectively drained. If you wish to
have a more uniform and conservative flushing
procedure, substitute the one for PAO – no varnish
here).
! Note
Any silicone-based fluids require a special
flushing procedure. Please consult Ingersoll-Rand
for guidance.
If unit has not been operating for an extended

period of time & varnish free, fluid can be changed
before 1,000 hrs.
In converting compressors manufactured prior to

1978 consult an authorized Ingersoll-Rand
distributor for guidance concerning compatibility with
old-style hoses and other components.

Material Safety Data Sheets






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?

Notes

Basic Centac Manual
Planning &
Installation
Section 5
Receiving Handling & Storage....................................1—5
Installation Planning ...................................................6—9
Air Piping ....................................................................10—18
Water System Piping ..................................................19—22
Electrical Connection..................................................23—24
Weights & Dimensions ...............................................25
Recommended Tools .................................................26
Shaft Alignment ..........................................................27—34
Short Test ...................................................................35—36
Shaft Alignment Software ...........................................37—42

Planning and Installation Section 5
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.

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
Blow off valve
installation.
Figure 1.2
Discharge
Typical 2AC11
Compressor
connection
Main motor
Ventilation
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 have to do with housekeeping.
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).

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 5
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 responsibility
flanges of rotating machinery. of the customer. Data and comments are offered as
an aid to ensure a successful installation, but
Piping alignment to the compressor mating flanges
Ingersoll-Rand cannot assume responsibility for its
is essential. The piping must be installed and design or installation. We recommend that the
supported to avoid strains on the casing. customer consult a specialist skilled in the design of
Misalignment, which is a frequent cause of vibration, piping systems to supplement and interpret the
can often be traced directly to piping strains. Three
piping information and to ensure a successful
sources of piping strains are: 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

The control air pipe connection is made at a
minimum of 10 pipe diameters downstream of the
discharge check valve in the discharge pipe (see
Figure 1.6). The control air line connects to the
control panel bulkhead fitting marked ‘CA’ (see
Figure 1.8), which is a 1/2 inch NPT connection. The
control air line should be a minimum of 1/2 inch
diameter, made of a non-rusting material such as
stainless steel, aluminum, or copper. If the control
air line is to be installed in a horizontal run of
discharge pipe, it should be located at the top of the
discharge pipe to minimize condensate or debris
buildup in the line.
The control air line should be routed to the control

panel in such a manner that the line will not have to
be disconnected in order to perform major
maintenance. A drip leg with a drain valve, which
can be used to remove condensate, is
recommended as part of the customer’s control air
line.
Seal Air
Power Air
Control Air PT3 PT4 Instrument Figure 1.8

PT1
Air Control Panel Connections

Air Piping
Instrument Air Piping

Instrument air must be provided for the operation of
the pneumatic control valves and for the seal buffer
air. The air used must be clean dry instrument
quality air. For best results, piping should be
connected to a refrigerated air dryer and filter prior
to connection on the unit. The Centac compressor
normally requires 10 SCFM (0.33 m 3 /m) of air at
60-120 PSIG (414-827 kPa).
The final filtering medium should be rated at a

theoretical efficiency of 99.9999%, particle size of
0.01 micron, and a minimum or 25 SCFM (0.82 m 3 /
m). This filter should be located close to the control
panel. An isolation valve may be located ahead of
the filter.
Piping from the instrument air source should be

constructed of 1/2 inch minimum non-corroding
material to limit the possibility of corrosion products
entering the system. Instrument air piping connects
to the control panel at the 1/2 inch NPT bulkhead
fitting marked “IA”.
Grade HE 40 ( High Efficiency Oil Remove)

0.01 Micron Instrument Air filter CPN: 88343611

Air Piping
Short Test
1 What type of Filter must be installed to the Instrument Air system?
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 5
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 must be
on the starter should not be used. The starter’s
at least one grounding strap from the compressor
120 VAC control circuit should be connected to
skid or baseplate. The connection must be made to
the control panel start circuit. Do not exceed 720
an independent ground and not to a plant system
VAC. The circuit must be wired in series with the
ground. Inadequate grounding, or lack of grounding,
starter. The starter must not be powered by any
may result in operational problems. Additional
other source other that Ingersoll-Rand’s control
grounding may be required for the compressor
panel.
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, overvoltage, the side of the motor to which the three-phase wiring
short circuit, and overload protection is the from the starter is to be terminated. Refer to 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 5
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.

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
• How to use the shaft alignment map Cold or ambient alignment is the procedure that
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
indicators, feeler gauges, micrometers or a
Most compressors are factory tested with their combination of these instruments. This positioning
contract drivers. The remainder are tested with shop should allow for thermal growth and material
drivers. deflections that will occur between ambient
conditions and stabilised operating temperatures.
The incremental movement used to establish the
Even though all drivers are aligned for factory cold shaft alignment may be actual measurements
testing, they must be checked for alignment after made during start up or shutdown, growths
completing installation of the compressor at the site. estimated by the machinery manufacturer or
They must be re-aligned if necessary to bring within estimates made by those installing the equipment.
the specified tolerance. The alignment tolerances
and recommended procedures are outlined in the Testing has shown that the compressor drive motor
following sections. will rise slightly higher than the compressor upon
! Note
reaching their normal operating temperature. The
vertical thermal growth of the motor is greater than
Flange mounted motors do not need alignment. the compressor due to the heat from the oil reservoir
which is located beneath the motor. It is
recommended that the motor shaft be aligned to the
compressor shaft in accordance with the Centac
Field Service Manual applicable to the frame size.
Dowel pins are not factory installed in the driver feet
due to the possible need for realignment in the field. Hot shaft alignment, also known as operating shaft
After final coupling alignment is complete, install alignment or service alignment is a procedure for
dowels in the driver fee as noted on the driver monitoring the change in shaft alignment from cold
outline drawing. Pilot holes are provided in the driver or ambient conditions to normal operating
feet for dowels. conditions. Knowing the cold shaft alignment and
measuring the change, provides a method for
Compressors and their drivers are connected by determining if the shaft alignment becomes collinear
flexible couplings. These couplings are used at normal operating conditions. This method is
because changes in temperature and loadings indirect, but if properly done, provides the most
during normal operation, start up or shutdown can realisable and acceptable methods available.
cause one shaft to move relative to its companion
shaft end. In Figure 14, the two machine shaft ends are
considered to be collinear aligned when the two
All flexible couplings have limits within which they shaft ends rotate about the same straight line (no
can operate without failure or undue wear. Even misalignment, vertically or horizontally). All
when operating within the design limits, these machinery shafts have some deflection; therefore,
couplings generate some resistance to flexing. The this reference is limited to the center of rotation of
force usually increases as the misalignment one shaft and relative to the opposite shaft end.
increases thereby increasing or decreasing bearing Operating with collinear shafts at normal operating
load fluctuations as the shaft rotates. conditions minimise tooth sliding velocity or
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.
diaphragm flexure while providing the maximum

Shaft Alignment
reserve for movement in any direction should it be alignment procedure when the distance between the
required. adjacent shaft ends is greater than one-half the
Figure 14 Collinear Aligned Shafts coupling diameter.
Parallel offset indicates the amount of parallel

Shaft Alignment Map
Preparation and use of a shaft alignment map
(Figure 18) is recommended. Use of a shaft
alignment map provides a convenient form on which
to record indicator readings and calculate equipment
moves. Maintaining this information for comparison
Offset during maintenance inspections or for future
reference can provide valuable diagnostic
misalignment between the centerlines of two information should problems develop.
adjacent shaft ends. Figure 15 shows two shafts
with only parallel offset. In addition to providing machine identification
Figure 15 Parallel Offset information, data and shaft alignment method used,
the shaft alignment map provides a plan (top) and
Angular or face displacement indicates the vertical (side) elevation of the machine shafts,
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
displacement while shaft end “B” has an angular should be scaled using some convenient scale such
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
Angular Displacement 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.
Mark North compass direction in plan view and
corresponding compass directions in indicator
“A” reading circles so no confusion develops during
“B”
measurements.
definitions say the same thing as can be seen by an
analysis of similar right triangles in Figure 16. When making shaft alignment corrections, it is
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
The solid, dark, heavy lines on the shaft alignment
map represent the designed hot shaft alignment; i.e.,
Axial Separation
collinear alignment. Plot historical or calculated
thermal expansion or contraction change for each
support location on shaft alignment map. Connect
points plotted for each machine with a dashed line.
Use dashed line for desired “cold alignment setting.”

acceptable. Check coupling drawing and coupling Read off differences between the two dashed lines
manufacturer’s drawing and/or instructions for in vertical plane and record desired readings in
precise limits. circles so marked. Plan or horizontal alignment
Figure 17 Axial Separation usually remains unchanged from ambient (cold) of
The reverse indicator method is the recommended

Shaft Alignment
Figure 18 Shaft Alignment Map

Shaft Alignment
! Note ! Note:
For all Rim Measurements
Actual measurement is 1/2 TIR (Total Indicator 1) The DBSE (Distance Between Shaft Ends)
Reading), therefore value of measurement shown on must be established when the motor shaft is
indicator reading circle should be twice the distance of magnetic centre, otherwise it is possible
indicated on plot. the motor bearings can be damaged due to
incorrect end-float.
Offset value is plus (+) if the projected centerline of 2) If a spacer coupling is used fitted with
machine that the indicator is attached to, is above phenolic disks - these must be installed to
coupling mark of the machine that the indicator is ensure correct end float.
riding on. 3) Do not carry out motor alignment if a soft
foot is present.
Refer to coupling alignment chart on TIR figures for A soft foot is movement of the motor foot
different frame sizes. when the hold down bolt is torqued down
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.
Coupling Alignment Chart
All readings are “plus” dial indicator readings. “Plus”
readings are obtained with the compressor indicator
“zeroed” and the indicator pointer originating at the
top of the compressor hub. The motor indicator is
zeroed with the indicator pointer originating at the
bottom of the motor hub.
Model Compressor Hub Motor Hub

Number
T.I.R. Actual T.I.R. Actual
0C 0.020” 0.010” 0.028” 0.014”
1C 0.020” 0.010” 0.028” 0.014”
Figure 19 Pictorial of Note 3 on Shaft Alignment Map 2C 0.030” 0.015” 0.037” 0.0185”
3C 0.050” 0.025” 0.066” 0.033”
4C 0.060” 0.030” 0.076” 0.038”
1ACII 0.010” 0.005” 0.010” 0.005”
2ACII 0.010” 0.005” 0.010” 0.005”
1CII 0.010” 0.005” 0.010” 0.005”
2CC 0.010” 0.005” 0.010” 0.005”
2CII 0.010” 0.005” 0.010” 0.005”
3CII 0.010” 0.005” 0.010” 0.005”
5CII 0.018” 0.009” 0.018” 0.009”
6CM 0.020” 0.010” 0.020” 0.010”
5CCH 0.010” 0.005” 0.010” 0.005”
Figure 20 Pictorial of Note 4 on Shaft Alignment Map 6CCH 0.010” 0.005” 0.010” 0.005”
Tolerances should not exceed +/- 0.002” T.I.R. All
values listed are for cold alignments

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 (only if POP is running) both shafts
together and record dial readings on alignment
Shaft “A” Shaft “B” map at 90o, 180o and 270o positions. On return
to the top position, the indicator should return to
Second Set of Readings
zero. Repeat this step several times to be
certain no mistake has been made or
something has moved.
Read here 11) The accuracy of the readings may be verified
by algebraically adding the side readings and
comparing this sum to bottom reading. The
readings should be equal to or within 1mil
Shaft “A” Shaft “B”
(0.03mm).
Figure 21 Reverse Indicator Readings 12) Remove the bracket from shaft “A” and install
on shaft “B”. Using the same procedure obtain
3) Lubricate bearings before rotating shaft. indicator readings from shaft “B” to the rim of
coupling hub “A”.
4) Mark both the coupling hubs at four locations 90o
apart so that their position can easily be seen at 13) Using the two equations shown on the
all times during the alignment work. suggested shaft alignment map, calculate the
vertical offset (Vo) and the horizontal or plan
5) All piping strain must be removed from the
view offset (Ho). Plot these results in the proper
equipment. For initial alignment work during
installation, all piping should be left unconnected view and in the axial location where indicator
from machinery. After cold alignment has been readings were taken. Note 3 or 4 on the
alignment map can assist in determining the
secured, arrange dial indicators between shaft
shaft location above or below other shaft.
ends, to detect any movement of the equipment.
Connect one flange at a time and observe
indicator readings continuously. Should

Shaft Alignment
When making this determination, it is Hot Alignment Check
sometimes helpful to locate the centerline of A hot alignment check can be made after the
shaft end “B” first that is shaft end of machine to compressor has operated for several hours and
be moved and then the projected centerline of stable operating temperatures have been reached.
shaft end “B” at shaft end “A”. In this This check will indicate any final adjustments
explanation shaft end “A” is fixed and therefore necessary to achieve collinear alignment of the
shaft “B” must be located relative to shaft “A”. driver and compressor under operating conditions.
! The purpose of the hot alignment procedure is to
Note measure the movement of one shaft and relative to
Correct the bottom for sag in the bracket by the opposite shaft end. As the shaft rotates, it is not
algebraically adding to the bottom indicator reading. practical to measure the actual position of one shaft
No correction is needed on the side readings since it and relative to its companion with dial indicators, or
is negative on both sides and will cancel out. similar instruments, as was the case during the cold
alignment procedures.
Therefore, most hot alignment procedures make the

14) In each view draw a straight line through points assumption that the machine casing and bearing
located in Step 13, extending the line to housing expand uniformly in a radial direction from
intersect both supports of machine “B”. Read off the shaft center of rotation and maintain this
the distance between line just completed and relationship to the shaft center regardless of the
the desired cold shaft position (dashed line) at casing temperature.
each support for machine “B”. This
measurement represents the movement This basic assumption appears to be valid as
necessary to obtain the correct cold alignment. compressors and turbines are nearly symmetrical
about the shaft; therefore, distortions are minimised.
15) Make the adjustments indicated in Step 14.
Using this principle, the following method may be
16) Repeat Steps 7 to 14 to verify the adjustments used to make a hot alignment check.
made in Step 15 were correct.
17) Unless otherwise noted, a final hot alignment The mechanical hot alignment method uses
should provide for an angular displacement accurate measurements between fixed reference
between the machine coupling hub centerlines points on the baseplate and the machinery bearing
and coupling spaces centerline of housings to indicate shaft movement between
approximately 0.25 mil per inch (0.25 mm/m) at ambient and normal operating conditions. This
the coupling gear teeth or flex elements. This method assumes that the fixed reference points do
angular displacement is not a limit but a not move between cold alignment conditions and
suggested alignment goal. Refer to the coupling machinery operation.
literature for more information on maximum
allowable misalignment. In general, this is a good assumption provided one
side or area of the baseplate is not exposed to direct
After cold alignment has been made, the baseplate sun when the other is not. Unprotected hot steam
must then be grouted. and process lines passing in close proximity to the
baseplate can also contribute to uncertainty in
incremental movements.

Shaft Alignment
Thermal Growth Offset

Final alignment (hot standard units)
When the compressor and motor are warmed up
(minimum of 2 hours), the final alignment must be
rechecked and values recorded.
In hot conditions, the final alignment must have no

vertical or horizontal offset and coupling hubs must
be parallel.
Alignment API unit and/or unit with external

coolers
1) Use a cold alignment of +0.00 / -0.13mm vertical
center line offset (set motor low), and 0.13mm
vertical center.
2) Run the unit for a minimum of 2 hours under load
and do a hot alignment check.
3) Verify that the vertical alignment is within +0.00 / -
0.05mm
4) Horizontal offset should be plus or minus
0.02mm.
Turbine Driven Hot alignment

Vertical center line, horizontal center line offset and
coupling hub face must be 0.0mm.
!
Note
On units operating without an aftercooler, it is a
standard practice to increase the vertical center line
offsets stated above. For distance between hubs,
see the General Arrangement Drawing.

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 analyzing 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.
Cold Alignment Standard Units

Centac Radial Readings Horizontal Coupling
Frames Vertical Center-Line Offset Center-Line Offset Hub Face
(motor high) (mm) (mm)
(mm)
Centac II
Frame 1/1A 0.10 0 0.05
Frame 2/2A CII 0.15 0 0.05
Frame CV2/E 0.15 0 0.05
Frame 3ACII 0.15 0 0.05
Frame 5CII 0.20 0 0.05
Centac I
Frame 0 0.10 0 0.05
Frame 1 0.15 0 0.05
Frame 2 0.20 0 0.05
Frame 3 0.25 0 0.05
Frame 4 0.35 0 0.05

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?
6. What is a soft foot?

Shaft Alignment
Short Test
7 Why must the motor shaft be at magnetic center when alignment is carried out?
8 What are phenolic disks used for on spacer couplings?
9 What is DBSE and why is it so important?

Shaft Alignment Software
Introduction In aligning the coupling, the distance between the

Reversed Indicator Alignment is an alignment compressor shaft must be set as per the General
method which uses two dial indicators spaced 180 Arrangement Drawing. On motor driven units, the
degrees apart. One indicator is attached to the motor must be positioned on the baseplate so that
shaft of the compressor while the other indicator is the motor is allowed to run on its loaded magnetic
attached to the driver. The indicator attached to the center while coupled.
compressor shaft reaches over to the driver shaft
so that the dial plunger touches the driver hub. The Basics of Reversed Indicator Alignment
indicator attached to the driver shaft reaches over The following basic steps should be followed before
to the compressor shaft so that the dial plunger you begin the actual shaft alignment portion of your
touches the driver hub. installation.
This shaft alignment program uses readings taken

1) Safety first. Driver switch gear (or valve) must
from these two indicators to quickly and accurately
be locked out.
calculate the vertical and horizontal movement
required at the driver's front and rear feet. 2) The Centac should be level and grouted with all
anchor bolts tight.
3) The compressor mounting bolts must be tight
! Note with the compressor doweled to the baseplate.
If alignment is off by a large amount, 15 - 20 4) The driver feet and the driver baseplate must
thousandth of an inch, then reverse indicator be clean and free of burrs.
alignment needs to be run again.
5) All shims must be clean and free of burrs.
Stacks of thin shims should be placed
Set Up with two or three thicker whims to avoid a
The Centac is furnished with a limited end float gear spongy shim stack.
type spacer between the driver and the compressor
6) The driver mounting bolts should be hardened
on the motor driven units. Turbine driven units are
(grade 5 or higher) and the washers must be at
supplied with the same type coupling without the
least 1/4" thick, so the washers will not bend
limited end float feature. The total axial float on
when the bolts are tightened.
motor driven units is limited to approximately three
sixteenth (3/16) of an inch (4.8mm) by a phenolic 7) Jacking bolts should be installed to aid in
disc located in the coupling system. horizontal alignment. The jacking bolts should
be completely loose during final alignment
Before proceeding with coupling alignment, check check.
the unit to see that it is level. The unit must be level 8) The indicator brackets must be made very rigid
and grouted before final alignment of the and must be bolted securely to the coupling
compressor shaft coupling hub. hubs as shown above.
9) The actual shaft center line offset is 1/2 the
Attach one dial indicator to the compressor shaft
Total Indicator Reading (T.I.R.).
and one indicator to the motor shaft. The two
indicators should be 180 degrees apart. 10) On frames 0C, 2C, 3C, and 4C, the indicator
readings are to be taken with motor,
On some models, holes are not provided in the compressor and oil at ambient temperature.
coupling hubs. On these units a spacer should be Turbines should be preheated before taking
placed between the end of the driver shaft coupling readings.
hub and the indicator bracket with the bracket 11) On all CII's and ACII's, oil should be preheated
bolted to the coupling sleeve. The spacer should to 110oF and circulated at least one hour
be of sufficient thickness to eliminate any before starting alignment. Also, be sure the
movement in the coupling sleeve after the indicator cooler housing supports are in contact with the
is bolted to the sleeve. cooler housing after the oil is hot.
! Note ! Note
Remove Bullgear Antirotation Pins on Model If alignment is off by a large amount, 15 - 20
C60 to C150. thousandth of an inch, then reverse indicator
alignment needs to be run again.

Procedures for Reversed Indicator Gather six indicator sweep readings

Both shafts must be rotated together so that the
Alignment indicators are always 180 degrees apart.
The following steps should be followed when
conducting your alignment using the reversed Position of Indicator Readings
indicator method. Indicator “A” T3=0 T4
Compressor R3 R4
1) Position the driver to obtain correct spacing Shaft L3 Driver Shaft
between the shafts, as specified on the general L4
arrangement drawing. Sleeve bearing motor B3 B4=0 Indicator “B”
shafts must be on magnetic center during this
step. Mechanical center and magnetic center 1)
Position Indicator 'A' on top of compressor hub
should be the same. and zero the indicator. In this position, Indicator
2) Mount the brackets as shown in the figure 'A' is reading point "T3" so "T3=0".
below. Tighten driver mounting bolts. 2) Position Indicator 'B' at the bottom of driver hub.
3) Check for a soft foot by releasing one bolt at a and zero the indicator. In this position, Indicator
time and checking indicator movement. 'B' is reading point "B4" so "B4=0".
4) Retighten the bolt before checking the Indicator 'B' shows
next foot. Each foot should have no amount of shim 3) Rotate both shafts together 90
more than .002 inch movement. needed to correct a degrees clockwise (direction of
soft foot at Foot #1 compressor rotation).
(the motor foot closest Indicator 'A' is now at the "R3"
Bracket Arm
to the shafts. It is the position and Indicator 'B' is at the
near foot). "L4" position.
Alignment
Bracket Record the "R3" and "L4" readings.
Dial
Indicator 4) Rotate both shafts together another
Hub “B” 90 degrees clockwise
Indicator 'A' is reading point "B3"
and Indicator 'B' is reading point
Compressor
Shaft Driver Shaft "T4".
Record these readings.
5) Rotate both shafts together another
Coupling
Sleeve
Dial 90 degrees
Indicator Indicator 'A' is reading point "L3"
“A”
and Indicator 'B' is reading point
"R4".
Record these readings.
Indicator “A” is the dial indicator whose
plunger touches the compressor shaft. It
indicates the amount of shim needed to You should now have six indicator readings:
correct a soft foot at Foot #2 (which is the • three off the Indicator 'A' and
motor foot furthest from the shafts. It is the • three off of Indicator 'B".
far foot).
The readings that you should have recorded are (see
5) Release all driver mounting bolts. figure above):
6) Bring the shafts into approximate horizontal
alignment using the jacking bolts and reading Indicator Indicator
Indicator 'A' and Indicator 'B' side to side. “A” “B”
T3=0 B4 = 0 Indicators zeroed in vertical position
7) Keep in mind that both shafts must be rotated
R3 L4
together and actual offset is 1/2 TIR. B3 T4
8) Correct Indicator 'B' offset by adjusting Foot #1 L3 R4
jacking screws and correct Indicator 'A' offset
by adjusting Foot #2 jacking screws. Leave all
4 jacking screws touching the driver, but not The final three inputs that you will need are "D1", "D2",
tight. and "D3". All three of these measurements must be in
inches.
9) Tighten mounting bolts.

• "D1" is the distance between the two plungers
on the indicators.
• "D2" is the distance from the plunger on
Indicator 'A' to the center line of the bolt at Foot
#1 on the driver.
• "D3" is the distance from the plunger on
Indicator 'A' to the center line of the bolt at Foot
#2 on the driver.
Make sure these readings are very accurate.
Alignment Setup
Indicator MOTOR
“A” T3=0
Compressor Motor
Shaft Shaft
B3=0 Indicator
“B”
Feet #1 Feet #2
Near Far
D1 (inches)
D2 (inches)
D3 (inches)

Data Required for Program Calculations Desired Readings - Thermal Growth Offsets
This alignment program requires you to input nine This section answers the question, "What should the
different readings and measurements for indicators read when the machine is aligned to
calculations: compensate for thermal growth?"
• D1 is the distance in inches between the two In this alignment program, the user selects the model
plungers of the indicators. of the compressor that he will be aligning. The
program automatically inputs eight (8) numbers for
• D2 is the distance in inches from the plunger of what the two dial indicators should read when they
dial 'A' (touching the compressor shaft) to the are swept simultaneously around the shafts.
Foot #1 (near foot) of the motor. D2 is always
less than D3. These eight readings are called desired state sweep
• D3 is the distance in inches from the plunger of readings at ambient conditions. Since alignment is
dial 'A' (touching the compressor shaft) to the not done when the unit is completely hot, the dial
Foot #2 (far foot) of the motor. indicators should not read zero when swept around
• T3 is the dial reading, in thousandths inch, at the the shafts when the unit is cold.
top of the compressor shaft. T3 is set to zero!!
• R3 is the dial reading, in thousandths inch, at the If the alignment could be done when the unit was as
right side (90 deg clockwise-direction of hot as it is when running, then the desired state
compressor rotation-from top) of the compressor sweep readings would all be zero. If all the
shaft. indicators read zero when swept, when the unit is
cold, the unit would be in perfect cold alignment, but
• B3 is the dial reading, in thousandths inch, at the would be misaligned after the unit became hot and
bottom of the compressor shaft. thermal growth occurred.
• L3 is the dial reading, in thousandths inch, at the
left side (270 deg clockwise-direction of
compressor rotation-from top) of the compressor
Repairing and Compacting Database
shaft.
Repair Database menu option
• T4 is the dial reading, in thousandths inch, at the This menu option repairs and compacts the
top of the driver shaft. language and report databases. Overtime the
• R4 is the dial reading, in thousandths inch, at the databases could become fragmented and this
right side of the driver shaft (180 deg opposite fragmentation decreases performance. So, from
reading R3). Take these readings at the same time to time you should click this menu option to
time. compact the databases, this will restore performance
• B4 is the dial reading, in thousandths inch, at the lost to fragmentation.
bottom of the driver shaft. B4 is set to zero!!
Also, if the database is left invalid by an incomplete
• L4 is the dial reading, in thousandths inch, at the
write operation the Repair Database menu option will
left side of the driver shaft (180 deg opposite
validate the system tables, indexes and repair the
reading L3).
invalid record, then compact the database. An
incomplete write operation can occur if the
Take these readings at the same time.
application quits unexpectedly because of power
failure or computer hardware problems.

Glossary of Terms CENTAC Software: Shaft Alignment

To install the software,
Reversed Indicator Alignment • Insert the CD into the drive
A method of alignment which uses two dial • Type win ?:/setup
indicators 180 degrees apart. More accurate and (? = the letter of your CD drive)
quicker than the single dial alignment method.
The following is a list of the files added to your
Spongy shim stack system by the setup program.
Springy, non- firm effect that using many thin shims
gives. Use as few thin shims as possible. Files added to Windows system directory:
D3 CRYSTAL.VBX
Is the distance, in inches, between the plunger on CRPE.DLL
Indicator 'A' to the centerline of the bolt at Foot #2 CRXLATE.DLL
(Far Feet) on the driver. Required for the program COMMDLG.DLL
calculations. THREED.VBX
MSAES110.DLL
D2 MSAJT110.DLL
Is the distance, in inches, between the plunger on VBDB300.DLL
Indicator 'A' to the centerline of the bolt at Foot #1 PDBJET.DLL
(Near Feet) on the dirver. Required for program PDIRJET.DLL
calculations. PDCTJET.DLL
MSABC110.DLL
D1 SHARE.EXE
Is the distance, in inches, between the two plungers MSAJT112.DLL
of the dial indicators. Required for the program MSAJT200.DLL
calculations.
Files in application directory:
TIR
Total Indicator Readings is the difference of the SHAFAL.EXE
vertical readings or the difference of the horizontal ALHELP.HLP
readings on an indicator. For example, if R3 = 5 REPORT2.MDB
and L3 = 3, the the TIR = 2. SHAFT.RPT
VSHARE.386
Foot #1
Is the motor foot closest to the shafts. It is the near To uninstall this application, delete all the files in
foot. the application directory. However, be careful
about deleting files from the Windows system
Foot #2 directory as other applications could need them to
Is the motor foot furtherest from the shafts. It is the run. The files
far foot. in the windows system directory could have been
there before this application was installed and
Zero unless you know for certain they were not, do not
Be sure to zero both indicators. Zero indicators in delete them.
the vertical positions as specified the procedures for
reversed indicator Alignment. SHARE.EXE may be needed for file sharing, but try
running the application(s) without SHARE.EXE.
Indicator 'B" However, if sharing violations occur then add the
Refers to the dial indicator whose plunger touches following line to your AUTOEXEC.BAT file:
the driver shaft.
<PATH>SHARE.EXE /L:500
Indicator 'A'
Refers to the dial indicator whose plunger touches
the compressor shaft.
Rotate
Always rotate both shafts together in the direction of
rotation when the machine is running.

Notes

Basic Centac Manual
Commissioning
Section 6
Pre-Start Checklist......................................................1—3
Initial Start Preparation ...............................................4—6
Natural Surge Testing.................................................7—8
Installation Checklist...................................................9
Short Test ...................................................................10
Start Up Registration Form.........................................11—16
Warranty and Limitation of Liability.............................17—19
Short Test ...................................................................20

Commissioning Section 6
Pre-Start Checklist
Checklist Summary
! Note
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.

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

Ideally there should be a one-to-one ratio between
the pressure developed by the compressor and the
discharge capacity.
The Pressure-Flow Plot gives a
linear pressure output for a given
100% flow condition. It does not account
for losses in a compressor.
Pre
ss ure
-Flo
w
PSIA
Plo
t
What Can We Really Use?

When dealing with a centrifugal air compressor only
a portion of the Actual ressure Plot or Natural Curve
can be used effectively to operate the compressor.
Losses
Inlet (CFM) If the flow in a centrifugal air compressor becomes
0 100%
Actual Pressure Plot accounts too low, a condition called surge will result.
for losses in a compressor.
Also if the flow is too high, the compressor will go
into a choke condition.
Therefore the Pressure-Flow Plot would give a linear
pressure output for a given flow condition. However, Both of these conditions are not ideal for operating a
this is ideal and does not account for the losses that centrifugal air compressor, thus limiting the useful
occur in real life. operating range for the compressor.
Typical losses in a centrifugal air compressor are: 100%
Friction
All rotating parts encounter friction of some type.
Restrictions
PSIA
When you have a fluid flowing through passages,

CHOKE
such as air through an air compressor, it will When the
encounter small passages or turns in the piping or flow is too
components. high, it will
result in a
Choke
Heat SURGE condition.
When air is compressed, heat is generated and this When the flow in
energy is lost. a compressor is
too low, it will
result in surge. USEFUL OPERATING
The Actual Pressure Plot, better known as Natural
Curve, accounts for these losses and is no longer RANGE
The actual operating range is
linear in nature. limited.
0 FLOW 100%

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 CYCLIC SURGE MODEL (LARGE VOLUME
necessarily detrimental to centrifugal air
compressor, repeated surging (called
Pumping) can be detrimental.
J P
This should be avoided for the safe
operation of a centrifugal air compressor
K Q
PSIA
- FLOW O + FLOW
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 are 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

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 to
patent or latent, in the manner and for the period of 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

Short Test
1 How many days should a new Centac compressor be stored for?
2 How and where should a new Centac compressor be stored?
3 How many months warranty period is given on a compressor from date of

shipment?
4 Which ‘Form’ must be completed after a new Centac compressor is

commissioned?

Notes

Basic Centac Manual
1CV Airend
Overhaul
Section 7
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—18
Short Test ...................................................................19

Airend Overhaul Section 7
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.

Issue: 01/Australia, uly, 2003 Page 7
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. If you see this label:
system to 7 PSIG. Test the circumference of
the vane plates using a soap and water or ATTENTION
leak detecting liquid on all stages. Test all
bolt and other plate penetrations for air Impeller in this box must be preloaded during
leakage. assembly to assure proper balance.
2) Test the seal air inter-lock with the prelube PRELOAD: Turn impeller opposite the direction of
pump starter to assure it is functioning rotation before torquing to match mark.
properly. Correct any discrepancy.
3) Verify all lube oil piping has been correctly QC-90 (11/19/90)
installed. Untag and energize controller
control power to the prelube pump. Start the Follow the procedure for Pre-loading:
prelube pump. Record oil temperature and 1) Lock the bullgear to prevent the pinion
pressure. turning when the impeller bolt is tightened.
4) Inspect the lubricating oil system for leaks. 2) After the impeller is installed on the pinion,
Inspect the area of the pinion air seal for any but before tightening the impeller bolt;
signs of oil migration. Inspect the gull gear
casing cover for any signs of oil leakage α) Grasp the impeller and
through the split line. rotate it in the opposite
direction of its powered
5) Allow the system to operate for a minimum rotation. This is the same
of one hour. Thoroughly inspect for leaks direction (CCW) as the
after the one-hour run time. Correct any impeller bolt tightens.
leaks.
β) While holding the impeller
6) Stop the prelube pump at the completion of over the CCW direction, tighten the bolt to
the satisfactory oil leak test. De-energize the match mark.
and retag the control power system. Shut off
the seal air. The impeller is now property installed.
7) Remove the thrust bearing covers when you
are finished with leak checking and continue Preloading the impeller closes any clearance
with the assembly. that may exist between the impeller and pinion
mating surfaces.
22 Install the clearance setting bracket to push and
hold the pinion toward the impeller end. Refer to Preload
the Impeller/Diffuser Clearance Setting
Procedure.
Preload
23 Lightly apply Tiolube 70 to the impeller polygon,
as recommended in the Field Service Manual.
24 Align the match marks and slide the impeller into
the pinion. With no preload With preload
NOTE: This sketch illustrates the reason for pre-
loading. The impeller to pinion fit up is greatly
27 Remove the clearance setting bracket installed

in step 12. Push the rotor assembly toward the
thrust end with the thrust bearing. This
procedure is intended to get the impeller out of
the way of the diffuser.

28 Install the diffuser, using M10 x 125 mm studs
to help facilitate installation. Tighten the bolts 32 Check the induction tip clearance
until the lockwashers just close.
33 Move the diffuser to achieve proper clearance.

The diffuser can be slightly tighter on the bottom
29 Install diffuser cap screws. (0.001”).
30 Tighten cap screws to specified torque.

34 Install the dial indicator to check the total axial
travel.
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.

36 Ensure the inactive button bearing adjustment 40 Install the cleaned moisture separator screens
screw is backed out. in the cooler casing(s). The fine screen goes in
37 Install the bearing cover. 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
38 Tighten up the bolts until the lock washers just 42 Install the inlet and bypass valves, bypass pipe
close up. and all instrumentation.
43 Install the vibration probe.
44 Reconnect any wiring and/or tubing to the

devices on the casing.
45 Supply seal air and set seal air pressure to 7 to

9 PSIG.
46 Turn on the power to the control panel. This will

start the pre-lube pump so that the machine can
39 Tighten the inactive adjustment screw, pushing be safely rolled over by hand. The re-assembly
the rotor assembly toward the diffuser until the is complete.
screw stops turning.
47 Adjustment of the vibration probes and other
controls will be necessary.
48 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.

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 1CV 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?

Notes

Basic Centac Manual
Airend Overhaul for
Models C250/C350
Section 8
Disassembly of Stage Components ...........................1—10
Disassemble the Bullgear...........................................11—13
Re-assemble the Bullgear ..........................................14—17
Re-assemble the Stage Components.........................18—26
Setting Rotor Assembly Clearances...........................27
Impeller/Diffuser Clearance Setting Procedure ..........28—31
Installing the Coupling ................................................32

Airend Overhaul C250/350 Section 8

• To disassemble the stage components
• To remove the Bull Gear from the casing
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.
2 Ensure that there is no power to the control

panel.
3 If necessary, tag the tubing and/or wiring to

facilitate reconnection
4 Rig for lifting. Make sure that you use an

adequate weight handling technique.

5 Remove all coolers • Quickly heat the coupling hub to 300oF - 400oF
6 Disconnect the tubing and/or wiring to any device (150oC-204oC).
on the cooler housing. • Two oxy-acetylene torches with “Rose Bud” tips
work best for rapid heating.
7 Remove Inlet Valve, By Pass Valve, Check Valve,
Filter housing and other necessary components. • Use one torch to sweep over the keyway and
the other torch to sweep the bottom and sides.
• Turn the puller Pull Bolt to remove the coupling.
• Keep the flame off the hub teeth.
8 Remove the coupling with a puller and heating

torch.
9 Remove the Seal Air Pipe from all stages, before

removing the Rotor Assembly, Diffuser and De-
swirl ring.
Procedure for Removing a Coupling
#1 Heating Torch
Sleeve
10 Remove the vibration probe cable.

½” to ¾” Plate
Pull Bolt @ 1” Drive

Shaft
Attachment Bolts Key
Hub
#2 Heating Torch

11 Remove the vibration probe. 14 Loosen the jamb
nut and remove the
set screw to prevent
damage to the thrust
bearing during
reassembly.
12 Make sure that the vibration probe is kept in a

safe place.
13 Install the Bullgear Lock Bolt before removing the

Rotor Assembly. A hardened bolt is best.
Note: During installation, install the set screw

and jamb nut. Screw in the set screw as far as
it will go, (do not force it) back off 1/4 turn. Lock
the jamb nut against the cover. This will set the
inactive thrust clearance.
15 Stage Removal.
Remove the thrust bearing cover.
The Bullgear lock bolt will ensure that the bullgear

does not turn when loosening the impeller bolt.

16 Place the thrust bearing cover on a work bench. 19 Remove the three (3) thrust bearing bolts and
shims.
Note: Install one bolt, a couple of turns, to protect

The Inactive Thrust the bearing from possible damage when removing
Bearing is in the Thrust the impeller.
Bearing cover.
20 Before removing the Diffuser and De-swirl Ring
• Record the pressure tip (Y) Clearance
17 The Thrust Bearing can be accessed when the • Record the Total Axial Float Clearance
thrust bearing cover is removed. • Record the Volume Tip (Z) Clearance
• Record the De-swirl Ring Clearance
18 Loosen the thrust collar bolt, but do not remove it

until you are ready to remove the thrust collar.

Record Pressure Tip (Y) Clearance Volume Tip (Z) Clearance

21 Install the Dial Gauge and push the rotor 23 Push the rotor assembly until it touches the
assembly toward the diffuser, until it touches the diffuser. Use the feeler gauge to check the
diffuser. clearance at four points; top, bottom, left and
right.
Record the pressure tip (Y) clearance.
Record the Volume Tip (Z) Clearance
Top
Left Right
Bottom
Record the Deswirl Ring Clearance

24 Use the feeler gauge to check the four points; top,
bottom, left and right.
Check Total Axial Float Clearance
Record the Deswirl Clearance to the casing.
22 Install the dial gauge at the impeller. Push the
rotor assembly to the back and check the Total Top
Axial Float Clearance
Record the reading.
Left Right
Bottom

25 Loosen the bolts holding the Deswirl Ring and the 27 Slowly remove the Deswirl Ring from the Diffuser.
Diffuser.
28 Slowly remove the Diffuser form the casing.
26 Remove the nuts and washes, there could be 5 -

8 studs depending on the stage).
Leave the three bolts, that hold the Diffuser and

Deswirl Ring together, in place.
29 Check the Deswirl and Diffuser Mark.
Remove the jacking jolts.

30 Remove the spacer plate at the 3rd Stage. Impeller Removal
32 Loosen the impeller bolt. Remember that this is a
left-hand thread.
There is an
‘O’ Ring at
the back of
the spacer 33 Remove the impeller bolt.
plate.
31 The impeller is now visible
34 Use isopropy alcohol to clean the pinion bolt

threads.
35 Use air to clean the pinion threads.

36 Use the special tool to 39 Use a spanner, if necessary, to ensure that the
remove the impeller. removal tool is tightened to the end of the pinion
threads.
This special impeller
removal tool can be
used for all stages.
Impeller Removal Tool
Rotor Removal
40 Install the rotor removal tool in the rotor bolt.
37 Position the removal tool to tighten it to the pinion Tighten the tool until it bottoms out.
shaft; note the left-hand thread.
41 Push the rotor towards the thrust bearing, as far

as it will go.
42 Strike the end of the tool with a three pound

hammer. This will break the impeller loose from
38 Continue to tighten the tool until it reaches the
the taper on the pinion. The tool will prevent the
bottom of the pinion shaft threads.
impeller from falling.

43 Hold the impeller firmly in one hand. With the 46 Remove the thrust
other hand, unscrew the impeller removal tool. collar bolt.
Install a 5/16-18 stud

in the thrust end of the
pinion.
Push the pinion out of

the collar.
Be careful, do not drop

the pinion.
47 Remove the three cap screws to remove the plain

bearing.
Stage Removal
44 Remove the bolt in the thrust bearing flange.
Slowly slide the bearing, with the pinion,
backwards out of the line bore.
Thrust 48 Install the plain bearing puller.

Bearing
49 Use the puller to remove the plain bearing.
45 Place the pinion and thrust bearing on a

workbench. Do not drop the pinion.

50 Place the plain bearing and jacking plate on a
workbench.
51 Remove the cap screws before removing the

carbon seal from the plain bearing.
52 Slowly jack out the carbon seal.
The carbon seal after removal from the plain

bearing.

Disassemble the Bullgear
Remove the Bullgear Disassembly of the Bullgear

53 Remove the coupling key at the bullgear shaft. 55 Remove all bullgear cover bolts.
56 Jack the bullgear cover out of the bullgear

housing using the jacking bolt.
54 Remove the bullgear shaft seal cover bolts.
57 Lift the bullgear cover.
To reveal the
bullgear shaft.
To reveal the
bullgear

58 Lift up the bullgear. 61 The drain back tank. The oil passes through the
oil passage to lubricate the bullgear gearing,
pinion bearing and all moving parts.
59 Remove all
cap screws
before
removing the
buckets. 62 Remove the cap screws to remove the bullgear
bearing from the bullgear casing.
Cap screw with

special washer.
The special washer

with seal.
60 Remove the bucket from the bullgear housing.
63 Slowly jack the bearing out.
The bucket with rabbet fit, no pins.

64 Place the bullgear bearing on a workbench.
65 Remove the cap screws to remove the bullgear

cover.

Re-assemble the Bullgear
4 Tighten the bearing with the cap screws and use
In this section, you will learn 271 Loctite.
• Re-assembly of the bullgear into the casing
• Re-assembly of the stage components
• Impeller and Diffuser Clearance settings
! Note
Make sure that all bolts use 271 Loctite when
re-assembling the Airend.
1 Install the new bearing into the bullgear cover

5 Make sure that the line bore was thoroughly
casing.
inspected.
Thoroughly clean the oil

passage with isopropy
alcohol and blow with
air until the passage is
free of foreign material.
6 Before assembling the bucket back into the

bullgear housing, clean the rabbet fit with
2 Install the bullgear bearing back into the bullgear isopropy alcohol.
casing.
7 Clean the bullgear housikng with isopropy

3 Make sure that the oil holes are at the bottom. alcohol.

8 Apply 515 Loctitle gasket. 12 Clean the cap screws with isopropy alcohol
before applying 271 Loctite.
13 Tighten all the cap screws.
9 Make sure that the bucket face is clean before

assembling it back into the bullgear housing.
14 Clean the bullgear housing before re-assembly.

Stone any suspected proud spots on the casing.
10 Lift up the bucket and install it into the bullgear

housing.
15 Inspect the bullgear and make certain that it is in

good condition.
11 Make sure that all the special washers are

replaced.

16 Assemble the bullgear into the bullgear housing. 20 Torque the cover bolts to 250 ft/lb
21 Make sure the bullgear shaft is clean.

17 Apply the 515 Loctite
gasket.
22 Use the special tool, that comes with the Seal Kit,
to install the bullgear seal.
18 Assemble the bullgear cover into the bullgear

housing.
23 Install the bullgear seal cover.
19 Slowly lower the bullgear cover with the jack

screws.

There are two types of bullgear shaft seal. Check the bullgear float clearance, which
Single Lip Seal should be .035”-.044”.
Oil Side
Bullgear Shaft
Double Lip
Hydrodynamic Seal.
25 Install a dial gauge to the bullgear shaft.
The hydrodynamic
pumping effect of the
seal is created by the
rotation of the Bullgear Shaft
bullgear shaft
on the thread like
surface of the sealing
lip. Lubricant, that has migrated along the shaft,
will be forced back into the casing through this
pumping action.
24 Tighten all of the seal cover bolts.
26 Using a chain or wire cable, lower and lift the

bullgear. Check that the float clearance is
between .035” - .044”.

Re-assemble the Stage Components
The Rotor Assembly after balancing. 29 Install the thrust bearing onto the pinion
26 Before assembly, check the pinion with a Gauss

Gauge. The maximum allowable is 2 gauss. Gauss
can be added or subtracted to the vibration reading 30 Spray the Tiolube 70 Lubricant to the thrust collar
on the panel. at the pinion seat
27 Check the impeller with the Gauss Gauge. 31 Apply the Tiolube 70 Lubricant to the pinion shaft
o
28 Heat the thrust collar to about 200 F
32 Remove the thrust collar from the heater. You must

wear protective clothing.

33 Install the thrust collar onto the pinion, aligned at Install the carbon seal to the plain bearing.
the mach marks.
34 Clean the bolt with isopropyl alcohol before

applying 271 Loctite to the screw.
36 Before installing the plain bearing, make sure that

the seal air pipe thread is OK.
35 Tighten the thrust collar bolt and match the mark

on the thrust collar.
37 Install a new ‘O’ ring and apply some ‘O’ ring

grease onto it.

38 Align the carbon seal to the plain bearing 41 The thrust bearing and pinion, to be installed to the
Bullgear housing.
39 Tighten the carbon seal to the plain bearing with

the cap screw. 42 Thoroughly clean and inspect the bullgear housing
and linebore. Install the studs to align the plain
bearing to the linebore.
43 Slowly push the plain bearing into the bullgear

housing.
40 Check the initial gap between the impeller and the

pinion. It should be .018” - .035”
44 Make sure that the plain bearing ‘O’ Ring is OK.

Align the plain bearing to the seal air pipe.

9 How the plain bearing looks after being installed
β) While holding the impeller
into the bullgear housing.
over the CCW direction, tighten the bolt to
the match mark.
The impeller is now properly installed.
Preloading the impeller closes any clearance that

may exist between the impeller and pinion mating
surfaces.
Preload
Preload
45 Make sure the bolts are cleaned with isopropyl
alcohol and apply 217 Loctite.
46 Tighten the cap screws to the bullgear housing With no preload With preload
NOTE: This sketch illustrates the reason for pre-
loading. The impeller to pinion fit up is greatly
48 Use the pinion to align the carbon seals.
47 Preload the Impeller. If you see this label:
ATTENTION 49 Clean the linebore

with isopropyl
Impeller in this box must be preloaded during alcohol.
assembly to assure proper balance.
PRELOAD: Turn impeller opposite the direction of

rotation before torquing to match mark.
QC-90 (11/19/90)
Follow the procedure for Pre-loading:

1) Lock the bullgear to prevent the pinion turning
when the impeller bolt is tightened. 50 Slowly install the pinion into the plain bearing.
2) After the impeller is installed on the pinion, but
before tightening the impeller bolt;
α) Grasp the impeller and
rotate it in the opposite
direction of its powered
rotation. This is the same
direction (CCW) as the
impeller bolt tightens.

51 Make sure that you do not damage the carbon 54 Install the bullgear lock bolt.
seals.
55 Install the bracket to push the pinion forward.
52 Tighten the cap screws after installing the thrust

bearing.
56 The pinion is now installed to the plain bearing and

it is ready to install the impeller.
53 Remove the plug at the bullgear housing
57 Use Tiolube 70 Lubricant

Stage Assembly 61 Install the impeller with the mach marks aligned.
58 Clean the impeller with isopropyl alcohol and a lint

free cloth.
62 Wiggle the impeller back and forth until the feet of

59 Match the mach mark
the keys contact.
on the back of the
Impeller, Key keeper
with the mark on the

pinion.
Pinion
Key
63 How the impeller should be fitted onto the pinion.
60 Slowly align the mach marks on the impeller and

pinion.
64 The impeller fitted to the pinion.

65 Hold the impeller with one hand, after engaging the Assembly procedure for the Deswirl Ring
slots on the ‘keeper’ preload impeller. Screw in the
bolt with the other hand. and Diffuser
Diffuser
Deswirl Ring
68 The word TOP is stamped on both the Diffuser and

Deswirl Ring.
66 Tighten the bolt to align the mach marks. Use 271

Loctite.
69 Use TOP to fit the two together and also to align

them in the compressor.
Mach marks
67 Clean the diffuser housing with isopropyl alcohol 70 Install the 3 hex head cap screws with lock
before installing the diffuser and deswirl ring. washers. Snug these bolts, do not tighten them.

71 Install the three centering bolts, hex-head cap 74 Snug the three studs for the diffuser.
screws with jamb nuts.
75 Center the diffuser carefully. Clearances are tight,

so use care. After centering the diffuser, tighten the
diffuser nuts and re-check clearances.
72 Install the diffuser & deswirl ring assembly into the
compressor, using “top” as a guide to locate the
assembly onto the studs.
76 Now center the deswirl ring using the same

method. Tighten the stud nuts on the deswirl, after
setting clearance. Tighten all nuts and bolts and re-
check clearances.
73 The assembly sits on the studs. Now install the flat

washes, lock washers and nuts.

77 Double check all clearances, then tighten all cap 3rd Stage
screws and nuts.
80 Place a new ‘O’ Ring in the 3rd Stage.
81 Install the spacer before installing the Diffuser and

Deswirl Ring.
78 Back off the centering bolts.

Lock the jamb nuts
Then remove the centering bolts entirely, if
desired.
79 The completed Diffuser and Deswirl Ring

Assembly in the casing.

Setting Rotor Assembly Clearances
Total Axial Float of the Pinion 3 Use a feeler gauge to check the clearance at four
points, as shown on the following diagram.
Check the total axial float of the pinion.
B a ck o f Im p elle r in con tact with C asing
The clearance must be the same at the Top, on the
Left side and on the Right side. The bottom can be
slightly tighter 0.001”.
Top
Left Right
T o ta l axia l floa t of p inion
1 Install a dial gauge. Carefully push the rotor

Bottom
assembly towards the diffuser, until it touches the
diffuser.
Use the 3 Deswirl jacking screws to adjust the
clearance.
Tip (Y) Pressure clearance

4 Set 3 dial gauges to check the pressure Tip (Y)
clearance.
4 th Dial if used Front View
1-Gauge
Jack Bolt
3-Gauge
Lock Bolt Lock Bolt
Volume Tip (Z) Clearance

2 Push the rotor assembly, that is touching the Jack Bolt
diffuser, and check the Volume Tip (Z) Clearance. Stud in bearing cover bolt hole
Jack Bolt
Lock Bolt
2-Gauge
Impeller Blades in contact with Diffuser
Total axial float of pinion
Volume tip or “Z” clearance

Side view of how to set the 3 dial gauges.
Side View Dial mounting fixtures

(EXAMPLE)
All thread
Jack Bolt
Measure each blade tip “Z”
Dial indicators
Use 3 dial
gauges
All thread in
cover bolt hole

! 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
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.

22 Grind the shims to the required thickness. 25 Back off the reverse thrust hearing adjusting bolt
1/4 to a 1/3 of a turn. This will establish 0.008”-
0.010” axial float clearance.
23 Re-check the shims thickness with a Micrometer.
26 Re-check the Pressure Tip (Y) clearance by

comparing the Total Axial float of the pinion with
shims and without shims.
24 Install the shims and tighten with cap screws.
Inactive or Reverse Thrust Setting

Procedure
Inactive
thrust
Shim
adjustment
screw and
locking nut.

Installing the Coupling
Procedure to install a Coupling

When installing anew coupling on a shaft, the
following should be observed prior to heating the
coupling:
• the diameter of the shaft

• the diameter of the coupling bore
• the depth and width of the keyway in the shaft
• the depth and width of the keyway in the coupling
Also inspect for burrs, nicks, etc., and remove or

smooth both the coupling and shaft as necessary.
The diameter of the shaft should be measured with

outside mics.
The inside bore of the coupling should be measured

The C250/350 uses a flange mounted motor that is with inside mics or callipers, use the same outside
coupled to the compressor through a KOP-FLEX 2H mics for checking, that were used to check the shaft.
gear type coupling.
The coupling inside diameter should be 0.0005” to
The coupling compensates 0.00075” per inch of diameter smaller than the shaft
for an angular misalignment diameter.
up to 1-1/2o between shafts.
The maximum offset
misalignment is 1.98mm
(.078 inches). The total end
float is 3.28mm (1/8 inch).
Fully interchangeable, by
coupling half with other
Competitive ‘O’ Ring style gear couplings available
on the market. It has large bore capacity and the
most economical design.
Sizes 1 to 30
• ‘O’ Ring style seal
• Shrouded or exposed bolt sleeves
• Reversible hubs
• Maximum bore up to 43.5” (1.1 meter)
• Maximum Torque up to 284 million lb-in (32100
kN-m)
• Many types available: Mill motor, Slide, Shear
Pin (overload torque protection), Floating shaft,
Limited end float, Electrically insulated, Alloy
steel and other custom design styles available
• ABS and DNV approved designs.

Notes

Basic Centac Manual
CMC Technical
Reference Manual
Section 9

CMC Reference Manual Section 9
Short test
Short Test
1 Which button do you press to re-start the machine?
2 Which button do you press to unload the machine?
Pre-work test Centac Certification course.

3 How
Answer eachdo you reset
question the
as fully MinLoad
as you Control
can, or tick Setpoint?
the best option.
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?
6 In CMC electronic control, what is the driver motor overload protection called?
7 In CMC electronic control, what is the minimum throttle point control function
called?
8 What should the nominal vibration probe gap setting be?

Short test
9 How do we check (a) the probe resistance and

(b) what should the reading be?
a)
b)
10 If the platinum show 98°F, what should the Ohm be?
11 How do we check the BMC if it fails?
12 How do we check if the RTD transmitter is faulty?
13 How do we check if the RTD is faulty?

a)
14 Which component does the BMC bus fuse F100 protect?

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
17 Which component does the BMC bus fuse?

a) The OUI
b) The CPU
d) The Analogue Inputs
18 What could cause a negative value to be shown for all the Analogue inputs on
the OUI display?
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
19 What could cause the E-Stop pressed indication to be checked on the OUI
display and to not clear, even with the E-Stop pulled out?
b) Fuse F103 has blown
c) The line filter has failed
d) A lossof the 110 VAC to the power supply
20 What can cause the OUI display to go completely dark and blank?
b) Fuse F101 has blown
c) F102 has blown

Short test
21 Which Fuse is used for the BMC?

a) 0.5 amps
b) 1.0amps
c) 1.5 amps
d) 2.0 amps
22 What supplies the power to the OUI?

a) Fuse F100
b) Fuse F103
c) Control PowerTransformer
d) 102 VAC to 24 VDC power supply
23 The probe gap corresponds to:

a) VCD and normal gap should be set
b) VCD
24 How do we check the transmitter loss of power?
25 How do we check the vibration transmitter malfunction?

Notes

Basic Centac Manual
Maintenance
Section 10
Scheduled Preventative Maintenance ........................1—4
Maintenance Procedures............................................5—6
Setting Impeller Clearance .........................................7—9
Maintenance Procedures............................................10—11
Short Test ...................................................................12

Maintenance Section 10
Scheduled Preventive Maintenance
Daily and Each Start-Up

• Procedure for setting Volume tip or “Z” 1 Check and record instrument air pressure.
clearance. 2 Check the compressor reservoir oil level.
• Procedure for setting Pressure tip or “Y”
clearance 3 Check and record the oil temperature to the
compressor.
• Procedure for setting Inactive or Reverse
thrust clearance. 4 Check and record the compressor oil supply
• Maintenance Schedules pressure.
5 Check the vibration level on each stage of the
compressor
6 Check and record all interstage pressures (if

The Centac compressor does not require constant available).
attendance. However, a few items should be 7 Check and record all interstage temperatures.
checked periodically.
8 Check and record the inlet air temperature (if
Scheduled preventive maintenance and inspection is available).
essential for continued optimum performance and
9 Inspect for tubing/fitting leakage.
long service life of the compressor. The following are
general requirements and schedules for inspection 10 Check and record the air cooler water temperature,
and preventive maintenance. Since unusual service both to and from the coolers (if available).
conditions and environment affect equipment
reliability, these items and schedules should be 11 Check and blow down the condensate traps.
adjusted in time and content as necessary to suit
12 Check and record the inlet air filter differential
your specific requirements. pressure.
Example Yearly Planner for 13 Check to make sure the air coolers are continuously
Scheduled Preventive Maintenance venting. Vent valves are located on top of the
casing.
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
Daily Maintenance
14 Drain the condensate from the inlet air line drip leg.
Daily Daily Daily Do not open the valve with the compressor
Maintenance Maintenance Quarterly Maintenance operating.
Maintenance
May June July August
15 Drain the condensate from the discharge header
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 drip leg.
Daily Maintenance
Daily Daily Daily
Maintenance Semi-Annual Maintenance Maintenance 16 Drain the condensate from the bypass air line drip
Maintenance leg.
September October November December
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 17 Drain the drip legs on any other horizontal run of air
Daily Maintenance Daily Maintenance piping.
Daily Daily
Quarterly Maintenance Maintenance Annual
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.
3 Change oil filter.
2 Drain control air drip leg.
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.
• Replace element as necessary.
• Inspect seams of the filter for cracks for potential
bypassing. Seal seams as needed.
6 Change oil mist arrestor element.
• Add oil to U-tube.

• Clean element housing.
• Inspect old element for over-crushing. Add
restricting nuts to prevent over-crushing.
• Eliminate lock washer under wing nut, if installed.
• Replace seal washer under wing nut.
• Check to insure the element cover is making
good contact with the element. The cover should
fit squarely on the housing.
7 Inspect the Mist Eliminator element and replace as

needed. Mist Eliminator elements are a long life
item and should not require routine replacement.
8 Inspect control panel.
• Watch for: loose wiring, wrong line filter, damaged

line filter, and adequate arc suppressors.
• Clean panel fan filters and panel.
• Disconnect and tie back all unused wires from
terminal strips.
• Check the vibration transmitter wires to make
sure they run directly to the microcontroller
terminal strips.

Annual Maintenance 12 Vibration Analysis
13 Oil Analysis
14 Condensate Analysis
1 Inspect the main driver per the manufacturer's
instructions found in the Operation Manual.
2 Visually inspect the coupling. Lubricate as
required.
! Caution
Servicing of the internal parts is not recommended
3 Manually rotate bullgear to feel for roughness on
models with bullgear anti-friction bearings. without the presence of an Ingersoll-Rand service
supervisor. For technical assistance, please call
4 Inspect and clean the oil reservoir suction screens. your local Ingersoll-Rand representative.
WARNING
5 Visually inspect the oil cooler tubes. Clean the
water side of the oil cooler if necessary.
6 Visually inspect the zinc anodes (pencils) in the oil !

cooler. Replace if necessary. Warning
Develop and use a “Red Tag” procedure or similar
7 Visually inspect the inlet throttle valve. system whereby maintenance personnel can lock off
8 Visually inspect the bypass valve the power switch during maintenance.
9 Visually inspect the discharge check valve.

Replacement coolers, rotor assemblies, bearings,
10 Change the oil once a year or after 8,000 hours of and seals are available in a variety of options:
use, unless Techtrol Gold III is used. When using
Techtrol Gold III, the lubricant must be changed
every three years / or after every 24,000 hours of • Exchange for factory trade-ins.
use. • Return the part for refurbishing.
11 Surge Testing must be carried out at • Return damaged parts for scrap and obtain credit
every Annual Maintenance. toward new parts.
• Factory warranty program on all exchange parts.
As build-up occurs, the compressor will require
disassembly and cleaning to restore its capacity. • Rapid cooler cleaning and hydrotesting.
How badly off a compressor is, in terms of the

effects of build-up, is related to a decrease in its
Natural Surge pressure. Periodic field testing for the
natural surgwe pressure provides accurate
information for diagnosing build-up related to
capacity deterioration.
The natural surge test involves intentionally surging

the compressor. This is normally done by
• blocking off the discharge,
• establishing maximum flow through the
bypass and then
• closing off the bypass valve until surge is
reached.
The surge pressure reading is compared to other

earlier test results and a determination is made as
to why any differences exist.
Maintenance action (such as an overhaul to restore

capacity), based on the capacity loss prediction, can
then be planned.

The following procedures should also be carried out
on a regular basis.
Main Driver
Depending upon the customer's requirements,
different drivers are used with the Centac
compressor. Consult the driver manufacturer's
literature provided in this manual to insure proper
lubrication and maintenance procedures.
Control Panel
The control panel checkout procedure is designed to
verify that a control panel is functioning properly. The
checkout can be used for initial testing or in
conjunction with routine maintenance schedules.
Refer to the control drawings and checkout
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 Inlet Valve

Periodically stroke the inlet valve to aid in optimum
Guidelines: performance of the compressor. See the
1 Unlatch the weatherhood and swing it up. Manufacturer’s Installation Bulletin located in the
Vendor Literature Section of this manual for
2 Grasp the removal strap located on the face of guidelines on stroking the inlet valve. Observe for
the panel filter and pull straight forward. freedom of movement of the inlet valve during the
3 Install cleaned or new prefilter, making sure the stroking procedure.
removal strap is facing you and is in a horizontal
position. Bypass Valve
Periodically stroke the bypass valve to aid in
4 Swing the weatherhood down and secure the
optimum performance of the compressor. See the
latches into the slots on the side of the filter
Manufacturer’s Installation Bulletin located in the
housing.
Vendor Literature Section of this manual for
5 Clean first by using compressed air. Blow off dust guidelines on stroking the bypass valve. In addition
by directing the compressed air from back to to stroking, the bypass valve should be removed
front. Next, water wash by agitating the panel filter from the air piping system annually to inspect the
in hot water (approx. 150°F) and mild cleaning seals for damage. Replace damaged seals as
agent solution. required and reinstall valve.
6 Rinse with clean water and air dry for at least 12

hours. The panel filter should be completely dry Checking Vibration
before reinstallation to prevent premature dirt Periodically monitor shaft vibration on both sides of
loading. 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 sure
they are not damaged. Do not touch the panel filter contacting probe, add one half (1/2) mil to the above
media portion of the panel element. Handle only by levels. If vibration levels exceed the above values
grasping the metal frame. shut the unit down and determine the cause of
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 panel any start-up after a rotor assembly or bearing has
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.
Maintenance
Setting Procedures
Impeller Clearance (excluding Centac Model 0CU)
Back of Impeller in Contact with Casing

To be carried out during Annual Maintenance
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

Maintenance
Setting Procedures
Impeller Clearance (excluding Centac Model 0CU)
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 Thrust bearing.
are moved in to establish and set the impeller to
diffuser running clearance.

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
The conical spring is to be installed with the large
When check valve is mounted in a horizontal run of end 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

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

Continuous air discharge from the trap indicates it
3 Remove element. Dispose of properly. has failed and should be repaired.
4 Replace with new element.
To clean the trap:
5 Replace top of breather and wing nut. 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.
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?

Notes

Basic Centac Manual
Troubleshooting
Section 11
Troubleshooting Guide ...............................................1—6
Common Conversions and Information ......................7—12

Centac Section 11
Troubleshooting Guide
Surge
Cause Solution
1 Dirty inlet air filter. Replace filter.
2 Too small inlet pipe (remote-mounted air filter). Replace pipe.
3 High interstage air temperatures. Investigate. Check to see what is necessary to lower
air temperatures. Check water temperature, water
flow, water pressure, etc.
4 Increase in water temperature. Investigate. Check to see if it is possible to lower
water temperature.
5 Increase in inlet air temperature. Lower setpoint.
6 Setpoint higher than design discharge pressure Lower setpoint.

of compressor.
7 Defective system pressure controller. Adjust or replace.
8 Too low CLL or LLR (throttle surge). Increase CLL or LLR setting.
9 Too low P1, PR3, or mechanical stop Increase P1, PR3 or adjust mechanical stop.
adjustment (unloaded surge).
10 Improper calibration of valve I/P, positioner, or Calibrate as necessary.
actuator.
11 Defective bypass valve. Repair or replace.
12 Restriction in customer's system. Investigate. Take necessary steps to correct

restriction. Check for closed block valve or excessive
dryer pressure drop.
13 Restricted air flow through air coolers. Clean air coolers.
14 Dirt build-up on impeller vanes. Clean impeller.
15 Blockage of diffuser air passage. Clean diffuser.
16 Improper wheel clearance. Reset clearance.
17 Worn or damaged impeller. Replace.
18 Butterfly valve pin broken. Replace pin.
19 Discharge check valve hanging up. Repair or replace.

Centac Section 11
Low Seal Air Pressure

Cause Solution
1 Seal air regulator malfunctioning. Adjust, clean, or replace regulator.
2 Low instrument air pressure. Increase instrument air pressure.
3 Damaged seal air line. Replace.
4 Leaking fitting. Replace or tighten
5 Leaking seals. Replace.
6 Seal air bleed valve open too far. Adjust.
7 Instrument air filter dirty. Clean or replace element.
8 Excessive clearance between pinion and seal. Replace seal and/or pinion.
Investigate.
Low System Air Pressure

Cause Solution
1 Incorrect setpoint. Adjust.
2 Incorrect valve calibration. Restroke valves.
3 Bad controller. Repair or replace.
4 Dirty inlet filter. Replace filter elements.
5 Compressor operating unloaded. Switch selector switch to load.
6 System demand greater than compressor Check for excessive air usage like open valves,
capacity. leaking fittings, etc., and correct. Start additional
compressor. Recommend that customer purchase
another Centac if additional capacity is required.
7 Compressor block valve closed. Open valve.

8 Incorrect controls calibration. Adjust controls.
9 Discharge check valve sticking. Repair or replace.
10 System air pressure sensing point in wrong Relocate control air connection
location.
11 Excessive pressure differential across air dryer. Investigate and correct.
12 Too low CLH setting. Increase setting (Do not exceed FLA+SF).
13 Leaking bypass valve. Investigate and correct. Replace seat; free up sticking
valve.
14 Bypass valve stays open; inlet valve functions Lower CLL to activate bypass valve on MP3 panel.
normally. Ensure 2TR is operating properly on Electro-
Pneumatic panel.

Centac Section 11
High Vibration
Cause Solution
1 Low oil temperature. Increase oil temperature by adjusting oil heater

thermostat. Close cooling water valves to oil cooler.
Circulate oil.
2 High oil pressure. Reduce pressure. Adjust main oil pump pressure relief
valve with oil at operating temperature.
3 Oil not draining properly from bearings. Investigate and correct. Check for restriction, improper
venting, too high oil level.
4 Incorrect coupling alignment. Realign coupling.
5 Worn coupling. Replace.
6 Excessive grease in coupling. Remove excessive grease.
7 Bad bullgear or intermediate gear bearings. Replace.
8 Unbalanced motor rotor. Have motor rotor balanced.
9 Bad motor bearings. Replace.
10 Worn rotor assembly parts. Replace rotor assembly or necessary parts.
11 Excessive build-up on impellers. Clean and balance rotor assembly.
12 Excessive pipe strain. Remove pipe strain.
13 Incorrect type of oil. Replace with correct oil.
14 Bad rotor assembly bearings or seals. Replace.
15 Excessive moisture carryover. Investigate and correct. Check for restriction in

condensate drainage system.
16 Inadequate oil supply to plain bearing. Investigate and correct. Ensure oil supply groove in
plain bearing shell is aligned properly with oil supply
hole through casing.
Low Control Air Pressure

Cause Solution
1 Too small control air line. Replace with larger diameter pipe.
2 Moisture in control air line. Remove moisture. Provide permanent method for
moisture removal.
3 Sensing control air pressure from wrong Change location of sensing pressure.
location.
4 Leaking fittings or damaged pipe. Repair or replace.
5 Closed C.A. valve. Open valve.

Centac Section 11
Low Instrument Air Pressure

Cause Solution
1 Instrument air line too small. Replace with a larger pipe.
2 Instrument air dryer malfunctioning. Repair or replace.
3 Instrument air valve closed. Open valve.
4 Instrument air supply pressure below Increase supply pressure. Obtain a different air source
recommended pressure. of adequate pressure.
5 Dirty I.A. filter. Clean or replace.
6 I.A. filter wrong size. Replace.
7 Leaking fittings or damaged pipe. Repair or replace.
Failure to Start
Cause Solution
1 No power to motor starter. Energize power.
2 Blown fuse. Replace blown fuse.

3 STOP button pushed in. Pull out STOP button.
4 Overloads tripped. Reset overloads. (If trip occurs do not reset find cause
of trip)
5 Control wiring incorrect. Investigate and correct.
6 Trips at transition. Mechanical linkage out of adjustment. Bad 2M
contactor. Replace or repair contactor.
7 Interlocks not satisfied. Investigate and correct. Adjust mechanical interlocks.
8 Bad motor starter. Repair or replace.
9 Loose or corroded wiring. Tighten and/or clean as necessary.
10 Control relay defective. Replace.
11 Low voltage. Investigate. Increase voltage supply. Increase wire size. Increase
breaker size.
12 Control circuit not grounded properly. Ground neutral at transformer. Check wiring.
13 Wiring to remote starter incorrect. Investigate and correct.

Centac Section 11
No Control Power
Cause Solution
1 POWER ON selector switch OFF. Turn POWER ON switch to ON.
2 Blown fuse. Replace fuse.
3 Bad control power transformer. Replace.
4 Control power transformer wired incorrectly. Correct transformer wiring.
Failure to Load
Cause Solution
1 LOAD selector switch in the wrong position. Turn switch to LOAD.
2 Inlet valve stuck. Investigate and correct.
3 Controller setpoint too low. Adjust.
4 No control air signal. Investigate and correct. Check for closed valve.
5 Surge sensor tripped. Adjust or replace.
6 Bypass valve will not close. Investigate and correct.
7 No power air to inlet or bypass valve. Investigate. Open power air shutoff valve.
8 Valve actuator or positioner malfunctioning. Repair or replace.
9 REMOTE/LOCAL switch for CEM in wrong Turn to REMOTE for CEM operation.
position.
10 10. Incorrect CLL setting. Reset to correct value.
Low Oil Pressure

Cause Solution
1 Incorrect relief valve adjustment. Adjust main oil relief valve to obtain 25-27 psi at
correct operating oil temperature.
2 Dirty oil filter. Replace.
3 Leaking check valve. Replace.
4 Defective main oil pump. Repair or replace.
5 Leaking bullgear cover seal. Remove cover and install new silicone sealant around
oil supply groove.
6 Leaking or pinched suction line. Repair or replace.
7 Low oil level. Ensure 1-1/2" - 2" oil cover (minimum) above top of
suction screens.
8 Excessive gerotor axial clearance. Tighten axial clearance.
9 Wrong prelube pump motor. Obtain correct prelube pump motor.
10 Wrong size pump. Install correct pump.
11 Too big prime line. Install smaller prime line or remove entirely.
12 Suction and discharge lines reversed. Correct.
13 Unloaded oil pressure low. Increase P1 value.

Centac Section 11
High Oil Temperature

Cause Solution
1 Inadequate water flow. Provide adequate water flow to the oil cooler.
2 High water temperature. Lower water temperature; use a cooler water source.
3 Bad AMOT valve. Replace.
4 Water control valve thermostat out of Calibrate controller.

calibration.
5 Dirty oil cooler on water side. Clean water side of oil cooler.
6 Incorrect oil. Check oil specification against I-R oil requirements;

install correct oil.
7 Water/glycol mixture greater than 50/50. Adjust mixture to ensure the glycol is not greater than
50%.
8 Water temperature supply higher than oil Install larger oil cooler or additional cooler.
cooler design.
9 Heat exchanger radiating fins dirty. Clean fins.
10 Incorrect number of water passes. Investigate. Orient return bonnet correctly; replace
bonnett gasket if bypassing; install cooler with more
passes.
High Air Temperature

Cause Solution
1 Inadequate water flow. Provide adequate water flow to the air cooler; adjust
water flow to the air cooler.
2 High water temperature. Lower water temperature; use a cooler water source.
3 Water control valve thermostat out of Calibrate controller.
calibration.
4 Plugged water passages or scale on the tubes. Clean water side of air cooler.
5 Water flow bypassing air cooler. Investigate and correct. Replace waffle gasket if it is
missing or damaged. Reglue it if it is loose. If shroud is
loose, reinstall with correct pop rivets. Never use
aluminum pop rivets.
6 Water/glycol mixture greater than 50/50. Adjust mixture to ensure the glycol is not greater than
50%.
7 Heat exchanger radiating fins dirty. Clean fins.
8 Water flows backward. Cold water inlet on Repipe if water piping is backwards; switch backflush
cooler hot air inlet side is backwards flow. valve to correct position.
Investigate.
9 Air cooler oriented incorrectly. Remove air cooler and rotate to align the water ports
correctly with the water connections of the casing.

Centac Section 11
Common Conversions and Information
Temperature
To convert Formula to use
1 Fahrenheit to Celsius °C = 5/9 (°F-32°)
2 Celsius to Fahrenheit °F = 9/5°C + 32°
Pressure – gauge
1 PSI to Atmosphere PSI X 0.06805
2 PSI to inches of H2O at 68°F PSI X 27.73
3 PSI to inches of mercury (in Hg) at 0°C PSI X 2.036
4 PSI to kPa PSI X 6.8948
5 PSI to Kg/cm2 PSI X 0.07031
6 Kg/cm2 to Atmosphere Kg/cm2 X 0.9678
7 Kg/cm2 to bars Kg/cm2 X 0.98066
8 Kg/cm2 to inches of mercury (in Hg) at 0°C Kg/cm2 X 28.96
9 Kg/cm2 to kPa Kg/cm2 X 98.066
10 Kg/cm2 to PSI Kg/cm2 X 14.223
11 kPa to PSI kPa X 0.145
12 bars to PSI bars X 14.504
13 inches of H2O at 68°F to inches of mercury (in Hg) at 0°C in H2O X 0.07342
14 inches of water at 68°F to psi in H2O X 0.03606
15 inches of water at 68°F to kPa in H2O X 0.2487
16 inches of water at 68°F to Kg/ cm2 in H2O X 0.002535
17 inches of water at 68°F to bar in H2O X 0.002487
18 inches of water at 68°F to standard atmosphere (atm) in H2O X 0.002454
19 inches of mercury at 0°C to inches of water at 68°F in Hg X 13.62
20 inches of mercury at 0°C to psi in Hg X 0.03606
21 inches of mercury at 0°C to kPa in Hg X 3.3864
22 inches of mercury at 0°C to Kg/cm2 in Hg X 0.034532
23 inches of mercury at 0°C to bar in Hg X 0.033864
24 inches of mercury at 0°C to standard atmospheres (atm) in Hg X 0.03342
25 atmosphere (standard) to bar atm X 1.01325
26 atmosphere (standard) to psi atm X 14.696
27 atmosphere (standard) to Kg/cm2 atm X 1.0332
28 atmosphere (standard) to Kg/m2 atm X 10332
29 atmosphere (standard) to kPa atm X 101.325

Centac Section 11
Length
1 inches to meters (m) in. X 0.0254
2 inches to centimeters (cm) in. X 2.54
3 inches to millimeters (mm) in. X 25.4
4 meters to inches (in.) m X 39.37
5 centimeters to inches (in.) cm X 0.3937
6 millimeters to inches (in.) mm X 0.03937
7 mills (0.001") to millimeters 0.001" X 0.0254
Flow
1 cubic feet per minute (scfm) to scfm X 0.0004719
cubic meters per second (nm3/s)
cubic meters per hour (nm3/h)
cubic centimeters per second (cm3/s)
cubic meters per minute (nm3/m).
1000 scfm = 28.32 nm3/m
5 cubic meters per hour (nm3/h) to nm3/h X 0.016667
cubic meters per minute (scfm)
6 cubic meters per hour (nm3/h) to nm3/h X 0.00027778
cubic meters per second (nm3/s)
7 cubic meters per minute (nm3/m) to nm3/m X 35.315
cubic feet per minute (scfm)
8 gallons per minute (US) to gpm X 0.0037854
cubic meters per minute (nm3/m)
9 gallons per minute (US) to cubic meters per hour (nm3/h) gpm X 0.2271
10 gallons per minute (US) to cubic feet per hour (scfh) gpm X 8.021
11 gallons per minute (US) to liters per second (L/s) gpm X 0.06309

Centac Section 11
Volume
3
1 gallons (US) to cubic inches (in ) gal. X 231
3
2 gallons (US) to cubic meters (m ) gal. X 0.0037854
3 gallons (US) to liters (L) gal. X 3.7854
4 liters (L) to cubic inches (in3) L X 61.024
3
5 liters (L) to cubic meters (m ) L X 0.001
6 liters (L) to gallons (US) L X 0.26418
3 3
7 cubic inches (in ) to cubic meters (m ) in3 X (16.387 X 10- 6)
8 cubic meters (m3) to cubic inches (in3) m3 X 61024
9 cubic meters (m3) to cubic ft. (ft3) m3 X 35.315
10 cubic feet (ft3) to cubic meters (m3) ft3 X 0.02832

Centac Section 11
Electrical
Quantities
1 Amps (I) = current

2 Ohm (R) = resistance
3 Watts (W) = electric power
4 Kilowatts (KW) = electric power
5 Kilovolt - amps (kVA) = apparent electric power
6 Kilowatt hour (KW/hr) = unit of electric energy or work
performed
7 Joule (J) = metric unit of energy in watt per sec.
8 Volt (E) = unit of electric pressure or electromotive force
9 eff = efficiency (expressed as a decimal)
10 pf = power factor (expressed as a decimal)
11 hp = horsepower output
12 AC = alternating current
13 Ohms Law Relationship (direct current - DC)
Mathematical Relationship of Quantities

E= I x R W E = WR W = I2 R E2 W=ExI
E = W =
I R
E W W E W E2
I = I = I = R = R = R =
R E R I I2 W
DC single phase AC 3- phase AC
IE 1.73IE
kva = kva =
1000 1000
IR IE ( pf ) 1 . 73 IE ( pf )
KW = KW = KW =
1000 1000 1000
IE (eff ) IE ( eff )( pf ) 1.73 IE (eff )( pf )
hp = hp = hp =
746 746 746
IE IE (eff )( pf ) 1.73 IE ( eff )( pf )
J = J = J =
sec sec sec
746 ( hp ) 746 ( hp ) 746 ( hp )
Amps (hp known) = Amps (hp known) = Amps (hp known) =
E ( eff ) E ( eff )( pf ) 1 .73 E ( eff )( pf )
1000 KW 1000KW 1000KW
Amps (KW known) = Amps (KW known) = Amps (KW known) =
E E( pf ) 1.73E( pf )
1000 kva 1000 kva
Amps (kva known) = Amps (kva known) =
E 1.73 E

Centac Section 11
Vibration
2
A = Acceleration in g’s (in/sec ) = Peak
V = Velocity in in/sec = Peak
D = Displacement in mils = Peak - Peak
f = Frequency in Hz
Mathematical Relationship of Quantities

A
V = 61 . 34 x V = 0.0031416 x f x D
f
V A
D = 318 .3 x D = 19 , 570 x
f f 2
A = 0.0000511 x D x f2 A = 0.0162 x V x f2
Definitions
Root Mean Square (RMS)
RMS = 0.707 x Peak RMS = 1.111 x average RMS = 0.354 x Pk - Pk
Average
Average = 0.637 x Peak Average = 0.900 x RMS2 Average = 0318 x Pk - Pk
Peak to Peak
Pk - Pk = 2 x Peak Pk - Pk = 2.828 x RMS Pk - Pk = = 3.142 x average
Peak
Pk = 1.414 x RMS Pk = 1.571 x average
0.707
0.637
+
0
- Average RMS Peak
Peak to Peak
in/sec. = mm/sec. x 0.03937

mm/sec. = in/sec. x 25.40
12000
Total vibration (in mils) = 1.25 x
RPM

Centac Section 11
Water Quality Requirements

Total hardness (expressed as CaCo3) less than 100 PPM
Suspended solids less than 50 PPM
Maximum water temperature (cooler discharge) 140°F/60°C
pH range 6.0 - 8.5
Langlier saturation index (LI) +0.5 - +1.0
• A low pH level promotes corrosion and high

levels of dissolved oxygen.
• A high pH level increases the chance of scale
formation.
• A low LI indicates the water tends to be corrosive.
• A high LI indicates a tendency to form scale.
It is recommended to contact a reputable water

treatment professional if there are questions
regarding water quality.

Notes


AP CentacTraining Manual V2 PDF

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Centac Training

Planning & Installation

Airend Overhaul - Models 1CV , C250/C350

Proprietary Notices and Disclaimer

Introduction Section 5—Planning & Installation

Basic Centac Training Manual

Basic Centac Training Manual

Description of the Machine

• A main driver that drives a bullgear, and is

Discharge 1st Stage

Bullgear Shaft Seal Bullgear

Inlet 1st Stage

Basic Centac Training Manual

Rotor Assemblies for Centac Models 1CV,

Centac Model 1CV Rotor Assembly

Centac Model C250/C350

The plain and thrust bearings are hydrodynamic

Centac Model 2CV Rotor Assembly

Basic Centac Training Manual

The bullgear bearings, for the Centac compressor

Centac Models 1CV & 1ACV

Centac Model C250/C350

Basic Centac Training Manual

Basic Centac Training Manual

Lubrication System Main Oil Pump

Basic Centac Training Manual

Main Oil Pump

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

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

Basic Centac Training Manual

CV Flange mounted motor with barrel coolers.

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

Basic Centac Training Manual

1 What are the moving components in a Centac compressor?

2 What type of bearings are used in Centac Compressors?

4 What type of moisture separator is used in Centac compressors?

6 Which Centac model has external coolers?

7 Why do the tubes, in the intercooler, have internal fins?

Basic Centac Training Manual

Centac Reference Manual

Centac Training Manual

4 The built-in intercooler

1 Atmospheric air is cleaned by an

2 Air flows to the first stage where the

Centac Training Manual

Inlet pressure (psia) 14.4 12.4* 14.4 14.4